MGTF en

MG TF
WORKSHOP
MANUAL
This manual should be used in conjunction with the
following overhaul manuals.
RCL 0057 'K' Series Engine
RCL 0124 'PG1' Manual Gearbox
Publication Part No. RCL0493ENG - 1st Edition
Published by MG Rover Group After Sales
MG Rover Group Limited 2002
NTRODUCTON
GENERAL NFORMATON
NFORMATON
MANTENANCE
ENGNE
EMSSON CONTROL
ENGNE MANAGEMENT SYSTEM
- MEMS 3
FUEL DELVERY SYSTEM
COOLNG SYSTEM
MANFOLD & EXHAUST SYSTEMS
CLUTCH
MANUAL GEARBOX
AUTOMATC GEARBOX - Em-CVT
DRVE SHAFTS
STEERNG
SUSPENSON
BRAKES
RESTRANT SYSTEMS
BODY
HEATNG & VENTLATON
AR CONDTONNG
WPERS & WASHERS
ELECTRCAL
NSTRUMENTS
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INTRODUCTION
CONTENTS Page
INTRODUCTION
NTRODUCTON 1 ......................................................................................................
REPARS AND REPLACEMENTS 2 ...........................................................................
SPECFCATON 2 ......................................................................................................
ABBREVATONS AND SYMBOLS 3 ..........................................................................
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INTRODUCTION
INTRODUCTION 1
INTRODUCTION
How to use this ManuaI
To assist in the use of this Manual the section title is
given at the top and the relevant sub-section is given
at the bottom each page.
Each major section starts with a contents page,
listing the information contained in the relevant
sub-sections. To assist filing of revised information
each sub-section is numbered from page 1.
The individual items comprising repair operations
are to be followed in the sequence in which they
appear. tem numbers in illustrations are referred to
in the text.
Adjustment and repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool. Where usage is not
obvious the tool is shown in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given a Repair
Operation Time number.
WARNNGS, CAUTONS and NOTES have the
following meanings:
WARNING: Procedures which must be
foIIowed preciseIy to avoid the possibiIity
of injury.
CAUTION: CaIIs attention to procedures
which must be foIIowed to avoid damage
to components.
NOTE: Gives heIpfuI information.
References
References to the LH or RH side given in this
Manual are made when viewing the vehicle from the
rear. With the engine and gearbox assembly
removed, the crankshaft pulley end of the engine is
referred to as the front.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. t is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.
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INTRODUCTION
2 INTRODUCTION
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only MG Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Safety features and corrosion prevention treatments
embodied in the car may be impaired if other than
MG Rover recommended parts are fitted. n certain
territories, legislation prohibits the fitting of parts not
to the manufacturer's specification. Torque wrench
setting figures given in this Manual must be used.
Locking devices, where specified, must be fitted. f
the efficiency of a locking device is impaired during
removal it must be renewed.
Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
fitted location on the car conform to legal
requirements.
The Terms of the vehicle Warranty may be
invalidated by the fitting of other than MG Rover
recommended parts.
All MG Rover recommended parts have the full
backing of the vehicle Warranty.
MG Rover Dealers are obliged to supply only MG
Rover recommended parts.
SPECIFICATION
MG Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. MG Rover Dealers are not
agents of MG Rover and have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation.
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INTRODUCTION
INTRODUCTION 3
ABBREVIATIONS AND SYMBOLS
After Bottom Dead Centre ABDC
After Top Dead Centre ATDC
Air Conditioning A/C
Air Fuel Ratio AFR
Alternating Current ac
Ambient Air Temperature AAT
Amperes A
Anti-Lock Brake System ABS
Before Bottom Dead Centre BBDC
Before Top Dead Centre BTDC
Bottom Dead Centre BDC
Brake proportioning valve BPV
British Standards BS
Camshaft Position CMP
Carbon Dioxide CO
2
Carbon Monoxide CO
Celsius (Centigrade) C
Centimetre cm
Chlorofluorocarbons CFC's
Crankshaft Position CKP
Cubic Centimetres cm
3
Degree (angle) deg. or
Degree (temperature) deg. or
Diagnostic Control Unit DCU
Dial Test ndicator DT
Diameter dia.
Direct Current dc
Double Overhead Camshaft DOHC
Engine Coolant Temperature ECT
Electric Power Assisted Steering EPAS
Electrically Eraseable
Programmable Read Only Memory EEPROM
Electronic Control Unit ECU
Electronic Air Control Valve EACV
Electro Mechanical - Continuously
Variable Transmission Em-CVT
Electromotive force e.m.f.
Engine Control Module ECM
Exhaust Gas Recirculation EGR
Evaporative Emission EVAP
Field Effect Transistor FET
Gramme (mass) g
Gearbox nterface Unit GU
Heated Oxygen Sensor HO
2
S
Hertz Hz
High Compression hc
High Tension (electrical) h.t.
Hour h
Hydraulic Control Unit HCU
Hydrocarbons HC
Hydrofluorocarbon HFC
nches in
dle Air Control AC
nstant Mobility System MS
nertia Fuel Shutoff FS
ntake Air Temperature AT
nternal Diameter i.dia.
nternational Organisation
for Standardization SO
Kilogramme kg
Kilometre km
Kilometres per hour km/h
KiloOhms k
KiloWatts kW
Left-Hand LH
Left-Hand Drive LHD
Light Emitting Diode LED
Liquid Crystal Display LCD
Litre l
Low Compression lc
Low tension lt
Malfunction ndicator Lamp ML
Manifold Absolute Pressure MAP
Maximum max
MegaWatts MW
Mercury Hg
Metre m
Miles Per Hour mph
Milliamp mA
Millimetre mm
Minimum min
Minus (of tolerance) -
Minute (angle) '
Modular Engine Management
System MEMS
Model Year MY
Multi-Function Unit MFU
Multi-Point njection MPi
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INTRODUCTION
4 INTRODUCTION
Negative (electrical) -
Negative Temperature Coefficient NTC
Newton Metre Nm
Nitrous Oxide NO
x
Number No.
On Board Diagnostics OBD
Ohms
Organic Acid Technology OAT
Outside Diameter o.dia.
Percentage %
Plus or Minus
Plus (tolerance) +
Positive (electrical) +
Positive Crankcase Ventilation PCV
Positive Temperature Coefficient PTC
Pounds Per Square nch lbf/in
2
Pounds Per Square nch psi
Pounds (mass) lb
Pulse Width Modulation PWM
Radius r
Ratio :
Reference ref
Revolutions Per Minute rev/min or rpm
Right-Hand RH
Right-Hand Drive RHD
Rover Engineering Standards RES
Second (angle) "
Single Overhead Camshaft SOHC
Specific Gravity sp.gr
Square Centimetres cm
2
Square inches in
2
Standard std.
Supplementary Restraint System SRS
Synchronizer/Synchromesh synchro
Thousand k
Throttle Position TP
Top Dead Centre TDC
United Kingdom UK
United States US
Variable Valve Control VVC
Vehicle dentification Number VN
Volt V
Water H
2
O
Watt W
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GENERAL INFORMATION
CONTENTS Page
VEHICLE IDENTIFICATION NUMBER
VEHCLE DENTFCATON NUMBER 1 ....................................................................
DENTFCATON NUMBER LOCATONS 2 ...............................................................
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
DANGEROUS SUBSTANCES 1 .................................................................................
Health Protection Precautions 1 ...............................................................................
ENVRONMENTAL PRECAUTONS 2 ........................................................................
PRECAUTONS AGANST DAMAGE 5 .......................................................................
SAFETY NSTRUCTONS 6 ........................................................................................
Jacking 6 ...................................................................................................................
Brake shoes and pads 6 ...........................................................................................
Brake hydraulics 6 ....................................................................................................
Cooling system caps and plugs 6 .............................................................................
GENERAL FTTNG NSTRUCTONS 7 ......................................................................
FLEXBLE PPES AND HOSES 14 .............................................................................
SERVCE TOOLS 16 ...................................................................................................
TestBook 16 ..............................................................................................................
Body repairs 16 .........................................................................................................
Replacement body panels 16 ...................................................................................
DYNAMOMETER TESTNG 17 ...................................................................................
FUEL HANDLING PRECAUTIONS
FUEL HANDLNG PRECAUTONS 1 ..........................................................................
ELECTRICAL PRECAUTIONS
ELECTRCAL PRECAUTONS 1 .................................................................................
SRS PRECAUTIONS
SUPPLEMENTARY RESTRANT SYSTEM PRECAUTONS 1 ..................................
NSTALLATON 2 ........................................................................................................
WARNNG LABELS 6 ..................................................................................................
VEHCLE RECOVERY 8 .............................................................................................
SRS COMPONENT DEPLOYMENT 8 ........................................................................
SRS COMPONENT REPLACEMENT POLCY 9 ........................................................
AIR CONDITIONING PRECAUTIONS
AR CONDTONNG SYSTEM PRECAUTONS 1 ......................................................
AR CONDTONNG COMPRESSOR REPLACEMENT 3 ..........................................
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GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER 1
VEHICLE IDENTIFICATION NUMBER
Location
The Vehicle dentification Number (VN) is provided
at the following locations:
Stamped on a plate attached to the RH side of the
under bonnet compartment and stamped into the
body above the RH front suspension strut.
Behind the LH lower corner of the windscreen.
VIN pIate detaiIs
The VN plate contains the following information:
1. Vehicle dentification Number (VN)
2. Gross Vehicle Weight (GVW)
3. Gross train weight (GTW)
4. Maximum front axle load
5. Maximum rear axle load
6. Paint code
7. Trim code
VIN code key
Example: S A R R D L B K J 2 D 000001
SAR = World dentifier : MG Rover Group (UK)
RD = Model: MG TF
L = Trim Level: 7.1
B = Body Style (2 door convertible)
K = Engine: K1.8 MPi, 100 kW
J = Steering and transmission: RHD CVT
2 = Model Year: 2002
D = Assembly Plant: Longbridge
6 figures = Serial number: 000001
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GENERAL INFORMATION
2 VEHICLE IDENTIFICATION NUMBER
Paint and Trim coIour codes
3-letter codes identifying the original Paint and Trim
colours are stamped on the VN plate
Paint
K M N
K = Basic colour
M = Mark identifier
N = Colour/Shade name
Trim
L Q P
L = Basic colour
Q = Mark identifier
P = Colour/Shade name
IDENTIFICATION NUMBER LOCATIONS
Engine number
K Series Engine: Stamped on the front face of the
cylinder block adjacent to the gearbox.
Gearbox number
Manual Gearbox: Stamped on a label attached to
the front face of the clutch housing.
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GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER 3
Automatic Gearbox (Em-CVT): Stamped on a label
attached by the gearbox to engine mounting bolt.
Body number
The body number is stamped on the bulkhead at the
back of the boot.
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GENERAL INFORMATION
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1
DANGEROUS SUBSTANCES
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
WARNING: Many Iiquids and other
substances used in motor vehicIes are
poisonous and shouId not be consumed
under any circumstances. As far as possibIe,
ensure such substances are prevented from
contact with the skin. These Iiquids and
substances incIude but are not Iimited to: acid,
anti-freeze, asbestos, brake fIuid, fueI,
windscreen washer additives, Iubricants,
refrigerant and various adhesives.
WARNING: AIways read the instructions
printed on IabeIs or stamped on
components and obey them impIicitIy.
Such instructions are incIuded for reasons of
your heaIth and personaI safety. Never disregard
them.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact made of synthetic materials called
Fluoroelastomers. Under normal operating
conditions this material is safe and does not present
a health hazard. However, if the material is
damaged by fire or excessive heating, it can break
down and produce highly corrosive Hydrofluoric
acid.
Contact with Hydrofluoric acid can cause serious
burns on contact with skin. f skin contact does
occur:
Remove any contaminated clothing immediately.
rrigate affected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
Obtain medical assistance immediately.
Should any material be in a burnt or overheated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.).
Decontaminate and dispose of gloves immediately
after use.
Lubricating oiIs
Avoid excessive skin contact with used lubricating
oils and always adhere to the health protection
precautions.
WARNING: Avoid excessive skin contact
with used engine oiI. Used engine oiI
contains potentiaIIy harmfuI contaminants
which may cause skin cancer or other serious
skin disorders.
WARNING: Avoid excessive skin contact
with mineraI oiI. MineraI oiIs remove the
naturaI fats from the skin, Ieading to
dryness, irritation and dermatitis.
HeaIth Protection Precautions
Avoid prolonged and repeated contact with oils,
particularly used engine oils.
Wear protective clothing, including impervious
gloves where practicable.
Do not put oily rags in pockets.
Avoid contaminating clothes (particularly those
next to the skin) with oil.
Overalls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
First aid treatment should be obtained
immediately for open cuts and wounds.
Apply barrier creams before each work period, to
help prevent lubricating oil from contaminating
the skin.
Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help).
Use moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
Do not use petrol/gasoline, kerosene, diesel fuel,
oil, thinners or solvents for cleaning skin.
f skin disorders develop, obtain medical advice
without delay.
Where practicable, degrease components prior
to handling.
Wear eye protection (e.g. goggles or face shield)
if there is a risk of eye contamination. Eye wash
facilities should be provided in close vicinity of
the work area.
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GENERAL INFORMATION
2 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
ENVIRONMENTAL PRECAUTIONS
GeneraI
This section provides general information which if
observed, can help reduce environmental damage
caused by activities carried out in workshops.
Emissions to air
Many of the activities that are carried out in
workshops emit gases and fumes which contribute
to global warming, depletion of the ozone layer
and/or the formation of photochemical smog at
ground level. By considering how the workshop
activities are carried out, these gases and fumes can
be minimised, thus reducing the impact on the
environment.
Exhaust fumes
Running car engines is an essential part of
workshop activities and exhaust fumes need to be
ventilated to atmosphere. However, the amount of
time engines are running and the position of the
vehicle should be carefully considered at all times, to
reduce the release of poisonous gases and minimise
the inconvenience to people living nearby.
SoIvents
Some of the cleaning agents used are solvent based
and will evaporate to atmosphere if used carelessly,
or if cans are left unsealed. All solvent containers
should be firmly closed when not being used and
solvent should be used sparingly. Suitable
alternative methods may be available to replace
some of the commonly used solvents. Similarly,
many paints are solvent based and the spray should
be minimised to reduce solvent emissions.
Refrigerant
t is illegal to release any refrigerants into the
atmosphere. Discharge and replacement of these
materials from air conditioning units should only be
carried out using the correct equipment.
CheckIist
Always adhere to the following:
Engines:
Don't leave engines running unnecessarily.
Minimise testing times and check where the
exhaust fumes are being blown.
Materials:
Keep lids on containers of solvents.
Only use the minimum quantity.
Consider alternative materials.
Minimise over-spray when painting.
Gases:
Use the correct equipment for collecting
refrigerants.
Don't burn rubbish on site.
Discharges to water
Most sites will have two systems for discharging
water: storm drains and foul drains. Storm drains
should only receive clean water, foul drains will take
dirty water.
The foul drain will accept many of the normal waste
waters such as washing water, detergents and
domestic type wastes but oil, petrol, solvent, acids,
hydraulic oil, antifreeze and other such substances
should never be poured down the drain. f in any
doubt, consult the Water Authority responsible for
your locality first.
Every precaution must be taken to prevent spillage
of oil, fuel, solvents etc. reaching the drains. All
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 into the
drain. f a spillage occurs, it should be soaked up
immediately. Having a spill kit available will make
this easier.
AdditionaI precautions
Check whether the surface water drains are
connected to an oil/water separator, this could
reduce the pollution if an incident was to occur.
Oil/water separators do need regular maintenance to
ensure effectiveness.
CheckIist
Disposal:
Never pour anything down a drain without first
checking that it is environmentally safe to do so,
and that it does not contravene any local
regulations or bye-laws.
Have oil traps emptied regularly.
Spillage prevention:
Store liquids in a walled area.
Make sure that taps on liquid containers are
secure and cannot be accidently turned on.
Protect bulk storage tanks from vandalism by
locking the valves.
Transfer liquids from one container to another in
an area away from open drains.
Ensure lids are replaced securely on containers.
Have spill kits available near to points of storage
and handling of liquids.
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GENERAL INFORMATION
SpiII kits
Special materials are available to absorb a number
of different substances. They can be in granular
form, ready to use and bought in convenient
containers for storage. Disposal of used
spill-absorbing material is dealt with in the 'Waste
Management' section.
Land contamination
Oil, fuels and solvents etc. can contaminate any soil
that they are allowed to contact. Such materials
should never be disposed of by pouring onto soil
and every precaution must be taken to prevent
spillage reaching soil. Waste materials stored on
open ground could also leak, or have polluting
substances washed off them that would contaminate
the land. Always store these materials in suitable
skips or other similarly robust containers.
CheckIist
Don't pour or spill anything onto the soil or bare
ground.
Don't store waste materials on bare ground, see
'Spillage prevention' list in 'AdditionaI
Precautions CheckIist'.
LegaI compIiance
Some sites may have a discharge consent for
effluent discharge to the foul drain for a car wash
etc. t is important to know what materials are
allowed in the drain and to check the results of any
monitoring carried out by the local Water authority.
Where paint-spraying operations are carried out, it
may be necessary to apply to the Local Authority for
an air emissions licence to operate the plant. f such
a licence is in operation, additional precautions will
be necessary to comply with the requirements, and
the results of any air quality monitoring must be
checked regularly.
CheckIist
Know what legal consents and licences apply to
the operations.
Check that the emissions and discharges comply
with legal requirements.
LocaI issues
A number of environmental issues will be of
particular concern to residents and other neighbours
close to the site. The sensitivity of these issues will
depend on the proximity of the site and the layout
and amount of activity conducted at the site.
Noise is a major concern and therefore
consideration should be given to the time spent
carrying out noisy activities and the location of those
activities that can cause excessive noise.
Car alarm testing, panel beating, hammering and
other such noisy activities should, whenever
possible, be carried out indoors with doors and
windows shut, or as far away as possible from local
residents and others who may be affected by the
disturbance.
Running vehicle engines may be an outside activity
which could cause nuisance to neighbours because
of noise and smell.
Be sensitive with regards the time of day when these
activities are performed, and minimise the time of
the noisy operation, particularly in the early morning
and late evening.
Another local concern will be the smell from the
various materials used. Using less solvent, paint and
petrol could help prevent this annoyance.
Local residents and other business users will also be
concerned about traffic congestion, noise and
exhaust fumes, be sensitive to these concerns and
try to minimise inconvenience caused by deliveries,
customers and servicing operations.
CheckIist
dentify where the neighbours who are likely to
be affected are situated.
Minimise noise, smell and traffic nuisance.
Prevent litter by putting waste in the correct
containers.
Have waste skips emptied regularly.
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GENERAL INFORMATION
Use of resource
Another environmental concern is the waste of
materials and energy that can occur in day to day
activities.
Electricity for heating, lighting and compressed air
uses resources and releases pollution during its
generation.
Fuel used for heating, running cars or vans and
mobile plant is another limited resource which
consumes large amounts of energy during its
extraction and refining processes.
Water has to be cleaned, piped to site and disposed
of; all of which creates more potential pollution.
Oil, spares, paint etc., have all produced pollution in
the process of manufacture and they become a
waste disposal problem if discarded.
CheckIist
Electricity and heating:
Keep doors and windows closed in the Winter.
Switch off machinery or lights when not needed.
Use energy efficient heating systems.
Switch off computers and photocopiers when not
needed.
Fuel:
Don't run engines unnecessarily
Think about whether journeys are necessary and
drive to conserve fuel.
Water:
Don't leave taps and hose pipes running.
Mend leaks quickly, don't be wasteful.
Compressed air:
Don't leave valves open.
Mend leaks quickly.
Don't leave the compressor running when not
needed.
Use of environmentally damaging materials:
Check whether a less toxic material is available.
Handling and storage of materials:
Have the correct facilities available for handling
liquids to prevent spillage and wastage as listed
above.
Provide suitable locations for storage to prevent
frost damage or other deterioration.
Burning used engine oiI
Burning of used engine oil in small space heaters or
boilers can be recommended only for units of
approved design. The heating system must meet the
regulatory standards for small burners(s) with a net
rated thermal input of less than 3MW. The use of
waste oil burners must be licensed by the local
authority.
Waste Management
One of the major ways that pollution can be reduced
is by the careful handling, storage and disposal of all
waste materials that occur on sites. Legislation
makes it illegal to dispose of waste materials other
than to licensed waste carriers and disposal sites.
This means that it is necessary to not only know
what the waste materials are, but also to have the
necessary documentation and licenses.
HandIing and storage of waste
Ensure that waste materials are not poured down
the drain or onto soils. They should be stored in
such a way as to prevent the escape of the material
to land, water or air.
They must also be segregated 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.
DisposaI of waste
Disposal of waste materials must only be to waste
carriers who are licensed to carry those particular
waste materials and all the necessary
documentation must be completed. The waste
carrier is responsible for ensuring that the waste is
taken to the correct disposal sites.
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GENERAL INFORMATION
Dispose of waste in accordance with the following
guidelines:
FueI, hydrauIic fIuid, anti-freeze and oiI: keep
separate and dispose of to specialist contractor.
Refrigerant: collect in specialist equipment and
reuse.
Detergents: safe to pour down the foul drain if
diluted.
Paint, thinners: keep separate and dispose of to
specialist contractor.
Components: send back to supplier for
refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
ordinary waste.
SmaII parts: reuse any suitable parts, dispose of
the remainder in ordinary waste.
MetaIs: can be sold if kept separate from general
waste.
Tyres: keep separate and dispose of to
Packaging: compact as much as possible and
dispose of in ordinary waste.
Asbestos-containing: keep separate and
dispose of to specialist contractor.
OiIy and fueI wastes (e.g. rags, used spiII kit
materiaI): keep separate and dispose of to
Air fiIters: keep separate and dispose of to
Rubber/pIastics: dispose of in ordinary waste.
Hoses: dispose of in ordinary waste.
Batteries: keep separate and dispose of to
Airbags - expIosives: keep separate and
dispose of to specialist contractor.
EIectricaI components: send back to supplier
for refurbishment, or disassemble and reuse any
ordinary waste.
EIectronic components: send back to supplier
for refurbishment, or disassemble and reuse any
ordinary waste.
CataIysts: can be sold if kept separate from
general waste.
Used spiII-absorbing materiaI: keep separate
and dispose of to specialist contractor.
Office waste: recycle paper and toner and ink
cartridges, dispose of the remainder in ordinary
waste.
PRECAUTIONS AGAINST DAMAGE
Always fit wing and seat covers before commencing
work.
Avoid spilling brake fluid or battery acid on
paintwork. Wash off with water immediately if this
occurs.
Disconnect the battery earth lead before starting
work, see ELECTRICAL PRECAUTIONS.
Always use the recommended service tool or a
satisfactory equivalent where specified.
Protect exposed bearing and sealing surfaces and
screw threads from damage.
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GENERAL INFORMATION
SAFETY INSTRUCTIONS
Jacking
The recommended jacking points are given in
LIFTING AND TOWING.
Always ensure that any lifting apparatus has
adequate load and safety capacity for the weight to
be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
Never rely on a jack as the sole means of support
when working beneath the vehicle. Use additional
safety supports beneath the vehicle.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area.
Brake shoes and pads
WARNING: AIways fit the correct grade
and specification of brake Iinings and
renew brake pads and brake shoes in axIe
sets onIy.
Brake hydrauIics
Observe the following recommendations when
working on the brake system:
Always use two spanners when loosening or
tightening brake pipe or hose connections.
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 hydraulic fluid must be kept
absolutely clean.
Do not store hydraulic 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 boiling point.
Do not allow hydraulic brake fluid to be
contaminated with mineral oil, or put new brake
fluid in a container which has previously
contained mineral oil.
Do not re-use brake fluid removed from the
system.
Always use clean brake fluid or a recommended
alternative to clean hydraulic components.
After disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to
prevent the ingress of dirt.
Only use the correct brake fittings with
compatible threads.
Absolute cleanliness must be observed when
working with hydraulic components.
WARNING: It is imperative that the correct
brake fittings are used and that threads of
components are compatibIe.
CooIing system caps and pIugs
Extreme care is necessary when removing engine
coolant caps and plugs when the engine is hot and
especially if it is overheated. To avoid the possibility
of scalding allow the engine to cool before
attempting coolant cap or plug removal.
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GENERAL INFORMATION
GENERAL FITTING INSTRUCTIONS
Component removaI
Whenever possible, clean components and
surrounding area before removal.
Blank off openings exposed by component
removal.
mmediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or plugs
to prevent loss of fluid and ingress of dirt.
Close the open ends of oilways exposed by
component removal with tapered hardwood plugs
or conspicuous plastic plugs.
mmediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
Clean bench and provide marking materials,
labels and containers before dismantling a
component.
DismantIing
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
serious malfunction if trapped in these systems.
Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
'O' rings used for sealing are correctly replaced
or renewed, if disturbed during the process.
Use marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could initiate
cracks or distortion in marked components.
Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
Wire labels on 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 its
correct replacement has been obtained.
CIeaning components
Always use the recommended cleaning agent or
equivalent.
Ensure that adequate ventilation is provided when
volatile degreasing agents are being used.
Do not use degreasing equipment for components
containing items which could be damaged by the
use of this process.
Whenever possible clean components and the area
surrounding them before removal. Always observe
scrupulous cleanliness when cleaning dismantled
components.
GeneraI inspection
All components should be inspected for wear or
damage before being reassembled.
Never inspect a component for wear or
dimensional check unless it is absolutely clean; a
slight smear of grease can conceal an incipient
failure.
When a component is to be checked
dimensionally against recommended values, use
the appropriate measuring equipment (surface
plates, micrometers, dial gauges etc.). Ensure
the measuring equipment is calibrated and in
good serviceable condition.
Reject a component if its dimensions are outside
the specified tolerances, or if it appears to be
damaged.
A part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition. Use 'Plastigauge' 12
Type PG-1 for checking bearing surface
clearances.
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GENERAL INFORMATION
BaII and RoIIer Bearings
When removing and installing bearings, ensure that
the following practices are observed to ensure
component serviceability.
Remove all traces of lubricant from bearing
under inspection by cleaning with a suitable
degreasant; maintain absolute cleanliness
throughout operations.
Conduct a visual inspection for markings on
rolling elements, raceways, outer surface of outer
rings or inner surface of inner rings. Reject any
bearings found to be marked, since marking in
these areas indicates onset of wear.
Hold inner race of bearing between finger and
thumb of one hand and spin outer race to check
that it rotates absolutely smoothly. Repeat,
holding outer race and spinning inner race.
Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation. Reject bearing if
action is not perfectly smooth.
Lubricate bearing with generous amounts of
lubricant appropriate to installation.
nspect shaft and bearing housing for
discoloration or other markings which indicate
movement between bearing and seatings.
Ensure that shaft and housing are clean and free
from burrs before fitting bearing.
f 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 serviceable condition.
When hub bearings are removed or displaced,
new bearings must be fitted; do not attempt to
refit the old hub bearings.
When fitting a bearing to a shaft, only apply force
to the inner ring of the bearing. When fitting a
bearing into a housing, only apply force to the
outer ring of the bearing.
n the case of grease lubricated bearings (e.g.
hub bearings) fill the space between bearing and
outer seal with the recommended grade of
grease before fitting seal.
Always mark components of separable bearings
(e.g. taper roller bearings) when dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring; always fit a complete new
bearing assembly.
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GENERAL INFORMATION
OiI seaIs
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly). NEVER use
a seal which has been improperly stored or handled,
such as hung on a hook or nail.
Carefully examine seal before fitting to ensure
that it is clean and undamaged.
Ensure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.
Protect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.
Lubricate the sealing lips with a recommended
lubricant before use to prevent damage during
initial use. On dual lipped seals, smear the area
between the lips with grease. Note: some oil
seals are coated with a protective wax and must
be fitted dry, unless instructed otherwise.
f a seal spring is provided, ensure that it is fitted
correctly. Place lip of seal towards 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. f 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 ensure
the seal is not tilted. n some cases it may be
preferable to fit seal to housing before fitting to
shaft. Never let weight of unsupported shaft rest
in seal.
Use the recommended service tool to fit an oil
seal. f the correct service tool is not available,
use a suitable tube approximately 0.4 mm (0.015
in) smaller than the outside diameter of the seal.
Use a hammer VERY GENTLY on drift if a
suitable press is not available.
Press or drift the seal in to the depth of its
housing, with the sealing lip facing the lubricant
to be retained if the housing is shouldered, or
flush with the face of the housing where no
shoulder is provided. Ensure that the seal does
not enter the housing in a tilted position.
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GENERAL INFORMATION
Joints and joint faces
Fit joints dry unless specified otherwise.
When jointing compound is used, apply in a thin
uniform film to metal surfaces; take care to
prevent jointing compound from entering oilways,
pipes or blind tapped holes.
f gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs on the joint
faces using an oil stone. Do not allow dirt or
jointing material to enter any tapped holes or
enclosed parts.
Prior to reassembly, blow through any pipes,
channels or crevices with compressed air.
Locking Devices
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 of the correct size
for the groove.
Keys and keyways - remove burrs from edges of
keyways with a fine file and clean thoroughly before
attempting to refit key.
Clean and inspect key closely; keys are suitable for
refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.
Split pins -
Always fit new split-pins of the correct size for the
hole in the bolt or stud. Do not sIacken back nut to
enter spIit-pin.
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GENERAL INFORMATION
Screw threads
Metric threads to SO standards are used.
Damaged nuts, bolts and screws must always be
discarded.
Cleaning up damaged threads with a die or tap
impairs the strength and closeness of fit of the
threads and is not recommended.
Castellated nuts must not be slackened back to
accept a split-pin, except in those recommended
cases when this forms part of an adjustment.
Do not allow oil or grease to enter blind threaded
holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.
To check or re-tighten a bolt or screw to a specified
torque figure, first slacken a quarter of a turn, then
retighten to the correct torque figure.
Oil thread lightly before tightening to ensure a free
running thread, except in the case of threads treated
with sealant/lubricant, and self-locking nuts.
BoIt identification
An SO metric bolt or screw made of steel and larger
than 6 mm in diameter can be identified by either of
the symbols SO M or M embossed or indented on
top of the head.
n addition to marks to identify the manufacturer, the
head is also marked with symbols to indicate the
strength grade, e.g. 8.8; 10.9; 12.9; 14.9. As an
alternative, some bolts and screws have the M and
strength grade symbol on the flats of the hexagon.
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GENERAL INFORMATION
Nut identification
A nut with an SO 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.
A clock face system is used as an alternative
method of indicating the strength grade. The
external chamfers or a face of the nut is marked in a
position relative to the appropriate hour mark on a
clock face to indicate the strength grade.
A dot is used to locate the 12 o'clock position and a
dash to indicate the strength grade. f the grade is
above 12, two dots identify the 12 o'clock position.
When tightening a slotted or castellated nut, never
loosen it to insert a split pin except where
recommended as part of an adjustment. f difficulty is
experienced, alternative washers or nuts should be
selected, or the washer thickness reduced.
Where bearing pre-load is involved, nuts should be
tightened in accordance with special instructions.
SeIf-Iocking nuts
Self-locking nuts, i.e. nylon insert or metal stiff nuts
can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the
same type.
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GENERAL INFORMATION
SeIf-Iocking boIts and screws
Self-locking bolts and screws, i.e. nylon patched or
trilobular thread can be re-used providing resistance
can be felt when the locking portion enters the
female thread.
Nylon patched bolts and screws have a locking
agent pre-applied to the threads. They are identified
by the presence of a coloured section of thread
which extends for up to 180 around the thread.
Trilobular i.e. Powerlok bolts have a special thread
form which creates a slight interference in the
tapped hole or threads of the nut into which it is
screwed.
DO NOT re-use self-locking fasteners in critical
locations (eg. engine bearings). Always use the
correct replacement self-locking nut, bolt or screw.
DO NOT fit non self-locking fasteners in applications
where a self-locking nut, bolt or screw is specified.
EncapsuIated boIts and screws
Encapsulated bolts and screws have a
micro-encapsulated locking agent pre-applied to the
thread. They are identified by the presence of a
coloured section of thread which extends completely
around the thread - 360 . The locking agent is
released and activated by the assembly process and
is then chemically cured to provide the locking
action.
Unless a specific repair procedure states otherwise,
encapsulated bolts may be re-used providing the
threads are undamaged and the following procedure
is adopted.
Remove loose adhesive from the bolt and
housing threads.
Ensure threads are clean and free of oil and
grease.
Apply an approved locking agent.
An encapsulated bolt may be replaced with a bolt of
equivalent specification provided it is treated with an
approved locking agent.
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GENERAL INFORMATION
FLEXIBLE PIPES AND HOSES
GeneraI
When removing and installing flexible hydraulic
pipes and hoses, ensure that the following practices
are observed to ensure component serviceability.
Before removing and refitting brake or power
steering hose, clean end fittings and area
surrounding them as thoroughly as possible.
Obtain appropriate plugs or caps before
detaching hose end fittings, so that the ports can
be immediately covered to prevent the ingress of
dirt.
Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.
When refitting a hose, ensure that no
unnecessary bends are introduced, and that the
hose is not twisted before or during tightening of
union nuts.
Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
Absolute cleanliness must be observed with
hydraulic components at all times.
After any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.
FueI system hoses
All fuel hoses are made up of two laminations, an
armoured rubber outer sleeve and an inner viton
core. f any of the fuel system hoses have been
disconnected, it is imperative that the internal bore is
inspected to ensure that the viton lining has not
become separated from the armoured outer sleeve.
A new hose must be fitted if separation is evident.
CooIing system hoses
The following precautions MUST be followed to
ensure the 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 fatigued or
damaged through contact with adjacent
components. Where 'timing' marks (2) are provided
on the hose and corresponding connection, these
must be used to ensure correct orientation. Hoses
must be pushed fully onto their connection points.
Usually, a moulded form (3) on the stub pipe
provides a positive indicator.
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GENERAL INFORMATION
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. f no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown. Worm
drive clips should be oriented with the crimped side
of the drive housing (5) facing towards the end of the
hose, or the hose may become pinched between the
clip and the stub pipe retaining lip. Worm drive clips
should be tightened to 3 Nm (2lbf.ft) unless
otherwise stated. Ensure that hose clips do not foul
adjacent components.
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident. Particular care must be taken when
routing hoses close to hot engine components, such
as the exhaust manifold. Hoses will deflect slightly
when hot; ensure this movement is taken into
account when routing and securing hoses.
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GENERAL INFORMATION
SERVICE TOOLS
GeneraI
Special service tools have been developed to
facilitate removal, dismantling and assembly of
mechanical components in a cost effective and time
efficient manner. The use of special tools also helps
prevent the potential for damage to components.
Some operations described in this Manual cannot be
carried out properly without the aid of the relevant
service tools.
Special service tools can be obtained from the
following suppliers:
CartooI (UK) Limited
Unit 3, Sterling Business Park
Salthouse Road
Brackmills
Northampton
NN4 7EX
England
TEL: +44 (0) 1604 760099
FAX: +44 (0) 1604 760017
e-maiI: salescartooluk.co.uk
CARTOOL GmbH
Straussenlettenstrasse 15
85053 ngolstadt
Germany
TEL: +49 (0) 841 9650080
FAX: +49 (0) 841 9650090
e-maiI: i.amanncartool.de
TestBook
TestBook is a computerised workshop tool which
provides your dealership with instant access to the
very latest Technical nformation from MG ROVER,
allowing for accurate and effective fault diagnosis
and repair of all MG Rover Vehicles.
Where specific garage equipment is required for
diagnosis and repair, reference should be made to
the Service Tools and Equipment Programme where
details of the equipment recommended by MG
Rover Service may be found.
Body repairs
Any damage found, that would affect the corrosion
resistance of the vehicle during the Warranty period
must be rectified by an authorised MG Rover Dealer
to the standards, and by the methods, detailed in the
Body Repair Manual.
RepIacement body paneIs
Body panels are supplied coated in cathodic
electrocoat primer.
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GENERAL INFORMATION
DYNAMOMETER TESTING
GeneraI
MPORTANT: Use a four wheel dynamometer for
brake testing if possible.
WARNING: Do not attempt to test an ABS
function on a dynamometer.
Four wheeI dynamometers
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the
tyres.
Before testing a vehicle with anti-lock brakes on a
four wheel dynamometer, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.
Two wheeI dynamometers
ABS will not function on a two wheel dynamometer.
The ABS light will illuminate during testing. Normal
braking will be available.
f brake testing on a two wheel dynamometer is
necessary, the following precautions should be
taken:
Traction control must be disabled
Neutral selected in gearbox
When checking brakes, run engine at idle speed to
maintain servo-vacuum.
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GENERAL INFORMATION
FUEL HANDLING PRECAUTIONS 1
FUEL HANDLING PRECAUTIONS
GeneraI
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. t also outlines other areas of risk
which must not be ignored. This information is
issued for basic guidance only, if in doubt consult
your local Fire Officer.
Fuel vapour is highly flammable and in confined
spaces is also explosive and toxic. The vapour is
heavier than air and will always fall to the lowest
level. The vapour can be easily distributed
throughout a workshop by air currents;
consequently, even a small spillage of fuel is
potentially very dangerous.
Always have a fire extinguisher containing FOAM,
CO
2
, GAS or POWDER close at hand when
handling or draining fuel or when dismantling fuel
systems. Fire extinguishers should also be located
in areas where fuel containers are stored.
Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.
Whenever fuel is being handled, drained or stored,
or when fuel systems are being dismantled, all forms
of ignition must be extinguished or removed; any
leadlamps must be flameproof and kept clear of
spillage.
WARNING: No one shouId be permitted to
repair components associated with fueI
without first having speciaIist training.
WARNING: Do not remove fueI system
components whiIe the vehicIe is over a pit.
FueI tank draining
Fuel tank draining should be carried out in
accordance with the procedure outlined in the 'FUEL
DELIVERY' section of this manual and observing
the following precautions:
WARNING: FueI must not be extracted or
drained from any vehicIe whiIst it is over a
pit.
Draining or extraction of fueI must be carried out
in a weII ventiIated area.
The capacity of containers for fueI must be more
than adequate for the fuII amount of fueI to be
extracted or drained. The container shouId be
cIearIy marked with its contents and pIaced in a
safe storage area which meets the requirements
of IocaI authority reguIations.
CAUTION: When fueI has been extracted
or drained from a fueI tank the precautions
governing naked Iights and ignition
sources shouId be maintained.
FueI tank removaI
When the fuel line is secured to the fuel tank outlet
by a spring steel clip, the clip must be released
before the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual fumes in the fuel tank being ignited when
the clip is released.
As an added precaution fuel tanks should have a
'FUEL VAPOUR' warning label attached to them as
soon as they are removed from the vehicle.
FueI tank repairs
No attempt should be made to repair a plastic fuel
tank. f the structure of the tank is damaged, a new
tank must be fitted.
Body repairs
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.
When body repairs involve the use of heat, all fuel
pipes which run in the vicinity of the repair area must
be removed, and the tank outlet plugged, BEFORE
HEAT S APPLED. f the repair is in the vicinity of
the fuel tank, the tank must be removed.
WARNING: If weIding is to be carried out
in the vicinity of the fueI tank, the fueI
system must be drained and the tank
removed before weIding commences.
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GENERAL INFORMATION
2 FUEL HANDLING PRECAUTIONS
Quick fit fueI hose connectors
WARNING: Hose connections between the
fueI pump and the fueI raiI contain fueI
under pressure, which MUST be reIieved
prior to disconnection of the hoses. See
ENGINE MANAGEMENT SYSTEM - MEMS,
Adjustments.
1. Wipe connection and surrounding area using a
lint free cloth.
NOTE: If the connection is heaviIy soiIed
with road saIt and dirt, gentIy twist
connector whiIe spraying with WD40.
2. f necessary use an air line to remove
contaminates from the retainer area of the
connector.
3. Depress collar and disconnect hose.
4. Ensure pipe end is clean and free from
corrosion.
5. Lubricate pipe end with clean engine oil.
6. Connect hose to pipe and push firmly into
position until a click is heard.
7. Check security of connection by pulling on
connector.
CAUTION: When checking security of
connector puII on connector body NOT on
the hose.
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GENERAL INFORMATION
ELECTRICAL PRECAUTIONS 1
ELECTRICAL PRECAUTIONS
GeneraI
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to
the electrical and electronic components fitted to the
vehicle. Where necessary, specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
Equipment
Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. t is particularly important to check
the condition of the lead and plugs of mains
operated equipment.
PoIarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.
High VoItage 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
ECU's. Exercise caution when measuring the
voltage on the coil terminals while the engine is
running, high voltage spikes can occur on these
terminals.
Connectors and Harness
The engine compartment of a vehicle is a
particularly hostile environment for electrical
components and connectors:
Always ensure electrically related items are dry
and oil free before disconnecting and connecting
test equipment.
Ensure disconnected multiplugs and sensors are
protected from being contaminated with oil,
coolant or other solutions. Contamination could
impair performance or result in catastrophic
failure.
Never force connectors apart using tools to prise
apart or by pulling on the wiring harness.
Always ensure locking tabs are disengaged
before disconnection, and match orientation to
enable correct reconnection.
Ensure that any protection (covers, insulation
etc.) is replaced if disturbed.
Having confirmed a component to be faulty:
Switch off the ignition and disconnect the battery.
Remove the component and support the
disconnected harness.
When replacing the component keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. f the
radio is to be serviced, ensure the security code has
been deactivated.
CAUTION: To prevent damage to eIectricaI
components, ALWAYS disconnect the
battery when working on the vehicIe's
eIectricaI system. The ground Iead must be
disconnected first and reconnected Iast.
AIways ensure that battery Ieads are routed
correctIy and are not cIose to any potentiaI
chafing points.
Battery charging
Only recharge the battery with it removed from the
vehicle. Always ensure any battery charging area is
well ventilated and that every precaution is taken to
avoid naked flames and sparks.
Ignition system safety precautions
The vehicle's ignition system produces high voltage
and the following precautions should be observed
before carrying out any work on the system.
WARNING: Before commencing work on
an ignition system, ensure aII high tension
terminaIs, adapters and diagnostic
equipment are adequateIy insuIated and
shieIded to prevent accidentaI personaI contacts
and minimise the risk of shock.
WARNING: Wearers of surgicaIIy
impIanted pacemaker devices shouId not
be in cIose proximity of ignition circuits or
diagnostic equipment.
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GENERAL INFORMATION
2 ELECTRICAL PRECAUTIONS
DiscipIines
Switch off the ignition prior to making any connection
or disconnection in the system to prevent electrical
surges caused by disconnecting 'live' connections
damaging electronic components.
Ensure hands and work surfaces are clean and free
of grease, swarf, etc. Grease collects dirt which can
cause electrical tracking (short-circuits) or
high-resistance contacts.
When handling printed circuit boards, treat with care
and hold by the edges only; note that some
electronic components are susceptible to body
static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors.
Damaged contacts can cause short- circuit and
open-circuit fault conditions.
Prior to commencing test, and periodically during a
test, touch a good vehicle body earth to discharge
static. Some electronic components are vulnerable
to static electricity that may be generated by the
operator.
Grease for eIectricaI connectors
Some under bonnet and under body connectors may
be protected against corrosion by the application of
a special grease during vehicle production. Should
connectors be disturbed in service, repaired or
replaced, additional grease should be applied:
Part No. BAU 5811, available in 150 g tubs.
NOTE: The use of greases other than
BAU 5811 must be avoided as they can
migrate into reIays, switches etc.
contaminating the contacts and Ieading to
intermittent operation or faiIure.
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GENERAL INFORMATION
SRS PRECAUTIONS 1
SUPPLEMENTARY RESTRAINT SYSTEM
PRECAUTIONS
GeneraI
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 of SRS
components fitted to the vehicle.
WARNING: AIways foIIow the 'SRS
Precautions' and the correct procedures
for working on SRS components. Persons
working on SRS systems must be fuIIy trained
and have been issued with copies of the safety
guideIines.
WARNING: It is imperative that before any
work is undertaken on the SRS system the
appropriate information is read
thoroughIy.
WARNING: Some airbag moduIes contain
sodium azide which is poisonous and
extremeIy fIammabIe. Contact with water,
acid or heavy metaIs may produce harmfuI or
expIosive compounds. Do not dismantIe,
incinerate or bring into contact with eIectricity,
before the unit has been depIoyed.
WARNING: AIways repIace a seat beIt
assembIy that has withstood the strain of
a severe vehicIe impact, or if the webbing
shows signs of fraying.
WARNING: AIways disconnect the vehicIe
battery before carrying out any eIectricaI
weIding on a vehicIe fitted with an SRS
system.
CAUTION: Do not expose an airbag
moduIe or seat beIt pre-tensioner to heat
exceeding 85 C (185 F).
t should be noted that these precautions are not
restricted to operations performed when servicing
the SRS system, the same care should be exercised
when working on ancillary systems and components
located in the vicinity of SRS components; these
include, but are not limited to:
Steering system - steering wheel airbag, rotary
coupler
Front fascia - passenger front airbag (where
fitted)
Centre consoIe - SRS DCU and SRS
harnesses.
EIectricaI system - SRS harnesses, link leads
and connectors
Making the system safe
Before working on, or in the vicinity of SRS
components, ensure the system is rendered safe by
performing the following procedures:
Remove the ignition key from the ignition switch.
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GENERAL INFORMATION
2 SRS PRECAUTIONS
Disconnect both battery leads, earth lead first
before beginning work.
Wait 10 minutes for the SRS DCU back-up
power circuit to discharge.
The SRS system uses energy reserve capacitors to
keep the system active in the event of electrical
supply failure under crash conditions. t is necessary
to allow the capacitor sufficient time to discharge (10
minutes) in order to avoid the risk of accidental
deployment.
WARNING: AIways disconnect both
battery Ieads before beginning work on
the SRS system. Disconnect the negative
battery Iead first. Never reverse connect the
battery.
INSTALLATION
n order to assure system integrity, it is essential that
the SRS system is regularly checked and
maintained so that it is ready for effective operation
in the event of a collision. Carefully inspect SRS
components before installation. Do not install a part
that shows signs of being dropped or improperly
handled, such as dents, cracks or deformation.
WARNING: The integrity of the SRS
system components are criticaI for safety
reasons. Ensure the foIIowing precautions
are aIways adhered to:
Never instaII used SRS components from
another vehicIe or attempt to repair an SRS
component.
When repairing an SRS system, onIy use
genuine new parts.
Never appIy eIectricaI power to an SRS
component unIess instructed to do so as part
of an approved test procedure.
SpeciaI Torx boIts are necessary for instaIIing
the airbag moduIe - do not use other boIts.
Ensure boIts are tightened to the correct
torque.
AIways use new fixings when repIacing an
SRS component.
Ensure the SRS Diagnostic ControI Unit
(DCU) is aIways instaIIed correctIy. There
must not be any gap between the DCU and
the bracket to which it is mounted. An
incorrectIy mounted DCU couId cause the
system to maIfunction.
CAUTION: Ensure SRS components are
not contaminated with oiI, grease,
detergent or water.
CAUTION: Torque wrenches shouId be
reguIarIy checked for accuracy to ensure
that aII fixings are tightened to the correct
torque.
NOTE: If the SRS component is to be
repIaced, the bar code of the new unit
must be recorded.
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GENERAL INFORMATION
SRS PRECAUTIONS 3
SRS component testing precautions
The SRS components are triggered using relatively
low operating currents, always adhere to the
following precautions:
WARNING: Do not use a muItimeter or
other generaI purpose test equipment on
SRS system components or accidentaI
depIoyment may occur. OnIy use 'Testbook' to
diagnose SRS system fauIts.
WARNING: Do not use eIectricaI test
equipment on the SRS harness whiIe it is
connected to any of the SRS system
components. It may cause accidentaI
depIoyment and personaI injury.
HandIing and storage
There are regulations for the safe storage of SRS
components which must be observed, consult your
local authority for details.
WARNING: The SRS components are
sensitive and potentiaIIy hazardous if not
handIed correctIy; aIways compIy with the
foIIowing handIing precautions:
Never drop a SRS component. The airbag
diagnostic controI unit is a particuIarIy shock
sensitive device and must be handIed with
extreme care. Airbag moduIes couId depIoy if
subjected to a strong shock.
Never wrap your arms around an airbag
moduIe. If an airbag moduIe has to be carried,
hoId it by the cover, with the cover uppermost
and the base away from your body.
Never transport airbag moduIes in the cabin
of a vehicIe. AIways use the Iuggage
compartment of the vehicIe for carrying
airbag moduIes.
WARNING: Never attach anything to an
airbag cover or any trim component
covering an airbag moduIe. Do not aIIow
anything to rest on top of an airbag moduIe.
WARNING: AIways keep components cooI,
dry and free from contamination.
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GENERAL INFORMATION
4 SRS PRECAUTIONS
WARNING: Store airbag moduIes with the
depIoyment side uppermost. If airbag
moduIes are stored depIoyment side
down, accidentaI depIoyment wiII propeI the
airbag moduIe with enough force to cause
serious injury.
WARNING: Airbag moduIes are cIassed as
expIosive devices. For overnight and
Ionger term storage, they must me stored
in a secure steeI cabinet which has been
approved as suitabIe for the purpose and has
been registered by the IocaI authority.
WARNING: Store the airbag moduIe in a
designated storage area. If there is no
designated storage area avaiIabIe, store in
the Iocked Iuggage compartment/Ioadspace of
the the vehicIe and inform the workshop
supervisor.
CAUTION: Improper handIing or storage
can internaIIy damage the airbag moduIe,
making it inoperative. If you suspect the
airbag moduIe has been damaged, instaII a new
moduIe and refer to the DepIoyment/DisposaI
Procedures to determine the correct method for
disposaI of the damaged moduIe.
WARNING: When handIing front seat beIt
buckIe pre-tensioners, hoId by the piston
tube, with the open end of the piston tube
pointing towards the ground and the buckIe
facing away from your body.
DO NOT cover the end of the piston tube.
DO NOT hoId buckIe pre-tensioners by the
bracket assembIy or steeI cabIe.
NEVER point the piston tube towards your
body or other peopIe.
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GENERAL INFORMATION
SRS PRECAUTIONS 5
SRS Harnesses and Connectors
CAUTION: AIways observe the foIIowing
precautions with regards to the SRS
system eIectricaI wiring:
Never attempt to modify, spIice or repair SRS
wiring.
Never instaII eIectronic equipment (such as a
mobiIe teIephone, two-way radio or in-car
entertainment system) in such a way that it
couId generate eIectricaI interference in the
SRS system harness. Seek speciaIist advice
when instaIIing such equipment.
NOTE: SRS system wiring can usuaIIy be
identified by a speciaI yeIIow outer sIeeve
protecting the wires (bIack with yeIIow
stripe protective coverings are sometimes used).
WARNING: AIways ensure SRS wiring is
routed correctIy. Be carefuI to avoid
trapping or pinching the SRS wiring. Do
not Ieave the connectors hanging Ioose or aIIow
SRS components to hang from their harnesses.
Look for possibIe points of chafing.
CAUTION: Ensure aII SRS component
harness connectors are mated correctIy
and secureIy fastened. Do not Ieave the
connectors hanging Ioose.
Rotary CoupIer Precautions
CAUTION: AIways foIIow the procedure for
fitting and checking the rotary coupIer as
instructed in the 'SRS Repairs' section of
this manuaI. CompIy with aII safety and
instaIIation procedures to ensure the system
functions correctIy. Observe the foIIowing
precautions:
Do not unIock and rotate the rotary coupIer
when it is removed from the vehicIe.
Do not turn the road wheeIs when the rotary
coupIer is removed from the vehicIe.
AIways ensure the rotary coupIer is removed
and instaIIed in its centered position and with
the front road wheeIs in a straight ahead
position - refer to the 'SRS Repairs' section of
this manuaI for the correct removaI and
instaIIation procedure.
If a new rotary coupIer is being instaIIed,
ensure the Iocking tab hoIding the coupIer's
rotationaI position is not broken; units with a
broken Iocking tab shouId not be used.
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GENERAL INFORMATION
6 SRS PRECAUTIONS
WARNING LABELS
Warning symbols relating to the SRS system are
displayed at various positions in the vehicle. SRS
components have additional warning labels
displayed on them to indicate that particular care is
needed when handling them. These include airbag
modules, DCU and the rotary coupler.
The following warning labels may be displayed
together or individually at various locations on the
vehicle:
A - The need for caution when working in close
proximity to SRS components.
B - Refer to the publication where the procedures,
instructions and advice can be found (usually
Workshop Manual or Owner's Handbook) for
working on the SRS system.
C - Do not use rear facing child seats in the front
passenger seat if the vehicle is fitted with a
passenger airbag.
WARNING: It is imperative that before any
work is undertaken on the SRS system the
appropriate information is read
thoroughIy.
NOTE: The foIIowing Iist indicates current
Iocations for warning IabeIs. Exact
positions may vary dependent on
IegisIation and market trends.
Bonnet Iocking pIatform
Refer to the Owner's Handbook for information on
the airbag system
Rotary CoupIer
A - SRS - Refer to the Workshop Manual for detailed
instructions.
B - Ensure wheels are in the straight ahead position
before removal and refitting of the rotary coupler.
C - MG Rover Part number/Bar code: the code
number must be recorded if the rotary coupler is to
be replaced.
CAUTION: DO NOT ROTATE THE ROTARY
COUPLER MECHANISM
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GENERAL INFORMATION
SRS PRECAUTIONS 7
Door gIass
Refer to the Owner's Handbook for information on
the airbag system.
Airbag moduIe - driver
A - MG Rover Part Number / Bar Code - The code
number must be quoted when ordering a
replacement module.
An 'SRS ARBAG' legend is also moulded into the
centre pad to identify the presence of a driver's
airbag.
Diagnostic ControI Unit
A - Refer to the Workshop Manual for information on
the airbag system.
B - MG Rover Part Number / Bar Code - The code
number must be recorded if the airbag control and
diagnostic unit is to be replaced.
Airbag moduIe - passenger
A - MG Rover Part Number / Bar code - The code
number must be quoted when ordering a
replacement module.
Front seat beIt pre-tensioners
Exercise caution.
Refer to the publication where the procedures,
instructions and advice can be found (usually
Workshop Manual or Owner's Handbook) for
working on the SRS system.
Do not attempt to repair or disassemble.
Bar codes
Bar codes are fitted to SRS components and other
components which are critically related to SRS
operation. The code number(s) must be recorded if
the component is to be replaced.
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GENERAL INFORMATION
8 SRS PRECAUTIONS
VEHICLE RECOVERY
Towing - SRS components not depIoyed:
Normal towing procedures are unlikely to cause an
airbag to deploy. However, as a precaution, switch
the ignition off and then disconnect both battery
leads. Disconnect the '-ve' lead first.
Towing - SRS components depIoyed:
f the driver's airbag has been deployed, the vehicle
must have a suspended tow. However, as a
precaution, switch the ignition off and then
disconnect both battery leads. Disconnect the '-ve'
lead first.
SRS COMPONENT DEPLOYMENT
f a vehicle is to be scrapped and it contains an
undeployed airbag or seat belt pre-tensioner
module, the module must be manually deployed.
Always observe the following precautions:
WARNING: OnIy personneI who have
undergone the appropriate training shouId
undertake depIoyment of air bag and seat
beIt pre-tensioner moduIes.
WARNING: A depIoyed airbag or seat beIt
pre-tensioner is very hot, DO NOT return
to a depIoyed airbag moduIe or seat beIt
pre-tensioner untiI at Ieast 30 minutes have
eIapsed since depIoyment.
WARNING: OnIy use approved
depIoyment equipment, and onIy depIoy
SRS components in a weII ventiIated and
speciaIIy designated area. Ensure SRS
components are not damaged or ruptured before
depIoyment. Notify the reIevant authorities.
WARNING: If a vehicIe is to be scrapped,
undepIoyed airbag moduIes and seat beIt
pre-tensioner units must be depIoyed in
accordance with the instructions provided in this
manuaI.
WARNING: Contact with chemicaIs from
depIoyed and damaged SRS components
couId present a heaIth hazard, wear
protective cIothing when handIing. DO NOT eat,
drink or smoke when handIing SRS components.
WARNING: DepIoyment of airbag moduIes
and seat beIt pre-tensioners can cause
injury to personneI in the cIose vicinity of
the depIoying unit. In case of injury seek urgent
medicaI advice. PossibIe sources of injury
incIude:
Impact - due to infIating airbag or depIoying
seat beIt pre-tensioner operation causing
component 'kick'.
Hearing - due to noise produced by depIoying
airbags and seat beIt pre-tensioner units.
Burns - hot component parts and gases.
Irritation to eyes and Iungs - from depIoying
gases or combustion residue.
WARNING: Ensure the SRS component to
be depIoyed is secureIy fastened to its
mounting.
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GENERAL INFORMATION
SRS PRECAUTIONS 9
WARNING: DepIoyment procedures
detaiIed in this manuaI shouId be strictIy
adhered to. CompIiance with the foIIowing
precautions MUST be ensured:
OnIy use depIoyment equipment approved for
the intended purpose.
Before commencing depIoyment procedure,
ensure the depIoyment tooI functions
properIy by performing the seIf test
procedure detaiIed in the 'SRS Repairs'
section of this manuaI.
DepIoyment of airbag / seat beIt pre-tensioner
moduIes shouId be performed in a weII
ventiIated area which has been speciaIIy
designated for the purpose.
Ensure the airbag / seat beIt pre-tensioner
moduIes are not damaged or ruptured before
attempting to depIoy
Notify the reIevant authorities of the intention
to depIoy airbag and seat beIt pre-tensioner
units.
When depIoying airbag and seat beIt
pre-tensioner units, ensure that aII personneI
are at Ieast 15 metres way from the
depIoyment zone.
Ensure the depIoyment tooI is connected
correctIy, in compIiance with the instructions
detaiIed in this manuaI. In particuIar, ensure
the depIoyment tooI is not connected to the
battery suppIy before connecting to the
airbag or seat beIt pre-tensioner moduIe
connector.
When depIoying seat beIt pre-tensioners in
the vehicIe, ensure the pre-tensioner unit is
fuIIy secured to its fixing point.
When removing depIoyed airbag and seat beIt
pre-tensioner moduIes, wear protective
cIothing. Use gIoves and seaI depIoyed units
in a pIastic bag.
FoIIowing depIoyment of any component of
the SRS system within the vehicIe, aII SRS
components must be repIaced. DO NOT
re-use or saIvage any parts of the SRS
system.
Do not Iean over airbag moduIes or seat beIt
pre-tensioner units when connecting
depIoyment equipment.
SRS COMPONENT REPLACEMENT POLICY
The following information details the policy for
replacement of SRS components; either as a result
of a vehicle accident or as a result of vehicle age.
Impacts which do not depIoy the airbags or seat
beIt pre-tensioners
Check for structural damage in the area of the
impact, paying particular attention to bumper
armatures, longitudinals, crash cans and bracketry.
Impacts which depIoy the airbags or
pre-tensioners
The replacement and inspection policy is dependent
on the type and severity of the crash condition. The
following guidelines are the minimum that should be
exercised as a result of the deployment of specific
SRS components.
Front airbag depIoyment (driver and passenger)
f the front airbags are deployed, the following parts
must be replaced:
Driver airbag module
Passenger airbag module (where fitted)
Flyleads (where applicable) connecting front
airbag modules to SRS harness
Front seat buckle pre-tensioners
Driver's seat belt retractor
Rotary coupler
SRS DCU
n addition, the following should be inspected for
damage and replaced as necessary.
Front passenger's seat belt retractor (webbing,
tongue latching and anchorage point)
Fascia moulding adjacent to passenger airbag
module (where fitted)
Steering wheel (if damage is evident)
Front seat frames and head restraints (if there is
evidence of damage to the seat frame or cushion
pan)
Steering column (if adjustment is lost or there are
signs of collapse)
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GENERAL INFORMATION
10 SRS PRECAUTIONS
Rear impacts
Rear impacts may cause the seat belt
pre-tensioners to deploy. f this occurs, both
pre-tensioner units must be replaced. n addition, the
following components should be inspected for
damage and replaced as necessary:
Seat frames
Seat belts (retractors, webbing, tongue latching
and body anchorage points)
SRS DCU
Periodic repIacement of SRS components
The performance of the propellants within airbags
and pre-tensioners will deteriorate over a period of
time. As a result, it is essential that the airbags and
pre-tensioners are periodically replaced to maintain
occupant safety. Airbags, seat belt pre-tensioners
and the rotary coupler should be replaced at 15 year
intervals.
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GENERAL INFORMATION
AIR CONDITIONING PRECAUTIONS 1
AIR CONDITIONING SYSTEM PRECAUTIONS
GeneraI
The air conditioning system contains fluids and
components which could be potentially hazardous to
the service engineer or the environment 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 of the Air
Conditioning operating conditions and components
fitted to the vehicle.
Where necessary, additional specific precautions
are detailed in the relevant sections of this Manual,
which should be referred to prior to commencing
repair operations.
The refrigerant used in the air conditioning system is
HFC-134a (Hydrofluorocarbon) R134a.
WARNING: Servicing must onIy be carried
out by personneI famiIiar with both the
vehicIe system and the charging and
testing equipment. AII operations must be
carried out in a weII ventiIated area away from
open fIame and heat sources.
WARNING: R134a is a hazardous Iiquid
and when handIed incorrectIy can cause
serious injury. SuitabIe protective
cIothing, consisting of face protection, heat
proof gIoves, rubber boots and rubber apron or
waterproof overaIIs, must be worn when carrying
out operations on the air conditioning system.
RemediaI actions
f an accident involving R134a should occur, conduct
the following remedial actions:
f liquid R134a enters the eye, do not rub it.
Gently run large quantities of eye wash over the
affected eye to raise the temperature. f an eye
wash is not available, cool clean water may be
used to flush the eye. After rinsing, cover the eye
with a clean pad and seek immediate medical
attention.
f liquid R134a is splashed onto the skin, run
large quantities of water over the affected area to
raise the temperature. mplement the same
action if the skin comes in contact with
discharging cylinders. Wrap the contaminated
body parts in blankets (or similar materials) and
seek immediate medical attention.
f the debilitating effects of inhalation of R134a
vapour is suspected, seek fresh air. f the
affected person is unconscious, move them away
from the contaminated area to fresh air and apply
artificial respiration and / or oxygen and seek
immediate medical attention.
WARNING: Due to its Iow evaporating
temperature, R134a must be handIed with
care. R134a spIashed on any part of the
body wiII cause immediate freezing of that area.
AIso, refrigerant cyIinders and repIenishment
troIIeys when discharging wiII freeze skin to
them if contact is made.
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GENERAL INFORMATION
2 AIR CONDITIONING PRECAUTIONS
Service precautions
Observe the following precautions when handling
components used in the air conditioning system:
Air conditioning units must not be lifted by their
hoses, pipes or capillary lines.
Hoses and lines must not be subjected to any
twist or stress; the efficiency of the system will be
impaired by kinks or restrictions. Ensure that
hoses are correctly positioned before tightening
couplings, and ensure that all clips and supports
are utilised.
Flexible hoses should not be positioned close to
the exhaust manifold (less than 100 mm) unless
protected by heat shielding.
Completed assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of components and panels may
transmit noise and so must be eliminated.
The appropriate torque wrench must be used
when tightening refrigerant connections to the
stipulated value. An additional spanner must be
used to hold the union to prevent twisting of the
pipe when tightening connections.
Before connecting any hose or pipe, ensure that
refrigerant oil is applied to the seat of the new 'O'
rings BUT NOT to the threads of the connection.
All protective plugs must remain in place to seal
the component until immediately prior to
connection.
Ensure components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters it.
Components must not remain uncapped for
longer than 15 minutes. n the event of a delay,
the caps must be fitted.
When disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt and
moisture into the system.
The receiver / drier contains dessicant which
absorbs moisture. t must be positively sealed at
all times. A receiver / drier that has been left
uncapped must not be used, fit a new unit.
The receiver / drier should be the last component
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 are marked for use with
R13a.
When a major repair has been completed, a leak
test should be conducted; refer to the 'AR
CONDTONNG' section of this manual for the
correct procedure.
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GENERAL INFORMATION
AIR CONDITIONING PRECAUTIONS 3
AIR CONDITIONING COMPRESSOR
REPLACEMENT
Air Conditioning Compressor RepIacement
A new compressor is supplied filled with a full
charge of (X cm
3
) of refrigerant oil. Refer to the
'CAPACITIES, FLUIDS AND LUBRICANTS'
section of this manuaI for the actuaI capacities.
A calculated quantity of oil must be drained from the
new compressor before fitting. To calculate the
quantity of oil to be drained:
1. Remove the drain plug from the old
compressor.
2. nvert the compressor and gravity drain the oil
into a calibrated measuring cylinder. Rotate the
compressor clutch to ensure the compressor is
completely drained.
3. Note the quantity of oil drained (Y cm
3
).
4. Calculate the quantity of oil to be drained from
the new compressor using the following
formula:
X cm
3
- (Y cm
3
+ 20 cm
3
) = Q cm
3
5. Remove the drain plug from the new
compressor and drain Q cm
3
of oil.
6. Fit and tighten the compressor drain plug.
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INFORMATION
CONTENTS Page
GENERAL DATA
ENGNE - K SERES 1 ................................................................................................
1.6MPi 1 ....................................................................................................................
1.8MPi 1 ....................................................................................................................
1.8 VVC 1 ..................................................................................................................
ENGNE - LUBRCATON 6 .........................................................................................
FUEL SYSTEM 6 .........................................................................................................
COOLNG SYSTEM 6 ..................................................................................................
CLUTCH 7 ...................................................................................................................
MANUAL GEARBOX 7 ................................................................................................
STEPSPEED (Em-CVT) GEARBOX 8 ........................................................................
GEARBOX - LUBRCATON 8 .....................................................................................
Manual Gearbox 8 ....................................................................................................
Stepspeed (Em-CVT) 8 .............................................................................................
FNAL DRVE 9 ............................................................................................................
Manual gearbox - MPi 9 ............................................................................................
Manual gearbox - VVC 9 ...........................................................................................
Stepspeed (Em-CVT) - 1.8 MPi 10 ...........................................................................
STEERNG 11 .............................................................................................................
FRONT SUSPENSON 12 ...........................................................................................
REAR SUSPENSON 12 .............................................................................................
BRAKES 13 .................................................................................................................
WHEELS 14 .................................................................................................................
TYRE SZES 14 ...........................................................................................................
TYRE PRESSURES 15 ...............................................................................................
AR CONDTONNG 15 ..............................................................................................
ELECTRCAL 16 ..........................................................................................................
DMENSONS 16 .........................................................................................................
WEGHTS 17 ...............................................................................................................
BULBS 18 ....................................................................................................................
ENGINE TUNING DATA
ENGNE TUNNG DATA 1 ...........................................................................................
TORQUE WRENCH SETTINGS
ENGNE 1 ....................................................................................................................
MODULAR ENGNE MANAGEMENT SYSTEM - MEMS 3 3 ......................................
COOLNG 4 .................................................................................................................
MANFOLD AND EXHAUST 4 .....................................................................................
CLUTCH 4 ...................................................................................................................
MANUAL GEARBOX 5 ................................................................................................
DRVE SHAFTS 6 ........................................................................................................
STEERNG 6 ...............................................................................................................
SUSPENSON 7 ..........................................................................................................
BRAKES 8 ...................................................................................................................
SUPPLEMENTARY RESTRANT SYSTEM 9 .............................................................
BODY 9 ........................................................................................................................
HEATNG AND VENTLATON 10 ...............................................................................
AR CONDTONNG 10 ..............................................................................................
WPERS AND WASHERS 10 ......................................................................................
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INFORMATION
CONTENTS Page
ELECTRCAL 11 ..........................................................................................................
LIFTING AND TOWING
JACKNG, SUPPORTNG AND TOWNG 1 ................................................................
WORKSHOP JACK 2 ..................................................................................................
WHEEL-FREE LFT 2 ..................................................................................................
RECOVERY 2 ..............................................................................................................
TOWNG 3 ...................................................................................................................
CAPACITIES, FLUIDS AND LUBRICANTS
CAPACTES 1 .............................................................................................................
FLUDS 1 .....................................................................................................................
LUBRCATON 3 ..........................................................................................................
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INFORMATION
GENERAL DATA 1
ENGINE - K SERIES
1.6 MPi
Type 16 valve DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder arrangement 4 in line - transverse, No.1 cylinder at front of engine . . . . . . . . . . . . . . . . . . . . . . . .
Bore - liner 80.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke 79.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity 1589 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order 1 - 3 - 4 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation Clockwise, viewed from the front of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression ratio 10.5 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
dle speed
1.6 MPi MEMS 3 825 50 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum power 85 kW (114 bhp) 6,250 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum torque 145 Nm 4,700 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum engine speed 6,800 rev/min. . . . . . . . . . . . . . . . . . . . . . .
1.8 MPi
Type 16 valve DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore - liner 80.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke 89.30 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity 1796 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order 1 - 3 - 4 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dle speed
1.8 MPi MEMS 3 (Manual and Stepspeed) 825 50 rpm . . . . . . .
Maximum power:
Manual Transmission 100 kW (134 bhp) 6,750 rev/min. . . . . . . . . . . . . . . . . . . . . . . .
Stepspeed (Em-CVT) 88 kW (118 bhp) 5,500 rev/min. . . . . . . . . . . . . . . . . . . . . . . .
Maximum torque:
Manual Transmission 165 Nm 5,000 rev/min. . . . . . . . . . . . . . . . . . . . . . . .
Stepspeed (Em-CVT) 165 Nm 3,000 rev/min. . . . . . . . . . . . . . . . . . . . . . . .
Maximum engine speed:
Manual transmission 6,800 rev/min. . . . . . . . . . . . . . . . . . . . . . . . .
Stepspeed (Em-CVT) 6,000 rev/min. . . . . . . . . . . . . . . . . . . . . . . .
1.8 VVC
Type 16 valve DOHC with Variable Valve Control on inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bore - liner 80.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke 89.30 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity 1796 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order 1 - 3 - 4 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dle speed
1.8 VVC MEMS3 925 50 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum power 118 kW (158 bhp) 6,900 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum torque 174 Nm 4,700 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum engine speed 7,100 rev/min. . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
2 GENERAL DATA
Engine weight - nominal (fully dressed, wet) 108 kg . . . . . .
Engine dimensions:
Length (nominal 654 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width (nominal) 600 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Height (nominal) 615 mm . . . . . . . . . . . . . . . . . . . . . . . . . . .
CyIinder bIock
Material Aluminium alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder liner type Damp, bottom half stepped - sliding fit into lower part of . . . . . . . . . . . . . . . . . . . . . . . . . . .
cylinder block
Cylinder liner bore:
RED grade A 80.000 - 80.015 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLUE grade B 80.016 - 80.030 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CyIinder head
Material Aluminium alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum warp 0.05 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head height (New) 118.95 - 119.50 mm . . . . . . . . . . . . . . . . . . . .
Reface limit 0.20 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft
End-float 0.10 - 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit 0.34 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearings
Quantity 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type Steel backed, aluminium / tin lined, oil grooves in upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
halves, plain in bearing caps
Thrust washers Halves at No.3 main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust washer halves thickness 2.61 - 2.65 mm . . . . . . . . . . . . . . . .
Main journal tolerance:
Grade 1 48.000 - 48.007 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grade 2 47.993 - 48.000 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grade 3 47.986 - 47.993 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in bearings 0.013 - 0.043 mm . . . . . . . . . . . . . . . . . . . . . . . .
Maximum out of round 0.010 mm . . . . . . . . . . . . . . . . . . . . . . . .
Big-end bearings
1.6:
Big-end journal diameter 47.986 - 48.007 mm . . . . . . . . . . . . . . . . . . . . .
Big-end journal tolerances:
- Grade A 43.000 - 43.007 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Grade B 42.993 - 43.000 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Grade C 42.986 - 42.993 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in bearings 0.021 - 0.049 mm . . . . . . . . . . . . . . . . . . . . . . .
Maximum out of round 0.010 mm . . . . . . . . . . . . . . . . . . . . . . .
1.8:
Big-end journal diameter 47.986 - 48.007 . . . . . . . . . . . . . . . . . . . . .
Big-end journal tolerances:
- Grade A 48.000 - 48.007 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Grade B 47.993 - 48.000 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Grade C 47.986 - 47.993 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in bearings 0.021 - 0.049 mm . . . . . . . . . . . . . . . . . . . . . . .
Maximum out of round 0.010 mm . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
GENERAL DATA 3
Connecting rods
Type Horizontally split big-end, plain small end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Big-end bearing / Connecting rod end-float 0.10 - 0.25 mm . . . . . . . .
Pistons
Type Aluminium alloy, tin plated, thermal expansion with offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gudgeon pin
Piston diameter:
Grade A 79.975 - 79.990 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grade B 79.991 - 80.005 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in bore 0.01 - 0.04 mm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum ovality 0.30 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston rings
Type:
Top compression ring Barrel faced, granulite coated . . . . . . . . . . . . . . . . . . . . . . .
2nd compression ring Tapered, phosphate coated . . . . . . . . . . . . . . . . . . . . . . .
Oil control ring Nitrided ring with radii and spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New ring to groove clearance:
Top compression ring 0.040 - 0.072 mm . . . . . . . . . . . . . . . . . . . . . . .
2nd compression ring 0.030 - 0.062 mm . . . . . . . . . . . . . . . . . . . . . . .
Oil control ring 0.010 - 0.180 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring fitted gap 20 mm from top of bore:
Piston ring width:
Gudgeon pins
Type Semi-floating, off-set towards thrust side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fit in connecting rod nterference fit . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter:
RED 17.997 - 18.000 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GREEN 17.994 - 17.997 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length 52.3 - 52.6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
4 GENERAL DATA
Camshaft
1.6 & 1.8 without VVC:
Camshaft position Camshaft incorporates target / reluctor ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . .
sensor
Drive Toothed belt driven from crankshaft gear, automatically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
tensioned
Bearings 6 per camshaft, direct line bored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing clearance 0.060 - 0.094 mm . . . . . . . . . . . . . . . . . . . . . . . . . .
- Service limit 0.15 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End-float 0.06 - 0.19 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Service limit 0.3 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 with VVC:
nlet camshaft end-float 0.03 - 0.15 mm . . . . . . . . . . . . . . . . . . . . . .
- Service limit 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust camshaft end-float 0.06 - 0.19 mm . . . . . . . . . . . . . . . . . . .
- Service limit 0.3 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing clearance:
nlet camshaft (25 mm diameter journals) 0.025 - 0.60 mm . . . . . . .
- Service limit 0.1 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
nlet camshaft (40 mm diameter journals) 0.03 - 0.07 mm . . . . . . .
- Service limit 0.1 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust camshaft 0.060 - 0.094 mm . . . . . . . . . . . . . . . . . . . . . . . . . .
- Service limit 0.15 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappets
Type Self-adjusting lightweight hydraulic tappets operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
directly from camshafts
Tappet outside diameter 32.959 - 32.975 mm . . . . . . . . . . . . . . . . . . . . . .
VaIve Springs
K16 without VVC
Colour code Plain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free length 50.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitted length 37.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load - valve closed 250 12 N . . . . . . . . . . . . . . . . . . . . . . . . .
Load - valve open 450 18 N . . . . . . . . . . . . . . . . . . . . . . . . . .
K16 - with VVC:
Colour code Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free length 47.6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitted length 37.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load - valve closed 210 13 N . . . . . . . . . . . . . . . . . . . . . . . . .
Load - valve open 440 22 N . . . . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
GENERAL DATA 5
VaIves
nlet valve stem diameter 5.952 - 5.967 mm . . . . . . . . . . . . . . . . . . . . . .
Exhaust valve stem diameter 5.947 - 5.962 mm . . . . . . . . . . . . . . . . . .
Valve guide inside diameter 6.000 - 6.025 mm . . . . . . . . . . . . . . . . . . .
nlet valve stem to guide clearance 0.033 - 0.063 mm . . . . . . . . . . . . . .
- Service limit 0.07 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust valve stem to guide clearance 0.038 - 0.078 mm . . . . . . . . . . .
-Service limit 0.11 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve guide fitted height 6.00 mm . . . . . . . . . . . . . . . . . . . . .
Valve stem fitted height 38.93 - 39.84 mm . . . . . . . . . . . . . . . . . . . . . .
-Service limit 40.10 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve face angle 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve seat angle (inlet and exhaust) 45 . . . . . . . . . . . . .
Valve seat width (inlet) 1.2 mm . . . . . . . . . . . . . . . . . . . . . . .
Valve seat width (exhaust) 1.6 mm . . . . . . . . . . . . . . . . . . . .
VaIve timing 1.6 & 1.8 MPi
nlet
Opens 11 BTDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 61 ABDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
Opens 21 BBDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 51 ATDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve open period 252 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum valve lift 9.5 mm - inlet . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 mm - exhaust
VaIve timing - 1.8 VVC
nlet
Opens 0 ATDC at minimum period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 40 ABDC at minimum period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
Opens 51 BBDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 21 ATDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve open period
Variable period - inlet 220 to 295 . . . . . . . . . . . . . . . . . . . . . . . .
Valve period - exhaust 252 . . . . . . . . . . . . . . . . . . . . . . .
Variable overlap 21 to 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve lift 9.5 mm - inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 mm - exhaust
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INFORMATION
6 GENERAL DATA
ENGINE - LUBRICATION
System type Wet sump, crankshaft driven eccentric rotor pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump outer rotor to housing clearance 0.28 - 0.36 mm . . . . . . . . . . .
Pump inner rotor tip clearance 0.05 - 0.13 mm . . . . . . . . . . . . . . . . . .
Pump rotor end-float 0.02 - 0.06 mm . . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve opening pressure 4.1 bar . . . . . . . . . . . . . . . . . .
Oil pressure at idle 1.7 to 3.5 bar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve spring length 38.9 mm . . . . . . . . . . . . . . . . . . . . .
Maximum oil pressure at 6500 rev/min 7.0 bar (below 40 C) . . . . . . . . . . .
Oil pressure warning light switch opens 0.3 - 0.5 bar . . . . . . . . . .
Oil filter Full flow disposable screw-on canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM
System Returnless Multipoint Fuel njection, electronically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
controlled with electro-mechanical fuel injectors.
Electronic fuel injection data See Engine tuning data. . . . . . . . . . . . . . . . . . . .
Fuel pump
Type Continuous flow, electrically driven roller vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
submerged in fuel tank.
Pump maximum pressure at 13.5 V 3.5 bar . . . . . . . . . . . . .
Regulated injection pressure 3.0 0.2 bar . . . . . . . . . . . . . . . . . . .
Fuel pump delivery 39 litres 3.0 bar . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter n-tank lifetime fit; mesh area 584 cm
2
, mesh size 8 to 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
microns
Air cleaner Paper element type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel grade 95 RON minimum - UNLEADED fuel to EN228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
specification
CAUTION: Serious damage to the engine may occur if a Iower octane number fueI than recommended
is used. Serious damage to the cataIyst wiII occur if LEADED fueI is used.
COOLING SYSTEM
Pressure cap opens 1.03 bar . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat
starts to open 86 to 90 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fully open 102 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling fan switch, operating temperature ON - 102 C, OFF - 96 C . . . . . . . .
Second cooling fan switch, operating temperature ON - 117 C, OFF - 112 C . .
Engine bay fan switch, operating temperature ON - 75 C, OFF - 65 C . . . . .
Engine bay ambient air, warning light switch:
MPi ON - 130 C, OFF - 110 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VVC ON - 85 C, OFF - 75 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
GENERAL DATA 7
CLUTCH
Type Single plate diaphragm spring, hydraulically operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch plate diameter
1.6 MPi 200 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 MPi & VVC 215 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diaphragm finger clearance 1.00 mm . . . . . . . . . . . . . . . . . . .
Diaphragm finger height
New 29.1 - 32.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit 36.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch plate thickness
New 7.40 - 6.90 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit 5.60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rivet depth
New 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit 0.20 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch plate run-out
New 0.80 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service limit 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure plate warping - service limit 0.18 mm . . . . . . . . . . . .
MANUAL GEARBOX
1.6 MPi
Gearbox code C6 BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear ratios
Fifth 0.765 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth 1.033 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third 1.308 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second 1.842 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First 3.167 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse 3.000 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 MPi
Gearbox code C4 BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear ratios
Fifth 0.765 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth 1.033 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third 1.308 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second 1.842 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First 3.167 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse 3.000 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 VVC
Gearbox code C4 BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear ratios
Fifth 0.765 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth 1.033 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third 1.308 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second 1.842 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First 3.167 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse 3.000 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
8 GENERAL DATA
STEPSPEED (Em-CVT) GEARBOX
1.8 MPi
Gearbox code VT1-11A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear ratios (Stepspeed manual mode only)
Sixth 0.518 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fifth 0.681 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth 0.845 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third 1.123 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second 1.520 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First 2.416 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse 2.658 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Em-CVT max. 0.443 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX - LUBRICATION
ManuaI Gearbox
Capacities
Refill 2.2 litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dry 2.4 litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluids and Lubricants
Gearbox oil specification Texaco MTF 94 . . . . . . . . . . . . . . . . . . . . . .
Caltex MTF94
Unipart MTF94
Gear linkage grease specification Unipart multi-purpose lithium grease or equivalent. . . . . . . . . . . . . . . .
Stepspeed (Em-CVT)
Capacities
Refill - gearbox only 4.5 litres . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid cooler and lines 1.0 litre . . . . . . . . . . . . . . . . . . . . . . . . .
Fluids and Lubricants
Gearbox fluid specification Esso EZL799 . . . . . . . . . . . . . . . . . . . .
Unipart CVT
Esso CVT
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INFORMATION
GENERAL DATA 9
FINAL DRIVE
ManuaI gearbox - 1.6 MPi
Gearbox code C6 BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratio 3.938 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road speed at 1000 rev/min
Fifth 35.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 mph
Fourth 26.4 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4 mph
Third 20.8 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0 mph
Second 14.8 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 mph
First 8.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 mph
ManuaI gearbox - 1.8 MPi
Gearbox code C4 BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratio 4.200 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Vehicles with 205 tyres)
Fifth 35.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 mph
Fourth 26.4 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4 mph
Third 20.8 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.0 mph
Second 14.8 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 mph
First 8.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 mph
Fifth 35.1 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 mph
Fourth 26.0 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2 mph
Third 20.5 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 mph
Second 14.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 mph
First 8.5 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 mph
ManuaI gearbox - 1.8 VVC
Gearbox code C4 BP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratio 4.200 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fifth 33.4 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.8 mph
Fourth 24.8 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 mph
Third 19.5 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 mph
Second 13.9 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 mph
First 8.1 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mph
Fifth 32.9 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 mph
Fourth 24.4 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 mph
Third 19.2 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 mph
Second 13.7 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mph
First 7.9 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 mph
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INFORMATION
10 GENERAL DATA
Stepspeed (Em-CVT) - 1.8 MPi
Gearbox code VT1-11A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratio (Manual mode) 5.763 : 1 . . . . . . . . . . . . . . . . . . . . . . . . .
(Stepspeed mode with 205 tyres only)
Sixth 35.9 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3 mph
Fifth 27.4 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.0 mph
Fourth 22.1 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7 mph
Third 16.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 mph
Second 12.3 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 mph
First 7.7 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 mph
(Stepspeed mode with 215 tyres only)
Sixth 35.4 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.0 mph
Fifth 27.0 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8 mph
Fourth 21.7 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mph
Third 16.3 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 mph
Second 12.1 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 mph
First 7.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 mph
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INFORMATION
GENERAL DATA 11
STEERING
NOTE: The foIIowing steering geometry settings are given in degrees and minutes, decimaI parts of a
degree and miIIimetres. Steering and suspension geometry settings are for a vehicIe at unIaden
weight.
Type Speed sensitive, electric power assisted rack and pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front wheel alignment - toe out - per side 0 0' 0 6' . . . . . . . . . 0 0.1
0 mm 0.665 mm
(15" wheels)
0 mm 0.709 mm
(16" wheels)
Front wheel camber - negative 0 30' 0 30' . . . . . . . . . . . . . . . . . 0.50 0.50
3.315 mm 0.315
mm
Front wheel caster - positive 4 50' 1 . . . . . . . . . . . . . . . . . . . 4.83 1.0
29.98 mm 6.71
King pin inclination 11 40' . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71
78.71 mm
Overall steering ratio 17.0 : 1 . . . . . . . . . . . . . . . . . . . . . . . . .
Rear wheel alignment - toe-in - per side 0 15' 0 6' . . . . . . . . . . 0.25 0.1
1.662 mm 0.67 mm
(15" wheels)
1.772 mm 0.71 mm
(16" wheels)
Rear wheel camber - negative 1 0' 0 30' . . . . . . . . . . . . . . . . . . 1.0 0.50
6.71 mm 0.315 mm
Steering wheel diameter 360 mm . . . . . . . . . . . . . . . . . . . . . .
Power Assisted Steering
Type 'Quick' rack and pinion assembly with electric motor power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
assistance to provide Speed Sensitive Steering controlled
by a dedicated Electronic Control Unit (ECU) using a
torque sensor signal and road speed signal to compute
level of steering assistance.
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INFORMATION
12 GENERAL DATA
FRONT SUSPENSION
Type Coil spring over gas filled damper, located by double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
wishbones and with anti-roll bar.
Trim height*
Standard suspension 358 mm 10 mm . . . . . . . . . . . . . . . . . . . . . . . . .
Sports suspension 348 mm 10 mm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front damper colour codes Blue . . . . . . . . . . . . . . . . . . . .
Front coiI spring data:
Total coils 7.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Active coils 6.45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire diameter 12 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free length 241.9 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-roll bar diameter 20 mm . . . . . . . . . . . . . . . . . . . . . . . . .
* = Height to wheel arch from hub centre at unladen weight
REAR SUSPENSION
Type 4-link with coil spring over gas-filled damper and with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
anti-roll bar.
Trim height*
Standard suspension 353 mm 10 mm . . . . . . . . . . . . . . . . . . . . . . . . .
Sports suspension 343 mm 10 mm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear damper colour codes Red . . . . . . . . . . . . . . . . . . . .
Front coiI spring data:
Total coils 7.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Active coils 6.45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire diameter 14 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free length 228.3 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-roll bar diameter 18 mm . . . . . . . . . . . . . . . . . . . . . . . . .
* = Height to wheel arch from hub centre at unladen weight
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INFORMATION
GENERAL DATA 13
BRAKES
Front brakes (Standard)
Type Ventilated disc with 2 pin-slider caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston diameter 48 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc diameter 240 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc thickness new 22 mm . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc minimum thickness 20 mm . . . . . . . . . . . . . . . . . . . . . .
Pad minimum thickness 3 mm . . . . . . . . . . . . . . . . . . . . . . .
Front brakes (Sports)
Type Ventilated disc with 4 pin-slider (opposed) caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc diameter 304 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pad minimum thickness 2.5 mm . . . . . . . . . . . . . . . . . . . . . . .
Rear brakes
Type Solid discs with 2 pin-slider caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc diameter 240 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pad minimum thickness 3 mm . . . . . . . . . . . . . . . . . . . . . . .
Brake servo
Servo boost ratio 4.6 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-lock brake system (where fitted) Bosch ABS5.3 three-channel electronically controlled . . . . . . . . . . . . .
ABS sensor to reluctor ring clearance 0.5 mm . . . . . . . . . . . .
Brake master cyIinder
Bore diameter 23.8 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handbrake
Type Cable operated on rear discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper clearance per side 1 - 2 mm . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
14 GENERAL DATA
WHEELS
Front 6.0J x 15 alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.0J x 16 alloy
Rear 6.0J x 15 alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.0J x 16 alloy
Spare* 5.5J x 14 steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.0J x 16 alloy
Road wheel nut torque 70 Nm . . . . . . . . . . . . . . . . . . . . . . .
TYRE SIZES
Front 185/55 R15 82V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
195/45 R16 84V
Rear 205/50 R15 86V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215/40 ZR16 82W
Spare*
5.5J x 14 steel 175/65 R14 82T . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.0J x 16 alloy 195/45 R16 84V . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE: * Some vehicIes are not fitted with a spare wheeI, but come equipped with an Instant MobiIity
System (IMS) instead. Refer to the Owner's Handbook for detaiIs of how to use the IMS.
CAUTION: The space-saver spare wheeI is for temporary use onIy. Maximum road speed shouId be
Iimited to 50 mph (80 km/h) when a space-saver tyre is in use. No more than one temporary
space-saver spare wheeI may be fitted at any one time.
CAUTION: Refer to the Owner's ManuaI for aII Cautions and Warnings reIated to the IMS. AIways keep
to the recommended speed and adhere to the precautions stipuIated when a defective tyre has been
infIated using the IMS.
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INFORMATION
GENERAL DATA 15
TYRE PRESSURES
NormaI driving conditions:
Front 1.8 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 lbf/in
2
Rear 2.5 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 lbf/in
2
Spare 2.2 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 lbf/in
2
High Speed:
Front 1.9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 lbf/in
2
Rear 2.5 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 lbf/in
2
NormaI driving conditions: - up to two passengers and luggage
High Speed: - driving at speeds in excess of 100 mph (160 km/h)
WARNING: The steeI spare wheeI suppIied with cars fitted with aIIoy wheeIs is for temporary use onIy
and must be changed as soon as possibIe after fitting. The car MUST be driven with caution and
speed MUST NOT exceed 50 mph (80 km/h) with the spare wheeI fitted. No more than one temporary
spare wheeI may be fitted at any one time. RepIacement tyres fitted to the temporary use spare wheeI must
be of the same make and specification as those originaIIy fitted.
CAUTION: Refer to the Owner's ManuaI for aII Cautions and Warnings reIated to the IMS. AIways keep
to the recommended speed and adhere to the precautions stipuIated when a defective tyre has been
infIated using the IMS.
AIR CONDITIONING
Type CFC free, sealed, closed loop system incorporating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
pressure and temperature sensors
Refrigerant type HFC - R134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant charge quantity*:
Manual gearbox 620 10 grammes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Em-CVT gearbox 720 10 grammes . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricating oil Seiko Seiki SK-20, Unipart SK-20, demitsu SK-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System oil fill quantity 170 cm
3
. . . . . . . . . . . . . . . . . . . . . . . .
Trinary switch operating pressures:
Low
Closing pressure 2.0 bar (200 kPa, 29 lbf.in
2
) . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening Pressure 2.4 bar (240 kPa, 34.8 lbf.in
2
) . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling fans switched ON in parallel 19 bar (1.90 MPa, 275.5 lbf.in
2
. . . . . . . . . . . .
High
Opening Pressure 27 bar (2.7 MPa, 391.5 lbf.in
2
) . . . . . . . . . . . . . . . . . . . . . . . . .
Closing Pressure 21 bar (2.1 MPa, 304.5 lbf.in
2
) . . . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
16 GENERAL DATA
ELECTRICAL
System 12 volt, negative earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery
Type YUASA H4 sealed for life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity 45 Ah . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIternator
Type Magnetti Marelli 11 5i 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum output 85 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor
Type M79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power 1.4 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSIONS
Overall length 3943 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155.2 in
Overall width (excluding door mirrors) 1626 mm . . . . . . . . . . . . 64 in
Overall width (including door mirrors) 1807 mm . . . . . . . . . . . . 71.1 in
Overall height*
Standard specification
Soft top 1261 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.7 in
Hard Top 1264 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.8 in
Sports specification
Soft Top 1249 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.2 in
Hard Top 1252 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.3 in
Ground clearance*
Standard specification 124 mm . . . . . . . . . . . . . . . . . . . . . . . 4.9 in
Sports specification 114 mm . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 in
Wheelbase 2375 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.5 in
Turning circle, kerb to kerb 10.56 m . . . . . . . . . . . . . . . . . . . . 34 ft 7.8 in
Track (except for models fitted with ultralight
wheels)
Front
Standard suspension 1403 mm . . . . . . . . . . . . . . . . . . . . . . 55.2 in
Sports suspension 1405 mm . . . . . . . . . . . . . . . . . . . . . . . . 55.3 in
Rear
Track (models fitted with ultralight wheels)
Front
Rear
Overhang
Front 841 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 in
Rear 726 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.6 in
* = at unladen weight
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INFORMATION
GENERAL DATA 17
WEIGHTS
UnIaden vehicIe weight
1
1.6 MPi 1095 - 1150 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2414 - 2536 lb
1.8 MPi with manual gearbox 1105 - 1150 kg . . . . . . . . . . . . . . . . . . 2435 - 2535 lb
1.8 VVC 1115 - 1285 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455 - 2830 lb
1.8 MPi Stepspeed (Em-CVT) 1150 - 1240 kg . . . . . . . . . . . . . . . . . . 2535 - 2730 lb
Maximum gross vehicIe weight (GVW)
1.6 & 1.8 MPi (with manual gearbox) 1320 kg . . . . . . . . . . . . . 2911 lb
1.8 VVC & 1.8 MPi with Stepspeed (Em-CVT) 1390 kg . . . . . 3065 lb
Maximum front axIe Ioad
1.6 & 1.8 MPi (with manual gearbox) 600 kg . . . . . . . . . . . . . 1323 lb
Maximum rear axIe Ioad
1.6 & 1.8 MPi (with manual gearbox 740 kg . . . . . . . . . . . . . 1632 lb
Maximum bootlid load
2
20 kg . . . . . . . . . . . . . . . . . . . . . . . 45 lb
Optional hard-top weight 20 kg . . . . . . . . . . . . . . . . . . . . . . 45 lb
1
= no occupants and fuel tank 90% full
2
= when approved luggage rack is fitted
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INFORMATION
18 GENERAL DATA
BULBS
BuIb Iocation BuIb specification
Headlamp dip beam 12V 55W H7 Halogen
Head lamp main beam 12V 55W H1 Halogen
Side light 12V 5W
Front direction indicator 12V 21W
Rear direction indicator 12V 21W
Licence plate 12V 5W
Brake light
1
12V 21W
Front fog light 12V 55W H1 Halogen
Rear fog light 12V 21W
Reverse light 12V 21W
Tail light 12V 5W
Footwell 12V 5W
Glovebox 12V 5W
Front load space 12V 10W
Rear load space 12V 10W
Side repeater lamps 12V 5W
nterior/courtesy lamp 12V 5W
1
= the centre high mounted stop lamp (CHMSL) uses LEDs
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INFORMATION
ENGINE TUNING DATA 1
ENGINE TUNING DATA
ModeI:1.6 MPi, 1.8 MPi and VVC MEMS 3
Engine
Type/Capacity
1.6 MPi 1.6 K16 / 1589 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 MPi & VVC 1.8 K16 / 1796 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order 1-3-4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression ratio 10.5 : 1 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust gas CO content at idle 0.5 % - maximum . . . . . . . . . . . . . . . . .
gnition timing at idle *
vacuum connected 12 BTDC . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition CoiI
Type Nippon Denso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part number NEC 100730 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary resistance 0.7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary resistance 10 k . . . . . . . . . . . . . . . . . . . . . . . .
Spark PIugs
Type Unipart GSP 66527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gap 1.0 0.05 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Management System
Type MEMS 3 breakerless, electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel injection ndirect multi-port fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEMS ECM Rover/Motorola NNN 100901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
njectors MJY 100550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump WFX 100670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pressure regulator MKW 10016 . . . . . . . . . . . . . . . . . . . . . . .
fuel pressure 3.0 0.2 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle position sensor MJC 100020 . . . . . . . . . . . . . . . . . . . . . . .
Sensor Values:
Total track resistance 4 k 20% . . . . . . . . . . . . . . . . . . . . . . .
Sensor supply 5 Volts 4% . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ntake air temperature sensor NNK 10001 . . . . . . . . . . . . . . . . . .
Engine coolant temperature sensor MEK 100170 . . . . . . . . . . . . . .
Crankshaft position sensor NSC 100630 . . . . . . . . . . . . . . . . . . . .
Camshaft position sensor NSC 100610+0 . . . . . . . . . . . . . . . . . . . . .
Oxygen sensor MHK 100720 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manifold absolute pressure sensor MHK 100820 . . . . . . . . . . . . . .
Oil temperature sensor
MPi MEMS3 MEK 100170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VVC MEMS3 (HCU) MEK 100160 . . . . . . . . . . . . . . . . . . . . . . . .
Ambient air (engine bay) temperature sensor MHK 100520 . . . . . .
Fuel grade 95 RON minimum - UNLEADED fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION: Serious damage to the engine may occur if a Iower octane number fueI than recommended
is used. Serious damage to the cataIyst wiII occur if LEADED fueI is used.
* = gnition timing in crankshaft degrees.
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INFORMATION
TORQUE WRENCH SETTINGS 1
Refer to appropriate section heading for component torque figures, e.g.
Road wheel nuts - refer to SUSPENSION
Exhaust front pipe to manifold - refer to MANIFOLD AND EXHAUST
ENGINE
Camshaft cover, bolts 9 Nm * . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Cover Plate 12 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft gear bolt
8 mm bolts 33 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 mm bolts 65 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft pulley bolt 205 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head bolts, tighten progressively
1st stage 20 Nm * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd stage 180 * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd stage 180 * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dipstick/filler tube mounting bracket 10 Nm . . . . . . . . . . . . .
Engine earth lead to cylinder block bolt 25 Nm . . . . . . . . . . .
Engine harness to oil pump bolt 10 Nm . . . . . . . . . . . . . . . .
Flywheel to crankshaft bolts 85 Nm * . . . . . . . . . . . . . . . . . . .
Flywheel cover plate 9 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting bracket 9 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil cooler to cylinder block (VVC) 25 Nm . . . . . . . . . . . . . . .
Oil cooler unions (VVC) 18 Nm . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure relief valve sealing plug 25 Nm . . . . . . . . . . . . .
Oil pressure switch 12 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump to cylinder block bolts 10 Nm + . . . . . . . . . . . . . . . . .
Sump bolts 25 Nm * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sump to gearbox, bolts 45 Nm . . . . . . . . . . . . . . . . . . . . . . .
Sump drain plug 25 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensioner pulley backplate bolt -
Manual timing belt tensioner (VVC) 10 Nm . . . . . . . . . . . . .
Tensioner pulley Allen screw -
Manual timing belt tensioner (VVC) 45 Nm . . . . . . . . . . . . .
Timing belt tensioner bolt -
Automatic timing belt tensioner 25 Nm + . . . . . . . . . . . . . . . .
Timing belt, upper front cover 9 Nm . . . . . . . . . . . . . . . . . .
Timing belt, front lower cover 9 Nm . . . . . . . . . . . . . . . . . . .
Timing belt rear cover 9 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Torsion damper to flywheel 22 Nm * . . . . . . . . . . . . . . . . . . . .
* Tighten in sequence
+ New Patchlok bolt must be fitted.
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INFORMATION
2 TORQUE WRENCH SETTINGS
Engine Mountings
Engine LH mounting to bracket bolts 45 Nm . . . . . . . . . . . . .
Engine LH mounting bracket to gearbox bolts
(manual gearbox models) 45 Nm . . . . . . . . . . . . . . . . . . . .
Engine LH mounting centre bolt
(manual gearbox models) 82 Nm . . . . . . . . . . . . . . . . . . . .
Engine mounting restraining loop bolts 45 Nm . . . . . . . . . . .
Gearbox mounting to LH buttress nut and bolt
(Em-CVT only) 82 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH mounting to engine 45 Nm . . . . . . . . . . . . . . . . . . . . . . .
LH buttress to subframe 45 Nm . . . . . . . . . . . . . . . . . . . . . .
LH mounting to gearbox bracket (Em-CVT only) 45 Nm . . . .
Rear engine steady to bracket on sump 85 Nm . . . . . . . . . .
Rear engine steady to subframe 85 Nm . . . . . . . . . . . . . . . .
Rear engine mounting tie-rod 45 Nm . . . . . . . . . . . . . . . . . .
Rear engine mount to subframe bolts 85 Nm . . . . . . . . . . . .
Rear engine mount to sump 80 Nm . . . . . . . . . . . . . . . . . . .
RH buttress to subframe 45 Nm . . . . . . . . . . . . . . . . . . . . . .
RH engine mounting bracket to hydramount 82 Nm . . . . . . .
RH engine steady to buttress 85 Nm . . . . . . . . . . . . . . . . . .
RH engine steady to engine mounting bracket 85 Nm . . . . .
Top arm to engine 100 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top arm to hydramount 82 Nm . . . . . . . . . . . . . . . . . . . . . . .
+ New Patchlok bolt must be fitted.
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INFORMATION
MODULAR ENGINE MANAGEMENT SYSTEM -
MEMS 3
Camshaft position sensor 9 Nm . . . . . . . . . . . . . . . . . . . . .
Crankshaft position sensor 6 Nm . . . . . . . . . . . . . . . . . . . .
ECM bracket bolts 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine coolant temperature sensor 6 Nm . . . . . . . . . . . . . .
Fuel filter, inlet and outlet union 30 Nm . . . . . . . . . . . . . . . . .
Fuel pump cover bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump locking ring 35 Nm . . . . . . . . . . . . . . . . . . . . . . .
Fuel rail to inlet manifold 10 Nm . . . . . . . . . . . . . . . . . . . . . .
Fuel rail to fuel feed pipe 8 Nm . . . . . . . . . . . . . . . . . . . . . .
HO
2
Sensors (pre and post catalyst) 55 Nm . . . . . . . . . . . . .
Hydraulic Control Unit Solenoid nuts (VVC) 12 Nm . . . . . . .
dle air control valve 1.5 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
gnition coil bolts 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gnition coil and ht lead cover bolts 8 Nm . . . . . . . . . . . . . .
ntake air temperature sensor 7 Nm . . . . . . . . . . . . . . . . . .
Manifold absolute pressure sensor (VVC) 3 Nm . . . . . . . . .
Oil temperature sensor - VVC 15 Nm . . . . . . . . . . . . . . . . . .
Spark plugs 27 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle body 9 Nm * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle position sensor screws 1.5 Nm . . . . . . . . . . . . . . . . .
CataIytic Converter
Catalyst overheat sensor 30 Nm . . . . . . . . . . . . . . . . . . . . . .
Catalytic converter to front pipe 50 Nm . . . . . . . . . . . . . . . . .
Catalytic converter to silencer 50 Nm . . . . . . . . . . . . . . . . . .
FueI Tank
Bulkhead closing panel 9 Nm . . . . . . . . . . . . . . . . . . . . . . .
Filler hose to tank 3 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filler neck to wing 3 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump cover to body 10 Nm . . . . . . . . . . . . . . . . . . . . . .
Fuel pump lock ring 35 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tank retaining strap 10 Nm . . . . . . . . . . . . . . . . . . . . . .
ThrottIe CabIe
Throttle pedal to bulkhead fixing 6 Nm . . . . . . . . . . . . . . . .
Throttle pedal bracket to pedal box 22 Nm . . . . . . . . . . . . . .
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INFORMATION
COOLING
Coolant pump to cylinder block 10 Nm . . . . . . . . . . . . . . . . .
Coolant pump to timing belt rear cover 10 Nm . . . . . . . . . . .
Coolant rail to cylinder block 9 Nm . . . . . . . . . . . . . . . . . . .
Engine bay cooling fan to body 9 Nm . . . . . . . . . . . . . . . . .
Expansion tank to mounting bracket 8 Nm . . . . . . . . . . . . .
Radiator to fan motor 3 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat housing cover 9 Nm . . . . . . . . . . . . . . . . . . . . .
Thermostat housing to cylinder block 9 Nm . . . . . . . . . . . .
BIeed points
Radiator bleed screw 5 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Heater bleed screw 7 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator return line, bleed screw 9 Nm . . . . . . . . . . . . . . . .
MANIFOLD AND EXHAUST
Alternator heat shield 9 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Catalyst to silencer 50 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant hose heat shield 9 Nm . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold heat shield
Nut 25 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold to cylinder head 45 Nm * . . . . . . . . . . . . . . .
Exhaust manifold to front pipe flange nuts 50 Nm . . . . . . . . .
Exhaust mountings to body 25 Nm . . . . . . . . . . . . . . . . . . . .
nlet manifold to cylinder head nuts and bolts 25 Nm * . . . . . .
nlet manifold support bracket - VVC 25 Nm . . . . . . . . . . . . .
nlet manifold to manifold chamber - VVC 25 Nm . . . . . . . . .
Silencer clamp, nut 30 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Silencer clamp to flange studs 50 Nm . . . . . . . . . . . . . . . . . .
Silencer RH mounting bracket 15 Nm . . . . . . . . . . . . . . . . . .
Silencer heat shield 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Stepper motor to inlet manifold 1.5 Nm . . . . . . . . . . . . . . . . .
Throttle housing to manifold chamber - VVC 9 Nm * . . . . . . .
CLUTCH
Clutch damper to bracket (VVC only) 15 Nm . . . . . . . . . . . .
Master cylinder to pedal box 25 Nm . . . . . . . . . . . . . . . . . . .
Master cylinder pipe union 18 Nm . . . . . . . . . . . . . . . . . . . . .
Pressure plate to flywheel 25 Nm * . . . . . . . . . . . . . . . . . . . . .
Slave cylinder to mounting bracket 25 Nm . . . . . . . . . . . . . .
Slave cylinder pipe union 18 Nm . . . . . . . . . . . . . . . . . . . . . .
Slave cylinder bleed screw 7 Nm . . . . . . . . . . . . . . . . . . . .
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INFORMATION
MANUAL GEARBOX
Drain plug 45 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filler / level plug 35 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel closing panel 80 Nm . . . . . . . . . . . . . . . . . . . . . . .
Gear lever assembly to body 9 Nm . . . . . . . . . . . . . . . . . . .
Gearbox to engine 80 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox to sump 45 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selector cable abutment bracket to gearbox
lower bracket 45 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road speed transducer 12 Nm . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod to selector lever nut 6 Nm . . . . . . . . . . . . .
Differential speed sensor 9 Nm . . . . . . . . . . . . . . . . . . . . . .
Dipstick tube retaining bolt 25 Nm . . . . . . . . . . . . . . . . . . . .
Drain plug 30 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid cooler pipe clamp bolt 10 Nm . . . . . . . . . . . . . . . . . . . .
Fluid cooler pipe to cooler bolt 10 Nm . . . . . . . . . . . . . . . . . .
Fluid cooler unions 14 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid pan bolts 10 Nm * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid pump bolts 10 Nm * . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel closing panel bolts 9 Nm . . . . . . . . . . . . . . . . . . .
Gear selector lever assembly to body 10 Nm . . . . . . . . . . . .
Gear shaft speed sensor retaining bolt 9 Nm . . . . . . . . . . .
Gearbox to engine 80 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox mounting to gearbox 48 Nm . . . . . . . . . . . . . . . . . .
Hydraulic control unit mounting bolts 10 Nm . . . . . . . . . . . . .
Lever to support bracket bolts 10 Nm . . . . . . . . . . . . . . . . . .
Park/Neutral switch 12 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Park solenoid bolts 15 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Pitot chamber bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary bearing nut 180 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary cover bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratio control motor harness connector nut 9 Nm . . . . . . . .
Road speed transducer retaining bolt 9 Nm . . . . . . . . . . . .
Secondary cover bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Selector cable bracket to gearbox 25 Nm . . . . . . . . . . . . . . .
Selector quadrant detent lever bolt 10 Nm . . . . . . . . . . . . . .
Selector valve bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequential gear change microswitch bolts 12 Nm . . . . . . . .
Shift lock solenoid 15 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter/nhibitor/Reverse switch 12 Nm . . . . . . . . . . . . . . . . .
Valve body bolts 10 Nm + . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+ Fit new bolts/nuts
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INFORMATION
DRIVE SHAFTS
Drive shaft nut 210 Nm, stake nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING
EPAS ECU to bracket 10 Nm . . . . . . . . . . . . . . . . . . . . . . . .
EPAS ECU bracket to fascia rail 25 Nm . . . . . . . . . . . . . . . .
gnition lock to steering column Shear bolts . . . . . . . . . . . . . . . . .
Pinion cover 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering rack clamp 22 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering rack 'U' bolt 22 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Steering rack to intermediate shaft 22 Nm . . . . . . . . . . . . . .
Steering column to intermediate shaft 22 Nm . . . . . . . . . . . .
Steering column mounting brackets 22 Nm . . . . . . . . . . . . .
Steering wheel to column 63 Nm . . . . . . . . . . . . . . . . . . . . .
Track-rod end to steering arm 30 Nm . . . . . . . . . . . . . . . . . .
Track-rod end lock nut 50 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Universal joint to steering rack pinion 20 Nm . . . . . . . . . . . .
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INFORMATION
SUSPENSION
Front Suspension
Anti-roll bar clamp bracket 22 Nm . . . . . . . . . . . . . . . . . . . . .
Anti-roll bar link 35 Nm ** . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Damper upper mounting 45 Nm . . . . . . . . . . . . . . . . . . . . . .
Damper lower mounting 100 Nm ** . . . . . . . . . . . . . . . . . . . . . .
Damper rod self locking nut 25 Nm . . . . . . . . . . . . . . . . . . . .
Hub nut 210 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower arm to subframe 85 Nm ** . . . . . . . . . . . . . . . . . . . . . . .
Lower ball joint to hub 45 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Lower ball joint to lower arm 40 Nm . . . . . . . . . . . . . . . . . . .
Upper arm pivot shaft retaining plate 10 Nm . . . . . . . . . . . . .
Upper arm pivot shaft 74 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Upper ball joint nut 54 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper ball joint to hub 105 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Rear Suspension
Anti-roll bar clamp bracket 22 Nm . . . . . . . . . . . . . . . . . . . . .
Anti-roll bar to link 35 Nm ** . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-roll bar link to trailing arm 35 Nm ** . . . . . . . . . . . . . . . . . .
Damper upper mounting 45 Nm . . . . . . . . . . . . . . . . . . . . . .
Damper lower mounting to upper arms 100 Nm ** . . . . . . . . . . .
Damper rod self locking nut 25 Nm . . . . . . . . . . . . . . . . . . . .
Lower link to hub 100 Nm ** . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower link to subframe 85 Nm ** . . . . . . . . . . . . . . . . . . . . . . .
Track control arm adjuster 50 Nm . . . . . . . . . . . . . . . . . . . . .
Track control arm to hub 38 Nm . . . . . . . . . . . . . . . . . . . . . .
Track control arm to subframe 60 Nm . . . . . . . . . . . . . . . . . .
Trailing arm to hub 60 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing arm compliance bush 100 Nm . . . . . . . . . . . . . . . . . .
Upper arm pivot shaft retaining plate 10 Nm . . . . . . . . . . . . .
Upper arm pivot shaft 100 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Upper ball joint nut 54 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper ball joint to hub 105 Nm . . . . . . . . . . . . . . . . . . . . . . . .
** = Tighten with suspension at nominal trim height
Front Subframe
Cross brace centre mounting to body 45 Nm . . . . . . . . . . . .
Cross brace to front subframe 45 Nm . . . . . . . . . . . . . . . . . .
Cross brace to rear subframe 45 Nm . . . . . . . . . . . . . . . . . .
Crash can to subframe 45 Nm . . . . . . . . . . . . . . . . . . . . . . .
Front mounting to body 30 Nm . . . . . . . . . . . . . . . . . . . . . . .
Front mounting to subframe 100 Nm . . . . . . . . . . . . . . . . . . . .
Rear mounting to body 45 Nm . . . . . . . . . . . . . . . . . . . . . . .
Rear mounting to subframe 100 Nm . . . . . . . . . . . . . . . . . . . .
Rear Subframe
Front subframe mounting to body 30 Nm . . . . . . . . . . . . . . .
Front centre mounting to subframe 100 Nm . . . . . . . . . . . . . .
Rear subframe mounting to body 45 Nm . . . . . . . . . . . . . . .
Rear mounting to subframe 100 Nm . . . . . . . . . . . . . . . . . . . .
Splash guard mounting bracket to subframe 30 Nm . . . . . . .
Trailing arm compliance bush to subframe 100 Nm . . . . . . . .
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INFORMATION
WheeI Nuts
Alloy wheel, nuts 70 Nm * . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare wheel, nuts 70 Nm * . . . . . . . . . . . . . . . . . . . . . . . . . . .
* = Tighten in sequence
BRAKES
ABS ECU to modulator 8 Nm . . . . . . . . . . . . . . . . . . . . . . .
ABS ECU to mounting spigot 15 Nm . . . . . . . . . . . . . . . . . . .
ABS harness support bracket 30 Nm . . . . . . . . . . . . . . . . . .
ABS hydraulic modulator to bracket 10 Nm . . . . . . . . . . . . .
ABS sensor bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master cylinder to servo 20 Nm . . . . . . . . . . . . . . . . . . . . . .
Master cylinder to pipe union 14 Nm . . . . . . . . . . . . . . . . . . .
Pedal box mounting bracket to top plate nuts and
bolts 22 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal box mounting bracket to bulkhead bolts 22 Nm . . . . .
Pedal crosstube bracket to bulkhead nut 22 Nm . . . . . . . . . .
Pedal pivot shaft to pedal box end bracket nut 22 Nm . . . . .
Proportioning valve to body 10 Nm . . . . . . . . . . . . . . . . . . . .
Proportioning valve to pipe union 14 Nm . . . . . . . . . . . . . . .
Servo to bracket 20 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo bracket to body 20 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Servo bracket to body bracket 30 Nm . . . . . . . . . . . . . . . . . .
Front Brakes
ABS speed sensor to hub 10 Nm . . . . . . . . . . . . . . . . . . . . .
Bleed nipple 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pipe unions 15 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pipes to subframe turrets 25 Nm . . . . . . . . . . . . . . . . .
Caliper body to carrier guide pin 45 Nm . . . . . . . . . . . . . . . .
Caliper carrier to hub 85 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Disc to drive flange 7 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose to caliper 30 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Brakes
ABS speed sensor to hub 10 Nm . . . . . . . . . . . . . . . . . . . . .
Bleed nipple 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pipe unions 15 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper to hub 85 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caliper body to carrier guide pin 45 Nm . . . . . . . . . . . . . . . .
Disc to drive flange 7 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose to caliper 30 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handbrake
Handbrake lever bracket to body 25 Nm . . . . . . . . . . . . . . . .
Handbrake assembly to bracket 25 Nm . . . . . . . . . . . . . . . .
Handbrake abutment bracket to mounting bracket 25 Nm . .
Handbrake cable to luggage bay bulk head 10 Nm . . . . . . .
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INFORMATION
SUPPLEMENTARY RESTRAINT SYSTEM
SRS DCU bracket to body 10 Nm . . . . . . . . . . . . . . . . . . . . .
SRS DCU to bracket 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Airbags
Passenger airbag to fascia bracket 8 Nm . . . . . . . . . . . . . .
Drivers airbag to steering wheel 8 Nm . . . . . . . . . . . . . . . .
Passenger airbag module bracket to fascia 9 Nm . . . . . . . .
Seat BeIts
Seat belt assembly to body 35 Nm . . . . . . . . . . . . . . . . . . . .
Seat belt assembly to seat 30 Nm . . . . . . . . . . . . . . . . . . . .
Seat belt pre-tensioner to seat 45 Nm . . . . . . . . . . . . . . . . . .
BODY
'A' post trim 6 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crossmember to floorpan 22 Nm . . . . . . . . . . . . . . . . . . . . .
Engine compartment cross-bracing
centre mounting 25 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Header trim 6 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamp to body 6 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Underbelly panel 22 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Splash guard mounting bracket to front subframe 30 Nm . . .
Bonnet
Bonnet locking platform 10 Nm . . . . . . . . . . . . . . . . . . . . . . .
Bonnet to hinges 9 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bonnet lock plate to body 25 Nm . . . . . . . . . . . . . . . . . . . . .
Bonnet release lever to bulkhead 9 Nm . . . . . . . . . . . . . . .
Boot
Boot lid to hinges 9 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot lid striker to body 10 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Boot latch to boot lid 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Bumpers
Crash can to body 25 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front bumper armature to body 25 Nm . . . . . . . . . . . . . . . . .
Front bumper valance to bumper armature 25 Nm . . . . . . . .
Front bumper to crash can 25 Nm . . . . . . . . . . . . . . . . . . . .
Rear bumper armature to body 22 Nm . . . . . . . . . . . . . . . . .
Rear bumper valance to armature 25 Nm . . . . . . . . . . . . . . .
Doors
Door finishers 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door glass regulator to door 7 Nm . . . . . . . . . . . . . . . . . . .
Door handle to door 2.5 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Door striker screws 18 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Latch assembly to door 5 Nm . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
Hood
Soft Top
Hood frame hinge to body 45 Nm . . . . . . . . . . . . . . . . . . . . .
Hood catch to header rail 20 Nm . . . . . . . . . . . . . . . . . . . . .
Hood header strikers 6 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Hard Top
Front top catch to hard top 10 Nm . . . . . . . . . . . . . . . . . . . .
Seats
Seat runners 45 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Squab frame to cushion frame 45 Nm . . . . . . . . . . . . . . . . . .
HEATING AND VENTILATION
Fascia rail support bracket 10 Nm . . . . . . . . . . . . . . . . . . . .
Heater mountings 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
ntake duct to body 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING
Compressor
Compressor to mounting bracket 45 Nm . . . . . . . . . . . . . . . .
Compressor to pipe union 25 Nm . . . . . . . . . . . . . . . . . . . . .
Condenser
Mounting bracket to striker plate panel 17 Nm . . . . . . . . . . .
Air conditioning pipe to condenser 5 Nm . . . . . . . . . . . . . . .
Evaporator
Evaporator to heater - clamp 3 Nm . . . . . . . . . . . . . . . . . . .
Evaporator to lower dash panel 9 Nm . . . . . . . . . . . . . . . . .
Receiver Drier
Air conditioning pipe to receiver drier 5 Nm . . . . . . . . . . . .
Thermostatic Expansion VaIve
Evaporator pipe clamp to expansion valve 5 Nm . . . . . . . .
Evaporator pipe, bracket 7 Nm . . . . . . . . . . . . . . . . . . . . . .
Trinary switch 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIPERS AND WASHERS
Wiper arm to spindle 20 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and linkage assembly to scuttle 10 Nm . . . . . . . . . . . .
Motor to linkage bracket 12 Nm . . . . . . . . . . . . . . . . . . . . . .
Crank to motor spindle 18 Nm . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
ELECTRICAL
Aerial locking nut 3 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm ECU 4 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator to pulley 25 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator to engine mounting clamp bolts 45 Nm . . . . . . . .
Alternator adjustment tensioner bracket bolts 25 Nm . . . . . .
Alternator tensioner pulley nut (A/C models only) 25 Nm . . .
CD autochanger to vehicle 5 Nm . . . . . . . . . . . . . . . . . . . .
Central locking motor to door 5 Nm . . . . . . . . . . . . . . . . . . .
Fusebox to body 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EPAS ECU to mounting 10 Nm . . . . . . . . . . . . . . . . . . . . . . .
Headlamp to front panel 10 Nm . . . . . . . . . . . . . . . . . . . . . .
Horn to valance 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor securing bolts 80 Nm . . . . . . . . . . . . . . . . . . . .
Tail Lamp to body 2 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INFORMATION
LIFTING AND TOWING 1
JACKING, SUPPORTING AND TOWING
1. Central jacking point - front
2. RH sill reinforced bracket - front
3. LH sill reinforced bracket - front
4. LH sill reinforced bracket - rear
5. RH sill reinforced bracket - rear
6. Subframe longitudinal members - front
7. Subframe longitudinal members - rear
8. Front towing eyes
To jack up the rear of the car, use the rear sill
jacking points (4 & 5), then place safety support
stands under the sill or subframe longitudinals.
WARNING: To avoid potentiaI damage to
the rear suspension Iinks, DO NOT use a
troIIey jack from the rear of the car.
WARNING: In accordance with normaI
workshop practice, and to avoid the
possibiIity of damage or personaI injury,
work must not be carried out, on or under a
vehicIe when it is supported soIeIy on a jack.
PIace safety supports under the siII reinforced
jacking areas (2, 3, 4 or 5).
WARNING: Do not position a jack, jack
stand or wheeI free support under the
suspension attachment points.
WARNING: Do not attempt to jack under
suspension attachment points.
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INFORMATION
2 LIFTING AND TOWING
CAUTION: When Iifting the side of the
vehicIe with a workshop jack, ensure that
the jack head is positioned under the
reinforced area of the siII, as shown.
WORKSHOP JACK
Front: Locate the jack head under the central
location bracket (1).
Position safety supports under both front sill
reinforced brackets (2 and 3).
Rear: Locate the jack head under the rear sill
jacking points (4 & 5), then place safety support
stands under the sill or subframe longitudinals.
Side Front: Locate the jack head under the sill
reinforced bracket (2 or 3) and position safety
support under front subframe longitudinal member
(6).
Side rear: Locate the jack head under the sill
reinforced bracket (4 or 5) and position safety
support under rear subframe longitudinal member
(7).
WHEEL-FREE LIFT
f crossbeams are available, locate the pads under
the sill reinforced jacking brackets (2, 3) and (4, 5).
f longitudinal beams are available, locate the beams
under the subframe longitudinals with lifting pads at
the front and rear positions (6 and 7). Raise the lift a
few inches and ensure the vehicle is firmly
supported. Raise the lift to full height and inspect the
lifting points for security.
RECOVERY
ManuaI gearbox modeIs
t is recommended that a recovery trailer or two
wheel car ambulance be used. n an emergency, the
car may be towed on its own wheels using the front
lashing/towing eyes (8).
Automatic (Em-CVT) gearbox modeIs
t is recommended that a recovery trailer or a two
wheel car ambulance is used on the rear wheels. n
an emergency, the car may be towed a short
distance on its own wheels using the front
lashing/towing eyes (8).
Suspended tow
CAUTION: A front suspended tow must
not be attempted on a vehicIe with an
automatic gearbox. Serious damage to the
transmission wiII occur.
A suspended tow cannot be carried out without
incurring damage. f additional damage is immaterial
because of existing crash damage, lifting chains can
be attached to the towing eyes.
Before towing commences release the handbrake,
place the gear lever in neutral and the ignition switch
at 'I'. Do not tow at a greater speed than 30 mph,
50 km/h.
On no account should the vehicle be towed with the
rear wheels on the ground if the transmission is
faulty, the transmission fluid level is low, or the
towing distance exceeds 30 miles or 50 km.
WARNING: MG TF modeIs have a Iower
ground cIearance than most other cars,
vehicIe recovery shouId ONLY be carried
out by a quaIified recovery speciaIist using a
transporter or traiIer. Other methods of vehicIe
recovery, incIuding the use of wheeI Iift
equipment to suspend the front or rear wheeIs,
and towing with rope, bar or chain , wiII cause
damage to the front of the vehicIe and are not
recommended.
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INFORMATION
LIFTING AND TOWING 3
Transporter or traiIer Iashing
Use the front towing eyes, and specific lashing
points for rear of car. DO NOT secure lashing hooks
or trailer fixings to other parts of the car.
CAUTION: Some of the information
incIuded in the recovery section DOES
NOT appIy to MG TF modeIs. PIease take
note of the information beIow.
Because the MG TF model has a lower ground
clearance than most other cars, vehicle recovery
should ONLY be carried out by a qualified recovery
specialist using a transporter or trailer.
Other methods of vehicle recovery, including the use
of wheel lift equipment to suspend the front or rear
wheels, and towing with rope, bar or chain, may
cause damage to the front of the vehicle and is NOT
recommended.
TOWING
GeneraI
Use the front lashing/towing eyes (8) for towing the
vehicle on all four wheels from the front.
WARNING: To ensure that the steering
does not Iock when the vehicIe is being
towed, it is essentiaI that the ignition key
is turned to position 'I', and remains there whiIe
the vehicIe is moving.
Ensure the foIIowing precautions are observed:
Do not tow if the gearbox or a drive shaft is
fauIty.
Do not tow if a wheeI or drive shafts are touching
the body or frame.
Ensure the gear Iever is in neutraI and the
handbrake is reIeased.
Remember that greater effort than normaI wiII be
necessary to appIy the brakes if the vehicIe is
being towed without the engine running.
Stepspeed (Em-CVT) gearbox modeIs
When a car with automatic gearbox is to be towed
on four wheels from the front, the following
precautions must be observed:
The gearbox fluid level must be correct before
starting to tow.
The selector must be at 'N'.
The car must not be towed at speeds greater than
30 mph, 50 km/h or for distances which exceed
30 miles, 50 km.
CAUTION: A front suspended tow must
not be attempted as serious damage wiII
be caused to the automatic transmission.
NOTE: A vehicIe fitted with an automatic
gearbox cannot be started by towing or
pushing.
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INFORMATION
CAPACITIES, FLUIDS AND LUBRICANTS 1
CAPACITIES
Fuel tank 50 litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil refill and filter change: 4.5 litres . . . . . . . . . . . . . . . .
Engine oil refill from dry: 5 litres . . . . . . . . . . . . . . . . . . . . . .
Manual gearbox:
Refill 2.2 litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
From dry 2.4 litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stepspeed (Em-CVT) Gearbox:
Refill - Gearbox only 4.5 litres . . . . . . . . . . . . . . . . . . . . . . . .
Fluid cooler and lines 1.0 litre . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system from dry: 10.5 litres . . . . . . . . . . . . . . . . . . . . . .
Washer reservoir: 2.2 litres . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLUIDS
Brake FIuid
Use only AP New Premium Super DOT 4
brake/clutch fluid or Castrol Universal DOT 4
brake/clutch fluid. DO NOT use any other type of
fluid.
Anti-Freeze SoIutions
The overall anti-freeze concentration should not fall,
by volume, below 50% to ensure that the
anti-corrosion properties of the coolant is
maintained. Anti-freeze concentrations greater than
60% are not recommended as cooling efficiency will
be impaired.
Organic Acid Technology (OAT) anti-freeze
Vehicles use Unipart OAT (or HavoIine XLC)
coolant which is Orange/Pink in colour. Vehicles
using OAT anti-freeze are identified by a label
attached around the expansion tank filler neck - see
illustration.
CAUTION: The anti-freeze used in the
cooIing system contains OAT corrosion
inhibitors. This anti-freeze must not be
used with any other anti-freeze and must not be
used as a repIacement in cooIing systems of
other vehicIes which previousIy contained
anti-freeze not of this type.
Use UNIPART OAT or HavoIine XLC Anti-freeze
and Summer CooIant or any ethyIene gIycoI
based anti-freeze (containing no methanoI) with
onIy OAT corrosion inhibitors, to protect the
cooIing system.
OnIy anti-freeze containing OAT corrosion
inhibitors shouId be used. Do not top-up or refiII
cooIing system with any other type of
anti-freeze.
In an emergency, if anti-freeze to this
specification is not avaiIabIe, top-up the cooIing
system with cIean water onIy, but be aware of
the resuItant reduction in frost protection. The
correct anti-freeze concentration must be
restored as soon as possibIe.
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INFORMATION
2 CAPACITIES, FLUIDS AND LUBRICANTS
Replacing coolant
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze
solution at the intervals given on the Service
Maintenance Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
The recommended quantities of anti-freeze for
different degrees of frost protection are:
SoIution Amount of anti-freeze Commences freezing Frozen soIid
50% Litres C F C F
5.25 -36 -33 -48 -53
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INFORMATION
CAPACITIES, FLUIDS AND LUBRICANTS 3
LUBRICATION
The engine and other lubricating systems are filled
with high performance lubricants giving prolonged
life.
CAUTION: You shouId aIways use a high
quaIity oiI of the correct viscosity range in
the engine and gearbox during
maintenance and when topping-up. The use of
oiI not to the correct specification can Iead to
high oiI and fueI consumption and uItimateIy to
damaged components.
Oil to the correct specification contains additives
which disperse the corrosive acids formed by
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives
should not be used.
Always adhere to the recommended servicing
intervals.
Engine oiI
Use oil meeting specification ACEA A2 or A3 and
having a viscosity band recommended for the
temperature range of your locality (e.g (10W/40).
Where oils to these MG Rover and European
specifications are not available, well known brands
of oils meeting AP SH or SJ quality should be used.
NOTE: OiIs meeting specification ACEA
A1 can be used if necessary, EXCEPT for
vehicIes with VVC engines.
ManuaI gearbox
Use Texaco MTF 94, Unipart MTF94 or Caltex
MTF94 for refill and topping-up.
Stepspeed (Em-CVT) gearbox
Use EZL799, Esso CVT or Unipart CVT for refilling
or topping up.
Gear Iinkage
Use Unipart Multi-purpose Lithium Grease or
equivalent.
GeneraI greasing
Use Unipart Multi-purpose Lithium Grease or
equivalent.
Boot hinges
Lubricate with Rocol Ultralube.
Locks, Iatches and hinges
Use Door Lock and Latch Lubricant,
Part No. CYL 100020.
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MAINTENANCE
CONTENTS Page
MAINTENANCE
ENGNE COMPARTMENT LOCATONS - MPi MEMS 1.9 1 . . . . . . . . . . . . . . . . . . .
ENGNE COMPARTMENT LOCATONS - VVC MEMS 2J 2 . . . . . . . . . . . . . . . . . . .
ENGNE COMPARTMENT LOCATONS - VVC MEMS 3 3 . . . . . . . . . . . . . . . . . . . .
ENGNE COMPARTMENT LOCATONS - MPi MEMS 3 4 . . . . . . . . . . . . . . . . . . . . .
UNDERBONNET LOCATONS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE OL 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OL FLTER RENEWAL 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT TMNG BELT MPi & VVC 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FLTER 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR CLEANER ELEMENT 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE TUNNG 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUGS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE VENT HOSES 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM HOSES, PPES AND UNONS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DSTRBUTOR CAP, h.t. CABLES AND COL TOWER - MPi MEMS 1.9 9 . . . . . . . .
GNTON COLS - VVC MEMS 2J 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GNTON COLS - MPi / VVC MEMS 3 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRVE SHAFT GATERS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLNG SYSTEM 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX FLUD - MANUAL MODELS 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX FLUD - STEPSPEED (Em-CVT) MODELS 12 . . . . . . . . . . . . . . . . . . . .
CLUTCH FLUD 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERNG 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSON DAMPERS, BALL JONTS, FXNGS AND GATERS 14 . . . . . . . . . .
ROAD WHEELS AND FASTENNGS 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYRE PRESSURES AND CONDTON 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOOTBRAKE 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDBRAKE 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUD 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE HOSES AND PPES 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DSC BRAKES 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR DSC BRAKES 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRVER AR BAG MODULE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASSENGER AR BAG MODULE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR BAG ROTARY COUPLER 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREEN WPERS AND BLADES 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WNDSCREEN WASHERS 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LAMPS, HORNS AND WARNNG NDCATORS 26 . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY CONNECTONS 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSEBOX 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROAD TEST 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CONTENTS Page
MAINTENANCE
ENGNE COMPARTMENT LOCATONS - VVC MEMS 3 1 . . . . . . . . . . . . . . . . . . . .
ENGNE COMPARTMENT LOCATONS - MPi MEMS 3 2 . . . . . . . . . . . . . . . . . . . . .
UNDERBONNET LOCATONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE OL 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OL FLTER RENEWAL 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT TMNG BELT MPi & VVC 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FLTER 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR CLEANER ELEMENT 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE TUNNG 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK PLUGS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE VENT HOSES 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM HOSES, PPES AND UNONS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GNTON COLS - MPi / VVC MEMS 3 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRVE SHAFT GATERS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLNG SYSTEM 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX FLUD - MANUAL MODELS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX FLUD - STEPSPEED (Em-CVT) MODELS 9 . . . . . . . . . . . . . . . . . . . . .
CLUTCH FLUD 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERNG 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSON DAMPERS, BALL JONTS, FXNGS AND GATERS 12 . . . . . . . . . .
ROAD WHEELS AND FASTENNGS 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYRE PRESSURES AND CONDTON 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOOTBRAKE 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDBRAKE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE FLUD 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE HOSES AND PPES 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DSC BRAKES 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR DSC BRAKES 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRVER AR BAG MODULE 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PASSENGER AR BAG MODULE 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AR BAG ROTARY COUPLER 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEATS AND SEAT BELTS 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREEN WPERS AND BLADES 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WNDSCREEN WASHERS 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LAMPS, HORNS AND WARNNG NDCATORS 24 . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER BLOWER 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY CONNECTONS 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSEBOX 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROAD TEST 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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MAINTENANCE 1
ENGINE COMPARTMENT LOCATIONS - VVC MEMS 3
1. Air cleaner
2. gnition coils
3. Coolant expansion tank and cap
4. Engine oil dipstick
5. Engine oil filler cap
6. Crankcase ventilation hoses
7. Fuel filter
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2 MAINTENANCE
ENGINE COMPARTMENT LOCATIONS - MPi
MEMS 3
1. Coolant expansion tank and cap
2. Engine oil dipstick
3. Engine oil filler cap
4. gnition coils
5. Crankcase ventilation hoses
6. Fuel filter
7. Air cleaner
8. Spark plugs
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MAINTENANCE 3
UNDERBONNET LOCATIONS
1. Brake fluid reservoir
2. Clutch fluid reservoir
3. Windscreen washer reservoir
4. Fusebox
5. Battery
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4 MAINTENANCE
ENGINE OIL
OiI IeveI check
Always check oil level and drain oil with vehicle
standing on level ground and use engine oil of
specification 10W/40 for topping up and refilling.
1. Pull the dipstick out, wiping the blade clean as
it is withdrawn by squeezing the dipstick wiping
mechanism (arrowed) between finger and
thumb. Re-insert dipstick fully and withdraw
again, this time releasing the dipstick wiping
mechanism. Check the oil level which must be
maintained between minimum mark 'MIN' and
maximum mark 'MAX' on dipstick.
2. f required, remove filler cap, REMOVE
DPSTCK and top-up with new engine oil to
specification 10W/40. See INFORMATION,
Capacities, fluids and lubricants.
OiI drain and refiII
The oil should be drained when engine is warm. The
oil filter can be renewed while oil is being drained.
WARNING: Observe due care when
draining engine oiI as the oiI can be very
hot.
ProIonged and repeated contact with used
engine oiI may cause serious skin disorders.
Wash thoroughIy after contact. Keep out of
reach of chiIdren.
1. Place a container under sump.
2. Remove drain plug and sealing washer, allow
oil to drain.
3. Clean the drain plug, fit NEW sealing washer
and refit drain plug. Tighten to 25 Nm.
4. Remove filler cap, REMOVE DPSTCK refill
with new engine oil to specification 10W/40.
Re-check oil level.
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MAINTENANCE 5
OIL FILTER RENEWAL
See ENGINE, Repairs.
CAMSHAFT TIMING BELT MPi & VVC
See ENGINE, Adjustments.
FUEL FILTER
See ENGINE MANAGEMENT SYSTEM - MEMS,
Repairs.
AIR CLEANER ELEMENT
Repairs.
ENGINE TUNING
Tuning must be carried out using TestBook.
SPARK PLUGS
Repairs.
CRANKCASE VENT HOSES
1. Check crankcase ventilation hoses for signs of
splitting and general condition.
2. Check hoses are routed correctly, secure and
serviceable.
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6 MAINTENANCE
FUEL SYSTEM HOSES, PIPES AND UNIONS
1. Check fuel pipes and connections for chafing
and leakage.
2. Check pipes are securely clipped.
3. Check fuel tank is free from leaks.
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MAINTENANCE 7
IGNITION COILS - MPi / VVC MEMS 3
1. Remove coil cover.
2. Check h.t. cables and multiplugs for security.
3. Clean each coil.
DRIVE SHAFT GAITERS
1. Check that drive shaft gaiters are not twisted,
split or damaged.
2. Check clips are secure.
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8 MAINTENANCE
COOLING SYSTEM
WARNING: To prevent injury such as
scaIding caused by escaping steam or
cooIant, do not remove pressure reIief cap
from expansion tank whiIe system is hot.
Check IeveI and top-up
CAUTION: The cooIant IeveI shouId onIy
be checked when the system is coId.
1. Visually check that coolant level is between the
two steps of the level marker inside the
expansion tank. f level is appreciably low,
suspect leakage or overheating.
CAUTION: If cooIant is not visibIe in
expansion tank, the system must be
refiIIed in accordance with RefiIIing
procedure.
2. f required, remove coolant expansion tank cap
and top-up with anti-freeze mixture. See
INFORMATION, Capacities, fluids and
lubricants.
CAUTION: The cooIant must not exceed
the expansion tank fIange.
3. Check specific gravity of coolant. The overall
anti-freeze concentration must not be below
50% by volume and must not exceed 60% by
volume.
4. Refit expansion tank cap.
5. For cooling system drain and refill. See
COOLING SYSTEM, Adjustments.
EXHAUST SYSTEM
1. Check for damage and signs of leakage.
2. Check security of system.
3. Check mountings and correct alignment.
4. Check security of heat shields.
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MAINTENANCE 9
GEARBOX FLUID - MANUAL MODELS
FIuid IeveI check and top-up
1. Ensure vehicle is standing on level surface.
2. Wipe clean area around filler/level plug and
remove plug and sealing washer. Discard
sealing washer.
3. Check that fluid is level with bottom of level
plug hole.
CAUTION: FIuid Iodged behind IeveI pIug
wiII trickIe out when pIug is removed and
can give impression that IeveI is correct.
4. Top-up, if required, until fluid just runs from
hole. Allow sufficient time for fluid to flow and
reach a common level within gearbox.
Use Texaco MTF 94 transmission oil. See
lubricants.
5. Refit filler/level plug and new sealing washer
and tighten to 35 Nm.
GEARBOX FLUID - STEPSPEED (Em-CVT)
MODELS
FIuid IeveI check and top-up
NOTE: AIways check fIuid IeveI with
vehicIe standing on IeveI ground and
gearbox at operating temperature.
1. With engine running at idle speed and
handbrake applied, select 'P' or 'N'. Withdraw
dipstick and wipe blade with clean lint free
cloth.
2. Re-insert dipstick fully, withdraw and check
fluid level which must be maintained between
minimum and maximum marks on dipstick.
3. Switch off engine and top-up to maximum mark
if required. See AUTOMATIC GEARBOX -
Em-CVT, Adjustments.
4. Refit dipstick.
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10 MAINTENANCE
CLUTCH FLUID
WARNING: Do not aIIow dirt or foreign
Iiquids to enter reservoir when topping up.
Use onIy AP New Premium Super DOT 4 or
CastroI UniversaI DOT 4 cIutch fIuid from airtight
containers.
CAUTION: Do not aIIow cIutch fIuid to
contact paint finished surfaces as paint
may be damaged. If spiIIed, remove fIuid
and cIean area with warm water.
LeveI check
1. Wipe reservoir body and filler cap, and check
level visually.
2. Remove filler cap and top-up, until fluid
reaches bottom of reservoir filler neck.
3. The baffle plate halfway up the reservoir acts
as the the clutch fluid minimum level.
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MAINTENANCE 11
STEERING
Steering coIumn, rack, joints and gaiters
1. Check security of steering rack, two mounting
fixings, tighten nuts to 22 Nm.
2. Restrain ball joint movement and check that
steering track rod, locknuts are tightened to
50 Nm.
3. Check security of 2 track rod end nuts, tighten
to 30 Nm.
4. Visually check that the rack sealing gaiters are
not twisted or damaged and clips are secure.
5. Check for signs of lubricant leakage.
6. Check intermediate shaft bolts are tightened to
22 Nm.
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12 MAINTENANCE
SUSPENSION DAMPERS, BALL JOINTS,
FIXINGS AND GAITERS
Front suspension
1. Check upper ball joint nut - 54 Nm.
2. Check anti-roll bar clamp, bushes and bolts -
22 Nm.
3. Check suspension dampers for oil leaks.
4. Check suspension damper top mounting,
bushes and nuts - 45 Nm
5. Check upper arm spindle bolt - 74 Nm
6. Check suspension damper lower mounting to
upper arm bushes and bolts - 100 Nm
7. Check lower arm to subframe, mounting
bushes and bolts - 85 Nm
8. Check anti-roll bar to lower arm link bushes
and bolts - 35 Nm
9. Check lower ball joint, clamp bolt - 45 Nm
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MAINTENANCE 13
Rear suspension
1. Check track control arm to hub nut - 38 Nm.
2. Check track control arm adjuster nuts - 50 Nm.
3. Check track control arm to subframe bushes
and bolts - 60 Nm.
4. Check anti-roll bar clamp, bushes and bolts -
22 Nm.
5. Check suspension damper, top mounting
bushes and nuts - 45 Nm.
6. Check suspension dampers for oil leaks.
7. Check upper arm to subframe, pivot shaft
bushes and bolts - 83 Nm.
8. Check upper arm to hub ball joint nuts - 54 Nm.
9. Check suspension damper lower mounting
bushes and bolts - 100 Nm.
10. Check anti-roll bar to trailing arm, link bushes
and bolts - 35 Nm.
11. Check lower link to hub, bushes and bolts -
100 Nm.
12. Check trailing arm to hub bolts - 60 Nm.
13. Check trailing arm to compliance bush
assembly (not shown) - 100 Nm.
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14 MAINTENANCE
ROAD WHEELS AND FASTENINGS
1. Check condition of road wheels including spare
(where fitted) for signs of buckling and rim
damage.
2. Push extractor tool over head of nut cover and
pull to remove.
3. Fit key socket over locking wheel nut, then fit
wheel nut spanner over key socket and
unscrew.
4. Working in a diagonal sequence slacken each
nut
1
/
2
turn and then tighten to 70 Nm.
TYRE PRESSURES AND CONDITION
1. Check for signs of tyre wear indicator in tread
pattern.
2. Check all tyres including spare (where fitted)
for uneven wear, external cuts in fabric,
exposure of ply or cord structure, lumps and
bulges.
3. Check and adjust tyre pressures. See
INFORMATION, General data.
FOOTBRAKE
1. Press brake pedal and check for firm
resistance after short pedal movement.
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MAINTENANCE 15
HANDBRAKE
Check
1. Check caliper clearance is between 1 and
2 mm, each side.
2. f the handbrake requires adjustment. See
BRAKES, Adjustments.
BRAKE FLUID
WARNING: Do not aIIow dirt or foreign
Iiquids to enter reservoir when topping-up.
Use onIy new AP New Premium Super
DOT 4 or CastroI UniversaI DOT 4 brake fIuid
from airtight containers.
CAUTION: Do not aIIow brake fIuid to
and cIean area with cIean warm water.
LeveI check
1. Wipe reservoir body and filler cap clean and
check level visually.
2. Remove filler cap and top-up to 'MAX' mark, if
required.
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16 MAINTENANCE
Renew fIuid, ABS and Non-ABS brake systems.
1. Raise vehicle on four post lift.
CAUTION: Ensure that fIuid IeveI in
reservoir is maintained during the
compIete operationaI sequence using new
brake fIuid.
CAUTION: Never re-use fIuid that has been
bIed from system.
Bleed sequence - non ABS and ABS systems
LH rear to RH rear.
RH front to LH front.
CAUTION: Braking efficiency may be
seriousIy impaired if wrong bIeed
sequence is used.
2. Attach a bleed tube to LH rear bleed nipple.
Submerge free end of tube into jar containing
brake fluid.
WARNING: Ensure vehicIe is in neutraI
before starting engine.
3. Start engine to build up vacuum in the brake
servo, keep engine running while carrying out
bleeding procedure.
4. Open bleed nipple, use an assistant to press
brake pedal to the floor and hold.
5. Close bleed nipple, and then release brake
pedal.
6. Repeat procedures 4 and 5 until no more air
bubbles can be seen flowing from the bleed
hose.
7. Hold pedal to floor and tighten bleed screw to
10 Nm.
8. Release brake pedal.
9. Repeat forgoing procedure at each wheel in
sequence illustrated, until clean, bubble free
fluid flows from the bleed hose at each
sequence stage.
10. Remove bleed tube. Apply brakes and check
for leakage.
11. Lower vehicle.
12. Check brake pedal for short firm travel when
brakes are applied.
13. Check/top up brake fluid level.
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MAINTENANCE 17
BRAKE HOSES AND PIPES
1. Visually check all brake fluid pipes, hoses and
connections for correct routing and security.
2. Check for signs of chafing, leakage and
corrosion.
NOTE: VehicIes without ABS have a Brake
Proportioning VaIve (BPV) incIuded in-Iine
in the brake hydrauIic system.
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18 MAINTENANCE
Renew brake hose - front
Remove
NOTE: Disconnect hose at end nearest to
master cyIinder first.
1. Release brake pipe union from hose using
correct union spanner.
2. Fit plug to pipe end to prevent excessive fluid
loss.
3. Withdraw brake hose clip from upper bracket.
4. Remove banjo bolt at caliper end of hose and
discard 2 sealing washers.
5. Remove hose and discard.
Refit
1. Fit banjo end of hose to caliper with banjo bolt
and 2 new sealing washers and tighten to
30 Nm.
2. Fit union end of hose to top bracket and secure
with clip.
3. Remove plug from pipe end, connect brake
pipe to hose and tighten union to 15 Nm.
4. Bleed brake system. See BRAKES,
Adjustments.
Renew brake hose - rear
Remove
NOTE: Disconnect hose at end nearest to
master assembIy first.
1. Release brake pipe union from hose using
correct union spanner.
2. Fit plug to pipe end to prevent excessive fluid
loss.
3. Withdraw brake hose clip from bracket.
4. Remove banjo bolt at caliper end of hose and
discard 2 sealing washers.
5. Remove hose and discard.
Refit
1. Fit banjo end of hose to caliper with banjo bolt
and 2 new sealing washers and tighten to
30 Nm.
2. Fit union end of hose to rear bracket and
secure with clip.
3. Remove plug from pipe end, connect brake
pipe to hose and tighten union to 15 Nm.
4. Bleed brake system. See BRAKES,
Adjustments.
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MAINTENANCE
MAINTENANCE 19
FRONT DISC BRAKES
Check
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove both front road wheels.
3. Check brake pads visually and assess lining
thickness.
Minimum brake pad thickness (Dimension A):
Standard = 3 mm
Sports = 2.5 mm
NOTE: Measurement does not incIude pad
backing thickness.
4. f the brake pads need to be renewed. See
BRAKES, Repairs.
5. Fit road wheel(s), fit wheel nuts and tighten in a
diagonal sequence to 70 Nm.
6. Remove stands and lower vehicle.
7. Depress footbrake several times in order to
give correct pad to disc clearance before road
testing.
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MAINTENANCE
20 MAINTENANCE
REAR DISC BRAKES
Check
1. Raise rear of vehicle.
2. Remove both rear road wheels.
3. Check brake pads visually and assess pad
thickness.
Minimum brake pad thickness:
Dimension A = 3 mm.
NOTE: Measurement does not incIude pad
backing thickness.
4. f the brake pads need to be renewed. See
BRAKES, Repairs.
7. Depress footbrake several times in order to
give correct pad to disc clearance before road
testing.
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MAINTENANCE
MAINTENANCE 21
BODY
Locks, hinges and Iatch mechanism
(not steering Iock)
1. Functionally check operation of all locks.
2. Operate driver's door lock and check that
electric central door locking operates.
3. Ensure that all locks, hinges and latch
mechanisms are lubricated using Door Lock
and Latch Lubricant, Part No. CYL 100020.
nject grease sparingly into lock barrels. Clean
off any surplus grease.
DO NOT Iubricate the steering Iock.
NOTE: Use RocoI UItraIube on the boot
hinges.
Exterior paintwork and body paneIs
1. Visually check paintwork and body panels for
damage and corrosion.
Underbody seaIer
1. Visually check underbody sealer for damage
and continuity.
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MAINTENANCE
22 MAINTENANCE
DRIVER AIR BAG MODULE
1. Visually check for signs of damage.
2. To renew an air bag. See RESTRAINT
SYSTEMS, Repairs.
PASSENGER AIR BAG MODULE
1. Visually check for signs of damage.
2. To renew an air bag. See RESTRAINT
SYSTEMS, Repairs.
AIR BAG ROTARY COUPLER
1. Rotate steering wheel one half turn in each
direction and check for noise from the rotary
coupler.
2. To renew the rotary coupler. See RESTRAINT
SYSTEMS, Repairs.
SEATS AND SEAT BELTS
1. Check seat frames are secured to floor and
show no signs of movement.
2. Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3. Check tightness of all seat belt anchorage
points.
4. Fully extract each seat belt and allow it to
return under its own recoil mechanism.
5. Connect each seat belt to its respective buckle
and check the seat belt buckle and tongue are
secure.
6. Check entire length of seat belt webbing for
signs of fraying and damage, replace seat belt
if fraying or damage is evident. See
RESTRAINT SYSTEMS, Repairs.
SCREEN WIPERS AND BLADES
1. Operate front screen wiper.
2. Check that blades wipe screen without
smearing.
3. Check that wipers park correctly.
4. Operate wiper switch in all modes.
5. Check that wipers operate at speeds selected.
Renew bIade
1. Lift wiper arm.
2. Press retaining lever.
3. Slide blade down arm.
4. Withdraw blade assembly from arm.
5. Position new blade to wiper arm.
6. Push blade into engagement with arm.
7. Check that it is retained.
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MAINTENANCE
MAINTENANCE 23
WINDSCREEN WASHERS
1. Visually check mixture level in reservoir.
2. Top-up by removing filler cap and adding
required concentration mixture of water and
'Screenwash'.
3. Clean windscreen washer jets using thin wire
as a probe.
4. Operate windscreen washer and check that
jets strike top and centre of area to be wiped.
5. Adjust jet by inserting a needle into jet hole and
repositioning.
6. Check operation of wash/wipe.
7. Observe that washer and wipers operate
correctly.
8. Recheck level in reservoir after adjustments.
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MAINTENANCE
24 MAINTENANCE
LAMPS, HORNS AND WARNING INDICATORS
1. Switch on sidelamps, and check that
sidelamps, tail lamps, rear number plate lamps,
and instrument lights illuminate.
2. Switch on headlamps, operate dip switch and
check that headlamps function in both dip and
main beam, and panel main beam indicator
operates.
3. Operate flash switch and check that
headlamps flash.
4. Open doors and check interior lamps
illuminate.
5. Open bonnet, and rear luggage compartment
and check lights illuminate.
6. Press horn and check that horn operates.
7. Switch on ignition and depress brake pedal,
check brake lights illuminate including Centre
High Mounted Stop Lamp (CHMSL).
8. Switch on ignition and operate direction
indicator switch to right and left and check that
the relative warning indicators flash at front and
rear.
9. Operate hazard warning switch and check that
all warning indicators flash.
HEATER BLOWER
1. Check operation of heater blower control
switch.
2. Open all vents and ensure air is flowing freely
when the relative selection is made on the air
distribution control panel. Remove any
obstruction from vents.
BATTERY CONNECTIONS
1. Lift flap covering positive terminal.
2. Wipe battery top clean and dry, smear terminal
posts with petroleum jelly.
3. Ensure terminals are tight.
4. Replace flap.
FUSEBOX
Underbonnet fuse box
1. Release and lift off cover.
2. Check security of fusible link and power lead
connections.
3. Refit cover and secure.
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MAINTENANCE
MAINTENANCE 25
ROAD TEST
Park/NeutraI (inhibitor) switch - Stepspeed
(Em-CVT)
1. Select 'D' selector lever position.
2. Check that engine will not start.
3. Select 'R' selector lever position and repeat
start check.
4. Check that engine will start with the selector
lever in the 'P' and 'N' positions.
SeIector cabIe - Stepspeed (Em-CVT)
1. Move selector lever through positions P R N
and D and check for correct setting of selector
cable.
Engine start and fast idIe speed
1. Start engine from cold and check that fast
engine idle speed is maintained until normal
engine temperature is reached.
Engine performance and throttIe operation
1. Start engine and check that it starts easily.
2. Check that 'oil pressure' and 'no charge'
warning lamps extinguish.
3. Check that throttle pedal movement is free and
unrestricted.
4. Check that engine is responsive to throttle
movement.
CIutch and gear seIection - manuaI transmission.
NormaI driving conditions
1. Check that clutch engages smoothly without
judder, slipping or noise.
2. Check for abnormal transmission noise.
3. Check for smooth, quiet gear change and that
gear selected engages easily.
Gear seIector and parking pawI engagement -
Stepspeed (Em-CVT). NormaI driving conditions.
1. Select position 'R' and check for smooth
take-up.
2. Select 'D', drive away and check for smooth
ratio change from rest.
3. Check for abnormal transmission noise.
4. Slow vehicle down and check for smooth ratio
change.
5. Select 'Sport', drive away and operate selector
lever and steering wheel switches in plus (+)
position from rest. Check for smooth
up-changes of ratio from rest.
6. Slow vehicle down and operate selector lever
and steering wheel switches in minus (-)
position. Check for smooth down-changes of
ratio.
7. Stop the vehicle on a slope.
8. Select position 'P' and release handbrake.
9. Check that vehicle does not move and selector
lever does not slip from 'P' position.
10. Complete the above check with the vehicle
facing in the opposite direction.
Steering
1. Check for noise, effort required, free play and
self-centering.
Suspension
1. Check for noise, irregularity in ride (e.g
dampers) and wheel imbalance.
Footbrake
1. Check for pedal effort, travel, braking
efficiency, pulling and binding.
Instruments
1. Check that all instruments operate.
2. Check speedometer for steady operation,
noise and operation of distance recorder.
Body
1. Check for abnormal body noise.
Seat beIts
1. Check for operation of inertia reels and
condition of belt webbing.
Handbrake
1. Apply handbrake firmly, check ratchet travel is
less than 5 clicks. Check handbrake is not
binding when released.
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ENGINE
CONTENTS Page
REPAIRS
OL SEAL - FRONT - EXHAUST CAMSHAFT - FRONT/LH - Em-CVT MODELS 1 . .
OL SEAL - FRONT - EXHAUST CAMSHAFT - FRONT/LH - VVC MODELS 4 . . . . .
CAMSHAFT REAR OL SEAL - EXHAUST 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OL SEAL - FRONT - NLET CAMSHAFT - REAR/RH - Em-CVT MODELS 8 . . . . . .
OL SEAL - FRONT - NLET CAMSHAFT - REAR/RH - VVC MODELS 11 . . . . . . . .
CAMSHAFT REAR OL SEAL - NLET 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULLEY - CRANKSHAFT - MANUAL GEARBOX MODELS 16 . . . . . . . . . . . . . . . . .
PULLEY - CRANKSHAFT - STEPSPEED (Em-CVT) MODELS 17 . . . . . . . . . . . . . .
PULLEY - CRANKSHAFT - VVC MODELS 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT FRONT OL SEAL 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT REAR OL SEAL 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET - CYLNDER HEAD - VVC MODELS 22 . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET - CYLNDER HEAD - Em-CVT MODELS 26 . . . . . . . . . . . . . . . . . . . . . . . .
GASKET - CAMSHAFT COVER 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE STEM OL SEAL 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE & GEARBOX ASSEMBLY - REMOVE - FOR ACCESS & REFT -
STEPSPEED (Em-CVT) MODELS 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE & GEARBOX ASSEMBLY - REMOVE FOR ACCESS & REFT -
MANUAL GEARBOX MODELS 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE COVER 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGNE MOUNTNG - REAR 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOUNTNG BRACKET - LH - MANUAL GEARBOX MODELS 49 . . . . . . . . . . . . . . .
MOUNTNG BRACKET - LH - STEPSPEED (Em-CVT) MODELS 50 . . . . . . . . . . . .
MOUNTNG BRACKET - RH - ALL MODELS 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL - MANUAL GEARBOX MODELS 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL - STEPSPEED (Em-CVT) MODELS 54 . . . . . . . . . . . . . . . . . . . . . . . . .
TORSON DAMPER - STEPSPEED (Em-CVT) MODELS 55 . . . . . . . . . . . . . . . . . . .
FLYWHEEL STARTER RNG GEAR 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OL FLTER 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET - OL PUMP 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OL SUMP 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWTCH - OL PRESSURE 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OL PRESSURE RELEF VALVE 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR - OL TEMPERATURE 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLER - ENGNE OL - VVC 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TMNG BELT - CAMSHAFT - CONVENTONAL VALVE CONTROL 62 . . . . . . . . . .
TMNG BELT - CAMSHAFT - VVC 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT TMNG BELT GEAR 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT TMNG BELT GEAR 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TMNG BELT UPPER FRONT COVER 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT TMNG BELT REAR COVER - MPi AND VVC - MANUAL
GEARBOX MODELS 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER - TMNG BELT LOWER FRONT 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE
REPAIRS 1
OIL SEAL - FRONT - EXHAUST CAMSHAFT -
FRONT/LH - Em-CVT MODELS
Service repair no - 12.13.07
Remove
1. Disconnect battery earth lead.
2. Remove RH engine hydramount. See this
section.
3. Remove 5 bolts securing camshaft timing belt
upper cover to rear cover.
4. Loosen lower bolt securing timing belt upper
cover, remove cover and collect seal.
5. Using a socket and extension bar on
crankshaft pulley bolt, rotate crankshaft
clockwise to align camshaft gear timing marks -
90 BTDC. Fit camshaft locking tool
18G 1570, between gears.
CAUTION: Never use the camshaft gear,
the camshaft gear retaining boIts or the
timing beIt to turn the crankshaft.
6. Check that the timing mark on crankshaft
pulley is aligned with mark on timing belt lower
cover.
7. Remove and discard timing belt tensioner bolt.
8. Disengage index wire from its fitted position, at
the same time removing timing belt tensioner.
9. With care, release timing belt from camshaft
gears.
CAUTION: Ease timing beIt from gears
using fingers onIy, metaI Ievers may
damage timing beIt and gears. Do not
rotate crankshaft with timing beIt removed and
cyIinder head fitted. Examine timing beIt for
signs of wear or contamination. RepIace a worn
or contaminated timing beIt.
10. Remove camshaft gear locking tool, 18G 1570
from camshaft gears.
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ENGINE
2 REPAIRS
11. Using tool 12-182, restrain camshaft gear and
remove bolt and plain washer securing
camshaft gear to camshaft.
12. Release and remove camshaft gear from
camshaft.
13. Position cloth under camshaft oil seal area to
collect any oil spillage.
14. Fit camshaft gear retaining bolt to camshaft.
15. Remove camshaft oil seal using 18G 1768 and
centre bolt 18G 1299A-1.
16. Remove and discard oil seal from 18G 1768.
17. Remove camshaft gear retaining bolt from
camshaft.
Refit
1. Clean oil seal recess in camshaft carrier and
cylinder head ensuring that all traces of rubber
are removed.
CAUTION: To prevent damage to
machined surfaces; Do Not use a metaI
scraper.
2. Fit oil seal protector, 18G 1749 to end of
camshaft. Position new oil seal and carefully
drift into position using 18G 1769A.
CAUTION: OiI seaIs are waxed and must
not be Iubricated prior to fitting.
3. Clean camshaft gear and mating face.
CAUTION: If sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in soIvent and then
thoroughIy washed in cIean soIvent before
refitting. Because of the porous construction of
sintered materiaI, oiI impregnated in the gear wiII
emerge and contaminate the beIt.
4. Position camshaft gear to camshaft ensuring
that the drive pin is located in correct slot in
gear. Fit and lightly tighten retaining bolt and
plain washer.
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ENGINE
REPAIRS 3
5. Using 12-182, align camshaft gear timing
marks and fit camshaft gear locking tool,
18G 1570.
6. Restrain camshaft gear using tool 12-182 and
tighten retaining bolt to 65 Nm.
cover.
8. Position timing belt tensioner ensuring that the
index wire is located over pillar bolt and that
tensioner lever is at 9 o'clock position.
9. Fit new tensioner Patchlok bolt, tighten bolt
until it is just possible to move tensioner lever.
10. Using fingers only, position timing belt to
camshaft gears, tensioner and coolant pump
drive gear, keeping the timing belt taut from
crankshaft gear and between camshaft gears.
11. Check that timing belt is positioned centrally
around all gears and tensioner pulley.
12. Remove camshaft gear locking tool,18G 1570
13. Using a 6 mm Allen key, rotate tensioner
anti-clockwise to align pointer to index wire. f
original timing belt is being refitted, align index
wire to lower land of pointer.
CAUTION: It is imperative that the pointer
approaches the index wire from above. If
the pointer passes the index wire, the
tension must be fuIIy reIeased and the
tensioning procedure must be repeated.
14. Ensuring that the pointer maintains correct
position, tighten tensioner bolt to 25 Nm.
15. Fit a suitable socket to crankshaft pulley bolt,
rotate crankshaft clockwise 2 complete
revolutions and align camshaft gear timing
marks.
16. Check that pointer is correctly aligned with
index wire.
17. Clean timing belt upper cover.
18. Position timing belt upper cover and seal, fit
and tighten bolts to 5 Nm.
19. Fit RH engine hydramount. See this section.
20. Connect battery earth lead.
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ENGINE
4 REPAIRS
OIL SEAL - FRONT - EXHAUST CAMSHAFT -
FRONT/LH - VVC MODELS
Remove
section.
90 BTDC. Fit camshaft locking tool,
18G 1570 between gears.
cover.
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ENGINE
REPAIRS 5
7. Mark position of tensioner backplate to cylinder
head for timing belt tensioning reference.
8. Loosen timing belt tensioner pulley Allen bolt
1/2 turn.
9. Loosen timing belt tensioner backplate bolt 1/2
turn.
10. Push tensioner pulley down to fully OFF
position and tighten backplate bolt to 10 Nm.
gears.
12. Remove camshaft gear locking tool,18G 1570
camshaft.
17. Remove camshaft oil seal using 18G 1768,
and centre bolt 18G 1299A-1.
camshaft.
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ENGINE
6 REPAIRS
Refit
are removed.
scraper.
2. Fit oil seal protector, 18G 1749 to end of
camshaft, position new oil seal and carefully
plain washer.
5. Using12-182, align camshaft gear timing
18G 1570.
6. Restrain camshaft gear using tool 12-182, and
cover.
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ENGINE
REPAIRS 7
turn.
11. Position tensioner, align to reference mark on
backplate and cylinder head. Tighten tensioner
backplate bolt to 10 Nm.
12. Tighten tensioner pulley Allen bolt to 45 Nm.
13. Remove camshaft gear locking tool,18G 1570,
14. Rotate crankshaft 2 complete turns clockwise
and check that the timing marks on the
camshaft gears and crankshaft pulley are
correctly aligned.
CAMSHAFT REAR OIL SEAL - EXHAUST
Remove
2. Remove engine cover. See this section.
3. Position absorbent cloth beneath vehicle to
catch any oil spillage.
4. Remove 2 bolts securing oil seal cover to
cylinder head and remove cover.
6. Discard camshaft oil seal.
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ENGINE
8 REPAIRS
Refit
1. Clean oil seal recess, ensuring all traces of
rubber are removed.
CAUTION: Do not use a metaI scraper or
the machined surfaces may be damaged.
2. Fit 18G 1749 to end of camshaft to protect seal
and fit new camshaft oil seal using 18G 1769A.
CAUTION: OiI seaI must be fitted dry. DO
NOT USE 18G 1769.
NOTE: Rear oiI seaIs are red.
3. Ensure area around camshaft oil seal is clean
and free from oil.
4. Position cover plate, fit bolts and tighten to
12 Nm.
5. Fit engine cover. See this section.
OIL SEAL - FRONT - INLET CAMSHAFT -
REAR/RH - Em-CVT MODELS
Remove
section.
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ENGINE
REPAIRS 9
90 BTDC. Fit camshaft locking tool
18G 1570, between gears. Never use the
camshaft gear, the camshaft gear retaining
bolts or the timing belt to turn the crankshaft.
cover.
gears.
10. Remove camshaft gear locking tool 18G 1570,
camshaft.
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ENGINE
10 REPAIRS
camshaft.
Refit
are removed.
scraper.
2. Fit oil seal protector,18G 1749 to end of
camshaft. Position new oil seal and carefully
plain washer.
18G 1570.
cover.
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ENGINE
REPAIRS 11
12. Remove camshaft gear locking tool, 18G 1570
13. Using a 6 mm Allen key, rotate tensioner
anti-clockwise to align pointer to index wire. f
original timing belt is being refitted, align index
wire to lower land of pointer.
marks.
index wire.
OIL SEAL - FRONT - INLET CAMSHAFT -
REAR/RH - VVC MODELS
Remove
section.
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ENGINE
12 REPAIRS
90 BTDC. Fit camshaft locking tool 18G 1570,
between gears.
cover.
7. Mark position of tensioner backplate to cylinder
head for timing belt tensioning reference.
1/2 turn.
turn.
gears.
12. Remove camshaft gear locking tool, 18G 1570,
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ENGINE
REPAIRS 13
camshaft.
17. Remove camshaft oil seal using 18G 1768
and centre bolt 18G 1299A-1.
camshaft.
Refit
1. Clean end of camshaft and oil seal recess in
VVC mechanism housing.
scraper.
2. Fit new camshaft oil seal using tool
18G 1604A, carefully drifting the oil seal into
the VVC mechanism housing until flush with
the housing face.
plain washer.
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ENGINE
14 REPAIRS
18G 1570 .
cover.
turn.
11. Position tensioner, align to reference mark on
backplate and cylinder head. Tighten tensioner
12. Tighten tensioner pulley Allen bolt to 45 Nm.
13. Remove camshaft gear locking tool,18G 1570,
14. Rotate crankshaft 2 complete turns clockwise
and check that the timing marks on the
camshaft gears and crankshaft pulley are
correctly aligned.
16. Position timing belt upper cover and seal,fit
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ENGINE
REPAIRS 15
CAMSHAFT REAR OIL SEAL - INLET
Remove
3. Position absorbent cloth beneath vehicle to
catch any oil spillage.
4. Disconnect CMP sensor multiplug and release
CMP harness from oil seal cover.
5. Remove 2 bolts securing oil seal cover to
cylinder head and position cover aside.
7. Discard camshaft oil seal.
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ENGINE
16 REPAIRS
Refit
1. Clean oil seal recess, ensuring all traces of
rubber are removed.
CAUTION: Do not use a metaI scraper or
machined surfaces may be damaged.
2. Fit 18G 1749 to end of camshaft to protect
seal and fit new camshaft oil seal using
18G 1769A. DO NOT USE 18G 1769.
NOTE: OiI seaIs are red.
3. Ensure area around camshaft oil seal is clean
and free from oil.
4. Position cover plate, fit bolts and tighten to
12 Nm.
5. Secure CMP harness to cover plate and
connect CMP multiplug.
PULLEY - CRANKSHAFT - MANUAL GEARBOX
MODELS
Remove
WARNING: Do not work on or under a
vehicIe supported onIy by a jack. AIways
support the vehicIe on safety stands.
3. Remove road wheel.
4. Remove auxiliary drive belt. See
ELECTRICAL, Repairs.
5. Remove starter motor. See ELECTRICAL,
Repairs.
6. Lock crankshaft using tool 18G 1742 .
7. Remove bolt securing crankshaft pulley and
collect washer.
8. Remove crankshaft pulley.
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ENGINE
REPAIRS 17
Refit
1. Clean crankshaft to pulley mating faces.
2. Fit crankshaft pulley to crankshaft, ensuring
that indent on pulley locates over lug on gear.
3. Fit washer and bolt securing crankshaft pulley
to crankshaft and tighten to 205 Nm.
4. Remove crankshaft locking tool 18G 1742 .
5. Fit starter motor. See ELECTRICAL, Repairs.
6. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
PULLEY - CRANKSHAFT - STEPSPEED
(Em-CVT) MODELS
Remove
Repairs.
6. Lock crankshaft using tool 18G 1571 .
collect washer.
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ENGINE
18 REPAIRS
Refit
4. Remove flywheel locking tool 18G 1571 .
Repairs.
PULLEY - CRANKSHAFT - VVC MODELS
Remove
Repairs.
6. Lock crankshaft using tool 1742 .
collect washer.
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ENGINE
REPAIRS 19
Refit
4. Remove crankshaft locking tool 18G 1742.
Repairs.
CRANKSHAFT FRONT OIL SEAL
Remove
1. Remove crankshaft timing belt gear. See this
section.
2. Fit thrust button tool 18G 705-1A/3 to
crankshaft.
3. Ensure bore of tool is burr free, fit and tighten
tool 18G 1566. into crankshaft front oil seal.
4. Tighten centre screw of tool to remove oil seal.
5. Remove thrust button from crankshaft.
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ENGINE
20 REPAIRS
Refit
1. Use lint free cloth to thoroughly clean seal
recess in oil pump and running surface on
crankshaft.
Clean crankshaft pulley and gear.
2. Fit protector, from oil seal kit, over crankshaft
end.
3. Fit new oil seal to crankshaft using tool
18G 1587 . Remove protector.
CAUTION: OiI seaI must be fitted dry.
4. Fit crankshaft timing belt gear. See this
section.
CRANKSHAFT REAR OIL SEAL
Remove
1. Remove flywheel. See this section.
2. Using a burr free flat ended screwdriver, ease
crankshaft rear oil seal from cylinder block,
remove and discard seal.
CAUTION: Do not mark seaIing surface on
crankshaft.
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ENGINE
REPAIRS 21
Refit
1. Remove all traces of oil and sealant from
cylinder block, oil seal recess and running
surface of crankshaft.
2. Apply a continuous bead of sealant, Part No.
GAC 8000 to replacement oil seal as shown.
CAUTION: Do not appIy oiI or grease to
any part of oiI seaI or running surface of
crankshaft. SeaI must be fitted
immediateIy after appIying seaIant.
3. Position oil seal to cylinder block and fit oil seal
replacer tool 18G 1574, retain tool using 3
slave bolts.
4. Evenly tighten oil seal replacer bolts to press
oil seal squarely into cylinder block.
5. Leave oil seal replacer tool and oil seal in
clamped position for one minute to allow oil
seal to relax.
6. Remove oil seal replacer tool.
7. Allow sealant to cure for a minimum of 30
minutes before topping-up oil or rotating
crankshaft.
8. Fit flywheel. See this section.
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ENGINE
22 REPAIRS
GASKET - CYLINDER HEAD - VVC MODELS
Remove
2. Remove engine compartment access cover.
3. Remove inlet manifold gasket. See this
section.
4. Remove camshaft timing belt. See this
section.
5. Restrain camshaft gears using 12-182 and
remove bolts and plain washers securing
camshaft gears to camshafts. Remove
18G 1570 from between camshaft gears.
6. Mark camshaft gears for assembly purposes.
Remove camshaft gears.
7. Remove bolt securing timing belt tensioner
backplate to cylinder head.
8. Remove Allen bolt securing camshaft timing
belt tensioner pulley to cylinder head and
remove timing belt tensioner.
rear cover to cylinder head and cylinder block.
Remove rear cover.
10. Remove camshaft cover gasket. See this
section.
11. Remove nut and 2 speed bolts securing heat
shield to cylinder head and exhaust manifold,
remove heat shield.
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ENGINE
REPAIRS 23
12. Remove spacer from heat shield retaining stud.
13. Remove 5 nuts securing exhaust manifold to
cylinder head, release exhaust manifold from
studs and position aside. Remove and discard
exhaust manifold gasket.
14. Disconnect multiplugs from coolant
temperature sensors.
15. Loosen 2 clips and disconnect coolant hoses
from elbow on cylinder head.
16. Release HO2S multiplug from bracket at rear
of cylinder head.
17. Disconnect multiplug from CMP sensor.
18. Disconnect oil temperature sensor multiplug.
19. Disconnect 2 multiplugs from hydraulic control
solenoids.
20. Temporarily fit camshaft timing gears, fit and
lightly tighten bolts.
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ENGINE
24 REPAIRS
21. Progressively loosen cylinder head to oil rail
bolts numbers 1 to 6 in sequence shown.
22. Using tool 12-182, rotate camshafts to gain
access to cylinder head bolts beneath
camshaft reluctor rings.
23. Working in the sequence shown, progressively
loosen cylinder head bolt numbers 7 to 10.
24. Remove camshaft gears.
25. Remove cylinder head bolts and store in fitted
order.
26. With assistance, remove cylinder head
assembly from cylinder block and support on
wooden blocks.
27. Remove and discard cylinder head gasket from
cylinder block.
CAUTION: Do not rotate crankshaft with
cyIinder head removed.
28. Remove cylinder head location dowels.
29. Fit cylinder liner clamps 18G 1736 to cylinder
block and secure with cylinder head bolts.
CAUTION: Ensure that cyIinder head boIts
used are those originaIIy fitted in that
Iocation.
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ENGINE
REPAIRS 25
Refit
1. Remove bolts securing cylinder liner clamps
18G 1736 to cylinder block and remove
clamps.
2. f necessary, decarbonise piston crowns and
combustion chambers.
3. Clean mating faces of cylinder head and
cylinder block.
4. Clean oil and coolant passages.
5. Clean inlet and exhaust manifold mating faces
on cylinder head.
6. Clean location dowels and fit to cylinder block.
7. Clean cylinder head bolts and wipe dry. Apply
clean engine oil to bolt threads and under head
of bolts.
8. Fit new cylinder head gasket, dry, to cylinder
block.
9. With assistance, fit cylinder head onto cylinder
block, ensure that dowels are correctly located.
10. Carefully enter cylinder head bolts, DO NOT
DROP. Screw boIts into pIace by hand.
11. Temporarily fit camshaft timing gears, fit and
lightly tighten bolts.
12. Using tool 12-182, rotate camshafts to gain
access to cylinder head bolts beneath
camshaft reluctor rings.
13. Working in the sequence shown, progressively
tighten the cylinder head bolts to 20 Nm. Use a
suitable angle torque gauge and tighten all
bolts in sequence 180`. Then tighten all bolts in
sequence a further 180`.
15. Fit camshaft cover gasket. See this section.
16. Connect multiplugs to hydraulic control
solenoids.
17. Connect multiplug to CMP sensor.
18. Connect multiplug to oil temperature sensor.
19. Connect multiplugs to coolant temperature
sensors.
20. Connect hoses to coolant elbow on cylinder
head and tighten clips.
21. Fit new exhaust manifold gasket, position
exhaust manifold, fit and tighten nuts in the
sequence shown to 45 Nm.
22. Secure HO2S multiplug in bracket at rear of
cylinder head.
23. Fit spacer onto stud, position heat shield on
exhaust manifold. Fit and tighten nut to 25 Nm
and speed bolts to 10 Nm.
24. Position camshaft front timing belt rear cover,
fit bolts and tighten to 9 Nm.
25. Position camshaft timing belt tensioner pulley
to cylinder head, fit Allen bolt but do not tighten
at this stage.
26. Fit tensioner backplate bolt, hold tensioner in
the fully OFF position, tighten tensioner
27. Clean camshaft gears and mating faces on
camshafts.
28. Fit camshaft gears to their respective
camshafts, ensuring that the drive pins are
located in correct slots on gears.
29. Fit bolts and washers securing camshaft gears
to camshafts. Using tool 12-182 restrain
camshaft gears and tighten bolts to 65 Nm.
18G 1570.
31. Fit camshaft timing belt. See this section.
32. Fit inlet manifold gasket. See this section.
33. Fit engine compartment access cover.
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ENGINE
26 REPAIRS
GASKET - CYLINDER HEAD - Em-CVT MODELS
Remove
1. Drain cooling system. See COOLING
SYSTEM, Adjustments.
section.
3. Remove inlet manifold gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
4. Using 12-182 to restrain camshaft gears,
remove bolts securing camshaft gears and
collect washers.
6. Remove 5 bolts from timing belt rear cover.
7. Remove rear cover.
8. Remove camshaft cover gasket. See this
section.
9. Remove nut securing alternator lead and
release lead, disconnect alternator multiplug.
10. Remove alternator top bolt and loosen lower
bolt.
11. Position alternator forwards to access
alternator bracket.
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ENGINE
REPAIRS 27
12. Remove nut and bolt securing alternator
bracket.
13. Remove 2 bolts securing exhaust heat shield
and remove heat shield.
14. Collect alternator bracket.
15. Remove 3 bolts securing coolant hose heat
shield and remove heat shield.
16. Remove 5 flange nuts securing exhaust
manifold to cylinder head.
17. Release exhaust manifold from cylinder head.
Position manifold aside, remove and discard
gasket.
18. Loosen clips and disconnect 2 coolant hoses
from cylinder head.
19. Disconnect 2 multiplugs from coolant sensors.
20. Loosen 10 x E12 cylinder head to oil rail bolts
in sequence shown. Remove bolts and store in
fitted order.
21. Remove cylinder head assembly from cylinder
block, use assistance.
22. Remove cylinder head gasket from cylinder
block and discard.
CAUTION: Do not rotate crankshaft with
cyIinder head removed.
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ENGINE
28 REPAIRS
23. Fit tool 18G 1736 to cylinder block and secure
using head bolts as shown.
Refit
1. Remove head bolts and tools 18G 1736 from
cylinder block.
2. Clean joint surfaces on cylinder head and
block, clean oil and coolant passages. Clean
exhaust manifold and cylinder head joint
surfaces. De-carbonise piston crowns and
cylinder head if necessary.
3. nspect cylinder head bolts, See this section.
4. Wash cylinder head bolts and wipe dry. Oil
threads and under head of bolts.
5. Fit new cylinder head gasket to cylinder block.
6. Fit cylinder head to cylinder block carefully
locating dowels, use assistance.
7. Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
8. Working in the sequence shown,progressively
tighten the cylinder head bolts to 20 Nm. Use a
suitable angle torque gauge and tighten all
bolts in sequence 180`. Then tighten all bolts in
sequence a further 180`.
CAUTION: If boIt is overtightened, back off
90 and reaIign.
9. Connect multiplugs to coolant sensors.
10. Position coolant hoses to cylinder head and
tighten clips.
11. Fit new exhaust manifold gasket to cylinder
head.
12. Position manifold and working in the sequence
shown, tighten nuts to 45 Nm.
13. Position coolant hose heat shield, fit bolts and
tighten to 9 Nm.
14. Position alternator bracket.
15. Position exhaust heat shield, fit bolts and
tighten to 9 Nm.
16. Tighten alternator bracket nut and bolt to
25 Nm.
17. Align alternator to bracket, fit top bolt, tighten
both bolts to 45 Nm.
18. Connect alternator multiplug and lead, secure
lead with nut.
19. Fit timing belt rear cover and secure with bolts.
20. Fit camshaft cover gasket. See this section.
21. Clean mating surfaces of camshaft and gears.
22. Fit gears to camshafts.
23. Using tool 12-182 to restrain gears, fit bolts
and washers and tighten to 65 Nm.
24. Check timing of gears and adjust if necessary.
25. Fit tool 18G 1570 to gears.
26. Fit inlet manifold gasket. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
28. Refill cooling system. See COOLING
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ENGINE
REPAIRS 29
GASKET - CAMSHAFT COVER
Remove
2. Remove coil set. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
3. Release 2 clips and disconnect 2 breather
hoses from camshaft cover.
4. Release coil harness from support bracket and
position aside.
5. Remove bolt securing CMP sensor to cylinder
head and position aside.
6. Progressively loosen and remove 15 bolts
securing camshaft cover.
7. Remove camshaft cover.
8. Remove gasket.
Refit
1. Clean mating surfaces of camshaft cover and
carrier.
2. Clean inside of camshaft cover. f necessary,
wash oil separator elements in solvent and
blow dry.
3. Fit new gasket with 'EXHAUST MAN SIDE'
mark towards exhaust manifold.
4. Fit camshaft cover to camshaft carrier.
5. Fit bolts and working in sequence illustrated,
tighten progressively to 9 Nm.
6. Fit CMP sensor, fit bolt and tighten to 9 Nm.
7. Fit coil set. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
8. Fit coil harness to support bracket.
9. Connect breather hoses and secure with clips.
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ENGINE
30 REPAIRS
VALVE STEM OIL SEAL
Remove
2. Remove inlet and exhaust camshafts. See 'K'
Series Engine OverhauI ManuaI - OverhauI.
3. Using a 16 mm spark plug socket, remove 4
spark plugs.
4. Fit and tighten air line adaptor tool MS 1567
into spark plug hole.
5. Connect an airline to adaptor and apply air
pressure.
6. Remove hydraulic tappet from each exhaust
valve.
CAUTION: Retain tappets in fitted order
and store inverted to prevent oiI Ioss.
7. Fit tool 18G 1657/18 and tool MS 1657/7 to
valve spring cap.
8. Strike head of tool firmly with hammer to
release valve spring collets.
9. Remove collets from magnetic end of tool.
10. Remove valve spring cap and spring.
11. Use tool 18G 1577 to remove valve stem oil
seal.
12. Repeat operations to remove second exhaust
valve oil seal.
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ENGINE
REPAIRS 31
Refit
1. Lubricate new valve stem oil seal with engine
oil.
2. Use tool 18G 1577 to fit new oil seals.
3. Fit valve spring and spring cap to each valve.
4. Assemble tool 18G 1657 over exhaust valve.
5. Locate valve spring cap with compressor tool
18G 1657/13 .
6. Screw down valve spring compressor until
valve stem collet groove is level with top face
of spring cap.
7. Attach collets to end of a small flat screwdriver
with grease and locate collets in valve stem
groove.
8. Unscrew valve spring compressor ensuring
collets are correctly located in valve spring cap.
9. Slide head of tool 18G 1657 along to second
exhaust valve position.
10. Repeat refit operations on second valve.
11. Remove valve spring compressor tool
18G 1657 .
12. Lubricate tappets with clean engine oil and refit
in original positions.
13. Disconnect air line from adaptor tool MS 1567 .
14. Remove air line adaptor tool MS 1567 .
15. Clean spark plugs and set gaps to 1.00 mm.
16. Fit inlet and exhaust camshafts. See this
section.
ENGINE & GEARBOX ASSEMBLY - REMOVE -
FOR ACCESS & REFIT - STEPSPEED (Em-CVT)
MODELS
Service repair no - 12.37.01.99
Remove
1. Position vehicle on a 2 post ramp.
3. Remove engine compartment access panel.
See BODY, Exterior fittings.
6. Release clip and disconnect hose from coolant
outlet elbow on cylinder head.
7. Release 3 clips and disconnect coolant hose
assembly between coolant outlet elbow, heater
coolant rail and feed hose to expansion tank.
rail.
9. Release clips securing air intake hose between
air cleaner and throttle body, remove intake
hose.
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ENGINE
32 REPAIRS
10. Release clip and evaporative emission pipe
from throttle body.
11. Disconnect throttle cable from abutment
bracket and throttle cam.
12. Release throttle cable from inlet manifold clip
and position cable aside.
13. Position absorbent cloth around fuel filter,
loosen union to relieve fuel pressure, retighten
union to 30 Nm.
14. Release quick release connector securing fuel
hose to fuel filter outlet pipe.
return hose to fuel return pipe.
16. Depress locking collar and release brake servo
pipe from inlet manifold.
17. Release clip and coolant hose from inlet
manifold.
18. Remove 2 bolts securing expansion tank to
body, raise expansion tank, release clip and
disconnect hose from expansion tank.
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ENGINE
REPAIRS 33
19. Disconnect Lucar connector from starter motor
solenoid.
20. Remove nut and disconnect battery lead from
starter motor solenoid.
21. Remove cover and main fuse from fuse holder.
Remove screw securing fuse holder to body,
position fuse holder aside.
22. Remove inner bolt and loosen outer bolt
securing ECM mounting bracket.
23. Disconnect multiplugs from ECM.
24. Disconnect engine harness and relay unit
multiplugs.
25. Disconnect multiplug from emission canister
purge control valve.
26. Raise vehicle on ramp.
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ENGINE
34 REPAIRS
27. Drain transmission fluid. See AUTOMATIC
GEARBOX - CVT, Information.
28. Remove road wheel(s).
29. Loosen unions and disconnect fluid cooler
pipes from gearbox.
CAUTION: AIways fit pIugs to open
connections to prevent contamination.
30. Remove bolts securing LH and RH ABS
sensors, release sensors and collect sensor
spacers.
31. Release LH and RH ABS sensor leads from
brackets on upper suspension arms, clips and
grommets on each subframe turret.
32. Remove bolts securing LH and RH brake
calipers to hubs. Release calipers and tie
aside.
33. Remove heat shield - rear silencer. See
34. Remove bolt securing engine earth lead to
cylinder block, position earth lead aside.
35. Remove 4 nuts securing anti-roll bar clamps
and rubber mountings to subframe. Collect
clamps and rubber mountings.
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ENGINE
REPAIRS 35
36. Remove nuts and bolts securing LH and RH
anti-roll bar links to trailing arms and remove
anti-roll bar.
37. Release selector cable from selector linkage
and abutment bracket, position cable aside.
38. Remove cable tie securing battery cable to
coolant hose, position battery cable aside.
39. Release clips and disconnect coolant hoses
from coolant rail underneath vehicle.
40. Release clips and disconnect heater hoses
from underneath vehicle.
41. Position engine table underneath rear of
vehicle, lower ramp sufficiently until engine and
subframe are supported by table.
42. Remove 4 front bolts and 6 rear bolts securing
subframe mountings to body.
43. Collect anti-roll bar mounting brackets.
44. Carefully raise ramp and guide engine and
subframe from body.
CAUTION: Ensure that subframe/engine
assembIy is positioned secureIy on engine
tabIe.
45. Remove nut and bolt securing trailing arm to
trailing arm bush.
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ENGINE
36 REPAIRS
46. Remove bolt securing lower link to rear hub.
47. Remove nut securing track control arm to hub.
48. Release track control arm taper joint from hub
using 18G-1584.
49. Remove and discard lock nut securing ball joint
to upper suspension arm.
50. Fit slave nut to ball joint threads, position
18G-1584 and release ball joint taper from
upper suspension arm. Remove 18G-1584
and slave nut.
51. Disconnect multiplug from starter inhibitor
switch and release lead from clip.
52. Remove starter inhibitor switch from gearbox.
53. Release drive shaft inner joint from gearbox
using 18G-1761.
54. Remove hub assembly and drive shaft.
55. Remove and discard circlip from drive shaft.
56. Repeat operations for opposite hub assembly.
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ENGINE
REPAIRS 37
remove heat shield.
of cylinder head and disconnect multiplug.
59. Release HO2S harness from clip on cylinder
block bracket.
60. Remove 6 nuts securing front pipe to exhaust
manifold.
61. Release front pipe from exhaust manifold and
support rubber, remove front pipe, remove and
discard gasket.
62. Remove 2 bolts securing exhaust camshaft
rear oil seal cover plate and remove cover
plate.
63. Position lifting brackets 18G-1572/1 and
18G-1572/2 to cylinder head and secure with
bolts.
64. Position adjustable lifting equipment, 18G-1598
to lifting brackets.
65. Connect hoist to 18G-1598, raise hoist to take
weight of engine and gearbox.
66. Remove bolt securing rear engine steady to
bracket on sump.
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ENGINE
38 REPAIRS
67. Remove nut and bolt securing gearbox
mounting to LH buttress.
68. Remove 4 bolts securing LH buttress to
subframe and remove buttress.
69. Remove nut securing RH engine mounting
bracket to hydramount.
70. Remove bolt securing RH engine steady to
engine mounting bracket. Loosen bolt securing
engine steady to RH buttress, pivot engine
steady from mounting bracket.
71. Remove bolt, loosen remaining bolt and move
engine mounting restraining loop aside.
72. With assistance, raise and remove engine and
gearbox from subframe.
73. Lower engine and gearbox assembly,
disconnect hoist from 18G-1598 .
Refit
1. Connect hoist to 18G-1598 , raise engine and
gearbox assembly.
2. Position subframe assembly under engine.
3. Lower engine and gearbox assembly onto
subframe, correctly position LH buttress and
gearbox mounting.
4. Fit and tighten bolts securing LH buttress to
subframe to 45 Nm.
5. Fit and tighten nut and bolt securing gearbox
mounting to LH buttress to 82 Nm.
6. Position engine mounting restraining loop, fit
7. Fit and tighten nut securing RH engine
mounting bracket to hydramount to 82 Nm.
8. Position RH engine steady to engine mounting
bracket, fit and tighten bolt to 85 Nm.
9. Tighten nut and bolt securing RH engine
steady to buttress to 85 Nm.
10. Position rear engine steady to bracket on
sump, fit and tighten bolt to 85 Nm.
11. Lower hoist and remove 18G-1598 , remove
lifting brackets 18G-1572/1 and 18G-1572/2 .
12. Position exhaust camshaft rear oil seal cover
plate, fit bolts and tighten to 12 Nm.
13. Fit a new gasket, position front pipe to exhaust
manifold. Fit and tighten nuts to 50 Nm.
Engage front pipe in support rubber.
14. Position heat shield, fit nut and bolts, tighten
nut to 25 Nm and bolts to 10 Nm.
15. Connect HO2S multiplug, secure multiplug in
support bracket.
16. Secure HO2S harness in clip on cylinder block
bracket.
17. Clean ends of both drive shafts.
18. Fit new circlip to groove on drive shaft inner
joint.
19. Wipe taper joints of both hub ball joints and
upper arms.
20. Fit both hub assemblies to upper arms and
engage both drive shafts in differential.
CAUTION: PuII outwards on drive shaft
inner joints to check for fuII engagement
in differentiaI.
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ENGINE
REPAIRS 39
21. Position ball joint to upper suspension arm, fit
and tighten new lock nut to 54 Nm.
22. Position lower link to rear hub, fit, but do not
tighten bolt at this stage
23. Wipe tapers and seats of track control arms
and hubs.
24. Position track control arms to both rear hubs, fit
and tighten nuts to 38 Nm.
25. Fit bolt and nut securing trailing arm to trailing
arm bush and tighten to 100 Nm.
26. Fit and tighten starter inhibitor switch to 12 Nm.
27. Connect multiplug to starter inhibitor switch,
secure lead in clip.
28. Position engine table under body, carefully
lower ramp over engine and gearbox
assembly.
29. Align subframe mountings to body, position
anti-roll bar mounting brackets and loosely fit
bolts.
30. Carefully lower body remaining distance onto
subframe mountings, tighten front mounting
bolts to 30 Nm and rear mounting bolts to
45 Nm.
31. Raise vehicle on ramp and remove table.
32. Fit mounting rubbers to anti-roll bar, position
anti-roll bar to subframe. Position clamps, fit
33. Position anti-roll bar, align links to LH and RH
trailing arms. Fit nuts and bolts but do not
tighten at this stage.
34. Clean brake calipers and mating faces.
35. Position LH and RH brake calipers to hubs, fit
36. Clean ABS sensors and mating faces.
37. Position ABS sensors and spacers, fit and
tighten bolts to 10 Nm.
38. Secure LH and RH ABS lead grommets and
leads into brackets and clips on each subframe
turret and upper suspension arms.
39. Position engine earth lead to cylinder block, fit
and tighten bolt to 25 Nm.
40. Fit heat shield - rear silencer. See MANIFOLD
& EXHAUST SYSTEMS, Repairs.
41. Clean gearbox fluid cooler pipe connections
and mating faces on gearbox.
42. Connect and tighten gearbox fluid cooler pipe
unions to 14 Nm.
43. Position selector cable to gearbox abutment
bracket and selector linkage, secure with clips.
44. Connect hoses to coolant rail on underside of
vehicle and secure with clips.
45. Connect heater hoses and secure with clips.
46. Secure battery cable to coolant hose with cable
tie.
48. Lower vehicle on ramp.
49. With the weight of the vehicle on the rear
suspension, tighten bolts securing lower links
to rear hubs to 100 Nm.
suspension, tighten anti-roll bar link nuts and
bolts to 35 Nm.
51. Connect road speed transducer multiplug.
52. Connect multiplug to emission canister purge
control valve.
53. Connect engine harness and relay unit
multiplugs.
54. Connect ECM multiplugs.
55. Position ECM bracket, fit and tighten bolts to
8 Nm.
56. Position main fuse holder to body and secure
with screw. Fit main fuse and cover.
57. Connect battery lead to starter motor solenoid,
fit and tighten terminal nut.
58. Connect Lucar to starter motor solenoid.
59. Connect coolant hose to expansion tank and
secure with clip. Position expansion tank, fit
60. Connect coolant hose to inlet manifold and
secure with clip.
61. Connect brake servo vacuum pipe to inlet
manifold.
62. Connect fuel return hose to fuel return pipe.
63. Connect fuel hose to fuel filter outlet pipe.
64. Connect throttle cable to throttle cam and
abutment bracket.
65. Secure throttle cable in clip on inlet manifold.
66. Connect evaporative emission pipe to throttle
body and secure with clip.
67. Position air intake hose and secure with clips.
68. Connect hose to coolant rail and secure with
clip.
69. Connect hose assembly between coolant outlet
elbow, heater coolant rail and expansion tank.
Secure hoses with clips.
70. Connect hose to coolant elbow on cylinder
head and secure with clip.
71. Refill transmission with fluid. See
AUTOMATIC GEARBOX - CVT,
Information.
72. Fill cooling system. See COOLING SYSTEM,
Repairs.
74. Fit engine compartment access panel. See
BODY, Exterior fittings.
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ENGINE
40 REPAIRS
ENGINE & GEARBOX ASSEMBLY - REMOVE
FOR ACCESS & REFIT - MANUAL GEARBOX
MODELS
Remove
outlet elbow on cylinder head.
7. Release 3 clips and disconnect coolant hose
assembly between coolant outlet elbow, heater
coolant rail and feed hose to expansion tank.
rail.
9. Release clips securing air intake hose between
air cleaner and throttle body, remove intake
hose.
10. Release clip and evaporative emission hose
from throttle body.
11. Disconnect throttle cable from abutment
bracket and throttle cam.
12. Release throttle cable from inlet manifold clip
and position cable aside.
13. Position absorbent cloth around fuel filter,
loosen union to relieve fuel pressure, retighten
union to 30 Nm.
hose to fuel filter outlet pipe.
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ENGINE
REPAIRS 41
return hose to fuel return pipe.
16. Depress locking collar and release brake servo
pipe from inlet manifold.
17. Release clip and coolant hose from inlet
manifold.
body, raise expansion tank, release clip and
disconnect hose from expansion tank.
19. Remove nut and disconnect battery lead from
20. Disconnect Lucar connector from starter motor
solenoid.
21. Release clip securing battery lead to clutch
slave cylinder mounting bracket.
22. Remove cover and main fuse from fuse holder.
Remove screw securing fuse holder to body,
position fuse holder aside.
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ENGINE
42 REPAIRS
23. Remove inner bolt and loosen outer bolt
securing ECM mounting bracket.
24. Disconnect multiplugs from ECM.
25. Disconnect engine harness and relay unit
multiplugs.
26. Disconnect multiplug from emission canister
purge control valve.
27. Remove 'R' clip, washer and clevis pin
securing clutch slave cylinder push rod to
release lever and remove push rod.
28. Remove 2 bolts securing clutch slave cylinder
to mounting bracket, position slave cylinder
aside.
31. Drain gearbox oil.
sensors to hubs, release sensors and collect
sensor spacers.
33. Release LH and RH ABS sensor lead
grommets and sensor leads into brackets and
clips on each subframe turret and upper
suspension arms.
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ENGINE
REPAIRS 43
calipers to hubs. Release calipers and tie
aside.
35. Remove bolt securing engine earth lead to
cylinder block, position earth lead aside.
37. Remove 4 nuts securing anti-roll bar clamps
and rubber mountings to subframe. Collect
clamps and rubber mountings.
anti-roll bar links to trailing arms and remove
anti-roll bar.
39. Remove and discard clips securing selector
cables to gearbox abutment brackets.
40. Release selector cables from selector linkage
and position cables aside.
from coolant rail underneath vehicle.
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ENGINE
44 REPAIRS
42. Release clips and disconnect heater hoses
from underneath vehicle.
43. Remove cable tie securing battery cable to
coolant hose, position battery cable aside.
44. Position engine table underneath rear of
vehicle, lower ramp sufficiently until engine and
subframe are supported by table.
45. Remove 4 front bolts and 6 rear bolts securing
subframe mountings to body.
46. Collect anti-roll bar mounting brackets.
47. Carefully raise ramp and guide engine and
subframe from body.
CAUTION: Ensure that subframe/engine
assembIy is positioned secureIy on engine
tabIe.
trailing arm bush.
50. Remove nut securing track control rod to hub.
51. Release track control rod taper joint from hub
using 18G-1584 .
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ENGINE
REPAIRS 45
and slave nut.
54. Release drive shaft inner joint from gearbox
using 18G-1761 .
55. Remove hub assembly and drive shaft.
57. Repeat operations for opposite hub assembly.
remove heat shield.
of cylinder head and disconnect multiplug.
60. Release HO2S harness from clip on cylinder
block bracket.
61. Remove 6 nuts securing front pipe to exhaust
manifold.
62. Release front pipe from exhaust manifold and
support rubber, remove front pipe, remove and
discard gasket.
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ENGINE
46 REPAIRS
63. Remove 2 bolts securing exhaust camshaft
rear oil seal cover plate and remove cover
plate.
64. Position lifting brackets 18G-1572/1 and
18G-1572/2 to cylinder head and secure with
bolts.
65. Position adjustable lifting equipment, 18G-1598
to lifting brackets.
66. Connect hoist to 18G-1598, raise hoist to take
weight of engine and gearbox.
67. Remove bolt securing rear engine steady to
bracket on sump.
68. Remove nut and bolt securing gearbox
mounting to LH buttress.
69. Remove 4 bolts securing LH buttress to
subframe and remove buttress.
70. Remove nut securing RH engine mounting
bracket to hydramount.
71. Remove bolt securing RH engine steady to
engine mounting bracket. Loosen nut and bolt
securing engine steady to RH buttress, pivot
engine steady from mounting bracket.
72. Remove bolt, loosen remaining bolt and move
engine mounting restraining loop aside.
73. With assistance, raise and remove engine and
gearbox from subframe.
74. Lower engine and gearbox assembly,
disconnect hoist from 18G-1598 .
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ENGINE
REPAIRS 47
Refit
1. Connect hoist to 18G-1598, raise engine and
gearbox assembly.
2. Position subframe assembly under engine.
3. Lower engine and gearbox assembly onto
subframe, correctly position LH buttress and
gearbox mounting.
4. Fit and tighten bolts securing LH buttress to
subframe to 45 Nm.
5. Fit and tighten nut and bolt securing gearbox
mounting to LH buttress to 82 Nm.
6. Position engine mounting restraining loop,fit
7. Fit and tighten nut securing RH engine
mounting bracket to hydramount to 82 Nm.
8. Position RH engine steady to engine mounting
bracket, fit and tighten bolt to 85 Nm.
9. Tighten nut and bolt securing RH engine
steady to buttress to 85 Nm.
10. Position rear engine steady to bracket on
sump, fit and tighten bolt to 85 Nm.
11. Lower hoist and remove 18G-1598, remove
lifting brackets 18G-1572/1 and 18G-1572/2 .
12. Position exhaust camshaft rear oil seal cover
plate, fit bolts and tighten to 12 Nm.
13. Fit a new gasket, position front pipe to exhaust
manifold. Fit and tighten nuts to 50 Nm.
Engage front pipe in support rubber.
14. Position heat shield, fit nut and bolts, tighten
nut to 25 Nm and bolts to 10 Nm.
15. Connect HO2S multiplug, secure multiplug in
support bracket.
16. Secure HO2S harness in clip on cylinder block
bracket.
17. Clean ends of both drive shafts.
joint.
19. Wipe taper joints of both hub ball joints and
upper arms.
20. Fit both hub assemblies to upper arms and
engage both drive shafts in differential.
CAUTION: PuII outwards on drive shaft
inner joints to check for fuII engagement
in differentiaI.
and tighten new lock nut to 54 Nm.
22. Position lower link to rear hub, fit, but do not
tighten bolt at this stage
23. Wipe tapers and seats of track control arms
and hubs.
24. Position track control arms to both rear hubs, fit
25. Fit bolt and nut securing trailing arm to trailing
arm bush and tighten to 100 Nm.
26. Position engine table under body, carefully
lower ramp over engine and gearbox
assembly.
27. Align subframe mountings to body, position
anti-roll bar mounting brackets and loosely fit
bolts.
28. Carefully lower body remaining distance onto
subframe mountings, tighten front mounting
bolts to 30 Nm and rear mounting bolts to
45 Nm.
30. Fit mounting rubbers to anti-roll bar, position
anti-roll bar to subframe. Position clamps, fit
31. Position anti-roll bar, align links to LH and RH
trailing arms. Fit nuts and bolts but do not
32. Clean brake calipers and mating faces.
33. Position LH and RH brake calipers to hubs, fit
34. Clean ABS sensors and mating faces.
35. Position ABS sensors and spacers, fit and
36. Secure LH and RH ABS lead grommets and
leads into brackets and clips on each subframe
turret and upper suspension arms.
37. Position engine earth lead to cylinder block, fit
and tighten bolt to 25 Nm.
39. Position selector cables to gearbox abutment
brackets and secure with new spring clips.
Connect selector cables in gearbox linkages.
40. Connect hoses to coolant rail on underside of
vehicle and secure with clips.
41. Connect heater hoses and secure with clips.
42. Secure battery cable to coolant hose with cable
tie.
suspension, tighten bolts securing lower links
to rear hubs to 100 Nm.
bolts to 35 Nm.
47. Connect road speed transducer multiplug.
48. Position clutch slave cylinder to mounting
bracket, fit and tighten bolts to 25 Nm.
49. Position push rod to slave cylinder, fit clevis pin
and washer through push rod and release lever
and secure with 'R' clip.
50. Connect multiplug to emission canister purge
control valve.
51. Connect engine harness and relay unit
multiplugs.
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ENGINE
48 REPAIRS
52. Connect ECM multiplugs.
53. Position ECM bracket, fit and tighten bolts to
8 Nm.
54. Position main fuse holder to body and secure
with screw. Fit main fuse and cover.
55. Connect battery lead to starter motor solenoid,
fit and tighten terminal nut.
56. Connect Lucar to starter motor solenoid.
57. Position battery cable to clutch slave cylinder
mounting bracket and secure with clip.
58. Connect coolant hose to expansion tank and
secure with clip. Position expansion tank, fit
secure with clip.
60. Connect vacuum pipe to inlet manifold.
61. Connect fuel hose to fuel filter outlet pipe.
62. Connect fuel return hose to fuel return pipe.
abutment bracket.
64. Secure throttle cable in clip on inlet manifold.
65. Connect evaporative emission pipe to throttle
body and secure with clip.
66. Position air intake hose and secure with clips.
67. Connect hose to coolant rail and secure with
clip.
68. Connect hose assembly between coolant outlet
elbow, heater coolant rail and expansion tank.
Secure hoses with clips.
69. Connect hose to coolant elbow on cylinder
head and secure with clip.
70. Fill gearbox with oil.
Adjustments.
ENGINE COVER
Service repair no - 12.37.04/99
Remove
1. Remove hoodwell trim. See BODY, Interior
trim components.
2. Remove sound deadener pad.
3. Remove 11 bolts securing engine cover.
4. Remove engine cover.
Refit
1. Position cover and secure with bolts.
2. Fit sound deadener pad.
3. Fit hoodwell trim. See BODY, Interior trim
components.
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ENGINE
REPAIRS 49
ENGINE MOUNTING - REAR
Remove
2. Support engine on jack.
CAUTION: PIace bIock of wood between
sump and jack to avoid damage occurring.
3. Remove nut and bolt securing mounting to
sump.
4. Remove bolt securing mounting to subframe.
5. Remove mounting.
Refit
1. Position mounting to subframe, fit bolt but do
not tighten.
2. Align mounting to sump bracket, fit bolt and
tighten to 85 Nm.
3. Tighten bolt securing mounting to subframe to
85 Nm.
4. Remove jack.
5. Remove stand(s) and lower vehicle.
MOUNTING BRACKET - LH - MANUAL GEARBOX
MODELS
Remove
2. Remove air cleaner assembly. See this
section.
3. Raise rear of vehicle and support on stand(s).
4. Remove LH rear road wheel.
5. Fit wooden block to jack and position jack to
support gearbox.
6. Remove centre nut and bolt securing mounting
to LH buttress.
7. Remove distance piece from centre of
mounting.
8. Raise jack sufficiently to gain access to bolts
securing mounting to gearbox bracket.
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ENGINE
50 REPAIRS
9. Remove 2 bolts securing mounting to gearbox
bracket and remove mounting.
Refit
1. Position mounting to gearbox bracket, fit and
2. Lower and remove jack from under gearbox.
3. Fit distance piece into centre of mounting.
4. Align mounting to LH buttress, position centre
bolt, fit nut, tighten nut and bolt to 82 Nm.
7. Fit air cleaner assembly. See this section.
MOUNTING BRACKET - LH - STEPSPEED
(Em-CVT) MODELS
Remove
2. Remove air cleaner assembly. See this
section.
support gearbox.
6. Remove centre nut and bolt securing mounting
to LH buttress.
7. Remove distance piece from centre of
mounting.
8. Raise jack sufficiently to gain access to bolts
securing mounting to gearbox bracket.
9. Remove 2 bolts securing mounting to gearbox
bracket and remove mounting.
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ENGINE
REPAIRS 51
Refit
1. Position mounting to gearbox bracket, fit and
2. Lower and remove jack from under gearbox.
3. Fit distance piece into centre of mounting.
4. Align mounting to LH buttress, position centre
bolt, fit nut, tighten nut and bolt to 82 Nm.
7. Fit air cleaner assembly. See this section.
MOUNTING BRACKET - RH - ALL MODELS
Remove
2. Remove engine compartment access grille.
See this section.
5. Remove RH rear road wheel.
6. Remove fixings securing closing panel and
remove panel.
7. Remove trailing arm. See REAR
SUSPENSION, Repairs.
support engine.
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ENGINE
52 REPAIRS
9. Remove nut and bolt securing engine steady to
RH buttress.
10. Loosen nut securing engine top arm bracket to
RH engine hydramount.
11. Remove 2 bolts securing top arm to engine.
12. Remove 4 bolts securing RH buttress to
subframe.
13. Raise engine on jack sufficiently and
manoeuvre RH buttress and engine mount
assembly from vehicle.
NOTE: Do not carry out further
dismantIing if component is removed for
access onIy.
14. Remove 2 bolts securing hydramount to
buttress, collect restraining loop and remove
hydramount.
15. Remove nut and top arm bracket from
hydramount.
Refit
1. Clean hydramount and mating face on
buttress.
2. Position top arm bracket to hydramount, fit nut
but do not tighten at this stage.
3. Position hydramount and restraining loop to
buttress. fit and tighten bolts to 45 Nm.
4. Position engine steady to buttress, fit nut and
bolt but do not tighten at this stage.
5. Position buttress assembly to subframe and
manoeuvre into position.
6. With assistance, manoeuvre engine and align
top arm to engine, fit bolts but do not tighten at
this stage.
7. Lower engine on jack, align buttress to bolt
holes. Fit and tighten bolts securing buttress to
subframe to 45 Nm.
8. Tighten bolts securing top arm to engine to 100
Nm.
9. Tighten nut securing top arm to hydramount to
82 Nm.
10. Tighten nut and bolt securing engine steady to
buttress to 85 Nm.
11. Remove jack from underneath engine.
12. Fit trailing arm. See REAR SUSPENSION,
Repairs.
13. Position closing panel and secure with fixings.
16. Fit engine compartment access cover. See
this section.
17. Fit engine compartment access grille. See
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ENGINE
REPAIRS 53
FLYWHEEL - MANUAL GEARBOX MODELS
Remove
1. Remove clutch assembly. See CLUTCH,
Repairs.
2. Disconnect multiplug from CKP sensor.
3. Remove bolt securing CKP sensor, release
and remove sensor.
4. Fit flywheel locking tool 18G 1674, to cylinder
block and secure with bolt.
5. Remove and discard 6 bolts securing flywheel
to crankshaft.
6. Remove bolt and flywheel locking tool,
18G 1674, from cylinder block.
7. Remove flywheel from crankshaft.
Refit
1. Clean adhesive from threads of flywheel bolt
holes in crankshaft using an old flywheel bolt,
with 2 saw cuts at an angle of 45 to the bolt
shank.
2. Clean flywheel and mating face of crankshaft.
3. Fit flywheel to crankshaft.
4. Fit new bolts securing flywheel to crankshaft
5. Fit flywheel locking tool 18G 1674 to cylinder
6. Working in a diagonal sequence, tighten
flywheel bolts to 85 Nm.
7. Clean CKP sensor and mating face.
8. Fit CKP sensor to cylinder block, fit bolt and
tighten to 6 Nm.
9. Connect multiplug to CKP sensor.
10. Fit clutch assembly. See CLUTCH, Repairs.
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ENGINE
54 REPAIRS
FLYWHEEL - STEPSPEED (Em-CVT) MODELS
Remove
1. Remove torsion damper. See this section.
3. Remove bolt securing CKP sensor to cylinder
block and remove sensor.
4. Fit flywheel locking tool 18G 1674 to sump and
secure with bolt.
5. Remove and discard 6 bolts securing flywheel
to crankshaft.
7. Remove flywheel from crankshaft.
Refit
1. Clean bolt holes in crankshaft using an old
flywheel bolt with two saw cuts at an angle of
45 to the bolt shank.
2. Clean flywheel and mating face of crankshaft.
3. Fit flywheel to crankshaft.
4. Fit new bolts, but do not tighten at this stage.
5. Fit flywheel locking tool 18G 1674 and secure
with bolt.
6. Working in a diagonal sequence tighten
flywheel bolts to 85 Nm.
8. Fit CKP sensor to cylinder block, fit bolt and
tighten to 6 Nm.
10. Fit torsion damper. See this section.
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ENGINE
REPAIRS 55
TORSION DAMPER - STEPSPEED (Em-CVT)
MODELS
Remove
1. Remove automatic gearbox assembly. See
AUTOMATIC GEARBOX - Em-CVT,
Repairs.
2. Fit flywheel locking tool 18G 1674 to sump and
tighten bolt.
3. Progressively loosen and then remove 6 bolts
securing torsion damper to flywheel.
4. Remove torsion damper.
Refit
1. Clean torsion damper and flywheel mating
faces.
2. Position torsion damper to flywheel, fit bolts but
do not tighten at this stage.
3. Working in a diagonal sequence, progressively
4. Remove bolt securing flywheel locking tool and
remove tool.
5. Refit automatic gearbox assembly. See
AUTOMATIC GEARBOX - Em-CVT,
Repairs.
FLYWHEEL STARTER RING GEAR
Remove
1. Remove flywheel. See this section.
2. Apply a cold chisel in root of one of ring gear
teeth, strike chisel with hammer to break ring
gear.
3. Remove starter ring gear.
Refit
1. Clean flywheel and new starter ring gear.
2. Heat new starter ring gear evenly to
approximately 350 C, indicated when the ring
is a light blue colour.
3. Locate ring gear on flywheel and press ring
gear hard against flange on flywheel.
4. Ensure ring gear is correctly seated around the
complete circumference of flywheel and allow
to cool.
5. Fit flywheel. See this section.
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ENGINE
56 REPAIRS
OIL FILTER
Remove
2. Clean area around filter head and place a
container beneath engine.
3. Using a strap wrench, unscrew and discard
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.
5. Top up engine with oil to specification 10w/40
until level is correct.
6. Start and run engine and check for oil leaks.
7. Stop engine, wait a few minutes, then check oil
level. Top up if necessary.
GASKET - OIL PUMP
Remove
section.
2. Remove 2 bolts securing engine harness to oil
pump and move harness clear of pump.
3. Remove 9 bolts securing oil pump to cylinder
block.
4. Remove lower bolt from timing belt rear cover.
5. Release rear cover to facilitate pump removal.
6. Remove pump and discard gasket.
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ENGINE
REPAIRS 57
Refit
1. Clean oil pump bolt holes in cylinder block.
2. Clean oil seal running surface on crankshaft.
3. Fit new oil pump gasket to cylinder block, align
and fit oil pump.
CAUTION: Do not Iubricate crankshaft
front oiI seaI or running surface of
crankshaft.
4. Fit new Patchlok bolts and tighten in sequence
shown to 10 Nm.
5. Fit and tighten bolt securing timing belt rear
cover to 9 Nm.
6. Align engine harness to oil pump, fit bolts and
tighten to 10 Nm.
OIL SUMP
Remove
1. Remove exhaust front pipe. See MANIFOLD
2. Drain engine oil. See MAINTENANCE.
3. Loosen bolt securing engine rear mount to
subframe.
4. Remove nut and bolt securing engine rear
mount to engine.
5. Remove 2 bolts securing oil sump to gearbox.
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ENGINE
58 REPAIRS
6. Remove 14 bolts securing oil sump to bearing
ladder noting the fitted positions of 2 longest
bolts.
7. Using a mallet, gently tap sump sideways to
release sealant bond; remove sump.
CAUTION: Do not Iever between sump
fIange and bearing Iadder.
Do not carry out further dismantling if
component is removed for access only.
8. Remove 4 bolts securing engine rear mount to
sump, remove mount.
Refit
1. Clean inside of sump. Remove all traces of
sealant using a suitable solvent.
2. Fit mount to sump, fit bolts and tighten to
80 Nm.
3. Apply sealant from kit,
Part No. GUG 705963GM to sump joint face
and spread to an even film using a brush or
roller.
CAUTION: To avoid contamination,
assembIy shouId be compIeted
immediateIy after appIication of seaIant.
Do not use RTV or any seaIant other than that
suppIied with kit.
4. Fit sump alignment pins 18G 1744 to bearing
ladder as shown.
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ENGINE
REPAIRS 59
5. Position sump to alignment pins, fit 2 bolts at
positions 5 and 6, tighten bolts to 4 Nm.
6. Fit 10 bolts into remaining holes ensuring that
2 longest bolts are in original fitted positions,
finger tighten bolts.
7. Remove alignment pins 18G 1744, fit and
finger tighten remaining 2 bolts.
8. Progressively tighten sump bolts in sequence
shown to 25 Nm.
Tighten sump to gearbox bolts to 45 Nm.
9. Position engine rear mount to subframe, fit bolt
10. Tighten engine rear mount to oil sump bolt to
85 Nm.
11. Fit exhaust front pipe. See MANIFOLD &
12. Fill engine with oil. See MAINTENANCE.
SWITCH - OIL PRESSURE
Remove
3. Position container below engine oil filter to
collect spillage.
4. Disconnect multiplug from oil pressure switch.
5. Remove oil pressure switch.
Refit
1. Clean oil pressure switch threads.
2. Fit oil pressure switch and tighten to 12 Nm.
3. Connect multiplug to oil pressure switch.
5. Top-up engine oil. See MAINTENANCE.
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ENGINE
60 REPAIRS
OIL PRESSURE RELIEF VALVE
Remove
3. Remove fixings securing closing panel and
remove panel.
4. Remove relief valve sealing plug and sealing
washer.
5. Remove spring and relief valve.
Refit
1. Clean oil pump housing.
2. Clean valve spring, valve and sealing washer.
3. Lubricate relief valve. Fit valve and spring.
4. Fit new sealing washer, fit and tighten sealing
plug to 25 Nm.
5. Fit closing panel and secure with fixings.
8. Check and top up oil level. See
MAINTENANCE.
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ENGINE
REPAIRS 61
SENSOR - OIL TEMPERATURE
Remove
3. Disconnect multiplug from oil temperature
sensor.
4. Position drain tin below switch to catch oil
spillage.
5. Remove oil temperature sensor.
Refit
1. Clean oil temperature sensor threads.
2. Fit oil temperature sensor and tighten to
15 Nm.
3. Connect multiplug to oil temperature sensor.
6. Check and if necessary top up engine oil.
COOLER - ENGINE OIL - VVC
Remove
3. Raise the vehicle on a ramp.
4. Position drain tray under engine oil cooler to
collect spillage.
from engine oil cooler.
6. Loosen and remove engine oil cooler pipe
unions from oil cooler, remove and discard 'O'
rings.
7. Remove 5 bolts securing engine oil cooler to
cylinder block and remove oil cooler.
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ENGINE
62 REPAIRS
Refit
1. Clean engine oil cooler and mating face on
cylinder block.
2. Position engine oil cooler to cylinder block, fit
3. Remove plugs from engine oil cooler and pipe
unions.
4. Use a lint free cloth and wipe oil cooler and
pipe unions.
5. Lubricate new 'O' rings with clean engine oil
and fit to pipe unions.
6. Correctly position pipes to oil cooler and
tighten unions to 18 Nm.
7. Connect coolant hoses to oil cooler and secure
with clips.
Adjustments.
TIMING BELT - CAMSHAFT - CONVENTIONAL
VALVE CONTROL
Remove
CAUTION: Timing beIts must be repIaced
if cyIinder head is to be removed or new
timing gears are to be fitted.
Timing beIts must be stored and handIed with
care.
AIways store a timing beIt on its edge with a
bend radius greater than 50 mm.
Do not use a timing beIt that has been twisted or
bent doubIe as this can damage the reinforcing
fibres.
Do not use a timing beIt if debris other than beIt
dust is found in the timing cover.
Do not use a timing beIt if partiaI engine seizure
has occurred.
Do not use a timing beIt if beIt miIage exceeds
48,000 (77,000 km).
Do not use an oiI contaminated timing beIt. The
cause of contamination MUST be rectified.
3. Remove RH rear road wheel.
4. Remove RH engine hydramount assembly.
See this section.
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ENGINE
REPAIRS 63
90` BTDC. Fit camshaft locking tool, 18G 1570
between gears.
8. Check that the timing mark on the crankshaft
cover.
9. f camshaft timing belt is to be refitted, mark
direction of rotation on timing belt.
10. Remove crankshaft pulley. See this section.
11. Remove 3 bolts securing timing belt lower
cover to cylinder block, remove cover and
rubber seal.
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ENGINE
64 REPAIRS
14. With care, release camshaft timing belt from
gears and remove camshaft timing belt.
CAUTION: Ease the beIt off gears using
fingers onIy. MetaI Ievers may damage the
beIt and gears. Do not rotate crankshaft
with timing beIt removed and cyIinder head
fitted.
15. Remove timing belt drive gear from crankshaft.
Refit
1. Clean crankshaft timing gear, camshaft timing
gears, coolant pump drive gear and tensioner
pulley.
2. Fit timing gear to crankshaft, ensure dots on
timing gear are aligned to flange on oil pump
housing.
3. Check that the timing marks on the camshaft
gears are correctly aligned and that 18G-1570,
is locking camshaft gears.
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ENGINE
REPAIRS 65
6. Using fingers only, fit timing belt. Ensure belt
run between the crankshaft gear and the
exhaust camshaft gear is kept taut during the
fitting procedure.
CAUTION: If the originaI timing beIt is
being refitted, ensure the direction of
rotation mark is facing the correct way.
8. Fit rubber seal to timing belt lower cover,
position cover to cylinder block, fit and tighten
bolts to 9 Nm.
9. Fit crankshaft pulley. See this section.
10. Remove camshaft gear alignment tool.
11. Use a 6mm Allen key to rotate tensioning lever
in an anti-clockwise direction and align pointer
to index wire as shown.
12. f original belt is to be refitted then the pointer
must be aligned so that the index wire is
adjacent to lower land of pointer.
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ENGINE
66 REPAIRS
marks.
15. Check alignment of pointer to index wire.
CAUTION: Ensure that the pointer
approaches the index wire from above.
ShouId the pointer go past index wire,
reIease tension compIeteIy and repeat
tensioning procedure.
16. f pointer is not correctly aligned, loosen bolt
until 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.
marks.
index wire.
22. Fit RH engine hydramount assembly. See this
section.
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ENGINE
REPAIRS 67
TIMING BELT - CAMSHAFT - VVC
Remove
CAUTION: Timing beIts must be repIaced
if cyIinder head is to be removed or new
timing gears are to be fitted.
Timing beIts must be stored and handIed with
care.
AIways store a timing beIt on its edge with a
bend radius greater than 50 mm.
Do not use a timing beIt that has been twisted or
bent doubIe as this can damage the reinforcing
fibres.
Do not use a timing beIt if debris other than beIt
dust is found in the timing cover.
Do not use a timing beIt if partiaI engine seizure
has occurred.
Do not use a timing beIt if beIt miIage exceeds
48,000 (77,000 km).
Do not use an oiI contaminated timing beIt. The
cause of contamination MUST be rectified.
3. Remove RH engine hydramount assembly.
See this section.
90` BTDC. Fit camshaft locking tool 18G-1570,
between gears.
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ENGINE
68 REPAIRS
cover.
9. Remove 3 bolts securing timing belt lower
cover to cylinder block, remove cover and
rubber seal.
10. f camshaft timing belt is to be reused, Mark
position of tensioner backplate to cylinder head
for belt tensioning reference.
1/2 turn.
12. Loosen timing belt tensioner pulley bolt 1/2
turn.
14. With care, release camshaft timing belt from
gears and remove camshaft timing belt.
CAUTION: Ease the beIt off gears using
fingers onIy. MetaI Ievers may damage the
beIt and gears. Do not rotate crankshaft
with timing beIt removed and cyIinder head
fitted.
15. Remove timing belt drive gear from crankshaft.
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ENGINE
REPAIRS 69
Refit
1. Clean crankshaft timing gear, camshaft timing
gears, coolant pump drive gear and tensioner
pulley.
2. Fit timing gear to crankshaft, ensure dots on
timing gear are aligned to flange on oil pump
housing.
3. Check that the timing marks on the camshaft
gears are correctly aligned and that 18G-1750,
is locking camshaft gears.
4. Fit and tighten pillar bolt supplied with new
replacement belt to cylinder head.
5. Connect tensioner spring, also supplied with
replacement timing belt to pillar bolt and
tensioner.
NOTE: The tensioner spring is not fitted
with a rubber sIeeve.
6. Loosen backplate bolt and ensure tensioner
moves fully through its adjustment range and
returns by spring tension.
8. Using fingers only, fit timing belt. Ensure belt
run between the crankshaft gear and the
exhaust camshaft gear is kept taut during the
fitting procedure.
CAUTION: If the originaI timing beIt is
being refitted, ensure the direction of
rotation mark is facing the correct way.
10. Clean timing belt lower cover.
11. Fit rubber seal to timing belt lower cover,
position cover to cylinder block, fit and tighten
bolts to 9 Nm
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ENGINE
70 REPAIRS
Tensioning an existing timing belt.
13. Loosen tensioner pulley bolt and Allen bolt 1/2
turn. Position tensioner to reference mark on
backplate and cylinder head.
14. Tighten tensioner backplate bolt to 10 Nm and
tensioner Allen bolt to 45 Nm.
15. Remove camshaft gear alignment tool
marks.
Tensioning replacement timing belt.
1/2 turn.
turn.
19. Apply tension to belt by applying finger
pressure to tensioner backplate.
20. With tensioner pulley against timing belt and
backplate held in position, tighten tensioner
21. Remove camshaft gear alignment tool
marks.
23. Loosen tensioner backplate bolt and check that
the timing belt is being tensioned by tension
spring.
24. Tighten tensioner backplate bolt to 10 Nm and
tensioner Allen bolt to 45 Nm.
25. Release tensioner spring from pillar bolt and
tensioner, discard spring.
26. Remove and discard pillar bolt.
29. Fit RH engine hydramount assembly. See this
section.
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ENGINE
REPAIRS 71
CAMSHAFT TIMING BELT GEAR
Remove
1. Remove and discard camshaft timing belt. See
this section.
NOTE: MPi timing gears iIIustrated.
2. Restrain camshaft gear using tool 12-182,
remove bolt and plain washer from camshaft
gear.
3. Remove tool 18G 1570.
4. Remove camshaft gear.
Refit
1. Clean gear to camshaft mating faces.
2. Fit camshaft gear and align timing marks using
12-182.
3. Fit plain washer and bolt to camshaft gear,
restrain gear using tool 12-182 and tighten bolt
to:
- M8 bolt - 33 Nm
- M10 bolt - 65 Nm
4. Fit camshaft locking tool 18G 1570 .
5. Fit new camshaft timing belt. See this section.
CRANKSHAFT TIMING BELT GEAR
Remove
1. Remove and discard camshaft timing belt. See
this section.
2. Remove crankshaft timing belt gear.
Refit
1. Clean timing gear mating faces.
2. Fit crankshaft timing belt gear.
3. Fit new camshaft timing belt. See this section.
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ENGINE
72 REPAIRS
TIMING BELT UPPER FRONT COVER
Remove
2. Loosen lower fixing bolt securing timing belt
upper front cover.
3. Remove 5 bolts from timing belt upper front
cover.
4. Remove timing belt upper front cover and seal.
Refit
1. Fit timing belt upper front cover, ensuring seal
is located correctly.
2. Fit bolts and tighten to 9 Nm .
CAMSHAFT TIMING BELT REAR COVER - MPi
AND VVC - MANUAL GEARBOX MODELS
Remove
1. Remove camshaft timing belt gear. See this
section.
2. Remove bolt securing second cam gear to
camshaft and remove gear.
3. Remove 3 bolts securing rear cover to engine.
4. Remove timing belt rear cover.
Refit
1. Fit timing belt rear cover.
2. Fit bolts and tighten to 9 Nm.
3. Fit camshaft gear and tighten bolt to 33 Nm
(8mm) or 65 Nm. (10mm)
4. Fit camshaft timing belt gear.
See this section.
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ENGINE
REPAIRS 73
COVER - TIMING BELT LOWER FRONT
Remove
2. Remove timing belt upper front cover. See this
section.
4. Remove 3 bolts securing lower front cover.
5. Remove lower cover.
Refit
1. Fit lower cover and tighten bolts to 9 Nm.
3. Fit timing belt upper front cover. See this
section.
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ENGINE MANAGEMENT SYSTEM - MEMS
CONTENTS Page
DESCRIPTION AND OPERATION
ENGNE COMPARTMENT COMPONENT LOCATONS - VVC MEMS 3 1 ................
ENGNE COMPARTMENT COMPONENT LOCATONS - MPi MEMS 3 2 .................
MPi/VVC MEMS 3 CONTROL DAGRAM 4 ................................................................
ENGNE MANAGEMENT SYSTEM - MPi/VVC MEMS 3 6 .........................................
FUEL DELVERY SYSTEM 33 ....................................................................................
EMSSON CONTROL SYSTEMS 35 ..........................................................................
ADJUSTMENTS
THROTTLE CABLE 1 ..................................................................................................
FUEL TANK DRANNG 2 ............................................................................................
FUEL SYSTEM DEPRESSURSE 2 ............................................................................
REPAIRS
AR CLEANER 1 ..........................................................................................................
ELEMENT - AR CLEANER 1 ......................................................................................
SENSOR - CAMSHAFT POSTON (CMP) - VVC 2 ....................................................
SENSOR - CAMSHAFT POSTON (CMP) - MPi 3 .....................................................
EVAPORATVE EMSSON CANSTER 3 ...................................................................
CATALYTC CONVERTER 4 .......................................................................................
SENSOR - CRANKSHAFT POSTON (CKP) 5 ..........................................................
ENGNE CONTROL MODULE (ECM) - MPi 6 .............................................................
SENSOR - ENGNE COOLANT TEMPERATURE (ECT) 7 .........................................
ENGNE MANAGEMENT RELAY MODULE 7 ............................................................
FUEL FLTER 8 ...........................................................................................................
FUEL NJECTORS - MPi 9 ..........................................................................................
FUEL NJECTORS - VVC 9 .........................................................................................
FUEL RAL AND NJECTORS - MPi 10 ......................................................................
FUEL PUMP 11 ...........................................................................................................
FLLER NECK 12 .........................................................................................................
HOSE - BREATHER - TANK TO FLLER NECK 14 ....................................................
FUEL RAL - VVC 15 ...................................................................................................
FUEL TANK 16 ............................................................................................................
HT LEAD - SET - MPi 19 .............................................................................................
VALVE - DLE AR CONTROL (AC) - MPi 19 .............................................................
HYDRAULC CONTROL UNT SOLENODS (HCU) - VVC 20 ....................................
GNTON COL - MPi 21 .............................................................................................
SWTCH - NERTA FUEL SHUT-OFF 21 ...................................................................
SENSOR - NTAKE AR TEMPERATURE (AT) - MPi 22 ...........................................
SENSOR - MANFOLD ABSOLUTE PRESSURE (MAP) - VVC 22 ............................
SENSOR - MANFOLD ABSOLUTE PRESSURE (MAP) - MPi 23 ..............................
SENSOR - OL TEMPERATURE - VVC 23 .................................................................
SENSOR - HEATED OXYGEN (HO 24 .......................................................................
SENSOR - HEATED OXYGEN (HO2S) - POST CAT 25 ............................................
SPARK PLUGS 25 .......................................................................................................
THROTTLE HOUSNG - (NCLUDES TUNNG) 26 .....................................................
THROTTLE CABLE 27 ................................................................................................
SENSOR - THROTTLE POSTON (TP) 29 .................................................................
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DESCRIPTION AND OPERATION 1
ENGINE COMPARTMENT COMPONENT
LOCATIONS - VVC MEMS 3
1. Fuel filter
2. Fuel pump
3. Air filter
4. Throttle position (TP) sensor
5. Engine coolant temperature (ECT) sensor
6. ntake air temperature (AT) sensor
7. Camshaft position (CMP) sensor
8. Upstream heated oxygen sensor (H0
2
S)
9. njector
10. Hydraulic control solenoid
11. Hydraulic control unit
12. Fuel pressure regulator
13. Ambient air temperature sensor
14. Manifold absolute pressure (MAP) sensor
15. Throttle cable
16. Oil temperature sensor
17. Fuel rail
18. dle air control (AC) valve
19. Crankshaft position (CKP) sensor
20. Throttle housing
21. Evaporative emission canister, purge valve
22. Evaporative emission canister
23. Downstream heated oxygen sensor (H0
2
S)
24. Engine management relay module
25. Engine control module (ECM)
26. nertia fuel shut-off switch
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2 DESCRIPTION AND OPERATION
ENGINE COMPARTMENT COMPONENT
LOCATIONS - MPi MEMS 3
1. Fuel filter
2. Fuel pump
3. Air filter
4. Throttle Position (TP) sensor
5. Engine Coolant Temperature (ECT) sensor
6. ntake Air Temperature (AT) sensor
7. Camshaft Position (CMP) sensor
8. Upstream Heated Oxygen Sensor (HO
2
S)
9. njector
10. Engine oil temperature sensor
13. Manifold Absolute Pressure (MAP) sensor
14. Fuel rail
15. dle Air Control (AC) valve
16. Crankshaft Position (CKP) sensor
17. Throttle housing
20. Downstream H0
2
S
22. Engine Control Module (ECM)
23. nertia fuel shut-off switch
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This page is intentionaIIy Ieft bIank
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MPi/VVC MEMS 3 CONTROL DIAGRAM
A = Hardwired connection; B = SeriaI Iink; J = Diagnostic ISO 9141 K Iine bus
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1. Passenger compartment fusebox
2. Engine bay cooling fan relay
3. A/C trinary switch
4. Alternator
5. ABS ECU
6. Gearbox differential speed sensor (Em-CVT)
7. MAP Sensor
8. gnition switch
9. AT sensor
10. Alarm ECU
11. ECT sensor
12. TP sensor
13. AC valve
14. Diagnostic socket
15. nstrument pack
16. Hydraulic control solenoids (VVC)
17. gnition coils
18. Engine oil temperature sensor
19. CKP sensor
20. CMP sensor
21. Park/Neutral switch (Em-CVT)
22. njectors (4 of)
23. Purge valve
24. Heated oxygen sensors (H0
2
S)
25. Gearbox nterface Unit (GU)
27. Ambient Air Temperature (AAT) (engine bay)
sensor
29. Cooling fan relay (Non A/C vehicles only)
30. Fusible link FL6 (60A)
31. Fusible link FL4 (40A) gnition switch
32. Fusible link FL3 (30A) Window lift relay, fuse 6
passenger fusebox, fuse 23 satellite fusebox
33. Under bonnet fusebox
34. Fuse 2 (30A) Engine management relay
module, inertia switch
35. Fuse 6 (20A) Cooling fan relay (non A/C
vehicles only) A/C relay pack (A/C vehicles
only)
36. A/C relay pack (A/C vehicles only)
37. Fuse 6 (10A) Engine bay cooling fan relay,
front window lift relay
38. Fuse 15 (20A) Cooling fan relay (non A/C
vehicles only) A/C relay pack, A/C switch pack
(A/C vehicles only)
39. Fuse 1 (10A) nstrument pack
40. Fuse 14 (15A) Alarm ECU, engine
management relay module, ECM
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ENGINE MANAGEMENT SYSTEM - MPi/VVC
MEMS 3
DESCRIPTION
GeneraI
The Modular Engine Management System Version 3
(MEMS 3) is a sequential, multipoint fuel injection
system controlled by the Engine Control Module
(ECM).
The ECM uses the components shown in the control
diagram to control the operation of the:
Fuel system
gnition system
Variable Valve Control (VVC) system (where
applicable)
Evaporative Emissions (EVAP) system
Engine cooling fan(s)
Air Conditioning (A/C) (where applicable)
Stepspeed Electro Mechanical Constantly
Variable Transmission (Em-CVT) (where
applicable)
The ECM uses the speed/density method of air flow
measurement to calculate fuel delivery. This method
calculates the density of intake air by measuring its
pressure and temperature. The density signal,
combined with the engine speed signal, allows the
ECM to make a calculation of the air volume being
inducted and determine the quantity of fuel to be
injected to give the correct air/fuel ratio.
Engine ControI ModuIe (ECM)
The ECM is located on a bracket on the rear
bulkhead in the engine compartment. Two harness
connectors are used to connect the ECM to the main
harness.
The ECM electronic components are housed in an
aluminium case for heat dissipation and protection
from electro-magnetic interference.
The ECM is connected to earth via pins 59, 66 and
73. With the ignition off, the ECM is supplied with
battery voltage to power the memory. The voltage is
supplied from the battery positive terminal via the
under bonnet fusebox - fuselink 6 and fuse 7 to pin
80 of the ECM.
When the ignition switch is in position (ignition on),
the ECM also receives battery voltage, via the
passenger compartment fusebox fuse 14, at pin 61.
The ECM energises the main relay by completing
the earth path for the relay coil which is connected to
the ECM at pin 54. The main relay provides battery
voltage to various peripheral components and also
to the ECM at pin 19.
When the ignition switch is turned to position , the
ECM primes the fuel system by running the fuel
pump for approximately two seconds. This is
achieved by completing the earth path for the fuel
pump relay coil. The fuel pump relay coil is
connected to battery voltage at the ignition switch,
the earth being supplied by the ECM at pin 68. The
ECM references the sensors and the AC valve
stepper motor prior to start up.
Security code information is exchanged between the
ECM and the alarm ECU via a wire connected
between pin 72 of the ECM and the alarm ECU.
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When the ignition is turned to position (crank), the
ECM communicates with the alarm ECU. f it
receives authority to start, the ECM begins ignition
and fuelling when CKP and CMP sensor signals are
detected. The ECM will run the fuel pump
continuously when CKP sensor signals are received
(crank turning).
When the ignition switch is turned to position 0 (off),
the ECM switches off ignition and fuelling to stop the
engine. The ECM continues to hold the main relay in
the on position until it has completed the power
down functions. Power down functions include
engine cooling and referencing the AC valve
stepper motor and also memorising data required for
the next start up.
When the power down process is completed, the
ECM switches off the main relay and enters a low
power mode. During low power mode the ECM will
consume less than 1mA.
f the ECM suffers an internal failure, such as a
break down of the processor or driver circuits, there
are no back up systems or limp home capability. f a
sensor circuit fails to supply an input, this will result
in a substitute or default value being adopted where
possible. This enables the vehicle to function, but
with reduced performance.
Heated Oxygen Sensor (HO
2
S)
A HO
2
S is located upstream of the catalytic
converter, in the twin pipe section of the exhaust
front pipe. A HO
2
S is also installed in the
downstream side of the catalytic converter. The
upstream HO
2
S provides a feedback signal to the
ECM to enable closed loop fuelling control. The
downstream HO
2
S provides a feedback signal to
enable the ECM to monitor the efficiency of the
catalytic converter, by comparing the signals from
the upstream and downstream HO
2
S.
f the upstream H0
2
S fails, the ECM adopts an open
loop fuelling strategy. f the downstream HO
2
S fails,
the ECM suspends catalytic converter monitoring.
A. Ambient Air.
B. Exhaust Gases.
1. Protective ceramic coating.
2. Electrodes.
3. Zirconium Oxide.
CAUTION: HO
2
sensors are easiIy
damaged by dropping, excessive heat or
contamination. Care must be taken not to
damage the sensor housing or tip.
The H0
2
S becomes very hot, take care when
working near it.
Do not measure the resistance of the sensing
eIement.
Observe the correct torque tightening vaIue
when instaIIing the HO
2
S.
Do not subject the HO
2
S to mechanicaI
shocks.
The HO
2
S may be contaminated if Ieaded fueI
is used.
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The HO
2
S consists of a sensing element, the outer
surface of which is exposed to exhaust gases, whilst
the inner surface is exposed to ambient air. The
sensor has a ceramic coating to protect the sensing
element from contamination and heat damage.
The amount of oxygen in ambient air is constant at
approximately 20%. The oxygen content of the
exhaust gases varies with the AFR with a typical
value for exhaust gas of around 2%.
The difference in oxygen content of the two gases
produces an electrical potential difference across the
sensing element. Rich mixtures, which burn almost
all of the available oxygen, produce high sensor
voltages. During lean running, there is an excess of
oxygen in the mixture and some of this oxygen
leaves the combustion chamber unburnt.
n these conditions, there is less difference between
the oxygen content of the exhaust gas and the
ambient air, and a low potential difference (voltage)
is output by the HO
2
S.
a. Rich AFR
b. Lean AFR
c. Lambda window
d. HO
2
S Output in mV.
The material used in the sensing element only
becomes active at a temperature of 300 C (572 F),
therefore it is necessary to provide additional
heating via an electrical resistive element. The
element uses a 12V supply provided by the ECM
and allows a short warm up time and minimises
emissions from start-up. The resistance of the
heating element can be measured using a
multimeter and should be 6 at 20 C (68 F).
Crankshaft Position (CKP) Sensor
The variable reluctance CKP sensor is mounted at
the rear of the engine with the sensor tip facing the
engine face of the flywheel and is secured in the
casting with a single screw. The sensor tip of the
CKP sensor is adjacent to a profiled target ring
formed on the inner face of the flywheel.
The signal produced by the CKP sensor allows the
ECM to calculate the rotational speed and angular
position of the crankshaft. This information is
required by the ECM to calculate ignition timing, fuel
injection timing and fuel quantity during all conditions
when the engine is cranking or running. f the CKP
sensor signal is missing, the vehicle will not run as
there is no substitute signal or default.
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The CKP sensor is a variable reluctance sensor and
provides an analogue voltage output to the ECM
relative to the speed and position of the target on the
flywheel. A permanent magnet inside the sensor
applies a magnetic flux to a sensing coil winding.
This creates an output voltage which is read by the
ECM.
As the gaps between the poles of the target pass the
sensor tip, the magnetic flux is interrupted and this
causes a change to the output voltage (e.m.f.).
t is important to note that the ECM is unable to
determine the exact position of the engine with its
four stroke cycle from the CKP sensor alone: the
CMP sensor must also be referenced to provide
sufficient data for ignition control and sequential
injection.
The 'spaces' on the target are spaced at a rate of
one hole per 10 . There are only 32 holes, this
leaves four 'spaces' where a single hole is missing.
When the crankshaft is positioned at TDC (cylinder
number one firing position) the CKP sensor is
positioned at 55 BTDC. The 'missing' holes are
positioned at 80 , 110 , 260 and 300 before the
CKP sensor position.
Camshaft Position (CMP) Sensor
The CMP sensor provides a signal which enables
the ECM to determine the position of the camshaft
relative to the crankshaft. This allows the ECM to
synchronise fuel injection and, on VVC engines,
monitor valve timing.
CMP Sensor - MPi Engines
The CMP sensor on MPi engines is located on the
camshaft cover (under the plastic cover) at the
opposite end to the camshaft drive and reads off a
reluctor on the exhaust camshaft.
The sensor is a Hall effect sensor which detects the
reluctor mounted on the exhaust camshaft. The
sensor receives a battery supply from the main
relay. The sensor operates on the principle of a
voltage generated when the sensor is exposed to a
magnetic flux. This causes a potential difference in
voltage as the reluctor passes the sensor which is
detected as a digital signal by the ECM.
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CMP Sensor - VVC Engines
The CMP sensor on VVC engines is located on the
rear face of the cylinder head and reads off a
reluctor on the inlet camshaft.
The CMP sensor is a variable reluctance sensor
which does not require a power supply. The sensor
consists of a permanent magnet and a sensing coil
winding.
The signal is generated by changes which occur in
the magnetic flux of the magnet. As the reluctor
passes the sensor, an electromotive force (e.m.f.) is
generated in the coil winding. The amplitude of the
e.m.f. is proportional to the frequency of the change
of magnetic flux which is detected by the ECM as an
analogue signal.
CMP Reluctor - MPi and VVC Engines
The reluctor consists of a single 'tooth' design which
extends over 180 of the camshaft's rotation, for this
reason it is known as a half moon cam wheel.
The half moon cam wheel reluctor enables the ECM
to provide sequential fuel injection at start up, but it
cannot provide a back-up signal in cases of CKP
sensor failure.
f the CMP sensor signal is missing, the engine will
still start and run, but the fuel injection may be out of
phase. This will be noticeable by a reduction in
performance and driveability, together with an
increase in fuel consumption and emissions.
As the camshaft rotates the signal will switch
between the high and low voltages. The position of
the half moon cam wheel relative to the camshaft is
not adjustable. The air gap between the CMP sensor
tip and the half moon cam wheel is not adjustable.
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ManifoId AbsoIute Pressure (MAP) Sensor
The output signal from the MAP sensor, together
with the CKP and AT sensors, is used by the ECM
to calculate the amount of air induced into the
cylinders. This enables the ECM to determine
ignition timing and fuel injection duration values.
The MAP sensor receives a 5V 4% supply voltage
from the ECM and provides the ECM with an
analogue signal which relates to the absolute
manifold pressure and allows the ECM to calculate
engine load.
f the MAP signal is missing, the ECM will substitute
a default manifold pressure reading based on
crankshaft speed and throttle angle. The engine will
continue to run with reduced driveability and
increased emissions, although this may not be
immediately apparent to the driver. The ECM will
store fault codes which can be retrieved using
TestBook.
Engine CooIant Temperature (ECT) Sensor
The ECT sensor is located in the cooling system
outlet elbow from the cylinder head and provides a
signal to the ECM which allows the engine
temperature to be determined.
The ECT sensor consists of an encapsulated
negative temperature coefficient (NTC) thermistor
which is in contact with the engine coolant. The
ECM uses engine temperature to calculate fuelling
and ignition timing parameters during start up. t is
also used to provide a temperature correction for
fuelling and ignition timing when the engine is
warming up, running normally or overheating. The
ECT signal is used by the ECM to control the engine
cooling fans.
f the ECT sensor fails or becomes disconnected,
the ECM will use a default value which is based on
values from the engine oil temperature sensor. The
driver may not notice that a fault is present although
a fault code will be stored in the ECM which can be
retrieved using TestBook. The default value will also
include operation of the cooling fans in fast mode
when the engine is running.
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Intake Air Temperature (IAT) Sensor
The AT sensor is located in the intake manifold near
cylinder number four fuel injector. The sensor
consists of an NTC thermistor mounted in an open
housing to allow air flow over the sensing element.
The AT sensor provides a signal which enables the
ECM to adjust ignition timing and fuelling quantity
according to the intake air temperature, thus
ensuring optimum performance, driveability and low
emissions.
The AT sensor is part of a voltage divider circuit
which consists of a regulated 5 volt supply, and a
fixed resistor (both are inside the ECM) and a
temperature dependent variable resistor (the AT
sensor).
The AT sensor operates in a similar manner to the
ECT sensor. Refer to ECT sensor diagram and
description for method of AT sensor operation.
f the AT sensor fails, or is disconnected, the vehicle
will continue to run. The ECM will substitute a default
value using the information from the speed/load map
to run the engine, but adaptive fuelling will be
disabled.
This condition would not be immediately apparent to
the driver, but the ECM will store fault codes which
can be retrieved using TestBook.
Engine OiI Temperature Sensor
The engine oil temperature sensor is located in the
oil filter housing on MPi engines and in the Hydraulic
Control Unit (HCU) on VVC engines. The sensor
provides a signal which allows the ECM to adjust
fuelling values according to engine oil temperature,
to produce optimum engine performance and
minimum emissions during the engine warm up
phase. On VVC engines, the ECM also uses the oil
temperature to derive the viscosity of the oil passing
through the HCU, which indicates how quickly the
VVC mechanism will respond.
The engine oil temperature sensor consists of an
encapsulated Negative Temperature Coefficient
(NTC) thermistor which is in contact with the engine
oil.
The engine oil temperature sensor operates in a
similar manner to the ECT sensor.
f the engine oil temperature sensor fails, the ECM
will substitute a default value which is ramped up
80 C (176 F). This condition will not be apparent to
the driver, with the exception of the temperature
gauge which will display incorrect readings
depending on the sensor failure.
The vehicle will run but may suffer from reduced
engine performance and increased emissions as
adaptive fuelling is disabled. The ECM will store fault
codes which can be retrieved using TestBook.
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ThrottIe Position (TP) Sensor
The TP sensor is mounted on the throttle body and
is driven from the end of the throttle spindle. The TP
sensor consists of a potentiometer which provides
an analogue voltage that the ECM converts to
throttle position information. The TP sensor signal is
required for the following vehicle functions:
dle speed control
Throttle damping
Deceleration fuel cut off
Engine load calculations
Acceleration enrichment
Full load enrichment
Automatic gearbox shift points.
The TP sensor is a potentiometer which acts as a
voltage divider in an external ECM circuit. The
potentiometer consists of a 4k 20% resistive
track and a wiper arm, driven by the throttle spindle,
which sweeps over the track.
The track receives a regulated 5 V 4% supply
from the ECM, together with an earth path. As the
wiper arm moves over the track it will connect to
areas of different voltage ranging from 0 to 5 volts.
The 'output' from the wiper arm is connected to the
ECM to provide an analogue voltage signal.
The TP sensor requires no adjustment as the ECM
will learn the lower voltage limit which correspond to
closed throttle.
f the TP sensor signal is missing the vehicle will
continue to run but may suffer from poor idle control
and throttle response. The ECM will store fault
codes which can be retrieved using TestBook.
IdIe Air ControI (IAC) VaIve
The AC valve is located on the inlet manifold. t
allows the ECM to control the engine idling speed by
regulating the amount of air which by-passes the
throttle valve. t also allows the ECM to provide a
damping function when the throttle is closed under
deceleration, this reduces hydrocarbon (HC)
emissions.
The AC valve is controlled by the ECM using a
stepper motor. This consists of a core which is
rotated by magnetic fields produced by two
electro-magnet bobbins set at 90 to each other.
The stepper motor controls the volume of air passing
through a duct which leads from the inlet manifold to
a pipe connected to the throttle body. The bobbins
are connected to the ECM driver circuits. Each of
the four connections can be connected to 12 volts or
earth, enabling four 'phases' to be obtained. The
ECM drives the four phases to obtain the desired
idle speed.
When the ignition is switched off the ECM enters a
power down routine which includes 'referencing' the
stepper motor. This means that the ECM will rotate
the motor so that it can memorise the position when
it next needs to start the engine.
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The stepper motor referencing procedure can take
from three to five seconds. f the ECM cannot
reference the stepper motor during power down, it
will do so at ignition on. f the stepper motor fails,
there are no back up idle control systems. The idle
speed may be too high or too low and if a load is
placed on the engine it may stall. The ECM will store
fault codes which can be retrieved by TestBook.
Ignition CoiIs
Two ignition coils are mounted on the camshaft
cover above the spark plugs for cylinders 1 and 3
and secured with screws.
Each coil operates a pair of spark plugs using the
wasted spark principle. The coil has a plug
connection on its lower face and an ht lead which
connects to the second plug.
The coil fitted above cylinder 1 is attached to the
spark plug for cylinder 1 and the ht lead connects to
the spark plug for cylinder 4.
The coil fitted above cylinder 3 is attached to the
spark plug for cylinder 3 and the ht lead connects to
the spark plug for cylinder 2.
WARNING: The ht voItage of the ignition
system is in excess of 50 kV and the It
voItage is in excess of 400 voIts. VoItages
this high can cause serious injury and may even
be fataI. Never touch any ignition components
whiIe the engine is running or being cranked.
CAUTION: Never crank or run the engine
with the ht Ieads disconnected from the
ignition coiIs; faiIure of the ECM and/or the
coiI wiII resuIt. AIways disabIe the ignition
system by disconnecting the It connectors from
the coiI.
Each ignition coil consists of a pair of windings
wrapped around a laminated iron core. The primary
winding has a resistance of 0.7 and the secondary
winding has a resistance of 10 k .
FueI Injectors
The fuel injectors are located directly under the fuel
rail and connect to the intake manifold runners. Each
injector delivers fuel to the engine in a targeted,
atomised spray (onto the intake valve heads) which
takes place once per cycle. Each injector opens
during the intake stroke of the cylinder it supplies.
An injector consists of a pintle type needle and seat,
and a solenoid winding which lifts the needle against
a return spring. The injector nozzle delivers the fuel
spray to precise areas of the intake ports to
maximise the benefits of the swirl and turbulence in
the manifold and head ports.
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The solenoid winding has a resistance of 13 - 16 at
20 C (68 F). The fuel injectors operate at a
regulated pressure of 3.5 bar (50 lbf/in
2
). The
regulator is located on the end of the fuel rail and
excess fuel is returned to the swirl pot via a return
line to the tank.
The injectors receive fuel under pressure from the
fuel rail and a 12 volts supply from the main relay.
To deliver fuel to the engine, the ECM has to lift the
needle off the injector seat by energising the
solenoid. To energise the solenoid the ECM supplies
an earth path to the injector winding.
f an injector fails, the engine may lose power and
driveability. The ECM will store fault codes which
Evaporative Emissions (EVAP) Canister Purge
VaIve
The EVAP canister purge valve is located in the
engine compartment on the rear bulkhead. The
purge valve is connected via a flexible pipe to the
inlet manifold.
The canister purge valve consists of a solenoid
operated valve which is controlled by the ECM using
a 12 volts PWM signal. The EVAP canister purge
valve controls the flow of fuel vapours from the
EVAP canister to the intake manifold of the engine.
When the vehicle is being driven the ECM will purge
the EVAP canister by opening the canister purge
valve, this allows the vacuum present in the intake
manifold to draw fuel vapour from the canister into
the cylinders for combustion.
When fuel vapour is being removed from the
canister, fresh air is allowed to enter via an
automatic one-way valve, this makes the canister
ready for the next 'absorption' phase.
The amount of fuel vapour which enters the
cylinders can affect the overall AFR, therefore the
ECM must only open the canister purge valve when
it is able to compensate by reducing fuel injector
duration. The canister purge valve will only operate
under the following conditions:
Engine at normal operating temperature
Adaptive fuelling enabled
Closed loop fuelling enabled.
AIternator
The alternator is located on a bracket which is
attached to the cylinder block on the front RH side of
the engine. The alternator is driven by a Polyvee belt
from the crankshaft pulley. The alternator converts
mechanical energy into electrical energy to power
the electrical systems and maintain the battery
charge.
The alternator outputs a signal to the ECM which
represents the electrical load on the vehicle systems
and the mechanical load exerted on the engine by
the alternator. The signal output from the alternator
is a variable PWM signal which is proportional to the
load applied to the engine.
The ECM uses the load signal to provide idle speed
compensation and to reduce engine speed
fluctuations. f the load signal fails, the ECM uses a
default value and stores a fault code which can be
retrieved using TestBook.
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Air Conditioning (A/C) Trinary Switch
The A/C trinary switch is located on the
receiver/drier at the rear of the under bonnet
compartment. t contains three pressure switches;
high, low and medium. The medium switch
completes an earth path between the ECM and an
earth header joint. The high and low switches are
connected between the A/C switch and the ECM.
The trinary switch has three functions:
1. To disengage the A/C compressor clutch if the
refrigerant pressure falls below the 'minimum'
specified value.
2. To disengage the A/C compressor clutch if the
refrigerant pressure exceeds the 'maximum'
specified value.
3. To switch the cooling fan to high speed if the
refrigerant pressure exceeds the 'high'
specified value.
A/C Trinary Switch Pressure Settings
Switch Opening Pressure bar (Ibf/in
2
) CIosing Pressure bar (Ibf/in
2
)
Low 1.96 (28) pressure decreasing 2.35 (34) pressure increasing
Medium 13.7 (198) pressure decreasing 18.6 (270) pressure increasing
High 28.4 (412) pressure increasing 22.6 (328) pressure decreasing
Functions 1 and 2 are performed by a single series
circuit containing both minimum and maximum
pressure switches. The switches are both normally
closed, so if either threshold is exceeded the
continuity of the earth path to the ECM is broken.
This causes the ECM strategy to disengage the A/C
compressor clutch on safety grounds.
Function 3 is performed by a separate circuit
containing a single normally open pressure switch.
This switch opens when the pressure exceeds a
specified value indicating that extra cooling is
required to reduce refrigerant pressure. this will
cause the ECM to energise the condenser fan relay
and start the fan.
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VVC Mechanism ControI (Where AppIicabIe)
Hydraulic Control Solenoid
The ECM controls two solenoids in order to control
the VVC mechanism. Only one solenoid will be
energised at a time to either drive the VVC
mechanism towards minimum cam period, or
towards maximum cam period. The desired cam
period is calculated by the ECM using engine speed
and manifold pressure (engine load). The current
cam period is measured by the ECM using the
camshaft position sensor. The ECM then energises
the correct solenoid in order to move the mechanism
towards the desired position.
Fault Detection
f the ECM detects any faults with cam period
measurement during start up and initial running, the
ECM will try and drive the mechanism to minimum
cam period.
f the ECM loses the cam period signal during
running, the cam period will remain frozen at the last
valid period. Engine speed may be limited as low as
5500 rpm depending on cam period when the fault
occurred. The engine idle speed will be raised and
will remain raised for the rest of the journey.
Stepspeed (Em-CVT) Gearbox (Where
AppIicabIe)
The MEMS 3 ECM controls the Em-CVT unit in
conjunction with the Gearbox nterface Unit (GU)
and several peripheral gearbox switches and
sensors.
The GU outputs gear selector lever position status,
manual/sport selection and snow mode selection to
the ECM. The ECM then provides an output to the
instrument pack to display the appropriate gear
position information in the LCD or illuminate the
snow mode or gearbox fault warning lamps.
For further information on (Em-CVT) Stepspeed
gearbox See AUTOMATIC GEARBOX - Em-CVT,
Description and operation.
Gearbox Interface Unit (GIU)
Electronic control of the Em-CVT Stepspeed
gearbox operates as an integral part of the MEMS 3
system software. The ECM accepts inputs from the
GU, communicates with the GU for gearbox
control, accepts driver inputs for gear selection and
communicates information to the driver via the
instrument pack.
The GU connection which supplies information to
the ECM is a serial communication link. This
supplies the ECM with all the driver inputs from the
gearbox switches.
The ECM output to the GU is a hardwired
connection which instructs the GU of the required
ratio control motor position. This information is
output in the form of 500 Hz PWM signals.
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Gearbox Shaft Speed Sensor
The ECM receives an input from the Em-CVT
gearbox differential speed sensor which is located at
the rear of the gearbox. The sensor is a Hall effect
sensor which reads off the differential crown wheel
teeth to provide a road speed signal. This signal is
used by the ECM to determine when the vehicle is
stationary and to allow accurate calculation of the
true gearbox ratio.
Park/Neutral Switch
The park/neutral switch is located at the rear of the
gearbox and is operated by a cam which moves via
a cable with the gear shift selector lever position. An
output from the park/neutral switch is connected to
the ECM to enable gearbox load compensation. The
ECM will adjust the AC valve stepper motor to the
appropriate position to maintain the idle speed when
the gearbox is moved into and out of drive or
reverse.
The park/neutral switch also operates the reverse
lamps via a hardwired connection and controls a
shift interlock solenoid which is fitted in selected
markets only.
Ignition Switch SignaI
A hardwired digital input to ECM pin 61 provides an
ignition on signal. When the ECM has been idle for a
period of time, it goes into 'sleep' (power saving)
mode.
When the ECM receives an ignition on signal from
the ignition switch, the ECM 'wakes up' and
energises the main relay.
Main ReIay
The main relay is located in the engine management
relay module which is positioned behind the ECM
mounting bracket. The relay module contains the
main relay, the fuel pump relay and the starter relay.
The relay is normally open when the ignition is off.
When the ignition is switched on to position , the
ECM provides an earth path for the relay coil which
energises, closing the contacts.
A permanent battery supply is provided to the relay
contacts from fuse 2 in the under bonnet fusebox.
The relay supplies battery voltage to the following
components:
ECM pin 19
HO
2
S sensors
CMP sensor
Purge control valve
Fuel injectors
gnition coils
Speed transducer
Gearbox nterface Unit (GU) via an in-line 10A
fuse (Em-CVT models only)
Gearbox secondary speed sensor (Em-CVT
models only)
Hydraulic Control Solenoids (VVC models only)
f the main relay fails, power will not be supplied to
the above components and the engine will not start.
The ECM will store fault codes which can be
retrieved using TestBook.
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FueI Pump ReIay
The fuel pump relay is located in the engine
management relay module which is positioned
behind the ECM mounting bracket. The relay is
normally open when the ignition is off.
When the ignition is switched on to position , the
ECM provides an earth path for the relay coil. With
the ignition on the relay receives a feed, via the
ignition switch, from fuse 14 in the passenger
compartment fusebox which energises the relay coil,
closing the contacts.
A permanent battery supply is provided to the relay
contacts from fuse 2 in the under bonnet fusebox,
via the inertia switch. The feed passes through the
relay contacts and operates the fuel pump to
pressurise the fuel system. The relay will be
energised for a short time only to pressurise the fuel
system.
When the ignition switch is moved to the crank
position , the ECM will energise the relay when the
engine starts cranking and will remain energised
until the engine stops.
f the engine stalls and the ECM stops receiving a
signal from the CKP sensor, the ECM will remove
the earth path for the relay, stopping the fuel pump.
WARNING: ALWAYS check for fueI Ieaks
and the integrity of the fueI system before
resetting the inertia switch.
The inertia switch, when tripped, cuts off the power
supply to the relay contacts, disabling the fuel pump
in the event of a sudden deceleration. f the fuel
pump fails to operate, check that the inertia switch is
not tripped. The switch is reset by depressing the
rubber cap on the top of the switch.
f the fuel pump relay fails, power will not be supplied
to the fuel pump and the engine will not start or will
stop if already running due to fuel starvation. The
ECM will store fault codes which can be retrieved
using TestBook.
A/C Compressor CIutch ReIay (Where
AppIicabIe)
On vehicles fitted with air conditioning, an A/C relay
module is located under the bonnet adjacent to the
under bonnet fusebox. When the engine is running
and the driver requests A/C on, the ECM receives a
signal from the A/C switch via the thermostat and
trinary switch to pin 56 of the ECM.
f conditions are correct, the ECM grants the A/C
request by completing an earth path from pin 53 to
the A/C clutch relay coil. The A/C clutch relay coil
receives a battery feed from the ignition switch
position . The feed is supplied via fuse 15 in the
passenger compartment fusebox to the relay coil.
The coil will energise closing the relay contacts.
A permanent battery supply, via fuse 5 in the under
bonnet fusebox, passes through the relay contacts
and operates the compressor clutch.
The ECM will disengage the A/C compressor clutch
if the coolant temperature exceeds 118 C (244 F)
and will re-engage the A/C compressor clutch when
the coolant temperature falls to less than 114 C
(237 F).
f the A/C clutch relay fails, the A/C will be
inoperative and the ECM will store fault codes which
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CooIing Fans
The cooling system comprises an engine coolant
cooling fan which is located behind the radiator and
an engine bay cooling fan located in the engine bay.
On vehicles fitted with A/C, an additional cooling fan
is located behind the radiator and A/C condenser.
An engine bay cooling fan is located in the engine
bay. The fan is used to reduce engine bay
temperatures especially when the vehicle is
stationary. The fan draws air through the RH air
intake into the engine bay.
On all vehicles the engine bay cooling fan relay is
located adjacent to the passenger compartment
fusebox.
On vehicles without A/C, the engine cooling fan
relay is located behind the under bonnet fusebox.
On vehicles with A/C, the engine cooling fan relay
and the condenser fan relay are located in the A/C
relay module which is located adjacent to the under
bonnet fusebox.
Engine Coolant Cooling Fan
The engine cooling fan relay is energised by the
ECM on receipt of an appropriate coolant
temperature signal from the ECT sensor.
When the engine is running, the ECM will energise
the relay to operate the fan at a coolant temperature
of 104 C (219 F) and will go off when the coolant
temperature decreases to less than 98 C (208 F).
When A/C is fitted, the engine cooling fan and the
condenser fan can operate at two speeds, being
operated in series or parallel by the ECM. Refer to
the Air Conditioning section for condenser fan
details.
Engine Bay Cooling Fan
The engine bay cooling fan relay is energised by the
ECM on receipt of an appropriate engine bay
temperature signal from the ambient air temperature
sensor.
When the engine is running, the ECM will energise
the relay to operate the fan when an engine bay
temperature of 75 C (167 F) is reached. The ECM
has a timer which energises the relay for a
predetermined period. f the temperature decreases
to less than 60 C (140 F) before the timer has
expired, the ECM will de-energise the relay.
f the engine bay temperature exceeds 130 C
(266 F), the ECM will illuminate the engine bay
overheat warning lamp in the instrument pack. The
warning lamp informs the driver that the engine bay
temperature is abnormally high or that a system fault
has occurred. When the engine bay temperature
falls below 110 C ( 230 F) the ECM will extinguish
the warning lamp.
When the engine is off, the fan remains active for a
predetermined period after the engine is switched
off.
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Ambient Air Temperature (AAT) Sensor
(Engine Bay)
The AAT sensor is located in the engine bay on the
header panel directly above the inlet manifold.
The AAT sensor receives a supply from ECM pin 21
and is earthed at ECM pins 37 and 71 which is a
common earth. The AAT sensor operates the engine
bay cooling fan as described in Cooling Fans.
f the AAT sensor fails, the engine bay cooling fan
will operate at all times when the ignition is on and
the engine bay overheat warning lamp in the
instrument pack will be illuminated.
Engine Bay CooIing Fan ReIay
The engine bay cooling fan relay is located adjacent
to the passenger compartment fusebox and is the
central relay in a block of three.
The relay coil and contacts receive a permanent
battery feed via fusible link 3 in the under bonnet
fusebox and fuse 6 in the passenger compartment
fusebox. The relay coil is connected to ECM pin 74
which provides an earth path when cooling fan
operation is required.
f the cooling fan relay fails, the cooling fan will not
operate and engine bay overheat may occur. The
ECM will store fault codes which can be retrieved
using TestBook.
Engine Bay Overheat Warning Lamp
The engine bay overheat warning lamp is located in
the centre warning lamp cluster in the instrument
pack. f the engine bay temperature exceeds 130 C
(275 F), the ECM will illuminate the warning lamp to
inform the driver that the engine bay temperature is
abnormally high. When the engine bay temperature
falls below 110 C ( 230 F) the ECM will extinguish
the warning lamp.
The ECM will also illuminate the warning lamp if a
cooling fan, relay or AAT sensor fault is detected.
The warning lamp receives a feed from the ignition
switch when the switch is in position . When the
ECM requires the warning lamp to be illuminated, it
completes an earth path from the warning lamp to
ECM pin 62.
Tachometer Drive
The ECM provides an output signal on pin 55 for
engine speed, derived from the CKP sensor. The
signal is passed to the instrument pack for
tachometer operation and is also used by the EPAS
ECU pin 15 for an engine speed signal.
Failure of this output will be shown by the
tachometer not functioning. The ECM will record
fault codes which can be retrieved using TestBook.
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VehicIe ImmobiIisation
The vehicle immobilisation system operates by the
alarm ECU transmitting a unique code to the ECM
when the ignition is switched on. f the code is
recognised by the ECM it will energise the injectors
and allow the engine to start.
f no code is received or the code is incorrect, the
ECM will disable the vehicle by not energising the
fuel injectors.
The alarm ECU also controls the starter relay and
will passively disarm the starter relay when the key
is removed from the ignition switch. Rearming is
performed by turning the ignition on which activates
a coil around the ignition key barrel.
The coil transmits a waveform signal which excites
the remote handset to transmit a re-mobilisation
signal. When the signal is received by the alarm
ECU, the starter relay will be enabled.
Replacement ECM's are supplied blank and must
learn the alarm ECU security code for the vehicle to
which it is fitted. When the ECM is connected to the
vehicle, TestBook is required to enable the ECM to
learn the alarm ECU code. f a new alarm ECU is
fitted, the ECM will need to learn the new security
code using TestBook.
Rough Road Detection
MEMS 3 has a misfire detection facility which is part
of the On-Board Diagnostics (OBD) system. Misfire
detection is disabled when the ECM senses that the
vehicle is on a 'rough road'. The system software
can detect variations in the signal output and disable
misfire detection to prevent incorrect faults being
logged by the ECM.
The 'rough road' signal is passed from the ABS ECU
on a hardwired output to the ECM pin 78. The signal
is in the form of a square wave digital pulse train of
between 0 and 5 V at 8000 pulses per mile.
On vehicles without ABS, an ABS reluctor ring is
fitted to the LH rear wheel and provides 48 pulses
per rotation of the wheel to a variable reluctance
sensor. The output from the sensor is received by
ECM pin 78 and the sensor is provided with a
positive supply signal from ECM pin 64.
FueI Pump
The electric fuel pump is located inside the fuel tank
and is energised by the ECM via the fuel pump relay
in the engine management relay module and the
inertia switch.
The fuel pump delivers more fuel than the maximum
load requirement for the engine, maintaining
pressure in the fuel system under all conditions.
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FueI Pressure ReguIator
The fuel pressure regulator is a mechanical device
mounted on the end of the fuel rail. Pressure is
controlled by diaphragm spring pressure and is
modified by a vacuum signal from the inlet manifold.
The regulator ensures that fuel pressure is
maintained at a constant pressure difference to that
in the inlet manifold. As manifold depression
increases, the regulated fuel pressure is reduced in
direct proportion.
When pressure exceeds the regulator setting,
excess fuel is returned to the fuel tank swirl pot
which contains the fuel pump pick-up.
Inertia FueI Cut-Off Switch
The electrical circuit for the fuel pump incorporates
an inertia switch which, in the event of a sudden
deceleration, breaks the circuit to the fuel pump
preventing fuel being delivered to the engine. The
switch is located adjacent to the ECM and can be
reset by pressing the rubber top.
WARNING: ALWAYS check for fueI Ieaks
and the integrity of the fueI system
connections before resetting the switch.
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Diagnostics
A diagnostic socket allows the exchange of
information between the ECM and TestBook or a
diagnostic tool using Keyword 2000 protocol.
The diagnostic socket is located in the passenger
compartment fusebox which is located below the
fascia on the driver's side.
A dedicated diagnostic (SO 9141 K Line) bus is
connected between the ECM and the diagnostic
socket and allows the retrieval of diagnostic
information and the programming of certain
functions using TestBook.
The ECM uses a 'P' code diagnostic strategy and
can record faults relating to the engine management
and Em-CVT gearbox interface unit functions.
The 'P' codes are qualified by one of the following
failure types:
Min - the minimum expected value has been
exceeded
Max - the maximum expected value has been
exceeded
Signal - the signal is not present
Plaus - an implausible condition has been
detected
After detecting a fault which causes an increase of
emissions above the legislated threshold, in addition
to storing a 'P' code the ECM also illuminates a
Malfunction ndicator Lamp (ML) in the instrument
pack. The ECM performs a 2 seconds bulb check of
the ML each time the ignition is switched on.
Diagnostic socket
MaIfunction Indicator Lamp
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ECM Harness Connector DetaiIs
The following tables give input/output information for the two harness connectors used on the ECM.
Connector C0914 - Black, 52 Pin
Pin No. Description Input/Output
1 Upstream HO
2
S heater Output
2 Not used -
3 Downstream HO
2
S positive Output
4 CKP sensor positive Output
5 CMP sensor screen earth (VVC only) nput
6 Oil temperature unit earth; oil temperature switch earth (VVC only) nput
7 ECT sensor earth nput
8 AT/MAP sensor supply +5V (Em-CVT gearbox only),
MAP sensor supply +5V (non Em-CVT gearbox only)
Output
9 Gearbox differential speed sensor signal - (Em-CVT gearbox only) nput
10 Oil temperature unit (VVC only) Output
11 Not used -
12 Decrease HCU solenoid valve (VVC only) Output
13 AC valve stepper motor phase B nput/Output
14 njector 3 earth nput
15 Upstream H0
2
S positive Output
16 CMP sensor signal nput
17 CKP sensor screened earth nput
18 AT sensor earth nput
19 Main relay supply signal nput
20 TP sensor signal nput
21 Engine bay temperature sensor signal nput
22 Trinary switch A/C fan request (A/C vehicles only) nput
23 Not used -
24 AC valve stepper motor phase D nput/Output
26 gnition coil 2 earth nput
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Connector C0914 - Continued
27 Downstream HO
2
S heater Output
28 Upstream HO
2
S screened earth nput
29 Downstream HO
2
S negative nput
30 CKP sensor negative nput
31 AT/MAP sensor earth (Em-CVT gearbox only);
MAP sensor earth (non Em-CVT gearbox only)
nput
32 Engine oil temperature unit signal (MPi only);
Engine oil temperature switch signal (VVC only)
nput
33 ECT sensor signal nput
34 TP sensor earth nput
35 Alternator load signal nput
36 Not used -
37 Engine bay temperature sensor earth nput
38 EVAP purge valve drive Output
39 AC valve stepper motor phase A nput/Output
41 Upstream H0
2
S negative nput
42 CMP sensor earth nput
43 Not used -
44 AT sensor signal nput
45 AT/MAP sensor signal (Em-CVT gearbox only);
MAP sensor signal (non Em-CVT gearbox only)
nput
46 TP sensor supply +5V Output
47 Not used -
48 nstrument pack - gearbox position display PWM signal
(Em-CVT gearbox only)
Output
49 ncrease HCU solenoid valve (VVC only) Output
50 AC valve stepper motor phase C nput/Output
52 gnition coil 1 earth nput
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Connector C0159 - Black, 28 Pin
53 A/C clutch relay coil earth (A/C vehicles only) nput
54 Main relay coil earth nput
55 nstrument pack - tachometer drive Output
56 A/C trinary switch hi/low (A/C vehicles only) nput
57 Not used -
58 Diagnostic SO 9141 K Line nput/Output
59 Main earth 1 nput
60 Cooling fan relay 2 coil earth (A/C vehicles only) nput
61 gnition switch via passenger compartment fusebox - fuse 14 nput
62 nstrument pack - engine bay overheat warning lamp Output
63 Park/Neutral switch (Em-CVT gearbox only),
Starter relay coil earth (Em-CVT gearbox only)
nput
64 Rough road sensor positive (non ABS only) nput
65 Not used -
67 Cooling fan relay 1 coil earth nput
68 Fuel pump relay coil earth nput
69 Malfunction ndicator Lamp (ML) Output
70 Not used -
71 Engine bay temperature sensor earth nput
72 Alarm ECU - immobilisation coded signal nput
74 Engine bay cooling fan relay coil earth nput
75 Gearbox nterface Unit (GU) data transmit (Em-CVT gearbox only) Output
76 Fuel tank gauge level signal (Em-CVT gearbox only) nput
77 Gearbox nterface Unit (GU) data receive (Em-CVT gearbox only) nput
78 Road road sensor signal (non ABS); ABS modulator rough road signal
(ABS)
nput
79 Not used -
80 Battery permanent supply - under bonnet fusebox Fuselink 6 and Fuse 7 nput
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OPERATION
AcceIeration Enrichment
When the throttle pedal is depressed, the ECM
receives a rising voltage from the TP sensor and
detects a rise in manifold pressure from the MAP
sensor. The ECM provides additional fuel by
increasing the normal injector pulse width and also
provides a number of extra additional pulses on
rapid throttle openings.
Over-Run FueI Cut-Off
The ECM implements over-run fuel cut-off when the
engine speed is above 1600 rpm with the engine at
normal operating temperature and the TP sensor in
the closed position, i.e. when ECM senses that the
vehicle is 'coasting' with the throttle pedal released.
The ECM indexes the AC valve open slightly to
increase the air flow through the engine to maintain
a constant manifold depression to keep emissions
low.
Fuel is immediately reinstated if the throttle is
opened. f the engine speed drops below 1600 rpm
on over-run, fuel is progressively reinstated.
Over-Speed Fuel Cut-Off
To prevent damage at high engine speeds the ECM
will implement fuel cut-off at engine speeds above
approximately 7000 rpm. Fuel is reinstated as the
engine speed falls.
Ignition Switch Off
n the first 10 seconds after the ignition is switched
off, the ECM drives the AC valve to its power down
position (ready for the next engine start), and stores
any required information.
The ECM then monitors the engine bay temperature
using the ambient air temperature sensor. f the
temperature is above a certain limit, the ECM will
drive the engine bay fan for 8 minutes, and will then
power down. f the engine bay temperature is below
the limit, the ECM will power down after 10 seconds.
FueI Quantity
The ECM controls fuel quantity by providing
sequential injection to the cylinder head intake ports.
Sequential injection allows each injector to deliver a
precise amount of fuel to the cylinder intake ports,
during the induction stroke, in cylinder firing order.
The CMP sensor and reluctor allows the ECM to
synchronise injection at cranking speed for starting.
The precise quantity of fuel delivered is controlled by
adjusting the duration of the injector open time.
To achieve optimum performance the ECM is able to
'learn' the individual characteristics of an engine and
adapt the fuelling strategy to suit. This capability is
known as adaptive fuel strategy.
Adaptive fuel strategy must be maintained under all
throttle positions except:
Cold start
Hot start
Wide open throttle.
All of the above throttle positions are deemed to be
'open loop'. Open loop fuelling does not rely on
information from the HO
2
S, but sets the air/fuel ratio
(AFR) according to the stored data in the ECM.
During a cold 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 HO
2
S is hot enough to provide
an accurate feedback signal.
The specific nature of the other open loop conditions
means that the HO
2
S feedback is unsuitable as a
control value for fuelling. Adaptive strategy also
allows the ECM to compensate for wear in engine
components and allow for production tolerances in
mass produced components such as sensors.
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To calculate the amount of fuel to be injected into
each cylinder, the ECM has to determine the
quantity of oxygen available in the cylinder to burn it.
This can be calculated by processing information
from the following sensors:
MAP sensor
CKP sensor
ECT sensor
TP sensor.
During one engine revolution, 2 of the 4 cylinders
draw in air. The ECM uses the CKP sensor signal to
determine the potential air intake volume in the
cylinders.
The oxygen content of the air contained in the
cylinders can be calculated by the ECM using
information from the MAP sensor and the AT
sensor. The pressure of the air in the intake manifold
will vary according to the following factors:
The position of the throttle valve (driver input)
The atmospheric pressure (altitude and weather
conditions)
The mechanical condition of the engine
(volumetric efficiency).
The pressure in the intake manifold, downstream of
the throttle valve, indicates how much air has flowed
into the cylinders. This will decrease at higher
altitudes as the air becomes 'thinner' or less dense.
This will also mean that there will be less oxygen
contained in the air which will be available for
combustion of fuel.
The temperature of the air will also affect the oxygen
content. Air which is cool has molecules packed
closer together than hot air, therefore; cooler air
contains more oxygen for any given volume than
hotter air.
From the above information, the ECM can calculate
how much air has been induced into the cylinders.
By comparing these values to a fuelling map stored
in the ECM memory, the amount of oxygen induced
into the cylinders can be calculated. The values
obtained from the ECT sensor, engine oil
temperature sensor and TP sensor provide 'fine
tuning' to the calculations.
To deliver the fuel the ECM completes an earth path
to the injector coil, opening the injector for the
precise amount of time required for the quantity
determined. The correct cylinder order is determined
by referencing the CMP sensor during start up to
synchronise the CMP sensor signal to the CKP
sensor signal. The fuel is injected into the inlet ports
of the intake manifold and is drawn into the cylinder
as an air and fuel mixture.
The ECM ensures that the amount of fuel injected is
not affected by the variations in inlet manifold
pressure. The ECM corrects the injector duration
time, using MAP sensor information.
The ECM references battery voltage to adjust
opening times to suit the state of battery charge.
This is required because low battery voltage will
mean slower response from the injectors, and could
give a leaner AFR than intended.
Ignition Timing
The ignition timing is an important part of the ECM
adaptive strategy. The ignition system consists of
two double ended coils, mounted on the cam cover
directly over the spark plugs, which operate using
the wasted spark principle. Each coil is connected to
a pair of spark plugs, 1 and 4, 2 and 3.
The spark plugs are connected in series with the
secondary winding of the coil so a spark occurs in
both cylinders at the same time. When a spark
occurs in the cylinder which is on the compression
stroke the air/fuel charge is ignited. The spark has
no effect on the cylinder at the end of the exhaust
stroke, hence the term 'wasted spark'.
The major advantage of this system is that a
distributor cap and rotor arm are eliminated thereby
improving performance and reliability. The timing of
the spark will affect the quality of combustion and
the power produced.
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The ECM will reference all relevant sensors to
achieve the optimum timing for any given condition.
This electronically increases the primary coil
charging time (dwell angle) as engine speed
increases to maintain coil ht voltage at high engine
speeds.
The ECM calculates ignition timing using inputs from
the following:
CKP sensor
TP sensor
ECT sensor
AT sensor.
The ECM calculates dwell angle using inputs from
the following:
CKP sensor
Battery voltage.
At start up the ECM sets ignition timing by
referencing the ECT sensor. After start up, the
ignition timing will be controlled according to maps
stored in the memory and modified according to
additional sensor inputs.
The choice of ignition point is critical in maintaining
engine power output with low emissions. Advancing
the ignition may increase power output under certain
conditions, but it also increases the amount of
oxides of nitrogen (NOx) and carbon monoxide (CO)
produced in the combustion chamber.
There is a narrow range of ignition points for all
engine conditions which give an acceptable
compromise between power output and emission
control.
The ignition mapping contained within the ECM
memory keeps the ignition timing within this narrow
band. The ignition timing is used to control engine
idle speed in conjunction with the AC valve stepper
motor.
As the MEMS 3 system does not have a knock
sensor, ignition timing advance is controlled using
different mapping at high engine and intake air
temperatures in order to avoid detonation (pinking).
IdIe Speed ControI
The ECM regulates the engine speed at idling. The
ECM uses two methods of idle speed control:
gnition timing adjustment
AC valve stepper motor.
When the engine idle speed fluctuates, and there
are no additional loads on the engine, the ECM will
vary the ignition timing and the AC valve to regulate
the idle speed.
This allows very rapid correction of out of tolerance
idle speeds. When an additional load is placed on
the engine, such as when the power steering is
turned on full lock, the ECM uses the AC valve
stepper motor to control the idle speed to
specification.
The idle speed is determined from the CKP sensor,
but there are also inputs to the ECM from the
following:
Alternator
Park/Neutral switch (Em-CVT)
A/C system
Cooling fan status.
f the ECM receives information from the above
inputs that an extra load is being placed on the
engine, it can immediately compensate and avoid
engine poor idle or stall conditions.
The AC valve stepper motor is mounted on the inlet
manifold and controls a throttle valve air by-pass
port.
To increase the idle speed, the stepper motor allows
more air to by-pass the throttle and enter the
cylinders. To decrease the idle speed, the stepper
motor allows less air to enter the cylinders.
The stepper motor is a bi-polar type which consists
of two windings controlled by pulse width modulated
(PWM) signals from the ECM.
The position of the stepper motor is always
referenced on power down of the ECM, this may
take from three to five seconds. The stepper motor
is also used to reduce manifold vacuum during
deceleration to control emissions.
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Evaporative Emissions (EVAP) ControI System
The hydrocarbon vapour given off by petrol is
harmful to health and the environment. Legislation
limits the amount of hydrocarbons (HC) which can
be emitted to atmosphere by a motor vehicle.
To meet the limits imposed, a charcoal canister is
fitted to the fuel system to absorb fuel vapour from
the tank when the vehicle is not in use. The charcoal
canister has a finite capacity and therefore needs to
be purged when the vehicle is driven.
This is achieved by drawing the fuel vapours out of
the canister and into the cylinders of the engine. The
HC vapours are converted into carbon dioxide (CO
2
)
and water (H
2
O) by the combustion process and
catalytic converter.
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AIR INTAKE SYSTEM - MPi/VVC MEMS 3
1. Air cleaner element
2. Throttle disc
3. AC valve
4. nlet manifold
5. njector
6. Evaporative emission canister purge valve
ntake air is drawn into the throttle housing through
the air filter element. ncorporated in the throttle
housing is the throttle disc and the TP sensor.
Air passes from the throttle housing via the manifold
chamber into the inlet tracts. Fuel is sprayed into the
inlet manifold by the injectors and the air/fuel mixture
is drawn into the combustion chamber.
nlet manifold depression is measured by the MAP
sensor which is mounted near the end of the inlet
manifold chamber. A signal from the MAP sensor is
used by the ECM to calculate the amount of fuel to
be delivered by the injectors.
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FUEL DELIVERY SYSTEM
RECIRCULATING FUEL SYSTEM
1. Fuel tank
2. Fuel pump
3. Swirl pot
4. Feed line
5. Fuel filter
6. Fuel rail
8. Return line
A recirculating fuel system is used to supply fuel to
the injectors at a constant pressure and return
excess fuel to the fuel tank.
Fuel pressure is produced by an electric pump
immersed in the fuel tank and operating in a swirl pot
to maintain a constant fuel level around the pump
pick-up.
Pressurised fuel is fed to an in-line fuel filter via a
non-return valve which prevents fuel returning to the
tank when the pump is not running. Fuel is delivered
from the fuel filter to the fuel rail which supplies the
injectors. A fuel pressure regulator mounted on the
fuel rail controls the pressure of fuel in the rail and
returns excess fuel to the swirl pot in the tank. A
venturi in the fuel tank causes returning fuel to draw
cool fuel into the swirl pot from the tank.
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FUEL TANK BREATHING SYSTEM
1. Fuel tank
2. Filler neck breather pipe
3. Filler cap
4. Two-way breather valve
7. Vent line
8. Fuel release line
9. Air intake line
When filling the fuel tank, air trapped in the fuel tank
by the rising fuel level is allowed to vent to the top of
the filler neck by a separate breather pipe.
With the filler cap in place, fuel tank breathing is via
a two-way breather valve which allows expanding
fumes to exit the tank. From the two-way breather
valve, fumes are directed to the evaporative
emission canister where they can be purged into the
engine via the evaporative emission canister purge
valve.
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EMISSION CONTROL SYSTEMS
The vehicle is fitted with various items of emission
and evaporative control components to comply with
emission regulation requirements.
Three control systems are used to reduce harmful
emissions released into the atmosphere from the
vehicle at all times, and under all conditions. These
are:
1. Crankcase emission control
2. Exhaust emission control
3. Fuel vapour evaporative loss control
n many countries it is against the law for a vehicle
owner or an unauthorised repair shop to modify or
tamper with emission control equipment. n this
event the vehicle owner and/or the repairer may be
liable for prosecution.
The emission control system fitted to the vehicle is
designed to keep the emissions within the legal
limits provided that the engine is correctly
maintained and is in good mechanical condition.
Crankcase Emission ControI System
Gases from the crankcase are drawn into the throttle
housing to be burnt in the combustion chambers
with the fuel mixture. The system provides effective
emission control while the engine is running under
all circumstances.
There are two breather pipes connected to the
throttle housing, one either side of the throttle disc.
When the engine is running with the throttle disc
open, both pipes are subject to manifold depression
and draw crankcase fumes into the manifold. When
the throttle disc is closed, only the pipe on the inlet
manifold side of the disc is subject to manifold
depression. This pipe incorporates a restrictor to
prevent engine oil being drawn into the engine by
the substantially greater manifold depression.
Exhaust Emission ControI
The engine management system provides
accurately metered quantities of fuel to the
combustion chambers to ensure the most efficient
air to fuel ratio under all conditions of operation. A
further improvement to combustion is made by
measuring the oxygen content of the exhaust gases
to enable the quantity of fuel injected to be varied
maintaining the ratio necessary for efficient gas
conversion by the catalytic converter.
The catalytic converter is situated between the
exhaust front pipe and exhaust silencer. The
catalytic converter reduces the emission of Carbon
Monoxide, Oxides of Nitrogen and Hydrocarbons
released into the atmosphere. The active
constituents of the converter are the precious metals
Platinum and Rhodium.
The correct operation of the catalytic converter is
dependent upon close control of the oxygen
concentration in the exhaust gas entering the
converter. The quantity of oxygen in the exhaust gas
is determined by a heated oxygen sensor situated
upstream of the catalytic converter, in the front pipe.
The heated oxygen sensor provides the engine
control module with a signal proportional to the
oxygen content. The ECM can then determine
whether any adjustment is required to the amount of
fuel being injected to achieve the correct exhaust
gas content, and implement the required changes.
A downstream heated oxygen sensor is installed in
the outlet of the catalytic converter. By comparing
the inputs from the upstream and downstream
heated oxygen sensors, the ECM can monitor the
efficiency of the catalytic converter.
CAUTION: Serious damage to the cataIytic
converter wiII occur if Ieaded fueI is used.
The fiIIer neck is designed to
accommodate onIy unIeaded fueI pump nozzIes.
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EVAPORATIVE EMISSION CONTROL
1. Fuel tank
2. Filler neck breather pipe
3. Filler cap
4. Two-way breather valve
7. Vent line
8. Fuel release line
9. Air intake line
Evaporative Emission Canister
The evaporative emission (EVAP) canister contains
charcoal which absorbs and stores fuel vapour from
the fuel tank while the engine is not running. When
the engine is running the vapour is purged from the
canister into the engine and burned.
The EVAP canister is purged when the EVAP
canister purge valve is opened. Manifold depression
draws fresh air into the canister through the
charcoal, which releases fuel vapour into the throttle
housing.
Evaporative Emission Canister, Purge VaIve
An EVAP canister, purge valve is operated by the
ECM. The purge valve remains closed when the
engine is cold or at idling speed, to protect engine
tune and catalyst performance. f the EVAP canister
was purged during cold running or at idling speed,
the additional enrichment in fuel mixture would delay
catalyst light off time and cause erratic idling. When
the engine is above 75 C, the purge valve solenoid
will become operational (modulated ON and OFF)
whenever the engine speed is above approximately
1800 rev/min. When the purge valve is opened, fuel
vapour from the EVAP canister is drawn into the
throttle housing for combustion.
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ADJUSTMENTS 1
THROTTLE CABLE
NOTE: Before adjustment, ensure the
cabIe is correctIy routed and Iocated. Do
not attempt to adjust the throttIe cabIe or
engine idIe speed by means of the throttIe stop
screw.
Adjust
1. Remove the engine compartment access
panel. See BODY, Exterior fittings.
2. Release cable adjusting nut from abutment
bracket.
3. Position outer cable to abutment bracket so
that adjusting nut is in contact with top of
abutment bracket.
4. Hold throttle cam in fully closed position,
ensure throttle cam contacts throttle stop
screw.
5. Rotate cable adjusting nut until all slack is
taken out of inner cable. Ensure throttle does
not open.
6. Locate throttle cable adjusting nut in abutment
bracket.
7. Operate throttle pedal and ensure that full
throttle pedal movement is available.
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2 ADJUSTMENTS
FUEL TANK DRAINING
WARNING: The fueI tank must be drained
before removing it from the vehicIe.
Ensure that both sides of the fueI tank are
compIeteIy drained.
2. Depressurise fuel system. See this section.
Drain
WARNING: PetroI/gasoIine vapour is
highIy fIammabIe, and in contained spaces
is aIso expIosive and toxic. AIways have a
fire extinguisher containing FOAM, CO
2
GAS OR
POWDER cIose at hand when handIing or
draining fueI.
3. Remove fuel pump. See Repairs.
4. Using a fuel recovery appliance, drain fuel from
the tank into a sealed container. Follow the
manufacturers instructions for the connection
and safe use of the appliance.
5. Due to the construction of the fuel tank, it will
be necessary to drain fuel from each side of
the tank separately.
NOTE: FueI vapour causes the fueI tank to
sweII, before attempting fueI tank removaI,
ensure fueI is compIeteIy drained and the
tank is Ieft in the drained condition for at Ieast 2
hours. See Repairs.
FUEL SYSTEM DEPRESSURISE
3. Position absorbent cloth around fuel filter outlet
union.
4. Loosen fuel filter outlet union to relieve fuel
pressure.
CAUTION: To prevent damage to the fueI
system pipes and components, use two
spanners when Ioosening or tightening
unions.
5. Tighten fuel filter outlet union to 30 Nm.
6. Remove absorbent cloth.
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REPAIRS 1
AIR CLEANER
Remove
1. Remove air cleaner element. See this section.
2. Remove 2 retaining studs securing air cleaner
to support bracket.
3. Release air cleaner from lower grommet.
4. Release front air intake hose.
5. Remove screw securing rear air intake hose.
6. Release rear air intake hose and manoeuvre
air cleaner from engine bay.
Refit
1. Position air cleaner and align rear air intake
hose.
2. Fit and tighten screw securing rear air intake
hose.
3. Align and connect front air intake hose.
4. Secure air cleaner in lower grommet.
5. Align air cleaner to support bracket and fit
retaining studs.
6. Fit air cleaner element. See this section.
ELEMENT - AIR CLEANER
Remove
2. Remove engine cover. See ENGINE, Repairs.
4. Remove nut securing LH cross bracing and
remove and discard bolt securing cross
bracing.
5. Remove LH cross bracing.
6. Release clip and disconnect air intake hose
from throttle body.
7. Loosen clip securing air intake hose to air
cleaner and remove hose.
8. Release 4 clips securing air cleaner cover.
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2 REPAIRS
9. Remove air cleaner cover and remove
element.
Refit
1. Clean inside of air cleaner.
2. Fit air cleaner element.
3. Fit air cleaner cover and secure clips.
4. Fit air intake hose to air cleaner and secure
with clip.
5. Fit air intake hose to throttle body and secure
with clip.
6. Position cross bracing, fit nut and new bolt and
tighten to 25 Nm.
8. Fit engine cover. See ENGINE, Repairs.
SENSOR - CAMSHAFT POSITION (CMP) - VVC
Remove
3. Remove bolt securing CMP sensor to cylinder
head.
4. Remove CMP sensor.
5. Remove 'O' ring seal from sensor.
Refit
1. Clean sealing faces of sensor and cylinder
head.
2. Fit new 'O' ring seal to CMP sensor.
3. Fit sensor to cylinder head and tighten bolt to
9 Nm.
4. Connect multiplug.
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REPAIRS 3
SENSOR - CAMSHAFT POSITION (CMP) - MPi
Remove
2. Remove three bolts securing coil cover to
engine and remove coil cover.
3. Release CMP multiplug from bracket and
disconnect multiplug.
4. Release sensor cable from clip.
5. Remove bolt securing camshaft sensor and
remove sensor.
Refit
1. Clean camshaft sensor and mating face.
2. Fit camshaft sensor, fit bolt and tighten to 9
Nm.
3. Connect CMP multiplug and secure in bracket.
4. Fit coil cover, fit bolts and tighten to 8 Nm.
EVAPORATIVE EMISSION CANISTER
Remove
3. Release clip and disconnect hose from inlet
manifold.
4. Release and disconnect feed hose.
5. Disconnect multiplug from purge valve.
6. Release EVAP canister from support bracket
and remove EVAP canister.
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4 REPAIRS
Refit
1. Position EVAP canister and secure in support
bracket.
2. Connect hose to inlet manifold and secure with
clip.
3. Connect feed hose.
4. Connect multiplug to purge valve.
ENGINE, Repairs.
CATALYTIC CONVERTER
Remove
2. Remove nut and special washer securing rear
silencer clamp.
3. Remove catalyst overheat sensor from catalyst
(if fitted) .
4. Remove 3 flange nuts securing catalytic
converter to front pipe.
5. Remove rear silencer clamp.
6. Remove 3 flange nuts securing catalytic
converter to silencer.
7. Remove catalytic converter.
8. Remove and discard gaskets.
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REPAIRS 5
Refit
1. Clean flange mating faces of front pipe,
silencer and catalytic converter.
2. Fit new gaskets to catalytic converter studs.
3. Fit catalytic converter to silencer, fit nuts and
tighten to 50 Nm.
4. Clean catalyst overheat sensor and mating
faces (if fitted) .
5. Fit and tighten catalyst overheat sensor to
30 Nm (if fitted) .
6. Position catalytic converter to front pipe.
7. Fit rear silencer clamp.
8. Fit nuts and tighten to 50 Nm.
9. Align rear silencer clamp strap, fit special
washer, fit nut and tighten to 30 Nm.
CAUTION: Ensure aII joints are free from
Ieaks. Exhaust gas Ieaks upstream of the
cataIyst couId Iead to internaI faiIure of the
cataIyst.
SENSOR - CRANKSHAFT POSITION (CKP)
Remove
4. Remove bolt securing CKP sensor to flywheel
housing.
5. Remove CKP sensor.
Refit
1. Clean CKP sensor and mating face of flywheel
housing.
2. Position CKP sensor, fit bolt and tighten to
9 Nm.
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6 REPAIRS
ENGINE CONTROL MODULE (ECM) - MPi
Remove
See BODY, Exterior fittings. See ENGINE,
Repairs.
3. Remove 2 bolts securing ECM mounting
bracket.
4. Release mounting bracket from support
bracket and position to access ECM screws.
5. Release ECM multiplug catches and
disconnect ECM multiplugs.
6. Remove 4 screws securing ECM to mounting
bracket.
7. Remove ECM.
Refit
1. Locate ECM to mounting bracket, fit and
tighten screws.
2. Connect multiplugs and secure multiplug
catches.
3. Position mounting bracket in support bracket,
BODY, Exterior fittings. See ENGINE,
Repairs.
6. nitiate ECM using TestBook.
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REPAIRS 7
SENSOR - ENGINE COOLANT TEMPERATURE
(ECT)
Remove
4. Position container below sensor.
5. Disconnect sensor multiplug.
6. Remove sensor from top coolant hose adapter.
Refit
1. Clean sensor threads and mating faces.
2. Fit sensor and tighten to 6 Nm.
3. Connect multiplug to sensor.
4. Remove container, and lower vehicle.
5. Top-up cooling system. See MAINTENANCE.
ENGINE MANAGEMENT RELAY MODULE
Remove
2. Remove 2 bolts securing ECM mounting
bracket.
3. Move bracket aside and release engine
management relay module.
4. Disconnect 2 multiplugs from relay module.
5. Remove relay module.
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8 REPAIRS
Refit
1. Connect multiplugs to relay module.
2. Secure relay module onto ECM mounting
bracket.
3. Fit ECM mounting bracket and tighten bolts to
8 Nm.
FUEL FILTER
Remove
3. Position cloth around fuel outlet union.
4. Loosen union to relieve fuel pressure and
disconnect pipe.
CAUTION: Use two spanners when
Ioosening or tightening unions.
5. Position cloth around fuel filter union.
6. Loosen union and disconnect fuel inlet pipe
from fuel filter.
7. Release clip and remove filter from housing.
8. Discard fuel filter.
Refit
1. Clean fuel pipe unions.
2. With arrow on the fuel filter pointing rearwards
position new filter into housing.
3. Tighten fuel inlet pipe to 30 Nm.
4. Connect fuel outlet pipe to fuel filter and tighten
to 30 Nm.
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REPAIRS 9
FUEL INJECTORS - MPi
Remove
2. Remove fuel rail. See this section.
3. Release multiplugs from injectors.
4. Release spring clips securing injectors to fuel
rail.
5. Remove injectors and discard 2 'O' rings from
each injector.
6. Fit protective caps to each injector.
Refit
1. Clean injectors and injector recesses in fuel rail
and inlet manifold.
2. Lubricate 8 new 'O' rings with castor oil and fit
to injectors.
3. Fit fuel rail to injectors.
4. Fit spring clips to secure injectors to fuel rail.
5. Fit multiplugs to injectors.
6. Fit fuel rail. See this section.
FUEL INJECTORS - VVC
Remove
2. Remove fuel rail. See this section.
3. Disconnect multiplugs from injectors.
4. Remove injectors from inlet manifold.
5. Remove and discard 'O' rings from injectors.
Refit
1. Lubricate new 'O' rings with castor oil and fit to
injectors.
2. Fit injectors to fuel rail and connect multiplugs.
3. Fit fuel rail. See this section.
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10 REPAIRS
FUEL RAIL AND INJECTORS - MPi
Remove
3. Release clip and disconnect vacuum pipe from
fuel pressure regulator.
4. Position absorbent cloth beneath fuel rail.
5. Remove 2 bolts securing fuel pipe to fuel rail.
6. Release fuel pipe from fuel rail, remove and
discard 'O' ring.
7. Remove 2 bolts securing fuel rail to inlet
manifold.
8. Release fuel rail and injectors from inlet
manifold.
9. Release and remove injector spacer.
10. Disconnect multiplugs from injectors.
11. Remove the fuel rail complete with injectors.
12. Release spring clips securing injectors to fuel
rail and remove fuel injectors.
13. Remove and discard 2 'O' rings from each
injector.
14. Fit protective caps to each end of injectors.
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REPAIRS 11
Refit
1. Remove protective caps from each injector.
2. Clean injectors and recesses in fuel rail and
inlet manifold.
each end of injectors.
4. Fit injectors to fuel rail.
5. Secure injectors to fuel rail with spring clips.
6. Position fuel rail assembly and connect injector
multiplugs.
7. Fit injector spacer.
8. Push each injector into inlet manifold.
9. Fit bolts securing fuel rail to inlet manifold and
tighten to 10 Nm.
10. Using a new 'O' ring, connect fuel feed to fuel
rail, fit bolts and tighten to 8 Nm.
11. Connect vacuum pipe to fuel pressure
regulator and secure with clip.
FUEL PUMP
Remove
2. Depressurise fuel system. See Adjustments.
3. Remove subwoofer assembly. See
WARNING: The spiIIing of fueI is
unavoidabIe during this operation. Ensure
that aII necessary precautions are taken to
prevent fire and expIosion.
5. Remove 4 bolts securing fuel pump access
cover to body and remove cover.
6. Release clip and disconnect hose securing fuel
pump breather hose to fuel pump.
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12 REPAIRS
WARNING: FueI vapour is highIy
fIammabIe and in confined spaces is aIso
expIosive and toxic. AIways have a fire
extinguisher containing foam, CO
2
, gas or
powder cIose at hand when handIing or draining
fueI.
7. Disconnect fuel pump multiplug.
8. Position absorbent cloth around fuel hoses to
collect any fuel spillage.
9. Noting fitted position, release fuel feed and
return hoses from pump.
10. Using tool 19-009, loosen and remove fuel
pump locking ring from tank.
11. Remove fuel pump retaining ring, release fuel
pump and remove from tank. Discard fuel tank
sealing ring.
Refit
1. Clean fuel pump and mating face.
2. Fit new fuel pump seal to pump body, locate
pump assembly through tank opening. Fit seal
to tank, push pump fully home taking care not
to dislodge the seal.
3. Fit fuel pump locking ring and using tool
19-009, tighten to 35 Nm.
4. Connect fuel feed and return hoses to pump.
5. Connect multiplug to fuel pump.
6. Connect fuel pump breather hose and secure
with clip.
7. Fit fuel pump access cover, fit and tighten bolts
to 10 Nm.
8. Fit subwoofer assembly. See ELECTRICAL,
Repairs.
FILLER NECK
Remove
2. Remove air cleaner. See this section.
3. Drain fuel tank. See Adjustments.
4. Release 3 cables from air cleaner support
bracket.
5. Remove 2 nuts securing fuel filter to air cleaner
support bracket.
6. Release fuel filter from support bracket and
position aside.
7. Remove 3 bolts securing air cleaner support
bracket to body and remove bracket.
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REPAIRS 13
8. Remove 4 nuts securing filler neck gaiter and
collect gaiter clamp.
9. Slide gaiter up filler neck, loosen clip and
release hose from filler neck.
10. Release clip securing breather hose to filler
neck and disconnect hose.
11. Remove fuel filler cap.
12. Remove 2 bolts securing filler neck to body
and remove filler neck.
Refit
1. Position filler neck, fit and tighten 2 bolts
securing neck to body.
2. Connect tank hose to filler neck and secure
with clip.
3. Connect breather hose to filler neck and
secure with clip.
4. Manoeuvre gaiter into position, fit clamping
plate and secure with nuts.
5. Position air cleaner support bracket, fit and
tighten bolts.
6. Connect cables to clips.
7. Fit fuel filter to support bracket and secure with
nuts.
8. Refill fuel tank. See Adjustments.
9. Fit fuel cap.
10. Fit air cleaner. See this section.
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14 REPAIRS
HOSE - BREATHER - TANK TO FILLER NECK
Remove
2. f fitted, remove subwoofer assembly. See
trim components.
5. Remove 4 bolts securing fuel pump cover and
remove cover.
6. Release clip and disconnect breather hose
from fuel pump.
from filler neck.
8. Remove breather hose.
Refit
1. Position hose and fit to filler neck and fuel
pump.
2. Secure hose with clips.
3. Fit fuel pump cover and secure with bolts.
4. f fitted, fit subwoofer assembly. See
components.
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REPAIRS 15
FUEL RAIL - VVC
Remove
2. Remove inlet manifold chamber. See
3. Position absorbent cloth around fuel filter outlet
union. Slacken union to relieve fuel pressure.
Retighten union to 30 Nm.
CAUTION: To prevent damage to fueI
system pipes and components, use two
spanners when Ioosening or tightening
unions.
4. Release clip and release fuel return pipe from
fuel rail.
5. Remove 2 bolts securing fuel feed pipe to fuel
rail.
6. Release fuel feed pipe from fuel rail.
7. Remove and discard 'O' ring.
manifold.
9. Remove spring clips securing injectors to fuel
rail.
10. Release fuel rail from injectors and remove.
11. Remove and discard 'O' rings from injectors.
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16 REPAIRS
Refit
injectors.
2. Position fuel rail and fit to injectors.
3. Fit spring clips securing fuel rail to injectors.
4. Fit bolts securing fuel rail to inlet manifold and
tighten to 10 Nm.
5. Connect fuel return pipe to fuel rail and secure
with clip.
6. Remove plugs from fuel feed pipe and fuel rail.
7. Lubricate new 'O' ring with silicone grease and
fit to fuel feed pipe.
8. Connect fuel feed pipe to fuel rail and tighten
bolts to 8 Nm.
9. Fit inlet manifold chamber. See MANIFOLD &
FUEL TANK
WARNING: See RESTRAINT SYSTEMS,
Precautions.
Remove
1. Make the SRS system safe. See RESTRAINT
SYSTEMS, Precautions.
2. Remove air cleaner. See this section.
3. Drain fuel tank. See Adjustments.
NOTE: FueI vapour causes the fueI tank to
sweII, before attempting fueI tank removaI
ensure fueI is compIeteIy drained and the
tank is Ieft in the drained condition for at Ieast 2
hours.
4. Remove 5 nuts securing fuel filler pipe gaiter to
bulkhead.
5. Remove fuel filler cap.
6. Loosen 2 bolts securing filler neck to rear wing.
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REPAIRS 17
7. Release clip securing filler hose to fuel tank
and position hose aside.
8. Remove front console. See BODY, Interior
trim components.
9. Lower hood.
10. Remove 9 retaining studs securing carpet to
rear bulkhead.
11. Remove 4 clips securing carpet to 'B' post.
12. Release carpet from door seals and velcro
strips.
13. Remove carpet.
14. Remove 9 retaining studs securing felt pad to
rear bulkhead and remove pad.
15. Remove 22 bolts securing closing panel to rear
bulkhead.
16. Remove 2 nuts securing closing panel to rear
bulkhead.
17. Remove closing panel.
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18 REPAIRS
18. Remove and discard plastic fuel tank sealing
sheet.
19. Remove 2 nuts securing tank retaining straps
to body and position aside.
20. Remove fuel tank.
Refit
1. Position fuel tank to body.
2. Align retaining straps to body and tighten nuts
to 10 Nm.
3. Align new plastic sheet to bulkhead and press
seal into place.
4. Fit bulkhead closing panel and tighten nuts and
bolts to 9 Nm.
5. Fit felt pad and secure with studs.
6. Fit carpet and secure with studs.
7. Position carpet to velcro and behind door seal.
8. Fit front console. See BODY, Interior trim
components.
9. Raise rear of hood.
CAUTION: Do not use any Iubricants on
fIexibIe fiIIer hose to ease assembIy.
10. Position filler hose to tank and tighten clip to
3 Nm .
11. Fit bolts securing filler neck to wing and tighten
to 3 Nm.
12. Fit filler cap.
13. Position filler gaiter to body studs and secure
with nuts.
14. Fit air cleaner. See this section.
15. Fit fuel pump. See this section.
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REPAIRS 19
HT LEAD - SET - MPi
Remove
2. Remove screws securing coil cover and
remove cover.
3. Disconnect ht leads from coils, release ht leads
from retainers.
4. Disconnect ht leads from plugs and remove ht
leads.
Refit
1. Connect ht leads to plugs.
2. Connect ht leads to coils and secure in
retainers.
3. Fit coil cover and tighten screws to 8 Nm.
VALVE - IDLE AIR CONTROL (IAC) - MPi
Remove
2. Disconnect multiplug from AC valve.
3. Release bypass hose from AC valve and
remove from throttle body.
4. Release breather hose from throttle body and
position aside.
5. Remove 4 Torx screws securing AC valve to
inlet manifold.
6. Remove AC valve.
Refit
1. Clean mating faces of AC valve and inlet
manifold.
fit to AC valve.
3. Fit AC valve to inlet manifold.
4. Tighten Torx screws to 1.5 Nm.
5. Connect breather hose to throttle body.
6. Connect air bypass hose to AC valve and
throttle body.
7. Connect multiplug to AC valve.
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20 REPAIRS
HYDRAULIC CONTROL UNIT SOLENOIDS (HCU)
- VVC
Remove
1. Remove engine compartment access
cover.See ENGINE, Repairs.
3. Release breather hose from inlet manifld
chamber. Release clip and remove breather
hose from camshaft cover.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are cIean. PIug open connections to
prevent contamination.
5. Release clip, disconnect breather hose from
camshaft cover and position hose aside.
6. Disconnect multiplugs from HCU solenoids.
7. Note angle at which each solenoid is
positioned relative to HCU.
8. Remove nut securing solenoids to HCU.
9. Remove 'O' ring.
10. Remove outer solenoid and 'O' ring.
11. Remove inner soleniod and 'O' ring.
Refit
1. Clean soleniod mounting faces.
2. Fit 'O' ring to inner solenoid, fit solenoid
ensuring end lettering faces away from HCU.
3. Fit 'O' ring to outer solenoid.
4. Fit outer soleniod ensuring lettering faces away
from HCU, align solenoids, fit and tighten nut to
12 Nm.
5. Connect multiplugs to HCU solenoids.
6. Connect breather hose to camshaft cover and
secure with clip.
7. Connect multiplug to CMP sensor.
8. Position breather hose to camshaft cover and
inlet manifold chamber, secure with clip.
10. Fit engine compartment access cover.See
ENGINE, Repairs.
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REPAIRS 21
IGNITION COIL - MPi
Remove
2. Remove 3 screws securing coil cover.
3. Remove cover.
4. Release ht lead from spark plug.
5. Remove 2 bolts securing coil and release coil
from spark plug.
6. Disconnect multiplug from coil and remove coil.
7. Remove ht lead from coil.
Refit
1. Fit ht lead to coil.
2. Fit coil and connect multiplug.
3. Fit and tighten bolts securing coil to 8 Nm.
4. Connect ht lead to spark plug and secure lead
in clip.
5. Fit coil cover and tighten bolts to 8 Nm.
SWITCH - INERTIA FUEL SHUT-OFF
Remove
3. Disconnect multiplug from switch.
4. Remove 2 Torx screws securing switch to
body.
5. Remove switch.
Refit
1. Fit switch and tighten screws.
2. Connect multiplug to switch.
3. To ensure switch is set in correct position,
press down on top.
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22 REPAIRS
SENSOR - INTAKE AIR TEMPERATURE (IAT) -
MPi
Remove
2. Disconnect AT sensor multiplug.
3. Loosen and remove AT sensor.
Refit
1. Fit and tighten AT sensor.
2. Connect AT sensor multiplug.
SENSOR - MANIFOLD ABSOLUTE PRESSURE
(MAP) - VVC
Remove
3. Disconnect MAP sensor multiplug.
4. Remove 2 Torx screws securing MAP sensor
to inlet manifold.
5. Remove MAP sensor from manifold.
Refit
1. Clean MAP sensor and manifold mating faces.
2. Ensure 2 'O' rings are fitted to sensor.
3. Fit sensor to manifold and tighten Torx screws
to 3 Nm.
4. Connect multiplug to MAP sensor.
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REPAIRS 23
SENSOR - MANIFOLD ABSOLUTE PRESSURE
(MAP) - MPi
Remove
to inlet manifold.
4. Remove MAP sensor from manifold.
Refit
1. Clean MAP sensor and manifold mating faces.
2. Fit MAP sensor to inlet manifold, fit and tighten
Torx screws.
3. Connect MAP sensor multiplug.
SENSOR - OIL TEMPERATURE - VVC
Remove
2. Disconnect multiplug from oil temperature
sensor.
3. Remove temperature sensor from hydraulic
control unit.
4. Remove and discard seal.
Refit
1. Clean sealing faces of sensor and hydraulic
control unit.
2. Fit seal to sensor.
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24 REPAIRS
SENSOR - HEATED OXYGEN (HO
2
S) - PRE CAT
Remove
3. Rotate HO
2
S sensor multiplug through 90 to
release from mounting.
4. Disconnect HO
2
S sensor multiplug from
harness.
6. Remove HO
2
S sensor lead from clip.
7. Using a 22 mm crows foot spanner, remove
HO
2
S sensor.
Refit
1. Fit HO
2
S sensor and tighten to 55 Nm.
2. Fit HO
2
S sensor lead to clip.
3. Connect multiplug and secure to mounting.
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REPAIRS 25
SENSOR - HEATED OXYGEN (HO2S) - POST CAT
Remove
3. Release HO
2
S sensor multiplug from bracket
and disconnect from harness.
5. Remove HO
2
S sensor.
Refit
1. Fit HO
2
S sensor and tighten to 55 Nm.
2. Connect and secure HO
2
S sensor multiplug.
SPARK PLUGS
Remove
1. Remove coils. See this section.
2. Clean area around spark plugs.
3. Using a 16 mm spark plug socket remove 4
spark plugs.
Refit
1. Fit terminals to new spark plugs.
2. Set gap of each new spark plug to
1.00 0.05 mm.
3. Fit spark plugs and tighten to 27 Nm.
4. Refit coils. See this section.
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26 REPAIRS
THROTTLE HOUSING - (INCLUDES TUNING)
Remove
2. Remove engine compartment access
panel.See BODY, Repairs.
3. Remove nuts securing cross bracing, remove
and discard bolt securing cross bracing and
remove cross bracing.
4. Release clips securing air intake hose and
disconnect air intake hose from throttle housing
and air cleaner, remove air intake hose.
5. Disconnect dle Air Control valve hose from
throttle housing.
6. Disconnect multiplug from throttle position
sensor.
from throttle housing.
8. Release throttle cable adjusting nut from
abutment bracket.
9. Release throttle cable from cam.
10. Remove 4 bolts securing throttle housing to
inlet manifold.
11. Remove throttle housing and position harness
mounting bracket aside.
12. Remove and discard throttle housing 'O' ring.
Refit
1. Clean throttle housing and inlet manifold
mating faces.
fit to throttle housing.
3. Position throttle housing to inlet manifold, align
harness bracket and fit bolts finger tight.
4. Tighten bolts in the sequence shown using the
following procedure. 1. Tighten to 4 Nm. 2.
Back off 1 flat. 3. Tighten to 9 Nm.
abutment bracket.
6. Connect breather hose to throttle housing and
secure clip.
7. Connect multiplug to throttle position sensor.
8. Connect dle Air Control valve hose to throttle
housing.
9. Adjust throttle cable.
10. Connect air intake hose to throttle housing and
air cleaner and secure clips.
11. Position cross bracing, fit nuts and new bolt
13. Retune using TestBook.
14. Fit engine compartment access panel.See
BODY, Repairs.
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REPAIRS 27
THROTTLE CABLE
Remove
3. Disconnect throttle cable abutment from
throttle bracket.
4. Remove 2 nuts securing throttle pedal bracket
to bulkhead.
5. Remove bolt securing throttle pedal bracket to
pedal box and collect spacer.
6. Position throttle pedal assembly and remove
cable retaining clip.
7. Release cable nipple and abutment from
throttle pedal.
8. Collect rubber washer.
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28 REPAIRS
9. Remove stud securing carpet to inner wheel
arch.
10. Release carpet from door seal and 5 velcro
strips.
11. Remove 2 studs securing carpet to 'B' post and
release carpet from door seal and velcro to
reveal cables.
12. Release cable from 3 sill clips and 3 'B' post
clips.
13. Release cable from floorpan crossmember.
14. Release throttle cable from throttle body
abutment and cam and position aside.
15. Position hoodwell insulation aside and release
cable grommet from hoodwell.
16. Remove throttle cable.
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REPAIRS 29
Refit
1. Feed cable through hoodwell panel and secure
throttle cable to throttle body cam.
2. Engage grommet to hoodwell.
3. Position cable to 'B' post and sill and engage
clips.
4. Position cable under insulation.
5. Fit rubber washer to cable abutment.
6. Fit cable abutment to throttle pedal bracket and
engage cable nipple to pedal.
7. Fit cable retaining clip to pedal.
8. Align throttle pedal to bulkhead fixings and
tighten nuts to 6 Nm.
9. Position harness clip to stud and secure with
nut.
10. Fit bolt and spacer and tighten to 22 Nm.
11. Position carpets and secure with studs and
velcro.
12. Position carpet beneath door seal.
13. Adjust cable length and fit cable abutment to
throttle body.
SENSOR - THROTTLE POSITION (TP)
Remove
2. Release air bypass hose from AC valve and
remove from throttle body.
3. Disconnect multiplug from TP sensor.
4. Remove and discard 2 Torx screws and wave
washers securing TP sensor to inlet manifold.
5. Remove TP sensor specification plate.
6. Pull TP sensor from throttle spindle.
CAUTION: DO NOT twist or appIy Ieverage
to TP sensor.
Refit
1. Clean mating faces of throttle housing and TP
sensor.
2. Fit TP sensor to throttle spindle. Ensure that
during fitting the machined flat on the throttle
spindle is aligned with the mating portion of the
TP sensor.
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30 REPAIRS
CAUTION: The TP sensor can easiIy be
damaged during fitting. When pressing the
sensor onto throttIe spindIe, use fingers
onIy and appIy pressure onIy to the area shown
shaded in the iIIustration.
3. Rotate TP sensor in an anti-clockwise direction
to align fixing holes.
CAUTION: Do not rotate TP sensor in a
cIockwise direction and ensure that it is
not rotated beyond it's internaI stops.
4. Fit TP sensor specification plate.
5. Fit new Torx screws and wave washers,
tighten Torx screws to 1.5 Nm.
CAUTION: Do not exceed specified torque
figure.
6. Connect multiplug to TP sensor.
7. Operate throttle cable cam 2 or 3 times and
ensure that full travel to the throttle open and
the throttle closed positions is available.
8. Fit air bypass hose to AC valve and connect to
throttle body.
NOTE: A 'throttIe initiaIisation' procedure
MUST be carried out using Testbook
whenever the TP sensor is removed or
renewed.
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COOLING SYSTEM
CONTENTS Page
COOLNG SYSTEM COMPONENTS 1 .......................................................................
COOLNG SYSTEM OPERATON 2 ...........................................................................
ADJUSTMENTS
DRAN AND REFLL 1 .................................................................................................
REPAIRS
EXPANSON TANK 1 ..................................................................................................
RADATOR FAN AND MOTOR 1 ................................................................................
ENGNE COMPARTMENT COOLNG FAN 2 .............................................................
ENGNE COMPARTMENT AMBENT AR TEMPERATURE (AAT) SENSOR 2 .........
RADATOR 3 ...............................................................................................................
THERMOSTAT - VVC 4 ...............................................................................................
THERMOSTAT - MPi 5 ................................................................................................
ENGNE COOLANT PUMP 7 ......................................................................................
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COOLING SYSTEM
COOLING SYSTEM COMPONENTS
1. Radiator
2. Hose - radiator top
3. Pipe assembly - underfloor
4. Hose - engine inlet
5. Hose - bleed line
6. Expansion tank
7. Adaptor
8. Hose - engine rail to thermostat housing
9. Hose - expansion tank to engine rail
10. Pipe assembly - engine rail/engine inlet
11. Adaptor
12. Jiggle valve
13. Hose assembly - bypass/heater return
14. Hose - engine outlet hose to heater feed pipe
15. Hose - engine outlet
16. Pipe assembly - heater feed and return
17. Hose - heater feed pipe to control valve
18. Control valve
19. Hose - heater matrix to heater return pipe
20. Hose - control valve to heater matrix
21. Hose - radiator bottom
22. Fan - radiator cooling
23. Fan - air conditioning vehicles only
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COOLING SYSTEM
COOLING SYSTEM OPERATION
A = HOT
B = COLD
1. Thermostat
2. Radiator top hose
3. Heater matrix
4. Radiator bottom hose
5. Radiator
6. Expansion tank
7. Heater valve
8. Water pump
9. Bleed screw
10. Bleed nipple
11. Bleed screw
12. Jiggle valve
The cooling system employed is the by-pass type,
allowing coolant to circulate around the engine while
the thermostat is closed. This prevents temperature
build up in the cylinder head prior to the thermostat
opening.
The siting of the thermostat in the inlet, rather than
the outlet side of the system, provides a more stable
control of coolant temperature in the engine.
When cold, the thermostat closes off the coolant
feed from the radiator outlet. Coolant is able to
circulate through the bypass and heater circuits,
returning back to the engine via the thermostat bulb.
As temperature increases the thermostat gradually
opens, bleeding cool fluid into the cylinder block and
allowing hot coolant to flow to the radiator, balancing
the flow of hot and cold fluid to maintain
temperature. As the thermostat opens further, so the
full flow of coolant passes through the radiator.
Any excess coolant created by heat expansion is
returned to the expansion tank via the bleed line. A
jiggle valve fitted at the start of the bleed line,
prevents pressure build-up in the expansion tank by
regulating the amount of returning coolant.
The coolant circulating pump is a rotor type drawing
coolant directly from the thermostat, the pump is
driven by a geared pulley from the camshaft timing
belt.
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COOLING SYSTEM
The radiator positioned at the front of the vehicle, is
a copper/brass cross - flow type with moulded
plastic end tanks. The radiator is mounted in rubber
bushes; the bottom of the radiator is located in the
front body member, and the top is located in the
bonnet locking platform. The hoses connecting the
radiator to the engine run underneath the vehicle.
Three bleed points are provided for bleeding the
system.
For additional air flow through the radiator matrix,
usually operational when the vehicle is stationary, an
electric cooling fan is fitted to the rear of the radiator.
The temperature of the cooling system is monitored
by the ECM via signals from an engine coolant
temperature sensor, which is mounted in the
cylinder block, outlet elbow. When a temperature of
102 C is reached the ECM switches the fan on via a
relay. The fan switches off at 96 C.
Vehicles fitted with air conditioning have 2 fans.
These operate either in series or parallel according
to engine coolant temperature or air conditioning
requirements.
The ECM disengages the compressor's clutch when
the coolant temperature exceeds 117 C and
re-engages when the coolant temperature drops
below 112 C.
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COOLING SYSTEM
ENGINE COMPARTMENT COOLING - Air cooling
system.
n addition to the normal water cooling system an air
cooling system is provided for the engine
compartment. This is achieved by a fan mounted in
the right hand side intake ducting, blowing cool air
over the engine.
The temperature of the engine compartment is
monitored by the ECM via signals from an ambient
air temperature sensor. The sensor is mounted on
the engine compartment header panel, directly
above the inlet manifold.
When a temperature of 75 C (85 C)* is reached in
the engine compartment the ECM switches the fan
on via a relay.
The engine compartment fan is controlled by a timer
and will operate for three minutes. However, if a
temperature of 65 C (75 C)* is reached before the
pre-set time has elapsed the fan will switch off
automatically.
f the engine compartment temperature rises to
130 C, the ECM will illuminate the engine
compartment warning light in the instrument panel.
This will warn the driver of abnormal engine
compartment temperature or that a fault exists in the
system. When the temperature drops below 110 C
the warning light will extinguish.
The fan will operate for up to eight minutes after the
ignition has been switched off to attain the required
engine compartment temperature.
* VVC temperatures are shown in brackets.
1. Engine compartment cooling fan
3. ECM
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COOLING SYSTEM
ADJUSTMENTS 1
DRAIN AND REFILL
Drain
WARNING: Do not remove expansion tank
fiIIer cap when the engine is hot. The
cooIing system is pressurised, accidentaI
scaIding couId resuIt.
CAUTION: Any cooIant spiIt on the
vehicIe's body must be washed off
immediateIy to prevent damage to the
paint work.
1. Position heater temperature control to
maximum heat position.
2. Remove expansion tank filler cap.
3. Position container to collect coolant.
4. Release clip and disconnect coolant hoses at
rear of under floor coolant rail.
5. Allow cooling system to drain.
RefiII
6. Flush system with water under low pressure.
CAUTION: High pressure water couId
damage the radiator.
7. Connect coolant hoses at the rear of the
underfloor coolant rail, secure with clips.
8. Prepare coolant to the required concentration.
See INFORMATION, Capacities, fluids and
lubricants.
9. Turn heater temperature control to maximum
heat position.
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COOLING SYSTEM
2 ADJUSTMENTS
10. Remove bleed screw from radiator, and open
heater bleed nipple.
11. Fill the system with coolant.
NOTE: To prevent introducing air into the
system, keep the expansion tank fiIIed.
12. When a constant flow of coolant is being
emitted from both bleed points, close bleed
points and tighten to:
Radiator bleed screw 5 Nm ,
Heater bleed screw 7 Nm .
13. Fill expansion tank to the brim.
14. Fit expansion tank filler cap and start the
engine.
15. Run the engine until the radiator cooling fan
operates.
NOTE: DO NOT operate the air
conditioning (if fitted).
16. Check the cooling system for leaks, and that
the heater is emitting heat.
f the heater is NOT emitting heat, see
AdditionaI bIeed.
17. Switch off engine and allow to cool.
18. Check level of coolant, top-up to 'MAX' mark
on expansion tank if necessary.
Additional bleed
19. Allow engine to cool.
21. Release clip and remove inlet air hose from
throttle housing.
22. Top-up the expansion tank with coolant.
23. Remove bleed screw from radiator return rail.
24. When a constant flow of coolant is being
emitted from bleed point, fit bleed screw and
tighten to 9 Nm.
25. Fit inlet hose to throttle housing and secure
with clip.
27. Check level of coolant, top-up to 'MAX' mark
on expansion tank if necessary.
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COOLING SYSTEM
REPAIRS 1
EXPANSION TANK
Remove
2. Remove 2 bolts securing tank to body.
3. Position container to catch spillage.
4. Release 2 hoses from tank and allow to drain.
5. Remove expansion tank.
Refit
1. Fit tank.
2. Connect coolant hoses to tank and secure
clips.
3. Position tank to body, fit and tighten bolts to 5
Nm.
4. Top-up cooling system. See MAINTENANCE.
RADIATOR FAN AND MOTOR
Remove
1. Remove front bumper valance. See BODY,
Exterior fittings.
2. Remove 9 bolts securing bonnet locking panel.
3. Position panel aside.
4. Disconnect multiplug from fan.
5. Remove 3 nuts securing fan cowl to radiator.
6. Remove fan assembly.
Refit
1. Fit fan assembly and tighten nuts to 3 Nm.
3. Position bonnet locking panel and tighten bolts
to 10 Nm.
4. Fit front bumper valance. See BODY, Exterior
fittings.
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COOLING SYSTEM
2 REPAIRS
ENGINE COMPARTMENT COOLING FAN
Service repair no - 26.25.39/20 A/C fitted
Remove
3. ModeIs with A/C: Remove alternator. See
4. Disconnect multiplug from motor.
5. Remove 2 nuts securing fan assembly to body.
6. Remove fan assembly.
Refit
1. Fit fan assembly and tighten nuts to 9 Nm.
3. ModeIs with A/C: Fit alternator. See
ENGINE COMPARTMENT AMBIENT AIR
TEMPERATURE (AAT) SENSOR
Remove
2. Disconnect AAT sensor multiplug.
3. Remove nut securing AAT sensor to bracket.
4. Remove AAT sensor.
Refit
1. Fit AAT sensor and secure with nut.
BODY, Exterior fittings. compartment
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COOLING SYSTEM
REPAIRS 3
RADIATOR
Service repair no - 26.40.01/20 A/C fitted
Remove
2. Remove bonnet locking platform. See BODY,
Exterior fittings.
3. Drain cooling system. See Adjustments.
4. Release clips securing top and bottom hoses
to radiator and remove hoses.
5. Disconnect multiplug from fan.
6. ModeIs with A/C: Disconnect multiplugs from
fans.
7. AII modeIs: Remove radiator assembly.
8. Remove 3 nuts securing fan to radiator and
remove fan.
9. ModeIs with A/C: Remove 6 nuts securing
fans to radiator and remove fans.
Refit
1. Fit fan/s to radiator and tighten nuts to 3 Nm.
2. Fit radiator to lower grommets.
3. Fit coolant hoses to radiator and secure with
clips.
5. ModeIs with A/C: Connect multiplugs to fans.
6. Refill cooling system. See Adjustments.
7. Fit bonnet locking platform. See BODY,
Exterior fittings.
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COOLING SYSTEM
4 REPAIRS
THERMOSTAT - VVC
Remove
4. Remove 2 bolts securing expansion tank and
position tank aside.
5. Remove 2 bolts securing coolant rail to cylinder
block.
6. Remove 3 bolts securing thermostat housing
cover.
7. Position coolant rail aside and remove
thermostat.
Refit
1. Clean sealing faces.
2. Fit thermostat.
3. Position housing and tighten bolts to 9 Nm.
4. Position coolant rail and tighten bolts to 9 Nm.
5. Position expansion tank, fit and tighten bolts to
5 Nm.
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COOLING SYSTEM
REPAIRS 5
THERMOSTAT - MPi
Remove
4. Remove 2 bolts securing coolant rail to cylinder
block.
5. Release coolant rail from thermostat housing.
6. Lower vehicle.
8. Remove bolt securing dipstick tube to inlet
manifold.
9. Depress collar and remove upper part of
dipstick tube.
10. Release clip and disconnect heater hose from
thermostat housing.
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COOLING SYSTEM
6 REPAIRS
11. Remove bolt securing thermostat housing to
cylinder block.
12. Release and remove thermostat housing.
13. Remove and discard 2 'O' rings from
thermostat housing outlets.
14. Remove 3 bolts securing thermostat housing
cover to thermostat housing.
15. Remove thermostat housing cover.
16. Remove thermostat from housing.
17. Remove rubber seal from thermostat.
Refit
1. Examine thermostat rubber seal for signs of
deterioration or damage, renew if necessary.
2. Fit rubber seal to thermostat.
3. Clean mating faces of thermostat and cover.
4. Align thermostat to shoulder in thermostat
housing.
5. Fit thermostat housing cover and tighten bolts
to 9 Nm.
6. Clean 'O' ring grooves on thermostat housing
outlets.
7. Lubricate new 'O' rings with rubber grease and
fit to thermostat housing outlets.
8. Position thermostat housing to coolant pump
and push into place.
9. Fit bolt securing thermostat housing to cylinder
block and tighten to 9 Nm.
10. Position upper part of dipstick tube and
connect to lower part.
12. Raise vehicle.
13. Connect coolant rail to thermostat housing.
14. Align coolant rail to cylinder block, fit bolts and
tighten to 9 Nm.
15. Connect CKP sensor multiplug.
16. Connect heater hose to thermostat housing
and secure with clip.
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COOLING SYSTEM
REPAIRS 7
ENGINE COOLANT PUMP
Remove
2. Remove camshaft timing belt. See ENGINE,
Repairs.
4. Remove bolt securing timing belt rear cover to
coolant pump.
5. Remove 5 bolts securing engine coolant pump
to cylinder block.
6. Release pump from 2 dowels.
7. Remove engine coolant pump.
8. Remove 'O' ring seal from pump body and
discard.
Refit
1. Clean pump and cylinder block mating faces.
2. Fit new 'O' ring seal to pump body and fit pump
to cylinder block.
3. Fit bolts securing engine coolant pump to
cylinder block and tighten to 10 Nm.
4. Fit bolt securing timing belt rear cover to
engine coolant pump and tighten to 10 Nm.
5. Fit camshaft timing belt. See ENGINE,
Repairs.
6. Refill coolant system. See Adjustments.
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MANIFOLD & EXHAUST SYSTEMS
CONTENTS Page
EXHAUST PPE 1 ........................................................................................................
EXHAUST MANFOLD 2 .............................................................................................
EXHAUST SYSTEM 2 .................................................................................................
NLET MANFOLD - MPi 2 ...........................................................................................
NLET MANFOLD - VVC 3 ..........................................................................................
REPAIRS
FRONT PPE 1 ............................................................................................................
SLENCER 2 ................................................................................................................
GASKET - EXHAUST MANFOLD TO FRONT PPE - VVC 3 .....................................
SLENCER HEAT SHELD 4 .......................................................................................
FUEL TANK HEAT SHELD 4 ......................................................................................
MANFOLD - NLET - MPi 5 .........................................................................................
GASKET - NLET MANFOLD - MPi 8 .........................................................................
GASKET - NLET MANFOLD - VVC 11 ......................................................................
GASKET - EXHAUST MANFOLD - MPi 13 ................................................................
GASKET(S) - MANFOLD CHAMBER - VVC 15 .........................................................
EXHAUST MOUNTNGS 17 ........................................................................................
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EXHAUST PIPE
1. Gasket - exhaust manifold
2. Flange nut - exhaust manifold to cylinder head
- 5 off
3. Exhaust manifold
4. Exhaust silencer
5. Gasket - silencer to catalytic converter
6. Catalytic converter
7. Downstream HO
2
S mounting boss
8. Flange nut - catalytic converter to silencer - 3
off
9. Gasket - manifold to front pipe
10. Exhaust front pipe
11. Flange nut - manifold to front pipe - 6 off
12. Upstream HO
2
S mounting boss
13. Mounting rubber
14. Gasket - catalytic converter to front pipe
15. Flange nut - catalytic converter to front pipe -
3 off
16. Clamp bracket - silencer
17. Washer - clamp bracket
18. Nut - clamp bracket
19. Nut - clamp bracket attachment
20. Nut - silencer mounting bracket - 2 off
21. Mounting bracket - silencer
22. Bolt - heat shield - 4 off
23. Mounting bracket - 2 off
24. Mounting rubber - 2 off
25. Heat shield - silencer
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EXHAUST MANIFOLD
The 4 branch fabricated steel exhaust manifold
terminates in a flange with two outlet ports. The
exhaust manifold flanges are sealed to the cylinder
head and exhaust front pipe by gaskets.
EXHAUST SYSTEM
The exhaust system consists of a twin front pipe,
terminating in an expansion chamber, a catalytic
converter and a twin tail pipe which incorporates a
large capacity silencer. The entire exhaust system is
manufactured from stainless steel.
The silencer contains a series of expansion
chambers, resonators and baffles designed to give
an improved exhaust system, and reduce
condensation to increase the life of the system.
NOTE: Service repair taiI pipes are
avaiIabIe to aIIow repair without repIacing
the siIencer.
Two HO
2
S are installed in the exhaust system:
One HO
2
S is installed upstream of the catalytic
converter, in a mounting boss in the front pipe
The 2nd HO
2
S is installed downstream of the
catalytic converter, in a mounting boss in the
catalytic converter outlet pipe
The catalytic converter operates in a closed loop
system. The exhaust gases are monitored by the
Engine Control Module (ECM) via signals sent from
the upsteam HO
2
S in the exhaust front pipe. The
ECM adjusts the fueling to maintain emissions
acceptable to the catalytic converter. The ECM uses
the signal from the downstream HO
2
S to monitor the
condition of the catalytic converter. For information
on the operation of the catalytic converter See
Information.
INLET MANIFOLD - MPi
1. nlet manifold - plastic
2. Gasket - inlet manifold
3. Nut - inlet manifold - 3 off
4. Bolt - inlet manifold - 4 off
The inlet manifold is a one piece plastic moulding
attached to the cylinder head with a gasket
interposed between the two components The throttle
housing is bolted to the manifold chamber, sealing
being effected by means of an 'O' ring. The intake
air temperature sensor is inserted above the pipe
flange.
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INLET MANIFOLD - VVC
1. nlet manifold chamber
2. nlet manifold
3. Gasket - manifold chamber to inlet manifold
4. Gasket - inlet manifold to cylinder head
5. Bolt - manifold chamber to inlet manifold
6. Bolt - inlet manifold to cylinder head
7. Nut - inlet manifold to cylinder head
8. Vacuum pipe union
9. nlet manifold support stay
The alloy inlet manifold assembly comprises a
manifold chamber bolted to the inlet manifold with a
gasket interposed between the two components.
The throttle housing is bolted to the manifold
chamber and sealed with an 'O' ring.
The manifold chamber incorporates the manifold
absolute pressure sensor and brake servo vacuum
hose union. The air intake temperature sensor is
incorporated in the inlet manifold. The inlet manifold
is attached to the cylinder head and sealed with a
gasket. A strut between the inlet manifold and the
cylinder block supports the inlet manifold assembly.
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REPAIRS 1
FRONT PIPE
Remove
2. Remove pre catalyst HO
2
S. See FUEL
DELIVERY SYSTEM, Repairs.
3. Remove 6 nuts, release front pipe from
exhaust manifold and discard gasket.
4. Remove nut and washer from silencer clamp.
5. Remove 3 nuts securing front pipe to catalyst.
6. Remove clamp from silencer.
7. Release rubber mounting, remove front pipe
and discard gasket.
Refit
1. Clean front pipe and mating faces.
2. Fit new gasket and tighten nuts securing front
pipe to manifold to 50 Nm.
3. Fit silencer clamp and tighten nuts securing
clamp to front pipe to 50 Nm.
4. Connect mounting to front pipe.
5. Fit washer and tighten silencer clamp nut to
30 Nm.
6. Fit pre catalyst HO
2
S. See FUEL DELIVERY
SYSTEM, Repairs.
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2 REPAIRS
SILENCER
Remove
2. Remove nut and special washer securing
silencer strap clamp.
3. Remove 2 flange nuts securing silencer strap
clamp.
4. Remove strap clamp.
5. Remove 2 flange nuts securing silencer RH
mounting bracket, remove mounting bracket.
6. Remove 3 flange nuts securing silencer to
catalyst.
7. Release catalyst from silencer, remove and
discard gasket.
8. Release silencer from LH mounting bracket,
remove silencer.
Refit
1. Clean mating faces of silencer and catalytic
converter.
2. Fit silencer to LH mounting bracket.
3. Fit silencer RH mounting bracket to mounting,
fit nuts and tighten to 15 Nm.
4. Fit new gasket to catalyst.
5. Position catalyst to silencer, fit nuts and tighten
to 50 Nm.
6. Fit rear silencer clamp to flange studs, fit nuts
7. Align rear silencer clamp strap, fit special
washer, fit nut and tighten to 30 Nm.
CAUTION: Ensure exhaust system is free
from Ieaks. Exhaust gas Ieaks upstream of
the cataIyst couId cause internaI damage
to the cataIyst.
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REPAIRS 3
GASKET - EXHAUST MANIFOLD TO FRONT PIPE
- VVC
Remove
3. Rotate HO
2
S multiplug through 90 to release
from mounting.
5. Release HO
2
S lead from clip.
6. Remove 6 nuts, release front pipe from
exhaust manifold and discard gasket.
Refit
1. Clean front pipe and manifold mating faces.
2. Fit new gasket and tighten nuts securing front
pipe to manifold to 50 Nm.
3. Fit HO
2
S lead to clip.
4. Secure HO
2
S multiplug to mounting.
5. Remove stand and lower vehicle.
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4 REPAIRS
SILENCER HEAT SHIELD
Remove
1. Remove silencer. See this section.
2. Remove 4 bolts securing silencer heat shield.
3. Remove heat shield.
Refit
1. Fit heat shield to underside of vehicle, fit bolts
2. Fit silencer. See this section.
FUEL TANK HEAT SHIELD
Remove
2. Remove 5 nuts securing heat shield to
bulkhead.
3. Remove heat shield.
Refit
1. Fit heat shield and secure with nuts.
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REPAIRS 5
MANIFOLD - INLET - MPi
Remove
1. Remove inlet manifold gasket. See this
section.
2. Remove 3 bolts securing coil cover and
remove coil cover.
3. Remove bolt securing RH coil, release coil and
disconnect coil multiplugs.
4. Release coil harness from harness clips.
5. Disconnect AC valve and TP sensor
multiplugs.
6. Disconnect AC valve hose.
7. Release and disconnect injector multiplug.
8. Manoeuvre inlet manifold to gain access to
bolts securing throttle body to inlet manifold.
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6 REPAIRS
9. Remove 4 bolts securing throttle body to inlet
manifold.
10. Remove throttle body from manifold.
11. Remove and discard 'O' ring seal from throttle
body.
12. Remove air filter. See ENGINE
13. Manoeuvre inlet manifold and remove from
engine compartment.
14. Remove air intake sensor from manifold.
15. Remove sealing washer from sensor.
16. Release pressure regulator vacuum hose from
inlet manifold.
and remove MAP sensor.
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REPAIRS 7
manifold.
19. Release 4 injectors from inlet manifold.
20. Collect injector spacer.
21. Remove fuel rail complete with injectors
pressure regulator and harness.
22. Remove and discard lower 'O' rings from
injectors.
23. Fit protective caps to each injector.
24. Remove 4 Torx screws securing AC valve,
remove AC valve and collect 'O' ring.
Refit
1. Using a new 'O' ring, fit AC valve and tighten
Torx screws.
2. Clean fuel rail and temperature sensor mating
surfaces.
3. Fit new seal to temperature sensor, fit sensor
4. Fit new 'O' ring seals to injectors.
5. Fit injector spacer.
6. Align injectors to inlet manifold and push fuel
rail into position.
7. Fit fuel rail retaining bolts and tighten to 10 Nm.
8. Fit MAP sensor and tighten Torx screws.
9. Connect pressure regulator vacuum hose to
inlet manifold.
10. Position manifold to engine compartment.
11. Clean throttle body to manifold mating faces.
12. Fit new seal to throttle body.
13. Tighten bolts in sequence shown, using the
following procedure.
i. Tighten to 4 Nm.
ii. Back off one flat.
iii. Tighten to 9 Nm.
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8 REPAIRS
14. Fit air filter. See ENGINE MANAGEMENT
15. Fit stud and bolt securing air cleaner to
mounting bracket.
16. Fit hose to throttle body and secure with clip.
17. Position hose to air cleaner and tighten clip
screw.
18. Connect hose to AC valve.
19. Connect and secure injector multiplug.
20. Connect AC valve and TP sensor multiplugs.
21. Secure coil harness to harness clips.
22. Position coil and connect coil multiplugs, fit bolt
23. Position coil cover, fit bolts and tighten to
8 Nm.
24. Fit inlet manifold gasket. See this section.
GASKET - INLET MANIFOLD - MPi
Remove
3. Remove nut securing LH cross bracing and
remove and discard bolt securing cross
bracing.
4. Remove LH cross bracing.
6. Release coil harness from harness support
bracket.
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REPAIRS 9
7. Remove dipstick.
8. Release vacuum pipe from dipstick/ oil filler
tube.
9. Remove bolt securing engine oil level
dipstick/filler tube bracket to manifold.
10. Release clip securing dipstick/filler tube to pipe
and remove tube.
11. Release brake servo vacuum pipe from
manifold chamber.
12. Release EVAP canister hose from inlet
manifold chamber.
13. Release EVAP canister from support bracket
and position canister aside.
14. Release throttle cable from manifold chamber
clip.
15. Release throttle cable from abutment bracket.
16. Release inner cable from throttle cam.
17. Release clip securing fuel return hose to inlet
manifold and release hose.
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10 REPAIRS
18. Remove 2 bolts securing return pipe to inlet
manifold and position pipe aside.
19. Disconnect AT sensor multiplug.
20. Release clip and disconnect coolant hose from
inlet manifold.
21. Release 2 clips and 2 breather hoses from
camshaft cover.
23. Position absorbent cloth to collect any fuel
spillage.
24. Release fuel feed hose from fuel filter pipe.
25. Remove 3 nuts and 4 bolts securing inlet
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REPAIRS 11
26. Release inlet manifold from cylinder head
studs.
27. Remove and discard gasket seal from inlet
manifold.
Refit
1. Clean manifold to cylinder head mating faces.
2. Fit new gasket seal to inlet manifold and
position inlet manifold to cylinder head studs.
3. Fit nuts and bolts securing inlet manifold to
cylinder head and tighten in sequence shown
to 25 Nm.
4. Secure fuel feed hose to fuel filter pipe.
6. Connect breather hoses to camshaft cover and
secure with clips.
secure with clip.
8. Connect fuel return hose to manifold and
secure with clip.
9. Fit and tighten bolts securing fuel return pipe to
manifold.
10. Connect AT sensor multiplugs.
11. Connect throttle inner cable to cam.
12. Secure throttle cable to abutment bracket.
13. Secure throttle cable to manifold clip.
14. Fit EVAP canister in support bracket.
15. Connect EVAP canister to inlet manifold hose
and secure clip.
16. Connect brake servo vacuum hose to inlet
manifold.
17. Fit dipstick/filler tube to pipe.
18. Align dipstick/filler tube mounting bracket, fit
bolt and tighten to 10 Nm.
19. Fit dipstick.
20. Secure coil harness to support bracket.
21. Position cross bracing, fit nut and new bolt and
tighten to 25 Nm.
GASKET - INLET MANIFOLD - VVC
Remove
1. Remove manifold chamber gasket. See this
section.
CAUTION: Depressurise fueI pressure
before disconnecting fueI pipes. See
Adjustments.
3. Position cloth to catch spillage.
4. Release fuel return hose from fuel return pipe.
5. Release fuel feed hose from fuel filter pipe.
6. Position drainage tray to collect coolant
spillage.
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12 REPAIRS
7. Loosen clip and disconnect coolant hose from
inlet manifold.
8. Disconnect air intake temperature sensor
multiplug from manifold.
9. Disconnect injector harness multiplug.
10. Release injector multiplug from bracket.
11. Remove bolt securing inlet manifold to support
bracket.
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REPAIRS 13
12. Remove 2 nuts and 7 bolts securing inlet
13. Remove inlet manifold from cylinder head
studs.
14. Remove and discard gasket seal from inlet
manifold.
Refit
1. Clean manifold to cylinder head mating faces.
2. Fit new gasket seal to cylinder head.
3. Fit inlet manifold to studs.
4. Fit nuts and bolts securing inlet manifold to
cylinder head and tighten in sequence shown
to 25 Nm.
5. Align support bracket and tighten bolt to
25 Nm.
6. Secure fuel feed hose to fuel filter pipe.
7. Secure fuel return hose to return pipe.
8. Connect air intake temperature sensor
multiplug.
9. Connect injector harness multiplug.
secure clip.
11. Fit manifold chamber gasket. See this
section.
GASKET - EXHAUST MANIFOLD - MPi
Remove
4. Remove LH road wheel.
5. Remove 2 scrivets and 1 Torx screw closing
splash panel and remove panel.
6. Release tension on alternator drive belt
tensioner and remove drive belt.
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14 REPAIRS
7. Remove nut securing alternator lead and
release lead, disconnect alternator multiplug.
8. Remove alternator top bolt and loosen lower
bolt.
9. Position alternator forwards to access
alternator bracket.
10. Remove nut and bolt securing alternator
bracket.
11. Remove 2 bolts securing alternator heat shield
12. Remove alternator bracket.
shield and remove heat shield.
14. Remove 5 flange nuts securing exhaust
15. Position manifold aside, remove and discard
gasket.
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REPAIRS 15
Refit
1. Clean exhaust manifold and cylinder head
mating faces.
2. Fit new exhaust manifold gasket to cylinder
head.
3. Position manifold and working in the sequence
shown, tighten nuts to 45 Nm.
4. Position coolant hose heat shield, fit bolts and
tighten to 9 Nm.
5. Position alternator bracket.
6. Position alternator heat shield, fit bolts and
tighten to 9 Nm.
7. Tighten alternator bracket nut and bolt to
25 Nm.
8. Align alternator to bracket, fit top bolt, tighten
both bolts to 45 Nm.
9. Connect alternator multiplug and lead, secure
lead with nut.
10. Fit alternator drive belt and engage to
tensioner. Ensure drive belt is located correctly
on pulleys.
11. Adjust alternator drive belt tension. See
ELECTRICAL, Adjustments.
12. Position closing panel and secure with scrivets
and Torx screw.
GASKET(S) - MANIFOLD CHAMBER - VVC
Remove
4. Remove nuts securing cross bracing, remove
and discard bolt securing cross bracing and
remove cross bracing.
5. Release brake servo vacuum hose from clip on
dipstick/oil filler tube.
6. Remove bolt securing engine oil level
dipstick/filler tube bracket to inlet manifold.
7. Depress locking collar and remove dipstick/oil
filler from tube.
8. Depress locking collar and disconnect brake
servo hose from inlet manifold chamber.
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16 REPAIRS
9. Release cable adjusting nut from abutment
bracket.
10. Release inner cable from throttle cam.
11. Release clip and disconnect hose, EVAP
canister to inlet manifold chamber.
12. Release clip and disconnect engine breather
hose from camshaft cover.
13. Disconnect hose from ACV.
14. Disconnect multiplug from ACV.
15. Disconnect vacuum hose connecting fuel
pressure regulator to inlet manifold chamber.
17. Remove 4 bolts securing throttle housing to
inlet manifold chamber. Position multiplug
bracket aside and remove throttle housing.
18. Remove 5 bolts securing inlet manifold
chamber to inlet manifold and remove inlet
manifold chamber.
19. Remove and discard gasket from inlet manifold
chamber.
20. Remove and discard 'O' ring seal from throttle
housing.
Refit
1. Clean inlet manifold chamber and inlet
manifold mating faces.
2. Fit new 'O' ring seal to throttle housing.
3. Position new gasket seal to inlet manifold and
fit inlet manifold chamber.
4. Fit and tighten bolts securing inlet manifold
chamber to inlet manifold to 25 Nm.
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REPAIRS 17
5. Position throttle housing to inlet manifold
chamber, align multiplug bracket, fit and lightly
tighten bolts.
6. Tighten bolts in the sequence shown using the
following procedure:
i. Tighten to 4 Nm.
ii. Back off one flat.
iii. Tighten to 9 Nm.
8. Connect multiplug to ACV.
9. Connect hose to ACV.
10. Connect engine breather hose to camshaft
cover and secure with clip.
11. Connect throttle cable to cam, abutment
bracket and clips on inlet manifold chamber.
12. Connect EVAP canister hose to inlet manifold
chamber and secure with clip.
13. Connect brake servo vacuum hose to inlet
manifold chamber.
14. Position dipstick/filler tube, align support
bracket to inlet manifold, fit and tighten bolt to
10 Nm.
15. Secure brake servo vacuum hose in clip on
dipstick/oil filler tube.
16. Position cross bracing, fit nuts and new bolt
ENGINE, Repairs.
EXHAUST MOUNTINGS
Remove
1. Remove silencer heat shield. See this
section.
2. Remove 4 bolts securing LH and RH exhaust
mountings.
3. Remove brackets and rubbers.
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18 REPAIRS
4. Remove mounting rubber securing front pipe to
subframe.
Refit
1. Fit mounting rubber securing front pipe to
subframe.
2. Fit LH and RH mounting rubbers and brackets,
3. Fit silencer heat shield. See this section.
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CLUTCH
CONTENTS Page
CLUTCH COMPONENTS 1 .........................................................................................
HYDRAULC CLUTCH SYSTEM 2 ..............................................................................
CLUTCH SYSTEM OPERATON 3 .............................................................................
MASTER CYLNDER COMPONENTS 4 .....................................................................
SLAVE CYLNDER COMPONENTS 5 ........................................................................
ADJUSTMENTS
CLUTCH - BLEED 1 ....................................................................................................
REPAIRS
CLUTCH ASSEMBLY/DRVE PLATE & RELEASE BEARNG - MANUAL
TRANSMSSON MODELS 1 ......................................................................................
CLUTCH MASTER CYLNDER 3 ................................................................................
CLUTCH SLAVE CYLNDER 4 ....................................................................................
DAMPER - CLUTCH - VVC 4 ......................................................................................
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CLUTCH
CLUTCH COMPONENTS
1. Flywheel
2. Clutch plate
3. Pressure plate
4. Release bearing
5. Release bearing fork
6. Fork retaining bolt
7. Pressure plate bolts
8. Clutch release shaft
9. Clutch release shaft, washer
10. Clevis pin
11. 'R' clip
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CLUTCH
HYDRAULIC CLUTCH SYSTEM
1. Clutch pedal
2. Master cylinder
3. Slave cylinder
4. Release arm
5. Release bearing
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CLUTCH
CLUTCH SYSTEM OPERATION
The diaphragm type clutch is operated via a
hydraulic system.
When pressure is applied to the clutch pedal, fluid is
pumped from the master cylinder to the slave
cylinder causing the slave cylinder piston to apply
pressure to the release lever. The release lever
rotates the release fork and shaft.
The release fork changes rotary movement of the
release lever into linear movement pushing the
release bearing against the pressure plate
diaphragm fingers, applying pressure to the drive
plate springs and dis-engaging the clutch.
When pressure is released from the clutch pedal the
master cylinder piston is returned by a spring which
causes a pressure decrease. The drop in pressure
allows the diaphragm fingers to push the release
bearing back, decreasing the pressure on the drive
plate springs and re-engaging the clutch.
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CLUTCH
MASTER CYLINDER COMPONENTS
1. Master cylinder
2. Spring
3. Spring seat
4. Seal and washer
5. Piston
6. Seal
7. Circlip
8. Boot
9. Push-rod
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CLUTCH
SLAVE CYLINDER COMPONENTS
1. Bleed screw
2. Slave cylinder
3. Return spring
4. Seal
5. Piston assembly
6. Dust cover
7. Push-rod
8. Clevis pin
9. R-clip
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CLUTCH
ADJUSTMENTS 1
CLUTCH - BLEED
CAUTION: Ensure master cyIinder is
topped up at frequent intervaIs. Use onIy
NEW fIuid.
1. Open bonnet.
2. Open luggage compartment.
4. Position cloth around master cylinder to catch
spillage.
5. Clean area around master cylinder pipe union.
6. Depress clutch pedal to floor and hold.
7. Loosen master cylinder pipe union and allow
air and fluid to escape.
8. Tighten pipe union.
9. Return clutch pedal to released position.
10. Repeat process until bubble free fluid emerges
and tighten union to 18 Nm.
11. Clean area around slave cylinder bleed nipple.
12. Position bleed bottle and connect hose to
bleed nipple.
14. Loosen bleed nipple and allow air and fluid to
escape.
15. Tighten nipple.
17. Repeat process until bubble free fluid emerges.
19. Open bleed nipple and by hand, pull clutch
lever to fully released position.
20. Tighten nipple to 7 Nm.
22. Remove bleed bottle.
23. Top up master cylinder.
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CLUTCH
REPAIRS 1
CLUTCH ASSEMBLY/DRIVE PLATE & RELEASE
BEARING - MANUAL TRANSMISSION MODELS
Remove
2. Remove gearbox assembly. See MANUAL
GEARBOX, Repairs.
3. Fit flywheel locking tool 18G 1674 to cylinder
4. Remove clutch release bearing from guide
sleeve and release fork.
5. Examine release bearing for signs of wear or
damage, renew if necessary.
CAUTION: Bearing is packed with grease.
Do not wash in soIvent.
6. Place a circular piece of flat plate across
diaphragm fingers, insert feeler gauges
between plate and each diaphragm finger,
measure finger clearance which has a service
limit of 1.0 mm. A single finger exceeding the
service limit should be ignored.
7. Measure diaphragm finger height above bolted
surface of pressure plate. Diaphragm finger
height on a new pressure plate is
29.1 - 32.0 mm with a service limit of 36.5 mm.
Renew pressure plate if clearances are outside
service limit.
8. Progressively loosen and remove 6 Torx bolts
securing clutch pressure plate to flywheel.
9. Remove clutch pressure plate and collect drive
plate.
10. nspect clutch drive plate for signs of wear or
oil contamination. Renew drive plate if
necessary.
11. Check pressure plate for signs of wear or
damage. Check for signs of overheating on
drive straps (deep yellow to blue colour), renew
pressure plate if necessary.
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CLUTCH
2 REPAIRS
12. Using a straight edge and feeler gauges, check
the surface of the pressure plate for flatness at
4 separate points. Renew pressure plate if
warping exceeds the service limit of 0.18 mm.
Refit
1. Clean pressure plate, flywheel dowels and
dowel holes in flywheel.
2. nspect flywheel for signs of scoring or other
damage. Renew if worn or damaged.
3. Smear clutch drive plate splines with
Molybdenum disulphide grease.
4. Position drive plate to pressure plate with
'GEARBOX SDE' facing towards gearbox.
5. Use 12-162 to align drive plate and pressure
plate.
6. Ensure drive plate is aligned to centre of
pressure plate.
7. Fit clutch assembly to flywheel and locate on
dowels.
8. Fit 6 bolts securing pressure plate to flywheel
and tighten finger tight.
9. Progressively tighten clutch pressure plate
bolts in a diagonal sequence to 25 Nm.
10. Remove drive plate alignment tool 12-162.
11. Clean clutch release fork and release bearing
guide sleeve.
12. Smear release fork shaft and bore of release
bearing with Molybdenum disulphide grease.
13. Fit release bearing to release fork and slide
onto guide sleeve.
14. Operate clutch release lever to ensure that
release bearing is correctly located on release
fork and slides smoothly on guide sleeve.
15. Remove bolt and flywheel locking tool,
18G 1674, from cylinder block.
16. Fit gearbox assembly. See MANUAL
GEARBOX, Repairs.
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CLUTCH
REPAIRS 3
CLUTCH MASTER CYLINDER
Remove
1. Remove underbonnet closing panel, See
2. Remove clevis pin from clutch pedal.
4. Loosen and release union securing fluid pipe to
master cylinder, position fluid pipe aside.
5. Remove 2 bolts securing master cylinder to
pedal box.
6. Remove master cylinder.
7. Remove and discard gasket.
Refit
1. Using new gasket, fit master cylinder and
2. Position pipe and tighten union to 18 Nm.
3. Position clutch pedal to push rod, fit clevis pin.
4. Fit washer and clip.
5. Bleed clutch. See Adjustments.
6. Fit underbonnet closing panel. See BODY,
Exterior fittings.
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CLUTCH
4 REPAIRS
CLUTCH SLAVE CYLINDER
Remove
2. Remove clevis pin from slave cylinder.
3. Release pipe union from slave cylinder and
position aside.
4. Remove 2 bolts securing slave cylinder to
bracket and remove slave cylinder.
Refit
1. Fit slave cylinder and tighten bolts to 25 Nm.
2. Position pipe and tighten union to 18 Nm.
3. Position cylinder rod to lever and secure with
clevis pin.
4. Bleed clutch. See Adjustments.
DAMPER - CLUTCH - VVC
Remove
1. Remove underbonnet closing panel, See
2. Place container underneath clutch damper to
collect fluid spillage.
3. Release 2 clutch pipe unions from clutch
damper.
4. Remove 2 bolts securing clutch damper to
bracket.
5. Collect clutch damper.
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CLUTCH
REPAIRS 5
Refit
1. Position clutch damper to bracket.
2. Fit bolts securing clutch damper to bracket and
tighten to 15 Nm.
3. Fit clutch pipe unions to clutch damper and
tighten to 18 Nm.
4. Bleed clutch hydraulic system. See
Adjustments.
5. Collect drip tray.
Exterior fittings.
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MANUAL GEARBOX
CONTENTS Page
REPAIRS
GEAR LEVER 1 ...........................................................................................................
GEAR CHANGE CABLE 2 ...........................................................................................
GEARBOX - MANUAL - REMOVE FOR ACCESS & REFT 5 ....................................
SELECTOR SHAFT OL SEAL 6 .................................................................................
REVERSE LAMP SWTCH 8 .......................................................................................
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MANUAL GEARBOX
REPAIRS 1
GEAR LEVER
Precautions.
Remove
trim components.
3. Remove 4 T x 30 Torx bolts securing SRS
DCU bracket to tunnel, position bracket aside.
4. Remove 4 nuts and 3 bolts securing lever
assembly to tunnel.
5. Remove bolt securing cable abutment clip to
lever assembly and release clip.
6. Release 2 cables from ball joints and lever
assembly.
7. Remove lever assembly.
Refit
1. Connect cables to lever assembly.
2. Position outer cables and secure with clip.
3. Secure retaining clip with bolt.
4. Position gear lever assembly to body.
5. Fit and tighten nuts and bolts to 9 Nm.
6. Position SRS bracket to body, fit harness earth
lead and tighten Torx bolts to 10 Nm.
components.
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MANUAL GEARBOX
2 REPAIRS
GEAR CHANGE CABLE
Precautions.
Remove
4. Drain engine coolant. See COOLING
5. Release handbrake to OFF position.
6. Release gear change cable from gearbox
linkage.
7. Remove and discard clip securing cable to
abutment bracket.
8. Release cable from abutment bracket.
9. Place support jack underneath engine sump
and support engine weight.
CAUTION: To prevent damage to sump
pIace a piece of wood between jack and
sump.
10. Remove 2 bolts securing each front subframe
mounting to body brackets.
11. Lower jack carefully, to allow access to closing
plate bolts.
CAUTION: Care must be taken that no
cabIes or pipes are stretched when
Iowering front of subframe.
12. Tie coolant hoses aside to allow access to
closing plate.
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MANUAL GEARBOX
REPAIRS 3
13. Release 2 upper bolts and remove 3 remaining
bolts securing closing plate to bulkhead.
14. Apply soft soap to all four closing plate cables,
to ease movement of closing plate.
15. Release closing plate from bulkhead and slide
along cables.
16. Release gear change cable grommet from
closing plate.
trim components.
18. Remove 4 Torx bolts securing SRS DCU
bracket to tunnel, position bracket aside.
19. Remove 4 nuts and 3 bolts securing gear
selector assembly to tunnel.
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MANUAL GEARBOX
4 REPAIRS
20. Position gear selector assembly and remove
bolt securing cable abutment clip to assembly.
21. Remove cable abutment clip and release cable
from assembly.
22. Remove gear change cable from tunnel and
engine compartment.
Refit
1. Position gear change cable to tunnel and feed
through rear bulkhead.
2. Position cable in engine compartment.
3. Lubricate all four cables with soft soap to ease
grommet movement on cables.
4. Position cable into closing plate slot and
secure with grommet.
5. Align closing plate to bulkhead and secure with
bolts.
6. Raise subframe on jack, fit subframe mounting
bolts and tighten to 30 Nm .
7. Position cable to gear selector abutment
bracket.
8. Engage cable to selector ball joint.
9. Fit new abutment bracket clip.
10. Fit cable to gear lever selector assembly.
11. Position cable to abutment, fit retaining clip and
secure with bolt.
12. Position gear lever assembly to tunnel, fit and
tighten nuts and bolts to 9 Nm.
13. Position SRS DCU bracket to tunnel, fit
harness earth connector, tighten Torx bolts to
10 Nm .
WARNING: The crash sensor is
incorporated inside the DCU, therefore it is
imperative that the DCU boIts are
tightened to their correct torque.
components.
15. Untie and position coolant hoses.
16. Fill engine coolant system. See COOLING
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MANUAL GEARBOX
REPAIRS 5
GEARBOX - MANUAL - REMOVE FOR ACCESS &
REFIT
Remove
2. Remove engine and gearbox assembly. See
ENGINE, Repairs.
3. Drain gearbox oil.
4. Remove 2 nuts and bolts securing starter
motor, remove starter motor and collect rear
closing plate.
5. Disconnect reverse light switch connectors.
6. Disconnect multiplug from road speed
transducer.
7. Remove 5 bolts and 3 nuts and bolts securing
gearbox to engine.
8. Collect front closing plate.
9. With assistance remove gearbox from engine.
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MANUAL GEARBOX
6 REPAIRS
Refit
1. Clean mating faces of gearbox and engine,
ensure locating dowels are fitted.
2. With assistance, fit gearbox, locate on dowels
and secure to engine.
3. Position front closing plate.
4. Fit nuts and bolts securing gearbox to engine.
Tighten gearbox to engine bolts to 80 Nm.
Gearbox to sump bolts to 45 Nm.
5. Connect multiplug to transducer.
6. Connect reverse lamp switch wires.
7. Clean starter motor and mating face on
gearbox housing.
8. Position rear closing plate.
9. Position starter motor to gearbox, fit and
tighten nuts and bolts to 80 Nm.
10. Fill gearbox with oil.
11. Fit engine and gearbox assembly. See
ENGINE, Repairs.
SELECTOR SHAFT OIL SEAL
Remove
2. Release 2 gear change cables from selector
linkage.
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MANUAL GEARBOX
REPAIRS 7
3. Remove clip securing selector linkage roll pin.
4. Using a suitable punch, drive out roll pin from
selector linkage and discard roll pin.
5. Remove selector linkage from shaft.
6. Remove bolt and Torx screw securing lower
gear change cable abutment bracket to
gearbox.
7. Remove gear change cable abutment bracket.
8. Remove oil seal cover from selector shaft.
9. Using a flat screwdriver remove oil seal from
gearbox and discard oil seal.
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MANUAL GEARBOX
8 REPAIRS
Refit
1. Clean oil seal housing and selector shaft.
2. Lubricate new seal using clean unused engine
oil.
3. Fit oil seal to selector shaft.
4. Secure seal to gearbox using a deep socket.
5. Fit oil seal cover and secure to seal flange.
6. Fit gear change cable abutment bracket, fit
bolts and tighten to 45 Nm.
NOTE: Position earth Iead to abutment
bracket retaining boIt.
7. Fit selector linkage to shaft, align holes, fit new
roll pin and secure clip.
8. Secure gear change cables to selector linkage.
REVERSE LAMP SWITCH
Remove
3. Disconnect reverse lamp switch connectors.
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MANUAL GEARBOX
REPAIRS 9
4. Remove reverse lamp switch.
5. Collect sealing washer and discard.
Refit
1. Clean threads and mating faces of reverse
lamp switch.
2. Fit NEW sealing washer to reverse lamp
switch.
3. Fit and tighten reverse lamp switch to gearbox.
4. Connect reverse lamp switch connectors.
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MANUAL GEARBOX
10 REPAIRS
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AUTOMATIC GEARBOX - 'Em-CVT'
CONTENTS Page
STEPSPEED (Em-CVT) COMPONENT LOCATON 1 ................................................
STEPSPEED (Em-CVT) GEARBOX - SECTONAL VEW 4 .......................................
STEPSPEED (Em-CVT) CONTROL DAGRAM 6 .......................................................
DESCRPTON 7 .........................................................................................................
OPERATON 17 ...........................................................................................................
FAULT DAGNOSS 19 ................................................................................................
ADJUSTMENTS
DRAN AND REFLL 1 .................................................................................................
REPAIRS
LEVER - GEAR CHANGE 1 ........................................................................................
CABLE - GEAR CHANGE 3 ........................................................................................
LED MODULE - GEAR SELECTON 5 ........................................................................
SWTCH - PRND 5 ......................................................................................................
PARK/NEUTRAL AND REVERSE LGHT SWTCH 6 .................................................
SOLENOD - SHFT LOCK 6 .......................................................................................
DFFERENTAL SPEED SENSOR 7 ...........................................................................
SWTCH - STEERNG WHEEL REMOTE 8 ................................................................
MCROSWTCH - MANUAL/SPORT AND +/- SWTCH 8 ...........................................
GEARBOX NTERFACE UNT (GU) 9 ........................................................................
GEARBOX & CONVERTER - STEPSPEED (Em-CVT) - REMOVE FOR
ACCESS & REFT 9 ....................................................................................................
SECONDARY COVER SEALS 12 ...............................................................................
GASKET - FLUD PAN 13 ...........................................................................................
FLTER - GEARBOX FLUD 14 ...................................................................................
COOLER - GEARBOX FLUD 14 ................................................................................
HOSE/PPE - FEED - NTERMEDATE TO FLUD COOLER 15 ................................
HOSE/PPE - RETURN - NTERMEDATE TO FLUD COOLER 16 ...........................
HOSE/PPE - NTERMEDATE - FEED 17 ..................................................................
HOSE/PPE - NTERMEDATE - RETURN 18 .............................................................
HOSE/PPE - FEED - NTERMEDATE TO GEARBOX 18 .........................................
HOSE/PPE - RETURN - NTERMEDATE TO GEARBOX 19 ....................................
PRMARY BEARNG 20 ..............................................................................................
ROAD SPEED TRANSDUCER 22 ..............................................................................
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STEPSPEED (Em-CVT) COMPONENT LOCATION
1. Fluid cooler
2. Brake switch
3. nstrument pack
4. Steering wheel switches
7. Stepspeed (Em-CVT) gearbox
8. Selector cable
9. Fluid cooler feed/return pipes
10. Gear selector lever
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1. Starter motor
2. Fluid level dipstick
3. Road speed transducer
4. Gearbox differential speed sensor
5. LH drive shaft connection
6. Park/Neutral switch
7. Fluid cooler return connection
8. Fluid cooler feed connection
9. Ratio control motor connector
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STEPSPEED (Em-CVT) GEARBOX - SECTIONAL
VIEW
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1. Ratio control motor
2. Fluid sump
3. Hydraulic control unit
4. Primary pulley
5. Fluid pump
6. Secondary pulley
7. Drive belt
8. Differential
10. Pinion shaft
11. Final drive reduction gear
12. Secondary reduction gear
13. Drive clutch
14. Reverse clutch
15. Planetary gear set
16. nput shaft
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STEPSPEED (Em-CVT) CONTROL DIAGRAM
A= Hardwired; B= SeriaI Iink; J= Diagnostic ISO9141 K Line
2. nstrument pack
3. Brake switch
5. Gearbox differential speed sensor
6. Park/Neutral switch
7. (Em-CVT) Stepspeed gearbox
8. Ratio control motor
9. Steering wheel switches
10. P R N D S LED module
11. P R N D switch
12. Manual/Sport switch
13. Sport +/- switch
14. Shift lock solenoid (if fitted)
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DESCRIPTION
GeneraI
The Electro Mechanical - Continuously Variable
Transmission (Em-CVT) is based on a standard
CVT unit with electronic components fitted to control
the gear ratio. This gives the driver a choice
between an automatic gearbox and a
semi-automatic Stepspeed manual gearbox.
The gearbox can be operated as a conventional
CVT unit by selecting P, R, N or D on the selector
lever. Moving the selector lever across the gate trips
a microswitch and puts the gearbox into
manual/sport mode.
n sport mode, the gearbox still operates as a
conventional CVT unit, but becomes more
responsive to changes in driver demands. Engine
speed is higher in this mode which gives improved
acceleration.
When in sport mode, if the selector lever or either of
the steering wheel switches are moved to the + or -
positions, the system changes to operate in manual
mode. Manual gear changes can be performed
sequentially using either the selector lever or the
steering wheel switches. Movement of the selector
lever in a forward direction (+) changes the gearbox
up the gear ratios and movement in a rearward (-)
direction changes the gearbox down the ratios.
Either of the + and - switches on the steering wheel
perform the same function as the selector lever
when in sport mode.
Gearbox operation is controlled by a Gearbox
nterface Unit (GU) and the ECM which
communicate via a dedicated serial link and a
hardwired connection. The MEMS3 ECM is
programmed with an Em-CVT control strategy to
operate the gearbox in conjunction with the GU.
Stepspeed Em-CVT unit
When in automatic mode, the Em-CVT provides an
infinite number of ratios within its operating range.
The stepless shifting pattern of the transmission
provides a smooth transfer of power to the road
wheels whilst allowing full vehicle performance to be
available at all times.
n sport mode, the Em-CVT operates as in automatic
mode but with a higher engine speed under all
driving conditions which gives improved
acceleration.
n manual mode, the Em-CVT provides electronic
selection of six predetermined ratios. Selection is
made by the driver using the selector lever or the
steering wheel switches.
The Em-CVT unit comprises mechanical and
electrical components which work together to
provide the automatic and manual operation of the
gearbox.
The following mechanical components comprise the
Em-CVT unit (Refer to Em-CVT sectional view):
Torsion damper
Planetary gear set
Clutches
Pulleys and steel belt
Pinion shaft
Differential unit
Hydraulic pump.
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Torsion damper
The transmission is driven from the engine via a
torsion damper. The torsion damper is attached to
the flywheel with six bolts and is constructed similar
to a conventional clutch drive plate, but without the
clutch lining. The torsion damper has a splined hub
which engages with the gearbox input shaft. The
hub is located on an inner plate which contains
compression springs. Engine power is transmitted
from the flywheel and damper attachment to the hub
via the compression springs which absorb torsional
vibrations from the engine and provide a smooth
power delivery to the gearbox.
Planetary gear set
The planetary gear set enables the gearbox to
provide a rotational output to the drive shafts in two
directions to provide the vehicle with forward and
reverse selections.
Engine torque is transmitted from the engine and the
torsional damper to the input shaft which is attached
to the planet carrier.
When forward is selected, the carrier is connected
directly to the sunwheel by the drive clutch. The
epicyclic gear set rotates as one unit and engine
torque is passed directly to the primary pulley.
When reverse is selected, the annulus of the
planetary gear set is held stationary by the reverse
clutch. Three pairs of planet gears then drive the
sunwheel in the opposite direction rotating the
primary pulley in the reverse direction.
Clutches
Each of the two clutches comprise a multiplate wet
clutch pack. Each pack has three friction plates
providing six friction surfaces. Hydraulic pressure
controls the clutches to allow the vehicle to move
away smoothly regardless of the degree of throttle
opening. Fluid from the fluid cooler is directed to the
clutch plates to prevent overheating of the friction
surfaces.
Pulleys and steel belt
The major drive components of the gearbox are a
pair of vee shaped pulleys and a steel drive belt.
Each pulley comprises one fixed sheave and one
moveable sheave. Both moveable sheaves are
positioned diagonally opposite each other to prevent
misalignment of the belt during shift changes. Each
moveable sheave is operated by a hydraulic cylinder
and piston, with hydraulic pressure controlled by the
hydraulic control unit. The moveable sheaves are
located on ball splines which prevents them rotating
in relation to the fixed sheaves.
Rotation of the planetary gear set rotates the primary
pulley. The V-belt transfers the primary pulley
rotation to the secondary pulley whose torque and
speed is controlled by the position of the V-belt on
the two pulleys.
A 24 mm wide steel, push type V-belt is used to
transfer engine torque between the two pulleys. The
belt is cooled and lubricated by a fluid jet.
The belt comprises two steel bands each
constructed from ten steel strips. The steel bands
contain approximately 350 steel segments which
abut each other to allow the belt to transmit torque
by compression. The belt has several different
thicknesses of steel segments which reduce the
noise of the segments contacting the pulleys by
changing the harmonic frequencies.
Pinion shaft
The pinion shaft, which is supported on two tapered
bearings, provides location for two gears which
provide a two step helical gear reduction between
the secondary pulley and the differential crownwheel
and provide the correct rotational direction of the
drive shafts.
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Differential
Drive from the final reduction gear is transferred to
the differential crownwheel. The crownwheel is
bolted to the differential case with eight bolts. Drive
from the crownwheel is transferred via bevel gears
to the drive shafts. The differential is supported on
tapered bearings.
Hydraulic pump
The hydraulic pump is located on the opposite side
of the gearbox to the planetary gear set. The pump
is driven directly from the torsion damper via a shaft
which is located through the centre of the input
shaft. The shaft is splined to the planet carrier which
always rotates at engine crankshaft speed.
The pump has a swept volume of 10.32 cc per
revolution and can produce a pressure of up to 40
bar (580 lbf/in
2
) for the highest torque requirement.
The pressurized fluid from the pump is used for
gearbox lubrication and transmission control.
The following electrical components are used on the
Em-CVT unit:
Ratio control motor
Gearbox differential speed sensor
Park/Neutral switch.
Ratio Control Motor
The ratio control motor operates to match the gear
ratio to the target engine speed. n any mode, the
motor position is varied to provide the 'kickdown'
function of a conventional automatic transmission. n
manual mode, the position of the motor is varied to
control the engine speed, fixing the current gear
ratio. The motor operates the hydraulic control unit
to adjust the primary pulley.
The ratio control motor is located inside the gearbox,
on one side of the hydraulic control unit. The motor
is connected to the main harness via a circular
seven way connector with four connections used for
the motor operation. The connector is screwed into
the forward face of the gearbox and is secured with
a nut.
The ratio control motor is a linear actuator which is
controlled by the GU in response to PWM signals at
500 Hz from the ECM. The motor itself is a bi-polar
stepper motor which contains two bobbins which
create magnetic fields to move the motor to the
required position.
Gearbox Differential Speed Sensor
The gearbox differential speed sensor is located in
the rear face of the gearbox adjacent to the road
speed transducer. The sensor is connected to the
main harness via a fly lead with a three pin
connector.
The gearbox differential speed sensor is a Hall effect
sensor which uses an 81 tooth target wheel which is
the teeth of the gearbox differential crown wheel.
The sensor output is read directly by the ECM which
calculates an accurate vehicle speed. The sensor
output is unaffected by locking of the wheels due to
the operation of the differential. The ECM vehicle
speed calculation allows the Em-CVT system to
calculate the current gear ratio.
Park/Neutral Switch
The park/neutral switch is screwed into the rear face
of the gearbox below the LH drive shaft. The switch
is connected to the main harness by a four pin
connector.
The switch is operated by a cam which also
operates the hydraulic control unit within the
gearbox. The cam is controlled by the selector lever
via a cable to the gearbox. The switch has two
positions and performs several functions.
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When the transmission is in any position other than
the Park (P) or Neutral (N) positions, the switch
interrupts the starter relay coil earth path to the
alarm ECU preventing starter operation. This signal
is also used by the ECM to adjust the stepper motor
of the AC valve to adjust the engine idle speed
when Reverse (R) or Drive (D) is selected.
When Reverse (R) is selected, the switch moves to
its second position and activates the reverse lamps.
n selected markets, when the selector lever is in the
'P' position and the ignition is switched on, the
park/neutral switch input causes the GU to energise
a shift lock solenoid on the selector lever. This locks
the lever in the 'P' position. The selector lever
cannot be moved from the 'P' position until the
ignition is switched on and the footbrake is applied.
The shift lock solenoid is only active when the
ignition is on.
Road speed transducer
The road speed transducer is located on the rear
face of the gearbox, above the RH drive shaft,
adjacent to the gearbox differential speed sensor.
The transducer is used by the instrument pack for
speedometer drive, the Electronic Power Assisted
Steering (EPAS) system and the ECM.
See INSTRUMENTS, Information.
See STEERING, Information.
Gearbox Interface Unit (GIU)
1. Harness connector
2. GU
3. Mounting nut (2 off)
4. GU fuse (10A)
The GU is located in the in the LH side of the
luggage compartment behind the trim. The GU has
two captive studs which are secured to the body with
two nuts.
When the engine control module relay is engaged
uner the control of the ECM, battery voltage is
supplied to the GU from fuse 2 in the engine
compartment fusebox via a 10 Amp in-line fuse
located on the harness near the GU connector.
The GU responds to control messages from the
ECM to control the gearbox operation. The GU also
passes messages to the ECM in response to driver
input commands enabling the ECM to operate the
gearbox accordingly.
The ECM and GU have a programmed default
strategy which is engaged when specific faults are
detected. Any condition requiring the default strategy
will be relayed to the driver by illumination of the
gearbox fault lamp in the instrument pack.
The ECM will need to learn the ratio control motor
position when a new ECM is fitted. This is performed
automatically by the ECM using a fast adaptation
procedure. Refer to Operation section for details.
A 'limp-home mode' is provided if the system detects
a fault but is still able to control the gearbox ratio. n
addition to the fault lamp illumination, the driver will
experience the engine speed being limited to
approximately 3000 rev/min.
f the system is unable to control the gearbox ratio,
the ECM will be unable to implement the default
strategy, the gearbox will remain in a single ratio and
the fault lamp will illuminate. f in the lowest gear, the
engine speed will increase rapidly to 6000 rev/min
and vehicle speed will be limited to a maximum of 30
mph (48.3 km/h). f in the highest gear, the driver will
experience very slow acceleration and engine
speeds of approximately 2000 to 2250 rev/min at 50
mph (80.5 km/h).
A single multiplug provides all input and output
connections to and from the GU. The following table
shows the harness connector pin numbers and
input/output information.
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GIU connector C0932 pin detaiIs
1 Shift lock solenoid drive (digital signal) Output
2 Not used -
3 12V Battery voltage from ECM relay module nput
4 Earth nput
5 Ratio control motor - Phase 1A (digital signal) nput/Output
6 Ratio control motor - Phase 1B (digital signal) nput/Output
7 Ratio control motor - Phase 2A (digital signal) nput/Output
8 Ratio control motor - Phase 2B (digital signal) nput/Output
9 Not used -
10 Not used -
11 Not used -
12 Not used -
13 Brake switch nput
14 Park/Neutral switch nput
15 Not used -
16 Not used -
17 GU to ECM serial link Output
18 ECM to GU (Ratio control motor position) nput
19 Not used -
20 Not used -
21 Not used -
22 Not used -
23 Not used -
24 Not used -
Continued.....
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Connector C0932 pin detaiIs (continued)
25 Not used -
26 Park (P) LED (digital) Output
27 Reverse (R) LED (digital) Output
28 Neutral (N) LED (digital) Output
29 Drive (D) LED Output
30 Manual (M) LED (digital) Output
31 Park/Neutral switch nput
32 Reverse switch nput
33 Neutral switch nput
34 Drive switch nput
35 Manual/sport switch nput
36 Selector lever manual UP (+) switch nput
37 Steering wheel manual UP (+) switch nput
38 Selector lever manual DOWN (-) switch nput
39 Steering wheel manual DOWN (-) switch nput
40 Not used -
41 Not used -
42 Not used -
NOTE: Pins 1 and 22, 2 and 23 and, 4 and 25 are connected together inside the GIU.
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Engine ControI ModuIe - Em-CVT controI
All electronic control of the Em-CVT operates as part
of the MEMS3 ECM control strategy. The ECM
receives an input from the gearbox differential speed
sensor and communicates with the GU to control
the gearbox. The ECM also provides driver
information via the LCD display in the instrument
pack for gear ratio selected and automatic/sport
mode selection.
The following input/output signals are used by the
ECM for Em-CVT control.
Crankshaft position (CKP) sensor
Em-CVT Road speed transducer
Throttle position (TP) sensor
Engine coolant temperature (ECT) sensor
Manifold absolute pressure (MAP) sensor
nstrument pack gear/mode display
Park/Neutral switch
Em-CVT Ratio control motor position
GU serial link.
Refer to Engine Management for full ECM pin-out
details. See ENGINE MANAGEMENT SYSTEM -
MEMS, Information.
Gear SeIector Lever assembIy
1. Park/Reverse release button
2. LED module
3. Selector lever
4. Shift lock solenoid (if fitted)
5. PRND switch
6. Selector cable
7. Manual/Sport switch
8. Sport +/- switch
The gear selector lever assembly comprises a shift
lock solenoid, LED module, manual/sport switch,
sport +/- switch and PRND switch.
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A die cast plate provides the attachment for the
selector lever components. The plate is secured to a
fabricated mounting with bolts, which in turn is
secured to the floor pan with bolts and nuts. Rubber
mounts between the mounting and the floor pan
isolate vibrations from the selector lever.
The selector lever is attached to a gimbal mounting
which allows gear selection in automatic and sport
mode in a forward and backward direction and
selection between automatic and sport in a left and
right transverse direction.
Accidental selection of reverse (R) or park (P) is
prevented by a locking mechanism on the lever. A
button on the lever releases the mechanism allowing
the lever to be moved to the 'P' or 'R' positions.
Shift Lock Solenoid (selected markets only)
When fitted, the shift lock solenoid is attached to a
plate which is secured to the die cast plate with two
screws in front of the selector lever. The solenoid is
connected to the main harness by a two pin
connector.
The solenoid is powered by the GU. When the
solenoid is energised, a pin is ejected which
engages with a hole in the selector lever, locking it in
the park position.
When the selector lever is in the 'P' position and the
ignition is on, the solenoid will be energised until the
footbrake is depressed. When the solenoid is
de-energised the pin is retracted allowing the
selector lever to be moved.
LED Module
The LED module is located in the selector lever
gaiter surround and is secured with two screws. The
module is connected to the main harness by an
eight pin connector C0245.
The LED module illuminates the selector position
display on the selector lever surround for the PRND
and S positions. When the side lamps are switched
on, all LED's are illuminated at a low intensity, with
the selected LED illuminated at a higher intensity.
Manual/Sport Switch
The manual/sport switch is located on the die cast
metal plate behind the selector lever and is secured
to the plate with a metal strap. The switch is
connected to the main harness by a four pin
connector C0675 which is shared with the manual
+/- switches. The manual/sport switch and the
manual +/- switch can only be replaced a pair.
The manual/sport switch is a cam operated
microswitch. A lever with a roller is attached to the
switch body. When the selector lever is moved from
automatic to the manual/sport position, the roller
contacts a cam plate which depresses the lever and
operates the switch. The switch contacts remain
closed when the selector lever is in the sport
position.
The operation of the switch is sensed by the GU
which switches the gearbox operation to
manual/sport when 'S' is selected and deselects
manual/sport mode when 'D' (automatic operation)
is selected.
Stepspeed Manual (+/-) Switch
The manual +/- switch is located on the LH side of
the selector lever and is secured to a bracket, which
is secured to the die cast plate with two cap screws.
The switch is connected to the main harness by a
four pin connector C0675 which is shared with the
manual/sport switch. The manual +/- switch and the
manual/sport switch can only be replaced as a pair.
When the selector lever is moved to the
manual/sport position, a dog engages with a slotted
abutment on the switch. When the lever is moved to
the + or - position the dog moves the switch
completing a contact. This is sensed by the GU
which initiates the appropriate gear ratio selection.
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PRND Switch
The PRND switch is located on the RH side of the
selector lever and is secured to the die cast plate
with two screws. The switch is connected to the
main harness by a six pin connector.
The PRND switch has a sliding contact which moves
with the selector lever. The switch has four contacts
which correspond to the PRND positions. Each
contact is connected to the GU which then
calculates the control strategy for the selection
made.
Brake Switch GIU input (seIected markets onIy)
The brake switch is located on the pedal box and is
activated by operation of the brake pedal. The
switch supplies an input to the GU in addition to
operating the brake lamps.
When the brake switch is operated, a 12V feed is
sensed by the GU. This is used by the GU to
de-energise the shift lock solenoid providing that the
ignition is on.
Steering WheeI Switches
Two additional selector switches are located on the
steering wheel. Each switch is a three position,
spring biased to centre switch. The switches can be
pushed in either direction (+/-) to change the
gearbox ratio. The switches provide the same
functionality as the selector lever +/- switches and
are only operative when the selector lever is in the
manual/sport position.
Each switch is connected to the GU via the rotary
coupler. When either switch is operated in the +/-
position, an earth path from the GU is completed.
This is sensed by the GU which initiates the
appropriate gear ratio selection.
Instrument Pack
The instrument pack displays gearbox selection and
illuminates a fault lamp if a gearbox fault is detected.
1. Gearbox fault lamp
2. Liquid crystal display
The gearbox related displays in the instrument pack
are controlled by the ECM which transmits PWM
signals to operate the lamps and the LCD.
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Liquid Crystal Display (LCD)
The LCD is located below the speedometer on the
instrument pack. n addition to displaying the
odometer and trip meter, the LCD also displays the
current gearbox status. The following table shows
the characters displayed and their definition.
Character Description
P Park
R Reverse
N Neutral
D Drive
D
Sport
Sport mode
1 Manual 1st ratio
2 Manual 2nd ratio
3 Manual 3rd ratio
4 Manual 4th ratio
5 Manual 5th ratio
6 Manual 6th ratio
F Fast adaptation
When the ECM is replaced, the ECM EEPROM
re-initialised by TestBook or the gearbox replaced,
the LCD alternately flashes 'F' and the selected
mode until the fast adaptation cycle is complete.
Gearbox fault lamp
The gearbox fault lamp is located in the instrument
pack and is illuminated by the ECM when a gearbox
fault is detected.
f a gearbox fault is detected by the ECM, in addition
to the gearbox fault lamp being illuminated, the LCD
transmission display is extinguished.
FIuid CooIer
The fluid cooler is located at the front of the vehicle
behind the bumper, in front of the engine cooling
radiator. The fluid cooler comprises eight horizontal
cores which allow fluid to flow across from one side
of the cooler to the other. Each core is joined by thin
fins which aid heat dissipation.
Two fluid lines from the gearbox, comprising alloy
pipes and flexible hoses, provide the feed and return
to and from the fluid cooler.
Diagnostics
information between the ECM and TestBook. The
diagnostic socket is located in the passenger
compartment fusebox which is below the fascia on
the driver's side.
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The diagnostic socket is connected to the ECM on
an SO9141 K Line. The system uses a 'P' code
diagnostic strategy and can record faults relating to
the gearbox differential speed sensor and the ratio
control motor.
The GU and ECM monitor all inputs and outputs
relating to the Em-CVT system. f a fault is detected,
a code applicable to that fault is stored in a fault log
in the GU. When TestBook is connected, GU codes
are accessed via the ECM diagnostic strategy.
The MEMS3 ECM is a major component in gearbox
control. Functionality of engine sensors should be
established to eliminate any ECM related faults from
the gearbox diagnostics.
OPERATION
GeneraI
The transmission is driven from the engine via a
torsion damper bolted to the flywheel. The torsion
damper drives the input shaft which in turn drives
the planet carrier. Depending on whether forward or
reverse is selected, the primary pulley will rotate,
transferring torque to the secondary pulley causing
the vehicle to move in the required direction.
The steel belt is fitted between the primary and
secondary pulleys. Each pulley consists of one fixed
sheave and one axially moveable sheave. The
moveable pulley sheaves are located diagonally
opposite to each other to prevent misalignment of
the belt during shift changes.
Each moving pulley sheave is connected to a
hydraulic cylinder which is controlled by hydraulic
pressure generated by the integral pump running at
engine speed. Moving the pulley sheaves together
increases their effective diameter and moving them
apart decreases the diameter due to the conical
faces of each pulley. n this way the gear ratios of
the Em-CVT unit are achieved.
The Em-CVT unit has two multiplate wet clutch
packs; one for forward and one for reverse. Each
pack comprises three friction plates. The clutches
are hydraulically controlled which enables the
vehicle to move smoothly from standstill irrespective
of the throttle position. The clutches are fed
hydraulic fluid from the fluid cooler to prevent them
overheating.
When the selector lever is in the Park (P) position, a
spring and cone operated pawl mechanically locks
the secondary pulley, consequentially locking the
rear wheels. f 'P' is selected when the vehicle is
moving, the pawl will not engage until the vehicle
speed falls to below 4 mph (7 km/h). A rattling sound
may be heard if 'P' is selected when the vehicle is
moving.
Driving - Automatic mode
To pull away from a standstill a low ratio is required.
The primary pulley is held fully open, reducing its
diameter and allowing the belt to seat at the bottom
of the pulley. The secondary pulley is held closed,
forcing the belt to run in its increased diameter.
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As the vehicle speed increases, higher ratios are
required. As engine speed increases the fluid
pressure generated by the pump increases. This
increase in pressure is felt by the primary pulley
cylinder which moves to gradually move the pulley
sheaves together increasing its effective diameter.
Simultaneously, the secondary pulley sheaves move
apart, reducing its diameter and increasing the
gearbox ratio. When the primary pulley is closed and
the secondary pulley is fully open, the gearbox
operates in an overdrive ratio, with the secondary
pulley rotating at approximately two and a half times
the speed of the primary pulley.
When kickdown is required, the ECM transmits a
message to the GU to control the ratio control motor
accordingly. The GU adjusts the ratio control motor
which, in turn, moves the hydraulic control valve to
lower the gearbox ratio to achieve the required
acceleration.
Driving - ManuaI/Sport mode
n manual/sport mode the gearbox functions as a
conventional CVT unit or a semi-automatic manual
transmission. n sport mode, the engine speed is
higher under all driving conditions which gives
improved acceleration.
By moving the selector lever to the + or - position, or
pressing a steering wheel switch, the system is
commanded to operate in manual mode. f required,
the driver can make sequential gear selections using
either the selector lever or the steering wheel
mounted switches.
The ratio control motor operates to match the gear
ratio to the target engine speed. n any mode, the
motor position is varied to provide the 'kickdown'
function of a conventional automatic transmission.
n manual mode, the position of the ratio control
motor is varied to control engine speed, fixing the
current gear ratio. The action of the motor operates
the hydraulic control unit to adjust the primary pulley.
The GU checks if a requested gear change made
by the driver is permitted. Gear changes will be
ignored if the driver requests a change which is
dangerous or could damage the transmission.
f a shift up is required and the driver has not made
the required selection using the selector lever or the
steering wheel switches, the next higher gear will be
selected when the engine speed reaches maximum
rev/min.
f the driver does not make a required shift down
when the vehicle is slowing, the next lower gear will
be selected automatically. The LCD in the
instrument pack will always display the current gear.
Manual/sport mode is deselected by moving the
selector lever back to the 'D' (automatic) position.
Fast Adaptation Procedure
When a new gearbox is fitted, the ECM replaced or
ECM EEPROM re-initialised by TestBook, the ECM
needs to learn the positions of the ratio control motor
for given engine speeds.The ECM will target twelve
engine speeds between 1400 and 4500 rev/min in
order to achieve fast adaptation.
Fast adaptation is performed as follows:
WARNING: Ensure that aII road tests are
conducted by suitabIy quaIified drivers in
a safe and IegaI manner, and where IocaI
traffic conditions aIIow.
With the selector lever in position 'D', accelerate
the vehicle up to 35 mph (55 km/h), then release
the accelerator pedal and allow the vehicle to
decelerate without braking.
As the vehicle decelerates, the ECM will learn
the ratio control motor adaptation points. This
procedure should be complete before the vehicle
stops moving.
f the gearbox reaches its lowest ratio before the
adaptation is complete, the engine speed will
drop from the target speed to idle.
To complete the procedure, accelerate up to a
speed of more than 25 mph (40 km/h) and
release the accelerator pedal again. Allow the
vehicle to decelerate without braking to enable
the ECM software to learn the remaining
adaptation points.
Fast adaptation is complete when the 'F' in the
instrument pack LCD stops flashing and only the
mode is displayed.
The ECM software continuously adapts to account
for gearbox wear and fast adaptation errors. The
driver will not be aware that any adaptation is taking
place and normal driving will be maintained.
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FAULT DIAGNOSIS
Before commencing any gearbox fault diagnosis
check that:
The engine is correctly tuned
The gearbox fluid and fluid level is correct
The selector cable is correctly adjusted
All gearbox and GU connectors are correctly
assembled.
The following tables list possible faults and
corrective action required. f the fault remains after
the corrective action has been applied, then the
gearbox must be replaced.
The tables show tests which can be carried out to
determine the fault. The tests are detailed at the end
of this section.
FauIt: Engine wiII not start in 'P' or 'N'
FauIt Action Test
Selector cable out of adjustment Adjust selector cable See Adjustments.
Park/Neutral switch fault Check switch Test 2
Park/Neutral switch open circuit Check harness continuity
FauIt: Park Iock does not hoId vehicIe
FauIt Action Test
Gearbox internal damage Replace gearbox See Repairs.
FauIt: VehicIe moves when 'N' is seIected
FauIt Action Test
Forward or reverse clutch dragging Check condition of fluid Test 1
FauIt: Engine can be started in 'D' or 'R' positions
FauIt Action Test
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FauIt: Engine can be started in aII seIector positions
FauIt Action Test
Park/Neutral switch open circuit Check harness continuity
FauIt: No drive when 'D' or 'R' is seIected
FauIt Action Test
Gearbox fluid level incorrect Check and top up gearbox with correct fluid
See MAINTENANCE.
Gearbox internal damage Replace gearbox See Repairs.
FauIt: VehicIe moves above 6 mph (10 km/h) when 'D' or 'R' seIected
FauIt Action Test
Engine idle speed too high Check and correct engine idle speed See
INFORMATION, Engine tuning data.
FauIt: VehicIe judders when 'D' or 'R' is seIected with engine at idIe
FauIt Action Test
See MAINTENANCE.
Engine idle speed too high Check and correct engine idle speed See
Gearbox internal damage Check condition of fluid Test 1
FauIt: AcceIeration poor but engine racing when coId onIy
FauIt Action Test
See MAINTENANCE.
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FauIt: AcceIeration poor but engine racing when hot
FauIt Action Test
See MAINTENANCE.
FauIt: Engine staIIs during braking
FauIt Action Test
Engine idle speed too low Check and correct engine idle speed See
FauIt: Kick down deIayed or insufficient
NOTE: Verify this fauIt by performing Test 3.
FauIt Action Test
Gearbox nterface Unit (GU)
electrical failure
Check harness connections and GU remote
fuse. Check for fault codes using TestBook.
Ratio control motor failure Measure resistance at gearbox connector
pins. Measure between pins which
correspond to the harness connector
blue/yellow and blue/grey wires and the
blue/red and blue/white wires. The resistance
must be between 18 and 30 .
FauIt: DeIayed response when Sport seIected from 'D' whiIe vehicIe moving
FauIt Action Test
Electrical circuit failure Check circuit continuity
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FauIt: DeIayed response when ManuaI mode is seIected from 'D' Sport with vehicIe moving
FauIt Action Test
Electrical circuit failure Check circuit continuity
FauIt: VehicIe moves forward or backward when starting in 'P' or 'N'
FauIt Action Test
FauIt: HydrauIic cavitation noises from gearbox
FauIt Action Test
See MAINTENANCE.
Fluid filter clogged or dirty Replace Fluid filter See Repairs.
Air ingress via fluid filter connection Replace 'O' ring See Repairs.
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FauIt: FIuid Ieaks from gearbox
FauIt Action
Leak from fluid dipstick tube Replace dipstick 'O' ring
Leak from gearbox fluid pan gasket Ensure fluid pan bolts are correctly tightened
Replace fluid pan gasket
Leak from Park/Neutral switch Ensure switch is correctly tightened
Replace switch 'O' ring
Leak from gearbox drain plug Ensure plug is correctly tightened
Replace drain plug sealing ring
Leak from speed transducer Ensure transducer is correctly tightened
Replace transducer 'O' ring
Leak from gearbox differential speed sensor Ensure sensor is correctly tightened
Replace sensor 'O' ring
Leak from primary cover Ensure that cover is correctly tightened
Replace 'O' ring
Leak from secondary cover Ensure that cover is correctly tightened
Replace cover 'O' rings
Leak from selector shaft lever Replace selector shaft lever seal
Leak from fluid cooler pipe connections Ensure that pipes are correctly tightened
Replace pipe to gearbox connection 'O' rings
Leak from input shaft Replace input shaft seal
Leak from differential oil seal(s) Replace oil seals
Leak from fluid cooler pipe connections Ensure that pipes are correctly tightened
Replace pipe to fluid cooler connection 'O' rings
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TESTS
TEST 1: Fluid condition check
1. Drain and examine gearbox fluid. See
Adjustments.
2. f fluid contains metallic particles, replace
gearbox and flush fluid cooler and pipes.
3. f fluid is discoloured, burnt or contains water:
Fill gearbox with correct fluid to the correct
level.
Test drive vehicle for at least 10 miles
(16 km) using all selector positions.
f fault is still present, replace gearbox.
4. f drained fluid is in good condition, re-check
selector cable adjustment.
5. f adjustments are correct and the fault is still
present, replace the gearbox. See Repairs.
TEST 2: Park/Neutral switch check
1. With engine stopped, disconnect multiplug
from park/neutral switch.
2. Connect a circuit continuity tester between
switch pins 4 and 2.
3. Move gear selector lever through all positions
and observe continuity tester. Circuit continuity
should only exist with selector in positions 'P'
and 'N'.
4. Disconnect continuity tester and reconnect
between switch pins 3 and 1.
5. Move gear selector lever through all positions
and observe continuity tester. Circuit continuity
should only exist with selector in position 'R'.
6. f park/neutral switch does not function as
described in steps 3 and 5, replace switch. See
Repairs.
TEST 3: Kick-down check
A stop watch and the vehicle tachometer is required
for this test.
1. With the gear selector lever in position 'D',
accelerate the vehicle up to 50 mph (80 km/h).
2. When 50 mph (80 km/h) is reached, release
the accelerator pedal and, without using the
brakes, allow the vehicle to decelerate to
38 mph (61 km/h).
3. When the vehicle has reached
38 mph (61 km/h) apply full throttle to initiate
kick-down.
4. f engine speed is between 3800 and 4200
rev/min within 1 to 2 seconds of reaching
38 mph (61 km/h), kick-down operation is
satisfactory.
TEST 4: Delayed shift response
for this test.
1. With gear selector lever in position 'D', apply
full throttle until 50 mph (80 km/h) is reached.
2. At 50 mph (80 km/h) move the selector lever
across the gate to the Sport position; the
instrument pack LCD should display 'D
Sport
'.
3. When selector lever is moved to the Sport
position, the engine speed should increase to
5500 rev/min within 1 to 2 seconds. f this
response is achieved gearbox shift operation is
satisfactory.
TEST 5: Manual mode response
for this test.
1. With the selector lever in position 'D Sport',
drive the vehicle at a steady 50 mph (80 km/h).
2. Release the throttle pedal and move the
selector lever to the minus (-) position (manual
mode). The instrument pack should display the
gear ratio number and the engine speed
should rise within 1 to 2 seconds. f this
response is achieved, manual mode operation
is satisfactory.
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ADJUSTMENTS 1
DRAIN AND REFILL
NOTE: The fIuid shouId be drained with
the gearbox at normaI operating
temperature.
WARNING: Observe due care when
draining gearbox fIuid, as the fIuid wiII be
very hot.
1. Remove dipstick.
3. Position container to collect fluid from gearbox.
4. Remove drain plug using an 5 mm Allen key
and discard sealing washer.
5. Allow fluid to drain into container.
NOTE: ApproximateIy 1 Iitre of fIuid is
retained in the primary and secondary
cyIinders of the gearbox.
RefiII
1. Clean drain plug and sealing face of gearbox.
2. Fit new sealing washer to drain plug, fit drain
plug and tighten to 30 Nm.
4. Remove dipstick and, using a funnel on the
end of the dipstick tube, carefully fill gearbox to
the minimum mark with new CVT fluid. See
lubricants.
5. Replace dipstick.
6. Start engine and run until normal operating
temperature is achieved.
7. Operate gearbox through full range of selector
positions 3 times to ensure fluid is in all parts of
the system.
8. With the vehicle on horizontal ground, the
selector lever in the 'N' position and the engine
running at idle speed, check the oil level and
add oil until the level lies between the minimum
and maximum marks on the dipstick.
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REPAIRS 1
LEVER - GEAR CHANGE
Remove
3. Remove centre console. See BODY, Interior
trim components.
4. Remove 4 Torx bolts securing SRS DCU
support bracket and release earth lead.
Position support bracket aside.
5. Remove 3 bolts and 4 nuts securing gear lever
assembly.
6. Disconnect 3 multiplugs from gear lever
assembly.
7. Release gear lever from floor tunnel to access
gear change cable.
8. Remove clevis pin and 'C' washer securing
cable to gear lever and remove gear lever
assembly.
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2 REPAIRS
9. Remove 3 nuts and bolts securing gear lever to
support bracket and remove lever.
10. Remove 2 screws securing selector slide
mechanism and remove selector slide.
11. Remove microswitch harness clip from gear
lever housing.
12. Remove clip securing microswitch and collect
microswitch spacer.
13. Remove 2 bolts securing sequential gear
change microswitch and remove microswitch
assembly.
14. Remove 2 bolts securing park solenoid to gear
lever.
15. Release park solenoid from gear lever and
remove park solenoid.
Refit
1. Fit sequential gear change microswitch. Fit
2. Fit microswitch spacer, position microswitch
3. Secure microswitch harness clip.
4. Position park solenoid, fit bolts and tighten to
15 Nm.
5. Position selector slide and secure with screws.
6. Position lever to support bracket. Fit bolts and
tighten to 10 Nm.
7. Position lever assembly to cable and secure
with 'C' washer and clevis pin.
8. Position lever assembly to tunnel and connect
gear lever multiplugs.
9. Fit nuts and bolts securing lever assembly to
floor and tighten to 10 Nm.
10. Position SRS DCU and align earth lead. Fit
Torx bolts and tighten to 10 Nm.
11. Fit centre console. See BODY, Interior trim
components.
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REPAIRS 3
CABLE - GEAR CHANGE
Remove
6. Disconnect cable from ball joint on gear
change quadrant and release cable from
support bracket on gearbox.
7. Remove gear change lever. See this section.
8. Release clips securing coolant hoses and
heater hoses and disconnect hoses.
9. Tie coolant and heater hoses aside to access
closing plate.
sump.
11. Remove 2 bolts securing both front subframe
mountings to body brackets.
plate bolts.
CAUTION: Care must be taken when
Iowering front of subframe, that no cabIes
or pipes are stretched.
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4 REPAIRS
13. Release 2 lower and remove 4 remaining bolts
securing closing plate to bulkhead.
14. Apply soft soap to all closing plate cables, to
ease movement of closing plate.
along cables, release gear change cable from
grommet.
16. Remove gear change cable from tunnel and
engine compartment.
Refit
1. Position gear change cable to tunnel and feed
2. Feed gear change cable into position in engine
compartment.
3. Lubricate all cables with soft soap to ease
4. Position gear change cable into closing plate
slots and secure with grommets.
bolts.
6. Raise subframe on jack, fit subframe front
mounting bolts and tighten to 30 Nm.
7. Connect coolant and heater hoses and secure
with clips.
8. Fit gear change lever. See this section.
9. Connect cable to support bracket on gear box
and gear change quadrant.
10. Check cable adjustment. See Adjustments.
11. Refill engine coolant. See COOLING
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REPAIRS 5
LED MODULE - GEAR SELECTION
Remove
1. Remove gearchange selector knob.
2. Release gaiter from centre console.
3. Disconnect LED module multiplug and remove
gaiter.
4. Remove 2 screws securing LED module and
remove module.
Refit
1. Position LED module to gaiter and secure with
screws.
2. Position gaiter to centre console, connect
multiplug and secure gaiter to centre console.
3. Fit gear selection knob.
SWITCH - PRND
Remove
trim components.
2. Disconnect PRND switch multiplug.
3. Remove 2 screws securing PRND switch and
remove switch.
Refit
1. Position PRND switch, engage pin to gear
lever and secure switch with screws.
2. Connect PRND switch multiplug.
components.
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6 REPAIRS
PARK/NEUTRAL AND REVERSE LIGHT SWITCH
Remove
3. Position container to collect fluid loss from
gearbox.
5. Loosen and remove switch from gearbox.
6. Remove and discard 'O' ring from switch.
Refit
1. Clean switch and mating face of gearbox.
2. Lubricate new 'O' ring with gearbox fluid and fit
to switch.
3. Fit switch to gearbox and tighten to 12 Nm.
4. Connect multiplug to switch.
6. Top-up gearbox fluid level. See
MAINTENANCE.
SOLENOID - SHIFT LOCK
Remove
1. Remove gear lever assembly. See this
section.
2. Remove 2 Allen bolts securing shift lock
solenoid.
3. Release shift lock solenoid from gear lever
housing and remove solenoid.
Refit
1. Position shift lock solenoid and engage to gear
lever housing.
2. Fit Allen bolts securing shift lock solenoid and
tighten to 15 Nm.
3. Fit gear lever assembly. See this section.
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REPAIRS 7
DIFFERENTIAL SPEED SENSOR
Remove
3. Release gear selector cable from selector
linkage.
4. Release selector cable from abutment bracket
by pressing tab upwards as shown.
5. Loosen nut securing connecting rod to selector
bracket.
6. Remove 2 bolts securing abutment bracket to
gearbox, release connecting rod from selector
bracket and remove abutment bracket.
7. Disconnect multiplug from speed sensor.
8. Remove bolt securing sensor to gearbox.
9. Remove sensor and discard 'O' ring.
Refit
1. Clean sealing faces of sensor and gearbox.
to sensor.
3. Fit sensor to gearbox and tighten bolt to 9 Nm.
4. Connect multiplug to harness.
5. Fit abutment bracket to gearbox ensuring
connecting rod is located into selector bracket.
Tighten bolts to 25 Nm.
6. Tighten nut securing connecting rod to selector
bracket to 6 Nm.
CAUTION: Do not exceed the specified
torque.
7. Connect gear selector cable to selector
linkage.
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8 REPAIRS
SWITCH - STEERING WHEEL REMOTE
Remove
2. Release horn switch from steering wheel and
position aside.
3. Release clip securing remote switch and
release switch from steering wheel.
4. Disconnect remote switch multiplug and
remove switch from steering wheel.
Refit
1. Position remote switch, connect multiplug and
secure switch to steering wheel.
2. Position horn switch and secure in steering
wheel.
MICROSWITCH - MANUAL/SPORT AND +/-
SWITCH
Remove
1. Remove gear lever assembly. See this
section.
2. Release clip securing harness to gear lever
housing.
3. Remove clip securing manual/sport
microswitch and collect microswitch spacer.
4. Remove 2 Allen bolts securing +/- switch to
gear lever housing and remove switch
assembly.
Refit
1. Position +/- switch to gear lever housing. Fit
Allen bolts and tighten to 12 Nm.
2. Fit microswitch spacer, position manual/sport
microswitch and secure with clip.
3. Secure harness clip to gear lever housing.
4. Fit gear lever assembly. See this section.
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REPAIRS 9
GEARBOX INTERFACE UNIT (GIU)
Remove
2. Release boot lid aperture seal from LH side of
aperture flange.
3. Remove clip securing LH side of luggage
compartment trim and release trim for access
to GU.
4. Remove 2 nuts securing GU to body.
5. Release GU, disconnect multiplug and remove
GU.
Refit
1. Position new GU and connect multiplug.
2. Fit GU to body and secure with nuts.
3. Refit trim and secure with clip.
4. Fit boot lid aperture seal to flange.
GEARBOX & CONVERTER - STEPSPEED
(Em-CVT) - REMOVE FOR ACCESS & REFIT
Remove
ENGINE, Repairs.
2. Disconnect Lucar from starter solenoid.
Disconnect multiplug from actuator control
motor and release lead from clip.
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10 REPAIRS
3. Remove 3 bolts securing exhaust heat shield
4. Remove bolt securing flywheel cover to
gearbox and remove cover.
5. Remove 2 bolts securing starter motor to
gearbox and remove starter motor.
6. Remove 2 bolts securing flywheel rear cover to
gearbox and remove cover.
7. Disconnect multiplugs from speed sensor and
speedometer transducer.
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REPAIRS 11
8. Remove 4 bolts securing gearbox to engine.
Collect mounting plate.
9. With assistance remove gearbox from engine.
Refit
1. Clean mating faces of engine and gearbox,
dowel and dowel holes.
2. With assistance, fit gearbox, locate on dowels
and secure to engine.
3. Position mounting plate, fit bolts securing
gearbox to engine and tighten to 80 Nm.
4. Connect speed sensor and speedometer
transducer multiplugs.
5. Fit flywheel rear cover and secure with bolts.
6. Position starter motor to gearbox, fit and
7. Fit flywheel front cover to gearbox and secure
with bolts.
8. Position exhaust heat shield and secure with
bolts.
9. Connect multiplug to actuator control motor
and secure lead to clip.
ENGINE, Repairs.
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12 REPAIRS
SECONDARY COVER SEALS
Remove
1. Remove LH engine mounting. See ENGINE,
Repairs.
2. Remove 4 bolts securing LH buttress and
manoeuvre buttress to access secondary
cover.
3. Remove 4 bolts securing secondary cover to
gearbox.
4. Remove secondary cover.
5. Remove and discard 2 'O' rings from cover.
6. Remove and discard split ring.
Refit
1. Clean secondary cover and mating faces of
cover and gearbox.
2. Lubricate new 'O' rings with clean gearbox fluid
and fit to secondary cover.
3. Fit new split ring to secondary cover.
4. Fit and align secondary cover to gearbox.
5. Fit bolts securing secondary cover to gearbox
6. Align LH buttress to subframe, fit bolts and
tighten to 45 Nm.
7. Fit LH engine mounting. See ENGINE,
Repairs.
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REPAIRS 13
GASKET - FLUID PAN
Remove
2. Drain gearbox fluid. See Adjustments.
3. Working in the sequence illustrated, loosen
then remove 13 bolts securing fluid pan to
gearbox.
4. Release fluid pan from gearbox and filter,
remove fluid pan.
5. Remove and discard gasket.
Refit
1. Clean mating faces of fluid pan and gearbox.
Clean fluid pan.
2. Lubricate new gasket with gearbox fluid and fit
to fluid pan.
CAUTION: Do not appIy adhesive to
gasket.
3. Position fluid pan to filter and gearbox.
4. Fit bolts securing fluid pan to gearbox and
working in the sequence illustrated, tighten to
10 Nm.
5. Refill gearbox with fluid. See Adjustments.
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14 REPAIRS
FILTER - GEARBOX FLUID
Remove
1. Remove fluid pan. See this section.
2. Release filter from valve block and remove
filter.
3. Remove filter magnet.
Refit
1. Clean magnet and fit to filter.
2. Lubricate new 'O' ring with clean gearbox fluid
and fit to filter.
3. Position filter to valve block and engage 'O'
ring in valve block.
4. Fit fluid pan. See this section.
COOLER - GEARBOX FLUID
Remove
Exterior fittings.
2. Position container underneath gearbox fluid
cooler connections to collect any spillage.
3. Remove 2 bolts securing fluid cooler pipe
connections to fluid cooler.
4. Release connections from fluid cooler and
discard 'O' rings.
CAUTION: PIug the connections.
5. Remove 2 bolts securing fluid cooler to body
and remove cooler.
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REPAIRS 15
Refit
1. Clean fluid cooler and pipe connections.
2. Fit fluid cooler and secure with bolts.
3. Using new 'O' rings connect pipes to fluid
cooler and tighten bolts to 14 Nm.
Exterior fittings.
MAINTENANCE.
HOSE/PIPE - FEED - INTERMEDIATE TO FLUID
COOLER
Remove
Exterior fittings.
cooler connections to collect any spillage.
4. Remove bolt securing fluid cooler pipe
connection to fluid cooler.
5. Release connection from fluid cooler and
discard 'O' ring.
6. Remove release catch, refit in reverse position
and release hose from intermediate pipe.
7. Remove pipe clamp clip, release pipe from
clamp and remove pipe.
8. Refit release catch in safe position.
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16 REPAIRS
Refit
1. Clean pipe end and mating faces.
2. Connect hose to intermediate pipe.
3. Using new 'O' ring, align pipe to fluid cooler, fit
4. Position pipe in clamp and secure clamp clip.
Exterior fittings.
MAINTENANCE.
HOSE/PIPE - RETURN - INTERMEDIATE TO
FLUID COOLER
Remove
Exterior fittings.
cooler connection to collect any spillage.
4. Remove bolt securing fluid cooler pipe
connections to fluid cooler.
5. Release connection from fluid cooler and
discard 'O' ring.
6. Remove release catch, refit in reverse position
and release hose from intermediate pipe.
7. Remove pipe clamp clip, release pipe from
clamp and remove pipe.
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REPAIRS 17
Refit
2. Connect hose to intermediate pipe.
3. Using new 'O' ring, align pipe to fluid cooler. Fit
4. Position pipe in clamp and secure clamp clip.
Exterior fittings.
MAINTENANCE.
HOSE/PIPE - INTERMEDIATE - FEED
Remove
1. Remove front underbelly panel. See BODY,
Exterior fittings.
2. Release pipe from 5 clips.
4. Remove pipe release catches and refit in
reverse position.
5. Release hoses from intermediate pipe and
remove intermediate pipe.
6. Refit release catches in safe position.
Refit
2. Position intermediate pipe and connect to
hoses.
3. Secure intermediate pipe with new cable ties.
4. Fit front underbelly panel. See BODY,
Exterior fittings.
MAINTENANCE.
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18 REPAIRS
HOSE/PIPE - INTERMEDIATE - RETURN
Remove
1. Remove front underbelly panel. See BODY,
Exterior fittings.
2. Release pipe from 5 clips.
4. Remove pipe release catches and refit in
reverse position.
5. Release hoses from intermediate pipe and
remove intermediate pipe.
6. Refit release catches in safe position.
Refit
2. Position intermediate pipe and connect to
hoses.
3. Secure intermediate pipe in clips.
4. Fit front underbelly panel. See BODY,
Exterior fittings.
MAINTENANCE.
HOSE/PIPE - FEED - INTERMEDIATE TO
GEARBOX
Remove
3. Remove bolt securing pipe clamp and remove
pipe clamp.
4. Loosen union on gearbox and release pipe
from gearbox, remove and discard 'O' ring.
5. Remove release catch and refit in reverse
position. Release pipe from intermediate pipe
and remove pipe.
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REPAIRS 19
Refit
2. Connect pipe to intermediate pipe.
3. Using a new 'O' ring, position pipe to gearbox
and tighten union to 14 Nm .
4. Position pipe clamp, fit and tighten clamp bolt
to 10 Nm.
MAINTENANCE.
HOSE/PIPE - RETURN - INTERMEDIATE TO
GEARBOX
Remove
3. Remove bolt securing pipe clamp and remove
pipe clamp.
4. Loosen union on gearbox and release pipe
from gearbox. Remove and discard 'O' ring.
5. Remove release catch and refit in reverse
position. Release pipe from intermediate pipe
and remove pipe.
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20 REPAIRS
Refit
2. Connect pipe to intermediate pipe.
3. Using a new 'O' ring, position pipe to gearbox
and tighten union to 14 Nm .
4. Position pipe clamp, fit and tighten clamp bolt
to 10 Nm.
MAINTENANCE.
PRIMARY BEARING
Remove
3. Remove air cleaner. See ENGINE
4. Release 2 hand brake cables and gear selector
cable from clips on air cleaner mounting
bracket.
5. Remove 2 nuts securing fuel filter to air cleaner
mounting bracket and release filter from
bracket.
6. Remove 3 bolts securing air cleaner mounting
bracket to body and remove bracket.
7. Remove gearbox primary cover seal. See this
section.
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REPAIRS 21
8. Remove 5 remaining bolts securing fluid pump.
9. With care, position 2 levers 180` apart and
remove fluid pump.
NOTE: To prevent damage to primary
housing, pIace 2 pieces of wood between
Ievers and primary housing when
removing oiI pump.
10. Remove and discard 2 'O' rings from oil pump.
11. Remove and discard belleville washer.
12. Using an air impact wrench with a torque
capacity of 300 Nm, remove primary bearing
nut.
NOTE: InitiaIIy start to undo nut with the
impact wrench in the minimum position.
Increase torque untiI nut is reIeased.
13. Using a small screwdriver, lever out seal from
primary bearing.
14. Position thrust button 44-022 into primary
shaft.
15. Assemble tool 44-023 underneath the exterior
ring of primary bearing.
16. Tighten centre bolt of tool 44-023 and remove
primary bearing.
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22 REPAIRS
Refit
1. Clean primary bearing bore and shaft.
2. Clean sealant from threads in fluid pump drive
shaft and clean fluid pump housing.
3. Position primary bearing with numbers on
bearing facing outwards.
4. Drift in primary bearing using tool 44-021.
5. Fit and tighten nut using an air impact wrench
for sufficient duration until a minimum torque of
180 Nm is achieved.
6. Fit new belleville washer.
7. Lubricate and fit new 'O' rings to fluid pump.
8. Position fluid pump into gearbox, aligning
feeder and pitot tube channels.
9. Fit 5 bolts and tighten in a diagonal sequence
to 10 Nm.
10. Fit gearbox primary cover seal. See this
section.
11. Fit air cleaner mounting bracket to body, fit and
tighten 3 bolts.
12. Fit fuel filter to air cleaner mounting bracket
and secure with nuts.
13. Secure hand brake cables and gear selector
cable to clips.
14. Fit air cleaner. See ENGINE MANAGEMENT
diagonal sequence to 70 Nm. See
INFORMATION, Torque wrench settings.
16. Lower vehicle.
17. Top-up gearbox fluid. See MAINTENANCE.
ROAD SPEED TRANSDUCER
Remove
3. Disconnect multiplug from transducer.
4. Remove bolt securing transducer to gearbox.
5. Remove transducer and discard 'O' ring.
Refit
1. Clean sealing faces of transducer and gearbox.
to transducer.
3. Fit transducer to gearbox and tighten to 9 Nm.
4. Connect multiplug to transducer.
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DRIVE SHAFTS
CONTENTS Page
DRVE SHAFT COMPONENTS 1 ...............................................................................
OPERATON 2 .............................................................................................................
REPAIRS
SHAFT WTH BOTH JONTS 1 ...................................................................................
DRVE SHAFT OUTER GATER 3 ..............................................................................
DRVE SHAFT OUTER JONT 4 .................................................................................
DRVE SHAFT NNER GATER 5 ................................................................................
DYNAMC DAMPER - DRVE SHAFT - RH 5 ..............................................................
OL SEAL - DFFERENTAL HOUSNG - LH - MANUAL TRANSMSSON
MODELS 6 ...................................................................................................................
OL SEAL - DFFERENTAL HOUSNG - LH - STEPSPEED (Em-CVT)
GEARBOX MODELS 7 ................................................................................................
OL SEAL - DFFERENTAL HOUSNG - RH - MANUAL TRANSMSSON
MODELS 7 ...................................................................................................................
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DRIVE SHAFTS
DRIVE SHAFT COMPONENTS
1. Circlip
2. nner joint and shaft
3. Large clip - inner joint gaiter
4. Gaiter
5. Small clip - inner joint gaiter
6. Damper clip - RH shaft only
7. Dynamic damper - RH shaft only
8. Small clip - outer joint gaiter
9. Gaiter
10. Large clip - outer joint gaiter
11. Stopper ring
12. Circlip
13. Outer joint
14. Drive shaft nut
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DRIVE SHAFTS
OPERATION
1. Drive shaft
2. Dynamic damper
3. nner joint
4. Outer joint
Drive from the power unit is transmitted to the rear
wheels by the drive shafts. Due to the RH drive shaft
being longer than the LH drive shaft, a dynamic
damper is fitted to reduce harmonic vibration.
The inner joint is of the tripode type with spherical
bushing to reduce sliding resistance; it cannot be
serviced separate from the shaft. The outer joint is of
the ball and socket type. The joints are sealed and
pre-packed with grease.
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DRIVE SHAFTS
REPAIRS 1
SHAFT WITH BOTH JOINTS
Remove
3. Knock back drive shaft nut stake.
4. With assistance, depress brake pedal, remove
and discard drive shaft nut.
5. Remove brake disc. See BRAKES, Repairs.
6. Remove 2 bolts securing trailing arm to rear
hub.
7. Remove bolt securing ABS sensor to hub,
release sensor and position aside.
8. Remove nut securing track control arm to rear
hub.
9. Using tool 18G-1584, release track control
arm ball joint from rear hub.
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DRIVE SHAFTS
2 REPAIRS
11. Remove lock nut from upper arm ball joint and
discard lock nut.
upper suspension arm. Remove18G-1584 and
slave nut.
13. Remove rear hub assembly from drive shaft.
14. Using 18G 1761, release drive shaft inboard
joint from differential and remove drive shaft
assembly.
Refit
1. Clean drive shaft ends and locations in front
hub and differential.
joint.
3. Fully insert oil seal protector tool Unipart TRV
100060, into differential oil seal so that oil seal
lip is protected and that the split end of tool is
butted correctly.
4. Keeping the drive shaft horizontal, insert drive
shaft through seal protector until drive shaft
engages with the differential splines.
5. Pull drive shaft outwards to ensure full
engagement.
6. Clean drive shaft end and hub mating faces.
7. Fit hub to drive shaft.
8. Clean upper arm ball joint and mating face.
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DRIVE SHAFTS
REPAIRS 3
9. Engage ball joint pin to upper arm.
10. Fit new lock nut and tighten to 54 Nm.
11. Align lower link to rear hub, fit bolt but do not
12. Clean track control arm ball joint and mating
face.
13. Engage track control arm ball joint to hub, fit
nut and tighten to 38 Nm.
14. Clean and thoroughly dry bolts securing trailing
arm to rear hub.
15. Apply Loctite 242 to the first 3 threads of bolts
securing trailing arm to rear hub.
16. Fit bolts securing trailing arm to rear hub, do
not tighten at this stage.
17. Position ABS sensor lead to hub, fit new bolt
18. Fit rear brake disc. See BRAKES, Repairs.
19. With assistance tighten new drive shaft nut to
210 Nm.
20. Stake drive shaft nut to shaft.
suspension, tighten bolt securing lower link to
rear hub to 100 Nm.
22. Tighten trailing arm to hub bolts to 60 Nm.
DRIVE SHAFT OUTER GAITER
Remove
1. Remove drive shaft outer joint. See this
section.
2. Slide gaiter from shaft.
3. nspect gaiter for signs of damage and renew if
necessary.
Refit
1. Fit gaiter to shaft.
2. Fit drive shaft outer joint. See this section.
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DRIVE SHAFTS
4 REPAIRS
DRIVE SHAFT OUTER JOINT
Remove
1. Remove drive shaft. See this section.
2. Place drive shaft in a vice.
3. Release both gaiter clips and discard.
4. Slide gaiter along shaft to gain access to outer
joint.
5. Bend the joint, and using a suitable drift
against the inner part of the joint, remove from
shaft.
6. Remove circlip from shaft and discard.
Refit
1. Fit new circlip to shaft.
2. Position outer joint to shaft, use a screwdriver
to press circlip into its groove and push joint
fully onto shaft.
3. Smear grease around joint.
4. Position gaiter to joint and use a band-it
thriftool to secure the 2 new clips.
5. Fit drive shaft. See this section.
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DRIVE SHAFTS
REPAIRS 5
DRIVE SHAFT INNER GAITER
Remove
1. Remove drive shaft outer joint. See this
section.
2. Slide outer gaiter off shaft.
3. Release both inner gaiter clips and discard.
4. Slide inner gaiter off shaft.
5. nspect gaiter for signs of damage and renew if
necessary.
6. Clean shaft and joint.
Refit
1. Smear grease around joint.
2. Position gaiter to inner joint and use a band-it
thriftool to secure 2 new clips.
3. Fit outer gaiter to shaft.
4. Fit outer joint. See this section.
DYNAMIC DAMPER - DRIVE SHAFT - RH
Remove
1. Remove drive shaft outer gaiter. See this
section.
2. Clean shaft with emery cloth to remove rust.
3. Lubricate shaft with liquid soap to aid damper
removal.
4. Slide damper from shaft.
Refit
1. Measure along shaft for fitted position of
damper.
2. Mark shaft for fitting position.
Dimension 'A' = 398.5 mm. 3 mm.
3. Lubricate shaft for fitting of damper.
4. Position damper to mark.
5. Clean lubricant from shaft.
6. Fit drive shaft outer gaiter. See this section.
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DRIVE SHAFTS
6 REPAIRS
OIL SEAL - DIFFERENTIAL HOUSING - LH -
MANUAL TRANSMISSION MODELS
Remove
1. Remove LH drive shaft. See this section.
2. Carefully remove oil seal from differential
housing, discard oil seal.
Refit
1. Thoroughly clean oil seal recess in differential
housing, splines and oil seal running surface
on drive shaft.
2. Locate new oil seal on 18G-1354/21 with
sealing lip facing towards differential housing.
3. Carefully drift oil seal into differential housing
until it is fully seated in recess.
4. Remove 18G-1354/21 .
5. Fully insert oil seal protector tool Unipart TRV
100060 into differential oil seal to protect oil
seal lip. Ensure that the split end of tool is
butted correctly.
6. Fit LH drive shaft. See this section.
7. Check, and if necessary, top-up gearbox oil.
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DRIVE SHAFTS
REPAIRS 7
OIL SEAL - DIFFERENTIAL HOUSING - LH -
STEPSPEED (Em-CVT) GEARBOX MODELS
Remove
1. Remove LH drive shaft. See this section.
Refit
on drive shaft.
2. Fit 18G-134-15 on to 18G-134, position new oil
seal onto 18G-134-15 with the sealing lip
facing towards differential housing.
4. Remove 18G-134-15 and 18G-134.
5. Fit LH drive shaft. See this section.
6. Check, and if necessary, top-up gearbox fluid.
OIL SEAL - DIFFERENTIAL HOUSING - RH -
MANUAL TRANSMISSION MODELS
Remove
1. Remove RH drive shaft. See this section.
Refit
on drive shaft.
2. Fit 18G-1354/16 onto 18G-1354.
3. Position new oil seal onto 18G-1354/16 with
the sealing lip facing towards the differential.
5. Remove 18G-1354/16 and 18G-1354.
6. Fully insert oil seal protector tool Unipart
TRV100060 into differential oil seal to protect
oil seal lip. Ensure that the split end of tool is
butted correctly.
7. Fit RH drive shaft. See this section.
8. Check, and if necessary, top-up gearbox oil.
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STEERING
CONTENTS Page
EPAS SYSTEM COMPONENT LOCATON 1 .............................................................
STEERNG WHEEL 2 ..................................................................................................
STEERNG RACK 3 .....................................................................................................
STEERNG COLUMN (with Electrical PAS) 4 ..............................................................
EPAS SYSTEM CONTROL DAGRAM 5 ....................................................................
DESCRPTON 6 .........................................................................................................
OPERATON 10 ...........................................................................................................
ADJUSTMENTS
FRONT WHEEL ALGNMENT 1 ..................................................................................
REAR WHEEL ALGNMENT 2 ....................................................................................
REPAIRS
RACK & PNON ASSEMBLY 1 ...................................................................................
STEERNG RACK GATER 3 ......................................................................................
STEERNG COLUMN 4 ...............................................................................................
STEERNG COLUMN NACELLE 7 ..............................................................................
GNTON SWTCH AND STEERNG LOCK 7 ............................................................
STEERNG COLUMN 8 ...............................................................................................
EPAS ECU 11 ..............................................................................................................
TRACK-ROD END 12 ..................................................................................................
STEERNG WHEEL 13 ................................................................................................
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STEERING
EPAS SYSTEM COMPONENT LOCATION
(RHD shown, LHD similar)
1. Steering rack
2. EPAS motor
3. Steering column
4. Steering wheel
6. EPAS ECU
7. EPAS System remote fuse (40A)
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STEERING
STEERING WHEEL
1. Steering wheel
2. Driver's airbag module
3. Torx bolt, 2 off
4. Rotary coupler
5. Cancel cam - indicator switch
6. Lighting, indicator and wiper switch assembly
7. Steering lock assembly
8. Bracket - steering lock
9. Shear bolt - steering lock, 2 off
10. Nacelle upper
11. Nacelle lower
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STEERING
STEERING RACK
1. Steering rack
2. Track-rod end
3. Locknut - track-rod end
4. Self locking nut - track-rod end to steering arm
5. Gaiter - steering rack
6. Clip inner
7. Clip outer
8. Clamp - steering rack
9. Spacer - steering rack
10. Bolt - steering rack to subframe
11. 'U' bolt - steering rack to subframe
12. Nut - steering rack to subframe
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STEERING
STEERING COLUMN (with EIectricaI PAS) WARNING: The steering coIumn is not
serviceabIe. A damaged coIumn must be
renewed otherwise crash performance
may be affected.
1. Bolt - intermediate shaft, 2 off
2. ntermediate shaft
3. Steering shaft
4. EPAS steering motor
5. Torque sensor
6. Bolt - bracket to body, 2 off
7. Bracket - steering column to body
8. Bolt - bracket to steering column, 4 off
9. Steering column
10. Column tilt adjustment lever
11. Bolt - steering column to body
12. Nut - pinion cover, 3 off
13. Stud - pinion cover, 3 off
14. Pinion cover seal
15. Pinion cover
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STEERING
EPAS SYSTEM CONTROL DIAGRAM
A= Hardwired; J= Diagnostic SO 9141 K Line
1. EPAS fuse 40A
2. Steering motor and clutch
3. Torque sensor
4. nstrument pack
8. EPAS ECU
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STEERING
DESCRIPTION
Steering coIumn
The steering column is secured to the body by two
brackets. The column consists of two sections that
telescopically collapse in the event of a frontal
impact. The steering shaft also consists of two
telescopic collapsible sections secured by two shear
pins. The steering shaft rotates in the steering
column via a ball-bearing at its upper end and two
ball bearings at its base.
When the steering wheel is rotated, the turning effort
of the shaft is transmitted to the pinion shaft of the
the steering rack via the intermediate shaft. The
intermediate shaft comprises two universal joints
which counter the varying angle between steering
shaft and rack; and a telescopic internal shaft which
acts as a damper. This construction limits intrusion
of the column in the event of a crash and also
prevents suspension movement and vibration being
transmitted through the steering column.
The steering column has a torque sensor, an electric
motor and gearbox positioned at the lower part of
the column which are integral components of the
Electrical Power Assisted Steering (EPAS) system.
No parts of the steering column are serviceable and
failure of any electrical or mechanical component will
require column replacement.
EPAS System
The EPAS system is based on a conventional rack
and pinion steering system, and also includes
updated EPAS ECU software to improve steering
response and characteristics and a column tilt
adjustment feature.
EPAS provides variable power assistance
depending on vehicle speed and driver's steering
effort. Power assistance will be most evident to the
driver when maneuvering the vehicle at low speeds,
this assistance reduces progressively as vehicle
speed increases.
Steering motor
Steering assistance is provided by a motor mounted
on the steering column. The motor is attached to a
cast housing which forms part of the column and is
secured with two Torx screws. A single connector
connects the motor to the main harness.
The motor drives a wormwheel attached to the
steering shaft to provide the power steering
assistance. The level of assistance provided by the
motor varies according to torque sensor output and
road speed.
The EPAS ECU calculates the required torque using
inputs from the torque sensor and road speed
transducer, and supplies a current to the motor of
the appropriate amperage to provide the necessary
steering assistance.
An electrically operated clutch connects the motor
drive to the column when assistance is required. f a
system failure occurs, the EPAS ECU will not
engage the clutch, disconnecting motor assistance
to the column.
Torque sensor
Driver steering effort is measured by a torque sensor
mounted on the steering column. This information is
sent to the EPAS ECU, which also monitors engine
and vehicle speed.
The torque sensor comprises a rotary potentiometer
with two tracks. The potentiometer is connected, via
a pin and bearing, to a track on a slider. The slider
moves axially depending on steering torque input
from the steering wheel. This axial movement is
converted, via the track, into rotary movement of the
potentiometer in proportion to the torque input. The
potentiometer passes information to the EPAS ECU
for torque input and direction.
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STEERING
The EPAS ECU uses this information to calculate
the ideal level of power assistance required for the
driving conditions and applies a current of the
applicable amperage to the electric motor mounted
on the steering column. The electric motor applies
the required torque to the steering shaft via a worm
gear.
EPAS ECU
The EPAS ECU is located above the glove box,
behind the fascia. The ECU is rubber mounted to a
bracket on the front bulkhead and is secured by a
bracket with two bolts to the body cross tube.
The EPAS system incorporates fail-safe devices
which cause it to revert to conventional manual
steering in the event of a system failure. The EPAS
ECU integral fault monitor sends a signal to the
electromagnetic clutch which disconnects the motor
mechanical drive to the column. Fault codes are
stored in the EPAS ECU memory, for identification
by TestBook.
f a fault occurs, the EPAS ECU illuminates the
EPAS warning lamp in the instrument pack. f, when
the ignition is switched off and back on again, the
fault is no longer present, the ECU will not illuminate
the fault lamp after the engine is started. The ECU
stores a fault code for the fault. f the fault does not
re-occur in the next twenty ignition cycles, the ECU
will erase the fault code.
Field Effect Transistors (FET's) in the ECU protect
the system from overload. f excessive use or
component failure causes the motor to overheat, the
FETS will become hot. As the temperature
increases, the FET's and the EPAS ECU gradually
decrease the level of steering assistance provided.
As the system cools the level of steering assistance
is progressively reinstated.
Permanent battery voltage is supplied to the EPAS
ECU via a dedicated EPAS 40A fuse which is
located remotely adjacent to the underbonnet
fusebox.
Two multiplugs provide input and output connections
to and from the ECU. The following tables show the
harness connector pin numbers and input/output
information.
Instrument pack
The EPAS ECU informs the driver of any
malfunctions via a warning lamp on the instrument
pack. The warning lamp receives a 12V supply from
fuse 1 in the passenger compartment fusebox when
the ignition is in position . The EPAS ECU connects
the warning lamp to earth when fault warning lamp
illumination is required.
1. EPAS warning lamp
Diagnostics
information between the EPAS ECU and TestBook.
The diagnostic socket is located in the passenger
compartment fusebox which is below the fascia on
the driver's side.
The EPAS ECU monitors inputs and outputs relating
to the EPAS system. f a fault is detected, a code
applicable to that fault is stored in a fault log in the
ECU.
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STEERING
EPAS ECU connector C0316 pin detaiIs
1 Clutch earth nput
2 EPAS instrument pack warning lamp Output
3 Not used -
4 Torque sensor earth nput
5 Torque sensor nput
6 Torque sensor 5V supply Output
7 Road speed signal nput
8 gnition ON signal nput
9 Clutch 12V supply Output
10 Not used -
11 Not used -
12 Not used (connected in parralel with pin 4) -
13 Torque sensor nput
14 Not used (connected in parallel with pin 6) -
15 Engine speed nput
16 Diagnostic socket nput/Output
CAUTION: The torque sensor potentiometers are connected in series, therefore, pins 12 and 14 are
not used. Wires are stiII present in harness connector but are unterminated in the torque sensor. DO
NOT short circuit either of these pins.
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STEERING
EPAS ECU connector C0317 pin detaiIs
1 Battery +12V permanent supply nput
2 Motor +ve PWM signal (right turn) nput
3 Earth nput
4 Motor -ve PWM signal (left turn) nput
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STEERING
OPERATION
1. Spring
2. Worm gear
3. Worm wheel
4. Output shaft
5. Ball bearing
6. Pin
7. Lever pin
8. Rotary potentiometer
9. Slider/ball bearing (inset)
10. Ball
11. Slider
12. Torsion bar
13. nput shaft
EPAS MechanicaI operation
The motor, clutch and motor worm gear are
mounted on the cast gear housing on the column.
The worm wheel is attached to the output shaft. The
input shaft and the output shaft are joined by a
torsion bar.
When the steering wheel is rotated, torque is applied
to the torsion bar which twists causing an angular
deflection between the input and output shafts.
The deflection causes the slider to rotate via the
balls in the ball groove which causes linear
movement of the slider along the axis of the output
shaft.
The rotary potentiometer in the torque sensor has a
pin, which is fitted with a ball bearing. The bearing
locates in a groove in the slider. The linear
movement of the slider is converted back to
rotational movement of the potentiometer, via the
bearing and pin. The torque sensor converts the
torque applied into an electrical signal which is
proportional to the steering torque.
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STEERING
EPAS electrical operation
EPAS ECU
1. Torque sensor
2. Main Potentiometer
3. Sub Potentiometer
4. Speed sensor
5. Engine revolution sensor
6. gnition switch supply
7. Battery supply
8. Earth
9. nterface
10. Main control computer
11. Fail safe relay
12. Motor drive circuit
13. Current control circuit
14. Clutch drive circuit
15. Motor
16. Clutch
17. Warning lamp
The torque sensor has two potentiometers. The
potentiometers share a power supply and earth
connection from the ECU and operate in the same
direction. One potentiometer provides the torque
data and the other potentiometer acts as a fault
monitor. The ECU checks the output from each
potentiometer and will illuminate the EPAS warning
lamp and suspend power assistance whilst the fault
is present.
When the ignition is switched on, the EPAS ECU
performs a start-up (diagnostic) check procedure.
The ECU illuminates the EPAS fault warning lamp in
the instrument pack. The lamp will remain
illuminated until the engine is started and the ECU
receives an engine running signal from the
crankshaft position (CKP) sensor.
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STEERING
The inputs from the torque sensor, CKP sensor
(engine running signal) and road speed transducer
are passed to the ECU and, via the interface, to the
main control computer.
The computer processes the data and calculates the
required steering assistance and outputs the
required current to the motor. The motor then
operates to apply torque via the worm gear in the
required direction to the worm wheel.
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STEERING
ADJUSTMENTS 1
FRONT WHEEL ALIGNMENT
Check
1. Ensure tyre pressures are correct.
2. Ensure that equipment is properly calibrated.
NOTE: OnIy use equipment recommended
in the STEP (Service TooIs and Equipment
Programme) ManuaI.
3. Check front wheel alignment is within
tolerance.
NOTE: The foIIowing steering geometry
settings are given in A - degrees and
minutes, B - decimaI parts of a degree and
C - miIIimetres. Steering and Suspension
geometry settings are for a vehicIe at unIaden
weight.
DATA
Front wheel alignment - toe-out - per side:
A - 0 0' 0 6'
B - 0 0.1
C - 0 mm 0.665 mm (15" wheels)
- 0 mm 0.709 mm (16" wheels).
Adjust
1. Mark track-rods for reference.
2. Loosen track-rod lock nut.
3. Release clip securing gaiter.
4. Adjust track-rod to obtain correct alignment.
CAUTION: Both track-rods must be
rotated an equaI amount.
5. Tighten track-rod lock nut to 50 Nm and secure
gaiter clip.
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STEERING
2 ADJUSTMENTS
REAR WHEEL ALIGNMENT
Check
1. Ensure tyre pressures are correct.
2. Ensure that equipment is properly calibrated.
NOTE: When adjusting rear wheeI
aIignment 4 turntabIes must be used, one
for each wheeI. OnIy use equipment
recommended in the STEP (Service TooIs and
Equipment Programme) ManuaI.
3. Ensure front wheel alignment is correct. See
this section.
4. Check rear wheel alignment is within tolerance.
NOTE: The foIIowing settings are given in
A - degrees and minutes, B - decimaI parts
of a degree and C - miIIimetres. Settings
are for a vehicIe at unIaden weight.
DATA
Rear wheel alignment = toe-in - per side:
A - 0 15' 0 6'
B - 0.25 0.1
C - 1.662 mm 0.67 mm (15 " wheels)
- 1.772 mm 0.71 mm (16" wheels)
Adjust
1. Loosen 2 lock nuts securing track control arm
adjuster.
2. Turn adjuster to obtain correct alignment.
3. Tighten lock nuts.
4. Settle suspension.
5. Recheck alignment, when correct tighten lock
nuts to 50 Nm.
6. Repeat check and adjust operation on other
side of vehicle.
CAUTION: After adjusting the rear wheeI
aIignment, ensure that the track controI
arm has rotationaI movement. This can be
checked by grasping the track controI arm and
rotating it backwards and forwards on the baII
joints.
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STEERING
REPAIRS 1
RACK & PINION ASSEMBLY
Remove
1. Remove bolt securing steering column
universal joint to rack pinion.
2. Release steering column universal joint from
rack pinion.
3. Remove 3 nuts securing steering rack pinion
cover to body.
4. Raise front of vehicle and support on stand(s).
6. Release pinion cover from steering rack pinion
housing and retaining studs.
7. Remove nuts securing RH and LH track rod
end ball joints.
8. Using 18G 1584, break taper joints and release
ball joints.
9. Remove bolt securing cross brace to centre
mounting.
10. Support rear of front subframe on a jack.
11. Remove 8 bolts securing cross brace and front
subframe rear mountings to body.
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STEERING
2 REPAIRS
12. Lower subframe on jack sufficiently to remove
steering rack.
13. Remove nuts securing steering rack 'U' bolt to
subframe and remove 'U' bolt.
14. Remove bolts securing steering rack clamp to
subframe and remove clamp.
15. Withdraw steering rack out through drivers side
wheel arch.
Refit
1. Clean steering rack and subframe mating
faces, 'U' bolt and clamp.
2. Position steering rack to subframe.
3. Fit 'U' bolt securing steering rack to subframe,
fit nuts but do not tighten at this stage.
4. Fit steering rack clamp, fit nuts and tighten to
22 Nm.
5. Tighten 'U' bolt nuts to 22 Nm, ensure that
thread protrusion behind each nut is equal.
6. Raise subframe on jack.
7. Align subframe to body mountings, fit bolts
securing rear mountings and cross brace, and
tighten to 45 Nm.
8. Fit and tighten bolt securing cross brace to
centre mounting to 45 Nm.
9. Clean steering rack ball joint tapers and mating
faces on hubs.
10. Position LH and RH track rod ends, fit and
11. Locate pinion cover on studs and secure to
steering rack pinion housing, fit and tighten
nuts to 8 Nm.
12. Align and connect steering column
intermediate shaft joint to rack pinion.
13. Fit bolt and tighten to 22 Nm.
16. Check front wheel alignment. See
Adjustments.
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STEERING
REPAIRS 3
STEERING RACK GAITER
Remove
3. Loosen track-rod end lock nut.
4. Remove nut securing track-rod end to steering
arm.
5. Using tool 18G 1584 , break track-rod end
taper joint.
6. Noting the number of complete turns remove
track-rod end, and lock nut.
7. Remove 2 gaiter clips.
8. Remove gaiter from rack.
Refit
1. Apply grease to gaiter. See INFORMATION,
2. Position inner gaiter clip to gaiter.
3. Fit gaiter and secure with clips.
4. Fit lock nut and track-rod end to rack.
NOTE: Rotate the track-rod end the same
amount of turns noted on the removaI.
5. Clean taper and position track-rod end to
steering arm.
6. Fit nut and tighten to 30 Nm.
7. Tighten track-rod end lock nut to 50 Nm.
10. Check and adjust wheel alignment. See
Adjustments.
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STEERING
4 REPAIRS
STEERING COLUMN
Precautions.
Remove
1. Make the SRS system safe See RESTRAINT
CAUTION: The steering coIumn upper
mountings have breakout capsuIes which
are criticaI to crash performance. Do not
cIamp the capsuIes in a vice or otherwise
mishandIe them.
WARNING: If the breakout capsuIes on the
upper mountings are damaged the
steering coIumn must be repIaced.
2. Remove steering column switch pack. See
3. Loosen 2 screws securing fuse box cover to
fascia and remove fuse box cover.
4. Disconnect 2 ignition switch multiplugs from
fusebox and harness.
5. Remove bolt securing intermediate shaft to
steering rack pinion.
6. Remove 2 nuts securing passenger fusebox to
body and position fusebox aside.
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STEERING
REPAIRS 5
CAUTION: The steering coIumn, upper
mounting boIts must be removed before
the Iower mounting boIts. This is to
prevent the weight of the steering coIumn
damaging the upper mounting breakout
capsuIes.
7. Remove 2 bolts securing upper steering
column to fascia rail.
8. Remove 4 bolts securing lower steering
column to bracket.
9. Release column assembly and remove from
steering rack pinion, remove steering column
from vehicle.
10. Remove clamping bolt securing steering
column to intermediate shaft. Remove
intermediate shaft.
11. Position steering column assembly in vice.
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STEERING
6 REPAIRS
12. Mark ignition lock shear bolt heads with centre
punch.
13. Drill out shear bolt heads.
14. Remove lock 'saddle' from column.
15. Remove lock assembly from column.
16. Remove shear bolts from lock assembly.
Refit
1. Remove key from ignition barrel to ensure
steering lock pin is protruding.
2. Fit ignition switch to column, locating steering
lock pin in groove on inner column.
3. Fit lock saddle.
4. Fit and nip up shear bolts.
5. Test operation of lock and switch prior to
tightening shear bolts.
6. Tighten both shear bolts progressively to
ensure lock and saddle sit level on column.
7. Tighten bolts until heads shear.
8. Remove column assembly from vice.
9. Fit intermediate shaft to steering column and
tighten clamping bolt to 22 Nm.
WARNING: Intermediate shafts are
suppIied in LH and RH drive variants. The
two shafts have different phase angIes,
and cars fitted with the incorrect shafts wiII have
defective steering.
It is essentiaI that aII RH drive cars are fitted with
shafts with bIue marks, and aII LH drive cars are
fitted with unmarked shafts.
10. Fit column assembly to steering rack pinion.
11. Align column to lower mounting and loosely fit
bolts.
12. Align column to upper mounting and loosely fit
bolts.
13. Tighten lower mounting bolts to 22 Nm.
14. Tighten upper mounting bolts to 22 Nm.
15. Fit and tighten clamping bolt securing
intermediate shaft to steering rack pinion to
22 Nm.
16. Fit fuse box to body and tighten nuts to 10 Nm.
17. Connect ignition switch multiplugs to fusebox
and harness.
18. Fit fuse box cover and secure with screws.
19. Fit steering column switch pack. See
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STEERING
REPAIRS 7
STEERING COLUMN NACELLE
Remove
1. Release 2 clips securing fascia fusebox cover.
2. Remove 3 screws securing nacelle to column.
3. Release upper nacelle from lower nacelle and
remove from column.
4. Remove ignition switch grommet from lower
nacelle.
Refit
1. Fit ignition switch grommet to lower nacelle.
2. Fit lower and upper steering column nacelle
and clip together.
3. Align nacelle to fixings and tighten screws.
4. Position fascia fusebox cover and secure
fasteners.
IGNITION SWITCH AND STEERING LOCK
Precautions.
Remove
mishandIe them.
1. Remove steering column assembly. See this
section.
3. Mark ignition switch shear bolt heads with
centre punch.
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STEERING
8 REPAIRS
Refit
3. Fit lock saddle.
4. Fit and nip up shear bolts.
8. Remove column assembly from vice.
9. Fit column assembly to vehicle. See this
section.
STEERING COLUMN
Remove
mishandIe them.
3. Release transponder coil from ignition switch,
disconnect multiplug and remove transponder
coil.
4. Loosen 2 screws and scrivets securing fuse
box cover to fascia and remove fusebox cover.
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STEERING
REPAIRS 9
5. Disconnect ignition switch multiplugs from
fusebox and main harness.
6. Remove 2 nuts securing passenger
compartment fusebox to body and position
aside.
7. Remove bolt securing universal joint to
steering rack pinion.
mounting boIts must be removed before
the Iower mounting boIts. This is to
prevent the weight of the steering coIumn
damaging the upper mounting breakout
capsuIes.
8. Remove 2 bolts securing upper steering
column to fascia rail.
9. Remove 4 bolts securing lower steering
column to bracket.
10. Lower steering column and disconnect 2
multiplugs.
11. Release column assembly from steering rack
pinion and remove from vehicle.
12. Remove clamping bolt securing steering
column to universal joint and remove joint.
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STEERING
10 REPAIRS
14. Mark shear bolt heads with centre punch.
18. Remove shear bolts from lock assembly.
19. Remove column from vice.
Refit
3. Fit lock saddle and loosely fit shear bolts.
7. Fit universal joint to steering column and
tighten clamping bolt to 22 Nm.
WARNING: Intermediate shafts are
suppIied in LH and RH drive variants. The
two shafts have different phase angIes,
and cars fitted with the incorrect shafts wiII have
defective steering.
It is essentiaI that aII RH drive cars are fitted with
shafts with bIue marks, and aII LH drive cars are
fitted with unmarked shafts.
8. Fit column assembly to steering rack pinion.
9. Connect column multiplugs.
10. Align lower column mounting bracket and
locate 2 bolts in slots.
11. Fit remaining 2 bolts into column lower
mounting bracket and tighten all bolts
to 22 Nm.
12. Align column to upper mounting bracket and fit
bolts. Tighten bolts to 22 Nm.
13. Fit and tighten clamping bolt securing universal
joint to steering rack pinion to 20 Nm.
14. Fit passenger compartment fuse box to body
15. Connect ignition switch multiplugs to
passenger compartment fusebox and harness.
16. Fit passenger compartment fuse box cover and
secure with screws and scrivets.
17. Position transponder coil, connect multiplug
and secure transponder coil to ignition switch.
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STEERING
REPAIRS 11
EPAS ECU
Remove
1. Remove glovebox. See BODY, Interior trim
components.
WARNING: Do not remove EPAS ECU
bracket from fascia raiI on vehicIes fitted
with a passenger airbag.
2. Remove 2 bolts securing ECU to fascia rail
bracket.
3. Release ECU from rubber mounting.
4. Disconnect 2 multiplugs from ECU.
5. Remove ECU.
Refit
1. Position ECU and connect multiplugs.
2. Fit ECU to mounting and tighten bolts to
10 Nm.
3. Connect multiplugs.
4. Fit glovebox. See BODY, Interior trim
components.
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STEERING
12 REPAIRS
TRACK-ROD END
Remove
3. Loosen track-rod end lock nut.
4. Remove nut securing track-rod end to steering
arm.
5. Using tool 18G 1584, break taper joint.
6. Noting the number of complete turns, remove
track-rod end.
Refit
1. Fit new track-rod end and position taper to
steering arm.
NOTE: Rotate the track-rod end the same
amount of turns noted on the removaI.
2. Tighten nut to 30 Nm.
3. Tighten lock nut to 50 Nm.
6. Check and adjust front wheel alignment. See
Adjustments.
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STEERING
REPAIRS 13
STEERING WHEEL
Remove
1. Remove driver's airbag. See RESTRAINT
SYSTEMS, Repairs.
2. Disconnect horn/sequential gear change switch
multiplug.
3. Centralise steering wheel with road wheels in
straight ahead position.
4. Restrain steering wheel and loosen nut
securing steering wheel to column.
5. Release steering wheel from column.
6. Remove steering wheel.
7. Attach tape across edge of rotary coupler to
retain correct setting and to prevent rotational
damage to rotary coupler.
8. Release horn switches, disconnect Lucar
connections and remove horn switches.
9. Release clips securing sequential gear change
switches, release switches from steering
wheel.
10. Disconnect gear change switch multiplugs and
remove switches from steering wheel.
11. Remove steering wheel harness.
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STEERING
14 REPAIRS
Refit
1. Position harness to steering wheel and locate
to switch recesses.
2. Position gear change switches, connect
multiplugs and secure switches to steering
wheel.
3. Position horn switches, connect Lucar
connections and secure horn switches to
steering wheel.
4. Remove tape from rotary coupler.
5. Ensure road wheels are in straight ahead
position and indicator cancelling cam is aligned
horizontally.
6. Fit steering wheel to column.
7. Connect horn/sequential gear change switch
multiplug.
8. Fit and tighten nut securing steering wheel to
column to 63 Nm.
9. Fit driver's airbag. See RESTRAINT
SYSTEMS, Repairs.
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FRONT SUSPENSION
CONTENTS Page
FRONT SUSPENSON 1 .............................................................................................
FRONT SUSPENSON COMPONENTS 2 ..................................................................
SUSPENSON 6 ..........................................................................................................
REPAIRS
ANT-ROLL BAR 1 .......................................................................................................
LNK - ANT-ROLL BAR 2 ............................................................................................
BALL JONT - UPPER 2 ..............................................................................................
BALL JONT - LOWER 4 .............................................................................................
BEARNGS - HUB 5 .....................................................................................................
DAMPER - LH 7 ...........................................................................................................
SUSPENSON ARM ASSEMBLY - UPPER 8 ..............................................................
SUSPENSON ARM - LOWER FRONT 11 ..................................................................
BEARNGS - SUSPENSON ARM ASSEMBLY - UPPER 14 ......................................
BUSH - SUSPENSON LOWER ARM - FRONT 15 .....................................................
SUB FRAME - FRONT SUSPENSON - MANUAL TRANSMSSON MODELS 17 ....
MOUNTNG - FRONT SUB FRAME - FRONT 24 .......................................................
MOUNTNG - FRONT SUB FRAME - REAR 24 ..........................................................
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FRONT SUSPENSION
FRONT SUSPENSION
1. Coil spring
2. Damper unit
3. Upper suspension arm
4. Lower suspension arm
5. Anti-roll bar
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FRONT SUSPENSION
FRONT SUSPENSION COMPONENTS
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FRONT SUSPENSION
1. Coil spring
2. Spring retainer
3. Bump washer
4. Spacer
5. Mounting cushion
6. Distance piece
7. Locknut
8. Spring seat
9. Rubber bush
10. Retaining washer
11. Self locking nut
12. Dust shield
13. Rebound rubber
14. Damper unit
15. Needle roller bearing
16. Sealing ring
17. Upper arm pivot shaft
18. Thrust washer
19. Flat washer
20. Locking nut
21. Suspension upper arm
22. Needle roller bearing
23. Sealing ring
24. Thrust washer
25. Bolt - retaining plate
26. Locking nut
27. Flat washer
29. Retaining plate - upper arm pivot shaft
30. Self locking nut
31. Grease nipple
32. Nut - upper ball joint
33. Brake hose bracket
34. Bolt - Damper lower mounting
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FRONT SUSPENSION
FRONT SUSPENSION COMPONENTS - continued
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FRONT SUSPENSION
1. Stub axle
2. Retaining clip (inner) - drive flange bearing
3. Lock washer
4. Upper balljoint
5. Steering arm bolt
6. Steering arm
7. Steering arm dowels
8. Swivel hub
9. Self locking nut - lower arm ball-joint
10. Bearing - drive flange
11. Retaining clip (outer) - drive flange bearing
12. Drive flange
13. Hub nut
14. Mounting bolt - lower arm
15. Bush - lower arm
16. Bracket - ball-joint to lower arm
17. Lower balljoint
18. Lower suspension arm
19. Bolt - anti-roll bar bracket
20. Clamp bracket - anti-roll bar
21. Self locking nut - anti-roll bar link
22. Anti-roll bar
23. Bush - anti-roll bar
24. Bolt - lower balljoint
25. Bolt - anti-roll bar link (upper)
26. Anti-roll bar link
27. Self-locking nut - anti-roll bar link (upper)
28. Bolt - anti-roll bar link (lower)
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FRONT SUSPENSION
SUSPENSION
GeneraI
The front suspension is of the independent type and
comprises the following main components:
Two coil springs
Two damper units
Two upper pivot arms
Two lower wishbones
Two swivel hubs
One anti-roll bar
Two anti-roll bar links
Peripheral subframe
The front suspension system consists of a
spring/damper unit at each front wheel. Each
spring/damper combination is mounted between the
vehicle's body and upper suspension arm.
There are two grades of suspension configuration,
Standard and Sports. The Sports version has a
lower (10 mm) and stiffer suspension than for the
Standard.
Damper and Spring Unit
Two damper and spring units control the damping of
the front suspension. The coil springs support the
weight of the vehicle, maintain ride height and
absorb road shock. When additional load is placed
on the coil springs (e.g. through deceleration), or
when the vehicle passes over bumps in the road, the
springs compress to absorb the change and ensure
ride comfort is maintained.
The coil spring is retained in a compressed condition
between the strut spring seat and the top (body)
mounting. The coil springs and the upper ball joints
support the weight of the vehicle which is
transmitted through the springs to the upper control
arms and then through the upper ball joints.
solators are fitted at each end of the spring/damper
units to reduce noise transmitted from the
suspension to the body.
The damper units assist in absorbing the energy
stored in the coil spring after passing a bump.
Quickly terminating the reciprocating motion of the
suspension and returning the coil spring to the rest
position.
Each damper is gas and oil filled and is of twin tube
construction. The twin tube construction allows the
damper piston to operate against hydraulic fluid in
an inner tube. The damper unit is fully displaced on
rebound and uses rod displaced valving during
compression.
As the suspension travels through the bump and
rebound phases, the hydraulic fluid in the inner tube
of the damper unit is forced through tiny holes inside
the piston and the base valve, this changing
pressure in the hydraulic fluid slows down the piston
and consequently slows down spring and
suspension movement. The damper units provide
velocity sensitive hydraulic damping, the amount of
resistance depending on the speed of the
suspension and the number and size of the holes in
the piston and base valve. The faster the
suspension moves, the more resistance the damper
units will provide. As a result, the damper units
reduce:
Bounce
Body roll or sway
Brake dive
Acceleration squat
An oil cavity between the inner and outer tubes is
used as a reserve tube to store excess hydraulic
fluid. A low pressure charge of nitrogen gas in the
reserve tube provides resistance to fluid entering the
reserve tube and with the hydraulic fluid under
pressure, aeration of the fluid is greatly reduced to
provide better ride comfort and improved handling.
Besides minimising oil cavitation this two-tube
design helps eliminate the effect of damage to the
outer tube affecting piston operation.
A compression valve is included in the base of the
piston inner pressure tube to control fluid movement
between the inner and outer chambers during the
compression cycle. The diameter of the piston and
inside diameter of the pressure tube is 30 mm
(1.18 in.).
The damper rod is secured at the top mounting to
the front wing valance with a washer and nut. The
damper rod passes through a bushing and low
friction seal at the upper end of the pressure tube to
keep it aligned and allow the piston to move freely. A
5mm hexagon socket is provided at the top end of
the damper to restrain the rod from rotating when the
nut is tightened.
NOTE: The front suspension dampers are
coIour coded BLUE, whereas the rear
suspension dampers are coIour coded
RED.
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FRONT SUSPENSION
A dust shield and bump stop rubber is fitted between
the damper unit and the top mounting, to protect the
damper rod from dirt and damage.
Lower suspension arm
The suspension lower arm is of the wishbone type
and is designed to provide fore-and-aft stiffness, to
restrain braking torque. Both lower suspension arms
are interconnected by an anti-roll bar which provides
the required stiffness to prevent body roll.
The front lower arm has replaceable, pressed-in
bushes which should be lubricated with Merlene 148
rubber lubricant.
The lower ball joint is attached to the lower arm via a
bracket and three rivets, if the ball joints need to be
replaced, the rivets have to be drilled out and the
new ball joint attached to the lower suspension arm
using three nuts and bolts. The lower ball joint has a
tapered stub which is attached to the hub using a
pinch clamp and a bolt and locknut. The ball-joint
allows vertical movement as the wheels pass over
dips and bumps and side-to-side motion as the
wheels are turned for cornering.
Upper suspension arm
The upper suspension arm uses a pivot shaft
incorporating needle roller bearings to facilitate up
and down movement of the arm at its inner end. The
lower mounting of the suspension damper connects
to a fixing point in the centre of the upper arm. An
upper ball joint is attached to the outer end of the
upper arm and connects to the hub steering knuckle
through a tapered stud held in position with a nut
and tab washer.
Anti-roII bar
A 20 mm solid spring steel anti-roll bar is used which
operates via anti-roll bar links on the lower
suspension arms. The anti-roll bar is attached to the
front subframe with two PTFE bushes which are
secured with clamp plates and bolts. The low friction
PTFE bushes require no additional greasing and
allow the anti-roll bar to rotate freely with quiet
operation. This allows the bar to respond quickly to
roll inputs.
Each anti-roll bar link has a ball joint fitting at each
end which improves response and efficiency. The
top ball-joint is attached by a bolt and self locking
nut to a bracket which is riveted to the lower ball joint
/ lower suspension arm assembly. The lower
ball-joint is attached to the anti-roll bar with a nut and
bolt.
CAUTION: The head of the boIt securing
the anti-roII bar Iinks to the Iower
suspension arms must face forward. This
is to aIIow cIearance between boIt head and front
hub.
Front subframe
The subframe is fabricated from hydro-formed tubing
providing a light and strong structure. All machining
of critical geometric locations is performed after
fabrication to ensure accurate location of the front
suspension and steering components.
The subframe is mounted to the body at the front
and rear and has a cross-bracing fitted beneath, with
fixings at front rear and centre to provide additional
rigidity.
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FRONT SUSPENSION
REPAIRS 1
ANTI-ROLL BAR
Remove
1. Position vehicle on 4 post ramp.
2. Remove nuts and bolts securing anti-roll bar
links to each lower suspension arm.
3. Remove 2 bolts securing each anti-roll bar
mounting rubber clamps to subframe.
4. Remove clamps and anti-roll bar.
5. Remove 2 mounting rubbers from anti-roll bar.
6. Remove nut and bolt securing each link to
anti-roll bar and remove links.
7. Check link bushes for wear.
Refit
1. Clean anti-roll bar and links.
2. Position links to anti-roll bar, fit nuts and bolts
3. Fit mounting rubbers to anti-roll bar.
4. Position anti-roll bar, align links to lower
suspension arms, fit nuts and bolts but do not
hub.
5. Position mounting rubbers, align clamps to bolt
holes in subframe, fit and tighten bolts to
22 Nm.
6. With the weight of the vehicle on the front
bolts to 35 Nm.
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FRONT SUSPENSION
2 REPAIRS
LINK - ANTI-ROLL BAR
Remove
1. Position vehicle on 4 post ramp.
2. Remove nut and bolt securing anti-roll bar link
to anti-roll bar.
to lower suspension arm and remove anti-roll
bar link.
Refit
1. Clean anti-roll bar link.
2. Position anti-roll bar link to lower arm, fit nut
and bolt but do not tighten at this stage.
hub.
3. Align anti-roll bar link to anti-roll bar, fit nut and
bolt but do not tighten at this stage.
bolts to 35 Nm.
BALL JOINT - UPPER
Remove
3. Position jack under lower suspension arm,
raise jack sufficiently and fit a suitable block
between upper suspension arm and subframe.
Lower jack.
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FRONT SUSPENSION
REPAIRS 3
and slave nut.
6. Release ball joint from upper suspension arm.
7. Knock back lock washer securing ball joint to
front hub.
8. Using ball joint retaining nut, secure 18G-1341
to ball joint. Attach a suitable socket and
socket bar to 18G-1341 and remove ball joint
from front hub.
9. Remove and discard lock washer.
Refit
1. Clean ball joint threads and mating threads in
front hub. Ensure threads are clean and dry.
2. Apply Loctite 242 to ball joint threads.
3. Fit new lock washer on hub.
4. Fit ball joint to front hub, and using 18G-1341 ,
tighten ball joint to 105 Nm.
5. Knock over lock washer to front hub and ball
joint nut.
6. Raise jack and position ball joint to upper
suspension arm, fit and tighten new lock nut to
54 Nm.
7. Raise jack and remove support block from
upper suspension arm.
8. Lower and remove jack from lower suspension
arm.
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FRONT SUSPENSION
4 REPAIRS
BALL JOINT - LOWER
Remove
1. Remove front lower arm. See this section.
2. Centre punch centres of rivet heads.
3. Drill pilot hole in rivet heads.
NOTE: Use pedestaI driII for accuracy.
4. Enlarge pilot hole to remove rivets.
CAUTION: Do not enIarge hoIes in Iower
arm.
5. Press out rivet studs.
6. Remove ball joint assembly.
Refit
1. Clean ball joint and lower arm mating faces.
2. Fit ball joint to lower arm.
3. Fit 3 nuts and bolts and tighten to 40 Nm.
NOTE: Ensure boIt heads are fitted above
the Iower arm.
4. Fit front lower arm. See this section.
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FRONT SUSPENSION
REPAIRS 5
BEARINGS - HUB
Remove
3. Knock back hub nut stake and remove hub nut.
4. Remove front brake disc. See BRAKES,
Repairs.
5. Position jack under lower suspension arm,
raise jack sufficiently and fit a suitable block
between upper suspension arm and subframe.
Lower jack.
6. Remove nut securing steering rack ball joint to
steering arm.
7. Release ball joint taper from steering arm using
18G-1584 .
and slave nut.
10. Remove nut and bolt securing hub to lower
suspension arm ball joint.
11. Release hub from lower ball joint and remove
hub assembly.
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FRONT SUSPENSION
6 REPAIRS
12. Position hub to press.
13. Press out drive flange using 18G 1358/4 .
14. Collect drive flange and remove hub from
press.
15. Remove bearing inner and outer circlips.
17. Position 18G 705-6/3 to bearing, press out
bearing and remove hub from press.
18. Position drive flange to press, fit universal
bearing splitter around bearing as shown.
19. Position thrust button, 18G-705-6/2 to drive
flange, press out drive flange from inner
bearing track.
20. Collect drive flange and remove bearing inner
track.
Refit
1. Clean hub, drive flange and bearing mating
faces.
2. Fit new bearing outer circlip to hub.
4. Position new bearing to hub, press bearing into
hub using 18G-705-6/3 .
5. Fit new bearing inner circlip to hub.
6. Using 18G-134BD and 18G-705-6/3 , press
drive flange into hub bearing.
7. Remove hub from press.
9. Clean lower ball joint to hub mating faces.
10. Clean ball joint to upper suspension arm
mating faces.
11. Position hub to lower ball joint, fit and tighten
nut and bolt to 45 Nm.
12. Position hub assembly to upper suspension
arm, fit and tighten new ball joint lock nut to
54 Nm.
13. Raise jack and remove support block from
upper suspension arm.
14. Clean steering rack ball joint to steering arm
mating faces.
15. Align steering rack ball joint to steering arm, fit
and tighten nut to 30 Nm.
16. Fit front brake disc. See BRAKES,
Information.
17. Fit and tighten new hub nut to 210 Nm.
18. Stake hub nut to shaft.
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FRONT SUSPENSION
REPAIRS 7
DAMPER - LH
Remove
support the vehicIe on safety stands
3. Remove 2 bolts securing fuse box in luggage
compartment, move fuse box aside.
4. Position 5 mm Allen key in top of damper shaft,
remove nut securing damper to front wing
valance.
5. Remove retaining washer and rubber bush.
6. Remove bolt securing damper to upper
suspension arm, remove damper/spring
assembly and collect spring isolator.
7. Position damper/spring assembly in vice.
8. Progressively loosen and remove spring
retainer nut, remove distance piece, flat
washer, steel cup washer and spring retainer.
Note fitted position of steel cup washer.
9. Remove spring, dust shield and rebound
rubber bush from damper.
10. Remove damper from vice.
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FRONT SUSPENSION
8 REPAIRS
Refit
1. nspect dust shield and rebound rubber bush
for deterioration and damage.
2. Clean damper and spring mating faces.
3. Prime new damper by operating it at least 3 full
strokes.
4. Position new damper in vice.
5. Position rebound rubber bush on damper shaft.
6. Correctly position spring and dust shield onto
damper.
7. Correctly position spring retainer, steel cup
washer, flat washer and distance piece. Fit and
tighten nut securing spring retainer to damper
to 25 Nm.
8. Position isolator on spring retaining plate.
9. Position damper assembly in subframe turret,
fit top bush, washer and nut. Do not tighten nut
at this stage.
10. Position damper assembly to upper
suspension arm, fit and tighten bolt to 100 Nm.
tighten nut to 45 Nm
12. Position fuse box, fit and tighten bolts to
10 Nm.
SUSPENSION ARM ASSEMBLY - UPPER
Remove
3. Remove front bumper armature. See BODY,
Exterior fittings.
4. Remove screw and 3 scrivets securing wheel
arch liner and remove wheel arch liner.
5. Remove bolt securing brake pipe bracket to
subframe turret, move brake pipe aside.
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FRONT SUSPENSION
REPAIRS 9
6. Remove 3 bolts securing crash can to
subframe and remove crash can.
7. Remove bolt securing damper assembly to
upper suspension arm, move damper aside.
8. Remove and discard nut securing upper ball
joint and remove nut.
and slave nut.
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FRONT SUSPENSION
10 REPAIRS
10. Remove nut securing rear most end of upper
suspension arm pivot shaft.
11. Remove bolt and nut and bolt securing pivot
shaft retaining plate to subframe.
12. Remove pivot shaft from subframe.
13. Remove upper suspension arm from subframe,
noting fitted position of rear thrust washer and
rubber seals at each end of suspension arm.
14. Secure pivot shaft in soft jawed vice, remove
front nut, plain washer, retaining plate and
thrust washer.
Refit
1. Clean upper suspension arm, pivot shaft, thrust
washers and mating faces in subframe.
2. Lubricate pivot shaft and thrust washers with
Dextragrease Super GP.
3. Fit rear thrust washer and rubber seals to
upper suspension arm, position suspension
arm in subframe.
4. Align upper suspension arm and fit pivot shaft.
5. Fit front thrust washer, retaining plate, plain
washer and nut, fit and tighten retaining plate
bolt and nut and bolt to 10 Nm.
6. Tighten front and rear pivot shaft nuts to
74 Nm.
7. Position hub to upper suspension arm, fit new
lock nut, and tighten ball joint nut to 54 Nm.
8. Position crash can in subframe, fit and tighten
bolts to 45 Nm.
10. Position brake pipe bracket to subframe turret,
fit and tighten bolt to 25 Nm.
11. Position wheel arch liner, fit screw and scrivets
securing wheel arch liner.
12. Fit front bumper armature. See BODY,
Exterior fittings.
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FRONT SUSPENSION
REPAIRS 11
SUSPENSION ARM - LOWER FRONT
Remove
universal joint to rack pinion.
2. Release steering column universal joint from
rack pinion.
cover to body.
7. Remove bolts securing damper assemblies to
upper suspension arms, move dampers aside.
8. Raise suspension and fit a suitable block
between upper arm and subframe.
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FRONT SUSPENSION
12 REPAIRS
9. Remove 2 bolts securing LH and RH brake
pipe support brackets to subframe turret.
10. Remove nut and bolt securing lower arm
ball-joint to hub.
11. Release ball-joint from lower arm.
to lower arm.
mounting.
14. Support rear of front subframe on a jack.
15. Loosen 2 bolts and 2 nuts and bolts securing
front subframe mountings to body.
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FRONT SUSPENSION
REPAIRS 13
16. Remove 8 bolts securing front subframe rear
mountings to body.
17. Remove lower arm bolt access grommet from
subframe.
18. Lower subframe on jack to gain access to
lower suspension arm rear retaining bolts.
19. Remove front bolt securing lower arm to
subframe.
20. Remove rear bolt securing lower arm to
subframe.
21. Remove lower arm.
Refit
1. Clean lower arm bushes, bush recesses and
pivot bolts.
2. Fit lower arm to subframe.
3. Fit bolts securing lower arm to subframe, do
5. Align subframe mountings and cross brace to
body. Fit and tighten bolts securing subframe
mountings and cross brace to 45 Nm.
6. Tighten nuts and bolts securing front subframe
mountings to body to 30 Nm.
8. Clean lower ball joint and seat.
9. Position hub to lower ball joint, fit and tighten
10. Raise suspension and remove support blocks,
align dampers, fit bolts and tighten to 100 Nm.
11. Align anti-roll bar link to lower arm.
12. Fit nut and bolt securing anti-roll bar link to
lower arm, do not tighten at this stage.
13. Position brake pipe brackets to subframe
turret, fit and tighten bolts to 25 Nm.
nuts to 8 Nm.
15. Align and connect steering column
intermediate shaft joint to rack pinion.
16. Fit bolt and tighten to 22 Nm.
17. Tighten lower arm to subframe bolts to 85 Nm.
- Tighten anti-roll bar link to lower arm nuts and
bolts to 35 Nm.
CAUTION: Nuts and boIts must be
tightened with the vehicIe weight on the
suspension.
18. Fit bolt access grommet to subframe.
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FRONT SUSPENSION
14 REPAIRS
BEARINGS - SUSPENSION ARM ASSEMBLY -
UPPER
Remove
1. Raise front of vehicle and support one side on
stand.
3. Remove upper suspension arm. See this
section.
4. With the pivot shaft and rubber seals removed,
note fitted position of bearings in upper
suspension arm.
5. Position upper suspension arm in vice.
6. Remove needle roller bearings from upper
suspension arm using 18G-581 .
CAUTION: CIean and inspect bearing
housings prior to reassembIy. If any wear
or damage is present due to worn
bearings, the suspension arm must be repIaced.
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FRONT SUSPENSION
REPAIRS 15
Refit
1. Align and carefully drift new needle roller
bearings into upper suspension arm using
18G 582 and 18G 582/1 .
2. Fit upper suspension arm. See this section.
BUSH - SUSPENSION LOWER ARM - FRONT
Remove
1. Remove front lower arm. See this section.
2. Remove front bush using press, position lower
arm with front bush uppermost and support
with tool 18G 1612-4 under rear bush.
3. Fit tool 18G 1612-1 to front bush and press
bush from lower arm.
4. Reposition arm under press with rear bush
uppermost.
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FRONT SUSPENSION
16 REPAIRS
5. Fit tool 18G 1612-1 to rear bush and press
bush from arm.
Refit
1. Clean lower arm and bush locations.
2. Position lower arm in press with rear bush
located uppermost.
3. Lubricate rear bush with Marlene 148 rubber
lubricant.
4. Fit tool 18G 1612-2 to rear bush location.
5. Fit rear bush into tool 18G 1612-2 with the
rounded flange uppermost with the arrows on
bush pointing 90` from ball joint.
6. Fit tool 18G 1612-1 to the rear bush and press
into lower arm.
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FRONT SUSPENSION
REPAIRS 17
7. Position lower arm with tool 18G 1612-4 .
8. Fit tool 18G 1612-3 to front bush location.
9. Lubricate front bush with Marlene 148 rubber
lubricant.
10. Fit bush into tool 18G 1612-3 with flat flange
uppermost.
11. Press bush into lower arm using tool
18G 1612-1 .
12. Remove arm from press.
13. Fit front lower arm. See this section.
SUB FRAME - FRONT SUSPENSION - MANUAL
TRANSMISSION MODELS
Remove
3. Disconnect battery positive lead,
4. Release main fuse and fuse box connections,
release from clips and position aside.
universal joint to steering rack.
6. Release steering column from steering rack.
cover to body.
8. Remove front road wheels.
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FRONT SUSPENSION
18 REPAIRS
9. Remove 2 bolts securing LH and RH brake
pipe support brackets to subframe turret.
sensors to calipers. Release sensors and
collect spacers.
11. Release LH and RH ABS sensor lead
grommets from each bracket on front hubs,
clips and grommet brackets on subframe turret.
calipers to front hubs. Release calipers from
hubs and tie calipers aside.
CAUTION: Do not aIIow caIiper to hang on
brake hose.
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FRONT SUSPENSION
REPAIRS 19
under floor.
17. Remove and discard cable tie securing battery
lead to subframe, position battery lead aside.
18. Release screen washer tube from 2 clips on
subframe.
19. Remove 2 bolts securing cross brace to front of
subframe.
20. Remove LH and RH bolts securing cross brace
and rear subframe mountings to body.
mounting and remove cross brace.
22. Position suitable table beneath front subframe.
23. Lower vehicle on ramp until subframe makes
contact with table.
LH and RH subframe mountings to body.
25. Slowly raise vehicle away from subframe.
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FRONT SUSPENSION
20 REPAIRS
access onIy.
links to anti-roll bar.
27. Remove 4 bolts securing anti-roll bar to
subframe, remove anti-roll bar. Collect anti-roll
bar clamps and mounting rubbers.
28. Remove nuts securing steering rack ball joints
to front hubs. Using 18G-1584 , release ball
joint tapers from hubs.
remove nut securing damper to subframe
turret.
33. Fit slave nut to ball joint threads, position tool
18G-1584, release ball joint taper from upper
suspension arm. Remove slave nut.
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FRONT SUSPENSION
REPAIRS 21
34. Remove nut and bolt securing ball joint to
lower arm, release ball joint and remove hub
assembly.
35. Remove 3 bolts securing LH crash can to
subframe and remove crash can.
36. Remove rear nut and plain washer securing
upper suspension arm pivot shaft to subframe.
37. Remove bolt and nut and bolt securing pivot
shaft retaining plate to subframe.
38. Remove pivot shaft from subframe.
39. Remove upper suspension arm from subframe,
noting fitted position of rear thrust washer and
rubber seals at each end of suspension arm.
40. Remove front and rear bolts securing lower
arm to subframe and remove lower arm.
41. Repeat operations for opposite side of
suspension.
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FRONT SUSPENSION
22 REPAIRS
42. Remove 2 nuts and bolts and 'U' bolt securing
steering rack to subframe, remove steering
rack and collect 'U' bolt and clamp.
front mountings to subframe and collect
mountings.
rear mountings to subframe and collect
mountings.
45. Remove 2 nuts securing splash guard
mounting bracket to subframe, remove splash
guard mounting bracket.
Refit
1. Position splash guard mounting bracket to
subframe, fit and tighten nuts to 30 Nm.
2. Position LH and RH front mountings to
subframe, fit and tighten nuts and bolts to
100 Nm.
3. Position LH and RH rear mountings to
100 Nm.
4. Position steering rack to subframe, fit 'U' bolt
and clamp. Fit and tighten nuts and bolts to
22 Nm.
5. Position lower arm in subframe, fit and tighten
bolts to 85 Nm.
6. Ensure that thrust washer and rubber seals are
correctly positioned on upper suspension arm.
7. Position upper suspension arm in subframe
and fit pivot shaft.
8. Align pivot shaft retaining plate to holes in
subframe, fit bolt, nut and bolt and tighten to
10 Nm.
9. Position plain washer, fit and tighten rear nut
securing pivot shaft to subframe to 74 Nm.
suspension.
11. Position crash can in subframe, fit and tighten
bolts to 45 Nm.
12. Clean hub assembly and ball joint locations in
suspension arms.
13. Position hub assembly to upper suspension
arm, fit and tighten new ball joint lock nut to
54 Nm.
14. Ensure bottom ball joint pin is fully engaged in
hub.
15. Fit and tighten nut and bolt securing bottom
ball joint to hub to 45 Nm.
16. Position isolator on spring retaining plate.
at this stage.
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FRONT SUSPENSION
REPAIRS 23
suspension.
21. Clean steering rack ball joint tapers and mating
faces on hubs.
22. Position steering rack ball joints to hubs, fit and
23. Clean anti-roll bar.
25. Position anti-roll bar to subframe, position
clamps and align to bolt holes. Fit and tighten
bolts to 22 Nm.
26. Align anti-roll bar links to anti-roll bar, fit nuts
and bolts but do not tighten at this stage.
27. Correctly position subframe underneath
vehicle. Slowly lower vehicle onto subframe.
28. Align subframe mountings to body.
29. Fit nuts and bolts securing subframe
mountings to body. Tighten rear mounting bolts
to 45 Nm and front mounting bolts to 30 Nm.
31. Position cross brace to subframe, fit and
tighten bolts securing cross brace to rear
mountings, front of subframe and centre
mounting to 45 Nm.
32. Connect coolant hoses and secure with clips.
33. Position battery lead to subframe and secure
with new cable tie.
34. Secure screen washer tube in clips on
subframe.
35. Release LH and RH front brake calipers,
position to hubs, fit and tighten bolts to 85 Nm.
36. Position LH and RH brake pipes to subframe
turrets, fit and tighten bolts to 25 Nm.
37. Fit LH and RH ABS sensors and spacers, fit
38. Secure LH and RH ABS sensor lead grommets
in brackets on front hubs, clips and grommet
brackets on subframe turret.
bolts to 35 Nm.
nuts to 8 Nm.
43. Position steering column universal joint,fit and
tighten clamp bolt to 22 Nm.
44. Connect battery positive lead, fuse box and
main fuse leads, secure leads in clips.
Adjustments.
47. Check front wheel alignment. See STEERING,
Adjustments.
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FRONT SUSPENSION
24 REPAIRS
MOUNTING - FRONT SUB FRAME - FRONT
Remove
2. Remove bolt and nut and bolt securing front
mounting to body.
subframe and remove mounting.
Refit
1. Position mounting to subframe, fit bolt and nut
but do not fully tighten at this stage.
2. Fit and tighten bolts securing subframe
mounting to body to 30 Nm.
3. Tighten nut and bolt securing mounting to
subframe to 100 Nm.
MOUNTING - FRONT SUB FRAME - REAR
Remove
mounting.
3. Remove 4 bolts securing cross brace and rear
subframe mounting to body.
subframe and remove mounting.
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FRONT SUSPENSION
REPAIRS 25
Refit
1. Position mounting to subframe, fit bolt through
subframe and mounting.
2. Fit and tighten bolts securing rear subframe
mounting and cross brace to body to 45 Nm.
3. Fit nut securing mounting to subframe, tighten
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REAR SUSPENSION
CONTENTS Page
REAR SUSPENSON 1 ...............................................................................................
REAR SUSPENSON COMPONENTS 2 .....................................................................
REAR SUSPENSON 6 ...............................................................................................
REPAIRS
BALL JONT - UPPER 1 ..............................................................................................
BEARNG(S) - HUB - ONE SDE 2 ..............................................................................
DAMPER - RH 5 ..........................................................................................................
ANT-ROLL BAR - REAR 7 ..........................................................................................
LNK - ANT-ROLL BAR 8 ............................................................................................
LOWER LNK - REAR 9 ...............................................................................................
TRACK CONTROL ARM 10 ........................................................................................
TRALNG ARM 11 ......................................................................................................
BUSH - TRALNG ARM 12 .........................................................................................
BUSH - TRALNG ARM TO HUB 13 ...........................................................................
BUSH - ARM ASSEMBLY - UPPER 14 .......................................................................
ARM ASSEMBLY - UPPER 15 ....................................................................................
SUB FRAME - REAR SUSPENSON - MANUAL TRANSMSSON MODELS 16 .......
REAR SUB FRAME - LH - FRONT MOUNTNG 18 ....................................................
REAR SUB FRAME - LH - REAR MOUNTNG 20 .......................................................
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REAR SUSPENSION
REAR SUSPENSION
1. Coil spring
2. Damper unit
3. Upper suspension arm
4. Trailing arm
5. Lower link
6. Anti-roll bar and links
7. Adjustable track control arm
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REAR SUSPENSION
REAR SUSPENSION COMPONENTS
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REAR SUSPENSION
1. ABS sensor lead bracket
2. Bolt - ABS sensor lead bracket
3. Spring seat
4. Rubber bush - top damper mounting
5. Retaining washer - top damper mounting
6. Locknut - top damper mounting
7. Dust shield
8. Bump stop rubber
9. Damper unit
10. Bolt - damper lower mounting
11. Nut - upper balljoint
12. Coil spring
13. Spring retainer
14. Cup washer
15. Spacer
16. Mounting cushion
17. Distance piece
18. Locknut - damper rod
19. Locknut - upper arm pivot
20. Washer - upper arm pivot
21. Spacer - upper arm pivot
22. Upper arm
23. Top hat spacer - upper arm pivot
25. Self locking nut - pivot retaining plate
26. Pivot shaft - upper arm
28. Retaining plate
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REAR SUSPENSION
REAR SUSPENSION COMPONENTS - continued
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REAR SUSPENSION
1. Lower link
2. Bolt - lower link
3. Locknut - anti-roll bar link
4. Bolt - anti-roll bar link
5. Link - anti-roll bar
6. Locknut - anti-roll bar link
7. Bush - anti-roll bar
8. Clamp - anti-roll bar
9. Anti-roll bar
10. Bolt - anti-roll bar link
11. Bolt - track control arm
12. Washer - track control arm
13. Self locking nut - track control arm
14. Track control arm
15. Nut - track control arm
16. Upper ball-joint
17. Lock washer
18. Retaining clip (inner) - drive flange bearing
19. Hub
20. Bearing
21. Retaining clip (outer) - drive flange bearing
22. Drive flange
23. Bolt (upper) - trailing arm
24. Bolt (lower) - trailing arm
25. Trailing arm
26. Snubber plate
27. Bolt - trailing arm compliance bush
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REAR SUSPENSION
REAR SUSPENSION
GeneraI
The rear suspension is of the independent type and
is a four-link system which comprises the following
main components:
Two coil springs
Two damper units
Two upper pivot arms
Two trailing arms
Two lower links
Two adjustable track control arms
Two swivel hubs
One anti-roll bar
Two anti-roll bar links
Peripheral subframe
The rear suspension system consists of a
spring/damper unit at each rear wheel. Each
spring/damper combination is mounted between the
vehicle's body and upper suspension arm.
There are two grades of suspension configuration,
Standard and Sports. The Sports version has a
lower (10 mm) and stiffer suspension than for the
Standard.
Damper and Spring Unit
Two damper and spring units control the damping of
the rear suspension. The coil springs support the
weight of the vehicle, maintain ride height and
absorb road shock. When additional load is placed
on the coil springs (e.g. through acceleration), or
when the vehicle passes over bumps in the road, the
springs compress to absorb the change and ensure
ride comfort is maintained.
The coil spring is retained in a compressed condition
between the strut spring seat and the top (body)
mounting. The coil springs and the upper ball joints
support the weight of the vehicle which is
transmitted through the springs to the upper control
arms and then through the upper ball joints.
solators are fitted at each end of the spring/damper
units to reduce noise transmitted from the
suspension to the body. The upper spring isolator
has a locating tag on its top surface which is used to
orientate it correctly by locating it through a hole in
the front of the subframe turret.
The damper units assist in absorbing the energy
stored in the coil spring after passing a bump to
quickly terminate the reciprocating motion of the
suspension and return the coil spring to the rest
position.
Each damper is gas and oil filled and is of twin tube
construction. The twin tube construction allows the
damper piston to operate against hydraulic fluid in
an inner tube. The damper unit is fully displaced on
rebound and uses rod displaced valving during
compression.
As the suspension travels through the bump and
rebound phases, the hydraulic fluid in the inner tube
of the damper unit is forced through tiny holes inside
the piston and the base valve, this changing
pressure in the hydraulic fluid slows down the piston
and consequently slows down spring and
suspension movement. The damper units provide
velocity sensitive hydraulic damping, the amount of
resistance depending on the speed of the
suspension and the number and size of the holes in
the piston and base valve. The faster the
suspension moves, the more resistance the damper
units will provide. As a result, the damper units
reduce:
Bounce
Body roll or sway
Brake dive
Acceleration squat
An oil cavity between the inner and outer tubes is
used as a reserve tube to store excess hydraulic
fluid. A low pressure charge of nitrogen gas in the
reserve tube provides resistance to fluid entering the
reserve tube and with the hydraulic fluid under
pressure, aeration of the fluid is greatly reduced to
provide better ride comfort and improved handling.
Besides minimising oil cavitation this two-tube
design helps eliminate the effect of damage to the
outer tube affecting piston operation.
A compression valve is included in the base of the
piston inner pressure tube to control fluid movement
between the inner and outer chambers during the
compression cycle. The diameter of the piston and
inside diameter of the pressure tube is 30 mm
(1.18 in.).
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REAR SUSPENSION
The damper rod is secured at the top mounting to
the rear wing valance with a washer and nut. The
damper rod passes through a bushing and low
friction seal at the upper end of the pressure tube to
keep it aligned and allow the piston to move freely. A
5mm hexagon socket is provided at the top end of
the damper to restrain the rod from rotating when the
nut is tightened.
NOTE: The rear suspension dampers are
coIour coded RED, whereas the front
suspension dampers are coIour coded
BLUE.
A dust shield and bump stop rubber is fitted between
the damper unit and the top mounting, to protect the
damper rod from dirt and damage.
Upper suspension arm
The upper suspension arm uses a pivot shaft to
facilitate up and down movement of the arm at its
inner end. The pivot end of the upper arm contains a
replaceable bush which must be fitted in the correct
orientation if being replaced.
The lower mounting of the suspension damper
connects to a fixing point in the centre of the upper
arm. An upper ball joint is attached to the outer end
of the upper arm and connects to the rear hub
through a tapered stud held in position with a nut
and tab washer.
A rebound rubber is mounted on a bracket which is
fitted below the upper arm to protect the suspension
components in the case of full rebound.
Track controI arm and Iower Iink
The track control arm and lower link make up the
lower suspension wishbone to provide the
necessary fore-and-aft stiffness to resist braking
torque. A lower link is fitted between the front of
each hub and the subframe, these help resist
longitudinal dynamic loads and braking torque.
An adjustable track control arm is fitted between the
rear of each hub and a bracket at the midpoint of the
rear subframe. The track control arm is bushed at its
inner end and has a ball joint at its hub connection.
See STEERING, Repairs.
TraiIing Arm
The rear suspension trailing arms are of cast iron
construction and are designed to provide optimum
camber compensation, counter brake lift and give
fore-and-aft stiffness to restrain acceleration torque.
The utilisation of trailing arm rear suspension also
allows both wheels to move independently. Both
trailing arms are interconnected by an anti-roll bar
which provides the required stiffness to prevent body
roll.
The forward end of each trailing arm is fitted with a
compliance bush which controls sideforce steer
performance, enhances ride and reduces noise
levels. Snubber plates are included at the
compliance bush fixings. f the snubber plates are
removed during repair operations, they must be
refitted in the same orientation as they were before
removal. The rear end of each trailing arm is
secured to their respective rear hub by two bolts.
Anti-roII bar
An 18 mm solid spring steel anti-roll bar is used
which operates via anti-roll bar links on the rear
trailing arms. The anti-roll bar is attached to the rear
subframe with two PTFE bushes which are secured
with clamp plates and bolts. The low friction PTFE
bushes require no additional greasing and allow the
anti-roll bar to rotate freely with quiet operation. This
allows the bar to respond quickly to roll inputs.
Each anti-roll bar link has a ball joint fitting at each
end which improves response and efficiency. The
top ball-joint is attached by a bolt and self locking
nut to the outer side of the anti-roll bar. The lower
ball-joint is attached to a fixing point on the trailing
arm. Each link must be attached to the anti-roll bar
with the ball joint on the outboard side of the anti-roll
bar and the locking nut on the inboard side.
CAUTION: The rear anti-roII bar is handed,
the Ietter 'R' denotes the Iink for the RH
side of the suspension.
Rear subframe
The subframe is fabricated from hydro-formed tubing
providing a light and strong structure. All machining
of critical geometric locations is performed after
fabrication to ensure accurate location of the rear
suspension components.
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REAR SUSPENSION
REPAIRS 1
BALL JOINT - UPPER
Remove
anti-roll bar links to anti-roll bar.
4. Remove nut and bolt securing damper to upper
suspension arm.
5. Release ABS sensor harness bracket.
6. Raise anti-roll bar and upper arm to access ball
joint.
and slave nut.
9. Knock back lock washer securing ball joint to
rear hub.
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REAR SUSPENSION
2 REPAIRS
10. Using ball joint retaining nut, secure 64R033
to ball joint. Attach a suitable socket and
socket bar to 64R033, remove ball joint from
rear hub.
11. Remove and discard lock washer.
Refit
1. Clean ball joint and mating face on rear hub.
2. Apply Loctite 242 to ball joint threads.
3. Fit new ball joint lock washer.
4. Fit ball joint to rear hub, and using 64R003 ,
tighten ball joint to 105 Nm.
5. Knock over lock washer to rear hub and ball
joint nut.
new lock nut and tighten nut to 54 Nm.
7. Align damper to upper arm, fit bolt and tighten
to 100 Nm.
8. Align ABS harness bracket fit nut and tighten to
30 Nm.
9. Align anti-roll bar links to anti-roll bar fit nuts
and bolts and tighten to 35 Nm.
BEARING(S) - HUB - ONE SIDE
Remove
3. Knock back drive shaft nut stake.
4. With assistance, depress brake pedal, remove
and discard drive shaft nut.
5. Remove brake disc. See BRAKES, Repairs.
hub.
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REAR SUSPENSION
REPAIRS 3
7. Remove bolt securing ABS sensor to hub,
release sensor and position aside.
8. Remove nut securing track control arm to rear
hub.
9. Using tool 18G-1584 , release track control
arm ball joint from rear hub.
11. Remove and discard lock nut from upper arm
ball joint.
and slave nut.
13. Remove rear hub assembly from drive shaft.
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REAR SUSPENSION
4 REPAIRS
15. Press out drive flange using tool 18G 1358/4 .
16. Collect drive flange.
18. Remove bearing outer circlip.
19. Remove bearing inner circlip.
21. Fit tool 18G 705-6/3 to bearing and press out
bearing.
23. Position drive flange to press.
24. Fit a universal bearing splitter to bearing as
shown.
25. Fit thrust button, tool 18G 705-6/2 to drive
flange and press out drive flange from inner
track.
26. Collect drive flange and remove bearing inner
track.
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REAR SUSPENSION
REPAIRS 5
Refit
1. Clean hub and bearing mating faces.
2. Fit new bearing outer circlip to hub.
4. Position new bearing to hub, press bearing into
hub using 18G-705-6/3 .
5. Fit new bearing inner circlip to hub.
6. Clean drive flange to bearing mating faces.
7. Using tools 18G 134BD and 18G 18 705-6/3
press drive flange into hub.
10. Fit hub to drive shaft.
11. Clean upper arm ball joint and mating face.
new lock nut and tighten to 54Nm.
13. Align lower link to rear hub, fit bolt but do not
14. Clean track control arm ball joint and mating
face.
arm to rear hub.
16. Engage track control arm ball joint to hub, fit
nut and tighten to 38 Nm.
19. Position ABS sensor lead to hub, fit new bolt
20. Fit rear brake disc. See BRAKES, Repairs.
21. With assistance tighten new drive shaft nut to
210 Nm.
22. Stake drive shaft nut to shaft.
suspension, tighten bolt securing lower link to
rear hub to 100 Nm.
DAMPER - RH
Remove
body, position expansion tank aside.
turret.
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REAR SUSPENSION
6 REPAIRS
7. Remove nut from RH damper retaining bolt
securing ABS lead support bracket and release
bracket.
9. Position damper/spring assembly in vice.
10. Progressively loosen and remove spring
retainer nut, remove distance piece, flat
washer, steel cup washer and spring retainer.
Note fitted position of steel cup washer.
11. Remove spring, dust shield and rebound
rubber bush from damper.
12. Remove damper from vice.
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REAR SUSPENSION
REPAIRS 7
Refit
1. Prime new damper by operating it at least 3 full
strokes.
2. Position new damper in vice.
3. Position rebound rubber bush on damper shaft.
4. Correctly position spring and dust shield onto
damper.
5. Correctly position spring retainer, steel cup
washer, flat washer and distance piece. Fit and
tighten nut securing spring retainer to damper
to 25 Nm.
6. Correctly position spring isolator, ensure
locating tag is located through front hole in
subframe turret.
at this stage.
10. Position ABS harness support bracket, fit and
tighten nut to 30 Nm.
11. Position expansion tank, fit and tighten bolts to
8 Nm.
ENGINE, Repairs.
ANTI-ROLL BAR - REAR
Remove
links to LH and RH trailing arms.
NOTE: Fitted position of Iink retaining nuts
and boIts and anti-roII bar to Iink.
5. Remove 2 nuts securing each anti-roll bar
mounting rubber clamp to subframe, remove
clamps and anti-roll bar.
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REAR SUSPENSION
8 REPAIRS
CAUTION: The rear anti-roII bar is handed,
the Ietter 'R' denotes RH side of
suspension.
6. Remove 2 mounting rubbers from anti-roll bar.
links to anti-roll bar.
8. Check anti-roll bar link bushes for wear.
Refit
1. Clean anti-roll bar and anti-roll bar links.
2. Correctly position links to anti-roll bar, fit bolts
and nuts but do not tighten at this stage.
4. Correctly position anti-roll bar, align anti-roll bar
links to LH and RH trailing arms. Fit bolts and
nuts but do not tighten at this stage.
5. Position mounting rubbers, fit clamps, fit and
bolts to 35 Nm.
LINK - ANTI-ROLL BAR
Remove
to anti-roll bar.
NOTE: Note fitted position of Iink retaining
nuts and boIts and anti-roII bar to Iink.
to trailing arm and remove link.
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REAR SUSPENSION
REPAIRS 9
Refit
1. Clean anti-roll bar link.
2. Correctly position anti-roll bar link to trailing
arm, fit bolt and nut but do not tighten at this
stage.
3. Correctly position anti-roll bar to anti-roll bar
link, fit bolt and nut but do not tighten at this
stage.
bolts to 35 Nm.
LOWER LINK - REAR
Remove
3. Remove lower link access grommet from
subframe.
4. Remove 2 bolts securing lower link to
subframe and rear hub.
5. Remove lower link assembly.
6. Collect lower link bush spacer.
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REAR SUSPENSION
10 REPAIRS
Refit
1. Position lower link to subframe and rear hub.
2. Fit lower link bush spacer.
3. With the weight of the vehicle on the
suspension, tighten lower link to subframe bolt
to 85 Nm and lower link to rear hub bolt to
100 Nm.
TRACK CONTROL ARM
Remove
3. Remove nut securing track control arm ball
joint to rear hub.
18G 1584 , release ball joint taper from rear
hub. Remove slave nut.
5. Remove torx bolt securing track control arm to
subframe and remove track control arm.
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REAR SUSPENSION
REPAIRS 11
Refit
1. Clean ball joint taper, track control arm and
subframe mating faces.
2. Position track control arm to subframe and rear
hub.
3. Fit and tighten torx bolt securing track control
arm to rear subframe to 60 Nm.
4. Fit and tighten nut securing track control arm to
rear hub to 38 Nm.
7. Check rear wheel alignment. See STEERING,
Adjustments.
TRAILING ARM
Remove
3. Remove wheel arch access panel (RH side
only).
trailing arm compliance bush.
hub.
6. Manoeuvre trailing arm from vehicle.
Refit
1. Clean mating faces of trailing arm and trailing
arm bushes.
arm to rear hub.
3. Manoeuvre trailing arm into position.
6. Ft nut and bolt securing trailing arm to trailing
arm compliance bush and tighten to 100 Nm.
8. Fit wheel arch access panel and secure with
screws (RH side only).
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REAR SUSPENSION
12 REPAIRS
BUSH - TRAILING ARM
Remove
2. Raise vehicle on a 2 post ramp.
4. Remove rear silencer heat shield. See
5. Remove trailing arm. See this section.
6. Remove 2 bolts securing brake caliper to hub.
Release caliper from hub and tie aside.
brake hose.
7. Loosen 2 bolts securing rear of buttress to
subframe.
8. Remove 2 bolts securing front of buttress to
subframe.
9. Remove 4 nuts securing anti-roll bar mounting
clamps to both rear subframe mountings and
collect clamps.
10. Support subframe with trolley jack.
11. Remove 2 bolts securing front subframe
mounting to body.
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REAR SUSPENSION
REPAIRS 13
12. Remove 3 bolts securing rear subframe
mounting to body.
13. Carefully lower subframe on trolley jack until
sufficient room is gained to remove the trailing
arm bush.
14. Support the weight of the gearbox and raise
sufficiently to release trailing arm bush from the
buttress.
components, cushion the jack pad with a
bIock of wood or hard rubber.
15. Release trailing arm bush from subframe and
remove trailing arm bush.
NOTE: If traiIing arm bush mounting
incIudes a separate snubber pIate this
must be retained and refitted in the same
orientation as orignaIIy fitted.
Refit
1. Position trailing arm bush to subframe and
align to buttress, fit bolts securing buttress, but
2. Remove gearbox support.
3. Raise subframe on trolley jack, fit and tighten
bolts securing rear subframe mounting to body
to 45 Nm.
4. Position anti-roll bar, fit clamps, fit and tighten
nuts to 22 Nm.
5. Fit and tighten bolts securing front subframe
6. Tighten buttress bolts to 45 Nm.
7. Fit trailing arm. See this section.
8. Clean mating faces of caliper and hub.
9. Position caliper to hub, fit and tighten bolts to
85 Nm.
BUSH - TRAILING ARM TO HUB
Remove
3. Remove trailing arm. See this section.
4. Note the fitted position of trailing arm bushes.
5. Using tool 64R032 with adaptor 64R032/3
remove trailing arm bushes.
Refit
1. Clean trailing arm bushes and bush recesses.
2. Ensure correct orientation of trailing arm
bushes.
3. Using tool 64R032 with adaptor 64R032/4 fit
trailing arm bushes.
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REAR SUSPENSION
14 REPAIRS
4. Fit trailing arm. See this section.
BUSH - ARM ASSEMBLY - UPPER
Remove
3. Remove upper suspension arm. See this
section.
4. Position upper suspension arm in vice.
5. Note the fitted position of upper arm bush.
6. Using 64R031 remove upper arm bush.
Refit
1. Clean upper arm bush and bush mating face.
2. Ensure correct orientation of upper arm bush.
3. Using 64R031 fit upper arm bush.
4. Remove upper arm assembly from vice.
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REAR SUSPENSION
REPAIRS 15
5. Fit upper suspension arm. See this section.
ARM ASSEMBLY - UPPER
Remove
3. Remove nut and bolt securing damper to upper
suspension arm.
4. Release ABS sensor harness bracket.
18G-1584, release ball joint taper from upper
suspension arm. Remove slave nut.
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REAR SUSPENSION
16 REPAIRS
7. Remove nut and bolt securing upper arm to
subframe.
8. Noting the position of spacers, remove upper
arm and spacers.
Refit
1. Clean upper arm bolt, spacers and upper arm
and subframe mating faces,
2. Position upper arm and spacers. Ensure top
hat spacer is fitted correctly.
3. Fit nut and bolt securing upper arm, do not
new lock nut and tighten nut to 54 Nm.
5. Align damper to upper arm, fit bolt and tighten
to 100 Nm.
6. Align ABS harness bracket fit nut and tighten to
30 Nm.
suspension, tighten upper arm bolt to 100 Nm.
SUB FRAME - REAR SUSPENSION - MANUAL
TRANSMISSION MODELS
Remove
ENGINE, Repairs.
2. Collect LH trailing arm bush.
3. Remove 4 bolts securing RH buttress to
subframe, remove buttress and trailing arm
bush.
turret.
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REAR SUSPENSION
REPAIRS 17
7. Remove nut and bolt securing upper arm to
subframe.
8. Noting the position of spacers, remove upper
arm and spacers.
9. Remove torx bolt securing track control arm to
subframe and remove track control arm.
10. Remove access grommet and remove bolt
securing lower link to subframe.
11. Noting the fitted position remove lower link.
12. Collect lower link bush spacer.
suspension.
14. Remove nut and bolt securing front mounting
to subframe and collect mounting.
15. Remove nut and bolt securing rear mounting to
subframe and collect mounting.
suspension.
17. Remove bolt securing rear engine mounting
tie-rod to subframe and collect tie-rod.
18. Remove exhaust mounting rubber from
subframe.
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REAR SUSPENSION
18 REPAIRS
Refit
1. Fit exhaust mounting rubber to subframe.
2. Position LH and RH front mountings to
100 Nm.
3. Position LH and RH rear mountings to
100 Nm.
4. Position rear engine mounting tie-rod to
subframe,fit and tighten bolt to 85 Nm.
5. Position RH buttress and trailing arm bush to
subframe, fit and tighten bolts to 45 Nm.
6. Ensuring correct orientation, position lower link
and lower link bush spacer, fit bolt but do not
7. Position upper arm and spacers. Ensure top
hat spacer is fitted correctly.
8. Fit nut and bolt securing upper arm, do not
9. Correctly position spring isolator, ensure
locating tag is located through front hole in
subframe turret.
at this stage.
13. Position RH track control arm to subframe, fit
and tighten torx bolt to 60 Nm.
suspension.
15. Position LH trailing arm bush.
ENGINE, Repairs.
suspension tighten lower link to subframe bolt
to 85 Nm.
suspension tighten upper arm bolt to 100 Nm.
20. Check rear wheel alignment. See STEERING,
Adjustments.
REAR SUB FRAME - LH - FRONT MOUNTING
Remove
3. Remove rear silencer heat shield. See
brake hose.
6. Remove nut from front subframe mounting
centre bolt.
7. Remove 2 bolts securing front subframe
mounting to body.
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REAR SUSPENSION
REPAIRS 19
8. Remove 4 nuts securing anti-roll bar mounting
clamps to both rear subframe mountings and
collect clamps.
mounting to body.
10. Carefully lower subframe on trolley jack until
sufficient room is gained to remove centre bolt
and front subframe mounting.
Refit
1. Position mounting and centre bolt to subframe,
fit nut but do not tighten at this stage.
2. Raise subframe on trolley jack, fit and tighten
bolts securing rear subframe mounting to body
to 45 Nm.
3. Position anti-roll bar, fit clamps, fit and tighten
nuts to 22 Nm.
4. Fit and tighten bolts securing front subframe
5. Tighten front subframe mounting centre nut
and bolt to 100 Nm.
85 Nm.
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REAR SUSPENSION
20 REPAIRS
REAR SUB FRAME - LH - REAR MOUNTING
Remove
3. Remove 2 nuts securing anti-roll bar clamp to
subframe, remove clamp and rubber mounting.
5. Remove centre nut securing rear subframe
mounting to subframe.
mounting to body.
7. Carefully lower subframe on trolley jack,
remove centre bolt and rear subframe
mounting.
Refit
1. Position mounting to subframe, fit centre bolt,
fit nut but do not tighten at this stage.
3. Fit and loosely tighten one bolt each side of
rear subframe mounting to hold mounting in
position. DO NOT fit anti-roll bar bracket at this
stage.
4. Tighten centre bolt and nut to 100 Nm.
5. Remove bolts holding rear subframe mounting
in position.
6. Position anti-roll bar bracket to subframe, fit
and tighten rear suspension mounting to body
bolts to 45 Nm.
7. Position mounting rubber and clamp to anti-roll
bar, fit and tighten nuts to 22 Nm.
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BRAKES
CONTENTS Page
MASTER CYLNDER COMPONENTS 1 .....................................................................
FRONT BRAKE CALPER COMPONENTS 2 .............................................................
REAR BRAKE CALPER COMPONENTS 3 ................................................................
ABS ANT-LOCK BRAKNG SYSTEM 4 ......................................................................
HANDBRAKE OPERATON 7 .....................................................................................
ADJUSTMENTS
FRONT BRAKE DSC - STANDARD - CHECK THCKNESS AND RUN-OUT 1 .........
FRONT BRAKE DSC - SPORTS - CHECK THCKNESS AND RUN-OUT 2 ..............
REAR BRAKE DSC - CHECK 4 .................................................................................
BRAKE SYSTEM - BLEED - STANDARD 5 ................................................................
BRAKE SYSTEM - BLEED - SPORTS 6 .....................................................................
HANDBRAKE - ADJUST 8 ..........................................................................................
BRAKE LGHT SWTCH - ADJUST 9 ..........................................................................
REPAIRS
FRONT BRAKE DSC - STANDARD 1 ........................................................................
FRONT BRAKE DSC - SPORTS 2 .............................................................................
REAR BRAKE DSC 3 .................................................................................................
FLUD LEVEL SWTCH 4 ............................................................................................
ABS HYDRAULC MODULATOR 4 .............................................................................
BRAKE PROPORTONNG VALVE 5 ..........................................................................
ABS SENSOR - FRONT WHEEL 6 .............................................................................
ABS SENSOR - REAR WHEEL 7 ................................................................................
PEDAL BOX ASSEMBLY 8 .........................................................................................
BRAKE MASTER CYLNDER 9 ...................................................................................
HANDBRAKE LEVER 10 .............................................................................................
HANDBRAKE CABLES 10 ..........................................................................................
HANDBRAKE WARNNG SWTCH 13 ........................................................................
BRAKE LGHT SWTCH 14 .........................................................................................
BRAKE PADS - FRONT - STANDARD 14 ..................................................................
BRAKE PADS - FRONT - SPORTS 15 .......................................................................
BRAKE PADS - REAR 16 ............................................................................................
BRAKE SERVO 17 ......................................................................................................
BRAKE CALPER HOUSNG - FRONT - STANDARD 19 ...........................................
BRAKE CALPER CARRER - FRONT - STANDARD 20 ............................................
BRAKE CALPER HOUSNG - FRONT - SPORTS 21 ................................................
HOSE - FRONT - PRMARY - LH 22 ...........................................................................
HOSE - REAR 23 .........................................................................................................
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BRAKES
MASTER CYLINDER COMPONENTS
1. Brake fluid reservoir
2. Seals
3. Cylinder body
4. Spring
5. Secondary plunger assembly
6. Stop pin secondary plunger
7. Pin securing screw
8. Spring
9. Primary plunger assembly
10. Washer
11. Circlip
12. Flat washer
13. Transfer housing
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BRAKES
FRONT BRAKE CALIPER COMPONENTS
Standard calipers shown, Sports version similar
1. Caliper body
2. Hose banjo bolt
3. Hose banjo washer
4. Bleed screw
5. Guide pin bolt
6. Brake pad
7. Piston seal
8. Piston
9. Dust cover
10. Guide pin
11. Boot
12. Caliper carrier
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BRAKES
REAR BRAKE CALIPER COMPONENTS
1. Caliper body
2. Bleed screw
3. Piston seal
4. Piston
5. Dust cover
6. Shim
7. Brake pad
8. Caliper carrier
9. Guide pin bolt
10. Guide pin
11. Boot
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BRAKES
ABS ANTI-LOCK BRAKING SYSTEM
1. ABS modulator unit
2. Electronic control unit
3. Master cylinder
4. Brake pressure proportioning valve
5. Brake pedal
6. Servo unit
7. Brake caliper
Description
The ABS system is an electronic control unit (ECU),
controlled system deriving its input from four speed
sensors, one mounted at each wheel, which allow
the ABS to control the hydraulic modulator to
prevent the wheels locking during braking.
The operation of the ABS is completely dependent
upon electronic signals. To prevent the ABS
responding to any inaccurate signals, a built in
safety circuit monitors all electric and electronic
signals, including battery voltage. f an inaccurate
signal or low battery voltage is detected, the ABS is
shut down immediately and the warning light on the
fascia is illuminated to inform the driver that the
brake system will respond to pedal pressure in the
same manner as a non ABS.
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BRAKES
Operation
Servo
nlet manifold vacuum is transmitted through a hose
and non-return valve to the servo. nside the servo,
this vacuum is felt on both sides of the diaphragm.
When the brake pedal is pressed, the servo push
rod opens a valve and allows atmospheric pressure
to be drawn through the filter into the pedal side of
the diaphragm. The pressure differential, acting on
the diaphragm, increases the pressure being applied
at the brake pedal and transmits it to the master
cylinder through a push rod.
Master cylinder
When the foot brake is applied the primary plunger
moves up the bore of the cylinder and the pressure
created acts in conjunction with the primary spring to
overcome the secondary spring, thus moving the
secondary plunger up the bore of the cylinder
simultaneously. nitial movement of both plungers
causes them to be pushed off their stop pins, thus
closing both primary and secondary centre valves.
Further movement of the plungers pressurises the
fluid which is directed into the two separate hydraulic
circuits connected to the hydraulic modulator.
The primary circuit operates the front brakes and the
secondary circuit operates the rear brakes.
The fluid in the chambers behind the plungers is
unaffected by any movement of the plungers and
can flow unrestricted between chamber and
reservoir both before and during brake application.
When the brake pedal is released, the primary and
secondary springs force their respective pistons
back down the bore of the cylinder. As the plungers
contact the stop pins the primary and secondary
centre valves are opened allowing fluid to circulate
unrestricted between the two hydraulic circuits and
the fluid reservoir.
The movement of fluid during brake
application/release is compensated for by fluid from
the separate reservoirs within the supply tank
moving through the feed holes in the cylinder.
Conversely the final movement of the plungers
causes any surplus fluid to move through the cut-off
holes in the fluid reservoirs.
Should a failure occur in one system, the remaining
system will still operate effectively, although the
brake pedal travel will increase.
Calipers
Pressure at the caliper forces the caliper piston
against the inner brake pad and, in turn, against the
disc. The caliper body reacts and slides on the guide
pins to bring the outer pad into contact with the disc.
Modulator operation
Type: ABS 5.3
For information on the electrical operation of ABS
5.3 See ELECTRICAL REFERENCE LIBRARY,
Description and Operation.
With the vehicle in motion, the ECU receives signals
from the four wheel sensors. From these signals the
ECU can determine the speed of the vehicle. This is
the speed which the ECU uses as a reference when
evaluating the deceleration of each wheel.
This reference speed is continually calculated, even
during braking. f one or more of the wheels are
decelerating faster than the others, indicating a
wheel is near the point of locking, the anti-lock
sequence will be initiated.
The hydraulic modulator has three operation
phases:
1. ncrease pressure phase: The ABS system is
at rest and fluid pressure from the master
cylinder is allowed to pass through the solenoid
valves in the hydraulic modulator to operate
the caliper on each wheel.
2. Maintain pressure phase: The caliper is
isolated from the master cylinder preventing
any pressure increase due to increased pedal
pressure.
3. Decrease pressure phase: The caliper is
connected to the return pump which pumps the
fluid back to the master cylinder.
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BRAKES
Brake pressure proportioning vaIve
The fluid line for the rear brake circuit is connected
to the proportioning valve. The circuit for the front
brakes uses a separate three way connector for
distribution.
Pressure to the rear brakes passes through a piston
sleeve, past a poppet valve and out to the rear
brakes. The same pressure is also felt on the top of
the piston, forcing the piston against spring
pressure, towards the valve centre until the piston
sleeve contacts the poppet valve and forms a seal.
nput pressure is now balanced with output
pressure. As further input pressure is applied from
the master cylinder, it overcomes output pressure
being felt on the piston and forces the piston
outwards slightly away from the poppet valve
allowing pressure past the poppet valve until output
pressure is again balanced with input pressure.
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BRAKES
HANDBRAKE OPERATION
1. Handbrake lever
2. Compensator spring
3. Compensator
4. Lever to compensator, retainer
5. Adjuster nut
6. Handbrake cable, abutment bracket
7. Handbrake cable, RH
8. Handbrake cable, LH
9. Plunger
10. Push rod
11. Spring
12. Cone seating
13. Piston
14. Brake pads
15. Adjuster nut
16. Push rod thread
17. Caliper lever
The handbrake operates on both rear discs via two
rear cables, compensator and an intermediate rod
which connects to the handbrake lever.
As the handbrake lever is applied, movement is
transmitted through the intermediate rod to the
compensator which, in turn, transmits movement to
the two rear cables. Each rear cable pulls on a lever
on a rear caliper.
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BRAKES
Rotational movement of the caliper lever is changed
to linear movement by a plunger which is forced out
of its location by its inclined seating. The plunger
contacts the push rod which, in turn, pushes the
piston down its bore and forces the brake pads into
contact with the disc.
Automatic adjustment of the disc brake pads is
maintained by operation of the foot brake. With the
brake pedal released, the piston is stationary in its
bore and the adjuster nut is held against a cone
seating inside the piston by the compression ring.
When the brake pedal is pressed, fluid pressure
forces the piston down its bore and the compression
spring causes the adjuster nut to follow. nitially the
nut remains against its cone seating and just takes
up the clearance between the push rod and its own
thread, and if piston movement is within this
tolerance no automatic adjustment takes place.
Further movement of the piston moves the cone
seating away from the adjuster nut. This allows the
compression spring to rotate the adjuster nut along
the push rod thread until it again contacts the cone
seating.
This extending action of the push rod assembly
maintains adjustment of the handbrake mechanism.
When fluid pressure is released, the piston moves
back and re-establishes the clearance between the
push rod thread and the adjuster nut thread.
Manual adjustment of the handbrake cables is
effected via the adjusting nut on the threaded
intermediate rod bearing upon the compensator.
See Adjustments.
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BRAKES
ADJUSTMENTS 1
FRONT BRAKE DISC - STANDARD - CHECK
THICKNESS AND RUN-OUT
4. Release caliper from disc. Tie caliper clear of
brake disc, ensuring that weight of caliper is
supported.
brake hose as weight of caIiper may
damage hose.
5. At 4 points around disc, measure disc
thickness using a micrometer; renew disc if
less than service limit or if maximum variation
is exceeded:
Disc thickness, new = 22.00 mm.
Service limit = 20.00 mm.
Thickness variation, maximum = 0.015 mm.
NOTE: Maximum variation Iimit:
Both brake discs must be renewed at the
same time, unIess one disc requires
changing at 1000 miIe service. OnIy in this
situation is renewaI of one disc permissibIe.
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BRAKES
2 ADJUSTMENTS
6. Position a suitable spacer to each wheel stud
and secure brake disc using wheel nuts.
Tighten wheel nuts in a diagonal sequence to
70 Nm.
7. Secure and position dial test indicator probe
6 mm from outer edge of brake disc. Zero dial
test indicator, rotate brake disc one complete
turn to measure disc run-out.
Disc run-out limit = 0.05 mm.
8. f run-out exceeds limit, mark disc to show
position on drive flange; remove 2 screws
retaining disc, remove disc and refit after
rotating 180 . Tighten disc securing screws to
7 Nm and re-check disc run-out.
9. Renew disc if run-out exceeds limit even after
re-positioning of disc on drive flange.
10. Untie caliper and support caliper weight.
11. Align caliper carrier to hub ensuring correct
positioning of brake pads. Fit and tighten bolts
to 85 Nm.
12. Apply foot brake several times to enable brake
pads to position correctly.
13. Remove wheel nuts and spacers. Fit road
wheel(s), fit wheel nuts and tighten in a
FRONT BRAKE DISC - SPORTS - CHECK
THICKNESS AND RUN-OUT
2. Check brake disc run-out. See SUSPENSION,
Adjustments.
brake hose.
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BRAKES
ADJUSTMENTS 3
less than service limit:
70 Nm.
7. f run-out exceeds limit, mark disc to drive
flange location; remove wheel nuts, spacers
and disc retaining screws. Remove disc, rotate
180 ; refit disc to drive flange. Fit and tighten
disc retaining screws to 7 Nm, fit spacers and
wheel nuts and tighten wheel nuts in a
CAUTION: Brake discs must be renewed
in pairs, unIess one disc requires
changing before 1000 miIes
(1500 kiIometeres) from new.
9. Untie caliper, position caliper to hub, fit and
10. Remove wheel nuts and spacers.
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BRAKES
4 ADJUSTMENTS
REAR BRAKE DISC - CHECK
brake disc, ensuring that weight of caliper is
supported.
damage hose.
less than service limit or if maximum variation
is exceeded:
Thickness variation, maximum = 0.015 mm.
NOTE: Maximum variation Iimit:
Both brake discs must be renewed at the
same time, unIess one disc requires
changing at 1000 miIe service. OnIy in this
situation is renewaI of one disc permissibIe.
70 Nm.
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BRAKES
ADJUSTMENTS 5
8. f run-out exceeds limit, mark disc to show
position on drive flange; remove 2 screws
retaining disc, remove disc and refit after
rotating 180 . Tighten disc securing screws to
7 Nm and re-check disc run-out.
10. Untie caliper and support caliper weight.
11. Align caliper carrier to hub ensuring correct
positioning of brake pads. Fit and tighten bolts
to 85 Nm.
13. Remove wheel nuts and spacers.
BRAKE SYSTEM - BLEED - STANDARD
The following procedure covers bleeding the
complete system but where only the primary or
secondary circuit have been disturbed, partial
bleeding is permissible if a brake pipe or hose has
been disconnected with only minor loss of fluid.
bIed from the system.
Never re-use fIuid that has been bIed from the
brake system.
Do not aIIow fIuid IeveI in master cyIinder to
faII beIow 'MIN' IeveI during bIeeding.
Do not fiII reservoir above 'MAX' IeveI.
1. Raise front and rear of vehicle.
2. Check all pipe and hose connections are tight
and there are no signs of leakage.
3. Top-up fluid level in brake reservoir to 'MAX'
mark. See INFORMATION, Capacities, fluids
and lubricants.
CAUTION: Use onIy NEW brake fIuid of the
recommended grade.
Bleed sequence - non ABS and ABS systems:
LH rear to RH rear
RH front to LH front
sequence is used.
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BRAKES
6 ADJUSTMENTS
4. Attach bleed tube to LH rear brake caliper
bleed screw, submerge free end in brake fluid
in a clear container.
5. Apply pressure to brake pedal several times,
then apply steady pressure.
6. Loosen bleed screw to release brake fluid and
air. Allow pedal to return unassisted.
7. Depress brake pedal steadily through its full
stroke and allow to return unassisted. Repeat
procedure until a flow of clean air-free fluid is
purged into container then, whilst holding pedal
at end of downward stroke, tighten bleed screw
to 10 Nm.
CAUTION: Maintain brake fIuid IeveI above
'MIN' mark during this procedure.
8. Top-up brake fluid level.
9. Repeat procedure at each wheel in the
sequence shown.
sequence is used.
10. Remove bleed tube. Apply brakes and check
for leakage.
12. Road test vehicle. Check brake pedal for short
firm travel when brakes are applied.
BRAKE SYSTEM - BLEED - SPORTS
The following procedure covers bleeding the
complete system but where only the primary or
secondary circuit have been disturbed in isolation, it
should only be necessary to bleed that system.
Partial bleeding of the hydraulic system is only
permissible if a brake pipe or hose has been
disconnected with only minor loss of fluid.
bIed from the system.
1. Raise front and rear of vehicle.
2. Check all pipe and hose connections are tight
and there are no signs of leakage.
3. Top-up brake fluid level to 'MAX' mark.
CAUTION: OnIy use new brake fIuid of the
recommended grade. See INFORMATION,
Bleed sequence - ABS systems with "Sports" front
brake calipers fitted:
LH rear to RH rear
RH front to LH front
NOTE: Two bIeed screws are fitted on
each brake caIiper. When bIeeding the
brake system, bIeed the outer bIeed screw
foIIowed by the inner bIeed screw in the same
sequence as shown above.
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BRAKES
ADJUSTMENTS 7
seriousIy impaired if the wrong bIeed
sequence is used.
4. Clean area around bleed screws and remove
dust seals.
5. Attach bleed tube to LH rear brake caliper
bleed screw, submerge free end of tube in
brake fluid in a clear container.
6. Apply pressure to brake pedal several times,
then apply steady pressure.
7. Loosen bleed screw to release brake fluid and
air. Allow pedal to return unassisted.
8. Depress brake pedal steadily through its full
stroke and allow to return unassisted. Repeat
procedure until a flow of clean air-free fluid is
purged into container then, whilst holding brake
pedal at end of downward stroke, tighten bleed
screw to 10 Nm.
CAUTION: Maintain brake fIuid IeveI above
'MIN' mark during this procedure.
9. Top-up brake fluid level.
10. Repeat procedure at each wheel in the
sequence shown.
sequence is used.
11. Remove bleed tube from bleed screw and fit
bleed screw dust cap.
12. Apply brakes and check for leakage.
13. Road test vehicle. Check brake pedal for short
firm travel when brakes are applied.
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BRAKES
8 ADJUSTMENTS
HANDBRAKE - ADJUST
Adjust
2. Remove front console storage bin.
NOTE: Depress brake pedaI severaI times
to ensure that automatic adjustment
cIearance is taken up.
3. Tighten adjuster nut
1
/
2
turn and check caliper
lever clearance.
CAUTION: Do not depress brake pedaI
untiI caIiper adjustment cIearance is
correct.
4. Repeat adjustment until caliper lever
clearances are between 1 & 2 mm each side.
5. Fit storage bin.
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BRAKES
ADJUSTMENTS 9
BRAKE LIGHT SWITCH - ADJUST
Adjust
1. Depress and hold brake pedal.
2. Reset switch by pulling plunger.
3. Release brake pedal to set switch adjustment.
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BRAKES
REPAIRS 1
FRONT BRAKE DISC - STANDARD
Remove
4. Move caliper aside. Tie caliper clear of brake
disc, ensuring that weight of caliper is
supported.
damage hose.
5. Remove 2 screws securing brake disc to drive
flange.
6. Remove brake disc.
Refit
CAUTION: Brake discs must be repIaced
in pairs.
1. Wire brush drive flange to remove all corrosion
deposits. Clean new brake disc.
2. Fit brake disc to drive flange, fit screws and
tighten to 7 Nm.
3. Check disc run-out. See Adjustments.
4. Examine brake pads and renew if necessary.
5. Fit brake caliper to hub, fit and tighten bolts to
85 Nm .
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BRAKES
2 REPAIRS
FRONT BRAKE DISC - SPORTS
Remove
3. Remove 2 bolts securing brake caliper
assembly to hub.
4. Remove caliper assembly from hub and tie
aside.
brake hose.
flange.
changing before 1000 miIes (1500
kiIometres) from new.
Refit
2. Fit brake disc to drive flange, fit screws and
tighten to 7 Nm.
4. Check brake disc run-out. See Adjustments.
5. Position brake caliper to hub, fit and tighten
bolts to 85 Nm.
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BRAKES
REPAIRS 3
REAR BRAKE DISC
Remove
3. Remove 2 bolts securing caliper assembly to
hub.
brake disc, ensuring the weight of the caliper is
supported.
brake hose.
flange.
Refit
changing before 1000 miIes (1500
kiIometers) from new.
2. Fit brake disc to drive flange. Tighten screws to
7 Nm.
3. Check brake disc runout. See Adjustments.
5. Untie caliper, position caliper to hub, fit and
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BRAKES
4 REPAIRS
FLUID LEVEL SWITCH
Remove
1. Disconnect switch multiplug.
2. Clean area around reservoir cap.
3. Remove cap/switch assembly.
Refit
1. Check and top-up fluid level.
2. Fit cap/switch assembly.
3. Connect switch multiplug.
ABS HYDRAULIC MODULATOR
Remove
2. Position cloth under modulator to absorb brake
fluid.
3. Release clip securing ABS modulator multiplug
and disconnect multiplug.
4. Disconnect 2 inlet brake pipe unions from top
of modulator.
5. Disconnect 3 outlet brake pipe unions from
modulator.
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BRAKES
REPAIRS 5
6. Loosen 2 nuts securing modulator to mounting
bracket.
7. Release modulator from mounting bracket and
remove modulator.
Refit
1. Remove 2 mounting rubbers and studs from
modulator.
2. Fit mounting rubbers and studs to new
modulator.
3. Fit modulator to mounting bracket and tighten
mounting nuts to 10 Nm.
4. Connect brake pipe unions to modulator,
ensuring pipes are connected to their correct
ports as follows:
MC 1 = Master cyIinder primary
MC 2 = Master cyIinder secondary
RF = Right hand front
LF = Left hand front
R = Right & Left hand rear
5. Connect multiplug to modulator and secure
clip.
6. Bleed brakes. See Adjustments.
BRAKE PROPORTIONING VALVE
Remove
2. Release 2 brake pipe unions and position
pipes aside.
3. Remove 2 bolts securing valve to body.
4. Remove valve.
Refit
1. Fit valve to body and tighten bolts to 10 Nm.
2. Align unions to valve and tighten to 14 Nm.
3. Bleed rear brakes. See Adjustments.
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BRAKES
6 REPAIRS
ABS SENSOR - FRONT WHEEL
Remove
4. Disconnect ABS sensor lead from main
harness.
5. Release ABS sensor lead from clips on
subframe turret.
6. Remove bolt securing ABS sensor to hub.
7. Remove ABS sensor and spacer from hub.
Refit
1. Fit ABS sensor and spacer to hub and tighten
bolt to 10 Nm.
2. Fit ABS sensor lead to clips on subframe turret.
3. Connect ABS sensor lead to main harness.
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BRAKES
REPAIRS 7
ABS SENSOR - REAR WHEEL
Remove
5. Disconnect ABS sensor lead from main
harness.
6. Release ABS sensor lead from clips on
subframe turret.
7. Remove bolt securing ABS sensor to hub.
8. Remove ABS sensor and spacer from hub.
Refit
1. Fit ABS sensor and spacer to hub and tighten
bolt to 10 Nm.
2. Fit ABS sensor lead to clips on suspension
turret.
3. Connect ABS sensor lead to main harness.
4. Connect battery earth lead.Fit road wheel(s), fit
wheel nuts and tighten in a diagonal sequence
to 70 Nm.
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BRAKES
8 REPAIRS
PEDAL BOX ASSEMBLY
Remove
1. Remove bulkhead closing panel. See BODY,
Repairs.
2. Remove 2 nuts and 1 bolt securing throttle
pedal. Release pedal and position aside.
3. Release brake light switch and position aside.
4. Remove clip securing brake pedal push rod
clevis pin and remove clevis pin.
5. With assistance, remove 3 nuts and bolts and
4 bolts securing pedal box assembly.
6. Manoeuvre pedal box assembly over steering
column and remove assembly.
7. Remove nut securing end bracket and remove
end bracket and pedal.
8. Remove return spring circlip and return spring
from pivot shaft.
Refit
1. Position return spring on pivot shaft and secure
with circlip.
2. Examine pedal bushes for wear or damage
and replace as required.
3. Position pedal and end bracket, fit nut and
tighten to 22 Nm.
4. Position pedal box assembly, manoeuvre over
steering column and align to bulkhead.
5. Fit and tighten nuts and bolts securing pedal
box assembly to 22 Nm.
6. Align brake pedal push rod, fit clevis pin and
secure with clip.
7. Position brake light switch and secure in end
bracket.
8. Position throttle pedal, fit nuts and tighten
to 6 Nm.
9. Fit bulkhead closing panel. See BODY,
Repairs.
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BRAKES
REPAIRS 9
BRAKE MASTER CYLINDER
Remove
1. Remove underbonnet closing panel. See
2. Disconnect fluid level switch.
3. Position cloth under master cylinder to absorb
spilled fluid.
4. Disconnect pipe unions at master cylinder.
5. Remove 2 nuts and plain washers securing
master cylinder to brake servo.
6. Remove master cylinder.
7. Collect and discard 'O' ring.
Refit
1. Clean master cylinder and servo mating
surfaces.
2. Fit new 'O' ring to master cylinder.
3. Align servo push rod and fit master cylinder to
servo.
4. Secure master cylinder with nuts and plain
washers. Tighten to 20 Nm.
5. Connect primary and secondary brake pipes,
tighten unions to 15 Nm.
6. Connect fluid level switch.
7. Bleed brake system. See Adjustments.
Exterior fittings.
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BRAKES
10 REPAIRS
HANDBRAKE LEVER
Remove
trim components.
2. Loosen cable adjuster nut and disconnect 2
cables from compensator.
3. Remove 2 bolts securing lever to body.
4. Disconnect Lucar from switch and remove
handbrake lever.
Refit
1. Connect Lucar to switch.
2. Position handbrake lever to body, fit and
3. Connect cables to compensator.
4. Adjust handbrake cables. See Adjustments.
components.
HANDBRAKE CABLES
NOTE: Handbrake cabIes have coIour
coded identification bands:
PurpIe - RH, Orange - LH.
WARNING: See GENERAL INFORMATION,
SRS Precautions.
Remove
2. Make the SRS system safe. See GENERAL
INFORMATION, SRS Precautions.
5. Release handbrake to off position.
6. Remove and discard 2 'R' clips, and remove 2
clevis pins securing handbrake cables to rear
calipers.
7. Remove and discard 2 clips securing
handbrake cable abutments to caliper brackets
and release cables.
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BRAKES
REPAIRS 11
8. Release air intake duct from subframe clip and
position duct aside.
9. Remove 2 bolts securing each handbrake
cable to luggage compartment bulkhead.
10. Release handbrake cables from air cleaner
mounting bracket.
sump.
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BRAKES
12 REPAIRS
13. Remove 2 bolts securing both front subframe
mountings to body brackets.
plate bolts.
CAUTION: Care must be taken that no
cabIes or pipes are stretched when
Iowering front of subframe.
15. Tie coolant pipes aside to allow access to
closing plate.
16. Release 2 upper and remove 3 remaining bolts
securing closing plate to bulkhead.
17. Apply soft soap to all four closing plate cables,
to ease movement of closing plate.
along cables.
19. Noting their fitted positions release 2
handbrake cable grommets from closing plate.
trim components.
21. Remove 2 bolts securing handbrake abutment
clamp to tunnel and remove clamp.
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BRAKES
REPAIRS 13
22. Release handbrake cables from compensator.
23. Remove handbrake cables from tunnel and
engine compartment.
Refit
1. Position handbrake cables to tunnel and feed
2. Feed handbrake cables into position in engine
compartment.
3. Lubricate all four cables with soft soap to ease
4. Position handbrake cables into closing plate
slots and secure with grommets.
bolts.
6. Lift subframe on jack, fit subframe front
mounting bolts and tighten to 30 Nm .
7. Position handbrake cable abutments to caliper
brackets and secure with new clips.
8. Align handbrake cables to calipers, fit clevis
pins and secure with new 'R' clips.
9. Position handbrake cables to luggage
compartment bulkhead and secure clips with
bolts.
10. Position air intake duct to subframe and secure
with clip.
11. Fit handbrake cables to air cleaner mounting
bracket.
12. Fit cables to handbrake compensator.
13. Position cables and secure with handbrake
abutment clamp.
components.
15. Untie and position coolant hoses.
16. Fill engine coolant. See COOLING SYSTEM,
Adjustments.
19. Adjust handbrake cable. See Adjustments.
HANDBRAKE WARNING SWITCH
Remove
1. Remove handbrake lever. See this section.
2. Remove 2 screws securing switch to lever and
collect switch.
Refit
1. Fit switch and secure with screws.
2. Fit handbrake lever. See this section.
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BRAKES
14 REPAIRS
BRAKE LIGHT SWITCH
Remove
1. Release 2 Lucar connectors from switch.
2. Release bayonet fixing and remove switch.
Refit
1. Fit switch to pedal box.
2. Connect Lucar connectors.
3. Adjust switch. See Adjustments.
BRAKE PADS - FRONT - STANDARD
Remove
3. Remove lower guide pin bolt from caliper and
pivot caliper body upwards.
4. Remove 2 brake pads from caliper carrier.
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BRAKES
REPAIRS 15
Refit
CAUTION: AIways fit correct grade and
specification of brake pads, and renew in
axIe set. Braking efficiency may otherwise
be impaired.
1. Clean caliper abutments and piston.
2. Clean area around fluid reservoir cap.
3. Remove cap from brake reservoir and position
cloth to catch spillage.
4. Using tool 18G 590, press piston into caliper
body.
5. Remove tool.
6. Remove backings from pad shims and fit pads
to carrier.
7. Position caliper body to carrier, fit and tighten
guide pin bolt to 45 Nm.
9. Top-up brake fluid to 'MAX' mark. See
MAINTENANCE.
10. Depress brake pedal several times to seat
pads.
NOTE: PedaI traveI may be Ionger than
normaI during first brake appIications.
BRAKE PADS - FRONT - SPORTS
Remove
3. Using a parallel punch, drift out brake pad
retaining pins and collect anti-squeal plate.
4. Remove brake pads from caliper housing.
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BRAKES
16 REPAIRS
Refit
1. Clean brake pad abutment areas in caliper's
retaining pins and anti-squeal plates.
2. Clean area around brake fluid reservoir cap.
3. Disconnect multiplug from brake fluid level
indicator, remove reservoir cap and position a
piece of cloth over reservoir to collect any
brake fluid spillage.
CAUTION: Brake fIuid wiII damage paint
finished surfaces. If spiIIed, immediateIy
remove fIuid and cIean area with water.
4. Using a suitable flat lever, retract caliper
pistons into housing.
5. Remove backings from brake pad shims.
CAUTION: AIways fit correct grade and
specification of brake pads, and renew in
axIe set. Braking efficiency may otherwise
be impaired.
6. Fit brake pads to caliper housing.
7. Fit brake pad retaining pins and anti-squeal
plate.
8. f necessary, top-up brake fluid reservoir.
9. Remove cloth, fit fluid reservoir cap and
connect multiplug to fluid level indicator.
pads.
BRAKE PADS - REAR
Remove
2. Release handbrake lever.
4. Remove guide pin bolts from caliper.
5. Release caliper body from carrier.
6. Tie caliper aside.
CAUTION: Do not aIIow weight of caIiper
to hang on hose, as damage may occur to
hose.
7. Remove brake pads from carrier.
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BRAKES
REPAIRS 17
CAUTION: Do not operate handbrake with
brake pads removed.
Refit
WARNING: AIways fit the correct grade
and specification of brake pads, and
renew in axIe set. Braking efficiency may
otherwise be impaired.
1. Remove old shims from caliper.
2. Fit new shims to replacement pads.
3. Clean area around fluid reservoir cap.
4. Remove cap from brake reservoir and position
cloth to catch spillage.
and cIean area with warm water.
5. Screw piston into caliper using 18G 1596
ensuring piston is fully retracted.
6. Clean components using methylated spirit or
denatured alcohol. Do not use any petroleum
based fluids.
7. Fit new pads to caliper carrier.
8. Untie caliper body and position to carrier.
9. Fit guide pin bolts and tighten to 45 Nm .
11. Top-up brake fluid to 'MAX' mark. See
MAINTENANCE.
12. Operate brake pedal several times to adjust
brake pads and the handbrake linkage.
CAUTION: Do not appIy the handbrake
before the brake pads have been adjusted
or incorrect brake operation wiII resuIt.
BRAKE SERVO
Remove
2. Remove spare wheel.
3. Disconnect fluid level switch.
4. Remove 2 nuts and washers securing master
cylinder to brake servo.
5. Release brake pipes from bulk head clips.
CAUTION: Do not bend brake pipes when
removing master cyIinder.
6. Remove master cylinder from brake servo.
7. Remove 'O' ring from master cylinder and
discard.
8. Tie master cylinder aside so that weight of
master cylinder is supported.
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BRAKES
18 REPAIRS
9. Carefully prise vacuum hose connection from
brake servo.
10. Remove and discard sealing rubber.
11. Remove 2 inboard bolts and loosen 2 outboard
bolts securing servo bracket.
12. Release servo from bracket for access to clevis
pin.
13. Remove split pin and withdraw clevis pin
securing crank to servo push rod.
14. Remove servo assembly.
15. Remove 4 nuts securing bracket to servo.
16. Collect spacers.
17. Remove bracket.
Refit
1. Position bracket to servo, fit spacers and
secure with nuts, tighten nuts to 20 Nm.
2. Position servo assembly and align servo push
rod.
3. Fit clevis pin and secure with new split pin.
4. Align servo and engage outboard bolts to slots
in bracket.
5. Fit inboard bolts. Tighten all bolts to 20 Nm.
6. Engage harness clip to bracket.
7. Fit new sealing rubber to vacuum hose.
8. Connect vacuum hose to servo.
9. Untie master cylinder.
10. Clean master cylinder and servo mating
surfaces.
11. Fit new 'O' ring to master cylinder.
12. Align servo push rod and fit master cylinder to
servo.
13. Fit nuts and washers securing master cylinder
to servo, tighten nuts to 20 Nm.
14. Fit brake pipes to clips.
15. Connect fluid level switch.
16. Fit spare wheel.
Exterior fittings.
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BRAKES
REPAIRS 19
BRAKE CALIPER HOUSING - FRONT -
STANDARD
Remove
1. Raise front of vehicle, one side.
3. Clamp brake hose to prevent fluid lose.
CAUTION: An approved brake hose cIamp
must be used.
4. Remove brake hose banjo bolt.
5. Remove and discard 2 sealing washers
6. Remove 2 guide pin bolts.
7. Remove caliper housing from caliper bracket.
8. Remove 2 brake pads and discard shims.
NOTE: Note Iocation of pads if same ones
are to be repIaced. Pads must be fitted in
originaI Iocations.
Refit
1. Rotate disc by hand and scrape all scale and
rust from around edge of disc. Scrape clean
abutment surfaces on caliper carrier.
2. Clean dust from brake parts using brake
cleaning fluid or industrial alcohol.
3. Using tool 18G 590, press piston back into
caliper.
4. Fit new shims to pads and fit pads to caliper
carrier.
5. Position caliper housing to carrier, fit and
tighten guide pin bolts to 45 Nm.
6. Clean brake hose banjo connection, fit new
sealing washers and tighten banjo bolt to 30
Nm.
7. Remove clamp from brake hose.
8. Bleed brake caliper. Fit road wheel(s), fit wheel
nuts and tighten in a diagonal sequence to 70
Nm.
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BRAKES
20 REPAIRS
BRAKE CALIPER CARRIER - FRONT -
STANDARD
Remove
3. Remove 2 guide pin bolts securing caliper
housing to carrier.
NOTE: Mark Iocation of pads if same ones
are to be repIaced. Pads must be refitted
to originaI Iocations.
4. Position caliper housing aside and remove 2
brake pads.
5. Remove and discard 2 shims from pads.
CAUTION: Do not aIIow caIiper to hang
from hose as damage may resuIt.
6. Remove 2 bolts securing caliper carrier to
swivel hub and remove carrier.
Refit
1. Position caliper carrier to hub, fit and tighten
bolts to 85 Nm.
2. Remove cap from brake fluid reservoir and
position cloth to catch any spillage.
3. Clean housing abutment and piston.
4. Using tool 18G 590, press piston fully into
caliper.
5. Fit new shims to pads and position to carrier.
6. Position caliper housing to carrier, fit and
tighten guide pin bolts to 45 Nm.
pads to discs. Pedal travel may be longer than
normal during first brake applications.
10. Top up fluid level if required and fit cap.
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BRAKES
REPAIRS 21
BRAKE CALIPER HOUSING - FRONT - SPORTS
Remove
3. Using a parallel punch, drift out brake pad
retaining pins and collect anti-squeal plate.
4. Remove brake pads from caliper housing,
mark their fitted position if they are to be
refitted.
5. Use a recommended brake hose clamp to
clamp brake hose.
6. Remove banjo bolt securing brake hose to
caliper, remove and discard sealing washers.
7. Remove 2 bolts securing caliper assembly to
hub and remove caliper.
Refit
1. Rotate disc by hand and scrape all scale and
rust from around edge of disc.
85 Nm.
4. Remove plug from brake hose banjo.
5. Clean brake hose banjo connection, fit NEW
sealing washers and tighten banjo bolt to
35 Nm.
6. Remove clamp from brake hose.
7. Using a suitable flat lever, retract caliper
pistons into housing.
8. Fit brake pads to caliper housing.
9. Fit brake pad retaining pins and anti-squeal
plate.
10. Bleed brake caliper.
pads.
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BRAKES
22 REPAIRS
HOSE - FRONT - PRIMARY - LH
Remove
4. Loosen and release union securing brake hose
to brake pipe.
5. Remove clip securing brake hose to support
bracket.
6. Release brake hose from support bracket and
remove brake hose.
Refit
1. Clean brake fluid spillage.
2. Clean brake pipe union, banjo bolt and caliper
mating face.
3. Position brake hose to support bracket, ensure
flat on brake hose is engaged in support
bracket recess and secure with clip.
4. Align brake pipe union to brake hose and
tighten union to 15 Nm .
5. Ensure brake hose is not kinked or twisted,
align to brake caliper. Using new sealing
washers fit banjo bolt and tighten to 30 Nm .
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BRAKES
REPAIRS 23
HOSE - REAR
Remove
4. Loosen and release union securing brake hose
to brake pipe.
5. Remove clip securing brake hose to support
bracket.
6. Release brake hose from support bracket and
remove brake hose.
Refit
1. Clean brake fluid spillage.
2. Clean brake pipe union, banjo bolt and caliper
mating face.
3. Position brake hose to support bracket, ensure
flat on brake hose is engaged in support
bracket recess and secure with clip.
4. Align brake pipe union to brake hose and
tighten union to 15 Nm .
5. Ensure brake hose is not kinked or twisted,
align to brake caliper. Using new sealing
washers fit banjo bolt and tighten to 30 Nm .
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RESTRAINT SYSTEMS
CONTENTS Page
COMPONENT LOCATON 1 .......................................................................................
DESCRPTON 2 .........................................................................................................
OPERATON 3 .............................................................................................................
ARBAG AND PRE-TENSONER, MANUAL DEPLOYMENT 4 ...................................
Deployment tool SMD 4082/1 self test procedure 4 .................................................
Deployment of seat belt pre-tensioner 5 ..................................................................
Deployment of driver airbag module 6 .....................................................................
Deployment of passenger airbag module 8 .............................................................
REPAIRS
DAGNOSTC CONTROL UNT (DCU) 1 .....................................................................
DRVER ARBAG MODULE 2 .....................................................................................
PASSENGER ARBAG MODULE 3 .............................................................................
SRS HARNESS 4 ........................................................................................................
SEAT BELT 5 ..............................................................................................................
SEAT BELT PRE-TENSONER 6 ................................................................................
ROTARY COUPLER 7 .................................................................................................
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RESTRAINT SYSTEMS
COMPONENT LOCATION
NOTE: LHD type is symmetricaI to RHD type.
1. Driver's airbag module *
2. SRS warning light
3. Diagnostic control unit *
4. Rotary coupler *
5. SRS harness (YELLOW) *
6. Fuse/relay box
7. Passenger's airbag module (optional) *
8. Seat belt pre-tensioners *
* Components to be renewed following system deployment.
Following deployment of the Supplementary
Restraint System (SRS), under any circumstances,
the above components marked with an asterisk must
be renewed.
mpacts which do not deploy airbags, check for
structural damage in the area of impact, paying
particular attention to bumper armatures,
longitudinals, crash cans and bracketry.
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RESTRAINT SYSTEMS
DESCRIPTION
The airbag Supplementary Restraint System (SRS)
is a safety device which, when deployed in the event
of a severe frontal impact, provides additional
protection to the driver's face and upper torso. The
airbag is designed to inflate when the vehicle is
exceeding a set speed and receives a frontal impact
within the area shown.
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RESTRAINT SYSTEMS
OPERATION
Diagnostic ControI Unit
CAUTION: The diagnostic controI unit is a
non-serviceabIe component and no
attempt shouId be made to repair or
modify the unit.
The diagnostic control unit which is mounted within
the passenger compartment performs two functions:
1. t monitors the airbag system for faults;
2. t provides a fire signal to the airbag(s) in the
event of a crash.
The warning lamp illuminates to inform the driver of
any airbag system faults.
The diagnostic control unit comprises of the
following circuits which control the airbag system:
1. The crash sensor determines the severity of
any impact and can discriminate between
rough road conditions and an actual crash.
2. The safing sensor is wired in series with the
crash sensor. The fire signal from the crash
sensor therefore, passes through the safing
sensor which confirms a crash is taking place.
3. The regulator circuit maintains stability of the
system in the event of battery voltage drop.
4. The back-up power supply provides power to
the system in the event of the battery being
damaged or disconnected during the impact.
5. nternal diagnostics continually monitor the
SRS system.
The fire signal from the diagnostic control unit
passes via the airbag harness to the airbag modules
and pretensioners. Grains of Nitrocellulose and
Nitroglycerine inside the airbag module, ignite and
combine in a chemical reaction to form a large
amount of Nitrogen gas leading to inflation of the
airbag in approximately 30 milli-seconds.
As the occupant moves forward into the airbag it
immediately deflates to provide progressive
deceleration and reduce the risk of injuries.
Sequence of operation:
1. The main sensor and the safing sensor are
activated.
2. Power is supplied to the airbag igniter by the
battery or the back-up circuit.
3. The airbag deploys.
t takes approximately 0.1 seconds from the
beginning of the airbag deployment until it is
completely deflated.
System check
The warning light, located in instrument pack
illuminates when the electrical circuits are switched
on whilst the system performs a self diagnosis test. f
the system finds no fault during self diagnosis the
light will extinguish after approximately 5 seconds
and remain extinguished.
n the event of a fault in the system, the warning light
will illuminate continuously or fail to illuminate during
the self diagnosis test.
FauIt finding diagnosis
Faults in the SRS system can be identified by
connecting TestBook into the diagnostic socket,
located on the passenger compartment fuse box.
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RESTRAINT SYSTEMS
AIRBAG AND PRE-TENSIONER, MANUAL
DEPLOYMENT
NOTE: Pre-tensioner depIoyment is done
in car onIy.
f a vehicle is to be scrapped and contains an
undeployed airbag module, or pre-tensioner, the
components must be manually deployed. This
operation should only be carried out using the
following recommended manual deployment
procedure.
Before deployment is started the deployment tool
self test procedure should be carried out.
DepIoyment tooI SMD 4082/1 seIf test procedure
1. nsert BLUE and YELLOW connectors of the
deployment tool lead into the corresponding
sockets on the face of the deployment tool.
2. Connect crocodile clips of the second
deployment tool lead to the battery, red to
positive and black to negative.
3. RED "READY" light should illuminate.
4. Press and hold both operating buttons.
5. GREEN "DEFECTVE" light should illuminate.
6. Release both operating buttons.
7. RED "READY" light should illuminate.
8. Disconnect the deployment tool from the
battery.
9. Disconnect the BLUE and YELLOW
connectors from the deployment tool face
sockets.
10. Deployment tool self-test is now complete.
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RESTRAINT SYSTEMS
DepIoyment of seat beIt pre-tensioner
These guidelines are written to aid authorised
personnel to carry out the safe manual deployment
and disposal of the seat belt pre-tensioners.
WARNING: AIways read and adhere to the
SRS depIoyment precautions outIined in
this workshop manuaI. See GENERAL
AIways remove the key from the ignition
switch and disconnect the vehicIe battery
(negative Iead first) before starting the
depIoyment procedures.
AIways observe the system safe time of 10
minutes (to aIIow the energy reserve
capacitors to discharge) before
disconnecting or removing any SRS
components.
OnIy use the MG Rover approved depIoyment
equipment.
DepIoy the seat beIt pre-tensioners in a weII
ventiIated, speciaIIy designated area.
Ensure the seat beIt pre-tensioner is not
damaged or ruptured before depIoying.
Notify the reIevant authorities.
Deploy
1. Carry out deployment tool SMD 4082/1 self
test.
2. Slide the front seat fully forward to access the
pre-tensioner harness connector.
3. Disconnect pre-tensioner harness connector.
WARNING: Ensure depIoyment tooI SMD
4082/1 is not connected to the battery.
4. Connect deployment tool flylead SMD 4082/5
to the pre-tensioner connector.
to deployment tool SMD 4082/1 .
WARNING: Ensure the pre-tensioner is
secured tightIy to the seat.
WARNING: Ensure aII personneI are
standing at Ieast 15 metres (50 ft.) away
from the pre-tensioner moduIe.
6. Connect deployment tool SMD 4082/1 to the
battery.
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RESTRAINT SYSTEMS
7. Press both operating buttons of deployment
tool SMD 4082/1 to deploy the pre-tensioner.
WARNING: A depIoyed pre-tensioner gas
generator wiII be very hot, DO NOT return
to the pre-tensioner for 30 minutes.
CAUTION: Wear a face shieId and gIoves
when handIing a depIoyed pre-tensioner
unit. Wash hands and rinse weII after
handIing a depIoyed pre-tensioner unit.
8. Remove the front seat belt pre-tensioner
assembly from the vehicle. See Repairs.
9. Wipe down the deployment tools with a damp
cloth.
10. Place the pre-tensioner in a strong plastic bag
and seal the bag.
11. Transport the deployed pre-tensioner to the
designated area for incineration.
NOTE: DO NOT transport the depIoyed
pre-tensioner unit in the vehicIe
passenger compartment.
12. Scrap all remaining parts of the seat belt and
pre-tensioner assembly. DO NOT re-use or
salvage any parts of the seat belt and
pre-tensioner assembly.
DepIoyment of driver airbag moduIe
and disposal of airbag modules when they are
removed from the vehicle.
components.
equipment.
DepIoy the airbag moduIes in a weII
Ensure the airbag moduIe is not damaged or
ruptured before depIoying.
Deploy
test.
2. Remove the airbag module from the steering
wheel. See Repairs.
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RESTRAINT SYSTEMS
3. Position tool SMD 4082/2 in a vice, ensuring
that the vice jaws grip the tool above the
bottom flange to prevent the possibility of the
tool being forced upwards from the vice.
Tighten the vice.
4. Secure the airbag module to tool SMD 4082/2
using the appropriate mounting brackets (e.g.
SMD 4082/8).
5. Ensure the airbag module mounting brackets
are secure.
WARNING: Ensure depIoyment tooI
SMD 4082/1 is not connected to the
battery.
to the driver airbag module.
to deployment tool SMD 4082/1.
WARNING: Do not Iean over the airbag
moduIe whiIst connecting.
from the airbag moduIe.
battery.
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RESTRAINT SYSTEMS
tool SMD 4082/1 to deploy the airbag module.
WARNING: A depIoyed airbag moduIe wiII
be very hot. DO NOT return to the airbag
moduIe for 30 minutes.
when handIing a depIoyed airbag moduIe.
Wash hands and rinse weII after handIing
a depIoyed airbag moduIe.
10. Remove the driver airbag module from the
deployment tools and place the deployed
airbag module in a strong plastic bag, and seal
bag.
cloth.
12. Transport the deployed driver airbag module to
the designated area for incineration.
NOTE: DO NOT transport the airbag
moduIe in the vehicIe passenger
compartment.
13. Scrap all remaining parts of airbag system. DO
NOT re-use or salvage any parts of the airbag
system.
DepIoyment of passenger airbag moduIe
and disposal of airbag modules when they are
removed from the vehicle.
components.
equipment.
DepIoy the airbag moduIes in a weII
Ensure the airbag moduIe is not damaged or
ruptured before depIoying.
Deploy
test.
2. Remove the passenger airbag module. See
Repairs.
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RESTRAINT SYSTEMS
3. Position tool SMD 4082/6 in a vice, ensuring
that the vice jaws grip the tool above the
bottom flange to prevent the possibility of the
tool being forced upwards from the vice.
Tighten the vice.
4. Position brackets SMD 4082/7 to tool
SMD 4082/6 , lightly tighten the bolts.
5. Position the airbag module to tool SMD 4082/6.
6. Ensure all the airbag module and mounting
bracket fixings are secure.
WARNING: Ensure tooI SMD 4082/1 is not
connected to the battery.
to the passenger airbag module.
to the deployment tool SMD 4082/1.
WARNING: Do not Iean over the airbag
moduIe whiIst connecting.
from the airbag moduIe.
battery.
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RESTRAINT SYSTEMS
tool SMD 4082/1 to deploy the airbag module.
WARNING: A depIoyed airbag moduIe wiII
be very hot. DO NOT return to the airbag
moduIe for 30 minutes.
when handIing a depIoyed airbag moduIe.
Wash hands and rinse weII after handIing
a depIoyed airbag moduIe.
11. Disconnect the passenger airbag module from
deployment tool SMD 4082/1 and remove the
airbag module from the mounting brackets.
cloth.
13. Place the deployed passenger airbag module
in a strong plastic bag and seal the bag.
14. Transport the deployed airbag module to the
designated area for incineration.
NOTE: DO NOT transport the airbag
moduIe in the vehicIe passenger
compartment.
15. Scrap all remaining parts of the airbag system.
DO NOT re-use or salvage any parts of the
airbag system.
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RESTRAINT SYSTEMS
REPAIRS 1
DIAGNOSTIC CONTROL UNIT (DCU)
SRS Precautions.
Remove
2. Remove centre console panel. See BODY,
Interior trim components.
3. Disconnect multiplug from DCU.
4. Remove 3 Torx bolts securing DCU to bracket.
5. Remove DCU.
Refit
WARNING: Because the crash sensor is
incorporated inside the DCU, it is
imperative that boIts securing the DCU are
tightened to their correct torque.
1. Position DCU to support bracket, fit and tighten
Torx bolts to 10 Nm.
CAUTION: Before connecting muItipIug
ensure that cIip is in the open position,
pointing away from the harness. Lock the
connector into position by pushing cIip towards
harness.
3. Fit centre console panel. See BODY, Interior
trim components.
4. Carry out system check using TestBook.
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RESTRAINT SYSTEMS
2 REPAIRS
DRIVER AIRBAG MODULE
SRS Precautions.
Remove
2. Remove 2 Tx30 Torx screws securing module
to steering wheel.
3. Release air bag module from steering wheel.
CAUTION: Do not aIIow the air bag moduIe
to hang by the air bag harness.
4. Disconnect multiplug from air bag module.
5. Remove air bag module.
CAUTION: Store the air bag moduIe in
accordance with the storage procedures
outIined in the precautions part of this
manuaI. See GENERAL INFORMATION, SRS
Precautions.
NOTE: If the air bag moduIe is to be
repIaced, the bar code must be recorded.
Refit
1. Position module to steering wheel and connect
harness multiplug.
2. Align module to steering wheel, fit Torx screws
and tighten to 8 Nm
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RESTRAINT SYSTEMS
REPAIRS 3
PASSENGER AIRBAG MODULE
SRS Precautions.
Remove
components.
3. Disconnect 2 multiplugs from airbag.
4. Remove bolt securing bracket to fascia cross
rail.
5. Remove 4 nuts securing airbag to bracket.
6. Remove airbag module.
CAUTION: Store the airbag moduIe in
accordance with the storage procedures
outIined in the precautions part of this
manuaI. See GENERAL INFORMATION, SRS
Precautions.
NOTE: If the airbag moduIe is to be
repIaced, the bar code must be recorded.
Refit
1. Position module to fascia bracket and tighten
nuts to 8 Nm.
2. Tighten bolt securing bracket to fascia rail
to 9 Nm.
components.
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RESTRAINT SYSTEMS
4 REPAIRS
SRS HARNESS
SRS Precautions.
Remove
2. Remove fascia. See BODY, Interior trim
components.
3. Disconnect SRS multiplug and SRS fuse
satellite from fusebox.
4. Disconnect multiplug from steering column.
5. Disconnect multiplug from DCU and release
harness from bracket clip.
6. Disconnect 2 multiplugs from seatbelt
pre-tensioners.
7. Remove 4 Torx bolts securing DCU bracket to
tunnel, release harness earth and position
DCU aside.
8. Remove 4 nuts and 3 bolts securing gear lever
assembly to tunnel and position assembly
aside.
9. Release 11 cable clips securing SRS harness
to main harness.
10. Remove SRS harness.
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RESTRAINT SYSTEMS
REPAIRS 5
Refit
1. Position harness to body.
2. Connect fuse satellite and multiplug to fusebox.
3. Connect multiplugs to seatbelt pre-tensioners.
4. Secure harness with clips.
CAUTION: Ensure that pre-tensioner Ieads
pass through grommets in centre consoIe
area.
5. Position gear lever assembly to tunnel and
tighten fixings to 9 Nm.
WARNING: Because the crash sensor is
incorporated inside the DCU, it is
imperative that aII boIts securing the DCU
are tightened to their correct torque.
6. Position DCU bracket to tunnel, fit harness
earth lead and tighten fixings to 10 Nm.
7. Connect multiplug to steering column.
CAUTION: Before connecting DCU
muItipIug ensure that cIip is in the open
position, pointing away from the harness.
Lock the connector into position by pushing cIip
towards the harness.
8. Connect multiplug to DCU and fit harness to
clip.
9. Fit fascia. See BODY, Interior trim
components.
SEAT BELT
Remove
1. Remove seat. See BODY, Interior trim
components.
2. Remove Torx bolt securing seat belt strap to
seat frame.
trim components.
4. Remove Torx screw securing seat belt reel to
body.
5. Remove seat belt.
Refit
1. Position seat belt reel to body, fit and tighten
Torx screw to 35 Nm.
components.
3. Position seat belt strap to seat, fit bolt and
tighten to 30 Nm.
4. Fit seat. See BODY, Interior trim
components.
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RESTRAINT SYSTEMS
6 REPAIRS
SEAT BELT PRE-TENSIONER
SRS Precautions.
Remove
CAUTION: Ensure pre-tensioner muItipIug
is disconnected before seat is removed.
2. Remove seat. See BODY, Interior trim
components.
3. Remove bolt securing pre-tensioner to seat.
4. Remove pre-tensioner.
Refit
1. Position pre-tensioner to seat and tighten bolt
to 45 Nm.
2. Ensure that pre-tensioner lead is correctly
clipped to seat base.
3. Fit seat. See BODY, Interior trim
components.
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RESTRAINT SYSTEMS
REPAIRS 7
ROTARY COUPLER
SRS Precautions.
Remove
2. Ensure wheels are in the straight ahead
position.
3. Remove steering wheel. See STEERING,
Repairs.
4. Remove steering column nacelle. See
STEERING, Repairs.
5. f the rotary coupler is being re-used, place
adhesive tape around moulding to prevent
rotation.
6. Remove 4 screws securing rotary coupler to
steering column switch pack.
7. Release rotary coupler from column and
disconnect 2 multiplugs.
8. Remove rotary coupler.
CAUTION: Do not dismantIe the rotary
coupIer. It has NO serviceabIe parts and
must be repIaced as a compIete assembIy.
Refit
1. Position rotary coupler to switch pack.
3. Fit and tighten screws.
4. Remove adhesive tape.
5. Fit steering column nacelle. See STEERING,
Repairs.
6. Fit steering wheel. See STEERING, Repairs.
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BODY
CONTENTS Page
DOORS
ELECTRC WNDOW LFT COMPONENTS 1 ............................................................
ELECTRC WNDOW OPERATON 2 .........................................................................
DOOR - CENTRAL LOCKNG COMPONENTS 3 .......................................................
DOOR CENTRAL LOCKNG - OPERATON 4 ............................................................
DOOR - ALGN ON HNGES 5 ....................................................................................
DOOR STRKER - ADJUST 5 .....................................................................................
DOOR GLASS - ADJUST 6 .........................................................................................
MRROR - EXTEROR - ELECTRC 6 .........................................................................
GLASS 7 ......................................................................................................................
DOOR GLASS REGULATOR 8 ...................................................................................
OUTER WAST SEAL 8 ...............................................................................................
DOOR AND HEADER SEAL 9 ....................................................................................
TRM CASNG 9 ..........................................................................................................
PLASTC SHEET 10 ....................................................................................................
REMOTE DOOR HANDLE 11 .....................................................................................
PRVATE LOCK 11 ......................................................................................................
OUTSDE HANDLE 12 ................................................................................................
EXTERIOR FITTINGS
BONNET - ADJUST 1 ..................................................................................................
BONNET LOCK PLATE - ADJUST 1 ...........................................................................
BOOT LD - ADJUST 2 ................................................................................................
BOOT LD STRKER - ADJUST 2 ...............................................................................
FRONT WHEEL ARCH LNER 3 .................................................................................
UNDERBONNET CLOSNG PANEL 3 ........................................................................
ENGNE COMPARTMENT ACCESS PANEL 4 ...........................................................
PANEL - FRONT UNDERBELLY - CENTRE 4 ............................................................
BONNET LOCKNG PLATFORM - R/R ACCESS 5 ....................................................
BONNET RELEASE CABLE 5 .....................................................................................
PRVATE LOCK - BOOT LD 8 ....................................................................................
BOOT LD LATCH 8 ....................................................................................................
FRONT BUMPER ARMATURE 9 ................................................................................
REAR BUMPER ARMATURE 9 ..................................................................................
BUMPER VALANCE - FRONT 10 ...............................................................................
REAR BUMPER VALANCE 11 ....................................................................................
AR VENT SDE 13 ......................................................................................................
HOOD
HOOD ASSEMBLY COMPONENTS - SOFT TOP 1 ...................................................
HOOD ASSEMBLY COMPONENTS - HARD TOP 2 ..................................................
HOOD SEALS AND DOOR GLASS - ADJUST 3 ........................................................
CANTRAL TENSONNG CABLES - ADJUST 7 .........................................................
HARDTOP - ADJUST 7 ...............................................................................................
HARD TOP 8 ...............................................................................................................
HOOD ASSEMBLY 9 ...................................................................................................
HOOD OUTER COVER 10 ..........................................................................................
HOOD FRAME 15 ........................................................................................................
BACKLGHT 16 ...........................................................................................................
HOOD CATCH 18 ........................................................................................................
CANTRAL TENSONNG CABLE 19 ..........................................................................
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BODY
CONTENTS Page
BACKLGHT ZP 20 .....................................................................................................
HARD TOP HEADLNNG 20 ......................................................................................
HARD TOP CATCH - REAR 21 ...................................................................................
HARD TOP CATCH - FRONT 21 ................................................................................
HARD TOP SEAL 22 ...................................................................................................
CANTRAL SEAL 23 ....................................................................................................
'B' POST SEAL 23 .......................................................................................................
HARD TOP - BACKLGHT 24 ......................................................................................
INTERIOR TRIM COMPONENTS
SUN VSOR 1 ..............................................................................................................
NTEROR MRROR 1 .................................................................................................
LUGGAGE COMPARTMENT TRM 2 .........................................................................
'A' POST TRM 2 .........................................................................................................
REAR BULKHEAD FNSHER 3 ..................................................................................
HEADER TRM 3 .........................................................................................................
FRONT CONSOLE 4 ...................................................................................................
REAR CONSOLE 5 .....................................................................................................
GEAR LEVER GATER 6 .............................................................................................
CENTRE CONSOLE PANEL 7 ....................................................................................
CONSOLE CLOSNG PANEL 9 ..................................................................................
FASCA PANEL 9 ........................................................................................................
GLOVEBOX 10 ............................................................................................................
GLOVEBOX LATCH 11 ...............................................................................................
HOODWELL TRM 11 ..................................................................................................
HEAD RESTRANT 12 .................................................................................................
SEAT - LH/RH 13 .........................................................................................................
SEAT SQUAB ASSEMBLY 14 .....................................................................................
COVER - ONE PECE - FRONT SEAT CUSHON 16 .................................................
COVER - SQUAB - FRONT SEAT 17 .........................................................................
SCREENS
WNDSCREEN 1 .........................................................................................................
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BODY
DOORS 1
ELECTRIC WINDOW LIFT COMPONENTS
1. Door glass
2. Regulator
3. Motor
4. Cheater assembly
5. Sash
6. Screw - sash to cheater, 2 off
7. Screw - cheater, 2 off
8. Fastener - cheater
9. Glass stop,
10. Bolt - glass to regulator, 2 off
11. Sash
12. Nut - upper rail bracket, 2 off
13. Stud bracket - glass retention
14. Nut - glass retention
15. Glass retention assembly
16. Sleeve - sash adjuster, 2 off
17. Screw - sash adjuster, 2 off
18. Nut - sash adjuster, 2 off
19. Bolt - glass retention
20. Bolt - regulator, 2 off
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BODY
2 DOORS
ELECTRIC WINDOW OPERATION
(RHD shown, LHD similar)
1. Window switch
2. Window lift ECU
3. Window relay
4. Glass
5. Regulator
6. Motor
The two window lift system is controlled by switches
fitted in the centre console. When the ignition is
switched on, the electric window relay located on the
passenger compartment fusebox, switches power
supply to the window circuit. The electric motor via
an integral gearbox, operates the regulator
assembly to lift and lower the window glass.
Battery supply from the electric window relay to the
window switches is via two fuses, one for each door,
located in the driver's compartment fusebox.
The driver's door window has a 'one-shot' down
facility which allows the window to be fully lowered
with a single press of the window switch. This is
controlled by a window lift ECU which is located at
the bottom of the 'A' post, behind the carpet. The
ECU controls all functions of the driver's window.
The passenger window remains controlled by the
multi function ECU and the window lift relay as on
previous models.
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BODY
DOORS 3
DOOR - CENTRAL LOCKING COMPONENTS
1. External door handle assembly
2. Retaining clip - cylinder block
3. Bolt - outer door handle
4. Latch assembly
5. Cable - remote door handle
6. Sill button and rod
7. Screw - latch assembly
8. Remote door handle assembly
9. Screw - inside door handle
10. Holder - lock rod
11. Escutcheon - remote door handle
12. Screw - escutcheon
13. Striker - door lock
14. Bolt - striker
15. Lock motor
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BODY
4 DOORS
DOOR CENTRAL LOCKING - OPERATION
1. Anti-theft alarm ECU
2. Latch assembly
3. Lock motor
4. nternal door handle
5. External door handle and lock
6. Sill button
Central door locking is operated by using any one of
the following:
- Remote handset,
- Key in the driver's door lock,
- Driver's door sill button.
Both door locks are operated by separate integral
lock motors which function simultaneously. They are
controlled by the alarm ECU mounted behind the
fascia centre console, below the heater control unit.
A signal from the remote handset is received by the
alarm ECU. Depending on this signal the ECU will
either lock or unlock the doors by controlling the
direction of electrical current sent to the lock motors.
When the driver's door key is turned or the sill button
is depressed, the driver's door is mechanically
locked by the door latch which triggers the latch
switch. The latch switch sends an earth signal to the
alarm ECU, which in turn controls the electrical
current sent to the passenger door motor to lock the
door.
Operation of the passenger door sill button will lock
or unlock the passenger door but will not operate the
central door locking system.
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BODY
DOORS 5
DOOR - ALIGN ON HINGES
1. Turn wheel in lock for access to wheel arch
liner screws.
2. Remove 3 screws and 3 scrivets securing
wheel arch liner.
3. Remove wheel arch liner to gain access to
hinge bolts.
4. Open door.
5. Remove screws securing door striker to 'B'
post collect striker.
6. Loosen bolts securing hinges to 'A' post.
7. Align door to meet the profile of adjacent
panels, and ensure all surrounding door gaps
are parallel.
8. Tighten door hinge bolts.
9. Re-check door alignment.
10. Position door striker and fit screws.
11. Adjust door striker so that the door closes
without the need for slamming it.
12. Tighten door striker screws to 18 Nm .
13. Fit wheel arch liner and secure with screws
and scrivets.
DOOR STRIKER - ADJUST
1. Using a Torx bit loosen 2 striker screws and
close door.
2. Check door for flush fit to adjacent panels and
edges for equal gap.
3. Open door and tighten striker screws to 18 Nm.
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BODY
6 DOORS
DOOR GLASS - ADJUST
1. For information on adjustment of the door
glass, see hood seals and door glass - adjust.
See Hood.
MIRROR - EXTERIOR - ELECTRIC
Remove
1. Remove front door casing. See this section.
2. Release plastic sheet to access mirror
multiplug.
3. Disconnect mirror multiplug and attach draw
string to mirror harness.
4. Remove 2 screw caps and screws securing
mirror.
5. Remove exterior mirror.
6. Remove draw string from mirror harness.
Refit
1. Attach draw string to mirror harness and feed
harness into door. Remove draw string from
mirror harness.
2. Position exterior mirror to door and secure with
screws.
3. Fit screw caps.
4. Connect mirror multiplug.
5. Secure plastic sheet in correct position.
6. Fit front door casing. See this section.
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DOORS 7
GLASS
Remove
1. Remove trim casing. See this section.
2. Release 5 clips securing outer waist seal to
door and remove seal.
3. Peel back plastic sheet to allow access to inner
door.
4. Switch ignition ON and lower window to allow
access to bolts.
5. Switch ignition OFF.
6. Remove 3 bolts securing glass to regulator.
7. Remove glass.
Refit
1. Position glass to regulator and align rear guide
to glass.
2. Fit bolts securing glass to regulator but do not
tighten.
3. Adjust door glass. See this section.
4. Position plastic sheet and secure in place.
5. Fit outer waist seal and secure with clips.
6. Fit trim casing. See this section.
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BODY
8 DOORS
DOOR GLASS REGULATOR
Remove
1. Remove glass. See this section.
2. Remove plastic sheet. See this section.
4. Remove 4 bolts securing regulator to door.
5. Loosen 2 bolts securing regulator to door.
6. Remove regulator.
Refit
1. Position regulator to door and feed multiplug
through aperture.
2. Align bolts to slotted holes and tighten to 7 Nm.
3. Fit and tighten bolts to 7 Nm.
4. Fit glass. See this section.
5. Fit plastic sheet. See this section.
OUTER WAIST SEAL
Remove
1. Starting from the rear of the door, release 5
clips securing seal to door.
2. Remove seal.
Refit
1. Position seal to door and align clips.
2. Fit seal and engage clips.
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DOORS 9
DOOR AND HEADER SEAL
Remove
1. Open both doors.
2. Lower both sun visors.
3. Release catches and lower hood.
4. Remove 2 Tx30 Torx screws securing each
hood striker and remove both strikers.
5. Remove 2 studs securing seal to 'A' posts.
6. Remove seal.
Refit
1. Position and centralise seal to header rail.
2. Secure seal to 'A' posts with studs.
3. Engage seal to flanges of header, 'A' posts and
sills.
4. Fit hood strikers and tighten screws to 6 Nm.
5. Reposition sun visors.
6. Raise hood and secure catches.
7. Close doors.
TRIM CASING
Remove
1. Remove 2 screws securing door pull.
2. Remove door pull from trim casing.
3. Remove screw securing remote door handle
escutcheon.
4. Remove remote door handle escutcheon.
5. Remove 3 screws securing trim casing.
6. Release 6 lower trim casing retaining clips,
remove trim casing.
Refit
1. Fit trim casing to door and secure with clips.
2. Fit screws securing trim casing to door.
3. Fit remote door handle escutcheon and secure
with screw.
4. Fit door pull to trim casing and secure with
screws.
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BODY
10 DOORS
PLASTIC SHEET
NOTE: A new pIastic sheet must aIways be
fitted, do not attempt to repair an existing
pIastic sheet.
NOTE: To obtain an effective seaI when
fitting a new pIastic sheet, ensure that the
pIastic sheet and door contact surface are
at room temperature: between 18 C to 30 C.
Remove
1. Remove the remote door handle. See this
section.
2. Remove 3 screws securing door speaker.
3. Release speaker, disconnect 2 Lucars and
remove speaker.
4. Remove 2 trim rear fixing clips from door.
5. Remove 2 screws securing door pull fixing
bracket to door, remove bracket.
6. Release 2 door harness retaining clips from
door.
7. Disconnect heated door mirror multiplug.
8. Remove trim casing rear upper fixing clip from
door.
9. Release plastic sheet from door. Feed harness
connectors through sheet and remove plastic
sheet.
Refit
1. Ensure door is clean and dry where it comes in
contact with the adhesive strip on the plastic
sheet.
2. Fit plastic sheet, by fitting the adhesive strip to
the bottom centre of the door first.
3. Starting from the bottom centre of the adhesive
strip apply even pressure along the strip in
both directions simultaneously, until the top
centre of seal is reached.
4. Feed harness connectors through sheet and
secure to door.
5. Fit fixing clips to door.
6. Connect heated door mirror multiplug.
7. Secure harness retaining clips to door.
8. Fit door pull fixing bracket to door and tighten
screws.
9. Fit trim casing rear fixing brackets to door.
10. Position door speaker, connect Lucars and
tighten screws.
11. Fit the remote door handle. See this section.
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BODY
DOORS 11
REMOTE DOOR HANDLE
Remove
2. Release latch operating cable from remote
door handle abutment bracket.
3. Remove 2 screws securing remote door
handle.
4. Release remote door handle from door by
sliding in a forward direction.
5. Release clip securing latch operating cable to
remote door handle, remove remote door
handle.
Refit
1. Fit latch operating cable to remote door handle
2. Position remote door handle to door and
secure with screws.
3. Secure latch operating cable to remote door
handle abutment bracket.
PRIVATE LOCK
Remove
2. Carefully peel back plastic sheet to allow
access to inner door.
3. Unclip link rod from lock.
4. Release spring clip from lock.
5. Remove private lock.
Refit
1. Fit lock to handle and secure with spring clip.
2. Engage link rod to lock.
3. Position plastic sheet and press into place.
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BODY
12 DOORS
OUTSIDE HANDLE
Remove
2. Switch the ignition ON and fully lower door
glass.
4. Carefully peel back corner of plastic sheet to
allow access to door latch.
5. Release clip securing door handle link rod to
latch assembly and position aside.
6. Drivers side: release lock link rod from lock.
7. Remove 2 bolts securing handle to door.
8. Release 2 clips retaining handle to door and
position handle.
9. Release clip securing lock to handle and
remove lock.
10. Remove handle.
11. Remove rod from handle.
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BODY
DOORS 13
Refit
1. Fit rod to handle and position handle to door.
2. Engage handle to door and tighten
bolts to 2.5 Nm.
3. Adjust rod length to align rod to latch.
4. Position rod and secure with clip.
5. Drivers side: engage lock connecting rod.
6. Fully raise door window.
7. Position lock to handle and secure with clip.
8. Secure plastic sheet.
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BODY
EXTERIOR FITTINGS 1
BONNET - ADJUST
Adjust
1. Check alignment of bonnet.
2. Open bonnet.
3. Loosen 4 bolts securing bonnet to hinges and
adjust bonnet.
4. Lightly tighten bolts and close bonnet.
5. Check gaps are equal and bonnet is aligned
with adjacent panels.
6. Open bonnet, adjust hinges if necessary and
7. f necessary, adjust bonnet locking plate. See
this section.
BONNET LOCK PLATE - ADJUST
Adjust
1. Open bonnet.
2. Loosen 2 bolts securing lock plate to body.
3. Position lock plate fully forward.
4. Gently lower bonnet. Align striker pin with lock
and ensure safety catch engages in lock plate.
5. Tighten bolts to 25 Nm.
6. Check correct operation of bonnet latch and
alignment of bonnet.
7. f necessary adjust bonnet. See this section.
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2 EXTERIOR FITTINGS
BOOT LID - ADJUST
Adjust
1. Check for equal gaps around boot and
alignment with adjacent panels.
2. Open boot lid.
3. Loosen 4 bolts securing boot lid to hinges and
adjust boot lid.
4. Lightly tighten bolts and close boot.
5. Check alignment of boot lid.
6. Open boot lid.
7. Adjust boot lid if necessary and tighten bolts to
9 Nm.
8. f necessary, adjust boot striker. See this
section.
BOOT LID STRIKER - ADJUST
Adjust
1. Open boot lid.
2. Loosen 2 bolts securing striker to body and
approximately position striker.
3. Lightly tighten bolts and close boot lid. Check
for equal gaps and alignment with adjacent
panels.
4. Open boot lid, re-position latch as necessary,
tighten latch and striker bolts to 10 Nm.
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BODY
EXTERIOR FITTINGS 3
FRONT WHEEL ARCH LINER
Remove
3. Release wheel arch flange seal from rear lower
edge of wing panel.
4. Remove 3 screws securing wheel arch liner.
5. Remove 3 scrivet screws securing wheel arch
liner, remove scrivets.
6. Remove wheel arch liner.
Refit
1. Fit and align wheel arch liner.
2. Fit scrivet fasteners securing wheel arch liner.
3. Fit and tighten screws securing wheel arch
liner.
4. Secure wheel arch flange seal.
5. Fit road wheel(s) and tighten wheel nuts to
70 Nm.
UNDERBONNET CLOSING PANEL
Remove
1. Open bonnet.
2. Remove 2 fixings securing closing panel to
spare wheel well.
3. Remove 2 fixings securing closing panel to
scuttle.
4. Remove fixing securing closing panel to air
intake plenum.
Refit
1. Fit closing panel to body studs and secure
fixings.
2. Close bonnet.
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4 EXTERIOR FITTINGS
ENGINE COMPARTMENT ACCESS PANEL
Remove
1. Release 4 retaining clips along front edge of
closing panel by pulling each clip away from
the seal and lifting upwards.
2. Remove panel.
3. Remove 6 screws securing LH plate to panel,
remove plate.
4. Remove 3 screws securing RH plate to panel,
remove plate.
Rebuild
5. Fit RH plate to panel and secure with screws.
6. Fit LH plate to panel and secure with screws.
Refit
1. Fit closing panel and secure.
PANEL - FRONT UNDERBELLY - CENTRE
Remove
2. Remove 22 bolts securing underbelly panel to
floorpan.
3. Remove underbelly panel.
Refit
1. Position underbelly panel to floorpan and
2. Lower vehicle.
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BODY
EXTERIOR FITTINGS 5
BONNET LOCKING PLATFORM - R/R ACCESS
Remove
1. Remove front bumper valance. See this
section.
bonnet locking platform. Release bonnet
locking platform from 4 location pegs.
3. Disconnect bonnet cable from bonnet catch
and remove bonnet locking platform.
Refit
1. Position bonnet locking platform and connect
bonnet cable to bonnet catch.
2. Fit bonnet locking platform and engage
platform in location pegs. Fit nuts and bolts and
tighten to 10 Nm.
3. Fit front bumper valance. See this section.
BONNET RELEASE CABLE
Remove
1. Remove headlamp assembly. See
2. Release cable from bonnet lock plate.
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BODY
6 EXTERIOR FITTINGS
3. Release grommet from body
4. Feed bonnet release cable through hole.
5. Loosen bolt securing earth header to inner
wing and release cable from 2 inner wing clips.
See this section.
7. Remove hoodwell trim. See Interior trim
components.
8. Position carpet aside and remove 2 bolts
securing bonnet release lever to luggage
compartment bulkhead.
9. Release cable abutment and cable from lever
assembly.
10. Release cable from rear, inner wing clip.
11. Position felt pad aside and release grommet
from hoodwell panel.
12. Feed cable through body holes and remove
grommet from cable.
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BODY
EXTERIOR FITTINGS 7
13. Remove stud securing carpet to inner wheel
arch.
14. Release carpet from door seal and 5 velcro
strips.
15. Remove 2 studs securing carpet to 'B' post,
and release carpet from door seal and velcro to
reveal cables.
16. Release cable from 3 sill clips and 3 'B' post
clips.
17. Release cable from floorpan crossmember.
18. Release grommet from scuttle and remove
cable.
Refit
1. Feed cable through scuttle and under carpet
insulation.
2. Position grommet to cable timing mark and
engage grommet to scuttle.
3. Position cable to front inner wing and through
hole in body.
4. Engage cable and abutment to bonnet lock
plate.
5. Engage grommet to body.
6. Fit headlamp assembly. See ELECTRICAL,
Repairs.
7. Engage cable to inner wing clip and tighten
earth header bolt to 9 Nm.
8. Feed cable through floorpan crossmember and
engage to clips.
9. Position carpet and secure with studs and
velcro.
10. Position carpet beneath door flip seal.
11. Fit grommet to cable and position to timing
mark.
12. Position cable through hole in hoodwell panel
and luggage compartment bulkhead.
13. Engage cable and abutment to bonnet release
lever.
14. Position lever to bulkhead and tighten bolts to
9 Nm.
15. Position carpet beneath luggage compartment
flip seal.
16. Engage grommet and cable clip.
17. Fit hoodwell trim. See Interior trim
components.
this section.
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BODY
8 EXTERIOR FITTINGS
PRIVATE LOCK - BOOT LID
Remove
1. Open boot lid.
2. Release multiplug from boot lid latch, bracket.
3. Disconnect multiplug.
4. Disconnect release cable from boot lid latch.
5. Remove clip securing lock to boot lid.
6. Remove lock assembly from boot lid.
Refit
1. Position lock to boot lid and secure with clip.
2. Connect release cable to boot lid latch.
4. Secure multiplug to boot lid latch, bracket.
BOOT LID LATCH
Remove
1. Open boot lid.
2. Disconnect 2 Lucars and multiplug from latch
assembly.
3. Release cable from latch.
4. Release clip and remove cover from latch.
5. Mark position of latch to boot for reference.
6. Remove 2 bolts securing latch to boot lid.
7. Remove latch assembly.
Refit
1. Position latch to boot lid using reference marks
2. Connect cable and secure to latch.
3. Connect Lucars and multiplug, and fit latch
cover.
4. Check latch operation and if necessary, adjust
boot lid striker. See this section.
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BODY
EXTERIOR FITTINGS 9
FRONT BUMPER ARMATURE
Remove
1. Remove front bumper valance. See this
section.
2. Remove 2 bolts and 2 nuts securing each end
of armature to front panel.
3. Remove armature.
Refit
1. Fit armature to fixing studs.
2. Fit nuts and bolts and tighten to 25 Nm.
REAR BUMPER ARMATURE
Remove
1. Remove rear bumper valance. See this
section.
2. Position luggage compartment carpet aside
and remove 4 bolts securing bumper armature
to body.
3. Remove bumper armature.
Refit
1. Align armature to body and tighten bolts to
22 Nm.
2. Fit rear bumper valance. See this section.
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BODY
10 EXTERIOR FITTINGS
BUMPER VALANCE - FRONT
Remove
2. Remove 2 screws securing each end of
bumper valance to wheel arch liners.
3. Remove 2 screws securing each end of
bumper valance to front wing.
4. Remove 5 screws securing bumper valance to
bonnet locking panel.
5. Remove 2 Torx bolts securing bumper valance
to bumper armature.
6. Disconnect fog/driving lamp multiplugs and
remove front bumper valance.
access onIy.
7. Remove 10 screws securing bumper valance
grille and remove grille.
8. Remove bumper valance badge.
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BODY
EXTERIOR FITTINGS 11
9. Remove 3 screws securing each fog lamp and
remove fog lamps.
10. Remove front number plate.
Refit
1. Clean number plate and mating face.
2. Fit number plate.
3. Clean bumper badge and mating face, fit
badge.
4. Position bumper grille, fit and tighten screws.
5. Position fog/driving lamps, fit and tighten
screws.
6. Fit front bumper valance and connect
fog/driving lamp multiplugs.
7. Fit Torx bolts securing bumper valance to
bumper armature and tighten to 25 Nm.
8. Fit and tighten screws securing bumper
valance to bonnet locking panel.
valance to front wings.
10. Fit and tighten screws securing front bumper to
both wheel arch liners.
REAR BUMPER VALANCE
Remove
2. Remove 2 screws securing bumper valance to
rear of both wheel arches.
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BODY
12 EXTERIOR FITTINGS
3. Remove 2 Torx bolts securing bumper valance
to bumper armature.
4. Open boot lid and position luggage
compartment carpet aside to access multiplugs
and bumper valance retaining nuts.
5. Disconnect both number plate illuminating
lamp multiplugs.
6. Release both number plate illuminating lamp
harness grommets from rear panel.
7. Remove 3 thread covers and 3 nuts securing
bumper valance to rear panel.
8. Release bumper valance from body, taking
care to withdraw number plate illuminating
lamp harnesses through rear panel. Remove
bumper valance.
access onIy.
9. Release and remove both number plate
illuminating lamps.
10. Remove 10 screws securing bumper valance
grille and remove grille.
Refit
1. Position bumper grille, fit and tighten screws.
2. Position number plate illuminating lamps and
secure to bumper valance.
3. Position bumper valance to body, feed number
plate illuminating lamp harnesses through rear
panel and align bumper valance to body.
4. Fit bolts securing bumper valance to bumper
armatures and tighten to 25 Nm.
5. Fit nuts securing bumper valance to rear panel
6. Fit thread covers.
7. Connect number plate illuminating lamp
multiplugs and secure harness grommets.
valance to rear of both wheel arches.
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EXTERIOR FITTINGS 13
AIR VENT - SIDE
Remove
1. Apply protective tape to paintwork around side
air vent.
2. Using a thin flat blade in the position shown
release side air vent from body.
3. Release side air vent from adhesive tape and
remove side air vent.
4. Release and remove air intake duct.
Refit
1. Clean side air vent and mating face of body.
2. Position air intake duct and secure to body.
3. Remove adhesive backing from side air vent
retaining tape.
4. Position side air vent to air intake duct, align
retaining pegs and secure side air vent to
body.
5. Remove protective tape, clean and inspect
paintwork.
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BODY
HOOD 1
HOOD ASSEMBLY COMPONENTS - SOFT TOP
1. Hood frame
2. Hood
3. Backlight
4. Backlight zip
5. Hood cover, tonneau
6. Retaining plate, 6 off
7. Tape elastic, 2 off
8. Tension cable, 2 off
9. Rear bow extrusion
10. Rear bow, canopy insert
11. Pop rivet - tonneau panel, 2 off
12. Stud - tonneau panel, 2 off
13. Link rod, 2 off
14. Front header fabric cover
15. Front header insert
16. Catch - front header, 2 off
17. Torx screw - catch, 6 off
18. Striker - front header, 2 off
19. Torx screw - striker, 4 off
20. Seal - cantrail, 2 off
21. Seal - B post, 2 off
22. Mounting plate - B post, 2 off
23. Screw - plate to body, 4 off
24. Catch - rear hoodwell, 5 off
25. Rivet - hoodwell catch, 10 off
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2 HOOD
HOOD ASSEMBLY COMPONENTS - HARD TOP
1. Hard top assembly
2. Backlight glass
3. Weatherstrip - backlight
4. Headlining
5. Trim stud - headlining, 2 off
6. Seal
7. Finisher - lower edge
8. Block spacer, 2 off
9. Harness extension
10. Catch assembly - front header, 2 off
11. Screw - front catch assembly, 6 off
12. Catch assembly - B post, 2 off
13. Mounting plate - B post, 2 off
14. Header finisher - front
15. Clip - header seal, 6 off
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BODY
HOOD 3
HOOD SEALS AND DOOR GLASS - ADJUST
1. Check door alignment. See Doors.
Adjust
CantraiI seaI
1. Check that cantrail seal butts up to 'A' post
seal correctly, the cantrail seal must not be
distorted when the hood is closed.
2. To adjust cantrail seal release hood and
carefully slide seal either backwards or
forwards in its channel.
3. Ensure seals are located correctly in their
channels.
'A' post seaI
1. Check that 'A' post seal is positioned square at
the corner of the 'A' post and header.
2. To adjust 'A' post seal remove 2 Torx screws
securing header striker and remove striker.
3. Manoeuvre 'A' post seal to its correct position.
4. Close hood and secure with opposite side
hood catch, apply downward pressure on hood
and check that 'A' post seal is aligning
correctly.
5. Release hood and fit header striker and secure
with Torx screws, tighten to 6 Nm .
Cheater
1. Check position of cheater, the cheater must be
parallel with 'A' post when viewed from the side
and front of vehicle.
2. f cheater is protruding out at the top when
viewed from the front it will hold the door glass
away from the seal.
3. To access cheater adjusters remove door
speaker. See ELECTRICAL, Repairs.
4. Lower window and loosen screws B and C .
5. Loosen lock-nut on adjuster A , position
adjuster screw so that it is level with the back
of the nut it screws in to.
6. Push cheater down and pull inboard as far as
possible.
7. Hold cheater in this position and tighten screws
B and C, and the adjuster lock nut A.
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BODY
4 HOOD
8. Ensure window can be raised and lowered
smoothly.
9. Close door and check cheater is positioned
correctly, this can be judged by the bulge made
by the glass on the 'A' post seal which should
be uniform along the seal.
10. Fit speaker. See ELECTRICAL, Repairs.
11. Fit door trim casing See Doors.
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HOOD 5
Door GIass
A: Glass deflection adjustment (pivoting at waist rail).
B: Glass deflection adjustment (pivoting at waist rail).
C: Glass height adjustment (this is also the glass stop).
D: Glass lateral and vertical adjustment.
E: Glass lateral and vertical adjustment.
F: Glass height adjustment (this is also the glass stop).
G: Used at beginning of adjustment to position the door glass centrally in waist rail slot. Tighten bolt to 7 Nm.
H: Positioned at rear glass rail at final stage of adjustment and tightened to 7 Nm.
NOTE: AII gIass adjustments must be
done before the upstroke of the gIass.
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6 HOOD
1. Remove door speaker. See ELECTRICAL,
Repairs.
2. Peel back water shedder to access adjusters.
Height
NOTE: GIass height is correct when
pressure is being appIied to the soft part
of the cantraiI seaI.
1. Lower glass slightly and loosen adjusters C
and F these also act as glass stops.
2. Raise glass to height required, pull adjusters
down in slots and tighten adjusters.
3. Lower glass and then raise fully to ensure
required height has been obtained.
ParaIIeIism
NOTE: The gIass is paraIIeI when it is in
the fuIIy raised position and there is a
constant cIearance of 7 mm between the
gIass and the rear face of the 'A' post.
1. Loosen two height adjusters C and F .
2. Lower glass sufficiently to gain access to
adjusters D and E, loosen adjusters.
3. Lower glass further to gain access to rear sash
rail bracket.
4. Loosen adjuster bolt H .
5. Raise glass until adjusters D and E can be
accessed, then close the door.
6. Adjust the position of the glass until it is parallel
with the 'A' post, tighten adjusters D and E .
7. Open door and lower glass then raise fully,
check that front edge of glass and cheater are
in line.
8. Close door by pushing on glass, check glass
height.
9. f glass height is correct, pull adjusters down in
slots and tighten adjusters C and F .
NOTE: If gIass height is incorrect refer to
height adjustment above.
10. Lower glass to access rear sash bracket,
tighten adjuster H.
11. Raise glass and ensure it pre-loads all
surrounding seals.
12. f pre-load is not sufficient loosen lock-nut on
adjuster B.
13. Position adjuster so that it is level with the back
of nut it is screwed in to, this will tilt the top
edge of the glass inwards.
14. Tighten lock-nut and check pre-load of glass
on seal.
15. f pre-load is still not sufficient loosen bolt G
and slide the bolt down one notch, tighten bolt.
16. Repeat previous instruction until pre-load is
correct.
17. Secure water shedder.
18. Fit speaker. See ELECTRICAL, Repairs.
19. Fit door trim casing See Doors.
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HOOD 7
CANTRAIL TENSIONING CABLES - ADJUST
1. Partially lower hood.
2. Loosen cable locking screws.
3. Raise hood fully, but do not secure catches.
4. Using pliers, pull cables taught and tighten
locking screws.
5. Secure hood catches and check cable tension.
6. f necessary, release hood catches, loosen
cable locking screws and adjust cable tension.
Tighten locking screws.
7. Secure catches.
HARDTOP - ADJUST
NOTE: Check that soft top hood fit is
correct before making any adjustments to
the hardtop fit. See this section.
1. Fit hardtop. See this section.
Adjust
NOTE: If necessary, onIy make
adjustments to the cantraiI seaI and gIass
height. It shouId not be necessary to
disturb any other settings.
CantraiI seaI
1. Check that cantrail seal butts up to 'A' post
seal correctly, the cantrail seal must not be
distorted when the hardtop is secured.
2. To adjust cantrail seal release hardtop and
carefully slide seal either backwards or
forwards in its channel.
3. Ensure seals are located correctly in their
channels.
GIass height
NOTE: If gIass height is incorrect adjust
the height to the minimum requirement, to
prevent too much disturbance to the soft
top hood settings.
1. Adjust glass height. See this section.
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8 HOOD
HARD TOP
Remove
1. Disconnect multiplug from heated rear window.
2. Release 2 catches securing hard top to header
rail.
3. Release 2 catches securing hard top to hood
mounting brackets.
4. With assistance, remove hard top from vehicle.
Refit
NOTE: Ensure side catches are in the
raised position before fitting the hard top
to the vehicIe.
1. With assistance, position hard top to vehicle.
2. Secure hard top to header rail with catches.
3. f necessary, release clips and adjust catches.
4. Secure hard top to hood mounting brackets.
5. Adjust catches if required.
6. Connect screen heater multiplug.
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HOOD 9
HOOD ASSEMBLY
Remove
1. Lower both windows.
2. Release both hood catches, but do not lower
hood.
3. Release rear edge of hoodwell carpet and
release 5 clips securing hood to body.
4. Fold rear of hood, up to release from body.
CAUTION: CIips must be fuIIy reIeased to
ensure that backIight is not damaged
when hood is Iowered.
5. Tilt both seat squabs forward.
6. Remove 3 screws securing bulkhead finisher.
Collect press studs.
7. Release 6 clips and position bulkhead finisher
aside.
8. Remove 4 bolts securing hood to body.
9. Collect 2 hard top strikers.
10. With assistance, remove hood assembly.
CAUTION: Support assembIy beneath
backIight and hinges during removaI.
11. Position hood on a soft covered work surface.
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BODY
10 HOOD
Refit
1. With assistance, position hood to body.
2. Position hard top strikers.
3. With assistance, align hinge brackets to body
and fit bolts but do not tighten at this stage.
4. Raise hood but do not secure catches.
5. Tighten hinge bracket bolts to 45 Nm.
6. Position bulkhead finisher and engage clips.
7. Position press studs and secure bulkhead
finisher with screws.
8. Return seat squabs to original positions.
9. Engage clips to secure rear of hood to body.
10. Engage hoodwell carpet beneath flip seal.
11. Secure catches to secure front of hood.
12. Raise windows.
HOOD OUTER COVER
Remove
The following operation involves the bonding of
fabric backed vinyl to various steel components of
the hood frame. f adhesive is to be applied to the
fabric backing, Dunlop 758 adhesive or equivalent
should be used. For direct application on vinyl
surfaces, use Dunlop S1588 adhesive or equivalent.
A thin coating of adhesive should be applied to both
surfaces and then allowed to cure, until just touch
dry, for between 5 and 10 minutes, before the bond
is made.
1. Remove both hood catches. See this section.
2. Remove both 'B' post seals. See this section.
3. With hood in the lowered position, remove
edge protector from rear of header rail.
4. Release forward 150 mm of cantrail seals from
retainers. release covering from rear of header
rail and fold cover forward to reveal retaining
strip.
5. Locally release foam from retaining strip to
reveal 11 rivets, drill out rivets.
6. Collect header cover assembly.
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BODY
HOOD 11
7. Release outer cover from adhesive on
underside of header rail.
8. Drill out 5 pop rivets securing each 'B' post
seal retainer. Collect retainers.
9. Release outer cover from adhesive on 'B' post
brackets.
10. Bend up tabs and release 'rivet' plates
securing outer cover to base of 'B' post
brackets.
11. Raise hood frame.
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BODY
12 HOOD
release 5 clips.
14. Drill out 5 pop rivets securing each retaining
strip and collect retaining strips.
15. Drill out any rivet heads still captive in hood
frame.
16. Loosen cable locking screws and release
cables from outer cover.
NOTE: Leave cabIes attached at header
raiI.
17. Release outer cover flaps from adhesive on 1st
and 2nd hood bows.
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BODY
HOOD 13
18. Release felt covering from 3rd hood bow.
19. Remove 7 nuts securing outer cover clamp rail
to 3rd hood bow.
20. Release clamp rail studs from bow and remove
outer cover assembly.
21. Remove clamp rail from outer cover.
22. Remove 4 bolts securing hood frame and with
assistance remove hood frame.
23. nvert frame and shake vigorously to remove
rivets and swarf from frame.
Refit
1. Position hood frame, fit and tighten bolts.
2. Remove any uneven deposits of adhesive from
'B' post brackets, clamp rail and header rail
using a suitable solvent.
3. Position new outer cover to a soft covered
work surface.
4. Fold outer cover in half and chalk centre line to
aid alignment.
5. Measure and mark centre line on underside of
hood header rail.
6. Apply adhesive to clamp rail and outer cover.
7. Bond clamp rail to outer cover with larger
flange towards edge of material.
8. f necessary, apply adhesive to clamp rail and
felt covering. Bond covering centrally to clamp
rail, ensuring that slotted ends remain free.
9. Position outer cover over raised hood frame
and engage clamp rail studs to bow.
10. Secure clamp rail with nuts.
11. Apply adhesive to 3rd hood bow and mating
surface of felt covering.
CAUTION: Ensure underside of outer
cover does not become contaminated with
adhesive.
12. Bond felt covering to 3rd bow, ensuring that
slots are correctly positioned around frame
straps.
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14 HOOD
13. Align hood rear quarters to lower rail, ensuring
that:
Lower edge of rail and cover reinforcement
strip are aligned.
Centre of rivet hole in lower rail is 5 mm from
end of reinforcement strip as shown.
14. Transfer holes from lower rail into outer cover,
using a bradawl or similar tool.
15. With careful use of a drill, open out holes to
3.5 mm.
16. Position retaining strips and secure hood rear
quarters to lower rail with pop rivets.
17. Raise backlight into position and secure with
zip.
20. Partially lower hood frame.
21. Apply adhesive to underside of header rail and
mating surface of outer cover.
22. Temporarily fit hood catches.
23. Position outer cover to header, then make
adhesive joint in three small areas.
CAUTION: Do not make a permanent joint
at this stage as adjustment may be
necessary.
25. Check outer cover tension.
26. Lower hood partially.
27. Adjust position of outer cover and recheck
tension if necessary.
28. Remove hood catches.
29. Bond outer cover securely to header rail,
ensuring cover does not crease.
30. Trim off excess material using a sharp knife.
31. Lower hood fully.
32. Position header cover assembly.
33. Transfer holes in header cover retainer through
outer cover into header rail.
34. Secure header cover retainer with pop rivets.
35. Apply adhesive to header rail and mating
surface of header cover.
adhesive.
36. Bond header cover.
37. Fit edge protector to rear of header rail.
38. Secure forward ends of cantrail seals in
retainers.
39. Fit hood catches. See this section.
40. Raise hood partially.
41. Engage outer cover rivet plates to 'B' post
brackets and bend over tabs to secure.
42. Apply adhesive to 'B' post brackets and mating
surfaces of outer cover.
43. Raise hood, but do not secure catches.
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HOOD 15
44. Thread cantrail cables through pockets in outer
cover and engage in frame locations.
45. Bond outer cover to 'B' post brackets, ensuring
that even tension is applied as bond is made.
46. Position 'B' post seal retainers.
47. Transfer holes in retainers through outer cover
into brackets.
48. Secure retainers with pop rivets.
49. Fit 'B' post seals. See this section.
50. Apply adhesive to outer cover flaps and mating
surfaces of 1st and 2nd hood bows.
CAUTION: Ensure that underside of outer
adhesive.
51. Check cosmetic appearance of hood.
52. Adjust cantrail cables. See this section.
53. Remove protection.
54. Secure hood catches.
55. Close windows.
HOOD FRAME
Remove
1. Remove outer cover. See this section.
2. Remove backlight. See this section.
3. Tilt both seat squabs forward.
4. Remove 3 screws securing bulkhead finisher,
collect press studs.
5. Release 6 clips and position bulkhead finisher
aside.
6. Remove 4 bolts securing hood frame to body.
7. Collect hard top strikers.
8. With assistance, remove hood frame.
9. Remove cantrail seals. See this section.
10. Bend up tabs securing cantrail tensioning
cables to header rail.
11. Remove tensioning cables.
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16 HOOD
Refit
1. Position cantrail tensioning cables to header
rail.
2. Secure cables top header rail by bending tabs.
3. Fit cantrail seals, leaving forward ends
disengaged from retainer. See this section.
4. With assistance, position frame.
5. Position hard top strikers.
6. With assistance, align hinge brackets to body
and secure with bolts. Tighten bolts to 45 Nm.
7. Raise hood frame.
8. Position bulkhead finisher and engage clips.
9. Position press studs and secure bulkhead
finisher with screws.
10. Return seat squabs to original positions.
11. Fit outer cover. See this section.
12. Fit backlight. See this section.
BACKLIGHT
Remove
2. Release hood catches, but do not lower hood.
release 5 clips.
CAUTION: CIips must be fuIIy reIeased to
ensure that backIight is not damaged.
5. Unzip backlight.
6. Lay backlight flat in hoodwell.
7. Place protective covering over backlight and
boot.
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HOOD 17
8. Remove 2 rivets securing ends of hood rear
quarter retaining strips.
9. Carefully bend back ends of strips to reveal
rivets.
10. Drill out 13 pop rivets securing backlight
retaining strip.
11. Collect retaining strip and remove backlight.
12. Release felt covering from 3rd hood bow.
13. Remove 7 nuts securing outer cover clamp rail.
14. Partially lower hood frame.
15. Release clamp rail studs from hood frame.
16. Lay protective sheet over backlight, luggage
compartment lid and seats.
17. Release foam from ends of zip retainer to
reveal pop rivets.
18. With assistance to hold outer cover aside, drill
out 9 pop rivets securing zip retainer to hood
frame.
19. Remove backlight zip.
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18 HOOD
Refit
1. Drill out any rivet heads still captive in hood
frame.
CAUTION: CIear away swarf from
protective covering to ensure that new
backIight does not become scratched.
2. With assistance, position backlight to frame,
centralise and transfer holes into backlight.
3. Position backlight to a soft covered work
surface.
4. With careful use of a drill, enlarge holes to 3.5
mm.
5. Position backlight to frame, align retainer and
secure with pop rivets.
NOTE: Start at the centre Iocation and
work outwards.
6. Secure ends of rear quarter retaining strips
with rivets.
7. Position zip assembly to frame and secure with
rivets.
8. Fit foam pads to both ends of hood bow.
NOTE: Foam pads are designed to prevent
outer cover being damaged by ends of
hood bow and zip retainer.
9. Position outer cover clamp rail to frame and
engage studs.
11. Secure outer cover, clamp rail with nuts.
12. Apply adhesive to 3rd hood bow and mating
surface of felt covering.
adhesive.
13. Bond felt covering to 3rd bow, ensuring that
slots are correctly positioned around frame
straps.
14. Remove protective covering.
15. Raise backlight into position and secure with
zip.
19. Raise windows.
HOOD CATCH
Remove
1. Lower hood.
2. Remove 3 Allen screws securing catch to hood
header rail.
3. Remove hood catch.
Refit
1. Position catch and fit screws, finger tight.
3. Align catch to striker and tighten screws to
20 Nm.
4. Check operation of hood catches. f necessary,
release locking wire and turn hexagonal
adjuster to give correct action.
5. Secure locking wire.
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HOOD 19
CANTRAIL TENSIONING CABLE
The following operation involves the bonding of
fabric backed vinyl to various steel components of
the hood frame. f adhesive is to be applied to the
fabric backing, Dunlop 758 adhesive or equivalent
should be used. For direct application on vinyl
surfaces, use Dunlop S1588 adhesive or equivalent.
A thin coating of adhesive should be applied to both
surfaces and then allowed to cure, until just touch
dry, for between 5 and 10 minutes, before the bond
is made.
2. Loosen cable locking screw.
3. Release cable from location.
4. Lower hood fully.
5. Release forward 100 mm of cantrail seal from
retainer.
6. Peel outer cover away from header in
immediate area of cable location.
7. Bend location tag up by minimum amount
necessary and release cantrail tensioning
cable from header rail.
8. Remove cantrail tensioning cable.
Refit
1. Locate cable loop over location tag in header
rail and bend tag over to retain cable.
2. Apply adhesive to outer cover and header rail.
3. Bond outer cover to header rail, ensuring that
beading at side of header is correctly
positioned.
4. Fit forward end of cantrail seal to retainer.
5. Partially raise hood.
6. nsert new cable into pocket of outer cover.
7. Thread cable through location in 2nd hood
bow.
8. Raise hood fully, but do not secure catches.
9. Using pliers, pull cable taught and tighten
locking screw.
10. Secure hood catches and check cable tension.
11. f necessary, release hood catches, loosen
cable locking screw and adjust cable tension.
Tighten locking screw.
12. Secure catches.
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20 HOOD
BACKLIGHT ZIP
Remove
1. Remove backlight assembly. See this section.
2. Entrust replacement of zip to trim specialist.
Refit
1. Refit backlight assembly. See this section.
HARD TOP HEADLINING
Remove
1. Remove front catches. See this section.
2. Remove 2 trim studs securing rear of
headlining to hard top.
3. Remove headlining.
Refit
1. Position headlining and secure with trim studs.
2. Fit front catches. See this section.
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HOOD 21
HARD TOP CATCH - REAR
Remove
1. Remove hard top. See this section.
2. nvert hard top on a soft covered work surface.
3. Position protection over headlining and
backlight.
4. Drill out 2 pop rivets securing catch to hard top.
5. Remove catch.
Refit
1. Position catch and secure with rivets.
2. Fit hard top. See this section.
3. Check operation of catch. f necessary, turn
adjuster to give correct action.
4. Secure catch.
HARD TOP CATCH - FRONT
Remove
3. Remove 3 Allen screws securing catch to hard
top.
4. Remove catch.
Refit
1. Position catch and tighten screws to 10 Nm.
3. Check operation of catch. f necessary, release
locking wire and turn hexagonal adjuster to
give correct action.
4. Secure locking wire.
5. Secure catch.
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22 HOOD
HARD TOP SEAL
Remove
3. Release seal from adhesive at header and
below backlight.
4. Release 26 studs securing seal to hard top.
5. Remove seal.
Refit
1. Remove all traces of dirt and grease from
surfaces to be bonded using a suitable mild
solvent.
2. Apply Loctite 401 to hard top using old
deposits as a guide.
3. Position seal, centralise and carefully bond to
hard top.
4. Engage studs securing seal to hard top.
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HOOD 23
CANTRAIL SEAL
2. Depress locking buttons and release both hood
catches.
4. Position protective covering beneath frame.
5. Drill out pop rivets securing seal to frame
channels.
6. Release seal from 2 retainers.
7. Remove seal.
Refit
1. Apply liquid soap to seal retainers.
2. Position seal and engage to retainers.
3. Raise hood and check seal fit.
4. f necessary, partially lower hood, reposition
seal in retainers and recheck.
5. Carefully transfer rivet holes into seal using a
3 mm drill bit.
CAUTION: Care must be taken not to driII
through the outer surface of the seaI.
6. Secure seal with pop rivets.
8. Raise windows.
'B' POST SEAL
2. Depress locking buttons and release both hood
catches.
4. Remove seal from retainer.
Refit
1. Apply liquid soap to seal retainer.
2. Fit seal to retainer.
3. Raise hood and check seal fit.
4. f necessary, partially lower hood, reposition
seal in retainer and recheck.
6. Raise windows.
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24 HOOD
HARD TOP - BACKLIGHT
Remove
3. Disconnect 2 Lucar terminals and remove
heated screen harness.
WARNING: GIoves and suitabIe eye
protection must be worn when removing
gIass.
4. Working from inside hard top and commencing
from lower LH corner, release sealing rubber.
Remove glass and seal.
CAUTION: Use assistance to support
gIass as it is removed.
5. Remove and discard rubber seal.
Refit
1. Clean hard top aperture and edge of glass.
2. Apply rubber lubricant to seal channels.
3. Fit sealing rubber to glass.
WARNING: GIoves and suitabIe eye
protection must be worn when fitting
gIass.
4. nsert a suitable length of cord in hard top
aperture channel of sealing rubber.
5. Using assistance, push glass against hard top
aperture whilst using cord to pull lip of seal
over aperture flange.
6. Clean all traces of rubber lubricant from glass
and hard top using white spirit.
7. Fit heated screen harness and connect Lucar
terminals.
9. Press firmly around outside edges of glass to
ensure that seal is fully seated.
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INTERIOR TRIM COMPONENTS 1
SUN VISOR
Remove
1. Lower sun visor.
2. Remove 2 screws securing visor to header rail.
3. Remove visor.
Refit
1. Position visor and secure with screws.
INTERIOR MIRROR
Remove
1. Release mirror from screen mounted clip.
2. Release cable and multiplug from header
finisher.
3. Disconnect multiplug and remove mirror.
Refit
1. Connect multiplug and position cable to recess
in mirror mounting.
2. Fit mirror to windscreen.
3. Position excess cable and multiplug behind
header finisher.
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2 INTERIOR TRIM COMPONENTS
LUGGAGE COMPARTMENT TRIM
Remove
1. Remove 4 clips securing trim to engine
compartment bulkhead.
2. Release trim from flip seal, bonnet release
lever and boot lid striker.
3. Remove trim.
Refit
1. Fit trim and secure with clips.
2. Position trim behind flip seal.
3. Position trim to bonnet release lever and boot
lid striker.
'A' POST TRIM
Remove
1. Lower sun visor.
3. Remove 2 Tx30 Torx screws securing hood
striker.
4. Remove striker.
5. Release 4 sprag clips securing trim to 'A' post.
6. Remove 'A' post trim.
Refit
1. Position trim and engage sprag clips.
2. Fit hood striker and tighten screws to 6 Nm.
3. Reposition sun visor.
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REAR BULKHEAD FINISHER
Remove
1. Remove front seats. See this section.
2. Remove 3 screws securing finisher and collect
press studs.
3. Release finisher from fixings.
4. Remove 4 screws securing belt guides to
finisher.
5. Release belt guides from finisher and remove
from belt.
6. Slide seat belts through finisher and remove
finisher from vehicle.
Refit
1. Position finisher and thread seat belts into
position.
2. Fit seat belt guides and locate guides into
position.
3. Secure guides with screws.
4. Align finisher to studs and secure into position.
5. Position press studs and secure with screws.
6. Fit front seats. See this section.
HEADER TRIM
Remove
1. Remove both sun visors. See this section.
3. Remove 2 Tx30 Torx screws securing each
hood striker and remove strikers.
4. Release 6 sprag clips securing trim to header
rail.
5. Remove trim.
Refit
1. Position trim and engage sprag clips.
2. Fit hood strikers and tighten screws to 6 Nm.
3. Fit sun visors. See this section.
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FRONT CONSOLE
SRS Precautions.
Remove
1. Make SRS system safe. See GENERAL
2. Remove centre console panel. See this
section.
CAUTION: Ensure pre-tensioner muItipIug
is disconnected before seat is removed.
3. Remove rear console. See this section.
4. Remove both console closing panels. See this
section.
5. Remove 6 screws securing console to tunnel.
6. Loosen handbrake adjustment and position
hand brake lever in ON position.
7. Release handbrake gaiter from console and
remove gaiter from handbrake.
8. Release console and disconnect multiplug from
cigar lighter.
9. Release volumetric sensor cable and remove
console.
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Refit
1. Position front console, connect cigar lighter
multiplug and position volumetric sensor cable.
2. Position console and secure with screws.
3. Fit handbrake gaiter and secure with band.
4. Engage gaiter to console.
5. Adjust handbrake. See BRAKES,
Adjustments.
6. Fit console closing panels. See this section.
7. Fit rear console. See this section.
CAUTION: Ensure that pre-tensioner
fIyIead is correctIy cIipped to seat base
before fitting seat, as shown in seat refit.
See this section.
8. Fit centre console panel. See this section.
9. Connect both battery terminals, earth lead last.
REAR CONSOLE
Remove
1. Remove rear bulkhead finisher. See this
section.
2. Disconnect multiplug from volumetric sensor.
3. Remove 2 screws securing rear console to rear
bulkhead.
4. Open rear console lid and remove 2 screws
securing console lid bracket to rear console.
5. Open front console lid and remove storage bin
from front console.
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6. Remove 2 screws securing console lid bracket
to front console and remove console lid
assembly.
7. Remove rear console.
8. Remove 2 screws securing volumetric sensor
to rear console and remove sensor.
Refit
1. Fit sensor to console and secure with screws.
2. Fit rear console to bulkhead and secure with 2
upper screws. Ensure correct position of cable.
3. Fit console lid assembly and secure with
screws.
4. Fit front console storage bin.
6. Fit rear bulkhead finisher. See this section.
GEAR LEVER GAITER
Remove
1. ManuaI modeIs: Unscrew and remove gear
knob.
2. Stepspeed (Em-CVT) modeIs: Select position
'D', pull gear selector lever sharply upwards
and remove.
3. AII modeIs: Release gaiter from centre
console.
4. Stepspeed (Em-CVT) modeIs: Disconnect
gearshift selector indicator multiplug.
5. Remove 2 screws securing gearshift selector
indicator and remove selector indicator.
6. AII modeIs: Remove gaiter.
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Refit
1. Position gaiter.
2. Stepspeed (Em-CVT) modeIs: Fit gearshift
selector indicator and secure with screws.
3. Connect multiplug to selector indicator.
4. AII modeIs: Secure gaiter to centre console.
5. Fit gear change selector knob.
CENTRE CONSOLE PANEL
Remove
2. Remove radio. See ELECTRICAL, Repairs.
3. Remove gear lever gaiter. See this section.
4. Release 5 clips securing console to fascia.
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5. Release 3 Lucars from clock.
6. Release multiplug and bulb holder from oil
temperature gauge.
7. Release hazard switch multiplug.
8. Release multiplugs from switches.
9. Remove centre console panel.
Refit
1. Position console and connect multiplugs,
Lucars and bulb holder.
2. Secure console clips to fascia.
3. Fit gear lever gaiter. See this section.
4. Fit radio. See ELECTRICAL, Repairs.
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CONSOLE CLOSING PANEL
Remove
1. Remove 2 screws securing panel to console.
2. Release panel and disconnect 2 Lucars from
lamp.
3. Remove lamp from panel.
Refit
1. Fit lamp to panel and connect Lucars.
2. Position panel and secure with screws.
FASCIA PANEL
SRS Precautions.
Remove
1. Make SRS system safe.See GENERAL
2. Remove front console. See this section.
4. Remove instrument pack. See
INSTRUMENTS, Repairs.
5. Remove glovebox. See this section.
6. Remove 4 screws securing heater controls to
fascia and position aside.
7. Loosen 2 screws securing fuse box cover to
fascia and remove cover.
8. Release both screen heater ducts from fascia
and position aside.
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9. Loosen 4 nuts securing fascia to lower 'A' post.
10. Release 4 retaining bolt caps from fascia and
collect caps.
11. Remove 4 bolts securing fascia to scuttle.
12. Remove fascia panel.
Refit
1. Position fascia to scuttle.
2. Align fascia and secure with nuts and bolts.
3. Fit retaining bolt caps.
4. Engage heater ducts to fascia.
5. Position fuse box cover to fascia and secure
with screws.
6. Align heater controls to fascia and secure with
screws.
7. Fit glovebox. See this section.
8. Fit instrument pack. See INSTRUMENTS,
Repairs.
10. Fit front console. See this section.
GLOVEBOX
Remove
1. Open glovebox lid.
2. Remove 4 screws securing glovebox to fascia.
3. Release glovebox and disconnect 4 Lucars.
4. Remove glovebox.
Refit
1. Position glovebox and connect Lucars.
2. Engage glovebox to fascia and secure with
screws.
3. Close glovebox lid.
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GLOVEBOX LATCH
Remove
1. Open glovebox lid.
2. Remove screw securing latch to glovebox lid.
3. Remove latch.
Refit
1. Position latch to glovebox lid and secure with
screw.
2. Close glovebox lid.
HOODWELL TRIM
Remove
2. Release hood catches, do not lower hood.
3. Release rear edge of hoodwell trim to reveal 5
clips.
4. Release clips securing rear of hood to body.
5. Raise rear edge of hood.
6. Remove hoodwell trim.
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Refit
1. Fit trim and engage beneath lip of bulkhead
finisher.
2. Reposition rear edge of hood.
4. Engage hoodwell trim beneath flip seal.
6. Raise windows.
HEAD RESTRAINT
Remove
1. Rotate inboard head restraint, guide cap 90 .
2. Remove head restraint.
Refit
1. Fit head restraint.
2. Rotate inboard head restraint, guide cap back
90 to lock head restraint.
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SEAT
Remove
WARNING: AIways remove the ignition
key from the ignition switch, disconnect
the vehicIe battery and wait 10 minutes
before commencing work on the SRS system.
2. Lift seat adjuster, move seat rearwards.
3. Remove Torx screw from front of each seat
runner.
4. Lift seat adjuster, move seat forwards.
5. Rotate recline handle to tilt squab fully forward.
6. Remove Torx screw from rear of each seat
runner.
7. Disconnect seat belt pre-tensioner multiplug.
8. Position seat and remove Torx screw securing
seat belt strap to seat frame.
9. Remove seat.
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Refit
1. Ensure harness lead does not become trapped
under seat runner when fitting seat.
2. Position seat belt strap to seat frame and
tighten Torx screw to 30 Nm.
3. Ensure that pre-tensioner lead is correctly
clipped to seat base.
4. Position seat and align runners to floor bolt
holes.
5. Connect pre-tensioner multiplug.
6. Fit but do not tighten Torx screw securing rear
of each seat runner.
7. Lift seat adjuster, move seat rearwards.
8. Fit Torx screw securing front of each seat
runner and tighten to 45 Nm.
9. Lift seat adjuster, move seat forwards.
10. Tighten Torx screw securing rear of each seat
runner to 45 Nm.
11. Connect both battery leads, earth lead last.
SEAT SQUAB ASSEMBLY
Remove
2. Remove front seat. See this section.
3. Release 2 clips securing pre-tensioner harness
to underside of seat.
4. Remove Torx bolt securing pre-tensioner to
seat and remove pre-tensioner.
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5. Remove outer half of squab recline control
handle.
6. Remove inner half of recline control handle.
7. Using a suitable punch, drive out 2 retaining
pins securing the side valance.
8. Remove side valance.
9. Remove 4 Torx bolts securing squab frame to
cushion frame.
10. Remove seat squab assembly.
Refit
1. Position squab frame to cushion frame, fit Torx
2. Fit side valance and secure with retaining pins.
3. Fit inner half of squab recline handle.
4. Fit outer half of squab recline handle.
5. Fit pre-tensioner to squab frame, fit Torx bolt
6. Secure pre-tensioner harness clips to
underside of seat.
7. Fit front seat. See this section.
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COVER - ONE PIECE - FRONT SEAT CUSHION
Remove
2. Remove seat squab assembly. See this
section.
3. Release 2 retainers securing sides of cushion
cover to seat frame.
4. Release retainer securing rear of cushion
5. Release retainer securing front of cushion
6. Release cushion cover from seat frame and
remove cushion assembly.
7. Remove seat membrane.
access onIy.
8. Noting the fitted position, remove and discard
16 hog rings securing cushion cover to cushion
pad.
9. Remove cushion cover from cushion pad.
Refit
1. Position cushion cover to cushion pad and
secure with new hog rings using 78 R002 .
2. Position seat membrane.
3. Position cushion cover assembly to cushion
frame.
4. Secure front, rear and side cushion retainers to
cushion frame.
5. Fit seat squab assembly. See this section.
6. Carry out system check by turning the ignition
on and checking the SRS warning light
illuminates for 4 seconds and then
extinguishes.
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COVER - SQUAB - FRONT SEAT
Remove
2. Remove seat squab assembly. See this
section.
3. Rotate inboard head restraint guide cap 90
and remove head restraint.
4. Remove head restraint guide tube caps.
5. Release squab cover lower retainer.
6. Release seat membrane from bottom of seat
frame.
7. Noting the fitted position, release shock cords
from pullmaflex and seat frame.
8. Raise squab cover to access other end of
shock cords.
9. Noting the fitted position, release shock cords
from pullmaflex.
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BODY
10. Untie and release seat membrane.
11. Remove squab frame from squab pad.
12. Remove seat membrane.
access onIy.
13. Release squab cover from squab pad to
access hog rings.
14. Noting the fitted position, remove and discard
12 hog rings.
15. Remove squab cover from squab pad.
16. Remove shock cords from squab cover.
Refit
1. Position shock cords to squab cover.
2. Position squab cover to squab pad and secure
with new hog rings using 78 R002 .
3. Align squab cover to squab pad.
4. Position seat membrane.
5. Fit squab cover and pad to frame.
6. Secure seat membrane to squab frame.
7. Align shock cords and secure to pullmaflex
frame.
8. Align squab cover to seat frame.
9. Align shock cords and secure to pullmaflex
frame.
10. Align seat membrane to bottom of squab
frame.
11. Secure squab cover lower retainer.
12. Fit head restraint guide tube caps.
13. Fit head restraint.
14. Fit seat squab assembly. See this section.
15. Carry out system check by turning the ignition
on and checking the SRS warning light
illuminates for 4 seconds and then
extinguishes.
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BODY
SCREENS 1
WINDSCREEN
NOTE: The foIIowing equipment is
required:
Cutting wire and handIes
Windscreen repair kit
SeaIer appIicator gun
Suction cups
WARNING: Wear protective gIoves when
handIing gIass, soIvents and primers.
WARNING: Wear suitabIe eye protection
when removing and refitting gIass.
Remove
1. Remove air intake panel. See HEATING &
VENTILATION, Repairs.
2. Remove header trim. See Interior trim
components.
3. Remove 'A' post trim, See Interior trim
components.
4. Remove interior mirror. See Interior trim
components.
5. Fit protection to bonnet and areas around
screen.
6. Cover heater ducts with masking tape.
7. Cover interior of vehicle with protective sheet.
8. Make knife cut in sealant at bottom of 'A' post.
9. nsert cutting wire through previously made
knife cut and fit handles as shown, with
approximately 200 mm of wire between
handles.
10. With assistance, wedge tube of handle A
between glass and body, ahead of cutting
position, and carefully cut sealer using a
continuous pull on handle B from the outside.
Ensure that glass is retained as last sealant is
cut.
NOTE: If muIti-strand cutting wire is used,
a sawing action can be used to cut
through heavy seaIant deposits around
corners.
CAUTION: Use of a sawing action may
overheat and break singIe strand wire.
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BODY
2 SCREENS
11. Attach suction cups and use assistance to
remove glass from body.
CAUTION: Lay gIass on feIt covered
supports. Do not stand on edge. Any
chipping of gIass edge may deveIop into
cracks.
Refit
1. Carefully remove excess sealer from body
leaving a smooth surface.
2. Use a vacuum cleaner to clear away any
waste.
3. Original glass: Carefully cut back old sealer to
obtain a smooth surface without damaging
obscuration band on glass.
4. Fit 2 brackets and tighten screws.
5. With assistance, locate screen upright on
brackets and then lay in position in body frame.
6. Carefully centre screen in body frame and
apply masking tape reference marks from
screen to body, on each side of lower screen.
7. Cut tape at edge of screen, and with
assistance remove screen and place aside.
8. Clean frame and edge of screen with solvent.
CAUTION: Do not touch cIeaned or primed
surfaces with fingers.
9. Apply etch primer to any bare metal on frame.
10. Apply bonding agent to screen and allow to
cure.
11. Apply primer over etch primer on frame.
12. Apply activator over old sealer on frame.
13. Allow activator to cure.
14. Fit pre-cut nozzle to sealer cartridge, remove
lid and shake out crystals, and install in
applicator gun.
NOTE: NozzIe wiII need modification to
achieve required bead section.
15. Apply a continuous bead of sealer around edge
of frame as shown. Make bead slightly thicker
at each corner.
16. Check for breaks and air bubbles in sealer.
17. With assistance, lift screen into place and align
to brackets and tape. Lightly press glass to
seat sealer.
18. Remove protective covers and tape.
19. Test sealer for leaks, apply additional sealer if
necessary. f water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
20. Fit 'A' post trim. See Interior trim
components.
21. Fit header trim. See Interior trim
components.
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BODY
SCREENS 3
22. Fit interior mirror. See Interior trim
components.
23. Fit air intake panel. See HEATING &
CAUTION: A curing time of 6 hours is
desirabIe, during this time Ieave a window
open and do not sIam the doors. If the car
must be used, drive sIowIy.
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HEATING & VENTILATION
CONTENTS Page
OPERATON 1 .............................................................................................................
REPAIRS
CONTROLS - HEATER 1 ............................................................................................
CABLE - WATER VALVE CONTROL 3 .......................................................................
CABLE - AR DSTRBUTON CONTROL 5 ................................................................
HEATER VALVE 6 .......................................................................................................
HEATER FAN SWTCH 7 ............................................................................................
FACE LEVEL VENT - RH 8 .........................................................................................
FACE LEVEL VENT - LH 9 ..........................................................................................
FACE LEVEL VENT - CENTRE 9 ................................................................................
AR NTAKE PANEL 10 ...............................................................................................
HEATER 10 .................................................................................................................
HEATER - WTH AR CONDTONNG 14 ...................................................................
RECRCULATON SERVO MOTOR 17 .......................................................................
HEATER BLOWER 18 .................................................................................................
HEATER RESSTOR 19 ..............................................................................................
HEATER MATRX 20 ...................................................................................................
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OPERATION
1. Heater duct
2. Heater and blower unit
3. Heater control unit
4. Blower switch
5. Temperature control
6. Distribution control
7. Control cable - air distribution
8. Control cable - temperature control
9. Distribution control, lever
10. Heater valve
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Air drawn through the intake below the windscreen,
passes through a heater duct into the heater unit to
enter the interior of the car through fascia vents, via
a moulded heater duct in the fascia.
When the temperature control is rotated towards the
heated air position it opens a heater valve in the
engine cooling system allowing hot coolant from the
engine to circulate through the heater matrix.
The distribution of air entering the car through the
heater is dependent on the positions of distribution
flaps inside the heater unit.
The distribution flaps are adjusted by rotation of the
distribution control to direct the air in various
proportions to the vents at face level, foot level and
the windscreen.
When the blower switch is switched off, the volume
of air entering the blower unit depends on the ram
effect of the car's forward motion. Four fan speeds
are available on the switch to supplement the ram
effect.
Operation of the thumb-wheel in either, the side or
centre face level vents will open or close the vents.
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REPAIRS 1
CONTROLS - HEATER
Remove
trim components.
2. Remove 2 nuts securing alarm ECU, release
ECU and position aside.
3. Remove 3 screws securing alarm ECU support
plate and remove support plate.
4. Remove 4 screws securing heater controls and
release controls from support bracket.
5. Disconnect heater control multiplugs.
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2 REPAIRS
6. Loosen screw securing temperature control
outer cable and release inner cable from
control lever.
7. Loosen screw securing distribution cable
control outer cable.
8. Release inner cable from control lever.
9. Remove control assembly.
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REPAIRS 3
Refit
1. Position control assembly and connect inner
cables.
2. Secure outer cables in clips, do not clamp
screws at this stage.
3. Connect control multiplugs.
4. Align controls to support bracket. Fit and
tighten screws.
5. Turn distribution control fully anti-clockwise to
face vent position.
6. Position air distribution lever fully forward.
7. Align outer cable to abutment and secure
clamp screw.
8. Turn heater control to 'cold' and heater valve
lever fully clockwise.
9. Secure outer cable clamp screw.
10. Position alarm ECU support plate, fit and
tighten screws.
11. Position alarm ECU, fit and tighten nuts.
components.
CABLE - WATER VALVE CONTROL
Remove
trim components.
2. Remove 2 nuts securing alarm ECU to heater
control unit and position alarm ECU aside.
3. Remove 3 screws securing alarm ECU support
plate and remove support plate.
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4 REPAIRS
4. Remove 4 screws securing controls to fascia.
5. Release controls from fascia.
6. Remove screw securing cable clamp to
controls and collect clamp.
7. Release cable from controls.
8. Remove clip securing cable outer to heater
valve.
9. Release cable from valve and remove cable.
Refit
1. Engage cable to heater valve.
2. Engage cable to heater controls and secure
cable clamp.
3. Turn heater control to 'COLD' and heater valve
lever fully clockwise.
4. Secure outer cable to valve with clip.
5. Position controls to fascia and secure with
screws.
6. Position alarm ECU support plate and secure
with screws.
7. Position alarm ECU to heater control unit, fit
components.
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REPAIRS 5
CABLE - AIR DISTRIBUTION CONTROL
Remove
trim components.
2. Remove 4 screws securing controls to fascia.
3. Release controls from fascia.
4. Remove screw securing cable clamp to
controls and collect clamp.
5. Release cable from controls.
6. Remove clip securing cable outer to heater.
7. Remove star washer securing cable to air
distribution control lever.
8. Remove cable from heater.
Refit
1. Position cable to air distribution control lever
and secure with star washer.
2. Engage cable to heater controls.
3. Align collar of outer cable to heater control
abutment and secure with clamp.
4. Turn distribution control fully anti-clockwise to
face vent position.
5. Position air distribution lever fully forward.
6. Align outer cable to abutment and secure with
clip.
7. Position controls to fascia and secure with
screws.
components.
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6 REPAIRS
HEATER VALVE
Remove
1. Drain coolant system. See COOLING
2. Remove both console closing panels. See
BODY, Interior trim components.
3. Remove 2 screws securing valve to heater
assembly.
4. Remove clip securing cable outer to valve and
release cable from valve lever.
5. Position cloth and container to catch spillage.
6. Release 2 clips securing hoses to valve.
7. Release top hose.
8. Remove valve from bottom hose.
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REPAIRS 7
Refit
1. Fit valve to lower hose and secure with clip.
2. Position upper hose to valve and secure with
clip.
3. Engage cable to valve lever.
4. Position valve to heater assembly and secure
with screws.
5. Turn heater control fully to 'COLD'.
6. Turn valve lever fully clockwise.
7. Position cable outer and secure with clip.
8. Fit console closing panels. See BODY,
9. Refill coolant system. See COOLING
HEATER FAN SWITCH
Remove
trim components.
2. Remove 4 screws securing heater control unit
to fascia and position control unit aside.
3. Disconnect multiplug from control unit.
4. Remove 3 knobs from control assembly.
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8 REPAIRS
5. Remove 2 screws securing illumination
housing to assembly and remove housing.
6. Remove 2 screws securing fan switch to
assembly.
7. Remove switch.
Refit
1. Position switch to assembly and secure with
screws.
2. Position illumination housing to assembly and
secure with screws.
3. Fit control knobs.
5. Position control unit to fascia and secure with
screws.
components.
FACE LEVEL VENT - RH
Remove
1. Turn clips securing fuse box cover
1
/
4
turn and
open cover.
2. Release 4 clips securing vent to fascia.
3. Remove vent.
Refit
1. Fit vent to fascia and engage clips.
2. Close fuse box cover and secure with clips.
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REPAIRS 9
FACE LEVEL VENT - LH
Remove
components.
3. Remove vent.
Refit
components.
FACE LEVEL VENT - CENTRE
Remove
3. Remove vent.
Refit
trim components.
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10 REPAIRS
AIR INTAKE PANEL
Remove
1. Remove wiper arms. See WIPERS &
WASHERS, Repairs.
2. Remove 6 retaining screw caps from intake
moulding.
3. Remove 6 screws and 6 clips securing panel to
scuttle.
4. Release intake panel from clips and remove
panel.
Refit
1. Position panel to scuttle and secure with clips
and screws.
2. Fit screw caps.
3. Fit wiper arms. See WIPERS & WASHERS,
Repairs.
HEATER
SRS Precautions.
Remove
1. Make the SRS system safe See GENERAL
2. Remove fascia. See BODY, Interior trim
components.
3. Remove 2 nuts securing anti-theft alarm ECU
to heater control unit, position ECU aside.
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REPAIRS 11
5. Remove 2 screws retaining outer cables to
control unit.
6. Release cables from control unit.
7. Disconnect 2 multiplugs and remove control
unit.
8. Remove 2 screen ducts from heater.
casing.
10. Position container beneath heater to catch
spillage.
11. Release clips and disconnect both hoses from
heater matrix. Allow matrix to drain.
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12 REPAIRS
12. Disconnect multiplug from heater blower.
13. Remove nut securing intake duct to body.
14. Remove intake duct.
15. Remove 2 nuts securing heater unit to
crossmember.
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REPAIRS 13
16. Remove bolt securing heater unit to bulkhead.
17. Remove heater unit.
Refit
1. Position heater to mountings.
2. Tighten all fixings to 10 Nm.
3. Position intake duct and tighten nut to 10 Nm.
4. Connect multiplug to heater blower.
5. Connect hoses to heater matrix and secure
with clips.
6. Position valve and secure with screws.
7. Fit screen ducts.
8. Connect multiplugs to control unit.
9. Position control cables and connect to control
unit.
10. Align cable outers to control unit and tighten
clamp screws.
11. Release clip securing cable outer to heater
valve.
12. Turn temperature control to COLD.
13. Push heater control valve to the cold position
and secure cable clip.
14. Position alarm ECU to control unit, fit and
16. Fit fascia. See BODY, Interior trim
components.
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14 REPAIRS
HEATER - WITH AIR CONDITIONING
SRS Precautions.
Remove
1. Make the SRS system safe See GENERAL
2. Remove evaporator. See AIR
CONDITIONING, Repairs.
3. Remove 2 nuts securing anti-theft alarm ECU
to heater control, position ECU aside.
5. Remove 2 screws retaining outer cables to
control unit.
6. Release cables from control unit.
7. Disconnect 2 multiplugs and remove control
unit.
8. Remove screen duct from heater.
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REPAIRS 15
casing.
10. Position container beneath heater to catch
spillage.
11. Release clips and disconnect both hoses from
heater matrix. Allow matrix to drain.
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16 REPAIRS
13. Remove 2 nuts securing heater unit to
crossmember.
14. Remove nut securing heater unit to bulkhead.
15. Remove heater unit.
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REPAIRS 17
Refit
1. Position heater to mountings.
2. Tighten all fixings to 10 Nm.
3. Connect multiplug to heater blower.
4. Connect hoses to heater matrix and secure
with clips.
5. Position valve and secure with screws.
6. Fit screen duct.
7. Connect multiplugs to control unit.
8. Position control cables and connect to control
unit.
9. Align cable outers to control unit and tighten
clamp screws.
10. Release clip securing cable outer to heater
valve.
11. Turn temperature control to COLD.
12. Push heater control valve to the COLD position
and secure cable clip.
14. Position alarm ECU to heater control, fit and
15. Fit evaporator. See AIR CONDITIONING,
Repairs.
RECIRCULATION SERVO MOTOR
Remove
components.
2. Disconnect multiplug from servo motor.
3. Remove 3 screws securing servo motor to
evaporator casing.
4. Remove servo motor.
Refit
1. Position servo motor and engage output crank
to recirculation flap lever.
2. Secure servo motor with screws.
components.
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18 REPAIRS
HEATER BLOWER
Remove
pedal box.
to bulkhead and position throttle pedal
assembly aside.
3. Remove heater duct.
5. Remove 3 screws securing blower to heater.
6. Remove heater blower.
7. Release armature cover and collect sleeve.
Refit
1. Position screw and sleeve to top location of
heater blower.
2. Position blower to heater and secure with
screws.
CAUTION: Ensure screw sIeeve does not
faII into bIower motor.
3. Connect multiplug to blower.
4. Fit heater duct.
5. Position throttle pedal assembly, fit and tighten
nuts to 6 Nm.
6. Fit and tighten bolt to 22 Nm.
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REPAIRS 19
HEATER RESISTOR
Remove
pedal box.
to bulkhead and position throttle pedal
assembly aside.
3. Disconnect multiplug from resistor.
4. Remove 2 screws securing resistor.
5. Remove heater resistor.
Refit
1. Position resistor to heater and secure with
screws.
2. Connect resistor multiplug.
3. Position throttle pedal assembly, fit and tighten
nuts to 6 Nm.
4. Fit and tighten bolt to 22 Nm.
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20 REPAIRS
HEATER MATRIX
Remove
1. Remove heater. See this section.
2. Disconnect multiplugs from blower and
resistor.
3. Release harness from 2 clips and position
aside.
4. Remove 15 clips and 2 screws securing two
halves of casing.
5. Remove foam seal from outlet vent and matrix
bleed nipple.
6. Separate two halves of casing.
7. Remove heater matrix.
Refit
1. Position matrix to heater.
2. Position two halves of casing, ensuring correct
location of flow direction flap.
3. Secure casing halves with clips and screws.
4. Clean sealing faces.
5. Fit foam seals to outlet vent and bleed nipple.
6. Engage harness clips and connect multiplugs.
7. Fit heater. See this section.
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AIR CONDITIONING
CONTENTS Page
AR CONDTONNG COMPONENTS 1 ......................................................................
SCHEMATC LAYOUT OF AR CONDTONNG SYSTEM 2 .....................................
AR CONDTONNG SYSTEM OPERATON 3 ...........................................................
AR CONDTONNG CONTROL SYSTEM 4 ..............................................................
ADJUSTMENTS
GENERAL PRECAUTONS 1 ......................................................................................
REMEDAL ACTONS 1 ...............................................................................................
SERVCE PRECAUTONS 2 .......................................................................................
REFRGERANT RECOVERY, RECYCLNG AND RECHARGNG 3 ..........................
REPAIRS
COMPRESSOR 1 ........................................................................................................
CONDENSER 2 ...........................................................................................................
RECEVER DRER 3 ...................................................................................................
SWTCH - TRNARY 4 .................................................................................................
THERMOSTATC EXPANSON VALVE 4 ...................................................................
CONTROL SWTCH 5 .................................................................................................
EVAPORATOR 6 .........................................................................................................
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AIR CONDITIONING
AIR CONDITIONING COMPONENTS
1. Condenser
2. Cooling fans
3. Evaporator
4. Compressor
5. Receiver/drier
6. Trinary pressure switch
7. Air conditioning, relay module
8. ECM
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AIR CONDITIONING
SCHEMATIC LAYOUT OF AIR CONDITIONING
SYSTEM
1. Compressor
2. Condenser
3. Trinary pressure switch
4. Receiver/drier
5. Drying agent - receiver/drier
6. Thermostatic expansion valve
7. Evaporator
8. Capillary tube
9. Heater blower motor
10. Condenser cooling fans
11. Compressor high pressure relief valve
A1. Ambient air flow through condenser
A2. Ambient air flow through fan and evaporator
A3. Cooled air flow to vehicle interior
F1. High pressure, high temperature refrigerant
vapour
F2. High pressure, slightly subcooled refrigerant
liquid
F3. High pressure, slightly subcooled refrigerant
liquid with moisture, vapour bubbles and foreign
matter removed
F4. Low pressure, low temperature mixed liquid and
vapour
F5. Low pressure, slightly superheated refrigerant
vapour
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AIR CONDITIONING
AIR CONDITIONING SYSTEM OPERATION
The air conditioning system provides the means of
supplying cooled and dehumidified, fresh or
recirculated air to the interior of the vehicle. The
cooling effect is obtained by blowing air through the
matrix of an evaporator unit and when required,
heating the air to provide the conditions required
inside the vehicle. The volume of the conditioned air
being supplied is controlled by a variable speed
blower.
SeaIed refrigerant
A sealed system, charged with Refrigerant R134a,
together with a blower unit, blend unit and control
system combine to achieve the cooled air condition.
The sealed system comprises of the following main
components:
1. Compressor
2. Condenser
3. Receiver/drier
4. Thermostatic expansion valve
5. Evaporator
Refrigeration cycIe
The compressor is driven by a belt from the
crankshaft pulley. The compressor pressurises and
circulates the refrigerant through the system.
Mounted on the compressor, an electro-mechanical
clutch maintains the correct temperature and
pressure of the refrigerant by engaging or
disengaging the compressor to support the systems
requirements. Operation of the clutch is controlled
by the engine control module (ECM), the trinary
(triple) pressure switch and a thermostatic switch
located on the exterior fins of the evaporator.
f the temperature at the evaporator falls low enough
for ice to form on the fins, the thermostatic switch will
open, breaking the circuit to the clutch and releasing
the drive on the compressor. The ECM detects that
the air conditioning system is not operating and
switches off the condenser cooling fan. When the
temperature at the evaporator rises sufficiently for
the thermostatic switch to close, the air conditioning
system will be restarted.
f the system pressure becomes excessive or drops
sufficiently to cause damage to the compressor, a
trinary pressure switch located in the high pressure
line at the receiver drier will break the electrical
circuit to the compressor clutch, releasing drive from
the compressor. The compressor also has an
internal thermal cut-out switch which disengages the
compressor's clutch to prevent the compressor oil
overheating. The clutch will re-engage when the oil
temperature has returned to normal.
The two cooling fans are controlled by the ECM and
operating conditions are dependent upon engine
coolant temperature and air conditioning system
pressure. With the air conditioning system switched
off, the (radiator) cooling fans are operated with the
ECM controlling the fan speed according to engine
temperature. With the air conditioning system
switched on, condenser (radiator) cooling fans are
connected in series by the ECM and operate at low
speed. As the pressure of the air conditioning
refrigerant rises above the threshold of the medium
pressure setting on the trinary pressure switch, the
cooling fans are connected in parallel and operate at
high speed.
f engine coolant temperature continues to rise with
both cooling fans running at high speed, the ECM
will break the circuit to the compressor clutch
releasing drive to the compressor. This reduces the
load on the engine whilst maintaining a high cooling
fan speed to lower the engine coolant temperature.
Once engine coolant temperature has dropped
sufficiently the air conditioning system will be
reinstated.
From the compressor, high pressure vaporised
refrigerant is passed to the condenser which is
mounted in front of the radiator.
Ram air passing through the condenser,
supplemented by the cooling fans, cools the
refrigerant vapour in the condenser sufficiently to
form a high pressure slightly subcooled liquid.
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AIR CONDITIONING
This subcooled liquid then passes to the
receiver/drier which extracts moisture from the
refrigerant as well as acting as a reservoir.
From the receiver/drier the moisture free refrigerant
liquid passes through a thermostatic expansion
valve to the evaporator unit. The thermostatic
expansion valve incorporates a restrictor which
converts the liquid refrigerant into a low temperature,
low pressure liquid vapour mixture. To prevent liquid
refrigerant passing into the evaporator unit, the
thermostatic expansion valve senses the evaporator
outlet pressure and controls the amount the valve
opens and closes.
Fan blown air is passed through the evaporator
where it is cooled by absorption due to the low
temperature refrigerant in the evaporator. Most of
the moisture being held in the air is condensed into
water by the evaporator and drains away beneath
the vehicle via a drain tube.
From the evaporator, low pressure slightly heated
refrigerant passes to the compressor to complete
the cycle. The compressor pressurises the
refrigerant vapour which becomes very hot and is
passed to the condenser to be converted into liquid.
AIR CONDITIONING CONTROL SYSTEM
The air conditioning control system comprises of
relays, a thermostatic switch, a trinary pressure
switch and a control panel. Together these controls,
in conjunction with the cooling fans, compressor
clutch, blower and heater distribution enable minimal
input to maintain the required environment inside the
vehicle.
When air conditioning is not selected, air is supplied
by ram effect or blower to the areas selected by the
air distribution control. The heater valve on the
heater matrix controls the temperature of the air
being delivered. No cooled air is available.
Selecting air conditioning provides the added facility
of cooled air which can be re-heated by the heater
matrix if required. When required a fully cold
condition can be selected by turning the temperature
control to cold, which automatically closes the
heated coolant access to the heater matrix. Mixtures
of cooled, fresh, and hot air can be selected to give
the required interior environmental conditions by
selection at the control panel.
Trinary pressure switch
The trinary (triple) pressure switch is located in the
high pressure line between the condenser and the
receiver drier. The trinary pressure switch detects
refrigerant pressure and by means of the ECM
controls the following system functions:
1. Refrigerant pressure drops below 2.0 bar (due
to possible leakage), the compressors
electro-mechanical clutch is disengaged.
When pressure rises above 2.4 bar the
compressors clutch is re-engaged.
2. Refrigerant pressure exceeds 19 bar the
cooling fan speed is increased by the ECM
switching the relays in the relay module to
connect the cooling fans in parallel supplying a
direct feed to each fan motor.
3. Refrigerant pressure rises above 27 bar even
with maximum cooling fan operation (due to
possible blockage), the compressor
electro-mechanical clutch is disengaged. The
high pressure switch resets when the pressure
drops to approximately 21 bar.
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AIR CONDITIONING
Condenser cooIing fans
The condenser cooling fans operate automatically
whenever the air conditioning system is switched on,
providing the system pressure is correct.
The cooling fans are controlled by the ECM,
thermostatic switch and trinary pressure switch. f
engine coolant temperature and air conditioning
system pressure are normal then the cooling fans
operate at low speed.
f the engine coolant temperature reaches 108 C or
the air conditioning refrigerant pressure exceeds 19
bar then the cooling fans will operate at high speed.
BIower controI
The blower can be operated at any one of four
speeds by rotating the blower switch to the required
position. When the blower is switched off the air
conditioning system will not operate.
The fresh air/recirculation flap has two positions and
is operated by pressing the button in the centre
console. n the recirculation position, air is drawn
into the heater from the vehicle by closing the
exterior air inlet and opening the interior inlet. n the
fresh air position, air is drawn into the heater from
outside the vehicle by opening the exterior air inlet
and closing the interior inlet.
Heater distribution and bIend unit controI
Blower unit air flow, having passed through the
evaporator passes into the heater unit to be heated,
if required. t is then directed into the vehicle interior
in accordance with the flap positions, which are
designated by the air distribution control on the
fascia panel.
The temperature control knob moves the heater
valve, allowing engine coolant to flow through the
heater matrix back to the engine when the control is
moved towards the hot position. The temperature of
the heated air flow into the vehicle interior is
controlled by the relative movement of the heater
valve.
The distribution control moves a flap which controls
the direction of the air flow into the interior of the
vehicle.
The face level vents have a permanent feed of
heated or unheated air from the heater unit and are
opened or shut by rotary thumbwheels on each face
level vent.
ECM controI
n addition to its various functions of controlling the
air conditioning system, the ECM also controls the
compressor's clutch for system safety.
A. To protect the discharge hose material from
excessive high refrigerant temperatures produced at
high speed. The ECM will disengage the
compressor clutch when an engine speed of 5000
rpm is reached and re-engage when the speed
drops below 4900 rpm.
B. To allow more power for vehicle acceleration the
compressor's clutch is disengaged when the throttle
disc angle is opened above 85 (fully open is 90 ).
The clutch is re-engaged when the throttle disc
angle is below 80 .
C. To protect the engine's cooling system the ECM
will disengage the compressor's clutch when the
coolant temperature exceeds 117 C. The clutch
re-engages when the coolant temperature drops
below 112 C.
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AIR CONDITIONING
ADJUSTMENTS 1
GENERAL PRECAUTIONS
The refrigerant used in the air conditioning system is
HFC (Hydrofluorocarbon) R134a.
WARNING:
R134a is a hazardous Iiquid and when
handIed incorrectIy can cause serious injury.
SuitabIe protective cIothing must be worn
when carrying out service operations on the
air conditioning system.
Do not aIIow a refrigerant container to be
heated by direct fIame or to be pIaced near
any heating appIiance. A refrigerant container
must not be heated above 50 C.
Do not Ieave a container of refrigerant without
its cap fitted. Do not transport a container of
refrigerant that is unrestrained, especiaIIy in
the boot of a car.
R134a is odourIess and coIourIess. Do not
handIe or discharge in an encIosed area, or
any area where the vapour and Iiquid can
come in contact with a naked fIame or hot
metaI. R134a is not fIammabIe but can cause
a highIy toxic gas.
Do not smoke or weId in areas where R134a
is in use. InhaIation of concentrations of
vapour can cause dizziness, disorientation,
narcosis, nausea or vomiting.
Do not aIIow fIuids other than R134a or
compressor Iubricant to enter the air
conditioning system. Spontaneous
combustion may occur.
R134a spIashed on any part of the body wiII
cause immediate freezing of that area. AIso
refrigerant cyIinders and repIenishment
troIIeys when discharging wiII freeze skin to
them if contact is made.
The refrigerant used in an air conditioning
system must be recIaimed in accordance with
the recommendations given by a Refrigerant
Recovery RecycIing Recharging Station.
NOTE: SuitabIe protective cIothing
comprises:
Wrap round safety gIasses or heImet, heat
proof gIoves, rubber apron, or waterproof
overaIIs and rubber boots.
REMEDIAL ACTIONS
1. f liquid R134a strikes the eye, do not rub it.
Gently run large quantities of eye wash off it to
raise the temperature. f eye wash is not
available, cool, clean water may be used.
Cover eye with a clean pad and seek
2. f liquid R134a is splashed on the skin run
large quantities of water over the area as soon
as possible to raise the temperature. Carry out
the same action if the skin comes in contact
with discharging cylinders. Wrap effected parts
in blankets or similar material and seek
3. f suspected of being overcome by inhalation of
R134a vapour seek fresh air. f a person
overcome by inhalation is unconscious move
them to fresh air, apply artificial respiration
and/or oxygen and seek immediate medical
attention.
NOTE: Due to its Iow evaporating
temperature of -26.1 C, R134a shouId be
handIed with care.
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AIR CONDITIONING
2 ADJUSTMENTS
SERVICE PRECAUTIONS
Care should be taken when handling the
components in the refrigeration system. Units must
not be lifted by their hoses, pipes or capillary lines.
Hoses and lines must not be subjected to any twist
or stress. Ensure that hoses are positioned in their
correct run before tightening couplings, and ensure
that all clips and supports are used. Torque
wrenches of the correct type must be used when
tightening refrigerant connections to the stated
value. An additional spanner must be used to hold
the union to prevent twisting of the pipe.
Before connecting any hose or pipe ensure that
refrigerant oil is applied to the seat of the new 'O'
ring seals but not to the threads.
Check the oil trap for the amount of oil lost.
All protective plugs must be left in place until
immediately prior to connection.
The receiver/drier contains desiccant which absorbs
moisture. t must be positively sealed at all times.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediateIy before
evacuating and recharging the system.
Use alcohol and a clean cloth to clean dirty
connections.
Ensure that all new parts fitted are marked for use
with R134a.
Refrigerant oiI
Use an approved refrigerant lubricating oil:
Seiko Seiki SK-20
Unipart SK-20
demitsu SK-20
CAUTION: Do not use any other type of
refrigerant oiI.
Refrigerant oil easily absorbs water and must not be
stored for long periods. Do not pour unused oil back
into the container.
When renewing system components, add the
following quantities of refrigerant oil:
Condenser 30cm
3
Evaporator 30cm
3
Pipe or hose 10cm
3
Receiver drier 30cm
3
Total amount of oil in the system: 170 cc
A new compressor is sealed and pressurised with
Nitrogen gas, slowly release the sealing cap, gas
pressure should be heard to release as the seal is
broken.
NOTE: A new compressor shouId aIways
have its seaIing cap in pIace and must not
be removed untiI immediateIy prior to
fitting the compressor air conditioning pipes.
Rapid refrigerant discharge
f the air conditioning system is involved in accident
damage and the circuit is punctured, the refrigerant
will discharge rapidly. The rapid discharge of
refrigerant will also result in the loss of most of the
oil from the system. The compressor must be
removed and all the remaining oil in the compressor
drained and refilled as follows:
1. Remove the drain plug and gravity drain all the
oil, assisted by rotating the clutch plate (not the
pulley).
2. Refit the compressor with the following amount
of new refrigerant oil: 170cm
3
3. Refit the drain plug and plug the inlet and outlet
port.
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AIR CONDITIONING
ADJUSTMENTS 3
REFRIGERANT RECOVERY, RECYCLING AND
RECHARGING
NOTE: An air conditioning portabIe Refrigerant Recovery, RecycIing and Recharging Station for use
with R134a refrigerant incorporates aII the features necessary to recover refrigerant R134a from the
A/C system, to fiIter and remove moisture, to evacuate and recharge with recIaimed refrigerant. The
unit can aIso be used for performance testing and air conditioning system anaIysis.
Service connections
1. High pressure
2. Low pressure
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AIR CONDITIONING
4 ADJUSTMENTS
Recovery and recycIing
2. Connect a refrigerant station to high and low
pressure servicing connections.
3. Operate the refrigerant recovery system in
accordance to the manufacturer's instructions.
WARNING: Refrigerant must aIways be
recycIed before re-use, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system.
RecycIing shouId aIways be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compIiance with
SAE - J1991. Other equipment may not recycIe
refrigerant to the required IeveI of purity.
A R134a Refrigerant Recovery RecycIing
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and
commerciaI sources must not be used in motor
vehicIe air conditioning systems.
Evacuation and recharging
1. Add calculated refrigerant oil to the compressor
as necessary.
2. Renew receiver/drier. See Repairs.
3. Connect a Refrigerant Station to the high and
low pressure servicing connections.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediateIy before
evacuating and recharging the system.
4. Operate the refrigerant evacuation system
according to the manufacturer's instructions.
NOTE: If the vacuum reading is beIow
700 mm/Hg after 15 minutes, suspect a
Ieak in the system. PartiaIIy recharge the
system and check for Ieaks using an eIectronic
Ieak tester.
CAUTION: The system must be evacuated
immediateIy before recharging
commences. DeIay between evacuation
and recharging is not permitted.
5. Operate the refrigerant recharging system
according to the manufacturer's instructions.
Amount of refrigerant required to charge
system is:
- 620 10 g for manual gearbox models
- 720 10 g for automatic gearbox models
For each 1.2 m of hose length used to connect
the charging trolley to the vehicle's air
conditioning system, add 5 g of refrigerant.
6. f the full charge has not been accepted by the
system, start the engine and run it at
1500 rev/min.
7. Switch on the air conditioning system, open the
car windows, set the temperature control to
cold and switch the blower to maximum speed.
8. Consult the Refrigerant Station Manual for the
correct procedure to complete the charge.
9. Carry out the air conditioning system
performance test.
10. Switch off air conditioning and wait for
pressures to equalize, before disconnecting
charging hoses from vehicle.
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AIR CONDITIONING
ADJUSTMENTS 5
Performance Guide-Iines
Carry out this test with bonnet, doors or windows
open; air conditioning switched on, temperature
control set to cold, face vent mode and blower at
maximum speed. Set the air supply control to supply
fresh air.
1. Close low pressure valve on Refrigerant
Station.
2. Close high pressure valve on Refrigerant
Station.
3. Connect Refrigerant Station to the high and
low pressure servicing connections.
4. With a thermometer measure the air intake
temperature, close to the outside air inlet at the
plenum.
5. With a thermometer measure the air outlet
temperature, at the centre vent outlet.
6. Run the engine at idle speed for 10 minutes or
until normal operating temperature is reached.
7. Read both pressure gauges and
thermometers. Check readings against the
guide-lines shown in the table below.
Ambient 20 C 25 C 30 C 35 C 40 C
OutIet Temperature ( C) 5 - 10 7 - 15 8 - 20 11 - 22 14 - 25
Low Pressure (bar) 1.6 - 2.4 1.8 - 2.6 2.0 - 3.2 2.2 - 3.5 2.4 - 3.8
High Pressure (bar) 14 - 19 14 - 19 14 - 21 18 - 23 19.6 - 24.8
Notes A + B A + B A + B B B
NOTES
The temperatures and pressures may be slightly
increased for high humidity conditions.
The varying air conditioner pressure will dictate
whether the fans operate in series or parallel,
which will itself cause the temperatures and
pressures to fluctuate. For example:
A = Condenser and cooling fan both running at
half speed (series)
B = Condenser and cooling fan both running at
full speed (parallel)
A + B = Fans switching from series to parallel.
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AIR CONDITIONING
REPAIRS 1
COMPRESSOR
Remove
1. Recover refrigerant from air conditioning
system. See Adjustments.
4. Remove alternator. See ELECTRICAL,
Repairs.
5. Disconnect multiplug from air conditioning
compressor.
6. Remove 2 Allen screws securing air
conditioning pipe unions to compressor.
7. Release air conditioning pipe unions from
compressor.
8. Remove and discard 2 'O' ring seals from pipe
unions.
CAUTION: ImmediateIy cap aII air
conditioning pipes to prevent ingress of
dirt and moisture into the system.
9. Remove 3 bolts securing compressor to
mounting bracket and collect 2 washers from
each bolt.
10. Remove compressor.
Fitting a new compressor
A new compressor is sealed and pressurised with
Nitrogen gas, slowly release the sealing cap, gas
pressure should be heard to escape as the seal is
broken.
NOTE: A NEW compressor shouId aIways
have its seaIing cap in pIace and must not
be removed untiI immediateIy prior to
fitting.
A NEW compressor is supplied with an oil fill
quantity (X cm
3
) of 170 cm
3
. A calculated quantity of
oil must be drained from a new compressor before
fitting.
To calculate the quantity to be drained:
1. Remove the drain plug from the old
compressor.
2. nvert compressor and gravity drain the oil into
a calibrated measuring cylinder. Rotating the
compressor clutch plate will assist complete
draining.
3. Note the quantity of oil drained (Y cm
3
).
4. Calculate the quantity of oil to be drained from
the NEW compressor using the following
formula:
X cm
3
- (Y cm
3
+ 20 cm
3
) = Q cm
3
5. Remove drain plug from NEW compressor and
drain Q cm
3
of oil. Fit and tighten compressor
drain plug.
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AIR CONDITIONING
2 REPAIRS
Fitting an existing compressor
When refitting an existing compressor a quantity of
refrigerant oil equivalent to the amount obtained
when the system was discharged must be added to
the compressor.
Use only an approved refrigerant lubricating oil:
Seiko SK-20
Unipart SK-20
demitsu SK-20
CAUTION: Do not use any other type of
refrigerant oiI.
Refrigerant oil easily absorbs water and must not be
stored for long periods. Do not pour unused oil back
into the container.
Refit
1. Fit bolts to compressor.
2. Position compressor to engine, fit washers to
3. Clean compressor and pipe connections.
4. Remove caps from compressor and pipe
connections.
5. Lubricate 2 new 'O' rings with refrigerant oil
and fit to pipes.
6. Position air conditioning pipe unions to
compressor, fit securing bolts and tighten to
25 Nm.
7. Connect multiplug to compressor.
8. Fit alternator. See ELECTRICAL, Repairs.
9. Replace receiver drier. See this section.
12. Recharge air conditioning system. See
Adjustments.
CONDENSER
Remove
Exterior fittings.
3. Remove 2 bolts securing top condenser
mounting brackets to striker plate panel.
4. Remove brackets from condenser.
5. Remove 2 bolts securing air conditioning pipe
connections to condenser and release pipes.
6. Remove and discard 2 'O' rings from air
conditioning pipes.
7. Release condenser from lower mountings and
remove condenser.
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AIR CONDITIONING
REPAIRS 3
Refit
1. Clean air conditioning pipe connections.
2. Lubricate new 'O' rings with refrigerant oil and
fit to air conditioning pipes.
3. Remove caps from new condenser and fit to
old condenser.
4. Position condenser to lower mountings.
5. Fit mounting brackets to condenser.
6. Align mounting brackets to striker plate panel
7. Align air conditioning pipes to condenser and
8. Renew receiver drier. See this section.
fittings.
Adjustments.
RECEIVER DRIER
Remove
1. Recover refrigerant from A/C system. See
Adjustments.
2. Disconnect multiplug from trinary switch.
3. Loosen and remove trinary switch, remove and
discard 'O' ring.
4. Remove 2 bolts securing A/C pipes to receiver
drier.
5. Remove and discard 2 'O' ring seals from
pipes.
6. Loosen 2 Allen screws clamping receiver drier
bracket.
7. Position pipes aside and remove receiver drier.
Refit
1. Clean A/C pipe connections.
2. Lubricate new 'O' ring seals with clean
refrigerant oil and fit to air conditioning pipes.
3. Remove caps from new receiver drier and fit to
old unit.
4. Fit receiver drier to bracket and secure bracket
clamp screws.
5. Engage A/C pipes to receiver drier and tighten
retaining bolts to 5 Nm.
6. Lubricate new trinary switch 'O' ring with clean
refrigerant oil and fit 'O' ring to trinary switch.
7. Fit trinary switch and tighten to 10 Nm.
9. Recharge A/C system. See Adjustments.
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AIR CONDITIONING
4 REPAIRS
SWITCH - TRINARY
Remove
1. Recover refrigerant from A/C system. See
Adjustments.
2. Disconnect trinary switch multiplug.
3. Remove trinary switch and discard 'O' ring.
Refit
1. Lubricate new 'O' ring with clean refrigerant oil
and fit to trinary switch.
2. Fit trinary switch and tighten to 10 Nm.
3. Connect trinary switch multiplug.
4. Recharge A/C system. See Adjustments.
THERMOSTATIC EXPANSION VALVE
Remove
2. Remove bolt securing pipe clamp to
thermostatic expansion valve.
3. Release 2 air conditioning pipes from valve.
4. Remove and discard 2 'O' rings from air
conditioning pipes.
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AIR CONDITIONING
REPAIRS 5
5. Remove 2 Allen bolts securing evaporator pipe
clamp to thermostatic expansion valve.
6. Remove thermostatic expansion valve from
evaporator pipes.
7. Remove and discard 2 'O' rings from
evaporator pipes.
Refit
1. Clean air conditioning pipe connections.
2. Lubricate new 'O' rings with refrigerant oil and
fit to air conditioning pipes.
3. Remove caps from new thermostatic
expansion valve and fit to old unit.
4. Engage valve to evaporator pipes.
5. Position evaporator pipe bracket, fit and tighten
Allen bolts to 7 Nm.
6. Engage pipes to valve and position pipe clamp.
7. Tighten pipe clamp bolt to 5 Nm.
8. Renew receiver drier. See this section.
Adjustments.
CONTROL SWITCH
Remove
1. Remove console closing panel. See BODY,
2. Release switch from centre console.
4. Remove switch.
Refit
1. Connect multiplug to switch and fit switch to
centre console.
2. Fit console closing panel. See BODY, Interior
trim components.
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AIR CONDITIONING
6 REPAIRS
EVAPORATOR
Remove
2. Remove fascia panel. See BODY, Interior
trim components.
3. Remove thermostatic expansion valve. See
this section.
4. Remove pipe clamp from evaporator pipes.
5. Remove screen vent duct from heater.
6. Remove clamp securing evaporator to heater.
7. Disconnect 2 multiplugs from evaporator.
8. Remove 2 nuts securing evaporator to lower
dash panel.
9. Release evaporator drain hose from
evaporator.
10. Remove evaporator assembly.
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AIR CONDITIONING
REPAIRS 7
11. Remove 3 screws securing recirculation servo
to casing and position aside.
12. Remove 7 clips securing casing halves.
13. Remove and discard foam seal from output
duct.
14. Release thermocouple from evaporator matrix.
15. Separate evaporator casing and remove
evaporator matrix.
Refit
1. Position matrix to casing.
2. Align casing halves and secure with clips.
3. nsert tip of thermocouple into centre of matrix
fins.
4. Position servo output crank to recirculation flap
lever and secure servo with screws.
5. Fit new foam seal to output duct.
6. Position evaporator, fit nuts but do not tighten.
7. Engage hose to drain pipe.
8. Fit clamp securing evaporator to heater and
tighten nut to 3 Nm.
9. Tighten nuts securing evaporator to lower dash
panel to 9 Nm.
11. Remove evaporator pipe caps and clean air
conditioning pipe connections.
12. Lubricate new 'O' rings with refrigerant oil.
13. Fit pipe bracket to evaporator pipes.
14. Fit thermostatic expansion valve. See this
section.
15. Fit fascia panel. See BODY, Interior trim
components.
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WIPERS & WASHERS
CONTENTS Page
WNDSCREEN WPER COMPONENTS 1 ..................................................................
WASHER COMPONENTS 2 .......................................................................................
WNDSCREEN WASHER AND WPER OPERATON 3 .............................................
REPAIRS
WASHER RESERVOR 1 ............................................................................................
RESERVOR AND PUMP 1 .........................................................................................
WASHER JET 2 ...........................................................................................................
WASHER PUMP 2 .......................................................................................................
WPER ARM 3 .............................................................................................................
WPER MOTOR AND LNKAGE 3 ...............................................................................
WPER MOTOR 4 ........................................................................................................
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WIPERS & WASHERS
WINDSCREEN WIPER COMPONENTS
1. Wiper motor
2. Bolt - motor to mechanism, 3 off
3. Wiper mechanism assembly
4. Sealing washer - spindle, 2 off
5. Washer - spindle, 2 off
6. Washer - spindle, 2 off
7. Nut - spindle, 2 off
8. Spindle cap, 2 off
9. Rubber grommet
10. Bolt - mechanism to body plate
11. Wiper arm - driver side
12. Wiper arm - passenger side
13. Cover
14. Bevel nut - wiper arm
15. Nut - wiper arm
16. Windscreen wiper - driver side
17. Windscreen wiper - passenger side
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WIPERS & WASHERS
WASHER COMPONENTS
1. Reservoir
2. Reservoir cap
3. Bush washer - reservoir
4. Pump - windscreen washer
5. Jet washer, 2 off
6. Gasket - jet washer, 2 off
7. Washer tube
8. Tee connector
9. Elbow connector
10. Clip - tube to bonnet, 4 off
11. Clip - tube to body, 2 off
12. Non-return valve
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WIPERS & WASHERS
WINDSCREEN WASHER AND WIPER
OPERATION
Operation of the windscreen wipers and washers is
controlled by the wash/wipe switch mounted on the
stalk on the RH side of the steering column. The
wiper switch may be rotated from the OFF position
to selected positions; ntermittent, Normal or Fast
wipe speeds (1). Single wipe is obtained by a
downward movement of the stalk, when in the OFF
position (2). The windscreen washer will operate
when the stalk is pulled towards the steering wheel
(3).
When any wiper function is selected, a 2 speed
wiper motor (4) provides drive through a rotary link
(5) to a wiper mechanism (6) which converts the
lateral motion of the links into the sweeping motion
of the wiper arms (7) and blades (8).
The fast, normal and intermittent speeds, when
selected, are controlled by the multi-function unit.
When the windscreen washer is operated, washer
fluid is drawn by an electric pump from the reservoir
(9); located behind the spare wheel compartment.
The washer fluid is sprayed onto the windscreen by
washer jets (10).
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WIPERS & WASHERS
REPAIRS 1
WASHER RESERVOIR
Remove
1. Remove reservoir and pump assembly. See
this section.
2. Remove pump from reservoir.
Refit
1. Fit pump to reservoir.
2. Fit reservoir and pump assembly. See this
section.
RESERVOIR AND PUMP
Remove
3. Release reservoir from body bracket.
4. Disconnect multiplug and washer hose.
5. Remove reservoir assembly.
Refit
1. Position reservoir.
2. Connect multiplug and hose.
3. Engage reservoir to body.
4. Fill reservoir with washer fluid.
Exterior fittings.
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WIPERS & WASHERS
2 REPAIRS
WASHER JET
Remove
1. Open bonnet.
2. Disconnect hose from washer jet.
3. Remove jet and collect seat.
Refit
1. Position seat and engage jet to bonnet.
2. Connect hose.
3. Adjust jets.
WASHER PUMP
Remove
1. Remove reservoir and pump. See this
section.
2. Remove pump from reservoir.
Refit
1. Fit pump to reservoir.
2. Fit reservoir and pump assembly. See this
section.
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WIPERS & WASHERS
REPAIRS 3
WIPER ARM
Remove
1. Open bonnet.
2. Remove cover from wiper arm.
3. Remove nut securing wiper arm to spindle.
4. Remove wiper arm.
Refit
1. Fit wiper arm to spindle and align blade to
screen.
2. Fit and tighten nut to 20 Nm.
3. Fit cover.
WIPER MOTOR AND LINKAGE
Remove
1. Remove air intake panel. See HEATING &
4. Remove cover from spindle.
5. Remove 2 nuts securing spindles to scuttle.
6. Remove bolt securing motor to pedal box.
7. Remove motor and linkage assembly.
Refit
1. Position motor and linkage assembly to scuttle.
NOTE: Ensure spindIe seaIs are correctIy
positioned to scuttIe apertures.
2. Tighten fixings to 10 Nm.
3. Fit spindle cover.
5. Fit air intake panel. See HEATING &
Exterior fittings.
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WIPERS & WASHERS
4 REPAIRS
WIPER MOTOR
Remove
1. Remove wiper motor and linkage assembly.
See this section.
2. Release multiplug clip from linkage.
3. Remove nut securing crank to motor spindle
and release crank.
4. Remove 3 bolts securing motor.
5. Remove motor.
Refit
1. Connect multiplug to harness.
2. Operate wipers to park motor.
3. Disconnect multiplug.
4. Fit motor to linkage bracket and tighten bolts to
12 Nm.
5. Align crank between timing marks and fit to
motor spindle.
6. Fit and tighten crank nut to 18 Nm.
7. Engage multiplug.
8. Fit wiper motor and linkage. See this section.
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ELECTRICAL
CONTENTS Page
ADJUSTMENTS
DRVE BELT - ALTERNATOR - CHECK & ADJUST TENSON - NON AR
CONDTONNG 1 .......................................................................................................
ALTERNATOR DRVE BELT - WTH AR CONDTONNG - ADJUST 2 ....................
HEADLAMPS - PAR - ALGN BEAM 3 .......................................................................
REPAIRS
ALTERNATOR - NON AR CONDTONNG 1 ............................................................
ALTERNATOR - WTH AR CONDTONNG 2 ...........................................................
DRVE BELT - ALTERNATOR - NON AR CONDTONNG 3 ....................................
ALTERNATOR DRVE BELT - WTH AR CONDTONNG 4 .....................................
ELECTRC WNDOW SWTCH 6 ................................................................................
CENTRAL DOOR LOCKNG MOTOR AND LATCH 6 .................................................
CONTROL UNT - ONE TOUCH WNDOW 8 ..............................................................
HORN 9 .......................................................................................................................
HEADLAMP ASSEMBLY 9 ..........................................................................................
LAMP ASSEMBLY - FOG/DRVNG 10 .......................................................................
LAMP ASSEMBLY - CENTRE HGH MOUNTED STOP (CHMSL) 11 ........................
TAL LAMP ASSEMBLY 12 .........................................................................................
GLOVEBOX LAMP 12 .................................................................................................
BOOT LD LAMP 13 ....................................................................................................
BONNET LAMP 13 ......................................................................................................
FRONT SPEAKER 14 ..................................................................................................
AERAL 14 ...................................................................................................................
SPEAKER - TWEETER 15 ..........................................................................................
SUBWOOFER ASSEMBLY 15 ....................................................................................
AUTO CHANGER - KENWOOD AUDO SYSTEMS 16 ..............................................
HEAD UNT - KENWOOD AUDO SYSTEMS 17 ........................................................
HEAD UNT AND AUTO CHANGER - KENWOOD AUDO SYSTEMS - RENEW 18 .
ANT-THEFT ALARM ECU 20 .....................................................................................
VOLUMETRC SENSOR 21 ........................................................................................
STARTER MOTOR 22 .................................................................................................
STARTER MOTOR - STEPSPEED (Em-CVT) MODELS 23 .......................................
STARTER SOLENOD 24 ............................................................................................
PANEL DMMER RESSTOR 24 .................................................................................
HAZARD WARNNG LAMP SWTCH 25 .....................................................................
STEERNG COLUMN SWTCH PACK 26 ...................................................................
SWTCH - EXTEROR MRROR 27 .............................................................................
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ELECTRICAL
ADJUSTMENTS 1
DRIVE BELT - ALTERNATOR - CHECK &
ADJUST TENSION - NON AIR CONDITIONING
Check
4. Remove 2 scrivets and Torx screw securing
closing panel and remove closing panel.
5. Check condition of drive belt, renew a belt that
shows signs of wear and splitting.
6. Apply a force of 10 kg. to auxiliary drive belt at
position 'X' and measure deflection between
crankshaft pulley and alternator pulley.
Deflection should be 6-8 mm.
Adjust
1. Loosen bolt securing alternator adjustment
bracket.
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ELECTRICAL
2 ADJUSTMENTS
2. Loosen 2 alternator clamp bolts.
CAUTION: Ensure that boIts are Ioosened
sufficientIy for aIternator to move freeIy.
3. Turn adjustment bolt in a clockwise direction to
increase belt tension.
CAUTION: Do not appIy excessive torque
to adjusting boIt or damage to boIt wiII
resuIt. If boIt appears to be seized or is
difficuIt to turn, appIy suitabIe anti-seize
Iubricant to boIt.
4. Check belt tension and re-adjust if necessary.
5. Tighten clamp bolts to 45 Nm.
6. Tighten adjustment bracket bolt to 25 Nm.
7. Position closing panel to body and secure with
scrivets and Torx screw.
ALTERNATOR DRIVE BELT - WITH AIR
CONDITIONING - ADJUST
Check
closing panel.
6. Check condition of drive belt. Renew a drive
belt that shows signs of wear and splitting.
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ELECTRICAL
ADJUSTMENTS 3
7. Apply a force of 10 kg to the drive belt at
position 'X' and measure the deflection
between the crankshaft pulley and air
conditioning compressor pulley.
Deflection must be 9 - 10 mm.
Adjust
1. Loosen nut securing drive belt, tensioner
pulley.
2. ncrease drive belt tension by turning the
tension adjusting bolt clockwise.
3. Tighten drive belt tensioner pulley securing nut
to 25 Nm.
4. Recheck drive belt tension.
HEADLAMPS - PAIR - ALIGN BEAM
Check
1. Before adjustment, ensure tyre pressures are
at correct settings.
2. Line up suitable beam setting equipment to
headlamp.
3. Switch on headlamps and check alignment;
Alignment figures = 1.0% Vertical ,
0.0% Horizontal.
Adjust
1. Adjust headlamp accordingly to achieve correct
alignment.
2. Turn adjuster for vertical alignment.
3. Turn adjuster for horizontal alignment.
4. Repeat above procedure for 2nd headlamp.
5. Switch off headlamps.
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ELECTRICAL
REPAIRS 1
ALTERNATOR - NON AIR CONDITIONING
Remove
2. Remove engine cover, See ENGINE, Repairs.
closing panel.
7. Remove alternator drive belt. See this
section.
8. Loosen 2 nuts securing cables to alternator.
9. Disconnect cables from alternator.
10. Remove nut and bolt securing alternator to
adjustment bracket.
11. Remove nut and bolt securing alternator to
engine.
12. Remove alternator.
13. Restraining the alternator shaft with an 8 mm
Allen key, remove nut securing pulley to
alternator shaft using tool 18G 1653.
14. Remove pulley from alternator.
15. Clean pulley and alternator shaft.
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ELECTRICAL
2 REPAIRS
Refit
1. Fit pulley to alternator shaft.
2. Fit alternator pulley nut, hold shaft with an
8 mm Allen key and tighten nut to 25 Nm using
tool 18G 1653.
3. Position alternator to engine.
4. Fit nut and bolt securing alternator to engine,
5. Fit bolt securing alternator to adjustment
bracket, but do not tighten.
6. Fit alternator drive belt. See this section.
7. Tighten bolt securing alternator to engine to
45 Nm.
8. Refit closing panel and secure with scrivets
and Torx screw.
11. Connect alternator leads to terminals and
tighten nuts.
ALTERNATOR - WITH AIR CONDITIONING
Remove
2. Raise rear of vehicle.and remove engine cover.
3. Remove alternator drive belt, See this
section.
4. Remove 2 nuts securing connections to
alternator and position aside.
5. Remove upper and lower bolts securing
alternator to mounting bracket.
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ELECTRICAL
REPAIRS 3
6. Remove bolt and loosen nut securing
alternator upper mounting bracket to cylinder
head.
7. Rotate bracket aside.
8. Remove alternator.
9. Restraining the alternator shaft with an 8 mm
Allen key, remove nut securing pulley to
alternator shaft using tool 18G 1653.
10. Remove pulley from alternator.
11. Clean pulley and alternator shaft.
Refit
1. Fit pulley to alternator shaft.
2. Fit alternator pulley nut, hold shaft with an
8 mm Allen key and tighten nut to 25 Nm using
tool 18G 1653.
3. Fit alternator to engine.
4. Align top bracket and tighten fixings to 25 Nm.
5. Position alternator to top bracket and tighten
fixings to 45 Nm.
6. Connect cables and secure nuts.
7. Fit alternator drive belt. See this section.
DRIVE BELT - ALTERNATOR - NON AIR
CONDITIONING
Remove
closing panel and remove closing panel.
5. Loosen bolt securing alternator adjustment
bracket.
6. Loosen 2 alternator clamp bolts.
CAUTION: Ensure that boIts are Ioosened
sufficientIy for aIternator to move freeIy.
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ELECTRICAL
4 REPAIRS
7. Loosen adjusting bolt until there is sufficient
free movement to remove the drive belt.
CAUTION: Do not appIy excessive torque
to adjusting boIt or damage to boIt wiII
resuIt. If boIt appears to be seized or is
difficuIt to turn, appIy suitabIe anti-seize
Iubricant to boIt.
8. Remove auxiliary drive belt.
Refit
1. Clean auxiliary drive belt pulleys and ensure
that pulley grooves are not damaged.
2. Fit drive belt. Ensure drive belt is correctly
located in pulley grooves.
3. Adjust auxiliary drive belt tension. See
Adjustments.
4. Position closing panel to body and secure with
scrivets and Torx screw.
ALTERNATOR DRIVE BELT - WITH AIR
CONDITIONING
Remove
closing panel.
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ELECTRICAL
REPAIRS 5
6. Loosen drive belt tensioner pulley securing nut.
7. Release drive belt tension by turning the
tension adjusting bolt anti-clockwise.
8. Release drive belt from alternator and
compressor pulleys.
9. Remove and discard drive belt.
Refit
1. Clean pulley 'V's.
2. Fit new drive belt to crankshaft pulley and
engage to alternator and compressor pulleys.
Ensure grooves on drive belt and pulleys are
correctly located.
3. ncrease drive belt tension by turning the
tension adjusting bolt clockwise.
4. Tighten drive belt tensioner pulley securing nut
to 25 Nm.
5. Apply a force of 10 kg to the drive belt at
position 'X' and measure the deflection
between the crankshaft pulley and air
conditioning compressor pulley.
Deflection must be 9 - 10 mm.
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ELECTRICAL
6 REPAIRS
ELECTRIC WINDOW SWITCH
Remove
1. Remove console closing panel. See BODY,
2. Release switch from centre console.
4. Remove switch.
Refit
1. Connect multiplug to switch and fit switch to
centre console.
2. Fit console closing panel See BODY, Interior
trim components.
CENTRAL DOOR LOCKING MOTOR AND LATCH
Remove
1. Remove door trim casing. See BODY, Doors.
2. Switch the ignition ON and fully lower door
glass.
4. Carefully peel back corner of plastic sheet to
allow access to door latch.
5. Release clip securing door handle link rod to
latch assembly and position aside.
6. Release lock link rod from lock.
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ELECTRICAL
REPAIRS 7
7. Remove 3 Tx25 Torx screws securing latch
assembly to door.
8. Position latch assembly and disconnect 2
multiplugs.
9. Release cable from 2 inner door panel clips.
10. Disconnect cable from remote door handle.
11. Switch ignition ON and fully raise door glass.
13. Remove latch assembly from door.
14. Remove sill button, lock link rod and cable from
latch assembly.
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ELECTRICAL
8 REPAIRS
Refit
1. Fit sill button, lock link rod and cable to latch
assembly.
2. Position latch assembly to door and guide sill
button through door aperture.
3. Switch ignition ON and fully lower door glass.
5. Connect multiplugs to latch assembly.
6. Connect door release cable to remote door
handle and secure to inner door panel clips.
7. Align exterior handle, link rod to latch assembly
NOTE: A smaII amount of free-pIay shouId
be evident between the exterior handIe
and Iatch. If necessary adjust the exterior
handIe, Iink rod trunnion.
8. Engage lock link rod to lock.
9. Fit Torx screws securing latch assembly to
door and tighten to 5 Nm.
10. Secure plastic sheet to door.
11. Fit door trim casing. See BODY, Doors.
CONTROL UNIT - ONE TOUCH WINDOW
Remove
1. Release RH lower section of door seal and
carpet to access control unit.
2. Release multiplug catch and disconnect
multiplug.
3. Release harness clip from control unit retaining
stud.
4. Remove 2 nuts securing control unit and
remove control unit.
Refit
1. Position control unit, fit and tighten nuts.
2. Connect multiplug and secure catch.
3. Connect harness clip to retaining stud.
4. Reposition carpet and door seal.
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ELECTRICAL
REPAIRS 9
HORN
Remove
1. Disconnect horn multiplug.
2. Remove bolt securing horn to valance.
3. Remove horn.
Refit
1. Position horn to valance fit bolt and tighten
to 8 Nm.
HEADLAMP ASSEMBLY
Remove
Exterior fittings.
2. Remove 4 bolts securing headlamp assembly
to front panel and release headlamp assembly.
3. Disconnect headlamp multiplug and remove
headlamp assembly.
4. Remove both headlamp bulb covers.
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ELECTRICAL
10 REPAIRS
5. Disconnect both headlamp bulb multiplugs.
6. Release bulb holders and remove both
headlamp bulbs.
7. Release and remove indicator bulb holder and
bulb.
Refit
1. Fit indicator bulb and bulb holder.
2. Fit headlamp bulbs and secure bulb holders.
3. Connect headlamp bulb multiplugs.
4. Fit headlamp bulb covers.
5. Position headlamp assembly to front panel and
connect headlamp multiplug.
6. Fit bolts securing headlamp to front panel and
tighten to 10 Nm.
fittings.
8. Check/adjust headlamp alignment. See
BODY, Adjustments.
LAMP ASSEMBLY - FOG/DRIVING
Remove
2. Disconnect fog/driving lamp multiplug.
3. Remove 3 screws securing fog/driving lamp to
bumper valance.
4. Remove fog/driving lamp from bumper
valance.
Refit
1. Position fog/driving lamp to bumper valance, fit
and tighten screws.
2. Connect fog/driving lamp multiplug.
4. Check operation and alignment of fog lamp.
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ELECTRICAL
REPAIRS 11
LAMP ASSEMBLY - CENTRE HIGH MOUNTED
STOP (CHMSL)
Remove
1. Apply protective tape to the area around
CHMSL.
2. Open boot lid.
3. Disconnect CHMSL multiplug and release
harness grommet.
4. Using a thin round edged flat blade bent to 20
at the tip, apply pressure to one side of the
CHMSL and release from retaining clip.
5. Slide CHMSL from remaining retaining clip.
6. Withdraw harness and CHMSL from boot lid.
7. Remove CHMSL retaining clips from boot lid.
Refit
1. Fit retaining clips to CHMSL.
2. Position CHMSL and feed harness through
boot lid.
3. Secure CHMSL retaining clips to boot lid.
4. Connect CHMSL multiplug and secure harness
grommet.
5. Remove protection from boot lid, clean and
inspect paintwork.
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ELECTRICAL
12 REPAIRS
TAIL LAMP ASSEMBLY
Remove
2. Remove 3 nuts securing tail lamp.
3. Release tail lamp and disconnect multiplug.
Refit
1. Connect multiplug to tail lamp.
2. Fit tail lamp and tighten nuts to 2 Nm.
GLOVEBOX LAMP
Remove
1. Open glove box.
2. Release lamp from glovebox.
3. Disconnect 2 Lucars from lamp.
4. Remove lamp.
Refit
1. Position lamp and connect Lucars.
2. Secure lamp in glovebox.
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ELECTRICAL
REPAIRS 13
BOOT LID LAMP
Remove
1. Release lamp from boot lid.
2. Disconnect 2 Lucars.
3. Remove lamp.
Refit
2. Secure lamp in boot lid.
BONNET LAMP
Remove
1. Open bonnet.
2. Release lamp from bonnet.
3. Disconnect 2 Lucars.
4. Remove lamp.
Refit
CAUTION: Ensure bIack wire is connected
to terminaI cIosest to the buIb.
2. Secure lamp in bonnet.
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ELECTRICAL
14 REPAIRS
FRONT SPEAKER
Remove
1. Remove front door trim casing. See BODY,
Doors.
2. Remove 3 screws securing speaker to door.
3. Release speaker from door, disconnect 2
Lucars.
4. Remove speaker.
Refit
1. Position speaker to door and connect Lucars.
2. Align speaker to door and secure with screws.
3. Fit front door trim casing. See BODY, Doors.
AERIAL
Remove
1. Remove engine compartment access grille.
2. Unscrew aerial from base.
3. Using a 17 mm open ended spanner, remove
aerial base locking nut.
4. Collect locking nut and outer sleeve.
5. Remove aerial base from body.
6. Disconnect aerial coaxial lead from harness.
Refit
1. Position aerial base in body.
2. Fit sleeve and tighten locking nut to 3 Nm.
NOTE: If the vehicIe is fitted with a rear
spoiIer ensure the aeriaI mast does not
contact the rear spoiIer before tightening
the Iocking nut.
3. Connect aerial coaxial lead to harness.
4. Screw aerial into base.
5. Fit engine compartment access grille. See
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ELECTRICAL
REPAIRS 15
SPEAKER - TWEETER
Remove
1. Remove door casing. See BODY, Doors.
2. Remove backing nut from tweeter assembly
and remove tweeter assembly from door
casing.
3. Release tweeter from finisher.
Refit
1. Fit tweeter to finisher ensuring correct
alignment of key and keyway in finisher.
2. Fit tweeter assembly to door casing and fit
backing nut.
3. Fit door casing. See BODY, Doors.
SUBWOOFER ASSEMBLY
Remove
1. Move both seats fully forwards.
2. Remove 3 screws securing finisher and collect
press studs.
3. Release finisher from fixings and slide
downwards for access to subwoofer assembly.
4. Disconnect multiplug from subwoofer.
5. Remove 4 bolts securing subwoofer to body
fixings and remove subwoofer assembly.
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ELECTRICAL
16 REPAIRS
Refit
1. Position subwoofer assembly and connect
multiplug.
2. Fit and tighten 4 bolts securing subwoofer to
body.
3. Align finisher to fixings and secure into
position.
4. Position press studs and secure with screws.
5. Return seats to original position.
AUTO CHANGER - KENWOOD AUDIO SYSTEMS
Remove
1. Release multiplug from auto changer. Remove
4 bolts securing auto changer to vehicle and
remove autochanger.
2. Remove 4 screws securing support brackets to
auto changer and remove brackets.
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ELECTRICAL
REPAIRS 17
Refit
1. Set the angle adjustment switches on the auto
changer to 90 .
2. Attach brackets to auto changer with 4 screws
and secure to vehicle with 4 bolts. Tighten
bolts to 5 Nm.
3. Connect auto changer multiplug to auto
changer.
4. Check head unit and auto changer for correct
operation.
HEAD UNIT - KENWOOD AUDIO SYSTEMS
Remove
2. Remove audio unit escutcheon.
3. nsert Kenwood removal tools into slots either
side of head unit. Push removal tools upwards
and pull head unit out of aperture.
4. Disconnect multiplugs, aerial cable and auto
changer data cable (if fitted). Remove head
unit.
5. Release retaining tags and remove cage from
centre console.
Refit
1. Position audio unit cage to centre console and
secure with retaining tags.
2. Position audio unit, fit threaded rubber bung,
connect aerial cable, CD auto changer data
cable (if fitted) and multiplugs.
3. Slide audio unit into cage until retaining clips
engage. Ensure that rubber support stud
locates in rear support plate.
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ELECTRICAL
18 REPAIRS
4. Fit audio unit escutcheon, ensuring that the felt
strip is located on the bottom inner edge.
Locate the top edge lugs and then push the
bottom edge in until the retaining tags click into
position.
6. Check audio unit including CD auto changer for
correct operation and program suitable radio
stations on all pre-sets.
HEAD UNIT AND AUTO CHANGER - KENWOOD
AUDIO SYSTEMS - RENEW
Remove
1. Lower both windows and release both hood
catches but do not lower hood.
release 5 clips.
3. Unzip top edge or rear window and lay window
in hoodwell.
4. Fold rear of hood up to release from body.
6. Remove head unit. See this section.
7. Remove centre console closing panel.
8. Release lower section of LH door seal to
release carpet.
9. Remove 5 trim clips securing carpet to LH side
of vehicle.
10. Pull back carpet from sill to access harness.
11. Fold back carpet and sound deadening in LH
footwell.
12. Release cable ties securing auto changer data
cable to harness.
13. Release grommet from body. Remove
grommet from auto changer data cable.
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ELECTRICAL
REPAIRS 19
14. Disconnect auto changer data cable from auto
changer, remove 4 bolts securing auto changer
brackets to vehicle and remove auto changer.
15. Remove luggage compartment trim. See
BODY, Interior trim components.
16. Remove cable ties securing auto changer data
cable to harness.
17. Remove auto changer data cable.
Refit
1. Route auto changer cable behind console
closing panel and into audio unit aperture.
2. Route auto changer data cable under sound
deadening and carpet in LH footwell and along
harness. Secure with cable ties.
3. Route auto changer data cable under roof
hinge and into hood compartment. Secure with
cable ties.
4. Replace sound deadening and secure carpet
with trim clips.
5. Position centre console closing panel, connect
Lucar connectors and secure closing panel
with screws.
6. Fit lower section of LH door seal to secure
carpet.
7. Fit new grommet to auto changer data cable.
Feed data cable through aperture and fit new
grommet to body.
8. Feed auto changer data cable along cavity and
into luggage compartment. Secure with
supplied cable tie clip and attach to body to
prevent damage to cable.
9. Secure auto changer data cable to harness
with cable ties and feed through luggage
compartment trim.
10. Position luggage compartment trim.
11. Feed auto changer data cable through slit in
luggage compartment trim.
12. Refit luggage compartment trim. See BODY,
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ELECTRICAL
20 REPAIRS
13. Attach brackets to auto changer with 4 screws
and secure to vehicle with 4 bolts. Tighten
bolts to 5 Nm.
14. Connect auto changer multiplug to auto
changer.
15. Lower rear of hood and engage clips to secure
rear of hood to body.
17. Position rear window and zip up top edge.
18. Secure catches to secure front of hood.
19. Fit head unit. See this section.
21. Raise windows.
22. Check audio unit including CD auto changer for
correct operation and program suitable radio
stations on all pre-sets.
ANTI-THEFT ALARM ECU
Remove
1. Remove 4 screws securing both closing panels
to front console and position panels aside.
2. Remove 2 nuts securing alarm ECU to heater
control unit.
3. Disconnect 2 multiplugs from alarm ECU.
4. Remove alarm ECU.
Refit
1. Connect multiplugs to alarm ECU.
2. Position alarm ECU to heater control unit and
3. Fit closing panels and secure with screws.
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ELECTRICAL
REPAIRS 21
VOLUMETRIC SENSOR
Remove
1. Position both seats fully forward and position
seat squab forward.
2. Remove 3 screws securing rear bulkhead
finisher to rear bulkhead and collect 3 studs.
3. Release finisher from 6 clips and position
aside.
4. Disconnect multiplug from sensor.
5. Remove 2 screws securing sensor to rear
console.
6. Remove sensor.
Refit
1. Fit sensor to console and secure with screws.
3. Locate bulkhead finisher and engage clips.
4. Fit studs and secure with screws.
5. Return seats to original position.
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ELECTRICAL
22 REPAIRS
STARTER MOTOR
Remove
2. Remove engine compartment access panel
4. Remove LH rear wheel.
5. Release EVAP canister from bracket and
position canister aside.
6. Remove clip and disconnect air intake hose
from throttle body.
7. Loosen clip and remove air intake hose from
air filter.
8. Disconnect Lucar and release cable tie from
9. Remove nut from solenoid and release 2 leads.
10. Remove 2 nuts and bolts securing starter
motor.
11. Remove starter motor.
12. Remove flywheel closing plate.
Refit
1. Clean mating faces of starter motor and
gearbox.
2. Fit starter motor.
3. Fit closing plate.
4. Fit nuts and bolts and tighten nuts to 80 Nm.
5. Fit leads to starter solenoid and tighten
terminal nut.
6. Connect Lucar to starter solenoid.
7. Secure cables to starter solenoid with cable tie.
8. Fit air intake hose to air filter and to throttle
body.
9. Tighten clip securing air intake hose to air filter,
fit clip securing air intake hose to throttle body.
10. Fit EVAP canister.
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ELECTRICAL
REPAIRS 23
STARTER MOTOR - STEPSPEED (Em-CVT)
MODELS
Remove
4. Remove bolt securing coolant hose heat shield
to bracket on exhaust manifold.
shield to cylinder block and remove heat
shield.
6. Disconnect Lucar from starter solenoid.
7. Remove nut from starter solenoid and release
2 leads.
8. Remove 1 bolt and remove flywheel cover.
9. Remove 2 bolts securing starter motor and
remove starter motor.
Refit
1. Clean mating faces of starter motor and
gearbox.
2. Fit starter motor and align to dowel.
3. Fit bolts and tighten to 80 Nm.
4. Fit leads to starter solenoid and tighten
terminal nut.
5. Connect Lucar to starter solenoid.
6. Fit flywheel cover and tighten bolt to 9 Nm.
7. Fit exhaust manifold heat shield and tighten
bolts to 9 Nm.
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ELECTRICAL
24 REPAIRS
STARTER SOLENOID
Remove
2. Remove starter motor. See this section.
3. Remove nut from solenoid and disconnect
lead.
4. Remove 2 bolts securing solenoid to starter
motor housing.
5. Remove solenoid from starter motor housing.
6. Remove plunger from starter.
Refit
1. Apply grease to lever end of plunger.
2. Fit starter solenoid to starter motor housing
and tighten bolts.
3. Fit lead to rear of solenoid and tighten nut.
4. Fit starter motor. See this section.
PANEL DIMMER RESISTOR
Remove
1. Release 2 clips and open fuse box cover.
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ELECTRICAL
REPAIRS 25
2. Release dimmer resistor from instrument cowl.
3. Disconnect multiplug from dimmer.
Refit
1. Connect multiplug and engage dimmer to cowl.
2. Position fuse box cover and secure with clips.
HAZARD WARNING LAMP SWITCH
Remove
1. Release radio from console. See this section.
2. Release hazard warning lamp switch from
console.
Refit
1. Connect multiplug and engage switch to
console.
2. Secure radio to console. See this section.
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ELECTRICAL
26 REPAIRS
STEERING COLUMN SWITCH PACK
Remove
1. Remove rotary coupler. See GENERAL
2. Remove direction indicator cancellation cam
from column.
3. Remove 2 screws securing switch pack to
steering column.
4. Release switch pack from column and
disconnect 3 multiplugs.
5. Remove switch pack.
6. Remove 2 screws securing direction/
headlamp stalk to switch pack.
7. Remove direction/headlamp stalk from switch
pack.
8. Remove 2 screws securing wash wipe stalk to
switch pack.
9. Remove wash wipe stalk from switch pack.
Refit
1. Fit wash wipe stalk to switch pack and secure
with screws.
2. Fit indicator/headlamp stalk to switch pack and
tighten screws.
3. Position switch pack to steering column,
connect 3 multiplugs and tighten screws.
4. Fit direction indicator cancellation cam to
steering column.
5. Fit rotary coupler. See GENERAL
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ELECTRICAL
REPAIRS 27
SWITCH - EXTERIOR MIRROR
Remove
1. Carefully remove switch from fascia.
3. Remove switch.
Refit
1. Position switch and connect multiplug.
2. Carefully push switch back into position.
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INSTRUMENTS
CONTENTS Page
NSTRUMENT PACK COMPONENTS - REAR VEW 1 ..............................................
NSTRUMENT PACK COMPONENTS - EXPLODED VEW 2 ....................................
NSTRUMENT PACK 3 ................................................................................................
REPAIRS
CLOCK 1 .....................................................................................................................
NSTRUMENT PACK 1 ................................................................................................
NSTRUMENT COWL 2 ...............................................................................................
NSTRUMENT PACK WNDOW 3 ...............................................................................
NSTRUMENT LLUMNATON HOUSNG 3 ...............................................................
PRNTED CRCUT BOARD 4 .....................................................................................
OL TEMPERATURE GAUGE 4 ..................................................................................
COOLANT TEMPERATURE GAUGE 5 ......................................................................
ENGNE COOLANT TEMPERATURE GAUGE SENSOR 5 ........................................
ENGNE OL TEMPERATURE GAUGE SENSOR 6 ...................................................
FUEL GAUGE 6 ...........................................................................................................
SPEEDOMETER 7 ......................................................................................................
TACHOMETER 7 .........................................................................................................
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INSTRUMENTS
INSTRUMENT PACK COMPONENTS - REAR VIEW
1. Rear fog lamps - warning light bulb
2. Gearbox fault (Stepspeed gearbox only) -
warning light bulb
3. Hazard warning lamps - warning light bulb
4. Brake fail / Handbrake - warning light bulb
5. RH direction indicator - warning light bulb
6. Main beam - warning light bulb
7. LH direction indicator - warning light bulb
8. Low oil pressure - warning light bulb
9. gnition / No charge - warning light bulb
10. Malfunction ndicator Lamp (ML) - warning
light bulb
11. ABS - warning light bulb
12. Main printed circuit board
13. Panel rear illumination bulb
14. Anti-theft alarm LED
15. LCD illumination bulb
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INSTRUMENTS
INSTRUMENT PACK COMPONENTS -
EXPLODED VIEW
1. Support bracket
2. Panel front illumination bulbs
3. Panel illumination and printed circuit
4. Boot open - warning light bulb
5. Engine bay cooling fan - warning light bulb
6. EPAS - warning light bulb
7. Seat belt - warning light bulb
8. Oil temperature - warning light bulb
9. SRS - warning light bulb
10. Anti-theft warning LED
11. Tachometer
12. nstrument panel housing
13. Fuel gauge
14. Speedometer
15. Control knob - trip distance
16. nstrument panel and face plate
17. Coolant temperature gauge
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INSTRUMENTS
INSTRUMENT PACK
Instrument pack
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INSTRUMENTS
Speedometer
The speedometer is operated electronically by a
signal output from a speed transducer fitted to the
gearbox. The transducer output is shared with the
EPAS ECU.
Odometer and trip distance is displayed on an LCD
located at the bottom of the speedometer. A button
allows the trip and odometer to be displayed
individually. The button will also reset the trip meter
if pressed and held. The LCD also shows gearbox
information when the vehicle is fitted with a
Stepspeed (Em-CVT) gearbox.
Tachometer
The tachometer signal is taken from the MEMS ECU
to the control board which is secured to the rear of
the tachometer sub-assembly. The instrument panel
display reading is averaged over all the engine
cylinders to reduce fluctuations due to individual
cylinder retardation in spark timing which may occur
on engines fitted with programmed ignition systems.
FueI gauge
The fuel gauge is driven by an air cored electronic
movement which is fluid damped. Fluid damping
reduces the movement of the gauge pointer caused
by fluid movement in the tank.
The fuel tank gauge unit comprises a float and is
connected to a wire-wound resistor which is
connected to the fuel gauge and back through the
instrument panel to earth. The resistor controls the
current flow through to the fuel gauge circuit, which
in turn drives the gauge movement against the
resistance of the fluid damping.
When the gauge unit float is at its lowest point,
indicating an empty fuel tank, the resistance to earth
is at its greatest. The resistance value to fuel gauge
position to earth is:
Sender resistance FueI gauge position
105 Empty
32.5 Half full
5 Full
The fuel gauge pointer will display the level of fuel in
the tank when the ignition was last switched off.
CooIant temperature gauge
The coolant temperature gauge is fitted with a return
magnet causing the gauge to return to zero when
the ignition is switched off.
Thermistor
resistance
Temperature Gauge position
142 56 C No movement
49 - 98 65 C - 85 C Approx. one third
24.6 - 32.1 100 C - 110 C Approx. halfway
16.9 125 C Enters red sector
Instrument iIIumination
Four bulbs provide instrument illumination, 2 x 14V,
1.4W for back illumination and 2 x 14V, 1.4W for
front illumination.
Operation
For operation of the instrument pack. See
ELECTRICAL REFERENCE LIBRARY,
Description and Operation.
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INSTRUMENTS
1. Oil temperature gauge
2. Analogue clock
OiI temperature gauge
Th oil temperature gauge (1) is fitted with a return
magnet causing the gauge to return to zero when
the ignition is switched off.
170 C sender
Sender resistance Temperature
574 71 60 C
202 24 90 C
84 9 120 C
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INSTRUMENTS
REPAIRS 1
CLOCK
Remove
2. Remove 2 screws securing clock to console.
3. Remove retaining bracket, clock and 'O' ring.
Refit
1. Position 'O' ring and clock to console.
2. Fit retaining bracket and secure with screws.
NOTE: Ensure correct orientation of cIock
in consoIe.
trim components.
INSTRUMENT PACK
SRS Precautions.
Remove
1. Make the system safe. See GENERAL
2. Remove instrument cowl. See this section.
3. Remove 4 screws securing instrument pack to
fascia.
4. Release instrument pack from fascia.
5. Release 3 multiplugs from pack and remove
instrument pack.
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INSTRUMENTS
2 REPAIRS
Refit
1. Position instrument pack to fascia and connect
multiplugs.
2. Position instrument pack and secure with
screws.
3. Fit instrument cowl. See this section.
INSTRUMENT COWL
Remove
1. Remove steering column nacelle. See
STEERING, Repairs.
2. Remove 4 screws securing instrument cowl to
fascia.
3. Release cowl from fascia.
4. Disconnect multiplugs from dimmer resistor
and door mirror selector switch.
5. Remove cowl.
6. Remove dimmer and mirror switch from cowl.
Refit
1. Fit dimmer and mirror switch to cowl.
2. Position cowl and connect multiplugs.
3. Position cowl to fascia and secure with screws.
4. Fit steering column nacelle. See STEERING,
Repairs.
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INSTRUMENTS
REPAIRS 3
INSTRUMENT PACK WINDOW
Remove
1. Remove instrument illumination housing. See
this section.
2. Release 4 clips securing panel window to
instruments.
3. Remove instrument pack window.
Refit
1. Fit pack window and secure with clips.
2. Fit instrument illumination housing. See this
section.
INSTRUMENT ILLUMINATION HOUSING
Remove
1. Remove instrument pack. See this section.
2. Remove 2 screws securing brackets to
instrument pack and collect brackets.
3. Release bulb holder from casing and cables
from 2 casing clips.
4. Remove instrument illumination housing.
Refit
1. Position illumination housing to casing.
2. Fit brackets and secure with screws.
3. Secure bulb holder and secure cables to clips.
4. Fit instrument pack. See this section.
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INSTRUMENTS
4 REPAIRS
PRINTED CIRCUIT BOARD
Remove
1. Remove instrument pack. See this section.
2. Noting their fitted positions remove 12 bulbs
from PCB.
3. Remove 14 screws securing PCB to casing.
4. Release PCB from 14 lugs and remove PCB.
Refit
1. Position PCB and engage lugs.
2. Secure PCB with screws.
3. Fit bulbs.
4. Fit instrument pack. See this section.
OIL TEMPERATURE GAUGE
Remove
2. Remove 2 screws securing gauge to console.
3. Remove retaining bracket, gauge and 'O' ring.
Refit
1. Position 'O' ring and gauge to console.
2. Fit retaining bracket and secure with screws.
NOTE: Ensure correct orientation of gauge
in consoIe.
trim components.
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INSTRUMENTS
REPAIRS 5
COOLANT TEMPERATURE GAUGE
Remove
1. Remove instrument pack window. See this
section.
2. Remove 3 screws securing temperature gauge
to casing.
3. Remove gauge.
Refit
1. Fit gauge to instrument pack and secure with
screws.
2. Fit instrument pack window. See this section.
ENGINE COOLANT TEMPERATURE GAUGE
SENSOR
Remove
4. Position a container below sensor to collect
coolant spillage
5. Remove sensor.
Refit
1. Clean threads of sensor.
2. Apply Loctite 577 to threads of sensor.
7. Top-up coolant, See COOLING SYSTEM,
Adjustments.
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INSTRUMENTS
6 REPAIRS
ENGINE OIL TEMPERATURE GAUGE SENSOR
Remove
3. Position spillage tray.
4. Remove sensor from oil filter housing.
Refit
1. Fit oil temperature sensor to oil filter housing
2. Remove spillage tray.
5. Check and top up engine oil level. See
MAINTENANCE.
FUEL GAUGE
Remove
section.
2. Remove 3 screws securing fuel gauge to
casing.
3. Remove gauge.
Refit
1. Fit gauge to instrument pack and secure with
screws.
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INSTRUMENTS
REPAIRS 7
SPEEDOMETER
Remove
1. Remove tachometer. See this section.
2. Remove 5 screws securing speedometer to
casing.
3. Remove speedometer.
Refit
1. Fit speedometer to instrument pack and secure
with screws.
2. Fit tachometer. See this section.
TACHOMETER
Remove
section.
2. Remove 3 screws securing tachometer to
casing.
3. Remove tachometer .
Refit
1. Fit tachometer to instrument pack and secure
with screws.
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