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Service Manual 2011

MG6

Version 2.0

This manual provides information on the specifications, the system introduction, the service procedures and the

adjustments for the 2011 series MG6 Vehicle.

The technicians, worked for the servicing station authorized by MG Motor, can provide better service for the owners of

MG6 vehicle based on a profound understanding this manual and related updated Service Bulletins.

You are suggested that please contact MG Motor. if you want to obtain related information mentioned in this manual

about the brand, the parts number, and special tools etc.

MG Motor.

Copy Right Reserved

All information received cutoff date is August 2011

Any information contained in this manual are the property of the MG Motor. No part of this manual may be copied,

stored in any retrieval system, or spread by any means (including but not limited in electronic, mechanical, photocopying

and recording) without written MG Motor authorization. This applies to all text, illustrations, and tables (not limited in

above) mentioned in this manual.

Summary of Contents for MG6 Series 2011

Page 1: ...gested that please contact MG Motor if you want to obtain related information mentioned in this manual about the brand the parts number and special tools etc MG Motor Copy Right Reserved All information received cutoff date is August 2011 Any information contained in this manual are the property of the MG Motor No part of this manual may be copied stored in any retrieval system or spread by any me...

Page 2: ......

Page 3: ...ge to any systems or components which are dependent upon the proper operation of the system or component under repair Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair Damage to fasteners basic tools or special tools The leakage of coolant lubricant or other vital fluids NOTE statement...

Page 4: ... terms of the vehicle warranty may be invalidated by the fitting of parts other than SMC recommended parts All SMC recommended parts have the full backing of the vehicle warranty SMC Dealers are obliged to supply only SMC recommended parts Special tools Special tools have been developed to facilitate removal dismantling and assembly of mechanical components in a cost effective and time efficient m...

Page 5: ...ed 61 Connecting Rod Bearings Overhaul 65 Pistons Liners 67 Crankshaft Rear Oil Seal 70 Crankshaft Front Oil Seal 71 Flywheel Manual Transmission 72 Torque Converter Drive Plate Automatic Transmission 72 Cylinder Head Gasket Overhaul with Engine Removed 73 Camshaft Cover Gasket 77 Valves 78 Hydraulic Tappets 82 Camshafts Inlet or Exhaust 82 Intake Manifold Gasket 84 Exhaust Manifold Gasket 86 Oil ...

Page 6: ... 8VCT Engine and Manual Transmission 196 1 8VCT Engine and Automatic Transmission 200 1 8VCT Solenoid Exhaust Camshaft 205 1 8VCT Solenoid Inlet Camshaft 205 1 8VCT Solenoid Housing Exhaust Camshaft 206 1 8VCT Solenoid Housing Inlet Camshaft 206 1 8VCT Cylinder Head GasketNew 207 Special Tools 210 Engine Cooling System 213 Specifications 213 Torque 213 Reference 214 Description and Operation 215 S...

Page 7: ...TMAP 319 Sensor manifold absolute pressure MAP 320 Sensor Knock KS 320 Sensor Heated Oxygen HO2S Front Turbocharger 321 Sensor Heated Oxygen H02S Rear Turbocharger 321 Solenoid Boost Control Turbocharger 322 Fuel Rail 322 Injectors 323 Charcoal Canister 324 Purge Control Valve 324 Pipe Assembly Body Underfloor Fuel Lines 325 Tank Fuel 326 Fuel Pump 328 Fuel System Depressurise 329 Fuel System Pres...

Page 8: ...ion and Operation 402 System Component Layout 402 Description 409 Operation 410 Service Procedures 411 Oil Seal Gear Change Rod 411 Lubrication System Drain Refill 412 Manual Transmission Assembly 412 Lamp Switch Reverse 416 Cover Reverse Access Reseal 416 Lubrication System Manual Transmission Top up 417 Oil Seal Differential LH 417 Oil Seal Differential RH 418 Manual Transmission Dismantling 418...

Page 9: ...Procedures 507 Control Assembly 507 Evaporator Temperature Sensor 508 Solar Light Sensor 508 Ambient Temperature Sensor ATC 509 Left Blend Flap Servo Motor 509 Heater Coolant Temperature Sensor 510 Right Blend Flap Servo Motor 510 Fresh Recirculated Air Flap Servo Motor 511 Distribution Flap Servo Mmotor 511 Steering System 513 Front Wheel Steering 513 Specifications 513 Torque 513 Specifications ...

Page 10: ...Anti Roll Bar Rear 583 Rubbers Anti Roll Bar 583 Link Anti Roll Bar 584 Hub Bearing Rear 584 Special Tools 586 Tyres and Wheels 587 Specifications 587 Torque 587 Specifications 588 Service Procedures 589 Wheel 589 Brake System 591 Brake 591 Specifications 591 Torque 591 Description and Operation 592 System Component Layout 592 Description 598 Operation 602 Service Procedures 608 Brake Pad Front 60...

Page 11: ...2 Torque 662 Description and Operation 663 System Component Layout 663 System Control Diagram 666 Description 667 Operation 669 Service Procedures 671 Seat Complete Passenger 671 Squab Foam Passenger Front 672 Cover Passenger Squab Front 672 Cushion Rear Seat 674 Cover Cushion Rear Seat 674 Squab Rear Seat 675 Cover Squab Rear Seat 675 Striker Squab Rear Seat 676 Side Board Outer Power Seat 677 Lu...

Page 12: ...res 718 Mirror Exterior Electric 718 Mirror Interior Dipping 718 Roof 719 Specifications 719 Torque 719 Description and Operation 720 System Component Layout 720 System Control System 721 Description 722 Operation 723 Service Procedures 724 Sun sliding Roof Assembly 724 Glass Panel Sun Sliding Roof 724 Sunshade Assembly Sun Sliding Roof 725 Wipers and Washer 726 Specifications 726 Torque 726 Descr...

Page 13: ...r 782 Rubber Felt Glass Channel Rear Door Each 783 Seal Waist Inner Rear Door Each 783 Seal Waist Outer Rear Door Each 784 Glass Glass Cassette Unit Rear Door Adjust 784 Glass Rear Door Each 785 Switch Electric Window Lift Rear Door Each 786 Motor and Control Unit Rear Door Each 787 Release Handle Interior Rear Door Each 788 Trim Casing Front Door 788 Trim Casing Rear Door 789 Switch Pack Electric...

Page 14: ...ption and Operation 837 General Welding Precautions 837 Body Sealing 842 Corrosion Prevention 862 Diagnostic 868 Water Leaks 868 Service Procedures 869 Front End Panel 870 Door Panel 872 Rear Floor Panel 873 Roof Panel 874 Bodyside Panel 876 Front Floor Panel 878 Wheel Arch Panel 879 Safety and Restraints 881 Vehicle Access 881 Description and Operation 881 Alarm and Locking System Component Layou...

Page 15: ...TAINMENT ICE Operation 921 Navigation System Component Layout 922 Navigation System Control Diagram 923 Navigation System Description 924 Navigation System Operation 926 Service Procedures 927 Woofer Rear Door 927 Woofer Front Door 927 Speaker Tweeter Front 928 Displays and Gages 929 Description and Operation 929 System Component Layout 929 System Control Diagram 931 Description 932 Operation 941 ...

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Page 17: ...ustrial gloves protective apron etc Decontaminate and dispose of gloves immediately after use Lubricating Oils Avoid excessive skin contact with used lubricating oils and always adhere to the health protection precautions Warning Avoid excessive skin contact with used engine oil Used engine oil contains potentially harmful contaminants which may cause skin cancer or other serious skin disorders Wa...

Page 18: ...twisted Ensure that hoses run in a natural curve and are not kinked or twisted Fit brake pipes securely in their retaining clips and ensure that the pipe cannot contact a potential chafing point Containers used for brake fluid must be kept absolutely clean Do not store brake fluid in an unsealed container it will absorb water and in this condition would be dangerous to use due to a lowering of its...

Page 19: ...ing refrigerants Don t burn rubbish on site Discharges to Water Oil petrol solvent acids hydraulic oil antifreeze and other such substances should never be poured down the drain and every precaution must be taken to prevent spillage reaching the drains Handling of such materials must take place well away from the drains and preferably in an area with a kerb or wall around it to prevent discharge i...

Page 20: ... into different types of waste e g oil metals batteries used vehicle components This will prevent any reaction between different materials and assist in disposal Disposal of Waste Disposal of waste materials must only be to waste carriers who are authorised to carry those particular waste materials and have all the necessary documentation The waste carrier is responsible for ensuring that the wast...

Page 21: ...her mating parts where necessary to prevent accidental interchange e g roller bearing components Attach labels to all parts which are to be renewed and to parts requiring further inspection before being passed for reassembly place these parts in separate containers from those containing parts for rebuild Do not discard a part due for renewal until after comparing it with a new part to ensure that ...

Page 22: ...ure that shaft and housing are clean and free from burrs before fitting bearing If one bearing of a pair shows an imperfection it is advisable to replace both with new bearings an exception could be if the faulty bearing had covered a low mileage and it can be established that damage is confined to only one bearing Never refit a ball or roller bearing without first ensuring that it is in a fully s...

Page 23: ...ds fluid to be sealed and slide into position on shaft Use fitting sleeve where possible to protect sealing lip from damage by sharp corners threads or splines If a fitting sleeve is not available use plastic tube or tape to prevent damage to the sealing lip Grease outside diameter of seal place square to housing recess and press into position using great care and if possible a bell piece to ensur...

Page 24: ...ssed air Locking Devices General Always replace locking devices with one of the same design Tab Washers Always release locking tabs and fit new locking washers Do not re use locking tabs Locking Nuts Always use a backing spanner when loosening or tightening locking nuts brake and fuel pipe unions Roll Pins Always fit new roll pins of an interference fit in the hole Circlips Always fit new circlips...

Page 25: ...h sealant lubricant and selflocking nuts Fasteners Identification Bolt Identification An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols ISO M or M embossed or indented on top of the bolt head In addition to marks identifying the manufacturer the top of the bolt head is also marked with symbols indicating the strength grade e g 8 8...

Page 26: ...ications where a self locking nut bolt or screw is specified Nut Identification A A nut with an ISO metric thread is marked on one face or on one of the flats of the hexagon with the strength grade symbol 8 12 or 14 Some nuts with a strength grade 4 5 or 6 are also marked and some have the metric symbol M on the flat opposite the strength grade marking When tightening a slotted or castellated nut ...

Page 27: ...ning has not become separated from the armoured outer sleeve A new hose must be fitted if separation is evident Cooling System Hoses The following precautions MUST be followed to ensure that integrity of cooling hoses and their connections to system components are maintained Hose Orientation and Connection Correct orientation of cooling hoses is important in ensuring that the hose does not become ...

Page 28: ...rained or stored or when fuel systems are being dismantled all forms of ignition must be extinguished or removed any lead lamps must be flameproof and kept clear of spillage Warning No one should be permitted to repair components associated with fuel without first having specialist training Warning Do not remove fuel system components while the vehicle is over a pit Fuel Tank Draining Fuel tank dr...

Page 29: ...mains operated equipment Polarity Never reverse connect the vehicle battery and always ensure the correct polarity when connecting test equipment High Voltage Circuits Whenever disconnecting live HT circuits always use insulated pliers and never allow the open end of the HT lead to contact other components particularly ECUs Exercise caution when measuring the voltage on the coil terminals while th...

Page 30: ...recautions The SRS system contains components which could be potentially hazardous to the service engineer if not serviced and handled correctly The following guidelines are intended to alert the service engineer to potential sources of danger and emphasise the importance of ensuring the integrity ofSRS components fitted to the vehicle Warning Always follow the SRS Precautions and the correct proc...

Page 31: ...arts without a clear identificationSRS label Never use an airbag orSRS ECU that has been dropped When repairing an SRS system only useSRS genuine new parts Never apply electrical power to an SRS component unless instructed to doSRS so as part of an approved test procedure Ensure the bolts are tightened to the correct torque Always use new fixingsSRS when replacing SRS components Ensure the ECU is ...

Page 32: ...ppermost and the base away from your body Never transport airbag modules or seat belt pre tensioners in the cabin of a vehicle Warning Never attach anything to an airbag cover or any trim componentcovering an airbag module Do not allow anything to rest on top of an airbag module Caution Do not apply grease or cleaning solvents to seat belt pretensioner units component failure could result Warning ...

Page 33: ...ag modules ECU SRS system wiring harness and connectors SRSECU andSRS system wiring harness and connectors If the airbag and seat belt pre tensioner are deployed during an accident SRSECU must be replaced and discarded Every SRS system on every carSRS has been paired and identified SRS illegally adding or modifying the SRS system and the wiring harness could injure people Modifying the vehicle str...

Page 34: ...are critically related to SRS operation The code number s must be recorded if the component is to be replaced Components featuring bar codes include the following Driver s front airbag module label attached to rear of module housing Passenger front airbag module label attached at side of module housing SRSECU IncludedSRSECU on label on top of ECU Rotary coupler several labels on front face Vehicle...

Page 35: ...liance with the following precautions MUST be ensured Only use deployment equipment approved for the intended purpose Before commencing deployment procedure ensure the deployment tool functions properly Deployment of airbag pre tensioner modules should be performed in a well ventilated area which has been designated for the purpose Ensure airbag pre tensioner modules are not damaged or ruptured be...

Page 36: ... which the deployment occurred Seat thorax airbag module Seat squab foam Seat squab cover Front seat belt buckle pre tensioners SRS ECU Side impact crash sensors both sides of vehicle In addition the following should be inspected for damage and replaced as necessary Front seat belts retractors webbing tongue latching D loop and body anchorage points Rear seat belt buckles webbing buckle covers ton...

Page 37: ...system is HFC 134a Hydrofluorocarbon R134a Warning Servicing must only be carried out by personnel familiar with both the vehicle system and the charging and testing equipment All operations must be carried out in a well ventilated area away from open flame and heat sources Warning R134a is a hazardous liquid and when handled incorrectly can cause serious injury Suitable protective clothing consis...

Page 38: ...ponent connected to the system to ensure optimum dehydration and maximum moisture protection of the system Whenever the refrigerant system is opened the receiver drier must be renewed immediately before evacuating and recharging the system Use alcohol and a clean lint free cloth to clean dirty connections Ensure that all new parts fitted are marked for use with R134a Refrigerant Oil Refrigerant oi...

Page 39: ... be added carry out the following procedure 1 Remove the filler drain plug from the old compressor 2 Invert the compressor and gravity drain the oil into a calibrated measuring cylinder Rotate the compressor clutch to ensure the compressor is completely drained 3 Record the quantity of oil drained discard the oil 4 Remove the filler drain plug from the new compressor 5 Invert the compressor and gr...

Page 40: ...X A Model year A 2010 S Assembly plant S Shanghai Lingang China XXXXXX 6 figures Serial number TheVIN is stamped in the following location On a plate behind the LH lower corner of the windshield On top of RH suspension turret Vehicle Identification Plate The VIN plate is located on the outer B post on the LH side The VIN plate contains the following information 1 Model identifier 2 Number of occup...

Page 41: ...ne Number Stamped on the rear LH side of the cylinder block Automatic Gearbox Number Stamped on the upper RH side of the gearbox casing Manual Gearbox Number A label is attached on the LH side of the gearbox casing Body Number Stamped onto the body around the suspension turret Version 2 0 25 ...

Page 42: ...ad of the jack must fit into the corresponding recess in the sill plate Warning Do not work on or under a vehicle supported only by a jack Always support the vehicle on safety stands Hydraulic Jack A hydraulic jack with a minimum 1500 kg 3300 lb load capacity must be used Warning Do not commence work on the underside of the vehicle until suitable safety supports have been positioned under the sill...

Page 43: ...tool box and should be returned to the tool box after use To fit the towing eye first remove the plug set into the RH side of the front bumper and then screw the towing eye into its mounting behind the bumper plug bumper armature Rear Towing Eye Saloon The removable rear towing eye must only be used for towing light vehicles On manual transmission vehicles the towing point can also be used for a r...

Page 44: ...ly Automatic Transmission Ideally cars fitted with an automatic gearbox should only be recovered using a trailer transporter or using a front suspended tow front wheels raised Caution A rear suspended tow must not be used for vehicles with an automatic transmission as serious damage will be caused to the transmission When a car with automatic gearbox is to be towed on four wheels from the front th...

Page 45: ...Do not top up or refill cooling system with any other type of antifreeze In an emergency if this type of antifreeze is not available top up the cooling system with clean water only but be aware of the resultant reduction in frost protection The correct antifreeze concentration must be restored as soon as possible The cooling system should be drained flushed and refilled with the correct amount of ...

Page 46: ...ich can block the oil ways Additional oil additives should not be used Always adhere to the recommended servicing intervals Engine Oil Use a 5w 40 oil meeting specification ACEA A3 B3 Engine oil viscosity temperature range chart Ambient temperature range Transmission Oil Use of transmission oils other than those specified may result in serious damage to the transmission Manual Transmission Use Tex...

Page 47: ...ing panel to gearbox block 22 28Nm Bolt cylinder head to cylinder block 20Nm 180 135 Bolt Alternator upper bracket to cylinder head 22 28Nm Stud Alternator upper bracket to cylinder head 8 11Nm Bolt Alternator heat shield to alternator bracket 25Nm Bolt compressor to compressor mounting bracket 22 28Nm Bolt Alternator to alternator lower bracket 40 50Nm Screw drive belt rear upper cover to coolant...

Page 48: ...BAY ERTH to TRSM 85Nm Nut Battery lead to starter motor 6 10Nm Bolt air dust installation bracket to body 45Nm Bolt transmission LH hydraulic mounting to body 50 65Nm Bolt engine mounting lower tie rod to subframe 50 65Nm Nut transmission LH mounting bracket to transmission LH hydraulic mounting 90 110Nm Nut selector arm to neutral start switch 25Nm Nut exhaust manifold to turbocharger 28 32Nm Bol...

Page 49: ...ndary resistance typical 10 2 2kΩ 20 C Fuel injection system Type Return less system MFI system controlled by ECM Controller SIEMENS 3 breakerless electronic full mapped engine management system Injector 4 DEKA 7 l Operation pressure 3 8 bar Injector static flow rate 229 8 g min Injector dynamic flow rate 8 675 mg pulse 2 5 ms 20 ms Valve operation Self adjusting lightweight hydraulic tappets oper...

Page 50: ...erance l Grade A 48 000 48 007 mm l Grade B 47 993 48 000 mm l Grade C 47 986 47 993 mm Main bearings Quantity 5 Type Steel backed aluminium tin lined No 2 3 and 4 journal upper halves shells are oil grooved No 1 and 5 upper and lower halves shells are plain Clearance in bearings 0 013 0 043 mm Thrust washers Two halves on the left and right at the third main bearing sticks to the thrust surface T...

Page 51: ...mpression ring 0 030 0 062 mm l Oil control ring 0 010 0 180 mm Piston ring fitted gap 20 mm from top of bore l Top compression ring 0 20 0 35 mm l 2nd compression ring 0 28 0 48 mm l Oil control ring segment 0 15 0 40 mm Piston ring width l Top compression ring 0 978 0 990 mm l 2nd compression ring 1 178 1 190 mm l Oil control ring 1 850 2 000 mm Camshaft Type DOHC acting directly on tappets inco...

Page 52: ...Max lift 8 8 mm Valve max lift l Inlet valves 8 8 mm l Exhaust valves 8 8 mm Valves Stem diameter l Inlet valves 5 952 5 967 mm l Exhaust valves 5 947 5 962 mm Stem to guide clearance l Inlet valves 0 033 0 073 mm l Exhaust valves 0 038 0 078 mm Valve stem fitted height l New 38 93 39 84 mm l Service limit 40 10 mm Valve stem diameter fitted height 6 00 mm Valve head diameter l Inlet valves 27 6 2...

Page 53: ...f valve spring free length 41 5 1mm Oil filter Full flow disposable screw on canister Pressure at 3500 rev min 4 4 2 bar Limit valve open pressure 5 4 6 5 bar Oil pressure switch open pressure 0 20 0 58 bar Sensor Crankshaft sensor Siemens VDO Hall effect acting on profiled on flywheel Camshaft sensor l Make Type Siemens VDO Hall effect acting on camshaft reluctor ring Oxygen sensor l Make Type UA...

Page 54: ... table 1 2 3 4 5 Cylinder block Plain With grooved With grooved With grooved Plain Bearing ladder Plain Plain Plain Plain Plain Connecting rod bearing group selection table Connecting rod big end journal group Connecting rod big end bearing bore group Grade A Grade B Grade C Grade 5 Blue Blue Red Blue Red Red Grade 6 Blue Yellow Blue Blue Red Blue Grade 7 Yellow Yellow Blue Yellow Blue Blue 1 Cran...

Page 55: ...Engine Mechanical 1 8T Engine Description and Operation Engine Component Layout K4 Engine Component Layout K4 engine general viewturbocharger engine Version 2 0 39 ...

Page 56: ...Engine Engine Mechanical 1 8T S102001 K4 engine internal viewturbocharger engine Version 2 0 40 ...

Page 57: ...ng to coolant pump 2 Thermostat housing 3 Screw thermostat housing to cylinder block 4 Thermostat seal 5 Thermostat cover 6 O ring thermostat cover to coolant pipe 7 Bolt connecting rod 8 Big end bearing cap 9 Big end bearing shell upper 10 Big end bearing shell lower Version 2 0 41 ...

Page 58: ...her vent screw to coolant pipe 19 Coolant pipe 20 Bolts coolant pipe to cylinder block 21 Cylinder head gasket 22 Bolts cover to housing 23 Cylinder block 24 O ring coolant pump to cylinder block 25 Bolt coolant pump to cylinder block 26 Screws coolant pump to cylinder block 27 Coolant pump 28 Dowels coolant pump to cylinder block 29 Dowels cylinder block to cylinder head Version 2 0 42 ...

Page 59: ...Oil Pump Pump Pump Assembly Assembly Assembly 1 Oil pump assembly 2 Gasket oil pump 3 Crankshaft 4 Thrust washers 2 off at No 3 main bearing 5 Main bearing shells upper 5 off plain in No 1 and 5 grooved in No 2 3 and 4 6 Dowel 7 Crankshaft rear oil seal 8 Flywheel drive plate assembly Version 2 0 43 ...

Page 60: ... filter adaptor to bearing ladder 24 Oil filter head 25 Gasket oil filter adaptor to bearing ladder 26 Oil rail 27 Studs bearing ladder to oil rail 28 Nuts bearing ladder to oil rail 29 Oil pressure switch 30 Sump gasket 31 Sump 32 Bolts long sump to bearing ladder 33 Plug sump oil drain 34 Sealing washer sump plug 35 Screws short sump to bearing ladder 36 Screw oil suction pipe to bearing ladder ...

Page 61: ...omponents 1 Bolts camshaft carrier to cylinder head 2 Camshaft carrier 3 Inlet camshaft 4 Oil seal camshaft 5 Exhaust camshaft 6 Cylinder head 7 Cover plate inlet camshaft 8 Screws cover plate to camshaft cover 9 Cover plate exhaust camshaft 10 Screws cover plate to camshaft cover Version 2 0 45 ...

Page 62: ... manifold 18 Nuts exhaust manifold to cylinder head studs 19 Exhaust manifold 20 Gasket exhaust manifold to cylinder head 21 Studs exhaust manifold to cylinder head 22 Valve guides 23 Exhaust valves 24 Exhaust valve seat inserts 25 Inlet valves 26 Inlet valve seat inserts 27 Valve stem oil seal 28 Valve spring 29 Valve spring cap 30 Collets cap 31 Hydraulic tappets 32 Ring dowel cylinder head to c...

Page 63: ...d Manifold Manifold 1 Bolts spark plug cover to camshaft cover 2 Spark plug cover 3 Bolts camshaft cover to camshaft carrier 4 Oil filler cap 5 Oil filler cap seal 6 Bolt camshaft sensor to camshaft cover 7 Camshaft sensor 8 O ring camshaft sensor 9 Gasket camshaft cover to camshaft carrier 10 Nuts inlet manifold to cylinder head studs Version 2 0 47 ...

Page 64: ...re Manifold Absolute Pressure TMAP sensor 16 Cap screws TMAP sensor to inlet manifold 17 Camshaft cover assembly 18 Spring clip part load breather hose to camshaft cover 19 Part load breather hose with one way valve camshaft cover to inlet manifold breather 20 Full load breather hose camshaft cover to turbocharger air inlet hose 21 Spring clip full load breather hose to camshaft cover Version 2 0 ...

Page 65: ... 9 Upper rear drive belt cover assembly 10 Screw long upper rear drive belt cover to cylinder block 11 Screws short upper rear drive belt cover to cylinder block 12 Exhaust camshaft drive gear 13 Seal lower front drive belt cover 14 Lower front drive belt cover assembly 15 Screw lower front drive belt cover to oil pump 16 Crankshaft drive gear 17 Screw lower front drive belt cover to upper rear dr...

Page 66: ...1 Gasket exhaust manifold to cylinder head 2 Flanged nut exhaust manifold to turbocharger 3 Exhaust manifold 4 Gasket exhaust manifold to turbocharger 5 Stud turbocharger to exhaust manifold 6 Flanged nut turbocharger to exhaust manifold 7 Turbocharger 8 Flanged nut exhaust manifold to cylinder head Version 2 0 50 ...

Page 67: ...nlet Inlet Manifold Manifold Manifold Components Components Components 1 Inlet manifold 2 Nuts inlet manifold to cylinder head 3 Gasket inlet manifold to cylinder head outside 4 Gasket inlet manifold to cylinder head inside Version 2 0 51 ...

Page 68: ...via drillings in the crankshaft to the connecting rod big end bearings Cylinder Head Components The cross flow cylinder head is a four valve per cylinder central spark plug design with the inlet ports designed to induce swirl of the air fuel mixture serving to improve combustion and hence fuel economy performance and exhaust emissions Hydraulic tappets are fitted on top of each valve and are opera...

Page 69: ...ger using 3 studs and nuts sealed with a metal gasket The turbocharger is composed of an exhaust gas driven turbine and a radial air compressor mounted at opposite ends of a common shaft enclosed in cast housings The compressor and turbine housings are attached to a centre housing in which the shaft is enclosed and supported by semi floating bearings making up a single rotating unit The turbocharg...

Page 70: ...harger oil drain pipe 8 Oil filter full flow cartridge type 9 Oil pick up pipe incorporating strainer 10 Oil pressure sensor 11 Oil pump pressure relief valve 12 Oil pump pressure relief port return to oil pump inlet 13 Oil pump 14 Cylinder block oil feed drilling to cylinder head The lubrication system is a wet sump full flow filtration forced fed type Oil is drawn through the pick up pipe which ...

Page 71: ...ocharger is an exhaust gas driven device that supplies compressed air or boost to the engine s cylinders increasing its volumetric efficiency The turbine wheel housed in the turbine housing receives the hot exhaust gases from the exhaust manifold driving the turbine wheel This drive is transmitted through a shaft supported by a bearing to the compressor wheel in the compressor housing The compress...

Page 72: ...shaft seal blanking plate to cylinder head and remove plate 6 Remove any debris from spark plug recesses 7 Remove spark plugs 8 Check camshaft end float using a DTI refer to specification 9 If end float is excessive fit new camshaft s and repeat check If end float is still excessive replace cylinder head and camshaft carrier assembly 10 Working in the sequence shown progressively loosen 26 bolts s...

Page 73: ...fit camshaft carrier and tighten bolts in sequence to 10 Nm DO NOT rotate camshafts 21 Progressively loosen bolts remove camshaft carrier 22 Measure widest portion of Plastigauge on each journal Refer to specification 23 If clearance is excessive fit new camshafts and repeat check If clearance is still excessive renew cylinder head and camshaft carrier assembly 24 Remove drive pin from old camshaf...

Page 74: ... of carbon on completion 38 Check existing valve stem diameter Check valve guide clearance using new valve Refer to specification 39 Renew valves as necessary If valve guides should be renewed new cylinder head and camshaft carrier assembly must be fitted 40 Check condition of valve seat and valve if to be reused 41 Re cut valve seat using pilot and the following cutters a 15 MS76 120 To cut first...

Page 75: ...m F 1 6mm G 26 43mm G 22 83mm H 29 475 to 29 500 mm H 25 913 to 25 888 mm J 5 95 to 6 00 mm J 5 45 to 5 80 mm K 6 16 to 6 32 mm K 5 70 to 5 86 mm 48 Check condition of valve spring a Free length 50 0 mm b Fitted length 37 0 mm c Load valve closed 250 12 5 N d Load valve open 450 18 N Refit 1 Clean sealing surfaces on cylinder head and camshaft carrier Use foam action gasket remover and a plastic s...

Page 76: ...aft seal shown other seals similar7 10Nm 10 Fit tool to end of camshafts to protect seals T10013to end of camshafts to protect seals 11 Please lubricate the lip of oil seals 12 Noting that front oil seals are coloured black and rear oil seals are coloured red fit new camshaft oil seals using tool T10015 13 Position exhaust camshaft rear seal blanking plate fit and tighten bolts to 22 28Nm 14 Set g...

Page 77: ...o cylinder block 6 Release oil pump from locating dowels remove oil pump remove and discard gasket 7 Remove and discard crankshaft front oil seal from oil pump body 8 Remove dipstick 9 Remove bolt securing coolant rail housing and dipstick tube to cylinder block 10 Remove 2 bolts securing dipstick tube to cylinder block 11 Remove dipstick tube and collect gasket 12 Remove and discard oil filter En...

Page 78: ...on pulley locates over lug on timing gear 24 Fit pulley bolt and washer lightly tighten bolt 25 Mark connecting rod bearing caps for refitment Caution Keep bearing caps bearings and bolts in their fitted order 26 Using crankshaft pulley bolt rotate crankshaft for access to connecting rod bearing cap bolts 27 Remove bolts securing bearing caps to connecting rods and remove bearing caps 28 Remove be...

Page 79: ...earing denotes bearing thickness as follows a GREEN thin b BLUE intermediate c RED thick Caution If two bearing colours are to be used on the same journal the thicker bearing must be fitted to the bearing ladder When original crankshaft is to be refitted bearing shells must be as selected from table 12 Use a lint free cloth and suitable solvent to clean sealing surfaces on cylinder block and beari...

Page 80: ...iently to secure cylinder liners 33 Clean oil pick up strainer 34 Clean O ring recesses 35 Lubricate new O ring with oil and fit to pick up strainer 36 Fit strainer to engine fit bolts and tighten to 7 10Nm 37 Clean inside of sump Use a lint free cloth and suitable solvent to clean mating faces of sump and bearing ladder 38 Fit new gasket and carefully lower sump onto bearing ladder 39 Fit 2 bolts...

Page 81: ...linder Head Head Head Gasket Gasket Gasket 3 Remove sump Sump Sump Sump Reseal Reseal Reseal 4 Temporarily remove cylinder liner retainer clamps T10018 Do not rotate crankshaft with clamps removed 5 Remove 2 bolts securing oil pick up to oil rail and remove oil pick up strainer 6 Remove and discard O ring from oil pick up strainer 7 Remove 2 bolts securing oil rail remove oil rail 8 Fit cylinder l...

Page 82: ... intermediate RED thick Caution If two bearing colours are to be used on the same journal the thicker bearing must be fitted to the bearing ladder When original crankshaft is to be refitted bearing shells must be as selected from table 5 Ensure crankshaft journals bearing caps and bearings are clean 6 Select the appropriate big end bearing shells from the table 7 Lubricate bearing halves and crank...

Page 83: ...that cylinder liner clampsT10018 do not protrude over cylinder liner bores 4 Push piston to top of cylinder liner 5 Ensuring that connecting rods do not contact cylinder bores carefully push piston assembly from liner Caution Please carefully mark each piston and match liner 6 Refit bearing cap onto connecting rod lightly tighten dowel screws 7 Using an expander remove and discard old piston rings...

Page 84: ...at 30 on other side of gudgeon pin axis 13 Check new ring to groove clearance Refer to specification 14 Measure wear and taper in two axes 65 mm from top of cylinder liner bore Caution Cylinder liners with excessively glazed worn scratched or scored bores must be replaced DO NOT attempt to hone or remove glazing from bore Ensure that if original liners are to be refitted reference marks made durin...

Page 85: ...stons and rings with engine oil ensure ring gaps are correctly spaced 23 Fit ring clampT10016 to piston Fit piston into cylinder liner with front mark on piston to front of engine 24 Push piston into bore until flush with top face of cylinder liner 25 Remove ring clampT10016 Caution Do not push pistons below top face of cylinder liner until big end bearings and caps are to be fitted 26 Fit connect...

Page 86: ...t ended screwdriver ease crankshaft rear oil seal from cylinder block and discard seal Take care not to mark sealing surface on crankshaft Refit 1 Clean oil seal recess in cylinder block and running surface on crankshaft It is essential that these areas are thoroughly clean free of old sealant and dry Tip Please use MG MOTOR recommended solvent 2 Please lubricate the lip of oil seals 3 FitT10059 t...

Page 87: ...ont Oil Seal Remove 1 Disconnect battery earth lead 2 Remove camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3 Remove crankshaft timing gear 4 Fit thrust buttonT10025 to end of crankshaft 5 FitT10031 to crankshaft front oil seal 6 Tighten centre bolt of tool T10031to remove seal 7 Discard crankshaft front oil seal Refit 1 Using a lint free cloth thoroughly clean oil...

Page 88: ...h Assembly Assembly Assembly Torque Converter Drive Plate Automatic Transmission Remove 1 Remove automatic transmission 2 Position T10028to starter ring gear and secure with bolt to cylinder block to restrain crankshaft 3 Remove and discard 6 Patchlock bolts securing drive plate to crankshaft 4 Remove drive plate from crankshaft Refit 1 Clean bolt holes in crankshaft using an old drive plate bolt ...

Page 89: ...scard camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 2 Remove camshaft cover Camshaft Camshaft Camshaft Cover Cover Cover Gasket Gasket Gasket 3 Remove upper and lower alternator fixings and remove alternator 4 Remove nut securing heat shield to upper bracket Remove bolt and stud securing alternator upper bracket to cylinder head and remove bracket 5 Remove 3 bolts...

Page 90: ... 8 10 Using sequence shown progressively loosen bolts 7 to 10 remove bolts and store in fitted order Do not rotate crankshaft until cylinder head is removed and cylinder liner retainer clamps are fitted 11 Suitably identify each timing gear to its respective camshaft 12 Restrain timing gears usingT10030 and remove bolts and washers securing timing gears to camshafts 13 Remove timing gears 14 Remov...

Page 91: ...damage pay particular attention to gasket face of cylinder head 5 Check cylinder head face for warping across centre and from corner to corner as shown 6 Check cylinder head height refer to specifications 7 Clean oil and coolant passages 8 Clean cylinder head bolts inspect bolts for signs of damage 9 Wash cylinder head bolts and wipe dry 10 Apply a light film of oil to bolt threads and underside o...

Page 92: ...d tighten bolt to 22 28Nm tighten stud to 8 11Nm 21 Fit nut securing heat shield to alternator upper bracket and tighten to 25Nm Fit compressor and tighten bolts to 22 28Nm 22 Fit alternator fit lower and upper bolts and tighten to 40 50Nm 23 Fit camshaft drive belt rear upper cover 24 Fit screws securing camshaft drive belt rear upper cover and tighten to 8 11Nm 25 Fit and tighten dipstick suppor...

Page 93: ...ng path It should be complete and attached to gasket Remove gasket from camshaft cover only if sealing path is damaged or detached from gasket Refit 1 Clean mating surfaces of camshaft cover and carrier 2 Clean inside of camshaft cover If necessary wash oil separator elements in solvent and blow dry 3 If camshaft cover gasket is to be renewed fit new gasket with EXHAUST MAN SIDE mark towards exhau...

Page 94: ...en then remove 7 nuts securing intake manifold to cylinder head 8 Remove intake manifold remove and discard gasket 9 Remove both camshafts and discard oil seals 10 Using a stick magnet remove 16 tappets from cylinder head 11 Using a stick magnet remove 16 tappets from cylinder head Caution Store hydraulic tappets in their fitted order and store inverted cupped upward Maintain absolute cleanliness ...

Page 95: ...the following Valve seat Angle 45 Width A Inlet 1 2 mm Exhaust 1 6 mm Valve face angle B Inlet 45 Exhaust 45 6 Lap valve to seat using fine grinding paste 7 Apply Prussian Blue to valve seat insert valve and press into position without rotating Remove and check for even and central seating Seating position shown by blue should be in centre of valve face 8 Lap and re check valve seating 9 Check val...

Page 96: ...move T10006 18 Lubricate and fit tappets to tappet bores 19 Clean camshafts and mating faces of cylinder head and camshaft carrier Tip Please use SAIC MOTOR recommended solvent 20 Blow out oilways and lubricate camshaft journals and bearings 21 Fit camshafts and position inlet drive pin at 4 o clock 120 degrees and exhaust camshaft drive pin at 8 o clock 240 degrees 22 Apply continuous thin bead o...

Page 97: ...r to fitting 27 Clean mating faces of intake manifold and cylinder head 28 Fit new intake manifold gasket to cylinder head 29 Position intake manifold fit and tighten 7 nuts in the sequence shown to15 18Nm 30 Clean mating faces of exhaust manifold and cylinder head 31 Fit new exhaust manifold gasket to cylinder head 32 Position exhaust manifold and fit and tighten nuts in sequence shown to 40 50Nm...

Page 98: ... Exhaust Exhaust Exhaust 4 Connect battery earth lead Camshafts Inlet or Exhaust Remove 1 Disconnect battery earth lead 2 Remove camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3 Remove timing gear locking tool T10029 4 Suitably identify each timing gear to its respective camshaft 5 Restrain timing gears using T10030 remove bolts and washers securing gears to camsha...

Page 99: ...nuous bead of recommended sealant to inside paths and outside paths on camshaft carrier as shown then spread to an even film using a roller Caution Ensure sealant does not block oil ways Caution To avoid contamination assembly should be completed immediately after application of sealant 7 Fit camshaft carrier to cylinder head 8 Fit and using sequence shown progressively tighten bolts securing cams...

Page 100: ...ring that timing marks are aligned and that drive pins are located in correct slot in gears 16 Restrain timing gears using tool T10030 17 Fit bolts and washers and tighten to 61 68Nm 18 Ensure timing marks on gears are aligned 19 Fit timing gear locking tool T10029 20 Fit camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 21 Connect battery earth lead Intake Manifold G...

Page 101: ...oth beneath fuel rail 15 Release fuel feed pipe from fuel rail Caution Always fit plugs to open connections to prevent contamination 16 Working in sequence shown progressively loosen then remove 7 nuts securing intake manifold to cylinder head 17 Remove intake manifold remove and discard gasket Refit 1 Ensure mating surfaces are clean and metal inserts are fitted in intake manifold stud and bolt h...

Page 102: ...t Coolant Drain Drain Drain and and and Refill Refill Refill 17 Connect battery earth lead Exhaust Manifold Gasket Remove 1 Disconnect battery earth lead 2 Drain coolant system Coolant Coolant Coolant Drain Drain Drain and and and Refill Refill Refill 3 Raise front of vehicle and support on stand s Warning Do not work on or under a vehicle supported only by a jack Always support the vehicle on saf...

Page 103: ... lower vehicle 14 Remove bolt and 2 washers securing oil feed pipe to turbocharger and release pipe 15 Release clip and disconnect top coolant hose from turbocharger 16 Remove alternator top nut and bolt loosen bottom nut and pivot alternator backwards 17 Remove nut and bolt securing alternator upper bracket to engine and remove bracket 18 Remove 3 bolts securing spark plug cover to engine and rem...

Page 104: ... and tighten nut and bolt to 22 28Nm 7 Position alternator tighten bottom nut to 40 50Nmfit and tighten top nut and bolt to 40 50Nm 8 Fit top coolant drain hose to turbocharger and secure with clip 9 Position oil feed pipe to turbocharger fit sealing washers to bolt Fit and tighten bolt to 17 21Nm 10 Raise front of vehicle and support on stand s 11 Fit coolant inlet hose to turbocharger and tighte...

Page 105: ...emove lower screw from drive belt rear upper cover 6 Release rear upper cover to facilitate oil pump removal 7 Release oil pump from locating dowels remove oil pump remove and discard gasket 8 Remove and discard crankshaft front oil seal from oil pump body Refit 1 Clean oil pump and mating face and crankshaft front oil seal recess in pump body 2 Clean oil seal running surface on crankshaft 3 Fit a...

Page 106: ... engine sump drain plug remove plug and discard sealing washer Warning Observe due care when draining engine oil as the oil can be very hot Warning Avoid excessive skin contact with used engine oil Used engine oil contains potentially harmful contaminants which may cause skin cancer or other serious skin disorders 4 Clean area around filter head and place a suitable container beneath filter to cat...

Page 107: ...itch Switch Oil Oil Oil Pressure Pressure Pressure 2 Fit sealing washer from oil pressure switch to oil pressure gauge adaptor 3 Fit and tighten oil pressure gauge adaptor to oil pump housing 4 Connect oil pressure gaugeT10001 to adaptor and tighten union 5 Check and if necessary top up engine oil 6 Start and run engine until normal operating temperature is reached 7 Note oil pressure readings wit...

Page 108: ...se front exhaust pipe and discard gasket 5 Remove bolt securing engine mounting lower tie rod to mounting lower tie rod bracket 6 Remove 4 bolts and remove engine mounting lower tie rod bracket from sump 7 Remove 3 bolts securing sump to transmission 8 Remove 4 bolts securing front exhaust pipe to sump and transmission 9 Remove 3 bolts securing front exhaust pipe to exhaust pipe 10 Noting the fitt...

Page 109: ...d fill with oil Engine Engine Engine Oil Oil Oil and and and Oil Oil Oil Filter Filter Filter 11 Remove stand s and lower vehicle 12 Connect battery earth lead Camshaft Drive Belt Cover Front Upper Remove 1 Disconnect battery earth lead 2 Loosen lower screw securing drive gear front upper cover 3 Remove 5 screws securing drive gear front upper cover to rear upper cover 4 Remove drive gear front up...

Page 110: ...r upper cover to coolant pump 8 Remove bolts securing drive belt rear upper cover to engine and remove cover Refit 1 Fit drive belt rear upper cover fit new bolts and tighten to 8 11Nm 2 Tighten bolt securing dipstick support bracket to 7 10Nm 3 Clean gears and camshaft mating faces 4 Fit timing gears to camshafts ensuring that drive pins are located in correct slot in gears Fit bolts and washers ...

Page 111: ...ansmission to flywheel housing and secure with bolts 7 Remove bolt securing pulley to crankshaft and collect washer 8 Remove crankshaft pulley Refit 1 Clean crankshaft pulley and mating face 2 Fit crankshaft pulley and ensure indent on pulley locates over lug on crankshaft timing gear 3 Fit washer and tighten bolt securing crankshaft pulley to 200 210Nm 4 Remove bolts and remove flyingwheel lockin...

Page 112: ...ng to body and tighten to 90 110Nm 3 Fit 3 bolts from engine RH mounting to engine and tighten to 90 110Nm 4 Fit bolts from PAS reservoir to engine RH mounting and tighten to 7 10Nm 5 Lower and remove jack 6 Connect battery earth lead Engine Mounting Lower Tie Rod Remove 1 Remove underbelly panel Undertray Undertray Undertray Assembly Assembly Assembly 2 Remove 2 bolts securing engine mounting low...

Page 113: ...protect oil seal 3 Noting that this oil seal is coloured black fit new camshaft oil seal using tool T10015 Caution Oil seals are waxed and must not be lubricated prior to fitting 4 Clean timing gear and camshaft mating faces Caution If sintered gears have been subjected to prolonged oil contamination they must be soaked in solvent and then thoroughly washed in clean solvent before refitting Becaus...

Page 114: ...o protect seal Exhaust camshaft shown inlet camshaft similar 3 Noting that this oil seal is coloured black fit new camshaft oil seal using T10015 Caution Oil seals are waxed and must not be lubricated prior to fitting 4 Clean timing gear and camshaft mating faces Caution If sintered gears have been subjected to prolonged oil contamination they must be soaked in solvent and then thoroughly washed i...

Page 115: ...ount to body 7 Remove engine RH hydramount 8 Rotate crankshaft clockwise to align camshaft timing gear marks Caution Never use the camshaft gear the camshaft gear retaining bolts or the timing belt to turn the crankshaft 9 Fit timing gear locking tool T10029 10 Check that timing mark on crankshaft pulley is aligned with mark on drive belt front lower cover 11 Remove crankshaft pulley Crankshaft Cr...

Page 116: ... Because of the porous construction of sintered material oil impregnated in the gear will emerge and contaminate a new belt 2 Fit crankshaft timing gear to crankshaft 3 Check correct alignment of dots on crankshaft gear with flange on oil pump 4 Fit drive belt tensioner with tensioner lever at 9 o clock position and tighten new fixing bolt until it is just possible to move tensioner lever 5 Ensure...

Page 117: ...it is just possible to move tensioning lever Rotate tensioning lever clockwise until tension is completely backed off then rotate tensioning lever anti clockwise until pointer is aligned correctly to index wire 21 Tighten tensioner bolt to 20 23Nm 22 Rotate crankshaft 2 complete revolutions and align timing marks 23 Check alignment of pointer to index wire if incorrect repeat adjustment procedure ...

Page 118: ...surise Depressurise Depressurise 7 Release clips securing engine harness and earth lead to air cleaner mounting bracket 8 Remove 3 bolts securing air cleaner mounting bracket to body and remove bracket 9 Release clips securing hoses to coolant elbow and disconnect hoses 10 Release clip securing coolant hose to coolant rail and disconnect hose Disconnect ECT sensor multiplug 11 Release clip securin...

Page 119: ...tment fuse box 18 Disconnect multiplug from engine compartment fuse box 19 Disconnect engine harness to main harness multiplug 20 Release clip and disconnect purge valve hose from intake manifold 21 Disconnect purge valve multiplug 22 Release clip and disconnect hose from fuel rail 23 Remove bolt securingPAS hose support bracket to coolant rail PAS hose support bracket to coolant rail Version 2 0 ...

Page 120: ...n mounting bracket 27 Release clip and disconnect reverse light switch multiplug 28 Release latch and disconnect multiplugs from ECM 29 FeedECM harness into engine bay 30 DisconnectPAS pressure sensor multiplug 31 ReleasePAS pump cover fromPAS pump 32 Position container underPAS pump 33 Remove 2 bolts securing fluid inlet hose toPAS pump release hose remove and discard O ring Version 2 0 104 ...

Page 121: ...ove front wheel 37 Drain transmission oil Capacity Capacity Capacity Fluid Fluid Fluid and and and Oil Oil Oil 38 Using a 13 mm spanner rotate tensioner to release tension and remove ancillary drive belt from A C compressor pulley 39 Remove 3 bolts and move A C compressor aside 40 Remove 3 nuts securing front exhaust pipe flange to turbocharger release front pipe 41 Remove and discard exhaust flan...

Page 122: ...t drain hose from turbocharger 47 Remove 2 bolts securing engine mounting lower tie rod to lower tie rod bracket and subframe remove tie rod 48 Remove nut securing RH track rod ball joint 49 Fit an nut to ball pin flush with end of pin and using T38008 release ball joint taper 50 Remove nut from ball pin 51 Remove clip securing RH brake hose and release brake hose from support bracket and clip onA...

Page 123: ...taper 59 Remove M10 nut from ball pin 60 Release clip securing LH brake hose and release brake hose from support bracket and clip onABS sensor harness ReleaseABS sensor harness from support bracket 61 Remove nut and bolt securing lower ball to LH lower suspension arm 62 Using T32020and T32011 release ball joint from lower suspension arm 63 Fit lower arm ball joint protector T32003 64 UsingT30001 r...

Page 124: ...o engine 72 Raise hoist to take weight of engine without exerting load on mountings 73 Remove 3 bolts securing engine RH hydramount to engine and 2 bolts to body remove RH hydramount 74 Remove nut securing LH transmission mounting bracket to LH transmission hydraulic 75 Remove 4 bolts securing LH transmission hydraulic to LH transmission hydraulic mounting bracket and remove hyraulic 76 Remove 4 b...

Page 125: ... Position ball joints into LH and RH hubs 16 Fit nuts and bolts securing ball joints to hubs and tighten to 40 50Nm 17 Ensure that ball joints are fully located in hubs and bolts are in grooves in ball joints 18 Position intermediate shaft support bearing to engine fit bolts and tighten to 25Nm 19 Position brake hoses pad wear sensor andABS sensor harnesses in support brackets and secure brake hos...

Page 126: ...ipe to intake manifold and secure with clip 55 Connect coolant hose to coolant rail and secure with clip 56 Connect coolant hoses to elbow and secure with clips 57 Connect heater hose to cylinder block and secure with clip 58 Position air cleaner mounting bracket to body fit and tighten bolts to 45Nm 59 Secure harness and earth lead to air cleaner mounting bracket 60 Fit air cleaner Air Air Air Cl...

Page 127: ...tiplug 13 Release clip securing heater hose to cylinder block and disconnect hose 14 Release clip securing expansion tank hose to intake manifold and disconnect hose 15 Disconnect servo vacuum pipe from intake manifold 16 Remove nut and disconnect battery lead from starter motor 17 Disconnect Lucar connector from starter motor 18 Remove bolt and release earth lead from transmission Version 2 0 111...

Page 128: ...ment fuse box 21 Disconnect engine harness to main harness multiplug 22 Release clip and disconnect purge valve hose from intake manifold 23 Disconnect purge valve multiplug 24 Release clip and disconnect hose from fuel rail 25 Remove bolt securing PAShose support bracket to coolant rail 26 Release latch and disconnect multiplugs from ECM Version 2 0 112 ...

Page 129: ...4 Release hose remove and discard sealing washers Caution Always fit plugs to open connections to prevent contamination 35 Remove 2 bolts and nut securing PASreservoir to engine RH hydramount and position reservoir aside 36 Remove front wheels 37 Drain transmission oil 38 Using a 13 mm spanner rotate tensioner to release tension and remove ancillary drive belt from A C compressor pulley 39 Remove ...

Page 130: ... turbocharger and wastegate 44 Loosen jubilee clip securing coolant inlet hose to turbocharger and release hose 45 Loosen jubilee clip securing intercooler intake hose to turbocharger and release hose 46 Release clip and disconnect coolant drain hose from turbocharger 47 Remove 2 bolts securing engine mounting lower tie rod to lower tie rod bracket and subframe remove tie rod Version 2 0 114 ...

Page 131: ...2011release ball joint from lower suspension arm 55 Fit lower arm ball joint protectorT32003 56 Remove 3 bolts securing intermediate shaft bearing support to engine 57 Remove nut from LH track rod ball joint 58 Fit an M10 nut to ball pin flush with end of pin 59 Using T38008release ball joint taper 60 Remove M10 nut from ball pin 61 Release clip securing LH brake hose and release brake hose from s...

Page 132: ...luid cooler hoses and discard O rings Caution Always fit plugs to open connections to prevent contamination 71 Remove nut securing selector lever to transmission release lever from transmission 72 Release clip and remove selector cable from transmission bracket 73 Remove 2 bolts and remove camshaft seal blanking plate 74 Fit lifting bracket T10035in place of plate and tighten bolts 75 Fit lifting ...

Page 133: ...4 Position LH transmission hydraulic mounting bracket to body fit bolts and tighten to85Nm 5 Fit transmission LH hydramount to hydraulic mounting bracket securing bolts and tighten to50 65Nm 6 Fit nuts securing transmission mounting bracket to transmission LH hydraulic and tighten to 90 110Nm 7 Fit engine RH hydramount to engine and body securing the bolts and tighten to 90 110Nm 8 Lower hoist dis...

Page 134: ...ings with transmission fluid and fit to transmission fluid cooler hoses 41 Connect transmission fluid cooler hoses to fluid cooler tighten unions 42 Position and connect multiplug to ECMand secure latch 43 Position PAShose support bracket to coolant rail fit bolt and tighten to 10Nm 44 Connect fuel hose to fuel rail 45 Connect hose to purge control valve 46 Connect purge control valve multiplug 47...

Page 135: ...haust manifold and collect gasket 8 Disconnect camshaft position sensor multiplug from engine harness 9 Remove 2 bolts and remove inlet camshaft seal blanking plate and position aside 10 Release clip and disconnect radiator top hose from coolant outlet elbow 11 Release clip and disconnect coolant hose from coolant outlet elbow 12 Disconnect multiplug from ECTsensor 13 Disconnect multiplug from ele...

Page 136: ...er Gasket Gasket Gasket 22 Using sequence shown progressively loosen cylinder head bolts 1 to 6 remove bolts and store in fitted order 23 Remove locking tool T10029from timing gears 24 Using tool T10030rotate both camshafts clockwise to gain access to cylinder head bolts 7 and 8 25 Using sequence shown progressively loosen cylinder head bolts 7 to 10 remove bolts and store in fitted order Do not r...

Page 137: ...ating faces of cylinder head and cylinder block 3 Check cylinder head for damage pay particular attention to gasket face of cylinder head 4 Check cylinder head face for warping across centre and from corner to corner as shown 5 Check cylinder head height Cylinder head may be refaced up to a maximum of 0 20 mm Refer to specification 6 Remove all debris from oil and coolant passages 7 Clean mating f...

Page 138: ...onic controlled throttle 26 Connect multiplug to ECTsensor and secure with clip 27 Fit hose to coolant outlet elbow and secure with clip 28 Fit radiator top hose to coolant outlet elbow and secure with clip 29 Fit upper camshaft seal blanking plate and tighten blots to 5 7Nm Fit lower camshaft seal blanking plate and tighten blots to 22 28Nm 30 Connect camshaft position sensor multiplug to engine ...

Page 139: ...at Heat Heat Shield Remove Shield Remove Shield Remove Alternator Alternator Alternator 6 Remove 2 bolts securing oil drain pipe to turbocharger 7 Remove 2 bolts securing oil drain pipe to engine 8 Remove oil drain pipe 9 Loosen jubilee clip securing air intake hose to turbocharger and release hose 10 Release pressure control hoses from turbocharger and wastegate 11 Loosen jubilee clip securing in...

Page 140: ...engine and remove bracket 18 Remove 3 bolts securing spark plug cover to engine and remove cover 19 Release circlip securing top coolant hose to engine release hose and position aside 20 Remove 7 nuts securing exhaust manifold to engine 21 With assistance manoeuvre turbocharger and exhaust manifold from engine compartment 22 Remove 4 nuts securing turbocharger to manifold release manifold from tur...

Page 141: ...on oil feed pipe to turbocharger fit sealing washers to bolt Fit and tighten bolt to 16 22Nm 10 Raise front of vehicle and support on stand s 11 Fit coolant inlet hose to turbocharger and tighten jubilee clip 12 Fit intercooler intake hose to turbocharger and tighten clip 13 Fit control hoses to turbocharger and wastegate 14 Fit air intake hose to turbocharger and tighten jubilee clip 15 Position ...

Page 142: ...rger Remove 1 Drain coolant system Coolant Coolant Coolant Drain Drain Drain and and and Refill Refill Refill 2 Remove underbelly panel Undertray Undertray Undertray Assembly Assembly Assembly 3 Loosen jubilee clip securing coolant inlet hose to turbocharger and release hose from turbocharger 4 Loosen jubilee clip securing coolant inlet hose to T piece in coolant bottom hose and remove hose from c...

Page 143: ...mbly Assembly Hose Air Intake Turbocharger Remove 1 Release jubilee clip securing turbocharger air intake hose to air cleaner and release hose from air cleaner AT model illustrated MT model is similar 2 Remove underbelly panel Undertray Undertray Undertray Assembly Assembly Assembly 3 Remove vacuum hose from boost control valve to turbocharger air intake hose 4 Loosen jubilee clip securing air int...

Page 144: ...shers and oil feed pipe to turbocharger fit and tighten bolt to 16 22Nm Hose Air Intake Electronic Throttle Remove 1 Remove battery carrier Battery Battery Battery Carrier Carrier Carrier Bracket Bracket Bracket 2 Remove air cleaner Air Air Air Cleaner Cleaner Cleaner 3 Disconnect theTMAP sensor mulitplug from throttle intake hose 4 Loosen the clips disconnect the throttle intake hose from throttl...

Page 145: ...hose from intercooler 8 Loosen clip and disconnect throttle intake hose from intercooler 9 Remove 2 bolts securing intercooler to radiator 10 Carefully move intercooler forward and remove it Refit 1 Carefully fit intercooler on radiator 2 Fit bolt securing intercooler to radiator tighten to 2 4Nm 3 Fit clip from throttle intake hose to intercooler 4 Fit clip from intercooler intake hose to interco...

Page 146: ... intake hose to turbocharger and release hose 3 Loosen jubilee clip securing intercooler air intake hose to intercooler and remove hose Refit 1 Fit intercooler air intake hose to intercooler and tighten with jubilee clip 2 Fit intercooler air intake hose to turbocharger and tighten with jubilee clip 3 Fit air cleaner Air Air Air Cleaner Cleaner Cleaner Version 2 0 130 ...

Page 147: ...e Camshaft Oil Seal T10015 Replacer camshaft oil seal T10018 Retainer clamps cylinder block line Tool Number Description Picture T10032 Replacer Front Crankshaft Camshaft Seals T10016 Piston ring compressor T10059 Protector Sleeve Crankshaft Rear oil seal T10040 Protector Sleeve Crankshaft Rear oil seal T10033 crankshaft oil seal replacer rear Version 2 0 131 ...

Page 148: ...shaft Front Oil Seal Remover T10028 flywheel locking tool T10029 timing gear locking tool T10030 timing gear retainer Tool Number Description Picture T10001 Engine oil pressure test equipment T10036 Flywheel lockingAT T10037 Flywheel locking MT T10022 Remover camshaft oil seal T10023 Adapter remover camshaft seal Version 2 0 132 ...

Page 149: ...ork T38008 Remover ball joint T32020 Spreader Front Lower Arm Ball Joint T32011 Lever front lower arm ball joint T32003 Protector front lower arm ball joint Tool Number Description Picture T30001 Remover drive shaft T10035 Engine lifting bracket T10007 Engine lift bracket Version 2 0 133 ...

Page 150: ...ng panel to gearbox block 22 28Nm Bolt cylinder head to cylinder block 20Nm 180 135 Bolt Alternator upper bracket to cylinder head 22 28Nm Stud Alternator upper bracket to cylinder head 8 11Nm Bolt Alternator heat shield to alternator bracket 25Nm Bolt compressor to compressor mounting bracket 22 28Nm Bolt Alternator to alternator lower bracket 40 50Nm Screw drive belt rear upper cover to coolant ...

Page 151: ...Nm Nut transmission LH mounting bracket to transmission LH hydraulic mounting 90 110Nm Bolts Battery box carrier fixing bracket to transmission LH hydraulic pressure suspension and bracket 7 10Nm Bolt INMD SHF bearing to engine 25Nm Bolt PAS pump bracket to cylinder block 45Nm Bolt mounting bracket to transmission 70 90Nm Bolt A C compressor to installation bracket 22 28Nm Bolt Battery box carrier...

Page 152: ...Engine Engine Mechanical 1 8 VCT Description and Operation Component Layout K4 Engine Component Layout K4 engine general view Version 2 0 136 ...

Page 153: ...Engine Mechanical 1 8 VCT Engine K4 engine internal view Version 2 0 137 ...

Page 154: ... housing to coolant pump 2 Thermostat housing 3 Screw thermostat housing to cylinder block 4 O ring thermostat cover to coolant pipe 5 Bolt connecting rod 6 Big end bearing cap 7 Big end bearing shell lower 8 Big end bearing shell upper 9 Connecting rod 10 Piston Version 2 0 138 ...

Page 155: ...her vent screw to coolant pipe 17 Coolant pipe 18 Bolts coolant pipe to cylinder block 19 Cylinder head gasket 20 Cylinder block 21 O ring coolant pump to cylinder block 22 Bolt coolant pump to cylinder block 23 Screws coolant pump to cylinder block 24 Coolant pump 25 Dowels coolant pump to cylinder block 26 Dowels cylinder block to cylinder head Version 2 0 139 ...

Page 156: ...Assembly 1 Oil pump assembly 2 Gasket oil pump 3 Crankshaft 4 Thrust washers 2 off at No 3 main bearing 5 Main bearing shells upper 5 off plain in No 1 and 5 grooved in No 2 3 and 4 6 Dowel 7 Crankshaft rear oil seal 8 Flywheel drive plate assembly Version 2 0 140 ...

Page 157: ...l filter adaptor to bearing ladder 22 23 Oil pressure switch 24 Sump gasket 25 Sump 26 Bolts long sump to bearing ladder 27 Sealing washer sump plug 28 Plug sump oil drain 29 Screws short sump to bearing ladder 30 Screw oil suction pipe to bearing ladder 31 Oil suction pipe 32 Seal oil suction pipe 33 Oil rail core plug 34 Bolts long bearing ladder to cylinder block 35 Bolts short bearing ladder t...

Page 158: ...Camshaft carrier 4 Inlet camshaft 5 Gasket exhaust camshaft oil control solenoid housing to camshaft carrier 6 Dowel 7 Bolt exhaust camshaft oil control solenoid to housing 8 Exhaust camshaft oil control solenoid 9 Exhaust camshaft oil control solenoid housing 10 Bolt exhaust camshaft oil control solenoid housing to camshaft carrier Version 2 0 142 ...

Page 159: ...oolant outlet elbow 21 Coolant temperature sensor 22 Screws coolant outlet elbow to cylinder head 23 Exhaust manifold 24 Bolt exhaust manifold to exhaust pipe 25 Nuts exhaust manifold to cylinder head studs 26 Gasket exhaust manifold to cylinder head 27 Studs exhaust manifold to cylinder head 28 Valve guides 29 Exhaust valves 30 Exhaust valve seat inserts 31 Inlet valve 32 Inlet valve seat inserts...

Page 160: ...Spark plug cover 3 Bolts camshaft cover to camshaft carrier 4 Oil filler cap 5 Oil filler cap seal 6 Gasket camshaft cover to camshaft carrier 7 Nuts inlet manifold to cylinder head studs 8 Studs inlet manifold to cylinder head 9 Gasket inlet manifold to cylinder head 10 Gasket inlet manifold to cylinder head Version 2 0 144 ...

Page 161: ...12 Blanking plate 13 Cap screws blanking plate 14 Camshaft cover 15 Full load breather hose 16 Spring clip part load breather hose to camshaft cover 17 Part load breather hose with one way valve camshaft cover to inlet manifold breather Version 2 0 145 ...

Page 162: ...mshaft phaser unit 9 Upper rear drive belt cover 10 Screw long upper rear drive belt cover to cylinder block 11 Screws short upper rear drive belt cover to cylinder block 12 Exhaust camshaft phaser unit 13 Seal lower front drive belt cover 14 Lower front drive belt cover 15 Screw lower front drive belt cover to oil pump 16 Crankshaft drive gear 17 Screw lower front drive belt cover to upper rear d...

Page 163: ...ft to the connecting rod big end bearings Cylinder Head Components The cross flow cylinder head is a four valve per cylinder central spark plug design with the inlet ports designed to induce swirl of the air fuel mixture serving to improve combustion and hence fuel economy performance and exhaust emissions Hydraulic tappets are fitted on top of each valve and are operated directly by the camshaft ...

Page 164: ...for fore aft roll during acceleration and deceleration Crankcase Ventilation A full and part load breather system is utilised Full load breathing is via pipe work attached to the camshaft cover at one end and the clean air ducting for the turbocharger intake Part load breathing is via a hose connecting the camshaft cover to the inlet manifold incorporating a pressure control valve designed to isol...

Page 165: ...f valve 10 Oil pump pressure relief port return to oil pump inlet 11 Oil pump 12 Cylinder block oil feed drilling to cylinder head The lubrication system is a wet sump full flow filtration forced fed type Oil is drawn through the pick up pipe which incorporates a strainer to prevent contaminates from entering the oil pump The oil pump is directly driven from the crankshaft which incorporates a pre...

Page 166: ...s are lubricated from oil collected on the underside of the piston crown Oil is fed from the con rod small ends to the gudgeon pins and bushes via a drilling A revised engine block and bearing ladder is used This incorporates a turbocharger oil drain facility The oil feed for the turbocharger is taken from the oil filter housing The oil circulates around the turbocharger providing cooling and lubr...

Page 167: ...to the crankcase these are known as blowby gases These gases formed mainly of unburned hydrocarbons HC contaminate engine oil and at higher engine speeds create excess crankcase pressure that can lead to oil leakage from seals and gaskets A positive crankcase ventilation system is used to vent these gases from the crankcase to the air intake system Version 2 0 151 ...

Page 168: ...mshaft seal blanking plate to cylinder head and remove plate 6 Remove any debris from spark plug recesses 7 Remove spark plugs 8 Check camshaft end float using a DTI refer to specification 9 If end float is excessive fit new camshaft s and repeat check If end float is still excessive replace cylinder head and camshaft carrier assembly 10 Working in the sequence shown progressively loosen 26 bolts ...

Page 169: ...efit camshaft carrier and tighten bolts in sequence to 10 Nm DO NOT rotate camshafts 21 Progressively loosen bolts remove camshaft carrier 22 Measure widest portion of Plastigauge on each journal Refer to specification 23 If clearance is excessive fit new camshafts and repeat check If clearance is still excessive renew cylinder head and camshaft carrier assembly 24 Remove drive pin from old camsha...

Page 170: ...s of carbon on completion 38 Check existing valve stem diameter Check valve guide clearance using new valve Refer to specification 39 Renew valves as necessary If valve guides should be renewed new cylinder head and camshaft carrier assembly must be fitted 40 Check condition of valve seat and valve if to be reused 41 Re cut valve seat using pilot and the following cutters a 15 MS76 120 To cut firs...

Page 171: ...mm F 1 6mm G 26 43mm G 22 83mm H 29 475 to 29 500 mm H 25 913 to 25 888 mm J 5 95 to 6 00 mm J 5 45 to 5 80 mm K 6 16 to 6 32 mm K 5 70 to 5 86 mm 48 Check condition of valve spring a Free length 50 0 mm b Fitted length 37 0 mm c Load valve closed 250 12 5 N d Load valve open 450 18 N Refit 1 Clean sealing surfaces on cylinder head and camshaft carrier Use foam action gasket remover and a plastic ...

Page 172: ...haft seal shown other seals similar7 10Nm 10 Fit tool to end of camshafts to protect seals T10013to end of camshafts to protect seals 11 Please lubricate the lip of oil seals 12 Noting that front oil seals are coloured black and rear oil seals are coloured red fit new camshaft oil seals using tool T10015 13 Position exhaust camshaft rear seal blanking plate fit and tighten bolts to 22 28Nm 14 Set ...

Page 173: ...to cylinder block 6 Release oil pump from locating dowels remove oil pump remove and discard gasket 7 Remove and discard crankshaft front oil seal from oil pump body 8 Remove dipstick 9 Remove bolt securing coolant rail housing and dipstick tube to cylinder block 10 Remove 2 bolts securing dipstick tube to cylinder block 11 Remove dipstick tube and collect gasket 12 Remove and discard oil filter E...

Page 174: ... on pulley locates over lug on timing gear 24 Fit pulley bolt and washer lightly tighten bolt 25 Mark connecting rod bearing caps for refitment Caution Keep bearing caps bearings and bolts in their fitted order 26 Using crankshaft pulley bolt rotate crankshaft for access to connecting rod bearing cap bolts 27 Remove bolts securing bearing caps to connecting rods and remove bearing caps 28 Remove b...

Page 175: ...bearing denotes bearing thickness as follows a GREEN thin b BLUE intermediate c RED thick Caution If two bearing colours are to be used on the same journal the thicker bearing must be fitted to the bearing ladder When original crankshaft is to be refitted bearing shells must be as selected from table 12 Use a lint free cloth and suitable solvent to clean sealing surfaces on cylinder block and bear...

Page 176: ...ciently to secure cylinder liners 33 Clean oil pick up strainer 34 Clean O ring recesses 35 Lubricate new O ring with oil and fit to pick up strainer 36 Fit strainer to engine fit bolts and tighten to 7 10Nm 37 Clean inside of sump Use a lint free cloth and suitable solvent to clean mating faces of sump and bearing ladder 38 Fit new gasket and carefully lower sump onto bearing ladder 39 Fit 2 bolt...

Page 177: ...ylinder Head Head Head Gasket Gasket Gasket 3 Remove sump Sump Sump Sump Reseal Reseal Reseal 4 Temporarily remove cylinder liner retainer clamps T10018 Do not rotate crankshaft with clamps removed 5 Remove 2 bolts securing oil pick up to oil rail and remove oil pick up strainer 6 Remove and discard O ring from oil pick up strainer 7 Remove 2 bolts securing oil rail remove oil rail 8 Fit cylinder ...

Page 178: ...E intermediate RED thick Caution If two bearing colours are to be used on the same journal the thicker bearing must be fitted to the bearing ladder When original crankshaft is to be refitted bearing shells must be as selected from table 5 Ensure crankshaft journals bearing caps and bearings are clean 6 Select the appropriate big end bearing shells from the table 7 Lubricate bearing halves and cran...

Page 179: ... that cylinder liner clampsT10018 do not protrude over cylinder liner bores 4 Push piston to top of cylinder liner 5 Ensuring that connecting rods do not contact cylinder bores carefully push piston assembly from liner Caution Please carefully mark each piston and match liner 6 Refit bearing cap onto connecting rod lightly tighten dowel screws 7 Using an expander remove and discard old piston ring...

Page 180: ... at 30 on other side of gudgeon pin axis 13 Check new ring to groove clearance Refer to specification 14 Measure wear and taper in two axes 65 mm from top of cylinder liner bore Caution Cylinder liners with excessively glazed worn scratched or scored bores must be replaced DO NOT attempt to hone or remove glazing from bore Ensure that if original liners are to be refitted reference marks made duri...

Page 181: ...istons and rings with engine oil ensure ring gaps are correctly spaced 23 Fit ring clampT10016 to piston Fit piston into cylinder liner with front mark on piston to front of engine 24 Push piston into bore until flush with top face of cylinder liner 25 Remove ring clampT10016 Caution Do not push pistons below top face of cylinder liner until big end bearings and caps are to be fitted 26 Fit connec...

Page 182: ...at ended screwdriver ease crankshaft rear oil seal from cylinder block and discard seal Take care not to mark sealing surface on crankshaft Refit 1 Clean oil seal recess in cylinder block and running surface on crankshaft It is essential that these areas are thoroughly clean free of old sealant and dry Tip Please use MG MOTOR recommended solvent 2 Please lubricate the lip of oil seals 3 FitT10059 ...

Page 183: ...ront Oil Seal Remove 1 Disconnect battery earth lead 2 Remove camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3 Remove crankshaft timing gear 4 Fit thrust buttonT10025 to end of crankshaft 5 FitT10031 to crankshaft front oil seal 6 Tighten centre bolt of tool T10031to remove seal 7 Discard crankshaft front oil seal Refit 1 Using a lint free cloth thoroughly clean oi...

Page 184: ...ch Assembly Assembly Assembly Torque Converter Drive Plate Automatic Transmission Remove 1 Remove automatic transmission 2 Position T10028to starter ring gear and secure with bolt to cylinder block to restrain crankshaft 3 Remove and discard 6 Patchlock bolts securing drive plate to crankshaft 4 Remove drive plate from crankshaft Refit 1 Clean bolt holes in crankshaft using an old drive plate bolt...

Page 185: ...iscard camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 2 Remove camshaft cover Camshaft Camshaft Camshaft Cover Cover Cover Gasket Gasket Gasket 3 Remove upper and lower alternator fixings and remove alternator 4 Remove nut securing heat shield to upper bracket Remove bolt and stud securing alternator upper bracket to cylinder head and remove bracket 5 Remove 3 bolt...

Page 186: ...d 8 10 Using sequence shown progressively loosen bolts 7 to 10 remove bolts and store in fitted order Do not rotate crankshaft until cylinder head is removed and cylinder liner retainer clamps are fitted 11 Suitably identify each timing gear to its respective camshaft 12 Restrain timing gears usingT10030 and remove bolts and washers securing timing gears to camshafts 13 Remove timing gears 14 Remo...

Page 187: ... damage pay particular attention to gasket face of cylinder head 5 Check cylinder head face for warping across centre and from corner to corner as shown 6 Check cylinder head height refer to specifications 7 Clean oil and coolant passages 8 Clean cylinder head bolts inspect bolts for signs of damage 9 Wash cylinder head bolts and wipe dry 10 Apply a light film of oil to bolt threads and underside ...

Page 188: ...nd tighten bolt to 22 28Nm tighten stud to 8 11Nm 21 Fit nut securing heat shield to alternator upper bracket and tighten to 25Nm Fit compressor and tighten bolts to 22 28Nm 22 Fit alternator fit lower and upper bolts and tighten to 40 50Nm 23 Fit camshaft drive belt rear upper cover 24 Fit screws securing camshaft drive belt rear upper cover and tighten to 8 11Nm 25 Fit and tighten dipstick suppo...

Page 189: ...ing path It should be complete and attached to gasket Remove gasket from camshaft cover only if sealing path is damaged or detached from gasket Refit 1 Clean mating surfaces of camshaft cover and carrier 2 Clean inside of camshaft cover If necessary wash oil separator elements in solvent and blow dry 3 If camshaft cover gasket is to be renewed fit new gasket with EXHAUST MAN SIDE mark towards exha...

Page 190: ...sen then remove 7 nuts securing intake manifold to cylinder head 8 Remove intake manifold remove and discard gasket 9 Remove both camshafts and discard oil seals 10 Using a stick magnet remove 16 tappets from cylinder head 11 Using a stick magnet remove 16 tappets from cylinder head Caution Store hydraulic tappets in their fitted order and store inverted cupped upward Maintain absolute cleanliness...

Page 191: ... the following Valve seat Angle 45 Width A Inlet 1 2 mm Exhaust 1 6 mm Valve face angle B Inlet 45 Exhaust 45 6 Lap valve to seat using fine grinding paste 7 Apply Prussian Blue to valve seat insert valve and press into position without rotating Remove and check for even and central seating Seating position shown by blue should be in centre of valve face 8 Lap and re check valve seating 9 Check va...

Page 192: ...emove T10006 18 Lubricate and fit tappets to tappet bores 19 Clean camshafts and mating faces of cylinder head and camshaft carrier Tip Please use SAIC MOTOR recommended solvent 20 Blow out oilways and lubricate camshaft journals and bearings 21 Fit camshafts and position inlet drive pin at 4 o clock 120 degrees and exhaust camshaft drive pin at 8 o clock 240 degrees 22 Apply continuous thin bead ...

Page 193: ...or to fitting 27 Clean mating faces of intake manifold and cylinder head 28 Fit new intake manifold gasket to cylinder head 29 Position intake manifold fit and tighten 7 nuts in the sequence shown to15 18Nm 30 Clean mating faces of exhaust manifold and cylinder head 31 Fit new exhaust manifold gasket to cylinder head 32 Position exhaust manifold and fit and tighten nuts in sequence shown to 40 50N...

Page 194: ...r Exhaust Exhaust Exhaust 4 Connect battery earth lead Camshafts Inlet or Exhaust Remove 1 Disconnect battery earth lead 2 Remove camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3 Remove timing gear locking tool T10029 4 Suitably identify each timing gear to its respective camshaft 5 Restrain timing gears using T10030 remove bolts and washers securing gears to camsh...

Page 195: ...inuous bead of recommended sealant to inside paths and outside paths on camshaft carrier as shown then spread to an even film using a roller Caution Ensure sealant does not block oil ways Caution To avoid contamination assembly should be completed immediately after application of sealant 7 Fit camshaft carrier to cylinder head 8 Fit and using sequence shown progressively tighten bolts securing cam...

Page 196: ...uring that timing marks are aligned and that drive pins are located in correct slot in gears 16 Restrain timing gears using tool T10030 17 Fit bolts and washers and tighten to 61 68Nm 18 Ensure timing marks on gears are aligned 19 Fit timing gear locking tool T10029 20 Fit camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 21 Connect battery earth lead Intake Manifold ...

Page 197: ...loth beneath fuel rail 15 Release fuel feed pipe from fuel rail Caution Always fit plugs to open connections to prevent contamination 16 Working in sequence shown progressively loosen then remove 7 nuts securing intake manifold to cylinder head 17 Remove intake manifold remove and discard gasket Refit 1 Ensure mating surfaces are clean and metal inserts are fitted in intake manifold stud and bolt ...

Page 198: ...ipe to intake manifold 13 Connect multiplug to electronic controlled throttle 14 Connect purge valve hose to intake manifold and tighten clip 15 Refit air cleaner Air Air Air Cleaner Cleaner Cleaner 16 Refill cooling system Coolant Coolant Coolant Drain Drain Drain and and and Refill Refill Refill 17 Connect battery earth lead 1 8VCT Exhaust Manifold Gasket Remove 1 Remove alternator Alternator Al...

Page 199: ...et to exhaust manifold and secure with nut Do not tighten fully at this stage 3 Fit exhaust manifold gasket to cylinder head studs 4 Fit exhaust manifold to cylinder head fit nuts align support bracket to engine studs 5 Tighten exhaust manifold nuts to40 50Nm 6 Fit nuts securing support bracket to engine and tighten to 7 Tighten support bracket nut 8 Fit nuts securing exhaust manifold to intermedi...

Page 200: ...om oil pump body Refit 1 Clean oil pump and mating face and crankshaft front oil seal recess in pump body 2 Clean oil seal running surface on crankshaft 3 Fit a new oil pump gasket dry align and fit oil pump 4 Fit new Patchlock bolts ensuring M6 x 20 bolt is in its correct position Tighten bolts in sequence shown to 8 11Nm 5 Fit and tighten screw securing drive belt rear upper cover to8 11Nm 6 Fit...

Page 201: ...lter to catch any oil spillage 5 Remove and discard engine oil filter Refit 1 Clean mating face of filter head 2 Lubricate sealing ring of new filter with clean engine oil 3 Fit new filter and tighten by hand until it seats then tighten a further half turn 4 Clean sump drain plug and fit new sealing washer 5 Fit sump drain plug and tighten to 25 30Nm 6 Remove engine oil filler cap and fill engine ...

Page 202: ...e engine running at idle and at 3500 rev min Refer to specification 8 Switch off engine unscrew gauge union and remove gauge 9 Remove adaptor 10 Wipe off oil spillage 11 Fit oil pressure switch Switch Switch Switch Oil Oil Oil Pressure Pressure Pressure Oil Pick Up Strainer Remove 1 Remove engine sump Sump Sump Sump Reseal Reseal Reseal 2 Remove 2 bolts securing oil pick up strainer to oil rail 3 ...

Page 203: ...mating faces of sump and bearing ladder are clean 2 Position new gasket and sump to engine bearing ladder and fit bolts ensuring that 2 longest bolts are in their original fitted positions Lightly tighten bolts Caution Do not work on or under a vehicle supported only by a jack Always support the vehicle on safety stands 3 Fit bolts securing sump to transmission housing lightly tighten and then loo...

Page 204: ... tighten to 5Nm 5 Tighten lower screw securing drive gear front upper cover to engine to 5Nm 6 Connect battery earth lead Camshaft Drive Belt Cover Rear Upper Remove 1 Disconnect battery earth lead 2 Remove camshaft drive belt Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3 Suitably identify each timing gear to its respective camshaft 4 Remove timing gear locking tool T10029 5 Use T1...

Page 205: ...nkshaft Pulley Remove 1 Disconnect battery earth lead 2 Remove starter motor Starter Starter Starter motor motor motor 3 Raise front of vehicle Warning Do not work on or under a vehicle supported only by a jack Always support the vehicle on safety stands 4 Remove RH front wheel 5 Remove ancillary drive belt Drive Drive Drive belt belt belt 6 Fit flywheel locking tool T10036 automatic transmission ...

Page 206: ... jack pad with a block of wood or hard rubber 3 Remove 3 bolts securing PAS reservoir to engine RH mounting and position reservoir aside 4 Remove 3 bolts securing engine RH mounting to engine 5 Remove 2 bolts securing engine RH mounting to body 6 Remove engine RH mounting Refit 1 Clean mounting mounting and body mating faces 2 Fit engine RH mounting to engine Secure 2 bolts from engine RH mounting...

Page 207: ...ont Oil Seal Exhaust Remove 1 Disconnect battery earth lead 2 Remove drive belt upper rear cover Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt Cover Cover Cover Rear Rear Rear Upper Upper Upper 3 Remove camshaft oil seal using T10022andT10023 4 Remove and discard seal 5 Remove bolt from camshaft Refit 1 Clean camshaft seal locations and running surfaces 2 Fit T10013to end of camshaft...

Page 208: ...r Rear Upper Upper Upper 5 Connect battery earth lead 1 8VCT Camshaft Drive Belt New Remove 1 Disconnect battery earth lead 2 Remove drive belt front upper cover Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt Cover Cover Cover Front Front Front Upper Upper Upper 3 Remove engine RH hydraulic mounting Engine Engine Engine Hydramount Hydramount Hydramount RH RH RH 4 Rotate crankshaft clo...

Page 209: ...dge with a bend radius greater than 50 mm Do not use a drive belt that has been twisted or bent double as this will damage the reinforcing fibres Do not use a drive belt if debris other than belt dust is found in the timing cover Do not use a drive belt if partial engine seizure has occurred Do not use a drive belt if belt mileage exceeds 72 000 km Do not use an oil or coolant contaminated belt ca...

Page 210: ... Position Position Sensor Sensor Sensor 16 Use a Allen key to rotate tensioning lever in an anti clockwise direction and align pointer to index wire as shown 17 If original belt is to be refitted then the pointer must be aligned so that the index wire is adjacent to lower land of pointer 18 Tighten tensioner bolt to 20 23Nm Caution It is imperative that the pointer approaches the index wire from a...

Page 211: ...ove Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt old old old version version version Remove Remove Remove 3 Remove phaser unit plug 4 Use a spanner fitted to camshaft hexagon to counteract torque Remove bolt and plain washer securing phaser unit to camshaft 5 Remove phaser unit Remove 1 Clean component mating faces 2 Fit phaser to camshaft fit and finger tighten retaining bolt and w...

Page 212: ...move battery carrier bracket Battery Battery Battery carrier carrier carrier bracket bracket bracket 9 Release clips securing battery lead and harness connector blocks to battery carrier 10 Remove 4 bolts securing battery carrier and remove bracket 11 Release 2 harness clips from battery carrier support bracket and remove bracket 12 Disconnect vacuum pipe from throttle body and position aside Caut...

Page 213: ...s to prevent contamination 20 Disconnect PASpump pressure sensor multiplug 21 Remove 2 nuts and 3 bolts from PASpump and tie aside 22 Release clip securing return hose to coolant reservoir at cylinder block 23 Disconnect coolant heater hose at coolant elbow and position aside 24 Release clip disconnect coolant top hose from coolant elbow and position aside 25 Release clip securing heater hose to e...

Page 214: ... around components to prevent ingress of foreign matter into fuel system 28 Disconnect transmission multiplug 29 Open fuse box lid and disconnect 3 electrical connectors 30 Cut cable tie securing starter motor solenoid lead to engine harness and position aside 31 Remove bolt securing battery ground cable to body and disconnect battery ground cable 32 Release clip from bottom hose elbow release hos...

Page 215: ...s to 25Nm 10 Fit LH inner drive shaft to transmission 11 Fit clutch slave cylinder and secure clip 12 Lower vehicle 13 Connect bottom hose elbow and secure the clip 14 Connect coolant top hose to coolant elbow and secure clip 15 Connect coolant heater hose to coolant elbow and secure clip 16 Fit bolt securing battery ground cable to body tighten 17 Secure starter motor solenoid lead to engine harn...

Page 216: ...efill Refill 43 Bleed the power steering system Power Power Power Assisted Assisted Assisted Steering Steering Steering System System System Bleeding Bleeding Bleeding 1 8VCT Engine and Automatic Transmission Remove 1 Position vehicle on a 2 post ramp 2 Drain coolant Coolant Coolant Coolant Drain Drain Drain Flush Flush Flush and and and Refill Refill Refill 3 Remove front subframe Subframe Subfra...

Page 217: ...lector cable from gearbox bracket 16 Remove 2 bolts securing gear selector cable bracket to automatic transmission and release gear selector cable bracket 17 Remove PAS reservoir screw top and syphon fluid 18 Remove 3 bolts securing PASreservoir to RH engine mounting and position aside 19 Release clip securing PASreturn hose to reservoir Caution Always fit plugs to open connections to prevent cont...

Page 218: ...in confined spaces is also explosive and toxic Always have a fire extinguisher containing foam CO2 gas or powder close Caution Always fit plugs to open connections to prevent contamination Caution Before disconnecting any part of the fuel system it is imperative that all dust dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system 28 Release crank ca...

Page 219: ...e and transmission 43 Remove nut securing gearbox to LH transmission hydramount 44 Remove 3 bolts securing RH engine hydramount to engine 45 Check the engine and transmission are stable and with assistance raise the ramp 46 With assistance manoeuvre engine and transmission to bench Refit 1 With assistance position engine and transmission assembly to engine bay and support on wood 2 Remove lifting ...

Page 220: ...Sreservoir to RH engine hydramount and tighten bolts to 7 10 Nm 29 Position gear selector cable align bracket to gearbox and tighten bolts to70 90Nm 30 Secure selector cable to transmission bracket with clip 31 Connect gear selector cable to starter inhibitor position sensor and tighten nut 32 Position AC compressor to mounting and secure with bolts to 22 28Nm 33 Connect vacuum pipe to throttle bo...

Page 221: ...solenoid to housing tighten bolt to 9Nm 3 Connect solenoid multiplug 4 Connect battery earth lead 1 8VCT Solenoid Inlet Camshaft Remove 1 Disconnect battery earth lead 2 Disconnect solenoid multiplug S 1 0 6 0 0 5 S 1 0 6 0 2 7 S 1 0 6 0 2 8 3 Position absorbent cloth to collect spillage remove bolt securing solenoid to housing and remove solenoid Refit 1 Clean mating faces of components Fit new O...

Page 222: ...camshaft solenoid Solenoid Solenoid Solenoid exhaust exhaust exhaust camshaft camshaft camshaft 1 8VCT Solenoid Housing Inlet Camshaft Remove 1 Remove inlet camshaft solenoid Solenoid Solenoid Solenoid inlet inlet inlet camshaft camshaft camshaft 101702 101702 101702 2 Remove 3 bolts securing housing to camshaft carrier remove housing and discard gasket S 1 0 6 0 0 5 S 1 0 6 0 2 7 S 1 0 6 0 2 8 Re...

Page 223: ...uel feed pipe and release pipe from fuel rail Caution Always fit plugs to open connections to prevent contamination 18 Release clip and disconnect purge hose from throttle housing 19 Depress collar and disconnect brake servo vacuum hose from inlet manifold 20 Release clip and disconnect expansion tank hose from inlet manifold 21 Remove camshaft alignment setting tool T10058 22 Using sequence shown...

Page 224: ...in sequence 180 Then tighten all bolts in sequence a further 135 20Nm180 135 17 Ensure radial marks are aligned Should any bolt be overtightened back off 90 and re align 18 Adjust camshaft to the position as the picture shown 19 FitT10058to the back of camshaft 20 Fit rear upper camshaft drive belt cover Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt Cover Cover Cover Rear Rear Rear U...

Page 225: ...Exhaust Manifold Manifold Manifold Gasket Gasket Gasket 35 Fit air cleaner Air Air Air Cleaner Cleaner Cleaner 36 Connect battery earth lead 37 Refill cooling system Coolant Coolant Coolant Drain Drain Drain Flush Flush Flush and and and Refill Refill Refill Version 2 0 209 ...

Page 226: ...eve Camshaft Oil Seal T10015 Replacer camshaft oil seal T10018 Retainer clamps cylinder block line Tool Number Description Picture T10032 Replacer Front Crankshaft Camshaft Seals T10016 Piston ring compressor T10059 Protector Sleeve Crankshaft Rear oil seal T10040 Protector Sleeve Crankshaft Rear oil seal T10033 crankshaft oil seal replacer rear Version 2 0 210 ...

Page 227: ...kshaft Front Oil Seal Remover T10028 flywheel locking tool T10029 timing gear locking tool T10030 timing gear retainer Tool Number Description Picture T10001 Engine oil pressure test equipment T10036 Flywheel lockingAT T10037 Flywheel locking MT T10022 Remover camshaft oil seal T10023 Adapter remover camshaft seal Version 2 0 211 ...

Page 228: ...Engine Engine Mechanical 1 8 VCT Tool Number Description Picture T10058 Adjuster VCT camshaft timing T30001 Remover drive shaft Version 2 0 212 ...

Page 229: ... to radiator 7 10 Nm Bolt Bonnet locking platform to body 7 10 Nm Bolt Bonnet locking platform bracket to platform 7 10 Nm Bolt Safety catch to bonnet locking platform 7 10 Nm Bolt Coolant outlet tube to auto transmission 18 Nm Bolt Coolant inlet tube to auto transmission 18 Nm Bolt Coolant pump to cylinder block 10Nm Bolt Camshaft timing belt back cover to coolant pump 10Nm Bolt Dipstick support ...

Page 230: ...ed 112 Off Low speed 94 High speed 106 Cooling fan switching points for engine cooling immediately after engine stops On High speed 104 Low speed Engine coolant temperature sensor failure Search time No more than 300 seconds Radiator Cross flow radiator Coolant pump Radial flow impeller mechanical Coolant pump drive ratio 1 1 Thermostat Wax element Thermostat operating temperature Initial opening ...

Page 231: ... pipe to radiator 8 Radiator right hand support bracket 9 Bleed hose radiator to expansion tank 10 Bleed hose cylinder head to expansion tank 11 Expansion tank cap 12 Expansion tank 13 Expansion tank bracket 14 Coolant level sensor 15 Hose coolant expansion tank to T piece 16 Hose heater return 17 T piece 18 Hose T piece to rear coolant pipe 19 Hose heater feed 20 Cooling fan motor heatshield 21 C...

Page 232: ...tor right hand support bracket 8 Bleed hose radiator to expansion tank 9 Bleed hose inlet manifold to expansion tank 10 Expansion tank cap 11 Expansion tank 12 Expansion tank bracket 13 Coolant level sensor 14 Hose coolant expansion tank to T piece 15 Hose heater return 16 T piece 17 Hose T piece to rear coolant rail 18 Hose heater feed 19 Cooling fan motor 20 Hose thermostat to coolant elbow 21 T...

Page 233: ...omponent Layout 1 Flanged bolts 2 Rear coolant pipe 3 Bleed screw 4 Sealing washer 5 Flanged bolt 6 ECT sensor 7 Sealing washer 8 Elbow engine outlet 9 Gasket 10 Pillar bolt 11 Flanged bolts 12 Coolant pump 13 Seal 14 Coolant pump location dowel Version 2 0 217 ...

Page 234: ...ear coolant pipe Additional hoses in the coolant system redirect flow through the turbocharger The turbocharger feed hose is connected to the engine lower coolant hose The turbocharger coolant return hose is connected to the front coolant pipe behind the radiator The feed and return hoses and coolant elbow outlet hose are manufactured from silicone rubber A bleed screw is fitted in the rear coolan...

Page 235: ...d in front of the lower section of the radiator The radiator cooling fan and motor assembly is fitted to a cowl at the rear of the radiator A heatshield is fitted to the rear of the motor to protect it from the high temperature generated by the turbocharger The fan is a pull through type drawing air through the radiator when in operation with the cowl featuring five additional vents on the LH side...

Page 236: ...Engine Engine Cooling System Operation Coolant Flow Turbocharger A Cold B Hot VCT Version 2 0 220 ...

Page 237: ... cooling system as the coolant expands with temperature rise This increase in pressure raises the boiling point of the coolant allowing the engine to run at a higher more efficient operating temperature without the risk of coolant boiling There is a limit to which the cooling system can be pressurised so the cap is fitted with a relief valve This will release any excess pressure in the cooling sys...

Page 238: ...he internal relay windings The cooling fan relay receives a 12V supply through fuse 4 in the engine compartment fusebox The fan motor is driven by the output from the internal relays through fuse 4 in the engine compartment fusebox To produce a slow fan speed theECM provides a ground path to pin 1 of connector EB037 at the relay To produce a fast fan speed theECM provides a ground path to pin 2 of...

Page 239: ... bleed valve and blow through to ensure bleed valve pin is not sticking 5 Connect hose to bleed valve and secure with clip 6 Remove bleed screw from coolant pipe 7 Prepare coolant to required concentration Fluids Fluids Fluids 8 Fill cooling system keeping coolant up to neck of expansion tank until a steady stream of coolant is emitted from bleed screw hole Fit and tighten bleed screw 9 Continue f...

Page 240: ... Refit Refit Refit Expansion Tank Cap Pressure Test Check 1 Visually check engine and cooling system for signs of coolant leaks 2 Examine hoses for signs of cracking distortion and security of connections 3 Remove expansion tank cap Warning Since injury such as scalding could be caused by escaping steam or coolant do not remove the filler cap from the coolant expansion tank while the system is hot...

Page 241: ...System Pressure Test Check 1 Examine hoses for signs of cracking distortion and security of connections 2 Remove expansion tank filler cap Warning Since injury such as scalding could be caused by escaping steam or coolant do not remove the filler cap from the coolant expansion tank while the system is hot 3 Fit adaptor from pressure testing kit T14001to expansion tank 4 Fit pressure hose from pres...

Page 242: ...of coolant in the tank to below the fluid level Coolant Coolant Coolant drain drain drain 4 Clamp hoses from expansion tank to T pieces 5 Release clips securing hoses to expansion tank 6 Position container to collect coolant 7 Release hoses from expansion tank 8 Disconnect coolant level sensor multiplug 9 Remove 2 bolts securing expansion tank to bracket and remove tank Refit 1 Position tank fit b...

Page 243: ... Remove Remove Remove 4 Remove 2 bolts securing bonnet locking platform supports to platform 5 Mark fitted position of safety catch Remove 2 bolts securing safety catch to bonnet locking platform and position aside 6 Remove 4 bolts securing bonnet locking platform to body and position aside 7 Disconnect cooling fan relay unit multiplugs 8 Remove 2 bolts securing relay unit to radiator 9 Position c...

Page 244: ... correctly in fan cowl 4 Position fan relay unit to radiator fit bolts and tighten to 7 10 Nm 5 Connect fan multiplugs and secure to body 6 Position safety catch to approximate fitted position and connect multiplug 7 Position bonnet locking platform to body and radiator fit and tighten bolts to 7 10 Nm 8 Position bonnet locking platform supports to platform fit and tighten bolts to 7 10 Nm 9 Align...

Page 245: ... screws Ensure that the lead and wire harness will not cause any interference 5 Fit cooling fan cowl and motor assembly Fan Fan Fan assembly assembly assembly Refit Refit Refit 6 After completing the replacement check the operation of the fan and ensure that the low speed condition of the fan is operational Radiator Assembly Remove 1 Drain cooling system Coolant Coolant Coolant Drain Drain Drain 2...

Page 246: ...hicle and secure in mountings taking care not to damage cooling fins 3 Connect cooling fan multiplugs 4 Position and secure transmission fluid hoses to radiator Automatic transmission models only 5 Fit relay unit to radiator fit bolts and tighten to 7 10 Nm 6 Connect radiator top hose and bleed hose to radiator and secure with clip 7 Fit thermostat to fan cowl lug and position hose to fan cowl bra...

Page 247: ...event contamination 5 Remove bolt securing hose to transmission release hose from transmission and remove from vehicle Caution Always fit plugs to open connections to prevent contamination 6 Remove and discard O ring Refit 1 Lubricate new O ring with clean transmission fluid and fit O ring to hose 2 Fit hose to transmission fit and tighten bolt to 18 Nm 3 Position hose and secure hose to radiator ...

Page 248: ...ent contamination 4 Remove bolt securing hose to transmission release hose from transmission and remove from vehicle Caution Always fit plugs to open connections to prevent contamination 5 Remove and discard hose O ring Refit 1 Lubricate new O ring with clean transmission fluid and fit O ring to hose 2 Fit hose to transmission fit and tighten bolt to 18 Nm 3 Position hose and secure to radiator 4 ...

Page 249: ...ling system Coolant Coolant Coolant Drain Drain Drain 4 Remove bolt securing dipstick tube support bracket 5 Remove bolt securing camshaft drive belt rear cover to coolant pump 6 Remove 5 bolts securing coolant pump to cylinder block 7 Release coolant pump from 2 dowels 8 Remove coolant pump 9 Remove and discard O ring from coolant pump body Refit 1 Clean component mating faces 2 Clean dowel and d...

Page 250: ...Engine Engine Cooling System Special Tools Tool Number Description Picture T14001 Cooling System Pressure Test Kit T84001 Harness Repair Kit Version 2 0 234 ...

Page 251: ...t system 55 75Nm Bolt Exhaust pipe frame to body 19 28Nm Nut Front Front pipe to turbocharger 45 55Nm Bolt Front pipe frame to engine oil pan 20 25Nm Bolt Heat shield to alternator bracket 40 50Nm Bolt Compressor to engine 22 28Nm Nut Heat shield to alternator 4 6Nm Screw Silencer heatshield to body 4 6Nm Bolt Exhaust pipe and Fuel tank heat shield to body 4 6Nm Bolt Throttle body to inlet manifol...

Page 252: ... Exhaust System Description and Operation System Component Layout 1 8T Inlet and Exhaust System Air Cleaner Component layout 1 8T 1 Air cleaner cover screw 2 Air cleaner cover 3 Inlet duct screw 4 Inlet duct Version 2 0 236 ...

Page 253: ...old Exhaust System Engine 5 Worm drive clamp 6 Outlet duct 7 Worm drive clamp 8 Air cleaner mounting bracket 9 Bolt air cleaner mounting bracket to body 10 Air cleaner housing 11 Air cleaner element Version 2 0 237 ...

Page 254: ...et Inlet Inlet Manifold Manifold Manifold Components Components Components 1 Inlet manifold 2 Nut inlet manifold to cylinder head 3 Gasket inlet manifold to cylinder head outside 4 Gasket inlet manifold to cylinder head inside Version 2 0 238 ...

Page 255: ...yout 1 8T 1 8T 1 8T 1 Gasket exhaust manifold to cylinder head 2 Flanged nut exhaust manifold to turbocharger 3 Exhaust manifold 4 Gasket exhaust manifold to turbocharger 5 Stud turbocharger to exhaust manifold 6 Flanged nut turbocharger to exhaust manifold 7 Turbocharger 8 Flanged nut exhaust manifold to cylinder head Version 2 0 239 ...

Page 256: ...out Layout Layout 1 8T 1 8T 1 8T 1 Gasket front pipe to turbocharger 2 Front pipe incorporating TWC 3 Intermediate pipe 4 Rubber mounting 5 Rear silencer and tail pipe 6 Rubber mounting 7 Rubber mounting 8 Rubber mounting 9 Nut front pipe to intermediate pipe 10 Gasket front pipe to intermediate pipe Version 2 0 240 ...

Page 257: ...Engine Manifold Exhaust System Engine 11 Bolt front pipe to sump Version 2 0 241 ...

Page 258: ...m Component Layout 1 8VCT Inlet and Exhaust System Inlet Manifold Components 1 Inlet manifold 2 Nuts inlet manifold to cylinder head 3 Gasket inlet manifold to cylinder head outside 4 Gasket inlet manifold to cylinder head inside Version 2 0 242 ...

Page 259: ... Component layout 1 Air cleaner cover screw 2 Air cleaner cover 3 HFM sensor housing seal 4 HFM sensor and housing 5 HFM sensor housing screw 2 off 6 Worm drive clip 7 Duct 8 Worm drive clip 9 Inlet duct screw 10 Inlet duct screw 2 off Version 2 0 243 ...

Page 260: ...Engine Engine Manifold Exhaust System 11 Air cleaner housing 12 Air cleaner mounting bracket 13 Bolt air cleaner mounting bracket to body 14 Air cleaner element Version 2 0 244 ...

Page 261: ...fold Manifold Manifold Component Component Component Layout Layout Layout 1 Exhaust manifold 2 Gasket exhaust manifold to cylinder head 3 Manifold nut 4 Bolt manifold to intermediate pipe 5 Stud support bracket to engine 6 Nut support bracket to engine Version 2 0 245 ...

Page 262: ...m Exhaust System Component Layout 1 Intermediate pipe 2 Rubber mounting 3 Rear silencer and tail pipe 4 Rubber mounting 5 Rubber mounting 6 Rubber mounting 7 Flanged nut 3 off 8 Gasket intermediate pipe to exhaust manifold Version 2 0 246 ...

Page 263: ...e ETB is fitted to the LH end of the inlet manifold and is secured with four bolts and sealed with an O ring A Temperature Manifold Absolute Pressure TMAP sensor is fitted on the top of the manifold on the RH side and sealed with an O ring Exhaust Manifold 1 8T The exhaust manifold is of cast stainless steel construction Four separate branches one from each exhaust port are welded to a flange secu...

Page 264: ...rate branches one from each exhaust port are welded to a flange secured to the cylinder head using seven studs with nuts A metal corrugated gasket seals the exhaust manifold to the cylinder head The four branches merge into the Three Way CatalystTWC A support bracket is fitted to the engine block with two studs and two nuts and is secured to theTWCusing a clamp A single pipe exits from theTWCand c...

Page 265: ...d this combined with increased fuelling results in greater engine torque and power The exhaust gases exit the turbocharger and pass through the catalytic converter and into the exhaust system where they enter the silencers The primary silencer is an absorption type with perforated tubing passing through the silencer body The perforations allow the noise energy to penetrate the silencing material r...

Page 266: ... to penetrate the silencing material reducing the exhaust noise to an acceptable level whilst also minimising the restriction to the flow The secondary rear silencer is a reflective type silencer that uses internal baffles to reflect the sound waves towards the source to reduce noise levels Three way Catalytic Converter TWC 1 8VCT Warning TWCs operate at very high temperatures therefore extreme ca...

Page 267: ... 2 9 6 Remove 2 screws and release intake ducting hose from front panel 7 Release air cleaner from 3 grommets and remove air cleaner Refit 1 Fit air cleaner and secure on grommets 2 Fit air intake ducting hose to front panel and secure with screws 3 Fit boost control solenoid to air cleaner Turbocharged models only 4 Clean HFMsensor housing and mating face Fit HFMsensor and housing to air cleaner ...

Page 268: ...Pipe and Silencer Remove Warning Exhaust components get extremely hot during operation Ensure exhaust components are sufficiently cooled before handling 1 Raise the vehicle on a lift 2 Loosen clamp bolt securing silencer to intermediate pipe 3 With assistance remove 2 rubber mountings from body remove tail pipe from intermediate pipe and remove from vehicle Refit 1 Clean mating faces of silencer a...

Page 269: ... Release 3 rubber mountings securing intermediate pipe to body 8 Remove intermediate pipe and collect gasket 9 Remove HO2S from intermediate pipe Turbocharged models only Refit 1 Clean component mating faces Apply anti seize compound to thread of HO2S 2 Fit HO2S to intermediate pipe and tighten to 45 60Nm Turbocharged models only 3 Clean mating faces of front and intermediate pipes and fit new gas...

Page 270: ...engine 8 Remove front pipe and collect gaskets 9 Remove HO2S from front pipe Refit 1 Clean components and mating faces 2 Apply anti seize compound to thread of HO2S 3 Fit HO2S to front pipe and tighten to 45 60Nm 4 Fit new exhaust gaskets 5 Position front pipe to intermediate pipe and turbocharger 6 Fit and tighten nuts securing front pipe to intermediate pipe and tighten to 55 75Nm 7 Fit lower 2 ...

Page 271: ...mpressor to engine 5 Fix compressor aside and support it 6 Remove bolt securing heat shield to alternator lower bracket and remove heatshield Refit 1 Position heat shield and secure to alternator lower bracket with bolt and tighten to 40 50Nm 2 Move A C compressor into position and tighten bolts to 22 28Nm 3 Release tension and fit drive belt 4 Fit undertray Undertray Undertray Undertray Assembly ...

Page 272: ...s to 4 6Nm 2 Fit tail pipe and silencer Tail Tail Tail Pipe Pipe Pipe and and and Silencer Silencer Silencer Heat Shield Exhaust Pipe and Fuel Tank Remove 1 Remove intermediate pipe Intermediate Intermediate Intermediate pipe pipe pipe 2 Remove 8 screws securing fuel tank heat shield to body Remove heat shield Refit 1 Fit fuel tank heat shield to body and tighten screws to 4 6Nm 2 Fit intermediate...

Page 273: ...olts securing throttle body to inlet manifold 6 Remove throttle body 7 Remove and discard O ring from throttle body Refit 1 Clean mating faces of throttle body and inlet manifold 2 Fit O ring to inlet manifold 3 Position throttle body to inlet manifold fit bolts and tighten in a diagonal sequence to 9Nm 4 Connect air duct to throttle body and secure with clip 5 Connect multiplug to throttle body 6...

Page 274: ...w MAP sensor to throttlebody inlet pipe 1 8 2 4Nm Bolt Knock sensor 25Nm Heated oxygen sensor 45 60Nm Bolt fuel rail to intake manifold 9Nm Bolt charcoal canister to body 10 15Nm Bolt fuel tank strap 21 25Nm Bolt handbrake cables to Fuel tank strap 19 22Nm Bolts anti roll bar bush and clamp to subframe 22 28Nm fuel tank unit locking ring 75 85Nm Bolt fuel pump closing panel to body 7 10Nm Bolt fue...

Page 275: ... Absolute Pressure sensorsTMAP 4 Knock sensor 5 Electronic Throttle Body ETB sensor 6 Engine Control ModuleECM 7 Crankshaft Position sensorCKP 8 Boost control solenoid valve 9 Main relay 10 A C compressor clutch relay 11 Cooling fan relay unit 12 Engine Coolant Temperature sensorECT 13 Heated Oxygen SensorHO2S 14 Camshaft Position sensorCMP 15 Engine oil pressure switch 16 Ignition coils 17 Fuel i...

Page 276: ...Engine Engine Fuel Management System Cruise Control System Component Location 1 Clutch switchMT only 2 Indication lamp 3 Main switch 4 ECM Version 2 0 260 ...

Page 277: ...Engine Fuel Management System Engine Control Diagram 1 8T Engine Management System Control Diagram A Hard wiredB HSCAN BusC MSCAN BUS Version 2 0 261 ...

Page 278: ...sor 3 Alternator 4 SCS ABSmodule 5 PAS pressure sensorWhere fitted 6 TMAP sensor 1 7 TMAP sensor 2 8 ECT Sensor 9 ETC 10 Ignition Coils 11 CKP sensor 12 CMP sensor 13 Boost valve 14 Fuel injectors 15 Purge valve 16 HO2S 17 TCMAT only 18 ECM 19 BCM 20 Instrument Pack Version 2 0 262 ...

Page 279: ...ise Cruise Cruise System System System Control Control Control Diagram Diagram Diagram A Hard wiredB HSCAN BusC MSCAN BUS 1 Clutch switchMT only 2 SCS ABSmodule 3 ECM 4 ETC 5 BCM 6 Instrument Pack 7 Main switch 8 Brake switch Version 2 0 263 ...

Page 280: ...ssion only The sensor connects to the engine management harness using connector EM012 It receives a 12V supply provided by the main relay and via fuse 2 The CKP sensor also requires a ground path this is provided by the ECM The teeth on the reluctor ring are spaced at 6 intervals There are 58 teeth this leaves a space where two teeth are missing When the crankshaft is positioned at 36 After Top De...

Page 281: ...or EM015 TheECT sensor consists of an NTC thermistor which is in contact with the engine coolant and is part of a voltage divider circuit which consists of a regulated 5 volt supply a fixed resistor inside the ECM and a temperature dependent variable resistor insideECT sensor Electronic Throttle Body ETB The ETB connects to the engine management harness using connector EM004 The sensor consists of...

Page 282: ...system is in excess of 50 kV and the LT voltage is in excess of 400V Voltages this high can cause serious injury and may even be fatal Never touch any ignition components while the engine is running or cranking Fuel Injectors Four fuel injectors are located in the inlet manifold ports sealed with O rings at their base The injectors are connected to the injector harness using connectors C0522 IL002...

Page 283: ...h switch consists of an inner sensor in an outer mounting sleeve To ensure correct orientation the sensor is keyed to the mounting sleeve and the mounting sleeve is keyed to the pedal mounting bracket Mating serrations hold the sensor in position in the mounting sleeve PAS Pressure Sensor ThePAS pump is driven from the crankshaft pulley via a polyvee drive belt Turning the steering wheel onto full...

Page 284: ...valves This description is limited to only the inputs and outputs which relate to the ECM For further information on the EAT refer to Automatic Transmission TheECM and theTCM are able to communicate via theCAN Bus This allows the sharing of information collected from sensors installed in the powertrain components TheECM transmits sensor information which is used by theTCM to control gear shift tim...

Page 285: ...e ECM When a correctly coded handset is used to attempt an engine start the immobilization module will energize the starter relay located in the engine compartment fusebox and crank the engine The immobilisation module will also authorize engine fuelling by transmitting a signal to the ECM The security code and authorization to start are transmitted between the immobilisation module and theCAN via...

Page 286: ...etect when the engine has completed a warm up cycle Throttle angle This message is transmitted by the ECM TheTCM uses this information to control gear shift scheduling Air Conditioning A C The A C system uses theECM to operate the electromagnetic clutch which drives the refrigerant compressor TheECM engages the compressor clutch by providing a ground path to the winding of the A C clutch relay Whe...

Page 287: ...g TheECM communicates with the following fuel system components Electric fuel pump Sender unit Purge valve The fuel tank contains a sender unit for the fuel gauge connected in series with the instrument pack The instrument pack uses a complex algorithm to accurately measure the quantity of fuel in the tank Evaporative Emission EVAP System The EVAP system prevents fuel vapour emissions to the atmos...

Page 288: ...ETB as necessary to maintain the vehicle at the set speed The cruise control warning light provides a visual indication of when the system is engaged Steering Wheel Switches The steering wheel switches the master SET and RES are non latching push switches that engage and disengage cruise control and adjust the set speed While pressed the switches connect a power supply to the ECM Warning Light The...

Page 289: ...elay Output K4 Not used L1 Fuel injector 1 ground Output L2 Fuel injector 2 ground Output L3 Fuel injector 3 ground Output L4 Fuel injector 4 ground Output M1 ETB actuator negative side Output M2 ETB actuator positive side Output M3 HO2S pre catalyst heater ground Output M4 HO2S post catalyst heater ground Output Connector EM056 black 32 pin Pin No Description Input Output A1 A C pressure sensor s...

Page 290: ...PS 1 ground Output C3 Not used C4 PPS 1 supply Output D1 Brake switch signal Input D2 PPS 2 signal Input D3 PPS 2 ground Output D4 PPS 2 supply Output E1 Brake switch safety Input E2 Not used E3 Not used E4 Not used F1 Not used F2 Not used F3 Not used F4 Not used G1 CAN Bus high Input Output G2 CAN Bus low Input Output G3 Clutch switch signal Input G4 Not used H1 Not used H2 CAN Bus Input Output H...

Page 291: ...ocessor Outputs Battery voltage ECM Handset position Fuel injector CKPsensor Coils CMPsensors 5V sensor supply for TMAPsensor TMAP sensor 1 ETB TMAP sensor 2 ECT signal Knock sensor A C compressor clutch relay ECT sensor Purge valve HO2S HO2S ETB Boost control solenoid valve A CA C pressure switch Fuel pump relay PASPAS pressure sensor Main relay Alternator load Cooling fan relays Fuel tank level ...

Page 292: ...ld start the ECM references the ECT sensor to calculate the appropriate amount of fuel required to support combustion and adjusts the idle speed to the correct fast idle value This strategy is maintained until the HO2S reaches a high enough temperature to provide an accurate feedback signal The specific nature of the other open loop conditions listed means that the HO2S feedback is unsuitable as a...

Page 293: ...urrent is supplied when the ignition is on to avoid sudden heating which can damage the ceramic sensor elements Each sensor is connected to the ECM using two wires which are screened to protect the signal from interference The pre catalyst sensor is connected to the ECM at pin E2 and E4 of connector EM056 The output from the sensor can be measured using a multimeter connected between pins 1 and 2 ...

Page 294: ...is reached It can be seen that the process is a continuous switching from rich to lean within the constraints of the Lambda window which allows theTWC to absorb and release oxygen for optimum efficiency For a quick test of closed loop functionality Start engine and run until normal operating temperature is reached Run engine at 2500 rpm to ensure that theHO2S is at normal operating temperature The...

Page 295: ...ow emissions Advancing the ignition may increase power output under certain conditions but it also increases the amount of oxides of nitrogen NOx and hydrocarbons HC produced in the combustion chamber There is a narrow band of ignition points for all engine conditions which give an acceptable compromise between power output and emission control The ignition mapping contained within theECM memory k...

Page 296: ...he ignition is on but does not run during cranking this would indicate that theECM is not seeing aCKP sensor signal Signal output from the CKP sensor can be checked using an oscilloscope connected to pin 15 of connector EM028 Set the scope to display a 12V digital pattern over a time base which allows individual holes to be identified Crank the engine and observe the pattern on the scope Camshaft ...

Page 297: ...erature of the inlet air increases the resistance in the thermistor decreases As the thermistor allows more current to pass to ground the voltage sensed at theECM decreases The change in voltage is proportional to the temperature change of the inlet air From the voltage output of the sensor theECM can correct the fuelling map for inlet air temperature This correction is an important requirement be...

Page 298: ... its viscosity varies This temperature change is detected by the EOT sensor which provides a signal that is inversely proportional to the oil temperature This allows theECM to compensate for these variations by adjusting the fuelling strategy The EOT sensor receives a regulated 5V reference supply from theECM when the ignition is on The ground path is through the ECM The signal voltage can be meas...

Page 299: ...he A C compressor clutch will be disengaged if theECT detects a temperature of more than 118 C 244 F and will not re engage until it falls below 114 C 237 F Failure TheECT sensor could fail or provide an incorrect signal in the following ways Lack of coolant in system due to leakage External wiring open circuit External wiring short circuit to ground External wiring short circuit to 5V External wi...

Page 300: ...upply in parallel through fuse 2 in the engine compartment fusebox from the main relay The fuel injectors operate at a pressure of 3 5 bar 50 lbf in2 To deliver fuel to the engine theECM has to lift the needle off the injector seat by energising the solenoid To energise the solenoid theECM supplies a ground path to the injector winding Each injector opens during the inlet stroke of the cylinder it...

Page 301: ...to pin 87 Pin 30 is connected to battery positive via the engine compartment fusebox there is no fuse protection and is permanently live Pin 86 is connected to battery positive via the engine compartment fusebox there is no fuse protection and is permanently live Pin 85 is connected to the ECM at pin A4 of connector EB042 Pin 87 is connected to the engine compartment fusebox output and supplies th...

Page 302: ...ver circuit the voltage measured may be one volt less than battery voltage A C Clutch Relay The relay coil is supplied with 12V through fuse 9 in the engine compartment fusebox and is live when the main relay is energised The relay coil ground path is controlled by the ECM ECM completes the ground path when anA C on request message is received For further details refer to AIR CONDITIONING Cooling ...

Page 303: ... by the ECM under the OBD legislation therefore the only faults which can be detected are electrical If the ECM detects an electrical fault in the driver circuit to the purge valve it will store fault codes which can be retrieved using the diagnostic tool Failure The valve could fail in the following ways Solenoid winding open circuit Solenoid winding short circuit External wiring short circuit to...

Page 304: ...ill will be be be cancelled cancelled cancelled when when when either either either the the the cruise cruise cruise control control control master master master switch switch switch is is is pressed pressed pressed or or or the the the handset handset handset removed removed removed With cruise control operating speed can be increased by normal use of the accelerator e g for overtaking When the a...

Page 305: ...ve 4 Knock sensor 5 Electronic Throttle Body ETB sensor 6 Engine Control ModuleECM 7 Crankshaft Position sensorCKP 8 Heated Flow Meter sensorHFM 9 Main relay 10 A C compressor clutch relay 11 Cooling fan relay unit 12 Engine Coolant Temperature sensorECT 13 Camshaft Position sensorCMP 14 Heated Oxygen Sensor HO2S 15 Engine oil temperature sensor 16 Engine oil pressure switch 17 Ignition coils 18 F...

Page 306: ...Engine Engine Fuel Management System Cruise Control System Component Location 1 Clutch switchMT only 2 Indication lamp 3 Main switch 4 ECM Version 2 0 290 ...

Page 307: ...Engine Fuel Management System Engine Control Diagram 1 8 VCT Engine Management System Control Diagram A Hard wiredB HSCAN BusC MSCAN BUS Version 2 0 291 ...

Page 308: ...ernator 4 SCS ABS module 5 PAS pressure sensorWhere fitted 6 HFM 7 EOT sensor 8 ECT Sensor 9 ETC 10 Ignition Coils 11 CKP sensor 12 CMP sensor 13 Engine Oil Control Valve 14 Fuel injectors 15 Purge valve 16 HO2S 17 TCMAT only 18 ECM 19 BCM 20 Instrument Pack 21 Knock sensor Version 2 0 292 ...

Page 309: ...ess using connector EM012 It receives a 12V supply provided by the main relay TheCKP sensor also requires a ground path this is provided by the ECM The teeth on the reluctor ring are spaced at 6 intervals There are 58 teeth this leaves a space where two teeth are missing When the crankshaft is positioned at 36 After Top Dead Centre ATDCthe sensor will align to the trailing edge of the first tooth ...

Page 310: ... dependent variable resistor the EOT sensor Engine Coolant Temperature ECT Sensor TheECT sensor is located in the cooling system outlet elbow from the cylinder head and connects to the engine management harness using connector EM015 TheECT sensor consists of an NTC thermistor which is in contact with the engine coolant and is part of a voltage divider circuit which consists of a regulated 5 volt s...

Page 311: ...ary winding has a resistance of 0 7Ω and the secondary winding has a resistance of 10 kΩ An ignition coil cover is fitted and is secured with three bolts Warning The HT voltage of the ignition system is in excess of 50 kV and the LT voltage is in excess of 400V Voltages this high can cause serious injury and may even be fatal Never touch any ignition components while the engine is running or crank...

Page 312: ... pedal mounting bracket A clevis pin and clip connect the input rod of the brake servo to the brake pedal A tang on the end of the brake pedal activates the instant make and break switch The brake switch includes two separate circuits one normally open and one normally closed connecting to ground The two circuits are referred to as brake main and brake safety Clutch Switch Manual Transmission Only...

Page 313: ...nstalled in the powertrain components TheECM transmits sensor information which is used by theTCM to control gear shift timing and ratio selection TheTCM transmits information which is used by theECM to control engine torque output and cooling fan operation On Board DiagnosticsOBD The EMS has been designed to meet the current exhaust emissions standards European Commission Directive Stage 4 EUCD 4...

Page 314: ... also authorise engine fuelling by transmitting a signal to the ECM The security code and authorisation to start are transmitted between the immobilisation module and theECM via the CAN Bus CAN Bus Data Received By The ECM From The TCM ECM The ECM receives the following information from the TCM via the CAN Bus Target gear This tells theECM what gear is currently engaged or if a gear change is in p...

Page 315: ...ted by the ECM The TCM uses this information to control gear shift scheduling Air Conditioning A C The A C system uses theECM to operate the electromagnetic clutch which drives the refrigerant compressor TheECM engages the compressor clutch by providing a ground path to the winding of the A C clutch relay When the A C system requests the compressor on theECM energises the A C compressor clutch rel...

Page 316: ...heECM communicates with the following fuel system components Electric fuel pump Sender unit Purge valve The fuel tank contains a sender unit for the fuel gauge connected in series with the instrument pack The instrument pack uses a complex algorithm to accurately measure the quantity of fuel in the tank Evaporative Emission EVAP System TheEVAP system prevents fuel vapour emissions to the atmospher...

Page 317: ... rear of the cylinder block and is connected via a flexible pipe to the inlet manifold and the charcoal canister The purge valve consists of a solenoid operated valve which is connected to the engine bay harness using connector EM060 is controlled by theECM using a 12V PWM signal Version 2 0 301 ...

Page 318: ...HO2S HO2S ETB Boost control solenoid valve A C pressure switch Fuel pump relay PAS pressure sensor Main relay Alternator load Cooling fan relays Fuel tank level sender MIL Vehicle speed and rough road signals from ABS DSC ECU CAN Bus Immobilisation module Diagnostic CAN Bus CAN Bus Diagnostic CAN Bus All system inputs are in the form of analogue or digital voltage signals all system outputs are dr...

Page 319: ...e speed to the correct fast idle value This strategy is maintained until theHO2S reaches a high enough temperature to provide an accurate feedback signal The specific nature of the other open loop conditions listed means that theHO2S feedback is unsuitable as a control value for fuelling Adaptive strategy also allows theECM to compensate for wear in engine components and for production tolerances ...

Page 320: ...oid sudden heating which can damage the ceramic sensor elements Each sensor is connected to theECM using two wires which are screened to protect the signal from interference The pre catalyst HO2S sensor is connected to theECM at pin E2 and E4 of connector EM056 The output from the sensor can be measured using a multimeter connected between pins 1 and 2 at connector EM018 The post catalystHO2S sens...

Page 321: ...closed loop functionality Start engine and run until normal operating temperature is reached Run engine at 2500 rpm to ensure that theECM is at normal operating temperature The voltage should switch between limits every one to two seconds at idle speed Signal amplitude should reach at least 550 mA when rich and drop below 400 mA when lean Open Loop Fuelling TheECM employs open loop fuelling when i...

Page 322: ...e conditions which give an acceptable compromise between power output and emission control The ignition mapping contained within theECM memory keeps the ignition timing within this narrow band Idle Speed Control TheECM uses two methods of idle speed control Ignition timing adjustment Adjusting the position of the throttle butterfly in the ETB When the engine idle speed fluctuates and there are no ...

Page 323: ...he pump primes when the ignition is on but does not run during cranking this would indicate that theECM is not seeing a CKP sensor signal Signal output from the CKP sensor can be checked using an oscilloscope connected to pin H2 of connector EM055 Set the scope to display a 12V digital pattern over a time base which allows individual holes to be identified Crank the engine and observe the pattern ...

Page 324: ...he resistance in the thermistor decreases As the thermistor allows more current to pass to ground the voltage sensed at theECM decreases The change in voltage is proportional to the temperature change of the inlet air From the voltage output of the sensor theECM can correct the fuelling map for inlet air temperature This correction is an important requirement because hot air is less dense and cont...

Page 325: ...The properties of the NTC thermistor are such that as the temperature of the coolant increases the resistance through theECT reduces This produces a fall in signal voltage as more current via theECM passes through theECT to ground It provides a signal to the ECM which allows the engine temperature to be determined The ECM uses engine coolant temperature to calculate fuelling and ignition timing pa...

Page 326: ...r as poor performance and will be detected by the misfire monitor within the OBD strategy TheECM will store fault codes which can be retrieved using the diagnostic tool In the event of a permanent misfire condition theECM will also shut off fuelling to the affected cylinders thereby protecting theTWC from damaging exhaust pulses Failure An ignition coil could fail in the following ways Primary win...

Page 327: ...the movement of fuel in the tank The fuel tank level is determined by the tank sender unit and interpreted by the instrument pack for display on the fuel gauge The tank sender unit comprising of variable resistors controlled by floats is installed inside the fuel tank The instrument pack receives the signal from the sender unit via the MS CAN Bus and determines fuel level using the resistance thro...

Page 328: ...run for 2 seconds at ignition on If the answer is negative check the inertia switch fuel cut off to ensure it has not been inadvertently triggered If the fuel pump does not appear to run but the inertia switch is ON remove the fuel pump relay and test Check that theECM is supplying a ground path to the fuel pump relay winding at ignition on for 2 seconds and during crank With the fuel pump relay r...

Page 329: ...s stationary and idling to 100 when the vehicle is travelling at speeds less than WOT The mechanical function of the valve can be tested using a vacuum pump If the purge valve fails there is no back up system TheEVAP canister will not be purged so there may be fuel vapours released if levels reach saturation point The driver may notice this condition as a fuel vapour smell from the vehicle when pa...

Page 330: ...will will be be be cancelled cancelled cancelled when when when either either either the the the cruise cruise cruise control control control master master master switch switch switch is is is pressed pressed pressed or or or the the the handset handset handset removed removed removed With cruise control operating speed can be increased by normal use of the accelerator e g for overtaking When the ...

Page 331: ... Coils Remove 1 Disconnect battery earth lead 2 Remove 3 bolts securing spark plug cover to camshaft cover and remove cover 3 Release HT lead from spark plug 4 Remove 2 bolts securing coil and release from spark plug 5 Disconnect multiplug from coil and remove coil 6 Remove HT lead from coil 7 Repeat steps 3 to 5 to remove the remaining coil Refit 1 Fit HT leads to coils 2 Fit coils to spark plugs...

Page 332: ...ic tool Sensor Engine Coolant Temperature ECT Remove 1 Disconnect battery earth lead 2 Remove coolant expansion tank cap to release system pressure then refit cap Warning Since injury such as scalding could be caused by escaping steam or coolant do not remove the filler cap from the coolant expansion tank while the system is hot 3 Disconnect multiplug from ECTsensor 4 Position container to collect...

Page 333: ... 27Nm 3 Connect multiplug to oil pressure switch 4 Remove drain tray 5 Fit undertray Undertray Undertray Undertray assembly assembly assembly 6 Connect battery earth lead 7 Check and if necessary top up engine oil Engine Engine Engine oil oil oil and and and filter filter filter Sensor Crankshaft Position CKP Remove 1 Disconnect battery earth lead 2 Raise the vehicle on a lift 3 Disconnect multipl...

Page 334: ...Psensor fit bolt and tighten to 8Nm 3 Connect CMPsensor multiplug 4 Fit spark plug cover tighten bolts to 7 10Nm 5 Connect battery earth lead Sensor inlet camshaft position CMP VCT Remove 1 Disconnect battery earth lead 2 Disconnect CMPsensor multiplug Exhaust CMPsensor illustrated 3 Remove bolt securing CMPsensor to cylinder head and remove CMPsensor Remove and discard gasket Refit 1 CMP O CMP 2 ...

Page 335: ...CMPsensors to cylinder head and secure with bolt to 8Nm 3 Connect CMPsensor multiplug 4 Connect battery earth lead Sensor temperature and manifold absolute pressure TMAP Remove 1 Disconnect battery earth lead 2 Disconnect TMAPsensor multiplug 3 Remove 2 screws securing TMAPsensor to inlet manifold and remove sensor Refit 1 Clean TMAPsensor and component mating faces 2 Fit TMAPsensor to inlet manif...

Page 336: ... Connect battery earth lead Sensor Knock KS Remove 1 Disconnect battery earth lead 2 Remove undertray Undertray Undertray Undertray assembly assembly assembly 3 Disconnect knock sensor multiplug 4 Remove bolt securing knock sensor to cylinder block and remove knock sensor Refit 1 Clean component mating faces 2 Position knock sensor to cylinder block ensuring harness is correctly routed fit bolt an...

Page 337: ...d tighten to 45 60Nm 3 Connect HO2S multiplug 4 Connect battery earth lead Sensor Heated Oxygen H02S Rear Turbocharger Remove 1 Disconnect battery earth lead 2 Raise the vehicle on a lift 3 Disconnect HO2S multiplug 4 Remove HO2S from intermediate pipe Warning Exhaust components get extremely hot during operation Ensure exhaust components are sufficiently cooled before handling Refit 1 Clean HO2S ...

Page 338: ...arth lead Fuel Rail Remove 1 Disconnect battery earth lead Warning Fuel vapour is highly flammable and in confined spaces is also explosive and toxic Always have a fire extinguisher containing foam CO2 gas or powder close 2 Remove engine oil dipstick 3 Depressurise fuel system Fuel Fuel Fuel system system system depressurise depressurise depressurise 4 Release fuel feed hose from fuel rail Caution...

Page 339: ...rail 5 Secure injectors to fuel rail with spring clips 6 Position fuel rail in inlet manifold and connect injector multiplugs 7 Push each injector into inlet manifold 8 Fit 2 bolts securing fuel rail to inlet manifold and tighten to 9Nm 9 Connect fuel feed hose to fuel rail 10 Fit engine oil dipstick 11 Connect battery earth lead 12 Check fuel rail for leakage Fuel Fuel Fuel system system system p...

Page 340: ...lve Remove 1 Disconnect battery earth lead 2 Raise the vehicle on a lift 3 Disconnect purge control valve multiplug Undertray Undertray Undertray assembly assembly assembly Remove Remove Remove 4 Disconnect purge control valve multiplug 5 Release clip and disconnect hose from inlet manifold 6 Release clip and disconnect breather hose from fuel tank 7 Remove purge control valve from bracket on cyli...

Page 341: ...m fuel tank 7 Release 8 pipe clamps and 12 clips securing fuel pipes assembly to body underfloor 8 Release underfloor pipes from charcoal canister 9 Remove underfloor fuel pipes Refit 1 Fit 8 pipe clamps and 12 clips securing fuel pipe assembly to body underfloor 2 Fit fuel pipe to charcoal canister 3 Fit fuel pipe to fuel tank 4 Fit fuel pipe to fuel filter 5 Fit fuel vent pipe to purge control v...

Page 342: ...l system it is imperative that all dust dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system 6 Raise the vehicle on a lift 7 Remove 2 bolts securing LH anti roll bar saddle clamp to rear subframe and remove clamp 8 Remove 2 bolts securing RH anti roll bar saddle clamp to rear subframe and remove clamp 9 Move rear anti roll bar aside for access to ...

Page 343: ... fit plugs to open connections to prevent contamination 17 Support weight of tank 18 Remove 4 bolts securing fuel tank straps to body and remove straps Lower fuel tank to access top of tank 19 Disconnect fuel pump multiplug 20 Disconnect fuel feed pipe and fuel return pipe from fuel pump to filter 21 With assistance remove fuel tank Refit 1 With assistance position fuel tank 2 Connect fuel feed an...

Page 344: ...Refit Refit Refit 17 Fit handbrake lever closing panel 18 Connect battery earth lead Fuel Pump Remove 1 Disconnect battery earth lead Warning Fuel vapour is highly flammable and in confined spaces is also explosive and toxic Always have a fire extinguisher containing foam CO2 gas or powder close Warning The spilling of fuel is unavoidable during this operation Ensure that all necessary precautions...

Page 345: ...on cushion Refit Refit Refit 8 Connect battery earth lead Fuel System Depressurise Check 1 Position absorbent cloth around fuel rail to catch any fuel spillage Warning Fuel vapour is highly flammable and in confined spaces is also explosive and toxic Always have a fire extinguisher containing foam CO2 gas or powder close Warning The spilling of fuel is unavoidable during this operation Ensure that...

Page 346: ...2and connect adaptor T18003to fuel rail Caution When connecting T18003 to fuel rail do not use excessive force to tighten Tighten only to ensure no leakage overtightening will damage T18003 O ring 5 Position drain tube in a container 6 Start engine allow engine to idle check reading and pressure drop over one minute if the reading is between 3 5 bar and 3 9 bar above manifold pressure the fuel sys...

Page 347: ... area which meets the requirements of local authority regulation 3 Refill fuel tank Fuel Filter Remove 1 Disconnect battery earth lead 2 Depressurise fuel system Fuel Fuel Fuel system system system depressurise depressurise depressurise Remove Remove Remove 3 Raise the vehicle on a lift 4 Disconnect fuel line connectors from fuel filter Caution Always fit plugs to open connections to prevent conta...

Page 348: ...em Caution Always fit plugs to open connections to prevent contamination 3 Drain fuel tank Tank Tank Tank drain drain drain fuel fuel fuel Remove Remove Remove 4 Release fuel filler cap from filler neck 5 Remove RH rear wheel arch liner Liner Liner Liner rear rear rear wheel wheel wheel arch arch arch each each each Remove Remove Remove 6 From underside of wheel arch remove bolt securing filler ne...

Page 349: ... Switch Inertia Fuel Cut Off Remove 1 Disconnect battery earth lead 2 Release the storage box from fascia 3 Remove 2 bolts securing inertia switch to fascia support release switch to access multiplug 4 Disconnect multiplug from inertia switch and remove switch Refit 1 Connect multiplug to inertia switch 2 Position inertia switch to body Fit bolts and tighten to 8Nm 3 Press top of switch to ensure ...

Page 350: ...Engine Engine Fuel Management System Special Tools Tool Number Description Picture T18007 Wrench fuel tank lock ring T18003 Adaptor fuel pressure test T18002 Fuel Pressure Test Equipment Version 2 0 334 ...

Page 351: ...bracket to cylinder head 8 11Nm Nut Alternator upper bracket to cylinder head 22 28Nm Bolt Alternator lower bracket to cylinder block 40 50Nm Bolt A C compressor to installation bracket 22 28Nm Bolt drive belt tensioner to cylinder head 20 23Nm Bolt Starter motor 40 50Nm Nut Battery lead to starter motor 6 10Nm Bolts Battery box carrier fixing bracket to transmission LH hydraulic pressure suspensi...

Page 352: ...Engine Engine Electrical System Description and Operation Component Layout ENGINE ELECTRICAL System View Starting and Charging Component Location 1 Alternator 2 Starter motor Version 2 0 336 ...

Page 353: ...ram Starting and Charging Control Diagram 1 Alternator 2 ECM 3 Starter motor 4 Battery 5 Instrument pack 6 Handset and dock 7 BCM 8 Main fusible linkFL1 150A 9 Ignition switch supply fuse 220A 10 ECMsupply fuse 510A 11 Main relay Version 2 0 337 ...

Page 354: ...nd an iron core and mounted on a shaft The iron core has extensions at each end which form North and South poles as current flows through the field winding The rotor is located inside the stator and is mounted on bearings for smooth running and to support the rotor due to the high side loading applied by the drive belt tension The rectifier located at the rear of the alternator comprises eight sem...

Page 355: ...n and can be used Darken becoming black indicates the lower battery and need to be charged Transparent or yellow indicates the battery can not be used and must be replaced If the indicator shows transparent or yellow the inner of the battery is damaged In this case do not attempt to charge the battery or start the vehicle by external power Version 2 0 339 ...

Page 356: ...th via the alternator field windings causing the warning light to illuminate and supplying the alternator with the initial current When the engine is started the rotor rotates within the stator generating 3 phase Alternating CurrentAC The AC produced is unsuitable for use by the vehicle s electrical system and passes through the rectifier semiconductor diodes The diodes only allow flow of current ...

Page 357: ...t 4 Connect battery earth lead 5 Fit undertray Undertray Undertray Undertray Assembly Assembly Assembly Alternator Remove 1 Disconnect battery earth lead 2 Remove drive belt Drive Drive Drive Belt Belt Belt 3 Remove nut securing battery cable to alternator and remove cable 4 Disconnect multiplug from alternator 5 Remove nut and bolt securing alternator to top support bracket 6 Remove bolt securing...

Page 358: ...ernator 2 Remove nut securing heatshield to alternator upper support bracket 3 Remove bolt and stud securing upper support bracket to cylinder head and remove bracket Refit 1 Fit upper support bracket and tighten bolt to22 28Nm and stud to 8 11Nm 2 Fit nut securing heatshield to upper support bracket and tighten to 22 28Nm 3 Fit alternator Alternator Alternator Alternator Version 2 0 342 ...

Page 359: ...aside 4 Remove bolt securing heat shield to alternator lower support bracket and remove heat insulation plate 5 Remove 4 bolts securing alternator lower support bracket to cylinder block and remove bracket Refit 1 Fit alternator lower support bracket to cylinder block fit 4 bolts and tighten to 40 50Nm 2 Fit alternator heatshield to alternator fit bolt and tighten 3 Fit compressor and tighten 3 bo...

Page 360: ... 3 Hold tensioner with a 13 mm spanner remove retaining pin and lower tensioner pulley onto drive belt 4 FitPAS pump belt Belt Belt Belt PAS PAS PAS Pump Pump Pump Starter Motor Remove 1 Disconnect battery earth lead 2 Disconnect Lucar from starter solenoid 3 Remove nut and disconnect battery lead from starter solenoid 4 Remove 2 bolts securing starter motor and remove starter motor Refit 1 Clean ...

Page 361: ...ay support bracket to LH transmission mounting bracket Remove tray support bracket S 1 2 4 0 0 3 Refit 1 Position battery tray support bracket to LH transmission mounting bracket fit bolts and tighten to 7 10Nm 2 Position battery tray to tray support bracket fit bolts and tighten to 19 25Nm 3 SecureECM to battery tray 4 Fit harness andECM multiplugs to battery tray and secure with clips 5 Position...

Page 362: ...ve 1 Remove drive belt Drive Drive Drive Belt Belt Belt 2 Remove bolt securing tensioner to alternator lower support bracket and remove tensioner Refit 1 Position tensioner fit bolt and tighten to 22 28Nm 2 Fit drive belt Drive Drive Drive Belt Belt Belt Version 2 0 346 ...

Page 363: ...rol AT Specifications Torque Description Value Nut selector cable to arm 14 18Nm Bolt selector cable bracket to transmission 40 50Nm Bolt front heat shield 4 6Nm Bolt selector to central tunnel 19 25Nm Bolt selector housing to vent 9Nm Version 2 0 347 ...

Page 364: ...in a rearward direction changes the transmission down the ratios Some models have additional controls on the steering wheel Once Tiptronic has been selected Sport mode cannot be accessed until the gear selector has been returned to the D position Shift Interlock Solenoid 1 Gear selector 2 Spring loaded interlock hook 3 Pivot 4 Solenoid pushrod 5 Interlock solenoid The transmission incorporates an ...

Page 365: ...y earth lead 3 Remove air cleaner Air Air Air Cleaner Remove Cleaner Remove Cleaner Remove 4 Mark position of pin on neutral start switch 5 Remove wood trim from centre console Wood Wood Wood Trim Remove Trim Remove Trim Remove 6 Release gear selector cable at gear selector assembly end and collect bushing 7 Carefully remove and collect C clip securing gear selector cable to body 8 Remove front RH...

Page 366: ...ntre console Console Console Console Assembly Remove Assembly Remove Assembly Remove 2 Release 2 screws and 1 bolt remove centre console duct 3 Disconnect 2 multiplugs 4 Release clip securing wiring harness to selector assembly 5 Release inner cable from selector lever 6 Remove clip securing outer cable to selector housing and release cable from gear selector assembly 7 Remove 4 bolts securing sel...

Page 367: ...Shift Lock Control MT Transmission Shift Lock Control MT Specifications Torque Description Value Bolt gear change mechanism to floor 19 25Nm Version 2 0 351 ...

Page 368: ... and secure with clips Remote Control Gear Change Manual Remove 1 Remove centre console Console Console Console Assembly Remove Assembly Remove Assembly Remove 2 Note fitted position and disconnect cable ball joints from shift and selector levers 3 Release clips and securing selector cables to abutment bracket 4 Remove 4 bolts securing remote control assembly to body 5 Remove remote control assemb...

Page 369: ... 29 4Nm Bolt transmission to engine 75 90Nm Bolt drive plate to converter 25 35Nm Bolt closing panel to transmission 22 28Nm Bolt CKP sensor to cylinder 10Nm Drain plug 23 5 54 9Nm Bolt dipstick to transmission 7 8 11 8Nm Bolt TCM bracket to body 6 7Nm Nut TCM bracket 8 10Nm Bolt input speed sensor to transmission 3 9 6 9Nm Bolt oil pan to automatic transmission 9 8 15 7Nm Version 2 0 353 ...

Page 370: ...e 1 Flange 1 Clutch disc 4 Clutch plate 4 Brake B1 B2 B3 B4 B5 Flange 1 Brake disc 2 Brake plate 2 Flange 1 Brake disc 3 Brake plate 3 Flange 2 Brake disc 5 Brake plate 4 Brake band 1 Flange 1 Brake disc 6 Brake plate 6 Cushion plate 1 One way clutch F1 F2 One way clutch 1 One way clutch 2 Shift solenoid 5 Linear solenoid 3 S1 S2 S3 S4 S5 SLT SLS SLU ATF JWS 3309 T IV Line pressure Idle speed D R ...

Page 371: ...ransmission AT Transmission Stall revolution 2567rpm Clearance Torque converter Oil seal oil pump LH differential oil seal RH differential oil seal 10 5mm 0 15 0 15mm 3 0 4 0mm 5 5 6 5mm Version 2 0 355 ...

Page 372: ...tic Transmission EAT Component Layout 1 Automatic transmission 2 Tiptronic 3 Gear selector 4 Shift lock solenoid 5 Ignition switch 6 Automatic Transmission FluidATFcoolerIn radiator 7 Brake switch 8 Body Control Module BCM 9 Transmission Control ModuleTCM 10 Neutral Start SwitchNSW Version 2 0 356 ...

Page 373: ...omponent Component Component Layout Layout Layout 1 Gearbox casing 2 Differential oil seal LH 3 Input speed sensor 4 Neutral start switch assembly 5 Transmission oil dipstick 6 Torque converter 7 Drain plug and seal 8 Differential oil seal RH 9 Breather assembly 10 Output speed sensor Version 2 0 357 ...

Page 374: ...f of of Transmission Transmission Transmission 1 Direct clutch C2 2 Forward clutch C1 3 1st and Reverse brake B3 4 One way clutch No 2 F2 5 2nd brake B2 6 2nd coast brake B1 7 One way clutch No 1 F1 8 Torque converter 9 Counter drive gear 10 Counter driven gear Version 2 0 358 ...

Page 375: ...Transmission AT Transmission 11 Differential 12 Underdrive U D brake B4 13 U D clutch C3 14 B5 brake B5 Version 2 0 359 ...

Page 376: ...id Valves Valves Valves 1 Oil temperature sensorOT 2 Line pressure control solenoidSLT 3 Lockup control solenoidSLU 4 Shift solenoid valve 2S2 5 Shift pressure control solenoidSLS 6 Shift solenoid valve 1S1 7 Shift solenoid valve 4S4 8 Shift solenoid valve 3S3 9 Shift solenoid valve 5S5 Version 2 0 360 ...

Page 377: ...em Automatic Transmission Control Diagram A Hard wired B HS CAN Bus C MS CAN Bus D LIN Bus 1 Neutral start switchNSW 2 Input speed sensor 3 Output speed sensor 4 Valve block assembly 5 Transmission ModuleTCM 6 Engine Control ModuleECM Version 2 0 361 ...

Page 378: ...U 10 Body Control ModuleBCM 11 Steering wheel controlsTiptronic 12 Fascia 13 Brake switch 14 Engine coolant temperatureECTsensor 15 Crankshaft positionCKPsensor 16 Throttle position sensor 17 Handset docking station 18 Shift interlock solenoid 19 Diagnostic socket Version 2 0 362 ...

Page 379: ...m System 1 TCM 2 Regulator and modulator solenoid valves 3 Line pressure 4 Shift and control solenoid valves 5 Clutches and brakes 6 Lubrication 7 Planetary gears 8 Sump side cover 9 Oil pump 10 Oil pump pressure 11 Oil cooler 12 Torque Converter TC 13 Oil output to TC 14 Voltage Version 2 0 363 ...

Page 380: ...er attached to a base The selector lever base is located on a gasket and secured to the transmission tunnel by 4 bolts A latch in the lever engages with detents in the base Transmission Gear Ratios Gear Ratio 1st 4 576 2nd 2 980 3rd 1 948 4th 1 318 5th 1 000 Reverse 5 024 Differential 1 8T 2 652 Differential 1 8VCT 2 864 Counter 1 018 Oil pump The TCM sends signals to the various solenoid valves b...

Page 381: ...Solenoid valve on Duty Solenoid Valves The duty solenoid valves are Lock up control solenoid valveSLU Line pressure control solenoid valveSLT Shift pressure control solenoid valveSLS Duty solenoid valves are used to adjust line pressure to give accurate control of the operation of the brakes and clutches They operate on signals from the TCM The lock up control solenoid valve SLU controls the lock ...

Page 382: ...cts the fluid returning from the turbine so that it reenters the impeller in the same direction of rotation as the impeller and at the best possible angle for efficient power transmission The one way clutch prevents the stator from moving backwards so that this accurate redirection of fluid can be achieved When the engine is idling the impeller directs very little fluid the turbine is not forced t...

Page 383: ...ored parameters the TCM will make adjustments to the operation of the transmission through the actuators to provide optimum driveability and performance Inputs to the TCM can be seen in the Automatic Transmission Control Diagram The TCM will make any required adjustment to the operation of the transmission through the following actuators Gear control solenoid valves Lock up solenoid valve Line pre...

Page 384: ...one of the seven selector lever positions Only one set of contacts will supply battery voltage to the TCM at any one time The TCM monitors the switch output The electrical input to the inhibitor switch is provided by fuse 4 of the engine compartment fuse box Speed Sensors The TCM sets correct gear change scheduling using three speed signal inputs input speed output speed vehicle speed The gearbox ...

Page 385: ...ission fluid Fluid Temperature Sensor Resistance Values Temperature Resistance kΩ 10 5 80 7 09 110 0 231 0 263 Brake Switch The brake switch is located in the pedal box within the passenger compartment The TCM uses this switch to monitor brake pedal status The BCM monitors the status of the switch and transmits data to the TCM on the CAN BUS The TCM can allow the transmission to apply more engine ...

Page 386: ...ation of the front ring gear 7 1 way clutch No 1 F1 Locks the counter clockwise rotation of the sun gear when the 2nd brake is active 8 Shows engine rotation Input from Torque Converter 9 Shows differential rotation To differential 10 U D brake B4 Locks the U D sun gear 11 U D clutch C3 Connects the U D sun gear to the U D front carrier 12 B5 brake B5 Locks the U D rear carrier A Shows direction o...

Page 387: ...Transmission AT Transmission 1st Gear D selected C1 C2 C3 B1 B2 B3 B4 B5 F1 F2 Gear S1 S2 S3 S4 S5 2 1 11 5 4 3 10 12 7 6 D 1st ON ON ON OFF OFF ON OFF OFF OFF OFF OFF OFF ON OFF ON Version 2 0 371 ...

Page 388: ...Transmission Transmission AT Version 2 0 372 ...

Page 389: ...Transmission AT Transmission 2nd Gear D selected C1 C2 C3 B1 B2 B3 B4 B5 F1 F2 Gear S1 S2 S3 S4 S5 2 1 11 5 4 3 10 12 7 6 D 2nd OFF OFF ON OFF OFF ON OFF OFF ON ON OFF OFF ON ON OFF Version 2 0 373 ...

Page 390: ...Transmission Transmission AT Version 2 0 374 ...

Page 391: ...Transmission AT Transmission 3rd Gear D selected C1 C2 C3 B1 B2 B3 B4 B5 F1 F2 Gear S1 S2 S3 S4 S5 2 1 11 5 4 3 10 12 7 6 D 3rd OFF OFF ON ON OFF ON OFF OFF ON ON OFF ON OFF ON OFF Version 2 0 375 ...

Page 392: ...Transmission Transmission AT Version 2 0 376 ...

Page 393: ...Transmission AT Transmission 4th Gear D selected C1 C2 C3 B1 B2 B3 B4 B5 F1 F2 Gear S1 S2 S3 S4 S5 2 1 11 5 4 3 10 12 7 6 D 4th OFF OFF OFF ON OFF ON OFF OFF ON ON OFF ON OFF ON OFF Version 2 0 377 ...

Page 394: ...Transmission Transmission AT Version 2 0 378 ...

Page 395: ...Transmission AT Transmission 5th Gear D selected C1 C2 C3 B1 B2 B3 B4 B5 F1 F2 Gear S1 S2 S3 S4 S5 2 1 11 5 4 3 10 12 7 6 D 5th OFF ON OFF ON OFF ON ON ON OFF ON OFF OFF OFF OFF OFF Version 2 0 379 ...

Page 396: ...Transmission Transmission AT Version 2 0 380 ...

Page 397: ...on Reverse Gear C1 C2 C3 B1 B2 B3 B4 B5 F1 F2 Gear S1 S2 S3 S4 S5 2 1 11 5 4 3 10 12 7 6 V 7 OFF OFF ON OFF ON OFF ON OFF OFF OFF ON OFF ON OFF OFF R V 7 ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF Version 2 0 381 ...

Page 398: ...Transmission Transmission AT Version 2 0 382 ...

Page 399: ... the optimum operating pressure at all times For example line pressure is lower under normal operating conditions than it would be under hard acceleration The TCM controls line pressure by actuating the line pressure solenoid valve in the valve block The TCM calculates the line pressure required by using engine speed vehicle speed and throttle position High line pressures will cause very harsh gea...

Page 400: ... when to lock up the torque converter Lock up control is possible in forward gears 2 3 4 and 5 For example lock up is possible when cruising at high vehicle speed with low throttle opening A refinement to the torque converter lock up system is the reduction of harshness or shock during lock and unlock The TCM actuates the lock up solenoid valve which gradually varies the fluid pressure to the lock...

Page 401: ...ngine torque values throttle angle and engine speed This mode delays upshift when the throttle is briefly released such as when approaching a corner on a steep gradient thus preventing unnecessary gear changes Hot Mode The purpose of the transmission fluid cooling strategy is to reduce engine and transmission temperatures during high load conditions Under these conditions the engine and transmissi...

Page 402: ...or from intercooler to throttle valve Electric Electric Electric Throttle Throttle Throttle Includes Includes Includes Tuning Remove Tuning Remove Tuning Remove 2 Release clips securing air cleaner to turbocharger and move aside 3 Remove 3 bolts securing air cleaner bracket to body 4 Release transmission multiplug from air filter bracket and remove bracket 5 Ensure vehicle is in Neutral 6 Release ...

Page 403: ...Neutral Neutral Start Start Start Inhibitor Switch Check Inhibitor Switch Check Inhibitor Switch Check and and and Adjust Adjust Adjust 6 Tighten the inhibitor switch bolts to 19 6 29 4Nm 7 Bend lock washer to nut 8 Fit harness clip to bolt 9 Check that the engine will start in P and N positions and that the engine start is inhibited when drive positions are selected 10 Connect air cleaner hose to...

Page 404: ... selection of all gears 6 Check that the engine will start in P or N positions and that the engine start is inhibited when drive positions are selected Transmission and Converter Remove 1 Remove engine and transmission assembly Engine Engine Engine and and and Automatic Automatic Automatic Transmission Remove Transmission Remove Transmission Remove 2 Disconnect CKP sensor multiplug 3 Remove bolt s...

Page 405: ...nasmission assembly Engine Engine Engine and and and Automatic Automatic Automatic Transmission Refit Transmission Refit Transmission Refit 14 Check and top up transmission fluid Lubrication Lubrication Lubrication System Automatic System Automatic System Automatic Transmission Transmission Transmission top top top up up up Automatic Transmission Fluid Drain and Refill Drain Warning Observe due ca...

Page 406: ...off from breather tube due to oil level increase by stirring and making bubbles inside the transmission Fluid is normally a clan red colour with a consistent viscosity Abnormal fluid could contain water emulsified or different ATF will cause shock harsh shift and bad durability of transmission and bad characteristics of disks and sealing materials 1 Check that fluid temperature is between 70 to 80...

Page 407: ...ll not work if fitted to another vehicle 1 Disconnect battery earth lead 2 Remove glovebox Glove Glove Glove Box Box Box Assembly Remove Assembly Remove Assembly Remove 3 Disconnect 3 BCM multiplugs J L and M and position harness aside 4 Disconnect 2 transmission control unit multiplugs and move harness aside to access front control unit fixing bolt 5 Remove 2 nuts securing control unit to mountin...

Page 408: ...ssembly Refit Assembly Refit 7 Connect battery earth lead Harness Automatic Transmission Remove 1 Remove air cleaner Air Air Air Cleaner Remove Cleaner Remove Cleaner Remove 2 Disconnect multiplug from input speed sensor 3 Disconnect multiplug from output speed sensor 4 Disconnect multiplug from neutral start switch 5 Disconnect transmission harness multiplug 6 Release 3 clips securing harness to ...

Page 409: ... tighten bolt to 3 9 6 9Nm 3 Fit air cleaner assembly Air Air Air Cleaner Refit Cleaner Refit Cleaner Refit Sensor Speed Output Remove Warning Switch off ignition switch and wait for 90 seconds before starting work 1 Remove air cleaner assembly Air Air Air Cleaner Remove Cleaner Remove Cleaner Remove 2 Remove bolt securing sensor to transmission and remove sensor Caution Care must be taken when re...

Page 410: ...on Lubrication Lubrication Lubrication System Drain System Drain System Drain and and and Refill Refill Refill 2 Remove drive shaft assembly Shaft Shaft Shaft with with with Both Both Both Joints Remove Joints Remove Joints Remove 3 Insert the tip of screwdriver between differential housing and oil seal in order to remove oil seal Caution Wrap tape around the tip of the screwdriver and lever caref...

Page 411: ...rive shaft assembly RH RH RH Shaft Shaft Shaft with with with Both Both Both Joints Remove Joints Remove Joints Remove 3 Insert the tip of screwdriver between differential housing and oil seal in order to remove oil seal Caution Wrap tape around the tip of the screwdriver and lever carefully Care must be taken to avoid any damage to the gearbox drive shaft side cover gearbox drive shaft body and h...

Page 412: ...ter Remove Converter Remove 3 Remove torque converter Caution Be careful not to damage the oil seal Caution Be careful not to drop the torque convertor Refit 1 Fit the torque converter on the automatic transmission Caution Be careful not to damage the oil seal Caution Be careful not to drop the torque convertor 2 Check the torque converter is installed correctly 3 Check the clearance between the e...

Page 413: ...emove any traces of sealant from the mating faces of the transmission assembly Caution Ensure that the mating faces are free from oil 2 Apply FIPG Formed in Place Gasket to the new side cover 3 Install the side cover on the transmission assembly 4 Fit 9 new bolts securing the side cover to the transmission assembly and tighten to 9 8 15 7Nm 5 Fit automatic transmission Transmission Transmission Tr...

Page 414: ...ing on the oil pump body Caution Be careful not to damage the input shaft Refit 1 Use T26005and a hammer to fit the new oil seal on oil pump Caution Be careful not to damage the oil seal Caution Be careful not to damage the input shaft 2 Ensure oil seal is 0 0 15 from the end of the oil pump body 3 Smear the oil seal lip with grease 4 Fit the torque convertor Torque Torque Torque Converter Refit C...

Page 415: ...ls Tool Number Description Picture T26001 Transmission pressure test equipment TPT00001 Adjusterneutral start switch T26002 Replacer drive shaft oil seal LH T26003 Replacer drive shaft oil seal RH T26005 Replacer oil pump seal Version 2 0 399 ...

Page 416: ...to slave cylinder bracket 18 22Nm Bolt RH drive shaft bracket to engine 19 25Nm Switch reverse light 32 44Nm Bolt base cover to rear housing 10 14Nm Bolt retainer plate of input shaft front bearing to front housing 22 30Nm Bolt front housing to rear housing 30 40Nm Bolt control assembly to rear housing 22 30Nm Bolt rear housing to reverse idler shaft 32 44Nm Bolt final drive gear to differential h...

Page 417: ...105 1 379 1 030 0 820 3 363 3 722 4 053 Center Distance of Transmission 78mm Rated Power of Mated Engine 120Kw Maximum Input Torque 215Nm Maximum Input Speed 6000r min Weight without oil 43kg Lubricant MTF 94 Capacity Drain and Refill Dry Fill 2 0L 2 2L Overall Dimensions of Transmission Length Width Height 400mm 543mm 365mm Sealant Mating face Thread 1596F Gray Silicone 1598 Black Silicone 1243 t...

Page 418: ...Transmission Transmission MT Description and Operation System Component Layout Transmission Assembly Component Layout Version 2 0 402 ...

Page 419: ...pring thrust plate 1st 2nd gears 14 Return spring 1st 2nd gears 15 Reverse lock 16 Selector reverse lock 17 Dowel 18 Torsional spring reverse lock 19 Shaft reverse lock 20 Washer reverse lock thrust plate to control housing 21 Bolt reverse lock thrust plate to control housing 22 Roll pin 23 Washer 24 Thrust plate reverse lock 25 Interlock assembly 26 Gear shift arm guide 27 Return spring 5th rever...

Page 420: ...using 46 Bolt base cover of rear housing 47 Bolt 48 Washer 49 Filler plug 50 Washer 51 Dowel front and rear housing 52 Front housing 53 Bush clutch release shaft 54 Bush clutch release shaft 55 Dust cover clutch release shaft 56 Clutch release shaft 57 Guide sleeve 58 Bolt guide sleeve 59 Release bearing 60 Bolt release fork 61 Washer release fork bolt 62 Release fork 63 Selector shaft 3rd 4th gea...

Page 421: ...ller bearing 4th gear 15 5th gear input shaft 16 Circlip selective input shaft 5th gear 17 Sleeve circlip 18 Rear bearing input shaft 19 Circlip input shaft rear bearing 20 Oil seal input shaft 21 Reverse idler shaft 22 Needle roller bearing reverse gear 23 Reverse idler gear 24 Thrust plate reverse idler gear 25 Circlip reverse idler gear 26 Front bearing output shaft 27 Output shaft 28 Needle ro...

Page 422: ...output shaft 41 Needle roller bearing output shaft 5th gear 42 5th gear output shaft 43 Synchro hub 5th gear 44 Needle roller bearing output shaft reverse gears 45 Reverse gear output shaft 46 Rear bearing output shaft 47 Snap ring selective output shaft rear bearing 48 Circlip selective output shaft rear bearing If fitted Version 2 0 406 ...

Page 423: ...nts Components 1 Oil seal drive shaft 2 Tapered roller bearing 3 Differential housing 4 Final drive gear 5 Roll pin pinion shaft 6 Bolt differential housing to final drive gear 7 Shim selective 8 Washer planetary gear 9 Planetary gear 10 Thrust washer selective sun gear 11 Sun gear 12 Pinion shaft Version 2 0 407 ...

Page 424: ...ccessories Accessories Component Component Component Location Location Location 1 Cable support bracket 2 Bolt 3 Bolt 4 Reverse lamp switch 5 Washer 6 Drain plug 7 Slave cylinder bracket if fitted 8 Slave cylinder bracket if fitted 9 Slave cylinder bracket if fitted Version 2 0 408 ...

Page 425: ...reverse idler shaft carries the reverse idler gear The output shaft features a machined gear on its front end It is supported by a front bearing and carries in order from the cylinder block end 1st gear 1st and 2nd gear inner mid and outer synchro rings and synchro hubs sleeves and synchro keys 2nd and 3rd gears and bearings 3rd and 4th gear spacer 4th and 5th gears and bearings 3rd 4th 5th and re...

Page 426: ...he detent of 3rd 4th gears selector One end of the interlock assembly blocks the detents of the 3rd 4th and 5th reverse gears selector but the other end is disengaged from the detent of the 1st 2nd gears selector The gear shift lever rotates the gear shift arm guide attached to the gear shift and selector shaft through the cross gate cable The gear shift arm guide turns the 1st 2nd gears selector ...

Page 427: ...emove lever 6 Remove and discard gear change oil seal Refit 1 Clean gear change oil seal recess gear change cover and transmission mating faces 2 UsingT24016 fit new seal to gear change cover ensuring stepped portion of seal faces outwards 3 Fit gear shift lever and secure with new roll pin 4 Fit selector lever bracket to transmission casing fit bolts and tighten to 22 30Nm 5 Connect cable ball jo...

Page 428: ... specified litres of oil through filler hole Drain and Refill 2 0L Dry fill 2 2L 11 Fit filler plug with a new sealing washer and tighten plug to 30 40Nm 12 Fit undertray Undertray Refit Undertray Refit Undertray Refit Manual Transmission Assembly Remove 1 Remove air cleaner Air Air Air Cleaner Remove Cleaner Remove Cleaner Remove 2 Disconnect ECM multiplugs 3 Remove battery carrier Battery Batter...

Page 429: ...cylinder block 11 With assistance release RH drive shaft from gearbox and position aside 12 Remove starter motor Starter Starter Starter Motor Remove Motor Remove Motor Remove 13 Remove bolt securing crankshaft position sensor CKP and position sensor aside 14 Remove 2 bolts from gearbox rear closing plate and remove plate 15 Remove 3 bolts securing front closing plate to gearbox and remove plate 1...

Page 430: ...move gearbox from beneath 21 Remove gearbox housing bolt securing engine earth lead release earth lead and position aside 22 Position jack to support engine 23 Connect lifting equipment to gearbox housing 24 Remove nut from gearbox mount 25 Remove 4 bolts securing gearbox mount to bracket and remove gearbox mount 26 Remove 4 bolts securing gearbox mounting bracket to gearbox and remove mounting br...

Page 431: ...g plate fit bolts and tighten to 22 28Nm 17 Fit rear closing plate fit bolts and tighten to 22 28Nm 18 Fit CKP sensor fit bolt and tighten to 10Nm 19 Fit starter motor Starter Starter Starter Motor Refit Motor Refit Motor Refit 20 Secure slave cylinder to bracket with a clip if fitted 21 Fit slave cylinder to bracket and tighten 2 nuts to 20 25Nm if fitted 22 Fit slave cylinder to bracket and tigh...

Page 432: ...il Lubrication Lubrication Lubrication System Drain System Drain System Drain Refill Refill Refill 2 Position suitable container under transmission to catch oil 3 Remove 6 bolts securing reverse access cover to transmission casing 4 Carefully break sealant joint to reverse access cover from transmission casing Discard reverse access cover Refit 1 Clean transmission casing mating face 2 Apply a bea...

Page 433: ... LH LH Shaft Shaft Shaft with with with Both Both Both Joints Remove Joints Remove Joints Remove 2 Carefully remove and discard differential oil seal take care not to damage oil seal recess Refit 1 Clean oil seal recess 2 Using T24010 fit a new differential oil seal Caution Oil seals are waxed and must not be lubricated prior to fitting 3 Fit LH drive shaft LH LH LH Shaft Shaft Shaft with with wit...

Page 434: ...sion assembly Manual Manual Manual Transmission Transmission Transmission Assembly Remove Assembly Remove Assembly Remove 2 Remove control assembly 3 Remove release mechanism Accessories Accessories Accessories and and and Release Release Release Mechanism Remove Mechanism Remove Mechanism Remove 4 Remove reverse idler gear Reverse Reverse Reverse Idler Idler Idler Gear Remove Gear Remove Gear Rem...

Page 435: ...or wear scratch damage and replace as necessary Caution Apply sealant to thread of bolt 1 Using T24011 fit input shaft oil seal to front housing 2 Using T24010 fit differential oil seal 3 Fit output shaft front bearing outer race to front housing 4 Using T24012 fit outer race of output shaft tapered roller bearing 5 Using T24013 1st 2nd selector shaft bush to front housing 6 Fit shaft and fork ass...

Page 436: ... Fit control assembly into rear housing and tighten bolts to 22 30Nm 23 Fit reverse idler gear Reverse Reverse Reverse Idler Idler Idler Gear Refit Gear Refit Gear Refit 24 Fit new cap rear housing base cover and tighten 6 securing bolts to 10 14Nm 25 Fit release mechanism Accessories Accessories Accessories and and and Release Release Release Mechanism Refit Mechanism Refit Mechanism Refit 26 Fit...

Page 437: ...h gear synchro spring ring and synchro ring 14 Remove synchro sleeve 15 Remove synchro hub and slide blocks 16 Remove 3rd synchro ring and spring ring 17 Using T32001 remove 3rd gear from input shaft 18 Remove 3rd gear needle roller bearing Refit Caution Clean all the parts before assembling Caution Fit new circlip after fitting the bearing Caution Use manual transmission fluid to lubricate bearin...

Page 438: ...aft Caution Ensure parts are fitted in correct order and orientation 9 Lubricate bearings with clean oil usingT24002 fit inner ring of 4th gear needle roller bearing 10 Fit 4th synchro ring spring ring and 4th gear assembly to input shaft 11 Fit 5th gear to input shaft 12 Measure and select correct size 5th gear split circlip Caution Refer to table for thrust washer selection Thickness mm Colour L...

Page 439: ...ratch damage and replace as necessary 1 Using T24005 fit inner race of 1st gear needle roller bearing 2 Fit 1st gear needle roller bearing 3 Fit 1st gear of output shaft 4 Fit 1st 2nd inner mid outer synchro rings and spring rings Caution Ensure Ensure Ensure parts parts parts are are are fitted fitted fitted in in in correct correct correct order order order and and and orientation orientation or...

Page 440: ...r order order and and and orientation orientation orientation 20 Using T24008 fit inner race of the Reverse gear needle roller bearing 21 Lubricate bearings with clean oil fit 3rd 5th Reverse gear needle roller bearings 22 Using press equipment fit rear bearing of output shaft and Reverse gear 23 Select and fit circlip of output shaft rear bearing Caution Refer to table for circlip selection Thick...

Page 441: ...le roller bearing from reverse idler shaft Refit 1 Lubricate bearings with clean oil 2 Fit needle bearing reverse idler gear and thrust plate to reverse idler shaft 3 Secure reverse idler gear to reverse idler gear shaft with a new circlip 4 Position reverse idler gear into rear housing 5 Fit reverse idler shaft bolt and tighten to 32 44Nm Use a new washer 6 Apply a bead of 1598 black silicone sea...

Page 442: ...efit 1 Measure original thrust washer thickness and according this thickness select two new for sun gears Caution Refer to table for shim selection Thickness mm Colour H 0 90 0 01 Yellow H 0 95 0 01 Green H 1 00 0 01 Blue H 1 05 0 01 Red H 1 10 0 01 White H 1 15 0 01 Black H 1 20 0 01 Purple H 1 25 0 01 Orange H 1 30 0 01 Brown H 1 35 0 01 Grey 2 Position thrust washer on each sun gear 3 Position ...

Page 443: ...rust plate 10 Remove 5th Reverse return spring 11 Remove interlock assembly gear shift arm guide 12 Remove reverse lock selector 13 Remove 1st 2nd gear return spring return spring thrust plate 14 Remove and discard needle roller bearing 15 Remove and discard oil seal 16 Remove gear shift lever 17 Remove nylon block 18 Remove and discard breather plug Refit 1 Using T24017 fit roll pin 2 Using T2402...

Page 444: ...hift and selector shaft 11 Fit assembled parts into housing and tighten bolts securing interlock assembly to30 40Nm 12 Position nylon block and fit gear selector lever 13 Fit manual transmission assembly Manual Manual Manual Transmission Transmission Transmission Assembly Refit Assembly Refit Assembly Refit Fittings and Release Mechanism Remove 1 Remove slave cylinder bracket 2 Remove cable suppor...

Page 445: ...nd tighten to 30 40Nm 6 Fit interlock assembly and tighten bolt to 30 40Nm 7 Apply 1596F gray silicone sealant to mating face of control assembly 8 Fit control assembly apply thread sealant to bolts and tighten to 22 30Nm 9 Fit new rear housing cap 10 Apply 1598 black silicone sealant to mating face of reverse access cover 11 Fit reverse access cover of rear housing apply thread sealant to bolts a...

Page 446: ... front oil seal input shaft T24012 Replacer outer track of taper bearing T24013 Replacer bush of fork 1st 2nd gears Tool Number Description Picture T24014 Replacer guide oil input output shafts T24015 Replacer roller bearing shift and selector shaft T32001 Puller universal T24001 Replacer front bearing input shaft T24002 Replacer inner track of roller bearing 4th gear Version 2 0 430 ...

Page 447: ...placer inner track of roller bearing 1st gear T24006 Replacer inner track of roller bearing 2nd gear T24007 Replacer 4th gear output shaft Tool Number Description Picture T24008 Replacer inner track of roller bearing reverse gear T24009 Replacer inner track of taper bearing T24017 Puncher Ø3 spring pin T24024 Replacer reverse lock shaft Version 2 0 431 ...

Page 448: ...on Value Bolt clutch cover to flywheel 25Nm Bolt clutch master cylinder to pedal bracket 7 10Nm Nut clutch slave cylinder to slave cylinder bracket 20 25Nm Nut clutch slave cylinder hose to pipe 15 19Nm Bleed plug clutch slave cylinder 12 17Nm Version 2 0 432 ...

Page 449: ...675 Diaphragm finger height when clamped on a thick gauge plate 28 45 30 45mm Diaphragm finger clearance service limit 64 0mm Clutch plate thickness under 6600 N axial load New 7 35 7 95mm Service limit 6 5mm Rivet depth New 1 2 mm above rivet head Service limit 0 2mm above rivet head Clutch plate run out New 0 8mm Grease Molybdenum disulphide grease Version 2 0 433 ...

Page 450: ...ayout Clutch System Component Layout 1 Clutch pedal 2 Clutch switch 3 Master cylinder 4 Quick fit connector 5 Pipe 6 Slave cylinder 7 Release lever 8 Release fork 9 Release bearing 10 Manual gearbox input shaft 11 Clutch cover assembly 12 Drive plate Version 2 0 434 ...

Page 451: ...Clutch Transmission 13 Flywheel 14 Bolt 6 off Version 2 0 435 ...

Page 452: ...aster Master Cylinder Cylinder Cylinder Component Component Component Layout Layout Layout 1 Flanged bolt 2 off 2 Master cylinder 3 Clip 4 Pivot shaft 5 Bush 6 Clutch pedal 7 Pedal box 8 Clip 9 Pedal return spring 10 Pedal return spring bush 11 Pedal rubber 12 Clip Version 2 0 436 ...

Page 453: ...sure plate and cover The pressure plate is manufactured from cast iron and is machined to ensure a smooth surface for the drive plate to engage on The outer diameter of the pressure plate features three lugs connecting it via leaf springs to the cover The leaf springs have three tempered steel leaves and pull the pressure plate away from the drive plate when the clutch pedal is depressed The cover...

Page 454: ...Transmission Clutch the mounting sleeve is keyed to the pedal mounting bracket Mating serrations hold the sensor in position in the mounting sleeve Version 2 0 438 ...

Page 455: ...lease bearing to be pushed back by the fingers of the diaphragm which pushes the piston into the slave cylinder The diaphragm pivots on its fulcrum on the pressure plate housing This applies pressure to the pressure plate and overcomes the pressure applied by the leaf springs The pressure plate moves towards the flywheel and applies force to the drive plate The force applied to the drive plate by ...

Page 456: ...ch drive plate for signs of wear or oil contamination Renew drive plate if necessary 3 Measure clutch plate thickness renew drive plate if less then service limit Drive Plate Thickness When Compressed New drive plate 7 5mm Service limit 5 9mm 4 Measure rivet depth renew plate if less than service limit Rivet Depth B New drive plate 1 2mm Service limit 0 2mm 5 Check pressure plate for signs of wear...

Page 457: ...ve splines with molybdenum disulphide grease 5 Position drive plate to pressure plate with correct direction 6 UseT22001 to align drive plate and pressure plate 7 Ensure drive plate is aligned to centre of pressure plate 8 UseT22001 to fit clutch assembly to flywheel 9 Fit 6 new bolts securing pressure plate to flywheel and tighten finger tight at this stage 10 UseT10028 to restrain flywheel and w...

Page 458: ...move Bracket Remove 2 UseT22002 to disconnect clutch slave cylinder pipe connection 3 Remove steering column lower panel assembly and the panel heater closure Panel Panel Panel Assembly Fascia Assembly Fascia Assembly Fascia Closing Closing Closing Panel Panel Panel Driver Remove Driver Remove Driver Remove Panel Heater Panel Heater Panel Heater Closure Remove Closure Remove Closure Remove 4 Relea...

Page 459: ...uid and clean area with water 2 Remove battery carrier Battery Battery Battery Carrier Carrier Carrier Bracket Remove Bracket Remove Bracket Remove 3 Disconnect master cylinder low pressure hose from brake fluid reservoir 4 Disconnect master cylinder pipe connection 5 Remove steering column lower panel assembly and the panel heater closure Panel Panel Panel Assembly Fascia Assembly Fascia Assembly...

Page 460: ...der low pressure hose to reservoir and secure with clip 8 Top up fluid level in brake reservoir to MAX mark 9 Bleed the clutch system Clutch Clutch Clutch System System System Bleeding Bleeding Bleeding 10 Fit battery carrier Battery Battery Battery Carrier Carrier Carrier Bracket Refit Bracket Refit Bracket Refit Clutch Slave Cylinder A Remove 1 Remove battery carrier Battery Battery Battery Carr...

Page 461: ...ed Bleeding of the hydraulic system is only permissible if a clutch pipe or hose has been disconnected Ensure the fluid in the reservoir is maintained between the minimum and maximum levels throughout the bleed procedure and use only new fluid Warning Do not allow brake fluid to come into contact with eyes or skin Caution Never reuse brake fluid that has been bled from the clutch operating system ...

Page 462: ...Transmission Clutch Special Tools Tool Number Description Picture T10028 flywheel locking tool T22001 Aligner clutch plate T22002 Pipe dismantling fork Version 2 0 446 ...

Page 463: ...nsor 10 Nm Bolt evaporator compressor pipe A to evaporator 7 10 Nm Nut evaporator compressor pipe A to evaporator compressor pipe B 8 10 Nm Bolt evaporator compressor pipe A to body clips 7 10 Nm Bolt evaporator compressor pipe B to compressor 19 25 Nm Bolt evaporator compressor pipe B to body clips 7 10 Nm Bolt condenser evaporator pipe A to condenser 7 10 Nm Nut condenser evaporator pipe A to co...

Page 464: ...1 3 bar Displacement Displacement Min 5 Displacement Max 100 Lubricating oil PAG 46 Oil fill quantity new 120 10 ml Evaporator thermostat Opens 2 Closes 4 Trinary switch operating pressure Low Closing pressure 2 bar Opening pressure 2 3 bar High Opening pressure 26 bar Closing pressure 32 bar Condenser fan control Low Closing pressure 10 bar Opening pressure 17 bar High Closing pressure 19 bar Ope...

Page 465: ... Heating and Ventilation Component Layout 1 Outboard front face duct 2 Front windscreen and front side window vent duct 3 Heater assembly 4 Front footwell outlet plate 5 Control panel 6 Rear footwell duct 7 Rear face vent duct 8 Filter housing 9 Boot outlet vent Version 2 0 449 ...

Page 466: ... Air Conditioning A C System Component Layout 1 Low pressure servicing connection 2 High pressure servicing connection 3 Refrigerant lines 4 Evaporator and Thermostatic Expansion ValveTXV 5 Condenser 6 Compressor Version 2 0 450 ...

Page 467: ... ventilation system controls the temperature and distribution of air supplied to the vehicle interior The system consists of a filter housing a heater assembly distribution ducts and a control panel Outlet vents are incorporated in the boot Version 2 0 451 ...

Page 468: ...to the vehicle interior Fresh air from the filter housing or recirculated air flows into the heater assembly where a variable speed blower and or ram effect forces the air through the system Depending on the settings on the control panel the air is then heated or cooled as required and supplied through the distribution ducts to the windscreen fascia and floor level outlets A thumbwheel on the fasc...

Page 469: ...rATC only 17 Fresh recirculated air flap mechanism and servo motor The heater assembly heats and distributes fresh or recirculated air as directed by selections made on the control panel The assembly is installed on the vehicle centre line between the fascia and the engine bulkhead and consists of a casing formed from a series of plastic mouldings which contains a blower a heater matrix and contro...

Page 470: ...lectric motor Operation of the blower is controlled by the and non latching switches on the control panel via a blower relay in position 5 in the engine compartment fuse box and a power controller fitted in the heater assembly Heater Matrix The heater matrix provides the heat source to warm the air being supplied to the distribution outlets The heater matrix is an aluminium single pass fin and tub...

Page 471: ...talled in the heater assembly to control the inlet source temperature and distribution of air Fresh Recirculated air flap The fresh recirculated air flap opens and closes the fresh and recirculated air inlets to control the source of incoming air The flap is operated by a servo motor controlled by a fresh recirculated air switch on the control panel The fresh air recycle servo motor consists of a ...

Page 472: ...er microswitch connection to earth the motor turns the cam through another 180 to complete the fresh recirculated air flap position cycle Blend flaps A blend flap regulates the flow of air through the heater matrix to control the temperature of the air leaving the heater assembly The blend flap is attached to a spindle located in the heater casing The blend flap is controlled by the blend flap ser...

Page 473: ...et vents promote the free flow of heating and ventilation air through the cabin The outlet vents are located in the LH and RH sides of the boot and vent cabin air into the sheltered area between the body and the rear bumper The vents are effectively non return valves and each consist of a grille covered by soft rubber flaps The flaps open and close automatically depending on the pressure different...

Page 474: ... system filled with a charge weight of R134a refrigerant as the heat transfer medium Oil is added to the refrigerant to lubricate the internal components of the compressor To accomplish the transfer of heat the refrigerant is circulated around the system where it passes through two pressure temperature regimes In each of the pressure temperature regimes the refrigerant changes state During the sta...

Page 475: ...es the refrigerant around the system by compressing low pressure low temperature vapor from the evaporator and discharging the resultant high pressure high temperature vapor to the condenser The compressor is attached to a mounting bracket on the engine and is a seven cylinder swash plate unit with variable displacement driven by the ancillary drive belt via a pulley and an electrically actuated c...

Page 476: ...e front of the housing A swash plate is installed on the shaft and connected to the lug plate by two guide pins The swash plate is a sliding fit on the shaft and biased away from the lug plate by a spring The outer circumference of the swash plate is engaged in the ends of seven pistons which are located in cylinders equally spaced around the housing interior Two pressure chambers in the rear of t...

Page 477: ...r to convert the vapour from the compressor into a liquid It also removes moisture and solid impurities from the refrigerant and provides a reservoir of liquid refrigerant to accommodate changes of heat load at the evaporator Ambient air passing through the heat exchanger due to ram effect and or the cooling fan absorbs heat from the refrigerant to change it from a vapor to a liquid The condenser ...

Page 478: ...evaporator The valve consists of an aluminum housing containing inlet and outlet passages A ball and spring metering valve is installed in the inlet passage The metering valve is controlled by a temperature sensitive tube connected to a diaphragm The top of the diaphragm senses evaporator outlet pressure and the tube senses evaporator outlet temperature The thermostatic expansion valve meters to b...

Page 479: ...f refrigerant flowing through the evaporator The warmer the air flowing through the evaporator matrix the more heat available to evaporate refrigerant and thus the greater the volume of refrigerant allowed through the metering valve Evaporator The evaporator is installed in the air inlet of the heater assembly and absorbs heat from the exterior or recirculated inlet air Low pressure low temperatur...

Page 480: ...ervo motors individually control each control flap ETC has four servo motors to operate the distribution flap with individual control of the LH and RH blend flaps and fresh recirculated air flap ETC has three servo motors to operate the distribution flap blend flap and fresh recirculated air flap The servo motors are installed on the outside of the casing and are controlled by the A C controller A...

Page 481: ... set for medium heat to face level and footwell outlets 1 Front face level outlet 2 Windscreen and side windows outlet 3 Heater assembly casing 4 Air inlet 5 Blower 6 Evaporator 7 Heater matrix 8 Rear footwells outlet 9 Rear face level outlet 10 Front footwells outlet Version 2 0 465 ...

Page 482: ...e switch is pressed for less than 1 second the control panel sets the inlet air source to recirculated air for 4 minutes after which it automatically reverts to fresh air Latched Recirculation If the switch is pressed for more than 2 seconds the icon in theLCD flashes for 5 seconds then illuminates permanently and the air source is latched in the fresh air position Parked Recirculation Parked reci...

Page 483: ...e lug plate and the swash plate holds the swash plate at the minimum tilt angle to minimise load during system start up When A C is requested the clutch is energised and the pulley turns the shaft The lug plate and the swash plate turn with the shaft and the angled swash plate produces reciprocating movement of the pistons Vapour from the inlet pressure chamber is drawn into the cylinders compress...

Page 484: ...or drive pulley visual check The temperature of the incoming air will not be lowered The A C compressor clutch relay could fail in the following ways Relay coil short circuit Relay coil open circuit Relay coil high resistance Relay contact stuck open Relay contact stuck closed Relay contact high resistance Relay wiring open circuit Relay wiring high resistance Relay wiring short circuit to 12V Rel...

Page 485: ...to request an increase in cooling fan speed Failure If the sensor fails the driver may notice that the A C system does not operate at all or it cuts out after a period of time The sensor could fail in the following ways Refrigerant gas pressure too low due to leakage or incorrect fill Refrigerant gas pressure too high due to incorrect fill Internal short circuit External wiring open circuit Extern...

Page 486: ...m recycling evacuating and recharging with one time Service station can filter the refrigerant in recycling and evacuating process to ensure the clean dry refrigerant to be recharged into system Filling machine can recycle discharged and recharged the refrigerant at one time To ensure the refrigerant to be recharged in A C system is clean and dry it will be filtrated when being recycled and discha...

Page 487: ...e tank 1 Ensure the high and low sides hoses have been connected with relevant valve on the service station 2 Open gas and liquid valve on the refrigerant tank Caution The evacuating procedure must be carried out before recharging process 3 Start vacuum pump and evacuate the system During the recycling the uncondensed gas most are air will be drained out from the tank The noise of pressure releasi...

Page 488: ...r s manual for the information about service station Compressor Remove 1 Disconnect battery earth lead 2 Recover refrigerant from A C system Refrigerant Refrigerant Refrigerant recovery recovery recovery 3 Remove undertray Undertray Undertray Undertray assembly assembly assembly remove remove remove 4 Release tension on ancillary drive belt and remove drive belt from compressor pulley Drive Drive ...

Page 489: ...echarging recharging recharging 10 Connect battery earth lead Evaporator Remove 1 Remove heater assembly Heater Heater Heater assembly assembly assembly remove remove remove 2 Remove screw securing block and pipe assembly to heater casing 3 Release insulation from TXV Thermostatic Expansion Valve 4 Remove 2 bolts securing block and pipe assembly to evaporator and remove block and pipe assembly 5 D...

Page 490: ...vaporator access panel fit and tighten screws 4 Fit heater harness to evaporator access panel 5 Connect evaporator temperature sensor multiplug and secure to heater casing 6 Fit heater air intake duct to heater assembly and secure with 3 screws 7 Connect fresh recirculated air servo multiplug 8 Clean mating faces and seal recesses on evaporator TXV and block and pipe assembly 9 Fit and pipe assemb...

Page 491: ...block and pipe assembly to TXV and tighten bolts to5 Nm 4 Fit insulation to TXV and block and pipe assembly 5 Secure evaporator block and pipe assembly to heater casing with screw 6 Fit heater assembly Heater Heater Heater assembly assembly assembly refit refit refit Condenser Remove 1 Recover refrigerant from A C system Refrigerant Refrigerant Refrigerant recovery recovery recovery 2 Remove front...

Page 492: ... and desiccant pack from condenser c Fit new desiccant pack Caution Do not remove desiccant pack from packaging until immediately before installation in condenser d Fit new filter e Lubricate new O rings and threads of plug with clean refrigerant oil f Fit O ring to plug g Fit plug to condenser and tighten to 12 Nm h Ensure the mating faces condenser and A C pipe are clean 2 Lubricate new O rings ...

Page 493: ...er only Intercooler Intercooler Intercooler remove remove remove 3 Remove Allen headed plug from condenser 4 Remove and discard O rings 5 Remove and discard filter and desiccant pack Refit 1 Fit new desiccant bag to condenser Caution Do not remove desiccant pack from packaging until immediately before installation in condenser 2 Fit new filter to condenser 3 Lubricate new O rings and threads of pl...

Page 494: ...Hose Compressor to Condenser Remove 1 Disconnect battery earth lead 2 Recover refrigerant from A C system Refrigerant Refrigerant Refrigerant recovery recovery recovery 3 Remove front bumper front front front bumper bumper bumper assembly assembly assembly remove remove remove 4 Remove bolt securing compressor condenser pipe to condenser Release pipe from condenser and remove pipe Caution Always f...

Page 495: ...and remove clip 4 Release nut securing pipe A and pipe B between compressor and evaporator Caution Always fit plugs to open connections to prevent contamination 5 Remove and discard O rings from A C pipes 6 Remove 1 bolt securing A C pipes to evaporator connector and remove pipe A between evaporator and compressor Caution Always fit plugs to open connections to prevent contamination 7 Remove and d...

Page 496: ... Recharge A C system Refrigerant Refrigerant Refrigerant recharging recharging recharging 8 Connect battery earth lead A C Pipe Condenser to Evaporator A Condenser to Connection Remove 1 Disconnect battery earth lead 2 Recover refrigerant from A C system Refrigerant Refrigerant Refrigerant recovery recovery recovery 3 Remove 1 bolt of clip securing A C pipes A to body and remove clip 4 Release nut...

Page 497: ...frigerant oil 2 Remove plug 3 Fit O ring on both side of evaporator condenser pipe B 4 Position A C pipe B to condenser side fit bolt and tighten to 7 10 Nm 5 Connect pipe A and pipe B between condenser and evaporator tighten nut to 8 10 Nm 6 Fit clip securing A C pipe to body tighten bolt to 7 10 Nm 7 Recharge A C system Refrigerant Refrigerant Refrigerant recharging recharging recharging 8 Conne...

Page 498: ...in cooling system Coolant Coolant Coolant drain drain drain 2 Recover refrigerant from A C system Refrigerant Refrigerant Refrigerant recovery recovery recovery 3 Release 2 clips securing heater hoses to heater and disconnect hoses 4 Remove 2 bolts securing air conditioning pipes to heater and disconnect pipes Discard the O ring seals Caution Always fit plugs to open connections to prevent contami...

Page 499: ...ly at bulkhead fit bolts and tighten bolts to between 7 10 Nm 6 Connect coolant hoses to heater and secure with clips 7 Fit fascia Fascia Fascia Fascia 8 Recharge A C system Refrigerant Refrigerant Refrigerant recharging recharging recharging 9 Refill cooling system Coolant Coolant Coolant refill refill refill 10 Connect battery earth lead Blower Assembly Remove 1 Remove centre console Console Con...

Page 500: ... 3 Loosen 2 clamps and remove heater pipes from matrix 4 Remove and discard 2 O ring seals 5 Remove matrix from heater assembly Refit 1 Fit matrix to heater assembly 2 Fit new O ring seals to pipes 3 Connect pipes to heater matrix and secure clamps 4 Fit heater pipe clamps and secure with screws 5 Fit heater assembly Heater Heater Heater assembly assembly assembly refit refit refit Version 2 0 484...

Page 501: ...move 2 Disconnect power controller connector 3 Remove 2 bolts securing power controller to heater case 4 Remove power controller Refit 1 Fit power controller to heater case and tighten bolts to 9 Nm 2 Reconnect power controller connector 3 Fit fascia Fascia Fascia Fascia refit refit refit Version 2 0 485 ...

Page 502: ...HVAC System HVAC ETC HVAC ETC Specifications Torque Description Value Bolt A C Controller 2 Nm Version 2 0 486 ...

Page 503: ...C ETC HVAC System Description and Operation System Component Layout A C Control Component Layout ETC 1 ETCcontrol panel 2 Evaporator temperature sensor 3 Pressure sensor 4 Power controller Version 2 0 487 ...

Page 504: ...trol Diagram ETC A Hard wired B MSCAN Bus C LIN Bus 1 Distribution flaps servo motor 2 RH blend flap servo motor 3 Fresh recirculated air flap servo motor 4 Diagnostic socket 5 Body Control Module BCM 6 Power controller 7 Blower 8 Blower relay 9 ETC Version 2 0 488 ...

Page 505: ...ontrol Diagram Diagram Diagram ETC ETC ETC A Hard wired B LIN Bus C HSCAN Bus 1 ETCcontrol panel 2 BCM 3 Pressure sensor 4 Compressor relay 5 Compressor 6 Cooling fan 7 Cooling fan relay unit 8 Fuse 4 engine compartment fuse box 9 Main relay 10 Evaporator temperature sensor 11 ECM Version 2 0 489 ...

Page 506: ...with theLIN to control the rear windscreen heater and diagnostic systems ETCECU also receives ambient temperature information from the ambient temperature sensor on the front bumper Control Panel ETC 1 Temperature control switch 2 Blower speed control switch 3 Face mode switch 4 Feet and front windscreen front window defrost mode switch 5 Defrost mode switch 6 Feet mode switch 7 Fresh Recirculated...

Page 507: ...HVAC ETC HVAC System Display Outputs ETC 1 Temperature 2 Defrost mode 3 Fresh recirculated air 4 Distribution mode 5 Blower speed 6 Heated Rear Window HRW 7 A C switch on Version 2 0 491 ...

Page 508: ...onsole 4 Disconnect Air Conditioning A C control multiplugs 5 Remove 4 screws and release clips securing A C controls to centre console Remove A C controls Refit 1 Connect A C controller multiplugs 2 Position A C controller to finisher and secure with screws to 2 Nm 3 Position finisher to centre console and secure clips 4 Position up finisher to centre console and secure clips 5 Connect battery ea...

Page 509: ...ations Torque Description Value Bolt A C Controller 2 Nm Bolt blend flap servo motor to heater case 9Nm Bolt fresh recirculated air flap servo motor to heater case 9 Nm Bolt distribution flap servo motor to heater case 9 Nm Version 2 0 493 ...

Page 510: ...senger two non latching push switches control the blower speed three non latching push switches control air distribution two non latching push switches control the selection of fresh recirculated air and operation of the Heated Rear Window HRW An icon in theLCD illuminates when the above switches are operated The control panel also features a non latching MONO function switch and a non latching OF...

Page 511: ...ent Layout ATC 1 Automatic Temperature Control ATC control panel ECU and in car temperature sensor 2 Evaporator temperature sensor 3 Solar light sensor 4 Pressure sensor 5 Heater coolant temperature sensor 6 Power controller Version 2 0 495 ...

Page 512: ...HVAC System HVAC ATC System Control Diagram Heater Assembly Control Diagram ATC A Hard wired B MSCAN Bus C HSCAN Bus Version 2 0 496 ...

Page 513: ...r 3 LH blend flap servo motor 4 Distribution flaps servo motor 5 RH blend flap servo motor 6 Fresh recirculated air flap servo motor 7 Diagnostic socket 8 Body Control Module BCM 9 SCS modulator 10 Power controller 11 Blower 12 Blower relay 13 ATC control panel Version 2 0 497 ...

Page 514: ...trol Diagram Diagram Diagram ATC ATC ATC A Hard wired B MSCAN Bus C HSCAN Bus 1 ATC control panel 2 BCM 3 Pressure sensor 4 Compressor relay 5 Compressor 6 Cooling fan 7 Cooling fan relay unit 8 Fuse 4 engine compartment fuse box 9 Main relay 10 Evaporator temperature sensor 11 ECM Version 2 0 498 ...

Page 515: ...tre of the fascia below the radio An integral control panel on theATCECU contains switches for system control inputs and a Liquid Crystal Display LCD to provide system status information Inputs from the sensors the control panel switches and theBCM are processed by theATC ECU and theATCECU then outputs the appropriate control signals ATCECU communicates with theBCM onMSCAN for operation of the rea...

Page 516: ... related temperature setting in steps of 1 C between 16 C and 28 C If the decrease side of the switch is pressed when a temperature of 16 C is set the display changes to LO maximum cold If the increase side of the switch is pressed when a temperature of 28 C is set the display changes to HI maximum hot Economy Mode ECON Switch Enabled only while the system is on Provides manual on off control of t...

Page 517: ... side windows demist windscreen side windows demist only If the switch is kept depressed after 1 second subsequent distribution changes occur every 0 5 second until distribution reaches windscreen side windows demist only Releasing and then pressing the switch again changes distribution back to face level only Defrost Mode Switch Defrost mode is operational when the ignition is on even if the engi...

Page 518: ... to LO or HI RH Temperature Illuminates to show the RH temperature selection together with the temperature scale ºC Blower Speed Illuminates when the blower speed is manually selected Also illuminates in the automatic mode when one of the temperatures is set to LO or HI and in the defrost mode Pressure Sensor The pressure sensor protects the refrigerant system from extremes of pressure and helps c...

Page 519: ...ignals The anion in the generator is formed by the high voltage discharge of direct current in the carbon fibre brush When the air conditioning is on press the button for more than 2 seconds the symbol appears in the LCD display to activate the anion generator Press this button again more than 2 seconds to turn off the generator and the symbol disappears in the display When the generator is on it ...

Page 520: ...operation is similar to the automatic mode but without the ability to cool the passenger compartment if the ambient temperature is higher than the temperature selections made on the control panel or to dehumidify the fresh or recirculated air In the defrost mode theATCECU sets the inlet air source to fresh air the blower to maximum speed the air distribution to windscreen and side windows and outp...

Page 521: ...ture are not set to LO or HI Once the compressor on request is granted the compressor remains on until the request is cancelled or the engine stops even if one of the grant conditions no longer exists If a compressor on request fails A C icon flashes to indicate a fault and on the display theAUTO icon extinguishes and the ECON icon illuminates Engine Cooling Fan Control The ECM operates a cooling ...

Page 522: ...ed is set to 3 for 5 seconds after the system is switched on Over the following 6 seconds the blower speed is progressively increased up to maximum speed Selected temperature correction As the temperature in the passenger compartment approaches the selected temperatures blower speed is progressively reduced until once the selected temperatures have been established blower speed stabilises at blowe...

Page 523: ...onsole 4 Disconnect Air Conditioning A C control multiplugs 5 Remove 4 screws and release clips securing A C controls to centre console Remove A C controls Refit 1 Connect A C controller multiplugs 2 Position A C controller to finisher and secure with screws to 2 Nm 3 Position finisher to centre console and secure clips 4 Position up finisher to centre console and secure clips 5 Connect battery ea...

Page 524: ...efit Solar Light Sensor Remove 1 Disconnect battery earth lead 2 Release clips securing solar light sensor to fascia 3 Ensuring multiplug does not drop below fascia disconnect multiplug from solar light sensor 4 Remove solar light sensor Refit 1 Position solar light sensor to fascia and connect multiplug 2 Fit solar light sensor to fascia and secure clips 3 Connect battery earth lead Version 2 0 5...

Page 525: ...ad 2 Remove left heater closure panel Panel Panel Panel Heater Heater Heater Closure Closure Closure Remove Remove Remove 3 Disconnect blend flap servo motor multiplug 4 Remove 3 bolts securing blend flap servo motor to heater unit 5 Disconnect servo motor and flap linkage 6 Remove blend flap servo motor Refit 1 Fit servo motor and flap linkage 2 Fit 3 bolts securing servo motor to heater and tigh...

Page 526: ...er heater closure panel 4 Connect battery earth lead Right Blend Flap Servo Motor Remove 1 Disconnect battery earth lead 2 Remove heater right closure panel 3 Disconnect blend flap servo motor multiplug 4 Remove 3 bolts securing blend flap servo motor to heater unit 5 Disconnect servo motor and flap linkage 6 Remove blend flap servo motor Refit 1 Fit servo motor and flap linkage 2 Fit 3 bolts secu...

Page 527: ...nd connect flap linkage 2 Fit screws securing servo motor to heater and tighten to9 Nm 3 Connect recirculating motor multiplug 4 Fit passenger s heater closure panel 5 Connect battery earth lead Distribution Flap Servo Mmotor Remove 1 Remove fascia 2 Disconnect servo motor connector 3 Remove 3 screws securing distribution flap servo motor 4 Disconnect servo motor and flap linkage 5 Remove distribu...

Page 528: ...Version 2 0 512 ...

Page 529: ...t steering rack to front subframe short 40 50Nm Tube assembly steering oil return pipe to steering rack 26 30Nm Bolt front subframe to body 110 120Nm Bolt power steering oil return pipe to subframe 19 25Nm Nut front exhaust pipe to intermediate exhaust pipe 20 25Nm Nut front anti roll bar link to anti roll bar 60 70Nm Nut track rod bar ball joint 28 32Nm Bolt road wheel 115 130Nm Locking nut power...

Page 530: ...pe Tilt and reach adjustable steering column with collapse mechanism Integral electronic steering column lock Steering wheel diameter 370 mm Turns lock to lock 2 81 Turning circle Smallest turning radius Overall ratio 11 3m 16 1 Power assisted steering Operating pressure Flow rate Nominal 90 Bar 8 15 litres min Version 2 0 514 ...

Page 531: ...ing Steering System Description and Operation System Component Layout Steering System Component Layout 1 Fluid reservoir 2 Pressure sensor 3 PAS pump 4 Steering column 5 Steering gear 6 PAS fluid cooler Version 2 0 515 ...

Page 532: ... Steering Steering Rack Component Location 1 Grommet 2 Valve unit 3 Track rod end lock nut 4 Flange bolt 2 off 5 Flange bolt 2 off 6 Gaiters 2 off 7 Track rod ball joint 8 Lock nut 2 off 9 Steering rack component Version 2 0 516 ...

Page 533: ...ont Wheel Steering Steering System PAS Hydraulic Component Location 1 PAS pump suction hose 2 PAS high pressure hose 3 PAS return hose 4 PAS fluid cooler 5 Return hose cooler to reservoir Version 2 0 517 ...

Page 534: ...adjustment of front wheel steering alignment Each track rod end is secured by a lock nut to the steering arm which extends from the front hub Valve Unit 1 Input shaft 2 Torsion bar 3 Circlip 4 Oil seal 5 Valve housing 6 PTFE ring 4 off 7 Outer sleeve 8 Pinion shaft 9 Bearing 10 Oil seal 11 Nut 12 Bearing 13 Pin pinion shaft to torsion bar 14 Pin rotor to torsion bar The valve unit is an integral p...

Page 535: ...p The amount of fluid delivered to the control valves and its pressure is regulated by the flow control valve built into the pump Excess fluid is returned to the intake side of the pump via internal fluid ways Warning Care is required when working on the hydraulic systems since the high pressure fluid can be hot and when the pump is operating reach pressures in excess of 10000 KPa 1450 lbf in2 cau...

Page 536: ...ng wheel being applied fluid flows from the pump to the valve unit The slots in the outer sleeve and the rotor are aligned so that the fluid pressure flows across the valve unit Some pressure is applied to the feed and return ports which in turn is felt at either side of the piston in the hydraulic cylinder With the forces equal on each side of the cylinder the steering remains in the neutral posi...

Page 537: ...t and block the return flow of fluid to the reservoir Fluid pressure from the pump now flows into the newly aligned slots in the rotor and outer sleeve The pressure is directed by the alignment of the slots into the left hand side of the hydraulic cylinder where the pressure increases The right hand side of the hydraulic cylinder is opened to return and allows fluid displaced from the right hand s...

Page 538: ...er assistance is dependant on the amount of road wheel resistance opposing the turning of the front wheels When the steering wheel is turned to the left or right the rotary movement is transferred through the steering column to the rotor shaft which rotates the same amount as the steering wheel The rotary movement is also transferred from the rotor to the torsion bar If the road wheel resistance i...

Page 539: ...ges as pressurised fluid at the discharge port where it passes through a hose to a valve unit If no steering effort is applied the pressure is applied equally to each side of the piston in the hydraulic cylinder The remainder of the flow is returned from the valve unit to the reservoir via the fluid cooler If steering effort is applied in either direction the fluid pressure is directed to the appl...

Page 540: ...k close the test valve for a maximum of five seconds Pump damage may occur if test valve is closed for longer periods 2 If the gauge does not register between 85 and 95 bar maximum pump pressure the pump is faulty 3 If maximum pump pressure is correct suspect the steering rack 4 On completion stop the engine 5 Disconnect battery earth lead 6 Remove test equipment from adaptors 7 Remove adaptors fr...

Page 541: ... outside the above tolerance indicates a fault 15 Remove test equipment from adaptors 16 Remove adaptors from PAS pump and steering rack feed pipe 17 Fit new sealing washers connect feed pipe to PAS pump fit and tighten banjo bolt to 38 42 Nm 18 Clean chassis and surrounding area 19 Check PAS fluid level 20 Connect battery earth lead Power Assisted Steering System Bleeding Adjust 1 Clean reservoir...

Page 542: ...to PASpump and remove pulley 8 Remove 2 bolts and nuts securing PASpump to mounting bracket and remove PASpump Refit 1 Fit PASpump to mounting bracket 2 Fit nuts and bolts securing PASpump to mounting bracket and tighten to45Nm 3 Fit PASpump pulley to PASpump fit bolts but do not fully tighten at this stage 4 Fit PASpump belt Belt Belt Belt PAS PAS PAS pump pump pump Refit Refit Refit 5 Tighten bo...

Page 543: ... wheels are positioned straight ahead and the steering wheel is prevented from turning Unrestricted turning of the steering wheel will damage the SRS rotary coupler 3 Remove nut and bolt securing steering joint to steering rack and discard nut 4 Release universal joint from steering rack 5 Remove undertray Undertray Undertray Undertray assembly assembly assembly Remove Remove Remove 6 Remove front...

Page 544: ... rack and discard O ring 20 Remove 4 bolts securing steering rack to subframe 21 Withdraw and remove steering rack from driver s side of vehicle position anti roll bar as necessary 22 Remove pinion seal 23 Note number of threads exposed from each track road end locknut for refitting reference 24 Remove track rod ends and lock nuts from steering rack Refit 1 Centre steering rack and position each l...

Page 545: ...efit Refit 18 Fit new bolt retaining steering joint to steering rack fit new nut and tighten to20 25Nm 19 Fit steering joint seal and reposition carpet 20 Bleed power steering system Power Power Power assisted assisted assisted steering steering steering system system system bleeding bleeding bleeding Refit Refit Refit 21 Check steering geometry Wheel Wheel Wheel alignment alignment alignment Refi...

Page 546: ...y Undertray Undertray Undertray Remove Remove Remove 5 Position container to collect spillage 6 Remove union securing pipe to steering rack remove and discard sealing washers Caution To prevent damage to components use two spanners when loosening or tightening unions Caution Always fit plugs to open connections to prevent contamination 7 Remove union securing feed pipe to steering pump remove and ...

Page 547: ...ure sensor multiplug 8 Connect battery earth lead 9 Bleed power steering system Power Power Power Assisted Assisted Assisted Steering Steering Steering System System System Bleeding Bleeding Bleeding Pipe Steering Rack To Oil Cooler Remove 1 Disconnect battery earth lead 2 Raise vehicle on lift 3 Remove undertray Undertray Undertray Undertray Remove Remove Remove 4 Position container to collect sp...

Page 548: ...teering Remove 1 Remove front bumper Front Front Front Bumper Bumper Bumper Remove Remove Remove 2 Position container to collect fluid spillage 3 Release 2 clips and disconnect PAShoses from oil cooler Caution Always fit plugs to open connections to prevent contamination 4 Remove 2 bolts securing oil cooler to body and remove oil cooler Refit 1 Position oil cooler fit bolts and tighten to 7 10Nm 2...

Page 549: ...ion Picture T38001 PAS pressure test equipment T38002 Adaptor hydraulic pressure test T38003 Adaptor hydraulic pressure test hose T38005 Adaptor power steering pump Tool Number Description Picture T38004 Adaptor power steering test T38008 Remover ball joint Version 2 0 533 ...

Page 550: ... Value Bolt steering column cover 2 4 3 4Nm Bolt and washer steering wheel to steering column 60 70Nm Locking nut power steering column to power steering rack input shaft 20 25Nm Bolt power steering column to instrument panel frame 21 25Nm Screw rotary coupler to steering column 4 5 5Nm Version 2 0 534 ...

Page 551: ...eering Wheel and Column Steering System Description and Operation System Component Layout Steering System 1 Fluid reservoir 2 PAS pump 3 Steering column 4 Steering gear 5 PAS fluid cooler Version 2 0 535 ...

Page 552: ... Component Location 1 7 8 6 5 2 4 3 S382001 1 Mounting screws 4 off 2 Upper universal joint 3 Sliding column joint 4 Lower universal joint 5 Grommet 6 Column adjustment lever 7 Electric steering column lock ESCL 8 Harness connection from ESCL Version 2 0 536 ...

Page 553: ... cast four spoke frame onto which model specific covering materials are moulded The hub is splined to locate with the splines on the steering column The horn switch is mounted in the centre pad of the steering wheel The trip computer remote switches and where fitted the cruise control remote radio volume mode and scroll and tiptronic paddle switches are also mounted on the steering wheel All the s...

Page 554: ...e gaiter clips Check 1 Ensure tyre pressures are correct and vehicle is at kerbside weight 2 Roll vehicle backwards and forwards to relieve stresses in steering and suspension 3 Ensure that wheel alignment equipment is properly calibrated and position equipment as per manufacturers instructions 4 Take an average of 3 readings 5 Check front wheel alignment is within tolerance Wheel Wheel Wheel Alig...

Page 555: ...ws securing lower cover to steering column 3 Release 6 clips securing both cover sections together 4 Release steering column adjustment lever and remove lower cover panel 5 Lower steering column adjustment lever 6 Remove top cover from steering column Refit 1 Position top cover to steering column 2 Release steering column adjustment lever and move column to upper position 3 Position lower cover to...

Page 556: ...l and remove both finishers 10 Disconnect horn switch multiplug from steering wheel switch harness and release harness from cable tie 11 Disconnect earth lead 12 Carefully release ribbon cable from steering wheel Refit 1 Fit horn switch assembly to steering wheel and secure with screws 2 Position ribbon cable and secure to steering wheel 3 Position harness to steering wheel 4 Fit LH and RH switch ...

Page 557: ... bracket 10 Disconnect 2 clips securing steering column harness to steering column and position steering column harness aside 11 Remove steering column assembly Refit 1 Locate universal joint to steering rack ensuring correct orientation 2 Fit new self locking nut and bolt to secure steering joint lightly tighten bolt 3 Check that a clearance of 4mm exists between steering joint and aperture seal ...

Page 558: ...tion rotary coupler to steering column and connect multiplugs 2 Secure rotary coupler to steering column with bolts and tighten to 4 5 5Nm 3 Remove tape from rotary coupler or remove locking peg if fitting a new rotary coupler 4 Ensure the rotary coupler is installed in its central position To obtain centre position rotate coupler gently clockwise and anticlockwise until the white segment appears ...

Page 559: ...Alignment Suspension System Wheel Alignment Specifications Torque Description Value Nuts pas ball joint 40 55Nm Nuts rear upper arm to subframe 90 110Nm Nuts rear wheel toe in adjust 90 110Nm Version 2 0 543 ...

Page 560: ...ent Specifications Wheel alignment Front Camber unladen condition Castor unladen condition King pin inclination Total toe in 0 21 30 3 30 30 12 41 30 0 10 10 Rear Camber unladen condition Total toe in 0 50 30 0 22 12 Version 2 0 544 ...

Page 561: ... Carry out run out compensation in accordance with equipment manufacturer s instructions Lower vehicle and allow vehicle suspension to return to level 11 Ensure steering wheel is in the central position Adjust 1 Observe readings from test equipment and adjust geometry as required General General General Data Data Data 2 Front wheel alignment adjust a Loosen lock nut on front track rod b Adjust tra...

Page 562: ...er to hub 90 110Nm Nuts steering rod outer ball joint 28 32Nm Bolt subframe to body 110 120Nm Screws subframe brace to body 19 25Nm Bolts steering rack to front subframe long 40 50Nm Bolts anti roll bar bush and clamp to subframe 22 28Nm Screws damper piston top 19 25Nm Bolts engine lower steady 90 110Nm Bolts turbocharger pipe to subframe 7 10Nm Screws subframe brace to subframe 19 25Nm Bolt stee...

Page 563: ...arm L shaped steel forged with lightening holes Ball joints at forward inner and outer joints Nominal height to wheel arch from hub centre 393 5mm Nominal height to wheel arch from hub centre 21 5mm Front coil spring data Total coils 5 Active coils 3 8 Wire diameter Approx 13 8mm Free length Approx 358 367mm Measurement taken with vehicle at unladen weight Version 2 0 547 ...

Page 564: ...sion Component Location 1 MacPherson strut assembly 2 off 2 Anti roll bar link 2 off 3 Subframe mountings 6 off 4 Subframe 5 Hub assembly 2 off 6 Lower arm 2 off 7 Anti roll bar 8 Anti roll bar bush and clamp 2 off 9 Subframe braces 2 off 10 Lower arm bush and housing assembly 2 off Version 2 0 548 ...

Page 565: ...per unit 2 Swivel hub 3 Hub nut 4 Drive flange 5 Circlip 6 Bearing 7 Inner ball joint 8 Outer ball joint 9 Lower arm bush and housing assembly 10 Lower arm 11 Anti roll bar 12 Anti roll bar bush 13 Anti roll bar clamp 14 Anti roll bar link 15 Coil spring Version 2 0 549 ...

Page 566: ...n Strut Components 1 Piston rod top nut 2 Washer 3 Locknut washer assembly 3 off 4 Top mounting plate 5 Bearing 6 Spring isolator 7 Bump stop washer 8 Bump stop 9 Dust cover 10 Coil spring 11 Damper 12 Spring isolator 13 Bump cup Version 2 0 550 ...

Page 567: ...operation The damper is attached at its lower end to a location in the swivel hub and is secured with a pinch bolt A tang on the damper locates in the swivel hub and ensures that the damper is correctly orientated The damper rod is located in steel inserts in rubber bushes which are integral with the top mounting plate and are secured with a washer and nut A hexagon is provided in the outer end of...

Page 568: ...age or misalignment may occur Anti Roll Bar ARB and Links A solid spring steel ARB is used that operates via ARB links from the spring seat on each strut The bar diameter is 21 5 mm The ARB is attached to the rear of the subframe with two Polytetrafluoroethylene PTFE bushes that are secured with clamp plates and bolts The low friction bushes PTFE require no additional greasing and allow the ARB to...

Page 569: ... outer ball joint protector T32003 10 Move anti roll bar aside for access to lower arm bush housing bolts 11 Remove 2 bolts securing lower arm bush housing to subframe 12 Remove nut securing lower arm inner ball joint to subframe 13 Release ball joint taper from subframe If necessary replace nut and use a soft mallet to release joint taper and remove lower arm 14 Pull front hub aside to make sure ...

Page 570: ...ndertray Asembly Undertray Asembly Refit Refit Refit 10 Check wheel alignment Wheel Wheel Wheel Alignment Alignment Alignment Refit Refit Refit Outer Ball Joint Boot Front Lower Arm Remove Caution This ball joint boot kit should only be used if the boot is damaged during a service It must not be used if the vehicle has been driven with a damaged boot 1 Remove front lower arm Lower Lower Lower Arm ...

Page 571: ...wer arm Lower Lower Lower Arm Front Arm Front Arm Front Remove Remove Remove 2 Using T32001 T32007 and T32009 remove front lower arm bush and bracket Refit 1 Clean front lower arm to bush and bracket mating faces 2 Position bush and bracket to front lower arm ensure bush is aligned to front lower arm according to the mark 3 Using T32008 T32001 andT32010 press bush and bracket to front lower arm un...

Page 572: ...k from anti roll bar 8 Remove nut and bolt securing lower arm ball joint to hub 9 UsingT32011 release lower arm ball joint from hub fit ball joint protector T32003 10 Temporarily support hub on top of lower arm 11 Remove bolt securing damper to hub 12 Remove hub from damper 13 Remove 3 nuts securing damper to body 14 Remove spring and damper assembly 15 Use an open ended spanner on the flats machi...

Page 573: ...panner on the flats provided to prevent ball stud rotation 13 Clean damper spring location on underside of wing 14 Position damper spring assembly to body fit and tighten nuts to 19 25Nm 15 Locate hub to damper 16 Remove lower ball joint protector and inspect ball joint boot for damage 17 Clean lower ball joint and hub mating faces 18 Connect lower arm to hub fit nut and bolt and tighten to 40 50N...

Page 574: ...is stage 7 Remove 4 bolts securing lower arm rear bushing to subframe 8 Tie lower arms to anti roll bar both sides 9 Tie steering rack aside 10 Remove 4 bolts securing steering rack to subframe 11 Remove 4 bolts securing anti roll bar bushings to subframe 12 Loosen 2 bolts securing both subframe braces to body floor 13 Remove 2 bolts securing both subframe braces to subframe 14 Remove 2 bolts secu...

Page 575: ...ighten bolts to110 120Nm 7 Remove rear 2 subframe mounting bolts 8 Fit subframe braces to subframe and tighten bolts to19 25Nm 9 Fit steering rack to subframe and tighten bolts to40 50Nm 10 Fit bolts securing anti roll bar clamps to subframe and tighten to22 28Nm 11 Fit bolts securing rear lower arm bushings to subframe and tighten bolts to140 170Nm 12 Fit bolts securing PAS pipe to subframe and t...

Page 576: ...to body fit and tighten bolt to 19 25Nm 3 Lower the vehicle Bush Front Subframe Remove 1 Remove front subframe Subframe Subframe Subframe Front Front Front Remove Remove Remove 2 Using tools T32002 T32019 andT32005 remove 4 subframe bushes 3 Remove special tools from bush 4 Using tools T32021 T32002 T32019 andT32022 remove middle suspension bush 5 Remove special tools from middle suspension bush R...

Page 577: ...e Remove 2 Remove front road wheels 3 Remove track rod end nuts and usingT38008 release track rod end from steering armand release track rod end from steering arm 4 Use an open ended spanner on the flats machined on the anti roll bar link to prevent ball stud from rotating 5 Remove nuts and disconnect both anti roll bar links from roll bar 6 Remove nut and bolt securing hub to lower arm passengers...

Page 578: ...ushes have a special coating and must not be lubricated 3 Fit clamps fit bolts securing clamps and tighten each bolt in turn to22 28Nm 4 Position steering rack fit bolts and tighten to40 50Nm 5 Remove lower arm ball joint boot protectorT32003 6 Pull hub outwards engage shaft to hub and fit hub to lower ball joint 7 Fit nut and bolt securing hub to lower arm and tighten to40 50Nm 8 Align anti roll ...

Page 579: ...ll bar bush clamp to subframe 6 Remove clamps and bushes Refit 1 Fit bushes to anti roll bar and locate to abutments Caution Anti roll bar bushes have a special coating and must not be lubricated 2 Fit clamps 3 Fit bolts and tighten each bolt in turn to22 28Nm 4 Check that each bolt is tightened Caution Failure to carry out this procedure can result in bolts being incorrectly tightened 5 Release s...

Page 580: ...g or tightening unions 2 Connect link to anti roll bar and tighten nut to60 70Nm Caution To prevent damage to components use two spanners when loosening or tightening unions 3 Fit road wheel and tighten bolts to115 130Nm 4 Lower the vehicle Hub Front Remove 1 Raise the vehicle on a lift 2 Remove front wheel 3 With an assistant applying brakes remove and discard drive shaft hub nut 4 RH side only D...

Page 581: ...int in hub 8 Fit bolt securing damper to hub and tighten to 90 110Nm 9 Fit nut and bolt securing lower arm to hub and tighten to 40 50Nm 10 Ensure ball joint is fully engaged in hub and bolt is in ball joint groove 11 Clean track rod to steering arm ball joint mating faces 12 Connect track rod ball joint to steering arm fit new nut and tighten to 28 32Nm 13 Clean wheel ABS sensor to hub mating fac...

Page 582: ...emove hub Hub Front Hub Front Hub Front Remove Remove Remove 2 Remove 3 bolts securing brake disc shield to hub 3 Position hub to press support on tools T32015 4 Fit toolT32012 to drive flange and press drive flange from hub bearing 5 Remove brake disc shield 6 UsingT32001 and T32012 remove the inner ring of bearing 7 Remove circlip from hub Version 2 0 566 ...

Page 583: ...g mating faces 2 UsingT32014 support hub useT32013 to press the new bearing into hub 3 Fit circlip to hub 4 Fit brake disc shield fit bolts and tighten to 5 7Nm 5 UsingT32013 support the hub flange usingT32012 press the hub flange into hub bearing 6 Fit hub Hub Front Hub Front Hub Front Refit Refit Refit Version 2 0 567 ...

Page 584: ...nd guide front lower arm outer ball joint boot T32025 Front lower arm outer ball joint spring ring clamp T32024 Replacer front lower arm outer ball joint boot Tool Number Description Picture T32001 Puller universal T32007 Remover front lower arm bush T32009 Remover cap front lower arm bush T32008 Replacer front lower arm bush T32010 Replacer cap front lower arm bush Version 2 0 568 ...

Page 585: ...2017 Adaptor coil spring compressor T32002 Puller bushes T32019 Centre screw Tool Number Description Picture T32005 Remover front subframe bush T32021 Remover front subframe middle suspension bush T32022 Remover front subframe middle suspension bush T32018 Centre screw T32004 Replacer Half Front Subframe Bush Version 2 0 569 ...

Page 586: ...sion Tool Number Description Picture T32006 Replacer front subframe bush T32015 Support plate front hub T32012 Remover replacer front hub flange T32013 Remover and replacer front hub bearing T32014 Support front hub Version 2 0 570 ...

Page 587: ...Nm Bolts rear damper to trailing arm 140 170Nm Bolt rear handbrake cable to rear lower arm 19 25Nm Bolts rear lower arm to subframe 90 110Nm Bolts rear lower arm to trailing arm 90 110Nm Screws rear anti roll bar saddle clamp to rear subframe 22 28Nm Bolts rear anti roll bar links to rear trailing arm 50 65Nm Nuts rear anti roll bar links to anti roll bar 50 65Nm Nuts rear hub 200 220Nm Screws rea...

Page 588: ... connected via ball jointed links to trailing arms Rear upper lateral link Fabricated steel Nominal height from hub centre to wheel arch 395 mm Anti roll bar diameter 17 mm Rear coil spring data Total coils 8 3 Active coils 7 3 Wire diameter 13 4 mm Free length 356 mm Measurement taken with vehicle at unladen weight Version 2 0 572 ...

Page 589: ...out Rear Suspension Component Location 1 Stub axle 2 off 2 Damper assembly 2 off 3 Upper arm 2 off 4 Rear subframe 5 Coil Spring 2 off 6 Rear subframe mounting 2 off 7 Front subframe mounting 2 off 8 Anti roll bar where fitted 9 Trailing arm 2 off 10 Lower arm 2 off Version 2 0 573 ...

Page 590: ... 3 Damper assembly 2 off 4 Trailing arm 2 off 5 Lower arm 2 off 6 Lower arm inner bush 2 off 7 Lower spring isolator 2 off 8 Coil spring 2 off 9 Upper spring isolator 2 off 10 Rear anti roll bar where fitted 11 Anti roll bar link where fitted 12 Anti roll bar clamp and bush 2 off Version 2 0 574 ...

Page 591: ...stem Rear Damper Assembly Components 1 Damper assembly 2 off 2 Dust cover 2 off 3 Bump stop 2 off 4 Bump stop plate 2 off 5 Top mounting 2 off 6 Rebound plate 2 off 7 Nut M10 flanged 2 off 8 Noise isolator cap 2 off Version 2 0 575 ...

Page 592: ...s full extension A spring aid plate and a spring aid are fitted over the rod and cushion the damper operation if maximum bump travel is reached A bump cup is fitted to the top of the damper body and protects the low friction damper rod seal from damage from the spring aid when maximum travel is reached A dust cover is fitted to protect the damper rod from dirt and damage Coil Springs Coil springs ...

Page 593: ...bility If replacing carefully observe and mark the orientation to aid reassembly Anti Roll Bar ARB and Links A solid spring steel ARB is used that operates directly from each trailing arm Each end of the ARB is attached to the trailing arm via non handed ARB links The ARB is 17 mm in diameter The ARB is attached to the rear of the subframe with two Polytetrafluoroethylene PTFE bushes that are secu...

Page 594: ...rame fit bolt align to marks but do not tighten at this stage 2 Position upper arm to trailing arm fit bolt but do not tighten at this stage 3 On RH upper arm position RH rear fuel tank strap tighten bolt to 21 25Nmand remove support 4 Fit clips securing harness to upper arm 5 Refit road wheel and tighten bolts to 115 130Nm 6 Lower the vehicle 7 Tighten bolt securing upper arm to subframe to 90 11...

Page 595: ...press to remove the other bush of the upper arm 5 Remove special tools from rubber bush Refit 1 Clean rubber bush recess 2 As shown usingT34018 and T34020 use hydraulic press to fit new rubber bush to rear upper arm 3 Remove special tools from rubber bush 4 Clean bush ball joint recess 5 As shown usingT34015 and T34017 use hydraulic press to fit new ball joint bush to rear upper arm Caution Ensure...

Page 596: ...ools from rubber bush Refit 1 Clean rubber bush recess 2 As shown usingT34018 and T34022 use hydraulic press to fit new rubber bush to rear lower arm 3 Remove special tools from rubber bush 4 Clean rear lower arm bush recess 5 As shown usingT34015 and T34021 use hydraulic press to fit new ball joint bush to rear lower arm Caution Ensure the rubber end of the bush is located fully in the special to...

Page 597: ...ve and discard nut from damper 10 Remove rebound plate mounting plate bump stop washer bump stop and dust cover from damper noting correct orientation of plate Refit 1 Fit dust cover bump stop bump stop washer mounting plate and rebound plate ensuring correct orientation of plate 2 Fit new nut and tighten to 25 34Nm 3 Clean damper to body mating faces 4 Fit damper to trailing arm fit bolt but do n...

Page 598: ...pring Rear Suspension Remove 1 Raise the vehicle on a lift 2 Remove road wheel 3 Support lower arm under spring pan Caution Do not jack the vehicle under the front or rear lower arm as damage or misalignment may occur 4 Remove bolt securing lower arm to trailing arm and release lower arm 5 Carefully release support and lower the lower arm 6 Remove spring 7 Remove upper and lower isolators from spr...

Page 599: ...t clamps fit bolts securing clamps and tighten each bolt in turn to 22 28Nm 3 Lower the vehicle 4 Align anti roll bar links fit nuts and use an open ended spanner on the flats machined on the anti roll bar link to prevent ball stud from rotating and tighten nuts to 50 65Nm Caution Nuts and bolts must be tightened with weight of vehicle on suspension Rubbers Anti Roll Bar Remove 1 Raise the vehicle...

Page 600: ...link from trailing arm 5 Remove anti roll bar link Refit 1 Fit anti roll bar link to trailing arm fit nut and tighten to 50 65Nm 2 Fit anti roll bar link to anti roll bar fit nut and tighten to 50 65Nm Caution Nuts and bolts must be tightened with weight of vehicle on suspension 3 Fit road wheel Wheel Wheel Wheel Refit Refit Refit 4 Lower the vehicle Hub Bearing Rear Remove 1 Raise the vehicle on ...

Page 601: ...Do not remove protective cover from bearing until hub is about to be fitted 3 Fit keyed washer to stub axle 4 Fit new hub nut and tighten to 200 220Nm 5 Stake flange on hub nut to stub axle shaft 6 Fit new grease cap to hub 7 Ensure mating surfaces of disc and hub are clean 8 Fit disc to hub fit countersunk screw and tighten to 30 36Nm 9 Release caliper and position to disc 10 Fit bolts securing c...

Page 602: ...bush T34016 Remove upper and lower arm ball joint bush T34018 Remove and replacer upper and lower arm bush T34019 Remove upper and lower arm bush T34020 replacer up arm bush Tool Number Description Picture T34017 Replacer rear upper arm ball joint bush T34022 Replacer rear lower arm bush T34021 Replacer lower arm ball bush Version 2 0 586 ...

Page 603: ...Tyres and Wheels Suspension System Tyres and Wheels Specifications Torque Description Value Bolt road wheel 115 130Nm Version 2 0 587 ...

Page 604: ... R17 91W 215 55 R17 93W Stow wheels With 6 5J x 16 wheels steel 215 55 R16 93W Note The tyre size is displayed on the outer wall of each tyre Tyre pressures Front 2 2 bar Tyre Pressures Normal driving conditions Rear 2 2 bar Front 2 2 bar Tyre pressures High speed in excess of 100 mph 160 km h Rear 2 2 bar Tip Normal driving conditions Carrying up to 4 passengers and luggage Version 2 0 588 ...

Page 605: ... are not properly cleaned the wheel bolts could become loose and may cause the wheel to fall off while the vehicle is moving This will cause the vehicle to go out of control and could cause injury 1 Fit a new tyre valve assembly 2 Fit tyre with tyre changer 3 Carry out wheel balance 4 Fit the wheel tighten 5 road wheel bolts to 115 130Nm Follow the sequence shown on the illustration below 1 to 5 W...

Page 606: ...Version 2 0 590 ...

Page 607: ...ear brake caliper bleed 7 9Nm Rear caliper housing to carrier guide pins 22 28Nm Screws rear brake disc to hub 30 36Nm Bolt rear brake caliper to trailing arm 61 66Nm Bolt rear back plate to trailing arm 55 60Nm Rear brake hose to caliper housing 16 18Nm Rear brake hose to rear brake pipe connection 14 17Nm Bolts accelerator pedal to pedal box 18 25Nm Nut pedal box to body 19 25Nm Bolts steering c...

Page 608: ...S if fitted 4 Yaw accelerator sensor if fitted 5 Flexible brake hose 6 RH rear brake backplate 7 RH rear brake calliper 8 Rear flexible brake hose 9 LH rear brake disc 10 Front flexible brake hose 11 Brake fluid low level switch 12 ABS DSC Modulator 13 RH front brake calliper 14 Inlet manifold 15 Brake vacuum pipe with non return valve 16 Brake fluid reservoir Version 2 0 592 ...

Page 609: ...tion control DSC warning light 6 Parking brake on Electronic Brake force Distribution EBD failure warning light 7 Brake fluid reservoir 8 Brake master cylinder 9 Brake servo 10 ABS DSC Modulator ECU 11 Modulator ECU connector 12 ABS DSC Modulator 13 Wheel speed sensor assembly front 14 Brake pad wear sensor front 15 DSC on off switch 16 Yaw accelerator sensor 17 Brake lamp switch 18 Brake fluid lo...

Page 610: ... Brakes Brakes Brakes Components Components Components 1 Front brake pad wear sensor 2 Bleed screw cap 3 Bleed screw 4 Calliper housing 5 Anti rattle spring 6 Piston seal 7 Piston 8 Piston dust cover 9 Shield 10 Brake disc Version 2 0 594 ...

Page 611: ...Brake Brake System 11 Calliper carrier 12 Calliper securing bolt 13 Brake pad 14 Guide pin dust cover 15 Guide pin 16 Guide pin dust cover cap Version 2 0 595 ...

Page 612: ...ear brake pad wear sensor 2 Bleed screw cap 3 Bleed screw 4 Calliper housing 5 Anti rattle spring 6 Piston seal 7 Piston 8 Piston dust cover 9 Brake disc 10 Calliper carrier 11 Calliper securing bolt 12 Brake pad 13 Guide pin dust cover 14 Guide pin 15 Guide pin dust cover cap Version 2 0 596 ...

Page 613: ...mponents 1 Rear backplate 2 Brake shoe return spring 3 Brake shoe adjuster 4 Brake shoe retaining pin 5 Forward brake shoe 6 Brake disc with integral drum 7 Brake shoe expander 8 Retaining clip 9 Brake shoe return spring 10 Rearward brake shoe 11 Brake shoe retaining pin 12 Guide plate Version 2 0 597 ...

Page 614: ... brakes via the SCS modulator the primary circuit supplies the front left and rear right brakes the secondary circuit supplies the front right and rear left brakes acuum for the brake servo assembly is obtained from the engine inlet manifold through a vacuum line and non return valve For the ABS EBD and TCS functions the modulator regulates the hydraulic pressure to the brakes to control wheel spe...

Page 615: ...ke pedal effort due to the lack of vacuum assistance The master cylinder assembly is attached to the forward ends of two tie bolts in the brake servo assembly The brake servo assembly consists of a circular housing which contains two diaphragms a central plate a control valve assembly input and output push rods and a filter The input push rod is connected to the brake pedal The output push rod loc...

Page 616: ...d secondary brake circuits Should a failure occur in one circuit the remaining circuit will still operate effectively although brake pedal travel and vehicle braking distances will increase If the fluid level in the reservoir is too low a level switch opens and breaks a circuit between the ABS modulator and the instrument pack which illuminates the brake warning light Front Brakes The front brakes...

Page 617: ... the warning switch connects an earth to the instrument pack which if the ignition is on illuminates the brake warning light In some markets the instrument pack performs a bulb check of the brake warning light each time the ignition is switched on A front cable is connected between the lever assembly and a cable tensioner and two handbrake cables are connected between the cable tensioner and the d...

Page 618: ...brake pedal released the piston in the control valve assembly positions the valve so that the vacuum port is open and the two pairs of chambers are connected together When the engine is running air is evacuated through the vacuum line and non return valve creating a partial vacuum in all four chambers When the engine stops the non return valve closes to maintain the partial vacuum Servo with Brake...

Page 619: ...utput push rod supplementing the pressure being applied by the brake pedal The force produced by the diaphragms in proportion to the input force i e the boost ratio is 5 6 1 The boost ratio remains constant as the input force from the brake pedal increases until the limit of assistance is reached when servo pressure is equal to ambient pressure Brakes Held On When the brake pedal effort is constan...

Page 620: ...ter cylinder 18 Return spring 19 Guide tube 20 Output push rod 21 Bush Master Cylinder Brakes Applied When the brake pedal is pressed the output rod in the brake servo assembly pushes the primary piston along the cylinder bore This produces pressure in the primary pressure chamber which in conjunction with the primary springs overcomes the secondary spring and simultaneously moves the secondary pi...

Page 621: ...nd the ECU detects a wheel spinning normally brake pressure is too low so the caliper outlet solenoid valve is shut allowing brake fluid to flow into the caliper via caliper inlet solenoid valve to increase brake pressure If the wheel is locking in a critical situation the caliper inlet solenoid valve and caliper outlet solenoid valve close to maintain brake pressure and ensure optimum brake perfo...

Page 622: ...rom rolling backwards while driving off up hill on an inclined surface Main requirements for activation of HHC are recognition of vehicle stand still and brake pressure build up by the driver via brake pedal Following detection of the vehicle standstill state after the driver has released the brake pedal the braking pressure built up by the driver during the stop procedure is maintained in the bra...

Page 623: ...f a fault exists in the warning light circuit the lamp will not illuminate during the lamp check but provided there are no other faults the related function will otherwise be fully operational When a fault is detected the SCS ECU stores a related fault code in memory and illuminates the appropriate fault warning light s for the remainder of the ignition cycle If a fault does not recur it is erased...

Page 624: ...bleed screw Loosen bleed screw 5 Press piston into caliper housing then tighten bleed screw to7 9Nm 6 Disconnect bleed hose and remove bottle 7 Secure bleed screw cap 8 Fit brake pads to caliper housing On RH brake ensure pad wear sensor is connected to inner pad Caution If brake pads low warning light was illuminated on the instrument pack before changing brake pads the sensor must be renewed oth...

Page 625: ...e Caution Do not tie brake caliper on brake hose 5 Remove Torx screw securing brake disc to drive flange 6 Remove brake disc Refit 1 Ensure mating surfaces of disc and drive flange are clean 2 Fit disc to drive flange fit countersunk screw and tighten to 30 36Nm 3 Check brake disc run out Thickness Thickness Thickness and and and Run out Run out Run out Check Check Check Front Front Front Brake Br...

Page 626: ... Remove 2 caps from guide pin dust covers 10 Remove 2 guide pins from caliper housing 11 Release caliper housing from caliper carrier 12 Remove brake pads from caliper housing Refit 1 Clean components and mating faces Warning Do not use compressed air to clean brake components Dust from friction materials can be harmful if inhaled 2 Remove any scale and loose corrosion from around edge of disc 3 F...

Page 627: ...tion bleed bottle connect bleed hose to bleed screw and loosen screw 5 Press piston into caliper housing then tighten bleed screw to7 9Nm 6 Disconnect bleed hose and remove bottle 7 Secure bleed screw cap 8 Fit brake pads to caliper housing On LH brake ensure pad wear sensor is connected to pad Caution If brake pads low warning light was illuminated on the instrument pack before changing brake pad...

Page 628: ...ow caliper to hang on brake hose 4 Remove countersunk screw securing brake disc to hub 5 Remove brake disc Refit 1 Ensure mating surfaces of disc and hub are clean 2 Fit disc to hub fit and tighten countersunk screw and tighten to30 36Nm Caution Brake discs must be renewed in pairs unless one disc requires changing before 1000 miles 1500 km from new 3 Examine brake pads and renew if necessary 4 Re...

Page 629: ...stment Brake Shoe Rear Remove 1 Remove rear brake disc Brake Brake Brake Disc Disc Disc Rear Rear Rear Remove Remove Remove 2 Remove brake shoe retainers 3 Release brake shoes from backplate 4 Release handbrake cable from expander 5 Remove brake shoes complete with return springs adjuster and expander 6 Noting fitted position release and remove return springs collect adjuster and expander Refit 1 ...

Page 630: ... from guide pin dust covers 10 Remove 2 guide pins from caliper housing 11 Release caliper housing from caliper carrier 12 Remove brake pads from caliper housing Refit 1 Clean components and mating faces Warning Do not use compressed air to clean brake components Dust from friction materials can be harmful if inhaled 2 Remove any scale or loose corrosion from around edge of disc 3 Fit brake pads t...

Page 631: ...f hub using caliper assembly bolt hole 6 Position DTI probe 10 mm from outer edge of disc 7 Fit wheel Wheel Wheel Wheel Refit Refit Refit 8 Zero DTI and rotate road wheel one complete turn to measure disc run out Disc run out must not exceed the 0 06mm limits 9 If disc runout is outside limits a Remove road wheel b Remove countersunk screw securing brake disc to hub and remove disc c Ensure disc t...

Page 632: ...d side of hub using caliper assembly bolt hole 6 Position DTI probe 5 mm from outside edge of disc 7 Fit wheel Wheel Wheel Wheel Refit Refit Refit 8 Zero DTI and rotate wheel one complete turn to measure disk runout Disc runout must not exceed 0 06 mm 9 If disc runout is outside limits a Remove wheel b Remove countersunk screw securing brake disc to hub and remove disc c Ensure disc to hub flange ...

Page 633: ...eering column from fascia beam 4 Remove clip and pin securing brake servo push rod to brake pedal 5 Remove clevis pin securing master cylinder push rod to clutch pedal 6 Remove 2 bolts securing clutch master cylinder to pedal bracket 7 Release clips securing Vacuum servo push rod to pedal box and remove nut and push rod 8 Remove 2 bolts and 4 nuts securing pedal box to body 9 Disconnect brake swit...

Page 634: ...tch master cylinder to clutch pedal and secure with bolts 9 Fit Clutch master cylinder push rod to clutch pedal and secure with nets 10 With brake pedal released ensure brake switch is in contact with operating tang on brake pedal 11 Position steering column to fascia beam fit bolts and tighten to21 25Nm 12 Fit steering column closing panel Panel Panel Panel Assembly Steering Assembly Steering Ass...

Page 635: ... with bolts and tighten to18 25Nm Warning When fitting accelerator pedal must correctly position the pedal into the groove of the pedal box Error positioning will result in non return 5 Position pedal box and connect multiplugs 6 Fit pedal box to body and secure with nuts and bolts to19 25Nm 7 Connect brake servo push rod to brake pedal with pin and clip 8 With brake pedal released ensure brake sw...

Page 636: ...inished surfaces If spilled immediately remove fluid and clean area with water 7 Release 2 brake pipes from master cylinder Caution Before disconnecting or removing components ensure the immediate area around joint faces and connections are clean Plug open connections to prevent contamination 8 Disconnect vacuum hose from brake servo 9 Remove steering column closing panel 10 Remove clip and pin se...

Page 637: ...rake Remove 1 Disconnect battery earth lead 2 Remove steering column closing panel Panel Panel Panel Assembly Steering Assembly Steering Assembly Steering Column Column Column Lower Lower Lower Cover Base Cover Base Cover Base Remove Remove Remove 3 Release brake switch from brake switch bracket in pedal box Disconnect multiplug and remove brake switch 4 Release clips securing brake switch bracket...

Page 638: ... LHD models remove bleed screw dust cap and attach tube to bleed screw Submerge free end of tube in clear container containing new brake fluid 4 Apply pressure to brake pedal several times then apply steady pressure 5 Loosen bleed screw to release brake fluid and air Allow pedal to return unassisted 6 Repeat procedure until a flow of clean airfree fluid is purged into the container then while hold...

Page 639: ...fluid low level indicator switch to brake fluid reservoir and secure clip 2 Connect multiplug to brake fluid low level indicator switch Master Cylinder and Fluid Reservoir Remove 1 Position absorbent cloth under ABS modulator to absorb fluid spillage Caution Brake fluid will damage paint finished surfaces If spilled immediately remove fluid and clean area with water 2 Disconnect multiplug from bra...

Page 640: ...er to servo fit washers and nuts and tighten to25Nm 2 Clean brake pipe unions 3 Connect brake pipes to master cylinder and tighten to16 18Nm 4 Position engine harness connector to battery carrier bracket and connect to main harness Secure connector to bracket 5 Connect multiplugs to ECM 6 Connect multiplug to brake fluid low level indicator switch 7 Bleed brake system Brake Brake Brake System Syst...

Page 641: ...Brake Brake System Special Tools Tool Number Description Picture TCH00022 Brake disc runout test kit Version 2 0 625 ...

Page 642: ...ar brake caliper to trailing arm 61 66Nm Bolt rear handbrake cable to subframe 19 25Nm Bolt rear handbrake cable to fuel tank strap 10Nm Bolt central heat shield to body 19 25Nm Bolt fuel tank heat shield to body 19 25Nm Bolt handbrake lever to centre channel 19 22Nm Version 2 0 626 ...

Page 643: ...em Component Layout Parking Brake Component Location 1 Lever assembly 2 Adjuster nut 3 Warning switch 4 Front cable and compensator 5 Parking brake cables assembly 6 Shield 7 Expander 8 Brake shoe adjuster 9 Protective sleeve 10 Brake shoe Version 2 0 627 ...

Page 644: ...ning light In some markets the instrument pack performs a bulb check of the brake warning light each time the ignition is switched on A front cable is connected between the lever assembly and a cable tensioner and two handbrake cables are connected between the cable tensioner and the drum brakes Clips and a guide bracket secure the handbrake cables to the underside of the vehicle and grommets seal...

Page 645: ...e heat shield and remove heat shield 6 Release handbrake cable from compensator 7 Remove bolt securing handbrake cable support bracket to fuel tank strap and release cable 8 Remove bolt securing cable to subframe 9 Remove bolt securing cable to lower arm 10 Release clip securing cable to trailing arm 11 Remove road wheel 12 Remove 2 bolts securing caliper to trailing arm release caliper and tie as...

Page 646: ...brake Handbrake Handbrake Adjustment Adjustment Adjustment 16 Fit road wheel 17 Lower the vehicle Handbrake Adjustment Adjust Warning Where possible a road test should be on well surfaced dry roads Always comply with speed limits and local traffic regulations 1 Open centre console cover 2 Loosen handbrake cable adjusting nut until nut is flush with end of thread 3 Raise the vehicle on a lift Warni...

Page 647: ...handbrake warning lamp in instrument pack on or off b Notch 2 rear brake discs turn with light resistance handbrake warning lamp in instrument pack on c Notch 3 and above rear brake discs locked handbrake warning lamp in instrument pack on 13 Switch ignition off 14 Fit handbrake adjust nut cover to centre console 15 Fit rear road wheels 16 Lower the vehicle Handbrake Lever Remove 1 Remove centre c...

Page 648: ...able Remove 1 Remove centre console Console Console Console Assembly Assembly Assembly Remove Remove Remove 2 Remove handbrake cable adjusting nut release cable collect washer 3 Raise the vehicle on a lift 4 Remove intermediate exhaust pipe Intermediate Intermediate Intermediate Pipe Pipe Pipe Remove Remove Remove 5 Remove bolts securing heat shield to body and remove heat shield 6 Release 2 rear ...

Page 649: ... System tighten adjusting nut 7 Fit centre console Console Console Console Assembly Assembly Assembly Refit Refit Refit 8 Adjust handbrake Handbrake Handbrake Handbrake Adjustment Adjustment Adjustment Version 2 0 633 ...

Page 650: ...ke Module Brake Module Specifications Torque Description Value Screws modulator to adjustor to upper bracket 7 10Nm Screws modulator lower bracket to body 19 22Nm Front brake pipes to modulator 16 18Nm Version 2 0 634 ...

Page 651: ...Description and Operation System Component Layout Brake System Control Diagram A Hard wired B HS CAN bus C MS CAN bus 1 ABS DSC Modulator 2 Body Control Module BCM 3 Yaw accelerator sensor 4 Steering angle sensor Version 2 0 635 ...

Page 652: ...tic transmission only 9 Electronic Steering Column Lock ESCL control unit 10 Brake switch 11 Instrument pack and message centre 12 LH brake lamp 13 High level brake lamp 14 RH brake lamp 15 Brake fluid low level sensor 16 Pad wear sensor front 17 Pad wear sensor rear 18 Parking brake switch 19 DSC TCS switch 20 Diagnostic socket Version 2 0 636 ...

Page 653: ... VSC Vehicle Stability Control The SCS modulator is a non serviceable 4 channel unit consisting of an integrated Hydraulic Control Unit HCU and SCS ECU Depending on the system components working condition the ECU can control the HCU in different operating modes including normal braking brake held on pressure decreasing and pressure increasing Hydraulic Control Unit Schematic HCU Hydraulic Modulato...

Page 654: ...ened restrictor 6 is shut off and the return pump 9 is activated The pressurised brake fluid enters the caliper 15 to increase the brake pressure See the following illustration The overflow valve 4 can protect the hydraulic system If the system pressure exceeds the limited value it will be opened to return the brake fluid back to the master cylinder 3 Brakes Held On To maintain system pressure the...

Page 655: ...fer These acceleration values are proportional to the angular velocity Steering Angle Sensor The steering angle sensor is integrated into the rotary coupler of the steering wheel switch assembly It monitors steering wheel as it is turned by the driver and transmits its position as input data to SCS ECU The SCS ECU compares the signal of the Yaw Lateral accelerator sensor and the steering angle sen...

Page 656: ...and disconnect pipes 6 Remove modulator and upper bracket from lower bracket 7 Remove 3 bolts securing modulator to upper bracket 8 Remove modulator 9 Remove 3 bolts securing lower modulator bracket to body and remove lower bracket Refit 1 Fit mounting bracket upper to modulator fit bolts and tighten to7 10Nm 2 Fit modulator bracket lower to body ensuring that fixing grommets are correctly engaged...

Page 657: ...ate shaft support bearing bracket to engine 19 25Nm Nut front hub to lower arm outer ball joint 40 50Nm Nut track rod ball joint 28 32Nm Bolt front anti roll bar to anti roll bar link 60 70Nm Nut front drive shaft 350 370Nm Bolt front hub to lower arm outer ball joint 40 50Nm Version 2 0 641 ...

Page 658: ...tion System Component Layout RH Drive Shaft Components 1 Outer joint 2 Snap ring 3 Clamp big 4 Gaiter 5 Clamp small 6 Dynamic damper 7 Clamp small 8 Gaiter 9 Clamp big 10 Shaft 11 Bearing housing 12 Dust shield 13 Bearing 14 Circlip Version 2 0 642 ...

Page 659: ...Drive Axle Driveline Axle LH Drive Shaft Components 1 Outer joint 2 Snap ring 3 Clamp big 4 Gaiter 5 Clamp small 6 Dynamic damper 7 Clamp small 8 Gaiter 9 Clamp big 10 Shaft 11 Circlip Version 2 0 643 ...

Page 660: ... The other solid shaft with inner and outer constant velocity joints is fitted to the differential on the LH side The inner joint is of the tripod type with spherical bushing to reduce sliding resistance The shaft and joint are one assembly The outer joint of the ball and socket type is splined to the shaft and secured with a snap ring The joints are packed with grease and protected by gaiters Bot...

Page 661: ...ve Axle Driveline Axle Operation The drive shaft transmits engine torque via the gearbox to the front wheels The dynamic dampers reduce any vibration produced by the drive shaft s rotation Version 2 0 645 ...

Page 662: ...to damage lower ball joint rubber gaiter 11 Fit lower ball joint boot protector T32003 12 Pull hub outward to release drive shaft from hub 13 Remove 3 bolts securing drive shaft carrier bracket to cylinder block 14 Release drive shaft from differential and remove 15 Remove dust shield 16 Remove and discard drive shaft circlip Refit 1 Fit dust shield 2 Fit new drive shaft circlip 3 Clean ends of dr...

Page 663: ... Liner front front front wheel wheel wheel arch arch arch front front front 18 Lower the vehicle LH Shaft Both Joints Remove 1 Raise the vehicle on a lift 2 Remove front wheel arch liner Liner Liner Liner front front front wheel wheel wheel arch arch arch front front front 3 Prise locking device from nut With an assistant pressing brake pedal remove and discard drive shaft nut 4 Remove nut from tr...

Page 664: ...wards engage drive shaft to hub and fit hub to lower ball joint 6 Fit nut and bolt securing hub to lower arm and tighten to 40 50Nm 7 Ensure lower ball joint is fully engaged in hub and bolt is located in ball joint groove 8 Ensure tapers in track rod end and steering arm are clean and rubber boot is not damaged 9 Fit track rod end to steering arm and tighten nut to 60 70Nm 10 Ensure anti roll bar...

Page 665: ...t and gaiter 2 Fit new circlip to drive shaft 3 Position outer joint to drive shaft using a tool press circlip into its groove and push joint fully onto drive shaft 4 Apply grease to the joint 5 Position gaiter to joint and secure with new clips 6 Fit drive shaft Shaft Shaft Shaft with with with both both both joints joints joints Outer CV Joint Gaiter Remove 1 Remove outer joint Outer Outer Outer...

Page 666: ... drive shaft Shaft Shaft Shaft with with with both both both joints joints joints Inner Joint Gaiter Remove 1 Remove outer joint gaiter Gaiter Gaiter Gaiter outer outer outer joint joint joint 2 Measure and record fitting dimensions of dynamic damper 3 Remove dynamic damper 4 Remove 2 gaiter clips Remove inner gaiter clips and gaiter 5 Check the gaiter and renew if necessary Refit 1 Clean drive sh...

Page 667: ...Driveline Axle Special Tools Tool Number Description Picture T38008 Remover ball joint T32011 Lever front lower arm ball joint T32003 Protector front lower arm ball joint T30001 Remover drive shaft Version 2 0 651 ...

Page 668: ...Version 2 0 652 ...

Page 669: ...ment Panel and Console Interior Fitting Instrument Panel and Console Specifications Torque Description Value Screw fascia cross car beam to A post LH 23 25Nm Bolt centre console bracket 6 8Nm Version 2 0 653 ...

Page 670: ... to retain correct setting 10 Remove screw securing RH tiptronic paddle switch to steering wheel if fitted and carefully release clips securing switch cover to steering wheel 11 Remove screw securing cruise control switch assembly to steering wheel 12 Disconnect switch ribbon cable multiplug and remove switch assembly Refit 1 Fit the switch assembly and connect switch ribbon cable multiplug 2 Fit ...

Page 671: ...b Remove Remove Remove 2 Remove automatic A C control assembly Automatic Automatic Automatic Air Air Air Conditioning Conditioning Conditioning Control Control Control Assembly Assembly Assembly Remove Remove Remove 3 Open storage box lid 4 Remove ashtray 5 Remove screw from ashtray housing 6 Release 6 clips and upper wood trim 7 Repeat the step on the passenger side 8 Remove the wood trim Do not ...

Page 672: ...mbly Assembly Assembly Refit Refit Refit 10 Fit gear knob Selector Selector Selector Lever Lever Lever Knob Knob Knob Refit Refit Refit Glove Box Assembly Remove 1 Open glove box and release the clips securing air damper to glove box 2 Apply inward pressure on side of glove box and release clips from fascia 3 Remove circlips retaining glove box hinge pins 4 Remove hinge pins and glove box assembly...

Page 673: ...lower A post trim finishers Lower Lower Lower A A A post post post Trim Trim Trim Finisher Finisher Finisher Remove Remove Remove 9 Pull back the carpet near LH lower A post remove 3 earth bolts 10 Pull back carpet near RH lower A post remove 3 bolts and disconnect earth leads 11 Disconnect 3 multiplugs connecting fascia harness to BCM 12 Release both door grommets and disconnect both fascia to do...

Page 674: ...ear LH A post 9 Connect fascia harness to BCM multiplugs 10 Connect both front door to fascia harness multiplugs and secure grommets 11 Secure harness clip to fascia 12 Position RH side finisher to fascia and connect multiplug in order to connect multiplug easily 13 Fit RH side finisher to fascia with clips 14 Fit LH side finisher to fascia and secure clips 15 Fit A post upper trim finishers Upper...

Page 675: ...nsmission models only 2 Disconnect battery earth lead 3 Release 10 clips securing gear lever gaiter pull gear knob firmly upwards and remove gear knob Manual transmission models only 4 Remove wood trim Wood Wood Wood trim trim trim Remove Remove Remove 5 Release 6 clips securing rear air vent assembly to console moulding and remove 6 Remove driver side fascia lower closing panel Panel Panel Panel ...

Page 676: ...sher Wood Wood Wood Trim Trim Trim Refit Refit Refit 11 Fit gear lever knob and secure gaiter clips Manual transmission only 12 Connect battery earth lead Centre Bezel Assembly Remove 1 Disconnect battery earth lead 2 Carefully release 9 clips securing centre bezel assembly to fascia 3 Disconnect SEL ESC switch multiplug 4 Remove centre bezel assembly 5 Remove 2 screws and SEL ESC switch from cent...

Page 677: ... Fit lower cover to instrument panel with bolts and clips Ventilator LH Remove 1 Release 5 clips securing LH side fascia finisher to fascia and remove LH side fascia finisher 2 Release 2 clips securing LH side ventilator and remove LH ventilator from fascia Refit 1 Fit LH ventilator to fascia and secure clips Ensure ducts are correctly engaged 2 Fit LH side fascia finisher to fascia with clips Ver...

Page 678: ...Interior Fitting Seats Seats Specifications Torque Description Value Screw front seat to floor 40 50Nm Bolt squab to cushion 40 50Nm Striker striker to body 22Nm Version 2 0 662 ...

Page 679: ...n and Operation System Component Layout Manual Seats Component Location 1 Lumbar adjustment handwheel driver s seat only 2 Backrest forward recline lever 3 Cushion height raise lower lever 4 Seat forward rearward lever Version 2 0 663 ...

Page 680: ...t Location 1 Lumbar adjustment handwheel driver s seat only 2 Backrest forward recline switch 3 Seat forward rearward switch and cushion height raise lower switch 4 Seat forward rearward switch and cushion height raise lower switch Version 2 0 664 ...

Page 681: ...Seats Interior Fitting Driver s Electric Seat Control Layout 1 Backrest forward recline motor 2 Seat forward rearward motor 3 Cushion height raise lower motor Version 2 0 665 ...

Page 682: ...trol Diagram Driver s Electric Seat Control Diagram 1 Driver seat forward rearward motor 2 Driver cushion height raise lower motor 3 Driver backrest forward recline motor 4 Fuse 21 30A on BCM 5 Driver s seat switchpack Version 2 0 666 ...

Page 683: ... seat forward rearward recline height and manual lumbar cloth or leather cover side airbag Passenger s Seat Different options of passenger s seats are fitted according to model and trim specification as follows 4 way or 6 way manual or electric passenger s seat forward rearward recline height cloth or leather cover SBR A storage tray is fitted under the seat cushion Version 2 0 667 ...

Page 684: ...Interior Fitting Seats Rear Rear Rear Seats Seats Seats Version 2 0 668 ...

Page 685: ...ht respectively Backrest forward recline lever enables adjustment of the backrest position Pulling the lever up releases the backrest With the backrest released it can be moved backwards or forwards as required Releasing the lever locks the backrest in the required position A lumbar adjustment handwheel is located on the outer face of the driver s backrest and allows for adjustment of the backrest...

Page 686: ...tment and lumbar adjustment Lumbar adjustment is always manually controlled When the handset is docked or the ignition is on the seats can be adjusted Operation of the seat in each axis is controlled from the driver s seat switchpack which is mounted on the outer seat trim panel The driver s seat switchpack contains one 2 way switch for recline adjustment and one 4 way switch to control both seat ...

Page 687: ...o body and discard bolts 7 Disconnect seat belt and side airbag multiplugs if fitted 8 Remove seat from vehicle Refit 1 Making sure the seat slides are correctly aligned position front seat to vehicle 2 Connect seat belt and side airbag multiplugs if fitted 3 Fit 2 new bolts securing rear of seat to body and tighten to 40 50Nm 4 Move seat fully back 5 Fit 2 new bolts securing front of seat to body...

Page 688: ...Passenger Refit Refit Refit Cover Passenger Squab Front Remove 1 Remove front seat Seat Seat Seat Complete Complete Complete Passenger Passenger Passenger Remove Remove Remove 2 Depress the clip securing the head rest and remove head rest 3 Release and remove 2 head rest guide tubes if necessary you can cut the covers 4 Remove screw securing outer valance to seat 5 Release clip securing outer vala...

Page 689: ...e with C rings 2 Secure squab cover fastening strip 3 Fit seat squab to cushion and secure with 4 bolts tighten to 40 50Nm 4 Secure squab cover to cushion frame with clips 5 Fit inner valance and secure with clip and screw 6 Fit outer valance and secure with clip and screw 7 Fit head rest guide tubes and secure with clips 8 Fit head rest 9 Fit front seat Seat Seat Seat Complete Complete Complete P...

Page 690: ...s locate in correct slots 3 Position front clips in slots and push down firmly until clips are correctly located Cover Cushion Rear Seat Remove 1 Remove rear seat cushion Cushion Cushion Cushion Rear Rear Rear Seat Seat Seat Remove Remove Remove 2 Noting exact positions remove 39 C rings securing cushion cover to frame 3 Remove cushion cover from cushion Refit 1 Fit cushion cover to cushion pad an...

Page 691: ...into fixing and push downwards to secure 3 Fit rear seat cushion Cushion Cushion Cushion Rear Rear Rear Seat Seat Seat Refit Refit Refit 4 Push squab to correct position and secure in locating clip Cover Squab Rear Seat Remove 1 Remove rear seat armrest 2 Remove rear seat squab Squab Squab Squab Rear Rear Rear Seat Seat Seat Remove Remove Remove 3 Remove head restraint from rear seat squab 4 Relea...

Page 692: ...t guide tubes and secure with clips 8 Fit head rest 9 Fit rear seat squab Squab Squab Squab Rear Rear Rear Seat Seat Seat Refit Refit Refit 10 Fit rear seat armrest Striker Squab Rear Seat Remove 1 Press release button and pull forward 2 Mark position of seat squab striker 3 Remove 2 bolts securing striker to body and remove striker Refit 1 Position striker to body fit bolts and tighten to22Nm 2 L...

Page 693: ...at Complete Complete Complete Driver Driver Driver Refit Refit Refit Lumbar support assembly front seat Remove 1 Back off the lumbar support fully 2 Remove front seat squab foam Foam Foam Foam driver driver driver squab squab squab front front front remove remove remove 3 Remove lumbar support mechanism from squab suspension bars 4 Remove 2 screws securing lumbar control to squab frame Refit 1 Fit...

Page 694: ...rews 2 Connect switch pack multiplug 3 Secure valance to seat with clips and screw 4 Fit front seat side board Side Side Side Board Board Board Outer Outer Outer Power Power Power Seat Seat Seat Refit Refit Refit Cover driver cushion front Remove 1 Fully raise seat cushion 2 Remove outer valance Side Side Side Board Board Board Outer Outer Outer Power Power Power Seat Seat Seat Remove Remove Remov...

Page 695: ...arness multiplug 5 Secure squab cover to cushion frame with clips 6 Fit inner valance and secure with clip and screw 7 Fit outer valance Side Side Side Board Board Board Outer Outer Outer Power Power Power Seat Seat Seat Refit Refit Refit Seat complete driver Remove Warning Always remove the ignition key from the ignition switch disconnect the vehicle battery and wait 10 minutes before commencing ...

Page 696: ...ighten to 40 50Nm 5 Connect battery earth lead 6 Move or power seat fully back 7 Fit 2 new bolts securing front of seat to body and tighten to 40 50Nm 8 Fit covers to front fixings Foam driver squab front Remove 1 Disconnect battery earth lead 2 Remove squab cover Cover Cover Cover driver driver driver squab squab squab front front front remove remove remove 3 Release squab foam from frame and rem...

Page 697: ...d rest and remove head rest 3 Release and remove 2 head rest guide tubes if necessary you can cut the covers 4 Remove screw securing inner valance to seat 5 Release inner valance from clip and remove valance 6 Release 3 clips securing squab cover to cushion frame 7 Disconnect squab harness multiplug 8 Remove 4 bolts securing squab to cushion frame and remove squab 9 Release squab cover fastening s...

Page 698: ...SS label with date of manufacture sewn inside the cover Warning For effective airbag performance when fitting the cover ensure retention wires shock cords and C rings are correctly located and secure 2 Fit lumbar support handwheel 3 Secure squab cover fastening strip 4 Fit seat squab to cushion and secure with 4 bolts tighten to 40 50Nm 5 Connect squab harness multiplug 6 Secure squab cover to cus...

Page 699: ...to door and secure with screws 3 Connect speaker multiplug 4 Fit rear door trim casing Trim Trim Trim casing casing casing rear rear rear door door door refit refit refit 5 Connect battery earth lead Trim Casing Rear Door Remove 1 Disconnect battery earth lead 2 Remove access cover from interior handle and remove screw securing handle to door 3 Release 2 clips securing grab handle trim to trim cas...

Page 700: ...dle to door with screw and fit access cover 6 Connect battery earth lead Plastic Sheet Front Door Remove 1 Remove front door trim casing Trim Trim Trim casing casing casing front front front door door door remove remove remove 2 Disconnect multiplug from speaker Remove 3 screws securing speaker assembly to door and remove speaker 3 Release plastic sheet pass harness and release cable through sheet...

Page 701: ...rom tweeter 8 Disconnect 2 multiplugs from window switch pack S523070 9 Release lock operating cable from interior handle release hook and remove trim casing 10 Carefully release 4 clips securing switch pack to door casing and remove switch pack Refit 1 Fit window switch pack 2 Connect multiplugs to window switch pack 3 Connect multiplug to tweeter 4 Connect operating cable and position trim casin...

Page 702: ...Interior Fitting Interior Trim and Paneling Interior Trim and Paneling Specifications Torque Description Value Front seat belt assembly 30 35Nm Bolt rear seat belt to body 30 35Nm Version 2 0 686 ...

Page 703: ...ts Persons working on SRS systems must be fully trained and have been issued with copies of the Safety guidelines Refit 1 Fit A post trim finisher to A post and secure clips 2 Fit screw securing A post trim finisher to A post 3 Fit screw cover to A post trim finisher and secure with clips 4 Fit front door seal Trim Finisher A Post Lower Each Remove 1 Release front door seal 2 Release and remove bo...

Page 704: ...ng upper BC post trim finisher to lower BC post trim finisher 6 Release seat belt and remove upper BC trim finisher Refit 1 Position BC post trim finisher and fit seat belt 2 Fit upper BC post trim finisher to lower BC post trim finisher and secure clips 3 Locate seat belt adjusting handle to adjusting mechanism and secure trim finisher to BC post with screws 4 Fit screw cover to BC post trim fini...

Page 705: ...her A A A post post post lower lower lower Refit Refit Refit 4 Fit upper BC post trim finisher Trim Trim Trim finisher finisher finisher BC BC BC post post post upper upper upper each each each Refit Refit Refit Trim Finisher D Post Upper Each Saloon Remove 1 Remove lower D post trim finisher Trim Trim Trim finisher finisher finisher D D D post post post lower lower lower each each each Remove Rem...

Page 706: ...r to upper D post trim finisher and remove Refit 1 Position lower D post trim finisher and secure to upper D post trim finisher with clips 2 Secure lower D post trim finisher to D post with clips and locating peg 3 Fit rear door seal 4 Fit rear seat squab Squab Squab Squab rear rear rear seat seat seat Refit Refit Refit 5 Fit rear seat cushion Cushion Cushion Cushion rear rear rear seat seat seat ...

Page 707: ... visor 12 Release clip securing sun visor retaining clip to body and remove clip 13 Remove sun visor retaining clips 14 Remove A post upper trim finisher Trim Trim Trim finisher finisher finisher A A A post post post upper upper upper each each each Remove Remove Remove 15 Remove remaining A post upper trim finisher 16 Remove BC post upper trim finisher Trim Trim Trim finisher finisher finisher BC...

Page 708: ...ly interior interior interior courtesy courtesy courtesy front front front Refit Refit Refit 10 Connect roof harness to body harness multiplugs 11 FitCHMSLcover and secure with screws 12 Fit rear interior lamp Lamp Lamp Lamp assembly assembly assembly interior interior interior courtesy courtesy courtesy rear rear rear Refit Refit Refit 13 Fit D post upper trim finishers Trim Trim Trim finisher fi...

Page 709: ...move Remove Remove 7 Release clips and remove 2 foot rest fixing covers 8 Remove 2 bolts securing foot rest to body and remove foot rest 9 Remove carpet from vehicle Refit 1 Position carpet into vehicle 2 Position foot rest and secure with bolts 3 Fit foot rest fixing covers 4 Fit lower D post trim finishers Trim Trim Trim finisher finisher finisher D D D post post post lower lower lower each each...

Page 710: ...30 35Nm 5 Fit LH D post upper trim finisher Trim Trim Trim Finisher Finisher Finisher D D D Post Post Post Upper Upper Upper Each Each Each Refit Refit Refit 6 Fit RH D post upper trim finisher Parcel Tray Rear Sun Blind Fitted Remove 1 Remove RH D post trim finisher Trim Trim Trim Finisher Finisher Finisher D D D Post Post Post Upper Upper Upper Each Each Each Remove Remove Remove 2 Remove LH D p...

Page 711: ...secure with screws 2 Position air vent and secure with brackets 3 Position sun blind to parcel tray and fit sun blind end finishers 4 Fit seat belts and seat belt trim finishers to parcel tray 5 Fit parcel tray 6 Fit bolts securing seat belts to floor 7 Fit LH parcel tray finisher 8 Fit RH parcel tray finisher 9 Fit LH D post upper trim finisher Trim Trim Trim Finisher Finisher Finisher D D D Post...

Page 712: ...tailgate 2 Release luggage compartment seal 3 Remove luggage compartment carpet 4 Remove 4 scrivets securing sill trim casing to body 5 Release 4 clips securing sill trim casing to body and remove trim casing Refit 1 Ensure that clips are correctly fitted in trim casing 2 Position sill trim casing to body and secure with clips and scrivets 3 Fit luggage compartment seal ensuring correct fitment al...

Page 713: ...partment compartment compartment sill sill sill Remove Remove Remove 3 Release 4 clips and remove side finisher from luggage compartment Refit 1 Fit side finisher to luggage compartment and secure with clips 2 Fit luggage compartment sill trim casing Trim Trim Trim casing casing casing luggage luggage luggage compartment compartment compartment sill sill sill Refit Refit Refit 3 Close boot lid tai...

Page 714: ...Version 2 0 698 ...

Page 715: ...ove 4 Remove interior mirror Mirror Mirror Mirror Interior Interior Interior Dipping Dipping Dipping Remove Remove Remove 5 Protect external bodywork and internal trim adjacent to glass 6 Cover trim and bodywork 7 Make hole in sealer and assemble cutting knife 8 Cut out glass and remove 9 Remove sealer from body and original screen if refitting Refit 1 Clean and polish windshield 2 Apply etch prim...

Page 716: ...y etch primer around backlight aperture 4 Apply etch primer around backlight body frame 5 Apply sealer to glass 6 With assistance lift backlight into place and align in aperture Lightly press glass to sealer 7 For the polyurethane glue to solidify completely it will take at least 24 hours 8 Remove the tapes and clean the body and rear backlight of residual polyurethane glue 9 Perform a water test ...

Page 717: ...Bumpers Fascias and Grille Exterior Fitting Bumpers Fascias and Grille Specifications Torque Description Value Bolt bumper cover to body 7 10Nm Version 2 0 701 ...

Page 718: ...per and remove 4 screws securing fog lamp to bumper 11 Remove 6 screws and remove the high bracket 12 Release 15 clips and remove bumper grille 13 Release 14 clips and remove lower grille 14 Release 2 clips and remove the bezel of front fog lamps Refit 1 Fit each bezel of fog lamps high and lower grille and secure clips 2 Fit fog lamps and secure with screws 3 With assistance position bumper to ve...

Page 719: ...n each side of bumper to release bumper from side mountings 7 Remove both reflectors to bumper Refit 1 Fit and secure reflectors to bumper 2 With assistance position bumper to vehicle 3 Slide bumper into position and engage each side of bumper in side mountings 4 Secure bumper to body with 6 screws 5 Fit both tail lamps Tail Tail Tail Lamps Refit Lamps Refit Lamps Refit 6 Secure bumper to body wit...

Page 720: ...h assistance remove rear bumper 9 Remove reflectors to bumper 10 Release 2 clips and remove each parking distance control sensor from its holder Refit 1 Fit and secure reflectors to bumper 2 With assistance position bumper to vehicle 3 Connect 4 multiplugs from parking distance control sensors 4 Slide bumper into position and engage each side of bumper in side mountings 5 Secure bumper to body wit...

Page 721: ... and secure with screws 2 Lower the vehicle Liner Rear Wheel Arch Each Remove 1 Raise the vehicle on a lift 2 Remove road wheel Wheel Wheel Wheel Remove Remove Remove 3 Remove 3 screws and 4 nuts securing wheel arch liner to wheel arch 4 Release and remove wheel arch liner Refit 1 Fit wheel arch liner to wheel arch 2 Secure wheel arch liner with screws 3 Fit road wheel Wheel Wheel Wheel Refit Refi...

Page 722: ...ase washer tube from 3 clips and grommet and remove tube 8 Mark fitted position of plenum drain hoses 9 Release 2 clips and remove 2 drain hoses from plenum Refit 1 Fit and align plenum drain hoses and secure with clips 2 Fit washer tube to clips and secure grommet 3 Fit and connect washer jets 4 Fit plenum to body ensure drain hoses align with body drain holes 5 Align plenum to windscreen surroun...

Page 723: ... cable grommets and pull multiplugs through wheel arch liner 8 Disconnect pad wear RH only andABSsensor multiplugs 9 Remove 7 screws and 2 spit pins securing wheel arch liner to body 10 Release and remove wheel arch liner from inner wing Refit 1 Fit wheel arch liner to inner wing and secure with screws 2 Feed pad wear RH only andABSsensor multiplugs through wheel arch liner and secure grommets to ...

Page 724: ...Exterior Fitting Mirrors Mirrors Specifications Torque Description Value Screw mirror 4 6Nm Version 2 0 708 ...

Page 725: ...Mirrors Exterior Fitting Description and Operation System Component Layout Mirrors Component Location 1 LH mirror assembly 2 RH mirror assembly 3 Driver s Door Switch Pack DDSP Version 2 0 709 ...

Page 726: ...rs System Control Diagram Interior Rear View Mirror Control Diagram A Hard wired 1 Neutral Switch Auto Models only Reverse selected 2 Interior rear view window anti dazzle with Rain Sensor 3 Fuse 44 5A in BCM Version 2 0 710 ...

Page 727: ...mum rear view vision while the vehicle is reversing When the reverse switch is activated a digital signal is transmitted to the mirror via the BCM The power supply for the mirror is supplied via fuse 44 in the BCM fusebox Light Sensors Two light sensors are positioned on the mirror facing forwards and rearwards Light levels are recorded and if the rearward sensor detects significantly higher light...

Page 728: ...Exterior Fitting Mirrors Operation General When the engine starts the electric rear view mirror automatic dazzle prevention function will become active and operate totally automatically Version 2 0 712 ...

Page 729: ...Mirrors Exterior Fitting System Component Layout Exterior Mirrors Component Layout 1 LH mirror assembly 2 RH mirror assembly 3 Driver s Door Switch Pack DDSP Version 2 0 713 ...

Page 730: ...rior Mirrors Control Diagram A Hard wired B LIN Bus 1 DDSP 2 Exterior mirror motor power supply Fuse 45 10A in BCM 3 Exterior mirror heater power supply Fuse 5 10A in BCM 4 Left hand door mirror assembly 5 Right hand door mirror assembly Version 2 0 714 ...

Page 731: ...ate and mirror glass The door mirrors assembly is secured to the door with three bolts and an orientation pin The three bolts are accessible by removing the front door frame finisher The mirror head and bracket are nonserviceable and must be replaced as a complete assembly Only the mirror glass is available as serviceable items Exterior Mirror Heaters The mirror glass is heated to prevent misting ...

Page 732: ...witches each have a red LED which illuminates to show which mirror is selected and active The DDSP has a Printed Circuit Board PCB which houses all the electronic components for mirror and window operation LEDs on the PCB provide for the switch illumination The light emitted from each LED is passed through a lens integral with the mat and transferred to the switch via a plastic optical lens Power ...

Page 733: ... is pressed the applicable contacts on the rubber membrane mat complete a circuit on the PCB The adjustment switch is designed so that only one motor can operate any one time A power supply via fuse 45 in the BCM when the handset is docked passes through the switch contacts in the DDSP The DDSP directs the power supply to the applicable motor The motor will operate for as long as the switch is ope...

Page 734: ...mirror Refit 1 Position exterior mirror to door fit and tighten 3 bolts to4 6Nm 2 Connect multiplug and fit plastic sheet 3 Fit cheater panel and secure clips 4 Fit front door trim casing Trim Trim Trim casing casing casing front front front door Refit door Refit door Refit Mirror Interior Dipping Remove 1 Release 4 clips and remove the cover of the mirror if fitted 2 Gently tap or push the mirror...

Page 735: ...Roof Exterior Fitting Roof Specifications Torque Description Value Screw sunshade assembly 5Nm Version 2 0 719 ...

Page 736: ... Layout Sunroof Assembly 1 Glass panel assembly 2 Drip rail 3 End cap 4 Rear frame 5 Guide rail 6 Slide tilt mechanism assembly 7 Trim lace 8 Sunroof Electronic Control Unit ECU and motor 9 Front frame 10 Wind deflector assembly 11 Sunshade assembly Version 2 0 720 ...

Page 737: ...Roof Exterior Fitting System Control System Sunroof Control Diagram A Hard wired 1 Fuse 43 20A in BCM 2 Motor and sunroof Electronic Control Unit ECU 3 Rotary switch Version 2 0 721 ...

Page 738: ...ium alloy Frame B is made from black E coated steel It is connected to the guide rail The end cap is constructed of PVC water drain tubes are included It is connected to the guide rail by ultrasonic welding The trim lace is made from PVC and connected to frame A guide rail and frame B Plastic blades with over moulded leaf springs are installed in the guide rail The height of the tilt up position i...

Page 739: ...e open operation This moves the glass panel to the fully open position in one movement A momentary counter clockwise rotation of the switch while the panel is moving will cause the panel to stop immediately Initialisation If the glass panel has been operated manually or has been replaced its initial position must be restored using the following procedure 1 Rotate and hold the switch clockwise the ...

Page 740: ... tighten bolts 3 Connect drain pipes to sunroof assembly and secure with clips 4 Fit headlining Headlining Headlining Headlining sunshine sliding sunshine sliding sunshine sliding roof Refit roof Refit roof Refit 5 Connect battery earth lead 6 Initialization Glass Panel Sun Sliding Roof Remove 1 Open sunroof blind 2 Remove 4 screws securing glass to sunroof frame 3 Remove glass Refit 1 Fit glass b...

Page 741: ...ews securing sunshade to LH and RH sunshade guides to rails 5 Slide sunshade rearwards to collect and remove LH and RH guides from sunroof guide rails 6 Slide sunshade forwards lift and remove sunshade Refit 1 Position sunshade to sunroof assembly install sunshade guides fit screws and tighten to5Nm 2 Fit rear sunshade bar to sunroof rail fit screws and tighten to5Nm 3 Operate sunshade to check al...

Page 742: ...Exterior Fitting Wipers and Washer Wipers and Washer Specifications Torque Description Value Nut Wiper Arm to Spindle 30Nm Screw Linkage Wiper 7 10Nm Version 2 0 726 ...

Page 743: ...scription and Operation System Component Layout Wiper Components 1 Wiper arm assembly passenger 2 Wiper blade passenger 3 Wiper blade driver 4 Wiper arm assembly driver 5 Wiper arm cap 6 Wiper motor 7 Wiper linkage assembly Version 2 0 727 ...

Page 744: ...er Washer Components 1 Front windscreen washer jet 2 T piece 2 way connector 3 T piece 3 way connector 4 Washer reservoir filler assembly 5 Washer reservoir 6 Windscreen washer pump 7 Washer tube 8 Non Return Valve NRV Version 2 0 728 ...

Page 745: ...hers Control Diagram A Hardwired B LIN Bus C HS CAN bus 1 Rain sensor if fitted 2 Wiper motor 3 Wiper column switch 4 Ambient air temperature sensor 5 Washer pump 6 Ignition switch 7 ABS DSC control module 8 Master Light Switch MLS 9 Body Control Module BCM Version 2 0 729 ...

Page 746: ...plete a slow speed wipe operation If the switch remains pressed the wipers operate at the fast wipe speed When the switch is released the wiper will complete a slow speed wipe operation until the motor reaches the park position Slow Speed Wipe When the slow speed position of the switch is selected the wipers will operate continuously at slow speed Fast Speed Wipe When the switch is operated to the...

Page 747: ...heel box attachment and the arm itself A spring is connected to each side of the pivot point and applies pressure to keep the wiper blade on the windscreen The boneless wiper blades are attached to the wiper arms with clips that allow the blade to pivot This design ensures increased screen cleaning efficiency at all driving speeds whilst reducing noise and wind resistance Windscreen Washers The wi...

Page 748: ...nected directly to the motor by passing the resistor used for slow speed operation The allows the motor to receive full battery voltage and to operate at fast speed Intermittent Operation The intermittent rotary switch completes an earth path through the switch from the BCM Each switch position has a different resistance and the resistance is measured by the BCM The BCM uses the readings to determ...

Page 749: ...iper column lever switch must be selected in the intermittent position A connection to the wiper motor park switch is monitored by the rain sensor logic to inform the rain sensor when the park switch is open or closed circuit and the wiper motor is operating or in the park position Intermittent wiper operation is controlled by the rain sensor via LIN Bus signals to the BCM The information provided...

Page 750: ...e the sensor will maintain the continuous operation to avoid switching back to intermittent from a continuous wipe and back again The rain sensor receives vehicle speed information from the ABS ECU via the BCM every two seconds The sensor increases the sensitivity as the speed increases to optimise the wiper operation When the vehicle speed is reduced to less than 8 km h the sensitivity is automat...

Page 751: ...ing cover 4 Close 4 Close bonnet Motor and Linkage Wiper Remove 1 Disconnect battery earth lead 2 Remove wiper arm 3 Remove air intake plenum Plenum Plenum Plenum air air air intake intake intake 4 Remove bolts securing motor and linkage to body 5 Disconnect multiplug from windscreen wiper motor and remove motor and linkage Refit 1 Connect multiplug to windscreen wiper motor 2 Fit motor and linkag...

Page 752: ...o catch any spillage 4 Release filler neck from clip on body and remove filler neck from reservoir 5 Remove 3 bolts securing washer reservoir to body 6 Disconnect windscreen washer pump multiplug and remove washer reservoir 7 Release hose from washer reservoir and disconnect hose from washer pump Refit 1 Position washer reservoir to body and secure with bolts 2 Position washer hose to washer reser...

Page 753: ...servoir Reservoir Reservoir washer washer washer 4 Connect battery earth lead Sensor Rain Remove 1 Disconnect battery earth lead 2 Release clips securing interior mirror cover to interior mirror and remove cover 3 Disconnect multiplug from rain sensor 4 Carefully release clips securing rain sensor to windscreen and remove rain sensor Refit 1 Fit rain sensor to windscreen and secure with clips 2 Co...

Page 754: ...Version 2 0 738 ...

Page 755: ...ayout Interior Lighting Component Location 1 Body Control Module BCM 2 Vanity mirrors lamp if fitted 3 a Front reading lamp b Front reading lamp with sunroof switch 4 Glovebox lamp switch 5 Boot lamp 6 a Rear reading lamp b Rear reading light with individual lights Version 2 0 739 ...

Page 756: ...N Bus 1 Diagnostic socket 2 Front reading lamp 3 Rear reading lamp 4 Boot lamp 5 Vanity mirror lamp 6 Glovebox lamp switch 7 RH front door open switch 8 LH front door open switch 9 RH rear door open switch 10 LH rear door open switch 11 Boot open switch 12 Interior lamp fuse 38 13 BCM Version 2 0 740 ...

Page 757: ...r screen The assembly secured to the headlining with tabs and can be removed from the headlining by carefully prising the lamp assembly from the metal ring The assembly is connected to the roof harness with a 3 pin connector Low or 4 pin connector High Boot Lamp The boot loadspace lamp is located in the panel in the load space under the parcel shelf The lamp comprises a plastic moulding which inco...

Page 758: ...nditions The fascia lamps use Pulse Width Modulation PWM enabling them to fade on and off as follows Fades on when the handset is docked or the ignition on and the headlamps or side lamps are illuminated Fades off when the side lamps are switched off Fades off when the ignition handset is removed Bulb Size Lamp Type Voltage Glovebox lamp T5 12V 1 2W Front reading lamp W5W 12V 5W Rear reading lamp ...

Page 759: ...ting an earth path to the BCM When the door is closed the earth path is removed and the connection becomes open circuit The interior lamps have two modes of operation manual operation using the momentary switch on the front interior lamp or automatic operation controlled by the BCM Manual Operation The master switch on the front interior lamp assembly can be used to switch all the front and rear i...

Page 760: ...l Confirmation is indicated by the interior lamps giving a short flash on and then off A further 5 second press of the switch will enable the automatic control of the interior lamps Confirmation is indicated by the interior lamps giving a short flash off on and then off again Inertia Switch Operation If the inertia switch is tripped and the alarm system is not armed the BCM will switch all interio...

Page 761: ...S into position in fascia ensuring clips are fully engaged 2 Close storage box 3 Connect battery earth lead Lamp Assembly CHMSL Remove 1 Disconnect battery earth lead 2 Remove 2 screws securing cover to CHMSL and remove cover 3 Disconnect multiplug from CHMSL 4 Remove 2 nuts securing CHMSL to rear window and remove Refit 1 Fit CHMSL to rear window and secure with nuts 2 Connect multiplug to CHMSL ...

Page 762: ...ct battery earth lead Lamp Assembly Interior Courtesy Front Remove 1 Disconnect battery earth lead 2 Remove interior lamp lens 3 Release 3 clips securing interior lamp bulb cover to interior lamp and remove cover 4 Remove 2 screws securing interior lamp to body 5 Disconnect multiplug from interior lamp and remove lamp assembly Refit 1 Connect lamp assembly multiplug locate 2 lugs into top trim the...

Page 763: ...ard warning switch 6 Body Control Module BCM 7 Centre High Mounted Stop Lamp CHMSL 8 Number plate lamp 9 Rear fog lamp 10 Bumper mounted reflector 11 Rear direction indicator 12 Brake lamp 13 Tail lamp 14 Reverse lamp 15 Direction indicator and dipped main beam column lever switch 16 Master light switch MLS 17 Fascia illumination thumbwheel 18 Side repeater Version 2 0 747 ...

Page 764: ...s 1 Dipped headlamps 2 Main headlamps 3 Engine compartment fusebox 4 Number plate lamps 5 CHMSL 6 Rear indicator lamp 7 Front fog lamp 8 Side repeater lamps 9 Rear fog lamps 10 Brake and tail lamps 11 Instrument pack 12 MLS 13 Direction indicator and dip main headlamp lever 14 Brake switch 15 BCM Version 2 0 748 ...

Page 765: ... applique on the boot lid Direction Indicators The front direction indicators are located within the central section of the headlamp assembly and the rear indicators are located in the upper section of the tail lamp assembly Both the front and rear indicator lenses are translucent and the orange indicator colour is provided by an orange coloured single filament bulb The side direction indicators a...

Page 766: ... rear fog lamps are located in the boot lid Each rear fog lamp bulb is located in the bulb holder behind the boot lamp lens assembly Each rear fog lamp has a single filament bayonet type bulb which locates in the holder The bulb protrudes through an aperture in the lamp assembly to illuminate the rear fog lamp lens section Reverse Lamps Each reverse lamp bulb is located in the bulb holder in the i...

Page 767: ...e MLS still has the higher priority in controlling the headlamps The auto lamp feature is a driver assistance system and has to be seen as a comfort feature rather than to be relied on by the driver The lamp sensitive components of the sensor are integrated into the housing of the rain sensor The sensor receives the following inputs Ambient brightness around the vehicle looking upward Angular brig...

Page 768: ...s docked or the ignition is on then the side lamps will be remain illuminated A parking lamp feature allows the driver to leave the vehicle with either the LH or RH side and tail lamps illuminated This is selected by moving the direction indicator lever to the LH or RH position as required when the handset is removed In this condition instrument pack illumination will remain off The feature is dea...

Page 769: ...warning lights will operate immediately Hazard warning light operation will continue until the hazard warning light switch is operated for a minimum of 5 seconds This is to prevent the switch being pressed due to impact during the crash The hazard warning lights will not be stopped when the inertia switch is reset but only when the hazard switch is pressed Direction Indicator and Dipped Main Beam ...

Page 770: ...n on when the time period has expired Circuit Protection Individual lighting circuits are protected by transistors within the BCM which contain Field Effect Transistors FET in place of conventional fuses The FETs respond to heat generated by increased current flow caused by short circuits and when applicable cut the supply to the affected feature Once the fault has been rectified or the FET has co...

Page 771: ...unctionality will also be maintained but the following exterior lighting features controlled by the BCM will be inhibited Direction indicator lamps Hazard warning lights Headlamp flash and main beam Front fog lamps Rear fog lamp s Version 2 0 755 ...

Page 772: ...f side repeater lamp and press the rear edge to secure clip Bulb Reverse Lamp Saloon Remove 1 Release boot lid latch 2 Remove boot seal 3 Remove luggage compartment sill trim casing 4 Release luggage compartment trim 5 Twist reverse lamp bulb holder anticlockwise and release from lamp unit 6 Remove reverse lamp bulb from bulb holder and discard Refit 1 Fit new stop tail lamp bulb into holder and r...

Page 773: ...b from holder Refit 1 Fit number plate lamp bulb into holder and refit holder into lamp assembly 2 Fit boot lid trim casing 3 Close boot lid Bulb Rear Fog Lamp Remove 1 Release boot lid latch 2 Remove boot lid trim casing panel 3 Twist rear fog lamp bulb holder anticlockwise and release from lamp unit 4 Remove rear fog lamp bulb from holder and discard Refit 1 Fit new rear fog lamp bulb into holde...

Page 774: ...eal 5 Close boot lid Bulb Dip Beam Remove 1 Disconnect battery earth lead 2 Remove engine compartment fuse box LH headlamp bulb only Engine Engine Engine compartment compartment compartment fuse fuse fuse box Remove box Remove box Remove 3 Remove dust cover from headlamp 4 Disconnect multiplug from bulb 5 Release clip securing bulb to headlamp and remove bulb Refit 1 Fit bulb to headlamp and secur...

Page 775: ...t dust cover to fog lamp 4 Fit front bumper Bumper Bumper Bumper assembly assembly assembly front Refit front Refit front Refit Lamp Assembly Front Fog Remove 1 Remove front bumper Bumper Bumper Bumper assembly assembly assembly front Remove front Remove front Remove 2 Remove 4 screws securing front fog lamp to front bumper 3 Remove front fog lamp from bumper Refit 1 Fit front fog lamp to front bu...

Page 776: ...igh beam 4 Turn outer adjuster as necessary to correct vertical beam setting high beam Headlamp Assembly Remove 1 Disconnect battery earth lead 2 Remove front bumper Bumper Bumper Bumper Assembly Assembly Assembly Front Remove Front Remove Front Remove 3 Remove 4 bolts securing headlamp to body 4 Disconnect multiplug from headlamp assembly 5 Remove headlamp assembly Refit 1 Position headlamp assem...

Page 777: ...om holder Refit 1 Fit bulb to bulb holder 2 Fit bulb holder to headlamp assembly 3 Connect battery earth lead Bulb Side Lamp Remove 1 Remove dust cover from headlamp 2 Remove side lamp bulb holder from headlamp 3 Remove bulb from side lamp bulb holder Refit 1 Fit bulb into side lamp bulb holder 2 Fit side lamp bulb holder to headlamp assembly 3 Fit dust cover to headlamp Version 2 0 761 ...

Page 778: ...tiplug to tail lamp 2 Fit tail lamp to body and secure with nuts 3 Secure luggage compartment trim 4 Fit luggage compartment sill trim casing 5 Fit boot seal 6 Close boot lid 7 Connect battery earth lead Bulb Main Beam Remove 1 Disconnect battery earth lead 2 Remove dust cover from headlamp 3 Disconnect multiplug from bulb 4 Release clip securing bulb to headlamp and remove bulb Refit 1 Fit bulb t...

Page 779: ...inge to door 30 36Nm Cap nut shaft upper hinge 18 22Nm Bolt door hinge to body 30 36Nm Screw exterior handle backplate to door 2 2 5Nm Bolt door lock 8 12Nm Bolt window regulator guide rail to door 6 5 7 5Nm Screw door striker 20 30Nm Bolt glass holder 6 5 7 5Nm Version 2 0 763 ...

Page 780: ... Driver s Door Switch Pack DDSP 2 Body Control Module BCM and fusebox 3 RH front window motor 4 Passenger front window switch 5 RH rear window switch 6 RH rear window motor 7 Remote handset 8 LH rear window motor 9 LH rear window switch 10 LH front door lock switch 11 LH front window motor Version 2 0 764 ...

Page 781: ...s Door Switch Pack DDSP 2 Passenger front window switch 3 RH rear window switch 4 LH rear window switch 5 Master Locking Switch 6 Remote handset 7 Diagnostic socket 8 LH front window motor 9 LH rear window motor 10 RH rear window motor 11 RH front window motor 12 Body Control Module BCM Version 2 0 765 DLDLSRXYLFXRFPHY ...

Page 782: ...m has a lift press type switch to control the window for that door DDSP has four switches to allow the driver to control operation of each window It also contains an isolation switch to prevent operation of the rear window from the door mounted switches DDSP also controls exterior mirror operation The electric windows will operate when the handset is docked or ignition on or for 30 seconds after t...

Page 783: ... hold the glass in position in the carrier Each friction pad is clamped in the carrier with a bolt which applies pressure to the pad and positively retains the glass in the carrier The window is raised and lowered by an upper cable a mid cable and a lower cable The upper cable is a sheathed Bowden type cable with one end attached to the carrier in the rear runner The cable is routed up the runner ...

Page 784: ...s pulled in the required direction by the cables and slides in the runner to raise or lower the glass A worm drive reduction gearbox between the motor output shaft and the drum reduces the effort required by the motor to raise or lower the window Version 2 0 768 ...

Page 785: ...ed in the track of the runner Two friction pads hold the glass in position in the carrier Each friction pad is clamped in the carrier with a bolt which applies pressure to the pad and positively retains the glass in the carrier The window is raised and lowered by two cables an upper cable and a lower cable The upper cable is unsheathed with one end attached to the carrier The cable is routed up th...

Page 786: ...ntrolled unit which is connected to theBCM via the LIN 1 Bus DDSPAll switch operations are converted to digital signals by Field Effect Transistors FET within LINand transmitted to theBCM BCMin a data stream via the LIN Bus The BCM converts the received digital signals into the requested window operation DDSPhas a Printed Circuit Board PCB which houses all the electronic components PCB on theLED p...

Page 787: ...w switches are located in the door trim panels Each door switch has electronic components mounted on a PCB and a connector An LED LEDon the PCB provides the switch illumination The light emitted from the LED is passed through a plastic optical lens A six pin connector provides the window operation connections to theBCM and switch LED LEDillumination Version 2 0 771 ...

Page 788: ...mal Protection BCMThe maximum default continuous motor operation is limited to 7 seconds Window motor There are two types anti trap and normal Anti trap motors thermal protection is triggered by operation time After continuous operation for 30 100 seconds the thermal protection starts Normal motors If the motor locks for about 30 seconds the motor will start thermal selfprotection Lazy Lock Unlock...

Page 789: ...ase lever 2 Fit door handle to front tags and rotate to locate into rear door aperture Caution Ensure door handle gaskets are fitted correctly 3 Fit private lock Private Private Private Lock Lock Lock Front Front Front Door Door Door Refit Refit Refit Door Assembly Front Remove 1 Disconnect battery earth lead 2 Open door 3 Release harness sleeve and disconnect multiplug from A post 4 Remove upper ...

Page 790: ...battery earth lead 7 Check door alignment Hinge Front Door Upper Remove 1 Remove front door Door Door Door Assembly Assembly Assembly Front Front Front Remove Remove Remove 2 Remove bolt securing upper hinge from outside of A post 3 Remove A post lower trim Trim Trim Trim Finisher Finisher Finisher A A A Post Post Post Lower Lower Lower Remove Remove Remove 4 Remove bolt securing upper hinge from ...

Page 791: ...ont Front Refit Refit Refit 4 Align door on hinges Door Door Door Front Front Front Align Align Align on on on Hinges Hinges Hinges Refit Refit Refit 5 Fit A post lower trim Trim Trim Trim Finisher Finisher Finisher A A A Post Post Post Lower Lower Lower Refit Refit Refit Door Front Align on Hinges Adjust 1 Open door 2 Place wooden block on jack and position jack to support door lower edge 3 Loose...

Page 792: ...1 Ensure window glass is fully closed 2 Remove front door plastic sheet Plastic Plastic Plastic Sheet Sheet Sheet Front Front Front Door Door Door Remove Remove Remove 3 Loosen top bolt and remove bottom bolt securing rear regulator guide to door 4 Lift regulator rear guide up and forward to release from door mounting and lay in bottom of door 5 Release clip and disconnect exterior handle control ...

Page 793: ...erior door handle 7 Position rear regulator guide to door fit bolts and tighten to 6 5 7 5Nm 8 Check latch for correct operation 9 Fit front door plastic sheet Plastic Plastic Plastic Sheet Sheet Sheet Front Front Front Door Door Door Refit Refit Refit Door Front Adjust on Striker Adjust 1 Open door 2 Loosen 2 striker screws and align striker to door latch tighten screws 3 Close door checking ease...

Page 794: ... loop round door inner release lever pull outwards to engage behind outside handle release lever 2 Fit door handle to front tags and rotate to locate into rear door aperture Caution Ensure door handle gaskets are fitted correctly 3 Position and fit outside capping to door handle assembly tighten screw to 2 2 5Nm 4 Refit grommet and ensure seal properly Door Assembly Rear Remove 1 Disconnect batter...

Page 795: ...door Door Door Door Assembly Assembly Assembly Rear Rear Rear Remove Remove Remove 2 Mark position of hinge and remove bolt securing hinge from outside of BC post 3 Remove BC post lower trim Trim Trim Trim Finisher Finisher Finisher BC BC BC Post Post Post Lower Lower Lower Remove Remove Remove 4 Remove bolt securing upper hinge from inside of BC post and remove hinge Refit 1 Position upper hinge ...

Page 796: ...Assembly Rrear Rrear Rrear Refit Refit Refit 4 Align door on hinges Door Door Door Rear Rear Rear Align Align Align on on on Hinges Hinges Hinges Refit Refit Refit 5 Fit BC post lower trim Trim Trim Trim Finisher Finisher Finisher BC BC BC Post Post Post Lower Lower Lower Refit Refit Refit Door Rear Align on Hinges Adjust 1 Open door 2 Place wooden block on jack and position jack to support door l...

Page 797: ...t and tighten screws to 8 12Nm 4 Position exterior handle clip at bottom of travel and ensure exterior handle is in the closed position Taking care not to move exterior handle control rod up or down secure control rod in clip 5 Fit plastic sheet Plastic Plastic Plastic Sheet Sheet Sheet Rear Rear Rear Door Door Door Refit Refit Refit Door Rear Adjust on Striker Adjust 1 Open door 2 Loosen 2 strike...

Page 798: ...3 screws securing quarter light division bar to door 7 Remove glass channel seal from quarter light division bar 8 Remove quarter light division bar Refit 1 Position quarter light division bar to door and secure with screws 2 Fit glass channel seal to quarter light division bar 3 Fit finisher to quarter light division bar 4 Fit outer waist seal to door Seal Seal Seal Waist Waist Waist Outer Outer ...

Page 799: ...to door 2 Position rear door pillar finisher to door and secure with screws 3 Fit seal to glass channel 4 Fit rear door glass Glass Glass Glass Rear Rear Rear Door Door Door Each Each Each Refit Refit Refit Seal Waist Inner Rear Door Each Remove 1 Remove rear door trim casing Trim Trim Trim Casing Casing Casing Rear Rear Rear Door Door Door Remove Remove Remove 2 Bend out 7 tags securing inner wai...

Page 800: ...nit Rear Door Adjust Adjust 1 Remove rear door plastic sheet Plastic Plastic Plastic Sheet Sheet Sheet Rear Rear Rear Door Door Door Remove Remove Remove 2 Release 2 clips and remove window switch from door casing 3 Connect window switch to door harness multiplug 4 Lower glass and loosen cassette fixed bolt 5 Loosen cassette adjustment bolts 6 Raise glass ensure glass is evenly aligned to guides 7...

Page 801: ...r Each Remove 1 Remove rear door trim casing Trim Trim Trim Casing Casing Casing Rear Rear Rear Door Door Door Remove Remove Remove 2 Remove rear door outer waist seal Seal Seal Seal Waist Waist Waist Outer Outer Outer Rear Rear Rear Door Door Door Remove Remove Remove 3 Release 2 clips and remove window switch from door trim casing 4 Connect switch to door harness multiplug 5 Raise door glass to ...

Page 802: ...just Adjust Adjust 7 Fit rear door outer waist seal Seal Seal Seal Waist Waist Waist Outer Outer Outer Rear Rear Rear Door Door Door Refit Refit Refit 8 Disconnect door switch multiplug 9 Fit switch to door casing 10 Fit rear door trim casing Trim Trim Trim Casing Casing Casing Rear Rear Rear Door Door Door Refit Refit Refit Switch Electric Window Lift Rear Door Each Remove 1 Disconnect battery ea...

Page 803: ...securing regulator to door 6 Disconnect multiplug from door glass motor 7 Manoeuvre and remove regulator unit through door aperture Refit 1 Position and fit regulator in door 2 Connect multiplug to door glass motor 3 Align and fit bolt securing regulator assembly to door and tighten to 6 5 7 5Nm 4 Fit glass to regulator glass clamps tighten bolts to 6 5 7 5Nm 5 Remove adhesive tape securing door g...

Page 804: ...e with screws 2 Fit rear door trim casing Trim Trim Trim casing casing casing rear rear rear door door door refit refit refit Trim Casing Front Door Remove 1 Disconnect battery earth lead 2 Remove access cover from interior handle and remove screw securing handle to door 3 Release clips securing grab handle trim to trim casing remove cover and 2 screws securing grab handle to door 4 Carefully rele...

Page 805: ...ccess cover from interior handle and remove screw securing handle to door 3 Release 2 clips securing grab handle trim to trim casing remove cover and 2 screws securing grab handle to door 4 Carefully release 8 clips securing trim casing to door 5 Lift trim casing and release from door 6 Disconnect multiplug from tweeter 7 Disconnect multiplug from window switch pack 8 Release lock operating cable ...

Page 806: ...rth lead Rubber Felt Glass Channel Front Door Each Remove 1 Ensure window is fully down 2 Remove front door trim casing Trim Trim Trim Casing Casing Casing Front Front Front Door Door Door Remove Remove Remove 3 Remove exterior door mirror Mirror Mirror Mirror Exterior Exterior Exterior Electric Electric Electric Remove Remove Remove 4 Remove outer waist seal Seal Seal Seal Waist Waist Waist Outer...

Page 807: ...rior Electric Electric Electric Refit Refit Refit 6 Fit front door trim casing Trim Trim Trim casing casing casing Front Front Front Door Door Door Refit Refit Refit Seal Waist Inner Front Door Each Remove 1 Remove front door trim casing Trim Trim Trim Casing Casing Casing Front Front Front Door Door Door Remove Remove Remove 2 Bend out 7 tags securing inner waist seal to door casing and remove se...

Page 808: ... 2 Fit exterior door mirror Mirror Mirror Mirror Exterior Exterior Exterior Electric Electric Electric Refit Refit Refit Glass Glass Cassette Unit Front Door Adjust Adjust 1 Remove front door plastic sheet Plastic Plastic Plastic Sheet Sheet Sheet Front Front Front Door Door Door Remove Remove Remove 2 Connect window switch multiplug 3 Lower glass and loosen glass clamp bolts 4 Loosen bolts securi...

Page 809: ...Channel Channel Channel Front Front Front Door Door Door Remove Remove Remove 2 Raise glass to regulator glass clamp access holes in door 3 Mark fitted position of glass 4 Loosen 2 bolts securing glass to regulator glass clamps 5 Manoeuvre glass and remove from door Refit 1 Position glass to door 2 Align door glass 3 Tighten regulator glass clamp bolts Refer to Torque table 4 Fit door seal Rubber ...

Page 810: ...uvre rearwards from mounting holes to access multiplug 7 Disconnect multiplug from door glass motor 8 Manoeuvre and remove regulator unit through door aperture Refit 1 Position and fit regulator assembly in door 2 Connect multiplug to door glass motor 3 Align front slide to glass and bolts into door mounting holes 4 Align rear slide to glass and bolts into door mounting holes 5 Fit bolts securing ...

Page 811: ...cover to trim casing and remove cover 4 Remove 2 screws securing grab handle to door 5 Remove rear screw securing trim casing to door 6 Carefully release 8 clips securing trim casing to door 7 Lift door trim casing and release from door 8 Disconnect multiplug from tweeter 9 Disconnect multiplug from switch pack 10 Release lock operating cable from interior handle release hook and remove trim casin...

Page 812: ...12Nm Bolt inner fender bracket 7 10Nm Bolt bonnet locks 7 10Nm Bolt member front end panel 7 10Nm Bolt member front end panel bracket 7 10Nm Bolt hinge to bonnet assembly 20 29Nm Bolt bonnet striker to bonnet assembly 7 10Nm Bolt bonnet safety latch to bonnet locking platform 7 10Nm Version 2 0 796 ...

Page 813: ...d bolt securing fenderto inner fender bracket 6 Remove fender Refit 1 Position and align front fender 2 Fit bolts securing fenderg to body but do not tighten at this stage 3 Align fender to profiles of adjacent panels with uniform gaps Tighten bolts securing fender to body to7 12Nmand inner fender bracket to body to7 10Nm 4 Position side repeater lamp and connect multiplug 5 Fit leading edge of si...

Page 814: ...er to the panel Remove member front end panel 7 Remove radiator mounting rubbers from bonnet member front end panel Refit 1 Fit radiator mounting rubbers to member front end panel 2 Position member front end panel to body and secure cable in clips 3 Position both bonnet locks to member front end panel fit bolts and tighten to 7 10Nm 4 Fit bolts securing member front end panel to body and tighten t...

Page 815: ...sition of bonnet to set correct bonnet to wing profile 4 Tighten hinge bolts to 20 29Nm Adjust Profile at Front of Bonnet 1 Loosen striker locknut 2 Adjust striker and bonnet buffer to set correct bonnet to wing profile 3 Tighten striker locknut Adjust Gaps on Front Corners 1 Mark outline of both hinges on body 2 Loosen bolts securing hinges to body 3 Adjust lateral and fore aft position of bonnet...

Page 816: ...it 1 Fit bonnet latches to bonnet tighten the bolts to 7 10Nm 2 With assistance position bonnet to hinges Fit but do not fully tighten bolts at this stage 3 Connect gas struts to bonnet and secure with clips 4 Check alignment of bonnet against both wings and bonnet platform Bonnet Bonnet Bonnet Alignment Alignment Alignment Check Check Check and and and Adjust Adjust Adjust 5 Tighten the bolts sec...

Page 817: ...ty catch to bonnet and tighten bolts to 7 10Nm 2 Close bonnet Lock Bonnet Remove 1 Open bonnet 2 Remove 2 bolts securing bonnet lock to bonnet locking platform and remove lock 3 Release cable from bonnet lock Refit 1 Position bonnet lock and fit cable 2 Position bonnet lock to bonnet locking platform fit bolts and tighten to 7 10Nm 3 Close bonnet Version 2 0 801 ...

Page 818: ...ower Remove Remove Remove 3 Release cable at bonnet release lever 4 Release bulkhead grommet 5 Draw cable through bulkhead and remove Refit 1 Draw cable through bulkhead and locate grommet 2 Attach cable to bonnet pull lever mechanism 3 Refit lower A post trim A A A Post Post Post Trim Lower Trim Lower Trim Lower Refit Refit Refit 4 Refit bonnet locks Lock Lock Lock Bonnet Bonnet Bonnet Refit Refi...

Page 819: ...Rear Closures Body Systems Rear Closures Specifications Torque Description Value Bolt hinge to boot lid inner panel 7 12Nm Bolt latch to boot lid 7 10Nm Version 2 0 803 ...

Page 820: ... earth lead Boot Lid Remove 1 Disconnect the battery earth lead 2 Remove the boot lid liner Trim Trim Trim Finisher Finisher Finisher boot boot boot lid lid lid Remove Remove Remove 3 Remove the boot lid latch Latch Latch Latch boot boot boot lid lid lid Remove Remove Remove 4 Disconnect the multiplug on the boot latch and number plate lamp 5 Remove the harness retainer on the boot lid and take th...

Page 821: ...inge to body 6 Align boot lid as necessary 7 Secure boot lid hinge bolts 8 Connect both support struts Fore and Aft 9 Use an assistant to support boot lid 10 Disconnect both boot lid support struts 11 Loosen bolts securing boot lid hinge to boot lid 12 Align boot lid as necessary 13 Secure boot lid hinge bolts 14 Connect both support struts Note After After After each each each adjustment adjustme...

Page 822: ...sen boot lid striker bolts 6 Align boot lid as necessary ensure ease of closure 7 Tighten boot lid striker bolts 8 Unscrew each boot lid bump stop to achieve acceptable fit 9 Ensure boot lid closure is satisfactory 10 Fit luggage compartment sill trim casing Trim Trim Trim Casing Casing Casing Luggage Luggage Luggage Compartment Compartment Compartment Sill Sill Sill Refit Refit Refit Trim Casing ...

Page 823: ... to boot lid 3 Disconnect latch multiplug 4 Pass release cable through boot lid aperture and remove latch from boot lid Refit 1 Position latch to boot lid and connect multiplug 2 Pass release cable through aperture position latch to boot lid fit bolts and tighten to7 10Nm 3 Fit boot lid trim casing Trim Trim Trim Casing Casing Casing Boot Boot Boot Lid Lid Lid Refit Refit Refit Version 2 0 807 ...

Page 824: ...Body Systems Horns Horns Specifications Torque Description Value Screw HI Lo Horn to the Horn Bracket 7 10Nm Version 2 0 808 ...

Page 825: ...assembly front front front Remove Remove Remove 3 Disconnect multiplug and remove horn Refit 1 Fit horn to bracket and secure with nut and tighten to7 10Nm 2 Position horn and connect multiplug to horn 3 Fit front bumper Bumper Bumper Bumper Assembly Assembly Assembly Front Front Front Refit Refit Refit 4 Connect battery earth lead Version 2 0 809 ...

Page 826: ...Body Systems Body Control Module Body Control Module Specifications Torque Description Value Screw BCM to the Bracket 5 7Nm Version 2 0 810 ...

Page 827: ...Body Control Module Body Systems Description and Operation Body Control Module BCM Component Location 1 Body Control Module BCM 2 Diagnostic connector Version 2 0 811 ...

Page 828: ...trol Module BCM Component Location A MS_CAN BUSB HS_CAN BUSC LIN BUS 1 Instrument pack and central In car Entertainment ICEdisplay 2 Engine Control UnitECU 3 Transmission Control UnitTCU 4 Supplementary Restraint SystemSRS ECU Version 2 0 812 ...

Page 829: ...teering Wheel SwitchesSWS 9 Rain SensorRS 10 Electronic Temperature ControlETC 11 Parking Distance ControlPDC ECU 12 Main Light SwitchMLS 13 Driver s Door Switch PackDDSP 14 SEL ESC Switch 15 Electronic Steering Column LockESCL ECU 16 Automatic Temperature ControlATC 17 Entertainment and Navigation Unit 18 Body Control Module BCM Version 2 0 813 ...

Page 830: ...load status This is published on the CAN for alternator load management purposes Vehicle odometer The BCM stores the vehicle odometer reading up to a maximum of 999999 km The instrument pack displays the latest maximum reading Once stored it is not possible to amend the odometer reading Vehicle Identification Number VIN storage The VIN is stored in the BCM It is not possible to amend the VIN once ...

Page 831: ...5 Not used 15 26 Heated rear window 25 27 Start stop switch 5 28 SAS 5 29 Not used 15 30 Auxiliary component 15 31 Common lock relay passenger common lock relay rear rest lock relay passenger and rest lock relay rear 25 32 Dipped beam headlamp LH 10 33 34 35 ABS ECU TCU 10 36 Front side light RH and tail light RH 5 37 Diagnostic socket 5 38 Interior lamp Vanity mirror lamps Glovebox lamp 5 39 Driv...

Page 832: ...mer will restart for a further 1 minute if either the wiper switch is moved or the handset is removed to the AUX position The vehicle load management configuration is changed from transit mode to normal mode by the dealer using diagnostic tool Normal Mode This is the default setting and is used during normal vehicle operation after the PDI has been completed Sleep Mode The BCM remains in sleep mod...

Page 833: ... panel to fascia and remove panel 4 Disconnect BCM multiplugs 5 Remove 2 bolts securing BCM to BCM bracket release from upper lugs and remove BCM Refit 1 Fit BCM to upper lugs on BCM bracket and secure with bolts and tighten to5 7Nm 2 Connect multiplugs to BCM 3 Fit glovebox Glove Glove Glove box box box assembly assembly assembly Refit Refit Refit 4 Fit closing panel to fascia and secure with cli...

Page 834: ...Version 2 0 818 ...

Page 835: ...an imaginary vertical plane which measures distances along the length of the vehicle The start point for this plane is through the centre of the front wheels The Y plane is an imaginary plane through the centre of the vehicle and measures distances across the vehicle As a rule body dimensions are symmetrical about the centre line The Z plane is an imaginary horizontal plane which measures distance...

Page 836: ...subframe mounting hole 53 452 90 C Front subframe mounting hole 367 455 122 D Front jacking bracket hole 468 733 139 E Rear subframe mounting hole 2093 616 17 F Rear jacking bracket hole 2013 733 139 G Rear subframe mounting hole 2425 541 30 H Rear damper mounting hole 2623 523 88 J Rear tooling hole 3270 513 97 Version 2 0 820 ...

Page 837: ...3 770 574 D Bonnet hinges mounting hole 275 713 588 E Front damper mounting hole 20 614 518 F Front damper mounting hole 80 635 526 G Front bumper bracket assembly mounting hole 590 478 301 H Front bumper bracket assembly mounting hole 590 478 91 I Front bumper bracket assembly mounting hole 590 478 301 J Front bumper bracket assembly mounting hole 590 478 91 Version 2 0 821 ...

Page 838: ...Body Repair Body Dimension Side Information Item X mm Y mm Z mm A 398 788 451 B 371 791 127 C 424 788 451 D 421 790 142 E 1488 801 472 F 1454 792 162 G 1513 801 471 H 1503 792 175 Version 2 0 822 ...

Page 839: ...Body Dimension Body Repair Point to Point Dimensional Information Note All dimensions are to hole slot centres Version 2 0 823 ...

Page 840: ... hole front door B post door striker top fixing hole 1042 F1 F2 Top hinge fixing rear hole rear door D post door striker top fixing hole 910 G1 G2 Bottom hinge fixing rear hole rear door D post door striker top fixing hole 967 H Roof top break line Body side top break line 26 J Roof top break line Body side top break line 26 K Roof top break line Body side top break line 26 Version 2 0 824 ...

Page 841: ...ernal Information Item From To Length mm A1 A2 Top tooling hole behind B post Seat belt reel anchorage lower fixing 1614 B1 B2 Seat belt reel anchorage lower fixing RHS Seat belt reel anchorage lower fixing LHS 1391 Version 2 0 825 ...

Page 842: ...2 Sidemember tooling slot RHS Transmission assembly mounting hole LHS 934 D1 D2 Fender second fixing hole RHS Wing first fixing hole LHS 1545 E1 E2 Front damper mounting hole RHS Front damper mounting hole LHS 1270 F1 D2 Fender fourth fixing hole RHS Fender first fixing hole LHS 1574 G1 G2 Fender third fixing hole RHS Fender third fixing hole LHS 1541 H1 H2 Top corner on bodyside panel Forward bon...

Page 843: ... Repair Rear End Information Item From To Length mm A1 A2 Outboard hole on parcel shelf Top corner on roof panel 1039 B1 B2 Top inboard rear lamp fixing hole LHS Top inboard rear lamp fixing hole RHS 1267 Version 2 0 827 ...

Page 844: ...ounting hole 506 D1 D2 Front subframe second mounting hole Front subframe third mounting hole 983 E1 E2 Front subframe second mounting hole Front subframe third mounting hole 379 F1 F2 Front subframe first mounting hole Front subframe third mounting hole 852 G1 G2 Front jacking bracket hole Rear jacking bracket hole 2130 H1 H2 Forward tooling hole Rear tooling hole 1144 J1 J2 Rear tooling hole Rea...

Page 845: ...mension Body Repair Dimension Length mm Dimension Length mm A 1000 J 503 B 904 K 817 C 910 L 918 D 1466 M 2463 E 1466 N 2543 F 1233 O 2875 G 1083 P 3720 H 1026 Gap Information Side Information Version 2 0 829 ...

Page 846: ...nsion mm Profile mm A Front bumper to fender 0 0 0 5 0 5 0 5 B Fender to front door 4 5 0 5 0 1 0 0 C Front door to rear door 4 5 0 5 0 1 0 0 D Rear door to rear body side 4 0 0 5 0 1 0 0 E Body side rear to rear bumper 0 0 0 5 0 5 0 0 5 Version 2 0 830 ...

Page 847: ... mm Profile mm A Headlamp to bonnet 5 0 1 0 2 3 1 0 B Headlamp to fender 3 2 1 0 2 5 0 5 C Headlamp to bumper 2 5 1 0 16 2 1 5 D Grille upstand to headlamp 2 5 1 0 3 5 1 0 E Grille upper edge to bonnet 5 0 0 5 1 5 0 5 F Grille upper edge to bonnet 5 0 0 5 0 8 0 5 Version 2 0 831 ...

Page 848: ...Body side rear to rear bumper 4 5 0 5 1 0 0 0 5 C Boot lid to rear fender 3 0 0 8 0 1 0 5 D Boot lid to rear fender 3 0 0 8 0 1 0 5 E Boot lid to rear bumper 5 0 1 3 Maximum gap across lid 1 5 F rear bumper to wheel arch alignment 0 0 1 NA G Tail lamp to rear fender 2 0 0 8 1 0 0 0 5 H Rear fog lamp to boot lid 0 9 0 8 1 0 0 0 5 Version 2 0 832 ...

Page 849: ...Body Dimension Body Repair Fuel Flap Information Gap Section Gap Profile mm A 4 0 0 8 0 5 0 5 B 4 0 0 8 0 5 0 5 C 4 5 0 8 0 5 0 5 D 4 5 0 8 0 0 0 5 Version 2 0 833 ...

Page 850: ...zinc rich primer to both joint faces and spot weld while the primer is still wet or according to the manufacturer s instructions 3 MIG weld butt joints where applicable 4 Dress weld joints 5 Clean the panel with a solvent wipe 6 Treat bare metal areas using an etch phosphate process 7 Re treat the affected area using either a separate acid etch primer and two pack surfacer or an integrated etch pr...

Page 851: ...panels with scratches down to baremetal 2 Refinishing new original replacement panels 3 Refinishing painted panels that are original equipment or two component material This is a guideline only Use specific Paint Manufacturers recommendations as per the individual data sheet systems Repairs to Panels with Scratches Down to Bare Metal Degrease area or panel that requires repair Abrade the damaged a...

Page 852: ...epuires repair Abrade complete panel with dry P240 grade paper or wet P800 grade paper with abrading block For optimum performance finalise with wet P1000 grade paper by hand Clean panel with airline blower gun and degrease Apply the base coat to achieve opacity After flash off of the basecoat solvents apply Clear coat to a minimum build of 45 50 microns Refinishing Original Equipment Painted Pane...

Page 853: ...les make it advisable to follow suitable precautions prior to carrying out welding repair operations Harsh conditions of heat and vibration may be generated during these operations which could cause damage to the units In particular it is essential to follow the appropriate precautions when disconnecting or removing the airbag Diagnostic Control Unit DCU Supplementary Restraint System Precautions ...

Page 854: ...nderbody coating using a hot air gun prior to exposing spot welds 2 Cut out welds using a cobalt drill 3 Alternatively use a clamp type spot weld remover 4 Cut away the bulk of the panel as necessary using an air saw Caution On certain panel joints MIG welds and braze should be removed using a sander where possible before cutting out the panel bulk 5 Separate spot welded joints and remove panel re...

Page 855: ... and trim to size leaving approximately 50 mm overlap with existing panel Offer up new panel section align with associated panels e g new body side panel aligned with door and boot lid Clamp into position 2 Cut new and existing panels as necessary to form butt joggle or brace joint as required Remove all clamps and metal remnants 3 Prepare new panel joint edges for welding by sanding to a bright f...

Page 856: ...g and shape electrode tips using a tip trimmer Tips should be dressed so the diameter is equal to twice the thickness of the metal to be welded plus 3 0 mm Caution Use arms not exceeding 300 mm in length 2 Fit resistance spot welding arms and test equipment for satisfactory operation using test coupons Where monitoring equipment is not available verify weld strength by checking that metal around t...

Page 857: ...use MIG plug welds where excessive metal thickness or limited access make resistance spot welding impractical Make plug welds either by using holes left by the spot weld cutter or through holes punched and drilled for the purpose approximately 8mm diameter 8 Dress all welds using either a sander with 36 grit disc or a belt type sander and or wire brush When dressing welds ensure an area as small a...

Page 858: ...act As a result the seam sealer in these areas may be disturbed by subsequent straightening and repair operations Check all seams in the vicinity of the area undergoing repair for evidence of cracked seam sealer then clean out as required and apply fresh seam sealer using the following procedure Clean the affected seam and re treat any exposed metal areas with a suitable etching primer Apply appro...

Page 859: ...ollision Repair Body Repair Seam Seam Seam sealer sealer sealer underside underside underside of of of vehicle vehicle vehicle front front front end end end and and and floor floor floor Version 2 0 843 ...

Page 860: ...Body Repair Collision Repair Seam sealer underside of vehicle rear Version 2 0 844 ...

Page 861: ...Collision Repair Body Repair Seam sealer engine bay Version 2 0 845 ...

Page 862: ...Body Repair Collision Repair Seam sealer main floor Seam sealer rear floor Version 2 0 846 ...

Page 863: ...Collision Repair Body Repair Seam sealer dash upper roof area Seam sealer front and rear door Version 2 0 847 ...

Page 864: ...Body Repair Collision Repair Seam sealer bonnet and boot lid Seam sealer tonneau lower extension Version 2 0 848 ...

Page 865: ...Collision Repair Body Repair Structural adhesive rear floor assembly Structural adhesive dash and plenum panel Version 2 0 849 ...

Page 866: ...Body Repair Collision Repair Structural adhesive rear parcel shelf Structural adhesive parcel shelf Version 2 0 850 ...

Page 867: ...Collision Repair Body Repair Structural adhesive rear panel Version 2 0 851 ...

Page 868: ...Body Repair Collision Repair Structural adhesive wheel arch rear Structural adhesive sunroof and front header Version 2 0 852 ...

Page 869: ...Collision Repair Body Repair Structural adhesive sun roof centre and rear header Version 2 0 853 ...

Page 870: ...Body Repair Collision Repair Structural adhesive fixed roof front centre and rear header Version 2 0 854 ...

Page 871: ... the seals is that they marginally increase the overall stiffness of the body and its structural performance in case of a crash The seals are manufactured from a modified Polyethylene Copolymer All the seals are fitted in the body in white areas and after going through the paint baking process expand up to eight times original size Replacing seals As paint oven temperatures used in a repair worksh...

Page 872: ... Between panels bolted 7 Clinch joints type a 2 Panel edges bolted 8 Clinch joints type b 3 Between panels spot welded 9 Clinch joints type c 4 Panel edges spot welded 10 Gaps between panels type a 5 Between panels bonded 11 Gaps between panels type b 6 Panel edges bonded 12 Lap joint Version 2 0 856 ...

Page 873: ...ear bolted spot welded and bonded panel edges type a and b gaps between panels type c clinch joints 3M 08401 Drip Check Heavy type b gaps between panels type c clinch joints 3M 08531 Polyurethane Seam Sealer bolted spot welded and bonded panel edges type a and b gaps between panels type b clinch joints 3M 08684 89 94 Polyurethane Sealer Sachet bolted panel edges type b clinch joints 3M 08684 83 88...

Page 874: ... panels Teroson 9320 Terostat 1K PU Seam Sealer SE20 spot welded and bonded panel edges type a and b gaps between panels Teroson Sealer bolted spot welded and bonded panel edges type b gaps between bonded panels Wurths 8901001 6 Structural adhesives Automotive Structural Adhesive between bonded panels type a clinch joints 3M 08122 Bi epoxy spot welded and bonded panel edges type a gaps between pan...

Page 875: ... 565 63 Screen adhesives Direct glazing adhesive Rover components BHM 705 Noise insulation material Sika primer Sika 210 Sikaflex Sika 255 FC Sikabaffle swell foam Sika 277 Column foam Redashe 4330 Gap filling seam sealer Flexible foam sealer shock resistant Redashe 4320 Version 2 0 859 ...

Page 876: ...positional accuracy inside box sections Carry out all spraying on the outward stroke of the lance Withdraw the lance slowly to ensure sufficient coverage Do not withdraw the lance too quickly Ensure that the nylon tube of the lance is kept away from the edges of the access hole to eliminate abrasion and extend the life of the tube Take care to ensure that spraying ceases just before the nozzle eme...

Page 877: ...t Schutz standards Type UBE specification Air consuming 7 ft3 min 200 litres min 45 lbf in2 Weight 23 3 oz 220 grams SATA HkD1 wax filling instrument This instrument can be used to do a retreatment SATA HKD1 instrument consist of the following parts high quality forging a gun with 1L compressed feeding container extendible nylon gun tube 1100 mm steel pipe hook like stick pipe The quick fastener a...

Page 878: ...temperature does not exceed 90 C 194 F Take care not to allow the steam jet to dwell on one area and keep the nozzle at least 300 mm from panel surfaces DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs Should it be necessary to steam clean these areas apply a new coating of wax or underbody protection as soon as possible Maintenance Inspection Carry out the following...

Page 879: ...have been disturbed Where such plugs are not available use rubber grommets of equivalent size ensuring that they are embedded in sealer 5 Mask off all mounting faces from which mechanical components hoses and pipe clips have been removed Underbody sealer must be applied before such components are refitted 6 Brush sealer into all exposed seams 7 Spray the affected area with an approved service unde...

Page 880: ... Treat body areas normally covered by trim before refitting items Check that body and door drain holes are clear after the protective wax has dried Keep all equipment clean especially wax injection nozzles Areas treated with cavity wax are shown in the following figures Cavity wax treatment areas and injection holes Upper sill section All areas symmetrically opposite to those shown are also treate...

Page 881: ... wax wax treatment treatment treatment areas areas areas and and and injection injection injection holes holes holes Lower Lower Lower sill sill sill section section section All areas symmetrically opposite to those shown are also treated Version 2 0 865 ...

Page 882: ...vity Cavity wax wax wax treatment treatment treatment areas areas areas and and and injection injection injection holes holes holes Side Side Side member member member extensions extensions extensions All areas symmetrically opposite to those shown are also treated Version 2 0 866 ...

Page 883: ...les holes Front Front Front and and and rear rear rear door door door All areas symmetrically opposite to those shown are also treated Cavity wax injection into inside of both front and rear doors Complete inner panels and frame to be coated with the wax preservative Large proportion will sit in the bottom part of the door when allowed to drain Version 2 0 867 ...

Page 884: ...ater cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells Even at this point it could still be wrongly assumed that the windscreen seal was at fault Another important part of identifying a water leak is by visual examination of door aperture seals grommets and weatherstrips for damage deterioration or misalignment together with the fit of the door itself a...

Page 885: ...Collision Repair Body Repair Service Procedures Version 2 0 869 ...

Page 886: ...t bumper mounting bracket assembly RH 10 Front sidemember assembly LH 11 Sidemember rear extension assembly LH 12 Front inner sidemember assembly LH 13 Front outer tower sidemember assembly LH 14 Front bumper mounting bracket assembly LH 15 Front end headlamp mounting assembly RH 16 Front end headlamp mounting assembly LH 17 Front end headlamp lower mounting to sidemember reinforcement 18 Front en...

Page 887: ...Collision Repair Body Repair 20 Clucth pipe bracket LH Version 2 0 871 ...

Page 888: ...Body Repair Collision Repair Door Panel 1 Front door assembly 2 Rear door assembly Version 2 0 872 ...

Page 889: ...nner assembly 3 Rear panel 4 Spare wheel well 5 Left side rear longitudinal member 6 Cross member rear floor 7 Right side seat squab lower assembly 8 Seat pan 9 Left side seat squab lower assembly 10 Cross member heel board 11 Left side rear wheel arch inner assembly 12 Left side rear sill extension Version 2 0 873 ...

Page 890: ...Body Repair Collision Repair Roof Panel 1 Roof fixed 2 Header rear 3 Centre bow 4 Header front Version 2 0 874 ...

Page 891: ...Collision Repair Body Repair 1 Roof sun roof fitted 2 Header rear 3 Sun roof reinforcing panel 4 Header front Version 2 0 875 ...

Page 892: ...Body Repair Collision Repair Bodyside Panel 1 Body side front section 2 Body side centre section 3 Body side rear section Version 2 0 876 ...

Page 893: ...ssembly 2 Inner quarter assembly 3 Front outer valance assembly 4 A post reinforcement assembly 5 Body side outer 6 B C post closing panel 7 Inner sill reinforcement 8 Tonneau extension 9 Rear lamp mounting and drain channel extension Version 2 0 877 ...

Page 894: ...Body Repair Collision Repair Front Floor Panel 1 Front floor assembly 2 right side sill inner assembly 3 left side sill inner assembly Version 2 0 878 ...

Page 895: ... 4 Left side rear wheel arch sill closing extension panel 5 Right side rear wheel arch inner assembly 6 Left side rear wheel arch inner assembly 7 Right side seat squab lower assembly 8 Left side seat squab lower assembly 9 Right side rear sill extension 10 Left side rear sill extension 11 Right side front squab panel 12 Left side front squab panel 13 Front squab panel bolt Version 2 0 879 ...

Page 896: ...Version 2 0 880 ...

Page 897: ...l Module ECM 3 Bonnet lock 4 Instrument pack 5 Body Control Module BCM 6 Passenger s switch and lock 7 Master locking switch 8 Rear door switch and lock RH 9 Fuel flap actuator 10 Boot switch and lock 11 Rear door switch and lock LH 12 Handset docking station 13 Driver s door switch and lock 14 Remote handset 15 Inertia switch Version 2 0 881 ...

Page 898: ...g System Control Diagram A Hard wired B MS_CAN BUS C Radio frequency signal 1 Remote handset 2 Master locking switch 3 Bonnet switch 4 Fuel flap switch and actuator 5 Inertia switch 6 Instrument pack 7 Horn 8 Passenger door switch and lock Version 2 0 882 ...

Page 899: ...Vehicle Access Safety and Restraints 9 Driver s door switch and lock 10 Rear door switch and lock RH 11 Rear door switch and lock LH 12 Boot release 13 Body Control Module BCM Version 2 0 883 ...

Page 900: ... Access Immobilisation System Control Diagram A Hard wired B MS CAN Bus C HS CAN Bus 1 Remote handset 2 Handset docking station 3 Body Control Module BCM 4 Instrument pack 5 Starter motor 6 Engine Control ModuleECM Version 2 0 884 ...

Page 901: ... the doors as applicable Passenger and Rear Door Latches The passenger and rear door latches each comprise a door open microswitch and a lock motor Each rear door latch assembly has a child lock facility A small lever on the inside of the door activates the child lock preventing the rear door from being opened from inside the vehicle Boot Lock The boot lock comprises a boot open microswitch and a ...

Page 902: ...te handset or the vehicle s battery is disconnected resynchronisation with the BCM will occur the next time the remote handset is docked Security System The primary function of the security system is to prevent unauthorized access to the vehicle When the ignition is in the AUX position The transponder built into the remote handset will mobilize the engine The cipher is read by the coil around the ...

Page 903: ...nterior Front LH door open switch Front RH door open switch Rear LH door open switch Rear RH door open switch Driver s door key unlock 15 second timer Docked position with incorrect handset transponder Master locking switch 3 rear Boot open switch Fully Armed State The BCM fully arms the system when All doors are closed The handset is removed A valid lock request is received from the handset A val...

Page 904: ...d and the doors locked inserting an incorrect handset causes the security system to be triggered Note If If If the the the security security security system system system has has has been been been triggered triggered triggered and and and the the the handset handset handset is is is removed removed removed a a a valid valid valid remote remote remote lock lock lock request request request will wi...

Page 905: ...traints Seat Belts Specifications Torque Description Value Front seat belt height adjuster 30 35Nm Bolt front seat belt retractor to BC post 30 35Nm Front seat belt assembly 30 35Nm Bolt Front seat belt 30 35Nm Version 2 0 889 ...

Page 906: ...em Component Layout SRS Component Location 1 Driver s front airbag module 2 Rotary coupler 3 SRS warning light in instrument pack 4 Passenger s airbag warning light 5 Passenger s front airbag module 6 Passenger airbag disable switch 7 BCM 8 SRS ECU Version 2 0 890 ...

Page 907: ...Seat Belts Safety and Restraints SRS Component Location 1 BCM 2 Passenger occupancy sensor 3 Head curtain airbag modules 4 Side airbag module 5 Crash sensor side impact 6 SRS ECU Version 2 0 891 ...

Page 908: ...at belt pre tensioner 3 Rear seat belt buckles 4 Front seat belt 5 Front seat belt pre tensioner 6 Front seat belt height adjuster 7 Rear centre lap belt and buckle 8 Driver s seat belt buckle and warning switch 9 SRS ECU 10 Seat belt warning light in instrument pack Version 2 0 892 ...

Page 909: ...enger s front airbag module 3 Driver s front airbag module 4 Rotary coupler 5 Passenger airbag disable switch 6 Passenger airbag disabled warning light 7 Seat buckle warning light 8 SRS warning light in instrument pack 9 Diagnostic socket 10 Seat belt buckle switch Drivers 11 Seat belt buckle switch Passengers 12 Passenger occupancy sensor where fitted Version 2 0 893 ...

Page 910: ...Safety and Restraints Seat Belts 13 Seat belt pre tensioner reel 14 Crash sensor side impact if fitted 15 Side airbag if fitted 16 SRS ECU 17 BCM and fuse 42 Version 2 0 894 ...

Page 911: ...tiate deployment of the relevant front airbag modules and seat belt pre tensioners Where fitted two additional crash sensors are mounted in positions remote from theSRSECU for the detection of side impacts If a side impact is detected which is greater than the deployment threshold value a signal is sent to theSRSECU to initiate deployment of the relevant side airbag modules An electronic safing se...

Page 912: ...ing circuitry for a short duration Side Impact Crash Sensors Where fitted the side impact crash sensors are located beneath the cross member in the vehicle sill The sensors are attached to the cross members by one bolt and have a location orientation feature that matches the vehicle body Each sensor consists of an electronic accelerometer microprocessor and serial link circuit The sensor determine...

Page 913: ...e fascia directly in front of the passenger seat The airbag module is securely mounted to the fascia by means of six nuts Two additional fixings attach the bracket from the Cross Car Beam The passenger s front airbags are activated by a signal from theSRSECU in the event of a severe frontal collision The modules house a folded nylon fabric bag and the gas generator module When a severe frontal imp...

Page 914: ...enger seat the passenger airbag must be manually disabled to prevent injury to the child The airbag disable switch is located on the passenger side of the fascia When the passenger airbag has been disabled using this switch a warning light is displayed The switch must be returned to the normal On position when the seat is no longer used by a child or a child with a child seat Version 2 0 898 ...

Page 915: ...s fixed under the outer bracket of the seat cover when side crash happens it can protect the rid pelvis and upper tripe The side airbag is activated by a signal from theSRSECU in the event of a severe collision The side airbag modules have a flying lead that terminates in a 4 pin connector The connector connects to theSRSECU via the main harness and is located beneath the seat cushion Caution Do n...

Page 916: ...o protect the impact side occupants heads from direct impact with the vehicle structure and from suffering impacts from intrusive objects in the event of a severe crash The airbag is located behind the interior trim above the front and rear doors The airbag housing and gas generator are fixed to a centre mounting bracket The front tether is connected at the lower end of the A post The airbag is he...

Page 917: ... the vehicle is subjected to sudden deceleration or a severe tilt angle such as in the event of a crash The inertia reel adds a locking mechanism which has woof sensor and vehicle sensor If the woof is pulled suddenly the woof sensor will start the locking equipment immediately If the vehicle decelerate suddenly or lange angle incline vehicle sensor will start the locking equipment immediately Tra...

Page 918: ...wer frame as the long end of the webbing for the centre seat belt The buckle assemblies for the rear right and centre seat occupants are supplied as a single component The seat belt for the left rear seat passes over the left shoulder of the occupant to a buckle close to the right hip The seat belt for the centre seat occupant is a manually adjusted lap belt The seat belt for the right seat occupa...

Page 919: ...an impact theSRSECU activates the side thorax airbag module and the head curtain airbag module on the side of the vehicle suffering the impact A current from theSRSECU triggers the module to ignite a quantity of gas propellant The expanding gas causes airbag inflation The inflating side thorax airbag bursts through the seat cover at the outboard seam At the same time the head airbag module deploys...

Page 920: ...n after the initial warning light test on every ignition cycle until the cause of the fault has been resolved In addition the diagnostic system will record a fault After detecting a fault the system may retain some operational capability If a fault is detected that is external to anSRSECU circuit SRSECU will still attempt to fire airbags and seat belt pre tensioners in the event of a collision If ...

Page 921: ...ndertaken on the SRS system the appropriate information is read thoroughly 2 Remove bolt securing seat belt lower anchorage 3 Remove lower BC post finisher Trim Trim Trim finisher finisher finisher BC BC BC post post post lower lower lower each each each Remove Remove Remove 4 Remove upper BC post finisher Trim Trim Trim finisher finisher finisher BC BC BC post post post upper upper upper each eac...

Page 922: ...Safety and Restraints Supplemental Inatable Restraints Supplemental Inatable Restraints Specifications Torque Description Value Bolt airbag gas generator LH 8 12Nm Bolt SRS ECU 7 10Nm Version 2 0 906 ...

Page 923: ...ia Fascia Fascia Fascia Remove Remove Remove 3 Disconnect multiplug from airbag 4 Remove 2 bolts securing passenger airbag bracket to fascia support rail 5 Remove 6 nuts securing passenger airbag to fascia and remove airbag Refit 1 Fit passenger airbag to fascia fit nuts and tighten to 8 12Nm 2 Tighten bolts securing passenger airbag bracket to fascia support rail to 8 12Nm 3 Connect multiplug to ...

Page 924: ...o cause serious injury Refit 1 Position airbag to steering wheel connect multiplug and spade connector 2 Fit airbag to steering wheel and secure with clips 3 Connect battery leads earth last 4 Switch ignition on and check theSRS warning light illuminates for 4 seconds and then extinguishes SRS Electronic Control UnitSRS Remove 1 Disconnect battery earth lead 2 Remove centre console Console Console...

Page 925: ...dule in the empty packaging for carriage 2 Remove headlining Headlining Headlining Headlining sunshine sliding sunshine sliding sunshine sliding roof roof roof Remove Remove Remove 3 Disconnect multiplugs from airbag module 4 Release airbag tether strap from A post 5 Remove 6 screws securing head airbag curtain to body and release curtain locating pegs from body 6 Remove bolt securing airbag gas g...

Page 926: ...iption and Operation System Component Layout Parking Distance Control System Location 1 Instrument pack incorporating audible warning sounder 2 BCM 3 Rear camera where fitted 4 Rear ultrasonic sensors 5 PDC ECU 6 Neutral Start Switch NSW Reverse lamp switch Version 2 0 910 ...

Page 927: ...am PDC Control Diagram A Hard wired B MSCAN C LIN bus 1 Instrument pack incorporating audible warning sounder 2 a Neutral Start Switch NSW b Reverse light switch 3 Reverse camera where fitted 4 PDCECU 5 Ultrasonic sensors 6 BCM incorporating fuse 44 Version 2 0 911 ...

Page 928: ...nstalled in inserts in the rear bumper All four sensors are identical body colour matched and keyed to the inserts to ensure correct orientation The centre sensors have a detection range of 1500 mm with the side sensors having a detection range of 600 mm from the corner of the bumper PDC ECU PDCECU provides automatic control without intervention from the driver TheECU without intervention from the...

Page 929: ...e of the detection area approximately 1500 mm from the rear of the vehicle the frequency of the audible warning tones increases by 1 Hz per 200 mm until at approximately 300 mm from the obstruction the audible warning tone is continuous The audible warning tone produced compared to the distance from the obstruction is shown in the table below Distance from obstruction mm Side sensors Central senso...

Page 930: ...mpartment Trim Trim Trim finisher finisher finisher luggage luggage luggage compartment compartment compartment Refit Refit Refit 4 Connect battery earth lead Remove 1 Remove rear bumper Bumper Bumper Bumper assembly assembly assembly rear rear rear with with with park park park distance distance distance control control control fitted fitted fitted Remove Remove Remove 2 Release clips securing se...

Page 931: ...on Description and Operation ICE Component Layout ICE Component Location 1 Steering wheel audio controls where fitted 2 Display screen 3 SEL ESC control 4 ICE head unit 5 Radio antenna 6 USB AUX port 7 LH rear door speaker 8 LH front door speaker 9 LH front door tweeter Version 2 0 915 ...

Page 932: ...ion ICE Control Diagram ICE Control Diagram A Hard wired B MSCAN Bus C LIN Bus 1 SEL ESC control 2 Display screen 3 Speakers 4 off and tweeters 2 off 4 USB AUX port 5 Radio antenna 6 Steering wheel controls where fitted 7 BCM 8 ICE head unit Version 2 0 916 ...

Page 933: ...rd slot colour display screen Bluetooth telephone For more information about the navigation functions of the head unit NAVIGATION NAVIGATION NAVIGATION SYSTEM SYSTEM SYSTEM DESCRIPTION DESCRIPTION DESCRIPTION Head Unit Audio only 1 Source select Tuner CD Aux 2 Radio waveband 3 Mix button 4 Mute button 5 Fast reverse previous track 6 Fast forward next track 7 Main menu button 8 Eject CD 9 Audio eff...

Page 934: ...on 5 RPT Repeat button 6 Equalizer control 7 SETUP button 8 Down 9 Dim display light 10 Up 11 Backward 12 Forward 13 List radio stations CD tracks Head Unit Audio Navigation and Bluetooth 1 TEL button 2 Start call button 3 End call button Caution For details on the other buttons please refer to the Navigation and Audio Head Unit Version 2 0 918 ...

Page 935: ... AUX SEL ESC Control The SEL ESC control is used to navigate through menu and other options displayed on the display screen Rotate the control to navigate through options and press SEL to select an option Press ESC to cancel an option or return to the previous option Display Screen The display screen is situated above the SEL ESC control The upper screen displays audio information and options Exte...

Page 936: ...n all four doors Speakers are secured to the door panel by three screws Tweeter Tweeter units are fitted in the front passenger and driver doors only Radio Antenna The roof mounted radio antenna is a selfcontained unit The power is supplied from the BCM The cable that transmits the signal from the antenna to the head unit is routed under the headlining Version 2 0 920 ...

Page 937: ...unit thermal protection is fitted to shut down audio functions if the internal vehicle temperature increases The sequence of action is as follows 1 Reduce volume 2 Mute rear speakers 3 Switch off radio and CD DVD functions 4 Switch off display screen and main processor Steps 1 3 of the shutdown sequence are accompanied by a pop up message on the display screen For more information on all of the fe...

Page 938: ...nt Entertainment and Navigation Navigation System Component Layout Navigation System Component Location 1 GPS antenna 2 Navigation screen 3 SEL ESC control 4 Navigation head unit with SD card slot 5 BCM 6 Speakers Version 2 0 922 ...

Page 939: ...tertainment Navigation System Control Diagram Navigation System Control Diagram A Hard wired B MSCAN Bus C LIN Bus 1 GPS antenna 2 Navigation head unit 3 SEL ESC control 4 BCM 5 Steering wheel switches 6 Speakers 7 Navigation screen Version 2 0 923 ...

Page 940: ...s which orbit the earth The computer determines which satellites are visible to the system and their current position and relationship to each other Using this information the computer can account for positional deviations of the satellites and compensate to enhance the accuracy of the navigation system The navigation system requires the almanac data from at least four different satellites to calc...

Page 941: ...xial cable and passes signals received from theGPS satellites to the receiver for processing It is possible for the antenna to lose the signals from the satellites in hilly or tree lined areas built up areas with tall buildings multi storey car parks garages tunnels bridges and during heavy rain thunderstorms When the signal is lost the navigation computer will continue to give guidance using memo...

Page 942: ...Information and Entertainment Entertainment and Navigation Navigation System Operation Overview For more information on the operation of the navigation unit refer to the Owner s Manual Version 2 0 926 ...

Page 943: ...d secure with screws 2 Fit door trim casing Trim Trim Trim casing casing casing rear rear rear door door door Refit Refit Refit Woofer Front Door Remove 1 Remove front door trim casing Trim Trim Trim casing casing casing front front front door door door Remove Remove Remove 2 Remove 3 screws securing woofer to door and remove speaker Refit 1 Position woofer to door and secure with screws 2 Fit doo...

Page 944: ...rim casing Trim Trim Trim casing casing casing front front front door door door Remove Remove Remove 2 Remove tweeter Refit 1 Position tweeter to trim casing and secure with clips 2 Fit front door trim casing Trim Trim Trim casing casing casing front front front door door door Refit Refit Refit Version 2 0 928 ...

Page 945: ...Automatic Transmission only 11 Left hand direction indicator 12 Message centre 13 Right hand direction indicator 14 Speedometer 15 Fuel level bar chart 16 Low fuel warning light 17 Alarm status and lock status indicator 18 Passenger airbag disabled warning light 19 Rear fog lamp indicator 20 Main beam headlamp indicator 21 Supplementary Restraint System airbag warning light 22 Low engine oil press...

Page 946: ...Information and Entertainment Displays and Gages Instrument Pack Component Location 1 Instrument Pack 2 Body Control Module BCM 3 Diagnostic socket Version 2 0 930 ...

Page 947: ...Fuel level sensor 3 Transmission Control Unit TCU 4 Diagnostic connector 5 ABS DSC module 6 Master light switch 7 Parking brake switch 8 ESCL ECU 9 Park Distance Control ECU 10 Engine control module 11 SRS ECU 12 Trip control button low line vehicles only 13 Steering wheel trip control high line vehicles only 14 BCM 15 In Car Entertainment head unit Version 2 0 931 ...

Page 948: ... the instrument pack receives all its information via the Medium SpeedCAN BUS The in car entertainment system Automatic Air conditioning ESCL andBCM are communicated via the MSCAN interface The instrument pack receives High SpeedCAN BUS andLIN BUS information viaBCM gateway Information on theCAN bus which is relevant to the instrument pack is shown in the following table Information type Transmitt...

Page 949: ... BCM Instrument pack Remote key Invalid BCM Instrument pack ESCL state ESCL Instrument pack Traction control state ABS DSC Instrument pack Inertia switch tripped BCM Instrument pack vehicle speed ABS DSC Instrument pack Vehicle lock state BCM Instrument pack VIN BCM Instrument pack Wheel speed pulse signal ABS DSC Instrument pack Tyre pressure monitoring system ABS DSC Instrument pack Version 2 0 ...

Page 950: ... TX2 8 IMM0 TX1 9 IMMO CLK 10 Fuel sender 11 MSCAN low 12 MSCAN high The following gauges are included on the instrument pack Tachometer The tachometer indicates engine speed on a dial marked in revolutions per minute x1000 The upper end of the scale features a red sector to warn the driver if the engine speed is high enough to risk potential engine damage if it is maintained at this high level fo...

Page 951: ...N via EMS Fuel Gauge The fuel gauge is on the right hand side of tachometer and uses an 7LED bar chart display The gauge is connected to the fuel level sensor via hard wire when the key is docked and IGN on the fuel gauge starts to operate There are two levels of low fuel warning the first warning level occurs when one bar remains illuminated The warning light on the right hand side of the fuel ga...

Page 952: ...ine failure For example the electric throttle accelerator pedal ECU voltage etc When the engine starts the message centre will display warning information with warning sound to alert the driver Engine Malfunction Warning MIL Light If the yellow warning light remains on after the engine starts this meansEMS has an emissions failure When the engine starts the message centre will display warning info...

Page 953: ...uise setting button again the car will use the last target speed as new target speed to restart cruise control During non stand by cruise control ifEMS detected the cruise control failure the cruise control warning light yellow will flash three times The message centre will display Cruise control failure Front Fog Lamp Warning Light The warning light illuminates green when the front fog lamps are ...

Page 954: ...eives a signal that the lights are switched on from theBCM via the Data BUS When theBCM detects that the key has been removed the driver s door is open and the lights are not switched off it triggers the warning message together with an audible warning which lasts for approximately 20 seconds or until the sidelights are switched off Overspeed Warning 120 When the vehicle speed exceeds the value se...

Page 955: ...tion is on the whole message centre screen will show SAIC MOTOR Message Centre Control Button The trip computer displays the following fuel consumption trip distance average fuel consumption average speed range By operating message centre control button it will display the status included default level menu trip computer function and four level menu Trip Button low line On the low line models the ...

Page 956: ...ng the dimmer control thumb wheel on the Master Light SwitchMLS The dimmer control also affects the brightness of illuminated switches message centre trip computer and navigation system display where fitted With the handset docked or the ignition on and the sidelights or headlamps switched on rotate the control up to increase brightness level and down to decrease brightness level Version 2 0 940 ...

Page 957: ...e trip meter distance and the odometer distance will be displayed The Service Interval Announcement SIA information is displayed after which the fuel quantity is displayed for the remaining time The Service Interval Announcement information SIA consists of a service symbol spanner icon the date of and distance to the next service together with the text of distance units km or miles The fuel quanti...

Page 958: ...ack from fascia and disconnect 1 instrument pack connector and either 1 or 2 display connectors depending on if a radio or navigation display is fitted 4 Remove instrument pack Refit 1 Connect multiplugs and secure instrument pack to fascia with screws 2 Connect battery earth lead 3 Connect diagnostic equipment Follow on screen instructions displayed by diagnostic equipment to configure new instru...

Page 959: ...aporative Emission GPS Global Positioning System HFM Hot film air mass HO2S Heated Oxygen Sensor HRW Heated Rear Window Name Description HS High Speed HVAC Heating Ventilation and Air Conditioning ICE In Car Entertainment ICS Inflatable Curtain Structure ISO International Organization for Standardization LCD Liquid Crystal Display LED Light Emitting Diode LIN Local Interconnect Network MAP Manifol...

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