MG MG6 Series 2011 Service Manual

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Service Manual 2011

MG6

Version 2.0

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

adjustments for the 2011 series MG6 Vehicle.

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

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

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

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

MG Motor.

Copy Right Reserved

All information received cutoff date is August 2011

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

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

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

above) mentioned in this manual.

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Summary of Contents for MG MG6 Series 2011

Page 1 All information received cutoff date is August 2011 Any information contained in this manual are the property of the MG Motor. No part of this manual may be copied, stored in any retrieval system, or spread by any means (including but not limited in electronic, mechanical, photocopying and recording) without written MG Motor authorization.
Page 3 How To Use This Manual NOTE statements emphasize a necessary characteristic of a diagnostic or repair procedure. NOTE statements are General designed to do the following: To assist in the use of this Manual, it is divided into sections • Clarify a procedure. and sub-sections.
Page 4 Repairs and Replacements Parts When replacement parts are required it is essential that only our company’s 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 vehicle may be impaired if other than SMC recommended parts are fitted.
Page 5: Table Of Contents
Contents General Information ......1 Connecting Rod Bearings Overhaul ....65 Pistons & Liners..........67 General Information ..........1 Crankshaft Rear Oil Seal ....... 70 General Precautions ........... 1 Crankshaft Front Oil Seal......71 Safety Instructions ..........2 Flywheel - Manual Transmission..... 72 Environmental Precautions........
Page 6 Contents Reference........... 135 1.8VCT Solenoid - Inlet Camshaft ....205 Description and Operation......136 1.8VCT Solenoid Housing - Exhaust Camshaft............ 206 Component Layout........136 1.8VCT Solenoid Housing - Inlet Description ..........147 Camshaft............ 206 Operation ..........149 1.8VCT Cylinder Head GasketNew .... 207 Service Procedures.........
Page 7 Contents Element - Air Cleaner......... 252 Solenoid - Boost Control - Turbocharger ..........322 Tail Pipe and Silencer ........252 Fuel Rail ............. 322 Intermediate Pipe ........253 Injectors ............ 323 Front Pipe - Turbocharger......254 Charcoal Canister ........324 Heat Shield - Alternator......
Page 8 Contents Shift Lock Control-MT........351 Oil Seal–Gear Change Rod ......411 Specifications ..........351 Lubrication System–Drain & Refill ....412 Torque ............351 Manual Transmission Assembly....412 Service Procedures......... 352 Lamp Switch–Reverse ......... 416 Knob–Gear Lever–Manual......352 Cover–Reverse Access–Reseal ....416 Remote Control–Gear Lubrication System–Manual Change–Manual ..........
Page 9 Contents Refrigerant Recovery, Recycling and Left Blend Flap - Servo Motor ..... 509 Recharging ..........470 Heater Coolant Temperature Sensor... 510 If Recharging is Completed Right Blend Flap - Servo Motor ....510 Successfully/Unsuccessfully: ......472 Fresh Recirculated Air Flap - Servo Compressor..........
Page 10 Contents Specifications ..........543 Tyres and Wheels ..........587 Torque ............543 Specifications ..........587 Specifications..........544 Torque ............587 Service Procedures......... 545 Specifications..........588 Wheel Alignment ........545 Service Procedures......... 589 Front Suspension ..........546 Wheel............589 Specifications ..........546 Brake System........591 Torque ............
Page 11 Contents Handbrake Lever ........631 Specifications ..........662 Handbrake Front Cable....... 632 Torque ............662 Brake Module.............634 Description and Operation......663 Specifications ..........634 System Component Layout ......663 Torque ............634 System Control Diagram......666 Description and Operation......635 Description ..........
Page 12 Contents Parcel Tray - Rear - Saloon ......694 Description and Operation......720 Parcel Tray - Rear - Sun Blind Fitted .... 694 System Component Layout ......720 Spectacles Box - Driver ......696 System Control System....... 721 Trim Casing - Luggage Compartment - Description ..........
Page 13 Contents Bulb - Directional - Indicator....... 756 Glass/Glass Cassette Unit - Rear Door - Adjust ............784 Bulb - Reverse Lamp- Saloon....... 756 Glass - Rear Door - Each ......785 Bulb - Number Plate Lamp ......757 Switch - Electric Window Lift - Rear Door Bulb - Rear Fog Lamp .........
Page 14 Contents Trim Casing - Boot Lid........ 806 Corrosion Prevention ......... 862 Latch - Boot Lid ......... 807 Diagnostic............868 Horns ..............808 Water Leaks..........868 Specifications ..........808 Service Procedures......... 869 Torque ............808 Front End Panel .......... 870 Service Procedures......... 809 Door Panel ..........
Page 15 Contents Operation ..........913 Service Procedures......... 914 Control Unit ( ......914 ..............914 Information and Entertainment ......... 915 Entertainment and Navigation ......915 Description and Operation......915 Component Layout ......915 -Control Diagram ........ 916 IN CAR ENTERTAINMENT -Description......... 917 IN CAR ENTERTAINMENT )-Operation.........
Page 17: General Information
General Information General Information Health Protection Precautions General Precautions The following precautions should be observed at all times. Dangerous Substances • Wear protective clothing, including impervious gloves Modern vehicles contain many materials and liquids which if not where practicable. handled with care can be hazardous to both personal health •...
Page 18: Safety Instructions
General Information Safety Instructions • Observe absolute cleanliness when working with Jacking hydraulic components. Cooling System Caps and Plugs Caution: It is best to use the lift when working under the vehicle. Be sure to hold the wheels with chocks and apply expansion tank caps and coolant drain or bleed screws when parking brake.
Page 19: Environmental Precautions
General Information Environmental Precautions Discharges to Water General Oil, petrol, solvent, acids, hydraulic oil, antifreeze and other such substances should never be poured down the drain and This section provides general information which can help to every precaution must be taken to prevent spillage reaching reduce the environmental impacts from the activities carried the drains.
Page 20 General Information Local Issues Dispose of waste in accordance with the following guidelines. A number of environmental issues will be of particular concern • Fuel, hydraulic fluid, anti-freeze and oil: keep separate to residents and other neighbours close to the site. The and dispose of to specialist contractor.
Page 21: General Fitting Instructions
General Information General Fitting Instructions • Never inspect a component for wear or dimensional Component Removal check unless it is absolutely clean; a slight smear of grease can conceal an incipient failure. Whenever possible, clean components and surrounding area • When a component is to be checked dimensionally before removal.
Page 22: Ball And Roller Bearings
General Information Ball and Roller Bearings • In the case of grease lubricated bearings (e.g. General bearings) fill the space between bearing and outer seal with the recommended grade of grease before fitting When removing and installing bearings, ensure that the seal.
Page 23: Oil Seals
General Information Oil Seals General 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. •...
Page 24: Joints And Joint Faces
General Information Joints and Joint Faces Locking Devices General General Fit joints dry unless specified otherwise. Always replace locking devices with one of the same design. Tab Washers • Always use the correct gaskets as specified. • When sealing compound is used, apply in a thin uniform Always release locking tabs and fit new locking washers.
Page 25: Screw Threads
General Information Screw Threads Fasteners Identification General Bolt Identification Metric threads to ISO 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.
Page 26 General Information An encapsulated bolt may be replaced with a bolt of equivalent also marked and some have the metric symbol M on the flat specification provided it is treated with an approved locking opposite the strength grade marking. agent. When tightening a slotted or castellated nut, never loosen it Self-locking Bolts and Screws to insert a split pin except where recommended as part of an...
Page 27: Flexible Pipes And Hoses
General Information Hose Orientation and Connection Flexible Pipes and Hoses General When removing and installing flexible hydraulic pipes and hoses, ensure that the following practices are observed to ensure component serviceability. • Clean end fittings and the area surrounding them as thoroughly as possible.
Page 28: Fuel Handling Precautions
General Information Fuel Handling Precautions when hot; ensure this movement is taken into account when routing and securing hoses. General 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.
Page 29: Electrical Precautions
General Information Electrical Precautions As an added precaution, fuel tanks should have a 'FUEL VAPOUR' warning label attached to them as soon as they are General removed from the vehicle. The following guidelines are intended to ensure the safety of Fuel Tank Repairs the operator while preventing damage to the electrical and electronic components fitted to the vehicle.
Page 30: Supplementary Restraint System Precautions
General Information Supplementary Restraint System Precautions Battery Disconnection General Precautions Before disconnecting the battery, disable the alarm system and switch off all electrical equipment. The SRS system contains components which could be potentially hazardous to the service engineer if not serviced Caution: To prevent damage to electrical components, and handled correctly.
Page 31 General Information Making the System Safe • Never apply electrical power to an SRS component unless instructed to doSRS so as part of an approved Before working on, or in the vicinity ofSRS components, test procedure. ensure the system is rendered safe by performing the following •...
Page 32 General Information Warning: Do not use electrical test equipment on the SRS Caution: Do not apply grease or cleaning solvents to seat harness while it is connected to any of the SRS system belt pretensioner units, component failure could result. components.
Page 33 General Information Always observe the following precautionsSRS with regards to Do not place any object on the steering wheel or instrument SRS system electrical wiring: panel that could penetrate an inflating airbag or be a thrown item likely to cause injury. •...
Page 34 General Information 4. Bar code. The code number must be recorded if the rotary coupler is to be replaced. A The need for caution when working in close proximity to SRS components.SRS in close proximity to SRS components. Bar Codes B Refer to the publication where the procedures,SRS Bar codesSRS are fitted to SRS system components and instructions and advice can be found (usually Workshop...
Page 35 General Information Warning: Only use approved deployment equipment, Warning: Compliance with the following precautions and only deploy SRS components in a well-ventilated MUST be ensured: designated area. Ensure SRS components are not • Only use deployment equipment approved for the damaged or ruptured before deployment.
Page 36: Srs Component Replacement Policy
General Information SRS Component Replacement Policy • SRS ECU Impacts Which Do Not Deploy the Airbags or • Side impact crash sensors (both sides of vehicle) Pre-tensioners In addition, the following should be inspected for damage and Check for structural damage in the area of the impact, paying replaced as necessary: particular attention to bumper armatures, longitudinals, crash •...
Page 37: Air Conditioning System Precautions
General Information Air Conditioning System Precautions • Front seat frames General • Seat belt automatic height adjusters on ‘B'- post • Front seat belts (retractors, webbing, tongue latching, 'D' The air conditioning system contains fluids and components loop and body anchorage points) which could be potentially hazardous to the service engineer or the environment if not serviced and handled correctly.
Page 38 General Information Warning: Due to its low evaporating temperature, R134a • Whenever the refrigerant system is opened, the must be handled with care. R134a splashed on any part receiver/drier must be renewed immediately before of the body will cause immediate freezing of that area. evacuating and recharging the system.
Page 39: Air Conditioning Compressor Replacement
General Information Air Conditioning Compressor Replacement Warning: Refrigerant R134a from domestic and commercial sources must not be used in motor vehicle air Replacement Instructions conditioning systems. A new compressor is supplied filled with a full charge of Caution: The system must be evacuated immediately refrigerant oil.
Page 40: Vehicle Identification Number
General Information Vehicle Identification Number Vehicle Identification Number Vehicle Identification Plate Vehicle Identification Vehicle Identification Number ( VIN ) Example:LSJW26G3X8SXXXXXX Manufacturer's identifier Marque/Model Type Body style 6 = Four door Engine G = 1.8T petrol Restraint system 3 = Seat belts, driver and passenger front air bag module Check digit, a single number...
Page 41: Other Identification Plate Locations
Vehicle Identification Number General Information Other Identification Plate Locations Engine Number Stamped on the rear LH side of the cylinder block. Automatic Gearbox Number Stamped on the upper RH side of the gearbox casing. Manual Gearbox Number A label is attached on the LH side of the gearbox casing. Body Number Stamped onto the body around the suspension turret.
Page 42: Lifting & Towing
General Information Lifting & Towing Lifting & Towing the wheel to be removed. Note that the domed head of the jack must fit into the corresponding recess in the sill plate. Lifting Lifting Instructions Warning: Do not work on or under a vehicle supported only by a jack.
Page 43: Vehicle Recovery
Lifting & Towing General Information Two Post Ramp Vehicle Recovery Recovery Instructions It is recommended that a recovery trailer or two-wheel car ambulance be used. In an emergency, the car may be towed on its own wheels using the front towing eye. Front Towing Eye Locate the pads under the reinforced jacking points on the sill.
Page 44 General Information Lifting & Towing Before towing commences, release the parking brake, place the gear lever in neutral with the ignition on. Do not tow at a speed greater than 30 mph (50 km/h). Ensure the following precautions are observed: To ensure that the steering does not lock when the vehicle is being towed, it is essential that the handset is docked;...
Page 45: Lubrication & Maintenance
Lubrication & Maintenance General Information Lubrication & Maintenance Fluids Fuel Capacities Fluid Capacities Always use the following recommended fluids: Petrol engines The following capacities are only an approximation of the amount of fluid required to fill the respective system: Use unleaded petrol with a minimum octane rating of 93 Component/system Capacity RON to GB17930 specification.RON Do not use petrol that...
Page 46: Lubrication
General Information Lubrication & Maintenance Lubrication General The engine and other lubricating systems are filled with high-performance lubricants giving prolonged life. Caution: Always use a high quality oil of the correct viscosity range in the engine. The use of oil of the incorrect specification can lead to high oil and fuel consumption and ultimately to damaged components.
Page 47: Engine
Engine Mechanical-1.8T Engine Engine Mechanical-1.8T Specifications Torque Description Value Bolt- camshaft carrier to cylinder head 7–10Nm Bolt- exhaust camshaft seal blanking plate to cylinder head 22–28Nm Spark plugs 22–28Nm Nut-intake manifold to cylinder head 15–18Nm Nut-exhaust manifold to cylinder head 40–50Nm Bolt-bearing ladder to cylinder block 28–32Nm...
Page 48: Reference
Engine Engine Mechanical-1.8T Description Value Bolt-engine RH mounting arm to engine 90–110Nm Bolt-power steering fluid collection to engine RH hydraulic 7–10Nm mounting Bolt-engine RH mounting tie rod to body 90–110Nm Bolt-drive belt front lower cover to cylinder block 8–11Nm Bolt-PAS belt tensioner 25Nm Bolt-drive belt tensioner to cylinder head 20–23Nm...
Page 49 Operation pressure 3.8 bar Injector static flow rate 229.8 g/min Injector dynamic flow rate 8.675 mg/ pulse @ 2.5 ms × 20 ms Valve operation Self - adjusting, lightweight hydraulic tappets operated directly by camshafts Emission standard ECD3 Cylinder block:...
Page 50 Engine Engine Mechanical-1.8T Cylinder head warp - maximum 0.05 mm Cylinder head height: l New 118.95 - 119.05 mm l Reface limit 0.20 mm Crankshaft: Crankshaft end-float: 0.205 ± 0.1 mm l Service limit 0.34 mm Main journal diameter: 47.986 - 48.007 mm l Maximum out of round 0.010 mm Main journal tolerance:...
Page 51 Engine Mechanical-1.8T Engine Pistons: Type Aluminium alloy, tin plated, thermal expansion with offset gudgeon pin Piston diameter: 79.974 - 79.990 mm Clearance in bore 0.01 - 0.04 mm Maximum ovality 0.5 mm Piston rings: Type: 2 compression, 1 oil control l Top compression ring Barrel faced, granulite coated l 2nd compression ring...
Page 52 Engine Engine Mechanical-1.8T Tappets: Type Lightweight hydraulic tappets; self-adjusting; camshafts directly driven Tappet outside diameter 32.959 - 32.975 mm Valve timing: Inlet valves: l Opens 12°BTDC l Closes 52°ABDC l Max lift 8.8 mm Exhaust valves: l Opens 52°BBDC l Closes 12°ATDC l Max lift 8.8 mm...
Page 53 Engine Mechanical-1.8T Engine l Exhaust 1.6 mm l Seat face angle - Inlet and Exhaust 45° Valve face angle - Inlet and Exhaust 45° Valve springs: Free length 50.0 mm Fitted length 37.0 mm Load at fitted length 250 ± 12.5 N Load at valve open length 450 ±...
Page 54 Engine Engine Mechanical-1.8T Motorola l Make/Type l Sensor supply voltage 5V ± 4% Coolant temperature sensor: l Make/Type TEMB NTC Main bearing group selection table 1 Crankshaft connecting rod journal grouping codes are marked on the rear side of the fourth connecting rod Crankshaft main journal group journal and the first letter indicates the first connecting Main bearing...
Page 55: Description And Operation
Engine Mechanical-1.8T Engine Description and Operation Engine Component Layout K4 Engine Component Layout K4 engine general view turbocharger engine Version 2.0...
Page 56 Engine Engine Mechanical-1.8T S102001 K4 engine internal view turbocharger engine Version 2.0...
Page 57 Engine Mechanical-1.8T Engine Cylinder Block Components 1. O-ring thermostat housing to coolant pump 6. O-ring thermostat cover to coolant pipe 2. Thermostat housing 7. Bolt connecting rod 3. Screw thermostat housing to cylinder block 8. Big-end bearing cap 4. Thermostat seal 9.
Page 58 Engine Engine Mechanical-1.8T 11. Connecting rod 21. Cylinder head gasket 12. Piston 22. Bolts cover to housing 13. Oil control ring 23. Cylinder block 14. 2nd compression ring 24. O-ring coolant pump to cylinder block 15. Top compression ring 25. Bolt coolant pump to cylinder block 16.
Page 59 Engine Mechanical-1.8T Engine Crankshaft, Crankshaft, Sump Crankshaft, Sump Sump and and Oil Oil Pump Pump Pump Assembly Assembly Assembly 1. Oil pump assembly 5. Main bearing shells (upper) (5 off; plain in No. 1 and 5, grooved in No. 2, 3 and 4) 2.
Page 60 Engine Engine Mechanical-1.8T 9. Bolts flywheel/drive plate to crankshaft (6 off) 29. Oil pressure switch 10. Main bearing shells (lower) (5 off) 30. Sump gasket 11. Dowels bearing ladder to cylinder block 31. Sump 12. Bearing ladder 32. Bolts (long) sump to bearing ladder 13.
Page 61 Engine Mechanical-1.8T Engine Cylinder Cylinder Head Cylinder Head Head Components Components Components 1. Bolts camshaft carrier to cylinder head 6. Cylinder head 2. Camshaft carrier 7. Cover plate inlet camshaft 3. Inlet camshaft 8. Screws cover plate to camshaft cover 4.
Page 62 Engine Engine Mechanical-1.8T 11. Gasket coolant outlet elbow 23. Exhaust valves 12. Coolant outlet elbow 24. Exhaust valve seat inserts 13. Screws coolant outlet elbow to cylinder head 25. Inlet valves 14. Washer coolant temperature sensor 26. Inlet valve seat inserts 15.
Page 63 Engine Mechanical-1.8T Engine Camshaft Camshaft Cover, Camshaft Cover, Engine Cover, Engine Cover Engine Cover Cover and and Inlet Inlet Manifold Inlet Manifold Manifold 1. Bolts spark plug cover to camshaft cover 6. Bolt camshaft sensor to camshaft cover 2. Spark plug cover 7.
Page 64 Engine Engine Mechanical-1.8T 11. Studs inlet manifold to cylinder head 18. Spring clip part load breather hose to camshaft cover 12. Gasket inlet manifold to cylinder head (outside) 19. Part load breather hose with one way valve camshaft cover to inlet manifold breather 13.
Page 65 Engine Mechanical-1.8T Engine Camshaft Camshaft Timing Camshaft Timing Timing Belt Belt Belt Components Components Components 1. Screws upper front to upper rear drive belt cover 12. Exhaust camshaft drive gear 2. Upper front drive belt cover 13. Seal lower front drive belt cover 3.
Page 66 Engine Engine Mechanical-1.8T Exhaust Exhaust Exhaust Manifold Manifold Components Manifold Components Components 1. Gasket - exhaust manifold to cylinder head 5. Stud turbocharger to exhaust manifold 2. Flanged nut exhaust manifold to turbocharger 6. Flanged nut turbocharger to exhaust manifold 3.
Page 67 Engine Mechanical-1.8T Engine Inlet Inlet Manifold Inlet Manifold Manifold Components Components Components 1. Inlet manifold 3. Gasket - inlet manifold to cylinder head (outside) 2. Nuts - inlet manifold to cylinder head 4. Gasket - inlet manifold to cylinder head (inside) Version 2.0...
Page 68: Description
Engine Engine Mechanical-1.8T Description Cylinder Head Components General The cross flow cylinder head is a four-valve per cylinder, central spark plug design with the inlet ports designed to induce swirl The K4 engine is constructed from seven machined aluminium of the air/ fuel mixture serving to improve combustion and castings: hence fuel economy, performance and exhaust emissions.
Page 69 Engine Mechanical-1.8T Engine gearboxes and four bolts on manual gearboxes. One nut is used to connect the two halves. • A LH engine mount mounted to the body using two bolts and to the engine using three bolts. • A lower tie-bar linked to the sump bracket and subframe cross member using two bolts.
Page 70: Operation
Engine Engine Mechanical-1.8T Operation Lubrication Circuit 1. Cylinder head oil supply drilling 8. Oil filter (full-flow cartridge type) 2. Cylinder head oilways (oil feed for hydraulic tappets and 9. Oil pick-up pipe (incorporating strainer) camshaft bearings) 10. Oil pressure sensor 3.
Page 71 Engine Mechanical-1.8T Engine The oil pump is directly driven from the crankshaft which turbine housing receives the hot exhaust gases from the incorporates a pressure relief valve. If oil pressure is too high, exhaust manifold, driving the turbine wheel. This drive the oil pressure relief valve opens and the excess oil is diverted is transmitted through a shaft supported by a bearing to back to the intake side of the oil pump.
Page 72: Service Procedures
Engine Engine Mechanical-1.8T Service Procedures 6. Remove any debris from spark plug recesses. Cylinder Head Overhaul - with Cylinder Head 7. Remove spark plugs. Removed 8. Check camshaft end-float using a DTI (refer to Remove specification). 1. Using sequence shown, remove 7 nuts securing exhaust manifold to cylinder head and remove manifold.
Page 73 Engine Mechanical-1.8T Engine 13. Remove and discard oil seals from camshafts. 14. Remove 16 tappets from cylinder head and store in fitted order. Invert tappets to prevent oil loss. 23. If clearance is excessive, fit new camshafts and repeat check. If clearance is still excessive renew cylinder head and camshaft carrier assembly.
Page 74 Engine Engine Mechanical-1.8T valves and springs in fitted order. 38. Check existing valve stem diameter. Check valve guide clearance using new valve (Refer to specification). 31. Remove T10006valve stem seal using tool. 39. Renew valves as necessary. If valve guides should be renewed, new cylinder head and camshaft carrier assembly must be fitted.
Page 75 Engine Mechanical-1.8T Engine 44. Apply Prussian Blue to valve seat, insert valve and press E=29.560 to 29.573 mm E=25.960 to 25.973 mm into position without rotating. Remove and check for F=1.2mm F=1.6mm even and central seating. Seating position shown by G=26.43mm G=22.83mm blue should be in centre of valve face.
Page 76 Engine Engine Mechanical-1.8T 8. Lubricate camshaft cams and journals. 9. Fit camshaft carrier and progressively tighten bolts, in sequence shown to 10 Nm. Exhaust rear camshaft seal shown, other seals similar7–10Nm. 10. Fit tool to end of camshafts to protect seals.T10013to end of camshafts to protect seals.
Page 77: Crankshaft Overhaul - With Engine Removed
Engine Mechanical-1.8T Engine Crankshaft Overhaul - with Engine Removed Remove 1. Remove crankshaft rear oil seal. Crankshaft Crankshaft Crankshaft Rear Rear Oil Rear Oil Seal Seal Seal 2. Remove cylinder head. Cylinder Head Head Gasket Gasket Cylinder Cylinder Head Gasket 3.
Page 78 Engine Engine Mechanical-1.8T ensuring that indent on pulley locates over lug on timing gear. 24. Fit pulley bolt and washer, lightly tighten bolt. 25. Mark connecting rod bearing caps for refitment. Caution: Keep bearing caps, bearings and bolts in their fitted order.
Page 79 12. Use a lint free cloth and suitable solvent to clean sealing surfaces on cylinder block and bearing ladder. Tip: Please use MG MOTOR recommended solvent. 13. Fit selected crankshaft main bearings and fit to cylinder block and bearing ladder.
Page 80 Engine Engine Mechanical-1.8T 7–10Nm. 32. Refit cylinder liner clamps T10018and tighten bolts sufficiently to secure cylinder liners. 33. Clean oil pick up strainer. 34. Clean 'O' ring recesses. 35. Lubricate new 'O' ring with oil and fit to pick-up strainer. 36.
Page 81: Connecting Rod Bearings Overhaul
Engine Mechanical-1.8T Engine Connecting Rod Bearings Overhaul Remove 1. Disconnect battery earth lead. 2. Remove cylinder head. Cylinder Cylinder Cylinder Head Head Head Gasket Gasket Gasket 3. Remove sump Sump Sump Sump Reseal Reseal Reseal 4. Temporarily remove cylinder liner retainer clamps T10018.
Page 82 Engine Engine Mechanical-1.8T Connecting Connecting rod big - end journal group rod big - end Grade A Grade B Grade C bearing bore group Blue - Blue Red - Blue Red - Red Blue - Blue - Blue Red - Blue Yellow Yellow - Blue -...
Page 83: Pistons & Liners
Engine Mechanical-1.8T Engine Pistons & Liners clamps are refitted. Remove 16. Fit oil rail to bearing ladder. CAUTION: A new oil rail must 1. Remove connecting rod bearings. 17. Fit and tighten nuts securing oil rail 7–10Nm. Connecting Rod Rod Bearings Bearings Overhaul Overhaul Connecting...
Page 84 Engine Engine Mechanical-1.8T 6. Position piston with bottom of skirt 30 mm from top of 14. Measure wear and taper in two axes 65 mm from top cylinder block. of cylinder liner bore. 7. Using feeler gauges, measure and record clearance Caution: Cylinder liners with excessively glazed, worn, between piston and left hand side of cylinder liner - scratched or scored bores must be replaced.
Page 85 Engine Mechanical-1.8T Engine Caution: Do not push pistons below top face of cylinder liner until big end bearings and caps are to be fitted. 26. Fit connecting rod bearing. Connecting Connecting Connecting Rod Rod Bearings Bearings Bearings Overhaul Overhaul Overhaul 20.
Page 86: Crankshaft Rear Oil Seal
It is essential that these areas are thoroughly clean, free of old sealant and dry. Tip: Please use MG MOTOR recommended solvent. 2. Please lubricate the lip of oil seals. 3. FitT10059 to the back of crankshaft.
Page 87: Crankshaft Front Oil Seal
Engine Mechanical-1.8T Engine Crankshaft Front Oil Seal Remove 1. Disconnect battery earth lead. 2. Remove camshaft drive belt. Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3. Remove crankshaft timing gear. 4. Fit thrust buttonT10025 to end of crankshaft. 8.
Page 88: Flywheel - Manual Transmission
Engine Engine Mechanical-1.8T Flywheel - Manual Transmission Torque Converter Drive Plate - Automatic Transmission Remove Remove 1. Remove clutch assembly. 1. Remove automatic transmission. Clutch Assembly Assembly Clutch Clutch Assembly 2. Position T10028to starter ring gear and secure with 2. Fit flywheel locking toolT10028 to cylinder block and bolt to cylinder block to restrain crankshaft.
Page 89: Cylinder Head Gasket Overhaul - With Engine Removed
Engine Mechanical-1.8T Engine Cylinder Head Gasket Overhaul - with Engine 8. Fit bolts from flywheel to hydraulic torque convert and Removed tighten to 25–35Nm. Remove 9. Fit bolts from LH and RH closing panel to auto 1. Remove and discard camshaft drive belt. transmission housing and tighten to 22–28Nm.
Page 90 Engine Engine Mechanical-1.8T 9. Using tool T10030rotate both camshafts clockwise to 6. Remove bolt securing alternator heat shield to cylinder gain access to bolts 7 and 8. block and remove heat shield. 10. Using sequence shown, progressively loosen bolts 7 to 10;...
Page 91 Engine Mechanical-1.8T Engine 16. Remove drive belt rear upper cover. 2. Remove bolts securing cylinder liner clampsT10018 and remove clamps. Do not rotate crankshaft with 17. Using assistance, remove cylinder head from cylinder clamps removed. block. 3. Clean joint surfaces of cylinder head and cylinder block. 18.
Page 92 Engine Engine Mechanical-1.8T rotate camshafts to gain access to cylinder head bolts. Use a felt tip pen and mark position of radial mark on each bolt head on the cylinder head. Use a suitable angle torque gauge and tighten all bolts in sequence 180°.
Page 93: Camshaft Cover Gasket
Engine Mechanical-1.8T Engine Camshaft Cover Gasket Remove 1. Disconnect battery earth lead. 2. Release 2 clips and disconnect 2 breather hoses from camshaft cover. 7. Remove camshaft cover. Caution: The gasket is reusable and should remain attached to the camshaft cover. 8.
Page 94: Valves
Engine Engine Mechanical-1.8T Valves 8. Remove intake manifold, remove and discard gasket. Remove 9. Remove both camshafts and discard oil seals. 1. Disconnect battery earth lead. 2. Remove cylinder head. Cylinder Head Head Gasket Gasket Cylinder Cylinder Head Gasket 3. Using sequence shown, remove 7 nuts securing exhaust manifold to cylinder head.
Page 95 Engine Mechanical-1.8T Engine 15. Remove valve spring, cap and valve. c. 60° MS76-111- To narrow valve seats and obtain seat widths 5. Cut valve face angle and valve seat to the following: • Valve seat: Angle = 45° Width A: Inlet = 1.2 mm;...
Page 96 Engine Engine Mechanical-1.8T 16. Fit collects. 17. Release valve spring and remove T10006. 18. Lubricate and fit tappets to tappet bores. 19. Clean camshafts and mating faces of cylinder head and camshaft carrier. Tip: Please use SAIC MOTOR recommended solvent. 20.
Page 97 Engine Mechanical-1.8T Engine 23. Fit camshaft carrier and progressively tighten bolts 30. Clean mating faces of exhaust manifold and cylinder securing camshaft carrier to cylinder head in the head. sequence shown to 7–10Nm. 31. Fit new exhaust manifold gasket to cylinder head. 24.
Page 98: Hydraulic Tappets
Engine Engine Mechanical-1.8T Hydraulic Tappets Camshafts - Inlet or Exhaust Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove camshafts. 2. Remove camshaft drive belt. Camshafts Camshafts Camshafts - - - Inlet Inlet or or or Exhaust Inlet Exhaust Exhaust...
Page 99 Engine Mechanical-1.8T Engine 6. Apply a 2 mm continuous bead of recommended sealant to inside paths and outside paths on camshaft carrier as shown then spread to an even film using a roller. Caution: Ensure sealant does not block oil ways. Caution: To avoid contamination, assembly should be completed immediately after application of sealant.
Page 100: Intake Manifold Gasket
Engine Engine Mechanical-1.8T Intake Manifold Gasket tool T10015. Remove Caution: Oil seals are waxed and must not be lubricated 1. Disconnect battery earth lead. prior to fitting. 2. Drain cooling system. 12. Fit camshaft cover. Coolant Coolant Coolant - - - Drain Drain Drain and and Refill...
Page 101 Engine Mechanical-1.8T Engine 9. Remove 2 bolts securing RH coil and release coil. 15. Release fuel feed pipe from fuel rail. Caution: Always fit plugs to open connections to prevent contamination. 16. Working in sequence shown, progressively loosen then remove 7 nuts securing intake manifold to cylinder head.
Page 102: Exhaust Manifold Gasket
Engine Engine Mechanical-1.8T Exhaust Manifold Gasket Remove 1. Disconnect battery earth lead. 2. Drain coolant system. Coolant Coolant Coolant - - - Drain Drain Drain and and Refill Refill Refill . . . 3. Raise front of vehicle and support on stand(s). Warning: Do not work on or under a vehicle supported only by a jack.
Page 103 Engine Mechanical-1.8T Engine 11. Loosen jubilee clip securing intercooler intake hose to 15. Release clip and disconnect top coolant hose from turbocharger and release hose. turbocharger. 16. Remove alternator top nut and bolt, loosen bottom nut and pivot alternator backwards. 12.
Page 104 Engine Engine Mechanical-1.8T Refit 19. Release circlip securing top coolant hose to engine, 1. Fit gasket and turbocharger to manifold, fit and tighten release hose and position aside. nuts to 30 Nm. 2. With assistance manoeuvre turbocharger and exhaust manifold into engine compartment and position over mounting studs.
Page 105: Oil Pump
Engine Mechanical-1.8T Engine Coolant Coolant Coolant - - - Drain Drain Drain and and Refill Refill Refill Oil Pump Remove 1. Remove camshaft drive belt. Camshaft Drive Drive Belt Belt Camshaft Camshaft Drive Belt 2. Remove crankshaft timing gear. 3. Remove 2 bolts securing engine harness to oil pump and move harness clear of pump.
Page 106: Engine Oil And Oil Filter
Engine Engine Mechanical-1.8T Engine Oil and Oil Filter cover to8–11Nm. Replace 6. Fit bolts securing engine harness to oil pump to Fit bolts securing engine harness to oil pump to9Nm. 1. Raise vehicle on ramp. 7. Fit oil seal guide from seal kit to crankshaft. 2.
Page 107: Engine Oil Pressure Check
Engine Mechanical-1.8T Engine Engine Oil Pressure Check correct level. Check Capacities Capacities Capacities 1. Remove oil pressure switch. Fluids Fluids Fluids and and Lubricants Lubricants Lubricants Switch - - - Oil Oil Pressure Pressure . . . Switch Switch Pressure 7.
Page 108: Oil Pick - Up Strainer
Engine Engine Mechanical-1.8T Oil Pick - Up Strainer Engine Sump Remove Remove 1. Remove engine sump. 1. Disconnect battery earth lead. 2. Raise front of vehicle. Sump Reseal Reseal Sump Sump Reseal Warning: Do not work on or under a vehicle supported 2.
Page 109: Camshaft Drive Belt Cover - Front Upper
Engine Mechanical-1.8T Engine Camshaft Drive Belt Cover - Front Upper 4. Working in the sequence shown, progressively tighten engine sump bolts to 28–32Nm. Remove 1. Disconnect battery earth lead. 2. Loosen lower screw securing drive gear front upper cover. 5. Tighten bolts securing transmission to sump to 75–90Nm.
Page 110: Camshaft Drive Belt Cover - Rear Upper
Engine Engine Mechanical-1.8T Camshaft Drive Belt Cover - Rear Upper Remove 1. Disconnect battery earth lead. 2. Remove camshaft drive belt. Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3. Suitably identify each timing gear to its respective camshaft. Refit 1.
Page 111: Crankshaft Pulley
Engine Mechanical-1.8T Engine Crankshaft Pulley to 200–210Nm Remove 4. Remove bolts and remove flyingwheel locking tool. 1. Disconnect battery earth lead. 5. Fit ancillary drive belt. 2. Remove starter motor. Drive Drive Drive Belt Belt Belt Starter Starter Starter motor motor motor 6.
Page 112: Engine Mounting - Rh
Engine Engine Mechanical-1.8T Engine Mounting - RH Engine Mounting Lower Tie Rod Remove Remove 1. Disconnect battery earth lead. 1. Remove underbelly panel. 2. Support engine on jack. Undertray - - - Assembly Assembly Undertray Undertray Assembly Caution: To prevent damage to components, cushion the 2.
Page 113: Camshaft Front Oil Seal - Exhaust
Engine Mechanical-1.8T Engine Camshaft Front Oil Seal - Exhaust Caution: Oil seals are waxed and must not be lubricated Remove prior to fitting. 1. Disconnect battery earth lead. 2. Remove camshaft drive belt. Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3.
Page 114: Camshaft Front Oil Seal - Inlet
Engine Engine Mechanical-1.8T Camshaft Front Oil Seal - Inlet Remove 1. Disconnect battery earth lead. 2. Remove camshaft drive belt. Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3. Remove timing gear locking toolT10029 from timing gears. Exhaust camshaft shown, inlet camshaft similar. 3.
Page 115: Camshaft Drive Belt
Engine Mechanical-1.8T Engine Camshaft Drive Belt Remove 1. Disconnect battery earth lead. 2. Remove drive belt front upper cover. Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Cover Belt Cover - - - Front Cover Front Front Upper Upper Upper 3.
Page 116 Engine Engine Mechanical-1.8T 15. Remove camshaft drive belt. 4. Fit drive belt tensioner with tensioner lever at 9 o'clock position and tighten new fixing bolt until it is just Caution: Ease the belt off gears using fingers only. Metal possible to move tensioner lever. levers may damage the belt and gears.
Page 117 Engine Mechanical-1.8T Engine Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Cover Belt Cover - - - Front Cover Front Front Upper Upper Upper 25. Clean engine RH mounting arm and mating face. 26. Fit engine RH hydramount to engine, secure 2 bolts from engine RH hydramount to body and tighten to 90–110Nm.
Page 118: Engine And Manual Transmission
Engine Engine Mechanical-1.8T Engine and Manual Transmission Remove 1. Position vehicle on a 2 post ramp. 2. Drain cooling system. Coolant Coolant Coolant - - - Drain Drain Drain and and Refill Refill Refill 3. Disconnect battery earth lead. 4. Remove battery carrier. Battery Battery Battery Carrier...
Page 119 Engine Mechanical-1.8T Engine 15. Disconnect Lucar connector from starter motor. 20. Release clip and disconnect purge valve hose from 16. Remove bolt and release earth lead from transmission. intake manifold. 21. Disconnect purge valve multiplug. 17. Remove bolt and disconnect engine earth lead from engine compartment fuse box.
Page 120 Engine Engine Mechanical-1.8T 24. UsingT22002 disconnect clutch fluid pipe. 28. Release latch and disconnect multiplugs from ECM. 25. Release gear change cables from selector shafts. 29. FeedECM harness into engine bay. 30. DisconnectPAS pressure sensor multiplug. 26. Release clips and disconnect gear change cables from transmission mounting bracket.
Page 121 Engine Mechanical-1.8T Engine 34. Remove banjo bolt securing fluid outlet hose toPAS 39. Remove 3 bolts and move A/C compressor aside. pump, release hose, remove and discard sealing washers. Caution: Always fit plugs to open connections to prevent contamination. 35. Remove 3 bolt securingPAS reservoir to engine RH hydramount and position reservoir aside.
Page 122 Engine Engine Mechanical-1.8T 43. Release pressure control hoses from turbocharger and 46. Release clip and disconnect coolant drain hose from wastegate. turbocharger. 44. Loosen jubilee clip securing intercooler intake hose to 47. Remove 2 bolts securing engine mounting lower tie rod turbocharger and release hose.
Page 123 Engine Mechanical-1.8T Engine 52. Disconnect pad wear indicator harness multiplug, 59. Remove M10 nut from ball pin. release harness from clip. 60. Release clip securing LH brake hose and release brake 53. Remove nut and bolt securing lower ball joint to RH hose from support bracket and clip onABS sensor front lower suspension arm.
Page 124 Engine Engine Mechanical-1.8T 67. Tie drive shaft aside. 72. Raise hoist to take weight of engine without exerting load on mountings. 68. Remove 2 bolts and remove camshaft seal blanking plate. 73. Remove 3 bolts securing engine RH hydramount to engine and 2 bolts to body, remove RH hydramount.
Page 125 Engine Mechanical-1.8T Engine 11. Release LH drive shaft, fit new circlip to drive shaft. Release RH drive shaft. 12. With assistance, fit drive shafts to transmission, keeping both shafts square to prevent damage to oil seals in transmission. 13. Remove lower arm ball joint protectors T32003. 14.
Page 126: Engine And Automatic Transmission
Engine Engine Mechanical-1.8T Engine and Automatic Transmission 35. Using a new 'O' ring, fitPAS inlet hose to pump, fit bolts and tighten to 10Nm. Remove 36. ConnectPAS pressure sensor multiplug and securePAS 1. Position vehicle on a 2 post ramp. pump cover.
Page 127 Engine Mechanical-1.8T Engine 15. Disconnect servo vacuum pipe from intake manifold. 11. Release clips securing hoses to coolant elbow and disconnect hoses. 16. Remove nut and disconnect battery lead from starter motor. 12. Release clip securing coolant hose to coolant rail and disconnect hose.
Page 128 Engine Engine Mechanical-1.8T 19. Remove bolt and disconnect engine earth lead from 24. Release clip and disconnect hose from fuel rail. engine compartment fuse box. 25. Remove bolt securing PAShose support bracket to 20. Disconnect multiplug from engine compartment fuse coolant rail.
Page 129 Engine Mechanical-1.8T Engine engine RH hydramount and position reservoir aside. 27. Feed ECMharness into engine bay. 28. Disconnect PASpressure sensor multiplug. 36. Remove front wheels. 37. Drain transmission oil. 38. Using a 13 mm spanner, rotate tensioner to release tension and remove ancillary drive belt from A/C compressor pulley.
Page 130 Engine Engine Mechanical-1.8T 41. Remove and discard exhaust flange gasket. 45. Loosen jubilee clip securing intercooler intake hose to 42. Loosen jubilee clip securing air intake hose to turbocharger and release hose. turbocharger and release hose. 46. Release clip and disconnect coolant drain hose from 43.
Page 131 Engine Mechanical-1.8T Engine suspension arm. 55. Fit lower arm ball joint protectorT32003. 56. Remove 3 bolts securing intermediate shaft bearing support to engine 48. Remove nut securing RH track rod ball joint. 49. Fit an M10 nut to ball pin, flush with end of pin and using T38008release ball joint taper.
Page 132 Engine Engine Mechanical-1.8T 67. With assistance, pull front hubs outwards and release 72. Release clip and remove selector cable from drive shaft and intermediate shaft from transmission. transmission bracket. Keep both shafts square to avoid damage to oil seals 73. Remove 2 bolts and remove camshaft seal blanking in transmission.
Page 133 Engine Mechanical-1.8T Engine bracket. 77. Raise hoist to take weight of engine without exerting load on mountings. 83. Remove transmission on mounting bracket. 78. Remove 3 bolts securing engine RH hydramount to 84. Raise hoist and manoeuvre engine automatic engine and 2 bolts to body, remove hydramount. transmission from vehicle.
Page 134 Engine Engine Mechanical-1.8T are in grooves in ball joints. 42. Position and connect multiplug to ECMand secure latch. 18. Position intermediate shaft support bearing to engine, fit bolts and tighten to 25Nm. 43. Position PAShose support bracket to coolant rail, fit bolt and tighten to 10Nm.
Page 135: Cylinder Head Gasket
Engine Mechanical-1.8T Engine Cylinder Head Gasket Remove 1. Disconnect battery earth lead. 2. 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. 3. Drain cooling system. Coolant - - - Drain Drain and and Refill...
Page 136 Engine Engine Mechanical-1.8T Camshaft Camshaft Camshaft Cover Cover Cover Gasket Gasket Gasket from manifold. 22. Using sequence shown, progressively loosen cylinder Caution: Always fit plugs to open connections to prevent head bolts 1 to 6; remove bolts and store in fitted order. contamination.
Page 137 Engine Mechanical-1.8T Engine Refit 29. Remove screw securing drive belt rear upper cover to coolant pump. 1. Remove bolts securing cylinder liner clamps 30. Remove screws securing drive belt rear upper cover to T10018and remove clamps. Do not rotate crankshaft cylinder head, remove cover.
Page 138 Engine Engine Mechanical-1.8T 14. To enable camshafts to be rotated in order to gain turbocharger and tighten nuts to 45–55Nm. access to cylinder head bolts, temporarily fit timing 32. Fit drive belt rear upper cover, fit screws noting that gears to their respective camshafts, fit but do not longest screw secures cover to coolant pump.
Page 139: Turbocharger
Engine Mechanical-1.8T Engine Turbocharger Remove 1. Disconnect battery earth lead. 2. Drain coolant system. Coolant Coolant Coolant - - - Drain Drain and Drain and Refill. Refill. Refill. 3. Raise front of vehicle and support on stand(s). Warning: Do not work on or under a vehicle supported only by a jack.
Page 140 Engine Engine Mechanical-1.8T 15. Release clip and disconnect top coolant drain hose 19. Release circlip securing top coolant hose to engine, from turbocharger. release hose and position aside. 16. Remove alternator top nut and bolt, loosen bottom nut and pivot alternator backwards. 20.
Page 141 Engine Mechanical-1.8T Engine Coolant Coolant Coolant - - - Drain Drain and Drain and Refill Refill . . . Refill Refit 1. Fit gasket and turbocharger to manifold, fit and tighten nuts to 28–32Nm. 2. With assistance manoeuvre turbocharger and exhaust manifold into engine compartment and position over mounting studs.
Page 142: Hose - Coolant Drain - Turbocharger
Engine Engine Mechanical-1.8T Hose - Coolant Drain - Turbocharger Hose - Coolant Intake - Turbocharger Remove Remove 1. Drain coolant system. 1. Drain coolant system. Coolant - - - Drain Drain and and Refill Refill Coolant - - - Drain Drain and and Refill Refill...
Page 143: Pipe - Oil Return - Turbocharger
Engine Mechanical-1.8T Engine Pipe - Oil Return - Turbocharger Hose - Air Intake - Turbocharger Remove Remove 1. Remove underbelly panel. 1. Release jubilee clip securing turbocharger air intake hose to air cleaner and release hose from air cleaner. Undertray - - - Assembly Assembly Undertray Undertray...
Page 144: Pipe - Oil Feed - Turbocharger
Engine Engine Mechanical-1.8T Pipe - Oil Feed - Turbocharger Hose - Air Intake - Electronic Throttle Remove Remove 1. Remove bolt and 2 copper washers securing oil feed 1. Remove battery carrier. pipe to turbocharger and release pipe. Battery Battery Battery Carrier Carrier Carrier Bracket...
Page 145: Intercooler
Engine Mechanical-1.8T Engine Intercooler 6. Remove battery carrier. Remove Battery Carrier Carrier Bracket Bracket Battery Battery Carrier Bracket 1. Disconnect battery earth lead. 2. Remove front bumper. Bumper Assembly Assembly - - - Front Front Bumper Bumper Assembly Front 3. Remove battery carrier. Battery Battery Battery Carrier...
Page 146: Hose - Air Intake - Intercooler
Engine Engine Mechanical-1.8T Hose - Air Intake - Intercooler Remove 1. Remove air cleaner. Air Cleaner Cleaner Cleaner 2. Loosen jubilee clip securing intercooler air intake hose to turbocharger and release hose. 3. Loosen jubilee clip securing intercooler air intake hose to intercooler and remove hose.
Page 147: Special Tools
Engine Mechanical-1.8T Engine Special Tools Tool Description Picture Number Tool Description Picture Number Replacer, Front T10032 Crankshaft / Valve spring Camshaft Seals T10005 compressor Piston ring T10016 compressor Remover valve T10006 stem seal Protector Sleeve T10059 Protector Crankshaft Rear T10013 Sleeve Camshaft oil seal Oil Seal...
Page 148 Engine Engine Mechanical-1.8T Tool Description Picture Tool Description Picture Number Number Cap remover Engine oil T10025 crankshaft front T10001 pressure test equipment oil seal Camshaft / Crankshaft Flywheel T10031 T10036 Front Oil Seal locking AT Remover flywheel locking Flywheel T10028 T10037 tool locking (MT)
Page 149 Engine Mechanical-1.8T Engine Tool Description Picture Tool Description Picture Number Number Pipe dismantling Remover drive T22002 T30001 fork shaft Remover ball Engine lifting T38008 T10035 joint bracket Spreader Front Engine lift T32020 Lower Arm T10007 bracket Ball Joint Lever front T32011 lower arm ball joint...
Page 150: Engine Mechanical-1.8 Vct
Engine Engine Mechanical-1.8 VCT Engine Mechanical-1.8 VCT Specifications Torque Description Value Bolt- camshaft carrier to cylinder head 7–10Nm Bolt- exhaust camshaft seal blanking plate to cylinder head 22–28Nm Spark plugs 22–28Nm Nut-intake manifold to cylinder head 15–18Nm Nut-exhaust manifold to cylinder head 40–50Nm Bolt-bearing ladder to cylinder block 28–32Nm...
Page 151: Reference
Engine Mechanical-1.8 VCT Engine Description Value Bolt-engine RH mounting arm to engine 90–110Nm Bolt-power steering fluid collection to engine RH hydraulic 7–10Nm mounting Bolt-engine RH mounting tie rod to body 90–110Nm Bolt-drive belt front lower cover to cylinder block 8–11Nm Bolt-PAS belt tensioner 25Nm Bolt-drive belt tensioner to cylinder head...
Page 152: Description And Operation
Engine Engine Mechanical-1.8 VCT Description and Operation Component Layout K4 Engine Component Layout K4 engine general view Version 2.0...
Page 153 Engine Mechanical-1.8 VCT Engine K4 engine internal view Version 2.0...
Page 154 Engine Engine Mechanical-1.8 VCT Cylinder Block Components 1. O-ring thermostat housing to coolant pump 6. Big-end bearing cap 2. Thermostat housing 7. Big-end bearing shell (lower) 3. Screw thermostat housing to cylinder block 8. Big-end bearing shell (upper) 4. O-ring thermostat cover to coolant pipe 9.
Page 155 Engine Mechanical-1.8 VCT Engine 11. Oil control ring 19. Cylinder head gasket 12. 2nd compression ring 20. Cylinder block 13. Top compression ring 21. O-ring coolant pump to cylinder block 14. Cylinder liner 22. Bolt coolant pump to cylinder block 15.
Page 156 Engine Engine Mechanical-1.8 VCT Crankshaft, Sump and Oil Pump Assembly 1. Oil pump assembly 5. Main bearing shells (upper) (5 off; plain in No. 1 and 5, grooved in No. 2, 3 and 4) 2. Gasket oil pump 6. Dowel 3.
Page 157 Engine Mechanical-1.8 VCT Engine 9. Bolts flywheel/drive plate to crankshaft 26. Bolts (long) sump to bearing ladder 10. Main bearing shells (lower) 27. Sealing washer sump plug 11. Dowels bearing ladder to cylinder block 28. Plug sump oil drain 12. Bearing ladder 29.
Page 158 Engine Engine Mechanical-1.8 VCT Cylinder Head Components 1. Bolts,camshaft carrier to cylinder head 6. Dowel 2. Inlet camshaft oil control solenoid housing 7. Bolt,exhaust camshaft oil control solenoid to housing 3. Camshaft carrier 8. Exhaust camshaft oil control solenoid 4. Inlet camshaft 9.
Page 159 Engine Mechanical-1.8 VCT Engine 11. Exhaust camshaft 25. Nuts,exhaust manifold to cylinder head studs 12. Cylinder head 26. Gasket,exhaust manifold to cylinder head 13. Bolt,inlet camshaft position sensor housing to cylinder 27. Studs,exhaust manifold to cylinder head head 28. Valve guides 14.
Page 160 Engine Engine Mechanical-1.8 VCT Camshaft Cover, Engine Cover and Inlet Manifold 1. Bolts spark plug cover to camshaft cover 6. Gasket camshaft cover to camshaft carrier 2. Spark plug cover 7. Nuts inlet manifold to cylinder head studs 3. Bolts camshaft cover to camshaft carrier 8.
Page 161 Engine Mechanical-1.8 VCT Engine 11. Inlet manifold 15. Full load breather hose 12. Blanking plate 16. Spring clip part load breather hose to camshaft cover 13. Cap screws blanking plate 17. Part load breather hose with one way valve camshaft cover to inlet manifold breather 14.
Page 162 Engine Engine Mechanical-1.8 VCT Camshaft Camshaft Camshaft Timing Timing Timing Belt Belt Belt Components Components Components 1. Screws upper front to upper rear drive belt cover 12. Exhaust camshaft phaser unit 2. Upper front drive belt cover 13. Seal lower front drive belt cover 3.
Page 163: Description
Engine Mechanical-1.8 VCT Engine Description Cylinder Head Components General The cross flow cylinder head is a four-valve per cylinder, central spark plug design with the inlet ports designed to induce swirl The K4 engine is constructed from seven machined aluminium of the air/ fuel mixture serving to improve combustion and castings: hence fuel economy, performance and exhaust emissions.
Page 164 Engine Engine Mechanical-1.8 VCT of the engine. Engine movement is caused by the torque reaction of engine operation and movement induced through the suspension during vehicle motion over varying road conditions. The tie-bar controls the torque inputs to dampen the engine's tendency for fore-aft roll during acceleration and deceleration.
Page 165: Operation
Engine Mechanical-1.8 VCT Engine Operation Lubrication Circuit 1. Cylinder head oil supply drilling 7. Oil pressure sensor 2. Cylinder head oilways (oil feed for hydraulic tappets and camshaft bearings) 9. Oil pump pressure relief valve 3. Crankshaft cross-drillings 10. Oil pump pressure relief port (return to oil pump inlet) 4.
Page 166 Engine Engine Mechanical-1.8 VCT Oil leaving via the outlet port of the oil pump is fed through A revised engine block and bearing ladder is used. This a full-flow cartridge type oil filter mounted on an adapter incorporates a turbocharger oil drain facility. The oil feed attached to the oil filter head.
Page 167 Engine Mechanical-1.8 VCT Engine Controlled position Crankcase Ventilation higher engine speeds create excess crankcase pressure that can lead to oil leakage from seals and gaskets. A positive During engine operation a small amount of combustion gases crankcase ventilation system is used to vent these gases from escape past the piston rings into the crankcase, these are the crankcase to the air intake system.
Page 168: Service Procedures
Engine Engine Mechanical-1.8 VCT Service Procedures 6. Remove any debris from spark plug recesses. Cylinder Head Overhaul - with Cylinder Head 7. Remove spark plugs. Removed 8. Check camshaft end-float using a DTI (refer to Remove specification). 1. Using sequence shown, remove 7 nuts securing exhaust manifold to cylinder head and remove manifold.
Page 169 Engine Mechanical-1.8 VCT Engine 13. Remove and discard oil seals from camshafts. 14. Remove 16 tappets from cylinder head and store in fitted order. Invert tappets to prevent oil loss. 23. If clearance is excessive, fit new camshafts and repeat check.
Page 170 Engine Engine Mechanical-1.8 VCT valves and springs in fitted order. 38. Check existing valve stem diameter. Check valve guide clearance using new valve (Refer to specification). 31. Remove T10006valve stem seal using tool. 39. Renew valves as necessary. If valve guides should be renewed, new cylinder head and camshaft carrier assembly must be fitted.
Page 171 Engine Mechanical-1.8 VCT Engine 44. Apply Prussian Blue to valve seat, insert valve and press E=29.560 to 29.573 mm E=25.960 to 25.973 mm into position without rotating. Remove and check for F=1.2mm F=1.6mm even and central seating. Seating position shown by G=26.43mm G=22.83mm blue should be in centre of valve face.
Page 172 Engine Engine Mechanical-1.8 VCT 8. Lubricate camshaft cams and journals. 9. Fit camshaft carrier and progressively tighten bolts, in sequence shown to 10 Nm. Exhaust rear camshaft seal shown, other seals similar7–10Nm. 10. Fit tool to end of camshafts to protect seals.T10013to end of camshafts to protect seals.
Page 173: Crankshaft Overhaul - With Engine Removed
Engine Mechanical-1.8 VCT Engine Crankshaft Overhaul - with Engine Removed Remove 1. Remove crankshaft rear oil seal. Crankshaft Crankshaft Crankshaft Rear Rear Oil Rear Oil Seal Seal Seal 2. Remove cylinder head. Cylinder Head Head Gasket Gasket Cylinder Cylinder Head Gasket 3.
Page 174 Engine Engine Mechanical-1.8 VCT ensuring that indent on pulley locates over lug on timing gear. 24. Fit pulley bolt and washer, lightly tighten bolt. 25. Mark connecting rod bearing caps for refitment. Caution: Keep bearing caps, bearings and bolts in their fitted order.
Page 175 12. Use a lint free cloth and suitable solvent to clean sealing surfaces on cylinder block and bearing ladder. Tip: Please use MG MOTOR recommended solvent. 13. Fit selected crankshaft main bearings and fit to cylinder block and bearing ladder.
Page 176 Engine Engine Mechanical-1.8 VCT 7–10Nm. 32. Refit cylinder liner clamps T10018and tighten bolts sufficiently to secure cylinder liners. 33. Clean oil pick up strainer. 34. Clean 'O' ring recesses. 35. Lubricate new 'O' ring with oil and fit to pick-up strainer.
Page 177: Connecting Rod Bearings Overhaul
Engine Mechanical-1.8 VCT Engine Connecting Rod Bearings Overhaul Remove 1. Disconnect battery earth lead. 2. Remove cylinder head. Cylinder Cylinder Cylinder Head Head Head Gasket Gasket Gasket 3. Remove sump Sump Sump Sump Reseal Reseal Reseal 4. Temporarily remove cylinder liner retainer clamps T10018.
Page 178 Engine Engine Mechanical-1.8 VCT Connecting Connecting rod big - end journal group rod big - end Grade A Grade B Grade C bearing bore group Blue - Blue Red - Blue Red - Red Blue - Blue - Blue Red - Blue Yellow Yellow - Blue -...
Page 179: Pistons & Liners
Engine Mechanical-1.8 VCT Engine Pistons & Liners clamps are refitted. Remove 16. Fit oil rail to bearing ladder. CAUTION: A new oil rail must 1. Remove connecting rod bearings. 17. Fit and tighten nuts securing oil rail 7–10Nm. Connecting Rod Rod Bearings Bearings Overhaul Overhaul...
Page 180 Engine Engine Mechanical-1.8 VCT 6. Position piston with bottom of skirt 30 mm from top of 14. Measure wear and taper in two axes 65 mm from top cylinder block. of cylinder liner bore. 7. Using feeler gauges, measure and record clearance Caution: Cylinder liners with excessively glazed, worn, between piston and left hand side of cylinder liner - scratched or scored bores must be replaced.
Page 181 Engine Mechanical-1.8 VCT Engine Caution: Do not push pistons below top face of cylinder liner until big end bearings and caps are to be fitted. 26. Fit connecting rod bearing. Connecting Connecting Connecting Rod Rod Bearings Bearings Bearings Overhaul Overhaul Overhaul 20.
Page 182: Crankshaft Rear Oil Seal
It is essential that these areas are thoroughly clean, free of old sealant and dry. Tip: Please use MG MOTOR recommended solvent. 2. Please lubricate the lip of oil seals. 3. FitT10059 to the back of crankshaft.
Page 183: Crankshaft Front Oil Seal
Engine Mechanical-1.8 VCT Engine Crankshaft Front Oil Seal Remove 1. Disconnect battery earth lead. 2. Remove camshaft drive belt. Camshaft Camshaft Camshaft Drive Drive Drive Belt Belt Belt 3. Remove crankshaft timing gear. 4. Fit thrust buttonT10025 to end of crankshaft. 8.
Page 184: Flywheel - Manual Transmission
Engine Engine Mechanical-1.8 VCT Flywheel - Manual Transmission Torque Converter Drive Plate - Automatic Transmission Remove Remove 1. Remove clutch assembly. 1. Remove automatic transmission. Clutch Assembly Assembly Clutch Clutch Assembly 2. Position T10028to starter ring gear and secure with 2.
Page 185: Cylinder Head Gasket Overhaul - With Engine Removed
Engine Mechanical-1.8 VCT Engine Cylinder Head Gasket Overhaul - with Engine 8. Fit bolts from flywheel to hydraulic torque convert and Removed tighten to 25–35Nm. Remove 9. Fit bolts from LH and RH closing panel to auto 1. Remove and discard camshaft drive belt. transmission housing and tighten to 22–28Nm.
Page 186 Engine Engine Mechanical-1.8 VCT 9. Using tool T10030rotate both camshafts clockwise to 6. Remove bolt securing alternator heat shield to cylinder gain access to bolts 7 and 8. block and remove heat shield. 10. Using sequence shown, progressively loosen bolts 7 to 10;...
Page 187 Engine Mechanical-1.8 VCT Engine 16. Remove drive belt rear upper cover. 2. Remove bolts securing cylinder liner clampsT10018 and remove clamps. Do not rotate crankshaft with 17. Using assistance, remove cylinder head from cylinder clamps removed. block. 3. Clean joint surfaces of cylinder head and cylinder block. 18.
Page 188 Engine Engine Mechanical-1.8 VCT rotate camshafts to gain access to cylinder head bolts. Use a felt tip pen and mark position of radial mark on each bolt head on the cylinder head. Use a suitable angle torque gauge and tighten all bolts in sequence 180°.
Page 189: Camshaft Cover Gasket
Engine Mechanical-1.8 VCT Engine Camshaft Cover Gasket Remove 1. Disconnect battery earth lead. 2. Release 2 clips and disconnect 2 breather hoses from camshaft cover. 7. Remove camshaft cover. Caution: The gasket is reusable and should remain attached to the camshaft cover. 8.
Page 190: Valves
Engine Engine Mechanical-1.8 VCT Valves 8. Remove intake manifold, remove and discard gasket. Remove 9. Remove both camshafts and discard oil seals. 1. Disconnect battery earth lead. 2. Remove cylinder head. Cylinder Head Head Gasket Gasket Cylinder Cylinder Head Gasket 3.
Page 191 Engine Mechanical-1.8 VCT Engine 15. Remove valve spring, cap and valve. c. 60° MS76-111- To narrow valve seats and obtain seat widths 5. Cut valve face angle and valve seat to the following: • Valve seat: Angle = 45° Width A: Inlet = 1.2 mm;...
Page 192 Engine Engine Mechanical-1.8 VCT 16. Fit collects. 17. Release valve spring and remove T10006. 18. Lubricate and fit tappets to tappet bores. 19. Clean camshafts and mating faces of cylinder head and camshaft carrier. Tip: Please use SAIC MOTOR recommended solvent. 20.
Page 193 Engine Mechanical-1.8 VCT Engine 23. Fit camshaft carrier and progressively tighten bolts 30. Clean mating faces of exhaust manifold and cylinder securing camshaft carrier to cylinder head in the head. sequence shown to 7–10Nm. 31. Fit new exhaust manifold gasket to cylinder head. 24.
Page 194: Hydraulic Tappets
Engine Engine Mechanical-1.8 VCT Hydraulic Tappets Camshafts - Inlet or Exhaust Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove camshafts. 2. Remove camshaft drive belt. Camshafts Camshafts Camshafts - - - Inlet Inlet or or or Exhaust Inlet Exhaust Exhaust...
Page 195 Engine Mechanical-1.8 VCT Engine 6. Apply a 2 mm continuous bead of recommended sealant to inside paths and outside paths on camshaft carrier as shown then spread to an even film using a roller. Caution: Ensure sealant does not block oil ways. Caution: To avoid contamination, assembly should be completed immediately after application of sealant.
Page 196: Intake Manifold Gasket
Engine Engine Mechanical-1.8 VCT Intake Manifold Gasket tool T10015. Remove Caution: Oil seals are waxed and must not be lubricated 1. Disconnect battery earth lead. prior to fitting. 2. Drain cooling system. 12. Fit camshaft cover. Coolant Coolant Coolant - - - Drain Drain Drain and and Refill...
Page 197 Engine Mechanical-1.8 VCT Engine 9. Remove 2 bolts securing RH coil and release coil. 15. Release fuel feed pipe from fuel rail. Caution: Always fit plugs to open connections to prevent contamination. 16. Working in sequence shown, progressively loosen then remove 7 nuts securing intake manifold to cylinder head.
Page 198: 1.8Vct Exhaust Manifold Gasket
Engine Engine Mechanical-1.8 VCT 1.8VCT Exhaust Manifold Gasket Remove 1. Remove alternator. Alternator Alternator Alternator 2. Raise vehicle on ramp. 3. Remove 3 nuts securing exhaust manifold to intermediate pipe. Remove and discard gasket. 4. Connect coolant hose to intake manifold and secure clip.
Page 199 Engine Mechanical-1.8 VCT Engine Refit 1. Clean component mating faces. 2. Fit support bracket to exhaust manifold and secure with nut. Do not tighten fully at this stage. 3. Fit exhaust manifold gasket to cylinder head studs. 4. Fit exhaust manifold to cylinder head, fit nuts, align support bracket to engine studs.
Page 200: Oil Pump
Engine Engine Mechanical-1.8 VCT Oil Pump cover to8–11Nm. Remove 6. Fit bolts securing engine harness to oil pump to Fit bolts securing engine harness to oil pump to9Nm. 1. Remove camshaft drive belt. 7. Fit oil seal guide from seal kit to crankshaft. Camshaft Drive Drive Belt Belt...
Page 201: Engine Oil And Oil Filter
Engine Mechanical-1.8 VCT Engine Engine Oil and Oil Filter correct level. Replace Capacities Capacities Capacities 1. Raise vehicle on ramp. Fluids Fluids Fluids and and Lubricants Lubricants Lubricants 2. Remove underbelly panel. 7. Fit oil filler cap. Undertray Undertray Undertray - - - Assembly Assembly Assembly 8.
Page 202: Engine Oil Pressure Check
Engine Engine Mechanical-1.8 VCT Engine Oil Pressure Check Oil Pick - Up Strainer Check Remove 1. Remove oil pressure switch. 1. Remove engine sump. Switch - - - Oil Oil Pressure Pressure . . . Sump Reseal Reseal Switch Switch Pressure Sump Sump...
Page 203: Engine Sump
Engine Mechanical-1.8 VCT Engine Engine Sump 4. Working in the sequence shown, progressively tighten Remove engine sump bolts to 28–32Nm. 1. Disconnect battery earth lead. 2. Raise front of vehicle. Warning: Do not work on or under a vehicle supported only by a jack.
Page 204: Camshaft Drive Belt Cover - Front Upper
Engine Engine Mechanical-1.8 VCT Camshaft Drive Belt Cover - Front Upper Camshaft Drive Belt Cover - Rear Upper Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Loosen lower screw securing drive gear front upper 2. Remove camshaft drive belt. cover.
Page 205: Crankshaft Pulley
Engine Mechanical-1.8 VCT Engine Crankshaft Pulley Remove 1. Disconnect battery earth lead. 2. Remove starter motor. Starter Starter Starter motor motor motor 3. Raise front of vehicle. Warning: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Page 206: Engine Mounting - Rh
Engine Engine Mechanical-1.8 VCT Engine Mounting - RH 4. Remove bolts and remove flyingwheel locking tool. Remove 5. Fit ancillary drive belt. 1. Disconnect battery earth lead. Drive Drive Drive Belt Belt Belt 2. Support engine on jack. 6. Fit wheel and tighten bolts to 115–130Nm. Caution: To prevent damage to components, cushion the 7.
Page 207: Engine Mounting Lower Tie Rod
Engine Mechanical-1.8 VCT Engine Engine Mounting Lower Tie Rod 1.8VCT Camshaft Front Oil Seal - Exhaust Remove Remove 1. Remove underbelly panel. 1. Disconnect battery earth lead. 2. Remove drive belt upper rear cover. Undertray - - - Assembly Assembly Undertray Undertray Assembly...
Page 208: 1.8Vct Camshaft Front Oil Seal - Inlet
Engine Engine Mechanical-1.8 VCT 1.8VCT Camshaft Front Oil Seal - Inlet 1.8VCT Camshaft Drive Belt (New) Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove camshaft drive belt. 2. Remove drive belt front upper cover. Camshaft Camshaft Camshaft dDrive...
Page 209 Engine Mechanical-1.8 VCT Engine 13. Remove camshaft drive belt. 9. Remove crankshaft pulley. Caution: Ease the belt off gears using fingers only. Metal Crankshaft Crankshaft Crankshaft Pulley Pulley Pulley levers may damage the belt and gears. Caution: Caution: Drive belt must be replaced if cylinder head is 10.
Page 210 Engine Engine Mechanical-1.8 VCT anti-clockwise direction and align pointer to index wire as shown. 4. Fit drive belt tensioner with tensioner lever at 9 o'clock position and tighten new fixing bolt until it is just possible to move tensioner lever. 17.
Page 211: 1.8Vct Camshaft Phaser Unit
Engine Mechanical-1.8 VCT Engine 1.8VCT Camshaft Phaser Unit 24. Fit drive belt front upper cover. Remove Camshaft Drive Drive Belt Belt Cover Cover - - - Front Front Upper Upper Camshaft Camshaft Drive Belt Cover Front Upper 1. Disconnect battery earth lead. 25.
Page 212: 1.8Vct Engine And Manual Transmission
Engine Engine Mechanical-1.8 VCT 1.8VCT Engine and Manual Transmission bracket and remove bracket. Remove 1. Position vehicle on a 2 post ramp. 2. Drain cooling system. Coolant Coolant Coolant - - - Drain Drain Drain and and Refill Refill Refill 3.
Page 213 Engine Mechanical-1.8 VCT Engine 16. Remove 2 bolts securing gear selector cable support 22. Release clip securing return hose to coolant reservoir bracket to transmission. at cylinder block. 17. Remove PAS reservoir screw top and syphon fluid. 18. Remove 3 bolts securing PASreservoir to RH hydramount and position aside.
Page 214 Engine Engine Mechanical-1.8 VCT 33. Raise vehicle. 34. Remove clip and release clutch slave cylinder from bracket, position aside. 27. Position cloth to collect spillage and carefully disconnect fuel line from fuel rail, ensuring fuel line is positioned aside. Intake hose removed for clarity. Warning: The spilling of fuel is unavoidable during this 35.
Page 215 Engine Mechanical-1.8 VCT Engine Refit 1. With assistance position engine and transmission assembly to engine bay and support on wood. 2. Remove lifting equipment. 3. Carefully lower the ramp, ensuring the engine and transmission are aligned to the engine bay. 4.
Page 216: 1.8Vct Engine And Automatic Transmission
Engine Engine Mechanical-1.8 VCT 1.8VCT Engine and Automatic Transmission bolts to 22–28Nm. Remove 32. Connect vacuum pipe to throttle body. 1. Position vehicle on a 2 post ramp. 33. Fit battery carrier support bracket and tighten bolts to 10 Nm. 2.
Page 217 Engine Mechanical-1.8 VCT Engine bracket. 17. Remove PAS reservoir screw top and syphon fluid. 18. Remove 3 bolts securing PASreservoir to RH engine mounting and position aside. 12. Disconnect vacuum pipe from throttle body and position aside. Caution: Always fit plugs to open connections to prevent contamination.
Page 218 Engine Engine Mechanical-1.8 VCT at cylinder block. Warning: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion. Warning: Fuel vapour is highly flammable and in confined spaces is also explosive and toxic. Always have a fire extinguisher containing foam, CO2, gas or powder close Caution: Always fit plugs to open connections to prevent contamination.
Page 219 Engine Mechanical-1.8 VCT Engine position aside. damage. 35. Raise vehicle. 42. Carefully lower ramp, position wood to support engine and transmission. 36. Using T30001release LH inboard drive shaft from transmission and tie aside. 43. Remove nut securing gearbox to LH transmission hydramount.
Page 220 Engine Engine Mechanical-1.8 VCT 9. Fit RH inner drive shaft to transmission, align support 39. Fit ECM.ECM. bracket and tighten bolts to25Nm. Engine Control Control Module Module (ECM) (ECM) Engine Engine Control Module (ECM) 10. Fit LH inner driveshaft to transmission. 40.
Page 221: 1.8Vct Solenoid - Exhaust Camshaft
Engine Mechanical-1.8 VCT Engine 1.8VCT Solenoid - Exhaust Camshaft 1.8VCT Solenoid - Inlet Camshaft Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Disconnect solenoid multiplug. 2. Disconnect solenoid multiplug. S 106027 S 106028 3. Position absorbent cloth to collect spillage, remove bolt 3.
Page 222: 1.8Vct Solenoid Housing - Exhaust Camshaft
Engine Engine Mechanical-1.8 VCT 1.8VCT Solenoid Housing - Exhaust Camshaft 1.8VCT Solenoid Housing - Inlet Camshaft Remove Remove 1. Remove exhaust camshaft solenoid. 1. Remove inlet camshaft solenoid. Solenoid - - - exhaust exhaust camshaft camshaft . . . Solenoid - - - inlet inlet camshaft camshaft 101702.
Page 223: 1.8Vct Cylinder Head Gasketnew
Engine Mechanical-1.8 VCT Engine 1.8VCT Cylinder Head GasketNew 18. Release clip and disconnect purge hose from throttle Remove housing. 19. Depress collar and disconnect brake servo vacuum 1. Disconnect battery earth lead. hose from inlet manifold. 2. Remove air cleaner. 20.
Page 224 Engine Engine Mechanical-1.8 VCT overtightened, back off 90° and re-align. 18. Adjust camshaft to the position as the picture shown. 5. Check cylinder head height. Cylinder head may be refaced. (Refer to specification). 6. Remove all debris from oil and coolant passages. 19.
Page 225 Engine Mechanical-1.8 VCT Engine 34. Fit exhaust manifold. Exhaust Manifold Manifold Gasket Gasket Exhaust Exhaust Manifold Gasket 35. Fit air cleaner. Air Cleaner Cleaner Cleaner 36. Connect battery earth lead. 37. Refill cooling system. . Coolant - - - Drain, Drain, Flush Flush and and Refill...
Page 226: Special Tools
Engine Engine Mechanical-1.8 VCT Special Tools Tool Description Picture Number Tool Description Picture Number Replacer, Front T10032 Crankshaft / Valve spring Camshaft Seals T10005 compressor Piston ring T10016 compressor Remover valve T10006 stem seal Protector Sleeve T10059 Protector Crankshaft Rear T10013 Sleeve Camshaft oil seal...
Page 227 Engine Mechanical-1.8 VCT Engine Tool Description Picture Tool Description Picture Number Number Cap remover Engine oil T10025 crankshaft front T10001 pressure test equipment oil seal Camshaft / Crankshaft Flywheel T10031 T10036 Front Oil Seal locking AT Remover flywheel locking Flywheel T10028 T10037 tool...
Page 228 Engine Engine Mechanical-1.8 VCT Tool Description Picture Number Adjuster VCT T10058 camshaft timing Remover drive T30001 shaft Version 2.0...
Page 229: Engine Cooling System
Engine Cooling System Engine Engine Cooling System Specifications Torque Description Value 5 Nm Bolt-Expansion tank to fixing bracket 5 - 7 Nm Bolt-Cooling fan, cowl and motor assembly to radiator lug Bolt-Cooling fan relay unit to radiator 7 - 10 Nm Bolt-Bonnet locking platform to body 7 - 10 Nm Bolt-Bonnet locking platform bracket to platform...
Page 230: Reference
Engine Engine Cooling System Reference Type Pressurised, spill return, thermostatically controlled water /OAT Cooling fan: 7 blade axial flow electric, thermostatically controlled Coolant capacity: 7.8L ∙Low speed 17 bar ∙High speed 22 bar ∙Low speed 10 bar ∙High speed 19 bar Cooling fan switching points - for engine cooling during normal running: ∙Low speed...
Page 231: Description And Operation
Engine Cooling System Engine Description and Operation System Component Layout Turbo Charger For connections F to I see illustration on following page A= Heater feed connection; B= Heater return connection; C= Cylinder head to bleed hose connection; D= Automatic transmission return connection; E= Automatic transmission feed connection 1.
Page 232 Engine Engine Cooling System VCT Engine For connections F to I see illustration on previous page A=Heater feed connection; B= Heater return connection; C=Cylinder head to bleed hose connection; 1. Cooling fan shroud 14. Hose - coolant expansion tank to T-piece 2.
Page 233 Engine Cooling System Engine Cooling System Cylinder Block Component Layout 1. Flanged bolts 8. Elbow - engine outlet 2. Rear coolant pipe 9. Gasket 3. Bleed screw 10. Pillar bolt 4. Sealing washer 11. Flanged bolts 5. Flanged bolt 12. Coolant pump 6.
Page 234: Description
Engine Engine Cooling System Description Expansion Tank General A plastic coolant expansion tank, fitted with a pressure relief The system circulates the engine coolant, a 50% water and cap, is mounted on a bracket on the RH suspension turret. A 50% Organic Acid Technology operating conditions.
Page 235 Engine Cooling System Engine Radiator and Cooling Fan The radiator is a cross flow type with an aluminium matrix with moulded plastic end tanks and, if fitted, an automatic transmission oil cooler. The radiator has features that carry the fan assembly and Air Conditioning (A/C) condenser and intercooler (Turbocharger).
Page 236: Operation
Engine Engine Cooling System Operation Coolant Flow Turbocharger A= Cold B= Hot Version 2.0...
Page 237 Engine Cooling System Engine A= Cold B= Hot Coolant Flow allowing the engine to run at a higher, more efficient operating temperature without the risk of coolant boiling. There is a limit The cooling system operates using the conduction principle, to which the cooling system can be pressurised so the cap is transferring heat from the engine components into the fitted with a relief valve.
Page 238 Engine Engine Cooling System Heated coolant exits the coolant elbow and enters the heater fuse 4 in the engine compartment fusebox. The fan motor is matrix feed pipe and is fed to the heater matrix. During engine driven by the output from the internal relays through fuse 4 in operation, coolant is constantly circulated through the heater the engine compartment fusebox.
Page 239: Service Procedures
Engine Cooling System Engine Service Procedures Coolant - Drain and Refill Caution: Engine coolant will damage paint finished surfaces. If spilled, immediately rinse area with plenty of water. Drain 1. Remove undertray. Undertray Undertray Undertray - - - Assembly Assembly Remove. Assembly Remove.
Page 240: Expansion Tank Cap- Pressure Test
Engine Engine Cooling System Expansion Tank Cap- Pressure Test remove excess coolant until level is at MAX mark. Check Warning: Since injury such as scalding could be caused by 1. Visually check engine and cooling system for signs of escaping steam or coolant, do not remove the filler cap coolant leaks.
Page 241: System - Pressure Test
Engine Cooling System Engine System - Pressure Test Check 1. Examine hoses for signs of cracking, distortion and security of connections. 6. Slowly pressurise cap to required pressure and check whether the pressure is between 140=160 KPa. 7. Release pressure by depressing pressure release valve on T14001.
Page 242: Coolant Expansion Tank
Engine Engine Cooling System Coolant Expansion Tank for leaks. Remove Warning: Do not exceed the setting pressure value, or the 1. Disconnect battery earth lead. cooling system will be damaged. 2. Remove expansion tank cap. 6. Visually check engine and cooling system for signs of coolant leaks.
Page 243: Fan Assembly
Engine Cooling System Engine Fan Assembly Remove Warning: Disconnect the battery to prevent operation of the cooling fan, which could cause personal injury. 1. Disconnect battery earth lead. 2. Remove front bumper. Front Front Front Bumper Bumper Assembly Bumper Assembly Remove. Assembly Remove.
Page 244 Engine Engine Cooling System 10. Fit air cleaner. Air Cleaner Cleaner Refit. Refit. Cleaner Refit. 11. Fit front bumper. Front Front Front Bumper Bumper Bumper Assembly Assembly Assembly Refit. Refit. Refit. 12. Connect battery earth lead. 13. Top-up coolant. Refill Refill Refill 11.
Page 245: Cooling Fan Resistor
Engine Cooling System Engine Cooling Fan Resistor Radiator Assembly Remove Remove Warning: Disconnect the battery to prevent operation of 1. Drain cooling system. the cooling fan, which could cause personal injury. Coolant - - - Drain Drain Coolant Coolant Drain 1.
Page 246 Engine Engine Cooling System Note: The left and right radiator tank or transmission oil 9. Top up gearbox oil (Automatic transmission models cooler cannot be replaced separately. If there is a fault only). in these components, the whole radiator assy must be Automatic Automatic Automatic Transmission...
Page 247: Supply Fluid Cooler Hose - Automatic
Engine Cooling System Engine Supply Fluid Cooler Hose - Automatic 3. Position hose and secure hose to radiator. Transmission 4. Top up transmission oil level. Remove automatic automatic automatic transmission transmission transmission - - - top-up top-up top-up . . . 1.
Page 248: Return Fluid Cooler Hose - Automatic Transmission
Engine Engine Cooling System Return Fluid Cooler Hose - Automatic automatic automatic automatic transmission transmission transmission - - - top-up top-up . . . top-up Transmission 5. Fit undertray. Remove Undertray - - - assembly assembly refit refit Undertray Undertray assembly refit 1.
Page 249: Thermostat
Engine Cooling System Engine Thermostat Pump-Coolant Remove Remove 1. Drain cooling system. 1. Disconnect battery earth lead. 2. Remove and discard camshaft drive belt. Coolant - - - Drain Drain Coolant Coolant Drain Camshaft Camshaft Camshaft Drive Drive Belt Drive Belt Remove.
Page 250: Special Tools
Engine Engine Cooling System Special Tools Tool Description Picture Number Cooling System T14001 Pressure Test Harness Repair T84001 Version 2.0...
Page 251: Engine Manifold & Exhaust System
Engine Manifold & Exhaust System Engine Engine Manifold & Exhaust System Specifications Torque Description Value Bolt-Silencer to intermediate pipe clamp 50–60Nm Heated oxygen sensor 45–60Nm 55–75Nm Nut-Front exhaust flange to exhaust system Bolt-Exhaust pipe frame to body 19–28Nm Nut-Front Front pipe to turbocharger 45–55Nm Bolt-Front pipe frame to engine oil pan 20–25Nm...
Page 252: Description And Operation
Engine Engine Manifold & Exhaust System Description and Operation System Component Layout-1.8T Inlet and Exhaust System Air Cleaner Component layout— 1.8T 1. Air cleaner cover screw 3. Inlet duct screw 2. Air cleaner cover 4. Inlet duct Version 2.0...
Page 253 Engine Manifold & Exhaust System Engine 5. Worm drive clamp 9. Bolt, air cleaner mounting bracket to body 6. Outlet duct 10. Air cleaner housing 7. Worm drive clamp 11. Air cleaner element 8. Air cleaner mounting bracket Version 2.0...
Page 254 Engine Engine Manifold & Exhaust System Inlet Inlet Inlet Manifold Manifold Manifold Components Components Components 1. Inlet manifold 3. Gasket - inlet manifold to cylinder head (outside) 2. Nut - inlet manifold to cylinder head 4. Gasket - inlet manifold to cylinder head (inside) Version 2.0...
Page 255 Engine Manifold & Exhaust System Engine Exhaust Exhaust Manifold Exhaust Manifold Manifold Component Component Component Layout— Layout— Layout— 1.8T 1.8T 1.8T 1. Gasket - exhaust manifold to cylinder head 5. Stud - turbocharger to exhaust manifold 2. Flanged nut - exhaust manifold to turbocharger 6.
Page 256 Engine Engine Manifold & Exhaust System Exhaust Exhaust Exhaust System System System Component Component Component Layout— Layout— Layout— 1.8T 1.8T 1.8T 1. Gasket - front pipe to turbocharger 6. Rubber mounting 2. Front pipe incorporating TWC 7. Rubber mounting 3. Intermediate pipe 8.
Page 257 Engine Manifold & Exhaust System Engine 11. Bolt - front pipe to sump Version 2.0...
Page 258: System Component Layout-1.8Vct Inlet And Exhaust System
Engine Engine Manifold & Exhaust System System Component Layout-1.8VCT Inlet and Exhaust System Inlet Manifold Components 1. Inlet manifold 3. Gasket - inlet manifold to cylinder head (outside) 2. Nuts - inlet manifold to cylinder head 4. Gasket - inlet manifold to cylinder head (inside) Version 2.0...
Page 259 Engine Manifold & Exhaust System Engine Air Cleaner Component layout 1. Air cleaner cover screw 6. Worm drive clip 2. Air cleaner cover 7. Duct 3. HFM sensor housing seal 8. Worm drive clip 4. HFM sensor and housing 9. Inlet duct screw 5.
Page 260 Engine Engine Manifold & Exhaust System 11. Air cleaner housing 13. Bolt, air cleaner mounting bracket to body 12. Air cleaner mounting bracket 14. Air cleaner element Version 2.0...
Page 261 Engine Manifold & Exhaust System Engine Exhaust Exhaust Manifold Exhaust Manifold Manifold Component Component Layout Component Layout Layout 1. Exhaust manifold 4. Bolt - manifold to intermediate pipe 2. Gasket - exhaust manifold to cylinder head 5. Stud - support bracket to engine 3.
Page 262 Engine Engine Manifold & Exhaust System Exhaust System Component Layout 1. Intermediate pipe 5. Rubber mounting 2. Rubber mounting 6. Rubber mounting 3. Rear silencer and tail pipe 7. Flanged nut (3 off) 4. Rubber mounting 8. Gasket - intermediate pipe to exhaust manifold Version 2.0...
Page 263: Description-1.8T Inlet And Exhuast System
Engine Manifold & Exhaust System Engine Description-1.8T Inlet and Exhuast System An HO2S is fitted in the front pipe upstream of the catalytic Air Cleaner-1.8T converter. Exhaust System-1.8T A flexible duct fits between the air cleaner lid and the turbocharger secured using worm drive clamps. A duct, A two piece, stainless steel fabricated exhaust system is fitted secured with two spring assisted worm drive clamps to ensure...
Page 264: Description-1.8Vct Inlet And Exhuast System
Engine Engine Manifold & Exhaust System Description-1.8VCT Inlet and Exhuast System Air Cleaner-1.8VCT All engines use a common inlet duct and a replaceable paper air cleaner element. TheHFMis fitted to the outlet of the air cleaner assembly and is secured with 2 screws. A flexible duct fits between the HFM and Electronic Throttle Body (ETB) secured using worm drive clips.
Page 265: Operation-1.8T Inlet And Exhuast System
Engine Manifold & Exhaust System Engine Operation-1.8T Inlet and Exhuast System enter the TWC. The TWC is only effective after reaching Air Cleaner–1.8T its minimum operating temperature. The exhaust gases pass through the monolith structure which is coated in platinum and Air enters the air duct at the front of the engine bay above rhodium (the catalysts) where two processes occur, reduction the radiator.
Page 266: Operation-1.8Vct Inlet And Exhaust System
Engine Engine Manifold & Exhaust System Operation-1.8VCT Inlet and Exhaust System Air Cleaner-1.8VCT Air enters the air duct at the front of the engine bay above the radiator. It passes through the air cleaner element where abrasive material is removed from the air and is retained by the cleaner.
Page 267: Service Procedures
Engine Manifold & Exhaust System Engine Service Procedures front panel. Air Cleaner 7. Release air cleaner from 3 grommets and remove air Remove cleaner. 1. Disconnect battery earth lead. Refit 1. Fit air cleaner and secure on grommets. 2. Fit air intake ducting hose to front panel and secure with screws.
Page 268: Element - Air Cleaner
Engine Engine Manifold & Exhaust System Element - Air Cleaner Tail Pipe and Silencer Remove Remove 1. Remove 5 screws securing air cleaner cover to air Warning: Exhaust components get extremely hot during cleaner casing (Turbocharged model shown, VCT operation. Ensure exhaust components are sufficiently similar).
Page 269: Intermediate Pipe
Engine Manifold & Exhaust System Engine Intermediate Pipe Remove Warning: Exhaust components get extremely hot during operation. Ensure exhaust components are sufficiently cooled before handling. 1. Disconnect battery earth lead. 2. Raise the vehicle on a lift. 3. Remove bolts securing brace to body and remove brace.
Page 270: Front Pipe - Turbocharger
Engine Engine Manifold & Exhaust System Front Pipe - Turbocharger Remove Warning: Exhaust components get extremely hot during operation. Ensure exhaust components are sufficiently cooled before handling. 1. Disconnect battery earth lead. 2. Disconnect pre catalyst HO2S multiplug. 7. Remove 4 bolts securing front pipe bracket to engine. 3.
Page 271: Heat Shield - Alternator
Engine Manifold & Exhaust System Engine Heat Shield - Alternator Refit Remove 1. Position heat shield and secure to alternator lower bracket with bolt and tighten to 40–50Nm. 1. Remove nut securing heat shield to alternator upper bracket. 2. Move A/C compressor into position and tighten bolts to 22–28Nm.
Page 272: Heat Shield - Rear Silencer
Engine Engine Manifold & Exhaust System Heat Shield - Rear Silencer Heat Shield - Exhaust Pipe and Fuel Tank Remove Remove 1. Remove tail pipe and silencer. 1. Remove intermediate pipe. Tail Pipe Pipe and and Silencer Silencer Intermediate pipe pipe Tail Tail...
Page 273: Electric Throttle - Includes Tuning
Engine Manifold & Exhaust System Engine Electric Throttle - Includes Tuning Refit Remove 1. Clean mating faces of throttle body and inlet manifold. 1. Disconnect battery earth lead. 2. Fit O-ring to inlet manifold. 2. Disconnect multiplug from MAPsensor.(Turbocharged 3. Position throttle body to inlet manifold, fit bolts and models only).) tighten in a diagonal sequence to 9Nm.
Page 274: Engine Fuel & Management System
Engine Engine Fuel & Management System Engine Fuel & Management System Specifications Torque Description Value Spark plugs 22–28Nm Bolt-Ignition coil Bolt-spark plug cover 7–10Nm nuts and bolts-ECM to bracket nuts and bolts 8–10Nm ECT sensor 15Nm Oil pressure switch 25–27Nm Bolt-CKP sensor Bolt-CMP sensor Screw-Camshaft position sensor...
Page 275: Description And Operation-1.8T
Engine Fuel & Management System Engine Description and Operation-1.8T System Component Layout Engine Management System Component Location 1. Purge valve 10. A/C compressor clutch relay 2. Air Conditioning (A/C) compressor pressure sensor 11. Cooling fan relay unit 3. Temperature Manifold Absolute Pressure sensorsTMAP 12.
Page 276 Engine Engine Fuel & Management System Cruise Control System Component Location 1. Clutch switch MT only 3. Main switch 2. Indication lamp 4. ECM Version 2.0...
Page 277: Control Diagram-1.8T
Engine Fuel & Management System Engine Control Diagram-1.8T Engine Management System Control Diagram A=Hard wired B=HSCAN Bus C=MSCAN BUS Version 2.0...
Page 278 Engine Engine Fuel & Management System 1. Cooling fan relay unit 11. CKP sensor 2. A/C pressure sensor 12. CMP sensor 3. Alternator 13. Boost valve 4. SCS/ABSmodule 14. Fuel injectors 5. PAS pressure sensorWhere fitted 15. Purge valve 6. TMAP sensor 1 16.
Page 279 Engine Fuel & Management System Engine Cruise Cruise System Cruise System Control System Control Diagram Control Diagram Diagram A=Hard wired B=HSCAN Bus C=MSCAN BUS 1. Clutch switch MT only 5. BCM 2. SCS/ABSmodule 6. Instrument Pack 3. ECM 7. Main switch 4.
Page 280: Description
Engine Engine Fuel & Management System Description receives a 12V supply provided by the main relay and via fuse 2. General The CKP sensor also requires a ground path, this is provided by the ECM. The Engine Management System EMS is used to control a number of aspects of an engine's operation.
Page 281 Engine Fuel & Management System Engine A piezo-ceramic knock sensor fitted to the rear of the cylinder the ECM) and a temperature dependent variable resistor block between cylinders 3 and 4 connected to the engine (insideECT sensor). management harness terminating in connector EM021. Electronic Throttle Body (ETB) Temperature Manifold Absolute Pressure (TMAP) Sensor...
Page 282 Engine Engine Fuel & Management System Ignition Coils Fuel Injectors Four fuel injectors are located in the inlet manifold ports, Two ignition coils are mounted on the camshaft cover. They sealed with O-rings at their base. The injectors are connected are fitted above cylinders 1 and 3 and are connected to the coil to the injector harness using connectors C0522 (IL002), harness using connectors C0052 and C0156.
Page 283 Engine Fuel & Management System Engine • Observe the correct torque tightening value when The clutch switch is identical to the brake switch. It is located installing the HO2S. on the pedal box assembly connected to the engine bay harness using connector EB059.
Page 284 Engine Engine Fuel & Management System A/C Pressure Sensor 5 Speed Electronic Automatic Transmission (EAT) The A/C pressure sensor is located on the A/C high pressure The 5 speed EAT has a separate Transmission Control Module refrigerant pipe on the RH side of the engine compartment and TCMwhich manages the functions and diagnostics relating to is connected to the engine bay harness using connector EB034.
Page 285 Engine Fuel & Management System Engine Engine Immobilization CAN Bus Data Received By The ECM From The The engine immobilization system prevents unauthorized TheECM via theCAN Bus receives the following information starting of the engine, i.e. without a correctly coded handset. from theTCM TCM: The system consists primarily of the following components: •...
Page 286 Engine Engine Fuel & Management System • Actual engine torque. • Throttle angle. TheECM produces this parameter. This signal indicates This message is transmitted by the ECM. TheTCM uses the actual engine torque produced at any moment. this information to control gear shift scheduling. TheTCM uses this parameter to control gear shift Air Conditioning (A/C) scheduling.
Page 287 Engine Fuel & Management System Engine Fuel Fuel System Fuel System System 1. RH float valve 6. Charcoal canister 2. Vent pipe to filler neck 7. Fuel tank strap (2 off) 3. Filler cap 8. Fuel tank 4. Filler neck anti-spill valve 9.
Page 288 Engine Engine Fuel & Management System Purge Valve Warning Light The warning light indicates the status of the cruise control The purge valve is located on a bracket on the rear of the system. Located in the instrument pack, the warning light cylinder block and is connected via a flexible pipe to the inlet consists of a motorway graphic on a yellow background that manifold and the charcoal canister.
Page 289 Engine Fuel & Management System Engine Input TMAP sensor 2 Fuel injector 4 Output pressure signal ground TMAP sensor 1 Input ETB actuator Output pressure signal (negative side) A/C pressure Output ETB actuator Output sensor supply (positive side) Not used HO2S Output pre-catalyst...
Page 290 Engine Engine Fuel & Management System Not used PPS 2 supply Output Not used Brake switch Input safety Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Ignition coil cylinders 2 and Not used Not used...
Page 291: Operation
Engine Fuel & Management System Engine Operation ECT sensor Purge valve ECM - General HO2S HO2S TheECM monitors the conditions required for optimum Boost control combustion of fuel in the cylinders using sensors located at solenoid valve points around the engine. From these sensor inputs, theECM A/CA/C pressure Fuel pump relay can control and adjust the fuel quantity and timing of the fuel...
Page 292 Engine Engine Fuel & Management System When the handset is removed, theECM switches off ignition maintained until the HO2S reaches a high enough temperature and fuelling to stop the engine. TheECM continues to hold the to provide an accurate feedback signal. The specific nature of main relay in the on position until it has completed the power the other open loop conditions listed means that the HO2S down functions.
Page 293 Engine Fuel & Management System Engine additional heating via an electrical resistive element. This Each sensor is connected to the ECM using two wires which element uses a 12V supply and is controlled by the ECM. are screened to protect the signal from interference. The This allows a short warm up time and minimises emissions pre-catalyst sensor is connected to the ECM at pin E2 and from start up.
Page 294 Engine Engine Fuel & Management System • Contamination by leaded fuel of the Lambda window which allows theTWC to absorb and release oxygen for optimum efficiency. • Contamination by carbon or silicon deposits • Impact damage/mechanical shock For a quick test of closed loop functionality: •...
Page 295 Engine Fuel & Management System Engine When a hot engine is turned off, the fuel in the injectors power output with low emissions. Advancing the ignition and injector rail absorb heat, this causes the combustion may increase power output under certain conditions, but it characteristics to change.
Page 296 Engine Engine Fuel & Management System theCKP sensor is adjacent to a missing tooth (an extended • Signal output from the CKP sensor can be checked using land) the voltage will remain low. an oscilloscope connected to pin 15 of connector EM028. Set the scope to display a 12V digital pattern over a time base which allows individual holes to be identified.
Page 297 Engine Fuel & Management System Engine Knock Sensor for inlet air temperature. This correction is an important requirement because hot air is less dense and contains less The knock sensor is used to detect knock or 'detonation' oxygen available for combustion than cold air for any given which occurs when the air/fuel mixture is ignited before the volume.
Page 298 Engine Engine Fuel & Management System change is detected by the EOT sensor which provides a signal that is inversely proportional to the oil temperature. This allows theECM to compensate for these variations by adjusting the fuelling strategy. The EOT sensor receives a regulated 5V reference supply from theECM when the ignition is on.
Page 299 Engine Fuel & Management System Engine pin B2 of connector EM056 on and comparing the measured The A/C compressor clutch will be disengaged if theECT voltage with the expected reading from the graph below. detects a temperature of more than 118 °C (244 °F), and will not re-engage until it falls below 114 °C (237 °F).
Page 300 Engine Engine Fuel & Management System energised. This acts across the entire engine speed range to opens during the inlet stroke of the cylinder it supplies. The achieve a smooth torque curve. The pulse width can be varied injectors deliver fuel to the engine as an atomised spray to between 0 and 100% of the full pulse period, and therefore maximise the benefits of the swirl and turbulence in the control the boost pressure over a wide range.
Page 301 Engine Fuel & Management System Engine Fuse 4 The vehicle speed signal is produced by rotation of the road wheels when ignition is on and is calculated by the ABS/DSC • Cooling fan relay unit ECU DSCABSECU from information received from all four •...
Page 302 Engine Engine Fuel & Management System crankshaft is rotating. The voltage input to the relay contact fuel pump relay. Switch the ignition on and check the outputs is via the inertia switch fuel cut off, this is also connected to against the diagram shown on the previous page.
Page 303 Engine Fuel & Management System Engine If the purge valve fails there is no back up system. TheEVAP canister will not be purged, so there may be fuel vapours released if levels reach saturation point. The driver may notice this condition as a fuel vapour smell emanating from the vehicle when parked.
Page 304: Cruise Control-1.8T
Engine Engine Fuel & Management System Cruise Control-1.8T 2. Press the thumb wheel (2) to set the road speed in the system memory. Cruise control will now maintain that speed without the need to use the accelerator pedal. Accelerate until the desired cruising speed is reached. This must be above the system's minimum operational speed of 40 km/h and below the maximum operating speed of 200 km/h.Cruise control can be enabled until...
Page 305: Description And Operation-1.8 Vct
Engine Fuel & Management System Engine Description and Operation-1.8 VCT System Component Layout-1.8VCT Engine Management System Component Location 1. Oil control switch 10. A/C compressor clutch relay 2. Air Conditioning (A/C) compressor pressure sensor 11. Cooling fan relay unit 3. Purge valve 12.
Page 306 Engine Engine Fuel & Management System Cruise Control System Component Location 1. Clutch switch MT only 3. Main switch 2. Indication lamp 4. ECM Version 2.0...
Page 307: Control Diagram-1.8 Vct
Engine Fuel & Management System Engine Control Diagram-1.8 VCT Engine Management System Control Diagram A=Hard wired B=HSCAN Bus C=MSCAN BUS Version 2.0...
Page 308 Engine Engine Fuel & Management System 1. Cooling fan relay unit 12. CMP sensor 2. A/C pressure sensor 13. Engine Oil Control Valve 3. Alternator 14. Fuel injectors 4. SCS/ABS module 15. Purge valve 5. PAS pressure sensorWhere fitted 16. HO2S 6.
Page 309: Description
Engine Fuel & Management System Engine Description sensor also requires a ground path, this is provided by the General ECM. The Engine Management System EMS is used to control a The teeth on the reluctor ring are spaced at 6° intervals. There number of aspects of an engine's operation.
Page 310 Engine Engine Fuel & Management System HFM Sensor Engine Coolant Temperature (ECT) Sensor The HFM sensor is located in a housing between the air cleaner TheECT sensor is located in the cooling system outlet element and the Electronic Throttle Body (ETB). It is sealed elbow from the cylinder head and connects to the engine to the housing using an O-ring, secured using 2 screws and management harness using connector EM015.
Page 311 Engine Fuel & Management System Engine Variable Camshaft Timing (VCT) Warning: The HT voltage of the ignition system is in excess of 50 kV and the LT voltage is in excess of 400V. Voltages this high can cause serious injury and may even be fatal. Never touch any ignition components while the engine is running or cranking.
Page 312 Engine Engine Fuel & Management System The HO2S consists of a sensing element which is exposed to Clutch Switch - Manual Transmission Only exhaust gases and ambient air. Caution: HO2S are easily damaged. Care must be taken not to damage the sensor housing or tip. •...
Page 313 Engine Fuel & Management System Engine Cooling Fan Relay Unit and outputs which relate to the ECM. For further information on the EAT refer to Automatic Transmission. TheECM and theTCM are able to communicate via the CAN Bus. This allows the sharing of information collected from sensors installed in the powertrain components.
Page 314 Engine Engine Fuel & Management System • Handset transponder. This tells theECM what gear is currently engaged or, if a gear change is in progress, the gear to which the EAT is • Transponder coil. shifting. This information is used by theECM to assist in •...
Page 315 Engine Fuel & Management System Engine • Indexed engine torque. This message is transmitted by the ECM. The TCM uses this information to control gear shift scheduling. TheECM produces this parameter. This signal indicates Air Conditioning (A/C) the maximum engine torque that it is possible for the engine to produce under normal circumstances.
Page 316 Engine Engine Fuel & Management System Fuel Fuel Fuel System System System 1. RH float valve 6. Charcoal canister 2. Vent pipe to filler neck 7. Fuel tank strap 3. Filler cap 8. Fuel tank 4. Filler neck anti-spill valve 9.
Page 317 Engine Fuel & Management System Engine Purge Valve of a solenoid operated valve, which is connected to the engine bay harness using connector EM060, is controlled by theECM The purge valve is located on a bracket on the rear of the using a 12V PWM signal.
Page 318: Operation
Engine Engine Fuel & Management System Operation A/C pressure Fuel pump relay ECM - General switch TheECM monitors the conditions required for optimum PAS pressure Main relay combustion of fuel in the cylinders using sensors located at sensor Alternator load Cooling fan relays points around the engine.
Page 319 Engine Fuel & Management System Engine down functions. Power down functions include engine cooling that theHO2S feedback is unsuitable as a control value for and referencing the position of the throttle butterfly for the fuelling. Adaptive strategy also allows theECM to compensate next start up.
Page 320 Engine Engine Fuel & Management System element uses a 12V supply and is controlled by the ECM. pre-catalyst HO2S sensor is connected to theECM at pin This allows a short warm up time and minimises emissions E2 and E4 of connector EM056. The output from the sensor from start up.
Page 321 Engine Fuel & Management System Engine • Contamination by carbon or silicon deposits • Start engine and run until normal operating temperature is reached • Impact damage/mechanical shock • Run engine at 2500 rpm to ensure that theECM is at •...
Page 322 Engine Engine Fuel & Management System When the vehicle is decelerating with a closed throttle, the contained within theECM memory keeps the ignition timing fuel injection can be switched off for a short period. During within this narrow band. this phase theECM looks at the following inputs to determine Idle Speed Control whether overrun fuel cut off should be enabled: TheECM uses two methods of idle speed control:...
Page 323 Engine Fuel & Management System Engine • Signal output from the CKP sensor can be checked using an oscilloscope connected to pin H2 of connector EM055. Set the scope to display a 12V digital pattern over a time base which allows individual holes to be identified.
Page 324 Engine Engine Fuel & Management System • If a dual trace oscilloscope is available both CKP andCMP at theECM decreases. The change in voltage is proportional sensor patterns could be observed at the same time to to the temperature change of the inlet air. From the voltage check relative timing.
Page 325 Engine Fuel & Management System Engine 1. Temperature °C 1. Temperature °C 2. Resistance Ω 2. Resistance Ω Failure TheECT consists of an NTC thermistor which is in contact with the engine coolant. The EOT sensor could fail or provide an incorrect signal, in the following ways: TheECT sensor is part of a voltage divider circuit which consists of a regulated 5V supply, and a fixed resistor (inside...
Page 326 Engine Engine Fuel & Management System Failure codes, which can be retrieved using the diagnostic tool. In the event of a permanent misfire condition, theECM will also TheECT sensor could fail, or provide an incorrect signal, in shut off fuelling to the affected cylinders, thereby protecting the following ways: theTWC from damaging exhaust pulses.
Page 327 Engine Fuel & Management System Engine • Nozzle contaminated with dirt or wax (reduced flow) Main Relay • Nozzle misaligned (spray not positioned correctly) The relay winding is connected to pins 85 and 86, the moving contact is connected to pin 30. The normally open contact •...
Page 328 Engine Engine Fuel & Management System Fuel Pump Relay • Relay contact stuck closed • Relay contact high resistance • Relay wiring open circuit • Relay wiring high resistance • Relay wiring short circuit to 12V • Relay wiring short circuit to ground •...
Page 329 Engine Fuel & Management System Engine the inlet manifold to draw fuel vapour from the canister into the cylinders for combustion. The amount of fuel vapour which enters the cylinders can affect the overall AFR, therefore theECM must only open the purge valve when it is able to compensate by reducing fuel injector duration.
Page 330: Cruise Control-1.8Vct
Engine Engine Fuel & Management System Cruise Control-1.8VCT 2. Press the thumb wheel (2) to set the road speed in the system memory. Cruise control will now maintain that speed without the need to use the accelerator pedal. Accelerate until the desired cruising speed is reached. This must be above the system's minimum operational speed of 40 km/h and below the maximum operating speed of 200 km/h.Cruise control can be enabled until...
Page 331: Service Procedures
Engine Fuel & Management System Engine Service Procedures Ignition Coils Remove Spark Plugs Remove 1. Disconnect battery earth lead. 1. Remove ignition coils. 2. Remove 3 bolts securing spark plug cover to camshaft cover and remove cover. Ignition coils coils Ignition Ignition coils...
Page 332: Engine Control Module (Ecm)
Engine Engine Fuel & Management System Engine Control Module (ECM) Sensor - Engine Coolant Temperature (ECT) Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Disconnect multiplugs from Engine Control 2. Remove coolant expansion tank cap to release system ModuleECM .
Page 333: Switch - Oil Pressure
Engine Fuel & Management System Engine Switch - Oil Pressure Sensor - Crankshaft Position (CKP) Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove undertray. 2. Raise the vehicle on a lift. Undertray Undertray Undertray - - - assembly assembly assembly 3.
Page 334: Sensor - Camshaft Position (Cmp) - Vct
Engine Engine Fuel & Management System Sensor - camshaft position (CMP) - VCT Sensor - inlet camshaft position (CMP) - VCT Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove 3 bolts and spark plug cover. 2.
Page 335: Sensor - Exhaust Camshaft Position (Cmp) - Vct
Engine Fuel & Management System Engine Sensor - Exhaust Camshaft Position (CMP) - VCT Sensor - temperature and manifold absolute pressure (TMAP) Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Disconnect CMPsensor multiplug. 2. Disconnect TMAPsensor multiplug. 3.
Page 336: Sensor - Manifold Absolute Pressure (Map)
Engine Engine Fuel & Management System Sensor - manifold absolute pressure (MAP) Sensor - Knock (KS) Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Disconnect MAPsensor multiplug. 2. Remove undertray. Undertray Undertray Undertray - - - assembly assembly assembly .
Page 337: Sensor - Heated Oxygen (Ho2S) - Front
Engine Fuel & Management System Engine Sensor - Heated Oxygen (HO2S) - Front - Sensor - Heated Oxygen (H02S) - Rear - Turbocharger Turbocharger Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Disconnect HO2S multiplug. 2.
Page 338: Solenoid - Boost Control - Turbocharger
Engine Engine Fuel & Management System Solenoid - Boost Control - Turbocharger Fuel Rail Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Noting their fitted locations, disconnect pressure Warning: Fuel vapour is highly flammable and in confined control hoses from solenoid.
Page 339: Injectors
Engine Fuel & Management System Engine Injectors Remove 1. Remove fuel rail. Fuel rail rail Fuel Fuel rail Refit 1. Fit fuel rail. Fuel Fuel Fuel rail. rail. rail. 9. Release spring clips securing injectors to fuel rail and remove injectors. 10.
Page 340: Charcoal Canister
Engine Engine Fuel & Management System Charcoal Canister Purge Control Valve Remove Remove 1. Raise the vehicle on a lift. 1. Disconnect battery earth lead. 2. Remove bolt securing canister to body and release 2. Raise the vehicle on a lift. canister.
Page 341: Pipe Assembly - Body Underfloor Fuel Lines
Engine Fuel & Management System Engine Pipe Assembly - Body Underfloor Fuel Lines Refill Refill Refill fuel fuel fuel tank tank tank Refit. Refit. Refit. Remove 1. Drain the fuel tank. Tank - - - drain drain fuel fuel Remove. Remove.
Page 342: Tank - Fuel
Engine Engine Fuel & Management System Tank - Fuel 9. Move rear anti roll bar aside for access to fuel tank. Remove 10. Remove exhaust and fuel tank heat shield. 1. Disconnect battery earth lead. Heat shield shield - - - exhaust exhaust pipe pipe and and fuel...
Page 343 Engine Fuel & Management System Engine for access to fuel tank. 19. Disconnect fuel pump multiplug. 15. Release charcoal canister to fuel tank vent pipe at charcoal canister and remove 3 clips securing pipe to body. 20. Disconnect fuel feed pipe and fuel return pipe from fuel pump to filter.
Page 344: Fuel Pump
Engine Engine Fuel & Management System Fuel Pump 6. Fit strap bolts and tighten to 21–25Nm Remove 7. Connect charcoal canister to fuel tank vent pipe at charcoal canister and refit 3 clips securing pipe to body. 1. Disconnect battery earth lead. 8.
Page 345: Fuel System - Depressurise
Engine Fuel & Management System Engine Fuel System - Depressurise Warning: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are Check taken to prevent fire and explosion. 1. Position absorbent cloth around fuel rail to catch any 9.
Page 346: Fuel System - Pressure Test
Engine Engine Fuel & Management System Fuel System - Pressure Test 11. Release clips and remove adaptor T18002from Check pressure gauge T18003. 1. Position absorbent cloth around fuel rail to catch any fuel spillage. Warning: Fuel vapour is highly flammable and in confined spaces is also explosive and toxic.
Page 347: Tank-Drain & Refill
Engine Fuel & Management System Engine Tank-Drain & Refill Fuel Filter Drain & Refill Remove Warning: Fuel vapour is highly flammable and in confined 1. Disconnect battery earth lead. spaces is also explosive and toxic. Always have a fire 2. Depressurise fuel system. extinguisher containing foam, CO2, gas or powder close Fuel Fuel...
Page 348: Filler Neck
Engine Engine Fuel & Management System Filler Neck Remove 1. Disconnect battery earth lead. 2. Depressurise fuel system. Fuel Fuel Fuel system system system - - - depressurise depressurise depressurise Remove. Remove. Remove. Warning: Fuel vapour is highly flammable and in confined spaces is also explosive and toxic.
Page 349: Switch - Inertia - Fuel Cut Off
Engine Fuel & Management System Engine Switch - Inertia - Fuel Cut Off 4. Position filler neck to filler cap aperture and fit grommet. Remove 5. Fit rear wheel arch liner. 1. Disconnect battery earth lead. Liner Liner Liner - - - rear rear rear wheel wheel arch...
Page 350: Special Tools
Engine Engine Fuel & Management System Special Tools Tool Description Picture Number Wrench fuel T18007 tank lock ring Adaptor fuel T18003 pressure test Fuel Pressure T18002 Test Equipment Version 2.0...
Page 351: Engine Electrical System
Engine Electrical System Engine Engine Electrical System Specifications Torque Description Value Bolt-Alternator to alternator upper bracket 40–50Nm Bolt-Alternator to alternator lower bracket 40–50Nm Nut-Battery lead to alternator 5–7Nm Bolt-Alternator upper bracket to cylinder head 22–28Nm Stud-Alternator upper bracket to cylinder head 8–11Nm Nut-Alternator upper bracket to cylinder head 22–28Nm...
Page 352: Description And Operation
Engine Engine Electrical System Description and Operation Component Layout ENGINE ELECTRICAL System View Starting and Charging Component Location 1. Alternator 2. Starter motor Version 2.0...
Page 353: Control Diagram
Engine Electrical System Engine Control Diagram Starting and Charging Control Diagram 1. Alternator 7. BCM 2. ECM 8. Main fusible linkFL1 150A 3. Starter motor 9. Ignition switch supply fuse 220A 4. Battery 10. ECMsupply fuse 5 10A 5. Instrument pack 11.
Page 354: Description
Engine Engine Electrical System Description the stator and is mounted on bearings for smooth running and General to support the rotor due to the high side loading applied by the drive belt tension. The rectifier, located at the rear of the The starting system on the vehicle comprises a 12V starter alternator comprises eight semi-conductor diodes mounted on motor.
Page 355 Engine Electrical System Engine indicator means different conditions of the battery as followings: • Green - indicates the battery is in a good charging condition and can be used. • Darken (becoming black) - indicates the lower battery and need to be charged. •...
Page 356: Operation
Engine Engine Electrical System Operation When the engine is started the rotor rotates within the Starter Motor stator, generating 3-phase Alternating Current AC . The AC produced is unsuitable for use by the vehicle's electrical system When the handset is docked, the immobilisation unit, located and passes through the rectifier semiconductor diodes.
Page 357: Service Procedures
Engine Electrical System Engine Service Procedures Alternator Remove Belt - PAS Pump Remove 1. Disconnect battery earth lead. 1. Remove undertray. 2. Remove drive belt. Undertray - - - Assembly Assembly Undertray Undertray Assembly Drive Drive Drive Belt Belt Belt 2.
Page 358: Bracket - Alternator - Upper
Engine Engine Electrical System Bracket - Alternator - Upper 6. Fit drive belt. Remove Drive Belt Belt Drive Drive Belt 1. Remove alternator. 7. Connect battery earth lead. Alternator Alternator Alternator 2. Remove nut securing heatshield to alternator upper support bracket 3.
Page 359: Bracket - Alternator - Lower
Engine Electrical System Engine Bracket - Alternator - Lower bracket to cylinder block and remove bracket. Remove 1. Remove alternator. Alternator Alternator Alternator 2. Remove bolt securing tensioner to alternator lower support bracket and remove tensioner. Refit 1. Fit alternator lower support bracket to cylinder block, fit 4 bolts and tighten to 40–50Nm.
Page 360: Drive Belt
Engine Engine Electrical System Drive Belt Starter Motor Remove Remove 1. RemovePAS pump belt. 1. Disconnect battery earth lead. 2. Disconnect Lucar from starter solenoid. Belt - - - PAS PAS Pump Pump Belt Belt Pump 2. Fit a 13mm spanner to hexagon on belt tensioner and rotate fully clockwise to release tension on drive belt.
Page 361: Battery Tray And Support Bracket
Engine Electrical System Engine Battery Tray and Support Bracket Remove 1. Disconnect the battery leads, earth lead first. 2. Remove battery cover. 3. Remove bolt securing battery fixing clamp and remove clamp. Refit 1. Position battery tray support bracket to LH transmission mounting bracket, fit bolts and tighten to 7–10Nm.
Page 362: Tensioner - Alternator Drive Belt
Engine Engine Electrical System Tensioner - Alternator Drive Belt Remove 1. Remove drive belt. Drive Belt Belt Drive Drive Belt 2. Remove bolt securing tensioner to alternator lower support bracket and remove tensioner. Refit 1. Position tensioner, fit bolt and tighten to 22–28Nm. 2.
Page 363: Transmission
Shift Lock Control-AT Transmission Shift Lock Control-AT Specifications Torque Description Value Nut-selector cable to arm 14–18Nm Bolt-selector cable bracket to transmission 40–50Nm Bolt-front heat shield 4–6Nm Bolt-selector to central tunnel 19–25Nm Bolt-selector housing to vent Version 2.0...
Page 364: Description And Operation
Transmission Shift Lock Control-AT Description and Operation models have additional controls on the steering wheel. Once Tiptronic has been selected Sport mode cannot be accessed Description until the gear selector has been returned to the D position. Selector Lever Shift Interlock Solenoid The selector lever assembly consists of a lever and a cover 1.
Page 365: Service Procedures
Shift Lock Control-AT Transmission Service Procedures Rod/Cable Assembly–Selector–Automatic Remove Knob–Selector Lever–Automatic Remove 1. Position selector lever in neutral. 1. Position gear selector lever to neutral. 2. Disconnect battery earth lead. 2. Carefully release selector knob finisher ring. 3. Remove air cleaner. Air Cleaner-Remove Cleaner-Remove Cleaner-Remove...
Page 366: Lever-Gearshift Selector Assembly-Automatic
Transmission Shift Lock Control-AT Lever–Gearshift Selector Assembly–Automatic through aperture to secure gear selector cable to neutral start switch. Tighten nut to 14–18Nm. Remove 2. Align cable to fitted position, fit bolts securing gear 1. Remove centre console. selector cable bracket to gearbox and tighten to Console Assembly–Remove Assembly–Remove Console...
Page 367: Shift Lock Control-Mt
Shift Lock Control-MT Transmission Shift Lock Control-MT Specifications Torque Description Value Bolt-gear change mechanism to floor 19–25Nm Version 2.0...
Page 368: Service Procedures
Transmission Shift Lock Control-MT Service Procedures Remote Control–Gear Change–Manual Remove Knob–Gear Lever–Manual Remove 1. Remove centre console. 1. Ensure neutral is selected. Console Assembly–Remove Assembly–Remove Console Console Assembly–Remove 2. Release 10 clips securing gaiter to centre console and 2. Note fitted position and disconnect cable ball joints release gaiter.
Page 369: Transmission-At
Transmission-AT Transmission Transmission-AT Specifications Torque Description Value Nut-neutral start switch 5.9–7.8Nm Nut-arm to neutral start switch 10–14Nm Bolt-neutral start switch 19.6–29.4Nm Bolt-transmission to engine 75–90Nm Bolt-drive plate to converter 25–35Nm Bolt-closing panel to transmission 22–28Nm Bolt-CKP sensor to cylinder 10Nm Drain plug 23.5–54.9Nm Bolt-dipstick to transmission...
Page 370: Specifications
Transmission Transmission-AT Specifications Type AW55–51SN 5 speed tiptronic transmission Gear Ratio ·First 4.576 ·Second 2.980 ·Third 1.948 ·Fourth 1.318 ·Fifth 1.000 ·Reverse 5.024 ·Differential(1.8T) 2.652 ·Differential(1.8VCT) 2.864 ·Counter 1.018 Clutch ·C1 Flange: 1, Clutch disc: 4, Clutch plate: 4 ·C2 Flange: 1, Clutch disc: 4, Clutch plate: 4 Cushion plate: 1 ·C3 Flange: 1, Clutch disc: 4, Clutch plate: 4...
Page 371 Transmission-AT Transmission Stall revolution 2567rpm Clearance Torque converter 10.5mm Oil seal–oil pump -0.15–0.15mm LH differential oil seal 3.0–4.0mm RH differential oil seal 5.5–6.5mm Version 2.0...
Page 372: Description And Operation
Transmission Transmission-AT Description and Operation System Component Layout Electronic Automatic Transmission (EAT) Component Layout 1. Automatic transmission 6. Automatic Transmission FluidATFcoolerIn radiator 2. Tiptronic 7. Brake switch 3. Gear selector 8. Body Control Module(BCM) 4. Shift lock solenoid 9. Transmission Control ModuleTCM 5.
Page 373 Transmission-AT Transmission Automatic Automatic Transmission Automatic Transmission Component Transmission Component Layout Component Layout Layout 1. Gearbox casing 6. Torque converter 2. Differential oil seal–LH 7. Drain plug and seal 3. Input speed sensor 8. Differential oil seal–RH 4. Neutral start switch assembly 9.
Page 374 Transmission Transmission-AT Sectional Sectional Sectional View View View of of of Transmission Transmission Transmission 1. Direct clutch (C2) 6. 2nd coast brake (B1) 2. Forward clutch (C1) 7. One-way clutch No.1 (F1) 3. 1st and Reverse brake (B3) 8. Torque converter 4.
Page 375 Transmission-AT Transmission 11. Differential 13. U/D clutch (C3) 12. Underdrive (U/D) brake (B4) 14. B5 brake (B5) Version 2.0...
Page 376 Transmission Transmission-AT Valve Valve Valve Block Block Block and and Solenoid Solenoid Solenoid Valves Valves Valves 1. Oil temperature sensorOT 6. Shift solenoid valve 1 S1 2. Line pressure control solenoidSLT 7. Shift solenoid valve 4 S4 3. Lockup control solenoidSLU 8.
Page 377: System Control System
Transmission-AT Transmission System Control System Automatic Transmission Control Diagram A = Hard wired; B = HS CAN Bus; C= MS CAN Bus; D=LIN Bus 1. Neutral start switchNSW 4. Valve block assembly 2. Input speed sensor 5. Transmission ModuleTCM 3. Output speed sensor 6.
Page 378 Transmission Transmission-AT 7. Gear selector 14. Engine coolant temperatureECTsensor 8. Wheel speed sensor 15. Crankshaft positionCKPsensor 9. DSC/ABS ECU 16. Throttle position sensor 10. Body Control ModuleBCM 17. Handset docking station 11. Steering wheel controlsTiptronic 18. Shift interlock solenoid 12. Fascia 19.
Page 379 Transmission-AT Transmission Hydraulic Hydraulic Control Hydraulic Control Control System System System 1. TCM 8. Sump/side cover 2. Regulator and modulator solenoid valves 9. Oil pump 3. Line pressure 10. Oil pump pressure 4. Shift and control solenoid valves 11. Oil cooler 5.
Page 380: Description
Transmission Transmission-AT Description Transmission Gear Ratios: General Gear Ratio Where specified, an Aisin AW 55-51SN automatic 4.576 transmission is fitted. It is an electronically controlled 2.980 five-speed transmission designed for front wheel drive vehicles, and includes an additional tiptronic feature which allows the 1.948 driver to manually select the five forward gears using the 1.318...
Page 381 Transmission-AT Transmission Shift Solenoid Valve Activation (cont'd.) X = Solenoid valve off; O = Solenoid valve on Duty Solenoid Valves The duty solenoid valves are: • Lock-up control solenoid valveSLU • Line pressure control solenoid valveSLT • Shift pressure control solenoid valveSLS Duty solenoid valves are used to adjust line pressure to give Shift solenoid valves 2, 3 and 5 are normally closed.
Page 382 Transmission Transmission-AT certain gears and operating conditions, through the torque converter lockup clutch to the transmission. The torque converter is connected to the engine by a drive plate. The torque converter consists of an impeller, stator and turbine. The engine drives the impeller, while the turbine drives the transmission.
Page 383 Transmission-AT Transmission two connectors. Connector 1 has 24 pins and connector 2 Lock-up control solenoid valve (SLU) (-) has 26 pins. Line pressure solenoid valve (SLT) (+) The TCM uses a 'flash' Electronic Erasable Programmable Read Lock-up control solenoid valve (SLU) (+) Only Memory (EEPROM).
Page 384 Transmission Transmission-AT The TCM determines the position of the selector lever by Output speed sensor (+) monitoring seven sets of contacts in the inhibitor switch Not used which are operated by the selector shaft. Each set of contacts Input speed sensor (+) corresponds to one of the seven selector lever positions.
Page 385 Transmission-AT Transmission Output Speed Sensor The brake switch is located in the pedal box within the passenger compartment. The TCM uses this switch to monitor brake pedal status. The BCM monitors the status of the switch and transmits data to the TCM on the CAN BUS. The TCM can allow the transmission to apply more engine braking, therefore slowing down the vehicle in a shorter distance and reducing brake pad wear.
Page 386: Operation
Transmission Transmission-AT Operation Power Flows The following figures show the power flow in the transmission for each forward gear and reverse. Clutch, Brake, Input/Output or Schematic Diagram Operation (when active) Direct clutch (C2) Connects the input shaft to the sun gear Forward clutch (C1) Connects the input shaft to the rear ring gear 1st and reverse brake (B3)
Page 387 Transmission-AT Transmission 1st Gear (D selected) Gear (11) (10) (12) Version 2.0...
Page 388 Transmission Transmission-AT Version 2.0...
Page 389 Transmission-AT Transmission 2nd Gear (D selected) Gear (11) (10) (12) Version 2.0...
Page 390 Transmission Transmission-AT Version 2.0...
Page 391 Transmission-AT Transmission 3rd Gear (D selected) Gear (11) (10) (12) Version 2.0...
Page 392 Transmission Transmission-AT Version 2.0...
Page 393 Transmission-AT Transmission 4th Gear (D selected) Gear (11) (10) (12) Version 2.0...
Page 394 Transmission Transmission-AT Version 2.0...
Page 395 Transmission-AT Transmission 5th Gear (D selected) Gear (11) (10) (12) Version 2.0...
Page 396 Transmission Transmission-AT Version 2.0...
Page 397 Transmission-AT Transmission Reverse Gear Gear (11) (10) (12) V<=7 OFF V>7 Version 2.0...
Page 398 Transmission Transmission-AT Version 2.0...
Page 399 Transmission-AT Transmission General gear shift action. The line pressure control is continuously responding to current driving conditions to regulate and The TCM controls the following functions: deliver the optimum operating pressure at all times. • Gear shift control example line pressure is lower under normal operating conditions than it would be under hard acceleration.
Page 400 Transmission Transmission-AT reduction in fuel economy especially during high speed cruising. This is eliminated by the torque converter lock-up mechanism. The lock-up mechanism is attached to the turbine. The TCM will actuate the lock-up solenoid valve, which operates the lock-up control valve to direct fluid to either lock, or unlock the torque converter.
Page 401 Transmission-AT Transmission In Tiptronic mode TCM will prevent automatic upshifts and Hot Mode the engine speed can be increased to maximum. The TCM, The purpose of the transmission fluid cooling strategy is to however, only allows manual gearshifts if the engine speed reduce engine and transmission temperatures during high is within preset parameters.
Page 402: Service Procedures
Transmission Transmission-AT Service Procedures Neutral start (inhibitor)–Switch Remove Automatic transmission–Pressure Test Test 1. Disconnect hose connector from intercooler to throttle valve. 1. Fully apply handbrake and chock road wheels. Electric Electric Electric Throttle Throttle - - - Includes Throttle Includes Tuning–Remove Includes Tuning–Remove Tuning–Remove...
Page 403 Transmission-AT Transmission Electric Electric Electric Throttle–Includes Throttle–Includes Throttle–Includes Tuning–Refit Tuning–Refit Tuning–Refit 11. Remove 2 bolts securing inhibitor switch to transmission casing and remove switch. Refit 1. Fit inhibitor switch and bolts to transmission casing, but do not fully tighten bolts. 2.
Page 404: Neutral Start (Inhibitor)-Switch-Check And Adjust
Transmission Transmission-AT Neutral Start (Inhibitor)–Switch–Check and Transmission and Converter Adjust Remove Check and Adjust 1. Remove engine and transmission assembly. 1. Ensure selector lever is at 'N’position. Engine and and Automatic Automatic Transmission–Remove Transmission–Remove Engine Engine Automatic Transmission–Remove 2. Release selector arm from neutral start switch, move 2.
Page 405: Automatic Transmission Fluid-Drain And Refill
Transmission-AT Transmission Automatic Transmission Fluid–Drain and Refill 7. Remove 5 remaining bolts securing transmission to engine. Drain 8. Release transmission from 2 dowels, make sure the Warning: Observe due care when draining gearbox fluid torque converter remains attached to the transmission. as the fluid can be very hot.
Page 406: Automatic Transmission-Top Up
Transmission Transmission-AT Air Cleaner–Refit Cleaner–Refit Cleaner–Refit Automatic Transmission–Top Up Check & Top-Up 9. Start engine, move selector from 'P' through all gear positions, pausing in each gear for 2-3 seconds and Condition of the ATF can be a useful diagnostic aid. return to 'P' position.
Page 407: Control Unit-Automatic Transmission
Transmission-AT Transmission Control Unit–Automatic Transmission 7. Wipe dipstick and check ATF oil level. Remove 8. Fit new O-ring to level/dipstick plug, fit and tighten bolt to 7.8–11.8Nm. Warning: The Transmission Control Module (TCM) is uniquely coded to this vehicle and therefore will not work if fitted to another vehicle.
Page 408: Harness-Automatic Transmission
Transmission Transmission-AT Harness–Automatic Transmission Remove 1. Remove air cleaner. Air Cleaner–Remove Cleaner–Remove Cleaner–Remove 2. Disconnect multiplug from input speed sensor. 3. Disconnect multiplug from output speed sensor. 4. Disconnect multiplug from neutral start switch. 7. Loosen front bolt securing control unit mounting bracket to body.
Page 409: Sensor-Speed Input
Transmission-AT Transmission Sensor–Speed Input Sensor–Speed Output Remove Remove Warning: Switch off ignition switch and wait for 90 Warning: Switch off ignition switch and wait for 90 seconds before starting work. seconds before starting work. 1. Remove air cleaner assembly. 1. Remove air cleaner assembly. Air Cleaner–Remove Cleaner–Remove Cleaner–Remove...
Page 410: Dipstick-Oil Level
Transmission Transmission-AT Dipstick–Oil Level Oil Seal–Differential–LH Remove Remove 1. Remove air cleaner assembly. 1. Drain fluid from automatic transmission. Air Cleaner–Remove Cleaner–Remove Lubrication System–Drain System–Drain and and Refill Refill Cleaner–Remove Lubrication Lubrication System–Drain Refill 2. Remove bolt securing dipstick to gearbox and remove 2.
Page 411: Oil Seal-Differential-Rh
Transmission-AT Transmission Oil Seal–Differential–RH Remove 1. Drain fluid from automatic transmission. Lubrication System–Dain System–Dain and and Refill Refill Lubrication Lubrication System–Dain Refill 2. Remove drive shaft assembly. RH RH RH Shaft Shaft with Shaft with with Both Both Both Joints–Remove Joints–Remove Joints–Remove 3.
Page 412: Torque Converter
Transmission Transmission-AT Torque Converter Remove 1. Drain ATF. Lubrication Lubrication Lubrication System System - - - Drain System Drain and Drain and Refill Refill Refill 2. Remove automatic transmission assembly. Transmission Transmission Transmission and and Converter–Remove Converter–Remove Converter–Remove 3. Remove torque converter. Caution: Be careful not to damage the oil seal.
Page 413: Side Cover
Transmission-AT Transmission Side Cover Remove 1. Drain ATF. Lubrication System System - - - Drain Drain and and Refill Refill Lubrication Lubrication System Drain Refill 2. Remove automatic transmission. Transmission Transmission Transmission and and Converter–Remove Converter–Remove Converter–Remove 3. Remove 9 bolts securing side cover to transmission assembly and remove cover.
Page 414: Oil Seal-Oil Pump
Transmission Transmission-AT Oil Seal–Oil Pump Remove 1. Remove torque converter. Torque Converter–Remove Converter–Remove Torque Torque Converter–Remove 2. Use tool to remove the oil seal from the oil pump. Caution: Be careful not to damage the bushing on the oil pump body. Caution: Be careful not to damage the input shaft.
Page 415: Special Tools
Transmission-AT Transmission Special Tools Tool Description Picture Number Transmission T26001 pressure test equipment Adjusterneutral TPT00001 start switch Replacer, drive T26002 shaft oil seal, LH Replacer, drive shaft oil seal, T26003 Replacer, oil T26005 pump seal Version 2.0...
Page 416: Transmission-Mt
Transmission Transmission-MT Transmission-MT Specifications Torque Description Value Bolt-cable support bracket to front housing 22–30Nm Drain plug 30–40Nm Filler plug 30–40Nm Bolt-battery earth lead 75–90Nm Bolt-mounting bracket to transmission 70–90Nm Bolt-transmission mounting to body bracket 50–65Nm Nut-transmission bracket to mounting 90–110Nm Bolt-closing panel to transmission 22–28Nm Bolt-CKP sensor to cylinder...
Page 417: Specifications
Transmission-MT Transmission Specifications SH78ZA 5 forward manual transmission1.8T Type SH78ZA1 5 forward manual transmission1.8VCT Gear Ratio ·First 3.583 ·Second 2.105 ·Third 1.379 ·Fourth 1.030 ·Fifth 0.820 ·Reverse 3.363 ·Final drive 1.8T 3.722 ·Final drive 1.8VCT 4.053 Center Distance of Transmission: 78mm Rated Power of Mated Engine: 120Kw...
Page 418: Description And Operation
Transmission Transmission-MT Description and Operation System Component Layout Transmission Assembly Component Layout Version 2.0...
Page 419 Transmission-MT Transmission Transmission Transmission Operation Transmission Operation and Operation and Housing Housing Components Housing Components Components 1. Gear shift lever 19. Shaft–reverse lock 2. Roll pin 20. Washer–reverse lock thrust plate to control housing 3. Nylon block 21. Bolt–reverse lock thrust plate to control housing 4.
Page 420 Transmission Transmission-MT 37. Selector–reverse light 51. Dowel–front and rear housing 38. Selector shaft–5th/reverse gears 52. Front housing 39. Self-locking dowel 53. Bush–clutch release shaft 40. Washer 54. Bush–clutch release shaft 41. Bolt–front and rear housing 55. Dust cover–clutch release shaft 42.
Page 421 Transmission-MT Transmission Gear Gear Drive Gear Drive Drive Mechanism Mechanism Mechanism Components Components Components 1. Circlip(selective)–input shaft front bearing 19. Circlip–input shaft rear bearing 2. Front bearing–input shaft 20. Oil seal–input shaft 3. Retainer plate–front bearing 21. Reverse idler shaft 4.
Page 422 Transmission Transmission-MT 37. 2nd gear–output shaft 43. Synchro hub–5th gear 38. 3rd gear–output shaft 44. Needle roller bearing–output shaft reverse gears 39. Spacer(selective)–output shaft 3rd/4th gears 45. Reverse gear–output shaft 40. 4th gear–output shaft 46. Rear bearing–output shaft 41. Needle roller bearing–output shaft 5th gear 47.
Page 423 Transmission-MT Transmission Differential Differential Assembly Differential Assembly Assembly Components Components Components 1. Oil seal–drive shaft 7. Shim(selective) 2. Tapered roller bearing 8. Washer–planetary gear 3. Differential housing 9. Planetary gear 4. Final drive gear 10. Thrust washer(selective)–sun gear 5. Roll pin–pinion shaft 11.
Page 424 Transmission Transmission-MT Transmission Transmission Transmission Accessories Accessories Accessories Component Component Component Location Location Location 1. Cable support bracket 6. Drain plug 2. Bolt 7. Slave cylinder bracket (if fitted) 3. Bolt 8. Slave cylinder bracket (if fitted) 4. Reverse lamp switch 9.
Page 425: Description
Transmission-MT Transmission Description • 5th and reverse gear synchro hubs, sleeves and synchro General keys • Reverse gear and bearing Where specified, a 5-speed manual transmission is fitted. • Rear bearing The selector lever, fitted within the passenger compartment in Gear Ratios the centre console, gives the driver a choice of six positions, 1st, 2nd, 3rd, 4th, 5th and reverse.
Page 426: Operation
Transmission Transmission-MT Operation Reverse Lock Transmission Components When 5th gear is selected, the reverse lock is pressed against the outer side of the reverse lock's thrust plate under pressure The drive train changes the speed and direction of rotation from the torsional spring. of the drive by engaging different gears between the input and output shafts to produce five forward ratios and one reverse When 5th gear is shifted, the reverse lock frees from the...
Page 427: Service Procedures
Transmission-MT Transmission Service Procedures Remove assembly and repeat refit instructions. Oil Seal–Gear Change Rod 7. Fit battery cover. Remove Battery Battery Battery Carrier Carrier Carrier Bracket–Refit Bracket–Refit Bracket–Refit 1. Remove battery carrier. Battery Battery Battery Carrier Carrier Carrier Bracket–Remove Bracket–Remove Bracket–Remove 2.
Page 428: Lubrication System-Drain & Refill
Transmission Transmission-MT Lubrication System–Drain & Refill Manual Transmission Assembly Drain & Refill Remove 1. Remove undertray. 1. Remove air cleaner. Air Cleaner–Remove Cleaner–Remove Cleaner–Remove Undertray–Remove Undertray–Remove Undertray–Remove 2. Disconnect ECM multiplugs. 2. Position suitable container under transmission. 3. Remove battery carrier. 3.
Page 429 Transmission-MT Transmission 7. Drain gearbox oil. Lubrication System–Drain System–Drain & & & Refill Refill Lubrication Lubrication System–Drain Refill 8. Remove LH drive shaft. LH LH LH Shaft Shaft with Shaft with with Both Both Both Joints–Remove Joints–Remove Joints–Remove 9. Remove front subframe. Front Front Front Subframe–Remove...
Page 430 Transmission Transmission-MT 18. Remove 1 bolt securing clutch slave cylinder to bracket, 22. Position jack to support engine. leave aside the slave cylinder. (if fitted) 23. Connect lifting equipment to gearbox housing. 24. Remove nut from gearbox mount. 19. Remove 3 bolts from gearbox flange lower. 25.
Page 431 Transmission-MT Transmission 19. Fit starter motor. Starter Motor–Refit Motor–Refit Starter Starter Motor–Refit 20. Secure slave cylinder to bracket with a clip. (if fitted) 21. Fit slave cylinder to bracket and tighten 2 nuts to 20–25Nm. (if fitted) 22. Fit slave cylinder to bracket and tighten a bolt to 18–22Nm.
Page 432: Lamp Switch-Reverse
Transmission Transmission-MT Lamp Switch–Reverse Cover–Reverse Access–Reseal Remove Remove 1. Disconnect battery earth lead. 1. Drain transmission oil. 2. Disconnect reverse lamp switch multiplug. Lubrication System–Drain System–Drain & & & Refill Refill Lubrication Lubrication System–Drain Refill 2. Position suitable container under transmission to catch oil.
Page 433: Lubrication System-Manual Transmission-Top Up
Transmission-MT Transmission Lubrication System–Manual Transmission–Top Oil Seal–Differential–LH Remove Check & Top Up 1. Remove LH drive shaft. 1. Raise vehicle on a lift. LH LH LH Shaft Shaft with with Both Both Joints–Remove Joints–Remove Shaft with Both Joints–Remove 2. Clean area around filler plug. 2.
Page 434: Oil Seal-Differential-Rh
Transmission Transmission-MT Oil Seal–Differential–RH Manual Transmission Dismantling Remove Remove 1. Remove RH drive shaft. 1. Remove transmission assembly. RH RH RH Shaft Shaft with with Both Both Joints–Remove Joints–Remove Manual Transmission Transmission Assembly–Remove Assembly–Remove Shaft with Both Joints–Remove Manual Manual Transmission Assembly–Remove 2.
Page 435 Transmission-MT Transmission 14. Remove retaining plate. 18. Remove and discard differential oil seal. 15. Raise both input and output shafts slightly from housing. 19. Remove and discard input shaft oil seal. 20. Remove and discard 1st/2nd selector shaft bush from front housing.
Page 436: Input Shaft Assembly
Transmission Transmission-MT Input Shaft Assembly 1.85 Remove 1.825 1. Dismantle transmission. 1.80 Transmission Dismantle Dismantle Transmission Transmission Dismantle 11. Measure original shim thickness and select suitable 2. Retain input shaft in suitable securing device for shim, fit into tapered roller bearing outer race by using operation access.
Page 437 Transmission-MT Transmission 9. Remove and discard 5th gear input shaft circlip. 13. Remove 4th gear synchro spring ring and synchro ring. 10. Using T32001, remove 5th gear from input shaft. 14. Remove synchro sleeve. 15. Remove synchro hub and slide blocks. 16.
Page 438 Transmission Transmission-MT Caution: Check components for wear,scratch,damage 15. UsingT24003 fit input shaft rear bearing. and replace as necessary. 16. Fit input shaft rear bearing circlip. 1. Position input shaft on press. 17. Lubricate and fit input shaft rear oil seal using T24004. 2.
Page 439: Output Shaft Assembly
Transmission-MT Transmission Output Shaft Assembly Remove 1. Dismantle transmission. Transmission Dismantle Dismantle Transmission Transmission Dismantle 2. Retain output shaft in suitable securing device for operation access. 3. Remove and discard output shaft front bearing circlip. 4. Inspect front bearing for wear or damage. If replacement is necessary, replace together with output shaft.
Page 440 Transmission Transmission-MT 22.63 1.85 22.73 1.825 1.80 12. Using T24007, fit 4th gear of output shaft. 13. Fit inner race of 5th gear needle roller bearing. 25. Fit front bearing of output shaft using press equipment. 14. Lubricate bearings with clean oil. 26.
Page 441: Reverse Idler Gear
Transmission-MT Transmission Reverse Idler Gear Remove 1. Remove and discard reverse access cover. 5. Remove thrust washer, needle roller bearing from reverse idler shaft. Refit 1. Lubricate bearings with clean oil. 2. Remove bolt retaining reverse idler shaft, discard washer. 2.
Page 442: Differential Assembly
Transmission Transmission-MT Differential Assembly Remove 1. Remove transmission assembly. Manual Transmission Transmission Assembly–Remove Assembly–Remove Manual Manual Transmission Assembly–Remove 2. Remove differential assembly. Transmission Transmission Transmission Dismantle Dismantle Dismantle 3. Remove inner race of tapered roller bearing using T32001, discard washer. Protect the the differential differential carrier...
Page 443: Control Assembly
Transmission-MT Transmission Control Assembly Remove 1. Remove transmission assembly. Manual Transmission Transmission Assembly–Remove Assembly–Remove Manual Manual Transmission Assembly–Remove 2. Remove bolts from interlock assembly. 3. Remove bolts securing control assembly to transmission assembly. 4. Remove control assembly. 5. Remove bolts securing gear selector lever to control assembly.
Page 444: Fittings And Release Mechanism
Transmission Transmission-MT Fittings and Release Mechanism 8. Position shift and selector shaft through control assembly. Remove 9. Fit 5th/Reverse gear return spring, interlock assembly, 1. Remove slave cylinder bracket. gear shift arm guide, reverse lock selector assembly, 2. Remove cable support bracket. 1st/2nd gear return spring and return spring thrust 3.
Page 445 Transmission-MT Transmission Refit 8. Remove and discard cap of rear housing. 1. Fit slave cylinder bracket and tighten bolts to 22–30Nm. 2. Fit cable support bracket and tighten bolts to 22–30Nm. 3. Apply thread sealant to reverse light switch, fit and tighten switch to 32–44Nm.
Page 446: Special Tools
Transmission Transmission-MT Special Tools Tool Description Picture Number Tool Description Picture Number Replacer, guide T24014 oil, input / Replacer, oil output shafts T24016 seal, shift and selector shaft Replacer, roller bearing, shift Replacer, front T24015 and selector T24010 oil seal, output shaft shaft Replacer, front...
Page 447 Transmission-MT Transmission Tool Description Picture Tool Description Picture Number Number Replacer, inner Replacer, rear track of roller T24003 bearing, input T24008 bearing, reverse shaft gear Replacer, inner Replacer, rear T24009 track of taper T24004 oil seal, input bearing shaft Puncher, Ø3 Replacer, inner T24017 T24005...
Page 448: Clutch
Transmission Clutch Clutch Specifications Torque Description Value Bolt-clutch cover to flywheel 25Nm Bolt-clutch master cylinder to pedal bracket 7–10Nm Nut-clutch slave cylinder to slave cylinder bracket 20–25Nm Nut-clutch slave cylinder hose to pipe 15–19Nm Bleed plug-clutch slave cylinder 12–17Nm Version 2.0...
Page 449: Specifications
Clutch Transmission Specifications Type: Hydraulic pressure assistant clutch Drive plate diameter: 228mm Pressure plate diameter 228mm Clutch plate friction material B1675 Diaphragm finger height when clamped on a thick gauge plate: 28.45-30.45mm Diaphragm finger clearance (service limit) 64.0mm Clutch plate thickness under 6600 N axial load: •...
Page 450: Description And Operation
Transmission Clutch Description and Operation System Component Layout Clutch System Component Layout 1. Clutch pedal 7. Release lever 2. Clutch switch 8. Release fork 3. Master cylinder 9. Release bearing 4. Quick fit connector 10. Manual gearbox input shaft 5. Pipe 11.
Page 451 Clutch Transmission 13. Flywheel 14. Bolt (6 off) Version 2.0...
Page 452 Transmission Clutch Clutch Clutch Clutch Pedal Pedal and Pedal and Master Master Cylinder Master Cylinder Component Cylinder Component Component Layout Layout Layout 1. Flanged bolt (2 off) 7. Pedal box 2. Master cylinder 8. Clip 3. Clip 9. Pedal return spring 4.
Page 453: Description
Clutch Transmission Description The pressure plate assembly comprises a diaphragm spring, General Clutch Operation pressure plate and cover. The pressure plate is manufactured from cast iron and is machined to ensure a smooth surface The clutch is a conventional three piece, diaphragm type fitted for the drive plate to engage on.
Page 454 Transmission Clutch the mounting sleeve is keyed to the pedal mounting bracket. Mating serrations hold the sensor in position in the mounting sleeve. Version 2.0...
Page 455: Operation
Clutch Transmission Operation The force applied to the drive plate by the pressure plate Hydraulic Operation increases the friction between the drive plate and the flywheel. As the clutch pedal is released the friction increases and When the clutch pedal is pressed, the piston is pushed into the rotary movement of the flywheel is transferred to the drive master cylinder.
Page 456: Service Procedures
Transmission Clutch Service Procedures Check Clutch Assembly 1. Visually check diaphragm fingers for wear and irregular Remove height. 1. Remove transmission assembly. 2. Inspect clutch drive plate for signs of wear or oil contamination. Renew drive plate if necessary. Manual Transmission Transmission Assembly–Remove Assembly–Remove Manual...
Page 457 Clutch Transmission Pressure Plate Distortion 8. UseT22001 to fit clutch assembly to flywheel. Service limit 0.15mm 8. Examine release bearing and sleeve for signs of wear or damage. Renew release bearing if necessary. 9. Clean pressure plate and flywheel, dowels and dowel holes.
Page 458: Clutch Release Bearing
Transmission Clutch Clutch Release Bearing Clutch Master Cylinder (A) Remove Remove 1. Remove transmission assembly. 1. Remove battery carrier. Battery Carrier Carrier Bracket–Remove Bracket–Remove Battery Battery Carrier Bracket–Remove Manual Transmission Transmission Assembly–Remove Assembly–Remove Manual Manual Transmission Assembly–Remove 2. UseT22002 to disconnect clutch slave cylinder pipe 2.
Page 459: Clutch Master Cylinder (B)
Clutch Transmission Clutch Master Cylinder (B) bolts to 7–10Nm. Remove 4. Position master cylinder push-rod to clutch pedal, fit clevis pin and secure with clip. 1. Drain brake fluid from reservoir. 5. Connect clutch fluid pipe. Caution: Brake fluid will damage paint finished surfaces. If spilled, immediately remove fluid and clean area with 6.
Page 460: Clutch Slave Cylinder (A)
Transmission Clutch Clutch Slave Cylinder (A) Refit Remove 1. Fit grommet from fluid pipe. 1. Remove battery carrier. 2. Manoeuvre fluid pipe through grommet holes and secure grommets in holes. Battery Carrier Carrier Bracket–Remove Bracket–Remove Battery Battery Carrier Bracket–Remove 3. Position master cylinder to pedal bracket, fit and tighten bolts to 7–10Nm.
Page 461: Clutch Slave Cylinder (B)
Clutch Transmission Clutch Slave Cylinder (B) Clutch System Bleeding Remove Bleed Bleeding of the hydraulic system is only permissible if a clutch 1. Drain brake fluid from reservoir. pipe or hose has been disconnected. Ensure the fluid in the reservoir is maintained between the minimum and maximum Caution: Brake fluid will damage paint finished surfaces.
Page 462: Special Tools
Transmission Clutch Special Tools Tool Description Picture Number flywheel locking T10028 tool Aligner, clutch T22001 plate Pipe dismantling T22002 fork Version 2.0...
Page 463: Hvac System
HVAC Structure HVAC System HVAC Structure Specifications Torque Description Value Bolt-compressor to compressor mounting bracket 22-28Nm Bolt-compressor/condenser pipe to compressor 19-25 Nm Bolt-evaporator pipe and expansion valve to evaporator 5 Nm Bolt-condenser plugs 12 Nm Bolt-condenser to Radiator 5 Nm Bolt-compressor/condenser pipe to condenser 7-10 Nm Bolt-cooling system air duct to radiator...
Page 464: Specifications
HVAC System HVAC Structure Specifications Type CFC free, sealed, closed loop system; controlled byA/C ECU Refrigerant type HFC-R134a Refrigerant charge quantity 480 ± 30 g Compressor: (25℃ - 40℃) Pressure (High side) 10.5-25.3 bar Pressure (Low side) 1-3 bar Displacement: Displacement Min.
Page 465: Description And Operation
HVAC Structure HVAC System Description and Operation System Component Layout Heating and Ventilation Component Layout 1. Outboard front face duct 6. Rear footwell duct 2. Front windscreen and front side window vent duct 7. Rear face vent duct 3. Heater assembly 8.
Page 466 HVAC System HVAC Structure Air Conditioning (A/C) System Component Layout 1. Low pressure servicing connection 4. Evaporator and Thermostatic Expansion ValveTXV 2. High pressure servicing connection 5. Condenser 3. Refrigerant lines 6. Compressor Version 2.0...
Page 467: Description
HVAC Structure HVAC System Description The system consists of a filter housing, a heater assembly, distribution ducts and a control panel. Outlet vents are The heating and ventilation system controls the temperature incorporated in the boot. and distribution of air supplied to the vehicle interior. Version 2.0...
Page 468 HVAC System HVAC Structure Filter Filter Filter Housing Housing Housing 1. Filter housing cover 3. Filter housing 2. Pollen filter 4. Bolt The filter housing is located in the passenger side of the plenum effect, forces the air through the system. Depending on the and secured to the bulkhead by two bolts.
Page 469 HVAC Structure HVAC System Heater Assembly 1. Windscreen and side window outlets 10. Engine coolant feed 2. Face level outlets 11. Heater matrix 3. Rear footwell outlet 12. Distribution flaps mechanism and servo motor 4. Front footwell outlet 13. LH blend flap mechanism and servo motorATC only 5.
Page 470 HVAC System HVAC Structure tunnel which direct any condensation from the casing interior in position 5 in the engine compartment fuse box and a power to beneath the vehicle. A dedicated wiring harness connects controller fitted in the heater assembly. the heater assembly to the vehicle wiring.
Page 471 HVAC Structure HVAC System Control Flaps Temperature and Distribution Control Graphic shows flaps set for medium heat to face level and footwell outlets 1. Front face level outlet 5. Blower 2. Windscreen and side windows outlet 6. Heater matrix 3. Heater assembly casing 7.
Page 472 HVAC System HVAC Structure the fresh/recirculated air flap from fresh air to recirculated air Blend flaps: and back to fresh air. A blend flap regulates the flow of air through the heater The positive side of the motor is connected to a battery matrix to control the temperature of the air leaving the heater power supply from the passenger compartment fuse box.
Page 473 HVAC Structure HVAC System Distribution Ducts Separate distribution ducts are installed for the rear footwells, vents are effectively non-return valves and each consist of a for the face level outlets in the fascia and the rear of the grille covered by soft rubber flaps. The flaps open and close centre console.
Page 474: 10. Low Pressure Servicing Connection
HVAC System HVAC Structure andETC is thatATC has solar light sensor, in-car temperature Refrigerant System sensor and evaporator temperature sensor, whileETC Schematic of A/C System doesn’t have. In addition, the two air conditioning controller assemblies and the control systems are different. A.
Page 475 HVAC Structure HVAC System Compressor releases heat and changes state from vapour to liquid in the condenser. 1. Pulley 4. Outlet connection 2. Clutch connector 5. Control valve vent 3. Inlet connection The compressor circulates the refrigerant around the system The compressor is attached to a mounting bracket on the by compressing low pressure, low temperature vapor from the engine, and is a seven cylinder swash plate unit with variable...
Page 476 HVAC System HVAC Structure Sectioned View of Compressor A. Inlet pressure B. Outlet pressure C. Servo pressure D. Ambient air pressure 1. Clutch and pulley assembly 8. Push rod 2. Shaft 9. Diaphragm 3. Guide pin 10. Suction valve 4. Outlet port 11.
Page 477 HVAC Structure HVAC System The control valve assembly consists of a ball valve operated by a outlet pressure and a spring acting on the ball valve. The push rod connected to a diaphragm. A spring and atmospheric ball valve controls a flow of vapour from the outlet pressure pressure on one side of the diaphragm are opposed by inlet chamber to produce the servo pressure in the swash plate pressure on the opposite side of the diaphragm, and also by...
Page 478 HVAC System HVAC Structure ( ( ( ））） and Evaporator 1. Evaporator 3. Connecting tube 2. Bolt 4. TXV The thermostatic expansion valve meters the flow of passage. The metering valve is controlled by a temperature refrigerant into the evaporator to match the refrigerant flow sensitive tube connected to a diaphragm.
Page 479: Refrigerant Lines
HVAC Structure HVAC System Thermostatic expansion valve 1. Diaphragm 4. Inlet passage to evaporator 2. Housing 5. Outlet passage from evaporator 3. Metering valve 6. Temperature sensitive tube Evaporator Liquid refrigerant flows through the metering valve into the evaporator. The restriction across the metering valve The evaporator is installed in the air inlet of the heater reduces the pressure and temperature of the refrigerant.
Page 480 HVAC System HVAC Structure Heater Heater Heater Assembly Assembly Assembly 1. Distribution servo motor 3. LH blend flap servo motor ATC only 2. Connecting tube toTXV and evaporator 4. RH blend flap servo motor The heater assembly controls the temperature and distribution and fresh/recirculated air flap.
Page 481 HVAC Structure HVAC System Temperature and Distribution Control Graphic shows flaps set for medium heat to face level and footwell outlets 1. Front face level outlet 6. Evaporator 2. Windscreen and side windows outlet 7. Heater matrix 3. Heater assembly casing 8.
Page 482: Operation
HVAC System HVAC Structure Operation controller, to produce corresponding differences of blower General operating voltage and speed. At the maximum, the power controller supplies full battery voltage to the blower to operate operate refrigerant system, theA/CECU it at maximum speed. communicates with the ECM.
Page 483 HVAC Structure HVAC System 1. Fresh/recirculated air servo motor 4. Blower 2. Control panel 5. Power controller 3. Blower relay Air Temperature holds the swash plate at the minimum tilt angle (to minimise load during system start-up). Turning the temperature rotary switch on the control panel operates the blend flap servo motor in the heater assembly.
Page 484 HVAC System HVAC Structure The control valve regulates the servo pressure in the swash • Relay contact stuck closed plate chamber as a function of inlet pressure, so that the • Relay contact high resistance flow rate of the compressor matches the thermal load •...
Page 485 HVAC Structure HVAC System there is a minimum refrigerant pressure, and thus refrigerant and oil in the system. When refrigerant pressure increases to a value that indicates additional condensing is required, theECM connects an earth to the cooling fan relay unit, to request an increase in cooling fan speed.
Page 486: Service Procedures
HVAC System HVAC Structure Service Procedures recharged in A/C system is clean and dry, it will be filtrated when being recycled and discharged. Refrigerant Recovery, Recycling and Recharging The life cycle and work efficiency of (A/C) system • Never recharge R-12 refrigerant to R-134a system. Two are depending on refrigerant’s stability.
Page 487 HVAC Structure HVAC System 5. Check low and high side meter on the control panel to Note: ensure A/C system is pressurized. No pressure means • Plug the lubrication bottle with the cap all the time to there is no refrigerant can be recycled. prevent humidity and contaminations from entering the 6.
Page 488: If Recharging Is Completed Successfully/Unsuccessfully
HVAC System HVAC Structure If Recharging is Completed Compressor Successfully/Unsuccessfully: Remove If Recharging is Completed Successfully: 1. Disconnect battery earth lead. 1. Close high pressure side valve on the service station. 2. Recover refrigerant from A/C system. 2 valves should be closed. Refrigerant recovery recovery Refrigerant...
Page 489: Evaporator
HVAC Structure HVAC System Evaporator 7. Fit ancillary drive belt to compressor pulley. Ensure ancillary drive belt is correctly located to all pulleys. Remove 1. Remove heater assembly. Drive Drive Drive belt. belt. belt. Heater assembly assembly remove. remove. Heater Heater assembly remove.
Page 490 HVAC System HVAC Structure 10. Fit insulation to TXV, block and pipe assembly. 11. Secure block and pipe assembly to heater casing with screw. 12. Fit heater assembly. Heater Heater Heater assembly assembly refit assembly refit refit 7. Release harness from passenger side. 8.
Page 491: Thermostatic Expansion Valve
HVAC Structure HVAC System Thermostatic Expansion Valve Condenser Remove Remove 1. Remove heater assembly. 1. Recover refrigerant from A/C system. Refrigerant recovery recovery Refrigerant Refrigerant recovery Heater assembly assembly remove remove Heater Heater assembly remove 2. Remove front bumper. 2. Remove screw securing block and pipe assembly to heater casing.
Page 492 HVAC System HVAC Structure 6. Move air filter duct aside. 12. Remove 2 bolts securing condenser to radiator, lift and release condenser from mounting lugs and remove 7. Release 3 clips securing air temperature sensor harness condenser. to front bumper armature. 8.
Page 493: Drier Desiccant Bag
HVAC Structure HVAC System Drier Desiccant Bag bolts to 7-10 Nm Remove 11. Position bonnet locking platform supports and fit bolts. 1. Recover refrigerant from A/C system. 12. Fit screws to air filter duct. Refrigerant recovery recovery Refrigerant Refrigerant recovery 13.
Page 494: Pressure Sensor - Air Conditioning
HVAC System HVAC Structure Pressure Sensor - Air Conditioning Hose - Compressor to Condenser Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Recover refrigerant from A/C system. 2. Recover refrigerant from A/C system. Refrigerant recovery recovery Refrigerant Refrigerant...
Page 495: A/C Pipe - Evaporator To Compressor A-Evaporator To Connection
HVAC Structure HVAC System A/C Pipe - Evaporator to Compressor 2. Remove plug. A-Evaporator to Connection 3. Fit new O-rings, to each end of the Remove compressor/condenser pipe. 1. Disconnect battery earth lead. 4. Position compressor/condenser pipe to compressor, fit 2.
Page 496: A/C Pipe - Evaporator To Compressor B - Compressor To Connection
HVAC System HVAC Structure A/C Pipe - Evaporator to Compressor B - A/C Pipe - Condenser to Evaporator A - Compressor to Connection Condenser to Connection Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Recover refrigerant from A/C system. 2.
Page 497: A/C Pipe - Condenser To Evaporator B
HVAC Structure HVAC System A/C Pipe - Condenser to Evaporator B - Filter Housing - Fresh Air Intake Connection to Evaporator Remove Remove 1. Remove plenum. 1. Disconnect battery earth lead. Plenum - - - air air intake intake remove remove Plenum Plenum...
Page 498: Fresh Air Filter
HVAC System HVAC Structure Fresh Air Filter Heater Assembly Remove Remove 1. Remove plenum. 1. Drain cooling system. Plenum - - - air air intake.remove intake.remove Coolant - - - drain drain Plenum Plenum intake.remove Coolant Coolant drain 2. Release clip and remove filter cover from housing. 2.
Page 499: Blower Assembly
HVAC Structure HVAC System Blower Assembly Remove 1. Remove centre console. Console assembly assembly remove remove Console Console assembly remove 2. Disconnect multiplug from blower assembly. 7. Release harness from RH centre console support bracket and remove RH bracket. 8. Disconnect heater harness from body harness multiplug. 9.
Page 500: Heater Core
HVAC System HVAC Structure Heater Core 3. Connect pipes to heater matrix and secure clamps. Remove 4. Fit heater pipe clamps and secure with screws. 1. Remove heater assembly. 5. Fit heater assembly. Heater Heater Heater assembly assembly remove assembly remove remove Heater...
Page 501: Power Controller
HVAC Structure HVAC System Power Controller Remove 1. Remove fascia. Fascia remove remove Fascia Fascia remove 2. Disconnect power controller connector. 3. Remove 2 bolts securing power controller to heater case. 4. Remove power controller. Refit 1. Fit power controller to heater case and tighten bolts to 9 Nm 2.
Page 502: Hvac-Etc
HVAC System HVAC-ETC HVAC-ETC Specifications Torque Description Value Bolt-A/C Controller 2 Nm Version 2.0...
Page 503: Description And Operation
HVAC-ETC HVAC System Description and Operation System Component Layout A/C Control Component Layout - ETC 1. ETCcontrol panel 3. Pressure sensor 2. Evaporator temperature sensor 4. Power controller Version 2.0...
Page 504: System Control Diagram
HVAC System HVAC-ETC System Control Diagram Heater Assembly Control Diagram - ETC A. Hard wired B. MSCAN Bus C.LIN Bus 1. Distribution flaps servo motor 6. Power controller 2. RH blend flap servo motor 7. Blower 3. Fresh/recirculated air flap servo motor 8.
Page 505: Compressor
HVAC-ETC HVAC System Compressor Compressor and Compressor and Fan Fan Control Control Control Diagram Diagram Diagram - - - ETC A. Hard wired B.LIN Bus C. HSCAN Bus 1. ETCcontrol panel 7. Cooling fan relay unit 2. BCM 8. Fuse 4, engine compartment fuse box 3.
Page 506: Description
HVAC System HVAC-ETC Description ETC ECU Control System ETC ETCECU working method and operation is similar to theATC ECU. The difference is that theETCECU TheETC control system consists of: throughBCM Bus communicates with theLIN to control the • ETC ECU rear windscreen heater and diagnostic systems.ETCECU also •...
Page 507 HVAC-ETC HVAC System Display Outputs ETC 1. Temperature 5. Blower speed 2. Defrost mode 6. Heated Rear Window (HRW) 3. Fresh/recirculated air 7. A/C switch on 4. Distribution mode Version 2.0...
Page 508: Service Procedures
HVAC System HVAC-ETC Service Procedures Control Assembly Remove 1. Disconnect battery earth lead. 2. Release 3 clips securing centre console upper finisher to fascia. Refit 1. Connect A/C controller multiplugs. 2. Position A/C controller to finisher and secure with screws to 2 Nm. 3.
Page 509: Hvac-Atc
HVAC-ATC HVAC System HVAC-ATC Specifications Torque Description Value Bolt-A/C Controller 2 Nm Bolt-blend flap servo motor to heater case Bolt-fresh recirculated air flap servo motor to heater case 9 Nm Bolt-distribution flap servo motor to heater case 9 Nm Version 2.0...
Page 510: Description And Operation
HVAC System HVAC-ATC Description and Operation System Component Layout Control panel The controls for heating and ventilation are installed on a Window (HRW). An icon in theLCD illuminates when the panel in the centre of the fascia, the control panel also forms above switches are operated.
Page 511 HVAC-ATC HVAC System A/C Control Component Layout - (ATC) 1. Automatic Temperature Control (ATC) control 4. Pressure sensor panel/ECU and in-car temperature sensor 5. Heater coolant temperature sensor 2. Evaporator temperature sensor 6. Power controller 3. Solar light sensor Version 2.0...
Page 512: System Control Diagram
HVAC System HVAC-ATC System Control Diagram Heater Assembly Control Diagram - (ATC) A. Hard wired B. MSCAN Bus C. HSCAN Bus Version 2.0...
Page 513 HVAC-ATC HVAC System 1. Heater coolant temperature sensor 8. Body Control Module (BCM) 2. Solar light sensor 9. SCS modulator 3. LH blend flap servo motor 10. Power controller 4. Distribution flaps servo motor 11. Blower 5. RH blend flap servo motor 12.
Page 514 HVAC System HVAC-ATC Compressor Compressor Compressor and and Fan Fan Control Control Control Diagram Diagram Diagram - - - (ATC) (ATC) (ATC) A. Hard wired B. MSCAN Bus C. HSCAN Bus 1. ATC control panel 7. Cooling fan relay unit 2.
Page 515: Description
HVAC-ATC HVAC System Description switches for system control inputs and a Liquid Crystal Display Control System –ATC (LCD) to provide system status information. The ATC control system automatically controls the operation Inputs from the sensors, the control panel switches and of the refrigerant system and the control flaps in the heater theBCM are processed by theATC ECU, and theATCECU assembly to control the temperature and distribution of air...
Page 516 HVAC System HVAC-ATC Control Control Control Panel Panel Panel - - - ATC 1. LH temperature control switch 8. LCD 2. RH temperature control switch 9. Heated Rear Window (HRW ) switch 3. Automatic mode (AUTO)switch 10. Economy mode (ECON) switch 4.
Page 517 HVAC-ATC HVAC System Automatic Mode (AUTO ) Switch: distribution reaches windscreen/side windows demist only. Releasing and then pressing the switch again Starts the system in, or switches the system to and from, changes distribution back to face level only. the automatic mode. The use of theAUTO button toggles Defrost Mode Switch: theAUTO icon on and off.
Page 518 HVAC System HVAC-ATC Display Outputs –ATC 1. LH temperature 7. Defrost mode 2. Anion 8. RH temperature 3. Automatic mode 9. Heated Rear WindowHRW 4. Manual distribution 10. Air Conditioning (A/C) 5. Blower speed 11. Economy mode 6. Mono mode 12.
Page 519 HVAC-ATC HVAC System as sensed coming from the LH side of the vehicle and one as than 2 seconds) to turn off the generator and the symbol sensed coming from the RH side. The inputs are used as a disappears in the display. measure of the solar heating effect on vehicle occupants.
Page 520: Operation
HVAC System HVAC-ATC Operation while the system is in the automatic or defrost mode, and ATC System Control the refrigerant compressor is manually selected off,ATCECU enters the economy mode to reduce the load on the engine. ATC system is a closed loop control system which aims to Economy mode operation is similar to the automatic mode, achieve a comfortable climate in the passenger compartment.
Page 521 HVAC-ATC HVAC System a compressor on/off request to theECM every 10 seconds. To • The icon on the display is illuminated provided the LH prevent damage to the compressor, and the formation of ice and RH temperature are not set to LO or HI. from blocking the evaporator matrix, theBCM withholds the Once the compressor on request is granted, the compressor change of request to compressor on, and extinguishes theLED...
Page 522 HVAC System HVAC-ATC Blower Control • Selected temperature correction. As the temperature in the passenger compartment approaches the selected Blower speed can be controlled by either manual selection temperatures, blower speed is progressively reduced or automatic control. The blower speed calculates automatic until, once the selected temperatures have been speed control using the following inputs: established, blower speed stabilises at blower speed 5.
Page 523: Service Procedures
HVAC-ATC HVAC System Service Procedures Control Assembly Remove 1. Disconnect battery earth lead. 2. Release 3 clips securing centre console upper finisher to fascia. Refit 1. Connect A/C controller multiplugs. 2. Position A/C controller to finisher and secure with screws to 2 Nm. 3.
Page 524: Evaporator Temperature Sensor
HVAC System HVAC-ATC Evaporator Temperature Sensor Solar Light Sensor Remove Remove 1. Remove evaporator. 1. Disconnect battery earth lead. 2. Release clips securing solar light sensor to fascia. Evaporator Remove Remove Evaporator Evaporator Remove Refit 1. Fit evaporator. Evaporator Evaporator Evaporator Refit Refit Refit...
Page 525: Ambient Temperature Sensor-Atc
HVAC-ATC HVAC System Ambient Temperature Sensor-ATC Left Blend Flap - Servo Motor Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Release sensor from mounting clip and manoeuvre 2. Remove left heater closure panel. through lower bumper grille. Panel Panel Panel - - - Heater...
Page 526: Heater Coolant Temperature Sensor
HVAC System HVAC-ATC Heater Coolant Temperature Sensor Right Blend Flap - Servo Motor Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove passenger heater closure panel. 2. Remove heater right closure panel. 3. Disconnect temperature sensor multiplug. 3.
Page 527: Fresh Recirculated Air Flap - Servo Motor
HVAC-ATC HVAC System Fresh Recirculated Air Flap - Servo Motor Distribution Flap - Servo Mmotor Remove Remove 1. Disconnect battery earth lead. 1. Remove fascia. 2. Remove passenger's heater closure panel. 2. Disconnect servo motor connector. 3. Disconnect fresh recirculated air flap servo motor 3.
Page 528 Version 2.0...
Page 529: Steering System
Front Wheel Steering Steering System Front Wheel Steering Specifications Torque Description Value Power steering pressure sensor 24–26Nm Bolt-power steering oil intake pipe to power steering pump 38–42Nm Bolt-power steering pump to mounting bracket 45Nm Bolt-power steering pump pulley to power steering pump 25Nm Bolt-belt tensioner to mounting bracket 25Nm...
Page 530: Specifications
Steering System Front Wheel Steering Specifications Type Servo-assisted rack and pinion, linear ratio system Steering column: Þ Type Tilt and reach adjustable steering column with collapse mechanism. Integral electronic steering column lock. Steering wheel diameter 370 mm Turns - lock to lock 2.81 Turning circle: Þ...
Page 531: Description And Operation
Front Wheel Steering Steering System Description and Operation System Component Layout Steering System Component Layout 1. Fluid reservoir 4. Steering column 2. Pressure sensor 5. Steering gear 3. PAS pump 6. PAS fluid cooler Version 2.0...
Page 532 Steering System Front Wheel Steering Steering Rack Component Location 1. Grommet 6. Gaiters (2 off) 2. Valve unit 7. Track rod ball joint 3. Track rod end lock nut 8. Lock nut (2 off) 4. Flange bolt (2 off) 9. Steering rack component 5.
Page 533 Front Wheel Steering Steering System PAS Hydraulic Component Location 1. PAS pump suction hose 4. PAS fluid cooler 2. PAS high pressure hose 5. Return hose - cooler to reservoir 3. PAS return hose Version 2.0...
Page 534: Description
Steering System Front Wheel Steering Description with two bolts through cast lugs near the valve unit and two General bolts which secure a clamp fixed to the opposite end of the rack. A 'Double D' arrangement together with a nut and The major steering components comprise a two stage cam bolt secures the steering column to the steering rack collapsible steering column, a power assisted steering rack, a...
Page 535 Front Wheel Steering Steering System The outer sleeve is located in the main bore of the valve unit. Warning: Care is required when working on the hydraulic Three annular grooves are machined on its outer diameter. systems, since the high pressure fluid can be hot and, when PTFE rings are located between the grooves and seal against the pump is operating, reach pressures in excess of 10000 the bore of the valve unit.
Page 536: Operation
Steering System Front Wheel Steering Operation converted into linear movement of the steering rack through the rack and pinion. Rotary movement of the steering wheel is transferred via the steering column to the valve unit which is mounted on Neutral Position the steering rack.
Page 537 Front Wheel Steering Steering System Steering To The Left 1. Rotor 5. Flow from pump 2. Twisted torsion bar 6. Return to reservoir 3. Outer sleeve 7. Flow from RH hydraulic cylinder 4. Pressure flow to LH hydraulic cylinder Counter-clockwise rotation of the steering wheel in turn cylinder where the pressure increases.
Page 538 Steering System Front Wheel Steering Steering To The Right 1. Rotor 5. Flow from pump 2. Twisted torsion bar 6. Return to reservoir 3. Outer sleeve 7. Flow to RH hydraulic cylinder 4. Return flow from LH hydraulic cylinder Clockwise rotation of the steering wheel in turn rotates the right, the rotary movement is transferred through the steering rotor and the torsion bar in the same direction.
Page 539 Front Wheel Steering Steering System to unwind. This reduces the misalignment between the slots in the rotor and the torsion bar, reducing the fluid pressure applied to the applicable side of the hydraulic cylinder. Hydraulic Circuit 1. Reservoir 6. Hydraulic cylinder pressure areas 2.
Page 540: Service Procedures
Steering System Front Wheel Steering Service Procedures Power Assisted Steering System - Pressure Test Prepare Pressure Sensor Remove 1. To determine if a fault is in the steering pump or steering rack, close the test valve for a maximum of 1.
Page 541: Power Assisted Steering System Bleeding
Front Wheel Steering Steering System Power Assisted Steering System Bleeding 7. Using the banjo bolt and new sealing washers, fit adaptor T38004to steering rack feed pipe. Adjust 8. Connect hoses T38003to T38004and 1. Clean reservoir around filler cap. T38005adaptors. 9. Ensure all pipes and fittings are clear of rotating parts. 10.
Page 542: Power Assisted Steering Pump
Steering System Front Wheel Steering Power Assisted Steering Pump 4. Fit PASpump belt. Remove Belt - - - PAS PAS pump pump Refit. Refit. Belt Belt pump Refit. 1. Disconnect battery earth lead. 5. Tighten bolts securing PASpump pulley to PASpump 2.
Page 543: Pas Pump Tensioner
Front Wheel Steering Steering System PAS Pump Tensioner Power Assisted Steering Rack Remove Remove 1. Remove PAS pump belt. 1. Raise vehicle on lift. 2. Remove 2 bolts securing PASpump drive belt tensioner 2. Peel back carpet and peel back seal to reveal bolt to PASpump mounting bracket.
Page 544 Steering System Front Wheel Steering downpipe (Turbocharged models) or exhaust manifold 18. Remove union securing return pipe to steering rack (VCT models), release intermediate pipe and collect and discard O-ring. gasket. 19. Remove union securing feed pipe to steering rack and discard O-ring.
Page 545: Track Rod Ball Joint
Front Wheel Steering Steering System Track Rod Ball Joint tighten to 40–50Nm. Remove 5. Fit 2 upper bolts and tighten to 40–50Nm. 1. Raise vehicle with a lift. 6. Clean pipe unions and mating faces. 7. Fit new O-ring to return pipe, connect pipe and tighten Warning: Do not work on or under a vehicle supported union to 26–30Nm.
Page 546: Pipe - Pas Pump To Steering Rack
Steering System Front Wheel Steering Wheel Wheel Wheel alignment. alignment. alignment. Pipe - PAS Pump to Steering Rack Remove 1. Disconnect battery earth lead. 2. RemovePAS pressure sensor multiplug. 3. Raise vehicle on the lift. 4. Remove undertray. Undertray Remove Remove Undertray Undertray...
Page 547: Pipe - Steering Rack To Oil Cooler
Front Wheel Steering Steering System Pipe - Steering Rack To Oil Cooler Remove 1. Disconnect battery earth lead. 2. Raise vehicle on lift. 3. Remove undertray. Undertray Remove Remove Undertray Undertray Remove 4. Position container to collect spillage. 5. Release clip securing return pipe to oil cooler and disconnect pipe from oil cooler.
Page 548: Oil Cooler - Steering
Steering System Front Wheel Steering Oil Cooler - Steering Caution: To prevent damage to components, use two spanners when loosening or tightening unions. Remove 1. Remove front bumper. 5. Using new sealing washers, position pipe to subframe and fit screws to 19–25Nm Front Bumper Bumper Remove Remove...
Page 549: Special Tools
Front Wheel Steering Steering System Special Tools Tool Description Picture Number Tool Description Picture Number Adaptor power T38004 steering test PAS pressure T38001 test equipment Remover ball T38008 Adaptor joint T38002 hydraulic pressure test Adaptor hydraulic T38003 pressure test hose Adaptor power T38005 steering pump...
Page 550: Steering Wheel And Column
Steering System Steering Wheel and Column Steering Wheel and Column Specifications Torque Description Value Bolt-steering column cover 2.4–3.4Nm Bolt and washer-steering wheel to steering column 60–70Nm Locking nut-power steering column to power steering rack 20–25Nm input shaft Bolt-power steering column to instrument panel frame 21–25Nm Screw-rotary coupler to steering column 4–5.5Nm...
Page 551: Description And Operation
Steering Wheel and Column Steering System Description and Operation System Component Layout Steering System 1. Fluid reservoir 4. Steering gear 2. PAS pump 5. PAS fluid cooler 3. Steering column Version 2.0...
Page 552 Steering System Steering Wheel and Column Steering Column Component Location S382001 1. Mounting screws (4 off) 5. Grommet 2. Upper universal joint 6. Column adjustment lever 3. Sliding column joint 7. Electric steering column lock(ESCL) 4. Lower universal joint 8. Harness connection from ESCL Version 2.0...
Page 553: Description
Steering Wheel and Column Steering System Description materials are moulded. The hub is splined to locate with the General splines on the steering column. The horn switch is mounted in the centre pad of the steering wheel. The trip computer The major steering components comprise a two stage remote switches and, where fitted, the cruise control, remote collapsible steering column, a power assisted steering rack, a...
Page 554: Service Procedures
Steering System Steering Wheel and Column Service Procedures Switch - Cruise Control Remove Steering Wheel Alignment - Adjustment Adjust 1. Remove steering wheel. 1. Mark position of track rods for reference. 2. Loosen RH and LH track rod end lock nuts. Caution: To avoid possible joint damage always use a spanner to hold track rod end when loosening or tightening track rod end lock nut.
Page 555: Steering Column Cover
Steering Wheel and Column Steering System Steering Column Cover Refit Remove 1. Fit cruise control switches to steering wheel and secure with screws. 1. Remove steering column closing panel. 2. Fit switch cover and secure Tiptronic paddle with screw Panel assembly assembly - - - fascia fascia closing closing panel...
Page 556: Steering Wheel
Steering System Steering Wheel and Column Steering Wheel Remove 1. Remove drivers airbag. Airbag - - - Steering Steering Sheel Sheel - - - Driver Driver Remove. Remove. Airbag Airbag Steering Sheel Driver Remove. 2. Disconnect steering wheel switch multiplugs. 3.
Page 557: Steering Column
Steering Wheel and Column Steering System Steering Column Remove 1. Remove handset from start switch, disconnect battery leads, earth first and wait 10 minutes for the SRSback-up power circuit to discharge before commencing work. 2. Remove steering wheel. Steering wheel wheel Remove.
Page 558: Switch Assembly - Steering Column
Steering System Steering Wheel and Column Switch Assembly - Steering Column Remove 1. Remove steering wheel. Steering wheel wheel Remove. Remove. Steering Steering wheel Remove. 2. Remove steering column cover Steering Steering Steering column column column cover cover cover Remove. Remove.
Page 559: Suspension System
Wheel Alignment Suspension System Wheel Alignment Specifications Torque Description Value Nuts-pas ball joint 40–55Nm Nuts-rear upper arm to subframe 90–110Nm Nuts-rear wheel toe-in adjust 90–110Nm Version 2.0...
Page 560: Specifications
Suspension System Wheel Alignment Specifications Wheel alignment: Front Camber-unladen condition -0°21' ± 30' Castor-unladen condition 3°30' ± 30' King-pin inclination 12°41' ± 30' Total toe-in 0°10’ ± 10' Rear Camber - unladen condition –0°50’ ± 30' Total toe-in 0°22' ± 12' Version 2.0...
Page 561: Service Procedures
Wheel Alignment Suspension System Service Procedures b. Adjust rear wheel camber to specification rotating cam bolt securing upper arm to subframe. Wheel Alignment Check c. Tighten lock nut to 90–110Nm. 1. Wheel alignment must only be carried out using d. Repeat above for other side. approved equipment.
Page 562: Front Suspension
Suspension System Front Suspension Front Suspension Specifications Torque Description Value Nut-lower arm inner ball joint to subframe lock 75–90Nm Bolts-lower arm bush housing to subframe 140–170Nm Nut-lower arm outer ball joint to swivel hub 40–50Nm Bolts-wheel 115–130Nm Nut-front strut damper top mounting 54–62Nm Nut-anti-roll bar links to damper 50–65Nm...
Page 563: Specifications
Front Suspension Suspension System Specifications Type MacPherson strut with L shaped rearward-facing lower arms. ARB connected via ball jointed link to strut. Front control arm L shaped, steel forged with lightening holes. Ball joints at forward inner and outer joints 393.5mm Nominal height to wheel arch from hub centre* Nominal height to wheel arch from hub centre*...
Page 564: Description And Operation
Suspension System Front Suspension Description and Operation System Component Layout Front Suspension Component Location 1. MacPherson strut assembly (2 off) 6. Lower arm (2 off) 2. Anti-roll bar link (2 off) 7. Anti-roll bar 3. Subframe mountings (6 off) 8. Anti-roll bar bush and clamp (2 off) 4.
Page 565 Front Suspension Suspension System Front Suspension Components 1. Damper unit 9. Lower arm bush and housing assembly 2. Swivel hub 10. Lower arm 3. Hub nut 11. Anti-roll bar 4. Drive flange 12. Anti-roll bar bush 5. Circlip 13. Anti-roll bar clamp 6.
Page 566 Suspension System Front Suspension MacPherson Strut Components 1. Piston rod top nut 8. Bump stop 2. Washer 9. Dust cover 3. Locknut/washer assembly (3 off) 10. Coil spring 4. Top mounting plate 11. Damper 5. Bearing 12. Spring isolator 6. Spring isolator 13.
Page 567: Description
Front Suspension Suspension System Description cavity between the inner and outer tubes. This minimises oil General cavitation and eliminates the effect of damage to the outer tube affecting piston operation. The front suspension comprises: The damper is attached at its lower end to a location in the •...
Page 568 Suspension System Front Suspension wheel axis to minimise the effects of camber. The inner ball are not serviceable and if replacement of either is necessary, a joint locates in a tapered seat in the subframe and is secured new link will be required. with a locknut.
Page 569: Service Procedures
Front Suspension Suspension System Service Procedures Lower Arm-Front Remove 1. Raise the vehicle on a lift. 2. Remove undertray. Undertray-Assembly Undertray-Assembly Undertray-Assembly Remove Remove Remove 3. Remove front road wheels. 4. Use an open ended spanner on the flats machined on the anti-roll bar links to prevent ball stud rotation.
Page 570: Outer Ball Joint Boot-Front Lower Arm
Suspension System Front Suspension Outer Ball Joint Boot-Front Lower Arm 5. Remove lower arm outer ball joint protectorT32003 and inspect ball joint boot for damage.Ensure lower Remove arm outer ball joint is fully engaged in swivel hub and Caution: This ball joint boot kit should only be used if the bolt is located in ball joint groove.
Page 571: Bush And Bracket-Front Lower Arm
Front Suspension Suspension System Bush and Bracket-Front Lower Arm Remove 1. Remove lower arm. Lower Arm-Front Arm-Front Remove Remove Lower Lower Arm-Front Remove 2. Using T32001,T32007 and T32009, remove front lower arm bush and bracket. 6. Using special toolT32025 position spring ring onT32023 , usingT32024 push spring ring until position on outer ball joint boot.
Page 572: Damper-Front
Suspension System Front Suspension Damper-Front Remove 1. Raise the vehicle on a lift. 2. Remove road wheel. 3. RH side only: Release pad wear sensor harness from damper. 4. ReleaseABS sensor harness and brake hose from damper. Release harness and brake hose from clip. 5.
Page 573 Front Suspension Suspension System top nut. Discard nut. 19. Ensure lower arm ball joint is fully engaged in swivel hub and bolt is located in the ball joint groove. 19. Remove washer and mounting turret with bearing. 20. Clean anti-roll bar joint, connect to anti-roll bar, fit nut 20.
Page 574: Subframe-Front
Suspension System Front Suspension Subframe-Front Remove 1. Disconnect battery earth lead. 2. Remove front road wheels. 3. Raise the vehicle on a lift. 4. Remove intermediate pipe and silencer. Intermediate Intermediate Intermediate Pipe Pipe Remove Pipe Remove Remove 5. Mark relative position of subframe to body to aid refit. 6.
Page 575 Front Suspension Suspension System to40–50Nm. 10. Fit bolts securing anti roll bar clamps to subframe and tighten to22–28Nm. 11. Fit bolts securing rear lower arm bushings to subframe and tighten bolts to140–170Nm. 12. Fit bolts securing PAS pipe to subframe and tighten to19–25Nm 13.
Page 576: Brace-Front Subframe
Suspension System Front Suspension Brace-Front Subframe Bush-Front Subframe Remove Remove 1. Raise the vehicle on a lift. 1. Remove front subframe. 2. Remove and discard Patchlok bolt securing brace to Subframe – – – Front Front Remove Remove Subframe Subframe Front Remove body.
Page 577: Anti Roll Bar-Front
Front Suspension Suspension System Anti Roll Bar-Front Remove 1. Remove intermediate pipe. Intermediate Pipe Pipe Remove Remove Intermediate Intermediate Pipe Remove 2. Remove front road wheels. 3. Remove track rod end nuts and usingT38008 release track rod end from steering armand release track rod end from steering arm.
Page 578 Suspension System Front Suspension 2. Fit bushes to anti-roll bar and locate to abutments. Caution: Anti roll bar bushes have a special coating and must not be lubricated. 3. Fit clamps, fit bolts securing clamps and tighten each bolt in turn to22–28Nm. 4.
Page 579: Mounting Rubbers-Anti Roll Bar-Set
Front Suspension Suspension System Mounting Rubbers-Anti Roll Bar-Set Undertray–Assembly Undertray–Assembly Undertray–Assembly Refit Refit Refit Remove 7. Lower the vehicle. 1. Raise the vehicle on a lift. 2. Remove undertray. Undertray–Assembly Remove Remove Undertray–Assembly Undertray–Assembly Remove 3. Remove 4 bolts securing steering rack to subframe. 4.
Page 580: Link-Anti Roll Bar
Suspension System Front Suspension Link-Anti Roll Bar Hub-Front Remove Remove 1. Raise the vehicle on a lift. 1. Raise the vehicle on a lift. 2. Remove road wheel. 2. Remove front wheel. 3. Remove nut securing link to anti-roll bar. 3.
Page 581 Front Suspension Suspension System 17. Fit lower arm ball joint protector. 18. Release drive shaft from hub. 19. Remove hub assembly from damper. Tip: Do not remove protective cover from bearing until hub is about to be fitted. Tip: Do not store hub bearings near magnetic fields or iron filings as damage may occur.
Page 582: Bearings-Front Hub
Suspension System Front Suspension Bearings-Front Hub 25. Lower the vehicle. Remove 26. Check wheel alignment. 1. Remove hub. Wheel Wheel Wheel Alignment Alignment Alignment Hub-Front Hub-Front Hub-Front Remove Remove Remove 2. Remove 3 bolts securing brake disc shield to hub. 3.
Page 583 Front Suspension Suspension System 6. Fit hub. 8. UsingT32013 and T32015, remove the hub bearing from hub. Hub-Front Hub-Front Hub-Front Refit Refit Refit Refit 1. Clean hub and bearing mating faces. 2. UsingT32014 support hub, useT32013 to press the new bearing into hub. 3.
Page 584: Special Tools
Suspension System Front Suspension Special Tools Tool Description Picture Number Tool Description Picture Number T32001 Puller universal Lever front T32011 lower arm ball joint Remover front T32007 Protector - lower arm bush T32003 front lower arm ball joint Replacer and Remover cap guide front T32009...
Page 585 Front Suspension Suspension System Tool Description Picture Tool Description Picture Number Number Remover ball Remover front T38008 T32005 joint subframe bush Remover front Coil spring subframe T32016 T32021 compressor middle suspension bush Remover front Adaptor subframe T32017 coil spring T32022 middle compressor suspension bush...
Page 586 Suspension System Front Suspension Tool Description Picture Number Replacer front T32006 subframe bush Support plate T32015 front hub Remover T32012 replacer front hub flange Remover and T32013 replacer front hub bearing Support front T32014 Version 2.0...
Page 587: Rear Suspension
Rear Suspension Suspension System Rear Suspension Specifications Torque Description Value Bolt-fuel tank strap 21–25Nm Bolts-wheel 115–130Nm Bolts-rear upper arm to subframe 90–110Nm Nuts-rear upper arm to trailing arm 90–110Nm Nut-LH rear damper to top mount 25–34Nm Nut-rear damper top mount to body 19–25Nm Bolts-rear damper to trailing arm 140–170Nm...
Page 588: Rear Suspension
Suspension System Rear Suspension Rear Suspension Type Independent, trailing arm suspension with transverse upper and lower arms. ARB connected via ball jointed links to trailing arms. Rear upper lateral link Fabricated steel Nominal height from hub centre to wheel arch* 395 mm Anti-roll bar diameter 17 mm...
Page 589: Description And Operation
Rear Suspension Suspension System Description and Operation System Component Layout Rear Suspension Component Location 1. Stub axle (2 off) 6. Rear subframe mounting (2 off) 2. Damper assembly (2 off) 7. Front subframe mounting (2 off) 3. Upper arm (2 off) 8.
Page 590 Suspension System Rear Suspension Rear Suspension Components 1. Rear subframe 7. Lower spring isolator (2 off) 2. Upper arm (2 off) 8. Coil spring (2 off) 3. Damper assembly (2 off) 9. Upper spring isolator (2 off) 4. Trailing arm (2 off) 10.
Page 591 Rear Suspension Suspension System Rear Damper Assembly Components 1. Damper assembly (2 off) 5. Top mounting (2 off) 2. Dust cover (2 off) 6. Rebound plate (2 off) 3. Bump stop (2 off) 7. Nut M10 flanged (2 off) 4. Bump stop plate (2 off) 8.
Page 592: Description
Suspension System Rear Suspension Description A spring aid plate and a spring aid are fitted over the rod General and cushion the damper operation if maximum bump travel is reached. A bump cup is fitted to the top of the damper body The rear suspension comprises: and protects the low friction damper rod seal from damage •...
Page 593 Rear Suspension Suspension System The trailing arm has two forged lugs that are provided for The ARB is 17 mm in diameter. The ARB is attached to the the attachment of the rear brake calliper. A non-serviceable, rear of the subframe with two Polytetrafluoroethylene (PTFE) machined hub spindle is press fitted into the arm and locates bushes that are secured with clamp plates and bolts.
Page 594: Service Procedures
Suspension System Rear Suspension Service Procedures 5. Refit road wheel and tighten bolts to 115–130Nm. Upper Arm-Rear 6. Lower the vehicle. Remove 7. Tighten bolt securing upper arm to subframe to 1. Raise the vehicle on a lift. 90–110Nm. 2. Remove road wheel. 8.
Page 595: Bush Set-Rear-Upper Arm
Rear Suspension Suspension System Bush Set-Rear-Upper Arm Remove 1. Remove rear upper arm. Upper Arm Arm - - - Rear Rear Remove Remove Upper Upper Rear Remove 2. As shown, usingT34015 and T34016, use hydraulic press to remove ball joint bush. Caution: Ensure the rubber end of the bush is located fully in the special tools.
Page 596: Lower Arm-Rear
Suspension System Rear Suspension Lower Arm-Rear Remove 1. Remove rear lower arm. Lower Arm–Rear Arm–Rear Remove Remove Lower Lower Arm–Rear Remove 2. As shown, usingT34015 and T34016, use hydraulic press to remove ball joint bush. 3. Remove special tools from rubber bush. 4.
Page 597: Bush Set-Rear Lower Arm
Rear Suspension Suspension System Bush Set-Rear Lower Arm Refit Remove 1. Fit dust cover, bump stop, bump stop washer, mounting plate and rebound plate ensuring correct orientation 1. Lower rear seat back and pull back luggage of plate. compartment trim to access damper fixing. 2.
Page 598: Damper-Rear
Suspension System Rear Suspension Damper-Rear Spring-Rear Suspension Remove Remove 1. Remove rear suspension spring. 1. Raise the vehicle on a lift. 2. Remove road wheel. Spring - - - Rear Rear Suspension Suspension Remove Remove Spring Spring Rear Suspension Remove 3.
Page 599: Anti-Roll Bar-Rear
Rear Suspension Suspension System Anti-Roll Bar-Rear Rubbers-Anti-Roll Bar Remove Remove 1. Raise the vehicle on a lift. 1. Raise the vehicle on a lift. 2. Use an open ended spanner on the flats machined on 2. Remove 4 bolts securing anti-roll bar clamps to the anti-roll bar link to prevent ball stud from rotating, subframe and remove clamps.
Page 600: Link-Anti Roll Bar
Suspension System Rear Suspension Link-Anti Roll Bar Hub Bearing-Rear Remove Remove 1. Raise the vehicle on a lift. 1. Raise the vehicle on a lift. 2. Remove road wheel. 2. Remove rear wheel. Wheel Wheel Wheel Remove Remove Remove Wheel Wheel Wheel Remove Remove...
Page 601 Rear Suspension Suspension System 7. Knock back staking locking hub nut to stub axle shaft. 8. Remove and discard hub nut. 9. Remove keyed washer from stub axle. 10. Remove hub assembly. Caution: Do not store hub bearings near magnetic fields or iron filings as damage may occur.
Page 602: Special Tools
Suspension System Rear Suspension Special Tools Tool Description Picture Number Tool Description Picture Number Remove and Replacer rear replacer upper T34015 T34017 upper arm ball and lower arm joint bush ball joint bush Remove upper T34016 and lower arm ball joint bush Replacer rear T34022 lower arm bush...
Page 603: Tyres And Wheels
Tyres and Wheels Suspension System Tyres and Wheels Specifications Torque Description Value Bolt-road wheel 115–130Nm Version 2.0...
Page 604: Specifications
Tyres and Wheels Suspension System Specifications Wheels Wheel size: Alloy 7.5J x 17 6.5J x 16 Steel 7.5J x 17 Tyre size: With 7.5J x 17 wheels (alloy) 215/50 R17 91W With 6.5J x 16 wheels (alloy and steel) 215/55 R17 93W Stow wheels With 6.5J x 16 wheels ( steel) 215/55 R16 93W...
Page 605: Service Procedures
Tyres and Wheels Suspension System Service Procedures Wheel Remove 1. Use a suitable wheel brace or the wrench supplied in the vehicle tool kit to loosen 5 road wheel bolts. 2. Raise the vehicle on a lift, and set to normal working height.
Page 606 Version 2.0...
Page 607: Brake System
Brake Brake System Brake Specifications Torque Description Value Screws-front brake caliper bleed 7–9Nm Bolts-wheel 115–130Nm Screws-front brake disk to hub 30–36Nm Bolt-front brake caliper to hub 90–110Nm Front caliper housing to carrier guide pins 28Nm Front brake hose to caliper housing 16–18Nm Front brake hose to brake pipe connection 16–18Nm...
Page 608: Description And Operation
Brake Brake System Description and Operation System Component Layout Brake System Component Location 1. Master cylinder assembly 9. LH rear brake disc 2. Brake servo assembly 10. Front flexible brake hose 3. Steering Angle Sensor (SAS) (if fitted) 11. Brake fluid low level switch 4.
Page 609 Brake Brake System Brake Brake System Brake System Control System Control Control Component Component Location Component Location Location 1. Wheel speed sensor assembly (rear) 11. Modulator ECU connector 2. Brake pad wear sensor (rear) 12. ABS/DSC Modulator 3. ABS warning light 13.
Page 610 Brake Brake System Front Front Front Brakes Brakes Components Brakes Components Components 1. Front brake pad wear sensor 6. Piston seal 2. Bleed screw cap 7. Piston 3. Bleed screw 8. Piston dust cover 4. Calliper housing 9. Shield 5. Anti-rattle spring 10.
Page 611 Brake Brake System 11. Calliper carrier 14. Guide pin dust cover 12. Calliper securing bolt 15. Guide pin 13. Brake pad 16. Guide pin dust cover cap Version 2.0...
Page 612 Brake Brake System Rear Rear Rear Brakes Brakes Components Brakes Components Components 1. Rear brake pad wear sensor 9. Brake disc 2. Bleed screw cap 10. Calliper carrier 3. Bleed screw 11. Calliper securing bolt 4. Calliper housing 12. Brake pad 5.
Page 613 Brake Brake System Parking Parking Drum Parking Drum Drum Brake Brake Brake Components Components Components 1. Rear backplate 7. Brake shoe expander 2. Brake shoe return spring 8. Retaining clip 3. Brake shoe adjuster 9. Brake shoe return spring 4. Brake shoe retaining pin 10.
Page 614: Description
Brake Brake System Description The system incorporates ABS, Electronic Brake force General Distribution (EBD) and brake pad wear sensing as standard on all models. The brakes consist of front and rear ventilated disc brakes operated by a diagonally split, dual circuit hydraulic system with Some vehicles are also fitted with SCS, which incorporates vacuum servo power assistance.
Page 615 Brake Brake System Brake Pedal and Switch The master cylinder assembly is attached to the forward ends of two tie bolts in the brake servo assembly. The brake pedal is installed on a pivot shaft in the pedal mounting bracket on the engine bulkhead. The brake servo assembly consists of a circular housing which contains two diaphragms, a central plate, a control valve A clevis pin and clip connect the input rod of the brake servo...
Page 616 Brake Brake System Master Master Master Cylinder Cylinder Cylinder Assembly Assembly Assembly 1. Secondary pressure chamber 8. Primary piston 2. Secondary piston 9. Primary springs 3. Secondary feed hole 10. Primary pressure chamber 4. Fluid reservoir ports 11. Secondary centre valve 5.
Page 617 Brake Brake System Rear Brakes In some markets, the instrument pack performs a bulb check of the brake warning light each time the ignition is switched on. The rear brakes each comprise of a hubmounted, single piston, sliding calliper assembly and a ventilated disc. A front cable is connected between the lever assembly and a cable tensioner, and two handbrake cables are connected The centre of each disc incorporates a drum for the parking...
Page 618: Operation
Brake Brake System Operation Brake Servo Assembly General Brake Off When the ignition is switched on, the modulator ABS ECU With the brake pedal released, the piston in the control valve performs a check of the brake related warning lights on the assembly positions the valve so that the vacuum port is open instrument pack as part of the power up procedure.
Page 619 Brake Brake System 15. Reaction disc 19. Guide tube 16. Central plate 20. Output push rod 17. Master cylinder 21. Bush 18. Return spring Brakes On The boost ratio remains constant, as the input force from the brake pedal increases, until the limit of assistance is reached When the brake pedal is pressed, the input push rod and the when servo pressure is equal to ambient pressure.
Page 620 Brake Brake System Servo with Brakes On A = Partial vacuum; B = Ambient pressure; C = Servo pressure 1. Vacuum line connector 12. Gaiter 2. Housing 13. Piston 3. Diaphragms 14. Ratio disc 4. Minor diaphragm 15. Reaction disc 5.
Page 621 Brake Brake System Further movement of the pistons then pressurizes the fluid in If, on the other hand, the ECU detects a wheel spinning the primary and secondary pressure chambers, and thus the normally, brake pressure is too low so the caliper outlet brake circuits.
Page 622 Brake Brake System the same way as ABS, using two additional restrictors in the Main requirements for activation of HHC are recognition of ABS modulator. “vehicle stand still” and brake pressure build-up by the driver via brake pedal. Generally, when the vehicle’s speed exceeds 60kph, brake intervention cannot be used.
Page 623 Brake Brake System ZTPMS If a fault exists in the warning light circuit, the lamp will not illuminate during the lamp check, but provided there are ZTPMS is an indirect tyre pressure monitoring system. no other faults, the related function will otherwise be fully The system does not directly measure tyre pressure but operational.
Page 624: Service Procedures
Brake Brake System Service Procedures cleaning fluid. Brake Pad-Front Warning: Do not use compressed air to clean brake Remove components. Dust from friction materials can be harmful Warning: Do not work on or under a vehicle supported if inhaled. only by a jack. Always support the vehicle on safety 3.
Page 625: Brake Disc-Front
Brake Brake System Brake Disc-Front 90–110Nm. Remove 6. Fit wheel. Caution: Brake discs must be renewed in pairs, unless one Wheel Wheel Wheel Refit Refit Refit disc requires changing before 1000 miles (1500 km) from 7. Lower the vehicle. new. 1.
Page 626: Caliper Housing - Front
Brake Brake System Caliper Housing - Front Remove 1. Raise the vehicle on a lift. Warning: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2. Remove front road wheel. 3.
Page 627: Brake Pad-Rear
Brake Brake System Brake Pad-Rear Warning: Do not use compressed air to clean brake Remove components. Dust from friction materials can be harmful if inhaled. Warning: Brake pads must be renewed in axle sets only, 3. Inspect caliper and seals for damage. otherwise braking efficiency may be impaired.
Page 628: Brake Disc-Rear
Brake Brake System Brake Disc-Rear 3. Examine brake pads and renew if necessary. Remove 4. Release caliper assembly and fit to trailing arm, fit and tighten bolts to61–66Nm. Caution: Brake discs must be renewed in pairs, unless one disc requires changing before 1000 miles (1500 km) from 5.
Page 629: Backplate-Rear Brake Disc
Brake Brake System Backplate-Rear Brake Disc Brake Shoe-Rear Remove Remove 1. Remove rear hub bearing 1. Remove rear brake disc. Hub Bearing Bearing - - - Rear Rear Remove Remove Brake Disc Disc - - - Rear Rear Remove Remove Bearing Rear Remove...
Page 630: Caliper Housing-Rear
Brake Brake System Caliper Housing-Rear 7. LH side only: Disconnect pad wear sensor from Remove inboard brake pad. 1. Raise the vehicle on a lift. Warning: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Page 631: Thickness And Run-Out Check-Rear Brake Disc
Brake Brake System Thickness and Run-Out Check-Rear Brake Disc Check 1. Raise the vehicle on a lift. Warning: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2. Remove road wheel. 3.
Page 632: Thickness And Run-Out Check-Front Brake Disc
Brake Brake System Thickness and Run-Out Check-Front Brake Disc Check 1. Raise the vehicle on a lift. Warning: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2. Remove road wheel. 3.
Page 633: Pedal Box-Automatic Transmission
Brake Brake System Pedal Box-Automatic Transmission Remove 1. Disconnect battery earth lead. 2. Remove steering column closing panel. Panel Panel Panel Assembly–Steering Assembly–Steering Column Assembly–Steering Column Column Lower Lower Lower Cover–Base Cover–Base Remove Cover–Base Remove Remove 3. Remove 4 bolts and release steering column from fascia beam.
Page 634: Pedal Box-Manual Transmission
Brake Brake System Pedal Box-Manual Transmission Remove 1. Disconnect battery earth lead. 2. Remove steering column closing panel. Panel Assembly–Steering Assembly–Steering Column Column Lower Lower Panel Panel Assembly–Steering Column Lower Cover–Base Remove Remove Cover–Base Cover–Base Remove 3. Remove 4 bolts and release steering column from fascia beam.
Page 635 Brake Brake System multiplugs and remove pedal box. contact with operating tang on brake pedal. 9. Position steering column to fascia beam, fit bolts and tighten to21–25Nm. 10. Fit steering column closing panel. Panel Panel Panel Assembly–Steering Assembly–Steering Column Assembly–Steering Column Column Lower Lower...
Page 636: Vacuum Servo-Brake
Brake Brake System Vacuum Servo-Brake Remove 1. Remove battery carrier. Battery Carrier Carrier Bracket Bracket Remove Remove Battery Battery Carrier Bracket Remove 2. Disconnect 3 multiplugs from ECM. 3. Remove strap securing engine harness to battery carrier bracket. 4. Remove 2 bolts securing battery carrier bracket to engine compartment and remove battery carrier bracket.
Page 637: Switch-Brake
Brake Brake System Switch-Brake 3. Fit servo assembly and secure to pedal box, fit nuts and tighten to22Nm. Remove 4. Position servo to brake pedal with pin and clip. 1. Disconnect battery earth lead. 5. Refit steering column closing panel. 2.
Page 638: Brake System Bleeding
Brake Brake System Brake System Bleeding Bleed 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.
Page 639: Low Level Indicator Switch-Brake Fluid
Brake Brake System Low Level Indicator Switch-Brake Fluid Master Cylinder and Fluid Reservoir Remove Remove 1. Disconnect multiplug from brake fluid low level 1. Position absorbent cloth under ABS modulator to indicator switch. absorb fluid spillage. Caution: Brake fluid will damage paint finished surfaces. If spilled, immediately remove fluid and clean area with water.
Page 640 Brake Brake System 5. Release the engine bay harness from battery carrier and disconnect main harness. 6. Remove 2 nuts and washers securing master cylinder to servo and discard nuts. 7. Remove master cylinder and fluid reservoir. Refit 1. Fit master cylinder to servo, fit washers and nuts and tighten to25Nm.
Page 641: Special Tools
Brake Brake System Special Tools Tool Description Picture Number Brake disc TCH00022 runout test kit Version 2.0...
Page 642: Park Brake
Park Brake Brake System Park Brake Specifications Torque Description Value Bolt-rear brake caliper to trailing arm 61–66Nm Bolt-rear handbrake cable to subframe 19–25Nm Bolt-rear handbrake cable to fuel tank strap 10Nm Bolt-central heat shield to body 19–25Nm Bolt-fuel tank heat shield to body 19–25Nm Bolt-handbrake lever to centre channel 19–22Nm...
Page 643: Description And Operation
Park Brake Brake System Description and Operation System Component Layout Parking Brake Component Location 1. Lever assembly 6. Shield 2. Adjuster nut 7. Expander 3. Warning switch 8. Brake shoe adjuster 4. Front cable and compensator 9. Protective sleeve 5. Parking brake cables assembly 10.
Page 644: Description
Park Brake Brake System Description Handbrake The handbrake consists of drum brakes, integrated into the rear discs of the main brakes, which are operated by cables connected to a lever assembly between the front seats. The lever assembly is mounted on the transmission tunnel. A warning switch on the lever operates the brake warning light in the instrument pack.
Page 645: Service Procedures
Park Brake Brake System Service Procedures Cable-Handbrake Remove 1. Release handbrake adjusting nut cover. 2. Loosen handbrake cable adjusting nut. 3. Remove intermediate exhaust pipe. Intermediate Intermediate Intermediate Pipe Pipe Pipe Remove Remove Remove 4. Remove bolts securing fuel tank heat shield and remove heat shield.
Page 646: Handbrake-Adjustment
Park Brake Brake System Handbrake-Adjustment Refit Adjust 1. Position handbrake cable and secure to expander. Warning: Where possible, a road test should be on well 2. Ensure mating surfaces of disc and hub are clean. surfaced, dry roads. Always comply with speed limits and 3.
Page 647: Handbrake Lever
Park Brake Brake System Handbrake Lever 7. Tighten handbrake cable adjusting nut until pull the handbrake lever for 100–110. Remove 8. Cycle handbrake lever fully on/off. 1. Remove centre console. 9. Apply handbrake lever 2 notches. Console Assembly Assembly Remove Remove Console Console...
Page 648: Handbrake Front Cable
Park Brake Brake System Handbrake Front Cable 7. Disconnect multiplug from handbrake warning switch and remove handbrake warning switch. Remove 1. Remove centre console. Console Assembly Assembly Remove Remove Console Console Assembly Remove 2. Remove handbrake cable adjusting nut, release cable collect washer.
Page 649 Park Brake Brake System tighten adjusting nut. 7. Fit centre console. Console Console Console Assembly Assembly Refit Assembly Refit Refit 8. Adjust handbrake. Handbrake Handbrake Handbrake - - - Adjustment Adjustment Adjustment Version 2.0...
Page 650: Brake Module
Brake Module Brake System Brake Module Specifications Torque Description Value Screws-modulator to adjustor to upper bracket 7–10Nm Screws-modulator lower bracket to body 19–22Nm Front brake pipes to modulator 16–18Nm Version 2.0...
Page 651: Description And Operation
Brake Module Brake System Description and Operation System Component Layout Brake System Control Diagram A. Hard wired B. HS CAN bus C. MS CAN bus 1. ABS / DSC Modulator 3. Yaw accelerator sensor 2. Body Control Module (BCM) 4. Steering angle sensor Version 2.0...
Page 652 Brake Module Brake System 5. Front wheel speed sensor 13. High level brake lamp 6. Rear wheel speed sensor 14. RH brake lamp 7. Engine Control Module (ECM) 15. Brake fluid low level sensor 8. Transmission Control Unit (TCU) (automatic 16.
Page 653: Description
Brake Module Brake System Description non serviceable, 4 channel unit consisting of an integrated SCS Modulator Hydraulic Control Unit (HCU) and SCS ECU. Depending on the system components’ working condition, the ECU (Slip control system) can help the driver to control the can control the HCU in different operating modes including: vehicle’s stability and handling to ensure maximum safety normal braking, brake held on, pressure decreasing and...
Page 654 Brake Module Brake System Pressure Increasing Mode Hydraulic operation only for one channel (other channels are the same). When the brake pressure needs to be increased, the SCS system starts to work, the inlet solenoid valve 7 is opened, restrictor 6 is shut off, and the return pump 9 is activated. The pressurised brake fluid enters the caliper 15 to increase the brake pressure.
Page 655 Brake Module Brake System the angular velocity produces an acceleration value, which is recorded on the plane of the wafer. These acceleration values are proportional to the angular velocity. Steering Angle Sensor The steering angle sensor is integrated into the rotary coupler of the steering wheel switch assembly.
Page 656: Service Procedures
Brake Module Brake System Service Procedures Refit 1. Fit mounting bracket upper to modulator, fit bolts and Remove tighten to7–10Nm. 1. Remove ignition handset and disconnect battery earth 2. Fit modulator bracket lower to body ensuring that lead. fixing grommets are correctly engaged. Tighten bolts to19–22Nm.
Page 657: Driveline/Axle
Drive Axle Driveline/Axle Drive Axle Specifications Torque Description Value Bolt-intermediate shaft support bearing bracket to engine 19–25Nm Nut-front hub to lower arm outer ball joint 40–50Nm Nut-track rod ball joint 28–32Nm Bolt-front anti roll bar to anti roll bar link 60–70Nm Nut-front drive shaft 350–370Nm...
Page 658: Description And Operation
Driveline/Axle Drive Axle Description and Operation System Component Layout RH Drive Shaft Components 1. Outer joint 8. Gaiter 2. Snap ring 9. Clamp (big) 3. Clamp (big) 10. Shaft 4. Gaiter 11. Bearing housing 5. Clamp (small) 12. Dust shield 6.
Page 659 Drive Axle Driveline/Axle LH Drive Shaft Components 1. Outer joint 7. Clamp (small) 2. Snap ring 8. Gaiter 3. Clamp (big) 9. Clamp (big) 4. Gaiter 10. Shaft 5. Clamp (small) 11. Circlip 6. Dynamic damper Version 2.0...
Page 660: Description
Driveline/Axle Drive Axle Description Drive shaft comprises a solid shaft with inner and outer constant velocity joints. The intermediate shaft is fitted with a roller bearing and bearing housing which is secured to the rear of the cylinder block on the RH side. The other solid shaft with inner and outer constant velocity joints is fitted to the differential on the LH side.
Page 661: Operation
Drive Axle Driveline/Axle Operation The drive shaft transmits engine torque, via the gearbox, to the front wheels. The dynamic dampers reduce any vibration produced by the drive shaft's rotation. Version 2.0...
Page 662: Service Procedures
Driveline/Axle Drive Axle Service Procedures RH Shaft & Both Joints Remove 1. Raise the vehicle on a lift. 2. Remove front wheel arch liner. Liner Liner Liner - - - front front front wheel wheel arch wheel arch arch - - - front front front 3.
Page 663: Lh Shaft & Both Joints
Drive Axle Driveline/Axle LH Shaft & Both Joints 10. Ensure lower ball joint is fully engaged in hub and bolt is located in ball joint groove. Remove 11. Ensure tapers in track rod end and steering arm are 1. Raise the vehicle on a lift. clean and rubber boot is not damaged.
Page 664 Driveline/Axle Drive Axle 4. Remove lower ball joint boot protector T32003. 5. Pull hub outwards, engage drive shaft to hub and fit hub to lower ball joint. 6. Fit nut and bolt securing hub to lower arm and tighten to 40–50Nm. 7.
Page 665: Outer Cv Joint
Drive Axle Driveline/Axle Outer CV Joint Outer CV Joint Gaiter Remove Remove 1. Remove drive shaft. 1. Remove outer joint. Shaft with with both both joints joints Outer joint joint Shaft Shaft with both joints Outer Outer joint 2. Place drive shaft in vice. 2.
Page 666: Inner Joint
Driveline/Axle Drive Axle Inner Joint Inner Joint Gaiter Remove Remove 1. Remove drive shaft. 1. Remove outer joint gaiter. Shaft with with both both joints joints Gaiter - - - outer outer joint joint Shaft Shaft with both joints Gaiter Gaiter outer joint...
Page 667: Special Tools
Drive Axle Driveline/Axle Special Tools Tool Description Picture Number Remover ball T38008 joint Lever front T32011 lower arm ball joint Protector - T32003 front lower arm ball joint Remover drive T30001 shaft Version 2.0...
Page 668 Version 2.0...
Page 669: Interior Fitting
Instrument Panel and Console Interior Fitting Instrument Panel and Console Specifications Torque Description Value Screw-fascia cross car beam to ‘A’ post (LH) 23-25Nm Bolt-centre console bracket 6–8Nm Version 2.0...
Page 670: Service Procedures
Interior Fitting Instrument Panel and Console Service Procedures Switch - Cruise Control Remove 1. Disconnect battery earth lead. 2. Remove driver's airbag. 3. Disconnect steering wheel multiplugs. 4. Centralise steering wheel in straight ahead position. 5. Restrain steering wheel and loosen bolt securing steering wheel to column - But do not fully remove the bolt.
Page 671: Panel Assembly - Fascia Closing Panel Driver Side
Instrument Panel and Console Interior Fitting Panel Assembly - Fascia Closing Panel Driver Wood Trim - Centre Console - Rear Side Remove Remove 1. Remove gear knob. 1. Remove 2 screws securing lower closing panel to Selector Lever Lever Knob Knob Remove Remove Selector...
Page 672: Glove Box Assembly
Interior Fitting Instrument Panel and Console Glove Box Assembly 4. Fit gear selector indicator assembly with clips. Remove 5. Position wood trim and connect electrical multiplug and connectors. 1. Open glove box and release the clips securing air damper to glove box. 6.
Page 673: Fascia
Instrument Panel and Console Interior Fitting Fascia 12. Release both door grommets and disconnect both Remove fascia to door harness connectors. 1. Disconnect battery earth lead. 2. Remove centre console Console Assembly Assembly Remove Remove Console Console Assembly Remove 3. Remove glovebox. Glovebox Glovebox Glovebox Remove...
Page 674 Interior Fitting Instrument Panel and Console 4. Fit wiper motor assembly. Wiper Motor Motor and and Linkage Linkage Refit Refit Wiper Wiper Motor Linkage Refit 5. Position storage box and fit USB connector to the storage box with screws. 6. Position the storage box with clips. 7.
Page 675: Ventilator - Rh
Instrument Panel and Console Interior Fitting Ventilator - RH Console Assembly Remove Remove 1. Disconnect battery earth lead. 1. Position gear selector lever in neutral. (Automatic transmission models only). 2. Release 5 clips securing RH side fascia finisher to fascia, disconnect passenger airbag disable multiplug and 2.
Page 676: Centre Bezel Assembly
Interior Fitting Instrument Panel and Console Centre Bezel Assembly 14. Release handbrake. Remove 15. Carefully remove centre console assembly. 1. Disconnect battery earth lead. Refit 1. Carefully fit centre console assembly. 2. Fit screws securing centre console to fascia. 3. Fit storage box bolts. 4.
Page 677: Panel Assembly - Steering Column Lower Cover - Base
Instrument Panel and Console Interior Fitting Panel Assembly - Steering Column Lower Cover Ventilator - LH - Base Remove Remove 1. Release 5 clips securing LH side fascia finisher to fascia 1. Remove 2 screws securing panel to fascia. and remove LH side fascia finisher. 2.
Page 678: Seats
Interior Fitting Seats Seats Specifications Torque Description Value Screw - front seat to floor 40-50Nm Bolt - squab to cushion 40–50Nm Striker - striker to body 22Nm Version 2.0...
Page 679: Description And Operation
Seats Interior Fitting Description and Operation System Component Layout Manual Seats Component Location 1. Lumbar adjustment handwheel (driver’s seat only) 3. Cushion height raise/lower lever 2. Backrest forward/recline lever 4. Seat forward/rearward lever Version 2.0...
Page 680 Interior Fitting Seats Electric Seat Component Location 1. Lumbar adjustment handwheel (driver’s seat only) 4. Seat forward/rearward switch and cushion height raise/lower switch 2. Backrest forward/recline switch 3. Seat forward/rearward switch and cushion height raise/lower switch Version 2.0...
Page 681 Seats Interior Fitting Driver’s Electric Seat Control Layout 1. Backrest forward/recline motor 3. Cushion height raise/lower motor 2. Seat forward/rearward motor Version 2.0...
Page 682: System Control Diagram
Interior Fitting Seats System Control Diagram Driver's Electric Seat Control Diagram 1. Driver seat forward/rearward motor 4. Fuse 21 (30A on BCM) 2. Driver cushion height raise/lower motor 5. Driver’s seat switchpack 3. Driver backrest forward/recline motor Version 2.0...
Page 683: Description
Seats Interior Fitting Description Passenger's Seat Driver's Seat Different options of passenger's seats are fitted according to model and trim specification, as follows: 4 way or 6 way; Different options of driver's seats are fitted according to model manual or electric passenger's seat (forward/ rearward, recline, and trim specification, as follows: 6 way manual or electric height);...
Page 684 Interior Fitting Seats Rear Rear Rear Seats Seats Seats Version 2.0...
Page 685: Operation
Seats Interior Fitting Operation Manual Seats 1. Lumbar adjustment handwheel (driver's seat only) 3. Cushion raise/lower adjustment lever (driver's seat only) 2. Backrest forward/recline lever 4. Seat slide forward/rearward lever The manual seats can be adjusted by means of levers and rotary in the required position.
Page 686 Interior Fitting Seats Electric Electric Electric Seat Seat Seat 1. Lumbar manual adjustment handwheel 5. Seat slide forward/rearward switch and cushion height up/down switch (4-way switch) 2. Driver's seat switchpack 3. Backrest forward/recline switch (2-way switch) 4. Seat slide forward/rearward switch and cushion height up/down switch (4-way switch) The driver's electric seat can be adjusted by using the driver's one 2-way switch for recline adjustment and one 4-way switch...
Page 687: Service Procedures
Seats Interior Fitting Service Procedures 6. Fit covers to front fixings. Seat Complete - Passenger 7. Connect battery earth lead. Remove 1. Disconnect battery earth lead. 2. Move seat fully back. 3. Remove 2 covers from front fixings. 4. Remove 2 bolts securing front of seat to body and discard bolts.
Page 688: Squab Foam - Passenger - Front
Interior Fitting Seats Squab Foam - Passenger - Front Cover - Passenger Squab - Front Remove Remove 1. Remove passenger squab cover. 1. Remove front seat. Seat Seat Seat Complete Complete - - - Passenger Complete Passenger Passenger Remove Remove Remove Squab Cover Cover - - - Passenger...
Page 689 Seats Interior Fitting 8. Release squab cover securing clips. 5. Fit inner valance and secure with clip and screw. 6. Fit outer valance and secure with clip and screw. 7. Fit head rest guide tubes and secure with clips. 8. Fit head rest. 9.
Page 690: Cushion - Rear Seat
Interior Fitting Seats Cushion - Rear Seat Cover - Cushion - Rear Seat Remove Remove 1. With assistance, pull front of cushion upwards until it 1. Remove rear seat cushion. releases from clips. Cushion - - - Rear Rear Seat Seat Remove Remove Cushion...
Page 691: Squab - Rear Seat
Seats Interior Fitting Squab - Rear Seat Cover - Squab - Rear Seat Remove Remove 1. Remove rear seat cushion. 1. Remove rear seat armrest. 2. Remove rear seat squab. Cushion - - - Rear Rear Seat Seat Remove Remove Cushion Cushion Rear...
Page 692: Striker - Squab - Rear Seat
Interior Fitting Seats Striker - Squab - Rear Seat Remove 1. Press release button and pull forward. Refit 1. Fit squab cover to squab foam and secure with new C rings. 2. Fit squab to frame. 2. Mark position of seat squab striker. 3.
Page 693: Side Board Outer - Power Seat
Seats Interior Fitting Side Board Outer - Power Seat Lumbar support assembly - front seat Remove Remove 1. Remove front seat. 1. Back off the lumbar support fully. 2. Remove front seat squab foam. Seat Complete Complete - - - Driver Driver Remove Remove Seat...
Page 694: Switch Pack Assembly - Driver Seat
Interior Fitting Seats Switch pack assembly - driver seat Cover - driver cushion - front Remove Remove 1. Remove front seat. 1. Fully raise seat cushion. 2. Remove outer valance. Side Board Board Outer Outer - - - Power Power Seat Seat Remove Remove Side...
Page 695: Seat Complete - Driver
Seats Interior Fitting Seat complete - driver Remove Warning: Always remove the ignition key from the ignition switch, disconnect the vehicle battery and wait 10 minutes before commencing work on the SRS system. 1. Move or power seat fully back. 2.
Page 696: Foam - Driver Squab - Front
Interior Fitting Seats Foam - driver squab - front Remove 1. Disconnect battery earth lead. 2. Remove squab cover. Cover Cover Cover - - - driver driver driver squab squab - - - front squab front front remove remove remove 3.
Page 697: Cover - Driver Squab - Front
Seats Interior Fitting Cover - driver squab - front Remove 1. Remove outer valance. Side Board Board Outer Outer - - - Power Power Seat Seat Remove Remove Side Side Board Outer Power Seat Remove 2. Depress the clip securing the head rest and remove head rest.
Page 698 Interior Fitting Seats Warning: For effective airbag performance, when fitting the cover, ensure retention wires, shock cords and C rings are correctly located and secure. 2. Fit lumbar support handwheel. 3. Secure squab cover fastening strip. 4. Fit seat squab to cushion and secure with 4 bolts, tighten to 40–50Nm.
Page 699: Door Trim
Door Trim Interior Fitting Door Trim Trim Casing - Rear Door Service Procedures Remove Plastic Sheet - Rear Door 1. Disconnect battery earth lead. Remove 2. Remove access cover from interior handle and remove 1. Disconnect battery earth lead. screw securing handle to door. 2.
Page 700: Plastic Sheet - Front Door
Interior Fitting Door Trim Plastic Sheet - Front Door Remove 1. Remove front door trim casing. Trim casing casing - - - front front door door remove remove Trim Trim casing front door remove 2. Disconnect multiplug from speaker. Remove 3 screws securing speaker assembly to door and remove speaker.
Page 701: Trim Casing - Front Door
Door Trim Interior Fitting Trim Casing - Front Door Remove 1. Disconnect battery earth lead. 2. Remove access cover from interior handle and remove screw securing handle to door. S 523069 6. Lift trim casing and release from door. 7. Disconnect multiplug from tweeter. 8.
Page 702: Interior Trim And Paneling
Interior Fitting Interior Trim and Paneling Interior Trim and Paneling Specifications Torque Description Value Front seat belt assembly 30–35Nm Bolt-rear seat belt to body 30–35Nm Version 2.0...
Page 703: Service Procedures
Interior Trim and Paneling Interior Fitting Service Procedures Trim Finisher - 'A' Post - Lower - Each Remove Trim Finisher - 'A' Post - Upper - Each Remove 1. Release front door seal. 1. Release front door seal. 2. Release and remove bonnet release handle (LH only). 2.
Page 704: Trim Finisher - 'Bc' Post - Upper - Each
Interior Fitting Interior Trim and Paneling Trim Finisher - 'BC' Post - Upper - Each Refit Remove 1. Position ‘BC’ post trim finisher and fit seat belt. 1. Release front and rear door seals. 2. Fit upper 'BC' post trim finisher to lower 'BC' post trim finisher and secure clips.
Page 705: Trim Finisher - 'Bc' Post - Lower - Each
Interior Trim and Paneling Interior Fitting Trim Finisher - 'BC' Post - Lower - Each Trim Finisher - 'D' Post - Upper - Each - Saloon Remove Remove 1. Remove upper 'BC' post trim finisher. 1. Remove lower 'D' post trim finisher. Trim finisher finisher - - - 'BC' 'BC' post...
Page 706: Trim Finisher - 'D' Post - Lower - Each - Saloon
Interior Fitting Interior Trim and Paneling Trim Finisher - 'D' Post - Lower - Each - Saloon Handle - Grab - Each Remove Remove 1. Remove rear seat cushion. 1. Remove 2 screw covers from handle. Cushion - - - rear rear seat seat Remove Remove...
Page 707: Headlining - Sunshine/Sliding Roof - Saloon
Interior Trim and Paneling Interior Fitting Headlining - Sunshine/Sliding Roof - Saloon Remove 1. Fully recline front seats. 2. Disconnect battery earth lead. 3. Remove 2 grab handles cover screws and remove the grab handles 4. Remove remaining 2 grab handles. Handle Handle Handle - - - grab...
Page 708 Interior Fitting Interior Trim and Paneling Refit 23. Remove sunroof flange finisher to headlining. 24. Release door seals from body as required. 1. Fit harness to headlining using adhesive. 25. Release 2 clips securing rear of headlining to body. 2. Carefully fit headlining through the door. Caution: Take care not to damage or crease headlining.
Page 709: Carpet - Main Floor
Interior Trim and Paneling Interior Fitting Carpet - Main Floor Seat Seat Seat complete complete complete - - - passenger passenger passenger - - - manual manual Refit manual Refit Refit Seat complete complete - - - passenger passenger - - - auto auto Refit Refit Seat...
Page 710: Parcel Tray - Rear - Saloon
Interior Fitting Interior Trim and Paneling Parcel Tray - Rear - Saloon Parcel Tray - Rear - Sun Blind Fitted Remove Remove 1. Remove RH 'D' post upper trim finisher. 1. Remove RH 'D' post trim finisher. 2. Remove LH 'D' post upper trim finisher. Trim Finisher Finisher - - - 'D' 'D' Post...
Page 711 Interior Trim and Paneling Interior Fitting 5. Fit parcel tray. 6. Fit bolts securing seat belts to floor. 7. Fit LH parcel tray finisher. 8. Fit RH parcel tray finisher. 9. Fit LH 'D' post upper trim finisher. Trim Trim Trim Finisher Finisher - - - 'D' Finisher...
Page 712: Spectacles Box - Driver
Interior Fitting Interior Trim and Paneling Spectacles Box - Driver Trim Casing - Luggage Compartment - Sill Remove Remove 1. Open glasses box and 2 screws cover. 1. Open boot lid/tailgate. 2. Release luggage compartment seal. 3. Remove luggage compartment carpet. 4.
Page 713: Trim Finisher - Luggage Compartment
Interior Trim and Paneling Interior Fitting Trim Finisher - Luggage Compartment Remove 1. Open boot lid/tailgate. 2. Remove luggage compartment sill trim casing. Trim Trim Trim casing casing casing - - - luggage luggage compartment luggage compartment compartment - - - sill sill sill Remove Remove...
Page 714 Version 2.0...
Page 715: Exterior Fitting
Fixed Windows Exterior Fitting Fixed Windows Windscreen Service Procedures Remove Glass - Rear Quarter Light 1. Remove air intake plenum. Remove Plenum - - - Air Air Intake Intake Remove Remove Plenum Plenum Intake Remove 1. Remove rear door glass. 2.
Page 716: Backlight
Exterior Fitting Fixed Windows Backlight Remove 1. Disconnect battery earth lead. 2. Disconnect multiplugs from heater elements. 3. Remove center high mounted stop lamp. Lamp Lamp Lamp Assembly Assembly - - - CHMSL Assembly CHMSL Remove CHMSL Remove Remove 4. Protect external bodywork and internal trim adjacent to glass.
Page 717: Bumpers, Fascias And Grille
Bumpers, Fascias and Grille Exterior Fitting Bumpers, Fascias and Grille Specifications Torque Description Value Bolt - bumper cover to body 7–10Nm Version 2.0...
Page 718: Service Procedures
Exterior Fitting Bumpers, Fascias and Grille Service Procedures Bumper Assembly - Front Remove 1. Disconnect battery earth lead. 2. Remove 6 screws securing front grille to bonnet locking platform. 9. Disconnect PDC sensor multiplugs (if fitted). 10. Remove the front bumper and remove 4 screws securing fog lamp to bumper.
Page 719: Bumper Assembly - Rear
Bumpers, Fascias and Grille Exterior Fitting Bumper Assembly - Rear Refit Remove 1. Fit and secure reflectors to bumper. 1. Disconnect battery earth lead. 2. With assistance, position bumper to vehicle. 2. Open boot lid/tailgate. 3. Slide bumper into position and engage each side of bumper in side mountings.
Page 720: Bumper Assembly - Rear - With Park Distance Control Fitted
Exterior Fitting Bumpers, Fascias and Grille Bumper Assembly - Rear - With Park Distance Control Fitted Remove 1. Disconnect battery earth lead. 2. Open boot lid/tailgate. 3. Remove 5 scrivets securing bumper to body. 8. With assistance, remove rear bumper. 9.
Page 721: Exterior Trim And Paneling
Exterior Trim and Paneling Exterior Fitting Exterior Trim and Paneling Liner - Rear Wheel Arch - Each Remove Service Procedures 1. Raise the vehicle on a lift. Undertray - Assembly Remove 2. Remove road wheel 1. Raise the vehicle on a lift. Wheel Wheel Wheel Remove...
Page 722: Plenum - Air Intake
Exterior Fitting Exterior Trim and Paneling Plenum - Air Intake Remove 1. Remove wiper arms. Arm - - - wiper wiper - - - each each Remove Remove wiper each Remove 2. Disconnect windscreen washer pipe. 9. Release 2 clips and remove 2 drain hoses from plenum. Refit 1.
Page 723: Liner - Front Wheel Arch - Front - Each
Exterior Trim and Paneling Exterior Fitting Liner - Front Wheel Arch - Front - Each Remove 1. Disconnect battery earth lead. 2. Raise the vehicle on a lift. 3. Remove undertray. Undertray Undertray Undertray - - - assembly assembly Remove assembly Remove Remove...
Page 724: Mirrors
Exterior Fitting Mirrors Mirrors Specifications Torque Description Value Screw-mirror 4–6Nm Version 2.0...
Page 725: Description And Operation
Mirrors Exterior Fitting Description and Operation System Component Layout Mirrors Component Location 1. LH mirror assembly 3. Driver’s Door Switch Pack (DDSP) 2. RH mirror assembly Version 2.0...
Page 726: System Control Diagram
Exterior Fitting Mirrors System Control Diagram Interior Rear View Mirror Control Diagram A. Hard wired 1. Neutral Switch - Auto Models only - Reverse selected 3. Fuse 44 (5A in BCM) 2. Interior rear-view window (anti-dazzle, with Rain Sensor) Version 2.0...
Page 727: Description
Mirrors Exterior Fitting Description General The electrochromatic rear view mirror darkens automatically to prevent glare from a following vehicle’s headlamps. The mirror clears again when light levels return to normal. When reverse gear is selected, the mirror clears automatically to provide maximum rear view vision while the vehicle is reversing.
Page 728: Operation
Exterior Fitting Mirrors Operation General When the engine starts, the electric rear view mirror automatic dazzle prevention function will become active and operate totally automatically. Version 2.0...
Page 729: System Component Layout
Mirrors Exterior Fitting System Component Layout Exterior Mirrors Component Layout 1. LH mirror assembly 3. Driver’s Door Switch Pack (DDSP) 2. RH mirror assembly Version 2.0...
Page 730: System Control Diagram
Exterior Fitting Mirrors System Control Diagram Exterior Mirrors Control Diagram A. Hard wired B. LIN Bus 1. DDSP 4. Left hand door mirror assembly 2. Exterior mirror motor power supply: Fuse 45 (10A in 5. Right hand door mirror assembly BCM) 3.
Page 731: Description
Mirrors Exterior Fitting Description door with three bolts and an orientation pin. The three bolts General are accessible by removing the front door frame finisher. Electrically operated door mirrors are fitted as standard on all The mirror head and bracket are nonserviceable and must be models.
Page 732 Exterior Fitting Mirrors Driver's Driver's Driver's Door Door Door Switch Switch Pack Switch Pack (DDSP) Pack (DDSP) (DDSP) 1. Exterior mirror adjustment switch 3. Driver's Door Switch Pack (DDSP) 2. RH exterior mirror selector switch 4. LH exterior mirror selector switch The DDSP is located in the driver door trim panel and is through a lens integral with the mat and transferred to the secured with four sprung clips.
Page 733: Operation
Mirrors Exterior Fitting Operation General The mirror can be controlled When the remote key insert the ignition or the engine start. However, the mirror heater are only active when the engine is running. Mirror Select Two mirror select switches are provided to select either the LH or RH mirror for adjustment.
Page 734: Service Procedures
Exterior Fitting Mirrors Service Procedures Mirror - Interior - Dipping Remove Mirror - Exterior - Electric Remove 1. Release 4 clips and remove the cover of the mirror. (if fitted) 1. Remove front door trim casing. Trim casing casing - - - front front door-Remove door-Remove Trim...
Page 735: Roof
Roof Exterior Fitting Roof Specifications Torque Description Value Screw-sunshade assembly Version 2.0...
Page 736: Description And Operation
Exterior Fitting Roof Description and Operation System Component Layout Sunroof Assembly 1. Glass panel assembly 7. Trim lace 2. Drip rail 8. Sunroof Electronic Control Unit (ECU) and motor 3. End cap 9. Front frame 4. Rear frame 10. Wind deflector assembly 5.
Page 737: System Control System
Roof Exterior Fitting System Control System Sunroof Control Diagram A. Hard wired 1. Fuse 43 (20A in BCM) 3. Rotary switch 2. Motor and sunroof Electronic Control Unit (ECU) Version 2.0...
Page 738: Description
Exterior Fitting Roof Description the glass panel when the sunroof is closed. When the sunroof General slides open, the rubber stops cause the sunshade panel to open with the glass panel. The sunroof consists of an electricallyoperated, tilt and slide glass panel with a wind deflector and a sunshade panel.
Page 739: Operation
Roof Exterior Fitting Operation and using a allen key to turn the manual drive socket on the General underside of the motor and drive gear. Motor Thermal Protection Operation of the sunroof is enabled while the handset is docked or when the ignition is on. To prevent damage to the motor, the ECU limits motor operation as follows: Sunroof Switch...
Page 740: Service Procedures
Exterior Fitting Roof Service Procedures Glass Panel - Sun/Sliding Roof Remove Sun/sliding Roof Assembly Remove 1. Open sunroof blind. 1. Disconnect battery earth lead. 2. Remove 4 screws securing glass to sunroof frame. 2. Remove headlining. Headlining Headlining Headlining - - - sunshine/sliding sunshine/sliding sunshine/sliding roof-Remove.
Page 741: Sunshade Assembly - Sun/Sliding Roof
Roof Exterior Fitting Sunshade Assembly - Sun/Sliding Roof Remove 1. Remove sunroof glass. Glass panel panel - - - sun/sliding sun/sliding roof-Remove. roof-Remove. Glass Glass panel sun/sliding roof-Remove. 2. Remove 2 screws securing rear sunshade bar to sunroof rail. 3. Tilt front of sunshade bar to release and remove bar from sunroof assembly.
Page 742: Wipers And Washer
Exterior Fitting Wipers and Washer Wipers and Washer Specifications Torque Description Value Nut-Wiper Arm to Spindle 30Nm Screw-Linkage-Wiper 7–10Nm Version 2.0...
Page 743: Description And Operation
Wipers and Washer Exterior Fitting Description and Operation System Component Layout Wiper Components 1. Wiper arm assembly (passenger) 5. Wiper arm cap 2. Wiper blade (passenger) 6. Wiper motor 3. Wiper blade (driver) 7. Wiper linkage assembly 4. Wiper arm assembly (driver) Version 2.0...
Page 744 Exterior Fitting Wipers and Washer Washer Components 1. Front windscreen washer jet 5. Washer reservoir 2. 'T'- piece (2-way) connector 6. Windscreen washer pump 3. 'T'- piece (3-way) connector 7. Washer tube 4. Washer reservoir filler assembly 8. Non Return Valve (NRV) Version 2.0...
Page 745: System Control Diagram
Wipers and Washer Exterior Fitting System Control Diagram Wipers and Washers Control Diagram A. Hardwired B. LIN Bus C. HS CAN bus 1. Rain sensor (if fitted) 6. Ignition switch 2. Wiper motor 7. ABS/DSC control module 3. Wiper column switch 8.
Page 746: Description
Exterior Fitting Wipers and Washer Description a few seconds, the wipers will wipe once more to remove General excess washer fluid on the windscreen. Flick Wipe The wipers and washers system is controlled by the Body Control Module (BCM) on receipt of requests made by the Press the wiper column switch down and quickly release, driver or the rain sensor unit (if fitted).
Page 747 Wipers and Washer Exterior Fitting achieves this by monitoring the wheel speed signals from the The reservoir is located in the right hand side wheel arch ABS ECU, via the HS CAN Bus. and has a capacity of approximately 3.8 litres. A filler neck, with a sealing cap, is accessible in the engine compartment for If the wiper switch is in the intermittent position the BCM replenishing the reservoir with a mixture of clean water and...
Page 748: Operation
Exterior Fitting Wipers and Washer Operation resistor. When the wipers are turned off, the BCM switches Wiper Column Switch the wiper relay to complete the cycle at slow speed. Fast Speed Operation When fast speed is selected the electronic switch energises the wiper enable relay as described for slow speed.
Page 749 Wipers and Washer Exterior Fitting Vehicle Speed Related Delay park switch is open or closed circuit and the wiper motor is operating or in the park position. Intermittent wiper operation The switch has four delay selections and six different speed is controlled by the rain sensor via LIN Bus signals to the ranges are used to determine the optimum wiping rate.
Page 750 Exterior Fitting Wipers and Washer 5. Receiver diodes (100% light received) switching back to intermittent from a continuous wipe and back again. 6. Water droplets/film 7. Receiver diodes (less than 100% light received) The rain sensor receives vehicle speed information from the ABS ECU via the BCM every two seconds.
Page 751: Service Procedures
Wipers and Washer Exterior Fitting Service Procedures Motor and Linkage - Wiper Remove Arm - Wiper - Each Remove 1. Disconnect battery earth lead. 1. Open bonnet. 2. Remove wiper arm. 2. Remove windscreen wiper arm fixing cover. 3. Remove air intake plenum. 3.
Page 752: Blade - Wiper - Each
Exterior Fitting Wipers and Washer Blade - Wiper - Each Reservoir - Washer Remove Remove 1. Lift wiper blade away from windscreen. 1. Disconnect battery earth lead. 2. Depress clips, rotate blade and remove from wiper arm. 2. Remove RH front wheel arch liner. Liner Liner Liner - - - Front...
Page 753: Pump - Washer
Wipers and Washer Exterior Fitting Pump - Washer Sensor - Rain Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove washer reservoir. 2. Release clips securing interior mirror cover to interior mirror and remove cover. Reservoir Reservoir Reservoir - - - washer...
Page 754 Version 2.0...
Page 755: Lighting Systems
Lighting Lighting Systems Lighting Description and Operation System Component Layout Interior Lighting Component Location 1. Body Control Module (BCM) 2. Vanity mirrors lamp (if fitted) 3. a Front reading lamp b Front reading lamp (with sunroof switch) 4. Glovebox lamp switch 5.
Page 756: System Control Diagram
Lighting Systems Lighting System Control Diagram Exterior Lighting Control Diagram A. Hardwired B. CAN Bus 1. Diagnostic socket 2. Front reading lamp 3. Rear reading lamp 4. Boot lamp 5. Vanity mirror lamp 6. Glovebox lamp switch 7. RH front door open switch 8.
Page 757: Description
Lighting Lighting Systems Description Rear Reading Lamp General The interior lighting system is controlled by the BCM which is located on the passenger side of the vehicle, behind the glovebox. The interior lighting comprises: • Front reading lamp. • Rear reading lamp. •...
Page 758 Lighting Systems Lighting Illumination is provided by two single filament, festoon type 3 Watt bulbs. Fascia Illumination A number of fascia components, including handset docking port and the instrument pack, are illuminated with LEDs under certain conditions. The fascia lamps use Pulse Width Modulation (PWM) enabling them to fade on and off, as follows: •...
Page 759: Operation
Lighting Lighting Systems Operation The interior lamps have two modes of operation; manual Overview operation using the momentary switch on the front interior lamp or automatic operation controlled by the BCM. The power supply for the interior lamp operation is from the Manual Operation battery, through fusible link 9 in the engine compartment fuse box to the passenger compartment fusebox.
Page 760 Lighting Systems Lighting 20 second delay (except if the lamps switched on from Fascia Illumination and Dimming the momentary switch). All switch, panel and instrument pack illumination is produced • The vehicle is locked using the handset. by LEDs. The LEDs are powered by the BCM when the rotary light switch is in the side lamp or headlamp position.
Page 761: Service Procedures
Lighting Lighting Systems Service Procedures Lamp Assembly - CHMSL Remove Main Light Switch (MLS) Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Remove 2 screws securing cover to CHMSL and remove cover. 2. Open storage box below MLS. Reach behind MLS and press to release 3 spring clips securing MLS to fascia.
Page 762: Lamp Assembly - Interior Courtesy - Rear
Lighting Systems Lighting Lamp Assembly - Interior Courtesy - Rear Lamp Assembly - Interior Courtesy - Front Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Release 3 clips securing interior lamp assembly to 2. Remove interior lamp lens. headlining.
Page 763: Lamps
Lamps Lighting Systems Lamps Description and Operation System Component Layout 1. Dipped beam headlamp 16. Master light switch (MLS) 2. Front direction indicator 17. Fascia illumination thumbwheel 3. Main beam headlamp 18. Side repeater 4. Front fog lamp 5. Hazard warning switch 6.
Page 764: System Control Diagram
Lamps Lighting Systems System Control Diagram Exterior Lighting Control Diagram A. Hard wired B. CAN Bus C. LIN Bus 1. Dipped headlamps 12. MLS 2. Main headlamps 13. Direction indicator and dip/main headlamp lever 3. Engine compartment fusebox 14. Brake switch 4.
Page 765: Description
Lamps Lighting Systems Description covered by sealing rubber covers to prevent the ingress of General moisture and dirt. Side Lamps The exterior lighting system comprises externally mounted lamps operated using the MLS and the auto-lamp control Each front side lamp is located in the side of each main beam sensor.
Page 766 Lamps Lighting Systems clip connect the input rod of the brake servo to the brake Tail lamps Reverse W16W 12V 16W lamps pedal. A tang on the end of the brake pedal activates the 'instant make and break' Hall effect brake switch in the pedal Direction W21W 12V 21W...
Page 767: Operation
Lamps Lighting Systems Operation Direction Indicators General The BCM controls and monitors the following exterior lights: • Direction indicators/Warning lights • Brake lamps The BCM controls the following lights: • Side lamps lamps • Dipped beam • Main beam • Front fog lamps •...
Page 768 Lamps Lighting Systems condition “twilight”, the filtered value for the ambient light or RH position as required when the handset is removed. In has to exceed another minimum threshold. The request for this condition instrument pack illumination will remain off. The turning the headlamps off will be sent after a delay.
Page 769 Lamps Lighting Systems Direction Indicators and Hazard Warning Light the inertia switch is reset, but only when the hazard switch is System pressed. With the handset docked or the ignition on, the direction Direction Indicator and Dipped/Main Beam indicators and side repeaters are operated using the Column Switch direction indicator lever.
Page 770 Lamps Lighting Systems position or removed, the rear fog lamp(s) will be extinguished. lamps will remain on whilst the timer is running and will remain If the rear fog lamp(s) is on when the MLS is switched off, the on when the time period has expired. MLS will rotate to the first latched position (front fog lamp Circuit Protection position) and the rear fog lamp(s) will not illuminate on the...
Page 771 Lamps Lighting Systems position. Brake lamp functionality will also be maintained but the following exterior lighting features controlled by the BCM will be inhibited: • Direction indicator lamps • Hazard warning lights • Headlamp flash and main beam • Front fog lamps •...
Page 772: Service Procedures
Lamps Lighting Systems Service Procedures Bulb - Reverse Lamp- Saloon Remove Bulb - Directional - Indicator Remove 1. Release boot lid latch. 1. Push side repeater lamp rearwards against spring 2. Remove boot seal. pressure and pull outwards to release. 3.
Page 773: Bulb - Number Plate Lamp
Lamps Lighting Systems Bulb - Number Plate Lamp Bulb - Rear Fog Lamp Remove Remove 1. Release boot lid latch. 1. Release boot lid latch. 2. Remove boot lid trim casing. 2. Remove boot lid trim casing panel. 3. Twist rear fog lamp bulb holder anticlockwise and Trim Trim Trim casing...
Page 774: Bulb - Rear Di
Lamps Lighting Systems Bulb - Rear DI Bulb - Dip Beam Remove Remove 1. Release boot lid latch. 1. Disconnect battery earth lead. 2. Remove boot seal. 2. Remove engine compartment fuse box - LH headlamp bulb only 3. Remove luggage compartment sill trim casing. Engine Engine Engine compartment...
Page 775: Cover Assembly- Front Fog Lamp
Lamps Lighting Systems Cover Assembly- Front Fog Lamp Lamp Assembly - Front Fog Remove Remove 1. Remove front bumper. 1. Remove front bumper. Bumper assembly assembly - - - front-Remove. front-Remove. Bumper assembly assembly - - - front-Remove. front-Remove. Bumper Bumper assembly front-Remove.
Page 776: Headlamps - Dip Beam, High Beam
Lamps Lighting Systems Headlamps - Dip Beam, High Beam Headlamp Assembly Check Remove 1. Position beam setting equipment to headlamp. 1. Disconnect battery earth lead. 2. Switch headlamps on and note main beam settings. 2. Remove front bumper. Beam must be 1.0% below the horizontal and parallel Bumper Bumper Bumper Assembly...
Page 777: Bulb - Front Directional Indicator
Lamps Lighting Systems Bulb - Front Directional Indicator Bulb - Side Lamp Remove Remove 1. Disconnect battery earth lead. 1. Remove dust cover from headlamp. 2. Twist bulb holder anti-clockwise and release from headlamp. 2. Remove side lamp bulb holder from headlamp. 3.
Page 778: Lamp Assembly - Tail
Lamps Lighting Systems Lamp Assembly - Tail Bulb - Main Beam Remove Remove 1. Disconnect battery earth lead. 1. Disconnect battery earth lead. 2. Release boot lid latch. 2. Remove dust cover from headlamp. 3. Remove boot seal 4. Remove luggage compartment sill trim casing. 5.
Page 779: Body Systems
Doors Body Systems Doors Specifications Torque Description Value Bolt - door hinge to door 30–36Nm Cap nut - shaft – upper hinge 18–22Nm Bolt - door hinge to body 30–36Nm Screw - exterior handle backplate to door 2–2.5Nm Bolt - door lock 8–12Nm Bolt - window regulator guide rail to door 6.5–7.5Nm...
Page 780: Description And Operation
Doors Body Systems Description and Operation System Component Layout Windows System Component Location 1. Driver's Door Switch Pack (DDSP) 7. Remote handset 2. Body Control Module (BCM) and fusebox 8. LH rear window motor 3. RH front window motor 9. LH rear window switch 4.
Page 781: System Control Diagram
Doors Body Systems System Control Diagram Windows System Control Diagram DLDLSRXYLFXRFPHY A. Hard wired B. MS CAN Bus C. LIN Bus 1. Driver's Door Switch Pack (DDSP) 7. Diagnostic socket 2. Passenger front window switch 8. LH front window motor 3.
Page 782: Description
Doors Body Systems Description Each door trim has a lift/press type switch to control the General window for that door.DDSP has four switches to allow the driver to control operation of each window. It also contains an The electric window system is controlled by the Body Control isolation switch to prevent operation of the rear window from Module (BCM) which is located on the passenger side of the the door mounted switches.DDSP also controls exterior...
Page 783 Doors Body Systems Front Front Electric Front Electric Electric Windows Windows Windows 1. Front door glass 4. Motor assembly 2. Rear runner 5. Cables 3. Friction pad (2 off) 6. Forward runner The front windows are electrically operated on all models and The window is raised and lowered by an upper cable, a mid can be controlled from individual switches for the applicable cable and a lower cable.
Page 784 Doors Body Systems When the motor is operated, each carrier is pulled in the between the motor output shaft and the drum reduces the required direction by the cables and slides in the runner to effort required by the motor to raise or lower the window. raise or lower the glass.
Page 785 Doors Body Systems Rear Rear Electric Rear Electric Windows Electric Windows Windows 1. Cables 4. Friction pads (2 off) 2. Runner 5. Rear door glass 3. Motor assembly The rear windows can be controlled from individual switches The window is raised and lowered by two cables; an upper for the applicable window or from theDDSPEach rear window cable and a lower cable.
Page 786 Doors Body Systems Driver's Driver's Driver's Door Door Door Switch Switch Pack Switch Pack (DDSP) Pack (DDSP) (DDSP) 1. Driver's Door Switch Pack (DDSP) 4. Rear window isolation switch 2. RH front window switch 5. LH rear window switch 3. RH rear window switch 6.
Page 787 Doors Body Systems Passenger Passenger and Passenger and Rear Rear Door Rear Door Door Switches Switches Switches The front passenger door and the rear door window switches are located in the door trim panels.Each door switch has electronic components mounted on a PCB and a connector. An LED LEDon the PCB provides the switch illumination.
Page 788: Operation
Doors Body Systems Operation Anti-trap motors: thermal protection is triggered by operation Electric Window time. After continuous operation for 30-100 seconds, the thermal protection starts. The electric window system will operate at all times whenever the handset is docked, or for 30 seconds after theBCM Normal motors: If the motor locks for about 30 seconds, the receives an ignition off message.
Page 789: Service Procedures
Doors Body Systems Service Procedures Door Assembly - Front Remove Handle - Outside - Front Door Remove 1. Disconnect battery earth lead. 1. Remove private lock. 2. Open door. Private Lock Lock - - - Front Front Door Door Remove Remove Private Private...
Page 790: Hinge - Front Door - Upper
Doors Body Systems Hinge - Front Door - Upper out from lower door hinge completely, then remove door assembly. Remove 1. Remove front door. Caution: Please protect paint from scratch when removing or refitting the door assembly. Door Assembly Assembly - - - Front Front Remove Remove Door...
Page 791: Hinge - Front Door - Lower
Doors Body Systems Hinge - Front Door - Lower Door - Front - Align on Hinges Remove Adjust 1. Remove front door. 1. Open door. 2. Place wooden block on jack and position jack to Door Assembly Assembly - - - Front Front Remove Remove Door...
Page 792: Private Lock - Front Door
Doors Body Systems Private Lock - Front Door Latch - Front Door Remove Remove 1. Remove grommet for access to screw securing private 1. Ensure window glass is fully closed. lock to inner door handle. 2. Remove front door plastic sheet. 2.
Page 793: Door - Front - Adjust On Striker
Doors Body Systems Door - Front - Adjust on Striker 9. Disconnect multiplug from latch. Adjust 1. Open door. 2. Loosen 2 striker screws and align striker to door latch, tighten screws. 10. Manoeuvre and remove latch from door. 11. Release cable from latch body. 3.
Page 794: Handle - Outside - Rear Door
Doors Body Systems Handle - Outside - Rear Door Door Assembly - Rear Remove Remove 1. Remove grommet for access to screw securing outside 1. Disconnect battery earth lead. handle capping to inner door handle. 2. Open front door for access. Release harness sleeve 2.
Page 795: Hinge - Rear Door - Upper
Doors Body Systems Hinge - Rear Door - Upper 6. With assistance, lift door up until centre bolt comes out from lower hinge completely, then remove door Remove assembly. 1. Remove rear door. Caution: Please protect paint from scratch when Door Assembly Assembly - - - Rear Rear Remove...
Page 796: Hinge - Rear Door - Lower
Doors Body Systems Hinge - Rear Door - Lower Door - Rear - Align on Hinges Remove Adjust 1. Remove rear door. 1. Open door. 2. Place wooden block on jack and position jack to Door Assembly Assembly - - - Rear Rear Remove Remove Door...
Page 797: Latch - Rear Door
Doors Body Systems Latch - Rear Door Door - Rear - Adjust on Striker Remove Adjust 1. Remove plastic sheet. 1. Open door. 2. Loosen 2 striker screws and align striker to door latch, Plastic Sheet Sheet - - - Rear Rear Door Door Remove Remove...
Page 798: Division Bar - Quarter Light - Rear
Doors Body Systems Division Bar - Quarter Light - Rear Seal Seal Seal - - - Waist Waist Waist Inner Inner Inner - - - Rear Rear Rear Door Door Door - - - Each Each Refit Each Refit Refit Remove 6.
Page 799: Rubber/Felt - Glass Channel - Rear Door - Each
Doors Body Systems Rubber/Felt - Glass Channel - Rear Door - Each Seal - Waist Inner - Rear Door - Each Remove Remove 1. Remove rear door glass. 1. Remove rear door trim casing. Glass - - - Rear Rear Door Door - - - Each Each Remove Remove...
Page 800: Seal - Waist Outer - Rear Door - Each
Doors Body Systems Seal - Waist Outer - Rear Door - Each Glass/Glass Cassette Unit - Rear Door - Adjust Remove Adjust 1. Lift the outer waist seal to release the securing clips 1. Remove rear door plastic sheet. and remove seal. Plastic Plastic Plastic Sheet...
Page 801: Glass - Rear Door - Each
Doors Body Systems Glass - Rear Door - Each 9. Raise and lower glass to check action and alignment.. Remove 10. Check torque of adjustable cassette bolts. 1. Remove rear door trim casing. 11. Tighten the fixed position cassette bolt to6.5–7.5Nm. Trim Casing Casing - - - Rear Rear Door...
Page 802: Switch - Electric Window Lift - Rear Door - Each
Doors Body Systems Switch - Electric Window Lift - Rear Door - Each Remove 1. Disconnect battery earth lead. 2. Remove rear door trim casing. Trim Trim Trim Casing Casing - - - Rear Casing Rear Rear Door Door Door Remove Remove Remove 3.
Page 803: Motor And Control Unit - Rear Door - Each
Doors Body Systems Motor and Control Unit - Rear Door - Each aperture. Remove Refit 1. Secure door glass in fully raised position to door frame 1. Position and fit regulator in door. using adhesive tape. 2. Connect multiplug to door glass motor. 2.
Page 804: Release Handle - Interior - Rear Door - Each
Doors Body Systems Release Handle - Interior - Rear Door - Each Trim Casing - Front Door Remove Remove 1. Remove rear door trim casing. 1. Disconnect battery earth lead. 2. Remove access cover from interior handle and remove Trim casing casing - - - rear rear door door remove...
Page 805: Trim Casing - Rear Door
Doors Body Systems Trim Casing - Rear Door 8. Release lock operating cable from interior handle, release hook and remove trim casing. Remove 1. Disconnect battery earth lead. 2. Remove access cover from interior handle and remove screw securing handle to door. 3.
Page 806: Switch Pack - Electric Window Lift Driver Door
Doors Body Systems Switch Pack - Electric Window Lift Driver Door Rubber/Felt - Glass Channel - Front Door - Each Remove Remove 1. Disconnect battery earth lead. 1. Ensure window is fully down. 2. Remove front door trim casing. 2. Remove front door trim casing. Trim Trim Trim casing...
Page 807: Seal - Waist Inner - Front Door - Each
Doors Body Systems Seal - Waist Inner - Front Door - Each Remove 1. Remove front door trim casing. Trim Casing Casing - - - Front Front Door Door Remove Remove Trim Trim Casing Front Door Remove 2. Bend out 7 tags securing inner waist seal to door casing and remove seal.
Page 808: Seal - Waist Outer - Front Door - Each
Doors Body Systems Seal - Waist Outer - Front Door - Each Glass/Glass Cassette Unit - Front Door - Adjust Remove Adjust 1. Remove exterior door mirror. 1. Remove front door plastic sheet. Plastic Plastic Plastic Sheet Sheet - - - Front Sheet Front Front Door...
Page 809: Glass - Front Door - Each
Doors Body Systems Glass - Front Door - Each 9. Raise and lower glass to check action and alignment. Remove 10. Disconnect switch pack multiplug. 1. Remove door seal. 11. Fit front door plastic sheet. Rubber/felt - - - Glass Glass Channel Channel - - - Front Front Door...
Page 810: Motor And Control Unit - Front Door - Each
Doors Body Systems Motor and Control Unit - Front Door - Each Remove 1. Secure door glass in fully raised position to door frame using adhesive tape. 2. Remove front door plastic sheet. Plastic Plastic Plastic Sheet Sheet - - - Front Sheet Front Front Door...
Page 811: Release Handle - Interior - Front Door
Doors Body Systems Release Handle - Interior - Front Door Switch - Electric Window Lift - Front Door - Passenger Remove Remove 1. Remove front door trim casing. 1. Disconnect battery earth lead. Trim casing casing - - - front front door door remove remove...
Page 812: Front Closures
Body Systems Front Closures Front Closures Specifications Torque Description Value Bolt - fender 7–12Nm Bolt - inner fender bracket 7–10Nm Bolt - bonnet locks 7–10Nm Bolt - member front end panel 7–10Nm Bolt - member front end panel bracket 7–10Nm Bolt - hinge to bonnet assembly 20–29Nm Bolt - bonnet striker to bonnet assembly...
Page 813: Service Procedures
Front Closures Body Systems Service Procedures rear edge to secure clip. Fender - Front - Each 6. Fit front bumper. Remove Front Front Front Bumper Bumper Assembly Bumper Assembly Assembly Refit. Refit. Refit. 1. Remove front wheel arch liner. 7. Fit front wheel arch liner. Front Wheel Wheel Arch Arch Liner...
Page 814: Member Front End Panel
Body Systems Front Closures Member Front End Panel Remove 1. Remove front bumper. Front Bumper Remove 2. Remove 2 screws securing air filter intake to member front end panel. 6. Raise member front end panel from body, release clips securing bonnet safety catch cable coupler to the panel. Remove member front end panel.
Page 815: Bonnet - Alignment - Check And Adjust
Front Closures Body Systems Bonnet – Alignment – Check and Adjust Check 1. Check bonnet alignment. Bonnet to wing profiles must be flush and gaps must be equal; front corners of bonnet must be level with wings. Adjust Gaps on Front Corners 1.
Page 816: Bonnet
Body Systems Front Closures Bonnet 3. Connect gas struts to bonnet and secure with clips. Remove 4. Check alignment of bonnet against both wings and bonnet platform. 1. Remove bolts securing hinges to bonnet. Bonnet Bonnet Bonnet - - - Alignment Alignment Alignment - - - Check Check...
Page 817: Safety Catch - Bonnet
Front Closures Body Systems Safety Catch – Bonnet Lock – Bonnet Remove Remove 1. Open bonnet. 1. Open bonnet. 2. Remove 2 nuts securing safety catch to bonnet and 2. Remove 2 bolts securing bonnet lock to bonnet locking remove safety catch. platform and remove lock.
Page 818: Control Cables Assembly - Bonnet
Body Systems Front Closures Control Cables Assembly – Bonnet Remove 1. Remove bonnet locks. Lock - - - Bonnet Bonnet Remove Remove Lock Lock Bonnet Remove 2. Remove lower 'A' post trim. A A A Post Post Trim–Lower Post Trim–Lower Trim–Lower Remove Remove Remove...
Page 819: Rear Closures
Rear Closures Body Systems Rear Closures Specifications Torque Description Value Bolt - hinge to boot lid inner panel 7–12Nm Bolt - latch to boot lid 7–10Nm Version 2.0...
Page 820: Service Procedures
Body Systems Rear Closures Service Procedures Boot Lid Remove Solenoid/Motor - Fuel Filler Flap Release Remove 1. Disconnect the battery earth lead. 1. Disconnect battery earth lead. 2. Remove the boot lid liner. Trim Finisher Finisher - - - boot boot lid lid Remove Remove...
Page 821: Boot Lid - Align On Hinges
Rear Closures Body Systems Boot Lid – Align on Hinges 6. Check alignment of boot lid to body. Adjust 7. Tighten the bolts securing hinge to boot lid to 7–12Nm. 1. Open boot lid. 8. Connect battery earth lead. 2. Protect paintwork where necessary. Boot Lid Height 3.
Page 822: Boot Lid - Align On Striker
Body Systems Rear Closures Boot Lid – Align on Striker Trim Casing - Boot Lid Adjust Remove 1. Open tailgate. 1. Open boot lid. 2. Protect paintwork where necessary. 2. Remove clips securing trim finisher to boot lid. 3. Remove luggage compartment sill trim casing. Trim Trim Trim Casing...
Page 823: Latch - Boot Lid
Rear Closures Body Systems Latch - Boot Lid Remove 1. Remove boot lid trim casing. Trim Casing Casing - - - Boot Boot Lid Lid Remove Remove Trim Trim Casing Boot Remove 2. Remove 3 bolts securing latch to boot lid. 3.
Page 824: Horns
Horns Body Systems Horns Specifications Torque Description Value Screw-HI/Lo Horn to the Horn Bracket 7-10Nm Version 2.0...
Page 825: Service Procedures
Horns Body Systems Service Procedures Horn - each Remove 1. Disconnect battery earth lead. 2. Remove front bumper. Bumper Bumper Bumper assembly assembly assembly - - - front front – – – Remove front Remove Remove 3. Disconnect multiplug and remove horn. Refit 1.
Page 826: Body Control Module
Body Systems Body Control Module Body Control Module Specifications Torque Description Value Screw-BCM to the Bracket 5-7Nm Version 2.0...
Page 827: Description And Operation
Body Control Module Body Systems Description and Operation Body Control Module (BCM) Component Location 1. Body Control Module (BCM) 2. Diagnostic connector Version 2.0...
Page 828: Body Control Module (Bcm) Component
Body Systems Body Control Module Body Control Module (BCM) Component Location A=MS_CAN BUS B=HS_CAN BUS C=LIN BUS 1. Instrument pack and central In car Entertainment 3. Transmission Control UnitTCU ICE display 4. Supplementary Restraint SystemSRS ECU 2. Engine Control UnitECU Version 2.0...
Page 829 Body Control Module Body Systems 5. Anti-lock Braking System(ABS)/Dynamic stability 12. Main Light Switch MLS control(DSC) 13. Driver’s Door Switch PackDDSP 6. Yaw Rate Sensor YRS 14. SEL/ESC Switch 7. Steering Angle SensorSAS 15. Electronic Steering Column LockESCL ECU 8. Steering Wheel SwitchesSWS 16.
Page 830: Description
Body Systems Body Control Module Description • Vehicle odometer General The BCM stores the vehicle odometer reading (up to a maximum of 999999 km). The instrument pack displays The BCM, incorporating the passenger compartment fusebox, the latest maximum reading. Once stored, it is not is located behind the glovebox on the vehicle bulkhead secured possible to amend the odometer reading with two bolts.
Page 831 Body Control Module Body Systems Inertia switch OUT/Fuel pump Airbag ECU Auxiliary power socket Sunroof Front window - LH Rain sensor, PDC ECU, steering wheel switches and Clutch, brake and reverse light electrochromatic mirror switch Not used Main beam headlamp - LH and RH Rear window - RH Number plate lamps, front side light - LH and rear tail light - LH...
Page 832: Operation
Body Systems Body Control Module Normal Mode Operation General This is the default setting and is used during normal vehicle operation after the PDI has been completed. With the handset removed, the BCM allows the security, lighting and diagnostic system to operate. With the handset Sleep Mode in the AUX position, the BCM also allows the wash/wipe and The BCM remains in sleep mode, drawing a minimal current,...
Page 833: Service Procedures
Body Control Module Body Systems Service Procedures Body Control Module (BCM) Remove 1. Disconnect battery earth lead. 2. Remove glovebox. Glove Glove Glove box box assembly assembly - - - Remove assembly Remove Remove 3. Remove 2 clips and 2 screws securing closing panel to fascia and remove panel.
Page 834 Version 2.0...
Page 835: Body Repair
Body Dimension Body Repair Body Dimension Service Procedures Basic Information Measurement Types The following dimensional information is shown to assist the technician in the diagnosis and repair of body panels. The information is shown in two different forms. In the first part of the information X, Y and Z dimensions are shown and in the second part actual point to point dimensions are shown.
Page 836: Floor Information
Body Repair Body Dimension Floor Information Item Description X(mm) Y(mm) Z(mm) Front subframe mounting hole -450 -500 Front subframe mounting hole -452 Front subframe mounting hole -122 Front jacking bracket hole -733 -139 Rear subframe mounting hole 2093 Rear jacking bracket hole 2013 -733 -139...
Page 837: Front End Information
Body Dimension Body Repair Front End Information Item Description X(mm) Y(mm) Z(mm) Fender mounting hole -274 Fender mounting hole Fender mounting hole Bonnet hinges mounting hole Front damper mounting hole Front damper mounting hole Front bumper bracket assembly mounting hole -590 -478 Front bumper bracket assembly mounting hole...
Page 838: Side Information
Body Repair Body Dimension Side Information Item X(mm) Y(mm) Z(mm) -788 -791 –788 –790 1488 -801 1454 -792 1513 –801 1503 –792 Version 2.0...
Page 839: Point To Point Dimensional Information
Body Dimension Body Repair Point to Point Dimensional Information Note: All dimensions are to hole/slot centres. Version 2.0...
Page 840: Side And Roof Information
Body Repair Body Dimension Side and Roof Information Item From Length (mm) C1-C2 Top hinge fixing - rear ‘B' post door striker - 1030 hole - front door top fixing hole D1-D2 Bottom hinge fixing - rear 1042 ‘B' post door striker - hole - front door top fixing hole F1-F2...
Page 841: Internal Information
Body Dimension Body Repair Internal Information Item From Length (mm) A1-A2 Top tooling hole (behind Seat belt reel anchorage 1614 B post) lower fixing B1-B2 Seat belt reel anchorage Seat belt reel anchorage 1391 lower fixing RHS lower fixing LHS Version 2.0...
Page 842: Front End Information
Body Repair Body Dimension Front End Information Item From Length (mm) A1-A2 Front bumper armature Front bumper armature 1016 fixing hole - RHS fixing hole - LHS B1-B2 Sidemember tooling hole Transmission assembly - RHS mounting hole - LHS C1-B2 Sidemember tooling slot Transmission assembly - RHS...
Page 843: Rear End Information
Body Dimension Body Repair Rear End Information Item From Length (mm) A1-A2 Outboard hole on parcel shelf Top corner on roof panel 1039 Top inboard rear lamp Top inboard rear lamp B1-B2 1267 fixing hole, LHS fixing hole, RHS Version 2.0...
Page 844: Under Body Information
Body Repair Body Dimension Under Body Information Item From Length (mm) A1-A2 Front subframe frist Front subframe second 1077 mounting hole mounting hole B1-B2 Front subframe frist Front subframe third 1279 mounting hole mounting hole C1-C2 Front subframe first Front subframe second mounting hole mounting hole D1-D2...
Page 845: Gap Information
Body Dimension Body Repair Dimension Length (mm) Dimension Length (mm) 1000 1466 2463 1466 2543 1233 2875 1083 3720 1026 Gap Information Side Information Version 2.0...
Page 846 Body Repair Body Dimension Section Description Dimension (mm) Profile (mm) Front bumper to fender 0.0+0.5 -0.5±0.5 Fender to front door 4.5±0.5 0+1.0/-0 Front door to rear door 4.5±0.5 0+1.0/-0 Rear door to rear body side 4.0±0.5 -0+1.0/-0 Body side rear to rear 0.0±0.5 -0.5±0/0.5 bumper...
Page 847: Front End Information
Body Dimension Body Repair Front End Information Section Description Dimension (mm) Profile (mm) Headlamp to bonnet 5.0±1.0 –2.3±1.0 Headlamp to fender 3.2±1.0 –2.5±0.5 Headlamp to bumper 2.5±1.0 –16.2±1.5 Grille upstand to headlamp 2.5±1.0 –3.5±1.0 Grille upper edge to bonnet 5.0±0.5 1.5±0.5 Grille upper edge to bonnet 5.0±0.5...
Page 848: Rear End Information
Body Repair Body Dimension Rear End Information Section Description Dimension (mm) profile (mm) Body side rear to rear 0.0+0.5 -0.5+0/-0.5 bumper Body side rear to rear 4.5+0.5 -1.0+0/-0.5 bumper Boot lid to rear fender 3.0±0.8 -0.1±0.5 Boot lid to rear fender 3.0±0.8 -0.1±0.5 Boot lid to rear bumper...
Page 849: Fuel Flap Information
Body Dimension Body Repair Fuel Flap Information Section Profile (mm) 4.0±0.8 -0.5±0.5 4.0±0.8 -0.5±0.5 4.5±0.8 0.5±0.5 4.5±0.8 0.0±0.5 Version 2.0...
Page 850: Paint And Coatings
Body Repair Paint and Coatings Paint and Coatings 6. Treat bare metal areas using an etch phosphate process. Description and Operation 7. Re-treat the affected area using either a separate acid-etch primer and two-pack surfacer, or an integrated General etch primer/filler. Panel Preparation 8.
Page 851 Paint and Coatings Body Repair 3. Ensure that damaged paintwork which has led to exposed • Local strip. The term "local" defines repairs limited to metal is abraded until the metal is clean, extending an area of approximately 380mm x 380mm (15in x 15in) beyond the area of the original damage.
Page 852 Body Repair Paint and Coatings • Do abrade Etch primer; Apply tinted two-component primer to the suggested micron build. (Tinted primer to replicate original sealer coat). • To aid sanding use a dark coloured guide coat. (Do not use black cellulose aerosol) Use a basecoat mix or dry powder type.
Page 853: Collision Repair
Collision Repair Body Repair Collision Repair its place. The number of plug welds must match exactly the number of spot welds which have been removed. Description and Operation • Where holes are left in an existing panel after removal General Welding Precautions of the spot welds, a single MIG plug weld will be made in General each hole as appropriate.
Page 854 Body Repair Collision Repair heat than panels manufactured from low carbon steel, it is advisable that the following procedure be observed at all times. Remove Panel 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.
Page 855 Collision Repair Body Repair Warning: Care must be taken to avoid excessive heat build-up when using the hot air gun. 2. Clean all panel joint edges to a bright smooth finish, using a belt-type sander. 2. Cut new and existing panels as necessary to form butt, joggle or brace joint as required.
Page 856 Body Repair Collision Repair 5. Apply correct sealant or adhesive, as applicable, to panel Caution: Use arms not exceeding 300 mm in length. joint surfaces. 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.
Page 857 Collision Repair Body Repair maintained to minimise welding distortion, by inserting a hacksaw blade as an approximate guide. 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 5.
Page 858: Body Sealing
Body Repair Collision Repair Body Sealing applied to such seams. Certain seams also become inaccessible Underbody Sealer Treatment Areas after the completion of panel repairs. In such instances apply seam sealer and paint before final assembly. Provided access Underfloor areas and sill outer panels are treated with a is adequate, apply seam sealer to both sides of a repair joint.
Page 859 Collision Repair Body Repair Seam sealer sealer - - - underside underside of of of vehicle vehicle - - - front front end end and and floor floor Seam Seam sealer underside vehicle front floor Version 2.0...
Page 860 Body Repair Collision Repair Seam sealer - underside of vehicle - rear Version 2.0...
Page 861 Collision Repair Body Repair Seam sealer - engine bay Version 2.0...
Page 862 Body Repair Collision Repair Seam sealer - main floor Seam sealer - rear floor Version 2.0...
Page 863 Collision Repair Body Repair Seam sealer - dash upper, roof area Seam sealer - front and rear door Version 2.0...
Page 864 Body Repair Collision Repair Seam sealer - bonnet and boot lid Seam sealer - tonneau lower extension Version 2.0...
Page 865 Collision Repair Body Repair Structural adhesive - rear floor assembly Structural adhesive dash and plenum panel Version 2.0...
Page 866 Body Repair Collision Repair Structural adhesive- rear parcel shelf Structural adhesive- parcel shelf Version 2.0...
Page 867 Collision Repair Body Repair Structural adhesive- rear panel Version 2.0...
Page 868 Body Repair Collision Repair Structural adhesive- wheel arch rear Structural adhesive- sunroof and front header Version 2.0...
Page 869 Collision Repair Body Repair Structural adhesive- sun roof centre and rear header Version 2.0...
Page 870 Body Repair Collision Repair Structural adhesive- fixed roof - front, centre and rear header Version 2.0...
Page 871 Collision Repair Body Repair Expanding Expanding Foam Expanding Foam Foam Acoustic Acoustic Seals Acoustic Seals Seals General Information Expanding foam acoustic seals are used in various closed seals in service. When replacing a seal, the following procedure sections of the body to improve vehicle refinement. The seals must be followed.
Page 872 Body Repair Collision Repair Identifying Identifying Identifying Body Body Body Seals Seals Seals Between panels - bolted Clinch joints - type (a) Panel edges - bolted Clinch joints - type (b) Between panels - spot welded Clinch joints - type (c) Panel edges - spot welded Gaps between panels - type (a) Between panels - bonded...
Page 873 Collision Repair Body Repair Approved Approved Materials Approved Materials Materials Description - Usage Supplier Part Number Cavity waxes Inner Cavity Wax (Amber) 08901/11/21 Inner Cavity Wax (Transparent) 08909/19/29 Cavity waxes Croda PW57 Engine compartment waxes and paints Aero engine chamber waxes and Astors DA3243/1 trim waxes...
Page 874 Body Repair Collision Repair Description - Usage Supplier Part Number Polyurethane Seam Sealer - bolted, spot 6500 welded and bonded panel edges; type (a) and (b) gaps between panels; Polyurethane Seam Sealer - bolted, Teroson spot welded and bonded panel edges; type (b) gaps between panels;...
Page 875 Collision Repair Body Repair Description - Usage Supplier Part Number Zinc primers P-565 63 Screen adhesives Direct glazing adhesive Rover components BHM 705 Noise insulation material Sika primer Sika Sikaflex Sika 255 FC Sikabaffle (swell foam) Sika Column foam Redashe 4330 Gap filling seam sealer Flexible foam sealer (shock resistant)
Page 876 Body Repair Collision Repair Equipment Equipment Equipment and and Suppliers Suppliers Suppliers Caution: Do not force the lance into access holes when using this attachment. Cavity wax equipment and techniques 1100 mm flexible nylon 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.
Page 877 Collision Repair Body Repair data. Kuper Pagele falcon junior pneumatic spray gun (airproof • Quing Dao, type). This pneumatic spray instrument is mainly used to • Shen Yang, spray wax. It has a 3L can with an entire hand pump. It •...
Page 878: Corrosion Prevention
Body Repair Collision Repair Corrosion Prevention DO NOT remove wax or lacquer from underbody or Factory Treatments underbonnet areas during repairs. Should it be necessary to steam clean these areas, apply a new coating of wax or During production, vehicle bodies are treated with the underbody protection as soon as possible.
Page 879 Collision Repair Body Repair Underbody Protection Repairs 8. Remove masking from component mounting faces, and touch-in where necessary. Whenever body repairs are carried out, ensure that full sealing and corrosion protection treatments are reinstated. This After refitting mechanical components, including hoses and applies both to the damaged areas and also to areas where pipes and other fixtures, mask off the brake discs and apply protection has been indirectly impaired, as a result either of...
Page 880 Body Repair Collision Repair • Mask off all areas not to be wax coated and which could • Keep all equipment clean, especially wax injection be contaminated by wax overspray. nozzles. • Remove body fixings, such as seat belt retractors, if Areas treated with cavity wax are shown in the following contamination is at all likely.
Page 881 Collision Repair Body Repair Cavity wax wax treatment treatment areas areas and and injection injection holes holes - - - Lower Lower sill sill section section Cavity Cavity treatment areas injection holes Lower sill section All areas symmetrically opposite to those shown are also treated. Version 2.0...
Page 882 Body Repair Collision Repair 1. Injection holes for lower sill section Cavity Cavity wax Cavity wax treatment treatment areas treatment areas and areas and injection injection injection holes holes holes - - - Side Side Side member member extensions member extensions extensions All areas symmetrically opposite to those shown are also treated.
Page 883 Collision Repair Body Repair Cavity wax wax treatment treatment areas areas and and injection injection holes holes - - - Front Front and and rear rear door door Cavity Cavity treatment areas injection holes Front rear door All areas symmetrically opposite to those shown are also treated. Cavity wax injection into inside of both front and rear doors.
Page 884: Diagnostic
Body Repair Collision Repair Diagnostic area while masking the leak in another. For example, if testing started at the level of the windscreen, any water cascading into Water Leaks the plenum chamber could leak through a bulkhead grommet General Information and into the footwells.
Page 885: Service Procedures
Collision Repair Body Repair Service Procedures Version 2.0...
Page 886: Front End Panel
Body Repair Collision Repair Front End Panel 1. Front side dash assembly RH 11. Sidemember rear extension assembly LH 2. Inner valance assembly RH 12. Front inner sidemember assembly LH 3. Front side dash LH 13. Front outer tower & sidemember assembly LH 4.
Page 887 Collision Repair Body Repair 20. Clucth pipe bracket LH Version 2.0...
Page 888: Door Panel
Body Repair Collision Repair Door Panel 1. Front door assembly 2. Rear door assembly Version 2.0...
Page 889: Rear Floor Panel
Collision Repair Body Repair Rear Floor Panel 1. Right side rear longitudinal member 2. Right side rear wheel arch inner assembly 3. Rear panel 4. Spare wheel well 5. Left side rear longitudinal member 6. Cross member rear floor 7. Right side seat squab lower assembly 8.
Page 890: Roof Panel
Body Repair Collision Repair Roof Panel 1. Roof fixed 2. Header rear 3. Centre bow 4. Header front Version 2.0...
Page 891 Collision Repair Body Repair 1. Roof (sun roof fitted) 2. Header rear 3. Sun roof reinforcing panel 4. Header front Version 2.0...
Page 892: Bodyside Panel
Body Repair Collision Repair Bodyside Panel 1. Body side - front section 2. Body side - centre section 3. Body side - rear section Version 2.0...
Page 893 Collision Repair Body Repair 1. Cantrail closing assembly 2. Inner quarter assembly 3. Front outer valance assembly 4. A post reinforcement assembly 5. Body side outer 6. B-C post closing panel 7. Inner sill reinforcement 8. Tonneau extension 9. Rear lamp mounting and drain channel extension Version 2.0...
Page 894: Front Floor Panel
Body Repair Collision Repair Front Floor Panel 1. Front floor assembly 2. right side sill inner assembly 3. left side sill inner assembly Version 2.0...
Page 895: Wheel Arch Panel
Collision Repair Body Repair Wheel Arch Panel 1. Right side rear wheel arch outer assembly 12. Left side front squab panel 2. Left side rear wheel arch outer assembly 13. Front squab panel bolt 3. Right side rear wheel arch sill closing extension panel 4.
Page 896 Version 2.0...
Page 897: Safety And Restraints
Vehicle Access Safety and Restraints Vehicle Access Description and Operation Alarm and Locking System Component Layout 1. Horn 11. Rear door switch and lock(LH) 2. Engine Control Module(ECM) 12. Handset docking station 3. Bonnet lock 13. Driver’s door switch and lock 4.
Page 898: Alarm And Locking System Control Diagram
Safety and Restraints Vehicle Access Alarm and Locking System Control Diagram A= Hard wired B= MS_CAN BUS C= Radio frequency signal 1. Remote handset 5. Inertia switch 2. Master locking switch 6. Instrument pack 3. Bonnet switch 7. Horn 4. Fuel flap switch and actuator 8.
Page 899 Vehicle Access Safety and Restraints 9. Driver’s door switch and lock 10. Rear door switch and lock(RH) 11. Rear door switch and lock(LH) 12. Boot release 13. Body Control Module(BCM) Version 2.0...
Page 900: Immobilisation System Control Diagram
Safety and Restraints Vehicle Access Immobilisation System Control Diagram A. Hard wired B. MS CAN Bus C. HS CAN Bus 1. Remote handset 2. Handset docking station 3. Body Control Module (BCM) 4. Instrument pack 5. Starter motor 6. Engine Control ModuleECM Version 2.0...
Page 901: Description
Vehicle Access Safety and Restraints Description and open the boot lid. The latch secures the boot lid in the General closed position on a striker which is secured to the rear boot panel. The boot open microswitch is connected to the latch This description covers all aspects of vehicle locking, alarm and is open circuit when the boot lid is closed.
Page 902 Safety and Restraints Vehicle Access Remote Handset resynchronisation with the BCM will occur the next time the remote handset is docked. Security System The primary function of the security system is to prevent unauthorized access to the vehicle. When the ignition is in the ‘AUX’...
Page 903 Vehicle Access Safety and Restraints detects the earth path open, will trigger the alarm. The boot 2(middle/ • Front LH door open switch open microswitch is also used by the BCM to display panel interior) • Front RH door open switch status information in the instrument pack and for automatic •...
Page 904 Safety and Restraints Vehicle Access Disarmed State then on again. When speed related locking is functional, an automatic unlock feature will unlock all the doors when the The BCM fully disarms the system on: ignition is turned off. On vehicles with an automatic gearbox, •...
Page 905: Seat Belts
Seat Belts Safety and Restraints Seat Belts Specifications Torque Description Value Front seat belt height adjuster 30–35Nm Bolt-front seat belt retractor to ‘BC’ post 30–35Nm Front seat belt assembly 30–35Nm Bolt-Front seat belt 30–35Nm Version 2.0...
Page 906: Description And Operation
Safety and Restraints Seat Belts Description and Operation System Component Layout Component Location 1. Driver’s front airbag module 5. Passenger’s front airbag module 2. Rotary coupler 6. Passenger airbag disable switch 3. SRS warning light in instrument pack 7. BCM 4.
Page 907 Seat Belts Safety and Restraints Component Location 1. BCM 4. Side airbag module 2. Passenger occupancy sensor 5. Crash sensor - side impact 3. Head curtain airbag modules 6. SRS ECU Version 2.0...
Page 908 Safety and Restraints Seat Belts Component Location 1. Rear seat belt 6. Front seat belt height adjuster 2. Rear seat belt pre-tensioner 7. Rear centre lap belt and buckle 3. Rear seat belt buckles 8. Driver’s seat belt buckle and warning switch 4.
Page 909: System Control Diagram
Seat Belts Safety and Restraints System Control Diagram System Control Diagram A. Hard wired B. HSCAN Bus C. MSLIN Bus 1. Head curtain airbag modules,where fitted 7. Seat buckle warning light 2. Passenger's front airbag module 8. SRS warning light in instrument pack 3.
Page 910 Safety and Restraints Seat Belts 13. Seat belt pre-tensioner reel 16. SRS ECU 14. Crash sensor side impact,if fitted 17. BCM and fuse 42. 15. Side airbag, if fitted Version 2.0...
Page 911: Description
Seat Belts Safety and Restraints Description Acceleration data ofSRSECU is electronically processed by an General internal microprocessor to determine the severity of the crash condition.SRSECU is able to use the input data to distinguish The Supplementary Restraint System(SRS) provides excellent between a severe crash situation and a minor impact or rough passive protection for vehicle occupants in the event of a road conditions and so prevent spurious deployment.
Page 912 Safety and Restraints Seat Belts • SRSECU internal accelerometer which determines the need for deployment of the restraint system. • SRSECU internal safing sensor • SRSECU microprocessor Caution: The side impact crash sensors must be fitted in the correct orientation. Ensure the fixing screws do not •...
Page 913 Seat Belts Safety and Restraints Passenger's Passenger's Front Passenger's Front Front Airbag Airbag Module Airbag Module Module Warning: If a new airbag module shows any sign of damage, do not use. Warning: After replacing the vehicle windscreen the Passenger Restraint System may not be capable of normal operation for 24 hours.
Page 914 Safety and Restraints Seat Belts Passenger Passenger Passenger Module Module Module Manual Manual Disable Manual Disable Disable Switch Switch Switch If a child seat is fitted in the front passenger seat, the passenger airbag must be manually disabled to prevent injury to the child. The airbag disable switch is located on the passenger side of the fascia.
Page 915 Seat Belts Safety and Restraints Side Side (Pelvis-Thorax) Side (Pelvis-Thorax) Airbags (Pelvis-Thorax) Airbags Airbags (Where (Where (Where Fitted) Fitted) Fitted) Warning: If a new airbag module shows any sign of damage, do not use. Bracket Cover Electrical connector The side (thorax) airbag module is fixed under the outer The side airbag modules have a flying lead that terminates in a bracket of the seat cover, when side crash happens, it can 4-pin connector.
Page 916 Safety and Restraints Seat Belts Head Head Head Curtain Curtain Curtain Airbag Airbag Airbag Modules Modules (Where Modules (Where (Where Fitted) Fitted) Fitted) Warning: If a new airbag module shows any sign of damage, do not use. Front tether fixing Gas generator/inflator Front tether strap Side curtain...
Page 917 Seat Belts Safety and Restraints Front Front Seat Front Seat Belt Seat Belt Belt Pre-tensioners Pre-tensioners Pre-tensioners The inertia reel adds a locking mechanism, which has woof sensor and vehicle sensor. If the woof is pulled suddenly, the woof sensor will start the locking equipment immediately. If the vehicle decelerate suddenly or lange-angle incline, vehicle sensor will start the locking equipment immediately.
Page 918 Safety and Restraints Seat Belts Rear Seat Belts Seat Belt Warning Indicators The inertia reels of the RH and LH rear seat belts are attached to the body parcel shelf, underneath the parcel shelf trim. Each inertia reel is fixed to the parcel shelf body by a bolt at the rear of each unit, a locating tag at the front of each inertia reel holds the assemblies in position on the parcel shelf.
Page 919: Operation
Seat Belts Safety and Restraints Operation gas causes airbag inflation. The inflating side (thorax) airbag General bursts through the seat cover at the outboard seam. At the same time, the head airbag module deploys from beneath the All system operations become active when the ignition is on headlining trim to protect the occupant from head injuries.
Page 920 Safety and Restraints Seat Belts While the ignition is on, the diagnostic function of theSRSECU monitors theSRS system for faults. If a fault is detected, theSRSECU stores a related fault code in non-volatile memory and sends an output to illuminate theSRS warning light.
Page 921: Service Procedures
Seat Belts Safety and Restraints Service Procedures Seat Belt Assembly - Front - Each Remove Adjustable Mounting - Seat Belt - BC Pillar - Each Remove 1. Remove handset from docking station, disconnect battery leads, earth first and wait 10 minutes for 1.
Page 922: Supplemental Inatable Restraints
Safety and Restraints Supplemental Inatable Restraints Supplemental Inatable Restraints Specifications Torque Description Value Bolt-airbag gas generator (LH) 8–12Nm Bolt-SRS ECU 7–10Nm Version 2.0...
Page 923: Service Procedures
Supplemental Inatable Restraints Safety and Restraints Service Procedures Airbag - Fascia - Passenger Remove 1. Remove handset from docking station, disconnect battery leads, earth first and wait 10 minutes for theSRS back-up power circuit to discharge before commencing work. Warning: It is imperative that before any work is undertaken on the SRS system the appropriate information is read thoroughly.
Page 924: Airbag - Steering Wheel - Driver
Safety and Restraints Supplemental Inatable Restraints Airbag - Steering Wheel - Driver Electronic Control Unit Remove Remove 1. Remove handset from docking station, disconnect 1. Disconnect battery earth lead. battery leads, earth first and wait 10 minutes for 2. Remove centre console. theSRS back-up power circuit to discharge before Console Console...
Page 925: Curtain Airbag - Head
Supplemental Inatable Restraints Safety and Restraints Curtain Airbag - Head Remove 1. Remove key from ignition switch, disconnect both battery leads, earth lead first, and wait 10 minutes for theSRS back-up power circuit to discharge before commencing work. Warning: It is imperative that before any work is undertaken on the SRS system the appropriate information is read thoroughly.
Page 926: Park Assistant System
Safety and Restraints Park Assistant System Park Assistant System Description and Operation System Component Layout Parking Distance Control System Location 1. Instrument pack incorporating audible warning sounder 2. BCM 3. Rear camera (where fitted) 4. Rear ultrasonic sensors 5. PDC ECU 6.
Page 927: System Control Diagram
Park Assistant System Safety and Restraints System Control Diagram Control Diagram A. Hard wired B. MSCAN C.LIN bus 1. Instrument pack incorporating audible warning sounder 6. BCM incorporating fuse 44 2. a Neutral Start Switch (NSW) b Reverse light switch 3.
Page 928: Description
Safety and Restraints Park Assistant System Description Where specified, a reverse camera is fitted to the number General plate applique to provide the driver with a real time view of the area behind vehicle in order to assist with reversing Parking Distance Control (PDC Electronic Control Unit manoeuvres.
Page 929: Operation
Park Assistant System Safety and Restraints Operation Caution: Blind spots, areas where the sensor cannot General detect obstructions, may occur if obstructions are present at distances of around 200 mm from the sensors. PDCECU receives a status of the ignition, reverse switch Reverse Camera (Where Fitted) position via theBCM Bus connection to theLIN With the ignition on, thePDC enters a self check mode.
Page 930: Service Procedures
Safety and Restraints Park Assistant System Service Procedures Remove Control Unit ( Remove 1. Remove rear bumper. 1. Disconnect battery earth lead. Bumper assembly assembly - - - rear rear - - - with with park park distance distance Bumper Bumper assembly rear...
Page 931: Information And Entertainment
Entertainment and Navigation Information and Entertainment Entertainment and Navigation Description and Operation Component Layout Component Location 1. Steering wheel audio controls (where fitted) 2. Display screen 3. SEL/ESC control 4. ICE head unit 5. Radio antenna 6. USB/AUX port 7. LH rear door speaker 8.
Page 932: Ice -Control Diagram
Information and Entertainment Entertainment and Navigation -Control Diagram Control Diagram A. Hard wired B. MSCAN Bus C.LIN Bus 1. SEL/ESC control 2. Display screen 3. Speakers (4 off) and tweeters (2 off) 4. USB/AUX port 5. Radio antenna 6. Steering wheel controls (where fitted) 7.
Page 933: In Car Entertainment Ice -Description
Entertainment and Navigation Information and Entertainment IN CAR ENTERTAINMENT -Description 3. Radio, CD/DVD player, USB port, satellite navigation (with General SD card slot), colour display screen, Bluetooth telephone. There are three levels of audio/navigation systems available, as For more information about the navigation functions of the follows head unit NAVIGATION...
Page 934 Information and Entertainment Entertainment and Navigation Head Unit (Audio and Navigation) 1. Mode switch 8. Down 2. SD card slot 9. Dim display light 3. NAV button 10. Up 4. DIVERT button 11. Backward 5. RPT (Repeat) button 12. Forward 6.
Page 935 Entertainment and Navigation Information and Entertainment Steering Steering Wheel Steering Wheel Controls Wheel Controls Controls SEL/ESC Control The audio unit can be controlled by the remote switches The SEL/ESC control is used to navigate through menu and mounted on the steering wheel. The three function switches other options displayed on the display screen.
Page 936 Information and Entertainment Entertainment and Navigation 3. Digital time 5. External temperature 4. Date (year, month, date) Speakers Tweeter units are fitted in the front passenger and driver doors only. Bass Speaker Radio Antenna Bass speakers are fitted in all four doors. Speakers are secured The roof-mounted radio antenna is a selfcontained unit.
Page 937: In Car Entertainment Ice )-Operation
Entertainment and Navigation Information and Entertainment IN CAR ENTERTAINMENT ( )-Operation General TheICE system can only be operated when the handset is docked or the ignition is on. Rotate the SEL/ESC control to navigate the options shown in the display screen. Thermal Protection To prevent damage to the unit, thermal protection is fitted to shut down audio functions if the internal vehicle temperature...
Page 938: Navigation System Component Layout
Information and Entertainment Entertainment and Navigation Navigation System Component Layout Navigation System Component Location 1. GPS antenna 2. Navigation screen 3. SEL/ESC control 4. Navigation head unit with SD card slot 5. BCM 6. Speakers Version 2.0...
Page 939: Navigation System Control Diagram
Entertainment and Navigation Information and Entertainment Navigation System Control Diagram Navigation System Control Diagram A. Hard wired B. MSCAN Bus C.LIN Bus 1. GPS antenna 2. Navigation head unit 3. SEL/ESC control 4. BCM 5. Steering wheel switches 6. Speakers 7.
Page 940: Navigation System-Description
Information and Entertainment Entertainment and Navigation Navigation System-Description General The navigation system provides computer generated audible and visual route guidance information to guide the driver to their desired destination. The system allows the driver to choose the desired route using minor or major roads or motorways and either the quickest or shortest route.
Page 941 Entertainment and Navigation Information and Entertainment Navigation Navigation Head Navigation Head Head Unit Unit Unit 1. Display main menu 7. System settings 2. On/off and volume control 8. Dim illumination 3. Select navigation mode 9. SD card slot 4. Calculate alternative route 5.
Page 942: Navigation System - Operation
Information and Entertainment Entertainment and Navigation Navigation System - Operation Overview For more information on the operation of the navigation unit, refer to the Owner's Manual. Version 2.0...
Page 943: Service Procedures
Entertainment and Navigation Information and Entertainment Service Procedures Woofer - Front Door Remove Woofer - Rear Door Remove 1. Remove front door trim casing. 1. Remove rear door trim casing. Trim casing casing - - - front front door door - - - Remove Remove Trim Trim...
Page 944: Speaker - Tweeter - Front
Information and Entertainment Entertainment and Navigation Speaker - Tweeter - Front Remove 1. Remove front door trim casing. Trim casing casing - - - front front door door - - - Remove Remove Trim Trim casing front door Remove 2. Remove tweeter. Refit 1.
Page 945: Displays And Gages
Displays and Gages Information and Entertainment Displays and Gages Description and Operation System Component Layout Instrument Pack Layout 1. High coolant temperature warning light 18. Passenger airbag disabled warning light 2. Engine coolant temperature bar chart 19. Rear fog lamp indicator 3.
Page 946 Information and Entertainment Displays and Gages Instrument Pack Component Location 1. Instrument Pack 2. Body Control Module (BCM) 3. Diagnostic socket Version 2.0...
Page 947: System Control Diagram
Displays and Gages Information and Entertainment System Control Diagram Instrument Pack System Control Diagram A=hard wire B=MS CAN C=HCAN D=LIN 1. Instrument pack 9. Park Distance Control ECU 2. Fuel level sensor 10. Engine control module 3. Transmission Control Unit (TCU) 11.
Page 948: Description
Information and Entertainment Displays and Gages Description Information type Transmitted by Received by General Instrument pack ABS warning light ABS/DSC The instrument pack is secured to the fascia by two screws and Instrument pack Airbag fault connecting to the vehicle main harness. On the Right hand side Passenger side airbag of the instrument panel there is a display screen, depending on Instrument pack...
Page 949 Displays and Gages Information and Entertainment Information type Transmitted by Received by Anti-theft alarm status BCM Instrument pack Alarm triggered state BCM Instrument pack Remote key battery Instrument pack Remote key Invalid Instrument pack ESCL state ESCL Instrument pack Traction control state ABS/DSC Instrument pack Inertia switch tripped BCM Instrument pack...
Page 950 Information and Entertainment Displays and Gages Harness Harness Harness connector connector connector ICE display screen Harness connector ICE display screen Instrument pack connector face view The following gauges are included on the instrument pack: Tachometer Instrument pack connector information Pin No. Description The tachometer indicates engine speed on a dial marked in IMMO data...
Page 951 Displays and Gages Information and Entertainment Speedometer Fuel Gauge The speedometer indicates the vehicle road speed in units of The fuel gauge is on the right hand side of tachometer, and km/h. The vehicle speed signal is sent to the instrument cluster uses an 7LED bar chart display.
Page 952 Information and Entertainment Displays and Gages Engine Malfunction Warning ( ) Light Warning Indications Direction Indicators (Left, Right) If the yellow warning light remains on after the engine starts, this meansEMS has an emissions failure. When the engine The left and right direction indicators are represented by green starts, the message centre will display warning information with directional arrows located at the top of the instrument pack.
Page 953 Displays and Gages Information and Entertainment warning until the seat belt are buckled correctly, or until 90 and the sidelights are on. The relevant information will be seconds has expired. displayed on message centre. SRS Warning Light Rear Fog Lamp Warning Light The warning light illuminates red.
Page 954 Information and Entertainment Displays and Gages Overspeed Warning Main Message Centre Display Icons The following are ‘non-tell-tale’ warnings and are only displayed When the vehicle speed exceeds the value set in the in the message centre display message centre, it triggers the warning icon together with an Ambient Air Temperature Low audible warning.
Page 955 Displays and Gages Information and Entertainment Trip Button (low line) Message Centre Main Display Area On the low line models, the trip button is fitted to the end of the left-hand combination switch. The trip button is fitted to In preview mode, this area displays ‘Next Service’, then the navigate the message centre menus and options.
Page 956 Information and Entertainment Displays and Gages Menu Menu Menu Display Display Display Instrument Pack Illumination The brightness level of the instrument pack display can be controlled by adjusting the dimmer control thumb wheel on the Master Light SwitchMLS. The dimmer control also affects the brightness of illuminated switches, message centre, trip computer and navigation system display (where fitted).
Page 957: Operation
Displays and Gages Information and Entertainment Operation centre displays any relevant ‘repeat-on-shutdown’ designated warnings that exist in priority order. Modes of Operation The functionality of the instrument pack features available at any particular time is dependent on the position of the ignition switch.
Page 958: Service Procedures
Information and Entertainment Displays and Gages Service Procedures Instrument Pack Remove 1. Disconnect battery earth lead. 2. Remove 2 screw covers and remove 2 screws securing instrument pack to fascia. 3. Release instrument pack from fascia and disconnect 1 instrument pack connector and either 1 or 2 display connectors (depending on if a radio or navigation display is fitted).
Page 959: Glossary List
Glossary List Name Description Name Description High Speed HVAC Heating, Ventilation and Air Air Conditioning Conditioning Anti-lock braking system In Car Entertainment Alternating current Inflatable Curtain Structure Air Fuel Ratio International Organization for Standardization Automatic Temperature Control Liquid Crystal Display ATDC After Top Dead Centre Light Emitting Diode...

MG MG6 Series 2011 Service Manual

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