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Ford 2002 Bantam, Workshop Manual

The Ford 2002 Bantam Workshop Manual is a comprehensive manual for DIY repairs and maintenance. Download it for free from manualshive.com to access step-by-step instructions and diagrams for servicing your vehicle. This essential manual will help you keep your Bantam running smoothly for years to come.

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310-01B-38  

Fuel Tank and Lines — Diesel Engines 

310-01B-38 

 

REMOVAL AND INSTALLATION 

E6371 EN   

 

09/2001 2002 Bantam 

Fuel Tank (23 554 0) 

 

General Equipment 

 

 

Fuel tank draining equipment 

 

 

Removal 

 

 

WARNING: This procedure involves fuel 

handling. Be prepared for fuel spillage 
at all times and always observe fuel 
handling precautions. Failure to follow 
these instructions may result in per-
sonal injury. 

 

 

 

CAUTION: Diesel fuel injection equip-

ment is manufactured to very precise 
tolerances and fine clearances. It is 
therefore essential that absolute 
cleanliness be observed when working 
with these components. Always fit 
blanking plugs to any open orifices or 
pipes. 

 

 

 

 

1.  Disconnect the battery ground cable.  For 

additional information, 

refer to Section 414-01. 

 

 

 

 

 

2.  Release the fuel pressure.  For additional 

information, 

refer to Section 310-00. 

 

 

 

 

 

3.  Drain the fuel tank.  For additional 

information, 

refer to Section 310-00. 

 

 

 

 

 

4.  Raise and support the vehicle.  For 

additional information,

refer to Section 100-02. 

 

 

 

 

5.  Disconnect the fuel tank filler tube. 

 

 

 

 

 

6.  Disconnect the fuel tank vent pipe from the 

fuel filler pipe. 

 

 

Summary of Contents for 2002 Bantam

Page 1: ...d specifications are the latest available at the time of printing As modifications affecting service occurs Dealers will be issued with Technical Bulletins Service Information sheets or supplementary...

Page 2: ...MAIN INDEX FORD BANTAM Group 1 General Information Group 2 Chassis Group 3 Powertrain Group 4 Electrical Group 5 Body and Paint GI CH PT EL BP Workshop Manual...

Page 3: ...Group General Information 1 SECTION TITLE PAGE Service Information General Information Identification Codes Jacking and Lifting Noise Vibration and Harshness 100 01 100 02 100 04 100 00...

Page 4: ...emical Materials 100 00 9 Chlorofluorocarbons CFC 100 00 10 Clutch Fluids 100 00 10 Clutch Linings and Pads 100 00 10 Corrosion Protection Materials 100 00 10 Cutting 100 00 10 Dewaxing 100 00 10 Dust...

Page 5: ...l 100 00 19 Alternative Fuel Do s 100 00 19 Alternative Fuel Do Nots 100 00 19 Towing the Vehicle 100 00 20 Connecting a Slave Battery Using Jumper Cables 100 00 20 Component Cleaning 100 00 21 Calibr...

Page 6: ...Manual WARNING Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury CAUTION Cautions are used to indicate that failure to follow a procedure correc...

Page 7: ...ep or specific corrective actions The boxed numbers indicate the order in which the described action is to be performed Component Tests A component test is used when a component is tested in multiple...

Page 8: ...Sodium Azide This material is hermetically sealed in the module and is completely consumed during deployment No attempt should be made to open an air bag inflator as this will lead to the risk of expo...

Page 9: ...halation of toxic fumes Use appropriate protective clothing and a thermostatically controlled heater with a thermal cut out and adequate extraction Resin based Adhesives Sealers for example Epoxide an...

Page 10: ...es released during charging are explosive Never use naked flames or allow sparks near charging or recently charged batteries Make sure there is adequate ventilation Brake and Clutch Linings and Pads S...

Page 11: ...at CFCs and Halons are depleting the upper ozone layer which filters out harmful ultraviolet radiation Decreased filtration of ultraviolet radiation may result in increases in skin cancer cataracts an...

Page 12: ...ese may be immediate or delayed Diesel engine Soot discomfort and irritation usually give adequate warning of hazardous fume concentrations Fibre Insulation See also Dusts Used in noise and sound insu...

Page 13: ...solene dries the skin and can cause irritation and dermatitis on prolonged or repeated contact Liquid in the eye causes severe smarting Motor gasolene may contain appreciable quantities of benzene whi...

Page 14: ...cylinders and lines and to avoid sources of ignition Only trained personnel should undertake work involving gas cylinders Gases See Gas Cylinders Gaskets Fluoroelastomer See Viton General Workshop To...

Page 15: ...skin disorders develop obtain medical advice without delay Where practicable degrease components prior to handling Where there is a risk of eye contact eye protection should be worn for example chemi...

Page 16: ...he skin in toxic or harmful quantities Splashes in the eye may cause severe irritation and could lead to loss of vision Brief exposure of high concentrations of vapours or mists will cause eye and thr...

Page 17: ...nd skin burns to the operator and to other persons nearby Gas shielded welding processes are particularly hazardous in this respect Personal protection must be worn and screens used to shield other pe...

Page 18: ...ing or attempting adjustments of any kind 2 Components or assemblies displaying the warning triangle with the electrified arrow and open book symbol give warning of inherent high voltages Never touch...

Page 19: ...1 2002 Bantam 6 Displaying this symbol normally in conjunction with 5 above warn of the presence of potentially explosive matter within the immediate vicinity 7 Displaying this symbol warn that childr...

Page 20: ...rical and air powered equipment evacuate the area ventilate the area contact fire control authorities remove the vehicle to a dedicated ventilated area Alternative Fuel Do s do work on the vehicle in...

Page 21: ...ed off This can cause arcing when the jumper cables are connected CAUTION While it is not recommended that the vehicle is jump started it is recognized that this may occasionally be the only practical...

Page 22: ...n when using this method removal of dry dust using vacuum equipment This method should always be used to remove friction lining material dust asbestos particles steam cleaning WARNING Most solvents re...

Page 23: ...ct the manufacturer of the product for information regarding storage handling and application The Health and Safety Precautions subsection refers to some commonly used chemicals and materials hazards...

Page 24: ...d off check The handbrake is applied The gear lever is in neutral All instrument gauges except fuel gauge read zero With the ignition switched on check Ignition controlled warning lights come on Engin...

Page 25: ...efficiency until the bedding in process is complete Test the brakes at several speeds within the normal operating range using both light and heavy pedal pressure Note any tendency to snatch pull or dr...

Page 26: ...TION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Identification Codes 100 01 26 Vehicle Identification Number VIN 100 01 26 27 World manufacturer 100 01 27 Year of manufacture 100 01 27 Month o...

Page 27: ...tion number VIN can be identified by an asterisk at its start and finish The vehicle identification plate is located in the engine compartment on the front body crossmember The codes stamped on the pl...

Page 28: ...4 1 AR 1 0 0 6 5 7 1 3 Item Description 1 World manufacturer identifier code 2 Model code Item Description 3 Sequential chassis number VIN Position 1 Code World Manufacturer AFA Ford Motor Company of...

Page 29: ...008 2009 2010 2011 January T E G P T E G P T E G February J L C B J L C B J L C March U Y K R U Y K R U Y K April M S D A M S D A M S D May P T E G P T E G P T E June B J L C B J L C B J L July R U Y...

Page 30: ...D MOTOR COMPANY OF SOUTHERN AFRICA 1 2 5 7 8 9 10 4 3 6 11 Item Description 1 Chassis number 2 Trim 3 Engine output kW 4 Build code 5 Maximum permissible rear axle loading 6 Gross vehicle mass Item De...

Page 31: ...Colour PA3 Satin white PGV Dolphin blue PA4 Solid red PD5 Atlantic blue PD6 Desert wind PD7 Titanium grey PB1 Pure silver PHU Desert glow PVV Ice blue PHL Aquarius blue PWG Berry red PDC Champagne sil...

Page 32: ...00 02 31 Jacking and Lifting 100 02 31 06 2001 2002 Bantam SECTION 100 02 Jacking and Lifting VEHICLE APPLICATION 2002 Bantam DESCRIPTION AND OPERATION Jacking 100 02 32 Lifting 100 02 33 SUBJECT PAGE...

Page 33: ...gonally opposite the jack Failure to follow these instructions may result in personal injury Before commencing any repairs that involve jacking the vehicle it is essential that the following instructi...

Page 34: ...RIPTION AND OPERATION E4448 EN 06 2001 2002 Bantam Lifting NOTE When lifting a vehicle with a two post lift vehicle levelling pads must be used under the lifting points It is important that only the c...

Page 35: ...ve the Cause 100 04 35 Be Positive the Cause is Found 100 04 35 Diagnostic Charts 100 04 35 36 DIAGNOSIS AND TESTING Noise Vibration and Harshness NVH 100 04 37 Inspection and Verification 100 04 37 N...

Page 36: ...ly Know the History of the System A clue in any one of these areas may save time How old or new is the system What kind of treatment has it had Has it been serviced in the past in such a manner that m...

Page 37: ...before others Simplicity of performing certain tests before others Elimination of checking huge portions of a system by performing simple tests Certainty of narrowing down the search to a small portio...

Page 38: ...Quick Checks are described within the step while more involved tests and adjustments are outlined in Service Procedures and Adjustments Always follow each step exactly and make notes to recall import...

Page 39: ...el halfshaft joint boots resulting in inadequate or contaminated lube in the outboard or inboard CV joint stub shaft pilot bearing housings Loose front wheel halfshaft joint boot clamps Another compon...

Page 40: ...ecks may not tell where the concern is but they will tell where it is not Road Test Quick Checks 1 24 80 km h 15 50 mph With light acceleration a moaning noise is heard and possibly a vibration is fel...

Page 41: ...speed range of interest using the Road Test Quick Checks as previously described 3 Carryout a coast down in NEUTRAL If the vehicle is free of vibration when operating at a steady indicated speed and...

Page 42: ...drive belt pulleys GO to Pinpoint Test C Engine accessory vibration Accessory drive belt pulleys Mounting hardware GO to Pinpoint Test D Tyre wheel run out Tires wheels Wheel bearings GO to Pinpoint T...

Page 43: ...CCESSORY DRIVE BELT AND PULLEYS 100 04 45 D3 CHECK THE MOUNTING HARDWARE 100 04 45 D4 CHECK WITH THE ENGINE IDLING 100 04 45 D5 CHECK FOR ACCESSORY DRIVE BELT NOISE 100 04 46 D6 CHECK THE ACCESSORIES...

Page 44: ...OUT 100 04 51 G4 CARRY OUT A STATIC BALANCE TEST 100 04 51 G5 CARRY OUT A ROAD TEST 100 04 51 PINPOINT TEST H ENGINE RUN UP CHECK H1 CARRY OUT SETUP FOR THE ENGINE RUN UP CHECK 100 04 51 H2 CARRY OUT...

Page 45: ...ssary to follow the chart to its conclusion Perform only the Pinpoint Test Steps necessary to correct the condition Then check operation of the system to make sure the condition has been corrected Aft...

Page 46: ...rry out the vibration diagnosis REFER to Section 204 00 Are the wheel bearings OK Yes GO TO A3 No INSTALL a new wheel bearing as necessary REFER to Section 204 01 front or REFER to Section 204 02A 204...

Page 47: ...NTS 1 Check the engine mounts Refer to the Engine Transaxle Mount Neutralizing procedure in this section Are the engine mounts OK Yes GO TO B3 No GO TO B4 B3 CHECK THE EXHAUST SYSTEM 1 Check the exhau...

Page 48: ...mal operation If the moan persists GO TO C2 C2 CHECK THE ENGINE MOUNTS 1 Check the engine mounts Inspect the engine support insulators for correct operation REFER to Section 303 01A or REFER to Sectio...

Page 49: ...o GO TO D3 D3 CHECK THE MOUNTING HARDWARE 1 Check the mounting hardware Check the mounting brackets and adjusting components for correct alignment and tightness Are the mounting and adjusting componen...

Page 50: ...LL new components as necessary GO TO D6 D6 CHECK THE ACCESSORIES 1 Check the accessories Run up the engine to the concern rpm and check each component Is the noisy component located Yes INSTALL a new...

Page 51: ...rear and rear to front Does the vehicle function correctly Yes Condition corrected No GO TO E4 E4 CHECK THE RUN OUT 1 Check the run out REFER to Section 204 03 Check total radial run out and total la...

Page 52: ...at a time from a different vehicle to isolate the offending tyre s INSTALL new tires as necessary BALANCE tires TEST the system for normal operation PINPOINT TEST F FRONT DISC BRAKES VIBRATION SHUDDER...

Page 53: ...KE DISCS 1 Refinish the brake discs Refinish brake discs and linings and road test the vehicle REFER to Section 206 03 Is a shudder or vibration present Yes GO TO F7 No Condition corrected F5 CHECK TH...

Page 54: ...g engine or transaxle mounts or worn or damaged wheel bearings for wear damage INSTALL new components as necessary TEST the system for normal operation No Condition corrected PINPOINT TEST G WHEEL END...

Page 55: ...GO TO G5 No INSTALL new wheels or tires as necessary TEST the system for normal operation G5 CARRY OUT A ROAD TEST 1 Carry out a road test Does the condition still exist Yes CHECK the following items...

Page 56: ...CHECK the engine transaxle mounts and or the exhaust system components TEST the system for normal operation PINPOINT TEST I ACCESSORY DRIVE BELT CHECK CONDITIONS DETAILS RESULTS ACTIONS I1 INSPECT TH...

Page 57: ...nd drive system as necessary REFER to Section 303 05 For pulley run out CHECK INSTALL new pulley or accessory as necessary TEST the system for normal operation No GO TO I4 I4 INSPECT THE BELT RIDE 1 I...

Page 58: ...sulator mount which is acting in a rigid manner because of a distorted or twisted mounting position As a result the support insulator does not absorb vibration as it should Loosen the engine insulator...

Page 59: ...onnection 2 Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress 3 Tighten the muffler connection 4 Position the exhaust pipes to the manifol...

Page 60: ...100 04 56 Noise Vibration and Harshness 100 04 56 SPECIFICATIONS E861 EN 062 2001 2002 Bantam Lubricants Fluids Sealers and Adhesives Item Specification Information not available at this time...

Page 61: ...em General Information 206 00 Drum Brake 206 02 Front Disc Brake 206 03 Wheels and Tyres 206 04 Parking Brake and Actuation 206 05 Hydraulic Brake Actuation 206 06 Power Brake Actuation 206 07 Steerin...

Page 62: ...spension System 204 00 2 Inspection and Verification 204 00 2 4 Symptom Chart 204 00 4 8 Pinpoint Tests 204 00 9 18 SECTION 204 00 Suspension General Information VEHICLE APPLICATION 2002 Bantam 204 00...

Page 63: ...information needed to find the source of a vibration During the road test drive the vehicle on a road that is smooth and free of undulations If a vibration is apparent note and record the following T...

Page 64: ...in which a thick film of oil may be deposited on the suspension unit outer tube body and is normally noticed due to the collection of dust in this area Suspension units which exhibit this seepage con...

Page 65: ...nt Refer to General Procedures in this section Vehicle ride height incorrect front or rear high or low CHECK for abnormal loading spring sag or non standard springs Lift Check 1 Noise Noise can be cau...

Page 66: ...the power steering sys tem REFER to Section 211 02 Brake pull Unequal tyre pressures INFLATE the tyres to the correct pressures REFER to Section 204 03 Brake system failure CHECK the brakes REFER to...

Page 67: ...rn or damaged front suspension unit s REPAIR or INSTALL new sus pension units as necessary REFER to Section 204 01 Front rear suspension noises Loose worn or damaged sus pension unit mounting compo ne...

Page 68: ...system damaged or worn CHECK the steering system REFER to Section 211 00 Damaged front suspension lower arm ball joint INSTALL a new front suspen sion lower arm ball joint REFER to Section 204 01 Wea...

Page 69: ...204 01 Damaged or loose front suspen sion lower arm mounting bolt bushing REPAIR or INSTALL a new front suspension lower arm mounting bolt bushing REFER to Section 204 01 Abnormal noise from the sus p...

Page 70: ...E3 INSPECT THE FRONT SUSPENSION LOWER ARM 204 00 13 E4 INSPECT THE BALL JOINT 204 00 13 E5 INSPECT THE FRONT WHEEL BEARINGS 204 00 13 E6 INSPECT THE TYRES 204 00 13 PINPOINT TEST F INCORRECT TYRE WEA...

Page 71: ...conditions must be met when evaluating the vehicle 1 Check the cold tyre pressure Drive the vehicle at 88 km h on a level and straight road Drive in the center lane of a three lane highway Be sure th...

Page 72: ...5 A5 ROTATE THE TYRES 1 Raise and support vehicle REFER to Section 100 01 Rotate the wheels in a cross pattern Does the vehicle drift Yes INSPECT the front suspension components for wear or damage INS...

Page 73: ...S C1 CHECK THE CASTER ANGLE 1 Check the caster angle Is the caster angle within specification Yes GO TO C2 No CHECK all suspension components for wear or damage INSTALL new or REPAIR worn or damaged c...

Page 74: ...EST the system for normal operation No Verify the customer concern PINPOINT TEST E EXCESSIVE NOISE CONDITIONS DETAILS RESULTS ACTIONS E1 INSPECT THE SUSPENSION 1 Raise and support the vehicle REFER to...

Page 75: ...to move it up and down Feel for any free movement There must be no free movement Is there any free movement Yes INSTALL a new ball joint REFER to Section 204 01 TEST the system for normal operation No...

Page 76: ...n CHECK wheel alignment TEST the system for normal operation No GO TO F2 F2 CHECK FOR CUPPED TYRES 1 Inspect the tyres for cupping or dishing Are the tyres cupped or dished Yes INSTALL new tyre s BALA...

Page 77: ...ion a dial test indicator gauge with mounting bracket against the front wheel hub Push and pull the wheel hub by hand in the axial direction and check for endplay of the wheel hub and front wheel bear...

Page 78: ...T the system for normal operation G6 MEASURE THE WHEEL TYRE RUN OUT ON THE VEHICLE 1 Measure the wheel and tyre run outs on the vehicle using a radial run out gauge Assembly run out should be less tha...

Page 79: ...unt the wheel on a wheel balancer Measure the run out on both flanges Run out should be less than 1 14 mm radial and lateral Is there run out correct Yes LOCATE and MARK the low spot on the wheel and...

Page 80: ...stud circle run out greater than 0 06 mm and rotor pilot radial run out greater than 0 05 mm Are the measurements correct Yes CHECK the front brake disc run out REFER to Section 206 00 TEST the syste...

Page 81: ...4 Wheel Bearing Inspection 14 117 0 204 01 5 6 REMOVAL AND INSTALLATION Wheel Bearing 14 411 0 204 01 7 9 Lower Arm 14 707 0 204 01 10 11 Wheel Knuckle 14 343 0 204 01 12 17 Lower Arm Ball Joint 14 7...

Page 82: ...204 01 2 Front Suspension 204 01 2 DIAGNOSIS AND TESTING E1054 EN 06 2001 2002 Bantam Front Suspension REFER to Section 204 00...

Page 83: ...ake sure there are no signs of damage or wear Check and if necessary adjust the tyre pressure to specification Make sure the vehicle is at curb weight and that the spare wheel jack and vehicle tools a...

Page 84: ...ension 204 01 4 GENERAL PROCEDURES CONTINUED E1051 EN 06 2001 2002 Bantam 3 Rotate each tie rod equally clockwise or counterclockwise to adjust the toe setting 4 Tighten the tie rod end locknuts 5 Che...

Page 85: ...efer to Section 100 02 2 Check for loose front wheel bearings by rocking the wheels at the top and bottom 3 Spin the wheel quickly by hand and make sure the wheel turns smoothly without noise from the...

Page 86: ...204 01 6 Front Suspension 204 01 6 GENERAL PROCEDURES CONTINUED E3137 EN 06 2001 2002 Bantam 6 Install the front brake caliper For additional information refer to Section 206 03...

Page 87: ...Crankshaft Rear Oil Seal 303 171 03 21 102 03 Installer Front Wheel Bearing 204 160 14 040 Installer Front Hub Oil Seal 204 256 14 046 Material Specification Engine oil WSS M2C913 A Removal 1 Remove t...

Page 88: ...installed CAUTION Do not use heat to remove the bearing inner ring Using the special tools remove the inner race from the wheel hub 4 Remove the circlip from the wheel knuckle 5 Install the old bearin...

Page 89: ...Lubricate the bore of the wheel knuckle with engine oil Using the special tools install the bearing to the wheel knuckle 2 NOTE Make sure the ends of the circlip are positioned in line with the lower...

Page 90: ...s 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Remove the front wheel 4 CAUTION Protect the ball joint seal using a soft cloth to prevent damage Detach the lowe...

Page 91: ...ND INSTALLATION CONTINUED E1057 EN 06 2001 2002 Bantam 2 CAUTION Make sure a heat shield is installed to prevent damage to the ball joint Install the heat shield 3 Install the lower arm to the wheel k...

Page 92: ...041 General Equipment Three leg puller Removal All Vehicles 1 CAUTION Use an Allen key to prevent the piston rod from rotating Loosen the top mount nut by five turns 1 Remove the cover if equipped 2 L...

Page 93: ...CAUTION Protect the ball joint seal using a soft cloth to prevent damage Using the special tool detach the tie rod end from the wheel knuckle Discard the tie rod end retaining nut 6 CAUTION Secure th...

Page 94: ...event damage Remove the wheel hub retaining nut and washer Discard the hub retaining nut 9 CAUTION Protect the ball joint seal using a soft cloth to prevent damage Detach the lower arm ball joint from...

Page 95: ...l and a puller detach the halfshaft from the wheel hub 13 Remove the wheel knuckle from the suspension unit 1 Insert the special tool and rotate through 90 degrees 2 Remove the wheel knuckle Secure th...

Page 96: ...d to prevent damage to the ball joint Install the heat shield 5 Install the lower arm to the wheel knuckle 6 Install the brake caliper and anchor plate to the wheel knuckle 7 WARNING Install a new tie...

Page 97: ...lt in personal injury With the aid of another technician apply the brakes and pre load the wheel bearing Install a new wheel hub retaining nut 9 Install the wheel and tyre For additional information r...

Page 98: ...all Joint 14 735 0 Removal 1 Remove the lower arm Refer to the procedure in this section 2 Drill out the rivets Installation 1 Install the new ball joint 2 Install the lower arm Refer to the procedure...

Page 99: ...1 Loosen the front wheel nuts 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Remove the front wheel 4 Detach the stabiliser bar connecting link and the flexible...

Page 100: ...int 1 Remove the bolt 2 Detach the lower arm ball joint 7 Remove the wheel knuckle to suspension unit pinch bolt 8 Remove the wheel knuckle from the suspension unit 1 Insert the special tool and rotat...

Page 101: ...l Vehicles 1 Position the suspension unit 2 CAUTION Use an Allen key to prevent the piston rod from rotating NOTE Do not fully tighten the suspension unit top mount nut Install the suspension unit top...

Page 102: ...tall the wheel knuckle to suspension unit pinch bolt 5 CAUTION Make sure a heatshield is installed to prevent damage to the ball joint Install the heatshield 6 Install the lower arm to the wheel knuck...

Page 103: ...N CONTINUED E1060 EN 06 2001 2002 Bantam 8 Install the wheel 9 Lower the vehicle 10 Tighten the suspension top mounting nut 1 Tighten the nut 2 Install the cover if equipped 11 Check the front wheel a...

Page 104: ...ring 204 167 14 042 Special Tool s Adapters for 204 157 204 167 01 14 042 01 Disassembly 1 Remove the suspension unit For additional information refer to the procedure in this section 2 WARNING As the...

Page 105: ...ng clamps removed for clarity 1 Remove the thrust bearing nut 2 Remove the thrust bearing 3 Remove the spring seat 4 Remove the spring 5 Remove the boot 6 Remove the bump stop 7 Remove the dust cover...

Page 106: ...nal Tolerance Range 1 3L Standard Manual 1 34 2 47 0 17 0 40 0 44 to 2 04 All Other Power 2 14 3 29 0 59 0 37 0 47 to 2 01 Maximum variation left to right hand side camber 1 00 Caster 1 15 Front Wheel...

Page 107: ...ts 85 Flexible coupling to steering shaft pinch bolt 28 Flexible coupling to steering gear pinion shaft pinch bolt 28 Wheel knuckle to strut and spring assembly pinch bolt 85 Caliper and anchor plate...

Page 108: ...D TESTING Rear Suspension 204 02 3 REMOVAL AND INSTALLATION Beam Axle and Suspension Assembly Removal 15 231 0 204 02 4 6 Tube Rear Axle Replace 15 730 0 204 02 7 9 Leaf Spring 15 366 0 204 02 10 11 S...

Page 109: ...the axle tube limit the vertical movement A stub axle is welded to each end of the axle tube These stub axles each carry two taper roller bearings which support the rear hubs The rear brake drums and...

Page 110: ...204 02 3 Rear Suspension 204 02 3 DIAGNOSIS AND TESTING E1064 EN 06 2001 2002 Bantam Rear Suspension REFER to Section 204 00...

Page 111: ...e wheels 4 Detach the parking brake equalizer yoke 1 Detach the primary cable from the equalizer yoke 2 Remove the rear cable retaining clip 3 Detach the rear cables from the retaining bracket 4 Detac...

Page 112: ...allation 1 Reposition the rear axle and suspension assembly ensuring the Load Active Valve LAV link rod engages into its spacer tube NOTE If necessary wipe the link rod clean and re grease 2 Refit the...

Page 113: ...er and fit the clevis pin and spring clip reconnect both brake hoses to the axle bracket 6 Bleed the brake system For additional information refer to Section 206 00 7 Lower the vehicle to the ground a...

Page 114: ...the vehicle does not exceed the maximum kerb weight if it is to be raised and supported on the axle tube 3 Remove the brake drum and hub assembly from the axle flange four bolts NOTE Protect the hub...

Page 115: ...6582 EN 06 2001 2002 Bantam 5 Repeat steps 3 to 4 for the remaining brake drum assembly 6 Remove the U bolts nuts securing the axle to the springs 7 Remove the axle tube from the vehicle whilst slidin...

Page 116: ...h the U bolts and nuts 3 Refit the carrier plate assembly with two new rivets 4 Refit the brake drum and hub assembly Torque specification for retaining bolts four off 66 Nm 5 Repeat steps 3 to 4 for...

Page 117: ...um kerb weight if it is to be raised and supported on the axle tube 2 Support the axle with stands or a jack 3 Remove the nuts securing the U bolts to the rear springs 4 Remove nuts and shackle plate...

Page 118: ...pring and body and refit the spring eye to shackle plates securing nut and bolt tighten shackle upper nut depending on design fitted 4 Fit the U bolts to the axle and spring ensuring that the bump rub...

Page 119: ...r sleeve 3 Repeat sub operation 2 for the spring rear eye bush Installation 1 Clean the spring in the region of both front and rear eyes 2 Prior to pressing new bushes into the spring eyes lightly app...

Page 120: ...r of the vehicle fit stands under the body and chock the front wheels For additional information refer to Section 100 02 NOTE It is essential that the vehicle does not exceed the maximum kerb weight i...

Page 121: ...14 REMOVAL AND INSTALLATION CONTINUED E6585 EN 06 2001 2002 Bantam Installation 1 Clean the axle mounting plate before installing the bump stop 2 Slide the bump stop rubber plate locating tag into the...

Page 122: ...eels For additional information refer to Section 100 02 NOTE It is essential that the vehicle does not exceed the maximum kerb weight if it is to be raised and supported on the axle tube 2 Remove the...

Page 123: ...4 15 0 Spring flat Wheel Alingment Note Rear wheel alignment is not adjustable Nominal Tolerence Camber 0 0 0 0 30 00 Toe 0 0 0 0 30 00 Tigntening Torques Item Nm Spring eye bolts front rear 70 95 Sh...

Page 124: ...Wheels and Tyres 204 03 3 Winter Tyres 204 03 3 DIAGNOSIS AND TESTING Wheels and Tyres 204 03 4 Inspection and Verification 204 03 4 Symptom Chart 204 03 5 8 REMOVAL AND INSTALLATION Wheel and Tyre 20...

Page 125: ...goggles or a face shield when performing any work with wheel and tyre assemblies WARNING Retighten the wheel nuts at 800 Km after any wheel change or anytime the wheel nuts are loosened WARNING Failur...

Page 126: ...075 EN 07 2001 2002 Bantam Wheels and Tyres Winter Tyres Always fit winter tyres to all four wheels Do not exceed the maximum speed specified by the tyre manufacturer When using winter tyres the tyre...

Page 127: ...rce of a vibration During the road test drive the vehicle on a road that is smooth and free of undulations If vibration is apparent note and record the following The speed at which the vibration occur...

Page 128: ...alignment ALIGN front end REFER to Section 204 00 Vehicle overloaded CHECK load specification against workload requirement Loose or leaking front suspen sion unit TIGHTEN or INSTALL new parts as nece...

Page 129: ...seen brake disc may have a heavy spot REFER to Section 206 00 Water in tyres REMOVE water Bent wheel INSTALL new wheel Attempts to straighten a wheel can cause fractures in the wheel and weaken wheel...

Page 130: ...ing load tyre size ply rating and tyre construction Incorrect use of tools CHECK mounting demounting and maintenance procedures Damaged wheel stud threads Sliding wheel across wheel studs during assem...

Page 131: ...sion or galling CAUTION Do not permit lubri cant to get on cone sets of stud holes or on cone angle of wheel nuts If corrosion is slight wire brush away corrosion If corro sion is excessive INSTALL ne...

Page 132: ...ction 100 02 3 Remove the wheel and tyre assembly Installation 1 WARNING Remove the corrosion or dirt from the mounting surfaces of the wheel wheel hub brake drum or brake disc as this may cause the w...

Page 133: ...10 210 300 165 80R135 1 6 RoCam Standard 1 3 RoCam Hi line 210 210 210 300 175 65R14T 1 6 RoCam Hi line 1 8 Diesel All 240 210 240 300 175 65R14T Wheel and Tyre Size Wheel Type Model Variants Rim Size...

Page 134: ...and corrosion prevention 205 04 4 DIAGNOSIS AND TESTING Front Drive Halfshafts 205 04 5 Symptom chart 205 04 5 REMOVAL AND INSTALLATION Halfshaft LH 14 320 0 205 04 6 9 Halfshaft RH 14 321 0 205 04 10...

Page 135: ...d nearest the transmission 3 Nearest the wheel fixed ball joints are fitted consisting of a tripod ball cage and shell 4 The left hand tripod joint is secured in the differential with a snap ring 5 Th...

Page 136: ...205 04 3 Front Drive Halfshafts 205 04 3 DESCRIPTION AND OPERATION E7823 EN 07 2001 2002 Bantam Exploded view of the front drive halfshaft...

Page 137: ...allow the boots to come into contact with sharp edges the engine when it is hot or the exhaust system 5 Do not drop the front axle drive halfshafts as this can cause interior damage to the boots whic...

Page 138: ...shaft Check and repair as necessary Worn or damaged wheel bear ing brakes suspension or steering components Check and repair as necessary Vibrations at high speeds Wheel imbalance Balance the wheels R...

Page 139: ...041 Remover drive halfshaft 308 256 16 089 General Equipment Two legged puller Material Specification Transmission fluid manual transmission SAE 75W90 Removal 1 NOTE Stop the piston rod from turning u...

Page 140: ...s The outer joint must not be bent at more than 45 degrees Unscrew and remove the axle stub nut and remove the washer Press the axle stub out of the wheel hub using a two legged puller and tie the hal...

Page 141: ...ust not be bent at more than 18 degrees The outer joint must not be bent at more than 45 degrees NOTE Make sure the snap ring snaps securely into place Install the front halfshaft in the transmission...

Page 142: ...front wheel For additional information refer to Section 204 03 6 Tighten the axle stub nut 7 NOTE Use an Allen key to stop the piston rod from turning Tighten the suspension strut top nut 8 Park the...

Page 143: ...er drive halfshaft 204 161 14 041 Boot clamp tightening tool 204 169 14 044 General Equipment Two legged puller Allen key Removal 1 NOTE Use an Allen key to stop the piston rod from turning Undo the s...

Page 144: ...joint must not be bent at more than 18 degrees The outer joint must not be bent at more than 45 degrees Unscrew and remove the axle stub nut and remove the washer Press the axle stub out of the wheel...

Page 145: ...the front halfshaft Install the front drive halfshaft into the tripod joint 2 NOTE Do not damage the boot Install the boot Slide the boot onto the halfshaft Install new clamping straps and secure the...

Page 146: ...EN 07 2001 2002 Bantam 5 Attach the lower suspension arms to the spindle carriers 6 Install the front wheel For additional information refer to Section 204 03 7 Tighten the axle stub nut 8 NOTE Use an...

Page 147: ...ng tool 204 169 14 044 General Equipment Snap ring pliers Clamping straps Material Specification High durability grease WSD M1C230 A Removal 1 NOTE Use an Allen key to stop the piston rod from turning...

Page 148: ...int must not be bent at more than 45 degrees Separate the tripod joint of the left hand halfshaft Remove the grease from inside the joint 6 Undo the boot clamps on the right hand halfshaft and slide t...

Page 149: ...tripod star Pull off the boot Installation 1 NOTE Chamfer points towards the front drive halfshaft Fit the tripod assembly Push on the boot Push on the tripod and secure it 2 CAUTION Support the halfs...

Page 150: ...clamping straps to 20 Nm Tighten the clamping strap using the special tool 5 CAUTION Support the halfshaft The inner joint must not be bent at more than 18 degrees The outer joint must not be bent at...

Page 151: ...8 REMOVAL AND INSTALLATION CONTINUED E6459 EN 07 2001 2002 Bantam 7 Attach the lower suspension arms to the spindle carriers 8 Lower the vehicle 9 NOTE Use an Allen key to stop the piston rod from tur...

Page 152: ...g tool 204 169 14 044 General Equipment Snap ring pliers Material Specification High durability grease WSD M1C230 A Clamping straps Removal 1 NOTE Use an Allen key to stop the piston rod from turning...

Page 153: ...and tie up the front drive halfshaft Remove the grease from inside the joint Open the snap ring using snap ring pliers and hold it open Remove the snap ring Installation 1 CAUTION Support the halfsha...

Page 154: ...t and secure it using new clamping straps Insert the clamp head in the special tool Apply the special tool so that the clamp head is vertical to the clamping strap head NOTE Tighten 0 8 mm thick clamp...

Page 155: ...erial Specification High durability grease WSD M2C230 A Boot clamps Removal 1 NOTE Use an Allen key to prevent the piston rod turning Loosen the left hand and the right hand strut and spring assembly...

Page 156: ...t more than 18 degrees the outer joint must not be bent at more than 45 degrees Remove the front drive halfshaft from the constant velocity joint 1 Lever open the retaining ring and hold it open 2 Car...

Page 157: ...ive halfshaft stub nut 2 CAUTION The inner constant velocity joint must not be bent at more than 18 degrees the outer joint must not be bent at more than 45 degrees NOTE Make sure the retaining ring i...

Page 158: ...en 0 8 mm thick boot clamps to 12 Nm and 1 1 mm thick boot clamps to 20 Nm Position the boot and using the special tool and adapter secure the boot clamps 6 Install the lower suspension arm and the fr...

Page 159: ...afts 205 04 26 REMOVAL AND INSTALLATION CONTINUED E6671 EN 07 2001 2002 Bantam 9 NOTE Use an Allen key to prevent the piston rod turning Tighten the left hand and the right hand side strut and spring...

Page 160: ...cation High durability grease WSD M1C230 A Clamping straps Disassembly NOTE Use protective covers 1 Disconnect the front drive halfshaft at the transmission end Clamp the front drive halfshaft in a cl...

Page 161: ...ach the front drive halfshaft from the halfshaft joint Open the circlip with circlip pliers and hold it Pull the front drive halfshaft from the halfshaft joint Remove the circlip from the halfshaft jo...

Page 162: ...ty grease and fit 1 Slide a small screwdriver under the boot seat to allow the air to escape 2 Slide the tripod joint inwards as far as the stop then pull it out 20 mm Remove the screwdriver 5 NOTE Ti...

Page 163: ...Pack the outer drive halfshaft joint with high durability grease and attach the boot Fill level for vehicles with Endura DE diesel engines 40 g each side Fill level for all other vehicles 30 g each s...

Page 164: ...g remover 15 092 Material Specification High durability grease WSD M1C230 A Disassembly 1 NOTE Use protective covers Loosen the clamping straps from the boot Detach the front drive halfshaft from the...

Page 165: ...the tripod assembly Remove the boot 5 CAUTION Do not damage the bearing cage Release the constant velocity joint at the wheel end 1 Separate and discard the clamping straps Push back the boot 2 Relea...

Page 166: ...D E1089 EN 07 2001 2002 Bantam 7 Press off the centre bearing Assembly 1 General note Renew all snap rings and clamping straps 2 Press on the centre bearing 3 Fit the boot at the transmission end 1 Sl...

Page 167: ...front drive halfshaft as far as it will go using a suitable tube 6 NOTE Use a new snap ring Assemble the tripod joint 1 Snap ring 2 Fit the constant velocity rollers applying high durability grease 7...

Page 168: ...tall the constant velocity joint at the wheel end 1 Slide on the boot with the inner clamping strap 2 Fit the snap ring 3 Fill the constant velocity joint with 80 grams of high durability grease and p...

Page 169: ...s Transmission fluid iB5 manual transmission 2 8 Fill Capacities Grams High durability grease tripod joint 125 High durability grease CV joints Endura DE engine 40 All other engines 30 Torque Specific...

Page 170: ...Tests 206 00 6 16 Symptom Chart 206 00 4 5 Component Tests 206 00 16 Brake System Check 206 00 17 Brake Booster Functional Test 206 00 17 18 GENERAL PROCEDURES Brake System Bleeding 12 141 0 206 00 19...

Page 171: ...low the brake shoes to wear at proportional rates The brakes self adjust during foot brake operation The parking brake control is located between the front seats and operates the rear brakes through a...

Page 172: ...because of the large amount of weight shifted to the low set of wheels on this type of road Once the route is established and consistently used the road surface variable can be eliminated from the tes...

Page 173: ...ke pads glazed lin ings INSTALL new brake shoes or brake pads Stuck or seized calipers GO to Pinpoint Test A Brake warning indicator always on Low brake fluid level FILL the reservoir CHECK the brake...

Page 174: ...ssive brake disc lateral run out or loose wheel bearings Install a new brake disc REFER to Section 206 03 REFER to Section 204 01 Worn brake shoes or brake pads INSTALL new brake shoes or brake pads G...

Page 175: ...e caliper slide pins GO to Pinpoint Test I ADJUST the brake light switch Excessive brake pedal effort Brake booster inoperative PERFORM a brake booster functional test Refer to the procedure in this s...

Page 176: ...RFORM A BRAKE MASTER CYLINDER BYPASS CONDITION CHECK 206 00 10 PINPOINT TEST E PEDAL EASES DOWN SLOWLY E1 CHECK BRAKE PEDAL OPERATION 206 00 10 E2 CHECK FOR BRAKE SYSTEM LEAKS 206 00 10 E3 PERFORM A B...

Page 177: ...RAKE BOOSTER CHECK VALVE VACUUM 206 00 15 J5 CHECK BRAKE BOOSTER 206 00 15 J6 CHECK BRAKE PEDAL LINKAGE 206 00 15 PINPOINT TEST K BRAKE NOISE K1 CHECK FOR PEDAL NOISE 206 00 15 K2 CHECK PUSH ROD ALIGN...

Page 178: ...ndition Yes GO TO A3 No INFLATE the tyres to the correct pressure INSTALL new tyres if excessively worn TEST the system for normal operation 206 00 6 Brake System General Information 206 00 6 DIAGNOSI...

Page 179: ...lied 1 2 Release the parking brake Check the fluid level in the reservoir is at the MAX mark Does the brake warning indicator illuminate Yes REFER to Section 413 01 No GO TO B2 B2 CHECK BRAKE SYSTEM F...

Page 180: ...LIED CONDITIONS DETAILS RESULTS ACTIONS C1 ROAD TEST THE VEHICLE 1 Road test the vehicle without applying the brakes at 40 80 km h Is a vibration present Yes REFER to Section 100 04 After servicing TE...

Page 181: ...apply the foot brake Was the brake pedal effort normal Yes Vehicle OK No GO TO D2 D2 CHECK BRAKE FLUID LEVEL 1 Check the brake master cylinder reservoir fluid level Is the fluid level acceptable Yes G...

Page 182: ...INSTALL a new brake master cylinder ADD fluid and BLEED the brake system REFER to Section 206 00 TEST the system for normal operation No System OK PINPOINT TEST E PEDAL EASES DOWN SLOWLY CONDITIONS DE...

Page 183: ...TEST F PEDAL IS LOW OR FEELS SPONGY CONDITIONS DETAILS RESULTS ACTIONS F1 ROAD TEST THE VEHICLE 1 Road test the vehicle and apply the foot brake Did the brake pedal feel spongy Yes GO TO F2 No Vehicle...

Page 184: ...ining nut loose Yes INSTALL a new front wheel hub retaining nut Do not reuse the front wheel hub retaining nut TEST the system for normal operation No CHECK the parking bake adjustment REFER to Sectio...

Page 185: ...under rough road conditions Apply the brakes slowly Is the pedal travel OK Yes Vehicle OK No GO TO H2 H2 CHECK WHEEL BEARING 1 Check for loose front wheel bearings Are the front wheel bearings loose...

Page 186: ...h the engine off apply and release the brake pedal five times to deplete all vacuum from the brake booster Apply the brake pedal hold with light pressure Start the engine Does the brake pedal hold Yes...

Page 187: ...heck the brake booster GO to the component test procedure in this section Is the brake booster OK Yes GO TO J6 No INSTALL a new brake booster TEST the system for normal operation J6 CHECK BRAKE PEDAL...

Page 188: ...tance The brake pedal should return to its original position Did the brake pedal return to its original position Yes Vehicle OK No GO TO L2 L2 CHECK FOR BRAKE PEDAL BINDING 1 Check the brake pedal for...

Page 189: ...ll tend to move downward under constant foot pressure If no motion is felt the vacuum booster system is not functioning 4 Remove the vacuum hose from the brake booster Manifold vacuum should be availa...

Page 190: ...m The rear brakes lock up during light pedal force This may be caused by incorrect tyre pressures grease or fluid on the brake shoes and linings damaged brake shoes and linings incorrectly adjusted pa...

Page 191: ...TION If brake fluid is spilt on the paintwork the affected area must be immediately washed down with cold wa ter NOTE Make sure that the vehicle is standing on a level surface NOTE The system consists...

Page 192: ...l the brake fluid reservoir 7 Continue operating the brake pedal until air free fluid is being pumped into the bleed jar 8 With the brake pedal fully depressed tighten the bleed nipple 9 CAUTION Make...

Page 193: ...ly drink water and induce vomiting Get medical attention immedi ately Failure to follow these instruc tions may result in personal injury CAUTION Make sure that the vehicle is standing on a level surf...

Page 194: ...Apply a small smear of grease to the axle end of the link rod and a liberal amount of grease to the other end Slide the link rod into the axle bracket bush 3 Slide the spacer tube assembly over the li...

Page 195: ...the measurement should be 10 to 12 mm if not adjust accordingly This measure ment is a datum to allow futures measurements Rotate the spacer tube B so that the distance between the end of the spacer...

Page 196: ...EN 07 2001 2002 Bantam Procedures B to be used when new rear springs are fitted 1 Follow sub operation 1 for new valve linkage or sub operation 2 for existing linkage of A above except that the settin...

Page 197: ...al information refer to Section 206 03 refer to Section 206 04 5 Reverse and install the wheel nuts to hold the brake disc in place 6 Install a Dial indicator gauge and holding fixture to the suspensi...

Page 198: ...be installed 9 Remove the brake disc For additional information refer to Section 206 03 refer to Section 206 04 10 NOTE Make sure the wheel hub face is clean and free of rust and foreign material Usi...

Page 199: ...mum brake disc run out installed 0 1 Maximum brake disc thickness variation 0 025 Brake caliper piston diameter 54 Minimum brake pad thickness 1 5 When the discard thickness has been reached install a...

Page 200: ...ESTING Drum Brake 206 02 3 REMOVAL AND INSTALLATION Brake Drum Replacement 12 275 0 206 02 4 5 Brake Shoes 12 285 0 206 02 6 10 Wheel Cylinder 12 305 0 206 02 11 12 Backing Plate 12 313 0 206 02 13 SP...

Page 201: ...206 02 2 Drum Brake 206 02 2 DESCRIPTION AND OPERATION E6593 EN 07 2001 2002 Bantam Drum Brake Item Description 1 Backing plate 2 Wheel cylinder Item Description 3 Brake shoes 4 Brake drum...

Page 202: ...206 02 3 Drum Brake 206 02 3 DIAGNOSIS AND TESTING E1097 EN 07 2001 2002 Bantam Drum Brake REFER to Section 206 00...

Page 203: ...r additional information refer to Section 206 02 2 Lower the parking brake control lever and loosen the adjustment nut 3 Loosen the wheel nuts 4 Raise and support the vehicle For additional informatio...

Page 204: ...drum Ensure the wheel bearing is not displaced from its housing Installation CAUTION Once tightened the hub retaining nut must not be disturbed If the torque setting requires to be checked the nut mus...

Page 205: ...spindle and wheel hub assembly For additional information refer to Brake Drum in this section 2 Remove the brake shoe hold down springs 3 Hold the wheel cylinder pistons in place with a rubber band 4...

Page 206: ...he cable from the secondary brake shoe 7 Remove the brake shoe return springs 1 Remove the lower spring 2 Remove the upper spring 8 Detach the primary brake shoe from the strut support 1 Pull the prim...

Page 207: ...s 2 Install the strut support to the secondary brake shoe 1 Install the spring 2 Rotate the brake shoe through 90 degrees into position 3 Install the primary brake shoe to the strut support 1 Position...

Page 208: ...ke cable 1 Connect the parking brake cable 2 Push the secondary brake shoe lever forwards 6 Remove the rubber band holding the wheel cylinder pistons in place 7 CAUTION Do not damage the wheel cylinde...

Page 209: ...ake 206 02 10 REMOVAL AND INSTALLATION CONTINUED 07 2001 2002 Bant am 10 Install the brake drum wheel spindle and wheel hub assembly 11 Adjust the parking brake cable For additional information refer...

Page 210: ...al 1 Remove the brake shoes For additional information refer to Brake Shoes in this section 2 Using a suitable brake hose clamp clamp the brake hose 3 Remove the wheel cylinder 1 Disconnect the brake...

Page 211: ...LLATION CONTINUED E1100 EN 07 2001 2002 Bantam 1 Install the wheel cylinder 1 Install the wheel cylinder bolts 2 Install the brake hose union 2 Remove the brake hose clamp 3 Bleed the brake system For...

Page 212: ...or additional information refer to Brake Shoes in this section 2 Remove the wheel cylinder For additional information refer to Wheel Cylinder in this section 3 Detach the parking brake cable 1 Depress...

Page 213: ...Wheel cylinder bore diameter 17 78 New primary brake shoe lining thickness 6 New secondary brake shoe lining thickness 3 1 Minimum brake shoe lining thickness 1 0 When the discard brake drum diameter...

Page 214: ...06 03 2 DIAGNOSIS AND TESTING Front Brake Disc 206 03 3 REMOVAL AND INSTALLATION Brake Pads 206 03 4 6 Brake Caliper 12 243 0 206 03 7 8 DISASSEMBLY AND ASSEMBLY Brake Caliper 206 03 9 10 SPECIFICATIO...

Page 215: ...rake 206 03 2 DESCRIPTION AND OPERATION E9360 EN 03 2001 2002 Bantam Front Brake Disc Item Description 1 Brake disc 2 Brake pad Item Description 3 Brake caliper retaining clip 4 Brake caliper 5 Brake...

Page 216: ...206 03 3 Front Disc Brake 206 03 3 DIAGNOSIS AND TESTING E490 EN 03 2001 2002 Bantam Front Brake Disc REFER to Section 206 00...

Page 217: ...Removal CAUTION If brake fluid is spilt on the paintwork the affected area must be immediately washed down with cold wa ter 1 Remove the wheel and tyre For additional information refer to Section 204...

Page 218: ...allation CAUTION When the brake caliper pis tons are retracted into the piston hous ing brake fluid will be displaced into the brake fluid reservoir 1 Using the special tool retract the brake caliper...

Page 219: ...ake caliper to the anchor plate 1 Install the bolts 2 Install the covers 4 Install the brake caliper retaining clip 5 Install the wheel and tyre For additional information refer to Section 204 03 6 De...

Page 220: ...f brake fluid is spilt on the paintwork the affected area must be immediately washed down with cold wa ter 1 Remove the wheel and tyre For additional information refer to Section 204 03 2 Loosen the f...

Page 221: ...ose to prevent fluid loss or dirt ingress Detach the brake caliper and anchor plate assembly from the flexible brake hose Turn the caliper and anchor plate assembly counter clockwise to remove Install...

Page 222: ...ke caliper dust seal Discard the seal 2 Place a suitable block of wood between the body of the brake caliper and the brake caliper piston 3 WARNING Use only as much compressed air as is necessary to r...

Page 223: ...aliper piston if rust pitting or scores are evi dent Failure to follow these instructions may result in personal injury WARNING Install a new brake caliper if rust pitting or scores are evident in the...

Page 224: ...al thickness 20 Worn brake disc discard thickness 18 Maximum brake disc run out installed 0 1 Maximum brake disc thickness variation 0 025 Brake caliper piston diameter 54 Minimum brake pad thickness...

Page 225: ...206 04 1 Wheels and Tyres 206 04 1 07 2001 2002 Bantam SECTION 206 04 Wheels and Tyres VEHICLE APPLICATION 2002 Bantam REMOVAL AND INSTALLATION Wheel and Tyre 206 04 2 SUBJECT PAGE...

Page 226: ...ction 100 02 3 Remove the wheel and tyre assembly Installation 1 WARNING Remove the corrosion or dirt from the mounting surfaces of the wheel wheel hub brake drum or brake disc as this may cause the w...

Page 227: ...rking Brake 206 05 3 Inspection and Verification 206 05 3 Symptom Chart 206 05 3 5 REMOVAL AND INSTALLATION Parking Brake Control 12 664 0 206 05 6 7 Parking Brake Cable and Conduit 12 675 0 206 05 8...

Page 228: ...5844 EN 07 2001 2002 Bantam Parking Brake Item Description 1 Adjusting nut 2 Bolt 3 Parking brake lever 4 Parking brake switch coupler 5 Grip Item Description 6 Push button 7 Return spring 8 Equaliser...

Page 229: ...ymptom and refer to the Symptom Chart Symptom Chart Symptom Chart Condition Possible Sources Action The parking brake will not apply Parking brake control Parking brake cable GO to Pinpoint Test A The...

Page 230: ...WILL NOT RELEASE CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK PARKING BRAKE CABLES 1 Loosen the parking brake cable tension Rotate the rear wheels by hand Did the rear wheel turn freely Yes INSTALL a n...

Page 231: ...cable REFER to Parking Brake Cable in this section TEST the system for normal operation No GO TO B4 B4 CHECK REAR PARKING BRAKE CABLES 1 Disconnect the rear parking brake cable at the rear brakes one...

Page 232: ...0 EN 07 2001 2002 Bantam Parking Brake Control 12 664 0 Removal 1 Remove the parking brake control cover trim 2 Lower the parking brake control lever 3 Remove the adjusting nut 4 Remove the parking br...

Page 233: ...move the parking brake control 1 Disconnect the parking brake warning indicator switch electrical connector 2 Remove the parking brake control Installation 1 To install reverse the removal procedure 2...

Page 234: ...trim 2 Lower the parking brake control lever and loosen the adjusting nut 3 Loosen the rear wheel nuts 4 Raise and support the vehicle For additional information refer to Section 100 02 5 Remove the...

Page 235: ...parking brake cable 9 Detach the rear parking brake cable 10 Detach the parking brake cable from the rear axle both sides 11 Remove the brake drum For additional information refer to Section 206 02 12...

Page 236: ...06 05 10 REMOVAL AND INSTALLATION CONTINUED E6602 EN 07 2001 2002 Bantam Installation 1 To install reverse the removal procedure 2 Adjust the parking brake For additional information refer to Parking...

Page 237: ...N E1113 EN 07 2001 2002 Bantam Parking Brake Warning Indicator Switch 33 546 0 Removal 1 Remove the parking brake control For additional information refer to Parking Brake Control in this section 2 Re...

Page 238: ...parking brake control cover trim 2 Lower the parking brake control lever 3 Loosen the adjusting nut 4 Depress the foot brake six times 5 Adjust the parking brake cable 1 Raise the parking brake contr...

Page 239: ...05 13 Parking Brake and Actuation 206 05 13 SPECIFICATIONS E1115 EN 07 2001 2002 Bantam Torque Specifications Description Nm Parking brake cable adjusting nut 4 Parking brake control nuts 24 Wheel nut...

Page 240: ...AND TESTING Hydraulic Brake Actuation 206 06 3 REMOVAL AND INSTALLATION Brake Master Cylinder 12 343 0 206 06 4 5 Brake Pedal 12 133 0 206 06 6 7 Brake Fluid Reservoir 12 341 0 206 06 8 9 Brake Pedal...

Page 241: ...ke Actuation 206 06 2 DESCRIPTION AND OPERATION E9397 EN 03 2001 2002 Bantam Hydraulic Brake Actuation Item Description 1 Brake pedal 2 Brake master cylinder and fluid reser voir Item Description 3 Br...

Page 242: ...206 06 3 Hydraulic Brake Actuation 206 06 3 DIAGNOSIS AND TESTING E1117 EN 03 2001 2002 Bantam Hydraulic Brake Actuation REFER to Section 206 00...

Page 243: ...rical connector 2 Remove the cap 2 NOTE It will be necessary to carry out this step on both sides in order to completely drain the brake fluid reservoir Drain the brake fluid reservoir 1 Connect one e...

Page 244: ...ake fluid reservoir assembly 1 Remove the nuts 2 Remove the brake master cylinder Installation CAUTION Make sure the brake booster actuator rod is correctly positioned be fore installation CAUTION Mak...

Page 245: ...n 414 01 2 Remove the stop lamp switch 3 Disengage the clutch pedal return spring 4 Remove the brake pedal 1 Remove the brake pedal cross shaft retaining clip clutch side 2 Push the brake pedal cross...

Page 246: ...1 NOTE When Installing the brake pedal make sure the brake booster actuator rod locates correctly into the brake pedal NOTE As the brake pedal cross shaft has to be disturbed adjustment of the clutch...

Page 247: ...ake fluid reservoir cap 3 NOTE It will be necessary to carry out this step on both sides in order to completely drain the brake fluid reservoir Drain the brake fluid reservoir 1 Connect one end of a s...

Page 248: ...AL AND INSTALLATION CONTINUED E9399 EN 03 2001 2002 Bantam 5 Remove the brake fluid reservoir Detach the securing pin Installation 1 To install reverse the removal procedure 2 Bleed the brake system F...

Page 249: ...Shaft 12 338 0 Removal 1 Remove the brake booster For additional information refer to Section 206 07 2 Disconnect the accelerator cable from the accelerator pedal 3 Remove the accelerator pedal 1 Remo...

Page 250: ...racket from the bulkhead 6 Detach the brake pedal cross shaft mounting bracket from the bulkhead 1 Pull the bracket from the bulkhead 2 Move the brake pedal cross shaft to the left 7 Disconnect the co...

Page 251: ...06 12 REMOVAL AND INSTALLATION CONTINUED E9400 EN 03 2001 2002 Bantam 9 Remove the brake pedal cross shaft from the brake booster support bracket 10 Remove the brake pedal cross shaft Installation 1 T...

Page 252: ...et Removal 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Disconnect the brake pedal position BPP switch and clutch on off switch electrical connectors from...

Page 253: ...ve the clip 2 Remove the pedal 6 Detach the brake pedal cross shaft actuating rod from the brake pedal Remove the clip 7 Detach the clutch master cylinder from the brake pedal and bracket 8 Detach the...

Page 254: ...6 06 15 Hydraulic Brake Actuation 206 06 15 REMOVAL AND INSTALLATION CONTINUED E9362 EN 03 2001 2002 Bantam 10 Remove the brake pedal and bracket Installation 1 To install reverse the removal procedur...

Page 255: ...001 2002 Bantam Lubricants Fluids Sealers and Adhesives Item Specification DOT 4 brake fluid SAM 6C9103 A Torque Specifications Description Nm Brake master cylinder brake tube unions 13 Brake master c...

Page 256: ...e Actuation VEHICLE APPLICATION 2002 Bantam DESCRIPTION AND OPERATION Brake Booster 206 07 2 DIAGNOSIS AND TESTING Power Brake System 206 07 3 REMOVAL AND INSTALLATION Brake Booster 12 451 0 206 07 4...

Page 257: ...206 07 2 Power Brake Actuation 206 07 2 DESCRIPTION AND OPERATION E1125 EN 07 2001 2002 Bantam Brake Booster Item Description 1 Brake booster...

Page 258: ...206 07 3 Power Brake Actuation 206 07 3 DIAGNOSIS AND TESTING E1126 EN 07 2001 2002 Bantam Power Brake System REFER to Section 206 00...

Page 259: ...information refer to Section 414 01 2 Remove the brake master cylinder For additional information refer to Section 206 06 3 Disconnect the vacuum hose from the brake booster 4 Detach the brake booste...

Page 260: ...206 07 5 Power Brake Actuation 206 07 5 REMOVAL AND INSTALLATION CONTINUED E9401 EN 07 2001 2002 Bantam Installation 1 To install reverse the removal procedure...

Page 261: ...206 07 6 Power Brake Actuation 206 07 6 SPECIFICATIONS E1128 EN 07 2001 2002 Bantam Torque Specifications Description Nm Brake booster retaining nuts 25 Brake master cylinder retaining nuts 25...

Page 262: ...2 Inspection and Verification 211 00 2 Symptom Chart 211 00 2 4 Component Tests 211 00 4 GENERAL PROCEDURES Power Steering System Filling 13 416 1 211 00 5 Power Steering System Bleeding 13 416 1 211...

Page 263: ...ectrical Tyre pressure Accessory drive belt Wheels and tyres Power steering line fluid leaks Power steering pressure PSP switch Fuse s Electrical connector s 3 If an obvious cause for an observed or r...

Page 264: ...pump pulleys for damage INSTALL new compo nents as necessary en Knock type noise Suspension components CHECK the suspension system REFER to Section 204 00 Steering linkage CHECK the steering linkage c...

Page 265: ...stated in the specifications If free play exceeds the limit stated the steering linkage or the steering column is worn or the backlash of the steering gear is excessive 3 If the steering linkage is w...

Page 266: ...r to use The fluid should be poured slowly into the reservoir to minimize the possibility of aeration The fluid level should be checked with the fluid cold Fill the reservoir to the MAX mark 2 Using t...

Page 267: ...e fluid should be poured slowly into the reservoir to minimize the possibility of aeration The fluid level should be checked with the fluid cold Fill the reservoir to the MAX mark 2 NOTE Make sure tha...

Page 268: ...ht just off the stop Switch OFF the engine and using the hand vacuum pressure pump apply a vacuum of 51 kPa 15 in Hg Maintain the vacuum until the air is evacuated from the system minimum of five minu...

Page 269: ...g 2 Slide the special tool along the pipe to release the locking tangs Allow the fluid to drain into a suitable container 3 Attach a tube of suitable length to the fluid return line 1 Using a suitable...

Page 270: ...tion The fluid level should be checked with the fluid cold Fill the power steering fluid reservoir to the MAX mark with power steering fluid 8 CAUTION Do not continuously crank the engine for more tha...

Page 271: ...700 06 for schematic and electrical information All vehicles 13 Lower the vehicle Vehicles with diesel engine 14 Connect the fuel injection pump electrical connector 1 Connect the electrical connecto...

Page 272: ...ould be checked with the fluid cold Fill the power steering fluid reservoir to the MAX mark with power steering fluid All except vehicles with diesel engine 2 Raise and support the vehicle For additio...

Page 273: ...result CAUTION Do not hold the steering wheel against the full lock stops for more than five seconds as damage to the steering pump may result While cranking the engine for no more than 30 seconds tur...

Page 274: ...ump electrical connector 1 Connect the electrical connector 2 Push in the locking handle All vehicles 11 Start the engine Turn the steering wheel from lock to lock if excessive noise is apparent bleed...

Page 275: ...to transmission retaining bolt 50 Track rod end locknuts 37 Wheel nuts 85 Flexible coupling to steering column shaft pinch bolt 22 Flexible coupling to pinion shaft pinch bolt 28 Track rod locknuts 63...

Page 276: ...TION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Manual Steering 211 01 16 DIAGNOSIS AND TESTING Manual Steering 211 01 17 REMOVAL AND INSTALLATION Steering Gear 13 116 0 211 01 18 23 SPECIFICA...

Page 277: ...bolt cage and aligner assembly The flexible coupling in turn is attached to the steering gear pinion shaft with a pinch bolt A floor seal protects the flexible coupling s entry into the engine compar...

Page 278: ...211 01 17 Manual Steering 211 01 17 DIAGNOSIS AND TESTING Manual Steering REFER to Section 211 00 E5854 EN 07 2001 2002 Bantam...

Page 279: ...1 Disconnect the battery ground cable 2 From inside the passenger compartment remove the flexible coupling to pinion shaft pinch bolt 3 From inside the passenger compartment slacken the flexible coupl...

Page 280: ...ocknuts 6 NOTE When the track rod ends are separated from the spindle carriers the ball joint seals should be wrapped in a cloth to protect them Disconnect the track rod end ball joints from the spind...

Page 281: ...crossmember assembly 11 Remove the crossmember assembly retaining bolts 12 Lower the crossmember assembly to gain access to the steering gear retaining nuts and bolts 13 Remove the pinion shaft body s...

Page 282: ...nual Steering 211 01 21 REMOVAL AND INSTALLATION CONTINUED 15 Remove the steering gear Installation 1 Install the steering gear 2 Install the crossmember 3 Install the roll restrictor E5855 EN 07 2001...

Page 283: ...NTINUED Vehicles with manual transaxle 4 Install the gearshift linkage 5 Install the tie rods 6 Install the wheels 7 CAUTION Make sure that the steering is in the straight ahead position Install the u...

Page 284: ...211 01 23 Manual Steering 211 01 23 REMOVAL AND INSTALLATION CONTINUED 8 Install the lower steering coupling pinch bolt E5855 EN 07 2001 2002 Bantam...

Page 285: ...ning bolts 103 Roll restrictor to transmission retaining bolt 50 Track rod end to spindle carrier locknuts 37 Flexible coupling to steering column shaft pinch bolt 22 Flexible coupling to pinion shaft...

Page 286: ...es with 1 3l petrol engine 13 434 0 211 02 34 37 Power Steering Pump Vehicles with 1 6l petrol engine 13 434 0 211 02 38 45 Power Steering Gear 13 116 0 211 02 46 54 Steering Gear Pinion Oil Seal 13 4...

Page 287: ...eering pump 3 Power steering pressure switch PSP 4 Steering wheel 5 Power steering fluid cooler 6 Tie rod Item Description Steering gear 8 Tie rod end 9 Steering gear boot 10 Steering column coupling...

Page 288: ...ory drive belt and has a remote fluid reservoir located on the right hand side of the engine compartment The power steering pump cannot be disassembled Install a new unit A power steering pressure PSP...

Page 289: ...electo hydrulic power steering pump The electro hydraulic power steering pump consists of an electro hydraulic motor and reservoir and is located in the engine compartment on the left hand side The fu...

Page 290: ...211 02 29 Power Steering 211 02 29 DIAGNOSIS AND TESTING Power Steering REFER to Section 211 00 E1209 EN 07 2001 2002 Bantam...

Page 291: ...er steering pump pulley 13 022 Special Tool s Installer camshaft pulley 21 192 Removal 1 Disconnect the battery ground cable 2 Raise the vehicle 3 Remove the power steering pump cover Remove the tie s...

Page 292: ...211 02 31 Power Steering 211 02 31 REMOVAL AND INSTALLATION CONTINUED 6 Remove the cable tie E6317 EN 07 2001 2002 Bantam...

Page 293: ...ble container 8 Disconnect the power steering pump ground cable 9 Remove the power steering pump mounting bracket upper bolts 10 Remove the power steering pump and mounting bracket 1 Remove the bolts...

Page 294: ...TINUED Installation 1 CAUTION Install a new O ring seal on the power steering high pressure line 2 Refit the components in the reverse order 3 Fill and bleed the power steering system For additional i...

Page 295: ...hicle For additional information refer to Section 100 02 2 Detach the accessory drive belt from the power steering pump pulley Rotate the accessory drive belt tensioner clockwise 3 CAUTION To prevent...

Page 296: ...isconnect the power steering high pressure line 1 Disconnect the power steering high pressure line from the power steering pump 2 Remove the power steering pump and power steering high pressure line s...

Page 297: ...p pulley Using the special tool install the power steering pump pulley 2 Install the power steering pump 3 Connect the power steering high pressure line 1 Connect the power steering high pressure line...

Page 298: ...100 02 6 Attach the accessory drive belt to the power steering pump pulley Rotate the accessory drive belt tensioner clockwise 7 Connect the power steering fluid cooler lines to the power steering fl...

Page 299: ...2 Special Tool s Installer Camshaft Pulley 303 458 21 192 Removal 1 Remove the auxiliary drive belt For additional information refer to Section 303 05 2 NOTE When installing a new power steering pump...

Page 300: ...ainer 5 Remove the power steering pump Installation 1 NOTE If installing a new power steering pump the unions that are supplied fitted to the pump should be removed and discarded Install a new union O...

Page 301: ...power steering pump drive pulley is installed CAUTION Make sure the pulley is flush with the end of the power steering pump shaft Using the special tool install a new power steering pump drive pulley...

Page 302: ...ive belt 1 Slacken the drive belt tensioner pulley centre bolt 2 Slacken the adjusting bolt 3 Remove the drive belt 7 Remove the power steering pump pulley Hold the centre of the pump shaft with an Al...

Page 303: ...tainer 12 Remove the power steering pump Installation 1 Note If the power steering pump is being renewed the unions that are supplied fitted to the pump should be removed and retained for future use 1...

Page 304: ...211 02 43 Power Steering 211 02 43 REMOVAL AND INSTALLATION CONTINUED Note Install the pump front retaining bolts first 2 Refit the components in reverse order E6318 EN 07 2001 2002 Bantam...

Page 305: ...211 02 44 Power Steering 211 02 44 REMOVAL AND INSTALLATION CONTINUED E6318 EN 07 2001 2002 Bantam...

Page 306: ...g Installation 1 Install the power steering pump drive belt 1 Slacken the drive belt tensioner pulley centre bolt 2 Install the drive belt 3 Tension the drive belt with the adjusting bolts Finger defl...

Page 307: ...s Guide pins subframe 15 097A Removal 1 Disconnect the battery ground cable 2 From inside the passenger compartment remove the flexible coupling to pinion shaft pinch bolt 3 From inside the passenger...

Page 308: ...cknuts 6 NOTE When the track rod ends are separated from the spindle carriers the ball joint seals should be wrapped in cloth to protect them Disconnect the track rod end ball joints from the spindle...

Page 309: ...shroud assembly Do not damage the radiator matrix Remove the cooling fan and shroud assembly 1 Disconnect the cooling fan motor and speed control assembly multiplug 2 Ease the fan and shroud assembly...

Page 310: ...ot overstress or damage any pipes or cables Tilt the engine forwards 14 Detach the power steering pipes from the retaining bracket 15 Disconnect the fluid cooler to steering gear pipes 16 Support the...

Page 311: ...the pinion shaft body seal 20 Remove the steering gear retaining nuts and bolts 21 CAUTION There is a very limited amount of space in which to remove the steering gear Do not overstress or damage the...

Page 312: ...steering gear is being renewed the unions that are supplied fitted to the steering gear should be removed and retained for future use Renew the union sealing rings 1 Push the sealing ring onto the to...

Page 313: ...ember 1 Push the guide pins through the crossmember aligning holes 2 Slide the locking plates into the locking grooves and tighten the guide pin sleeves 4 Raise the crossmember engaging the guide pins...

Page 314: ...er Steering 211 02 53 REMOVAL AND INSTALLATION CONTINUED Vehicles with manual transaxle 6 Install the gearshift linkage For additional information refer to Section 308 06 All vehicles E6320 EN 07 2001...

Page 315: ...ng 211 02 54 REMOVAL AND INSTALLATION CONTINUED 7 CAUTION Make sure the steering is in the straight ahead position 8 Bleed the power steering system refer to procedure contained in this section E6320...

Page 316: ...ification Grease power steering gear ESA MIC45 A Removal 1 Remove the steering gear refer to procedure contained in this section 2 Remove the water splash shield from the pinion shaft 3 CAUTION Make s...

Page 317: ...he circlip 6 CAUTION Make sure the pinion bearing underneath the seal is not damaged by the punch CAUTION Make sure no particles of the seal enter the steering gear Drive a hole into the oil seal stee...

Page 318: ...using and pinion shaft are thoroughly cleaned with lint free paper Examine the pinion shaft for signs of pitting scoring wear or corrosion Install a new seal 2 NOTE Make sure the circlip is correctly...

Page 319: ...he lower radiator shield five screws 3 Remove the lower engine compartment shield 10 screws 4 Disconnect the fluid cooler pipe and hose connections 1 Disconnect the right hand side pipe union and hose...

Page 320: ...CONTINUED 5 Remove the high pressure pipe bracket one bolt 6 Remove the fluid cooler two bolts Installation 1 Refit the components in the reverse order 2 Bleed the power steering system refer to proce...

Page 321: ...097 A Special Tool s Expander Teflon Seal 211 188 13 015 General Equipment Transmission jack Removal All Vehicles 1 Remove the steering column coupling to steering gear pinion shaft pinch bolt 2 Loos...

Page 322: ...Support the flexible pipe with a support wrap or suitable splint assembly Vehicles with manual transaxle 9 Detach the shift rod and gearshift stabilizer 1 Shift rod 2 Gearshift stabilizer All Vehicle...

Page 323: ...he steering gear floor seal Vehicles with 1 6L 1 3L engine 17 Remove the PSP switch 1 Disconnect the electrical connector 2 Remove the PSP switch 18 Disconnect the power steering pump high pressure li...

Page 324: ...ehicles with diesel engine 21 Disconnect the power steering pump high pressure line 1 Detach the power steering line high pressure line support bracket 2 Disconnect the power steering high pressure li...

Page 325: ...power steering high pressure line support bracket Vehicles with 1 6L 1 3L engine 24 Detach the power steering high pressure line support bracket All Vehicles 25 Remove the power steering high pressur...

Page 326: ...ol install a new O ring seal 1 Push the new O ring seal onto the special tool 2 Locate the special tool onto the union and push on the O ring seal 2 Install the power steering high pressure line Vehic...

Page 327: ...the power steering high pressure line support brackets Vehicles with diesel engine 6 Install the power steering pump high pressure line 1 Connect the power steering pump high pressure line 2 Install...

Page 328: ...e power steering high pressure line to the power steering pump 1 Install the power steering pump high pressure line 2 Install the power steering pump high pressure line support brackets 10 Install the...

Page 329: ...2 Slide the locking plate into the grooves and tighten the alignment pin sleeves 3 Raise the crossmember engaging the guide pins into the chassis aligning holes 13 Install the crossmember retaining b...

Page 330: ...nd gearshift stabilizer 1 Connect the gearshift stabilizer 2 Connect the shift rod 21 NOTE Before lowering the vehicle make sure the steering is in the straight ahead position Lower the vehicle 25 Ins...

Page 331: ...s Alignment Pins Subframe 205 316 15 097A Special Tool s Expander Teflon Seal 211 188 13 015 General Equipment Transmission jack Removal All Vehicles 1 Remove the steering column coupling to steering...

Page 332: ...accessory drive belt lower guard Detach the clips Vehicles with 1 6L 1 3L engine 5 Disconnect the power steering fluid cooler line to the power steering gear Allow the fluid to drain into a suitable...

Page 333: ...a suitable container 8 CAUTION Over bending or twisting of the flexible pipe may cause damage resulting in failure Support the flexible pipe with a support wrap or suitable splint assembly 9 Disconnec...

Page 334: ...3 Remove the rear support insulator to transmission bolt 15 Using a suitable Transmission jack support the crossmember 16 NOTE Lower the crossmember to gain access to the power steering gear Remove th...

Page 335: ...low the fluid to drain into a suitable container Installation All Vehicles 1 Using the special tool install a new O ring seal 1 Push the new O ring seal onto the special tool 2 Locate the special tool...

Page 336: ...onnect the power steering fluid cooler line 4 Connect the power steering fluid cooler line to the power steering gear support bracket All Vehicles 5 Connect the power steering fluid cooler to the powe...

Page 337: ...es into the grooves and tighten the alignment pin sleeves 3 Raise the crossmember engaging the guide pins into the chassis aligning holes 8 Install the crossmember retaining bolts 9 Install the rear s...

Page 338: ...t rod and gearshift stabilizer 1 Connect the gearshift stabilizer 2 Connect the shift rod All Vehicles 16 Install the power steering fluid cooler to power steering gear return line to the accessory dr...

Page 339: ...NTINUED 19 Install the steering column coupling to the power steering gear pinion 20 Tighten the steering column shaft coupling pinch bolt 21 Fill and bleed the power steering system For additional in...

Page 340: ...el nuts 85 Flexible coupling to steering column shaft pinch bolt 22 Flexible coupling to pinion shaft pinch bolt 28 Tie rod rod locknuts 63 Power steering pump retaining bolts 24 Power steering pump p...

Page 341: ...UBJECT PAGE DESCRIPTION AND OPERATION Steering Linkage 211 03 81 DIAGNOSIS AND TESTING Steering Linkage 211 03 82 REMOVAL AND INSTALLATION Tie Rod End 13 273 0 211 03 83 84 Steering Gear Boot 13 134 0...

Page 342: ...gear movement is transferred to the wheels by means of Tie rods Tie rod ends Wheel knuckles The tie rod end is secured to the tie rod with a lock nut The tie rod entry into the steering gear is prote...

Page 343: ...211 03 82 Steering Linkage 211 03 82 DIAGNOSIS AND TESTING Steering Linkage REFER to Section 211 00 E1217 EN 07 2001 2002 Bantam...

Page 344: ...cle For additional information refer to Section 100 02 3 Remove the front road wheel 4 Loosen the tie rod end nuts 1 Loosen the lock nut 2 Loosen the retaining nut 5 CAUTION When the tie rod end is se...

Page 345: ...ke sure the tie rod end is screwed on by the same number of turns as was required to remove it If the number of turns is not known install the tie rod end so that the visible screw threads on the tie...

Page 346: ...e procedure in this section 2 Remove the steering gear boot retaining clips 3 CAUTION Make sure the tie rod is clean before removing the steering gear boot Remove the steering gear boot 1 Disconnect t...

Page 347: ...211 03 86 Steering Linkage 211 03 86 SPECIFICATIONS Torque Specifications Description Nm Tie rod end retaining nut 37 Tie rod end lock nut 63 Wheels nuts 85 E1220 EN 07 2001 2002 Bantam...

Page 348: ...SUBJECT PAGE DESCRIPTION AND OPERATION Steering Column 211 04 88 REMOVAL AND INSTALLATION Steering Wheel 13 524 0 211 04 89 Air Bag Sliding Contact 33 392 0 211 04 90 Steering Column 13 542 0 211 04...

Page 349: ...211 04 88 Steering Column 211 04 88 DESCRIPTION AND OPERATION Steering Column Item Description 1 Steering wheel 2 Steering column Item Description 3 Flexible coupling E1221 EN 07 2001 2002 Bantam...

Page 350: ...when removed Remove the steering wheel 1 Disconnect the air bag sliding contact electrical connector 2 Remove the steering wheel retaining bolt 4 Remove the air bag sliding contact For additional inf...

Page 351: ...211 04 90 Steering Column 211 04 90 REMOVAL AND INSTALLATION Air Bag Sliding Contact 33 392 0 For additional information refer to Section 501 20B E1224 EN 07 2001 2002 Bantam...

Page 352: ...lity of accidentally deploying the air bag s and pyrotechnic safety belt pre tensioner s 1 Remove the multi function switch For additional information refer to Section 211 05 2 Centre the steering whe...

Page 353: ...connector 6 Detach the wiring harness electrical connectors from the steering column bracket 7 Disconnect the hood latch remote control cable 8 From inside the passenger compartment disconnect the fle...

Page 354: ...VAL AND INSTALLATION CONTINUED 9 Remove the steering column Remove the two retaining nuts Installation 1 CAUTION Make sure the steering is in the straight ahead position To install reverse the removal...

Page 355: ...lumn 211 04 94 SPECIFICATIONS Torque Specifications Description Nm Steering wheel retaining bolt 45 Steering column retaining nuts 23 Steering column coupling to steering column pinch bolt 22 E1225 EN...

Page 356: ...Switches 211 05 96 Multi function Switch 211 05 96 97 Ignition Switch 211 05 97 DIAGNOSIS AND TESTING Steering Column Switches 211 05 98A Inspection and Verification 211 05 98A Symptom Chart 211 05 9...

Page 357: ...ion switch Multi function Switch The multi function switch located on the left hand side of the steering column controls the following Exterior lights Direction indicator lamps Headlamp high beam Head...

Page 358: ...es independently from the ignition switch The direction indicator system is deactivated when the hazard flasher system is in operation Ignition Switch The ignition switch is mounted on the steering co...

Page 359: ...n remains proceed to the Symptom Chart 4 Additional information on connectors is available Refer to the relevant wiring diagrams Symptom Chart Symptom Chart Condition Possible Sources Action The ignit...

Page 360: ...CK FOR OPEN ON CIRCUITS 15 GN AND 15 GN BU 211 05 102 C5 CHECK THE IGNITION RELAY GROUND 211 05 102 C6 CHECK THE IGNITION RELAY POWER FEED 211 05 102 103 C7 CHECK FOR OPEN ON CIRCUIT 15 GN 211 05 103...

Page 361: ...CH CONNECTOR 1 Remove the steering column shrouds and check the ignition switch connector Is the ignition switch connector clean and secure Yes GO TO A2 No CLEAN and SECURE the ignition switch connect...

Page 362: ...he system for normal operation If the fuse fails again GO TO A3 A3 CHECK CIRCUIT 30 RD FOR SHORT TO GROUND 1 Fuse 40 60A 2 Measure the resistance between the fuse 40 connector pin 1 circuit 30 RD and...

Page 363: ...witch TEST the system for normal operation PINPOINT TEST B NO POWER IN ACC CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK FOR OPEN SHORT TO GROUND ON CIRCUIT 75 YE 1 Ignition switch connector C61 2 Fuse...

Page 364: ...SHORT TO GROUND ON CIRCUIT 30 RD 1 Fuse 38 60A 2 Ignition relay C47 3 Measure the resistance between the fuse 38 connector pin 1 circuit 30 RD and ground Is the resistance greater than 10 000 ohms Ye...

Page 365: ...voltage greater than 10 volts Yes GO TO C5 No Repair circuit 15 GN or 15 GN BU TEST the system for normal operation C5 CHECK THE IGNITION RELAY GROUND 1 Interior light relay 2 Ignition switch 3 Measu...

Page 366: ...system for normal operation C7 CHECK FOR OPEN ON CIRCUIT 15 GN 1 Fuse 17 15A 2 Measure the resistance between ignition relay C47 pin 5 circuit 15 GN and supply side of Fuse F17 15A Is the resistance...

Page 367: ...sistance between the fuse 36 60A connector pin 1 circuit 30 RD and ground Is the resistance greater than 10 000 ohms Yes GO TO D1 No REPAIR circuit 30 RD TEST the system for normal operation D3 CHECK...

Page 368: ...in 3 circuit 50 GY and pin 2 circuit 50 GY less than 5 ohms Yes GO TO D5 No REPAIR circuit 50 GY TEST the system for normal operation D5 CHECK THE START INHIBIT RELAY GROUND 1 Measure the resistance b...

Page 369: ...normal operation No REPAIR circuit 50 GY BK TEST the sys tem for normal operation PINPOINT TEST E THE MULTIFUNCTION SWITCH HAZARD WARNING SWITCH DOES NOT OPERATE CORRECTLY CONDITIONS DETAILS RESULTS...

Page 370: ...ry ground cable For additional information refer to Section 414 01 2 Remove the steering column upper and lower shrouds 3 Remove the multifunction switch 1 Disconnect the multi function switch electri...

Page 371: ...moval 1 Disconnect the battery ground cable 2 Remove the steering column upper and lower shrouds 3 Disconnect the ignition switch electrical connector 4 Remove the ignition switch Release the switch r...

Page 372: ...08 06 Exhaust System Exhaust System General Information 309 00 Fuel System Fuel System General Information 310 00 Acceleration Control 310 02 Clutch 308 01 SECTION TITLE PAGE Engine 1 6 1 3 RoCam 303...

Page 373: ...End Play 303 00 6 Camshaft Lobe Surface 303 00 7 Camshaft Lobe Lift 303 00 8 Crankshaft End Play 303 00 9 Crankshaft Main Bearing Journal Diameter 303 00 10 Crankshaft Main bearing Journal Clearance...

Page 374: ...303 00 2 Engine System General Information 303 00 2 DIAGNOSIS AND TESTING E6626 EN 07 2001 2002 Bantam Engine Inspection and Verification Symptom Chart Pinpoint Tests Component Tests...

Page 375: ...aring Inspection 1 Inspect bearings for the following defects 1 Cratering fatigue failure 2 Spot polishing incorrect seating 3 Imbedded dirt engine oil 4 Scratching dirty engine oil 5 Base exposed poo...

Page 376: ...er 1 Determine the diameter of the camshaft journals Using a micrometer measure the diameter at 90 degrees intervals to determine if the journals are out of round Measure at two different points on th...

Page 377: ...n a length of plastigage on the bearing cap Insert the camshaft without lubrication into the cylinder head Position a plastigage strip which should be equal to the width of the bearing cap on the bear...

Page 378: ...OTE Make sure that the camshaft is to specification Using a Dial Indicator Gauge measure the endplay Slide the camshaft in both directions Read and note the maximum and minimum values on the Dial Indi...

Page 379: ...m General Information 303 00 7 GENERAL PROCEDURES E234 EN 07 2001 2002 Bantam Camshaft Lobe Surface 1 Inspect the camshaft lobes for pitting or damage in the active area Minor pitting is acceptable ou...

Page 380: ...al Information 303 00 8 GENERAL PROCEDURES E3255 EN 07 2001 2002 Bantam Camshaft Lobe Lift 1 Determine the cam lift Using a micrometer measure the cam in two directions The difference between the two...

Page 381: ...antam Crankshaft End Play General Equipment Dial indicator Dial indicator fixture Determine the end float Place on the dial indicator and bracket Determine the end float by raising the crankshaft with...

Page 382: ...ain Bearing Journal Diameter General Equipment Micrometer 1 Measure the diameter of the main bearing journals and the big end bearing journals Repeat the measurement using the micrometer offset by 90...

Page 383: ...303 00 11 Engine System General Information 303 00 11 GENERAL PROCEDURES E4546 EN 07 2001 2002 Bantam Crankshaft Main bearing Journal Clearance Main bearings Minimum 0 020 mm Maximum 0 056 mm...

Page 384: ...ghtened to the specified torque however the bearing shells should not be installed Measure the cylinder bore with an internal micrometer Carry out the measurements in different directions and at diffe...

Page 385: ...EN 07 2001 2002 Bantam Piston Diameter General Equipment Micrometer 1 NOTE Mark piston in case a piston has to be again installed Using a Micrometer measure the piston in two directions Measure the p...

Page 386: ...2 Bantam Piston Ring End Gap 1 CAUTION Do not mix up the piston rings Install the piston rings in the same position and location Take the piston ring and use a piston without rings to push the piston...

Page 387: ...EN 07 2001 2002 Bantam Piston Pin Diameter 1 NOTE The piston and piston pins are a matched pair Do not mix up the components Measure the piston pin diameter Measure the diameter in two directions If...

Page 388: ...002 Bantam Piston Pin to Bore Diameter 1 NOTE The piston and piston pin form a matched pair Do not mix up the components Measure the diameter of the piston pin bore Measure the diameter in two directi...

Page 389: ...nspection 1 CAUTION Do not use any aggressive cleaning fluid or a wire brush to clean the piston Carry out a visual inspection Clean the piston skirt pin bush ring grooves and crown and check for wear...

Page 390: ...m Piston Ring to Groove Clearance General Equipment Feeler Gauge 1 NOTE The piston ring must protrude from the piston groove To determine the piston ring clearance insert the Feeler Gauge right to the...

Page 391: ...19 GENERAL PROCEDURES E247 EN 07 2001 2002 Bantam Connecting Rod Large End Bore 1 Measure the bearing bore in two directions The difference is the connecting rod bore out of round Verify the out of r...

Page 392: ...System General Information 303 00 20 GENERAL PROCEDURES E4547 EN 07 2001 2002 Bantam Cylinder Head Distortion Cylinder Head Flatness 0 050 mm over any 0 150 mm Surface Finish Waveness Specification R3...

Page 393: ...General Information 303 00 21 GENERAL PROCEDURES E248 EN 07 2001 2002 Bantam Valve Stem Diameter 1 Using a micrometer measure the diameter of the valve stems If the measurements are not to specificat...

Page 394: ...PROCEDURES E250 EN 07 2001 2002 Bantam Valve Seat Inspection General Equipment Valve seat width scale 1 Measure the width of the valve seat Measure the valve seat width using the Valve seat width sca...

Page 395: ...amaged gasket surfaces or other damage that would make it unfit for further use Flywheel Inspection 1 Inspect the flywheel for 1 Any cracks 2 Worn ring gear teeth 3 Chipped or cracked ring gear teeth...

Page 396: ...51 Timing Chain 303 01B 52 55 Crankshaft Rear Oil Seal 303 01B 56 57 Exhaust Manifold 21 186 0 303 01B 58 60 Cylinder Head 21 163 0 303 01B 61 70 Oil Pan 21 154 0 303 01B 71 74 Oil Pump 21 154 0 303 0...

Page 397: ...001 2002 Bantam Crankshaft 303 01B 128 Piston 303 01B 128 Connecting rod 303 01B 129 Valve train 303 01B 129 Cylinder block 303 01B 129 Camshaft 303 01B 129 130 Torque Specifications 303 01B 130 132 S...

Page 398: ...engine is a 4 cylinder in line four stroke unit with single overhead camshaft and cross flow cylinder head The engine is a new development and includes the following technical features Cast iron cylin...

Page 399: ...air control IAC valve manifold absolute pressure sensor with integrated temperature and manifold absolute pressure T MAP sensor and fuel rail with four injectors Four into one exhaust manifold Cranks...

Page 400: ...ulic lash adjuster 6 Cylinder head The five bearing camshaft runs directly in the aluminum cylinder head An additional reference cam is provided for the camshaft position CMP sensor The cam followers...

Page 401: ...l Seal Retainer Item Description 1 Rear oil seal retainer 2 Oil pan mating surface 3 Bolt 4 Assembly guide The rear oil seal retainer is made of plastic It incorporates an integral crankshaft oil seal...

Page 402: ...ription 1 M8 bolts 2 M11 bolts 3 Cylinder head gasket 4 Guide dowels The cylinder head is made of cast aluminum alloy and is accurately positioned on the cylinder block with two guide dowels The lamin...

Page 403: ...02 Bantam Oil Pan The structural oil pan is made of cast aluminum and provides a mounting bracket for the air conditioner A C compressor The single piece oil pan gasket has an aluminum core with an ex...

Page 404: ...ide 4 Tensioner arm exhaust side 5 Timing chain 6 Hydraulic chain tensioner The overhead camshaft is driven from the crankshaft by the timing chain The steel camshaft sprocket has 38 teeth and is prod...

Page 405: ...fixed to the cylinder block with one bolt each The chain guide and tensioner arm reduce chain vibration and noise The hydraulic chain tensioner is operated by engine oil pressure Coolant Flow Control...

Page 406: ...303 01B 34 Engine 1 6L 1 3L RoCam 303 01B 34 DIAGNOSIS AND TESTING E3278 EN 07 2001 2002 Bantam Engine REFER to Section 303 00...

Page 407: ...able ties Removal 1 Disconnect the battery ground cable 2 Remove the air cleaner intake pipe 3 WARNING Watch for and collect escaping fuel Observe the safety regulations for working with fuel Disconne...

Page 408: ...V hose 3 Crankcase breather hose 4 Engine coolant temperature ECT sensor electrical connector 5 Brake booster vacuum hose 6 Disconnect the electrical connectors 1 Powertrain control module PCM 2 Camsh...

Page 409: ...Lower the vehicle 11 Remove the intake manifold Installation 1 NOTE Install a new gasket if the original is damaged Install the intake manifold 2 Raise and support the vehicle For additional informati...

Page 410: ...nd CMP electrical connectors 7 Install the hoses and connect the electrical connector 1 EVAP solenoid valve vacuum hose 2 PCV hose 3 Crankcase breather hose 4 ECT sensor electrical connector 5 Brake b...

Page 411: ...03 01B 39 Engine 1 6L 1 3L RoCam 303 01B 39 IN VEHICLE REPAIR CONTINUED E6632 EN 07 2001 2002 Bantam 9 Connect the fuel lines 10 Install the air cleaner intake pipe 11 Connect the battery ground cable...

Page 412: ...CAUTION Do not pull the cable when removing spark plug connector If necessary remove the ignition cables from the ignition coil to avoid kinking the cables Turn the spark plug connector slightly befo...

Page 413: ...tam 5 Remove the valve cover Installation 1 NOTE Install a new gasket if the original is damaged Install the valve cover 2 Connect the hoses 1 Connect the EVAP solenoid valve vacuum hose 2 Connect the...

Page 414: ...303 01B 42 Engine 1 6L 1 3L RoCam 303 01B 42 IN VEHICLE REPAIR CONTINUED E6633 EN 07 2001 2002 Bantam 4 Connect the PCM CMP sensor and EI coil electrical connectors 5 Connect the battery ground cable...

Page 415: ...Special Tool s Remover Oil Seal 303 112 21 051 Special Tool s Installer Oil Seal 303 656 21 233 Removal 1 Remove the accessory drive belt Turn the belt tensioner clockwise and slip the belt off the p...

Page 416: ...ation sleeve housing and sealing lip must be free of oil NOTE The new oil seal is supplied with a plastic installation sleeve Install the oil seal to the crankshaft pulley 1 Place the installation sle...

Page 417: ...pulley out more than 3 mm during seal installation Tighten the crankshaft pulley bolt until the oil seal is fully installed 4 Remove the crankshaft pulley bolt 5 Install the crankshaft pulley bolt 6 I...

Page 418: ...61 303 461 01 21 194 01 Pliers Valve Stem Oil Seal 303 508 21 211 Removal 1 Remove the valve cover For additional information refer to Valve Cover in this section 2 Remove the camshaft For additional...

Page 419: ...NOTE To aid correct reassembly keep all parts in the order removed Using special tools remove the valve spring 1 Compress the valve spring 2 Remove the valve collets the valve spring retainer and the...

Page 420: ...valve collets 3 Remove the high pressure airline and special tool 4 Remove the camshaft For additional information refer to Camshaft in this section 5 Install the roller finger cam followers Cylinder...

Page 421: ...030 A Material Specification Hypoid oil SAE 90 Removal 1 Remove the valve cover For additional information refer to Valve Cover in this section 2 NOTE The camshaft sprocket timing mark and both color...

Page 422: ...l the camshaft is released 6 Remove the camshaft bearing caps and the camshaft Installation 1 NOTE Make sure the sprocket alignment slot in the camshaft is uppermost 12 o clock when installing the cam...

Page 423: ...on the camshaft sprocket and both colored links on the timing chain must line up Remove the wire tie and using the special tool install the camshaft sprocket with the timing chain 3 Install the timin...

Page 424: ...move the oil pump For additional information refer to Oil Pump in this section 2 Lower the vehicle 3 Remove the valve cover For additional information refer to Valve Cover in this section 4 NOTE The c...

Page 425: ...tion refer to Section 100 02 8 Remove the timing chain 1 Remove the chain tensioner arm 2 Remove the chain guide Remove the timing chain and the crankshaft sprocket Installation 1 NOTE The crankshaft...

Page 426: ...ner arm 2 Install the chain guide 3 Lower the vehicle 4 NOTE The camshaft sprocket timing mark and both colored links on the timing chain must line up NOTE The mark on the camshaft sprocket must be in...

Page 427: ...01B 55 IN VEHICLE REPAIR CONTINUED E6637 EN 07 2001 2002 Bantam 7 Install the valve cover For additional information refer to Valve Cover in this section 8 Install the oil pump For additional informat...

Page 428: ...dditional information refer to Section 308 01 3 Remove the flywheel 4 Remove the oil pan For additional information refer to Oil Pan in this section 5 Remove and discard the rear oil seal retainer and...

Page 429: ...8 EN 07 2001 2002 Bantam 2 Install the oil pan For additional information refer to Oil Pan in this section 3 Install the flywheel 4 Install the clutch For additional information refer to Section 308 0...

Page 430: ...Detach the exhaust hanger insulator Remove and discard the gasket 4 Lower the vehicle 5 CAUTION Do not pull the cable when removing the spark plug connector If necessary remove the ignition cables fr...

Page 431: ...UED E6639 EN 07 2001 2002 Bantam 7 Remove the upper heat shield shown on removed engine 8 Remove the exhaust manifold shown on removed engine Remove and discard the gasket Installation 1 NOTE Use a ne...

Page 432: ...the EI coil 4 Install the spark plug electrical connectors 5 Raise and support the vehicle For additional information refer to Section 100 02 6 Connect the exhaust down pipe to the exhaust manifold 1...

Page 433: ...ge Holding Tool 205 072 15 030 A Angle Gauge Bolt Tightening 303 174 21 540 General Equipment Trolley jack Material Specification Sealer Green Loctite 648 re taining compound Engine oil SAE 15W 40 SH...

Page 434: ...ensor electrical connector 5 Brake booster vacuum hose 6 Disconnect the electrical connectors 1 Powertrain control module PCM 2 Camshaft position CMP sensor 3 Electronic ignition EI coil 7 CAUTION Do...

Page 435: ...scalding if the engine is warm Drain the coolant shown from below Install the drain plug after draining 9 Disconnect the coolant hoses 10 Raise and support vehicle For additional information refer to...

Page 436: ...side 1 Remove the nuts 2 Disconnect the hanger insulator Remove and discard the gasket 14 Lower the vehicle 15 Remove the valve cover 16 NOTE The camshaft sprocket mark and both colored links on the t...

Page 437: ...NOTE Secure the timing chain to a wire hook to prevent it from falling down into the cylinder block Using the special tool remove the camshaft sprocket 20 Place a trolley jack with a wooden block und...

Page 438: ...r head bolts NOTE Use a new gasket Using the special tool tighten the bolts in four stages Stage 1 Tighten all M11 bolts in the indicated numerical sequence to 40 Nm Stage 2 Tighten all M8 bolts in th...

Page 439: ...g chain must line up Install the timing chain on the camshaft sprocket The camshaft sprocket timing mark must be at the 12 o clock position 5 Using the special tool install the camshaft sprocket 6 NOT...

Page 440: ...ginal is damaged Install the intake manifold 9 Raise and support the vehicle For additional information refer to Section 100 02 10 Connect the exhaust down pipe 1 Install the nuts 2 Connect the retain...

Page 441: ...coolant hoses 1 To coolant expansion tank 2 To cabin heater 3 From cabin heater 15 NOTE Install a new gasket if the original is damaged Install the valve cover 16 Install the spark plugs and connect...

Page 442: ...rankcase breather hose 4 ECT sensor electrical connector 5 Brake booster vacuum hose 19 Install the accelerator cable 1 Hook in the inner cable 2 Install the cable in the bracket adjust cable and secu...

Page 443: ...gine oil SAE 15W 40 SH Removal All vehicles 1 Remove the transaxle For additional information refer to Section 308 03 2 Remove the clutch For additional information refer to Section 308 01 3 Remove th...

Page 444: ...ONTINUED E6641 EN 07 2001 2002 Bantam Vehicles with air conditioning 7 Remove the air conditioning compressor and secure it to the radiator crossmember All Vehicles 8 Drain the engine oil 9 Install th...

Page 445: ...mating faces must be free of oil and gasket residue Clean the oil pan to remove any oil residue or sludge 2 NOTE Apply a 3 to 5 mm bead of sealer LOCTITE 5910 to the marked areas NOTE Install the oil...

Page 446: ...y drive belt Turn the belt tensioner clockwise and install the belt 8 Raise and support the vehicle For additional information refer to Section 100 02 9 Install the flywheel 10 Install the clutch and...

Page 447: ...Pump 21 154 0 Special Tool s Remover Oil Seal 303 112 21 051 Removal 1 Remove the oil pan For additional information refer to Oil Pan in this section 2 Remove the crankshaft pulley 3 Using the special...

Page 448: ...are clean NOTE Use a new oil pump and gasket NOTE The oil pump sealing flange must be within 20mm of cylinder block bottom sealing flanges Install oil pump bolts 2 Install a new front oil seal For add...

Page 449: ...ountings and the engine support insulators are described looking from the transaxle to the engine Steps which apply only to particular variants are indicated with a note If necessary cut the cable tie...

Page 450: ...ion hose 3 Brake booster vacuum hose 6 WARNING Escaping fuel Observe the safety regulations for working with fuel Disconnect the fuel lines 7 Remove the accelerator cable 1 Remove the clip and pull th...

Page 451: ...right hand coolant hose bracket 11 Remove the left hand coolant hose bracket 12 Disconnect the ground cable the electrical connectors and the transmission breather 1 Disconnect the ground cable 2 Disc...

Page 452: ...onnect the heated oxygen sensor HO2S 2 Disconnect the powertrain control module PCM 3 Disconnect the electronic ignition EI coil 4 Disconnect the vehicle speed VSS sensor Vehicles with 1 3L engine 14...

Page 453: ...2002 Bantam 16 Disconnect the speedometer drive cable from the transaxle 17 Disconnect the clutch slave cylinder hydraulic line 18 Disconnect the cooling fan electrical connectors 19 Remove the coolin...

Page 454: ...g Loosen the suspension strut retaining nut five turns on both sides right hand side shown 21 Remove the accessory drive belt Turn the belt tensioner clockwise and slip the belt off the pulleys 22 Rai...

Page 455: ...to the radiator crossmember All Vehicles 26 Disconnect the exhaust down pipe from the exhaust manifold and position it to one side 1 Remove the nuts 2 Detach the exhaust hanger insulator Remove and di...

Page 456: ...amp on both sides right hand side shown 31 CAUTION To prevent damage to the halfshaft joints and boots do not bend the inner halfshaft joints by more than 18 degrees the outer one by not more than 45...

Page 457: ...return hose 34 Position the assembly stand with wooden blocks on it under the vehicle 35 Carefully lower the vehicle until the engine and transaxle assembly is on the assembly stand 36 Secure the engi...

Page 458: ...9 Move the assembly stand forward with the engine and transaxle assembly 40 Install an engine lifting eye 41 Disconnect the engine wiring harness electrical connectors 1 Remove the generator electrica...

Page 459: ...303 01B 87 REMOVAL CONTINUED E6642 EN 07 2001 2002 Bantam 43 Remove the transaxle right hand flange bolts 44 Remove the transaxle lower flange bolts 45 Remove the transaxle upper flange bolt 46 Separ...

Page 460: ...03 122 21 068 A Socket Cylinder Head Bolt 303 392 21 167 Mounting Stand 303 435 21 187 Special Tool s Mounting Bracket for 21 187 303 435 06 21 031 B Mounting Plate for 21 031 303 435 11 21 146 C Mate...

Page 461: ...3L RoCam 303 01B 89 DISASSEMBLY CONTINUED E6643 EN 07 2001 2002 Bantam 3 Using the special tools secure the engine to the mounting stand 4 Remove the special tool 5 Remove the engine mounting bracket...

Page 462: ...TINUED E6643 EN 07 2001 2002 Bantam 7 Remove the generator bracket 8 Drain the engine oil 9 Install the drain plug 10 Disconnect the vacuum hoses 11 Disconnect the camshaft position CMP sensor and the...

Page 463: ...for clarity All vehicles 14 CAUTION Do not pull the cable when removing the spark plug connector If necessary remove the ignition cables from the ignition coil to prevent kinking the cables Turn the s...

Page 464: ...am 303 01B 92 DISASSEMBLY CONTINUED E6643 EN 07 2001 2002 Bantam 15 Remove the valve cover 16 Remove the crankshaft position CKP sensor and the oil pressure switch 17 Remove the oil filter 18 Remove t...

Page 465: ...level indicator tube retaining bolt 21 CAUTION Secure the timing chain with a wire hook to prevent it from falling down into the cylinder block Using the special tool remove the camshaft sprocket 22...

Page 466: ...01B 94 Engine 1 6L 1 3L RoCam 303 01B 94 DISASSEMBLY CONTINUED E6643 EN 07 2001 2002 Bantam 23 Remove the water pump pulley 24 Remove the water pump 25 Remove the crankshaft pulley 26 Remove the flywh...

Page 467: ...t downwards to prevent oil deposits or abraded particles from entering the engine Remove the oil pan Remove and discard the gasket 28 Remove and discard the rear oil seal retainer 29 Remove the oil pu...

Page 468: ...r surfaces Keep the connecting rods bearing shells and bearing caps in order for reassembly Remove the pistons 1 Remove the connecting rod bearing cap 2 Push out the pistons with connecting rods and b...

Page 469: ...2001 2002 Bantam Cylinder Head 21 165 6 Special Tool s Compressor Valve Spring 303 461 21 194 Adapter for 303 461 303 461 01 21 194 01 Special Tool s Pliers Valve Stem Oil Seal 303 508 21 211 Disasse...

Page 470: ...t flow control housing 4 Remove the engine mounting bracket 5 Remove the camshaft bearing caps and the camshaft Slacken each bolt of the camshaft bearing caps by one turn until the camshaft is release...

Page 471: ...ydraulic lash adjusters 8 Install the camshaft and the camshaft bearing caps 1 Install the camshaft 2 Install the camshaft bearing caps 9 NOTE Keep all parts in order for reassembly Using the special...

Page 472: ...emove the valves 1 Exhaust valve 2 Intake valve 12 NOTE Keep all parts in order for reassembly Remove the camshaft bearing caps and the camshaft 1 Remove the camshaft bearings caps 2 Remove the camsha...

Page 473: ...ssed in by valve spring pressure Using the special tool install the valve seals 4 Using the special tools install the valve spring 1 Compress the valve spring and the valve spring retainer 2 Insert th...

Page 474: ...uppermost 12 o clock when installing the camshaft NOTE Apply a drop of hypoid oil WSQ 2C9002 AA to each cam bearing upper and lower half Install the camshaft and the camshaft bearing caps 1 Install t...

Page 475: ...BLY AND ASSEMBLY OF SUBASSEMBLIES CONTINUED E6644 EN 07 2001 2002 Bantam 10 NOTE Install a new gasket if the original is damaged Install the coolant flow control housing 11 Install the exhaust manifol...

Page 476: ...Tool s Mounting Plate 303 435 11 21 146 C General Equipment Assembly stand Cable ties Wire Piston ring compressor Material Specification Engine oil SAE 15W 40 SH Sealer Loctite 5910 Sealer Loctite 648...

Page 477: ...alf washers must be visible Install the main bearing shells 1 Insert the main bearing shells 2 Insert the thrust half washers into the center main bearing 8 NOTE The bearing cap numbering starts at th...

Page 478: ...ssor Using the handle of a hammer press pistons 1 and 4 into the cylinders The connecting rod bearing journal must be at BDC Check the bearing shells are clean and dry and install them in the associat...

Page 479: ...all the timing chain 14 NOTE Use a new oil pump NOTE Use a new gasket NOTE The oil pump sealing flange must be within 0 20 mm of cylinder block bottom sealing flanges Install the oil pump 15 NOTE The...

Page 480: ...ft pulley 4 New oil seal 17 CAUTION To prevent damage to the oil seal do not pull the crankshaft pulley out more than 3 mm during seal installation Tighten the crankshaft pulley bolt until the oil sea...

Page 481: ...ust be free of oil NOTE Make sure that the dowel pins are correctly located Install a new rear oil seal retainer 22 NOTE Apply a bead of sealer LOCTITE 5910 3 to 5 mm wide to the marked areas Apply se...

Page 482: ...he indicated numerical sequence to 40 Nm Stage 2 Tighten all M8 bolts in the indicated alphabetical order to 15 Nm Stage 3 Tighten all M8 bolts in the indicated alphabetical order to 45 degrees Stage...

Page 483: ...tool install the camshaft sprocket 30 NOTE Apply sealer Loctite 648 to the lower end of the oil level indicator tube Tighten the oil level indicator tube retaining bolt 31 Install the timing chain hy...

Page 484: ...Y CONTINUED E6645 EN 07 2001 2002 Bantam 33 Install the oil filter with a new gasket 34 Install the crankshaft position CKP sensor and the oil pressure switch Vehicles with 1 3L engine 35 Install the...

Page 485: ...new gasket if the original is damaged Install the valve cover 37 Install the spark plugs and connect the spark plug wires 38 NOTE Install a new gasket if the original is damaged Install the intake man...

Page 486: ...4 Engine 1 6L 1 3L RoCam 303 01B 114 ASSEMBLY CONTINUED E6645 EN 07 2001 2002 Bantam 40 Install the vacuum hoses 41 Install the generator bracket 42 Install the generator 43 Install the engine mountin...

Page 487: ...1 6L 1 3L RoCam 303 01B 115 ASSEMBLY CONTINUED E6645 EN 07 2001 2002 Bantam 44 Install the special tool 45 Secure the engine to the assembly table with retaining straps 46 Install the exhaust manifold...

Page 488: ...g Tool Boot Retaining Strap 204 169 14 044 General Equipment Retaining straps Assembly stand Material Specification Engine oil SAE 15W 40 SH High temperature grease WSD M1C230 A Installation All vehic...

Page 489: ...onnect the engine wiring harness electrical connectors 1 Connect the generator electrical connectors 2 Connect the oil pressure switch electrical connectors 3 Connect the CKP sensor electrical connect...

Page 490: ...Install the bolts and nuts finger tight Install the engine rear mounting bracket 12 CAUTION Brake fluid will escape Observe the safety regulations for the use of brake fluid For additional informatio...

Page 491: ...N The inner part of the constant velocity joint must not be bent at more than 18 degrees the outer part no more than 45 degrees NOTE Fill the joint housing with 60 grams of high temperature grease WSD...

Page 492: ...earshift stabilizer 1 Install the shift rod 2 Install the gearshift stabilizer 20 Install the exhaust lower heat shield 21 Connect the exhaust down pipe to the exhaust manifold with a new gasket 1 Ins...

Page 493: ...accessory drive belt cover 24 Install the engine undershield 25 Lower the vehicle 26 Install the accessory drive belt Turn the belt tensioner clockwise and slip the belt onto all the pulleys 27 NOTE...

Page 494: ...22 INSTALLATION CONTINUED E6646 EN 07 2001 2002 Bantam 28 Install the cooling fan 29 Connect the cooling fan electrical connectors 30 Connect the speedometer drive cable to the transaxle 31 Connect th...

Page 495: ...e the engine lifting eye 33 Tighten the engine front mounting bracket 34 Tighten the engine rear mounting bracket 35 Connect the heated oxygen HO2S sensor powertrain control module PCM electronic igni...

Page 496: ...l connectors and the transmission breather 1 Ground cable 2 Generator electrical connector 3 Starter motor electrical connector 4 Transmission breather 37 Install the left hand coolant hose bracket 38...

Page 497: ...elerator cable 1 Hook in the inner cable 2 Install the cable into the bracket adjust and secure using the clip 41 Connect the fuel lines 42 Install the hoses and the vacuum lines 1 EVAP solenoid valve...

Page 498: ...ecessary fill the engine with low friction oil meeting specification SAE 15W 40 or SAE 10W 30 46 Install the battery For additional information refer to Section 414 01 47 Fill the cooling system For a...

Page 499: ...850 910 Engine Oil Recommended engine oil Viscosity Temperature Specification SAE 15W 40 SH WSD M2C 904 B Lubricants Fluids Sealers and Adhesives Item Specification Sealer WSK M2G349 A4 Sealer LOCTIT...

Page 500: ...r thickness standard mm 2 80 2 85 Crankshaft thrust washer thickness oversize mm 2 99 3 04 Crankshaft must not be re machined Piston Piston diameter standard mm 82 015 82 030 Piston diameter oversize...

Page 501: ...3 7 Number of valve spring coils mm 6 7 6 7 Valve intake overall length mm 109 37 109 83 109 37 109 83 Valve exhaust overall length mm 109 95 110 05 109 95 110 05 Valve head intake diameter mm 39 87...

Page 502: ...0 075 0 185 Torque Specifications Description Nm Oil gallery plug 22 Main bearing bolts 95 Rear oil seal retainer 10 Connecting rod bolts Stage 1 4 Connecting rod bolts Stage 2 90 degrees Hydraulic ti...

Page 503: ...s 18 Intake manifold retaining bolts 18 Exhaust manifold retaining nuts 15 Exhaust manifold heat shield upper retaining bolts 10 Exhaust manifold heat shield upper retaining nut 10 Lower heat shield r...

Page 504: ...N 07 2001 2002 Bantam Description Nm Suspension strut retaining nuts 45 Cooling fan retaining bolts 12 Left hand coolant hose bracket nut 20 Right hand coolant hose bracket nut 20 Accessory drive belt...

Page 505: ...556 0 303 01D 21 23 Valve Seals 21 238 0 303 01D 24 33 Timing Belt Engines with Automatic Timing Belt Tensioner 21 304 0 303 01D 34 48 Timing Belt Engines with Manual Timing Belt Tensioner 21 304 0 30...

Page 506: ...ion 303 01D 171 Lubricants Fluids and Sealers 303 01D 171 Filling Capacities 303 01D 171 172 Torque Specifications 303 01D 172 Torque Specifications 303 01D 172 173 Torque Specifications 303 01D 173 T...

Page 507: ...d by pins that locate into the crankshaft on one surface and the camshaft timing belt pulley on the other On the front pulley there is an O ring seal which must be renewed during every installation It...

Page 508: ...is determined by the number of notches on the gasket thickness indicator Crankshaft oil seals NOTE The crankshaft rear oil seal is supplied complete with the oil seal carrier It must be fitted using...

Page 509: ...303 01D 5 Engine 1 8L Diesel Endura DE 303 01D 5 DIAGNOSIS AND TESTING E3278 EN 09 2001 2002 Bantam Engine REFER to Section 303 00...

Page 510: ...er for 21 140 21 140 01 Adapter for 21 140 21 140 02 Adapter for 21 140 21 140 03 Special Tool s Centering tool remover and installer oil seal 21 148 A Remover crankshaft timing pulley 21 200 Angle ga...

Page 511: ...DE 303 01D 7 IN VEHICLE REPAIR CONTINUED E5881 EN 09 2001 2002 Bantam 3 Attach the engine support bar 4 Remove the front engine mounting auxiliary bracket 5 Remove the front engine mounting bracket 6...

Page 512: ...pport bar 8 Remove the top bolts of the lower timing belt cover 9 Remove the injection pump timing belt cover 10 Remove the injection pump timing belt Slacken the bolts of the timing pulley Loosen the...

Page 513: ...01 2002 Bantam 11 Lower the engine with the engine support bar 12 Raise the vehicle 1 Undo the bolt CAUTION To slacken turn the bolt clockwise 2 Slacken and remove the drive belt 13 Remove the drive b...

Page 514: ...nect the alternator and remove it 18 Turn the crankshaft to the TDC position Unscrew the blanking plug from the cylinder block NOTE The timing pin must be screwed in as far as it will go Screw in the...

Page 515: ...emove the camshaft timing belt 1 Slacken the clamp bolt of the timing belt tensioner 2 Slacken the timing belt by compressing the spring using water pump pliers 22 Tighten the clamp bolt of the timing...

Page 516: ...punch four holes with a punch and screw in the self tapping screws 27 Pull out the oil seal together with the flange bolt from the crankshaft front timing pulley Installation 1 CAUTION Only install th...

Page 517: ...from the oil seal NOTE Fit the oil seal dry Fit the oil seal together with the bolt of the crankshaft front timing pulley flange Remove the special tool and the support ring 3 Fit the crankshaft rear...

Page 518: ...pin into the cylinder block Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin 7 CAUTION Renew the timing belt CAUTION Only instal...

Page 519: ...g belt tensioner 2 Tighten the bolts of the timing pulley 9 Remove timing pins 21 104 23 019 and 23 029 10 Preparations for tensioning the timing belts NOTE Turn the crankshaft two turns in the normal...

Page 520: ...hat the timing belt tensioner presses against the timing belt 2 Tighten the bolt of the injection pump timing belt tensioner 3 Tighten the bolts of the injection pump timing pulley 12 CAUTION Used tim...

Page 521: ...ver 14 Raise the vehicle 15 Screw in the lower bolts of the lower timing belt cover 16 Fit the crankshaft pulley vibration damper 17 CAUTION Position the generator and screw in the bolts finger tight...

Page 522: ...REPAIR CONTINUED E5881 EN 09 2001 2002 Bantam 18 Fit the drive belt tensioner 19 Fit the drive belt 1 Fit the drive belt and tension it as described in Operation No 31 413 0 2 Tighten the bolt 20 Lowe...

Page 523: ...E 303 01D 19 IN VEHICLE REPAIR CONTINUED E5881 EN 09 2001 2002 Bantam 22 Screw in the remaining bolts of the lower 23 Lower the engine with the engine support bar 24 Fit the upper timing belt cover 25...

Page 524: ...Bantam 26 Attach the front engine mounting auxiliary bracket 27 Detach the engine support bar 28 Connect the battery ground cable 29 Standard finishing operations Enter the radio keycode Reprogram the...

Page 525: ...56 0 Material Specification Engine Oil ACEA A3 B3 1 NOTE Immobilise the timing belt pulley with the old timing belt Remove the camshaft timing belt as described in Operation No 21 304 0 Slacken the bo...

Page 526: ...ng 1 Coat the auxiliary shaft bearing journal with engine oil 2 Slide the new oil seal housing with the integrated oil seal and the plastic fitting bush onto the auxiliary shaft bearing journal 3 Oil...

Page 527: ...Bantam 3 NOTE The auxiliary shaft guide pin and the hole in the timing belt pulley must line up NOTE Immobilise the timing belt pulley with the old timing belt Fit the auxiliary shaft timing belt pul...

Page 528: ...aller oil seal 21 110 Special Tool s Installer valve stem collets 21 156 Pliers valve stem oil seals 21 165 Remover installer cooling hose clamp 24 003 General Equipment Two legged puller Material Spe...

Page 529: ...ing belt as described in Operation No 21 304 0 described in Operation No 21 304 0 3 Raise the vehicle 4 Lower the vehicle 5 CAUTION Support the engine with a trolley jack Detach the engine support bar...

Page 530: ...02 Bantam 9 Remove the flange bolt of the camshaft timing pulley 10 Pull off the flange of the camshaft timing pulley using a proprietary two legged puller Remove the Woodruff key 11 Remove the cylind...

Page 531: ...aft Take out the bearing caps bearing shells and camshaft and put them down in order Remove the camshaft seal 14 NOTE Put down the valve tappets in order Remove the valve tappets and the valve shims a...

Page 532: ...the valve springs 1 Compress the valve springs 2 Remove the valve collets Remove the valve spring retainers and valve springs and put them down in order 18 Remove the valve stem seals Installation 1 C...

Page 533: ...ings Locate the valve springs and valve spring retainers in position 1 Compress the valve springs 2 Fit the valve collets 3 Turn the crankshaft to bring the pistons of cylinders nos 2 and 3 to TDC Tur...

Page 534: ...and fit them 7 Turn the crankshaft a further 1 1 3 turns until it is just before TDC 8 Put the camshaft bearing shell lower halves in place and coat them with engine oil Fit the camshaft and turn it...

Page 535: ...ring cap no 1 in the areas indicated 12 Install the camshaft NOTE The bearing caps must lie flat Fit camshaft bearing caps nos 1 3 and 5 NOTE Tightening sequence Screw on the nuts and tighten them 13...

Page 536: ...itting the gasket coat it lightly with engine oil Fit the cylinder head cover 1 Screw in the bolts 2 Attach the crankcase ventilation hoses 16 NOTE Coat the running surface and the sealing lip of the...

Page 537: ...21 Raise the vehicle NOTE The timing pin must be screwed in as far as it will go Fit the timing pin Carefully turn the crankshaft in the normal direction of rotation of the engine until it comes up ag...

Page 538: ...dapter for 303 290 21140 303 290 01 2114001 Adapter for 303 290 21140 303 290 02 2114002 Special Tool s Adapter for 303 290 21140 303 290 03 2114003 Timing tool camshaft 303 376 21162B Universal flang...

Page 539: ...01D 35 IN VEHICLE REPAIR CONTINUED E6447 EN 09 2001 2002 Bantam 4 Remove the front engine mounting auxiliary bracket 5 Remove the front engine mounting bracket 6 Remove the upper timing belt cover 7 R...

Page 540: ...over 9 Lower the engine with the engine support bar 10 Raise the vehicle 11 Remove the lower drive belt cover 1 Remove the bolts from the drive belt cover 2 Unclip the drive belt cover 3 Unclip the po...

Page 541: ...E 303 01D 37 IN VEHICLE REPAIR CONTINUED E6447 EN 09 2001 2002 Bantam 13 Remove the crankshaft belt pulley vibration damper 14 Remove the lower timing belt cover 15 Remove the belt tensioner 16 Remove...

Page 542: ...ulley is at 11 o clock 18 Remove the cylinder head cover Remove the gasket 1 Detach the PCV hoses 2 Unscrew the bolts 19 Turn the crankshaft approximately to TDC 20 Raise the vehicle 21 Turn the crank...

Page 543: ...ert the timing tool in the camshaft groove 25 Loosen the camshaft timing pulley NOTE Hold the camshaft timing pulley with the special tool Undo the camshaft timing pulley bolt three turns 26 NOTE Posi...

Page 544: ...ff for at least four hours CAUTION The crankshaft must be resting against the timing pin and the timing tool must be inserted in the camshaft NOTE Running direction of the timing belt arrows Make sure...

Page 545: ...5 030A to prevent movement of the camshaft timing belt pulley Tighten the bolt of the camshaft timing pulley 4 Turn the crankshaft six turns in the normal direction of rotation to settle the timing be...

Page 546: ...th the special tool Undo the camshaft timing pulley bolt three turns 9 NOTE Position a screwdriver between the camshaft timing pulley and the rear timing belt cover Release the camshaft timing pulley...

Page 547: ...justment cam in a clockwise direction so that the arrow on the camshaft timing belt tensioner points to the right hand corner of the adjustment range 12 NOTE Use the Allen key socket on the adjustment...

Page 548: ...the pointer is in range A continue with the next step If the pointer is not in range A repeat the adjustment procedure from step 10 16 Raise the vehicle 17 Remove the special tools 18 Turn the cranksh...

Page 549: ...If the pointer is in range A continue with the next step If the pointer is not in range A repeat the adjustment procedure from step 10 22 Remove the special tools and tighten the blanking plug to 24...

Page 550: ...tion the generator and screw in the bolts finger tight First tighten the bolt on the pulley side then the rear upper long bolt and finally the rear lower short bolt Install the generator 26 Fit the be...

Page 551: ...09 2001 2002 Bantam 29 Fit the drive belt 1 Fit the drive belt and tension as described in Operation No 31 413 0 2 Tighten the bolt 30 Lower the vehicle 31 Raise the engine with the engine support ba...

Page 552: ...ver 35 Fit the front engine mounting bracket 36 Install the front engine mounting auxiliary bracket 37 Detach the engine support bar 38 Connect the battery ground lead 39 Standard finishing operations...

Page 553: ...ort bar 303 290 21140 Adapter for 303 290 21140 303 290 01 2114001 Adapter for 303 290 21140 303 290 02 2114002 Special Tool s Adapter for 303 290 21140 303 290 03 2114003 Timing pin injection pump 31...

Page 554: ...01D 50 IN VEHICLE REPAIR CONTINUED E6346 EN 09 2001 2002 Bantam 4 Remove the front engine mounting auxiliary bracket 5 Remove the front engine mounting bracket 6 Remove the upper timing belt cover 7 R...

Page 555: ...Bantam 8 Unscrew the top bolts of the lower timing belt cover 9 Lower the engine with the engine support bar 10 Raise the vehicle 11 Remove the drive belt 1 Undo the bolt CAUTION To slacken turn the...

Page 556: ...ming belt cover 14 Remove the belt tensioner 15 Disconnect the alternator and remove it 16 NOTE Turn the engine in the direction of engine rotation Turn the crankshaft approximately to TDC Turn the cr...

Page 557: ...y turn the crankshaft in the normal direction of rotation of the engine until it comes up against the timing pin 18 Lower the vehicle 19 Insert the alignment pin into the camshaft timing belt pulley 2...

Page 558: ...of the timing belt tensioner and let the timing belt tensioner snap against the belt Fit the new camshaft timing belt 1 Tighten the clamp bolt of the timing belt tensioner 2 Tighten the bolts of the c...

Page 559: ...so that the timing belt tensioner presses against the timing belt Tension the timing belt 1 Tighten the camshaft timing belt tensioner bolt 2 Tighten the camshaft timing belt pulley bolts 3 Remove th...

Page 560: ...NTINUED E6346 EN 09 2001 2002 Bantam 6 Fit the lower timing belt cover two bolts at the bottom 7 Fit the crankshaft pulley vibration damper 8 Fit the drive belt 1 Fit the drive belt and tension as des...

Page 561: ...E 303 01D 57 IN VEHICLE REPAIR CONTINUED E6346 EN 09 2001 2002 Bantam 10 Raise the engine with the engine support bar 11 Attach the lower timing belt cover 12 Lower the engine with the engine support...

Page 562: ...t engine mounting bracket 15 Install the front engine mounting auxiliary bracket 16 Detach the engine support bar 17 Connect the battery negative lead 18 Standard finishing operations Enter the radio...

Page 563: ...quipment Two legged puller Material Specification Sealer SPM 4G 9112 F Valve stem installation sleeves Engine Oil ACEA B3 E3 Removal 1 General note This operation was carried out on an engine with a m...

Page 564: ...60 IN VEHICLE REPAIR CONTINUED E5883 EN 09 2001 2002 Bantam 4 Slacken the flange bolt of the camshaft timing pulley 5 Remove the camshaft timing pulley 6 Detach the crankcase ventilation hose 7 Remov...

Page 565: ...tary two legged puller Remove the Woodruff key 9 Remove the cylinder head cover 1 Detach the crankcase ventilation hoses 2 Remove the screws 10 Remove the oil baffle 11 CAUTION Slacken the nuts of the...

Page 566: ...ation 1 NOTE The lettering on the valve shims faces downwards NOTE Installation order Coat the valve tappets and valve shims with engine oil and fit them 2 Lay the camshaft bearing shell lower halves...

Page 567: ...ing shell upper halves in place and coat them with engine oil 5 Apply sealer SPM 4G 9112 F G to bearing cap no 1 in the areas indicated 6 Install the camshaft NOTE The bearing caps must lie flat Locat...

Page 568: ...The gasket can be reused several times if it is in good condition NOTE Before fitting the gasket coat it lightly with engine oil Fit the cylinder head cover 1 Tighten the bolts 2 Attach the crankcase...

Page 569: ...TINUED E5883 EN 09 2001 2002 Bantam 12 Fit the camshaft timing pulley 13 Attach the crankcase ventilation hose 14 Tighten the flange bolt of the camshaft timing pulley 15 Attach the engine support bar...

Page 570: ...l 21 110 Special Tool s Remover camshaft oil seal 21 143 General Equipment Two legged puller Material Specification Engine Oil ACEA B3 E3 Removal 1 General note This operation was carried out on an en...

Page 571: ...VEHICLE REPAIR CONTINUED E5884 EN 09 2001 2002 Bantam 5 Remove the camshaft timing pulley 6 Remove the flange bolt of the camshaft timing pulley 7 Pull off the flange of the camshaft timing pulley Tak...

Page 572: ...g lip of the oil seal with engine oil The text on the oil seal faces outwards during installation Draw in the camshaft seal using the installer and an M8 bolt 10 Fit the flange of the camshaft timing...

Page 573: ...D 69 Engine 1 8L Diesel Endura DE 303 01D 69 IN VEHICLE REPAIR CONTINUED E5884 EN 09 2001 2002 Bantam 13 Attach the engine support bar 14 Fit a new camshaft timing belt as described in Operation No 21...

Page 574: ...03 Material Specification Coolant L405F Sealer SPM 4G 9112 F G Valve stem installation sleeves Removal 1 General Remarks This operation was carried out on an engine with a mechanical timing belt tensi...

Page 575: ...n the plug again after draining 4 CAUTION Support the engine with a trolley jack Remove camshaft timing belt as described in Operation No 21 304 0 5 Remove the camshaft timing belt pulley Take out the...

Page 576: ...with adhesive tape Detach the air intake hose 9 Detach the coolant hoses from the thermostat housing 10 Disconnect the following plugs and wiring 1 Glow plug wiring 2 Plug engine coolant temperature...

Page 577: ...Bantam 12 Detach bracket of the glow plug wiring 13 Detach the brake servo vacuum line 14 Detach the fuel feed line 15 Detach the fuel line to the fuel heater Unclip the fuel heater 16 Disconnect vacu...

Page 578: ...ection pipes and disconnect the leak off hoses 19 Detach the catalytic converter from the exhaust manifold 20 Support the engine with a trolley jack so that the front engine mounting is free of load 2...

Page 579: ...Endura DE 303 01D 75 IN VEHICLE REPAIR CONTINUED E5970 EN 09 2001 2002 Bantam 23 Remove the oil baffle 24 NOTE Loosening sequence Remove the cylinder head Take off the cylinder head and put it down on...

Page 580: ...e largest measurement determines the choice of cylinder head gasket see General Specifications 2 Line up the crankshaft and camshaft Turn the crankshaft until the piston of cylinder no 1 is at TDC Tur...

Page 581: ...Fit the cylinder head and tighten the new cylinder head bolts in two stages 5 Fit the cylinder head continued NOTE For stage 3 slacken one cylinder head bolt by itself and then tighten it to the speci...

Page 582: ...both sides with a thin bead of sealer SPM 4G9112 F G 8 NOTE Clean the cylinder head cover gasket and check it for damage Only renew if damaged If it is in good condition re use it several times NOTE...

Page 583: ...E5970 EN 09 2001 2002 Bantam 10 Fit the injection pipes and connect the leak off hoses 11 Connect the vacuum hose and plug to the EGR valve 12 Attach the heater coolant hose 13 Attach the fuel line to...

Page 584: ...Attach the fuel feed line 16 Attach the bracket of the glow plug wiring 17 Attach the vacuum pump oil return hose 18 Connect the following plugs and wiring 1 Glow plug wiring 2 Plug ECT sensor 3 Plug...

Page 585: ...he adhesive tape Fit the air intake hose 21 Fit the camshaft timing belt tensioner 1 Timing belt tensioner 2 Compress the spring of the timing belt tensioner and secure it with the clamp bolt 22 NOTE...

Page 586: ...ge Check the routing of the vacuum hoses and wiring and secure them with cable ties where necessary Enter the radio keycode Re program the preset radio stations Reset the clock Carry out a road test t...

Page 587: ...ler Removal 1 General note 2 When removing coolant and ventilation hoses if necessary For additional information refer to Section 303 03 3 WARNING Risk of scalding if the engine is hot Preparatory ope...

Page 588: ...e engine is warm NOTE After draining tighten the drain plug to 22 Nm Drain off the coolant 7 Remove the air intake pipe 1 From the intake manifold clamp 2 Unclip 3 Pull it out of the air cleaner housi...

Page 589: ...e plugs and wiring 1 Plug of injection pump wiring loom 2 Glow plug wiring 3 Plug of the temperature gauge sender unit 4 Plug of the engine coolant temperature sensor ECT sensor 5 Plug of oil pressure...

Page 590: ...ach the accelerator cable with the rubber bush and retainer from the bracket 2 Unhook the accelerator cable 16 Disconnect the fuel lines 1 Fuel return line 2 Fuel feed line 17 Detach the transmission...

Page 591: ...NUED E5886 EN 09 2001 2002 Bantam 19 Detach the bracket of the power steering pressure pipe 20 NOTE Collect the power steering fluid Detach the power steering hose and pressure pipe 21 Remove the belt...

Page 592: ...iesel Endura DE 303 01D 88 REMOVAL CONTINUED E5886 EN 09 2001 2002 Bantam 23 Remove the battery Detach the retaining strap Lift out the battery 24 Remove the battery box 25 Raise the vehicle 26 Detach...

Page 593: ...Disconnect the air conditioning plug Cut the two cable ties 28 Detach the lower right hand coolant hose 29 Disconnect the three plugs at the bottom of the radiator on the left hand side 30 NOTE Do not...

Page 594: ...wo bolts on each side right hand side shown Carefully withdraw the radiator radiator crossmember and fan plate with the fan from below 32 Detach the air conditioning compressor Let the compressor hang...

Page 595: ...2002 Bantam 35 Disconnect the plug of the reversing lamp switch where fitted 36 Detach the shift rod and gearshift stabilizer and tie up 1 Shift rod 2 Shift rod stabilizer 37 Detach the rear exhaust...

Page 596: ...isconnect the speedometer drive cable 41 CAUTION The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees NOTE Escaping oil Close off the o...

Page 597: ...CAUTION The inner joint must not be bent at more than 18 degrees and the outer joint must not be bent at more than 45 degrees NOTE Do not damage the boots of the drive shaft Tie up the right hand fro...

Page 598: ...emove the rear engine mounting 1 Screws 2 Nuts 3 Remove the transmission breather 49 Remove the front engine mounting 50 Raise the vehicle slowly until the engine and transmission are clear 51 Attach...

Page 599: ...95 Engine 1 8L Diesel Endura DE 303 01D 95 REMOVAL CONTINUED E5886 EN 09 2001 2002 Bantam 53 Remove the resonator 54 Remove the starter motor 55 Unscrew the front flange bolts 56 Unscrew the rear flan...

Page 600: ...303 01D 96 Engine 1 8L Diesel Endura DE 303 01D 96 REMOVAL CONTINUED E5886 EN 09 2001 2002 Bantam 57 Press the transmission off the engine and remove it Remove the adapter plate...

Page 601: ...iming belt pulley 21 200 Socket injectors 23 045 Disassembly 1 General Remarks It is not possible to renew any of the gears or the belt itself with replacement parts from previous build years If neces...

Page 602: ...shown with the air conditioning compressor 1 Slacken and remove the drive belt 2 Detach the belt tensioner 3 Remove the alternator bolts 5 Remove the injection pump belt pulley 6 Remove the crankshaf...

Page 603: ...ED E6007 EN 09 2001 2002 Bantam 8 Remove the timing belt lower cover 9 Remove the injection pump timing belt cover 10 Slacken the bolt of the auxiliary shaft timing belt pulley 11 Remove the cylinder...

Page 604: ...he adjusting cam and the timing belt 2 Detach the camshaft timing belt tensioner 3 Undo the bolt of the camshaft timing belt pulley Engines with automatic timing belt tensioner 13 NOTE Position a scre...

Page 605: ...belt Tighten the timing belt tensioner clamp bolt Remove timing belt and discard All vehicles 15 Remove the injection pump timing belt Undo the bolts of the timing belt pulley Release the timing belt...

Page 606: ...iming belt tensioner 17 WARNING The timing belt tensioner is spring loaded Remove the timing belt tensioner and the camshaft timing belt pulley 1 Timing belt tensioner bolts 2 Camshaft timing belt pul...

Page 607: ...ra DE 303 01D 103 DISASSEMBLY CONTINUED E6007 EN 09 2001 2002 Bantam 21 Detach the hose 22 Remove the fuel feed line 23 Disconnect the injection pipes and leak off hoses 24 Remove the injection pump b...

Page 608: ...EN 09 2001 2002 Bantam 26 Remove the thermostat housing coolant hose and coolant pipe 27 Remove the alternator bracket 28 Remove the coolant pipe bracket 29 Remove the oil baffle 30 Remove injectors a...

Page 609: ...f the cylinder head and put it down on wooden blocks Remove the seal 32 Remove the flange of the crankshaft front timing belt pulley 33 Remove the auxiliary shaft timing belt pulley and oil seal housi...

Page 610: ...Remove the auxiliary shaft with the thrust plate 35 Remove the coolant pump 36 CAUTION Only use a collet Remove the crankshaft rear timing belt pulley 1 Fit the collet 2 Pull the collet back as far a...

Page 611: ...303 01D 107 DISASSEMBLY CONTINUED E6007 EN 09 2001 2002 Bantam 38 Remove the clutch 39 Remove the flywheel 40 Remove the crankshaft position sensor CKP 41 NOTE The oil seal is integrated in the housin...

Page 612: ...44 Remove the front plate Press out the crankshaft front oil seal 45 Remove the oil intake pipe with the bracket 46 CAUTION Do not damage the piston ring zone Remove the pistons NOTE Put the big end...

Page 613: ...a DE 303 01D 109 DISASSEMBLY CONTINUED E6007 EN 09 2001 2002 Bantam 47 Remove the crankshaft Remove the main bearing caps Take out the crankshaft Take out the bearing shells and thrust half washers an...

Page 614: ...1 007 A Installer valve stem seals Valve spring compressor 21 024 Adaptor for 21 024 21 024 05 Installer oil seal 21 110 Special Tool s Installer valve stem collets 21 156 Pliers valve stem oil seals...

Page 615: ...ASSEMBLY OF SUBASSEMBLIES CONTINUED E6008 EN 09 2001 2002 Bantam 2 Remove the vacuum pump 3 Remove the retaining plate with the fuel heater and remove the fuel filter 4 Remove the exhaust gas re circu...

Page 616: ...ng belt pulley with the old timing belt Remove the timing belt pulley 7 Remove the oil pressure switch 8 Remove the bracket of the power steering pump 9 Remove the injectors and glow plugs 1 Injectors...

Page 617: ...rn at a time Remove the camshaft 1 Remove camshaft bearing caps nos 2 and 4 2 Slacken the nuts of the remaining camshaft bearing caps evenly a turn at a time Remove the bearing caps bearing shells and...

Page 618: ...valve springs Lay the cylinder head on wooden blocks Release the valves by tapping lightly with a brass drift on the ends of the valve stems 1 1 Compress the valve springs 2 2 Remove the valve collet...

Page 619: ...antam Assembly 1 Preparatory measures Check all parts for wear Thoroughly clean all reusable parts 2 Renew the studs for the inlet and exhaust manifold 3 Grind in the valves 1 Valve collets 2 Valve sp...

Page 620: ...after fitting the valve stem seals Lubricate the new valve stem seals with engine oil and fit them 7 Fit the valve springs with the valve spring retainers 1 Compress the valve springs using the instal...

Page 621: ...ing shims with engine oil and fit them 11 Lay the camshaft bearing shell lower halves in place and coat them with engine oil Fit the camshaft and turn it until the groove in the eccentric on the camsh...

Page 622: ...and 5 in installation position and screw on the nuts NOTE Tightening sequence Tighten the nuts 16 Fit the vacuum pump plunger 17 NOTE Tightening sequence Tighten the nuts of the camshaft bearing caps...

Page 623: ...w plugs and injectors 1 Glow plugs 2 Glow plug wiring 3 Injectors 21 Fit the power steering pump bracket 22 NOTE Immobilise the timing belt pulley using the old timing belt Fit the timing belt rear co...

Page 624: ...ASSEMBLY OF SUBASSEMBLIES CONTINUED E6008 EN 09 2001 2002 Bantam 25 Fit the EGR valve 1 Tighten the bolts 2 Tighten the retaining clip bolt 26 Install the retaining plate with the fuel heater and the...

Page 625: ...sition 21 104 Centering tool remover and installer oil seal 21 148A Adjustment tool camshaft TDC 21 162B Socket cylinder head bolts 21 164 Locking tool crankshaft 21 168 Special Tool s Aligner cranksh...

Page 626: ...ssembly 1 Preparatory operations Thoroughly clean all mating faces and reusable parts and check for damage 2 Clean the piston cooling oil splash nozzles and oil ways 3 Measure the diameter of the main...

Page 627: ...for measuring the bearing clearance NOTE Carry out the following steps to the letter Measure each bearing individually using a length of Plastigage thread The bearing shells and journals must be free...

Page 628: ...s to the main bearing clearance The main bearing shells should be renewed as necessary according to the bearing clearance measurement 9 Install the crankshaft NOTE The main bearing cap numbering start...

Page 629: ...easure the piston ring clearance with the piston ring protruding Measure the piston ring clearances The maximum clearance of the upper compression ring is 0 09 0 12 mm The maximum clearance of the 2nd...

Page 630: ...the pistons into the cylinders with the handle of a hammer guiding the connecting rods onto the big end bearing journals Place the appropriate bearing shells clean and dry in the connecting rods 16 M...

Page 631: ...immediately before installation NOTE Install the oil seal dry Draw in the crankshaft front oil seal Draw in the oil seal with the installer and the bolt of the crankshaft timing belt pulley 20 Instal...

Page 632: ...he oil seal housing 23 Tighten the oil pan bolts 24 CAUTION The sealing lip of the oil seal and the crankshaft sealing surface must be free of oil NOTE The support ring must sit in the oil seal Instal...

Page 633: ...crankshaft oil seal housing working diagonally Remove the locator 26 NOTE Use new bolts Fit the flywheel Immobilise the crankshaft with the ring gear 27 Center the clutch disc on the pressure plate 28...

Page 634: ...ate must face outwards Fit the auxiliary shaft together with the thrust plate Tighten the thrust plate bolts 31 NOTE Do not tighten the bolt of the auxiliary shaft timing belt pulley NOTE The auxiliar...

Page 635: ...t measurement determines the choice of cylinder head gasket see General Specifications 35 NOTE The straightedge must be at least 500 mm long Check the cylinder head mating face for distortion Permitte...

Page 636: ...the camshaft is parallel with the upper edge of the cylinder head with the larger semi circle at the top The crankshaft and camshaft must not be turned any more 37 NOTE The cylinder head gasket is mar...

Page 637: ...cylinder head bolt by itself and then tighten it to the specified torque and angle Only then move on to the next bolt Wait three minutes and then tighten the cylinder head bolts according to tighteni...

Page 638: ...303 01D 134 ASSEMBLY CONTINUED E6005 EN 09 2001 2002 Bantam 42 Fit the coolant pipe bracket 43 Fit the thermostat housing coolant hose and coolant pipe 44 Fit the injection pump 45 Fit the injection...

Page 639: ...ra DE 303 01D 135 ASSEMBLY CONTINUED E6005 EN 09 2001 2002 Bantam 46 Connect the injection pipes and the leak off hoses 47 Connect the fuel feed line 48 Install the oil dipstick tube 49 Attach the hos...

Page 640: ...ts NOTE Center the slots on the injection pump timing belt pulley Fit the injection pump timing belt pulley 53 Fit the injection pump timing belt tensioner Compress the spring of the timing belt tensi...

Page 641: ...lts of the camshaft timing belt pulley 1 Fit the camshaft timing belt pulley 2 Fit the timing belt tensioner two bolts 3 Squeeze the springs of the timing belt tensioner together and fix in place with...

Page 642: ...st rest against the timing pin 2 Remove the bolt and screw the timing pin into the cylinder block Turn the crankshaft to the TDC position 58 CAUTION Renew the toothed belt NOTE The direction of rotati...

Page 643: ...OTE The direction of rotation is marked NOTE Make sure the belt is seated correctly Install the camshaft timing belt Fit the timing belt with the slack side nearest the timing belt tensioner 1 Release...

Page 644: ...029 Engines with automatic timing belt tensioner 65 NOTE Hold the camshaft timing belt pulley steady Loosen the bolt of the camshaft timing belt pulley and slacken the camshaft timing belt Engines wi...

Page 645: ...engine until it comes up against the timing pin 2 The timing pin must be able to be inserted into the camshaft timing belt pulley 3 The timing pin must be able to be inserted into the injection pump t...

Page 646: ...en the bolt smoothly NOTE Hold the camshaft timing belt pulley steady Tighten the bolt smoothly Tension the camshaft timing belt 1 Tension the camshaft timing belt clockwise via the hexagon socket of...

Page 647: ...ble to be inserted The timing tool must be able to be inserted in the camshaft The arrows on the camshaft timing belt tensioner must not be offset by more than 3 mm Remove the special tools and fit th...

Page 648: ...on both sides with a thin bead of sealer SPM 4G9112 F G 76 NOTE Clean the cylinder head cover gasket and check it for damage Only renew if damaged If it is in good condition re use it several times N...

Page 649: ...SEMBLY CONTINUED E6005 EN 09 2001 2002 Bantam 78 Tighten the bolt of the auxiliary shaft timing belt pulley 79 Fit the lower timing belt cover 80 Fit the upper timing belt cover 81 Fit the crankshaft...

Page 650: ...ger within the measuring range and readjust it again Place the angle gauge on the pulley vibration damper and position the disc to 10 Turn the pulley vibration damper until the arrows on the angle gau...

Page 651: ...pper long bolt and finally the rear lower short bolt Install the alternator shown with the air conditioning compressor 1 Tighten the alternator bolts in accordance with the tightening sequence 2 Fit t...

Page 652: ...303 01D 148 Engine 1 8L Diesel Endura DE 303 01D 148 ASSEMBLY CONTINUED E6005 EN 09 2001 2002 Bantam 89 Detach the engine from the assembly stand...

Page 653: ...g hydraulic fluid ESPM 2C 166 H Ford DOT 4 brake fluid for hydraulic clutch system SAM 6C9103 A High temperature grease for transmis sion input shaft guide sleeve clutch release bearing pilot bearing...

Page 654: ...wo guide sleeves on the cylinder block Fix the adapter plate with a small amount of high temperature grease ESD M1C220 A 3 NOTE The transmission is centered with two guide sleeves on the engine Locate...

Page 655: ...e lifting bracket 9 General Remarks Renew circlips and self locking nuts When installing coolant and ventilation hoses if necessary For additional information refer to Section 303 03 10 Locate the eng...

Page 656: ...ntam 13 NOTE Do not tighten the nuts Attach the front engine mounting Remove the tensioning straps 14 Raise the vehicle 15 Fit the engine roll restrictor 16 NOTE Do not tighten the bolt on the shift r...

Page 657: ...s of the front engine mounting bracket 19 Tighten the bolts and nuts of the rear engine mounting bracket 20 Put the transmission into 4th gear 21 Raise the vehicle 22 CAUTION The inner joint must not...

Page 658: ...t at more than 18 degrees and the outer joint must not be bent at more than 45 degrees CAUTION When inserting the front axle driveshafts always use the installation sleeve supplied with every new oil...

Page 659: ...Adjust the gearshift mechanism Lock the gearshift mechanism in the 4th gear position using the shank of a new 9 mm twist drill bit 30 Adjust the gearshift mechanism continued The detailed illustration...

Page 660: ...l Endura DE 303 01D 156 INSTALLATION CONTINUED E5915 EN 09 2001 2002 Bantam 32 Attach the speedometer drive cable 33 Connect the generator 34 Connect the starter motor 35 Connect the plug of the multi...

Page 661: ...ch where fitted 37 Fit the A C compressor 38 Fit the drive belt 1 Lay the drive belt in place and tension it via the bolt of the belt tensioner For additional information refer to Section 303 05 2 Tig...

Page 662: ...radiator bolt Install the radiator two bolts on each side right hand side shown 41 NOTE The air conditioning condenser is a push fit at the top Align the air conditioning condenser and screw it in pl...

Page 663: ...DE 303 01D 159 INSTALLATION CONTINUED E5915 EN 09 2001 2002 Bantam 44 Connect the bottom right hand coolant hose to the radiator 45 Connect the bottom coolant hose 46 Lower the vehicle 47 Attach the f...

Page 664: ...r steering hose and pressure pipe 49 Connect the bracket of the power steering pressure pipe to the cylinder block 50 NOTE Insert new O rings Attach the hydraulic pipe of the clutch operating mechanis...

Page 665: ...d clip onto the bracket 2 Hook the accelerator cable in place 55 Connect the plugs and wiring 1 Plug of the injection pump wiring loom 2 Glow plug wiring 3 Plug of the coolant temperature gauge sender...

Page 666: ...1 8L Diesel Endura DE 303 01D 162 INSTALLATION CONTINUED E5915 EN 09 2001 2002 Bantam 58 Fit the battery box 59 Install the battery 60 Attach the radiator vent hose 61 Attach the hoses 1 Vent hose 2 H...

Page 667: ...p 2 Insert it in the air cleaner housing push fit 3 Clip it in place 4 Attach it to the intake manifold clamp 64 NOTE When tightening the nuts hold with an Allen key to prevent from turning Tighten th...

Page 668: ...nishing operations Fill up with coolant Check the transmission fluid level and correct as necessary Check the routing of vacuum hoses and wiring and secure with cable ties Connect the battery Enter th...

Page 669: ...ims 21 107 Remover installer cooling hose clamp 24 003 General Equipment Feeler gauge Material Specification Valve shims Sealer SPM 4G 9112 F G 1 General note When removing and installing coolant and...

Page 670: ...y as necessary by changing the shims as described in step 5 NOTE Turn the crankshaft further through approx 90 degrees The piston of the cylinder that is to be adjusted must not be at TDC NOTE The let...

Page 671: ...OTE Clean the cylinder head cover gasket and check it for damage Only renew it if it is damaged The gasket can be reused several times if it is in good condition NOTE Before fitting the gasket coat it...

Page 672: ...speed continuous 5350 rev min 50 rev min Max intermittent engine speed 5200 rev min 50 rev min Dimensions Endura DE Cylinder Block Number of main bearings 5 Dimensions in mm Cylinder bore Class A 82...

Page 673: ...30 008 Distance between connecting rod bores Class C 129 992 130 068 Distance between connecting rod bores Class D 130 052 130 128 Big end bearing radial clearance 0 016 0 074 Pistons Piston Class A 8...

Page 674: ...5 030 Bore valve tappet oversize 35 500 35 530 Bore valve stem guide standard 8 000 8 025 Bore valve stem guide 1st oversize 8 263 8 288 Bore valve stem guide 2nd oversize 8 463 8 488 Thickness of cyl...

Page 675: ...max inner outer rotor clearance 0 174 mm Lubricants Fluids and Sealers Ford Specification Transmission fluid WSD M2C200 C Hypoid oil SQM 2C9002 AA Power steering hydraulic fluid ESPM 2C 166 H Ford DO...

Page 676: ...50 Engine roll restrictor to front axle 70 Right hand front driveshaft center bearing 24 Lower suspension arm to spindle carrier 52 Track rod to spindle carrier 36 Stabiliser link rod to suspension s...

Page 677: ...iator 24 Coolant drain plug to radiator 22 Torque Specifications Description Nm Power steering pump bracket 23 Tensioning pulley for power steering drive belt 6 Power steering pump 23 Bracket for powe...

Page 678: ...e of crankshaft front timing belt pulley stage 4 60 Crankshaft pulley vibration damper 35 Alternator bracket 46 Alternator to bracket 25 Clamp bolt for alternator belt tensioner 6 Crankshaft position...

Page 679: ...ors 70 Glow plugs 28 EGR valve 20 EGR pipe clip 10 Clamp bolt of camshaft timing belt tensioner 50 Camshaft timing belt pulley 9 Camshaft timing belt pulley with automatic timing belt tensioner with M...

Page 680: ...Engine 24 454 0 303 03 180 181 Cooling Fan Motor 24 222 0 303 03 182 185 Radiator Vehicles with 1 8L Endura DE Diesel Engine 24 254 0 303 03 186 188 Water Pump Vehicles with 1 8L Endura DE Diesel Eng...

Page 681: ...aken internally and can be absorbed into the skin after prolonged contact Antifreeze content should be checked through the neck of the expansion tank with a hydrometer The specific gravity sg of corre...

Page 682: ...ncern by operating the system 2 Visually inspect for obvious signs of mechanical or electrical damage 3 If an obvious cause for an observed or reported concern is found correct the cause if possible b...

Page 683: ...ntam Thermostat Vehicles with 1 8L Endura DE Diesel Engine 24 454 0 Special Tool s Remover Installer cooling hose clamp 24 003 Removal 1 Drain the cooling system Refer to the procedure in this section...

Page 684: ...ATION CONTINUED E5887 EN 09 2001 2002 Bantam Installation 1 Install a new O ring seal 2 Install the thermostat and thermostat housing 3 Install the remaining components in the reverse order 4 Refill t...

Page 685: ...otor 24 222 0 Removal 1 Disconnect the battery ground cable 2 Support the radiator Use suitable wire to support the radiator to the front panel 3 Raise the vehicle 4 Remove the lower air deflector fou...

Page 686: ...TINUED E6343 EN 09 2001 2002 Bantam 7 Detach the multiplug from the radiator support 8 Remove the radiator support four bolts Vehicles with automatic transmission 9 Loosen the transmission fluid coole...

Page 687: ...cooler retaining bolt 12 Detach the transmission fluid cooler from the radiator 1 Move the bottom of the cooler away from the radiator 2 Move the cooler downwards Take care not to stress the pipes wh...

Page 688: ...Engine Cooling 303 03 185 REMOVAL AND INSTALLATION CONTINUED E6343 EN 09 2001 2002 Bantam Installation 1 Refit the components in reverse order Make sure the lugs on the fan shroud assembly are located...

Page 689: ...1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in...

Page 690: ...E5890 EN 09 2001 2002 Bantam 6 Disconnect the fan multiplug and unclip the wiring loom 7 Detach the multiplug from the radiator support 8 Disconnect the lower radiator hose Vehicles with air condition...

Page 691: ...four support retaining bolts left hand side shown 11 Remove the fan and radiator assembly complete 12 If the radiator is to be renewed remove the fan assembly Installation 1 To install reverse the re...

Page 692: ...to Section 414 01 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 Remove the timing belt For additional information refer...

Page 693: ...remove the three bolts 2 Fully loosen the remaining bolt 7 Raise the engine using a suitable jack and packing material to allow the bolt to be withdrawn through the body bracket 8 Remove the engine fr...

Page 694: ...0 Disconnect the coolant hose from the water pump 11 Remove the remaining water pump bolts Take care not to put undue stress on any pipes or wiring 12 Raise the engine using a suitable jack and packin...

Page 695: ...303 03 192 Engine Cooling 303 03 192 REMOVAL AND INSTALLATION CONTINUED E6441 EN 09 2001 2002 Bantam...

Page 696: ...the expansion tank hoses 1 Disconnect the radiator to expansion tank hose 2 Disconnect the engine to expansion tank hose 3 Disconnect the engine supply hose 3 Remove the expansion tank 1 Remove the e...

Page 697: ...k cloth to prevent the possibility of coolant scalding Relieve the cooling system pressure Unscrew the cap slowly 2 Remove the cap 3 Raise and support the vehicle For additional information refer to S...

Page 698: ...h a diesel engine it is necessary to add a further one litre of coolant above the MAX mark to make sure that the correct level is achieved after the system degasses Refill the expansion tank to the MA...

Page 699: ...nt flow direction In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation it will be necessary to use the pressure flushing method using Cooling Syst...

Page 700: ...den hose from a tap with a male adapter into the end of the heater outlet hose Secure with a hose clamp 2 Connect a garden hose to the engine intake connector and secure with a hose clamp Allow the op...

Page 701: ...fitting adapter in the end of the heater outlet water hose Secure with a hose clamp 2 Connect the female hose end of the heater outlet water hose to the male end of a water supply garden hose 3 Discon...

Page 702: ...ifreeze L405F Torque Specifications Description Nm Endura DE Diesel Engine Water pump retaining bolts 33 Endura DE Diesel Engine Thermostat housing retaining bolts 18 Endura DE Diesel Engine Water pum...

Page 703: ...N AND OPERATION Starting System 303 06 201 DIAGNOSIS AND TESTING Starting System 303 06 202 Inspection and Verification 303 06 202 Symptom Chart 303 06 202 Pinpoint Tests 303 06 202 210 REMOVAL AND IN...

Page 704: ...ive of model all starter motors have an integral solenoid and all types have pinions which engage with a ring gear during starting The ring gear is located on the outside of the flywheel Some starter...

Page 705: ...tion Chart Mechanical Electrical Starter motor Battery Fuse Wiring Connectors 3 If inspection reveals an obvious cause rectify this before continuing If the concern remains proceed to the symptom char...

Page 706: ...6 205 A10 CHECK CIRCUIT 30 RD CONTINUITY 303 06 206 A11 CHECK THE IGNITION SWITCH 303 06 206 A12 CHECK CIRCUIT 50 GY CONTINUITY 303 06 206 207 A13 CHECK THE CONTINUITY OF CIRCUIT 50 GY BK 303 06 207 A...

Page 707: ...in 2 3 Measure the voltage between the starter motor solenoid connector single pin circuit 50 GY BK and ground when the starter is operated Is the voltage greater than 10 volts Yes GO TO A4 No GO TO A...

Page 708: ...HE STARTER GROUND CIRCUIT 1 Measure the resistance between the starter motor casing and negative battery terminal Is the resistance less than 5 ohms Yes INSTALL a new starter motor TEST the system for...

Page 709: ...Is the resistance less than 5 ohms Yes GO TO A8 No REPAIR circuit 31 BK TEST the system for normal operation A8 CHECK RELAY SWITCHING CIRCUIT 1 2 Measure the voltage between the starter relay connecto...

Page 710: ...onnector pin 1 circuit 30 RD and ignition switch connector pin 4 circuit 30 RD Is the resistance less than 5 ohms Yes GO TO A11 No REPAIR circuit 30 RD TEST the system for normal operation A11 CHECK T...

Page 711: ...A13 CHECK THE CONTINUITY OF CIRCUIT 50 GY BK 1 Measure the resistance between the starter motor solenoid connector circuit 50 GY BK and starter relay connector pin 3 circuit 50 GY BK Is the resistance...

Page 712: ...HORT TO GROUND 1 Ignition switch 2 Measure the resistance between the ignition switch connector pin 3 citcuit 50 GY and ground Is the resistance greater than 10 000 ohms Yes CONNECT the ignition switc...

Page 713: ...1 Measure the resistance between the starter motor casing and negative battery terminal Is the resistance less than 5 ohms Yes INSTALL a new starter motor TEST the system for normal operation No CLEA...

Page 714: ...C2 CHECK THE STARTER DRIVE 1 Remove the starter motor Refer to the procedure in this section 2 Inspect the ring gear for damage and wear Is the ring gear damaged Yes REPAIR ring gear as required TEST...

Page 715: ...002 Bantam Starter Motor Vehicles with 1 8L Endura DE Diesel Engine 26 204 0 Removal 1 Disconnect the battery ground cable 2 Raise the vehicle 3 Disconnect the starter motor wiring 4 Remove the starte...

Page 716: ...303 06 212 Starting System 303 06 212 REMOVAL AND INSTALLATION CONTINUED E5909 EN 09 2001 2002 Bantam Installation 1 Refit the components in reverse order...

Page 717: ...2001 2002 Bantam Torque Specifications Description Nm Starter motor retaining bolts 35 Support bracket retaining bolt 25 Support bracket retaining nuts 6 Starter motor solenoid power cable retaining...

Page 718: ...GNOSIS AND TESTING Engine Emission Control 303 08B 216 Inspection and Verification 303 08B 216 REMOVAL AND INSTALLATION Exhaust Manifold to Exhaust Gas Re circulation EGR Valve Tube 23 301 0 303 08B 2...

Page 719: ...e flow through hoses out of the valve cover into the intake air system It is a completely sealed system which helps to reduce hydrocarbon emissions from the engine Exhaust Gas Re circulation The exhau...

Page 720: ...ors and controls Exhaust gas recirculation clamps Exhaust gas Recirculation tube for cracks Vacuum pipes for leaks Coolant pipes for leaks Exhaust gas recirculation gaskets Loose or corroded connectio...

Page 721: ...the exhaust manifold to exhaust gas re circulation valve pipe one bolt Installation 1 Remove and discard the two exhaust manifold to exhaust gas re circulation valve pipe sealing rings 2 Examine the e...

Page 722: ...STALLATION E6363 EN 09 2001 2002 Bantam Exhaust Gas Re circulation EGR Valve 23 312 0 Removal 1 Remove the air intake pipe two clips 2 Disconnect the exhaust gas re circulation valve lift sensor multi...

Page 723: ...the exhaust gas re circulation valve two bolts Installation 1 CAUTION When cleaning is required take care not to allow debris to fall into the inlet manifold exhaust manifold or exhaust gas Recirculat...

Page 724: ...Bantam Exhaust Gas Re circulation EGR Valve Vehicles with 1 8L Endura DE Diesel Engine 23 312 0 Removal 1 Disconnect the exhaust gas re circulation EGR valve electrical connector and vacuum line 2 Di...

Page 725: ...303 08B 221 REMOVAL AND INSTALLATION CONTINUED E7850 EN 09 2001 2002 Bantam 4 Detach the exhaust manifold to EGR valve tube 5 Discard the EGR valve clamp 6 Remove and discard the EGR valve gasket 7 Re...

Page 726: ...AND INSTALLATION CONTINUED E7850 EN 09 2001 2002 Bantam Installation NOTE Install a new exhaust manifold to EGR valve tube gasket NOTE Install a new EGR valve gasket NOTE Install a new exhaust manifo...

Page 727: ...2001 2002 Bantam Torque Specifications Description Nm Endura DE Diesel Engine Exhaust gas Recirculation valve retaining bolts 20 Endura DI Diesel Engine Exhaust gas Recirculation valve tube retaining...

Page 728: ...OPERATION Engine Emission Controls 303 14D 225 DIAGNOSIS AND TESTING Electronic Engine Controls 303 14D 226 Inspection and Verification 303 14D 226 REMOVAL AND INSTALLATION Crankshaft Position CKP Sen...

Page 729: ...take air temperature IAT sensor 5 Crankshaft position CKP sensor The engine management system consists of a powertrain control module PCM a number of sensors and a clutch pedal position switch The PCM...

Page 730: ...electrical damage Visual Inspection Chart Mechanical Electrical Fuel leak s Vacuum line s Sensor s Clutch pedal position switch Wiring harness Loose or corroded electrical connector s Powertrain contr...

Page 731: ...ankshaft Position CKP Sensor Vehicles with 1 8L Endura DE Diesel Engine 29 230 0 Removal 1 Raise and support the vehicle For additional information refer to Section 100 02 2 Disconnect the crankshaft...

Page 732: ...9 2001 2002 Bantam Engine Coolant Temperature ECT Sensor 21 190 0 Removal 1 Drain the cooling system For additional information refer to Section 303 03 2 Disconnect the engine coolant temperature sens...

Page 733: ...ronic Engine Controls Diesel Engine 303 14D 229 SPECIFICATIONS E5898 EN 09 2001 2002 Bantam Torque Specifications Description Nm Exhaust gas Re circulation valve retaining bolts 20 Engine coolant temp...

Page 734: ...E Diesel Engine 303 03 143 144 Thermostat Housing Vehicles with 1 6L 1 3L Engine 24 001 0 303 03 145 147 Water Pump Vehicles with 1 6L 1 3L Engine 24 404 0 303 03 148 150 Water Pump Vehicles with Dies...

Page 735: ...303 03 134 DESCRIPTION AND OPERATION E6861 EN 07 2001 2002 Bantam Engine Cooling Vehicles with 1 6L 1 3L engine Item Description 1 Water pump 2 Engine coolant temperature ECT sender unit Item Descrip...

Page 736: ...em Description 1 Water pump 2 Engine coolant temperature ECT sender unit 3 Thermostat All Vehicles WARNING Never remove the coolant expansion tank cap under any circumstances while the engine is opera...

Page 737: ...f the coolant expansion tank with a hydrometer The acceptable range of specific gravity sg of correctly balanced fluids is between 1 06 and 1 07 kg l which represents an engine coolant concentration o...

Page 738: ...AND OPERATION CONTINUED E6861 EN 07 2001 2002 Bantam Vehicles with Petrol or Diesel engine Engine Coolant Temperature ECT Sender Unit The ECT sender unit measures engine coolant temperature and contro...

Page 739: ...obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 If the concern is not visually evident verify the symptom and refer to the...

Page 740: ...y drive belt if necessary ECT sensor CHECK the ECT sensor for cor rect operation REFER to WDS to diagnose the system Cooling fan motor switch CHECK the cooling fan motor switch for correct operation R...

Page 741: ...for approximately two minutes The pressure should not drop during this time If the system holds pressure proceed to Step 5 If the system does not hold pressure check it thoroughly for coolant leaks I...

Page 742: ...2 Bantam Thermostat Vehicles with 1 6L 1 3L Engine 24 454 0 Removal 1 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 2 Detach...

Page 743: ...303 03 142 Engine Cooling 303 03 142 REMOVAL AND INSTALLATION CONTINUED E5887 EN 07 2001 2002 Bantam Installation 1 NOTE Install a new thermostat O ring seal To install reverse the removal procedure...

Page 744: ...02 Bantam Thermostat Vehicles with 1 8L Endura DE Diesel Engine 24 454 0 Special Tool s Remover Installer cooling hose clamp 24 003 Removal 1 Drain the cooling system Refer to the procedure in this se...

Page 745: ...ATION CONTINUED E5887 EN 07 2001 2002 Bantam Installation 1 Install a new O ring seal 2 Install the thermostat and thermostat housing 3 Install the remaining components in the reverse order 4 Refill t...

Page 746: ...over Installer Hose Clamp 303 397 24 003 Removal 1 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 2 Lower the vehicle 3 Using...

Page 747: ...TALLATION CONTINUED E6653 EN 07 2001 2002 Bantam 5 Using the special tool disconnect the coolant hose from the thermostat housing 6 Disconnect the coolant hose from the thermostat housing 7 Remove the...

Page 748: ...03 03 147 Engine Cooling 303 03 147 REMOVAL AND INSTALLATION CONTINUED E6653 EN 07 2001 2002 Bantam Installation 1 NOTE Install a new thermostat housing gasket To install reverse the removal procedure...

Page 749: ...L 1 3L Engine 24 404 0 Removal 1 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 2 Remove the splash shield 3 Loosen the water...

Page 750: ...002 Bantam 5 Remove the water pump pulley 6 Remove the water pump crankshaft pulley shown removed for clarity 7 Remove and discard the water pump gasket crankshaft pulley shown removed for clarity Ins...

Page 751: ...303 03 150 Engine Cooling 303 03 150 REMOVAL AND INSTALLATION CONTINUED E6655 EN 07 2001 2002 Bantam...

Page 752: ...Section 414 01 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 Remove the timing belt For additional information refer to...

Page 753: ...remove the three bolts 2 Fully loosen the remaining bolt 7 Raise the engine using a suitable jack and packing material to allow the bolt to be withdrawn through the body bracket 8 Remove the engine fr...

Page 754: ...0 Disconnect the coolant hose from the water pump 11 Remove the remaining water pump bolts Take care not to put undue stress on any pipes or wiring 12 Raise the engine using a suitable jack and packin...

Page 755: ...303 03 154 Engine Cooling 303 03 154 REMOVAL AND INSTALLATION CONTINUED E6441 EN 07 2001 2002 Bantam...

Page 756: ...battery ground cable For additional information refer to Section 414 01 Vehicles with air conditioning 2 Remove the radiator grille 1 Detach the clips 2 Remove the radiator grille 3 Secure the air co...

Page 757: ...g the special tool disconnect the coolant hose from the thermostat housing 7 Using the special tool disconnect the coolant hose from the radiator All except vehicles with diesel engine 8 Using the spe...

Page 758: ...002 Bantam All vehicles 10 Remove the engine undershield For additional information refer to Section 502 00 11 Remove the splash shield Vehicles with diesel engine 12 Using the special tool disconnect...

Page 759: ...nect and detach the cooling fan motor resistor electrical connector 15 Disconnect and detach the cooling fan motor relay electrical connector 16 Disconnect the cooling fan motor electrical connector A...

Page 760: ...cooling fan motor resistor cooling fan motor and cooling fan motor relay electrical connectors 19 Detach the cooling fan motor wiring Vehicles with air conditioning 20 Remove the A C condenser upper r...

Page 761: ...CONTINUED E6656 EN 07 2001 2002 Bantam 22 Remove the A C condenser right hand retaining bolt All vehicles 23 Remove the radiator support bracket right hand retaining bolts 24 Remove the radiator suppo...

Page 762: ...or and shroud 1 Loosen the cooling fan shroud nuts 2 Remove the cooling fan motor and shroud 27 Using the special tool remove the coolant hose from the radiator 28 Remove the radiator left hand insula...

Page 763: ...N CONTINUED E6656 EN 07 2001 2002 Bantam Installation All vehicles 1 NOTE Make sure the A C condenser upper locating tangs are correctly installed into the radiator upper locating brackets To install...

Page 764: ...303 03 163 Engine Cooling 303 03 163 REMOVAL AND INSTALLATION CONTINUED E6656 EN 07 2001 2002 Bantam...

Page 765: ...battery ground cable For additional information refer to Section 414 01 2 Remove the cooling fan shroud right hand retaining nut 3 Remove the cooling fan shroud left hand retaining nut 4 Remove the en...

Page 766: ...isconnect and detach the cooling fan motor relay electrical connector 7 Disconnect the cooling fan motor electrical connector 8 Remove the cooling fan motor and shroud Raise the cooling fan motor and...

Page 767: ...303 03 166 Engine Cooling 303 03 166 REMOVAL AND INSTALLATION CONTINUED E6657 EN 07 2001 2002 Bantam 10 Remove the cooling fan motor Installation 1 To install reverse the removal procedure...

Page 768: ...the expansion tank hoses 1 Disconnect the radiator to expansion tank hose 2 Disconnect the engine to expansion tank hose 3 Disconnect the engine supply hose 3 Remove the expansion tank 1 Remove the e...

Page 769: ...thick cloth to prevent the possibility of coolant scalding Relieve the cooling system pressure Unscrew the cap slowly 2 Remove the cap 3 Raise and support the vehicle For additional information refer...

Page 770: ...h a diesel engine it is necessary to add a further one liter of coolant above the MAX mark to make sure that the correct level is achieved after the system degasses Refill the expansion tank to the MA...

Page 771: ...nt flow direction In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation it will be necessary to use the pressure flushing method using Cooling Syst...

Page 772: ...rden hose from a tap with a male adapter into the end of the heater outlet hose Secure with a hose clamp 2 Connect a garden hose to the engine intake connector and secure with a hose clamp Allow the o...

Page 773: ...and fitting adapter in the end of the heater outlet water hose Secure with a hose clamp 2 Connect the female hose end of the heater outlet water hose to the male end of a water supply garden hose 3 D...

Page 774: ...volume Remains fluid to Solidifies at 1 061 at 15 C 30 25 C 13 F 30 C 22 F Pressures Description Pressure bar Radiator pressure test 1 38 Coolant expansion tank cap release pressure 0 89 1 28 Torque S...

Page 775: ...IPTION AND OPERATION Fuel Charging and Controls 303 04B 175 176 DIAGNOSIS AND TESTING Fuel Charging and Controls 303 04B 177 Inspection and Verification 303 04B 177 REMOVAL AND INSTALLATION Throttle B...

Page 776: ...e body 5 Fuel injection supply manifold Fuel Charging Wiring Harness The fuel charging wiring harness links the fuel injectors to the engine management system Fuel Pressure Regulator The fuel pressure...

Page 777: ...achieved by means of six O ring seals Throttle Body The throttle body is of aluminum construction with a hole for the throttle position sensor Sealing is achieved by means of a gasket and an O ring se...

Page 778: ...l damage Visual Inspection Chart Mechanical Electrical Fuel leak s Fuel pressure regulator vacuum line Fuel injector s Fuel pressure regulator Throttle body Fuel injection supply manifold Wiring harne...

Page 779: ...Bantam Throttle Body 23 198 0 Removal CAUTION Do not attempt to clean the throttle body The bore and throttle plate have a special coating applied during manufacture which should not be re moved 1 Re...

Page 780: ...4B 179 REMOVAL AND INSTALLATION CONTINUED E6661 EN 07 2001 2002 Bantam 4 Disconnect the air cleaner outlet pipe 5 Remove the air cleaner outlet pipe 6 Disconnect the throttle position TP sensor electr...

Page 781: ...TION CONTINUED E6661 EN 07 2001 2002 Bantam Installation CAUTION Do not attempt to clean the throttle body The bore and throttle plate have a special coating applied during manufacture which should no...

Page 782: ...onal injury WARNING Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components Highly flammable mixtures are always present and can ig nite Fai...

Page 783: ...TION CONTINUED E6662 EN 07 2001 2002 Bantam 5 Detach the fuel charging wiring harness Remove the cable ties 6 Disconnect the fuel injector electrical connectors 7 Disconnect the fuel lines For additio...

Page 784: ...sconnect the fuel pressure regulator vacuum line 10 Remove the fuel injectors 1 Remove the clip 2 Remove the fuel injectors 11 Remove and discard the O ring seals Installation WARNING This procedure i...

Page 785: ...fuel related components Highly flammable mixtures are always present and can ig nite Failure to follow these instructions may result in personal injury 1 CAUTION Do not use silicone grease to lubricat...

Page 786: ...s 36 437 0 Removal 1 Detach the fuel charging wiring harness and disconnect the electrical connector 2 Disconnect the camshaft position CMP sensor electrical connector and detach the fuel charging wir...

Page 787: ...onnect the temperature and manifold absolute pressure T MAP sensor electrical connector 6 Disconnect the idle air control IAC valve electrical connector 7 Disconnect the throttle position TP sensor el...

Page 788: ...303 04B 187 Fuel Charging and Controls 1 6L 1 3L Engine 303 04B 187 REMOVAL AND INSTALLATION CONTINUED E6663 EN 07 2001 2002 Bantam Installation 1 To install reverse the removal procedure...

Page 789: ...Charging and Controls 1 6L 1 3L Engine 303 04B 188 SPECIFICATIONS E6664 EN 07 2001 2002 Bantam Torque Specifications Description Nm Throttle body retaining bolts 10 Fuel injection supply manifold ret...

Page 790: ...8L Diesel Engine VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Fuel Charging and Controls 303 04D 2 Fuel Injection Pump 303 04D 2 Light Load Retard Device 303 04D 2 Cold Star...

Page 791: ...olenoid which advances the injection timing throughout the engine speed load range The amount of time which the solenoid is energized decreases as engine coolant temperature increases The solenoid is...

Page 792: ...sition of the motor and therefore the position of the idle lever To prevent excess slack in the control cable the idle speed control motor is fitted with an idle tracking switch which prevents further...

Page 793: ...antam SECTION 303 04D Fuel Charging and Controls 1 8L Diesel Engine VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE GENERAL PROCEDURES Idle Speed Adjustment Vehicles Without Air Conditioning 23 413 0 303...

Page 794: ...ith the manufacturer s instructions 2 Start the engine and allow it to idle 3 Loosen the idle speed adjustment screw lock nut 4 Adjust the idle speed screw as necessary refer to Specifications contain...

Page 795: ...Remove the idle speed control cable retaining clip 3 Start the engine and allow it to idle 4 Loosen the idle speed adjustment screw lock nut 5 Adjust the minimum engine speed as necessary refer to Sp...

Page 796: ...uel Charging and Controls 1 8L Diesel Engine 303 04D 7 GENERAL PROCEDURES CONTINUED E6451 EN 09 2001 2002 Bantam 11 Refit the idle speed control cable retaining clip 12 Disconnect the tachometer from...

Page 797: ...04D 8 09 2001 2002 Bantam SECTION 303 04D Fuel Charging and Controls 1 8L Diesel Engine VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Fuel Injection Pump Removal 23 414 0 303...

Page 798: ...njection Pump Timing 310 018 23 019 Timing Peg Fuel Injection Pump Timing 310 033 23 029 Removal All vehicles WARNING This procedure in volves fuel handling Be prepared for fuel spillage at all times...

Page 799: ...all the special tools 3 Remove the engine front mounting auxiliary bracket 4 Remove the engine front mounting bracket 5 Raise and support the vehicle For additional information refer to Section 100 02...

Page 800: ...m 8 Remove the crankshaft pulley vibration damper 9 Remove the timing belt lower cover retaining bolts 10 Lower the vehicle Vehicles with power steering 11 Loosen the power steering pump pulley retain...

Page 801: ...eering pump pulley All vehicles 15 Remove the timing belt cover 16 Turn the engine clockwise until the slot in the fuel injection pump pulley reaches the 11 o clock position 17 Raise and support the v...

Page 802: ...the engine to lock the crankshaft do so slowly to avoid bending the special tool Turn the engine clockwise until the crankshaft locks against the special tool 20 Install the special tool to lock the c...

Page 803: ...ator cable from the retaining bracket 25 Disconnect the accelerator cable from the fuel injection pump fuel lever Vehicles without air conditioning 26 Remove the waxstat cable retaining clip 27 Discon...

Page 804: ...on pump idle lever All vehicles 30 Detach the fuel injection pump wiring from the retaining clip and disconnect the electrical connector 31 Disconnect the fuel return line from the fuel injection pump...

Page 805: ...2 Bantam 34 Loosen the fuel injection pump drive belt tensioner bolt 35 De tension the fuel injection pump drive belt 36 Tighten the fuel injection pump drive belt tensioner bolt 37 Loosen the fuel in...

Page 806: ...t the vehicle For additional information refer to Section 100 02 42 Remove the three bolts which retain the fuel injection pump rear support bracket to the cylinder block 43 Lower the vehicle 44 CAUTI...

Page 807: ...red to very precise tolerances and fine clearances It is there fore essential that absolute cleanliness be observed when working with these compo nents Always fit blanking plugs to any open orifices o...

Page 808: ...Bantam 6 Tighten the rear support bracket bolts 7 Install the fuel injection pump pulley Do not tighten the bolts at this stage 8 Install the special tool to lock the fuel injection pump 9 Install a...

Page 809: ...injection pump pulley retaining bolts Make sure that the elongated holes in the fuel injection pump pulley are centralized with the retaining bolts 13 Install a new timing belt For additional informat...

Page 810: ...jection pump pulley reaches the 11 o clock position 20 Raise and support the vehicle For additional information refer to Section 100 02 21 Install the special tool to the cylinder block CAUTION When t...

Page 811: ...sary For additional information refer to Idle Speed Adjustment in this section Vehicles without air conditioning 28 Remove the waxstat cable retaining clip 29 NOTE This adjustment must be carried out...

Page 812: ...sel Engine 303 04D 23 REMOVAL AND INSTALLATION E6445 EN 09 2001 2002 Bantam SECTION 303 04D Fuel Charging and Controls 1 8L Diesel Engine VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE REMOVAL AND INSTA...

Page 813: ...y precise tolerances and fine clearances It is there fore essential that absolute cleanliness be observed when working with these com ponents Always fit blanking plugs to any open orifices or pipes Re...

Page 814: ...303 04D 25 Fuel Charging and Controls 1 8L Diesel Engine 303 04D 25 REMOVAL AND INSTALLATION CONTINUED E6445 EN 09 2001 2002 Bantam...

Page 815: ...D INSTALLATION E6446 EN 09 2001 2002 Bantam SECTION 303 04D Fuel Charging and Controls 1 8L Diesel Engine VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Fuel Injector Delivery P...

Page 816: ...CAUTION Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances It is there fore essential that absolute cleanliness be observed when working with these com pon...

Page 817: ...rew the four unions from the fuel injectors and remove the fuel injector delivery pipes Installation 1 Refit the fuel injector delivery pipes and loosely assemble the four unions to the fuel injectors...

Page 818: ...ntrols 1 8L Diesel Engine 303 04D 29 REMOVAL AND INSTALLATION CONTINUED E6446 EN 09 2001 2002 Bantam 4 Tighten the four fuel injector delivery pipe unions to the fuel injection pump 5 Refit the remain...

Page 819: ...l Engine 303 04D 30 09 2001 2002 Bantam SECTION 303 04D Fuel Charging and Controls 1 8L Diesel Engine VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE GENERAL PROCEDURES Waxstat Cable Adjustment 303 04D 3...

Page 820: ...6449 EN 09 2001 2002 Bantam Waxstat Cable Adjustment NOTE This adjustment must be carried out with the engine cold 1 Remove the waxstat cable adjuster clip 2 Hold the idle lever against its stop and r...

Page 821: ...must be used to prevent stretching of the outer cable 4 Push the outer section of the idle speed control cable away from the idle lever until the idle lever is pulled against the high idle screw and r...

Page 822: ...2 EN 09 2001 2002 Bantam SECTION 303 04D Fuel Charging and Controls 1 8L Diesel Engine VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE SPECIFICATIONS Specifications 303 04D 34 Fuel Injection Pump 303 04D...

Page 823: ...158 165 Back leakage bar maximum of 5 seconds allowed for the pressure to fall from the upper to the lower value quoted 125 100 Needle seat leakage bar hold for 10 seconds 125 Glow Plugs Specification...

Page 824: ...2002 Bantam Description Nm Endura DE Diesel Engine Fuel injection pump retaining bolts 20 Endura DE Diesel Engine Fuel injector delivery pipe unions 20 Endura DE Diesel Engine Fuel injectors 75 Endura...

Page 825: ...IAGNOSIS AND TESTING Accessory Drive 303 05 192 Inspection and Verification 303 05 192 193 Symptom Chart 303 05 193 194 Component Tests 303 05 194 195 REMOVAL AND INSTALLATION Accessory Drive Belt Ten...

Page 826: ...e Vehicles with 1 6L 1 3L Engine Item Description 1 Accessory drive belt 2 Power steering pump pulley or idler pulley vehicles without power steering 3 Generator pulley 4 Idler pulley Item Description...

Page 827: ...ibrated to provide the correct amount of tension to the drive belt for a given accessory drive system Vehicles with Diesel Engine Item Description 1 Crankshaft pulley 2 Accessory drive belt 3 Generato...

Page 828: ...t tensioner pulley bearing and idler pulley s bearing may occur NOTE Up to 15 cracks in a belt rib over a distance of 100 mm may be considered acceptable If the cracks exceed the acceptable limit or a...

Page 829: ...running and the belt re moved only run the engine for a very short period If a noise is apparent the cause is not the accessory drive system If a noise is not apparent the cause is the accessory driv...

Page 830: ...ed CHECK the belt tensioner for correct operation or damage INSTALL a new belt tensioner as necessary Component Tests Manual Belt Tensioner and Idler Pulley s The manual belt tensioner and idler pulle...

Page 831: ...test the tensioner dynamically If the tensioner does not meet the above criteria install a new tensioner Automatic Tensioner Dynamic Check The automatic tensioner may be checked dynamically as follow...

Page 832: ...Engine Removal All vehicles 1 Remove the generator For additional information refer to Section 414 02 2 Lower the vehicle 3 Remove the accessory drive belt tensioner pulley Vehicles with power steeri...

Page 833: ...NSTALLATION CONTINUED E5903 EN 07 2001 2002 Bantam All vehicles 6 Remove the accessory drive belt lower idler pulley 7 Remove the accessory drive belt tensioner and bracket assembly Installation All v...

Page 834: ...303 05 198 Accessory Drive 303 05 198 REMOVAL AND INSTALLATION CONTINUED E5903 EN 07 2001 2002 Bantam Vehicles without power steering Vehicles with power steering All vehicles...

Page 835: ...round cable 2 Raise the vehicle 3 Remove the drive belt 1 Loosen the adjuster clamping bolt 2 De tension the belt by turning the adjuster bolt anticlockwise Installation 1 Refit the drive belt Make su...

Page 836: ...ery ground cable 2 Raise the vehicle 3 Remove the drive belt 1 Loosen the adjuster clamping bolt 2 De tension the belt by turning the adjuster bolt anticlockwise Installation 1 Refit the drive belt Ma...

Page 837: ...rive belt lower idler pulley retaining bolt 1 6L 1 3L 48 Accessory drive belt upper idler pulley retaining bolts 1 6L 1 3L 25 Power steering pump retaining bolts 1 6L 1 3L 25 Accessory drive belt tens...

Page 838: ...06 203 DIAGNOSIS AND TESTING Starting System 303 06 204A Inspection and Verification 303 06 204A Symptom Chart 303 06 204A Pinpoint Tests 303 06 204B 212 REMOVAL AND INSTALLATION Starter Motor Vehicl...

Page 839: ...ive of model all starter motors have an integral solenoid and all types have pinions which engage with a ring gear during starting The ring gear is located on the outside of the flywheel Some starter...

Page 840: ...Electrical Starter motor Battery Fuse Wiring Connectors 3 If inspection reveals an obvious cause rectify this before continuing If the concern remains proceed to the symptom chart Symptom Chart Condi...

Page 841: ...06 207 A10 CHECK CIRCUIT 30 RD CONTINUITY 303 06 208 A11 CHECK THE IGNITION SWITCH 303 06 208 A12 CHECK CIRCUIT 50 GY CONTINUITY 303 06 208 209 A13 CHECK THE CONTINUITY OF CIRCUIT 50 GY BK 303 06 209...

Page 842: ...DITIONS DETAILS RESULTS ACTIONS A1 CHECK THE BATTERY CONNECTIONS 1 Inspect the battery connections for loose corroded connections Are the battery terminals clean and tight Yes GO TO A2 No CLEAN and TI...

Page 843: ...OK Yes GO TO A3 No CHARGE or INSTALL a new battery as re quired Refer to Section 414 00 TEST the system for normal operation A3 CHECK SWITCHED POWER SUPPLY TO THE SOLENOID 1 Solenoid single pin 2 3 M...

Page 844: ...HE STARTER GROUND CIRCUIT 1 Measure the resistance between the starter motor casing and negative battery terminal Is the resistance less than 5 ohms Yes INSTALL a new starter motor TEST the system for...

Page 845: ...Is the resistance less than 5 ohms Yes GO TO A8 No REPAIR circuit 31 BK TEST the system for normal operation A8 CHECK RELAY SWITCHING CIRCUIT 1 2 Measure the voltage between the starter relay connecto...

Page 846: ...onnector pin 1 circuit 30 RD and ignition switch connector pin 4 circuit 30 RD Is the resistance less than 5 ohms Yes GO TO A11 No REPAIR circuit 30 RD TEST the system for normal operation A11 CHECK T...

Page 847: ...A13 CHECK THE CONTINUITY OF CIRCUIT 50 GY BK 1 Measure the resistance between the starter motor solenoid connector circuit 50 GY BK and starter relay connector pin 3 circuit 50 GY BK Is the resistance...

Page 848: ...r pin 1 circuit 30 RD and ground Is the resistance greater than 10 000 ohms Yes GO TO A16 No REPAIR circuit 30 RD TEST the system for normal operation A16 CHECK CIRCUIT 50 FOR SHORT TO GROUND 1 Igniti...

Page 849: ...414 00 TEST the system for normal operation B2 CHECK THE SUPPLY TO STARTER 1 2 Measure the voltage between the starter terminal B circuit 30 RD and ground Is the voltage greater than 12 5 volts Yes GO...

Page 850: ...alignment Is the starter mounted correctly Yes GO TO C2 No INSTALL the starter motor Refer to the procedure in this section TEST the system for normal operation C2 CHECK THE STARTER DRIVE 1 Remove th...

Page 851: ...e 26 204 0 Removal 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the engine undershield For additional information refer to Section 502 00 3 Disconn...

Page 852: ...303 06 214 Starting System 303 06 214 REMOVAL AND INSTALLATION CONTINUED E5909 EN 07 2001 2002 Bantam...

Page 853: ...001 2002 Bantam Starter Motor Vehicles with 1 8L Endura DE Diesel Engine 26 204 0 Removal 1 Disconnect the battery ground cable 2 Raise the vehicle 3 Disconnect the starter motor wiring 4 Remove the s...

Page 854: ...303 06 216 Starting System 303 06 216 REMOVAL AND INSTALLATION CONTINUED E5909 EN 07 2001 2002 Bantam Installation 1 Refit the components in reverse order...

Page 855: ...217 SPECIFICATIONS E6678 EN 07 2001 2002 Bantam Torque Specifications Description Nm Starter motor retaining bolts 35 Starter motor electrical connector upper retaining nut 12 Starter motor electrica...

Page 856: ...JECT PAGE DESCRIPTION AND OPERATION Engine Ignition 303 07 219 DIAGNOSIS AND TESTING Engine Ignition 303 07 220 Inspection and Verification 303 07 220 REMOVAL AND INSTALLATION Ignition Coil Pack Vehic...

Page 857: ...time the closing of the ignition coils primary circuits Ignition timing is determined by the PCM in response to engine operating conditions Once ignition timing has been determined the PCM interrupts...

Page 858: ...us signs of damage Refer to the following chart Visual Inspection Chart Mechanical Electrical Damaged spark plug wires Damaged spark plugs Connections to spark plugs and coil Loose or corroded ignitio...

Page 859: ...t the spark plug wires from the ignition coil pack 2 Disconnect the ignition coil pack electrical connector 3 Remove the ignition coil pack Installation CAUTION The ignition coil pack and spark plug w...

Page 860: ...303 07 222 Engine Ignition 303 07 222 REMOVAL AND INSTALLATION CONTINUED E6681 EN 07 2001 2002 Bantam 1 To install reverse the removal procedure...

Page 861: ...303 07 223 Engine Ignition 303 07 223 SPECIFICATIONS E6682 EN 07 2001 2002 Bantam Torque Specifications Description Nm Ignition coil pack retaining screws 6...

Page 862: ...ntake Air Distribution and Filtering Vehicles with 1 6L 1 3L engine 303 12 225 Intake Air Distribution and Filtering Vehicles with Diesel engine 303 12 226 DIAGNOSIS AND TESTING Intake Air Distributio...

Page 863: ...AND OPERATION E6687 EN 07 2001 2002 Bantam Intake Air Distribution and Filtering Vehicles with 1 3L or 1 6L Engine Item Description 1 Air cleaner outlet pipe 2 Air cleaner housing cover Item Descripti...

Page 864: ...SCRIPTION AND OPERATION E6687 EN 07 2001 2002 Bantam Vehicles with Diesel Engine Item Description 1 Air cleaner outlet pipe 2 Air cleaner housing cover 3 Air cleaner element Item Description 4 Air cle...

Page 865: ...303 12 227 Intake Air Distribution and Filtering 303 12 227 DIAGNOSIS AND TESTING E1029 EN 07 2001 2002 Bantam Intake Air Distribution and Filtering REFER to Section 303 00...

Page 866: ...e 23 175 0 Removal NOTE The procedure shown is for vehicles with 1 6L 1 3L engines the procedure is similar for vehicles with diesel engine 1 Disconnect the air cleaner outlet pipe from the throttle b...

Page 867: ...m 4 Remove the air cleaner element 5 Disconnect the air cleaner intake pipe from the air cleaner Release the tang 6 Loosen the left hand front wheel nuts 7 Raise and support the vehicle For additional...

Page 868: ...2 230 REMOVAL AND INSTALLATION CONTINUED E6688 EN 07 2001 2002 Bantam 10 Remove the air cleaner intake pipe 1 Rotate the air cleaner intake pipe counterclockwise 2 Remove the air cleaner intake pipe I...

Page 869: ...1 Remove the air cleaner intake pipe For additional information refer to Air Cleaner Intake Pipe in this section Vehicles with 1 6L 1 3L engines 2 Disconnect the engine ventilation hose All vehicles 3...

Page 870: ...303 12 232 Intake Air Distribution and Filtering 303 12 232 SPECIFICATIONS E6721 EN 07 2001 2002 Bantam Torque Specifications Description Nm Wheel nuts 85 Air cleaner housing cover retaining screws 10...

Page 871: ...ion 303 14 237 REMOVAL AND INSTALLATION Powertrain Control Module PCM Vehicles with Petrol Engine 29 200 0 303 14 238 239 Crankshaft Position CKP Sensor Vehicles with Petrol Engine 29 230 0 303 14 240...

Page 872: ...rols Vehicles with 1 6L 1 3L Engines Item Description 1 Camshaft position CMP sensor 2 Oxygen sensor O2S 3 Engine coolant temperature ECT sensor 4 Throttle position TP sensor 5 Crankshaft position CKP...

Page 873: ...ture dependent resistor which has a negative temperature coefficient This means its resistance decreases with increased temperature It is supplied with a reference voltage by the PCM When the engine c...

Page 874: ...les with Diesel Engine Air Conditioning A C Cutoff Switch The A C cutoff switch is secured to the fuel injection pump and operated by the fuel injection pump throttle linkage When the throttle linkage...

Page 875: ...pect for obvious signs of damage Refer to the following chart Visual Inspection Chart Mechanical Electrical Damaged sensors Damaged actuators Damaged electrical connections Damaged wiring harness s Lo...

Page 876: ...Bantam Powertrain Control Module PCM Vehicles with Petrol Engine 29 200 0 Removal 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Detach the left hand door o...

Page 877: ...TALLATION CONTINUED E6670 EN 07 2001 2002 Bantam 5 Remove the PCM Installation 1 CAUTION When installing the PCM electrical connector start the bolt by hand before tightening to avoid damaging the ele...

Page 878: ...s with 1 6L 1 3L Engines 29 230 0 Removal 1 Remove the engine undershield For additional information refer to Section 502 00 2 Disconnect the crankshaft position CKP sensor electrical connector starte...

Page 879: ...wer Steering Pressure PSP Switch Vehicles with Petrol Engine 33 611 0 Removal 1 Raise and support the vehicle For additional information refer to Section 100 02 2 Disconnect the power steering pressur...

Page 880: ...ion TP Sensor Vehicles with 1 6L 1 3L Engines 23 325 0 Removal 1 Remove the throttle body For additional information refer to Section 303 04B 2 Remove the throttle position TP sensor 3 Remove and disc...

Page 881: ...21 190 0 Removal 1 Drain the cooling system For additional information refer to Section 303 03 2 Disconnect the engine coolant temperature ECT sensor electrical connector 3 Remove the ECT sensor 1 Re...

Page 882: ...Removal 1 Disconnect the battery ground cable 2 Remove the air cleaner intake pipe 3 WARNING Watch for and collect escaping fuel Observe the safety regulations for working with fuel Disconnect the fue...

Page 883: ...acuum hose 2 Positive crankcase ventilation PCV hose 3 Crankcase breather hose 4 Engine coolant temperature ECT sensor electrical connector 5 Brake booster vacuum hose 6 Disconnect the electrical conn...

Page 884: ...Engine Controls 303 14 246 REMOVAL AND INSTALLATION CONTINUED 9 Remove the intake manifold lower retaining bolts shown with the engine removed 10 Lower the vehicle 11 Remove the intake manifold 14 Re...

Page 885: ...01 2002 Bantam Installation 1 Install the knock sensor 2 NOTE Install a new gasket if the original is damaged Install the intake manifold 3 Raise and support the vehicle For additional information ref...

Page 886: ...ectrical connectors 8 Install the hoses and connect the electrical connector 1 EVAP solenoid valve vacuum hose 2 PCV hose 3 Crankcase breather hose 4 ECT sensor electrical connector 5 Brake booster va...

Page 887: ...249 Electronic Engine Controls 303 14 249 REMOVAL AND INSTALLATION CONTINUED E6694 EN 07 2001 2002 Bantam 10 Connect the fuel lines 11 Install the air cleaner intake pipe 12 Connect the battery ground...

Page 888: ...0 SPECIFICATIONS E6697 EN 07 2001 2002 Bantam Torque Specifications Description Nm Crankshaft position CKP sensor retaining bolt 10 Power steering pressure PSP switch 10 Throttle position TP sensor re...

Page 889: ...rification Clutch 308 00 3 Inspection and Verification Manual Transaxle 308 00 3 Symptom Charts 308 00 4 8A Pinpoint Tests 308 00 8B 14 GENERAL PROCEDURES Clutch Disc Check 308 00 15 Clutch Master Cyl...

Page 890: ...ION AND OPERATION E4459 EN 07 2001 2002 Bantam Manual Transaxle and Clutch Clutch For additional information refer to Section 308 01 Clutch Controls For additional information refer to Section 308 02...

Page 891: ...tch pedal as far as the stop If 1st or 2nd gear can be selected with no problem with the engine running and the parking brake applied the clutch is OK If the gear cannot be selected repair the clutch...

Page 892: ...reverse gear syn chronizer Gearshift problems in different gears stiff or partially seized Transaxle assembly error miss ing snap rings or synchronizer components foreign materials in the transaxle Bo...

Page 893: ...ting face Disassemble the transaxle clean the mating faces CHECK the surfaces for damage Seal the transaxle with liquid sealer as described in the Service Mi crofiche General Concerns Condition Possib...

Page 894: ...n the gearshift lever and gearshift lever hous ing Adjust the gearshift mechanism or repair the defect 3rd gear jumps out of engage ment Internal selector mechanism loose causing the selector fin ger...

Page 895: ...pedal free play Sticking clutch pedal Diaphragm springs Clutch pressure plate Clutch disc facing Hardened or oiled clutch disc facing surface Flywheel Go To Pinpoint Test A Clutch chatter or shudder E...

Page 896: ...Sources Action Excessive noise Clutch pedal free play Clutch release bearing Poor lubrication of clutch release bearing Pilot bearing Excessive crankshaft endplay Go To Pinpoint Test G Fluid leakage...

Page 897: ...TCH PEDAL PULSATION D1 CHECK THE CLUTCH PEDAL 308 00 10 PINPOINT TEST E CLUTCH RELATED VIBRATIONS E1 CHECK FOR ENGINE COMPONENT GROUNDING 308 00 11 E2 CHECK FOR ACCESSORY DRIVE VIBRATIONS 308 00 11 E3...

Page 898: ...he engine at approximately 2000 rpm 5 Release the clutch pedal slowly Does the engine stall when the clutch pedal is fully released Yes Clutch OK No GO TO A2 A2 CHECK THE CLUTCH PEDAL FREE TRAVEL 1 De...

Page 899: ...e engine transaxle mountings isolator roll resistor for damage or loose bolts Are the engine transaxle isolator roll restrictor loose or damaged Yes Tighten bolts or install new ones as necessary TEST...

Page 900: ...2 Measure the pedal travel Is the measured dimension within 10 mm Yes GO TO C3 No GO TO B3 C3 CHECK THE BELLEVILLE SPRING WASHER OF THE CLUTCH PRESSURE PLATE 1 Remove the transaxle REFER to Section 3...

Page 901: ...the system for normal operation No GO TO E2 E2 CHECK FOR ACCESSORY DRIVE VIBRATIONS 1 Check for accessory vibration at the clutch en gage disengage when engine torque changes 2 Disconnect the accesso...

Page 902: ...K THE FLUID LEVEL NOTE The hydraulic clutch fluid is supplied from the brake master cylinder 1 2 Inspect the brake fluid level in the brake master cylinder reservoir Is the fluid within the MAX and MI...

Page 903: ...2 TEST THE CLUTCH PEDAL FREE TRAVEL 1 Depress the clutch down manually until resis tance is felt then release it again 2 Measure the pedal travel Is the travel within 10 mm Yes GO TO G3 No REFER to th...

Page 904: ...THE CLUTCH MASTER CYLINDER 1 Check clutch master cylinder for leaks Is the clutch master cylinder OK Yes GO TO H2 No REPAIR or INSTALL a new clutch master cylinder as necessary REFER to Section 308 0...

Page 905: ...AL PROCEDURES E4579 EN 07 2001 2002 Bantam Clutch Disc Check 1 CAUTION Do not use paraffin based cleaning agents and solvents Clean the clutch disc Check the clutch disc for Oil fouling Burn marks Thi...

Page 906: ...8 00 16 Manual Transaxle and Clutch General Information 308 00 16 GENERAL PROCEDURES E4580 EN 07 2001 2002 Bantam Clutch Master Cylinder Check 1 Check the clutch master cylinder For leaks Retaining cl...

Page 907: ...07 2001 2002 Bantam Clutch Pressure Plate Check 1 CAUTION Do not use paraffin based cleaning agents and solvents Clean the clutch pressure plate Check the clutch pressure plate for Broken or worn dia...

Page 908: ...Clutch General Information 308 00 18 GENERAL PROCEDURES E4582 EN 07 2001 2002 Bantam Clutch Slave Cylinder Check 1 Check the clutch slave cylinder with release bearing For leaks Extreme wear on the in...

Page 909: ...at small amounts of air trapped in the system are removed automatically 5 Remove the brake fluid from the brake fluid reservoir under suction until the level is at the MIN mark 6 Put about 100 ml of b...

Page 910: ...n If necessary top up the brake fluid reservoir with DOT4 brake fluid 9 NOTE Carefully engage reverse gear Check that the clutch operates correctly Start the engine and carefully engage reverse gear a...

Page 911: ...shift Linkage Adjustment 16 513 0 All vehicles 1 Raise and support the vehicle For additional information refer to Section 100 02 2 Remove the exhaust heat shield Vehicles with diesel engine 3 Remove...

Page 912: ...gear starting with the selector shaft in the neutral position Using 9 mm diameter drill bit lock the gearshift lever in fourth gear position 7 NOTE If the gearshift stabilizer cannot be installed loo...

Page 913: ...ion 308 00 23 GENERAL PROCEDURES CONTINUED E6761 EN 07 2001 2002 Bantam Vehicles with diesel engine 10 Install the inner drive shaft joint heat shield Vehicles with 1 6L 1 3L engine 11 Install the inn...

Page 914: ...OT 4 brake fluid SAE J1703 JUN91 Clutch Description mm Clutch disc wear limit 7 00 Torque Specifications Description Nm Clutch bleed nipple 10 Gearshift stabilizers retaining nut 55 Heat shield retain...

Page 915: ...APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Clutch 308 01 26 DIAGNOSIS AND TESTING Clutch 308 01 27 REMOVAL AND INSTALLATION Clutch Disc and Pressure Plate 308 01 28 29 SPECIFICATIO...

Page 916: ...el The clutch transfers the engine power to the transmission The clutch consists of a friction disc and a pressure plate which is bolted to the flywheel When the clutch pedal is operated the power tra...

Page 917: ...308 01 27 Clutch 308 01 27 DIAGNOSIS AND TESTING E3535 EN 07 2001 2002 Bantam Clutch REFER to Section 308 00...

Page 918: ...l s Aligner clutch disc 308 206 16 067 Removal 1 Detach the transmission For additional information refer to Section 308 03 2 Detach the clutch from the flywheel 1 Unscrew the bolts 6x 2 Lift the clut...

Page 919: ...ttach the clutch to the flywheel 1 Fit the clutch pressure plate with centered clutch disc 2 Locate the clutch over the locating dowels on the flywheel 3 Secure the bolts working diagonally 3 Remove t...

Page 920: ...Operation Hydraulic Clutch disc diameter mm outer inner 1 6L 1 3L SOHC 190 134 Clutch disc diameter mm outer inner 1 8L diesel engine 210 160 Torque Specifications Description Nm Clutch pressure plate...

Page 921: ...TION Clutch Controls 308 02 32 33 DIAGNOSIS AND TESTING Clutch Controls 308 02 34 REMOVAL AND INSTALLATION Clutch Master Cylinder 16 856 0 308 02 35 36 Clutch Slave Cylinder 16 862 0 308 02 37 SPECIFI...

Page 922: ...stem remains fully operative Clutch Master Cylinder The clutch master cylinder generates the system pressure for operating the clutch If the clutch pedal is pushed down the piston rod moves the clutch...

Page 923: ...TION E1148 EN 07 2001 Clutch operating mechanism components Item Description 1 Brake fluid reservoir 2 Clutch master cylinder 3 Clutch slave cylinder with integral re lease bearing Item Description 4...

Page 924: ...308 02 34 Clutch Controls 308 02 34 DIAGNOSIS AND TESTING E3543 EN 07 2001 Clutch Controls REFER to Section 308 00...

Page 925: ...ion if irritation persists If taken internally drink water and induce vomiting Get medical attention immedi ately Failure to follow these instructions may result in personal injury CAUTION If brake fl...

Page 926: ...ly 15 mm sidewards 5 Remove the clutch master cylinder 1 Remove the two bolts 2 Pull the piston rod from the clutch pedal and remove the clutch master cylinder Installation 1 To install reverse the re...

Page 927: ...tch slave cylinder 1 Remove the bolts 2 Remove the clutch slave cylinder Installation 4 Fit the clutch slave cylinder 1 Coat the input shaft splines with high temperature grease 2 Insert the clutch sl...

Page 928: ...and Adhesives Item Specification DOT 4 brake fluid SAE J1703 JUN91 Clutch Controls Description Operation Hydraulic Adjustment Automatic Torque Specifications Description Nm Clutch master cylinder reta...

Page 929: ...Transaxle Vehicles with 1 6L 1 3L Engine 16 114 0 308 03 56 65 DISASSEMBLY Transaxle 16 118 8 308 03 66 72 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Selector Plate 16 284 5 308 03 73 75 Input Shaft 16...

Page 930: ...ssion The clutch is operated hydraulically On a 2 shaft transmission all gearwheels are constantly in mesh Each gear ratio is achieved through one pair of gearwheels The direction of rotation of the o...

Page 931: ...ad valve 1 bar vehicles built up to build month 08 1999 2 Oil seal accessible from the outside 3 Clutch release bearing separately re newable 4 Front drive halfshaft intermediate shaft Item Descriptio...

Page 932: ...d to the output shaft by the synchronizer clutches No power is transferred to the differential Internal Gearshift Mechanism Item Description 1 Main shift rod 2 Boot vent pointing downwards 3 Radial oi...

Page 933: ...60 EN 07 2001 Input shaft Item Description 1 Ball bearing 2 Input shaft 3 Reverse gear idler 4 Gearwheel 1st gear 5 Gearwheel reverse gear 6 Gearwheel 2nd gear Item Description 7 Gearwheel 3rd gear 8...

Page 934: ...n 1 Parallel roller bearing 2 Output shaft 3 1st gearwheel 4 Inner synchronizer ring 5 Synchronizer cone 6 Outer synchronizer ring Item Description 7 1st 2nd gear synchronizer clutch with reverse gear...

Page 935: ...synchronizer ring 5 Synchronizer hub Double synchronization The first and second gears are double synchronised Because a second synchronizer ring is used the effective surface compared with the simpl...

Page 936: ...drive halfshaft pinions which are connected to the front drive halfshafts by splines When there is a speed difference between the two front wheels for instance when driving through a curve the front d...

Page 937: ...lutch 6 5th gearwheel Reverse gear Item Description 1 Input shaft 2 Output shaft 3 Output pinion 4 Reverse gearwheel 5 Teeth reverse gear 6 Reverse gear idler The reverse gear idler is driven by the i...

Page 938: ...308 03 48 Manual Transaxle 308 03 48 DIAGNOSIS AND TESTING E3553 EN 07 2001 Manual Transaxle REFER to Section 308 00...

Page 939: ...ll vehicles 1 Remove the clutch slave cylinder 1 Remove the bolts 2 Detach the clutch slave cylinder from the clutch housing 2 NOTE Also see the following job step Punch mark the input shaft oil seal...

Page 940: ...ew a 2 5 x 15 mm self tapping screw a maximum of two turns into the input shaft oil seal 2 Lever out the input shaft oil seal Installation 1 Fit the drive halfshaft oil seal and the clutch slave cylin...

Page 941: ...must not be bent more than 18 degrees The outer joint must not be bent more than 45 degrees CAUTION Pull the right hand halfshaft out straight otherwise the oil seal will be damaged NOTE Escaping oil...

Page 942: ...6738 EN 07 2001 Installation 1 Using the special tool install the left hand halfshaft oil seal 2 Install the left hand halfshaft For additional information refer to Section 205 04 3 Install the right...

Page 943: ...fshaft Oil Seal 308 039 16 018 Special Tool s Remover Oil Seal 303 112 21 051 Removal Vehicles with diesel engine 1 Remove the halfshaft heat shield Vehicles with 1 6L 1 3L engine 2 Remove the halfsha...

Page 944: ...E REPAIR CONTINUED E6739 EN 07 2001 4 Using the special tool remove the right hand halfshaft oil seal Installation 1 Using the special tool install the right hand halfshaft oil seal Vehicles with dies...

Page 945: ...le 308 03 55 IN VEHICLE REPAIR CONTINUED E6739 EN 07 2001 Vehicles with 1 6L 1 3L engine 3 Install the halfshaft heat shield All Vehicles 4 Install the right hand halfshaft For additional information...

Page 946: ...pter for 303 290 303 290 03 21 140 03 General Equipment Engine lifting eye Transmission jack Auxiliary plugs Retaining straps Material Specification Manual transmission fluid BOT 130 Cable ties Remova...

Page 947: ...cleaner intake pipe Vehicles with diesel engine 4 Remove the air cleaner intake pipe 1 Remove the air cleaner intake from the intake manifold 2 Detach the air cleaner intake pipe from the retaining cl...

Page 948: ...ted areas with water immediately Failure to follow these instructions may result in personal injury CAUTION If brake fluid is spilt on the paintwork the affected area must be immediately washed down w...

Page 949: ...2 Disconnect the generator electrical connector 3 Disconnect the starter motor electrical connector 4 Detach the transaxle ventilation hose 10 Remove the transaxle upper flange bolts Vehicles with die...

Page 950: ...1 3L engine 13 Install an engine cylinder No 4 using the existing thread in the cylinder head 14 Using the special tools support the engine and transaxle assembly All vehicles 15 Remove the engine rea...

Page 951: ...ehicles 17 Raise and support the vehicle For additional information refer to Section 100 02 18 Disconnect the reversing lamp switch electrical connector 19 Disconnect the speedometer drive cable from...

Page 952: ...d secure it to one side 1 Remove the nuts 2 Detach the hanger insulator Remove and discard the gasket All vehicles 23 Disconnect the shift rod and shift rod stabilizer 1 Disconnect the shift rod 2 Dis...

Page 953: ...clamp 27 CAUTION The inner joint must not be bent at more than 18 degrees the outer joint must not be bent at more than 45 degrees NOTE Remove the grease filling Remove the halfshafts on both sides l...

Page 954: ...lower the transaxle 31 Raise and support the vehicle For additional information refer to Section 100 02 Vehicles with 1 6L 1 3L engine 32 Push the engine forward and position a wooden block 260 mm be...

Page 955: ...3 65 REMOVAL CONTINUED E6700 EN 07 2001 34 Remove the transaxle lower flange bolts 35 NOTE Secure the transaxle with a retaining strap and support it by using a transmission jack Withdraw the transaxl...

Page 956: ...15 105 Installer 308 045 16 015 Special Tool s Remover fifth gearwheel 308 082 16 035 Transmission mounting bracket 303 435 06 21 031B Oil seal remover 303 112 21 051 General Equipment Assembly stand...

Page 957: ...linder 4 Remove the vehicle speed sensor VSS 1 Pull out the retaining pin 2 Pull out the VSS 5 Detach the cover and the detent mechanism 1 Cover 2 Fifth gear detent mechanism 3 Auxiliary shift rod det...

Page 958: ...gear synchronizer and selector fork 8 NOTE Mark the installation position of the synchronizer clutch assembly before dismantling it Dismantle the 5th gear synchronizer assembly 1 Snap ring 2 Retainin...

Page 959: ...out the auxiliary plug 1 Gasket 2 Output shaft snap ring 3 Input shaft snap ring 4 Pull out the auxiliary plug 12 Remove both oil seals left hand side shown Lever out the front drive halfshaft oil sea...

Page 960: ...he shift rod guide sleeve 1 Remove the guide sleeve lower snap ring 2 Pull out the shift rod guide sleeve 16 NOTE Attach a rubber band to the auxiliary shift rod as an aid during assembly Lift out the...

Page 961: ...net 4 Drive out the drive halfshaft oil seal 19 Remove the output shaft taper roller bearing 1 Press the rollers out of the bearing cage 2 Remove the bearing cage 20 CAUTION Use the special tool only...

Page 962: ...308 03 72 DISASSEMBLY CONTINUED E1162 EN 07 2001 22 NOTE Disc pack installation position see following job step Remove the bearing cone 23 Order of installation of differential shim pack 1 Bearing co...

Page 963: ...ift rod oil seal 308 040 16 019 Material Specification Universal sealant Hylomar Disassembly 1 Remove the shift rod oil seal Pull off the boot 2 CAUTION The shift gate is set in production If it is un...

Page 964: ...bolt Pull out the shift rod and take out the selector block 2 Detach the snap ring and remove the reverse gear shift lever with spring Assembly 1 Install the shift rod and the reverse gear shift leve...

Page 965: ...308 03 75 Manual Transaxle 308 03 75 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES CONTINUED E1163 EN 07 2001 3 Install the shift rod oil seal Fit the boot...

Page 966: ...cification Transmission fluid BOT 130 Disassembly CAUTION Handle synchronizer rings and cones with care 1 Pull off the ball bearing on the transmission end 1 Fit the snap ring 2 Engage a proprietary p...

Page 967: ...ASSEMBLY OF SUBASSEMBLIES CONTINUED E1164 EN 07 2001 2 Press on the ball bearing clutch end with the workshop press 3 NOTE The groove on the ball bearing should be towards the outside Press on the ba...

Page 968: ...ollet for 15 050 A 307 217 17 048 General Equipment Puller Press Material Specification Transmission fluid BOT 130 Disassembly CAUTION Handle synchronizer rings and cones carefully 1 Detach the ball b...

Page 969: ...onizer clutch the 3rd 4th gear synchronizer assembly and the 3rd gearwheel 3 Remove the third gear synchronizer ring 1 Synchronizer ring 2 Third gearwheel 4 NOTE Double synchronisation as shown in the...

Page 970: ...ring 5 Synchronizer cone 6 Outer synchronizer ring 6 NOTE Detach the 1st gearwheel and synchronizer assembly together Detach the 1st gearwheel and the reverse gearwheel together with the synchronizer...

Page 971: ...g 2 Synchronizer spring 3 Blocker bar 4 Synchronizer clutch hub 8 NOTE Insert the thrust ring into the oil slinger bore Detach the output shaft bearing cone 1 Remove the snap ring Locate the expanding...

Page 972: ...d synchronizer clutch hub Assemble the synchronizer clutch 1 Synchronizer clutch hub 2 Place the shift ring onto the synchronizer clutch hub 3 Install the blocker bar 4 Install the synchronizer spring...

Page 973: ...bly on the output shaft 1 Outer synchronizer ring 2 Synchronizer cone 3 Inner synchronizer ring 4 2nd gearwheel 5 Half rings 6 Retaining ring 6 NOTE Double synchronizer shown is used for servicing Ass...

Page 974: ...wards Fit the 3rd 4th gear synchronizer 1 Put on the synchronizer clutch the 3rd 4th gear synchronizer assembly and the 3rd gearwheel 2 Fit the snap ring 9 NOTE Fit the ball bearing with the annular g...

Page 975: ...bearing 205 062 15 025A Remover basic tool 205 295 15 050A Special Tool s Collet for 15 050 A 308 197 16 062 General Equipment Press Material Specification Transmission fluid BOT 130 Disassembly 1 Pul...

Page 976: ...Carefully clean and check all parts and coat with transmission fluid before assembling 2 Install the differential pinions 1 Pull on the crown wheel evenly using the old bolts Position the plastic thr...

Page 977: ...16 020 Replacer snap ring 308 076 16 031 Special Tool s Valve spring compressor 303 060 21 024 Adapter for 21 024 303 060 02 21 024 02 Adapter for 21 024 303 060 07 21 024 07 General Equipment Press...

Page 978: ...r bearing with bearing cone 1 Fit the oil slinger 2 Drive in the roller bearing as far as the stop 3 Fit the differential bearing cone 4 Install the differential assembly and permanent magnet 1 Perman...

Page 979: ...3rd 4th gear selector fork into position 8 Install the input shaft and output shaft Attach a rubber band to the auxiliary shift rod as an aid to assembly 1 Guide the input shaft in about 50 mm and an...

Page 980: ...h gear position the 5th gear selector rod moves downwards 11 Move the inner selector mechanism into 5th gear Turn the auxiliary shift rod clockwise until the reverse 5th gear gate is reached 12 Move t...

Page 981: ...nt Assemble the transmission housing Fit the special tool with the longer bolt Fit the auxiliary plug Tighten the bolts Turn the transmission through 180 degrees 15 Fit the special tool Remove the ass...

Page 982: ...o 0 05 mm and rounded up from 0 06 mm The shims are available in thicknesses from 0 1 mm to 1 1 mm in increments of 0 1 mm Continue with step 18 18 Establish the required adjustment shim example Thick...

Page 983: ...ch 1 Spring washers 2 Required shim 3 Fit the bearing cone and secure it with a blow from a punch on the edge of the housing 22 On transmissions with a black end cover apply transmission housing seale...

Page 984: ...Fit the snap rings for the input and output shafts 25 NOTE Turn the snap rings so that these lie in the recesses in the gasket Fit the gasket Insert the assembly plug 26 Install the 5th gear housing C...

Page 985: ...kshop press Mount the transmission on an assembly stand 28 Fit the 5th gearwheel snap ring 1 Fit the snap ring on the special tool 2 Put the special tool in place and drive on the snap ring 29 NOTE Ma...

Page 986: ...tor finger 2 Move the selector finger and 5th gear synchronizer unit into position together 3 Fit the 5th gear synchronizer snap ring 32 NOTE Only fit in the neutral position Installation setting of t...

Page 987: ...elector finger 1 Turn the main shift rod clockwise and press it down 2 Remove the end float of the selector finger by lifting it 3 Tighten the bolt in this position 38 On transmissions with a black en...

Page 988: ...tall the clutch release bearing in the clutch slave cylinder All vehicles 43 Fit the drive halfshaft oil seal and the clutch slave cylinder 1 Position the input shaft oil seal 2 Position the clutch sl...

Page 989: ...3 21 140 03 General Equipment Engine lifting eye Transmission jack Auxiliary plugs Retaining strap Material Specification Manual transmission fluid BOT 130 High durability grease WSD M1C230 A Cable ti...

Page 990: ...01 EN 07 2001 3 Install the transaxle lower flange bolts 4 Install the transaxle right hand flange bolts 5 Install the left hand transaxle flange bolt and starter motor bolts Vehicles with 1 6L 1 3L e...

Page 991: ...ing bracket Vehicles with diesel engine 10 NOTE Do not tighten the nuts Install the engine front mounting bracket All vehicles 11 Raise and support the vehicle For additional information refer to Sect...

Page 992: ...45 degrees CAUTION Use the installation sleeve supplied with every new oil seal to protect the oil seal when inserting the front halfshaft NOTE Fill the inner constant velocity housing with High dura...

Page 993: ...with 1 6L 1 3L engine 17 NOTE Use a new gasket Install the exhaust down pipe 1 Install the nuts 2 Connect the exhaust hanger insulator 18 Install the halfshaft heat shield Vehicles with diesel engine...

Page 994: ...UED E6701 EN 07 2001 21 Connect the reversing lamp switch electrical connector 22 Lower the vehicle Vehicles with 1 6L 1 3L engine 23 Tighten the bolts and nuts of the engine rear mounting bracket 24...

Page 995: ...s with diesel engine 26 CAUTION Always tighten the engine front mounting before tightening the engine rear mounting Tighten the engine front mounting 27 Tighten the engine rear mounting bracket 28 Rem...

Page 996: ...the electrical connectors and the hose 1 Install the flange bolt with ground cable 2 Reconnect the generator electrical connector 3 Reconnect the starter motor electrical connector 4 Attach the trans...

Page 997: ...spilt on the paintwork the affected area must be immediately washed down with cold water Install the clutch slave cylinder high pressure line Insert the clutch slave cylinder high pressure line in the...

Page 998: ...2001 All Vehicles 38 NOTE Use an Allen key to prevent the piston rod turning Tighten the suspension strut nut on both sides 39 Install the battery tray 1 Install new the cable ties 2 Install the bolts...

Page 999: ...f necessary renew the bearing see bearing checks 2 Bearing cage damaged at the top or side through incorrect use of a special tool or use of the wrong tool Renew the bearing 3 The taper roller ends ar...

Page 1000: ...e bearing if its surface is rough or if it is noisy 7 Dark blue coloring from overheating yellow or brown color is normal due to excessive bearing preload or inadequate lubrication Overheating can cau...

Page 1001: ...1 93 1 92 1 926 Third gear 1 28 1 41 1 281 Fourth gear 0 95 1 10 0 951 Fifth gear 0 76 0 87 0 756 Reverse gear 3 61 3 61 3 615 Differential 4 06 4 25 4 25 Speedometer driven pinion 19 19 19 Speedomet...

Page 1002: ...strut 47 Lower suspension arm to spindle carrier 52 Driveshaft stub nut 270 Suspension strut top nut 46 Battery box 25 Gear selector finger 17 Transaxle filler plug 35 Wheel nuts 85 Catalytic converte...

Page 1003: ...l Controls 308 06 114 DIAGNOSIS AND TESTING External Controls 308 06 115 Pinpoint Test 308 06 115 116 REMOVAL AND INSTALLATION Gearshift Linkage 16 534 0 308 06 117 121 Gearshift Stabilizer Bar Bushin...

Page 1004: ...hanism housing top cover 8 Gearshift mounting 9 Gearshift mechanism housing lower cover 10 Gearshift stabiliser A selector rod operates the iB5 manual transmission in the 2002 Bantam In order to isola...

Page 1005: ...lly identified resolve it and check that the system operates correctly 4 If the concern cannot be clearly located use the following troubleshooting table to exactly identify it Troubleshooting Table C...

Page 1006: ...stabiliser from the transmission Is the stabiliser stressed Yes Undo the engine transmission mountings align the engine transmission in such a way that the gearshift stabiliser can be installed free...

Page 1007: ...E6707 EN 07 2001 Gearshift Linkage 16 534 0 Removal 1 Remove the gearshift lever knob 2 Remove the gearshift lever outer boot 3 Remove the gearshift lever inner boot 4 Raise and support the vehicle Fo...

Page 1008: ...07 EN 07 2001 Vehicles with diesel engine 6 Remove the halfshaft heat shield Vehicles with 1 6L 1 3L engine 7 Remove the halfshaft heat shield 8 Disconnect the shift rod and the shift rod stabilizer 1...

Page 1009: ...tion 308 00 3 NOTE If the gearshift stabilizer cannot be installed without stress loosen the engine transaxle mounting and align Install the gearshift stabilizer and shift rod 1 Attach the shift rod 2...

Page 1010: ...INSTALLATION CONTINUED E6707 EN 07 2001 Vehicles with diesel engine 6 Install the halfshaft heat shield Vehicles with 1 6L 1 3L engine 7 Install the halfshaft heat shield 8 Lower the vehicle 9 Install...

Page 1011: ...308 06 121 Manual Transaxle External Controls 308 06 121 REMOVAL AND INSTALLATION CONTINUED E6707 EN 07 2001 11 Install the gearshift lever knob...

Page 1012: ...he gearshift mechanism and detach the gearshift stabiliser For additional information refer to Section 308 06 2 Press out the stabiliser bush using a suitable thrust element Installation 1 NOTE The bu...

Page 1013: ...2001 Gearshift Stabilizer Bar 16 588 0 Removal 1 Remove the gearshift mechanism For additional information refer to Section 308 06 2 Detach the gearshift stabiliser Installation 1 Fit the gearshift st...

Page 1014: ...l Seal 308 045 16 015 Disassembly 1 Remove the following parts 1 Remove the stabilizer 2 Remove the noise damping pad 3 Remove the gearshift mounting 2 Remove the gearshift lever 1 Press the mounting...

Page 1015: ...cover Assembly 1 Reassemble the gearshift mechanism 1 Insert the shift rod 2 Install the housing cover 3 Slide on the shift rod boot 4 Slide on the gearshift mounting 5 Slide the mounting sleeve onto...

Page 1016: ...308 06 126 Manual Transaxle External Controls 308 06 126 DISASSEMBLY AND ASSEMBLY CONTINUED E6748 EN 07 2001 2 Install the gearshift stabilizer bar...

Page 1017: ...ls 308 06 127 SPECIFICATIONS E1177 EN 07 2001 Torque Specifications Nm Gearshift mechanism pilot bearing to body 14 Gearshift stabiliser to transmission 55 Gearshift stabiliser to gearshift mechanism...

Page 1018: ...tem Petrol Engine 309 00 3 DIAGNOSIS AND TESTING Exhaust System 309 00 4 Inspection and Verification 309 00 4 Symptom Chart 309 00 4 REMOVAL AND INSTALLATION Exhaust System 25 250 0 309 00 5 6 Exhaust...

Page 1019: ...0 2 Exhaust System General Information 309 00 2 DESCRIPTION AND OPERATION Exhaust System Diesel engine 1 2 Item Description 1 Flexible coupling Item Description 2 Rear muffler E1178 EN 07 2001 2002 Ba...

Page 1020: ...309 00 3 Exhaust System General Information 309 00 3 DESCRIPTION AND OPERATION Petrol Engine 1 2 Item Description 1 Front muffler 2 Rear muffler E1178 EN 07 2001 2002 Bantam...

Page 1021: ...s 3 If an obvious cause is observed or reported concern is found correct the cause if possible before proceeding to the next step 4 If the concern is not visually evident verify the symptom and refer...

Page 1022: ...round cable 2 Disconnect the heated oxygen sensor multiplug 3 Remove the manifold heat shield 4 Disconnect the exhaust downpipe from the manifold Discard the retaining nuts and any studs that may have...

Page 1023: ...02 and lower the rear axle to allow the removal of the center and rear muffler 7 Disconnect the exhaust system from the downpipe and remove the exhaust system Installation 1 Install components in rev...

Page 1024: ...icle Refer to Section 100 02 2 Support the flexible pipe with a support wrap or suitable splint 3 Remove the flexible pipe Discard the gasket and nuts Installation 1 CAUTION Over bending or twisting o...

Page 1025: ...t System General Information 309 00 8 REMOVAL AND INSTALLATION CONTINUED 2 Install the flexible pipe Install a new gasket and nuts 3 Remove the flexible pipe support 4 Lower the vehicle E5947 EN 07 20...

Page 1026: ...ust system as the portion starting from the flange joint after the flexible coupling and in front of the center muffler 1 Disconnect the battery ground cable 2 NOTE If no part of the exhaust system is...

Page 1027: ...ors Four or five rubber insulators depending on variant Installation 1 Assemble the exhaust system Loosely connect the service exhaust components 2 Install the exhaust system Examine the rubber insula...

Page 1028: ...wisting of the flexible pipe may cause damage resulting in failure Loosely refit the flexible coupling to the exhaust system Install new gaskets and nuts Coat the studs with anti seize grease 4 Check...

Page 1029: ...Adhesives Item Specification Anti seize grease Loctite Never Seize Torque Specifications Description Nm Exhaust pipe flange bolts and nuts 47 Manifold downpipe to exhaust pipe flange nuts and bolts 1...

Page 1030: ...EHICLE APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Fuel System 310 00 2 3 GENERAL PROCEDURES Fuel System Pressure Relief 23 420 0 310 00 4 Fuel Tank Draining 23 551 0 310 00 5 Push...

Page 1031: ...side of the vehicle All fuel pipe connectors are of the quick release type Supply pipe connectors are white or are identified by a white band and return pipe connectors are red or are identified by a...

Page 1032: ...the powertrain control module energizes the solenoid which inhibits the operation of the light load retard device thus advancing the injection timing Cold Start Advance Solenoid The powertrain contro...

Page 1033: ...e to follow these instructions may result in personal injury WARNING The fuel system remains pressurized for a long time after the ig nition is switched off The fuel pressure must be released before a...

Page 1034: ...nstructions may result in personal injury WARNING The fuel system remains pressurized for a long time after the ig nition is switched off The fuel pressure must be relieved before attempting any repai...

Page 1035: ...ess be ob served when working with these com ponents Always install blanking plugs to any open orifices or lines NOTE Fuel supply line connectors are white or are identified by a white band Fuel retur...

Page 1036: ...and can ignite Failure to follow these instructions may result in personal injury CAUTION Fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore es sen...

Page 1037: ...line quick release coupling 1 Install the fuel line quick release coupling locking tang 2 Rotate the fuel line quick release coupling locking tang into position 3 NOTE Make sure the collar on the fuel...

Page 1038: ...System General Information 310 00 9 09 2001 2002 Bantam Capacities Litres Fuel tank capacity 54 litres Torque Specifications Description Nm Engine cover retaining bolts 6 Fuel tank retaining bolts 21...

Page 1039: ...nspection and Verification 310 01A 12 REMOVAL AND INSTALLATION Fuel Tank 23 554 0 310 01A 13 16 Fuel Filter 310 01A 17 18 Fuel Pump Module 23 534 0 310 01A 19 20 Fuel Tank Filler Pipe 23 572 0 310 01A...

Page 1040: ...310 01A 11 Fuel Tank and Lines Petrol Engines 310 01A 11 DESCRIPTION AND OPERATION E6462 EN 09 2001 2002 Bantam Fuel Tank and Lines Refer to Section 310 00...

Page 1041: ...ectrical damage Visual Inspection Chart Mechanical Electrical Damaged fuel lines Damaged push connect fittings Fuel Leaks Damaged fuel tank filler cap Damaged fuel tank filler pipe Incorrectly fitted...

Page 1042: ...re always present and may ig nite Failure to follow these instructions may result in personal injury 1 Drain the fuel tank For additional information refer to Section 310 00 2 Raise and support the ve...

Page 1043: ...E1192 EN 09 2001 2002 Bantam 6 CAUTION When supporting the fuel tank use a suitable packing material to prevent damage to the underside of the fuel tank Support the fuel tank with a suitable jack 7 Re...

Page 1044: ...ne connectors are red or identified by a red band Disconnect the fuel return line from the fuel tank For additional information refer to Section 310 00 10 Disconnect the fuel tank ventilation hose fro...

Page 1045: ...emove the fuel tank Installation WARNING Do not smoke or carry lighted tobacco or open flame of any type when working on or near fuel re lated components Highly flammable mixtures are always present a...

Page 1046: ...ted components Highly flammable mixtures are always present and can ig nite Failure to follow these instructions may result in personal injury 1 Disconnect the battery ground cable For additional info...

Page 1047: ...f any type when working on or near any fuel related components Highly flammable mixtures are always present and can ig nite Failure to follow these instructions may result in personal injury 1 NOTE Wh...

Page 1048: ...rking on or near any fuel related components Highly flammable mixtures are always present and can ig nite Failure to follow these instructions can result in personal injury 1 Remove the fuel tank For...

Page 1049: ...Remove the fuel pump Installation WARNING Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components Highly flammable mixtures are always prese...

Page 1050: ...ese instructions may result in personal injury 1 Remove the fuel tank filler pipe retaining bolts 2 Remove the fuel filler cap 3 Remove the fuel tank For additional information refer to Fuel Tank in t...

Page 1051: ...gnite Fail ure to follow these instructions can re sult in personal injury 1 De pressurize the fuel system For additional information refer to Section 310 00 2 Remove the fuel tank For additional info...

Page 1052: ...Bantam Installation WARNING Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components Highly flammable vapours are always present and may ig n...

Page 1053: ...l times and always observe fuel handling precautions Failure to follow these in structions can result in personal injury NOTE It will be necessary to raise the vehicle in order to carry out this proce...

Page 1054: ...ally lower the front crossmember For additional information refer to Section 502 00 7 Detach the exhaust system from the front and centre rubber insulators 8 Detach the exhaust system from the three r...

Page 1055: ...etach the handbrake cable from the two retaining clips 11 Detach the fuel supply pipe from the six retaining clips 12 Release the fuel supply and return pipes from the six retaining clips 13 Disconnec...

Page 1056: ...Petrol Engines 310 01A 27 REMOVAL AND INSTALLATION CONTINUED E6463 EN 09 2001 2002 Bantam 14 Disconnect the fuel supply pipe from the fuel filter 15 Remove the fuel supply pipe Installation 1 Refit t...

Page 1057: ...rve fuel handling precautions Failure to follow these in structions can result in personal injury NOTE It will be necessary to raise the vehicle in order to carry out this procedure Removal 1 Disconne...

Page 1058: ...2001 2002 Bantam 7 Partially lower the front crossmember For additional information refer to Section 502 00 8 Partially lower the fuel tank refer to procedure contained in this section 9 Detach the h...

Page 1059: ...supply and return pipes from the four retaining clips 12 Disconnect the fuel return pipe from the fuel rail return pipe Fuel return pipe connectors are red or are identified by a red band 13 Disconnec...

Page 1060: ...310 01A 31 Fuel Tank and Lines Petrol Engines 310 01A 31 REMOVAL AND INSTALLATION CONTINUED E6464 EN 09 2001 2002 Bantam Installation 1 Refit the components in reverse order...

Page 1061: ...ATION E1198 EN 09 2001 2002 Bantam Inertia Fuel Shutoff IFS Switch 33 577 0 Removal 1 Detach the right hand door weather strip 2 Detach the cowl side trim panel 3 Detach the inertia fuel shutoff IFS s...

Page 1062: ...rol Engines 310 01A 33 REMOVAL AND INSTALLATION CONTINUED E1198 EN 09 2001 2002 Bantam Installation 1 NOTE Make sure the IFS switch is in the reset position Depress the button on the IFS switch To ins...

Page 1063: ...ines Petrol Engines 310 01A 34 SPECIFICATIONS E1199 EN 09 2001 2002 Bantam Torque Specifications Description Nm Flexible coupling to the column shaft pinch bolt 28 Flexible coupling to steering gear p...

Page 1064: ...6 DIAGNOSIS AND TESTING Fuel Tank and Lines 310 01B 37 REMOVAL AND INSTALLATION Fuel Tank 23 554 0 310 01B 38 40 Fuel Sender Unit 33 286 0 310 01B 41 43 Fuel Filter Element 23 546 0 310 01B 44 Fuel Ta...

Page 1065: ...310 01B 36 Fuel Tank and Lines Diesel Engines 310 01B 36 DESCRIPTION AND OPERATION E6465 EN 09 2001 2002 Bantam Fuel Tank and Lines For additional information refer to Section 310 01A...

Page 1066: ...310 01B 37 Fuel Tank and Lines Diesel Engines 310 01B 37 DIAGNOSIS AND TESTING E6466 EN 09 2001 2002 Bantam Fuel Tank and Lines REFER to Section 310 01A...

Page 1067: ...actured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness be observed when working with these components Always fit blanking plugs to any open orifices...

Page 1068: ...erial to prevent damage to the underside of the fuel tank Support the fuel tank with a suitable jack 8 Remove the four fuel tank retaining bolts 9 Partially lower the fuel tank 10 Detach the fuel tank...

Page 1069: ...dentified by a red band Disconnect the fuel return pipe from the fuel tank 13 Disconnect the fuel supply pipe from the fuel tank Fuel supply pipe connectors are white or are identified by a white band...

Page 1070: ...quipment is manufactured to very precise tolerances and fine clearances It is therefore essen tial that absolute cleanliness be observed when working with these components Al ways fit blanking plugs t...

Page 1071: ...N CONTINUED E5951 EN 09 2001 2002 Bantam 4 Detach the fuel filter inlet pipe from the retaining clip 5 Disconnect the inlet pipe from the fuel filter 6 Remove the diesel fuel heater and bracket assemb...

Page 1072: ...310 01B 43 Fuel Tank and Lines Diesel Engines 310 01B 43 REMOVAL AND INSTALLATION CONTINUED E5951 EN 09 2001 2002 Bantam Installation 1 Refit the components in reverse order...

Page 1073: ...2 Bantam Fuel Filter Element 23 546 0 Renewal 1 Disconnect the battery ground cable 2 Drain the fuel filter 3 Remove the bolt Catch the displaced fuel in a suitable container 4 Remove the filter eleme...

Page 1074: ...structions can result in personal injury CAUTION Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essen tial that absolute cleanliness be...

Page 1075: ...INSTALLATION CONTINUED E5952 EN 09 2001 2002 Bantam 4 Loosen the flexible coupling to column shaft pinch bolt 5 Remove the exhaust down pipe refer to Operation Number 25 250 0 6 Partially lower the f...

Page 1076: ...09 2001 2002 Bantam 7 Partially lower the fuel tank refer to procedure contained in this section 8 Lower exhaust system 9 Remove the heat sheilds 10 Detach the handbrake cable and fuel supply pipe fr...

Page 1077: ...uel supply pipe from the diesel fuel heater inlet pipe Fuel supply pipe connectors are white or are identified with a white band 13 Disconnect the fuel supply pipe from the fuel tank Fuel supply pipe...

Page 1078: ...310 01B 49 Fuel Tank and Lines Diesel Engines 310 01B 49 REMOVAL AND INSTALLATION CONTINUED E5952 EN 09 2001 2002 Bantam...

Page 1079: ...ons can result in personal injury CAUTION Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essen tial that absolute cleanliness be observe...

Page 1080: ...ED E5953 EN 09 2001 2002 Bantam 4 Loosen the flexible coupling to column shaft pinch bolt 5 Remove the exhaust down pipe For additional information refer to Section 309 00 6 Partially lower the front...

Page 1081: ...ntained in this section 9 Detach the handbrake cable and the fuel return pipe from the five retaining clips 10 Release the supply and return pipes from the five retaining clips 11 Disconnect the fuel...

Page 1082: ...0 01B 53 Fuel Tank and Lines Diesel Engines 310 01B 53 REMOVAL AND INSTALLATION CONTINUED E5953 EN 09 2001 2002 Bantam 12 Remove the fuel return pipe Installation 1 Refit the components in reverse ord...

Page 1083: ...Fluids Sealers and Adhesives Item Specification Fuel tank filler pipe seal Clean engine oil Fuel tank roll over valve seal Clean engine oil Capacities Litres Fuel tank 54 Torque Specifications Descrip...

Page 1084: ...celeration Control 310 02 56 Vehicles with Petrol Engine 310 02 56 Vehicles with Diesel Engine 310 02 56 DIAGNOSIS AND TESTING Acceleration Control 310 02 57 Inspection and Verification 310 02 57 GENE...

Page 1085: ...onsists of an accelerator pedal accelerator cable and accelerator cable bracket which is fitted to the throttle body Accelerator pedal return is achieved by means of throttle return springs Vehicles w...

Page 1086: ...edal Worn accelerator pedal pivot or bush INSTALL a new accelerator pivot or bushing Accelerator cable binding INSTALL a new accelerator ca ble Accelerator pedal feels rough or jerky Frayed or binding...

Page 1087: ...cable adjuster through the grommet until the grommet is at the end of the accelerator cable adjuster 3 Depress the accelerator pedal to the floor stop and hold 4 Install the accelerator cable retainin...

Page 1088: ...or cable adjuster through the grommet until the grommet is at the end of the accelerator cable adjuster 3 Depress the accelerator pedal to the floor stop and hold 4 Install the accelerator cable retai...

Page 1089: ...04 Instrumentation and Warning Systems Instrument Cluster 413 01 Battery and Charging Systems Charging System General Information 414 00 Battery Mounting and Cables 414 01 Generator and Regulator 414...

Page 1090: ...tment 34 628 6 412 00 40 Electronic Leak Detection 34 620 5 412 00 41 Air Conditioning A C System Flushing 412 00 42 45 Tracer Dye Leak Detection 34 620 5 412 00 46 Vacuum Leak Detection 34 620 5 412...

Page 1091: ...to the control panel The potentiometer operates the control valve which controls the flow of hot water through the heat exchanger in accordance with the selected interior temperature The heat exchange...

Page 1092: ...art Condition Possible Sources Action No insufficient heating power Fuse s Circuit s Heater control module Heater control solenoid valve Go To Pinpoint Test A The A C system is inoperative the heater...

Page 1093: ...ossible Sources Action Condensed water from the air conditioning system in the foot well Air conditioning outlet pipe is not connected to the heater Air conditioning outlet pipe is incorrectly routed...

Page 1094: ...ND SUPPLY OF THE HEATER CONTROL MODULE 412 00 8 A14 CHECK THE HEATER CONTROL SOLENOID VALVE 412 00 9 A15 CHECK THE CIRCUIT 31 CA82 FOR SHORT TO GROUND 412 00 9 PINPOINT TEST B THE A C SYSTEM IS INOPER...

Page 1095: ...22 C6 CHECK THE CIRCUIT 31S CA18 BK RD FOR OPEN 412 00 22 C7 CHECK THE GROUND SUPPLY OF THE HEATER BLOWER SWITCH 412 00 23 C8 CHECK THE CIRCUIT FOR HEATER BLOWER HIGH SPEED 412 00 23 C9 CHECK THE CIRC...

Page 1096: ...2 00 30 31 D10 CHECK THE GROUND CONNECTION OF RELAY A C RE CIRCULATION FLAP 412 00 31 D11 CHECK THE RELAY A C RE CIRCULATION FLAP 412 00 32 D12 CHECK THE CONTROL CIRCUIT OF THE RELAY A C RE CIRCULATIO...

Page 1097: ...g diagrams TEST the system for nor mal operation A2 CHECK THE POWER SUPPLY OF THE FUSE F13 1 Fuse F13 CJB 2 3 Measure the voltage between fuse F13 and ground Is battery voltage indicated Yes GO TO A3...

Page 1098: ...LT CONDITION OF THE HEATING SYSTEM 1 2 Check the temperature of the airflow Is the airflow permanently cold Yes GO TO A14 No GO TO A6 A6 CHECK THE HEATER CONTROL SOLENOID VALVE WARNING The heater cont...

Page 1099: ...between fuse F13 and heater control solenoid valve by us ing the wiring diagrams TEST the system for normal operation A8 CHECK THE HEATER CONTROL SOLENOID VALVE NOTE If the temperature adjustment is c...

Page 1100: ...heater control module by using the wiring diagrams TEST the system for nor mal operation A10 CHECK THE POWER SUPPLY OF THE HEATER CONTROL MODULE 1 Measure the voltage between heater control module co...

Page 1101: ...onnector C49 pin 2 circuit 31S CA82 BK GN harness side and heater control solenoid valve connector C28 pin 5 circuit 31S CA82 BK GN harness side Is the resistance less than 2 ohms Yes GO TO A13 No REP...

Page 1102: ...for normal operation No GO TO A15 A15 CHECK THE CIRCUIT 31 CA82 FOR SHORT TO GROUND NOTE The proper function of the heater control solenoid valve is dependent from the signal of the ta chometer 1 2 H...

Page 1103: ...sor clutch diode and INSTALL a new one TEST the system for normal op eration B2 CHECK THE POWER SUPPLY OF THE FUSE F14 1 Fuse F14 CJB 2 3 Measure the voltage between fuse F14 and ground Is battery vol...

Page 1104: ...lay socket A C W O T connector C18 pin 2 circuit 14 CA11 VT YE and ground Is battery voltage indicated Yes GO TO B6 No REPAIR the open circuit s between fuse F14 and relay A C W O T by using the wir i...

Page 1105: ...ect a jumper wire at the relay socket A C W O T connector C18 between pin 3 cir cuit 14 CA67 VT BK and pin 5 circuit 14S CA1 VT BU 3 Is the A C compressor clutch engaged Yes GO TO B10 No GO TO B8 B8 C...

Page 1106: ...ND SUPPLY OF THE A C COMPRESSOR CLUTCH 1 2 Measure the resistance between A C compressor clutch connector C75 pin 2 circuit 31 CA6 BK harness side and ground Is the resistance less than 2 ohms Yes CHE...

Page 1107: ...ound Is battery voltage indicated Yes GO TO B14 No GO TO B12 B12 CHECK THE POWER SUPPLY OF THE HEATER AND A C CONTROL ASSEMBLY 1 2 Heater and A C control assembly C329 3 4 Measure the voltage between...

Page 1108: ...If necessary INSTALL a new one TEST the system for normal operation No REPAIR the open circuit s between heater and A C control assembly and relay A C switch by using the wiring diagrams TEST the sys...

Page 1109: ...CH 1 Measure the resistance between relay socket A C switch connector C19 pin 3 circuit 31 CA66B BK and ground Is the resistance less than 2 ohms Yes GO TO B16 No REPAIR the open circuit s between rel...

Page 1110: ...tion No GO TO B17 B17 CHECK THE A C COMPRESSOR CYCLING SWITCH 1 2 Relay A C switch C19 3 A C compressor cycling switch C91 4 Measure the resistance between A C compressor cycling switch connector C91...

Page 1111: ...No GO TO B22 B19 CHECK CIRCUIT 31S PC72 BK BU FOR OPEN 1 2 PCM C43 3 Measure the resistance between A C compressor cycling switch C91 pin 4 circuit 31S PC72 BK BU harness side and PCM connector C43 pi...

Page 1112: ...blower 2 Measure the resistance between PCM connector C43 pin 41 circuit 31S CA12A BK BU harness side and ground Is battery voltage indicated Yes CHECK the PCM If necessary INSTALL a new one TEST the...

Page 1113: ...wir ing diagrams TEST the system for normal operation B24 CHECK THE A C INHIBIT DIODE 1 Check the A C inhibit diode referring to the diode test Is the A C diode OK Yes REPAIR the open circuit s betwe...

Page 1114: ...F16 1 Fuse F16 CJB 2 3 Measure the voltage between fuse F16 and ground Is battery voltage indicated Yes GO TO C4 No REPAIR the power supply of the fuse F16 TEST the system for normal operation C4 CHEC...

Page 1115: ...e heater blower motor INSTALL a new one if necessary TEST the system for normal operation No GO TO C6 C6 CHECK THE CIRCUIT 31S CA18 BK RD FOR OPEN 1 Heater blower switch C72 2 Measure the resistance b...

Page 1116: ...y using the wir ing diagrams TEST the system for normal operation C8 CHECK THE CIRCUIT FOR HEATER BLOWER HIGH SPEED 1 2 Heater blower switch C72 3 4 Measure the voltage between heater blower switch co...

Page 1117: ...er series re sistor by using the wiring diagrams TEST the system for normal operation C11 CHECK THE CIRCUIT FOR HEATER BLOWER MEDIUM SPEED 1 2 Measure the resistance between heater blower series resis...

Page 1118: ...LOWER LOW SPEED 1 2 Heater blower se ries resistor C90 3 Measure the resistance between heater blower series resistor connector C90 pin 2 circuit 31S CA31 BK YE harness side and heater blower switch c...

Page 1119: ...connector C90 pin 3 circuit 31S CA30 BK WH harness side and heater blower switch connector C72 pin 3 circuit 31S CA30 BK WH harness side Is the resistance less than 2 ohms Yes CHECK the heater blower...

Page 1120: ...sys tem for normal operation D3 CHECK THE FUSE F13 1 2 Fuse F13 CJB Is the fuse OK Yes GO TO D4 No INSTALL a new fuse F13 15 A If the fuse blows again LOCATE and REPAIR the short to ground of the circ...

Page 1121: ...cated Yes GO TO D6 No REPAIR the open circuit s between fuse F16 and re circulation air actuator by using the wiring diagrams TEST the system for normal operation D6 CHECK THE GROUND SUPPLY OF THE RE...

Page 1122: ...RE CIRCULATION AIR ACTUATOR 1 Relay A C re circulation flap C342 2 Re circulation air actuator C54 3 Connect a jumper wire between relay socket A C re circulation flap connector C342 pin 5 circuit 31S...

Page 1123: ...irculation flap relay connector C342 pin 5 circuit 31S CA76 BK OG Is the resistance less than 2 ohms Yes CHECK the re circulation air actuator INSTALL a new one if necessary TEST the system for normal...

Page 1124: ...tween relay A C re circulation flap and ground G6 by us ing the wiring diagrams TEST the system for normal operation D10 CHECK THE GROUND CONNECTION OF RELAY A C RE CIRCULATION FLAP 1 3 4 Connect a ju...

Page 1125: ...elay A C re circulation flap TEST the system for normal operation D12 CHECK THE CONTROL CIRCUIT OF THE RELAY A C RE CIRCULATION FLAP 1 Re circulation switch C353 2 3 Measure the voltage between re cir...

Page 1126: ...he system for normal operation Component Test Relay A C W O T 1 Check the relay contact in normal condition Measure the resistance at the relay between pin 3 and pin 5 Is the resistance greater than 1...

Page 1127: ...a new relay Relay high speed engine cooling fan 1 Check the relay contacts in normal condition Measure the resistance at the relay between pin 3 and pin 5 and between pin 3 and pin 2 Is in both measu...

Page 1128: ...ks Leaks In the event of any leaks rectify the leak s renew any faulty components and drain and refill the air conditioning system System Test Three values are used for the fault diagnosis Low pressur...

Page 1129: ...Total cycle time s 2 Outside temperature C Check the on off cycles The following conditions must be met before checking the switching cycle 1 Connect the pressure gauges to the high and low pressure s...

Page 1130: ...ntly Normal or not at all Contaminants in the circuit or too much refrigerant oil Normal Too low Too slow Too long Too long Low pressure switch faulty Normal to too low Too high Compressor running con...

Page 1131: ...Fit the special tool so that the inner collar can be guided into the clamping spring 2 Press the special tool into the clamping spring 3 Disconnect the refrigerant line Discard the O ring seals 4 Conn...

Page 1132: ...igerant oil and a lint free cloth Press the indicator ring into the clamping spring 6 NOTE Install new refrigerant line O ring seals NOTE Coat the refrigerant line O ring seals in clean refrigerant oi...

Page 1133: ...r 3 Drive plate NOTE The refrigerant circuit can remain closed if possible 2 If the air gap A is outside the tolerance range if necessary detach the air conditioning compressor For additional informat...

Page 1134: ...revented 1 Attach R 134a Manifold Gauge Set to the service gauge port valves Leave both R 134a Manifold Gauge Set valves closed Both gauges should indicate 4 1 5 5 bar 413 551 kPa at 24 C with the eng...

Page 1135: ...f as hazardous waste For all equip ment follow the equipment manufactur ers instructions CAUTION Suction accumulator muffler hoses thermal expansion valve and fixed orifice tube should be removed when...

Page 1136: ...irection of normal refrigerant flow back flushing Particulate matter picked up during flushing is filtered from the returning solvent before the solvent is returned to the reservoir for continued circ...

Page 1137: ...nit is also intended for use on one vehicle only 7 Flush component for a minimum of 15 minutes 8 Apply 6 2 8 6 bar 621 862 kPa pressurised air to the component for a minimum of 30 minutes The 30 minut...

Page 1138: ...ENERAL PROCEDURES CONTINUED 12 Add additional refrigerant oil as required For additional information refer to Refrigerant Oil Addition in this section 13 Evacuate charge and leak test A C system 14 Ch...

Page 1139: ...of refrig erant oil at the spring lock couplers This may be caused from the assembly process which ap plies to the fittings before installation to aid in assembly When a spring lock coupler is sus pec...

Page 1140: ...is section 2 NOTE If an air conditioning system that was filled with refrigerant is being evacuated then some refrigerant will still be in the refrigerant oil in the compressor This residual amount of...

Page 1141: ...ler valves Pull back the lock on the quick release connector 1 Larger inside diameter for high pressure side 2 Smaller inside diameter for low pressure side 2 WARNING Avoid releasing the refrigerant i...

Page 1142: ...ar 2 kPa this means that the system is leaking If the air conditioning system is leaking fill it with approximately 300 g refrigerant and check using a leakage detector For additional information refe...

Page 1143: ...t Top up with the remaining refrigerant whilst the air conditioning is switched on Let the engine run at about 1200 1500 rpm for this purpose Switch the air conditioning to maximum cooling power and f...

Page 1144: ...ications in this section NOTE Always keep refrigerant oil in a closed and sealed container to prevent entry of moisture Top up with the calculated quantity of new refrigerant oil 2 NOTE Only remove th...

Page 1145: ...dor eliminating agent can remove deposits in the heater housing but cannot prevent odorous that are distributed by the ventilation system for example those caused by damp carpets Disconnect the low pr...

Page 1146: ...entire surface of the evaporator Spray the entire odor eliminating agent into the opening Allow the odor eliminating agent to take effect for 10 minutes 11 Install the components in reverse order 12...

Page 1147: ...erify contaminated refrigerant is present 2 Advise the customer of the contaminated A C system and any additional cost to repair the system The customer may wish to return to the repair facility perfo...

Page 1148: ...r is less than 90 ml Add 90 ml Air conditioning compressor if the quantity of oil taken from the compressor is between 90 ml and 150 ml Fill with the same quantity 30 ml Air conditioning compressor if...

Page 1149: ...N 412 01 Air Distribution and Filtering VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Air Distribution and Filtering 412 01 2 DIAGNOSIS AND TESTING Air Distribution and Filter...

Page 1150: ...ment The vehicle may also have recirculated air mode as an option and which can be activated by operating a switch on the control panel From the air intake aperture fresh air passes through the fan an...

Page 1151: ...412 01 3 Air Distribution and Filtering 412 01 3 DIAGNOSIS AND TESTING E3103 EN 07 2001 2002 Bantam Air Distribution and Filtering REFER to Section 412 00...

Page 1152: ...zzle 34 489 0 Removal 1 Remove the instrument cluster bezel Unclip the cover 2 Remove the instrument cluster bezel continued 1 Screws 2 Clips Disconnect the plug 3 Remove the switches bezel shown remo...

Page 1153: ...tilation 412 02 2 DIAGNOSIS AND TESTING Heating and Ventilation 412 02 3 REMOVAL AND INSTALLATION Blower Motor 34 374 0 412 02 4 7 Heater Core Housing 34 354 0 412 02 8 11 Heater Core 34 364 0 412 02...

Page 1154: ...g noises coming from the fascia crash padding area The water flow through the heater control valve can cause a regular knocking noise when the operating temperature switch is set between Min and Max T...

Page 1155: ...412 02 3 Heating and Ventilation 412 02 3 DIAGNOSIS AND TESTING E2890 EN 07 2001 2002 Bantam Heating and Ventilation REFER to Section 412 00...

Page 1156: ...moval Vehicles with air conditioning NOTE Observe the Health and Safety regula tions for working with refrigerant For additional information refer to Section 100 00 1 Drain the air conditioning system...

Page 1157: ...er seal Unclip the cover of the central junction box CJB Remove the single screw 5 Remove the bulkhead extension continued 1 Remove the bolts 2 Disconnect the plug 6 Remove the bulkhead extension cont...

Page 1158: ...cover 10 Remove the blower motor Unscrew the bolts Separate the connector located in the passenger footwell Pull out the grommet together with the wire and the plug Installation 1 Install the blower...

Page 1159: ...lter opening 4 Install the remaining components in reverse order Vehicles with air conditioning NOTE Before connecting the refrigerant lines fit them with new O rings Coat the new O rings with refrige...

Page 1160: ...o Section 100 00 1 Standard preparatory measures Make a note of the radio keycode Make a note of the preset radio stations Place protective covers over the fenders CAUTION Disconnect the battery nega...

Page 1161: ...ubber seal Unclip the central junction box CJB cover Remove the single screw 6 Remove the bulkhead extension continued 1 Remove the bolts 2 Unclip the connector 7 Remove the bulkhead extension continu...

Page 1162: ...rculation valve control motor 3 Blower motor resistor assembly 11 Remove the heater Pull off the side air ducts 1 Unscrew the three nuts Undo the wiring harness 2 Undo the heater from the bracket Vehi...

Page 1163: ...nditioning system For additional information refer to Section 412 03 4 Fill the cooling system with coolant For additional information refer to Section 303 03 5 Standard finishing operations Connect t...

Page 1164: ...additional information refer to Section 100 00 1 Standard preparatory measures Make a note of the radio keycode Make a note of the preset radio stations Place protective covers over the fenders Vehic...

Page 1165: ...rubber seal Unclip the central junction box CJB cover Remove the single screw 5 Remove the bulkhead extension continued 1 Remove the bolts 2 Unclip the connector 6 Remove the bulkhead extension contin...

Page 1166: ...l valve 2 Undo the clamps and detach the coolant hoses 9 Remove the heater cover Remove the four bolts Vehicles with air conditioning 10 Pull out the evaporator heat exchanger 1 Evaporator push fit 2...

Page 1167: ...system and fill it For additional information refer to Section 412 03 3 Standard finishing operations Connect the battery negative lead Remove the protective covers Enter the radio keycode Reprogram...

Page 1168: ...a note of the preset radio stations CAUTION Disconnect the battery nega tive lead 2 Detach the coolant expansion tank Remove the single screw Unhook the coolant expansion tank from its bracket 3 Remo...

Page 1169: ...Disconnect the plug from the heater control valve 2 Undo the four clamps and detach the coolant hoses Installation NOTE Only carry out steps 1 to 4 if there is a regular knocking noise coming from the...

Page 1170: ...ections on the heater control valve and around the refrigerant lines NOTE Do not allow the coolant hose clamps to touch the bodywork Install a new left hand heater coolant hose Route the heater coolan...

Page 1171: ...412 02 19 Heating and Ventilation 412 02 19 REMOVAL AND INSTALLATION CONTINUED E1245 EN 07 2001 2002 Bantam 8 Check the operation of the heater...

Page 1172: ...E1251 EN 07 2001 2002 Bantam Heater Core Housing 34 354 8 Disassembly 1 Remove the heater housing cover Vehicles with air conditioning 2 Pull out the evaporator heat exchanger push fit 1 Evaporator 2...

Page 1173: ...BLY CONTINUED E1251 EN 07 2001 2002 Bantam 4 Remove the blower motor cover 5 Remove the blower motor 6 Dismantle the heater housing held together by clips heater shown from the front 7 Dismantle the h...

Page 1174: ...412 02 22 Heating and Ventilation 412 02 22 DISASSEMBLY AND ASSEMBLY CONTINUED E1251 EN 07 2001 2002 Bantam Assembly 1 Assemble the components in reverse order Use new clips if necessary...

Page 1175: ...412 02 23 Heating and Ventilation 412 02 23 SPECIFICATIONS E1252 EN 07 2001 2002 Bantam Torque Specifications Description Nm Heater to bulkhead 9 Pollen filter housing 5...

Page 1176: ...ssor 34 626 0 412 03 7 8 Clutch and Clutch Field Coil 34 628 0 412 03 9 12 Evaporator Core 34 622 0 412 03 13 16 Evaporator Core Orifice 34 624 0 412 03 17 19 Suction Accumulator 34 630 0 412 03 20 22...

Page 1177: ...t heats up to a temperature between 70 C and 110 C The gas is then pumped to the condenser The condenser consists of many cooling fins through which the gas is passed The refrigerant gas is cooled so...

Page 1178: ...by the heater air conditioning system fan through the air distribution system into the vehicle The refrigerant gas is then passed to the collector dehydrator before being sucked up again by the compre...

Page 1179: ...03 4 Air Conditioning 412 03 4 DESCRIPTION AND OPERATION CONTINUED Air Conditioning System Components Item Description 1 Condenser 2 Compressor 3 Compressor line connection E1253 EN 07 2001 2002 Bant...

Page 1180: ...NTINUED Compressor The compressor draws the gaseous refrigerant out of the evaporator The compressor pumps gaseous refrigerant to the condenser As a result of this compression the gaseous refrigerant...

Page 1181: ...412 03 6 Air Conditioning 412 03 6 DIAGNOSIS AND TESTING Air Conditioning REFER to Section 412 00 E3671 EN 07 2001 2002 Bantam...

Page 1182: ...00 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Remove the accessory drive belt Turn the belt tensioner clockwise 4 Disconnect the A C compressor clutch electr...

Page 1183: ...nd the A C compressor to prevent dirt in gress 6 Disconnect the refrigerant lines and remove the A C compressor Discard the O ring seals Installation NOTE Install new refrigerant line O ring seals NOT...

Page 1184: ...refrigerant circuit If necessary the compressor must be held in place using a cable tie so that the refrigerant lines are not damaged Remove the air conditioning compressor For additional information...

Page 1185: ...ALLATION CONTINUED 4 Pull out the compressor magnetic coil Installation CAUTION After attaching the magnetic coil remove the thrust washer NOTE Do not skew the electromagnetic pull in clutch when fitt...

Page 1186: ...ompressor magnetic coil using a suitable thrust washer 1 Bolt M6x30 with washer 2 Drive plate 3 Thrust washer 4 Electromagnetic pull in clutch NOTE Renew the pulley snap ring 2 Fit the compressor pull...

Page 1187: ...washer from spacer washer set to set the gap 3 Fit the compressor drive plate and check the gap at several places around the circumference 4 Install the air conditioning compressor For additional info...

Page 1188: ...ake a note of the preset radio stations CAUTION Disconnect the battery nega tive lead NOTE Safety Precautions and General Re quirements and Safety Measures for Mainte nance and Repair Work For additio...

Page 1189: ...central junction box CJB Remove the single screw 5 Remove the bulkhead extension continued 1 Remove the bolts 2 Unclip the connector 6 Remove the bulkhead extension continued Remove the single screw...

Page 1190: ...the coolant hoses 9 Remove the heater cover Remove the four bolts 10 Pull out the evaporator push fit Installation NOTE Before connecting the refrigerant lines fit them with new O rings Coat the new O...

Page 1191: ...CONTINUED 3 Connect the battery negative lead Enter the radio keycode Reprogram the preset radio stations Reset the clock Road test the vehicle to collect data for the PCM 4 Check that the heater air...

Page 1192: ...inch blue 412 027 34 001 Remover Installer Fixed Orifice 412 034 34 004 Special Tool s Remover Broken Orifice 412 035 34 005 Removal 1 Drain the air conditioning system For additional information ref...

Page 1193: ...ulkhead extension left hand retaining bolt 5 Remove the bulkhead extension right hand retaining bolts 6 Remove the bulkhead extension 1 Remove the bolts 2 Unclip the clips from the bulkhead extension...

Page 1194: ...the tool clockwise and pull out the evaporator core orifice 9 NOTE Only necessary if the evaporator core orifice is broken Using the special tool remove the broken evaporator core orifice Installation...

Page 1195: ...Section 100 00 1 Standard preparatory measures Make a note of the radio keycode Make a note of the preset radio stations Place protective covers over the fenders CAUTION Disconnect the battery nega t...

Page 1196: ...right hand wheelhouse cover Remove the bolts 7 Remove the accumulator dehydrator from below Installation NOTE Tightening torques For additional in formation refer to Section 412 03 Specifications NOTE...

Page 1197: ...information refer to Section 412 03 3 Standard finishing operations Connect the battery negative lead Remove the protective covers Enter the radio keycode Reprogram the preset radio stations Set the c...

Page 1198: ...e preset radio stations Place protective covers over the fenders CAUTION Disconnect the battery nega tive lead 2 Detach the coolant expansion tank Remove the single screw Unhook the coolant expansion...

Page 1199: ...g contacts for the air conditioning low pressure switch Start the engine Switch on the air conditioning NOTE Run the engine at idle for 30 seconds with the air conditioning switched on before re movin...

Page 1200: ...he air conditioning low pressure switch Connect the plug of the air conditioning low pressure switch 2 Standard finishing operations Connect the battery negative lead Remove the protective covers Ente...

Page 1201: ...attery nega tive lead 2 Remove the right hand headlamp assembly For additional information refer to Section 417 01 3 Remove the air conditioning high pressure switch Disconnect the plug Installation N...

Page 1202: ...hing operations Connect the battery negative lead Remove the protective covers Enter the radio keycode Re program the preset radio stations Reset the clock Road test the vehicle to collect data for th...

Page 1203: ...sures Make a note of the radio keycode Make a note of the preset radio stations CAUTION Disconnect the battery nega tive lead NOTE Safety Precautions and General Re quirements and Safety Measures for...

Page 1204: ...er of the central junction box CJB Remove the single screw 5 Remove the bulkhead extension continued 1 Remove the bolts 2 Unclip the connector 6 Remove the bulkhead extension continued Remove the sing...

Page 1205: ...hem Coat the new O rings with refrigerant oil before fitting them 1 Refit the components in reverse order 2 Evacuate the air conditioning system and fill it For additional information refer to Section...

Page 1206: ...ional information refer to Section 100 00 1 Standard preparatory measures Make a note of the radio keycode Make a note of the preset radio stations Place protective covers over the fenders CAUTION Dis...

Page 1207: ...2 03 Specifications NOTE Before connecting the refrigerant lines fit them with new O rings Coat the new O rings with refrigerant oil before fitting them 1 Refit the components in reverse order 2 Evacu...

Page 1208: ...412 03 33 Air Conditioning 412 03 33 REMOVAL AND INSTALLATION CONTINUED 4 Check the operation of the air conditioning system E1265 EN 07 2001 2002 Bantam...

Page 1209: ...03 34 Air Conditioning 412 03 34 REMOVAL AND INSTALLATION Suction Accumulator to Evaporator Line 34 644 0 Special Tool s Disconnecting tool refrigerant line 5 8 black 34 003 E1267 EN 07 2001 2002 Ban...

Page 1210: ...stations Place protective covers over the fenders CAUTION Disconnect the battery nega tive lead 2 Drain the air conditioning system For additional information refer to Section 412 03 3 Detach the cool...

Page 1211: ...the bolts 2 Unclip the electrical connector 6 Remove the bulkhead extension continued Remove the single screw 7 Remove the air conditioning low pressure switch Disconnect the plug NOTE Plug the refri...

Page 1212: ...nt lines fit them with new O rings Coat the new O rings with refrigerant oil before fitting them 1 Refit the components in reverse order 2 Evacuate and refill the air conditioning system For additiona...

Page 1213: ...n 412 00 Torque Specifications Description Nm Condenser to radiator 6 Collector dehydrator to bracket 6 High pressure switch to refrigerant line 8 Compressor to bracket 25 Suction pressure pipe to com...

Page 1214: ...APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Control Components 412 04 2 DIAGNOSIS AND TESTING Control Components 412 04 3 REMOVAL AND INSTALLATION Climate Control Assembly 34 300 0...

Page 1215: ...r different speeds The temperature control switch allows choice of temperature and controls the heater regulator valve The air distribution switch uses a cable to provide step less control of the air...

Page 1216: ...412 04 3 Control Components 412 04 3 DIAGNOSIS AND TESTING E3108 EN 07 2001 2002 Bantam Control Components REFER to Section 412 00...

Page 1217: ...radio keycode Make a note of the preset radio stations CAUTION Disconnect the battery nega tive lead 2 Remove the instrument cluster bezel Unclip the cover 3 Remove the instrument cluster bezel conti...

Page 1218: ...ion 415 01 6 Remove the bezel 1 Remove the screws 2 Unclip the clips Pull the bezel forwards Disconnect the plug 7 Unclip the air distribution shaft 8 Remove the heater air conditioning module and the...

Page 1219: ...ONTINUED E1276 EN 07 2001 2002 Bantam 3 Connect the battery ground lead Enter the radio keycode Reprogram the preset radio stations Reset the clock Carry out a road test to enable the PCM to collect d...

Page 1220: ...keycode Make a note of the preset radio stations Place protective covers over the wings CAUTION Disconnect the battery ground lead 2 Remove the radio For additional information refer to Section 415 01...

Page 1221: ...efit the components in the reverse order 2 Install the radio For additional information refer to Section 415 01 3 Standard finishing operations Connect the battery ground lead Remove the protective co...

Page 1222: ...note of the radio keycode Make a note of the preset radio stations 2 Disconnect the battery ground cable 3 Remove the instrument panel For additional information refer to Section 501 12 4 Remove the...

Page 1223: ...t Cluster Inspection and Verification All Vehicles Symptom Chart With or Without Tachometer Self Diagnostic Mode Worldwide Diagnostic System WDS Tester Diagnostics All Vehicles Instrument Cluster Diag...

Page 1224: ...am indicator Item Description 14 Low fuel indicator 15 Door ajar indicator not specified for South Africa 16 Trip meter reset button 17 Odometer 18 Parking brake brake warning indicator 19 Charge warn...

Page 1225: ...ceived the LCD will not increment Incorporated into the odometer is a tripmeter which is reset by using the trip meter reset button Tachometer The instrument cluster receives tachometer information fr...

Page 1226: ...icator 8 Turn signal indicator 9 Door ajar indicator not specified for South Africa 10 Low fuel indicator 11 High beam indicator Item Description 12 Temperature warning indicator 13 Glow plug indicato...

Page 1227: ...ible before proceeding to the next step 4 If the concern is not visually evident verify the symptom and refer to the Symptom Chart applicable to the vehicle build date Symptom Chart With or Without Ta...

Page 1228: ...cator is always on Circuit Charging system Accessory drive belt Instrument cluster Use WDS to diagnose The air bag indicator is always on Circuit Air bag module Instrument cluster Use WDS to diagnose...

Page 1229: ...scroll through if there is more than 1 7 Vehicle speed mph EXXX X Speedometer Displays the speed signal in put in mph 8 Vehicle speed km h XXX X Speedometer Displays the speed signal in put in km h 9...

Page 1230: ...int Test A 9204 B1204 Fuel pump module short to ground Instrument cluster Go To Pinpoint Test A 9342 B1342 Instrument cluster electronic control unit is defective Instrument cluster Use WDS to diagnos...

Page 1231: ...RETRIEVE ANY STORED DTCS 413 01 12 C3 TEST OPERATION OF THE ENGINE COOLANT TEMPERATURE SENSOR 413 01 13 PINPOINT TEST D THE TACHOMETER IS INOPERATIVE D1 TEST OPERATION OF THE TACHOMETER 413 01 13 D2 R...

Page 1232: ...WARNING INDICATOR IS INOPERATIVE FROM 01 99 ONWARDS H1 TEST OPERATION OF WARNING INDICATOR 413 01 17 PINPOINT TEST J THE CHARGING SYSTEM WARNING INDICATOR IS INOPERATIVE FROM 01 99 ONWARDS J1 TEST OP...

Page 1233: ...INPOINT TEST A INCORRECT FUEL GAUGE INDICATION CONDITIONS DETAILS RESULTS ACTIONS A1 TEST OPERATION OF FUEL GAUGE 1 Select the instrument cluster self diagnostic mode test 1 gauge sweep Does the fuel...

Page 1234: ...t test Is the value F010 or less Yes GO TO A4 No If the value is between F011 and F254 GO TO A6 If the value is F255 GO TO A7 A4 TEST FOR SHORT TO GROUND ON FUEL PUMP MODULE UNIT 1 Fuel Pump Mod ule C...

Page 1235: ...o INSTALL a new instrument cluster TEST the system for normal operation A6 RETRIEVE ANY STORED DTCS 1 Instrument Clus ter C39 2 Fuel Pump Module C88 3 Select the Instrument cluster self diagnostic mod...

Page 1236: ...tance less than 5 ohms Yes INSTALL a new fuel pump module TEST system for normal operation No REPAIR circuit 31 GA7 BK TEST the sys tem for normal operation PINPOINT TEST B THE SPEEDOMETER IS INOPERAT...

Page 1237: ...ument cluster TEST the system for normal operation No USE WDS to diagnose the PCM the ISO link and the VSS PINPOINT TEST C INCORRECT TEMPERATURE GAUGE INDICATION CONDITIONS DETAILS RESULTS ACTIONS C1...

Page 1238: ...E TACHOMETER IS INOPERATIVE CONDITIONS DETAILS RESULTS ACTIONS D1 TEST OPERATION OF THE TACHOMETER 1 Select the instrument cluster self diagnostic mode test 1 gauge sweep Does the tachometer carry out...

Page 1239: ...nt cluster C39 pin 30 circuit 14 LE11 VT WH harness side and ground Is the voltage greater than 10 volts Yes GO TO E3 No REPAIR circuit 14 LE11 TEST the system for normal operation E3 CHECK CIRCUIT 31...

Page 1240: ...nd ground Does the low oil pressure warning indicator illuminate Yes INSTALL a new oil pressure switch TEST the system for normal operation No REPAIR circuit 31S WD9 BK GN OR 31 PC2C BK TEST the syste...

Page 1241: ...circuit 31 WB7 BK harness side Does the brake warning indicator illuminate Yes INSTALL a new brake fluid level switch TEST the system for normal operation No REPAIR circuit 31 WB37 BK or circuit 31S W...

Page 1242: ...rking brake switch TEST the system for normal operation PINPOINT TEST H THE LOW FUEL WARNING INDICATOR IS INOPERATIVE FROM 01 99 ONWARDS CONDITIONS DETAILS RESULTS ACTIONS H1 TEST OPERATION OF WARNING...

Page 1243: ...OF CHARGING SYSTEM WARNING INDICATOR 1 Select the instrument cluster self diagnostic mode test 3 illuminate warning indicators Does the charging system warning indicator illuminate Yes Charging syste...

Page 1244: ...column upper shroud 2 Remove the multi function switch 1 Disconnect the multi function switch electrical connectors 2 Remove the retaining screw 3 Remove the switch 3 Lever the instrument cluster bez...

Page 1245: ...ng wheel shown removed for clarity 6 Remove the instrument cluster 9 CAUTION Do not place the instrument cluster lens down Disconnect the electrical connectors and remove the instrument cluster E1283...

Page 1246: ...nt Cluster 413 01 21 REMOVAL AND INSTALLATION CONTINUED E1283 EN 09 2001 2002 Bantam BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO MODEL INDEX CONTINUED Installation 1 To install reverse the...

Page 1247: ...ove the instrument cluster Refer to the procedure in this section 2 Remove the lens 1 Remove the two bulbs 2 Release the retaining lugs and remove the lens 3 Remove the tachometer 4 Remove the fuel te...

Page 1248: ...5 Remove the speedometer head 6 Remove the bulb holders 7 Remove the printed circuit electrical connector retainers 8 Release the pin contacts from the cluster moulding E1284 EN 09 2001 2002 Bantam BA...

Page 1249: ...g it off the locating dowels Remove the printed circuit 10 Remove the pin contacts from the printed circuit Installation CAUTION Take care not to bend or damage the printed circuit and the elec trical...

Page 1250: ...413 01 25 Instrument Cluster 413 01 25 REMOVAL AND INSTALLATION CONTINUED E1284 EN 09 2001 2002 Bantam BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO MODEL INDEX CONTINUED...

Page 1251: ...luster bezel retaining screws 1 Instrument cluster retaining screws 1 Speedometer cable to speed sender unit retaining nut 7 Tachometer retaining screws 1 Fuel temperature gauge retaining screws 1 E12...

Page 1252: ...APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Charging System 414 00 2 3 DIAGNOSIS AND TESTING Charging System 414 00 4 Inspection and Verification 414 00 4 Symptom Chart 414 00 4 Pin...

Page 1253: ...engine cylinder block and is driven by the crankshaft pulley at approximately twice engine speed through a drive belt For additional information refer to Section 303 05 When the engine is started the...

Page 1254: ...e is an open circuit in the regulator or generator rotor circuits the charge warning indicator will not illuminate The generator should be repaired as an assembly and not dismantled for repair For add...

Page 1255: ...art Symptom Chart Condition Possible Sources Action The charging system warning indicator stays on Auxiliary drive belt CHECK the auxiliary drive belt tension REFER to Section 303 05 Circuit Generator...

Page 1256: ...tion Is there an increase in voltage Yes GO TO A2 No GO TO A4 A2 CHECK CIRCUIT 31 BK 1 2 Generator C303a 3 C1 4 Measure the resistance between the generator connector C303a pin 1 circuit 31 BK and gro...

Page 1257: ...cuit 64 BU BK TEST the sys tem for normal operation A4 CHECK FOR VOLTAGE 1 Generator C303a 2 3 Measure the voltage between the generator connector C303a pin 1 circuit 31 BK and ground Is the voltage g...

Page 1258: ...1 circuit 31 BK and ground Does the lamp illuminate Yes INSTALL a new generator TEST the system for normal operation No INSTALL a new bulb TEST the system for normal operation B3 CHECK CIRCUIT 64 A1 B...

Page 1259: ...e engine at 1500 rpm with no electrical load 6 Read the voltage The voltage should be in the range of 14 1 to 15 1 volts If the voltage increase is less than 2 5 volts above the base voltage perform t...

Page 1260: ...orking near the battery always shield your face and protect your eyes Always provide adequate ventilation Failure to follow these instructions may result in personal injury WARNING Always observe all...

Page 1261: ...teries should be allowed to warm up to approximately 5 C before charging This may require four to eight hours at room temperature depending on the initial temperature and the battery size 4 A battery...

Page 1262: ...charged by this procedure a new one should be installed 7 A rapid recharge procedure has been developed for recharging batteries that have passed the Load Test and only need a recharge This can be du...

Page 1263: ...ttery and Cables 414 01 2 DIAGNOSIS AND TESTING Battery 414 01 3 REMOVAL AND INSTALLATION Battery 414 01 4 5 Battery to Starter Motor Solenoid Cable Vehicles with 1 6L 1 3L Engine 414 01 6 9 Battery t...

Page 1264: ...414 01 2 DESCRIPTION AND OPERATION E1300 EN 07 2001 2002 Bantam Battery and Cables Item Description 1 Battery cables 2 Battery Item Description 3 Battery tray BACK TO CHAPTER INDEX FORD BANTAM PAGES...

Page 1265: ...01 3 Battery Mounting and Cables 414 01 3 DIAGNOSIS AND TESTING E1301 EN 07 2001 2002 Bantam Battery REFER to Section 414 00 BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO MODEL INDEX CONTINU...

Page 1266: ...1302 EN 07 2001 2002 Bantam Battery 31 214 0 Removal 1 Disconnect the battery ground cable 2 Disconnect the battery power and auxiliary power cable 3 Remove the battery clamp 4 Remove the battery BACK...

Page 1267: ...ting and Cables 414 01 5 REMOVAL AND INSTALLATION CONTINUED E1302 EN 07 2001 2002 Bantam Installation 1 To install reverse the removal procedure BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO...

Page 1268: ...s with 1 6L 1 3L Engine Removal 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Disconnect and detach the battery auxiliary positive cable 3 Disconnect the b...

Page 1269: ...using 6 Detach the electrical cables below the battery tray 7 Detach the battery to starter motor solenoid cable from the transaxle mounting bracket 8 Remove the engine undershield For additional info...

Page 1270: ...ble from the oil filter housing 11 Disconnect the crankshaft position CKP sensor and oil pressure switch electrical connectors 12 Disconnect the starter motor electrical connector 13 Disconnect the ge...

Page 1271: ...ting and Cables 414 01 9 REMOVAL AND INSTALLATION CONTINUED E6741 EN 07 2001 2002 Bantam Installation 1 To install reverse the removal procedure BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO...

Page 1272: ...Motor Solenoid Cable Vehicles with 1 8L Endura DE Diesel Engine Removal 1 Disconnect the battery ground cable 2 Open the battery positive terminal cover 3 Disconnect the battery auxiliary positive ca...

Page 1273: ...tor solenoid cable Cut the tie strap 6 Disconnect the generator electrical connector 7 Raise and support the vehicle For additional information refer to Section 100 02 8 Remove the battery to starter...

Page 1274: ...TE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy It may need to be driven 16 km or more to relearn its adapti...

Page 1275: ...ntam Battery Tray 44 271 4 Removal 1 Remove the battery For additional information refer to Battery in this section 2 Remove the cable tie 3 Remove the battery tray Installation 1 To install reverse t...

Page 1276: ...s 8 Battery terminal clamp retaining nuts 5 Generator electrical connector retaining nut s 5 Starter motor electrical connector upper retaining nut 12 Starter motor electrical connector lower retainin...

Page 1277: ...LE APPLICATION 2002 Bantam SUBJECT PAGE DIAGNOSIS AND TESTING Generator 414 02 2 REMOVAL AND INSTALLATION Generator Vehicles with 1 6L Engine 31 414 0 414 02 3 Generator Vehicles with 1 8L Endura DE d...

Page 1278: ...4 02 2 Generator and Regulator 414 02 2 DIAGNOSIS AND TESTING E3753 EN 07 2001 2002 Bantam Generator REFER to Section 414 00 BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO MODEL INDEX CONTINUE...

Page 1279: ...1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the accessory drive belt 1 Rotate the belt tensioner clockwise 2 Remove the accessory drive belt 3 Di...

Page 1280: ...f the radiator 6 Support the left hand side of the radiator 7 Remove the engine undershield For additional information refer to Section 502 00 8 Remove the radiator support bracket left hand retaining...

Page 1281: ...ON CONTINUED E6745 EN 07 2001 2002 Bantam 10 Remove the radiator support bracket Vehicles with power steering 11 Detach the power steering lines clamp All vehicles 12 Remove the generator BACK TO CHAP...

Page 1282: ...AL AND INSTALLATION CONTINUED E6745 EN 07 2001 2002 Bantam Installation All vehicles 1 To install reverse the removal procedure Vehicles with power steering All vehicles BACK TO CHAPTER INDEX FORD BAN...

Page 1283: ...414 02 7 Generator and Regulator 414 02 7 REMOVAL AND INSTALLATION CONTINUED E6745 EN 07 2001 2002 Bantam BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO MODEL INDEX CONTINUED...

Page 1284: ...with power assisted steering 2 Remove the power assisted steering pump assembly For additional information refer to Section 211 02 All vehicles 3 Remove the generator drive belt For additional inform...

Page 1285: ...Remove the generator two bolts Installation CAUTION Make sure the generator is tightened using the following graphical sequence otherwise premature failure of the mounting bracket may occur 1 Refit t...

Page 1286: ...414 02 10 Generator and Regulator 414 02 10 REMOVAL AND INSTALLATION CONTINUED E5960 EN 07 2001 2002 Bantam BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO MODEL INDEX CONTINUED...

Page 1287: ...l 1 Disconnect the battery ground cable 2 Remove the generator drive belt For additional information refer to Section 303 05 3 Detach the air conditioning compressor four bolts Support the compressor...

Page 1288: ...rator upper bolt 7 Remove the generator two bolts Installation CAUTION Make sure the generator is tightened using the following graphical sequence otherwise premature failure of the mounting bracket m...

Page 1289: ...414 02 13 Generator and Regulator 414 02 13 REMOVAL AND INSTALLATION CONTINUED E5961 EN 07 2001 2002 Bantam BACK TO CHAPTER INDEX FORD BANTAM PAGES FROM MANUAL TO MODEL INDEX CONTINUED...

Page 1290: ...ator support bracket retaining bolts 25 Generator upper retaining bolts 1 6L 45 Generator electrical connector retaining nut 1 6L 5 Generator lower retaining nuts diesel 25 Generator upper retaining n...

Page 1291: ...1 SECTION 415 00 Audio System General Information VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE DIAGNOSIS AND TESTING Audio System 415 00 2 Inspection and Verification 415 00 2 Symptom Chart 415 00 2 3...

Page 1292: ...rim reso nance incorrectly fit ted trim Fuse 2 10 A Fuse 19 10 A Wiring harness Loose or corroded electrical connectors Over stressed wiring internally dam aged chaffing of wires 3 Visually inspect fo...

Page 1293: ...D Condition Possible Sources Action Distorted sound from one or more speakers Speaker s Trim resonance Wiring to speaker s Audio unit Go to Pinpoint Test C No sound from all of the speak ers Speaker s...

Page 1294: ...OR RECEPTION B1 CHECK THE ANTENNA RECEPTION 415 00 6 B2 CHECK THE ANTENNA GROUND 415 00 6 7 B3 CHECK THE ANTENNA CORE RESISTANCE 415 00 7 B4 CHECK THE ANTENNA BASE CONNECTOR RESISTANCE 415 00 7 B5 CHE...

Page 1295: ...THE AUDIO UNIT 1 2 Switch the radio receiver on Is the display illuminated Yes GO TO A2 No GO TO A3 A2 CHECK FOR SOUND FROM THE SPEAKERS 1 Verify that sound is coming from the speakers Is there sound...

Page 1296: ...e audio unit 2 3 Using a digital multimeter measure the voltages between the audio unit C52 pin 1 circuit 29 MD15 OG BK pin 3 circuit 74 MD15 BU BK Are the voltages 10 volts or greater Yes GO TO A6 No...

Page 1297: ...s Yes REPAIR circuit 29 MD15 OG BK 74 MD15 BU BK as appropriate TEST the system for normal operation No CHECK the CJB and associated circuits GO TO A8 A8 CHECK CIRCUIT 29 MD15 74 MD15 FOR SHORT 1 Usin...

Page 1298: ...Guide supplied with the vehicle No INSTALL a new audio control unit TEST the system for normal operation PINPOINT TEST B POOR RECEPTION CONDITIONS DETAILS RESULTS ACTIONS B1 CHECK THE ANTENNA RECEPTI...

Page 1299: ...meter measure the resistance between the center pin on the antenna connector and the antenna mast screw thread Is the resistance less than 1 ohms Yes GO TO B5 No CHECK the in line connectors INSTALL a...

Page 1300: ...es GO TO B2 No GO TO B6 B6 CHECK THE ANTENNA CABLE FOR SHORT 1 Antenna Base Connector 2 Using a digital multimeter measure the resistance between the center pin antenna core and the antenna screen Is...

Page 1301: ...E 1 2 Audio Unit C52b 3 Using a digital multimeter measure the resistance at the audio unit C52b between pins for the appropriate speaker s Pin 1 circuit 33 MD10 YE BK and pin 2 circuit 32 MD10 WH BK...

Page 1302: ...33 MD10 YE BK and C116 pin 1 circuit 33 MD28 YE LHF C52b pin 2 circuit 32 MD10 WH BK and C116 pin 2 circuit 32 MD28 WH LHF C52b pin 3 circuit 33 MD11 YE VT and C91 pin 2 circuit 33 MD28 YE VT LHR C52b...

Page 1303: ...connector terminals engage fully TEST the system for normal operation D2 CHECK THE SPEAK OSITIVE CIRCUIT FOR SHORT TO GROUND ER P 1 Audio Unit C52b 2 Using a digital multimeter measure the appropriate...

Page 1304: ...iate speaker circuit between C52b pin 2 circuit 32 MD10 WH BK and ground LHF C52b pin 4 circuit 32 MD11 WH VT and ground LHR C52b pin 6 circuit 32 MD17 WH RD and ground RHF C52b pin 8 circuit 32 MD18...

Page 1305: ...Audio Unit 415 01 1 07 2001 2002 Bantam SECTION 415 01 Audio Unit VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE DIAGNOSIS AND TESTING Audio System 415 01 2 REMOVAL AND INSTALLATION Audio Unit 38 222 0...

Page 1306: ...415 01 2 Audio Unit 415 01 2 DIAGNOSIS AND TESTING E4281 EN 07 2001 2002 Bantam Audio System REFER to Section 415 00...

Page 1307: ...radio removal tools into the locating holes until they click into place 2 Pull the tools gently towards the side of the unit to release the locking tangs 3 Pull the unit out of the instrument panel 2...

Page 1308: ...1 07 2001 2002 Bantam SECTION 415 02 Antenna VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Antenna 415 02 2 DIAGNOSIS AND TESTING Antenna 415 02 3 REMOVAL AND INSTALLATION Ant...

Page 1309: ...7 2001 2002 Bantam Antenna Item Description 1 Antenna mast 2 Antenna base 3 Insulator clip 4 Antenna cable Item Description 5 Retaining screw The fixed roof mounted mast antenna is connected to the au...

Page 1310: ...415 02 3 Antenna 415 02 3 DIAGNOSIS AND TESTING E3772 EN 07 2001 2002 Bantam Antenna REFER to Section 415 00...

Page 1311: ...415 02 4 Antenna 415 02 4 REMOVAL AND INSTALLATION E6865 EN 07 2001 2002 Bantam Antenna 38 352 0 Removal 1 Detach the interior lamp 2 Remove the interior lamp 3 Detach the antenna cable...

Page 1312: ...INSTALLATION CONTINUED E6865 EN 07 2001 2002 Bantam 4 Remove the antenna and seal Installation 1 NOTE Make sure the antenna cable insulator clip is correctly located before installing the antenna To...

Page 1313: ...001 2002 Bantam SECTION 415 03 Speakers VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Speakers 415 03 2 DIAGNOSIS AND TESTING Speakers 415 03 3 REMOVAL AND INSTALLATION Front...

Page 1314: ...415 03 2 Speakers 415 03 2 DESCRIPTION AND OPERATION E6677 EN 07 2001 2002 Bantam Speakers Large diameter round speakers are fitted to the front doors...

Page 1315: ...415 03 3 Speakers 415 03 3 DIAGNOSIS AND TESTING E3778 EN 07 2001 2002 Bantam Speakers REFER to Section 415 00...

Page 1316: ...Remove the front door trim panel For additional information refer to Section 501 05 2 Detach the loudspeaker four screws 3 CAUTION When disconnecting the multiplugs do not pull the wiring pull on the...

Page 1317: ...oint Tests 417 01 9 26 Component Tests 417 01 26 Stop lamps 417 01 27 Inspection and Verification 417 01 27 Pinpoint Tests 417 01 27 31 Turn Signal and Hazard Lamps 417 01 32 Inspection and Verificati...

Page 1318: ...01 77 Exterior Lighting 417 01 77 Headlamp Adjustment 417 01 77 General Specifications 417 01 77 Torque Specifications 417 01 77 07 2001 2002 Bantam BACK TO CHAPTER INDEX FORD BANTAM CONTINUED TO MODE...

Page 1319: ...beam relay to the high beam bulb The left and right hand high beams are fused separately through fuses F21 and F22 These fuses are located in the CJB Multifunction switch The multifunction switch has...

Page 1320: ...al and hazard warning lamp indicator in the instrument cluster Wiring harness Fuses F5 and F17 The turn signal relay is supplied with voltage through fuse F17 in the CJB and the turn signal lamp switc...

Page 1321: ...ction switch 5 Fuse F21 headlamp LH instrument cluster illumination 6 Fuse F22 headlamp RH Item Description 7 Fuse F11 headlamp RH 8 Fuse F10 headlamp LH 9 Fuse F9 multifunction switch 10 Fuse F7 fron...

Page 1322: ...on 1 Ignition relay 2 Windshield wiper relay 3 Horn relay 4 A C switch relay 5 Not used Item Description 6 WOT relay petrol 7 Power hold relay 8 Fuel pump relay petrol 9 Low beam relay 10 High beam re...

Page 1323: ...ND OPERATION Multifunction switch Item Description 1 Connection point for connector C15a Item Description 2 Connection point for connector C15b E6750 EN 07 2001 2002 Bantam BACK TO CHAPTER INDEX FORD...

Page 1324: ...ve Fuse Circuit s Multifunction switch Central Junction Box CJB Go To Pinpoint Test A The low beams are inoperative Circuit s Relay low beam Multifunction switch Go To Pinpoint Test B The high beams a...

Page 1325: ...E THE FAULT CONDITION 417 01 13 14 D2 CHECK THE FUSE F10 417 01 14 D3 CHECK THE POWER SUPPLY OF HEADLAMP LEFT HAND SIDE 417 01 14 D4 CHECK THE GROUND CONNECTION OF HEADLAMP LEFT HAND SIDE 417 01 15 D5...

Page 1326: ...R SHORT TO POWER 417 01 23 F7 CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION 417 01 23 F8 CHECK RELAY HIGH BEAM FOR PROPER FUNCTION 417 01 23 F9 CHECK THE CONTROL CIRCUIT OF RELAY HIGH BEAM FOR SH...

Page 1327: ...se blows again LOCATE and REPAIR the short circuit by using the wiring diagrams TEST the system for normal op eration A2 CHECK THE POWER SUPPLY OF FUSE F9 1 Fuse F9 CJB 2 3 Measure the voltage between...

Page 1328: ...H HEADLAMPS 1 Measure the resistance between headlamp left hand side connector C45 pin 7 circuit 31 LE31A BK harness side and ground Is the resistance less than 2 ohms Yes CHECK the multifunction swit...

Page 1329: ...ed Yes INSTALL a new relay low beam TEST the system for normal operation No REPAIR the power supply of relay low beam by using the wiring diagrams TEST the system for normal operation B3 CHECK THE MUL...

Page 1330: ...12 VT YE and ground Is battery voltage indicated Yes GO TO C3 No GO TO C2 C2 CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION 1 2 Check the multifunction switch according to Component Testing attach...

Page 1331: ...Measure the resistance between relay socket high beam connector C5 pin 1 circuit 31 LE12 BK and ground Is the resistance less than 2 ohms Yes INSTALL a new relay high beam TEST the system for normal o...

Page 1332: ...fuse blows again LOCATE and REPAIR the short cir cuit by using the wiring diagrams TEST the system for normal operation D3 CHECK THE POWER SUPPLY OF HEADLAMP LEFT HAND SIDE 1 Fuse F10 CJB 2 Headlamp l...

Page 1333: ...etween head lamp left hand side and ground G9 by us ing the wiring diagrams TEST the system for normal operation D5 CHECK THE POWER SUPPLY OF FUSE F10 1 Measure the voltage between fuse F10 10 A CJB a...

Page 1334: ...tion D7 CHECK THE POWER SUPPLY OF HEADLAMP RIGHT HAND SIDE 1 Fuse F11 CJB 2 Headlamp right hand side C46 3 4 Turn the multifunction switch to the LOW BEAM position 5 Measure the voltage between headla...

Page 1335: ...e between fuse F11 10 A CJB and ground Is battery voltage indicated Yes REPAIR the open circuit s between fuse F11 and headlamp right hand side by using the wiring diagrams TEST the system for normal...

Page 1336: ...or normal operation E3 CHECK THE POWER SUPPLY OF HEADLAMP LEFT HAND SIDE 1 Fuse F21 CJB 2 Headlamp left hand side C45 3 4 Turn the multifunction switch to the LOW BEAM and HIGH BEAM position 5 Measure...

Page 1337: ...PPLY OF FUSE F21 1 Measure the voltage between fuse F21 10 A CJB and ground Is battery voltage indicated Yes REPAIR the open circuit s between fuse F21 and headlamp left hand side by using the wiring...

Page 1338: ...tage indicated Yes GO TO E8 No GO TO E9 E8 CHECK THE GROUND CONNECTION OF HEADLAMP RIGHT HAND SIDE 1 2 Measure the resistance between headlamp right hand side connector C46 pin 6 circuit 31 LE30 BK ha...

Page 1339: ...DLAMPS 1 2 Check whether the high and low beam headlamps are on continuously Are the high and low beam headlamps on continuously Yes CHECK the multifunction switch according to Component Testing attac...

Page 1340: ...t s connected with the multifunction switch connector C15a pin 1 by using the wiring diagrams TEST the system for normal operation No INSTALL a new relay low beam TEST the system for normal operation...

Page 1341: ...e short to power circuit s con nected with the relay low beam connector C6 pin 3 by using the wiring diagrams TEST the system for normal operation F7 CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION...

Page 1342: ...eration No INSTALL a new relay high beam TEST the system for normal operation F10 CHECK THE CIRCUIT TO RIGHT HAND HIGH BEAM HEADLAMP FOR SHORT TO POWER 1 2 Fuse F22 10 A CJB 3 4 Check if the right han...

Page 1343: ...1 2 Instrument cluster C37a 3 4 Check if the left hand high beam headlamp is on continuously Is the left hand high beam headlamp on continuously Yes REPAIR the short to power circuit s connected with...

Page 1344: ...ent Tests Relays Component testing applies to the following relays Relay low beam Relay high beam 1 Check the relay contact in normal condition Measure the resistance between pin 3 and 5 VFE0015897 Is...

Page 1345: ...on The stop lamps are inoperative Fuse Circuit s Stop lamp switch Go To Pinpoint Test H One or more stop lamps are in operative Bulb s Circuit s Rear lamp assembly right hand side left hand side Go To...

Page 1346: ...CHECK THE STOP LAMP SWITCH FOR PROPER FUNCTION 1 Connect a jumper wire between stop lamp switch connector C50 circuit 14 LG23 VT WH and circuit 14S LG1 VT BK harness side Are the stop lamps illuminate...

Page 1347: ...C42 3 4 Depress the brake pedal 5 Measure the voltage between rear lamp assembly right hand side connector C42 circuit 14S LG38 VT harness side and ground Is battery voltage indicated Yes GO TO I3 No...

Page 1348: ...iring diagrams TEST the system for normal operation I4 CHECK THE POWER SUPPLY OF RE R LAMP ASSEMBLY LEFT HAND SIDE A 1 2 Rear lamp assem bly left hand side C39 3 4 Depress the brake pedal 5 Measure th...

Page 1349: ...s between rear lamp assembly left hand side and ground G4 by using the wiring diagrams TEST the system for normal operation PINPOINT TEST J STOP LAMPS ARE ON CONTINUOUSLY CONDITIONS DETAILS RESULTS AC...

Page 1350: ...If the cause is not visually evident verify the symptom and refer to the Symptom Chart Symptom Chart Condition Possible Sources Action Turn signal lamps are inopera tive or on continuously Fuse F17 Ci...

Page 1351: ...TION SWITCH FOR PROPER FUNCTION 417 01 37 K13 CHECK THE INSTRUMENT CLUSTER 417 01 37 38 K14 CHECK THE RELAY ANTI THEFT FLASHER FOR PROPER FUNCTION 417 01 38 K15 CHECK THE RELAY TURN SIGNAL FOR PROPER...

Page 1352: ...ND CONNECTION OF SIDE TURN SIGNAL LAMP RIGHT HAND SIDE 417 01 46 L19 CHECK THE POWER SUPPLY OF REAR TURN SIGNAL LAMP RIGHT HAND SIDE 417 01 46 47 L20 CHECK THE GROUND CONNECTION OF REAR TURN SIGNAL LA...

Page 1353: ...NDEX FORD BANTAM TO MODEL INDEX PAGES FROM MANUAL Pinpoint Tests PINPOINT TEST K TURN SIGNAL LAMPS ARE INOPERATIVE OR ON CONTINUOUSLY CONDITIONS DETAILS RESULTS ACTIONS K1 DETERMINE THE FAULT CONDITIO...

Page 1354: ...F MULTIFUNCTION SWITCH 1 2 Multifunction switch C15a 3 4 Measure the voltage between multifunction switch connector C15a pin 9 circuit 14 LG5 VT harness side and ground Is battery voltage indicated Ye...

Page 1355: ...und Is battery voltage indicated Yes GO TO K6 No CHECK the multifunction switch according to Component Testing attached to the wiring diagrams If necessary INSTALL a new one TEST the system for normal...

Page 1356: ...Measure the resistance between multifunction switch connector C15a pin 5 circuit 49 LG1 BU harness side and rear turn signal lamp left hand side connector C68 circuit 14S LG12 BU harness side Is the r...

Page 1357: ...ration No REPAIR the open circuit s between multi function switch and splice S35 by using the wiring diagrams TEST the system for nor mal operation K10 CHECK THE RELAY ANTI THEFT FLASHER FOR PROPER FU...

Page 1358: ...TION SWITCH FOR PROPER FUNCTION I 1 2 Multifunction switch C15a 3 4 Check if the left hand turn signal lamps are on continuously Are the left hand turn signal lamps on continuously Yes GO TO K13 No CH...

Page 1359: ...a new one TEST the system for normal operation K14 CHECK THE RELAY ANTI THEFT FLASHER FOR PROPER FUNCTION 1 2 Relay anti theft flasher C323 3 Check if the right hand turn signal lamps are on continuo...

Page 1360: ...for normal operation K16 CHECK THE MULT FUNCTION SWITCH FOR PROPER FUNCTION I 1 2 Multifunction switch C15a 3 4 Check if the right hand turn signal lamps are on continuously Are the right hand turn s...

Page 1361: ...r normal operation PINPOINT TEST L ONE TURN SIGNAL HAZARD LAMP IS INOPERATIVE CONDITIONS DETAILS RESULTS ACTIONS L1 DETERMINE THE INOPERATIVE TURN SIGNAL LAMP 1 2 Turn the multifunction switch to the...

Page 1362: ...t hand side connector C45 pin 6 circuit 31 LE31 BK harness side and ground Is the resistance less than 2 ohms Yes CHECK the headlamp left hand side If necessary INSTALL a new one TEST the system for n...

Page 1363: ...DE 1 Measure the resistance between side turn signal lamp left hand side connector C145 pin 1 circuit 31 LG13 BK harness side and ground Is the resistance less than 2 ohms Yes CHECK the side turn sign...

Page 1364: ...HE GROUND CONNECTION OF REAR TURN SIGNAL LAMP LEFT HAND SIDE 1 Measure the resistance between rear turn signal lamp left hand side connector C68 circuit 31 LG12 BK harness side and ground Is the resis...

Page 1365: ...1 Measure the voltage between instrument cluster connector C37 pin 29 circuit 49 LG22 BU YE harness side and ground Is battery voltage indicated Yes CHECK the instrument cluster If necessary INSTALL...

Page 1366: ...MP 1 Measure the resistance between headlamp right hand side connector C46 pin 6 circuit 31 LE30 BK harness side and ground Is the resistance less than 2 ohms Yes CHECK the headlamp right hand side If...

Page 1367: ...m for normal operation L18 CHECK THE GROUND CONNECTION OF SIDE TURN SIGNAL LAMP RIGHT HAND SIDE 1 Measure the resistance between side turn signal lamp right hand side connector C144 pin 1 circuit 31 L...

Page 1368: ...ght hand side connector C66 circuit 31 LG19 BK harness side and ground Is the resistance less than 2 ohms Yes CHECK the rear turn signal lamp right hand side If necessary INSTALL a new one TEST the sy...

Page 1369: ...ircuit 31 LE29 BK harness side and ground Is the resistance less than 2 ohms Yes GO TO M5 No REPAIR the open circuit s between multi function switch and ground G6 by using the wiring diagrams TEST the...

Page 1370: ...rn signal terminal 31and ground Is the resistance less than 2 ohms Yes GO TO M7 No CHECK the multifunction switch according to Component Testing attached to the wiring diagrams If necessary INSTALL a...

Page 1371: ...ystem for normal operation M9 CHECK THE RELAY ANTI THEFT FLASHER FOR PROPER FUNCTION 1 2 Relay anti theft flasher C323 3 Check if the hazard warning lamps are on continuously Are the hazard warning la...

Page 1372: ...ymptom and refer to the Symptom Chart Symptom Chart Condition Possible Sources Action One or more parking rear or license plate lamp s is are in operative Fuse s Bulb s Circuit s Headlamp left hand si...

Page 1373: ...5 N12 CHECK THE POWER SUPPLY OF FRONT PARKING LAMP RIGHT HAND SIDE 417 01 55 N13 CHECK THE GROUND CONNECTION OF FRONT PARKING LAMP RIGHT HAND SIDE 417 01 56 N14 DETERMINE THE FAULT CONDITION 417 01 56...

Page 1374: ...ECK THE POWER SUPPLY OF FUSE F15 417 01 59 60 P4 CHECK THE POWER SUPPLY OF FUSE S F6 AND F7 417 01 60 BACK TO CHAPTER INDEX FORD BANTAM TO MODEL INDEX PAGES FROM MANUAL CONTINUED Pinpoint Tests PAGE 2...

Page 1375: ...M TO MODEL INDEX PAGES FROM MANUAL E9427 EN 07 2001 2002 Bantam Pinpoint Tests PINPOINT TEST N ONE OR MORE PARKING REAR OR LICENSE PLATE LAMP S IS ARE INOPERATIVE CONDITIONS DETAILS RESULTS ACTIONS N1...

Page 1376: ...lice S9 by using the wiring diagrams TEST the system for normal operation No INSTALL a new fuse F6 If the fuse blows again LOCATE and REPAIR the short cir cuit by using the wiring diagrams TEST the sy...

Page 1377: ...the front parking lamp left hand side inoperative Yes GO TO N6 No GO TO N8 N6 CHECK THE POWER SUPPLY OF FRONT PARKING LAMP LEFT HAND SIDE 1 Turn the multifunction switch to the OFF posi tion 2 Headla...

Page 1378: ...g diagrams TEST the system for normal operation N8 DETERMINE THE FAULT CONDITION 1 Determine the fault condition Is the rear parking lamp left hand side inoperative Yes GO TO N9 No GO TO N11 N9 CHECK...

Page 1379: ...nd by using the wiring diagrams TEST the sys tem for normal operation N11 DETERMINE THE FAULT CONDITION 1 Determine the fault condition Is the front parking lamp right hand side inoperative Yes GO TO...

Page 1380: ...wiring diagrams TEST the system for normal operation N14 DETERMINE THE FAULT CONDITION 1 Determine the fault condition Is the rear parking lamp right hand side inoperative Yes GO TO N15 No GO TO N17 N...

Page 1381: ...s between rear lamp assembly right hand side and ground G3 by using the wiring diagrams TEST the system for normal operation N17 CHECK THE POWER SUPPLY OF LICENSE PLATE LAMP 1 License plate lamp C40a...

Page 1382: ...REAR OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY CONDITIONS DETAILS RESULTS ACTIONS O1 CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION 1 Multifunction switch C15a 2 Check if the parking lamps are o...

Page 1383: ...onnector C15a pin 6 circuit 29 LE29 OG BK harness side and ground Is battery voltage indicated Yes GO TO P4 No GO TO P2 P2 CHECK THE FUSE F15 1 Fuse F15 CJB Is the fuse F15 5 A OK Yes GO TO P3 No INST...

Page 1384: ...HECK THE POWER SUPPLY OF FUSE S F6 AND F7 1 Measure the resistance between multifunction switch connector C15a pin 7 circuit 29S DB7 OG YE harness side and fuse F6 5 A or fuse F7 5A Is the resistance...

Page 1385: ...ymptom Chart Symptom Chart Condition Possible Sources Action The reversing lamp is inopera tive Fuse Circuit s Reversing lamp Transmission switch Go To Pinpoint Test Q The reversing lamp is on con tin...

Page 1386: ...o REPAIR the open circuit s between fuse F13 and transmission switch by using the wiring diagrams TEST the system for nor mal operation Q3 CHECK THE TRANSMISSION SWITCH FOR PROPER FUNCTION 1 2 Connect...

Page 1387: ...witch and reversing lamp by using the wiring diagrams TEST the system for nor mal operation Q5 CHECK THE GROUND CONNECTION OF REVERSING LAMP 1 2 Measure the resistance between reversing lamp connector...

Page 1388: ...sing lamp switch C51 3 Are the reversing lamps on continuously Yes REPAIR the short to power circuit s connected with transmission switch connector C51 pin 1 by using the wiring diagrams TEST the syst...

Page 1389: ...fer to the Symptom Chart Symptom Chart Symptom Chart Condition Possible Sources Action The fog lamps are inoperative Fuse s Circuit s Relay fog lamps Front fog lamp switch Central Junction Box CJB Go...

Page 1390: ...system for normal operation S2 CHECK THE POWER SUPPLY OF FUSE F14 1 2 Measure the voltage between fuse F14 CJB and ground Is battery voltage indicated Yes GO TO S3 No REPAIR the power supply of fuse F...

Page 1391: ...PARKING LIGHT position 2 Switch ON the front fog lamps 3 Measure the voltage between relay socket fog lamps connector C320 pin 1 circuit 29S LD8 OG and ground Is battery voltage indicated Yes GO TO S...

Page 1392: ...VT WH and pin 5 circuit 14 LD9 VT BK 3 Do the front fog lamps illuminate Yes INSTALL a new relay fog lamps TEST the system for normal operation No REPAIR the open circuit s between front fog lamp lef...

Page 1393: ...front fog lamp switch connector C328 pin 2 circuit 29S LD10 OG GN harness side and ground Is battery voltage indicated Yes REPAIR the open circuit s between front fog lamp switch and relay fog lamps...

Page 1394: ...and ground Is the resistance less than 2 ohms Yes REPAIR the open circuit s between relay fog lamp and front fog lamp left hand side by using the wiring diagrams TEST the system for normal operation I...

Page 1395: ...cuit s between front fog lamp right hand side and ground G9 by using the wiring diagrams TEST the system for normal operation If necessary INSTALL a new front fog lamp PINPOINT TEST U THE FOG LAMPS AR...

Page 1396: ...ew relay fog lamps TEST the system for normal operation Component Tests Relays Component testing applies to the following relays Relay fog lamps 1 Check relay contact in normal condition Measure the r...

Page 1397: ...assembly left hand side shown Disconnect the headlamp assembly electrical connector Installation 1 NOTE Position the headlamp assembly with the guide pin To install reverse the removal procedure 2 Ad...

Page 1398: ...lamp electrical connector 2 Unclip the lens cover Push the hook up using your fingers 4 Remove the bulbs bayonet fit 1 Screw 2 Lens 3 Rear turn light bulb 4 Reverse light bulb 5 Brake taillight bulb I...

Page 1399: ...Check that no other load is in the vehicle other than a half tank of gas Set the measuring screen of the beam setting equipment to the following headlamp adjustment value X X 10 cm 10 m 0 degrees 34...

Page 1400: ...r horizontal adjustment readjustment of the vertical axis might be necessary Horizontal adjustment LHD variant shown Adjust the low beam so that the rising line of the light dark boundary lies at the...

Page 1401: ...amp Type Wattage Halogen headlamp high low beam Bayonet 55 60 Side lamps Push fit 5 Front turn signal lamps Bayonet 21 Side turn signal lamps Push fit 5 Rear turn signal lamps Bayonet 21 Stop lamps re...

Page 1402: ...ule Communications Network VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE DESCRIPTION AND OPERATION Communications Network 418 00 2 DIAGNOSIS AND TESTING Communications Network 418 00 2 Inspection and V...

Page 1403: ...ule PCM Instrument cluster Anti theft warning system central locking module Air bag module Connector s loose or oxidised Symptom Chart Condition Possible Sources Action Powertrain control module PCM d...

Page 1404: ...pin 7 circuit 4 DA1 GY harness side Is the resistance less than 2 ohms Yes CHECK the PCM If necessary INSTALL a new one TEST the system for normal operation No REPAIR the open circuit s between PCM a...

Page 1405: ...or normal operation PINPOINT TEST C AIR BAG MODULE DOES NOT RESPOND TO THE WDS CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK THE ISO 9141 LINE TO THE AIR BAG MODULE FOR OPEN 1 2 Air bag module C330 3 Me...

Page 1406: ...central locking module If necessary INSTALL a new one TEST the system for normal operation No REPAIR the open circuit s between anti theft central locking module and data link connector by using the...

Page 1407: ...nd Is battery voltage indicated Yes GO TO E4 No REPAIR the open circuit s between fuse F2 and data link connector by using the wiring diagrams TEST the system for normal op eration E4 CHECK THE GROUND...

Page 1408: ...etween anti theft central locking module connector C330 pin 17 circuit 4 MB13 GY harness side and data link connector C31 pin 7 circuit 4 DA1 GY harness side Is the resistance less than 2 ohms Yes CHE...

Page 1409: ...4 Symptom Chart 419 01B 5 6 Pinpoint Tests 419 01B 6 10 REMOVAL AND INSTALLATION Passive Anti Theft System PATS Module 419 01B 11 Fuel Injection Pump Actuator Vehicles with Diesel Engine 419 01B 12 1...

Page 1410: ...ine If the control module receives the correct code signal the engine will start Should the code received not be recognised the engine will not crank as the PATS is still armed and the engine is still...

Page 1411: ...nds turn the ignition key to the position 0 and remove the key Then turn the ignition key to the position II with the correct programmed key PATS Control Function The PATS control function is containe...

Page 1412: ...iver Starter relay 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 If the concern is not visually evident verify t...

Page 1413: ...mum Vehicle does not start Incorrect number of keys pro grammed or PATS en coded ignition key REFER to WDS PATS test Follow the instruc tions B2141 22 Non volatile memory configuration failure Vehicle...

Page 1414: ...sceiver C54 pin 1 circuit 7 MB37 YE GN harness side and ground Is the voltage greater than 10 volts Yes GO TO A2 No REPAIR circuit 7 MB37 YE GN REPEAT the self test CLEAR the DTCs A2 CHECK THE TRANSCE...

Page 1415: ...6 No GO TO A4 A4 CHECK THE TRANSCEIVER TRANSMIT CIRCUIT FOR SHORT TO GROUND CIRCUIT 10 MB37 GY OG NOTE When a new PCM is installed the encoded ignition keys must be reprogrammed 1 2 PCM C165 3 PATS Tr...

Page 1416: ...gramming in this section REPEAT the self test CLEAR the DTC s No REPAIR circuit 10 MB37 GY OG CLEAR the DTCs REPEAT the self test A6 CHECK THE TRANSCEIVER RECEIVE CIRCUIT FOR VOLTAGE CIRCUIT 8 MB37 WH...

Page 1417: ...Transceiver C54 2 Using a digital multimeter measure the resistance between PATS transceiver C54 pin 4 circuit 8 MB37 WH GN harness side and ground Is the resistance greater than 10 000 ohms Yes INSTA...

Page 1418: ...d the encoded ignition keys must be reprogrammed TURN the ig nition to position 0 then to position II RETRIEVE DTCs If PATS DTCs are present GO to Powertrain Control Module PCM Diagnostic Trouble Code...

Page 1419: ...coded to the im mobiliser system To code the system two valid keys must be available before fitting a new module NOTE If two valid keys are not available it will be necessary to code the system using...

Page 1420: ...ctuator Vehicles with Diesel Engine Removal 1 Disconnect the battery ground cable 2 Remove the wax stat cable adjusting clip 3 Detach the wax stat cable from the fuel injection pump 4 Detach the accel...

Page 1421: ...ring pull on the multiplug body Disconnect the fuel injection pump wiring multiplug 8 NOTE When dismantling multiplugs connectors refer to Connector Repair Procedure in the appropriate wiring diagram...

Page 1422: ...tach the accelerator damper and immobiliser solenoid wiring from the fuel injection pump 11 Remove the immobiliser solenoid shield five bolts 12 Remove the immobiliser solenoid two bolts fuel injectio...

Page 1423: ...heft Passive 419 01B 15 REMOVAL AND INSTALLATION CONTINUED E6379 EN 07 2001 2002 Bantam Installation 1 Refit the components in reverse order BACK TO CHAPTER INDEX FORD BANTAM TO MODEL INDEX PAGES FROM...

Page 1424: ...ve the steering column lower shroud 2 Disconnect the passive anti theft system PATS transceiver electrical connector 3 Remove the PATS transceiver 1 Remove the PATS transceiver retaining screw 2 Remov...

Page 1425: ...peat the Key Program ming procedure from step 1 If the failure re peats refer to Diagnostic and testing to review DTCs an carry out Pinpoint Tests NOTE A maximum of eight ignition keys can be programm...

Page 1426: ...key new key into the lock cylinder and turn the lock cylinder from the OFF position to the RUN position maintain the ignition lock cylinder in the RUN position for less than 5 seconds 6 Check the new...

Page 1427: ...convenience for rental company fleets or other fleet purchasers who may not want the Spare Key Programming procedure available to the vehicle driver NOTE The default setting on delivery of all new ve...

Page 1428: ...emaining keys are with the cus tomer and are not available with the vehicle then instruct the customer to refer to the Owner s Manual under the Programming Spare PATS Key Procedure for instructions on...

Page 1429: ...Theft Passive 419 01B 21 GENERAL PROCEDURES CONTINUED E3810 EN 07 2001 2002 Bantam 9 The vehicle should now start with both ignition keys BACK TO CHAPTER INDEX FORD BANTAM TO MODEL INDEX PAGES FROM M...

Page 1430: ...ayed which offers various command options NOTE Once security access has been granted multiple security access commands should be executed if necessary prior to exiting the command menu This avoids rep...

Page 1431: ...ms 501 11 Instrument Panel 501 12 Handles Locks latches and Entry Systems 501 14 Wipers and Washers 501 16 Bumpers 501 19 Occupant Restraint Active 501 20A Occupant Restraint Passive Supplementary Air...

Page 1432: ...JECT PAGE DESCRIPTION AND OPERATION Interior Trim 501 05 2 REMOVAL AND INSTALLATION Front Door Trim Panel 43 705 0 501 05 3 5 Headliner 43 612 0 501 05 6 7 A Pillar Trim Panel 43 616 0 501 05 8 B Pill...

Page 1433: ...ings and trim panels In most instances one component overlaps another component If this condition is found it will be necessary to loosen or remove the overlapping component before removal of the desi...

Page 1434: ...remote control lever bezel 1 Remove the screw cover 2 Remove the screw Vehicles with Power Windows 2 Remove the power window switch and the exterior rear view mirror switch if equipped 1 Pry out the s...

Page 1435: ...AND INSTALLATION CONTINUED 07 2001 2002 Bantam Vehicles with Manual Windows 4 Remove two retaining screws Vehicles with electric Power Windows 5 Remove the two trim panel retaining screws Vehicles wi...

Page 1436: ...ch the mirror inner trim panel 1 Remove the blanking plug 2 Remove the screw 8 Remove the mirror inner trim panel 1 Unlock the remote control lever cover 2 Remove the remote control lever cover All ve...

Page 1437: ...r additional information refer to A Pillar Trim Panel in this section 2 Remove the rear panel trim panel For additional information refer to Rear Trim Panel in this section 3 Remove the B pillar trim...

Page 1438: ...p 8 Remove the passenger assist handle 9 CAUTION When removing fasteners take extreme care as they may be easily broken NOTE Remove the headliner rear fastener centre pins before removing the fastener...

Page 1439: ...501 05 8 REMOVAL AND INSTALLATION 07 2001 2002 Bantam A Pillar Trim Panel 43 616 0 Removal 1 Locally detach the door aperture weather strip 2 Remove the A pillar trim panel three clips Installation 1...

Page 1440: ...seat belt anchor bolt one Torx bolt 2 CAUTION Extreme care should be used when removing items of trim as retaining clips are easily broken Fully recline both seats and remove the cab back panel trim s...

Page 1441: ...501 05 10 Interior Trim and Ornamentation 501 05 10 REMOVAL AND INSTALLATION CONTINUED 07 2001 07 2001 2002 Bantam Installation 1 To install reverse the removal procedure 38 Nm...

Page 1442: ...2002 Bantam Cab Back Panel Trim Plastic Panel Removal 1 CAUTION Extreme care should be used when removing items of trim as retaining clips are easily broken Fully recline both seats and remove the ca...

Page 1443: ...501 05 12 Interior Trim and Ornamentation 501 05 12 SPECIFICATIONS 07 2001 2002 Bantam Torque Specifications Description Nm Safety belt anchor bolts 38...

Page 1444: ...BJECT PAGE DIAGNOSIS AND TESTING Rear View Mirrors 501 09 2 Inspection and Verification 501 09 2 Symptom Chart 501 09 2 Pinpoint Test 501 09 2 8 REMOVAL AND INSTALLATION Exterior Mirror Electrically O...

Page 1445: ...Possible Sources Action The mirrors are inoperative Exterior mirror control switch CARRY OUT the Exterior Mirror Control Switch Component Test REFER to the Wiring Diagrams Circuit s Go To Pinpoint Te...

Page 1446: ...rcuit 29 AD12 OG YE harness side and ground Is the voltage greater than 10 volts Yes GO TO A2 No REPAIR circuit 29 AD12 OG YE TEST the system for normal operation A2 CHECK CIRCUIT 31 AD12 BK FOR CONTI...

Page 1447: ...IONS DETAILS RESULTS ACTIONS B1 CHECK FOR CONTINUITY TO THE INOPERATIVE EXTERIOR MIRROR 1 Exterior Mirror Control Switch C325 2 Measure the resistance between NOTE Driver Exterior Mirror the exterior...

Page 1448: ...tion PINPOINT TEST C A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK THE EXTERIOR MIRROR FUNCTIONS WITH SWITCH LOGIC 1 Operate the exterior mirror contr...

Page 1449: ...rior mirror TEST the system for normal operation C3 CHECK THE DRIVER EXTERIOR MIRROR LEFT RIGHT CIRCUIT 1 Exterior Mirror Control Switch C325 2 Measure the resistance between the exterior mirror contr...

Page 1450: ...D11 GY WH FOR CONTINUITY A 1 Passenger Exte rior Mirror C311 2 Measure the resistance between the exterior mirror control switch C325 pin 1 circuit 10 AD11 GY WH harness side and the passenger exterio...

Page 1451: ...e customer concern No GO TO C7 C7 CHECK CIRCUIT 8 AD10 WH BK FOR CONTINUITY 1 Passenger Exte rior Mirror C311 2 Measure the resistance between the exterior mirror control switch C325 pin 7 circuit 8 A...

Page 1452: ...w 1 Remove the front door trim panel For additional information refer to Section 501 05 3 CAUTION Do not touch the adhesive surfaces as re bonding will be impaired Detach the watershield from the door...

Page 1453: ...NUED 1 Disconnect the mirror electrical connector 6 NOTE Note the position of the gasket Remove the mirror Remove the mirror retaining screws Installation 1 NOTE Make sure the gasket is correctly posi...

Page 1454: ...AND INSTALLATION CONTINUED 07 2001 2002 Bantam Exterior Mirror Manually Operated 43 364 0 Removal 1 Detach the mirror inner trim panel 1 Remove the blanking plug 2 Remove the screw 2 Remove the mirro...

Page 1455: ...501 09 12 Rear View Mirrors 501 09 12 REMOVAL AND INSTALLATION CONTINUED 5 Remove the mirror three bolts Installation 1 Refit the components in reverse order 07 2001 2002 Bantam...

Page 1456: ...e inboard edge of the glass towards the back of the mirror case 2 Detach the door mirror glass 1 Holding the outboard edge of the glass pull it outwards 2 While pulling the glass outwards pull it towa...

Page 1457: ...the back of the mirror case 2 NOTE Connect the electrical connector where fitted Locate the glass onto the door mirror glass mounting 1 Attach the inboard edge of the door mirror glass mounting to th...

Page 1458: ...Seats 501 10 2 REMOVAL AND INSTALLATION Front Seat 501 10 3 4 Front Seat Cushion 501 10 7 Front Seat Backrest 501 10 8 9 DISASSEMBLY AND ASSEMBLY Front Seat Cushion 40 104 0 501 10 10 11 Front Seat Ba...

Page 1459: ...contoured for lateral support Both front seats can be folded forward to allow access to the vehicle jack and wheel spanner and are fitted with two way adjustable head restraints with foam pads Seat tr...

Page 1460: ...tal restraint system SRS or any component s adjacent to the SRS sensors Failure to follow these instruc tions may result in personal injury WARNING Always wear safety glasses when working on an air ba...

Page 1461: ...er electrical connector All vehicles 5 Move the seat fully rearwards 6 Remove the seat front retaining bolts 7 Move the seat fully forwards 8 Remove the seat rear retaining bolts and remove the seat I...

Page 1462: ...the front outer retaining bolt 4 Move the seat fully forwards 5 Tighten the seat in the following sequence 1 Tighten the rear inner retaining bolt 2 Tighten the rear outer retaining bolt Vehicles with...

Page 1463: ...vehicles 7 Attach the seat side trim panel 8 Install the head restraint 9 Connect the battery ground cable For additional information refer to Section 414 01 E9364 EN 07 2001 2002 Bantam FORD BANTAM...

Page 1464: ...g harness to aid assembly An incorrectly routed wiring harness may lead to the wiring harness becoming damaged on the seat mechanism Detach the safety belt buckle pre tensioner wiring harness from the...

Page 1465: ...ont Seat in this section 2 Remove the seat outer trim panel 1 Detach the front retaining clip 2 Detach the rear locating tang 3 Remove the backrest recliner hand wheel Remove the cover Vehicles withou...

Page 1466: ...OTE The seat may be equipped with an additional inner trim panel depending on seat specifications Care must be taken when removing the backrest not to damage the inner trim panel Remove the backrest 1...

Page 1467: ...h the seat cover Cut the 15 hog rings 3 Remove the seat cover 1 Roll the seat cover towards the centre of the foam pad to access the pleating hog rings 2 Cut the six hog rings 4 NOTE Note the position...

Page 1468: ...ueak mat is available as a one size service part which should be cut to match the mat it is replacing Use hog ring pliers to close the hog rings Do not use any other tool The hog rings must be closed...

Page 1469: ...ad restraint 2 Remove the head restraint guides 3 Detach the retaining strip from the base of the backrest 4 Roll the seat cover up the backrest to access the lower lateral tensioner rod retaining cli...

Page 1470: ...ateral tension rod retaining clips 8 NOTE Make sure the lateral tension rod retaining clips do not enter the retaining sleeves Roll the backrest cover upwards to access the pleating hog rings Cut the...

Page 1471: ...t Remove the springs Assembly 1 To assemble reverse the disassemble procedure NOTE The anti squeak mat is available as a one size service part which should be cut to match the mat it is replacing Use...

Page 1472: ...scription Nm Front seat front retaining bolts 25 Front seat rear outer retaining bolt 25 Front seat rear inner retaining bolt 40 Front safety belt buckle bolt 50 E6774 EN 07 2001 2002 Bantam FORD BANT...

Page 1473: ...ent Tests 501 11 3 REMOVAL AND INSTALLATION Front Door Window Glass 42 314 0 501 11 9 12 Opera Window Glass 501 11 13 16 Rear Window Glass 501 11 17 20 Front Door Window Regulator and Motor 42 338 0 5...

Page 1474: ...ive Driver power window control switch CARRY OUT the Driver Power Window Control Switch Compo nent Test REFER to the Wiring Diagrams Single power window is inopera tive driver side Driver power window...

Page 1475: ...TOR CIRCUIT FOR CONTINUITY 1 2 Driver Window Con trol Switch C55a 3 Measure the resistance between the driver power window control switch C55a pin 1 circuit 32 AJ26 WH and pin 7 circuit 33 AJ26 YE har...

Page 1476: ...h C55a pin 7 circuit 33 AJ26 YE and the driver power window motor C106 pin 1 circuit 33 AJ26 YE Is the resistance less than 5 ohms Yes INSTALL a new motor TEST the system for normal operation No REPAI...

Page 1477: ...14 AJ18 VT WH TEST the system for normal operation No GO TO B2 B2 CHECK THE DRIVER SIDE PASSENGER POWER WINDOW CONTROL SWITCH LED 1 Observe the driver side passenger power window control switch LED Is...

Page 1478: ...control switch to the UP position 2 Measure the voltage between the passenger power window control switch C56 pin 6 circuit 32 AJ18 WH VT harness side and ground Is the voltage greater than 10 volts Y...

Page 1479: ...e system for normal operation B7 CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW CONTROL SWITCH UP CIRCUIT AND THE PASSENGER POWER WINDOW MOTOR 1 Measure the resistance between passenger power...

Page 1480: ...AIR circuit 31 AJ9 BK TEST the sys tem for normal operation B9 CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH 1 2 Measure the voltage between the driver power window control switch C55b p...

Page 1481: ...the adhesive surface as re bonding will be impaired Detach the watershield from the door panel 3 Detach the door glass top run retainer 4 Remove the door glass top run retainer Vehicles with power win...

Page 1482: ...r window shown Align the retaining screws with the access hole 8 Detach the window glass from the regulator 9 Lower the window glass to the bottom of the door 10 Remove the window glass weather strip...

Page 1483: ...eather strip 3 NOTE Do not fully tighten the retaining screws at this stage Attach the front door window glass to the window regulator power window shown Install the retaining screws 4 Align the retai...

Page 1484: ...Vehicles with power windows 7 Disconnect the window control switch electrical connector All vehicles 8 Install the door glass top run retainer 9 Attach the watershield to the door panel 10 Install the...

Page 1485: ...all below 10 C heat the cartridges for approximately 15 minutes by placing them on a warm radiator or by using a hot air gun set at approximately 25 C Heat the polyurethane PU adhesive if necessary Al...

Page 1486: ...changes to avoid damage to the body and trim panels NOTE Some resistance may be encountered when cutting through the glass locating pegs in the top corners of the glass NOTE Carefully remove the rema...

Page 1487: ...approximately 1 mm of trimmed PU adhesive adhered to the opening flange 2 Check window aperture sealing area for damaged sheet metal rust or foreign material which may have caused or may cause glass...

Page 1488: ...be overlapped by 20 mm Apply the PU adhesive in a continuous bead of between 8 and 10 mm height to the rear window glass along the bond line Apply the PU adhesive in a continuous bead of between 8 and...

Page 1489: ...a hot air gun set at approximately 25 C Heat the polyurethane PU adhesive if necessary 2 CAUTION When removing fasteners take extreme care as they may be easily broken NOTE Remove the headliner rear...

Page 1490: ...age to the body and trim panels NOTE Some resistance may be encountered when cutting through the glass locating pegs in the top corners of the glass NOTE Carefully remove the remaining part of the loc...

Page 1491: ...n material which may have caused or may cause glass breakage 3 CAUTION To make sure the PU adhesive cures it is essential that all bonding surfaces are free of moisture Using a hot air gun apply warm...

Page 1492: ...her technician use suction cups to install the rear window glass 7 Should the ambient temperature fall below 10 C use a hot air gun at a distance of approximately 50 mm from the surface and apply warm...

Page 1493: ...red Detach the door panel watershield 3 Connect the window control switch electrical connector 4 Remove the window glass retaining screws Align the retaining screws with the access hole 5 Detach the w...

Page 1494: ...indow regulator motor electrical connector 8 Remove the window regulator and motor Installation 1 Install the window regulator and motor 2 Connect the window regulator motor electrical connector E6781...

Page 1495: ...tach the window glass to the window regulator clamp 6 Adjust the window glass For additional information refer to Door Window Glass Adjustment in this section 7 Disconnect the window control switch el...

Page 1496: ...n refer to Section 414 01 2 NOTE Should the ambient temperature fall below 10 C heat the cartridges for approximately 15 minutes by placing them on a warm radiator or by using a hot air gun set at app...

Page 1497: ...ing clip 1 Open the screw cover 2 Remove the screw 9 Remove the rear view mirror 10 Detach the door weather strip on each side 11 Remove the A pillar trim panels on each side 1 Unclip the trim panel 2...

Page 1498: ...re changed where the cutting depth changes to avoid damage to the body and trim panels NOTE Some resistance may be encountered when cutting through the glass locating pegs in the top corners of the gl...

Page 1499: ...foreign material which may have caused or may cause glass breakage 3 CAUTION To make sure the PU adhesive cures it is essential that all bonding surfaces are free of moisture Using a hot air gun apply...

Page 1500: ...ening flange along the bond line 8 NOTE Firmly and evenly press in position With the aid of another technician use suction cups to install the windshield 9 Should the ambient temperature fall below 10...

Page 1501: ...rip on each side 13 Install the rear view mirror 14 Install the sun visor retaining clips 1 Install the screw 2 Close the screw cover 15 Install the sun visors 16 Install the interior lamp 17 Raise th...

Page 1502: ...d Mechanisms 501 11 30 REMOVAL AND INSTALLATION CONTINUED 18 Install the windshield wipers 19 Lower the hood 20 Connect the battery ground cable For additional information refer to Section 414 01 E678...

Page 1503: ...TION Do not touch the adhesive surface as re bonding will be impaired Detach the door panel watershield Using a plastic knife disposable cutlery cut through the Butyl strip to enable the watershield t...

Page 1504: ...bottom 7 Standing inside the door apply rearward hand pressure on the outside of the window glass at the same time raising the glass to its fully closed position 8 Tighten the window glass clamp reta...

Page 1505: ...Item Specification Cleaner SKM 2G9524 A Primer SKM 2G9525 A 1K Adhesive WSKM 2G309 B 2K Adhesive ESK M2G369 A1 2K Hardener ESK M2G369 A2 Torque Specifications Description Nm Wiper arm retaining nuts...

Page 1506: ...1 07 2001 2002 Bantam SECTION 501 12 Instrument Panel VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Instrument Panel 43 644 0 501 12 2 5 SPECIFICATIONS Specifications 501 12 6...

Page 1507: ...ipped with an air bag and when handling the air bag module Failure to follow this in struction may result in personal injury 1 Remove the audio unit For additional information refer to Section 415 01...

Page 1508: ...clip the trim panel 2 Slide the trim panel upwards 7 Remove the instrument cluster For additional information refer to Section 413 01 8 Detach the central junction box 1 Remove the cover 2 Remove the...

Page 1509: ...eveal the instrument panel lower bolts Remove the instrument panel left hand side retaining bolts 12 Remove the instrument panel right hand side retaining bolts 13 Remove the instrument panel upper re...

Page 1510: ...ole 501 12 5 REMOVAL AND INSTALLATION CONTINUED E902 EN 07 2001 2002 Bantam 16 Remove the air ducting 17 Detach the instrument panel wiring harness 18 Remove the instrument panel Installation 1 To ins...

Page 1511: ...Panel 501 12 6 SPECIFICATIONS E6720 EN 07 2001 2002 Bantam Torque Specifications Description Nm Instrument panel upper retaining bolts 3 Instrument panel side retaining bolts 19 Instrument panel lower...

Page 1512: ...n 501 14 3 REMOVAL AND INSTALLATION Hood Latch 41 232 0 501 14 4 Front Door Latch 41 351 0 501 14 5 8 Hood Latch Release Handle 41 226 0 501 14 9 Exterior Door Handle 41 333 0 501 14 10 11 Door Latch...

Page 1513: ...ave a single lever to lock unlock and open the doors from the interior A cable operates the hood latch and release handle On vehicles equipped with central locking actuators supplement the door latche...

Page 1514: ...art Mechanical Electrical Misaligned door s Misaligned hood Door latch s Actuating rod s Exterior door handle s Door latch remote control s Door lock cylinder s Cable s Door latch actuator s Battery F...

Page 1515: ...es and Entry Systems 501 14 4 REMOVAL AND INSTALLATION E907 EN 08 2001 2002 Bantam Hood Latch 41 232 0 Removal 1 Detach the hood latch release cable 2 Remove the hood latch Installation 1 To install r...

Page 1516: ...2 Bantam Front Door Latch 41 351 0 Removal 1 Remove the front door trim panel For additional information refer to Section 501 05 2 CAUTION Do not touch the adhesive surface as re bonding will be impai...

Page 1517: ...Bantam 5 Disconnect the door latch actuating rods 6 Remove the front door latch and front door latch remote control assembly 7 Detach the front door latch actuator wiring harness 8 Remove the front do...

Page 1518: ...08 2001 2002 Bantam 9 Remove the front door latch cover retaining screws 10 Slide the front door latch cover away from the front door latch Detach the front door latch cover grommet 11 Remove the fro...

Page 1519: ...es and Entry Systems 501 14 8 REMOVAL AND INSTALLATION CONTINUED E6787 EN 08 2001 2002 Bantam 13 Remove the front door latch remote control outer cable from the door latch Installation 1 To install re...

Page 1520: ...ND INSTALLATION E906 EN 08 2001 2002 Bantam Hood Latch Release Handle 41 226 0 Removal 1 Remove the steering column upper and lower shrouds 2 Detach the hood latch release cable 3 Remove the hood rele...

Page 1521: ...ation refer to Section 501 05 3 CAUTION Do not touch watershield adhesive surfaces as re bonding will be impaired Locally detach the watershield Using a plastic knife disposable cutlery cut through th...

Page 1522: ...ms 501 14 11 REMOVAL AND INSTALLATION CONTINUED E5848 EN 08 2001 2002 Bantam 6 Disconnect the door lock actuating rod Prise open the clip and pull out the rod 7 Remove the door handle two screws Insta...

Page 1523: ...paired Locally peel back the trim watershield Using a plastic knife disposable cutlery cut through the Butyl strip to enable the protective sheet to be peeled back for access Do not attempt to peel th...

Page 1524: ...AND INSTALLATION CONTINUED E6000 EN 08 2001 2002 Bantam Tailgate Hinge Removal 1 Using an axle stand and a piece of wood support the tailgate 2 Remove the hinge from the tailgate 3 Remove the hinge se...

Page 1525: ...TALLATION CONTINUED E6000 EN 08 2001 2002 Bantam Tailgate Handle Assembly Removal 1 Remove the access panels 3 off 2 Unclip the actuating rods from the han dle 3 Remove the handle retaining screws and...

Page 1526: ...val 1 Remove the access panels 3 off 2 Unclip the actuating rods from the handle 3 Unclip the actuating rods from the latch 4 Remove the two bolts and remove the latch 5 Remove the two screws and remo...

Page 1527: ...2002 Bantam Ignition Lock Cylinder 33 513 0 Removal 1 Remove the passive anti theft system PATS transceiver 2 Remove the ignition switch lock cylinder 1 Turn the key to accessory position I 2 Depress...

Page 1528: ...Lock Cylinder 41 336 0 Special Tool s Remover Installer Door Lock Cylinder 501 033 41 020 A Removal 1 Remove the front door trim panel For additional information refer to Section 501 05 2 CAUTION Do n...

Page 1529: ...2001 2002 Bantam 4 Disconnect the door lock actuating rod 5 Using the special tool remove the door lock cylinder locking ring 6 Remove the door lock cylinder Installation 1 NOTE Make sure the door loc...

Page 1530: ...rs by reading the notches on each tumbler edge and make a note of the key code Read the key code The key code can be read as follows 1 notch 1 2 notches 2 3 notches 3 and 0 notches 4 Assembly 1 NOTE T...

Page 1531: ...e cutout slot in the side of the tumbler magazine 5 NOTE Make sure the roller locates into the corresponding slot in the lock housing Insert the tumbler magazine into the lock housing 6 NOTE Keep the...

Page 1532: ...08 2001 2002 Bantam 8 Fit the alarm actuator 9 NOTE Cross the lever return spring tangs Install the lever return spring 10 NOTE An R for right hand or L for left hand stamped on to the operating leve...

Page 1533: ...Handles Locks Latches and Entry Systems 501 14 22 SPECIFICATIONS E6791 EN 08 2001 2002 Bantam Torque Specifications Description Nm Hood latch retaining bolts 10 Luggage compartment lid latch retaining...

Page 1534: ...ests 501 16 5 23 Component Tests 501 16 23 25 REMOVAL AND INSTALLATION Mounting Arm and Pivot Table 32 554 0 501 16 26 27 Windshield Wiper Motor 32 524 0 501 16 28 30 Windshield Washer Pump 32 624 0 5...

Page 1535: ...osition If the wiper lever is moved from any other setting to the OFF position then the windshield wiper motor continues to run at slow speed until the wipers reach the park position This is affected...

Page 1536: ...position Current flows from the multi function switch connector C65b pin 2 via the washer pump back to the multi function switch connector C65b pin 1 The multi function switch makes the ground connect...

Page 1537: ...s Windshield wiper motor Multifunction switch Go To Pinpoint Test B The high low wiper speeds do not operate correctly intermit tent wiper mode OK Circuit s Relay intermittent wipe Windshield wiper mo...

Page 1538: ...FOR PROPER FUNCTION 501 16 8 A10 CHECK THE WIND HIELD WIPER OTOR FOR PROPER FUNCTION 501 16 9 A11 CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION 501 16 9 10 PINPOINT TEST B THE WIPERS STAY ON CON...

Page 1539: ...ATE CORRECTLY HIGH LOW SPEEDS OK D1 CHECK THE POWER SUPPLY OF RELAY INTERMITTENT WIPE 501 16 15 D2 CHECK THE CONTROL VOLTAGE INTERMITTENT WIPE TO RELAY INTERMITTENT WIPE 501 16 15 16 D3 CHECK THE MULT...

Page 1540: ...IFUNCTION SWITCH FOR PROPER FUNCTION 501 16 22 23 DIAGNOSIS AND TESTING PINPOINT TESTS PAGE 3 OF 3 PINPOINT TEST F THE WIPERS WILL NOT PARK AT THE CORRECT POSITION F1 CHECK THE RELAY INTERMITTENT WIPE...

Page 1541: ...d inoperative Yes GO TO A2 No GO TO A8 A2 DETERMINE THE FAULT CONDITION 1 Turn the multifunction switch to the FAST WIPER SPEED position Is the fast wiper speed inoperative Yes GO TO A3 No GO TO A10 A...

Page 1542: ...T the system for normal op eration A5 CHECK THE POWER SUPPLY OF MULTIFUNCTION SWITCH 1 2 Multifunction switch C15b 3 4 Measure the voltage between multifunction switch connector C15b pin 7 circuit 14...

Page 1543: ...w one TEST the system for normal operation A7 CHECK THE GROUND CONNECTION OF WINDSHIELD WIPER MOTOR 1 Measure the resistance between windshield wiper motor connector C47 pin 1 circuit 31 AK8 BK harnes...

Page 1544: ...dshield wiper motor C47 3 Multifunction switch C15b 4 5 Connect a jumper wire between multifunction switch connector C15b pin 5 circuit 14S AK11 VT OG and pin 7 circuit 14 AK19 VT OG harness side Does...

Page 1545: ...LOW WIPER SPEED position 5 Measure the voltage between windshield wiper motor connector C47 pin 4 circuit 14S AK10 VT BK harness side and ground Is battery voltage indicated Yes CHECK the windshield w...

Page 1546: ...s between multi function switch connector C15b pin 3 and windshield wiper motor by using the wiring diagrams TEST the system for normal op eration PINPOINT TEST B THE WIPERS STAY ON CONTINUOUSLY COND...

Page 1547: ...it 31S AK9 BK OG and ground Is battery voltage indicated Yes REPAIR the short to power circuit s connected with the relay intermittent wipe connector C48 pin 1 by using the wiring diagrams TEST the sy...

Page 1548: ...e system for normal operation No CHECK the multifunction switch according to Component Testing attached to the wiring diagrams If necessary INSTALL a new one TEST the system for normal operation B6 CH...

Page 1549: ...r normal operation PINPOINT TEST C THE HIGH LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY INTERMITTENT WIPER MODE OK CONDITIONS DETAILS RESULTS ACTIONS C1 CHECK THE POWER SUPPLY OF WINDSHIELD WIPER MOTOR...

Page 1550: ...HE CIRCUIT FAST WIPER SPEED FOR OPEN 1 2 Multifunction switch C15b 3 Measure the resistance between multifunction switch connector C15b pin 5 circuit 14S AK11 VT BU harness side and windshield wiper m...

Page 1551: ...wiper motor If nec essary INSTALL a new one TEST the sys tem for normal operation PINPOINT TEST D THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY HIGH LOW SPEEDS OK CONDITIONS DETAILS RESULTS...

Page 1552: ...ector C15b pin 10 circuit 14S AK14 VT BK harness side and relay socket intermittent wipe connector C48 pin 5 circuit 14S AK14 VT BK Is the resistance less than 2 ohms Yes CHECK the multifunction switc...

Page 1553: ...TION 1 Multifunction switch C15b 2 Measure the resistance between multifunction switch connector C15b pin 9 circuit 31S AK19 BK RD harness side and relay socket intermittent wipe connector C48 pin 3 c...

Page 1554: ...for normal operation If necessary INSTALL a new CJB PINPOINT TEST E THE WASH AND WIPE FUNCTION ARE INOPERATIVE CONDITIONS DETAILS RESULTS ACTIONS E1 CHECK THE GROUND CONNECTION OF MULTIFUNCTION SWITC...

Page 1555: ...19 BK RD Actuate the SINGLE WIPE Does the wipers park in the correct position Yes INSTALL a new relay intermittent wipe TEST the system for normal operation No GO TO F2 F2 CHECK THE POWER SUPPLY WIPER...

Page 1556: ...ion F4 CHECK THE MULTIFUNCTION SWITCH FOR PROPER FUNCTION 1 Measure the resistance between multifunction switch connector C15b pin 9 circuit 31S AK15 BK RD and pin 2 circuit 31S AK15 BK RD harness sid...

Page 1557: ...ration F6 CHECK THE WINDSHIELD WIPER MOTOR FOR PROPER FUNCTION 1 2 Measure the voltage between windshield wiper motor connector C47 pin 3 circuit 14 AK8 VT BU harness side and ground Is battery voltag...

Page 1558: ...ation No REPAIR the open circuit s between multi function switch and relay intermittent wipe by using the wiring diagrams TEST the sys tem for normal operation PINPOINT TEST H THE WASHER PUMP IS INOPE...

Page 1559: ...stem for normal operation H3 CHECK THE WASHER PUMP MOTOR FOR PROPER FUNCTION 1 2 Actuate the WINDSHIELD WASHER and hold it during the measure 3 Measure the resistance between washer pump motor connect...

Page 1560: ...the windshield wiper motor 2 pin 5 The windshield wiper motor will run at fast speed Measure the amperage Is the value at the ammeter next to 2 2 A If yes GO to 3 If no INSTALL a new windshield wiper...

Page 1561: ...the windshield wiper motor Connect the battery positive terminal with windshield wiper motor connector C47 pin 3 Connect the battery negative terminal with windshield wiper motor connector C47 pin 1 C...

Page 1562: ...n of the wiper motor crank before undoing it Detach the wiper motor crank Unscrew the nut from the crank Release the crank from the taper by moving it back and forth 3 Detach the wiper linkage from th...

Page 1563: ...7 Wipers and Washers 501 16 27 REMOVAL AND INSTALLATION CONTINUED 3 Install the wiper motor For additional information refer to 32 524 0 in this section 4 Check operation of wipers E923 EN 07 2001 200...

Page 1564: ...position Remove the wiper arms Unclip the cover Undo the nuts two turns Lift the wiper arms and release them from the taper by moving them from side to side Unscrew the nuts and remove the wiper arms...

Page 1565: ...ctor 6 Remove the bulkhead cover cont Remove the bolt 7 Remove the wiper motor Unscrew the bolts Unplug the connector Take out the wiper motor with linkage Installation 1 Install the wiper motor Conne...

Page 1566: ...ion Fit the wiper arms Tighten the pivot shaft bearing nuts Attach the wiper arms and tighten the nuts finger tight Connect the battery negative lead Switch on the wipers and check that the wiper blad...

Page 1567: ...100 02 3 Detach the right hand front wheel 4 Remove the wheelhouse cover 5 Remove the washer pump 1 Disconnect the hoses and drain the washer reservoir 2 Disconnect the plug Pull out the washer pump p...

Page 1568: ...hers 501 16 32 REMOVAL AND INSTALLATION CONTINUED 2 Install the wheelhouse cover 3 Fit the front wheel Lower the vehicle 4 Fill up the washer reservoir 5 Check the operation of the washer system E4469...

Page 1569: ...the A pillar working from the inside 2 NOTE There is no need to empty the coolant expansion tank Detach the coolant expansion tank Remove the single screw Unhook the coolant expansion tank from its br...

Page 1570: ...es at the pump Remove the single screw 7 Remove the washer reservoir continued Disconnect the plug Take out the washer reservoir Installation 1 NOTE When inserting the reservoir check that the filler...

Page 1571: ...upport of the aligner must be placed on the windshield NOTE Required values For additional information refer to General Specifications in this section Using the special tool read off the angle between...

Page 1572: ...C 9111 A Capacities Litres Washer reservoir 3 Setting angle between wiper arms and windshield Description Angle Windshield wiper arms 4 degrees Torque Specifications Description Nm Windshield wiper ar...

Page 1573: ...501 19 Bumpers VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Front Bumper 43 423 0 501 19 2 3 Rear Bumperettes 43 432 0 501 19 4 SPECIFICATIONS Specifications 501 19 5 Torque S...

Page 1574: ...itional information refer to Section 100 02 Raise and support the vehicle 2 Remove the front bumper right hand retaining bolt 3 Remove the front bumper left hand retaining bolt 4 Disconnect the fog la...

Page 1575: ...ove the radiator grille 1 Detach the clips 2 Remove the radiator grille 7 Remove the front bumper retaining screws 8 Remove the front bumper 1 Remove the fasteners 2 Remove the front bumper Installati...

Page 1576: ...Rear Bumperette 43 432 0 Removal 1 Remove the tail light assembly refer to Section 417 01 2 Remove the foam seal 3 Remove the bumperette retaining nuts 4 Remove the bumperette Installation 1 To instal...

Page 1577: ...501 19 5 Bumpers 501 19 5 SPECIFICATIONS Torque Specifications Description Nm Front Bumper retaining nuts 10 Rear Bumperette retaining nuts 10 08 2001 2002 Bantam...

Page 1578: ...AND TESTING Occupant Restraint System 501 20A 3 Principles of Operation 501 20A 3 Inspection and Verification 501 20A 3 Symptom Chart 501 20A 3 Safety Belt Testing 501 20A 4 Component Test 501 20A 4 R...

Page 1579: ...ety belts in the front seat positions The front safety belt retractors incorporate a webbing grabber and a load limiting device The webbing grabber is activated by sudden deceleration of the vehicle e...

Page 1580: ...In an emergency the ELR will lock preventing webbing payout and hence forward movement of the occupant Locking may be achieved by one of two mechanisms Vehicle Motion Sensor VMS The ELRs VMS is opera...

Page 1581: ...d at all times Both driver and passenger should adopt a normal comfortable seating position Both occupants should wear the safety belts and the safety belt webbing must be correctly adjusted with no s...

Page 1582: ...es when the safety belt is detached or removed Detach the safety belt lower anchor from the floor panel 2 CAUTION The bolt securing the safety belt anchor is held captive by a paper washer The bolt sp...

Page 1583: ...able screwdriver remove the four lower clips 5 Remove the cowl side trim panel Using a suitable screwdriver remove the two front clips 6 Remove the front safety belt retractor 1 Remove the retaining b...

Page 1584: ...501 20A 7 Occupant Restraints Active 501 20A 7 REMOVAL AND INSTALLATION CONTINUED 08 2001 2002 Bantam...

Page 1585: ...Section 501 10 2 CAUTION Note the position and routing of the safety belt buckle pretensioner wiring harness to aid assembly An incorrectly routed wiring harness may lead to the wiring harness becomi...

Page 1586: ...CONTINUED Installation WARNING Never probe the electrical connectors of air bag modules or any other supplemental restraint system component Failure to follow this in struction may result in personal...

Page 1587: ...501 20A 10 Occupant Restraints Active 501 20A 10 SPECIFICATIONS Torque Specifications Description Nm Pretensioner bolt 50 Safety belt Torx bolts All 38 08 2001 2002 Bantam...

Page 1588: ...Reactivation 501 20B 6 Glossary 501 20B 6 Principles of Operation 501 20B 6 7 Diagnostic Instructions Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS 501 20B 8 Pinpoint Tests Ai...

Page 1589: ...bag control module 5 Safety belt buckle and pretensioner The supplementary restraint system SRS is AC fired and has been specifically designed to protect the driver and passenger from sustaining sever...

Page 1590: ...ently The behaviour of the warning indicator depends on the type of fault present The warning indicator is located in the instrument cluster The wiring harness provides power to the air bag control mo...

Page 1591: ...bag with a filled volume of 30 litres The passenger air bag module has a single inflator and an air bag with a filled volume of 60 litres The air bag s are a one piece woven item with a silicon coati...

Page 1592: ...follow these instructions may result in personal injury Most air bag system diagnostic procedures require the use of system deactivation and system reactivation procedures These procedures require the...

Page 1593: ...assenger air bag simulator from the passenger air bag module harness 6 Connect and install the passenger air bag module REFER to Passenger Air Bag Module in this section 7 Remove the driver safety bel...

Page 1594: ...dule contains a micro controller to evaluate and process impact data and two micro machine sensors An electronic accelerometer which converts the actual acceleration and deceleration force along the v...

Page 1595: ...nts Passive Supplemental Air 501 20B 8 Bag System DIAGNOSIS AND TESTING Diagnostic Instructions Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS Information not available at this...

Page 1596: ...HE AIR BAG CONTROL MODULE GROUND CIRCUIT 501 20B 13 PINPOINT TEST D DTC B1869 AIR BAG WARNING INDICATOR OPEN CIRCUIT OR SHORT TO GROUND D1 CHECK THE AIR BAG WARNING INDICATOR 501 20B 13 14 D2 CHECK TH...

Page 1597: ...AIR BAG CIRCUIT 501 20B 27 J2 CHECK THE PASSENGER AIR BAG MODULE 501 20B 27 J3 CHECK THE PASSENGER AIR BAG CIRCUIT FOR A SHORT TO GROUND 501 20B 28 PINPOINT TEST K DTC B1925 PASSENGER AIR BAG SHORT T...

Page 1598: ...E DRIVE SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND 501 20B 37 38 PINPOINT TEST R DTC B1885 DRIVER SAFETY BELT PRETENSIONER LOW RESISTANCE R1 CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT 501 2...

Page 1599: ...TO GROUND V1 CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT 501 20B 44 45 V2 CHECK THE PASSE GER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND 501 20B 45 46 PINPOINT TEST W DTC B1886 PASSENGER...

Page 1600: ...native system to check the DLC Is WDS able to communicate with the selected system Yes GO TO A2 No CHECK the DLC For additional information refer to the Wiring Diagrams Petrol and Diesel A2 CHECK THE...

Page 1601: ...Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No REPAIR circuit 4 JA7 GY RD REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safe...

Page 1602: ...CUIT 1 Air Bag Control Module C334 2 Measure the resistance between the air bag control module C334 pin 9 circuit 91 JA10 BK RD and the air bag control module housing Is the resistance less than 5 ohm...

Page 1603: ...efer to the Wiring Diagrams Petrol and Diesel REPEAT the self test CLEAR the DTCs C2 CHECK THE CONDITION OF THE FUSE 1 Fuse 60 10A 2 Fuse 60 10A 3 Check the condition of fuse 60 10A Is any corrosion p...

Page 1604: ...E AIR BAG CONTROL MODULE GROUND CIRCUIT 1 Measure the resistance between the air bag control module C334 pin 9 circuit 91 JA10 BK RD and the air bag control module ground G4 Is the resistance less tha...

Page 1605: ...re to follow this instruction may sult in personal injury re 1 2 Deactivate the supplemental restraint system REFER to Air Bag and Safety Belt Preten sioner Supplemental Restraint System SRS in this s...

Page 1606: ...a fused 15A jumper wire between the air bag control module C334 pin 4 circuit 91S JA14 BK GN harness side and ground 3 Is the air bag warning indicator illuminated Yes INSTALL a new automatic detach...

Page 1607: ...his sec tion D5 CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS WARNING Wait at least one minute after disconnecting the battery ground cable before disconnecting any supplemental restraint system ele...

Page 1608: ...tion No INSTALL a new air bag wiring harness REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supple mental Restraint System SRS in this sec tion...

Page 1609: ...n this section E2 CHECK THE AIR BAG WARNING INDICATOR SUB HARNESS 1 2 Instrument Cluster C333 3 4 Measure the voltage between the instrument cluster C333 pin 3 circuit 91S JA14 BK GN harness side and...

Page 1610: ...oes the system prove out correctly Yes GO TO F2 No GO TO F3 F2 CHECK THE DRIVER AIR BAG MODULE WARNING Do not proceed with the test unless using WDS Failure to follow this instruc tion may result in p...

Page 1611: ...dule C334 pin 2 circuit 94S JA8 VT harness side and ground and the air bag control module C334 pin 3 circuit 91S JA8 BK OG and pin 9 circuit 91 JA10 BK RD harness side and the air bag control module C...

Page 1612: ...AR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No INSTALL a new air bag wiring harness REPEAT the self test CLEAR the...

Page 1613: ...bag control module C1511a pin 3 circuit 91S JA8 BK OG and pin 9 circuit 91 JA10 BK RD harness side and the air bag control module C1511a pin 3 circuit 91S JA8 BK OG harness side and ground Is any vol...

Page 1614: ...REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No INSTALL a new air bag sliding contact REFER to Air Bag Sliding Contact in this section REPEAT the sel...

Page 1615: ...o the driver air bag module 2 Select DMM specific on WDS 3 Connect the Test and Deployment Lead to WDS 4 Measure the resistance of the air bag module squib Is the resistance between 2 and 3 ohms Yes R...

Page 1616: ...ntal Restraint System SRS in this section No INSTALL a new air bag wiring harness REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supple mental...

Page 1617: ...IVATE the system REFER to Air Bag and Safety Belt Pretensioner Supple mental Restraint System SRS in this sec tion I3 CHECK THE AIR BAG SLIDING CONTACT FOR LOW RESISTANCE 1 2 Air Bag Sliding Con tact...

Page 1618: ...s the system prove out correctly Yes GO TO J2 No GO TO J3 J2 CHECK THE PASSENGER AIR BAG MODULE WARNING Do not proceed with this test unless using WDS Failure to follow this instruc tion may result in...

Page 1619: ...cuit 91S JA11 BK WH and ground Are the resistances greater than 10 000 ohms Yes REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Res...

Page 1620: ...EAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No CONNECT the passenger air bag module simulator and the air bag con...

Page 1621: ...r bag module 2 Select DMM specific on WDS 3 Connect the Test and Deployment lead to WDS 4 Measure the resistance of the air bag module squib Is the resistance between 2 and 3 ohms Yes REPEAT the self...

Page 1622: ...Do not proceed with this test unless using WDS Failure to follow this instruc tion may result in personal injury 1 Connect the Test and Deployment Lead to the passenger air bag module 2 Select DMM sp...

Page 1623: ...System SRS in this section No INSTALL a new air bag wiring harness REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supple mental Restraint Syste...

Page 1624: ...INPOINT TEST O DTC B1877 DRIVER SAFETY BELT PRETENSIONER OPEN CIRCUIT CONDITIONS DETAILS RESULTS ACTIONS WARNING Wait at least one minute after disconnecting the battery ground cable before disconnect...

Page 1625: ...he self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No INSTALL a new air bag wiring harness REPEAT the sel...

Page 1626: ...ut correctly Yes INSTALL a new driver safety belt pretensioner REFER to Section 501 20A REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Suppleme...

Page 1627: ...bag wiring harness REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No REPEAT the self test CL...

Page 1628: ...ut correctly Yes INSTALL a new driver safety belt pretensioner REFER to Section 501 20A REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Suppleme...

Page 1629: ...EAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No INSTALL a new air bag wiring harness REPEAT th...

Page 1630: ...HE DRIVER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE 1 Air Bag Control Module C335 2 Driver Safety Belt Pretensioner Simu lator 3 Measure the resistance between the air bag control module C335 pin 11...

Page 1631: ...safety belt pretensioner REFER to Section 501 20A REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this sec...

Page 1632: ...ectly Yes INSTALL a new passenger safety belt pretensioner REFER to Section 501 20A REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental...

Page 1633: ...lt Pretensioner Supplemental Restraint System SRS in this section No INSTALL a new air bag wiring harness REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pre...

Page 1634: ...ectly Yes INSTALL a new passenger safety belt pretensioner REFER to Section 501 20A REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental...

Page 1635: ...ag wiring harness REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No REPEAT the self test CLEA...

Page 1636: ...orrectly Yes INSTALL a new passenger safety belt pretensioner REFER to Section 501 20A REPEAT the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemen...

Page 1637: ...the self test CLEAR the DTCs REACTIVATE the system REFER to Air Bag and Safety Belt Pretensioner Supplemental Restraint System SRS in this section No INSTALL a new air bag wiring harness REPEAT the s...

Page 1638: ...E PASSENGER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE 1 Air Bag Control Module C335 2 Passenger Safety Belt Pretensioner Simulator 3 Measure the resistance between the air bag control module C335 pi...

Page 1639: ...bag s and pyrotechnic pre tensioner s WARNING Always carry the air bag module with the cover side away from the body and stand it with the cover up permost Do not attempt to repair open or apply elec...

Page 1640: ...REMOVAL AND INSTALLATION CONTINUED 4 Remove the driver air bag module Disconnect the air bag module electrical connector Installation 1 CAUTION When installing make sure that the inflator wiring is c...

Page 1641: ...ility of premature deployment do not use radio key code savers when working on the supplemental restraint system Failure to follow this instruction may result in personal injury WARNING To minimize th...

Page 1642: ...to paint discoloured or damaged air bag module trim covers Install a new component Failure to fol low this instruction may result in per sonal injury 1 Disconnect the battery ground cable For addition...

Page 1643: ...ING To minimize the possibility of premature deployment live air bag modules must only be placed on work benches which have been ground bonded Failure to follow this instruc tion may result in persona...

Page 1644: ...ary restraint system electrical connectors wait two minutes Failure to follow these procedures could increase the possibility of accidentally deploying the air bag s and pyrotechnic pre tensioner s 1...

Page 1645: ...carried out before installing the sliding contact WARNING If there is any doubt about the centralization of the air bag sliding contact The centralization procedure must be repeated Centralize the cl...

Page 1646: ...carry a live air bag module with the bag and trim pointed away from the body Failure to follow this instruction may result in personal injury WARNING To minimize the possibility of premature deploymen...

Page 1647: ...cess to the air bag control module Detach the air bag control module 3 Disconnect the electrical connectors Installation 1 To install reverse the removal procedure 2 NOTE New air bag control modules s...

Page 1648: ...nal injury NOTE All unserviceable air bag modules have been placed on the Mandatory Return List All discoloured or damaged air bag modules should be treated the same as any unserviceable live air bag...

Page 1649: ...mstances is an unserviceable air bag module s to be returned through the local mailing system Failure to follow this instruction may result in personal injury Seal the unserviceable air bag module s i...

Page 1650: ...body Failure to follow this instruction may result in per sonal injury WARNING To minimize the possibility of premature deployment live air bag modules must only be placed on work benches which have...

Page 1651: ...st lead electrical connector s from damage during deployment raise the air bag module off the ground on two wooden blocks Place the air bag module inside a suitable rigid wire cage with the air bag mo...

Page 1652: ...ceeding make sure that all personnel in the vicinity are aware that a loud noise bang is about to occur Do not let anybody approach closer than six meters Failure to follow this instruction may result...

Page 1653: ...tating to the skin Use protective gloves when handling any deployed air bag module Failure to follow this instruction may re sult in personal injury 1 Remove the deployed air bag module s For addition...

Page 1654: ...Passive Supplemental Air 501 20B 63 Bag System SPECIFICATIONS Torque Specifications Description Nm Air bag control module screws 8 Driver air bag control module screws 5 Passenger air bag control modu...

Page 1655: ...0 Uni Body Subframe and Mounting Frame General Information VEHICLE APPLICATION 2002 Bantam SUBJECT PAGE REMOVAL AND INSTALLATION Subframe 502 00 2 8 SPECIFICATIONS Specifications 502 00 9 Lubricants F...

Page 1656: ...2 From inside the passenger compartment remove the flexible coupling to pinion shaft pinch bolt 3 From inside the passenger compartment slacken the flexible coupling to column shaft pinch bolt 4 Remo...

Page 1657: ...knuts 1 Hold the ball joint studs with an Allen key 2 Remove the locknuts 7 NOTE When the track rod ends are separated from the spindle carriers the ball joint seals should be wrapped in cloth to prot...

Page 1658: ...ove the lower arm to spindle carrier pinch bolts and nuts 10 Disconnect the lower arms from the spindle carriers 11 Detach the connecting link from the suspension unit assembly 12 Remove the roll rest...

Page 1659: ...ering valve body pipes 16 Remove the pinion shaft to body seal 17 CAUTION Whenever the steering gear unions are disconnected the steering gear must be plugged to prevent dirt ingress Disconnect the po...

Page 1660: ...on 1 Refit the components in the reverse order 2 Align the crossmember 1 Push the guide pins through the crossmember aligning holes 2 Slide the locking plates into the locking grooves and tighten the...

Page 1661: ...ame and Mounting Frame General 502 00 7 Information REMOVAL AND INSTALLATION CONTINUED 7 CAUTION Make sure a heat shield is installed to prevent damage to the ball joint Install the heat shield E6015...

Page 1662: ...NSTALLATION CONTINUED 10 Install the gearshift linkage For additional information refer to Section 308 06 12 CAUTION Make sure the steering is in the straight ahead position 14 Bleed the power steerin...

Page 1663: ...smember retaining bolts 103 Roll restrictor to transmission retaining bolt 50 Track rod end locknuts 37 Wheel nuts 85 Flexible coupling to steering column shaft pinch bolt 28 Flexible coupling to pini...

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