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Lotus 2013 Exige S, Service & Parts Manual

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Lotus 2013 Exige S Service & Parts Manual Download Page 57

Service Parts List

Dep

Part Description

Part Number

Remarks

Qty

Function Code 12.04 Roof Panel, Seals & Fixings

Option

01

Hard Top Roof Assembly

A138B0209J

Quote Lotus Paint Code with 
order

1

Painted, trimmed

02

Seal, hard top to side glass, LH

A116V0249F

1

02a

Seal, hard top to side glass, RH

A116V0248F

1

03

Double Sided Tape, 5mm, seal to carrier

A117B0362V

Cut to fit

As req.

04

Seal Carrier, LH

A116V0241F

1

04a

Seal Carrier, RH

A116V0240F

1

05

Double Sided Tape, 12mm, carrier to hard top

C075U6071V

Cut to fit, 2 strips per side

As req.

06

Pop Rivet, seal carrier to hard top

A116W6707F

12

07

Hard top seal

B116U0211F

8mm thick

As req.

08

Edging Strip, hard top sides

A120U0097F

2

09

Trim/Clamp Panel, front, hard top to screen header

A116B1078J

1

10

Trim Panel, bracket rear RH  covering

A116B1076J

1

11

Trim Panel, bracket rear LH  covering

A116B1077J

1

12

Spacer, plastic, panel to header

B116V0221F

3

13

Screw, M8 x 20, button  hd. torx, clamps & frontcover fixing

A116W5258F

Black finish

3

14

Washer, flat, M8 x 21 x 1.6, clamps & front cover fixing

A111W4159F

Black finish

3

15

Retainer, nylon, screws to clamps & front cover

A116W4189F

5

16

Pin Clamp, hard top front

A116V0350F

2

Function Code: 12.04, Page: 1

Updated 31st May 2013

Summary of Contents for 2013 Exige S

Page 1: ...Updated 1st October 2013 ...

Page 2: ...art numbers used in this publication are in the format as follows Modification Functional Supply Route Identifier Group internal use A 138 B 1234 F Vehicle Engine Type Part Serial Number of First Usage Number Modification Identifier This letter identifies a version or modification of the part Part numbers with different prefix letters may or may not be interchangeable refer to the remarks and opti...

Page 3: ...by V I N or engine number The vehicle licence number should be considered irrelevant since it may not accurately reflect the vehicle age and may also be changed during the car s life The V I N comprises 17 characters coded in accordance with European Economic Community EEC directives For change point identification in Service Notes and Service Parts Lists characters 10 model year and 15 17 or 14 1...

Page 4: ... 13 27 Seat Belts front 14 00 Pedal Box Fascia 14 01 Pedal Box Pedals Throttle Control 14 05 Fascia Structure Supporting Hardware 14 10 Instrument Cowling 15 00 Interior Trim 15 05 Interior Driving Mirror Sunvisors 15 11 Interior Trim Stowage Provision 15 13 Front Door Trims 15 18 Interior Trim Chassis Trim Panels 15 19 Centre Tunnel Trim Gear Lever Gaiters Shrouds 15 24 Luggage Compartment Carpet...

Page 5: ...o ABS Controller Pipes Hoses 33 05 Parking Brake Mechanism 34 00 Wheels Tyres 34 01 Wheels Tyres Valves 40 00 Engine 40 00 Engine Assemblies 40 01 Engine Block Oil Pick up 40 01a Engine Mounts 40 02 Gaskets Sealants Top Overhaul Set 40 02a Gaskets Sealants Bottom Overhaul Set 40 03 Sump Assembly 40 05 Cylinder Head Valves Springs 40 07 Camshafts Tappets Cam Cover 40 08 Camshaft Drive Chain Sprocke...

Page 6: ...6 07 Single Oil Cooler System Engine 47 00 Transmission 47 01 Clutch Release Mechanism 47 03 Transmission Assembly 47 05 Gearchange Mechanism External 47 06 Gear Selector Mechanism Internal 47 07 Gears Shafts Bearings 47 11 Final Drive Bearings 47 15 Driveshafts Seals 60 00 Special tools 60 01 Tool Kit 60 01a Diagnostic Equipment 60 02 Special Tools 80 00 Bulk Items 80 20a Touch in Paint Pencil Ra...

Page 7: ...10 01 2 4 3 1 10 17 6 8 9 8 28 22 21 5 10 19 20 7 40 11 11 39 12 15 14 13 16 23 35 18 27 26 11 12 25 24 31 34 30 33 32 29 36 37 38 41 Updated 27th february 2013 ...

Page 8: ...to A post LH A120B4079F 1 07 Bracket front clamshell to A post RH A120B4080F 1 08 Screw M6 x 16 hex hd clamshell fixing A075W1028Z 10 09 Washer flat M6 x 20 x 2 5 clamshell fixing B082W4016F 6 10 Screw M6 x 20 hex flg hd clamshell fixing A132W5004F 8 11 Screw M8 x 25 button hd S S clamshell fixing A111W7175F 6 12 Washer flat M8 x 16 5 x 1 6 clamshell fixing A111W4175F 4 13 Screw M5 x16 hex hd s s ...

Page 9: ...ex hd wheel arch bracket A075W1026F 2 27 Washer flat M6 x 18 x 1 0 wheel arch bracket B082W4018F 2 28 Bolt M8 x 25 hex flg bootbox to subframe A132W5006F 1 fixing used for battery tray 5 29 Washer flat M8 x 25 x 1 5 bootbox to subframe B075W4021F 1 fixing used for battery tray 5 30 Bracket Assembly rool hoop LH A138B4123F 1 30a Bracket Assembly rool hoop RH A138B4124F 1 31 Shim 9 x 28 x 3 clamshel...

Page 10: ...release cable hole A138W6011F 1 37 Screw M6 x 16 hex flg hd wheel arch bracket A132W5003F 2 38 Blanking Patch 20 mm dia A111V0206F 4 39 Washer flat M8 x 25 x 1 5 clamshell fixing B075W4021F 2 40 Washer flat M6 x 25 x 1 4 clamshell fixing A075W4017F 4 41 Shim front clamshell alignment 1 6mm A116B0985F 4 Function Code 10 01 Page 3 Updated 31st May 2013 ...

Page 11: ...10 02 5 4 7 6 1 2 3 See 10 04 8 8 10 9 12 11 13 13 14 Updated 17th August 2012 ...

Page 12: ... Panel Rear Bulkhead B138B0095F 1 06 Side Intake Assembly LH A138B4127K 1 07 Side Intake Assembly RH A138B4128K 1 08 Bondnut M6 A117B0299F 6 09 Finisher Panel front sill recess LH B117U0169F 1 09a Finisher Panel front sill recess RH B117U0168F 1 10 Plastic Fastener panel fix A100W6479F 4 11 Screw M6 x 16 hex flg hd side intake A126W1215F 6 12 Washer Flat M6 side intake A126W4213F 6 13 Edge Finishe...

Page 13: ...10 04 1 2 11 10 6 9 5 4 3 8 7 12 13 14 Updated 1st July 2013 ...

Page 14: ...5 x 16 hex A111W1163F 6 05 Washer Flat 3 6 x 3 4 x16g B075W4009Z 6 06 Speed Nut M5 B100W6372F 6 07 Setscrew M6 x 25 hex flg hd A132W5014F 4 08 Washer M6 x 25 x 1 4 s s B075W4017F 4 09 Speed Nut M5 B100W6372F 5 10 Side Impact Foam LH A138B4063F 1 11 Side Impact Foam RH A138B4064F 1 12 Screw M5 x16 hex hd s s A111W1163F 5 13 Washer Flat 3 16 x 3 4 x 16g s s B075W4009Z 5 14 Edge Finisher A111V6034V 2...

Page 15: ...10 09 1 5 10 16 2 6 9 7 25 24 21 4 22 12 15 17 11 14 8 18 19 23 13 3 20 26 27 28 Updated 4th April 2013 ...

Page 16: ... 2 06 Grommet A138W6004F 3 07 Shim A132U0340F 4 08 Bracket latch striker C138B0039F 1 09 Nut M6 hex flg A117W3180F 2 10 Washer M6 x 20 x 2 5 A075W4016F 4 11 Lever access cover release B138B0044F 1 12 Knob taper female A138W2012F 1 13 Bush Flanged A138W4000F 1 14 Screw M6 x 16 btn cap s s black A082W7105F 1 15 Nut Nyloc M6 A075W3009F 1 16 Nut M6 hex flg A117W3180F 4 17 Washer M6 x 15 x 1 5 s s blac...

Page 17: ...0323F As req 21 Screw M8 x 25 btn cap A111W7175F 2 22 Screw M6 x 35 btn cap s s black A132W7004F 1 23 Washer M6 x 15 x 1 5 s s black A082W4133F 2 24 Pin access cover latch A138B0212F 1 25 Washer A132U6081F 1 26 Screw M5 x 16 pan pozi A082W5184F 1 27 Washer M8 x 25 x 1 5 s s B075W4021F 2 28 Buffer alarm switch A138W6007F To be confirmed 1 Function Code 10 09 Page 2 Updated 31st May 2013 ...

Page 18: ...10 11 1 5 18 12 6 22 21 20 19 14 4 2 3 24 23 9 8 11 9 8 7 15 16 17 13 25 26 27 28 29 30 31 32 33 36 35 34 37 Updated 1st October 2013 ...

Page 19: ...Hinge Assembly tailgate A122B0084F 2 07 Screw M6 x 18 hex hd hinge to clamshell A075W1029Z 4 08 Washer spring M6 hinge to clamshell tailgate A075W4035Z 8 09 Washer flat M6 x 20 hinge to tailgate A075W4016Z 4 10 Washer flat M6 x 12 hinge to clamshell A100W4127F 4 11 Screw M6 x 25 hex hd hinge to tailgate A075W1031F 4 12 Shim hinge rotor to tailgate A122B0199F As req 13 Striker Pin A116B0468F 1 14 N...

Page 20: ...e handle to chassis RH B122B0152F 1 24 Handle Assembly tailgate release LHD A122B0251S 1 24a Handle Assembly tailgate release RHD A122B0252S 1 25 Striker Cover bootbox A138V0110F 1 26 Anti Tamper Bracket B138B0228F 1 27 Solderless Nipple A116W6762F 1 28 Washer M10 x 20 5 x 1 5 A075W4023F 1 29 Bush cable retaining A111U6049F 2 30 Screw M8 x 25 skt btn s s A111W7175F 2 31 Washer M8 x 25 x 1 5 s s B0...

Page 21: ... Number Remarks Qty Function Code 10 11 Tailgate Release Mechanism Option 35 Fir Tree A116U0201F 1 36 Double Sided Tape B075U6070V 1 37 Bracket slider protection A128U0027F 1 Function Code 10 11 Page 3 Updated 1st October 2013 ...

Page 22: ...10 13 13 6 7 5 8 9 4 1 10 3 11 2 12 14 15 16 18 17 19 Updated 27th September 2012 ...

Page 23: ... 1 07 Engine Cover Bracket RH B138E0018F 1 08 Stud Special M6 cam cover mounting A138W6001F 2 09 Isolator front cover mounting B120B0291F 3 10 Screw M6 x 20 hex flg A132W5004F 4 11 Screw M6 x 20 dome hd s s black A100W7096F 7 12 Washer M6 x 15 x 1 5 s s black A082W4133F 7 13 Tower Clip engine cover A132W6019F 3 14 Bolt special cover retention A120E7232S 3 15 Supercharger Pulley Cover A138E0022F 1 ...

Page 24: ... Part Description Part Number Remarks Qty Function Code 10 13 Engine Compartment Cover Latch Mechanism Option 19 Screw M6 x 20 skt cap hd A138W5007F 2 Function Code 10 13 Page 2 Updated 27th September 2012 ...

Page 25: ...10 15 28 29 1 31 32 18 33 17 19 16 15 3 30 20 25 13 14 21 10 26 11 12 27 2 4 5 6 9 8 21 9 10 11 7 23 22 9 21 24 Updated 27th february 2013 ...

Page 26: ... 05 Washer shakeproof M6 A075W4046Z 4 06 Washer flat M6 x 1 5 A075W4015Z 4 07 Shim door hinge 1 0mm A111B0316F As req 07a Shim door hinge 1 25mm A116B0388F As req 07b Shim door hinge 1 5mm A111B0317F As req 07c Shim door hinge 2 0mm B111B0314F As req 08 Screw M8 x 30 cap hd A089W7052F 8 09 Washer flat M8 x 16 6 x 1 4 A075W4020Z 18 10 Screw M6 x M20 hex hd A075W1030Z 4 11 Washer flat M6 A075W4013Z ...

Page 27: ...is 4 23 Bolt M8 x 45 hex hd beam to rear bracket upper A075W2040Z 2 24 Setscrew M8 x 25 hex hd thin beam to rear bracket lower A075W1081Z 2 25 Follower door check spring A116B0418F Fit to item 13 2 26 Finisher Ring door drainholes A075P6064F 2 27 Bump Stop Scrivet A116U0137F 2 28 Door Reinforcement inner LH A117B0663F Bonded inside doorshell 1 28a Door Reinforcement inner RH A117B0664F Bonded insi...

Page 28: ...s Qty Function Code 10 15 Door Shells Beams Hinges Option 33 Nutplate door to beam lower A111B0081K Bonded inside doorshell 2 34 Door Curtain weather sealing A117U0152F Not illustrated 2 Function Code 10 15 Page 3 Updated 27th february 2013 ...

Page 29: ... 9 8 2 10 15 14 44 16 36 7 6 57 5 4 7 6 4 7 4 21 53 43 17 11 18 12 37 20 19 42 6 4 3 41 30 4 13 34 24 31 31 23 25 29 30 26 35 33 11 35 47 27 22 28 48 32 50 40 39 38 38a 46 49 54 55 52 1 51 Updated 31st May 2013 ...

Page 30: ...pport Bracket release button RH A117U0002F 1 06 Washer wavy 0 25 support brkt fix A075W4087F 6 07 Setscrew M6 x 16 support brkt fix A075W1028Z 6 08 Screw M5 x 10 pozi cover plate fix A111W5223F 2 09 Reflector Cover A117M6026F 2 10 Fixing Strap cover plate A111U0095F 2 11 Nylon Clip linkage retention A082U6267F 6 11a Bush nylon A120U6012F Not illus fits clip 11 into handle 22 22a see SB 2008 15 2 1...

Page 31: ... x 3 4 pozi door release fix A117W5274F 8 24 Spire Nut No 8 captive door release fix A075W6016Z 6 25 Plastic Clip interior release rod guide A075J6027Z 4 26 Rod interior release to latch LH B117U0137F See SB 2008 15 1 26a Rod interior release to latch RH B117U0138F See SB 2008 15 1 27 Foam Strip 19 x 3mm A082U6067F As req 28 Latch mechanism LH A111U0389S 1 28a Latch mechanism RH A111U0388S 1 29 Ro...

Page 32: ...see 17 33b excludes blade 2 38a Key uncut A120H0008S PFK alarm see 17 33b excludes transmitter fob 2 38b Key cut A120H0009S PFK alarm Order from Bolton Lock excludes transmitter fob 2 39 Actuator central door locking B116M6039F 2 40 Screw No 8 x 3 4 flg hd pozi CDL Actuator to door A075W5074Z Black finish 4 41 Rod CDL to sill button A117U0329F 2 42 Grommet button through sill X036L6004Z 2 43 Butto...

Page 33: ... door release rod LH A117U0321F 1 49a Cover door release rod RH A117U0320F 1 50 Clip release rod to cover A082W6457F 6 51 Washer ABS reflector to door A116B0978K 2 52 Rivet door release lever pivot A117H6006S 4 53 Sleeve door release button A117H6005S 2 54 Nut M5 A100W3113F 4 55 Washer M5 A075W4011F 4 56 Lock Lubricant A117U6019S 25ml 57 Washer M5 Neoprene reflector to door A082W4115F 2 NOTE For f...

Page 34: ...10 23 6 7 15 18 18 14 10 9 16 8 17 18 11 13 12 19 1 3 5 2 4 20 22 21 18 Updated 27th february 2013 ...

Page 35: ...ng LH primed A138B4135K 1 07a Cap Rear Wing RH primed A138B4136K 1 08 Upright Rear Wing B138B0137F 2 09 Bracket wing to upright LH B138B4109F 1 09a Bracket wing to upright RH B138B4110F 1 10 Plate Rear Wing B138B0087F 2 11 Gasket rear wing A138B0166F 2 12 Screw M8 x 20 hex flg upright to tailgate A120W5278F 4 13 Washer M8 x 21 x 1 6 s s blk upright to tailgate A111W4159F Forward fixings only 2 14 ...

Page 36: ...rew M6 x 16 torx pan hd A117W2213F 4 18 Decorative Washer M6 s s A138B0112F 16 19 Panel Undertray Flat LH A138B4137F 1 19a Panel Undertray Flat RH A138B4138F 1 20 Nut Captive M6 A117W6715F 8 21 Rivet Pop A075W6068Z 2 22 Washer Flat 3 16 x 1 2 x 16g A075W4000Z 2 Function Code 10 23 Page 2 Updated 27th february 2013 ...

Page 37: ...10 25 1 11 3 4 5 4 7 8 9 10 12 13 14 15 16 17 19 20 21 18 22 2 22 25 24 26 27 17 29 28 31 30 5 6 32 33 21 34 35 32 4 7 36 23 37 Updated 1st September 2013 ...

Page 38: ... s A079W4019F 9 06 Screw M8 x 20 hex flg A132W5005F 6 07 Spacer rear diffuser A132W4002F 3 08 Screw M5 x 12 hex flg hd A132W5002F 6 09 Washer Flat M5 x 25 x 1 5 A082W4098F 6 10 Bracket Assembly rear diffuser mounting LH A138U4001F 1 10a Bracket Assembly rear diffuser mounting RH A138U4002F 1 11 Screw M8 x 20 hex flg A132W5005F 4 12 Screw M6 x 16 hex flg A132W5003F 2 13 Nut M6 hex flg A117W3180F 2 ...

Page 39: ... skt btn hd A100W7096F 4 25 Washer M6 x 15 x 1 5 A082W4133F 8 26 Rivet A132A6022H 6 27 Bracket central diffuser mounting B138B0159F 1 28 Speed Nut M5 B100W6372F 5 29 Screw M5 x 16 hex flg A132W5003F 2 30 Screw M8 x 20 skt btn hd A075W7022F 11 31 Washer M8 x 25 x 1 5 A075W4021F 11 32 Threaded Adaptor A120A0183F 3 33 Foam self adhesive A100B0431F 1 34 Speed Nut M5 undertray fixing B100W6372F 6 35 Ed...

Page 40: ...10 31 1 3 2 4 5 ...

Page 41: ...ssembly Towing Front A138U0010F 1 02 Setscrew M8 x 25 hex A120W1000F 4 03 Washer M8 x 21 x 1 6 s s blk A111W4159F 4 04 Nutplate bonded upper towing strut A120B0203F Bonded to crash structure 1 05 Nutplate bonded lower towing strut A121B0102F Bonded to crash structure 1 Function Code 10 31 Page 1 ...

Page 42: ...11 01 1 7 2 15 5 3 4 8 10 11 6 14 9 12 12 13 Part of item 5 6 Updated 24th January 2013 ...

Page 43: ...s plastic fastener 1 06 Seal Assembly door waist LH B117U0009F Includes plastic fastener 1 07 Door Front Roof Seal Assembly A116V0273F 1 08 Door Rear Roof Seal Assembly A116V0098F 1 09 Door Cheater Seal RH B117U0134F 1 10 Door Cheater Seal LH B117U0133F 1 11 Plastic Fastener cheater seal fix A079W6195F 2 12 Nyloc Nut M6 glass to lift channel A907E6285F 6 13 Plastic Fastener header seal fix A116W67...

Page 44: ...11 02 8 2 17 3 8 5 4 18 3 1 7 15 6 7 3 11 12 5 14 4 3 7 6 10 7 18 13 12 9 15 16 Updated 4th April 2013 ...

Page 45: ...ide rail RH thread A116U0021F 4 06 Stud rail adjusting A116U0022F 4 07 O Ring A116U0023F 8 08 Screw M5 x 12 csk cap hd rail to door A117W7207F Black dacromet finish 4 09 Window Lift Mechanism electric LH B117U0389F 1 09a Window Lift Mechanism electric RH B117U0390F 1 10 Studplate Adaptor mechanism to glass B117U0391H 2 11 Screw M6 x 20 hex hd mechanism to door A075W1030Z 6 12 Washer flat M6 x 15 x...

Page 46: ... x 1 5 studplate to mechanism A075W4015Z 2 17 Plate adjuster block to door rear A116B0437F 2 18 Washer flat M6 x 20 x 2 5 A075W4016F 2 19 Downstop door glass A116B0314F Not illustrated bonded to door 2 20 Tape self adhesive downstop to door A100B6142V Not illustrated 0 25M Function Code 11 02 Page 2 Updated 4th April 2013 ...

Page 47: ...12 01 1 2 7 5 6 9 8 4 3 11 15 12 15 13 14 17 16 18 12 19 20 21 10 Updated 27th february 2013 ...

Page 48: ...heel arch liner support A138B0096F 2 08 Mud Guard LH A138B4043F 1 09 Mud Guard RH A138B4044F 1 10 Cup Washer black mud guard A082W6482F 4 11 Speed Nut M6 front wheelarch liner A130W6813F 2 12 Screw M6 x 16 hex flg front wheelarch liner bracket A132W5003F 6 13 Speed Nut M5 front wheelarch liner B100W6372F 2 14 Screw M5 x 18 skt btn s s front wheelarch liner A138W5001F 2 15 Scrivet front wheelarch l...

Page 49: ...marks Qty Function Code 12 01 Wheelarch Liners Option 19 Washer M6 x 25 x 1 4 s s black A082W4131F 2 20 Fixing Fir Tree rear wheelarch liner A116U0201F 2 21 Edge Finisher A117B6010V 1 Function Code 12 01 Page 2 Updated 27th february 2013 ...

Page 50: ...12 02 1 25 23 11 6 24 4 9 10 18 2 12 20 19 8 3 13 7 16 21 15 25 22 5 16 15 17 8 14 26 25 x 2 27 ...

Page 51: ... 12 09 Pocket stay to header rail RH A116B0184F Bonded to windscreen frame 1 10 Pocket stay to header rail LH A116B0183F Bonded to windscreen frame 1 11 Latch Plate front RH A116B0002F Bonded to windscreen frame 1 12 Latch Plate front LH A116B0001F Bonded to windscreen frame 1 13 Latch Plate with tongue rear RH C116B0466F Also fixing for hard top 1 14 Latch Plate with tongue rear LH C116B0467F Als...

Page 52: ... Spacer pocket to shroud B117B0480K 2 If fitted 23 Cable soft top tensioning front A138U0026H 1 Side adjusting 23a Cable soft top tensioning rear C116V0064H 1 Centre adjusting 24 Screw cables to soft to assy A111W7150F 4 25 End Cap latching pin A116V0150H See item 27 4 26 Soft Top Stowage Bag A120V0314H 1 27 End Cap Kit per side A120B0470S Includes item 25 set supplied per side 2 28 Soft Top Care ...

Page 53: ...12 03 1 19 2 3 4 5 6 7 9 8 10 11 12 13 15 14 17 16 18 26 21 27 33 18 23 20 20 22 30 29 28 28 28 28 24 24 25 29 31 32 Updated 31st May 2013 ...

Page 54: ...B4088F 1 07 Grille A Panel Upper LH A138B4027F 1 08 Grille A Panel Upper RH A138B4028F 1 09 Grille A Panel Lower LH A138B4111F 1 10 Grille A Panel Lower RH A138B4112F 1 11 Grille Side Intake LH A138B4055F 1 12 Grille Side Intake RH A138B4056F 1 13 Grille Tailgate Centre A138B0031F 1 14 Grille Tailgate LH A138B4039F 1 15 Grille Tailgate RH A138B4040F 1 16 Grille Transom LH A138B4089F 1 17 Grille Tr...

Page 55: ...87F 8 24 Nut self threading tailgate grilles A121W3185F 10 25 Grub Screw M5 x 35 skt btn blk tailgate grilles A138W1001F 6 26 Screw 50 x 25 torx flg s s grille front exit A124W5289F 4 27 Easyboss A124W3193F 8 28 Double Sided Tape grille A panel upper transom C075U6071V 100mm 29 Screw M5 x 18 skt btn flg blk tailgate grille side A138W5001F 4 30 Nut M5 hex flg tailgate side grille A138W3003F 6 31 Sp...

Page 56: ...1 7 9 7 15 10 12 13 8 11 4 5 16 19 14 20 2 3 22 21 17 18 14 22 12 04 14 6 23 29 30 31 32 28 Updated 31st May 2013 ...

Page 57: ... fit 2 strips per side As req 06 Pop Rivet seal carrier to hard top A116W6707F 12 07 Hard top seal B116U0211F 8mm thick As req 08 Edging Strip hard top sides A120U0097F 2 09 Trim Clamp Panel front hard top to screen header A116B1078J 1 10 Trim Panel bracket rear RH covering A116B1076J 1 11 Trim Panel bracket rear LH covering A116B1077J 1 12 Spacer plastic panel to header B116V0221F 3 13 Screw M8 x...

Page 58: ...op A116W5260F Black finish 8 20 Washer flat M6 x 12 x 1 5 rear brackets to hard top B100W4127F Black finish 8 22 Screw M8 x 20 pn torx btn hd tamper proof fixing A138W5008F 4 23 Clamp rear retention A120V0296J 1 23a Clamp Kit rear retention A120V0347S Includes fixings items 24 26 1 24 Screw M8 x 32 centre clamp rr A120V0348S 2 25 Washer M8 x 21x 1 6 s s blk centre clamp rr A111W4159F 2 26 Captive ...

Page 59: ... 2 7 8 6 12 05 1 5 2 4 3 6 8 7 7a 9 10 13a 16a 11a 16 11 13 12a 12 15 17 14 15a 17a 14a 18 Updated 1st July 2013 ...

Page 60: ...ar Wheelarch rear front LH B138B4145F 1 07a Chip Protection Rear Wheelarch rear front RH B138B4146F 1 08 Chip Protection Kit B138B0185S 1 Option 09 Decal Side Air Duct LH A138U4009F 1 09a Decal Side Air Duct RH A138U4010F 1 10 Decal Mirror Plinth LH A138B4183F 1 10a Decal Mirror Plinth RH A138B4184F 1 11 Chip Protection rear bumper LH A138B4147H 1 11a Chip Protection rear bumper RH A138B4148H 1 12...

Page 61: ...ction front clamshell inner RH A138B4154H 1 15 Chip Protection door mirror LH A138B4167H 1 15a Chip Protection door mirror RH A138B4168H 1 16 Chip Protection headlamp LH A138B4171H 1 16a Chip Protection headlamp RH A138B4172H 1 17 Chip Protection front splitter LH A138B4203H 1 17a Chip Protection front splitter RH A138B4204H 1 18 Chip Protection front clamshell upper A138B0186H 1 Function Code 12 ...

Page 62: ...12 07 1 2 4 3 5 5 10 7 8 6 9 9 6 Updated 4th April 2013 ...

Page 63: ...license plate A138B0157F 1 Japan 03 Plinth rear license plate A138B0213F Unpainted 1 Euro 04 Bracket Assembly rear license plate A138B0155F 1 Japan 05 Scrivet A120W6848F 2 06 Bolt M6 x 16 hex flg A918W5208F 2 07 Screw M5 x 16 pan pozi A082W5184F 3 08 Rawnut M5 A075W6074F 3 09 Screw M6 x 16 pan torx A117W2213F 4 10 Double Sided Tape A117B6043V 1 Function Code 12 07 Page 1 Updated 1st May 2013 ...

Page 64: ...12 09 3 1 4 2 9 6 8 5 7 10 9 Updated 1st July 2013 ...

Page 65: ...3 Mirror Housing A138U0030F Not painted 2 RH LH 04 Glass convex B111U6046F 2 RH LH 05 Blanking Plug dia 9 5 black door holes covering A124W6857F 2 06 Screw M5 x 16 cap hd A117W7216F 4 Forward fixings 07 Screw M5 x 12 cap hd plinth to door A111W7183F 2 Rearward fixings 08 Blanking Decal 20mm door holes covering A111V0206F 4 09 Washer internal shakeproof M5 plinth to door A075W4046Z 6 10 Washer flat...

Page 66: ...2 3 8 7 1 3 5 6 4 13 01 ...

Page 67: ...cap hd runner rear mtg frame front fix A111W7130F 4 04 Stop seat runner A138V0324F 2 05 Screw M8 x 25 hex hd black runner front fix B075W1039F 2 06 Washer flat M8 x 16 6 x 1 4 runner front fix A075W4020Z 2 07 Screw M8 x 16 cap hd mounting frame rear fix A111W7125F 2 08 Screw M8 x 12 button hd side brackets to seat A111W7131F 4 09 Seat Mounting Bracket set fixed seats FIA approved A128U0047S Track ...

Page 68: ...13 02 2 1 3 Coupe Roadster Updated 1st May 2013 ...

Page 69: ...her 02f Front Seat Assembly sport A138V0462S Silver stitching 2 Black leather 02g Front Seat Assembly sport heated A138V0463S Silver stitching 2 Black leather 02h Front Seat Assembly sport A138V0448S Black stitching 2 Suedetex black leather 02i Front Seat Assembly sport heated A138V0449S Black stitching 2 Suedetex black leather 02j Front Seat Assembly sport A138V0450S Red stitching 2 Suedetex blac...

Page 70: ...leather 02z Front Seat Assembly premium A138V0474S 2 Ash gray leather 02az Front Seat Assembly premium heated A138V0475S 2 Ash gray leather 03 Front Seat Assembly sport premium A138V0476S Quilted Black stitching 2 Black leather 03a Front Seat Assembly sport premium heated A138V0477S Quilted Black stitching 2 Black leather 03b Front Seat Assembly sport A138V0478S Quilted Red stitching 2 Black leath...

Page 71: ...nt Seat Assembly premium A138V0492S Quilted 2 Ivory white leather 03q Front Seat Assembly premium heated A138V0493S Quilted 2 Ivory white leather 03r Front Seat Assembly premium A138V0494S Quilted 2 Cognac brown leather 03s Front Seat Assembly premium heated A138V0495S Quilted 2 Cognac brown leather 03t Front Seat Assembly premium A138V0496S Quilted 2 Venom red leather 03u Front Seat Assembly prem...

Page 72: ...13 27 1 4 2 6 7 5 8 9 3 Updated 6th June 2012 ...

Page 73: ...le seat belt switched A120B0025F With lead and connector 2 Japan airbag driver 03 Spacer Block belt to bracket A121U0008F 2 04 Cover Assembly upper anchorage A116U6007S 2 05 Bolt 7 16 UNF csk skt hd seat belt buckle B121W2209F 2 06 Spacer stepped seat belt buckle A121B0045F 2 07 Spring seat belt buckle A111U6016F 2 08 Bolt shoulder 7 16 seat belt fixing B121W2210F 2 09 Spacer 19 0 dia x 12 5mm sea...

Page 74: ...See 47 01 14 01 2 26 10 13 12 14 15 19 18 19 24 27 8 21 4 5 6 7 20 22 11 24 25 17 28 9 3 23 16 30 31 1 32 33 34 35 29 37 36 38 39 Updated 1st August 2013 ...

Page 75: ...5F 1 05 Screw M5 x 30 hex flg A120J6017F 1 06 Nut M5 hex flg A138W3003F 1 07 Shaft Pedal A116J0043H 1 08 Clutch Pedal Assembly A138Q0016F Includes pad and clevis bearing 1 09 Brake Pedal Assembly LHD A138J4075K Includes pad 1 09a Brake Pedal Assembly RHD A138J4076K Includes pad 1 10 Electronic Throttle A116J0003L 1 11 Bearing 20mm flanged A116J6021F 4 12 Screw M6 x 16 hex flg A132J6025F 6 13 Bolt ...

Page 76: ...n A120J6006F 2 25 Clevis Pin brake pedal to pushrod LHD A138J0093F 1 25a Clevis Pin brake pedal to pushrod RHD A138J0094F 1 26 Clevis Pin clutch pedal to pushrod A120Q0008H 1 27 Spacer brake pedal A138J0090F 2 off LHD 1 28 Bracket switch A116J0072K 1 29 Clip clevis pin retention A132J6031F 1 30 Bracket clutch brake return springs to chassis D116Q0014F 1 31 Pop Rivet bracket to chassis A075W6068Z 2...

Page 77: ...r Footrest Assembly LHD B111A0102J Includes velcro foam 1 37 Driver Footrest RHD C120U0007F 1 37a Driver Footrest LHD A111A0104F Not illustrated bonded to chassis 1 38 Pop Rivet footrest RHD to chassis A111W6613F 4 39 Clevis Pin Bearing pin to clutch pedal A138Q0018H 1 Function Code 14 01 Page 3 Updated 1st August 2013 ...

Page 78: ...47 14 05 1 34 2 36 12 30 37 29 38 6 3 13 9 5 4 46 42 40 31 14 23 43 32 11 7 15 33 41 16 44 27 17 8 20 10 21 22 19 18 28 26 35 39 24 25 45 5 Updated 1st July 2013 ...

Page 79: ...ther 02b Column Cowl upper A138V0381S 1 Ash grey leather 02c Column Cowl upper A138V0382S 1 Imperial blue leather 02d Column Cowl upper A138V0383S 1 Venom red leather 02e Column Cowl upper A138V0384S 1 Cocoa brown leather 03 Column Cowl lower with exh valve button senosoft black A138V0099F 1 03a Column Cowl lower with exh valve button A138V0385S 1 Black leather 03b Column Cowl lower with exh valve...

Page 80: ...om red leather 07e Panel heater control mounting A138V0394S 1 Cocoa brown leather 08 Support heater control panel mounting A121U0071F 1 09 Mounting Assembly centre FLV senosoft black A138V0113F 1 09a Mounting Assembly centre FLV A138V0395S 1 Black leather 09b Mounting Assembly centre FLV A138V0396S 1 Ash grey leather 09c Mounting Assembly centre FLV A138V0397S 1 Imperial blue leather 09d Mounting ...

Page 81: ...rew No 10 x 1 2 support to panel A075W5040Z 2 23 Screw M6 x 25 hex hd dash panel upper to body A075W1031F 4 24 Washer spring M6 dash panel upper to body A075W4035Z 4 25 Washer flat M6 x 12 1 x 1 4 dash panel upper to body A075W4013F 4 26 Pop Rivet dash panel lower to chassis A085W6259F 4 27 Closing Panel stowage shelf LH A121U0051F 1 28 Closing Panel stowage shelf RH A121U0052F 1 29 Screw self tap...

Page 82: ...5 1 Black leather 41b Cover Assembly passenger airbag A138V0401S Also see 17 35 1 Ash grey leather 41c Cover Assembly passenger airbag A138V0402S Also see 17 35 1 Imperial blue leather 41d Cover Assembly passenger airbag A138V0403S Also see 17 35 1 Venom red leather 41e Cover Assembly passenger airbag A138V0404S Also see 17 35 1 Cocoa brown leather 42 Insert dash panel to body LH A121U0103F 1 42a ...

Page 83: ...14 10 1 2 ...

Page 84: ...ng A120V0363S 1 Black leather 01b Instrument Cowling A138V0406S 1 Ash grey leather 01c Instrument Cowling A138V0407S 1 Imperial blue leather 01d Instrument Cowling A138V0408S 1 Venom red leather 01e Instrument Cowling A138V0409S 1 Cocoa brown leather 02 Clip cowling retention A121U0156S Also for FLV panels five clips total 4 Function Code 14 10 Page 1 Updated 24th January 2013 ...

Page 85: ...15 05 6 5 2 4 4 1 5 3 3 6 8 7 ...

Page 86: ...7V0713J 1 03 Pivot Pin M8 sun visor A117U0468F 2 04 Bracket visor to header rail B117U0419F 2 05 Nut M8 Kaylock visor to bracket A100C6022F 2 06 Washer M8 shakeproof pin to bracket A075W4048Z 2 07 Mirror interior rear view 22 cm wide A120U6009F 1 08 Mounting Plinth interior mirror A120U6010F 1 09 Adhesive Kit mirror mounting plinth A116U0194F Not illustrated 1 10 Betaclean 3900 glass preparation A...

Page 87: ...15 11 1 2 5 7 3 4 8 9 10 6 11 12 13 Updated 1st July 2013 ...

Page 88: ...75 net to panel A075W4001Z 5 05 Cup Holder Assembly A120U0065J 1 Optional 06 Screw M4 x 12 pan pozi cup holder to chassis A075W5132F 2 Optional 07 Divider stowage tray A120U0060F 2 Optional 08 Plastic Fastener trim panel fixing A100W6391F 6 09 Trim Panel Rear Header B121U0111F 1 10 Fixing trim panel rear header A100W6481F 5 11 Stowage Tray Mat Set RHD A120V0240F 1 11a Stowage Tray Mat Set LHD A120...

Page 89: ...15 13 1 2 3 9 4 7 5 6 8 10 Updated 16th July 2012 ...

Page 90: ...lver stitching 1 Black leather 01g Assembly Door Trim Panel RH A138V4182S Silver stitching 1 Black leather 01h Assembly Door Trim Panel LH A138V4183S 1 Ivory white leather 01i Assembly Door Trim Panel RH A138V4184S 1 Ivory white leather 01j Assembly Door Trim Panel LH A138V4185S 1 Venom red leather 01k Assembly Door Trim Panel RH A138V4186S 1 Venom red leather 01l Assembly Door Trim Panel LH A138V...

Page 91: ...02S Silver stitching 1 Suedetex 02 Assembly Door Trim Panel Insert LH A138V4203S Black stitching 1 Black leather 02a Assembly Door Trim Panel Insert RH A138V4204S Black stitching 1 Black leather 02b Assembly Door Trim Panel Insert LH A138V4205S Red stitching 1 Black leather 02c Assembly Door Trim Panel Insert RH A138V4206S Red stitching 1 Black leather 02d Assembly Door Trim Panel Insert LH A138V4...

Page 92: ...or Trim Panel Insert LH A138V4239S 1 Suedetex 02u Assembly Door Trim Panel Insert RH A138V4240S 1 Suedetex 02v Assembly Door Trim Panel Insert LH A138V4245S Quilted 1 Black leather 02w Assembly Door Trim Panel Insert RH A138V4246S Quilted 1 Black leather 02x Assembly Door Trim Panel Insert LH A138V4247S Quilted 1 Ivory white leather 02y Assembly Door Trim Panel Insert RH A138V4248S Quilted 1 Ivory...

Page 93: ...no 5 x 1 2 A057W5020F 8 10 Trim Panel interior door pull recess LH A117B0371F Bonded to inner door 1 10a Trim Panel interior door pull recess RH A117B0372F Bonded to inner door 1 10b Trim Panel interior door pull recess LH A120V4045S Bonded to inner door 1 Black leather 10c Trim Panel interior door pull recess RH A120V4046S Bonded to inner door 1 Black leather 10d Trim Panel interior door pull rec...

Page 94: ...r door red stitching 1 Black leather 10q Trim Panel interior door pull recess RH A138V4144S Bonded to inner door red stitching 1 Black leather 10u Trim Panel interior door pull recess LH A138V4145S Bonded to inner door yellow stitching 1 Black leather 10v Trim Panel interior door pull recess RH A138V4146S Bonded to inner door yellow stitching 1 Black leather 10w Trim Panel interior door pull reces...

Page 95: ... Trims Option 10cz Trim Panel interior door pull recess LH A138V4153S Bonded to inner door silver stitching 1 Suedetex 10dz Trim Panel interior door pull recess RH A138V4154S Bonded to inner door silver stitching 1 Suedetex Function Code 15 13 Page 6 Updated 27th february 2013 ...

Page 96: ...15 18 8 7 10 1 6 3 13 2 5 4 11 14 12 12 9 15 15 16 Updated 1st July 2013 ...

Page 97: ...oft black A138V4112F 1 02a Sill Trim Panel RH A138V4156S 1 Black leather 02b Sill Trim Panel RH A138V4158S 1 Ash grey leather 02c Sill Trim Panel RH A138V4160S 1 Imperial blue leather 02d Sill Trim Panel RH A138V4162S 1 Venom red leather 02e Sill Trim Panel RH A138V4164S 1 Cocoa brown leather 03 A Post Trim Panel LH senosoft black A138V4113F 1 03a A Post Trim Panel LH A138V4165S 1 Black leather 03...

Page 98: ...erture A138V0411S 1 Ash grey leather 05c Cover A post trim panel aperture A138V0412S 1 Imperial blue leather 05d Cover A post trim panel aperture A138V0413S 1 Venom red leather 05e Cover A post trim panel aperture A138V0414S 1 Cocoa brown leather 06 Bracket trim to chassis A121U0033F 2 07 Pop Rivet bracket to chassis A075W6071Z 2 08 Screw self tap No 6 x 3 4 panels to bracket A075W5028Z 4 09 Spire...

Page 99: ...1 Imperial blue leather 13d Switch Panel Housing sport A138V0418S 1 Venom red leather 13e Switch Panel Housing sport A138V0419S 1 Cocoa brown leather 14 Grommet Blanking 35 9mm unused USB hole A138W6009F 1 15 Mat A post pocket A121V0005K Requires double sided tape sourced locally to secure it 2 16 Screw No 6 x 0 5 flg hd S S black sill trim panel A089W5138F 2 Function Code 15 18 Page 3 Updated 1st...

Page 100: ...15 19 3 21 19 17 18 16 1 15 14 13 2 22 20 7 11 6 4 5 9 10 12 11 8 2a 23 24 25 26 27 28 29 Updated 1st July 2013 ...

Page 101: ...4S Includes gaiters 1 Ash gray leather 01i Centre Console LHD A120V4105S Includes gaiters 1 Cognac brown leather 01j Centre Console RHD A120V4106S Includes gaiters 1 Cognac brown leather 01k Centre Console LHD A120V4107S Includes gaiters 1 Cocoa brown leather 01l Centre Console RHD A120V4108S Includes gaiters 1 Cocoa brown leather 01m Centre Console LHD A120V4109S Includes gaiters 1 Imperial blue ...

Page 102: ...01z Centre Console RHD A138V4234S Includes gaiters Yellow stitching 1 Suedetex 01az Centre Console LHD A138V4235S Includes gaiters Silver stitching 1 Suedetex 01bz Centre Console RHD A138V4236S Includes gaiters Silver stitching 1 Suedetex 01cz Centre Console LHD A120V0417J Includes gaiters 1 Cloth 01dz Centre Console RHD A120V0418K Includes gaiters 1 Cloth 02 Cover tunnel front parallel LHD A111A0...

Page 103: ...20V0494S 1 16c Console rear lower Venom red leather A120V0495S 1 16d Console rear lower Ash grey leather A120V0496S 1 16e Console rear lower Cognac brown leather A120V0497S 1 16f Console rear lower Cocoa brown leather A120V0498S 1 16g Console rear lower Imperial blue leather A120V0499S 1 16h Console rear lower Suedetex A138V0420S 1 16i Console rear lower cloth A120V0492S 1 17 Gaiter Gear Shift A12...

Page 104: ... stitching 1 Suedetex 18 Gaiter Parking Brake A120V0412K Black stitching 1 Black leather 18a Gaiter Parking Brake A138V0434S Red stitching 1 Black leather 18b Gaiter Parking Brake A138V0435S Yellow stitching 1 Black leather 18c Gaiter Parking Brake A138V0436S Silver stitching 1 Black leather 18d Gaiter Parking Brake A138V0437S 1 Ivory white leather 18e Gaiter Parking Brake A138V0438S 1 Venom red l...

Page 105: ... A120U0028F 1 20 Pop Rivet bracket to chassis A111W6613F 3 21 Screw No 6 x 3 8 flg pozi console to bracket A075W5019F 3 22 Spirenut No 6 console to bracket A075W6014F 3 23 Bezel gear lever B120V0415F 1 24 Bezel parking brake gaiter B120V0410F 1 25 Scrivet cover fix A120W6488F 2 Premium carpet 26 Retainer Gear Shift Gaiter A138V0218F 1 27 Cable Tie gaiter to gearknob A075W6038Z 1 28 Plate A138V0292...

Page 106: ...15 24 1 ...

Page 107: ...Service Parts List Dep Part Description Part Number Remarks Qty Function Code 15 24 Luggage Compartment Carpet Option 01 Boot Carpet A138V0222F 1 Function Code 15 24 Page 1 Updated 31st May 2013 ...

Page 108: ...15 30 1 2 3 5 4 6 9 8 10 12 11 7 16 14 15a 14 15 18 17 Updated 1st May 2013 ...

Page 109: ...4a Carpet Passenger bulkhead LHD A138V0287F 1 05 Carpet Sill Driver RHD A138V0279F 1 05a Carpet Sill Driver LHD A138V0288F 1 06 Carpet Sill Passenger RHD A138V0280F 1 06a Carpet Sill Passenger LHD A138V0289F 1 07 Carpet Rear Bulkhead A138V0283F 1 08 Front Floor Mat Driver LHD base A120V0060K No emblem 1 008a Front Floor Mat Driver RHD base A120V0058K No emblem 1 008b Front Floor Mat Driver LHD pre...

Page 110: ...et A124V0055F 4 12 Pop Rivet fixing to floor A111W6574F 4 12a Pop Rivet fixing to floor A089W6297F When secondary floor fitted 4 Premium mats 13 Washer flat M5 x 10 fixing to floor A075W4011F 4 14 Finisher Strip RHD driver and passenger C117U0430F 2 15 Finisher Strip LHD driver A138V0325F 1 15a Finisher Strip LHD passenger C117U0430F 1 16 Finisher Strip Extension LHD driver A138V0326F 1 17 Spacer ...

Page 111: ...16 01 1 3 2 4 11 5 7 8 10 12 13 9 6 15 14 Updated 16th July 2012 ...

Page 112: ...F shield A121B0134F Self adhesive foil 1 07 NVH Foam bodyside front B120B0074F 1 NVH pack 08 Tape Tessaband 4661 sill holes covering A116V6008F 1 2M NVH pack 09 NVH Mat rear bulkhead purge valve A120V0136F 1 NVH pack 10 Seal Seat Belt Anchor Frame to bulkhead A120B0207F 2 NVH pack 11 NVH Mat inner tank bay panel A116V0120F 2 NVH pack 12 Blanking Patch scuttle beam holes 38mm dia A116A0184F 10 NVH ...

Page 113: ...17 01 1 2 8 12 6 3 4 13 10 14 5 9 7 11 15 Updated 1st July 2013 ...

Page 114: ...witch Jumper A138M0032F 2 08 Harness Door E117M0118F 2 09 Lead Extension wheel speed sensor front suspension A120M6046F 2 10 Cable Gearbox to chassis earth A138M0015F 1 11 Cable CDL power up negative B122M0012F front services compartment 1 12 Cable front positive stud to rear positive stud A138M0013F See also 17 31 1 13 Battery Negative Cable ECU plate to battery A138M0016F See also 17 31 1 14 Cab...

Page 115: ...17 03 10 1 2 4 9 7 12 11 3 5 6 8 22 12 21 13 19 14 20 23 27 26 27 26 24 25 28 29 Updated 31st May 2013 ...

Page 116: ...RH LHD A138M4004F 1 09 Module wiper delay A082M6457F Located in footwell 1 10 Module flasher unit A120M0056F LED front indicators 1 Non USA Canada 11 Relay single contact changeover 30A C079M6141F Heated Rear Screen Main Start 3 12 Relay single contact c o micro A132M6002F Fan 1 2 3 Horn Rad Fan F Pump H Seat A C Clutch 9 13 Fuse 3A violet A082M6243F See Service Notes section MP 1 14 Fuse 2A grey ...

Page 117: ...Maxi Fuse 40A orange Not available See Service Notes section MP 1 22 Maxi Fuse 25A black Not available See Service Notes section MP 1 23 Fuse Box Cover A138M6005F 1 24 Nut Nyloc M5 fuse box bracket A132W3000F 1 25 Screw M8 x 20 hex flg fuse box bracket A132W5005F 2 26 Screw M6 x 16 hex flange fuse box brackets A132J6025F 4 27 Nut M6 hex flg fuse box bracket A117W3180F 7 28 Screw M4 x 12 pan pozi A...

Page 118: ...17 05 1 2 6 5 15 16 14 13 12 9 8 7 4 3 17 10 11 18 19 Updated 27th September 2012 ...

Page 119: ... Auxiliary Power Socket A117M6024F 1 06 Switch central door locking A117M0124F 1 07 Switch window lift A117M6064F 2 08 Bezel Assembly window lift switch A138V0008J 2 09 Bracket switch bezel LH A138V4067F 1 09a Bracket switch bezel RH A138V4068F 1 10 Nyloc Nut M4 backplate to trim panel A075W3049F 4 11 Washer flat M4 x 9 backplate to trim panel A082W4099F 4 12 Switch rear fog A138M0023F 1 13 Switch...

Page 120: ...ior Switches Auxiliary Power Socket Option 16a Switch sport multi position C138M0007F 1 17 Ignition Switch A111M6108S Part of upper steering column 1 18 Switch exhaust valve A127M6008F 1 19 Gasket sport switch A138M0041F 1 Function Code 17 05 Page 2 Updated 31st May 2013 ...

Page 121: ...Switch oil pressure see 40 15 Throttle Body see 42 04 14 10 9 8 7 3 2 4 1 5 6 5 6 7 8 12 11 13 15 17 06 16 17 Updated 1st July 2013 ...

Page 122: ...07 Wheel Speed Sensor rear suspension A132J6001F 2 08 Bolt flg hd A132W5002F 4 09 Sensor knock control A132E6298S 2 10 Bolt flg hd A132E6469S 2 11 Sensor coolant temperature A132E6258S 1 12 Gasket coolant temperature sensor A120E6378S 1 13 Meter air intake flow A132E6482S 1 14 Bracket ECU A138E0006F 1 15 Electronic Control Module ECM Lotus programmed LOTAC05544 Special Order using LSL618 See TSB 2...

Page 123: ... 2 7 8 6 17 07 2 1 3 Updated 1st May 2013 ...

Page 124: ...es Displays Option 1 Instrument Pack MPH C121N0007F Pack needs to be variant coded using TechCentre 1 1a Instrument Pack Km h C121N0008F Pack needs to be variant coded using TechCentre 1 02 Nut M4 pack to brackets A075W3019F 4 03 Washer flat M4 A082W4099F 4 Function Code 17 07 Page 1 Updated 1st May 2013 ...

Page 125: ...17 11 8 7 1 6 2 3 5 4 9 10 Updated 24th January 2013 ...

Page 126: ... turn stop tail LED B120M0034F Grey body moulding 1 04 Nyloc Nut M5 thin lamp to body A100W3113F 8 05 Washer flat M5 x 18 x 1 5 S S lamp to body B075W4009Z 8 06 CHMSL A138M6000F 1 07 Bulb 12v 5w license plate A083M6292F 2 08 Lamp rear number plate A138M6002F 2 09 Bezel licence plate lamp LH A138B4113F Unpainted 1 09a Bezel licence plate lamp RH A138B4114F Unpainted 1 10 Clip Star 9 x 4 bezel to nu...

Page 127: ...1 17 13 7 6 8 9 5 4 3 2 4 5 11 10 Updated 27th february 2013 ...

Page 128: ...bber lower main bulb Part not available separately 2 04 Bolt M6 x 14 hex flg lamp retention A116W5233F 2 05 Washer Flat M6 x 25 x 1 4 lamp retention B075W4017Z 2 06 Screw M6 x 12 hex flg lamp retention A075W1027F 1 07 Washer Flat M6 x 18 x 1 lamp retention B082W4018F 4 08 Headlamp Bracket LH A120B4089F 1 08a Headlamp Bracket RH A120B4090F 1 09 Nut M6 hex flg A117W3180F 4 10 Shim 9 x 28 x 3 A124B02...

Page 129: ...17 17 2 1 ...

Page 130: ...ep Part Description Part Number Remarks Qty Function Code 17 17 Interior Lamps Option 01 Interior Lamp A082M6644F 1 02 Bulb interior lamp 5W LOTAC05345 Part of bulb fuse kit 1 Function Code 17 17 Page 1 ...

Page 131: ...17 21 4 12 10 11 13 13 16 14 17 19 22 20 15 2 3 5 6 1 6 5 9 18 7 8 25 24 23 26 27 28 21 29 30 Updated 31st May 2013 ...

Page 132: ...spring motor bracket to body A075W4036Z 3 07 Washer Bottle Assembly A138B0174F Includes pump and grommet 1 08 Pump screen wash A138B0175F 1 09 Grommet washer bottle A082U6197F 1 10 Windscreen Washer Jet A120W6796F 2 11 Spacer washer jet A111M6046K 2 12 Sleeve washer jet A111M0065F Bonded over jet spacer 1 13 Tube T piece to jet A116M0040V Cut to fit As req 14 Tube non return vave to T piece A116M0...

Page 133: ...motor bracket A132U6128F 2 22 Screw M5 x 16 hex flg A132W5016F 2 23 Screw M6 X 16mm hex flg A132W5003F 2 24 Tie Wrap A138W6014F 2 25 Foam Strip 25mm X 12 5mm A082U6065V 0 40m 26 Wiper Motor Cover RHD A120B0133F 1 26a Wiper Motor Cover LHD A120B0134F 1 27 Screw No 10 x pozi cover fix A075W5040Z 2 28 Spire Nut No 8 cover wiper motor fix A075W6016Z 2 29 Pop Rivet A132W6024F 3 30 Washer flat M4 x 9 x ...

Page 134: ...17 27 1 2 3 6 4 5 9 9 8 7 10 12 11 Updated 31st May 2013 ...

Page 135: ...A120M6047F 1 04 Antenna Cable A138M0009F 1 05 Di Pole Antenna Cable A138M0008F 1 06 Ipod Adaptor KCE 433i A120M6041F 1 07 Ipod Holder Foam A120U0094F Fits in trinket tray 1 08 Clip Cable self adhesive A138W6005F 3 09 Clip Cable self adhesive A138W6006F 8 10 Bush antenna cable thro chassis A132K6005F 1 11 Screw No 6 x 0 75 A075W5028Z 8 12 Spire Nut No 8 A075W6016Z 8 13 Link Lead A138M0049F No radio...

Page 136: ...17 31 7 4 2 6 1 3 5 11 8 9 10 14 13 12 16 17 18 15 19 See 15 11 21 20 22 23 24 25 26 27 26 27 28 29 28 29 31 30 Updated 1st July 2013 ...

Page 137: ...gative Cable ECU plate to battery A138M0016F 1 09 Cable front positive stud to rear A138M0013F See also 17 01 1 10 Cable positive stud to starter motor A138M0014F See also 17 01 1 11 Cable engine gearbox to chassis earth A138M0015F See also 17 01 1 12 Bracket battery post front C122B0147F 1 13 Pop Rivet 5 32 x 1 2 battery post bracket A075W6068F 2 14 Battery Post A089M6033F 2 15 Battery Clamp A132...

Page 138: ... pipe A082W5587F 1 22 Tube battery vent B132M0050F 1 23 Grommet vent tube to battery box A124W6790F 1 24 Elbow A132W6028F 1 25 Battery Post 2 stud A340M6007F On scuttle 1 26 Washer Shakeproof M8 A075W4048Z 5 27 Nut M8 A075W3021Z 5 28 Nyloc M5 battery post A075W3008Z 2 29 Washer Flat 3 16 x 1 2 x16 battery post A075W4000Z 2 30 Screw M8 cable to gearbox A075W1035Z 1 31 Washer Flat M8 x 16 6 cable to...

Page 139: ... 2 7 6 3 3 2 17 33b 2 12 1 7 8 11 5 9 10 6 3 4 4a 13 15 14 Updated 1st May 2013 ...

Page 140: ...udes transmitter fob 2 04b Key cut A120H0009S Order from Bolton Lock excludes transmitter fob 2 05 Switch boot alarm A111M6035F 1 06 Microswitch alarm activation doors A111M6035F Also for courtesy lamp 2 07 ECU parking aid system A138M0029F 1 08 Bracket parking aid ECU A132M0121F 1 09 Sensor Kit parking aid system B132M0151F 1 10 Sounder parking aid A132M0191F 1 11 Nyloc Nut M5 flg bracket to boot...

Page 141: ...ty Function Code 17 33b Security Alarm System PFK 2008 MY Option 15 Pop rivet domed black bracket to clamshell A082W6512F 3 NOTE For full information on all Lotus Security Sytems see LSL483e Function Code 17 33b Page 2 Updated 1st October 2013 ...

Page 142: ...17 35 12 2 1 13 4 5 6 10 8 11 11 18 19 3 17 7 16 9 14 15 Updated 1st August 2013 ...

Page 143: ...66F 1 08 Mounting Bracket passenger airbag rail LH B121U0069F 1 09 Mounting Bracket passenger airbag rail RH B121U0070F 1 10 Bolt M8 x 20 flg hex hd bracket to chassis A120W5278F 4 11 Pop Rivet bracket to chassis A100W6037F 8 12 Nyloc Nut M6 SRS unit to bracket A075W3009Z 4 13 Washer flat M6 x 12 5 x 1 6 SRS unit to bracket A100W6307F 4 14 Cover Assembly passenger airbag senosoft paint A138V0151F ...

Page 144: ...ectrical SIR Inflator Modules DERM Sensors Option 19 Captive Nut bracket to dash panel A120W3186F 2 These parts can only be fitted by Lotus Dealers who must complete and return the SIR registration card supplied with the part Function Code 17 35 Page 2 Updated 1st July 2013 ...

Page 145: ...18 01 4 3 7 1 6 2 5 Updated 24th January 2013 ...

Page 146: ...embly A120P0185F 1 02 Actuator heater AC flaps A117M6052S 1 03 Expansion Valve See 18 03 1 04 Cover actuator A117P0158K 1 05 Thermostat Unit A120P6012S 1 06 Drive Belt heater flap A117P6001S 1 07 Screw M6 x 20 hex flg hd AC htr assy to chassis A117W2203F 2 08 Rubber self adhesive actuator cover A036B6221V 1 Function Code 18 01 Page 1 Updated 24th January 2013 ...

Page 147: ...18 03 1 2 9 3 4 5 7 8 6 14 10 11 12 13 20 19 15 16 18 17 21 21 21 21 21 23 22 22 24 24 25 26 27 34 29 30 31 31 33 32 22 28 Updated 1st October 2013 ...

Page 148: ...07 Pipe Assembly bodyside to condenser A138P0002F Includes no 6 O rings 1 08 Hose Assembly HVAC discharge A120P0025S 1 A138P0014F R B 09 Hose Assembly HVAC suction A120P0024S 1 A138P0015F R B 10 Pipe Assembly bodyside suction RHD A138P0004F Includes no 10 O rings 1 10a Pipe Assembly bodyside suction LHD A138P0020F Includes no 10 O rings 1 11 Hose Assembly AC compressor discharge A138P0006F Include...

Page 149: ... 22 O Ring No 8 pipe joints expansion valve to evaporator A082P6079F 3 23 O Ring No 10 pipe joints A082P6080F 2 24 O Ring No 12 pipe joints A082P6081F 2 25 Nut Nyloc M6 thin A907E6285F 2 26 Washer Flat M6 x 18 x 1 6 A121W4196F 2 27 Bolt M6 x 30 hex flg A124W5294F 3 28 Washer Flat M6 x 25 x 1 4 B075W4017F 3 29 Swivel Clip Male A089W6296F 1 30 Swivel Clip Female A132W6047F 1 31 Trinary Switch A117P0...

Page 150: ...6 1 9 3 4 2 9 7 8 5 18 05 Updated 27th february 2013 ...

Page 151: ...ter feed LHD A117P0024F 1 03 Pipe heater return A138P0012F 1 04 Hose heater return RHD A117P0021F 1 04a Hose heater return LHD A117P0022F 1 05 Hose Assembly pump to heater B138P0017F See 46 01 1 06 Hose heater return A138P0009F See 46 01 1 07 Clip Hose 25 27mm A120W6776F 1 08 Clip Hose 27mm A116K6016F 1 09 Clip Hose 22 3 24 1mm A132W6021F 4 Function Code 18 05 Page 1 Updated 27th february 2013 ...

Page 152: ...18 07a 1 2 Updated 24th January 2013 ...

Page 153: ...art Description Part Number Remarks Qty Function Code 18 07a AC Interior Blower Motor Option 01 Blower Motor Assembly B117P0163F 1 02 Resistor Kit blower motor A120P0148S 1 Function Code 18 07a Page 1 Updated 24th January 2013 ...

Page 154: ... 18 09a 2 3 5 4 6 7 1b 1c 1 1a 1d 1e ...

Page 155: ... cars 01c Switch Panel Assembly heater LHD A138P0024F Incl temp fan dist Switches 1 Heater cars 01d Switch Panel Assembly RHD A138P0025F Incl temp fan dist Switches 1 AC no heated seats or Heater with heated seats 01e Switch Panel Assembly LHD A138P0026F Incl temp fan dist Switches 1 AC no heated seats or Heater with heated seats 02 Screw Ejot 1452K 50 x 18 black panel fix A117W5277F 4 03 Knob ill...

Page 156: ...18 12 1 3 2 ...

Page 157: ...de 18 12 AC Heater Air Distribution Plenum Option 01 Air Distribution Plenum LHD B117P0041F 1 01a Air Distribution Plenum RHD A117P0042F 1 02 Actuator distribution flaps A117M6052S 1 03 Hose heater to plenum insulated A124P0025F 1 Function Code 18 12 Page 1 ...

Page 158: ...18 13 1 6 4 1 1 1 3 3 3 3 7 11 5 8 11 9 10 11 2 2 ...

Page 159: ...0 8m 04 Deflector footwell RHD A120P0016F 1 04a Deflector footwell LHD A120P0017F 1 05 Duct intermediate FLV centre A121U0029F Includes foam gaskets 1 06 Duct side FLV RH A121U0028F 1 07 Duct side FLV LH A121U0027F 1 08 Gasket FLV A121V0006H 4 09 Duct FLV centre B121P0002H 1 10 Duct air distribution demist A121P0001H P O fascia top panel assy 1 11 Screw self tap No 10 x 3 4 ducts to panels A075W50...

Page 160: ...18 14 6 5 2 7 4 3 1 ...

Page 161: ... AC cars 02a Recirc Air Plenum LH LHD B117P0037F With aperture 1 AC cars 03 Recirc Air Plenum RH RHD B117P0036F With aperture 1 AC cars 03a Recirc Air Plenum RH LHD B117P0038F Without aperture 1 AC cars 04 Actuator fresh air flap A117M6052S 1 AC cars 05 Blanking Panel alloy A117P0123F Driver footwell 1 AC cars 06 Deflector Panel alloy A117P0126F Passenger footwell 1 AC cars 07 Pop Rivet panels to ...

Page 162: ... 7 1 6 7 1 2786 56 7 0 18 785 8 6 7 4 8 7 4 8 8 74 2 4 8 8 74 2 2 6 0 4 6 4 4 490 002 G G G G 2786 5 51 1 7 6 816 72 86 9 7 7 6758 785 6 5 3 1 5 029 1685 2 76 72548 1P 19 01 3 1 7 8 2 4 5 6 5 9 10 11 12 13 14 15 Updated 27th february 2013 ...

Page 163: ... 07 Label tyre loading Australia A138U0025F 1 Australia 08 Label E mark A120U0213F 1 09 Label SIR warning A082U7350F On battery cover 1 10 Label fuel consumption Australia A138U0022F Standard tyres 1 Australia 11 Label Do Not Remove Roof A138U0024F 1 12 Label Mind Your Head A138U0023F 1 13 Label oil level warning A132U0460F On intake manifold 1 14 Label child seat warning RHD B124U0094F 1 14a Labe...

Page 164: ...19 03 1 ...

Page 165: ...rench E120T0324JF Includes maintenance record 1 01b Owner s Handbook German E120T0324JD Includes maintenance record 1 01c Owner s Handbook Italian E120T0324JI Includes maintenance record 1 01d Owner s Handbook Arabic E120T0324JAR Includes maintenance record 1 02 Maintenance Record English E120T0324JM P O item 01 03 New Vehicle Warranty booklet English E120T0324JW P O item 01 Function Code 19 03 Pa...

Page 166: ...30 01 1 2 3 4 8 6 5 17 16 15 14 18 7 11 12 13 9 See 3103 Updated 24th January 2013 ...

Page 167: ...Bolt M12 x 60 skt cap hd A138W2010F 2 06 Washer Flat M12 x 23 5 x 2 3 A075W4028F 2 07 Nut M12 hex flg A132W3010F 2 08 Nut Plate Assembly chassis mounting A138A0101F 2 09 Assembly Shear Panel tank bay A138A0110F 1 10 Rivnut M8 rear undertray fixing A111W6605F 8 11 Setscrew M5 x 16 hex hd shear panel to chassis sill A111W1163F 10 12 Washer flat M5 x 25 x 1 4 shear panel to chassis sill B100W6372F 6 ...

Page 168: ... Remarks Qty Function Code 30 01 Chassis Subframes Option 16 Washer flat M8 x 16 6 x 1 4 A111W4164F 9 17 Nyloc Nut M8 A907E6284F 9 18 Adapter diffuser shear panel 16mm hex A120A0183F 3 Function Code 30 01 Page 2 Updated 31st May 2013 ...

Page 169: ...30 02 2 5 3 4 1 7 8 6 9 10 11 13 13 12 12 Updated 1st May 2013 ...

Page 170: ... SBAF Stay Assembly RH A138A4010F 1 06 Bolt M10 x 30 hex flg A132W2004F 4 07 Bolt M10 x 60 hex flg A132W2009F 2 08 Nut M10 hex flg A132W3005F 2 09 Bolt M10 x 35 hex flg A116W5247F 12 10 Screw M8 x 25 skt cap hd A111W7132F 8 11 Washer Flat M8 x 16 6 x 1 4 A075W4020 8 12 Seal Seatbelt anchorage A120B0207F 2 13 Shim base plate 2mm B111A0071F 2 13a Shim base plate 3mm A116A0164F 2 13b Shim base plate ...

Page 171: ...2 17 16 25 26 16 24 25 28 16 11 29 10 14 19 27 9 6 43 12 23 4 8 7 37 38 39 13 1 16 20 16 40 30 16 See 34 01 23 3 35 42 34 14 33 35 2 36 31 32 16 18 34 33 22 See 33 01 5 21 44 41 45 30 14 Updated 1st July 2013 ...

Page 172: ...0 9G cap hd steering arm to hub carrier A117W7213F 4 07 Shim 1 0mm camber adjustment D111C0062F As req 07a Shim 1 5mm camber adjustment B120C0022F As req 08 Shim bracket connector retainer LH A120C4005F 1 08a Shim bracket connector retainer RH A120C4006F 1 09 Bush suspension A116C0035F 2 10 Damper ABS Unit Mounting Bracket assy LH RHD LHD A138C0062F 1 10a Damper Bracket top front RH A138C4030F 1 1...

Page 173: ... bracket to chassis A111W4175F 2 21 Spring Seat lower front A138C0011H 2 22 Balljoint suspension B111C6012F 4 23 Nyloc Nut M12 x 1 5 ball joint B100C6019F 4 24 Pivot Bolt M10 x 80 hex hd wishbone upper front A075W2061Z 8 25 Nut M10 hex flg wishbone fixings A138W3006F 4 26 Shim Castor Adjust 1 5 mm large A111C0077F 6 27 Snubber Washer rubber coated upper wishbone A111C0081F 2 28 Shim Castor Adjust ...

Page 174: ...ush ARB A111C0094F 2 39 Backing Plate 5 0mmm A138C0055F 1 39a Backing Plate ARB mounting A111C0109F 2 40 Screw M8 x 30 skt cap hd A117W7215F 4 41 Spreader Plate Front Damper Bracket A138A0119F 2 42 Washer M8 x 25 x 1 5 s s B075W4021Z 2 43 Assembly Wishbone Upper front LH C138C4001J 1 43a Assembly Wishbone Upper front RH C138C4002J 1 44 Bump Stop Front A138C0009H 2 45 Assembly Spring Damper Sport f...

Page 175: ...31 03 24 34 20 22 29 29 28 7 19 8 32 15 3 14 5 9 4 1 6 10 12 13 2 30 43 21 31 26 27 42 23 25 36 37 35 40 31 39 38 33 41 11 17 18 16 44 45 46 47 B Level C Level Grooves Updated 1st August 2013 ...

Page 176: ...per Assembly Sport rear LH D138D4031F 2 06a Spring Damper Assembly Sport rear RH D138D4032F 2 06b Spring Damper Assembly Race rear LH D138D4023F 2 06c Spring Damper Assembly Race rear RH D138D4024F 2 07 Damper Assembly Sport rear D138D0085F Cars fitted with B level dampers to be replaced in pairs 2 07a Damper Assembly Race rear D138D0031F Cars fitted with B level dampers to be replaced in pairs 2 ...

Page 177: ...6000F 2 15a Rubber Mount ARB A138D6002F 2 Roadster 16 Bush wishbone rear upper B132C0020F 4 17 Bush wishbone rear lower frt B132C0020F 2 18 Bush wishbone rear lower rr A132C0019F 2 19 Washer Flat M14 x 30 damper lower B132D0033F 4 20 Bolt M14 x 125 hex flg damper lower A132W2010F 2 21 Nut M14 hex flg damper lower A132W3023F 2 22 Bolt M14 x 125 hex flg upright lower A132W2010F 2 23 Nut M14 hex flg ...

Page 178: ...ex flg wishbone lower A132W2040F 2 36 Washer Cam wishbone lower A132W4000F 2 37 Nut M12 hex flg wishbone upper A132W3010F 2 38 Bolt M10 x 55 hex flg top damper mount A138W2003F 2 39 Nut M10 hex flg top damper mount A132W3005F 2 40 Bolt M10 x 100 hex flg wishbone mtg brkt A116W5235F 2 41 Nut M10 hex flg wishbone mtg brkt A132W3005F 2 42 Screw M10 x 50 hex hd hub A132W2045F 8 43 Washer Flat M14 x 30...

Page 179: ...32 01 15 16 17 18 20 19 21 1 3 2a 7 10 9 8 3 5 4 4 5 14 12 13 11 2 22 6 23 19 24 Updated 1st October 2013 ...

Page 180: ...eering arm A111W3157F 2 06 Intermediate Steering Shaft Assembly B120H0011F 1 07 Adjuster Plate rack height setting 10 notch A111H0021F 2 08 Washer flat M8 rack mounting A075W4020Z 2 09 Setscrew M8 x 25 hex hd rack mounting A082W1110F 2 10 Setscrew M10 x 30 hex hd rack mounting A100A6028F 2 11 Washer flat M10 rack mounting A075W4024Z 2 12 Bolt M8 x 40 hex hd 10 9 grade steering shaft to U J A918W21...

Page 181: ... 1 18 Sensor steering angle A132J0092F 1 19 Screw M5 x 25 Socket hd cap SWA collar A132W7001F 2 20 Nut Spire No 8 sensor steering angle A075W6016F 3 21 Screw No 6 flg pozi sensor steering angle A075W5012F 3 22 Pop Rivet sensor bracket A082W6259F 4 23 Pop Rivet A082W6512F 2 24 Collar SWA sensor A120J0094F To be confirmed 1 Function Code 32 01 Page 2 Updated 1st October 2013 ...

Page 182: ...11 9 16 12 15 10 3 10 14 5 16 12 See 17 05 6 11 16 8 4 1 13 12 7 12 11 12 18 13 20 2 17 19 See 17 05 32 05 Updated 1st October 2013 ...

Page 183: ... column mounting B111H0004F 1 06 Column Mounting Bracket LH E117U0135F 1 07 Nutplate upper column support B111H0007F 2 08 Pop Rivet nutplate to bracket A075W6092F 2 09 Bolt M8 x 35 hex hd column to bracket B075W2038F 2 10 Washer flat M8 x 20 x 2 5 A079W4019F 3 11 Setscrew M6 x 16 side to forward brk chassis A075W1028Z 6 12 Washer flat M6 x 12 1 x 1 4 A075W4013Z 10 13 Nyloc Nut M6 A907E6285F 4 14 S...

Page 184: ... Remarks Qty Function Code 32 05 Upper Column Steering Wheel Option 18 Washer spring M6 A075W4035F 2 19 Shear Bolt steering lock A111H6026S 2 20 Lock Plate steering wheel A111H6009F 1 Function Code 32 05 Page 2 Updated 1st August 2013 ...

Page 185: ... 0564 0564 33 01 1 20 5 12 6 11a 13 11 7 10 8 10a 2 14 18 19 16 15 4 21 3 20 9 17 Updated 4th April 2013 ...

Page 186: ...1 02c Brake Disc rear 2 piece cross drilled RH B138J4048F Optional 03 Brake Caliper front grey LH A138J4033F Includes pads 1 03a Brake Caliper front grey RH A138J4034F Includes pads 1 03b Brake Caliper front red LH A138J4037F Includes pads 1 03c Brake Caliper front red RH A138J4038F Includes pads 1 03d Brake Caliper front yellow LH A138J4041F Includes pads 1 03e Brake Caliper front yellow RH A138J...

Page 187: ...rear black LH A138J4020F Includes pads 1 04h Brake Caliper rear silver LH A138J4057F Includes pads 1 Roadster 04i Brake Caliper rear silver RH A138J4058F Includes pads 1 Roadster 05 Assembly Caliper Mount Front LH C138J4015F 1 05a Assembly Caliper Mount Front RH C138J4016F 1 06 Bolt M12 x 70 lobe hd caliper mounting A138J6001F 8 07 Brake Pad set front A132J0001S Includes clips and pins 1 08 Brake ...

Page 188: ...rking brake B132J0134F 2 15 Fastener quarter turn shoe retaining A132J6047F 4 16 Spring fastener to backplate A132J6048F 4 17 Support Block shoe assembly A132J6045F 2 18 Bolt M10 x 45 hex flg backplate to hub A132W2005F 4 19 Bolt M10 x 40 hex flg backplate to hub A132W2044F 2 20 Screw M8 x 12 skt hd cap disc to hub A111W7131F 4 21 Screw M6 x 7 button hd block to backplate A132W5024F 4 Function Cod...

Page 189: ...23 15 16 17 18 19 20 23 21 22 24 25 26 29 30 30 30 30 31 31 31 31 32 32 32 32 33 33 34 35 36 37 38 39 41 42 43 44 45 46 38 38 38 47 48 49 49 48 40 51 28 28 51 52 50 27 2 3 53 54 50 55 56 57 58 59 62 60 61 58 59 29 Updated 1st August 2013 ...

Page 190: ...oir mounting A138J0084F 1 07 Hose reservoir to M C front LHD A132J0141V Cut to length 337mm 07a Hose reservoir to M C front RHD A132J0141V Cut to length 337mm 08 Hose reservoir to M C rear LHD A132J0141V Cut to length 337mm 08a Hose reservoir to M C rear RHD A132J0141V Cut to length 337mm 09 ESP Module Assembly uncalibrated A132J0223S Supplied pre filled dealer programmed on tech centre 1 10 Brack...

Page 191: ...pe Assembly bodyside front to rear LH B138J4027F 1 20 Brake Pipe Assembly bodyside front to rear RH B138J4028F 1 21 Brake Pipe Assembly rear to flexi LH B138J4011F 1 22 Brake Pipe Assembly rear to flexi RH B138J4012F 1 23 Brake Hose Assembly Front A138J0009F 2 24 Brake Hose Assembly Rear LH A132J4037F 1 25 Brake Hose Assembly Rear RH A132J4038F 1 26 Vacuum Hose Side RHD A138J0008F 1 26a Vacuum Hos...

Page 192: ...nel trim 1 42 Screw M6 x 20 hex flg hd sensor mounting A117W2203F 2 43 Nut M6 flg sensor mounting A117W3180F 2 44 Steering Angle Sensor A132J0092F See 32 05 1 45 Screw M8 x 25 hex flg hd spacer to pedal box A132W5006F 2 46 Nut M8 hex flg spacer to pedal box A132J6024H 2 47 Screw M6 x 10 hex hd bobbin to bracket A075W1026Z 3 48 Washer spring M6 bobbin to bracket A075W4035Z 6 49 Washer flat M6 x 15 ...

Page 193: ...P Clip vacuum hose A111W6666F 1 56 Clip Swivel 6 10mm brake hose A116W6656F 6 57 Clip wheel speed sensor A082W6325F 6 58 Clip 10mm dia x 15 wide hose retention A111W6595F 2 59 Nyloc Nut M6 thin Zn clip to wishbone A907E6285F 2 60 Speed Nut M6 A117W3181F 2 61 Screw M6 x 16 hex flg A132W5003F 2 62 Washer M6 x 25 x 1 4 s s A082w4131F 2 Function Code 33 03 Page 4 Updated 1st May 2013 ...

Page 194: ...33 05 1 3 4 2 7 6 13 14 10 8 9 12 5 11 15 Updated 16th July 2012 ...

Page 195: ...ualiser 1 05 R Clip A075W6175F 1 06 Screw M8 x 25 hex hd lever fixing A075W1039Z 2 07 Washer flat M8 x 16 x 1 4 lever fixing A075W4020Z 2 08 Switch parking brake tell tale A116J6009H 1 09 Screw M3 x 16 pan hd pozi switch fixing A082W5110F 2 10 Nyloc Nut M3 switch fixing A079W3060F 2 11 Screw M6 x 12 hex flg secondary cable A132W5010F 2 12 Clevis Pin 8 x 16 mm A111W6674F 1 13 Clevis Pin A132J0236S ...

Page 196: ...34 01 3 6 1 7 8 4 5 9 10 12 11 13 Updated 27th february 2013 ...

Page 197: ...02 Winter Wheel Front 7 5J x17 ET30 A138G0007F Not iIllustrated 2 02a Winter Wheel Rear 8 0J x18 ET15 A138G0008F Not iIllustrated 2 03 Tyre Front Pirelli Corsa 205 45 ZR17 A138G0003F 2 With Sports Suspension 03a Tyre Rear Pirelli Corsa 265 35 ZR18 A138G0004F 2 With Sports Suspension 03b Tyre Front Trofeo 205 45 R17 88Y A138G0030F 2 WIth Race Suspension 03c Tyre Rear Trofeo 265 35 R18 93Y A138G0031...

Page 198: ...259F 2 09 Security Wheelbolt Kit A132G0047F Incl ID strip instruction card 1 10 Adaptor wheel bolt A117G0036F 1 11 Tyre Valve TPMS Transmitter A121G6000F Does not include item 12 4 12 Nut conical seal TPMS transmitter A121G6001H 4 13 Tyre Valve A117G6007H 4 Non TPMS For replacement keys contact Technical Service quoting ID Function Code 34 01 Page 2 Updated 1st August 2013 ...

Page 199: ...1 40 00 ...

Page 200: ...Part Description Part Number Remarks Qty Function Code 40 00 Engine Assemblies Option 01 Engine Assembly 2GR FE undressed A132E6097S 1 01a Engine Short Block Assembly A132E6098S 1 Function Code 40 00 Page 1 ...

Page 201: ...4 4 1 5 3 3 2 3 10 12 9 3 14 10 8 11 15 16 13 6 7 40 01 ...

Page 202: ...07 Bolt main bearing cap outer A132E6146S 8 08 Bolt main bearing cap cross retention A132E6148S Front and centre pair of caps 6 09 Bolt main bearing cap cross retention rear A132E6149S Rear cap 2 10 Sealing Washer cross bolts A132E6154S 4 11 Drain Cock Assembly A132E6159S Includes screw 2 11a Plug screw drain cock A120E6441S 2 12 Stud block to front cover A132E6152S 2 13 Oil Pick up Pipe Assembly ...

Page 203: ...40 01a 2 5 5 12 22 8 5 18 30 28 27 29 33 32 24 25 36 6 35 13 26 35 37 20 3 21 3 19 10 7 1 3 14 15 17 16 39 38 11 4 31 23 40 34 41 42 9 43 44 Updated 1st May 2013 ...

Page 204: ...0 flg insulator fixing A132W3005F 3 08 Nut M8 flg bracket to subframe A132W3006F 2 09 Insulator Assembly engine mount front A132F0226J 1 10 Insulator Assembly engine mount LH B132F0043J 1 11 Bolt M12 x 30 hex flg hd insulator to subframe A132W2016F 2 12 Plate bumper retaining rear mount A132F0045F 1 13 Insulator engine mount RH A138E6005F 1 14 Bolt hex flg hd bracket to transmission A120E6412S 2 1...

Page 205: ... to bracket engine mounting A132E6307S 1 28 Bolt hex flg hd w washer stay to insulator A132E6056H 1 29 Nut M8 flg stay to bracket engine mounting A132E6059H 2 30 Bolt hex flg hd bracket to transmission A132F6014H 4 31 Bracket Assembly engine idler mounting A138E6000F Also see 41 03 1 32 Stay bracket engine mounting to inlet manifold A132E6186S 1 33 Bolt hex flg hd bracket engine mounting A132E6191...

Page 206: ...ulator RH A138E0020K 1 41 Nut M10 insulator to subframe B111W3151F 1 42 Washer Flat M10 x 50 x 3 insulator to subframe A138E6006F 1 43 Snubber engine mount RH A138E0039F To be confirmed 1 44 Insulator engine mount snubber RH A138E6009F To be confirmed 1 Function Code 40 01a Page 3 Updated 1st May 2013 ...

Page 207: ...10 1 includes items 2 to 22 7 8 15 5 23 4 16 9 9 17 11 14 2 12 3 13 40 02 6 19 20 22 21 18 ...

Page 208: ...nifold A132E6308S Also see 40 21 2 10 Gasket throttle body to intake plenum A132E6454S Also see 42 04 42 07 1 11 Gasket plate to cover A132E6433S Also see 40 08 1 12 Gasket water pump A132E6452S Also see 40 13 1 13 Oil Seal crankshaft front A132E6308S Also see 40 11 1 14 Oil Seal crankshaft rear A132E6162S Also see 40 11 1 15 Washer sealing bolt no 4 camshaft cover centre A132E6129S Also see 40 07...

Page 209: ...mber Remarks Qty Function Code 40 02 Gaskets Sealants Top Overhaul Set Option 22 Oil Seal valve stem inlet A132E6464S Also see 40 05 12 23 Gasket spark plug tube A132E6431S Not P O gasket set see 40 05 6 Function Code 40 02 Page 2 ...

Page 210: ...1 Includes items shown plus items 2 to 22 in section 40 02 5 6 2 3 7 8 9 4 40 02a ...

Page 211: ...l by pass water inlet housing A132E6252S Also see 46 01 1 04 Gasket water outlet A132E6259S Also see 46 01 2 05 Gasket oil pump A132E6137S Also see 40 15 1 06 O Ring sump upper to block A132E6171S Also see 40 03 2 07 Gasket oil pick up pipe A132E6234S Also see 40 01 1 08 Gasket sump plug A120E6461S Also see 40 03 1 09 O Ring lower guide tube to block A132E6165S Also see 40 15 1 Also items 2 to 22 ...

Page 212: ...3 10 14 1 4 13 15 2 16 12 11 8 9 6 7 40 03 5 ...

Page 213: ...ket sump plug A120E6461S 1 07 Bolt flg hd lower to upper sump A132E6456S 12 08 Stud upper to lower sump A132E6174S 2 09 Nut flange lower to upper sump A132E6458S 2 10 Bolt Washer baffle retention A132E6173S 8 11 Bolt flg hd lupper sump A132E6479S 2 12 Bolt flg hd upper sump A132E6478S 2 13 Bolt flg hd upper sump A132E6478S 2 14 Stud lupper sump A132E6116S 2 15 Nut flange upper sump A132E6474S 2 16...

Page 214: ...4 3 41 40 1 45 37 20 28 27 40 05 42 41 40 42 39 43 34 36 32 35 30 31 33 24 25 26 36 21 15 14 10 11 18 12 13 19 5 9 8 7 6 22 23 44 2 16 17 17 15 14 38 46 47 48 Updated 27th September 2012 ...

Page 215: ...2S 12 06 Valve Seat exhaust A132E6103S 12 07 Inlet Valve A132E6223S 12 08 Exhaust Valve A132E6224S 12 09 Seat valve spring A132E6225S 24 10 Retainer valve spring A132E6226S 24 11 Valve Spring A132E6227S 24 12 Oil Seal valve stem inlet A132E6464S 12 13 Oil Seal valve stem exhaust A132E6229S 12 14 Valve Collet A131E6212S 48 15 Cap valve stem A132E6231S 24 16 Rocker Arm valve actuating A132E6449S 24 ...

Page 216: ... A132E6123S 16 25 Washer head to block A132E6122S 16 26 Bolt hex flg hd head to block front LH bank A132E6121S 2 27 Gasket cylinder head RH A132E6119S Also see 40 02 1 28 Gasket cylinder head LH A132E6120S Also see 40 02 1 30 Gasket camshaft bearing cap oil hole A132E6124S 4 31 O Ring special camshaft housing A132E6130S 2 32 Dowel Pin no 1 camshaft housing A120F6033S 3 33 Bolt hex flg hd no 1 cams...

Page 217: ...ipe upper A132E6243S 4 42 Gasket union bolt oil pipe lower A132E6244S 2 43 Stud exhaust manifold to head A132E6117S Also see 40 21 8 44 Stud water outlet to head A132E6115S 4 45 Stud inlet manifold to head A132E6116S Also see 42 07 12 46 P Clip oil feed pipe A132E0134F 1 47 Pillar oil feed pipe A132E0135F 1 48 Screw M6 x 30 hex flg oil feed pipe A124W5294F 1 Function Code 40 05 Page 3 Updated 27th...

Page 218: ...25 30 34 33 19 26 30 27 27 17 21 18 23 35 20 5 15 22 16 6 10 9 8 9 2 7 11 3 1 See 40 08 4 40 07 32 29 12 28 13 14 24 27 27 31 20 36 37 38 Updated 1st October 2013 ...

Page 219: ...kets 1 07 Gasket cam cover LH A132E6134S Also see 40 02 1 08 Gasket cam cover RH A132E6126S Also see 40 02 1 09 Gasket spark plug tube A132E6431S Also see 40 02 6 10 Bolt hex flg hd no 1 camshaft cover A132E6127S 17 11 Bolt hex flg hd no 2 camshaft cover A132E6128S 3 12 Bolt hex flg hd no 3 camshaft cover A132E6132S 2 13 Bolt hex flg hd no 4 camshaft cover centre A132E6131S 2 14 Washer sealing bol...

Page 220: ...5S Includes O ring 1 26 Valve Assy cam timing control RH bank 1 intake A132E6236S Includes O ring 1 27 O Ring Valve Assy cam timing control A132E6419S 4 28 Filter oil control valve A132E6237S 2 29 Sensor camshaft position A132E6283S Also see 17 06 4 30 Bolt hex flg hd valves to cam cover A132E6480S 4 31 Bolt hex flg hd sensors to cam cover A132E6478S 4 32 Bolt Washer hex hd camshaft gear A132E6211...

Page 221: ...8 14 1 16 18 18 14 20 2 13 4 6 2 25 5 7 12 26 15 27 28 23 19 11 9 17 3 21 40 08 18 24 22 10 ...

Page 222: ...ipper chain tensioner A132E6214S 1 10 Tensioner Assembly chain no 2 LH A132E6215S 1 11 Damper chain vibration lower A132E6216S 1 12 Damper chain vibration no 2 upper A132E6217S 2 13 Chain camshaft drive no 1 main A132E6221S 1 14 Chain camshaft drive no 2 inlet to exhaust camshaft A132E6222S 2 15 Bolt hex flg hd tensioner assembly chain no 1 A132E6218S 2 16 Bolt hex flg hd tensioner assembly chain ...

Page 223: ...A132E6140S 10 23 Bolt hex flg hd cover assy to block A132E6141S 12 24 Bolt hex flg hd cover assy to block A132E6470S 1 25 Bolt hex flg hd cover assy no 2 upper to main cover A132E6467S 2 26 Plate timing chain cover A132E6432S 1 27 Gasket plate to cover A132E6433S 1 28 Bolt hex flg hd plate to main cover A132E6416S 4 Function Code 40 08 Page 2 ...

Page 224: ...1 3 2 4 6 5 40 09 ...

Page 225: ...6 02 Circlip gudgeon pin retaining A132E6192S 12 03 Piston Ring Set A132E6193S 6 04 Connecting Rod A132E6194S 6 05 Bolt hex flg hd cap to rod A132E6195S 12 06 Con rod Bearing Set size 1 A132E6440S 6 06a Con rod Bearing Set size 2 A132E6491S 6 06b Con rod Bearing Set size 3 A132E6492S 6 06c Con rod Bearing Set size 4 A132E6493S 6 Function Code 40 09 Page 1 ...

Page 226: ...7 10 12 9 17 6 1 2 18 3 4 5 11 16 8 13 14 15 40 11 Updated 31st May 2013 ...

Page 227: ... size 2 A132E6483S 2 06b Bearing Set crankshaft No 2 No 3 size 3 A132E6484S 2 06c Bearing Set crankshaft No 2 No 3 size 4 A132E6485S 2 06d Bearing Set crankshaft No 2 No 3 size 5 A132E6486S 2 07 Bearing Set crankshaft No 1 No 4 size 1 A132E6435S 2 07a Bearing Set crankshaft No 1 No 4 size 2 A132E6487S 2 07b Bearing Set crankshaft No 1 No 4 size 3 A132E6488S 2 07c Bearing Set crankshaft No 1 No 4 s...

Page 228: ...eel flex plate to crankshaft A132E6356S 8 13 Oil Seal crankshaft front A132E6138S Also see 40 02a 1 14 Oil Seal crankshaft rear A132E6162S Also see 40 02a 1 15 Retainer Plate oil seal crankshaft rear A132E6161S 1 16 Bolt retainer to block A132E6478S 6 17 Spacer drive plate front A132E6290S 1 18 Spacer drive plate rear A132E6291S 1 Function Code 40 11 Page 2 Updated 31st May 2013 ...

Page 229: ...5 8 2 1 3 9 10 6 4 7 7 12 11 13 15 16 14 40 13 ...

Page 230: ...E6256S 2 07 Nut flange water inlet engine to thermostat housing A132E6473S 3 08 Bolt flg hd thermostat housing to engine A132E6131S 2 09 O Ring water inlet pipe to water inlet housing A132E6273S 1 10 O Ring special by pass water inlet housing A132E6252S 1 11 Water Pump A132E6414S 1 12 Gasket water pump A132E6452S 1 13 Bolt flange hd No 1 water pump body A132E6415S 9 14 Bolt flange hd No 2 water pu...

Page 231: ...9 6 8 1 10 12 2 7 3 14 4 20 13 23 5 15 11 16 21 18 17 22 19 40 15 ...

Page 232: ...ousing to cover A132E6417S 3 09 Dipstick A132E6310S 1 10 Dipstick Guide Tube A132E6301S Includes O Ring 1 11 Dipstick Guide Tube lower A132E6164S 1 12 Bolt guide tube retention A132E6249S 1 13 Bolt lower guide tube retention A132E6472S 1 14 O ring guide tube to lower guide tube A120E6281S 1 15 O Ring lower guide tube to block A132E6165S 1 16 Nozzle oil feed A132E6246S 1 17 Bolt nozzle to block A13...

Page 233: ... Part Description Part Number Remarks Qty Function Code 40 15 Lubrication System Option 22 O Ring plug to housing A132E6475S P O filter kit 1 23 Switch oil pressure A132E6297S 1 Function Code 40 15 Page 2 ...

Page 234: ...1 3 2 1 40 17 ...

Page 235: ...t Number Remarks Qty Function Code 40 17 Ignition System Spark plugs Plug Top Coils Option 01 Ignition Coil A132E6279S 6 02 Spark Plug A132E6503F 6 03 Bolt flg hd ignition coil retention A132E6423S 6 Function Code 40 17 Page 1 ...

Page 236: ...1 4 3 6 5 2 9 8 12 7 10 11 40 19 ...

Page 237: ...d alternator lower fixing A132E6470S 1 06 Bolt hex flg hd alternator bracket A132E6025H 2 07 Adaptor starter motor A132F0013F 1 08 Bracket Strap starter motor B132F0022F 1 09 Bolt M10 x 35 hex flg hd starter to adaptor A132F6421S 1 10 Bolt M12 x 90 hex flg hd starter to main adaptor plate A132F6360S 1 11 Bolt M10 x 65 hex flg hd adaptor to main adaptor plate A132F6022H 2 12 Screw M8 x 16 hex flg h...

Page 238: ...2 1 3 4 5 9 7 10 6 8 40 21 ...

Page 239: ...ket exhaust manifold assy to head A132E6318S 2 04 Stud exhaust manifold to head A132E6117S 12 05 Nut flange exhaust manifold to head A132E6394S 12 06 Stay exhaust manifold no 1 A132E6313S 1 07 Bolt hex flg hd stay to manifold LH A132E6047H 1 08 Stud LH manifold to downpipe A132E6153S See see section 45 01 2 09 Nut flange stay fixing A132E6048H 1 10 Stud stay fixing A132E6153S 1 Function Code 40 21...

Page 240: ...8 1 9 2 3 4 5 7 6 40 23 ...

Page 241: ...y AC compressor A132E6351S 1 03 Shim Kit magnetic clutch A120E6493S 1 04 Circlip clutch A132E6354S 1 05 Shaped Circlip clutch A132E6353S 1 06 Bolt hex flg hd AC compressor clutch A120E6484S 1 07 Bolt hex flg hd compressor mounting A132E6367S 4 08 Bracket harness retention A132E6352S 1 09 Bolt hex flg hd bracket to compressor A132E6467S 1 Function Code 40 23 Page 1 Updated 1st October 2013 ...

Page 242: ...See 40 19 41 03 16 17 5 4 25 12 13 2 3 8 9 10 15 14 11 10 9 7 1 6 8 19 18 20 21 22 22 23 24 21 Updated 4th April 2013 ...

Page 243: ... 1 07 Bolt hex flg hd pulley to pump A132E6249S Also see 40 13 4 08 Pulley idler A132E6261S 2 09 Bolt hex flg hd idler pulley retention A132E6421S 2 10 Plate idler pulley cover front A132E6264S 2 11 Plate idler pulley cover rear A132E6262S 2 12 Idler Assemblyy AC pump replacement A138E0005J 1 Non A C 13 Drive Belt Tensioner Assembly A132E6263S 1 14 Bolt hex flg hd tensioner upper fixing A132E6266S...

Page 244: ...2 5mm A132E6515S 1 20 Screw M10 x 50 button hd cap A132W5042F 1 21 Screw M10 x 50 skt hd cap A132W5043F 3 22 Washer pulley transfer A132W4006F 3 23 Pulley idler internal 52 mm nut mount A138E6010S 1 24 Nut idler mounting A138E6011S 1 25 Bolt hex flg hd idler assembly A132W2048F 3 Function Code 41 03 Page 2 Updated 31st May 2013 ...

Page 245: ...12 14 See 17 06 9 10 4 3 13 11 8 11 5 7 6 42 01 16 17 15 1 2 18 19 20 Updated 1st August 2013 ...

Page 246: ...ain airbox C132E0027F 1 08 Hose intake snorkel bypass A132E0018F 1 09 Hose Main Intake Snorkel B138E0004F 1 10 Hose Clip 110 130mm main hose to retention A132W6037F 2 11 Hose Clip bypass hose A075L6044F 2 12 Hose Clip plenum to airbox throttle body A132E6022H 2 13 Screw M8 x 30 flg hd airbox to bracket A116W5245F 3 14 Screw flg hd sensor to airbox upper A120E6447S 2 15 Bracket airbox mounting C132...

Page 247: ... Remarks Qty Function Code 42 01 Airboxes Trunking Air Filters Option 19 Screw M6 x 14 hex flg hd bracket mounting A116W5233F 2 20 Screw M6 x 20 hex flg hd pump clamping A132W5004F 1 Function Code 42 01 Page 2 Updated 1st August 2013 ...

Page 248: ...1 2 3 42 04 ...

Page 249: ...Remarks Qty Function Code 42 04 Throttle Body Mechanism IAC Valve Option 01 Throttle Body A132E6327S 1 02 Gasket throttle body to intake plenum A132E6454S 1 03 Bolt throttle body to intake plenum A132E6379S 4 Function Code 42 04 Page 1 ...

Page 250: ...5 6 1 8 7 3 2 4 42 05 ...

Page 251: ...8 1 02 Fuel Injector high flow A132E6498H Includes O ring 6 03 O Ring injector to rail A132E6460S 6 04 Insulator injector A132E6285S 6 05 Bolt hex flg hd rail to engine A132E6287S 5 06 Fuel Pressure Valve A132E6508S Includes O ring 1 07 O Ring valve to rail A132E6460S 1 08 Clip valve retention to rail A132E6509S 1 Function Code 42 05 Page 1 ...

Page 252: ...42 09 1 3 2 7 6 4 5 8 9 10 11 Updated 21st November 2012 ...

Page 253: ...E6275S 1 04 Nut flange supercharger to head A132E6474S 6 05 Bolt Washer socket cap hd supercharger to head A132E6363S 4 06 Bracket A138E0021K 1 07 Bolt hex flg hd A132E6191S 2 08 Vacuum actuator supercharger A132E6516S 1 09 Hose vacuum actuator supercharger A132E6517S 1 10 Stud M8 x 25 A132E6116S 6 11 Bolt hex flg hd M8 x 75 bracket to timing case A138W1000F 1 Function Code 42 09 Page 1 Updated 21...

Page 254: ...43 03 1 12 2 3 4 7 13 5 6 19 10 8 9 6 18 15 16 17 10 14 20 10 18 11 10 14 Updated 4th April 2013 ...

Page 255: ...Hose Vacuum valve to pipe B138S0047F 2 07 Y Piece B120E6524F 1 08 Swivel Clip tie wrap hose airbox to valve A082W6324F 2 09 Swivel Clip hose airbox to valve A132W6088F 2 10 P Clip vacuum pipe A132W6090F 6 11 Screw M5 x 12 hex flg A132W5002F 1 12 Heat Wrap Protection vacuum hose to valve A120L0061F 1 13 Hose Vacuum valve to pipe A138S0060F 1 14 Washer 3 16 x 3 4 B075W4009Z 2 15 Tie Wrap A124W6800F ...

Page 256: ...ption Part Number Remarks Qty Function Code 43 03 Vacuum System Hoses Pipes Fittings Option 19 Screw M6 x 25 hex flg A132W5014F 2 20 Screw M6 x 20 hex flg A132W5004F 2 Function Code 43 03 Page 2 Updated 31st May 2013 ...

Page 257: ...24 44 01 15 14 18 11 16 28 25 19 7 9 20 17 22 11 21 13 12 6 10 27 23 12 8 2 4 5 1 27 8 3 24 Updated 27th february 2013 ...

Page 258: ...4F 2 08 Rear Restraint tank mounting A120L0045F 2 09 Hose fuel filler A117L0060F 1 10 Hose fuel breather C117L0062F 1 11 Hose Clip filler hose A120L6016F 2 12 Hose Clip breather hose A079K6018F 2 13 Fuel Filler Neck D120L0048F 1 14 Fuel Cap less lock barrel A117L0058F Order vehicle lock set or 14a 1 14a Lock Barrel Keys for the fuel cap A117L6050S Lock set req for L 1 15 Finisher Ring cap to clams...

Page 259: ... 1 21 Nyloc Nut M5 braid to filler neck A100W3113F 2 22 Washer flat M5 x 10 x 0 8 braid to filler neck A075W4011F 2 23 Earth Lead fuel tank A120M0030H 1 24 Screw M8 x 25 hex flg hd brackets to chassis A132W5006F 6 25 O Ring finisher ring A117L6005F 1 26 Foam Pad tank bay aperture A120L0056F Bonded to access panel 1 27 Support Pad fuel tank front B120L0058F 1 28 Gasket finisher ring to clamshell B1...

Page 260: ...44 03 2 6 3 17 16 4 7 15 1 9 8 10 12 13 18 19 20 11 14 5 22 21 Updated 1st October 2013 ...

Page 261: ...Fuel with filter A132E6499H Discard filter supplied 1 08 Spacer pump to module A120L6004S 1 09 Seal pump to module A120L6005S 1 10 Filter fuel pump pickup A120L6001S 1 11 Clip star washer A132L6003S 1 12 Cushion Support fuel pump A120L6006S 1 13 Cap fuel pump module base A120L6010S 1 14 Sender Assembly fuel gauge A120L0020S 1 15 Clip fuel feed to pump A132L6024F 2 16 Fuel Feed Pipe Assembly A138L0...

Page 262: ...e 44 03 Fuel Pump Filter Pipes Option 19 Spacer Ring fuel pump B121L0031H 1 20 Nyloc Nut M6 pump to tank A120L0014H 8 21 Access Panel fuel pump connections A120L0046F 1 22 Screw panel to chassis A111W7117F 4 Function Code 44 03 Page 2 Updated 1st October 2013 ...

Page 263: ...44 05 2 1 6 20 11 5 13 12 17 18 24 10 22 23 21 14 15 21 16 27 7 8 21 19 9 3 4 25 22 26 ...

Page 264: ...132L6008F 1 07 Nut M6 hex flg A117W3180F 1 08 Screw M6 x 16 hex flg A132W5003F 1 09 Bolt M6 x 20 hex flg A117W2203F 3 10 Clip Oetiker 13 3mm s s A124W6818F 1 11 Bolt M6 x 16 hex flg A918W5208F 1 12 Screw M6 x 16 but cap s s blk A082W7105F 1 13 Clip A111W6595F 1 14 Support Bracket fuel feed bulkhead B132L0070F 1 15 Pop Rivet A082W6512F 2 16 Plate fuel feed pipe mounting A138L0024F 1 17 Support Brac...

Page 265: ...coal Canister Evaporative Loss System Option 22 Swivel Clip Tie Wrap A082W6324F 5 23 Swivel Clip A082W6587F 1 24 Pipe Clip 10 14 A128W6831F 1 25 Grommet A138L0016H 2 26 Cable Clip A132W6047F 4 27 Pop Rivet brackets to boot bulkhead A089W6297F 3 Function Code 44 05 Page 2 ...

Page 266: ...45 01 1 3 6 2 15 14 6 13 8 4 5 7 11 10 9 11 10 9 12 16 18 17 ...

Page 267: ...A120S6000S 1 08 Exhaust Hanger catalyst mounting A132S6004F 1 09 Exhaust Hanger silencer mounting B138S0023F 2 10 Exhaust mounting A132S0171F 2 11 Bolt M8 x 20 hex flg hd strap to subframe A132W5005F 4 12 Nutplate M8 strap to subframe A132S0063F 2 13 Gasket downpipe to main catalytic converter pipe A132S0062F 1 14 Bolt RH manifold to downpipe A132E6362S 2 15 Nut LH manifold to downpipe A132E6504S ...

Page 268: ...05 3 4 2 1 5 6 8 9 16 17 35 14 19 25 10 11 12 20 21 22 23 28 27 26 29 31 24 21 33 34 33 34 32 7 24 27 15 37 19 34 20 20 20 18 33 35 41 35 40 39 41 36 32 42 13 43 44 30 32 32 32 30 30 Updated 1st July 2013 ...

Page 269: ...8S0015F 1 07 Heatshield Assembly bootbox front A138S0003F 1 08 Heatshield bootbox lower A138S0005F 1 09 Heatshield anti roll bar sleeve B132S0119F Also for gear cables 3 10 Insulation rear bulkhead A138U0008F 1 11 Heatshield bootbox front RH A138S0042F 1 12 Heatshield bootbox front LH A138S0043F 1 13 Heatshield Scoop bootbox lower A138S0040F 1 14 Heatshield rear cylinder head A138S0020F 1 15 Heats...

Page 270: ...ar engine mounting A117S0053F 1 27 Speed nut M6 A117W6715F 5 28 Screw M6 x 20 hex flg A132W5004F 1 29 Screw M6 x 12 hex flg A132W5010F 2 30 Spacer heatshield bootbox lower A138S0041F 4 31 Pop Rivet A138W6022F 8 32 Spacer heatshield bootbox front A138S0045F 4 33 Washer Flat 3 16 x 3 4 x 16 B075W4009Z 9 34 Nut M5 hex flg A138W3005F 12 35 Washer M6 x18 x 1 B082W4018F 11 36 Pop Rivet A111W6613F 4 37 C...

Page 271: ...Spacer A907E0696K 2 41 P Clip A132W6090F 4 42 Cable Tie gear cable heatshield A075W6038F 2 43 Heatshield exhaust manifold LH A132E6317S 1 44 Flange bolt washer exhaust manifold heatshield LH A132E6390S 3 RH heatshield supplied with manifold Function Code 45 05 Page 3 Updated 1st July 2013 ...

Page 272: ... 10 9 38 37 6 22 18 35 34 2 20 11 12 23 8 13 5 21 8 23 30 19 25 32 31 25 25 25 19 24 24 24 24 3 35 40 39 15 33 14 16 27 26 17 4 28 29 7 41 41 44 45 47 46 48 49 50 51 52 11 11 11 53 42 43 Updated 16th January 2013 ...

Page 273: ...38K0004F 1 08 Pipe Coolant Feed Return B116K0018F 2 09 Panel Radiator Shroud B138B0009F 1 10 Captive Nut M8 big hd housing to clamshell B111W6592F 2 11 Foam end seal A138B0110F Cut into 2 equal sections for rad end seal 3 12 Foam end seal LH A138B0108F Remove pre cut slots 1 13 Foam end seal RH A138B0109F Remove pre cut slots 1 14 Auxillary Radiator Assembly A138K0001F 1 15 Duct Assembly side cool...

Page 274: ...4 auxillary radiator A082W4165F 4 28 Compression Sleeve auxillary radiator A132K6006F 4 29 Bush auxillary radiator A132K6005F 4 30 Clip Speed Fix radiator shroud B100W6372F 3 31 Screw M5 x 16 radiator shroud A111W1163F 3 32 Washer Flat 3 16 x 3 4 x 16 radiator shroud B075W4009Z 3 33 Screw M6 x 20 hex flg side cooler bracket A132W5004F 2 34 Screw M6 x 16 hex hd bracket to radiator A075W1028Z 8 35 W...

Page 275: ...3009F 4 45 Washer flat 6 x 15 x 1 5 duct side cooler A075W4015Z 4 46 Nut Nyloc M6 thin fan A907E6285F 4 47 Washer flat 6 x 15 x 1 5 fan A075W4015F 4 48 Screw M8 x 20 hex flg side cooler bracket A132W5005F 2 49 Screw M5 x 16 hex s s side cooler bracket A111W1163F 2 50 Washer Flat 3 16 x 3 4 x16g side cooler bracket B075W4009Z 2 51 Speed Clip M5 side cooler bracket B100W6372F 2 52 Bracket Assembly A...

Page 276: ...46 02 7 5 8 4 16 23 20 21 22 29 28 2 8 13 23 18 17 15 12 11 9 29 28 7 1 27 26 3 7 6 14 10 24 25 9 19 Chassis pipe Chassis pipe See 42 01 30 34 35 33 32 31 32 31 36 Updated 4th April 2013 ...

Page 277: ...27mm heater feed return hoses A116K6016F 3 09 Hose Clamp 17 7mm hose to header tank A120W6739F 2 10 Tank Assembly reserve radiator pressure system A132E6312S 1 11 Bracket Assembly Header Tank Left A138K0021F 1 12 Bracket Assembly Header Tank Right A138K0022F 1 13 Screw M8 x 20 hex flg hd header tank to bracket A132W5005F 2 14 Cap header tank 108kPa A120E6341S 1 15 Water Outlet A132E6257S 1 16 Gask...

Page 278: ...A132E6271S 4 24 Hose Clip water by pass No 1 A132E6270S 2 25 O Ring water inlet pipe to water inlet housing A132E6273S 1 26 O Ring water outlet housing to by pass pipe A132E6272S 1 27 Bolt hex flg hd water inlet pipe retention A132E6471S 2 28 Clamp Hose 40mm A116K6015F 2 29 Clamp Hose 44mm A116K6014F 2 30 Bolt M8 x 16 hex flg header tank bracket A132W5013F 2 31 Blanking Cap A132E0080F 2 32 Clip A1...

Page 279: ...46 07 1 15 16 35 36 9 19 18 17 21 20 22 6 3 11 12 13 7 8 5 4 14 37 23 10 28 23 29 25 27 26 32 30 34 33 24 2 31 38 Updated 31st May 2013 ...

Page 280: ...0031F 1 07 Hose Assembly Feed oil cooler A138K0035F 1 08 Hose Assembly Feed Rear oil cooler B138K0032F 1 09 Duct Assembly Side Cooler A138B4008J 1 10 Sandwich Plate Assemby with thermostat B120K6001F 1 11 Cap sandwich plate A132E0068F 1 12 O Ring sandwich plate outer A132E0070F 1 13 O Ring sandwich plate inner A132E0071F 1 14 Edge Clip oil cooler hose A126W6896F 2 15 Compression Sleeve oil cooler ...

Page 281: ...embly to housing A132E6087H 1 27 Screw hex flg hd housing to block A132E6081H 2 28 Stud housing to block A132E6082H 1 29 Nut flange housing to block A132E6474S 1 30 Nut flange hose assembly to housing A132E6474S 3 31 Stud hose assembly to housing A132E6116S 2 32 Bolt M8 x 25 hex flg hd hose assembly to housing A132W5006F 1 33 Bolt M8 x 25 hex flg hd hose assembly to sump A132W5006F 1 34 Nut flange...

Page 282: ...47 01 22 1 2 3 4 9 10 7 21 8 16 20 17 19 18 15 13 12 6 25 27 5 26 23 29 30 24 11 31 32 14 28 33 34 Updated 1st July 2013 ...

Page 283: ...Q0005F 1 06 Clutch Pipe Assembly rear damper to slave cylinder A132Q0022F 1 07 Bracket clutch hose to chassis B120Q0005F 1 08 Slave Cylinder clutch A132Q6010S 1 09 Boot slave cylinder A120Q6013S 1 10 Clutch Driven Plate A132F0139F 1 11 Clutch Cover A132F0116F 1 12 Clutch Release Bearing A132Q6007S 1 13 Clip clutch release bearing A132Q6008S 1 14 Clutch Release Fork A132Q6006S 1 15 Support Pivot cl...

Page 284: ...2 25 Damper clutch actuation A132Q0021F 1 26 Bracket damper mounting A132Q0024F 1 27 Bolt M6 x 12 hex flg hd damper to bracket A132W5010F 2 28 Screw M8 x 20 hex flg hd bracket to chassis A132W5005F 3 29 Bolt M8 x 25 hex flg A132W5006F 2 30 Hose Clutch Reservoir LHD A138Q0009F 1 30a Hose Clutch Reservoir RHD A138Q0035F 1 31 Bracket slave cylinder A120Q6016S 1 32 Adaptor clutch release bearing A132F...

Page 285: ...11 17 10 3 12 16 14 17 15 6 5 14 13 23 47 03 1 18 2 8 9 22 7 20 21 24 19 27 4 31 28 25 29 30 26 ...

Page 286: ...ing lower A132E6300S 1 06 Bolt hex flg hd cover fixing A132E6390S 2 07 Magnet swarf attraction A132F6098S 1 08 Pipe oil receiver A132F6046S 1 09 Separator transmission oil A132F6048S 1 10 Separator transmission oil A132F6049S 1 11 Cover speedometer drive hole A132E6334S Includes O ring 1 12 Drain Plug A120F6041S 1 13 Filler Plug A131F6053S 1 14 Washer plug sealing A132F6170S 2 15 Plug transmission...

Page 287: ...saxle casing A120E6196S 1 25 Bolt M12 x 50 hex flg hd transmission to engine A132F6020H 2 26 Bolt M12 x 40 hex flg hd plate to engine A132F6024H 3 27 Bolt M12 x 80 hex flg hd transmission to engine A132F6031H 2 28 Bolt M10 x 70 hex flg hd engine to transmission A132E6266S 1 29 Bolt M12 x 90 hex flg hd transmission to engine A132E6360S 1 30 Bolt M10 x 60 hex flg hd engine to transmission A132E6381S...

Page 288: ...47 05 3 26 26 22 24 11 19 16 18 17 10 14 1 5 8 9 7 4 6 13 12 20 21 2 25 23 23 15 28 27 30 29 31 32 Updated 1st August 2013 ...

Page 289: ...g hd assy to chassis A116W5235F 2 05 Screw M8 x 45 skt cap hd assy to chassis A111W7137F 1 06 Spacer gearshift asm chassis A120F0015F 1 07 Washer M8 x 25 x1 5 B075W4021F 1 08 Gear Knob 6 speed D120U0012F 1 09 Lift Tube reverse select round lever B120U0017F 1 10 Abutment cables to transmission A132F6103S 1 11 Screw hex flg hd abutment to transmission A120F6040S 3 12 Retainer gearshift cables A138F0...

Page 290: ...cables A132F0207F 4 23 Washer Gear Cables A132F0208F 4 24 Nut M6 x 1 5 gearshift cables A132F0209F 2 25 Nut Tube M6 x 1 5 gearshift cables A132F0210F 2 26 R Clip cables to levers A075W6175F 2 27 Cable Connector cable to transmision A132F6307S 2 28 Grub Screw lift tube retention A120F0028S 1 29 Guide cables to subframe A138F0028F 1 30 Screw M6 x 12 skt btn hd guide to subframe A126W7226F 1 31 Grub ...

Page 291: ...31 28 48 35 47 1 26 9 35 3 15 33 27 8 40 35 39 13 32 2 10 24 35 28 14 11 6 17 16 23 22 12 35 36 35 30 28 47 06 33 34 44 43 38 45 7 4 41 5 42 18 19 37 21 45 44 43 38 44 43 38 45 46 ...

Page 292: ...hift no 3 A132F6055S 1 07 Head gearshift no 2 A132F6056S 1 08 Head gearshift no 3 A132F6057S 1 09 Shaft selector fork no 1 A132F6058S 1 10 Shaft selector fork no 2 A132F6059S 1 11 Shaft selector fork no 3 A132F6060S 1 12 Shaft selector fork no 4 A132F6061S 1 13 Shaft selector fork no 5 A132F6062S 1 14 Shift Lever inner no 1 A132F6063S 1 15 Shaft shift and select lever A132F6064S 1 16 Plate shift i...

Page 293: ...32F6104S 1 27 Boot shift lever A132F6105S 1 28 Bolt hex flg hd fork to shaft A132F6133S 3 30 Bolt hex flg hd plate retention A132F6134S 2 31 Bolt hex flg hd damper to lever A132F6138S 2 31a Bolt hex M8 x 35 damper mass to lever A075W2038F 2 32 Dowel Pin cover to casing A132F6141S 1 33 Pin slotted spring head to shaft A132F6142S 2 34 Oil Seal cover assembly A132F6143S 2 35 Bearing selector shaft A1...

Page 294: ...E Clip shift arm pivot A132F6255S 1 42 O Ring A132F6256S 1 43 Spring Seat shift detent A120F6162S 4 44 Plug shift detent assy A120F6163S 4 45 Detent Ball A120F6164S 4 46 Pin slotted spring fork to shaft A120F6184S 2 47 Mass gear selector A132F0112F 3 48 Washer 8 x 16 6 damper mass to lever A075W4020Z 2 Function Code 47 06 Page 3 Updated 21st November 2012 ...

Page 295: ...5 23 9 36 25 26 5 21 44 14 20 62 67 2 6 24 5 63 72 22 60 73 1 53 37 65 58 60 45 8 7 48 11 71 16 55 15 18 38 64 58 43 13 27 12 31 29 19 67 54 74 3 28 32 53 30 28 60 75 4 47 68 58 34 41 35 33 36 25 26 36 25 26 Updated 21st November 2012 ...

Page 296: ...Set no 1 A132F6043S 3 06 Synchro Ring Set no 4 A132F6044S 1 07 Cover output shaft A132F6047S 1 08 Input Shaft A132F6073S 1 09 Output Shaft no 1 A132F6074S 1 10 Output Shaft no 2 A132F6075S 1 11 Plate bearing lock A132F6076S 2 12 Sleeve synchro hub no 4 A132F6077S 1 13 Reverse Gear A132F6078S 1 14 2nd Gear A132F6079S 1 15 3rd Gear B132F0046F 1 Sports Ratio G box 16 4th 5th Gear B132F0160F 1 Sports ...

Page 297: ... no 1 A132F6091S 9 27 Synchromesh Ring no 4 A132F6092S 1 28 Synchromesh Ring Outer no 4 A132F6093S 1 29 Spring synchromesh shifting key no 3 A132F6094S 1 30 Synchro Hub no 3 A132F6095S 1 31 Key synchromesh shifting no 3 A132F6096S 1 32 Sleeve synchro hub no 3 A132F6097S 1 33 Shaft reverse idler gear A132F6099S 1 34 Reverse Idler Gear A132F6100S 1 35 Thrust Washer reverse idler gear A132F6101S 1 36...

Page 298: ...S 1 47 Bearing tapered roller A132F6160S 1 48 Bearing tapered roller A132F6161S 1 49 Bearing tapered roller A132F6162S 1 50 Bearing tapered roller A132F6163S 1 51 Bearing A132F6164S 1 52 Bearing A132F6165S 1 53 Collar A132F6166S 2 54 Collar A132F6167S 1 55 Collar 3rd gear A132F0047F 1 Sports Ratio G box 56 Collar A132F6169S 1 57 Snap Ring bearing to shaft A132F6173S 1 58 Snap Ring bearing to shaft...

Page 299: ...ap Ring bearing to shaft 3 2 20mm A132F6185S 3 59d Snap Ring bearing to shaft 4 2 25mm A132F6186S 3 59e Snap Ring bearing to shaft 5 2 30mm A132F6187S 3 59f Snap Ring bearing to shaft 6 2 35mm A132F6188S 3 60 Snap Ring bearing to shaft 1 2 25mm A132F6189S 2 60a Snap Ring bearing to shaft 1 2 30mm A132F6190S 2 60b Snap Ring bearing to shaft 1 2 35mm A132F6191S 2 60c Snap Ring bearing to shaft 1 2 4...

Page 300: ...F6205S 1 63b Snap Ring bearing to shaft C 2 35mm A132F6206S 1 63c Snap Ring bearing to shaft D 2 40mm A132F6207S 1 63d Snap Ring bearing to shaft E 2 45mm A132F6208S 1 63e Snap Ring bearing to shaft F 2 50mm A132F6209S 1 63f Snap Ring bearing to shaft G 2 55mm A132F6210S 1 63g Snap Ring bearing to shaft H 2 60mm A132F6211S 1 64 Snap Ring bearing to shaft A132F6212S 1 65 Snap Ring bearing to shaft ...

Page 301: ...t L 2 30mm A132F6226S 1 68k Snap Ring bearing to shaft M 2 35mm A132F6227S 1 68l Snap Ring bearing to shaft N 2 40mm A132F6228S 1 68m Snap Ring bearing to shaft P 2 45mm A132F6229S 1 68n Snap Ring bearing to shaft Q 2 50mm A132F6230S 1 68o Snap Ring bearing to shaft R 2 55mm A132F6231S 1 68p Snap Ring bearing to shaft S 2 60mm A132F6232S 1 68q Snap Ring bearing to shaft T 2 65mm A132F6233S 1 69 Sc...

Page 302: ...Dep Part Description Part Number Remarks Qty Function Code 47 07 Gears Shafts Bearings Option 75 Bearing needle roller A132F6153S 1 Function Code 47 07 Page 7 Updated 21st November 2012 ...

Page 303: ...11 13 10 8 6 4 7 3 1 3 5 7 4 9 2 6 14 12 47 11 ...

Page 304: ...fferential side gear 1 40mm A132F6118S 2 07c Thrust Washer differential side gear 1 45mm A132F6119S 2 07d Thrust Washer differential side gear 1 50mm A132F6120S 2 07e Thrust Washer differential side gear 1 55mm A132F6121S 2 07f Thrust Washer differential side gear 1 60mm A132F6122S 2 07g Thrust Washer differential side gear 1 65mm A132F6123S 2 07h Thrust Washer differential side gear 1 70mm A132F6...

Page 305: ...7S 1 09d Shim bearing to housing 4 2 20mm A132F6238S 1 09e Shim bearing to housing 5 2 25mm A132F6239S 1 09f Shim bearing to housing 6 2 30mm A132F6240S 1 09g Shim bearing to housing 7 2 35mm A132F6241S 1 09h Shim bearing to housing 8 2 40mm A132F6242S 1 09i Shim bearing to housing 9 2 45mm A132F6243S 1 10 Pin gear to casing A120F6216S 1 11 Oil Seal output RH A132F6145S Also see 47 15 1 12 Oil Sea...

Page 306: ...6 7 9 10 2 15 8 4 11 13 3 14 8 1 12 7 5 47 15 16 17 Updated 21st November 2012 ...

Page 307: ...nt kit outer RH Includes shaft gaiters clips and grease 1 07 Gaiter Kit outboard A132D6007S Includes clips and grease 2 08 Gaiter Kit inboard A132D6008S Includes clips snap ring grease 2 09 Bracket intermediate drive shaft manual A132F0008F 1 10 Bolt flg hd bracket to block A132E6062H 3 11 Bolt M10 x 50 hex hd bracket to shaft A132W2045F 2 12 Locknut M24 flange driveshaft to hub A132F6029F 2 13 Oi...

Page 308: ...60 01 3 4 1 2 ...

Page 309: ...t Number Remarks Qty Function Code 60 01 Tool Kit Option 01 Tool Kit Complete A138T0002J 1 02 Adaptor Key A117G0036F 1 03 Allen Key 5 x 160mm A117T6001H 1 04 Wrench T Bar torx 25 x 100mm A138T6000F 1 Function Code 60 01 Page 1 ...

Page 310: ...2PLWHF 7HFKFHQWUH QVWDOODWLRQ LVF 3DUW 1R 7 7 1 2 60 01a 3 ...

Page 311: ... 01 Techcentre Installation Disc T000T1510F 1 02 Kit Vehicle Communication Device T000T1472F Includes leads yellow 2x USB and case 1 03 Lead Programming communications yellow T000T1497F 1 04 Lead Vehicle Communication Device VCD to PC T000T1537F Not illustrated 1 Function Code 60 01a Page 1 Updated 4th April 2013 ...

Page 312: ...60 02 Not Illustrated ...

Page 313: ...S 1 03 Flange bolt engine hanger A132E6184S 4 04 Oil Filter Wrench T000T1441F 1 05 Clutch Tool T000T1524F For use when fitting clutch to flywheel 1 06 Fuel Pipe Release Tool T000T1450F 1 07 Fuel Gauge Kit T000T1451F 1 08 Fuel Measure Set T000T1452F 1 09 Fuel Tube Connector T000T1453F 1 10 Fuel Tank Connector T000T1454F 1 Function Code 60 02 Page 1 ...

Page 314: ...80 20a ...

Page 315: ...82B6408F 1 105 B105 Nightfall Blue A082B6415F 1 111 B111 Motorsport Black A120B6045S 1 113 B113 Aspen White A120B6028S 1 114 B114 Solar Yellow A120B6029S 1 119 B119 Racing Green A120B6034S 1 120 B120 Laser Blue A120B6035S 1 130 B130 Arctic Silver A120B6050S 1 137 B137 Carbon Grey A120B6062S 1 149 C149 Velvet Red A120B6087S 1 151 C151 Sienna Brown A120B6088S 1 158 C158 Military Grey 1 161 C161 Pear...

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