kOVEk 25 J MG Zk

WORKSHOP MANUAL - SERVICE

PROCEDURES
Publication Part No. RCL 0534ENG
Published by MG Rover Group After Sales
© MG Rover Group Limited 2003
All right reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form,
electronic, mechanical, photocopying, recording or other means without prior written permission of MG Rover Group Ltd.
CONTENTS
CONTENTS 1
INTRODUCTION ...................................................................................... 01-1
ÌNTRODUCTÌON ............................................................................................................................ 01-1
REPAÌRS AND REPLACEMENTS ................................................................................................. 01-1
SPECÌFÌCATÌON ............................................................................................................................ 01-2
ABBREVÌATÌONS AND SYMBOLS................................................................................................ 01-3
GENERAL INFORMATION ...................................................................... 03-1
VEHÌCLE ÌDENTÌFÌCATÌON NUMBER.......................................................................................... 03-1
VÌN NUMBER LOCATÌONS............................................................................................................ 03-2
COMPONENT ÌDENTÌFÌCATÌON NUMBER LOCATÌONS............................................................. 03-3
DANGEROUS SUBSTANCES ....................................................................................................... 03-4
SAFETY ÌNSTRUCTÌONS.............................................................................................................. 03-5
ENVÌRONMENTAL PRECAUTÌONS.............................................................................................. 03-6
PRECAUTÌONS AGAÌNST DAMAGE............................................................................................. 03-10
GENERAL FÌTTÌNG ÌNSTRUCTÌONS............................................................................................ 03-10
BALL AND ROLLER BEARÌNGS.................................................................................................... 03-11
OÌL SEALS...................................................................................................................................... 03-12
JOÌNTS AND JOÌNT FACES .......................................................................................................... 03-13
LOCKÌNG DEVÌCES....................................................................................................................... 03-14
SCREW THREADS ........................................................................................................................ 03-15
BOLT ÌDENTÌFÌCATÌON................................................................................................................. 03-15
NUT ÌDENTÌFÌCATÌON................................................................................................................... 03-17
FLEXÌBLE PÌPES AND HOSES ..................................................................................................... 03-18
SERVÌCE TOOLS........................................................................................................................... 03-19
DYNAMOMETER TESTÌNG........................................................................................................... 03-20
FUEL HANDLÌNG PRECAUTÌONS ................................................................................................ 03-20
ELECTRÌCAL PRECAUTÌONS....................................................................................................... 03-21
SUPPLEMENTARY RESTRAÌNT SYSTEM PRECAUTÌONS........................................................ 03-23
WARNÌNG LABELS........................................................................................................................ 03-27
VEHÌCLE RECOVERY ................................................................................................................... 03-30
SRS COMPONENT DEPLOYMENT............................................................................................... 03-30
SRS COMPONENT REPLACEMENT POLÌCY.............................................................................. 03-31
AÌR CONDÌTÌONÌNG SYSTEM PRECAUTÌONS............................................................................ 03-32
AÌR CONDÌTÌONÌNG COMPRESSOR REPLACEMENT................................................................ 03-34
INFORMATION ........................................................................................ 04-1
LÌFTÌNG AND TOWÌNG.................................................................................................................. 04-1
LÌFTÌNG.......................................................................................................................................... 04-2
VEHÌCLE RECOVERY ................................................................................................................... 04-3
CONTENTS
2 CONTENTS
GENERAL DATA ..................................................................................... 05-1
ENGÌNE - 'K' SERÌES..................................................................................................................... 05-1
ENGÌNE - 'L' SERÌES..................................................................................................................... 05-8
FUEL SYSTEM - 'K' SERÌES ......................................................................................................... 05-11
FUEL SYSTEM - 'L' SERÌES.......................................................................................................... 05-12
COOLÌNG SYSTEM - 'K' SERÌES.................................................................................................. 05-13
COOLÌNG SYSTEM - 'L' SERÌES .................................................................................................. 05-14
CLUTCH......................................................................................................................................... 05-15
MANUAL GEARBOX - R65 ............................................................................................................ 05-16
MANUAL GEARBOX - PG1............................................................................................................ 05-17
AUTOMATÌC GEARBOX - EM-CVT............................................................................................... 05-18
FÌNAL DRÌVE.................................................................................................................................. 05-19
STEERÌNG ..................................................................................................................................... 05-20
BRAKES......................................................................................................................................... 05-21
FRONT SUSPENSÌON................................................................................................................... 05-22
REAR SUSPENSÌON..................................................................................................................... 05-23
WHEELS......................................................................................................................................... 05-24
TYRE SÌZES................................................................................................................................... 05-25
TYRE PRESSURES - 1.1, 1.4 & 1.6 'K' SERÌES ........................................................................... 05-26
TYRE PRESSURES - 1.8 'K' SERÌES WÌTH VVC......................................................................... 05-28
TYRE PRESSURES - 1.8 'K' SERÌES WÌTH EM-CVT................................................................... 05-29
TYRE PRESSURES - 2.0 'L' SERÌES DÌESEL ENGÌNES............................................................. 05-31
AÌR CONDÌTÌONÌNG...................................................................................................................... 05-33
ELECTRÌCAL - 'K' SERÌES ............................................................................................................ 05-34
ELECTRÌCAL - 'L' SERÌES............................................................................................................. 05-35
DÌMENSÌONS - Rover 25 ............................................................................................................... 05-36
DÌMENSÌONS - MG ZR.................................................................................................................. 05-37
WEÌGHTS....................................................................................................................................... 05-38
TOWÌNG WEÌGHTS....................................................................................................................... 05-39
TORQUE WRENCH SETTINGS .............................................................. 06-1
ENGÌNE - 'K' SERÌES..................................................................................................................... 06-1
ENGÌNE - 'L' SERÌES..................................................................................................................... 06-3
ENGÌNE MANAGEMENT SYSTEM - MEMS ................................................................................. 06-5
ENGÌNE MANAGEMENT SYSTEM - EDC..................................................................................... 06-6
FUEL DELÌVERY SYSTEM............................................................................................................ 06-7
COOLÌNG....................................................................................................................................... 06-8
MANÌFOLD AND EXHAUST........................................................................................................... 06-9
CLUTCH......................................................................................................................................... 06-10
MANUAL GEARBOX - R65 ............................................................................................................ 06-11
MANUAL GEARBOX - PG1............................................................................................................ 06-12
AUTOMATÌC GEARBOX - EMCVT................................................................................................ 06-13
DRÌVE SHAFTS.............................................................................................................................. 06-14
STEERÌNG ..................................................................................................................................... 06-15
SUSPENSÌON................................................................................................................................ 06-16
BRAKES......................................................................................................................................... 06-17
RESTRAÌNT SYSTEMS................................................................................................................. 06-19
BODY.............................................................................................................................................. 06-20
HEATÌNG AND VENTÌLATÌON....................................................................................................... 06-22
AÌR CONDÌTÌONÌNG...................................................................................................................... 06-23
WÌPERS AND WASHERS.............................................................................................................. 06-24
ELECTRÌCAL.................................................................................................................................. 06-25
ÌNSTRUMENTS.............................................................................................................................. 06-26
CONTENTS
CONTENTS 3
CAPACITIES, FLUIDS AND LUBRICANTS ............................................ 09-1
CAPACÌTÌES................................................................................................................................... 09-1
FUEL REQUÌREMENTS................................................................................................................. 09-2
RECOMMENDED FUEL................................................................................................................. 09-2
FLUÌDS ........................................................................................................................................... 09-3
ANTÌ-FREEZE CONCENTRATÌON................................................................................................ 09-3
LUBRÌCATÌON................................................................................................................................ 09-4
MAINTENANCE........................................................................................ 10-1
MAINTENANCE
UNDERBONNET LOCATÌONS - 'K16' (except 1.8 with VVC)........................................................ 10-1
UNDERBONNET LOCATÌONS - 'K16 (1.8 with VVC)' .................................................................. 10-2
UNDERBONNET LOCATÌONS - 'L' SERÌES.................................................................................. 10-3
CHECK ENGÌNE AND TRANSMÌSSÌON........................................................................................ 10-4
ENGÌNE OÌL AND FÌLTER - 'K' SERÌES ........................................................................................ 10-4
ENGÌNE OÌL AND FÌLTER - 'L' SERÌES......................................................................................... 10-5
CRANKCASE VENT HOSES - 'K' SERÌES .................................................................................... 10-7
CRANKCASE PRESSURE LÌMÌTER VALVE - 'L' SERÌES ............................................................ 10-7
FUEL SYSTEM HOSES, PÌPES AND UNÌONS ............................................................................. 10-8
ENGÌNE TUNÌNG ........................................................................................................................... 10-9
ÌGNÌTÌON COÌLS ............................................................................................................................ 10-9
COOLÌNG SYSTEM........................................................................................................................ 10-10
EXHAUST SYSTEM....................................................................................................................... 10-10
CLUTCH ......................................................................................................................................... 10-11
GEARBOX OÌL - 'R65' .................................................................................................................... 10-11
GEARBOX OÌL - 'PG1'.................................................................................................................... 10-12
AUTOMATÌC GEARBOX OÌL - 'EM-CVT' ....................................................................................... 10-12
DRÌVE SHAFT GAÌTERS ............................................................................................................... 10-13
STEERÌNG...................................................................................................................................... 10-13
SUSPENSÌON DAMPERS, BALL JOÌNTS, FXÌNGS AND GAÌTERS ............................................ 10-15
ROAD WHEELS AND FASTENÌNGS............................................................................................. 10-17
TYRE PRESSURES AND CONDÌTÌON.......................................................................................... 10-17
FOOTBRAKE.................................................................................................................................. 10-18
HANDBRAKE.................................................................................................................................. 10-18
BRAKE FLUÌD ................................................................................................................................ 10-19
BRAKE HOSES AND PÌPES.......................................................................................................... 10-21
FRONT BRAKES-HYDRAULÌCS, PADS, DÌSCS AND CALÌPERS................................................ 10-23
REAR DRUM BRAKES................................................................................................................... 10-23
REAR DÌSC BRAKES..................................................................................................................... 10-25
BODY.............................................................................................................................................. 10-26
DRÌVER AÌR BAG MODULE .......................................................................................................... 10-27
PASSENGER AÌR BAG MODULE.................................................................................................. 10-27
ROTARY COUPLER....................................................................................................................... 10-28
SEATS AND SEAT BELTS............................................................................................................. 10-28
SCREEN WÌPERS AND BLADES.................................................................................................. 10-29
WÌNDSCREEN AND REAR SCREEN WASHERS......................................................................... 10-29
LAMPS, HORNS AND WARNÌNG ÌNDÌCATORS........................................................................... 10-30
HEATER BLOWER......................................................................................................................... 10-31
BATTERY CONNECTÌONS............................................................................................................ 10-31
FUSEBOX....................................................................................................................................... 10-32
AUXÌLÌARY DRÌVE BELT ............................................................................................................... 10-32
ANTÌ-CORROSÌON CHECK........................................................................................................... 10-33
ROAD TEST ................................................................................................................................... 10-33
CONTENTS
4 CONTENTS
ENGINE - 'K16' ......................................................................................... 12-1-1
REPAIRS
OÌL SEAL - FRONT - EXHAUST CAMSHAFT ............................................................................... 12-1-1
OÌL SEAL - REAR - EXHAUST CAMSHAFT.................................................................................. 12-1-4
OÌL SEAL - REAR - ÌNLET CAMSHAFT ........................................................................................ 12-1-5
CARRÌER - CAMSHAFT - A/C ....................................................................................................... 12-1-6
CRANKSHAFT FRONT PULLEY................................................................................................... 12-1-9
CRANKSHAFT FRONT OÌL SEAL................................................................................................. 12-1-11
CRANKSHAFT REAR OÌL SEAL ................................................................................................... 12-1-12
GASKET - CYLÌNDER HEAD......................................................................................................... 12-1-13
GASKET - CAMSHAFT COVER .................................................................................................... 12-1-19
VALVE STEM OÌL SEAL ................................................................................................................ 12-1-21
ENGÌNE AND GEARBOX - MODELS WÌTHOUT A/C ................................................................... 12-1-23
ENGÌNE AND GEARBOX - MODELS WÌTH A/C........................................................................... 12-1-31
ENGÌNE STEADY - LOWER.......................................................................................................... 12-1-37
HYDRAMOUNT - ENGÌNE RH....................................................................................................... 12-1-38
MOUNTÌNG - ENGÌNE LH - 'R65 GEARBOX'................................................................................ 12-1-39
ENGÌNE LH MOUNTÌNG - 'EM-CVT' GEARBOX MODELS WÌTH ABS........................................ 12-1-40
FLYWHEEL - 1.1, 1.4 & 1.6 MODELS WÌTH MANUAL GEARBOX............................................... 12-1-42
FLYWHEEL - 'EM-CVT' MODELS.................................................................................................. 12-1-42
TORSÌON DAMPER - 'EM-CVT' MODELS .................................................................................... 12-1-43
FLYWHEEL STARTER RÌNG GEAR ............................................................................................. 12-1-44
OÌL FÌLTER..................................................................................................................................... 12-1-44
DÌPSTÌCK TUBE............................................................................................................................. 12-1-45
OÌL PUMP....................................................................................................................................... 12-1-47
SUMP - ENGÌNE - RESEAL........................................................................................................... 12-1-48
OÌL PRESSURE SWÌTCH.............................................................................................................. 12-1-50
OÌL PRESSURE RELÌEF VALVE................................................................................................... 12-1-51
SENSOR - OÌL TEMPERATURE ................................................................................................... 12-1-52
CAMSHAFT TÌMÌNG BELT ............................................................................................................ 12-1-53
COVER - UPPER - CAMSHAFT TÌMÌNG BELT............................................................................. 12-1-57
COVER - LOWER - CAMSHAFT TÌMÌNG BELT............................................................................ 12-1-58
CONTENTS
CONTENTS 5
ENGINE - 'K16 WITH VVC' ....................................................................... 12-2-1
REPAIRS
OÌL SEAL - EXHAUST CAMSHAFT - FRONT................................................................................ 12-2-1
OÌL SEAL - EXHAUST CAMSHAFT - REAR.................................................................................. 12-2-4
OÌL SEAL - ÌNLET CAMSHAFT - FRONT ...................................................................................... 12-2-5
OÌL SEAL - ÌNLET CAMSHAFT REAR........................................................................................... 12-2-9
CARRÌER - CAMSHAFT................................................................................................................. 12-2-10
CRANKSHAFT FRONT PULLEY.................................................................................................... 12-2-15
CRANKSHAFT FRONT OÌL SEAL ................................................................................................. 12-2-16
CRANKSHAFT REAR OÌL SEAL.................................................................................................... 12-2-17
GASKET - CYLÌNDER HEAD......................................................................................................... 12-2-18
GASKET - CAMSHAFT COVER..................................................................................................... 12-2-24
HYDRAULÌC CONTROL UNÌT ....................................................................................................... 12-2-25
ENGÌNE AND GEARBOX............................................................................................................... 12-2-32
ENGÌNE STEADY BAR .................................................................................................................. 12-2-37
HYDRAMOUNT - ENGÌNE - RH..................................................................................................... 12-2-37
MOUNTÌNG - ENGÌNE - LH............................................................................................................ 12-2-38
FLYWHEEL..................................................................................................................................... 12-2-39
FLYWHEEL STARTER RÌNG GEAR.............................................................................................. 12-2-40
OÌL FÌLTER..................................................................................................................................... 12-2-40
DÌPSTÌCK TUBE............................................................................................................................. 12-2-41
OÌL PUMP....................................................................................................................................... 12-2-41
SUMP - ENGÌNE - RESEAL ........................................................................................................... 12-2-43
OÌL PRESSURE SWÌTCH.............................................................................................................. 12-2-45
OÌL PRESSURE RELÌEF VALVE ................................................................................................... 12-2-46
SENSOR - OÌL TEMPERATURE.................................................................................................... 12-2-47
COOLER - OÌL................................................................................................................................ 12-2-48
CAMSHAFT TÌMÌNG BELT............................................................................................................. 12-2-49
COVER - UPPER - CAMSHAFT TÌMÌNG BELT ............................................................................. 12-2-52
COVER - LOWER - CAMSHAFT TÌMÌNG BELT ............................................................................ 12-2-53
COVER - CAMSHAFT REAR TÌMÌNG BELT.................................................................................. 12-2-53
CAMSHAFT REAR TÌMÌNG BELT.................................................................................................. 12-2-54
CONTENTS
6 CONTENTS
ENGINE - 'L' SERIES................................................................................ 12-3-1
REPAIRS
OÌL SEAL - CAMSHAFT - FRONT ................................................................................................. 12-3-1
OÌL SEAL - CAMSHAFT - REAR.................................................................................................... 12-3-2
BEARÌNG CARRÌER - RESEAL - CAMSHAFT.............................................................................. 12-3-4
PULLEY - CRANKSHAFT - Up to VÌN Number RF 545050........................................................... 12-3-9
PULLEY - CRANKSHAFT - From VÌN Number RF 545051 ........................................................... 12-3-13
OÌL SEAL - CRANKSHAFT - FRONT............................................................................................. 12-3-15
CRANKSHAFT REAR OÌL SEAL ................................................................................................... 12-3-16
CYLÌNDER HEAD GASKET........................................................................................................... 12-3-17
GASKET - CAMSHAFT COVER .................................................................................................... 12-3-27
COVER - ACOUSTÌC - ENGÌNE.................................................................................................... 12-3-28
ENGÌNE AND GEARBOX............................................................................................................... 12-3-29
ENGÌNE STEADY - LOWER.......................................................................................................... 12-3-37
HYDRAMOUNT - ENGÌNE - RH..................................................................................................... 12-3-38
ENGÌNE STEADY - UPPER........................................................................................................... 12-3-39
ENGÌNE MOUNTÌNG - LH.............................................................................................................. 12-3-39
FLYWHEEL .................................................................................................................................... 12-3-40
FLYWHEEL STARTER RÌNG GEAR ............................................................................................. 12-3-41
ENGÌNE OÌL FÌLTER...................................................................................................................... 12-3-41
DÌPSTÌCK TUBE............................................................................................................................. 12-3-42
OÌL STRAÌNER AND PÌCK-UP PÌPE ............................................................................................. 12-3-42
OÌL PUMP....................................................................................................................................... 12-3-43
GASKET - SUMP - ENGÌNE........................................................................................................... 12-3-47
OÌL PRESSURE SWÌTCH.............................................................................................................. 12-3-49
VALVE - OÌL PRESSURE RELÌEF................................................................................................. 12-3-49
OÌL COOLER.................................................................................................................................. 12-3-50
CAMSHAFT TÌMÌNG BELT ............................................................................................................ 12-3-51
COVER - CAMSHAFT TÌMÌNG BELT - UPPER............................................................................. 12-3-55
COVER - CAMSHAFT TÌMÌNG BELT - LOWER............................................................................ 12-3-56
FUEL ÌNJECTÌON PUMP (FÌP) - TÌMÌNG BELT - UP TO VÌN NUMBER RF 545050.................... 12-3-57
FUEL ÌNJECTÌON PUMP (FÌP) - TÌMÌNG BELT - FROM VÌN NUMBER RF 545051 .................... 12-3-60
COVER - FUEL ÌNJECTÌON PUMP (FÌP) - TÌMÌNG BELT ............................................................ 12-3-64
DAMPER - CAMSHAFT GEAR...................................................................................................... 12-3-64
EMISSION CONTROL .............................................................................. 17-1
REPAIRS
CRANKCASE PRESSURE LÌMÌTER VALVE - 'L' SERÌES............................................................ 17-1
EVAPORATÌVE EMÌSSÌON CANNÌSTER - 'K' SERÌES................................................................. 17-1
VALVE - EXHAUST GAS RECÌRCULATÌON (EGR) - 'L-SERÌES' ................................................. 17-2
EXHAUST GAS RECÌRCULATÌON (EGR) SOLENOÌD - 'L' SERÌES............................................ 17-2
COOLER - EXHAUST GAS RECÌRCULATÌON (EGR) - 'L' SERÌES ............................................. 17-3
CATALYTÌC CONVERTER - 'L' SERÌES........................................................................................ 17-3
CONTENTS
CONTENTS 7
ENGINE MANAGEMENT SYSTEM - MEMS............................................ 18-1-1
ADJUSTMENTS
THROTTLE CABLE ........................................................................................................................ 18-1-1
REPAIRS
THROTTLE CABLE ........................................................................................................................ 18-1-3
AÌR CLEANER................................................................................................................................ 18-1-4
AÌR CLEANER ELEMENT.............................................................................................................. 18-1-5
SPARK PLUGS - 'K16' .................................................................................................................... 18-1-5
COÌL - EACH .................................................................................................................................. 18-1-6
ENGÌNE CONTROL MODULE (ECM) ............................................................................................ 18-1-6
ENGÌNE CONTROL UNÌT (ECM) - WÌTH SECURÌTY SHÌELD FÌTTED........................................ 18-1-7
ÌDLE AÌR CONTROL (ÌAC) VALVE ................................................................................................ 18-1-8
SENSOR - ÌNTAKE AÌR TEMPERATURE (ÌAT)............................................................................. 18-1-8
SENSOR - ENGÌNE COOLANT TEMPERATURE (ECT)............................................................... 18-1-9
SENSOR - CRANKSHAFT POSÌTÌON (CKP) ................................................................................ 18-1-9
SENSOR - THROTTLE POSÌTÌON (TP)......................................................................................... 18-1-10
SENSOR - CAMSHAFT POSÌTÌON (CMP) .................................................................................... 18-1-11
HYDRAULÌC CONTROL UNÌT (HCU) SOLENOÌDS - 'K16 WÌTH VVC'......................................... 18-1-11
SENSOR - OÌL TEMPERATURE - 'K16 WÌTH VVC' ...................................................................... 18-1-12
SENSOR - MANÌFOLD ABSOLUTE PRESSURE (MAP) - 'K16 WÌTH VVC' ................................. 18-1-13
SENSOR - CAMSHAFT POSÌTÌON (CMP) - 'K16 WÌTH VVC' ....................................................... 18-1-13
SENSOR - HEATED OXYGEN (HO2S) - 'K16'............................................................................... 18-1-14
SENSOR - HEATED OXYGEN (HO2S) - 'K16 WÌTH VVC' ............................................................ 18-1-15
HOUSÌNG - THROTTLE................................................................................................................. 18-1-16
SENSOR - HEATED OXYGEN - (HO2S) - POST CATALYST - 'K16' ............................................ 18-1-17
FUEL RAÌL AND ÌNJECTORS - 'K16 WÌTH VVC' .......................................................................... 18-1-18
FUEL RAÌL AND ÌNJECTOR SET - 'K16' ....................................................................................... 18-1-19
AÌR ÌNTAKE RESONATOR ............................................................................................................ 18-1-21
CONTENTS
8 CONTENTS
ENGINE MANAGEMENT SYSTEM - EDC............................................... 18-2-1
ADJUSTMENTS
THROTTLE CABLE........................................................................................................................ 18-2-1
GLOW PLUG TEST........................................................................................................................ 18-2-1
REPAIRS
AÌR CLEANER................................................................................................................................ 18-2-3
AÌR CLEANER ELEMENT.............................................................................................................. 18-2-3
THROTTLE CABLE........................................................................................................................ 18-2-4
ENGÌNE CONTROL MODULE (ECM)............................................................................................ 18-2-5
SENSOR - ENGÌNE COOLANT TEMPERATURE (ECT) .............................................................. 18-2-5
SENSOR - CRANKSHAFT POSÌTÌON (CKP) ................................................................................ 18-2-6
SENSOR - THROTTLE POSÌTÌON (TP) ........................................................................................ 18-2-6
SENSOR - MANÌFOLD ABSOLUTE PRESSURE (MAP)............................................................... 18-2-7
ÌNJECTOR - NEEDLE LÌFT SENSOR............................................................................................ 18-2-7
SENSOR - MASS AÌR FLOW (MAF) & ÌNTAKE AÌR TEMPERATURE (ÌAT) ................................ 18-2-8
PUMP - FUEL ÌNJECTÌON (FÌP) .................................................................................................... 18-2-9
TURBOCHARGER......................................................................................................................... 18-2-12
PLENUM CHAMBER...................................................................................................................... 18-2-13
ÌNTERCOOLER.............................................................................................................................. 18-2-13
AÌR ÌNTAKE PÌPE........................................................................................................................... 18-2-14
ÌNJECTORS - FUEL - SET............................................................................................................. 18-2-15
GLOW PLUGS................................................................................................................................ 18-2-16
FUEL DELIVERY SYSTEM....................................................................... 19-1
REPAIRS
FUEL TANK DRAÌNÌNG - 'K' SERÌES............................................................................................ 19-1
FUEL TANK DRAÌNÌNG - 'L' SERÌES............................................................................................. 19-1
ÌNERTÌA FUEL SHUT-OFF (ÌFS) SWÌTCH - 'K' SERÌES............................................................... 19-2
FUEL FÌLTER - 'K' SERÌES............................................................................................................ 19-2
FUEL FÌLTER - 'L' SERÌES ............................................................................................................ 19-3
ELECTRÌC FUEL PUMP - 'K' SERÌES........................................................................................... 19-4
FUEL TANK - 'K' SERÌES............................................................................................................... 19-5
FUEL TANK - 'L' SERÌES............................................................................................................... 19-7
FUEL TANK BREATHER VALVE - 'L' SERÌES.............................................................................. 19-10
CONTENTS
CONTENTS 9
COOLING SYSTEM - 'K' SERIES ............................................................ 26-1-1
ADJUSTMENTS
DRAÌN AND REFÌLL....................................................................................................................... 26-1-1
COOLANT - VACUUM REFÌLL SYSTEM - 'K' SERÌES 1800cc..................................................... 26-1-2
COOLANT - VACUUM REFÌLL SYSTEM - 'K' SERÌES 1100, 1400 AND 1600cc ......................... 26-1-4
SYSTEM - PRESSURE TEST ........................................................................................................ 26-1-7
CAP - EXPANSÌON TANK - PRESSURE TEST............................................................................. 26-1-8
REPAIRS
COOLANT EXPANSÌON TANK...................................................................................................... 26-1-9
RADÌATOR COOLÌNG FAN............................................................................................................ 26-1-9
COOLÌNG FAN - RADÌATOR - A/C ................................................................................................ 26-1-10
RADÌATOR ..................................................................................................................................... 26-1-11
THERMOSTAT ............................................................................................................................... 26-1-12
COOLANT PUMP ........................................................................................................................... 26-1-13
COOLING SYSTEM - 'L' SERIES............................................................. 26-2-1
ADJUSTMENTS
DRAÌN AND REFÌLL....................................................................................................................... 26-2-1
COOLANT - VACUUM REFÌLL SYSTEM....................................................................................... 26-2-2
SYSTEM - PRESSURE TEST ........................................................................................................ 26-2-4
CAP - EXPANSÌON TANK - PRESSURE TEST............................................................................. 26-2-5
REPAIRS
COOLANT EXPANSÌON TANK...................................................................................................... 26-2-7
RADÌATOR COOLÌNG FAN............................................................................................................ 26-2-7
RADÌATOR ..................................................................................................................................... 26-2-8
THERMOSTAT ............................................................................................................................... 26-2-9
PUMP - COOLANT ......................................................................................................................... 26-2-10
COOLANT PUMP - MODELS WÌTH AÌR CONDÌTÌONÌNG............................................................ 26-2-11
GASKET - HOUSÌNG - COOLANT PUMP...................................................................................... 26-2-13
GASKET - HOUSÌNG - COOLANT PUMP - WÌTH A/C.................................................................. 26-2-14
CONTENTS
10 CONTENTS
MANIFOLD & EXHAUST SYSTEMS........................................................ 30-1
REPAIRS
FRONT PÌPE - 'K' 1.1 / 1.4 / 1.6 ..................................................................................................... 30-1
FRONT PÌPE - 'L' SERÌES ............................................................................................................. 30-2
FRONT PÌPE - 'K16 WÌTH VVC'..................................................................................................... 30-2
ÌNTERMEDÌATE PÌPE - 'K' SERÌES............................................................................................... 30-4
ÌNTERMEDÌATE PÌPE - 'L' SERÌES............................................................................................... 30-5
TAÌL PÌPE - 'K' SERÌES.................................................................................................................. 30-6
TAÌL PÌPE - 'L' SERÌES.................................................................................................................. 30-6
GASKET - FRONT PÌPE TO MANÌFOLD 'K' SERÌES.................................................................... 30-7
GASKET - FRONT PÌPE TO MANÌFOLD 'K16 WÌTH VVC' ........................................................... 30-7
GASKET - FRONT PÌPE TO MANÌFOLD - 'L' SERÌES.................................................................. 30-8
HEAT SHÌELD - FRONT PÌPE - 'K' SERÌES.................................................................................. 30-8
TAÌL PÌPE HEAT SHÌELD .............................................................................................................. 30-9
HEAT SHÌELD - REAR BÌB SPOÌLER............................................................................................ 30-10
MODULATOR - VACUUM VALVE - TAÌL PÌPE - EXHAUST ......................................................... 30-10
VACUUM RESERVOÌR - VACUUM VALVE - TAÌL PÌPE - EXHAUST .......................................... 30-11
GASKET - ÌNLET MANÌFOLD - 'K16' ............................................................................................. 30-11
GASKET - ÌNLET MANÌFOLD - 'K16 WÌTH VVC'........................................................................... 30-13
HEAT SHÌELD - EXHAUST MANÌFOLD - 'K-SERÌES' ................................................................... 30-15
HEAT SHÌELD - EXHAUST MANÌFOLD - A/C - 'K-SERÌES' .......................................................... 30-15
HEAT SHÌELD - EXHAUST MANÌFOLD - 'K16 WÌTH VVC' ........................................................... 30-17
MANÌFOLD - EXHAUST - 'K16' WÌTH A/C..................................................................................... 30-18
GASKET - EXHAUST MANÌFOLD - 'K16' ...................................................................................... 30-21
GASKET - EXHAUST MANÌFOLD 'K16 WÌTH VVC' ...................................................................... 30-22
GASKET - ÌNLET AND EXHAUST MANÌFOLD 'L' SERÌES........................................................... 30-22
GASKET - ÌNLET MANÌFOLD CHAMBER - 'K16 WÌTH VVC'........................................................ 30-25
PLASTÌC MANÌFOLD STUB PÌPES - RENEW .............................................................................. 30-26
CLUTCH.................................................................................................... 33-1
REPAIRS
CLUTCH ASSEMBLY AND RELEASE BEARÌNG - 'K' SERÌES 1.1 / 1.4 / 1.6 R65....................... 33-1
CLUTCH ASSEMBLY AND RELEASE BEARÌNG - 'K16 WÌTH VVC' ............................................ 33-3
CLUTCH ASSEMBLY AND RELEASE BEARÌNG - 'L' SERÌES..................................................... 33-5
CLUTCH CABLE - 'R65' GEARBOX .............................................................................................. 33-7
CLUTCH CABLE - 'PG1' GEARBOX.............................................................................................. 33-8
CLUTCH RELEASE FORK AND BUSHES - 'R65' GEARBOX...................................................... 33-10
CLUTCH RELEASE FORK - 'PG1' GEARBOX.............................................................................. 33-11
MANUAL GEARBOX - 'R65'..................................................................... 37-1-1
ADJUSTMENTS
OÌL DRAÌN AND REFÌLL................................................................................................................ 37-1-1
REPAIRS
GEAR SELECTOR MOUNTÌNG..................................................................................................... 37-1-3
GEARBOX - 'K16' ........................................................................................................................... 37-1-3
SEAL - ÌNPUT SHAFT.................................................................................................................... 37-1-6
SEAL - SELECTOR SHAFT ........................................................................................................... 37-1-7
REVERSE LAMP SWÌTCH............................................................................................................. 37-1-8
DÌFFERENTÌAL OÌL SEAL - R65 ................................................................................................... 37-1-9
CONTENTS
CONTENTS 11
MANUAL GEARBOX - 'PG1'.................................................................... 37-2-1
ADJUSTMENTS
OÌL DRAÌN AND REFÌLL ................................................................................................................ 37-2-1
REPAIRS
GEAR SELECTOR MOUNTÌNG..................................................................................................... 37-2-3
MANUAL GEARBOX - 'K16 WÌTH VVC' ......................................................................................... 37-2-3
MANUAL GEARBOX - 'L' SERÌES.................................................................................................. 37-2-7
OÌL SEAL- SELECTOR SHAFT...................................................................................................... 37-2-12
REVERSE LAMP SWÌTCH............................................................................................................. 37-2-13
DÌFFERENTÌAL OÌL SEAL - LH...................................................................................................... 37-2-13
DÌFFERENTÌAL OÌL SEAL - RH..................................................................................................... 37-2-14
AUTOMATIC GEARBOX - 'EM-CVT' ....................................................... 44-1
ADJUSTMENTS
DRAÌN AND REFÌLL....................................................................................................................... 44-1
SELECTOR CABLE........................................................................................................................ 44-2
REPAIRS
LEVER - GEAR CHANGE .............................................................................................................. 44-3
KNOB - GEAR SELECTÌON........................................................................................................... 44-4
CABLE - GEAR CHANGE .............................................................................................................. 44-4
SWÌTCH - STARTER ÌNHÌBÌTOR/REVERSE................................................................................. 44-5
SELECTOR SHAFT SEAL.............................................................................................................. 44-6
SENSOR - SPEED ......................................................................................................................... 44-7
GEARBOX ÌNTERFACE UNÌT (GÌU).............................................................................................. 44-8
HARNESS - RATÌO CONTROL MOTOR........................................................................................ 44-8
MOTOR - RATÌO CONTROL.......................................................................................................... 44-11
GEARBOX - ABS - WÌTH A/C ........................................................................................................ 44-14
ÌNPUT SHAFT SEAL ...................................................................................................................... 44-17
PRÌMARY COVER.......................................................................................................................... 44-18
SECONDARY COVER SEALS....................................................................................................... 44-18
DÌPSTÌCK TUBE SEAL................................................................................................................... 44-22
FLUÌD PAN GASKET...................................................................................................................... 44-23
FÌLTER - GEARBOX FLUÌD ........................................................................................................... 44-24
FLUÌD COOLER ............................................................................................................................. 44-24
HOSE - OÌL COOLER - FEED........................................................................................................ 44-25
HOSE - OÌL COOLER - RETURN................................................................................................... 44-26
PÌPE - OÌL COOLER - FEED.......................................................................................................... 44-27
PÌPE - OÌL COOLER - RETURN .................................................................................................... 44-28
BEARÌNG - PRÌMARY .................................................................................................................... 44-29
OÌL SEAL - DÌFFERENTÌAL ........................................................................................................... 44-32
CONTENTS
12 CONTENTS
DRIVE SHAFTS ........................................................................................ 47-1
REPAIRS
DRÌVE SHAFT - LH........................................................................................................................ 47-1
DRÌVE SHAFT - RH........................................................................................................................ 47-3
DRÌVE SHAFT GAÌTER - OUTER.................................................................................................. 47-5
DRÌVE SHAFT - OUTER JOÌNT - EMCVT..................................................................................... 47-5
DRÌVE SHAFT GAÌTER - ÌNNER................................................................................................... 47-6
DRÌVE SHAFT AND ÌNNER JOÌNT................................................................................................ 47-7
STEERING ................................................................................................ 57-1
ADJUSTMENTS
FRONT WHEEL ALÌGNMENT........................................................................................................ 57-1
REAR WHEEL ALÌGNMENT.......................................................................................................... 57-1
POWER STEERÌNG SYSTEM BLEED - 'K' SERÌES..................................................................... 57-2
POWER STEERÌNG SYSTEM BLEED - 'L' SERÌES ..................................................................... 57-2
POWER STEERÌNG SYSTEM - PRESSURE TEST...................................................................... 57-3
REPAIRS
POWER STEERÌNG RACK............................................................................................................ 57-5
BELT - PAS PUMP - 'K' SERÌES.................................................................................................... 57-8
PUMP - POWER STEERÌNG - PAS 'K SERÌES' ............................................................................ 57-9
PUMP - POWER ASSÌSTED STEERÌNG - PAS - 'L' SERÌES....................................................... 57-11
TENSÌONER - PAS PUMP DRÌVE BELT 'K' SERÌES' ................................................................... 57-12
STEERÌNG RACK GAÌTER............................................................................................................ 57-13
STEERÌNG COLUMN ASSEMBLY ................................................................................................ 57-13
STEERÌNG COLUMN NACELLE ................................................................................................... 57-15
STEERÌNG LOCK........................................................................................................................... 57-16
TRACK ROD END.......................................................................................................................... 57-18
STEERÌNG WHEEL........................................................................................................................ 57-18
FRONT SUSPENSION.............................................................................. 60-1
REPAIRS
FRONT DAMPER........................................................................................................................... 60-1
FRONT HUB................................................................................................................................... 60-3
FRONT HUB BEARÌNG.................................................................................................................. 60-6
ANTÌ-ROLL BAR............................................................................................................................. 60-7
ANTÌ-ROLL BAR LÌNK.................................................................................................................... 60-8
ANTÌ-ROLL BAR BUSHES............................................................................................................. 60-8
SUSPENSÌON LOWER ARM ASSEMBLY..................................................................................... 60-9
SUSPENSÌON LOWER ARM BUSH.............................................................................................. 60-11
FRONT BEAM................................................................................................................................ 60-11
REAR BEAM - WÌTH POWER STEERÌNG RACK ......................................................................... 60-12
TÌE ROD......................................................................................................................................... 60-15
CONTENTS
CONTENTS 13
REAR SUSPENSION................................................................................ 64-1
REPAIRS
REAR DAMPER.............................................................................................................................. 64-1
REAR HUB AND BEARÌNG - MODELS WÌTH DÌSC BRAKES...................................................... 64-3
REAR HUB AND BEARÌNG - MODELS WÌTH DRUM BRAKES WÌTHOUT ABS.......................... 64-3
REAR HUB AND BEARÌNG - MODELS WÌTH DRUM BRAKES AND ABS................................... 64-4
REAR STUB AXLE - MODELS WÌTH DÌSC BRAKES.................................................................... 64-6
REAR STUB AXLE - MODELS WÌTH DRUM BRAKES ................................................................. 64-7
'H' FRAME BUSH............................................................................................................................ 64-12
'H' FRAME - MODELS WÌTH DÌSC BRAKES................................................................................. 64-13
'H' FRAME - MODELS WÌTH DRUM BRAKES............................................................................... 64-17
'H' FRAME MOUNTÌNG BRACKET................................................................................................ 64-21
BRAKES ................................................................................................... 70-1
ADJUSTMENTS
BRAKE SYSTEM BLEEDÌNG......................................................................................................... 70-1
HANDBRAKE CABLE..................................................................................................................... 70-2
BRAKE LÌGHT SWÌTCH - MANUAL ADJUSTÌNG TYPE ONLY .................................................... 70-3
REPAIRS
HANDBRAKE WARNÌNG SWÌTCH................................................................................................ 70-5
BRAKE LÌGHT SWÌTCH - MANUAL ADJUSTÌNG TYPE............................................................... 70-5
BRAKE LÌGHT SWÌTCH - SELF ADJUSTÌNG TYPE..................................................................... 70-6
FLUÌD LEVEL SWÌTCH .................................................................................................................. 70-7
HANDBRAKE LEVER..................................................................................................................... 70-8
ABS SENSOR - FRONT ................................................................................................................. 70-9
ABS SENSOR - REAR - MODELS WÌTH DÌSC BRAKES.............................................................. 70-11
BRAKE PROPORTÌONÌNG VALVE - ABS ..................................................................................... 70-12
BRAKE PROPORTÌONÌNG VALVE - NON ABS ............................................................................ 70-12
BRAKE MASTER CYLÌNDER......................................................................................................... 70-13
SERVO ASSEMBLY....................................................................................................................... 70-13
BRAKE SERVO VACUUM PUMP .................................................................................................. 70-14
FRONT BRAKE PADS.................................................................................................................... 70-15
REAR BRAKE SHOES ................................................................................................................... 70-16
REAR BRAKE PADS...................................................................................................................... 70-19
FRONT BRAKE CALÌPER.............................................................................................................. 70-21
REAR BRAKE CALÌPER ................................................................................................................ 70-23
REAR WHEEL BRAKE CYLÌNDER................................................................................................ 70-24
FRONT BRAKE DÌSC..................................................................................................................... 70-26
REAR BRAKE DÌSC ....................................................................................................................... 70-27
REAR BRAKE DRUM..................................................................................................................... 70-28
ABS HYDRAULÌC MODULATOR................................................................................................... 70-30
ABS SENSOR - REAR - MODELS WÌTH DRUM BRAKES............................................................ 70-31
CONTENTS
14 CONTENTS
RESTRAINT SYSTEMS............................................................................ 75-1
REPAIRS
DRÌVER AÌRBAG............................................................................................................................ 75-1
PASSENGER AÌRBAG................................................................................................................... 75-2
AÌRBAG CONTROL AND DÌAGNOSTÌC UNÌT .............................................................................. 75-3
SEAT BELT PRE-TENSÌONER...................................................................................................... 75-3
FRONT SEAT BELT AND PRE-TENSÌONER - 3 DOOR............................................................... 75-4
FRONT SEAT BELT AND PRE-TENSÌONER - 5 DOOR............................................................... 75-5
ROTARY COUPLER ...................................................................................................................... 75-7
DOORS...................................................................................................... 76-1-1
REPAIRS
DOOR STRÌKER - ADJUST ........................................................................................................... 76-1-1
TAÌLGATE STRÌKER - ADJUST..................................................................................................... 76-1-1
TAÌLGATE ALÌGNMENT ................................................................................................................ 76-1-2
EXTERÌOR MÌRROR GLASS......................................................................................................... 76-1-3
EXTERÌOR MÌRROR - MANUAL.................................................................................................... 76-1-4
EXTERÌOR MÌRROR - ELECTRÌC................................................................................................. 76-1-4
FRONT DOOR TRÌM CASÌNG....................................................................................................... 76-1-5
REAR DOOR TRÌM CASÌNG ......................................................................................................... 76-1-6
FRONT DOOR PLASTÌC SHEET................................................................................................... 76-1-8
REAR DOOR PLASTÌC SHEET..................................................................................................... 76-1-9
FRONT DOOR GLASS................................................................................................................... 76-1-9
REAR DOOR GLASS..................................................................................................................... 76-1-10
REAR QUARTER GLASS - 5 DOOR MODELS............................................................................. 76-1-11
FRONT DOOR GLASS REGULATOR........................................................................................... 76-1-11
REAR DOOR GLASS REGULATOR.............................................................................................. 76-1-12
TAÌLGATE TRÌM CASÌNG.............................................................................................................. 76-1-13
TAÌLGATE SÌDE FÌNÌSHER........................................................................................................... 76-1-13
TAÌLGATE UPPER FÌNÌSHER....................................................................................................... 76-1-14
FRONT DOOR OUTSÌDE HANDLE............................................................................................... 76-1-14
REAR DOOR OUTSÌDE HANDLE ................................................................................................. 76-1-15
FRONT DOOR ÌNTERÌOR HANDLE.............................................................................................. 76-1-15
REAR DOOR ÌNTERÌOR HANDLE................................................................................................ 76-1-16
TAÌLGATE LATCH.......................................................................................................................... 76-1-16
DRÌVERS DOOR LOCK................................................................................................................. 76-1-17
TAÌLGATE LOCK............................................................................................................................ 76-1-17
TAÌLGATE STRUT ......................................................................................................................... 76-1-18
CONTENTS
CONTENTS 15
EXTERIOR FITTINGS............................................................................... 76-2-1
REPAIRS
BONNET ALÌGNMENT ................................................................................................................... 76-2-1
WHEEL ARCH LÌNER .................................................................................................................... 76-2-1
UNDERTRAY - 'L' SERÌES............................................................................................................. 76-2-2
SPLASH SHÌELD - 'K16' WÌTH 'VVC' ............................................................................................. 76-2-2
BONNET......................................................................................................................................... 76-2-3
LOCK - BONNET............................................................................................................................ 76-2-4
BONNET RELEASE CABLE........................................................................................................... 76-2-4
FRONT BUMPER ........................................................................................................................... 76-2-5
BUMPER VALANCE - FRONT ....................................................................................................... 76-2-7
FRONT BUMPER ARMATURE...................................................................................................... 76-2-10
GRÌLLE - FRONT............................................................................................................................ 76-2-10
GRÌLLE - FRONT - MG................................................................................................................... 76-2-11
REAR BUMPER.............................................................................................................................. 76-2-11
BUMPER VALANCE - REAR.......................................................................................................... 76-2-12
SPOÌLER - BOOT/TAÌLGATE - TOP - RENEW.............................................................................. 76-2-14
EXTREME SPOÌLER - BOOT/TAÌLGATE - RENEW...................................................................... 76-2-15
BÌB SPOÌLER - FRONT BUMPER - RENEW................................................................................. 76-2-16
BÌB SPOÌLER - REAR BUMPER - RENEW.................................................................................... 76-2-17
MOULDÌNG - SÌLL EXTERÌOR - RENEW...................................................................................... 76-2-17
TAÌLGATE APPLÌQUE.................................................................................................................... 76-2-18
FRONT DOOR RUBBÌNG STRÌP................................................................................................... 76-2-19
REAR DOOR RUBBÌNG STRÌP ..................................................................................................... 76-2-20
REAR QUARTER RUBBÌNG STRÌP............................................................................................... 76-2-21
FRONT TREAD PLATE.................................................................................................................. 76-2-22
REAR TREAD PLATE .................................................................................................................... 76-2-22
CONTENTS
16 CONTENTS
INTERIOR TRIM COMPONENTS............................................................. 76-3-1
REPAIRS
BULKHEAD - LOADSPACE - VAN................................................................................................. 76-3-1
GUARD - LOADSPACE - VAN....................................................................................................... 76-3-2
FLOOR FRAME - LOADSPACE - VAN.......................................................................................... 76-3-2
REAR CONSOLE........................................................................................................................... 76-3-3
FRONT CONSOLE......................................................................................................................... 76-3-4
FASCÌA........................................................................................................................................... 76-3-5
FASCÌA VENEERED PANEL......................................................................................................... 76-3-8
GLOVE BOX................................................................................................................................... 76-3-8
GLOVE BOX LATCH...................................................................................................................... 76-3-9
FUSE BOX COVER........................................................................................................................ 76-3-9
'A' POST UPPER TRÌM CASÌNG................................................................................................... 76-3-10
'A' POST LOWER TRÌM CASÌNG .................................................................................................. 76-3-10
'B' POST LOWER TRÌM CASÌNG - 5 DOOR ................................................................................. 76-3-11
REAR QUARTER TRÌM CASÌNG - 3 DOOR.................................................................................. 76-3-11
REAR QUARTER TRÌM CASÌNG - 5 DOOR.................................................................................. 76-3-13
HEADLÌNÌNG.................................................................................................................................. 76-3-14
PARCEL TRAY SUPPORT PANEL - 3 DOOR MODELS .............................................................. 76-3-15
PARCEL TRAY SUPPORT PANEL - 5 DOOR MODELS .............................................................. 76-3-17
REAR QUARTER LOWER TRÌM CASÌNG - 3 DOOR ................................................................... 76-3-18
REAR QUARTER LOWER TRÌM CASÌNG - 5 DOOR ................................................................... 76-3-18
LUGGAGE COMPARTMENT SÌDE CARPET................................................................................ 76-3-19
LUGGAGE COMPARTMENT TRÌM CASÌNG................................................................................ 76-3-19
PARCEL TRAY............................................................................................................................... 76-3-20
SCREENS ................................................................................................. 76-4-1
REPAIRS
WÌNDSCREEN............................................................................................................................... 76-4-1
REAR SCREEN.............................................................................................................................. 76-4-4
REAR QUARTER GLASS - 3 DOOR MODELS............................................................................. 76-4-7
CONTENTS
CONTENTS 17
SEATS AND SEAT BELTS ...................................................................... 76-5-1
REPAIRS
FRONT SEAT ................................................................................................................................. 76-5-1
FRONT SQUAB COVER ................................................................................................................ 76-5-2
FRONT SEAT AND SQUAB FRAME.............................................................................................. 76-5-3
OUTER VALANCE - FRONT CUSHÌON......................................................................................... 76-5-5
ÌNNER VALANCE - FRONT CUSHÌON.......................................................................................... 76-5-6
SEAT HEÌGHT ADJUSTMENT HANDLE ....................................................................................... 76-5-6
ARM REST - REAR SEAT.............................................................................................................. 76-5-7
REAR SEAT CUSHÌON.................................................................................................................. 76-5-7
REAR SEAT SQUAB...................................................................................................................... 76-5-8
COVER - SQUAB - REAR SEAT - SÌDE - LH................................................................................. 76-5-8
COVER - SQUAB - REAR SEAT - RH............................................................................................ 76-5-9
LEVER ASSEMBLY - REAR SQUAB RELEASE............................................................................ 76-5-11
CABLE - REAR SQUAB LATCH..................................................................................................... 76-5-12
REAR SQUAB LATCH.................................................................................................................... 76-5-12
REAR SEAT BELT - SÌDE - 3 DOOR............................................................................................. 76-5-14
REAR SEAT BELT - SÌDE - 5 DOOR............................................................................................. 76-5-15
SEAT BELT - CENTRE - REAR ..................................................................................................... 76-5-16
SUNROOF................................................................................................. 76-6-1
REPAIRS
SUN ROOF GLASS HEÌGHT ADJUSTMENT ................................................................................ 76-6-1
SUN ROOF GLASS........................................................................................................................ 76-6-1
SUN ROOF SUNSHADE................................................................................................................ 76-6-2
SUN ROOF SWÌTCH...................................................................................................................... 76-6-2
SUN ROOF MOTOR....................................................................................................................... 76-6-3
SUN ROOF DRAÌN TUBE .............................................................................................................. 76-6-3
SUN ROOF..................................................................................................................................... 76-6-5
CONTENTS
18 CONTENTS
PANEL REPAIRS...................................................................................... 77-1
INTRODUCTION
BODY REPAÌRS............................................................................................................................. 77-1
BODY DIMENSIONS
DÌMENSÌONAL ÌNFORMATÌON..................................................................................................... 77-9
SEALING AND CORROSION PROTECTION
APPROVED MATERÌALS .............................................................................................................. 77-23
REPLACEMENT PANELS
SERVÌCE CONDÌTÌON OF PANELS.............................................................................................. 77-43
GENERAL WELDING PRECAUTIONS
GENERAL WELDÌNG PRECAUTÌONS.......................................................................................... 77-53
PROCEDURES
PANEL REPLACEMENT PROCEDURE........................................................................................ 77-55
REPAIRS
RADÌATOR LOWER CROSSMEMBER ......................................................................................... 77-61
VALANCE....................................................................................................................................... 77-61
FRONT VALANCE ASSEMBLY..................................................................................................... 77-62
VALANCE MEMBER REÌNFORCEMENT...................................................................................... 77-63
SÌDEMEMBER ASSEMBLY........................................................................................................... 77-64
'A' POST......................................................................................................................................... 77-65
FRONT BODY SÌDE....................................................................................................................... 77-66
'BC' POST - 5-DOOR..................................................................................................................... 77-67
BODY SÌDE SÌLL............................................................................................................................ 77-68
BODY SÌDE ASSEMBLY - 3-DOOR............................................................................................... 77-69
BODY SÌDE ASSEMBLY - 5-DOOR............................................................................................... 77-71
REAR BODY SÌDE - 3-DOOR........................................................................................................ 77-73
REAR BODY SÌDE - 5-DOOR........................................................................................................ 77-75
REAR QUARTER ASSEMBLY - 3-DOOR...................................................................................... 77-77
REAR QUARTER ASSEMBLY - 5-DOOR...................................................................................... 77-78
REAR ÌNNER WHEELARCH.......................................................................................................... 77-80
SPARE WHEEL WELL ASSEMBLY............................................................................................... 77-80
REAR LONGÌTUDÌNAL MEMBER ................................................................................................. 77-81
ROOF PANEL ASSEMBLY............................................................................................................ 77-81
REAR BODY ASSEMBLY.............................................................................................................. 77-82
LOAD FLOOR SÌDE....................................................................................................................... 77-83
TIMES
PANEL/ ASSEMBLY REPLACEMENT TÌMES............................................................................... 77-85
PAINT
PAÌNT ............................................................................................................................................. 77-89
PANEL PREPERATÌON................................................................................................................. 77-89
CONTENTS
CONTENTS 19
HEATING & VENTILATION...................................................................... 80-1
REPAIRS
ÌNTAKE AÌR FÌLTER....................................................................................................................... 80-1
AÌR ÌNTAKE PLENUM.................................................................................................................... 80-2
RESÌSTOR UNÌT ............................................................................................................................ 80-3
HEATER CONTROLS .................................................................................................................... 80-3
CONTROL CABLE - AÌR DÌSTRÌBUTÌON...................................................................................... 80-6
CONTROL CABLE - AÌR RECÌRCULATÌON.................................................................................. 80-7
HEATER VALVE............................................................................................................................. 80-7
HEATER ......................................................................................................................................... 80-8
HEATER MATRÌX........................................................................................................................... 80-9
BLOWER ASSEMBLY.................................................................................................................... 80-9
BLOWER ASSEMBLY MOTOR...................................................................................................... 80-10
HEATER FAN SWÌTCH.................................................................................................................. 80-11
AIR CONDITIONING................................................................................. 82-1
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING
REFRÌGERANT RECOVERY, RECYCLÌNG AND RECHARGÌNG................................................ 82-1
REPAIRS
AÌR CONDÌTÌONÌNG RELAY MODULE ......................................................................................... 82-3
COMPRESSOR - K-SERÌES.......................................................................................................... 82-3
COMPRESSOR - 'L' SERÌES ......................................................................................................... 82-5
CONDENSER FAN AND MOTOR.................................................................................................. 82-6
CONDENSER................................................................................................................................. 82-8
RECEÌVER/ DRÌER ........................................................................................................................ 82-8
AÌR CONDÌTÌONÌNG SWÌTCH ....................................................................................................... 82-10
EVAPORATOR............................................................................................................................... 82-10
WIPERS & WASHERS ............................................................................. 84-1
REPAIRS
WÌNDSCREEN WASHER RESERVOÌR......................................................................................... 84-1
WASHER JET - WÌNDSCREEN..................................................................................................... 84-1
WASHER PUMP - WÌNDSCREEN................................................................................................. 84-2
WÌNDSCREEN WÌPER ARM.......................................................................................................... 84-2
WÌNDSCREEN WÌPER BLADE...................................................................................................... 84-3
WÌNDSCREEN WÌPER MOTOR .................................................................................................... 84-3
WÌNDSCREEN WÌPER LÌNKAGE.................................................................................................. 84-4
WÌNDSCREEN WASHER AND WÌPER SWÌTCH.......................................................................... 84-5
REAR SCREEN WASHER JET...................................................................................................... 84-5
REAR SCREEN WÌPER ARM........................................................................................................ 84-6
REAR SCREEN WÌPER BLADE .................................................................................................... 84-6
REAR SCREEN WÌPER MOTOR................................................................................................... 84-7
CONTENTS
20 CONTENTS
ELECTRICAL............................................................................................ 86-1
ADJUSTMENTS
HEADLAMPS ADJUST................................................................................................................... 86-1
AUXÌLÌARY DRÌVE BELT - 'K' SERÌES.......................................................................................... 86-1
AUXÌLÌARY DRÌVE BELT - 'K' SERÌES WÌTH A/C......................................................................... 86-2
AUXÌLÌARY DRÌVE BELT - 'L' SERÌES .......................................................................................... 86-3
REPAIRS
ALTERNATOR - 'K' SERÌES .......................................................................................................... 86-5
ALTERNATOR - 'K' SERÌES WÌTH A/C......................................................................................... 86-6
ALTERNATOR - 'L' SERÌES........................................................................................................... 86-6
ALTERNATOR - 'L' SERÌES WÌTH A/C.......................................................................................... 86-8
AUXÌLÌARY DRÌVE BELT - 'K' SERÌES.......................................................................................... 86-11
AUXÌLÌARY DRÌVE BELT - 'K' SERÌES - WÌTH A/C ...................................................................... 86-12
AUXÌLÌARY DRÌVE BELT - 'L' SERÌES .......................................................................................... 86-13
AUXÌLÌARY DRÌVE BELT TENSÌONER - 'L' SERÌES.................................................................... 86-13
BATTERY....................................................................................................................................... 86-14
FRONT DOOR GLASS MOTOR.................................................................................................... 86-14
ELECTRÌC WÌNDOW SWÌTCH...................................................................................................... 86-15
WÌNDOW LÌFT ECU....................................................................................................................... 86-16
FRONT DOOR LOCK MOTOR ...................................................................................................... 86-17
REAR DOOR LOCK MOTOR......................................................................................................... 86-18
HORN SWÌTCH.............................................................................................................................. 86-19
HORN............................................................................................................................................. 86-19
LAMP ASSEMBLY - FRONT FLASHER ........................................................................................ 86-20
HEADLAMP ASSEMBLY................................................................................................................ 86-20
SÌDE REPEATER........................................................................................................................... 86-22
LAMP ASSEMBLY - TAÌL............................................................................................................... 86-22
NUMBER PLATE LAMP................................................................................................................. 86-23
LAMP - FRONT FOG...................................................................................................................... 86-23
LAMP ASSEMBLY - CENTRE HÌGH MOUNTED STOP................................................................ 86-24
ÌNTERÌOR LÌGHT........................................................................................................................... 86-24
GLOVEBOX LAMP......................................................................................................................... 86-25
LUGGAGE COMPARTMENT LAMP.............................................................................................. 86-25
HEATER CONTROL ÌLLUMÌNATÌON BULB.................................................................................. 86-26
ÌNSTRUMENT PACK ÌLLUMÌNATÌON BULB................................................................................. 86-27
RADÌO ............................................................................................................................................ 86-27
REAR SPEAKER............................................................................................................................ 86-28
REMOTE ÌCE CONTROLS ............................................................................................................ 86-28
FRONT SPEAKER ......................................................................................................................... 86-29
AERÌAL........................................................................................................................................... 86-29
COAXÌAL CABLE ........................................................................................................................... 86-31
TWEETER - FRONT DOOR........................................................................................................... 86-33
CD PLAYER ................................................................................................................................... 86-34
NAVÌGATÌON SYSTEM - BECKER................................................................................................ 86-34
CONTROL UNÌT (ECU) - PARKÌNG AÌD ....................................................................................... 86-36
SENSOR - PARKÌNG AÌD.............................................................................................................. 86-37
SOUNDER - PARKÌNG AÌD ........................................................................................................... 86-37
FLASHER UNÌT.............................................................................................................................. 86-38
DOOR SWÌTCH.............................................................................................................................. 86-39
BONNET SWÌTCH.......................................................................................................................... 86-39
MULTÌ FUNCTÌON UNÌT (MFU) - MODELS WÌTH SERVÌCABLE FUSEBOX .............................. 86-40
MULTÌ FUNCTÌON UNÌT (MFU) - MODELS WÌTH HARD-WÌRED FUSEBOX.............................. 86-41
STARTER MOTOR 1.1, 1.4 AND 1.6 MODELS............................................................................. 86-42
STARTER MOTOR - 'L' SERÌES.................................................................................................... 86-43
CONTENTS
CONTENTS 21
STARTER MOTOR - 'EM-CVT' MODELS ...................................................................................... 86-43
STARTER MOTOR - 'K16 WÌTH VVC' ........................................................................................... 86-44
STARTER SWÌTCH........................................................................................................................ 86-45
FRONT FOG LÌGHT SWÌTCH........................................................................................................ 86-47
HEATED REAR SCREEN SWÌTCH ............................................................................................... 86-47
HAZARD WARNÌNG LÌGHT SWÌTCH............................................................................................ 86-48
ÌNDÌCATOR/HEADLAMP SWÌTCH ................................................................................................ 86-48
STEERÌNG COLUMN SWÌTCH ASSEMBLY.................................................................................. 86-49
REAR FOG LÌGHT SWÌTCH .......................................................................................................... 86-50
DOOR MÌRROR SWÌTCH............................................................................................................... 86-50
ENGÌNE COMPARTMENT FUSE BOX.......................................................................................... 86-51
SWÌTCH - HEADLAMP LEVELLÌNG .............................................................................................. 86-52
MOTOR - HEADLAMP LEVELLÌNG............................................................................................... 86-52
ANTÌ-THEFT ALARM ECU............................................................................................................. 86-53
BATTERY BACKED UP SOUNDER - BBUS.................................................................................. 86-54
TRANSPONDER COÌL................................................................................................................... 86-54
ANTÌ-THEFT ALARM LED.............................................................................................................. 86-55
INSTRUMENTS......................................................................................... 88-1
REPAIRS
CLOCK............................................................................................................................................ 88-1
ÌNSTRUMENT PACK...................................................................................................................... 88-1
ÌNSTRUMENT PANEL WÌNDOW AND FACE PLATE ................................................................... 88-2
COOLANT TEMPERATURE GAUGE............................................................................................. 88-3
ENGÌNE COOLANT TEMPERATURE GAUGE SENSOR - 'K' SERÌES ........................................ 88-3
ENGÌNE COOLANT TEMPERATURE GAUGE SENSOR -'L' SERÌES.......................................... 88-4
FUEL GAUGE................................................................................................................................. 88-4
FUEL GAUGE TANK UNÌT - 'L' SERÌES........................................................................................ 88-5
SPEEDOMETER ............................................................................................................................ 88-6
VEHÌCLE SPEED SENSOR - 'R65' GEARBOX ............................................................................. 88-6
VEHÌCLE SPEED SENSOR - 'PG1' GEARBOX............................................................................. 88-7
TACHOMETER............................................................................................................................... 88-8
CONTENTS
22 CONTENTS
ÌNTRODUCTÌON
01-1
ÌNTRODUCTÌON
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 of 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.
Ìtem numbers in the illustration 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 its
Repair Operation Time number.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be followed
precisely to avoid the possibility of injury.
CAUTION: CaIIs attention to procedures which
must be foIIowed to avoid damage to components.
NOTE: Gives helpful 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. Ìt 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.
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. Ìn 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. Ìf 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.
ÌNTRODUCTÌON
01-2
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.
ÌNTRODUCTÌON
01-3
ABBREVIATIONS AND SYMBOLS
ABDC After Bottom Dead Centre
ATDC After Top Dead Centre
A/C Air Conditioning
AFR Air Fuel Ratio
ATC Air Temperature Control
ac Alternating Current
AAP Ambient Air Pressure
AAT Ambient Air Temperature
AP Ambient Pressure
A Amperes
Ah Amperes per hour
ABS Anti-lock Brake System
ASC Anti-shunt Control
ACEA Association of Constructors of
European Automobiles
AUX Auxiliary
ALR Automatic Locking Retractor
AVC Automatic Volume Control
BBDC Before Bottom Dead Centre
BTDC Before Top Dead Centre
BDC Bottom Dead Centre
bhp Brake horse power
BPP Brake Pedal Position
BS British Standards
CMP Camshaft Position
CO
2
Carbon Dioxide
CO Carbon Monoxide
C Celcius (Centigrade)
cm Centimetre
cm
2
Square centimetres
cm
3
Cubic centimetres
CCU Central Control Unit
CDL Central Door Locking
CHMSL Centre High Mounted Stop Lamp
CFCs Chlorofluorocarbons
CPP Clutch Pedal Position
CR Common Rail
CD Compact Disc
CD-ROM Compact Disc - Read Only
Memory
CVT Continuously Variable
Transmission
CAN Controller Area Network
CKP Crankshaft Position
dB Decibels
deg. or ° Degree (angle or temperature)
DÌN Deutsche Ìndustrie Normen
(German Ìndustrial Standards)
DTÌ Dial Test Ìndicator
dia. Diameter
DSP Digital Signal Processing
dc Direct current
DÌ Direct Ìnjection
DCV Directional Control Valve
DOHC Double Overhead Camshaft
ERL Electrical Reference Library
EACV Electronic Air Control Valve
EAT Electronic Automatic Transmission
EBD Electronic Brake pressure
Distribution
ECU Electronic Control Unit
EDC Electronic Diesel Control
EEPROM Electronic Erasable Programmable
Read Only Memory
ETC Electronic Traction Control
EVR Electronic Vacuum Regulator
EM-CVT Electro Mechanical - Continuously
Variable Transmission
EKA Emergency Key Access
ELR Emergency Locking Retractor
ECM Engine Control Module
ECT Engine Coolant Temperature
EON Enhanced Other Network
ECD European Community Directive
EN European Norm
EOBD European On Board Diagnostics
EVAP Evaporative Emission
EGR Exhaust Gas Recirculation
F Fahrenheit
FTC Fast Throttle Control
ft. Feet
FET Field effect Transistor
FÌP Fuel Ìnjection Pump
g Gramme (mass) or gravity
gal. Gallons
GÌU Gearbox Ìnterface Unit
GTW Gross Train Weight
GVW Gross Vehicle Weight
HO
2
S Heated oxygen sensor
HRW Heated Rear Window
hc High compression
ht High tension
h Hour
HC Hydrocarbons
ÌACV Ìdle Air Control Valve
ÌCE Ìn Car Entertainment
in. Ìnches
in2 Square inches
in3 Cubic inches
ÌAT Ìntake Air Temperature
i.dia. Ìnternal diameter
ÌSO Ìnternational Organisation for
Standardization
kg Kilogramme
kg/h Kilogrammes per hour
km Kilometre
km/h Kilometres per hour
kPa KiloPascal
KS Knock sensor
l Lambda
ÌNTRODUCTÌON
01-4
LH Left-hand
LHD Left-hand drive
LED Light emitting diode
LCD Liquid Crystal Display
l Litre
lc Low compression
MÌL Malfunction Ìndicator Lamp
MAP Manifold absolute pressure
MAF Mass air flow
max. Maximum
MPa MegaPascal
Hg Mercury
m Metre
m Micro
mph Miles per hour
mm Millimetre
min Minimum
- Minus (of tolerance)
' Minute (angle)
MY Model Year
MEMS Modular Engine Management
System
MFU Multi-function unit
MPi Multi-point injection
-ve Negative (electrical)
NTC Negative Temperature Coefficient
Nm Newton metre
NO
2
Nitrogen dioxide
NRV Non Return Valve
No. Number
W Ohms
OBD On Board Diagnostics
OAT Organic Acid Technology
o.dia. Outside diameter
NO
X
Oxides of Nitrogen
% Percentage
pts. Pints
± Plus or minus
+ Plus (tolerance)
PTFE Polytetrafluorethylene
+ve Positive (electrical)
PCV Positive Crankcase Ventilation
PTC Positive Temperature Coefficient
lb(s) Pounds
lbf Pounds force
lbf.in Pounds force inches
lbf/in2 Pounds per square inch
lbf.ft Pounds force feet
PAS Power Assisted Steering
PCB Printed Circuit Board
PPS Pulse Per Second
PWM Pulse Width Modulation
RDS Radio data Service
r Radius
: Ratio
ROM Read Only Memory
ref Reference
RON Research Octane Number
ROW Rest of World
rev/min Revolutions per minute
RH Right-hand
RHD Right-hand drive
RES MG Rover Engineering Standards
" Second (angle)
SOHC Single Overhead Camshaft
SPE Single Point Entry
SAE Society of Automotive Engineers
sp.gr Specific gravity
cm
2
Square centimetres
std. Standard
SRS Supplementary Restraint System
synchro Synchronizer/synchromesh
TMAP Temperature, Manifold Absolute
Pressure
TXV Thermostatic Expansion Valve
k Thousand
TWC Three Way Catalyst
TP Throttle Position
TDC Top Dead Centre
TV Torsional Vibration
TA Traffic Announcement
UK United Kingdom
US United States
Var. Variable
VRS Variable Reluctance Sensor
VVC Variable Valve Control
VÌN Vehicle identification number
VSS Vehicle Speed Sensor
V Volt
W Watt
GENERAL ÌNFORMATÌON
03-1
GENERAL Ì NFORMATÌ ON
VEHICLE IDENTIFICATION NUMBER
VIN pIate detaiIs
The VÌN plate contains the following information:
1 Vehicle Ìdentification Number (VÌN)
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 F X N M E 1 D 441071
Paint and Trim coIour codes
3-letter codes identifying the original Paint and Trim
colours are stamped on the VÌN plate.
Paint
Example: J R J
Trim
Example: S C D
SAR = World Ìdentifier (MG Rover Group)
RF = Marque/Model
X = Trim level
N = Body Style (N = 3 door)
M = Engine (M = 1.8 160 PS)
E = Transmission and Steering (E = RHD,
G4 manual gearbox)
1 = Model year
D = Assembly plant (D = Longbridge)
6 figures = Serial number
J = Basic colour
R = Mark identifier
J = Colour/Shade name
S = Basic colour
C = Mark identifier
D = Colour/Shade name
GENERAL ÌNFORMATÌON
03-2
VIN NUMBER LOCATIONS
The Vehicle Ìdentification Number (VÌN) plate is
attached to front of the LH 'B' post on 3-door models.
The Vehicle Ìdentification Number (VÌN) plate is
attached on the outside of the LH 'B' post on 5-door
models.
The VÌN is also stamped in the following locations:
At the top centre of the engine bulkhead.
On a plate behind the LH lower corner of the
windscreen.
GENERAL ÌNFORMATÌON
03-3
COMPONENT IDENTIFICATION NUMBER
LOCATIONS
Engine number
'K' Series Engines: Stamped on the rear LH side of
the cylinder block.
'L' Series Engine: Stamped on the LH side of the
cylinder block at top centre.
Gearbox number
ManuaI Gearbox - R65 and PG1: Barcode on a label
attached to the front face of the clutch housing.
Automatic Gearbox (EM-CVT): Stamped on a label
attached by the gearbox to engine mounting bolt at top
RH side of the gearbox.
GENERAL ÌNFORMATÌON
03-4
Body number
The body number is stamped on a plate fixed to the
floor to the LH side of the spare wheel compartment.
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 liquids and other substances
used in motor vehicles are poisonous and should
under no circumstances be consumed and should,
as far as possible, be kept from contact with the
skin. These liquids and substances include acid,
anti- freeze, asbestos, brake fluid, fuel, windscreen
washer additives, lubricants, refrigerant and
various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal 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. Ìf skin contact does occur:
¤ Remove any contaminated clothing immediately.
¤ Ìrrigate 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.
GENERAL ÌNFORMATÌON
03-5
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 oil. Used engine oil contains potentially
harmful contaminants which may cause skin
cancer or other serious skin disorders.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
HeaIth Protection Precautions
The following precautions should be observed at all
times:
¤ 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 (proprietary 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.
¤ Where practicable, degrease components prior to
handling.
¤ Ìf skin disorders develop, obtain medical advice
without delay.
¤ 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.
SAFETY INSTRUCTIONS
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points, the
recommended jacking points are given in LIFTING
AND TOWING
Always ensure that any lifting apparatus has sufficient
load 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.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
WARNING: Always fit the correct grade and
specification of brake linings and renew brake
pads and brake shoes in axle sets only.
GENERAL ÌNFORMATÌON
03-6
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 compatible.
CooIing system caps and pIugs
Extreme care is necessary when removing cooling
system expansion tank caps and coolant drain or bleed
screws 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.
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
Ìt 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.
MateriaIs:
¤ Keep lids on containers of solvents.
¤ Only use the minimum quantity.
¤ Consider alternative materials.
¤ Minimise over-spray when painting.
GENERAL ÌNFORMATÌON
03-7
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. Ìf 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. Ìf 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
Always adhere to the following:
DisposaI:
¤ 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.
SpiIIage 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.
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
Always adhere to the following:
¤ 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. Ìt 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. Ìf 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
Always adhere to the following:
¤ Know what legal consents and licences apply to
the operations.
¤ Check that the emissions and discharges comply
with legal requirements.
GENERAL ÌNFORMATÌON
03-8
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
Always adhere to the following:
¤ Ìdentify 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.
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
Always adhere to the following:
EIectricity 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.
FueI:
¤ 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 environmentaIIy damaging materiaIs:
¤ Check whether a less toxic material is available.
HandIing and storage of materiaIs:
¤ 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.
GENERAL ÌNFORMATÌON
03-9
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.
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 specialist
contractor.
¤ 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
specialist contractor.
¤ Air fiIters: keep separate and dispose of to
specialist contractor.
¤ Rubber/pIastics: dispose of in ordinary waste.
¤ Hoses: dispose of in ordinary waste.
¤ Batteries: keep separate and dispose of to
specialist contractor.
¤ Airbags - expIosives: keep separate and
dispose of to specialist contractor.
¤ EIectricaI components: send back to supplier for
refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
ordinary waste.
¤ EIectronic components: send back to supplier
for refurbishment, or disassemble and reuse any
suitable parts. Dispose of the remainder in
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.
GENERAL ÌNFORMATÌON
03-10
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.
GENERAL FITTING INSTRUCTIONS
Component removaI
Whenever possible, clean components and
surrounding area before removal.
¤ Blank off openings exposed by component
removal.
¤ Ìmmediately 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.
¤ Ìmmediately 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.
GENERAL ÌNFORMATÌON
03-11
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.
BALL AND ROLLER BEARINGS
GeneraI
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.
¤ Ìnspect 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.
¤ Ìf 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 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.
GENERAL ÌNFORMATÌON
03-12
¤ 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.
¤ Ìn 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.
OIL SEALS
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.
¤ Ìf 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. Ìf 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. Ìn some cases it may be
preferable to fit seal to housing before fitting to
shaft. Never let weight of unsupported shaft rest in
seal.
GENERAL ÌNFORMATÌON
03-13
¤ Use the recommended service tool to fit an oil
seal. Ìf 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.
JOINTS AND JOINT FACES
GeneraI
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.
¤ Ìf 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.
GENERAL ÌNFORMATÌON
03-14
LOCKING DEVICES
GeneraI
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.
RoII pins
Always fit new roll pins of an interference fit in the hole.
CircIips
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.
SpIit 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.
GENERAL ÌNFORMATÌON
03-15
SCREW THREADS
GeneraI
Metric threads to ÌSO standards are used.
Damaged nuts, bolts and screws must always be
discarded. Cleaning damaged threads with a die or tap
impairs the strength and fit of the threads and is not
recommended.
Always ensure that replacement bolts are at least
equal in strength to those replaced. Castellated nuts
must not be loosened to accept a split-pin, except in
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 loosen 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.
BOLT IDENTIFICATION
An ÌSO metric bolt or screw made of steel and larger
than 6 mm in diameter can be identified by either of the
symbols ÌSO M or M embossed or indented on top of
the bolt head.
Ìn addition to marks to identifying the manufacturer, the
top of the bolt is also marked with symbols indicating
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 stamped on the flats of the
hexagon.
GENERAL ÌNFORMATÌON
03-16
EncapsuIated boIts and screws
Encapsulated bolts and screws have a micro-
encapsulated locking agent pre-applied to the thread.
They are identified by a coloured section of thread
which extends 360° around the thread. 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.
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 bolts (i.e. Powerlok) have a special thread
form which creates a slight interference with the thread
of the hole or nut into which it is screwed.
DO NOT re-use self-locking fasteners in critical
locations (e.g. engine bearings flywheel). 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.
GENERAL ÌNFORMATÌON
03-17
NUT IDENTIFICATION
A nut with an ÌSO 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. Ìf 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. Ìf 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 deferred thread
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.
GENERAL ÌNFORMATÌON
03-18
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 any 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 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.
Ìf 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.
GENERAL ÌNFORMATÌON
03-19
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. Ìf 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 (2 lbf.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 and the Exhaust Gas Recirculation
(EGR) pipe. Hoses will relax and deflect slightly when
hot; ensure this movement is taken into account when
routing and securing hoses.
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
e +44 (0) 1604 760099
± +44 (0) 1604 760017
e-mail: sales©cartooluk.co.uk
CARTOOL GmbH
Straussenlettenstrasse 15
85053 Ìngolstadt
Germany
e +49 (0) 841 9650080
± +49 (0) 841 9650090
e-mail: i.amann©cartool.de
GENERAL ÌNFORMATÌON
03-20
DYNAMOMETER TESTING
GeneraI
ÌMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
WARNING: Do not attempt to test 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.
Ìf 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.
FUEL HANDLING PRECAUTIONS
GeneraI
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. Ìt 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 should be permitted to repair
components associated with fuel without first
having specialist training.
WARNING: Do not remove fuel system
components while the vehicle is over a pit.
GENERAL ÌNFORMATÌON
03-21
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: Fuel must not be extracted or drained
from any vehicle whilst it is over a pit.
Draining or extraction of fuel must be carried out in
a well ventilated area.
The capacity of containers for fuel must be more
than adequate for the full amount of fuel to be
extracted or drained. The container should be
clearly marked with its contents and placed in a
safe storage area which meets the requirements of
local authority regulations.
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.
Ìf 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 a 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 ÌS APPLÌED. Ìf the repair is in the vicinity of the
fuel tank, the tank must be removed.
WARNING: If welding is to be carried out in the
vicinity of the fuel tank, the fuel system must be
drained and the tank removed before welding
commences.
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. Ìt 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.
GENERAL ÌNFORMATÌON
03-22
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. Ìf 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.
WARNING: Always ensure that battery leads are
routed correctly and are not close to any potential
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 all high tension terminals,
adapters and diagnostic equipment are adequately
insulated and shielded to prevent accidental
personal contacts and minimise the risk of shock.
Wearers of surgically implanted pacemaker
devices should not be in close proximity of ignition
circuits or diagnostic equipment.
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 relays, switches
etc. contaminating the contacts and leading to
intermittent operation or failure.
GENERAL ÌNFORMATÌON
03-23
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: Always follow the 'SRS Precautions'
and the correct procedures for working on SRS
components. Persons working on SRS systems
must be fully trained and have been issued with
copies of the Safety guidelines.
WARNING: It is imperative that before any work is
undertaken on the SRS system the appropriate
information is read thoroughly.
WARNING: Some airbag modules contain sodium
azide which is poisonous and extremely
flammable. Contact with water, acid or heavy
metals may produce harmful or explosive
compounds. Do not dismantle, incinerate or bring
into contact with electricity, before the unit has
been deployed.
WARNING: Always replace a seat belt assembly
that has withstood the strain of a severe vehicle
impact, or if the webbing shows signs of fraying.
WARNING: Always disconnect the vehicle battery
before carrying out any electrical welding on a
vehicle fitted with an SRS system.
CAUTION: Do not expose an airbag moduIe or seat
beIt pre-tensioner to heat exceeding 85°C (185°F).
Ìt 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 the SRS components; these include,
but are not limited to:
¤ Steering system - steering wheel airbag, rotary
coupler
¤ Front fascia - passenger front airbag (where
fitted)
¤ Rear seats and interior trim SRS DCU (beneath
rear seat) and SRS harnesses.
¤ Front seats - front seat belt pre-tensioners
¤ 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.
¤ Disconnect both battery leads, earth lead first.
¤ 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. Ìt is necessary to allow
the capacitor sufficient time to discharge (10 minutes)
in order to avoid the risk of accidental deployment.
WARNING: Always disconnect both battery leads
before beginning work on the SRS system.
Disconnect the negative battery lead first. Never
reverse connect the battery.
GENERAL ÌNFORMATÌON
03-24
InstaIIation
Ìn 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 critical for safety reasons. Ensure
the following precautions are always adhered to:
¤ Never install used SRS components from
another vehicle or attempt to repair an SRS
component.
¤ When repairing the SRS system, only use
genuine new parts.
¤ Never apply electrical power to an SRS
component unless instructed to do so as part
of an approved test procedure.
¤ Special Torx bolts are necessary for installing
the airbag module - do not use other bolts.
Ensure bolts are tightened to the correct
torque.
¤ Always use new fixings when replacing an
SRS component.
¤ Ensure the SRS Diagnostic Control Unit (DCU)
is always installed correctly. There must not
be any gap between the DCU and the bracket
to which it is mounted. An incorrectly
mounted DCU could cause the system to
malfunction.
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: Following seat belt pre-tensioner deployment,
the seat belts can still be used as conventional seat
belts, but will need to be replaced as soon as possible
to re-establish full SRS PROTECTION.
NOTE: If the SRS component is to be replaced, the bar
code of the new unit must be recorded.
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 multimeter or other
general purpose test equipment on SRS system
components or accidental deployment may occur.
Only use 'Testbook´ to diagnose SRS system
faults.
WARNING: Do not use electrical test equipment on
the SRS harness while it is connected to any of the
SRS system components. It may cause accidental
deployment and personal injury.
GENERAL ÌNFORMATÌON
03-25
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
potentially hazardous if not handled correctly;
always comply with the following handling
precautions:
¤ Never drop a SRS component. The airbag
diagnostic control unit is a particularly shock
sensitive device and must be handled with
extreme care. Airbag modules and seat belt
pre-tensioner units could deploy if subjected
to a strong shock.
¤ Never wrap your arms around an airbag
module. If an airbag module has to be carried,
hold it by the cover, with the cover uppermost
and the base away from your body.
¤ Never transport airbag modules or seat belt
pre-tensioners in the cabin of a vehicle.
Always use the luggage compartment of the
vehicle for carrying airbag modules and seat
belt pre-tensioner units.
WARNING: Never attach anything to an airbag
cover or any trim component covering an airbag
module. Do not allow anything to rest on top of an
airbag module.
WARNING: Always keep components cool, dry and
free from contamination.
CAUTION: Do not appIy grease or cIeaning
soIvents to seat beIt pre-tensioner units,
component faiIure couId resuIt.
WARNING: Store airbag modules with the
deployment side uppermost. If airbag modules are
stored deployment side down, accidental
deployment will propel the airbag module with
enough force to cause serious injury.
WARNING: Airbag modules and seat belt pre-
tensioners are classed as explosive devices. For
overnight and longer term storage, they must be
stored in a secure steel cabinet which has been
approved as suitable for the purpose and has been
registered by the local authority.
WARNING: Store the airbag module or seat belt
pre-tensioner in a designated storage area. If there
is no designated storage area available, store in
the locked luggage compartment/loadspace of the
vehicle and inform the workshop supervisor.
CAUTION: Improper handIing or storage can
internaIIy damage the airbag moduIe, making it
inoperative. If you suspects the airbag moduIe has
been damaged, instaII a new moduIe and refer to
the DepIoyment/DisposaI Procedures for disposaI
of the damaged moduIe.
GENERAL ÌNFORMATÌON
03-26
WARNING: When handling front seat belt buckle
pre-tensioners, hold by the piston tube, with the
open end of the piston tube pointing towards the
ground and the buckle facing away from your
body.
¤ DO NOT cover the end of the piston tube.
¤ DO NOT hold buckle pre-tensioners by the
bracket assembly or steel cable.
¤ NEVER point the piston tube towards your
body or other people.
SRS Harnesses and Connectors
CAUTION: AIways observe the foIIowing
precautions with regards to 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 be identified by a
special yellow outer sleeve protecting the wires (black
with yellow stripe protective coverings are sometimes
used).
WARNING: Always ensure SRS wiring is routed
correctly. Be careful to avoid trapping or pinching
the SRS wiring. Do not leave the connectors
hanging loose or allow SRS components to hang
from their harnesses. Look for possible points of
chafing.
GENERAL ÌNFORMATÌON
03-27
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 the 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.
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,
seat belt pre-tensioners 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 thoroughly.
NOTE: The following list indicates possible locations
and content for warning labels. Exact positions and
content may vary dependent on model year, legislation
and market trends.
GENERAL ÌNFORMATÌON
03-28
Side windows
Etched onto driver and front passenger side windows.
Fascia
End of fascia label - DO NOT use rear facing child seat
in front passenger seat of vehicles fitted with a
passenger airbag.
Rotary coupler
1 The need for caution when working in close
proximity to SRS components.
2 Refer to Workshop Manual for detailed
instructions.
3 Ensure the wheels are in the straight ahead
position before removal and refitting.
4 Rover bar code - the code number must be
recorded if the rotary coupler is to be replaced.
GENERAL ÌNFORMATÌON
03-29
Front seat belt 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.
Similar caution labels are attached to the DCU and
others may be applied to trim close to SRS
components and harnesses. The driver's steering
wheel has an 'AÌRBAG' symbol moulded into the
centre pad to identify the presence of a driver's front
airbag and a similar 'SRS' identifier is included on the
passenger side fascia to alert to the presence of a
passenger front airbag (where fitted).
Bar codes
Bar codes are fitted to SRS components and
components which are critically related to SRS
operation. The code number(s) must be recorded if the
component is to be replaced. Components featuring
bar codes include the following:
¤ DCU - included on label on top of DCU
¤ Driver's front airbag module - label attached to
rear of module housing
¤ Passenger front airbag module - label attached at
side of module housing
¤ Front seat belt pre-tensioners - label attached to
piston tube
¤ Rotary coupler - included on label on front face of
coupler housing
GENERAL ÌNFORMATÌON
03-30
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 negative '-ve' lead first.
Towing - SRS components depIoyed:
Once 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 negative '-ve' lead
first.
SRS COMPONENT DEPLOYMENT
Ìf a vehicle is to be scrapped and contains an
undeployed airbag or seat belt pre-tensioner module,
the module must be manually deployed. Always
observe the following precautions:
WARNING: Only personnel who have undergone
the appropriate training should undertake
deployment of airbag and seat belt pre-tensioner
modules.
WARNING: A deployed airbag or seat belt pre-
tensioner is very hot, DO NOT return to a deployed
airbag module or seat belt pre-tensioner until at
least 30 minutes have elapsed since deployment.
WARNING: Only use approved deployment
equipment, and only deploy SRS components in a
well ventilated designated area. Ensure SRS
components are not damaged or ruptured before
deployment. Notify the relevant authorities.
WARNING: If a vehicle is to be scrapped,
undeployed airbag modules and pre-tensioner
units must be deployed in accordance with the
instructions in this manual.
WARNING: Contact with chemicals from deployed
and damaged SRS components could present a
health hazard, wear protective clothing when
handling. DO NOT eat, drink or smoke when
handling SRS components.
WARNING: Deployment of airbag modules and
seat belt pre-tensioners can cause injury to
personnel in the close vicinity of the deploying
unit. In case of injury seek urgent medical advice.
Possible sources of injury include:
¤ Impact - due to inflating airbag or deploying
seat belt pre-tensioner operation causing
component 'kick´.
¤ Hearing - due to noise produced by deploying
airbags and seat belt pre-tensioner units.
¤ Burns - hot component parts and gases.
¤ Irritation to eyes and lungs - from deploying
gases or combustion residue.
WARNING: Ensure the SRS component to be
deployed is securely fastened to its mounting.
WARNING: Deployment procedures detailed in
this manual should be strictly adhered to.
Compliance with the following precautions MUST
be ensured:
¤ Only use deployment equipment approved for
the intended purpose.
GENERAL ÌNFORMATÌON
03-31
¤ Before commencing deployment procedure,
ensure the deployment tool functions properly
by performing the self test procedure detailed
in the 'SRS Repairs' section of this manual.
¤ Deployment of airbag/pre-tensioner modules
should be performed in a well ventilated area
which has been designated for the purpose.
¤ Ensure the airbag/pre-tensioner modules are
not damaged or ruptured before attempting to
deploy.
¤ Notify the relevant authorities of intention to
deploy airbag and pre-tensioner units.
¤ When deploying airbag and seat belt pre-
tensioner units, ensure that all personnel are
at least 15 metres away from the deployment
zone.
¤ Ensure deployment tool is connected
correctly, in compliance with the instructions
detailed in this manual. In particular, ensure
deployment tool is NOT connected to battery
supply before connecting to the airbag or seat
belt pre-tensioner module connector.
¤ When deploying seat belt pre-tensioners in
the vehicle, ensure the pre-tensioner unit is
fully secured to its fixing point.
¤ When removing deployed airbag and seat belt
pre-tensioner modules, wear protective
clothing. Use gloves and seal deployed units
in a plastic bag.
¤ Following deployment of any component of
the SRS system within the vehicle, all SRS
components must be replaced. DO NOT re-use
or salvage any parts of the SRS system.
¤ Do not lean over airbag modules or seat belt
pre-tensioner units when connecting
deployment 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 deployment (driver and passenger)
Ìf 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 belt buckle pre-tensioners
¤ Driver's seat belt retractor
¤ Rotary coupler
¤ SRS DCU
Ìn addition, the following should be inspected for
damage and replaced as necessary:
¤ Front passenger's seat belt retractor (webbing,
tongue latching, 'D' loop, body anchorage point)
¤ Rear seat belt buckles (webbing, buckle covers,
body anchorage and tongue latching function)
¤ Fascia moulding adjacent 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)
GENERAL ÌNFORMATÌON
03-32
Rear impacts
Rear impacts may cause the seat belt pre-tensioners
to deploy. Ìf this occurs, all pre-tensioner units must be
replaced. Ìn addition, the following components should
be inspected for damage and replaced as necessary:
¤ Front seat frames
¤ Front seat belts (retractors, webbing, tongue
latching, 'D' loop and body anchorage points)
¤ Rear seat belt buckles (webbing, buckle covers,
tongue latching and body anchorage).
¤ 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.
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 only be carried out by
personnel familiar with both the vehicle system
and the charging and testing equipment. All
operations must be carried out in a well ventilated
area away from open flame and heat sources.
WARNING: R134a is a hazardous liquid and when
handled incorrectly can cause serious injury.
Suitable protective clothing, consisting of face
protection, heat proof gloves, rubber boots and
rubber apron or waterproof overalls, must be worn
when carrying out operations on the air
conditioning system.
GENERAL ÌNFORMATÌON
03-33
RemediaI actions
Ìf an accident involving R134a should occur, conduct
the following remedial actions:
¤ Ìf liquid R134a enters the eye, do not rub it. Gently
run large quantities of eye wash over affected eye
to raise the temperature. Ìf 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.
¤ Ìf liquid R134a is splashed onto the skin, run large
quantities of water over the affected area to raise
the temperature. Ìmplement 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.
¤ Ìf the debilitating effects of inhalation of R134a
vapour is suspected, seek fresh air. Ìf 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 low evaporating temperature,
R134a must be handled with care. R134a splashed
on any part of the body will cause immediate
freezing of that area. Also, refrigerant cylinders
and replenishment trolleys when discharging will
freeze skin to them if contact is made.
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. Ìn 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 desiccant which
absorbs moisture. Ìt 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 fitted are marked for use
with R134a.
When a major repair has been completed, a leak test
should be conducted; refer to the 'AÌR
CONDÌTÌONÌNG' section of this manual for the correct
procedure.
GENERAL ÌNFORMATÌON
03-34
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 Ìnvert 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.
ÌNFORMATÌON
04-1
ÌNFORMATÌON
LIFTING AND TOWING
JACKING, SUPPORTING AND TOWING
Jacking and support points
1 Front jacking point, lashing/towing eye - front
2 Rear jacking point, lashing/towing eye - rear
3 LH sill re-inforced bracket front
4 RH sill re-inforced bracket front
5 LH sill re-inforced bracket rear
6 Longitudinal members - front
7 RH sill re-inforced bracket rear
8 Longitudinal members - rear
WARNING: In accordance with normal workshop
practice and to avoid the possibility of damage or
personal injury, work must not be carried out on or
under a vehicle when it is supported solely on a
jack. Place safety supports under the floor
longitudinal members (6 and 8).
WARNING: Do not position a jack, jack stand or
wheel free support under the suspension
attachment points or the rear suspension 'H´
frame.
ÌNFORMATÌON
04-2
LIFTING
The following instructions must be carried out before
raising the vehicle off the ground:
¤ Use a solid level ground surface.
¤ Apply hand brake.
¤ Select 'P' or 1st. gear in main gearbox.
To avoid damage occurring to the under body
components of the vehicle only position jacks or axle
stands at the points recommended in this section of the
workshop manual.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS
¤ Body structure
¤ Bumpers
¤ Fuel lines
¤ Brake lines
¤ Front / Rear Suspension arms
¤ Fuel tank
¤ Engine sump
¤ Gearbox
VehicIe jack
The jack provided with the vehicle is only intended for
use in an emergency, for changing a tyre. DO NOT use
the vehicle jack for any other purpose.
To use the vehicle jack for changing a wheel, ensure
the jack is positioned on firm level ground under the
jacking point nearest the wheel to be removed (3, 4, 5
or 7 - see jacking point iIIustration shown earIier in
this section ).
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Workshop Jack
A hydraulic jack with a minimum 1500 kg (3,300 lbs)
load capacity must be used.
WARNING: Do not attempt to jack under
suspension attachment points or the rear
suspension 'H´ frame.
WARNING: Do not commence work on the
underside of the vehicle until suitable safety
supports have been positioned under the relevant
longitudinal members.
WARNING: Always chock the wheels when
jacking.
Front
Locate the jack head under the central towing bracket
(1 - see jacking point iIIustration shown earIier in
this section ).
Position safety supports under both front longitudinal
members (6 - see jacking point iIIustration shown
earIier in this section).
Rear
Locate the jack head under the rear towing eye (2 -
see jacking point iIIustration shown earIier in this
section ).
Position safety supports under both rear longitudinal
members (8 - see jacking point iIIustration shown
earIier in this section).
Side
CAUTION: The side jacking points are designed to
accomodate the vehicIe jack onIy.
WHEEL-FREE LIFT
Two-post lift and crossbeams:
Locate the pads under the sill reinforced jacking
brackets at the front (3, 4 ) and rear ( 5, 7) - see
jacking point iIIustration earIier in this section of
the workshop manuaI
Longitudinal beams:
Locate the beams under the floor longitudinals with the
lifting pads at the front and rear positions (6 and 8 -
see jacking point illustration earlier in this section of the
workshop manual ).
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.
ÌNFORMATÌON
04-3
VEHICLE RECOVERY
Towing
Ìt is recommended that a recovery trailer or two wheel
car ambulance be used. Ìn an emergency, the car may
be towed on its own wheels using the front lashing/
towing eye (1- see jacking point iIIustration earIier
in this section of the workshop manuaI).
The fixed rear lashing/towing eye must only be used
for towing a light vehicle, do not use for towing a trailer
or caravan. The lashing point can also be used for
rearward recovery of the vehicle providing it has a
manual gearbox (2-see jacking point iIIustration
earIier in this section of the workshop manuaI).
Manual gearbox models
Use the front lashing/towing eye for towing the vehicle
on all four wheels from the front (1- see jacking point
iIIustration earIier in this section of the workshop
manuaI).
WARNING: To ensure that the steering does not
lock when the vehicle is being towed, it is essential
that the ignition key is turned to position 'I´, and
remains there while the vehicle is moving. Ensure
the following precautions are observed:
Do not tow if the gearbox or a driveshaft is faulty.
Do not tow if a wheel or drive shafts are touching
the body or frame.
Ensure the gear lever is in neutral and the hand
brake is released.
Remember that greater effort than normal will be
necessary to operate the brakes and steering if the
vehicle is being towed without the engine running.
CAUTION: On no account shouId the vehicIe be
towed with the front wheeIs on the ground if the
transmission is fauIty, the transmission fIuid IeveI
is Iow, or the towing distance exceeds 30 miIes, 50
km.
Automatic gearbox modeIs
When a car with an automatic gearbox is to be towed,
a suspended tow must be used because the gearbox
is not adequately lubricated without the engine
running. The following precautions must be observed:
The selector must be at 'N'
CAUTION: A rear suspended tow must not be
attempted as serious damage wiII be caused to the
automatic transmission.
NOTE: A vehicle fitted with an automatic gearbox
cannot be started by towing or pushing.
Suspended tow
A front wheel lift should be used with a cross beam and
body protection.
Before towing commences, release the handbrake,
place the gear lever in neutral and the ignition switch at
'I' Do not tow at a speed greater than 30 mph (50 km/
h).
CAUTION: For vehicIes with automatic
transmission, a rear suspended tow must not be
attempted as serious damage wiII be caused to the
automatic transmission.
Transporter / TraiIer Iashing
Only use the recommended lashing points during
transportation. Do not secure lashing hooks, 'T' bars or
trailer fixings to any other part of the car.
Position the vehicle on the trailer and apply the
handbrake. Select neutral in the manual gearbox ('N'
on automatic gearbox). Selecting 'N' will prevent
damage to the parking pawl in the automatic gearbox.
ÌNFORMATÌON
04-4
GENERAL DATA
05-1
GENERAL DATA
ENGINE - 'K' SERIES
GeneraI
Type:
K16 (without VVC) 16 valve DOHC
K16 (with VVC) 16 valve DOHC with Variable Valve Control on inlet valves
Cylinder arrangement 4 in line - transverse, No.1 cylinder at front of engine
Bore:
1.1 & 1.4 75.00 mm
1.6 & 1.8 80.00 mm
Stroke
1.1 62.3 mm
1.4 & 1.6 79.00 mm
1.8 89.30 mm
Capacity:
1.1 1119 cm
3
1.4 1396 cm
3
1.6 1588 cm
3
1.8 1796 cm
3
Compression ratio:
1.1 9.4:1
1.4 10.4:1
1.6 10.5:1
1.8 10.5:1 ± 0.5:1
Maximum power:
1.1 55 kW (70 bhp) © 6,000 rev/min.
1.4 62 kW (84 bhp) © 6,000 rev/min.
1.4 Plus/MG ZR 1.4 76 kW (103 bhp) © 6,000 rev/min
1.6 80 kW (109 bhp) © 6,000 rev/min.
1.8 (without VVC)/MG ZR 1.8 88 kW (120 bhp) © 5,500 rev/min.
1.8 (MG ZR 160) 118 kW (160 bhp) © 5,500 rev/min.
Maximum torque:
1.1 95 Nm (75 lbf.ft) © 5,000 rev/min.
1.4 110 Nm (81 lbf.ft) © 4,500 rev/min.
1.4 Plus/MG ZR 1.4 123 Nm (91 lbf.ft) © 4,500 rev/min.
1.6 138 Nm (102 lbf.ft) © 4,500 rev/min.
1.8 (without VVC)/MG ZR 1.8 160 Nm (118 lbf.ft) © 4,000 rev/min.
1.8 (MG ZR 160) 174 Nm (128 lbf.ft) © 4,500 rev/min.
Ìdle speed controlled by ECM 825 ± 50 rev/min.
Maximum intermittent engine speed
1.1, 1.4, 1.6 & 1.8 (without VVC) 6,800 rev/min.
1.8 (with VVC) 7,100 rev/min.
Weight (fully dressed, wet) 108 kg (238 lb)
Dimensions:
Length (nominal) 654 mm
Width (nominal) 600 mm
Height (nominal) 615 mm
Firing order 1 - 3 - 4 - 2
Rotation Clockwise, viewed from front of engine
GENERAL DATA
05-2
CyIinder bIock
CyIinder head
Crankshaft
Main bearings
Material Aluminium alloy
Cylinder liner type Damp, bottom half stepped - sliding fit into lower part of cylinder
block
Cylinder liner bore:
1.1 & 1.4
RED grade A 74.970 - 74.985 mm
BLUE grade B 74.986 - 75.000 mm
1.6 & 1.8
RED grade A 80.000 - 80.015 mm
BLUE grade B 80.016 - 80.030 mm
Material Aluminium alloy
Maximum warp 0.05 mm
Cylinder head height (New) 118.95 - 119.5 mm
Reface limit 0.20 mm
End-float 0.10 - 0.25 mm
Service limit 0.34 mm
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 diameter 47.986 - 48.007 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
GENERAL DATA
05-3
Big-end bearings
Connecting rods
Pistons
1.1, 1.4 & 1.6:
Big-end journal diameter 42.986 - 43.007 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 mm
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
Type Horizontally split big-end, plain small end
Big-end bearing / Connecting rod end-float 0.10 - 0.25 mm
Type Aluminium alloy, tin plated, thermal expansion with offset
gudgeon pin
Piston diameter:
1.1 & 1.4
Grade A 74.940 - 74.955 mm
Grade B 74.956 - 74.970 mm
1.6 & 1.8
Grade A 79.975 - 79.990 mm
Grade B 79.991 - 80.005 mm
Clearance in bore:
1.1 & 1.4 0.015 - 0.045 mm
1.6 & 1.8 0.01 - 0.04 mm
Maximum ovality 0.30 mm
GENERAL DATA
05-4
Piston rings
Gudgeon pins
Type:
Top compression ring Barrel faced, granulite coated
2nd compression ring Tapered, phosphate coated
Oil control ring Nitrided ring with radii and spring
1.1 & 1.4 - New ring to groove clearance:
Top compression ring 0.04 - 0.08 mm
2nd compression ring 0.03 - 0.062 mm
Oil control ring 0.044 - 0.055 mm
1.6 & 1.8 - 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
1.1 & 1.4 - Ring fitted gap 20 mm from top of bore:
Top compression ring 0.17 - 0.37 mm
2nd compression ring 0.37 - 0.57 mm
Oil control ring 0.15 - 0.40 mm
1.6 & 1.8 - Ring fitted gap 20 mm from top of bore:
Top compression ring 0.20 - 0.35 mm
2nd compression ring 0.28 - 0.48 mm
Oil control ring 0.15 - 0.40 mm
Piston ring width:
Top compression ring 0.978 - 0.990 mm
2nd compression ring 1.178 - 1.190 mm
Oil control ring 0.33 - 0.38 mm
Type Semi-floating, off-set towards thrust side
Fit in connecting rod Ìnterference
Diameter:
RED 17.997 - 18.000 mm
GREEN 17.994 - 17.997 mm
Length 52.3 - 52.6 mm
GENERAL DATA
05-5
Camshaft
VaIve Springs
1.1, 1.4, 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):
Ìnlet 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
Ìnlet camshaft (25 mm diameter journals) 0.025 - 0.060 mm
Service limit 0.1 mm
Ìnlet 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
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 closed 440 ± 22 N
GENERAL DATA
05-6
VaIve timing
VaIves
Tappets
K16 engines without VVC
Ìnlet valves:
Opens 12° BTDC
Closes 52° ABDC
Maximum lift 8.8 mm
Exhaust valves:
Opens 52° BBDC
Closes 12° ATDC
Maximum lift 8.8 mm
K16 engines with VVC
Ìnlet valves:
Opens 0° ATDC (at minimum period)
Closes 40° ABDC (at minimum period)
Maximum lift 9.5 mm
Exhaust valves:
Opens 51° BBDC
Closes 21° ATDC
Maximum lift 9.2 mm
Valve open period:
Variable period - inlet 220° to 295°
Variable period - exhaust 252°
Variable overlap 21° to 58°
K16:
Ìnlet 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
Ìnlet 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) 1.6 mm
Valve seat width (exhaust) 1.2 mm
Type Hydraulic, self-adjusting, directly operated from camshafts
Tappet outside diameter 32.959 - 32.975 mm
GENERAL DATA
05-7
Lubrication
Engine management system
System Type Wet sump, crankshaft driven eccentric rotor pump
Outer rotor to housing clearance 0.28 - 0.36 mm
Ìnner rotor tip clearance 0.05 - 0.13 mm
Rotor end-float 0.02 - 0.06 mm
Pressure at idle 1.7 to 3.5 bar
Relief valve opening pressure 4.1 bar
Relief valve spring free length 38.9 mm
Maximum pressure at 6500 rev/min 7.0 bar (below 40°C)
Oil pressure warning light switch opens 0.3 to 0.5 bar
Oil filter Full flow disposable screw-on cannister
Model: 1.1, 1.4, 1.6 & 1.8 K16
Controller type MEMS 3 breakerless, electronic, fully mapped engine
management system
Ìgnition coils
Make Nippon Denso NEC 100730
Type 2 twin output coils, plug top mounted; cylinders 1 & 4 and 2 & 3
Primary resistance (typical) 0.7W
Secondary resistance (typical) 10W
Spark Plugs - standard
Make / Type Unipart GSP 66527
Gap 1.0 ± 0.05 mm
Spark Plugs - Double Platinum
Make / Type Unipart GSP 9652 or Champion RC8 PYP
Gap 0.85 mm
Emissions standard ECD3
GENERAL DATA
05-8
ENGINE - 'L' SERIES
GeneraI
CyIinder bIock
CyIinder head and camshaft carrier
Crankshaft
Main bearings
Big-end bearings
Type 8 valve SOHC, turbocharged, intercooled
Cylinder arrangement 4 in line - transverse
Bore 84.5 mm
Stroke 88.9 mm
Capacity 1994 cm
3
Compression ratio (nominal) 19.5:1
Firing order 1 - 3 - 4 - 2
Rotation Clockwise, viewed from the front of the engine
Maximum Power 74 kW (101 bhp) © 4,200 rev/min.
Maximum Torque 240 Nm (177 lbf.ft) © 2,000 rev/min.
Maximum intermittent engine speed 4,900 rev/min.
Material Cast iron
Cylinder bore diameter2 84.442 - 84.460 mm
Material Aluminium alloy
Cylinder head maximum warp 0.010 mm
Cylinder head bolt length 243.41 mm
End-float 0.03 - 0.26 mm
Quantity 5
Type Grooved shells in cylinder block, plain shells in main bearing caps
Thrust washer type Single size thrust washers at centre main bearing
Thrust washer halves thickness 2.31 - 2.36 mm
Main journal diameter 60.703 - 60.719 mm
Clearance in bearings ± 0.005 mm
Type Plain shells in connecting rods and end caps
Big-end journal diameter 57.683 - 57.696 mm
Clearance in bearings ± 0.005 mm
GENERAL DATA
05-9
Connecting rods
Gudgeon pins
Pistons
Piston rings
Camshaft
Tappets
VaIve springs
Type Fracture split bearing caps
Type Fully floating, offset towards thrust side of piston
Diameter 29.995 - 30.000 mm
Type Aluminium alloy, graphite coated; combustion chamber in domed
crown
Piston diameter 84.262 mm
Clearance in bore 0.18 - 0.20 mm
New ring to groove clearance:
Top compression ring 0.115 - 0.135 mm
2nd compression ring 0.050 - 0.082 mm
Oil control ring 0.050 - 0.082 mm
Ring fitted gap on piston:
Top compression ring 0.30 - 0.50 mm
2nd compression ring 0.40 - 0.60 mm
Oil control ring 0.25 - 0.50 mm
Ring fitted gap 30mm from top of cylinder bore:
Top compression ring 0.25 - 0.27 mm
2nd compression ring 0.40 - 0.42 mm
Oil control ring 0.30 - 0.32 mm
Drive via toothed belt from gear on crankshaft
Number of bearings 5
Camshaft maximum end-float 0.51 mm
Bearing clearance 0.043 - 0.094 mm
Camshaft timing belt tensioner spring free length 65 mm
Outside diameter 34.959 - 34.975 mm
Free length 37.00 mm
GENERAL DATA
05-10
VaIves
VaIve guides
VaIve seat inserts
Lubrication
Engine Management System
Valve stem diameter:
Ìnlet 6.907 - 6.923 mm
Exhaust 6.897 - 6.913 mm
Valve stem to guide clearance:
Ìnlet 0.056 mm
Exhaust 0.066 mm
Valve face angle 45° - 45° 30'
Valve head stand down:
Ìnlet 1.45 mm
Exhaust 1.35 mm
Ìnside diameter after reaming 6.950 - 6.963 mm
Fitted length above cylinder head 61.1 - 61.7 mm
Seat angle:
Ìnlet 60°
Exhaust 58° - 62°
Ìnsert diameter:
Ìnlet 35.697 mm
Exhaust 31.05 - 31.55 mm
System Type Wet sump, crankshaft driven eccentric rotor pump
Oil pump:
Type Rotor
Drive Front of crankshaft
Outer rotor to body clearance 0.05 - 0.10 mm
Rotor lobe clearance 0.025 - 0.120 mm
Outer rotor end-float 0.03 - 0.08 mm
Pressure at idle 0.7 bar
Relief valve opening pressure 4.5 bar
Pressure at 3000 rev/min hot 3.8 bar
Oil pressure warning light switch opens 0.4 to 0.7 bar
Oil filter Full flow with disposable cannister
ECM Bosch EDC15M
Ìdle speed: 805 ± 50 rev/min
Max. no load engine speed 5300 rev/min
Glow plugs:
Type 0100226 184
Make BERU
GENERAL DATA
05-11
FUEL SYSTEM - 'K' SERIES
GeneraI
FueI Pump
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.
* Different octane ratings may be defined nationally. 90 RON minimum if retuned via Testbook.
System Returnless Multipoint Fuel Ìnjection, electronically controlled with
electro-mechanical fuel injectors.
Type Continuous flow electrically driven roller vane pump submerged
in fuel tank.
Pump maximum pressure at 13.5V 4.1 bar
Regulated injection pressure range 3.0 ±0.2 bar, controlled by in-tank pressure regulator.
Fuel pump delivery 39 litres © 3.0 bar
Fuel filter 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
GENERAL DATA
05-12
FUEL SYSTEM - 'L' SERIES
Fuel filter Ìn-line cannister type - Bosch 0450 906172
Fuel injection pump Bosch electronic VP30
Fuel pump drive via belt from rear of camshaft
Fuel line Ìn-line hand operated primer
Fuel injectors:
Make Bosch
Type 2-stage needle lift injectors, with needle lift sensing on number
one injector
Opening pressure
1st. stage 210 bar
2nd. stage 380 bar
Fuel specification EN590 diesel *
Turbocharger Garrett GT 1549 with intercooler
GENERAL DATA
05-13
COOLING SYSTEM - 'K' SERIES
WARNING: Fans can start (or run on) for up to 4 minutes after the ignition is switched off.
Type Pressurised, spill return, thermostatically controlled water/anti-
freeze mixture
Cooling fans 7 blade 2 speed axial flow, electric, thermostatically controlled
Expansion tank pressure relief cap opens 0.9 to 1.2 bar
Thermostat Wax element
Thermostat starts to open 88°±2°C
Thermostat fully open 100°±2°C
Coolant pump Radial flow impeller - mechanical
Coolant pump drive ratio 1:1
Cooling fan operation:
without air conditioning On - 104°C, Off - 98°C
with air conditioning
Slow speed On - 104°C, Off - 98°C
Fast speed On - 112°C, Off - 106°C
Power down On - 112°C, Off - 106°C (or 8 minutes)
GENERAL DATA
05-14
COOLING SYSTEM - 'L' SERIES
WARNING: Fans can start (or run on) for up to 4 minutes after the ignition is switched off.
Type Pressurised, spill return, thermostatically controlled water/anti-
freeze mixture
Cooling fan 6 blade 2 speed axial flow, electric, thermostatically controlled
Expansion tank pressure relief cap opens 0.9 to 1.2 bar
Thermostat Wax element
Thermostat fully open 82° ±5°C
Coolant pump Radial flow impeller - mechanical
Coolant pump drive ratio 1:1
Cooling fan operation
Without air conditioning On - 104°C, Off - 94°C
With air conditioning:
Slow speed On - 104°C, Off - 94°C
Fast speed On - 112°C, Off - 106°C
Power down On - 112°C, Off - 106°C (or 8 minutes)
GENERAL DATA
05-15
CLUTCH
Type Diaphragm spring, hydraulic operation
Clutch plate diameter:
1.1, 1.4 and 1.6 'K' Series 200 mm
1.8 'K' Series 215 mm
2.0 'L' Series 228 mm
Friction material wear limit 1.5 mm
GENERAL DATA
05-16
MANUAL GEARBOX - R65
Gearbox code:
1.1 & 1.4 'K' series 5C 39 WUR
1.6 'K' series 5C 37 WUC
Gear ratios:
Fifth 0.854 : 1
Fourth 1.054 : 1
Third 1.333 : 1
Second 1.947 : 1
First 3.471 : 1
Reverse 3.583 : 1
GENERAL DATA
05-17
MANUAL GEARBOX - PG1
Gearbox code
1.8 'K' series with VVC C4BS
2.0 'L' series S6BSU
Gear ratios: C4BS S6BSU
Fifth 0.765 : 1 0.649 : 1
Fourth 1.033 : 1 0.848 : 1
Third 1.308 : 1 1.222 : 1
Second 1.842 : 1 1.895 : 1
First 3.167 : 1 3.250 : 1
Reverse 3.000 : 1 3.000 : 1
GENERAL DATA
05-18
AUTOMATIC GEARBOX - EM-CVT
Type Constantly Variable Transmission (EM-CVT) Stepspeed
Gearbox code VT1
Gear ratios (manual mode only)
Sixth 2.99:1
Fifth 3.92:1
Fourth 4.87:1
Third 6.48:1
Second 8.76:1
First 13.92:1
Reverse 15.32:1
Gear ratios ('D' drive mode only)
Over drive 2.553:1
First 13.92:1
Reverse 15.32:1
GENERAL DATA
05-19
FINAL DRIVE
ManuaI Gearbox
Stepspeed (EM-CVT):
Ratios:
1.1 & 1.4 'K' series 3.765 : 1
1.6 'K' series 3.556 : 1
1.8 'K' series with VVC 4.200 : 1
2.0 'L' series 3.938 : 1
Ratios:
1.6 'K' series 4.059 : 1
1.8 'K' series without VVC 4.059 : 1
GENERAL DATA
05-20
STEERING
GeneraI
WheeI aIignment
Power Assisted Steering
NOTE: The following steering geometry settings are given in degrees and minutes, for a vehicle at unladen weight.
Type Servo-assisted rack and pinion, linear ratio system
Steering column Collapsible with height adjustment
Turns - lock to lock
R25 3.0
MG ZR 2.8
Turning circle (kerb to kerb)
5.5 x 14 wheels 10.90 m
6 x 15 wheels 10.90 m
6.5 x 16 wheels 11.21 m
Turning circle (wall to wall)
5.5 x 14 wheels 11.20 m
6 x 15 wheels 11.20 m
6.5 x 16 wheels 11.47 m
Front (R25):
Camber angle - unladen condition -0.20' ± 0.45'
Castor angle - unladen condition 1°42' ±1°
King-pin inclination 12°7'
Toe (total) - unladen condition 0° ± 15'
Front (MG ZR):
Camber angle - unladen condition -0.40' ± 45'
Castor angle - unladen condition 2°12' ±1°
King-pin inclination 12°24'
Toe (total) - unladen condition 0° ± 15'
Rear (All models):
Camber angle - unladen condition - 0.20' ± 45'
Thrust angle 0° ± 6'
Toe-in (total) 16' ± 15'
Operating Pressure (nominal) 65 bar
Flow rate 7.0 litres/min.
Pump displacement 9.1 cm
3
/rev.
Fluid type Dexron ÌÌÌ
GENERAL DATA
05-21
BRAKES
Front disc brakes:
Rear brakes
Anti-Iock braking system
Type:
1.1, 1.4 & 1.6 'K' series Pin-slider caliper with solid discs
1.8 'K' series Pin-slider caliper with ventilated discs
2.0 'L' series Pin-slider caliper with solid discs
Disc diameter: 262 mm
Disc wear limit (minimum thickness)
Solid disc 11.0 mm
Ventilated disc 19.0 mm
Pad minimum thickness 3.0 mm
Disc run out - max (with wheel on) 0.040 mm
Type:
1.1, 1.4 & 1.6 'K' series Drum brakes
1.8 'K' series Pin-slider caliper with solid discs
2.0 'L' series Drum brakes
Rear disc brakes;
Disc diameter 239 mm
Disc wear limit (minimum thickness) 8.0 mm
Pad minimum thickness 3.0 mm
Rear drum brakes;
Drum inside diameter 203.33 mm
Drum wear limit (maximum diameter) 204 mm
Drum ovality limit 0.012 mm
Lining minimum thickness 2.0 mm
Master cylinder;
Bore diameter 22.21 mm
Brake servo
Servo boost ratio: 4.0 : 1
Handbrake Cable operated on rear drums or discs
System type Bosch ABS 5.3 electronic
ABS sensor to reluctor ring clearance 0.5 mm
GENERAL DATA
05-22
FRONT SUSPENSION
GeneraI
Front coiI spring data
* At unladen weight
NOTE: Spring selection within the categories outlined in the table above is dependent on vehicle specification (e.g.
trim level, with or without air conditioning etc.)
Type Ìndependent, MacPherson strut damper with coil spring and anti-
roll bar.
Nominal height to wheel arch from hub centre * :
R25 386 mm ± 10 mm
MG ZR 366 mm ± 10 mm
Front damper colour codes:
1.1, 1.4, 1.6 & 1.8 'K' series standard suspension Yellow
2.0 'L' series (diesel suspension) Brown
1.8 'K' series sports suspension Blue
Total coils (R25) 5.5
Total coils (MG ZR) 4.5
Wire diameter (R25) 13.95 ± 0.05 mm
Wire diameter (MG ZR) 14.341 ± 0.05 mm
Free length:
1.1, 1.4, 1.6 & 1.8 'K' series (standard suspension)
Green / Grey 356.72 mm
Green / Pink 347.82 mm
Green / Orange 362.99 mm
2.0 'L' series (diesel suspension)
Green / Brown 367.79 mm
Green / Yellow 389.59 mm
Green / Green 376.68 mm
1.8 'K' series sports suspension
Green / Blue 330.8 mm
MG ZR 1.4 & 1.8 'K' series (non VVC)
Blue / Red 277.91 mm
MG ZR 1.8 'K' series (with VVC)
Blue / Blue 284.86 mm
MG ZR 2.0 'L' series (diesel)
Blue / Purple 293.19 mm
Anti-roll bar:
Diameter 25 mm
GENERAL DATA
05-23
REAR SUSPENSION
GeneraI
Road spring data:
* At unladen weight
Type Ìndependent, torsion beam 'H' frame with dampers and coil
springs.
Nominal height to wheel arch from hub centre *:
R25 386 mm ± 10 mm
MG ZR 366 mm ± 10 mm
Damper / spring combinations:
Standard / Diesel damper unit Green / White spring
Sport damper unit Green / Orange spring
Total coils (R25) 8.4
Total coils (MG ZR) 8.0
Wire diameter (R25) 10.5 ± 0.5 mm
Wire diameter (MG ZR) 11.24 ± 0.05 mm
Spring free length:
Green / White 390.71 mm
Green / Orange 370.71 mm
Pink / Pink 343.37 mm
GENERAL DATA
05-24
WHEELS
WheeI type and size:
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.
Steel 5.5J x R14
Alloy 5.5J x R14 (Rough Terrain 'RTS' type)
6.0J x R15
6.5J x R16
7.0J x R17
Space-saver spare (steel) 3.5J x R15
Spare - full-size steel 6.0J x R15
5.5J x R14
GENERAL DATA
05-25
TYRE SIZES
CAUTION: RepIacement tyres fitted to the temporary use spare wheeI must be of the same make and
specification as those originaIIy fitted.
Wheel size:
5.5J x 14 steel wheels 175/65 R14 82T
5.5J x 14 alloy wheels 185/55 R14 86T
6.0J x 15 alloy wheels 185/55 R15 82H
6.5J x 16 alloy wheels 205/45 R16 83V
205/50 R16 87H
7.0J x 17 alloy wheels 205/45 R17 84V
3.5 x 15 space saver wheel T125/80 R15 95M
GENERAL DATA
05-26
TYRE PRESSURES - 1.1, 1.4 & 1.6 'K'
SERIES
NormaI driving conditions
Max. Ioad conditions
High Speed
bar Ibf/in2
175/65 R14 (1.1 & 1.4 only) - Front and rear 2.1 30
185/65 R14 (1.6 only) - Front and rear 1.9 28
185/55 R15 (all models) - Front and rear 2.1 30
205/50 R16 (1.4 only) - Front and rear 1.9 28
205/45 R17 (1.4 only) - Front and rear 1.9 28
bar Ibf/in2
175/65 R14 (1.1 & 1.4 only) - Front and rear 2.1 30
185/65 R14 (1.6 only) - Front and rear 1.9 28
185/55 R15 (all models) - Front and rear 2.2 32
205/50 R16 (1.4 only) - Front and rear 1.9 28
205/45 R17 (1.4 only) - Front and rear 1.9 28
bar Ibf/in2
175/65 R14 (1.1 & 1.4 only) - Front and rear 2.3 33
185/65 R14 (1.6 manual transmission) - Front and rear 2.1 30
185/65 R14 (1.6 automatic transmission) - Front and
rear
2.0 29
185/55 R15 (all models) - Front and rear 2.4 35
205/50 R16 (1.4 only) - Front and rear 1.9 28
205/45 R17 (1.4 only) - Front and rear 1.9 28
GENERAL DATA
05-27
Towing
NormaI driving conditions - up to 4 passengers and luggage
Max. Ioad conditions - car loaded to maximum gross vehicle weight
High Speed - driving at speeds in excess of 100 mph (160 km/h)
bar Ibf/in2
175/65 R14 (1.1 & 1.4 only)
Front 2.1 30
Rear 2.3 34
185/65 R14 (1.6 only)
Front 1.9 28
Rear 2.2 32
185/55 R15 (all models)
Front 2.2 32
Rear 2.5 36
205/50 R16 (1.4 only) - Front and rear 1.9 28
205/45 R17 (1.4 only) - Front and rear 1.9 28
GENERAL DATA
05-28
TYRE PRESSURES - 1.8 'K' SERIES WITH
VVC
NormaI driving conditions
Max. Ioad conditions
High Speed
Towing
NormaI driving conditions - up to 4 passengers and luggage
Max. Ioad conditions - car loaded to maximum gross vehicle weight
High Speed - driving at speeds in excess of 100 mph (160 km/h)
bar Ibf/in2
205/50 R16 OR 205/45 R17 Front and rear 1.9 28
205/45 R17 (160 models only) Front and rear 2.1 30
bar Ibf/in2
205/50 R16 OR 205/45 R17 Front and rear 1.9 28
205/45 R17 (160 models only) Front and rear 2.1 30
bar Ibf/in2
205/50 R16 OR 205/45 R17 Front and rear 1.9 28
205/45 R17 (160 models only) Front and rear 2.1 30
bar Ibf/in2
205/50 R16 OR 205/45 R17 Front and rear 1.9 28
205/45 R17 (160 models only) Front and rear 2.1 30
GENERAL DATA
05-29
TYRE PRESSURES - 1.8 'K' SERIES WITH
EM-CVT
NormaI driving conditions
Max. Ioad conditions
High Speed
bar Ibf/in2
185/65 R14 Front and rear 1.9 28
185/55 R15 Front and rear 2.1 30
205/45 R16 Front and rear 2.1 30
205/50 R16 Front and rear 2.1 30
205/45 R17 Front and rear 2.1 30
bar Ibf/in2
185/65 R14 Front and rear 1.9 28
185/55 R15 Front and rear 2.2 32
205/45 R16 Front and rear 2.1 30
205/50 R16 Front and rear 2.1 30
205/45 R17 Front and rear 2.1 30
bar Ibf/in2
185/65 R14 Front and rear 2.1 30
185/55 R15 Front and rear 2.4 35
205/45 R16
Front 2.4 35
Rear 2.2 32
205/50 R16 Front and rear 2.1 30
205/45 R17 Front and rear 2.1 30
GENERAL DATA
05-30
Towing
NormaI driving conditions - up to 4 passengers and luggage
Max. Ioad conditions - car loaded to maximum gross vehicle weight
High Speed - driving at speeds in excess of 100 mph (160 km/h)
bar Ibf/in2
185/65 R14
Front 1.9 28
Rear 2.2 32
185/55 R15
Front 2.2 32
Rear 2.5 36
205/45 R16
Front 2.1 30
Rear 2.3 34
205/50 R16 Front and rear 2.1 30
205/45 R17 Front and rear 2.1 30
GENERAL DATA
05-31
TYRE PRESSURES - 2.0 'L' SERIES
DIESEL ENGINES
NormaI driving conditions
Max. Ioad conditions
High Speed
bar Ibf/in2
185/65 R14 Front and rear 2.1 30
185/55 R15
Front 2.3 33
Rear 2.1 30
205/50 R16 and 205/45 R17
Front 2.2 32
Rear 1.9 28
bar Ibf/in2
185/65 R14 Front and rear 2.1 30
185/55 R15
Front 2.4 35
Rear 2.2 32
205/50 R16 and 205/45 R17
Front 2.2 32
Rear 1.9 28
bar Ibf/in2
185/65 R14 Front and rear 2.3 33
185/55 R15
Front 2.6 38
Rear 2.4 35
205/50 R16 and 205/45 R17
Front 2.2 32
Rear 1.9 28
GENERAL DATA
05-32
Towing
NormaI driving conditions - up to 4 passengers and luggage
Max. Ioad conditions - car loaded to maximum gross vehicle weight
High Speed - driving at speeds in excess of 100 mph (160 km/h)
bar Ibf/in
185/65 R14
Front 2.1 30
Rear 2.3 34
185/55 R15
Front 2.4 35
Rear 2.5 36
205/50 R16
Front 2.2 32
Rear 1.9 28
205/45 R17
Front 2.3 33
Rear 1.9 28
GENERAL DATA
05-33
AIR CONDITIONING
Type CFC free, sealed, closed loop manual system, incorporating
pressure and temperature sensors
Refrigerant type HFC - R134a
Refrigerant charge quantity
LHD vehicles 640 ± 25 grammes
RHD vehicles 560 ± 25 grammes
Compressor:
Pressure (High side) 35.3 bar (512 lbf/in2)
Pressure (Low side) 16.7 bar (242 lbf/in2)
Displacement (Min.) 5 %
Displacement (Max.) 100 %
Lubricating oil SP10
Oil fill quantity (new) 135 cm
3
GENERAL DATA
05-34
ELECTRICAL - 'K' SERIES
System 12 volt, negative earth
Battery
Type Yuasa H5 (sealed for life)
Capacity 61 Ah
Alternator
Type Bosch
Maximum output
1.1, 1.4 & 1.6 75A
1.8 85A
Starter motor
Type
Manual transmission Bosch
CVT Nippon Denso
Power
1.1 & 1.4 0.8 kW
1.6 0.9 kW
1.8 1.0 kW
GENERAL DATA
05-35
ELECTRICAL - 'L' SERIES
System 12 volt, negative earth
Battery
Type Yuasa H6 (sealed for life)
Capacity 75 Ah
Alternator
Type Nippon Denso
Maximum output 80A
Starter motor
Type Nippon Denso
Power 1.8 kW
GENERAL DATA
05-36
DIMENSIONS - Rover 25
Overall length 3990 mm
Overall width:
Ìncluding mirrors 1931 mm
Excluding mirrors 1688 mm
Overall height (excluding aerial)* 1419 mm
Ground clearance (between axles)* 135 mmm
Wheelbase 2500 mm
Turning circle (kerb to kerb) 11.21 m
Track:
Front 1470 mm
Rear 1457 mm
Overhang
Front 805 mm
Rear 685 mm
* At unladen weight
GENERAL DATA
05-37
DIMENSIONS - MG ZR
Overall length 4011 mm
Overall width:
Ìncluding mirrors 1931 mm
Excluding mirrors 1688 mm
Overall height (excluding aerial)* 1400 mm
Ground clearance (between axles)* 119 mmm
Wheelbase 2500 mm
Turning circle (kerb to kerb) 11.64 m
Track:
Front 1470 mm
Rear 1457 mm
Overhang
Front 819 mm
Rear 692 mm
* At unladen weight
GENERAL DATA
05-38
WEIGHTS
Approximate unIaden (fueI tank 90% fuII)
Maximum gross vehicIe weight:
NOTE: Axle weights are non-additive. The individual maximum weights and gross vehicle weight must not be
exceeded.
Petrol models (manual transmission)
1.1 'K' Series 1020 - 1110 kg
1.4 'K' Series 1020 - 1135 kg
1.6 'K' Series 1030 - 1120 kg
1.8 'K' Series 1030 - 1135 kg
1.8 'K' Series 160 models 1090 - 1145 kg
1.4 VAN models 1000 kg
MG ZR 1.4 VAN models 1015 kg
MG ZR 1.8 VVC VAN models 1070 kg
Petrol models (automatic transmission)
1.6 'K' Series 1045 - 1135 kg
1.8 'K' Series 1060 - 1160 kg
Diesel models
2.0 'L' Series 1130 - 1230 kg
2.0 VAN 1115 kg
MG ZR 2.0 VAN 1125 kg
Petrol Models
1.1, 1.4 & 1.6 'K' Series, - Manual transmission 1500 kg
1.8 'K' Series - Manual transmission 1520 kg
1.6 & 1.8 'K' Series - Automatic transmission 1550 kg
1.4 VAN models (inc MG ZR VAN) 1520 kg
MG ZR 1.8 VVC VAN models 1050 kg
Diesel models (inc. VAN models) 1600 kg
Maximum front axle load
1.1, 1.4 & 1.6 'K' Series - Manual transmission 805 kg
1.8 'K' Series - Manual transmission 830 kg
1.6 & 1.8 'K' Series - Automatic transmission 850 kg
1.4 & 1.8 VVC VAN models (inc. MG ZR VAN) 830 kg
Diesel models (inc. VAN models) 915 kg
Maximum rear axle load (must NOT be exceeded) 750 kg
GENERAL DATA
05-39
TOWING WEIGHTS
* restart on 12% (1 in 8) gradient with two occupants)
Maximum towing weight - braked trailer *
1.1 'K' Series models 700 kg
All other models 1000 kg
Maximum trailer weight (unbraked) 500 kg
Towing hitch downward load (max.) 70 kg
Coupling device maximum overhang:
Fixed coupling 749 mm
Removable coupling 779 mm
Maximum roof rack load (includes weight of rack) 65 kg
Gross train weight (maximum weight of vehicle plus
trailer)
1.1, 1.4 & 1.6 'K' Series - Manual transmission 2500 kg
1.8 'K' Series-Manual transmission 2520 kg
1.6 & 1.8 'K' Series - Automatic transmission 2550 kg
2.0 'L' Series 2600 kg
GENERAL DATA
05-40
TORQUE WRENCH SETTÌNGS
06-1
TORQUE WRENCH SETTÌNGS
ENGINE - 'K' SERIES
Camshaft carrier bolts + 10 Nm
Camshaft cover bolts + 10 Nm
Camshaft timing gear bolts 65 Nm
Camshaft oil seal cover plate bolts:
Ìnlet camshaft 6 Nm
Exhaust camshaft 25 Nm
CMP sensor bolt 5 Nm
Timing belt top cover screws 5 Nm
Timing belt lower cover screws 9 Nm
Crankshaft pulley bolt 205 Nm
Cylinder head bolts:
1st stage + 20 Nm
2nd stage + a further 180°
3rd stage + a final 180°
Dipstick tube to cylinder block/bearing ladder 9 Nm
Drive belt tensioner to steering pump bracket 25 Nm
Hydramount/Restraint bar to RH mounting bodybracket nuts 45 Nm
Engine lifting bracket bolts 9 Nm
Engine torsion bar bolts 25 Nm
Flywheel to crankshaft bolts + * 80 Nm
Flywheel lower cover bolts 9 Nm
LH mounting bracket to body bolts 55 Nm
LH mounting bracket to gearbox bracket bolts 100 Nm
LH mounting bracket to gearbox bracket nut - automatic models 160 Nm
LH mounting through bolt - manual models 85 Nm
LH mounting to bracket nuts 45 Nm
Lower engine steady to subframe bolt 80 Nm
Lower engine steady to sump bolt 45 Nm
Oil pressure switch 17 Nm
Oil pump to block bolts + * 10 Nm
RH mounting body bracket to body bolts 25 Nm
RH mounting engine bracket to engine bolts 135 Nm
RH mounting engine bracket to hydramount nut 85 Nm
Sump drain plug 28 Nm
TORQUE WRENCH SETTÌNGS
06-2
Sump to bearing ladder +:
Short bolts 25 Nm
Long bolts 30 Nm
Timing belt rear cover bolts 9 Nm
Timing belt tensioner to cylinder head:
Non VVC * 25 Nm
VVC 45 Nm
Torsion damper to flywheel bolts 22 Nm
Torsion bar bolts 25 Nm
Upper engine steady bolts 85 Nm
VVC housings to cylinder head and camshaft carrier* 10 Nm
VVC hydraulic control unit solenoid nut 12 Nm
VVC hydraulic control unit spool valve nut 26 Nm
VVC hydraulic control unit to camshaft carrier 25 Nm
VVC hydraulic control unit oil temperature sensor 17 Nm
+ Tighten in sequence
* Fit new bolts
TORQUE WRENCH SETTÌNGS
06-3
ENGINE - 'L' SERIES
Camshaft carrier bolts 11 Nm
Camshaft cover bolts 11 Nm
Camshaft drive gear bolt * 20 Nm then further 90°
Camshaft drive gear damper screws * 10 Nm
Crankshaft pulley bolt 63 Nm then further 90°
Crankshaft rear oil seal housing bolts + 8 Nm
Cylinder head bolts:
First stage + 30 Nm
Second stage + 65 Nm
Third stage + a further 90°
Fourth stage + a final 90°
Dipstick tube to coolant elbow bolt 25 Nm
Flywheel to crankshaft bolts + * 15 Nm then further 90°
Fuel injection pump belt cover bolts 5 Nm
Fuel injection pump belt drive gear bolts 25 Nm
Fuel injection pump belt drive hub bolt * 20 Nm then further 90°
Fuel injection pump belt tensioner bolt 44 Nm
Fuel injection pump backplate bolts 8 Nm
Fuel spill return pipes to injectors 10 Nm
Hydramount/Restraint bar to RH mounting body bracket nuts 45 Nm
LH mounting bracket to body bolts 55 Nm
LH mounting bracket to gearbox bracket bolts 100 Nm
LH mounting through bolt 85 Nm
Lower engine steady bolts 85 Nm
Lower engine steady bracket to sump bolts 85 Nm
Oil cooler pipe clamp bolts 9 Nm
Oil cooler pipe unions 25 Nm
Oil cooler to block:
M8 bolts 25 Nm
M10 bolts 45 Nm
Oil filter 17 Nm
Oil pressure relief valve nut 25 Nm
Oil pressure switch 15 Nm
Oil pump pipe unions 25 Nm
Oil pump to block:
M6 bolts + 10 Nm
M10 bolts + 45 Nm
TORQUE WRENCH SETTÌNGS
06-4
RH engine mounting plate
Nuts 30 Nm then 120°
Bolts 45 Nm
RH mounting body bracket to body bolts 25 Nm
RH mounting engine bracket to engine bolts 100 Nm
RH mounting engine bracket to hydramount nut 85 Nm
Sump bolts + 25 Nm
Sump drain plug 25 Nm
Timing belt front cover bolts 5 Nm
Timing belt rear cover bolts 9 Nm
Timing belt tensioner pivot bolt 45 Nm
Timing belt tensioner pulley bolt * 55 Nm
Torsion link outer nuts 25 Nm
Upper engine steady bolts 85 Nm
+ Tighten in sequence
* Fit new bolts
TORQUE WRENCH SETTÌNGS
06-5
ENGINE MANAGEMENT SYSTEM - MEMS
Air cleaner to battery tray bolts 9 Nm
Air intake resonator to battery tray bolts 9 Nm
Camshaft position sensor (CMP) bolt: 5 Nm
Crankshaft position sensor bolt 6 Nm
ECM to bracket nuts 4 Nm
Engine coolant temperature sensor 15 Nm
Expansion tank to body bolts 9 Nm
Fuel rail to manifold bolts 9 Nm
Fuel feed pipe to fuel rail bolts - VVC 5 Nm
Heated oxygen sensors 55 Nm
Ìdle air control valve to inlet manifold Torx screws 6 Nm
Ìntake air temperature sensor to inlet manifold 7 Nm
Manifold absolute pressure sensor Torx screws 3 Nm
Oil temperature sensor 17 Nm
Plug top coils to camshaft cover 9 Nm
Spark plug/coil cover to camshaft cover 9 Nm
Spark plugs to cylinder head 25 Nm
Throttle body to inlet manifold bolts + 9 Nm
Throttle position sensor to housing Torx screws 1.5 Nm
+ Tighten in sequence
TORQUE WRENCH SETTÌNGS
06-6
ENGINE MANAGEMENT SYSTEM - EDC
Crankshaft position sensor 9 Nm
ECM clamp bolts 5 Nm
Engine Coolant Temperature (ECT) sensor 14 Nm
Exhaust Gas Recirculation (EGR):
EGR cooler to EGR pipe 25 Nm
EGR cooler to EGR valve 25 Nm
EGR valve to exhaust manifold 25 Nm
EGR pipe to inlet plenum bolts 9 Nm
Fuel injector clamp plate bolt 23 Nm
Fuel injector pipe to injector union 28 Nm
Fuel injector pipe to pump union 28 Nm
Fuel injector spill return banjo bolt 10 Nm
Fuel injection pump adapter bracket bolts 10 Nm
Fuel injection pump drive gear Torx bolts 20 Nm
Fuel injection pump feed/return banjo bolts 25 Nm
Fuel injection pump to gearbox nut/bolts 25 Nm
Fuel injection pump support bracket nuts/bolts 25 Nm
Glow plug 20 Nm
Glow plug lead terminal nut 2.5 Nm
Ìntercooler to bonnet locking platform bolt 9 Nm
Ìntercooler to radiator bolts 25 Nm
Manifold absolute pressure sensor bolt 9 Nm
Oil drain tube to turbocharger nuts 10 Nm
Oil feed/return pipe to turbocharger nuts 20 Nm
Throttle position sensor bracket to body bolts 10 Nm
Throttle position sensor to bracket nuts 4 Nm
Turbocharger outlet pipe to cylinder head bolts:
M6 10 Nm
M8 25 Nm
Turbocharger oil drain pipe flange bolts 10 Nm
Turbocharger oil drain pipe union nut 20 Nm
Turbocharger oil feed pipe banjo bolt 20 Nm
Turbocharger support bracket to engine bolts 25 Nm
Turbocharger support bracket to turbocharger bolts 25 Nm
Turbocharger to exhaust manifold nuts * 25 Nm
* Fit new bolts
TORQUE WRENCH SETTÌNGS
06-7
FUEL DELIVERY SYSTEM
'K' Series
Fuel filter bracket to bulkhead 10 Nm
Fuel filter union, inlet/outlet 28 Nm
Fuel pump to tank nuts 9 Nm
Ìnertia fuel shut-off switch 2 Nm
TORQUE WRENCH SETTÌNGS
06-8
COOLING
'K' Series
'L' Series
Bleed screw to coolant rail 9 Nm
Coolant pump to cylinder block bolts 10 Nm
Coolant rail to cylinder block bolts 25 Nm
Cooling fan housing to radiator nuts 9 Nm
Expansion tank to body bolts 5 Nm
Radiator to bonnet locking platform bolt 9 Nm
Thermostat housing cover bolts 9 Nm
Thermostat housing to cylinder block bolt 10 Nm
Coolant pump and cover to housing bolts 10 Nm
Coolant pump housing bolts 45 Nm
Cooling fan housing to radiator bolt 9 Nm
Expansion tank to body bolts 5 Nm
Radiator to bonnet locking platform bolt 9 Nm
Thermostat housing to oil cooler housing bolts 10 Nm
TORQUE WRENCH SETTÌNGS
06-9
MANIFOLD AND EXHAUST
GeneraI
'K' Series
'L' Series
Underfloor heat shield fixing bolts 6 Nm
Exhaust manifold to cylinder head nuts + 45 Nm
Front pipe to manifold nuts 45 Nm
Ìnlet manifold to cylinder head nuts/bolts:
Non VVC 17 Nm
VVC 25 Nm
Ìntermediate pipe to front pipe nuts 45 Nm
Support strut to inlet manifold bolt 25 Nm
Support strut to cylinder block bolt 45 Nm
Tail pipe to intermediate pipe nuts 45 Nm
Catalytic converter to front pipe nuts 50 Nm
Exhaust/Ìnlet manifold to cylinder head:
Bolts + 33 Nm
Nuts + 25 Nm
Exhaust manifold support bracket bolt 25 Nm
Front pipe to manifold nuts 50 Nm
Ìntermediate pipe to catalytic converter nuts 50 Nm
Plenum chamber to inlet manifold bolts 25 Nm
Plenum chamber to camshaft cover bracket bolt 9 Nm
Tail pipe to intermediate pipe nuts 50 Nm
Turbocharger oil drain pipe bolts 10 Nm
Turbocharger oil drain pipe union nut 20 Nm
Turbocharger oil feed banjo bolt 20 Nm
Turbocharger outlet pipe to cylinder head bolts:
M6 10 Nm
M8 25 Nm
Turbocharger to exhaust manifold nuts 25 Nm
TORQUE WRENCH SETTÌNGS
06-10
CLUTCH
'K' Series
'L' Series
Pressure plate to flywheel Torx bolts: +
1.1, 1.4 and 1.6 18 Nm
1.8 26 Nm
+ Tighten in sequence
Pressure plate to flywheel Torx bolts + 26 Nm
Release fork to shaft 29 Nm
+ Tighten in sequence
TORQUE WRENCH SETTÌNGS
06-11
MANUAL GEARBOX - R65
Drain plug 25 Nm
Engine steady bar to gearbox bolts 25 Nm
Filler/Level plug 25 Nm
Flywheel front cover plate bolts 9 Nm
Flywheel rear cover plate bolt 9 Nm
Gear selector mounting to body bolts 22 Nm
Gearchange linkage to rear beam bolts 24 Nm
Gearbox mounting bracket to engine mounting bolts 60 Nm
Gearbox to engine sump bolts 45 Nm
Gearbox mounting through bolt 85 Nm
Gearbox to engine bolts + 85 Nm
LH engine mounting to body bolts 55 Nm
Reverse light switch 25 Nm
TORQUE WRENCH SETTÌNGS
06-12
MANUAL GEARBOX - PG1
Drain plug 45 Nm
Earth lead to gearbox bolt 25 Nm
Engine to differential bolt 85 Nm
Filler/level plug 40 Nm
Front closing plate nuts and bolts 85 Nm
Gear selector mounting to body bolts 22 Nm
Gearbox lifting eye bolt 45 Nm
Gearbox mounting bracket to gearbox bolts 60 Nm
Gearbox to engine sump bolts 45 Nm
Gearbox to engine/mounting plate nuts and bolts + 85 Nm
Gearchange steady bar to gearbox 10 Nm
LH mounting to body bracket through bolt 85 Nm
LH engine mounting to gearbox bolts 100 Nm
Reverse light switch 25 Nm
Torsion bar to gearbox nut and bolt 25 Nm
+ Tighten in sequence
TORQUE WRENCH SETTÌNGS
06-13
AUTOMATIC GEARBOX - EMCVT
Dipstick tube retaining bolt 25 Nm
Drain plug 30 Nm
Connecting rod to selector lever nut 6 Nm
Earth lead bolt 25 Nm
Fluid cooler unions to gearbox 14 Nm
Fluid pan bolts + 10 Nm
Fluid pump bolts + 10 Nm
Flywheel cover plate bolts 9 Nm
Gear selector lever assembly to body 10 Nm
Gearbox differential speed sensor bolt 9 Nm
Gearbox mounting to gearbox 48 Nm
Gearbox mounting bracket to engine mounting nut 180 Nm
Gearbox to engine + 80 Nm
Hydraulic control unit mounting bolts 10 Nm
Pitot tube 10 Nm
Primary cover bolts 10 Nm
Ratio control motor harness connector nut 9 Nm
Road speed transducer retaining bolt 12 Nm
Secondary cover bolts 10 Nm
Selector cable bracket to gearbox 25 Nm
Selector lever to selector shaft nut 8 Nm
Selector quadrant detent lever bolt 10 Nm
Selector valve bolts 10 Nm
Starter inhibitor/reverse switch 12 Nm
TORQUE WRENCH SETTÌNGS
06-14
DRIVE SHAFTS
Drive shaft nut * 180 Nm
+ Tighten in sequence
* Fit new nut
TORQUE WRENCH SETTÌNGS
06-15
STEERING
GeneraI
'K' Series
'L' Series
Steering arm ball joint nut 45 Nm
Steering column lower clamp bolt/nut 22 Nm
Steering column universal joint bolts 28 Nm
Steering column upper bracket bolts/nuts 15 Nm
Steering pipe clip 9 Nm
Steering rack clamp bolts 38 Nm
Steering rack feed pipe union 37 Nm
Steering rack pinion flange bolts 58 Nm
Steering rack return pipe union 28 Nm
Steering wheel nut 50 Nm
Track-rod end locknut 45 Nm
PAS pump drive belt tensioner bolts 25 Nm
PAS pump outlet hose union 20 Nm
PAS pump pulley bolts 9 Nm
PAS pump to mounting bracket nuts and bolts 25 Nm
High pressure hose union to PAS pump 20 Nm
PAS pump oil feed flange bolts 10 Nm
PAS pump pulley bolts * 10 Nm
PAS pump to coolant pump bolts 25 Nm
PAS pump to mounting bracket bolts 25 Nm
* Fit new bolts
TORQUE WRENCH SETTÌNGS
06-16
SUSPENSION
GeneraI
Front Suspension
Rear Suspension
Road wheel nuts + 110 Nm
+ Tighten in sequence
Anti-roll bar clamp to rear beam bolts 22 Nm
Anti-roll bar link to lower arm bolt 60 Nm
Anti-roll bar to link bolt 45 Nm
Damper shaft nut 40 Nm
Damper to hub clamp bolt1 80 Nm
Damper top mounting nuts1 30 Nm
Front beam to body bolts 100 Nm
Lower arm ball joint nut 55 Nm
Lower arm to rear beam pivot bolt1 60 Nm
Rear beam to body bolts 100 Nm
Tie-rod to lower arm bolts 80 Nm
Tie-rod to front beam nut 45 Nm
1 Tighten with weight of vehicle on suspension
Damper mounting plate nuts1 38 Nm
Damper to 'H' frame bolt1 80 Nm
Damper to mounting plate, self locking nut 29 Nm
'H' frame pivot bush bolt 100 Nm
'H' frame to body bolts 100 Nm
Hub shaft nut * 185 Nm
Stub axle to 'H' frame bolts 45 Nm
+ Tighten in sequence
* Fit new nut
1 Tighten with weight of vehicle on suspension
TORQUE WRENCH SETTÌNGS
06-17
BRAKES
GeneraI
ABS ECU to modulator screws 8 Nm
ABS front sensor harness bracket bolts 10 Nm
ABS front sensor bolt 6 Nm
ABS modulator mounting nuts 21 Nm
ABS modulator pipe unions 14 Nm
ABS rear sensor adapter bolts:
Disc brakes 10 Nm
Drum brakes 45 Nm
ABS rear sensor harness bracket bolts 10 Nm
ABS rear sensor to adapter bolt (disc brakes) 6 Nm
Bleed screw - calipers 10 Nm
Brake hose support bracket bolt 25 Nm
Brake proportioning valve bracket nuts 10 Nm
Brake proportioning valve pipe unions 19 Nm
Brake servo to bulkhead nuts 13 Nm
Front caliper banjo bolt 34 Nm
Front caliper guide pin bolts 27 Nm
Front caliper mounting bolts 108 Nm
Front disc shield bolts 9 Nm
Front disc to drive flange screws 5 Nm
Handbrake cable brackets bolts 22 Nm
Handbrake cable retaining plate to back plate bolts 22 Nm
Handbrake lever to body bolts 22 Nm
Handbrake switch to handbrake screw 5 Nm
Master cylinder to servo nuts 15 Nm
Pipe unions to master cylinder 19 Nm
Rear caliper banjo bolt 34 Nm
Rear caliper guide pin bolts 27 Nm
Rear caliper mounting bolts 108 Nm
Rear disc shield bolts 10 Nm
Rear disc to hub screws 10 Nm
TORQUE WRENCH SETTÌNGS
06-18
'L' Series
Rear drum brakes
Brake servo vacuum pipe to camshaft cover bolt 9 Nm
Vacuum adaptor to pump 25 Nm
Vacuum oil feed pipe to pump union 12 Nm
Vacuum pump to alternator bolts 8 Nm
Back plate to 'H' stub axle 45 Nm
Bleed screw - rear wheel cylinder 7 Nm
Brake hose bracket to trailing arm bolt 22 Nm
Rear brake drum to hub screws 7 Nm
Rear wheel cylinder pipe union 19 Nm
Rear wheel cylinder to backplate bolts 8 Nm
TORQUE WRENCH SETTÌNGS
06-19
RESTRAINT SYSTEMS
Driver's airbag module Torx screws 9 Nm
Passenger's airbag module to fascia screws 9 Nm
Passenger's airbag support bracket bolt 9 Nm
Diagnostic and Control Unit (DCU) bolts 9 Nm
TORQUE WRENCH SETTÌNGS
06-20
BODY
Doors
Exterior fittings
Interior trim
Door glass channel bolts 8 Nm
Door glass regulator roller guide 8 Nm
Door glass regulator to door bolts 9 Nm
Door glass regulator to motor screws 7 Nm
Door glass to regulator bolts 9 Nm
Door latch to door screws 6 Nm
Door lock motor screws 7 Nm
Door lock striker to body screws 18 Nm
Door lock to outside handle bolt 9 Nm
Door outside handle bolts 9 Nm
Front door glass rear channel bolts 8 Nm
Rear door upper rear glass channel nuts 8 Nm
Tailgate hinges to body nuts 22 Nm
Tailgate latch to tailgate screws 7 Nm
Tailgate lock motor screws 9 Nm
Tailgate lock striker to body screws 9 Nm
Applique to tailgate screws 2 Nm
Bonnet hinge bolts 9 Nm
Bonnet lock to body bolts 10 Nm
Bonnet locking platform support bracket bolts 9 Nm
Front bumper armature to body 10 Nm
Front bumper to bonnet locking platform screws 3 Nm
Rear bumper to body bolts 6 Nm
Rubbing strip to door nuts 0.5 Nm
Splash shield to body bolts 5 Nm
Tailgate spoiler to tailgate bolts 6 Nm
Undertray bolts and nuts 10 Nm
Bonnet release handle bolts 10 Nm
Fascia mounting bolts 9 Nm
Fascia rail bolts:
M6 10 Nm
M8 20 Nm
Fascia support panel to body bolts 20 Nm
Glovebox to fascia screws 10 Nm
Rear console screws 3 Nm
TORQUE WRENCH SETTÌNGS
06-21
Seats and seat beIts
Screens
Centre rear seat belt reel to seat frame bolt 50 Nm
Front seat belt floor guide to sill bolt 50 Nm
Front seat belt lower anchorage bolt 50 Nm
Front seat belt upper anchorage to 'B' post bolt 50 Nm
Front seat belt pretensioner to seat bolt 30 Nm
Front seat belt reel to 'B' post bolt 50 Nm
Front seat belt runner to floor bolts 34 Nm
Outer rear seat belt lower anchorage bolt 50 Nm
Outer rear seat belt reel locating bolt 10 Nm
Outer rear seat belt reel to squab bolt 50 Nm
Outer rear seat belt stalk to floor bolt 50 Nm
Outer rear seat belt upper anchorage bolt 50 Nm
Rear seat cushion to floor bolts 10 Nm
Hinged rear quarter glass to body nuts 9 Nm
Hinged rear quarter glass latch to body screws 4 Nm
Sunroof glass to frame screws 5 Nm
Sunroof motor bolts 9 Nm
Sunroof to body bolts 9 Nm
TORQUE WRENCH SETTÌNGS
06-22
HEATING AND VENTILATION
Blower motor screws 9 Nm
Heater unit to bulkhead nuts 22 Nm
TORQUE WRENCH SETTÌNGS
06-23
AIR CONDITIONING
Compressor to mounting bracket bolts 25 Nm
Condenser cooling fan housing to condenser bolts 9 Nm
Condenser cooling fan support bracket bolts 9 Nm
Condenser cooling fan to housing nuts 9 Nm
Cooling fan relay module to body bolt 9 Nm
Evaporator casing to bulkhead nuts 10 Nm
Pipe to alternator bracket bolt 10 Nm
Pipe to compressor bolt 35 Nm
Pipe to condenser bolts 6 Nm
Pipe to evaporator bolt 10 Nm
Pipe to receiver/drier bolts 6 Nm
Pipe to thermostatic expansion valve bolt 6 Nm
Receiver/drier mounting bracket to body bolts 10 Nm
Refrigerant pressure sensor 12 Nm
Thermostatic expansion valve to evaporator pipe bolts 9 Nm
TORQUE WRENCH SETTÌNGS
06-24
WIPERS AND WASHERS
Rear wiper arm nut 10 Nm
Rear wiper motor bolts 8 Nm
Rear wiper motor spindle nut 2 Nm
Windscreen wiper arm nut 10 Nm
Windscreen wiper motor bolts 5 Nm
Windscreen wiper motor linkage to motor nut 10 Nm
Windscreen wiper motor linkage to body bolts 10 Nm
TORQUE WRENCH SETTÌNGS
06-25
ELECTRICAL
GeneraI
'K' Series
'L' Series
Battery tray to body bolts 10 Nm
Earth lead to body bolt 9 Nm
Headlamp to body bolts 5 Nm
Horn bracket to body nut 5 Nm
Horn to bracket nut 10 Nm
Engine compartment fusebox to body bolts 10 Nm
Passenger compartment fusebox to body bolts 10 Nm
Starter switch:
Lower clamp bolts 22 Nm
Top bracket nuts 16 Nm
Alternator mounting bracket to engine bolt/nut 25 Nm
Alternator pulley nut 25 Nm
Alternator to mounting bracket nuts/bolts:
Models without A/C 25 Nm
Models with A/C 45 Nm
Battery cable to alternator nut 8 Nm
Drive belt tensioner bolt 25 Nm
Starter motor support bracket nuts 25 Nm
Starter motor bolts:
1.6 and 1.8 automatic 25 Nm
1.4 and 1.6 manual 45 Nm
1.8 manual 85 Nm
Alternator lower fixing nut and bolt 45 Nm
Alternator mounting bracket to coolant elbow bolts 25 Nm
Alternator upper fixing bolt 25 Nm
Auxiliary drive belt idler pulley bolts - non A/C 25 Nm
Auxiliary drive belt tensioner bolt 45 Nm
Battery cable to alternator stud 4 Nm
Starter motor bolts 80 Nm
TORQUE WRENCH SETTÌNGS
06-26
INSTRUMENTS
Engine coolant temperature sensor
'K' Series 17 Nm
'L' Series 14 Nm
Speedometer pinion housing to gearbox 9 Nm
CAPACÌTÌES, FLUÌDS AND LUBRÌCANTS
09-1
CAPACÌTÌES, FLUÌDS AND LUBRÌCANTS
CAPACITIES
The following capacities are only an approximation of the amount of fluid required to fill the respective system.
* Refill capacity is approx. 0.7 litre less than the fill from
dry figures.
Fuel tank 50 litres
Engine oil refill and filter change:
1.1, 1.4, 1.6 & 1.8 'K' Series 4.5 litres
2.0 'L' Series 4.5 litres
Engine oil refill from dry:
1.1, 1.4, 1.6 & 1.8 'K' Series 4.8 litres
2.0 'L' Series 4.9 litres
Manual gearbox - R65
Refill 1.8 litres
From dry 2.0 litres
Manual gearbox - PG1
Refill 2.0 litres
From dry 2.2 litres
Stepspeed (EM-CVT) Gearbox:
v Refill - Gearbox only 4.5 litres
Fill from dry 5.0 litres
Power steering 0.3 litre
Cooling system fill from dry: *
1.1, 1.4, 1.6 & 1.8 'K' Series 5.5 litres
2.0 'L' Series 7.0 litres
Washer reservoir 6.5 litres
CAPACÌTÌES, FLUÌDS AND LUBRÌCANTS
09-2
FUEL REQUIREMENTS
Vehicles equipped with a catalytic converter are
designed to use ONLY unleaded fuel. Unleaded fuel
must be used for the emission control system to
operate properly. Ìts use will also reduce spark plug
fouling, exhaust system corrosion and engine oil
deterioration.
Using fuel that contains lead will result in damage to
the emission control system and could result in loss of
warranty coverage. The effectiveness of the catalysts
in the catalytic converters will be seriously impaired if
leaded fuel is used. The vehicle is equipped with an
engine management system including HO
2
sensors.
The use of leaded fuel will damage the HO
2
sensors
and cause deterioration of the emission control
system.
Regulations require that pumps delivering unleaded
fuel be labelled UNLEADED. Only these pumps have
nozzles which fit the filler neck of the vehicle fuel tank.
RECOMMENDED FUEL
Always use the following recommended fuels:
PetroI engines
Use unleaded petrol with a minimum octane rating of
95 RON to EN 228 specification.
CAUTION: Using fueI with an octane rating Iower
than stated above couId seriousIy impair vehicIe
performance.
Ìn an emergency (and only if the correct fuel is
unavailable), lower octane rated fuel can be used for
very limited periods of moderate, low speed motoring,
provided engine 'knocking' does not occur.
Fuels of 90 RON is used in some markets. 90 RON
fuels can be used if the engine has been tuned
specifically to suit low octane fuel.
Leaded fuels (90 RON minimum) are used in some
markets for vehicles WÌTHOUT catalytic converters.
DieseI engines
Use diesel fuel conforming to European standard EN
590; minimum cetane No. 45
NOTE: It is important that the sulphur content of diesel
fuel does not exceed 0.3%
Ensure the fuel filter element is changed at the
recommended service intervals.
AIternative fueIs and additives
Ìn the interests of optimum vehicle performance, the
use of oxygenated fuels such as blends of methanol/
gasoline (e.g. 'Gasohol') is not recommended. Ìf
oxygenated fuels are to be used, be aware of the
maximum limits for the percentage of fuel additive that
is allowed in the relevant market.
European specification (EN228):
CAUTION: Take care not to spiII fueI during
refueIIing.
Methyl Tertiary Butyl Ether (MTBE) 15%
Ethyl Tertiary Butyl Ether (ETBE) 15%
Ethanol (Ethyl or grain alcohol) 5%
Methanol with co-solvents 3%
CAPACÌTÌES, FLUÌDS AND LUBRÌCANTS
09-3
FLUIDS
Brake FIuid
Use only AP New Premium Super DOT 4 brake fluid or
Castrol Universal DOT 4 brake/clutch fluid. DO NOT
use any other type of fluid.
PAS fIuid
Use fluid to Dexron ÌÌD specification.
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 are maintained. Anti-freeze
concentrations greater than 70% are not
recommended as cooling efficiency will be impaired.
Use UNIPART (Organic Acid TechnoIogy) OAT
Anti-freeze and Summer CooIant mixed with the
appropriate amount of water to protect the cooling
system.
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.
CAUTION: No other 'universaI' anti-freeze shouId
be used with UNIPART OAT.
Ìf UNIPART OAT LongIife Anti-freeze and Summer
CooIant is not available, use an ethylene glycol based
anti-freeze (containing no methanol) with OAT
corrosion inhibitors.
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.
ANTI-FREEZE CONCENTRATION
The overall anti-freeze concentration should not fall, by
volume, below 50% to ensure that the anti-corrosion
properties of the coolant are maintained. Anti-freeze
concentrations greater than 60% are not
recommended as cooling efficiency will be impaired.
The following recommended quantities of anti-freeze
will provide frost protection to -48°C (-53°F):
Engine - K- Series
Engine - L-Series
Concentration 50%
Amount of Anti-freeze 2.7 litres
Concentration 50%
Amount of Anti-freeze 3.5 litres
CAPACÌTÌES, FLUÌDS AND LUBRÌCANTS
09-4
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
PetroI vehicIes
Use a 10W/40 oil meeting specification ACEA A2 or
A3, and having a viscosity band recommended for the
temperature range of your locality. Where oils to these
Rover and European specifications are not available,
well known brands of oils meeting APÌ SH or SJ quality
should be used.
Alternatively, a 10W/40 engine oil meeting
specification ACEA A1 can be used, and this
specification may improve fuel economy.
CAPACÌTÌES, FLUÌDS AND LUBRÌCANTS
09-5
DieseI vehicIes
Use a 10W/40 or 15W/40 oil meeting specification
ACEA A3 and ACEA B3 and having a viscosity band
recommended for the temperature range of your
locality.
ManuaI gearbox - R65
Use the following oils for refill or topping-up:
ESSO Gear oil BV 75W/80W, MOBÌL Mobilube 1 SHC,
SHELL SF5288 75W/80W, UNÌPART Gear oil BV
75W/80W
The following oils may be used for topping-up only:
BP Hypogear TL 75W/80W, CASTROL EPX 75W/
80W, DUCKHAMS Hypoid PT 75W/80W
ManuaI gearbox - PG1
Use the following oils for refill or topping-up:
TEXACO MTF 94, UNÌPART MTF 94, Caltex MTF94
The following oils may be used for topping-up only:
Automatic gearbox - EM-CVT
Use the following oils for refill or topping-up: ESSO
EZL799 CVT Fluid, UNÌPART CVT Fluid
Gear Iinkage
Use grease Part No. AFU 1500 containing 3%
Molybdenum Disulphide.
GeneraI Greasing
Use Multipurpose Lithium Base Grease NLGÌ
consistency No. 2.
Bonnet Iatch
Lubricate cable and latch with oil.
Locks, Latches and Hinges
Use Door Lock and Latch Lubricant, Part No. CYL
100020.
CAPACÌTÌES, FLUÌDS AND LUBRÌCANTS
09-6
MAÌNTENANCE
MAÌNTENANCE 10-1
MAÌNTENANCE MAÌNTENANCE
UNDERBONNET LOCATIONS - 'K16'
(except 1.8 with VVC)
1 Brake fluid reservoir (RHD shown)
2 Fuel filter
3 Coolant expansion tank (RHD shown)
4 Engine compartment fusebox
5 Battery
6 Air cleaner
7 Engine oil filler cap
8 Crankcase ventilation hoses
9 Windscreen and rear screen washers reservoir
10 Power assisted steering reservoir
11 Engine oil dipstick
12 EM-CVT gearbox oil dipstick (Ìf fitted)
MAÌNTENANCE
10-2 MAÌNTENANCE
UNDERBONNET LOCATIONS - 'K16 (1.8
with VVC)'
1 Brake fluid reservoir (RHD shown)
2 Fuel filter
3 Coolant expansion tank (RHD shown)
4 Engine compartment fusebox
5 Battery
6 Air cleaner
7 Engine oil filler cap
8 Crankcase ventilation hoses
9 Windscreen and rear screen washers reservoir
10 Power assisted steering reservoir
11 Engine oil dipstick
MAÌNTENANCE
MAÌNTENANCE 10-3
UNDERBONNET LOCATIONS - 'L' SERIES
1 Brake fluid reservoir (RHD shown)
2 Hand operated primer
3 Fuel filter
4 Coolant expansion tank and cap (RHD shown)
5 Engine compartment fusebox
6 Battery
7 Air cleaner
8 Engine oil dipstick
9 Windscreen and rear screen washers reservoir
10 Power assisted steering reservoir
11 Engine oil filler cap
MAÌNTENANCE
10-4 MAÌNTENANCE
CHECK ENGINE AND TRANSMISSION
Check
1. Visually inspect for oil leaks from engine and
transmission, pay particular attention to areas of
gaskets and seals.
ENGINE OIL AND FILTER - 'K' SERIES
OiI IeveI check
1. Always check oil level and drain oil with vehicle
standing on level ground and use 10W/40 engine
oil to specification ACEA A2 (for temperature
range -20°C to 30°C) for topping up and refilling.
2. Withdraw dipstick and wipe blade. Re-insert
dipstick fully, withdraw it and check oil level which
must be maintained between minimum mark and
maximum mark on dipstick.
3. Ìf required, remove filler cap and top-up with new
10W/40 engine oil to specification ACEA A2 (for
temperature range -20°C to 30°C). See
INFORMATION, Capacities, FIuids and
Lubricants.
MAÌNTENANCE
MAÌNTENANCE 10-5
OiI drain and refiII
1. 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 oil as the oil can be very hot.
Prolonged and repeated contact with used
engine oil may cause serious skin disorders,
wash thoroughly after contact. Keep out of
reach of children.
2. Place a container under sump.
3. Remove drain plug and sealing washer, allow oil
to drain.
4. Clean the drain plug, fit new sealing washer and
refit drain plug. Tighten to 28 Nm.
5. Remove filler cap, refill with new 10W/40 engine
oil to specification ACEA A2 (for temperature
range -20°C to 30°C). Re-check oil level.
OiI fiIter renewaI
1. For information on replacement of the oil filter
refer to one of the following engine sections:
'K16' models: See ENGINE - 'K16', Repairs.
'K16 with VVC' models: See ENGINE - 'K16 with
VVC', Repairs.
ENGINE OIL AND FILTER - 'L' SERIES
OiI IeveI check
1. Always check oil level and drain oil with vehicle
standing on level ground and use 10W/40 or
15W/40 engine oil of specification ACEA B2 (for
temperature range -20°C to 30°C) for topping up
and refilling.
2. Withdraw dipstick and wipe blade. Re-insert
dipstick fully, withdraw it and check oil level which
must be maintained between minimum and
maximum marks on dipstick.
3. Ìf required, remove filler cap and top-up with new
10W/40 or 15W/40 engine oil to specification
ACEA B2 (for temperature range -20°C to 30°C).
See INFORMATION, Capacities, FIuids and
Lubricants.
OiI drain and refiII
1. 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 oil as the oil can be very hot.
Prolonged and repeated contact with used
engine oil may cause serious skin disorders,
wash thoroughly after contact. Keep out of
reach of children.
2. Raise front of vehicle.
WARNING: Support on safety stands.
MAÌNTENANCE
10-6 MAÌNTENANCE
3. Remove 2 bolts securing undertray to front beam.
4. Remove 2 nuts securing undertray to rear beam.
5. Release and remove undertray.
6. Place a container under sump.
7. Remove drain plug and sealing washer, allow oil
to drain.
8. Clean drain plug, fit new sealing washer and refit
drain plug. Tighten to 25 Nm.
9. Position undertray and locate on studs on rear
beam.
10. Fit nuts securing undertray to rear beam and
tighten to 10 Nm.
11. Fit bolts securing undertray to front beam and
tighten to 10 Nm.
12. Remove stand(s) and lower vehicle.
13. Remove filler cap, refill with new 10W/40 or 15W/
40 engine oil to specification ACEA B2 (for
temperature range -20°C to +30°C). Re-check oil
level.
CAUTION: Do not fiII oiI IeveI above the 'MAX'
mark on dipstick.
14. Start and run engine and check for oil leaks.
15. Stop engine, wait a few minutes, then check oil
level and top up if necessary.
CAUTION: Ensure oiI does not drop onto the
aIternator when extracting the dipstick.
OiI fiIter renewaI
1. For information on replacement of the oil filter
refer to the engine section. See ENGINE - 'L'
Series, Repairs.
MAÌNTENANCE
MAÌNTENANCE 10-7
CRANKCASE VENT HOSES - 'K' SERIES
Check
Without VVC shown, VVC similar
1. Check crankcase ventilation hoses for signs of
splitting and general condition.
2. Check hoses are routed correctly, secure and
serviceable.
CRANKCASE PRESSURE LIMITER VALVE
- 'L' SERIES
Check
1. Check hoses for signs of splitting and general
condition.
2. Check valve connections are secure.
3. Check hoses are routed correctly, secure and
serviceable.
MAÌNTENANCE
10-8 MAÌNTENANCE
FUEL SYSTEM HOSES, PIPES AND
UNIONS
Check
K Series
L Series
1. Check fuel pipes and connections for chafing and
leakage.
2. Check pipes are securely clipped.
3. Check fuel tank connections for security.
4. Check fuel tank is free from leaks and corrosion.
5. Check fuel tank for security of fixings.
MAÌNTENANCE
MAÌNTENANCE 10-9
ENGINE TUNING
1. Engine tuning must be carried out using
TestBook.
IGNITION COILS
Check
1. Remove coil cover.
2. Check ht cables and multiplugs for security
3. Clean each coil.
MAÌNTENANCE
10-10 MAÌNTENANCE
COOLING SYSTEM
Check IeveI top-up
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove pressure relief cap
from expansion tank while system is hot. Wait
until system has cooled, use a cloth or glove
to protect hands from escaping steam.
CAUTION: The cooIant IeveI shouId onIy be
checked when the system is coId.
1. Visually check that coolant level is between the
'MAX' and 'MÌN' marks on expansion tank. Ìf level
is appreciably low, suspect leakage or
overheating.
CAUTION: If cooIant is not visibIe in
expansion tank, system must be refiIIed in
accordance with refiIIing procedure.
'K' Series modeIs: See COOLING SYSTEM -
'K' Series - Adjustments.
'L' Series modeIs: See COOLING SYSTEM - 'L'
Series - Adjustments.
2. Ìf required, remove coolant expansion tank cap
and top-up with anti-freeze mixture. See
INFORMATION, Capacities, FIuids and
Lubricants.
CAUTION: The cooIant must not exceed the
maximum IeveI indication.
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.
EXHAUST SYSTEM
Check
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.
MAÌNTENANCE
MAÌNTENANCE 10-11
CLUTCH
Check
1. Check operation of the clutch and free movement
of the pedal.
2. Check the cable for fraying.
GEARBOX OIL - 'R65'
OiI 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 oil is level with bottom of level plug
hole.
CAUTION: OiI 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 oil just runs from hole.
Allow sufficient time for oil to flow and reach a
common level within gearbox. Use a BV 75W/
80W transmission oil. See INFORMATION,
Capacities, FIuids and Lubricants.
5. Refit filler/level plug and new sealing washer and
tighten to 28 Nm.
MAÌNTENANCE
10-12 MAÌNTENANCE
GEARBOX OIL - 'PG1'
OiI IeveI check and top-up
1. Ensure vehicle is standing on a level surface.
'L´ Series models:
2. Remove underbelly panels. See EXTERIOR
FITTINGS, Repairs.
All models:
3. Clean area around filler/level plug.
4. Remove filler/level plug.
5. Check that oil is level with bottom of filler/level
plug hole.
CAUTION: OiI Iodged behind fiIIer/IeveI pIug
wiII trickIe out when pIug is removed and can
give the impression that IeveI is correct.
6. Top-up, if required, until oil just runs from filler/
level hole. Allow sufficient time for oil to flow until
it reaches a common level in the gearbox. Use
the correct specification oil (MTF94). See
INFORMATION, Capacities, FIuids and
Lubricants.
7. Fit filler/level plug and tighten to 40 Nm.
'L´ Series models:
8. Fit underbelly panel. See EXTERIOR FITTINGS,
Repairs.
AUTOMATIC GEARBOX OIL - 'EM-CVT'
NOTE: Always check fluid level with vehicle standing
on level ground and gearbox at operating temperature.
OiI IeveI check and top-up
1. With engine running at idle speed and handbrake
applied, select 'P' or 'N'. Withdraw dipstick and
wipe blade with clean 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.
4. Refit dipstick.
MAÌNTENANCE
MAÌNTENANCE 10-13
DRIVE SHAFT GAITERS
Check
1. Check that drive shaft gaiters are not twisted,
split or damaged.
2. Check clips are secure.
STEERING
Check and top-up power steering fIuid
1. Carry out fluid level check when engine is
stopped and system is cold.
NOTE: It is essential that power steering system
should not have been operated since engine was
stopped.
2. Clean reservoir around filler cap and level
indicators.
3. Visually check fluid level is between level
indicators.
4. Ìf required, remove filler cap and top-up with
DEXRON ÌÌÌ specification fluid. Do not overfiII
CAUTION: Ensure no dirt is aIIowed to enter
reservoir when cap is removed.
5. Refit filler cap.
MAÌNTENANCE
10-14 MAÌNTENANCE
Steering coIumn, rack, joints and gaiters
1. Check security of pinion flange bolts, tighten to
58 Nm.
2. Check security of steering rack clamp bolt,
tighten to 38 Nm.
3. Restrain ball joint movement and check that
steering track rod locknuts are tightened to 45
Nm.
4. Check that ball joint nuts are tightened to 45 Nm.
5. Visually check that the rack sealing gaiters are
not twisted or damaged and clips are secure.
6. Check for signs of lubricant leakage.
MAÌNTENANCE
MAÌNTENANCE 10-15
SUSPENSION DAMPERS, BALL JOINTS,
FXINGS AND GAITERS
Front suspension
1. Check suspension dampers for oil leaks.
2. Check tie rod front mounting nuts - 45 Nm.
3. Check tie rod to lower arm bolts - 80 Nm.
4. Check damper top mounting nuts - 30 Nm.
5. Check swivel hub to MacPherson strut bolts - 80
Nm.
6. Check lower arm to body bolts - 60 Nm.
7. Check anti-roll bar to link bolts- 45 Nm.
8. Check anti-roll bar link to lower arm bolts - 60
Nm.
9. Check anti-roll bar clamp bolts - 22 Nm.
10. Check condition of anti-roll bar bushes.
11. Check condition of lower arm bushes.
12. Check that a split pin is fitted to lower arm ball
joint nuts.
13. Check condition of tie rod bushes.
MAÌNTENANCE
10-16 MAÌNTENANCE
Rear suspension
1. Check damper top mounting nuts - 30 Nm.
2. Check suspension dampers for oil leaks.
3. Check damper assembly to 'H' frame fixing bolts
- 80 Nm.
4. Check condition of pivot bushes.
5. Check condition of body bracket bolts - 100 Nm.
6. Check pivot bush fixing bolts - 100 Nm.
7. Check stub axle fixing bolts - 45 Nm.
MAÌNTENANCE
MAÌNTENANCE 10-17
ROAD WHEELS AND FASTENINGS
Check
Steel Wheel:
1. Remove wheel trim.
2. Check condition of road wheels including spare
for signs of buckling and rim damage.
3. Working in a diagonal sequence loosen each nut
half a turn and then tighten to 110 Nm.
Alloy wheels
4. Push extractor tool over head of nut cover and
pull to remove.
5. Fit key socket over locking wheel nut, then fit
wheel nut spanner over key socket and unscrew.
Steel wheels:
6. Refit wheel trim, ensuring valve stem locates
between stem guides. Use firm pressure around
edge to push trim securely into position.
TYRE PRESSURES AND CONDITION
Check
1. Check for signs of tyre wear indicator in tread
pattern.
2. Check all tyres including spare for uneven wear,
external cuts in fabric, exposure of ply or cord
structure, lumps and bulges.
3. Check and adjust tyre pressures. See
INFORMATION, GeneraI Data.
MAÌNTENANCE
10-18 MAÌNTENANCE
FOOTBRAKE
Check
1. Press brake pedal and check for firm resistance
after short pedal movement.
HANDBRAKE
Check
1. Apply handbrake lever one notch at a time and
count number of notches to apply the brakes
firmly, equivalent to 21.5 Nm applied
perpendicular at a point 50 mm from the end of
the handbrake grip.
Handbrake lever travel = 10 ± 2 notches at 21.5
Nm for drum brakes.
Handbrake lever travel = 12 ± 2 notches at 21.5
Nm for disc brakes.
2. Adjust handbrake cable tension if travel is outside
limits. See BRAKES, Adjustments.
MAÌNTENANCE
MAÌNTENANCE 10-19
BRAKE FLUID
LeveI check
WARNING: Do not allow dirt or foreign liquids
to enter reservoir when topping-up. Use only
new AP New Premium Super DOT 4 or Castrol
Universal DOT 4 brake fluid from airtight
containers.
CAUTION: Do not aIIow brake fIuid to contact
paint finished surfaces as paint may be
damaged. If spiIIed, remove fIuid and cIean
area with cIean warm water.
1. Wipe reservoir body and filler cap clean and
check level visually.
2. Remove filler cap and top-up to 'MAX' mark, if
required.
Renew fIuid
1. Raise vehicle.
WARNING: Support on safety stands.
CAUTION: Never re-use fIuid that has been
bIed from system.
2. Attach a bleed tube to LH front bleed screw.
Ìnsert free end of tube into bottle containing fluid.
3. Open bleed screw and use an assistant to press
brake pedal to floor and release.
4. Repeat operation until clean fluid flows from
bleed screw.
5. When clear, bubble free fluid flows, hold pedal to
floor and tighten bleed screw to 10 Nm on
calipers and 7 Nm on wheel cylinders.
CAUTION: Ensure that fIuid IeveI in reservoir
is maintained during the compIete
operationaI sequence using new brake fIuid.
6. Remove bleed tube.
MAÌNTENANCE
10-20 MAÌNTENANCE
Bleed sequence
7. Repeat procedure for each wheel, using
sequence illustrated.
CAUTION: Braking efficiency may be
seriousIy impaired if wrong bIeed sequence
is used.
8. Apply brakes and check for fluid leakage.
9. Remove stand(s) and lower vehicle.
10. After completion of bleed sequence, check pedal
for short firm travel when brakes are applied. See
BRAKES, Adjustments.
MAÌNTENANCE
MAÌNTENANCE 10-21
BRAKE HOSES AND PIPES
Check
RHD shown, LHD similar
1. Visually check all brake fluid pipes, hoses and
connections for correct routing and security.
2. Check for signs of chafing, leakage or corrosion.
MAÌNTENANCE
10-22 MAÌNTENANCE
Renew brake hose
NOTE: Disconnect hose at end nearest to master
cylinder first.
1. Release brake pipe union from hose using
correct union spanner.
2. Fit plug to pipe end to prevent undue fluid loss.
3. Withdraw brake hose clip from upper bracket.
4. Remove bolt and release hose from bracket, front
brake hose only.
5. Release banjo bolt at other end of hose and
discard 2 sealing washers.
6. Remove hose and discard.
7. Position new hose through bracket.
8. Fit banjo end to caliper or wheel cylinder with
banjo bolt and 2 new sealing washers and tighten
to 34 Nm.
9. Fit brake hose clip to bracket and tap home with
hide mallet.
10. Remove plug from pipe end, connect brake pipe
to hose and tighten union.
11. Secure hose to bracket with bolt and tighten.
Front brake only.
12. Bleed brake system. See BRAKES,
Adjustments.
MAÌNTENANCE
MAÌNTENANCE 10-23
FRONT BRAKES-HYDRAULICS, PADS,
DISCS AND CALIPERS
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 = 3 mm
4. Renew brake pads if thickness is less than
minimum dimension. See BRAKES, Repairs.
NOTE: Measurement does not include pad
backing thickness.
5. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
6. Remove stand(s) and lower vehicle.
7. Depress footbrake several times in order to give
correct pad to disc clearance before road testing.
REAR DRUM BRAKES
Check
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove inspection grommet from brake
backplate.
3. Check brake linings for contamination and
assess wear.
Minimum lining thickness = 2.0 mm
Inspect
1. Remove road wheel(s).
2. Release handbrake.
3. Remove 2 screws retaining brake drum.
4. Remove brake drum. Ease drum from hub using
2 screws.
MAÌNTENANCE
10-24 MAÌNTENANCE
5. Ìf drum cannot be removed due to a wear/
corrosion lip, proceed as follows. Slacken
handbrake cable.
6. Remove rubber grommet from rear of brake
backplate.
7. Disengage handbrake lever stop from behind
lever with a screwdriver to increase shoe to drum
clearance, and then remove drum.
8. Ìf the brake shoes need to be renewed. See
BRAKES, Repairs.
9. Clean down backplate with brake cleaning fluid.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluid as damage will occur to rubber
components.
10. Ensure handbrake lever and quadrant lever are
free to rotate.
11. Lubricate contact faces of strut, handbrake lever
and quadrant lever with brake grease.
12. Apply Molycote 111 Grease to shoe platforms on
backplate and contact areas of adjuster strut and
backplate.
13. Apply Molycote 111 Grease to shoe steady
platforms and tips of shoes as shown.
CAUTION: Keep grease away from shoe
Iinings and aII hydrauIic parts.
14. Ìnspect drum for cracks, score marks and
corrosion. Ìf serviceable, remove any loose rust
with a wire brush and wipe inside of drum with
damp cloth.
15. Check quadrant is in minimum adjustment
position.
16. Reset adjustment by placing a piece of wood
between hub and trailing brake shoe to prevent it
from moving forward. Lever leading shoe away
from wheel cylinder with a screwdriver. Move
quadrant in required direction, ease shoe back
into position and remove wood.
17. Refit brake drum and 2 screws and tighten to 7
Nm.
18. Repeat brake assembly inspection and cleaning
procedure for the remaining rear brake
assembly.
19. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
20. Apply footbrake 3 times to set shoe to drum
clearance.
21. Adjust handbrake cable. See BRAKES,
Adjustments.
22. Remove stand(s) and lower vehicle.
MAÌNTENANCE
MAÌNTENANCE 10-25
REAR DISC BRAKES
Check
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Check brake pads visually and assess pad
thickness.
Minimum pad thickness Dimension A = 3 mm
4. Renew brake pads if thickness is less than
minimum dimension. See BRAKES, Repairs.
NOTE: Measurement does not include pad
backing thickness.
5. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
6. Remove stand(s) and lower vehicle.
MAÌNTENANCE
10-26 MAÌNTENANCE
BODY
Locks, hinges and Iatch mechanism (not steering Iock)
5-door vehicle shown, 3-door vehicle similar
1. Functionally check operation of all locks.
2. Operate front door lock and check that electric
central door locking operates.
3. Ensure that all locks, hinges and latch
mechanisms are lubricated using Rover LOCU
grease (including bonnet and fuel filler flap).
Ìnject grease sparingly into lock barrels. Clean off
any surplus grease. DO NOT Iubricate the
steering Iock.
4. Lubricate sunroof lid seal very sparingly using
Non-Staining Grease.
5. Check operation of bonnet safety catch and latch
mechanisms. Ensure bonnet closes securely.
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.
MAÌNTENANCE
MAÌNTENANCE 10-27
DRIVER AIR BAG MODULE
Check
1. Visually check for signs of damage.
2. To renew an airbag. See RESTRAINT
SYSTEMS, Repairs.
PASSENGER AIR BAG MODULE
Check
1. Visually check for signs of damage.
2. To renew an airbag. See RESTRAINT
SYSTEMS, Repairs.
MAÌNTENANCE
10-28 MAÌNTENANCE
ROTARY COUPLER
Check
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 ELECTRICAL,
Repairs.
SEATS AND SEAT BELTS
Check
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 operation of front seat belt shoulder height
adjusters.
4. Check tightness of all accessible front and rear
seat belt anchorage points.
5. Fully extract each seat belt and allow it to return
under its own recoil mechanism.
6. Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure.
7. Check entire length of seat belt webbing for signs
of fraying and damage. Replace any seat belt
showing such signs.
MAÌNTENANCE
MAÌNTENANCE 10-29
SCREEN WIPERS AND BLADES
Check
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.
6. Operate rear screen wiper and check that blade
wipes screen without smearing.
Renew bIade
1. Press retaining lever.
2. Lift wiper arm.
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.
WINDSCREEN AND REAR SCREEN
WASHERS
Check
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.
MAÌNTENANCE
10-30 MAÌNTENANCE
6. Clean rear screen washer jets using thin wire as
a probe.
7. Operate rear screen washer and check that jet
strikes centre of area to be wiped.
8. Adjust jet by inserting a needle into jet hole and
repositioning.
9. Check operation of programmed wash/wipe by
switching on ignition and operating washer lever.
10. Observe that washer and wiper operate for as
long as lever is operated and wiper operates for
a further 5 seconds after lever is released.
11. Recheck level in reservoir after adjustments.
LAMPS, HORNS AND WARNING
INDICATORS
Check
1. Check for correct operation of all lamps, warning
lamps, switches and horn.
MAÌNTENANCE
MAÌNTENANCE 10-31
HEATER BLOWER
Check
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. Remove any obstruction from
vents.
BATTERY CONNECTIONS
Check
1. Wipe battery top clean and dry.
2. Pull back protector to expose terminal posts and
smear with petroleum jelly.
3. Ensure terminals are tight.
4. Replace protector.
MAÌNTENANCE
10-32 MAÌNTENANCE
FUSEBOX
Check
Engine compartment fusebox
1. Release and lift off cover.
2. Check security of fusible link and power lead
connections.
3. Refit cover and secure.
AUXILIARY DRIVE BELT
RepIace
1. Replace auxiliary drive belt. See ELECTRICAL,
Repairs.
MAÌNTENANCE
MAÌNTENANCE 10-33
ANTI-CORROSION CHECK
Check
1. Carry out anti-corrosion check using the annual
anti-corrosion inspection check sheet.
ROAD TEST
WARNING: Ensure that all road tests are
conducted by suitably qualified drivers in a safe
and legal manner, and where local traffic
conditions allow.
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 '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.
MAÌNTENANCE
10-34 MAÌNTENANCE
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 vehicle and check for smooth
ratio change from rest.
3. Check for abnormal transmission noise.
4. Slow vehicle down and check for smooth ratio
changes.
5. Select 'Sport', drive away and operate selector
lever in plus (+) position from rest. Check for
smooth up-changes of ratio from rest.
6. Slow vehicle down and operate selector lever 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 that
selector does not slip from 'P' position.
10. Carry out a similar check with 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 correctly.
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 travel and ratchet
hold and release.
ENGÌNE - 'K16'
REPAÌRS 12-1-1
ENGÌNE - ' K16' REPAÌ RS
OIL SEAL - FRONT - EXHAUST
CAMSHAFT
´÷ 12.13.07
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove RH hydramount. See ENGINE - 'K16',
Repairs.
4. Raise engine to access bolts and seals.
5. Remove timing belt upper cover. See ENGINE -
'K16', Repairs.
6. Using a socket and extension bar on crankshaft
pulley bolt, rotate crankshaft clockwise to align
camshaft gear timing marks - 90° BTDC.
CAUTION: Never use the camshaft gears,
gear retaining boIts or timing beIt to rotate
crankshaft.
NOTE: If necessary, use a small mirror to ensure
camshaft gear timing marks are aligned correctly.
7. Fit camshaft gear locking tool 18G 1570.
8. Loosen camshaft timing belt tensioner bolt.
9. Move tensioner aside to release belt tension.
10. Release timing belt from camshaft gears.
CAUTION: Ease timing beIt from gears using
fingers onIy, metaI Ievers may damage 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.
11. Use tool 12-182 to restrain camshaft gear and
remove bolt and plain washer securing camshaft
gear to camshaft.
12. Remove camshaft gear locking tool 18G 1570.
13. Remove camshaft gear.
14. Position a cloth to catch oil spillage.
ENGÌNE - 'K16'
12-1-2 REPAÌRS
15. Fit camshaft gear retaining bolt to camshaft.
16. Remove camshaft oil seal using tool 18G 1768
and centre bolt 18G 1299A-1.
17. Discard camshaft oil seal.
18. Remove bolt from camshaft.
Refit
1. Clean sealing area of cylinder head and camshaft
carrier ensuring all traces of rubber are removed.
CAUTION: Do not use a metaI scraper or the
machined surfaces may be damaged. Do not
Iubricate seaIing surfaces or oiI seaI running
surface of camshaft.
2. Fit tool 18G 1749 to end of camshaft to protect
seal and fit new seal using 18G 1769A.
CAUTION: OiI seaI must be fitted dry. DO NOT
use tooI 18G 1769.
NOTE: Front oil seals are coloured BLACK.
3. Clean camshaft gear.
CAUTION: If the sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in a soIvent bath before
refitting. Because of the porous construction
of sintered materiaI, oiI impregnated in the
gears wiII emerge and contaminate the beIt.
4. Fit camshaft gear to camshaft ensuring that drive
pin is located in correct slot in gear. Fit and lightly
tighten retaining bolt and washer.
5. Using tool 12-182, align camshaft gear timing
marks.
6. Fit camshaft gear locking tool 18G 1570.
7. Restrain camshaft gear using tool 12-182 and
tighten bolt to 65 Nm.
8. Using fingers only, fit camshaft timing belt to
camshaft gears and around tensioner ensuring
that belt run between crankshaft gear and
exhaust camshaft gear is kept taut.
9. Check that camshaft timing belt is positioned
centrally around gears and tensioner pulley.
10. Remove camshaft gear locking tool 18G 1570.
ENGÌNE - 'K16'
REPAÌRS 12-1-3
11. Using a 6 mm Allen key, rotate tensioner anti-
clockwise and align the pointer to the index wire.
NOTE: If original belt is being refitted align index
wire to lower land of pointer.
CAUTION: Ensure that the pointer
approaches the index wire from above.
ShouId pointer go past index wire, reIease
tension compIeteIy and repeat tensioning
procedure.
12. Ensuring that the pointer maintains correct
position, tighten tensioner bolt to 25 Nm.
13. Using a suitable socket and extension bar on
crankshaft pulley bolt, rotate crankshaft 2 turns
clockwise and align camshaft gear timing marks.
CAUTION: Do not use camshaft gears,
camshaft gear retaining boIts or timing beIt to
rotate crankshaft.
14. Check that pointer is correctly aligned with index
wire.
CAUTION: If pointer is not correctIy aIigned,
carry out the foIIowing procedure.
ENGÌNE - 'K16'
12-1-4 REPAÌRS
15. Loosen tensioner bolt until it is just possible to
move the tensioner lever.
16. Using a 6 mm Allen key, rotate tensioner lever
clockwise until pointer is just above the index wire
then rotate the lever anti-clockwise until pointer is
correctly aligned with index wire.
17. Ensuring pointer maintains correct position,
tighten tensioner bolt to 25 Nm.
18. Using the crankshaft pulley bolt rotate crankshaft
2 turns clockwise and align camshaft gear timing
marks.
19. Check that the pointer is correctly aligned with
index wire.
20. Fit timing belt upper cover. See ENGINE - 'K16',
Repairs.
21. Fit RH hydramount. See ENGINE - 'K16',
Repairs.
22. Connect battery earth lead.
23. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
24. Remove stand(s) and lower vehicle.
OIL SEAL - REAR - EXHAUST CAMSHAFT
´÷ 12.13.08
Remove
1. Disconnect battery earth lead.
2. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
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.
5. Remove camshaft oil seal using 18G 1768 and
centre bolt 18G 1299A-1.
6. Discard camshaft oil seal.
ENGÌNE - 'K16'
REPAÌRS 12-1-5
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. Do not
Iubricate seaIing surfaces or oiI seaI running
surface on camshaft.
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 tooI 18G 1769.
NOTE: Rear oil seals are coloured RED.
3. Clean oil seal cover plate.
4. Position cover plate, fit bolts and tighten to 25
Nm.
5. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
6. Connect battery earth lead.
OIL SEAL - REAR - INLET CAMSHAFT
´÷ 12.13.10
Remove
1. Disconnect battery earth lead.
2. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
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.
ENGÌNE - 'K16'
12-1-6 REPAÌRS
6. Remove camshaft oil seal using 18G 1768 and
centre bolt 18G 1299A-1.
7. Discard camshaft oil seal.
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. Do not
Iubricate seaIing surfaces or oiI seaI running
surface on camshaft.
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 tooI 18G 1769.
NOTE: Rear oil seals are coloured RED.
3. Clean oil seal cover plate.
4. Position cover plate, fit bolts and tighten to 6 Nm.
5. Secure CMP harness to cover plate and connect
CMP multiplug.
6. Connect battery earth lead.
7. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
CARRIER - CAMSHAFT - A/C
´÷ 12.13.22/20
Remove
1. Disconnect battery earth lead.
2. Disconnect CMP sensor multiplug and release
CMP harness from inlet camshaft rear cover
plate.
3. Remove 2 bolts securing inlet camshaft rear
cover plate, remove cover plate and position
aside.
ENGÌNE - 'K16'
REPAÌRS 12-1-7
4. Remove 2 bolts securing exhaust camshaft rear
cover plate, remove cover plate.
5. Remove camshaft timing belt. See ENGINE -
'K16', Repairs.
6. Remove camshaft gear locking tool 18G 1570.
7. Suitably identify each camshaft gear to its
respective camshaft.
8. Restrain camshaft gears using tool 12-182,
remove bolts securing gears to camshaft, collect
washers.
9. Remove camshaft gears.
10. Remove 5 bolts securing camshaft timing belt
rear cover to cylinder head and block.
11. Remove timing belt rear cover.
12. Remove camshaft cover. See ENGINE - 'K16',
Repairs.
13. Using sequence shown, progressively loosen 26
bolts securing camshaft carrier to cylinder head,
until valve spring pressure is no longer acting on
camshafts.
14. Remove camshaft carrier.
15. Remove both camshafts.
ENGÌNE - 'K16'
12-1-8 REPAÌRS
16. Remove and discard oil seals from camshafts.
17. Using a stick magnet, remove 16 tappets from
camshaft carrier.
CAUTION: Keep tappets in their fitted order
and store them inverted to prevent oiI Ioss.
Do not squeeze tappet chambers together.
Refit
1. Clean camshafts.
2. Clean mating faces of cylinder head and
camshaft carrier.
CAUTION: Do not use a metaI scraper.
3. Clean camshaft carrier bolt holes and dowels.
4. Blow out oil ways and lubricate camshaft
journals.
CAUTION: Do not Iubricate seaIing surfaces
or oiI seaI running surface on camshafts.
5. Lubricate tappets and tappet bores with engine
oil and fit tappets ensuring they are in their
original fitted order.
6. Fit camshafts and position inlet drive pin at 4
o'clock and exhaust camshaft drive pin at 8
o'clock.
7. Apply continuous thin beads of sealant, Part No.
GUG 705963GM to paths on camshaft carrier as
shown then spread to an even film using a roller.
CAUTION: Ensure seaIant is kept cIear of oiI
feed hoIes and oiI grooves. AssembIy must
be compIeted within 20 minutes of appIying
seaIant.
8. Fit camshaft carrier to cylinder head.
9. Fit bolts securing camshaft carrier to cylinder
head and using sequence shown, tighten
progressively to 10 Nm.
10. Clean camshaft seal locations and running
surfaces.
11. Fit seals using tools 18G 1749 and 18G 1769A.
CAUTION: OiI seaIs must be fitted dry. DO
NOT use tooI 18G 1769.
NOTE: Front oil seals are coloured BLACK. Rear
oil seals are coloured RED.
12. Fit camshaft cover. See ENGINE - 'K16',
Repairs.
13. Clean inlet and exhaust camshaft rear cover
plates.
14. Fit exhaust camshaft rear cover plate, fit bolts
and tighten to 25 Nm.
15. Fit inlet camshaft rear cover plate, fit bolts and
tighten to 6 Nm.
16. Connect CMP multiplug and secure to rear cover
plate.
17. Fit camshaft timing belt rear cover, fit bolts and
tighten to 9 Nm.
18. Ensure camshaft gears are clean and free from
oil or grease.
ENGÌNE - 'K16'
REPAÌRS 12-1-9
19. Fit gears to their respective camshafts ensuring
that drive pins are located in correct slot in gears.
20. Restrain camshaft gears using tool 12-182.
21. Fit bolts and washers and tighten to 65 Nm.
22. Align camshaft gears timing marks and fit
camshaft gear locking tool 18G 1570.
23. Fit camshaft timing belt. See ENGINE - 'K16',
Repairs.
24. Connect battery earth lead.
CRANKSHAFT FRONT PULLEY
´÷ 12.21.01
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel(s).
4. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
5. Remove starter motor. See ELECTRICAL,
Repairs.
6. Fit flywheel locking tool to flywheel housing and
secure with 2 bolts: 'R65' and 'EM-CVT' gearbox
- use tool 18G 1571. 'PG1' gearbox - use tool
18G 1742.
ENGÌNE - 'K16'
12-1-10 REPAÌRS
7. Remove bolt securing pulley to crankshaft and
collect washer.
8. Remove crankshaft pulley.
Refit
1. Fit crankshaft pulley to crankshaft gear ensuring
that indent on pulley locates over lug on gear
(arrowed in illustration).
2. Fit washer and bolt securing crankshaft pulley to
crankshaft and tighten to 205 Nm.
3. Remove 2 bolts securing flywheel locking tool,
remove tool.
4. Fit starter motor. See ELECTRICAL, Repairs.
5. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
6. Fit road wheel and tighten nuts to correct torque.
See INFORMATION, Torque Wrench Settings.
7. Lower vehicle.
8. Connect battery earth lead.
ENGÌNE - 'K16'
REPAÌRS 12-1-11
CRANKSHAFT FRONT OIL SEAL
´÷ 12.21.14
Remove
1. Remove camshaft timing belt. See ENGINE -
'K16', Repairs.
2. Remove crankshaft gear.
3. Fit thrust button, tool 18G 705-1A/3 to end of
crankshaft.
4. Ensure bore of tool 18G 1566 is free from burrs.
Screw tool 18G 1566 into crankshaft front oil
seal.
5. Tighten centre bolt of tool 18G 1566 to remove
seal
6. Discard crankshaft front oil seal.
7. Remove tool 18G 705-1A/3.
Refit
1. Using a lint free cloth, thoroughly clean oil seal
recess in oil pump and running surface on
crankshaft.
CAUTION: Do not Iubricate oiI seaI recess or
oiI seaI running surface on crankshaft.
2. Fit oil seal guide, from seal kit, over end of
crankshaft.
3. Position new seal on crankshaft up against oil
pump housing. Drift seal into place using tool
18G 1587.
CAUTION: OiI seaI must be fitted dry.
4. Remove tool 18G 1587 and oil seal guide.
5. Clean crankshaft gear.
6. Fit crankshaft gear to crankshaft.
7. Fit camshaft timing belt. See ENGINE - 'K16',
Repairs.
ENGÌNE - 'K16'
12-1-12 REPAÌRS
CRANKSHAFT REAR OIL SEAL
´÷ 12.21.20
Remove
1. Remove engine flywheel. See ENGINE - 'K16',
Repairs.
2. Using a burr free flat ended screwdriver, ease
crankshaft rear oil seal from cylinder block and
discard seal. Take care not to mark sealing
surface on crankshaft.
Refit
1. Clean oil seal recess in cylinder block and
running surface on crankshaft. Ìt is essential that
these areas are thoroughly clean, free of old
sealant and dry.
2. Apply a 1.5 mm bead of GAC 8000 sealant to
new oil seal as shown.
CAUTION: Do not appIy oiI or grease to any
part of oiI seaI or running surface of
crankshaft, oiI seaI must be fitted dry. OiI seaI
must be fitted immediateIy after appIying
seaIant.
3. Position oil seal to cylinder block and fit oil seal
replacer 18G 1574, retain tool using 3 slave bolts.
4. Evenly tighten oil seal replacer bolts to press oil
seal squarely into cylinder block, leave seal
replacer 18G 1574 in position for 1 minute.
5. Remove oil seal replacer 18G 1574.
6. Allow sealant to cure for a minimum of 30
minutes before topping-up oil or rotating
crankshaft.
7. Fit engine flywheel. See ENGINE - 'K16',
Repairs.
8. Top-up engine oil. See MAINTENANCE.
ENGÌNE - 'K16'
REPAÌRS 12-1-13
GASKET - CYLINDER HEAD
´÷ 12.29.02
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove and discard camshaft timing belt. See
ENGINE - 'K16', Repairs.
4. Remove 2 nuts securing exhaust front pipe to
exhaust manifold. Release front pipe, remove
and discard gasket.
Models with A/C:
5. Remove exhaust manifold gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
All models:
6. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
7. Remove camshaft cover. See ENGINE - 'K16',
Repairs.
8. Release HO
2
sensor multiplug from bracket.
Disconnect multiplug.
9. Remove 2 bolts securing inlet camshaft rear
cover plate, release cover plate and position
aside.
10. Loosen clip and disconnect radiator top hose
from coolant outlet elbow.
11. Loosen clip and disconnect coolant hose from
coolant outlet elbow.
12. Release hose clip from bracket on cylinder head.
13. Disconnect multiplugs from ECT sensors.
ENGÌNE - 'K16'
12-1-14 REPAÌRS
14. Remove clip and disconnect air intake hose from
throttle housing.
15. Disconnect multiplug from TP sensor.
16. Disconnect multiplug from injector harness.
17. Disconnect multiplug from ÌAT sensor.
18. Disconnect multiplug from ÌAC.
19. Position cloth around fuel feed and return hose
connections to absorb spillage.
20. Depress plastic collars on hoses and release
hoses from pipes.
CAUTION: PIug the connections.
ENGÌNE - 'K16'
REPAÌRS 12-1-15
21. Release clip and disconnect purge hose from
throttle housing.
22. Release throttle cable adjusting nut from
abutment bracket.
23. Release throttle cable from throttle cam.
24. Depress plastic collar on quick release connector
and disconnect brake servo vacuum hose from
inlet manifold.
25. Release throttle cable from clip on inlet manifold.
26. Loosen clip and disconnect expansion tank hose
from inlet manifold.
27. Remove exhaust manifold heatshield. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
28. Working in sequence shown, progressively
loosen cylinder head bolts numbers 1 to 6.
ENGÌNE - 'K16'
12-1-16 REPAÌRS
29. Remove camshaft gear locking tool 18G 1570.
30. Using tool 12-182, rotate camshafts to gain
access to cylinder head bolts 7 and 8 beneath
camshaft reluctor rings.
31. Working in sequence shown, progressively
loosen cylinder head bolts numbers 7 to 10.
32. Remove cylinder head bolts and store in fitted
order.
CAUTION: RemovaI of cyIinder head boIts
resuIts in a 'tightening-up' of crankshaft;
rotation of crankshaft must, therefore, be
kept to a minimum. Do not rotate crankshaft
untiI cyIinder Iiner retainer cIamps 18G 1736
are fitted.
33. Mark camshaft gears for identification when
refitting.
34. Restrain camshaft gears using tool 12-182 and
remove bolts securing camshaft gears to
camshafts.
35. Remove camshaft gears.
36. Remove bolt securing dipstick tube support
bracket.
ENGÌNE - 'K16'
REPAÌRS 12-1-17
37. Remove 5 bolts securing camshaft timing belt
rear cover to cylinder head and block.
38. Remove timing belt rear cover.
39. Using assistance, remove cylinder head
assembly.
CAUTION: CyIinder head is doweI Iocated, do
not tap it sideways to free it from cyIinder
bIock. Take care not to damage HO
2
S when
removing cyIinder head. PIace cyIinder head
on bIocks of wood to prevent damaging
vaIves.
40. Remove and discard cylinder head gasket.
41. Remove 2 location dowels from cylinder block.
42. Fit cylinder liner clamps 18G 1736 to cylinder
block and secure with cylinder head bolts.
Tighten bolts sufficiently to retain clamps.
CAUTION: Ensure that boIts used are those
originaIIy fitted in that position.
Refit
1. Clean mating faces of cylinder head and cylinder
block.
2. Check cylinder head for damage, pay particular
attention to gasket face of cylinder head.
3. Check cylinder head face for warping, across
centre and from corner to corner as shown:
Maximum warp = 0.05 mm
4. Check cylinder head height: :
New = 118.95 to 119.05 mm
Reface limit = 0.20 mm
5. Clean oil and coolant passages.
6. Clean mating faces of exhaust manifold and
exhaust front pipe.
7. Clean cylinder head bolts and inspect for signs of
damage.
8. Wash cylinder head bolts and wipe dry.
9. Apply a light film of oil to bolt threads and
underside of bolt heads.
ENGÌNE - 'K16'
12-1-18 REPAÌRS
10. Clean location dowels and fit to cylinder block.
CAUTION: If crankshaft has been rotated,
check that dots on crankshaft timing gear are
aIigned with fIange on oiI pump.
11. Remove bolts securing cylinder liner clamps 18G
1736 to cylinder block and remove clamps.
CAUTION: Do not rotate crankshaft with
cIamps removed.
12. Fit new cylinder head gasket, dry, to cylinder
block.
13. Using assistance, fit cylinder head onto cylinder
block carefully locating on dowels.
14. Clean timing belt rear cover.
15. Fit timing belt rear cover and tighten screws to 9
Nm.
16. Align dipstick support bracket, fit bolt and tighten
to 9 Nm.
17. Clean camshaft gears.
18. Fit camshaft gears to their respective camshafts
ensuring that drive pins are located in correct slot
in gears.
19. Fit bolts and washers securing camshaft gears.
Using tool 12-182, restrain camshaft gears and
tighten bolts to 65 Nm.
20. Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
21. Working in the sequence shown, progressively
tighten the cylinder head bolts using the following
procedure:
¤ All bolts to 20 Nm.
¤ Using a felt tip pen, mark position of radial
mark on each bolt head.
¤ Turn all bolts through 180°.
¤ Turn all bolts through another 180° and align
radial mark.
CAUTION: If any boIt is overtightened, back
off 90° then reaIign radiaI marks.
NOTE: Rotate camshafts using tool 12-182 in
order to gain access to cylinder head bolts 3 and
4.
22. Using tool 12-182, align camshaft gear timing
marks and fit camshaft gear locking tool 18G
1570.
23. Fit exhaust manifold heatshield. See MANIFOLD
& EXHAUST SYSTEMS, Repairs.
24. Connect expansion tank hose to inlet manifold
and tighten clip.
25. Connect servo vacuum hose.
26. Connect throttle cable to throttle cam, locate
throttle cable adjusting nut in abutment bracket
and secure cable in clip.
27. Connect purge hose to throttle housing and
secure with clip.
28. Connect fuel feed and return hoses
29. Connect multiplugs to ÌAC valve, and ÌAT sensor.
30. Connect injector harness multiplug.
31. Connect multiplug to TP sensor.
32. Connect air intake hose and secure with clip.
33. Connect multiplugs to ECT sensors.
34. Connect hose to coolant outlet elbow and tighten
clip. Secure hose in clip.
35. Connect radiator top hose to coolant outlet elbow
and tighten clip.
36. Fit camshaft cover. See ENGINE - 'K16',
Repairs.
37. Fit inlet camshaft rear cover plate, fit bolts and
tighten to 6 Nm.
38. Connect HO
2
sensor multiplug to engine harness
and secure to camshaft end cover plate.
39. Clean exhaust manifold and front pipe mating
faces.
40. Fit new gasket to exhaust manifold flange,
connect exhaust front pipe and tighten nuts to 45
Nm.
ENGÌNE - 'K16'
REPAÌRS 12-1-19
Models with A/C:
41. Fit exhaust manifold gasket. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
All models:
42. Fit new camshaft timing belt. See ENGINE -
'K16', Repairs.
43. Remove stand(s) and lower vehicle.
44. Refill cooling system. See MAINTENANCE.
45. Connect battery earth lead.
46. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments.
GASKET - CAMSHAFT COVER
´÷ 12.29.40
Remove
1. Disconnect battery earth lead.
2. Release 2 clips and disconnect 2 breather hoses
from camshaft cover.
3. Remove ignition coils. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
4. Release coil and CMP sensor harness clip from
camshaft cover.
5. Remove bolt securing CMP sensor to cover,
release sensor and position aside.
6. Remove and discard 'O' ring from CMP sensor.
ENGÌNE - 'K16'
12-1-20 REPAÌRS
7. Progressively loosen and remove 15 bolts
securing camshaft cover.
8. Remove camshaft cover, remove and discard
gasket.
NOTE: Check condition of sealing path. It should
be complete and attached to gasket. Remove
gasket from camshaft cover only if sealing path is
damaged or detached from gasket.
Refit
1. Clean mating surfaces of camshaft cover and
carrier.
2. Clean inside of camshaft cover. Ìf necessary,
wash oil separator elements in solvent and blow
dry.
3. Fit new camshaft cover gasket.
4. Fit camshaft cover to camshaft carrier, fit bolts
and working in sequence illustrated, tighten
progressively to 10 Nm.
5. Lubricate a new 'O' ring with engine oil and fit to
CMP sensor.
6. Fit CMP sensor and tighten bolt to 5 Nm. Secure
harness clip to cover.
7. Fit ignition coils. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
8. Connect breather hoses and secure with clips.
9. Connect battery earth lead.
ENGÌNE - 'K16'
REPAÌRS 12-1-21
VALVE STEM OIL SEAL
´÷ 12.30.26
Remove
1. Disconnect battery earth lead.
2. Remove camshaft housing/carrier. See ENGINE
- 'K16', Repairs.
3. Remove inlet and exhaust camshafts.
4. Clean spark plug recess and using a 16 mm
spark plug socket, remove spark plug.
5. Fit and tighten air line adaptor tool MS 1567 into
spark plug hole.
6. Connect an airline to adaptor and apply air
pressure.
7. Using a magnet, remove tappet.
CAUTION: Store tappet(s) inverted and in
fitted order .
8. Fit tool MS 1657/18 and tool MS 1567/7 to valve
spring cap.
9. Strike head of tool firmly with hammer to release
valve spring collets.
10. Remove collets from magnetic end of tool.
11. Remove valve spring cap and spring.
ENGÌNE - 'K16'
12-1-22 REPAÌRS
12. Use tool 18G 1577 to remove valve stem oil seal.
13. Repeat above operations to remove additional
seals.
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 MS 1657 over valve.
5. Locate valve spring cap with compressor tool MS
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. Remove valve spring compressor tool MS 1657.
10. Repeat refit operations on remaining valves.
11. Lubricate tappet(s) with clean engine oil and refit.
12. Disconnect air line from adaptor tool MS 1567.
13. Remove air line adaptor tool MS 1567.
14. Clean spark plug and set gap to 1.00 mm ± 0.05
mm.
15. Fit spark plug and tighten to 25 Nm.
16. Fit inlet and exhaust camshafts.
17. Fit camshaft housing/carrier. See ENGINE -
'K16', Repairs.
18. Connect battery earth lead.
ENGÌNE - 'K16'
REPAÌRS 12-1-23
ENGINE AND GEARBOX - MODELS
WITHOUT A/C
´÷ 12.37.01.99
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel(s).
4. Ìf required, drain engine oil. See ENGINE - 'K'
Series, Adjustments.
5. Fit new sealing washer to drain plug, fit drain plug
and tighten to 28 Nm.
6. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
7. Drain gearbox oil. See MANUAL GEARBOX -
'R65', Adjustments. 'EM-CVT' gearbox: See
AUTOMATIC GEARBOX - 'EM-CVT',
Adjustments.
8. Remove both drive shafts. See DRIVE SHAFTS,
Repairs.
9. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
10. Remove ECM. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
Manual gearbox starter shown
11. Remove bolt securing negative lead to starter
motor.
Manual gearbox:
12. Remove 2 bolts securing engine torsion bar and
remove torsion bar.
13. Remove 2 bolts securing resonator to battery
tray.
14. Remove resonator.
ENGÌNE - 'K16'
12-1-24 REPAÌRS
All models, if fitted:
15. Release ABS fuse holder from battery tray.
16. Remove 3 bolts securing battery tray to body.
17. Loosen 3 bolts securing battery tray to body.
18. Remove battery tray from vehicle.
Manual gearbox:
19. Disconnect clutch cable from clutch release
lever.
20. Release clutch cable from abutment bracket on
gearbox and position aside.
All models:
21. Loosen clip and disconnect radiator top hose
from coolant outlet elbow.
22. Loosen clip and disconnect radiator bottom hose
from coolant rail.
23. Loosen clip and disconnect heater hose from
coolant outlet elbow.
ENGÌNE - 'K16'
REPAÌRS 12-1-25
24. Release heater hose from 2 clips on coolant rail
and engine harness.
25. Remove fuse box cover.
26. Remove screw securing positive lead to fuse box.
27. Disconnect multiplug from fuse box.
28. Release 2 multiplugs from bracket.
29. Disconnect engine harness multiplugs from main
harness.
30. Remove engine harness clip from bracket.
31. Lay engine harness across engine to avoid being
caught when the engine is removed.
32. Remove EVAP cannister. See EMISSION
CONTROL, Repairs.
33. Remove 2 nuts securing exhaust front pipe to
manifold, release front pipe. Remove and discard
gasket.
34. Position absorbent cloth around fuel feed pipe
connection.
35. Depress quick release connectors and release
fuel feed and return pipes.
CAUTION: PIug the connections.
ENGÌNE - 'K16'
12-1-26 REPAÌRS
36. Release throttle cable adjusting nut from
abutment bracket.
37. Release throttle cable from throttle cam.
38. Depress plastic collar on quick release connector
and disconnect brake servo vacuum pipe from
inlet manifold.
39. Release throttle cable from clip on inlet manifold.
40. Loosen clip and disconnect expansion tank hose
from inlet manifold.
41. Loosen clip and disconnect coolant hose from
thermostat housing.
42. Loosen clip and disconnect heater hose from
coolant rail.
43. Position container to catch fluid loss from power
steering system.
44. Loosen clip securing fluid inlet hose to power
steering pump.
45. Disconnect fluid inlet hose from power steering
pump.
46. Remove bolt securing fluid outlet hose clamp to
bracket.
47. Loosen union and disconnect fluid outlet hose
from power steering pump.
CAUTION: To prevent damage to pipes and
components use two spanners when
Ioosening or tightening unions.
48. Remove and discard 'O' ring from fluid outlet
hose.
49. Plug hose and power steering pump connections
to prevent excess fluid loss and the ingress of dirt
into the system.
Manual gearbox:
50. Using tool 18G 1592 release gear selector
linkage ball joint from gear selector lever.
51. Using tool 18G 1592 release gear change linkage
ball joint from gear change lever.
ENGÌNE - 'K16'
REPAÌRS 12-1-27
'EM-CVT´ gearbox:
52. Loosen nut securing gearchange cable to
gearchange lever, release gearchange cable
from support bracket and position cable aside.
All models:
53. Remove 2 bolts securing camshaft rear cover
plate to cylinder head.
54. Remove exhaust camshaft rear cover plate.
55. Fit engine lifting bracket tool 18G 1572/1 to
cylinder head. Fit bolts and tighten to 9 Nm .
56. Fit engine lifting bracket tool 18G 1572/2 to
cylinder head. Fit bolt and tighten to 9 Nm.
57. Connect adjustable lifting bracket tool 18G 1598
to engine lifting brackets.
58. Connect a hoist to lifting bracket tool 18G 1598
and raise hoist to take weight of engine without
exerting load on engine mounting bolts.
ENGÌNE - 'K16'
12-1-28 REPAÌRS
59. Loosen bolt securing engine RH steady to body.
60. Remove bolt securing engine RH steady to
mounting and release engine steady.
61. Remove 2 nuts securing engine RH mounting
restraining strap and remove strap.
62. Remove nut securing engine RH mounting
bracket to hydramount, collect mass damper.
63. Remove 2 bolts securing mounting bracket to
engine and remove bracket.
Manual gearbox:
64. Remove through bolt securing engine LH
mounting to bracket on body.
65. Remove 2 bolts securing engine LH mounting to
gearbox mounting bracket.
66. Remove 4 bolts securing LH mounting to body.
67. Remove engine LH mounting.
'EM-CVT´ gearbox:
68. Loosen oil cooler unions and release pipes,
remove and discard 'O' rings.
CAUTION: PIug the connections.
69. Remove 2 bolts and 1 nut securing modulator
mounting bracket to body.
70. Remove and discard nut securing gearbox
mounting to bracket.
71. Lower engine/gearbox sufficient to gain access
to gearbox mountings.
72. Release clip securing engine harness to
modulator mounting bracket.
ENGÌNE - 'K16'
REPAÌRS 12-1-29
73. Remove 4 bolts securing engine LH mounting
bracket to body.
74. Remove engine mounting and bracket.
All models:
75. Using adjustable lifting bracket tool 18G 1598, tilt
engine with the gearbox as low as possible.
76. Using assistance, manoeuvre engine and
gearbox from vehicle.
CAUTION: Take care not to damage the ABS
moduIator or brake pipes when removing the
engine.
77. Lower engine and gearbox assembly and
disconnect hoist from adjustable lifting bracket.
Refit
1. Connect hoist to adjustable lifting bracket tool
18G 1598.
2. Using assistance, raise engine and manoeuvre
into position in vehicle.
3. Adjust lifting bracket tool so engine is horizontal
in engine compartment.
4. Position engine LH mounting.
5. Fit bolts securing mounting to body and tighten to
55 Nm.
Manual gearbox:
6. Fit bolts securing engine LH mounting to
mounting bracket and tighten to 100 Nm.
7. Align gearbox mounting bracket to engine
mounting, fit bolt and tighten to 85 Nm.
'EM-CVT´ gearbox:
8. Raise engine and gearbox assembly to align
gearbox mounting bracket to engine mounting.
9. Fit new Nyloc nut securing gearbox mounting
bracket to engine mounting and tighten to 160
Nm.
If fitted:
10. Position modulator mounting bracket, fit and
tighten nut and bolts.
11. Clean mating faces of gearbox oil cooler and
pipes.
12. Lubricate new 'O' rings with gearbox oil and fit to
gearbox oil cooler pipes.
13. Align oil cooler pipes and tighten unions to 14
Nm.
All models:
14. Fit engine RH mounting bracket, align engine, fit
bolts and tighten to 135 Nm.
15. Position mass damper, fit and tighten nut
securing mounting bracket to hydramount to 85
Nm.
16. Position RH mounting restraining strap fit nuts
and tighten to 45 Nm.
17. Align RH mounting steady bar, fit bolt, tighten
both bolts to 85 Nm.
18. Lower hoist and disconnect adjustable lifting
bracket tool 18G 1598 from lifting brackets.
19. Remove bolt securing lifting bracket tool 18G
1572/2 to cylinder head and remove bracket.
20. Remove 2 bolts securing lifting bracket tool 18G
1572/1 to cylinder head and remove bracket.
21. Clean exhaust camshaft rear cover plate.
22. Position exhaust camshaft rear cover plate to
cylinder head, fit bolts and tighten to 25 Nm.
Manual gearbox:
23. Clean gear selector linkage and gear change
linkage ball joints.
24. Using tool 18G 1594 connect gear selector
linkage ball joint to gear selector lever.
25. Using tool 18G 1594 connect gear change
linkage ball joint to gear change lever.
'EM-CVT´ gearbox:
26. Connect gearchange cable to gearchange lever
and secure to support bracket.
All models:
27. Remove plugs from power steering pump and
hose connections.
28. Lubricate new 'O' ring with clean PAS fluid and fit
to fluid outlet hose.
29. Connect fluid outlet hose to power steering pump
and tighten union to 20 Nm.
30. Align fluid outlet hose clamp to bracket, fit and
tighten bolt to 9 Nm.
31. Connect fluid inlet hose to PAS pump and tighten
clip.
32. Connect heater hose to coolant pipe and secure
with clip.
33. Connect coolant hose to thermostat housing and
tighten clip.
ENGÌNE - 'K16'
12-1-30 REPAÌRS
34. Connect expansion tank hose to inlet manifold
and tighten clip.
35. Connect throttle cable to throttle cam.
36. Locate throttle cable adjusting nut in abutment
bracket.
37. Ensure throttle cable is correctly routed and
secure to clip on inlet manifold.
38. Connect brake servo vacuum pipe to inlet
manifold.
39. Connect pipes to fuel return and fuel feed
connections.
40. Fit new exhaust front pipe gasket, align front pipe
to manifold, fit nuts and tighten to 45 Nm.
41. Fit EVAP cannister. See EMISSION CONTROL,
Repairs.
42. Connect the engine harness to main harness
connectors.
43. Fit engine harness multiplugs to bracket on
bulkhead.
44. Fit engine harness clip to bracket.
45. Connect multiplug to fuse box.
46. Fit positive lead to fuse box and secure with
screw.
47. Fit fuse box cover.
48. Connect heater hose to coolant outlet elbow and
tighten clip.
49. Secure heater hose to clips on coolant rail and
harness.
50. Connect radiator bottom hose to coolant rail and
tighten clip.
51. Connect radiator top hose to coolant outlet elbow
and tighten clip.
52. Fit driveshafts to gearbox. See DRIVE SHAFTS,
Repairs.
Manual gearbox:
53. Feed clutch cable through abutment bracket and
connect to clutch release lever.
All models:
54. Position battery tray in vehicle.
55. Tighten 6 bolts, battery tray to body, and tighten
to 10 Nm.
Manual gearbox:
56. Fit resonator to air intake pipe.
57. Fit and tighten bolts securing resonator to battery
tray.
All models, if fitted:
58. Secure ABS fuse holder to battery tray.
Manual gearbox:
59. Fit engine torsion bar and tighten bolts to 25 Nm.
All models:
60. Fit negative lead to starter motor and tighten bolt
to 8 Nm.
61. Fit ECM. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
62. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
63. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
64. Remove stand(s) and lower vehicle.
65. Refill gearbox with oil. See MANUAL GEARBOX
- 'R65', Adjustments. 'EM-CVT' gearbox: See
AUTOMATIC GEARBOX - 'EM-CVT',
Adjustments.
66. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
67. Ìf required: Refill engine with oil. See
MAINTENANCE.
68. Connect battery earth lead.
69. Bleed power steering system. See STEERING,
Adjustments.
70. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments. 'EM-CVT' gearbox: Adjust gear
selector cable. See AUTOMATIC GEARBOX -
'EM-CVT', Adjustments.
ENGÌNE - 'K16'
REPAÌRS 12-1-31
ENGINE AND GEARBOX - MODELS WITH
A/C
´÷ 12.37.01/20
Remove
1. Disconnect battery earth lead.
2. Raise vehicle on a 2 post ramp.
3. Ìf required: Drain engine oil. See
MAINTENANCE.
All Models:
4. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments.
5. Remove drive shafts. See DRIVE SHAFTS,
Repairs.
6. Remove front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
7. Remove alternator. See ELECTRICAL, Repairs.
8. Drain gearbox oil. See MANUAL GEARBOX -
'R65', Adjustments. 'EM-CVT' gearbox: See
AUTOMATIC GEARBOX - 'EM-CVT',
Adjustments.
9. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
10. Remove front beam. See FRONT
SUSPENSION, Repairs.
11. Remove 4 bolts securing tie rods to lower arm
and remove tie rods.
12. Release clip and disconnect top hose from
coolant elbow.
13. Release clip and disconnect heater hose from
coolant elbow and release from clips.
14. Remove bolt securing A/C pipe to support
bracket.
ENGÌNE - 'K16'
12-1-32 REPAÌRS
15. Disconnect compressor multiplug.
16. Remove 3 bolts securing compressor, release
compressor and tie aside.
17. Depress quick release connector and disconnect
servo vacuum pipe from manifold.
18. Disconnect throttle cable from throttle cam and
release from abutment bracket.
19. Release clips securing coolant hoses to coolant
rail and release hoses.
20. Release clip securing expansion tank hose to
inlet manifold and release hose.
21. Loosen clip securing PAS pump feed hose and
release hose.
22. Remove bolt securing PAS high pressure hose to
PAS pump.
23. Loosen union securing PAS pump high pressure
hose and release union, remove and discard 'O'
ring.
CAUTION: PIug the connections.
ENGÌNE - 'K16'
REPAÌRS 12-1-33
24. Position absorbent cloth around fuel feed pipe
connections.
25. Depress quick release catches and disconnect
fuel feed and return hoses.
CAUTION: PIug the connections.
26. Disconnect EVAP pipe from manifold.
27. Disconnect multiplugs from main harness and
EVAP cannister.
28. Disconnect engine harness multiplug from
fusebox.
29. Remove bolt securing positive lead to fusebox
and release lead.
30. Disconnect ECM multiplug.
Manual gearbox:
31. Disconnect clutch cable from clutch lever,
release cable from abutment bracket and
position cable aside.
ENGÌNE - 'K16'
12-1-34 REPAÌRS
'EM-CVT´ gearbox:
32. Loosen nut securing selector cable to selector
lever and release cable from support bracket and
position aside.
All models:
33. Disconnect starter positive lead and position
aside.
34. Remove bolt securing earth lead and position
earth lead aside.
'EM-CVT´ gearbox:
35. Loosen unions securing oil cooler pipes, release
pipes, remove and discard 'O' rings.
CAUTION: PIug the connections.
Manual gearbox:
36. Disconnect starter positive lead and position
aside.
37. Remove bolt securing earth lead and position
earth lead aside.
ENGÌNE - 'K16'
REPAÌRS 12-1-35
38. Using tool 18G 1592 release gear selector rods
from gear change selector and gear change
lever.
All models:
39. Fit lifting bracket 18G-1572/2 to rear of cylinder
head, fit bolt and tighten to 9 Nm.
40. Remove 2 bolts securing exhaust camshaft rear
cover and remove cover.
41. Fit lifting bracket 18G 1572/1 fit bolts to secure
bracket and tighten to 9 Nm.
42. Attach lifting arm 18G 1598 to suitable lifting
equipment and connect to lifting brackets.
43. Take the weight of engine without putting
pressure on engine mountings.
44. Remove bolt securing engine RH steady bar to
mounting.
45. Loosen rear bolt securing steady bar to body and
release bar.
46. Remove 2 bolts securing engine RH mounting
bracket to engine.
ENGÌNE - 'K16'
12-1-36 REPAÌRS
Manual gearbox:
47. Remove bolts securing torsion bar and remove
torsion bar.
48. Remove 2 bolts securing LH mounting to
gearbox.
'EM-CVT´ gearbox:
49. Remove nut securing LH mounting to gearbox.
50. With assistance, lower engine and manoeuvre
from engine bay.
51. Take care not to damage engine harness on A/C
pipe.
Refit
1. Position engine under vehicle and with
assistance manoeuvre into engine bay and align
to engine mountings.
2. Position engine harness around A/C pipe.
Manual gearbox:
3. Fit bolts securing LH mounting and tighten to 100
Nm.
4. Align gearbox mounting bracket to engine
mounting, fit bolt and tighten to 85 Nm.
5. Position torsion bar, fit bolts and tighten to 25
Nm.
'EM-CVT´ gearbox:
6. Fit new Nyloc nut securing gearbox mounting
bracket to engine mounting and tighten to 160
Nm .
All models:
7. Fit bolts securing RH mounting and tighten to 135
Nm.
8. Position RH steady bar and tighten bolts to 85
Nm.
9. Remove lifting arm 18G 1598.
10. Remove 2 bolts securing lifting bracket, remove
brackets.
11. Fit camshaft cover plate, fit bolts and tighten to 25
Nm.
12. Remove bolt securing lifting bracket to cylinder
head and remove lifting bracket.
Manual gearbox:
13. Clean gear selector linkage and gear change
linkage ball joints.
14. Connect gear change selector and gear lever ball
joints using tool 18G 1594.
15. Connect clutch cable to abutment bracket and
secure to clutch lever.
'EM-CVT´ gearbox:
16. Connect gearchange cable to gearchange lever
and secure to support bracket.
17. Clean mating faces of gearbox oil cooler and
pipes.
18. Lubricate new 'O' rings with gearbox oil and fit to
oil cooler pipes.
19. Align oil cooler pipes and tighten unions to 14
Nm.
20. Position earth lead, fit bolt and tighten to 25 Nm.
All models:
21. Position starter lead and secure with nut.
22. Position engine harness around engine.
23. Connect ECM multiplug
24. Connect fuse box multiplug and positive lead and
secure lead with bolt.
25. Connect EVAP cannister and main harness
multiplugs.
26. Connect EVAP pipe to manifold.
27. Clean ends of fuel feed and return hoses.
28. Connect fuel feed and return hoses.
29. Clean ends of PAS feed and high pressure
hoses.
30. Lubricate new 'O' ring with PAS fluid and fit to
PAS high pressure hose.
31. Align PAS high pressure hose to pump and
tighten union to 20 Nm.
32. Fit and tighten support bracket bolt to 9 Nm.
33. Connect PAS pump feed hose and secure with
clip.
ENGÌNE - 'K16'
REPAÌRS 12-1-37
34. Connect expansion tank hose and secure with
clip.
35. Connect coolant hoses to coolant rail and secure
with clips.
36. Connect throttle cable to cam and secure to
abutment bracket.
37. Connect servo vacuum pipe.
38. Align compressor, fit bolts and tighten 25 Nm.
39. Fit bolt securing A/C pipe to support bracket and
tighten to 9 Nm.
40. Connect top hose and heater hoses to coolant
elbow and secure with clips.
41. Fit alternator. See ELECTRICAL, Repairs.
42. Position tie rods to lower arms, fit bolts and
tighten to 80 Nm.
43. Fit front beam. See FRONT SUSPENSION,
Repairs.
44. Fit drive shafts. See DRIVE SHAFTS, Repairs.
45. Fit front pipe. See MANIFOLD & EXHAUST
SYSTEMS, Repairs.
46. Remove stand(s) and lower vehicle.
47. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
48. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Adjustments.
49. Refill gearbox with oil. See MANUAL GEARBOX
- 'R65', Adjustments. 'EM-CVT' gearbox: See
AUTOMATIC GEARBOX - 'EM-CVT',
Adjustments.
50. Ìf required: Refill engine oil. See
MAINTENANCE.
51. Connect battery earth lead.
52. Bleed PAS system. See STEERING,
Adjustments.
53. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments.
ENGINE STEADY - LOWER
´÷ 12.45.08
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove through bolt securing engine steady bar
to subframe.
3. Remove through bolt securing engine steady bar
to bracket on sump.
4. Remove engine steady bar.
Refit
1. Position engine steady bar to subframe and fit
through bolt.
2. Fit and tighten through bolt securing steady bar to
bracket on sump to 45 Nm.
3. Tighten through bolt securing steady bar to
subframe to 80 Nm.
4. Remove stand(s) and lower vehicle.
ENGÌNE - 'K16'
12-1-38 REPAÌRS
HYDRAMOUNT - ENGINE RH
´÷ 12.45.12
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Fit wooden block to jack and position jack to
support engine.
3. Remove bolt securing RH steady bar to engine
mounting bracket.
4. Loosen bolt securing steady bar to body and
release steady bar.
5. Remove 2 bolts securing mounting bracket to
engine.
6. Remove nut securing mounting bracket to
hydramount and collect mass damper.
7. Remove nut securing hydramount and restraint
bar to body.
8. Loosen nut securing restraint bar to body and
move aside.
9. Remove engine mounting bracket.
10. Remove nut securing hydramount to body.
11. Remove hydramount.
Refit
1. Fit RH hydramount to body, fit and lightly tighten
rear nut.
2. Position mounting bracket to hydramount and
engine.
3. Fit bolts securing mounting bracket to engine and
tighten to 135 Nm.
4. Align restraint bar and fit and tighten nuts to 45
Nm.
5. Tighten nut securing hydramount to body to 45
Nm.
6. Position mass damper, fit nut securing mounting
bracket to hydramount and tighten to 85 Nm.
7. Fit bolt securing mounting bracket to steady bar
and tighten to 85 Nm.
8. Tighten bolt securing steady bar to body to 85
Nm.
9. Remove jack.
10. Remove stand(s) and lower vehicle.
ENGÌNE - 'K16'
REPAÌRS 12-1-39
MOUNTING - ENGINE LH - 'R65 GEARBOX'
´÷ 12.45.30
Remove
1. Disconnect battery earth lead.
2. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
3. Using a rubber block or piece of wood to protect
the gearbox, support the weight of the gearbox
on a jack.
4. Remove 2 bolts securing LH mounting steady bar
and remove steady bar.
5. Remove 2 bolts securing LH mounting to gearbox
bracket.
6. Remove through bolt securing LH mounting to
body bracket.
7. Lower gearbox and remove LH mounting.
8. Collect snubber rubbers.
Refit
1. Fit snubber rubbers to mounting and position
mounting to body bracket.
2. Fit through bolt but do not tighten at this stage.
3. Align gearbox to mounting bracket and bolts but
do not tighten at this stage.
4. Position steady bar and fit bolts but do not tighten
at this stage.
5. Tighten bolts securing LH mounting to gearbox to
100 Nm.
6. Tighten through bolt to 85 Nm.
7. Tighten steady bar bolts to 25 Nm .
8. Remove support jack.
9. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
10. Connect battery earth lead.
ENGÌNE - 'K16'
12-1-40 REPAÌRS
ENGINE LH MOUNTING - 'EM-CVT'
GEARBOX MODELS WITH ABS
´÷ 12.45.30.35
Remove
1. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
2. Remove ECM. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
3. Release 2 relays from battery carrier and position
aside.
4. Release clip securing ABS ECU multiplug to
battery carrier.
5. Remove 3 bolts securing battery carrier to body.
6. Loosen 3 bolts securing battery carrier to body
and remove carrier.
7. Remove 2 bolts and 1 nut securing modulator
mounting bracket to body.
8. Connect hoist to gearbox lifting bracket and
support weight of engine/gearbox.
ENGÌNE - 'K16'
REPAÌRS 12-1-41
9. Remove and discard nut securing gearbox
mounting to bracket.
10. Lower engine/gearbox sufficient to gain access
to gearbox mountings.
11. Release clip securing engine harness to
modulator mounting bracket.
12. Remove 4 bolts securing engine LH mounting
bracket to body.
13. Remove engine mounting and bracket.
14. Remove 2 nuts securing engine mounting to
bracket and remove mounting.
Refit
1. Fit engine mounting to mounting bracket, fit nuts
but DO NOT tighten at this stage.
2. Position engine mounting assembly in vehicle,
ensure modulator rear fixing is correctly
positioned.
3. Fit 2 bolts securing lower half of engine mounting
bracket to body and tighten to 55 Nm.
4. Fit 2 bolts securing upper half of engine mounting
bracket to body and tighten to 55 Nm.
5. Raise engine and gearbox assembly to align
gearbox mounting bracket to engine mounting.
6. Tighten front nut securing engine mounting to
mounting bracket to 45 Nm.
7. Lower engine and gearbox to access rear nut
securing engine mounting to mounting bracket.
8. Tighten rear nut securing engine mounting to
mounting bracket to 45 Nm.
9. Raise engine and gearbox assembly and locate
gearbox mounting bracket on engine mounting.
10. Fit new Nyloc nut securing gearbox mounting
bracket to engine mounting and tighten to 160
Nm.
11. Disconnect hoist from gearbox lifting bracket.
12. Position modulator mounting bracket, fit and
tighten nut and bolts.
13. Fit battery carrier and tighten 6 bolts securing
carrier to body to 10 Nm.
14. Fit ABS ECU multiplug to battery carrier.
15. Fit 2 relays to battery carrier.
16. Fit ECM. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
17. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
ENGÌNE - 'K16'
12-1-42 REPAÌRS
FLYWHEEL - 1.1, 1.4 & 1.6 MODELS WITH
MANUAL GEARBOX
´÷ 12.53.07
Remove
1. Remove clutch assembly. See CLUTCH,
Repairs.
2. Leave flywheel locking tool attached to cylinder
block.
3. Remove CKP sensor. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
4. Remove and discard 6 bolts securing flywheel to
crankshaft.
5. Remove flywheel from crankshaft.
NOTE: Dowel located.
Refit
1. Using an old flywheel bolt with two saw cuts at
45° to bolt shank, clean adhesive from threads of
flywheel bolt holes in crankshaft.
2. Clean flywheel and mating face of crankshaft.
3. Fit flywheel to crankshaft.
4. Fit new bolts securing flywheel to crankshaft and
working in a diagonal sequence tighten bolts to
80 Nm.
5. Fit CKP sensor. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
6. Fit clutch assembly. See CLUTCH, Repairs.
FLYWHEEL - 'EM-CVT' MODELS
´÷ 12.53.07
Remove
1. Remove torsion damper. See ENGINE - 'K16',
Repairs.
2. Disconnect multiplug from CKP sensor.
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.
6. Remove flywheel locking tool 18G 1674.
7. Remove flywheel from crankshaft.
NOTE: Dowel located.
ENGÌNE - 'K16'
REPAÌRS 12-1-43
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 80 Nm.
7. Remove flywheel locking tool 18G 1674.
8. Fit CKP sensor to cylinder block, fit bolt and
tighten to 6 Nm.
9. Connect multiplug to CKP sensor.
10. Fit torsion damper. See ENGINE - 'K16',
Repairs.
TORSION DAMPER - 'EM-CVT' MODELS
´÷ 12.53.13
Remove
1. Remove 'EM-CVT' 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
tighten bolts to 22 Nm.
4. Remove bolt securing flywheel locking tool and
remove tool.
5. Refit 'EM-CVT' gearbox assembly. See
AUTOMATIC GEARBOX - 'EM-CVT', Repairs.
ENGÌNE - 'K16'
12-1-44 REPAÌRS
FLYWHEEL STARTER RING GEAR
´÷ 12.53.19
Remove
1. Remove flywheel. See ENGINE - 'K16', Repairs.
2. Drill a 3 mm diameter hole at root of 2 teeth.
3. Apply a cold chisel to root of ring gear teeth,
strike chisel with hammer to break ring gear.
WARNING: Suitable eye protection must be
worn.
4. Remove starter ring gear.
Refit
1. Clean flywheel and starter ring gear.
2. Heat new starter ring gear evenly to 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 ENGINE - 'K16', Repairs.
OIL FILTER
´÷ 12.60.04
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
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.
4. Remove stand(s) and lower vehicle.
5. Top-up engine oil. See MAINTENANCE.
6. Start and run engine and check for leaks.
7. Stop engine, wait a few minutes, then check oil
level. Top up if necessary.
ENGÌNE - 'K16'
REPAÌRS 12-1-45
DIPSTICK TUBE
´÷ 12.60.09
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Disconnect battery earth lead.
3. Loosen 3 bolts securing PAS pump pulley.
4. Remove PAS pump drive belt. See STEERING,
Repairs.
5. Remove PAS pump pulley bolts and remove
pulley.
6. Remove 3 nuts and bolts securing PAS pump to
mounting bracket.
7. Release PAS pump from bracket and move
aside.
8. Remove 3 bolts securing PAS pump mounting
bracket to cylinder block and remove bracket.
ENGÌNE - 'K16'
12-1-46 REPAÌRS
9. Remove dip stick.
10. Remove bolt securing dipstick tube bracket to
thermostat housing.
11. Remove 2 bolts securing dipstick tube to cylinder
block.
12. Remove dipstick tube, remove and discard
gasket.
Refit
1. Clean dipstick tube and mating face.
2. Fit new gasket, dry and dip stick tube.
3. Fit bolts securing tube to cylinder block.
4. Fit bolt securing dip stick tube to thermostat
housing.
NOTE: Set bolt distance pieces in PAS pump
bracket back 3 mm or so to aid fitting of PAS
pump.
5. Position PAS pump bracket, fit bolts and tighten
to 45 Nm.
6. Locate and align PAS pump to bracket, fit nuts
and bolts and tighten to 25 Nm.
7. Clean PAS pump pulley and mating face.
8. Position pulley and lightly tighten bolts.
9. Fit PAS pump drive belt. See STEERING,
Repairs.
10. Tighten PAS pump pulley bolts to 9 Nm.
11. Remove stand(s) and lower vehicle.
12. Fit dip stick.
13. Check and top-up engine oil level.See
MAINTENANCE.
14. Connect battery earth lead.
ENGÌNE - 'K16'
REPAÌRS 12-1-47
OIL PUMP
´÷ 12.60.26
Remove
1. Remove camshaft timing belt. See ENGINE -
'K16', Repairs.
2. Remove crankshaft gear.
3. Remove 2 bolts securing engine harness to oil
pump.
4. Remove and discard 9 bolts securing oil pump to
cylinder block.
5. Remove lower bolt from timing belt rear cover
and release cover to facilitate oil pump removal.
6. Remove oil pump and discard gasket.
7. Remove and discard crankshaft front oil seal
from oil pump body.
Refit
1. Clean oil pump bolt holes in cylinder block. Clean
mating surfaces of oil pump and cylinder block
and oil seal running surface on crankshaft.
2. Turn oil pump rotor to align drive with crankshaft.
3. Fit new oil pump gasket, dry, to cylinder block.
CAUTION: Do not Iubricate crankshaft front
oiI seaI recess or running surface of
crankshaft.
4. Fit oil seal protection sleeve from seal kit over
end of crankshaft.
NOTE: This will assist in locating oil pump inner
rotor.
5. Position oil pump to cylinder block.
6. Fit new Patchlok bolts and tighten in sequence
shown to 10 Nm.
7. Align engine harness to oil pump, fit bolts and
tighten to 10 Nm.
8. Ensure oil seal protection sleeve is located over
end of crankshaft.
9. Position new crankshaft front oil seal against oil
pump body. Drift oil seal into position using tool
18G 1587.
CAUTION: OiI seaI must be fitted dry.
10. Fit timing belt rear cover bolt and tighten to 9 Nm.
11. Clean crankshaft gear.
12. Fit gear to crankshaft.
13. Fit camshaft timing belt. See ENGINE - 'K16',
Repairs.
ENGÌNE - 'K16'
12-1-48 REPAÌRS
SUMP - ENGINE - RESEAL
´÷ 12.60.38
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain engine oil. See MAINTENANCE.
4. Fit new sealing washer to engine oil drain plug, fit
drain plug and tighten to 28 Nm.
5. Remove 2 nuts securing exhaust front pipe to
manifold, release front pipe. Remove and discard
gasket.
6. Tie front pipe aside.
7. Loosen bolt securing engine lower steady bar to
rear subframe.
8. Remove bolt securing steady bar to sump
bracket.
9. Release steady bar from bracket.
Maual gearbox:
10. Remove 3 bolts securing sump rear flange to
gearbox housing.
All models:
11. Remove 14 bolts securing sump to engine
bearing ladder noting fitted position of 2 longest
bolts, adjacent to sump rear flange.
12. Using a mallet, gently tap sump sideways to
release sealant bond. Remove sump.
ENGÌNE - 'K16'
REPAÌRS 12-1-49
Refit
1. Clean inside of sump and mating faces of sump
and bearing ladder.
2. Fit 18G 1744 alignment pins to bearing ladder in
positions shown.
3. Apply sealant, Part No. GUG 705963GM to sump
joint face then spread to an even film using a
roller.
CAUTION: To avoid contamination, assembIy
shouId be compIeted immediateIy after
appIication of seaIant.
4. Position sump to engine bearing ladder, fit 2 bolts
at positions 5 and 6 and tighten to 4 Nm.
5. Fit 10 bolts into remaining holes ensuring that 2
longest bolts are in original fitted positions,
adjacent to sump rear flange. Lightly tighten
bolts.
6. Remove 18G 1744 alignment pins and fit and
lightly tighten 2 remaining bolts.
Manual gearbox:
7. Fit bolts securing sump rear flange to gearbox
housing, lightly tighten then loosen bolts. This will
align the sump rear flange to gearbox housing.
All models:
8. Progressively tighten shorter sump bolts to 25
Nm and 2 longer bolts to 30 Nm, in the sequence
shown.
ENGÌNE - 'K16'
12-1-50 REPAÌRS
Manual gearbox:
9. Tighten bolts securing sump rear flange to
gearbox housing to 45 Nm.
All models:
10. Position steady bar to sump.
11. Tighten bolt securing engine lower steady bar to
subframe to 80 Nm.
12. Clean exhaust manifold and front pipe mating
faces.
13. Fit new gasket to front pipe, connect front pipe to
exhaust manifold fit nuts and tighten to 45 Nm.
14. Remove stand(s) and lower vehicle.
15. Fill engine with oil. See MAINTENANCE.
16. Connect battery earth lead.
OIL PRESSURE SWITCH
´÷ 12.60.50
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
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 17 Nm .
3. Connect multiplug to oil pressure switch.
4. Remove stand(s) and lower vehicle.
5. Top-up engine oil. See MAINTENANCE.
6. Connect battery earth lead.
ENGÌNE - 'K16'
REPAÌRS 12-1-51
OIL PRESSURE RELIEF VALVE
´÷ 12.60.56
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Disconnect battery earth lead.
3. Loosen 3 bolts securing PAS pump pulley.
4. Remove PAS pump drive belt. See STEERING,
Repairs.
5. Remove PAS pump pulley bolts and remove
pulley.
6. Remove 2 nuts and bolts and lower bolt securing
PAS pump to mounting bracket.
7. Release PAS pump from bracket and move
aside.
8. Remove 3 bolts securing PAS pump mounting
bracket to cylinder block and remove bracket.
9. Remove oil pressure relief valve sealing plug and
Dowty washer, discard washer.
10. Remove spring and relief valve.
ENGÌNE - 'K16'
12-1-52 REPAÌRS
11. Check that valve slides freely in bore and that
valve and bore are free from scoring and
corrosion.
NOTE: Light corrosion may be removed using
grade 600 emery cloth soaked in oil.
12. Check free length of spring:
Spring free length = 38.9 mm.
13. Replace relief valve as an assembly if scoring is
evident or if free length of spring is less than
specified.
Refit
1. Remove all traces of Loctite from threads in relief
valve bore.
2. Clean oil pump housing, valve spring and relief
valve.
3. Lubricate relief valve with clean engine oil.
4. Fit relief valve and spring.
5. Fit new Dowty washer to plug.
6. Apply Loctite 577 to threads of plug, fit and
tighten plug.
7. Set bolt distance pieces in PAS pump mounting
bracket back 3 mm to aid fitting of PAS pump.
8. Position PAS pump bracket, fit bolts and tighten
to 45 Nm.
9. Locate and align PAS pump to bracket, fit 2 nuts
and bolts and lower bolt securing PAS pump to
mounting bracket and tighten to 25 Nm.
10. Clean PAS pump pulley and mating face.
11. Position pulley and lightly tighten bolts.
12. Fit PAS pump drive belt. See STEERING,
Repairs.
13. Tighten PAS pump pulley bolts to 10 Nm.
14. Remove stand(s) and lower vehicle.
15. Connect battery earth lead.
SENSOR - OIL TEMPERATURE
´÷ 12.60.65
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Position drain tin below engine oil filter to collect
spillage.
4. Disconnect multiplug from oil temperature
sensor.
5. Remove oil temperature sensor.
Refit
1. Clean oil temperature sensor threads.
2. Fit oil temperature sensor and tighten to 17 Nm.
3. Connect multiplug to oil temperature sensor.
4. Connect battery earth lead.
5. Top up engine oil. See MAINTENANCE.
ENGÌNE - 'K16'
REPAÌRS 12-1-53
CAMSHAFT TIMING BELT
´÷ 12.65.18
Remove
CAUTION: Camshaft timing beIt must be
repIaced if cyIinder head is to be removed or
new timing gears, tensioner or cooIant pump
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 cover. Do not use a timing beIt if
partiaI engine seizure has occurred. Do not
use a timing beIt if beIt miIeage exceeds
45,000 miIes (72,000 km). Timing beIt must be
repIaced at the specified intervaIs. Do not use
an oiI or cooIant contaminated timing beIt.
The cause of contamination MUST be
rectified.
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove RH front road wheel.
4. Release coolant hose from 3 clips and position
aside.
5. Remove camshaft timing belt upper cover. See
ENGINE - 'K16', Repairs.
6. Using a socket and extension bar on the
crankshaft pulley bolt, rotate crankshaft
clockwise to align camshaft gear timing marks
with mark on backplate - 90°BTDC.
CAUTION: Never use the camshaft gears,
gear retaining boIts or timing beIt to rotate the
crankshaft.
7. Fit camshaft gear locking tool 18G 1570.
8. Remove crankshaft pulley. See ENGINE - 'K16',
Repairs.
9. Fit wooden block to jack and position jack to
support engine.
10. Loosen through bolt securing engine steady bar
to body mounting.
11. Remove through bolt securing engine steady bar
to RH engine mounting and release engine
steady bar.
ENGÌNE - 'K16'
12-1-54 REPAÌRS
12. Remove 2 bolts securing mounting bracket to
engine.
13. Remove nut securing mounting bracket to engine
mounting.
14. Remove 2 nuts securing restraint bar and remove
bar.
15. Remove engine RH mounting.
NOTE: If camshaft timing belt is to be reused,
mark direction of rotation of belt with chalk.
16. Remove and discard timing belt tensioner bolt.
17. Disengage index wire from its fitted position, at
the same time removing timing belt tensioner.
Models with A/C:
18. Hold auxiliary drive belt tensioner, remove pin
and allow tensioner to move fully anti-clockwise.
All models:
19. Remove 3 bolts securing camshaft timing belt
lower cover to cylinder block.
20. Remove camshaft timing belt lower cover and
rubber seal.
21. Remove timing belt
CAUTION: Ease timing beIt off gears using
fingers onIy. MetaI Ievers may damage the
beIt and gears. Do not rotate the engine with
the timing beIt removed and the cyIinder head
fitted.
22. Remove drive gear from crankshaft.
Refit
1. Clean timing belt gears, coolant pump gear and
tensioner pulley.
CAUTION: If the sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in a soIvent bath and
then thoroughIy washed in cIean soIvent
before refitment. Because of the porous
construction of sintered materiaI, oiI
impregnated in the gear wiII emerge and
contaminate a new beIt.
ENGÌNE - 'K16'
REPAÌRS 12-1-55
2. Check that timing marks on camshaft gears are
correctly aligned and that tool 18G 1570 is
locking camshaft gears.
3. Fit drive gear to crankshaft, ensure dots on gear
are aligned with flange on oil pump and that tool
is locking flywheel.
4. Fit timing belt tensioner ensuring that index wire
is positioned over pillar bolt and that tensioner
lever is at 9 o'clock position.
5. Fit new Patchlok bolt and tighten bolt until it is just
possible to move tensioner lever.
6. Fit timing belt over crankshaft drive gear and then
over camshaft gears, keeping belt taut between
crankshaft drive gear and exhaust camshaft
gear.
7. Position belt using fingers only over tensioner
and coolant pump drive gear.
8. Check that timing belt is positioned centrally
around all gears and pulley.
CAUTION: If originaI beIt is being fitted, check
direction of rotation mark is facing correct
way.
9. Fit and align lower timing belt cover, ensuring
correct position of rubber seal.
10. Fit lower timing belt cover screws and tighten to
9 Nm.
NOTE: Do not fit timing belt upper cover at this
stage.
Models with A/C:
11. Rotate auxiliary drive belt tensioner fully
clockwise. Whilst holding tensioner in this
position, with assistance, fit pin into hole in
tensioner backplate
ENGÌNE - 'K16'
12-1-56 REPAÌRS
All models:
12. Fit crankshaft pulley. See ENGINE - 'K16',
Repairs.
13. Using a 6 mm Allen key, rotate tensioner anti-
clockwise and align the pointer to the index wire.
NOTE: If original belt is being refitted align index
wire to lower land of pointer.
CAUTION: Ensure that the pointer
approaches the index wire from above.
ShouId pointer go past index wire, reIease
tension compIeteIy and repeat tensioning
procedure.
14. Ensuring that the pointer maintains correct
position, tighten tensioner bolt to 25 Nm.
15. Remove camshaft gear locking tool 18G 1570.
16. Using crankshaft pulley bolt, rotate crankshaft 2
complete turns clockwise and align camshaft
gear timing marks.
CAUTION: Do not use camshaft gears,
camshaft gear retaining boIts or timing beIt to
rotate crankshaft.
17. Check that pointer is correctly aligned with index
wire.
CAUTION: If pointer is not correctIy aIigned,
carry out the foIIowing procedure.
18. Loosen tensioner bolt until it is just possible to
move the tensioner lever.
19. Using a 6 mm Allen key, rotate tensioner lever
clockwise until pointer is just above the index wire
then rotate the lever anti-clockwise until pointer is
correctly aligned with index wire.
ENGÌNE - 'K16'
REPAÌRS 12-1-57
20. Ensuring pointer maintains correct position,
tighten tensioner bolt to 25 Nm.
21. Using the crankshaft pulley bolt rotate crankshaft
2 complete turns clockwise and align camshaft
gear timing marks.
22. Check that the pointer is correctly aligned with
index wire.
23. Fit engine RH mounting, fit nut and bolts but do
not tighten at this stage.
24. Fit restraint bar, fit nuts and tighten to 45 Nm.
25. Position engine steady bar, fit bolt and tighten to
85 Nm.
26. Tighten bolt securing engine steady bar to body
mounting to 85 Nm.
27. Tighten 2 bolts securing mounting bracket to
engine to 135 Nm.
28. Fit camshaft timing belt upper cover. See
ENGINE - 'K16', Repairs.
29. Fit coolant hose to clips.
30. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
31. Remove stand(s) and lower vehicle.
32. Connect battery earth lead.
COVER - UPPER - CAMSHAFT TIMING
BELT
´÷ 12.65.41
Remove
1. Disconnect battery earth lead.
2. Loosen lower bolt securing camshaft timing belt
upper cover to engine.
3. Remove 5 screws securing camshaft timing belt
upper cover to rear cover.
4. Remove camshaft timing belt upper cover and
rubber seal.
Refit
1. Clean timing belt upper cover.
2. Fit timing belt upper cover, ensuring correct
position of rubber seal.
3. Fit 5 screws securing camshaft timing belt upper
cover to rear cover and tighten to 5 Nm.
4. Tighten bolt securing camshaft timing belt top
cover to engine, to 5 Nm.
5. Connect battery earth lead.
ENGÌNE - 'K16'
12-1-58 REPAÌRS
COVER - LOWER - CAMSHAFT TIMING
BELT
´÷ 12.65.43
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove camshaft timing belt upper cover. See
ENGINE - 'K16', Repairs.
4. Remove crankshaft pulley. See ENGINE - 'K16',
Repairs.
Models with A/C:
5. Hold auxiliary drive belt tensioner, remove pin
and allow tensioner to move fully anti-clockwise.
All models:
6. Remove 3 screws securing camshaft timing belt
lower cover to cylinder block.
7. Remove camshaft timing belt lower cover and
rubber seal.
Refit
1. Clean timing belt lower cover.
2. Fit timing belt lower cover ensuring correct
position of rubber seal.
3. Fit screws securing timing belt lower cover and
tighten to 9 Nm.
Models with A/C:
4. Rotate auxiliary drive belt tensioner fully
clockwise. Whilst holding tensioner in this
position, with assistance, fit pin into hole in
tensioner backplate.
All models:
5. Fit crankshaft pulley. See ENGINE - 'K16',
Repairs.
6. Fit camshaft timing belt upper cover. See
ENGINE - 'K16', Repairs.
7. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-1
ENGÌNE - ' K16 WÌTH VVC' REPAÌ RS
OIL SEAL - EXHAUST CAMSHAFT -
FRONT
´÷ 12.13.07
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel(s).
4. Remove timing belt upper cover. See ENGINE -
'K16 with VVC', Repairs.
5. Using a socket and extension bar on crankshaft
pulley bolt, rotate crankshaft clockwise to align
camshaft gear timing marks - 90° BTDC. Fit 18G
1570 camshaft locking tool between gears.
CAUTION: Do not use camshaft gears, gear
retaining boIts or timing beIt to rotate
crankshaft.
6. Support engine on jack.
CAUTION: PIace a bIock of wood between
sump and jack to prevent damaging the
sump.
7. Loosen bolt securing RH engine steady bar to
body.
8. Remove bolt securing RH engine steady bar to
mounting bracket and release engine steady.
9. Remove nut securing RH hydramount and
restraint bar to body.
10. Loosen nut securing restraint bar to body and
move restraint bar aside.
11. Remove nut securing engine mounting bracket to
hydramount and collect mass damper.
12. Remove 2 bolts securing mounting bracket to
engine and remove bracket.
13. Raise engine on jack.
14. Mark position of tensioner backplate to cylinder
head for belt tensioning reference.
15. Loosen timing belt tensioner pulley Allen screw /
turn.
16. Loosen timing belt tensioner backplate bolt /
turn.
ENGÌNE - 'K16 WÌTH VVC'
12-2-2 REPAÌRS
17. Push tensioner pulley down to fully OFF position
and tighten backplate bolt to 10 Nm.
18. Release timing belt from camshaft gears.
CAUTION: Ease timing beIt from camshaft
gears using fingers onIy, metaI Ievers may
damage beIt and gears. Do not rotate
crankshaft with timing beIt removed. Examine
timing beIt for signs of wear or
contamination. RepIace a timing beIt if worn
or contaminated.
19. Remove 18G 1570 from between camshaft
gears.
20. Using 12-182 to restrain camshaft gear, remove
bolt and plain washer securing camshaft gear to
camshaft and remove gear.
21. Position a cloth to catch oil spillage when oil seal
is removed.
22. Fit camshaft gear bolt back into end of camshaft.
23. To remove the camshaft oil seal, obtain the
centre bolt from 18G 1299A-1 and fit to 18G
1768.
24. Screw 18G 1768 into camshaft oil seal, tighten
centre bolt and extract oil seal from cylinder
head.
25. Discard camshaft oil seal.
26. Remove bolt from camshaft.
Refit
1. Clean sealing area of cylinder head and camshaft
carrier ensuring that all traces of rubber are
removed.
CAUTION: Do not use a metaI scraper or the
machined surfaces may be damaged. Do not
Iubricate seaIing surfaces or oiI seaI running
surface of camshaft.
2. Position 18G 1749 oil seal protector onto end of
camshaft.
3. Fit new camshaft oil seal using 18G 1769A.
CAUTION: OiI seaI must be fitted dry. DO NOT
use tooI 18G 1769 to fit oiI seaI.
NOTE: Camshaft front oil seals are coloured
black.
4. Clean gear and camshaft mating faces.
CAUTION: Do not use a metaI scraper or the
machined surfaces may be damaged. If the
sintered gears have been subjected to
proIonged oiI contamination, they must be
soaked in a soIvent bath before refitting.
Because of the porous construction of
sintered materiaI, oiI impregnated in the
gears wiII emerge and contaminate the beIt.
5. Fit gear to camshaft, fit plain washer and bolt.
6. Using 12-182 to restrain camshaft gear, tighten
bolt to 65 Nm.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-3
7. Align camshaft gears and fit locking tool 18G
1570.
8. Check that the timing marks on the camshaft
gears are correctly aligned.
9. Using fingers only, fit timing belt over exhaust
and inlet camshaft gears and tensioner pulley
keeping belt taut between crankshaft timing gear
and exhaust camshaft gear.
10. Check that timing belt is positioned centrally
around camshaft gears and pulley.
11. Loosen tensioner backplate bolt / turn.
12. Position tensioner, align to reference mark on
backplate and cylinder head.
13. Tighten tensioner backplate bolt to 10 Nm.
14. Tighten tensioner pulley Allen screw to 45 Nm.
15. Remove camshaft gear locking tool 18G 1570.
16. Rotate crankshaft 2 complete turns clockwise
and check that camshaft gear timing marks are
aligned.
CAUTION: Do not use camshaft gears, gear
retaining boIts or timing beIt to rotate
crankshaft.
ENGÌNE - 'K16 WÌTH VVC'
12-2-4 REPAÌRS
17. Fit timing belt upper cover. See ENGINE - 'K16
with VVC', Repairs.
18. Position mounting bracket to engine and
hydramount, fit mass damper and nut, lightly
tighten nut.
19. Align mounting bracket to engine, fit bolts and
tighten to 135 Nm.
20. Align restraint bar, fit and tighten nuts to 45 Nm.
21. Tighten nut securing mounting bracket to
hydramount to 85 Nm.
22. Position RH steady bar to mounting bracket, fit
and tighten bolt to 85 Nm.
23. Tighten bolt securing RH steady bar to body to 85
Nm.
24. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
25. Remove stand(s) and lower vehicle.
26. Connect battery earth lead.
OIL SEAL - EXHAUST CAMSHAFT - REAR
´÷ 12.13.08
Remove
1. Disconnect battery earth lead.
2. Remove camshaft rear timing belt. See ENGINE
- 'K16 with VVC', Repairs.
3. Position a cloth to collect oil spillage.
4. Fit camshaft gear bolt back into end of camshaft.
5. To remove the camshaft oil seal, obtain the
centre bolt from 18G 1299A-1 and fit to 18G
1768.
6. Screw 18G 1768 into camshaft oil seal, tighten
centre bolt and extract oil seal from cylinder
head.
7. Discard camshaft oil seal.
8. Remove bolt from camshaft.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-5
Refit
1. Clean sealing area of cylinder head and
camshaft, ensuring all traces of rubber are
removed.
CAUTION: Do not use a metaI scraper or
seaIing surfaces may be damaged. Do not
Iubricate seaIing surfaces or oiI seaI running
surface of camshaft.
2. Fit 18G 1749 to end of camshaft and fit oil seal
using 18G 1769A.
CAUTION: Camshaft oiI seaI must be fitted
dry. DO NOT use tooI 18G 1769. to fit oiI seaI.
NOTE: Camshaft rear oil seals are coloured red.
3. Fit camshaft rear timing belt.See ENGINE - 'K16
with VVC', Repairs.
4. Connect battery earth lead.
OIL SEAL - INLET CAMSHAFT - FRONT
´÷ 12.13.09
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel(s).
4. Remove timing belt upper cover.See ENGINE -
'K16 with VVC', Repairs.
5. Using a socket and extension bar on crankshaft
pulley bolt, rotate crankshaft clockwise to align
camshaft gear timing marks - 90° BTDC. Fit 18G
1570 camshaft locking tool between gears.
CAUTION: Do not use camshaft gears, gear
retaining boIts or timing beIt to rotate
crankshaft.
6. Support engine on jack.
CAUTION: PIace a bIock of wood between
sump and jack to prevent damaging the
sump.
ENGÌNE - 'K16 WÌTH VVC'
12-2-6 REPAÌRS
7. Loosen bolt securing RH engine steady bar to
body.
8. Remove bolt securing RH engine steady bar to
mounting bracket and release engine steady.
9. Remove nut securing RH hydramount and
restraint bar to body.
10. Loosen nut securing restraint bar to body and
move bar aside.
11. Remove nut securing mounting bracket to
hydramount and collect mass damper.
12. Remove 2 bolts securing mounting bracket to
engine and remove bracket.
13. Raise engine on jack.
14. Mark position of tensioner backplate to cylinder
head for belt tensioning reference.
15. Loosen timing belt tensioner pulley Allen screw /
turn.
16. Loosen timing belt tensioner backplate bolt /
turn.
17. Push tensioner pulley down to fully OFF position
and tighten backplate bolt to 10 Nm.
18. Release timing belt from camshaft gears.
CAUTION: Remove timing beIt using fingers
onIy, metaI Ievers may damage beIt and
gears. Do not rotate crankshaft with timing
beIt removed. Examine timing beIt for signs of
wear and contamination. RepIace a timing
beIt if worn or contaminated.
19. Remove 18G 1570 from between camshaft
gears.
20. Using 12-182 to restrain camshaft gear, remove
bolt and plain washer securing camshaft gear to
camshaft and remove gear.
21. Position a cloth to catch oil spillage when oil seal
is removed.
22. Fit camshaft gear bolt back into end of camshaft.
23. To remove the camshaft oil seal, obtain the
centre bolt from 18G 1299A-1 and fit to 18G
1768.
24. Screw 18G 1768 into camshaft oil seal, tighten
centre bolt and extract oil seal from cylinder
head.
25. Discard camshaft oil seal.
26. Remove bolt from camshaft.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-7
Refit
1. Clean sealing area of cylinder head and camshaft
carrier ensuring that all traces of rubber are
removed.
CAUTION: Do not use a metaI scraper or the
machined surfaces may be damaged. Do not
Iubricate seaIing surfaces or oiI seaI running
surface of camshaft.
2. Fit new camshaft oil seal using 18G 1604A.
CAUTION: OiI seaI must be fitted dry. DO NOT
use tooI 18G 1604. to fit oiI seaI.
NOTE: Camshaft front oil seals are coloured
black.
3. Clean gear and camshaft mating faces.
CAUTION: Do not use a metaI scraper or the
machined or the machined surfaces may be
damaged. If the sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in a soIvent bath before
refitting. Because of the porous construction
of sintered materiaI, oiI impregnated in the
gears wiII emerge and contaminate the beIt.
4. Fit gear to camshaft.
5. Fit plain washer and bolt and using 12-182 to
restrain camshaft gear, tighten bolt to 65 Nm.
6. Align camshaft gears and fit locking tool 18G
1570.
7. Check that the timing marks on the camshaft
gears are correctly aligned.
8. Using fingers only, fit timing belt over exhaust
and inlet timing gears and tensioner pulley
keeping belt taut between crankshaft timing gear
and exhaust camshaft gear.
9. Check that timing belt is positioned centrally
around camshaft gears and pulley.
ENGÌNE - 'K16 WÌTH VVC'
12-2-8 REPAÌRS
10. Loosen tensioner backplate bolt / turn.
11. Position tensioner, align to reference mark on
backplate and cylinder head.
12. Tighten tensioner backplate bolt to 10 Nm.
13. Tighten tensioner pulley Allen screw to 45 Nm.
14. Remove camshaft gear locking tool 18G 1570.
15. Rotate crankshaft clockwise 2 complete turns
clockwise and check that camshaft gear timing
marks are aligned.
CAUTION: Do not use camshaft gears, gear
retaining boIts or timing beIt to rotate
crankshaft.
16. Position mounting bracket to engine and
hydramount, fit mass damper and nut, lightly
tighten nut.
17. Align mounting bracket to engine, fit bolts and
tighten to 135 Nm.
18. Align restraint bar, fit and tighten nuts to 45 Nm.
19. Tighten nut securing mounting bracket to
hydramount to 85 Nm.
20. Position RH steady bar to mounting bracket, fit
and tighten bolt to 85 Nm.
21. Tighten bolt securing RH steady bar to body to 85
Nm.
22. Fit timing belt upper cover. See ENGINE - 'K16
with VVC', Repairs.
23. Remove jack.
24. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
25. Remove stand(s) and lower vehicle.
26. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-9
OIL SEAL - INLET CAMSHAFT REAR
´÷ 12.13.10
Remove
1. Disconnect battery earth lead.
2. Remove camshaft rear timing belt. See ENGINE
- 'K16 with VVC', Repairs.
3. Fit camshaft gear bolt back into end of camshaft.
4. To remove the camshaft oil seal, obtain the
centre bolt from 18G 1299A-1 and fit to 18G
1768.
5. Screw 18G 1768 into camshaft oil seal, tighten
centre bolt and extract oil seal from cylinder
head.
6. Discard camshaft oil seal.
7. Remove bolt from camshaft.
Refit
1. Clean sealing area of cylinder head and
camshaft, ensuring all traces of rubber are
removed.
CAUTION: Do not use a metaI scraper or the
machined surfaces may be damaged. Do not
Iubricate seaIing surfaces or oiI seaI running
surface of camshaft.
2. Fit camshaft oil seal using 18G 1604A.
CAUTION: Camshaft oiI seaI must be fitted
dry. Do not use tooI 18G 1604. to fit oiI seaI.
NOTE: Camshaft rear oil seals are coloured red.
3. Fit camshaft rear timing belt. See ENGINE - 'K16
with VVC', Repairs.
4. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
12-2-10 REPAÌRS
CARRIER - CAMSHAFT
´÷ 12.13.22
Remove
1. Remove hydraulic control unit. See ENGINE -
'K16 with VVC', Repairs.
2. Remove camshaft gear locking tool 18G 1570.
3. Suitably identify each camshaft timing gear to its
respective camshaft.
4. Using tool 12-182, restrain each camshaft timing
gear in turn and remove bolt and washer securing
each gear to camshaft; remove gears.
5. Remove 5 screws securing camshaft timing belt
rear cover, remove cover.
NOTE: Longest screw secures rear cover to
coolant pump.
6. Remove 4 bolts securing rear camshaft timing
belt rear cover, remove cover.
7. Remove and discard 2 bolts securing each VVC
housing to cylinder head.
8. Loosen 2 bolts securing each VVC housing to
camshaft carrier by one turn.
CAUTION: Do not exceed one turn.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-11
9. Using sequence shown, progressively loosen
and noting the fitted position of 4 longest bolts,
remove 32 bolts securing camshaft carrier to
cylinder head.
CAUTION: During the foIIowing operations, it
is essentiaI to ensure that front and rear inIet
camshafts are retained in their respective
VVC assembIies. If camshafts are removed
from their VVC assembIies, then compIete
assembIy must be repIaced; it is not
permissibIe to refit camshafts to VVC
assembIies.
10. Ensuring that front and rear inlet camshafts are
retained in camshaft carrier and VVC
assemblies, carefully release camshaft carrier
from cylinder head.
NOTE: Dowel located.
11. Lift camshaft carrier together with front and rear
inlet camshafts off cylinder head.
CAUTION: Ensure that exhaust camshaft is
retained in cyIinder head as camshaft carrier
is removed.
12. Ensuring that front and rear inlet camshafts are
retained in camshaft carrier, invert carrier.
13. Loosen but do not remove 2 bolts securing each
VVC housing to camshaft carrier.
CAUTION: BoIts shouId onIy be Ioosened
sufficientIy to enabIe timing pIates 18G 1770/
1 and 18G 1770/2 to be fitted.
14. Fit timing plates 18G 1770/1 to front and 18G
1770/2 to rear VVC assemblies.
15. Assemble clamps 18G 1770 to front and rear inlet
camshafts and VVC assemblies, fit camshaft
gear bolts and washers to retain clamps.
ENGÌNE - 'K16 WÌTH VVC'
12-2-12 REPAÌRS
16. Suitably identify each VVC assembly to its fitted
position. Do not attempt to interchange front and
rear assemblies.
17. Remove and discard 2 bolts securing each VVC
housing to camshaft carrier.
18. Remove front and rear camshafts together with
VVC assemblies.
CAUTION: Do not remove cIamps 18G 1770.
19. Remove control shaft from camshaft carrier.
20. Remove exhaust camshaft from cylinder head.
21. Remove and discard exhaust camshaft oil seals.
22. Using a stick magnet, remove 16 tappets from
cylinder head.
CAUTION: Retain tappets in their fitted order
and invert to prevent oiI Ioss. Do not squeeze
tappet chambers together.
NOTE: With VVC assemblies removed, it will be
necessary to replace VVC housing gaskets, to do
this, carry out the following procedures.
VVC housing gasket - remove
23. Secure VVC housing and camshaft in a soft-
jawed vice with camshaft positioned upwards.
CAUTION: OnIy tighten vice sufficientIy to
retain housing, damage to housing wiII resuIt
if vice is overtightened.
24. Taking care not to allow camshaft to become
separated from VVC mechanism, remove clamp
18G 1770 and timing plate 18G 1770/1 - front or
18G 1770/2 - rear.
25. Remove and discard VVC housing gasket.
26. Repeat above procedures for remaining housing
gasket.
VVC housing gasket - refit
27. Remove all traces of old gasket from VVC
housing.
CAUTION: Do not use a metaI scraper.
28. Lubricate new gasket with engine oil.
NOTE: To assist correct location of VVC housing
gasket in its fitted position, apply a light film of
grease to gasket face of VVC housing.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-13
29. Fit timing plate 18G 1770/1 - front or 18G 1770/2
- rear.
30. Fit gasket, align bolt holes.
31. Assemble clamp 18G 1770 to camshaft and VVC
assembly, fit camshaft gear bolt and washer to
retain clamp.
32. Remove VVC housing and camshaft from vice.
33. Repeat above procedures for remaining VVC
housing gasket.
Refit
1. Clean camshafts, clean mating faces of cylinder
head and camshaft carrier.
CAUTION: Do not use a metaI scraper. CIean
boIt and doweI hoIes.
2. Blow out oilways and lubricate control shaft and
camshaft journals.
CAUTION: Do not Iubricate oiI seaI running
surfaces on exhaust camshaft.
3. Lubricate tappets and tappet bores with engine
oil.
4. Ensuring that tappets are in original fitted order,
position each tappet in its bore.
5. Position control shaft in camshaft carrier
ensuring that shaft is fully seated in journals and
centre of slot in shaft is aligned with cylinder head
mating surface of carrier.
6. Position front and rear inlet camshafts and VVC
assemblies in camshaft carrier at the same time
engaging teeth of control shaft in VVC
assemblies.
7. Check that bolt holes in VVC housings are
aligned with bolt holes in camshaft carrier, that
centre of slot in control shaft is still aligned with
mating surface of carrier and timing plates 18G
1770/1 - front and 18G 1770/2 - rear are correctly
located in the control sleeves and control shaft is
still seated in journals.
CAUTION: If boIt hoIes are not correctIy
aIigned or sIot in controI shaft has moved, re-
position VVC assembIies and shaft as
necessary untiI aIignment is correct. Ensure
gasket boIt hoIes are stiII correctIy aIigned.
8. Fit and lightly tighten slave bolts to secure front
and rear VVC assemblies to camshaft carrier.
CAUTION: SIave boIts must be repIaced with
new PatchIok boIts when camshaft carrier is
fitted.
ENGÌNE - 'K16 WÌTH VVC'
12-2-14 REPAÌRS
9. Remove clamps 18G 1770.
CAUTION: Do not remove timing pIates at this
stage or damage to VVC housing seaIs wiII
resuIt.
10. Apply continuous, thin beads of sealant, Part No.
GUG 705963GM to paths on cylinder head as
shown then spread to an even film using a roller.
CAUTION: Ensure that seaIant is kept cIear of
oiI feed hoIes, oiI grooves and controI shaft
journaIs and that assembIy is compIeted
within 20 minutes of appIying seaIant.
11. Position exhaust camshaft in cylinder head.
CAUTION: During the foIIowing operations, it
is essentiaI to ensure that front and rear inIet
camshafts are retained in the camshaft
carrier and their respective VVC assembIies.
Take great care not to rotate camshafts or
controI shaft.
12. Ìnvert camshaft carrier and fit to cylinder head.
13. Fit 32 bolts noting that 4 longest bolts are fitted at
each end of camshaft carrier.
14. Using sequence shown, progressively tighten
bolts to 10 Nm.
15. Remove timing plates 18G 1770/1 - front and
18G 1770/2 - rear.
16. Remove slave bolts securing VVC housings to
camshaft carrier and fit and tighten new Patchlok
bolts - front and rear VVC housings to camshaft
carrier to 10 Nm.
17. Fit and tighten new Patchlok bolts - VVC
housings to cylinder head to 10 Nm.
Exhaust camshaft rear oil seal illustrated.
18. Fit new exhaust camshaft front and rear oil seals
using oil seal protector 18G 1749 and tool 18G
1769A.
NOTE: Front oil seals are coloured BLACK, rear
oil seals are coloured RED.
CAUTION: OiI seaIs must be fitted dry. DO
NOT use tooI 18G 1769.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-15
19. Fit rear timing belt rear cover, fit bolts and tighten
to:
¤ M5 bolts - 6 Nm
¤ M6 bolts - 10 Nm
20. Fit camshaft timing belt rear cover, fit screws and
tighten to 9 Nm.
21. Fit front camshaft gears to their respective
camshafts, fit bolts and washers.
22. Using tool 12-182, restrain each gear in turn and
tighten retaining bolt to 65 Nm.
23. Using tool 12-182, align camshaft gear timing
marks and fit locking tool 18G 1570.
24. Fit hydraulic control unit. See ENGINE - 'K16
with VVC', Repairs.
CRANKSHAFT FRONT PULLEY
´÷ 12.21.01
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
4. Remove starter motor. See ELECTRICAL,
Repairs.
5. Fit flywheel locking tool 18G 1742 to flywheel
housing and secure with 2 bolts.
6. Remove bolt securing pulley to crankshaft and
collect washer.
7. Remove crankshaft pulley.
ENGÌNE - 'K16 WÌTH VVC'
12-2-16 REPAÌRS
Refit
1. Fit crankshaft pulley to crankshaft gear ensuring
that indent on pulley locates over lug on gear
(arrowed in illustration).
2. Fit washer and bolt securing crankshaft pulley to
crankshaft and tighten to 205 Nm.
3. Remove 2 bolts securing tool 18G 1742 to
flywheel housing and remove tool 18G 1742.
4. Fit starter motor. See ELECTRICAL, Repairs.
5. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
6. Connect battery earth lead.
CRANKSHAFT FRONT OIL SEAL
´÷ 12.21.14
Remove
1. Remove camshaft timing belt. See ENGINE -
'K16 with VVC', Repairs.
2. Remove crankshaft gear.
3. Fit thrust button, tool 18G 705-1A/3 to end of
crankshaft.
4. Ensure bore of tool 18G 1566 is free from burrs.
Screw tool 18G 1566 into crankshaft front oil
seal.
5. Tighten centre bolt of tool 18G 1566 to remove oil
seal.
6. Discard crankshaft front oil seal.
7. Remove thrust button 18G 705-1A/3 from
crankshaft.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-17
Refit
1. Using a lint free cloth, thoroughly clean oil seal
recess in oil pump and running surface on
crankshaft.
CAUTION: Do not Iubricate oiI seaI recess or
running surface on crankshaft.
2. Fit oil seal guide, from seal kit, over end of
crankshaft.
3. Position new seal on crankshaft up against oil
pump housing. Drift seal into place using tool
18G 1587.
CAUTION: OiI seaI must be fitted dry.
4. Remove tool 18G 1587 and oil seal guide.
5. Clean crankshaft gear.
6. Fit crankshaft gear to crankshaft.
7. Fit camshaft timing belt. See ENGINE - 'K16 with
VVC', Repairs.
CRANKSHAFT REAR OIL SEAL
´÷ 12.21.20
Remove
1. Remove engine flywheel. See ENGINE - 'K16
with VVC', Repairs.
2. Using a burr free flat ended screwdriver, ease
crankshaft rear oil seal from cylinder block and
discard seal.
CAUTION: Do not mark seaIing surface on
crankshaft.
Refit
1. Clean oil seal recess in cylinder block and
running surface on crankshaft. Ìt is essential that
these areas are thoroughly clean, free of old
sealant and dry.
2. Apply a 1.5 mm thick continuous bead of sealant,
Part no. GAC 8000 to new oil seal as shown.
CAUTION: Do not appIy oiI or grease to any
part of the oiI seaI or running surface of
crankshaft. OiI seaI must be fitted
immediateIy after appIying seaIant.
ENGÌNE - 'K16 WÌTH VVC'
12-2-18 REPAÌRS
3. Position oil seal to cylinder block and fit oil seal
replacer 18G 1574, using 3 slave bolts to retain
tool.
4. Evenly tighten oil seal replacer bolts to press oil
seal squarely into cylinder block.
5. Leave oil seal replacer 18G 1574 and oil seal in
the clamped position for one minute to allow oil
seal to relax.
6. Remove 18G 1574 oil seal replacer.
7. Allow sealant to cure for a minimum of 30
minutes before topping-up engine oil or rotating
crankshaft.
8. Fit flywheel. See ENGINE - 'K16 with VVC',
Repairs.
GASKET - CYLINDER HEAD
´÷ 12.29.02
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
4. Remove bolt securing dipstick tube to access
rear cover bolt.
5. Remove and discard camshaft timing belt. See
ENGINE - 'K16 with VVC', Repairs.
6. Remove bolt securing camshaft timing belt
tensioner backplate to cylinder head.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-19
7. Remove Allen bolt securing camshaft timing belt
tensioner pulley to cylinder head.
8. Remove camshaft timing belt tensioner.
9. Remove 18G 1570 from between camshaft
gears.
10. Restrain camshaft gears using 12-182 and
remove bolts and washers securing camshaft
gears to camshafts.
11. Mark camshaft gears for assembly purposes.
Remove camshaft gears.
12. Remove 5 screws securing camshaft timing belt
rear cover to cylinder head and block.
NOTE: Longest screw secures rear cover to
coolant pump.
13. Remove rear cover.
14. Release brake servo vacuum hose from inlet
manifold.
15. Release clip and remove evaporative emission
cannister hose from inlet manifold.
16. Release throttle cable adjustment nut from
abutment bracket.
17. Release throttle cable from throttle cam.
18. Position absorbent cloth around fuel feed and
return pipes and release quick release
connections.
ENGÌNE - 'K16 WÌTH VVC'
12-2-20 REPAÌRS
19. Release clip and disconnect coolant hose from
inlet manifold.
20. Disconnect multiplug from MAP sensor.
21. Remove bolt securing inlet manifold to support
stay.
22. Remove clip and disconnect air intake pipe from
throttle body.
23. Disconnect multiplug from TP sensor.
24. Release injector harness multiplug from
mounting bracket and disconnect from engine
harness.
25. Disconnect multiplug from ÌAT sensor.
26. Release HO
2
S multiplug from rear timing belt
cover.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-21
27. Disconnect multiplug from CMP sensor.
28. Disconnect multiplug from oil temperature
sensor.
29. Disconnect 2 multiplugs from hydraulic control
solenoids.
30. Disconnect multiplug from ÌAC valve.
31. Remove camshaft cover gasket. See ENGINE -
'K16 with VVC', Repairs.
32. Remove exhaust manifold gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
33. Loosen clips and disconnect 2 coolant hoses
from coolant outlet elbow.
34. Disconnect 2 multiplugs from coolant outlet
elbow.
35. Progressively loosen cylinder head to oil rail bolts
numbers 1 to 6 in sequence shown.
36. Temporarily fit camshaft timing gears, fit and
lightly tighten bolts.
37. Using tool 12-182 rotate camshafts to gain
access to cylinder head bolts numbers 7 and 8
beneath camshaft reluctor rings.
38. Working in sequence shown, progressively
loosen cylinder head bolts numbers 7 to 10.
39. Remove camshaft timing gears.
40. Remove cylinder head bolts and store in fitted
order.
CAUTION: RemovaI of cyIinder head boIts
resuIts in a 'tightening-up' of crankshaft;
rotation of crankshaft must, therefore, be
kept to a minimum. Do not rotate crankshaft
untiI cyIinder Iiner retainer cIamps 18G 1736
are fitted.
41. Using assistance, remove cylinder head from
cylinder block.
CAUTION: CyIinder head is doweI Iocated, do
not tap it sideways to free it from cyIinder
bIock. PIace cyIinder head on bIocks of wood
to prevent damaging vaIves.
ENGÌNE - 'K16 WÌTH VVC'
12-2-22 REPAÌRS
42. Remove and discard cylinder head gasket from
cylinder block.
43. Remove 2 location dowels from cylinder block.
44. Fit cylinder liner clamps 18G 1736 to cylinder
block and secure using cylinder head bolts.
Tighten bolts sufficiently to retain clamps.
CAUTION: Ensure that boIts used are those
originaIIy used in that Iocation.
Refit
1. Clean mating faces of cylinder head and cylinder
block.
2. Clean oil and coolant passages, inlet and
exhaust manifold and cylinder head joint
surfaces.
3. Ìf necessary, de-carbonise piston crowns and
cylinder head.
4. Check cylinder head for damage, pay particular
attention to gasket face of cylinder head.
5. Check cylinder head face for warping, across
centre and from corner to corner as shown:
Maximum warp = 0.05 mm
6. Check cylinder head height:
New = 118.95 to 119.05 mm
Reface limit = 0.20 mm
7. Clean cylinder head bolts and inspect for
damage.
8. Wash cylinder head bolts and wipe dry. Apply a
light film of oil to bolt threads and underside of
bolt heads.
9. Clean location dowels and fit to cylinder block.
CAUTION: If crankshaft has been rotated,
check that dots on crankshaft timing gear are
aIigned with fIange on oiI pump.
10. Remove bolts securing cylinder liner clamps 18G
1736 to cylinder block and remove clamps.
CAUTION: Do not rotate crankshaft with
cIamps removed.
11. Fit NEW cylinder head gasket, dry, to cylinder
block.
12. With assistance, fit cylinder head onto cylinder
block and carefully locate on dowels.
13. Carefully enter cylinder head bolts, DO NOT
DROP. Screw bolts into place by hand.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-23
14. Temporarily fit camshaft timing gears, fit and
lightly tighten bolts.
15. Rotate camshafts using tool 12-182 to gain
access to cylinder head bolts 3 and 4.
16. Working in the sequence shown, progressively
tighten the cylinder head bolts using the following
procedure:
¤ All bolts to 20 Nm. Use a felt tip pen and mark
position of radial mark on each bolt head
¤ Turn all bolts through 180°
¤ Turn all bolts through another 180° and align
mark
CAUTION: If any boIt is overtightened, back
off 90° and reaIign radiaI marks.
17. Remove camshaft timing gears.
18. Fit camshaft cover gasket. See ENGINE - 'K16
with VVC', Repairs.
19. Connect multiplugs to coolant outlet elbow.
20. Fit coolant hoses to outlet elbow and secure with
clips.
21. Fit exhaust manifold gasket. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
22. Position inlet manifold support stay, fit and
tighten bolt to 25 Nm.
23. Connect multiplugs to hydraulic control
solenoids.
24. Connect multiplug to CMP sensor.
25. Connect multiplug to oil temperature sensor.
26. Connect multiplug to ÌAC valve.
27. Connect injector harness multiplug and secure to
mounting bracket.
28. Connect multiplug to TP sensor.
29. Connect multiplug to ÌAT sensor.
30. Connect multiplug to MAP sensor.
31. Connect fuel feed and return pipes.
32. Connect air intake pipe to throttle body and
secure with clip.
33. Fit camshaft timing belt rear cover to cylinder
head and cylinder block.
34. Fit screws securing camshaft timing belt rear
cover to cylinder head and block and tighten to 9
Nm.
35. Fit bolt securing dipstick tube and tighten to 9
Nm.
36. Fit 2 camshaft gears to their respective
camshafts ensuring that drive pins are located in
correct slots in gears.
37. Fit bolts and washers securing camshaft gears to
camshafts. Using 12-182 restrain camshaft gears
and tighten bolts to 65 Nm.
38. Using 12-182, align camshaft gear timing marks
and fit camshaft gear locking tool 18G 1570.
39. Fit camshaft timing belt tensioner to cylinder
head.
40. Fit tensioner pulley Allen bolt.
41. Fit new camshaft timing belt. See ENGINE - 'K16
with VVC', Repairs.
42. Connect brake servo vacuum hose to inlet
manifold.
43. Connect EVAP cannister hose to inlet manifold
and secure with clip.
44. Fit coolant hose to inlet manifold and secure with
clip.
45. Connect throttle cable to throttle cam.
46. Connect throttle cable adjustment nut to
abutment bracket.
47. Remove stand(s) and lower vehicle.
48. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments.
49. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
50. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
12-2-24 REPAÌRS
GASKET - CAMSHAFT COVER
´÷ 12.29.40
Remove
1. Disconnect battery earth lead.
2. Remove ignition coils. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
3. Release 2 clips and disconnect 2 breather hoses
from camshaft cover.
4. Release harness clip from camshaft cover.
5. Remove bolt securing CMP sensor to camshaft
cover, remove sensor and position aside.
6. Remove and discard 'O' ring from CMP sensor.
7. Progressively loosen and remove 15 bolts
securing camshaft cover.
8. Remove camshaft cover, remove and discard
gasket.
NOTE: Check condition of sealing path. It should
be complete and attached to gasket. Remove
gasket from camshaft cover only if sealing path is
damaged or detached from gasket.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-25
Refit
1. Clean mating surfaces of camshaft cover and
carrier.
2. Clean inside of camshaft cover. Ìf necessary,
wash oil separator elements in solvent and blow
dry.
3. Fit new camshaft cover gasket with 'EXHAUST
MANÌFOLD SÌDE' mark towards exhaust
manifold.
4. Fit camshaft cover to camshaft carrier, fit bolts
and working in the sequence shown,
progressively tighten bolts to 10 Nm.
5. Lubricate a new 'O' ring with engine oil and fit to
CMP sensor.
6. Fit CMP sensor, fit bolt and tighten to 5 Nm.
7. Secure harness clip to camshaft cover.
8. Connect breather hoses and secure with clips.
9. Fit ignition coils. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
10. Connect battery earth lead.
HYDRAULIC CONTROL UNIT
´÷ 12.30.30
Remove
1. Remove inlet manifold. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove front road wheels.
4. Remove camshaft timing belt upper cover. See
ENGINE - 'K16 with VVC', Repairs.
5. Using a socket and extension bar on crankshaft
pulley bolt, rotate crankshaft clockwise to align
camshaft gear timing marks - 90° BTDC. Fit 18G
1570 camshaft gear locking tool between gears.
CAUTION: Do not use camshaft gears, gear
retaining boIts or timing beIt to rotate
crankshaft.
6. Support engine on jack.
CAUTION: PIace a bIock of wood between
sump and jack to prevent damaging the
sump.
ENGÌNE - 'K16 WÌTH VVC'
12-2-26 REPAÌRS
7. Loosen bolt securing RH engine steady bar to
body.
8. Remove bolt securing RH engine steady bar to
mounting bracket and release engine steady.
9. Remove nut securing RH hydramount and
restraint bar to body.
10. Loosen nut securing restraint bar to body and
move restraint bar aside.
11. Remove nut securing engine mounting bracket to
hydramount and collect mass damper.
12. Remove 2 bolts securing mounting bracket to
engine and remove bracket.
13. Raise engine on jack.
14. Mark position of tensioner backplate to cylinder
head for belt tensioning reference.
15. Loosen timing belt tensioner pulley Allen screw /
turn
16. Loosen timing belt tensioner backplate bolt /
turn.
17. Push tensioner pulley down to fully OFF position
and tighten backplate bolt to 10 Nm.
18. Release timing belt from camshaft gears.
CAUTION: Use fingers onIy to reIease timing
beIt, metaI Ievers may damage beIt and gears.
Do not rotate crankshaft with timing beIt
removed. Examine timing beIt for signs of
wear or contamination. RepIace a timing beIt
if worn or contaminated.
19. Remove camshaft rear timing belt. See ENGINE
- 'K16 with VVC', Repairs.
20. Remove camshaft cover gasket. See ENGINE -
'K16 with VVC', Repairs.
21. Remove camshaft gear locking tool 18G 1570.
22. Disconnect multiplug from oil temperature
sensor.
23. Disconnect 2 multiplugs from hydraulic control
unit solenoids.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-27
24. Remove oil temperature sensor, remove and
discard sealing washer.
25. Remove 3 bolts securing hydraulic control unit to
camshaft carrier.
26. Remove hydraulic control unit, remove seal
plate.
27. Remove and discard 2 labyrinth seals and rack
seal from seal plate.
CAUTION: Take care not to damage seaI
retaining Iugs on seaI pIate.
NOTE: If hydraulic control unit only is to be
replaced, it will be necessary to transfer
solenoids to the replacement unit.
28. Suitably identify each solenoid to its fitted
position.
29. Remove sleeve bolt nut, remove and discard 'O'
ring.
30. Remove outer solenoid, washer and 'O' ring;
discard 'O' ring.
31. Remove inner solenoid, remove and discard 'O'
ring.
32. Remove spool valve, remove and discard 'O'
rings from valve.
33. Remove and discard 'O' ring from inner solenoid.
ENGÌNE - 'K16 WÌTH VVC'
12-2-28 REPAÌRS
Refit
1. Clean seal plate and mating surfaces on
camshaft carrier, ensure bolt holes are clean and
dry.
2. Lubricate new labyrinth seals with engine oil.
3. Using the fingers only, fit labyrinth seals each
side of seal plate.
CAUTION: Ensure seaIs are Iocated beneath
retaining Iugs.
4. Fit rack seal to seal plate.
5. Lubricate 3 new 'O' rings with engine oil and fit to
spool valve.
6. Lubricate new 'O' rings with engine oil and fit to
each side of spool valve nut, washer, inner
solenoid and sleeve bolt side of outer solenoid.
7. Lubricate spool valve and bore in hydraulic
control unit with engine oil.
8. Position spool valve to hydraulic control unit, fit
valve, twisting it slightly as it is inserted to avoid
damaging 'O' rings.
9. Tighten spool valve to 26 Nm.
10. Position inner solenoid on spool valve ensuring
that lettering on end of solenoid is facing away
from hydraulic control unit.
11. Fit washer and 'O' ring.
12. Position outer solenoid on spool valve ensuring
that lettering on end of solenoid is facing away
from hydraulic control unit.
13. Fit 'O' ring to outer solenoid.
14. Fit but do not tighten sleeve bolt nut.
NOTE: This will enable solenoids to be
positioned when hydraulic control unit is fitted.
15. Ensure that hydraulic control unit piston rack is
positioned with rack teeth facing towards fixing
bolt hole adjacent to solenoid side of control unit.
16. Position seal plate to hydraulic control unit taking
care that teeth of piston rack do not contact rack
seal.
17. Align seal plate fixing bolt holes.
18. Check that camshaft gear locking tool 18G 1570
is removed.
CAUTION: Do not rotate crankshaft.
19. Ìnsert a screwdriver through piston rack hole in
camshaft carrier ensuring that screwdriver is
positioned towards outside of carrier.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-29
20. Position screwdriver to control shaft teeth and
rotate control shaft as far as possible in an anti-
cIockwise direction (viewed from front of
camshaft carrier).
21. Check that timing slots in both front and rear VVC
control sleeves are visible.
22. Push hydraulic control unit rack and piston to top
of bore, check that rack teeth will be aligned to
control shaft when unit is fitted.
23. Fit hydraulic control unit, engaging teeth of piston
rack with those of control shaft, fit and lightly
tighten 3 bolts.
24. Check that timing slots in both front and rear VVC
control sleeves are still visible. Ìf slots are not
visible, repeat the above procedures as
necessary.
25. Apply low air pressure to oil temperature sensor
port in hydraulic control unit to extend piston and
rack.
26. Check that rack is fully extended i.e. rack teeth
are at limit of travel and that timing slots in both
front and rear VVC control sleeves are no longer
visible.
27. Tighten hydraulic control unit bolts to 25 Nm.
28. Position solenoids to enable multiplugs to be
fitted, tighten sleeve bolt nut to 12 Nm.
CAUTION: Do not exceed specified torque.
29. Fit new sealing washer to oil temperature sensor,
fit sensor and tighten to 17 Nm.
ENGÌNE - 'K16 WÌTH VVC'
12-2-30 REPAÌRS
30. Fit rear inlet camshaft timing gear, fit but do not
tighten bolt.
31. Fit rear exhaust camshaft timing gear, fit but do
not tighten bolt.
32. Using tool 12-182, rotate both timing gears until
timing marks are facing outwards.
33. Check alignment of timing marks using a straight
edge.
NOTE: With timing marks in this position, the
lobes of numbers 3, 4, 5 and 6 inlet cams will be
facing upwards.
34. Remove bolt securing rear exhaust camshaft
gear and withdraw gear sufficiently to enable the
rear timing belt to be fitted.
35. Fit rear timing belt, refit bolt and washer.
CAUTION: Due to vaIve spring pressure, the
timing mark on the inIet camshaft gear may
become misaIigned during beIt fitting; hoId
gear in the timed position with tooI 12-182.
Ensure the camshafts do not rotate.
36. Restrain each camshaft gear in turn using tool
12-182 and tighten timing gear bolts to 65 Nm.
37. Using tool 12-182 rotate rear camshaft gears until
timing marks are facing inwards.
38. Check that timing marks on front camshaft gears
are aligned i.e. facing inwards.
39. Check alignment of each pair of timing marks
using a straight edge.
40. Fit camshaft gear locking tool 18G 1750.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-31
41. Using fingers only, fit timing belt over exhaust
and inlet timing gears and tensioner pulley
keeping belt taut between crankshaft timing gear
and exhaust camshaft gear.
42. Check that timing belt is positioned centrally
around camshaft gears and pulley.
43. Loosen tensioner backplate bolt / turn.
44. Position tensioner, align to reference mark on
backplate and cylinder head.
45. Tighten tensioner backplate bolt to 10 Nm.
46. Tighten tensioner pulley Allen screw to 45 Nm.
47. Remove camshaft gear locking tool 18G 1570.
48. Rotate clockwise 2 complete turns clockwise and
check that camshaft gear timing marks are
aligned.
CAUTION: Do not use camshaft gears, gear
retaining boIts or timing beIt to rotate
crankshaft.
49. Position mounting bracket to engine and
hydramount, fit mass damper and nut, lightly
tighten nut.
50. Align mounting bracket to engine, fit bolts and
tighten to 135 Nm.
51. Align restraint bar, fit and tighten nuts to 45 Nm.
52. Tighten nut securing mounting bracket to
hydramount to 85 Nm.
53. Position RH steady bar to mounting bracket, fit
and tighten bolt to 85 Nm.
54. Tighten bolt securing RH steady bar to body to 85
Nm.
55. Fit timing belt upper cover. See ENGINE - 'K16
with VVC', Repairs.
56. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
57. Remove stand(s) and lower vehicle.
58. Fit camshaft cover gasket. See ENGINE - 'K16
with VVC', Repairs.
59. Connect multiplugs to hydraulic control solenoids
and oil temperature sensor.
60. Fit camshaft rear timing belt cover, fit screws and
tighten to 5 Nm.
61. Fit inlet manifold. See MANIFOLD & EXHAUST
SYSTEMS, Repairs.
ENGÌNE - 'K16 WÌTH VVC'
12-2-32 REPAÌRS
ENGINE AND GEARBOX
´÷ 12.37.01/20
Remove
1. Disconnect battery earth lead.
2. Raise vehicle on a 2 post ramp.
3. If required: Drain engine oil. See
MAINTENANCE.
4. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments.
5. Remove drive shafts. See DRIVE SHAFTS,
Repairs.
6. Remove front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
7. Remove alternator. See ELECTRICAL, Repairs.
8. Drain gearbox oil. See MANUAL GEARBOX -
'PG1', Adjustments.
9. Drain coolant. See COOLING SYSTEM - 'K'
Series, Adjustments.
10. Remove front beam. See FRONT
SUSPENSION, Repairs.
11. Remove 4 bolts securing tie rods to lower arm
and remove tie rods.
12. Release clip and disconnect top hose from
coolant elbow.
13. Release clip and disconnect heater hose from
coolant elbow and release from clips.
14. Remove bolt securing A/C pipe to support
bracket.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-33
15. Disconnect compressor multiplug.
16. Remove 3 bolts securing compressor, release
compressor and tie aside.
17. Depress quick release and disconnect servo
vacuum pipe from manifold.
18. Disconnect throttle cable from throttle cam and
release from abutment bracket.
19. Release clips securing coolant hoses to coolant
rail and release hoses.
20. Release clip securing expansion tank hose to
inlet manifold and release hose.
21. Loosen clip securing PAS pump feed hose and
release hose.
22. Remove bolt securing PAS high pressure hose to
PAS pump.
23. Loosen union securing PAS pump high pressure
hose and release union, remove and discard 'O'
ring.
CAUTION: PIug the connections.
ENGÌNE - 'K16 WÌTH VVC'
12-2-34 REPAÌRS
24. Depress quick release catches and disconnect
fuel feed and return hoses.
CAUTION: PIug the connections.
25. Disconnect EVAP pipe from manifold.
26. Disconnect multiplugs from main harness and
EVAP cannister.
27. Disconnect engine harness multiplug from
fusebox.
28. Remove bolt securing positive lead to fusebox
and release lead.
29. Disconnect ECM multiplug.
30. Disconnect clutch cable from clutch lever,
release from abutment bracket and position
cable aside.
31. Remove bolt securing earth lead and position
earth lead aside.
32. Disconnect starter positive lead and position
aside.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-35
33. Remove clip and remove roll pin securing
selector rod and release rod from gearbox.
34. Remove bolt securing gearchange steady rod
and release steady rod.
35. Fit lifting bracket 18G-1760 to cylinder head and
secure with bolts.
36. Attach lifting arm 18G-1598 to suitable lifting
equipment and connect to lifting bracket.
37. Take the weight of engine without putting
pressure on engine mountings.
38. Remove bolt securing engine RH steady bar to
mounting bracket.
39. Loosen bolt securing steady bar to body and
release steady bar.
40. Remove 2 bolts securing engine RH mounting
bracket to engine.
41. Remove 2 nuts securing LH steady bar and
remove steady bar.
42. Remove 2 bolts securing LH mounting to
gearbox.
43. With assistance, lower engine and manoeuvre
from engine bay.
44. Take care not to damage engine harness on A/C
pipe.
ENGÌNE - 'K16 WÌTH VVC'
12-2-36 REPAÌRS
Refit
1. Position engine under vehicle and with
assistance manoeuvre into engine bay and align
to engine mountings.
2. Position engine harness around A/C pipe.
3. Fit bolts securing LH mounting and tighten to 100
Nm.
4. Fit LH steady bar, fit nuts and tighten to 25 Nm.
5. Fit bolts securing RH mounting and tighten to 135
Nm.
6. Position RH steady bar and tighten to bolts to 85
Nm.
7. Remove lifting arm.
8. Remove 2 bolts securing lifting bracket and
remove bracket.
9. Connect selector steady bar, fit bolt and tighten to
10 Nm.
10. Align gearchange rod and secure with new roll
pin, fit clip.
11. Connect clutch cable to abutment bracket and
secure to clutch lever.
12. Position earth lead, fit bolt and tighten to 25 Nm.
13. Position starter lead and secure with nut.
14. Position engine harness around engine.
15. Connect ECM multiplug
16. Connect fuse box multiplug and positive lead and
secure lead with bolt.
17. Connect EVAP cannister and main harness
multiplugs.
18. Clean ends of fuel feed and return hoses.
19. Connect fuel feed and return hoses.
20. Clean ends of PAS feed and high pressure
hoses.
21. Fit new 'O' ring to PAS high pressure hose, align
hose to pump and tighten union, fit and tighten
support bracket bolt.
22. Connect PAS pump feed hose and secure with
clip.
23. Connect expansion tank hose and secure with
clip.
24. Connect coolant hoses to coolant rail and secure
with clips.
25. Connect throttle cable to cam and secure to
abutment bracket.
26. Connect servo vacuum pipe.
27. Align compressor, fit bolts and tighten to 25 Nm.
28. Fit bolt securing A/C pipe to support bracket and
tighten to 9 Nm.
29. Connect top hose and heater hoses to coolant
elbow and secure with clips.
30. Fit alternator. See ELECTRICAL, Repairs.
31. Position tie rods to lower arms, fit bolts and
tighten to 80 Nm.
32. Fit front beam. See FRONT SUSPENSION,
Repairs.
33. Fit drive shafts. See DRIVE SHAFTS, Repairs.
34. Fit front pipe. See MANIFOLD & EXHAUST
SYSTEMS, Repairs.
35. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
36. Refill gearbox with oil. See MANUAL GEARBOX
- 'PG1', Adjustments.
37. Bleed PAS system. See STEERING,
Adjustments.
38. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments.
39. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
40. If required: Refill engine oil. See
MAINTENANCE.
41. Remove stand(s) and lower vehicle.
42. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-37
ENGINE STEADY BAR
´÷ 12.45.08
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove through bolt securing engine steady bar
to subframe.
3. Remove through bolt securing engine steady bar
to bracket on sump.
4. Remove engine steady bar.
Refit
1. Position engine steady bar to subframe and fit
through bolt.
2. Fit and tighten through bolt securing steady bar to
bracket on sump to 80 Nm.
3. Tighten through bolt securing steady bar to
subframe, to 80 Nm.
4. Remove stand(s) and lower vehicle.
HYDRAMOUNT - ENGINE - RH
´÷ 12.45.12
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Fit wooden block to jack and position jack to
support engine.
3. Remove bolt securing RH steady bar to engine
mounting bracket.
4. Loosen bolt securing steady bar to body and
release steady bar.
5. Remove 2 bolts securing mounting bracket to
engine.
6. Remove nut securing mounting bracket to
hydramount and collect mass damper.
7. Remove nut securing hydramount and restraint
bar to body.
8. Loosen nut securing restraint bar to body and
move aside.
9. Remove engine mounting bracket.
10. Remove nut securing hydramount to body.
11. Remove hydramount.
ENGÌNE - 'K16 WÌTH VVC'
12-2-38 REPAÌRS
Refit
1. Fit RH hydramount to body, fit and lightly tighten
rear nut.
2. Position mounting bracket to hydramount and
engine.
3. Fit bolts securing mounting bracket to engine and
tighten to 135 Nm.
4. Align restraint bar, fit and tighten nuts to 45 Nm.
5. Tighten nut securing hydramount to body to 45
Nm.
6. Position mass damper, fit nut securing mounting
bracket to hydramount and tighten to 85 Nm.
7. Fit bolt securing mounting bracket to steady bar
and tighten to 85 Nm.
8. Tighten bolt securing steady bar to body to 85
Nm.
9. Remove jack.
10. Remove stand(s) and lower vehicle.
MOUNTING - ENGINE - LH
´÷ 12.45.30
Remove
1. Disconnect battery earth lead.
2. Fit block to jack and position jack to support
engine.
3. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
4. Remove 2 nuts securing LH mounting steady bar
and remove steady bar.
5. Remove through bolt securing LH mounting to
body.
6. Remove 2 bolts securing LH mounting to gearbox
bracket.
7. Carefully lower engine and remove engine
mounting.
8. Collect snubber rubbers.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-39
Refit
1. Fit snubber rubbers to mounting.
2. Position engine mounting and raise engine and
gearbox assembly.
3. Align gearbox mounting bracket to engine
mounting, fit bolts and tighten to 100 Nm.
4. Fit bolt securing LH mounting to body, and
tighten to 85 Nm.
5. Position steady bar, fit nuts and tighten to 25 Nm.
6. Lower jack supporting engine, and remove from
beneath vehicle.
7. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
8. Connect battery earth lead.
FLYWHEEL
´÷ 12.53.07
Remove
1. Remove clutch assembly. See CLUTCH,
Repairs.
2. Leave tool 18G 1674 attached to cylinder block.
3. Remove CKP sensor. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
4. Remove and discard 6 bolts securing flywheel to
crankshaft.
5. Remove flywheel from crankshaft.
NOTE: Dowel located.
Refit
1. Using an old flywheel bolt with 2 saw cuts at 45°
to bolt shank, clean adhesive from threads of
flywheel bolt holes in crankshaft.
2. Clean flywheel and mating face of crankshaft.
3. Fit flywheel to crankshaft.
4. Fit NEW bolts securing flywheel to crankshaft
and working in a diagonal sequence tighten bolts
to 80 Nm.
5. Fit CKP sensor. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
6. Fit clutch assembly. See CLUTCH, Repairs.
ENGÌNE - 'K16 WÌTH VVC'
12-2-40 REPAÌRS
FLYWHEEL STARTER RING GEAR
´÷ 12.53.19
Remove
1. Remove flywheel. See ENGINE - 'K16 with
VVC', Repairs.
2. Drill a 3 mm diameter hole at root of 2 teeth.
3. Apply a cold chisel at root of ring gear teeth,
strike chisel with hammer to break ring gear.
WARNING: Suitable eye protection must be
worn.
4. Remove starter ring gear.
Refit
1. Clean flywheel and starter ring gear.
2. Heat new starter ring gear evenly to 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 ENGINE - 'K16 with VVC',
Repairs.
OIL FILTER
´÷ 12.60.04
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
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.
4. Remove stand(s) and lower vehicle.
5. Top up engine oil. See MAINTENANCE.
6. Start and run engine and check for leaks.
7. Stop engine, wait a few minutes, then check oil
level. Top up if necessary.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-41
DIPSTICK TUBE
´÷ 12.60.09
Remove
1. Remove dipstick.
2. Remove bolt securing thermostat housing and
dipstick tube to cylinder block.
3. Remove 2 bolts securing dipstick tube to cylinder
block.
4. Remove dipstick tube and collect gasket.
Refit
1. Fit new gasket, dry and dipstick tube to cylinder
block.
2. Fit bolts securing dipstick tube to cylinder block
and tighten to 10 Nm.
3. Fit bolt securing dipstick tube and thermostat
housing to cylinder block and tighten to 10 Nm.
4. Fit dipstick. block.
OIL PUMP
´÷ 12.60.26
Remove
1. Remove camshaft timing belt. See ENGINE -
'K16 with VVC', Repairs.
2. Remove crankshaft gear.
3. Remove 2 bolts securing engine harness to oil
pump.
4. Remove and discard 9 bolts securing oil pump to
cylinder block.
5. Remove oil pump and discard gasket.
6. Remove and discard crankshaft front oil seal
from oil pump body.
ENGÌNE - 'K16 WÌTH VVC'
12-2-42 REPAÌRS
Refit
1. Clean oil pump bolt holes in cylinder block. Clean
mating surfaces of oil pump and cylinder block
and oil seal running surface on crankshaft.
2. Turn oil pump rotor to align drive with crankshaft.
3. Fit new oil pump gasket, dry to cylinder block.
CAUTION: Do not Iubricate crankshaft front
oiI seaI recess or running surface of
crankshaft.
4. Fit oil seal protection sleeve from seal kit over
end of crankshaft.
NOTE: This will assist in locating oil pump inner
rotor.
5. Position oil pump to cylinder block.
6. Fit new Patchlok bolts and tighten in sequence
shown to 10 Nm.
7. Align engine harness to oil pump, fit bolts and
tighten to 10 Nm.
8. Ensure oil seal protection sleeve is located over
end of crankshaft.
9. Position new crankshaft front oil seal against oil
pump body. Drift seal into position using tool 18G
1587.
CAUTION: OiI seaI must be fitted dry.
10. Clean crankshaft gear.
11. Fit gear to crankshaft.
12. Fit camshaft timing belt. See ENGINE - 'K16 with
VVC', Repairs.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-43
SUMP - ENGINE - RESEAL
´÷ 12.60.38
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain engine oil. See MAINTENANCE.
4. Fit new sealing washer to engine oil drain plug, fit
drain plug and tighten to 28 Nm.
5. Release HO
2
S multiplug from timing belt rear
cover and disconnect HO
2
S multiplug.
6. Remove 6 nuts securing exhaust front pipe
flange, release front pipe and collect gasket.
7. Disconnect front pipe mounting rubber.
8. Loosen bolt securing engine lower steady bar to
front suspension rear subframe.
9. Remove bolt securing steady bar to sump
bracket.
10. Release steady bar from bracket.
11. Remove 2 bolts securing sump rear flange to
gearbox housing.
12. Remove 14 bolts securing sump to engine
bearing ladder noting fitted position of 2 longest
bolts, adjacent to sump rear flange.
13. Using a mallet, gently tap sump sideways to
release sealant bond. Remove sump.
ENGÌNE - 'K16 WÌTH VVC'
12-2-44 REPAÌRS
Refit
1. Clean inside of sump and mating faces of sump
and bearing ladder.
2. Fit 18G 1744 alignment pins to bearing ladder in
positions shown.
3. Apply sealant, Part No. GUG 705963GM to sump
joint face then spread to an even film using a
roller.
CAUTION: To avoid contamination, assembIy
shouId be compIeted immediateIy after
appIication of seaIant.
4. Position sump to engine bearing ladder, fit 2 bolts
at points 5 and 6 and tighten to 4 Nm.
5. Fit 10 bolts into remaining holes ensuring that 2
longest bolts are in original fitted positions,
adjacent to sump rear flange. Lightly tighten
bolts.
6. Remove 18G 1744 alignment pins, fit and lightly
tighten 2 remaining bolts.
7. Fit bolts securing sump rear flange to gearbox
housing, lightly tighten and then loosen bolts.
This will align the sump rear flange to gearbox
housing.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-45
8. Progressively tighten shorter sump bolts to 25
Nm and 2 longer bolts to 30 Nm, in the sequence
shown.
9. Tighten bolts securing sump rear flange to
gearbox housing to 45 Nm.
10. Position steady bar to sump bracket, fit bolt and
tighten to 80 Nm.
11. Tighten bolt securing engine lower steady bar to
front suspension rear beam to 80 Nm.
12. Clean exhaust manifold and front pipe mating
faces.
13. Connect front pipe mounting rubber.
14. Fit new gasket to front pipe, connect front pipe to
exhaust manifold fit nuts and tighten to 45 Nm.
15. Connect HO
2
S multiplug and secure to rear
timing belt cover.
16. Remove stand(s) and lower vehicle.
17. Fill engine with oil. See MAINTENANCE.
18. Connect battery earth lead.
OIL PRESSURE SWITCH
´÷ 12.60.50
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
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 15 Nm.
3. Connect multiplug to oil pressure switch.
4. Remove stand(s) and lower vehicle.
5. Top-up engine oil. See MAINTENANCE.
6. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
12-2-46 REPAÌRS
OIL PRESSURE RELIEF VALVE
´÷ 12.60.56
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Disconnect battery earth lead.
3. Loosen 3 bolts securing PAS pump pulley.
4. Remove PAS pump drive belt. See STEERING,
Repairs.
5. Remove PAS pump pulley bolts and remove
pulley.
6. Remove 2 nuts and bolts and lower bolt securing
PAS pump to mounting bracket.
7. Release PAS pump from bracket and move
aside.
8. Remove 3 bolts securing PAS pump mounting
bracket to cylinder block and remove bracket.
9. Remove oil pressure relief valve sealing plug and
Dowty washer, discard washer.
10. Remove spring and relief valve.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-47
11. Check that valve slides freely in bore and that
valve and bore are free from scoring and
corrosion.
NOTE: Light corrosion may be removed using
grade 600 emery cloth soaked in oil.
12. Check free length of spring:
Spring free length = 38.9 mm
13. Replace relief valve as an assembly if scoring is
evident or if free length of spring is less than
specified.
Refit
1. Remove all traces of Loctite from threads in relief
valve bore.
2. Clean oil pump housing, valve spring and relief
valve.
3. Lubricate relief valve with clean engine oil.
4. Fit relief valve and spring.
5. Fit new Dowty washer to plug.
6. Apply Loctite 577 to threads of plug, fit and
tighten plug.
7. Set bolt distance pieces in PAS pump mounting
bracket back 3 mm to aid fitting of PAS pump.
8. Position PAS pump bracket, fit bolts and tighten
to 45 Nm.
9. Locate and align PAS pump to bracket, fit 2 nuts
and bolts and lower bolt securing PAS pump to
mounting bracket and tighten to 25 Nm.
10. Clean PAS pump pulley and mating face.
11. Position pulley and lightly tighten bolts.
12. Fit PAS pump drive belt. See STEERING,
Repairs.
13. Tighten PAS pump pulley bolts to 10 Nm.
14. Remove stand(s) and lower vehicle.
15. Connect battery earth lead.
SENSOR - OIL TEMPERATURE
´÷ 12.60.65
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Position drain tin below engine oil filter to collect
spillage.
4. Disconnect multiplug from oil temperature
sensor.
5. Remove oil temperature sensor.
Refit
1. Clean oil temperature sensor threads.
2. Fit oil temperature sensor and tighten to 17 Nm.
3. Connect multiplug to oil temperature sensor.
4. Connect battery earth lead.
5. Top up engine oil. See MAINTENANCE.
ENGÌNE - 'K16 WÌTH VVC'
12-2-48 REPAÌRS
COOLER - OIL
´÷ 12.60.68
Remove
1. Disconnect battery earth lead.
2. Drain cooling system. See COOLING SYSTEM,
Adjustments.
3. Raise the vehicle on a ramp.
4. Release clips and disconnect coolant hoses from
engine oil cooler.
5. Position drain tray under engine oil cooler to
collect spillage.
6. Loosen and remove engine oil cooler pipe unions
from oil cooler, remove and discard 'O' rings.
CAUTION: AIways fit pIugs to open
connections to prevent contamination.
7. Remove 5 bolts securing engine oil cooler to
cylinder block and remove oil cooler.
Refit
1. Clean engine oil cooler and mating face on
cylinder block.
2. Position engine oil cooler to cylinder block, fit and
tighten bolts to 25 Nm.
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.
8. Lower vehicle on ramp.
9. Fill cooling system. See COOLING SYSTEM,
Adjustments.
10. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-49
CAMSHAFT TIMING BELT
´÷ 12.65.18
CAUTION: Camshaft timing beIt must be repIaced
if cyIinder head is to be removed or new timing
gears, tensioner or cooIant pump 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 wiII
damage the reinforcing fibres. Do not use a timing
beIt if debris other than beIt dust is found in cover.
Do not use a timing beIt if partiaI engine seizure
has occurred. Do not use a timing beIt if beIt
miIeage exceeds 45,000 miIes (72,000 km). Timing
beIt must be repIaced at specified miIeage
intervaIs. Do not use an oiI or cooIant
contaminated timing beIt. The cause of
contamination MUST be rectified.
Remove
1. Disconnect battery earth lead.
2. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
3. Remove camshaft timing belt upper cover. See
ENGINE - 'K16 with VVC', Repairs.
4. Using a socket and extension bar on crankshaft
pulley bolt, rotate crankshaft` clockwise to align
camshaft gear timing marks - 90° BTDC. Fit 18G
1570 camshaft locking tool between gears.
5. Support engine on jack.
CAUTION: PIace a bIock of wood between
sump and jack to prevent damage to sump.
6. Loosen bolt securing engine RH steady to body.
7. Remove bolt securing engine RH steady to
mounting bracket and release engine steady.
8. Remove nut securing RH hydramount and
restraint bar to body.
9. Loosen nut securing restraint bar to body and
move restraint bar aside
10. Remove nut securing mounting bracket to RH
hydramount, collect mass damper.
11. Remove 2 bolts securing mounting bracket to
engine and remove bracket.
12. Remove camshaft timing belt lower cover. See
ENGINE - 'K16 with VVC', Repairs.
ENGÌNE - 'K16 WÌTH VVC'
12-2-50 REPAÌRS
13. Ìf camshaft timing belt is to be reused, Mark
position of tensioner backplate to cylinder head
for belt tensioning reference. mark direction of
rotation on timing belt using chalk.
14. Loosen timing belt tensioner pulley Allen screw /
turn.
15. Loosen timing belt tensioner backplate bolt /
turn.
16. Push tensioner pulley down to fully OFF position
and tighten backplate bolt to 10 Nm.
17. Lower engine sufficiently for removal of timing
belt.
18. Ease timing belt from camshaft gears, crankshaft
drive gear and coolant pump timing gear, remove
timing belt.
CAUTION: Ease timing beIt off gears using
fingers onIy. MetaI Ievers may damage the
beIt and gears. Do not rotate the engine with
the timing beIt removed and the cyIinder head
fitted.
19. Remove drive gear from crankshaft.
Refit
1. Clean timing gears, crankshaft drive gear,
coolant pump drive gear and tensioner pulley.
CAUTION: If the sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in a soIvent bath and
then thoroughIy washed in cIean soIvent
before refitment. Because of the porous
construction of sintered materiaI, oiI
impregnated in the gear wiII emerge and
contaminate a new beIt.
2. Check correct alignment of camshaft gear timing
marks and that 18G 1570 is locking camshaft
gears.
3. Fit drive gear to crankshaft, ensure dots on gear
are aligned with flange on oil pump.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-51
Replacement timing belt:
4. Fit and tighten pillar bolt supplied with
replacement timing belt to cylinder head.
5. Connect spring, also supplied with replacement
timing belt to pillar bolt and tensioner.
6. Loosen backplate bolt and ensure tensioner
moves fully through its adjustment range and
returns under spring tension.
Replacement and existing timing belts:
7. Push tensioner down to the fully OFF position
and tighten backplate bolt to 10 Nm.
CAUTION: If originaI timing beIt is being
refitted, ensure direction of rotation mark is
facing the correct way.
8. Using fingers only, fit timing belt over crankshaft
gear then over camshaft gears, keeping belt taut
between crankshaft drive gear and exhaust
camshaft gear. Then position belt over tensioner
pulley and coolant pump drive gear.
9. Check that the timing belt is positioned centrally
around all gears and pulley.
10. Fit timing belt lower cover. See ENGINE - 'K16
with VVC', Repairs.
11. Raise engine to correct height.
12. Position mounting bracket to engine and RH
hydramount, fit mass damper, fit and lightly
tighten nut.
13. Fit bolts securing mounting bracket to engine and
tighten to 135 Nm.
14. Align restraint bar, fit and tighten nuts to 45 Nm.
15. Position RH steady bar to mounting bracket, fit
and tighten bolt to 85 Nm.
16. Tighten bolt securing RH steady bar to body
mounting to 85 Nm.
17. Tighten nut securing mounting bracket to RH
hydramount to 85 Nm.
18. Remove jack.
Tensioning an existing timing belt:
19. Loosen tensioner pulley Allen screw / turn.
20. Loosen tensioner backplate bolt / turn.
21. Position tensioner to align to reference mark on
backplate and cylinder head.
22. Tighten tensioner backplate bolt to 10 Nm.
23. Tighten tensioner pulley Allen screw to 45 Nm.
24. Remove camshaft gear locking tool 18G 1570.
Tensioning replacement timing belt:
25. Loosen tensioner pulley Allen screw / turn.
26. Loosen tensioner backplate bolt / turn.
27. Apply tension to belt by applying finger pressure
to tensioner backplate.
ENGÌNE - 'K16 WÌTH VVC'
12-2-52 REPAÌRS
28. With tensioner pulley against timing belt and
backplate held in position, tighten tensioner
backplate bolt to 10 Nm.
29. Remove camshaft gear locking tool 18G 1570.
30. Rotate crankshaft clockwise two complete
revolutions and align camshaft gear timing
marks.
CAUTION: Do not use camshaft gear retaining
boIts or timing beIt to rotate engine.
31. Loosen tensioner backplate bolt and check that
belt is being tensioned by tensioner spring.
32. Tighten tensioner backplate bolt to 10 Nm.
33. Tighten tensioner pulley Allen screw to 45 Nm.
34. Release tensioner spring from pillar bolt and
tensioner, remove and discard spring.
35. Remove and discard pillar bolt.
Replacement and existing timing belts:
36. Fit camshaft timing belt upper cover. See
ENGINE - 'K16 with VVC', Repairs.
37. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
38. Connect battery earth lead.
COVER - UPPER - CAMSHAFT TIMING
BELT
´÷ 12.65.41
Remove
1. Disconnect battery earth lead.
2. Loosen lower bolt securing camshaft timing belt
upper cover to engine.
3. Remove 5 screws securing camshaft timing belt
upper cover to rear cover.
4. Remove camshaft timing belt upper cover and
rubber seal.
Refit
1. Clean timing belt upper cover.
2. Fit timing belt upper cover, ensuring correct
position of rubber seal.
3. Fit 5 screws securing camshaft timing belt upper
cover to rear cover and tighten to 5 Nm.
4. Tighten lower bolt securing camshaft timing belt
top cover to engine, to 5 Nm.
5. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-53
COVER - LOWER - CAMSHAFT TIMING
BELT
´÷ 12.65.43
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove timing belt upper cover. See ENGINE -
'K16 with VVC', Repairs.
4. Remove crankshaft front pulley. See ENGINE -
'K16 with VVC', Repairs.
5. Remove 3 screws securing camshaft timing belt
lower cover to engine.
6. Remove camshaft timing belt lower cover and
rubber seal.
Refit
1. Clean timing belt lower cover.
2. Fit timing belt lower cover ensuring correct
position of rubber seal.
3. Fit screws securing timing belt lower cover to
engine and tighten to 5 Nm.
4. Fit crankshaft front pulley. See ENGINE - 'K16
with VVC', Repairs.
5. Fit timing belt upper cover. See ENGINE - 'K16
with VVC', Repairs.
6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
COVER - CAMSHAFT REAR TIMING BELT
´÷ 12.65.46
Remove
1. Release front HO
2
S multiplug from rear timing
belt cover.
2. Release coil harness from clip on rear timing belt
cover.
3. Remove 4 screws securing rear timing belt cover
and remove cover.
Refit
1. Clean camshaft rear cover and mating face.
2. Position timing belt rear cover, fit and tighten
screws to 5 Nm.
3. Secure coil harness in clip on rear timing belt
cover.
4. Secure HO
2
S multiplug to rear timing belt cover.
ENGÌNE - 'K16 WÌTH VVC'
12-2-54 REPAÌRS
CAMSHAFT REAR TIMING BELT
´÷ 12.65.56
CAUTION: Camshaft timing beIts must be repIaced
if 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 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 miIeage exceeds 45,000 miIes (72,000km).
Timing beIt must be repIaced at the specified
intervaIs. Do not use an oiI contaminated timing
beIt. The cause of contamination MUST be
rectified.
Remove
1. Disconnect battery earth lead.
2. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
3. Remove camshaft timing belt upper cover. See
ENGINE - 'K16 with VVC', Repairs.
4. Using a socket and extension bar on crankshaft
pulley bolt, rotate crankshaft clockwise to align
camshaft gear timing marks - 90° BTDC.
CAUTION: Do not use camshaft gears, gear
retaining boIts or timing beIt to rotate
crankshaft.
5. Fit 18G 1570 between camshaft gears to lock
camshafts.
6. Release front HO
2
S multiplug from rear timing
belt cover.
7. Release coil harness from clip on rear timing belt
cover.
8. Remove 4 screws securing rear timing belt cover
and remove cover.
9. Using a straight edge, check that the timing
marks on the rear camshaft gears are aligned
with the timing mark on the cover backplate.
ENGÌNE - 'K16 WÌTH VVC'
REPAÌRS 12-2-55
10. Using 12-182, restrain camshaft gears and
remove camshaft gear retaining bolts.
11. Remove both gears from camshafts complete
with timing belt. Discard rear timing belt.
Refit
1. Clean camshaft gears and mating faces on
camshafts.
2. Check that tool 18G 1570 is still locking camshaft
gears and that timing marks are aligned.
3. Fit inlet camshaft gear onto camshaft, fit and
lightly tighten retaining bolt.
4. Position new timing belt onto inlet camshaft gear.
CAUTION: Due to vaIve spring pressure, the
timing marks on the inIet camshaft gear may
be misaIigned. Prior to fitting the timing beIt
onto the gear, use 12-182 to hoId the gear in
the timed position.
5. Locate 12-182 into inlet camshaft gear, align
timing mark on gear with timing mark on cover
backplate and hold gear in position.
6. With assistance, align exhaust camshaft gear
with drive pin on camshaft, position timing belt
onto exhaust camshaft gear and locate gear onto
exhaust camshaft. Fit and lightly tighten retaining
bolt.
7. Remove tool 12-182 from inlet camshaft gear.
8. Using a straight edge, check that the timing
marks on the camshaft gears are aligned with the
timing mark on the cover backplate.
9. Using 12-182, restrain camshaft gears and
tighten bolts to 65 Nm.
10. Check that timing belt is positioned centrally
around both camshaft gears.
11. Position timing belt rear cover, fit and tighten
screws to 5 Nm.
12. Secure coil harness in clip on rear timing belt
cover.
13. Secure HO
2
S multiplug to rear timing belt cover.
14. Remove 18G 1570 from front camshaft gears.
15. Fit timing belt upper front cover. See ENGINE -
'K16 with VVC', Repairs.
16. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
17. Connect battery earth lead.
ENGÌNE - 'K16 WÌTH VVC'
12-2-56 REPAÌRS
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-1
ENGÌNE - ' L' SERÌES REPAÌ RS
OIL SEAL - CAMSHAFT - FRONT
´÷ 12.13.05
Remove
1. Disconnect battery earth lead.
2. Remove camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
3. Raise engine on jack.
4. Restrain camshaft gear using tool 12-182.
5. Remove camshaft gear retaining bolt, do not
discard bolt at this stage.
6. Remove tool 12-182.
7. Remove camshaft gear.
CAUTION: If the sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in a soIvent bath and
thoroughIy washed with soIvent before
refitment. Because of the porous
construction of the sintered materiaI, oiI
impregnated in the gear wiII emerge and
contaminate a new beIt. If camshaft timing
beIt shows any sign of oiI or cooIant
contamination renew camshaft timing beIt.
8. Fit but do not tighten the original camshaft gear
retaining bolt.
CAUTION: Ensure camshaft does not rotate
during this operation.
9. Fit and tighten seal remover tool 18G 1476 to
camshaft seal.
10. Tighten seal remover centre screw to remove
camshaft seal.
11. Remove seal remover 18G 1476.
12. Remove and discard seal from seal remover tool.
13. Remove and discard camshaft gear retaining
bolt.
CAUTION: Ensure camshaft does not rotate
during this operation.
Refit
1. Thoroughly clean seal recess and seal running
face on camshaft.
CAUTION: Do not Iubricate seaIing surfaces
or oiI seaI running surface on camshaft.
2. Ensure seal fitting tool 18G 1716 is clean.
3. Drift oil seal into recess using tool 18G 1716.
Ensure seal is fully located in recess.
CAUTION: OiI seaI must be fitted dry.
ENGÌNE - 'L' SERÌES
12-3-2 REPAÌRS
4. Remove tool 18G 1716.
5. Clean camshaft gear.
6. Fit camshaft gear to camshaft ensuring that drive
pin is located in slot in gear.
CAUTION: Ensure timing marks on camshaft
gear and rear cover are aIigned.
7. Apply engine oil to threads of new camshaft gear
retaining bolt.
8. Restrain camshaft gear using tool 12-182.
9. Fit camshaft gear bolt and tighten to 20 Nm + 90°.
10. Remove tool 12-182.
11. Lower engine, remove jack.
12. Fit camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
13. Connect battery earth lead.
OIL SEAL - CAMSHAFT - REAR
´÷ 12.13.06
Remove
1. Disconnect battery earth lead.
2. Remove FÌP timing belt. See ENGINE - 'L'
Series, Repairs.
3. Restrain camshaft drive gear using 12-182.
4. With assistance remove bolt retaining FÌP belt
drive gear to camshaft. Do not discard bolt at this
stage.
5. Remove FÌP belt drive gear from camshaft.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-3
FIP automatic timing belt tensioner illustrated.
6. Remove bolt securing FÌP drive belt tensioner,
remove tensioner.
7. Remove 3 bolts retaining FÌP belt backplate to
cylinder head and move aside.
8. Fit but do not tighten the original FÌP drive gear
retaining bolt to camshaft.
CAUTION: Ensure camshaft does not rotate
during this operation.
9. Screw body of tool 18G 1476 into camshaft rear
oil seal.
10. Tighten centre screw of tool 18G 1476 and
withdraw oil seal. Discard oil seal.
11. Remove and discard FÌP belt drive gear bolt.
CAUTION: Ensure camshaft does not rotate
during this operation.
Refit
1. Thoroughly clean seal recess and running
surface of camshaft.
CAUTION: Do not Iubricate seaIing surfaces
or oiI seaI running surface on camshaft.
2. Ensure tool 18G 1716 is clean.
3. Drift oil seal into recess using tool 18G 1716.
Ensure seal is fully located in recess.
CAUTION: OiI seaI must be fitted dry.
4. Clean FÌP belt backplate and cylinder head
mating face.
5. Fit FÌP belt backplate, tighten bolts to 8 Nm.
6. Position FÌP drive belt tensioner to backplate, fit
and lightly tighten bolt.
7. Clean FÌP belt drive gear and camshaft
mounting.
8. Fit FÌP belt drive gear to camshaft ensuring that
drive pin is located in slot in gear.
9. Apply engine oil to threads of new FÌP belt drive
gear bolt.
10. Restrain camshaft gear using 12-182.
11. Fit FÌP belt drive gear bolt and using assistance,
tighten bolt to 20 Nm + 90°.
12. Fit FÌP timing belt. See ENGINE - 'L' Series,
Repairs.
13. Connect battery earth lead.
ENGÌNE - 'L' SERÌES
12-3-4 REPAÌRS
BEARING CARRIER - RESEAL -
CAMSHAFT
´÷ 12.13.25
Remove
1. Disconnect battery earth lead.
2. Remove FÌP timing belt. See ENGINE - 'L'
Series, Repairs.
3. Remove camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
4. Remove plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
5. Loosen clip and remove engine breather hose
from camshaft cover.
6. Loosen clip and disconnect intercooler hose from
turbocharger outlet pipe.
7. Remove 2 bolts securing turbocharger pipe to
engine.
8. Loosen clip and remove outlet pipe from
turbocharger outlet hose.
FIP automatic timing belt tensioner illustrated.
9. Use 12-182 to hold camshaft gear, and using
assistance, remove and discard FÌP belt drive
gear bolt.
10. Remove FÌP belt drive gear.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-5
FIP automatic timing belt tensioner illustrated.
11. Remove bolt securing FÌP drive belt tensioner
and remove tensioner.
12. Remove 3 bolts and remove FÌP belt backplate.
13. Use 12-182 to hold camshaft gear, remove and
discard retaining bolt.
14. Remove camshaft gear.
15. Release engine harness clips from camshaft
timing belt rear cover.
16. Remove 5 bolts and remove camshaft timing belt
rear cover.
17. Remove bolt securing brake servo vacuum pipe
to camshaft cover.
18. Release clip and disconnect brake servo vacuum
hose from vacuum pump.
CAUTION: PIug hose and pump.
19. Move vacuum pipe aside.
ENGÌNE - 'L' SERÌES
12-3-6 REPAÌRS
20. Remove 12 bolts securing camshaft cover.
21. Remove camshaft cover.
22. Release gasket from fixings on camshaft cover
and discard gasket.
23. Using sequence shown, loosen the 10 camshaft
carrier bolts 2 to 3 turns.
CAUTION: Do not fuIIy remove boIts at this
stage.
24. Gently tap the camshaft carrier upwards to break
the sealant bond.
CAUTION: The camshaft carrier is doweI
Iocated, do not tap sideways.
25. Using the same sequence, continue to
progressively loosen the camshaft carrier
retaining bolts until all loading is removed from
the carrier.
26. Remove retaining bolts, remove camshaft
carrier.
27. Remove camshaft, remove and discard front and
rear oil seals.
28. Using a stick magnet, remove 8 tappets from the
cylinder head.
CAUTION: Keep tappets in their fitted order
and store inverted to prevent oiI Ioss. Do not
squeeze tappet chambers together.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-7
Refit
1. Check camshaft cams and bearing journals for
signs of scoring and excessive wear.
2. Check camshaft gear and FÌP belt drive gear
drive pins for damage and wear, replace if
necessary ensuring that split in pin faces towards
centre of camshaft.
3. Check bearing journals in cylinder head and
camshaft carrier for signs of scoring and
excessive wear.
CAUTION: The cyIinder head and camshaft
carrier are machined together as an
assembIy. If the bearing journaIs in either
component are found to be damaged, the
compIete assembIy must be repIaced.
4. Clean camshaft and all mating faces.
5. Using suitable solvent, remove all traces of
sealant from cylinder head and camshaft carrier.
CAUTION: Do not use a metaI scraper.
6. Lubricate tappets and tappet bores with engine
oil.
7. Fit tappets ensuring they are in correct fitted
order.
8. Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
CAUTION: Do not Iubricate oiI seaI running
surfaces on camshaft.
9. Position camshaft in cylinder head with camshaft
gear drive pin at approximately 2 o'clock position.
10. Apply a 2 mm bead of sealant, Part No. GUG
705963GM to paths on cylinder head as shown
then spread to an even film using a roller.
CAUTION: Ensure seaIant does NOT bIock
oiIways or is spread on to bearing journaIs.
AssembIy must be compIeted within 20
minutes of appIying seaIant.
11. Fit camshaft carrier, fit and lightly tighten bolts.
ENGÌNE - 'L' SERÌES
12-3-8 REPAÌRS
12. Using sequence shown, progressively tighten
camshaft carrier bolts to 11 Nm.
CAUTION: BoIts must be tightened to correct
torque within 20 minutes of appIying seaIant
13. Fit new front and rear oil seals to camshaft using
18G 1716. Ensure seals are fully located in
recesses.
CAUTION: OiI seaIs must be fitted dry.
14. Clean camshaft cover and mating face on
camshaft carrier.
15. Fit new gasket to camshaft cover, fit camshaft
cover and tighten bolts in sequence shown to 11
Nm.
16. Connect brake servo vacuum hose to vacuum
pump and secure with clip.
17. Fit brake servo vacuum pipe to camshaft cover
and tighten bolt to 9 Nm.
18. Fit FÌP belt backplate and tighten bolts to 8 Nm.
19. Clean FÌP drive belt tensioner.
20. Fit FÌP drive belt tensioner, fit bolt but do not
tighten at this stage.
21. Fit camshaft timing belt rear cover and tighten
bolts to 9 Nm.
22. Align engine harness to belt cover and secure
with clips.
23. Clean camshaft gear and mating face.
24. Fit camshaft gear ensuring that drive pin is
located in slot in gear.
CAUTION: Ensure timing marks on camshaft
gear and rear cover are aIigned.
25. Apply engine oil to threads of new camshaft gear
bolt.
26. Restrain camshaft gear using 12-182, fit
camshaft gear bolt and tighten to 20 Nm + 90°.
27. Clean FÌP belt drive gear and mating face.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-9
FIP automatic timing belt tensioner illustrated.
28. Fit FÌP belt drive gear ensuring that drive pin is
located in slot in gear.
29. Apply engine oil to threads of new FÌP belt drive
gear bolt.
30. Restrain camshaft gear using 12-182, fit FÌP belt
drive gear bolt and using assistance, tighten bolt
to 20 Nm + 90°.
31. Fit camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
32. Fit FÌP timing belt. See ENGINE - 'L' Series,
Repairs.
33. Fit engine breather hose to camshaft cover and
tighten clip.
34. Fit turbocharger outlet pipe to outlet hose and
tighten clip.
35. Fit bolts securing turbocharger outlet pipe and
tighten to 10 Nm.
36. Fit intercooler hose to turbocharger outlet pipe
and tighten clip.
37. Fit plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
38. Connect battery earth lead.
PULLEY - CRANKSHAFT - Up to VIN
Number RF 545050
´÷ 12.21.01
NOTE: This procedure covers engines fitted with FIP
automatic timing belt tensioners.
Remove
1. Disconnect battery earth lead.
2. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
3. Remove RH front road wheel.
4. Remove camshaft gear damper. See ENGINE -
'L' Series, Repairs.
5. Ìnsert timing pin 18G 1523 through hole in
gearbox adaptor plate, hold pin in contact with
flywheel and using assistance, rotate crankshaft
clockwise until timing pin can be felt to enter hole
in flywheel. Check that timing marks on camshaft
gear and timing belt rear cover are aligned.
CAUTION: Never use the camshaft gear, gear
retaining boIt or timing beIt to rotate
crankshaft.
ENGÌNE - 'L' SERÌES
12-3-10 REPAÌRS
6. Remove bolt securing crankshaft pulley.
7. Remove crankshaft pulley.
Refit
1. Clean and fit pulley to crankshaft, fit bolt securing
pulley and tighten to 63 Nm + 90°.
2. Remove FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
3. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate.
CAUTION: Timing pin must be a sIiding fit. If
pin is a tight fit, proceed as foIIows.
4. Loosen 4 bolts securing FÌP timing belt drive gear
to hub.
5. Loosen FÌP timing belt tensioner bolt.
6. Using 12-184, rotate tensioner cIockwise until
index pointer passes tension indicator. Allow
tensioner to return anti-clockwise until pointer is
in line with bottom edge of land as shown. Hold
tensioner in this position and tighten tensioner
bolt to 44 Nm.
CAUTION: Do not exceed the specified torque
figure.
7. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523 from flywheel.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-11
8. Using crankshaft pulley bolt, rotate crankshaft 2
complete revolutions cIockwise (as viewed from
front of engine) and fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted into
hoIe in fIywheeI.
9. Check that timing marks on camshaft gear and
timing belt rear cover are aligned.
10. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate. Ìf
necessary, rotate FÌP drive gear slightly using a
socket on drive gear nut.
CAUTION: Check that automatic tensioner
pointer is in Iine with Iand on tensioner as
shown. If not, beIt adjustment must be
repeated.
ENGÌNE - 'L' SERÌES
12-3-12 REPAÌRS
11. Fit torque wrench to square hole in FÌP timing belt
drive gear as shown and apply an anti-
cIockwise (as viewed from rear of engine) torque
loading of 25 Nm. Maintain loading and tighten 4
bolts securing gear to 25 Nm.
12. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523 from flywheel.
13. Using crankshaft pulley bolt, rotate crankshaft 2
complete revolutions cIockwise (as viewed from
front of engine) and fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted in
fIywheeI.
14. Check that camshaft gear timing mark is still
aligned with mark on rear cover.
15. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate.
CAUTION: To ensure FIP timing is correct, FIP
drive gear timing pin must be a sIiding fit. If
pin is a tight fit, adjustment procedure must
be repeated.
16. On completion, remove FÌP drive gear timing pin
12-185 and timing pin 18G 1523 from flywheel.
17. Fit camshaft gear damper. See ENGINE - 'L'
Series, Repairs.
18. Fit FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
19. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
20. Fit RH front road wheel. See INFORMATION,
Torque Wrench Settings.
21. Connect battery earth lead.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-13
PULLEY - CRANKSHAFT - From VIN
Number RF 545051
´÷ 12.21.01
NOTE: This procedure covers engines fitted with FIP
manual timing belt tensioner.
Remove
1. Disconnect battery earth lead.
2. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
3. Remove RH front road wheel.
4. Remove camshaft gear damper. See ENGINE -
'L' Series, Repairs.
5. Ìnsert timing pin 18G 1523 through hole in
gearbox adaptor plate, hold pin in contact with
flywheel and using assistance, rotate crankshaft
clockwise until timing pin can be felt to enter hole
in flywheel. Check that timing marks on camshaft
gear and timing belt rear cover are aligned.
CAUTION: Never use the camshaft gear, gear
retaining boIt or timing beIt to rotate
crankshaft.
6. Remove bolt securing crankshaft pulley.
7. Remove crankshaft pulley.
Refit
1. Clean and fit pulley to crankshaft, fit bolt securing
pulley and tighten to 63 Nm + 90°.
2. Remove FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
3. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate.
CAUTION: Timing pin must be a sIiding fit. If
pin is a tight fit, proceed as foIIows.
4. Loosen 4 bolts securing FÌP timing belt drive gear
to hub.
5. Loosen FÌP timing belt tensioner pulley Allen bolt.
ENGÌNE - 'L' SERÌES
12-3-14 REPAÌRS
6. Using a torque wrench fitted to tensioner pulley
backplate, apply a cIockwise (as viewed from
rear of engine) torque loading of 6 Nm to drive
belt. Maintain loading and tighten tensioner
pulley Allen bolt to 44 Nm.
CAUTION: Do not exceed specified torque
figure.
7. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523.
8. Using crankshaft pulley bolt, rotate crankshaft 2
complete revolutions cIockwise (as viewed from
front of engine) and fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted in
fIywheeI.
9. Check that timing marks on camshaft gear and
rear cover are aligned.
10. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate. Ìf
necessary, rotate FÌP drive gear slightly using a
socket on drive gear nut.
11. Fit torque wrench to square hole in FÌP timing belt
drive gear as shown and apply an anti-
cIockwise (as viewed from rear of engine) torque
loading of 25 Nm. Maintain loading and tighten 4
bolts securing gear to 25 Nm.
12. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523.
13. Rotate crankshaft 2 complete revolutions
cIockwise (as viewed from front of engine) and
fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted in
fIywheeI.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-15
14. Check that camshaft gear timing mark is still
aligned with mark on rear cover.
15. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP gear and into hole in adaptor plate.
CAUTION: To ensure FIP timing is correct, FIP
drive gear timing pin must be a sIiding fit. If
pin is a tight fit, timing beIt adjustment must
be repeated.
16. On completion, remove FÌP drive gear timing pin
12-185 and timing pin 18G 1523 from flywheel.
17. Fit camshaft gear damper. See ENGINE - 'L'
Series, Repairs.
18. Fit FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
19. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
20. Fit RH front road wheel. See INFORMATION,
Torque Wrench Settings.
21. Connect battery earth lead.
OIL SEAL - CRANKSHAFT - FRONT
´÷ 12.21.14
Remove
1. Disconnect battery earth lead.
2. Remove camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
3. Remove timing gear from crankshaft.
4. Ensure bore of tool 18G 1718 is burr free, screw
tool into crankshaft front oil seal.
5. Remove oil seal by tightening centre bolt of tool.
Discard oil seal.
ENGÌNE - 'L' SERÌES
12-3-16 REPAÌRS
Refit
1. Use lint free cloth and thoroughly clean seal
recess in oil pump and running surface on
crankshaft.
CAUTION: Do not Iubricate oiI seaI recess or
oiI seaI running surface on crankshaft.
2. Fit guide tools 18G 1510 and 18G 1510-1 onto
crankshaft.
3. Using guide tools, position new seal on
crankshaft journal and against oil pump. Drift into
place using tool 18G 1509.
CAUTION: OiI seaI must be fitted dry.
4. Remove guide tools from crankshaft.
5. Clean crankshaft timing gear and slide onto
crankshaft.
6. Fit camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
7. Connect battery earth lead.
CRANKSHAFT REAR OIL SEAL
´÷ 12.21.20
Remove
1. Remove flywheel. See ENGINE - 'L' Series,
Repairs.
2. Remove sump gasket. See ENGINE - 'L' Series,
Repairs.
3. Remove 5 bolts securing oil seal housing.
Remove oil seal and housing.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-17
Refit
1. Clean seal and housing seating area of cylinder
block.
CAUTION: Do not Iubricate oiI seaI or running
surface on crankshaft. Do not separate
protector sIeeve from oiI seaI and do not
touch Iip of oiI seaI.
2. Fit oil seal protector sleeve, oil seal and housing
over crankshaft and align to cylinder block.
NOTE: Oil seal protector sleeve will be displaced
as seal and housing are fitted.
3. Fit and tighten seal housing bolts in sequence
shown to 8 Nm.
4. Fit sump gasket. See ENGINE - 'L' Series,
Repairs.
5. Fit flywheel. See ENGINE - 'L' Series, Repairs.
CYLINDER HEAD GASKET
´÷ 12.29.02
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
4. Remove camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
5. Loosen clip and disconnect engine breather hose
from camshaft cover.
6. Disconnect multiplug from MAF sensor.
7. Loosen clip and disconnect air intake pipe from
turbocharger.
8. Remove air intake pipe, MAF sensor and engine
breather valve assembly.
9. Plug turbocharger intake.
10. Disconnect exhaust front pipe from turbocharger.
See MANIFOLD & EXHAUST SYSTEMS - 'L'
Series, Repairs.
11. Disconnect boost pressure sensing pipe from
turbocharger.
ENGÌNE - 'L' SERÌES
12-3-18 REPAÌRS
12. Loosen clips and disconnect 2 coolant hoses
from EGR cooler.
13. Disconnect vacuum pipe from EGR valve.
14. Loosen clip and disconnect intercooler hose from
turbocharger outlet pipe.
15. Remove 2 bolts securing turbocharger outlet pipe
to cylinder head.
16. Loosen clip and remove outlet pipe from
turbocharger outlet hose. Plug turbocharger
outlet hose.
17. Loosen clip and disconnect intercooler hose from
plenum.
18. Remove 2 bolts securing EGR pipe to plenum.
19. Remove bolt securing plenum bracket to
camshaft cover.
20. Remove 2 bolts and remove plenum from inlet
manifold. Discard gasket.
21. Disconnect multiplug from ÌAT sensor.
22. Remove banjo bolt securing oil feed pipe to
turbocharger, remove and discard sealing
washers.
23. Remove 2 bolts securing oil drain pipe to
turbocharger.
24. Remove and discard gasket.
25. Remove 2 bolts securing exhaust manifold to
support bracket.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-19
26. Remove 6 bolts securing manifolds to cylinder
head and collect 4 washers.
27. Remove 6 nuts securing manifolds to cylinder
head.
28. Remove inlet and exhaust manifolds.
29. Remove and discard manifold gasket.
FIP automatic timing belt tensioner illustrated.
30. Ìnsert timing pin 12-185 through FÌP drive gear
and into hole in adaptor plate.
NOTE: Timing pin 12-185 must be a sliding fit. If
difficulty is experienced, rotate FIP drive gear
using a socket on hub nut until pin can be
inserted.
31. Remove FÌP belt tensioner bolt and remove
tensioner.
CAUTION: If FIP timing beIt is to be refitted,
mark direction of rotation on beIt.
32. Remove FÌP timing belt.
CAUTION: Do not rotate camshaft or FIP with
timing beIt removed. Ease beIt from gears
using fingers onIy, metaI Ievers may damage
beIt and gears. Store a beIt on its edge with a
radius greater than 50 mm. Do not use a beIt
that has been twisted or bent doubIe as this
can fracture the reinforcing fibres. Do not use
an oiI contaminated beIt. Cause of
contamination must be rectified. Timing beIts
have a service Iife of: Up to VIN No. RF 545050
- 84,000 miIes (135,000km) From VIN No. RF
545051 - 48,000 miIes (80,000km) Existing
beIts shouId, however, onIy be refitted if they
have compIeted: Up to VIN No. RF 545050 -
Iess than 42,000 miIes (65,000km). From VIN
No. RF 545051 - Iess than 24,000 miIes (40,000
km)
33. Restrain camshaft gear using 12-182.
34. Using assistance, remove and discard bolt
securing FÌP belt drive gear to camshaft.
35. Remove FÌP belt drive gear from camshaft.
ENGÌNE - 'L' SERÌES
12-3-20 REPAÌRS
36. Restrain camshaft gear using 12-182.
37. Remove and discard camshaft gear retaining
bolt.
38. Remove camshaft gear.
CAUTION: If the sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in a soIvent bath and
thoroughIy washed with soIvent before
refitment. Because of the porous
construction of sintered materiaI, oiI
impregnated in the gear wiII emerge and
contaminate a new beIt.
39. Release 3 clips securing engine harness to rear
cover.
40. Remove 5 bolts securing camshaft timing belt
rear cover to cylinder head and cylinder block.
41. Remove camshaft timing belt rear cover.
42. Remove 3 bolts and remove FÌP timing belt
backplate.
43. Remove bolt securing brake servo vacuum pipe
to camshaft cover.
44. Release clip, disconnect vacuum hose from
vacuum pump and move hose and pipe aside.
CAUTION: PIug the connections.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-21
45. Remove 3 bolts securing alternator upper
mounting bracket and remove bracket.
46. Disconnect multiplug from ECT sensor.
47. Disconnect engine coolant temperature gauge
Lucar from harness.
48. Loosen clip and disconnect radiator top hose
from coolant outlet elbow.
49. Remove bolt securing dipstick tube bracket to
coolant outlet elbow.
50. Disconnect injector needle lift sensor multiplug
from harness.
51. Position cloth to absorb fuel spillage from injector
pipe unions.
52. Loosen unions securing pipes to injectors and
FÌP.
CAUTION: To prevent damage to fueI
injection pipes or components, use 2
spanners when Ioosening unions.
53. Remove pipes from injectors and FÌP.
54. Disconnect fuel spill return hose from No.3
injector.
CAUTION: PIug the connections.
55. Remove nut and disconnect feed lead from No.2
glow plug.
ENGÌNE - 'L' SERÌES
12-3-22 REPAÌRS
56. Remove 12 bolts and remove camshaft cover.
Release and discard gasket.
57. Working in sequence shown, progressively
loosen and remove 10 Tx14 Torx bolts securing
cylinder head.
NOTE: Store cylinder head bolts in fitted order.
58. With assistance, remove cylinder head assembly
from cylinder block and stand on wooden blocks
or stands.
CAUTION: The cyIinder head is doweI
Iocated, do not tap it sideways to reIease it
from cyIinder bIock. The tips of the injectors
and gIow pIugs protrude beIow the face of the
cyIinder head and wiII be damaged if the
cyIinder head is stood face down on a work
bench.
59. Remove cylinder head gasket from cylinder block
and discard.
CAUTION: Note the gasket thickness
indicator i.e. 1, 2 or 3 hoIes and ensure the
same thickness gasket is used when refitting
the cyIinder head.
60. Clean mating face of cylinder head.
61. Ìnspect cylinder head for signs of damage.
62. Check cylinder head for warping, across centre
and from corner to corner.
Maximum warp = 0.10mm.
CAUTION: CyIinder heads may not be
refaced. RepIace a cyIinder head if warping
exceeds figure given.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-23
Refit
1. Clean mating face of cylinder block. De-
carbonise piston crowns if necessary. Clean oil
and coolant passages. Clean dowels and dowel
holes.
2. Check oil restrictor is clear and below cylinder
block face.
3. Clean and dry cylinder head bolts.
4. Measure length of cylinder head bolts. if any bolt
exceeds the maximum length of 243.41 mm, then
all bolts must be renewed.
5. Apply a light film of engine oil to bolt threads and
underside of bolt heads.
CAUTION: Do not Iubricate underside of
washers.
6. Temporarily fit crankshaft pulley bolt, remove
timing pin 18G 1523 and using crankshaft pulley
bolt, rotate crankshaft anti-cIockwise until
numbers 1 and 4 pistons are approximately 25
mm below face of cylinder block.
7. Check and if necessary, fit camshaft gear to
rotate camshaft for alignment of drive pin at 2
o'clock position.
8. Ensure locating dowels are in cylinder block.
CAUTION: Ensure that new gasket has same
thickness indicator as the originaI i.e. 1, 2 or
3 hoIes.
9. Fit new cylinder head gasket, dry, to cylinder
block.
10. With assistance, fit cylinder head onto cylinder
block and locate on dowels.
11. Fit and tighten cylinder head bolts progressively
in the sequence shown, using the following
procedure:
¤ Tighten all bolts to 30 Nm.
¤ Tighten all bolts to 65 Nm. Using a felt tip pen,
make a radial mark on each bolt head.
¤ Turn all bolts through 90 °.
¤ Turn all bolts through another 90°.
CAUTION: Ensure that correct tightening
sequence is foIIowed for aII four stages.
ENGÌNE - 'L' SERÌES
12-3-24 REPAÌRS
12. Clean mating faces of camshaft carrier and
camshaft cover.
13. Use new gasket, fit camshaft cover and tighten
bolts in sequence shown to 11 Nm.
14. Connect glow plug feed lead to No. 2 glow plug
and tighten nut to 2.5 Nm.
15. Clean spill return connection.
16. Connect spill return hose.
17. Clean injector pipes and unions.
18. Fit injector pipes and tighten union nuts to 28 Nm.
CAUTION: To prevent damage to fueI system
pipes or components use 2 spanners when
tightening unions.
19. Connect injector needle lift sensor multiplug to
harness.
20. Connect radiator top hose to coolant outlet elbow
and tighten clip.
21. Align dipstick tube bracket to coolant outlet
elbow, fit bolt and tighten to 25 Nm.
22. Connect engine coolant temperature gauge
sensor Lucar to harness.
23. Connect multiplug to ECT sensor.
24. Fit alternator upper mounting bracket and tighten
bolts to 25 Nm.
25. Connect brake servo vacuum hose to vacuum
pump, align vacuum pipe to camshaft cover and
tighten bolt to 9 Nm. Secure hose to vacuum
pump with clip.
26. Clean FÌP timing belt backplate.
27. Fit FÌP timing belt backplate, fit bolts and tighten
to 8 Nm.
28. Clean camshaft timing belt rear cover and mating
face.
29. Fit camshaft timing belt rear cover, fit bolts and
tighten to 9 Nm.
30. Fit engine harness clips to camshaft timing belt
rear cover.
31. Clean camshaft gear and mating face.
32. Fit camshaft gear ensuring that drive pin is
located in slot in gear.
33. Apply engine oil to threads of new camshaft gear
retaining bolt, fit bolt and using 12-182 to restrain
gear, tighten bolt to 20 Nm + 90°.
34. Clean FÌP belt drive gear and mating face.
35. Fit FÌP belt drive gear to camshaft ensuring that
drive pin is located in slot in gear.
36. Apply engine oil to threads of new FÌP belt drive
gear retaining bolt, fit bolt and using 12-182 to
restrain camshaft gear, tighten bolt to 20 Nm +
90°.
37. Clean mating faces of inlet manifold, exhaust
manifold and cylinder head.
38. Fit new manifold gasket to cylinder head.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-25
39. Fit inlet and exhaust manifolds, fit clamp washers
and in sequence shown, tighten nuts to 25 Nm,
and bolts to 33 Nm.
40. Fit and tighten bolts securing exhaust manifold to
support bracket to 25 Nm.
41. Clean turbocharger oil drain pipe flange and
mating face.
42. Use a new gasket, align oil drain pipe to
turbocharger and tighten bolts to 11 Nm.
43. Clean turbocharger oil feed pipe union banjo bolt
and sealing washers.
44. Fit sealing washers, align oil feed pipe and
tighten banjo bolt to 28 Nm.
45. Connect multiplug to ÌAT sensor.
46. Clean mating faces of inlet manifold, EGR pipe
and plenum.
47. Fit new gasket to inlet manifold, fit plenum and
tighten bolts to 25 Nm.
48. Tighten bolt securing plenum bracket to 9 Nm.
49. Align EGR pipe to plenum and tighten bolts to 9
Nm.
50. Connect intercooler hose to plenum and tighten
clip.
51. Remove plug from turbocharger outlet.
52. Fit turbocharger pipe to outlet hose, align pipe to
cylinder head and tighten bolts to 10 Nm. Tighten
hose clip.
53. Connect intercooler hose to turbocharger outlet
pipe and tighten clip.
54. Connect EGR coolant hoses and tighten clips.
55. Connect vacuum pipe to EGR valve.
56. Connect boost pressure sensing pipe to
turbocharger.
57. Connect exhaust front pipe to turbocharger. See
MANIFOLD & EXHAUST SYSTEMS - 'L'
Series, Repairs.
58. Remove plug from turbocharger intake.
59. Fit air intake pipe and MAF sensor to
turbocharger, tighten clip.
60. Connect multiplug to MAF sensor.
61. Connect engine breather hose to camshaft cover
and tighten clip.
62. Using tool 12-182, align camshaft gear timing
marks.
63. Hold timing pin 18G 1523, in contact with
flywheel and using assistance, rotate crankshaft
clockwise by means of crankshaft pulley bolt until
18G 1523 can be felt to enter hole in flywheel.
CAUTION: Do not rotate crankshaft too far,
pistons may contact vaIves.
ENGÌNE - 'L' SERÌES
12-3-26 REPAÌRS
FIP automatic timing belt tensioner illustrated.
64. Ensure that timing pin 12-185 is locking FÌP drive
gear.
65. Use 12-182 to restrain camshaft gear and using
assistance, loosen 4 bolts securing FÌP belt drive
gear to hub, enough for gear to rotate within slots
without tipping.
66. Clean FÌP belt tensioner.
67. Fit FÌP belt tensioner, fit bolt but do not tighten at
this stage.
CAUTION: Do not remove timing pin 12-185 at
this stage.
68. Fit camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
69. Fit FÌP timing belt. See ENGINE - 'L' Series,
Repairs.
70. Remove stand(s) and lower vehicle.
71. Refill cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
72. Connect battery earth lead.
73. Check engine oil and top-up if necessary.
74. Start engine and check for leaks.
NOTE: If tappet noise is evident, run engine for
20 minutes at 2000 to 2500 rev/min. Do not
exceed 3000 rev/min until noise ceases.
75. Stop engine and allow to cool. Check for leaks
and top-up fluid level if necessary.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-27
GASKET - CAMSHAFT COVER
´÷ 12.29.40
Remove
1. Remove plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
2. Loosen clip and disconnect intercooler hose from
turbocharger outlet pipe.
3. Remove 2 bolts securing turbocharger pipe to
engine.
4. Loosen clip and remove outlet pipe from
turbocharger outlet hose.
5. Loosen clip and disconnect engine breather hose
from camshaft cover.
6. Remove engine oil filler cap.
7. Remove bolt securing brake servo vacuum pipe
to camshaft cover.
8. Remove 12 bolts securing camshaft cover.
9. Remove camshaft cover.
10. Release gasket from fixings on camshaft cover
and discard gasket.
ENGÌNE - 'L' SERÌES
12-3-28 REPAÌRS
Refit
1. Clean camshaft cover and mating face on
camshaft carrier.
2. Fit new gasket to camshaft cover.
3. Fit camshaft cover and tighten bolts in sequence
shown to 11 Nm.
4. Align brake servo vacuum pipe bracket to
camshaft cover and tighten bolt to 9 Nm.
5. Fit oil filler cap.
6. Connect engine breather hose to camshaft cover
and tighten clip.
7. Fit turbocharger outlet pipe to outlet hose.
8. Fit bolts securing turbocharger outlet pipe to
engine and tighten to 10 Nm.
9. Connect intercooler hose to turbocharger outlet
pipe and tighten clip.
10. Tighten clip securing turbocharger outlet hose to
pipe.
11. Fit plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
COVER - ACOUSTIC - ENGINE
´÷ 12.30.50
Remove
1. Release 3 turnbuckles securing acoustic cover to
engine.
2. Remove engine acoustic cover.
3. Remove grommets and turnbuckles from
acoustic cover.
Refit
1. Fit grommets and turnbuckles to acoustic cover.
2. Fit acoustic cover to engine and secure with
turnbuckles.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-29
ENGINE AND GEARBOX
´÷ 12.37.01.99
Remove
1. Raise vehicle on a 2 post ramp.
2. Disconnect battery earth lead.
3. Release bonnet stay and tie bonnet back.
4. Remove under tray. See EXTERIOR FITTINGS,
Repairs.
5. Drain gearbox oil. See MANUAL GEARBOX -
'PG1', Adjustments.
6. Drain cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
7. Ìf required, drain engine oil. See
MAINTENANCE.
8. Fit new sealing washer to drain plug, fit drain plug
and tighten to 25 Nm.
9. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
10. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
11. Release clutch cable from lever and abutment
bracket. Position cable clear of gearbox.
12. Release battery lead from clip on battery tray.
13. Loosen 3 lower bolts and remove 3 upper bolts
securing battery tray.
14. Release battery tray from lower bolts.
15. Release and disconnect 2 multiplugs from EDC
ECM and remove battery tray.
ENGÌNE - 'L' SERÌES
12-3-30 REPAÌRS
16. Release clip and raise fuse box cover.
17. Remove bolt and disconnect alternator lead from
fuse box.
18. Disconnect engine harness multiplug from fuse
box.
19. Remove 3 screws and release fuse box from its
brackets.
20. Disconnect engine harness multiplug from
underside of fuse box.
21. Remove terminal cover, remove nut and
disconnect battery lead from starter motor.
22. Release engine harness clip from bracket on
bulkhead.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-31
23. Release 2 engine harness multiplugs from
bracket on bulkhead and disconnect from main
harness.
24. Remove bolt and move 2 earth leads from
gearbox.
25. Disconnect multiplug from MAF sensor.
26. Loosen clip and disconnect engine breather
valve hose from camshaft cover.
27. Loosen clip and remove air intake pipe from
turbocharger.
28. Release clips and disconnect fuel feed and return
hoses from fuel rail.
CAUTION: PIug the connections.
29. Loosen clip and disconnect hose from coolant
rail.
30. Disconnect pressure sensing hose from
turbocharger.
ENGÌNE - 'L' SERÌES
12-3-32 REPAÌRS
31. Loosen clips and disconnect coolant hoses from
EGR cooler.
32. Disconnect vacuum pipe from EGR valve.
33. Disconnect multiplug from MAP sensor.
34. Disconnect multiplug from EGR control valve.
35. Release clip and disconnect hose from vacuum
pump pipe.
36. Position cloth under PAS rack fluid feed pipe to
collect spillage.
37. Loosen union, disconnect PAS rack fluid feed
pipe and discard 'O' ring.
CAUTION: To prevent damage to pipes or
unions, aIways use 2 spanners when
Ioosening unions.
38. Position container under PAS fluid reservoir to
collect spillage.
39. Release PAS reservoir from bracket, release clip
and disconnect PAS pump fluid feed hose from
reservoir.
CAUTION: PIug the connections.
40. Disconnect glow plug relay from clip.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-33
41. Loosen clips and remove intercooler inlet hose.
42. Loosen clips and remove intercooler outlet hose.
43. Loosen clip and disconnect radiator top hose.
44. Disconnect engine harness multiplug from
cooling fan.
45. Loosen clip, disconnect coolant bleed from
radiator and move bleed pipe aside.
46. Remove bolt and disconnect gear change steady
bar from gearbox. Collect 2 washers.
47. Remove clip securing selector rod roll pin.
48. Using a suitable punch, remove roll pin from gear
selector shaft.
49. Release gear selector rod from selector shaft.
50. Tie selector rod and steady bar aside.
51. Remove LH and RH drive shafts from gearbox as
detailed in differential oil seals. See MANUAL
GEARBOX - 'PG1', Repairs.
52. Remove front beam. See FRONT
SUSPENSION, Repairs.
53. Remove 4 bolts and remove suspension LH and
RH tie rods.
ENGÌNE - 'L' SERÌES
12-3-34 REPAÌRS
54. Loosen clip and disconnect bottom hose from
radiator.
Models with A/C
55. Using a 15 mm ring spanner on drive belt
tensioner pulley bolt, rotate pulley fully clockwise
and hold.
56. With assistance, release drive belt from
alternator pulley.
57. Remove drive belt from remaining pulleys and
remove from vehicle.
58. Remove cover from battery lead terminal on
alternator.
59. Remove terminal nut and remove battery lead
from alternator.
60. Disconnect multiplug from alternator.
61. Remove bolt securing A/C low pressure pipe to
alternator upper mounting bracket.
62. Disconnect multiplug from A/C compressor.
63. Remove 3 bolts, release A/C compressor from
mounting and tie aside.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-35
All models
64. Fit adjustable bracket 18G 1598 to lifting chains
and connect to engine lifting eyes.
65. Raise chains and adjust 18G 1598 to take weight
of engine and gearbox.
66. Remove bolt securing engine upper steady to RH
engine mounting bracket.
67. Loosen 2 nuts and move restraint bar to clear
engine mounting bracket.
68. Remove 3 bolts securing RH mounting bracket to
engine.
69. Remove nut securing mounting bracket to engine
RH mounting and remove mounting bracket.
70. Remove nut cover, remove 2 nuts and remove
outer part of torsion link.
71. Loosen through bolt securing engine LH
mounting to bracket on body.
72. Remove 2 bolts securing engine mounting to
bracket on gearbox.
73. With assistance, lower engine and gearbox from
vehicle.
74. Disconnect lifting chains from 18G 1598.
75. Remove engine and gearbox from beneath
vehicle.
ENGÌNE - 'L' SERÌES
12-3-36 REPAÌRS
Refit
1. With assistance, position engine and gearbox
beneath vehicle and connect lifting chains to 18G
1598.
2. Raise engine and gearbox into position.
3. Clean LH mounting and mating face.
4. Adjust 18G 1598 to align gearbox mounting
bracket to LH mounting and fit and tighten bolts
to 100 Nm.
5. Clean engine RH mounting bracket and mating
face. Clean dowels and dowel holes.
6. Fit RH mounting bracket to engine and tighten
bolts to 100 Nm.
7. Lower engine onto RH mounting and tighten nut
to 85 Nm.
8. Tighten LH mounting through bolt to 85 Nm.
9. Align restraint bar and tighten nuts to 45 Nm.
10. Align upper steady and tighten bolt to 85 Nm.
11. Lower chains and remove 18G 1598.
12. Fit outer part of torsion link, tighten nuts to 25 Nm
and fit cover to inner nut.
Models with A/C
13. Clean A/C compressor and mating face.
14. Fit A/C compressor to mounting and tighten bolts
to 25 Nm.
15. Connect multiplug to A/C compressor.
16. Fit bolt securing A/C low pressure pipe to
alternator upper mounting bracket and tighten to
10 Nm.
17. Connect multiplug to alternator.
18. Connect battery lead to alternator, tighten nut to
4 Nm and fit cover over terminal.
19. Clean drive belt pulley grooves and ensure
grooves are not damaged.
20. Fit drive belt around pulleys, except alternator
pulley, ensure belt is correctly aligned in pulley
grooves.
21. Hold tensioner pulley fully clockwise, with
assistance fit drive belt around alternator pulley.
All models
22. Connect bottom hose to radiator and tighten clip.
23. Fit suspension tie rods and tighten bolts to 80
Nm.
24. Fit front beam. See FRONT SUSPENSION,
Repairs.
25. Fit LH and RH drive shafts as detailed in
differential oil seals. See MANUAL GEARBOX -
'PG1', Repairs.
26. Connect gear selector rod to selector shaft and fit
new roll pin.
27. Fit clip to retain roll pin.
28. Fit gear change steady bar with washers to
gearbox and tighten retaining bolt to 10 Nm.
29. Connect coolant bleed to radiator and tighten
clip.
30. Connect engine harness multiplug to cooling fan.
31. Connect top hose to radiator and tighten clip.
32. Fit intercooler outlet hose and tighten clips.
33. Fit intercooler inlet hose and tighten clips.
34. Fit glow plug relay to clip.
35. Connect PAS fluid hose to reservoir, fasten clip
and fit reservoir to bracket.
36. Clean PAS rack feed pipe union.
37. Lubricate a new 'O' ring with PAS fluid and fit to
PAS rack feed pipe.
38. Connect PAS rack feed pipe and tighten union
nut to 20 Nm.
CAUTION: To prevent damage to pipes or
unions, use 2 spanners when tightening
unions.
39. Connect vacuum hose to pipe and secure with
clip.
40. Connect vacuum pipe to EGR valve.
41. Connect multiplug to EGR control valve.
42. Connect multiplug to MAP sensor.
43. Connect hoses to EGR cooler and tighten clips.
44. Connect pressure sensing hose to turbocharger.
45. Connect hose to coolant rail and tighten clip.
46. Connect fuel feed and return hoses and secure
with clips.
47. Fit air intake pipe to turbocharger and tighten clip.
48. Connect engine breather valve hose to camshaft
cover and tighten clip.
49. Connect multiplug to MAF sensor.
50. Fit earth leads to gearbox and tighten bolt to 25
Nm.
51. Connect engine harness multiplugs to main
harness, fit multiplugs to bracket and secure
harness clip.
52. Fit battery lead to starter motor, tighten nut to 8
Nm and fit terminal cover.
53. Connect engine harness multiplug to underside
of fuse box.
54. Fit fuse box to bracket and tighten screws.
55. Connect engine harness multiplug to fuse box.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-37
56. Fit alternator lead to fuse box, tighten bolt to 10
Nm and close fuse box cover.
57. Position battery tray and connect multiplugs to
EDC ECU.
58. Fit battery tray to lower fixing bolts, fit upper bolts
and tighten all bolts to 10 Nm.
59. Fit battery lead to clip on battery tray.
60. Fit clutch cable through abutment bracket and
connect to clutch release lever.
61. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
62. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
63. Ìf required, refill engine with oil. See
MAINTENANCE.
64. Fill gearbox with oil. See MANUAL GEARBOX -
'PG1', Adjustments.
65. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
66. Connect battery earth lead.
67. Untie bonnet and support with stay.
68. Refill cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
69. Bleed power steering system. See STEERING,
Adjustments.
ENGINE STEADY - LOWER
´÷ 12.45.08
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Remove through bolt securing engine steady to
subframe.
4. Remove through bolt securing engine steady to
bracket on sump.
5. Remove engine steady.
Refit
1. Position engine steady to subframe and fit
through bolt.
2. Fit and tighten through bolt, securing steady to
bracket on sump to 85 Nm.
3. Tighten through bolt steady to subframe to 85
Nm.
4. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
5. Remove stand(s) and lower vehicle.
ENGÌNE - 'L' SERÌES
12-3-38 REPAÌRS
HYDRAMOUNT - ENGINE - RH
´÷ 12.45.12
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
4. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
5. Fit wooden block to jack and position jack to
support engine.
6. Remove bolt securing engine upper steady to
engine mounting bracket.
7. Remove 3 bolts securing mounting bracket to
engine.
8. Remove nut securing mounting bracket to engine
mounting.
9. Remove nut securing engine mounting and
restraint bar to body.
10. Loosen nut securing restraint bar to body and
move aside.
11. Remove engine mounting bracket.
12. Remove nut securing engine mounting to body.
13. Remove engine RH mounting.
Refit
1. Clean engine mounting bracket and mating face,
dowels and dowel holes.
2. Fit engine mounting to vehicle and lightly tighten
rear nut.
3. Fit mounting bracket to engine mounting, steady
bar, and engine.
4. Align restraint bar and fit and tighten nuts to 45
Nm.
5. Tighten nut securing engine mounting to body to
45 Nm.
6. Fit nut securing engine mounting to mounting
bracket and tighten to 85 Nm.
7. Align engine with mounting bracket and fit bolts.
Tighten bolts to 100 Nm.
8. Fit bolt securing mounting bracket to steady bar
and tighten to 85 Nm.
9. Remove jack.
10. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
11. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
12. Remove stand(s) and lower vehicle.
13. Connect battery earth lead.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-39
ENGINE STEADY - UPPER
´÷ 12.45.16
Remove
1. Disconnect battery earth lead.
2. Remove bolt to release PAS high pressure hose
support bracket.
3. Remove 2 bolts and remove engine upper
steady.
Refit
1. Fit engine upper steady and tighten bolts to 80
Nm.
2. Tighten bolt securing PAS high pressure pipe
support bracket to 10 Nm.
3. Connect battery earth lead.
ENGINE MOUNTING - LH
´÷ 12.45.30
Remove
1. Remove battery. See ELECTRICAL, Repairs.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Remove nut cover, 2 nuts and remove outer part
of torsion link.
4. Support gearbox on jack, use wood block to
protect gearbox casing.
5. Remove bolt securing engine LH mounting to
bracket on body.
6. Remove 2 bolts securing engine LH mounting to
gearbox mounting bracket.
7. Remove engine LH mounting and remove
snubber washers.
ENGÌNE - 'L' SERÌES
12-3-40 REPAÌRS
Refit
1. Fit snubber washers to engine LH mounting.
2. Fit engine LH mounting and tighten bolts to
gearbox bracket to 100 Nm.
3. Tighten bolt securing engine LH mounting to
bracket on body to 85 Nm.
4. Remove jack from under gearbox.
5. Fit torsion link, tighten nuts to 25 Nm and fit cap
to inner nut.
6. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
7. Fit battery. See ELECTRICAL, Repairs.
FLYWHEEL
´÷ 12.53.07
Remove
1. Remove clutch assembly. See CLUTCH,
Repairs.
2. Remove CKP sensor. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
3. Remove and discard 6 bolts securing flywheel to
crankshaft.
4. Remove flywheel locking pin 18G 1523.
5. Remove flywheel from crankshaft.
NOTE: Dowel located.
Refit
1. Use an old flywheel retaining bolt with saw cuts at
45° to bolt shank to clean old adhesive from
threads of flywheel bolt holes in crankshaft.
2. Clean flywheel and mating face of crankshaft.
Clean dowel and dowel hole.
3. Fit flywheel to crankshaft.
4. Fit flywheel locking pin 18G 1523.
5. Fit new bolts securing flywheel to crankshaft and
working in a diagonal sequence tighten bolts to
15 Nm + 90°.
6. Fit CKP sensor. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
7. Fit clutch assembly. See CLUTCH, Repairs.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-41
FLYWHEEL STARTER RING GEAR
´÷ 12.53.19
Remove
1. Remove engine flywheel. See ENGINE - 'L'
Series, Repairs.
2. Drill a 3 mm diameter hole at root of 2 teeth.
3. Apply a cold chisel to root of teeth, strike chisel
with hammer to break ring gear.
WARNING: Suitable eye protection must be
worn.
4. Remove starter ring gear.
Refit
1. Clean flywheel and starter ring gear.
2. Heat new starter ring gear evenly to 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 engine flywheel. See ENGINE - 'L' Series,
Repairs.
ENGINE OIL FILTER
´÷ 12.60.04
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Clean area around filter head and place a
container beneath engine.
4. Using a strap wrench, unscrew and discard filter.
Refit
1. Clean mating face of filter head.
2. Lubricate sealing ring of new filter with engine oil.
3. Fit filter until it seats against filter head then
tighten one complete turn or to 17 Nm.
4. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
5. Remove stand(s) and lower vehicle.
6. Top-up engine oil.See MAINTENANCE.
CAUTION: Do not raise oiI IeveI above the
'MAX' mark on dipstick.
7. Start and run engine and check for oil leaks.
8. Stop engine, wait a few minutes, then check oil
level and top up if necessary.
CAUTION: Ensure oiI does not drop onto the
aIternator when extracting the dipstick.
ENGÌNE - 'L' SERÌES
12-3-42 REPAÌRS
DIPSTICK TUBE
´÷ 12.60.09
Remove
1. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Release engine harness clip from dipstick tube.
4. Remove dipstick from tube.
5. Remove bolt securing dipstick tube to coolant
outlet elbow.
6. Twist to release and remove dipstick tube from
cylinder block.
Refit
1. Clean dipstick tube and mating face on block.
2. Apply Loctite 638 to dipstick tube and fit to
cylinder block.
3. Fit bolt securing dipstick tube to coolant outlet
elbow and tighten to 25 Nm.
4. Fit engine harness clip to dipstick tube.
5. Fit dipstick to tube.
6. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
7. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
OIL STRAINER AND PICK-UP PIPE
´÷ 12.60.20
Remove
1. Remove sump. See ENGINE - 'L' Series,
Repairs.
2. Remove 3 bolts securing oil strainer and pick-up
pipe to cylinder block and main bearing cap
noting that shortest bolt is fitted in main bearing
cap.
3. Remove oil strainer and pick-up pipe, remove
and discard 'O' ring.
CAUTION: Later engines are fitted with a
modified sump gasket which has an
additionaI Iocating/seaIing area retained by
the oiI pick-up pipe fIange. The modified
gasket shouId be used as a repIacement on
aII engines.
Engines fitted with modified sump gasket
4. Remove and discard sump gasket.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-43
Refit
1. Clean oil strainer and pick-up pipe.
2. Ensure bolt holes in cylinder block and main
bearing cap are clean and dry.
3. Lubricate a new 'O' ring with engine oil and fit to
pick-up pipe flange.
4. Position new sump gasket to cylinder block
ensuring that locating lugs are inserted in holes in
block.
CAUTION: Gasket must be fitted dry.
5. Position oil strainer and pick-up pipe to cylinder
block and main bearing cap.
6. Fit 3 bolts noting that shortest bolt is fitted into
main bearing cap. Tighten bolts to 8 Nm.
NOTE: Patchlok bolts may be re-used provided
threads are undamaged.
7. Fit sump. See ENGINE - 'L' Series, Repairs.
OIL PUMP
´÷ 12.60.26
Remove
1. Disconnect battery earth lead.
2. Drain engine oil. See MAINTENANCE.
3. Remove camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
4. Remove timing gear from crankshaft.
5. Disconnect multiplug from oil pressure switch.
6. Raise engine sufficiently only for access to
camshaft timing belt idler pulley nut.
ENGÌNE - 'L' SERÌES
12-3-44 REPAÌRS
7. Remove nut securing camshaft timing belt idler
pulley and remove pulley.
8. Remove pivot bolt and remove timing belt
tensioner.
9. Remove 2 bolts securing camshaft timing belt
lower backplate and remove backplate with
seals.
10. Position container to collect oil spillage.
11. Using a strap wrench, remove oil filter. Discard
filter.
12. Remove bolt securing oil cooler pipe clip to
bracket on coolant pump housing.
13. Loosen union nut, and release oil cooler pipe
from oil pump. Discard 'O' ring.
14. Remove 2 bolts securing oil cooler pipe clips to
sump.
15. Loosen union nut and release oil cooler pipe from
oil pump. Discard 'O' ring.
CAUTION: PIug the connections.
16. Remove bolt securing turbocharger oil feed pipe
clip to cylinder block.
17. Loosen union nut and disconnect turbocharger
oil feed pipe from oil pump. Discard 'O' ring.
CAUTION: PIug the connections.
18. Using sequence shown, remove 9 bolts and
remove oil pump. Discard gasket.
NOTE: Long M6 bolt at position 9. Patchlok bolts
may be re-used provided threads are
undamaged.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-45
19. Remove oil pressure switch.
20. Remove Woodruff key from crankshaft.
21. Ìf oil pump is to be refitted, remove and discard
crankshaft front oil seal from pump body.
Refit
1. Clean oil pressure switch.
2. Apply Loctite sealant 242 to thread and tighten
switch to 15 Nm.
3. Clean oil pump and mating face on cylinder
block. Clean oil seal running surface on
crankshaft.
CAUTION: Do not Iubricate oiI seaI recess or
oiI seaI running surface on crankshaft.
4. Ensure that bolt holes in cylinder block are clean
and dry.
5. Fit new crankshaft front oil seal to pump using
tool 18G 1509.
CAUTION: OiI seaI must be fitted dry.
NOTE: Replacement oil pumps are supplied with
oil seal fitted.
6. Fit woodruff key to crankshaft.
7. Use sealant Part No. GUG 705963GM and apply
a 1 mm thick bead of sealant to joint line of front
main bearing cap and cylinder block.
8. Fit new gasket to cylinder block.
NOTE: Gasket must be fitted dry.
9. Fit oil seal protector 18G 1510 and adaptor
sleeve 18G 1510-1 onto crankshaft.
10. Align rotor and fit oil pump.
CAUTION: OiI pump rotor is a tight fit on
crankshaft, do not use force to position oiI
pump against cyIinder bIock. FinaI fitting of
pump is achieved by the boIt tightening
sequence.
11. Remove tools 18G 1510 and 18G 1510-1.
ENGÌNE - 'L' SERÌES
12-3-46 REPAÌRS
12. Fit and lightly tighten bolts ensuring that longest
M6 bolt is fitted at position 1 and M10 bolt is fitted
at position 9.
13. Gradually tighten bolts in sequence shown until
oil pump is pulled against cylinder block.
CAUTION: BoIt tightening must be carried out
graduaIIy due to tight fit of pump rotor on
crankshaft. Damage to oiI pump wiII resuIt if
this procedure is not foIIowed.
14. Finally, tighten bolts in sequence to: - M10 bolt -
45 Nm M6 bolts - 8 Nm
15. Ensure sealing strips are fitted and fit timing belt
lower backplate. Tighten bolts to 9 Nm.
16. Clean turbocharger oil feed pipe connection.
17. Lubricate a new 'O' ring with engine oil and fit to
turbocharger oil feed pipe.
18. Fit oil feed to oil pump and tighten union nut to 25
Nm.
19. Align turbocharger oil feed pipe clip and tighten
bolt to 10 Nm.
20. Clean oil cooler pipe unions.
21. Lubricate new 'O' rings with engine oil and fit to
oil cooler pipes.
22. Fit pipes to oil pump and tighten union nuts to 25
Nm. Tighten oil cooler pipe clip bolts to 9 Nm.
23. Fit new engine oil filter. See ENGINE - 'L' Series,
Repairs.
24. Clean timing belt idler pulley and mating face.
25. Fit timing belt idler pulley with recessed side of
centre boss facing away from engine.
26. Apply Loctite 275 to threads of idler pulley nut, fit
nut and tighten to 45 Nm.
NOTE: If stud was unscrewed during nut
removal, clean old Loctite from threads of stud
and ensure hole in cylinder block is clean and
dry. Apply Loctite 275 to threads of stud and fit it
into block, tighten stud to 12 Nm.
27. Clean timing belt tensioner.
28. Fit timing belt tensioner and tighten pivot bolt to
45 Nm.
29. Clean crankshaft timing gear.
30. Fit timing gear to crankshaft.
31. Connect oil pressure switch multiplug.
32. Fit camshaft timing belt. See ENGINE - 'L'
Series, Repairs.
33. Connect battery earth lead.
34. Refill engine with oil. See MAINTENANCE.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-47
GASKET - SUMP - ENGINE
´÷ 12.60.38
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain engine oil and remove oil filter. See
MAINTENANCE.
4. Remove dipstick.
5. Remove engine steady bar. See ENGINE - 'L'
Series, Repairs.
6. Remove 3 bolts securing support bracket to
gearbox and sump.
7. Release clip and disconnect vacuum pump drain
hose from sump.
8. Loosen and remove oil cooler pipe union from oil
pump. Discard 'O' ring.
CAUTION: PIug the connections.
9. Remove 2 bolts securing oil cooler pipe clips to
sump.
10. Remove 17 bolts securing sump to cylinder
block.
11. Remove sump.
Later engines
12. Remove oil strainer and pick-up pipe. See
ENGINE - 'L' Series, Repairs.
NOTE: Later engines are fitted with a modified
sump gasket which has an additional locating/
sealing area retained by the oil pick-up pipe
flange. The modified gasket should be used as a
replacement for all engines. In order to remove
and refit the modified gasket, it will be necessary
to remove the oil strainer and pick-up pipe.
All engines
13. Remove and discard gasket from sump.
Refit
1. Ensure bolt holes in cylinder block are clean and
dry.
2. Clean sump and cylinder block mating faces.
3. Remove all traces of sealant from rear oil seal
housing, rear main bearing cap, cylinder block
and front main bearing cap using suitable
solvent.
ENGÌNE - 'L' SERÌES
12-3-48 REPAÌRS
4. Using sealant, Part Number GUG 705963GM, fill
grooves on each side of front main bearing cap
and along joint lines of bearing cap and cylinder
block.
5. Apply a 1 mm thick bead of sealant, Part No.
GUG 705963GM to joint line and around bolt
holes of crankshaft rear oil seal housing, rear
main bearing cap and cylinder block and sump
bolt holes adjacent to rear main bearing cap.
CAUTION: Do not appIy seaIant untiI
immediateIy prior to fitting sump. Do not
spread seaIant bead.
6. Position new gasket to cylinder block ensuring
that locating lugs are inserted in holes in block.
CAUTION: Gasket must be fitted dry.
Modified sump gasket
7. Fit oil strainer and pick-up pipe. See ENGINE -
'L' Series, Repairs.
All engines
8. Fit sump to cylinder block, fit and lightly tighten 17
bolts.
9. Using sequence shown, tighten bolts to 25 Nm.
10. Using same sequence, check that all bolts are
torqued to 25 Nm.
11. Align engine oil cooler pipe clips and tighten bolts
to 10 Nm.
12. Clean vacuum pump oil drain hose connection,
connect hose and secure with clip.
13. Clean engine oil cooler pipe union, fit 'O' ring and
tighten union to 25 Nm.
14. Fit bolt securing oil pipe to sump.
15. Connect vacuum pump oil drain pipe to sump.
16. Fit support bracket and tighten bolts to adaptor
plate to 70 Nm and bolt to sump to 25 Nm.
17. Fit engine steady bar. See ENGINE - 'L' Series,
Repairs.
18. Fit new oil filter and fill engine with oil. See
MAINTENANCE.
19. Remove stand(s) and lower vehicle.
20. Connect battery earth lead.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-49
OIL PRESSURE SWITCH
´÷ 12.60.50
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Position drain tin 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. Apply Loctite 577 to threads of switch.
3. Fit oil pressure switch and tighten to 15 Nm.
4. Connect multiplug to oil pressure switch.
5. Remove stand(s) and lower vehicle.
6. Top-up engine oil. See MAINTENANCE.
7. Connect battery earth lead.
VALVE - OIL PRESSURE RELIEF
´÷ 12.60.56.
Remove
1. Disconnect battery earth lead.
2. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
Early engines
3. Remove plug nut from oil filter head.
4. Remove spring and relief valve plunger.
Later engines
5. Remove and discard plug.
6. Remove and discard Dowty washer.
7. Remove spring and relief valve plunger.
ENGÌNE - 'L' SERÌES
12-3-50 REPAÌRS
Refit
1. Check plunger and bore for wear, corrosion and
scoring.
NOTE: Light scoring may be removed using
grade 600 emery cloth soaked in oil.
2. Check spring free length:
Free length = 38.9 mm
3. Renew relief valve as an assembly.
4. Remove all traces of sealant from plug threads in
oil pump body.
5. Lubricate spring, relief valve plunger and bore
with engine oil.
6. Fit relief valve plunger and spring.
Early engines
7. Apply Loctite 577 to threads of replacement plug.
8. Fit plug and tighten to 25 Nm.
CAUTION: Do not attempt to reseaI and fit
originaI pIug.
Later engines
9. Fit new Dowty washer to replacement plug.
10. Apply Loctite 577 to threads of replacement plug.
11. Fit plug and tighten to 25 Nm.
CAUTION: Do not attempt to reseaI and fit
originaI pIug.
All engines
12. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
13. Check engine oil level, top up if necessary. See
MAINTENANCE.
14. Connect battery earth lead.
OIL COOLER
´÷ 12.60.68
Remove
1. Remove radiator. See COOLING SYSTEM - 'L'
Series, Repairs.
2. Loosen clip and remove bottom hose from oil
cooler.
3. Loosen clip and disconnect top hose from oil
cooler.
4. Loosen clip and disconnect coolant pump hose
from oil cooler.
5. Loosen clips and disconnect hoses from coolant
rails.
6. Remove bolt and oil pipe clamp.
7. Position container to collect oil spillage.
8. Loosen union nuts and remove oil pipes from
cooler. Discard 'O' rings.
9. Remove 3 bolts and remove oil cooler.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-51
Refit
1. Clean oil cooler and mating face.
2. Fit oil cooler and tighten M10 bolts to 45 Nm. and
M8 bolt to 25 Nm.
3. Clean oil pipe unions.
4. Lubricate new 'O' rings with engine oil and fit to
oil cooler pipes.
5. Fit pipes to oil cooler and tighten union nuts to 25
Nm.
6. Fit pipe clamp and tighten bolt to 9 Nm.
7. Fit bottom hose to oil cooler and tighten clip.
8. Fit coolant pump hose and top hose to oil cooler
and secure with clips.
9. Fit coolant hoses to coolant rails and tighten
clips.
10. Fit radiator. See COOLING SYSTEM - 'L'
Series, Repairs.
11. Top-up engine oil. See MAINTENANCE.
CAMSHAFT TIMING BELT
´÷ 12.65.18
Remove
1. Disconnect battery earth lead.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Remove through bolt securing engine lower
steady, to bracket on sump and release steady
arm from mounting.
4. Remove 3 bolts securing bracket to sump and
move aside.
5. Remove RH engine hydramount. See ENGINE -
'L' Series, Repairs.
6. Remove camshaft timing belt lower cover. See
ENGINE - 'L' Series, Repairs.
ENGÌNE - 'L' SERÌES
12-3-52 REPAÌRS
7. Ensure that timing pin 18G 1523 is inserted in
hole in flywheel.
8. Check that timing marks on camshaft gear and
rear cover are exactly aligned.
9. Remove 4 nuts and 2 bolts from RH engine
mounting plate.
10. Remove RH engine mounting plate.
11. Ìf timing belt is to be refitted, mark direction of
rotation.
12. Remove timing belt tensioner access plug from
lower rear cover.
13. Loosen bolt securing belt tensioner pulley.
14. Fit 18G 1719 to tensioner.
15. Pull back camshaft timing belt tensioner plunger
using 18G 1719.
16. Tighten tensioner pulley bolt.
17. Remove timing belt.
CAUTION: Ease timing beIt from gears using
fingers onIy. MetaI Ievers may damage the
beIt and gears. Do not rotate engine with
timing beIt removed and cyIinder head fitted.
Timing beIts must be stored and handIed with
care. Store a beIt on its edge with a radius
greater than 50mm. Do not use a beIt which
has been twisted or bent doubIe as this can
fracture reinforcing fibres. Do not use an oiI
or cooIant contaminated beIt. Cause of
contamination must be rectified. AIthough
the beIt has a service Iife of 84,000 miIes,
(135,000 km) an existing beIt shouId onIy be
refitted if it has compIeted Iess than 42,000
miIes (65,000 km).
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-53
Refit
1. Clean timing belt gears and pulleys.
CAUTION: If the sintered gears have been
subjected to proIonged oiI contamination,
they must be soaked in a soIvent bath and
thoroughIy cIeaned and dried before reuse.
The cause of oiI contamination must be
rectified.
2. Remove all traces of Loctite from engine front
mounting cover plate.
3. Ensure that timing pin 18G 1523 is inserted in
hole in flywheel and camshaft gear timing mark is
aligned exactly with mark on timing belt rear
cover.
4. Tighten nut on tool 18G 1719 and fully retract
timing belt tensioner.
5. Using fingers only, ease timing belt over
crankshaft and camshaft gears keeping it as taut
as possible on the idler pulley side.
6. Loosen bolt until tensioner pulley moves easily
without tipping.
7. Loosen nut on tool 18G 1719 until tensioner is
released; tighten bolt to 55 Nm.
CAUTION: Do not exceed the specified torque
figure.
8. Remove tool 18G 1719.
9. Ìnsert timing belt tensioner access plug in lower
rear cover.
10. Apply Loctite 638 to mating face of engine front
mounting cover plate
11. Fit engine front mounting cover plate, fit 4 nuts
and 2 bolts. Tighten bolts to 45 Nm and nuts to 30
Nm then further 120°.
ENGÌNE - 'L' SERÌES
12-3-54 REPAÌRS
12. Locate crankshaft pulley on crankshaft, fit and
lightly tighten bolt. Do not tighten bolt further at
this stage.
13. Remove timing pin 18G 1523.
14. Using crankshaft pulley bolt, rotate crankshaft 2
turns clockwise and refit timing pin 18G 1523
ensuring that pin is inserted in hole in flywheel.
CAUTION: Do not use camshaft gear, gear
retaining boIt or timing beIt to rotate
crankshaft.
15. Check that camshaft gear timing mark is aligned
with mark on rear cover.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-55
16. Loosen bolt until timing belt tensioner pulley
moves to tension belt then tighten bolt to 55 Nm.
CAUTION: Do not exceed the specified torque
figure.
17. Remove crankshaft pulley bolt and pulley.
18. Fit camshaft timing belt lower cover. See
ENGINE - 'L' Series, Repairs.
19. Fit engine RH hydramount. See ENGINE - 'L'
Series, Repairs.
20. Clean steady bracket and sump mounting.
21. Fit steady bracket to sump and tighten bolts to 85
Nm.
22. Align steady arm, fit and tighten bolt to 85 Nm.
23. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
24. Connect battery earth lead.
COVER - CAMSHAFT TIMING BELT -
UPPER
´÷ 12.65.41
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
3. Remove 2 nuts retaining engine mounting
restraint and move aside.
4. Remove 4 bolts securing timing belt upper cover
to rear cover.
5. Remove timing belt upper cover.
ENGÌNE - 'L' SERÌES
12-3-56 REPAÌRS
Refit
1. Clean timing cover mating faces.
2. Check that sealing strips are correctly located in
timing belt upper cover.
3. Fit timing belt upper cover and tighten bolts to 5
Nm.
4. Fit engine mounting restraint and tighten bolts to
45 Nm.
5. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
6. Connect battery earth lead.
COVER - CAMSHAFT TIMING BELT -
LOWER
´÷ 12.65.43
Remove
1. Disconnect battery earth lead.
2. Remove crankshaft front pulley. See ENGINE -
'L' Series, Repairs.
3. Remove 6 bolts securing lower cover.
4. Remove lower cover.
Refit
1. Clean lower cover mating faces.
2. Fit lower cover to engine and tighten bolts to 5
Nm.
NOTE: The 3 longer bolts are fitted in the bottom
of the cover.
3. Fit crankshaft front pulley. See ENGINE - 'L'
Series, Repairs.
4. Connect battery earth lead.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-57
FUEL INJECTION PUMP (FIP) - TIMING
BELT - UP TO VIN NUMBER RF 545050
´÷ 12.65.51
NOTE: This procedure covers engines fitted with FIP
automatic timing belt tensioners.
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
4. Remove camshaft gear damper. See ENGINE -
'L' Series, Repairs.
5. Remove RH front road wheel.
6. Ìnsert timing pin 18G 1523 through hole in
gearbox adaptor plate, hold pin in contact with
flywheel and using assistance, rotate crankshaft
clockwise until timing pin can be felt to enter hole
in flywheel.
7. Check timing marks on camshaft gear and rear
cover are aligned.
CAUTION: Never use the camshaft gear, gear
retaining boIt or timing beIt to rotate
camshaft.
8. Loosen 4 bolts securing FÌP timing belt drive gear
to hub.
9. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate.
CAUTION: Timing pin must be a sIiding fit. If
pin is tight, rotate FIP drive gear sIightIy using
a socket on gear nut untiI pin can be inserted
correctIy.
10. Loosen FÌP timing belt tensioner bolt, move
tensioner away from belt and tighten bolt.
CAUTION: If timing beIt is to be refitted, mark
direction of rotation on beIt.
11. Remove timing belt.
CAUTION: Do not rotate camshaft or FIP with
timing beIt removed. Ease beIt from gears
using fingers onIy. Store a beIt on its edge
with a radius greater than 50 mm. DO NOT use
a beIt which has been twisted or bent doubIe
as this can fracture reinforcing fibres. Do Not
use an oiI or cooIant contaminated beIt.
Cause of contamination must be rectified.
AIthough the beIt has a service Iife of 84,000
miIes, (135,000 km) an existing beIt shouId
onIy be refitted if it has done Iess than 42,000
miIes, (65,000 km)
ENGÌNE - 'L' SERÌES
12-3-58 REPAÌRS
Refit
1. Clean timing belt gears.
CAUTION: If the gears have been subjected to
proIonged oiI contamination, they must be
soaked in a soIvent bath and thoroughIy
cIeaned and dried before re-use. The cause of
contamination must be rectified.
2. Leave 4 bolts securing FÌP belt drive gear to hub
just loose enough for gear to rotate within slots
without tipping.
3. Rotate FÌP belt drive gear fully clockwise within
slots. Fit timing belt using fingers only. Ìf
necessary, rotate drive gear anti-clockwise until
timing belt locates in gear teeth. Fitting belt with
drive gear in other possible position will not allow
for correct belt adjustment.
CAUTION: If originaI beIt is refitted, ensure
direction of rotation is correct.
4. Loosen FÌP timing belt tensioner bolt.
5. Using 12-184, rotate tensioner cIockwise until
index pointer passes tension indicator. Allow
tensioner to return anti-clockwise until pointer is
in line with bottom edge of land as shown. Hold
tensioner in this position and tighten tensioner
bolt to 44 Nm.
CAUTION: Do not exceed specified torque
figure.
6. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523 from flywheel.
7. Using crankshaft pulley bolt, rotate crankshaft 2
complete revolutions cIockwise (as viewed from
front of engine) and fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted into
hoIe in fIywheeI.
8. Check that camshaft gear timing mark is aligned
with mark on rear cover.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-59
9. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate. Ìf
necessary, rotate FÌP drive gear slightly using a
socket on drive gear nut.
CAUTION: Check that automatic tensioner
pointer is in Iine with Iand on tensioner as
shown. If not, beIt adjustment must be
repeated.
10. Fit torque wrench to square hole in FÌP timing belt
drive gear as shown and apply an anti-
cIockwise (as viewed from rear of engine) torque
loading of 25 Nm. Maintain loading and tighten 4
bolts securing gear to 25 Nm.
11. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523 from flywheel.
12. Using crankshaft pulley bolt, rotate crankshaft 2
complete revolutions cIockwise (as viewed from
front of engine) and fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted in hoIe
in fIywheeI.
13. Check that camshaft gear timing mark is still
aligned with mark on rear cover.
14. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate.
CAUTION: To ensure FIP timing is correct, FIP
drive gear timing pin must be a sIiding fit. If
pin is a tight fit, adjustment procedure must
be repeated.
ENGÌNE - 'L' SERÌES
12-3-60 REPAÌRS
15. On completion, remove timing pins 18G 1523
and 12-185.
16. Fit FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
17. Fit camshaft gear damper. See ENGINE - 'L'
Series, Repairs.
18. Fit RH front road wheel.
19. Remove stand(s) and lower vehicle.
20. Connect battery earth lead.
FUEL INJECTION PUMP (FIP) - TIMING
BELT - FROM VIN NUMBER RF 545051
´÷ 12.65.51
NOTE: This procedure covers engines fitted with FIP
manual timing belt tensioners.
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
4. Remove camshaft gear damper. See ENGINE -
'L' Series, Repairs.
5. Remove RH front road wheel.
6. Ìnsert timing pin 18G 1523 through hole in
gearbox adaptor plate, hold pin in contact with
flywheel and using assistance, rotate crankshaft
clockwise until timing pin can be felt to enter hole
in flywheel.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-61
7. Check timing marks on camshaft gear and rear
cover are aligned.
CAUTION: Never use the camshaft gear, gear
retaining boIt or timing beIt to rotate
camshaft.
8. Loosen 4 bolts securing FÌP timing belt drive gear
to hub.
9. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate.
CAUTION: Timing pin must be a sIiding fit. If
pin is tight, rotate FIP drive gear sIightIy using
a socket on gear nut untiI pin can be inserted
correctIy.
10. Loosen FÌP timing belt tensioner pulley Allen bolt,
move tensioner away from belt and tighten bolt.
CAUTION: If timing beIt is to be refitted, mark
direction of rotation on beIt.
11. Remove timing belt.
CAUTION: Do not rotate camshaft or FIP with
timing beIt removed. Ease beIt from gears
using fingers onIy. Store a beIt on its edge
with a radius greater than 50 mm. DO NOT use
a beIt which has been twisted or bent doubIe
as this can fracture reinforcing fibres. Do Not
use an oiI or cooIant contaminated beIt.
Cause of contamination must be rectified.
AIthough the beIt has a service Iife of 48,000
miIes, (80,000 km) an existing beIt shouId
onIy be refitted if it has done Iess than 24,000
miIes, (40,000 km)
Refit
1. Clean timing belt gears.
CAUTION: If the gears have been subjected to
proIonged oiI contamination, they must be
soaked in a soIvent bath and thoroughIy
cIeaned and dried before re-use. The cause of
contamination must be rectified.
2. Leave 4 bolts securing FÌP belt drive gear to hub
just loose enough for gear to rotate within slots
without tipping.
3. Rotate FÌP belt drive gear fully clockwise within
slots. Fit timing belt using fingers only. Ìf
necessary, rotate drive gear anti-clockwise until
timing belt locates in gear teeth. Fitting belt with
drive gear in other possible position will not allow
for correct belt adjustment.
CAUTION: If originaI beIt is refitted, ensure
direction of rotation is correct.
ENGÌNE - 'L' SERÌES
12-3-62 REPAÌRS
4. Loosen timing belt tensioner pulley Allen bolt.
5. Using a torque wrench fitted to tensioner pulley
backplate, apply a cIockwise (as viewed from
rear of engine) torque loading of 6 Nm to drive
belt. Maintain loading and tighten tensioner
pulley Allen bolt to 44 Nm.
CAUTION: Do not exceed specified torque
figure.
6. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523.
7. Using crankshaft pulley bolt, rotate crankshaft 2
complete revolutions cIockwise (as viewed from
front of engine) and fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted into
hoIe in fIywheeI.
8. Check that camshaft gear timing mark is aligned
with mark on rear cover.
ENGÌNE - 'L' SERÌES
REPAÌRS 12-3-63
9. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate. Ìf
necessary, rotate FÌP drive gear slightly using a
socket on drive gear nut.
10. Fit torque wrench to square hole in FÌP timing belt
drive gear as shown and apply an anti-
cIockwise (as viewed from rear of engine) torque
loading of 25 Nm. Maintain loading and tighten 4
bolts securing gear to 25 Nm.
11. Remove FÌP drive gear timing pin 12-185 and
timing pin 18G 1523.
12. Rotate crankshaft 2 complete revolutions
cIockwise and fit timing pin 18G 1523.
CAUTION: Ensure pin is fuIIy inserted into
hoIe in fIywheeI.
13. Check that camshaft gear timing gear mark is still
aligned with mark on rear cover.
14. Ìnsert FÌP drive gear timing pin 12-185 through
FÌP drive gear and into hole in adaptor plate.
CAUTION: To ensure FIP timing is correct, FIP
drive gear timing pin must be a sIiding fit. If
pin is a tight fit, adjustment procedure must
be repeated.
15. On completion, remove timing pins 18G 1523
and 12-185.
16. Fit FÌP timing belt cover. See ENGINE - 'L'
Series, Repairs.
17. Fit camshaft gear damper. See ENGINE - 'L'
Series, Repairs.
18. Fit RH front road wheel.
19. Remove stand(s) and lower vehicle.
20. Connect battery earth lead.
ENGÌNE - 'L' SERÌES
12-3-64 REPAÌRS
COVER - FUEL INJECTION PUMP (FIP) -
TIMING BELT
´÷ 12.65.53
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
3. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
4. Remove 5 bolts and remove FÌP timing belt
cover.
Refit
1. Fit timing belt cover and tighten bolts to 5 Nm.
2. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
3. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
4. Connect battery earth lead.
DAMPER - CAMSHAFT GEAR
´÷ 12.65.58
Remove
1. Disconnect battery earth lead.
2. Remove timing gear front upper cover. See
ENGINE - 'L' Series, Repairs.
3. Remove and discard 3 Torx screws securing
damper to camshaft gear.
4. Remove damper from camshaft gear.
Refit
1. Clean damper and mating face.
2. Fit damper to camshaft gear with timing groove in
damper aligned with groove in gear, fit new Torx
screws and tighten to 10 Nm.
3. Fit timing gear front upper cover. See ENGINE -
'L' Series, Repairs.
4. Connect battery earth lead.
EMÌSSÌON CONTROL
REPAÌRS 17-1
EMÌSSÌ ONCONTROL REPAÌ RS
CRANKCASE PRESSURE LIMITER VALVE
- 'L' SERIES
´÷ 17.10.25
Remove
1. Loosen clip and disconnect engine breather hose
from valve.
2. Loosen clip and remove valve from air intake
pipe.
Refit
1. Fit valve to air intake pipe and tighten clip.
2. Connect engine breather hose to valve and
tighten clip.
EVAPORATIVE EMISSION CANNISTER -
'K' SERIES
´÷ 17.15.13
Remove
1. Disconnect battery earth lead.
2. Release clip and disconnect hose from inlet
manifold.
3. Disconnect hose from fuel tank vent pipe.
4. Disconnect multiplug from purge valve.
5. Release evaporative emission cannister from
mounting bracket.
6. Remove evaporative emission cannister.
Refit
1. Fit evaporative emission cannister to mounting
bracket.
2. Locate evaporative emission cannister breather
hose in subframe.
3. Connect hose to fuel tank vent pipe.
4. Connect hose to inlet manifold and secure with
clip.
5. Connect multiplug to purge valve.
6. Connect battery earth lead.
EMÌSSÌON CONTROL
17-2 REPAÌRS
VALVE - EXHAUST GAS RECIRCULATION
(EGR) - 'L-SERIES'
´÷ 17.45.01
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
3. Disconnect vacuum pipe from EGR valve.
4. Remove 2 Allen screws securing EGR valve to
EGR cooler.
5. Remove 2 Allen screws securing EGR valve to
exhaust manifold.
6. Remove EGR valve.
7. Remove and discard 2 gaskets.
Refit
1. Clean mating faces of EGR valve, exhaust
manifold and EGR cooler.
2. Fit new gaskets to EGR valve.
3. Align EGR valve to exhaust manifold and EGR
cooler.
4. Fit 2 Allen screws securing EGR valve to exhaust
manifold and tighten to 25 Nm.
5. Fit 2 Allen screws to EGR cooler and tighten to 25
Nm. Connect vacuum pipe from EGR solenoid to
EGR valve.
6. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
7. Connect battery earth lead.
EXHAUST GAS RECIRCULATION (EGR)
SOLENOID - 'L' SERIES
´÷ 17.45.04
Remove
1. Disconnect multiplug from EGR solenoid.
2. Disconnect 2 vacuum pipes from EGR solenoid.
3. Remove 2 bolts securing EGR solenoid to
bracket.
4. Remove EGR solenoid.
Refit
1. Fit EGR solenoid to bracket and secure with
bolts.
2. Connect vacuum pipes to EGR solenoid.
3. Connect multiplug to EGR solenoid
EMÌSSÌON CONTROL
REPAÌRS 17-3
COOLER - EXHAUST GAS
RECIRCULATION (EGR) - 'L' SERIES
´÷ 17.45.40
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
3. Drain cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
4. Loosen clips and remove coolant hoses from
EGR cooler.
5. Remove 2 Allen screws from EGR cooler to EGR
valve.
6. Remove 2 Allen screws from EGR cooler to EGR
pipe.
7. Remove EGR cooler and discard gaskets.
Refit
1. Clean gasket mating faces EGR cooler pipe and
EGR valve.
2. Fit EGR cooler and gaskets tighten Allen bolts to
25 Nm.
3. Fit coolant hoses to EGR cooler and tighten clips.
4. Refill cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
5. Fit acoustic engine cover. See ENGINE - 'L'
Series, Repairs.
6. Connect battery earth lead.
CATALYTIC CONVERTER - 'L' SERIES
´÷ 17.50.01
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 3 nuts securing catalytic converter to
front pipe.
3. Remove 3 nuts securing catalytic converter to
intermediate pipe.
4. Disconnect catalytic converter from intermediate
pipe. Remove catalytic converter from front pipe.
5. Remove and discard gaskets.
CAUTION: CataIytic converters are
manufactured from ceramic materiaI which is
very fragiIe, avoid heavy impacts on
converter casing.
Refit
1. Clean mating faces of catalytic converter, front
pipe and intermediate pipe.
2. Fit new gasket to each catalytic converter flange.
3. Fit catalytic converter to front pipe and connect to
intermediate pipe. Fit nuts and tighten to 50 Nm.
4. Remove stand(s) and lower vehicle.
EMÌSSÌON CONTROL
17-4 REPAÌRS
ENGÌNE MANAGEMENT SYSTEM - MEMS
ADJUSTMENTS 18-1-1
ENGÌNE MANAGEMENT SYSTEM - MEMS ADJUSTMENTS
THROTTLE CABLE
´÷ 19.20.05
Before adjusting cable, ensure that cable is correctly
routed and located. Do not attempt to adjust throttle
cable or engine idle speed by means of the throttle stop
screw.
Adjust
1. Release cable adjusting nut from abutment
bracket.
2. Hold throttle cam in fully closed position, ensure
throttle cam contacts throttle stop screw.
3. Rotate cable adjusting nut until all slack is taken
out of inner cable and nut is in contact with rear
face of abutment bracket. Ensure throttle does
not open.
4. Fit throttle cable adjusting nut in abutment
bracket.
5. Operate throttle pedal and ensure that full throttle
pedal movement is available.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-2 ADJUSTMENTS
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-3
REPAÌ RS
THROTTLE CABLE
´÷ 19.20.06
Remove
1. Release cable adjusting nut from abutment
bracket.
2. Release inner cable from cam.
3. Release cable from clip on inlet manifold.
4. Rotate collar through 90° and release cable from
bulkhead.
5. Release 2 turnbuckles and remove closing panel.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-4 REPAÌRS
6. Depress nylon clips and disconnect throttle cable
from pedal.
7. Remove throttle cable.
Refit
1. Feed cable through bulkhead and connect inner
cable to pedal.
2. Fit closing panel and secure with turnbuckles.
3. Smear rubber grease of both sides of the rubber
seal and secure cable to bulkhead.
4. Fit throttle cable to clip on inlet manifold.
5. Connect throttle cable to throttle cam.
6. Connect cable adjusting nut to abutment bracket.
7. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments.
AIR CLEANER
´÷ 19.10.01
Remove
1. Remove battery. See ELECTRICAL, Repairs.
2. Release clip and disconnect air intake hose from
throttle housing.
3. Remove 2 bolts securing air cleaner to battery
tray.
4. Disconnect intake hose from throttle housing.
5. Release air cleaner from air intake hose.
6. Remove air cleaner.
Refit
1. Position air cleaner in vehicle and connect to air
intake hose.
2. Align air cleaner to battery tray.
3. Fit 2 bolts securing air cleaner to battery tray and
tighten to 9 Nm.
4. Connect intake hose to throttle housing and
secure with clip.
5. Fit battery.See ELECTRICAL, Repairs.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-5
AIR CLEANER ELEMENT
´÷ 19.10.10
Remove
1. Release 4 clips securing 2 halves of air cleaner.
2. Release top half of air cleaner and position aside.
3. Remove and discard air cleaner element.
Refit
1. Clean inside of air cleaner casing.
2. Fit new air cleaner element in casing.
3. Position top half of air cleaner casing and secure
with clips.
SPARK PLUGS - 'K16'
´÷ 18.20.02
Remove
1. Remove coils. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
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 mm.
3. Fit spark plugs and tighten to 25 Nm.
4. Refit coils. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-6 REPAÌRS
COIL - EACH
´÷ 18.20.44
Remove
1. Disconnect battery earth lead.
2. Remove 3 bolts securing coil lead 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 2 bolts securing coil to 9 Nm.
Secure coil lead to clip.
4. Connect ht lead to spark plug and secure lead to
clip.
5. Fit coil cover and tighten bolts to 9 Nm.
ENGINE CONTROL MODULE (ECM)
´÷ 18.30.01
Remove
1. Disconnect battery earth lead.
2. Open fuse box cover.
3. Remove 3 bolts securing fuse box to mounting
brackets.
4. Position fuse box aside to access ECM.
5. Remove 2 bolts securing ECM to battery carrier.
6. Release ECM and disconnect multiplugs.
7. Remove ECM.
Refit
1. Connect multiplugs to ECM.
2. Fit ECM to battery carrier and secure with bolts.
3. Tighten bolts securing fuse box and close fuse
box lid.
4. Connect battery earth lead.
NOTE: If a new ECM has been fitted, the ECM
will need to be programmed with the code from
the anti-theft security unit using TestBook, before
the engine can be started.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-7
ENGINE CONTROL UNIT (ECM) - WITH
SECURITY SHIELD FITTED
´÷ 18.30.01
1. Battery. See EIectricaI, Repairs
2. Engine compartment fusebox bolts x 3
¤ 10 Nm
3. Shear bolts (a) x 2
¤ 9 Nm
4. Security shield (b)
5. Multiplug (c,d) x 2
6. ECM (e)
c
d
e
a
a
b
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-8 REPAÌRS
IDLE AIR CONTROL (IAC) VALVE
´÷ 18.30.05
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from ÌAC valve.
3. Remove 2 TX20 Torx screws securing ÌAC valve
to inlet manifold.
4. Remove ÌACV from inlet manifold.
5. Remove and discard 'O' ring from ÌAC valve.
Refit
1. Clean mating faces of ÌAC valve and inlet
manifold.
2. Lubricate new 'O' ring with silicone grease and fit
to ÌAC valve.
3. Fit ÌAC valve to inlet manifold. Fit Torx screws
and tighten to 6 Nm.
4. Connect multiplug to ÌAC valve.
5. Connect battery earth lead.
SENSOR - INTAKE AIR TEMPERATURE
(IAT)
´÷ 18.30.09
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from ÌAT sensor.
3. Remove ÌAT sensor.
Refit
1. Clean threads of ÌAT sensor.
2. Clean mating faces of ÌAT sensor and inlet
manifold.
3. Fit ÌAT sensor to inlet manifold and tighten to 7
Nm.
4. Connect multiplug to ÌAT sensor.
5. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-9
SENSOR - ENGINE COOLANT
TEMPERATURE (ECT)
´÷ 18.30.10
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from ECT sensor.
3. Position container to collect spillage.
4. Remove ECT sensor.
Refit
1. Clean threads of ECT sensor.
2. Apply Loctite 577 to threads of ECT sensor.
3. Fit ECT sensor and tighten to 15 Nm.
4. Connect multiplug to ECT sensor.
5. Connect battery earth lead.
6. Top-up coolant. See MAINTENANCE.
SENSOR - CRANKSHAFT POSITION (CKP)
´÷ 18.30.12
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect multiplug from CKP sensor.
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 6 Nm.
3. Connect multiplug to CKP sensor.
4. Lower vehicle.
5. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-10 REPAÌRS
SENSOR - THROTTLE POSITION (TP)
´÷ 18.30.17
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from TP sensor.
3. Remove and discard 2 TX20 Torx screws and
wave washers securing TP sensor to throttle
housing.
4. Remove TP sensor specification plate.
5. 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.
CAUTION: The TP sensor can be easiIy
damaged during fitting. When pressing the
sensor onto the throttIe spindIe, use fingers
onIy, and onIy appIy pressure 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 sensor in a cIockwise
direction, and ensure that it is not rotated
beyond its internaI stops.
4. Fit TP sensor specification plate.
5. Fit new Torx screws and wave washers, and
tighten 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. Connect battery earth lead.
NOTE: A 'throttle initialisation' procedure MUST
be carried out using Testbook whenever the TP
sensor is removed or renewed.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-11
SENSOR - CAMSHAFT POSITION (CMP)
´÷ 18.30.24
Remove
1. Disconnect battery earth lead.
2. Remove three bolts securing coil cover to engine
and remove cover.
3. Release CMP multiplug from bracket and
disconnect multiplug.
4. Remove bolt securing CMP sensor.
5. Release sensor cable from clip and remove
sensor.
Refit
1. Clean CMP sensor and mating face.
2. Fit CMP 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 9 Nm.
5. Connect battery earth lead.
HYDRAULIC CONTROL UNIT (HCU)
SOLENOIDS - 'K16 WITH VVC'
´÷ 18.30.39
Remove
1. Release breather hose from inlet manifold
chamber. Release clip and remove hose from
camshaft cover.
2. Disconnect multiplug from CMP sensor.
3. Release clip, disconnect breather hose from
camshaft cover and move aside.
4. Disconnect 2 multiplugs from HCU solenoids.
5. Note angle at which each solenoid is positioned
relative to HCU.
6. Remove nut securing solenoids to HCU.
7. Remove 'O' ring.
8. Remove outer solenoid, washer and 'O' ring.
9. Remove inner solenoid and 'O' ring.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-12 REPAÌRS
Refit
1. Clean spool valve shaft, solenoid mating faces
and washer.
2. Fit 'O' ring to inner solenoid and fit solenoid
ensuring that lettering on end of solenoid is facing
away from HCU.
3. Fit washer and 'O' ring.
4. Fit outer solenoid ensuring that lettering on end of
solenoid is facing away from HCU.
5. Align solenoids, fit nut and tighten to 12 Nm.
6. Connect multiplugs to solenoids.
7. Connect breather hose to camshaft cover and
secure with clip.
8. Connect multiplug to camshaft position sensor.
9. Fit breather hose to camshaft cover, connect
hose to inlet manifold chamber and secure with
clip.
SENSOR - OIL TEMPERATURE - 'K16
WITH VVC'
´÷ 18.30.41
Remove
1. Disconnect multiplug from oil temperature
sensor.
2. Remove temperature sensor from HCU.
3. Remove and discard seal.
Refit
1. Clean sealing faces of sensor and HCU.
2. Fit new seal to sensor.
3. Fit sensor and tighten to 17 Nm.
4. Connect multiplug to sensor.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-13
SENSOR - MANIFOLD ABSOLUTE
PRESSURE (MAP) - 'K16 WITH VVC'
´÷ 18.30.56
Remove
1. Disconnect multiplug from MAP sensor.
2. Remove 2 Torx screws securing MAP sensor
manifold chamber.
3. Remove MAP sensor.
Refit
1. Clean sealing faces of sensor and manifold
chamber.
2. Fit sensor to manifold chamber and tighten Torx
screws to 3 Nm.
3. Connect multiplug to sensor.
SENSOR - CAMSHAFT POSITION (CMP) -
'K16 WITH VVC'
´÷ 19.22.07
Remove
1. Disconnect multiplug from CMP sensor.
2. Remove bolt securing CMP sensor to cylinder
head.
3. Remove CMP sensor.
4. Remove 'O' ring from CMP sensor.
Refit
1. Clean sealing faces of sensor and cylinder head.
2. Lubricate and fit 'O' ring to CMP sensor.
3. Fit sensor to cylinder head and tighten bolt to 6
Nm.
4. Connect multiplug to CMP sensor.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-14 REPAÌRS
SENSOR - HEATED OXYGEN (HO
2
S) -
'K16'
´÷ 19.22.16
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Release HO
2
S multiplug from bracket and
disconnect multiplug from engine harness.
4. Using a 22 mm split crows foot attachment,
remove HO
2
S from exhaust manifold. Remove
and discard sealing washer.
Refit
1. Clean HO
2
S and exhaust manifold mating face.
2. Fit sealing washer to HO
2
S.
3. Position HO
2
S to exhaust manifold, use a 22 mm
crows foot attachment and torque wrench.
Tighten HO
2
S to 55 Nm.
4. Connect HO
2
S multiplug to engine harness and
secure multiplug in mounting bracket.
5. Remove stand(s) and lower vehicle.
6. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-15
SENSOR - HEATED OXYGEN (HO
2
S) - 'K16
WITH VVC'
´÷ 19.22.16
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove exhaust front pipe gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
4. Release HO
2
S multiplug from rear timing belt
cover and disconnect multiplug from engine
harness.
5. Release front pipe from mounting rubber.
6. Using 18G-1687 loosen HO
2
S, remove HO
2
S
from front pipe. Remove and discard sealing
washer.
Refit
1. Clean HO
2
S and exhaust manifold mating face.
2. Fit sealing washer to HO
2
S.
3. Position HO
2
S to exhaust front pipe, using 18G-
1687 tighten HO
2
S to 55 Nm.
4. Fit front pipe to mounting rubber.
5. Connect HO
2
S multiplug to engine harness and
secure multiplug to rear cam cover.
6. Fit exhaust front pipe gasket. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
7. Remove stand(s) and lower vehicle.
8. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-16 REPAÌRS
HOUSING - THROTTLE
´÷ 19.22.45
Remove
1. Disconnect battery earth lead.
2. Release clip and disconnect air intake hose from
throttle housing.
3. Release clip and remove air intake hose from air
cleaner.
4. Disconnect ÌAC hose from throttle housing.
5. Disconnect multiplug from TP sensor.
6. Release clip and disconnect breather hose from
throttle housing.
7. Release throttle cable adjusting nut from
abutment bracket.
8. Disconnect throttle cable from throttle cam.
9. Remove 4 bolts securing throttle housing to inlet
manifold.
10. Remove throttle housing.
11. Remove and discard 'O' ring from throttle
housing.
Refit
1. Clean mating faces of throttle housing and inlet
manifold.
2. Lubricate new 'O' ring with silicone grease and fit
to throttle housing.
3. Position throttle housing to inlet manifold, fit and
lightly tighten bolts.
4. Tighten bolts in sequence shown, using the
following procedure;
¤ Tighten to 4 Nm.
¤ Back off one flat.
¤ Tighten to 9 Nm.
5. Connect throttle cable to throttle cam.
6. Locate throttle cable adjusting nut in abutment
bracket.
7. Connect breather hose to throttle housing and
secure with clip.
8. Connect multiplug to TP sensor.
9. Fit ÌAC hose and align orientation marks.
10. Connect air intake hose to throttle housing and
air cleaner and secure with clips.
11. Connect battery earth lead.
12. Retune using TestBook.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-17
SENSOR - HEATED OXYGEN - (HO
2
S) -
POST CATALYST - 'K16'
´÷ 19.22.71
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Release post catalyst HO
2
S sensor lead
grommet from tunnel, manoeuvre sensor lead
and multiplug through grommet aperture in
tunnel.
3. Disconnect multiplug from post catalyst HO
2
S
sensor lead.
4. Release harness from support bracket.
5. Remove HO
2
S from front pipe and collect sealing
washer.
Refit
1. Fit sealing washer to HO
2
S, fit HO
2
S and tighten
to 55 Nm.
2. Connect multiplug to post catalyst HO
2
S sensor
lead.
3. Position HO
2
S multiplug and lead through
grommet aperture in tunnel and fit grommet.
4. Secure harness in support bracket.
5. Remove stand(s) and lower vehicle.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-18 REPAÌRS
FUEL RAIL AND INJECTORS - 'K16 WITH
VVC'
´÷ 19.60.04
Remove
1. Disconnect battery earth lead.
2. Remove inlet manifold chamber. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
3. Release clip and remove vacuum pipe from fuel
pressure regulator.
4. Position absorbent cloth around fuel return hose
at fuel pressure regulator.
5. Release clip and disconnect fuel return hose from
pressure regulator.
CAUTION: PIug the connections.
6. Position absorbent cloth around fuel feed hose
connection.
7. Disconnect fuel feed hose.
CAUTION: PIug the connections.
8. Remove 2 bolts securing fuel rail to inlet
manifold.
9. Release fuel rail and injectors from inlet manifold.
10. Disconnect multiplugs from injectors.
11. Remove fuel rail complete with injectors.
12. Remove 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.
Do not carry out further dismantling if component
is removed for access only.
15. Remove 2 bolts securing fuel feed hose adapter
to fuel rail.
16. Remove fuel feed hose.
17. Remove and discard 'O' ring.
18. Clean hose adapter.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-19
Refit
1. Fit 'O' ring to fuel hose adapter.
2. Fit hose, fit bolts and tighten to 5 Nm.
3. Remove protective caps from each injector.
4. Clean injectors and recesses in fuel rail and inlet
manifold.
5. Lubricate new 'O' rings with silicone grease and
fit to each end of injectors.
6. Fit injectors to fuel rail.
7. Secure injectors to fuel rail with spring clips.
8. Position fuel rail assembly and connect injector
multiplugs.
9. Push each injector into inlet manifold.
10. Fit bolts securing fuel rail to inlet manifold and
tighten to 9 Nm.
11. Connect fuel feed hose to fuel rail.
12. Connect fuel return hose and secure with clip.
13. Fit vacuum pipe to fuel pressure regulator and
secure with clip.
14. Fit inlet manifold chamber. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
15. Connect battery earth lead.
FUEL RAIL AND INJECTOR SET - 'K16'
´÷ 19.60.04
Remove
1. Disconnect battery earth lead.
2. Release clip and disconnect vacuum pipe from
fuel pressure regulator.
3. Remove engine oil dipstick.
4. Position absorbent cloth beneath fuel rail.
5. Release fuel feed hose from fuel rail.
CAUTION: PIug the connections.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-20 REPAÌRS
6. Remove 2 bolts securing fuel rail to inlet
manifold.
7. Release fuel rail and injectors from inlet manifold.
8. Release and remove injector spacer.
9. Disconnect multiplugs from injectors.
10. Remove the fuel rail complete with injectors.
11. Release spring clips securing injectors to fuel rail
and remove fuel injectors.
12. Remove and discard 2 'O' rings from each
injector.
13. Fit protective caps to each end of injectors.
Refit
1. Remove protective caps from each injector.
2. Clean injectors and recesses in fuel rail and inlet
manifold.
3. Lubricate new 'O' rings with silicone grease and
fit to 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 9 Nm.
10. Connect fuel feed hose to fuel rail.
11. Fit engine oil dipstick.
12. Connect vacuum pipe to fuel pressure regulator
and secure with clip.
13. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - MEMS
REPAÌRS 18-1-21
AIR INTAKE RESONATOR
´÷ 19.70.03
Remove
1. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
2. Remove 2 bolts securing resonator to battery
tray.
3. Release resonator from air intake pipe and
remove.
Refit
1. Fit resonator and connect to air intake pipe.
2. Fit bolts securing resonator to battery tray and
tighten to 9 Nm.
3. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
ENGÌNE MANAGEMENT SYSTEM - MEMS
18-1-22 REPAÌRS
ENGÌNE MANAGEMENT SYSTEM - EDC
ADJUSTMENTS 18-2-1
ENGÌNE MANAGEMENT SYSTEM - EDC ADJUSTMENTS
THROTTLE CABLE
´÷ 19.20.05
NOTE: Before adjusting cable, ensure that cable is
correctly routed and located.
Disconnect battery earth lead.
Adjust
1. Release cable adjusting nut from abutment
bracket.
2. Position outer cable to abutment bracket with
adjusting nut in contact with outside face of
bracket
3. Hold throttle position sensor lever in closed
position.
4. Rotate cable adjusting nut until all slack is taken
out of inner cable.
5. Without further rotation, fit cable adjusting nut
into abutment bracket.
6. Connect battery earth lead.
GLOW PLUG TEST
´÷ 19.90.20.01
Check
1. Remove glow plug. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
2. Using DX-900, connect RED lead to battery '+'
positive and the BLACK lead to battery '-'
negative.
3. Position heater plug into tester and retain with
spring loaded bar.
4. Connect YELLOW lead to heater plug terminal.
5. Press red button on tester and note ammeter
reading. keep button depressed, heater plug tip
should start to glow after 5 seconds
CAUTION: The heater pIug tip must gIow first,
if it faiIs to do so, repIace heater pIug.
6. The ammeter reading should show an initial
current draw of 25 amps, which should fall to 12
amps after 20 seconds.
7. Refit glow plug. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-2 ADJUSTMENTS
ENGÌNE MANAGEMENT SYSTEM - EDC
REPAÌRS 18-2-3
REPAÌ RS
AIR CLEANER
´÷ 19.10.01
Remove
1. Remove battery. See ELECTRICAL, Repairs.
2. Release clip and disconnect air intake hose from
throttle housing.
3. Remove 2 bolts securing air cleaner to battery
tray.
4. Disconnect intake hose from throttle housing
5. Release air cleaner from air intake hose.
6. Remove air cleaner.
Refit
1. Position air cleaner in vehicle and connect to air
intake hose.
2. Align air cleaner to battery tray
3. Fit 2 bolts securing air cleaner to battery tray and
tighten to 9 Nm.
4. Connect intake hose to throttle housing and
secure with clip.
5. Fit battery. See ELECTRICAL, Repairs.
AIR CLEANER ELEMENT
´÷ 19.10.10
Remove
1. Release coolant pipe from clips on air cleaner.
2. Release 4 clips securing 2 halves of air cleaner.
3. Release 2 clips securing top half of air cleaner to
MAF sensor, remove sealing ring.
4. Release top half of air cleaner and position aside.
5. Remove and discard air cleaner element.
Refit
1. Clean inside of air cleaner casing.
2. Check MAF sensor sealing ring for condition,
replace if necessary.
3. Fit new air cleaner element in casing.
4. Position top half of air cleaner casing and secure
with clips.
5. Secure air cleaner to MAF sensor with clips.
6. Secure coolant pipe to clips on air cleaner.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-4 REPAÌRS
THROTTLE CABLE
´÷ 19.20.06
Remove
1. Disconnect battery earth lead.
2. Release cable adjusting nut from abutment
bracket.
3. Release inner cable from cam on throttle position
sensor.
4. Rotate collar through 90° and release cable from
bulkhead.
5. Release 3 turnbuckles and remove closing panel.
6. Depress nylon clips and disconnect throttle cable
from pedal.
7. Remove throttle cable.
Refit
1. Feed cable through bulkhead and connect inner
cable to pedal.
2. Fit closing panel and secure with turnbuckles.
3. Smear rubber grease on both sides of the rubber
seal and secure cable to bulkhead.
4. Connect throttle cable to cam on throttle position
sensor.
5. Connect cable adjusting nut to abutment bracket.
6. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - EDC, Adjustments.
7. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - EDC
REPAÌRS 18-2-5
ENGINE CONTROL MODULE (ECM)
´÷ 18.30.01
Remove
1. Disconnect battery earth lead.
2. Remove 2 bolts and remove ECM clamp.
3. Release and disconnect 2 multiplugs.
4. Remove ECM.
Refit
1. Position ECM, connect and secure multiplugs.
2. Fit ECM to battery tray, fit clamp and tighten bolts
to 5 Nm.
3. Connect battery earth lead.
NOTE: A new ECM will need to be programmed
with code from anti-theft security unit using
TestBook before the engine can be started.
SENSOR - ENGINE COOLANT
TEMPERATURE (ECT)
´÷ 18.30.10
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
3. Disconnect multiplug from ECT sensor.
4. Position drain tray to collect spillage.
5. Remove ECT sensor from coolant outlet elbow.
Refit
1. Clean ECT sensor and mating face.
2. Apply Loctite 577 to threads of ECT sensor.
3. Fit ECT sensor to outlet elbow and tighten to 14
Nm.
4. Connect multiplug to ECT sensor.
5. Top-up cooling system. See MAINTENANCE.
6. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
7. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-6 REPAÌRS
SENSOR - CRANKSHAFT POSITION (CKP)
´÷ 18.30.12
Remove
1. Disconnect battery earth lead.
2. Release CKP sensor multiplug from bracket and
disconnect from engine harness.
3. Remove bolt and remove CKP sensor from
gearbox adaptor plate.
Refit
1. Clean CKP sensor and mating face of gearbox
adaptor plate.
2. Fit CKP sensor and tighten bolt to 9 Nm.
3. Connect CKP sensor multiplug to harness and
secure to bracket.
4. Connect battery earth lead.
SENSOR - THROTTLE POSITION (TP)
´÷ 18.30.17
Remove
1. Disconnect battery earth lead.
2. Release PAS fluid reservoir from bracket.
3. Remove 2 bolts securing TP sensor mounting
bracket to body.
4. Release throttle cable adjusting nut from
abutment bracket and disconnect inner cable
from TP sensor cam.
5. Disconnect harness multiplug and remove TP
sensor and bracket assembly.
6. Release TP sensor multiplug from clip.
7. Remove 2 nuts and bolts and remove TP sensor
from bracket.
Refit
1. Fit TP sensor to mounting bracket and tighten
nuts and bolts to 4 Nm.
2. Fit TP sensor multiplug to clip.
3. Position TP sensor assembly and connect
harness multiplug.
4. Fit throttle cable to TP sensor cam and
temporarily fit cable adjusting nut to abutment
bracket.
5. Fit TP sensor assembly to body and tighten bolts
to 10 Nm.
6. Fit PAS reservoir to bracket.
7. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - EDC, Adjustments.
8. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - EDC
REPAÌRS 18-2-7
SENSOR - MANIFOLD ABSOLUTE
PRESSURE (MAP)
´÷ 18.30.56
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from MAP sensor.
3. Disconnect pressure sensing pipe from MAP
sensor.
4. Remove bolt and remove MAP sensor.
Refit
1. Fit MAP sensor and tighten bolt to 9 Nm.
2. Connect pressure sensing pipe and connect
multiplug.
3. Connect battery earth lead.
INJECTOR - NEEDLE LIFT SENSOR
´÷ 18.30.72
NOTE: The injector needle lift sensor is an integral part
of No. 1 injector and cannot be replaced separately.
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
3. Loosen injector pipe union at injector.
4. Position absorbent cloth around fuel injection
pump connection to catch fuel spillage.
5. Loosen injector pipe union at FÌP.
CAUTION: To prevent damage to fueI system
pipes or components, use 2 spanners when
Ioosening or tightening unions.
6. Release clip securing injector pipes together.
7. Disconnect injector pipe unions from fuel
injection pump and injector, remove injector pipe.
CAUTION: PIug the connections.
8. Disconnect injector needle lift sensor multiplug
from harness.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-8 REPAÌRS
9. Remove spill return hose banjo bolt and 2 sealing
washers.
CAUTION: PIug the connections.
10. Remove bolt and collect clamp plate securing
injector to cylinder head.
11. Remove injector from cylinder head, remove and
discard sealing washer.
Refit
1. Thoroughly clean injector and injector seat in
cylinder head.
2. Fit new sealing washer to injector and fit injector
to cylinder head.
CAUTION: Domed surface of seaIing washer
must face towards injector.
3. Fit clamp plate to injector and tighten bolt to 23
Nm.
4. Clean spill return banjo, banjo bolt and new
sealing washers.
5. Fit spill return with new sealing washers and
tighten banjo bolt to 10 Nm.
6. Connect needle lift sensor multiplug to harness.
7. Clean injector pipe unions.
8. Fit injector pipe and tighten unions to 28 Nm.
9. Fit clip to pipe.
CAUTION: To prevent damage to fueI system
pipes or components, use 2 spanners when
Ioosening or tightening unions.
10. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
11. Connect battery earth lead.
SENSOR - MASS AIR FLOW (MAF) &
INTAKE AIR TEMPERATURE (IAT)
´÷ 19.22.38
Remove
1. Disconnect battery earth lead.
2. Release clip and disconnect multiplug from MAF
sensor.
3. Loosen clip securing air intake hose to MAF
sensor and disconnect hose.
4. Release 2 clips securing MAF sensor to air
cleaner.
5. Release MAF sensor from air cleaner.
6. Remove MAF sensor.
7. Remove and discard 'O' ring.
Refit
1. Fit new 'O' ring to MAF sensor.
2. Fit MAF sensor to air cleaner, secure with clips.
3. Connect intake hose to MAF sensor and tighten
clip.
4. Connect multiplug to MAF sensor.
5. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - EDC
REPAÌRS 18-2-9
PUMP - FUEL INJECTION (FIP)
´÷ 19.30.07
Remove
1. Disconnect battery earth lead.
2. Remove plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
3. Drain cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
4. Loosen clip and disconnect radiator top hose
from radiator.
5. Loosen clip and disconnect radiator top hose
from coolant outlet elbow.
6. Loosen clip and remove radiator top hose from oil
cooler housing.
7. Remove FÌP timing belt. See ENGINE - 'L'
Series, Repairs.
FIP automatic timing belt tensioner illustrated.
8. Fit 12-185 to FÌP drive flange. Remove 3 Torx
bolts, flywheel and drive gear from mounting.
9. Remove nut and disconnect harness feed lead
from No. 2 glow plug.
10. Release injector needle lift sensor multiplug from
FÌP mounting bracket and disconnect from
engine harness.
11. Disconnect multiplug from FÌP.
12. Release engine harness clips from support
brackets.
13. Remove banjo bolt securing fuel feed pipe to FÌP
and discard sealing washers.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-10 REPAÌRS
14. Disconnect fuel return spill pipe from No. 3
injector.
15. Remove cap nut, disconnect fuel return pipe
banjo from FÌP and discard sealing washers.
CAUTION: PIug the connections.
16. Position absorbent cloth around injector pipe
connections to absorb fuel spillage.
17. Loosen No.1 and No. 2 injector pipe unions at
injectors and FÌP.
CAUTION: To prevent damage to fueI
injection pipes or components use 2
spanners when Ioosening unions.
18. Disconnect injector pipe unions from injectors
and FÌP and remove injector pipe assembly.
CAUTION: PIug the connections.
19. Repeat above procedure to remove injector
pipes No. 3 and No. 4.
20. Remove bolt securing dipstick bracket to coolant
elbow, move as required for access.
21. Remove 4 bolts securing FÌP support bracket to
cylinder block.
22. Remove 2 bolts securing support bracket to FÌP
and move bracket aside.
ENGÌNE MANAGEMENT SYSTEM - EDC
REPAÌRS 18-2-11
23. Remove 2 Torx bolts and nut securing FÌP to
gearbox adaptor plate.
24. Remove FÌP and collect FÌP mounting bracket.
25. Remove 3 Allen and 1 Torx headed screw
securing adaptor bracket to FÌP, collect bracket.
26. Remove fuel feed banjo adaptor from FÌP and
discard sealing washer.
27. Remove fuel return banjo adaptor from FÌP and
discard sealing washer.
CAUTION: PIug the connections.
28. Fit fuel return banjo adaptor to FÌP using new
sealing washer and tighten adaptor to 23 Nm.
29. Fit fuel feed banjo adaptor to FÌP using new
sealing washer and tighten adaptor to 23 Nm.
30. Fit adaptor bracket to FÌP and tighten Allen and
Torx screws to 10 Nm.
Refit
1. Clean mating faces of FÌP and gearbox mounting
plate.
2. Position mounting bracket to engine.
3. Fit FÌP to gearbox mounting plate and tighten torx
bolts and nut to 25 Nm.
4. Fit FÌP support bracket to engine, fit bolts but do
not tighten.
5. Fit nuts and bolts securing support bracket to FÌP
and tighten to 25 Nm.
6. Tighten bolts, FÌP support bracket to engine, to
25 Nm.
7. Align dipstick bracket to dowel on coolant elbow
fit and tighten bolt to 25 Nm.
8. Remove plugs from injector pipes, FÌP and
injector union connections.
9. Clean unions of injector pipes, FÌP and injectors.
10. Position injector pipes No. 3 and No. 4 to FÌP and
injectors and tighten unions to 28 Nm.
11. Position injector pipes No. 1 and No. 2 to FÌP and
injectors and tighten unions to 28 Nm.
CAUTION: To prevent damage to fueI system
pipes or components use 2 spanners when
tightening unions.
12. Connect fuel return spill pipe to injector No. 3.
13. Using new sealing washers, fit fuel return pipe to
FÌP and tighten banjo bolt to 25 Nm.
14. Using new sealing washers, connect fuel return
banjo to FÌP, fit cap nut and tighten to 25 Nm.
15. Secure engine harness clip to FÌP abutment
bracket.
16. Connect multiplug to FÌP.
17. Secure injector needle lift sensor multiplug to
injection pump mounting bracket.
18. Connect engine harness feed lead to glow plug
No. 2 and tighten terminal nut to 2.5 Nm.
19. Clean FÌP drive flange, drive gear and flywheel.
20. Fit flywheel and drive gear to FÌP drive flange,
tighten Torx bolts to 20 Nm.
21. Remove 12-185 from FÌP.
22. Fit FÌP timing belt. See ENGINE - 'L' Series,
Repairs.
23. Fit radiator top hose to oil cooler and tighten clip.
24. Connect radiator top hose to coolant outlet elbow
and tighten clip.
25. Connect radiator top hose to radiator and tighten
clip.
26. Fit plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
27. Refill cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
28. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-12 REPAÌRS
TURBOCHARGER
´÷ 19.42.01
Remove
1. Disconnect battery earth lead.
2. Remove turbocharger inlet hose. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
3. Remove exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
4. Loosen clip and disconnect intercooler hose from
turbocharger outlet pipe.
5. Remove 2 bolts securing turbocharger outlet pipe
to cylinder head.
6. Loosen clip and remove outlet pipe with hose
from turbocharger.
CAUTION: PIug aII connections.
7. Disconnect boost sensing pipe from
turbocharger.
8. Remove banjo bolt securing oil feed pipe to
turbocharger, remove and discard sealing
washers.
9. Remove 2 bolts securing oil drain pipe to
turbocharger and discard gasket.
10. Remove turbocharger oil drain pipe from cylinder
block.
11. Remove 2 bolts securing turbocharger to support
bracket.
12. Remove and discard 3 nuts from turbocharger.
13. Remove turbocharger from vehicle and discard
gasket.
Refit
1. Clean turbocharger and manifold mating faces.
2. Fit turbocharger and gasket to exhaust manifold,
tighten new nuts to 25 Nm.
3. Fit bolts securing support bracket to turbocharger
and tighten to 25 Nm.
4. Clean turbocharger oil drain pipe and cylinder
block mounting.
5. Fit turbocharger oil drain pipe union nut to
cylinder block, fit new gasket, align flange with
turbocharger and tighten bolts to 10 Nm.
6. Finally tighten oil drain union nut to 20 Nm.
7. Clean turbocharger oil feed banjo and mounting.
8. Fit new sealing washers to banjo bolt, align oil
pipe with turbocharger and tighten union to 20
Nm.
9. Connect boost sensing pipe to turbocharger.
10. Fit turbocharger outlet hose and tighten clip.
11. Fit bolts securing turbocharger outlet pipe to
cylinder head and tighten: M6 to 10 Nm and M8
to 25 Nm.
12. Fit exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
13. Fit turbocharger inlet hose. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
14. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - EDC
REPAÌRS 18-2-13
PLENUM CHAMBER
´÷ 19.42.02
Remove
1. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
2. Remove 2 bolts securing EGR pipe to plenum
chamber.
3. Remove bolt securing plenum chamber to
camshaft cover bracket.
4. Remove 2 bolts securing plenum chamber to inlet
manifold.
5. Loosen clip and disconnect intercooler outlet
hose from plenum chamber.
6. Release plenum chamber and discard gasket.
Refit
1. Clean mating faces of inlet manifold and plenum
chamber.
2. Using a new gasket, position plenum chamber to
inlet manifold, fit bolts and tighten to 25 Nm.
3. Position EGR pipe to plenum chamber, fit bolts
and tighten to 9 Nm.
4. Fit bolt securing plenum chamber to camshaft
cover bracket and tighten to 9 Nm.
5. Connect intercooler outlet hose to plenum
chamber and secure clip.
6. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
INTERCOOLER
´÷ 19.42.15
Remove
1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
3. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
4. Loosen 2 clips securing intercooler top hose to
intercooler and turbocharger pipe. Remove hose.
5. Loosen clip securing bottom hose to intercooler,
release hose and move aside.
6. Remove 2 Torx bolts securing intercooler to
radiator.
7. Remove bolt and bracket securing intercooler top
mounting to bonnet locking platform.
8. Release and remove intercooler from lower
mounting.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-14 REPAÌRS
Refit
1. Clean intercooler and radiator mountings.
2. Check lower intercooler mounting rubber, if
necessary replace.
3. Fit intercooler and align to radiator.
4. Fit Torx bolts, do not tighten at this stage.
5. Clean bracket and check intercooler upper
mounting rubber, if necessary replace.
6. Fit intercooler upper mounting bracket to bonnet
locking platform and tighten to 9 Nm.
7. Tighten Torx bolts to 25 Nm.
8. Fit bottom hose and tighten clip.
9. Fit upper intercooler hose and tighten clips.
10. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
11. Fit acoustic cover. See ENGINE - 'L' Series,
Repairs.
12. Connect battery earth lead.
AIR INTAKE PIPE
´÷ 19.42.28
Remove
1. Disconnect battery earth lead.
2. Loosen clip and disconnect pipe from MAF
sensor.
3. Loosen clip and disconnect crankcase pressure
limiter valve from pipe.
4. Loosen clip and disconnect pipe from
turbocharger.
5. Remove air intake pipe.
Refit
1. Connect air intake pipe to turbocharger and
tighten clip.
2. Connect pipe to MAF sensor and tighten clip.
3. Connect crankcase pressure limiter valve pipe
and tighten clip.
4. Connect battery earth lead.
ENGÌNE MANAGEMENT SYSTEM - EDC
REPAÌRS 18-2-15
INJECTORS - FUEL - SET
´÷ 19.60.12
Remove
1. Disconnect battery earth lead.
2. Remove plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
3. Position cloth around fuel injectors to absorb fuel
spillage.
NOTE: No. 1 injector incorporates needle lift
sensor.
4. No. 1 injector, remove needle lift sensor
multiplug.
5. Remove spill return hose banjo bolts and discard
8 sealing washers.
CAUTION: To prevent damage to fueI system
pipes or components use 2 spanners when
Ioosening or tightening unions.
6. Loosen injector pipe unions at injectors and FÌP.
7. Disconnect injector pipes from injectors and
move aside.
CAUTION: PIug the connections.
8. Remove bolts and collect clamp plates securing
injectors to cylinder head.
9. Remove injectors from cylinder head and discard
sealing washers.
ENGÌNE MANAGEMENT SYSTEM - EDC
18-2-16 REPAÌRS
Refit
1. Throughly clean injectors and injector seats in
cylinder head.
2. Fit new sealing washers to injectors and fit to
cylinder head.
CAUTION: Domed surface of seaIing washer
must face towards injectors.
3. Fit clamp plates to injectors and tighten bolts to
23 Nm.
4. Using new sealing washers fit spill return hose
banjo bolts to injectors and tighten to 10 Nm.
5. Clean injector pipes and unions.
6. Fit injector pipes and tighten to 28 Nm.
CAUTION: To prevent damage to fueI system
pipes or components, use 2 spanners when
Ioosening and tightening unions.
7. Connect No. 1 injector multiplug
8. Fit plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
9. Connect battery earth lead.
GLOW PLUGS
´÷ 19.60.31
Remove
1. Disconnect battery earth lead.
2. Remove FÌP. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
NOTE: Glow plugs, numbers 1, 2 and 3, can be
removed without the removal of the FIP.
3. Remove 4 terminal nuts securing feed leads to
glow plugs.
4. Disconnect and remove glow plug leads.
5. Remove 4 glow plugs.
Refit
1. Thoroughly clean glow plugs and glow plug
seating area in cylinder head.
2. Apply a suitable anti-seize compound to threads
of glow plugs.
3. Fit glow plugs and tighten to 20 Nm.
4. Fit leads to glow plugs with feed lead connected
to No 2.
5. Fit and tighten terminal nuts to 2.5 Nm. plug.
6. Fit fuel injection pump. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
7. Connect battery earth lead.
FUEL DELÌVERY SYSTEM
REPAÌRS 19-1
FUEL DELÌ VERY SYSTEM REPAÌ RS
FUEL TANK DRAINING - 'K' SERIES
´÷ 19.55.02
WARNING: Before removing the fuel tank from the
vehicle it must be drained.
WARNING: Petrol/gasoline vapour is highly
flammable and in confined spaces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO
2
, GAS or
POWDER close at hand when handling or draining
fuel. See INTRODUCTION, Information.
Drain
1. Remove fuel tank filler cap and allow fuel tank to
vent in an open space before commencing work.
2. Disconnect battery earth lead.
3. Using a bowser, drain fuel from the tank into a
sealed container. Follow the manufacturers
instructions for the connection and safe use of
the bowser.
4. Continue draining until air bubbles appear and
fuel ceases to flow.
5. Disconnect bowser from fuel tank.
FUEL TANK DRAINING - 'L' SERIES
´÷ 19.55.02
WARNING: Before removing the fuel tank from the
vehicle it must be drained. Use gloves or suitable
protective barrier cream to protect the hands
against contact with diesel fuel.
Drain
1. Remove fuel tank filler cap and allow fuel tank to
vent in an open space before commencing work.
2. Disconnect battery earth lead.
3. Using a bowser, drain fuel from the tank into a
sealed container. Follow the manufacturers
instructions for the connection and safe use of
the bowser.
4. Continue draining until air bubbles appear and
fuel ceases to flow.
5. Disconnect bowser from fuel tank.
FUEL DELÌVERY SYSTEM
19-2 REPAÌRS
INERTIA FUEL SHUT-OFF (IFS) SWITCH -
'K' SERIES
´÷ 19.22.09
Remove
1. Disconnect multiplug from ÌFS switch.
2. Remove 2 screws securing ÌFS switch to
mounting bracket.
3. Remove ÌFS switch.
Refit
1. Align ÌFS switch to mounting bracket.
2. Fit screws securing ÌFS switch to mounting
bracket and tighten to 2 Nm.
3. Connect multiplug to ÌFS switch.
4. Press top of ÌFS switch to reset.
FUEL FILTER - 'K' SERIES
´÷ 19.25.02
Remove
1. Disconnect battery earth lead.
2. Release evaporative emission cannister from
mounting bracket and move aside.
3. Position absorbent cloth around fuel union.
4. Loosen union to relieve fuel pressure.
CAUTION: To prevent damage to fueI system
pipes and components, use two spanners
when Ioosening or tightening unions.
5. Disconnect fuel outlet pipe from fuel filter.
6. Position absorbent cloth around fuel filter union.
7. Loosen union and allow fuel to seep into cloth.
8. Disconnect fuel inlet pipe from fuel filter.
9. Loosen bolt securing fuel filter to bracket.
10. Remove and discard filter.
FUEL DELÌVERY SYSTEM
REPAÌRS 19-3
Refit
1. Position new filter in bracket with arrow pointing
upwards and tighten bolt.
2. Clean fuel pipe unions.
3. Connect fuel inlet pipe to fuel filter and tighten
union to 28 Nm.
4. Connect fuel outlet pipe to fuel filter and tighten
union to 28 Nm.
5. Fit evaporative emission cannister to mounting
bracket.
6. Connect battery earth lead.
FUEL FILTER - 'L' SERIES
´÷ 19.25.02
Remove
1. Disconnect battery earth lead.
2. Position absorbent cloth, release clip and
disconnect fuel inlet hose from filter.
3. Release clip and disconnect fuel outlet hose from
filter.
CAUTION: PIug the connections.
4. Remove fuel filter bracket from body mounting.
5. Loosen fuel filter bracket clamp bolt.
6. Remove fuel filter from fuel filter bracket.
Refit
1. Fit fuel filter to fuel filter bracket.
2. Tighten fuel filter bracket clamp bolt.
3. Fit fuel filter bracket to body mounting.
4. Remove plugs from connections.
5. Connect fuel outlet hose to filter and secure clip.
6. Connect fuel inlet hose to filter and secure clip.
7. Loosen bleed screw.
8. Repeatedly squeeze fuel hand primer until fuel,
issuing from bleed screw is free from air bubbles;
tighten bleed screw.
9. Continue to squeeze fuel hand primer until
resistance is felt.
10. Remove absorbent cloth.
11. Connect battery earth lead.
FUEL DELÌVERY SYSTEM
19-4 REPAÌRS
ELECTRIC FUEL PUMP - 'K' SERIES
´÷ 19.45.08
NOTE: The fuel pump and fuel gauge tank unit are
integral parts of the fuel pump housing and cannot be
renewed separately.
Remove
1. Remove fuel tank assembly. See FUEL
DELIVERY SYSTEM, Repairs.
2. Release clip and disconnect fuel feed hose from
fuel pump.
3. Release clip and disconnect fuel return hose from
fuel pump.
4. Remove 6 nuts securing fuel pump housing to
fuel tank.
5. Release fuel pump housing from fuel tank.
6. Remove fuel pump housing from fuel tank.
7. Remove seal from fuel pump housing.
Refit
1. Clean mating face of fuel pump housing and fuel
tank.
2. Clean seal and fit to fuel pump housing.
3. Fit fuel pump housing to fuel tank.
4. Fit nuts securing fuel pump housing to fuel tank
and tighten to 9 Nm.
5. Connect fuel return hose to fuel pump and secure
with clip.
6. Connect fuel feed hose to fuel pump and secure
with clip.
7. Refit fuel tank assembly. See FUEL DELIVERY
SYSTEM, Repairs.
FUEL DELÌVERY SYSTEM
REPAÌRS 19-5
FUEL TANK - 'K' SERIES
´÷ 19.55.01
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Support on safety stands.
3. Drain fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
4. Remove bolt securing handbrake cable to 'H'
frame LH mounting.
5. Release handbrake cable from 'H' frame
mounting.
6. Remove screw securing filler neck to body.
7. Release clip and disconnect breather hose from
filler neck.
8. Loosen clip and disconnect filler hose from filler
neck.
9. Release clip and disconnect fuel feed hose from
fuel feed pipe.
10. Release clip and disconnect fuel return hose from
fuel return pipe.
11. Clean area around quick fit connector and
disconnect breather hose from pipe.
12. Fit wooden block to jack and position jack to
support fuel tank.
13. Loosen 2 fuel tank strap locknuts and remove 2
tank strap nuts.
14. Release fuel tank straps from vehicle body.
15. Using assistance, release fuel tank from body
and lower.
FUEL DELÌVERY SYSTEM
19-6 REPAÌRS
16. Disconnect fuel pump multiplug from harness.
17. Remove fuel tank from beneath vehicle.
Do not carry out further dismantling if component
is removed for access only
18. Release clip securing breather hose to fuel tank
and remove breather hose.
19. Loosen clip securing filler neck hose to fuel tank
and remove filler neck hose.
20. Release clip and disconnect breather hose from
fuel tank.
21. Release breather hose from 2 clips on tank and
remove hose.
22. Remove 6 nuts securing fuel pump housing to
fuel tank.
23. Release fuel pump housing from fuel tank.
24. Remove fuel pump housing from fuel tank.
25. Remove seal from fuel pump housing.
26. Remove rubber pads from old fuel tank, apply
adhesive and fit to new tank.
27. Remove breather hose clips from old fuel tank
and fit to new.
28. Clean mating face of fuel pump housing and fuel
tank.
29. Clean seal and fit to fuel pump housing.
30. Fit fuel pump housing to fuel tank.
31. Fit nuts securing fuel pump housing to fuel tank
and tighten to 9 Nm
32. Connect breather hose to fuel tank and secure
with clip.
33. Secure breather hose to clips on tank.
FUEL DELÌVERY SYSTEM
REPAÌRS 19-7
34. Fit filler hose to fuel tank and tighten clip.
35. Fit breather hose to fuel tank and secure with clip.
Refit
1. Using assistance, position fuel tank beneath
vehicle and raise into position using a trolley jack.
2. Connect fuel pump multiplug to harness.
3. Align fuel tank to body and hook into position.
4. Align fuel tank straps to fuel tank and hook into
body.
5. Fit and tighten nuts securing fuel tank straps to
body. Tighten locknuts securing fuel tank straps.
6. Ensure fuel tank is properly located and remove
trolley jack.
7. Connect fuel feed hose to fuel pipe and secure
with clip.
8. Connect fuel breather hose to pipe, ensure
connection to pipe is secure.
9. Connect fuel return hose to fuel return pipe and
secure with clip.
10. Connect filler hose to filler neck and tighten clip.
11. Connect breather hose to filler neck and secure
with clip.
12. Fit hand brake cable to 'H' frame LH mounting, fit
bolt and tighten to 22 Nm.
13. Align filler neck to body and secure with screw.
14. Remove stand(s) and lower vehicle.
15. Connect battery earth lead.
FUEL TANK - 'L' SERIES
´÷ 19.55.01
Remove
1. Disconnect battery earth lead.
2. Drain fuel tank. See FUEL DELIVERY SYSTEM,
Adjustments.
3. Raise rear of vehicle.
WARNING: Support on safety stands.
4. Remove LH rear road wheel.
5. Remove 5 screws securing wheel arch liner to
wheel arch.
6. Release and remove wheel arch liner.
7. Remove nut securing filler neck to body.
8. Release filler neck from body panel.
FUEL DELÌVERY SYSTEM
19-8 REPAÌRS
9. Release clip securing breather hose to filler neck.
10. Loosen clip securing filler hose to filler neck.
11. Disconnect filler neck from hoses and remove
filler neck.
12. Remove bolt securing handbrake cable to 'H'
frame LH mounting.
13. Release handbrake cable from 'H' frame
mounting.
14. Clean area around 'quick fit' connectors and
disconnect fuel feed hose, fuel return hose and
vent hose.
CAUTION: PIug the connections.
15. Fit wooden block to jack and position jack to
support fuel tank.
16. Loosen 2 fuel tank strap locknuts and remove 2
tank strap nuts.
17. Release fuel tank straps from body.
18. Using assistance, release fuel tank from body
and lower.
FUEL DELÌVERY SYSTEM
REPAÌRS 19-9
19. Disconnect fuel tank sender multiplug from
harness.
20. Remove fuel tank from beneath vehicle.
Do not carry out further dismantling if component
is removed for access only.
21. Release clip securing breather hose to fuel tank
and remove hose.
22. Loosen clip securing filler neck hose to fuel tank
and remove hose.
23. Release clip and disconnect vent hose from fuel
tank. Release hose from clip on tank and remove
hose.
24. Remove 6 nuts securing fuel tank sender housing
to fuel tank.
25. Release and remove fuel tank sender housing
from fuel tank.
26. Remove seal from fuel tank sender housing.
27. Remove rubber pads from old fuel tank, apply
adhesive and fit to new tank.
28. Remove vent hose clip from old fuel tank and fit
to new.
29. Clean mating face of fuel tank sender housing
and fuel tank.
30. Clean seal and fit to fuel tank sender housing.
31. Fit fuel tank sender unit to tank, fit nuts and
tighten to 9 Nm.
32. Connect vent hose to fuel tank and secure with
clip.
33. Secure vent hose to clip on tank.
34. Fit filler hose to fuel tank and tighten clip.
35. Fit breather hose to fuel tank and secure with clip.
FUEL DELÌVERY SYSTEM
19-10 REPAÌRS
Refit
1. Using assistance, position fuel tank beneath
vehicle and raise into position using a trolley jack.
2. Connect fuel tank sender multiplug to harness.
3. Align fuel tank to body and hook into position.
4. Align fuel tank straps to fuel tank and hook into
body.
5. Fit and tighten nuts securing fuel tank straps to
body. Tighten locknuts securing fuel tank straps.
6. Ensure fuel tank is properly located and remove
trolley jack.
7. Connect fuel feed hose, fuel return hose and vent
hose 'quick fit' connectors.
CAUTION: Ensure connectors are secure.
8. Align hand brake cable to 'H' frame LH mounting,
fit bolt and tighten to 22 Nm.
9. Ìnsert filler neck into filler hose and breather hose
and locate to body.
10. Fit and tighten nut securing filler neck to body.
11. Secure breather hose with clip.
12. Tighten clip to secure filler hose to filler neck.
13. Ìnsert liner into wheel arch, align and secure to
wheel arch with screws.
14. Align filler neck and wheel arch liner and secure
to body with screw.
15. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
16. Remove stand(s) and lower vehicle.
17. Connect battery earth lead.
FUEL TANK BREATHER VALVE - 'L'
SERIES
´÷ 19.55.25
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Release breather hose and valve from clips on
tank.
3. Release clip and remove breather valve from
hose on tank.
4. Release clip and disconnect hose from breather
valve.
Refit
1. Connect hose to breather valve and secure with
clip.
2. Connect breather valve to hose on fuel tank and
secure with clip.
3. Secure breather valve and hose to clips on tank.
4. Remove stand(s) and lower vehicle.
COOLÌNG SYSTEM - 'K' SERÌES
ADJUSTMENTS 26-1-1
COOLÌNGSYSTEM - ' K' SERÌES ADJUSTMENTS
DRAIN AND REFILL
´÷ 26.10.01
Drain
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion,
and security of connections.
3. Remove air cleaner assembly. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
4. Position heater temperature control to maximum
heat position.
5. Remove expansion tank filler cap.
6. Position drain tin to collect coolant.
7. Loosen clip and disconnect bottom hose from
radiator.
8. Allow cooling system to drain.
RefiII
1. Flush system with water under low pressure.
CAUTION: High pressure water couId damage
the radiator.
2. Connect bottom hose to radiator and tighten clip.
3. Prepare coolant to required concentration. See
INFORMATION, Capacities, FIuids and
Lubricants.
4. Remove bleed screw from coolant rail.
5. Fill system slowly until a steady flow of coolant is
emitted from the bleed hole in coolant rail.
6. Fit bleed screw to coolant rail and tighten to 9
Nm.
7. Continue filling system until coolant level reaches
'MAX' mark on expansion tank.
8. Fit expansion tank filler cap.
9. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
10. Start and run engine until radiator cooling fan
operates.
11. Switch off engine and allow to cool.
12. Check for leaks and top-up coolant to 'MAX' mark
on expansion tank.
COOLÌNG SYSTEM - 'K' SERÌES
26-1-2 ADJUSTMENTS
COOLANT - VACUUM REFILL SYSTEM -
'K' SERIES 1800cc
´÷ 26.10.04
Drain
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion
and security of connections.
3. Position heater temperature control to maximum
heat position.
4. Remove expansion tank filler cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from the
coolant expansion tank while the system is
hot.
5. Position vehicle on 4 post ramp.
6. Remove underbelly panel. See EXTERIOR
FITTINGS, Repairs.
7. Position container to collect coolant.
8. Loosen clip and disconnect bottom hose from
radiator.
9. Allow cooling system to drain.
Check
1. Flush system with water under low pressure.
Do not use water under high pressure as it could
damage the radiator.
2. Connect bottom hose to radiator and secure with
clip.
3. Prepare sufficient amount of coolant to required
concentration and transfer to coolant container.
See CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.
4. Ensure heater temperature control is set to
maximum.
RefiII
1. Position vacuum adaptor to expansion tank and
tighten hand wheels. Ensure seal is positioned
midway in expansion tank neck.
2. Assemble both parts of vacuum adaptor, ensure
both valves on vacuum adaptor are closed.
COOLÌNG SYSTEM - 'K' SERÌES
ADJUSTMENTS 26-1-3
3. Position fresh coolant container so that the lower
level is above the expansion tank neck.
4. Connect fresh coolant hose to container,
ensuring no air can enter hose.
5. Position evacuated air hose in a container.
6. Connect a regulated compressed air supply to
vacuum adaptor.
7. Open air supply valve (arrowed).
8. Apply air pressure progressively from 0 to 10 bar
max. Maintain air pressure until gauge reads
between -0.85 and - 0.95 bar and is stable.
9. Briefly open coolant supply valve (arrowed), to
prime coolant supply hose. Close valve. Coolant
wil exhaust from evacuated air hose.
10. Check that vacuum is holding and gauge is
steady.
11. Close air supply valve and disconnect air supply.
COOLÌNG SYSTEM - 'K' SERÌES
26-1-4 ADJUSTMENTS
12. Open vacuum valve and allow coolant to be
drawn into system. Wait until 0 bar is indicated on
gauge.
13. When expansion tank is full and coolant
movement has ceased close vacuum valve.
14. Disconnect vacuum hose from container and
remove container.
15. Remove vacuum adaptor from expansion tank.
16. Syphon excess coolant from expansion tank to
correct level.
17. Fit expansion tank filler cap.
18. Fit underbelly panel. See EXTERIOR FITTINGS,
Repairs.
19. Start and run engine until radiator cooling fan
operates.
20. Monitor temperature gauge during warm up to
prevent over heating.
21. Switch off engine and allow to cool.
22. Check for leaks and top-up coolant to 'MAX' mark
on expansion tank
COOLANT - VACUUM REFILL SYSTEM -
'K' SERIES 1100, 1400 AND 1600cc
´÷ 26.10.04
Drain
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion
and security of connections.
3. Position heater temperature control to maximum
heat position.
4. Remove expansion tank filler cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from the
coolant expansion tank while the system is
hot.
5. Position vehicle on 4 post ramp.
6. Position container to collect coolant.
7. Loosen clip and disconnect bottom hose from
radiator.
8. Allow cooling system to drain.
COOLÌNG SYSTEM - 'K' SERÌES
ADJUSTMENTS 26-1-5
Check
1. Flush system with water under low pressure.
Do not use water under high pressure as it could
damage the radiator.
2. Connect bottom hose to radiator and secure with
clip.
3. Prepare sufficient amount of coolant to required
concentration and transfer to coolant container.
See CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.
4. Ensure heater temperature control is set to
maximum.
RefiII
1. Position vacuum adaptor to expansion tank and
tighten hand wheels. Ensure seal is positioned
midway in expansion tank neck.
2. Assemble both parts of vacuum adaptor, ensure
both valves on vacuum adaptor are closed.
3. Position fresh coolant container so that the lower
level is above the expansion tank neck.
4. Connect fresh coolant hose to container,
ensuring no air can enter hose.
5. Position evacuated air hose in a container.
6. Connect a regulated compressed air supply to
vacuum adaptor.
COOLÌNG SYSTEM - 'K' SERÌES
26-1-6 ADJUSTMENTS
7. Open air supply valve (arrowed).
8. Apply air pressure progressively from 0 to 10 bar
max. Maintain air pressure until gauge reads
between -0.85 and - 0.95 bar and is stable.
9. Briefly open coolant supply valve (arrowed), to
prime coolant supply hose. Close valve. Coolant
wil exhaust from evacuated air hose.
10. Check that vacuum is holding and gauge is
steady.
11. Close air supply valve and disconnect air supply.
12. Open vacuum valve and allow coolant to be
drawn into system. Wait until 0 bar is indicated on
gauge.
13. When expansion tank is full and coolant
movement has ceased close vacuum valve.
14. Disconnect vacuum hose from container and
remove container.
15. Remove vacuum adaptor from expansion tank.
16. Syphon excess coolant from expansion tank to
correct level.
17. Fit expansion tank filler cap.
18. Start and run engine until radiator cooling fan
operates.
19. Monitor temperature gauge during warm up to
prevent over heating.
20. Switch off engine and allow to cool.
21. Check for leaks and top-up coolant to 'MAX' mark
on expansion tank
COOLÌNG SYSTEM - 'K' SERÌES
ADJUSTMENTS 26-1-7
SYSTEM - PRESSURE TEST
´÷ 26.10.07
Check
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion
and security of connections.
3. Position heater temperature control to maximum
heat position.
4. Remove expansion tank filler cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from the
coolant expansion tank while the system is
hot.
5. Select correct adaptor and fit to expansion tank.
6. Connect pressure hose to adaptor.
7. Position pressure pump, connect pressure hose
to pump.
8. Slowly pump up system to required pressure and
check for leaks.
9. Release pressure by depressing pressure
release valve on pump.
10. Remove pump from pressure hose.
11. Remove hose from adaptor.
12. Remove adaptor from expansion tank and refit
expansion tank filler cap.
COOLÌNG SYSTEM - 'K' SERÌES
26-1-8 ADJUSTMENTS
CAP - EXPANSION TANK - PRESSURE
TEST
´÷ 26.10.08
Check
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion
and security of connections.
3. Remove expansion tank filler cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from the
coolant expansion tank while the system is
hot.
4. Select correct pressure cap adaptor, fit cap to
adaptor.
5. Connect pressure hose to adaptor.
6. Position pressure pump, connect pressure hose
to pump.
7. Slowly pressurize cap to required pressure and
check for leaks.
8. Release pressure by depressing pressure
release valve on pump.
9. Remove adaptor from pressure hose, remove
pressure hose from pump.
10. Remove cap from adaptor.
11. Fit pressure cap to expansion tank.
COOLÌNG SYSTEM - 'K' SERÌES
REPAÌRS 26-1-9
REPAÌ RS
COOLANT EXPANSION TANK
´÷ 26.15.01
Remove
1. Position container to collect coolant loss from
expansion tank.
2. Loosen clip and disconnect hose from expansion
tank.
3. Release clip and disconnect coolant bleed hose
from expansion tank.
4. Remove 2 bolts securing expansion tank to body.
5. Release expansion tank from body and allow
coolant to drain.
6. Remove coolant expansion tank.
Refit
1. Position coolant expansion tank.
2. Fit 2 bolts securing expansion tank to body and
tighten to 5 Nm.
3. Connect coolant bleed hose to expansion tank
and tighten clip.
4. Connect hose to expansion tank and tighten clip.
5. Top-up cooling system. See MAINTENANCE.
6. Remove container positioned to catch fluid loss.
RADIATOR COOLING FAN
´÷ 26.25.22
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from radiator cooling fan.
3. Release radiator top hose from clip on cooling fan
housing.
4. Remove 2 nuts securing bottom of cooling fan
housing to radiator.
5. Remove 2 nuts securing top of cooling fan
housing to radiator.
6. Release cooling fan housing from studs on
radiator.
7. Manoeuvre cooling fan housing around radiator
top hose and remove from vehicle.
COOLÌNG SYSTEM - 'K' SERÌES
26-1-10 REPAÌRS
Refit
1. Manoeuvre cooling fan housing around radiator
top hose and into position on radiator studs.
2. Fit nuts securing cooling fan housing to radiator
and tighten to 9 Nm.
3. Secure radiator top hose to clip on cooling fan
housing.
4. Connect multiplug to radiator cooling fan.
5. Connect battery earth lead.
COOLING FAN - RADIATOR - A/C
´÷ 26.25.22/20
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove front beam. See FRONT
SUSPENSION, Repairs.
4. Release radiator top hose from clip on cooling fan
housing.
5. Disconnect multiplug from cooling fan.
COOLÌNG SYSTEM - 'K' SERÌES
REPAÌRS 26-1-11
6. Remove 2 nuts securing bottom of cooling fan
housing to radiator.
7. Remove 2 nuts securing top of cooling fan
housing to radiator.
8. Release cooling fan housing from studs on
radiator.
9. Lower cooling fan housing from vehicle and
remove fan assembly.
Refit
1. Position cooling fan housing on radiator studs.
2. Fit nuts securing cooling fan housing to radiator
and tighten to 9 Nm.
3. Secure radiator top hose to clip on cooling fan
housing.
4. Connect multiplug to radiator cooling fan.
5. Fit front beam. See FRONT SUSPENSION,
Repairs.
6. Remove stand(s) and lower vehicle.
7. Connect battery earth lead.
RADIATOR
´÷ 26.40.01
Remove
1. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
2. Remove radiator cooling fan. See COOLING
SYSTEM - 'K' Series, Repairs.
3. Loosen clip and disconnect top hose from
radiator.
4. Remove 2 bolts securing radiator top mounting
brackets to bonnet locking platform.
5. Remove 2 radiator top mounting brackets.
6. Remove radiator by lowering to floor.
COOLÌNG SYSTEM - 'K' SERÌES
26-1-12 REPAÌRS
Do not carry out further dismantling if component
is removed for access only.
7. Remove 2 lower mounting rubbers from radiator.
8. Fit lower mounting rubbers to new radiator.
Refit
1. Position radiator and locate on lower mountings.
2. Fit top mounting brackets.
3. Fit bolts securing radiator top mounting bracket to
bonnet locking platform and tighten to 9 Nm.
4. Connect top hose to radiator and tighten clip.
5. Fit radiator cooling fan. See COOLING SYSTEM
- 'K' Series, Repairs.
6. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
THERMOSTAT
´÷ 26.45.09
Remove
1. Disconnect battery earth lead.
2. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
3. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
4. Loosen clip and disconnect heater hose from
thermostat housing.
5. Remove 2 bolts securing coolant rail to cylinder
block.
6. Release coolant rail from thermostat housing.
7. Remove bolt securing thermostat housing to
cylinder block.
8. Release thermostat housing from coolant pump
and remove thermostat housing.
9. Remove and discard 2 'O' rings from thermostat
housing.
10. Remove 3 bolts securing cover to thermostat
housing.
11. Remove thermostat housing cover.
12. Remove thermostat from housing.
COOLÌNG SYSTEM - 'K' SERÌES
REPAÌRS 26-1-13
13. 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.
8. Fit 'O' rings to thermostat housing.
9. Position thermostat housing and engage fully to
coolant pump.
10. Align dipstick tube bracket to thermostat housing.
11. Fit bolt securing thermostat housing to cylinder
block and tighten to 10 Nm.
12. Connect coolant rail to thermostat housing.
13. Align coolant rail to cylinder block, fit bolts and
tighten to 25 Nm.
14. Connect heater hose to thermostat housing and
tighten clip.
15. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
16. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
17. Connect battery earth lead. pump housing.
coolant rail.
COOLANT PUMP
´÷ 26.50.01
Remove
1. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
2. Remove camshaft timing belt. 'K16': See
ENGINE - 'K16', Repairs. 'K16 WITH VVC': See
ENGINE - 'K16 with VVC', Repairs.
3. Remove bolt securing rear cover to coolant
pump.
4. Remove 3 bolts and 2 pillar bolts securing
coolant pump to cylinder block.
5. Remove coolant pump from dowels and rear
cover.
6. Remove and discard 'O' ring from coolant pump.
Refit
1. Clean pump and mating face, dowel and dowel
hole.
2. Fit new 'O' ring to coolant pump, retain 'O' ring
with RTV sealant.
3. Fit coolant pump to cylinder block, fit and tighten
bolts to 10 Nm.
4. Fit and tighten pillar bolts to 10 Nm.
5. Fit and tighten bolt, rear cover to coolant pump,
to 10 Nm.
6. Fit camshaft timing belt. 'K16': See ENGINE -
'K16', Repairs. 'K16 WITH VVC': See ENGINE -
'K16 with VVC', Repairs.
7. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments. cylinder block.
COOLÌNG SYSTEM - 'K' SERÌES
26-1-14 REPAÌRS
COOLÌNG SYSTEM - 'L' SERÌES
ADJUSTMENTS 26-2-1
COOLÌNGSYSTEM - ' L' SERÌES ADJUSTMENTS
DRAIN AND REFILL
´÷ 26.10.01
Drain
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion,
and security of connections.
3. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
4. Position heater temperature control to maximum
heat position.
5. Remove expansion tank filler cap.
6. Position drain tin to collect coolant.
7. Loosen clip and disconnect bottom hose from
radiator.
8. Allow cooling system to drain.
RefiII
1. Flush system with water under low pressure.
CAUTION: High pressure water couId damage
the radiator.
2. Connect bottom hose to radiator and tighten clip.
3. Prepare coolant to required concentration. See
INFORMATION, Capacities, FIuids and
Lubricants.
4. Fill system until coolant level reaches 'MAX' mark
on expansion tank.
5. Fit expansion tank filler cap.
6. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
7. Start and run engine until radiator cooling fan
operates.
8. Switch off engine and allow to cool.
9. Check for leaks and top-up coolant to 'MAX' mark
on expansion tank.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-2 ADJUSTMENTS
COOLANT - VACUUM REFILL SYSTEM
´÷ 26.10.04
Drain
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion
and security of connections.
3. Position heater temperature control to maximum
heat position.
4. Remove expansion tank filler cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from the
coolant expansion tank while the system is
hot.
5. Raise vehicle on 4 post ramp.
6. Remove underbelly panel. See EXTERIOR
FITTINGS, Repairs.
7. Position container to collect coolant.
8. Loosen clip and disconnect bottom hose from
radiator.
9. Allow cooling system to drain.
Check
1. Flush system with water under low pressure. Do
not use water under high pressure as it couId
damage the radiator.
2. Connect bottom hose to radiator and secure with
clip.
3. Prepare sufficient amount of coolant to required
concentration and transfer to coolant container.
See CAPACITIES, FLUIDS AND
LUBRICANTS, Anti-Freeze Concentration.
4. Ensure heater temperature control is set to
maximum.
RefiII
1. Position vacuum adaptor to expansion tank and
tighten hand wheels. Ensure seal is positioned
midway in expansion tank neck.
2. Assemble both parts of vacuum adaptor, ensure
both valves on vacuum adaptor are closed.
COOLÌNG SYSTEM - 'L' SERÌES
ADJUSTMENTS 26-2-3
3. Position fresh coolant container so that the lower
level is above the expansion tank neck.
4. Connect fresh coolant hose to container,
ensuring no air can enter hose.
5. Position evacuated air hose in a container.
6. Connect a regulated compressed air supply to
vacuum adaptor.
7. Open air supply valve (arrowed).
8. Apply air pressure progressively from 0 to 10 bar
max. Maintain air pressure until gauge reads
between -0.85 and - 0.95 bar and is stable.
9. Briefly open coolant supply valve (arrowed), to
prime coolant supply hose. Close valve. Coolant
wil exhaust from evacuated air hose.
10. Check that vacuum is holding and gauge is
steady.
11. Close air supply valve and disconnect air supply.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-4 ADJUSTMENTS
12. Open vacuum valve and allow coolant to be
drawn into system. Wait until 0 bar is indicated on
gauge.
13. When expansion tank is full and coolant
movement has ceased close vacuum valve.
14. Disconnect vacuum hose from container and
remove container.
15. Remove vacuum adaptor from expansion tank.
16. Syphon excess coolant from expansion tank to
correct level.
17. Fit expansion tank filler cap.
18. Fit underbelly panel. See EXTERIOR FITTINGS,
Repairs.
19. Start and run engine until radiator cooling fan
operates.
20. Monitor temperature gauge during warm up to
prevent over heating.
21. Switch off engine and allow to cool.
22. Check for leaks and top-up coolant to 'MAX' mark
on expansion tank
SYSTEM - PRESSURE TEST
´÷ 26.10.07
Check
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion
and security of connections.
3. Position heater temperature control to maximum
heat position.
4. Remove expansion tank filler cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from the
coolant expansion tank while the system is
hot.
5. Select correct adaptor and fit to expansion tank.
COOLÌNG SYSTEM - 'L' SERÌES
ADJUSTMENTS 26-2-5
6. Connect pressure hose to adaptor.
7. Position pressure pump, connect pressure hose
to pump.
8. Slowly pump up system to required pressure and
check for leaks.
9. Release pressure by depressing pressure
release valve on pump.
10. Remove pump from pressure hose.
11. Remove hose from adaptor.
12. Remove adaptor from expansion tank and refit
expansion tank filler cap.
CAP - EXPANSION TANK - PRESSURE
TEST
´÷ 26.10.08
Check
1. Visually check engine and cooling system for
signs of coolant leaks.
2. Examine hoses for signs of cracking, distortion
and security of connections.
3. Remove expansion tank filler cap.
WARNING: Since injury such as scalding
could be caused by escaping steam or
coolant, do not remove the filler cap from the
coolant expansion tank while the system is
hot.
4. Select correct pressure cap adaptor, fit cap to
adaptor.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-6 ADJUSTMENTS
5. Connect pressure hose to adaptor.
6. Position pressure pump, connect pressure hose
to pump.
7. Slowly pressurize cap to required pressure and
check for leaks.
8. Release pressure by depressing pressure
release valve on pump.
9. Remove adaptor from pressure hose, remove
pressure hose from pump.
10. Remove cap from adaptor.
11. Fit pressure cap to expansion tank.
COOLÌNG SYSTEM - 'L' SERÌES
REPAÌRS 26-2-7
REPAÌ RS
COOLANT EXPANSION TANK
´÷ 26.15.01
Remove
1. Position container to collect fluid loss from
expansion tank.
2. Release clip and disconnect bleed hose from
expansion tank.
3. Release clip and disconnect coolant feed hose
from expansion tank.
4. Remove 2 bolts securing expansion tank to body.
5. Release expansion tank from body and allow
coolant to drain.
6. Remove coolant expansion tank.
Refit
1. Position coolant expansion tank.
2. Fit 2 bolts securing expansion tank to body and
tighten to 5 Nm.
3. Connect coolant feed hose to expansion tank and
secure with clip.
4. Connect hose to expansion tank and secure with
clip.
5. Top-up cooling system. See MAINTENANCE.
6. Remove container positioned to catch fluid loss.
RADIATOR COOLING FAN
´÷ 26.25.22
Remove
1. Disconnect battery earth lead.
2. Remove intercooler. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
3. Loosen clip and remove intercooler hose from
plenum.
4. Disconnect multiplug from radiator cooling fan.
5. Remove 2 bolts securing cooling fan housing to
radiator.
6. Release cooling fan from lower mounting.
7. Remove cooling fan.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-8 REPAÌRS
Refit
1. Fit cooling fan, engage in lower mounting and
tighten bolts to 9 Nm.
2. Connect multiplug to cooling fan.
3. Fit intercooler hose to plenum and tighten clip.
4. Fit intercooler. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
5. Connect battery earth lead.
RADIATOR
´÷ 26.40.01
Remove
1. Disconnect battery earth lead.
2. Drain cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
3. Remove radiator cooling fan. See COOLING
SYSTEM - 'L' Series, Repairs.
4. Loosen clip, disconnect top hose from radiator
and position hose aside.
5. Loosen clip, disconnect expansion tank hose
from radiator and position hose aside.
COOLÌNG SYSTEM - 'L' SERÌES
REPAÌRS 26-2-9
6. Remove bolt and remove remaining radiator
upper mounting.
7. Lift radiator from lower mounting bracket and
remove from vehicle.
8. Remove mounting rubber from radiator.
Refit
1. Fit mounting rubber to new radiator.
2. Fit radiator to vehicle and locate on lower
mounting bracket.
3. Fit radiator upper mounting bracket and tighten
bolt to 9 Nm.
4. Connect expansion tank hose to radiator and
tighten clip.
5. Connect top hose to radiator and tighten clip.
6. Fit cooling fan. See COOLING SYSTEM - 'L'
Series, Repairs.
7. Connect battery earth lead.
8. Refill cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
THERMOSTAT
´÷ 26.45.09
Remove
1. Disconnect battery earth lead.
2. Remove front beam. See FRONT
SUSPENSION, Repairs.
3. Drain cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
4. Place container beneath oil cooler to collect
coolant spill.
5. Release clip and remove coolant hose from
thermostat housing.
6. Release clip and remove vacuum pump oil return
hose from sump.
7. Remove 3 Torx bolts securing thermostat
housing to engine oil cooler housing.
8. Remove thermostat housing.
9. Remove 'O' ring from engine oil cooler housing
and discard.
10. Remove thermostat from housing.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-10 REPAÌRS
Refit
1. Clean both thermostat housing and oil cooler
housing mating surfaces.
2. Fit new 'O' ring to oil cooler housing.
3. Fit thermostat into housing, ensuring thermostat
spindle locates in housing recess.
4. Position thermostat housing to oil cooler housing,
fit bolts and tighten to 10 Nm.
5. Fit front beam. See FRONT SUSPENSION,
Repairs.
6. Refill cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
7. Connect battery earth lead.
PUMP - COOLANT
´÷ 26.50.01
Remove
1. Disconnect battery earth lead.
2. Remove coolant pump housing. See COOLING
SYSTEM - 'L' Series, Repairs.
3. Remove 5 bolts securing cover to coolant pump
housing.
4. Remove coolant pump cover and discard 'O' ring.
5. Remove coolant pump from housing and discard
2 'O' rings.
Refit
1. Clean mating faces of coolant pump, housing and
cover.
2. Lubricate 3 new 'O' rings with Loctite 405 and fit
to coolant pump and cover.
3. Fit coolant pump and cover to housing, fit bolts
and tighten to 10 Nm.
4. Fit coolant pump housing. See COOLING
SYSTEM - 'L' Series, Repairs.
5. Connect battery earth lead.
COOLÌNG SYSTEM - 'L' SERÌES
REPAÌRS 26-2-11
COOLANT PUMP - MODELS WITH AIR
CONDITIONING
´÷ 26.50.01.20
Remove
1. Remove alternator. See ELECTRICAL, Repairs.
2. Drain cooling system. See COOLING SYSTEM -
'L' Series, Repairs.
3. Recover refrigerant from air conditioning system.
See AIR CONDITIONING, Adjustments.
4. Release clip securing intercooler hose to inlet
manifold.
5. Release hose from inlet manifold and move
aside.
6. Release 3 clips securing coolant hose between
radiator, outlet elbow, and thermostat housing.
7. Remove coolant hose.
8. Release clip securing hose to coolant pump and
move hose aside.
9. Remove bolt securing air conditioning pipes to
compressor.
10. Release pipes from compressor and remove and
discard 'O' rings.
CAUTION: ImmediateIy cap aII air
conditioning pipes to prevent ingress of dirt
and moisture into the system.
11. Loosen union and disconnect vacuum pump oil
feed pipe from block.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-12 REPAÌRS
12. Remove 5 bolts securing coolant pump cover to
housing.
13. Remove cover.
14. Remove pump from housing.
15. Remove 3 'O' rings from pump and discard.
Refit
1. Clean mating faces of coolant pump, housing,
and cover.
2. Lubricate new 'O' rings with Loctite 405 and fit to
coolant pump.
3. Fit coolant pump and cover to housing.
4. Fit bolts securing cover to housing and tighten to
10 Nm.
5. Connect vacuum pump oil feed pipe to block and
tighten union.
6. Lubricate new 'O' rings with refrigerant oil and fit
to air conditioning pipes.
7. Connect air conditioning pipes to compressor
and tighten bolt to 35 Nm.
8. Connect coolant hose to pump and tighten clip.
9. Connect coolant hose between radiator, outlet
elbow, and thermostat housing and tighten clips.
10. Connect intercooler hose to inlet manifold and
tighten clip.
11. Fit alternator. See ELECTRICAL, Repairs.
12. Replace receiver/dryer. See AIR
CONDITIONING, Repairs.
13. Refill cooling system. See COOLING SYSTEM -
'L' Series, Repairs.
14. Recharge air conditioning system. See AIR
CONDITIONING, Adjustments.
COOLÌNG SYSTEM - 'L' SERÌES
REPAÌRS 26-2-13
GASKET - HOUSING - COOLANT PUMP
´÷ 26.50.43
Remove
1. Disconnect battery earth lead.
2. Drain cooling system. See COOLING SYSTEM -
'L' Series, Repairs.
3. Raise front of vehicle.
WARNING: Support on safety stands.
4. Remove front beam. See FRONT
SUSPENSION, Repairs.
5. Remove alternator. See ELECTRICAL, Repairs.
6. Release clip and disconnect hose from coolant
pump.
7. Remove 3 bolts from auxilliary drive belt jockey
pulley bracket and move assembly aside.
8. Release PAS reservoir from mounting, remove
cap and pour PAS fluid into container.
9. Place absorbent cloth beneath PAS reservoir.
10. Release clip and disconnect outlet hose from
PAS reservoir to pump.
11. Remove 6 bolts from coolant pump housing and
with assistance remove from vehicle.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-14 REPAÌRS
12. Remove and discard 'O' ring from pump housing.
Refit
1. Clean coolant pump housing and cylinder block
mountings.
2. Lubricate new 'O' ring with Loctite 405 and fit to
coolant pump housing.
3. With assistance locate coolant pump on dowels,
fit and tighten bolts to 45 Nm.
4. Fit PAS outlet hose to reservoir and tighten clip.
5. Fit PAS reservoir to mounting bracket.
6. Fit auxilliary drive belt jockey pulley bracket and
tighten bolts to 25 Nm.
7. Fit hose to coolant pump and tighten clip.
8. Fit alternator. See ELECTRICAL, Repairs.
9. Fit front beam. See FRONT SUSPENSION,
Repairs.
10. Remove stands and lower vehicle.
11. Connect battery earth lead.
12. Fill cooling system. See COOLING SYSTEM - 'L'
Series, Repairs.
13. Bleed PAS pump. See STEERING,
Adjustments.
GASKET - HOUSING - COOLANT PUMP -
WITH A/C
´÷ 26.50.03.20
Remove
1. Disconnect battery earth lead.
2. Drain cooling system. See COOLING SYSTEM -
'L' Series, Repairs.
3. Raise front of vehicle.
WARNING: Support on safety stands.
4. Recover refrigerant from air conditioning system.
See AIR CONDITIONING, Adjustments.
5. Remove front beam. See FRONT
SUSPENSION, Repairs.
6. Remove alternator. See ELECTRICAL, Repairs.
7. Release clip and disconnect hose from coolant
pump.
8. Disconnect multiplug from A/C compressor
9. Remove 3 bolts from A/C compressor and
remove compressor from vehicle.
COOLÌNG SYSTEM - 'L' SERÌES
REPAÌRS 26-2-15
10. Release PAS reservoir from mounting, remove
cap and pour PAS fluid into container .
11. Place absorbent cloth beneath PAS reservoir.
12. Release clip and disconnect outlet hose from
PAS reservoir to pump.
13. Remove 6 bolts from coolant pump housing and
with assistance remove from vehicle.
14. Remove and discard 'O' ring from pump housing.
Refit
1. Clean coolant pump housing and cylinder block
mountings.
2. Lubricate new 'O' ring with Loctite 405 and fit to
coolant pump housing.
3. With assistance locate coolant pump on dowels,
fit and tighten bolts to 45 Nm.
4. Fit PAS outlet hose to reservoir and tighten clip.
5. Fit PAS reservoir to mounting bracket.
6. Fit A/C compressor to coolant pump housing and
tighten bolts to 25 Nm.
7. Connect A/C compressor multiplug.
8. Fit hose to coolant pump and tighten clip.
9. Fit alternator. See ELECTRICAL, Repairs.
10. Fit front beam. See FRONT SUSPENSION,
Repairs.
11. Remove stands and lower vehicle.
12. Connect battery earth lead.
13. Recharge air conditioning system. See AIR
CONDITIONING, Adjustments.
14. Fill cooling system. See COOLING SYSTEM - 'L'
Series, Repairs.
15. Bleed PAS pump. See STEERING, Repairs.
COOLÌNG SYSTEM - 'L' SERÌES
26-2-16 REPAÌRS
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-1
MANÌ FOLD & EXHAUST SYSTEMS REPAÌ RS
FRONT PIPE - 'K' 1.1 / 1.4 / 1.6
´÷ 30.10.09
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Release post catalyst HO
2
S sensor lead
grommet from tunnel, manoeuvre sensor lead
and multiplug through grommet aperture in
tunnel.
3. Disconnect multiplug from post catalyst HO
2
S
sensor lead.
4. Remove 2 flange nuts securing front pipe to
intermediate pipe.
5. Release mounting rubber from front pipe support
bracket.
6. Remove 2 flange nuts securing front pipe to
exhaust manifold.
7. Release front pipe from manifold and remove
front pipe.
8. Remove gaskets from manifold and intermediate
pipe flanges.
9. Remove HO
2
S.
Refit
1. Fit HO
2
S to front pipe.
2. Clean pipe flanges.
3. Fit new gasket to intermediate pipe flange.
4. Position front pipe to intermediate pipe, fit nuts
but DO NOT tighten at this stage.
5. Fit new gasket to manifold flange.
6. Position front pipe to exhaust manifold.
7. Fit and tighten flange nuts to 45 Nm.
8. Tighten front pipe to intermediate pipe nuts to 45
Nm.
9. Connect rubber mounting to pipe bracket.
10. Connect multiplug to post catalyst HO
2
S sensor
lead.
11. Position HO
2
S multiplug and lead through
grommet aperture in tunnel and fit grommet.
12. Remove stand(s) and lower vehicle.
MANÌFOLD & EXHAUST SYSTEMS
30-2 REPAÌRS
FRONT PIPE - 'L' SERIES
´÷ 30.10.09
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Remove 3 nuts securing front pipe to catalytic
converter.
4. Release mounting rubber from pipe bracket.
5. Remove 3 nuts securing front pipe to manifold.
6. Release front pipe from manifold and remove
from catalytic converter.
7. Remove flange gaskets.
Refit
1. Clean pipe flanges.
2. Fit new gasket to catalytic converter flange.
3. Fit front pipe to catalytic converter, fit nuts but DO
NOT tighten.
4. Fit new gasket to manifold flange.
5. Raise front pipe and engage flange.
6. Fit manifold to front pipe nuts and tighten to 50
Nm.
7. Tighten nuts securing front pipe to catalytic
converter to 50 Nm.
8. Secure front pipe rubber mounting to bracket on
body.
9. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
10. Remove stand(s) and lower vehicle.
FRONT PIPE - 'K16 WITH VVC'
´÷ 30.10.09
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Release and disconnect pre catalyst multiplug.
3. Release post catalyst HO
2
S lead grommet from
tunnel, manoeuvre sensor lead and multiplug
through grommet aperture in tunnel.
4. Disconnect multiplug from post catalyst HO
2
S
lead.
5. Release 6 clips securing HO
2
S lead to bracket.
6. Remove 2 flange nuts securing front pipe to
intermediate pipe.
CAUTION: When reIeasing the intermediate
pipe from the front pipe, the front pipe must
be supported to avoid damage to the fIexibIe
joint.
7. Remove 6 flange nuts securing front pipe to
exhaust manifold.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-3
8. Release mounting rubber from front pipe support
bracket.
9. Release front pipe from manifold and remove
front pipe.
10. Remove gaskets from manifold and intermediate
flanges.
11. Using 18G 1687, remove pre and post catalyst
HO
2
S from front pipe.
Refit
1. Clean pipe flanges, sensors and mating faces.
2. Fit pre and post catalyst HO
2
S to new front pipe.
Using 18G 1687, tighten sensors to 55 Nm.
3. Fit new gasket to intermediate flange.
4. Fit new gasket to manifold flange.
5. Position front pipe to intermediate pipe, fit nuts
but DO NOT tighten at this stage.
6. Position front pipe to exhaust manifold.
7. Fit and tighten flange nuts evenly to 45 Nm.
8. Tighten front pipe to intermediate pipe nuts to 45
Nm.
9. Connect rubber mounting to pipe bracket.
10. Connect multiplug to post catalyst HO
2
S sensor
lead.
11. Clip HO
2
S lead to bracket.
12. Position HO
2
S multiplug and lead through
grommet aperture in tunnel and fit grommet.
13. Connect multiplug to pre catalyst HO
2
S lead and
secure in position.
14. Remove stand(s) and lower vehicle.
MANÌFOLD & EXHAUST SYSTEMS
30-4 REPAÌRS
INTERMEDIATE PIPE - 'K' SERIES
´÷ 30.10.11
Remove
1. Raise vehicle on 4 post ramp.
2. Remove 2 nuts securing tail pipe to intermediate
pipe.
3. Remove 2 nuts securing intermediate pipe to
front pipe.
4. Release intermediate pipe from front pipe.
Remove and discard gasket.
5. Release 2 rubber mountings securing
intermediate pipe to body.
6. Release and remove intermediate pipe. Remove
and discard gasket from tail pipe flange end of
intermediate pipe.
Refit
1. Clean mating faces of intermediate pipe, catalytic
converter and tail pipe.
2. Fit new gaskets to tail pipe flange end of
intermediate pipe and catalytic converter flange.
3. Fit intermediate pipe to tail pipe, align and
connect to catalytic converter flange.
4. Fit nuts securing intermediate pipe to catalytic
converter and tighten to 45 Nm.
5. Fit nuts securing intermediate pipe to tail pipe
and tighten to 45 Nm.
6. Secure intermediate pipe mounting rubbers to
body.
7. Lower vehicle.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-5
INTERMEDIATE PIPE - 'L' SERIES
´÷ 30.10.11
Remove
1. Raise vehicle on 4 post ramp.
2. Remove 2 nuts securing tail pipe to intermediate
pipe.
3. Remove 3 nuts securing intermediate pipe to
catalytic converter.
4. Release intermediate pipe from catalytic
converter. Remove and discard gasket
5. Release 2 rubber mountings securing
intermediate pipe to body.
6. Release and remove intermediate pipe. Remove
and discard gasket from tail pipe flange end of
intermediate pipe.
Refit
1. Clean mating faces of intermediate pipe, catalytic
converter and tail pipe.
2. Fit new gaskets to tail pipe flange end of
intermediate pipe and catalytic converter flange.
3. Fit intermediate pipe to tail pipe, align and
connect to catalytic converter flange.
4. Fit nuts securing intermediate pipe to catalytic
converter and tighten to 50 Nm.
5. Fit nuts securing intermediate pipe to tail pipe
and tighten to 50 Nm.
6. Secure intermediate pipe mounting rubbers to
body.
7. Lower vehicle.
MANÌFOLD & EXHAUST SYSTEMS
30-6 REPAÌRS
TAIL PIPE - 'K' SERIES
´÷ 30.10.22
Remove
1. Raise vehicle on 4 post ramp.
2. Remove 2 nuts securing intermediate pipe to tail
pipe.
3. Release 3 rubber mountings securing tail pipe to
body.
4. Remove tail pipe.
5. Remove and discard gasket.
Refit
1. Clean intermediate pipe and tail pipe mating
faces.
2. Fit new gasket to intermediate pipe flange studs.
3. Fit tail pipe and secure rubber mountings to body.
4. Fit nuts to flange and tighten to 45 Nm.
5. Lower vehicle.
TAIL PIPE - 'L' SERIES
´÷ 30.10.22
Remove
1. Raise vehicle on 4 post ramp.
2. Remove 2 nuts securing intermediate pipe to tail
pipe.
3. Release 3 rubber mountings securing tail pipe to
body.
4. Remove tail pipe.
5. Remove and discard gasket.
Refit
1. Clean intermediate pipe and tail pipe mating
faces.
2. Fit new gasket to intermediate pipe flange studs.
3. Fit tail pipe and secure rubber mountings to body.
4. Fit nuts to flange and tighten to 50 Nm.
5. Lower vehicle.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-7
GASKET - FRONT PIPE TO MANIFOLD 'K'
SERIES
´÷ 30.10.26
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 2 flange nuts securing front pipe to
exhaust manifold.
3. Release front pipe from exhaust manifold.
4. Remove gasket from exhaust manifold flange.
Refit
1. Clean manifold and front pipe flanges.
2. Fit new gasket to manifold flange.
3. Raise front pipe and engage manifold flange.
4. Fit and tighten flange nuts to 45 Nm.
5. Remove stand(s) and lower vehicle.
GASKET - FRONT PIPE TO MANIFOLD
'K16 WITH VVC'
´÷ 30.10.26
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 6 flange nuts securing front pipe to
exhaust manifold.
3. Release front pipe from exhaust manifold.
4. Remove gasket from exhaust manifold flange.
Refit
1. Clean manifold and front pipe flanges.
2. Fit new gasket to manifold flange.
3. Raise front pipe and engage manifold flange.
4. Fit and tighten flange nuts to 45 Nm.
5. Remove stand(s) and lower vehicle.
MANÌFOLD & EXHAUST SYSTEMS
30-8 REPAÌRS
GASKET - FRONT PIPE TO MANIFOLD - 'L'
SERIES
´÷ 30.10.26
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 3 nuts securing front pipe to manifold.
3. Release front pipe from manifold.
4. Remove gasket from manifold flange.
Refit
1. Clean manifold and front pipe flanges.
2. Fit new gasket to manifold flange.
3. Position front pipe to manifold, fit nuts and tighten
to 50 Nm.
4. Remove stand(s) and lower vehicle.
HEAT SHIELD - FRONT PIPE - 'K' SERIES
´÷ 30.10.28
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 2 nuts securing front pipe to
intermediate pipe, release front pipe from
intermediate pipe, remove and discard gasket.
NOTE: Support the weight of the front pipe.
3. Remove 3 bolts securing post catalyst sensor
harness support bracket and position bracket
aside.
4. Remove remaining 4 bolts securing heat shield
and remove heat shield.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-9
Refit
1. Position heat shield, fit bolts but do not tighten.
2. Align harness support bracket and fit bolts.
3. Tighten all bolts to 9 Nm.
4. Fit new gasket and align front pipe to
intermediate pipe.
5. Fit nuts securing front pipe to intermediate pipe
and tighten to 45 Nm.
6. Remove stand(s) and lower vehicle.
TAIL PIPE HEAT SHIELD
´÷ 30.10.44
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Release exhaust tailpipe from 3 mounting
rubbers.
3. Remove 4 bolts securing heat shield to body.
4. Remove tail pipe heat shield.
Refit
1. Position tail pipe heat shield, fit bolts and tighten
to 9 Nm.
2. Secure exhaust tailpipe to mounting rubbers.
3. Remove stand(s) and lower vehicle.
MANÌFOLD & EXHAUST SYSTEMS
30-10 REPAÌRS
HEAT SHIELD - REAR BIB SPOILER
´÷ 30.10.45
Remove
1. Remove rear bib spoiler. See EXTERIOR
FITTINGS, Repairs.
2. Remove 6 nuts and bolts securing heat shield
and remove heat shield.
Refit
1. Clean mating faces of heat shield and bib spoiler.
2. Position heat shield to bib spoiler, fit nuts and
bolts and tighten to 6 Nm.
3. Fit rear bib spoiler. See EXTERIOR FITTINGS,
Repairs.
MODULATOR - VACUUM VALVE - TAIL
PIPE - EXHAUST
´÷ 30.10.71
Remove
1. Release and disconnect vacuum modulator
multiplug.
2. Release catch and disconnect vacuum
modulator from support bracket.
3. Disconnect vacuum hoses from vacuum
modulator and remove vacuum modulator.
Refit
1. Position vacuum modulator, connect vacuum
hoses and secure vacuum modulator to support
bracket.
2. Connect vacuum modulator multiplug.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-11
VACUUM RESERVOIR - VACUUM VALVE -
TAIL PIPE - EXHAUST
´÷ 30.10.72
Remove
1. Disconnect vacuum reservoir vacuum hoses.
2. Remove vacuum reservoir from support bracket.
Refit
1. Position vacuum reservoir to support bracket.
2. Connect vacuum reservior vacuum hoses.
GASKET - INLET MANIFOLD - 'K16'
´÷ 30.15.08
Remove
1. Disconnect battery earth lead.
2. Drain cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
3. Position absorbent cloth around fuel feed and
return hose connections.
4. Release connectors and disconnect fuel feed
and return hoses.
CAUTION: PIug the connections.
5. Release clip and disconnect air intake hose from
throttle body.
6. Release clip and disconnect purge hose from
inlet manifold.
7. Release clip and disconnect breather hose from
throttle body.
8. Release and remove hose, ÌAC valve to throttle
body.
MANÌFOLD & EXHAUST SYSTEMS
30-12 REPAÌRS
9. Disconnect multiplug from TP sensor.
10. Disconnect multiplug from ÌAC valve and release
harness from clip on throttle body.
11. Disconnect MAP sensor multiplug.
12. Release throttle cable from clips on inlet manifold
and fuel return pipe.
13. Release throttle cable adjusting nut from
abutment bracket and inner cable from throttle
cam.
14. Disconnect breather hose from inlet manifold.
15. Depress locking collar and disconnect brake
servo hose from inlet manifold.
16. Loosen clip and disconnect coolant hose from
inlet manifold.
17. Remove 3 screws securing coil cover and
remove cover.
18. Remove 2 bolts securing RH ignition coil and
release coil.
19. Disconnect coil multiplugs and release coil
harness from retaining clips.
20. Release injector harness multiplug from bracket
and disconnect multiplug.
21. Working in the sequence shown, progressively
loosen then remove 7 nuts securing inlet
manifold to cylinder head.
22. Remove inlet manifold, remove and discard
gasket.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-13
Refit
1. Ensure mating surfaces are clean and that metal
inserts are fitted in inlet manifold stud and bolt
holes.
2. Fit new gasket to inlet manifold.
CAUTION: Gasket must be fitted dry.
3. Position inlet manifold, fit nuts and tighten in the
sequence shown to 17 Nm.
4. Connect coolant hose to inlet manifold and
tighten clip.
5. Connect multiplug to injector harness and secure
multiplug to bracket.
6. Connect multiplugs to ignition coils, position RH
coil, fit bolts and tighten to 10 Nm.
7. Secure coil harness in clips.
8. Position coil cover, fit bolts and tighten bolts to 10
Nm.
9. Connect brake servo hose to inlet manifold.
10. Connect breather pipe to inlet manifold.
11. Connect throttle cable inner to throttle cam.
12. Position throttle cable adjusting nut in abutment
bracket and secure throttle cable in clips on inlet
manifold and fuel return pipe.
13. Connect multiplug to MAP sensor.
14. Connect multiplug to ÌAC valve and secure
harness in clip on throttle body.
15. Connect multiplug to TP sensor.
16. Position and secure hose, ÌAC valve to throttle
body.
17. Connect breather hose to throttle body and
secure with clip.
18. Connect purge hose to inlet manifold and secure
with clip.
19. Connect air intake hose to throttle body and
secure with clip.
20. Remove plugs from fuel hoses.
21. Connect fuel feed and return hoses.
22. Refill cooling system. See COOLING SYSTEM,
Adjustments.
23. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - Siemens,
Adjustments.
GASKET - INLET MANIFOLD - 'K16 WITH
VVC'
´÷ 30.15.08
Remove
1. Disconnect battery earth lead.
2. Remove inlet manifold chamber gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
3. Position cloth around fuel return hose
connection.
4. Release fuel return hose.
CAUTION: PIug the connections.
5. Position cloth around fuel feed hose connection.
6. Release fuel feed hose.
CAUTION: PIug the connections.
7. Position container to collect coolant spillage.
8. Release clip and disconnect coolant hose from
inlet manifold.
9. Remove bolt securing support stay to inlet
manifold.
MANÌFOLD & EXHAUST SYSTEMS
30-14 REPAÌRS
10. Disconnect multiplug from ÌAT sensor.
11. Disconnect multiplugs from injectors and move
harness aside.
12. Remove 2 nuts and 7 bolts securing inlet
manifold to cylinder head.
13. Remove inlet manifold.
14. Remove and discard inlet manifold gasket.
Refit
1. Clean manifold and cylinder head mating
surfaces.
2. Fit new inlet manifold gasket to cylinder head.
3. Fit inlet manifold to cylinder head.
4. Fit nuts and bolts securing inlet manifold to
cylinder head and tighten in sequence shown to
25 Nm.
5. Align support stay to inlet manifold, fit bolt and
tighten to 25 Nm.
6. Connect multiplugs to injectors.
7. Connect multiplug to ÌAT sensor.
8. Connect fuel feed and return hoses.
9. Connect coolant hose to inlet manifold and
secure with clip.
10. Fit inlet manifold chamber gasket.See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
11. Connect battery earth lead.
12. Refill cooling system. See COOLING SYSTEM -
'K' Series, Adjustments.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-15
HEAT SHIELD - EXHAUST MANIFOLD - 'K-
SERIES'
´÷ 30.15.09
Remove
1. Disconnect battery earth lead.
2. Remove nut and 2 speed bolts securing heat
shield to exhaust manifold
3. Release heat shield from top stud and remove
heat shield.
4. Remove spacer from stud.
Refit
1. Position spacer on stud.
2. Position heat shield to exhaust manifold and
locate on stud.
3. Fit nut and tighten to 25 Nm.
4. Fit and tighten 2 speed bolts.
5. Connect battery earth lead.
HEAT SHIELD - EXHAUST MANIFOLD - A/
C - 'K-SERIES'
´÷ 30.15.09/20
Remove
1. Disconnect battery earth lead.
2. Remove splash shield. See EXTERIOR
FITTINGS, Repairs.
3. Remove bolt securing heat shield to exhaust
flange bracket.
4. Remove nut and bolt securing heat shield to
manifold and alternator brackets.
MANÌFOLD & EXHAUST SYSTEMS
30-16 REPAÌRS
5. Release tension on alternator drive belt and fit
suitable pin, not exceeding 3 mm diameter, to
hold tensioner in position.
6. Release drive belt from alternator.
7. Remove top bolt securing alternator and loosen
lower bolt.
8. Position alternator forward to access alternator
bracket.
9. Remove bolt securing alternator bracket, rotate
bracket clear of alternator and remove bracket.
10. Remove alternator bracket stud.
11. Manoeuvre heat shield from engine and remove
heat shield.
Refit
1. Position heat shield and manoeuvre into location.
2. Fit and tighten alternator bracket stud.
3. Fit alternator bracket on stud and rotate into
position.
4. Fit bolt securing alternator bracket and tighten to
25 Nm.
5. Align alternator to bracket, fit top bolt.
6. Tighten alternator bolts to 45 Nm.
7. Locate drive belt on alternator pulley, remove
locking pin and release drive belt tensioner.
8. Ensure drive belt is correctly located on all
pulleys.
9. Fit heat shield to alternator bracket.
10. Fit nut and bolts, tighten nut to 25 Nm and bolts
to 10 Nm.
11. Fit splash shield. See EXTERIOR FITTINGS,
Repairs.
12. Connect battery earth lead.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-17
HEAT SHIELD - EXHAUST MANIFOLD -
'K16 WITH VVC'
´÷ 30.15.09/20
Remove
1. Disconnect battery earth lead.
2. Remove 2 bolts securing heat shield to exhaust
flange bracket.
3. Remove nut and bolt securing heat shield to
manifold and alternator brackets.
4. Release tension on alternator drive belt by
rotating hexagon on belt tensioner fully
clockwise.
5. Fit suitable pin, not exceeding 3 mm diameter, to
hold tensioner in position.
6. Release drive belt from alternator.
7. Remove top bolt securing alternator and loosen
lower bolt.
8. Position alternator forward to access alternator
bracket.
9. Remove bolt securing alternator bracket, rotate
bracket clear of alternator and remove bracket.
MANÌFOLD & EXHAUST SYSTEMS
30-18 REPAÌRS
10. Remove alternator bracket stud.
11. Manoeuvre heat shield from engine and remove
heat shield.
Refit
1. Position heat shield and manoeuvre into location.
2. Fit and tighten alternator bracket stud.
3. Fit alternator bracket on stud and rotate into
position.
4. Fit bolt securing alternator bracket and tighten to
25 Nm.
5. Align alternator to bracket, fit top bolt.
6. Tighten alternator bolts to 45 Nm.
7. Locate drive belt on alternator pulley, remove
locking pin and release drive belt tensioner.
8. Ensure drive belt is correctly located on all
pulleys.
9. Fit heat shield to alternator bracket.
10. Fit nut and bolts, tighten nut to 25 Nm and bolts
to 10 Nm.
11. Connect battery earth lead.
MANIFOLD - EXHAUST - 'K16' WITH A/C
´÷ 30.15.10/20
Remove
1. Disconnect battery earth lead.
2. Remove exhaust manifold heat shield. See
MANIFOLD & EXHAUST SYSTEMS - 'K'
Series, Repairs.
3. Disconnect alternator multiplug, loosen nut
securing alternator lead and release lead from
alternator.
4. Remove alternator bottom bolt.
5. Release alternator from bracket and remove
alternator.
6. Remove 3 bolts securing A/C compressor,
release A/C compressor and tie aside.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-19
7. Remove 2 nuts securing front pipe to manifold,
release front pipe from manifold.
8. Remove and discard front pipe flange gasket.
NOTE: Support the weight of the front pipe.
9. Remove bolt securing engine RH mounting
engine steady bracket.
10. Loosen steady bar bracket bolt and release
steady bar.
11. Remove bolt securing steady bar to sump
bracket.
12. Loosen bolt securing engine lower steady bar to
rear subframe and release steady bar.
13. Using sequence shown, loosen but do not
remove 5 nuts securing exhaust manifold to
engine.
14. Release HO
2
S multiplug from bracket and
disconnect HO
2
S multiplug.
15. Using a crowsfoot spanner loosen HO
2
S.
MANÌFOLD & EXHAUST SYSTEMS
30-20 REPAÌRS
16. Remove 5 nuts securing exhaust manifold.
17. Release exhaust manifold from studs, remove
and discard exhaust manifold gasket.
18. Remove HO
2
S and collect sealing washer.
19. With assistance, rock top of the engine
backwards to increase access to remove exhaust
manifold.
20. Manoeuvre exhaust manifold from engine and
remove exhaust manifold.
Refit
1. Clean exhaust manifold and cylinder head
mating faces.
2. Fit new exhaust manifold gasket.
3. With assistance, rock the top of the engine
backwards to increase access, manoeuvre the
exhaust manifold into position.
4. Fit sealing washer to HO
2
S and fit HO
2
S.
5. Align exhaust manifold to cylinder head studs.
6. Fit nuts securing exhaust manifold, but do not
tighten at this stage.
7. Tighten HO
2
S sensor to 55 Nm.
8. Connect HO
2
S multiplug and secure in bracket.
9. Using sequence shown, tighten nuts securing
manifold to 45 Nm.
10. Align upper and lower engine steady brackets to
engine, fit bolts and tighten to 85 Nm.
11. Clean front pipe and exhaust manifold mating
faces.
12. Fit new gasket to front pipe flange and align front
pipe to exhaust manifold.
13. Fit nuts securing front pipe flange and tighten to
45 Nm.
14. Align A/C compressor to engine, fit bolts and
tighten to 25 Nm.
15. Position alternator to support bracket and fit
bottom bolt.
16. Connect alternator multiplug, fit alternator lead
and tighten nut.
17. Fit exhaust manifold heat shield. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
18. Connect battery earth lead.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-21
GASKET - EXHAUST MANIFOLD - 'K16'
´÷ 30.15.12
Remove
1. Disconnect battery earth lead.
2. Remove exhaust manifold heat shield. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
3. Remove front pipe to manifold flange gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
4. Release HO
2
S multiplug from bracket and
disconnect multiplug.
5. Remove 5 nuts securing exhaust manifold to
cylinder head, using the sequence shown.
6. Remove exhaust manifold.
7. Remove and discard exhaust manifold gasket.
Refit
1. Clean exhaust manifold and mating face on
cylinder head.
2. Fit new gasket to manifold studs on cylinder
head.
3. Position exhaust manifold, fit and tighten nuts in
the sequence shown to 45 Nm.
4. Connect HO
2
S multiplug and secure to bracket.
5. Fit front pipe to manifold flange gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
6. Fit exhaust manifold heat shield. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
7. Connect battery earth lead.
MANÌFOLD & EXHAUST SYSTEMS
30-22 REPAÌRS
GASKET - EXHAUST MANIFOLD 'K16
WITH VVC'
´÷ 30.15.12
Remove
1. Disconnect battery earth lead.
2. Remove exhaust manifold heat shield. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
3. Remove front pipe to manifold flange gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
4. Remove 5 nuts securing exhaust manifold to
cylinder head.
5. Remove exhaust manifold.
6. Remove and discard exhaust manifold gasket.
Refit
1. Clean exhaust manifold and mating face on
cylinder head.
2. Fit new gasket to manifold studs on cylinder
head.
3. Position exhaust manifold, fit and tighten nuts in
the sequence shown to 45 Nm.
4. Fit front pipe to manifold flange gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
5. Fit exhaust manifold heat shield. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
6. Connect battery earth lead.
GASKET - INLET AND EXHAUST
MANIFOLD 'L' SERIES
´÷ 30.15.15
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain cooling system. See COOLING SYSTEM -
'L' Series, Adjustments.
4. Remove plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
5. Remove 3 nuts securing exhaust front pipe to
exhaust manifold.
6. Release front pipe from exhaust manifold and
remove gasket.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-23
7. Loosen clip and disconnect engine breather hose
from camshaft cover.
8. Loosen clip and disconnect air intake pipe from
MAF sensor.
9. Loosen clip and disconnect air intake pipe from
turbocharger.
10. Remove air intake pipe, and engine breather
valve assembly.
CAUTION: PIug the connections.
11. Disconnect multiplug from ÌAT sensor.
12. Loosen clips and disconnect 2 coolant hoses
from EGR cooler.
13. Disconnect vacuum pipe from EGR valve.
14. Loosen clip and disconnect intercooler hose from
turbocharger outlet pipe.
15. Remove 2 bolts securing turbocharger outlet pipe
to cylinder head.
16. Loosen clip and remove outlet pipe and hose
from turbocharger outlet.
CAUTION: PIug the connections.
17. Disconnect boost pressure sensing pipe from
turbocharger.
MANÌFOLD & EXHAUST SYSTEMS
30-24 REPAÌRS
18. Remove banjo bolt securing oil feed pipe to
turbocharger, remove and discard sealing
washers.
19. Remove 2 bolts securing oil drain pipe to
turbocharger.
20. Remove and discard gasket.
21. Remove 2 bolts securing exhaust manifold to
support bracket.
22. Remove 6 bolts securing manifolds to cylinder
head and collect 4 washers.
23. Remove 6 nuts securing manifolds to cylinder
head.
24. Remove inlet and exhaust manifolds.
25. Remove and discard manifold gasket.
Refit
1. Clean mating faces of inlet manifold, exhaust
manifold and cylinder head.
2. Fit new manifold gasket to cylinder head.
3. Fit inlet and exhaust manifolds, fit clamp washers
and in sequence shown, tighten nuts to 25 Nm.
and bolts to 33 Nm.
4. Fit and tighten bolts securing support bracket to
turbocharger to 25 Nm.
5. Clean turbocharger oil drain pipe flange and
mating face.
6. Fit new gasket, align oil drain pipe to
turbocharger and tighten bolts to 10 Nm.
7. Clean turbocharger oil feed pipe union, banjo bolt
and sealing washers.
8. Fit sealing washers, align oil feed pipe and
tighten banjo bolt to 20 Nm.
9. Fit turbocharger outlet pipe and hose, align pipe
to cylinder head and tighten bolts to 10 Nm.
Tighten hose clip.
10. Connect intercooler hose to turbocharger outlet
pipe and tighten clip.
11. Connect multiplug to ÌAT sensor.
12. Connect EGR coolant hoses and tighten clips.
13. Connect vacuum pipe to EGR valve.
14. Connect boost pressure sensing pipe to
turbocharger.
15. Fit air intake pipe to turbocharger, and MAF
sensor. Tighten clips.
16. Connect engine breather hose to camshaft cover
and tighten clip.
17. Clean exhaust pipe flange and mating face.
18. Fit new gasket, connect exhaust front pipe to
manifold and tighten nuts to 45 Nm.
19. Fit plenum chamber. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
20. Remove stand(s) and lower vehicle.
21. Connect battery earth lead.
22. Refill cooling system. See COOLING SYSTEM -
'L' Series, Adjustments. feed pipe.
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-25
GASKET - INLET MANIFOLD CHAMBER -
'K16 WITH VVC'
´÷ 30.15.37
Remove
1. Disconnect battery earth lead.
2. Disconnect brake servo vacuum pipe.
3. Disconnect fuel pressure regulator vacuum hose.
4. Disconnect multiplug from MAP sensor.
5. Disconnect breather hose.
6. Release throttle cable from abutment bracket.
7. Release throttle cable from throttle cam.
8. Release clip and disconnect purge hose.
9. Disconnect multiplug from ÌACV.
10. Remove clips securing air intake hose.
11. Release and remove intake hose.
12. Release clip and disconnect breather from
throttle housing.
13. Remove bolt securing harness bracket to throttle
housing.
14. Disconnect multiplug from TP sensor.
15. Remove 5 bolts securing manifold chamber to
inlet manifold.
16. Remove inlet manifold chamber.
17. Remove and discard gasket.
MANÌFOLD & EXHAUST SYSTEMS
30-26 REPAÌRS
Refit
1. Clean mating faces of inlet manifold and manifold
chamber.
2. Fit new gasket to inlet manifold and position
manifold chamber.
3. Progressively tighten bolts securing manifold
chamber to inlet manifold to 25 Nm.
4. Position harness bracket to throttle housing, fit
bolt and tighten to 9 Nm.
5. Connect breather hose and secure with clip.
6. Fit air intake hose and secure with clips.
7. Connect multiplug to ÌACV.
8. Connect multiplug to TP sensor.
9. Connect throttle cable to throttle cam.
10. Secure throttle cable adjusting nut to abutment
bracket.
11. Connect purge hose and secure with clip.
12. Connect multiplug to MAP sensor.
13. Connect hose to fuel pressure regulator.
14. Connect breather hose.
15. Connect brake servo vacuum pipe.
16. Connect battery earth lead.
17. Adjust throttle cable. See ENGINE
MANAGEMENT SYSTEM - MEMS,
Adjustments. manifold.
PLASTIC MANIFOLD STUB PIPES -
RENEW
´÷ 30.15.42
Ìn the event of one of the plastic manifold stub pipes
breaking during a repair operation they can be
replaced using the following procedure. Read and
study the procedure before commencing a repair.
Remove
1. Remove plastic inlet manifold. See MANIFOLD
& EXHAUST SYSTEMS, Repairs.
2. Position manifold on a work surface and clamp
on manifold flange.
NOTE: Support manifold chamber.
3. Ìf the damaged pipe has broken above the boss
face, file the pipe level with the boss face.
4. Using a Vernier caliper, micrometer or similar,
measure the diameter of the stub pipe which has
broken.
5 mm stub pipe (Part No. UKC 2487)
5. Select a 5 mm drill.
NOTE: The drill must be clean and free of grease
and oil.
6. Position a fibre washer on drill shaft, 13 mm from
tip of drill (dimension A in illustration).
MANÌFOLD & EXHAUST SYSTEMS
REPAÌRS 30-27
6 mm stub pipe (Part No. JZX 2000)
7. Select a 6 mm drill.
NOTE: The drill must be clean and free of grease
and oil.
8. Position a fibre washer on drill shaft, 15 mm from
tip of drill (dimension A in illustration).
Both stub pipes
9. Carefully drill hole to depth.
WARNING: Safety goggles must be worn
when drilling.
10. Lightly chamfer edge of drilled hole.
Refit
1. Select replacement stub pipe, spray stub and
drilled hole with Loctite activator N.
2. Allow activator to fully dry and DO NOT
contaminate surfaces.
3. Lightly smear drilled hole and stub pipe with
Loctite 648.
4. Fit stub pipe into plastic manifold.
NOTE: Leave manifold for one hour to allow
Loctite to partially cure.
5. Un-clamp manifold from work bench and using
an air line, blow out any excess Loctite from stub
pipe and swarf from manifold.
6. Fit plastic inlet manifold. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
NOTE: When connecting hose to repaired stub
pipe, avoid twisting or excessive bending.
NOTE: The vehicle is fit for service, but full
strength of joint will be achieved after
approximately ten hours.
MANÌFOLD & EXHAUST SYSTEMS
30-28 REPAÌRS
CLUTCH
REPAÌRS 33-1
CLUTCH REPAÌ RS
CLUTCH ASSEMBLY AND RELEASE
BEARING - 'K' SERIES 1.1 / 1.4 / 1.6 R65
´÷ 33.10.07
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX - 'R65', Repairs.
2. Remove release bearing from guide sleeve and
release fork.
3. Examine release bearing for signs of wear or
damage, renew if necessary.
CAUTION: Bearing is packed with grease, DO
NOT wash in soIvent.
4. Place a circular piece of flat plate across
diaphragm fingers and insert feeler gauges
between plate and fingers.
Diaphragm finger clearance limit = 1.0 mm
5. Measure diaphragm finger height above bolted
surface of pressure plate. Renew pressure plate
if clearances are outside service limit. Diaphragm
finger height:
New clutch plate = 29.1 - 32.0 mm
Service limit = 36.5 mm
6. Position 18G 1571 to cylinder block and ring gear
and secure with bolts.
7. Progressively loosen and then remove 6 Torx
bolts securing pressure plate to flywheel.
8. Remove clutch pressure plate and collect drive
plate.
9. Ìnspect clutch drive plate for signs of wear or oil
contamination. Check for broken or loose springs
and signs of cracking at spring windows. Renew
drive plate if necessary.
CLUTCH
33-2 REPAÌRS
10. Measure depth of rivets on drive plate, renew
drive plate if less than service limit. Drive plate
rivet depth:
New clutch plate = 0.9 mm minimum
Service limit = 0.1 - 0.2 mm
11. Measure drive plate run-out by fitting drive plate
to a gearbox mainshaft and use a dial gauge as
drive plate is rotated.
12. 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.
NOTE: Renew a pressure plate which has been
accidentally dropped.
13. 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 service limit. Pressure plate warping:
service limit = 0.20 mm maximum
Refit
1. Clean pressure plate and flywheel, dowels and
dowel holes.
2. Ìnspect 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 flywheel with 'FLYWHEEL
SÌDE' marking towards flywheel.
5. Fit pressure plate to flywheel and fit alignment
tool 18G 1575.
6. Fit and lightly tighten 6 Torx bolts securing
pressure plate to flywheel.
7. Working in a diagonal sequence, progressively
tighten Torx bolts to 18 Nm.
8. Remove drive plate alignment tool 18G 1575.
9. Remove 2 bolts securing flywheel locking tool
18G 1571 to engine and remove flywheel locking
tool.
10. Clean clutch release fork and release bearing
guide sleeve.
11. Smear release fork shaft and bore of release
bearing with Molybdenum disulphide grease.
12. Fit release bearing to release fork and slide onto
guide sleeve.
13. Operate release lever to ensure that release
bearing is correctly located on release fork and
slides smoothly on guide sleeve.
14. Fit gearbox assembly, See MANUAL GEARBOX
- 'R65', Repairs.
CLUTCH
REPAÌRS 33-3
CLUTCH ASSEMBLY AND RELEASE
BEARING - 'K16 WITH VVC'
´÷ 33.10.07
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX - 'PG1', Repairs.
2. Remove release bearing from guide sleeve and
release fork.
3. Examine release bearing for signs of wear or
damage, renew if necessary.
CAUTION: Bearing is packed with grease, DO
NOT wash in soIvent.
4. Place a circular piece of flat plate across
diaphragm fingers and insert feeler gauges
between plate and fingers.
Diaphragm finger clearance limit = 1.0 mm
5. Measure diaphragm finger height above bolted
surface of pressure plate. Renew pressure plate
if clearances are outside service limit. Diaphragm
finger height:
New clutch plate = 29.1 - 32.0 mm
Service limit = 36.5 mm
6. Fit flywheel locking tool 18G 1674 and secure
with bolt.
7. Progressively loosen and then remove 6 bolts
securing pressure plate to flywheel.
8. Remove clutch pressure plate and collect drive
plate.
9. Ìnspect clutch drive plate for signs of wear or oil
contamination. Check for broken or loose springs
and signs of cracking at spring windows. Renew
drive plate if necessary.
10. Measure depth of rivets on drive plate, renew
drive plate if less than service limit. Drive plate
rivet depth:
New clutch plate = 1.0 mm
Minimum Service limit = 0.2 mm
CLUTCH
33-4 REPAÌRS
11. Measure drive plate run-out by fitting drive plate
to a gearbox mainshaft and use a dial gauge as
drive plate is rotated. Renew drive plate if outside
service limit. Drive plate run-out:
New clutch plate = 0.8 mm
Service limit = 1.0 mm
12. 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.
NOTE: Renew a pressure plate which has been
accidentally dropped.
13. 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 service limit. Pressure plate warping:
Service limit = 0.18 mm maximum
Refit
1. Clean pressure plate and flywheel, dowels and
dowel holes.
2. Ìnspect 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 flywheel with 'FLYWHEEL
SÌDE' marking towards flywheel.
5. Fit pressure plate to flywheel and fit alignment
tool 18G 1483.
6. Fit 6 bolts securing pressure plate to flywheel,
tighten bolts sufficiently until drive plate is held in
its central position. Remove 18G 1483 from
pressure plate.
7. Working in a diagonal sequence, progressively
tighten bolts to 26 Nm.
8. Remove drive plate alignment tool 18G 1483.
9. Remove flywheel locking tool 18G 1674.
10. Clean clutch release fork and release bearing
guide sleeve.
11. Smear release fork shaft and bore of release
bearing with Molybdenum disulphide grease.
12. Fit release bearing to release fork and slide onto
guide sleeve.
13. Operate release lever to ensure that release
bearing is correctly located on release fork and
slides smoothly on guide sleeve.
14. Fit gearbox assembly. See MANUAL GEARBOX
- 'PG1', Repairs.
CLUTCH
REPAÌRS 33-5
CLUTCH ASSEMBLY AND RELEASE
BEARING - 'L' SERIES
´÷ 33.10.07
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX - 'PG1', Repairs.
2. Remove release bearing from guide sleeve and
release fork.
3. Examine release bearing for signs of wear or
damage, renew if necessary.
CAUTION: Bearing is packed with grease, DO
NOT wash in soIvent.
4. Place a circular piece of flat plate across
diaphragm fingers and insert feeler gauges
between plate and fingers.
Diaphragm finger clearance limit = 1.0 mm
5. Measure diaphragm finger height above bolted
surface of pressure plate. Renew pressure plate
if clearances are outside service limit. Diaphragm
finger height:
New clutch plate = 29.1 - 32.0 mm
Service limit = 36.5 mm
6. Using a socket and extension bar on crankshaft
pulley bolt, rotate crankshaft until flywheel
locking pin 18G 1523 can be inserted through
hole in gearbox mounting plate and into hole in
flywheel.
7. Progressively loosen and then remove 6 bolts
securing pressure plate to flywheel.
8. Remove clutch pressure plate and collect drive
plate.
9. Ìnspect clutch drive plate for signs of wear or oil
contamination. Check for broken or loose springs
and signs of cracking at spring windows. Renew
drive plate if necessary.
10. Measure depth of rivets on drive plate, renew
drive plate if less than service limit. Drive plate
rivet depth:
New clutch plate = 1.0 mm
Minimum Service limit = 0.2 mm
CLUTCH
33-6 REPAÌRS
11. Measure drive plate run-out by fitting drive plate
to a gearbox mainshaft and use a dial gauge as
drive plate is rotated. Renew drive plate if outside
service limit. Drive plate run-out:
New clutch plate = 0.8 mm
Service limit = 1.0 mm
12. 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.
NOTE: Renew a pressure plate which has been
accidentally dropped.
13. 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 service limit. Pressure plate warping:
Service limit = 0.18 mm maximum
Refit
1. Clean pressure plate and flywheel, dowels and
dowel holes.
2. Ìnspect 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 flywheel with 'FLYWHEEL
SÌDE' marking towards flywheel.
5. Fit pressure plate to flywheel and ensure located
on dowels.
6. Fit 6 bolts securing pressure plate to flywheel but
do not tighten.
7. Fit alignment tool 18G 1767 and secure to
gearbox adaptor plate with 3 bolts.
8. Rotate centre screw of 18G 1767 clockwise until
clutch is fully depressed.
9. Working in diagonal sequence, progressively
tighten bolts to 26 Nm.
10. Rotate centre screw of 18G 1767 anti-clockwise
to release clutch.
11. Remove 3 bolts and remove 18G 1767.
12. Remove flywheel locking pin tool 18G 1523.
13. Clean clutch release fork and release bearing
guide sleeve.
14. Smear release fork shaft and bore of release
bearing with Molybdenum disulphide grease.
15. Fit release bearing to release fork and slide onto
guide sleeve.
16. Operate release lever to ensure that release
bearing is correctly located on release fork and
slides smoothly on guide sleeve.
17. Fit gearbox assembly. See MANUAL GEARBOX
- 'PG1', Repairs.
CLUTCH
REPAÌRS 33-7
CLUTCH CABLE - 'R65' GEARBOX
´÷ 33.25.05
Remove
1. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect clutch cable from clutch release
lever.
4. Release cable from abutment bracket.
RHD models only:
5. Release clutch cable from clip on bracket.
All models:
6. Release 3 turnbuckles securing fuse box cover to
lower fascia.
7. Remove fuse box cover.
8. Release 2 turnbuckles securing closing panel to
underside of fascia.
9. Remove closing panel.
10. Release inner cable from clutch pedal and
withdraw cable through bulkhead into engine
compartment.
CLUTCH
33-8 REPAÌRS
11. Release clutch cable from between hoses and
cables and remove.
Refit
1. Lubricate rubber bush on clutch cable with RED
rubber grease.
2. Route cable between hoses and cables at rear of
engine and through bulkhead.
3. Connect inner cable to clutch pedal. Press rubber
bush fully into bulkhead tube so that steel washer
on cable is abutted.
4. Position closing panel to underside of fascia and
secure with turnbuckles.
5. Fit fuse box cover and secure with turnbuckles.
RHD models only:
6. Secure clutch cable to clip on bracket.
All models:
7. Feed clutch cable through abutment bracket and
connect to clutch release lever.
8. To check operation of self adjust mechanism, pull
clutch release lever through its full stroke and
then release.
9. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
CLUTCH CABLE - 'PG1' GEARBOX
´÷ 33.25.05
Remove
1. Remove air cleaner. 'L' series models: See
ENGINE MANAGEMENT SYSTEM - EDC,
Repairs. 'K' series models with 'VVC': See
ENGINE MANAGEMENT SYSTEM - MEMS,
Repairs.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect clutch cable from clutch release
lever.
4. Release cable from abutment bracket.
RHD models only:
5. Releae clutch cable from clip on coolant hose.
CLUTCH
REPAÌRS 33-9
All models:
6. Release 3 turnbuckles securing fuse box cover to
lower fascia.
7. Remove fuse box cover.
8. Release 2 turnbuckles securing closing panel to
underside of fascia.
9. Remove closing panel.
10. Release inner cable from clutch pedal and
withdraw cable through bulkhead into engine
compartment.
11. Release clutch cable from between hoses and
cables and remove.
Refit
1. Lubricate rubber bush on clutch cable with RED
rubber grease.
2. Route cable between hoses and cables at rear of
engine and through bulkhead.
3. Connect inner cable to clutch pedal. Press rubber
bush fully into bulkhead tube so that steel washer
on cable is abutted.
4. Position closing panel to underside of fascia and
secure with turnbuckles.
5. Fit fuse box cover and secure with turnbuckles.
RHD models only:
6. Secure clutch cable to clip on coolant hose.
All models:
7. Feed clutch cable through abutment bracket and
connect to clutch release lever.
8. To check operation of self adjust mechanism, pull
clutch release lever through its full stroke and
then release.
9. Remove stand(s) and lower vehicle.
10. Fit air cleaner. 'L' series models: See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs. 'K'
series with 'VVC': See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
CLUTCH
33-10 REPAÌRS
CLUTCH RELEASE FORK AND BUSHES -
'R65' GEARBOX
´÷ 33.25.18
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX - 'R65', Repairs.
2. Remove release bearing from guide sleeve and
release fork.
3. Remove roll pin securing release lever to release
fork shaft.
4. Remove release lever from release fork shaft.
5. Extract and discard both release fork bushes
from flywheel housing.
6. Withdraw release fork shaft from flywheel
housing.
7. Examine release bearing for signs of wear or
damage and renew if necessary.
CAUTION: Bearing is packed with grease, DO
NOT wash in soIvent.
Refit
1. Clean clutch release fork and release bearing
guide sleeve.
2. Smear release fork shaft and bore of release
bearing with Molybdenum disulphide grease.
3. Position release fork in flywheel housing.
4. Fit 2 new bushes ensuring that locating tags on
bushes engage in slots on housing.
5. Fit release lever to release fork shaft, align holes
in lever and shaft and secure with new roll pin.
6. Fit release bearing to release fork and slide onto
guide sleeve.
7. Operate release lever to ensure that release
bearing is correctly located on release fork and
slides smoothly on guide sleeve.
8. Fit gearbox assembly. See MANUAL GEARBOX
- 'R65', Repairs.
CLUTCH
REPAÌRS 33-11
CLUTCH RELEASE FORK - 'PG1'
GEARBOX
´÷ 33.25.18
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX - 'PG1', Repairs.
2. Remove release bearing from guide sleeve and
release fork.
3. Examine release bearing for signs of wear or
damage; renew if necessary.
CAUTION: Bearing is packed with grease, DO
NOT wash in soIvent.
4. Remove bolt and washer securing fork to release
shaft.
5. Withdraw clutch release shaft from gearbox and
remove fork.
6. Examine clutch release shaft for signs of scoring
or damage; renew if necessary.
7. Renew clutch release shaft bushes if necessary.
See PG1 MANUAL GEARBOX OVERHAUL
MANUAL.
Refit
1. Position release fork and fit clutch release shaft.
2. Align holes in release fork and shaft.
3. Fit bolt and washer securing release fork to shaft
and tighten to 29 Nm.
4. Fit release bearing to release fork and slide onto
guide sleeve.
5. Operate release lever to ensure that release
bearing is correctly located on release fork and
slides smoothly on guide sleeve.
6. Fit gearbox assembly. See MANUAL GEARBOX
- 'PG1', Repairs.
CLUTCH
33-12 REPAÌRS
MANUAL GEARBOX - 'R65'
ADJUSTMENTS 37-1-1
MANUAL GEARBOX - ' R65' ADJUSTMENTS
OIL DRAIN AND REFILL
´÷ 37.24.01
Drain
1. The oil should be drained when the gearbox is
warm and the vehicle is standing on a level
surface.
WARNING: Observe due care when draining
gearbox as oil can be very hot.
2. Position container beneath gearbox to catch oil
loss.
3. Clean area around gearbox filler/level plug.
4. Remove filler/level plug.
5. Remove gearbox drain plug and discard sealing
washer.
6. Allow gearbox oil to drain.
RefiII
1. Clean gearbox drain plug and fit new sealing
washer.
2. Fit drain plug and tighten to 25 Nm.
3. Fill gearbox through filler level hole, until oil is
level with filler/level hole. Allow sufficient time for
oil to reach a common level within gearbox. Use
the correct specification oil. See INFORMATION,
Capacities, FIuids and Lubricants.
4. Fit filler level plug and tighten to 25 Nm.
5. Remove container positioned to collect gearbox
oil.
MANUAL GEARBOX - 'R65'
37-1-2 ADJUSTMENTS
MANUAL GEARBOX - 'R65'
REPAÌRS 37-1-3
REPAÌ RS
GEAR SELECTOR MOUNTING
´÷ 37.16.25
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 2 bolts securing mounting to body.
3. Remove mounting plate and rubber from gear
selector.
Refit
1. Position mounting rubber and plate, fit and
tighten bolts to 22 Nm.
2. Remove stand(s) and lower vehicle.
GEARBOX - 'K16'
´÷ 37.20.02.99
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel(s).
4. Remove starter motor. See ELECTRICAL,
Repairs.
5. Disconnect speed sensor transducer multiplug.
6. Disconnect reverse light switch multiplug.
7. Release battery positive lead from clip on
gearbox.
8. Disconnect clutch cable from clutch release
lever.
9. Release clutch cable from abutment bracket on
gearbox and position aside.
MANUAL GEARBOX - 'R65'
37-1-4 REPAÌRS
10. Using tool 18G 1592 release gear selector
linkage ball joint from gear selector lever.
11. Using tool 18G 1592 release gear change linkage
ball joint from gear change lever.
12. Remove 2 bolts securing steady bar and remove
steady bar.
13. Remove 2 bolts securing mounting bracket to
flywheel housing.
14. Remove mounting bracket from flywheel
housing.
15. Remove bolt securing flywheel rear cover plate to
flywheel housing.
16. Remove flywheel rear cover plate.
17. Drain gearbox oil. See MANUAL GEARBOX -
'R65', Adjustments.
18. Remove both drive shafts from gearbox. See
DRIVE SHAFTS, Repairs.
19. Remove LH front tie rod. See FRONT
SUSPENSION, Repairs.
20. Release 2 clips securing starter motor cable to
flywheel front cover plate.
21. Remove 3 bolts securing flywheel front cover
plate to flywheel housing.
22. Remove flywheel front cover plate.
23. Fit lifting eye to gearbox and connect suitable
lifting equipment to lifting eye.
24. Take weight of gearbox with lifting equipment.
MANUAL GEARBOX - 'R65'
REPAÌRS 37-1-5
25. Remove through bolt securing engine LH
mounting to body bracket.
26. Remove 2 bolts securing engine LH mounting to
gearbox mounting bracket.
27. Remove engine LH mounting.
28. Fit wooden block to jack and position jack to
support engine.
29. Remove 2 upper bolts securing gearbox to
engine.
30. Remove 5 lower bolts securing gearbox to
engine.
31. With assistance, release gearbox from engine.
32. Manoeuvre gearbox from engine and lower from
vehicle.
33. Disconnect lifting equipment from gearbox and
remove gearbox from beneath vehicle.
Refit
1. Clean mating faces of engine and flywheel
housing.
2. Lightly grease gearbox splines.
3. Position gearbox beneath vehicle and connect
lifting equipment.
4. With assistance, raise gearbox and manoeuvre
into position, locate on 2 engine dowels.
5. Fit 5 lower bolts securing gearbox to engine.
6. Clean and degrease threads of 2 upper bolts
securing gearbox to engine.
7. Apply Loctite 243 to threads of 2 upper bolts.
8. Fit 2 upper bolts securing gearbox to engine and
tighten to 85 Nm.
9. Tighten lower bolts securing gearbox to engine to
85 Nm.
10. Position engine LH mounting.
11. Raise engine, align gearbox mounting bracket to
engine mounting, fit bolts and tighten to 60 Nm.
12. Fit through bolt securing LH mounting to body
and tighten to 85 Nm.
13. Remove jack and disconnect lifting equipment.
MANUAL GEARBOX - 'R65'
37-1-6 REPAÌRS
14. Fit flywheel front cover plate and tighten bolts to
9 Nm.
15. Secure starter motor cable clip to flywheel front
cover plate.
16. Fit flywheel rear cover plate and tighten bolt to 9
Nm.
17. Fit mounting bracket to flywheel housing and
secure with bolts.
18. Fit steady bar, fit bolts and tighten to 25 Nm.
19. Fit LH front tie rod. See FRONT SUSPENSION,
Repairs.
20. Fit both drive shafts to gearbox.See DRIVE
SHAFTS, Repairs.
21. Using tool 18G 1594 connect gear change
linkage ball joint to gear change lever.
22. Using tool 18G 1594 connect gear selector
linkage ball joint to gear selector lever.
23. Connect multiplug to reverse lamp switch.
24. Feed clutch cable through abutment bracket and
connect to clutch release lever.
25. Connect speed sensor multiplug.
26. Secure battery positive lead to clip.
27. Fit starter motor. See ELECTRICAL, Repairs.
28. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
29. Remove stand(s) and lower vehicle.
30. Connect battery earth lead.
31. Refill gearbox with oil. See MANUAL GEARBOX
- 'R65', Adjustments.
SEAL - INPUT SHAFT
´÷ 37.23.06
Remove
1. Remove gearbox assembly. See MANUAL
GEARBOX - 'R65', Repairs.
2. Remove clutch release bearing from guide
sleeve and release fork.
3. Remove and discard 3 bolts securing release
bearing guide sleeve to gearbox.
4. Remove and discard release bearing guide
sleeve from gearbox.
MANUAL GEARBOX - 'R65'
REPAÌRS 37-1-7
Refit
1. Fit guide sleeve onto input shaft and align bolt
holes to those in gearbox.
2. Fit 3 new bolts securing guide sleeve to gearbox.
3. Fit clutch release bearing to release fork.
4. Fit gearbox assembly. See MANUAL GEARBOX
- 'R65', Repairs.
SEAL - SELECTOR SHAFT
´÷ 37.23.10
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove LH front wheel.
3. Remove engine LH mounting. See ENGINE -
'K16', Repairs.
4. Using tool 18G 1592 release gear selector
linkage ball joint from gear selector lever.
5. Accessed from under the LH wheel arch and
requiring assistance, use a punch and extension
pieces to drive out roll pin retaining selector lever
to selector shaft. Discard roll pin.
6. Lower engine and remove selector lever from
selector shaft.
7. Raise engine, remove and discard selector shaft
oil seal.
MANUAL GEARBOX - 'R65'
37-1-8 REPAÌRS
Refit
1. Clean oil seal recess and gearbox casing around
oil seal location.
2. Clean gearbox selector shaft and selector lever.
3. Lubricate new oil seal with clean gearbox oil.
4. Locate oil seal on shaft with sealing lip towards
casing.
5. Press seal fully home into recess of gearbox
housing using a 10 mm plug socket.
6. Lower engine, fit selector lever to selector shaft,
7. Align holes in shaft and lever and fit new roll pin.
8. Using assistance, drift roll pin into position to
retain lever on shaft.
9. Connect gear selector linkage to selector lever.
10. Fit engine LH mounting. See ENGINE - 'K16',
Repairs.
11. Fit LH front wheel and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
12. Remove stand(s) and lower vehicle.
REVERSE LAMP SWITCH
´÷ 37.27.01
Remove
1. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
2. Disconnect multiplug from reverse lamp switch.
3. Remove reverse lamp switch and discard sealing
washer.
Refit
1. Clean mating faces of reverse lamp switch and
gearbox.
2. Fit new sealing washer to reverse lamp switch.
3. Fit reverse lamp switch and tighten to 25 Nm.
4. Connect multiplug to reverse lamp switch
5. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
MANUAL GEARBOX - 'R65'
REPAÌRS 37-1-9
DIFFERENTIAL OIL SEAL - R65
´÷ 54.10.18
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove drive shaft. See DRIVE SHAFTS,
Repairs.
3. Position container to collect oil loss from gearbox.
4. Carefully prise oil seal out of differential housing
and discard oil seal.
Refit
1. Thoroughly clean oil seal recess and splines of
drive shaft.
2. Fit 18G 1354-16 onto 18G 1354, position new
oil seal onto 18G 1354-16 with sealing lip facing
towards housing.
3. Carefully drift oil seal into differential housing until
it is fully seated in recess.
4. Remove tool 18G 1354 and 18G 1354-16.
5. Fit drive shaft. See DRIVE SHAFTS, Repairs.
6. Remove stand(s) and lower vehicle.
7. Top-up gearbox oil. See MAINTENANCE.
MANUAL GEARBOX - 'R65'
37-1-10 REPAÌRS
MANUAL GEARBOX - 'PG1'
ADJUSTMENTS 37-2-1
MANUAL GEARBOX - ' PG1' ADJUSTMENTS
OIL DRAIN AND REFILL
´÷ 37.24.01
Drain
1. The oil should be drained when the gearbox is
warm and the vehicle is standing on a level
surface.
WARNING: Observe due care when draining
gearbox as oil can be very hot.
'L´ series models
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
All models
3. Position container beneath gearbox to catch oil
loss.
4. Clean area around gearbox filler/level plug.
5. Remove filler/level plug.
6. Remove gearbox drain plug and discard sealing
washer.
7. Allow gearbox oil to drain.
RefiII
1. Clean gearbox drain plug and fit new sealing
washer.
2. Fit drain plug and tighten to 45 Nm.
3. Fill gearbox through filler level hole, until oil is
level with filler/level hole. Allow sufficient time for
oil to reach a common level within gearbox. Use
the correct specification oil. See INFORMATION,
Capacities, FIuids and Lubricants.
4. Fit filler level plug and tighten to 40 Nm.
5. Remove container positioned to collect gearbox
oil.
'L´ series models
6. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
MANUAL GEARBOX - 'PG1'
37-2-2 ADJUSTMENTS
MANUAL GEARBOX - 'PG1'
REPAÌRS 37-2-3
REPAÌ RS
GEAR SELECTOR MOUNTING
´÷ 37.16.25
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 2 bolts securing mounting to body.
3. Remove mounting plate and rubber from gear
selector.
Refit
1. Position mounting rubber and plate, fit and
tighten bolts to 22 Nm.
2. Remove stand(s) and lower vehicle.
MANUAL GEARBOX - 'K16 WITH VVC'
´÷ 37.20.02.99
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Drain gearbox oil. See MANUAL GEARBOX -
'PG1', Adjustments.
3. Remove starter motor. See ELECTRICAL,
Repairs.
4. Release clutch cable from lever and abutment
bracket. Position cable clear of gearbox.
5. Remove bolt securing earth lead to gearbox.
6. Disconnect 2 reverse lamp switch leads from
engine harness.
7. Disconnect multiplug from vehicle speed sensor.
8. Remove bolt securing A/C pipe bracket to
bracket secured by top gearbox housing bolts.
9. Remove exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS - 'K' Series, Repairs.
MANUAL GEARBOX - 'PG1'
37-2-4 REPAÌRS
10. Loosen bolt securing lower engine steady to
subframe.
11. Remove bolt securing lower engine steady to
mounting bracket on sump, release engine
steady from bracket.
12. Remove bolt and disconnect gear change steady
bar from gearbox, collect 2 washers.
13. Remove clip retaining selector rod roll pin.
14. Using a suitable punch, drive out roll pin securing
selector rod to selector shaft. discard roll pin.
15. Release selector rod from selector shaft.
16. Tie selector rod and steady bar aside.
17. Release LH and RH drive shafts from gearbox.
See DRIVE SHAFTS, Repairs.
18. Remove LH front tie bar. See FRONT
SUSPENSION, Repairs.
19. Remove 2 bolts securing gearbox housing to
engine sump.
20. Fit wooden block to jack and position jack to
support engine.
21. Remove 3 nuts and bolts securing gearbox to
engine and collect front closing plate.
MANUAL GEARBOX - 'PG1'
REPAÌRS 37-2-5
22. Remove bolt at rear of engine, securing engine to
differential housing.
23. Remove through bolt securing engine LH
mounting bracket to body.
24. Remove 2 bolts securing engine LH mounting to
bracket on gearbox and remove mounting.
25. Lower engine and gearbox assembly sufficiently
to gain access to remove gearbox mounting
bracket bolts.
26. Loosen bolt securing torsion bar to gearbox
mounting bracket and remove nut securing
torsion bar to gearbox.
27. Remove 2 bolts securing mounting bracket to
gearbox and remove bracket and torsion bar as
an assembly.
28. Remove gearbox housing bolt as shown, secure
a suitable lifting eye to gearbox housing with
original bolt.
29. Connect suitable lifting equipment to lifting eye.
30. Remove 2 top bolts securing gearbox to engine.
MANUAL GEARBOX - 'PG1'
37-2-6 REPAÌRS
Models with A/C
31. Collect A/C pipe mounting bracket.
All models
32. Release gearbox from 2 locating dowels,
manoeuvre and lower gearbox to floor.
Refit
1. Clean mating face of engine and gearbox.
2. Clean dowels and dowel holes.
3. Ìnspect differential oil seals for signs of damage;
renew if necessary.
4. Lightly grease gearbox splines.
5. Raise gearbox, align to dowels and secure to
engine.
6. Position front closing plate, fit nuts and bolts and
tighten to 85 Nm.
7. Fit rear bolt securing engine to differential and
tighten to 85 Nm.
8. Fit 2 lower bolts securing gearbox to engine
sump and tighten to 45 Nm.
9. Position A/C pipe mounting bracket to top of
gearbox housing.
10. Clean and degrease threads of 2 top bolts
securing gearbox to engine.
11. Apply Loctite 243 to threads of 2 top bolts.
12. Fit top bolts securing gearbox to engine and
tighten to 85 Nm.
13. Disconnect lifting equipment from lifting eye.
14. Remove bolt securing lifting eye to gearbox,
remove lifting eye. Refit bolt to gearbox and
tighten to 45 Nm.
15. Position mounting bracket and torsion bar to
gearbox, fit bolts securing mounting bracket to
gearbox and tighten to 60 Nm.
16. Fit nut securing torsion bar to gearbox, tighten
nut and bolt to 25 Nm.
17. Position engine LH mounting to gearbox
mounting bracket, fit bolts and tighten to 100 Nm.
18. Raise engine and gearbox and align engine LH
mounting to bracket on body.
19. Fit through bolt and tighten to 85 Nm.
20. Remove jack supporting engine and gearbox.
21. Fit exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
22. Connect LH and RH drive shafts. See DRIVE
SHAFTS, Repairs.
23. Fit LH front tie bar. See FRONT SUSPENSION,
Repairs.
24. Clean mating faces of gear change selector and
steady rod.
25. Connect selector rod to shaft and align holes.
26. Fit new roll pin securing selector rod to shaft and
fit roll pin retaining clip.
27. Fit washers to gear change steady bar and
connect to gearbox.
28. Fit bolt securing gear change steady bar to
gearbox and tighten to 10 Nm.
29. Position lower engine steady to mounting bracket
on sump, fit and tighten bolt to 100 Nm.
30. Tighten bolt securing lower engine steady to
subframe to 100 Nm.
31. Connect multiplug to vehicle speed sensor.
32. Connect reverse lamp switch leads to engine
harness.
33. Position earth lead to gearbox, fit bolt and tighten
to 25 Nm.
Models with A/C
34. Align A/C pipe bracket to bracket on gearbox
housing, fit and tighten bolt to 9 Nm.
All models
35. Feed clutch cable through abutment bracket and
connect to clutch release lever.
36. Fit starter motor. See ELECTRICAL, Repairs.
37. Remove stand(s) and lower vehicle.
38. Fill gearbox with oil. See MANUAL GEARBOX -
'PG1', Adjustments.
MANUAL GEARBOX - 'PG1'
REPAÌRS 37-2-7
MANUAL GEARBOX - 'L' SERIES
´÷ 37.20.02.99
Remove
1. Disconnect battery earth lead.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
4. Release clutch cable from lever and abutment
bracket. Position cable clear of gearbox.
5. Release positive battery cable from clip on
battery tray.
6. Loosen 3 lower bolts and remove 3 upper bolts
securing battery tray.
7. Release battery tray from lower bolts.
8. Release and disconnect 2 multiplugs from EDC
ECM and remove battery tray.
9. Remove starter motor. See ELECTRICAL,
Repairs.
10. Drain oil from gearbox. See MANUAL
GEARBOX - 'PG1', Adjustments.
MANUAL GEARBOX - 'PG1'
37-2-8 REPAÌRS
11. Remove bolt and move 2 earth leads from
gearbox.
12. Disconnect 2 reverse lamp switch leads from
engine harness.
13. Disconnect multiplug from MAF sensor.
14. Loosen clip and disconnect crankcase breather
valve from air intake pipe.
15. Loosen clip and remove air intake pipe from
turbocharger.
16. Remove nut and release coolant rail from support
bracket.
17. Disconnect multiplug from vehicle speed sensor.
18. Remove nut and move CKP sensor multiplug
bracket from gearbox stud.
MANUAL GEARBOX - 'PG1'
REPAÌRS 37-2-9
19. Remove bolt and disconnect gear change steady
bar from gearbox, collect 2 washers.
20. Remove clip retaining selector rod roll pin.
21. Using a suitable punch, drive out roll pin securing
selector rod to selector shaft.
22. Release selector rod from selector shaft and tie
selector rod and steady bar aside.
23. Remove both drive shafts as detailed in
differential oil seals. See DRIVE SHAFTS,
Repairs.
24. Remove LH front tie rod. See FRONT
SUSPENSION, Repairs.
25. Fit wooden block to jack and position jack to
support engine.
26. Loosen through bolt securing engine LH
mounting to bracket on body.
27. Remove 2 bolts securing engine LH mounting to
bracket on gearbox.
28. Lower engine and gearbox for access to gearbox
mounting bracket bolts.
29. Loosen bolt securing torsion bar to gearbox
mounting bracket and remove nut torsion bar to
gearbox.
30. Remove 2 bolts and remove mounting bracket
and torsion bar assembly from gearbox.
31. Remove gearbox bolt, fit suitable lifting eye and
refit bolt to secure eye.
MANUAL GEARBOX - 'PG1'
37-2-10 REPAÌRS
32. Connect lifting chains to eye and take weight of
gearbox.
33. Remove bolt securing support bracket to sump.
34. Remove 2 lower bolts securing gearbox and
support bracket to mounting plate. Remove
support bracket.
35. Remove 2 bolts securing gearbox to mounting
plate.
36. Remove 2 nuts and bolts securing gearbox to
mounting plate.
37. Remove upper bolt securing gearbox to
mounting plate.
38. With assistance, release gearbox from locating
dowels on mounting plate, lower and remove
gearbox from under vehicle.
SP370015
M37 1673A
MANUAL GEARBOX - 'PG1'
REPAÌRS 37-2-11
Refit
1. Clean mating face of gearbox and mounting
plate.
2. Ìnspect differential oil seals for signs of damage;
renew if necessary.
3. Lightly grease gearbox splines.
4. Position gearbox beneath vehicle and connect
lifting equipment.
5. With assistance, raise gearbox and manoeuvre
into position. Locate gearbox on dowels in
mounting plate.
6. Fit upper bolt securing gearbox to mounting plate
and tighten to 85 Nm.
7. Fit 2 nuts and bolts securing gearbox to mounting
plate and tighten to 85 Nm.
8. Fit bolt at rear of engine securing gearbox to
mounting plate and tighten to 85 Nm.
9. Fit support bracket and tighten bolts securing
gearbox to 85 Nm and bolt into sump to 45 Nm.
10. Disconnect lifting chains from eye and move
chains clear.
11. Remove lifting eye, fit and tighten bolt to 45 Nm.
12. Position mounting bracket to gearbox, fit bolts
and tighten to 60 Nm.
13. Tighten nuts securing torsion bar to gearbox and
LH engine mounting to 25 Nm.
14. Raise engine and gearbox and align to engine LH
mounting. Tighten bolts securing mounting to
bracket on gearbox to 100 Nm.
15. Tighten LH mounting through bolt to 85 Nm.
16. Remove jack supporting engine and gearbox.
17. Fit LH front tie rod. See FRONT SUSPENSION,
Repairs.
18. Fit both drive shafts as detailed in differential oil
seals. See DRIVE SHAFTS, Repairs.
19. Connect gear selector rod to selector shaft and fit
new roll pin.
20. Fit clip to retain roll pin.
21. Fit gear change steady bar with washers to
gearbox and tighten retaining bolt to 10 Nm.
22. Fit CKP sensor multiplug bracket to gearbox and
tighten nut to 25 Nm.
23. Connect multiplug to vehicle speed sensor.
24. Fit coolant rail to bracket and secure with nut.
25. Fit intake pipe to turbocharger and tighten clip.
26. Fit crankcase breather valve to air intake pipe
and tighten clip.
27. Connect multiplug to MAF sensor.
28. Connect reverse lamp switch leads.
29. Position earth leads to gearbox and tighten bolt to
25 Nm.
30. Fit starter motor. See ELECTRICAL, Repairs.
31. Position battery tray, connect and secure
multiplugs to EDC ECM.
32. Fit battery tray onto lower bolts, fit upper bolts
and tighten all bolts to 10 Nm.
33. Fit positive battery cable to clip on battery tray.
34. Fit clutch cable through abutment bracket and
connect to clutch release lever.
35. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
36. Fill gearbox with oil. See MANUAL GEARBOX -
'PG1', Adjustments.
37. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
38. Remove stand(s) and lower vehicle.
MANUAL GEARBOX - 'PG1'
37-2-12 REPAÌRS
OIL SEAL- SELECTOR SHAFT
´÷ 37.23.10
Remove
1. Disconnect battery earth lead.
'L´ series models:
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
All models
3. Raise front of vehicle.
WARNING: Support on safety stands.
4. Remove bolt and disconnect gear change steady
bar from gearbox; collect 2 washers.
5. Remove clip retaining selector rod roll pin.
6. Using a suitable punch, drive out roll pin securing
selector rod to selector shaft. Discard roll pin.
7. Release selector rod from selector shaft.
8. Position container beneath gearbox to catch fluid
loss.
9. Remove gaiter from selector shaft.
10. Remove and discard selector shaft oil seal.
Refit
1. Clean selector shaft.
2. Using a suitable piece of tubing, fit new selector
shaft oil seal.
3. Fit gaiter to selector shaft and ensure lip on gaiter
is located in grove on gearbox casing.
4. Remove container from beneath gearbox.
5. Connect selector rod to shaft and align holes.
6. Fit new roll pin securing selector rod to shaft and
fit roll pin retaining clip.
7. Fit washers to gear change steady bar and
connect to gearbox.
8. Fit bolt securing gear change steady bar to
gearbox and tighten to 10 Nm.
'L´ series models
9. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
All models
10. Remove stand(s) and lower vehicle.
11. Top-up gearbox oil. See MAINTENANCE.
12. Connect battery earth lead.
MANUAL GEARBOX - 'PG1'
REPAÌRS 37-2-13
REVERSE LAMP SWITCH
´÷ 37.27.01
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
'L´ series models
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
All models
3. Disconnect 2 reverse lamp switch leads from
engine harness.
4. Remove reverse lamp switch and discard sealing
washer.
Refit
1. Clean reverse lamp switch and fit new sealing
washer.
2. Fit reverse lamp switch and tighten to 25 Nm.
3. Connect reverse lamp switch leads to engine
harness.
'L´ series models
4. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
All models
5. Remove stand(s) and lower vehicle.
DIFFERENTIAL OIL SEAL - LH
´÷ 54.10.18
Remove
1. Remove drive shaft. See DRIVE SHAFTS,
Repairs.
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 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. Fit drive shaft. See DRIVE SHAFTS, Repairs.
MANUAL GEARBOX - 'PG1'
37-2-14 REPAÌRS
DIFFERENTIAL OIL SEAL - RH
´÷ 54.10.21
Remove
1. Remove drive shaft. See DRIVE SHAFTS,
Repairs.
2. Carefully prise oil seal out of differential housing
and discard oil seal.
Refit
1. Thoroughly clean oil seal recess in differential
housing, splines and oil seal running surface on
drive shaft.
2. Fit 18G 1354-16 onto 18G 1354.
3. Position new seal onto 18G 1354-16 with sealing
lip facing towards differential housing.
4. Carefully drift oil seal into differential housing until
it is fully seated in recess.
5. Remove 18G 1354 and 18G 1354-16.
6. Fit drive shaft. See DRIVE SHAFTS, Repairs.
AUTOMATÌC GEARBOX - 'EM-CVT'
ADJUSTMENTS 44-1
AUTOMATÌC GEARBOX - 'EM-CVT' ADJUSTMENTS
DRAIN AND REFILL
´÷ 44.24.02
NOTE: The fluid should be drained with the gearbox at
normal operating temperature.
WARNING: Observe due care when draining
gearbox fluid, as the fluid will be very hot.
Drain
1. Release 2 clips securing hose to air cleaner and
throttle body.
2. Remove air intake hose.
3. Remove dipstick.
4. Raise front of vehicle.
WARNING: Support on safety stands.
5. Position container to collect fluid from gearbox.
6. Remove drain plug using an 8 mm Allen key and
discard sealing washer.
7. Allow fluid to drain into container.
NOTE: Approximately 1 litre of fluid is retained in
the primary and secondary cylinders 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.
3. Remove stand(s) and lower vehicle.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-2 ADJUSTMENTS
4. Using a funnel on the end of the dipstick tube,
carefully fill gearbox to the minimum mark with
new CVT fluid. See INFORMATION, Capacities,
FIuids and Lubricants.
5. Replace dipstick tube.
6. Start engine and run until normal operating
temperature is achieved.
7. Chock the wheels, apply footbrake and
handbrake. 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.
9. Fit hose between air cleaner and throttle body
and secure with clips.
SELECTOR CABLE
´÷ 44.30.04
Adjust
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Move gear selector lever to position 'P'.
3. Loosen nut securing selector cable rod to
selector lever.
4. Push selector lever fully forwards.
5. Ensure the park mechanism is engaged by trying
to rotate both front wheels.
6. Tighten nut securing selector cable rod to
selector lever to 6 Nm.
7. Remove stand(s) and lower vehicle.
8. Check that vehicle will only start in position 'P'
and 'N'.
9. Check that forward drive is achieved in position
'D' and 'M', and reverse drive in position 'R'.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-3
REPAÌ RS
LEVER - GEAR CHANGE
´÷ 44.15.04
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove front pipe heat shield. See MANIFOLD
& EXHAUST SYSTEMS, Repairs.
4. Remove 6 nuts securing gear lever assembly to
body.
5. Remove front console. See INTERIOR TRIM
COMPONENTS, Repairs.
6. Remove 'C' clip securing outer cable to gear
lever housing.
7. Release inner cable ball joint from gear lever.
8. Disconnect PRND switch multiplug.
9. Release carpet from gear lever assembly.
10. Remove gear lever assembly.
Refit
1. Position gear lever assembly and engage outer
cable.
2. Secure inner cable ball joint to gear lever and
secure outer cable with 'C' clip.
3. Connect PRND switch multiplug.
4. Secure carpet to gear lever assembly.
5. Fit nuts securing lever assembly to floor and
tighten to 10 Nm.
6. Fit front pipe heat shield. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
7. Fit centre console. See INTERIOR TRIM
COMPONENTS, Repairs.
8. Connect battery earth lead.
9. Remove stand(s) and lower vehicle.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-4 REPAÌRS
KNOB - GEAR SELECTION
´÷ 44.15.07
Remove
1. Release gear selection knob from lever and
remove gear selection knob.
Refit
1. Position gear selection knob and engage to lever.
CABLE - GEAR CHANGE
´÷ 44.15.08
Remove
1. Disconnect battery earth lead.
2. Remove centre console. See INTERIOR TRIM
COMPONENTS, Repairs.
3. Release inner cable ball joint from gear lever.
4. Remove 'C' clip securing outer cable to gear
lever housing.
5. Raise front of vehicle.
WARNING: Support on safety stands.
6. Remove front pipe heat shield. See MANIFOLD
& EXHAUST SYSTEMS - 'K' Series, Repairs.
7. Loosen nut securing inner cable to selector lever.
8. Release catch on outer cable and release cable
from support bracket on gear box.
9. Release outer cable from support clip and gear
lever assembly and remove cable.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-5
Refit
1. Position gear change cable to gear lever housing
and support clip.
2. Locate inner cable in selector lever and secure
outer cable in support bracket.
3. Secure outer cable to gear lever housing with 'C'
clip and inner cable to gear lever.
4. Check cable adjustment. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
5. Fit front pipe heat shield. See MANIFOLD &
EXHAUST SYSTEMS - 'K' Series, Repairs.
6. Fit centre console. See INTERIOR TRIM
COMPONENTS, Repairs.
7. Connect battery earth lead.
8. Remove stand(s) and lower vehicle.
SWITCH - STARTER INHIBITOR/REVERSE
´÷ 44.15.19
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Drain gearbox fluid. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
3. Disconnect multiplug from switch.
4. Loosen and remove switch from gearbox.
5. Remove and discard 'O' ring from switch.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-6 REPAÌRS
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.
5. Remove stand(s) and lower vehicle.
6. Refill gearbox fluid. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
SELECTOR SHAFT SEAL
´÷ 44.15.34
Remove
1. Remove sump. See ENGINE - 'K16', Repairs.
2. Move gear selector lever to position 'P'.
3. Remove nut securing selector cable rod to
selector lever.
4. Release selector cable rod from selector lever.
5. Remove nut and washer securing selector lever
to selector shaft.
6. Release and remove lever from selector shaft.
7. Remove and discard selector shaft seal.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-7
Refit
1. Clean selector shaft and seal register.
2. Lubricate oil seal with gearbox fluid and fit over
selector shaft.
3. Push oil seal into place in gearbox casing using
suitable size socket.
4. Clean selector lever.
5. Fit nut securing selector lever to selector shaft
and tighten to 8 Nm.
6. Connect selector cable rod to selector lever but
DO NOT tighten nut.
7. Fit sump. See ENGINE - 'K16', Repairs.
8. Top-up gearbox fluid. See MAINTENANCE.
9. Adjust selector cable. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
SENSOR - SPEED
´÷ 44.15.47
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect speed sensor multiplug from
harness.
4. Remove bolt securing sensor to gearbox.
5. Release speed sensor from gearbox and remove
sensor. Remove and discard 'O' ring.
Refit
1. Clean sealing faces of sensor and gearbox.
2. Lubricate new 'O' ring with gearbox fluid and fit to
sensor.
3. Fit sensor to gearbox and tighten bolt to 9 Nm.
4. Connect multiplug to harness.
5. Remove stand(s) and lower vehicle.
6. Connect battery earth lead.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-8 REPAÌRS
GEARBOX INTERFACE UNIT (GIU)
´÷ 44.15.81
Remove
1. Disconnect battery earth lead.
2. Remove 2 bolts securing GÌU to support plate,
located underneath heater unit.
3. Release GÌU, release and disconnect GÌU
multiplug.
4. Remove GÌU.
Refit
1. Position new GÌU, connect and secure multiplug.
NOTE: Ensure RH bolt is located in GIU before
fitting.
2. Fit GÌU to support plate, fit and tighten bolts.
3. Connect battery earth lead.
HARNESS - RATIO CONTROL MOTOR
´÷ 44.15.82
Remove
1. Remove fluid filter. See AUTOMATIC
GEARBOX - 'EM-CVT', Repairs.
2. Remove bolt securing selector quadrant detent
lever and remove lever.
3. Remove bolt arrowed and fit secondary valve
restraining tool 44-025.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-9
4. Remove 11 bolts securing valve body to casing.
NOTE: DO NOT remove the 4 bolts securing the
selector valve.
5. Release valve body from selector quadrant.
CAUTION: Take care not to dispIace seIector
vaIve spooI.
6. Disconnect ratio control motor multiplug and
remove valve body assembly.
7. Disconnect connector block multiplug.
8. Remove nut securing connector block to casing
and remove harness.
9. Remove and discard 'O' ring.
Refit
1. Clean connector block and gearbox mating faces
with lint free cloth.
2. Lubricate new 'O' ring with clean fluid and fit to
connector block.
3. Position connector block in casing, fit nut and
tighten to 9 Nm. Ensure connector block does not
rotate when nut is tightened.
4. Connect connector block multiplug.
5. Clean valve body and casing mating faces with
lint free cloth.
6. Position valve body and connect ratio control
motor multiplug.
CAUTION: Take care not to dispIace seIector
vaIve spooI.
7. Align valve body to selector quadrant, fit and
lightly tighten bolts.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-10 REPAÌRS
8. Remove secondary valve restraining tool 44-
025, and fit remaining bolt.
CAUTION: Ensure correct aIignment of
secondary vaIve shoe and secondary drum
position fork, incorrect aIignment wiII
damage the gearbox.
9. Tighten bolts in the sequence shown to 10 Nm.
10. Position selector quadrant detent lever, fit bolt
and tighten to 10 Nm.
11. Fit fluid filter. See AUTOMATIC GEARBOX -
'EM-CVT', Repairs.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-11
MOTOR - RATIO CONTROL
´÷ 44.15.83
Remove
1. Remove fluid filter. See AUTOMATIC
GEARBOX - 'EM-CVT', Repairs.
2. Remove bolt securing selector quadrant detent
lever and remove lever.
3. Remove bolt arrowed and fit secondary valve
restraining tool 44-025.
4. Remove 11 bolts securing valve body to casing.
NOTE: DO NOT remove the 4 bolts securing
selector valve at this stage.
5. Release valve body from selector quadrant.
CAUTION: Take care not to dispIace seIector
vaIve spooI.
6. Disconnect ratio control motor multiplug and
remove valve body assembly.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-12 REPAÌRS
7. Remove 4 bolts securing selector valve and
remove selector valve.
8. Remove top cover from valve body.
CAUTION: Do not disturb vaIve baIIs or
spring.
9. Remove pin securing ratio control motor and
remove ratio control motor.
Refit
1. Clean ratio control motor and mating faces with a
lint free cloth.
2. Position ratio control motor and secure with pin.
3. Clean mating faces of valve body, top and bottom
cover plates with a lint free cloth.
4. Position cover plates and locate on dowel,
position selector valve and locate on dowel.
5. Fit bolts securing selector valve and tighten to 10
Nm.
6. Clean valve body and casing mating faces with a
lint free cloth.
7. Position valve body and connect ratio control
motor multiplug.
8. Align valve body to selector quadrant, fit and
lightly tighten bolts.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-13
9. Remove secondary valve restraining tool 44-
025, and fit remaining bolt.
CAUTION: Ensure correct aIignment of
secondary vaIve shoe and secondary drum
position fork, incorrect aIignment wiII
damage the gearbox.
10. Tighten bolts in the sequence shown to 10 Nm.
11. Position selector quadrant detent lever, fit bolt
and tighten to 10 Nm.
12. Fit fluid filter. See AUTOMATIC GEARBOX -
'EM-CVT', Repairs.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-14 REPAÌRS
GEARBOX - ABS - WITH A/C
´÷ 44.20.02.99
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove road wheel(s).
4. Drain gearbox fluid. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
5. Remove drive shafts. See DRIVE SHAFTS,
Repairs.
6. Remove 3 bolts securing flywheel front cover
plate and remove cover plate.
7. Loosen nut securing starter lead and release lead
and disconnect Lucar.
8. Release starter lead from clip on oil filler pipe.
9. Remove 2 bolts securing starter motor and
remove starter motor.
10. Disconnect ratio control motor multiplug.
11. Remove bolt securing engine earth lead to
gearbox and position earth lead aside.
12. Loosen fluid cooler unions and release fluid
cooler pipes.
13. Remove and discard 'O' rings.
CAUTION: PIug the connections.
14. Disconnect multiplugs from vehicle speed sensor
and transducer.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-15
15. Disconnect multiplug from starter inhibitor/
reverse switch and release harness from clip.
16. Remove nut securing selector cable rod to
selector lever.
17. Release selector cable rod from selector lever.
18. Release selector cable from abutment bracket.
19. Disconnect rubber mounting securing front pipe
to body.
20. Remove 2 nuts securing front pipe to exhaust
manifold, release front pipe and collect gasket.
NOTE: Support the front pipe, do not allow the
exhaust pipe to hang on the flexible joint.
Models with air conditioning
21. Remove bolt securing air conditioning pipe to
mounting bracket.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-16 REPAÌRS
All models
22. Fit bolt securing lifting bracket to gearbox.
23. Remove 2 bolts securing flywheel rear cover
plate to flywheel housing.
24. Remove flywheel rear cover plate.
25. Fit wooden block to jack and position jack to
support engine.
26. Connect suitable lifting equipment to mounting
bracket on gearbox.
27. Take weight of gearbox with lifting equipment.
28. Remove engine LH mounting. See ENGINE -
'K16', Repairs.
29. Remove 2 lower bolts securing gearbox to
engine.
30. Remove 2 upper bolts securing gearbox to
engine.
Models with air conditioning
31. Collect mounting bracket.
All models
32. With assistance, release gearbox from engine.
33. Manoeuvre gearbox from engine and lower from
vehicle.
34. Disconnect lifting equipment from gearbox and
remove gearbox from beneath vehicle.
Refit
1. Clean mating faces of engine and flywheel
housing.
CAUTION: Do not appIy grease to gearbox
input shaft spIines.
2. Position gearbox beneath vehicle and connect
lifting equipment.
3. With assistance, raise gearbox and manoeuvre
into position. Locate on 2 dowels.
4. Fit 2 lower bolts securing gearbox to engine.
5. Clean and degrease threads of 2 upper bolts
securing gearbox to engine.
6. Apply Loctite 243 to threads of 2 upper bolts.
Models with air conditioning
7. Position A/C pipe bracket to flywheel housing.
All models
8. Fit 2 upper bolts securing gearbox to engine and
tighten to 80 Nm.
9. Tighten 2 lower bolts securing gearbox to engine
to 80 Nm.
10. Raise engine and gearbox into position and fit
engine LH mounting. See ENGINE - 'K16',
Repairs.
11. Remove jack positioned to support engine.
12. Fit flywheel rear cover plate to flywheel housing,
fit bolts and tighten to 9 Nm.
Models with air conditioning
13. Align A/C pipe to bracket, fit bolt and tighten to 9
Nm.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-17
All models
14. Remove bolt securing lifting bracket to gearbox.
15. Remove plugs from fluid cooler hose unions,
lubricate new 'O' rings with gearbox fluid and fit to
unions.
16. Connect fluid cooler hoses to gearbox and
tighten unions to 14 Nm.
17. Clean mating faces of front pipe and exhaust
manifold.
18. Fit new gasket to exhaust manifold, align front
pipe, fit nuts and tighten to 45 Nm.
19. Secure front pipe rubber mounting to bracket on
body.
20. Fit selector cable to gearchange lever and secure
selector cable in abutment bracket.
21. Connect multiplug to starter inhibitor/reverse
switch and secure harness to clip on gearbox.
22. Connect multiplugs to vehicle speed sensor and
transducer.
23. Connect ratio control motor multiplug.
24. Position engine earth lead, fit bolt and tighten to
25 Nm.
25. Secure positive lead to bracket.
26. Position starter motor, fit bolts and tighten to 25
Nm.
27. Position starter lead, tighten nut and connect
Lucar.
28. Position flywheel front cover plate, fit bolts and
tighten to 9 Nm.
29. Fit drive shafts. See DRIVE SHAFTS, Repairs.
30. Adjust selector cable. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
31. Refill gearbox with fluid. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
32. Remove stand(s) and lower vehicle.
33. Connect battery earth lead.
INPUT SHAFT SEAL
´÷ 44.20.17
Remove
1. Remove gearbox assembly. See AUTOMATIC
GEARBOX - 'EM-CVT', Repairs.
2. Remove input shaft seal using suitable lever.
Discard seal.
Refit
1. Clean seal housing and input shaft.
2. Lubricate new 'O' ring with gearbox fluid and fit
onto input shaft.
3. Push seal into place using tool 18G 1509.
4. Refit gearbox assembly. See AUTOMATIC
GEARBOX - 'EM-CVT', Repairs.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-18 REPAÌRS
PRIMARY COVER
´÷ 44.20.28
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove LH front road wheel.
3. Clean area around primary cover.
4. Position container to collect fluid loss.
5. Remove 3 bolts and brackets securing primary
cover to gearbox.
6. Remove primary cover from gearbox.
Refit
1. Clean primary cover and mating face of gearbox.
2. Fit primary cover to gearbox.
3. Fit primary cover bolts and brackets and tighten
to 10 Nm.
4. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
5. Remove stand(s) and lower vehicle.
6. Top-up gearbox fluid. See MAINTENANCE.
SECONDARY COVER SEALS
´÷ 44.20.33
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove LH front road wheel.
4. Release selector cable from bracket on rear
beam.
5. Loosen nut securing selector cable to selector
lever, release selector cable from support
bracket and position cable aside.
6. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
7. Release radiator top hose from clip on radiator
cooling fan.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-19
8. Disconnect rubber mounting securing front pipe
to body.
9. Remove 2 nuts securing front pipe to exhaust
manifold, release front pipe and collect gasket.
NOTE: Do not let the front pipe hang on the
flexible pipe.
10. Position container to collect fluid loss from
gearbox.
11. Loosen unions and disconnect 2 fluid cooler
hoses from gearbox.
12. Remove and discard 'O' rings from fluid cooler
hose unions.
13. Remove bolt securing earth lead to gearbox and
release earth lead.
14. Remove 2 bolts securing exhaust camshaft rear
cover plate to cylinder head.
15. Remove camshaft rear cover plate.
16. Fit lifting bracket to 18G 1572/1 to cylinder head.
Fit bolts and tighten to 9 Nm.
17. Fit lifting bracket tool 18G 1572 to cylinder head
and tighten bolt to 9 Nm.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-20 REPAÌRS
18. Connect adjustable lifting bracket tool 18G 1598
to lifting brackets.
19. Connect hoist to tool 18G 1598 and raise hoist to
take weight of engine without exerting load on
engine mounting bolts.
20. Loosen through bolt securing engine lower
steady bar to body.
21. Remove through bolt securing engine steady bar
to bracket on sump.
22. Remove bolt securing RH steady bar to engine
mounting bracket.
23. Remove nut securing mounting bracket to engine
mounting, collect mass damper.
24. Remove 2 nuts securing engine mounting
restraint bar to body.
25. Remove 2 bolts securing mounting bracket to
engine.
26. Remove engine mounting bracket.
27. Remove and discard nut securing gearbox
mounting bracket to engine mounting.
28. Adjust tool 18G 1598 to tilt engine with gearbox
as low as possible.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-21
29. Remove 3 Torx bolts securing mounting bracket
to gearbox.
30. Remove mounting bracket from gearbox.
31. Remove 4 bolts securing secondary cover to
gearbox.
32. Remove secondary cover.
33. Remove and discard 2 'O' rings from cover.
34. Remove and discard split ring.
Refit
1. Clean secondary cover and mating faces of cover
and gearbox.
2. Lubricate new 'O' rings with 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
and tighten to 10 Nm.
6. Position mounting bracket to gearbox, fit Torx
bolts and tighten to 65 Nm.
7. Adjust lifting bracket tool so engine is horizontal
in engine compartment.
8. Fit new Nylock nut securing engine LH mounting
to bracket on gearbox and tighten to 160 Nm.
9. Fit mounting bracket to engine RH mounting,
steady bar and engine.
10. Align mounting bracket to engine and tighten
bolts to 135 Nm. Tighten nuts securing restraint
bar to body to 45 Nm.
11. Fit nut securing mounting bracket to engine
mounting and tighten to 85 Nm.
12. Fit bolt securing steady bar to mounting bracket
and tighten to 85 Nm.
13. Connect engine steady bar to bracket on sump
and tighten bolt to 80 Nm.
14. Tighten through bolt, engine steady bar to body,
to 85 Nm.
15. Lower hoist and disconnect lifting bracket tool
18G 1598 from engine lifting brackets.
16. Remove bolt securing engine lifting bracket tool
18G 1572/2 to cylinder head and remove lifting
bracket.
17. Remove 2 bolts securing lifting bracket tool 18G
1572/1 to cylinder head and remove lifting
bracket.
18. Clean camshaft rear cover plate.
19. Position camshaft rear cover plate to cylinder
head and tighten bolts to 25 Nm.
20. Clean fluid cooler hose and gearbox unions.
21. Lubricate and fit new 'O' rings to fluid cooler hose
unions.
22. Connect fluid cooler hoses to gearbox and
tighten unions to 12 Nm.
23. Clean mating faces of front pipe and exhaust
manifold.
24. Fit new gasket to exhaust manifold. flange.
25. Connect front pipe to exhaust manifold, fit nuts
and tighten to 45 Nm.
26. Secure front pipe rubber mounting to bracket on
body.
27. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
28. Secure radiator top hose to clip on radiator
cooling fan.
29. Connect selector cable to selector lever and
secure cable in support bracket.
30. Secure selector cable to clip on rear beam.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-22 REPAÌRS
31. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
32. Remove stand(s) and lower vehicle.
33. Top-up gearbox fluid. See MAINTENANCE.
34. Connect battery earth lead.
DIPSTICK TUBE SEAL
´÷ 44.24.01
Remove
1. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
2. Remove dipstick from tube.
3. Clean gearbox case around dipstick tube entry
point.
4. Remove bolt securing dipstick tube bracket to
gearbox.
5. Remove dipstick tube from gearbox.
6. Remove and discard 'O' ring from gearbox.
Refit
1. Clean dipstick tube and its mating face on
gearbox.
2. Lubricate new 'O' ring with gearbox fluid and fit to
end of dipstick tube.
3. Fit and align dipstick tube to gearbox.
4. Fit bolt securing dipstick tube to gearbox and
tighten to 25 Nm.
5. Fit dipstick.
6. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-23
FLUID PAN GASKET
´÷ 44.24.04
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain gearbox fluid. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
4. Working in the sequence illustrated, loosen then
remove 13 bolts securing fluid pan to gearbox.
5. Release gasket from gearbox, remove fluid pan
and discard gasket.
Refit
1. Clean mating faces of fluid pan and gearbox.
2. Lubricate new gasket with gearbox fluid and fit to
fluid pan.
CAUTION: Do not appIy adhesive to gasket.
3. Fit 13 bolts securing fluid pan to gearbox and
working in the sequence illustrated, tighten to 10
Nm.
4. Remove stand(s) and lower vehicle.
5. Connect battery earth lead.
6. Refill gearbox with fluid. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-24 REPAÌRS
FILTER - GEARBOX FLUID
´÷ 44.24.07
Remove
1. Remove fluid pan. See AUTOMATIC GEARBOX
- 'EM-CVT', Repairs.
2. Release filter from valve block and remove filter.
3. Remove filter magnet.
4. Remove and discard 'O' ring.
Refit
1. Clean magnet and fit to filter.
2. Lubricate new 'O' ring with clean fluid and fit to
filter.
3. Position filter to valve block and engage 'O' ring
in valve block.
4. Fit fluid pan. See AUTOMATIC GEARBOX -
'EM-CVT', Repairs.
FLUID COOLER
´÷ 44.24.10
Remove
1. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
2. Position container to collect fluid loss.
3. Remove nut and bolt securing pipe clamp to fluid
cooler.
4. Remove Torx bolts securing feed and return
pipes to fluid cooler.
5. Release feed and return pipes from fluid cooler.
6. Remove and discard 'O' rings from pipe
connections.
CAUTION: PIug the connections.
7. Remove 3 bolts securing fluid cooler to body.
8. Remove fluid cooler and collect spacer.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-25
Refit
1. Position fluid cooler and spacer to body, fit bolts
and tighten to 10 Nm.
2. Clean feed and return pipe unions.
3. Lubricate and fit new 'O' rings to feed and return
pipe connections.
4. Connect feed and return pipes to fluid cooler.
5. Fit Torx bolts securing feed and return pipes to
fluid cooler and tighten to 9 Nm.
6. Position pipe clamp, fit nut and bolt and tighten to
10 Nm.
7. Fit front bumper. See EXTERIOR FITTINGS,
Repairs.
8. Top-up gearbox fluid. See MAINTENANCE.
HOSE - OIL COOLER - FEED
´÷ 44.24.13
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Position container to collect spillage.
3. Loosen union on gear box and release hose.
4. Remove connector release sleeve, refit in
reverse position and release hose from oil cooler
pipe.
5. Remove oil cooler hose.
6. Remove and discard 'O' ring.
7. Remove connector release sleeve and refit in
safe position.
CAUTION: PIug the connections.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-26 REPAÌRS
Refit
1. Clean oil cooler pipe and gearbox union.
2. Fit new 'O' ring to hose.
3. Position hose to oil cooler pipe and engage quick
release sleeve.
4. Align hose to gearbox and tighten union to 12
Nm.
5. Remove stand(s) and lower vehicle.
6. Check and top up gearbox fluid level. See
MAINTENANCE.
HOSE - OIL COOLER - RETURN
´÷ 44.24.14
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Position container to collect spillage.
3. Loosen union on gear box and release hose.
4. Remove connector release sleeve, refit in
reverse position and release hose from oil cooler
pipe.
5. Remove oil cooler hose.
6. Remove and discard 'O' ring.
7. Remove connector release sleeve and refit in
safe position.
CAUTION: PIug the connections.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-27
Refit
1. Clean oil cooler pipe and gearbox union.
2. Fit new 'O' ring to hose.
3. Position hose to oil cooler pipe and engage
release sleeve.
4. Align hose to gearbox and tighten union to 12
Nm.
5. Remove stand(s) and lower vehicle.
6. Check and top up gearbox fluid level. See
MAINTENANCE.
PIPE - OIL COOLER - FEED
´÷ 44.24.19
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
3. Position container to collect spillage.
4. Remove bolt securing pipe to oil cooler, release
pipe from oil cooler.
5. Remove and discard 'O' ring.
6. Remove connector release sleeve, refit in
reverse position and release hose from oil cooler
pipe.
7. Remove oil cooler pipe.
8. Remove connector release sleeve and refit in
safe position.
CAUTION: PIug the connections.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-28 REPAÌRS
Refit
1. Clean oil cooler pipe and hose ends.
2. Fit new 'O' ring to pipe.
3. Position hose to oil cooler pipe and engage
release sleeve.
4. Align hose to oil cooler, fit bolt and tighten to 9
Nm.
5. Fit front bumper. See EXTERIOR FITTINGS,
Repairs.
6. Remove stand(s) and lower vehicle.
7. Check and top up gearbox fluid level. See
MAINTENANCE.
PIPE - OIL COOLER - RETURN
´÷ 44.24.20
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
3. Position container to collect spillage.
4. Remove bolt securing pipe to oil cooler, release
pipe from oil cooler.
5. Remove and discard 'O' ring.
6. Remove connector release sleeve, refit in
reverse position and release hose from oil cooler
pipe.
7. Remove oil cooler pipe.
8. Remove connector release sleeve and refit in
safe position.
CAUTION: PIug the connections.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-29
Refit
1. Clean oil cooler pipe and hose ends.
2. Fit new 'O' ring to pipe.
3. Position hose to oil cooler pipe and engage
release sleeve.
4. Align hose to oil cooler, fit bolt and tighten to 9
Nm.
5. Fit front bumper. See EXTERIOR FITTINGS,
Repairs.
6. Remove stand(s) and lower vehicle.
7. Check and top up gearbox fluid level. See
MAINTENANCE.
BEARING - PRIMARY
´÷ 44.36.14
Remove
1. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
2. Remove ECM. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
3. Release 2 relays from battery carrier and position
aside.
4. Release clip securing ABS ECU multiplug to
battery carrier.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-30 REPAÌRS
5. Remove 3 bolts securing battery carrier to body.
6. Loosen 3 bolts securing battery carrier to body
and remove carrier.
7. Remove gearbox primary cover. See
AUTOMATIC GEARBOX - 'EM-CVT', Repairs.
8. Connect hoist to gearbox lifting bracket and
support weight of engine/gearbox.
9. Remove nut securing LH gearbox mounting to
bracket.
10. Lower engine/gearbox sufficient to gain access
to primary housing.
11. Remove and discard 4 bolts securing engine pitot
chamber to oil pump drive.
12. Rotate pitot chamber sufficient to remove lower
RH oil pump bolt which secures the engine pitot
tube.
13. Rotate pitot tube 180° anti-clockwise and remove
pitot chamber, collect pitot tube.
14. Remove 5 remaining bolts securing oil pump.
AUTOMATÌC GEARBOX - 'EM-CVT'
REPAÌRS 44-31
15. With care, using 2 levers, positioned 180° apart,
remove oil pump.
NOTE: To prevent damage to primary housing,
place 2 pieces of wood between levers and
primary housing when removing oil pump.
16. Remove and discard 2 'O' rings from oil pump.
17. Remove and discard Belleville washer.
18. Using an air impact wrench with a torque capacity
of ± 300 Nm, remove primary bearing nut.
NOTE: Initially start to undo nut in the minimum
position of the impact wrench, increase torque
until nut is released.
19. Using a small screwdriver, lever out seal from
primary bearing.
20. Position thrust button 44-022 into primary shaft.
21. Assemble 44-023 underneath the exterior ring of
primary bearing.
22. Tighten centre bolt of 44-023 and remove primary
bearing.
Refit
1. Clean primary bearing bore and shaft.
2. Clean sealant from threads in oil pump drive shaft
and clean oil pump housing.
3. Position primary bearing, numbers on bearing
facing outwards.
4. Drift in primary bearing using 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 oil pump.
8. Position oil pump into gearbox, aligning feeder
and pitot tube channels.
AUTOMATÌC GEARBOX - 'EM-CVT'
44-32 REPAÌRS
9. Fit 5 bolts and tighten in a diagonal sequence to
10 Nm.
10. Lubricate and fit new primary cover 'O' ring to
gearbox housing.
11. Position pitot tube in oil pump, fit pitot chamber
ensuring pitot tube is located in oil pick-up
channel in pitot chamber.
12. Rotate pitot chamber sufficient to align pitot tube,
fit remaining oil pump bolt and tighten to 10 Nm.
13. Align pitot chamber to oil pump drive, fit new bolts
and tighten to 10 Nm.
14. Fit primary cover. See AUTOMATIC GEARBOX
- 'EM-CVT', Repairs.
15. Raise engine/gearbox with hoist to align gearbox
mounting to bracket.
16. Fit new Nyloc nut securing gearbox mounting
bracket to engine mounting and tighten to 160
Nm.
17. Release hoist from lifting bracket.
18. Fit battery carrier and tighten 6 bolts securing
carrier to body to 10 Nm.
19. Fit ABS ECU multiplug to battery carrier.
20. Fit 2 relays to battery carrier.
21. Fit ECM. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
22. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
23. Top-up gearbox fluid. See MAINTENANCE.
OIL SEAL - DIFFERENTIAL
´÷ 54.10.18
Remove
1. Remove drive shaft. See DRIVE SHAFTS,
Repairs.
2. Carefully prise oil seal out of differential housing
and discard oil seal.
Refit
1. Thoroughly clean oil seal recess.
2. Lubricate new oil seal with gearbox fluid.
3. Locate new seal on tool 18G 134 and replacer
18G 134-15. with sealing lip facing toward
housing.
4. Carefully drift oil seal into differential housing until
it is fully seated in recess.
5. Remove tools 18G 134 and 18G 134-15.
6. Fit drive shaft. See DRIVE SHAFTS, Repairs.
7. Top-up gearbox fluid. See MAINTENANCE.
DRÌVE SHAFTS
REPAÌRS 47-1
DRÌVE SHAFTS REPAÌ RS
DRIVE SHAFT - LH
´÷ 47.10.01
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
Diesel models:
3. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
All Models:
4. Release drive shaft nut stake.
5. With assistance remove and discard drive shaft
nut.
6. Remove and discard nut securing track rod end
to front hub.
7. Release taper joint using 18G 1584 and release
track rod from front hub.
8. Remove bolt securing anti-roll bar link to lower
arm.
9. Remove bolt securing brake hose to support
bracket.
10. Release ABS harness from 2 retainers.
11. Remove clamp bolt securing front hub to damper.
12. Release front hub from damper.
NOTE: Support the front hub, do not allow the
front hub to hang on front brake hose.
13. Release drive shaft from front hub.
14. Position container to catch spillage.
DRÌVE SHAFTS
47-2 REPAÌRS
EM-CVT models:
15. Disconnect inhibitor switch multiplug and position
harness aside.
CAUTION: To prevent causing damage to
inhibitor switch when reIeasing LH drive shaft
from gearbox, position 18G 1761 with fIat face
of tooI adjacent to gearbox. ReIease drive
shaft by appIying hand pressure and moving
the tooI away from gearbox.
All models:
16. Release and remove drive shaft from differential.
'R65' gearbox use tool 18G 1578. 'PG1' and
'EMCVT' gearbox use tool 18G 1761.
17. Remove and discard drive shaft circlip.
Refit
1. Fit new circlip to drive shaft.
2. Clean drive shaft splines, oil seal running surface
and front hub mating faces.
3. Lubricate oil seal running surfaces with clean oil.
4. Position drive shaft and push fully home to
engage circlip.
5. Lightly pull drive shaft out to ensure circlip
engagement.
6. Connect inhibitor switch multiplug.
7. Engage drive shaft in front hub.
8. Clean damper and front hub mating faces.
9. Position front hub to damper, ensuring full
engagement of damper in front hub and correct
alignment of clamp bolt groove.
10. Fit clamp bolt and tighten to 80 Nm.
11. Clean track rod end taper and register.
12. Position track rod end, fit new nut and tighten to
45 Nm.
13. Position anti-roll bar link, fit bolt and tighten to 60
Nm.
14. Position brake hose to support bracket, fit bolt
and tighten to 25 Nm.
15. Secure ABS harness in retainers.
16. With assistance fit new drive shaft nut and tighten
to 180 Nm.
17. Stake drive shaft nut.
18. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
19. Check and top up gearbox fluid level. See
MAINTENANCE.
Diesel models:
20. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
All models:
21. Remove stand(s) and lower vehicle.
DRÌVE SHAFTS
REPAÌRS 47-3
DRIVE SHAFT - RH
´÷ 47.10.02
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
Diesel models:
3. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
All models:
4. Loosen 2 engine lower steady bar bolts.
5. Remove 4 bolts securing lower steady bar
bracket to sump and release bracket.
6. Release drive shaft nut stake.
7. With assistance remove and discard drive shaft
nut.
8. Remove and discard nut securing track rod end
to front hub.
9. Release taper joint using 18G 1584 and release
track rod from front hub.
10. Remove bolt securing anti-roll bar link to lower
arm.
11. Remove bolt securing brake hose to support
bracket.
12. Release ABS harness from 2 retainers.
13. Remove clamp bolt securing front hub to damper.
14. Release front hub from damper.
NOTE: Support the front hub, do not allow the
front hub to hang on front brake hose.
15. Release drive shaft from front hub.
PG1 Gearbox:
16. Remove bolt securing gear change steady bar
and remove bar.
All models:
17. Position container to catch spillage.
DRÌVE SHAFTS
47-4 REPAÌRS
18. Release and remove drive shaft from differential.
'R65' gearbox use tool 18G 1578. 'PG1' and
'EMCVT' gearbox use tool 18G 1761.
19. Remove and discard drive shaft circlip.
Refit
1. Fit new circlip to drive shaft.
2. Clean drive shaft splines, oil seal running surface
and front hub mating faces.
3. Lubricate oil seal running surfaces with clean oil.
4. Position drive shaft and push fully home to
engage circlip.
5. Lightly pull drive shaft out to ensure circlip
engagement.
6. Engage drive shaft in front hub.
PG1 Gearbox:
7. Fit gear change steady bar and secure with bolt.
All models:
8. Clean damper and front hub mating faces.
9. Position front hub to damper, ensuring full
engagement of damper in front hub and correct
alignment of clamp bolt groove.
10. Fit clamp bolt and tighten to 80 Nm.
11. Clean track rod end taper and register.
12. Position track rod end, fit new nut and tighten to
45 Nm.
13. Position anti-roll bar link, fit bolt and tighten to 60
Nm.
14. Position brake hose to support bracket, fit bolt
and tighten to 25 Nm.
15. Secure ABS harness in retainers.
16. With assistance fit new drive shaft nut and tighten
to 180 Nm.
17. Stake drive shaft nut.
18. Position engine lower steady bar bracket, fit bolts
and tighten to 85 Nm.
19. Tighten engine steady bar bolts to 85 Nm.
20. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
21. Check and top up gearbox fluid level. See
MAINTENANCE.
Diesel models:
22. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
All models:
23. Remove stand(s) and lower vehicle.
DRÌVE SHAFTS
REPAÌRS 47-5
DRIVE SHAFT GAITER - OUTER
´÷ 47.10.03
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove drive shaft outer joint. See DRIVE
SHAFTS, Repairs.
3. Slide gaiter from shaft.
Refit
1. Clean drive shaft and gaiter.
2. Fit new gaiter to shaft.
3. Fit drive shaft outer joint. See DRIVE SHAFTS,
Repairs.
4. Remove stand(s) and lower vehicle.
DRIVE SHAFT - OUTER JOINT - EMCVT
´÷ 47.10.04
Remove
1. Remove drive shaft. See DRIVE SHAFTS,
Repairs.
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.
DRÌVE SHAFTS
47-6 REPAÌRS
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 DRIVE SHAFTS, Repairs.
DRIVE SHAFT GAITER - INNER
´÷ 47.10.16
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove drive shaft damper. See DRIVE
SHAFTS, Repairs.
3. Release both gaiter clips and discard.
4. Slide gaiter from shaft.
Refit
1. Clean shaft and gaiter.
2. Fit gaiter to shaft.
3. Secure gaiter with clips.
4. Fit drive shaft damper. See DRIVE SHAFTS,
Repairs.
5. Remove stand(s) and lower vehicle.
DRÌVE SHAFTS
REPAÌRS 47-7
DRIVE SHAFT AND INNER JOINT
´÷ 47.10.25
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove drive shaft outer joint. See DRIVE
SHAFTS, Repairs.
3. Slide damper from shaft.
4. Fit new drive shaft to vice.
Refit
1. Lubricate shaft to aid fitting of damper.
2. Fit new damper to shaft with flange facing inner
joint.
NOTE: Dampers for LH and RH shafts are not
interchangeable.
3. Clean lubricant from shaft.
4. Fit drive shaft outer joint. See DRIVE SHAFTS,
Repairs.
5. Measure along shaft for positioning new damper.
1.1, 1.4, 1.6 and Diesel models;
R.H. shaft 'A' = 163 mm ± 3 mm
L.H. shaft 'B' = 173 mm ± 3 mm
Automatic models:
R.H. shaft 'A' = 173 mm ± 3 mm
L.H. shaft 'B' = 163 mm ± 3 mm
'K16 VVC' models:
R.H. shaft 'A' = 170 mm ± 3 mm
L.H. shaft 'B' = 163 mm ± 3 mm
6. Remove stand(s) and lower vehicle.
DRÌVE SHAFTS
47-8 REPAÌRS
STEERÌNG
ADJUSTMENTS 57-1
STEERÌNG ADJUSTMENTS
FRONT WHEEL ALIGNMENT
´÷ 57.65.01
Check
1. Ensure tyre pressures are correct and vehicle is
at kerbside weight.
2. Roll vehicle backwards and forwards to relieve
stresses in steering and suspension.
3. Ensure that equipment is properly calibrated and
take an average of 3 readings.
NOTE: Only use equipment recommended in the
STEP (Service Tools and Equipment
Programme) Manual.
4. Check front wheel alignment is within tolerance.
See INFORMATION, GeneraI Data.
Adjust
1. Mark position of track rod ends for reference.
2. Loosen track rod end locknuts.
3. Release clip securing gaiter to track rod.
4. Rotate track rod to obtain correct alignment.
CAUTION: Both track rods must be rotated an
equaI amount.
5. Recheck front wheel alignment.
6. Tighten track rod end locknuts to 45 Nm.
7. Ensure gaiters are not strained or twisted, then
secure with clip.
REAR WHEEL ALIGNMENT
´÷ 57.65.06.01
Adjust
1. Loosen 3 bolts securing LH 'H' frame mounting
bracket to body.
2. Adjust 'H' frame in the required direction to
achieve correct wheel alignment. Ìf LH wheel
value is greater than RH, move LH side of 'H'
frame rearwards. Ìf LH wheel value is less than
RH, move LH side of 'H' frame forwards.
CAUTION: Take care to avoid damaging
wheeI arch.
3. Maintain force on 'H' frame and tighten bolts,
mounting bracket to body, to 100 Nm.
4. Recheck rear wheel alignment.
STEERÌNG
57-2 ADJUSTMENTS
POWER STEERING SYSTEM BLEED - 'K'
SERIES
´÷ 57.15.02
Check
1. Clean reservoir around filler cap and fluid level
indicators.
2. Visually check fluid level is between 'UPPER' and
'LOWER' indicators
Adjust
1. Remove filler cap from reservoir and fill reservoir
to 'UPPER' mark with the recommended fluid.
See INFORMATION, Capacities, FIuids and
Lubricants.
2. Disconnect coil h.t. lead from distributor to
prevent engine starting.
3. Crank engine for 5 seconds to prime power
steering pump.
4. Top-up power steering fluid reservoir.
5. Turn steering to full RH lock and crank engine for
5 seconds.
6. Top-up power steering fluid reservoir.
7. Turn steering to full LH lock and crank engine for
5 seconds.
8. Top-up power steering fluid reservoir.
9. Connect coil h.t. lead to distributor.
10. Start and run engine for 2 minutes to circulate
fluid through the system.
11. Turn steering to LH then RH full lock.
CAUTION: Do not hoId steering at fuII Iock for
Ionger than 10 seconds.
12. Switch off engine.
13. Check power steering fluid, if aerated, wait until
fluid is free from bubbles then top-up reservoir to
'UPPER' level mark.
14. Fit reservoir filler cap.
POWER STEERING SYSTEM BLEED - 'L'
SERIES
´÷ 57.15.02
Check
1. Clean reservoir around filler cap and fluid level
indicators.
2. Visually check fluid level is between 'UPPER' and
'LOWER' indicators
Adjust
1. Remove filler cap from reservoir and fill reservoir
to 'UPPER' mark with Dexron ÌÌ D power steering
fluid. Fluid must always be present in reservoir
while bleeding.
2. Start engine and allow to run at idle for 10
seconds. Stop engine.
3. Top-up steering fluid reservoir.
4. Start engine and turn steering fully to LH and RH
locks. Stop engine.
5. Top-up steering fluid reservoir.
6. Start and run engine for 2 minutes, turn steering
fully to RH and LH locks.
CAUTION: Do not hoId steering at fuII Iock for
Ionger than 10 seconds.
7. Switch off engine.
8. Check power steering fluid, if aerated, wait until
fluid is free from bubbles then top-up reservoir to
'UPPER' level mark.
9. Fit reservoir filler cap.
STEERÌNG
ADJUSTMENTS 57-3
POWER STEERING SYSTEM - PRESSURE
TEST
´÷ 57.90.10/01
Check
Test Equipment - Assembly:
1. Fit gauge and hose 18G 1496 to valve assembly
18G 1496-1 and tighten union.
2. Fit 2 hoses 18G 1496-2 to valve assembly 18G
1496-1 and tighten unions.
3. Disconnect battery earth lead.
Diesel models only:
4. Use 18G 1496/15-1 and 57-042.
K16 models only:
5. Remove 2 bolts securing return pipe to body.
6. Remove bolt securing pipe to pump.
All models:
7. Position cloth and container to collect PAS fluid
spillage.
8. Clean PAS pump, PAS pipes and unions.
9. Remove banjo bolt securing steering rack feed
pipe to PAS pump, remove and discard sealing
washers.
10. Fit adaptor 57-042 and sealing washer to PAS
pump.
11. Using the banjo bolt and sealing washers fit
adaptor 57-035 to steering rack feed pipe.
12. Connect hoses 18G 1496-2 to adaptors.
13. Ensure all pipes and fitting are clear of rotating
parts.
14. Hang pressure gauge in a safe position under
bonnet.
15. Connect battery earth lead.
16. Refill PAS reservoir and bleed PAS system.
17. Start engine and allow air to bleed from PAS
system, by turning steering from lock to lock.
Stop engine.
18. Check PAS fluid level.
Test Procedure:
19. Ensure steering system is free from leaks and
maintain maximum fluid level during test.
20. With the test rig valve open, start the engine.
21. With the engine at idle and normal running
temperature, slowly turn the steering wheel and
hold on lock.
22. Repeat pressure check on opposite lock.
23. The test pressure should progressively rise from
5 bar to 65 bar on Diesel and K16 engines.
Pressure will rise to 65 or 80 bar when held on full
lock.
24. With the engine at idle, release the steering
wheel. Pressure should read 5 bar or below.
Adjust
1. Pressure outside the above tolerance indicates a
fault.
2. To determine if fault is in steering pump or
steering rack, close the test valve for a maximum
of five seconds. Pump damage may occur if test
valve is closed for longer periods.
3. Ìf the gauge does not register between 60 and 70
bar on diesel and K16 engines (maximum pump
pressure), the pump is faulty.
4. Ìf maximum pump pressure is correct, suspect
the steering rack.
5. On completion, stop engine.
6. Disconnect battery earth lead.
7. Remove test equipment from adaptors.
8. Remove adaptors from PAS pump and steering
rack feed pipe.
9. Fit new seals, connect feed pipe to PAS pump, fit
and tighten banjo bolt to 25 Nm.
10. Clean chassis and surrounding area.
K16 models only:
11. Fit bolt securing pipe to pump and tighten to 9
Nm.
12. Fit bolts securing return pipe to body and tighten
to 9 Nm.
All models:
13. Check PAS fluid level and bleed PAS system.
See STEERING, Adjustments.
14. Connect battery earth lead.
STEERÌNG
57-4 ADJUSTMENTS
STEERÌNG
REPAÌRS 57-5
REPAÌ RS
POWER STEERING RACK
´÷ 57.10.01
Remove
1. Align road wheels to straight ahead position and
remove starter key from steering lock.
2. Remove 2 bolts securing column universal joint.
Slide joint up column and disconnect from
steering rack pinion shaft.
3. Raise front of vehicle.
WARNING: Support on safety stands.
4. Remove road wheel(s).
5. Remove bolt securing engine steady bar to
engine.
6. Move steady bar aside and remove 4 bolts
securing steady bar mounting bracket to rear
beam.
7. Remove steady bar and mounting bracket.
8. Remove nuts securing LH and RH track rod ends
to front hubs, break taper joints using tool 18G
1584. Discard nuts.
9. Note number of threads exposed from each track
rod end locknut for reference.
10. Loosen locknuts and remove track rod ends from
steering rack.
11. Remove exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
Models with 'K16 VVC':
12. Remove 4 bolts securing front pipe heat shield
and remove heat shield.
STEERÌNG
57-6 REPAÌRS
Models with 'PG1 Gearbox':
13. Remove bolt and disconnect gear change steady
bar from gearbox, collect 2 washers.
14. Remove clip securing selector rod roll pin.
15. Using a suitable punch, drive out roll pin securing
selector rod to selector shaft; discard roll pin.
16. Release selector rod from selector shaft.
Models with 'R65 Gearbox':
17. Using 18G 1592 disconnect 3 gearchange and
selector linkage ball joints.
18. Remove 3 bolts securing gearchange support
bracket and position linkage aside.
Models with 'EMCVT Gearbox':
19. Loosen nut securing selector cable, release
cable from support bracket and position cable
aside.
All models:
20. Support the weight of the rear beam.
21. Remove 4 bolts securing rear beam and lower
rear beam to access steering rack pipe unions.
STEERÌNG
REPAÌRS 57-7
22. Loosen steering rack pipe unions and release
unions.
23. Remove and discard 'O' rings.
24. Remove 2 bolts securing steering rack clamp.
25. Remove clamp and collect rubber.
26. Remove 2 flange bolts securing steering rack to
rear beam.
27. Manoeuvre steering rack to passenger side and
remove from rear beam.
28. Remove aperture seal.
Refit
1. Ensure body aperture seal is seated correctly on
steering rack.
2. Feed rack into passenger side first, then
manoeuvre pinion end into position.
3. Align rack and loosely fit flange bolts securing
rack to rear beam. DO NOT tighten.
4. Fit steering rack clamp and rubber, fit bolts and
tighten to 38 Nm.
5. Tighten flange bolts securing steering rack to rear
beam to 58 Nm.
6. Clean steering rack pipe ends and fit new 'O'
rings.
7. Position pipes to steering rack and tighten
unions.
8. Align rear beam to body, fit bolts and tighten to
100 Nm.
NOTE: Ensure aperture seal is correctly located.
Models with 'EMCVT gearbox':
9. Connect selector cable to gear change lever and
secure selector cable in abutment bracket.
10. Adjust selector cable. See AUTOMATIC
GEARBOX - 'EM-CVT', Adjustments.
Models with 'R65 gearbox':
11. Align gearchange support bracket to rear beam fit
bolts and tighten bolts to 25 Nm.
12. Using 18G 1594 connect gear change and gear
selector linkage ball joints.
Models with 'PG1 gearbox':
13. Connect selector rod to shaft and align holes.
14. Fit new roll pin securing selector rod to selector
shaft and fit roll pin retaining clip.
15. Fit washers to gear change steady bar and
connect to gearbox.
16. Fit bolt securing gear change steady bar to
gearbox and tighten to 10 Nm.
Models with K16 VVC:
17. Position exhaust pipe heat shield, fit bolts and
tighten to 6 Nm.
STEERÌNG
57-8 REPAÌRS
All models:
18. Fit exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
19. Position each locknut on track rods with same
amount of thread exposed as noted during
removal.
20. Centralise steering rack and screw both track rod
ends onto track rods up to locknuts, with ball pins
facing upwards.
21. Connect track rod ends and tighten new nuts to
45 Nm.
22. Position steady bar mounting bracket to rear
beam and tighten bolts to 60 Nm.
23. Align steady bar to engine sump and tighten bolt
to 45 Nm.
24. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
25. Remove stand(s) and lower vehicle.
26. Connect column universal joint ensuring bolts are
located in grooves. Tighten bolts to 28 Nm.
27. Check and adjust front wheel alignment. See
STEERING, Adjustments.
28. Bleed power steering system. See STEERING,
Adjustments.
BELT - PAS PUMP - 'K' SERIES
´÷ 57.20.02
Remove
1. Check condition of drive belt, renew a belt that
shows signs of wear and splitting. Belt must be
renewed before indicator reaches LH end of
recess in tensioner backplate casting, see
illustration.
2. Disconnect battery earth lead.
3. Raise front of vehicle.
WARNING: Support on safety stands.
STEERÌNG
REPAÌRS 57-9
4. Fit a 13 mm spanner to hexagon on belt tensioner
and rotate fully clockwise to release tension on
drive belt.
5. To hold tensioner in this position, fit a suitable
pin, not exceeding 3 mm diameter, through
centre of hexagon into tensioner backplate.
6. Release drive belt from pulleys and tensioner and
remove drive belt.
Refit
1. Ensure PAS pump belt pulleys are clean and
damage free.
2. Fit drive belt. Ensure belt is located correctly in
pulley grooves.
3. Use a 13 mm spanner, remove pin retaining
tensioner and allow tensioner pulley to rest on
PAS drive belt.
4. Remove stand(s) and lower vehicle.
5. Connect battery earth lead.
PUMP - POWER STEERING - PAS 'K
SERIES'
´÷ 57.20.14
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Loosen PAS pump pulley bolts.
4. Remove PAS pump drive belt. See STEERING,
Repairs.
5. Remove PAS pump pulley bolts and remove
pulley.
6. Position container to collect fluid loss.
STEERÌNG
57-10 REPAÌRS
7. Loosen clip securing fluid inlet hose to power
steering pump.
8. Disconnect fluid inlet hose from power steering
pump.
9. Remove bolt securing fluid outlet hose clamp to
bracket.
10. Loosen union and disconnect fluid outlet hose
from power steering pump.
CAUTION: To prevent damage to
components, use two spanners when
Ioosening or tightening unions.
11. Plug hose and power steering pump connections
to prevent excess fluid loss and the ingress of dirt
and moisture into the system.
12. Remove bolt securing power steering pump to
mounting bracket.
13. Remove 2 through bolts and nuts securing power
steering pump to mounting bracket.
14. Remove power steering pump.
Refit
1. Remove plugs from hose connections on new
power steering pump and fit to old pump.
2. Set bolt distance pieces in pump bracket back 3
mm to aid fitting of pump.
3. Position power steering pump and align to
mounting bracket.
4. Fit nuts and bolts securing power steering pump
to mounting bracket and tighten to 25 Nm.
5. Remove plug from fluid outlet hose.
6. Remove and discard 'O' ring from fluid outlet
hose.
7. Lubricate and fit new 'O' ring to fluid outlet hose.
8. Connect fluid outlet hose to power steering pump
and tighten union to 20 Nm.
9. Align fluid outlet hose clamp to bracket, fit and
tighten bolt to 9 Nm.
10. Remove plug from fluid inlet hose and connect to
power steering pump.
11. Tighten clip securing fluid inlet hose to power
steering pump.
12. Remove container positioned to collect fluid loss.
13. Clean PAS pump pulley and mating face.
14. Position PAS pump pulley and align bolt holes.
Ensure FRONT mark is facing outwards.
15. Fit bolts but do not tighten at this stage.
16. Fit PAS pump drive belt. See STEERING,
Repairs.
17. Tighten PAS pump pulley bolts to 9 Nm.
18. Remove stand(s) and lower vehicle.
19. Connect battery earth lead.
20. Bleed PAS system. See STEERING,
Adjustments.
STEERÌNG
REPAÌRS 57-11
PUMP - POWER ASSISTED STEERING -
PAS - 'L' SERIES
´÷ 57.20.14
Remove
1. Disconnect battery earth lead.
2. Remove coolant pump housing. See COOLING
SYSTEM - 'L' Series, Repairs.
3. Restrain PAS pulley, remove and discard 3 Torx
bolts.
4. Remove PAS pump drive pulley.
5. Remove 5 bolts securing PAS pump to coolant
pump housing and move mounting bracket aside.
6. Remove PAS pump from coolant pump housing.
7. Remove 2 bolts securing PAS fluid oil feed flange
to PAS pump, discard 'O' ring seal and move
hose aside.
Refit
1. Clean PAS feed hose flange and pump mounting
faces.
2. Fit new 'O' ring seal to PAS pump oil feed flange,
fit flange to pump and tighten bolts to 10 Nm.
3. Fit PAS pump to coolant pump housing.
4. Fit PAS pump mounting bracket, locate bolts and
tighten assembly to 25 Nm.
5. Fit PAS pulley to drive flange, restrain pulley and
tighten new Torx bolts to 10 Nm.
6. Fit coolant pump housing. See COOLING
SYSTEM - 'L' Series, Repairs.
7. Connect battery earth lead.
STEERÌNG
57-12 REPAÌRS
TENSIONER - PAS PUMP DRIVE BELT 'K'
SERIES'
´÷ 57.20.25
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove PAS pump drive belt. See STEERING,
Repairs.
4. Remove 2 bolts securing tensioner and remove
tensioner.
5. Secure tensioner in a vice, release spring tension
and remove locking pin.
Refit
1. Secure tensioner in a vice, rotate spring and fit
locking pin.
2. Clean tensioner and support bracket mating
faces.
3. Position tensioner, fit bolts and tighten to 25 Nm.
4. Fit PAS pump drive belt. See STEERING,
Repairs.
5. Remove stand(s) and lower vehicle.
6. Connect battery earth lead.
STEERÌNG
REPAÌRS 57-13
STEERING RACK GAITER
´÷ 57.25.03
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove track rod end. See STEERING,
Repairs.
3. Remove clip securing outer end of gaiter to
steering rack.
4. Cut cable tie securing inner end of gaiter to
steering rack.
5. Remove gaiter from rack.
Refit
1. Fit gaiter to rack.
2. Secure inner end of gaiter with cable tie.
3. Fit clip securing outer end of gaiter.
4. Fit track rod end. See STEERING, Repairs.
5. Remove stand(s) and lower vehicle.
STEERING COLUMN ASSEMBLY
´÷ 57.40.01
WARNING: SRS procedures must be followed and
all precautions observed. See RESTRAINT
SYSTEMS, Precautions.
Remove
1. Remove rotary coupler. See ELECTRICAL,
Repairs.
2. Disconnect 4 multiplugs from switch pack.
3. Disconnect transponder multiplug.
STEERÌNG
57-14 REPAÌRS
Models with serviable fusebox:
4. Disconnect starter switch multiplugs from fuse
box and main harness.
Models with hard¬wired fusebox:
5. Disconnect main harness multiplug from starter
switch.
All models:
6. Remove 2 clips securing universal joint cover to
column.
7. Pull back drivers footwell carpet.
8. Remove studs securing universal joint cover to
floor and remove cover.
9. Remove bolt securing universal joint to column.
10. Remove nut and bolt securing lower column
clamp to pivot bracket.
11. Remove clamp.
12. Remove 2 flange nuts and 2 bolts securing
column upper bracket to underside of fascia.
13. Remove column assembly.
Do not carry out further dismantling if component
is removed for access only.
14. Remove transponder. See ELECTRICAL,
Repairs.
15. Remove indicator cancelling cam.
16. Remove 2 screws and withdraw column switch
assembly.
Models with lock shield fitted:
17. Centre punch and drill out 2 lock shield shear
bolts using a 5mm drill.
18. Remove lower half of lock shield.
19. Remove upper half of lock shield.
All models:
20. Centre punch and using a 5 mm drill remove 2
shear bolts securing steering lock to steering
column.
CAUTION: Take care not to damage Iock body
if Iock is to be refitted.
21. Remove steering lock and bracket.
Refit
1. Position steering lock to column and fit shear
bolts loosely.
2. Ìnsert starter key, check operation of steering
lock and ensure the key turns freely.
3. Tighten shear bolts fully and shear heads off.
Models with lock shield fitted:
4. Position upper half of lock shield to ignition barrel
and steering column.
5. Position lower half of lock shield to ignition barrel
and steering column.
6. Fit 2 shear bolts to lock shield and tighten until
heads shear off.
STEERÌNG
REPAÌRS 57-15
All models:
7. Fit column switch assembly and tighten screws.
8. Fit indicator cancelling cam, set engagement
tags.
9. Fit transponder. See ELECTRICAL, Repairs.
10. Position column assembly, engage universal
joint splines aligning the bolt hole with the flat on
the shaft and fit bolt securing column to universal
joint, DO NOT tighten.
11. Raise column, engage top bracket on studs and
fit nuts and bolts. DO NOT tighten.
12. Fit lower clamp, and tighten nut and bolt to 22
Nm.
13. Tighten top bracket nuts and bolts to 15 Nm.
14. Tighten universal joint bolt to 28 Nm.
15. Position universal joint cover and fit cover
retaining clips and studs.
16. Refit drivers footwell carpet.
17. Connect starter switch multiplugs.
18. Connect switch pack multiplugs.
19. Connect transponder multiplug.
20. Fit rotary coupler. See ELECTRICAL, Repairs.
STEERING COLUMN NACELLE
´÷ 57.40.29
Remove
1. Disconnect battery earth lead.
2. Remove steering wheel. See STEERING,
Repairs.
3. Remove keys from starter switch.
4. Release 3 turnbuckles and remove fusebox
cover.
5. Remove 3 screws securing lower half of nacelle
to steering column.
6. Remove lower and upper halves of nacelle.
STEERÌNG
57-16 REPAÌRS
Refit
1. Fit upper and lower halves of nacelle to steering
column.
2. Fit and tighten screws securing lower half of
nacelle to steering column.
3. Fit fuse box cover and secure turnbuckles.
4. Fit steering wheel. See STEERING, Repairs.
5. Connect battery earth lead.
STEERING LOCK
´÷ 57.40.31
WARNING: SRS procedures must be followed and
all precautions observed. See RESTRAINT
SYSTEMS, Precautions.
Remove
1. Remove steering column nacelle. See
STEERING, Repairs.
2. Remove transponder. See ELECTRICAL,
Repairs.
Models with lock shield fitted:
3. Centre punch and drill out 2 lock shield shear
bolts using a 5mm drill.
4. Remove lower half of lock shield.
5. Disconnect multiplugs C0036 and C0041.
6. Remove upper half of lock shield.
Models with servicable fusebox:
7. Disconnect starter switch multiplugs from fuse
box and main harness.
Models with hard¬wired fusebox:
8. Disconnect main harness multiplug from starter
switch
STEERÌNG
REPAÌRS 57-17
All models:
9. Remove nut and bolt securing lower column
clamp to pivot bracket.
10. Remove clamp.
11. Remove 2 flange nuts and 2 bolts securing
column upper bracket.
12. Lower the steering column assembly.
13. Centre punch and drill out 2 shear bolts using a 5
mm drill.
CAUTION: Take care not to damage Iock body
if Iock is to be refitted.
14. Remove steering lock and bracket.
Refit
1. Position steering lock to column and fit shear
bolts loosely.
2. Ìnsert starter key, check operation of steering
lock and key turns freely.
Models with lock shield fitted:
3. Tighten shear bolts until heads shear off.
4. Position upper half of lock shield to ignition barell
and steering column.
5. Connect multiplugs C0036 and C0041.
NOTE: Ensure harness is routed around the
upper half of the lock shield towards the front of
the vehicle.
6. Position lower half of lock shield to ignition barrel
and steering column.
7. Fit 2 shear bolts to lock shield and tighten until
heads shear off.
All models:
8. Raise column and engage top bracket on studs
and fit nuts and bolts. DO NOT tighten.
9. Fit lower clamp, tighten nut and bolt to 22 Nm.
10. Tighten top bracket nuts and bolts to 15 Nm.
11. Connect starter switch multiplug(s).
12. Fit transponder. See ELECTRICAL, Repairs.
13. Fit steering column nacelle. See STEERING,
Repairs.
STEERÌNG
57-18 REPAÌRS
TRACK ROD END
´÷ 57.55.02
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Loosen track rod end locknut.
4. Remove nut from ball pin and discard.
5. Fit M10 nut to ball pin, flush with end of pin.
6. Using tool 18G 1584, separate ball pin from
knuckle arm.
7. Unscrew track rod end from track rod.
NOTE: Retain the track rod locknut in position as
fitting reference.
Refit
1. Screw track rod end onto track rod up to locknut
with ball pin facing upwards.
2. Connect ball pin to front hub. Tighten new nut to
45 Nm.
3. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
4. Remove stand(s) and lower vehicle.
5. Check and adjust front wheel alignment. See
STEERING, Adjustments.
STEERING WHEEL
´÷ 57.60.01
Remove
1. Remove driver's airbag module. See
RESTRAINT SYSTEMS, Repairs.
2. Disconnect multiplug from rotary coupler.
3. Centralise steering wheel with road wheels in
straight ahead position.
4. Restrain steering wheel and loosen self-locking
nut securing steering wheel to column.
WARNING: Do not remove nut until steering
wheel has been released from splines.
5. Release steering wheel from column splines by
rocking steering wheel from side-to-side and
pulling with both hands.
6. Remove and discard self-locking nut.
7. Remove steering wheel.
STEERÌNG
REPAÌRS 57-19
8. Attach tape across edge of rotary coupler to
retain correct setting.
Refit
1. Remove retaining tape from rotary coupler.
2. Ensure road wheels are in straight ahead position
and indicator cancelling cam are aligned
horizontally.
3. Engage rotary coupler and fit steering wheel to
column, ensure wheel spokes are horizontal.
4. Fit new self-locking nut, tighten to 50 Nm.
5. Connect multiplug to rotary coupler.
6. Fit driver's airbag module. See RESTRAINT
SYSTEMS, Repairs.
STEERÌNG
57-20 REPAÌRS
FRONT SUSPENSÌON
REPAÌRS 60-1
FRONT SUSPENSÌON REPAÌ RS
FRONT DAMPER
´÷ 60.30.02
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front road wheel.
3. Remove bolt securing anti-roll bar link to
suspension lower arm.
4. Remove bolt securing brake hose to front
damper.
5. Remove pinch bolt securing front hub to damper.
6. Disconnect damper from front hub.
7. Mark relationship of body and top of front
damper.
8. Remove 3 nuts securing front damper and spring
assembly to body.
9. Remove front damper from vehicle.
Do not carry out further dismantling if component
is removed for access only
10. Position spring compressor tool 18G 1516 in
vice.
11. Position spring and damper assembly on spring
compressor and ensure lugs and arms on
compressor firmly hold spring, refer to illustration.
12. Compress spring approximately 5-8 cm.
FRONT SUSPENSÌON
60-2 REPAÌRS
13. Restrain damper shaft using a 6 mm Allen key,
remove the damper shaft nut using a 19 mm
spanner.
14. Remove washer, mounting base and spring
mounting plate.
15. Remove washer and bump stop from damper
shaft.
16. Remove dust cover from damper.
17. Remove damper from spring.
18. Remove spring from spring compressor tool 18G
1516.
19. Ìnspect damper dust cover and bump stop for
signs of deterioration or damage.
20. Clean damper dust cover, spring mounting plate
and mounting base.
21. Position spring on spring compressor and ensure
lugs and arms on compressor firmly hold spring.
Compress spring.
22. Fit damper to spring and ensure base of spring is
correctly located on damper.
23. Fit damper dust cover, bump stop and washer.
Ensure dust cover is pushed fully down damper
shaft.
24. Fit spring mounting plate, mounting base and
washer to damper and spring assembly.
25. Fit damper shaft nut, restrain damper shaft using
a 6 mm Allen key and tighten nut to 40 Nm.
26. Remove damper and spring assembly from
spring compressor tool.
FRONT SUSPENSÌON
REPAÌRS 60-3
Refit
1. Fit and align front damper and spring assembly to
body.
2. Fit 3 nuts, securing damper and front spring
assembly to body and tighten to 30 Nm.
3. Locate base of front damper in hub, ensure
locating lug on damper engages in slot on hub.
4. Fit pinch bolt securing front hub to damper and
tighten to 80 Nm.
5. Align anti-roll bar link to suspension lower arm, fit
bolt and tighten to 60 Nm.
6. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
7. Remove stand(s) and lower vehicle.
FRONT HUB
´÷ 60.25.01
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front road wheel.
3. Release drive shaft nut stake.
4. With assistance remove and discard drive shaft
nut.
5. Remove and discard nut securing track rod end
to front hub.
6. Release taper joint using 18G 1584 and release
track rod from front hub.
FRONT SUSPENSÌON
60-4 REPAÌRS
7. Remove bolt securing anti-roll bar link to lower
arm.
8. Remove bolt securing brake hose to support
bracket.
9. Release ABS harness from 2 retainers.
10. Remove Torx bolt securing ABS sensor, release
ABS sensor and position aside.
11. Remove 2 bolts securing brake caliper, release
brake caliper and tie aside.
12. Mark brake disc in relation to hub, remove 2
screws securing brake disc and remove brake
disc.
13. Remove clamp bolt securing front hub to damper.
14. Release front hub from damper.
15. Release drive shaft from front hub and tie aside.
16. Remove and discard split pin from castellated nut
securing front hub to lower arm.
17. Loosen castellated nut securing front hub to
lower arm, until flush with the end of the joint. Ìf
necessary, apply penetrating oil to joint.
FRONT SUSPENSÌON
REPAÌRS 60-5
18. Break taper joint using tool 18G 1584.
CAUTION: Be carefuI not to damage the
rubber boot on Iower baII joint.
19. Remove nut from lower ball joint and release
lower arm from front hub.
20. Remove front hub assembly.
Refit
1. Clean lower ball joint and mating face of front
hub.
2. Locate front hub on lower arm ball joint.
3. Fit castellated nut securing hub to lower arm and
tighten to 55 Nm, then align next slot in nut with
split pin hole.
4. Fit new split pin through castellated nut and
secure.
5. Engage drive shaft in front hub.
6. Clean damper and front hub mating faces.
7. Position front hub to damper, ensuring full
engagement of damper in front hub and correct
alignment of clamp bolt groove.
8. Fit clamp bolt and tighten to 80 Nm.
9. Clean track rod end taper and register.
10. Position track rod end, fit new nut and tighten to
45 Nm.
11. Position anti-roll bar link, fit bolt and tighten to 60
Nm .
12. Position brake disc to hub, fit and tighten screws.
13. Position brake caliper to disc, fit bolts and tighten
to 108 Nm .
14. Position brake hose to support bracket, fit bolt
and tighten to 25 Nm.
15. Clean ABS sensor and hub mating faces,
position ABS sensor fit Torx bolt and tighten to 6
Nm .
16. Secure ABS harness in retainers.
17. With assistance fit new drive shaft nut and tighten
to 180 Nm.
18. Stake drive shaft nut.
19. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
20. Remove stand(s) and lower vehicle.
FRONT SUSPENSÌON
60-6 REPAÌRS
FRONT HUB BEARING
´÷ 60.25.14
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front road wheel.
3. Remove front hub. See FRONT SUSPENSION,
Repairs.
4. Position hub beneath press.
5. Using a suitable size drift, press out drive flange
from front hub.
NOTE: Part of the bearing inner track will remain
on the drive flange.
6. Remove front hub from press.
7. Hold drive flange securely in vice.
8. Clamp 2 halves of bearing separator around the
bearing inner track on drive flange, ensure inner
lip of tool engages behind inner track.
9. Using tool 18G 2 and thrust pad 18G 1390
withdraw bearing inner track from drive flange.
10. Remove 3 screws securing brake disc shield to
front hub.
11. Remove brake disc shield.
12. Remove circlip securing bearing in front hub.
13. Position front hub beneath press.
14. Position tool 18G 1597 to bearing and press out
bearing from front hub. Discard bearing.
CAUTION: Never re-use an existing bearing.
FRONT SUSPENSÌON
REPAÌRS 60-7
Refit
1. Thoroughly clean front hub and drive flange.
2. Position front hub beneath press.
3. Locate new bearing on tool 18G 1599/1.
4. Fit tool 18G 1599/2 to front hub and carefully
press hub onto new bearing.
5. Fit circlip securing bearing in hub.
6. Fit brake disc shield to front hub.
7. Fit 3 screws securing brake disc shield to front
hub and tighten to 9 Nm.
8. Support front hub on tool 18G 1597.
9. Press drive flange into front hub.
10. Fit front hub. See FRONT SUSPENSION,
Repairs.
11. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
12. Remove stand(s) and lower vehicle.
ANTI-ROLL BAR
´÷ 60.10.01
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove bolts securing anti-roll bar to anti-roll bar
links and collect nuts and washers.
3. Remove anti-roll bar bushes. See FRONT
SUSPENSION, Repairs.
4. Remove anti-roll bar.
Refit
1. Fit anti-roll bar.
2. Fit anti-roll bar bushes. See FRONT
SUSPENSION, Repairs.
3. Fit bolts, nuts and washers securing anti-roll bar
to anti-roll bar links and tighten bolts to 45 Nm.
4. Remove stand(s) and lower vehicle.
FRONT SUSPENSÌON
60-8 REPAÌRS
ANTI-ROLL BAR LINK
´÷ 60.10.02
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front road wheel.
3. Remove bolt and washer securing anti-roll bar
link to lower arm.
4. Remove nut, washer and bolt securing link to
anti-roll bar.
5. Remove anti-roll bar link.
Refit
1. Position link to anti-roll bar and lower arm.
2. Fit bolt, washer and nut securing link to anti-roll
bar, but do not tighten.
3. Fit bolt and washer securing link to lower arm and
tighten to 60 Nm.
4. Tighten nut and bolt securing link to anti-roll bar
to45 Nm.
5. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
6. Remove stand(s) and lower vehicle.
ANTI-ROLL BAR BUSHES
´÷ 60.10.05
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 2 bolts securing anti-roll bar bush clamp
to rear beam.
3. Remove clamp and bush.
4. Remove bush from clamp.
Refit
1. Clean bush mating surfaces.
2. Smear bore of bush with rubber grease.
3. Fit bush to anti-roll bar, ensuring split faces
rearwards.
4. Fit clamp to bush.
5. Fit and tighten bolts to 22 Nm.
6. Repeat remove and refit operations on second
bush.
7. Remove stand(s) and lower vehicle.
FRONT SUSPENSÌON
REPAÌRS 60-9
SUSPENSION LOWER ARM ASSEMBLY
´÷ 60.35.02
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front road wheel.
3. Release drive shaft nut stake.
4. With assistance remove and discard drive shaft
nut.
5. Remove and discard nut securing track rod end
to front hub.
6. Release taper joint using 18G 1584 and release
track rod from front hub.
7. Remove bolt securing anti-roll bar link to lower
arm.
8. Remove bolt securing brake hose to support
bracket.
9. Release ABS harness from 2 retainers.
10. Remove clamp bolt securing front hub to damper.
11. Release front hub from damper.
12. Release drive shaft from front hub and tie aside.
13. Refit front hub to damper, fit and lightly tighten
bolt to support front hub.
14. Remove and discard split pin from castellated nut
securing front hub to lower arm.
15. Loosen castellated nut securing front hub to
lower arm, until flush with the end of the joint. Ìf
necessary, apply penetrating oil to joint.
FRONT SUSPENSÌON
60-10 REPAÌRS
16. Break taper joint using tool 18G 1584.
CAUTION: Be carefuI not to damage the
rubber boot on Iower baII joint.
17. Remove nut from lower ball joint and release
lower arm from front hub.
18. Remove 2 bolts securing tie rod to lower arm.
19. Remove bolt securing lower arm to rear beam.
20. Remove lower arm assembly.
Refit
1. Clean lower arm and rear beam mating faces.
2. Clean lower ball joint and mating face of front
hub.
3. Position lower arm to rear beam, fit bolt, but do
not tighten.
4. Locate front hub on lower arm ball joint.
5. Fit castellated nut securing hub to lower arm and
tighten to 55 Nm, then align next slot in nut with
split pin hole.
6. Fit new split pin through castellated nut and
secure.
7. Align tie rod to lower arm, fit bolts and tighten to
80 Nm.
8. Remove bolt retaining front hub to damper and
release front hub from damper.
9. Engage drive shaft in front hub.
10. Clean damper and front hub mating faces.
11. Position front hub to damper, ensuring full
engagement of damper in front hub and correct
alignment of clamp bolt groove.
12. Fit clamp bolt and tighten to 80 Nm .
13. Tighten bolt securing lower arm to rear beam to
60 Nm.
14. Clean track rod end taper and register.
15. Position track rod end, fit new nut and tighten to
45 Nm.
16. Position anti-roll bar link to lower arm, fit bolt and
tighten to 60 Nm .
17. Position brake hose to support bracket, fit bolt
and tighten to 25 Nm.
18. Secure ABS harness in retainers.
19. With assistance fit new drive shaft nut and tighten
to 180 Nm.
20. Stake drive shaft nut.
21. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
22. Remove stand(s) and lower vehicle.
FRONT SUSPENSÌON
REPAÌRS 60-11
SUSPENSION LOWER ARM BUSH
´÷ 60.35.26
Remove
1. Remove suspension lower arm. See FRONT
SUSPENSION, Repairs.
2. Hold tool 18G 1600/1 securely in a vice.
3. Position lower arm to tool 18G 1600/1.
4. Using the small diameter end of tool 18G 1600/2,
press out bush from lower arm.
Refit
1. Clean hole in lower arm where bush will be
situated.
2. Position lower arm to tool 18G 1600/1. Hold
securely in a vice.
3. Using the larger diameter end of tool 18G 1600/2
press new bush into lower arm.
4. Fit suspension lower arm. See FRONT
SUSPENSION, Repairs.
FRONT BEAM
´÷ 60.35.21
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
'L´ Series:
2. Remove undertray. EXTERIOR FITTINGS,
Repairs.
K16 with VVC
3. Remove splash shield. EXTERIOR FITTINGS,
Repairs.
All Models
4. Remove nut securing each tie rod to front beam.
5. Remove 2 flanged washers and 2 bushes.
6. Remove 4 bolts securing front beam to body.
7. Remove front beam.
FRONT SUSPENSÌON
60-12 REPAÌRS
Refit
1. Clean mating faces of front beam and body.
2. Position front beam to body.
3. Fit 4 bolts securing front beam to body and
tighten to 100 Nm.
4. Fit bushes and flanged washers to tie rods, fit
nuts and tighten to 45 Nm.
'L´ Series:
5. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
K16 with VVC
6. Fit splash shield. See EXTERIOR FITTINGS,
Repairs.
All Models
7. Remove stand(s) and lower vehicle.
REAR BEAM - WITH POWER STEERING
RACK
´÷ 60.35.23
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
4. Remove steering rack. See STEERING,
Repairs.
5. Remove 2 bolts securing both lower arms to rear
beam.
6. Remove 2 bolts securing both anti-roll bar links to
anti-roll bar.
FRONT SUSPENSÌON
REPAÌRS 60-13
7. Remove bolt securing power steering pipe to rear
beam.
8. Remove bolt securing clutch cable bracket to rear
beam.
'K´ Series only
9. Release evaporative emission cannister vent
hose from rear beam.
All Models
10. Loosen 4 bolts securing rear beam to body.
11. Lower beam to gain access to bolt securing PAS
pipe to beam.
12. Remove bolt securing pipe to beam.
FRONT SUSPENSÌON
60-14 REPAÌRS
13. With assistance, remove 4 bolts securing beam
to body. Release beam from lower arms and
lower to floor.
Do not carry out further dismantling if component
is removed for access only.
14. Remove steering column mounting rubber.
'K´ Series only
15. Remove evaporative emission cannister vent
hose plastic collar from beam.
All models
16. Remove 2 bolts securing exhaust front pipe
mounting bracket to beam.
17. Remove anti-roll bar bushes. See FRONT
SUSPENSION, Repairs.
18. Remove anti-roll bar and position to new beam.
19. Fit anti-roll bar bushes. See FRONT
SUSPENSION, Repairs.
20. Position exhaust front pipe mounting bracket to
beam and secure with bolts.
21. Fit steering column mounting rubber to beam.
'K´ Series only
22. Fit evaporative emission cannister vent hose
plastic collar to beam.
FRONT SUSPENSÌON
REPAÌRS 60-15
Refit
1. With assistance, offer beam to body and engage
lower arms.
2. Fit bolts securing beam to body. DO NOT tighten
bolts.
3. Position PAS pipe to beam and secure with bolt.
4. Tighten bolts securing beam to body to 100 Nm.
'K´ Series only
5. Fit evaporative emission cannister vent hose to
beam.
All Models
6. Position clutch cable to beam and secure with
bolt.
7. Position PAS pipe to beam and secure with bolt.
8. Fit bolts securing anti-roll bar to anti-roll bar links
and tighten to 45 Nm.
9. Fit bolts securing lower arms to beam and tighten
to 60 Nm.
10. Fit steering rack. See STEERING, Repairs.
11. Fit exhaust front pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
12. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
13. Remove stand(s) and lower vehicle.
TIE ROD
´÷ 60.40.09
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove front road wheel.
Diesel models
3. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
All Models
4. Remove nut securing tie rod to front beam.
5. Remove flanged washer and bush.
6. Remove 2 bolts securing tie rod to lower arm.
7. Remove tie rod.
8. Remove spacer, bush and flanged washer from
tie rod.
FRONT SUSPENSÌON
60-16 REPAÌRS
Refit
1. Clean threads of tie rod bolts and holes in lower
suspension arm.
2. Fit flanged washer, bush and spacer to tie rod.
3. Locate tie rod in front beam, fit bush and flanged
washer.
4. Fit nut securing tie rod to front beam, but do not
tighten.
5. Fit bolts securing tie rod to lower arm and tighten
to 80 Nm.
6. Tighten nut, tie rod to front beam, to 45 Nm.
Diesel models
7. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
All Models
8. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
9. Remove stand(s) and lower vehicle.
REAR SUSPENSÌON
REPAÌRS 64-1
REAR SUSPENSÌON REPAÌ RS
REAR DAMPER
´÷ 64.30.02
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove screw securing side carpet and pull
aside for access.
4. Remove upper cover from damper.
5. Remove 2 nuts securing damper to body.
6. Support 'H' frame on jack.
7. Remove bolt securing damper to 'H' frame.
8. Release and remove spring and damper
assembly.
Do not carry out further dismantling if component
is removed for access only.
9. Position spring compressor tool 18G 1516 in
vice.
10. Position spring and damper assembly to spring
compressor with lower mounting and upper
mounting studs vertical and spring stop to rear,
as illustrated.
11. Compress spring 2 - 3 cm, hold shaft with 5 mm
Allen key and remove spring mounting plate nut.
Discard nut.
REAR SUSPENSÌON
64-2 REPAÌRS
12. Remove washer and mounting plate.
13. Remove damper from spring.
14. Remove bump stop plate, bump stop and dust
cover.
15. Ìnspect damper and spring mounting rubbers for
deterioration and damage.
16. Ìnspect dust cover for damage.
Refit
1. Fit bump stop, bump stop plate and dust cover to
damper.
2. Fit damper to spring ensuring lower mounting is
vertical and spring stop is to rear.
3. Compress spring and fit spring mounting plate
ensuring studs are vertical, fit washer and new
nut.
4. Hold shaft with Allen key and tighten nut to 29
Nm.
5. Release tension ensuring spring mounting plate
and damper are aligned.
6. Remove spring and damper assembly from
spring compressor.
7. Remove spring compressor from vice.
8. Fit and align spring and damper assembly to
vehicle. Fit new top mounting nuts but DO NOT
tighten.
9. Raise 'H' frame and fit damper bolt, DO NOT
tighten.
10. Raise jack to support weight of vehicle, tighten
damper top mounting nuts to 38 Nm and fit cover.
11. Tighten bolt securing damper to 'H' frame to 80
Nm.
12. Remove jack.
13. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
14. Remove stand(s) and lower vehicle.
15. Position boot side carpet and secure with screw.
REAR SUSPENSÌON
REPAÌRS 64-3
REAR HUB AND BEARING - MODELS
WITH DISC BRAKES
´÷ 64.15.14
The rear hub and bearings are serviced as an
assembly and cannot be individually renewed.
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove brake disc. See BRAKES, Repairs.
3. Remove dust cover from centre of hub.
4. Knock back staking and remove hub nut and
washer. Discard nut.
NOTE: The nut threads are handed, i.e the hub
nut on the LH side has a LH thread.
5. Remove hub assembly.
Refit
1. Clean hub and stub axle.
2. Lubricate seal running surface with grease.
3. Fit hub assembly.
4. Fit washer and new nut. Tighten nut to 185 Nm.
5. Stake the nut to stub axle and fit dust cover.
6. Fit brake disc. See BRAKES, Repairs.
7. Remove stand(s) and lower vehicle.
8. Apply foot brake several times and then check
handbrake operation.
REAR HUB AND BEARING - MODELS
WITH DRUM BRAKES WITHOUT ABS
´÷ 64.15.14
The rear hub and bearings are serviced as an
assembly and cannot be individually renewed.
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove brake drum. See BRAKES, Repairs.
3. Remove dust cover from centre of hub.
4. Knock back staking and remove hub nut and
washer. Discard nut.
NOTE: The nut threads are handed, i.e the hub
nut on the LH side has a LH thread.
5. Remove hub assembly.
Refit
1. Clean hub and stub axle.
2. Lubricate seal running surface with grease.
3. Fit hub assembly.
4. Fit washer and new nut. Tighten nut to 185 Nm .
5. Stake the nut to stub axle and fit dust cover.
6. Fit brake drum. See BRAKES, Repairs.
7. Remove stand(s) and lower vehicle.
8. Apply foot brake several times and then check
handbrake operation.
REAR SUSPENSÌON
64-4 REPAÌRS
REAR HUB AND BEARING - MODELS
WITH DRUM BRAKES AND ABS
´÷ 64.15.14
The rear hub and bearings are serviced as an
assembly and cannot be individually renewed.
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove brake drum. See BRAKES, Repairs.
3. Remove dust cover from centre of hub.
4. Knock back staking and remove hub nut and
washer. Discard nut.
NOTE: The nut threads are handed, i.e the hub
nut on the LH side has a LH thread.
5. Remove hub assembly.
6. Remove 2 clips and 2 pins retaining brake shoes.
7. Ease one shoe out of retaining groove in
abutment followed by other shoe.
8. Detach return spring from leading shoe end and
remove spring.
NOTE: The forward shoe is the LEADING shoe,
the TRAILING shoe has the handbrake lever
attached to it.
9. Disconnect handbrake cable from brake lever.
10. Remove brake shoe assembly.
CAUTION: Ensure edges of brake shoes do
not damage wheeI cyIinder dust covers.
REAR SUSPENSÌON
REPAÌRS 64-5
11. Fit an elastic band around wheel cylinder to retain
pistons.
Refit
1. Clean hub and stub axle.
2. Lubricate seal running surface with grease.
3. Fit hub assembly.
4. Fit washer and new nut. Tighten nut to 185 Nm.
5. Stake the nut to stub axle and fit dust cover.
6. Loosen ABS adapter clamp screw.
7. Using a feeler gauge, set clearance 'A' between
sensor and reluctor ring. Clearance 'A' = 0.5 mm.
8. Tighten adapter clamp screw to 0.5 Nm.
9. Manoeuvre shoe assembly into position between
hub and wheel cylinder and connect hand brake
cable to brake shoe lever.
10. Fit lower return spring to trailing shoe and
connect spring to leading shoe.
11. Remove elastic band from wheel cylinder.
12. Engage leading shoe to wheel cylinder followed
by trailing shoe and align.
NOTE: During this operation the adjuster may
become extended, this is not important but it
must be reset prior to fitting brake drum.
13. Fit trailing shoe into abutment bracket followed by
leading shoe.
14. Check adjuster cam and if necessary set to
minimum adjustment position as follows: lever
leading shoe away from wheel cylinder, move
adjuster cam back fully and ease shoe back into
position.
15. Fit brake shoe retaining pins and clips.
16. Fit brake drum. See BRAKES, Repairs.
17. Remove stand(s) and lower vehicle.
18. Apply foot brake several times and then check
handbrake operation.
19. To ensure correct operation, the ABS MUST be
checked using TestBook.
REAR SUSPENSÌON
64-6 REPAÌRS
REAR STUB AXLE - MODELS WITH DISC
BRAKES
´÷ 64.15.20
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove rear brake disc. See BRAKES,
Repairs.
4. Remove Torx screw securing ABS sensor to stub
axle.
5. Remove ABS sensor.
6. Remove 4 bolts securing stub axle to 'H' frame.
7. Remove stub axle.
Do not carry out further dismantling if component
is removed for access only.
8. Remove 2 Torx screws securing ABS sensor
mounting to stub axle and remove mounting.
REAR SUSPENSÌON
REPAÌRS 64-7
9. Remove dust cover from centre of hub.
10. Knock back staking and remove nut securing hub
to stub axle. Discard nut.
11. Remove hub from stub axle and collect washer.
12. Remove 4 bolts securing disc shield to stub axle.
13. Remove disc shield.
14. Clean disc shield.
15. Fit disc shield to new stub axle and tighten bolts
to 10 Nm.
16. Fit hub to stub axle.
17. Fit washer and new nut to hub. Tighten nut to 185
Nm. Stake the nut to stub axle.
18. Fit dust cover to hub.
19. Position ABS sensor mounting to stub axle and
tighten Torx screws to 10 Nm.
Refit
1. Position stub axle to 'H' frame, fit bolts and
tighten to 45 Nm.
2. Fit ABS sensor to mounting on stub axle and
tighten Torx screw to 6 Nm.
3. Fit rear brake disc. See BRAKES, Repairs.
4. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
5. Remove stand(s) and lower vehicle.
REAR STUB AXLE - MODELS WITH DRUM
BRAKES
´÷ 64.15.20
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove rear brake drum. See BRAKES,
Repairs.
4. Remove 2 clips and 2 pins retaining brake shoes.
REAR SUSPENSÌON
64-8 REPAÌRS
5. Ease one brake shoe out of retaining groove in
abutment followed by other shoe.
6. Detach return spring from leading shoe end and
remove spring.
NOTE: The forward shoe is the LEADING shoe,
the TRAILING shoe has the handbrake lever
attached to it.
7. Disconnect handbrake cable from brake lever.
8. Manoeuvre shoe assembly around wheel
cylinder and remove.
CAUTION: Ensure edges of brake shoes do
not damage wheeI cyIinder dust covers.
9. Fit an elastic band around wheel cylinder to retain
pistons.
10. Using a 12 mm ring spanner, release handbrake
cable retainer from backplate and withdraw
handbrake cable.
11. Position container to collect any fluid spillage.
REAR SUSPENSÌON
REPAÌRS 64-9
12. Disconnect brake pipe union from wheel cylinder.
CAUTION: PIug the connections.
Models with ABS:
13. Release ABS sensor multiplug from clip.
Disconnect multiplug and release harness from
'H' frame.
REAR SUSPENSÌON
64-10 REPAÌRS
All models:
Model without ABS illustrated:
14. Remove 4 bolts securing stub axle to 'H' frame.
15. Remove stub axle.
Do not carry out further dismantling if component
is removed for access only.
16. Remove dust cover from centre of hub.
17. Knock back staking and remove hub nut and
washer. Discard nut.
NOTE: The nut threads are handed, i.e the hub
nut on the LH side has a LH thread.
18. Remove hub assembly.
19. Remove 4 bolts securing backplate to stub axle.
Release and remove backplate.
Refit
1. Fit backplate to stub axle.
Models with ABS:
2. Align ABS sensor adapter to backplate.
All models:
3. Fit bolts securing backplate and tighten to 45 Nm.
4. Clean hub and stub axle.
5. Lubricate seal running surface with grease.
6. Fit hub assembly.
7. Fit washer and new nut. Tighten nut to 185 Nm.
8. Stake nut to stub axle and fit dust cover.
9. Position stub axle to 'H' frame, fit bolts and
tighten to 45 Nm.
Models with ABS:
10. Connect harness multiplug. Secure multiplug to
clip and harness to 'H' frame.
All models:
11. Connect brake pipe to wheel cylinder and tighten
union to 19 Nm.
Models with ABS:
12. Loosen ABS adapter clamp screw.
13. Using a feeler gauge, set clearance 'A' between
sensor and reluctor ring. Clearance 'A' = 0.5 mm.
14. Tighten adapter clamp screw to 0.5 Nm.
REAR SUSPENSÌON
REPAÌRS 64-11
All models:
15. Secure handbrake cable to backplate.
16. Manoeuvre shoe assembly into position between
hub and wheel cylinder and connect hand brake
cable to brake shoe lever.
17. Fit lower return spring to trailing shoe and
connect spring to leading shoe.
18. Remove elastic band from wheel cylinder.
19. Engage leading shoe to wheel cylinder followed
by trailing shoe and align both shoes to wheel
cylinder.
NOTE: During this operation the adjuster may
become extended, this is not important but it
must be reset prior to fitting brake drum.
20. Fit trailing shoe into abutment bracket followed by
leading shoe.
21. Check adjuster cam and if necessary set to
minimum adjustment position as follows: lever
leading shoe away from wheel cylinder, move
adjuster cam back fully and ease shoe back into
position.
22. Fit brake shoe retaining pins and clips.
23. Fit rear brake drum. See BRAKES, Repairs.
24. Bleed brakes. See BRAKES, Adjustments.
25. Check handbrake operation, adjust if necessary.
See BRAKES, Adjustments.
26. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
27. Remove stand(s) and lower vehicle.
Models with ABS:
28. To ensure correct operation, the system MUST
be checked using TestBook.
REAR SUSPENSÌON
64-12 REPAÌRS
'H' FRAME BUSH
´÷ 64.35.68
NOTE: The 'H' frame bush should be inspected at
regular intervals. Twist the inner of the bush relative to
the housing to check for splits. If any exceed 5 mm in
depth the bush must be replaced.
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove rear road wheel.
3. Remove clip securing brake pipe to 'H' frame.
4. Release brake pipe from 'H' frame.
5. Support hub with trolley jack.
6. Remove 'H' frame pivot bolt.
7. Remove bolt securing rear damper assembly to
'H' frame.
Models with ABS:
8. Release ABS harness from 'H' frame.
All models:
9. Lower 'H' frame and release bush from mounting
bracket.
REAR SUSPENSÌON
REPAÌRS 64-13
10. Fit tools 18G 1756/12, 18G 1756/2, and 18G
1756/4 to bush as shown in illustration.
11. Rotate handle of tool to withdraw bush.
Refit
1. Position bush to 'H' frame and fit tools 18G 1756/
12,18G 1756/3, and 18G 1756/5 as shown in
illustration.
2. Rotate handle of tool to press bush into 'H' frame.
3. Raise 'H' frame on jack and fit bolt securing
damper assembly and tighten to 80 Nm.
4. Position 'H' frame and fit pivot bolt. Tighten bolt to
100 Nm.
5. Position brake hose to 'H' frame and secure with
clip.
6. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
7. Remove stand(s) and lower vehicle.
'H' FRAME - MODELS WITH DISC BRAKES
´÷ 64.35.67
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
4. Remove handbrake cable adjusting nut.
REAR SUSPENSÌON
64-14 REPAÌRS
5. Remove 2 bolts securing handbrake cables to 'H'
frame and release cables.
6. Remove handbrake cable clevis pin spring clips
and discard.
7. Remove handbrake cable clevis pins.
8. Remove retaining clips from cable abutments.
9. Release handbrake cables from abutment
brackets.
10. Position container under hub to collect spillage.
11. Clamp brake hoses to prevent fluid loss.
CAUTION: A brake hose cIamp must be used.
12. Remove brake hose banjo bolts and discard
sealing washers.
CAUTION: PIug the connections.
13. Remove clips securing brake pipes to 'H' frame
and release pipes.
REAR SUSPENSÌON
REPAÌRS 64-15
14. Release ABS sensor multiplugs from clips and
disconnect.
15. Position trolley jack to support centre of 'H' frame.
16. Remove 2 bolts securing both damper
assemblies to 'H' frame.
17. Carefully lower trolley jack to disengage dampers
from 'H' frame.
18. With an assistant to support 'H' frame, remove 2
pivot bolts securing 'H' frame to body.
19. With assistance, remove 'H' frame from vehicle.
Do not carry out further dismantling if component
is removed for access only.
REAR SUSPENSÌON
64-16 REPAÌRS
20. Remove 2 nuts securing anti-roll bar to 'H' frame.
21. Remove 4 bolts securing each hub/stub axle
assembly to 'H' frame and remove hubs.
22. Position hub/stub axle assembly to new 'H' frame
and tighten bolts to 45 Nm.
23. Position new pivot bush to 'H' frame and fit tools
18G 1756/12,18G 1756/3 and 18G 1756/5 as
shown in illustration.
24. Rotate handle of tool to press bush into 'H' frame
and remove tools.
25. Fit second pivot bush to 'H' frame.
Refit
1. With assistance, position 'H' frame to vehicle and
fit pivot bolts. DO NOT tighten.
2. Using a trolley jack, raise centre of 'H' frame and
locate damper assemblies.
3. Tighten bolts securing damper assemblies to 'H'
frame to 80 Nm.
4. Remove trolley jack.
5. Tighten 'H' frame pivot bolts to 100 Nm.
6. Manoeuvre handbrake cables into position with
abutment brackets.
7. Fit cable retaining clips to abutments.
8. Align cables to levers. Fit clevis pins and secure
with new spring clips.
9. Align handbrake cables to location points on 'H'
frame and secure with bolts.
10. Fit brake pipes to mounting brackets and secure
with clips.
11. Clean banjo bolts and fit new sealing washers.
12. Position hoses to calipers and tighten banjo bolts
to 34 Nm.
13. Connect ABS sensor multiplugs and secure to
body with clips.
14. Bleed brakes. See BRAKES, Adjustments.
15. Connect handbrake cables to equaliser.
16. Ensure spring is in place and engage equaliser
on adjusting rod.
17. Fit cable adjusting nut.
18. Adjust handbrake cable. See BRAKES,
Adjustments.
19. Fit rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
20. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
21. Remove stand(s) and lower vehicle.
22. Check rear wheel alignment and adjust if
necessary. See STEERING, Adjustments.
REAR SUSPENSÌON
REPAÌRS 64-17
'H' FRAME - MODELS WITH DRUM
BRAKES
´÷ 64.35.67
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
4. Remove handbrake cable adjusting nut.
5. Remove 2 bolts securing handbrake cables to 'H'
frame and release cables.
6. Remove both rear drums. See BRAKES,
Repairs.
7. Remove 4 clips and 4 pins retaining LH and RH
brake shoe assemblies.
REAR SUSPENSÌON
64-18 REPAÌRS
8. Disconnect both trailing shoes from abutment
brackets.
9. Disconnect both handbrake cables from brake
levers.
CAUTION: Ensure edges of brake shoes do
not damage wheeI cyIinder dust covers.
10. Using a 12 mm ring spanner, release cables from
backplates and withdraw cables.
11. Position container to collect fluid spillage.
12. Disconnect brake pipe unions from wheel
cylinders.
CAUTION: PIug the connections.
13. Remove clips securing brake pipes to 'H' frame
and release pipes.
Models with ABS:
14. Release ABS sensor multiplugs from clips.
Disconnect multiplugs.
REAR SUSPENSÌON
REPAÌRS 64-19
All models:
15. Position trolley jack to support centre of 'H' frame.
16. Remove 2 bolts securing both damper
assemblies to 'H' frame.
17. Carefully lower trolley jack to disengage dampers
from 'H' frame.
18. With an assistant to support 'H' frame, remove 2
pivot bolts securing 'H' frame to body.
19. With assistance, remove 'H' frame from vehicle.
Do not carry out further dismantling if
component is removed for access only.
Models with ABS:
20. Release ABS sensor harnesses from 'H' frame.
REAR SUSPENSÌON
64-20 REPAÌRS
All models:
21. Remove 4 bolts securing each hub/stub axle
assembly to 'H' frame.
22. Remove each hub/stub axle assembly.
23. Position each hub/sub axle assembly to new 'H'
frame and tighten bolts to 45 Nm.
Models with ABS:
24. Secure ABS sensor harnesses to 'H' frame.
All models:
25. Position new pivot bush to 'H' frame and fit tools
18G 1756/12,18G 1756/3 and 18G 1756/5 as
shown in illustration.
26. Rotate handle of tool to press bush into 'H' frame
and remove tools.
27. Fit second pivot bush to 'H' frame.
Refit
1. With assistance, position 'H' frame to vehicle and
fit pivot bolts. DO NOT tighten.
2. Using a trolley jack, raise centre of 'H' frame and
locate damper assemblies.
3. Tighten bolts securing damper assemblies to 'H'
frame to 80 Nm.
4. Remove trolley jack.
5. Tighten 'H' frame pivot bolts to 100 Nm.
Models with ABS:
6. Connect sensor multiplugs and secure to clips.
All models:
7. Manoeuvre handbrake cables into position and
connect to handbrake levers.
8. Connect lower springs and fit trailing shoes onto
abutments.
9. Fit brake shoe retaining pins and secure with
clips.
10. Fit brake drums. See BRAKES, Repairs.
11. Align handbrake cables to location points on 'H'
frame and secure with bolts.
12. Fit brake pipes to mounting brackets and secure
with clips.
13. Connect brake pipes to wheel cylinders and
tighten unions to 19 Nm.
14. Bleed brakes. See BRAKES, Adjustments.
15. Connect handbrake cables to equaliser.
16. Ensure spring is in place and engage equaliser
on adjusting rod.
17. Fit cable adjusting nut.
18. Adjust handbrake cable. See BRAKES,
Adjustments.
19. Fit rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
20. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
21. Remove stand(s) and lower vehicle.
22. Check rear wheel alignment and adjust if
necessary. See STEERING, Adjustments.
REAR SUSPENSÌON
REPAÌRS 64-21
'H' FRAME MOUNTING BRACKET
´÷ 64.35.69
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove rear road wheel.
3. Remove clip securing brake pipe to 'H' frame.
4. Release brake pipe from 'H' frame.
5. Support hub with trolley jack.
6. Remove 'H' frame pivot bolt.
7. Remove bolt securing rear damper assembly to
'H' frame.
Models with ABS:
8. Release ABS harness from 'H' frame.
All models:
9. Lower 'H' frame and release bush from mounting
bracket.
REAR SUSPENSÌON
64-22 REPAÌRS
10. Remove 3 bolts securing mounting bracket to
body.
11. Remove mounting bracket.
Refit
1. Position mounting bracket to body.
2. Fit bolts securing mounting bracket to body and
tighten to 100 Nm.
3. Raise 'H' frame on jack and fit bolt securing
damper assembly and tighten to 80 Nm.
Models with ABS:
4. Secure ABS sensor harness to 'H' frame.
All models:
5. Position 'H' fame and fit pivot bolt. Tighten bolt to
100 Nm.
6. Position brake hose to 'H' frame and secure with
clip.
7. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
8. Remove stand(s) and lower vehicle.
9. Check rear wheel alignment. See STEERING,
Adjustments.
BRAKES
ADJUSTMENTS 70-1
BRAKES ADJUSTMENTS
BRAKE SYSTEM BLEEDING
´÷ 70.25.02
The following procedure covers bleeding the complete
system, but where only the primary or secondary
circuit has been disturbed in isolation it should only be
necessary to bleed that circuit. Partial bleeding of the
hydraulic system is only permissible if a brake pipe or
hose has been disconnected with only minor loss of
fluid.
CAUTION: Never re-use fIuid that has been bIed
from the system. Do not aIIow fIuid IeveI in master
cyIinder to faII beIow 'mim' mark during bIeeding.
Do not fiII reservoir above 'max' mark
CAUTION: Do not aIIow brake fIuid to contact paint
finished sufaces as paint may be damaged. If
spiIIed, remove fIuid and cIean area with cIean
warm water.
BIeed
1. Raise front and rear of vehicle.
WARNING: Support on safety stands.
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, fIuids
and Iubricants.
CAUTION: Use onIy new brake fIuid of the
recommended grade.
Bleed sequence.
LH front. RH rear.
RH front. LH rear.
4. Attach bleed tube to LH front brake caliper bleed
screw, submerge free end in a clear container
containing brake fluid.
NOTE: Bleed brakes with engine running and
handbrake in OFF position.
5. Apply pressure to brake pedal several times, then
apply steady pressure.
6. Loosen bleed screw to release brake fluid and
air.
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 on calipers and 7 Nm on wheel cylinders.
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.
CAUTION: Braking efficiency may be
seriousIy impaired if wrong bIeed sequence
is used.
10. Remove bleed tube. Apply brakes and check for
leakage.
11. Remove stand(s) and lower vehicle.
12. Road test vehicle. Check brake pedal for short
firm travel when brakes are applied.
BRAKES
70-2 ADJUSTMENTS
HANDBRAKE CABLE
´÷ 70.35.10
NOTE: If carrying out handbrake adjustment after
installation of new pads/shoes, loosen handbrake
cable adjusting nut, start engine and depress brake
pedal several times to set self adjust mechanism.
Check
1. Apply handbrake lever one notch at a time and
count number of notches required to apply the
brakes firmly, equivalent to a pull of 20 kgf, 44 lbf
applied 50 mm (2 in) from the end of the lever.
Handbrake lever travel = 7 - 11 notches
2. Adjust handbrake cable tension if travel is outside
limits.
Adjust
1. Raise rear of vehicle.
WARNING: Support on safety stands.
Models with disc brakes fitted
2. Remove road wheel(s).
3. Ensure handbrake arm on each caliper contacts
the brake caliper pin.
4. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
All Models
5. Remove ashtray from rear console.
6. Check handbrake cable connections for free
movement in handbrake equaliser.
7. Apply handbrake one notch.
8. Tighten equaliser adjusting nut until rear wheels
drag slightly when turned.
9. Release handbrake lever and check that rear
wheels do not drag when turned. readjust if
necessary.
10. Apply handbrake one notch at a time and count
the number of notches until both rear wheels
lock. Readjust if necessary.
11. Release handbrake lever.
12. Fit ash tray to rear console.
13. Remove stand(s) and lower vehicle.
BRAKES
ADJUSTMENTS 70-3
BRAKE LIGHT SWITCH - MANUAL
ADJUSTING TYPE ONLY
´÷ 70.35.41
Adjust
1. Release 3 turnbuckles securing fuse box cover to
lower fascia.
2. Remove fuse box cover.
3. Release 2 turnbuckles securing closing panel to
underside of fascia.
4. Remove closing panel.
5. Remove 2 nuts securing passenger
compartment fuse box to mounting bracket.
6. Release fuse box from mounting bracket.
7. Disconnect multiplug from brake light switch.
8. Loosen locknut securing brake light switch to
pedal box.
9. Connect an ohmmeter across switch terminal 2
and 3.
BRAKES
70-4 ADJUSTMENTS
10. Screw switch in until an open circuit condition
exists with the pedal released and a closed circuit
condition exists with the pedal depressed.
11. Screw switch in one further turn.
12. Tighten brake light switch locknut.
CAUTION: Ensure the switch does not
prevent the brake pedaI returning fuIIy.
13. Connect multiplug to brake light switch.
14. Fit fuse box to mounting bracket, fit nuts and
tighten to 10 Nm.
15. Position closing panel to underside of fascia and
secure with turnbuckles.
16. Fit fuse box cover and secure with turnbuckles.
BRAKES
REPAÌRS 70-5
REPAÌ RS
HANDBRAKE WARNING SWITCH
´÷ 70.35.40
Remove
1. Remove rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Disconnect Lucar from switch.
3. Remove screw securing switch to handbrake.
4. Remove switch from handbrake.
Refit
1. Fit switch to handbrake and tighten screw to 5
Nm.
2. Connect Lucar to switch.
3. Fit rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
BRAKE LIGHT SWITCH - MANUAL
ADJUSTING TYPE
´÷ 70.35.42
Remove
1. Release 3 turnbuckles securing fuse box cover to
lower fascia.
2. Remove fuse box cover.
3. Release 2 turnbuckles securing closing panel to
underside of fascia.
4. Remove closing panel.
BRAKES
70-6 REPAÌRS
5. Remove 2 nuts securing passenger
compartment fuse box to mounting bracket.
6. Release fuse box from mounting bracket.
7. Disconnect multiplug from brake light switch.
8. Loosen locknut securing brake light switch to
pedal box.
9. Remove brake light switch.
Refit
1. Fit brake light switch.
2. Adjust brake light switch. See BRAKES,
Adjustments.
3. Connect multiplug to brake light switch.
4. Fit fuse box to mounting bracket, fit nuts and
tighten to 10 Nm.
5. Position closing panel to underside of fascia and
secure with turnbuckles.
6. Fit fuse box cover and secure with turnbuckles.
BRAKE LIGHT SWITCH - SELF
ADJUSTING TYPE
´÷ 70.35.42
Remove
1. Remove drivers pocket from fascia lower cover.
2. Remove 3 screws securing lower cover and
remove cover.
3. Disconnect multiplug from brake light switch.
4. Rotate brake light switch clockwise, release and
remove from pedal bracket.
SP70 0059
BRAKES
REPAÌRS 70-7
Refit
1. Position brake light switch, rotate and secure in
pedal bracket.
2. Connect multiplug to brake light switch.
3. Position fascia lower cover, fit and tighten
screws.
4. Fit drivers pocket to lower cover.
FLUID LEVEL SWITCH
´÷ 70.25.08
Remove
1. Disconnect switch lead.
2. Clean area around reservoir cap.
3. Remove cap/switch assembly.
CAUTION: Do not aIIow brake fIuid to contact
paint finished surfaces as paint may be
damaged. If spiIIed, remove fIuid and cIean
area with cIean warm water.
Refit
1. Check and top-up fluid level.
2. Fit cap/switch assembly.
3. Connect switch lead.
BRAKES
70-8 REPAÌRS
HANDBRAKE LEVER
´÷ 70.35.08
Remove
1. Remove rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Disconnect Lucar from handbrake warning
switch.
3. Remove cable adjusting nut.
4. Remove 2 bolts securing handbrake lever
assembly.
5. Remove spring from adjusting rod.
Refit
1. Fit spring to adjusting rod.
2. Position handbrake. Fit and tighten bolts to 22
Nm .
3. Fit cable adjusting nut.
4. Connect Lucar to handbrake warning switch.
5. Adjust handbrake cable. See BRAKES,
Adjustments.
6. Fit rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
BRAKES
REPAÌRS 70-9
ABS SENSOR - FRONT
´÷ 70.25.32
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
Located on ABS modulator bracket.
Located below brake servo.
3. Release sensor multiplug from clip on body and
disconnect multiplug.
BRAKES
70-10 REPAÌRS
4. Release sensor harness from 5 clips in wheel
arch.
5. Release grommet and withdraw harness into
wheel arch.
6. Remove screw securing sensor to hub.
7. Remove sensor and harness.
Refit
1. Clean mating surfaces of sensor and hub.
2. Fit sensor to hub and tighten screw to 6 Nm.
3. Pass harness through body and locate grommet.
4. Secure harness to clips in wheel arch.
5. Ensuring 'O' ring is in place, connect sensor
harness multiplug and secure multiplug in clip.
6. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
7. Remove stand(s) and lower vehicle.
8. To ensure correct operation, the system MUST
be tested using TestBook.
BRAKES
REPAÌRS 70-11
ABS SENSOR - REAR - MODELS WITH
DISC BRAKES
´÷ 70.65.31
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove rear road wheel.
3. Remove Tx30 screw securing ABS sensor to hub
and release sensor.
4. Release sensor harness from 4 clips on 'H'
frame.
5. Release sensor multiplug from mounting clip.
6. Disconnect sensor multiplug and remove sensor.
Refit
1. Fit ABS sensor to hub and secure with screw.
Tighten screw to 6 Nm.
2. Secure sensor harness to clips on 'H' frame.
3. Connect harness multiplug and secure to clip.
4. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
5. Remove stand(s) and lower vehicle.
BRAKES
70-12 REPAÌRS
BRAKE PROPORTIONING VALVE - ABS
´÷ 70.25.15
Remove
1. Position cloth to absorb fluid spillage.
CAUTION: Do not aIIow brake fIuid to contact
paint finished surfaces as paint may be
damaged. If spiIIed, remove fIuid and cIean
area with cIean warm water.
2. Disconnect 4 brake pipes from valve.
CAUTION: PIug the connections.
3. Remove 2 nuts securing valve bracket to
bulkhead.
4. Remove valve and bracket assembly.
CAUTION: Do not remove screws securing
vaIve to bracket.
Refit
1. Position valve and bracket assembly and align
pipes to valve and start unions.
2. Align valve bracket to body and tighten nuts to 10
Nm.
3. Tighten pipe unions to 19 Nm.
4. Remove cloth.
5. Bleed brakes. See BRAKES, Adjustments.
BRAKE PROPORTIONING VALVE - NON
ABS
´÷ 70.25.15
Remove
1. Position cloth to absorb fluid spillage.
CAUTION: Do not aIIow brake fIuid to contact
paint finished surfaces as paint may be
damaged. If spiIIed, remove fIuid and cIean
area with cIean warm water.
2. Disconnect 6 brake pipes from valve.
CAUTION: PIug the connections.
3. Remove 2 nuts securing valve bracket to
bulkhead.
4. Remove valve and bracket assembly.
CAUTION: Do not remove screws securing
vaIve to bracket.
Refit
1. Position valve and bracket assembly and align
pipes to valve and start unions.
2. Align valve bracket to body and tighten nuts to 10
Nm.
3. Tighten pipe unions to 19 Nm.
4. Remove cloth.
5. Bleed brakes. See BRAKES, Adjustments.
BRAKES
REPAÌRS 70-13
BRAKE MASTER CYLINDER
´÷ 70.30.08
Remove
1. Disconnect fluid level multiplug.
2. Position cloth under master cylinder to absorb
spilled fluid.
CAUTION: Do not aIIow brake fIuid to contact
paint finished surfaces as paint may be
damaged. If spiIIed, remove fIuid and cIean
area with cIean warm water.
3. Disconnect secondary system pipe union from
master cylinder.
4. Disconnect primary system pipe union from
master cylinder.
CAUTION: PIug the connections.
5. Remove 2 nuts and spring washers securing
master cylinder.
6. Remove master cylinder.
Refit
1. Clean master cylinder and servo mating
surfaces.
2. Ensure rod seal is fitted to master cylinder.
3. Align servo push rod and fit master cylinder to
servo.
4. Fit nuts and spring washers, tighten to 15 Nm.
5. Connect primary and secondary brake pipes,
tighten unions to 19 Nm.
6. Connect fluid level multiplug.
7. Bleed brake system. See BRAKES, Repairs.
SERVO ASSEMBLY
´÷ 70.50.01
CAUTION: The domed nut on the push rod must
not be adjusted. The servo gasket acts as a spacer,
the correct gasket must be fitted.
Remove
1. Remove brake master cylinder. See BRAKES,
Repairs.
2. Disengage 3 turnbuckles and remove fusebox
cover.
3. Remove and discard spring clip from clevis pin.
BRAKES
70-14 REPAÌRS
4. Remove clevis pin securing brake pedal servo
push rod.
5. Remove 4 flange nuts securing servo to body.
6. Release vacuum hose from servo.
7. Remove servo assembly.
8. Remove gasket from servo.
Refit
1. Fit gasket to servo.
2. Fit servo to bulkhead, vacuum connection
uppermost, tighten nuts to13 Nm.
3. Align push rod to brake pedal, fit clevis pin and
secure with NEW spring clip.
4. Grease clevis pin.
5. Fit fuse box cover and secure turnbuckles.
6. Connect brake vacuum hose to servo. Fit brake
master cylinder. See BRAKES, Repairs.
BRAKE SERVO VACUUM PUMP
´÷ 70.50.19
Remove
1. Disconnect battery earth lead.
2. Remove alternator. See ELECTRICAL, Repairs.
3. Remove 4 bolts securing vacuum pump to
alternator.
4. Remove vacuum pump.
Refit
1. Clean mating face of alternator and vacuum
pump.
2. Fit vacuum pump to alternator, fit bolts and
tighten to 8 Nm.
3. Fit alternator. See ELECTRICAL, Repairs.
4. Connect battery earth lead.
BRAKES
REPAÌRS 70-15
FRONT BRAKE PADS
´÷ 70.40.02
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
WARNING: Brake pads must be renewed in
axle sets only. Braking efficiency may
otherwise be impaired.
3. Remove lower guide pin bolt from caliper and
pivot caliper upwards.
4. Remove 2 brake pads, shims and retainers from
caliper bracket.
5. Remove inner shim from caliper piston.
Refit
1. Rotate disc by hand and scrape all scale and rust
from around edge of disc.
2. Scrape rust from pad locating surfaces on
caliper.
3. Clean dust from calipers using brake cleaning
fluid or industrial alcohol.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluid as damage will occur to rubber
components.
4. Position bleed bottle, connect bleed hose to
bleed screw and loosen screw.
5. Press piston back into housing.
6. Tighten bleed screw to 10 Nm .
7. Remove bleed bottle.
8. Fit pad retainers to caliper bracket.
9. Apply Molykote M77 to both sides of shims.
10. Fit inner shim to piston.
11. Fit shims to pads and fit pads to caliper bracket.
NOTE: Fit pad with wear indicator on the inside.
BRAKES
70-16 REPAÌRS
12. Lower caliper housing over pads.
13. Ensure flats 'A' on guide pins locate with lugs on
caliper housing. Fit bolt and tighten to 27 Nm.
14. Repeat procedure for other side.
15. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
16. Remove stand(s) and lower vehicle.
17. Depress brake several times to set pad to disc
clearance.
18. Check and top-up brake fluid. See
INFORMATION, Capacities, FIuids and
Lubricants.
REAR BRAKE SHOES
´÷ 70.40.09
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Release handbrake.
4. Remove rear brake drum. See BRAKES,
Repairs.
5. Depress clips to release brake shoe retaining
pins.
6. Remove retaining pins.
BRAKES
REPAÌRS 70-17
7. Ease one shoe out of retaining groove in
abutment followed by other shoe.
8. Detach shoe abutment return spring from leading
shoe end and remove spring.
NOTE: The forward shoe is the LEADING shoe,
the TRAILING shoe has the handbrake lever
attached to it.
9. Release hand brake cable from brake shoe lever.
10. Manoeuvre shoe assembly around wheel
cylinder and remove.
CAUTION: Ensure edges of brake shoes do
not damage wheeI cyIinder dust covers.
11. Fit an elastic band around wheel cylinder to retain
pistons.
12. Position trailing shoe and ease strut from slot in
shoe.
13. Detach short spring from strut and remove from
trailing shoe.
14. Remove trailing shoe from upper return spring
and remove return spring from leading shoe.
BRAKES
70-18 REPAÌRS
15. Remove adjuster strut from leading shoe by
pulling on shoe and fully extending cam so that
shoe pivots out of engagement.
16. Clean backplate and drum with brake cleaning
fluid.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluid as damage will occur to rubber
components.
17. Use a wire brush to remove any corrosion taking
care not to damage wheel cylinder covers.
18. Ìnspect all parts for wear or damage.
19. Examine adjuster strut to ensure it is in working
order with no signs of wear or damage. The
quadrant lever, when pulled away from the
knurled wheel against spring pressure, should
move smoothly and freely within its slot in the
strut.
20. Ensure teeth on quadrant and knurled wheel are
undamaged and wheel is firmly attached to strut.
21. Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if free fluid is
apparent, lift dust seal and check for excessive
leakage. Renew wheel cylinder if brake linings
have become contaminated.
22. Check wheel cylinder pistons for freedom of
movement.
23. Check condition of springs, renew if necessary.
Refit
1. Fully extend cam on strut and rotate leading shoe
into strut slot, as illustrated.
2. Fit upper return spring to leading shoe and fit
trailing shoe to return spring.
3. Engage trailing shoe to adjuster plate fit adjuster
spring to trailing shoe and secure spring to
adjuster plate.
4. Smear shoe contact points with Molykote 111
grease, ensure grease does not contact linings or
dust covers.
5. Manoeuvre shoe assembly into position between
hub and wheel cylinder and connect hand brake
cable to brake shoe lever.
6. Fit lower return spring to trailing shoe and
connect spring to leading shoe.
7. Remove elastic band from wheel cylinder.
8. Engage leading shoe in wheel cylinder followed
by trailing shoe and align.
NOTE: During this operation the adjuster may
become extended, this is not important but it
must be reset prior to fitting brake drum.
9. Fit trailing shoe into abutment bracket followed by
leading shoe.
BRAKES
REPAÌRS 70-19
10. Check adjuster cam and if necessary set to
minimum adjustment position as follows: lever
leading shoe away from wheel cylinder. Move
adjuster cam back fully and ease shoe back into
position.
11. Fit shoe steady pins through backplate, and
secure with spring clips.
12. Clean brake drum, scrape ridge from edge of
drum.
13. Fit brake drum and tighten screws to 7 Nm.
14. Repeat procedure and fit brake shoes and drum
to opposite hub.
15. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
16. Remove stand(s) and lower vehicle.
17. Apply brake pedal several times to set self adjust
mechanism.
18. Check and top up brake fluid. See
INFORMATION, Capacities, FIuids and
Lubricants.
19. Check handbrake operation, adjust if necessary.
See BRAKES, Adjustments.
REAR BRAKE PADS
´÷ 70.40.10
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
WARNING: Brake pads must be renewed in
axle sets only. Braking efficiency may
otherwise be impaired.
3. Remove 2 guide pin bolts securing caliper to
carrier.
4. Release caliper from carrier and tie aside.
BRAKES
70-20 REPAÌRS
5. Remove brake pads and shims.
6. Remove pad abutment shims.
7. Examine disc for wear, cracking and scoring.
8. Clean dust from caliper using brake cleaning fluid
or industrial alcohol.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluid as damage will occur to rubber
components.
9. Examine caliper for signs of fluid leakage.
Refit
1. Rotate disc by hand and scape all scale and rust
from around edge of disc.
2. Clean rust from pad locating surfaces of caliper.
3. Position bleed bottle and connect bleed bottle
hose to bleed screw.
4. Loosen bleed screw.
5. Screw piston fully back into caliper using tool 18G
1596.
6. Tighten bleed screw to 10 Nm, disconnect bleed
hose and remove bleed bottle.
7. Fit pad retainer springs to carrier.
8. Apply Molykote M77 to both sides of pad shims
and back of pads.
9. Fit shims to pads and position pads to carrier.
10. Untie caliper and position to carrier.
11. Ensure that lug on brake pad locates in cruciform
slot in piston.
BRAKES
REPAÌRS 70-21
12. Ensure flats 'A' on guide pins locate with lugs on
caliper housing.
13. Fit guide pin bolts and tighten to 27 Nm.
14. Repeat operations for other rear brake assembly.
15. Check and top-up brake fluid. See
INFORMATION, Capacities, FIuids and
Lubricants.
16. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
17. Adjust handbrake cable. See BRAKES,
Adjustments.
18. Remove stand(s) and lower vehicle.
FRONT BRAKE CALIPER
´÷ 70.55.24
Remove
1. Raise front of vehicle, one side.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Clamp brake hose to prevent fluid loss.
CAUTION: A brake hose cIamp must be used.
4. Remove brake hose banjo bolt.
5. Discard 2 sealing washers
CAUTION: PIug the connections.
6. Remove 2 guide pin bolts.
7. Remove caliper housing from carrier.
BRAKES
70-22 REPAÌRS
8. Remove 2 brake pads, shims and retainers from
caliper bracket.
9. Remove inner shim from caliper piston.
Refit
1. Rotate disc by hand and scrape all scale and rust
from around edge of disc. Scrape clean location
surfaces on caliper bracket.
2. Clean dust from brake parts using brake cleaning
fluid or industrial alcohol.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluid as damage will occur to rubber
components.
3. Fit pad retainers to caliper bracket.
4. Apply Molykote M77 to both sides of shims.
5. Fit inner shim to piston. Fit shims to pads and fit
pads to caliper carrier.
NOTE: Fit pad with wear indicator strip on the
inside.
6. Position caliper housing to carrier, align flats 'A'
on guide pins with caliper housing.
7. Fit and tighten guide pin bolts to 27 Nm .
8. Clean banjo bolt and fit NEW sealing washers.
9. Position hose to caliper and tighten banjo bolt
to34 Nm .
10. Remove clamp from brake hose.
11. Bleed brakes. See BRAKES, Adjustments.
12. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
13. Remove stand(s) and lower vehicle.
BRAKES
REPAÌRS 70-23
REAR BRAKE CALIPER
´÷ 70.55.25
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove handbrake cable clevis pin clip. Discard
clip.
4. Remove clevis pin.
5. Remove handbrake cable clip and release cable
from abutment.
6. Clamp brake hose to prevent fluid loss.
CAUTION: A brake hose cIamp must be used.
7. Remove brake hose banjo bolt.
8. Discard 2 sealing washers.
CAUTION: PIug the connections.
9. Remove 2 guide pin bolts.
10. Remove caliper housing from carrier.
11. Remove 2 brake pads.
12. Noting their fitted positions, remove 2 shims from
pads. Remove 2 pad abutment shims from
carrier.
13. Remove spring from caliper.
BRAKES
70-24 REPAÌRS
Refit
1. Clean carrier, shims, retainers and spring.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluids as damage will occur to rubber
components.
2. Fit retainers to carrier.
3. Apply Molykote M77 to both sides of shims.
4. Fit shims to pads and fit pads to carrier, ensuring
lug on inner pad locates with cruciform slot in
piston.
NOTE: Fit pad with wear indicator on the inside.
5. Fit spring to caliper housing and fit housing.
6. Ensure flats 'A' on guide pins locate with lugs on
caliper housing. Fit bolts and tighten to 27 Nm .
7. Clean banjo bolt and fit new sealing washers.
8. Position hose to caliper and tighten banjo bolt
to34 Nm .
9. Fit handbrake cable to abutment and fit clip.
10. Clean handbrake cable clevis pin and smear with
grease.
11. Align handbrake cable yoke to lever, fit clevis pin
and NEW clevis pin clip.
12. Remove clamp from brake hose.
13. Bleed brakes. See BRAKES, Adjustments.
14. Adjust handbrake cable. See BRAKES,
Adjustments.
15. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
16. Remove stand(s) and lower vehicle.
REAR WHEEL BRAKE CYLINDER
´÷ 70.60.19
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Release handbrake.
4. Remove rear brake shoes. See BRAKES,
Repairs.
CAUTION: Ensure edges of brake shoes do
not damage wheeI cyIinder dust covers.
5. Disconnect pipe union from wheel cylinder.
CAUTION: PIug the connections.
6. Remove 2 bolts securing wheel cylinder to
backplate.
BRAKES
REPAÌRS 70-25
7. Remove wheel cylinder.
8. Remove and discard sealing ring.
9. Clean backplate and drum with brake cleaning
fluid.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluid as damage will occur to rubber
components.
10. Use a wire brush to remove any corrosion.
11. Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if free fluid is
apparent, lift dust seal and check for excessive
leakage. Renew wheel cylinder if brake linings
have become contaminated.
12. Check wheel cylinder pistons for freedom of
movement.
Refit
1. Fit new sealing ring to wheel cylinder.
2. Fit wheel cylinder to backplate, tighten bolts to8
Nm .
3. Connect brake pipe to wheel cylinder, tighten
union to 19 Nm .
4. Smear shoe contact points with Molykote 111
grease, ensure grease does not contact linings or
dust covers.
5. Fit rear brake shoes. See BRAKES, Repairs.
6. Bleed brakes. See BRAKES, Adjustments.
7. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
8. Remove stand(s) and lower vehicle.
9. Check handbrake operation and adjust if
necessary. See BRAKES, Adjustments.
BRAKES
70-26 REPAÌRS
FRONT BRAKE DISC
´÷ 70.10.10
CAUTION: Brake discs must be renewed in pairs,
unIess one disc requires changing before 1000
miIes (1500 km) from new.
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove 2 bolts securing brake caliper to swivel
hub.
4. Release caliper and tie aside clear of brake disc.
CAUTION: Do not aIIow caIiper to hang on
brake hose.
5. Remove 2 screws securing disc to drive flange.
6. Remove brake disc from drive flange using
jacking screws if necessary.
Refit
CAUTION: Excessive disc run-out can exist
after fitting a new disc, with no immediate
symptoms being evident whiIst driving. The
most IikeIy cause of run-out is the presence
of contaminants (e.g. rust or paint) or damage
to the mating faces of disc and fIange, and
disc and wheeI. Excessive run-out wiII cause
progressive uneven wear of the disc, Ieading
to disc thickness variation, which is the cause
of judder. AIways ensure that the disc run-out
check given here is strictIy adhered to.
1. Ìnspect mating surfaces of new disc and drive
flange and clean throughly using a wire brush.
2. Fit brake disc to drive flange.
3. Fit and tighten screws to 10 Nm.
4. Fit caliper and lightly tighten top mounting bolt.
BRAKES
REPAÌRS 70-27
Disc run-out check:
5. Mount a dial test indicator to caliper lower
mounting using tool 18G 191-9 and tighten bolt.
Tighten top mounting bolt.
6. Position dial test indicator probe 10 mm from disc
outer edge.
7. Fit road wheel and tighten nut to correct torque.
See INFORMATION, Torque Wrench Settings.
8. Rotate wheel at least one turn and measure disc
run-out.
Disc run-out limit with wheel on = 0.040 mm
Run-out exceeds limit:
9. Mark wheel to stud relationship. remove wheel,
again check mating surfaces for contaminants,
then refit wheel 90° from previous position and
recheck run-out.
10. Ìf run-out is still excessive, move wheel through a
further 90° and recheck run-out.
11. Ìf run-out is still excessive, fit a new disc.
Run-out within limit:
12. Remove dial test indicator and tool 18G 191-9
13. Fit caliper lower mounting bolt and tighten both
bolts to 108 Nm
14. Remove stand(s) and lower vehicle.
REAR BRAKE DISC
´÷ 70.10.33
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove 2 bolts securing caliper to stub axle.
4. Release caliper and tie aside.
5. Remove 2 screws securing brake disc to hub.
6. Remove disc from hub, use jacking screws if
necessary.
BRAKES
70-28 REPAÌRS
Refit
1. Clean hub and disc mating surfaces.
2. Fit disc to hub. Fit and tighten screws to 10 Nm.
3. Clean caliper and stub axle mating faces.
4. Fit caliper to stub axle ensuring brake pads are
correctly located each side of disc. Fit bolts and
tighten to 108 Nm .
5. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
6. Remove stand(s) and lower vehicle.
REAR BRAKE DRUM
´÷ 70.10.03
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Release handbrake.
4. Remove 2 screws securing brake drum.
5. Screw 2 screws into drum, tightening equally to
ease drum from hub.
CAUTION: If drum is heId, reIease the shoes
to increase cIearance as foIIows:
BRAKES
REPAÌRS 70-29
6. Remove rubber grommet from rear of backplate.
7. Using a flat screwdriver, disengage handbrake
lever stop to increase shoe to drum clearance. Ìf
drum is still held, loosen handbrake cable
adjuster.
Inspect:
8. Clean backplate and brake drum with brake
cleaning fluid.
WARNING: Do not use an air line to blow dust
from brake assembly. Do not use petroleum
based fluid as damage will occur to rubber
components.
9. Renew brake drum if scored, grooved or cracked.
10. Measure inside diameter of drum at 2 points.
Drum internal diameter: Renew drum if outside
limits.
New = 203.20 - 203.33 mm
Service limit = 204 mm
Drum ovality limit = 0.012 mm
11. Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if free fluid is
apparent, lift dust seal and check for excessive
leakage. Renew wheel cylinder if excessive fluid
leakage is apparent.
12. Check wheel cylinder pistons for freedom of
movement.
Refit
1. Check adjuster cam and if necessary set to
minimum adjustment position as follows: Lever
leading shoe away from wheel cylinder. Move
adjuster cam back fully and ease shoe back into
position.
2. Apply Molykote 111 grease to brake shoe and
spring contact points.
3. Fit brake drum, tighten screws to 7 Nm.
NOTE: Clean inside of NEW brake drum with
brake cleaning fluid.
4. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
5. Remove stand(s) and lower vehicle.
6. Check handbrake operation, adjust if necessary.
See BRAKES, Adjustments.
BRAKES
70-30 REPAÌRS
ABS HYDRAULIC MODULATOR
´÷ 70.25.12
Remove
1. Disconnect battery earth lead.
2. Connect bleed tube to bleed screw, front RH
caliper. Open bleed screw and pump brake fluid
from master cylinder. Tighten bleed screw.
3. Connect bleed tube to bleed screw, front LH
caliper. Repeat above operation.
4. Pull clip outwards and disconnect multiplug from
modulator ECU.
5. Position cloth under modulator to absorb fluid
spillage.
CAUTION: Do not aIIow brake fIuid to contact
paint finished surfaces as paint may be
damaged. If spiIIed, remove fIuid and cIean
area with cIean warm water.
6. Disconnect 2 inlet brake pipe unions from top of
modulator.
CAUTION: PIug the connections.
7. Disconnect 2 front outlet brake pipe unions from
top of modulator.
CAUTION: PIug the connections.
8. Disconnect 2 rear outlet brake pipe unions from
front of modulator.
CAUTION: PIug the connections.
9. Loosen 2 nuts securing modulator to mounting
bracket.
10. Release modulator lower bush from mounting
bracket spigot.
11. Extract ABS modulator from mounting bracket.
Do not carry out further dismantling if component
is removed for access only.
12. Remove mounting rubber assembly from each
side of modulator and mounting rubber from
underneath.
13. Fit parts to new modulator.
Refit
1. Engage spigot and fit modulator to mounting
bracket and tighten mounting nuts to 21 Nm.
2. Connect brake pipe unions to modulator,
ensuring pipes are connected to their correct
ports.
MC 1 = Master cylinder primary
MC 2 = Master cylinder secondary
RF = Right hand front
LF = Left hand front
RR = Right hand rear
LR = Left hand rear
3. Tighten unions to 14 Nm .
4. Connect multiplug to modulator and press clip in
fully to secure.
5. Bleed brakes. See BRAKES, Adjustments.
6. Connect battery earth lead.
7. To ensure correct operation, the system MUST
be tested using TestBook.
BRAKES
REPAÌRS 70-31
ABS SENSOR - REAR - MODELS WITH
DRUM BRAKES
´÷ 70.65.31
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove rear brake drum. See BRAKES,
Repairs.
4. Remove 2 clips and 2 pins retaining brake shoes.
5. Ease one brake shoe out of retaining groove in
abutment followed by other shoe.
6. Detach return spring from leading shoe end and
remove spring.
NOTE: The forward shoe is the LEADING shoe,
the TRAILING shoe has the handbrake lever
attached to it.
7. Release hand brake cable from brake shoe lever.
8. Manoeuvre shoe assembly around wheel
cylinder and remove.
CAUTION: Ensure edges of brake shoes do
not damage wheeI cyIinder dust covers.
BRAKES
70-32 REPAÌRS
9. Fit an elastic band around wheel cylinder to retain
pistons.
10. Release ABS sensor multiplug from from clips.
Disconnect multiplug and release harness from
'H' frame.
11. Remove 2 bolts securing sensor adaptor.
BRAKES
REPAÌRS 70-33
12. Release sensor harness grommet from
backplate and withdraw sensor harness.
13. Remove sensor and adapter assembly.
14. Loosen adapter clamp screw and remove sensor
from adapter.
Refit
1. Fit sensor to adapter, DO NOT tighten clamp
screw at this stage.
2. Position sensor, feed harness through backplate
and secure grommet.
3. Align sensor, fit bolts and tighten to 45 Nm.
4. Using a feeler gauge, set clearance 'A' between
sensor and reluctor ring.
Clearance 'A' = 0.5 mm.
5. Tighten adapter clamp screw to 0.5 Nm.
6. Connect multiplug, secure multiplug to clip and
harness to 'H' frame.
7. Manoeuvre shoe assembly into position between
hub and wheel cylinder and connect hand brake
cable to brake shoe lever.
8. Fit lower return spring to trailing shoe and
connect spring to leading shoe.
9. Remove elastic band from wheel cylinder.
10. Engage leading shoe to wheel cylinder followed
by trailing shoe and align.
NOTE: During this operation the adjuster may
become extended, this is not important but it
must be reset prior to fitting brake drum.
11. Fit trailing shoe into abutment bracket followed by
leading shoe.
12. Check adjuster cam and if necessary set to
minimum adjustment position as follows: lever
leading shoe away from wheel cylinder. move
adjuster cam back fully and ease shoe back into
position.
13. Fit brake shoe retaining pins through backplate
and secure with spring clips.
14. Fit brake drum. See BRAKES, Repairs.
15. Check handbrake operation, adjust if necessary.
16. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
17. Remove stand(s) and lower vehicle.
18. To ensure correct operation, the system MUST
be checked using TestBook.
BRAKES
70-34 REPAÌRS
RESTRAÌNT SYSTEMS
REPAÌRS 75-1
RESTRAÌNT SYSTEMS REPAÌ RS
DRIVER AIRBAG
´÷ 76.73.71
CAUTION:
¤ RepIace the airbag every 10 years.
¤ Do not instaII used SRS parts from another
car. When repairing an SRS system, aIways
use genuine new MG Rover parts.
¤ CarefuIIy inspect the airbag assembIy before
instaIIing it. Do not instaII an airbag assembIy
that shows signs of being dropped or
improperIy handIed, such as dents, cracks, or
deformation.
¤ Do not try to disassembIe, or tamper with the
airbag assembIy.
¤ SpeciaI boIts are necessary for instaIIing the
airbag assembIy. Do not use other boIts.
Remove
1. Remove key from starter switch and wait 10
minutes to allow SRS back-up power circuit to
discharge before commencing work.
2. Disconnect both battery leads, earth lead first.
3. Remove 2 Torx bolts securing the air bag module
to steering wheel.
4. Release air bag module from steering wheel.
CAUTION: Do not aIIow the air bag moduIe to
hang by the air bag harness.
5. Disconnect harness connector from air bag
module.
6. Remove air bag module.
CAUTION: Store the air bag moduIe in
accordance with the storage procedures
outIined in the precautions part of this
section.
NOTE: If airbag is to be replaced, bar code of
new airbag must be recorded.
Refit
1. Position air bag module and make connection
with harness upwards as shown in illustration.
2. Fit air bag to steering wheel and hand start the 2
Torx screws. Tighten screws to 9 Nm.
3. Connect battery leads, earth lead last.
4. Carry out system check by turning the ignition on
and checking that the SRS warning light
illuminates then extinguishes after 3 seconds.
RESTRAÌNT SYSTEMS
75-2 REPAÌRS
PASSENGER AIRBAG
´÷ 76.74.69
CAUTION:
¤ RepIace the airbag every 10 years.
¤ Do not instaII used SRS parts from another
car. When repairing an SRS system, aIways
use genuine new MG Rover parts.
¤ CarefuIIy inspect the airbag assembIy before
instaIIing it. Do not instaII an airbag assembIy
that shows signs of being dropped or
improperIy handIed, such as dents, cracks, or
deformation.
¤ Do not try to disassembIe, or tamper with the
airbag assembIy.
¤ SpeciaI boIts are necessary for instaIIing the
airbag assembIy. Do not use other boIts.
Remove
1. Remove key from starter switch and wait 10
minutes to allow SRS back-up power circuit to
discharge before commencing work.
2. Disconnect both battery leads, earth lead first.
3. Remove glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
4. Remove 2 Torx screws securing airbag to
support panel.
5. Release airbag from fascia and disconnect
harness multiplug.
CAUTION: Do not aIIow the airbag moduIe to
hang by the airbag harness.
6. Remove airbag.
CAUTION: Store the airbag moduIe in
accordance with the storage procedures
outIined in the precautions part of this
section.
NOTE: If airbag is to be replaced, bar code of
new airbag must be recorded.
Refit
1. Position airbag to fascia and connect harness
multiplug.
2. Fit airbag to fascia.
3. Fit Torx screws securing airbag to fascia and
tighten to 9 Nm.
4. Fit glovebox. See INTERIOR TRIM
COMPONENTS, Repairs.
5. Connect battery leads, earth lead last.
6. Carry out systems check by turning the ignition
on and checking that the SRS warning light
illuminates then extinguishes after 3 seconds.
RESTRAÌNT SYSTEMS
REPAÌRS 75-3
AIRBAG CONTROL AND DIAGNOSTIC
UNIT
´÷ 76.74.72
CAUTION: See safety precautions before
commencement of repair.
CAUTION: Ensure unit and bracket faces are cIean
and free from burrs. An incorrectIy mounted unit
couId cause the system to maIfunction.
Remove
1. Remove key from starter switch and wait 10
minutes to allow SRS back-up power circuit to
discharge before commencing work.
2. Disconnect both battery leads, earth lead first.
3. Remove rear seat cushion. See SEATS AND
SEAT BELTS, Repairs.
4. Remove control and diagnostic unit cover.
5. Disconnect multiplug from unit.
6. Remove Torx bolt securing earth lead to body.
7. Remove 3 Torx bolts securing unit to body.
8. Remove control and diagnostic unit.
Refit
1. Position unit and fit and tighten Torx bolts to 9
Nm.
2. Connect multiplug to control and diagnostic unit.
3. Fit Torx bolt securing earth lead to body.
4. Fit control and diagnostic unit cover.
5. Fit rear seat cushion. See SEATS AND SEAT
BELTS, Repairs.
6. Connect both battery leads, earth lead last.
7. Carry out system check by turning the ignition on
and checking that the SRS warning light
illuminates then extinguishes after 3 seconds.
SEAT BELT PRE-TENSIONER
´÷ 76.73.75
CAUTION: See safety precautions in SRS section
before starting work.
Remove
1. Disconnect battery earth lead.
2. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
3. Release pre-tensioner harness from clip on
underside of seat cushion.
4. Remove bolt securing pre-tensioner to seat.
5. Remove pre-tensioner from seat.
Refit
1. Fit pre-tensioner to seat.
2. Fit bolt securing pre-tensioner to seat and tighten
to 30 Nm.
3. Secure pre-tensioner harness to clip.
4. Fit front seat. See SEATS AND SEAT BELTS,
Repairs.
5. Connect battery earth lead.
SP76 0207
RESTRAÌNT SYSTEMS
75-4 REPAÌRS
FRONT SEAT BELT AND PRE-
TENSIONER - 3 DOOR
´÷ 76.73.13
CAUTION: See safety precautions in SRS section
before starting work.
WARNING: If vehicle is fitted with a passenger
airbag a Load Limiting Seat Belt must be fitted. If
vehicle is fitted without a passenger airbag a Non
Load Limiting Seat Belt must be fitted.
Remove
1. Disconnect battery earth lead.
2. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
3. Remove seat belt upper bolt cover and remove
bolt.
4. Release seat belt guide from 'B' post.
5. Remove Torx bolt securing lower seat belt guide.
6. Remove belt from guide.
7. Remove bolt securing seat belt reel to 'B' post
and remove reel.
8. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
RESTRAÌNT SYSTEMS
REPAÌRS 75-5
9. Release pre-tensioner harness from clip on seat
cushion.
10. Remove Torx bolt securing pre-tensioner to seat.
11. Remove pre-tensioner.
Refit
1. Position pre-tensioner to seat and tighten Torx
bolt to 30 Nm.
2. Secure pre-tensioner harness to clip on seat
cushion.
3. Fit front seat. See SEATS AND SEAT BELTS,
Repairs.
4. Position seat belt reel to 'B' post and tighten bolt
to 50 Nm.
5. Fit seat belt to lower guide and tighten Torx bolt
to 50 Nm.
6. Fit seat belt guide to 'B' post.
7. Fit seat belt upper bolt and tighten to 50 Nm.
8. Fit cover to bolt.
9. Fit rear quarter lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
10. Connect battery earth lead.
FRONT SEAT BELT AND PRE-
TENSIONER - 5 DOOR
´÷ 76.73.13
CAUTION: See safety precautions in SRS section
before starting work.
WARNING: If vehicle is fitted with a passenger
airbag a Load Limiting Seat Belt must be fitted. If
vehicle is fitted without a passenger airbag a Non
Load Limiting Seat Belt must be fitted.
Remove
1. Disconnect battery earth lead.
2. Remove 'B' post lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
3. Remove seat belt upper bolt cover and remove
bolt.
4. Release seat belt guide from 'B' post.
RESTRAÌNT SYSTEMS
75-6 REPAÌRS
5. Remove seat belt lower Torx bolt.
6. Remove bolt securing seat belt reel to 'B' post
and remove reel.
7. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
8. Release pre-tensioner harness from clip on seat
cushion.
9. Remove Torx bolt securing pre-tensioner to seat.
10. Remove pre-tensioner.
Refit
1. Position pre-tensioner to seat and tighten bolt to
30 Nm.
2. Secure pre-tensioner harness to clip on seat
cushion.
3. Fit front seat. See SEATS AND SEAT BELTS,
Repairs.
4. Position seat belt reel to 'B' post and tighten bolt
to 50 Nm.
5. Fit seat belt lower Torx bolt and tighten to 50 Nm.
6. Fit seat belt guide to 'B' post.
7. Fit seat belt upper bolt and tighten to 50 Nm.
8. Fit cover to bolt.
9. Fit 'B' post lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
10. Connect battery earth lead.
RESTRAÌNT SYSTEMS
REPAÌRS 75-7
ROTARY COUPLER
´÷ 86.65.85
CAUTION: See SRS safety precautions before
commencement of repair. See RESTRAINT
SYSTEMS, Precautions.
¤ Ensure wheeIs are aIigned straight ahead.
Remove
1. Remove key from starter switch and wait 10
minutes to allow the SRS back-up power circuit to
discharge before commencing work.
2. Disconnect both battery leads, earth lead first.
3. Remove steering column nacelle. See
STEERING, Repairs.
4. Ìf the rotary coupler is being re-used place
adhesive tape around moulding to prevent
rotation.
5. Disconnect 2 multiplugs from rotary coupler.
6. Remove 4 screws and 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. Fit rotary coupler and secure with screws.
2. Connect multiplugs to coupler.
3. Remove retaining tape from rotary coupler.
4. Fit steering column nacelle. See STEERING,
Repairs.
RESTRAÌNT SYSTEMS
75-8 REPAÌRS
DOORS
REPAÌRS 76-1-1
DOORS REPAÌ RS
DOOR STRIKER - ADJUST
´÷ 76.28.05
Adjust
1. Loosen 2 TX40 Torx screws securing striker 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.
TAILGATE STRIKER - ADJUST
´÷ 76.28.28
Adjust
1. Remove rubber buffer from tailgate striker.
2. Loosen striker bolts and close tailgate.
3. Check for equal gap and alignment to adjacent
panels.
4. Open tailgate and tighten striker screws to 9 Nm.
5. Fit rubber buffer to tailgate striker.
DOORS
76-1-2 REPAÌRS
TAILGATE ALIGNMENT
´÷ 76.28.25
Adjust
1. Check alignment of tailgate against both rear
quarter panels.
2. Open tailgate and mark outline of hinges.
3. Release seal from top of tailgate aperture.
4. Remove sealant from around tailgate hinges.
5. Remove 2 trim studs securing rear of headlining
to roof.
DOORS
REPAÌRS 76-1-3
6. Lower rear of headlining to gain access to hinge
bolts.
7. Loosen 4 bolts and adjust position of tailgate.
8. Tighten bolts.
9. Close tailgate and check alignment against both
rear quarter panels.
10. Open tailgate and re-adjust tailgate position if
necessary.
11. Close tailgate and check alignment against both
rear quarter panels.
12. Apply sealant to both hinges.
13. Wipe away any excess sealant with suitable
cleaning solvent.
14. Reposition headlining and secure with trim studs.
15. Fit seal to tailgate to aperture.
EXTERIOR MIRROR GLASS
´÷ 76.11.08
Remove
1. Place hand on glass and push down on the inside
edge.
2. Keeping glass depressed slide away from vehicle
to release.
3. Lift glass away from case ensuring damper blade
stays with glass.
Models with electric mirrors only:
4. Disconnect 2 Lucars from glass.
All models:
5. Remove glass.
Refit
Models with electric mirrors only:
1. Position glass to mirror and connect Lucars.
All models:
2. Fit glass to mirror ensuring damper blade is
located into slot and secure to clips.
DOORS
76-1-4 REPAÌRS
EXTERIOR MIRROR - MANUAL
´÷ 76.10.52
Remove
1. Remove front door trim casing. See DOORS,
Repairs.
2. Remove interior trim from cheater panel.
3. Remove escutcheon from interior.
4. Remove 3 Torx bolts securing exterior mirror to
cheater.
5. Remove exterior mirror.
6. Release clips and remove mirror glass. See
DOORS, Repairs.
Refit
1. Fit mirror glass and secure to clips. See DOORS,
Repairs.
2. Fit exterior mirror to cheater and secure with Torx
bolts.
3. Fit escutcheon to interior trim.
4. Fit interior trim to cheater panel.
5. Fit front door trim casing. See DOORS, Repairs.
EXTERIOR MIRROR - ELECTRIC
´÷ 76.10.57
Remove
1. Remove front door trim casing. See DOORS,
Repairs.
2. Disconnect multiplug from exterior mirror.
3. Remove interior trim from cheater panel.
4. Remove 3 Torx bolts securing exterior mirror to
cheater.
5. Remove exterior mirror.
6. Remove mirror glass. See DOORS, Repairs.
Refit
1. Fit mirror glass. See DOORS, Repairs.
2. Fit exterior mirror to cheater panel and secure
with Torx bolts.
3. Fit interior trim to cheater panel.
4. Connect multiplug to exterior mirror.
5. Fit front door trim casing. See DOORS, Repairs.
DOORS
REPAÌRS 76-1-5
FRONT DOOR TRIM CASING
´÷ 76.34.01.99
Remove
1. Remove escutcheon from door pull.
2. Remove 3 screws securing door pull to door.
3. Release 3 clips securing door handle escutcheon
centre to escutcheon and remove escutcheon
centre.
4. Release 4 clips securing door handle escutcheon
to door and remove escutcheon.
Models with manual windows only:
5. Release spring clip securing regulator handle
and collect handle and finisher.
All models:
6. Release screw cover and remove 2 screws
securing trim casing to door.
7. Release 6 clips securing trim casing to door and
release from sill button.
DOORS
76-1-6 REPAÌRS
8. Disconnect multiplug from tweeter and remove
trim casing.
Refit
1. Position trim casing to door and connect tweeter
multiplug.
2. Fit trim casing over sill button and secure to door
with clips.
3. Secure trim casing to door with screws and fit
screw cover.
Models with manual windows only:
4. Fit regulator handle and finisher and secure with
spring clip.
All models:
5. Fit door handle escutcheon and secure clips.
6. Fit door handle escutcheon centre to escutcheon
and secure clips.
7. Fit door pull to door and secure with screws.
8. Fit door pull escutcheon to door pull and secure
clips.
REAR DOOR TRIM CASING
´÷ 76.34.04.99
Remove
1. Release 3 clips securing door handle escutcheon
centre to escutcheon and remove escutcheon
centre.
2. Remove 4 clips securing door handle escutcheon
to door and remove escutcheon.
3. Remove escutcheon from door pull.
4. Remove 3 screws securing door pull to door.
5. Remove door pull.
DOORS
REPAÌRS 76-1-7
Models with manual windows:
6. Release spring clip securing regulator handle
and collect handle and escutcheon.
All models:
7. Release cover and remove screw securing trim
casing to door.
8. Release 6 clips securing door trim casing to door
and release over sill button.
Models with electric windows:
9. Disconnect multiplug from window switch.
Refit
Models with electric windows:
1. Position door trim casing and connect multiplug
to window switch.
All models:
2. Guide trim casing over sill button and secure to
door with clips and screw and fit cover.
Models with manual windows:
3. Fit regulator handle and escutcheon to door and
secure with spring clip.
All models:
4. Fit door pull to door and secure with screws.
5. Fit escutcheon to door pull.
6. Fit handle escutcheon to door and secure clips.
7. Fit door handle escutcheon centre to escutcheon
and secure clips.
DOORS
76-1-8 REPAÌRS
FRONT DOOR PLASTIC SHEET.
´÷ 76.34.26
Remove
1. Remove front door trim casing. See DOORS,
Repairs.
2. Remove 2 screws securing bracket to door and
remove bracket.
3. Remove 3 screws securing speaker to door.
4. Disconnect multiplug and remove speaker.
5. Remove locating dowels from plastic sheet.
6. Release and remove plastic sheet from door.
Refit
1. Fit plastic sheet to door and fit locating dowels.
2. Fit bracket to door and secure with screws.
3. Position speaker to door and connect multiplug.
4. Fit screws securing speaker to door.
5. Fit front door trim casing. See DOORS, Repairs.
DOORS
REPAÌRS 76-1-9
REAR DOOR PLASTIC SHEET
´÷ 76.34.28
Remove
1. Remove rear door trim casing. See DOORS,
Repairs.
2. Remove 2 locating dowels from plastic sheet.
3. Release and remove plastic sheet from door.
Refit
1. Fit plastic sheet to door and fit locating dowels.
2. Fit rear door trim casing. See DOORS, Repairs.
FRONT DOOR GLASS
´÷ 76.31.01
Remove
1. Remove front door plastic sheet. See DOORS,
Repairs.
2. Move window glass to gain access to fixing bolts.
3. Loosen bolts securing glass to regulator.
4. Release glass from regulator and remove glass
from door.
Refit
1. Position glass to door, align to regulator and
tighten bolts to 9 Nm.
2. Fit front door plastic sheet. See DOORS,
Repairs.
DOORS
76-1-10 REPAÌRS
REAR DOOR GLASS
´÷ 76.31.02
Remove
1. Remove rear door plastic sheet. See DOORS,
Repairs.
2. Position glass to gain access to fixing bolts.
3. Remove bolts securing glass to regulator.
4. Release glass from regulator and move glass to
bottom of door.
5. Release rubber from glass rear channel.
6. Remove 2 nuts securing rear channel to door.
7. Remove channel from door.
8. Raise glass and remove from door.
Refit
1. Position glass to door.
2. Fit glass rear channel to door and tighten nuts to
8 Nm.
3. Fit rubber to channel.
4. Position glass to regulator and fit and tighten
bolts to 9 Nm.
5. Fit rear door plastic sheet. See DOORS,
Repairs.
DOORS
REPAÌRS 76-1-11
REAR QUARTER GLASS - 5 DOOR
MODELS
´÷ 76.31.31
Remove
1. Remove rear door glass. See DOORS, Repairs.
2. Remove rear quarter glass, complete with seal,
from door.
3. Remove seal from glass.
Refit
1. Fit rubber seal to glass.
2. Apply soap solution to rubber to aid refitment.
3. Fit glass and rubber to door.
4. Fit rear door glass. See DOORS, Repairs.
FRONT DOOR GLASS REGULATOR
´÷ 76.31.45
Remove
1. Remove front door glass. See DOORS, Repairs.
Power windows:
2. Disconnect multiplug from front door glass motor
and release harness clip from door.
All models:
3. Mark position of roller guide bolts on door before
removal. Loosen 2 bolts securing regulator to
door.
4. Remove 4 bolts securing regulator to door.
DOORS
76-1-12 REPAÌRS
5. Release and remove regulator assembly from
door.
NOTE: Before removing power window motor
mark the location by scribing a line across the
sector gear and regulator.
Power windows:
6. Using a Torx bit remove 3 screws securing motor
to regulator, then remove the motor.
Refit
1. Apply grease to motor gear and regulator pivot
points.
2. Ensure regulator marks are aligned, position
motor to regulator and tighten screws to 7 Nm.
3. Position and align regulator assembly to door.
4. Fit bolts to secure regulator, tighten to 8 Nm.
5. Align roller guide, fit bolts to align with original
marks and tighten to 8 Nm.
Power windows:
6. Connect motor multiplug, secure clip to door.
All models:
7. Refit front door glass. See DOORS, Repairs.
REAR DOOR GLASS REGULATOR
´÷ 76.31.46
Remove
1. Remove rear door glass. See DOORS, Repairs.
2. Remove 2 bolts securing regulator to door.
3. Remove 2 bolts securing glass channel to door.
4. Loosen bolt securing channel to door.
5. Remove regulator and channel assembly from
door.
Refit
1. Position regulator and channel assembly to door.
2. Fit bolts securing channel to door and tighten to
8 Nm.
3. Tighten bolt securing channel to door to 8 Nm.
4. Fit and tighten bolts securing regulator to door to
8 Nm.
5. Fit rear door glass. See DOORS, Repairs.
DOORS
REPAÌRS 76-1-13
TAILGATE TRIM CASING
´÷ 76.34.10
Remove
1. Remove 2 screws securing tailgate trim casing to
tailgate.
2. Release 9 clips securing trim casing to tailgate.
3. Remove trim casing from tailgate.
Refit
1. Position trim casing to tailgate and secure with
clips.
2. Fit and tighten screws securing tailgate trim
casing to tailgate.
TAILGATE SIDE FINISHER
´÷ 76.34.11
Remove
1. Release parcel shelf ties from tailgate.
2. Remove 2 screws securing side finisher to
tailgate.
3. Release 2 clips securing side finisher to tailgate.
4. Remove side finisher.
Refit
1. Fit side finisher to tailgate and secure with clips.
2. Fit screws securing side finisher to tailgate.
3. Secure parcel shelf ties to side finishers.
DOORS
76-1-14 REPAÌRS
TAILGATE UPPER FINISHER
´÷ 76.34.37
Remove
1. Remove tailgate side finishers. See DOORS,
Repairs.
2. Release 8 clips securing upper finisher to
tailgate.
3. Remove upper finisher.
Refit
1. Fit upper finisher to tailgate and secure clips.
2. Fit tailgate side finishers. See DOORS, Repairs.
FRONT DOOR OUTSIDE HANDLE
´÷ 76.58.07
NOTE: Fit protection on door to avoid damage to
paintwork.
Remove
1. Raise door glass fully.
2. Remove front door plastic sheet. See DOORS,
Repairs.
3. Remove 2 bolts securing outside handle and lock
shield to door.
4. Remove lock shield
5. Release control rod and private lock rod from
handle.
6. Remove handle from door.
Refit
1. Position handle to door and connect control rods.
2. Position lock shield to door.
3. Fit bolts and tighten to 9 Nm.
4. Fit front door plastic sheet. See DOORS,
Repairs.
DOORS
REPAÌRS 76-1-15
REAR DOOR OUTSIDE HANDLE
´÷ 76.58.02
NOTE: Fit protection on door to avoid damage to
paintwork.
Remove
1. Raise door glass fully.
2. Remove rear door plastic sheet. See DOORS,
Repairs.
3. Remove 2 bolts securing outside handle to door.
4. Release handle from door and disconnect control
rod.
5. Remove outside door handle.
Refit
1. Position handle to door and connect control rod.
2. Fit handle to door and tighten screws to 9 Nm.
3. Fit rear door plastic sheet. See DOORS,
Repairs.
FRONT DOOR INTERIOR HANDLE
´÷ 76.58.20
Remove
1. Remove front door trim casing. See DOORS,
Repairs.
2. Remove screw securing handle to door.
3. Release control rod and remove handle from
door.
Refit
1. Connect control cable to handle and position
handle to door.
2. Fit and tighten screw securing handle to door.
3. Fit front door trim casing. See DOORS, Repairs.
DOORS
76-1-16 REPAÌRS
REAR DOOR INTERIOR HANDLE
´÷ 76.58.19
Remove
1. Remove rear door trim casing. See DOORS,
Repairs.
2. Remove screw securing handle to door.
3. Release handle from door and disconnect control
rod.
Refit
1. Connect control cable to handle and position
handle to door.
2. Fit and tighten screw securing handle to door.
3. Fit rear door trim casing. See DOORS, Repairs.
TAILGATE LATCH
´÷ 76.37.17
Remove
1. Remove tailgate trim casing. See DOORS,
Repairs.
2. Remove cover from tailgate latch.
3. Remove 2 bolts securing latch to tailgate.
4. Release latch from tailgate and disconnect 2
Lucars and release cable.
5. Remove latch from tailgate.
Refit
1. Position latch to tailgate and connect release
cable and Lucars.
2. Fit bolts securing latch to tailgate and tighten to 7
Nm.
3. Fit cover to tailgate latch.
4. Fit tailgate trim casing. See DOORS, Repairs.
DOORS
REPAÌRS 76-1-17
DRIVERS DOOR LOCK
´÷ 76.37.39
Remove
1. Remove front door plastic sheet. See DOORS,
Repairs.
2. Remove bolt securing lock to outside door handle
and lock shield
3. Release control rod from lock.
4. Remove lock from door.
Refit
1. Position lock in door and fit control rod.
2. Fit lock to handle, fit lock shield and tighten bolt
to 9 Nm.
3. Fit front door plastic sheet. See DOORS,
Repairs.
TAILGATE LOCK
´÷ 76.37.41
Remove
1. Remove tailgate trim casing. See DOORS,
Repairs.
2. Disconnect multiplug from motor.
3. Loosen 2 screws securing lock motor to tailgate.
4. Remove 2 screws securing lock to tailgate.
5. Release lock and motor from tailgate.
6. Release tailgate release cable from lock and
remove lock.
7. Release lock from motor.
Refit
1. Fit lock to motor and position to tailgate.
2. Connect release cable to lock.
3. Fit and tighten screws securing lock to tailgate.
4. Tighten screws securing motor to tailgate to 9
Nm.
5. Connect multiplug to motor.
6. Fit tailgate trim casing. See DOORS, Repairs.
DOORS
76-1-18 REPAÌRS
TAILGATE STRUT
´÷ 76.40.33
Remove
1. Open and support tailgate.
2. Release clip securing strut to tailgate.
3. Release strut from tailgate.
4. Release clip securing strut to body.
5. Release strut from body.
Refit
1. Fit new strut to body and secure with clip.
2. Fit strut to tailgate and secure with clip.
3. Remove tailgate support.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-1
EXTERÌOR FÌTTÌNGS REPAÌ RS
BONNET ALIGNMENT
´÷ 76.16.02
Adjust
1. Check alignment of bonnet against both wings.
2. Open bonnet and mark outline of hinges.
3. Loosen 4 bolts and adjust position of bonnet.
4. Tighten bolts to 9 Nm.
5. Close bonnet and check alignment against both
wings.
6. Open bonnet and re-adjust bonnet position if
necessary.
7. Close bonnet and check alignment against both
wings.
WHEEL ARCH LINER
´÷ 76.10.48
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove 3 screws securing wheel arch liner to
front bumper.
4. Remove 3 screws and 6 scrivets securing liner to
wheel arch.
5. Remove wheel arch liner.
Refit
1. Fit liner to wheel arch.
2. Fit and tighten screws and scrivets securing liner
to wheel arch.
3. Fit and tighten screws securing liner to front
bumper.
4. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
5. Remove stand(s) and lower vehicle.
EXTERÌOR FÌTTÌNGS
76-2-2 REPAÌRS
UNDERTRAY - 'L' SERIES
´÷ 76.10.50
WARNING: Support on safety stands.
Remove
1. Raise front of vehicle.
2. Remove 2 bolts securing undertray to front beam.
3. Remove 2 nuts securing undertray to rear beam.
4. Release and remove undertray.
Refit
1. Position undertray and locate on studs on rear
beam.
2. Fit nuts securing undertray to rear beam and
tighten to 10 Nm.
3. Fit bolts securing undertray to front beam and
tighten to 10 Nm.
4. Remove stand(s) and lower vehicle.
SPLASH SHIELD - 'K16' WITH 'VVC'
´÷ 76.10.50
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 3 bolts securing LH end of splash shield
to body.
3. Remove 2 bolts securing RH end of splash shield
to body.
4. Remove 3 bolts securing front edge of splash
shield to body.
5. Remove 2 bolts securing splash shield to front
beam and remove shield.
Refit
1. Position splash shield to vehicle and secure to
front beam with bolts. Tighten bolts to 5 Nm.
2. Fit bolts securing front end of splash shield to
body and tighten bolts to 5 Nm.
3. Fit bolts securing RH end of splash shield to body
and tighten to 5 Nm.
4. Fit bolts securing LH end of splash shield to body
and tighten to 5 Nm.
5. Remove stand(s) and lower vehicle.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-3
BONNET
´÷ 76.16.01.99
Remove
1. Support bonnet in open position.
2. Fit protection covers to wings.
3. Ìf bonnet is to be refitted, mark outline of hinges.
4. Disconnect washer tube at 'T' piece.
Vehicles fitted with heated washer jets:
5. Disconnect heated washer jet multiplugs.
6. Release 2 trim studs securing sound deadening
pad to bonnet.
7. Move pad aside and release washer jet harness
from bonnet.
All models:
8. With assistance, remove 4 bolts securing hinges
to bonnet
9. Remove bonnet.
Refit
1. With assistance position bonnet to hinges and
lightly tighten bolts.
2. Connect washer tube.
Vehicles fitted with heated washer jets:
3. Connect heated washer jet multiplugs.
4. Position harness to bonnet and secure sound
deadening pad with trim studs.
All models:
5. Remove protection covers.
6. Close bonnet to safety catch position and check
that bonnet is aligned to both front wings and that
gaps are equal.
7. Tighten hinge bolts to 9 Nm.
EXTERÌOR FÌTTÌNGS
76-2-4 REPAÌRS
LOCK - BONNET
´÷ 76.16.21
Remove
1. Remove front grille. See EXTERIOR FITTINGS,
Repairs.
2. Mark position of bonnet lock.
3. Remove 3 bolts securing lock to body.
4. Release bonnet cable from lock and remove lock.
Refit
1. Position lock and engage bonnet cable.
2. Align lock to marks made during remove.
3. Fit and tighten bolts to 10 Nm.
4. Close and open bonnet to check lock operation
and alignment.
5. Loosen bolts securing lock and adjust lock
alignment.
6. Tighten bolts to 10 Nm.
7. Close and open bonnet to check lock operation
and alignment.
8. Fit front grille. See EXTERIOR FITTINGS,
Repairs.
BONNET RELEASE CABLE
´÷ 76.16.29
Remove
1. Remove drivers side headlamp. See
ELECTRICAL, Repairs.
2. Remove bonnet lock. See EXTERIOR
FITTINGS, Repairs.
3. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
4. Release cable from bonnet locking platform.
5. Feed cable through aperture in locking platform
valance.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-5
6. Remove fascia lower cover.
7. Remove 2 bolts securing bonnet pull to mounting
bracket to body.
8. Release bonnet pull from mounting bracket.
9. Release cable grommet from bulkhead and feed
cable into car.
Refit
1. Feed cable through bulkhead and secure
grommet.
2. Feed cable through aperture in locking platform
valance.
3. Fit cable to bonnet locking platform.
4. Fit bonnet pull to mounting bracket.
5. Position mounting bracket to body and tighten
bolts to 10 Nm.
6. Fit fascia lower cover.
7. Fit wheel arch liner. See EXTERIOR FITTINGS,
Repairs.
8. Fit bonnet lock. See EXTERIOR FITTINGS,
Repairs.
9. Fit drivers side headlamp. See ELECTRICAL,
Repairs.
FRONT BUMPER
´÷ 76.22.08
Remove
1. Remove 2 nuts securing bumper to bonnet
locking platform.
2. Remove 4 screws securing bumper to bonnet
locking platform.
3. Remove 6 screws securing bottom edge of
bumper to wheel arch liners.
4. Remove 3 screws securing lower edge of bumper
to body.
EXTERÌOR FÌTTÌNGS
76-2-6 REPAÌRS
5. Move liners aside and remove 4 nuts securing
bumper to both wings.
6. Remove retaining straps.
7. Remove number plate.
8. Remove screw securing centre of bumper to
body.
9. With assistance, release bumper from front
wings, disconnect indicator and fog lamp
multiplugs and remove bumper.
Do not carry out further dismantling if component
is removed for access only.
10. Remove 2 scrivets securing front grille, release
bottom of grille from 3 pegs and remove grille.
11. Release and remove indicator lamps and bumper
inserts.
12. Remove 4 screws securing fog lamps and
remove fog lamps.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-7
13. Remove 7 clips securing air intake grille and
remove grille.
Refit
1. Position air intake grille and secure with clips.
2. Position fog lamps and secure with screws.
3. Position indicator lamps and bumper inserts and
secure to bumper.
4. Position front grille, align to pegs and secure with
scrivets.
5. With assistance, position bumper to body
connect indicator and fog lamp multiplugs and
align bumper to front wings.
6. Fit screw securing centre of bumper to body.
7. Fit screws securing lower edge of bumper to
body.
8. Fit retaining straps to front wings, fit and tighten
nuts.
9. Reposition wheel arch liners.
10. Fit screws securing bumper to wheel arch liners.
11. Fit nuts securing bumper to bonnet locking
platform and tighten to 3 Nm.
12. Fit screw securing bumper to bonnet locking
platform.
13. Clean mating faces of number plate and bumper
to ensure both are free from grease and dirt.
14. Attach adhesive pads to rear of number plate.
15. Fit number plate to bumper.
BUMPER VALANCE - FRONT
´÷ 76.22.72
Remove
1. Remove 2 nuts securing bumper to bonnet
locking platform.
2. Remove 4 bolts securing bumper to bonnet
locking platform.
3. Remove 6 screws securing bumper to wheel arch
liners.
4. Remove 3 bolts securing lower edge of bumper
to body.
EXTERÌOR FÌTTÌNGS
76-2-8 REPAÌRS
5. Move wheel arch liners aside and remove 4 nuts
securing bumper to front wings.
6. With assistance, release bumper from body and
disconnect fog lamp and indicator lamp
multiplugs.
7. With assistance, remove bumper assembly.
Do not carry out further dismantling if component
is removed for access only.
8. Remove 2 scrivets securing grille, release grille
from 3 retaining lugs and remove grille.
9. Release and remove indicator lamps and bumper
inserts.
10. Release and remove fog lamp bezels.
11. Remove 3 screws securing each fog lamp and
remove fog lamps.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-9
12. Remove 7 clips securing air intake grille and
remove air intake grille.
13. Remove 2 screws securing each closing panel
and remove closing panels.
14. Carefully release bib spoiler from bumper
valance and remove bib spoiler.
Refit
1. Clean mating faces of bib spoiler and bumper
valance with spirit wipe or hot air gun.
2. Apply adhesion promoter to the tape contact area
of bumper.
3. Ensure panels are at room temperature, fit 3M
6mm X 1mm double sided tape to bib spoiler.
4. Allow 2 to 10 minutes for promoter to cure and
remove tape backing.
5. Position bib spoiler to bumper valance and
secure double sided tape.
6. Apply firm pressure to bib spoiler to ensure full
adhesion contact.
7. Fit closing panels and secure with screws.
8. Position air intake grille and secure with clips.
9. Position fog lamps and secure with screws.
10. Fit fog lamp bezels.
11. Fit bumper inserts and indicator lamps.
12. Position bumper grille in retaining pegs and
secure with scrivets.
13. With assistance position bumper to vehicle,
connect fog lamp and indicator multiplugs and
align bumper to front wings.
14. Fit nuts securing bumper to front wings and
tighten to 6 Nm.
15. Reposition wheel arch liners.
16. Fit bolts securing lower edge of bumper to body
and tighten to 6 Nm.
17. Fit and tighten screws securing bumper to wheel
arch liners.
18. Fit bolts securing bumper to bonnet locking
platform and tighten to 6 Nm.
19. Fit nuts securing bumper to bonnet locking
platform and tighten to 3 Nm.
EXTERÌOR FÌTTÌNGS
76-2-10 REPAÌRS
FRONT BUMPER ARMATURE
´÷ 76.22.49
Remove
1. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
2. Remove 4 bolts securing armature to body.
3. Remove armature.
Refit
1. Position armature to body and fit and tighten bolts
to 10 Nm.
2. Fit front bumper. See EXTERIOR FITTINGS,
Repairs.
GRILLE - FRONT
´÷ 76.55.03
Remove
1. Remove 2 scrivets securing front grille to bonnet
landing panel.
2. Release front grille from retaining pegs and
remove front grille.
Refit
1. Position front grille, engage retaining pegs.
2. Secure front grille with scrivets.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-11
GRILLE - FRONT - MG
´÷ 76.55.03
Remove
1. Remove 2 scrivets securing grille to bumper.
2. Release front grille from 3 retaining pegs and
remove grille.
Refit
1. Position front grille and engage retaining pegs.
2. Secure front grille with scrivets.
REAR BUMPER
´÷ 76.22.15
Remove
1. Open tailgate.
2. Remove 5 scrivets securing upper edge of
bumper to body.
3. Remove screw either side securing bumper to
wheel arch liner.
4. Remove bolt either side securing bumper to rear
wing.
5. Remove bolt securing lower edge of bumper to
underbody.
6. Remove rear bumper.
Refit
1. Fit rear bumper to body.
2. Fit bolt securing lower edge and tighten to 6 Nm.
3. Fit bolts securing ends of bumper to rear wing
and tighten to 6 Nm.
4. Fit screws securing ends of bumper to wheel arch
liners.
5. Fit scrivets securing upper edge of bumper.
EXTERÌOR FÌTTÌNGS
76-2-12 REPAÌRS
BUMPER VALANCE - REAR
´÷ 76.22.74
Remove
1. Remove both rear tail lamps. See ELECTRICAL,
Repairs.
2. Remove 2 bolts securing bumper to body.
3. Remove 5 scrivets securing bumper to body.
4. Remove 2 screws securing bumper lower section
to each rear wheel arch liner.
5. Remove 2 bolts securing bumper to rear wing.
6. Remove bolt securing bumper to spare wheel
well.
7. With assistance, remove rear bumper.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-13
8. Remove 7 nuts and 4 screws securing bib spoiler
to bumper valance.
9. Remove rear bib spoiler.
10. Release bumper inserts from 6 clips and remove
bumper inserts.
11. Release foam insert from 2 clips and 6 pads and
remove foam insert.
Refit
1. Clean mating faces of bib spoiler and bumper
valance.
2. Position bib spoiler to bumper and align to fixing
holes.
3. Fit and tighten nuts and screws securing bib
spoiler to bumper valance.
4. Position foam insert and secure to pads and
clips.
5. Position side inserts and secure in clips.
6. Fit rear bumper.
7. Fit scrivets securing bumper to body.
8. Fit bolts securing bumper to rear wing and tighten
to 6 Nm.
9. Fit and tighten screws securing bumper to wheel
arch liner.
10. Fit bolt securing bumper to spare wheel well and
tighten to 6 Nm.
11. Fit bolts securing bumper to body and tighten to
6 Nm.
12. Fit both rear tail lamps. See ELECTRICAL,
Repairs.
EXTERÌOR FÌTTÌNGS
76-2-14 REPAÌRS
SPOILER - BOOT/TAILGATE - TOP -
RENEW
´÷ 76.10.93
Remove
1. Remove tailgate upper finisher.See EXTERIOR
FITTINGS, Repairs.
2. Disconnect CHMSL multiplug.
3. Remove 2 nuts and 2 bolts securing spoiler to
tailgate.
4. Release spoiler from tailgate, feed CHMSL lead
through tailgate and remove spoiler.
5. Remove 2 nuts securing extreme spoiler to
tailgate spoiler and remove extreme spoiler.
6. Drill two 10 mm holes in marked indents to
access CHMSL screws.
7. Using a long magnetic screwdriver, remove 2
screws securing CHMSL, feed CHMSL lead
through spoiler and remove CHMSL.
Refit
1. Position CHMSL and feed lead through spoiler.
2. Fit and tighten screws securing CHMSL.
3. Cover holes in indents with waterproof tape.
4. Position extreme spoiler to tailgate spoiler and
align to fixing studs.
5. Fit nuts securing extreme spoiler and tighten to 6
Nm.
6. Position spoiler to tailgate, feed CHMSL lead
through tailgate and align spoiler studs to
tailgate.
7. Fit nuts and bolts securing spoiler and tighten to
6 Nm.
8. Connect multiplug to CHMSL.
9. Fit tailgate upper finisher. See EXTERIOR
FITTINGS, Repairs.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-15
EXTREME SPOILER - BOOT/TAILGATE -
RENEW
´÷ 76.10.98
Remove
1. Remove tailgate upper finisher. See EXTERIOR
FITTINGS, Repairs.
2. Disconnect CHMSL multiplug.
3. Remove 2 nuts and 2 bolts securing spoiler to
tailgate.
4. Release spoiler from tailgate, feed CHMSL lead
through tailgate and remove spoiler.
5. Remove 2 nuts securing extreme spoiler to
tailgate spoiler and remove extreme spoiler.
Refit
1. Position extreme spoiler to tailgate spoiler and
align to fixing studs.
2. Fit nuts securing extreme spoiler and tighten to 6
Nm.
3. Position spoiler to tailgate, feed CHMSL lead
through tailgate and align spoiler studs to
tailgate.
4. Fit nuts and bolts securing spoiler and tighten to
6 Nm.
5. Connect multiplug to CHMSL.
6. Fit tailgate upper finisher. See EXTERIOR
FITTINGS, Repairs.
EXTERÌOR FÌTTÌNGS
76-2-16 REPAÌRS
BIB SPOILER - FRONT BUMPER - RENEW
´÷ 76.22.55
Remove
1. Raise front of vehicle.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
2. Remove 2 screws securing each closing panel
and remove closing panels.
3. Remove 6 screws and 3 bolts securing bib spoiler
to bumper valance.
4. Carefully release bib spoiler from bumper
valance and remove bib spoiler.
Refit
1. Clean mating faces of bib spoiler and bumper
valance with spirit wipe or hot air gun.
2. Ensure panels are at room temperature, fit 3M
6mm X 1mm double sided tape to bib spoiler.
3. Prefit bib spoiler and mark top line position.
4. Apply adhesion promoter to bumper surface area
in the final tape position.
5. Allow 2 to 10 minutes for promoter to cure and
remove tape backing.
6. Position bib spoiler to bumper valance and
secure double sided tape, apply firm pressure to
ensure full adhesion contact.
7. Fit and tighten screws and bolts securing bib
spoiler to bumper valance.
8. Fit closing panels and secure with screws.
9. Remove stands and lower vehicle.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-17
BIB SPOILER - REAR BUMPER - RENEW
´÷ 76.22.56
Remove
1. Raise rear of vehicle.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
2. Remove 7 nuts and 4 screws securing bib spoiler
to bumper valance.
3. Carefully release bib spoiler from bumper
valance and remove bib spoiler.
Refit
1. Clean mating faces of bib spoiler and bumper
valance.
2. Position bib spoiler to bumper and align to fixing
holes.
3. Fit and tighten nuts and screws securing bib
spoiler to bumper valance.
4. Remove stands and lower vehicle.
MOULDING - SILL EXTERIOR - RENEW
´÷ 76.43.84
Remove
1. Raise front and rear of vehicle.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
2. Noting their fitted position. carefully remove 5
clips securing sill moulding to body sill lip.
3. Carefully release sill moulding from body sill and
remove sill moulding.
Refit
1. Clean mating faces of sill moulding and body sill
with spirit wipe or hot air gun.
2. Ensure panels are at room temperature, fit 3M
6mm X 1mm double sided tape to sill moulding.
3. Prefit moulding to sill and mark top line position.
4. Apply adhesion promoter to sill surface area in
the final tape position.
5. Allow 2 to 10 minutes for promoter to cure and
remove tape backing.
6. Align sill moulding to body and secure double
sided tape, apply firm pressure to sill to ensure
full adhesion contact.
7. Fit clips securing sill moulding to body sill lip.
8. Remove stands and lower vehicle.
9. Allow 24 hrs. to achieve full bonding strength.
EXTERÌOR FÌTTÌNGS
76-2-18 REPAÌRS
TAILGATE APPLIQUE
´÷ 76.28.76
Remove
1. Using special tool 18G 1766, remove 4 fixings
securing applique to tailgate.
2. Remove tailgate trim finisher. See DOORS,
Repairs.
3. Release 2 clips securing applique to tailgate.
4. Disconnect 4 Lucars from number plate lights
and remove applique.
5. Remove 4 screws securing number plate lights to
applique and remove lights.
Refit
1. Fit tailgate lights to new applique and secure with
screws.
2. Fit self adhesive badge to applique.
3. Position applique to tailgate and connect number
plate light Lucars.
4. Fit applique to tailgate and secure clips.
5. Fit tailgate trim finisher. See DOORS, Repairs.
6. Fit screws securing applique to tailgate and
tighten to 2 Nm.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-19
FRONT DOOR RUBBING STRIP
´÷ 76.43.66
Remove
1. Remove nut securing rear edge of rubbing strip to
door.
2. Remove plastic sheet from door. See DOORS,
Repairs.
3. Compress tags on clips and release rubbing strip
from door.
4. Remove rubbing strip from door.
5. Rotate clips to remove from rubbing strip.
EXTERÌOR FÌTTÌNGS
76-2-20 REPAÌRS
Refit
1. Fit clips to new rubbing strip.
2. Fit rubbing strip to door and secure clips.
3. Fit nut securing rubbing strip to door and tighten
to 0.5 Nm.
4. Fit plastic sheet to door. See DOORS, Repairs.
REAR DOOR RUBBING STRIP
´÷ 76.43.86
Remove
1. Remove nut securing forward edge of rubbing
strip to door.
2. Remove rear door plastic sheet. See DOORS,
Repairs.
3. Compress tags on 3 clips and release rubbing
strip from door.
EXTERÌOR FÌTTÌNGS
REPAÌRS 76-2-21
4. Remove clips from rubbing strip by rotating.
Refit
1. Fit clips to new rubbing strip.
2. Fit rubbing strip to door and secure with clips.
3. Fit nut securing forward edge of rubbing strip to
door and tighten to 0.5 Nm.
4. Fit rear door plastic sheet. See DOORS,
Repairs.
REAR QUARTER RUBBING STRIP
´÷ 76.43.87
Remove
1. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Compress tags on 3 clips and release rubbing
strip from rear quarter panel.
3. Remove clips from rubbing strip by rotating.
Refit
1. Fit clips to new rubbing strip.
2. Fit rubbing strip to rear quarter panel and secure
with clips.
3. Fit rear quarter lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
EXTERÌOR FÌTTÌNGS
76-2-22 REPAÌRS
FRONT TREAD PLATE
´÷ 76.76.01
Remove
1. Remove 3 screws securing tread plate to sill.
2. Release tread plate from door seal and remove.
Refit
1. Fit tread plate to door sill and seal.
2. Secure tread plate with screws.
REAR TREAD PLATE
´÷ 76.76.02
Remove
1. Remove 2 screws securing tread plate to sill.
2. Release tread plate from door seal and remove.
Refit
1. Fit tread plate to door sill and seal.
2. Secure tread plate with screws.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-1
ÌNTERÌOR TRÌM COMPONENTS REPAÌ RS
BULKHEAD - LOADSPACE - VAN
´÷ 76.13.82
Remove
1. Open tailgate.
2. Remove loadspace rear floor panel.
3. Remove 4 bolts securing LH and RH loadspace
floor panels and remove floor panels.
4. Remove 2 torx bolts securing loadspace
bulkhead to floor.
5. Remove 4 bolts securing loadspace bulkhead to
floor.
6. With assistance remove loadspace bulkhead
from vehicle.
Refit
1. With assistance manouvre loadspace bulkhead
into fitted position.
2. Fit and tighten 4 bolts securing loadspace
bulkhead to floor to 20 Nm.
3. Fit and tighten torx bolts securing loadspace
bulkhead to floor to 50 Nm.
4. Fit LH and RH loadspace floor panels, fit and
tighten bolts.
5. Fit loadspace rear floor panel.
6. Close tailgate.
SP76 0195
SP76 0196
SP76 0197
SP76 0198
ÌNTERÌOR TRÌM COMPONENTS
76-3-2 REPAÌRS
GUARD - LOADSPACE - VAN
´÷ 76.13.83
Remove
1. Remove 2 bolts securing loadspace guard to roof
lining brackets.
2. Tilt drivers and passengers seats forward.
3. Remove 2 nuts and bolts securing loadspace
guard to loadspace bulkhead.
4. Remove loadspace guard from vehicle.
Refit
1. Manouvre loadspace gaurd into fitted position.
2. Fit and tighten nuts and bolts securing loadspace
guard to loadspace bulkhead to 10 Nm.
3. Fit and tighten bolts securing loadspace guard to
roof lining brackets to 10 Nm.
FLOOR FRAME - LOADSPACE - VAN
´÷ 76.13.84
Remove
1. Open tailgate.
2. Remove loadspace rear floor panel.
3. Remove 4 bolts securing LH and RH loadspace
floor panels and remove floor panels.
4. Remove 2 torx bolts securing loadspace frame to
floor.
5. Raise vehicle on 4 post ramp.
SP76 0192
SP76 0195
SP76 0196
SP76 0193
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-3
6. Remove 2 nuts securing loadspace frame to
floor.
7. Lower vehicle.
8. Remove loadspace frame from vehicle.
Refit
1. Manoeuvre loadspace frame into fitted position.
2. Fit but do not tighten torx bolts securing
loadspace frame to floor.
3. Raise vehicle on 4 post ramp.
4. Fit and tighten nuts securing loadspace frame to
floor to 22 Nm.
5. Lower vehicle.
6. Tighten torx bolts securing loadspace frame to
floor to 50 Nm.
7. Fit LH and RH loadspace floor panels, fit and
tighten bolts.
8. Fit loadspace rear floor panel.
9. Close tailgate.
REAR CONSOLE
´÷ 76.25.04
Remove
1. Remove rear ashtray.
2. Remove finisher from console.
3. Remove 2 bolts securing console to body.
4. Remove rear console.
Refit
1. Align rear console to front console.
2. Fit bolts securing rear console to body and
tighten to 3 Nm.
3. Fit finisher to console.
4. Fit rear ashtray.
SP76 0194
ÌNTERÌOR TRÌM COMPONENTS
76-3-4 REPAÌRS
FRONT CONSOLE
´÷ 76.25.01
Remove
1. Disconnect battery earth lead.
2. Remove rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
3. Remove radio. See ELECTRICAL, Repairs.
4. Remove gear selector knob.
Models with electric windows:
5. Release switch panel, disconnect multiplugs and
remove switch panel.
Models with CVT:
6. Release PRND indicator, disconnect multiplug
and remove PRND indicator.
Models with snow mode:
7. Release snow mode switch from front console.
8. Disconnect multiplug and remove switch.
All models:
9. Remove 4 screws securing front console to
fascia.
10. Release front console from fascia to gain access
to multiplugs and release.
11. Release fog light, hazard, heated rear screen and
A/C multiplugs and release.
12. Release Lucar and multiplug from cigar lighter.
13. Remove front console.
Do not carry out further dismantling if component
is removed for access only.
14. Remove fog light, hazard, heated rear screen
and A/C switches from console.
15. Remove switch blank from console.
16. Remove 4 screws and collect switch bezel.
17. Bend 8 tabs to release radio cage from console.
18. Remove ashtray.
19. Remove 3 screws and collect ashtray mounting
bracket.
20. Remove cigar lighter element from holder.
21. Remove bulb holder from cigar lighter holder.
22. Depress clips and release cigar lighter holder
from console.
23. Remove 4 screws and collect cassette tray.
24. Remove 4 screws securing gaiter assembly to
console and remove gaiter assembly.
Refit
1. Fit gaiter assembly to console and secure with
screws.
2. Fit cassette tray to console and secure with
screws.
3. Fit cigar lighter holder to console.
4. Fit bulb holder and element to cigar lighter.
5. Fit ashtray mounting bracket to console and
secure with screws.
6. Fit ashtray to console.
7. Fit radio cage to console and bend tabs to
secure.
8. Fit switch bezel to console and secure with
screws.
9. Fit switch blank to console.
10. Fit fog light, hazard, heated rear window and A/C
switches to console.
11. Position front console to fascia and connect
multiplugs to fog light, hazard, heated rear screen
and A/C switches.
12. Connect Lucar and multiplug to cigar lighter.
13. Align front console to fascia, fit and tighten
screws.
14. Fit gear selection knob.
Models with snow mode:
15. Position switch, connect multiplug and secure
switch to front console.
Models with CVT:
16. Position PRND indicator, connect multiplug and
secure indicator to front console.
Models with electric windows:
17. Position switch panel, connect multiplugs and
secure switch panel to front console.
18. Fit radio. See ELECTRICAL, Repairs.
All models:
19. Fit rear console. See INTERIOR TRIM
COMPONENTS, Repairs.
20. Connect battery earth lead.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-5
FASCIA
´÷ 76.46.23.99
WARNING: Refer to SRS section for safety
precautions.
Remove
1. Disconnect both battery leads, earth lead first.
2. Remove front console. See INTERIOR TRIM
COMPONENTS, Repairs.
3. Remove glovebox. See INTERIOR TRIM
COMPONENTS, Repairs.
Vehicles fitted with passenger airbag:
4. Remove 2 Torx screws securing passenger
airbag to fascia.
5. Remove bolt securing passenger airbag support
bracket to support arm.
6. Release passenger airbag from fascia and
disconnect multiplug.
7. Remove passenger airbag.
All models:
8. Remove heater controls. See HEATING &
VENTILATION, Repairs.
9. Remove steering column. See STEERING,
Repairs.
Models with servicable fusebox:
10. Disconnect 2 fascia harness multiplugs from
fusebox.
Models with hard¬wired fusebox:
11. Disconnect 2 fascia/main muliplugs.
SP57 0043
ÌNTERÌOR TRÌM COMPONENTS
76-3-6 REPAÌRS
All models:
12. Remove end covers from fascia and remove
bolts securing fascia to body.
13. Remove finisher from clock.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-7
14. Remove nut securing fascia to body.
15. Remove bolt securing passengers side of fascia
to mounting bracket.
16. Remove 2 bolts securing centre of fascia to
mounting bracket.
17. Remove bolt securing drivers side of fascia to
mounting bracket.
18. Release 2 clips securing harness to heater and
fascia frame.
19. Release SRS multiplug from clip on fascia frame.
20. Release 2 clips securing SRS cable to fascia
frame.
21. Release clip securing relay to fascia frame and
position relay aside.
22. Remove 2 scrivets securing power window
control unit to fascia frame and position aside.
23. Pull fascia forward and disconnect multiplugs
from headlight dip control switch and electric
mirror control.
24. Remove fascia.
Refit
1. Position fascia to vehicle.
2. Connect multiplugs to headlight dip control
switch and electric mirror control.
3. Fit power window control unit to fascia frame and
secure with scrivets.
4. Fit relay to fascia frame and secure clip.
5. Position SRS cable to fascia frame and secure
clips.
6. Fit SRS multiplug to clip on fascia frame.
7. Position harness to heater and fascia frame and
secure clips.
8. Fit centre mounting nut and tighten to 9 Nm.
9. Fit bolt securing drivers side of fascia to mounting
bracket and tighten to 9 Nm.
10. Fit bolts securing centre of fascia to mounting
bracket and tighten to 9 Nm .
11. Fit bolt securing passengers side of fascia to
mounting bracket and tighten to 9 Nm.
12. Fit bolts securing ends of fascia to body.
13. Fit end covers to fascia.
14. Fit finisher to clock.
15. Connect multiplugs to interior fusebox.
16. Fit steering column. See STEERING, Repairs.
17. Fit heater controls. See HEATING &
VENTILATION, Repairs.
Vehicles fitted with passenger airbag:
18. Fit bolt securing passenger airbag support
bracket to support arm and tighten to 9 Nm.
19. Position passenger airbag to fascia and connect
multiplugs.
20. Fit passenger airbag to fascia. Fit and tighten
Torx screws to 9 Nm.
All models:
21. Fit glovebox. See INTERIOR TRIM
COMPONENTS, Repairs.
22. Fit front console. See INTERIOR TRIM
COMPONENTS, Repairs.
23. Connect both battery leads, earth lead last.
ÌNTERÌOR TRÌM COMPONENTS
76-3-8 REPAÌRS
FASCIA VENEERED PANEL
´÷ 76.46.24
CAUTION: Fit protection to fascia before removing
veneered paneI.
Remove
1. Using a flat blade, carefully release veneered
panel from fascia and remove.
Refit
1. Position panel to fascia and secure clips.
GLOVE BOX
´÷ 76.52.02
Remove
1. Remove lower closing panel.
2. Remove 2 screws securing glove box to fascia.
3. Remove glove box.
Refit
1. Fit glove box to fascia and tighten screws to 10
Nm.
2. Fit lower closing panel to fascia.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-9
GLOVE BOX LATCH
´÷ 76.52.08
Remove
1. Open glove box.
2. Remove screw securing latch to glove box.
3. Remove latch.
Refit
1. Fit latch to glove box and secure with screw.
2. Close glove box.
FUSE BOX COVER
´÷ 76.46.30
Remove
1. Remove fascia lower cover.
2. Release 3 turnbuckles securing fuse box cover to
fascia.
3. Release cover from fascia.
Refit
1. Fit fuse box cover to fascia and secure
turnbuckles.
2. Fit fascia lower cover.
ÌNTERÌOR TRÌM COMPONENTS
76-3-10 REPAÌRS
'A' POST UPPER TRIM CASING
´÷ 76.13.26
Remove
1. Open front door and pull seal away from aperture
to gain access to trim casing.
2. Release 'A' post trim casing from behind 'B' post
trim.
3. Release 'A' post trim from 7 clips and remove.
Refit
1. Position 'A' post trim to body, 'B' post trim, and
fascia.
2. Secure 'A' post trim clips.
3. Fit front door seal to aperture.
'A' POST LOWER TRIM CASING
´÷ 76.13.27
Remove
1. Open door and remove seal from front door
aperture to gain access to trim casing.
2. Remove 3 trim studs securing trim casing to 'A'
post.
3. Remove trim casing.
Refit
1. Fit trim casing to 'A' post and secure with trim
studs.
2. Fit seal to front door aperture.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-11
'B' POST LOWER TRIM CASING - 5 DOOR
´÷ 76.13.29
Remove
1. Open front door and remove seal from aperture
to gain access to 'B' post trim casing.
2. Open rear door and remove seal from aperture to
gain access to 'B' post trim casing.
3. Release trim casing from 6 clips.
4. Remove trim casing.
Refit
1. Fit trim casing to 'B' post and secure with clips.
2. Fit rear door seal to aperture.
3. Fit front door seal to aperture.
REAR QUARTER TRIM CASING - 3 DOOR
´÷ 76.13.13
Remove
1. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Remove scrivet securing trim casing to 'B' post.
3. Remove scrivet securing trim casing to 'D' post.
4. Release volumetric sensor from trim casing and
disconnect multiplug.
ÌNTERÌOR TRÌM COMPONENTS
76-3-12 REPAÌRS
5. Remove cover from seat belt upper anchorage
bolt.
6. Remove seat belt upper anchorage bolt and
discard.
7. Remove tailgate aperture seal.
8. Release trim casing from 7 clips and remove.
Refit
1. Fit trim casing and secure clips.
2. Fit scrivet securing trim casing to 'D' post.
3. Fit tailgate aperture seal.
4. Fit new seat belt upper anchorage bolt and
tighten to 50 Nm.
5. Fit cover to anchorage bolt.
6. Connect multiplug to volumetric sensor and
secure to trim casing.
7. Fit scrivet securing trim casing to 'B' post.
8. Fit rear quarter lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-13
REAR QUARTER TRIM CASING - 5 DOOR
´÷ 76.13.13
Remove
1. Remove 'B' post lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Remove scrivet securing trim casing to 'B' post.
3. Remove cover from seat belt upper anchorage
bolt.
4. Remove seat belt upper anchorage bolt and
discard.
5. Release volumetric sensor from trim casing and
disconnect multiplug.
6. Open tailgate and remove seal from aperture.
7. Fold rear seat forward.
8. Release 7 clips securing trim casing to body and
remove trim casing.
Refit
1. Position trim casing to body and secure with
clips.
2. Fit tailgate aperture seal and reposition rear seat.
3. Position upper seat belt anchorage to body and
secure with new bolt to 50 Nm.
4. Fit cover to upper anchorage bolt.
5. Connect multiplug to volumetric sensor and
secure sensor to trim casing.
6. Fit scrivet securing trim casing to 'B' post.
7. Fit 'B' post lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
ÌNTERÌOR TRÌM COMPONENTS
76-3-14 REPAÌRS
HEADLINING
´÷ 76.64.15
Remove
1. Remove both 'A' post upper trim casings. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Remove both rear quarter trim casings. See
INTERIOR TRIM COMPONENTS, Repairs.
3. Release sun visors from clips and remove 2
screws securing each sun visor to body.
4. Remove sun visors.
5. Remove 2 screws securing sun visor clips to
body.
6. Remove both clips.
7. Remove roof lamp. See ELECTRICAL, Repairs.
8. Remove 2 covers and 4 screws securing each
grab handle to body.
9. Remove both grab handles.
10. Release sealing rubber from top of tailgate
aperture.
Models fitted with sunroof:
11. Remove sunroof switch escutcheon.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-15
12. Remove trim finisher from sunroof aperture.
All models:
13. Release 4 trim clips securing headlining to roof.
14. Remove headlining.
NOTE: Take care not to bend headlining on
removal and refitting.
Refit
1. With assistance position headlining to roof.
2. Fit trim clips securing headlining to roof.
Models fitted with sunroof:
3. Fit trim finisher to sunroof aperture.
4. Fit sunroof switch escutcheon.
All models:
5. Fit sealing rubber to top of tailgate aperture.
6. Fit grab handles to roof and secure with screws.
7. Fit roof lamp. See ELECTRICAL, Repairs.
8. Fit sun visor clips to roof and secure with screws.
9. Fit sun visors to roof and secure with screws.
10. Fit both rear quarter trim casings. See INTERIOR
TRIM COMPONENTS, Repairs.
11. Fit both 'A' post upper trim casings. See
INTERIOR TRIM COMPONENTS, Repairs.
PARCEL TRAY SUPPORT PANEL - 3
DOOR MODELS
´÷ 76.67.11
Remove
1. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Remove rear seat cushion. See SEATS AND
SEAT BELTS, Repairs.
3. Remove rear seat belt lower anchorage bolt and
discard.
4. Remove seat belt upper anchorage trim finisher
from parcel tray support panel.
ÌNTERÌOR TRÌM COMPONENTS
76-3-16 REPAÌRS
5. Disconnect 2 Lucars from luggage compartment
light.
6. Disconnect multiplug from rear speaker.
7. Remove 2 screws and scrivet securing support
panel to body.
8. Release support panel from clip and remove.
Do not carry out further dismantling if component
is removed for access only.
9. Remove luggage compartment light from support
panel.
10. Remove 4 screws securing rear speaker to
support panel and remove rear speaker.
Refit
1. Fit speaker to support panel and secure with
screws.
2. Fit luggage compartment light to support panel.
3. Fit support panel over rear seat belt and secure
to body with clip.
4. Fit screws and scrivet securing support panel to
body.
5. Connect multiplug to rear speaker.
6. Connect Lucars to luggage compartment light.
7. Fit upper seat belt anchorage trim finisher.
8. Fit seat belt lower anchorage bolt and tighten to
50 Nm.
9. Fit rear seat cushion. See SEATS AND SEAT
BELTS, Repairs.
10. Fit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-17
PARCEL TRAY SUPPORT PANEL - 5
DOOR MODELS
´÷ 76.67.11
Remove
1. Remove parcel tray.
2. Remove seat belt upper anchorage trim finisher
from parcel tray support panel.
3. Disconnect 2 Lucars from luggage compartment
light.
4. Disconnect multiplug from rear speaker.
5. Remove 2 screws and scrivet securing support
panel.
6. Release support panel from clip and remove.
Do not carry out further dismantling if component
is removed for access only.
7. Remove luggage compartment light from support
panel.
8. Remove 4 screws securing rear speaker to
support panel and remove rear speaker.
Refit
1. Position rear speaker to support panel and
secure with screws.
2. Fit luggage compartment light to support panel.
3. Fit support panel over rear seat belt and secure
to body with clip.
4. Fit screws and scrivet securing support panel to
body.
5. Connect multiplug to rear speaker.
6. Connect Lucars to luggage compartment light.
7. Fit upper seat belt anchorage trim finisher.
8. Fit parcel tray.
ÌNTERÌOR TRÌM COMPONENTS
76-3-18 REPAÌRS
REAR QUARTER LOWER TRIM CASING -
3 DOOR
´÷ 76.13.12
Remove
1. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Remove rear seat squab. See SEATS AND
SEAT BELTS, Repairs.
3. Open front door and remove seal from aperture.
4. Open rear window and remove seal from
aperture.
5. Remove 3 screws securing trim casing to body.
6. Remove rubber grommet from seat catch.
7. Release trim casing from 6 clips and remove.
Refit
1. Fit trim casing and secure with clips.
2. Fit rubber grommet to seat catch.
3. Fit and tighten screws securing trim casing to
body.
4. Fit seal to rear window aperture.
5. Fit seal to front door aperture.
6. Fit rear seat squab. See SEATS AND SEAT
BELTS, Repairs.
7. Fit parcel shelf support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
REAR QUARTER LOWER TRIM CASING -
5 DOOR
´÷ 76.13.12
Remove
1. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Remove rear seat squab. See SEATS AND
SEAT BELTS, Repairs.
3. Remove 3 screws securing trim casing to body.
4. Remove seal from door aperture.
5. Remove trim casing.
Refit
1. Fit trim casing to body and secure with screws.
2. Fit door seal to aperture.
3. Fit rear seat squab. See SEATS AND SEAT
BELTS, Repairs.
4. Fit parcel shelf support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
ÌNTERÌOR TRÌM COMPONENTS
REPAÌRS 76-3-19
LUGGAGE COMPARTMENT SIDE
CARPET
´÷ 76.49.15
Remove
1. Remove 2 screws securing carpet to rear seat
squab support panel.
2. Remove luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
3. Release side carpet from trim stud.
4. Remove carpet.
Refit
1. Fit carpet to vehicle and secure with clip.
2. Fit luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
3. Fit screws securing carpet to rear seat squab
support panel.
LUGGAGE COMPARTMENT TRIM
CASING
´÷ 76.13.53
Remove
1. Remove seal from tailgate aperture.
2. Remove 3 scrivets securing trim casing.
3. Remove trim casing.
Refit
1. Fit trim casing and secure with scrivets.
2. Fit seal to tailgate aperture.
ÌNTERÌOR TRÌM COMPONENTS
76-3-20 REPAÌRS
PARCEL TRAY
´÷ 76.67.06
Remove
1. Release parcel tray cables from tailgate.
2. Release parcel tray from support panels.
3. Remove parcel tray.
Refit
1. Fit parcel tray and secure to support panels.
2. Attach parcel tray cables to tailgate.
SCREENS
REPAÌRS 76-4-1
SCREENS REPAÌ RS
WINDSCREEN
´÷ 76.81.01
NOTE: The following equipment is required:
Cutting wire and handles.
Windscreen repair kit.
Sealer applicator gun.
Suction cups.
WARNING: Wear protective gloves when handling
glass, solvents, and primers.
WARNING: Wear suitable eye protection when
removing and refitting glass.
Remove
1. Remove rear view mirror from windscreen.
2. Remove both 'A' post upper trim casings. See
INTERIOR TRIM COMPONENTS, Repairs.
3. Remove 4 screws securing both sun visors to
headlining.
4. Release sun visors from catches and remove.
5. Remove 2 screws securing both sun visor clips to
headlining and remove clips.
Models with sun roof:
6. Remove sunroof switch escutcheon.
7. Remove 2 trim studs securing headlining to roof.
8. Remove sunroof aperture finisher.
SCREENS
76-4-2 REPAÌRS
All models:
9. Remove air intake plenum. See HEATING &
VENTILATION, Repairs.
10. Fit protection to bonnet and areas around screen.
11. Apply masking tape to heater vents.
12. Fit protective cover to interior of vehicle.
13. Carefully run a sharp blade around screen and
remove outer lip of screen finisher.
14. Remove 2 screws securing spacers to body.
15. Ìnsert cutting wire through sealant at top of 'A'
post.
16. Ìnsert cutting wire through sealant at bottom of 'A'
post.
17. Fit handles to cutting wire.
18. Fit dash guard to interior of vehicle.
19. Make a double cut along top and bottom of
screen, and down 'A' post.
NOTE: If multi-strand cutting wire is used, a
sawing action can be used to cut through heavy
sealant deposits around corners.
CAUTION: Use of a sawing action may
overheat and break singIe strand wire.
20. Ìnsert cutting wire through sealant at top and
bottom of remaining 'A' post.
21. Make a double cut down remaining 'A' post.
SCREENS
REPAÌRS 76-4-3
22. Attach suction cups to screen 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 approximately 1 to 2
mm thick.
2. Remove masking near screen aperture.
3. Use a vacuum cleaner to clear away any waste.
4. Apply T-Cut around screen aperture to erase any
witness marks made by old screen finisher.
5. Fit spacers to aperture. DO NOT fit screws.
6. With assistance, locate screen to aperture.
7. Apply masking tape reference marks to aid
fitment.
8. With assistance, remove screen and place aside.
9. Apply de-greasant agent (yellow top) around
screen aperture.
CAUTION: Do not touch cIeaned or primed
surfaces with fingers.
10. Apply etch primer to any bare metal around
screen aperture.
11. Clean and polish new glass.
12. Apply de-greasant agent (yellow top) to screen
obscuration band.
13. Apply primer (green top) to screen obscuration
band.
NOTE: Allow 15 minutes for primer to cure.
14. Apply primer (red top) to screen aperture.
NOTE: At this point, sealant re-activator (blue
top) may be applied to old sealant band around
screen aperture.
15. Fit pre-cut nozzle to sealer cartridge, remove lid
and shake out crystals. Ìnstall in applicator gun.
NOTE: Nozzle will need modification to achieve
required bead section.
SCREENS
76-4-4 REPAÌRS
16. Apply a continuous bead of sealant around
aperture as shown. Make bead slightly thicker at
each corner.
17. Check for breaks or air bubbles in sealant.
18. With assistance, lift screen into place and align to
tape. Lightly press glass to seat sealer.
19. Fit and tighten screws to spacers.
20. Remove protective covers and tape.
21. Test screen for leaks and apply additional sealant
if necessary. Ìf water is used, allow sealant to dry
before testing.
22. Fit air intake plenum. See HEATING &
VENTILATION, Repairs.
23. Fit trim studs securing headlining to roof.
24. Fit sunroof aperture finisher.
25. Fit sunroof switch escutcheon.
26. Fit sun visor catches to headlining and secure
with screws.
27. Fit sun visors to headlining and secure with
screws.
28. Fit both 'A' post upper trim casings. See
INTERIOR TRIM COMPONENTS, Repairs.
29. Fit rear view mirror to windscreen.
CAUTION: VehicIes fitted with drivers or
passenger airbags shouId NOT be driven for
24 hours. During this time Ieave a window
open and do not sIam the doors.
REAR SCREEN
´÷ 76.81.10
NOTE: The following equipment is required:
Cutting wire and handles.
Windscreen repair kit.
Sealer applicator gun.
Suction cups.
WARNING: Wear protective gloves when handling
glass, solvents, and primers.
WARNING: Wear suitable eye protection when
removing and refitting glass.
Remove
1. Remove rear screen wiper motor. See WIPERS
& WASHERS, Repairs.
2. Remove tailgate spoiler. See EXTERIOR
FITTINGS, Repairs.
3. Disconnect 2 leads from rear screen demister.
4. Fit protection to rear of vehicle.
5. Fit protective cover to interior of vehicle.
SCREENS
REPAÌRS 76-4-5
6. Carefully run a sharp blade around rear screen
and remove outer lip of screen finisher.
7. Ìnsert cutting wire through sealant at bottom
corner of screen.
8. Fit handles as shown, with approximately 200
mm of wire between handles.
9. With assistance, wedge tube of handle 'A'
between glass and body, ahead of cutting
position. Carefully cut sealant from screen
aperture.
NOTE: If multi-strand cutting wire is used, a
sawing action can be used to cut through heavy
sealant deposits around corners.
CAUTION: Use of a sawing action may
overheat and break singIe strand wire.
10. Attach suction cups to screen 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.
SCREENS
76-4-6 REPAÌRS
Refit
1. Carefully remove excess sealer from body
leaving a smooth surface approximately 1 to 2
mm thick.
2. Use a vacuum cleaner to clear away any waste.
3. Apply T-Cut around screen aperture to erase any
witness marks made by old screen finisher.
4. With assistance, locate screen to aperture.
5. Apply masking tape reference marks to aid
fitment.
6. With assistance, remove screen and place aside.
7. Apply de-greasant agent (yellow top) around
screen aperture.
CAUTION: Do not touch cIeaned or primed
surfaces with fingers.
8. Apply etch primer to any bare metal around
screen aperture.
9. Clean and polish new glass.
10. Apply de-greasant agent (yellow top) to screen
obscuration band.
11. Apply primer (green top) to screen obscuration
band.
NOTE: Allow 15 minutes for primer to cure.
12. Apply primer (red top) to screen aperture.
NOTE: At this point, sealant re-activator (blue
top) may be applied to old sealant band around
screen aperture.
13. Fit pre-cut nozzle to sealer cartridge, remove lid
and shake out crystals. Ìnstall in applicator gun.
NOTE: Nozzle will need modification to achieve
required bead section.
14. Apply a continuous bead of sealant around
aperture as shown. Make bead slightly thicker at
each corner.
15. Check for breaks or air bubbles in sealant.
16. With assistance, lift screen into place and align to
tape. Lightly press glass to seat sealer.
17. Remove protective covers and tape.
18. Test screen for leaks and apply additional sealant
if necessary. Ìf water is used, allow sealant to dry
before testing.
19. Connect 2 leads to rear screen demister.
20. Fit tailgate spoiler. See EXTERIOR FITTINGS,
Repairs.
21. Fit rear screen wiper motor. See WIPERS &
WASHERS, Repairs.
CAUTION: A curing time of 6 hours is
desirabIe, during this time Ieave a window
open and do not sIam the doors.
SCREENS
REPAÌRS 76-4-7
REAR QUARTER GLASS - 3 DOOR
MODELS
´÷ 76.81.24
Remove
1. Remove rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
2. Remove 2 nuts securing window to body.
3. Remove 3 screws securing window latch to body.
4. Release window from clip on 'B' post and
remove.
Do not carry out further dismantling if component
is removed for access only.
5. Remove screw securing latch to window and
remove latch.
Refit
1. Fit latch to new glass and secure with screw.
2. Position window to body and secure to clip on 'B'
post.
3. Fit nuts securing window to body and tighten to 9
Nm.
4. Fit screws securing window latch to body and
tighten to 4 Nm.
5. Fit rear quarter trim casing. See INTERIOR TRIM
COMPONENTS, Repairs.
SCREENS
76-4-8 REPAÌRS
SEATS AND SEAT BELTS
REPAÌRS 76-5-1
SEATS AND SEAT BELTS REPAÌ RS
FRONT SEAT
´÷ 78.10.44.99
CAUTION: See safety precautions in SRS section
before starting work.
Remove
1. Disconnect battery earth lead.
2. Move seat fully forward.
3. Remove 2 bolts securing rear of runners.
4. Move seat fully rearwards and remove 2 bolts
securing front of runners.
5. Move seat aside and disconnect SRS pre-
tensioner multiplug.
6. Remove seat.
Refit
1. Position seat to vehicle and connect pre-
tensioner multiplug.
2. Fit bolts securing front of runners to floor and
tighten to 34 Nm.
3. Move seat fully forwards.
4. Fit bolts securing rear of runners to floor and
tighten to 34 Nm.
5. Connect battery earth lead.
SEATS AND SEAT BELTS
76-5-2 REPAÌRS
FRONT SQUAB COVER
´÷ 78.90.08
Remove
1. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
2. Remove head restraint.
3. Release spring clips and remove head restraint
guides from squab frame.
4. Release cover hooks and retainer from rear bar.
5. Remove 2 rear hog rings from squab.
6. Release cover hooks from pullmaflex and pass
through cushion.
7. Release Velcro securing squab cover to pad and
remove cover.
SEATS AND SEAT BELTS
REPAÌRS 76-5-3
Refit
1. Position squab cover, fit head restraint
escutcheons and secure with clips.
2. Pull cover to position and secure front with
Velcro.
3. Pass cover hooks through cushion and secure to
squab frame.
4. Position cover and secure rear with new hog
rings.
5. Pass cover hooks under base of squab and
secure to frame.
6. Secure lower retainer to frame rear bar.
7. Fit head restraint.
8. Fit front seat. See SEATS AND SEAT BELTS,
Repairs.
FRONT SEAT AND SQUAB FRAME
´÷ 78.30.18
Remove
1. Remove front squab cover. See SEATS AND
SEAT BELTS, Repairs.
2. Remove front squab pad.
3. Release spring clips and remove head restraint
escutcheons from squab frame.
4. Release 8 springs securing squab suspension to
frame and remove suspension.
SEATS AND SEAT BELTS
76-5-4 REPAÌRS
5. Release adjustment wheel from seat valance.
6. Release inner valance from 2 clips and remove
from seat.
7. Release outer upper cushion valance from 3 clips
and remove.
8. Remove 2 escutcheons from side of lower
valance.
9. Remove 3 screws securing lower valance to seat.
10. Remove outer valance from seat.
11. Release SRS pre-tensioner harness from seat
cushion.
12. Remove bolt securing pre-tensioner to seat
frame and remove pre-tensioner.
13. Release 4 cushion cover retainers.
14. Release Velcro securing cushion cover to pad.
15. Remove cushion cover.
16. Remove cushion pad.
SEATS AND SEAT BELTS
REPAÌRS 76-5-5
17. Release 4 springs securing cushion suspension
to seat frame.
18. Remove cushion suspension.
Refit
1. Position cushion suspension to seat frame and
secure with springs.
2. Fit cushion pad to seat frame.
3. Fit cushion cover over pad.
4. Secure cover to pad Velcro.
5. Secure cushion cover retainers.
6. Fit pretensioner to seat and tighten bolt to 30 Nm.
7. Secure pre-tensioner harness to seat cushion
with clip.
8. Fit outer valance to seat frame and secure with
screws.
9. Fit escutcheons to valance.
10. Fit upper valance to seat.
11. Fit inner valance to seat.
12. Fit adjustment wheel to valance.
13. Position squab suspension to seat frame and
secure with springs.
14. Fit head restraint escutcheons to squab frame
and secure spring clips.
15. Fit squab pad to frame.
16. Fit front squab cover. See SEATS AND SEAT
BELTS, Repairs.
OUTER VALANCE - FRONT CUSHION
´÷ 78.30.42
Remove
1. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
2. Release upper valance from 3 clips and remove.
3. Remove 2 escutcheons from side of lower
valance.
4. Remove 3 screws securing lower valance to seat.
5. Remove valance from seat.
Refit
1. Fit lower valance to seat and secure with screws.
2. Fit escutcheons to lower valance.
3. Fit upper valance to seat and secure clips.
4. Fit front seat. See SEATS AND SEAT BELTS,
Repairs.
SEATS AND SEAT BELTS
76-5-6 REPAÌRS
INNER VALANCE - FRONT CUSHION
´÷ 78.30.46
Remove
1. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
2. Release adjustment wheel from seat.
3. Release valance from 2 clips and remove from
seat.
Refit
1. Fit valance to seat and secure with clips.
2. Fit adjustment wheel to seat.
3. Fit front seat. See SEATS AND SEAT BELTS,
Repairs.
SEAT HEIGHT ADJUSTMENT HANDLE
´÷ 78.80.07
Remove
1. Remove screw securing handle to height
adjustment mechanism.
2. Remove height adjustment handle.
Refit
1. Fit handle to mechanism and secure with screw.
SEATS AND SEAT BELTS
REPAÌRS 76-5-7
ARM REST - REAR SEAT
´÷ 78.10.07
Remove
1. Lower arm rest.
2. Remove arm rest back board.
3. Remove 2 nuts securing arm rest to seat frame.
4. Release arm rest from retaining pegs and
remove arm rest.
Refit
1. Position arm rest and align to retaining pegs.
2. Fit and tighten nuts securing arm rest.
3. Fit arm rest backboard.
4. Raise arm rest.
REAR SEAT CUSHION
´÷ 78.10.17.99
Remove
1. Remove 3 bolts securing seat cushion to body.
2. Pull seat cushion forward and release from body.
3. Remove seat cushion from vehicle.
Refit
1. Position seat cushion in vehicle and locate
tongues along forward edge.
2. Fit bolts securing cushion to floor and tighten
to10 Nm.
SEATS AND SEAT BELTS
76-5-8 REPAÌRS
REAR SEAT SQUAB
´÷ 78.10.58.99
Remove
1. Remove rear seat cushion. See SEATS AND
SEAT BELTS, Repairs.
2. Remove and discard bolt from lower seat belt
anchorage.
3. Turn hinge clamping bolt anti-clockwise until
hinge pin can be removed from hinge.
4. Release outer hinge pin and remove seat squab.
Refit
1. Position squab outer hinge pin.
2. Fit inner pin to centre hinge.
3. Fully tighten centre hinge clamping bolt.
4. Fit new seat belt lower anchorage bolt and
tighten to 50 Nm.
5. Fit rear seat cushion. See SEATS AND SEAT
BELTS, Repairs.
COVER - SQUAB - REAR SEAT - SIDE - LH
´÷ 78.90.12
Remove
1. Remove rear seat squab assembly.See SEATS
AND SEAT BELTS, Repairs.
2. Release and remove head restraint.
3. Remove seat belt guide.
4. Release sides of squab cover from frame.
5. Release squab cover from hinge pins.
SEATS AND SEAT BELTS
REPAÌRS 76-5-9
6. Raise squab cover assembly, release and
remove head restraint guide tubes.
7. Release squab cover and pad from frame and
remove squab cover and pad assembly.
8. Release squab cover from squab pad and
remove squab cover.
Refit
1. Position squab cover to squab pad and secure to
Velcro strips.
2. Fit squab cover and pad to frame.
3. Align squab cover to hinge pins.
4. Secure squab cover to side of squab frame.
5. Fit seat belt guide.
6. Fit head restraint guide tubes.
7. Fit head restraint.
8. Fit rear squab assembly.See SEATS AND SEAT
BELTS, Repairs.
COVER - SQUAB - REAR SEAT - RH
´÷ 78.90.13
Remove
1. Remove rear seat squab assembly.See SEATS
AND SEAT BELTS, Repairs.
2. Release and remove head restraint.
3. Remove arm rest back board.
4. Remove 2 nuts securing arm rest to seat frame.
5. Release arm rest from retaining pegs and
remove arm rest.
SEATS AND SEAT BELTS
76-5-10 REPAÌRS
6. Release squab cover from arm rest recess.
7. Remove seat locking button escutcheon.
8. Remove 2 screws securing seat belt finisher and
remove seat belt finisher.
9. Release sides of squab cover from frame.
10. Release squab cover from hinge pins.
11. Raise squab cover assembly, release and
remove head restraint guide tubes.
12. Release squab cover and pad from frame and
remove squab cover and pad assembly.
SEATS AND SEAT BELTS
REPAÌRS 76-5-11
13. Release squab cover from squab pad and
remove squab cover.
Refit
1. Position squab cover to squab pad and secure to
Velcro strips.
2. Fit squab cover and pad to frame.
3. Align squab cover to hinge pins.
4. Secure squab cover to side of squab frame.
5. Position seat belt finisher and secure with
screws.
6. Fit seat locking button escutcheon.
7. Secure squab cover to arm rest recess.
8. Position arm rest and align to retaining pegs.
9. Fit and tighten nuts securing arm rest.
10. Fit arm rest backboard.
11. Fit head restraint guide tubes.
12. Fit head restraint.
13. Fit rear squab assembly. See SEATS AND
SEAT BELTS, Repairs.
LEVER ASSEMBLY - REAR SQUAB
RELEASE
´÷ 78.80.03
Remove
1. Fold rear seat forward.
2. Remove and discard seat release lever
escutcheon.
3. Release catches securing release lever to squab
frame and release lever from squab frame.
4. Rotate lever and release from squab frame.
5. Release and disconnect cable from seat release
lever.
Refit
1. Connect release cable to latch lever.
2. Position latch lever and secure to frame.
3. Fit new release lever escutcheon.
4. Reposition rear seat.
SEATS AND SEAT BELTS
76-5-12 REPAÌRS
CABLE - REAR SQUAB LATCH
´÷ 78.80.04
Remove
1. Remove rear seat squab cover. See SEATS
AND SEAT BELTS, Repairs.
2. Release and disconnect cable from seat release
lever.
3. Remove 2 Torx bolts securing latch to frame and
disconnect button spring from latch.
4. Disconnect release cable from latch and remove
latch.
Refit
1. Connect release cable and button spring to latch.
2. Align latch to seat frame, fit and tighten Torx
bolts.
3. Connect release cable to latch lever.
4. Fit rear squab cover. See SEATS AND SEAT
BELTS, Repairs.
REAR SQUAB LATCH
´÷ 78.80.16
Remove
1. Open tailgate.
RH latch only:
2. Remove 2 screws securing centre seat belt reel
cover and move cover aside.
Both latches:
3. Remove escutcheon from top of squab cover.
4. Release retainer securing squab cover to rear
carpet.
5. Fold rear seat slightly forward and place block of
wood between squab and squab support panel.
6. Move squab cover and cushion aside to gain
access to latch mechanism.
SEATS AND SEAT BELTS
REPAÌRS 76-5-13
7. Remove squab release handle from rear squab
panel.
8. Remove 2 Torx screws securing latch to seat
frame.
9. Release cables from latch.
10. Remove latch assembly.
Refit
1. Position latch assembly to seat frame and
connect cable.
2. Fit and tighten Torx screws securing latch to seat
frame.
3. Secure squab release handle to rear squab
panel.
4. Reposition squab cushion and cover to frame
and secure retainer.
5. Fit escutcheon to top of seat squab.
6. Reposition rear seat.
RH latch only:
7. Position seat belt reel cover to seat and secure
with screws.
SEATS AND SEAT BELTS
76-5-14 REPAÌRS
REAR SEAT BELT - SIDE - 3 DOOR
´÷ 76.73.23
Remove
1. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Remove and discard Torx screw securing seat
belt stalk to body.
3. Remove seat belt stalk.
4. Remove and discard Torx screw securing seat
belt reel to rear squab support panel.
5. Remove seat belt reel locating bolt.
6. Remove seat belt.
Refit
1. Fit seat belt reel to squab support panel and fit
locating bolt. DO NOT tighten.
2. Fit new Torx screw securing reel to squab
support panel and tighten to 50 Nm.
3. Tighten locating bolt to 10 Nm.
4. Position seat belt stalk to floor and tighten new
Torx screw to 50 Nm.
5. Fit rear quarter lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
SEATS AND SEAT BELTS
REPAÌRS 76-5-15
REAR SEAT BELT - SIDE - 5 DOOR
´÷ 76.73.23
Remove
1. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
2. Remove and discard Torx screw securing seat
belt stalk to body.
3. Remove seat belt stalk.
4. Remove and discard Torx screw securing seat
belt to floor.
5. Remove and discard Torx screw securing seat
belt reel to rear squab support panel.
6. Remove seat belt reel locating bolt.
7. Remove seat belt.
SEATS AND SEAT BELTS
76-5-16 REPAÌRS
Refit
1. Fit seat belt reel to squab support panel and fit
locating bolt. DO NOT tighten.
2. Fit new Torx screw securing reel to squab
support panel and tighten to 50 Nm.
3. Tighten locating bolt to 10 Nm.
4. Fit Torx screw securing seat belt to floor and
tighten to 50 Nm.
5. Position seat belt stalk to floor fit and tighten new
Torx screw to 50 Nm.
6. Fit rear quarter lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
SEAT BELT - CENTRE - REAR
´÷ 76.73.20
Remove
1. Remove RH rear seat squab cover. See SEATS
AND SEAT BELTS, Repairs.
2. Remove Torx bolt securing centre seat belt reel
to squab frame and remove reel.
Refit
1. Position seat belt reel to seat frame, fit Torx bolt
and tighten to 50 Nm.
2. Fit RH rear seat squab cover.See SEATS AND
SEAT BELTS, Repairs.
SUNROOF
REPAÌRS 76-6-1
SUNROOF REPAÌ RS
SUN ROOF GLASS HEIGHT ADJUSTMENT
´÷ 76.82.04
Adjust
1. Sun roof glass should sit within its aperture as
follows:
¤ Front corners - Flush with roof to 1 mm low.
¤ Rear corners - Flush with roof to 1 mm high.
¤ Equal seal pressure front and rear. Ìf outside
these limits, carry out the following procedure.
2. Move sun roof glass to tilt position.
3. Remove 2 finishers from sun roof glass frame.
4. Close sun roof from tilt position.
5. Slide sun roof to open position and then close.
6. Loosen 6 Torx screws securing glass to sun roof
frame.
7. Adjust glass as required.
8. Tighten Torx screws to 5 Nm.
NOTE: Apply thread locking fluid to the screws.
9. Move sun roof glass to tilt position.
10. Fit finishers to sun roof glass frame.
SUN ROOF GLASS
´÷ 76.82.05
Remove
1. Open the sunshade and tilt up the glass.
2. Remove 2 finishers from sun roof glass frame.
3. Remove 6 TX25 Torx screws securing glass to
frame.
4. Remove glass.
Refit
1. Position glass to sunroof.
NOTE: Apply thread locking fluid to the screws.
2. Lightly tighten screws securing glass to frame.
3. Adjust height of sun roof glass. See SUNROOF,
Repairs.
4. Fit finishers to sun roof glass frame.
SUNROOF
76-6-2 REPAÌRS
SUN ROOF SUNSHADE
´÷ 76.82.03
Remove
1. Remove sun roof glass. See SUNROOF,
Repairs.
2. Close sunshade.
3. Depress front sunshade plungers and release
front of sunshade from sun roof frame.
4. Remove 2 screws securing frame cross beam to
gain access to rear plungers.
5. Depress rear sunshade plungers.
6. Remove sunshade from frame by pulling
forwards and upwards.
Refit
1. Fit sunshade to frame and secure all 4 plungers.
NOTE: Ensure plungers are fully engaged.
2. Fit and tighten screws securing cross beam to
frame.
3. Fit sun roof glass. See SUNROOF, Repairs.
SUN ROOF SWITCH
´÷ 76.82.59
Remove
1. Remove finisher from switch.
2. Remove 2 screws securing switch to roof.
3. Release from roof and disconnect multiplug.
4. Remove switch.
Refit
1. Position switch to roof and connect multiplug.
2. Fit switch to roof and secure with screws.
3. Fit finisher to switch.
SUNROOF
REPAÌRS 76-6-3
SUN ROOF MOTOR
´÷ 76.84.07
Remove
1. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Remove 2 Lucars from sun roof motor.
3. Remove multiplug from sun roof motor.
4. Remove 3 screws securing motor to sun roof
tray.
5. Remove motor.
Refit
1. Position motor to sun roof tray and tighten bolts
to 9 Nm.
2. Fit multiplug and Lucars to motor.
3. Fit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
SUN ROOF DRAIN TUBE
´÷ 76.84.20
Remove
1. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Release clip securing drain tube to sun roof tray.
3. Release drain tube from sun roof tray.
4. Raise vehicle.
WARNING: Support on safety stands.
5. Remove road wheel(s).
6. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
7. Remove grommet from lower end of drain tube.
8. Withdraw drain tube down through wheel arch.
SUNROOF
76-6-4 REPAÌRS
Refit
1. Feed drain tube through aperture in wheel arch
and up 'A' post.
2. Fit grommet to lower end of drain tube and
secure to wheel arch.
3. Fit wheel arch liner. See EXTERIOR FITTINGS,
Repairs.
4. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque Wrench
Settings.
5. Remove stand(s) and lower vehicle.
6. Fit drain tube to sun roof tray and secure with clip.
7. Fit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
SUNROOF
REPAÌRS 76-6-5
SUN ROOF
´÷ 76.84.01
Remove
1. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Release 4 clips and disconnect drain tubes.
3. Disconnect multiplug from sun roof control unit.
4. Release interior lamp harness from sun roof tray.
5. Remove 11 bolts securing sun roof assembly to
roof and remove sun roof.
NOTE: Assistance may be required to remove
sun roof assembly.
Refit
1. Fit sun roof assembly and tighten bolts to 9 Nm.
2. Secure interior lamp harness to sun roof tray.
3. Connect multiplug to sun roof control unit.
4. Connect drain tubes to sun roof and secure with
clips.
5. Fit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
SUNROOF
76-6-6 REPAÌRS
PANEL REPAÌRS
ÌNTRODUCTÌON 77-1
PANEL REPAÌRS ÌNTRODUCTÌON
BODY REPAIRS
GeneraI
Body shells are of monocoque construction. Front and rear sections of the shell are designed as 'energy absorbing'
zones. This means they are designed to deform progressively when subjected to impact in order to minimise the
likelihood of injury to vehicle occupants.
Ìt is essential that design dimensions and strength are restored in accident rectification. Ìt is important that neither
structural weakness nor excessive local stiffness are introduced into the vehicle during body repair.
Repairs usually involve a combination of operations ranging from straightening procedures to renewal of individual
panels or panel assemblies. The repairer will determine the repair method and this decision will take into account a
balance of economics between labour and material costs and the availability of repair facilities in both equipment and
skills. Ìt may also involve considerations of vehicles' downtime, replacement vehicle availability and repair turn-around
time.
Ìt is expected that a repairer will select the best and most economic repair method possible, making use of the facilities
available. The instructions given are intended to assist a skilled body repairer by expanding approved procedures for
panel replacement. The objective is to restore the vehicle to a safe running condition by carrying out a repair which is
as close as is feasible to original standard. The results should not advertise to the experienced eye that the vehicle
has been damaged, although the repair might not be identical in all respects to the original factory build. Commercial
bodyshop repair facilities cannot always duplicate methods of construction used during production.
Operations covered in this section do not include reference to testing the vehicle after repair. Ìt is essential that work
is inspected and suspension geometry checked after completion. Where necessary a road test of the vehicle should
be carried out, particularly where safety-related items are concerned.
Where major units have been disconnected or removed it is necessary to ensure that fluid levels are checked and
topped up where necessary. Ìt is also necessary to ensure that the repaired vehicle is in a roadworthy condition in
respect of tyre pressures, lights, washer fluid etc.
Body repairs often involve the removal of mechanical and electrical units and associated wiring. Where necessary,
refer to the relevant section within this Workshop Manual for removal and refitting instructions.
Safety Precautions
Before beginning work:
¤ Disconnect the battery to reduce the possibility of fire caused by electrical shorts.
¤ Check for fuel leaks and repair as necessary.
¤ Remove the fuel tank and/or fuel lines if welding equipment is to be used near the fuel system.
¤ Before welding, sanding or cutting, protect carpets and seats with fireproof covers.
¤ Follow standard safety practices when using toxic or flammable liquids.
¤ Use standard safety equipment when spraying paint, welding, cutting, sanding or grinding. Standard safety
equipment includes:
1 Respirator and filter masks - Designed to filter out toxic fumes, mist, dust or other airborne particles. Use a
respirator or filter mask designed to protect you from the hazards of the particular job; some respirators, for
example, are designed to filter out only dust and airborne particles, not toxic fumes.
2 Safety goggles or glasses - Designed to protect your eyes from projectiles, dust particles or splashing liquid.
3 Gloves - Rubber gloves protect against corrosive chemicals. Welding gloves protect against burns and
abrasions caused by welding, sanding or grinding.
4 Safety shoes - Non-slip soles protect against slipping. Metal toe inserts protect against falling objects.
5 Ear plugs - Protect eardrums from harmful noise levels.
PANEL REPAÌRS
77-2 ÌNTRODUCTÌON
During work:
¤ Do not smoke while working near the fuel system.
¤ Always attach a safety cable when using a hydraulic ram or a frame straightening table; do not stand in direct
line with the chains used on such equipment.
PREPARATION OF WORK
Visual Inspection
Damage to the exterior of the body can be inspected visually, but where there has been an external impact, it is
necessary to inspect the extent of the damage. Ìn some cases, the deformation may have spread beyond the actual
areas which were in the collision and must therefore be inspected closely.
Damaged Parts should be visually checked as follows:
Seat Belts
Replace the seat belts if:
1 The belt material is cut, punctured, burned or in any way damaged.
2 The buckle or retractor does not work properly.
3 They were being worn at the time of a collision (check for damage at the seat belt anchor points).
4 Their condition is questionable.
Front Section:
1 Ìs there any bending, splitting, denting or other damage to the suspension and its related parts?
2 Ìs there any deformation of the front bulkhead or radiator core? Have any of the connected sections come apart?
3 Are there any creases or distortion in the front inner wing or side frame? Have any of the connected sections
come apart?
4 Ìs there any bending or twisting of the whole front area?
5 Ìs there any deformation like creases, bulges, or dents in the front pillar, dashboard, floor, etc.?
6 Ìs there any vertical twisting or misaligned clearance in the door?
7 Ìs the windscreen seal broken?
8 Ìs there any deformation in the vicinity of the top part of the roof panel's centre pillar?
9 Ìs there any damage inside the vehicle (is there any twisting of the dashboard, or anything irregular with the
clearances of sheet-mounting parts)?
10 Ìs there any damage to the steering wheel? Ìs there any deformation in the column and the column-mounted
parts?
11 Ìs there any oil or water leakage and damage to the engine, transmission or brakes?
12 Ìs there any irregular noise in the gear changing operation, engine and transmission rotation?
13 Are there any traces of contact between the engine block and the centre cross member?
14 Ìs there any damage to brake or fuel lines, or wire harnesses?
Rear Section:
1 Ìs there any twisting, bulging or denting of the rear floor and parcel shelf squab support? Have any of the
connected sections come apart?
2 Ìs there any irregular bulging or denting in the rear wing?
3 Ìs there any distortion in the rear inner panel? Ìs there any bending and denting in the vicinity of the rear pillar?
4 Ìs there any distortion or creasing in the rear inner wing and arch sections? Have any of the connected sections
come apart?
5 Ìs there any twisting or misalignment of the clearance of the tailgate opening section?
6 Ìs there any bending, splitting, denting or other damage to the suspension and its related parts?
7 Ìs there any deformation of the rear floor, rear floor cross member and rear inner wing? Have any of the
connected sections come apart?
PANEL REPAÌRS
ÌNTRODUCTÌON 77-3
Body Alignment Inspection
Taking into consideration the differences in body styles, steering and suspension systems and engine and
transmission layouts, the location of the following components as applicable to a particular vehicle is critical:
¤ Front suspension upper damper mountings.
¤ Front suspension or sub frame mountings.
¤ Engine mounting on RH and LH valances.
¤ Rear suspension upper damper mountings.
¤ Rear suspension mountings or lower pivots.
¤ Steering rack mountings.
Additional points which can be used to check alignment and assembly are:
¤ Ìnner holes in crossmember - side - main floor.
¤ Holes in front longitudinals.
¤ Holes in extension - side member - front.
¤ Holes in rear longitudinals.
¤ Holes in rear lower panels or extension rear floor.
¤ Petrol tank mountings.
Apertures for windscreen, backlight, bonnet and doors can best be checked by offering up an undamaged component
as a gauge.
Follow basic alignment measurements for relevant model. See INFORMATION, Body Dimensions.
PANEL REPAÌRS
77-4 ÌNTRODUCTÌON
REPAIR OF THE DAMAGED AREA
Mild Steel Repair
1 Apply load to the damaged section and pull it out until the section is almost restored to the original shape.
2 Check that the parts of the body they cover have been more or less restored to their original shapes.
NOTE: Check the original position using the body dimensional drawings and the positioning jigs.
3 Remove the parts that require replacement.
4 Decide whether to cut the weld joint parts and replace partially, or whether to replace all the parts.
5 Cut off and separate the damaged parts.
NOTE: When cutting the parts off, take special care that you do not damage adjacent parts on the car.
6 Ensure that the following conditions can be met for the setting of replacement parts/joint sections:
¤ you can perform straightening work after welding.
¤ the locations are not susceptible to distortion caused by other parts.
¤ there are few removable parts and that the location allows safe welding.
¤ that the joints are short and that paint repair can be performed easily.
¤ the locations are such that the joints can be finished in a way that does not affect the outward appearance.
¤ the locations do not hinder the removing and attaching of parts.
NOTE: Bear in mind all of these conditions, and after determining the joint locations, cut the joints for an overlap
of 20-30 mm.
7 Mould the related parts.
8 Set and tack weld the replacement parts.
NOTE: Temporarily mount the related parts and check the clearance and level differences.
9 Weld the replacement parts.
CAUTION: Protect body parts with the heat-resistant protective cover to prevent damage, when weIding.
NOTE: Use of the positioning jig is recommended.
10 Apply anti-rust agent.
NOTE: The paint film, which is designed to prevent corrosion caused by moisture, is destroyed around the edges
of the locations which have been repaired by welding. Therefore, in such places and especially in those areas
which are not visible, apply another coat of the paint, referring to the rust-preventive treatments. This operation
is designed to maintain durability and quality.
PANEL REPAÌRS
ÌNTRODUCTÌON 77-5
Zinc-plated Steel Repair
The zinc-plated steel used in some panels of the vehicle requires different repair techniques than for ordinary mild
steel.
¤ Before spot welding the zinc-plated steel, remove the paint from both sides of the flange to be welded. Apply
sealer to the flange after welding.
NOTE: Seal the sanded surfaces thoroughly to prevent rust.
WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.
¤ The electric continuity properties of zinc-plated steel is different from ordinary steel. When spot welding, increase
the current by 10-20%, or increase the resistance welding time. Also increase the number of weld spots by 20-
30%.
NOTE: The MIG welding procedures for zinc-plated steel are the same as for ordinary steel plate.
WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and
safety shoes.
¤ Before applying putty or body filler to the zinc-plated steel, sand the zinc plating thoroughly to promote adhesion
and prevent blistering.
NOTE: Use only epoxy-based putties and fillers on zinc-plated steel. Follow the manufacturer's specification.
¤ When performing paint work, place a suitable bung into the earth wire mounting position on the body to protect
the threads from paint.
A Zinc Plating (5-6 microns)
B Steel plate
PANEL REPAÌRS
77-6 ÌNTRODUCTÌON
¤ When performing paint work, place a suitable bung into the earth wire mounting position on the body to protect
the threads from paint.
Door Reinforcement Beams
A Special Bolt
B Ground Wire
C Ground Wire Mounting Hole
D Caulking
PANEL REPAÌRS
ÌNTRODUCTÌON 77-7
Door reinforcement beams are made from a metal equivalent to High Strength Steel.
Should High Strength Steel be heated, the strength of the steel will be reduced. Ìf High Strength Steel is damaged,
as in an accident where the door reinforcement beams are bent, the beams may crack should any attempt be made
to straighten them.
For this reason, Door Reinforcement Beams should never be repaired, they should be replaced if they become
damaged.
NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.
A Front Door Reinforcement Beam
B Rear Door Reinforcement Beam
PANEL REPAÌRS
77-8 ÌNTRODUCTÌON
COMPONENT LOCATIONS
1 Multi function unit (MFU)
2 Anti theft alarm ECU
3 Window lift ECU
4 Diagnostic control unit (DCU)
5 Mirror powerfold ECU (Japanese market only)
6 Gearbox interface unit (GÌU)
7 ABS ECU
8 Engine control module (ECM)
The electronic control units fitted to Rover vehicles make it advisable to follow suitable precautions prior to carrying
out welding repair operations. Harsh conditions of heat and vibration may be generated during these operations which
could cause damage to the units. See GENERAL INFORMATION, EIectricaI Precautions.
Ìn particular, it is essential to follow the appropriate precautions when disconnecting or removing the SRS diagnostic
unit. See RESTRAINT SYSTEMS, Precautions.
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. This particularly applies to electronic control
units.
PANEL REPAÌRS
BODY DÌMENSÌONS 77-9
BODY DÌMENSÌONS
DIMENSIONAL INFORMATION
The following dimensional information is shown so as to assist the technician in the diagnosis and repair of body
panels. The information is shown in two different ways. There are X,Y,Z dimensions and actual point to point
dimensions.
The X,Y,Z dimensions are the measuring planes used within Rover Group for the measurement of body panels. The
whole bodyshell is within a parallel grid system.
The X plane is an imaginary vertical plane starting at the front of the vehicle. Ìt is parallel and at right angles to the
centre line of the vehicle and measures distances along the length of the vehicle.
The Y plane is an imaginary plane through the centre of the vehicle. All Y dimensions start from this plane. As a rule,
body dimensions are symmetrical about the centre line.
The Z plane is set at a fixed distance parallel to the underside of the vehicle. All Z dimensions start from this plane.
The point to point measurements are actual distances between two points. These points can be holes or intersection
points. Where holes are taken, the point of measurement is always from the hole centre.
All measurements shown are in millimetres.
PANEL REPAÌRS
77-10 BODY DÌMENSÌONS
LONGITUDINAL DIMENSIONS
All dimensions taken at centre line of jig hole.
Location Dimension Reference
Headlamp mounting jig hole to datum line 399mm 1
Front suspension reinforcement to datum line 1020mm 2
Front sidemember jig hole to datum line 506mm 3
Sidemember to sill jig hole to datum line 1400mm 4
Rear longitudinal front jig hole to datum line 2960mm 5
Rear longitudinal rear jig hole to datum line 3775mm 6
Rear body jig hole to datum line 4011mm 7
Rear damper mount to datum line 3497mm 8
PANEL REPAÌRS
BODY DÌMENSÌONS 77-11
VERTICAL DIMENSIONS
All dimensions taken at centre line of jig hole.
Location Dimension Reference
Headlamp mounting jig hole to datum line 330mm±1.5mm 1
Front sidemember jig hole to datum line 139.4mm±1.5mm 2
Front suspension reinforcement to datum line 677.6mm±1.5mm 3
Sidemember to sill jig hole to datum line 50.8mm±0mm 4
Rear longitudinal front jig hole to datum line 121mm±1.5mm 5
Rear longitudinal rear jig hole to datum line 259mm±0mm 6
Rear body jig hole to datum line 346mm±1.5mm 7
Rear damper mount to datum line 536mm±1.5mm 8
PANEL REPAÌRS
77-12 BODY DÌMENSÌONS
FRONT END INFORMATION
All dimensions taken at centre line of jig hole.
Item Description X Y Z
A Wing first fixing hole 615.2 654.5 598.6
B Wing middle fixing hole 830.0 671.3 656.0
C Wing third fixing hole 1167.0 683.5 701.5
D Damper location hole 1020.2 561.5 677.5
E Servo bottom outboard mounting hole 1239.5 390.0 500.4
F Wing, rear top fixing hole 1472.8 758.9 719.0
G Wing, rear bottom fixing hole 1466.2 771.4 186.5
PANEL REPAÌRS
BODY DÌMENSÌONS 77-13
SIDE INFORMATION
All dimensions taken at centre line of jig hole.
Item Description X Y Z
A 'A' post top tooling hole 1426.0 760.0 619.0
B 'A' post bottom tooling hole 1426.0 766.5 289.5
C 'B/C' post top tooling hole 2497.0 760.5 648.2
D 'B/C' post bottom tooling hole 2472.0 760.5 318.8
PANEL REPAÌRS
77-14 BODY DÌMENSÌONS
TRANSVERSE DIMENSIONS
All dimensions taken at centre line of jig hole.
Location Dimension Reference
Headlamp mounting jig hole right hand to left hand 800mm±2mm 1
Front suspension reinforcement right hand to left hand 1123mm±2.0mm 2
Rear damper mount right hand to left hand 1038mm±2.0mm 3
Rear body jig hole right hand to left hand 780mm±2.0mm 4
PANEL REPAÌRS
BODY DÌMENSÌONS 77-15
Transverse Dimensions - continued
All dimensions taken at centre line of jig hole.
Location Dimension Reference
Front sidemember jig hole right hand to left hand 912mm±3.0mm 5
Sidemember to sill jig hole right hand to left hand 970mm±2.0mm 6
Rear longitudinal front jig hole right hand to left hand 1180mm±3.0mm 7
Rear longitudinal rear jig hole right hand to left hand 1000mm±2.0mm 8
PANEL REPAÌRS
77-16 BODY DÌMENSÌONS
DIAGONAL DIMENSIONS
All dimensions taken at centre line of jig hole. Diagonal dimensions are taken in the horizontal plane.
Location Dimension Reference
Front sidemember jig hole to opposite sidemember to
sill jig hole
1319mm±1.5mm 1
Front sidemember jig hole to opposite rear longitudinal
front jig hole
2679mm±3.0mm 2
Sidemember to sill jig hole to opposite rear longitudinal
front jig hole
1894.5mm±3.0mm 3
Sidemember to sill jig hole to opposite rear
longitiudinal rear jig hole
2571mm±3.0mm 4
Rear longitudinal front jig hole to opposite rear jig hole 1361mm±1.5mm 5
PANEL REPAÌRS
BODY DÌMENSÌONS 77-17
GAP AND PROFILE MEASUREMENTS
Figures shown are metric measurements (millimeters)
Front end information
Gaps
ProfiIes
Section Gap Description Dimension
A-A a Bonnet to grille 6.7 to 7.0
B-B b Bonnet to bumper 7.0±1.0
C-C c Bumper to wing 1.5±0.5
Section Description Dimension
A-A Profile of bonnet to grille 0.0 +1 to -0
B-B Profile of bonnet to bumper 0.0 +1 to -0
C-C Profile at bottom of 'S' feature, bumper underflush to wing 0.7±0.5
PANEL REPAÌRS
77-18 BODY DÌMENSÌONS
Front end side information
Gaps
ProfiIes
Section Gap Description Dimension
A-A a Bonnet to wing 3.0±0.5
B-B b Bonnet to wing 3.2±0.5
C-C c Bonnet to wing 3.0±0.5
D-D d Bonnet to wing 3.4±0.5
E-E e 'A' post to wing 3.0±1.0
Section Description Dimension
A-A Profile of bonnet to wing 0+0 to -1
B-B Profile of bonnet to wing 0+0 to -1
C-C Profile of bonnet to wing 0+0 to -1
D-D Profile of bonnet to wing 0+0 to -1
PANEL REPAÌRS
BODY DÌMENSÌONS 77-19
Side information
Gaps
ProfiIes
Section Gap Description Dimension
G-G g Wing to front door 5.0±0.5
H-H h Front door to rear door 5.0±0.5
J-J j Rear door to body side panel 5.0±0.5
K-K k Rear bumper to body side panel 1.5±0.5
Section Description Dimension
G-G Profile of wing to front door 0+1 to -0
H-H Profile of front door to rear door 0+1 to -0
J-J Profile of rear door to body side panel 0+1 to -0
K-K Profile of bumper to body side panel 0.7±0.5
PANEL REPAÌRS
77-20 BODY DÌMENSÌONS
Rear end information
Gaps
ProfiIes
Section Gap Description Dimension
L-L l Tailgate to body side panel 6.0±0.5
M-M m Bumper to tail lamp 1.5±0.5
N-N n Rear bumper to tailgate 8.0±0.5
Section Description Dimension
L-L Profile of tailgate to body side 0+0 to -1.5
M-M Profile of bumper to tail lamp 0.7±0.5
PANEL REPAÌRS
BODY DÌMENSÌONS 77-21
FueI fIap information
Gaps
ProfiIes
Section Gap Description Dimension
P-P p Fuel flap 3.0±0.5
Section Description Dimension
P-P Profile of fuel flap to body side panel -1.0
PANEL REPAÌRS
77-22 BODY DÌMENSÌONS
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-23
SEALÌNGAND CORROSÌON PROTECTÌON
APPROVED MATERIALS
SeaIers
Adhesives
Description Make Part Number
Drip-Chek Clear 3M 08401
Drip-Chek Heavy 3M 08531
Polyurethane Cartridge Sealer 3M 08684/89/94
Polyurethane Sealer (sachet) 3M 08703/83/88
Super Seam Sealer 3M 08537
Sprayable Sealer 3M 08800/23
Windscreen Sealer 3M 08509
Betafill Clinch & Brushable Sealer Gurit-Essex 10211/15/20
Polyurethane Seam Sealer PPG 6500
Polyurethane Seam Sealer Teroson 92
Terostat Preformed Strip Teroson V11
Terostat 1k PU Seam Sealer Teroson -
Terostat Sprayable Seam Sealer Teroson 9320
Terolan Light Seam Sealer Teroson -
Terolan Special Brushable Seam Sealer Teroson -
Clinch Joint & Underbody Coating Gurit-Essex 10101/7
Leak-Chek Clear Putty Kent Ìndustries 10075
Promatch Bolted Panel Sealer Unipart UBS111
Body Caulking 3M 08568
Sealing Compound Wurth 890100/1-6
Description Make Part Number
Automotive Structural Adhesive 3M 08120
Aerosol Auto Adhesive (Trim) 3M 08080
Refix Tape (Trim) 3M 06506
Spray 80 Adhesive 3M 08090
Structural Two-Part Epoxy Ciba-Geigy XB5106/7
Evo-Stik Multi-Purpose Clear Adhesive Evode -
PANEL REPAÌRS
77-24 SEALÌNG AND CORROSÌON PROTECTÌON
Underbody Coatings
Wax Coatings
WeId-through Primers
GeneraI MateriaIs
Description Make Part Number
Crodapol Brushable Underbody Sealer Croda PV75
Tectacote Underbody Wax Dinol 205
Body Schutz 3M 08861
Spray Schutz 3M 08877
Terotex Underseal CP02 Teroson 9320
Promatch Underbody Schutz Unipart UBS410
Promatch Underbody Wax Unipart PW61
Stonechip Coating (Textured) 3M 08868/78/79
Stonechip Coating (Smooth) 3M 08158/60
08886
Bodygard (Aerosol) 3M 08158/9
Description Make Part Number
Ìnner Cavity Wax (Transparent) 3M 08909/19/29
Ìnner Cavity Wax (Amber) 3M 08901/11/21
Cavity Wax Croda PW57
Description Make Part Number
Weld Thru' Coating 3M 05913
Zinc Rich Primer ÌCÌ P-565634
Zinc Spray 3M 09113
Description Make Part Number
Flexible Parts Repair Material (FPRM) 3M 05900
Cleaner & Wax Remover 3M 08984
Water Shedder Repair (Aerosol) Teroson -
Waterproof Tape Unipart GWS121
Urethane Butyl Tape Unipart BHM605
Expanding foam Redashe 4330
Flexible foam (anti - flutter) Redashe 4320
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-25
MATERIALS APPLICATIONS
1 Between panels - bolted
2 Panel edges - bolted
3 Between panels - spot welded
4 Panel edges - spot welded
5 Between panels - bonded
6 Panel edges - bonded
7 Clinch joints (type a)
8 Clinch joints (type b)
9 Clinch joints (type c)
10 Gaps between panels (type a)
11 Gaps between panels (type b)
12 Lap joint
PANEL REPAÌRS
77-26 SEALÌNG AND CORROSÌON PROTECTÌON
MateriaI/ Joint Type Description Method
ÌCÌ P565 634, 3M 09113 - between bolted panels,
spot welded panels and type (a) clinch joints
Zinc rich primers Brush or spray
Terostat V11 - between bolted panels Preformed strip Hand
Kent Ìndustries 10075 - between bolted panels Seam sealer Applicator gun. By
hand.
3M 08401, 08684, 08689, 08694, 08703, 08783,
08788 - PPG 6500, Teroson 92, Teroson Light,
Terostat 9320, Unipart UBS 605/6/7, Wurth 890100/
1/2/3/4/5/6 - bolted panel edges
Seam sealers Applicator gun. By
hand.
Ciba-Geigy XBS 106/7 - between spot welded
panels
Structural adhesive Applicator gun
Kent Ìndustries 10075, 3M 08401 and 08684, PPG
6500, Teroson 92, Terolan Light, Terostat 9320,
Terostat 1k PU SE20, Unipart UBS 605/6/7, Wurth
890100/1/2/3/4/5/6 - spot welded and bonded panel
edges
Seam sealers (light) Hand applicator gun
Ciba-Geigy XBS 106/7, 3M 8120 - between bonded
panels and type (a) clinch joints
Structural adhesives Caulking gun
PPG 6500, Teroson 92, Teroson Light, Teroson
9320, Unipart UBS 605/6/7, Wurth 890100/1/2/3/4/
5/6 - between bonded panels
Semi-structural adhesives Caulking gun
Gurit-Essex 10211, 10215, 10220, 3M 08531,
08537, 08703, 08783, 08788 - clinch joints type (b)
Seam sealers Caulking gun
Kent Ìndustries 10075, 3M 08401, 08531, Terolan
Light - clinch joints type (c)
Seam sealers (light) Hand applicator,
caulking gun
Kent Ìndustries 10075, 3M 8401, 8684, 8689, PPG
6500, Terolan Light, Terostat 1k PU SE20, Unipart
UBS 605/6/7, Wurth 890100/1/2/3/4/5/6 - gaps
between panels type (a)
Seam sealers (light) Hand applicator gun
Kent Ìndustries Putty and 10075, 3M 08401, 08531,
08568, 08684, 08689, 08694, PPG 6500, Teroson
92, Terolan Light, Terostat 1k PU SE20, 9320,
Unipart UBS 605/6/7, Wurth 890100/1/2/3/4/5/6 -
gaps between panels type (b)
Seam sealer heavy Applicator gun, tube or
hand applicator
Gurit-Essex 10101, 10707, 3M 08537, Teroson
Brushable Sealer - overlap joints (e.g. wheel arch
and floor pan seams)
Brushable sealers Brush
Croda PW57, 3M 08901, 08909, 08911, 08919,
08921, 08929, Unipart UBS 508 - box sections and
cavities
Cavity waxes Wax injection
equipment
Astors 3241/3, Croda PW197, Dinol 4010 - engine
compartment
Engine bay cosmetic wax & lacquer Spray gun or brush
Croda PW61, Dinol 205 Unipart PW61 - underbody Underbody wax Spray gun or brush
Croda PV75, 3M8861, 8877, Terotex CP02 9320
Underseal, Unipart UBS 410 - underbody
Underbody sealer coat Schutz gun or aerosol
3M YS3998, Unipart GS121 - panel apertures Waterproof tape Hand
3M 08509 - dry glazing Windscreen sealer Applicator gun
Unipart BHM 705 - direct glazing Urethane butyl tape Caulking gun
3M 05900 Flexible Parts Repair Material - rubber-
modified polypropylene parts (e.g. Pocan)
Flexible parts repair material (two-pack) Palette knife or
spreader
3M 08158, 08159, 08160, 08868, 08878, 08879,
08886 - stone chip-prone areas (e.g. sill panels)
Stone chip protective coatings Schutz gun
Evode Evo-Stik, 3M 8080, 8090 - trim parts Ìmpact adhesive Brush or aerosol
3M 08984 - Cleaning Adhesive cleaner and wax remover Hand/clean cloth
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-27
APPLICATION EQUIPMENT
Suitable application equipment is available from the following manufacturers and suppliers:
3M
Automotive Trades Group
3M UK Plc
3M House
PO Box 1
Market Place
Bracknell
Berks.
RG12 1JU
e (01344) 42526
Cooper PegIer
Burgess Hill
Sussex
RH15 9LA
e (014446) 42526
SATA Spray Equipment
Minden Ìndustrial Ltd
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk
ÌP32 7DX
e (01284) 760791
SATA Schutz Gun Model UBE
The SATA Schutz Gun is approved for the retreatment of vehicle underbody areas with protective coatings as
supplied in 1 litre, purpose-designed 'one-way' containers. The screw thread fitting (female on the gun) is standard to
most Schutz-type packs.
Full operating details are supplied with the equipment.
NOTE: Always clean gun after use with appropriate solvent to maintain efficiency.
SATA HKD1 Wax Injection Injection Equipment
This equipment is approved for carrying out cavity wax re-treatment on Rover vehicles. The SATA HKD1 set
comprises a high quality forged gun with 1-litre pressure feed container, a flexible nylon lance, a straight 1100mm
steel lance and hooked- wand lance. A quick-change coupling is provided as a standard fitting to allow lances to be
easily interchanged. Each lance has an integral, machined nozzle with specialised spray characteristics to suit the
type of box section to be treated.
Specifications of Model UBE:
Air consumption: 7cu.ft/min (200 litres/min) © 45psi
Weight: 23.3oz (220 grams)
3M Body Schutz Pistol Spraygun 08996
A pistol type spraygun constructed from case and machined light alloy and designed for use with 3M screw fit Body
Schutz containers.
NOTE: Always clean gun after use with appropriate solvent to maintain efficiency.
PANEL REPAÌRS
77-28 SEALÌNG AND CORROSÌON PROTECTÌON
3M Pneumatic Cartridge Gun 08012
Air line-fed gun for applying 3M cartridge products. Excellent for ease of application to obtain a smooth bead.
Regulator valve for additional control.
3M Pneumatic Applicator Guns 08006/7
Air line-fed gun for application of 3M sachet sealers (Part Number 08006 for 200ml and 310ml sachet applications,
and Part Number 08007 for all size sachets including 600ml).
Also available: Heavy Duty ManuaI Gun 08013
3M Applicator Gun 08190.
For the application of 3M Structural Adhesive 08120.
3M Inner Cavity Wax Applicator Gun 08997
This equipment accepts 1-litre cannister and has a 750mm flexible tube.
The approved system is available from all 3M refinishing factors.
Cooper Pegler Falcon Junior Pneumatic Gun (Airless)
Ìntended primarily for applying transit wax, this pneumatic sprayer has a 5-litre container with integral hand pump and
provides an effective means of wax spraying without the need for compressed air or additional services.
A selection of nozzles, lances, hose lengths and a trigger valve assembly with integral filter allows flexibility in use.
Additional applications include general maintenance, wax injection and paint application. Heavy-bodied materials may
also be applied. All parts are fully replaceable and a wide range of nozzle configurations is available.
MATERIALS GUIDE
3M Automotive Structural Adhesive 08120
A two-part epoxy structural adhesive, twin cartridge with 'Automix' dispensing. For doorskin application and for
bonding panels and stiffeners. Supplied in two-pack form for use in small trigger-type gun (Part Number 08190).
3M Body Caulking 08568
Thumbing compound in preformed strips 6mm x 300mm long. For sealing all large openings and cracks. Non-
hardening, does not dry out or crack. Can be overpainted immediately.
Supplied in packs of 60 strips.
3M Drip-Chek Sealer Heavy 08531
For use on vertical seams and cracks up to 3mm wide to give a firm but flexible seal which does not harden or shrink.
Self-levelling but will not deform on vertical surfaces. May be tooled or smoothed with a wet finger.
Supplied in 150ml tubes.
3M Drip-Chek Clear 08401
Sealer with good flow qualities similar to Drip-Chek Heavy but of clear consistency. Can achieve almost invisible spot
sealing over finished paintwork. May be painted over or mixed with paint colour to give self-coloured sealing medium.
Supplied in 150ml tubes.
3M Super Seam Sealer 08537
A brushable sealer which is designed to simulate the original factory-applied sealer on all overlap joints on floor
panels, wheel arches, boot and load space seams, and petrol filler cap areas. Petrol, oil and water resistant.
Supplied in 1 litre tins.
NOTE: Note: Brush on in ONE direction only for best results.
WARNING: Must be stored under normal conditions for highly flammable materials.
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-29
3M Polyurethane Cartridge Sealer 08684, 08689, 08694
A high solids, non-shrinking polyurethane sealer for use in either a hand-operated gun or a pneumatic applicator gun.
Offers firm adhesion and sealing. Water, oil and petrol resistant. Available in black, white or grey.
Supplied in 310ml cartridges.
3M Polyurethane Sachet Sealer 08703, 08783, 08788
Similar to Flexseal polyurethane but available in collapsible aluminium foil sachets. Available in black, white or grey
and in 310ml or 600ml sachet sizes.
3M Windscreen Sealer 08509
Non-hardening sealant for sealing dry-glazed weatherstrip windscreens. Applied to joint using the applicator gun.
Supplied in 310ml cartridges.
3M Spray Schutz 08877, Body Schutz 08861
Quick-drying, flexible rubberised coatings which dry to a black textured finish.
Supplied in 400g aerosol (Spray Schutz) and 1-litre cartridges to fit Schutz spray gun.
3M Flexible Parts Repair Material 05900
A two-part, rapid-curing system for repairing minor damage to plastic bumpers, air dams, valances etc. Drying time
30 minutes.
Supplied in two-part 10fl.oz. kit.
3M Adhesive Cleaner and Wax Remover 08984
For surface preparation prior to application of most types of adhesives, coatings and sealant materials, and for
removal of tar, silicone polish, wax, grease and oil. Non-staining. May also be used for removing disc pad adhesive
from sander backing pads.
Supplied in 1-litre cannister.
3M Zinc Spray 09113
Anti-corrosive coating for joints and seams in spot welding applications.
Supplied in 500ml aerosol packs.
3M Inner Cavity Wax 08901/29
For providing a protective wax coating on inner panels. Supplied in 1-litre cannister or 500ml aerosol packs.
3M Stone Chip Coating (smooth) 08158/9, 08158/60
A rubber-based coating for stone chip protection on panels. Quick-drying, paintable and low bake compatible.
Supplied in 1-litre cannister or aerosols in a choice of white or grey.
PANEL REPAÌRS
77-30 SEALÌNG AND CORROSÌON PROTECTÌON
CORROSION PREVENTION
Factory Treatments
The Rover 25 is treated with the following anti-corrosion materials in production:
¤ A PVC-based underbody sealer material which is sprayed onto the underfloor, wheel arches and undersill areas.
¤ An application of cavity wax which is sprayed into sill panels and lower inner door panels.
The information given on the following pages is intended as a guide and shows the areas to be treated with cavity
wax, as well as the access holes used during manufacture. Use only recommended materials and application
procedures in repair. See INFORMATION, SeaIing and Corrosion Protection.
Underbody Sealer
Underfloor areas and sill outer panels are treated with a Plastisol PVC underbody sealer. This material is not suitable
for re-treatment.
When repairing areas of underbody sealer, strip the factory-applied underbody sealer back to a suitable break point,
ensuring that a clean metal surface is exposed and that the edge of the existing sealer adheres soundly to the panel.
Ensure that blanking plugs and grommets in the floor pan (except those used for wax injection) are fitted before
underbody sealer application. Refit any heat-fusible plugs which have been disturbed in repair with the aid of a hot air
blower, or replace with rubber grommets.
NOTE: Apply new underbody sealer between primer and surfacer paint operations. Apply seam sealer as necessary
before application of underbody sealer.
CAUTION: Ensure that suspension units, wheeIs, tyres, power unit, driveshafts, exhaust and brakes
(incIuding aII mounting points) are shieIded prior to appIication of fresh underbody seaIer.
Stone Chip Resistant Paint/Primer
Ensure that all areas protected with anti-chip primer during manufacture are re-treated in repair with a suitable
approved material.
Inspections during Maintenance Servicing
Ìt is a requirement of the Rover Corrosion Warranty that the vehicle body is checked for corrosion by an authorised
Rover Dealer at least once a year, to ensure that the factory-applied protection remains effective.
Service Job Sheets include the following operations to check bodywork for corrosion:
¤ With the vehicle on a lift, carry out visual check of underbody sealer for damage.
¤ With the vehicle lowered, inspect exterior paintwork for damage and body panels for corrosion.
NOTE: The vehicle must be washed and free from deposits prior to inspection. It is part of the owner's responsibility
to ensure that the vehicle is kept free of accumulations of mud which could accelerate the onset of corrosion. It will
be necessary for the vehicle to be washed by the Dealer prior to inspection of bodywork if the customer has offered
the vehicle in a dirty condition. Particular attention should be paid to areas where access is difficult.
NOTE: The checks described above are intended to be visual only. It is not intended that the operator should remove
trim panels, finishers, rubbing strips or sound-deadening materials when checking the vehicle for corrosion and paint
damage.
With the vehicle on a lift, and using an inspection or spot lamp, visually check for the following:
¤ Corrosion damage and damaged paintwork, condition of underbody sealer on front and rear lower panels, sills
and wheel arches.
¤ Damage to underbody sealer on main floor and chassis members. Corrosion in areas adjacent to suspension
mountings and fuel tank fixings.
NOTE: The presence of small blisters in PVC underbody sealer is acceptable, providing they do not expose bare
metal.
Pay special attention to signs of damage caused to panels or corrosion protection material by incorrect jack
positioning.
It is essentiaI to foIIow the correct jacking and Iifting procedures. See INFORMATION, Lifting and Towing.
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-31
With the vehicle lowered, visually check for evidence of damage and corrosion on all visible painted areas, in
particular the following:
¤ Front edge of bonnet.
¤ Visible flanges in engine compartment and boot.
¤ Lower body and door panels.
Rectify any bodywork damage or evidence of corrosion found during inspection as soon as is practicable, both to
minimise the extent of the damage and to ensure the long term effectiveness of the factory-applied corrosion
prevention treatment. Where the cost of rectification work is the owner's responsibility, the Dealer must advise the
owner and endorse the relevant documentation accordingly.
Where corrosion has become evident and is emanating from beneath a removable component (e.g. trim panel,
window glass, seat etc.), remove the component as required to permit effective rectification.
Underbody Protection Repairs
Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated.
This applies both to the damaged areas and also to areas where protection has been indirectly impaired, as a result
either of accident damage or repair operations.
Remove corrosion protection from the damaged area before straightening out or panel beating. This applies in
particular to panels coated with wax, PVC underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas equipment to remove corrosion prevention materials whenever
possible. Large volumes of fumes and gases are liberated by these materials when they burn.
Equipment for the removal of tough anti-corrosion sealers offers varying degrees of speed and effectiveness. The
compressed air-operated scraper (NOT an air chisel) offers a relatively quiet mechanical method using an extremely
rapid reciprocating action. Move the operating end of the tool along the work surface to remove the material.
The most common method of removal is by means of a hot air blower with integral scraper.
NOTE: High temperatures can be generated with this equipment which may cause fumes. Take care during its use.
Another tool, and one of the most efficient methods, is the rapid-cutting 'hot knife'. This tool uses a wide blade and is
quick and versatile, able to be used easily in profiled sections where access is otherwise difficult.
Use the following procedure when repairing underbody coatings:
1 Remove existing underbody coatings.
2 After panel repair, clean the affected area with a solvent wipe, and treat bare metal with an etch phosphate
material.
3 Re-prime the affected area. DO NOT under any circumstances appIy underbody seaIer directIy to bare
metaI surfaces.
4 Replace all heat-fusible plugs which have been disturbed. Where such plugs are not available use rubber
grommets of equivalent size, ensuring that they are embedded in sealer.
5 Mask off all mounting faces from which mechanical components, hoses and pipe clips, have been removed.
Underbody sealer must be applied before such components are refitted.
6 Brush sealer into all exposed seams.
7 Spray the affected area with an approved service underbody sealer.
8 Remove masking from component mounting faces, and touch-in where necessary.
Proprietary Anti-Corrosion Treatments
The application of proprietary anti-corrosion treatments in addition to the factory-applied treatment could invalidate
the Corrosion Warranty and should be discouraged. This does not apply to approved, compatible, preservative waxes
which may be applied on top of existing coatings.
PANEL REPAÌRS
77-32 SEALÌNG AND CORROSÌON PROTECTÌON
Fitting Approved Accessories
When fitting accessories ensure that the vehicle's corrosion protection is not affected, either by breaking the protective
coating or by introducing a moisture trap.
Do not screw self-tapping screws directly into body panels. Fit suitable plastic inserts to the panel beforehand. Always
ensure that the edges of holes drilled into panels, chassis members and other body parts are protected with a suitable
zinc rich or acid etch primer, and follow with a protective wax coating brushed onto the surrounding area.
Do not attach painted metal surfaces of any accessory directly to the vehicle's bodywork unless suitably protected.
Where metal faces are bolted together always interpose a suitable interface material such as weldable zinc rich
primer, extruded strip, or zinc tape.
Cavity Wax Injection
Box sections treated with cavity wax are shown in this section. Following repairs to these areas always re-treat with
an approved cavity wax, using the access points illustrated. Ìn addition, treat all interior surfaces which have been
disturbed during repairs whether they have been treated in production or not. This includes all box members, cavities
and door interiors. Ìt is permissible to drill extra holes for access where necessary, provided these are not positioned
in load-bearing members. Ensure that such holes are treated with a suitable zinc rich primer, brushed with wax and
then sealed with a rubber grommet.
Before wax injection, ensure that the cavity to be treated is free from any contamination or foreign matter. Where
necessary, clear out any debris using a compressed air supply.
Carry out wax injection AFTER final paint operations.
During application, ensure that the wax covers all flange and seam areas and that it is adequately applied to all
repaired areas of both new and existing panels.
NOTE: Ensure that cavity wax is applied AFTER the final paint process and BEFORE refitting any trim components.
Ìt should be noted that new panel assemblies and complete body shells serviced as replacements are supplied
without wax injection treatment. Ensure that such treatment is carried out after repairs.
Effective cavity wax protection is vital. Always observe the following points:
¤ Complete all paint refinish operations before wax application.
¤ Clean body panel areas and blow-clean cavities if necessary, before treatment.
¤ Maintain a temperature of 18°C during application and drying.
¤ Check the spray pattern of injection equipment.
¤ Mask off all areas not to be wax coated and which could be contaminated by wax overspray.
¤ Remove body fixings, such as seat belt retractors, if contamination is at all likely.
¤ Move door glasses to fully closed position before treating door interiors.
¤ Treat body areas normally covered by trim before refitting items.
¤ Check that body and door drain holes are clear after the protective wax has dried.
¤ Keep all equipment clean, especially wax injection nozzles.
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-33
Application Equipment and Techniques
1 Air inlet
2 Flow control (spray pattern adjustment)
3 Pressure cup (1 litre capacity). Maximum pressure 140 psi (9.7 bar, 9.84kg/cm
3
)
4 Gun connector
5 Lance nipple connection
6 Flexible lance
7 Rigid directional hook wand (forward cone spray pattern)
8 Flexible nylon lance (1100 mm) with 360° spray pattern
9 Rigid lance (1100mm) with 360° spray pattern
When re-treating wax-injected areas which have been disturbed during repairs, it is necessary to use a compressed
air spray gun with integral pressure cup and a selection of interchangeable lances.
The following points must be observed during use, according to the attachments fitted:
¤ Use the rigid or flexible lance attachments with 360° spray dispersal when treating enclosed areas, to ensure
maximum coverage.
¤ Where openings are restricted, use the hook nozzle to provide a more directional spray (e.g. inside narrow or
short box sections).
¤ Spray exposed underbody surfaces directly from the gun less lance attachment and without disconnecting the
fluid coupling.
1100mm Rigid Lance: The nozzle on the rigid lance produces a 360° circular spray pattern combined with a forward-
directed spray. Although wax is distributed to all box section surfaces in a single stroke, effective and complete
coverage is obtained in long straight structures and box section cavities by spraying on both outbound and return
strokes of the lance.
The rigid lance also provides the positional accuracy required in shaped sections, by allowing visual assessment.
CAUTION: Do not force the Iance into access hoIes when using this attachment.
1100mm FIexibIe NyIon Lance: This lance is similar in pattern to the rigid version, but provides the additional
penetration required for curved sections or in places where access is difficult. Ìts main limitation is a lack of positional
accuracy inside box sections.
Carry out all spraying on the outward stroke of the lance. Withdraw the lance slowly to ensure sufficient coverage. Do
not withdraw the Iance too quickIy.
Ensure that the nylon tube of the lance is kept away from the edges of the access hole to eliminate abrasion and
extend the life of the tube. Take care to ensure that spraying ceases just before the nozzle emerges from the access
hole. To assist in this process paint the final 30mm of the nozzle with RED paint.
PANEL REPAÌRS
77-34 SEALÌNG AND CORROSÌON PROTECTÌON
Hook NozzIe on FIexibIe Lance: The rigid hook produces a highly atomised, forward-directed, fully conical spray
pattern having long range and good dispersion characteristics. This combination has good directional capabilities for
treating short, narrow sections, and may also be used for direct spraying of inner wheel arches etc.
Ìn use, position the flat area at the end of the lance at 180° to the nozzle spray direction. This will help to guide the
spray more accurately when it is concealed in a box section or access hole.
For general spraying, move the nozzle in an arc from side to side as required, to ensure full coverage.
NOTE: Ensure that all wax injection/application equipment is kept clean. Use white spirit for this purpose immediately
after wax injection operations.
Precautions during Body Repairs and Handling
Take care when handling the vehicle in the workshop. PVC underbody sealers, seam sealers, underbody wax and
body panels may be damaged if the vehicle is carelessly lifted.
Steam Cleaning and Dewaxing
Due to the high temperatures generated by steam cleaning equipment, there is a risk that certain trim components
could be damaged and some adhesives and corrosion prevention materials softened or liquified.
Adjust the equipment so that the nozzle temperature does not exceed 90°C (194°F). Take care not to allow the steam
jet to dwell on one area, and keep the nozzle at least 300mm from panel surfaces.
DO NOT remove wax or lacquer from underbody or underbonnet areas during repairs. Should it be necessary to
steam clean these areas, apply a new coating of wax or underbody protection as soon as possible.
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-35
CAVITY WAX
1 Ìnjection hole to sill outer
2 Ìnjection hole to sill middle panel
3 Ìnjection hole to sill inner
4 Ìnjection into door cavity
All areas symmetrically opposite to those shown are also treated. See INFORMATION, SeaIing and Corrosion
Protection.
PANEL REPAÌRS
77-36 SEALÌNG AND CORROSÌON PROTECTÌON
SEALANTS AND ADHESIVES
Structural Adhesive
Metal-to-metal adhesive is applied to critical joint areas during factory assembly. The material used is a high-
temperature, heat cured, nitrile phenolic which serves to bond two metal surfaces and also to seal the joint against
ingress of dust, water, petrol and fumes. This material is not suited for service use, and should be substituted in repair
using a suitable medium strength adhesive.
When separating a joint treated with metal-to-metal adhesive, it is important to avoid distortion. Heat the joint gradually
until the bond weakens sufficiently to permit panel separation.
NOTE: Spot welding through metal-to-metal adhesive is feasible, but take particular care to adjust the transformer
setting to ensure a reliable weld. DO NOT carry out MIG welding on a joint area which has been treated with metal-
to-metal adhesive until all traces of adhesive have been removed.
Seam Sealers
A heat cured, PVC Plastisol sealer is applied to joint areas during factory assembly. This material is not suitable for
service use.
Carry out all seam sealing after the application of primer, and before surfacer and top coats. Ensure that all surfaces
are first cleaned of all grease and oil. Apply sealer materials to the joint as a bead, either by hand or using an applicator
gun, and brush well into the joint. Following application, smooth the sealer with a cloth soaked with solvent such as
white spirit or Shell SBP3. This will ensure an acceptable cosmetic finish.
Ensure that ALL accessible joints are sealed following repair work. Note that damage to a vehicle can often result in
deflection to those areas of the body which are remote from the impact. As a result the sealers in these areas may be
disturbed by subsequent straightening and repair operations. Check all joints in the vicinity of the area undergoing
repair for evidence of cracked sealer, then clean out as required and apply fresh sealer using the following procedure:
¤ Clean the affected joint or seam and re-treat any exposed metal areas with a suitable etch phosphate primer.
¤ Treat affected area with an etch-acid primer.
¤ Apply appropriate seam sealer as necessary.
¤ Apply appropriate colour coat (and underbody sealer as applicable).
Where joints are inaccessible following the reassembly or fitment of components, ensure that a paste-type sealer is
applied to such joints. Certain seams also become inaccessible after the completion of panel repairs. Ìn such
instances apply paint and sealers before final assembly.
Provided access is adequate, apply sealer to both sides of a repair joint. Where access is limited to one side only (e.g.
box sections), treat the affected box member with cavity wax.
CAUTION: In the interests of HeaIth & Safety, aIways depIoy an extractor unit adjacent to the work area to
remove toxic fumes, especiaIIy if oxy-acetyIene equipment is being used to remove paneIs treated with wax
and seaIers.
Sealing Water Leaks
Sealing charts in this section show those areas of the bodyshell most likely to be affected by accident damage and
water leaks, and which could therefore require re-treatment in repair. They do not show those joint areas which only
apply to factory assembly operations and which are unlikely to be disturbed in service (e.g. transmission tunnel), or
where the damage would be so severe that the entire bodyshell would normally be written off.
Where water leakage is involved, always adopt a logical approach to the problem using a combination of skill,
experience and intuition. Do not reach a conclusion based only on visual evidence, such as assuming that a wet
footwell is caused by a leak emanating from the windscreen. Ìt will often be found that the source of the leak is
elsewhere. Use of the correct procedure will increase the chance of locating a leak, however obscure it may seem.
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-37
TooIs and Equipment:
The following tools and equipment are recommended for the purpose of detection and rectification of water leaks:
1 Garden sprayer (hand-operated).
2 Wet/dry vacuum cleaner.
3 Dry, absorbent cloths.
4 Battery torch.
5 Small mirror.
6 Weatherstrip locating tool.
7 Trim panel remover.
8 Small wooden or plastic wedges.
9 Dry compressed air supply.
10 Hot air blower.
11 Sealer applicators.
12 Ultrasonic leak detector.
During leak detection, the vehicle should be considered in three basic sections:
¤ The front interior space,
¤ The rear passenger space (where applicable), and
¤ The rear loadspace or boot.
Testing:
From the information supplied by the customer it should be possible for the bodyshop operator to locate the starting
point from which the leak may be detected. After the area of the leak has been identified, find the actual point of entry
into the vehicle.
A simple and effective means in the first instance is an ordinary garden spray with provision for pressure and jet
adjustment, which will allow water to be directed in a jet or turned into a fine spray. Use a mirror and a battery-powered
torch (NOT a mains voltage inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start at the lowest point and work slowly upwards, to avoid testing
in one area while masking the leak in another. For example, if testing started at the level of the windscreen, any water
cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells. Even at this point
it could still be wrongly assumed that the windscreen seal was at fault.
Another important part of identifying a water leak is by visual examination of door aperture seals, grommets and
weatherstrips for damage, deterioration or misalignment, together with the fit of the door itself against the seals.
SeaIing:
When the point of the leak has been detected, it will then be necessary to rectify it using the following procedure:
1 Renew all door aperture seals and weatherstrips which have suffered damage, misalignment or deterioration.
2 Check all body seals to ensure that they are correctly located on their mounting flanges/faces using a lipping
tool if necessary.
3 Dry out body seams to be treated using compressed air and/or a hot air blower as necessary.
4 Apply sealant on the outside of the joint wherever possible to ensure the exclusion of water.
5 When rectifying leaks between a screen glass and its weatherstrip (or in the case of direct glazing, between the
glass and bodywork), avoid removing the glass if possible. Apply the approved material at the appropriate
location (i.e. glass to weatherstrip or glass to body).
PANEL REPAÌRS
77-38 SEALÌNG AND CORROSÌON PROTECTÌON
SEALING CHARTS
1 Seam sealer light
2 Structural adhesive (RH only)
3 Structural adhesive
4 Seam sealer light
5 Structural adhesive
6 Seam sealer light
7 Seam sealer light
8 Structural adhesive
9 Seam sealer light
10 Seam sealer heavy
11 Seam sealer heavy
12 Seam sealer heavy
13 Seam sealer light, structural adhesive
14 Structural adhesive
15 Seam sealer heavy
16 Structural adhesive
All areas symmetrically opposite to those shown are also treated. See INFORMATION, SeaIing and Corrosion
Protection.
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-39
1 Semi-structural adhesive/anti-flutter material
2 Seam sealer light
3 Seam sealer light
4 Seam sealer heavy
5 Seam sealer heavy
6 Seam sealer heavy
7 Structural adhesive
8 Structural adhesive
9 Structural adhesive
10 Structural adhesive
11 Structural adhesive
12 Structural adhesive
13 Seam sealer light
14 Seam sealer light
15 Structural adhesive
All areas symmetrically opposite to those shown are also treated. See INFORMATION, SeaIing and Corrosion
Protection.
PANEL REPAÌRS
77-40 SEALÌNG AND CORROSÌON PROTECTÌON
1 Semi-structural adhesive/anti-flutter material
2 Structural adhesive, seam sealer light
3 Structural adhesive, seam sealer light
4 Semi-structural adhesive/anti-flutter material
5 Semi-structural adhesive/anti-flutter material
6 Brushable sealer
7 Structural adhesive, seam sealer light
8 Structural adhesive
9 Structural adhesive (LH only)
10 Seam sealer light
11 Seam sealer light
12 Seam sealer light
13 Seam sealer light (LH only)
All areas symmetrically opposite to those shown are also treated. See INFORMATION, SeaIing and Corrosion
Protection.
PANEL REPAÌRS
SEALÌNG AND CORROSÌON PROTECTÌON 77-41
INTERNAL SEALING
Expanding foam acoustic seals
Body in white seals
Foam block seals
Expanding foam acoustic seals are used in various closed sections of the body to improve vehicle refinement, see
illustration above.
The main function of the seals is to insulate the cabin from noise and vibrations, particularly road noise.
Two types of seals are fitted; type 'A' seals are fitted in the body - in - white areas and after going through the paint
baking process expand up to eight times original size.
The second, type 'B' seal is a foam block in a polythene bag, the bag and foam is pierced by a lance with a hole in it,
the lance then draws the air from the foam block causing it to shrink. The foam block can then be inserted to a section
of the body and when the lance is released the foam block then expands filling the section completely and ensuring
a well insulated body is obtained.
Replacing type 'A´ seals
As paint oven temperatures used in a repair workshop are significantly lower than those that are used during
manufacture of the vehicle, a different process is required to replace the seals in service.When replacing a seal, the
following procedure must be followed.
PANEL REPAÌRS
77-42 SEALÌNG AND CORROSÌON PROTECTÌON
BODY REPAIRS
Straightening
Whenever possible, structural members should be cold straightened under tension. Do not attempt to straighten with
a single pull but rework the damaged area using a series of pulls, releasing tension between each stage and using
the opportunity to check alignment.
Body Jig
Unless damage is limited to cosmetic panels, all repair work to body members must be carried out on a body jig, to
ensure that impact damage has not spread into more remote parts of the structure. Mounting on a jig will also ensure
that the straightening and panel replacement procedures do not cause further distortion.
Ìf original dimensions cannot be satisfactorily restored by these methods, damaged structural members should be
replaced. Damaged areas should be cut away using a high speed saw, NOT an oxy-acetylene torch.
As a rule, body dimensions are symmetrical about the centre line. A good initial check for distortion is therefore to
measure diagonally and to investigate apparent differences in dimensions.
Inspection
Every accident produces individual variations in damage. Each repair is influenced by the extent of the damage and
the facilities and equipment available for its rectification.
Most accident damage can be visually inspected and the approximate extent of damage assessed. Sometimes
deformation will extend beyond the directly damaged area, and the severity of this must be accurately established so
that steps can be taken to restore critical body components to their original dimensions. An initial check can be carried
out by means of drop checks or, preferably, trammels. Gauges are available which will accurately check for body twist.
Where repairs necessitate renewal of a critical body component it is recommended that a body jig is used.
PANEL REPAÌRS
REPLACEMENT PANELS 77-43
REPLACEMENT PANELS
SERVICE CONDITION OF PANELS
BodysheII AssembIy
Bodyshells are serviced with or without sunroof aperture, and less front fenders, door assemblies and tailgate.
Front Wing
Wings are serviced as bolt-on panels.
PANEL REPAÌRS
77-44 REPLACEMENT PANELS
Front BuIkhead AssembIy
The front bulkhead consists of bonnet locking platform (1), bulkhead assemblies (2, 3), centre stay bracket (4) and
radiator lower crossmember (5).
Bonnet AssembIy
The bonnet assembly is serviced without hinges which are available separately.
PANEL REPAÌRS
REPLACEMENT PANELS 77-45
VaIance
Valances are serviced with front valance assembly (1), reinforcement (2) and RH tie-bar gusset (3). Valance
reinforcement members are serviced separately (4).
Sidemember AssembIy
Sidemembers are serviced either as an assembly or as separate front sidemember (1), sidemember closing (2),
engine mounting brackets (3, 4), front sidemember bracket (5) and sidemember to sill (6).
PANEL REPAÌRS
77-46 REPLACEMENT PANELS
'A' Post
'A' posts are serviced as closing assembly (1), reinforcement assembly (2) and body side 'A' post (3).
PANEL REPAÌRS
REPLACEMENT PANELS 77-47
Body Side
Body sides are serviced as a complete assembly (1), also as a body side front (2), rear (3), sill (4) centre body side
(5). The fuel filler pocket (6) is serviced separately.
PANEL REPAÌRS
77-48 REPLACEMENT PANELS
Door AssembIy
Front and rear doors are serviced without hinges which are available separately. Outer door skins are also available
as separate items.
PANEL REPAÌRS
REPLACEMENT PANELS 77-49
Rear Quarter AssembIy
Rear quarter assemblies are serviced as complete panels (2). Drain channel assemblies are also available separately
(1).
Roof PaneI AssembIy
Roof panels are serviced as an assembly including front and rear header assemblies (1, 2), which are also available
as separate items.
PANEL REPAÌRS
77-50 REPLACEMENT PANELS
Rear Inner WheeIarch
Ìnner rear wheelarches are available separately.
Spare WheeI WeII AssembIy
The spare wheel well assembly is serviced either as a separate part or as part of a rear floor assembly.
Rear LongitudinaI Member
Rear longitudinal members are serviced either as separate items (2) or as part of a longitudinal member assembly (1).
PANEL REPAÌRS
REPLACEMENT PANELS 77-51
Rear Body AssembIy
Rear body parts are serviced as an assembly (4) and also as separate rear body reinforcement assembly (1) with
reinforcements (2, 3).
TaiIgate
The tailgate is serviced as an assembly without hinges, which are available separately.
PANEL REPAÌRS
77-52 REPLACEMENT PANELS
Load FIoor Side
Load floor sides are serviced as separate panels.
PANEL REPAÌRS
GENERAL WELDÌNG PRECAUTÌONS 77-53
GENERAL WELDÌNGPRECAUTÌONS
GENERAL WELDING PRECAUTIONS
For ease of reference the diagrams on the following pages show only the type of weld used in repair where it varies
from that used in production.
When carrying out welding operations the following criteria must be observed:
¤ Where resistance spot welds have been used in production, these must be reproduced with new spot welds in
replacement where possible. All such reproduction spot welds must be spaced 30mm apart.
¤ When spot welding, it is recommended that test coupons of the same metal gauges and materials are produced
to carry out peel tests to ensure that welding equipment being used can produce a satisfactory joint. Plug welds
must be used if a satisfactory spot weld cannot be produced.
¤ The electrode arms on hand-held spot welding guns must not exceed 300mm in length.
¤ Single-side spot welding is not acceptable.
¤ Brazing and gas welding are not acceptable EXCEPT where they have been specified in production.
¤ Where 3 metal thicknesses or more are to be welded together it is imperative to use MÌG plug welds to ensure
joint strength.
¤ MÌG plug welds must be used in repair joints where there is no access for a resistance spot welder. To replace
each production spot weld a hole must be drilled and/or punched, and a MÌG plug weld then made in its place.
The number of plug welds must match exactly the number of spot welds which have been removed.
¤ Where holes are left in an existing panel after removal of the spot welds, a single MÌG plug weld will be made in
each hole as appropriate.
¤ The replacement welds in the welding diagrams are denoted by the following symbols:
A. Single thickness plug welds
B. Multiple thickness plug welds
C. MÌG seam weld
D. Spot weld
PANEL REPAÌRS
77-54 GENERAL WELDÌNG PRECAUTÌONS
Seat Belt Anchorages
Seat belt anchorages are safety critical. When making repairs in these areas it is essential to follow design
specifications. Note that High Strength Low Alloy (HSLA) steel may be used for seat belt anchorages.
Where possible, the original production assembly should be used, complete with its seat belt anchorages, or the cut
line should be so arranged that the original seat belt anchorage is not disturbed.
All welds within 250mm of seat belt anchorages must be carefully checked for weld quality, including spacing of spot
welds.
WARNING: Body parts incorporating seat belt anchorages MUST be renewed completely if damaged beyond
repair, as the welds in these areas are safety critical and cannot be disturbed.
High Strength Steels
Body panels are being increasingly manufactured in high strength steels to meet design requirements for safety and
weight saving. As panels in high strength steels cannot be visually identified by the repairer, and as they can be more
sensitive to excess heat than would be the case with low carbon steels, it is advisable that the following procedure be
observed at all times.
While individual repairs will differ in detail, the following Panel Replacement Procedure has been devised placing
emphasis on ease of repair and the elimination of unnecessary work. Where replacement of a particular panel
involves departure from the Panel Replacement Procedure, a note to that effect is included in the relevant panel
replacement operation
PANEL REPAÌRS
PROCEDURES 77-55
PROCEDURES
PANEL REPLACEMENT PROCEDURE
This procedure is designed to explain the basic panel
removal and replacement method. The main criterion
in removal and replacement of body panels is that the
original standard is maintained as far as possible.
While individual repairs will differ in detail, this
procedure has been devised placing emphasis on
ease of repair and the elimination of unnecessary
work.
Body panels are being increasingly manufactured in
high strength steels to meet design requirements for
safety and weight saving. As panels in high strength
steels cannot be visually identified, and as they are
more sensitive to excess heat than panels
manufactured from low carbon steel, it is advisable that
the following procedure be observed at all times.
Remove paneI
1. Expose resistance spot welds. For those spot
welds which are not obviously visible, use a
rotary drum sander or wire brush fitted to an air
drill, or alternatively a hand held wire brush.
NOTE: In wheel arch areas it may be necessary
to soften underbody coating, using a hot air gun,
prior to exposing spot welds.
2. Cut out welds using a cobalt drill.
3. Alternatively, use a clamp-type spot weld
remover.
PANEL REPAÌRS
77-56 PROCEDURES
4. Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds and
braze should be removed using a sander where
possible, before cutting out the panel bulk.
5. Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.
Prepare oId surfaces
1. Remove any remaining sealant using a hot air
gun to minimise the risk of toxic fumes caused by
heat generated during welding.
CAUTION: Care must be taken to avoid
excessive heat buiId-up when using the hot
air gun.
2. Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: As an alternative, a disc sander may be
used.
3. Straighten existing panel joint edges using a
shaping block and hammer.
PANEL REPAÌRS
PROCEDURES 77-57
Prepare new surfaces
1. Mark out bulk of new panel and trim to size,
leaving approximately 50 mm overlap with
existing panel. Offer up new panel/section, align
with associated panels (e.g. new body side panel
aligned with door and trunklid). Clamp into
position.
2. Cut new and existing panels as necessary to
form butt, joggle or brace joint as required.
Remove all clamps and metal remnants.
3. Prepare new panel joint edges for welding by
sanding to a bright finish. This must include inner
as well as outer faces.
4. Apply suitable weld-through primer, to panel joint
surfaces to be welded, using brush or aerosol
can.
PANEL REPAÌRS
77-58 PROCEDURES
5. Apply correct sealant or adhesive, as applicable,
to panel joint surfaces.
. PANEL REPAIRS, SEALING AND
CORROSION PROTECTION, APPROVED
MATERIALS.
Offer up and aIign
1. Offer up new panel and align with associated
panels. Clamp into position using welding clamps
or Mole grips. Where a joggle or brace joint is
being adopted, make a set in the original panel
joint edge or insert a brace behind the joint.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to use
tack welds.
WeIding
1. Select arms for resistance spot welding and
shape electrode tips using a tip trimmer. Tips
should be dressed so the diameter is equal to
twice the thickness of the metal to be welded plus
3.0 mm.
CAUTION: Use arms not exceeding 300 mm
in Iength.
NOTE: To maintain weld efficiency, the tips will
require regular cleaning and dressing.
2. Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.
PANEL REPAÌRS
PROCEDURES 77-59
3. Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
welding monitor where possible.
4. MÌG tack weld butt joints and re-check alignment
and panel contours where necessary. Ensure
that a gap is maintained to minimise welding
distortion, by inserting a hacksaw blade as an
approximate guide.
5. Dress MÌG tack welds using a sander with 36 grit
disc, or a belt-type sander where access is
limited.
6. MÌG seam weld butt joints.
PANEL REPAÌRS
77-60 PROCEDURES
7. Always use MÌG plug welds where excessive
metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot weld
cutter, or through holes punched and drilled for
the purpose, approximately 8mm diameter.
8. Dress all welds using either a sander with 36 grit
disc, or a belt-type sander and/or wire brush.
When dressing welds ensure an area as small as
possible is removed to protect the zinc coating.
PANEL REPAÌRS
REPAÌRS 77-61
REPAÌ RS
RADIATOR LOWER CROSSMEMBER
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front bumper armature. See EXTERIOR
FITTINGS, Repairs.
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
2. Refit front bumper armature. See EXTERIOR
FITTINGS, Repairs.
3. Reconnect alternator.
4. Reconnect airbags and sensor system.
5. Reconnect all ECUs.
6. Remove stands and lower vehicle.
7. Reconnect battery earth lead.
VALANCE
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front bumper armature. See EXTERIOR
FITTINGS, Repairs.
7. Remove front wing.
8. Remove headlamp. See ELECTRICAL,
Repairs.
9. Remove front grille. See EXTERIOR FITTINGS,
Repairs.
10. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
11. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
12. Remove splash shield. See EXTERIOR
FITTINGS, Repairs.
13. Remove front suspension. See FRONT
SUSPENSION, Repairs.
14. Remove engine. See ENGINE, Repairs.
PANEL REPAÌRS
77-62 REPAÌRS
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
2. Refit engine. See ENGINE, Repairs.
3. Refit front suspension. See FRONT
SUSPENSION, Repairs.
4. Refit splash shield. See EXTERIOR FITTINGS,
Repairs.
5. Refit undertray. See EXTERIOR FITTINGS,
Repairs.
6. Refit wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
7. Refit front grille. See EXTERIOR FITTINGS,
Repairs.
8. Refit headlamp. See ELECTRICAL, Repairs.
9. Refit front wing.
10. Refit front bumper armature. See EXTERIOR
FITTINGS, Repairs.
11. Reconnect alternator.
12. Reconnect airbags and sensor system.
13. Reconnect all ECUs.
14. Remove stands and lower vehicle.
15. Reconnect battery earth lead.
FRONT VALANCE ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front bumper armature. See EXTERIOR
FITTINGS, Repairs.
7. Remove front wing.
8. Remove headlamp. See ELECTRICAL,
Repairs.
9. Remove front grille. See EXTERIOR FITTINGS,
Repairs.
10. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
11. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
12. Remove splash shield. See EXTERIOR
FITTINGS, Repairs.
13. Remove front suspension. See FRONT
SUSPENSION, Repairs.
14. Remove engine. See ENGINE, Repairs.
PANEL REPAÌRS
REPAÌRS 77-63
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
WARNING: When replacing a RH valance
assembly, remove ALL traces of adhesive
from the suspension turret front edge before
plug welding.
2. Refit engine. See ENGINE, repairs.
3. Refit front suspension. See FRONT
SUSPENSION, Repairs.
4. Refit splash shield. See EXTERIOR FITTINGS,
Repairs.
5. Refit undertray. See EXTERIOR FITTINGS,
Repairs.
6. Refit wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
7. Refit front grille. See EXTERIOR FITTINGS,
Repairs.
8. Refit headlamp. See ELECTRICAL, Repairs.
9. Refit front wing.
10. Refit front bumper armature. See EXTERIOR
FITTINGS, Repairs.
11. Reconnect alternator.
12. Reconnect airbags and sensor system.
13. Reconnect all ECUs.
14. Remove stands and lower vehicle.
15. Reconnect battery earth lead.
VALANCE MEMBER REINFORCEMENT
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
7. Remove front wing.
8. Remove headlamp. See ELECTRICAL,
Repairs.
9. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
10. Remove front door. See DOORS, Repairs.
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown. Cut member reinforcement to form seam
welded butt joint with existing panel.
2. Refit front door. See DOORS, Repairs.
3. Refit wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
4. Refit headlamp. See ELECTRICAL, Repairs.
5. Refit front wing.
6. Refit front bumper. See EXTERIOR FITTINGS,
Repairs.
7. Reconnect alternator.
8. Reconnect airbags and sensor system.
9. Reconnect all ECUs.
10. Remove stands and lower vehicle.
11. Reconnect battery earth lead.
PANEL REPAÌRS
77-64 REPAÌRS
SIDEMEMBER ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
7. Remove front wing.
8. Remove headlamp. See ELECTRICAL,
Repairs.
9. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
10. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
11. Remove splash shield. See EXTERIOR
FITTINGS, Repairs.
12. Remove front suspension. See FRONT
SUSPENSION, Repairs.
13. Remove engine. See ENGINE, Repairs
PANEL REPAÌRS
REPAÌRS 77-65
Refit
1. Prepare and clean panel joint faces. Plug weld
using holes left by spot weld cutter as shown.
2. Refit engine. See ENGINE, Repairs
3. Refit front suspension. See FRONT
SUSPENSION, Repairs.
4. Refit splash shield. See EXTERIOR FITTINGS,
Repairs.
5. Refit undertray. See EXTERIOR FITTINGS,
Repairs.
6. Refit wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
7. Refit headlamp. See ELECTRICAL, Repairs.
8. Refit front wing.
9. Refit front bumper. See EXTERIOR FITTINGS,
Repairs.
10. Reconnect alternator.
11. Reconnect airbags and sensor system.
12. Reconnect all ECUs.
13. Remove stands and lower vehicle.
14. Reconnect battery earth lead.
'A' POST
NOTE: In this operation, the body side 'A' post,
reinforcement assembly and closing assembly are
replaced in combination.
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
7. Remove front wing.
8. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
9. Remove windscreen. See SCREENS, Repairs.
10. Remove bonnet. See EXTERIOR FITTINGS,
Repairs.
11. Remove front door. See DOORS, Repairs.
12. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
13. Remove fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
14. Remove 'A' post trim upper casing. See
INTERIOR TRIM COMPONENTS, Repairs.
15. Remove 'A' post trim lower casing. See
INTERIOR TRIM COMPONENTS, Repairs.
PANEL REPAÌRS
77-66 REPAÌRS
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown. Cut panels to from seam welded butt
joints as shown. Make a seam weld at base of
closing assembly.
WARNING: Remove ALL traces of adhesive
from inner sill upper and lower edges before
plug welding.
2. Refit 'A' post trim lower casing. See INTERIOR
TRIM COMPONENTS, Repairs.
3. Refit 'A' post trim upper casing. See INTERIOR
TRIM COMPONENTS, Repairs.
4. Refit fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
5. Refit front treadplate. See EXTERIOR
FITTINGS, Repairs.
6. Refit front door. See DOORS, Repairs.
7. Refit bonnet. See EXTERIOR FITTINGS,
Repairs.
8. Refit windscreen. See SCREENS, Repairs.
9. Refit wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
10. Refit front wing.
11. Refit front bumper. See EXTERIOR FITTINGS,
Repairs.
12. Reconnect alternator.
13. Reconnect airbags and sensor system.
14. Reconnect all ECUs.
15. Reconnect battery earth lead.
FRONT BODY SIDE
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Support on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front wing.
7. Remove wheel arch liner. See EXTERIOR
FITTINGS, Repairs. See EXTERIOR FITTINGS,
Repairs.
8. Remove windscreen. See SCREENS, Repairs.
9. Remove bonnet. See EXTERIOR FITTINGS,
Repairs.
10. Remove front door. See DOORS, Repairs.
11. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
12. Remove fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
13. Remove 'A' post trim upper casing. See
INTERIOR TRIM COMPONENTS, Repairs.
14. Remove 'A' post trim lower casing. See
INTERIOR TRIM COMPONENTS, Repairs.
PANEL REPAÌRS
REPAÌRS 77-67
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding. Cut
panel to form seam welded butt joints as shown.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
2. Refit 'A' post trim lower casing. See INTERIOR
TRIM COMPONENTS, Repairs.
3. Refit 'A' post trim upper casing. See INTERIOR
TRIM COMPONENTS, Repairs.
4. Refit fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
5. Refit front treadplate. See EXTERIOR
FITTINGS, Repairs.
6. Refit front door. See DOORS, Repairs.
7. Refit bonnet. See EXTERIOR FITTINGS,
Repairs.
8. Refit windscreen. See SCREENS, Repairs.
9. Refit wheel arch liner. See EXTERIOR
FITTINGS, Repairs.
10. Refit front wing.
11. Refit front bumper. See EXTERIOR FITTINGS,
Repairs.
12. Reconnect alternator.
13. Reconnect airbags and sensor system.
14. Reconnect all ECUs.
15. Reconnect battery earth lead.
16. Remove stands and lower vehicle.
'BC' POST - 5-DOOR
NOTE: In this operation, the centre body side, 'BC'
post closing assembly and reinforcement are replaced
in combination.
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
7. Remove rear treadplate. See EXTERIOR
FITTINGS, Repairs.
8. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
9. Remove front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
10. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
11. Remove 'BC' post lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
12. Remove rear door.
PANEL REPAÌRS
77-68 REPAÌRS
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panels for plug welding, and cut
panels to form seam welded butt joints as shown.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
2. Refit rear door.
3. Refit 'BC' post lower trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
4. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
5. Refit front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
6. Refit front seat. See SEATS AND SEAT BELTS,
Repairs.
7. Refit rear treadplate. See EXTERIOR FITTINGS,
Repairs.
8. Refit front treadplate. See EXTERIOR
FITTINGS, Repairs.
9. Reconnect alternator.
10. Reconnect airbags and sensor system.
11. Reconnect all ECUs.
12. Reconnect battery earth lead.
13. Remove safety stands and lower vehicle.
BODY SIDE SILL
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
7. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
8. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding, and cut
panel to form seam welded butt joints as shown.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
2. Refit front seat. See SEATS AND SEAT BELTS,
Repairs.
3. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
4. Reconnect alternator.
5. Reconnect air bags and sensor system.
6. Reconnect all ECUs.
7. Reconnect battery earth lead.
8. Remove safety stands and lower vehicle.
PANEL REPAÌRS
REPAÌRS 77-69
BODY SIDE ASSEMBLY - 3-DOOR
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
7. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
8. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
9. Remove rear quarter rubbing strip. See
EXTERIOR FITTINGS, Repairs.
10. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
11. Remove rear quarter glass. See EXTERIOR
FITTINGS, Repairs.
12. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
13. Remove front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
14. Remove rear seat belt.See SEATS AND SEAT
BELTS, Repairs.
15. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
16. Remove rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
17. Remove rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
18. Remove luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
19. Remove luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
20. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
21. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
22. Remove tail lamp. See ELECTRICAL, Repairs.
23. Remove luggage compartment lamp. See
ELECTRICAL, Repairs.
24. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
25. Remove door.
MG ZR models and Rover 25 models fitted with 16"
wheels only:
26. Remove rear road wheel.
27. Remove rear wheel arch liner.
28. Using tool 76-003 positioned on edge of wheel
arch flange, straighten flange to gain access to
spot welds.
PANEL REPAÌRS
77-70 REPAÌRS
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding, and cut
panel to form seam welded butt joints as shown.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
WARNING: Failure to carry out the following
procedure can result in the tyre fouling the
wheel arch.
MG ZR models and Rover 25 models fitted with 16"
wheels only:
2. From rear bumper bolt hole in rear quarter panel
- point A, measure 100 mm (3.9 in) to point B,
make suitable reference mark using felt tip pen.
3. From bottom of outer wheel arch - point D,
measure 160 mm (6.3 in) to point C, make
suitable reference mark using felt tip pen.
4. Position tool 76-003 against inner wheel arch at
point B and moving between points B and C,
progressively dress the outer 5 to 7 mm (0.20 to
0.275 in) of the wheel arch flange upwards until it
is approximatly 30° from the horizontal.
5. Fit rear wheel arch liner.
6. Fit rear road wheel
PANEL REPAÌRS
REPAÌRS 77-71
All models:
7. Refit door.
8. Refit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
9. Refit luggage compartment lamp. See
ELECTRICAL, Repairs.
10. Refit tail lamp. See ELECTRICAL, Repairs.
11. Refit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Refit parcel tray support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
13. Refit luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
14. Refit luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
15. Refit rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
16. Refit rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
17. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
18. Refit rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
19. Refit front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
20. Refit front seat. See SEATS AND SEAT BELTS,
Repairs.
21. Refit rear quarter glass. See EXTERIOR
FITTINGS, Repairs.
22. Refit rear bumper. See EXTERIOR FITTINGS,
Repairs.
23. Refit rear quarter rubbing strip. See EXTERIOR
FITTINGS, Repairs.
24. Refit front treadplate. See EXTERIOR
FITTINGS, Repairs.
25. Refit rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
26. Refit rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
27. Reconnect alternator.
28. Reconnect airbags and sensor system.
29. Reconnect all ECUs.
30. Reconnect battery earth lead.
31. Remove safety stands and lower vehicle.
BODY SIDE ASSEMBLY - 5-DOOR
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
7. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
8. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
9. Remove rear treadplate. See EXTERIOR
FITTINGS, Repairs.
10. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
11. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
12. Remove front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
13. Remove rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
14. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
15. Remove rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
16. Remove rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
17. Remove luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
18. Remove luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
19. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
20. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
21. Remove tail lamp. See ELECTRICAL, Repairs.
22. Remove luggage compartment lamp. See
ELECTRICAL, Repairs.
23. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
24. Remove rear door.
PANEL REPAÌRS
77-72 REPAÌRS
MG ZR models and Rover 25 models fitted with 16"
wheels only:
25. Remove rear road wheel.
26. Remove rear wheel arch liner.
27. Using tool 76-003 positioned on edge of wheel
arch flange, straighten flange to gain access to
spot welds.
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding, and cut
panel to form seam welded butt joints as shown.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
WARNING: Failure to carry out the following
procedure can result in the tyre fouling the
wheel arch.
MG ZR models and Rover 25 models fitted with 16"
wheels only:
2. From rear bumper bolt hole in rear quarter panel
- point A, measure 100 mm (3.9 in) to point B,
make suitable reference mark using felt tip pen.
3. From bottom of outer wheel arch - point D,
measure 160 mm (6.3 in) to point C, make
suitable reference mark using felt tip pen.
4. Position tool 76-003 against inner wheel arch at
point B and moving between points B and C,
progressively dress the outer 5 to 7 mm (0.20 to
0.275 in) of the wheel arch flange upwards until it
is approximatly 30° from the horizontal.
5. Fit rear wheel arch liner.
6. Fit rear road wheel
PANEL REPAÌRS
REPAÌRS 77-73
All models:
7. Refit rear door.
8. Refit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
9. Refit luggage compartment lamp. See
ELECTRICAL, Repairs.
10. Refit tail lamp. See ELECTRICAL, Repairs.
11. Refit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Refit parcel tray support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
13. Refit luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
14. Refit luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
15. Refit rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
16. Refit rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
17. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
18. Refit rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
19. Refit front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
20. Refit front seat. See SEATS AND SEAT BELTS,
Repairs.
21. Refit rear bumper. See EXTERIOR FITTINGS,
Repairs.
22. Refit rear treadplate. See EXTERIOR FITTINGS,
Repairs.
23. Refit front treadplate. See EXTERIOR
FITTINGS, Repairs.
24. Refit rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
25. Refit rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
26. Reconnect alternator.
27. Reconnect airbags and sensor system.
28. Reconnect all ECUs.
29. Reconnect battery earth lead.
30. Remove safety stands and lower vehicle.
REAR BODY SIDE - 3-DOOR
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
7. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
8. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
9. Remove rear quarter rubbing strip. See
EXTERIOR FITTINGS, Repairs.
10. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
11. Remove rear quarter glass. See EXTERIOR
FITTINGS, Repairs.
12. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
13. Remove front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
14. Remove rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
15. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
16. Remove rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
17. Remove rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
18. Remove luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
19. Remove luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
20. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
21. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
22. Remove tail lamp. See ELECTRICAL, Repairs.
23. Remove luggage compartment lamp. See
ELECTRICAL, Repairs.
24. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
25. Remove door.
PANEL REPAÌRS
77-74 REPAÌRS
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding, and cut
panel to form seam welded joints as shown.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
2. Refit door. See Body Side AssembIy - 3 Door -
refit.
3. Refit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
4. Refit luggage compartment lamp. See
ELECTRICAL, Repairs.
5. Refit tail lamp. See ELECTRICAL, Repairs.
6. Refit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
7. Refit parcel tray support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
8. Refit luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
9. Refit luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
10. Refit rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
11. Refit rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
13. Refit rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
14. Refit front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
15. Refit front seat. See SEATS AND SEAT BELTS,
Repairs.
16. Refit rear quarter glass. See EXTERIOR
FITTINGS, Repairs.
17. Refit rear bumper. See EXTERIOR FITTINGS,
Repairs.
18. Refit rear quarter rubbing strip. See EXTERIOR
FITTINGS, Repairs.
19. Refit front treadplate. See EXTERIOR
FITTINGS, Repairs.
20. Refit rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
21. Refit rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
22. Reconnect alternator.
23. Reconnect airbags and sensor system.
24. Reconnect all ECUs.
25. Reconnect battery earth lead.
26. Remove safety stands and lower vehicle.
PANEL REPAÌRS
REPAÌRS 77-75
REAR BODY SIDE - 5-DOOR
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
7. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
8. Remove rear treadplate. See EXTERIOR
FITTINGS, Repairs.
9. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
10. Remove rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
11. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Remove rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
13. Remove rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
14. Remove luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
15. Remove luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
16. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
17. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
18. Remove tail lamp. See ELECTRICAL, Repairs.
19. Remove luggage compartment lamp. See
ELECTRICAL, Repairs.
20. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
21. Remove rear door.
PANEL REPAÌRS
77-76 REPAÌRS
Refit
NOTE: In this operation, the rear body side is cut
either at point A or point B as shown, depending
on the extent of the damage.
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding, and cut
panel to form seam welded butt joints as shown.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
2. Refit rear door.
3. Refit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
4. Refit luggage compartment lamp. See
ELECTRICAL, Repairs.
5. Refit tail lamp. See ELECTRICAL, Repairs.
6. Refit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
7. Refit parcel tray support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
8. Refit luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
9. Refit luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
10. Refit rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
11. Refit rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
13. Refit rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
14. Refit rear bumper. See EXTERIOR FITTINGS,
Repairs.
15. Refit rear treadplate. See EXTERIOR FITTINGS,
Repairs.
16. Refit rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
17. Refit rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
18. Reconnect alternator.
19. Reconnect airbags and sensor system.
20. Reconnect all ECUs.
21. Reconnect battery earth lead.
22. Remove safety stands and lower vehicle.
PANEL REPAÌRS
REPAÌRS 77-77
REAR QUARTER ASSEMBLY - 3-DOOR
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
7. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
8. Remove front treadplate. See EXTERIOR
FITTINGS, Repairs.
9. Remove rear quarter rubbing strip. See
EXTERIOR FITTINGS, Repairs.
10. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
11. Remove rear quarter glass. See EXTERIOR
FITTINGS, Repairs.
12. Remove front seat. See SEATS AND SEAT
BELTS, Repairs.
13. Remove front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
14. Remove rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
15. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
16. Remove rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
17. Remove rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
18. Remove luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
19. Remove luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
20. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
21. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
22. Remove tail lamp. See ELECTRICAL, Repairs.
23. Remove luggage compartment lamp. See
ELECTRICAL, Repairs.
24. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
25. Remove door.
Refit
NOTE: In this operation, the rear quarter
assembly, rear body side and drain channel are
replaced in combination.
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding, and cut
panel to form seam welded butt joints as shown.
Ìn addition to plug welds, make seam welds to
inner wheelarch, rear body, floor and sill inner.
WARNING: Remove ALL traces of adhesive
from inner sill lower edge before plug
welding.
2. Refit door.
3. Refit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
4. Refit luggage compartment lamp. See
ELECTRICAL, Repairs.
5. Refit tail lamp. See ELECTRICAL, Repairs.
6. Refit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
7. Refit parcel tray support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
8. Refit luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
9. Refit luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
10. Refit rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
11. Refit rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
13. Refit rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
14. Refit front seat belt and pre-tensioner. See
RESTRAINT SYSTEMS, Repairs.
PANEL REPAÌRS
77-78 REPAÌRS
15. Refit front seat. See SEATS AND SEAT BELTS,
Repairs.
16. Refit rear quarter glass. See EXTERIOR
FITTINGS, Repairs.
17. Refit rear bumper. See EXTERIOR FITTINGS,
Repairs.
18. Refit rear quarter rubbing strip. See EXTERIOR
FITTINGS, Repairs.
19. Refit front treadplate. See EXTERIOR
FITTINGS, Repairs.
20. Refit rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
21. Refit rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
22. Reconnect alternator.
23. Reconnect airbags and sensor system.
24. Reconnect all ECUs.
25. Reconnect battery earth lead.
26. Remove safety stands and lower vehicle.
REAR QUARTER ASSEMBLY - 5-DOOR
Remove
1. Disconnect battery earth lead.
2. Raise side of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
7. Remove rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
8. Remove rear treadplate. See EXTERIOR
FITTINGS, Repairs.
9. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
10. Remove rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
11. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Remove rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
13. Remove rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
14. Remove luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
15. Remove luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
16. Remove parcel tray support panel. See
INTERIOR TRIM COMPONENTS, Repairs.
17. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
18. Remove tail lamp. See ELECTRICAL, Repairs.
19. Remove luggage compartment lamp. See
ELECTRICAL, Repairs.
20. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
21. Remove rear door.
PANEL REPAÌRS
REPAÌRS 77-79
Refit
NOTE: In this operation, the rear quarter
assembly and rear body side are replaced in
combination. The panel may be replaced either
complete, OR as a part panel with the shaded
section discarded from the new panel as shown.
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding, and cut
panel to form seam welded butt joints as shown.
Ìn addition to plug welds, make seam welds to
inner wheelarch.
2. Refit rear door.
3. Refit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
4. Refit luggage compartment lamp. See
ELECTRICAL, Repairs.
5. Refit tail lamp. See ELECTRICAL, Repairs.
6. Refit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
7. Refit parcel tray support panel. See INTERIOR
TRIM COMPONENTS, Repairs.
8. Refit luggage compartment trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
9. Refit luggage compartment side carpet. See
INTERIOR TRIM COMPONENTS, Repairs.
10. Refit rear seat squab. See INTERIOR TRIM
COMPONENTS, Repairs.
11. Refit rear seat cushion. See INTERIOR TRIM
COMPONENTS, Repairs.
12. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
13. Refit rear seat belt. See SEATS AND SEAT
BELTS, Repairs.
14. Refit rear bumper. See EXTERIOR FITTINGS,
Repairs.
15. Refit rear treadplate. See EXTERIOR FITTINGS,
Repairs.
16. Refit rear quarter lower trim casing. See
INTERIOR TRIM COMPONENTS, Repairs.
17. Refit rear quarter trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
18. Reconnect alternator.
19. Reconnect airbags and sensor system.
20. Reconnect all ECUs.
21. Reconnect battery earth lead.
22. Remove safety stands and lower vehicle.
PANEL REPAÌRS
77-80 REPAÌRS
REAR INNER WHEELARCH
Remove
1. Remove and refit all associated parts as for rear
quarter assembly and rear body side in addition
to the following items:
2. Remove child restraints. See SEATS AND SEAT
BELTS, Repairs.
3. Rear suspension. See REAR SUSPENSION,
Repairs.
NOTE: In this operation, the rear inner wheelarch
is replaced in combination with a rear quarter
assembly and rear body side.
4. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
WARNING: Remove ALL traces of adhesive
from side flanges of spare wheel well and
load floor side before plug welding.
5. Refit associated parts.
SPARE WHEEL WELL ASSEMBLY
Remove
1. Remove and refit all associated parts as for rear
inner wheelarch, rear quarter assembly and rear
body side in addition to the following items:
2. Remove child restraints. See SEATS AND SEAT
BELTS, Repairs.
3. Rear suspension. See REAR SUSPENSION,
Repairs.
NOTE: In this operation, the spare wheel well
assembly is replaced in combination with a rear
inner wheelarch, rear quarter assembly and rear
body side.
4. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
WARNING: Remove ALL traces of adhesive
from front and side flanges and longitudinal
upper flanges, before plug welding.
5. Refit associated parts.
PANEL REPAÌRS
REPAÌRS 77-81
REAR LONGITUDINAL MEMBER
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove all trim items as for rear body and spare
wheel well assembly.
Refit
NOTE: In this operation, the rear longitudinal
member is replaced in combination with the rear
body and spare wheel well assembly.
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding.
WARNING: Remove ALL traces of adhesive
from joint to spare wheel well lower face
before plug welding.
2. Refit associated parts.
3. Reconnect alternator.
4. Reconnect airbags and sensor system.
5. Reconnect all ECUs.
6. Reconnect battery earth lead.
7. Remove safety stands and lower vehicle.
ROOF PANEL ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Disconnect all ECUs.
3. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
4. Disconnect alternator.
5. Remove tailgate. See DOORS, Repairs.
6. Remove windscreen. See SCREENS, Repairs.
7. Remove headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown. Ìn addition to plug welding, make seam
welds inside vehicle at front and rear corners of
inner frame to upper 'A' posts and quarter panels.
2. Refit headlining. See INTERIOR TRIM
COMPONENTS, Repairs.
3. Refit windscreen. See SCREENS, Repairs.
4. Refit tailgate. See DOORS, Repairs.
5. Reconnect alternator.
6. Reconnect airbags and sensor system.
7. Reconnect all ECUs.
8. Reconnect battery earth lead.
PANEL REPAÌRS
77-82 REPAÌRS
REAR BODY ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
7. Remove both luggage compartment side
carpets. See INTERIOR TRIM COMPONENTS,
Repairs.
8. Remove both luggage compartment trim casings.
See INTERIOR TRIM COMPONENTS, Repairs.
9. Remove parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
10. Remove luggage compartment lamp. See
ELECTRICAL, Repairs.
11. Remove both tail lamps. See ELECTRICAL,
Repairs.
12. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
PANEL REPAÌRS
REPAÌRS 77-83
Refit
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
WARNING: Remove ALL traces of adhesive
from joint to spare wheel well lower face
before plug welding.
2. Refit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
3. Refit both tail lamps. See FUEL DELIVERY
SYSTEM, Repairs.
4. Refit luggage compartment lamp. See
ELECTRICAL, Repairs.
5. Refit parcel tray. See INTERIOR TRIM
COMPONENTS, Repairs.
6. Refit both luggage compartment trim casings.
See INTERIOR TRIM COMPONENTS, Repairs.
7. Refit both luggage compartment side carpets.
See INTERIOR TRIM COMPONENTS, Repairs.
8. Refit rear bumper. See EXTERIOR FITTINGS,
Repairs.
9. Reconnect alternator.
10. Reconnect airbags and sensor system.
11. Reconnect all ECUs.
12. Reconnect battery earth lead.
13. Remove safety stands and lower vehicle.
LOAD FLOOR SIDE
Remove
1. Disconnect battery earth lead.
2. Raise rear of vehicle.
WARNING: Place on safety stands.
3. Disconnect all ECUs.
4. Disconnect airbags and sensor system.
WARNING: See RESTRAINT SYSTEMS,
Precautions.
5. Disconnect alternator.
6. Remove all trim items as for rear body assembly,
rear quarter assembly and rear inner wheelarch.
Refit
NOTE: In this operation, the load floor side is
replaced in combination with a rear body
assembly, rear quarter assembly and rear inner
wheelarch.
1. Prepare and clean panel joint faces. Punch or
drill holes in new panel for plug welding as
shown.
WARNING: Remove ALL traces of adhesive
from joints to spare wheel well outer flange
and longitudinal upper flange before plug
welding.
2. Refit associated parts.
3. Reconnect alternator.
4. Reconnect airbags and sensor system.
5. Reconnect all ECUs.
6. Reconnect battery earth lead.
7. Remove safety stands and lower vehicle.
PANEL REPAÌRS
77-84 REPAÌRS
PANEL REPAÌRS
TÌMES 77-85
TÌMES
PANEL/ ASSEMBLY REPLACEMENT
TIMES
The following information shows the total time taken to
replace single panels and complete assemblies. This
time includes removal of Mechanical, Electrical and
Trim (MET) items, plus paint times based on Metallic
Clear Over Base Paint.
The times shown were generated by Thatcham (the
Motor Ìnsurance Repair and Research Centre) and are
to be used as a guide only.
5 Door
Combination paneI repIacement times
The following panel combination times show the total
time to remove/refit body panels, MET items and any
paint processes.
5 Door - Front end combination paneI times
PaneI Description TotaI time
Bonnet 6.8
Bonnet locking platform 6.4
Front bumper 1.9
Rear bumper 1.0
Front door - each 8.0
Rear door - each 7.7
Door skin front - each 12.1
Door skin rear - each 11.5
Front bulkhead assembly 8.4
Rear body assembly 10.5
Roof panel 18.7
Tailgate 8.6
Wing - each 7.0
Rear body side cut at 'A' LH 18.5
Rear body side cut at 'B' LH 16.6
Rear body side cut at 'A' RH 17.7
Rear body side cut at 'B' RH 15.7
PaneI Description TotaI Time
Front bumper
Front bulkhead assembly
Wing 13.5
Front bumper
Front bulkhead assembly
Wing RH & LH 15.5
Front bumper
Side member assembly
Front bulkhead assembly
Wing
Valance
Valance member reinforcement 27.7 LH
28.1 RH
Front bumper
Side member assembly LH
Side member assembly RH
Front bulkhead assembly
Wing LH & RH
Valance LH & RH
Valance reinforcement LH & RH 38.8
Front bumper
Side member assembly
Front bulkhead assembly 12.4 LH
12.6 RH
PANEL REPAÌRS
77-86 TÌMES
5 door - Body side combination paneI times
5 door - Rear end combination paneI times
PaneI/ assembIy repIacement times
3 Door
PaneI description TotaI time
Front door
Wing 10.9
Rear door
Rear body side panel cut at 'B' 22.4 LH
21.3 RH
Front door
Rear door
'BC' post
'BC' post closing assembly
'BC' post reinforcement 28.6
Front door
Rear door
Body side assembly
'BC' post closing panel
'BC' post reinforcement 38.1 LH
37.2 RH
Front door
Front bodyside panel 'A' post
'A' post reinforcement assembly
'A' post closing assembly
Wing 28.2 LH
28.3 RH
PaneI description TotaI time
Rear bumper
Rear body assembly
Rear body side 22.6 LH
22.5 RH
Rear bumper
Rear body assembly
Rear body side cut at 'A' LH & RH 30.7
Rear bumper
Spare wheel well assembly
Load floor side
Rear longitudinal member
Rear body assembly
Rear drain channel
Rear body side cut at 'B'
Rear quarter assembly
Rear inner wheelarch 40.3 LH
41.0 RH
Rear bumper
Spare wheel well
Rear body assembly
Load floor side
Rear longitudinal member
Rear body side cut at 'A' 30.8 LH
31.4 RH
PaneI Description TotaI time
Bonnet 7.0
Bonnet locking platform 6.4
Front bumper 1.4
Rear bumper 0.9
Front door - each 8.2
Front door skin - each 12.5
Front bulkhead assembly 8.4
Rear body assembly 10.5
Roof panel 19.2
Body side sill LH 10.8
Body side sill RH 11.1
Tailgate 8.6
Wing - each 7.0
Rear body side cut at 'A' LH 21.6
Rear body side cut at 'A' RH 20.8
PANEL REPAÌRS
TÌMES 77-87
Combination paneI repIacement times
3 Door - Front end combination times will be the same
as 5 door models.
3 Door - Body side combination paneI times
3 door - Body side combination paneI times
3 Door - Rear end combination paneI times
PaneI description TotaI time
Front bumper
Wing
Front bulkhead assembly 13.5
Front bumper
Front bulkhead assembly
Wing LH & RH 15.5
Front bumper
Side member assembly
Front bulkhead assembly
Front wing
Valance
Valance member reinforcement 27.7 LH
28.1 RH
Front bumper
Side member assembly LH
Side member assembly RH
Front bulkhead assembly
Wing LH
Wing RH
Valance LH
Valance RH
Valance member reinforcement LH
Valance member reinforcement RH 38.8
Front bumper
Front bulkhead assembly
Side member assembly 12.4 LH
12.6 RH
PaneI description TotaI time
Front door
Wing 11.1
Front door
Rear body side panel cut at 'A' 26.1 LH
24.9 RH
Front door
Body side sill 16.0 LH
16.2 RH
Front door
Wing
Body side assembly 40.0 LH
29.9 RH
Front door
Front body side panel 'A' post
'A' post reinforcement assembly
'A' post closing assembly
Wing 28.3 LH
28.5 RH
PaneI description TotaI time
Rear bumper
Rear body side panel cut at 'A'
Rear body assembly 27.7 LH
27.6 RH
Rear bumper
Rear body side cut at 'A' LH & RH
Rear body assembly 40.7
Load floor side
Rear bumper
Rear longitudinal member
Rear drain channel
Rear body assembly
Spare wheel well
Rear inner wheel arch
Rear quarter assembly
Rear body side 44.6 LH
44.8 RH
Rear bumper
Spare wheel well
Load floor side
Rear longitudinal member
Rear body assembly
Rear body side cut at 'A' 35.9 LH
36.4 RH
PANEL REPAÌRS
77-88 TÌMES
PANEL REPAÌRS
PAÌNT 77-89
PAÌNT
PAINT
RepIacement PaneIs
1. Service panels are supplied with a cathodic
primer coating as part of the panel protection,
and in compliance with the vehicle's Corrosion
Warranty where applicable. DO NOT remove
the primer before paint refinishing. In the
event of IocaIised surface damage or
imperfections, ensure that onIy the minimum
of primer is removed during rectification work
for effective repair.
2. Rectify damage as far as possible by panel
beating or straightening. To remove corrosion or
paint runs on outer surfaces, abrade the primer
coat in the affected area as necessary using the
following procedure:
3. Clean the panel using a solvent wipe.
4. Treat exposed areas of metal with an etch
phosphate process.
5. Re-treat the affected area using either a separate
acid-etch primer and two-pack surfacer, or an
integrated etch primer/filler.
PANEL PREPERATION
BoIted PaneIs:
1. Before fitting bolt-on panels, ensure that all
mating and adjacent surfaces on the vehicle and
replacement panel are free from damage and
distortion. Rectify if necessary as described in
this section, and apply preformed strip sealer
where specified. See INFORMATION, SeaIing
and Corrosion Protection.
WeIded PaneIs:
1. Remove primer from the immediate vicinity of
new and existing panel flanges, cleaning to bright
metal finish.
2. On joints to be spot welded, apply weld-through
zinc rich primer to joint faces of both flanges.
Make spot welds while primer is still wet or
according to the manufacturer's instructions.
3. Dress accessible weld seams.
4. Clean panel using solvent wipe.
5. Treat bare metal with an etch phosphate process.
6. Re-treat repaired areas.
NOTE: It is not satisfactory to use weld-through,
zinc rich primers in conjunction with arc or MIG
welding.
Sectioned PaneIs:
1. When replacing part or sectioned panels, the
basic procedure is the same as for welded panels
described above, with the following variations:
2. Remove primer from both new and existing joint
faces, cleaning to a bright metal finish.
3. Where an overlap joint with the existing panel is
to be spot welded, apply weld-through, zinc rich
primer to both joint faces and spot weld while the
primer is still wet, or according to the
manufacturer's instructions.
4. MÌG weld butt joints where applicable.
5. Clean the panel with a solvent wipe.
6. Treat bare metal areas using an etch phosphate
process.
7. Re-prime affected areas as necessary as for
rectifying transit damage.
8. Treat the inner faces of lap or butt joints with a
suitable cavity wax. See PANEL REPAIRS,
SeaIing and Corrosion Protection.
PANEL REPAÌRS
77-90 PAÌNT
CIinch PaneIs (e.g. Doorskins etc.):
1. Abrade primer on new and existing panel joint
faces, and clean using a solvent wipe.
2. Apply metal-to-metal adhesive where applicable.
3. Where joints are to be spot welded, apply
suitable weld-through, zinc rich primer to weld
areas.
4. Where joints are to be MÌG, arc or gas welded,
apply zinc rich primer in adjacent areas but Ieave
the weIded area untreated
5. To retain the panel whilst clinching the flanges,
tack spot weld or plug weld as appropriate.
6. Clean the panel with a solvent wipe.
7. Treat bare metal areas with a suitable etch
phosphate process.
8. Re-prime affected areas as necessary as for
rectifying transit damage.
NOTE: Replacement doors, bonnets and boot
lids must be treated with a suitable seam sealer
on clinched seams, following the primer coat.
Paint Refinishing
1. Seal all accessible exterior and interior seams
with an approved seam sealer. Certain joints
such as sill lower flange seams must be left
unsealed. See PANEL REPAIRS, SeaIing and
Corrosion Protection.
2. Apply suitable anti-chip primer where specified.
3. Apply a two-pack paint refinishing system.
4. Repair any damage to underbody sealers either
at this stage or before paint operations. See
PANEL REPAIRS, SeaIing and Corrosion
Protection.
5. Apply cavity wax to all interior surfaces which
have not received refinish paint.
Paint Repairs
1. Before carrying out paintwork repairs, clean the
vehicle thoroughly using either a steam cleaner
or high-pressure washer.
2. Wash locally repaired areas using a mild water-
mixable detergent and wipe them clean with
solvent, immediately before paint application.
A Two-pack top coat
B Two-pack primer filler and etch primer
C Etch phosphate
3. Ensure that damaged paintwork which has led to
exposed metal is abraded until the metal is clean,
extending beyond the area of the original
damage. Treat the bare metal with an etch
phosphate to remove all traces of rust and to
provide a key for new paint coats. Re-treat the
affected area using either a separate acid-etch
primer and two-pack surfacer or an integrated
etch primer/filler, and follow with a two-pack paint
system. Treat those surfaces not receiving paint
using an approved cavity wax, following paint
operations. See PANEL REPAIRS, SeaIing and
Corrosion Protection.
HEATÌNG & VENTÌLATÌON
REPAÌRS 80-1
HEATÌNG& VENTÌLATÌON REPAÌ RS
INTAKE AIR FILTER
´÷ 80.15.42
The intake air filter should be renewed every 12,000
miles (20,000 km) or 12 months, whichever comes
first. Ìn hot or dusty climates the filter may require
renewing more frequently.
Remove
1. Remove glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Remove 1 screw and loosen second screw
securing glove box support bar to fascia.
3. Move glove box support bar aside.
HEATÌNG & VENTÌLATÌON
80-2 REPAÌRS
4. Release 2 clips and remove cover from heater
housing.
5. Remove and discard intake air filter.
Refit
1. Fit new intake air filter to heater housing. Ensure
arrow indicating direction of air flow is facing the
correct way.
2. Clean intake air filter cover and fit to heater
housing.
3. Fit glove box support bar to fascia and secure
with screws.
4. Fit glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
AIR INTAKE PLENUM
´÷ 80.15.62
Remove
1. Remove wiper arms. See WIPERS &
WASHERS, Repairs.
2. Remove 7 screw covers and screws along upper
edge of plenum.
3. Release 8 studs securing lower edge of plenum
to body.
4. Release plenum from bonnet hinges and 'A' post
finishers.
5. Remove air intake plenum.
Refit
1. Fit air intake plenum.
2. Fit trim clips securing lower edge of plenum to
body.
3. Fit and tighten screws securing upper edge of
plenum to body.
4. Fit screw covers along upper edge of plenum.
5. Fit wiper arms. See WIPERS & WASHERS,
Repairs.
HEATÌNG & VENTÌLATÌON
REPAÌRS 80-3
RESISTOR UNIT
´÷ 80.20.17
Remove
1. Remove glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Disconnect multiplug from resistor unit.
3. Remove 2 screws securing resistor unit to heater.
4. Remove resistor unit.
Refit
1. Fit resistor unit to heater and secure with screws.
2. Connect multiplug to resistor unit.
3. Fit glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
HEATER CONTROLS
´÷ 80.10.02
Remove
1. Remove front console. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Remove glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
3. Release 3 turnbuckles and remove fascia lower
cover.
4. Disconnect air distribution control cable from
heater unit.
5. Disconnect heater control cable from heater unit.
6. Disconnect fresh air vent control cable from
heater unit.
HEATÌNG & VENTÌLATÌON
80-4 REPAÌRS
7. Disconnect heater control cable from heater
valve and release from bulkhead.
8. Disconnect air recirculation control cable from
blower assembly.
9. Remove 4 screws securing heater controls and
withdraw from fascia.
10. Disconnect multiplugs from heater controls.
HEATÌNG & VENTÌLATÌON
REPAÌRS 80-5
11. Remove heater controls from fascia.
12. Carefully prise knobs from heater controls.
13. Release 6 clips securing trim finisher to heater
controls.
14. Remove 2 screws securing bezel to heater
controls and remove.
15. Remove 2 screws securing heater fan switch and
remove.
16. Remove screw securing air recirculation cable
and release from heater controls.
17. Remove screw securing air distribution cable and
release from heater controls.
18. Remove screw securing heater control cables
and release from heater controls.
HEATÌNG & VENTÌLATÌON
80-6 REPAÌRS
19. Remove screw securing fresh air vent control
cable to heater controls.
Refit
1. Fit fresh air vent control cable to new heater
controls and secure with screw.
2. Fit heater control cables to heater controls and
secure with screws.
3. Fit air distribution cable to heater controls and
secure with screw.
4. Fit air recirculation cable to heater controls and
secure with screw.
5. Fit fan switch to heater controls and secure with
screws.
6. Fit bezel to heater controls and secure with
screws.
7. Fit trim finisher to heater controls.
8. Fit knobs to heater controls.
9. Position heater controls to fascia and connect
multiplugs.
10. Fit and tighten screws securing heater controls to
fascia.
11. Rotate heater control and control lever on heater
assembly to cool positions.
12. Connect heater control cable to lever and secure
with clip.
13. Set heater valve to closed position.
14. Feed heater control cable through bulkhead and
connect to heater valve. Secure with clip.
15. Set air distribution control and lever on heater
assembly to vent positions.
16. Connect air distribution cable to lever and secure
with clip.
17. Feed air recirculation cable behind blower
assembly and connect to lever. Secure with clip.
18. Fit fresh air vent control cable to heater assembly
and secure with clip.
19. Fit fascia lower cover and secure turnbuckles.
20. Fit glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
21. Fit front console. See INTERIOR TRIM
COMPONENTS, Repairs.
CONTROL CABLE - AIR DISTRIBUTION
´÷ 80.10.12
Remove
1. Remove heater controls. See HEATING &
VENTILATION, Repairs.
2. Remove screw securing air distribution cable and
remove from heater controls.
Refit
1. Fit air distribution cable to heater controls and
secure with screw.
2. Fit heater controls. See HEATING &
VENTILATION, Repairs.
HEATÌNG & VENTÌLATÌON
REPAÌRS 80-7
CONTROL CABLE - AIR RECIRCULATION
´÷ 80.10.17
Remove
1. Remove heater controls. See HEATING &
VENTILATION, Repairs.
2. Remove screw securing air recirculation cable
and remove from heater controls.
Refit
1. Fit air recirculation cable to heater controls and
secure with screw.
2. Fit heater controls. See HEATING &
VENTILATION, Repairs.
HEATER VALVE
´÷ 80.10.16
Remove
1. Position drain tin to collect any coolant spillage.
2. Loosen 2 clips securing coolant hoses to heater
valve.
3. Disconnect coolant hoses from heater valve.
CAUTION: PIug the connections.
4. Remove 2 screws securing heater valve to
mounting bracket.
5. Release heater valve from control lever and
remove.
Refit
1. Fit heater valve to control lever.
2. Position heater valve to mounting bracket and
secure with screws.
3. Remove plugs from hoses and connect to heater
valve.
4. Secure hoses to heater valve with clips.
5. Top-up engine coolant.
6. Remove drain tin.
HEATÌNG & VENTÌLATÌON
80-8 REPAÌRS
HEATER
´÷ 80.20.01
Remove
1. Disconnect battery earth lead.
2. Drain cooling system. See COOLING SYSTEM,
Adjustments.
3. Release clips and remove coolant hoses from
heater pipes.
4. Remove nut securing heater to bulkhead.
5. Remove fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
6. Release harness from heater.
7. Remove screw securing heater to heater duct.
8. Remove screw securing heater duct to blower
assembly.
9. Remove heater duct.
10. Remove nuts securing heater to bulkhead.
11. Remove trim stud securing heater to centre
console duct.
12. Release duct from heater.
13. Remove heater from vehicle.
CAUTION: Be carefuI not to aIIow any cooIant
in the heater matrix to spiII into the interior of
the vehicIe.
Refit
1. Position heater to vehicle.
2. Fit nuts securing heater to bulkhead and tighten
to 22 Nm.
3. Position duct to heater and secure with trim stud.
4. Fit heater duct between blower assembly and
heater and secure with screws.
5. Secure harness to heater.
6. Fit fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
7. Fit nut securing heater to bulkhead and tighten to
22 Nm.
8. Fit coolant hoses to heater pipes and secure with
clips.
9. Refill cooling system. See COOLING SYSTEM,
Adjustments.
10. Connect battery earth lead.
HEATÌNG & VENTÌLATÌON
REPAÌRS 80-9
HEATER MATRIX
´÷ 80.20.29
Remove
1. Remove heater. See HEATING &
VENTILATION, Repairs.
2. Remove screw securing heater pipe bracket to
heater and collect bracket.
3. Remove 2 screws securing matrix cover to
heater.
4. Withdraw heater matrix from heater.
Refit
1. Fit matrix to heater.
2. Position cover to matrix and secure with screws.
3. Fit bracket to heater pipes and secure with screw.
4. Fit heater. See HEATING & VENTILATION,
Repairs.
BLOWER ASSEMBLY
´÷ 80.20.12
Remove
1. Disconnect battery earth lead.
2. Remove fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
3. Release coaxial cable from heater/blower
assembly.
4. Disconnect 2 multiplugs from blower assembly.
5. Remove 3 bolts securing fascia end support
panel to body.
6. Remove bolt securing blower assembly to
support panel.
7. Remove support panel.
8. Remove 2 nuts securing blower assembly to
body.
9. Remove screw securing blower assembly to
heater duct.
10. Release blower assembly from heater duct and
remove.
HEATÌNG & VENTÌLATÌON
80-10 REPAÌRS
Refit
1. Fit blower assembly to heater duct and position to
body.
2. Fit and tighten screw securing blower assembly
to heater duct.
3. Fit and tighten nuts securing blower assembly to
body.
4. Fit fascia support panel and tighten bolts to body
to 20 Nm.
5. Fit and tighten bolt securing blower assembly to
support panel.
6. Connect multiplugs to blower assembly.
7. Secure coaxial cable to clips on heater/blower
assembly.
8. Fit fascia. See INTERIOR TRIM
COMPONENTS, Repairs.
9. Connect battery earth lead.
BLOWER ASSEMBLY MOTOR
´÷ 80.20.15
Remove
1. Remove blower assembly. See HEATING &
VENTILATION, Repairs.
2. Remove 3 screws securing motor to blower
assembly.
3. Release pipe from motor.
4. Remove motor from blower assembly.
Refit
1. Fit motor to blower assembly and secure pipe.
2. Fit screws securing motor to blower assembly
and tighten to 9 Nm.
3. Fit blower assembly. See HEATING &
VENTILATION, Repairs.
HEATÌNG & VENTÌLATÌON
REPAÌRS 80-11
HEATER FAN SWITCH
´÷ 80.10.22
Remove
1. Remove heater controls. See HEATING &
VENTILATION, Repairs.
2. Carefully prise knobs from heater controls.
3. Release 6 clips securing trim finisher to heater
controls.
4. Remove 2 screws securing bezel to heater
controls and remove.
5. Remove 2 screws securing heater fan switch and
remove.
Refit
1. Fit fan switch to heater controls and secure with
screws.
2. Fit bezel to heater controls and secure with
screws.
3. Fit trim finisher to heater controls.
4. Fit knobs to heater controls.
5. Fit heater controls. See HEATING &
VENTILATION, Repairs.
HEATÌNG & VENTÌLATÌON
80-12 REPAÌRS
AÌR CONDÌTÌONÌNG
REFRÌGERANT RECOVERY, RECYCLÌNG AND RECHARGÌNG 82-1
AÌR CONDÌTÌONÌNG REFRÌ GERANT RECOVERY, RECYCLÌ NGAND RECHARGÌNG
REFRIGERANT RECOVERY, RECYCLING
AND RECHARGING
´÷ 82.30.02
WARNING: Servicing must only be carried out by
personnel familiar with both the vehicle system
and the charging and testing equipment. All
operations must be carried out in a well ventilated
area away from open flame and heat sources.
Recovery
1. Remove dust caps from high and low pressure
connectors.
2. Connect high and low pressure hoses to
appropriate connections.
3. Open valves on connectors.
4. Turn valves on refrigerant station to correct
positions.
5. Turn Process switch to correct position.
6. Turn Main switch to 'ON'.
7. Allow station to recover refrigerant from system.
WARNING: Refrigerant must always be
recycled before re-use to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system.
Recycling should always be carried out with
equipment which is design certified by
Underwriter Laboratory Inc. for compliance
with SAE J1991. Other equipment may not
recycle refrigerant to the required level of
purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with
any other type of refrigerant.
Refrigerant R134a from domestic and
commercial sources must not be used in
motor vehicle air conditioning systems.
8. Close valves on refrigerant station.
9. Turn Main switch to 'OFF'.
10. Close valves on connectors.
11. Disconnect connectors high and low pressure
hoses from connectors.
12. Fit dust caps to connectors.
13. Open tap at rear of station to drain refrigerant oil.
14. Measure and record quantity of refrigerant oil
recovered from system.
15. Close tap at rear of station.
Evacuation
1. Remove dust caps from high and low pressure
connectors.
2. Connect high and low pressure hoses to
appropriate connections.
3. Open valves on connectors.
4. Turn valves on refrigerant station to correct
positions.
5. Turn Process switch to correct position.
6. Turn Main switch to 'ON'.
7. Allow station to evacuate system.
Recharging
CAUTION: The system must be evacuated
immediateIy before recharging commences.
DeIay between evacuation and recharging is
not permitted.
1. Close valves on refrigerant station.
2. Close valve on oil charger.
3. Disconnect yellow hose from refrigerant station.
4. Remove lid from oil charger.
5. Pour same quantity of refrigerant oil into oil
charger as collected during recovery. Ìf the
following components have been renewed, add
the following additional quantity of lubricating oil:
Condenser = 40 cm
Evaporator = 30 cm
Pipe or hose = 5 cm /metre
6. Fit lid to oil charger.
7. Connect yellow hose to refrigerant station.
8. Open valve on oil charger.
9. Move pointer on refrigerant gauge to mark
position of refrigerant charge quantity.
System charge weight is:
LHD = 560 ± 25g
RHD = 640 ± 25g
NOTE: When recharging the A/C system, always
allow additional weight of refrigerant to fill the
charging line between refrigerant station and
vehicle. Calculate the additional refrigerant
weight required at 30 grammes per metre of
charging line.
10. Slowly open correct valve on refrigerant station
and allow vacuum to pull refrigerant into system.
11. Close valve on refrigerant station when correct
amount of refrigerant has been drawn into air
conditioning system.
12. Turn Main switch to 'OFF'.
13. Close valves on connectors.
14. Disconnect high and low pressure hoses from
connectors.
15. Fit dust caps to connectors.
AÌR CONDÌTÌONÌNG
82-2 REFRÌGERANT RECOVERY, RECYCLÌNG AND RECHARGÌNG
AÌR CONDÌTÌONÌNG
REPAÌRS 82-3
REPAÌ RS
AIR CONDITIONING RELAY MODULE
´÷ 82.20.01
Remove
1. Remove bolt securing relay module mounting
bracket to body.
2. Release mounting bracket from body.
3. Disconnect 2 multiplugs from relay module.
4. Remove relay module from vehicle.
5. Remove mounting bracket from relay module.
Refit
1. Fit mounting bracket to relay module.
2. Position relay module and connect multiplugs.
3. Fit relay module to body, fit bolt and tighten to9
Nm.
COMPRESSOR - K-SERIES
´÷ 82.10.20
Remove
1. Recover refrigerant from A/C system. See AIR
CONDITIONING, Adjustments.
2. Disconnect battery earth lead.
3. Remove front beam. See FRONT
SUSPENSION, Repairs.
4. Remove alternator. See ELECTRICAL, Repairs.
5. Disconnect multiplug from compressor clutch.
6. Remove bolt securing A/C pipe union to
compressor.
7. Release A/C pipe union from compressor.
8. Remove and discard 2 'O' rings from
compressor.
CAUTION: ImmediateIy cap aII air
conditioning pipes to prevent ingress of dirt
and moisture into the system.
9. Remove top bolt securing compressor to support
housing.
10. Remove 2 bolts securing compressor to support
housing.
11. Manoeuvre compressor from mounting bracket
and remove from beneath vehicle.
AÌR CONDÌTÌONÌNG
82-4 REPAÌRS
Fitting a new compressor:
12. 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 should always have its
sealing cap in place and must not be removed
until immediately prior to fitting. A new
compressor is supplied with an oil fill quantity
(Xcm
3
) of 135 cm
3
. A calculated quantity of oil
must be drained from a new compressor before
fitting. To calculate the quantity to be drained:
13. Remove the drain plug from the old compressor.
14. Ìnvert compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotating the
compressor clutch plate will assist complete
draining.
15. Note the quantity of oil drained (Ycm
3
)
16. Calculate the quantity of oil to be drained from the
NEW compressor using the following formula:
Xcm
3
- (Ycm
3
+ 20 cm
3
) = Qcm
3
17. Remove drain plug from new compressor and
drain Qcm
3
of oil. Fit and tighten compressor
drain plug.
Fitting an existing compressor:
18. 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: Sanden SP-
10 Unipart SP-10
CAUTION: Do not use any other type of
refrigerant oiI. Refrigerant oiI easiIy absorbs
water and must not be stored for Iong
periods. Do not pour unused oiI back into the
container.
Refit
1. Position compressor and manoeuvre onto
mounting bracket.
2. Fit bolts securing compressor to support housing
and tighten to 25 Nm.
3. Fit upper bolt and tighten to 25 Nm.
4. Clean compressor and pipe connections.
5. Remove caps from compressor and pipe
connections.
6. Lubricate 2 new 'O' rings with refrigerant oil and
fit to compressor.
7. Position A/C pipe union to compressor, fit
securing bolt and tighten to 35 Nm.
8. Connect multiplug to compressor clutch.
9. Fit front beam. See FRONT SUSPENSION,
Repairs.
10. Fit alternator. See ELECTRICAL, Repairs.
11. Replace receiver/dryer. See AIR
CONDITIONING, Repairs.
12. Connect battery earth lead.
13. Recharge A/C system. See AIR
CONDITIONING, Adjustments.
AÌR CONDÌTÌONÌNG
REPAÌRS 82-5
COMPRESSOR - 'L' SERIES
´÷ 82.10.20
Remove
1. Recover refrigerant from A/C system. See AIR
CONDITIONING, Adjustments.
2. Disconnect battery earth lead.
3. Remove front beam. See FRONT
SUSPENSION, Repairs.
4. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
5. Remove bolt securing A/C low pressure pipe to
alternator upper mounting bracket.
6. Disconnect multiplug from compressor clutch.
7. Remove bolt securing A/C pipe union to
compressor.
8. Release A/C pipe union from compressor.
9. Remove and discard 2 'O' rings from
compressor.
CAUTION: ImmediateIy cap aII air
conditioning pipes to prevent ingress of dirt
and moisture into the system.
10. Remove 3 bolts and remove compressor.
Fitting a new compressor:
11. 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 should always have its
sealing cap in place and must not be removed
until immediately prior to fitting. A new
compressor is supplied with an oil fill quantity
(Xcm
3
) of 135 cm
3
. A calculated quantity of oil
must be drained from a new compressor before
fitting. To calculate the quantity to be drained:
12. Remove the drain plug from the old compressor.
13. Ìnvert compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotating the
compressor clutch plate will assist complete
draining.
14. Note the quantity of oil drained (Ycm
3
)
15. Calculate the quantity of oil to be drained from the
NEW compressor using the following formula:
Xcm
3
- (Ycm
3
+ 20cm
3
) = Qcm
3
16. Remove drain plug from new compressor and
drain Qcm
3
of oil. Fit and tighten compressor
drain plug.
Fitting an existing compressor:
17. 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: Sanden SP-
10 Unipart SP-10
CAUTION: Do not use any other type of
refrigerant oiI. Refrigerant oiI easiIy absorbs
water and must not be stored for Iong
periods. Do not pour unused oiI back into the
container.
AÌR CONDÌTÌONÌNG
82-6 REPAÌRS
Refit
1. Clean compressor and mating face.
2. Fit compressor and tighten bolts to 25 Nm.
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 compressor.
6. Position A/C pipe union to compressor, fit bolt
and tighten to 35 Nm.
7. Fit bolt securing A/C pipe to alternator bracket
and tighten to 10 Nm.
8. Connect multiplug to compressor.
9. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
10. Fit front beam. See FRONT SUSPENSION,
Repairs.
11. Replace receiver/dryer. See AIR
CONDITIONING, Repairs.
12. Connect battery earth lead.
13. Recharge A/C system. See AIR
CONDITIONING, Adjustments.
CONDENSER FAN AND MOTOR
´÷ 82.15.01
Remove
1. Disconnect battery earth lead.
2. Remove front bumper valance. See EXTERIOR
FITTINGS, Repairs.
3. Remove 4 bolts securing bumper armature and
remove armature.
Models with automatic gearbox:
4. Remove 3 bolts securing oil cooler and tie oil
cooler aside.
AÌR CONDÌTÌONÌNG
REPAÌRS 82-7
All models:
5. Remove 3 bolts securing bonnet lock and
position bonnet lock aside.
6. Remove 3 bolts securing bonnet locking platform
support bracket and remove bracket.
7. Disconnect cooling fan multiplug.
8. Remove 2 bolts securing cooling fan assembly
mounting brackets and remove mounting
brackets.
9. Ease assembly forward and remove 2 bolts
securing cooling fan assembly to condenser.
10. Release cooling fan assembly from condenser
and remove cooling fan assembly.
Do not carry out further dismantling if component
is removed for access only.
11. Release harness and harness multiplug from
retaining clips.
12. Remove 3 nuts securing cooling fan, and remove
cooling fan.
13. Position cooling fan, fit nuts and tighten to 9 Nm.
14. Secure harness in retaining clips.
Refit
1. Position cooling fan assembly to condenser.
2. Fit bolts securing cooling fan assembly to
condenser and tighten to 9 Nm.
3. Position cooling fan assembly support brackets,
fit bolts and tighten to 9 Nm.
4. Connect cooling fan multiplug.
5. Position bonnet locking platform support bracket,
fit bolts and tighten to 9 Nm.
6. Position bonnet lock, fit bolts and tighten to 10
Nm.
Models with automatic gearbox:
7. Position oil cooler, fit bolts and tighten to 9 Nm.
All models:
8. Position bumper armature, fit bolts and tighten to
10 Nm.
9. Fit front bumper valance. See EXTERIOR
FITTINGS, Repairs.
10. Connect battery earth lead.
AÌR CONDÌTÌONÌNG
82-8 REPAÌRS
CONDENSER
´÷ 82.15.07
Remove
1. Disconnect battery earth lead.
2. Recover refrigerant from A/C system. See AIR
CONDITIONING, Adjustments.
3. Remove condenser cooling fan assembly. See
AIR CONDITIONING, Repairs.
4. Remove 2 bolts securing A/C pipes to condenser.
5. Disconnect 2 A/C pipes from condenser.
6. Remove and discard 2 'O' rings from A/C pipe
connections.
7. Remove condenser.
CAUTION: ImmediateIy cap aII air
conditioning pipes to prevent ingress of dirt
and moisture into the system.
Refit
1. Clean A/C pipe connections.
2. Lubricate new 'O' rings with refrigerant oil and fit
to A/C pipes.
3. Remove caps from new condenser and fit to old
condenser.
4. Position condenser to body, remove caps from A/
C pipes and connect to condenser.
5. Fit bolts securing A/C pipes to condenser and
tighten to 6 Nm.
6. Fit condenser cooling fan assembly. See AIR
CONDITIONING, Repairs.
7. Replace receiver/dryer. See AIR
CONDITIONING, Repairs.
8. Recharge A/C system. See AIR
CONDITIONING, Adjustments.
9. Connect battery earth lead.
RECEIVER/ DRIER
´÷ 82.17.03
Remove
1. Recover refrigerant from A/C system. See AIR
CONDITIONING, Adjustments.
2. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
3. Disconnect multiplug from refrigerant pressure
sensor.
4. Remove 2 bolts securing receiver/drier mounting
bracket to body.
AÌR CONDÌTÌONÌNG
REPAÌRS 82-9
5. Remove 2 bolts securing A/C pipe connections to
receiver/drier.
6. Disconnect A/C pipe connections from receiver/
drier and remove receiver drier.
7. Remove and discard 2 'O' rings from A/C pipe
connections.
CAUTION: ImmediateIy cap aII air
conditioning pipe connections to prevent the
ingress of dirt and moisture into the system.
8. Remove refrigerant pressure sensor.
9. Remove and discard 'O' ring from refrigerant
pressure sensor.
10. Loosen 2 screws securing mounting bracket to
receiver/drier.
11. Remove mounting bracket from receiver/drier.
12. Discard receiver/drier.
Refit
1. Fit mounting bracket to receiver/drier and tighten
screws.
2. Remove caps from new receiver/drier.
3. Clean mating faces of refrigerant pressure
sensor and receiver/drier.
4. Lubricate new 'O' ring with refrigerant oil and fit to
refrigerant pressure sensor.
5. Fit refrigerant pressure sensor to receiver/drier
and tighten to 12 Nm.
6. Clean receiver/drier and A/C pipe connections.
7. Lubricate new 'O' rings with clean refrigerant oil
and fit to A/C pipe connections.
8. Remove caps from A/C pipe connections
9. Position receiver/drier and connect A/C pipes.
10. Fit bolts securing A/C pipes to receiver/drier and
tighten to 6 Nm.
11. Align receiver/drier mounting bracket to body, fit
bolts and tighten to 10 Nm.
12. Connect multiplug to refrigerant pressure sensor.
13. Fit front bumper. See EXTERIOR FITTINGS,
Repairs.
14. Recharge A/C system. See AIR
CONDITIONING, Adjustments.
AÌR CONDÌTÌONÌNG
82-10 REPAÌRS
AIR CONDITIONING SWITCH
´÷ 82.20.07
Remove
1. Release air conditioning switch from centre
console.
2. Disconnect multiplug from rear of switch.
3. Remove switch.
Refit
1. Position switch to centre console and connect
multiplug.
2. Fit switch to centre console.
EVAPORATOR
´÷ 82.25.20
Remove
1. Recover refrigerant from A/C system. See AIR
CONDITIONING, Adjustments.
2. Remove bolts securing expansion tank to
bulkhead and move aside.
3. Remove bolt securing A/C pipes to thermostatic
expansion valve.
4. Release pipes from valve.
5. Remove and discard 2 'O' rings from A/C pipes.
6. Remove 2 Allen screws securing thermostatic
expansion valve to evaporator pipes.
7. Remove valve.
8. Remove expansion valve clamping bracket from
evaporator pipes.
9. Remove glovebox. See INTERIOR TRIM
COMPONENTS, Repairs.
AÌR CONDÌTÌONÌNG
REPAÌRS 82-11
10. Remove 2 bolts securing rail to fascia.
11. Remove rail.
12. Disconnect 2 Lucars from evaporator thermostat.
13. Remove screw securing evaporator to blower
assembly strap.
14. Remove strap.
15. Remove screw securing evaporator to heater
assembly strap.
16. Remove strap.
17. Remove 2 nuts securing evaporator to bulkhead.
18. Remove evaporator.
Do not carry out further dismantling if component
is removed for access only.
19. Remove air filter cover.
20. Remove air filter from evaporator.
21. Remove 5 clips securing casing.
22. Remove 4 screws securing casing.
23. Using a sharp blade, cut foam seals across
casing mating faces.
AÌR CONDÌTÌONÌNG
82-12 REPAÌRS
24. Withdraw temperature sensor probe from
evaporator.
25. Remove upper casing from evaporator.
26. Remove evaporator assembly from lower casing.
27. Clean A/C pipe connections.
Refit
1. Remove caps from new evaporator.
2. Locate evaporator in lower casing.
3. Ìnsert temperature sensor probe 30 mm into
vanes at centre of evaporator.
4. Fit upper casing and secure with clips and
screws.
5. Ìnsert air filter into casing.
6. Fit air filter cover.
7. Manoeuvre evaporator into position between
heater and blower assemblies.
8. Feed drain tube through bulkhead and locate
grommet.
9. Fit nuts securing evaporator casing to bulkhead
and tighten to 10 Nm.
10. Fit strap securing evaporator to heater and
tighten screw.
11. Fit strap securing evaporator to blower and
tighten screw.
12. Connect Lucars to evaporator thermostat.
13. Position fascia rail, fit and tighten bolts to; M6 bolt
to 10 Nm. M8 bolt to 20 Nm.
14. Fit glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
15. Fit expansion valve clamping bracket to
evaporator pipes.
16. Fit thermostatic expansion valve to evaporator
pipes and tighten Allen screws to 10 Nm.
17. Lubricate new 'O' rings with refrigerant oil and fit
to A/C pipes.
18. Fit A/C pipes to valve and tighten bolt to 6 Nm.
19. Position expansion tank to bulkhead and tighten
bolts to 5 Nm.
20. Replace receiver/dryer. See AIR
CONDITIONING, Repairs.
21. Recharge A/C system. See AIR
CONDITIONING, Adjustments.
WÌPERS & WASHERS
REPAÌRS 84-1
WÌPERS & WASHERS REPAÌ RS
WINDSCREEN WASHER RESERVOIR
´÷ 84.10.01
Remove
1. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
2. Position container to collect any fluid loss.
3. Disconnect multiplugs and hoses from washer
pumps.
4. Remove bolt securing reservoir filler neck and
remove filler neck.
5. Remove 3 bolts securing washer reservoir and
remove reservoir.
6. Release pumps from reservoir and remove seals.
Refit
1. Lubricate and fit pump seals to reservoir.
2. Fit pumps to reservoir.
3. Position reservoir and secure with bolts.
4. Connect hoses and multiplugs to pumps.
5. Position filler neck and secure with bolt.
6. Fit front bumper. See EXTERIOR FITTINGS,
Repairs.
WASHER JET - WINDSCREEN
´÷ 84.10.08
Remove
1. Disconnect tube from washer jet.
Models with heated washer jets:
2. Disconnect multiplug from washer jet.
All models:
3. Depress plastic lugs and remove washer jets
from bonnet.
Refit
1. Fit washer jet to bonnet and connect tube.
Models with heated washer jets:
2. Connect multiplug to washer jet.
All models:
3. Adjust jet so that the inside spray is to the centre
of the screen, and the outer spray is to the top of
the screen.
WÌPERS & WASHERS
84-2 REPAÌRS
WASHER PUMP - WINDSCREEN
´÷ 84.10.21
Remove
1. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
2. Position container to collect any fluid loss.
3. Disconnect multiplug and hose from windscreen
washer pump.
4. Release pump from reservoir and remove seal.
Refit
1. Lubricate and fit pump seal to reservoir.
2. Fit pump to reservoir.
3. Connect hose and multiplug to pump.
4. Refit front bumper. See EXTERIOR FITTINGS,
Repairs.
5. Refill washer reservoir.
WINDSCREEN WIPER ARM
´÷ 84.15.02
Remove
1. Remove wiper spindle nut.
2. Remove wiper arm from spindle.
Do not carry out further dismantling if component
is removed for access only.
3. Remove wiper blade. See WIPERS &
WASHERS, Repairs.
Refit
1. Fit wiper blade to arm, check blade is retained.
2. Fit wiper arm to spindle. Set blades to dimension
'A' 37 mm, or dimension 'B' 40 mm.
3. Fit nut and tighten to 10 Nm.
WÌPERS & WASHERS
REPAÌRS 84-3
WINDSCREEN WIPER BLADE
´÷ 84.15.06
Remove
1. Lift wiper arm from screen.
2. Press retaining lever.
3. Slide blade down arm and withdraw.
Refit
1. Position new blade to wiper arm.
2. Push blade into engagement with arm. Check
blade is retained.
3. Lower wiper arm onto screen.
WINDSCREEN WIPER MOTOR
´÷ 84.15.12
Remove
1. Disconnect battery earth lead.
2. Remove 3 bolts securing wiper motor bracket to
bulkhead.
3. Move wiper motor and bracket aside to gain
access to nut securing linkage to motor.
4. Remove nut securing linkage to motor.
5. Release clip securing harness to wiper motor
bracket.
6. Disconnect harness multiplug from wiper motor.
WÌPERS & WASHERS
84-4 REPAÌRS
7. Remove wiper motor and bracket.
8. Remove 3 bolts securing wiper motor to bracket.
9. Remove wiper motor from bracket.
Refit
1. Fit wiper motor to bracket and tighten bolts to 5
Nm.
2. Connect harness multiplug to wiper motor.
3. Secure harness to wiper motor bracket with clip.
4. Fit linkage to wiper motor and tighten nut to 10
Nm.
5. Fit bolts securing wiper motor bracket to
bulkhead.
6. Connect battery earth lead.
WINDSCREEN WIPER LINKAGE
´÷ 84.15.26
Remove
1. Remove air intake plenum. See HEATING &
VENTILATION, Repairs.
2. Remove nut securing wiper linkage to wiper
motor.
3. Remove 6 bolts securing wiper linkage to
bulkhead.
4. Withdraw wiper linkage from body.
Refit
1. Position wiper linkage in body.
2. Fit bolts securing wiper linkage to scuttle and
tighten to 10 Nm.
3. Fit nut securing linkage to wiper motor and
tighten to 10 Nm.
4. Fit air intake plenum. See HEATING &
VENTILATION, Repairs.
WÌPERS & WASHERS
REPAÌRS 84-5
WINDSCREEN WASHER AND WIPER
SWITCH
´÷ 84.15.34
Remove
1. Remove steering column switch pack. See
ELECTRICAL, Repairs.
2. Remove 2 screws securing washer and wiper
switch to switch pack.
3. Depress retaining tag and remove washer and
wiper switch assembly.
Refit
1. Fit washer and wiper switch assembly and
secure with screws.
2. Fit steering column switch pack. See
ELECTRICAL, Repairs.
REAR SCREEN WASHER JET
´÷ 84.30.09
Remove
1. Release washer jet from spindle and remove
from wiper arm.
Refit
1. Fit washer jet to rear wiper arm.
WÌPERS & WASHERS
84-6 REPAÌRS
REAR SCREEN WIPER ARM
´÷ 84.35.01
Remove
1. Raise rear screen washer jet and remove nut.
2. Remove wiper arm.
3. Remove wiper blade. See WIPERS &
WASHERS, Repairs.
Refit
1. Fit wiper blade. See WIPERS & WASHERS,
Repairs.
2. Operate the motor and then switch off. Ensure
spindle is in 'park' position.
3. Fit wiper arm, tighten nut to 10 Nm. Fit rear
screen washer jet.
NOTE: Position end of wiper blade to alignment
mark on screen.
REAR SCREEN WIPER BLADE
´÷ 84.35.02
Remove
1. Lift wiper arm from rear screen.
2. Press retaining lever and slide blade down arm.
Refit
1. Position new blade to wiper arm.
2. Push blade into engagement with arm. Check
blade is retained.
3. Lower wiper arm onto rear screen.
WÌPERS & WASHERS
REPAÌRS 84-7
REAR SCREEN WIPER MOTOR
´÷ 84.35.12
Remove
1. Remove tailgate trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
2. Remove rear wiper arm. See WIPERS &
WASHERS, Repairs.
3. Remove spindle nut cover, spindle nut, flat
washer and rubber seal.
4. Disconnect tailgate harness from wiper motor.
5. Disconnect washer jet tube from wiper motor.
6. Remove 3 bolts and remove wiper motor from
tailgate.
Refit
1. Fit wiper motor to tailgate and tighten bolts to 8
Nm.
2. Connect multiplug to wiper motor.
3. Connect washer jet tube to wiper motor.
4. Fit rubber seal, flat washer and nut. Tighten nut
to2 Nm.
5. Fit nut cover.
6. Fit rear screen wiper arm. See WIPERS &
WASHERS, Repairs.
7. Fit tailgate trim casing. See INTERIOR TRIM
COMPONENTS, Repairs.
WÌPERS & WASHERS
84-8 REPAÌRS
ELECTRÌCAL
ADJUSTMENTS 86-1
ELECTRÌCAL ADJUSTMENTS
HEADLAMPS ADJUST
´÷ 86.40.17
NOTE: Ensure headlamp beam height control switch is
set to zero before inspection.
Inspect
1 Align suitable beam setting equipment to
headlamp.
2 Switch on headlamps. headlamp setting = 1.2%
below horizontal and parallel.
Adjust
1. Adjust headlamp using a 6 mm Allen key.
2. Turn Allen screw for vertical alignment.
3. Turn Allen screw for horizontal alignment.
4. Align beam setting equipment to 2nd headlamp.
5. Adjust 2nd headlamp as detailed in steps 1 to 3
above.
6. Switch off headlamps.
7. Remove beam setter.
AUXILIARY DRIVE BELT - 'K' SERIES
´÷ 86.10.05
Check
1. Check condition of drive belt, renew a drive belt
that shows signs of wear and splitting.
2. Apply a force of 10 kg to the drive belt at position
'X' and measure the deflection between the
crankshaft pulley and alternator pulley.
Deflection must be 6 - 8 mm.
ELECTRÌCAL
86-2 ADJUSTMENTS
Adjust
1. Loosen 2 alternator mounting bolts.
2. Loosen adjusting strap bolt.
3. Ìncrease drive belt tension by turning the tension
adjusting bolt clockwise.
CAUTION: Do not appIy excessive torque to
adjusting boIt. If adjusting boIt is seized,
appIy suitabIe anti-seize compound to boIt
threads.
4. Tighten alternator mounting bolts and adjusting
strap bolt to 25 Nm.
5. Recheck drive belt tension.
AUXILIARY DRIVE BELT - 'K' SERIES
WITH A/C
´÷ 86.10.05.20
Check
1. Turn steering to RH lock.
2. Using a socket and extension bar on the
crankshaft pulley bolt, rotate engine a sufficient
number of turns to check condition of drive belt.
Renew a drive belt that shows signs of wear,
splitting or oil contamination.
3. Check belt length, belt must be renewed before
indicator reaches RH end of slot.
ELECTRÌCAL
ADJUSTMENTS 86-3
AUXILIARY DRIVE BELT - 'L' SERIES
´÷ 86.10.05
Check
1. Turn steering to RH lock.
2. Using a socket and extension bar on the
crankshaft pulley bolt, rotate engine a sufficient
number of turns to check condition of drive belt.
Renew a drive belt that shows signs of wear,
splitting or oil contamination.
3. Check belt length, belt must be renewed before
indicator reaches RH end of slot.
ELECTRÌCAL
86-4 ADJUSTMENTS
ELECTRÌCAL
REPAÌRS 86-5
REPAÌ RS
ALTERNATOR - 'K' SERIES
´÷ 86.10.02
Remove
1. Disconnect battery earth lead.
2. Remove cover, remove nut securing cable to
alternator and release cable.
3. Disconnect multiplug from alternator.
4. Remove nut and bolt securing alternator to
adjustment bracket.
5. Loosen bolt securing alternator to engine.
6. Release drive belt tension by turning the tension
adjusting bolt anti-clockwise.
CAUTION: Do not appIy excessive torque to
adjusting boIt. If adjusting boIt is seized,
appIy suitabIe anti-seize compound to boIt
threads.
7. Release drive belt from alternator pulley.
8. Remove nut and bolt securing alternator to
engine.
9. Release alternator from bracket and remove
alternator.
Do not carry out further dismantling if component
is removed for access only.
10. Restraining the alternator shaft with an 8 mm
Allen key, remove nut securing pulley to
alternator shaft using tool 18G 1653.
11. Remove pulley from alternator.
12. Clean pulley and alternator shaft.
13. Fit pulley to alternator shaft.
14. Fit alternator pulley nut, hold shaft with an 8 mm
Allen key and tighten nut to 25 Nm using tool 18G
1653.
Refit
1. Position alternator to engine and locate in
support bracket.
2. Fit nut and bolt securing alternator to engine, but
do not tighten.
3. Clean pulley vee's.
4. Locate drive belt to alternator pulley. Ensure
grooves on drive belt and pulleys are correctly
located.
5. Fit nut and bolt securing alternator to adjustment
bracket.
6. Adjust drive belt tension. See ELECTRICAL,
Adjustments.
7. Connect multiplug and cable to alternator, fit and
tighten cable nut to 8 Nm, position cover..
8. Connect battery earth lead.
ELECTRÌCAL
86-6 REPAÌRS
ALTERNATOR - 'K' SERIES WITH A/C
´÷ 86.10.02/20
Remove
1. Disconnect battery earth lead.
2. Remove manifold heat shield. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
3. Disconnect alternator multiplug, release cover ,
remove nut securing alternator lead and release
lead from alternator.
4. Remove alternator bottom bolt.
5. Release alternator from bracket and remove
alternator.
Refit
1. Position alternator to support bracket and fit
bottom bolt.
2. Connect alternator multiplug, fit alternator lead, fit
and tighten nut to 8 Nm, position cover.
3. Fit exhaust manifold heat shield. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
4. Connect battery earth lead.
ALTERNATOR - 'L' SERIES
´÷ 86.10.02
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
4. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
5. Fit wooden block to jack and position jack to
support engine.
6. Remove through bolt securing RH steady bar to
engine mounting bracket.
7. Remove nut securing RH mounting bracket to
engine mounting.
8. Loosen 2 nuts securing restraint bar to body.
9. Disconnect multiplug from alternator.
ELECTRÌCAL
REPAÌRS 86-7
10. Release cover, remove nut and disconnect
battery cable from alternator.
11. Remove bolt securing brake servo vacuum pipe
to camshaft cover.
12. Release clip and disconnect vacuum hose from
vacuum pump.
13. Place absorbent cloth beneath oil feed pipe, to
contain spill.
14. Loosen union and disconnect oil feed pipe.
15. Remove 3 bolts and alternator upper mounting
bracket.
16. Raise engine on jack to remove alternator bolt.
17. Remove nut and bolt from alternator lower
mounting bracket.
18. Release alternator from mounting, release clip
and remove oil return pipe.
19. Remove alternator from vehicle.
CAUTION: PIug the connections.
20. Transfer vacuum pump to new alternator. See
BRAKES, Repairs.
ELECTRÌCAL
86-8 REPAÌRS
Refit
1. Clean all pipe connections.
2. Fit oil return hose to vacuum pump and secure
with clip, fit alternator to lower mounting bracket.
3. Fit nut and bolt to alternator lower mounting but
do not tighten at this stage.
4. Fit bolts securing alternator upper mounting
bracket to coolant elbow and tighten to 25 Nm .
5. Fit oil feed pipe union to vacuum pump and
tighten union to 12 Nm .
6. Fit and tighten alternator upper mounting bolt to
25 Nm .
7. Tighten alternator lower mounting bolt to 45 Nm.
8. Connect vacuum hose to vacuum pump and
secure hose with clip.
9. Align vacuum pipe bracket to camshaft cover and
tighten bolt.
10. Connect battery cable to alternator stud tighten
nut to 4 Nm and position cover.
11. Connect multiplug to alternator.
12. Lower engine, fit nut securing RH mounting
bracket to engine mounting and tighten to 85 Nm.
13. Tighten engine mounting restraint bar nuts to 45
Nm.
14. Connect steady bar to engine mounting bracket,
fit through bolt and tighten to 80 Nm.
15. Remove jack positioned to support engine.
16. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
17. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
18. Connect battery earth lead.
ALTERNATOR - 'L' SERIES WITH A/C
´÷ 86.10.02.20
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove engine acoustic cover. See ENGINE -
'L' Series, Repairs.
4. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
5. Remove receiver drier. See AIR
CONDITIONING, Repairs.
6. Fit wooden block to jack and position jack to
support engine.
7. Remove through bolt securing RH steady bar to
engine mounting bracket.
8. Remove nut securing RH mounting bracket to
engine mounting.
9. Loosen 2 nuts securing restraint bar to body.
ELECTRÌCAL
REPAÌRS 86-9
10. Remove bolt securing low pressure A/C pipe, to
alternator upper mounting bracket.
11. Disconnect multiplug from alternator.
12. Release cover, remove nut and disconnect
battery cable from alternator.
13. Release clip and remove intake hose from
plenum chamber for access.
14. Remove bolt, release A/C pipes from compressor
and discard 'O' rings.
CAUTION: ImmediateIy cap aII A/C pipes to
prevent ingress of dirt and moisture into the
system.
15. Tie A/C pipe aside to clear alternator.
ELECTRÌCAL
86-10 REPAÌRS
16. Remove bolt securing brake servo vacuum pipe
to camshaft cover.
17. Release clip and disconnect vacuum hose from
vacuum pump.
18. Place absorbent cloth beneath oil feed pipe, to
contain spill.
19. Loosen union and disconnect oil feed pipe.
20. Remove 3 bolts and alternator upper mounting
bracket.
21. Raise engine on jack, remove nut and bolt from
alternator lower mounting bracket.
22. Release alternator from mounting, release clip
and remove oil return pipe.
23. Remove alternator from vehicle.
CAUTION: PIug the connections.
24. Transfer vacuum pump to new alternator. See
BRAKES, Repairs.
ELECTRÌCAL
REPAÌRS 86-11
Refit
1. Clean all pipe connections.
2. Fit oil return hose to vacuum pump and secure
with clip, fit alternator to lower mounting bracket.
3. Fit nut and bolt to alternator lower mounting but
do not tighten at this stage.
4. Fit bolts securing alternator upper mounting
bracket to coolant elbow and tighten to 25 Nm .
5. Fit oil feed pipe union to vacuum pump and
tighten union to 12 Nm.
6. Fit and tighten alternator upper mounting bolt to
25 Nm.
7. Tighten alternator lower mounting bolt to 45 Nm.
8. Connect vacuum hose to vacuum pump and
secure with clip.
9. Align vacuum pipe bracket to camshaft cover and
tighten bolt.
10. Clean A/C pipe connections and compressor
mounting face.
11. Lubricate new 'O' rings with refrigerant oil and fit
to compressor. Connect A/C pipe union to
compressor and tighten bolt to 35 Nm.
12. Fit bolt retaining A/C low pressure pipe, to
alternator upper mounting bracket and tighten
bolt to 10 Nm.
13. Connect battery cable to alternator stud, tighten
nut to 4 Nm and position cover.
14. Connect multiplug to alternator.
15. Lower engine, fit nut securing RH mounting
bracket to engine mounting and tighten to 85 Nm.
16. Tighten engine mounting restraint bar nuts to 45
Nm.
17. Connect steady bar to engine mounting bracket,
fit through bolt and tighten to 80 Nm.
18. Fit air intake hose to plenum and tighten clip.
19. Remove jack positioned to support engine.
20. Fit receiver drier. See AIR CONDITIONING,
Repairs.
21. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
22. Fit engine acoustic cover. See ENGINE - 'L'
Series, Repairs.
23. Connect battery earth lead.
AUXILIARY DRIVE BELT - 'K' SERIES
´÷ 86.10.03
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Remove PAS pump drive belt. See STEERING,
Repairs.
4. Loosen alternator pivot nut and bolt.
5. Loosen bolt securing alternator adjustment
bracket to engine.
6. Loosen nut securing alternator adjustment
bracket.
7. Rotate alternator drive belt adjustment bolt anti-
clockwise to release tension from belt and
remove belt.
CAUTION: Do not appIy excessive torque to
adjusting boIt. If adjusting boIt is seized,
appIy suitabIe anti-seize compound to boIt
threads.
8. Tighten alternator mounting bolts and adjusting
strap bolt to 25 Nm .
ELECTRÌCAL
86-12 REPAÌRS
Refit
1. Ensure pulleys are clean and damage free.
2. Fit new drive belt and adjust tension. See
ELECTRICAL, Adjustments.
3. Fit PAS pump drive belt. See STEERING,
Repairs.
4. Remove stand(s) and lower vehicle.
5. Connect battery earth lead.
AUXILIARY DRIVE BELT - 'K' SERIES -
WITH A/C
´÷ 86.10.03/20
Remove
1. Disconnect battery earth lead.
2. Remove PAS pump drive belt. See STEERING,
Repairs.
3. Fit a 13 mm spanner to hexagon on belt tensioner
and rotate fully clockwise to release tension on
drive belt.
4. To hold tensioner in this position, fit a suitable
pin, not exceeding 3 mm. diameter, into tensioner
backplate.
5. Release drive belt from tensioner, compressor,
alternator and bottom pulley.
6. Remove drive belt.
Refit
1. Clean pulley 'Vs' and ensure pulleys are damage
free.
2. Fit drive belt to compressor, alternator tensioner
and bottom pulley.
3. Release tension on tensioner and remove
retaining pin and allow tensioner pulley to rest on
alternator drive belt.
4. Fit PAS pump drive belt. See STEERING,
Repairs.
5. Connect battery earth lead.
ELECTRÌCAL
REPAÌRS 86-13
AUXILIARY DRIVE BELT - 'L' SERIES
´÷ 86.10.03
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Using a 15 mm ring spanner on drive belt
tensioner pulley bolt, rotate pulley fully clockwise
and hold.
4. With assistance, release drive belt from
alternator pulley.
5. Remove drive belt from remaining pulleys and
remove from vehicle.
Refit
1. Clean drive belt pulley grooves and ensure
grooves are not damaged.
2. Fit new drive belt around pulleys, except
alternator pulley, ensure belt is correctly aligned
in pulley grooves.
3. Hold tensioner pulley fully clockwise, with
assistance fit drive belt around alternator pulley.
4. Remove stand(s) and lower vehicle.
5. Connect battery earth lead.
AUXILIARY DRIVE BELT TENSIONER - 'L'
SERIES
´÷ 86.10.06
Remove
1. Remove auxiliary drive belt. See ELECTRICAL,
Repairs.
2. Remove centre bolt securing tensioner to
mounting bracket.
3. Remove tensioner.
Refit
1. Clean tensioner and mating face.
2. Locate tensioner on dowel. Fit and tighten centre
bolt to 45 Nm.
3. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
ELECTRÌCAL
86-14 REPAÌRS
BATTERY
´÷ 86.15.01
Remove
1. Disconnect both battery leads, earth lead first.
2. Remove bolt securing battery clamp to battery
tray.
3. Remove battery clamp.
4. Release and remove battery from vehicle.
Refit
1. Clean battery terminals and coat with petroleum
jelly.
2. Position battery to battery tray.
3. Fit battery clamp and secure with bolt.
4. Position and connect battery leads, earth lead
last
FRONT DOOR GLASS MOTOR
´÷ 86.25.04
Remove
1. Remove front door glass. See DOORS, Repairs.
2. Disconnect door glass motor multiplug and
release harness clip from door.
NOTE: Mark position of roller guide bolts on door
before removal.
3. Loosen 2 bolts securing regulator to door.
4. Remove 4 bolts securing regulator to door.
5. Release and remove regulator assembly from
door.
NOTE: Before removing power window motor
mark the location by scribing a line across the
sector gear and regulator.
ELECTRÌCAL
REPAÌRS 86-15
6. Using a Torx bit remove 3 screws securing motor
to regulator, then remove the motor.
Refit
1. Apply grease to motor gear and regulator pivot
points.
2. Ensure regulator marks are aligned, position
motor to regulator and tighten screws to 7 Nm.
3. Position and align regulator assembly to door.
4. Fit bolts to secure regulator, tighten to 8 Nm.
5. Align roller guide, fit bolts to align with original
marks and tighten to 8 Nm.
6. Connect motor multiplug, secure clip to door.
7. Refit front door glass. See DOORS, Repairs.
ELECTRIC WINDOW SWITCH
´÷ 86.25.07
Remove
1. Remove finisher from centre console.
2. Disconnect multiplug from switch.
3. Remove 2 screws securing switch to finisher.
4. Remove switch from finisher.
Refit
1. Fit switch to finisher and secure with screws.
2. Connect multiplug to switch.
3. Fit finisher to centre console.
ELECTRÌCAL
86-16 REPAÌRS
WINDOW LIFT ECU
´÷ 86.25.39
Remove
1. Remove front console. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Remove 2 scrivets securing window lift ECU to
fascia frame.
3. Disconnect 2 multiplugs from ECU and remove
ECU.
Refit
1. Position ECU to fascia and connect multiplugs.
2. Position ECU, connect multiplugs, secure ECU to
fascia frame with scrivits.
3. Fit front console. See INTERIOR TRIM
COMPONENTS, Repairs.
ELECTRÌCAL
REPAÌRS 86-17
FRONT DOOR LOCK MOTOR
´÷ 86.26.08
Remove
1. Remove front door outside handle. See
EXTERIOR FITTINGS, Repairs.
2. Release clip and remove outside handle control
rod from latch.
3. Release private lock control rod from latch.
4. Remove 3 screws securing inside door handle to
door.
5. Release inside door handle control rod from
handle.
6. Remove bolt securing door glass rear channel to
door.
7. Disconnect multiplug from lock.
8. Remove 3 Torx screws securing latch to door.
9. Push rear channel forward and remove latch from
door.
10. Remove inside door handle and sill button control
rod from latch.
Refit
1. Fit inside door handle and sill button control rod
to latch.
2. Position latch to door and tighten Torx screws to6
Nm.
3. Align rear channel and tighten bolt to 8 Nm.
4. Connect lock multiplug.
5. Fit control rod to inside door handle.
6. Fit inside handle to door and tighten screws.
7. Fit private lock control rod to latch.
8. Fit outside handle control rod to latch and secure
with clip.
9. Fit front door outside handle. See EXTERIOR
FITTINGS, Repairs.
ELECTRÌCAL
86-18 REPAÌRS
REAR DOOR LOCK MOTOR
´÷ 86.26.09
Remove
1. Remove rear door outside handle. See DOORS,
Repairs.
2. Remove screw securing rear door interior handle
to door.
3. Release interior handle and sill locking button
control rods from lock motor.
4. Remove 3 Torx screws securing lock motor to
door.
5. Disconnect multiplug from lock motor.
6. Remove lock motor from door.
Refit
1. Position lock motor to door and connect
multiplug.
2. Connect interior handle and sill locking button
control rods to lock motor.
3. Position lock motor in door. Fit Torx screws and
tighten to 7 Nm.
4. Fit interior handle to door and secure with screw.
5. Fit rear door outside handle. See DOORS,
Repairs.
ELECTRÌCAL
REPAÌRS 86-19
HORN SWITCH
´÷ 86.30.01
Remove
1. Remove drivers airbag module. See
RESTRAINT SYSTEMS, Repairs.
2. Release earth connector from steering wheel
base.
3. Disconnect multiplug from steering column rotary
coupler.
4. Using a flat blade carefully ease switch from
steering wheel.
5. Disconnect 2 Lucars from switch.
6. Remove horn switch.
Refit
1. Position horn switch and connect 2 Lucars to
switch.
2. Fit switch to steering wheel.
3. Connect multiplug to rotary coupler.
4. Secure earth connector to steering wheel base.
5. Fit drivers airbag module. See RESTRAINT
SYSTEMS, Repairs.
HORN
´÷ 86.30.10
Remove
1. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
2. Disconnect multiplug from horn.
3. Remove nut securing horn to mounting bracket.
4. Remove horn.
Refit
1. Position horn to mounting bracket and tighten nut
to 10 Nm.
2. Connect multiplug to horn.
3. Fit front bumper. See EXTERIOR FITTINGS,
Repairs.
ELECTRÌCAL
86-20 REPAÌRS
LAMP ASSEMBLY - FRONT FLASHER
´÷ 86.40.42
Remove
1. Release clip and remove lamp from front bumper.
2. Disconnect multiplug and remove front flasher
lamp.
Refit
1. Positon front flasher lamp and connect multiplug.
2. Fit lamp to front bumper and secure clip.
HEADLAMP ASSEMBLY
´÷ 86.40.49
Remove
1. Remove front bumper. See EXTERIOR
FITTINGS, Repairs.
2. Remove 3 bolts securing headlamp to bonnet
locking platform and inner wing.
3. Disconnect headlamp and headlamp leveling
motor multiplugs.
4. Remove headlamp assembly.
5. Remove both bulb covers.
ELECTRÌCAL
REPAÌRS 86-21
6. Remove sidelamp bulb holder from headlamp.
7. Remove bulb from sidelamp bulb holder.
8. Disconnect multiplug from dip beam headlamp
bulb.
9. Release retaining clip and remove headlamp dip
beam bulb
10. Disconnect multiplug from driving lamp bulb.
11. Release retaining clip and remove driving lamp
bulb.
12. Release headlamp leveling motor and remove
motor.
Refit
1. Position headlamp leveling motor and engage in
retainer.
2. Fit driving lamp bulb and secure with clip.
3. Connect Lucar connector to driving lamp bulb.
4. Fit headlamp dip beam bulb and secure with clip.
5. Connect multiplug to headlamp dip beam bulb.
6. Fit side lamp bulb to holder.
7. Fit side lamp bulb holder to headlamp assembly.
8. Fit both bulb dust covers.
9. Position headlamp and connect multiplug.
10. Fit headlamp to bonnet locking platform and
tighten bolts to 10 Nm.
11. Fit front bumper. See BODY, Repairs.
ELECTRÌCAL
86-22 REPAÌRS
SIDE REPEATER
´÷ 86.40.53
Remove
1. Carefully slide repeater lamp; LH lamp rearward,
RH lamp forward, to compress clip and remove
lamp from front wing.
2. Rotate bulb holder anti-clockwise and remove
lamp lens. Remove 'O' ring.
Refit
1. Fit 'O' ring to bulb holder.
2. Fit lens to bulb holder and fit lamp to front wing.
NOTE: Lamp vent hole must face down.
LAMP ASSEMBLY - TAIL
´÷ 86.40.70
Remove
1. Release 2 trim studs securing luggage
compartment carpet to body and move carpet
aside.
2. Disconnect multiplug from tail lamp.
3. Remove 3 nuts securing tail lamp to body.
4. Position rear wiper relay aside.
5. Remove tail lamp.
Refit
1. Fit tail lamp to body.
2. Position rear wiper relay to tail lamp.
3. Fit nuts to secure tail lamp to body and tighten
evenly.
4. Connect multiplug to tail lamp.
5. Reposition luggage compartment carpet and
secure with trim stud.
ELECTRÌCAL
REPAÌRS 86-23
NUMBER PLATE LAMP
´÷ 86.40.86
Remove
1. Remove 2 screws securing lamp to applique.
2. Withdraw lamp from applique and disconnect 2
Lucar connectors.
Refit
1. Position lamp to applique and connect lucars.
2. Fit and tighten screws securing lamp to applique.
LAMP - FRONT FOG
´÷ 86.40.96
Remove
1. Remove finisher from front bumper.
2. Remove 3 screws securing lamp to front bumper.
3. Release lamp from bumper and disconnect
multiplug.
4. Remove fog lamp.
Refit
1. Position front fog lamp and connect multiplug.
2. Fit lamp to bumper and secure with screws.
3. Fit fog lamp finisher to bumper.
ELECTRÌCAL
86-24 REPAÌRS
LAMP ASSEMBLY - CENTRE HIGH
MOUNTED STOP
´÷ 86.41.32
Remove
1. Remove tailgate spoiler.See INTERIOR TRIM
COMPONENTS, Repairs.
2. Drill two 10 mm. holes in marked indents to
access CHMSL screws.
3. Using a long magnetic screwdriver, remove 2
screws securing CHMSL, feed CHMSL lead
through spoiler and remove CHMSL.
Refit
1. Position CHMSL and feed lead through spoiler.
2. Fit and tighten screws securing CHMSL.
3. Cover holes in indents with waterproof tape.
4. Fit tailgate spoiler.See INTERIOR TRIM
COMPONENTS, Repairs.
INTERIOR LIGHT
´÷ 86.45.02
Remove
1. Carefully prise out the lens from the light housing.
2. Remove 2 bolts securing interior light to roof.
3. Disconnect multiplug and remove interior light.
Refit
1. Position interior light to roof and connect
multiplug.
2. Fit and tighten bolts securing interior light to roof.
3. Fit lens to interior light.
ELECTRÌCAL
REPAÌRS 86-25
GLOVEBOX LAMP
´÷ 86.45.08
Remove
1. Open glovebox.
2. Release lamp from fascia.
3. Disconnect 2 Lucar connectors and remove
lamp.
Refit
1. Position lamp to fascia and connect Lucars.
2. Fit lamp to fascia.
3. Close glovebox.
LUGGAGE COMPARTMENT LAMP
´÷ 86.45.16
Remove
1. Release luggage compartment lamp from parcel
tray support panel.
2. Disconnect 2 Lucar connectors and remove
lamp.
Refit
1. Position lamp to support panel and connect
Lucars.
2. Fit lamp to support panel.
ELECTRÌCAL
86-26 REPAÌRS
HEATER CONTROL ILLUMINATION BULB
´÷ 86.45.41
Remove
1. Remove front console. See INTERIOR TRIM
COMPONENTS, Repairs.
2. Remove knobs from fresh air and air recirculation
controls.
3. Remove 4 screws securing heater control panel
to fascia and lower control panel.
4. Remove knobs from heater controls.
5. Remove 2 screws securing faceplate to heater
controls.
6. Release 6 clips securing faceplate to heater
controls and release faceplate.
7. Remove bulbs from rear of faceplate.
Refit
1. Fit bulbs to rear of heater control faceplate.
2. Position faceplate to heater control and secure
with clips.
3. Fit and tighten screws securing faceplate to
heater controls.
4. Fit and tighten screws securing heater controls to
fascia.
5. Fit knobs to heater controls.
6. Fit front console. See INTERIOR TRIM
COMPONENTS, Repairs.
ELECTRÌCAL
REPAÌRS 86-27
INSTRUMENT PACK ILLUMINATION
BULB
´÷ 86.45.48
Remove
1. Remove instrument pack. See INSTRUMENTS,
Repairs.
2. Remove bulb from rear of instrument pack.
Refit
1. Fit bulb to rear of instrument pack.
2. Fit instrument pack. See INSTRUMENTS,
Repairs.
RADIO
´÷ 86.50.03
Remove
1. Fit radio removal tools SMD 4091 to release
retaining clips. Pull on tool to release radio from
fascia.
2. Disconnect multiplugs and aerial lead. Remove
radio.
Refit
1. Position radio to aperture. Connect multiplugs
and aerial lead.
2. Slide radio into fascia until retaining clips engage.
3. Enter security code and check radio for correct
operation.
ELECTRÌCAL
86-28 REPAÌRS
REAR SPEAKER
´÷ 86.50.12
Remove
1. Disconnect multiplug from rear speaker.
2. Remove 4 screws securing rear speaker to
parcel tray support panel.
3. Remove speaker.
Refit
1. Position speaker to parcel tray support panel and
fit and tighten screws.
2. Connect multiplug to speaker.
REMOTE ICE CONTROLS
´÷ 86.50.13
Remove
1. Disconnect battery earth lead.
2. Remove both horn switches. See ELECTRICAL,
Repairs.
3. Release multiplug from rotary coupler.
4. Remove 2 screws securing remote controls to
steering wheel.
5. Release remote controls from steering wheel.
6. Remove controls and harness from steering
wheel.
Refit
1. Fit harness to steering wheel and secure remote
controls to steering wheel.
2. Fit and tighten screws securing controls to
steering wheel.
3. Connect multiplug to rotary coupler.
4. Fit both horn switches. See ELECTRICAL,
Repairs.
5. Connect battery earth lead.
ELECTRÌCAL
REPAÌRS 86-29
FRONT SPEAKER
´÷ 86.50.15
Remove
1. Remove front door trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
2. Remove 3 screws securing speaker to door.
3. Release speaker from door and disconnect
multiplug.
Refit
1. Connect multiplug to speaker and position to
door.
2. Fit screws securing speaker to door.
3. Fit front door trim casing. See INTERIOR TRIM
COMPONENTS, Repairs.
AERIAL
´÷ 86.50.18
Remove
1. Remove aerial from aerial base.
2. Remove both 'A' post upper trim casings. See
INTERIOR TRIM COMPONENTS, Repairs.
3. Remove 2 screws securing each sun visor to
roof.
4. Remove both sun visors.
5. Remove 2 screws securing both sun visor clips.
6. Remove clips.
ELECTRÌCAL
86-30 REPAÌRS
7. Remove 2 trim studs securing headlining to roof.
Models with sun roof:
8. Release sun roof switch finisher from headlining
and remove.
9. Remove sun roof finisher.
All models:
10. Carefully lower front edge of headlining to gain
access to aerial.
Models with sun roof:
11. Remove 2 screws securing sun roof switch
mounting to roof and remove mounting.
All models:
12. Remove cover from end of coaxial cable.
13. Remove nut securing coaxial cable to aerial
base.
14. Remove aerial base.
Refit
1. Fit aerial base to roof.
2. Fit and tighten nut securing aerial base to roof.
3. Connect coaxial cable to aerial base and fit
cover.
Models with sun roof:
4. Position sun roof switch mounting and secure
with screws.
All models:
5. Position front of headlining to roof and secure
with trim studs.
Models with sun roof:
6. Fit sun roof finisher.
7. Position sun roof switch finisher and secure to
headlining.
All models:
8. Fit sun visor clips to headlining and secure with
screws.
9. Fit sun visors to headlining and secure with
screws.
10. Fit 'A' post upper trim casings. See INTERIOR
TRIM COMPONENTS, Repairs.
11. Fit aerial to aerial base.
ELECTRÌCAL
REPAÌRS 86-31
COAXIAL CABLE
´÷ 86.50.24
Remove
1. Fit radio removal tools SMD 4091 to release
retaining clips. Pull on tools to release radio from
fascia.
2. Disconnect coaxial cable from radio.
3. Remove glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
4. Release coaxial cable from 2 clips on heater/
blower assembly.
5. Remove both 'A' post upper trim casings. See
INTERIOR TRIM COMPONENTS, Repairs.
6. Release coaxial cable from 3 clips on LH 'A' post.
7. Remove 2 screws securing each sun visor to
roof.
8. Remove both sun visors.
9. Remove 2 screws securing both sun visor clips.
10. Remove clips.
ELECTRÌCAL
86-32 REPAÌRS
11. Remove 2 trim studs securing headlining to roof.
Models with sun roof:
12. Release sun roof switch finisher from headlining
and remove.
13. Remove sun roof finisher.
All models:
14. Carefully lower front edge of headlining to gain
access to aerial.
15. Release coaxial cable from clip on roof.
Models with sun roof:
16. Remove 2 screws securing sun roof switch
mounting to roof and remove mounting.
All models:
17. Remove cover from end of coaxial cable.
18. Remove nut securing coaxial cable to aerial
base.
19. Release coaxial cable from aerial base.
20. Remove coaxial cable.
Refit
1. Feed coaxial cable through roof aperture, down
LH 'A' post and behind fascia.
2. Fit and tighten nut securing coaxial cable to aerial
base.
3. Fit cover to coaxial cable.
4. Secure coaxial cable to clip on roof.
Models with sun roof:
5. Position sun roof switch mounting and secure
with screws.
All models:
6. Position front of headlining to roof and secure
with trim studs.
ELECTRÌCAL
REPAÌRS 86-33
Models with sun roof:
7. Fit sun roof finisher.
8. Position sun roof switch finisher and secure to
headlining.
All models
9. Fit sun visor clips to headlining and secure with
screws.
10. Fit sun visors to headlining and secure with
screws.
11. Secure coaxial cable to clips on 'A' post.
12. Fit 'A' post upper trim casings. See INTERIOR
TRIM COMPONENTS, Repairs.
13. Fit seals to front door apertures.
14. Secure coaxial cable to clips on heater blower
assembly.
15. Connect coaxial cable to radio.
16. Slide radio into fascia until retaining clips engage.
17. Fit glove box. See INTERIOR TRIM
COMPONENTS, Repairs.
TWEETER - FRONT DOOR
´÷ 86.50.34
Remove
1. Remove front door trim casing. See INTERIOR
TRIM COMPONENTS, Repairs.
2. Rotate tweeter and remove from door trim
casing.
Refit
1. Fit tweeter to door trim casing and rotate to
secure.
2. Fit front door trim casing. See INTERIOR TRIM
COMPONENTS, Repairs.
ELECTRÌCAL
86-34 REPAÌRS
CD PLAYER
´÷ 86.50.81
Remove
1. Disconnect battery earth lead.
2. Release access tab from each side of unit.
3. Using a 2.5 mm Allen key, slacken 2 captive
screws securing unit.
4. Withdraw unit sufficiently to gain access to
multiplugs and aerial lead.
CAUTION: Take care not to damage face of
unit.
5. Noting their fitted positions, disconnect 2
multiplugs and aerial lead plug; remove unit.
Refit
1. Position unit, connect 2 multiplugs and aerial lead
plug.
2. Fit unit, tighten 2 captive screws.
3. Secure access tab to each side of unit.
4. Connect battery earth lead.
5. Enter security code and check unit for correct
operation.
NAVIGATION SYSTEM - BECKER
´÷ 86.53.08
Remove
1. Disconnect battery earth lead.
2. Ìnsert Becker removal tools into slots to
disengage retaining tags. Release unit from
fascia.
3. Disconnect multiplugs, aerial lead and GPS
coaxial cable from back of navigation unit.
Remove navigation unit.
4. Remove instrument pack. See INSTRUMENTS,
Repairs.
SP86 0208
TOP L
T O P R
ELECTRÌCAL
REPAÌRS 86-35
5. Remove cable ties securing GPS antenna to
harness.
6. Release GPS antenna base plate from Velcro
fixing and remove.
Refit
1. Attach GPS antenna base plate to inner fascia
shelf behind instrument pack using supplied self
adhesive Velcro.
2. Attach magnetic GPS antenna to base plate.
3. Feed GPS coaxial cable to audio unit aperature.
Ensure cable is routed around rear of support
plate and secure with cable ties.
4. Fit instrument pack. See INSTRUMENTS,
Repairs.
5. Fit rubber support to stud on rear of audio unit.
6. Position audio unit, connect aerial cable, GPS
antenna cable and multiplugs.
7. Slide audio unit into cage until retaining clips
engage. Ensure that rubber support stud locates
in rear support plate.
NOTE: The springs on the navigation unit can be
adjusted for correct fitment using the removal
tools supplied - refer to removal/installation
guide.
8. Connect battery earth lead.
9. Activate navigation unit and input security code
provided.
10. Check navigation unit including CD player for
correct operation and program suitable radio
stations on all presets.
11. Set the system ready for the customer to carry
out calibration road test as laid out in the
accompanying documents.
ELECTRÌCAL
86-36 REPAÌRS
CONTROL UNIT (ECU) - PARKING AID
´÷ 86.54.10
Remove
1. Remove parcel tray.
2. Release catch and fold rear seat forward.
3. Remove 1 scrivet from RH side luggage
compartment trim.
4. Remove 1 screw from RH wheel arch trim finisher
above suspension turret.
5. Fold back RH side luggage compartment trim to
allow access to PDC bracket.
6. Remove multiplugs from PDC ECU and speaker.
7. Remove 2 nuts securing PDC bracket to body.
8. Remove cable tie clip from RH side of bracket.
9. Manoeuvre PDC bracket into luggage
compartment, and using a pair of pliers, remove
multiplug from bracket.
10. Remove nut and washer securing PDC speaker
to bracket.
11. Remove PDC speaker.
12. Remove 2 nuts securing PDC ECU to bracket.
13. Remove PDC ECU.
Refit
1. Position PDC ECU on bracket and secure using
2 nuts.
2. Position PDC speaker on bracket and secure
with nut and washer.
3. Attach multiplug to bracket and manoeuvre
bracket into cavity on RH side of luggage
compartment.
4. Secure PDC bracket to body using 2 nuts.
5. Ìnsert cable tie clip into RH side of PDC bracket.
6. Connect multiplugs to PDC ECU and speaker.
7. Fit luggage compartment trim and secure with
screw and scrivet.
8. Raise rear seat and fit parcel tray.
SP86 0183
SP86 0184
SP86 0185
ELECTRÌCAL
REPAÌRS 86-37
SENSOR - PARKING AID
´÷ 86.54.14
Remove
1. Remove rear bumper. See EXTERIOR
FITTINGS, Repairs.
2. Disconnect multiplug from sensor.
3. Release 2 clips securing sensor to bumper.
4. Remove sensor from rear bumper.
Refit
1. Position and fit sensor to rear bumper.
2. Connect multiplug to sensor.
3. Fit rear bumper. See EXTERIOR FITTINGS,
Repairs.
SOUNDER - PARKING AID
´÷ 86.54.18
Remove
1. Remove parcel tray.
2. Release catch and fold rear seat forward.
3. Remove 1 scrivet from RH side luggage
compartment trim.
4. Remove 1 screw from RH wheel arch trim finisher
above suspension turret.
5. Fold back RH side luggage compartment trim to
allow access to PDC bracket.
6. Remove multiplugs from PDC ECU and speaker.
7. Remove 2 nuts securing PDC bracket to body.
8. Remove cable tie clip from RH side of bracket.
9. Manoeuvre PDC bracket into luggage
compartment, and using a pair of pliers, remove
multiplug from bracket.
SP86 0190 SP86 0183
SP86 0184
ELECTRÌCAL
86-38 REPAÌRS
10. Remove nut and washer securing PDC speaker
to bracket.
11. Remove speaker from bracket.
Refit
1. Position PDC speaker on bracket and secure
with nut and washer.
2. Attach multiplug to bracket and manoeuvre
bracket into cavity on RH side of luggage
compartment.
3. Secure PDC bracket to body using 2 nuts.
4. Ìnsert cable tie clip into RH side of PDC bracket.
5. Connect multiplugs to PDC ECU and speaker.
6. Fit luggage compartment trim and secure with
screw and scrivet.
7. Raise rear seat and fit parcel tray.
FLASHER UNIT
´÷ 86.55.68
Remove
1. Release 3 turnbuckles and remove passenger
compartment fuse box cover.
2. Remove flasher unit from passenger
compartment fuse box / mounting bracket.
Refit
1. Fit flasher unit to fuse box.
2. Fit fuse box cover and secure with turnbuckles.
SP86 0185
ELECTRÌCAL
REPAÌRS 86-39
DOOR SWITCH
´÷ 86.55.88
Remove
1. Disconnect battery earth lead.
2. Remove screw securing door switch to body.
3. Release door switch and disconnect Lucar.
Refit
1. Position switch to door and connect Lucar.
2. Fit switch to door and secure with screw.
3. Connect battery earth lead.
BONNET SWITCH
´÷ 86.55.89
Remove
1. Disconnect battery earth lead.
2. Release bonnet switch from mounting bracket.
3. Disconnect multiplug from bonnet switch and
remove switch.
Refit
1. Connect multiplug to bonnet switch.
2. Secure switch to mounting bracket.
3. Connect battery earth lead.
ELECTRÌCAL
86-40 REPAÌRS
MULTI FUNCTION UNIT (MFU) - MODELS
WITH SERVICABLE FUSEBOX
´÷ 86.55.75
Remove
1. Disconnect battery earth lead.
2. Release 3 turnbuckles and remove passenger
compartment fuse box cover.
3. Remove 2 nuts securing passenger
compartment fuse box to brackets and release
fuse box.
4. Release 2 clips securing MFU to rear of
passenger compartment fuse box and release
MFU.
5. Disconnect 2 multiplugs from MFU.
Refit
1. Connect multiplugs to MFU.
2. Position MFU and engage to fuse box clips.
3. Position fuse box and tighten nuts to 10 Nm .
4. Fit fuse box cover and secure with turnbuckles.
5. Connect battery earth lead.
ELECTRÌCAL
REPAÌRS 86-41
MULTI FUNCTION UNIT (MFU) - MODELS
WITH HARD-WIRED FUSEBOX
´÷ 86.55.75
1. Front console. See INTERIOR TRIM
COMPONENTS, Repairs.
2. MFU bracket (c).
¤ Release lugs
3. MFU (d).
4. Multipugs (a,g).
SP86 0239
a
g
b
b
b
f
c
d
e
ELECTRÌCAL
86-42 REPAÌRS
STARTER MOTOR 1.1, 1.4 AND 1.6
MODELS
´÷ 86.60.01
Remove
1. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Release cover from nut securing battery cable to
starter solenoid.
4. Remove nut securing battery cable to starter
solenoid.
5. Disconnect battery cable from starter solenoid.
6. Disconnect Lucar from starter solenoid.
7. Remove upper bolt securing starter motor to
engine.
8. Disconnect earth lead from bolt.
9. Remove 2 lower bolts securing starter motor to
engine.
10. Remove starter motor.
Refit
1. Clean starter motor and mating faces of starter
motor and flywheel housing.
2. Fit and align starter motor to engine.
3. Fit 2 lower bolts securing starter motor to engine,
but do not tighten.
4. Connect earth lead to starter motor upper bolt.
5. Fit upper bolt securing starter motor to engine
and tighten to 45 Nm .
6. Tighten lower bolts securing starter motor to
engine to 45 Nm .
7. Connect Lucar to starter solenoid.
8. Connect battery cable to starter solenoid, fit nut
and tighten to 13 Nm . Secure cover to nut.
9. Remove stand(s) and lower vehicle.
10. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
ELECTRÌCAL
REPAÌRS 86-43
STARTER MOTOR - 'L' SERIES
´÷ 86.60.01
Remove
1. Disconnect battery earth lead.
2. Remove undertray. See EXTERIOR FITTINGS,
Repairs.
3. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - EDC, Repairs.
4. Disconnect Lucar from starter solenoid.
5. Remove nut cover, remove nut and disconnect
battery lead from starter solenoid.
6. Remove nut cover, loosen inner nut and remove
outer nut securing torsion link.
7. Remove 2 bolts securing starter motor, remove
torsion link assembly and remove starter motor.
Refit
1. Clean mating faces of starter motor and flywheel
housing.
2. Fit starter motor, fit torsion link and tighten starter
motor bolts to 80 Nm.
3. Tighten nuts securing torsion link to 25 Nm. and
fit cover to inner nut.
4. Fit battery cable to starter solenoid, tighten nut to
13 Nm and fit cover to nut.
5. Connect Lucar to starter solenoid.
6. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - EDC, Repairs.
7. Fit undertray. See EXTERIOR FITTINGS,
Repairs.
8. Connect battery earth lead.
STARTER MOTOR - 'EM-CVT' MODELS
´÷ 86.60.01
Remove
1. Disconnect battery earth lead.
2. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
3. Remove 3 bolts securing flywheel front cover
plate and remove cover plate.
4. Disconnect Lucar from starter solenoid.
5. Remove nut from starter motor solenoid and
release battery lead.
6. Remove 2 bolts securing starter motor and
remove starter motor.
ELECTRÌCAL
86-44 REPAÌRS
Refit
1. Clean mating faces of starter motor and gearbox.
2. Fit starter motor.
3. Fit bolts and tighten to 25 Nm.
4. Fit leads to starter solenoid and tighten terminal
nut to 13 Nm.
5. Connect Lucar to starter solenoid.
6. Fit flywheel cover and tighten bolts to to 9 Nm.
7. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
8. Connect battery earth lead.
STARTER MOTOR - 'K16 WITH VVC'
´÷ 86.60.01
Remove
1. Disconnect battery earth lead.
2. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
3. Disconnect Lucar from starter solenoid.
4. Release cover and remove nut securing battery
lead to starter solenoid, disconnect lead.
5. Remove upper bolt and flanged nut, securing
bracket and starter motor to gearbox housing.
6. Remove cover and nut securing bracket to ABS
modulator.
7. Remove bracket.
8. With assistance, remove flanged nut from lower
bolt securing starter motor to gearbox housing
and withdraw bolt.
9. Release and remove starter motor from gearbox
housing, collect rear closing plate.
ELECTRÌCAL
REPAÌRS 86-45
Refit
1. Clean starter motor and gearbox housing mating
faces.
2. Manoeuvre starter motor into gearbox housing
and position rear closing plate.
3. With assistance fit lower bolt and nut securing
starter motor to gearbox housing. Do not tighten
at this stage.
4. Position bracket to starter motor and ABS
modulator.
5. Fit upper retaining bolt and flanged nut, but do
not tighten at this stage.
6. Fit nut securing bracket and tighten to 25 Nm. Fit
cap.
7. Fit cover on bracket nut.
8. Tighten lower starter bolt and nut to 85 Nm.
9. Tighten upper starter bolt and nut to 85 Nm.
10. Connect battery cable to starter solenoid, fit nut
and tighten to 13 Nm.
11. Fit cover on battery cable nut.
12. Connect Lucar to starter solenoid.
13. Fit air cleaner. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
14. Connect battery earth lead.
STARTER SWITCH
´÷ 86.65.03
CAUTION: See SRS safety precautions before
commencement of repair. See RESTRAINT
SYSTEMS, Precautions.
Remove
1. Remove transponder coil. See ELECTRICAL,
Repairs.
Models with servicable fusebox:
2. Disconnect starter switch multiplugs from fuse
box and main harness.
Models with hard-wired fusebox:
3. Disconnect main harness multiplug from starter
switch.
ELECTRÌCAL
86-46 REPAÌRS
All models:
4. Remove nut and bolt securing lower column
clamp to pivot bracket.
5. Remove clamp.
6. Remove 2 flange nuts and 2 bolts securing
column upper bracket to body.
7. Lower the steering column assembly.
Models with lock shield fitted:
8. Centre punch and drill out 2 lock shield shear
bolts using a 5mm drill.
9. Remove lower half of lock shield.
10. Remove upper half of lock shield.
All models:
11. Centre punch and drill out 2 shear bolts using a 5
mm drill.
CAUTION: Take care not to damage switch
body if switch is to be refitted.
12. Remove starter switch and bracket.
Refit
1. Position starter switch to column, fit and lightly
tighten shear bolts.
2. Ìnsert starter key, check operation of steering
lock and key turns freely.
3. Tighten shear bolts fully and shear heads off.
Models with lock shield fitted:
4. Position upper half of lock shield to ignition barrel
and steering column.
5. Position lower half of lock shield to ignition barrel
and steering column.
6. Fit 2 shear bolts to lock shield and tighten until
heads shear off.
All models:
7. Raise column and engage top bracket on studs
and fit nuts, DO NOT tighten.
8. Fit lower clamp, tighten nut and bolt to 22 Nm .
9. Tighten top bracket nuts and bolts to 16 Nm.
10. Connect ignition switch multiplugs.
11. Fit transponder coil. See ELECTRICAL,
Repairs.
12. Fit steering column nacelle. See STEERING,
Repairs.
ELECTRÌCAL
REPAÌRS 86-47
FRONT FOG LIGHT SWITCH
´÷ 86.65.19
Remove
1. Release front fog light switch from centre
console.
2. Disconnect multiplug from rear of switch.
3. Remove switch.
Refit
1. Position switch to centre console and connect
multiplug.
2. Fit switch to centre console.
HEATED REAR SCREEN SWITCH
´÷ 86.65.36
Remove
1. Release heated rear screen switch from centre
console.
2. Disconnect multiplug from rear of switch.
3. Remove switch.
Refit
1. Position switch to centre console and connect
multiplug.
2. Fit switch to centre console.
ELECTRÌCAL
86-48 REPAÌRS
HAZARD WARNING LIGHT SWITCH
´÷ 86.65.50
Remove
1. Release hazard warning light switch from centre
console.
2. Disconnect multiplug from rear of switch.
3. Remove switch.
Refit
1. Position switch to centre console and connect
multiplug.
2. Fit switch to centre console.
INDICATOR/HEADLAMP SWITCH
´÷ 86.65.55
Remove
1. Remove rotary coupler. See ELECTRICAL,
Repairs.
2. Remove 2 screws securing indicator/headlamp
switch to switch pack.
3. Depress retaining tag and remove switch
assembly.
Refit
1. Fit indicator/headlamp switch assembly and
secure with screws.
2. Fit rotary coupler. See ELECTRICAL, Repairs.
ELECTRÌCAL
REPAÌRS 86-49
STEERING COLUMN SWITCH ASSEMBLY
´÷ 86.65.64
Remove
1. Remove rotary coupler. See RESTRAINT
SYSTEMS, Repairs.
2. Remove indicator cancelling cam from column.
3. Remove 2 screws securing switch assembly to
steering column.
4. Release switch assembly from column and
disconnect 4 multiplugs.
5. Remove switch assembly.
6. Remove 2 screws securing direction indicator/
headlamp stalk to switch assembly.
7. Remove direction indicator/headlamp stalk from
switch assembly.
8. Remove 2 screws securing wash/wipe stalk to
switch assembly.
9. Remove wash/wipe stalk from switch assembly.
Refit
1. Fit wash/wipe stalk to switch assembly and
secure with screws.
2. Fit direction indicator/headlamp stalk to switch
assembly and secure with screws.
3. Position switch assembly to steering column,
connect multiplugs and tighten retaining screws.
4. Fit direction indicator cancelling cam to steering
column.
5. Fit rotary coupler. See RESTRAINT SYSTEMS,
Repairs.
ELECTRÌCAL
86-50 REPAÌRS
REAR FOG LIGHT SWITCH
´÷ 86.65.65
Remove
1. Release rear fog light switch from centre console.
2. Disconnect multiplug from rear of switch.
3. Remove switch.
Refit
1. Position switch to centre console and connect
multiplug.
2. Fit switch to centre console.
DOOR MIRROR SWITCH
´÷ 86.65.75
Remove
1. Release door mirror switch from fascia.
2. Disconnect multiplug from rear of switch.
3. Remove switch.
Refit
1. Position switch to fascia and connect multiplug.
2. Fit switch to fascia.
ELECTRÌCAL
REPAÌRS 86-51
ENGINE COMPARTMENT FUSE BOX
´÷ 86.70.01
Remove
1. Disconnect both battery leads, earth lead first.
2. Remove fuse box cover.
3. Remove 2 bolts securing positive leads to main
fuse and remove leads.
4. Disconnect multiplug from fuse box.
5. Remove 3 bolts securing fuse box to body.
6. Disconnect multiplugs from fuse box and remove
fuse box.
Refit
1. Position fuse box and connect multiplugs.
2. Position fuse box to body, fit bolts and tighten to
10 Nm.
3. Connect multiplug to fuse box.
4. Fit positive leads to fuse box and secure with
bolts.
5. Fit fuse box cover.
6. Connect both battery leads, earth lead last.
ELECTRÌCAL
86-52 REPAÌRS
SWITCH - HEADLAMP LEVELLING
´÷ 86.65.16
Remove
1. Release 3 turnbuckles and remove passenger
compartment fuse box cover.
2. Disconnect multiplug from switch.
3. Release and remove switch.
Refit
1. Fit switch and secure multiplug.
2. Position fuse box cover and secure turnbuckles.
MOTOR - HEADLAMP LEVELLING
´÷ 86.41.44
Remove
1. Remove headlamp. See ELECTRICAL,
Repairs.
2. Remove headlamp bulb access cover.
3. Rotate headlamp adjuster clockwise to fully
extend motor link rod.
4. Rotate motor assembly 45° to release from
headlamp casing.
5. Lift motor to release link rod ball end from its
location in rear of headlamp lens.
ELECTRÌCAL
REPAÌRS 86-53
Refit
1. Rotate adjusting screw of NEW motor to fully
extend pin.
2. Fit motor to lamp engaging ball end of pin into
location at rear of lens.
3. Fit bulb access cover to lamp.
4. Fit headlamp. See ELECTRICAL, Repairs.
5. Adjust headlamp alignment. See ELECTRICAL,
Adjustments.
ANTI-THEFT ALARM ECU
´÷ 86.77.01
Remove
1. Disconnect battery earth lead.
2. Release 2 turnbuckles and remove closing panel.
3. Remove 2 nuts securing anti-theft alarm ECU to
body and release ECU.
4. Disconnect 2 multiplugs from anti-theft alarm
ECU.
Refit
1. Connect multiplugs to anti-theft alarm ECU.
2. Position anti-theft alarm ECU to body and secure
with nuts.
3. Fit closing panel and secure with turnbuckles.
4. Connect battery earth lead.
NOTE: If a new anti-theft alarm ECU has been
fitted, the ECM will need to be reprogrammed
with TestBook.
ELECTRÌCAL
86-54 REPAÌRS
BATTERY BACKED UP SOUNDER - BBUS
´÷ 86.77.13
Remove
1. Remove plenum chamber cover. See HEATING
& VENTILATION, Repairs.
2. Centre punch and drill out using 5mm drill bit, 2
shear bolts securing sounder shield to bracket.
Remove sounder shield.
3. Disconnect multiplug from sounder.
4. Remove nut and bolt securing sounder bracket to
bulkhead. Remove sounder and bracket.
5. Remove nut securing sounder to bracket, note
fitted position of sounder on bracket and remove
sounder.
6. Remove shear bolt threads from mounting
bracket.
Refit
1. Fit sounder to bracket ensuring correct aligment
and location of fitting register, fit nut and tighten
to 10 Nm.
2. Position sounder and bracket to bulkhead
ensuring fitting tag is located correctly, fit nut and
bolt and tighten to 10 Nm.
3. Fit multiplug to sounder.
4. Position shield to sounder bracket, fit shear bolts
and tighten until heads shear off.
5. Fit plenum chamber cover. See HEATING &
VENTILATION, Repairs.
TRANSPONDER COIL
´÷ 86.77.35
Remove
1. Remove steering column nacelle. See
STEERING, Repairs.
2. Disconnect transponder coil multiplug.
3. Carefully remove bezel from column switch.
4. Remove coil.
Refit
1. Fit coil.
2. Fit switch bezel ensuring cut-out in bezel is
aligned with lug on switch.
3. Connect multiplug.
4. Fit steering column nacelle. See STEERING,
Repairs.
ELECTRÌCAL
REPAÌRS 86-55
ANTI-THEFT ALARM LED
´÷ 86.77.50
Remove
1. Remove instrument pack. See INSTRUMENTS,
Repairs.
2. Remove anti-theft alarm LED from rear of
instrument pack.
Refit
1. Fit LED to rear of instrument pack.
2. Fit instrument pack. See INSTRUMENTS,
Repairs.
ELECTRÌCAL
86-56 REPAÌRS
ÌNSTRUMENTS
REPAÌRS 88-1
ÌNSTRUMENTS REPAÌ RS
CLOCK
´÷ 88.15.07
Remove
1. Remove clock finisher from fascia.
2. Remove 2 screws securing clock to fascia.
3. Move clock to gain access to multiplug.
4. Disconnect multiplug from clock and remove
clock.
Refit
1. Position clock to fascia and connect multiplug.
2. Fit and tighten screws securing clock to fascia.
3. Fit finisher to fascia.
INSTRUMENT PACK
´÷ 88.20.01
Remove
1. Disconnect battery earth lead.
2. Release clamp and lower steering column.
3. Remove 4 screws securing instrument pack
surround to fascia.
4. Remove rubber finisher from instrument pack.
5. Release 2 clips securing instrument pack
surround to fascia.
6. Remove instrument pack surround.
7. Remove 4 screws securing instrument pack to
fascia.
8. Move instrument pack to gain access to
multiplugs.
ÌNSTRUMENTS
88-2 REPAÌRS
9. Disconnect 3 multiplugs from rear of instrument
pack.
10. Remove instrument pack.
Refit
1. Position instrument pack to fascia and connect
multiplugs.
2. Fit and tighten screws securing instrument pack
to fascia.
3. Fit instrument pack surround to fascia, secure
clips and fit and tighten screws.
4. Fit rubber finisher to instrument pack.
5. Connect battery earth lead.
INSTRUMENT PANEL WINDOW AND
FACE PLATE
´÷ 88.20.06
Remove
1. Remove instrument pack. See INSTRUMENTS,
Repairs.
2. Remove screws and support brackets from
housing.
3. Release 6 clips securing instrument panel
window to instrument panel and remove window.
4. Release 4 clips securing face plate to instrument
panel and remove face plate.
Refit
1. Fit face plate to housing and secure clips.
2. Fit instrument panel window to instrument pack
and secure clips.
3. Fit support brackets and tighten screws.
4. Fit instrument pack. See INSTRUMENTS,
Repairs.
ÌNSTRUMENTS
REPAÌRS 88-3
COOLANT TEMPERATURE GAUGE
´÷ 88.25.14
Remove
1. Remove instrument panel window and face plate.
See INSTRUMENTS, Repairs.
2. Remove 3 screws and remove coolant
temperature gauge.
Refit
1. Fit coolant temperature gauge and secure with
screws.
2. Fit instrument panel window and face plate. See
INSTRUMENTS, Repairs.
ENGINE COOLANT TEMPERATURE
GAUGE SENSOR - 'K' SERIES
´÷ 88.25.20
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from engine coolant
temperature gauge sensor.
3. Position container below sensor to collect coolant
spillage.
4. Remove engine coolant temperature gauge
sensor.
Refit
1. Clean threads of engine coolant temperature
gauge sensor.
2. Apply Loctite 577 to threads of engine coolant
temperature gauge sensor.
3. Fit engine coolant temperature gauge sensor and
tighten to 10 Nm.
4. Connect multiplug to engine coolant temperature
gauge sensor.
5. Connect battery earth lead.
6. Top-up coolant. See MAINTENANCE.
ÌNSTRUMENTS
88-4 REPAÌRS
ENGINE COOLANT TEMPERATURE
GAUGE SENSOR -'L' SERIES
´÷ 88.25.20
Remove
1. Remove alternator. See ELECTRICAL, Repairs.
2. Disconnect engine coolant temperature gauge
sensor Lucar from harness.
3. Position container below sensor to collect coolant
spillage.
4. Remove engine coolant temperature gauge
sensor.
Refit
1. Clean threads of engine coolant temperature
gauge sensor.
2. Apply Loctite 577 to threads of engine coolant
temperature gauge sensor.
3. Fit engine coolant temperature gauge sensor and
tighten to 5 Nm.
4. Connect engine coolant temperature gauge
sensor Lucar to harness.
5. Top-up coolant level. See MAINTENANCE.
6. Fit alternator. See ELECTRICAL, Repairs.
FUEL GAUGE
´÷ 88.25.26
Remove
1. Remove instrument panel window and face plate.
See INSTRUMENTS, Repairs.
2. Remove 3 screws and remove fuel gauge.
Refit
1. Fit fuel gauge and secure with screws.
2. Fit instrument panel window and face plate. See
INSTRUMENTS, Repairs.
ÌNSTRUMENTS
REPAÌRS 88-5
FUEL GAUGE TANK UNIT - 'L' SERIES
´÷ 88.25.32
Remove
1. Remove fuel tank assembly. See FUEL
DELIVERY SYSTEM, Repairs.
2. Release clip and disconnect fuel feed hose from
sender unit.
3. Release clip and disconnect fuel return hose from
sender unit.
4. Remove 6 nuts securing sender unit to fuel tank.
5. Release sender unit from fuel tank.
6. Remove sender unit from fuel tank.
7. Remove seal from sender unit.
Refit
1. Clean mating face of sender unit and fuel tank.
2. Clean seal and fit to sender unit.
3. Fit sender unit to fuel tank.
4. Fit nuts securing sender unit to fuel tank and
tighten to 9 Nm .
5. Connect fuel return hose to sender unit and
secure with clip.
6. Connect fuel feed hose to sender unit and secure
with clip.
7. Refit fuel tank assembly. See FUEL DELIVERY
SYSTEM, Repairs.
ÌNSTRUMENTS
88-6 REPAÌRS
SPEEDOMETER
´÷ 88.30.01
Remove
1. Remove instrument panel window and face plate.
See INSTRUMENTS, Repairs.
2. Remove 3 screws and remove speedometer.
Refit
1. Fit speedometer to instrument pack and secure
with screws.
2. Fit instrument panel window and face plate. See
INSTRUMENTS, Repairs.
VEHICLE SPEED SENSOR - 'R65'
GEARBOX
´÷ 88.30.14
Remove
1. Disconnect battery earth lead.
2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Disconnect multiplug from vehicle speed sensor.
4. Position container beneath sensor to collect any
oil spillage.
5. Remove bolt securing speedometer drive pinion
housing to gearbox.
6. Release speedometer drive pinion housing from
gearbox.
7. Remove speedometer drive pinion housing.
ÌNSTRUMENTS
REPAÌRS 88-7
8. Remove and discard 'O' ring from speedometer
drive pinion housing.
9. Remove vehicle speed sensor.
Refit
1. Fit and tighten vehicle speed sensor to
speedometer drive pinion housing.
2. Clean mating faces of gearbox and speedometer
drive pinion housing.
3. Lubricate with gearbox oil and fit new 'O' ring to
speedometer drive pinion housing.
4. Fit speedometer drive pinion housing to gearbox
and align bolt holes.
5. Fit bolt securing speedometer drive pinion
housing to gearbox and tighten to 9 Nm.
6. Connect multiplug to vehicle speed sensor.
7. Top-up gearbox oil level. See MAINTENANCE.
8. Remove stand(s) and lower vehicle.
9. Connect battery earth lead.
VEHICLE SPEED SENSOR - 'PG1'
GEARBOX
´÷ 88.30.14
Remove
1. Disconnect battery earth lead.
2. Disconnect multiplug from vehicle speed sensor.
3. Position container to collect fluid loss from
gearbox.
4. Remove bolt securing speedometer drive pinion
housing to gearbox.
5. Release speedometer drive pinion housing from
gearbox.
6. Remove speedometer drive pinion housing.
7. Remove and discard 'O' ring from speedometer
drive pinion housing.
8. Remove vehicle speed sensor.
ÌNSTRUMENTS
88-8 REPAÌRS
Refit
1. Fit and tighten vehicle speed sensor to
speedometer drive pinion housing.
2. Clean mating faces of gearbox and speedometer
drive pinion housing.
3. Lubricate with gearbox oil and fit new 'O' ring to
speedometer drive pinion housing.
4. Fit speedometer drive pinion housing to gearbox
and align bolt holes.
5. Fit bolt securing speedometer drive pinion
housing to gearbox and tighten to 9 Nm.
6. Connect multiplug to vehicle speed sensor.
7. Top-up gearbox oil level. See MAINTENANCE.
8. Connect battery earth lead.
TACHOMETER
´÷ 88.30.21
Remove
1. Remove instrument panel window and face plate.
See INSTRUMENTS, Repairs.
2. Remove 3 screws and remove tachometer.
Refit
1. Fit tachometer and secure with screws.
2. Fit instrument panel window and face plate. See
INSTRUMENTS, Repairs.