Aston Martin DB9 2005 Workshop Manual

DB9

Workshop Manual

Issue 2

Aston Martin Lagonda Limited

Banbury Road, Gaydon, WARWICK, Warwickshire,

England, MK16 9AN

Telephone: (01926) 644700 Fax: (01926) 644733

Aston Martin are constantly seeking to improve the specification, design and production of their vehicles and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular vehicle.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form, electronic, mechanical, photocopying, recording or other means without prior written permission from Aston Martin

Lagonda Limited.

The manufacturer reserves the right to vary specifications without notice in accordance with its policy of continual product improvement.

Produced by the Technical Publications Department

Aston Martin Lagonda Limited

Issue 2 - February 2005 Part No. 4G43-43-10032

DB9 Workshop Manual

Contents

Introduction

Welcome............................................................... i-i-iv

Safety Precautions................................................... i-i-v

Lifting and Jacking................................................. i-i-vii

Vehicle Recovery ..................................................i-i-viii

Vehicle Identification Number ............................... i-i-ix

Body System (01.00)

Body Structure (01.01)..........................................1-1-3

Front End System (01.02) ......................................1-2-1

Body Closures (01.03)...........................................1-3-1

Interior Trim (01.05) .............................................1-4-1

Exterior Trim (01.08).............................................1-5-1

Mirrors (01.09)......................................................1-6-1

Seating (01.10)......................................................1-7-1

Glass, Frame and Mechanism (01.11)....................1-8-1

Instrument Panel (IP) (01.12).................................1-9-1

Handles and Lock Mechanisms (01.14) ...............1-10-1

Wipers and Washer System (01.16).....................1-11-1

Bumpers (01.19) .................................................1-12-1

Restraining Devices (01.20).................................1-13-1

Frame and Mounting (02.00)

Subframes (02.03).................................................2-1-2

Engine System (03.00)

Engine Assembly (03.00) .......................................3-1-3

Engine Structure (03.01)........................................3-2-1

Lubrication System (03.02)....................................3-3-1

Cooling System (03.03) .........................................3-4-1

Fuel Charging System (03.04)................................3-5-1

Accessory Drive System (03.05).............................3-6-1

Engine Cranking System (03.06) ............................3-7-1

Ignition System (03.07) .........................................3-8-1

Emission Control (03.08) .......................................3-9-1

Valve Train (03.09) .............................................3-10-1

Engine Sealing (03.10).........................................3-11-1

Power Conversion (03.11)...................................3-12-1

Air Charging (03.12)............................................3-13-1

Evaporative Emissions (03.13) .............................3-14-1

Engine Management System (03.14)....................3-15-1

Throttle Control (03.16) ......................................3-16-1

Suspension (04.00)

Road Wheel Alignment (04.00) .............................4-1-2

Front Suspension (04.01).......................................4-2-1

Rear Suspension (04.02)........................................4-3-1

Road Wheels and Tyres (04.04) ............................4-4-1

Driveline (05.00)

Driveshaft (05.01) .................................................5-1-2

Rear Drive System (05.02) ....................................5-2-1

Halfshafts (05.05)..................................................5-3-1

Brake System (06.00)

Description...........................................................6-1-2

Front Disc Brake (06.03) .......................................6-2-1

Rear Disc Brakes (06.04).......................................6-3-1

Hand Brake (06.05) ..............................................6-4-1

Brake Actuation System (06.06) ............................6-5-1

Power Brake System (06.09) .................................6-6-1

Transmission (07.00)

Automatic Transmission (07.01) ............................7-1-2

Transmission Cooling (07.02) ................................7-2-1

Manual Transmission (07.03) ................................7-3-1

Automatic Control System (07.05).........................7-4-1

Clutch (08.00)

Clutch Controls (08.02).........................................8-2-1

Exhaust (09.00)

Exhaust Overview .................................................9-1-2

Silencer Assembly (09.01) .....................................9-1-3

Pipes and Supports (09.03) ...................................9-2-1

Fuel (10.00)

Fuel Tank and Lines (10.01)................................10-1-2

Steering (11.00)

Steering Gear (11.01)..........................................11-1-2

Power Steering (11.02)........................................11-2-1

Steering Column (11.04) .....................................11-3-1

Steering Column Switches (11.05).......................11-4-1

Steering Wheel (11.06) .......................................11-5-1

Climate Control (12.00)

Body Ventilation system (12.01)..........................12-1-3

Heater System (12.02) ........................................12-2-1

Air Conditioning (A/C) System (12.03).................12-3-1

A/C Control System (12.04).................................12-4-1

Information, Gauge and Warning (13.00)

Instrument Cluster (13.01) ..................................13-1-2

Power Supply (14.00)

Battery System (14.01) ........................................14-1-2

Alternator and Regulator System (14.02) .............14-2-1

Issue 2 February 2005 Workshop Manual I-I-III

Vehicle Entertainment (15.00)

Audio System ..................................................... 15-1-1

Vacuum Distribution (16.00)

Body Vacuum System (16.01)............................. 16-1-1

Lighting (17.00)

Front Lights (17.01) ............................................ 17-1-2

Interior Lighting (17.02)...................................... 17-2-1

Rear Lights (17.03) ............................................. 17-3-1

Lighting Mechanisms (17.04) .............................. 17-4-1

Electric Distribution/Electronic Control (18.00)

Wiring and Circuit Protection (18.01) ................. 18-1-2

Vehicle Control System (18.08) .......................... 18-2-1

Electronic Features (19.00)

Active Anti-Theft System (19.01)......................... 19-1-2

Appendix & Glossary

Diagnostic Ports................................................... 20-1-2

Fluids/Capacities.................................................. 20-1-3

Abbreviations ...................................................... 20-1-3

Terms.................................................................. 20-1-3

Special Tools - Pictorial Index.............................. 20-1-4

Specialist Tool Operation .................................... 20-1-8

Maintenance Schedules..................................... 20-1-11

Torque Figures .................................................. 20-1-14

Torque Conversion Tables ................................. 20-1-31

I-I-IV Workshop Manual Issue 2 February 2005

Introduction

Contents

Welcome................................................................ I-I-VI

Chapters ................................................................ I-VI

Chapter Navigation ................................................I-VI

Numbering ............................................................ I-VI

Special Tools.......................................................... I-VI

Location References............................................... I-VI

Warnings, Cautions and Notes.............................. I-VI

Repairs and Replacements .................................... I-VI

Safety Precautions ................................................I-I-VII

Battery Disconnection .......................................... I-VII

Air Conditioning (A/C) System.............................. I-VII

Chemical Handling and Storage........................... I-VII

Electrical Equipment............................................. I-VII

Exhaust Fumes..................................................... I-VIII

Fire Precautions................................................... I-VIII

Tools and Equipment........................................... I-VIII

Used Engine Oil................................................... I-VIII

Health Protection Precautions............................. I-VIII

Environmental Protection.................................... I-VIII

Lifting and Jacking ................................................. I-I-IX

Safety ..................................................................... I-IX

Jacking Points ........................................................ I-IX

Stands................................................................. I-IX

Workshop Hoist..................................................... I-IX

Vehicle Recovery .................................................... I-I-X

General....................................................................I-X

Transporting............................................................I-X

Suspended Towing ................................................. I-X

Front Suspended Tow........................................... I-X

Rear Suspended Tow............................................ I-X

Towing an Automatic Vehicle ................................. I-X

Towing Regulations................................................. I-X

Towing by Another Vehicle..................................... I-X

Push-start ................................................................I-X

Identification Numbers ......................................... I-I-XI

Vehicle Identification Number (VIN)......................I-XI

VIN Number Location............................................ I-XI

Engine Number..................................................... I-XII

Gearbox Number.................................................. I-XII

Automatic Gearbox............................................... I-XII

Manual Gearbox................................................... I-XII

Issue 2 February 2005 Workshop Manual I-I-V

Welcome

Introduction

Introduction

Welcome

This Workshop Manual is part of a suite of technical manuals provided for DB9. Other technical manuals include:

• Parts manual

• OBDII Diagnostic manual

• Man hour schedules

Chapters

The DB9 suite of manuals incorporate a new chapter structure.

Each chapter in this workshop manual is associated with a 4 digit number, i.e. Transmission (07.00). Each chapter is then further broken into sections, i.e. Automatic Transmission

(07.01).

Chapter Navigation

Example 1:

Previous workshop manuals would have Steering and

Suspension together in one chapter. The new structure now places Steering and Suspension into their own chapters.

Road wheels are also now included in Suspension.

Example 2:

Fuel, emissions and exhaust is now in three different chapters. Fuel has its own chapter and includes all fuel aspects up to the fuel rails (Fuel rails and fuel injection now come under Engine System). Exhaust, not including manifolds, has its own chapter and Emissions now come under the Engine system.

When required references are made out to other chapters.

Numbering

03. 02.

System, i.e. Engine system

Subsystem, i.e. Engine lubrication system

Location References

References to left, right, front or rear of the vehicle or of a component are referenced from sitting in the drivers seat facing forward. Any such references to assemblies removed from the vehicle are to the normal orientation of the assembly when installed in the vehicle.

Warnings, Cautions and Notes

The following Warnings, Cautions and Notes are used within this workshop manual to call your attention to specific types of information.

Warnings

Warning

Identifies procedures which must be followed precisely to help avoid the risk of personal injury.

Cautions

Caution

Provided to indicate procedures which must be followed precisely to reduce the possibility of damage to the vehicle.

Notes

Provided to indicate procedures which will help to avoid difficulties in the operation of the vehicle.

Chapters and sections within chapters are numbered using the system detailed above. All technical manuals for this vehicle use the same numbering system. When carrying out a procedure, the relevant parts illustration and spare parts list can be found using the same numbering system.

To avoid excessive repetition, each procedure is fully detailed once in its appropriate chapter. In any other location where this procedure is required, it is referenced by its title and chapter / page number.

Special Tools

Where special service tools are required to perform an operation, the tool number is recorded at the point of use within the procedure. Where the operation of a special service tool is complicated or not obvious, refer to the

Appendix and Glossary for detailed operation procedures. A pictorial list of special service tools available for this vehicle can also be found in the Appendix and Glossary.

Repairs and Replacements

Where replacement parts are required, it is essential that only genuine Aston Martin parts are used. Your attention is drawn to the following points concerning repairs and the fitting of genuine Aston Martin parts and accessories:

• Safety features embodied in the vehicle may be impaired if other than genuine Aston Martin parts are installed. In certain territories, legislation prohibits the installation of parts which are not produced to the manufacturers specification

• Adhere to torque wrench settings given in this manual

• Locking devices, where specified, must be installed. If the efficiency of a locking device is impaired during removal, it must be renewed

• The vehicle warranty may be invalidated by the installation of other than genuine Aston Martin parts

I-I-VI Workshop Manual Issue 2 February 2005

Safety Precautions

Introduction


All service workshops are a source of potential danger and repair work should only be performed by technically trained staff following procedures detailed in this manual. A safety conscious approach to the performance of all service procedures must be observed at all times. Statutory requirements governing all aspects of health and safety at work including directives for the proper use of materials and equipment must be implemented.

The following headings highlight particular safety precautions which should be observed (The list is not intended to be exhaustive).

Battery Disconnection

Where a procedure requires the vehicle battery to be physically disconnected (disconnect the vehicle battery earth (Negative) lead), the following items will have to be reset or re-learnt on connection:

• Seats memory

• Radio pre-sets

• DTCs will be lost

Air Conditioning (A/C) System

Do not break into the A/C refrigeration system until the refrigerant has been evacuated using the procedure detailed in this manual. Do not disconnect any A/C refrigerant system pipes unless trained and instructed to do so. The refrigerant used can cause blindness if allowed to contact your eyes.

Chemical Handling and Storage

Warning

Strictly adhere to handling and safety information found on containers and labels.

Warning

Do not store chemicals in unlabelled or incorrectly labelled containers.

Warning

Containers used for storing chemicals should not be left open; there is a risk of spilling, or evaporation of fumes which may be inflammable or toxic.

Warning

Do not mix chemicals unless instructed to do so, following manufacturers guidelines.

Warning

Do not inhale chemical materials to determine identity, they may be toxic.

Warning

Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin.

Warning

Chemicals based on solvents such as paint should not be sprayed in a confined space; work areas used for such operations should be well ventilated and fume extraction equipment should be utilised.

Warning

Containers whose capacity is over 25 litres (5 gallons) require a bund wall in order to contain spillages.

Warning

Avoid splashing the skin, eyes and clothing.

Warning

Ensure that adequate ventilation is provided when volatile de-greasing agents are being used.

Warning

Clean chemicals from the skin and clothing as soon as possible after soiling.

Warning

Wear protective clothing such as goggles, non porous gloves and apron when handling battery acid and other corrosive and toxic substances.

Warning

Do not smoke in the vicinity of volatile de-greasing agents.

Warning

Fume extraction equipment must be in operation when solvents are used e.g. trichloroethane, white spirit,

SBP3, methylene chloride, perchloroethylene.

Chemicals used in the servicing of motor vehicles include acids, adhesives, antifreeze, brake fluids, coolants, grease, oil, paint, resin and solvents. Exposure to certain chemicals through direct contact or inhalation can be fatal.

Potential hazards may also be present through the incorrect use, storage and handling of chemicals causing a fire risk.

Electrical Equipment

Warning

Ensure that electrical equipment is in safe working order before use.

Warning

Inspect power leads of all mains electrical equipment for damage and security, and check that it is properly earthed.

Warning

Ensure that electrical equipment is protected by a fuse of the correct current rating.

Warning

Disconnect the battery before commencing repair operations to the electrical system, fuel system and engine or when working beneath the vehicle.

Issue 2 February 2005 Workshop Manual I-I-VII


Introduction

Exhaust Fumes

Warning

Do not breathe exhaust fumes. Exhaust fumes contain carbon monoxide. Carbon monoxide is a dangerous gas, which is colourless and odourless and can cause unconsciousness and may be fatal. Never start or leave the engine running in an enclosed, unventilated area.

Warning

Avoid skin contact with all exhaust system and engine components, engine fluids and escaping steam. They may be hot and will burn you.

Engines must only be run where there is fume extraction equipment in operation or where there is adequate ventilation.

Fire Precautions

Warning

Ensure that a suitable form of fire extinguisher is conveniently located near the work area.

Warning

Keep oils, solvents and combustible materials away from naked flames and other sources of ignition.

Warning

Ensure that NO SMOKING signs are posted around areas where combustible materials and vapour may be present and ensure that the warnings are strictly observed.

Warning

Ensure that dry sand is available to soak up any spillage of fuel or other flammable solutions.

Warning

Fume extraction equipment must be available and in full working order to remove combustible and toxic vapours.

Warning

All personnel should be aware of the fire drill procedures and precautions.

Tools and Equipment

Warning

Do not leave tools, equipment, spilt oil, etc. around or on the work area.

Warning

Ensure that tools and equipment used are in good condition; do not use damaged or defective tools or equipment.

Caution

Do not apply heat in an attempt to free stiff nuts or fittings; as well as causing damage to protective coatings, the stray heat may damage electronic equipment, harnesses and brake lines .

Use the recommended service tool where instructed to do so.

Used Engine Oil

Warning

Prolonged and repeated contact with used engine oils can cause serious skin disorders, including dermatitis and cancer. Avoid excessive contact, wash thoroughly after contact.

In addition, observe all laws regarding the disposal of waste oil and toxic fluids.

Adequate means of skin protection and washing facilities should be provided.

Health Protection Precautions

Warning

Prolonged and repeated contact with used engine oils can cause serious skin disorders, including dermatitis and cancer. Avoid excessive contact, wash thoroughly after contact.

• Wear protective clothing, including impervious gloves where practicable.

• Do not put oily rags in pockets.

• Avoid contaminating clothes with oil.

• Overalls must be cleaned regularly. Discard un-washable clothes and oil impregnated footwear.

• First aid treatment should be obtained immediately for open cuts or wounds.

• Use barrier creams, apply before each work period to help the removal of oil from the skin.

• Wash with soap and water to ensure all oil is removed.

Preparations containing lanolin replace the natural skin oils which have been removed.

• Do not use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing skin.

• If skin disorders develop, obtain medical advice.

• Where practicable, degrease components prior to handling.

• Where there is a risk of eye contact, eye protection should be worn. In addition, an eye wash facility should be provided.

Environmental Protection

It is illegal to pour used oil on the ground, down sewers or drains, or into water courses. The burning of used engine oil in small space heaters or boilers is not recommended unless emission control equipment is installed; in case of doubt, contact the Local Authority for advice on disposal facilities.

I-I-VIII Workshop Manual Issue 2 February 2005

Lifting and Jacking

Introduction

Lifting and Jacking

Safety

Warning

Recommended procedures for lifting, jacking and towing must be strictly observed to ensure personal safety.

Warning

Always use a vehicle hoist, ramp or pit for working beneath the vehicle in preference to jacking.

Warning

Never rely on a jack to support a car independently, use axle stands or blocks carefully placed at jacking points to provide rigid support.

Warning

When working beneath a vehicle, chock wheels as well as applying handbrake.

Warning

Ensure vehicle is standing on firm, level ground before jacking or lifting.

Warning

Check lifting equipment has adequate capacity for load being lifted and is in full working order.

Jacking Points

Caution

Do not jack the vehicle on the lower suspension arms

(front or rear).

This vehicle jacking points are at positions shown.

The vehicle may also be jacked with the jack placed on the front subframe, front crossmember.

Front Crossmember

Always use a jack with a rubber contact pad. Avoid the use of jacks with sharp contact pads which could damage the vehicle floor pan Always chock the opposite road wheels as well as applying the handbrake when using a hydraulic jack.

To prevent body distortion, avoid single point or one side jacking with the tunnel shear panel removed.

To avoid any danger of bodywork damage when using a hydraulic jack, the vehicle must only be lifted at the jacking points.

Stands

When carrying out work (other than a wheel change) which requires a wheel to be raised, a stand must be used, located at the jacking point, to provide a secure support for the vehicle.

Workshop Hoist

Use of a workshop hoist is recommended for all operations where vehicles must be raised. Follow manufacturers instructions. If using an adjustable arm type, ensure lifting pads are correctly positioned at the four jacking points before lifting.

Issue 2 February 2005 Workshop Manual I-I-IX

Vehicle Recovery

Introduction

Vehicle Recovery

General

The preferred method of vehicle recovery is by a flat bed, covered, transporter.

The towing eye is primarily for emergency use when towing for short distances, e.g. removing vehicle if it is causing an obstruction or winching vehicle onto a flatbed transporter.

If moving this vehicle in such a situation, install the towing eye to the bracket, which is located behind the registration number plate.

Rear Suspended Tow

1. Set the steering in the ‘straight ahead’ position.

2. Remove the ignition key from the ignition. Ensure the steering is locked in the straight ahead position.

3. Raise the vehicle using a 'spectacle frame' style lifting device where a cradle is positioned under each rear wheel as indicated below.

Caution

Take care to protect the paint work when installing the towing eye. Ensure the towing eye is tight.

Towing an Automatic Vehicle

Transporting

If vehicle is to be transported on a trailer or flat bed transporter the handbrake must be applied and the road wheels must be chocked.

Suspended Towing

Caution

Do not tow with ‘sling’ type equipment, damage to bodywork will result.

Take care when using 'spectacle frame' type towing equipment that the towing device is well clear of front or rear apron. Body damage may occur if vehicle passes over uneven road surfaces.

Ensure the recovery team follow the following towing instructions:

Front Suspended Tow

Automatic Transmission Only

1. Switch the ignition ‘On’.

2. Pull back twice on both paddles, simultaneously, to force the gearbox into ‘Neutral’.

Switch the ignition ‘Off’ within three seconds.

Manual and Automatic Transmissions

3. Remove the ignition key from the ignition.

4. Raise the vehicle using a 'spectacle frame' type lifting device with a cradle positioned under each front wheel as indicated below.

Caution

This vehicle installed with an automatic transmission can be towed on its driven wheels at not more than 70 km/h road speed and for a maximum distance of 500 km.

The selector lever must be in Neutral (N).

If the above speed and distance limits are exceeded, the automatic transmission will be severely damaged.

Towing Regulations

In certain countries the registration number plate of the towing vehicle and an ‘ON TOW’ sign or warning triangle must be displayed in a prominent position at the rear of vehicle being towed.

Towing by Another Vehicle

Ward the brake booster will become ineffective after a few applications of the brakes. Be prepared for relatively heavy steering and the need for greatly increased brake pedal pressure.

This vehicle may be towed short distances by another vehicle provided that a speed of 48 km/h (30 mph) is not exceeded. Ensure that the towed vehicle gear selection is in

‘Neutral’ (manual) or position ‘N’ (automatic), the ignition key turned to position ‘II’ (to release steering lock and to render the horn, indicators and brake lights operational).

Push-start

Vehicle’s installed with automatic transmissions cannot be started by push-starting.

I-I-X Workshop Manual Issue 2 February 2005

Identification Numbers

Introduction


Vehicle Identification Number (VIN)

The Vehicle Identification Number (VIN) is a 17 character number which uniquely identifies the vehicle and gives fundamental data on the build site, date and initial configuration of the vehicle.

S C F A C 1 3 A 4 1 G A 0 0 0 0 1

Code for AML

Restraint System

Transmission and Steering

Body Type

Engine Type

Calculated Check Digit

Model Year

Manufacturing Plant

Series Identifier

Sequential Chassis Number

VIN Number Location

The VIN number is stamped / plated in the following locations:

Under the lower edge of the windscreen.

Front of the engine bay.

VIN Number

01-00-004

Stamped on the floorpan in the RH front footwell.

VIN Number

Issue 2 February 2005

01-00-011

Workshop Manual I-I-XI


Introduction

Engine Number

The engine number is stamped on the LH side of the engine block.

Gearbox Number

Automatic Gearbox

The automatic gearbox number plate is located on the LH side of the gearbox.

Manual Gearbox

To follow.

Image to Follow

I-I-XII Workshop Manual Issue 2 February 2005


Contents

Body Structure (01.01)...........................................1-1-3

Overview ................................................................ 1-3

Front End (01.02)...................................................1-2-1

Front Wings ............................................................ 2-1

Specifications......................................................... 2-1

Maintenance.......................................................... 2-1

Front Wing.......................................................... 2-1

Body Closures (01.03) ...........................................1-3-1

Specifications.......................................................... 3-1

Doors .................................................................... 3-1

Boot Lid................................................................. 3-1

Bonnet................................................................... 3-1

Maintenance........................................................... 3-2

Doors .................................................................... 3-2

Removal.............................................................. 3-2

Installation .......................................................... 3-2

New Door Assembly .............................................. 3-3

Preliminary Hinge Setup ...................................... 3-3

Boot Lid................................................................. 3-4

Removal.............................................................. 3-4

Installation .......................................................... 3-4

Bonnet................................................................... 3-5

Removal.............................................................. 3-5

Installation / Realignment .................................... 3-5

Interior Trim (01.05)..............................................1-4-1

Specifications.......................................................... 4-1

Maintenance........................................................... 4-1

IP Trim................................................................... 4-1

Remove............................................................... 4-1

Installation Notes ................................................ 4-1

Roof Trim .............................................................. 4-2

Removal.............................................................. 4-2

Installation .......................................................... 4-2

Door Trim.............................................................. 4-3

Removal.............................................................. 4-3

Installation .......................................................... 4-4

Rear Trim............................................................... 4-5

Removal (Coupe)................................................. 4-5

Install (Coupe)..................................................... 4-6

Removal (Volante) ............................................... 4-6

Install (Volante) ................................................... 4-6

Boot Trim .............................................................. 4-7

Removal.............................................................. 4-7

Installation ............................................................. 4-7

Exterior Trim (01.08) .............................................1-5-1

Maintenance........................................................... 5-1

Side Trim ............................................................... 5-1

Removal.............................................................. 5-1

Installation .......................................................... 5-1

Sill Trim ................................................................. 5-2

Remove............................................................... 5-2

Installation .......................................................... 5-2

Mirrors (01.09) ......................................................1-6-1

Specifications ......................................................... 6-1

Maintenance........................................................... 6-1

Door Mirrors.......................................................... 6-1

Removal.............................................................. 6-1

Installation.......................................................... 6-1

Seating (01.10).......................................................1-7-1

Description............................................................. 7-1

Heated Seats ......................................................... 7-1

Seat Module .......................................................... 7-1

Specifications ........................................................ 7-1

Maintenance........................................................... 7-1

Front Seat .............................................................. 7-1

Removal.............................................................. 7-1

Installation.......................................................... 7-2

Seat Base Control Motors....................................... 7-2

Seat Module .......................................................... 7-2

Removal.............................................................. 7-2

Installation.......................................................... 7-2

Seat Module Calibration ........................................ 7-3

Rear Seats.............................................................. 7-3

Removal (Coupe) ................................................ 7-3

Installation (Coupe)............................................. 7-3

Removal (Volante) ............................................... 7-4

Installation (Volante)............................................ 7-4

Glass, Frame and Mechanism (01.11)...................1-8-1

Description............................................................. 8-1

Frameless doors ..................................................... 8-1

Specifications......................................................... 8-1

Maintenance........................................................... 8-1

Glass Regulator ...................................................... 8-1

Removal.............................................................. 8-1

Installation.......................................................... 8-2

Door Glass............................................................. 8-3

Removal.............................................................. 8-3

Installation.......................................................... 8-4

Door Glass Setup ................................................... 8-5

Rear Quarter Glass (Coupe) ................................... 8-6

Remove .............................................................. 8-6

Installation.......................................................... 8-6

Rear Quarter Glass (Volante).................................. 8-6

Remove .............................................................. 8-6

Installation.......................................................... 8-8

Instrument Panel (IP) (01.12) ................................1-9-1

Specifications ......................................................... 9-1

Maintenance........................................................... 9-1

IP .......................................................................... 9-1

Removal.............................................................. 9-1

Installation.......................................................... 9-3

Issue 2 February 2005 Workshop Manual 1-1-1

Handles and Lock Mechanisms (01.14).............. 1-10-1

Description ...........................................................10-1

Vehicle Key / Remote Transmitter.........................10-1

Central Locking System ........................................10-1

Remote Transmitter..............................................10-1

Fuel Filler Assembly..............................................10-1

Manual Boot Release............................................10-1

Boot Emergency Release ......................................10-1

Specifications........................................................10-2

Maintenance .........................................................10-2

Door Handle / Latch Unit.....................................10-2

Removal ............................................................10-2

Installation ........................................................10-3

Wipers and Washer System (01.16).................... 1-11-1

Headlamp Washing ..............................................11-2

Specifications........................................................11-2

Maintenance .........................................................11-2

Windscreen Wiper Motor.....................................11-2

Removal ............................................................11-2

Installation ........................................................11-4

Wiper Arms..........................................................11-5

Removal ............................................................11-5

Installation ........................................................11-5

Convertible Roof (01.17)..................................... 1-12-1

Description ...........................................................12-1

Specifications........................................................12-1

Maintenance .........................................................12-2

Roof.....................................................................12-2

Removal ............................................................12-2

Installation ........................................................12-3

Roof Material .......................................................12-3

Removal ............................................................12-3

Installation ........................................................12-5

Weather Seals ......................................................12-9

Removal ............................................................12-9

Installation ........................................................12-9

Roof Pump...........................................................12-9

Removal ............................................................12-9

Installation ......................................................12-11

Roof Module......................................................12-12

Removal ..........................................................12-12

Installation ......................................................12-12

Roof Lid Hydraulic Rams....................................12-12

Removal ..........................................................12-12

Installation ......................................................12-13

Bumpers (01.19) ..................................................1-13-1

Front Bumper........................................................13-1

Specifications .......................................................13-1

Maintenance........................................................13-1

Removal............................................................13-1

Installation ........................................................13-2

Rear Bumper.........................................................13-3

Specifications .......................................................13-3

Maintenance........................................................13-3

Removal............................................................13-3

Installation ........................................................13-5

Restraining Devices (01.20).................................1-14-1

Seat Belts ..............................................................14-1

Pre-tensioner and Load Limiting Systems ............14-1

Emergency Locking Retractor (ELR) .....................14-2

Automatic Locking Retractor (ALR) .....................14-2

Specifications .......................................................14-2

Airbag System .......................................................14-3

Airbag Deployment ..........................................14-3

Dual Inflation Technology..................................14-3

Driver airbag Module.........................................14-3

Passenger Airbag Module...................................14-3

Side Airbag Module ...........................................14-3

Clockspring .......................................................14-3

Restrains Control Module (RCM) ........................14-4

Impact Sensors ..................................................14-4

Specifications........................................................14-4

Maintenance........................................................14-4

Driver Airbag.....................................................14-4

Passenger Airbag................................................14-4

Side Impact Airbag ............................................14-5

Deployable Rollbars .............................................14-6

Specifications .......................................................14-6

Maintenance........................................................14-6

Rollbar Unit.......................................................14-6

Rollbar Sensor ...................................................14-8

1-1-2 Workshop Manual Issue 2 February 2005

Body Structure (01.01)




Overview

The all aluminium body underframe is bonded using an immensely strong hot-cured XD4600 red adhesive.

The rear quarter panels, roof and side mouldings are bonded to the structure using cold-cured 2810 MV adhesive. The curing cycle is improved by using a hot air impingement system. In addition, the roof panel is connected to the rear quarter panels through ultrasonic welds.

The composite front wings are bolted to the structure.

At no time should the body structure be subjected to temperatures in excess of 120°C (248°F).

01-01-020






Front End (01.02)

Front Wings

Specifications

1

2

Front End (01.02)


Maintenance

Front Wing

Repair Operation Time (ROT)

Item

Front Wing Renew

Removal

1. Disconnect the vehicle battery.

2. Remove the wing top nut.

Code

(LH) 01.02.KB

(RH) 01.02.LB

3

4

Wing Standard (mm)

Item

Nominal gap 3.5

Tolerance

1

±0.75

2

2.0

3

3.75

4

3.0

+0.5 / -0.0 ± 0.75 ±0.5

Flush

Tolerance

-0.0

±1.5

0.0

0.0

+0.0 / -0.5 ±1.5

-0.5

±0.5

Taper

Symmetry

N/A

N/A

Torque Figures

Description

Wing Top

Wing Top Single nut

Lower Rear

Slam panel

PCM Bracket

Bonnet Damper

8

8

10

25

Nm.

8 lbs / ft.

6

Tight with

‘Threadlock’

6

6

7

18

If using a two post vehicle lift, remove the screws that secure the rear section of the road wheel arch liner. Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly.

(Refer to ’Jacking Points’, page I-I-IX)

3. Remove the front road wheel and road wheel arch liner.


Front End (01.02)


4. Disconnect the side repeater lamp wiring harness plug.

7. Remove bolts (x3).

5. Disconnect the wing from the bumper (Refer to ’Front

Bumper’, page 1-13-1).

6. Remove the slam panel (bolts x12). Remove the front grill bolt (x2).

01-02-007


8. Loosen bolts (x2).

Installation

1. Place the wing to the body.

2. Locate:

• The wing top stud

Front End (01.02)


9. Lift from the rear lower edge to disengage the wing from the two loosened bolts. Pull the wing from the body.

• The rear lower wing to the loosened bolts

3. Install the wing lower edge clips and bolt.

4. Connect the wing to the bumper.

5. Install bolts to the wing top edge. Do not tighten.

Front bolt on each wing

The two lower rear wing bolts have the same bolt / washer arrangement.


Front End (01.02)


6. Install the slam panel.

01-02-007

7. Check wing alignment. Refer to specifications. Adjust if required.

8. Torque all wing fixings.

9. Connect the side repeater lamp wiring harness plug.

10. Install the road wheel and road wheel arch liner (Refer to ’Road Wheel Nut Torque Tightening’, page 4-5-7).

11. Connect the vehicle battery.



Body Closures (01.03)

Specifications

Doors

Boot Lid



1

2

Door Standard (mm)

Item

Nominal gap 3.5

Tolerance

Flush

Tolerance

1

±0.75

0.0

*2

3.00

±1.0

-1.0

3

3.00

4

3.75

±1.0 ± 0.75

-1.0

0.0

±1.5 / 0.0 +0.0 / -1.0 ±1.0 ±1.5

Taper

Symmetry

N/A

N/A

* Flushness blends to 0.0 at the rear quarter

* Gap blends to 3.5 at rear quarter

Torque Figures

Description

Hinge to Door

Hinge to Body

Door Striker plate

Nm.

47.5

36 lb. / ft.

33.5

26.5

Boot Standard (mm)

Item

Nominal gap

Tolerance

Flush

Tolerance

1

3.5

±0.75

-0.5

2

3.5

±1.0

N/A

+0.5 / -1.0 N/A

Taper

Symmetry

1 mm Max. across the length

1 mm Max. difference LH to RH

Torque Figures

Description

Hinge to Body

Bonnet

1

Nm

25 lb. / ft.

18


Bonnet Standard (mm)

Item

Nominal gap

Tolerance

1

3.5

±0.75

Flush

Tolerance

Taper

Symmetry

-0.0

±1.5

N/A

N/A

Torque Figures

Description

Hinge to Body

Workshop Manual

Nm

25 lb. / ft.

18

1-3-1



Maintenance

Doors

5. Lift the door off the support studs and withdraw the door enough to gain access to the door wiring harness plug. Disconnect the wiring harness plug.


Item

Remove and reinstall

Code

LH 01.03.EA

RH 01.03.FA

Removal

Warning

The doors are heavy. Removal is a two person operation.

Caution

Before removing the door ensure that the vehicle body work is sufficiently protected from possible damage.


2. Open the vehicle door.

3. Slightly loosen the door hinge lock screws (x2).

6. Withdraw the door from the vehicle and install on service tool (Refer to ’501-F111 (Door Service Trolley)’, page 20-1-8).

Installation

4. Remove part of the roadwheel arch liner to gain access to the door check rod. Disconnect the door check rod.

Warning

The doors are heavy. Replacement is a two person operation.

Caution

Before installing the door ensure that the vehicle body work is sufficiently protected from possible damage.

1. Place the door to the vehicle. Connect the door wiring harness plug.

2. Align the door to the upper and lower hinges. Install the door onto the hinges.

1-3-2

3. Connect the door check rod. Install the roadwheel arch liner.

4. Align the door. Manoeuvre the door to achieve correct gaps and flush (add / remove shims as required). Tighten the bolts. Do not torque.

Workshop Manual Issue 2 February 2005




Warning

Never touch the door lock linkage with electrical power available to the door. The window mechanism can move and trap hands, arms, etc. in door frame.

6. Check door alignment and closure of the door catch.

Adjust striker plate if required.

7. When satisfied with the door install - torque the hinge bolts.

• Hinge to Body - 36 Nm .

• Hinge to Door - 47.5 Nm .

New Door Assembly


Item

Remove and install

Code

LH 01.03.CB

RH 01.03.DB

Preliminary Hinge Setup

1. Install the door onto the hinges.

2. Place a weight of 16 kg (to compensate for weight of door windows, locks etc.) hanging from inner door skin as shown.

Weight and position are critical to accurately simulate weight and distribution of door furniture. Adjustment is difficult on a fully installed door.

3. If removed, install the front wing (Refer to ’Front Wing’, page 1-2-1).

4. Gently close the door. Check for an acceptable initial install.

5. Align the door. Manoeuvre the door to achieve correct gaps and flush (add / remove shims as required). Tighten the bolts. Do not torque.

6. Open the door and torque all hinge bolts. Remove the door weight.

• Hinge to Body - 36 Nm .

• Hinge to Door - 47.5 Nm .

8. Check for:

• Correct operation of all door lock functions.

• Correct operation and sealing of the door window.


7. Release the hinge locking screws and remove the door for installation of window, locks etc.

Workshop Manual 1-3-3



Boot Lid


Item


Code

01.03.BB

Removal

Warning

The boot lid is heavy. Removal / replacement is a two person operation.

1. Open the boot lid.

2. Remove the boot lid trim panel (Fir trees).

3. Disconnect the boot lid harness.

4. Lower the boot lid. Check for correct alignment and readjust if required.

5. Fully raise the boot lid. Torque the hinge bolts to 2 5

Nm .

4. Slightly loosen the bolts (x4) that secure the boot lid to the boot lid hinges.

5. Support the boot lid. Remove the hinge bolts.

6. Withdraw the boot lid from the vehicle.

Installation

1. Align the boot lid to it’s hinges. Install bolts (x4) sufficiently to manoeuvre the boot lid on it’s hinges.

Gently lower the boot lid rear edge, ensure the front corners do not touch the rear wings.

2. Align the boot lid front edge centrally in the boot aperture. Manoeuvre as required to achieve correct gaps.

3. Partially raise the boot lid and ‘nip’ up the hinge bolts.

6. Gently close the boot lid. Check for correct engagement of the boot latch.

Adjust the boot latch if required. Torque the boot latch bolts, to 9 Nm .

7. Connect the boot lid wiring harness plugs.

8. Fully close the boot lid.

Check for correct operation of the boot release switch and remote transmitter boot lid enable.

9. Install the boot lid trim.




Bonnet


Item


Code

01.03.AB

Removal

Warning

The bonnet is heavy. Removal is a two person operation.

1. Open the bonnet.

2. Disconnect the windscreen wash pipe.

3. Slightly loosen the bolts (x4) that secure the bonnet to the hinge.

4. With the bonnet supported, disconnect the gas struts and remove the hinge bolts (x4).

N M

2. Partially raise the bonnet. ‘Nip’ up one hinge bolt either side.

3. Lower the bonnet. Check for correct alignment.

Readjust if required.

5. Withdraw the bonnet from the vehicle.

Installation / Realignment

Warning

The bonnet is heavy. Replacement is a two person operation.

1. Align the bonnet to it’s hinges. Install bolts (x4) sufficiently to manoeuvre the bonnet on it’s hinges.

Gently lower the bonnet. Adjust so that the corners do not touch the wings at the front and rear. Align the bonnet front edge centrally in the aperture.

4. Fully raise the bonnet. Torque all hinge bolts to 25 Nm .

5. Install the bonnet gas struts.

6. Gently close the bonnet. Check for correct engagement of the bonnet latch. Adjust if required to achieve the flush specification.

• Turn the nut anti-clockwise to raise or clockwise to lower the bonnet catch until the bonnet is flush with the wings when closed.


7. Fully close the bonnet. Check for correct operation of the bonnet release lever.





Interior Trim (01.05)




This section covers removal and installation of the interior mouldings and trim panels. In many instances, one component overlaps another component. If this condition is found, it will be necessary to loosen or remove the overlapping component before removal, to prevent damage to either component.

Specifications

Torque Figures

Description

Door Handle

Seat Belt Mounts

Maintenance

IP Trim

If required, removal of the IP trim can be achieved while the IP is in the vehicle.

Remove

1. Panel (1)- Pull off.

2. Hood (2) - Pull off.

3. Panel (3) - Pull off.

4. Panel (4) - Pull off. Disconnect the air temperature pipe.

5. Panel (5) - Front, screws (x3)

6. Glove box.

6.1 Pull of the outer trim panel.

Disconnect the glovebox release switch wiring harness plug.

6.2 Release the damper cord.

6.3 Remove screws (x3) from the glovebox door hinge. Remove door.

6.4 Remove screws (x4) from the sight shield. Remove the sight shield and glovebox.

7. Panel, Airbag (7).

Nm

9

35

6.1

6.3

lb. / ft.

6.5

26

9

Caution

Withdraw the airbag panel carefully. The airbag panel can crease if forced out.

7.1 Remove screws (x3).

7.2 Lift from the front edge. Withdraw out of clips (x3).

8. Remove the airbag.

Warning

When removed, place the airbag in a sercure container to prevent personal injuries if the airbag activates.

8.1 Disconnect the wiring harness plugs (x2).

8.2 Remove bolts (x4). Withdraw the airbag.

9. Panel (9) - Screws (x2), then pull off.

10. Panel (10) - Screws (x4).

10

7

6.4

3

2

1

4

5

11. If required, remove the center stack.

11.1 Pull off the veneer panel (Service tool No. TBA).

Disconnect the wiring harness plugs.

11.2 Remove the speaker grill - Screws (x2).

11.3 Remove the center panel (Radio etc.) - Screws (x4)

11.4 Remove the center stack - Screws (x6).

11.5 Remove the media player - Screws (x2). Disconnect the wiring harness plugs.

Installation Notes

The panels, etc., are best replaced in the order they were removed. Note the following:

1. When installing the glovebox shield ensure that the tab in the top centre locates into the slot in the substrate.




Roof Trim

Removal

1. Remove (pull away) the cant rail.

The cant rail is held in by

‘FirTrees’.

The front of the cant rail is held in place by the ‘IP’. Pull the cant rail away from the back first then pull the front out from the ‘IP’.

2. Remove the interior mirror

(screw x1).

3. Remove the reading lamp pod

(clips x2, screw x1, wiring harness plugs x2)

4. Remove the sun visors (screws x2 (x2).

The front headlining will fall away.

5. Remove the headlining.

Held in place with ‘FirTrees’ and two velcro panels at the rear.

Installation

1. Install the roof lining.

2. Install the front headling.

While holding the front headling in place install the sun visors.

3. Install the interior mirror.

4. Install the cant rails.

Place the front of the cant rail into location at the IP, and work towards the rear, locating the ‘FirTrees’.


Door Trim

Removal

1. Lower the door glass fully.

2. Disconnect vehicle battery.

3. Release the door handle (Bolts x2).



5. Remove the door mirror cheater panel.

6. Remove outer chrome waist rail trim.

4. Remove the door handle trim plate and disconnect the release cable.

7. From the outside remove screws (x2).




8. Remove the door trim panel screws (x6). Withdraw the door trim panel to gain access to the window and mirror switches. Disconnect the switches.

Installation

1. Place the door trim panel to the door and connect the wiring harness plugs.

2. Install the door trim panel screws (x6).

3. Install screws (x2).

1-4-4

4. Install the outer weather seal strip.

5. Install the door mirror cheater panel.

6. Install the door pull

6.1 Connect the door inner release cable.

6.2 Install the door pull trim plate.

6.3 Install the door handle. Torque to 9 Nm .



Rear Trim

Removal (Coupe) 6

1

2

3



Issue 2 February 2005 Workshop Manual

7

1-4-5



9

Install (Coupe)

Install the trim in reverse order to remove.

Torque seat belt mounts to 35 Nm .

Removal (Volante)

1. Remove the seat bases.

2. Remove the seat backs.

2.1 Pull off and up to remove the head support.

2.2 Remove screws (x2 (Bottom) and x2 (top)).

3. Remove the door ‘kick’ plates.

3.1 Remove screws x2.

3.2 Remove screws x4. Withdraw the ‘kick’ plate.

3.3 Repeat for the second ‘kick’ plate.

4. Remove the rear seat belt top mounts.

5. Remove the rear quarter panels.

Screws (x2 (lower)), screw (x1 (upper)) and pull the front away (firtrees). Repeat for the second quarter panel.

6. Remove the 1st trim panel of the rear console.

Pull up at the front and lift off.

7. Remove the 2nd trim (speaker) panel of the rear console.

Remove the screws (x2).

8. Remove the 3rd trim panel of the rear console.

Remove the screws (x2) from the bottom and screws

(x2) from the rear of the ROPS closure panel.

9. Remove the rear center console.

Install (Volante)

1. Install the rear center console.

2. Install the center console trim panels.

3. Install the rear quarter panels.

4. Install the door ‘kick’ plates.

5. Install the seat belt top mounts. Torque to 35 Nm .

6. Install the seat backs and bases.


Boot Trim

Removal

1. Remove the boot weather seal.

2. Remove the boot trim in the following order detailed above.



Item Fixings

1.

Fir trees

2.

Fir trees

3.

Fir trees

4.

Fir trees

5.

Fir trees

Item Fixings

6.

Fir trees

7.

Fir trees

8.

Fir trees

9.

Fir trees

10. Fir trees

11. Fir trees

Installation

The rear trim is best installed in reverse order of the removal procedure.





Exterior Trim (01.08)




Maintenance

Side Trim

Removal

1. Remove the trim panel.

1.1 Remove the top / bottom screws (x2). Remove the outer panel.

Pull the top of the outer panel away from the vehicle and slide it forward.

5. Remove the chrome trim screws (x18). Remove the chrome trim.

Support the trim as it is removed.

Screws

Front

01-01-026

Screws

Rear

2. Pull the inner trim panel away from the vehicle.

Pull the inner trim panel downwards.

3. Remove the door sealing rubber.

4. Remove the rear ¼ glass and seal.

Installation

1. Install the chrome trim.

2. Rear ¼ glass seal and glass.

3. Install the mirror trim panels. Insert the section of door sealing rubber as the inner and outer trim panels are installed.

The lower screw, screws into fibre glass. Ensure that the lower screw is screwed into the original threads.

4. Install the door sealing rubber.




Sill Trim

Remove

1. Remove the front and rear road wheel arch liners sufficiently to gain access.

2. Remove (x3) screws and (x2) scrivnuts.

5. Unclip the sill trim from the vehicle body. Withdraw the sill trim.

Installation

1. Offer the sill trim to the vehicle.

2. Install the sill trim using 3 clips (front x1, rear x2).

3. Install the door aperture screws (x3).

4. Install (x3) nut and bolt (front x2, rear x1). Torque to 6

Nm .

3. Remove (x3) nut and bolt (front x2, rear x1).

4. Remove the door aperture screws (x3).


5. Install (x3) screws and (x2) scrivnuts.

6. Install the front and rear road wheel arch liners.







Mirrors (01.09)



Mirrors (01.09)

Specifications

Torque Figures

Description

Mirror Mounting

Maintenance

Nm

20-25 lb. / ft.

15-18.5


Item


Code

LH 01.09.AB

RH 01.09.BB

Door Mirrors

Removal

1. Remove the door trim panel (Refer to ’Door Trim’, page

1-4-3).

2. Remove the door mirror ‘cheater’ panel (pull off).

Installation

1. Place the mirror into position. Install bolts (x2).

The spring washer goes between the mirror bracket and the door. On the front bolt of each mirror, ensure that the plain washer goes between the bolt head and the mirror bracket.

Torque to 20-25 Nm . As the front bolt is tightened ensure a flush install with the door.

The front bolt hole on each mirror has an enlarged hole, to allow a small amount of adjustment.

2. Connect the wiring harness plug.

3. Install the door mirror ‘cheater’ panel.

4. Install the door trim panel (Refer to ’Door Trim’, page 1-

4-3).

3. Disconnect the wiring harness plug.

4. Remove bolts (x2) and withdraw mirror.


Mirrors (01.09)



Seating (01.10)



Seating (01.10)

Description

The front seats are installed with the following features:

• Integral side airbags

• Head restraints

• Safety belt buckle / pretensioner

• Electrically adjustable seat positioning and lumbar support

• Heated seat (optional)

Heated Seats

The heated seat system comprises:

• Heated seat switches

• Backrest heater element

• Cushion heater element and thermostat

The heated seat function permits the electrical heating of the seat back and cushion on the driver and front passenger seats. The heating system of each seat is selected by separate switches located on the inside of each seat base.

Once the heated seat function has been activated, it will operate until one of the following conditions have been satisfied:

• A fixed period of time has expired (10 minutes)

• If the engine is not running and the ignition key is removed

• A malfunction is detected by the heated seat module

Confirmation that the heated seat function is active is indicated by the illumination of an amber light in the instrument cluster.

Seat Module

The seat module is located under the front edge of the seat.

Specifications

Maintenance


Item


Code

LH 01.10.AA

RH 01.10.BA

Front Seat

Removal

The front and rear seat rail mountings are positioned on four washers. Ensure the washers are collected during seat removal.

1. Motor the seat forward.

To power the drivers seat the ignition switch must be in the

‘II’ position

2. Remove bolts (x2) that secure the rear of the seat rails.

3. Motor the seat to the rear. Remove bolts (x2) that secure the front of the seat rails.

Bolt

Torque Figures

Description

Seat mountings

Seat Belt Mounts

Nm.

lb. / ft.

20-25 15-18.5

35 26

01-01-028

4. Tip the seat rearwards and disconnect the wiring harness plugs (x4).


Seating (01.10)


5. Remove the seat assembly.

Installation

1. Place the seat in the vehicle.

2. Connect the wiring harness plugs (x4).

3. Place the two spacers in position. Locate the seat over the seat mountings.

Spacer

Seat Base Control Motors

The seat base control motors are an integral part of the seat base.

Seat Module

Removal

1. Remove seat from vehicle.

2. Remove the seat module. The seat module is held in by fir trees (x4).

Installation

4. Install the front bolts, power the seat forwards and install the rear bolts. Torque bolts (x4) to 20-25 Nm .

1. Remove seat from vehicle.

2. Remove the seat module. The seat module is held in by fir trees (x4).


Seat Module Calibration Rear Seats

This mode allows the seat module to learn its position. The seat needs to know exactly where it is to electronically prevent seat movement into certain areas within the mechanical seat movement envelope.

Removal (Coupe)

1

Once the seat has been put in to calibration mode it will remain in this mode until it as been re-taught its position.

There is no physical indication that the seat is in calibration mode, the seat could be left in this mode for some time before a user notices.

There is nothing wrong with the seat being in calibration mode for extended periods of time, it will only be apparent to the user when a rearward / downward seat movement is required.

The seat must be calibrated before rearward / downward movement is allowed.

Calibration mode is activated by a diagnostic command or by switching on the BDS while holding up the seat height switches.

1. With the Interior light relay ‘On’, i.e. door open, move the seat forwards or backwards, then disconnect the vehicle battery (either physically or via the BDS) before the interior light relay switches ‘Off’ (five minutes unlocked, 30 second locked).

The seat module is now in calibration mode.

The seat will not go into calibration mode if the interior light relay has been allowed to switch off since the last seat movement.

2. Drive the seat fully forward, allow the motors to stall against the seats mechanical end stops.

3. Drive the seat fully upwards, allow the motors to stall against the seats mechanical end stops.

The seat up switch needs to be operated front up then back up.

2

Installation (Coupe)

Install the rear seat in reverse order.


When each end stop is reached the motor will know where it is on that particular axis, the seat will only allow forward of upward movement until each axis position has been learnt

4. The seat module is now out of calibration mode.

Seating (01.10)



Seating (01.10)


Removal (Volante)

1. Remove the seat bases. Pull off.

1

2. Remove the headrest panel. Pull off at the top and pull up to remove.

3. Remove screws (x4) that secure the seat back. Withdraw the seat back.

Installation (Volante)

Install the rear seat in reverse order.



Glass, Frame and Mechanism (01.11)




Description

Power to the door window regulator motor is available when the ignition switch is at position ‘0’ and is supplied, through a thermal cut-out, to the left and right window switches. The switches are double pole earth so that the current through a window regulator motor may be switched in either direction to raise or lower the glass.

Frameless doors

To avoid damaging the body seals during door opening, the door glass must be lowered before the door can be opened.

This function is controlled by the door modules.

The door module senses the rotation of the latch claw as the door opens, the door module then drives the door window regulator motor briefly to lower the door glass until it clears the glass seals. After closing a door, the window regulator motor operates to raise the door glass to seat against the body seals.

Specifications

Maintenance

Glass Regulator


Item

Door Glass Motor

Door Glass Regulator

LH

RH

LH

RH

Code

01.11.LH

01.11.RH

01.11.FB

01.11.GB

Removal

1. Remove the door trim panel (Refer to ’Door Trim’, page

1-4-3).

2. Power the door glass to a ‘half open’ position.

To enable access to the screws which secure the door glass.

Torque Figures

Description

Door regulator

Glass grip screws

Door Handle

Rear quarter regulator

Seat belt and speaker plate

M6

M10

Nm

9

10-15

5-6 lb. / ft.

7

7.5-11.5

4-4.5

9

M6 9

7

7

M10 10-15 7.5-11.5

8-10 6-7.5


4. Remove the door glass grip screws. Withdraw the door glass from the door.

5. Release the window regulator motor from the door.


6. Release nuts (x4). Withdraw the window regulator from the door.




2. Install nuts. Torque nuts (x3) M6 to 9 Nm . and (x1) M10

10-15 Nm .

Installation

1. Install the window regulator assembly.

3. Install the window regulator motor (screws x3). Torque to 5-6 Nm .

Ensure the window regulator cable remains in place during installation.

Ensure that the wiring harness running by the adjuster bolt locates above the adjuster bolt.

Ensure the wiring harness does not get ‘trapped’.

Window regulators are ‘Handed’ (L/H and R/H). The adjuster is always located at the bottom rear of the door.

Place the window regulator unit into position and locate the four mountings through the door inner skin.

Ensure the window regulator motor wiring harness clips to the window regulator motor.

4. Install the weather strips (x2). If removed.

5. Lower the door glass into the door.

Insert the front end of the door glass first then lower the door glass and insert the rear end.

5.1 Locate the rear end of the door glass into it’s grip.

5.2 Locate the front end of the door glass into it’s grip.

The front grip has to be located by feel alone.

5.3 Line up the holes in door glass with the openings in the grips (x2).

6. Install the grip screws (x2). Do not tighten.

The grip screws are, apart from length, the same as the latch unit screws (x3). Do not install the, shorter, latch unit screws to the grips.




7. Align the door glass. Ensure the following when installing a new door glass.

• The glass is flush with the mirror trim edge

Door Glass


Item

Door Glass Renew

Door Glass Adjust

Removal

1. Remove the door outer weather strip.

LH

RH

LH

RH

Code

01.11.BB

01.11.HB

01.11.CD

01.11.JD

• The two dots on the door glass are equal distance from the door edge.

F ront

2. Release the door handle (Bolts x2).

R ear

8. Install the door module (if removed).

Warning

Danger of hands being trapped in the window regulator mechanism. Do not put your hands through the door glass aperture with the door harness connected.


10. Check alignment of the door glass to the door seals.

If required, disconnect the power to the door and realign the door glass.

Once satisfactory alignment is achieved, torque both grip screws to 5-6 Nm .

11. Install the door mirror. If removed.

12. Install the outer weather strip. If removed.

13. Install the door trim.




3. Remove the door handle trim plate and disconnect the release cable.


6. Remove the door glass grip screws. Withdraw the door glass from the door.

Installation

1. Lower the door glass into the door.

Insert the front end of the door glass first then lower the door glass and insert the rear end.

1.1 Locate the rear end of the door glass into it’s grip.

1.2 Locate the front end of the door glass into it’s grip.

The front grip has to be located by feel alone.

1.3 Line up the holes in door glass with the openings in the grips (x2).

2. Install the grip screws (x2). Do not tighten.

The grip screws are, apart from length, the same as the latch unit screws (x3). Do not install the, shorter, latch unit screws to the grips.

3. Align the door glass. Ensure the following when installing a new door glass.

• The glass is flush with the mirror trim edge

4. While looking through the access holes provided by removing the door handle, power the door glass to show the glass grip screws.

• The two dots on the door glass are equal distance from the door edge.

F ront

1-8-4 Workshop Manual

R ear




4. Connect the inner release cable and install the door handle trim plate.

6. Install the door outer weather strip.

5. Install the door handle Torque bolts (x2) to 9 Nm .


8. Check that the door glass operates correctly. Perform the ‘Door glass Setup’ procedure.

Door Glass Setup

1. Sit in the driver’s seat.

2. Ensure both doors are closed and switch the ignition to

‘0’.

3. Press firmly and hold the window switch until the window is at the maximum down position. Continue to hold the button for 5 seconds then release.

4. Pull back and hold the window switch until the window is in the maximum up position. Continue to hold the switch for a further 5 seconds, then release.

5. The window is now reset. Repeat for the second window.




Rear Quarter Glass (Coupe)

5. Remove the seat belt top mount.


Item

Rear Quater Glass Renew LH

RH

Code

01.11.LB

01.11.MB

Remove

1. Pull the door sealing rubber away from the rear quarter glass.

2. Remove screws (x2).

3. Pull the rear quarter glass away from the body.

Installation

1. Install the rear quarter glass.

2. Install screws (x2).

6. Remove the rear 1/4 panel.

6.1 bolts x2

6.2 fir trees x3

3. Install the door sealing rubber.

Rear Quarter Glass (Volante)


Item

Rear Quater Glass Renew LH

RH

Remove

1. Power the front seat forward.

2. Lower the convertible roof.

3. Remove the rear seat back and seat base.


Code

7. Remove bolts (x10) that secure the seat belt and speaker plate. Withdraw the plate.


8. Disconnect the wiring harness plugs (x2).



11. Remove the two glass securing screws and withdraw the glass.

9. Disconnect the glass regulator wiring harness plug.

12. Power the glass regulator down.

13. Remove the nuts (x2) that secure the bottom of the glass regulator. Pull the bottom of the glass regulator to reveal bolts (x2). Remove the bolts (x2).

10. Power up the glass regulator to line up the two glass securing screws through the two holes in the top bracket.


14. Remove the nut from the top of the glass regulator and withdraw the glass regulator.




Installation

1. Install the glass regulator. Install the nut to the top of the glass regulator. Do not torque.

7. Adjust the lower mountings (2) to achieve the 5 mm gap between the glass and the edge of the vehicle body.

2. Install the lower bolts (x2). Push the bottom of the glass regulator into place and install nuts (x2).

3. Power up the glass regulator to line up the two glass securing screw holes through the two holes in the top bracket.

4. Install the glass. Secure with screws (x2). Do not torque

5. Remove the outer chrome trim.

6. Torque the upper nut (1) of the glass regulator to 9 Nm .

1-8-8

1

2

10-15 Nm.

When adjusted, torque the outer nuts to 10-15 Nm .

8. Secure the qurater glass. Torque the screws to 5-6 Nm .

9. Connect the glass regulator wiring harness plug.

10. Check glass alignment.

10.1 Raise the convertible roof.

Check the alignment of the glass to the door glass.

Check the alignment of the glass with the convertible roof seals.

11. Install the seat belt and speaker plate. Torque bolts to 8-

10 Nm .


13. Install the rear 1/4 panel.

14. Install the seat belt top mount. Torque bolt to 35 Nm .

15. Install the rear seat back and seat base.

16. Power the front seat forward.


Instrument Panel (IP) (01.12)




11. Remove the A/C evaporator pipes.

Cap the open ends of all pipes.

Specifications

Torque Figures

Description

IP Mountings

Glue pot bolts

Blower motor to bulkhead

Maintenance

IP

Nm

22.5

lb. / ft.

17

8 6

10-14 7.5-10.5


Item

IP Renew

Removal

Code

01.12.AA

1. Evacuate the A/C system (Refer to ’Air Conditioning (A/

C) System (12.03)’, page 12-3-1).

2. Remove both doors (Refer to ’Body Closures (01.03)’, page 1-3-1).

3. Remove both seats (Refer to ’Seating (01.10)’, page 1-7-

1).


5. Remove the passenger side road wheel and arch liner.

6. Remove the cant rails (pull off) (Refer to ’Roof Trim’, page 1-4-2).

7. Remove the steering column (Refer to ’Steering Wheel’, page 11-5-1).

8. Remove the rear trim panels (Refer to ’Rear Trim’, page

1-4-5). Including the centre arm rest and surround.

9. Remove / Pull back the front carpet (allowing access to the IP mounts and wiring harness plugs).

10. Remove the engine bay fusebox and fusebox mounting bracket.

12. Disconnect the wiring harness plugs.

Remove the bonnet pull lever to gain access to L/H harness plugs.




13. Manual Gearbox Only.

Remove the gear-lever.

13.1 Disengage the manual shift control cables (x2).

13.2 Remove screws (x6) that secure the gear lever pivot block. Withdraw the gear lever.

14. Remove, L/H and R/H, bolts securing the IP to vehicle.

14.1 Bolts (x6 L/H and R/H).

14.2 Bolts (x2).


14.3 Glue pot bolts (x2).

14.4 Bolt (x1) from heater blower.



17. Move the IP rearwards sufficient to gain access to the heater pipes. Disconnect the heater pipes.

One person to open the spring clip from inside the vehicle and one person to pull the pipes off from inside the engine bay.

Caution

Take care not to let coolant drip onto the vehicle carpet.

15. Remove the window defrost air duct screws (x3 each side).

To prevent the screws falling down the air ducts - place a rag / cloth into the air ducts.

15.1 Disengage clips (x3) from each window defrost air duct) to release the window defrost air ducts from the IP.

15.2 Remove screws (x3 for each duct).

16. Manoeuvre the service tool (Refer to ’501-F116 (IP

Removal)’, page 20-1-8) into position, through the passenger side opening, and attach to the IP.

18. Withdraw the IP from the vehicle.

As the IP is withdrawn from the vehicle the evaporator drain pipe will come with it.

Take care not to break the blower motor bracket when manoeuvring over the vehicle tunnel.

Installation

1. Manoeuvre the IP, attached to service tool, through the passenger side opening.

2. Place the A/C Evaporator drain pipe through the opening provided.

Ensure A/C breather pipe is secure and correctly located. It is not accessible once the IP is installed.

3. Install the heater pipes.

4. Raise the IP and locate into position.

5. Install the following bolts

5.1 Bolts (x6 (L and R/H)). Do not torque.




5.2 Install bolts (x2 L and R/H). Do not tighten.

6.3 Bolts (x2 L and R/H). Torque bolts to 22.5 Nm.

5.3 Install the glue pot bolts (x2). Do not tighten.

7. Install the heater blower to the bulkhead bolt. Torque to

10-14 Nm.

6. Torque the bolts in the following order.

6.1 Bolts (x6 (L and R/H)).

Torque bolts (1) to 22.5 Nm

Torque bolts (2) to 22.5 Nm .

6.2 The glue pot bolts (x2). Torque bolts to 8 Nm .

1-9-4

8. Connect the wiring harness plugs.

If removed, install the bonnet pull lever.

9. Install screws (x3 each) that secure the window defrost air ducts.

10. Engage clips (x3) for each window defrost air duct vent panel.

11. Install the steering column (Refer to ’Steering Column’, page 11-3-1).

Note the steering rack to steering column position from removal.

12. Install the cant rail (Refer to ’Roof Trim’, page 1-4-2).

13. Connect the A/C pipes.

14. Install the fusebox mounting bracket, fusebox and fusebox wiring harness blocks.

15. Install the rear trim (Refer to ’Rear Trim’, page 1-4-5), front carpets and centre arm rest.


Install the gear-lever.

17. Install the road wheel arch liner.

18. Install the road wheels (Refer to ’Road Wheel Nut

Torque Tightening’, page 4-5-7).

19. Install the seats (Refer to ’Seating (01.10)’, page 1-7-1).

20. Install the doors (Refer to ’Body Closures (01.03)’, page

1-3-1).


22. Charge the A/C system (Refer to ’Air Conditioning (A/C)

System (12.03)’, page 12-3-1).


Handles and Lock Mechanisms (01.14)




Description

Vehicle Key / Remote Transmitter

The vehicle key operates the ignition and the door lock, the remote transmitter operates the central locking and alarm systems.

Do not leave them in the vehicle .

Central Locking System

The Central Locking system consists of lock actuators in both doors, the boot and the fuel flap. Central locking control is through the door modules.

Each lock actuator incorporates a microswitch which signals a change of state when any motor runs to drive the actuator.

The microswitches are of the change over type and provide an earth for lock / unlock signals to the door module.

Fuel Filler Assembly

Manual Boot Release

In the event of a total loss of vehicle power the boot can be opened by pulling the manual boot release handle.

The boot will remain locked or will be unlocked simultaneously with the doors dependant on the boot lock position. The boot lock can be enabled at any time using the remote transmitter irrespective of the Central Locking status.

Remote Transmitter

The remote control system consists of a transmitter and an antenna (radio frequency system). The remote control transmitter for the radio frequency system will operate without the transmitter being directed at the vehicle. The normal range between the transmitter and the antenna is up to 5 meters. Before the remote control system can be used, each transmitter must be initialized to the vehicle. A maximum number of four transmitters can be initialized to any vehicle. All remote transmitters must be initialized at the same time.The keyless entry / remote operated locks will not operate when the ignition key is in the ignition switch.

(A) Lock - One step vehicle locking and alarm enable.

Remove the LH rear seat base and undo the two knurled bolts that secure the cover. Remove the cover and pull the boot release.

Boot release assembly

Image to follow

Boot Emergency Release

The boot can be opened from inside the boot by pulling the luminous emergency release handle.

The vehicle will deadlock after 25 seconds.

(B) Un-lock - One step vehicle unlocking or two step vehicle unlocking and alarm disable.

(C) Boot Open - Press to enable the boot catch.

(D) Panic Alarm - Activates / deactivates the panic alarm.

(E) Approach Light - Activates the front and rear side lights.




Specifications

Torque Figures

Description

Door handle

Latch

Maintenance

Door Handle / Latch Unit


Item

Door Catch and Outer Lock

Nm

5

9 lb. / ft.

4

7

Removal


2. Remove the door handle (Bolts x2).

LH

RH

Code

01.14.MB

01.14.NB

4. Remove the door trim (Refer to ’Door Trim’, page 1-4-

3).

5. Remove the door glass and regulator (Refer to ’Glass

Regulator’, page 1-8-1).


3. Remove the door handle trim plate and disconnect the inner release cable.

7. Disconnect the outer release cable from the outer handle and feed the inner release cable back through the door.

Take care not to break the cable mounts.




Installation

1. Install the outer door handle.

The outer door handle is reversible (installs to L/H and R/H).

Caution

Ensure the Inertia block is in the ‘Floating’ position.

Ensure that the fir tree on the release cable is removed.

8. Remove the lock and latch assembly.

8.1 Remove the latch screws (x3).

Secure with nuts (x3). Torque to 5 Nm .

Do not over tighten. If over tightened the studs may pull from their mounts.

8.2 Remove the lock lower bolt and loosen the top nut.

8.3 Rotate and withdraw the lock along with latch assembly.

9. Remove the nuts (x3) from the outer handle. Withdraw the outer handle from the door.




2. Connect the outer, inner and lock cables to the latch.

Insert the lock and latch assembly into position. Feed the inner cable through the hole provided in the door.

Do not push the inner cable when it is hanging from the door. This may disconnect the link at the latch end.

4. Install the latch (screws x3). Torque to 9 Nm .

5. Install the outer release cable to the outer release handle.

Ensure that both the release and lock cables locate behind the lock and barrel unit top nut (rear of door).

Ensure that the fir tree on the release cable is installed.

3. Install the lock.

3.1 Locate the barrel through the door and rotate the lock into position.

3.2 Install nut on lower mount.

3.3 Tighten both nuts.


7. Install the door glass and regulator (Refer to ’Glass

Regulator’, page 1-8-1).

8. Install the door trim and the inner release handle (Refer to ’Door Trim’, page 1-4-3).

9. Connect the vehicle battery. Check operation of the door latches.


Wipers and Washer System (01.16)




The wipers and washer system consists of the following components:

• Wipers and washers

• Mounting arm and pivot shaft

• Wiper motor

• Reservoir and washer pump

• Headlamp washing system

The wipers have a two speed control (low and high) and an intermittent wipe mode. The wipers will park automatically irrespective of their position when the ‘Off’ position of the ignition or control switch is selected or the bonnet is opened.

Within the wiper and washer system the following features can be attained:

• Adjustable interval intermittent wiping

The intermittent wiping has six speed settings, 3, 6, 9, 12, 15, 18 seconds.

• Programmable wash and wipe sequences

The programmable wash and wipe sequence is driver controlled.

With a depression of the wash / wipe switch between 40 milliseconds and 1.2 seconds the wash pump will be activated for a duration of 1.2 seconds. When the wash/wipe switch is depressed for longer than 1.2 seconds the wash pump will be activated for the duration of switch depression, a 10 second duration is the maximum available.

The wiping system is automatically activated with a depression of the wash switch of more than 0.5 seconds. If the wash switch is only pressed for 0.5 seconds or less then only the water pump will operate.




Headlamp Washing

The headlamp washers operate once per ignition cycle and are activated the first time the window washers are operated.

Headlamp washing is only available when the headlamps are switched on.

Specifications

Torque Figures

Description

Wiper link to wiper motor

Wiper motor mounting bolts

Wiper assembly plate M6 Torx

M6 bolt

Nm lb. / ft.

35-42 26-31

7-10 5.5-7.5

6 4.5

8 6

Brake servo nuts

Brake master cylinder nuts

Wiper arm (Driver)

Wiper arm (Passenger) M10

M6

Maintenance

Windscreen Wiper Motor

21-24 15.5-18

25 18.5

17

24

6

13

18

4.5


Item

Wiper Motor Renew

Removal

Code

01.16.HB


2. Remove the inlet manifolds (Refer to ’Inlet Manifold’, page 3-2-7).

3. Remove the wiper arms. Note the position of the wiper arms on the glass for installation.

Do not remove the nut that secures the idle arm to the wiper spindle. Remove the 4 bolts securing the idle arm mounting plate.

Image to follow

4. Remove the wiper box to scuttle panel bolts (x6).




5. Remove the brake master cylinder. Lay the master cylinder to one side.

8. Remove the wiper assembly mounting bolts and allow the wiper assembly drop sufficiently to access the wiper motor bolts.

01-6-014

6. From inside remove the brake booster fixings. Allow the brake booster to drop slightly.

7. Disconnect the engine breather hose from the rear of the camshaft cover.

9. Remove the wiper motor bolts (x3).




10. Disconnect the wiper linkage from the wiper motor (bolt x1). Withdraw the wiper motor.

3. Install the wiper assembly plate

3.1 Torque bolts to 8 Nm .

Installation

1. Connect the wiper linkage to the wiper motor (bolt x1) using service tool (Refer to ’501-112 (Wiper Linkage to

Wiper Motor)’, page 20-1-8). Torque nut to 35-42 Nm .

3.2 Torque bolt to 6 Nm .

2. Install the wiper motor bolts (x3).

Torque bolts to 7-10 Nm .

4. Connect the engine breather hose to the rear of the camshaft cover.

5. From inside the vehicle install the brake servo fixings.

Torque to 21-24 Nm .

6. Install the brake master cylinder. Torque to 25 Nm .

7. Install the wiper box. Torque bolts to 7-10 Nm .




8. Install the wiper arms. Position the wiper arms as per their position on removal.

Passenger Arm

Torque M10 nut to 24 Nm.

Torque M6 (x4) nuts to 6 Nm.

Driver Arm

Torque M8 nut to 17 Nm .

Installation

1. Install the wiper arms. Position the wiper arms as per their position on removal.

Passenger Arm

Torque M10 nut to 24 Nm.

Torque M6 (x4) nuts to 6 Nm.

Driver Arm

Torque M8 nut to 17 Nm .

9. Install the inlet manifolds (Refer to ’Inlet Manifold’, page

3-2-7).


Wiper Arms


Item

Wiper Arm Renew LHF

RHF

Code

01.16.KG

01.16.LB

Removal

Note the position of the wiper arms on the glass for installation.

Do not remove the nut that secures the idle arm to the wiper spindle. Remove the 3 bolts securing the idle arm mounting plate.

1. Remove the following screws and nuts.


01-01-169a





Convertible Roof (01.17)




Description

The convertible roof system comprises an electrically driven hydraulic pump and six hydraulic rams, four for raising and lowering the roof and two for raising and lowering the tonneau cover. The pump is powered via either the 'Roof Up' or

Roof Down' relay. Two further pairs of change-over relays power the rear quarter windows (one pair for each window).

The roof hydraulic pump is protected by a 30A fuse.

The Roof control module is actuated by the roof switch on the centre console and controls the operation of both the roof and rear quarter window circuits. They can only be operated in a pre-programmed manner.

Header Rail

1st Cross Bar

2nd Cross Bar

3rd Cross Bar

Specifications

Torque Figures

Description

Pump plate

Module plate

Roof Mountings

Nm.

7-10

7-10 lb. / ft.

5.5-7.5

5.5-7.5


Tension Bow

1-12-1



Maintenance

Roof

Removal

Warning

Do not place any objects on the top of the deployable rollbar covers behind the rear seat backs.

6. Manually raise the tension bow to 90°.

For access to the hydraulic pipes and wiring harness plugs.

With the roof in the raised position and the tension bow in the 90 ° position the hydraulic rams have the minimum amount of hydraulic oil in them.

Warning

Do not allow any person to sit on the deployable rollbar covers at any time.

Warning

If the roof is not stowed and the deployable rollbars deploy they will break through the rear glass.

1. Raise the roof. Do not lock in position.

2. Remove the ignition key and wait for a minimum of five seconds. The roof can now be moved in any direction.

Warning

Keep fingers clear of the roof linkage when moving the roof manually.

During this time the roof hydraulics will relax allowing manual movement of the roof. Some hydraulic fluid resistance will still be present in the operating rams. It may take considerable effort to fully raise the roof manually.

7. Disconnect the hydraulic pipes (x2) for each hydraulic ram.

Hydraulic pipes are self sealing.

3. Disconnect the vehicle battery at the negative terminal and ensure the ignition key is removed.

Warning

Allow a two minute power down period before proceeding. This will ensure that there is no power to the deployable rollbar system.

tonneau cover pipes to Follow

image

Warning

Do not lean over the rollbars. If the rollbars deploy while someone is leaning over them, they will cause severe injury.

4. Remove the rear seats and trim panels (Refer to ’Rear

Trim’, page 1-4-5).

5. Raise the tonneau cover and secure in the fully open position.

8. Disconnect the wiring harness plug from the LH hydraulic ram unit.

Image to Follow




9. Disconnect the two wiring harness plugs from inside the boot RH area. Route the cables into the roof storage area.

Roof Material

Warning


Warning


Image to Follow

Warning


Removal

10. Remove bolts (x6 (3 each side)). Withdraw the roof mechanism.

Installation

1. Place the roof mechanism into position. Locate on the dowels provided and secure using bolts x6 (3 each side).

Torque the bolts to TBA Nm .


Warning


Warning


The locating dowels are adjustable. In normal circumstances the dowels will not require to be adjusted.

2. If the roof is raised and locked, unlock and open, slightly.

2. Connect the hydraulic pipes.

3. Connect the LH hydraulic ram unit wiring harness plug.

4. Route the RH cable into the boot area. Connect the wiring harness plugs (x3) in the boot RH area.

5. Install the rear trim panels (Refer to ’Rear Trim’, page 1-

4-5).

6. Install the rear seat belt top mount. Torque to 35 Nm .

7. Install the rear seat bases and backs.


9. Reset both door windows (Refer to ’Door Glass Setup’, page 1-8-5).

10. Operate the roof and check for correct installation.


Warning




5. Raise the roof lid and secure in the fully raised position.

6. Raise the tension bow to 90° to the vehicle.




7. Remove the rear roof seal.

11.2 Remove the three tension cord mounts.

Remove the Rear Seal

01-01-217

8. Remove the screws retaining the trim strip.

9. Remove the roof material from the roof frame (rear).

01-01-213

12. Roll the roof material back to the 3rd cross bar.

Remove the screws that secure the roof lining to the cross bar.

Pull the roof material from the cross bar.

13. Roll the roof material back to the 2rd cross bar.



14. Remove the front of the roof material from the header rail.

10. Lift the roof material from the rear of the tension bow.

11. Disconnect the window tension cord.

11.1 Remove the window tension cord springs.

01-01-216

15. Remove the corners of the front of the roof material from the header plate.

The outer screws on both sides of the header plate are not currently used.

1-12-4

01-01-212

01-01-214

16. Pull the roof material from the roof header rail.




17. Remove the two side cable securing clips (two each side) and withdraw the side tension cables through the roof lining.

2. Lay the roof material on the roof frame.

2.1 Locate the strip in the roof material to the header rail. Secure with screws x4.

Remove Cable

01-01-215

Ensure that the two cable securing clips (each side) are retained for installation.

18. Roll the roof material back to the 1st cross bar.



19. Remove the strip in the roof material from the front of the header rail.

3. Roll the roof material to the 1st cross bar.

4. Remove the sticky strip protection and locate to the first cross bar.

Ensuring that the material is central, stick to the frame cross bar. Affix from centre out, ensuring the holes in the material locate over the holes in the cross bar.

The material with the sticky surface goes under and up around the cross bar.

Installation

1. Manually raise the roof to the raised position.




5. Locate the roof lining strip to the cross bar and secure with screws x5.

9. Install the front of the roof material to the header rail.

Secure with screws.

The outer screws on both sides of the header plate are not currently used.

6. Roll the roof material to the 2nd frame cross bar.

7. Repeat step 6 and 7.

The material with the sticky surface goes over and down around the cross bar

8. Feed the side tension cables through the roof lining and install the end of the cables to the header rail. Ensure that the two cable securing clips are installed.

10. Place the material with the sticky pads into position.

Remove the sticky pads protection and affix to the header rail.




11. Roll the roof material to the 3rd cross bar.

Repeat steps 6 and 7.

The material with the sticky surface goes over and down around the cross bar

Ensure that the heated window cable goes under the adhesive strip.

13. Install the ends of the tension cord.

Install the spring, on the end of the tension cord, facing forward.

12. Install the window tension cord (if not install).

12.1 Thread the tension cord through the center hole.

14. Raise the tension bow to 90°.

15. Slide the roof material over the rear of the tension bow.

12.2 Install the three tension cord mounts.

16. Install the trim strip. Do not tighten the screws.




17. Raise the roof to the open position and lock into place.

Ensure the two lock arms are located in their catches.

20. Unlock the roof and lower to enable access to the trim strip. Tighten the remaining screws.

Using the allen key provided in the vehicle tool kit, lock the roof in position.

Continue to turn the allen key until no more movement is possible.

Locking the roof manually may require the assistance of a second person to push down so the catches engage while the allen key is turned.

18. Check that the roof material is correctly installed.

21. Install the roof material over the roof side frame.

The screw holes in the roof material are used when the sealing strip is installed.

19. Tighten 4 or 5, evenly, trim strip screws while the roof is in the open position.


Weather Seals

Removal

1.

Installation

1.



Roof Pump

Warning


Warning


Warning


Removal


Warning


Warning



Warning




4. Remove the LH road wheel and arch liner.

The fuel filler drain off pipe is attached to the arch liner.

Ensure that the fuel filler drain off pipe does not disconnect from it’s stub pipe.

5. Remove bolts (x6). Support the pump plate as the screws are removed.

The pump is attached to the pump plate.




6. Disconnect two wiring harness plugs.

9. Remove the rear closing panel.

7. Manually raise the tension bow to 90°.

For access to the hydraulic pipes and wiring harness plugs.

8. Remove the rollbar trim cover.

10. Disconnect the hydraulic pipes.

Connect feed and return hydraulic pipes to create an hydraulic loop.

Creating hydraulic loops will enable the hydraulic rams to continue to operate.

Connect the hydraulic pipes, feed to return.




11. Disconnect the two wiring harness plugs from inside the boot area.

3. Connect the two pump wiring harness plugs.

12. Withdraw the hydraulic pipes and the wiring harness cables through the vehicle body, while lowering the pump.

Installation

4. Raise the pump and pump plate assembly into position and secure. Torque bolts to 7-10 Nm.

1. Feed the hydraulic pipes through the vehicle body. Feed the wiring harness plugs into the boot area.


Feed Harness and Plugs into Boot Area

Take care not to trap hydraulic pipes and wiring harness cables.

The hydraulic pipes are numbered, i.e. connect pipes numbered 32 together, etc.

6. Install the rear closing panel.

2. Connect the two boot wiring harness plugs.

01-01-219


7. Install the rollbar trim cover.

8. Install the road wheel arch liner and road wheel.

(Refer to ’Road Wheel Nut Torque Tightening’, page 4-

5-7).




Roof Module

Installation

Removal


Warning


1. Raise the roof module into position and connect the two wiring harness plugs.

2. Install the roof module and plate assembly. Torque bolts to 7-10 Nm .

Roof Lid Hydraulic Rams

Removal



3. Remove the LH road wheel and arch liner.


Warning





4. Remove bolts (x4). Support the module plate as the screws are removed.

The roof module is attached to the plate.


3. Raise the tension bow to 90° to the vehicle.

4. Raise the roof lid and support.

5.

LH ram only .

5.1 Withdraw the pump and pump plate unit.

5.2 Connect the vehicle battery. Open the boot lid.

5.3 Disconnect the wiring harness plug. Feed the wiring harness cable through into the pump area.

Warning

Take care to avoid sharp edges.

Disconnect plug from the

Boot image

5. Lower the module plate to access the two wiring harness plugs. Disconnect the two wiring harness plugs and withdraw the roof module.

5.4 Close the boot lid. Disconnect the vehicle battery.

5.5 Disconnect the wiring harness plugs.

Disconnect plug from the front of the mech image




6. Disconnect the hydraulic pipes.

Connect feed and return hydraulic pipes to create an hydraulic loop.

Creating hydraulic loops will enable the hydraulic rams to continue to operate.

The hydraulic pipes are numbered, i.e. connect pipes, feed to return, numbered 32 together, etc.

3.

LH ram only .

3.1 Connect the wiring harness plug (x1).

Disconnect plug from the front of the mech

Disconnect hydraulic Pipes

7. Disconnect both ends of the hydraulic ram and withdraw the ram.

Installation

1. Connect the ram to it’s mounts.


The hydraulic pipes are numbered, i.e. connect pipes, feed to return, numbered 32 together, etc.

3.2 Feed the wiring harness cable (x1) through into the boot area.

Warning

Take care to avoid sharp edges.

3.3 Install the pump and pump plate unit.

4. Remove the roof lid support.

5. Connect the vehicle battery. Open the boot lid.

6. Connect the boot area wiring harness plug.

Connect hydraulic Pipes






Bumpers (01.19)

Front Bumper

Bumpers (01.19)


Specifications

Torque Figures

Description

Bumper to bumper bracket

Maintenance

Nm

4-5 lb. / ft.

3-4


Item

Bumper Remove / Install

Code

01.19.AB

Removal

1. Remove the road wheel and arch liner.

2. Remove the bolts (x6) that secure the under tray to the bumper.

The air intake for the alternator is located in the front under tray.

3. Remove the LH and RH air boxes (Refer to ’Air Filter

Box’, page 3-13-3).

4. Remove bolts (x8 (x4 each side)) that secure the bumper.


Bumpers (01.19)


5. Disconnect the retaining clips (x2).

Use a tool, i.e. a long screwdriver, to unclip the bumper from the vehicle body.

Image to follow

6. Pull the bumper from the clips located in the front grill.

Withdraw the bumper from the vehicle.

Installation

1. Place the bumper in position. Push install onto the clips located in t he front grill.

2. Locate on the retaining clips (x2).

3. Install bolts (x8 (x4 each side)) to the bumper. Torque to

4-5 Nm .

4. Install the LH and RH air boxes (Refer to ’Air Filter Box’, page 3-13-3).

5. Install the undertray.

6. Install the road wheel arch liner and wheel.


Rear Bumper

Bumpers (01.19)


Specifications

Torque Figures

Description

Bumper to bumper bracket

Maintenance

Nm

2-3 lb. / ft.

1.5-2.5


Item

Bumper Remove / Install

Removal

Code

01.19.BB

1. Remove the light clusters.

1.1 Open the boot and remove the trim from around the light cluster mounts.

1.2 Release and remove nuts (x3).

1.3 Withdraw the rear light cluster unit. Disconnect the wiring harness plug.

2. Remove the bumper tag screw.


Bumpers (01.19)


3. Remove screws x4 (2 each side).

4. Remove bolt from inside the boot (1 each side).

7. Remove screws (x4 (x2 each side)) from the bumper.

5. Remove the roadwheel and disconnect the rear section of the roadwheel arch liner.

6. Disconnect the wiring harness plugs (x2 (RH side)) and

(x2 (LH side)).

8. Remove bolts (x4 (x2 each) that secure the exhaust mount to the end pipe trim.


9. Disconnect the retaining clips (x2).

Use a tool, i.e. a long screwdriver, to unclip the bumper from the vehicle body.

Image to follow

10. Disconnect the two clips in the top centre of the bumper. Withdraw the bumper from the vehicle.

Installation

1. Place the bumper to the vehicle. Locate the two clips in the center top of the bumper.

2. Locate the retaining clips (x2).

3. Install the bumper ‘Tag’ screw.

4. Install screws (x4 (x2 each side)). Torque to 2-3 Nm .

5. Install the screws (x4) in the light cluster opening.

6. Install the light clusters.

6.1 Place a light cluster unit to vehicle and connect the wiring harness plug.

6.2 Insert the light cluster unit into position.

6.3 Ensure the rubber seal is in position. Tighten nuts

(x3).

6.4 Repeat for the second light cluster.

7. Install the bolts (x2) to the bumper boot mount.

Install Bolt (each side)

8. Install the exhaust mounts.


10. Install the road wheel arch liner and wheel.

01-01-181a


Bumpers (01.19)


1-13-5

Bumpers (01.19)




Restraining Devices (01.20)

Seat Belts



This vehicle is installed with four inertia reel safety belts. The inertia belt reels automatically tension the belts to provide security with comfort. In the event of a collision or during severe braking, the belt reels will lock.

The driver and front passenger safety belt buckles are installed with a switch, which is connected to a warning indicator housed within the DIM. When the ignition is first turned on the warning indicator will illuminate only if the seat belt is not fastened. If the safety belt is fastened before the ignition is turned on the circuit is broken and the indicator will remain off.

Pre-tensioner and Load Limiting Systems

The driver and front passenger seat belts are equipped with pre-tensioner and load limiting systems.

When required, the front airbag and pre-tensioner systems will deploy simultaneously.

In some moderate frontal or near frontal accidents, only the pre-tensioner system will deploy.

The pre-tensioners take up slack in the front seat belts as the airbags are expanding. The load limiting system releases belt webbing in a controlled manner to reduce belt force on the occupant’s chest.

The Restraints Control Module (RCM) receives information on the status of the safety belt buckles from a switch contained in the buckle. Only fastened safety belts will activate.

The safety belt retractors, which are mounted within the base of the B pillars, incorporate a torsion bar load limiting device. This device consists of a retractor reel which is mounted onto a spindle (torsion bar) which once the sensor has locked the retractor reel and a predetermined load is applied, twists and allows additional webbing into the system. The deceleration force required to initiate this sequence is approximately the same as that required to initiate airbag deployment. The torsion bar load limiting device will only react if the safety belt is in use at the time of the impact.

Caution

It should be considered that during any event that utilizes the full capability of the safety belts, the webbing may have been elongated and the torsion bar may have twisted. For this reason, if a vehicle is involved in an accident which results in the deployment of the airbag(s), all the safety belts that were in use at the time of the accident MUST be renewed.




Emergency Locking Retractor (ELR)

The retractors in all seat positions feature ELR. During any period of sudden deceleration, or under lateral load when cornering at speed, a sensor weight within the safety belt retractor moves a locking pawl against the teeth on the retractor reel, which then locks the retractor preventing any further release of webbing. As soon as the load applied onto the retractor through the safety belt webbing is removed the locking pawl releases the retractor reel and normal movement is returned to the retractor.

Automatic Locking Retractor (ALR)

Automatic locking retractors (ALR) are installed to all passenger seat positions.

The safety belt webbing on these are clearly marked to show their operating feature. To initiate the ALR system, fasten the safety belt into it’s buckle and pull all of the webbing from the retractor, as the safety belt is released the retractor locks allowing travel in only one direction thus producing a fixed length restraint and preventing the safety belt from introducing slack, making any child seat it may be restraining secure. The ALR system of the retractor is disengaged by unfastening the safety belt and allowing the safety belt to fully retract onto the reel.

Specifications

Torque Figures

Description

Torque Figures

Description

Rear Seat

Belts

35 nm.

(26 lb / ft.)

35 nm.

(26 lb / ft.)

Front Seat

Belts

20-25 Nm.

(15-18.5 lb / ft.)

35 nm.

(26 lb / ft.)

35 nm.

(26 lb / ft.)

40 Nm.

(30 lb / ft.)

35 nm.

(26 lb / ft.)

35 nm.

(26 lb / ft.)




Airbag System

D N R P

The airbag system is designed to provide increased collision protection for front seat occupants in addition to that provided by the safety belt system. Safety belt use is necessary to obtain the best occupant protection and to receive the full advantages of the airbag system.

This vehicle is equipped with driver, passenger, side impact airbags and seat belt pretensioners, which are electrically controlled by a Restraints Control Module (RCM).

The purpose of the driver, passenger and side airbags is to provide additional protection for the front seat occupants in the event of a serious impact (front or side impacts). The airbags are supplementary to the seat belts.

Airbag Deployment

Warning

Airbags inflate rapidly and with considerable force, there is therefore a risk of death or serious injury such as fractures, facial and eye injuries or internal injuries, particularly to occupants who are not properly restrained by seat belts or are not sitting correctly when the airbags deploy. The risk of injury from a deploying airbag is greatest close to the trim covering the airbag.

Warning

The whole sequence of airbag deployment, from sensing the impact to full inflation of the airbag takes place in a fraction of a second.

Dual Inflation Technology

When activated, the airbags will deploy at either a normal or reduced level of inflation, depending on crash severity.

Various sensors determine the direction and severity of an impact. The system analyses this information then deploys the appropriate airbags.

Driver airbag Module

The driver airbag module is installed in the steering wheel, the cover forming the outer surface of the steering wheel boss. The cover has a split line moulded into its surface allowing the airbag to exit through the cover when the system deploys.

No routine maintenance is required and there are no serviceable parts. The driver airbag module is replaced as an assembly.

Passenger Airbag Module

The passenger airbag module is located above the glove compartment behind a deployment panel.

The passenger airbag deployment panel hinges up out of the way during airbag deployment.

The passenger airbag module is replaced as an assembly.

There is no routine maintenance required and there are no serviceable parts.

Side Airbag Module

A side impact airbag module is mounted in the outboard bolster of each front seat. In a side airbag module deployment situation, the airbag module deploys from behind a hard trim panel.

Clockspring

The airbag clockspring continuously transfers electrical signals from the driver airbag module to the airbag sensor.

The airbag clockspring is mounted on the steering column, behind the steering wheel and does not contain any serviceable components. Ensure that the steering wheel is locked in the central position before commencing any work on the steering column, wheel or airbag.




Restrains Control Module (RCM)

The primary purpose of the RCM is to discriminate between an event that warrants an airbag system deployment and an event that does not. The RCM governs the operation of the whole system and performs continual system diagnostics.

Information on the severity of an impact is received from the impact sensors.

Variations in the deployment of the front airbag modules are dependent on the status of the front safety belt buckles.

Impact Sensors

Side Impact - Side impact sensors are mounted to the base of each B-pillar. In the event of a side impact, the RCM processes the impact data sent by the side impact sensor against stored data. The RCM will deploy both side impact airbags dependant on seat belt buckle status.

Front Impact

Front impact sensors (x2) are located under the grill opening panel.

The SRS module processes the impact data sent by the front impact sensor against stored data, and deploys the front airbags, and the seat belt pre-tensioners.

Specifications

Torque Figures

Description

Drive Airbag

Passenger Airbag

Side Airbag

Nm lb. / ft.

8-10 6-7.5

11.5

10

8.5

7.5

Maintenance

Driver Airbag


Item

Drivers Airbag Renew

Code

01.20.AB

Removal

1. Remove the earth (‘-ve’) terminal from the vehicle battery and ensure the ignition key is removed.

Warning

Allow a two minute power down period before proceeding. This will ensure that there is no power to the airbag system.

2. Remove bolts (x2) that secure the driver airbag.

Rotate the steering wheel to gain access to the two bolts.

3. Withdraw the driver airbag to gain access to the wiring harness plug. Disconnect the plug.

4. Withdraw the driver airbag.

Installation

1. Place the airbag module to the steering wheel. Connect the wiring harness plug.

2. Install the bolts (x2). Torque to 8-10 Nm .

3. Connect the vehicle battery with the ignition in the ‘Off’ position.

Passenger Airbag


Item

Passenger Airbag Renew

Removal

Code

01.20.BB


Warning


2. Remove the glove box.

2.1 Pull of the outer trim panel. Disconnect the glovebox release switch wiring harness plug.

2.2 Release the damper cord.

2.3 Remove screws (x3) from the glovebox door hinge.

Remove door.

2.4 Remove screws (x4) from the sight shield. Remove the sight shield and glovebox.




3. Remove the airbag trim panel.

Caution

Withdraw the airbag panel carefully. The airbag panel can crease if forced out.

3.1 Remove screws (x3).

3.2 Lift from the front edge. Withdraw out of clips (x3).

Side Impact Airbag

Removal


Warning


2. Remove the seat lower side trim.


Disconnect Wiring Harness Plugs


5. Remove bolts (x4) and withdraw the airbag.

01-00-218

4. Remove bolt (x1) that secures the airbag module to the seat.

Installation

1. Install the airbag. Torque bolts to 11.5 Nm .


3. Install the airbag trim panel. Torque bolts to 11.5 Nm .

4. Install the glovebox.


Installation

1. Place the airbag to the seat. Torque bolt to 10 Nm .


3. Install the seat lower trim panel.





Deployable Rollbars 6. Remove the rear closing panel.

Warning


Warning


Warning


Specifications

Torque Figures

Description

Deployable Rollbar Unit

Deployable Rollbar Sensor Unit

Nm lb. / ft.

20-30 15-22.5

TBA

Maintenance

Rollbar Unit

Remove


Warning


Warning


2. Remove the rear seat bases and backs (Refer to ’Rear

Seats’, page 1-7-3).

3. Remove the rollbar trim cover.

4.

LH Rollbar unit only .

Remove the rear centre console (Refer to ’Rear Trim’, page 1-4-5).

To gain access to the LH ROPS unit wiring harness plug.


7. Drill out the pop rivits (x2) that secure the seat back bracket to the ROPS unit.

8. Remove bolts (x2 on each) that secure the seat back bracket.

Image to follow




Warning

Ensure that the deployable rollbars are secured in the lowered position.

4. Install the rear closing panel.

The two center screws are installed when the 3rd center console trim panel is installed.

9. Remove bolts x6 that secure the deployable rollbar unit.

Withdraw the ROPS unit.

Install

Warning

Do not connect the vehicle battery unitll the ROPS unit is fully installed.

1. Install the deployable rollbar unit. Torque bolts (x6) to

20-30 Nm .

2. Pop rivit (x2) the seat back bracket to the ROPS unit.


6.

LH Rollbar Unit Only .

Install the rear centre console (Refer to ’Rear Trim’, page

1-4-5).

7. Install the rear seat bases and backs (Refer to ’Rear

Seats’, page 1-7-3).

3. Install the bolts (x2) that secure the seat back bracket.




Rollbar Sensor

Remove


Warning


2. Remove the boot trim to gain access to the rollbar sensor unit.

3. Remove the bolts (x4) that secure the rollbar sensor and bracket assembly.

4. Withdraw the rollbar sensor and bracket assembly to access the wirining harness plug. Disconnect the wiring harness plug.

5. Remove the rollbar sensor unit from its bracket (screws x3).

Install

Warning

Do not connect the vehicle battery unitll the rollbar sensor is fully installed.

Warning


1. Install the deployable rollbar sensor unit to it’s bracket.

Torque bolts (x3) to TBA Nm .


3. Install the bolts (x4) that secure the rollbar sensor and bracket assembly. Torque to TBA Nm .

4. Install the boot trim.

5. Connect the vehicle battery at the negative terminal.



Contents

Engine Assembly (03.00) ......................................3-1-3

Description ............................................................. 1-3

Maintenance ........................................................... 1-4

Engine ................................................................... 1-4

Removal.............................................................. 1-4

Installation ........................................................ 1-11

Engine Removal from the Frame .......................... 1-13

Removal............................................................ 1-13

Installation ........................................................ 1-14

Engine Structure (03.01) .......................................3-2-1

Description ............................................................. 2-1

Engine Block .......................................................... 2-1

Cylinder Heads ...................................................... 2-2

Inlet / Exhaust Manifolds ........................................ 2-2

Specifications.......................................................... 2-2

Maintenance ........................................................... 2-3

Cylinder Head ....................................................... 2-3

Removal.............................................................. 2-3

Installation .......................................................... 2-4

Inlet Manifold ........................................................ 2-7

Removal.............................................................. 2-7

Installation .......................................................... 2-9

Exhaust Manifold ................................................. 2-10

Removal............................................................ 2-10

RH manifold...................................................... 2-10

LH Manifold ...................................................... 2-11

Installation ........................................................ 2-13

Lubrication System (03.02)...................................3-3-1

Description ............................................................. 3-1

Oil flow ................................................................. 3-1

Specifications.......................................................... 3-2

Engine Oil Specification ......................................... 3-2

Maintenance ........................................................... 3-2

Oil Drain ............................................................... 3-2

Oil Filter ................................................................ 3-2

Removal.............................................................. 3-2

Installation .......................................................... 3-3

Sump..................................................................... 3-3

Removal.............................................................. 3-3

Installation .......................................................... 3-4

Oil Pump............................................................... 3-6

Removal.............................................................. 3-6

Installation .......................................................... 3-6

Cooling System (03.03) ........................................ 3-4-1

Description............................................................. 4-1

Coolant Circuit ...................................................... 4-1

Water Pump .......................................................... 4-2

Thermostat ............................................................ 4-2

Radiator................................................................. 4-2

Cooling Fans.......................................................... 4-2

Coolant Reservoir .................................................. 4-2

Engine Oil Cooler .................................................. 4-2

In-Vehicle Heating ................................................. 4-2

Specifications ......................................................... 4-2

Maintenance........................................................... 4-3

Coolant Drain / Fill ................................................ 4-3

Pressure Tests ........................................................ 4-3

Cooling System ................................................... 4-3

Pressure Cap ....................................................... 4-3

Radiator................................................................. 4-4

Removal.............................................................. 4-4

Installation .......................................................... 4-5

Thermostat ............................................................ 4-5

Removal.............................................................. 4-5

Installation .......................................................... 4-6

Water Pump .......................................................... 4-6

Removal.............................................................. 4-6

Installation .......................................................... 4-6

Fuel Charging System (03.04)............................... 3-5-1

Description............................................................. 5-1

Safety Precautions .................................................. 5-1

Maintenance........................................................... 5-2

Depressurising .................................................... 5-2

Fuel Rails ............................................................... 5-2

Removal.............................................................. 5-2

Installation .......................................................... 5-2

Injectors................................................................. 5-3

Removal.............................................................. 5-3

Installation .......................................................... 5-3

Accessory Drive System (03.05) ........................... 3-6-1

Description............................................................. 6-1

Auxiliary Drives...................................................... 6-1

Automatic Belt Tensioner....................................... 6-1

Maintenance........................................................... 6-1

Drive Belt .............................................................. 6-1

Removal.............................................................. 6-1

Installation .......................................................... 6-1


Engine Cranking System (03.06) .......................... 3-7-1

Starting System .......................................................7-1

Specifications ..........................................................7-1

Maintenance ...........................................................7-1

Starter Motor..........................................................7-1

Removal ..............................................................7-1

Installation ..........................................................7-2

Ignition System (03.07) ........................................ 3-8-1

Description .............................................................8-1

Specifications ..........................................................8-1

Maintenance ...........................................................8-2

Spark Plugs.............................................................8-2

Removal ..............................................................8-2

Installation ..........................................................8-2

Emission Control (03.08) ..................................... 3-9-1

System Description .................................................9-1

Valve Train (03.09)............................................. 3-10-1

Description ...........................................................10-1

Camshafts ............................................................10-1

Specifications ........................................................10-1

Maintenance .........................................................10-1

Valve Timing Chains.............................................10-1

Removal ............................................................10-1

Installation ........................................................10-2

LH Cylinder Head (Cylinders 7-12).....................10-2

RH Cylinder Head (Cylinders 1-6) ......................10-3

Valve Timing Check .............................................10-4

Camshafts / Camshaft Followers / Lash Adjusters...10-4

Removal ............................................................10-4

Installation ........................................................10-5

Engine Sealing (03.10) ....................................... 3-11-1

Specifications ........................................................11-1

Maintenance .........................................................11-1

Camshaft Cover....................................................11-1

Removal ............................................................11-1

Installation ........................................................11-2

Timing Cover .......................................................11-3

Removal ............................................................11-3

Installation ........................................................11-4

Crankshaft Rear Oil Seal.......................................11-6

Removal ............................................................11-6

Installation ........................................................11-6

Crankshaft Front Oil Seal......................................11-7

Removal ............................................................11-7

Installation ........................................................11-7

Power Conversion (03.11) ..................................3-12-1

Description ...........................................................12-1

Crankshaft............................................................12-1

Pistons and Connecting Rods ...............................12-1

Specifications........................................................12-1

Piston Skirt Grading Chart ....................................12-2

Main Bearing Grade Chart....................................12-2

Maintenance .........................................................12-3

Crankshaft............................................................12-3

Removal ............................................................12-3

Component Checks ...........................................12-5

Installation ........................................................12-5


Overhaul...........................................................12-8

Reassembly .......................................................12-8

Flywheel ..............................................................12-9

Removal ............................................................12-9

Installation ......................................................12-10

Air Charging (03.12) ...........................................3-13-1

Description ...........................................................13-1

Air Induction System ............................................13-1

Specifications........................................................13-1

Maintenance .........................................................13-2

Air Filter...............................................................13-2

Removal ............................................................13-2

Installation ........................................................13-2

Air Filter Box ........................................................13-3

Removal ............................................................13-3

Installation ........................................................13-3

Engine Management System (03.14) ..................3-14-1

Schematic Diagram...............................................14-1

Specifications........................................................14-2

Powertrain Control Modules (PCMs).....................14-2

PCM A ..............................................................14-2

PCM B ..............................................................14-3

Maintenance .........................................................14-4

WDS Connection .................................................14-4

PCM ....................................................................14-5

Removal ............................................................14-5

Installation ........................................................14-5

Evaporative Emissions (03.13) ............................3-15-1

Description ...........................................................15-1

System Operation ................................................15-1

Throttle Control (03.16)......................................3-16-1

Description ...........................................................16-1

Motorised Throttles ..............................................16-1

Specifications........................................................16-1

Maintenance .........................................................16-1

Throttle Body .......................................................16-1

Removal ............................................................16-1

Installation ........................................................16-2


Engine (03.00)

Engine Assembly (03.00)

Description


Engine (03.00)

The engine is an all aluminium 6.0 litre 60° V12 configuration. The cylinder heads have dual overhead camshafts and four valves per cylinder. An electronic engine management system controls the sequential multi-port fuel injection and distributor-less ignition systems.

The engine uses the latest ‘fast-burn’ combustion technology. Heated oxygen sensors monitor the oxygen content of exhaust gasses. The engine management system uses the oxygen sensor signals together with other engine information to

‘fine tune’ fuelling levels and ignition timing. This helps to achieve the best possible fuel burn with minimum exhaust emissions. The exhaust system incorporates six catalytic convertors to minimise the levels of harmful gasses passing into the atmosphere. Additional oxygen sensors are placed after the catalysts so that long term catalyst efficiency can be monitored.

The engine runs on unleaded fuel only.



Engine (03.00)

Maintenance

Engine


Item

Engine Remove and Install

Including engine removal from the frame

Removal

Code

03.00.AA

To remove the engine from the vehicle the complete power train will be removed.

1. Disconnect the earth (‘- ve) terminal from the vehicle battery.

2. Evacuate the A/C unit (Refer to ’Air Conditioning (A/C)

System (12.03)’, page 12-3-1).

3. Disconnect the A/C pipes.

6. Remove the washer bottle neck bracket.

7. Remove the ‘slam’ panel.

8. Withdraw the plastic cover and disconnect the forward wiring harness plugs.

Side Marker

Light

(FED Only)

Horn

Temperature Sensor

4. Drain the coolant (Refer to ’Coolant Drain / Fill’, page 3-

4-3).

9. Remove the bonnet release cable.

Caution

Before removing the engine bay corner cross-braces ensure that the at the vehicle is resting on it’s roadwheels.

5. Remove the engine bay corner cross-braces. Do not remove the engine bay cross brace.


10. Disconnect the following from the forward cross member.

• The reinforcement struts


Engine (03.00)

12. Remove the bolts and the reinforcement brackets from the inner wing.

Remove the header tank to gain access. Be aware that there is a wiring harness plug connected to the header tank on the under side.

• The ‘Jump start’ plug

• The power steering reservoir

13. Centre the steering wheel. Remove the ignition key and engage the steering lock with the wheel as accurately centred as possible.

Failure to centre the steering wheel may cause damage to the restraint bag clock-spring and also may cause difficulties in attaining correct alignment of the steering wheel in the straight ahead position.

14. From inside the cabin, pull back the steering colum bulkhead seal. Remove the pinch bolt that secures the upper column to the intermediate shaft.

15. Disconnect the engine harness from inside the vehicle cabin.


Disconnect the clutch pipe.



Engine (03.00)

16. Raise the vehicle and make safe.

Remove the screws that secure the rear section of the road wheel arch liner. Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly.

(Refer to ’Jacking Points’, page I-I-IX).

Caution

Ensure the vehicle is ‘strapped’ to the lift.

24. Remove the engine bay fusebox and bracket.

Remove harness plugs.

17. Remove the undertrays and shear plates.

Note the positions of the (x4) spacers when removing the front shear plate.

23.

18. Remove all road wheels and arches.

19. Remove the air filter boxes.

20. Remove the front bumper.

21. Disconnect the headlight units lower mount.

22. Disconnect the following forward wiring harness plugs.

• Fan pack

• Headlight levelling sensor

• MAF sensor

• ABS speed sensor

• Header tank level sensor

Remove

Power cable.

25. Disconnect the earth points from the bulkhead. Mark the leads at the clean earth studs.

These are ‘Clean Earths’ labelled ‘Bank A’ and ‘Bank B’.

Reconnect to correct stud.

• Right Hand side

Headlight level switch

• Left Hand Side



Engine (03.00)

26. Remove the PCMs. Disconnect the engine wiring harness plugs and remove the three screws that secure the PCM (each side).

27. Move the removed engine wiring harness plugs into the engine bay and secure to the engine cross brace.

30. Disconnect the front brake pipes:

Caution

Brake fluid must not be allowed to contact vehicle paint work. Remove spilt brake fluid from paint work by rinsing away with running water.

30.1 Disconnect the brake pipe from the brake modulator to the L/H front brake caliper.

28. Remove the brake booster vacuum pipe

29. Disconnect the heater coolant pipes.

On LH drive vehicles the heater coolant pipes enter the bulkhead on the RH side.

30.2 Disconnect the brake pipe in the RH wing.

31. Remove the intermediate steering shaft.

31.1 Remove the lower pinch bolt. Open the lower mount.

31.2 Pull the intermediate steering shaft downwards and remove.



Engine (03.00)

32. Disconnect the fuel lines.

37. Disconnect the handbrake cable from the rear subframe

(Refer to ’Hand Brake (06.05)’, page 6-3-1).

Use the brake cable release tool (Refer to ’206-103

(Handbrake Cable Removal)’, page 20-1-4).

33. Remove the VMV to inlet manifold pipe from the VMV.

38. Disconnect the subframe wiring harness.

34. Disconnect the torque tube to body (engine) earth lead.

35. Disconnect the Starter / Alternator / Jump terminal cable from the chassis.

39. Disconnect the rear brake pipes.

36. Disconnect the silencer from the two rear exhaust pipes.

Caution



40. Remove the rear brake pipe brackets.


Engine (03.00)

43. Ensure that the relation of the front subframe / front structure to the vehicle body is marked (scribed), for accurate installation.

44. Remove bolts (x12) that secure the front subframe / front structure to the body.

41. Automatic Gearbox Only.

Disconnect the manual override cable.

Image to Follow

45. Remove the bolts (x3) that secure the emmisions filter unit. This allows access to the spring and damper unit top mount.

Disconnect from the body

42. Position the subframe trolleys, front and rear (Refer to

’303-F715 (Multi-purpose Trolley) x2’, page 20-1-5) under the subframes. Lower the vehicle until the front and rear subframes rests on the subframe trolleys.

Connect the two trolleys together (Refer to ’303-F715-06

(Trolley Brace Bars)’, page 20-1-5).

Front Pin

01-03-227

46. Remove bolts (x4) that secure the rear spring and damper units.

Ensure the rear spring and damper assemblies are fully extended to release spring tension. A small amount of tension will remain.

Lever the rear spring and damper mounting turret against spring tension to allow removal of bolts.

Rear Pin Image to Follow



Engine (03.00)

47. Remove the rear subframe securing bolts.

The anti-roll bar must be removed before the two rear bolts can be completely removed.

48.

Manual Transaxle only .

Raise the vehicle to allow access to disconnect the gear selector cables.

Use the service tool (Refer to ’501-F116 (IP Removal)’, page 20-1-8) to remove the horseshoe clips (x2) and lever the cables from the ball joints.

Caution

There is a risk of bending the end of the cable. Lever cable from ball joint at a point closest to the ball joint.

Ensure the vehicle raises without catching pipes, cables, etc.

3-1-10

49. Slowly raise the vehicle.

As the vehicle raises disconnect the wings from front grill.

Ensure all pipes, cables, etc., are clear as the vehicle raises.

LH drive vehicles - ensure that the coolant pipe is in front of the brake booster.

50. Retain the spacers from each rear subframe mounting pad. These should be installed in the same positions when the subframe is installed.



Engine (03.00)

Installation

1. Lower the vehicle to the powertrain assembly.

Ensure all pipes, cables, etc., are clear as the vehicle lowers.

As the vehicle lowers pull the wings from front grill.

8. Torque the front subframe and front structure bolts.

Ensure that the front subframe / front structure to body alignment marks are lined up.

Torque bolts (x12) to 105-125 Nm .

2. Install the rear spring and damper assemblies. Do not tighten the bolts.

3. Install the front subframe and front structure mounting bolts (x12). Do not tighten.

4. Install the rear subframe mounting bolts (x4). Do not tighten.

Spacers from rear subframe mounting pads should be installed in the same positions as removed.

5. Install the rear subframe reinforcement plates.

6. Torque the rear spring and damper assemblies - 85.5

Nm .

9. Torque the rear subframe mounting bolts.

1 Torque the bolts that secure the subframe to the body to 175 Nm .

2 Torque the bolts that secure the subframe reinforcement plates to 62 Nm .

7. Install the emmisions filter unit.

Connect to the body


01-03-228

10. Connect the rear subframe wiring harness.



Engine (03.00)


Install the manual override cable.


• Install the gear change linkage

• Install the wiring harness plugs


Caution

Clutch fluid must not be allowed to contact the vehicle paint work. Remove spilt clutch fluid from the paint work by rinsing away with running water.

Install the clutch pipe.

14. Install the brake pipes:

Caution

Brake fluid must not be allowed to contact the vehicle paint work. Remove spilt brake fluid from the paint work by rinsing away with running water.

25. Connect the earth points to the bulkhead.

• RH side

• LH Side

• Install the LH front brake caliper pipe to the modulator

• Install the rear brake pipe brackets.

• Install the brake pipes to all remaining brake calipers.

15. Install the handbrake cable to the handbrake lever

16. Connect the torque tube to body (engine) earth lead.

17. Connect the Starter / Alternator / Jump terminal cable to the body.

26. Install the steering intermediate shaft.

27. Install the fusebox.

27.1 Connect the wiring harness plugs

27.2 Connect the main power feed

27.3 Install the fusebox bracket and fusebox

28. Install the power steering reservoir.

29. Install the jump start cable.

30. Install the A/C pipes.

31. Install the bolts and reinforcement struts along the inner wings.

32. Install the header tank.

Caution

Before installing the engine bay cross-braces ensure that the at the vehicle is resting on it’s roadwheels.

18. Install the heater coolant pipes.

19. Connect the VMV.

20. Connect the fuel lines.

21. Install the headlight units (L/H and R/H).

22. Install both air filter boxes.

23. Install the PCMs. Connect the engine wiring harness plugs.

24. Connect the following forward wiring harness plugs.

• Fan pack


• MAF sensor



33. Install the engine bay corner cross braces. tighten

34. Install the front bumper.

35. Install the road wheel arch liners.

36. Install:

.

• Front and rear undertrays

• Shear plates

Note the positions of the (x4) spacers from removal on the front shear plate.

Do not

37. Bleed the brakes (Refer to ’Brake Bleeding - WDS’, page

6-4-4).



39. Torque the engine bay cross-braces to 49 Nm.

40. Fill the coolant (Refer to ’Coolant Drain / Fill’, page 3-4-

3)



Engine (03.00)

41. Charge the A/C unit (Refer to ’Air Conditioning (A/C)

System (12.03)’, page 12-3-1).

7. Attach the lifting eyes (x4) to the cylinder heads.

42. Check the road wheel alignment (Refer to ’Road Wheel

Alignment (04.00)’, page 4-1-2).

9. Raise the hoist to take up ‘slack’ in lifting gear.

10. Remove the torque tube.

Always check the steering angle sensor (viaWDS) after any work carried out on the steering or the suspension systems or the yaw rate sensor.

10.1 Ensure the torque tube is supported.

10.2 Remove bolts (x) that secure the torque tube to the engine block.


Engine Removal from the Frame

Removal

10.3 Ensuring the torque tube and engine are adequately supported, move the engine frame and hoist forward until there is room to manoeuvre the torque tube away from the engine block and exhaust manifolds.

1. Release the exhaust manifolds from the catalysts.

8. Install the engine lifting gear to a suitable hoist.

2. Remove the following hoses:

3. Disconnect the AC pipe from the condensor.

4. Remove the hose from the header tank.

11. Remove the engine mount nuts (x2).

5. Disconnect the cables from the starter motor and the alternator.

6. Remove the power steering pump hoses.

12. Lift the engine clear of the frame assembly. Secure the engine to an appropriate stand.

Detach the lifting gear.



Engine (03.00)

Installation


2. Raise and manoeuvre the engine to the frame.

3. Ensuring the torque tube is adequately supported, manoeuvre the engine to torque tube.

4. Locate the propshaft splines and ‘face up’ the engine block to the torque tube.

5. Install the bolts that secure the torque tube to the engine block. Torque the bolts to:

• M8 - 25 Nm .

• M10 - 50 Nm .

6. Install the engine mounts. Torque the nuts (x2) to 47

Nm .

7. Remove the lifting equipment and lifting eyes.

8. Install the hose to the header tank.

9. Connect the AC pipe to the condensor.

10. Install the following hoses:

11. Install the power steering pump hoses.

12. Install the cables to the starter motor and the alternator.

13. Install the exhaust manifolds to the catalysts. Torque the nuts and bolts to 25.5 Nm .


Engine (03.00)

Engine Structure (03.01)

Description

Engine Block


Engine (03.00)

Dowels are installed to the principal mating faces of the block to ensure accurate alignment of cylinder heads, front timing cover, auxiliaries, etc.

The 60° V12 aluminium engine block incorporates paths for water cooling, oil distribution and positive crankcase ventilation. The seven main bearing caps supporting the crankshaft are bolted laterally as well as vertically to provide additional crankcase stiffening whilst keeping engine weight to a minimum. Each bearing cap is numbered to identify its position in the engine block The 12 cast iron cylinder liners are inserted and machined during block production and require specialist equipment for replacement.

The crankshaft is mounted in 7 main bearings with end loads absorbed by thrust washers at number 4 main bearing. Main bearing bolts are of the ‘torque to yield’ type and must be renewed if removed.

A twin sprocket installed to the front end of the crankshaft drives the camshaft chains. A damper pulley installed on the crankshaft nose drives the engine auxiliaries via a polyvee drive belt. Also at the front of the engine a timing disc is installed together with two crankshaft sensors. The sensors provide engine position signals to the two Engine control modules.



Engine (03.00)

Cylinder Heads

Each cylinder is provided with two inlet and two exhaust valves. The valves are operated by cam followers beneath each camshaft. Valve clearances are maintained at zero by a hydraulic tappet system (lash adjuster) pressurised from the main engine lubrication system.

Inlet / Exhaust Manifolds

Two six-branch exhaust manifolds, locate four primary catalytic converters and eight oxygen sensors.

Four engine management oxygen sensors are mounted before the primary catalysts. Four catalyst monitor oxygen sensors are mounted after the primary catalysts.

Specifications

Block

Cylinder Bore Grade 2

Main Bearing Bore (without shells)

Cylinder Heads

Head Face-Roof Button

Valve Seat Width - Inlet

Valve Seat Width - Exhaust

Camshaft Bore

Camshaft Journals

Head Volume

MM

89.010 - 89.020

72.400 - 72.424

MM

14.75 - 15.25

1.10 - 1.40

1.40 - 1.70

26.987 - 27.012

26.936 - 26. 962

46.70 - 49.70 ml.

Camshaft End Play

0.025 - 0.165 mm (using a force of 30-50 lbs - do not exceed 50 lb. as damage may occur to the thrust washer).

Camshaft Sensors

Air Gap

MM

1 (±0.5)

Intake air is filtered and passed through mass air flow meters

(MAF). The air then passes through the throttle bodies into the six branch inlet manifolds.

Torque Figures

Description

Cylinder head 1. Bolts 1 to 14

2. Bolts 15-16

3. Bolts 1-14

4. Release bolts 1-14

5. Bolts 1 to 14

6. Bolts 15-16

7. Bolts 1 to 14

8. Bolts 1 to 14

Camshaft bearing caps

Nm.

lb./ft.

37-43 27.5-32

15-20 11.5-15

85°-95°

Min. 360°

37-43 27.5-32

23-27 17-20

85°-95°

85°-95°

8-12 6-9



Engine (03.00)

Maintenance

Cylinder Head

Removal

1. Remove the engine from vehicle (Refer to ’Engine’, page

3-1-4)

2. Remove the inlet manifold (Refer to ’Inlet Manifold’, page 3-2-7).

3. Remove the exhaust manifold (Refer to ’Exhaust

Manifold’, page 3-2-10).

4. Drain the engine coolant (Refer to ’Coolant Drain / Fill’, page 3-4-3).

5. Remove the accessory drive belt (Refer to ’Drive Belt’, page 3-6-1).

6. Remove the thermostat housing (Refer to ’Thermostat’, page 3-4-5).

7. Remove the camshaft cover (Refer to ’Camshaft Cover’, page 3-11-1).

8. Remove the timing cover (Refer to ’Timing Cover’, page

3-11-3).

9. Remove the timing chains (Refer to ’Valve Timing

Chains’, page 3-10-1)

10. Remove both camshafts.

11. Remove the camshaft followers and lash adjusters.

Ensure they are retained in the sequence removed.

10.1 Progressively release all bolts that secure each bearing cap.

The thrust camshaft bearing cap, of each camshaft

(No.1 and No. 8 cap), must be removed first and installed last.

10.2 Withdraw the bearing caps. Ensure they are retained in the sequence withdrawn.

10.3 Withdraw the camshafts.


10

4

8

6

2

12


Engine (03.00)

12. Remove bolts (x2 (M8) and (x14 (M10)) from the cylinder head in order as shown below.

L eft S ide S hown

15

E ngine

F ront 16

13. Withdraw the cylinder head. Discard the cylinder head gasket.

Cover the engine block to prevent ingress of foreign material.

14 11

7

3

1

5

9

13

14. Remove the second cylinder head if required.

15. Overhaul the cylinder head(s) as required (Refer to

’Cylinder Head’, page 3-2-3).

Installation

Ensure all mating surfaces are clean, smooth and free of any contamination.

1. Place a new cylinder head gasket over the locating dowels.

2. Lubricate beneath the head of all the cylinder head bolts

(x14 (M10) and x2 (M8) with engine oil. Do not lubricate the threads.

Place the bolts to the cylinder head.



Engine (03.00)

Caution

The following ‘Torque - Release - Torque’ sequence must be performed exactly as specified to ensure correct cylinder head to engine block sealing.

3. Torque the cylinder head in stages using the following procedure:

15

14

10

E ngine

F ront

L eft S ide S hown

16

11

7

3.2

Release

1 Loosen bolts 1-14 (M10) a minimum of one full turn

(360°).

3.3

Final Torque

1 Torque bolts 1-14 (M10) to 37-43 Nm.

in the sequence shown.

2 Torque bolts 15-16 (M8) to 23-27 Nm .

3 Torque bolts 1-14 (M10) a further 85-95° in the sequence shown.

4 Torque bolts 1-14 (M10) an additional 85-95° in the sequence shown.

4. Repeat for the second cylinder head.

5. Install all lash adjusters.

Soak the lash adjusters in engine oil.

Insert each lash adjuster into its correct recess in the cylinder head.

6. Install the camshaft followers to their valves.

Caution

Ensure that the dimpled end of the camshaft followers are installed to the lash adjusters.

Soak the cam followers in engine oil.

6 3

2 1

4 5

8 9

12 13

3.1

Initial Torque

1 Torque bolts 1 -14 (M10) to 37-43 Nm . in the sequence shown.



7. Lubricate the camshaft journals, camshaft bearing caps with engine oil.

8. Ensure the crankshaft key is vertical.

Caution

The crankshaft key must remain in the vertical position until the camshaft chains are correctly installed and tensioned. Movement of the crankshaft before completion of valve timing may cause contact between a piston and a valve, resulting in valve and / or piston damage.

The crankshaft key is exactly in line with No.1 crankshaft throw. With the crankshaft key vertical, No.1 piston is 30°

ATDC and all pistons are below engine block surface.



Engine (03.00)

9. Place the camshafts in position, with the timing marks in the positions shown.

The positions shown allow the camshafts to lay at their lowest in the journals.

13. Torque down the camshafts.

13.1 Progressively ‘nip’ down all bolts in the sequence shown. Ensure the camshaft bearing caps pull down evenly into contact with the cylinder head.

15° 15°

13.2 In the sequence shown, torque the camshaft bearing caps to 8-12 Nm .

15° 15°

E ngine

F ront

15 1

16

10. Work on one cylinder head at a time.

11. Install all camshaft bearing caps, except the two thrust camshaft bearing caps (No.1 and No. 8 cap) at the front of each camshaft. Loosely secure each cam cap.

Bearing Caps

1-7 1-7

8-14 8-14

17

18

19

20

21

The bearing caps are numbered and correspond with numbers stamped on the cylinder head adjacent to the journal.

12. Test install No.1 and No. 8 bearing caps over their thrust flanges. If the bolt holes do not perfectly align, move the camshafts forward or rearward as required until the bearing caps locate correctly. Loosely secure the bearing caps.

22

23

24

25

26

27

28

2

10

11

8

9

3

6

7

4

5

12

13

14

3-2-6

14. Repeat from step 10. for the second cylinder head.

15. Install the timing chains. Perform the camshaft timing procedure

16. (Refer to ’Valve Train (03.09)’, page 3-10-1).

17. Install the timing cover (Refer to ’Timing Cover’, page 3-

11-3).



Engine (03.00)

18. Install the accessory drive belt (Refer to ’Drive Belt’, page 3-6-1)

19. Install the camshaft cover (Refer to ’Camshaft Cover’, page 3-11-1).

20. Install the thermostat housing (Refer to ’Thermostat’, page 3-4-5).

21. Fill the engine coolant system (Refer to ’Coolant Drain /

Fill’, page 3-4-3).

5. Remove the following from the inlet manifold.

22. Install the exhaust manifold (Refer to ’Exhaust Manifold’, page 3-2-10).

23. Install the inlet manifold (Refer to ’Inlet Manifold’, page

3-2-7).

24. Install the engine to vehicle (Refer to ’Engine’, page 3-1-

4).

Inlet Manifold


Item

Inlet Manifold Renew LH

RH

Code

03.01.BB

03.01.DB

Removal

1. Depressurise the fuel system (Refer to ’Depressurising’, page 10-1-8).


3. Remove the engine bay corner braces (x2), engine bay cross brace and manifold brace.

4. Remove the air intake pipe.



Engine (03.00)

7. Remove the following:

• Fuel rail temperature sender wiring harness plug

• Fuel rail pressure sensor wiring harness plug

• Injector wiring harness plugs

6. Remove the thermostat housing by-pass hose. Plug the open ends.

Warning

If the fuel system is pressurised, fuel will be released and may contaminate eyes and / or skin.

8. Remove the fuel rails and injectors.

8.1

Remove bolts (x6) that secure the fuel rails.

8.2

Withdraw the fuel rails sufficiently to remove the injectors.

8.3

Discard the injector ‘O’ rings.



Engine (03.00)

9. Disconnect the fuel rails from the fuel supply hoses.

Installation

Left and right hand fuel rails to the fuel supply hose unions are different sizes.

Ensure all faces are clean and free of damage / contamination.

9.1

Remove the secondary latch clip from each fuel line.

9.2

Locate correct size of service tool around the union.

• (Refer to ’412-038 (Quick Disconnect

Tool)’, page 20-1-7)

1. Place a new inlet manifold gasket to the inlet manifold.

Locate the two ‘lipped’ holes in the gasket through the two corresponding bolt inserts in the inlet manifold.

2. Install the inlet manifold.



9.3

Push back on the tool. While pushed back withdraw the fuel rail.

2.1

Place the inlet manifold to the cylinder head and install the vacuum harness to the rear of the inlet manifold.

2.2

Locate the inlet manifold to the cylinder head.

Ensure the gasket remains in position.

2.3

Secure the inlet manifold to the cylinder head.

Torque bolts (x7), in the order detailed below, to 8 -

12 Nm .

Engine Front

Remove Secondary

Latch Clips

10. Remove the inlet manifold.

10.1 Remove bolts (x7) that secure the inlet manifold to the cylinder head.

10.2 Withdraw the inlet manifold sufficiently to gain access to it’s rear and disconnect the vacuum harness.

10.3 Withdraw the inlet manifold. Discard the gaskets.

11. Cover the inlets to the cylinder head to prevent contamination of the cylinders.



Engine (03.00)

3. Install the injectors to the inlet manifold, complete with new ‘O’ rings.

Exhaust Manifold


Note position of ‘O’ rings

• Blue (top)

• Green (bottom)

4. Install the fuel rails.

4.1

Locate fuel rails over injectors.

Item

Exhaust Manifold Renew

Removal

LH

RH

Code

09.03.DB

09.03.EB

4.2

Pull down’ fuel rail onto injectors by tightening bolts

(x3). Torque bolts to 8-12 Nm .



5. Connect fuel rails to fuel supply lines.

3. Remove the front roadwheels and wheel arch liners.

Ensure each fuel rail and fuel supply line are ‘in-line’ before connection.

4. Remove the undertray.

5. Remove the lower suspension arms.

6. Install the secondary latch clips to the fuel lines.

7. Connect the following wiring harness plugs:

• Temperature sender to fuel rail

• Pressure sensor to fuel rail

• To the injectors

8. Connect thermostat housing by-pass pipe.

9. Install the air intake hose.

10. Install the engine bay corner braces (x2), engine bay cross brace and manifold brace. Torque bolts to:

• Engine cross brace - 49 Nm.

• Manifold brace - 8-12 Nm .

• Corner braces - 49 Nm.

6. Disconnect the anti-roll bar links.

7. Remove the front subframe (Refer to ’Front Subframe’, page 2-1-2).

RH manifold

1. Remove the steering column (RH drive only).


2. Remove the starter motor.


Engine (03.00)

6. Remove exhaust manifold.

6.1

Remove manifold nuts (x12).

3. Disconnect the heated oxygen sensors (x2) and the

Catalyst Monitor sensors (x2).

4. Remove the exhaust heat shields.

6.2

Remove nut and bolt (x3).



6.3

Withdraw the manifold.

Discard the manifold gasket.

LH Manifold

1. Remove the lower steering column (LH drive only).



Engine (03.00)


5. Remove the exhaust manifold.

5.1


3. Remove the dip stick.

5.2




5.3




Installation

Use new gaskets.

1. Place a new gasket and the exhaust manifold to the cylinder head.

2. Install nuts (x12). Torque nuts, in sequence shown, to

18-22 Nm .

Engine Front

9

5

1

5

1

3

7

11

6

2

10

11

6

2

4

8

12 12

3. Install the Heated Oxygen sensors (x2) and the Catalyst

Monitor sensors (x2).

4. Install the exhaust heat shields.

5. Install:

5.1

LH Manifold .

• The Dip stick

• The Lower steering column (LH drive only)

5.2

RH Manifold .

• The Alternator

• The Starter motor

• The Lower steering column (RH drive only)

6. Install the front subframe (Refer to ’Front Subframe’, page 2-1-2).

7. Install the lower suspension arms and anti-roll bar links

(Refer to ’Front Suspension (04.01)’, page 4-2-1).


9. Install the road wheels.(Refer to ’Road Wheel Nut




Engine (03.00)

3-2-13


Engine (03.00)


Engine (03.00)

Lubrication System (03.02)

Description


Engine (03.00)

The engine uses a wet sump lubrication system.

Oil is drawn from the sump via an oil strainer and pick-up tube to the crankshaft driven oil pump. Pressure from the oil pump is limited by a built in oil pressure relief valve. Pressurised oil then flows from the left side of the engine through a filter and cooler then back into the engine main oil gallery.

Oil pressure at the re-entry point is approximately 60 psi with the engine hot and should reach at least 100 psi when cold.

Oil flow

Sump Oil strainer Oil pump

Oil filter and cooler

Main oil gallery

Crankshaft mains

Connecting rod big ends

Oil squirters

Connecting rod small ends

Timing chain tensioners

Vertical oil feed gallery

Both cylinder heads

Camshaft bearings

Sump

Splash feed

Timing chains and sprockets



Engine (03.00)

0W-30

Authority

API

ACEA

ILSAC

0W-40

Authority

API

ACEA

ILSAC

Specifications Maintenance

Engine oil

Europe / Aus

USA

Mobil 1

0W-40

0W-30 or 0W-40

To achieve the required high performance of synthetic lubricants, do not mix with mineral oils.

Oil Drain

1. Remove the front undertray.

2. Remove the sump plug. Drain the oil into a suitable receptacle.

3. Install a new sump plug. Torque to 23-27 Nm .

Caution

Always install a new oil drain bolt.

Capacity

Engine sump (incl. filter)

Europe

(Litres)

10.0

UK

(Pints)

17.6

USA

(Qts.)

10.6

Torque Figures

Description

Sump plug

Sump bolts (two stage)

Oil pump bolts

Nm.

lb. / ft.

23-27 17-20

1.

15 11.5

(in sequence)

2.

A further 90°

(same sequence)

M8 23-27 17-20

M6 8-12 6-9

Engine Oil Specification

An oil of 0W-30 viscosity meeting Aston Martin specification WSS

M2C913-A/B or 0W-40 viscosity meeting Aston Martin specification WSS-M2C937-A is preferred. Where this is not possible, oil meeting the following standards may be used.

4. Wipe the area clean before installing the front undertray. Install the front undertray.

Oil Filter


Item

Oil Filter Renew

Removal

RH Drive.


2. Remove the oil filter.

LHD

RHD

Code

TBA

03.02.AB

Standard

SL / SJ / EC / CF

A1 / A5 / B1 / B5

GF3

Standard

SL / SJ / EC / CF

A3 / B3 / B4

GF3

To lessen the amount of engine oil spillage, cover the oil filter with a plastic bag.

3. Clean any excess oil from around and below the oil filter.

Caution

Engine oil may drain onto the steering rack and rubber hoses. Ensure excess engine oil is removed before installing the undertray.

Engine oil which remains may drip, in time, onto the undertray and indicate a false engine oil leak.



Engine (03.00)

LH Drive.


2. Remove the air intake from the throttle body. Remove the throttle body.

Installation

1. Smear the lip of the oil filter with clean engine oil.

2. Install the oil filter to the engine block. Tighten the oil filter hand tight.

3.

L/H drive only .

Install the throttle body and air intake pipe.

4. Install the front undertray.

Sump


Item

Sump Remove / Install

Removal

Code

LH 03.02.BN

1. Drain the engine oil.

2. Remove the lower suspension arms (from the front subframe) and the anti-roll bar (Refer to ’Front

Suspension (04.01)’, page 4-2-1).

Remove

Anti-roll Bar




Caution



3. Support the engine from above (Refer to ’303-1080

(Engine Support Adaptor)’, page 20-1-6).


5. Withdraw the coolant pipe from the sump.



Engine (03.00)

6. Remove bolts (x15 M8) and (x5 M6) that secure the sump. Withdraw the sump. Discard the sump gasket and oil seal (oil pump).

7. Clean the sump and engine block mating surfaces.

Installation

1. Ensure the sump is clean.

2. Install a new sump gasket. Ensure that the gasket protrudes evenly from its groove all around the sump.

4. Apply dots (10 mm Dia approx.) of sealant to the sump sealing surface in the positions indicated.

The sump must be installed and secured within 6 minutes of applying beads of sealant.

3. Install a new oil seal to the sump (oil pump to sump).



Engine (03.00)

5. Install the sump.

Ensure that the sump oil outlet seal locates to the oil pump inlet before the sump is faced up to the engine block.

Do not use a mallet etc. to face up the sump to engine block.

Ensure the sump is flush to 0.25mm underflush to the rear face of the cylinder block.

Secure the sump using bolts (x15 M8) and (x5 M6).

Tighten the bolts using a two stage procedure:

1 Tighten all bolts to 15 Nm.


6. Install the coolant pipe.


8. Install the lower suspension arms (Do not torque bolts)

9. Install the anti-roll bar. Torque the stabiliser nut to 110

Nm .

10. Remove the engine support.

11. Fill the engine with the recommended quantity and grade of engine oil (Refer to ’Specifications’, page 3-3-

2).

12. Torque the suspension fixings with the vehicle at normal ride height (Refer to ’Front Suspension (04.01)’, page 4-

2-1):

• Lower suspension arms to the subframe - 115 Nm .

13. Check and adjust the front wheel alignment (Refer to

’Road Wheel Nut Torque Tightening’, page 4-5-7).

14. Raise the vehicle and install the front undertray.

2 Tighten all bolts through a further 90° following the same sequence.



Engine (03.00)

Oil Pump


Item

Oil Pump Renew

Code

TBA

Removal


2. Remove the engine from the vehicle (Refer to

’Removal’, page 3-1-4).

3. Remove the sump (Refer to ’Sump’, page 3-3-3).

Discard the sump gasket and oil seal.


Chains’, page 3-10-1).

5. Remove bolts (x1 M6) and (x3 M8) that secure the oil pump. Withdraw the oil pump.

4. Install the sump (Refer to ’Sump’, page 3-3-3) complete with new gasket and oil seal.





4).


2).



Installation

1. Locate the oil pump onto the crankshaft.

Install the oil pump.

• Torque bolts (M8 x3) to 23-27 Nm.


23-27 nm.

8-12 Nm.

01-03-105a

2. Install the timing chains (Refer to ’Valve Timing Chains’, page 3-10-1).


11-3).


Engine (03.00)

Cooling System (03.03)

Description


Engine (03.00)

• Water pump

• Thermostat

• Radiator

• Pressure cap

• Coolant Reservoir

• Electric cooling fans (x2)

• Cooling fan motor control module

• Engine oil cooler

Coolant Circuit



Engine (03.00)

Water Pump In-Vehicle Heating

The water pump is of a conventional design and is located at the front of the engine. It is driven by the accessory drive belt.

Thermostat

The thermostat allows rapid engine warm-up by redirecting coolant flow through the engine below 88.3°C (190.9°F).

The thermostat also assists in keeping the engine operating temperature within predetermined limits. The thermostat starts to open between 88.3 - 92.2°C (190.9 - 198°F) and is fully open at 103.9°C (219°F).

A hose from the front of the thermostat housing directs coolant to the heater water valve which remains closed below 30°C ± 10°C (86°F ± 50°F). Above this temperature, the heater water valve will open and warm water will be available to the heater water pump. This pump will only run when the temperature is > 10°C (50°F) and will supply warm water to the air conditioning heater matrix. The A/C heater matrix outlet is connected through the return side of the water valve, back to the rear of the engine water pump.

Specifications

Cold Engine (By-pass Circuit) - When the engine is cold and the thermostat is closed, coolant flows from the water pump through the engine, then returns directly to the water pump.

Warm Engine - When the engine is warm and the thermostat is open, coolant flows from the water pump, through the engine, through the thermostat, into the radiator upper coolant hose, through the radiator and then returns to the water pump via the radiator lower coolant hose.

Antifreeze Mix 50% OAT coolant / 50% water.

Pressure Cap 150 kpa.

Thermostat Starts to opens between 88.3 - 92.2°C

(190.9 - 198°F).

Fully open at 103.9°C (219°F).

Leakage Rates 30 cm / Min. 150 - 180 kpa.

60 cm / Min. 10 kpa Man.

Up to 75 kpa @ 150 c m / h.

The heater core is on a parallel circuit and is unaffected by the position of the thermostat.

The anti-freeze is unique and cannot be mixed with other anti-freeze solutions. The OAT coolant/water mixture has a life of 150,000 miles or 5 years (which ever comes first).

Radiator

The radiator is of aluminium construction with plastic end tanks. Foam seals are installed to the radiator to prevent the cooling air from by passing the radiator core. The radiator is located by four isolator mountings and supported by the radiator support beam. A coolant drain plug is provided in the lower RH side for the draining of the coolant. The

Cooling fan shroud is attached to the radiator.

Torque Figures

Description

Condenser A/C pipes

Thermostat housing

Thermostat housing support bracket

Water pump

Water pump pulley

Nm.

8-10

8-12

23-27

23-27

23-27 lb./ft.

6-7.5

6-9

17-20

17-20

17-20

Cooling Fans

Two variable speed electric cooling fans are housed in the cooling fan pack for the cooling of the radiator. The speed of the electric cooling fans is adjusted by the Powertrain

Control Module (PCM).

Coolant Reservoir

A pressurized Coolant Reservoir system is used which continuously removes any air from the cooling system. A continuous vent from the engine and radiator to the coolant expansion tank prevents air locks from forming in the cooling system. No manual bleed points are provided on the system.

The Coolant Reservoir should be full when the coolant system is cold.



Engine (03.00)

Maintenance

Caution

‘Spring band’ clips

‘Spring band’ clips must be installed as detailed below:

2

3

Coolant Hose

Alignment Marks

Spigott

5. Fill the cooling system with the specified coolant to maximum level in the Coolant Reservoir. Install the pressure cap.

Warning

Do not remove the pressure cap when the coolant is hot. Allow time for the coolant / engine to cool. Take particular care to avoid burns from the cooling system.

6. Run the engine until fully warm. Stop the engine and allow to cool down. Any coolant displaced due to expansion will be drawn back into the Coolant Reservoir as the system cools.

7. Re check the level at the Coolant Reservoir. Top-up as necessary to the maximum level.

8. Ensure the filler cap is secure after topping up.

Caution

Do not over tighten.


Pressure Tests

Cooling System

4

All coolant hoses and spigots must be de-greased before assembly.

1. Select the correct pressure tester adaptors and install the pressure tester to the Coolant Reservoir.

2. Bring the engine up to it’s correct working temperature.

3. Test the cooling system following the pressure tester manufacture instructions.

Coolant Drain / Fill


Item

Drain / Fill

Code

03.03.BE

Pressure leakage (Refer to ’Specifications’, page 3-4-2).

Pressure Cap

1. Select the correct pressure tester adaptors and install the pressure tester to the pressure cap.


Warning


2. Remove the pressure cap from the Coolant Reservoir.

3. Loosen the drain plug. Drain the coolant into a suitable container.

Rinse the pressure cap in water to remove any sediment

2. Test the pressure cap following the pressure tester manufacture instructions.

3. Pressure leakage (Refer to ’Specifications’, page 3-4-2).

If replacing a pressure cap, always install one of identical pressure specification to original equipment.

4. Install the drain plug. Ensure the drain plug is secure.



Engine (03.00)

Radiator


Item

Radiator Renew

Code

03.03.EB

Removal

1. Discharge the A/C system.

2. Drain the engine coolant.

3. Remove the airfilter boxes (Refer to ’Air Charging

(03.12)’, page 3-13-1).

4. Remove the headlight units (Refer to ’Front Lights

(17.01)’, page 17-1-2).

5. Remove the ‘Slam’ panel.

6. Remove the A/C pipes from the condenser.

Caution

Ensure open ends are plugged immediately after disconnecting refrigeration parts.

If moist air or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other faults may occur.

7. Remove the front crossmember.

The vehicle wings have to be manoeuvred to remove the crossmember.

Remove bolts (x4) and loosen bolts (x2) from the wings.

When the crossmember is ready to be removed the wings then need to be gently pulled to allow crossmember removal.

7.1

Disconnect the wiring harness plug from the crash sensors (x2).

7.2

Remove wiring harness locaters (x2).

7.3

Remove bolts (x2 each side (inside the wings)).



Engine (03.00)

7.4

Remove bolts (x3 each side).

7.5

Remove bolts (x2).

Withdraw the front crossmember.

8. Remove the fan pack from the radiator.

8.1

Remove bolts (x2) that secure the fan pack to the radiator.

8.2

Withdraw the fan pack from the radiator.

10. Withdraw the radiator complete with the condenser.

Installation

1. Install the radiator, complete with the condenser.

Connect the radiator hoses.

2. Install the fan pack.

3. Install the front crossmember. Install the wings.

4. Install the condenser A/C pipes. Torque bolts to 8-10

Nm .

5. Install the ‘Slam’ panel.

6. Install the headlight units (Refer to ’Front Lights (17.01)’, page 17-1-2).

7. Install the air filter boxes (Refer to ’Air Charging (03.12)’, page 3-13-1).

8. Fill the coolant system.

9. Charge the A/C system.

Thermostat


Item

Thermostat Renew

Removal


2. Disconnect the hoses.

Code

03.03.GB

9. Remove hoses from the radiator.


3. Remove bolt (x1) from the timing cover (thermostat housing support bracket).

4. Remove the bolts (x3) that secure the thermostat.



Engine (03.00)

5. Remove the thermostat housing. Discard the thermostat housing gasket.

6. Withdraw the thermostat from the thermostat housing.

Installation

1. Clean all the mating surfaces and install a new thermostat housing gasket.

2. Install the thermostat into the thermostat housing.

3. Install the thermostat housing support bracket, do not tighten.

4. Install the thermostat housing. Torque bolts (x3) to 8-12

Nm . Torque the thermostat housing support bracket bolt (x1) to 23-27 Nm.

5. Fill the cooling system.

Water Pump


Item

Water Pump Renew

Removal

Code

03.03.LB

1. Drain the cooling system.


4. Remove and discard the water pump ‘O’-ring.

Installation

1. Clean the mating surface of the water pump and install a new 'O' ring.

2. Place the water pump to the water pump body. Secure the water pump. Torque bolts (x4) to 23-27 Nm .

3. Secure the water pump pulley to the water pump.


4. Install the accessory drive belt (Refer to ’Drive Belt’, page 3-6-1).


3. Remove the water pump.


Fuel Charging System (03.04)

Engine (03.00)

Engine (03.00)


Description

The electronic return-less fuel system utilized has the advantages of reduced fuel tank vapor, requires less electrical power and does not require a fuel return line. Fuel is supplied at high pressure to the injectors via two fuel rails (primary and secondary). Each fuel rail incorporates six fuel injectors, and a fuel pressure regulator. A fuel temperature sensor is installed in the primary fuel rail. Powertrain Control Modules (PCMs) maintain 280 kPa across the injectors, by increasing the pulse width modulation signal to the fuel pump controller. This in turn controls the voltage output to the fuel pump.

Fuel rails and injectors are detailed in this chapter. For fuel delivery to the fuel rails and injectors refer to

Chapter 10 (Fuel System).


Operations on fuel system will result in fuel liquid and vapour being present in the working environment. This presents a very serious risk and the following precautions must be strictly observed:

Warning

Operations on refuelling and the fuel system must only be performed by personnel who have completed training on fuel handling.

Warning

Smoking must not be allowed near the working area.

“NO SMOKING” signs must be posted around the working area.

Warning

Any operation which could involve sparks or naked lights (e.g. battery testing, welding, metal grinding, etc.) must not be allowed near the working area.

Warning

A CO2 fire extinguisher must be available close at hand.

Warning

Dry sand must be available close at hand to soak up any accidental fuel spillage.

Warning

If necessary, empty the fuel into an explosion proof container using suitable fireproof fuel handling equipment.

Warning

The working area must be well ventilated.

Warning

Disconnect the battery before commencing work on the fuel system.

Warning

Depressurise the fuel system before disconnecting any fuel lines.

Warning

The engine must be cool before working on the fuel charging system.



Engine (03.00)

Maintenance

Depressurising


Item

Fuel System Depressurising

Code

10.01.EK

1. Read and observe fuel system safety precautions (Refer to ’Safety Precautions’, page 3-5-1).

2. Remove the fuel pump relay from the CEM.

4. Remove the following wiring harness plugs:

• Temperature sender plugs

• Pressure sensor plugs

• Injector harness plugs

5. Remove bolts (x3) securing the fuel rail to the inlet manifold.

6. Remove the secondary latch clip from each fuel line.

7. Disconnect the fuel rails from their supply pipes.

3. Attempt to start the engine.

The engine will run for approx. 11 seconds then stall.

With the fuel pumps disabled the fuel lines will depressurise.

Two fault codes will show on each bank.

• P0087 ‘fuel pressure too low’

• P1233 ‘fuel pump driver module disabled or off line’

Both of these codes can be erased from each bank after the repairs to the fuel system

Fuel Rails

Use a rag / cloth to collect any residual fuel from the opened fuel pipe.

Left and right hand fuel rails to fuel supply hose unions are different sizes.


(Refer to ’412-038 (Quick Disconnect Tool)’, page 20-1-

7)


7)

Push back on the tool. While pushing back on the tool withdraw the fuel rail. Note left and right hand fuel rail for installation.

Installation

Warning

Fire Risk. Before starting work on the fuel system disconnect the earth lead from the vehicle battery .

4. Switch off the ignition and install the fuel pump relay.

1. Locate the fuel rails over the injectors.

2. ‘Pull down’ the fuel rails onto the injectors by tightening bolts (x3). Tighten bolts to 8-12 Nm .

3. Connect the fuel rails to their supply pipes.

Repair Operation Time (ROT) Ensure the fuel rail and fuel supply line are in-line before connection.

Item Code

Fuel Rail Renew x1 03.04.AB

4. Install the secondary latch clip to each fuel line.

Removal x2 03.04.BB

To aid injector and fuel rail removal it may be required to disconnect the coolant pipe, from the thermostat housing, running between the two inlet manifolds.

5. Connect the wiring harness plugs:



1. Depressurise the fuel lines.

3. Remove the engine bay cross brace and the inlet manifold brace.


2. Disconnect the earth (- ve) lead from the vehicle battery.

6. If removed, connect the coolant pipe to thermostat housing.

7. Install the inlet manifold brace and the engine bay cross brace .


Injectors


Item

Fuel Injectors x1 x12

Code

03.04.GB

03.04.FB

Removal

1. Remove the fuel rails.

2. Remove the injectors. Discard the ‘O’ rings.

Installation

1. Install the injectors, complete with new ‘O’ rings.

Position of ‘O’ rings.

Blue (top)

Green (bottom)



Engine (03.00)



Engine (03.00)


Accessory Drive System (03.05)

Engine (03.00)

Engine (03.00)


Description

Maintenance

Drive Belt


Item

Drive Belt Renew

Removal

Code

03.05.AB


2. Using a 3/8 inch ratchet handle 'T' bar, rotate the drive belt tensioner clockwise and slip the drive belt off the idler pulley indicated (A).

Slip the drive belt off the remaining drive pulleys.

3. Check condition of the drive belt. Replace if required.

Auxiliary Drives

A damper pulley installed to the front of the crankshaft drives a ‘polyvee’ drive belt to power all of the engine auxiliaries.

• Air Conditioning Compressor

• Alternator

• Power Steering Pump

• Water Pump

Automatic Belt Tensioner

The automatic belt tensioner consists of an idler pulley which is free to rotate on a bearing, located at the end of a spring-loaded pivot arm.The pivot arm can be turned clockwise (viewed from the front of the engine) for belt removal and installation.

Installation

1. Install the drive belt around all drive pulleys except the idler pulley.

2. Rotate the tensioner assembly clockwise. Install the drive belt to the idler pulley and release the tensioner.

3. Check all pulleys to ensure correct belt location.



Engine (03.00)


Engine Cranking System (03.06)

Engine (03.00)

Engine (03.00)


Maintenance

Starting System Starter Motor

The starting system consists of a pre-engaged type starter motor, battery, remote control switch (ignition switch) and relay. The operation of the starter relay is controlled by the

Powertrain Control Module (PCM).

To protect the starter motor from damage, the PCM prevents the starter from being engaged when the engine is running.

This is done by the PCM inhibiting the starter relay operation. The PCM will only operate the starter relay providing the following conditions are met:

• The ignition switch has been in the start position for a predetermined time

• The security response between the PCM and the Driver

Information Module (DIM) has passed


Item

Starter motor Renew

Removal

Code

03.06.AB



3. Remove the R/H road wheel, road wheel arch liner and the front undertray.

4. Remove the oxygen gas sensors. Disconnect the oxygen gas sensors electrics.

This may provide better access to remove the starter motor.

• The engine is not running

• The transmission range switch is in the Neutral or Park position (vehicles installed with automatic transmission)

• The clutch pedal is operated (USA vehicles installed with manual transmission)

The starter relay remains energized until one of the following occur:

• The PCM detects an engine running signal

• The starter button is on longer pressed

• The transmission range switch is no longer in the Neutral or Park position (vehicles installed with automatic transmission)

• The clutch pedal is released (USA vehicles installed with manual transmission)

With the ignition switch in the start position, providing the

PCM start conditions are met, the starter relay is energized and the engagement lever moves the pinion into mesh with the flywheel ring gear teeth. The electrical contacts within the solenoid complete the high power circuit and the starter motor operates to turn the engine.

5. Remove the VMV valve.

Specifications

Torque Figures

Description

Starter motor

Nm.

50 lb./ft.

37

6. Remove the heat shield.

7. Disconnect the starter motor electrics.



Engine (03.00)

8. Remove bolts (x2) that secure the starter motor.

9. Withdraw the starter motor and oxygen gas sensors bracket.

Installation

1. Place the starter motor and the oxygen gas sensors bracket to the bell housing. Torque bolts to 50 Nm .

2. Connect the starter motor electrics.

3. Install the heat shield.

4. Install the oxygen gas sensors (if removed).

5. Install the front under tray and road wheel arch liner.

6. Install the road wheels and ‘nip-up’ road wheel nuts.

7. Lower the vehicle. Tighten the road wheel nuts (Refer to



Ignition System (03.07)

Engine (03.00)

Engine (03.00)


Description

The ignition system consists of an ignition coil for each individual cylinder located on each individual spark plug.

There are two crankshaft sensors located on the front of the engine - only the RH sensor is used. The second crankshaft sensor is located on the flywheel housing (LH side).

An alternating voltage signal from two Crankshaft Position Sensors (CPS) is converted by the Powertrain Control modules

(PCMs). This digital signal is then used to position the ‘On’ and ‘Off’ time of the primary circuit of the ignition coil. The effective range for ignition timing control is increased by the fact that there are no rotating parts. On the basis of engine speed and load inputs, the PCMs determine the ignition timing. This function also takes other inputs into consideration such as engine temperature, throttle position and transmission control module (TCM) inputs.

• In the event of a short circuit to ground between the fusebox and the coil or the coil and the PCM the fuse would blow and all ignition coils on that bank would cease to function.

• If an ignition coil ‘short circuits’ internally the ignition coil will fail instead of its fuse. This allows the remaining ignition coils to continue functioning.

• In the event of a wiring harness failure between the PCM an7d the ignition coil, the ignition coil will fail instead of its fuse. This allows the remaining ignition coils to continue functioning.

The twelve spark plugs are fired in sequence by the two PCMs. Ignition timing can vary from 55° before TDC to 10° after

TDC.

Crank position sensors

Specifications

Spark Plugs

Firing order 1 - 7 - 5 - 11 - 3 - 9 - 6 - 12 - 2 - 8 - 4 - 10.

Type

Gap

Torque

Dual Platinum Fine Wire

1.2 - 1.3 mm

16-20 Nm


Air Gap 1 ±0.5 mm

Torque Figures

Description

Spark plugs

Ignition coils

Spark plug cover


011-1-014

Nm

16-20

5-7

2.5-3.5

lb./ft.

12-15

4-5.5

2-3

3-8-1


Engine (03.00)

Maintenance

Spark Plugs


Item

Spark Plug Renew All

LH Bank

RH Bank

Code

03.07.DB

03.07.EB

03.07.FB

Removal


2. Remove the spark plug cover.

Installation

1. Install the spark plugs. Torque to 16-20 Nm .

2. Install the ignition coils. Torque bolts to 5-7 Nm .

Connect the ignition coils wiring harness plugs.

3. Install the spark plug cover. Torque bolts to 2.5-3.5 Nm .


3-2-7).

3. Disconnect the ignition coils. Remove the ignition coils.

4. Remove the spark plugs.


Emission Control (03.08)

Engine (03.00)

Engine (03.00)


System Description

To avoid environmental pollution from the crankcase gases (blow-by), the crankcase (engine) is ventilated into the intake system. Any noxious fumes in the crankcase gases are then burned in the normal combustion process.

The system consists of a part load and full load breather system which ensures sufficient engine venting under all running conditions.

Crankcase gases escape through channels in the block walls where they are fed into oil separators to minimise the oil pullover. From the separators, pipe work channels the vent gases to the intake manifold at part load or intake system at full load.

Under part load conditions the system is controlled by the PCV valve which regulates a constant flow of vent gases (engine blowby varies across the range of part load sites). The PCV valve flow is balanced by the ‘make up air’ pipes to the cam covers. The pressure difference across the ends of these pipes (i.e. across the throttle valve) activates the PCV valve.

At full load, the system vents through a 1-way valve to the RH inlet system (pre-throttle) only.

The diameter of the pipes in the system is critical in the control of the Full and Part load operating conditions.Vacuum

Pipework Layout

'Part Load' breather pipe.

Downstream of the throttle body.

'Full Load' breather pipe

Upstream of the throttle body.

'Make up air' pipe under part load running conditions.

Oil seperators (x2)

(Mounted to the cylinder block)

One way 'Duck' valves

Valve assembly

Crankcase vent regulator

(PCV)



Engine (03.00)


Valve Train (03.09)

Engine (03.00)

Engine (03.00)


Description

Camshafts

Inlet and exhaust camshafts in each head are chain driven directly from the crankshaft.

The twin crankshaft sprocket has 18 teeth and each camshaft sprocket has 36 teeth, the timing chains have 61 links. Three chain links are marked and are aligned with timing marks on the crankshaft and camshaft sprockets during valve timing. Because of the odd number of links in the timing chains, the timing marks and marked links will only align once every 122 engine revolutions.

Specifications

Maintenance

Valve Timing Chains


Item

Timing Chain Renew

Removal

Code

TBA

1. Remove the engine from the vehicle (Refer to ’Engine’, page 3-1-4).

2. Remove the camshaft covers (Refer to ’Camshaft Cover’, page 3-11-1)


3-11-3).

4. Remove the crankshaft timing disc.

Note the orientation of the disc for installation.

Valves, Guides & Springs

Spring Force at 40mm Spring Height

Installed Spring Height (Exhaust / Inlet)

Valve Guide Internal Diameter

Valve Guide Maximum Runout

Valve Stem Diameter - Inlet

Valve Stem Diameter - Exhaust

Valve Stem Clearance - Inlet

Valve Stem Clearance - Exhaust

Valve Face Maximum Runout

Valve Lash Adjusters

Bore

Outside Diameter

Clearance

Torque Figures

Description

Timing chain guide

Tensioners

Timing cover bolts

Nm.

290

MM

39.69-40.29

6.015 - 6.044

0.030

5.975 - 5.995

5.950 - 5.970

0.020-0.069

0.046-0.095

0.050

16.018 - 16.057

15.988 - 16.000

0.018 - 0.069

Nm lb. / ft.

20-30 15-22.5

20-30 15-22.5

23-27 17-20

Image to Follow

5. Turn the crankshaft to place the crankshaft key in the vertical position.

Caution






Engine (03.00)

6. Insert the camshaft set tool (Refer to ’303-713 (Camshaft

Set)’, page 20-1-5).

With the crankshaft Key in the vertical position the camshaft flats will accept the camshaft set tool.

LH Cylinder Head (Cylinders 7-12)

2. Engage the camshaft timing service tool (Refer to ’303-

713 (Camshaft Set)’, page 20-1-5) to flats on the camshafts.

7. Remove the RH or LH timing chain tensioner, tensioner arm and timing chain guides.

3. Install the fixed timing chain guide.

Do not remove the timing chain.

7.1

Compress the timing chain tensioner and insert the locking pin (Refer to ’303-1072 (Timing Chain

Tensioner Pins)’, page 20-1-6). Remove bolts (x2) that secure the timing chain tensioner and withdraw.

7.2

Remove the floating tensioner arm.

7.3

Remove the fixed timing chain guide (bolts x2).

Repeat for the second timing chain tensioner and timing chain guides.

8. Remove both timing chains and the crankshaft twin sprocket from the crankshaft.

Installation

Caution


1. Ensure the crankshaft key is vertical and all camshafts are in the initial positions shown.



4. Install the timing chain with the marked links (x3) matching the marks on the crankshaft and camshaft sprockets.

Timing Mark

45

Timing

Mark

45

Crankshaft

Key

Vertical

Crankshaft

Key

Vertical

Timing

Mark

5. Install and tension the timing chain arm and tensioner.

Withdraw the timing chain tensioner lock pin.

6. Ensure that all three marked timing chain links align with the timing marks on the camshaft and crankshaft sprockets.



Engine (03.00)

RH Cylinder Head (Cylinders 1-6)

7. Ensure the crankshaft key is in the vertical position (No.1 cylinder at 30° ATDC). Ensure that the camshafts are in the initial positions shown.

10. Install the timing chain with the marked links (x3) matching timing marks on the camshaft and crankshaft sprockets.

Timing

Mark

Timing

Mark

Crankshaft

Key

Vertical

Crankshaft

Key

Vertical

Timing

Mark




11. Install the timing chain tensioner arm.

12. Install the timing chain tensioner. Remove it’s lock pin.

13. Ensure all three marked links on the timing chain align with the timing marks on the camshaft and crankshaft sprockets.

14. Remove the camshaft timing service tool.

15. Install the crankshaft timing disc, noting orientation from removal.

Image to Follow


16. Check the valve timing (Refer to ’Valve Timing Check’, page 3-10-4).


11-3).

18. Install the engine to the vehicle (Refer to ’Engine’, page

3-1-4).



Engine (03.00)

Valve Timing Check

1. Rotate the crankshaft anti-clockwise at least 60°, then rotate clockwise to TDC No. 1 (crankshaft key 30° before vertical).

2. At TDC No.1, the timing marks on the REAR of the camshaft sprockets should be precisely aligned as shown.



3-11-3).



9. Progressively release all bolts that secure each bearing cap.



On a correctly timed engine, when No. 1 cylinder is at TDC compression the timing marks on the rear of the camshaft sprockets will always align.

10. Withdraw the bearing caps. Ensure they are retained in the sequence withdrawn.

11. Withdraw the camshafts.



Timing marks on the timing chains, camshaft and crankshaft sprockets will only aligned once every 122 crankshaft revolutions on a correctly timed engine.

Be aware - engine oil will bleed from timing chain tensioner.

Camshafts / Camshaft Followers / Lash

Adjusters


Item


Adjusters

Removal

Code

TBA


3-1-4)







Engine (03.00)

13. Cover the engine block to prevent ingress of foreign material.

Installation



Soak the lash adjusters in engine oil and ensure that they are ‘pumped up’ with engine oil.



Caution


15°

15°

Bearing Caps

15°

15°




1-7 1-7

8-14 8-14



Caution










Engine (03.00)

16

24

25

22

23

17

20

21

18

19

26

27

28


9.1

Progressively ‘nip’ down all bolts in the sequence shown. Ensure the camshaft bearing caps pull down evenly into contact with the cylinder head.



9.2

In the sequence shown, torque the camshaft bearing caps to 8-12 Nm .



15

E ngine

F ront

1


3-2-7).


4).

2

10

11

8

9

3

6

7

4

5

12

13

14


11. Install the timing chains. Perform the camshaft timing procedure (Refer to ’Valve Train (03.09)’, page 3-10-1).


11-3).



Engine Sealing (03.10)

Engine (03.00)

Engine (03.00)


Specifications


Torque Figures

Description

Camshaft cover

Timing cover

Idler pulley

Sump bolts

Crankshaft damper

1.

2.

1.

2.

Nm.

8-12 lb. / ft.

6-9

23-27 17-18.5

25-27 18.5-20

15 11.5

90°

120 89

Back out a minimum of 360°

3.

47-53 35-39.5

4.

85°-95°

8-12

5-7

6-9

4-5.5

2.5-3.5

2-3

4. Disconnect the ignition coil connectors. Remove the ignition coils.

Camshaft sensor

Ignition coils

Spark plug cover

Maintenance

Camshaft Cover


Item

Camshaft Covers

Removal

Code

TBA


2. Disconnect the camshaft cover ventilation pipe and the camshaft sensor wiring harness plug.

5. Lower the rear suspension (Refer to ’Rear Suspension

(04.02)’, page 4-3-1).

To gain access to the bolts (x2) that secure the wiring harness carrier to the camshaft covers.

6. Remove bolts (x2) that secure the wiring harness carrier and the electrical device. Lift the wiring harness carrier off the camshaft studs.



Engine (03.00)

7. Remove bolts (x15) that secure the camshaft cover.

Withdraw the camshaft cover.

Discard all camshaft cover seals.

8. Repeat from Step 1. for second camshaft cover.

Installation

1. Apply a bead of sealant where indicated.

RTV Sealant

2. Install new camshaft cover gaskets.

03-01-216

3. Install the camshaft cover. Torque bolts (x15) to 8-12

Nm . in the sequence shown below.

E ngine

F ront

L H C over R H C over

15

16 15

11

17

5

12

9

11

5

6

3 6

1

7

1

8

2

8

4

13

10 4

13

14

01-03-214

4. Place the wiring harness carrier and the electrical device over the camshaft studs. Torque bolts (x2) to 8-12 Nm .

5. Install the rear suspension (Refer to ’Rear Suspension

(04.02)’, page 4-3-1).




8. Connect the camshaft cover ventilation pipe and camshaft sensor wiring harness plug.


3-2-7).

01-03-222



Engine (03.00)

Timing Cover


Item

Timing Chain Cover

Code

TBA

Removal


2. Remove the engine from vehicle (Refer to ’Removal’, page 3-1-4).


4. Remove the top idler pulley and the accessory drive belt from timing cover.

6. Remove bolts (x2) securing water pump to the timing cover.

7. Prevent crankshaft from turning (Refer to ’303-1047

(Crankshaft Holding)’, page 20-1-6) and remove the bolt

/ washer that secures the crankshaft damper.

5. Remove bolts (x4) and withdraw the power steering pump.

8. Using a universal puller, remove the crankshaft damper.

9. Remove the crankshaft position sensors (x2).


10. Remove the camshaft covers (Refer to ’Camshaft Cover’, page 3-11-1).



Engine (03.00)

11. Remove the thermostat housing.

11.1 Remove hoses (x4).

11.2 Remove bolts (x3).

11.3 Remove bolt (x1) from the timing cover.

Installation

1. Ensure mating surfaces are clean and smooth. Install new timing cover seals.

E ngine

B lock S ide

12. Remove bolts (x2) securing the sump to the timing cover.

01-03-223

2. Apply RTV sealant at the cylinder head joints as shown.

The timing cover must be installed and secured within 6 minutes of applying beads of sealant.

13. Remove the remaining bolts (x14) that secure the timing cover. Withdraw the timing cover. Discard the timing cover gaskets.

3-11-4

RTV Sealant

Gasket Trimming

3. Secure with bolts (x14).

The shorter bolt locates in position 2.

Do not install the thermostat bracket bolt.

Torque the bolts, in sequence, to 23-27 Nm .

When the timing cover bolts are torqued, the ends of the timing cover seals may protrude from the joints. Trim flush with a sharp knife.

0 1 - 0 3 - 1 0 4



Engine (03.00)

4. Install the thermostat housing complete with the thermostat and a new ‘O’-ring (Refer to ’Thermostat’, page 3-4-5). Torque bolts (x3) to 8-12 Nm . Torque the thermostat housing support bracket bolt (x1) to 23-27

Nm.

1 Tighten to 120 Nm .

2 Back out a minimum of 360° .

3 Tighten to 47-53 Nm .

4 Tighten a further 85°-95° .

8-12 Nm.

23-27 Nm.

5. Install the upper idler pulley. Torque bolt to 25-27 Nm .

6. Install the accessory drive belt tensioner. Torque bolt to

25-27 Nm .

9. Install the crankshaft sensors (x2). Torque bolts to 8-12

Nm . Connect the wiring harness plugs.

10. Secure the power steering pump and the water pump to the timing cover. Torque bolts to 23-27 Nm .



13. Fill the coolant system (Refer to ’Cooling System

(03.03)’, page 3-4-1).


2).

7. Install the sump bolts (x2). Torque to 15 Nm. + 90° .

8. Install the crankshaft damper.

8.1

Clean all sealant from the crankshaft key-way and oil the crankshaft damper seal surface.

Apply silicone sealant to seal the key-way end.

8.2

Prevent crankshaft from turning (Refer to ’303-1047

(Crankshaft Holding)’, page 20-1-6) and torque the crankshaft damper bolt in four stages:



Engine (03.00)

Crankshaft Rear Oil Seal


Item

Crankshafts Rear Oil Seal

Code

TBA

3. Install the oil seal slinger (Refer to ’TBA (Crankshaft Rear

Oil Seal Slinger Install)’, page 20-1-4).

The oil seal slinger installs one way only on the oil seal slinger install tool.

Removal

1. Automatic Gearbox Only

Remove the rear subframe complete with the transaxle

(Refer to ’Rear Subframe’, page 2-1-4).

2. Manual Gearbox Only

Remove the transaxle (Refer to ’Manual Transmission

(07.03)’, page 7-3-1)

3. Remove the torque tube (Refer to ’Torque Tube’, page

5-1-2).

4. Remove the flywheel (Refer to ’Flywheel’, page 3-12-9).

5. Using the service tools (Refer to ’TBA (Crankshaft Rear

Oil Seal and Slinger Removal)’, page 20-1-4) extract the oil seal slinger and oil seal from the oil seal retainer.

Details on removal procedure (Refer to ’Crankshaft Rear Oil

Seal Remove (TBA)’, page 20-1-11)

6. Clean the oil seal recess and mating surface of the oil seal retainer. Clean the mating surfaces on the engine block and sump. Ensure all mating surfaces are oil free.

Installation

Caution

Throughout this procedure it is essential that all parts remain clean, free of dirt, grease and debris.

1. Lubricate the seal recess and seal surface with engine oil.

2. Install the rear crankshaft oil seal (Refer to ’303-664

(Crankshaft Rear Oil Seal Install)’, page 20-1-5).

Spring side towards the engine

When the oil seal install tool has bottomed out on the oil seal housing the new oil seal has been installed to the correct depth.

Insert the seal ensuring it sits squarely into the retainer recess.

Oil Seal Slinger

4. Install the flywheel (Refer to ’Flywheel’, page 3-12-9).

5. Install the torque tube (Refer to ’Torque Tube’, page 5-

1-2).


Install the transaxle (Refer to ’Manual Transmission

(07.03)’, page 7-3-1)


Install the rear subframe complete with the transaxle





Crankshaft Front Oil Seal


Item

Crankshafts Front Oil Seal

Code

TBA

Removal

1. Remove the timing cover (Refer to ’Camshaft Cover’, page 3-11-3).

2. Remove the oil seal from the timing cover.

Installation

1. Clean the seal recess in the timing cover.

Lubricate the outside of the new seal and seal recess with engine oil.

2. Install the timing cover (Refer to ’Camshaft Cover’, page

3-11-3).

3. Position a new seal on the seal recess.


Install the seal (Refer to ’303-664 (Crankshaft Rear Oil

Seal Install)’, page 20-1-5).


Engine (03.00)

Lubricate the seal surface with engine oil before installing the crankshaft damper.



Engine (03.00)


Power Conversion (03.11)

Engine (03.00)

Engine (03.00)


Description

Crankshaft


A twin sprocket, installed to the front end of the crankshaft, drives the camshaft timing chains. A damper pulley on the crankshaft drives the engine auxiliaries via the accessory drive belt.

Also at the front of the engine a timing disc is installed together with a crankshaft sensor (RH side). The sensor provides engine position signals to PCMs.

A second crankshaft sensor (LH side) is installed at the front of the engine - but is not used.

Specifications

Crankshaft

Main Bearing Diameter

MM

67.480 - 67.504

Main Bearing Clearance 0.025 - 0.050

Refer to the Main Bearing Grade Chart for bearing shell selection.

Connecting Rod Bearing Diameter

Connecting Rod Bearing Clearance

Crankshaft End Float

49.97 - 49.99

0.028 - 0.066

0.130 - 0.301

Turning Torque

Guideline figures only

Crankshaft and rear seal only

Crank, rear seal + pistons & rods

Crank, rear seal, pistons & rods + camshafts & tensioned chains

Nm.

6

16 - 20

36 - 44

Crankshaft Sensors

Air Gap

MM

1 (±0.5)

Pistons and Connecting Rods

Six crankshaft big end journals each carry a pair of connecting rods. The connecting rods are secured to the crankshaft by individual connecting rod caps enclosing the connecting rod bearing shells. Connecting rod bolts are of the ‘torque to yield’ type and must be renewed if removed.

Piston Ring Gaps at 89.000

Cylinder Bore Diameter

Upper compression ring

Lower compression ring

Oil control rings

MM

0.100 - 0.250

0.270 - 0.420

0.150 - 0.650

Compression Ring Vertical

Clearance



MM

0.040 - 0.075

0.040 - 0.885

011-1-006

Piston Pin

Piston pin to rod clearance

Interference

Clearance at 20°C (68°F)

MM

0.005

0.001

Connecting Rods

Piston pin to connecting rod clearance

Piston pin to piston interference

Big End Side Clearance (2 rods)

MM

0.004 - 0.020

-0.005 - 0.001

0.225 - 0.625

Piston Height Above the Block

Face at TDC MM

Average of two readings taken along the crankshaft axis. A straight line must pass between the two readings and the center of the pistion.

0.415 (Below)

0.115 (Above)

Each piston carries two compression rings and one oil control ring. The arrow on each piston crown must point to the front of the engine during installation.

Connecting rods are manufactured as a single piece with fracture lines at the connecting rod bearing. Each connecting rod cap is cracked from the connecting rod after machining and drilling. Thus each connecting rod cap will only install to, in correct orientation, its matching connecting rod.



Engine (03.00)

Torque Figures

Description

Engine block spread tool

Nm.

25 lb./ft.

18.5

Main bearings 1. Bolts 1 to 14.

2. Bolts 15 to 28.

3. Bolts 1 to 28.

37-43

22-28

27.5-32

16.5-21

85°-95°

Main cap side bolts 1. Bolts 29 to 42. 22-28 16.5-21

Connecting rods

2. Bolts 29 to 42.

1.

85°-95°

20-25 15-18.5

Windage tray

2.

3.

40-45

1.

5-7

30-33.5

105°-120°

4-5.5

2.

Sump 1.

15

45°

11.5

2.

Flywheel

Damper plate (Auto only)

90°

75-81 55.5-60

30 22.5

Piston Skirt Grading Chart

Main Bearing Grade Chart

The finished diameter of the crankshaft main bearing bores is indicated by letters stamped on the cylinder block face.

The first letter, e.g. ‘D’, refers to No.1 journal, the second letter element refers to No.2 journal and so on.

The finished diameter of the seven crankshaft main bearing journals are indicated by seven letters stamped in bearing number sequence on No.1 counterweight.

The first letter in the sequence refers to No.1 journal, the second letter refers to No.2 journal and so on.

1. Read the first letter on the cylinder block face and note it.

2. Read the first letter on No. 1 crankshaft counterweight and note it.

3. Using the letters, select the correct bearing grade for No.

1 journal.

4. Repeat steps 1-3 to obtain the correct bearing grades for journals 2-7.

Grade

1

2

Piston Diameter

‘A1’Prior to Skirt

Coating

88.970 / 88.980

88.978 / 88.992


89.000 / 89.010

89.008 / 89.022

3 88.990 / 89.000

89.020 / 89.030

Skirt Coating adds 0.020 - 0.030 to the diameter as follows:

Grade

1

Piston Diameter

(Coated)

88.990 / 89.010

2

3

88.998 / 89.022

89.010 / 89.030

Clearance with Coating

New Build -0.014

(interference)

New Build + 0.024

(clearance)

Service Limit + 0.050

(clearance)



Engine (03.00)

Minimum Block Diameter

A B C D E F G H I J K L M N O P Q R S T U V W X

72.400

.401 .402 .403 .404 .405 .406 .407 .408 .409 .410 .411 .412 .413 .414 .415 .416 .417 .418 .419 .420 .421 .422 .423 .424

X 67.504

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2

W 67.503

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2

V 67.502

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2

U 67.501

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2

T 67.500

1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2

S 67.499

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2

R 67.498

1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2

Q 67.497

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3

P 67.496

1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3

O 67.495

1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3

N 67.494

1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3

M 67.493

1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3

L 67.492

1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3

K 67.491

1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3

J 67.490

1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3

I 67.489

1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3

H 67.488

1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3

G 67.487

2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3

F 67.486

2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

E 67.485

2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3

D 67.484

2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3

C 67.483

2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

B 67.482

2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

A 67.481

2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

Bearing Grade 1 = Orange

Bearing Grade 2 = Blue

Bearing Grade 3 = Green

The bearing grade is stamped, in ink, on the inside of the bearing.

Maintenance

Crankshaft


Item

Crankshaft Renew

Code

TBA

Removal


2. Remove the cylinder heads (Refer to ’Cylinder Heads’, page 3-2-2).


4. Remove the windage baffle.



Engine (03.00)

5. Remove bolts (x6) that secure the rear oil seal retainer and withdraw the seal retainer and oil seal.

7. Remove the piston and connecting rod assemblies.

7.1

Remove the connecting rod bolts and withdraw the connecting rod caps, complete with bearings.

6. Remove the oil pump.

3-12-4

7.2

Withdraw the piston and connecting rod assemblies, complete with bearings, from the top of the bore.

Ensure each piston / connecting rod / connecting rod cap set remain together in order for installation to their original locations.

Connecting rods and caps have identification marks which must match and align upon reassembly.

An arrow stamped on the piston upper face must point towards the front of the engine when reassembled.

Connecting rods are symmetrical and do not require front to rear orientation.

Connecting rod bolts have ferrules pressed into the caps for new build bolt retention / ease of assembly. Replacement bolts do not have the captive ferrule. Original bolts can be removed by tapping the bolt out of the cap with a rubber mallet.



Engine (03.00)

8. Remove the main bearing caps and bearing shells.

To withdraw the bearing caps, spread the engine block side walls using the engine block spreading tool (Refer to ’303-

664 (Crankshaft Rear Oil Seal Install)’, page 20-1-5), tensioned to 25 Nm .

To avoid overstriking engine block walls, do not exceed 25 Nm . on engine block spreader bolt.

Component Checks

1. Examine the crankshaft journals for wear, scuffing or other defects. Replace the crankshaft if un-serviceable.

2. Examine all bearing shells and thrust washers for wear, scuffing or other defects. Replace if un-serviceable.

3. If required, measure the diameter of the crankshaft main and big end bearings.

Compare results with data in engine specifications.

• The finished diameter of crankshaft main bearing bores is indicated by numbers stamped on engine block face

• The finished diameter of crankshaft main bearing journals are indicated by seven letters, stamped in bearing number sequence, on No.1 counter weight

4. Refer to Main Bearing Grade Chart in Engine

Specifications if the main bearings are to be replaced.

Installation

Caution

Lubricate all bearing surfaces with SAE 50 Assembly Oil.

Ensure all components are clean and free of damage prior to reassembly.

8.1

Remove the side bolts (x14).

8.2

Remove the outer bolts (x14) from the main bearing caps.

1. Install the upper bearing shells and thrust washers (No 4 bearing). Check the oil feed hole alignment.

Record positions of the stud bolts at No. 3 and 6 main bearing caps.

The thrust washers are installed with the groove facing the crankshaft.

2. Install the crankshaft into the upper main bearings.

8.3

Remove the inner bolts (x14) from the main bearing caps.

Retain all components in order for installation to their original locations, if serviceable.

9. Remove the crankshaft from the engine.

10. Remove the thrust washers from No. 4 main bearing.

11. Remove the upper bearing shells from all the main bearings.

If serviceable, retain all bearings, in order, for refitting to their original locations.



Engine (03.00)

3. Install and ‘seat’ the main bearings and caps.

Caution

Oil beneath the head of all the main bearing bolts. Do not oil threads. ‘Hand start’ them into their holes.

Note the positions of the stud bolts at No. 3 and 6 main bearing caps from removal.

3.1

Insert the inner and outer bolts to all main bearing caps.

3.2

Lightly ‘run down’ the bolts to seat the main bearing caps.

3.3

Release all bolts approx. one turn.

To install the bearing caps spread the engine block side walls using the engine block spreading tool (Refer to ’303-


To avoid overstriking engine block walls, do not exceed 25 Nm.

on engine block spreader bolt.

6. Insert the main caps side bolts. Torque the main cap side bolts, in sequence detailed, to:

1 Bolts 29 to 42 - 22-28 Nm. + 40°-50°

4 0

3 6

Front of Engine

2 6

1 8

2 2

1 2

8

1 1

7

2 5

1 7

2 1

3 9

3 5

3 2

3 1

4 3

1 6 1 5

3 0

2 9

2 1

2 4

3 4

3 3

6 5

3 8

2 0

1 9

3 7

1 0 9

4 2

2 8

2 7

4. Set No. 4 main bearing so the end loads are taken on both the upper and lower bearing thrust faces.

4.1

Bias the crankshaft maximum rearward against the upper thrust bearing.

4.2

With the crankshaft fully rearward, bias No. 4 bearing cap maximum rearward against the crankshaft thrust face.

4.3

Bias the crankshaft forward.

5. Torque the main bearing cap bolts, in the sequence detailed, to:

1 Bolts 1 to 14 - 37-43 Nm .

2 Bolts 15 to 28 - 22-28 Nm .

3 Bolts 1 to 28 - rotate 85°-95°

Check and, if required, adjust No. 1 main bearing cap so that the front face does not protrude forward of the oil pump mounting face.

Main bearing bolts are torqued to yield. They must be tightened precisely as specified.

1 4

Dial Indicator

1 3

7. Check the crank shaft end play.

FRONT OF ENGINE

0.130 - 0.301 mm

Crankshaft

4 1



Engine (03.00)

8. Check the crankshaft turning torque.

The turing torque must not exceed 6 Nm .

9. Complete with their upper big end bearing shell, install the pistons and connecting rods in their numbered positions. If new pistons or connecting rods are being installed, check the piston height (Refer to

’Specifications’, page 3-12-1).

Ensure that the piston rings are installed and located correctly (Refer to ’Pistons and Connecting Rods’, page 3-

12-1).


Ensure that the sump oil outlet locates to the oil pump inlet before the sump is faced up to the engine block.


Arrows stamped on the piston upper surface must point towards the front of the engine during reassembly.

Use cylinder protectors during piston and connecting rod installation (Refer to ’303-535 (Cylinder Bore Protectors)’, page 20-1-4).

10. Install the connecting rod bearing caps and shells, noting correct orientation of each cap.

Check that connecting rod and cap identification marks match and align.

Secure caps using two new bolts to each cap.

Torque all connecting rod bolts in three stages:

1 To 20-25 Nm .

2 To 40-45 Nm .

3 Rotate a further 105°-120° .







11. Install the windage tray.

Torque nuts (x4) to 5-7 Nm + 45° .

12. Install new a ‘O’-ring to the oil pick-up pipe.



Engine (03.00)

Caution

Ensure that the crankshaft key is in the vertical position.

14. Install the cylinder heads and camshafts (Refer to

’Cylinder Heads’, page 3-2-2).

15. Install the timing chains. Check and ensure that the valve timing is correct (Refer to ’Valve Timing Check’, page 3-10-4).


11-3).


18. Install the engine auxiliaries.

19. Install and tension the accessory drive belt.

20. Complete engine reassembly and prepare to install to vehicle.

Ensure that the connecting rods and caps are a matched set.

1. Heat the piston to approximately 70°C and install the connecting rod and piston pin.

Warning

Pistons are heated to approx. 70°C. Wear protective clothing, e.g. gloves, to avoid burns.

Install the connecting rod to the piston with the ‘notch’ in the little end bearing (3) facing the same direction as the arrow stamped on the piston head (4).

1

2

1

4

3



Item

Pisteo and Connecting Rods Renew

Overhaul

Code

TBA

Keep all components in sets for installing in their original locations, if serviceable.

1. Remove the piston pin circlips. Discard the circlips.

Warning


2. Heat the piston to approx. 70°C and push out the piston pin. Allow the components to cool.

3. Using a ring spreader, remove the piston rings from the piston.

4. Wash all components. Replace any with obvious wear or other signs of deterioration.

Check that components meet dimensional specifications

(Refer to ’Specifications’, page 3-12-1).

5. Repeat for all pistons.

Reassembly

Pistons are graded for each cylinder bore. If the pistons and

/ or connecting rods are to be reinstalled, they must be in their original sets and in their original positions.

The grade of a cylinder bore (1, 2 or 3) is marked on outside of engine block, adjacent to the bore. Pistons are similarly graded (1,2 or 3) on their upper surface. Make sure the correct piston grade is chosen when installing a new piston.

Secure the piston pin (2) with new circlips (1).

Allow the pistons cool.

2. Before installing to the engine, rotate the piston rings as necessary to the positions shown on the following diagram.

Front

Front

Rear

30°

30°

Front



Engine (03.00)

Flywheel


Item

Flywheel Renew

Code

TBA

Removal

1. Disconnect the vehicle battery .

Warning

If rasing vehicle on a ‘two post’ ramp (vehicle supported by underbody), Ensure that the rear end of the vehicle is securely strapped to the ramp. Failure to strap the rear of vehicle down may lead to the vehicle falling off the ramp.

Caution

The flywheel assembly, including the mounting bolts, is a balanced assembly. Use the same bolts when reassembling to retain balance.

8. Place a support surface under the flywheel. Insert flywheel bolts (x2) into the threaded ‘jacking’ holes in the flywheel.

Warning

The flywheel is heavy. Take care to provide adequate support when removing or replacing it.

If using a two post vehicle lift, remove the screws that secure the rear section of the road wheel arch liner. Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly (Refer to ’Jacking Points’, page I-I-IX).


3. Remove the rear road wheel(s) and road wheel arch liners.

4. Remove the front and rear undertrays and the shear plate.

Lower the front undertray to reveal the air intake for the alternator. Release the spring clip and part the flex pipe from the undertray.

5. Remove the rear subframe and torque tube.

• (Refer to ’Rear Subframe’, page 2-1-4)

• (Refer to ’Torque Tube’, page 5-1-2)


Remove the clutch assembly (Refer to ’Clutch (08.00)’, page 8-1-1).

7.

Automatic Gearbox Only.

Remove the drive damper plate (bolts x8).Retain for installation.

9. Tighten the bolts in stages to ease the flywheel from its location on the crankshaft.



Engine (03.00)

Installation

1. Using a suitable support surface under the flywheel, offer the flywheel to the crankshaft and align the attachment holes.

2. Loosely install the flywheel mounting bolts (x8) and hand tighten.

3. Tighten the bolts in half turn stages in sequence shown. Continue until the flywheel face is in full contact with the crankshaft flange.

4. Loosen the bolts. Then torque to

75-81 Nm in the same sequence.


8

6

1

4

3

2

5

7

Install the clutch assembly (Refer to ’Clutch (08.00)’, page 8-1-1).


7. Install the drive damper plate. Torque bolts (x8) to 30

Nm .

The damper plate will only install one way, locating on dowels provided.

8. Install the torque tube and the rear subframe.



9. Install the front and rear undertrays.


11. Bleed the brakes. (Refer to ’Brake Bleeding - WDS’, page 6-4-4).



13. Remove the vehicle securing strap, if installed.



Air Charging (03.12)

Engine (03.00)

Engine (03.00)


Description

Air Induction System

Intake air is filtered and then passed through mass air flow (MAF) meters. Signals from the MAF meters are fed to the PCMs and are used together with other signals in calculating the required amount of fuel (Air fuel ratio approx. 14.3 parts air to

1.0 part fuel by weight). The air then passes through the throttle bodies into the six branch inlet manifolds.

Specifications

Torque Figures

Description

Air box cover

Outlet pipe

Air box mountings

Nm (lb. / ft.)

1.5-2.0

1.5

1.5-2.0

1.5

2.5-3.5

2-2.5



Engine (03.00)

Maintenance

Air Filter

20. Remove air filter.


Item

Air Filter Renew LH

RH

Code

03.12.CB

03.12.DB

Removal




16. Remove the road wheel(s).


18. Remove the screws (x3). Pull the front section of the wheel arch down to gain access the air filter box.

21. Repeat for second air filter.

Installation

1. Push the air filter onto the filter adaptor. Install the box cover. Torque bolts to 1.5-2.0 Nm .

19. Remove bolts (x7) and remove filter box cover.

1.5-2.0 Nm. (x7)

2. Install the front section of the road wheel arch liner.


4. Install the road wheel(s) (Refer to ’Road Wheel Nut




Engine (03.00)

Air Filter Box


Item

Air Box Renew LH

RH

Code

03.12.AB

03.12.BB

Removal





3. Remove the road wheel(s) and arch liner.


6. Remove the air filter box mounting bracket (x1) and mounting bolts (x2). Withdraw the air filter box.


Installation

1. Place the air filter box into position and secure.

5. Disconnect the air outlet and inlet pipes.

Outlet pipe - Remove fixing screw. Twist the outlet pipe and pull away.


2. Connect the outlet and inlet pipes.

Outlet pipe - Insert and twist, install fixing screw.


4. Install the road wheel arch liner and front undertray.





Engine (03.00)


Engine Management System (03.14)

Engine (03.00)

Engine (03.00)


The electronic engine control system consists of two

Powertrain Control Modules (PCM’s) and a number of sensing and actuating devices. The sensors supply the PCM’s with input signals which relate to the engine operating conditions and driver requirements. The sensor information is evaluated by the PCM’s using the results to activate the appropriate response from the actuating devices.

The system provides the necessary engine control accuracy and adaptability to:

• Minimize exhaust emissions and fuel consumption

• Provide optimum driver control under all conditions

• Minimize evaporative emissions

• Provide system diagnostics

In addition to these functions the PCM’s also interface with other vehicle systems through the controller area network

(CAN).

Refer to the Vehicle OBDII manual for inputs / outputs and diagnostic information

Schematic Diagram

P C M

F uel P ump

Drive Module

T o other half of E ngine

V apour

Management

V alve

P C M

P C M

F uel T ank

P res s ure S ens or

F uel T ank

F iller

Neck

T o atmos phere

P C M C arbon

C anis ter

F uel P ump

F uel Level

S ens or P C M

F uel F ilter C anis ter

V ent V alve

F uel R ail

Drain

T ube

P C M

C oolant

T emp S ens or

011-1-016

F uel

Injector

Inlet Manifold

S park

P lug

Ignition

C oil

P C M

C ams haft

P os ition S ens or

P C M

Motoris ed

T hrottle

Intake Air

T emp S ens or

P C M

E xhaus t

Manifold

T hrottle

P edal

P C M

C ranks haft

P os ition S ens or

Oxygen S ens or

H02S 1-1

C atalytic

C onverter

P C M

Oxygen S ens or

H02S 1-2

E xhaus t

MAF

P C M

Air F ilter

F uel

V acuum

V apour



Engine (03.00)

Specifications

Powertrain Control Modules (PCMs)

Secondary (B) Primary (A)

T - Transmission

C0634- Description

47 HTR 12

48 HTR 22

50 CNVNT

LH and RH Drive

PCM A

View looking into the PCM connectors.

T

Caution

Check plugs to ensure correct connector

C E

(Refer to ’Circuit Diagrams’, page 18-1-17)



4 PRND

9 MAF+

10 MAF-

14 CB2+

17 Drive TT

18 Sport TT

19 Tip up

20 Tip down

21 MIL

24 HEGO 12

25 HEGO 22

26 CB2-

28 Rev TT

29 PRND 2

30 CB 3+

31 CB 3-

32 Neutral TT

33 Sport SW

36 Bap

38 Engine off

40 Ref. voltage C

41 Signal return C

43 Park ST

45 Park TT

I

I

0

I

0

I

I

I

I

0

0

I / 0 Circuit Page

I 8

I

I 67

67

13

9

8

9

9

30

43

43

0

I

I

0

16

9

8

68

13

8

8

16

9

9, 68

43, 68

9

8

C - Cowl


2 Start enable

3 ISO-K

4 App1 Ref. voltage

5 App 1

6 App 1 Return

7 Brake pedal switch

8 Brake On / Off switch

9 Fuel tank pressure

10 Case ground

11 CB 1+

12 Motor fuel pump

14 Power steering pressure

15 Accs (Aircon demand)

16 App 2 Ref. voltage

17 App 2

18 App 2Return

19 Sccs (Speed Con Demand)

20 Restraint deploy Ind

21 Fuel pump monitor

22 Oil Pressure

23 CB 1-

24 Power hold

25 Aircon clutch relay

26 Aircon pressure

29 Clutch (Top of travel)

30 Sccs (Speed Con Return

31 TX out (PATS Comms)

32 Vehicle speed sensor+

33 Vehicle speed sensor-

34 EVMV

35 Power

36 Power

37 PATIL (PATS LED)

38 PBI (Start button ILL)

39 Clutch (Bottom of travel)

40 Ref. voltage B

41 Signal return B

42 RXIN (PATS Comms)

43 EBV

44 FEPS

45 Keep alive power

47 Power ground



0

0

0

43

43

68


I

I

I


0 70

9

72

I 72

72

39

39

68

56

16

41 0

I

I

I

65

6

72

72

I

72

71

I

0

I

0

0

I

0

0

I

I

I

I

2

41

65

16

I

I

0 50, 56, 63

0 6

6

70

65

56

56

30

71

63

68

68

70

70

6, 65, 68

6, 65, 68, 70

63

68

16

56

56


Engine (03.00)

C - Cowl


48 Power ground

49 Power ground

50 IGNSNS


I

56

56

56

PCM B

View looking into the PCM connectors

.

Caution


T C E

E - Engine


1 (CD1) Clyinder 1

2 Injector 1

3 Injector 6

4 Injector 4

5 Injector 3

7 Throttle pot return

8 Injector 5

9 Injector 2

10 Injector 7

11 Injector 8

12 (CD5) Cylinder 5

13 Inlet air temperature

14 Fan Control

15 Camshaft / Crankshaft Return

18 Throttle Pot Reference Volume

19 TP1-NS

24 (CD3) Cylinder 3

25 CID 1

29 TP2-PS

30 HEGO 11

31 Hego21

33 Engine Coolant Temperature

34 Crankshaft Position

35 (CD6) Cylinder 6

36 Fuel Rail Temperature

37 Fuel Rail Pressure Tran

38 (CD2) Cylinder 2

39 (CD4) Cylinder 4

40 Ref. Voltage A

41 Signal Return

45 Crankshaft Positive

47 Throttle Mtr +

48 Throttle Mtr -

49 HTR11

50 HTR21

0

0

I

0

0

0

I

I

I

I

I

I

I

I

0

0

0

0

0

0


0 47

0

0

48

48

0

0

48

48

72

48

48

48

48

47 0

I

0

67

21

65

72

I

0

72

47

65

47

47

65

43, 65, 67

65

72

72

43

43

65

65

47

65

65

72

43

43


E - Engine


1 (CD7) Cylinder 1

2 Injector 1

3 Injector 6

4 Injector 4

5 Injector 3


8 Injector 5

9 Injector 2

10 Injector 7

11 Injector 8

12 (CD11) Cylinder 5




19 TP1-NS

24 (CD9) Cylinder 3

25 CID 1

29 TP2-PS

30 HEGO 11

31 HEGO 21

34 Crankshaft Position+


37 Fuel tank pressure tran

38 (CD8) Cylinder 2


40 Ref. Voltage A

41 Signal Return

45 Crankshaft Positive -

47 Throttle Mtr +

48 Throttle Mtr -

49 HTR11

50 HTR21

0

0

I

0

0

0

0

0

0

0

I

I

0

I

I

I

I

I

0

I

0

0


0

0

0

0

0

47

66

44, 66, 67

72

72

72

44

44

66

47

66

47

66

72

44

44

66

72

72

47

48

48

47

67

48

72

48

48

47

48

48

48




4 Engine coolant level

6 PRI / Sec switch

9 MAF +

10 MAF -

14 CB 2 +

24 HEGO 12

25 HEGO 22

26 CB 2 -

30 CB 3 +

31 CB 3 -

38 Altmon

41 Signal return C

47 HTR 12

48 HTR 22

C -Cowl



5 App 1

6 App 1 return



10 Case ground

11 CB 1+

12 Motor fuel pump


17 App 2

18 App 2 Return



23 CB 1-

24 Power hold



34 EVMV

35 Power

36 Power

44 FEPS

45 Keep alive power

47 Power ground

48 Power ground

49 Power ground

50 IGNSNS

Torque Figures

Description

PCM mount


Engine (03.00)

I

I

I


I 66

I

I

I

44

67

67

13

44

44

13

16

I

0

0

16

69

44

44

44

Maintenance

WDS Connection

The port for WDS connection is located in the drivers side footwell on the transmission tunnel.

I

0

0

I


72

I

I

72

72

39

I 39

56

0

I

I

I

I

56

56

16

56

56

68

68

66

56

56

56

56

72

2

41

16

16

41

72

72

LHD

000000

CRUISE

Body

000 0

000000 MILES

CRUISE

D

Engine

RHD

Nm.

8-10 lb./ft.

6-7.5



Engine (03.00)

PCM


Item

PCM Renew LH

RH

Code

03.14.AB

03.14.BB

Removal



3. Remove the road wheel and road wheel arch liner.


Installation

1. Install the PCM and the bracket. Torque bolts (x3) to 8-

10 Nm .


3. Install the door check rod.





5. Disconnect the door check rod.

6. Remove bolts (x3) and withdraw the bracket and the

PCM.



Engine (03.00)


Evaporative Emissions (03.13)

Engine (03.00)

Engine (03.00)


System Operation

Description

The evaporative loss system prevents escape of fuel vapours into the atmosphere.

Fuel vapour is displaced from the fuel tank during filling.

Vapour is also displaced due to fuel evaporation in higher temperatures. Displaced fuel vapour is absorbed in the carbon canister filter located on top of the fuel tank.

During normal engine running, absorbed fuel vapour is purged from the carbon canisters and mixed with the normal fuel/air charge in the inlet manifold.

Displaced fuel vapour leaves the fuel tank via the normally open fill level vent valve and the roll over valves. It passes through the carbon canister where fuel hydrocarbons are absorbed. Clean air leaves the system via the normally open canister vent valve. This valve is only closed during diagnostic pressure testing of the fuel system.

During normal engine running, the single vapour management valve in the engine bay is periodically opened allowing fresh air flow into the open canister vent valve, through the carbon canister, through the vapour management valve and into the primary inlet manifold. This fresh air flow progressively purges any absorbed fuel vapour from the carbon canister.



Engine (03.00)


Throttle Control (03.16)

Engine (03.00)

Engine (03.00)


Specifications

Description

Motorised Throttles

The motorised throttles (x2, one to each inlet manifold) allow accurate control of the inlet air.

A throttle position sensor (TPS) is incorporated into each motorised throttle unit. During normal engine run, TPS signals are used by the PCMs to indicate power demand from the engine. If not already at the desired position, the

PCMs will drive the throttle motors to open or close the throttles by the required amount.

At idle, the throttle butterflies are almost closed and idle speed is controlled by small throttle movements.

The throttle butterflies are spring loaded to fail in the idle position. In the event of the throttle butterflies springs failing, air flow will allow the throttle butterflies to fail in the idle position.

No set-up procedure is required.

Torque Figures

Description

Throttle body

Maintenance

Throttle Body


Item

Throttle Body Renew

Removal

1. Disconnect the air intake pipe.

Nm.

8-12 lb./ft.

6-9

LH

RH

Code

03.04.HB

03.04.JB




4. Withdraw throttle body complete with gasket. Discard the ‘O’ ring.



Engine (03.00)

Installation

1. Install the throttle body complete with a new ‘O’ ring.


2. Install the air intake pipe and wiring harness plug.



Contents

Subframes (02.03) .................................................2-1-2

Specifications.......................................................... 1-2

Maintenance........................................................... 1-2

Front Subframe ...................................................... 1-2

Removal.............................................................. 1-2

Installation .......................................................... 1-3

Rear Subframe ....................................................... 1-4

Removal.............................................................. 1-4

Installation .......................................................... 1-8


Subframes (02.03)




Specifications

Torque Figures

Description

Subframe to Front Structure

Subframe to Body

Engine Mounts

Steering Rack

Torque tube (rear)

Drive Plate (auto only)

Spring and Damper top mounting

(rear)

Rear subframe to Body 175

Rear subframe reinforcement plates 62

Maintenance

Front Subframe

Nm.

lb. / ft.

105-125 77.5-92.5

105-125 77.5-92.5

47 35

115 85

43-57 32-42.5

72

85

53.5

63

129.5

46


Item

Front Subframe

Code

02.01.AB

Removal







4. Remove the front road wheels and road wheel arch liners.


Lower the undertray to reveal the air intake for the alternator. Release the jubilee clip and part flex pipe from the undertray. Remove the front undertray.

6. Disconnect the lower suspension arms (Refer to ’Front


Disconnect the anti-roll bar from the lower arms. Leave the anti-roll bar attached to the subframe.

7. Remove bolts (x2) that secure the engine mounts to the subframe.

8. Remove bolts (x3) that secure the steering rack to the subframe.

‘Ty-wrap’ the steering rack in position.

9. Support the subframe.

10. Ensure that the relation of the subframe to the front structure and the vehicle body is marked (scribed), for accurate installation.


11. Remove bolts (x12) that secure the subframe to the body and the front structure.

Withdraw the subframe.

Bolts x2 (each side)



2 Torque the bolts that secure the subframe to the body to 105-125 Nm .

Bolts x4 (each side)

01-02-14a 3 Torque the bolts that secure the subframe to the front structure to 105-125 Nm .

Installation

1. Raise the subframe to the front structure. Install the subframe mounting bolts (x12).

Ensure that the subframe to the front structure and the vehicle body alignment marks are lined up.

Tighten the bolts in three stages:

1 ‘Nip-up’ the bolts that secure the subframe to the front structure.

2. Install the engine mount nuts (x2). Torque nuts to 47

Nm .

'Nip Up' Bolts




3. Install the steering rack bolts (x3). Torque bolts to 115

Nm .

Release the ‘Ty-wraps’ on the steering rack.

4. Install the lower suspension arms (Refer to ’Front


The bolts that secure the lower suspension arm must be torqued only when the vehicle is at normal ride height

(Refer to ’Road Wheel Alignment (04.00)’, page 4-1-2).

5. Remove the engine support service tool.


7. Install the road wheel arch liners and road wheels.


5-7).


9. Check / Adjust the camber, Toe and Castor settings

(Refer to ’Road Wheel Alignment (04.00)’, page 4-1-2).

Rear Subframe


Item

Rear Subframe

Code

02.01.CA

Removal


Warning

If rasing vehicle on a ‘two post’ ramp (vehicle supported by underbody), ensure that the rear end of the vehicle is securely strapped to the ramp. Failure to strap the rear of vehicle down may lead to the vehicle falling off the ramp.

Caution

If using a two post vehicle lift, remove the screws that secure the rear section of the road wheel arch liner.

Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly (Refer to ’Jacking Points’, page I-I-IX).


3. Remove the rear road wheels and road wheel arch liners.





Lower the undertray to reveal the air intake for the alternator. Release the spring clip and part the flex pipe from the undertray.

• Shear plate

5. Remove the intermediate exhaust pipe and the rear LH and RH exhaust pipes (Refer to ’Pipes and Supports

(09.03)’, page 9-2-1).




6. Remove the silencer assembly.


Remove the gearbox coolant pipes.

7.1 Remove the coolant thermostat from it’s mounting bracket.

7.2 Disconnect the coolant pipes from the gearbox.

7.3 Cap the pipes open ends.

Gearbox ends are self sealing.

9. Manual Transaxle Only.

Disconnect the wiring harness plug.

8. Automatic Transaxle Only.

Disconnect the following from the transaxle:

• Wiring harness plugs 10. Remove accessible bolts from around the torque tube.

Do not remove the lower bolts (x2) facing towards the gearbox.

• Manual override cable

Disconnect manual override cable




11. Automatic Transaxle Only.

Remove the bolts (x3) that secure the torque tube drive plate to the torque converter.

14. Disconnect the brake pipes.


13. Disconnect the handbrake cable from the calipers and subframe (Refer to ’206-103 (Handbrake Cable

Removal)’, page 20-1-4).

End of Handbrake Cable

Caution


15. Position the subframe trolley (Refer to ’303-F715 (Multipurpose Trolley) x2’, page 20-1-5) under the subframe.

Lower the vehicle until the subframe rests on the subframe support.

Subframe Trolley

01-02-048

01-02-049

16. Remove bolts (x4) that secure the spring and damper units.

Ensure the spring and damper assemblies are fully extended to release spring tension. A small amount of tension will remain.

Lever spring and damper mounting turret against spring tension to allow removal of bolts.




17. Remove the subframe securing bolts.


18.




Caution



19. Raise the vehicle for access and remove the bolts that secure the torque tube to the gearbox.



20. Move the subframe rearwards on its support to give a clearance between the torque tube and the gearbox.

Slowly raise the vehicle from the subframe.





21.


Install a torque converter transit bracket.

Transit Bracket image


Install the gear selector cables.


Install the gearbox to the torque tube.

6.1 Remove the torque converter transit bracket.

6.2 Move the subframe forward. Place the torque converter to the torque tube drive plate.

6.3 Install the bolts around the torque tube. Torque to

43-57 Nm .


23. If required, remove the transaxle from the subframe

(Refer to ’Transmission (07.00)’, page 7-1-1)

Installation

1. If removed, install the transaxle.

• Automatic (Refer to ’Automatic Transaxle

(07.01)’, page 7-1-2)

• Manual (Refer to ’Manual Transmission

(07.03)’, page 7-3-1).

2. Ensure the spacers from each rear subframe mounting pad are located correctly.

3. Lower the vehicle to the subframe.

Ensure the vehicle lowers without catching pipes, cables, etc.

Ensure the suspension assembly is placed slightly to the rear of the final position. This will enable installation to the torque tube.


Install the gearbox to the torque tube.

4.1 Lower the vehicle to enable the gearbox to line up with the propshaft splines.

4.2 Move the subframe forward. Engage the gearbox to the propshaft splines.

4.3 Install the bolts around the torque tube. Torque to

43-57 Nm .


Connect the drive plate.

7.1 Install bolts (x3). Torque bolts to 60-85 Nm .

8. Install the handbrake cable to the subframe and the calipers.

End of Handbrake Cable


01-02-048




9. Install the spring and damper units.

9.1 Lower the vehicle to line up the spring and damper mounts to the body.

9.2 Install bolts (x4) to each mount. Torque to 85 Nm .

10. Lower the vehicle to meet the subframe mounts.

Install bolts (x4) that secure the subframe to the body.

Torque bolts to 175 Nm .

If the anti-roll bar was removed ensure the two rear bolts are installed.


Install to the gearbox:

• Manual override cable

• Coolant pipes

• Wiring harness plugs

• Breather pipe


Install the wiring harness plugs.

Caution


15. Connect the brakes pipes.

16. Install the exhaust system.

17. Install the front and rear undertrays and the shear plate.



The fuel filler drain off pipe is attaches to the arch liner.




22. Connect vehicle battery.

11. Install the subframe reinforcement plates. Torque bolts to 62 Nm .

12. Connect the subframe wiring harness plugs.






Contents

Engine Assembly (03.00) ......................................3-1-3

Description ............................................................. 1-3

Maintenance ........................................................... 1-4

Engine ................................................................... 1-4

Removal.............................................................. 1-4

Installation ........................................................ 1-11

Engine Removal from the Frame .......................... 1-13

Removal............................................................ 1-13

Installation ........................................................ 1-14

Engine Structure (03.01) .......................................3-2-1

Description ............................................................. 2-1

Engine Block .......................................................... 2-1

Cylinder Heads ...................................................... 2-2

Inlet / Exhaust Manifolds ........................................ 2-2

Specifications.......................................................... 2-2

Maintenance ........................................................... 2-3

Cylinder Head ....................................................... 2-3

Removal.............................................................. 2-3

Installation .......................................................... 2-4

Inlet Manifold ........................................................ 2-7

Removal.............................................................. 2-7

Installation .......................................................... 2-9

Exhaust Manifold ................................................. 2-10

Removal............................................................ 2-10

RH manifold...................................................... 2-10

LH Manifold ...................................................... 2-11

Installation ........................................................ 2-13

Lubrication System (03.02)...................................3-3-1

Description ............................................................. 3-1

Oil flow ................................................................. 3-1

Specifications.......................................................... 3-2

Engine Oil Specification ......................................... 3-2

Maintenance ........................................................... 3-2

Oil Drain ............................................................... 3-2

Oil Filter ................................................................ 3-2

Removal.............................................................. 3-2

Installation .......................................................... 3-3

Sump..................................................................... 3-3

Removal.............................................................. 3-3

Installation .......................................................... 3-4

Oil Pump............................................................... 3-6

Removal.............................................................. 3-6

Installation .......................................................... 3-6

Cooling System (03.03) ........................................ 3-4-1

Description............................................................. 4-1

Coolant Circuit ...................................................... 4-1

Water Pump .......................................................... 4-2

Thermostat ............................................................ 4-2

Radiator................................................................. 4-2

Cooling Fans.......................................................... 4-2

Coolant Reservoir .................................................. 4-2

Engine Oil Cooler .................................................. 4-2

In-Vehicle Heating ................................................. 4-2

Specifications ......................................................... 4-2

Maintenance........................................................... 4-3

Coolant Drain / Fill ................................................ 4-3

Pressure Tests ........................................................ 4-3

Cooling System ................................................... 4-3

Pressure Cap ....................................................... 4-3

Radiator................................................................. 4-4

Removal.............................................................. 4-4

Installation .......................................................... 4-5

Thermostat ............................................................ 4-5

Removal.............................................................. 4-5

Installation .......................................................... 4-6

Water Pump .......................................................... 4-6

Removal.............................................................. 4-6

Installation .......................................................... 4-6

Fuel Charging System (03.04)............................... 3-5-1

Description............................................................. 5-1


Maintenance........................................................... 5-2

Depressurising .................................................... 5-2

Fuel Rails ............................................................... 5-2

Removal.............................................................. 5-2

Installation .......................................................... 5-2

Injectors................................................................. 5-3

Removal.............................................................. 5-3

Installation .......................................................... 5-3

Accessory Drive System (03.05) ........................... 3-6-1

Description............................................................. 6-1

Auxiliary Drives...................................................... 6-1

Automatic Belt Tensioner....................................... 6-1

Maintenance........................................................... 6-1

Drive Belt .............................................................. 6-1

Removal.............................................................. 6-1

Installation .......................................................... 6-1


Engine Cranking System (03.06) .......................... 3-7-1

Starting System .......................................................7-1

Specifications ..........................................................7-1

Maintenance ...........................................................7-1

Starter Motor..........................................................7-1

Removal ..............................................................7-1

Installation ..........................................................7-2

Ignition System (03.07) ........................................ 3-8-1

Description .............................................................8-1

Specifications ..........................................................8-1

Maintenance ...........................................................8-2

Spark Plugs.............................................................8-2

Removal ..............................................................8-2

Installation ..........................................................8-2

Emission Control (03.08) ..................................... 3-9-1

System Description .................................................9-1

Valve Train (03.09)............................................. 3-10-1

Description ...........................................................10-1

Camshafts ............................................................10-1

Specifications ........................................................10-1

Maintenance .........................................................10-1

Valve Timing Chains.............................................10-1

Removal ............................................................10-1

Installation ........................................................10-2

LH Cylinder Head (Cylinders 7-12).....................10-2

RH Cylinder Head (Cylinders 1-6) ......................10-3

Valve Timing Check .............................................10-4

Camshafts / Camshaft Followers / Lash Adjusters...10-4

Removal ............................................................10-4

Installation ........................................................10-5

Engine Sealing (03.10) ....................................... 3-11-1

Specifications ........................................................11-1

Maintenance .........................................................11-1

Camshaft Cover....................................................11-1

Removal ............................................................11-1

Installation ........................................................11-2

Timing Cover .......................................................11-3

Removal ............................................................11-3

Installation ........................................................11-4

Crankshaft Rear Oil Seal.......................................11-6

Removal ............................................................11-6

Installation ........................................................11-6

Crankshaft Front Oil Seal......................................11-7

Removal ............................................................11-7

Installation ........................................................11-7

Power Conversion (03.11) ..................................3-12-1

Description ...........................................................12-1

Crankshaft............................................................12-1


Specifications........................................................12-1

Piston Skirt Grading Chart ....................................12-2

Main Bearing Grade Chart....................................12-2

Maintenance .........................................................12-3

Crankshaft............................................................12-3

Removal ............................................................12-3

Component Checks ...........................................12-5

Installation ........................................................12-5


Overhaul...........................................................12-8

Reassembly .......................................................12-8

Flywheel ..............................................................12-9

Removal ............................................................12-9

Installation ......................................................12-10

Air Charging (03.12) ...........................................3-13-1

Description ...........................................................13-1

Air Induction System ............................................13-1

Specifications........................................................13-1

Maintenance .........................................................13-2

Air Filter...............................................................13-2

Removal ............................................................13-2

Installation ........................................................13-2

Air Filter Box ........................................................13-3

Removal ............................................................13-3

Installation ........................................................13-3

Engine Management System (03.14) ..................3-14-1

Schematic Diagram...............................................14-1

Specifications........................................................14-2

Powertrain Control Modules (PCMs).....................14-2

PCM A ..............................................................14-2

PCM B ..............................................................14-3

Maintenance .........................................................14-4

WDS Connection .................................................14-4

PCM ....................................................................14-5

Removal ............................................................14-5

Installation ........................................................14-5

Evaporative Emissions (03.13) ............................3-15-1

Description ...........................................................15-1

System Operation ................................................15-1

Throttle Control (03.16)......................................3-16-1

Description ...........................................................16-1

Motorised Throttles ..............................................16-1

Specifications........................................................16-1

Maintenance .........................................................16-1

Throttle Body .......................................................16-1

Removal ............................................................16-1

Installation ........................................................16-2


Engine (03.00)


Description


Engine (03.00)

The engine is an all aluminium 6.0 litre 60° V12 configuration. The cylinder heads have dual overhead camshafts and four valves per cylinder. An electronic engine management system controls the sequential multi-port fuel injection and distributor-less ignition systems.

The engine uses the latest ‘fast-burn’ combustion technology. Heated oxygen sensors monitor the oxygen content of exhaust gasses. The engine management system uses the oxygen sensor signals together with other engine information to

‘fine tune’ fuelling levels and ignition timing. This helps to achieve the best possible fuel burn with minimum exhaust emissions. The exhaust system incorporates six catalytic convertors to minimise the levels of harmful gasses passing into the atmosphere. Additional oxygen sensors are placed after the catalysts so that long term catalyst efficiency can be monitored.

The engine runs on unleaded fuel only.



Engine (03.00)

Maintenance

Engine


Item

Engine Remove and Install

Including engine removal from the frame

Removal

Code

03.00.AA

To remove the engine from the vehicle the complete power train will be removed.

1. Disconnect the earth (‘- ve) terminal from the vehicle battery.

2. Evacuate the A/C unit (Refer to ’Air Conditioning (A/C)

System (12.03)’, page 12-3-1).

3. Disconnect the A/C pipes.

6. Remove the washer bottle neck bracket.


8. Withdraw the plastic cover and disconnect the forward wiring harness plugs.

Side Marker

Light

(FED Only)

Horn

Temperature Sensor

4. Drain the coolant (Refer to ’Coolant Drain / Fill’, page 3-

4-3).

9. Remove the bonnet release cable.

Caution

Before removing the engine bay corner cross-braces ensure that the at the vehicle is resting on it’s roadwheels.

5. Remove the engine bay corner cross-braces. Do not remove the engine bay cross brace.


10. Disconnect the following from the forward cross member.

• The reinforcement struts


Engine (03.00)

12. Remove the bolts and the reinforcement brackets from the inner wing.

Remove the header tank to gain access. Be aware that there is a wiring harness plug connected to the header tank on the under side.

• The ‘Jump start’ plug

• The power steering reservoir

13. Centre the steering wheel. Remove the ignition key and engage the steering lock with the wheel as accurately centred as possible.

Failure to centre the steering wheel may cause damage to the restraint bag clock-spring and also may cause difficulties in attaining correct alignment of the steering wheel in the straight ahead position.

14. From inside the cabin, pull back the steering colum bulkhead seal. Remove the pinch bolt that secures the upper column to the intermediate shaft.

15. Disconnect the engine harness from inside the vehicle cabin.


Disconnect the clutch pipe.



Engine (03.00)


Remove the screws that secure the rear section of the road wheel arch liner. Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly.

(Refer to ’Jacking Points’, page I-I-IX).

Caution

Ensure the vehicle is ‘strapped’ to the lift.

24. Remove the engine bay fusebox and bracket.

Remove harness plugs.

17. Remove the undertrays and shear plates.

Note the positions of the (x4) spacers when removing the front shear plate.

23.

18. Remove all road wheels and arches.

19. Remove the air filter boxes.

20. Remove the front bumper.

21. Disconnect the headlight units lower mount.

22. Disconnect the following forward wiring harness plugs.

• Fan pack


• MAF sensor



Remove

Power cable.

25. Disconnect the earth points from the bulkhead. Mark the leads at the clean earth studs.

These are ‘Clean Earths’ labelled ‘Bank A’ and ‘Bank B’.

Reconnect to correct stud.

• Right Hand side

Headlight level switch

• Left Hand Side



Engine (03.00)

26. Remove the PCMs. Disconnect the engine wiring harness plugs and remove the three screws that secure the PCM (each side).

27. Move the removed engine wiring harness plugs into the engine bay and secure to the engine cross brace.

30. Disconnect the front brake pipes:

Caution


30.1 Disconnect the brake pipe from the brake modulator to the L/H front brake caliper.

28. Remove the brake booster vacuum pipe

29. Disconnect the heater coolant pipes.

On LH drive vehicles the heater coolant pipes enter the bulkhead on the RH side.

30.2 Disconnect the brake pipe in the RH wing.

31. Remove the intermediate steering shaft.

31.1 Remove the lower pinch bolt. Open the lower mount.

31.2 Pull the intermediate steering shaft downwards and remove.



Engine (03.00)

32. Disconnect the fuel lines.

37. Disconnect the handbrake cable from the rear subframe

(Refer to ’Hand Brake (06.05)’, page 6-3-1).

Use the brake cable release tool (Refer to ’206-103

(Handbrake Cable Removal)’, page 20-1-4).

33. Remove the VMV to inlet manifold pipe from the VMV.


34. Disconnect the torque tube to body (engine) earth lead.

35. Disconnect the Starter / Alternator / Jump terminal cable from the chassis.

39. Disconnect the rear brake pipes.

36. Disconnect the silencer from the two rear exhaust pipes.

Caution



40. Remove the rear brake pipe brackets.


Engine (03.00)

43. Ensure that the relation of the front subframe / front structure to the vehicle body is marked (scribed), for accurate installation.

44. Remove bolts (x12) that secure the front subframe / front structure to the body.


Disconnect the manual override cable.

Image to Follow

45. Remove the bolts (x3) that secure the emmisions filter unit. This allows access to the spring and damper unit top mount.

Disconnect from the body

42. Position the subframe trolleys, front and rear (Refer to

’303-F715 (Multi-purpose Trolley) x2’, page 20-1-5) under the subframes. Lower the vehicle until the front and rear subframes rests on the subframe trolleys.

Connect the two trolleys together (Refer to ’303-F715-06

(Trolley Brace Bars)’, page 20-1-5).

Front Pin

01-03-227

46. Remove bolts (x4) that secure the rear spring and damper units.

Ensure the rear spring and damper assemblies are fully extended to release spring tension. A small amount of tension will remain.

Lever the rear spring and damper mounting turret against spring tension to allow removal of bolts.

Rear Pin Image to Follow



Engine (03.00)

47. Remove the rear subframe securing bolts.


48.




Caution



3-1-10

49. Slowly raise the vehicle.

As the vehicle raises disconnect the wings from front grill.

Ensure all pipes, cables, etc., are clear as the vehicle raises.

LH drive vehicles - ensure that the coolant pipe is in front of the brake booster.




Engine (03.00)

Installation

1. Lower the vehicle to the powertrain assembly.

Ensure all pipes, cables, etc., are clear as the vehicle lowers.

As the vehicle lowers pull the wings from front grill.

8. Torque the front subframe and front structure bolts.

Ensure that the front subframe / front structure to body alignment marks are lined up.


2. Install the rear spring and damper assemblies. Do not tighten the bolts.

3. Install the front subframe and front structure mounting bolts (x12). Do not tighten.

4. Install the rear subframe mounting bolts (x4). Do not tighten.

Spacers from rear subframe mounting pads should be installed in the same positions as removed.

5. Install the rear subframe reinforcement plates.

6. Torque the rear spring and damper assemblies - 85.5

Nm .

9. Torque the rear subframe mounting bolts.

1 Torque the bolts that secure the subframe to the body to 175 Nm .

2 Torque the bolts that secure the subframe reinforcement plates to 62 Nm .

7. Install the emmisions filter unit.

Connect to the body


01-03-228

10. Connect the rear subframe wiring harness.



Engine (03.00)


Install the manual override cable.


• Install the gear change linkage

• Install the wiring harness plugs


Caution


Install the clutch pipe.

14. Install the brake pipes:

Caution


25. Connect the earth points to the bulkhead.

• RH side

• LH Side

• Install the LH front brake caliper pipe to the modulator

• Install the rear brake pipe brackets.

• Install the brake pipes to all remaining brake calipers.

15. Install the handbrake cable to the handbrake lever

16. Connect the torque tube to body (engine) earth lead.

17. Connect the Starter / Alternator / Jump terminal cable to the body.

26. Install the steering intermediate shaft.

27. Install the fusebox.

27.1 Connect the wiring harness plugs

27.2 Connect the main power feed

27.3 Install the fusebox bracket and fusebox

28. Install the power steering reservoir.

29. Install the jump start cable.

30. Install the A/C pipes.

31. Install the bolts and reinforcement struts along the inner wings.

32. Install the header tank.

Caution

Before installing the engine bay cross-braces ensure that the at the vehicle is resting on it’s roadwheels.

18. Install the heater coolant pipes.

19. Connect the VMV.


21. Install the headlight units (L/H and R/H).

22. Install both air filter boxes.

23. Install the PCMs. Connect the engine wiring harness plugs.

24. Connect the following forward wiring harness plugs.

• Fan pack


• MAF sensor



33. Install the engine bay corner cross braces. tighten

34. Install the front bumper.


36. Install:

.


• Shear plates

Note the positions of the (x4) spacers from removal on the front shear plate.

Do not

37. Bleed the brakes (Refer to ’Brake Bleeding - WDS’, page

6-4-4).



39. Torque the engine bay cross-braces to 49 Nm.

40. Fill the coolant (Refer to ’Coolant Drain / Fill’, page 3-4-

3)



Engine (03.00)

41. Charge the A/C unit (Refer to ’Air Conditioning (A/C)

System (12.03)’, page 12-3-1).

7. Attach the lifting eyes (x4) to the cylinder heads.

42. Check the road wheel alignment (Refer to ’Road Wheel

Alignment (04.00)’, page 4-1-2).

9. Raise the hoist to take up ‘slack’ in lifting gear.

10. Remove the torque tube.

Always check the steering angle sensor (viaWDS) after any work carried out on the steering or the suspension systems or the yaw rate sensor.


10.2 Remove bolts (x) that secure the torque tube to the engine block.


Engine Removal from the Frame

Removal

10.3 Ensuring the torque tube and engine are adequately supported, move the engine frame and hoist forward until there is room to manoeuvre the torque tube away from the engine block and exhaust manifolds.

1. Release the exhaust manifolds from the catalysts.


2. Remove the following hoses:

3. Disconnect the AC pipe from the condensor.

4. Remove the hose from the header tank.

11. Remove the engine mount nuts (x2).

5. Disconnect the cables from the starter motor and the alternator.

6. Remove the power steering pump hoses.

12. Lift the engine clear of the frame assembly. Secure the engine to an appropriate stand.

Detach the lifting gear.



Engine (03.00)

Installation


2. Raise and manoeuvre the engine to the frame.

3. Ensuring the torque tube is adequately supported, manoeuvre the engine to torque tube.

4. Locate the propshaft splines and ‘face up’ the engine block to the torque tube.

5. Install the bolts that secure the torque tube to the engine block. Torque the bolts to:

• M8 - 25 Nm .

• M10 - 50 Nm .

6. Install the engine mounts. Torque the nuts (x2) to 47

Nm .

7. Remove the lifting equipment and lifting eyes.

8. Install the hose to the header tank.

9. Connect the AC pipe to the condensor.

10. Install the following hoses:

11. Install the power steering pump hoses.

12. Install the cables to the starter motor and the alternator.

13. Install the exhaust manifolds to the catalysts. Torque the nuts and bolts to 25.5 Nm .


Engine (03.00)


Description

Engine Block


Engine (03.00)

Dowels are installed to the principal mating faces of the block to ensure accurate alignment of cylinder heads, front timing cover, auxiliaries, etc.

The 60° V12 aluminium engine block incorporates paths for water cooling, oil distribution and positive crankcase ventilation. The seven main bearing caps supporting the crankshaft are bolted laterally as well as vertically to provide additional crankcase stiffening whilst keeping engine weight to a minimum. Each bearing cap is numbered to identify its position in the engine block The 12 cast iron cylinder liners are inserted and machined during block production and require specialist equipment for replacement.


A twin sprocket installed to the front end of the crankshaft drives the camshaft chains. A damper pulley installed on the crankshaft nose drives the engine auxiliaries via a polyvee drive belt. Also at the front of the engine a timing disc is installed together with two crankshaft sensors. The sensors provide engine position signals to the two Engine control modules.



Engine (03.00)

Cylinder Heads

Each cylinder is provided with two inlet and two exhaust valves. The valves are operated by cam followers beneath each camshaft. Valve clearances are maintained at zero by a hydraulic tappet system (lash adjuster) pressurised from the main engine lubrication system.

Inlet / Exhaust Manifolds

Two six-branch exhaust manifolds, locate four primary catalytic converters and eight oxygen sensors.

Four engine management oxygen sensors are mounted before the primary catalysts. Four catalyst monitor oxygen sensors are mounted after the primary catalysts.

Specifications

Block

Cylinder Bore Grade 2

Main Bearing Bore (without shells)

Cylinder Heads

Head Face-Roof Button

Valve Seat Width - Inlet

Valve Seat Width - Exhaust

Camshaft Bore

Camshaft Journals

Head Volume

MM

89.010 - 89.020

72.400 - 72.424

MM

14.75 - 15.25

1.10 - 1.40

1.40 - 1.70

26.987 - 27.012

26.936 - 26. 962

46.70 - 49.70 ml.

Camshaft End Play

0.025 - 0.165 mm (using a force of 30-50 lbs - do not exceed 50 lb. as damage may occur to the thrust washer).


Air Gap

MM

1 (±0.5)

Intake air is filtered and passed through mass air flow meters

(MAF). The air then passes through the throttle bodies into the six branch inlet manifolds.

Torque Figures

Description

Cylinder head 1. Bolts 1 to 14

2. Bolts 15-16

3. Bolts 1-14

4. Release bolts 1-14

5. Bolts 1 to 14

6. Bolts 15-16

7. Bolts 1 to 14

8. Bolts 1 to 14

Camshaft bearing caps

Nm.

lb./ft.

37-43 27.5-32

15-20 11.5-15

85°-95°

Min. 360°

37-43 27.5-32

23-27 17-20

85°-95°

85°-95°

8-12 6-9



Engine (03.00)

Maintenance

Cylinder Head

Removal


3-1-4)


3. Remove the exhaust manifold (Refer to ’Exhaust

Manifold’, page 3-2-10).






3-11-3).



10. Remove both camshafts.



10.1 Progressively release all bolts that secure each bearing cap.



10.2 Withdraw the bearing caps. Ensure they are retained in the sequence withdrawn.

10.3 Withdraw the camshafts.


10

4

8

6

2

12


Engine (03.00)

12. Remove bolts (x2 (M8) and (x14 (M10)) from the cylinder head in order as shown below.

L eft S ide S hown

15

E ngine

F ront 16

13. Withdraw the cylinder head. Discard the cylinder head gasket.

Cover the engine block to prevent ingress of foreign material.

14 11

7

3

1

5

9

13

14. Remove the second cylinder head if required.

15. Overhaul the cylinder head(s) as required (Refer to

’Cylinder Head’, page 3-2-3).

Installation


1. Place a new cylinder head gasket over the locating dowels.

2. Lubricate beneath the head of all the cylinder head bolts

(x14 (M10) and x2 (M8) with engine oil. Do not lubricate the threads.

Place the bolts to the cylinder head.



Engine (03.00)

Caution

The following ‘Torque - Release - Torque’ sequence must be performed exactly as specified to ensure correct cylinder head to engine block sealing.

3. Torque the cylinder head in stages using the following procedure:

15

14

10

E ngine

F ront

L eft S ide S hown

16

11

7

3.2

Release

1 Loosen bolts 1-14 (M10) a minimum of one full turn

(360°).

3.3

Final Torque

1 Torque bolts 1-14 (M10) to 37-43 Nm.




4 Torque bolts 1-14 (M10) an additional 85-95° in the sequence shown.

4. Repeat for the second cylinder head.


Soak the lash adjusters in engine oil.



Caution



6 3

2 1

4 5

8 9

12 13

3.1

Initial Torque

1 Torque bolts 1 -14 (M10) to 37-43 Nm . in the sequence shown.





Caution






Engine (03.00)




13.1 Progressively ‘nip’ down all bolts in the sequence shown. Ensure the camshaft bearing caps pull down evenly into contact with the cylinder head.

15° 15°

13.2 In the sequence shown, torque the camshaft bearing caps to 8-12 Nm .

15° 15°

E ngine

F ront

15 1

16



Bearing Caps

1-7 1-7

8-14 8-14

17

18

19

20

21



22

23

24

25

26

27

28

2

10

11

8

9

3

6

7

4

5

12

13

14

3-2-6


15. Install the timing chains. Perform the camshaft timing procedure

16. (Refer to ’Valve Train (03.09)’, page 3-10-1).


11-3).



Engine (03.00)






5. Remove the following from the inlet manifold.

22. Install the exhaust manifold (Refer to ’Exhaust Manifold’, page 3-2-10).


3-2-7).


4).

Inlet Manifold


Item

Inlet Manifold Renew LH

RH

Code

03.01.BB

03.01.DB

Removal



3. Remove the engine bay corner braces (x2), engine bay cross brace and manifold brace.

4. Remove the air intake pipe.



Engine (03.00)


• Fuel rail temperature sender wiring harness plug

• Fuel rail pressure sensor wiring harness plug

• Injector wiring harness plugs

6. Remove the thermostat housing by-pass hose. Plug the open ends.

Warning

If the fuel system is pressurised, fuel will be released and may contaminate eyes and / or skin.

8. Remove the fuel rails and injectors.

8.1

Remove bolts (x6) that secure the fuel rails.

8.2

Withdraw the fuel rails sufficiently to remove the injectors.

8.3

Discard the injector ‘O’ rings.



Engine (03.00)

9. Disconnect the fuel rails from the fuel supply hoses.

Installation

Left and right hand fuel rails to the fuel supply hose unions are different sizes.

Ensure all faces are clean and free of damage / contamination.

9.1

Remove the secondary latch clip from each fuel line.

9.2




1. Place a new inlet manifold gasket to the inlet manifold.

Locate the two ‘lipped’ holes in the gasket through the two corresponding bolt inserts in the inlet manifold.

2. Install the inlet manifold.



9.3

Push back on the tool. While pushed back withdraw the fuel rail.

2.1

Place the inlet manifold to the cylinder head and install the vacuum harness to the rear of the inlet manifold.

2.2

Locate the inlet manifold to the cylinder head.

Ensure the gasket remains in position.

2.3

Secure the inlet manifold to the cylinder head.

Torque bolts (x7), in the order detailed below, to 8 -

12 Nm .

Engine Front

Remove Secondary

Latch Clips

10. Remove the inlet manifold.

10.1 Remove bolts (x7) that secure the inlet manifold to the cylinder head.

10.2 Withdraw the inlet manifold sufficiently to gain access to it’s rear and disconnect the vacuum harness.

10.3 Withdraw the inlet manifold. Discard the gaskets.

11. Cover the inlets to the cylinder head to prevent contamination of the cylinders.



Engine (03.00)

3. Install the injectors to the inlet manifold, complete with new ‘O’ rings.

Exhaust Manifold


Note position of ‘O’ rings

• Blue (top)

• Green (bottom)


4.1

Locate fuel rails over injectors.

Item

Exhaust Manifold Renew

Removal

LH

RH

Code

09.03.DB

09.03.EB

4.2

Pull down’ fuel rail onto injectors by tightening bolts

(x3). Torque bolts to 8-12 Nm .



5. Connect fuel rails to fuel supply lines.

3. Remove the front roadwheels and wheel arch liners.

Ensure each fuel rail and fuel supply line are ‘in-line’ before connection.


5. Remove the lower suspension arms.

6. Install the secondary latch clips to the fuel lines.

7. Connect the following wiring harness plugs:

• Temperature sender to fuel rail

• Pressure sensor to fuel rail

• To the injectors

8. Connect thermostat housing by-pass pipe.

9. Install the air intake hose.

10. Install the engine bay corner braces (x2), engine bay cross brace and manifold brace. Torque bolts to:

• Engine cross brace - 49 Nm.

• Manifold brace - 8-12 Nm .

• Corner braces - 49 Nm.

6. Disconnect the anti-roll bar links.


RH manifold

1. Remove the steering column (RH drive only).


2. Remove the starter motor.


Engine (03.00)

6. Remove exhaust manifold.

6.1





6.2




6.3



LH Manifold




Engine (03.00)


5. Remove the exhaust manifold.

5.1


3. Remove the dip stick.

5.2




5.3




Installation

Use new gaskets.

1. Place a new gasket and the exhaust manifold to the cylinder head.

2. Install nuts (x12). Torque nuts, in sequence shown, to

18-22 Nm .

Engine Front

9

5

1

5

1

3

7

11

6

2

10

11

6

2

4

8

12 12

3. Install the Heated Oxygen sensors (x2) and the Catalyst

Monitor sensors (x2).


5. Install:

5.1

LH Manifold .

• The Dip stick

• The Lower steering column (LH drive only)

5.2

RH Manifold .

• The Alternator

• The Starter motor

• The Lower steering column (RH drive only)


7. Install the lower suspension arms and anti-roll bar links

(Refer to ’Front Suspension (04.01)’, page 4-2-1).


9. Install the road wheels.(Refer to ’Road Wheel Nut




Engine (03.00)

3-2-13


Engine (03.00)


Engine (03.00)


Description


Engine (03.00)

The engine uses a wet sump lubrication system.

Oil is drawn from the sump via an oil strainer and pick-up tube to the crankshaft driven oil pump. Pressure from the oil pump is limited by a built in oil pressure relief valve. Pressurised oil then flows from the left side of the engine through a filter and cooler then back into the engine main oil gallery.

Oil pressure at the re-entry point is approximately 60 psi with the engine hot and should reach at least 100 psi when cold.

Oil flow

Sump Oil strainer Oil pump

Oil filter and cooler

Main oil gallery

Crankshaft mains

Connecting rod big ends

Oil squirters

Connecting rod small ends

Timing chain tensioners

Vertical oil feed gallery

Both cylinder heads

Camshaft bearings

Sump

Splash feed

Timing chains and sprockets



Engine (03.00)

0W-30

Authority

API

ACEA

ILSAC

0W-40

Authority

API

ACEA

ILSAC


Engine oil

Europe / Aus

USA

Mobil 1

0W-40

0W-30 or 0W-40

To achieve the required high performance of synthetic lubricants, do not mix with mineral oils.

Oil Drain


2. Remove the sump plug. Drain the oil into a suitable receptacle.

3. Install a new sump plug. Torque to 23-27 Nm .

Caution

Always install a new oil drain bolt.

Capacity

Engine sump (incl. filter)

Europe

(Litres)

10.0

UK

(Pints)

17.6

USA

(Qts.)

10.6

Torque Figures

Description

Sump plug

Sump bolts (two stage)

Oil pump bolts

Nm.

lb. / ft.

23-27 17-20

1.

15 11.5

(in sequence)

2.

A further 90°

(same sequence)

M8 23-27 17-20

M6 8-12 6-9

Engine Oil Specification

An oil of 0W-30 viscosity meeting Aston Martin specification WSS

M2C913-A/B or 0W-40 viscosity meeting Aston Martin specification WSS-M2C937-A is preferred. Where this is not possible, oil meeting the following standards may be used.

4. Wipe the area clean before installing the front undertray. Install the front undertray.

Oil Filter


Item

Oil Filter Renew

Removal

RH Drive.



LHD

RHD

Code

TBA

03.02.AB

Standard

SL / SJ / EC / CF

A1 / A5 / B1 / B5

GF3

Standard

SL / SJ / EC / CF

A3 / B3 / B4

GF3



Caution





Engine (03.00)

LH Drive.


2. Remove the air intake from the throttle body. Remove the throttle body.

Installation

1. Smear the lip of the oil filter with clean engine oil.

2. Install the oil filter to the engine block. Tighten the oil filter hand tight.

3.

L/H drive only .

Install the throttle body and air intake pipe.


Sump


Item

Sump Remove / Install

Removal

Code

LH 03.02.BN


2. Remove the lower suspension arms (from the front subframe) and the anti-roll bar (Refer to ’Front


Remove

Anti-roll Bar




Caution






5. Withdraw the coolant pipe from the sump.



Engine (03.00)

6. Remove bolts (x15 M8) and (x5 M6) that secure the sump. Withdraw the sump. Discard the sump gasket and oil seal (oil pump).

7. Clean the sump and engine block mating surfaces.

Installation

1. Ensure the sump is clean.

2. Install a new sump gasket. Ensure that the gasket protrudes evenly from its groove all around the sump.

4. Apply dots (10 mm Dia approx.) of sealant to the sump sealing surface in the positions indicated.

The sump must be installed and secured within 6 minutes of applying beads of sealant.

3. Install a new oil seal to the sump (oil pump to sump).



Engine (03.00)









6. Install the coolant pipe.


8. Install the lower suspension arms (Do not torque bolts)

9. Install the anti-roll bar. Torque the stabiliser nut to 110

Nm .

10. Remove the engine support.


2).

12. Torque the suspension fixings with the vehicle at normal ride height (Refer to ’Front Suspension (04.01)’, page 4-

2-1):

• Lower suspension arms to the subframe - 115 Nm .







Engine (03.00)

Oil Pump


Item

Oil Pump Renew

Code

TBA

Removal


2. Remove the engine from the vehicle (Refer to

’Removal’, page 3-1-4).


Discard the sump gasket and oil seal.


Chains’, page 3-10-1).

5. Remove bolts (x1 M6) and (x3 M8) that secure the oil pump. Withdraw the oil pump.

4. Install the sump (Refer to ’Sump’, page 3-3-3) complete with new gasket and oil seal.





4).


2).



Installation

1. Locate the oil pump onto the crankshaft.

Install the oil pump.



23-27 nm.

8-12 Nm.

01-03-105a

2. Install the timing chains (Refer to ’Valve Timing Chains’, page 3-10-1).


11-3).


Engine (03.00)


Description


Engine (03.00)

• Water pump

• Thermostat

• Radiator

• Pressure cap

• Coolant Reservoir

• Electric cooling fans (x2)

• Cooling fan motor control module

• Engine oil cooler

Coolant Circuit



Engine (03.00)

Water Pump In-Vehicle Heating

The water pump is of a conventional design and is located at the front of the engine. It is driven by the accessory drive belt.

Thermostat

The thermostat allows rapid engine warm-up by redirecting coolant flow through the engine below 88.3°C (190.9°F).

The thermostat also assists in keeping the engine operating temperature within predetermined limits. The thermostat starts to open between 88.3 - 92.2°C (190.9 - 198°F) and is fully open at 103.9°C (219°F).

A hose from the front of the thermostat housing directs coolant to the heater water valve which remains closed below 30°C ± 10°C (86°F ± 50°F). Above this temperature, the heater water valve will open and warm water will be available to the heater water pump. This pump will only run when the temperature is > 10°C (50°F) and will supply warm water to the air conditioning heater matrix. The A/C heater matrix outlet is connected through the return side of the water valve, back to the rear of the engine water pump.

Specifications

Cold Engine (By-pass Circuit) - When the engine is cold and the thermostat is closed, coolant flows from the water pump through the engine, then returns directly to the water pump.

Warm Engine - When the engine is warm and the thermostat is open, coolant flows from the water pump, through the engine, through the thermostat, into the radiator upper coolant hose, through the radiator and then returns to the water pump via the radiator lower coolant hose.

Antifreeze Mix 50% OAT coolant / 50% water.

Pressure Cap 150 kpa.

Thermostat Starts to opens between 88.3 - 92.2°C

(190.9 - 198°F).

Fully open at 103.9°C (219°F).

Leakage Rates 30 cm / Min. 150 - 180 kpa.

60 cm / Min. 10 kpa Man.

Up to 75 kpa @ 150 c m / h.

The heater core is on a parallel circuit and is unaffected by the position of the thermostat.

The anti-freeze is unique and cannot be mixed with other anti-freeze solutions. The OAT coolant/water mixture has a life of 150,000 miles or 5 years (which ever comes first).

Radiator

The radiator is of aluminium construction with plastic end tanks. Foam seals are installed to the radiator to prevent the cooling air from by passing the radiator core. The radiator is located by four isolator mountings and supported by the radiator support beam. A coolant drain plug is provided in the lower RH side for the draining of the coolant. The

Cooling fan shroud is attached to the radiator.

Torque Figures

Description

Condenser A/C pipes

Thermostat housing

Thermostat housing support bracket

Water pump

Water pump pulley

Nm.

8-10

8-12

23-27

23-27

23-27 lb./ft.

6-7.5

6-9

17-20

17-20

17-20

Cooling Fans

Two variable speed electric cooling fans are housed in the cooling fan pack for the cooling of the radiator. The speed of the electric cooling fans is adjusted by the Powertrain

Control Module (PCM).

Coolant Reservoir

A pressurized Coolant Reservoir system is used which continuously removes any air from the cooling system. A continuous vent from the engine and radiator to the coolant expansion tank prevents air locks from forming in the cooling system. No manual bleed points are provided on the system.

The Coolant Reservoir should be full when the coolant system is cold.



Engine (03.00)

Maintenance

Caution

‘Spring band’ clips

‘Spring band’ clips must be installed as detailed below:

2

3

Coolant Hose

Alignment Marks

Spigott

5. Fill the cooling system with the specified coolant to maximum level in the Coolant Reservoir. Install the pressure cap.

Warning


6. Run the engine until fully warm. Stop the engine and allow to cool down. Any coolant displaced due to expansion will be drawn back into the Coolant Reservoir as the system cools.

7. Re check the level at the Coolant Reservoir. Top-up as necessary to the maximum level.

8. Ensure the filler cap is secure after topping up.

Caution

Do not over tighten.


Pressure Tests

Cooling System

4

All coolant hoses and spigots must be de-greased before assembly.

1. Select the correct pressure tester adaptors and install the pressure tester to the Coolant Reservoir.

2. Bring the engine up to it’s correct working temperature.

3. Test the cooling system following the pressure tester manufacture instructions.

Coolant Drain / Fill


Item

Drain / Fill

Code

03.03.BE

Pressure leakage (Refer to ’Specifications’, page 3-4-2).

Pressure Cap

1. Select the correct pressure tester adaptors and install the pressure tester to the pressure cap.


Warning


2. Remove the pressure cap from the Coolant Reservoir.

3. Loosen the drain plug. Drain the coolant into a suitable container.

Rinse the pressure cap in water to remove any sediment

2. Test the pressure cap following the pressure tester manufacture instructions.

3. Pressure leakage (Refer to ’Specifications’, page 3-4-2).

If replacing a pressure cap, always install one of identical pressure specification to original equipment.

4. Install the drain plug. Ensure the drain plug is secure.



Engine (03.00)

Radiator


Item

Radiator Renew

Code

03.03.EB

Removal

1. Discharge the A/C system.


3. Remove the airfilter boxes (Refer to ’Air Charging

(03.12)’, page 3-13-1).

4. Remove the headlight units (Refer to ’Front Lights

(17.01)’, page 17-1-2).


6. Remove the A/C pipes from the condenser.

Caution

Ensure open ends are plugged immediately after disconnecting refrigeration parts.

If moist air or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other faults may occur.

7. Remove the front crossmember.

The vehicle wings have to be manoeuvred to remove the crossmember.

Remove bolts (x4) and loosen bolts (x2) from the wings.

When the crossmember is ready to be removed the wings then need to be gently pulled to allow crossmember removal.

7.1

Disconnect the wiring harness plug from the crash sensors (x2).

7.2

Remove wiring harness locaters (x2).

7.3

Remove bolts (x2 each side (inside the wings)).



Engine (03.00)

7.4

Remove bolts (x3 each side).

7.5

Remove bolts (x2).

Withdraw the front crossmember.

8. Remove the fan pack from the radiator.

8.1

Remove bolts (x2) that secure the fan pack to the radiator.

8.2

Withdraw the fan pack from the radiator.

10. Withdraw the radiator complete with the condenser.

Installation

1. Install the radiator, complete with the condenser.

Connect the radiator hoses.

2. Install the fan pack.

3. Install the front crossmember. Install the wings.

4. Install the condenser A/C pipes. Torque bolts to 8-10

Nm .

5. Install the ‘Slam’ panel.

6. Install the headlight units (Refer to ’Front Lights (17.01)’, page 17-1-2).

7. Install the air filter boxes (Refer to ’Air Charging (03.12)’, page 3-13-1).

8. Fill the coolant system.

9. Charge the A/C system.

Thermostat


Item

Thermostat Renew

Removal


2. Disconnect the hoses.

Code

03.03.GB

9. Remove hoses from the radiator.


3. Remove bolt (x1) from the timing cover (thermostat housing support bracket).

4. Remove the bolts (x3) that secure the thermostat.



Engine (03.00)

5. Remove the thermostat housing. Discard the thermostat housing gasket.

6. Withdraw the thermostat from the thermostat housing.

Installation

1. Clean all the mating surfaces and install a new thermostat housing gasket.

2. Install the thermostat into the thermostat housing.

3. Install the thermostat housing support bracket, do not tighten.

4. Install the thermostat housing. Torque bolts (x3) to 8-12

Nm . Torque the thermostat housing support bracket bolt (x1) to 23-27 Nm.


Water Pump


Item

Water Pump Renew

Removal

Code

03.03.LB

1. Drain the cooling system.


4. Remove and discard the water pump ‘O’-ring.

Installation

1. Clean the mating surface of the water pump and install a new 'O' ring.

2. Place the water pump to the water pump body. Secure the water pump. Torque bolts (x4) to 23-27 Nm .

3. Secure the water pump pulley to the water pump.




3. Remove the water pump.



Engine (03.00)

Engine (03.00)


Description

The electronic return-less fuel system utilized has the advantages of reduced fuel tank vapor, requires less electrical power and does not require a fuel return line. Fuel is supplied at high pressure to the injectors via two fuel rails (primary and secondary). Each fuel rail incorporates six fuel injectors, and a fuel pressure regulator. A fuel temperature sensor is installed in the primary fuel rail. Powertrain Control Modules (PCMs) maintain 280 kPa across the injectors, by increasing the pulse width modulation signal to the fuel pump controller. This in turn controls the voltage output to the fuel pump.

Fuel rails and injectors are detailed in this chapter. For fuel delivery to the fuel rails and injectors refer to

Chapter 10 (Fuel System).


Operations on fuel system will result in fuel liquid and vapour being present in the working environment. This presents a very serious risk and the following precautions must be strictly observed:

Warning


Warning



Warning


Warning


Warning


Warning


Warning


Warning


Warning


Warning

The engine must be cool before working on the fuel charging system.



Engine (03.00)

Maintenance

Depressurising


Item


Code

10.01.EK



4. Remove the following wiring harness plugs:




5. Remove bolts (x3) securing the fuel rail to the inlet manifold.

6. Remove the secondary latch clip from each fuel line.

7. Disconnect the fuel rails from their supply pipes.








Fuel Rails

Use a rag / cloth to collect any residual fuel from the opened fuel pipe.

Left and right hand fuel rails to fuel supply hose unions are different sizes.



7)


7)

Push back on the tool. While pushing back on the tool withdraw the fuel rail. Note left and right hand fuel rail for installation.

Installation

Warning



1. Locate the fuel rails over the injectors.

2. ‘Pull down’ the fuel rails onto the injectors by tightening bolts (x3). Tighten bolts to 8-12 Nm .

3. Connect the fuel rails to their supply pipes.

Repair Operation Time (ROT) Ensure the fuel rail and fuel supply line are in-line before connection.

Item Code

Fuel Rail Renew x1 03.04.AB

4. Install the secondary latch clip to each fuel line.

Removal x2 03.04.BB

To aid injector and fuel rail removal it may be required to disconnect the coolant pipe, from the thermostat housing, running between the two inlet manifolds.

5. Connect the wiring harness plugs:



1. Depressurise the fuel lines.

3. Remove the engine bay cross brace and the inlet manifold brace.


2. Disconnect the earth (- ve) lead from the vehicle battery.

6. If removed, connect the coolant pipe to thermostat housing.

7. Install the inlet manifold brace and the engine bay cross brace .


Injectors


Item

Fuel Injectors x1 x12

Code

03.04.GB

03.04.FB

Removal

1. Remove the fuel rails.

2. Remove the injectors. Discard the ‘O’ rings.

Installation

1. Install the injectors, complete with new ‘O’ rings.

Position of ‘O’ rings.

Blue (top)

Green (bottom)



Engine (03.00)



Engine (03.00)



Engine (03.00)

Engine (03.00)


Description

Maintenance

Drive Belt


Item

Drive Belt Renew

Removal

Code

03.05.AB


2. Using a 3/8 inch ratchet handle 'T' bar, rotate the drive belt tensioner clockwise and slip the drive belt off the idler pulley indicated (A).

Slip the drive belt off the remaining drive pulleys.

3. Check condition of the drive belt. Replace if required.

Auxiliary Drives

A damper pulley installed to the front of the crankshaft drives a ‘polyvee’ drive belt to power all of the engine auxiliaries.

• Air Conditioning Compressor

• Alternator

• Power Steering Pump

• Water Pump

Automatic Belt Tensioner

The automatic belt tensioner consists of an idler pulley which is free to rotate on a bearing, located at the end of a spring-loaded pivot arm.The pivot arm can be turned clockwise (viewed from the front of the engine) for belt removal and installation.

Installation

1. Install the drive belt around all drive pulleys except the idler pulley.

2. Rotate the tensioner assembly clockwise. Install the drive belt to the idler pulley and release the tensioner.

3. Check all pulleys to ensure correct belt location.



Engine (03.00)



Engine (03.00)

Engine (03.00)


Maintenance

Starting System Starter Motor

The starting system consists of a pre-engaged type starter motor, battery, remote control switch (ignition switch) and relay. The operation of the starter relay is controlled by the

Powertrain Control Module (PCM).

To protect the starter motor from damage, the PCM prevents the starter from being engaged when the engine is running.

This is done by the PCM inhibiting the starter relay operation. The PCM will only operate the starter relay providing the following conditions are met:

• The ignition switch has been in the start position for a predetermined time

• The security response between the PCM and the Driver

Information Module (DIM) has passed


Item

Starter motor Renew

Removal

Code

03.06.AB



3. Remove the R/H road wheel, road wheel arch liner and the front undertray.

4. Remove the oxygen gas sensors. Disconnect the oxygen gas sensors electrics.

This may provide better access to remove the starter motor.


• The transmission range switch is in the Neutral or Park position (vehicles installed with automatic transmission)

• The clutch pedal is operated (USA vehicles installed with manual transmission)

The starter relay remains energized until one of the following occur:

• The PCM detects an engine running signal

• The starter button is on longer pressed

• The transmission range switch is no longer in the Neutral or Park position (vehicles installed with automatic transmission)

• The clutch pedal is released (USA vehicles installed with manual transmission)

With the ignition switch in the start position, providing the

PCM start conditions are met, the starter relay is energized and the engagement lever moves the pinion into mesh with the flywheel ring gear teeth. The electrical contacts within the solenoid complete the high power circuit and the starter motor operates to turn the engine.

5. Remove the VMV valve.

Specifications

Torque Figures

Description

Starter motor

Nm.

50 lb./ft.

37

6. Remove the heat shield.

7. Disconnect the starter motor electrics.



Engine (03.00)

8. Remove bolts (x2) that secure the starter motor.

9. Withdraw the starter motor and oxygen gas sensors bracket.

Installation

1. Place the starter motor and the oxygen gas sensors bracket to the bell housing. Torque bolts to 50 Nm .

2. Connect the starter motor electrics.

3. Install the heat shield.

4. Install the oxygen gas sensors (if removed).

5. Install the front under tray and road wheel arch liner.

6. Install the road wheels and ‘nip-up’ road wheel nuts.

7. Lower the vehicle. Tighten the road wheel nuts (Refer to




Engine (03.00)

Engine (03.00)


Description

The ignition system consists of an ignition coil for each individual cylinder located on each individual spark plug.

There are two crankshaft sensors located on the front of the engine - only the RH sensor is used. The second crankshaft sensor is located on the flywheel housing (LH side).

An alternating voltage signal from two Crankshaft Position Sensors (CPS) is converted by the Powertrain Control modules

(PCMs). This digital signal is then used to position the ‘On’ and ‘Off’ time of the primary circuit of the ignition coil. The effective range for ignition timing control is increased by the fact that there are no rotating parts. On the basis of engine speed and load inputs, the PCMs determine the ignition timing. This function also takes other inputs into consideration such as engine temperature, throttle position and transmission control module (TCM) inputs.

• In the event of a short circuit to ground between the fusebox and the coil or the coil and the PCM the fuse would blow and all ignition coils on that bank would cease to function.

• If an ignition coil ‘short circuits’ internally the ignition coil will fail instead of its fuse. This allows the remaining ignition coils to continue functioning.

• In the event of a wiring harness failure between the PCM an7d the ignition coil, the ignition coil will fail instead of its fuse. This allows the remaining ignition coils to continue functioning.

The twelve spark plugs are fired in sequence by the two PCMs. Ignition timing can vary from 55° before TDC to 10° after

TDC.

Crank position sensors

Specifications

Spark Plugs

Firing order 1 - 7 - 5 - 11 - 3 - 9 - 6 - 12 - 2 - 8 - 4 - 10.

Type

Gap

Torque

Dual Platinum Fine Wire

1.2 - 1.3 mm

16-20 Nm


Air Gap 1 ±0.5 mm

Torque Figures

Description

Spark plugs

Ignition coils

Spark plug cover


011-1-014

Nm

16-20

5-7

2.5-3.5

lb./ft.

12-15

4-5.5

2-3

3-8-1


Engine (03.00)

Maintenance

Spark Plugs


Item

Spark Plug Renew All

LH Bank

RH Bank

Code

03.07.DB

03.07.EB

03.07.FB

Removal



Installation

1. Install the spark plugs. Torque to 16-20 Nm .





3-2-7).

3. Disconnect the ignition coils. Remove the ignition coils.

4. Remove the spark plugs.



Engine (03.00)

Engine (03.00)


System Description

To avoid environmental pollution from the crankcase gases (blow-by), the crankcase (engine) is ventilated into the intake system. Any noxious fumes in the crankcase gases are then burned in the normal combustion process.

The system consists of a part load and full load breather system which ensures sufficient engine venting under all running conditions.

Crankcase gases escape through channels in the block walls where they are fed into oil separators to minimise the oil pullover. From the separators, pipe work channels the vent gases to the intake manifold at part load or intake system at full load.

Under part load conditions the system is controlled by the PCV valve which regulates a constant flow of vent gases (engine blowby varies across the range of part load sites). The PCV valve flow is balanced by the ‘make up air’ pipes to the cam covers. The pressure difference across the ends of these pipes (i.e. across the throttle valve) activates the PCV valve.

At full load, the system vents through a 1-way valve to the RH inlet system (pre-throttle) only.

The diameter of the pipes in the system is critical in the control of the Full and Part load operating conditions.Vacuum

Pipework Layout

'Part Load' breather pipe.

Downstream of the throttle body.

'Full Load' breather pipe

Upstream of the throttle body.

'Make up air' pipe under part load running conditions.

Oil seperators (x2)

(Mounted to the cylinder block)

One way 'Duck' valves

Valve assembly

Crankcase vent regulator

(PCV)



Engine (03.00)



Engine (03.00)

Engine (03.00)


Description

Camshafts

Inlet and exhaust camshafts in each head are chain driven directly from the crankshaft.

The twin crankshaft sprocket has 18 teeth and each camshaft sprocket has 36 teeth, the timing chains have 61 links. Three chain links are marked and are aligned with timing marks on the crankshaft and camshaft sprockets during valve timing. Because of the odd number of links in the timing chains, the timing marks and marked links will only align once every 122 engine revolutions.

Specifications

Maintenance

Valve Timing Chains


Item

Timing Chain Renew

Removal

Code

TBA


2. Remove the camshaft covers (Refer to ’Camshaft Cover’, page 3-11-1)


3-11-3).

4. Remove the crankshaft timing disc.

Note the orientation of the disc for installation.

Valves, Guides & Springs

Spring Force at 40mm Spring Height

Installed Spring Height (Exhaust / Inlet)

Valve Guide Internal Diameter

Valve Guide Maximum Runout

Valve Stem Diameter - Inlet

Valve Stem Diameter - Exhaust

Valve Stem Clearance - Inlet

Valve Stem Clearance - Exhaust

Valve Face Maximum Runout

Valve Lash Adjusters

Bore

Outside Diameter

Clearance

Torque Figures

Description

Timing chain guide

Tensioners

Timing cover bolts

Nm.

290

MM

39.69-40.29

6.015 - 6.044

0.030

5.975 - 5.995

5.950 - 5.970

0.020-0.069

0.046-0.095

0.050

16.018 - 16.057

15.988 - 16.000

0.018 - 0.069

Nm lb. / ft.

20-30 15-22.5

20-30 15-22.5

23-27 17-20

Image to Follow

5. Turn the crankshaft to place the crankshaft key in the vertical position.

Caution






Engine (03.00)

6. Insert the camshaft set tool (Refer to ’303-713 (Camshaft

Set)’, page 20-1-5).

With the crankshaft Key in the vertical position the camshaft flats will accept the camshaft set tool.

LH Cylinder Head (Cylinders 7-12)



7. Remove the RH or LH timing chain tensioner, tensioner arm and timing chain guides.


Do not remove the timing chain.

7.1

Compress the timing chain tensioner and insert the locking pin (Refer to ’303-1072 (Timing Chain

Tensioner Pins)’, page 20-1-6). Remove bolts (x2) that secure the timing chain tensioner and withdraw.

7.2

Remove the floating tensioner arm.

7.3

Remove the fixed timing chain guide (bolts x2).

Repeat for the second timing chain tensioner and timing chain guides.

8. Remove both timing chains and the crankshaft twin sprocket from the crankshaft.

Installation

Caution


1. Ensure the crankshaft key is vertical and all camshafts are in the initial positions shown.



4. Install the timing chain with the marked links (x3) matching the marks on the crankshaft and camshaft sprockets.

Timing Mark

45

Timing

Mark

45

Crankshaft

Key

Vertical

Crankshaft

Key

Vertical

Timing

Mark

5. Install and tension the timing chain arm and tensioner.

Withdraw the timing chain tensioner lock pin.

6. Ensure that all three marked timing chain links align with the timing marks on the camshaft and crankshaft sprockets.



Engine (03.00)

RH Cylinder Head (Cylinders 1-6)

7. Ensure the crankshaft key is in the vertical position (No.1 cylinder at 30° ATDC). Ensure that the camshafts are in the initial positions shown.

10. Install the timing chain with the marked links (x3) matching timing marks on the camshaft and crankshaft sprockets.

Timing

Mark

Timing

Mark

Crankshaft

Key

Vertical

Crankshaft

Key

Vertical

Timing

Mark




11. Install the timing chain tensioner arm.

12. Install the timing chain tensioner. Remove it’s lock pin.

13. Ensure all three marked links on the timing chain align with the timing marks on the camshaft and crankshaft sprockets.

14. Remove the camshaft timing service tool.

15. Install the crankshaft timing disc, noting orientation from removal.

Image to Follow


16. Check the valve timing (Refer to ’Valve Timing Check’, page 3-10-4).


11-3).

18. Install the engine to the vehicle (Refer to ’Engine’, page

3-1-4).



Engine (03.00)

Valve Timing Check

1. Rotate the crankshaft anti-clockwise at least 60°, then rotate clockwise to TDC No. 1 (crankshaft key 30° before vertical).

2. At TDC No.1, the timing marks on the REAR of the camshaft sprockets should be precisely aligned as shown.



3-11-3).



9. Progressively release all bolts that secure each bearing cap.



On a correctly timed engine, when No. 1 cylinder is at TDC compression the timing marks on the rear of the camshaft sprockets will always align.

10. Withdraw the bearing caps. Ensure they are retained in the sequence withdrawn.

11. Withdraw the camshafts.



Timing marks on the timing chains, camshaft and crankshaft sprockets will only aligned once every 122 crankshaft revolutions on a correctly timed engine.

Be aware - engine oil will bleed from timing chain tensioner.


Adjusters


Item


Adjusters

Removal

Code

TBA


3-1-4)







Engine (03.00)

13. Cover the engine block to prevent ingress of foreign material.

Installation



Soak the lash adjusters in engine oil and ensure that they are ‘pumped up’ with engine oil.



Caution


15°

15°

Bearing Caps

15°

15°




1-7 1-7

8-14 8-14



Caution










Engine (03.00)

16

24

25

22

23

17

20

21

18

19

26

27

28


9.1

Progressively ‘nip’ down all bolts in the sequence shown. Ensure the camshaft bearing caps pull down evenly into contact with the cylinder head.



9.2

In the sequence shown, torque the camshaft bearing caps to 8-12 Nm .



15

E ngine

F ront

1


3-2-7).


4).

2

10

11

8

9

3

6

7

4

5

12

13

14


11. Install the timing chains. Perform the camshaft timing procedure (Refer to ’Valve Train (03.09)’, page 3-10-1).


11-3).




Engine (03.00)

Engine (03.00)


Specifications


Torque Figures

Description

Camshaft cover

Timing cover

Idler pulley

Sump bolts

Crankshaft damper

1.

2.

1.

2.

Nm.

8-12 lb. / ft.

6-9

23-27 17-18.5

25-27 18.5-20

15 11.5

90°

120 89

Back out a minimum of 360°

3.

47-53 35-39.5

4.

85°-95°

8-12

5-7

6-9

4-5.5

2.5-3.5

2-3

4. Disconnect the ignition coil connectors. Remove the ignition coils.

Camshaft sensor

Ignition coils

Spark plug cover

Maintenance

Camshaft Cover


Item

Camshaft Covers

Removal

Code

TBA


2. Disconnect the camshaft cover ventilation pipe and the camshaft sensor wiring harness plug.

5. Lower the rear suspension (Refer to ’Rear Suspension

(04.02)’, page 4-3-1).

To gain access to the bolts (x2) that secure the wiring harness carrier to the camshaft covers.

6. Remove bolts (x2) that secure the wiring harness carrier and the electrical device. Lift the wiring harness carrier off the camshaft studs.



Engine (03.00)

7. Remove bolts (x15) that secure the camshaft cover.

Withdraw the camshaft cover.

Discard all camshaft cover seals.

8. Repeat from Step 1. for second camshaft cover.

Installation

1. Apply a bead of sealant where indicated.

RTV Sealant

2. Install new camshaft cover gaskets.

03-01-216

3. Install the camshaft cover. Torque bolts (x15) to 8-12

Nm . in the sequence shown below.

E ngine

F ront

L H C over R H C over

15

16 15

11

17

5

12

9

11

5

6

3 6

1

7

1

8

2

8

4

13

10 4

13

14

01-03-214

4. Place the wiring harness carrier and the electrical device over the camshaft studs. Torque bolts (x2) to 8-12 Nm .

5. Install the rear suspension (Refer to ’Rear Suspension

(04.02)’, page 4-3-1).




8. Connect the camshaft cover ventilation pipe and camshaft sensor wiring harness plug.


3-2-7).

01-03-222



Engine (03.00)

Timing Cover


Item

Timing Chain Cover

Code

TBA

Removal


2. Remove the engine from vehicle (Refer to ’Removal’, page 3-1-4).


4. Remove the top idler pulley and the accessory drive belt from timing cover.

6. Remove bolts (x2) securing water pump to the timing cover.

7. Prevent crankshaft from turning (Refer to ’303-1047

(Crankshaft Holding)’, page 20-1-6) and remove the bolt

/ washer that secures the crankshaft damper.

5. Remove bolts (x4) and withdraw the power steering pump.

8. Using a universal puller, remove the crankshaft damper.

9. Remove the crankshaft position sensors (x2).


10. Remove the camshaft covers (Refer to ’Camshaft Cover’, page 3-11-1).



Engine (03.00)

11. Remove the thermostat housing.

11.1 Remove hoses (x4).


11.3 Remove bolt (x1) from the timing cover.

Installation

1. Ensure mating surfaces are clean and smooth. Install new timing cover seals.

E ngine

B lock S ide

12. Remove bolts (x2) securing the sump to the timing cover.

01-03-223

2. Apply RTV sealant at the cylinder head joints as shown.

The timing cover must be installed and secured within 6 minutes of applying beads of sealant.

13. Remove the remaining bolts (x14) that secure the timing cover. Withdraw the timing cover. Discard the timing cover gaskets.

3-11-4

RTV Sealant

Gasket Trimming

3. Secure with bolts (x14).

The shorter bolt locates in position 2.

Do not install the thermostat bracket bolt.

Torque the bolts, in sequence, to 23-27 Nm .

When the timing cover bolts are torqued, the ends of the timing cover seals may protrude from the joints. Trim flush with a sharp knife.

0 1 - 0 3 - 1 0 4



Engine (03.00)

4. Install the thermostat housing complete with the thermostat and a new ‘O’-ring (Refer to ’Thermostat’, page 3-4-5). Torque bolts (x3) to 8-12 Nm . Torque the thermostat housing support bracket bolt (x1) to 23-27

Nm.

1 Tighten to 120 Nm .

2 Back out a minimum of 360° .

3 Tighten to 47-53 Nm .

4 Tighten a further 85°-95° .

8-12 Nm.

23-27 Nm.

5. Install the upper idler pulley. Torque bolt to 25-27 Nm .

6. Install the accessory drive belt tensioner. Torque bolt to

25-27 Nm .

9. Install the crankshaft sensors (x2). Torque bolts to 8-12

Nm . Connect the wiring harness plugs.

10. Secure the power steering pump and the water pump to the timing cover. Torque bolts to 23-27 Nm .




(03.03)’, page 3-4-1).


2).

7. Install the sump bolts (x2). Torque to 15 Nm. + 90° .

8. Install the crankshaft damper.

8.1

Clean all sealant from the crankshaft key-way and oil the crankshaft damper seal surface.

Apply silicone sealant to seal the key-way end.

8.2

Prevent crankshaft from turning (Refer to ’303-1047

(Crankshaft Holding)’, page 20-1-6) and torque the crankshaft damper bolt in four stages:



Engine (03.00)

Crankshaft Rear Oil Seal


Item

Crankshafts Rear Oil Seal

Code

TBA

3. Install the oil seal slinger (Refer to ’TBA (Crankshaft Rear

Oil Seal Slinger Install)’, page 20-1-4).

The oil seal slinger installs one way only on the oil seal slinger install tool.

Removal






(07.03)’, page 7-3-1)

3. Remove the torque tube (Refer to ’Torque Tube’, page

5-1-2).

4. Remove the flywheel (Refer to ’Flywheel’, page 3-12-9).

5. Using the service tools (Refer to ’TBA (Crankshaft Rear

Oil Seal and Slinger Removal)’, page 20-1-4) extract the oil seal slinger and oil seal from the oil seal retainer.

Details on removal procedure (Refer to ’Crankshaft Rear Oil

Seal Remove (TBA)’, page 20-1-11)

6. Clean the oil seal recess and mating surface of the oil seal retainer. Clean the mating surfaces on the engine block and sump. Ensure all mating surfaces are oil free.

Installation

Caution

Throughout this procedure it is essential that all parts remain clean, free of dirt, grease and debris.

1. Lubricate the seal recess and seal surface with engine oil.

2. Install the rear crankshaft oil seal (Refer to ’303-664

(Crankshaft Rear Oil Seal Install)’, page 20-1-5).




Oil Seal Slinger

4. Install the flywheel (Refer to ’Flywheel’, page 3-12-9).

5. Install the torque tube (Refer to ’Torque Tube’, page 5-

1-2).



(07.03)’, page 7-3-1)







Crankshaft Front Oil Seal


Item

Crankshafts Front Oil Seal

Code

TBA

Removal

1. Remove the timing cover (Refer to ’Camshaft Cover’, page 3-11-3).

2. Remove the oil seal from the timing cover.

Installation

1. Clean the seal recess in the timing cover.

Lubricate the outside of the new seal and seal recess with engine oil.

2. Install the timing cover (Refer to ’Camshaft Cover’, page

3-11-3).

3. Position a new seal on the seal recess.


Install the seal (Refer to ’303-664 (Crankshaft Rear Oil

Seal Install)’, page 20-1-5).


Engine (03.00)

Lubricate the seal surface with engine oil before installing the crankshaft damper.



Engine (03.00)



Engine (03.00)

Engine (03.00)


Description

Crankshaft


A twin sprocket, installed to the front end of the crankshaft, drives the camshaft timing chains. A damper pulley on the crankshaft drives the engine auxiliaries via the accessory drive belt.

Also at the front of the engine a timing disc is installed together with a crankshaft sensor (RH side). The sensor provides engine position signals to PCMs.

A second crankshaft sensor (LH side) is installed at the front of the engine - but is not used.

Specifications

Crankshaft

Main Bearing Diameter

MM

67.480 - 67.504

Main Bearing Clearance 0.025 - 0.050

Refer to the Main Bearing Grade Chart for bearing shell selection.

Connecting Rod Bearing Diameter

Connecting Rod Bearing Clearance

Crankshaft End Float

49.97 - 49.99

0.028 - 0.066

0.130 - 0.301

Turning Torque

Guideline figures only

Crankshaft and rear seal only

Crank, rear seal + pistons & rods

Crank, rear seal, pistons & rods + camshafts & tensioned chains

Nm.

6

16 - 20

36 - 44

Crankshaft Sensors

Air Gap

MM

1 (±0.5)


Six crankshaft big end journals each carry a pair of connecting rods. The connecting rods are secured to the crankshaft by individual connecting rod caps enclosing the connecting rod bearing shells. Connecting rod bolts are of the ‘torque to yield’ type and must be renewed if removed.

Piston Ring Gaps at 89.000




Oil control rings

MM

0.100 - 0.250

0.270 - 0.420

0.150 - 0.650

Compression Ring Vertical

Clearance



MM

0.040 - 0.075

0.040 - 0.885

011-1-006

Piston Pin

Piston pin to rod clearance

Interference

Clearance at 20°C (68°F)

MM

0.005

0.001

Connecting Rods

Piston pin to connecting rod clearance

Piston pin to piston interference

Big End Side Clearance (2 rods)

MM

0.004 - 0.020

-0.005 - 0.001

0.225 - 0.625

Piston Height Above the Block

Face at TDC MM

Average of two readings taken along the crankshaft axis. A straight line must pass between the two readings and the center of the pistion.

0.415 (Below)

0.115 (Above)

Each piston carries two compression rings and one oil control ring. The arrow on each piston crown must point to the front of the engine during installation.

Connecting rods are manufactured as a single piece with fracture lines at the connecting rod bearing. Each connecting rod cap is cracked from the connecting rod after machining and drilling. Thus each connecting rod cap will only install to, in correct orientation, its matching connecting rod.



Engine (03.00)

Torque Figures

Description

Engine block spread tool

Nm.

25 lb./ft.

18.5

Main bearings 1. Bolts 1 to 14.

2. Bolts 15 to 28.

3. Bolts 1 to 28.

37-43

22-28

27.5-32

16.5-21

85°-95°

Main cap side bolts 1. Bolts 29 to 42. 22-28 16.5-21

Connecting rods

2. Bolts 29 to 42.

1.

85°-95°

20-25 15-18.5

Windage tray

2.

3.

40-45

1.

5-7

30-33.5

105°-120°

4-5.5

2.

Sump 1.

15

45°

11.5

2.

Flywheel

Damper plate (Auto only)

90°

75-81 55.5-60

30 22.5

Piston Skirt Grading Chart

Main Bearing Grade Chart

The finished diameter of the crankshaft main bearing bores is indicated by letters stamped on the cylinder block face.

The first letter, e.g. ‘D’, refers to No.1 journal, the second letter element refers to No.2 journal and so on.

The finished diameter of the seven crankshaft main bearing journals are indicated by seven letters stamped in bearing number sequence on No.1 counterweight.

The first letter in the sequence refers to No.1 journal, the second letter refers to No.2 journal and so on.

1. Read the first letter on the cylinder block face and note it.

2. Read the first letter on No. 1 crankshaft counterweight and note it.

3. Using the letters, select the correct bearing grade for No.

1 journal.

4. Repeat steps 1-3 to obtain the correct bearing grades for journals 2-7.

Grade

1

2

Piston Diameter

‘A1’Prior to Skirt

Coating

88.970 / 88.980

88.978 / 88.992


89.000 / 89.010

89.008 / 89.022

3 88.990 / 89.000

89.020 / 89.030

Skirt Coating adds 0.020 - 0.030 to the diameter as follows:

Grade

1

Piston Diameter

(Coated)

88.990 / 89.010

2

3

88.998 / 89.022

89.010 / 89.030

Clearance with Coating

New Build -0.014

(interference)

New Build + 0.024

(clearance)

Service Limit + 0.050

(clearance)



Engine (03.00)

Minimum Block Diameter

A B C D E F G H I J K L M N O P Q R S T U V W X

72.400

.401 .402 .403 .404 .405 .406 .407 .408 .409 .410 .411 .412 .413 .414 .415 .416 .417 .418 .419 .420 .421 .422 .423 .424

X 67.504

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2

W 67.503

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2

V 67.502

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2

U 67.501

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2

T 67.500

1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2

S 67.499

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2

R 67.498

1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2

Q 67.497

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3

P 67.496

1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3

O 67.495

1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3

N 67.494

1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3

M 67.493

1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3

L 67.492

1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3

K 67.491

1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3

J 67.490

1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3

I 67.489

1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3

H 67.488

1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3

G 67.487

2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3

F 67.486

2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

E 67.485

2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3

D 67.484

2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3

C 67.483

2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

B 67.482

2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

A 67.481

2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

Bearing Grade 1 = Orange

Bearing Grade 2 = Blue

Bearing Grade 3 = Green

The bearing grade is stamped, in ink, on the inside of the bearing.

Maintenance

Crankshaft


Item

Crankshaft Renew

Code

TBA

Removal


2. Remove the cylinder heads (Refer to ’Cylinder Heads’, page 3-2-2).


4. Remove the windage baffle.



Engine (03.00)

5. Remove bolts (x6) that secure the rear oil seal retainer and withdraw the seal retainer and oil seal.

7. Remove the piston and connecting rod assemblies.

7.1

Remove the connecting rod bolts and withdraw the connecting rod caps, complete with bearings.

6. Remove the oil pump.

3-12-4

7.2

Withdraw the piston and connecting rod assemblies, complete with bearings, from the top of the bore.

Ensure each piston / connecting rod / connecting rod cap set remain together in order for installation to their original locations.

Connecting rods and caps have identification marks which must match and align upon reassembly.

An arrow stamped on the piston upper face must point towards the front of the engine when reassembled.

Connecting rods are symmetrical and do not require front to rear orientation.

Connecting rod bolts have ferrules pressed into the caps for new build bolt retention / ease of assembly. Replacement bolts do not have the captive ferrule. Original bolts can be removed by tapping the bolt out of the cap with a rubber mallet.



Engine (03.00)

8. Remove the main bearing caps and bearing shells.

To withdraw the bearing caps, spread the engine block side walls using the engine block spreading tool (Refer to ’303-


To avoid overstriking engine block walls, do not exceed 25 Nm . on engine block spreader bolt.

Component Checks

1. Examine the crankshaft journals for wear, scuffing or other defects. Replace the crankshaft if un-serviceable.

2. Examine all bearing shells and thrust washers for wear, scuffing or other defects. Replace if un-serviceable.

3. If required, measure the diameter of the crankshaft main and big end bearings.

Compare results with data in engine specifications.

• The finished diameter of crankshaft main bearing bores is indicated by numbers stamped on engine block face

• The finished diameter of crankshaft main bearing journals are indicated by seven letters, stamped in bearing number sequence, on No.1 counter weight

4. Refer to Main Bearing Grade Chart in Engine

Specifications if the main bearings are to be replaced.

Installation

Caution

Lubricate all bearing surfaces with SAE 50 Assembly Oil.

Ensure all components are clean and free of damage prior to reassembly.

8.1

Remove the side bolts (x14).

8.2

Remove the outer bolts (x14) from the main bearing caps.

1. Install the upper bearing shells and thrust washers (No 4 bearing). Check the oil feed hole alignment.

Record positions of the stud bolts at No. 3 and 6 main bearing caps.

The thrust washers are installed with the groove facing the crankshaft.

2. Install the crankshaft into the upper main bearings.

8.3

Remove the inner bolts (x14) from the main bearing caps.

Retain all components in order for installation to their original locations, if serviceable.

9. Remove the crankshaft from the engine.

10. Remove the thrust washers from No. 4 main bearing.

11. Remove the upper bearing shells from all the main bearings.

If serviceable, retain all bearings, in order, for refitting to their original locations.



Engine (03.00)

3. Install and ‘seat’ the main bearings and caps.

Caution

Oil beneath the head of all the main bearing bolts. Do not oil threads. ‘Hand start’ them into their holes.

Note the positions of the stud bolts at No. 3 and 6 main bearing caps from removal.

3.1

Insert the inner and outer bolts to all main bearing caps.

3.2

Lightly ‘run down’ the bolts to seat the main bearing caps.

3.3

Release all bolts approx. one turn.

To install the bearing caps spread the engine block side walls using the engine block spreading tool (Refer to ’303-


To avoid overstriking engine block walls, do not exceed 25 Nm.

on engine block spreader bolt.

6. Insert the main caps side bolts. Torque the main cap side bolts, in sequence detailed, to:

1 Bolts 29 to 42 - 22-28 Nm. + 40°-50°

4 0

3 6

Front of Engine

2 6

1 8

2 2

1 2

8

1 1

7

2 5

1 7

2 1

3 9

3 5

3 2

3 1

4 3

1 6 1 5

3 0

2 9

2 1

2 4

3 4

3 3

6 5

3 8

2 0

1 9

3 7

1 0 9

4 2

2 8

2 7

4. Set No. 4 main bearing so the end loads are taken on both the upper and lower bearing thrust faces.

4.1

Bias the crankshaft maximum rearward against the upper thrust bearing.

4.2

With the crankshaft fully rearward, bias No. 4 bearing cap maximum rearward against the crankshaft thrust face.

4.3

Bias the crankshaft forward.

5. Torque the main bearing cap bolts, in the sequence detailed, to:

1 Bolts 1 to 14 - 37-43 Nm .

2 Bolts 15 to 28 - 22-28 Nm .

3 Bolts 1 to 28 - rotate 85°-95°

Check and, if required, adjust No. 1 main bearing cap so that the front face does not protrude forward of the oil pump mounting face.

Main bearing bolts are torqued to yield. They must be tightened precisely as specified.

1 4

Dial Indicator

1 3

7. Check the crank shaft end play.

FRONT OF ENGINE

0.130 - 0.301 mm

Crankshaft

4 1



Engine (03.00)

8. Check the crankshaft turning torque.

The turing torque must not exceed 6 Nm .

9. Complete with their upper big end bearing shell, install the pistons and connecting rods in their numbered positions. If new pistons or connecting rods are being installed, check the piston height (Refer to


Ensure that the piston rings are installed and located correctly (Refer to ’Pistons and Connecting Rods’, page 3-

12-1).


Ensure that the sump oil outlet locates to the oil pump inlet before the sump is faced up to the engine block.


Arrows stamped on the piston upper surface must point towards the front of the engine during reassembly.

Use cylinder protectors during piston and connecting rod installation (Refer to ’303-535 (Cylinder Bore Protectors)’, page 20-1-4).

10. Install the connecting rod bearing caps and shells, noting correct orientation of each cap.

Check that connecting rod and cap identification marks match and align.

Secure caps using two new bolts to each cap.

Torque all connecting rod bolts in three stages:

1 To 20-25 Nm .

2 To 40-45 Nm .

3 Rotate a further 105°-120° .







11. Install the windage tray.

Torque nuts (x4) to 5-7 Nm + 45° .

12. Install new a ‘O’-ring to the oil pick-up pipe.



Engine (03.00)

Caution

Ensure that the crankshaft key is in the vertical position.

14. Install the cylinder heads and camshafts (Refer to

’Cylinder Heads’, page 3-2-2).

15. Install the timing chains. Check and ensure that the valve timing is correct (Refer to ’Valve Timing Check’, page 3-10-4).


11-3).


18. Install the engine auxiliaries.

19. Install and tension the accessory drive belt.

20. Complete engine reassembly and prepare to install to vehicle.

Ensure that the connecting rods and caps are a matched set.

1. Heat the piston to approximately 70°C and install the connecting rod and piston pin.

Warning


Install the connecting rod to the piston with the ‘notch’ in the little end bearing (3) facing the same direction as the arrow stamped on the piston head (4).

1

2

1

4

3



Item

Pisteo and Connecting Rods Renew

Overhaul

Code

TBA

Keep all components in sets for installing in their original locations, if serviceable.

1. Remove the piston pin circlips. Discard the circlips.

Warning


2. Heat the piston to approx. 70°C and push out the piston pin. Allow the components to cool.

3. Using a ring spreader, remove the piston rings from the piston.

4. Wash all components. Replace any with obvious wear or other signs of deterioration.

Check that components meet dimensional specifications

(Refer to ’Specifications’, page 3-12-1).

5. Repeat for all pistons.

Reassembly

Pistons are graded for each cylinder bore. If the pistons and

/ or connecting rods are to be reinstalled, they must be in their original sets and in their original positions.

The grade of a cylinder bore (1, 2 or 3) is marked on outside of engine block, adjacent to the bore. Pistons are similarly graded (1,2 or 3) on their upper surface. Make sure the correct piston grade is chosen when installing a new piston.

Secure the piston pin (2) with new circlips (1).

Allow the pistons cool.

2. Before installing to the engine, rotate the piston rings as necessary to the positions shown on the following diagram.

Front

Front

Rear

30°

30°

Front



Engine (03.00)

Flywheel


Item

Flywheel Renew

Code

TBA

Removal


Warning

If rasing vehicle on a ‘two post’ ramp (vehicle supported by underbody), Ensure that the rear end of the vehicle is securely strapped to the ramp. Failure to strap the rear of vehicle down may lead to the vehicle falling off the ramp.

Caution

The flywheel assembly, including the mounting bolts, is a balanced assembly. Use the same bolts when reassembling to retain balance.

8. Place a support surface under the flywheel. Insert flywheel bolts (x2) into the threaded ‘jacking’ holes in the flywheel.

Warning

The flywheel is heavy. Take care to provide adequate support when removing or replacing it.

If using a two post vehicle lift, remove the screws that secure the rear section of the road wheel arch liner. Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly (Refer to ’Jacking Points’, page I-I-IX).





5. Remove the rear subframe and torque tube.




Remove the clutch assembly (Refer to ’Clutch (08.00)’, page 8-1-1).

7.


Remove the drive damper plate (bolts x8).Retain for installation.

9. Tighten the bolts in stages to ease the flywheel from its location on the crankshaft.



Engine (03.00)

Installation

1. Using a suitable support surface under the flywheel, offer the flywheel to the crankshaft and align the attachment holes.

2. Loosely install the flywheel mounting bolts (x8) and hand tighten.

3. Tighten the bolts in half turn stages in sequence shown. Continue until the flywheel face is in full contact with the crankshaft flange.

4. Loosen the bolts. Then torque to

75-81 Nm in the same sequence.


8

6

1

4

3

2

5

7

Install the clutch assembly (Refer to ’Clutch (08.00)’, page 8-1-1).


7. Install the drive damper plate. Torque bolts (x8) to 30

Nm .

The damper plate will only install one way, locating on dowels provided.

8. Install the torque tube and the rear subframe.












Engine (03.00)

Engine (03.00)


Description

Air Induction System

Intake air is filtered and then passed through mass air flow (MAF) meters. Signals from the MAF meters are fed to the PCMs and are used together with other signals in calculating the required amount of fuel (Air fuel ratio approx. 14.3 parts air to

1.0 part fuel by weight). The air then passes through the throttle bodies into the six branch inlet manifolds.

Specifications

Torque Figures

Description

Air box cover

Outlet pipe

Air box mountings

Nm (lb. / ft.)

1.5-2.0

1.5

1.5-2.0

1.5

2.5-3.5

2-2.5



Engine (03.00)

Maintenance

Air Filter

20. Remove air filter.


Item

Air Filter Renew LH

RH

Code

03.12.CB

03.12.DB

Removal




16. Remove the road wheel(s).


18. Remove the screws (x3). Pull the front section of the wheel arch down to gain access the air filter box.


Installation

1. Push the air filter onto the filter adaptor. Install the box cover. Torque bolts to 1.5-2.0 Nm .

19. Remove bolts (x7) and remove filter box cover.

1.5-2.0 Nm. (x7)

2. Install the front section of the road wheel arch liner.






Engine (03.00)

Air Filter Box


Item

Air Box Renew LH

RH

Code

03.12.AB

03.12.BB

Removal





3. Remove the road wheel(s) and arch liner.


6. Remove the air filter box mounting bracket (x1) and mounting bolts (x2). Withdraw the air filter box.


Installation

1. Place the air filter box into position and secure.

5. Disconnect the air outlet and inlet pipes.

Outlet pipe - Remove fixing screw. Twist the outlet pipe and pull away.


2. Connect the outlet and inlet pipes.

Outlet pipe - Insert and twist, install fixing screw.


4. Install the road wheel arch liner and front undertray.





Engine (03.00)



Engine (03.00)

Engine (03.00)


The electronic engine control system consists of two

Powertrain Control Modules (PCM’s) and a number of sensing and actuating devices. The sensors supply the PCM’s with input signals which relate to the engine operating conditions and driver requirements. The sensor information is evaluated by the PCM’s using the results to activate the appropriate response from the actuating devices.

The system provides the necessary engine control accuracy and adaptability to:

• Minimize exhaust emissions and fuel consumption

• Provide optimum driver control under all conditions

• Minimize evaporative emissions

• Provide system diagnostics

In addition to these functions the PCM’s also interface with other vehicle systems through the controller area network

(CAN).

Refer to the Vehicle OBDII manual for inputs / outputs and diagnostic information

Schematic Diagram

P C M

F uel P ump

Drive Module

T o other half of E ngine

V apour

Management

V alve

P C M

P C M

F uel T ank

P res s ure S ens or

F uel T ank

F iller

Neck

T o atmos phere

P C M C arbon

C anis ter

F uel P ump

F uel Level

S ens or P C M

F uel F ilter C anis ter

V ent V alve

F uel R ail

Drain

T ube

P C M

C oolant

T emp S ens or

011-1-016

F uel

Injector

Inlet Manifold

S park

P lug

Ignition

C oil

P C M

C ams haft

P os ition S ens or

P C M

Motoris ed

T hrottle

Intake Air

T emp S ens or

P C M

E xhaus t

Manifold

T hrottle

P edal

P C M

C ranks haft

P os ition S ens or

Oxygen S ens or

H02S 1-1

C atalytic

C onverter

P C M

Oxygen S ens or

H02S 1-2

E xhaus t

MAF

P C M

Air F ilter

F uel

V acuum

V apour



Engine (03.00)

Specifications

Powertrain Control Modules (PCMs)

Secondary (B) Primary (A)



47 HTR 12

48 HTR 22

50 CNVNT

LH and RH Drive

PCM A

View looking into the PCM connectors.

T

Caution


C E




4 PRND

9 MAF+

10 MAF-

14 CB2+

17 Drive TT

18 Sport TT

19 Tip up

20 Tip down

21 MIL

24 HEGO 12

25 HEGO 22

26 CB2-

28 Rev TT

29 PRND 2

30 CB 3+

31 CB 3-

32 Neutral TT

33 Sport SW

36 Bap

38 Engine off

40 Ref. voltage C

41 Signal return C

43 Park ST

45 Park TT

I

I

0

I

0

I

I

I

I

0

0


I 8

I

I 67

67

13

9

8

9

9

30

43

43

0

I

I

0

16

9

8

68

13

8

8

16

9

9, 68

43, 68

9

8

C - Cowl


2 Start enable

3 ISO-K

4 App1 Ref. voltage

5 App 1

6 App 1 Return



9 Fuel tank pressure

10 Case ground

11 CB 1+

12 Motor fuel pump

14 Power steering pressure

15 Accs (Aircon demand)


17 App 2

18 App 2Return

19 Sccs (Speed Con Demand)



22 Oil Pressure

23 CB 1-

24 Power hold

25 Aircon clutch relay

26 Aircon pressure

29 Clutch (Top of travel)

30 Sccs (Speed Con Return

31 TX out (PATS Comms)



34 EVMV

35 Power

36 Power

37 PATIL (PATS LED)

38 PBI (Start button ILL)

39 Clutch (Bottom of travel)

40 Ref. voltage B

41 Signal return B

42 RXIN (PATS Comms)

43 EBV

44 FEPS

45 Keep alive power

47 Power ground



0

0

0

43

43

68


I

I

I


0 70

9

72

I 72

72

39

39

68

56

16

41 0

I

I

I

65

6

72

72

I

72

71

I

0

I

0

0

I

0

0

I

I

I

I

2

41

65

16

I

I

0 50, 56, 63

0 6

6

70

65

56

56

30

71

63

68

68

70

70

6, 65, 68

6, 65, 68, 70

63

68

16

56

56


Engine (03.00)

C - Cowl


48 Power ground

49 Power ground

50 IGNSNS


I

56

56

56

PCM B

View looking into the PCM connectors

.

Caution


T C E

E - Engine


1 (CD1) Clyinder 1

2 Injector 1

3 Injector 6

4 Injector 4

5 Injector 3


8 Injector 5

9 Injector 2

10 Injector 7

11 Injector 8

12 (CD5) Cylinder 5


14 Fan Control



19 TP1-NS

24 (CD3) Cylinder 3

25 CID 1

29 TP2-PS

30 HEGO 11

31 Hego21

33 Engine Coolant Temperature

34 Crankshaft Position

35 (CD6) Cylinder 6

36 Fuel Rail Temperature

37 Fuel Rail Pressure Tran

38 (CD2) Cylinder 2

39 (CD4) Cylinder 4

40 Ref. Voltage A

41 Signal Return

45 Crankshaft Positive

47 Throttle Mtr +

48 Throttle Mtr -

49 HTR11

50 HTR21

0

0

I

0

0

0

I

I

I

I

I

I

I

I

0

0

0

0

0

0


0 47

0

0

48

48

0

0

48

48

72

48

48

48

48

47 0

I

0

67

21

65

72

I

0

72

47

65

47

47

65

43, 65, 67

65

72

72

43

43

65

65

47

65

65

72

43

43


E - Engine


1 (CD7) Cylinder 1

2 Injector 1

3 Injector 6

4 Injector 4

5 Injector 3


8 Injector 5

9 Injector 2

10 Injector 7

11 Injector 8





19 TP1-NS

24 (CD9) Cylinder 3

25 CID 1

29 TP2-PS

30 HEGO 11

31 HEGO 21

34 Crankshaft Position+


37 Fuel tank pressure tran

38 (CD8) Cylinder 2


40 Ref. Voltage A

41 Signal Return

45 Crankshaft Positive -

47 Throttle Mtr +

48 Throttle Mtr -

49 HTR11

50 HTR21

0

0

I

0

0

0

0

0

0

0

I

I

0

I

I

I

I

I

0

I

0

0


0

0

0

0

0

47

66

44, 66, 67

72

72

72

44

44

66

47

66

47

66

72

44

44

66

72

72

47

48

48

47

67

48

72

48

48

47

48

48

48




4 Engine coolant level

6 PRI / Sec switch

9 MAF +

10 MAF -

14 CB 2 +

24 HEGO 12

25 HEGO 22

26 CB 2 -

30 CB 3 +

31 CB 3 -

38 Altmon

41 Signal return C

47 HTR 12

48 HTR 22

C -Cowl



5 App 1

6 App 1 return



10 Case ground

11 CB 1+

12 Motor fuel pump


17 App 2

18 App 2 Return



23 CB 1-

24 Power hold



34 EVMV

35 Power

36 Power

44 FEPS

45 Keep alive power

47 Power ground

48 Power ground

49 Power ground

50 IGNSNS

Torque Figures

Description

PCM mount


Engine (03.00)

I

I

I


I 66

I

I

I

44

67

67

13

44

44

13

16

I

0

0

16

69

44

44

44

Maintenance

WDS Connection

The port for WDS connection is located in the drivers side footwell on the transmission tunnel.

I

0

0

I


72

I

I

72

72

39

I 39

56

0

I

I

I

I

56

56

16

56

56

68

68

66

56

56

56

56

72

2

41

16

16

41

72

72

LHD

000000

CRUISE

Body

000 0

000000 MILES

CRUISE

D

Engine

RHD

Nm.

8-10 lb./ft.

6-7.5



Engine (03.00)

PCM


Item

PCM Renew LH

RH

Code

03.14.AB

03.14.BB

Removal





Installation

1. Install the PCM and the bracket. Torque bolts (x3) to 8-

10 Nm .


3. Install the door check rod.





5. Disconnect the door check rod.

6. Remove bolts (x3) and withdraw the bracket and the

PCM.



Engine (03.00)



Engine (03.00)

Engine (03.00)



Description

The evaporative loss system prevents escape of fuel vapours into the atmosphere.




Displaced fuel vapour leaves the fuel tank via the normally open fill level vent valve and the roll over valves. It passes through the carbon canister where fuel hydrocarbons are absorbed. Clean air leaves the system via the normally open canister vent valve. This valve is only closed during diagnostic pressure testing of the fuel system.

During normal engine running, the single vapour management valve in the engine bay is periodically opened allowing fresh air flow into the open canister vent valve, through the carbon canister, through the vapour management valve and into the primary inlet manifold. This fresh air flow progressively purges any absorbed fuel vapour from the carbon canister.



Engine (03.00)



Engine (03.00)

Engine (03.00)


Specifications

Description

Motorised Throttles

The motorised throttles (x2, one to each inlet manifold) allow accurate control of the inlet air.

A throttle position sensor (TPS) is incorporated into each motorised throttle unit. During normal engine run, TPS signals are used by the PCMs to indicate power demand from the engine. If not already at the desired position, the

PCMs will drive the throttle motors to open or close the throttles by the required amount.

At idle, the throttle butterflies are almost closed and idle speed is controlled by small throttle movements.

The throttle butterflies are spring loaded to fail in the idle position. In the event of the throttle butterflies springs failing, air flow will allow the throttle butterflies to fail in the idle position.

No set-up procedure is required.

Torque Figures

Description

Throttle body

Maintenance

Throttle Body


Item

Throttle Body Renew

Removal

1. Disconnect the air intake pipe.

Nm.

8-12 lb./ft.

6-9

LH

RH

Code

03.04.HB

03.04.JB




4. Withdraw throttle body complete with gasket. Discard the ‘O’ ring.



Engine (03.00)

Installation

1. Install the throttle body complete with a new ‘O’ ring.


2. Install the air intake pipe and wiring harness plug.



Contents

Road Wheel Alignment (04.00) ............................4-1-2

Specifications ......................................................... 1-2

Maintenance........................................................... 1-2

Caster Angle .......................................................... 1-3

Adjustment (Front) .............................................. 1-3

Camber Angle........................................................ 1-3

Adjustment ......................................................... 1-3

Toe........................................................................ 1-3

Adjustment (Front) .............................................. 1-3

Adjustment (Rear)................................................ 1-3

Front Suspension (04.01)......................................4-2-1

Description ............................................................. 2-1

Suspension Arms.................................................... 2-1

Anti-roll Bar ........................................................... 2-1

Vertical link............................................................ 2-1

Specifications.......................................................... 2-1

Symptoms............................................................... 2-2

Maintenance........................................................... 2-3

Road Wheel Bearing .............................................. 2-3

Inspection........................................................... 2-3

Ball Joints............................................................... 2-4

Inspection........................................................... 2-4

Front Suspension ................................................... 2-4

Removal.............................................................. 2-4

Installation .......................................................... 2-6

Anti-roll Bar ........................................................... 2-8

Removal.............................................................. 2-8

Installation .......................................................... 2-8

Vertical Link........................................................... 2-9

Removal.............................................................. 2-9

Installation .......................................................... 2-9

Rear Suspension (04.02).......................................4-3-1

Description ............................................................. 3-1

Suspension Arms.................................................... 3-1

Anti-roll Bar ........................................................... 3-1

Vertical Link........................................................... 3-1

Specifications.......................................................... 3-2

Maintenance........................................................... 3-2

Rear Suspension..................................................... 3-2

Removal.............................................................. 3-2

Installation .......................................................... 3-4

Anti-roll Bar ........................................................... 3-6

Removal.............................................................. 3-6

Installation .......................................................... 3-6

Vertical link............................................................ 3-7

Removal.............................................................. 3-7

Installation .......................................................... 3-8

Shock Absorber System (04.03)............................4-4-1

Description............................................................. 4-1

Specifications ......................................................... 4-1

Maintenance (Front)............................................... 4-1

Spring and Damper Assembly ................................ 4-1

Removal.............................................................. 4-1

Installation.......................................................... 4-2

Maintenance (Rear) ................................................ 4-3

Spring and Damper Assembly ................................ 4-3

Removal.............................................................. 4-3

Installation.......................................................... 4-3

Road Wheels and Tyres (04.04) ...........................4-5-1

Specifications ......................................................... 5-1

USA Tyre Gradings ................................................. 5-2

Tread Wear ........................................................... 5-2

Temperature.......................................................... 5-2

Maintenance........................................................... 5-2

Safety ................................................................... 5-2

Tyre Replacement and Wheel Interchanging ......... 5-3

Winter (Snow) tyres................................................ 5-3

Inspection and Verification .................................... 5-3

Visual Inspection Chart........................................ 5-3

Tyre Wear ............................................................. 5-3

Tyre Wear Diagnosis............................................ 5-3

Road Test............................................................ 5-4

Symptoms........................................................... 5-4

Tyre Damage ......................................................... 5-5

Repairs .................................................................. 5-6

Care of Alloy Road Wheels .................................... 5-6

Road Wheel Alignment.......................................... 5-6

Misalignment Effects............................................ 5-7

Alignment Precautions......................................... 5-7

Road Wheel and Tyre Balance............................... 5-7

Static Balance ..................................................... 5-7

Dynamic Balance ................................................ 5-7

Road Wheel Nut Torque Tightening....................... 5-7

Tyre Pressure Sensing (Option).............................. 5-8

Pressure Sensing with Winter Wheels and Tyres..... 5-8

Warnings ............................................................... 5-8

Display Unit .......................................................... 5-9

Display Panel ...................................................... 5-9

Connection and Normal Operation ..................... 5-9

System Programming ............................................. 5-9

Level 1 Programming........................................... 5-9

Level 2 Programming......................................... 5-11

Level 3 Programming......................................... 5-11


Road Wheel Alignment (04.00)




Specifications

Toe

Total Toe

Front

2.5’ (±2’)

5’ (±4’)

Rear

10’ (+5’ / -0’)

20’ (+10’ / -0’)

Camber -15’ (±5’)

Cross Camber 0’ (±10’)

Caster 5° (+30’ / -15’)

Cross Castor 0° (±15’)

KPI

Bumpstop free travel

10° 51’

12.0 mm

-1° 30’ (±5’)

0’ (±10’)

N/A

N/A

N/A

14.5 mm

Normal Ride

Height

2 x 68 kg (driver and passenger seat)

+ 14 kg in the boot

+ full fuel tank.

Maintenance


Item

All Wheel Alignment

Code

04.00.AD

Refer to the geometry setup tool manufacture operating instructions.

Check vehicle geometry in the following order:

1 Caster Angle

2 Camber Angle

3 Toe

Adjustments to caster, camber and toe settings may impact each other. After checking / adjusting each setting, minor adjustments to caster, camber and toe may have to be made to reach the correct set up for the vehicle.

Both LH and RH Toe need to be adjusted when adjusting caster and camber.

Ride height is measured from the centre of the road wheel, vertically, up to the road wheel arch.

Check tyre pressures before checking road wheel alignment.

Front Rear

Ride Height 378.5mm (±15mm) 376.5mm (±15mm)

Wheel centre to wheel arch

(front and rear)

Over time this vehicle’s ride height will settle (up to 20mm).

Therefore, as this vehicle ages it’s ride height will tend to sit towards the lower end of the ride height tolerance band.

This needs to be taken into account when checking vehicle ride height.




Caster Angle

Adjustment (Front)

Check and if required adjust the camber angle. If the camber angle is correct but the caster angle is still incorrect, suspect damage to the suspension components.

Ensure that the vehicle is at normal ride height.

Check tyre pressures.

1. Check the caster settings. Follow the equipment manufacturer’s instructions.

2. Release the cam bolt lock nuts.

3. Rotate the lower arm caster adjustment cam bolts.

4. When the caster angle is correct, tighten the cam bolt lock nuts.

5. Re-check alignment settings. Adjust if required.

Camber Angle

Adjustment



1. Check the camber settings. Follow the equipment manufacturer’s instructions.


3. Rotate the lower arm camber adjustment cam bolt to adjust the camber angle.

4. Tighten the cam bolt lock nuts.

5. Re-check alignment settings. Adjust if required.

Toe

Adjustment (Front)



1. Start the engine and centre the steering rack.

2. Turn the engine off. Lock the steering position.

3. Check the Toe settings. Follow the equipment manufacturer’s instructions.

If Adjustment is Required.

4. Clean the lock nuts and the threads of the track-rod ends.

Do not allow the steering gear boot to twist when the trackrod ends are rotated. If required release the steering gear boot clamps.

01-11-003

5. Loosen the lock nuts and rotate the track-rod ends (in equal amounts) to adjust the Toe.

6. Tighten the lock nuts to 70 Nm.

, and re-check the Toe.

Adjust if required.

When correct, secure the steering gear boot clamps (if released).

Adjustment (Rear)



1. Check the toe settings. Follow the equipment manufacturer’s instructions


3. Rotate the toe control rod adjustment cam bolt to adjust the rear toe.

4. Tighten the lock nut.

5. Re check the Toe settings. Adjust if required.





Front Suspension (04.01)




Description

Suspension Arms

The upper suspension arm is attached to the body structure.

The lower suspension arm is attached to the front subframe.

Each upper suspension arm has a press-fit ball joint, and two interleaved rubber bushes. Two bolts attach the upper suspension arm to the body structure.

Each lower suspension arm has a press fit ball joint and metal-to-rubber bonded bushes which are attached to the front subframe by two eccentric cam bolts (Camber and castor settings).

Anti-roll Bar

The anti-roll bar, is attached to the subframe in two positions by rubber bushes and clamps. The outer ends of the anti-roll bar are attached to the lower suspension arms by drop links.

The anti-roll bar provides the required stiffness to control body roll.

Vertical link

The Vertical link (Knuckle Joint) swivels on the upper and lower suspension arms via ball joints, and carries the hub, a unit 3 wheel bearing (including the ABS encoder ring), the wheel speed sensor, the brake caliper, and the brake disc and shield. The position of the Vertical link is determined by the movement of the steering rack, which is connected to the Vertical link by the steering track rod.

Specifications

Torque Figures

Description

Brake dust shield.

Bearing Assembly to the Vertical link.

Vertical Link to the Lower

Suspension Arm.

Vertical Link to the Upper

Suspension Arm.

Track-rod End Lock Nut.

Vehicle Ride Height Sensor.

Nm

9

55

90

90 lb. / ft.

7

41

66.5

66.5

Anti-roll Bar Link Nuts

Anti-roll Bar Mounting Bolts

Torque bolt 1, then bolt 2, then bolt 1 again (to allow for rubber compression)

M8

M5

70

22.5

9

110

22.5

52

17

7

81.5

17

Torque the following suspension fixings with the vehicle at normal ride height

Lower Suspension Arm front bush to the Subframe

115 85

185 137 Lower Suspension Arm rear bush to the Subframe.

Upper Suspension Arm to the

Front Structure

Spring and Damper Bolts Top

Lower

115

22.5

175

85

17

129.5

Normal ride height 2 x 68 kg + 14kg in the boot +full fuel tank.




Symptoms

Symptom

Crabbing

Front ‘Bottoming’ or Riding Low

Drift / Pull

Rough Ride

Incorrect Tyre

Wear

‘Shimmy’ or ‘Road

Wheel Tramp’

Poor ‘Return ability’ of Steering

Steering Wheel

Off-Centre

Sway or Roll

Possible Cause

Front or rear suspension components / road wheel alignment

Drive axle damaged

Spring(s)

Dampers

Unequal tyre pressure

Incorrect road wheel alignment

Tyres

Action

Inspect front and rear suspension systems.

Check / adjust road wheel alignment

New drive axle.

Check ride height.

Check dampers.

Check / adjust tyre pressures.

Inspect tyre for excessive wear.

Check / adjust road wheel alignment.

Check / adjust tyre pressures. Inspect tyre for excessive wear.

Unevenly loaded or overloaded vehicle Notify customer of incorrect vehicle loading.

Damaged steering components Check steering system for mechanical or hydraulic bias.

Brake drag Check brakes.

Check steering system for mechanical or hydraulic bias.

Spring(s)

Shock absorber(s)

Incorrect tyre pressure

Check springs.

Check shock absorbers.

Check and adjust tyre pressure. Inspect tyre for excessive wear.

Check and adjust road wheel alignment (Refer to ’Road

Wheel Alignment (04.00)’, page 4-1-2).



Balance tyres.

Excessive front or rear Toe (rapid inner or outer edge wear)

Excessive negative or positive camber

(rapid or outer edge wear)

Tyres out of balance (tyres cupped or dished)

Loose road wheel nut(s)

Loose front suspension

Front road wheel bearing(s)

Road wheel / tyres

Shock absorber(s)

Spring(s)

Loose, worn or damaged ball joint(s)

Loose, worn or damaged steering components

Front road wheel alignment

Check and tighten road wheel nuts to specification.

Check and tighten suspension fixings to specification.

Check road wheel bearings.

Check road wheels / tyres.

Check shock absorbers.

Check springs.

Check ball joint(s) (Refer to ’Ball Joints’, page 4-2-4).

Check components.

Worn or damaged suspension bushes

Ball joints

Steering components

Unequal front or rear Toe settings

Steering components

Overloaded, unevenly or incorrectly loaded vehicle

Loose road wheel nut(s)

Spring(s)

Shock absorber(s)

Loose front stabilizer bar or rear stabilizer bar



Check suspension bushes

Check ball joint(s).

Check for excessive friction in steering system.

Check tyre pressures

Check and adjust road wheel alignment.

Check and install new components as required.

Notify customer of incorrect vehicle loading

Check. Tighten road wheel nut(s) to specification

Check. Install new springs as required.

Check. Install new shock absorbers as required.

Check. Tighten anti-roll bar to specification.




Symptom Possible Cause

Vibration / Noise Tyres / road wheel

Road wheel bearing assemblies

Brake components

Suspension components

Spring and damper units

Steering components

Vehicle Leans to

One Side

Wander

Action

Check. Install new components as required.


Front or rear suspension components Inspect front and rear suspension systems.

Spring and damper assemblies

Incorrect ride height. Lateral tilt out of specification

Suspension bushes not torqued at ride height

Check spring and damper assemblies.

Check ride height.

Check / adjust suspension bushes torque.


Ball joint(s) Check ball joint(s) (Refer to ’Ball Joints’, page 4-2-4).

Front road wheel bearing(s)

Loose, worn or damaged suspension components

Check road wheel bearings.

Check suspension components.

Loose suspension fasteners

Steering components

Road wheel alignment (excessive total front Toe-out)

Check and tighten suspension fasteners to specification.

Check steering components for wear and / or free play.

Check / adjust road wheel alignment

(Refer to ’Road Wheel Alignment (04.00)’, page 4-1-2).

Maintenance

Caution

Treat the suspension components with care. The suspension components are libel to damage if struck with, e.g. a metal faced hammer.

Road Wheel Bearing

Inspection

1. Raise and support the vehicle.

2. Make sure the road wheel rotates freely and that the brake pads are sufficiently retracted, allowing free movement of the road wheel.

3. Firmly grasp the road wheel at the top and bottom.

Attempt to move the road wheel inward / outward while lifting the weight of the road wheel off the road wheel bearing.

Observe upper and lower ball joints for movement.

4. If there is any excess movement in the road wheel bearing, replace the bearing assembly.




Ball Joints

Inspection

1. Raise and support the vehicle.

Prior to carrying out any inspection of the ball joints, inspect the road wheel bearings.

2. Pull and push the bottom of the road wheel. Check for any relative movement between the ball joint and the lower suspension arm.

Install new components if required.

Removal


2. For each affected wheel station remove the road wheel(s).

3. Remove the brake caliper (bolts x2). Move the brake caliper to one side and secure.

4. Disconnect the ABS sensor wiring harness plug.

3. Pull and push the top of road wheel. Check the relative movement between the ball joint and the upper suspension arm.

Install new components as required.

4. Lower the vehicle.

Front Suspension


Item

Upper Suspension Arm

Lower Suspension Arm

Vertical link

Spring and Damper Unit

(LH)

(RH)

(LH)

(RH)

(LH)

(RH)

(LH)

(RH)

Code

04.01.NB

04.01.PB

04.01.LB

04.01.MB

04.01.GB

04.01.HB

04.03.AB

04.03.BB

04.01.AB

Anti-roll Bar

Caution

Treat the suspension components with care. The suspension components are libel to damage if struck with, e.g. a metal faced hammer.

5. Disconnect the vehicle ride height sensor.




6. Using service tool (Refer to ’204-523 (Ball Joint Splitter)’, page 20-1-3), remove the track rod-end.

Caution

Do not use a hammer, etc., to ‘shock’ the track rod-end.

8. If required, remove the hub from the vertical link.


Take care not to damage the ball joint boot.

7. Remove the upper suspension arm and vertical link as a unit.

7.1 Remove bolts (x2) that secure the upper suspension arm to the body structure.

8.2 Press the hub from the vertical link.

8.3 Remove the brake dust shield (bolts x4).

7.2 Using service tool (Refer to ’204-523 (Ball Joint

Splitter)’, page 20-1-3), remove the vertical link from the lower suspension arm.

Split Joint

Remove nut

7.3 If required separate the upper suspension arm from the vertical link.




9. Remove the spring and damper assembly.

Caution

Ensure the damper is fully extended.

If removing both spring and damper units - the engine bay cross brace will be released.

9.1 Remove nuts (x3) from the top of the spring and damper assembly.

11.Remove bolts (x2) that secure the lower suspension arm to the subframe. Withdraw the lower suspension arm.

9.2 Remove the spring and damper assembly lower mounting bolt.

Installation

Caution

Final tightening of the suspension components must be carried out with the suspension arms at normal ride height. Failure to do this will over stress the suspension bushes when the suspension is deflected to max. upward travel.

1. Install the lower suspension arm to the subframe. Do not torque.

2. Place the engine bay cross brace, complete with mounts, in position. Install the spring and damper assembly. Do not torque bolts.

10. Disconnect the anti-roll bar link assembly.




3. Install the bearing assembly to the vertical link (if removed).

3.1 Install the brake dust shield. Torque bolts (x3) to 9

Nm .

4. Install the anti-roll bar link assembly to the lower arm.

Torque to 110 Nm .

Ensure that the washer installs as shown below.

3.2 Install the bearing assembly. Torque bolts to 55 Nm .

S

5. Install the upper suspension arm to the vertical link, if removed. Torque nut to 90 Nm .

6. Install the vertical link to the lower suspension arm.

Torque nut to 90 Nm .

7. Install the upper suspension arm to the body structure.

Do not torque.

8. Install the track-rod end. Torque nut to 70 Nm .

9. Install the vehicle ride height sensor (LH side). Torque nut to 22.5 Nm .

10. Install the ABS sensor wiring harness plug.

11. Install the brake caliper (Refer to ’Brake Caliper (Front and Rear)’, page 6-1-3).

Torque bolts to 20 Nm + 66°-70°




12.Torque the suspension fixings with the vehicle at normal ride height (Refer to ’Specifications’, page 4-2-1):

• Lower suspension arm to the subframe (rear bush) - 185 Nm .

• Lower suspension arm to the subframe (front bush) - 115 Nm .

• Upper suspension arm to the front structure - 115 Nm .

• Spring and damper bolts to (top) 25.5 Nm .

(bottom) 175 Nm .

Installation

1. Place the anti-roll bar in position and install the stabiliser mountings.

Caution

The anti-roll bar must be installed with the cut off section at the top.

The engine bay cross brace must be torqued with the weight of the vehicle on the roadwheels.



14. Check / adjust the Camber, Castor and Toe settings.

Anti-roll Bar


Item

Anti-roll Bar Renew

Removal

Code

04.01.AB




4. Remove the anti-roll bar from the anti-roll bar drop links.

2. Connect the anti-roll bar to the anti-roll bar drop links.

Torque the fixings.

• Anti-roll bar mounting bolts to 22.5 Nm .

Torque bolt 1, then bolt 2, then bolt 1 again (to allow for rubber compression)

• Anti-roll bar link nuts to 110 Nm .

Ensure that the washer installs as shown below.

01-04-123a

5. Remove the anti-roll bar mountings (strap and bush) from the subframe and withdraw the anti-roll bar.

4-2-8







Vertical Link


Item

Vertical link Renew (LH)

(RH)

Code

04.01.GB

04.01.HB

Removal



3. Remove the brake caliper bolts (x2). Move the brake caliper to one side and secure.

7. Disconnect the upper suspension arm from the vertical link.


5. Remove the track-rod end.

Installation


Torque bolt to 90 Nm .

2. Install the vertical link to the upper suspension arm.

Torque bolt to 90 Nm .

3. Install the track-rod end. Torque nut to 70 Nm .

4. Connect the ABS sensor wiring harness plug.

5. Install the brake caliper (Refer to ’Brake Caliper (Front and Rear)’, page 6-1-3). Torque bolts to 20 Nm + 66°-

70°.



7. Check / adjust the Camber, Caster and Toe settings.

6. Separate the lower suspension arm from the vertical link

6.1 Install service tool (Refer to ’204-524 (Front

Suspension Support)’, page 20-1-4). Lower the vehicle until the lower suspension arm is horizontal.

6.2 Using a service tool(Refer to ’204-523 (Ball Joint

Splitter)’, page 20-1-3) part the lower suspension arm from the Vertical link.

Caution

Do not use a hammer, etc., to ‘shock’ the track rod-end.

Take care not to damage the ball joint boot.

6.3 Raise the vehicle and remove the service tool (Refer to ’204-524 (Front Suspension Support)’, page 20-1-

4).






Rear Suspension (04.02)

Description



Suspension Arms

The upper suspension arms are each installed with a pressfit ball joint, and two interleaved rubber bushes. Two bolts attach each upper suspension arm to the rear subframe.

The lower suspension arms each have press fit ball joints installed and metal-to-rubber bonded bushes which are attach to the rear subframe by two eccentric cam bolts.

The camber setting is adjusted by rotating the lower suspension arm rear eccentric cam bolt.

Anti-roll Bar

An anti-roll bar, mounted on the rear subframe connects to the LH and RH lower suspension arms via drop links. The drop links, with a ball joint at either end, transmit vertical movement of the rear suspension to the anti-roll bar, minimising body roll.

Vertical Link

The vertical link carries the hub, the cartridge wheel bearing, the ABS rotor, the wheel speed sensor, the brake caliper, the hand brake caliper and the brake disc and shield.

A toe control (track-rod) arm secures the rear of the vertical link to the subframe. The toe control arm is adjustable, on an eccentric cam, to alter the rear road wheel toe alignment.




Specifications

Torque Figures

Description

Brake Dust Shield.

Bearing Assembly to the Vertical link.

Halfshaft Nut

Spring and Damper Bracket

Mounting

Spring and Damper Top

Mounting to Bracket

Spring and Damper Lower

Mounting

Track rod Arm to Vertical Link

Anti-roll Bar Link

Anti-roll Bar Mounting Bolts

Torque bolt 1, then bolt 2, then bolt 1 again (to allow for rubber compression)

Nm

9

50

300

75-80 55.5-59.5

22.5 17

175

115

110

30 lb. / ft.

7

37

221.5

129.5

85

81.5

22.5

Ride Height Sensor

Vertical Link to the Lower

Suspension Arm.

M8 22.5

Torque the following suspension fixings with the vehicle at normal ride height

175 129.5

90 66.5

Vertical Link to the Upper

Suspension Arm.

Lower Suspension Arm to the

Subframe.

115 85

Upper Suspension Arm to the

Subframe

Track-Rod Arm to Subframe

115

115

85

85

Normal ride height: 2 x 68 kg + 14kg in the boot +full fuel tank.

Maintenance

For details on:

• Alignment

• Inspections

(Refer to ’Road Wheel Alignment

(04.00)’, page 4-1-2)

(Refer to ’Suspension (04.00)’, page

4-2-1)

• Symptoms

• Road Wheel

Bearing

Procedures

• Ball Joints

Procedures

Rear Suspension


Item

Upper Suspension Arm Renew

Lower Suspension Arm Renew

Vertical link Renew

Spring and Damper Unit Renew

(LH)

(RH)

(LH)

(RH)

(LH)

(RH)

(LH)

(RH)

Code

04.02.RB

04.02.SB

04.02.NB

04.02.PB

04.02.GB

04.02.HB

04.03.CB

04.03.DB

04.02.AB


Removal



3. Remove the bolts securing the service brake and handbrake calipers to the vertical link. Move the calipers to one side and secure.




6. Remove the anti-roll bar drop links.

4. Remove the halfshaft nut.

7. Disconnect the vehicle height sensor (LH side).


8. Remove the bolt that secures the track-rod arm to the vertical link.

9. Remove the bolt that secures the upper suspension arm to the vertical link.

10. Press the halfshaft from the vertical link.

11. Remove the bolt that secures the vertical link to the lower suspension arm.




12.If required, remove the bearing assembly from the vertical link.

12.1 Remove bolts (x4) that secure the bearing assembly to the vertical link.

12.2 Press the bearing assembly from the vertical link.

14.Remove the upper suspension arm.

15. Remove the lower suspension arm.

13. Remove the spring and damper assembly.

Ensure the damper is fully extended.

13.1 Remove the bolts (x4) from the spring and damper assembly upper mounting bracket.

13.2 Remove the bolt from the lower spring and damper mounting. Withdraw the spring and damper assembly.

Installation

1. Install the lower suspension arm to the rear subframe.

Do not torque.

2. Install the spring and damper assemblies. Torque to:

• Top mounting bracket bolts (x4) - 75-80

Nm .

• Bottom mounting bolt - 175 Nm .

3. Install the upper suspension arm to the subframe. Do not torque.




4. Install the bearing assembly (if removed).

• Bearing bolts to 50 Nm .

• Dust shield bolts to 9 Nm .

9. Install the service brake and the handbrake calipers.

Torque bolts to:

• Service brake caliper to 20 Nm. + 66°-70°

• Handbrake caliper to 15 Nm. + 90°-94°

10. Install the anti-roll bar drop link. Torque to 110 Nm .

Ensure that the washer is installed between the nut and the anti-roll bar.

5. Install the vertical link. Do not torque bolts.

11. Install the vehicle ride height sensor (LH side).

Torque nut to - 22.5 Nm .



6. Install the track-rod end. Do not torque.


8. Install the halfshaft nut. Torque to 300 Nm .




Caution


13. Torque the suspension fixings with the vehicle at normal ride height (Refer to ’Specifications’, page 4-1-2).

• Lower suspension arm to the subframe -

115 Nm .

• Vertical link to the lower suspension arm -

175 Nm .

• Upper suspension arm to the vertical link -

115 Nm .

• Upper suspension arm to the subframe -

115 Nm .

• Track-rod end to vertical link - 115 Nm .

• Track-rod arm to subframe - 115 Nm .

Anti-roll Bar


Item


Removal

Code

04.02.AB

1. Remove the rear under tray.

2. Disconnect the anti-roll bar link assembly from the lower arm (x2).

3. Remove the bolts (x2) from the bush strap (x2).

4. Withdraw the anti-roll bar.

Installation

Caution


1. Place the anti-roll bar in position.

1.1 Install both bush straps (bolts x4). Do not torque.

Caution

The anti-roll bar must be installed with the cut off section at the top.

1.2 Secure both ends of the anti-roll bar link assembly to the lower arm (bolts x2).

Torque the fixings.

• Anti-roll bar mounting bolts to 30 Nm .

Torque bolt 1, then bolt 2, then bolt 1 again (to allow for rubber compression)

14. Check / adjust the Camber and Toe settings.




• Anti-roll bar link nuts to 110 Nm .

Ensure that the washer installs between the stud and the suspension arm.

2. Install the rear undertray.

Vertical link


Item

Vertical link Renew (LH)

(RH)

Code

04.02.GB

04.02.HB

Removal



3. Remove the service brake and handbrake calipers.

Move the calipers to one side and secure.


6. Disconnect the track-rod arm.





7. Disconnect the upper suspension arm.

7. Install the halfshaft nut. Torque to 300 Nm .

8. Press the halfshaft from the vertical link.

9. Remove the Vertical link from the lower suspension arm.

Installation


2. Install the halfshaft through the vertical link.

3. Install the vertical link to the upper suspension arm.

4. Torque the following:

• Vertical link to the lower suspension arm -

175 Nm .

• Vertical link to the upper suspension arm -

115 Nm .

5. Install the track-rod arm. Torque to - 115 Nm .

8. Install the service brake and the handbrake calipers

(Refer to ’Brake System (06.00)’, page 6-1-1). Torque bolts to:

• Service brake caliper to 20 Nm. + 66°-70°

• Handbrake caliper to 15 Nm. +90°- 94°






Shock Absorber System (04.03)




Description

Movement of each road spring is independently damped by a telescopic, hydraulically-controlled shock absorber. Each shock absorber is installed coaxially within the road spring.

Front spring and damper assemblies are located between the upper suspension arm and attach to the lower suspension arm and the body structure.

Rear spring and damper assemblies attach to the lower suspension arm and the rear subframe, via a mounting bracket, laying to the rear of the upper suspension arm.

Specifications

4. Remove the upper suspension arm from the body structure.

Allow the upper suspension arm and the Vertical link to fall back, giving access to the spring and damper assembly.

Caution

Ensure the brake flex hose is not over stretched.

Torque Figures

Description

Front

Spring and Damper Top Mounts

Spring and Damper Bottom Mount

Upper Suspension Arm

Nm

22.5

175

115 lb. / ft.

17

129.5

85

Rear

Spring and Damper Bracket Mounting 75-80 55.5-59.5

Spring and Damper Top Mounting to

Bracket

22.5 17

Spring and Damper Lower Mounting 175

Vertical Link to Lower Suspension

Arm

175

129.5

129.5

85 Track-rod Arm to Lower Suspension

Arm

115

Maintenance (Front)

Spring and Damper Assembly


Item

Spring and Damper Unit Renew (LH)

(RH)

Code

04.03.AB

04.03.BB

Removal




Ensure the spring and damper assembly is fully extended.

5. Remove the spring and damper top mount nuts (x3).

If removing both spring and damper units - the engine bay cross brace will be released.

6. Remove the lower mounting nut and bolt. Withdraw the spring and damper assembly.




Installation

If removed, place the engine bay cross brace, complete with mounts, in position.

5. Torque the suspension fixings with the vehicle at normal ride height:

• Upper suspension arm to the front structure - 115 Nm .

• Spring and damper bolts to (top) 22.5 Nm .

(bottom) 175 Nm .

The engine bay cross brace must be torqued with the weight of the vehicle on the roadwheels.

Caution

Ensure the brake flex hose is not over stretched.

1. Install the spring and damper unit. Do not torque bolts.

The engine bay cross brace mount must be torqued with the weight of the vehicle on the roadwheels.

2. Install the upper suspension arm. Do not torque.




Caution

Final tightening of the suspension components must be carried out with the full weight of the vehicle on its road wheels. Failure to do this will over stress the suspension bushes when the suspension is deflected to max. upward travel.




Maintenance (Rear)

Spring and Damper Assembly


Item

Spring and Damper Unit Renew (LH)

(RH)

Code

04.03.CB

04.03.DB

Removal



3. Remove the track-rod arm bolt.

6. Remove the vertical link lower bolt.

7. Remove the bolts (x4) from the spring and damper assembly upper mounting.

Ensure the spring and damper assembly is fully extended.

4. Remove the bolt from the lower spring and damper mounting.

8. Withdraw the spring and damper assembly.

Installation

1. Install the spring and damper assembly upper mounting bracket. Torque bolts (x4) to 75-80 Nm .





2. Install the spring and damper assembly to the lower suspension arm. Torque bolt to 175 Nm .


Torque to 175 Nm.

4. Install the track-rod arm. Torque to 115 Nm .





Road Wheels and Tyres (04.04)




Specifications

Tyres

Warning

Do not mix different types of tyres on the same vehicle such as radial, bias or bias belted tyres except in emergencies (temporary spare usage).

The tyres recommended by Aston Martin meet the high speed performance of this vehicle. Only tyres of identical specification may be installed as replacements. Under no circumstances must cross-ply tyres be installed.

Warning

Never run the engine with one wheel off the ground, for example when changing a wheel. The wheel resting on the ground may cause the vehicle to move.

Warning

After market aerosol tyre sealants are extremely flammable. Always question the customer to make sure these products have not been used.

Warning

Correct tyre installation is critical to personal and vehicle safety. The recommended tyres for this vehicle are asymmetrical and must be installed to the wheel with the tyre mark ‘Outside’ on the outside of the wheel rim.

Unique Aston Martin lightweight aluminium alloy road wheels.

Warning

Always wear safety goggles or a face shield when performing any work with wheel and tyre assemblies.

• Front - 8.5j x 19

• Rear - 9.5J x 19

The tyres are made exclusively for Aston Martin.

• Front - Bridgestone 235/40 ZR 19 Warning

Check road wheel nuts torque at 32 km (20 miles) after any wheel change or any time the wheel nuts are loosened.

• Rear - Bridgestone 275/35 ZR 19

Tyre Pressures

Tyre pressures must be checked with the tyres cold.

Warning

When changing a wheel, make sure that the vehicle cannot move. Always apply the parking brake and select the transmission park position (Automatic transmission only).

Warning

Reduce air pressure as much as possible by pushing the valve core plunger in before removing the valve core.

Warning

PDI Inspection.

Tyre pressures must be reduced to normal level during

PDI. The vehicle must never be run on road with elevated tyre pressures, driveability may be seriously compromised.

Warning

Each individual axle, road wheel and tyre has its own maximum weight or tyre inflation rating. Do not overload or over-inflate beyond the capacity of the lowest rated components of the system.

Caution

In order to protect tyres against flat spots during storage and transportation, tyre pressures should be increased to 65 - 70 psi (450 - 500 kPa). Ensure that the tyre pressure are set to the recommended tyre pressures before driving.

• Front - 2.5 bar (250 kpa / 36 psi)

Caution

Do not clean the aluminium alloy wheels with steel wool, abrasive type cleaners or detergents. Failure to follow these instructions may result in damage to the vehicle.

• Rear - 2.6 bar (260 kpa / 38 psi)

Torque Figures

Description

Road wheel nuts

Caution

Paraffin (kerosene) must not be used as a cleansing agent on tyres.

Nm

135 lb. / ft.

100

In two stages. (Refer to ’Road Wheel

Nut Torque Tightening’, page 4-5-7)




USA Tyre Gradings

The following information relates to the tyre grading system developed by the National Highway Traffic Safety

Administration which grades tyres by tread wear, traction and temperature performance.

Tread Wear

Tread wear grade is a comparative rating based on the wear rate of the tyre when tested under controlled conditions

(specified government test course). For example, a tyre graded 150 would wear one and a half times less on the government course than a tyre graded 100. Relative performance of the tyres depends upon actual conditions of use and may depart significantly from normal due to variations in driving habits, service practices and differences in road characteristics and climate.

Traction

Traction grades, A (highest), B and C represent a tyre’s ability to stop in wet conditions measured on specified government test surfaces of asphalt and concrete.

Warning

PDI Inspection.

Traction grade is based on braking (straight ahead) traction tests and does not include cornering (turning) traction.

Maintenance

Factory installed tyres and road wheels are designed to operate satisfactory when inflated to the recommended inflation pressures (Refer to ’Inspection and Verification’, page 4-5-3). The recommended pressures apply to vehicle loads up to and including the full-rated load capacity.

Correct tyre pressures and driving technique have an important influence on tyre life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tyre wear.

Replacement tyres should follow the recommended:

• Size

• Speed rating

• Load range

• Radial construction type

The use of any other size or type may seriously affect:

• Safety

• Ride

• Handling

• Speedometer and

Odometer calibration

• Vehicle ground clearance

• Tyre clearance between body and chassis

• Wheel bearing life

• Brake cooling

Wheels need to be renewed when:

• Impact damaged

• Heavily corroded

• Porous

• Wheel stud holes or seats become damaged

• They have excessive radial or lateral runout.

Temperature

Safety

Temperature grades, A (highest), B and C, represent a tyre’s resistance to the generation of wear and its ability to dissipate heat when tested under controlled conditions

(specified indoor laboratory test road wheel). Sustained high temperature can cause the material of a tyre to degenerate and reduce tyre life; excessive temperatures can lead to sudden tyre failure. Grade ‘C’ corresponds to a level of performance which all passenger vehicle tyres must meet under Federal Motor Vehicle Safety Standard No. 109.

Grades ‘B’ and ‘A’ represent higher levels of performance than the minimum required by law.

Warning

Temperature grade is established for a tyre that is properly inflated and not overloaded. Excessive speed, under inflation or excessive loading, whether separately or in combination, can cause heat build-up and possible tyre failure.

Warning

Do not mix different types of tyres on the same vehicle.

Handling may be seriously affected resulting in loss of control.

Warning

Ensure that tyres are mounted with the sidewall marking ‘Outside’ showing on the outer sidewall face.

Correct tyre rotational direction is critical.

Warning

A tyre and wheel must always be correctly matched.

Wider or narrower tyres than recommended could cause danger through sudden deflation.

Warning

When changing a wheel, make sure that the vehicle cannot move. Always apply the parking brake and select the transmission park position (Automatic transmission only).

Warning

Never run the engine with one wheel off the ground, for example, when changing the wheel. The wheel resting on the ground may cause the vehicle to move.

Warning

Always tighten the wheel nuts to specification. Too tight may cause damage, too loose may allow the wheel to become detached.




Warning

Use only wheels and wheel nuts supplied by Aston

Martin. After market wheels or wheel nuts may not install or function correctly and could cause injury or damage.

Tyre Replacement and Wheel

Interchanging

Caution

When a new tyre is installed, always renew the tyre valve.

When replacement of tyres is required it is preferable to install a complete vehicle set. Should either the front or rear tyres only show excessive wear, new tyres must be installed to replace worn ones. Under no circumstances interchange tyres from side to side, front to rear or vice versa as individual tyre wear produces unique characteristics depending upon their position. If the position is changed after wear has occurred, the performance of the tyre will be adversely affected.

New tyres must be balanced before installing to the vehicle.

Winter (Snow) tyres

Winter tyres must only be installed in complete four-wheel sets of the same type. The maximum speed with winter tyres installed (without snow chains) is 210 km/h (131 mile/h) for

H rated tyres or 240 km/h (149 mile/h) for V rated tyres.

When using snow chains, note that:

Inspection and Verification

Verify the customer's concern by driving the vehicle.

Visually inspect for obvious signs of damage:

Visual Inspection Chart

• Incorrect tyre pressure

• Wheel imbalance

• Bulges (blister)

• Cuts

• Abrasions

• Tyres worn beyond tread wear indicators

• Ply separation

• Embedded objects

• Impact damage

• Incorrect speed rating

• Incorrect load rating

• Tyres installed with the

‘Outside’ marking not shown

1 If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

2 If the concern is not visually evident, verify the symptom and refer to Symptom Chart.

Tyre Wear

Tread wear indicators (A) are moulded into the bottom of the tread grooves across the width of the tyre. When the tread wear indicators become visible at the surface of the tread, in two or more adjacent tread grooves, only

1.6 mm of tread remains.

• Snow chains must only be installed to the rear wheels

• Only Aston Martin snow chains should be used

• Snow chains must not be used on roads which are clear of snow

• The maximum speed with winter tyres and snow chains fitted is 48 km/h (30 mile/h)

• Traction control must be switched Off when using snow chains

Tyre tread depth and condition must comply with prevailing local legislation.

To maximize tyre performance, inspect the tyres for signs of incorrect inflation and uneven wear which may indicate a need for balancing, rotation or front suspension alignment. tyres should also be checked frequently for cuts, stone bruises, abrasions, blisters, and for objects that may have become embedded in the tread. More frequent inspections are recommended when rapid or extreme temperature changes occur or when road surfaces are rough or occasionally littered with debris.

Tyre Wear Diagnosis

New tyres should be installed if the wear indictors are exposed or if there is severe shoulder wear. Shoulder wear is usually caused by either excessive camber or excessive toe on radial tyres.

Sometimes incorrect rear toe settings or damaged struts will cause severe cupping' or scalloped' tyre wear on non-drive wheels.

Incorrect rear toe alignment will also cause other unusual wear patterns.




Road Test

A tyre vibration diagnostic procedure always begins with a road test. The road test and customer interview (if available) will provide much of the information needed to find the source of a vibration.

During the road test, drive the vehicle on a road that is smooth and free of undulations. If vibration is apparent, note and record the following:

• The speed at which the vibration occurs

• What type of vibration occurs in each speed range

• How the vibration is affected by changes in the following types of vibration-sensitivity:

Torque Sensitive - This means that the condition may be improved or made worse by accelerating, decelerating, coasting, maintaining a steady vehicle speed or applying engine torque.

Vehicle Speed Sensitive - This means that the vibration always occurs at the same vehicle speed and is not affected by engine torque, engine speed or the transmission gear selected.

Engine Speed Sensitive - This means that the vibration occurs at varying vehicle speeds when a different transmission gear is selected. It may sometimes be isolated by increasing or decreasing engine speed with the transmission in NEUTRAL or by stall testing with the transmission in gear. If the condition is engine speed sensitive, the cause is probably not related to the tyres.

If the road test indicates that there is tyre whine, but no shake or vibration, the noise originates with the contact between the tyre and the road surface.

A thumping noise usually means that the tyre has a flat or soft spot making a noise as they slap the roadway. Tyre whine may be distinguished from axle noise. Tyre whine remains the same over a range of speeds.

Symptoms

Symptom

Tyres show excess wear on edge of treads

Possible Source(s):

Tyres under-inflated

Vehicle overloaded

Incorrect toe setting

Action(s)

Correct pressure to specification.

Correct as required.

Set to specification.

Tyres show excess wear on edge of treads (having the correct tyre pressures)

Tyres show excess wear in center of tread

Other excessive tyre wear problems

Tyres over-inflated

Incorrect tyre pressure



Incorrect tyre and wheel usage

Geometry out of alignment

Loose, worn or damaged suspension components

Wheel and tyre assembly out of balance

Wobble or shimmy affecting wheel runout

Excessive lateral or radial runout of wheel or tyre

Wheel mounting is difficult Incorrect application or mismatched parts, including wheel studs and wheel nuts. Corroded, worn or damaged parts

Damaged wheel (eventually damaging wheel bearings and causing uneven tyre wear)

Excessive vibration, rough steering or severe tyre wear

Loose or incorrect attaching parts

Install correct tyre and wheel combination.

Check and adjust.

Inspect, repair or install new suspension components as necessary.

Balance wheel and tyre assembly.

Check, repair or install a new wheel or tyre as necessary.

Clean or install new parts.

Inspect wheel rims for damage and runout.

Install a new wheel rim as necessary.

Tighten or install new parts.




Symptom

Vehicle vibrations

Possible Source(s):

Tyres and wheels mismatched

Action(s)

Install correct tyre and wheel combination.

Inflation pressure too high or too low Correct pressure to specification

Uneven tyre wear Refer to Diagnosis and Testing.

Out-of-balance wheel, tyre, wheel hub or disc assembly

Damaged or distorted wheel from road impact hazard or incorrect handling

Excessive radial runout

Excessive lateral runout

Determine the out-of-balance component and balance or install a new part.

Install a new wheel.

Install a new wheel or tyre. Check for incorrect wheel and tyre specifications.

Install a new wheel or tyre.

Incorrectly seated tyre

Loose wheel mountings - damaged wheel studs, wheel nuts, worn or broken wheel hub face or foreign material on mounting faces

Defective wheel bearings

Brake disc imbalance

Water in tyres

Remount the tyre.

Tighten or install new parts. Clean mounting surfaces.

Install a new bearing set.

Remove water.

Damaged wheel hub stud threads

Broken wheel studs

Corrosion and contamination streaks from the wheel hub wheel stud holes

Damaged wheel nuts

Frozen wheel nuts

Loose engine or transmission mounts Install new mount nuts / install new mounts.

Incorrect front end alignment Align front end.

Loose or worn driveline or suspension parts

Excessive driveshaft runout or imbalance

Repair or install new parts.

Install a new driveshaft.

Worn or damaged flexible drive joint Install a new driveshaft.

Sliding wheel across the wheel studs during installation. Loose wheel nuts

Loose or over tightened wheel nuts

Loose wheel nuts

Loose wheel assembly

Over-tightened wheel nuts

Corrosion or galling

Install new wheel studs.

Install new wheel studs.

Check complete assembly. Install new parts.

Install new wheel nuts.

Install new wheel nuts.

If corrosion is light, wire brush away corrosion.

If corrosion is excessive install new wheel studs and wheel nuts.

Tyre Damage

Symptom

Age Deterioration

Neglected Cut

Impact Fracture

Description

Cracking and crazing of the tread and sidewall rubber, sometimes accompanied by carcass deformation. An indication that the tyres have been in service for a very long time.

Damage through accidental cuts or penetrations will extend in use due to continued flexing and / or ingress of moisture and road matter.

Resultant damage from impact fractures is not always visible externally and, therefore, as a safety precaution the tyre should be removed and examined.

Casing fracture caused by severe localized impact through driving over kerbs, hitting potholes and

/ or objects in the road.

A double fracture caused by crushing the side wall of the tyre between an object and the rim flange.

In both instances, such damage can lead to sudden and dangerous tyre deflation some time after the impact occurred.




Repairs

In view of the high performance capability of the vehicle, damaged tyres should be renewed and not repaired.

Caution

When a new tyre is installed, always renew the tyre valve.

Care of Alloy Road Wheels

Aluminium alloy road wheels are covered with a protective coating. To prevent corrosion it is essential that this coating is not damaged. When removing or installing tyres only equipment utilizing spigot or stud hole clamping must be used. The equipment must not have any moving parts which contact the road wheel, and tyre levers must not be used.

To clean road wheels use warm soapy water; stubborn stains can be removed using a soft brush or by using a proprietary alloy road wheel cleaner.

Road Wheel Alignment

It is important that correct road wheel alignment be maintained. Misalignment causes tyre tread to be scrubbed off laterally because the natural direction of the road wheel differs from that of the vehicle.

A sharp ‘fin’ protrusion on the edge of each pattern rib is a sure sign of misalignment.

• ‘Fins’ on the inside edges of the pattern ribs, particularly on the nearside tyre, indicate Toe-in.

• ‘Fins’ on the outside edges, particularly on the offside tyre, indicate Toe-out.

With minor misalignment, the evidence is less noticeable and sharp pattern edges may be caused by road camber even when the road wheel alignment is correct. In such cases it is better to make sure by checking with an alignment gauge. Road camber affects the direction of the vehicle by imposing a side thrust and, if left to follow its natural course, the vehicle will drift towards its nearside. This is instinctively corrected by steering towards the road centre and, as a result, the vehicle runs crabwise. The diagram shows why nearside tyres are very sensitive to too much Toe-in and offside tyres to Toe-out.

It also shows why sharp ‘fins’ appear on one tyre but not on the other, and why the direction of misalignment can be determined by noting the position of the ‘fins’. Severe misalignment produces clear evidence on both tyres.

Front road wheels on a moving vehicle should be parallel.

Tyre wear can be affected noticeably by quite small variations from this condition. It will be noted from the diagram that even with parallel road wheels, the vehicle is still out of line with its direction of movement, but there is less tendency for the wear to be concentrated on one tyre.

The near front tyre sometimes persists in wearing faster and more unevenly than the other tyres, even when the mechanical condition of the vehicle and tyre maintenance are satisfactory. The more severe the average road camber, the more marked this tendency will be.




Misalignment Effects

Misalignment

Road wheels are correctly aligned but crabbing due to road camber

Shows road wheels ‘Toed-out’ in motion

Shows road wheels ‘Toed-in’ in motion

Alignment Precautions

Effect

All tyres will wear equally.

RH front tyre will wear faster.

LH front tyre will wear faster.

Road Wheel and Tyre Balance

Static Balance

Dynamic imbalance of the tyre and road wheel assemblies can be measured on suitable tyre balancing equipment, and corrections implemented. Where it is clear that a damaged road wheel is the primary cause of severe imbalance, it is advisable for the road wheel to be renewed.

Road Wheel Nut Torque Tightening

The following alignment precautions should be observed:

For smooth riding, precise steering and the avoidance of high speed ‘tramp’ or ‘road wheel hop’, all tyres are balance checked to predetermined limits. To ensure the best degree of tyre balance, the covers are marked with yellow spots on the outer sidewall and these indicate the lightest balance point of the cover.

The original degree of balance is not necessarily maintained.

It can be affected by uneven tread wear, tyre removal or refitting, by road wheel damage or eccentricity. The vehicle may also become sensitive to imbalance due to normal wear of moving parts. If roughness or high speed steering troubles develop and mechanical investigation fails to disclose a possible cause, road wheel and tyre balance should be suspected.


Item

Road Wheel

1. The vehicle should have come to rest from a forward movement. This ensures, as far as possible, that the road wheels are in natural running positions.

2. It is preferable for alignment to be checked with the vehicle laden (Refer to ’Specifications’, page 4-1-2).

Order - Tighten every second nut until all five nuts are tightened.

Tighten all road wheel nuts in two stages.

1. To 80 Nm (60 lb.

/ ft) in one continuous movement.

2. To 135 Nm (100 lb. / ft.) in one continuous movement.

(LHF)

(RHF)

(LHR)

(RHR)

Code

04.04.AB

04.04.CB

04.04.BB

04.04.DB

Inform the customer that the wheel nuts are to be torque checked after 32 km (20 mile).

Warning

If balancing equipment is used to dynamically balance road wheels, always jack both rear road wheels off the ground when rear road wheel balancing, otherwise damage may be caused to differential. This is doubly important in case of vehicles installed with a limited slip differential, as in addition to possible damage to the differential, the vehicle may drive itself off the jack or stand.

Dynamic Balance

Static imbalance can be measured when the tyre and road wheel assembly is stationary. There is another form known as dynamic imbalance which can be detected only when the assembly is revolving.

There may be no heavy spot, i.e. there is no natural tendency for the tyre and road wheel assembly to rotate about its centre due to gravity, but the weight may be unevenly distributed each side of the tyre centre line.

Laterally, the eccentric road wheels give the same effect.

During rotation, the offset weight distribution sets up a situation which tends to steer the road wheel to the right and left alternately.




Tyre Pressure Sensing (Option)

Warning

Tyre pressure sensing is not intended to replace driver awareness of tyre performance or the need for recommended weekly checks on tyre condition and pressure.

Tyre pressure sensing monitors the vehicle tyre pressures and feeds-back this information to the driver.

Each road wheel is installed with a tyre pressure sensing device which sends tyre pressure information to a control unit mounted in the centre, rear wall of the boot.

Each pressure sensing device has a colour coded collar.

Ensure the coloured collars are always installed in their original positions, i.e. after new tyres are installed.

Road wheel Colour

Front right

Front Left

Rear Right

Rear Left

Green

Red

Blue

Yellow

The control unit provides a visual warning by illuminating the tyre pressure warning lamp

(A) on the instrument panel if any tyre pressure falls below specification.

Pressure Sensing with Winter Wheels and Tyres

If the tyre pressure sensing option is installed on the vehicle, the winter road wheel and tyre option with the tyre pressure sensing system should be installed. The tyre pressure sensing system will need to be programmed to recognize additional tyres.

Warnings

Instrument

Cluster

Lamp constant / Message ‘Check Tyres’.

Control module Tyre LED constant red .

Fault Tyre pressure below specification.

Action

Reduce speed to 48 km/h (30 mph). Stop in safe place as soon as possible.

One of the coloured LEDs on the control module will illuminate to indicate which tyre requires inflating. The

LED colour corresponds to the colour of the band below each tyre valve cap. Inspect affected tyre. Re-inflate if necessary. If on inspection the tyre is found to be OK, continue at 48 km/h (30 mph) maximum.

Ensure that the coloured band remains in position.

Instrument

Cluster

Lamp constant / Message ‘Check Tyres’.

Control module Tyre LED constant amber .

Fault Tyre transmitter fault.

Action

Reduce speed to 48 km/h (30 mph). Stop in safe place as soon as possible.

Inspect affected tyre. Re-inflate if necessary.

If on inspection the tyre is found to be OK, continue at 48 km/h (30 mph) maximum.

Instrument

Cluster

Lamp constant / Message ‘Tyre system

Fault’

Control module Module LED constant amber .

Fault Control module fault.

Action

Stop in safe place as soon as possible.

Check all tyres for flats. If OK, continue at 48 km/h (30 mph) maximum.




Display Unit

The display unit provides additional features when correctly connected to a previously installed ‘Smartyre’ system. The display unit connects directly to the front of the basic

‘Smartyre’ receiver and is powered from the vehicle circuits.

The display will be fully illuminated during use but will go into ‘Energy Saver’ mode when no activity is detected.

Display Panel

Programmed wheel position

No data

Data received

Alarm light

Low pressure warning

Alert indicator

Learn mode

MODE button

TYRE button

4. If any tyre pressure sensor is defective, the display will show three dashes to indicate the absence of data for that tyre.

5. To return to normal mode, press the SET button.

System Programming

The system may be programmed by the user on three different levels. Enter Programming Mode by pressing the

‘Set’ button:

• 2 seconds to enter level 1



The following parameters may be set in each level:

Towing vehicle indicator

Numerical display

Units of pressure or temperature

Set button

Tyre rotation program

Cold pressure program

Programming mode

36-5-038

Level 1

Level 2

Level 3

• Cold Pressure

• Tyre Rotation

• Low Pressure Warning

• Pressure Deviation

• High Temperature Alert

• Units Selection

• Slope

• Learn Transmitter ID

• Low Pressure Alert

Connection and Normal Operation

1. Remove the front bezel of the Pressure Sensor Receiver.

Install the extension lead to the display unit and to the receiver module. Turn on the ignition.

All icons will illuminate briefly and then extinguish leaving only the vehicle outline.

Level 1 Programming

Cold inflation pressure

PSI

36-5-045

1. Press ‘Set’ for 2 seconds to enter level 1 programming.

2. Press ‘Tyre’ to select the front or rear axle. Front or rear tyres will be highlighted.

3. Press ‘Mode’ to show the current value. Press ‘Tyre’ to increase or ‘Mode’ to decrease the current value.

4. Press ‘Set’ to save the new values.

5. Repeat steps 2 - 4 to set the cold inflation pressure for other the axle.

36-5-039

2. When tyre pressure data is received, (drive the vehicle or spin the road wheels), all the road wheel icons will appear. Press the Tyre icon to access the recorded data for each of the four road wheels.

3. Press the Mode button to scroll through the pressure, temperature and pressure deviation readings for the selected tyre.




Tyre Rotation

Warning

The road wheels and tyres are asymmetrical and different sizes front and rear. They must not be rotated front to rear. This function should be used only to verify correct tyre position. Do not change the programmed data.

5. Press ‘Set’ to enter the new value into memory.

Pressure Deviation Alert

PSI

36-5-047

36-5-049


2. Press ‘Mode’ repeatedly until ‘Tyre Rotation’ icon is displayed.

3. Press ‘Tyre’ to scroll to a tyre position. Press ‘Mode’ to display the current sensor identity.

Each sensor is identified by the colour of a washer on the tyre valve. Tyres are always installed in fixed positions and must remain as follows:

• Right Front - Green (Code 1)

• Left Front - Red (Code 2)

• Right Rear - Blue (Code 3)

• Left Rear - Yellow (Code 4)

If the current data is incorrect, revise as follows:

This function sets the threshold for warning of a deviation from normal tyre pressures.


2. Press ‘Mode’ repeatedly until the ‘+-’ icon is displayed.

3. Press ‘Tyre’ to display the current value.

4. Press ‘Tyre’ to increase or ‘Mode’ to decrease the current value

5. Press ‘Set’ to save the amended value.

6. Press ‘Set’ again to revert to normal operation.

High Temperature Alert

4. Ensure that the road wheels and tyres are installed in the correct locations (see the colour code list above). Note the correct code number for each road wheel.

5. Use ‘Tyre’ or ‘Mode’ to correct the sensor identity code if required.

6. Repeat for the remaining tyres.

7. Press ‘Set’ twice to exit the programme.

Low Pressure Warning

36-5-044


2. Press ‘Mode’ until ‘alert’ icon is displayed.

3. Press ‘Tyre’ to display the current value of the high temperature alert.

4. Press ‘Tyre’ to increase or ‘Mode’ to decrease current value

5. Press ‘Set’ to save the amended value.

6. Press ‘Set’ again to return to normal mode.

Units Selection

PSI

Bar

36-5-043


2. Press ‘Mode’ repeatedly until ‘Flat Tyre’ icon is displayed.

36-5-050

3. Press ‘Tyre’ to scroll to the desired axle. Press ‘Mode’ to display the current low pressure warning value.

4. Press ‘Tyre’ to increase or ‘Mode’ to decrease current value.

Use this function to select the combination of units for pressure and temperature.





2. Press ‘Mode’ until pressure / temperature units are displayed.

3. Press ‘Tyre’ to enter ‘Units Selection’ mode.

4. Use ‘Tyre’ or ‘Mode’ to scroll through four combinations of pressure / temperature units.

5. Press ‘Set’ to save the selected combination of units.

6. Press the ‘Set’ button again to revert to normal mode.


Slope

2. Add new Transmitters.

2.1 Press ‘Set’ for 5 seconds to enter level 2 programming.

2.2 Press ‘Mode’ to select ‘Transmitter Learn’ mode.

2.3 Press ‘Tyre’ to display possible tyre positions (filled rectangles represent currently programmed transmitters).

2.4 Press ‘Tyre’ to scroll to the desired position. The chosen road wheel icon will flash.

2.5 Program a new transmitter by either:

2.6 Vigorously shaking the transmitter (bounce the road wheel on the ground) to promote a transmission.

2.7 Inflate or deflate the tyre by more than 3 psi (0.2 bar).

The unit will ‘beep’ when new transmitter is recognised.

36-5-052

Sets rate of pressure change for tyres in use. This parameter is set at manufacture and is specific only to the recommended tyres for DB9.

2.8 Press ‘Tyre’ to scroll to the next position. Repeat steps 4 and 5 as required to programme additional transmitters.

2.9 Press ‘Set’ to save the new transmitter data and to exit ‘learn’ mode. If no error is found, the system will return to ‘normal’ mode.



2. Press ‘Tyre’ until the desired vehicle axle is displayed.

3. Press ‘Mode’ to display the current SLOPE entry (DB9 is set at?)

4. If required, use ‘Tyre’ to increase or ‘Mode’ to decrease current value.

5. Press ‘Set’ to save the final value.

6. Press ‘Set’ again to return to normal mode.

Transmitter Learn Mode

This mode is used to add or delete transmitters from the system memory. It is vital that transmitter signals are correctly recognised to avoid system reaction to other transmitters (e.g. from passing vehicles with similar sensors).

Low Pressure Alert

36-5-051

1. Remove a Redundant Transmitter

1.1 Press ‘Set’ for 5 seconds to enter level 2 programming.

1.2 Press ‘Mode’ to select ‘Transmitter Learn’ mode.

1.3 Press ‘Tyre’ to display possible tyre positions (filled rectangles represent currently programmed transmitters).

1.4 Press ‘Tyre’ to scroll to the desired position.

1.5 To delete a transmitter, press the ‘Mode’ once.

1.6 If required, scroll to other positions using ‘Tyre’ and, if required, delete any other transmitters using

‘Mode’ button.


2. Press ‘Tyre’ button to scroll to the desired axle.

3. Press ‘Mode’ to view the current low pressure alert value.

4. Press ‘Tyre’ to increase the current value or press

‘Mode’ to the decrease current value.

5. Press ‘Set’ to save when the desired value is reached.

6. Repeat steps 2 to 5 until the Low Pressure Alert Level has been set for all road wheels.

7. Press ‘Set’ button to exit this mode.

8. Press the ‘Set’ button again to return to normal mode.





Contents

Driveshaft (05.01).................................................5-1-2

Description ............................................................. 1-2

Specifications.......................................................... 1-2

Maintenance........................................................... 1-2

Torque Tube.......................................................... 1-2

Remove............................................................... 1-2

Installation .......................................................... 1-5

Halfshafts (05.05) .................................................5-2-1

Specifications.......................................................... 2-1

Maintenance........................................................... 2-1

Halfshaft ................................................................ 2-1

Removal.............................................................. 2-1

Installation .......................................................... 2-1



Driveshaft (05.01)




Description

The driveshaft consists of a torque tube assembly, incorporating the propshaft, transferring drive from the power unit to the gearbox.

Engine power is transmitted to the rear wheels via a carbon fibre prop shaft. To prevent any shunting of the engine under high acceleration, the engine and transaxle are connected with an aluminium torque tube which surrounds the prop shaft.

This arrangement is used on both the automatic and manual transmission cars.


Torque Tube

Torque Figures

Description

Torque Tube (front)

Torque Tube (rear)

Exhaust Manifold

Starter Motor

Drive Plate (Auto only) - Torque converter to prop shaft

M8

M10

Nm.

25 lb. / ft.

18.5

50 37

43-57 32-42.5

18-22 13.5-16.5

50 37

72 53.5


Item

Torque Tube Renew

Code

05.01.AB

Remove

1. Disconnect the vehicle battery. Raise the vehicle and make safe.

Caution

On a two post ramp ensure vehicle is ‘strapped’ to the lift.

If using a two post vehicle lift, remove the screws that secure the rear section of the front road wheel arch liners.

Hold back the rear section of the road wheel arch liner to allow the foot of the vehicle lift to be positioned correctly.


2. Remove the front road wheels and road wheel arch liners.

3. Remove the shear panel and both undertrays.

4. Remove the exhaust system (Refer to ’Exhaust System’, page 9-2-1).


5. Remove the heat shields.

Heatshield

Remove Front Nut

Rear of Heatshield

01 05 019

Remove Bolts

01-05-020


Remove the drive plate.



12.


Remove the transmission oil coolant pipes from the torque tube.

Remove Bolts

01-05-018


7. Remove the dip stick tube.

8. Remove the LH exhaust heat shields and manifold.

Remove the manifold and lay to one side.






(07.03)’, page 7-3-1).

11. Allow the torque tube to lower until the engine is resting on the front subframe rear crossmember.

14.


Remove the propshaft.

Remove the wire clip and pull the propshaft from the torque tube.





Remove the propshaft.

Remove the horseshoe clip and pull the propshaft from the torque tube.

Suggestion: To pull the prop shaft from the torque tube install a jubilee clip around the end of the prop shaft and use this to lever against.

Warning

The torque tube is heavy. To avoid personal injury or damage to the torque tube, torque tube removal is at least a two person operation.

17. Remove the bolts (x2) that secure the starter motor.

Withdraw the starter motor and place to one side.

18. Disconnect the earth cable.

16.

Manual gearbox Only.

Warning

Avoid skin / eye contact or ingestion of clutch fluid.

If skin or eyes are splashed with clutch fluid, rinse the affected area immediately with plenty of water and obtain medical attention. If clutch fluid is ingested, obtain immediate medical attention.

Caution


Place suitable absorbent material around the affected area to absorb any possible clutch fluid spillage.

Disconnect the clutch salve cylinder bleed and supply pipes. Pull the wire clips back to release the unions.

Caution

Ensure that the seal on the ‘male’ end remains connected to the ‘male’ end when disconnecting.

19. Loosen and undo the engine mount nuts sufficently to allow the front of the engine to be raised.

Do not remove the nuts - leave them in place, one or two threads only.

20. Raise the front of the engine. This then provides access to the two top bolts of the torque tube and enables move movement of the torque tube.

21. Ensure the torque tube is supported. Remove the bolts

(x9) that secure the torque tube to the engine block.

Withdraw the torque tube.

Remove Bolts x9

01-05-008

5-1-4

01-5-007




Installation

Warning

The torque tube is heavy. To avoid personal injury or damage to the torque tube, torque tube removal is at least a two person operation.

1. Feed the torque tube into position against the engine block.

2. Secure the torque tube to the engine block.

• M8 25 Nm.

• M10 50 Nm.

4. Install the exhaust manifold. Torque the nuts, in sequence shown, to 18-22 Nm .

Engine Front

5

1

9

3

7

Torque 50 Nm (M10x7)

Torque 25 Nm (M8x2)

11

10

6

2

4

8

12

01-05-012

3. Lower the engine onto its mounts. Torque the two engine mount nuts to 47 Nm .


6. Install the lower steering column (LH drive only) and the dip stick tube.

7. Install the earth cable.

8. Install the starter motor. Torque bolts to 50 Nm.


Install the propshaft to the torque tube. Install the wire clip.

When installing the propshaft use a lever through the opening in the bell housing to manoeuvre the splines of the propshaft to the crankshaft.

Use a soft face hammer to fully locate the propshaft





Install the drive plate. Torque bolts to 72 Nm.

Push the wire clip back into position on the female end, then connect the male to the female.


Install the propshaft to the torque tube. Install the horseshoe clip.

When installing the propshaft use a lever through the opening in the bell housing to manoeuvre the splines of the propshaft to the crankshaft.

Use a soft face hammer to fully locate the propshaft.

Bell Housing Opening


Install the transmission oil coolant pipes to the torque tube.

14. Install the heat shield brackets to the torque tube.




16. Manual gearbox Only.


(07.03)’, page 7-3-1).


Bleed the clutch.

18. Install the heat shields.

19. Install the exhaust system (Refer to ’Exhaust System’, page 9-2-1).

20. Install the shear panel and both undertrays.

21. Install the road wheel arch liners and road wheels.


5-7).


01-05-017


Warning

Avoid skin / eye contact or ingestion of clutch fluid.

If skin or eyes are splashed with clutch fluid, rinse affected area immediately with plenty of water and obtain medical attention.

If clutch fluid is ingested, obtain immediate medical attention.

Caution


Place suitable absorbent material around the affected area to absorb any possible clutch fluid spillage.

Install the clutch salve cylinder bleed and supply pipes.


Halfshafts (05.05)




Specifications

Torque Figures

Description

Halfshaft nut

Halfshaft to differential

Maintenance

Halfshaft

Nm.

300

70 lb. / ft.

221.5

52


Item

Halfshaft Renew (LH)

(RH)

Code

05.05.AB

05.05.BB

Removal




Installation

1. Position the halfshaft through the vertical link.

01-05-013

2. Place the halfshaft up to the differential output.

4. Remove bolts (x6) and washer tabs (x3). Discard bolts.

70 Nm

01-05-014

3. Install the washer tabs (x3) and new bolts (x6). Torque bolts to 70 Nm .

New bolts should have a thread lock coating.

4. Install the halfshaft nut. Torque nut to 300 Nm .



5. Withdraw the halfshaft.






Contents

Front Disc Brake (06.03)........................................6-1-2

Description ............................................................. 1-2

Specifications.......................................................... 1-2

Maintenance........................................................... 1-3

Brake Caliper (Front and Rear) ............................... 1-3

Removal.............................................................. 1-3

Installation .......................................................... 1-3

Brake Discs (Front and rear) ................................... 1-4

Removal.............................................................. 1-4

Installation .......................................................... 1-5

Brake Pads (Front and rear) .................................... 1-5

Removal.............................................................. 1-5

Installation .......................................................... 1-5

Brake Pad ‘Bedding-in’ .......................................... 1-6

Procedure ........................................................... 1-6

Rear Disc Brakes (06.04) .......................................6-2-1

Description ............................................................. 2-1

Specifications.......................................................... 2-1

Maintenance........................................................... 2-2

Brake Calipers ..................................................... 2-2

Brake Discs ......................................................... 2-2

Brake pads .......................................................... 2-2

Hand Brake (06.05) ...............................................6-3-1

Description ............................................................. 3-1

Specifications.......................................................... 3-1

Maintenance........................................................... 3-2

Brake Caliper......................................................... 3-2

Removal.............................................................. 3-2

Installation .......................................................... 3-2

Brake Pads............................................................. 3-3

Removal.............................................................. 3-3

Installation .......................................................... 3-3

Handbrake Cable................................................... 3-4

Removal.............................................................. 3-4

Installation .......................................................... 3-4

Adjustment ......................................................... 3-5

Brake Actuation System (06.06).............................6-4-1

Description ............................................................. 4-1

Tandem Master Cylinder........................................ 4-1

Specifications.......................................................... 4-1

Maintenance........................................................... 4-2

Master Cylinder ..................................................... 4-2

Removal.............................................................. 4-2

Installation .......................................................... 4-2

Brake Fluid Reservoir ............................................. 4-3

Removal.............................................................. 4-3

Installation .......................................................... 4-4

Brake Bleeding - WDS ........................................... 4-4

Brake Bleed - Manual ............................................ 4-4

Preparation ......................................................... 4-4

Procedure ........................................................... 4-5

Disconnection..................................................... 4-5

Power Brake System (06.09)..................................6-5-1

Brake Booster ......................................................... 5-1

Panic Brake Assist................................................... 5-1

Specifications ......................................................... 5-2

Maintenance........................................................... 5-2

Brake Booster ........................................................ 5-2

Removal.............................................................. 5-2

Installation.......................................................... 5-2

Anti-lock Braking System (ABS) (06.09).................6-6-1

Dynamic Stability Control ...................................... 6-1

Concept ................................................................ 6-1

System Overview ................................................... 6-2

Operation Summary .............................................. 6-2

Traction Control ..................................................... 6-2

Functional Description........................................... 6-2

Engine Intervention................................................ 6-3

Brake Intervention ................................................. 6-3

ABS / DSC Circuit .................................................. 6-3

Specifications ......................................................... 6-3

Maintenance........................................................... 6-4

ABS Modulator ...................................................... 6-4

Removal.............................................................. 6-4

Installation.......................................................... 6-5

Issue 2 Feburary 2005 Workshop Manual 6-1-1

Front Disc Brake (06.03)

Brake Systems (06.00)



Description

The front, four piston, brake caliper is bolted directly to the vertical link by two bolts. The caliper is a monobloc assembly. The steel brake discs are ventilated and grooved.

They are secured to the hub by two retaining bolts.

The two-pairs of opposed pistons act directly on the brake pads mounted one each side of the disc.

Specifications

Oils/Greases

Brake Fluid Castrol Super Response DOT 4 (Not silicon based brake fluid).

Qty. 2.5 ltrs

Brake discs

Initial thickness

Min. thickness

Front

32 mm

30 mm

Brake Disc ‘Runout’ <70 µm measured @ 2 mm in from the brake disc edge.

Brake pads

New pad thickness 9.4 mm

Minimum lining thickness

2.5 mm

Torque Figures

Description

Brake hose unions

Brake Caliper to Vertical

Link

Handbrake Caliper to

Vertical Link

Brake Disc Screws

Nm.

22 lb. / ft.

16.5

20 + 66°-70° 15 + 66°-70°

15 +90°-94° 11.5 + 90°-94°

10.5

8

6-1-2 Workshop Manual Issue 2 Feburary 2005



Maintenance

Brake Caliper (Front and Rear)

5. Remove bolts (x2) that secure the caliper to the vertical link. Withdraw the caliper.


Item

Brake Caliper Renew (LH)

(RH)

(LH)

(RH)

Code

TBA

TBA

TBA

TBA

Removal

Front calipers shown.

Place a cloth around the brake reservoir filler neck to absorb any possible brake fluid spillage.



Retract the caliper pistons (allowing easier removal of caliper). Retracting the caliper pistons may cause the brake fluid reservoir to overflow.

3. Disconnect the brake pad wear sensor.

Installation

1. Install the caliper to the vertical link. Torque bolts (x2) to

20 Nm. + 66°-70° .

20 Nm. + 66°-70° than 1

Consider renewing the brake pads when less

/

3

of the friction material remains, especially if the vehicle is regularly used and some time remains before next service.

Warning

Always use a vacuum brush or aqueous brake cleaner to remove brake lining dust. Never use compressed air.

Warning

Avoid skin / eye contact or ingestion of brake fluid.

If skin or eyes are splashed with brake fluid, rinse the affected area immediately with plenty of water and obtain medical attention. If brake fluid is ingested, obtain immediate medical attention.

Caution


4. Disconnect the brake hose union. ‘Cap’ the union bolt and plug the hose aperture in the caliper.

2.

Front Caliper Brake pipes.

Caution

Ensure that the alignment line on the flexible brake pipe remains in a straight line.

Caution

On LH and RH calipers the brake pipe must route towards the front of the car.

2.1 Insert the brake pipe union to the caliper.

• Ensure that the flex hose alignment line is straight

• Ensure that the brake pipe faces forward and locates correctly in the alignment tool

Torque to 22 Nm .




2.2 Install the brake pipe alignment tool. Check that the brake pipe orientation is correct:

• The flex hose alignment line is straight

• The brake pipe faces forward and locates correctly in the alignment tool

Brake Discs (Front and rear)


Item

Brake Disc Renew

Code

(Front) 06.03.CB

(Rear) 06.04.CB

Removal

Place a cloth around the brake reservoir filler neck to absorb any possible brake fluid spillage.




2.3 If the alignment is not correct, carefully back off the pipe union at the brake calliper until the pipe can be rotated backwards to allow forward movement when being re-torqued. Re torque the brake pipe union to

22 Nm then re check alignment as detailed above.

3. Rear Caliper brake pipes.

3.1 Insert the brake pipe union to the caliper. Torque to

22 Nm .

3.2 Check that the brake pipe orientation is correct.

• Flex hose alignment line is straight

3.3 If the alignment is not correct, carefully back off the pipe union at the brake calliper until the pipe can be rotated backwards to allow forward movement when being re-torqued. Re torque the brake pipe union to

22 Nm then re check alignment as listed above.

4. Install the brake pads and brake pad wear sensor. Note

LH and RH shims from removal.

3. Rear Road Wheels Only.

Remove the parking brake caliper (Refer to ’Brake

Caliper’, page 6-3-2).

4. Remove bolts (x2) and withdraw the caliper.

Support the caliper to prevent excessive strain on flexible hose.

When installing new brake pads, install a new brake pad wear sensor.

5. Remove retaining screws. Withdraw the brake disc.

5. Bleed the brakes (Refer to ’Brake Bleed - Manual’, page

6-4-4).



7. ‘Bed-In’ the brakes (Refer to ’Brake Pad ‘Bedding-in’’, page 6-1-6).




Installation

1. Install the brake disc to the road wheel hub. Ensure that the surfaces of the disc and hub are clean and free from debris.

Torque screws (x2) to 10.5 Nm .

2. Check brake disc ‘runout’ (Refer to ’Specifications’, page 6-1-2).

3. Install the caliper. Torque bolts (x2) to

20 Nm. + 66°-70° Nm .

4. Rear Road Wheels Only.

5. Install the handbrake caliper. Torque bolts (x2) to 15 Nm. + 90°-94° .



Warning

Always use a vacuum brush or aqueous brake cleaner to remove the brake lining dust. Never use an air line.

5. Clean the caliper area using approved brake cleaning equipment.

Installation

1. Install the brake pads. Note LH and RH shims from removal. Install the pad locating pins.

Warning

Before moving off, pump the foot brake pedal 2 or 3 times to ensure the foot brake works correctly. Brake caliper pistons may require travel to contact the brake pads and disc.

7. ‘Bed-in’ the brake pads (Refer to ’Brake Pad ‘Beddingin’’, page 6-1-6).

Brake Pads (Front and rear)


Item

Brake Pads Renew

Code

(Front) 06.03.DB

(Rear) 06.04.DB

Removal

Front calipers shown.

Place a cloth around the brake reservoir filler neck to absorb any possible brake fluid spillage.




3. Disconnect the brake pad wear sensor.

When installing new brake pads, install a new brake pad wear sensor.

2. Connect the brake pad wear sensor to the brake pads.



Warning

Before moving off, pump the foot brake pedal 2 or 3 times to ensure the foot brake works correctly. Brake caliper pistons may require travel to contact the brake pads and disc.

4. ‘Bed-in’ the brake pads (Refer to ’Brake Pad ‘Beddingin’’, page 6-1-6).

4. Remove the brake pads. Note LH and RH shims for installation.




Brake Pad ‘Bedding-in’


Item

Bedding-in

Code

TBA

Caution

Failure to ‘bed-in’ new brake pads will result in reduced brake performance and possible brake judder or squeal.

After the installation of new brake pads, brake performance will be limited, as the brake discs and pads need to be

‘Bedded-in'.

Procedure

This procedure, in a controlled environment, requires approximately 17 minutes to complete. It is recommended that an analogue decelerometer be used for this procedure.

Ensure the brakes are cold (Less than 80° C) before starting this procedure.

Use light brake applications only, if possible, when the vehicle is driven to a suitable location to carry out this procedure.

Use light brake applications only, if possible, during all cooling down periods.

The cool down periods are the minimum required and can be extended.

1. Decelerate the vehicle three times from 100 km/h to 32 km/h at 0.3g accelerating normally in between each deceleration.

2. Drive 3 km (allowing the brakes to cool).

3. Decelerate the vehicle three times from 100 km/h to 32 km/h @ 0.5g accelerating normally in between each deceleration.


5. Decelerate the vehicle three times from 100 km/h to 0 km/h using the ABS, accelerating normally in between each deceleration.



Brake system (06.00)

Rear Disc Brakes (06.04)

Description



The rear, four piston, brake caliper is bolted directly to the vertical link by two bolts. The caliper is a monobloc assembly.

The steel brake discs are ventilated and grooved. They are secured to the hub by two retaining bolts.

Specifications

Oils/Greases

Brake Fluid Castrol Super Response DOT 4 (Not silicon based brake fluid)

Brake discs

Brake disc initial thickness 28.0 mm

Brake disc Min. thickness 26.0 mm

Brake Disc ‘Runout’ <70 µm measured @ 2 mm in from the brake disc edge.

Torque Figures

Description

Brake hose unions

Service brake Caliper to

Vertical Link

Handbrake Caliper to

Vertical Link

Nm.

22 lb. / ft.

16.5

20 + 66°-70° 15 + 66°-70°

15 + 90°-94° 11.5 + 90°-94°

Brake pads

Minimum lining thickness 2.5




Maintenance

For symptoms and maintenance of the rear brake system

(Brake Discs, Pads and Calipers) follow the same procedures as detailed for the front brake system.

Brake Calipers (Refer to ’Brake Caliper (Front and

Rear)’, page 6-1-3)

Brake Discs (Refer to ’Brake Discs (Front and

Brake pads rear)’, page 6-1-4)

(Refer to ’Brake Pads (Front and rear)’, page 6-1-5)



Hand Brake (06.05)

Description

Handbrake

Lever

Trunnion

Unlock

Button

Stop Assembly

Handbrake Cable



Handbrake Caliper

& Pad Assy

The hand brake control lever is located on the outside of the drivers seat and brakes the rear road wheels through a cable system and two mechanical handbrake calipers. Hand brake pads are applied by the mechanical brake calipers (x2), one acting on each rear road wheel brake disc. The calipers are bolted to the vertical links. Return springs on each caliper retract the pads when the parking brake is released.

Wear in the parking brake pads is compensated for automatically by a mechanism within the calipers. Cable stretch is compensated by cable adjusters.

A hand brake switch is wired normally closed. The switch is held open whilst the hand brake is ‘off’ and closes when the hand brake is applied. The hand brake warning lamp on the instrument panel is illuminated when the hand brake is applied.

Specifications

Brake pads

Minimum lining thickness

Torque Figures

Description

Brake Caliper to Vertical Link

6 mm

Nm.

lb. / ft.

15 + 92° 11.5 + 92°




Maintenance

Brake Caliper


Item

Handbrake Caliper Renew LH

RH

Code

06.05.AB

06.05.BB

Removal



3. Remove the handbrake cable from the caliper.

3.1 Screw in the cable adjustment on both handbrake calipers.

3.2 Remove the handbrake cable ‘eyelet’ from the caliper actuator arm.

3.3 Withdraw the handbrake cable.

Warning

Always use a vacuum brush or aqueous brake cleaner to remove brake pad dust. Never use compressed air.

5. Carefully remove brake dust or dirt from the parking brake system components.

6. If required, remove the handbrake pads (Refer to ’Brake

Pads’, page 6-3-3)

7. Check the caliper is free on its mounting pins. Service as required.

Installation

1. If removed, install the handbrake pads (Refer to ’Brake

Pads’, page 6-3-3).

Always replace handbrake pads in axle sets.

2. Using new bolts, install the caliper to the vertical link.

Torque bolts (x2) to 15 Nm + 92° .

15 Nm

4. Remove the caliper from the vertical link. Discard the mounting bolts (x2).

3. Operate the caliper lever several times by hand.

This will take up the free play between the piston / pads and the brake disc.

6-3-2

4. Install the handbrake cable to the caliper.

4.1 Install the handbrake cable through the mount on the caliper.

4.2 Locate the handbrake cable ‘eyelet’ over the caliper actuator arm.

Workshop Manual Issue 2 Feburary 2005



5. Adjust the handbrake cable (Refer to ’Adjustment’, page

6-3-5).

2. Install the brake pads.

Warning

Before moving off, operate the handbrake 2 or 3 times to ensure the handbrake works correctly. Handbrake caliper pistons may require travel to contact the brake pads and disc.



Brake Pads


Item

Handbrake Pads Renew

Code

06.05.DB

Removal



3. Remove the handbrake brake pads.

01-06-020

3. Operate the caliper lever several times by hand.

This will take up the free play between the piston / pads and the brake disc.

01-06-020

Warning

Always use a vacuum brush or aqueous brake cleaner to remove brake pad dust. Never use compressed air.

4. Carefully remove brake dust or dirt from the handbrake system components.

Installation

Warning

Before moving off, operate handbrake 2 or 3 times to ensure the handbrake works correctly. Handbrake caliper pistons may require travel to contact the brake pads and disc.



1. Screw back the caliper pistons.

Use a proprietary service tool to screw back the piston.

4. Adjust the handbrake cable (Refer to ’Adjustment’, page

6-3-5).




Handbrake Cable


Item

Handbrake Cable Renew

Code

06.05.DB

Removal

1. Back off the cable adjustment from each caliper.

2. Remove the drivers seat (Refer to ’Seating (01.10)’, page

1-7-1).

3. Remove the clevis pin and washers. Withdraw the handbrake cable from the vehicle body. Discard the clevis pin and spring clip.

5. Disconnect the cable from the subframe.

4. Remove the handbrake cable from the calipers.

Use service tool 206-103 (Refer to ’206-103 (Handbrake

Cable Removal)’, page 20-1-4) to disconnect the handbrake cable outer from the caliper mount.

Image - RH drive vehicle

Caution

Do not attempt to disconnect the handbrake cables from the equaliser unit.

Use service tool 206-103 (Refer to ’206-103 (Handbrake

Cable Removal)’, page 20-1-4) to disconnect the handbrake cable outer from the subframe mounts.

01-06-012

6. Withdraw the cable through the vehicle body and the subframe.

Installation

1. Feed the handbrake cable through the vehicle body and the subframe.

Ensure that all snap install clips are correctly located.

2. Engage the operator cable ‘eyelets’ to the calipers.

Ensure that the handbrake lever is fully released.

3. Using a new clevis pin, washers and spring clip, connect to the handbrake lever.

4. Adjust the handbrake cable.


Adjustment

1. Ensure the handbrake lever is fully released.

2. Release the handbrake cable lock nuts and screw the adjustment fully in.

3. Screw the adjustment ‘out’ or ‘in’ on each caliper, in equal amounts, to obtain a rise 4 clicks on the handbrake lever.

Warning

Before moving off, operate parking brake 2 or 3 times to ensure the parking brake works correctly. Parking brake caliper pistons may require travel to contact the brake pads and disc.

4. Check the functionality of the handbrake system:

4.1 When handbrake lever is in the fully down position

(handbrake released), the brake warning light should be extinguished.

If the brake warning light does not extinguish, adjust the handbrake cable until correct function of brake warning light occurs.

4.2 Check the handbrake pads for binding by driving the vehicle.

If the pads are binding a squeal will be emitted from the rear brakes)

If the pads are binding the handbrake cable adjusters are over adjusted. Slacken the adjusters as necessary, then check brake warning light functionality.







Brake Actuation System (06.06)




Description

Tandem Master Cylinder

A pressure sensor attached to the master-cylinder provides the ABS / DSC module with brake pressure information. This information informs the system how hard the driver is braking and is used as an aid for the ABS / DSC to achieve accurate brake pressure control.

Brake Fluid Reservoir

The brake fluid reservoir is mounted directly on the tandem master cylinder and secured with a pin. Two stub pipes, on the base of the reservoir, locate into the primary and secondary chambers of the tandem master cylinder.

An integral fluid-level switch is incorporated in the reservoir.

If the brake fluid level is low, the brake warning lamp in the

Driver Information Module (DIM) will illuminate and ‘LOW

BRAKE FLUID’ will be displayed in the message center right.

The short-stroke tandem master-cylinder controls two separate brake circuits which are jointly activated by the brake pedal. In the event of a major leak in one system, the other will still function. The two systems are supplied by a common brake fluid reservoir.

Specifications

Oils/Greases

Brake Fluid Castrol Super Response Dot 4

Torque Figures

Description

Master Cylinder Mount

Brake Pipe Unions

Nm.

25 (+/- 4) 18.5 (+/- 3)

17

Brake fluid reservoir securing pin 4 lb. / ft.

13

3

Pressure Sensor 35 (+/- 2) 26 (+/- 1.5)




Maintenance

Master Cylinder


Item

Master Cylinder Renew

Removal

Code

06.06.EB

1. Remove the coolant reservoir (LH drive only).

To give better access. Be aware that there is a wiring harness plug connected to the header tank on the under side.

Warning

Avoid skin / eye contact or ingestion of brake fluid. If skin or eyes are splashed with brake fluid, rinse the affected area immediately with plenty of water and obtain medical attention. If brake fluid is ingested, obtain immediate medical attention.

Caution


Place suitable absorbent material around the brake fluid reservoir area to catch any spilt brake fluid.

2. Disconnect the two outlet pipes. Install blanking plugs to all ports and pipe ends to prevent brake fluid leakage.

Mark each pipe - for correct installation.

01-6-014

3. Disconnect the pressure sensor wiring harness plug.

4. Remove the two nyloc nuts that secure the master cylinder to the brake booster. Withdraw the master cylinder. Discard the ‘O’ ring and nyloc nuts.

01-6-014

Installation

1. Install a new ‘O’ ring.




2. Secure the master cylinder with new nyloc nuts (x2).

Torque to 25 Nm (+/- 4 Nm.) .

25 Nm.

(+/- 4 Nm.)

3. Install the two outlet pipe unions to their original positions on the tandem master cylinder.

4. Connect the pressure sensor wiring harness plug.

Brake Fluid Reservoir


Item

Brake Fluid Reservoir Renew

Code

06.06.AB

Removal

Warning


If skin or eyes are splashed with brake fluid, rinse the affected area immediately with plenty of water and obtain medical attention.

If brake fluid is ingested, obtain immediate medical attention.

Caution


Place suitable absorbent material around the brake fluid reservoir area to catch any spilt brake fluid.

1. Remove the master cylinder (Refer to ’Master Cylinder’, page 6-4-2).

2. Drain as much brake fluid as possible from the brake fluid reservoir.

3. Remove the brake fluid reservoir securing pin.

4. Withdraw the brake fluid reservoir. Take care to minimise brake fluid spill. Clear any spilt brake fluid immediately.

5. Discard the brake fluid reservoir ‘O’ rings.

01-6-016

5. Install the coolant reservoir (LH drive only). Top up the coolant system if required.

6. Bleed the brake system (Refer to ’Brake Bleeding -

WDS’, page 6-4-4).

Caution

Do not bleed the brake system at the brake master cylinder.

01-6-017




Installation

1. Install new ‘O’ rings to the brake fluid reservoir.

Lightly lubricate ’O’ rings with brake fluid.

2. Install the brake fluid reservoir to the master cylinder.

Ensure correct location of the ‘O’ rings.

3. Install the brake fluid reservoir securing pin.

Torque to 4 Nm. (+/- 0.5 Nm.) .

Warning

Brake fluid is hygroscopic. If kept in opened containers, it will absorb water vapour. Use only brake fluid from freshly opened containers when topping up the brake fluid reservoir.

4. Fill the brake fluid reservoir with the specified brake fluid from a new, unopened container (Refer to



WDS’, page 6-4-4).

Brake Bleeding - WDS

2. Clean each caliper in the area of the bleed screws.

Remove the dust caps.

Warning

Avoid skin / eye contact or ingestion of brake fluid. If skin / eyes are splashed with brake fluid, rinse the affected area immediately with plenty of water and obtain medical attention. If brake fluid is ingested, obtain immediate medical attention.

Caution


Use the WDS to bleed the brakes if bleeding the brake system after installing a major component, i.e. a modulator or master cylinder or when filling from empty.

If bleeding a caliper a manual brake bleed procedure can be used.

1. Connect the WDS.

The diagnostic sockets, Body and Engine, differ for LHD and RHD vehicles (Refer to ’Diagnostic Ports’, page 20-

1-2).

RHD

Warning

Brake fluid is hygroscopic. If kept in opened containers, it will absorb water vapour. Use only brake fluid from freshly opened containers when topping up brake fluid reservoir.

3. Prepare a bleed tube and a bottle containing a small quantity of clean brake fluid.

4. If necessary, top up the brake fluid reservoir with brake fluid from a freshly opened container.

5. Switch on the WDS and load the ‘Anti-lock braking diagnostics’ software.

When bleeding a brake caliper always bleed the inner bleed screw first, followed by the outer bleed screw, then bleed the inner bleed screw once again.

6. Select ‘Brake Bleed’ and follow the WDS instructions.

Brake Bleed - Manual

After a Caliper Replacement

Preparation

1. Connect the bleed bottle tube to the bleed screws of front LH and rear LH calipers. Open the front LH and rear LH calipers bleed screws.

2. Actuate the brake pedal (>60mm) and secure it by using a pedal support.

This closes the TMC central valves and prevents fluid flowing out of the opened brake system.

3. Close the front LH and rear LH calipers bleed screws and remove the bleed bottle tubes.

4. Remove the caliper. Install the new caliper.

5. Remove the pedal support.

6. Remove the brake fluid reservoir cap and fill the reservoir to ‘MAX’ with new DOT 4 brake fluid.


7. Bleed the brake system.

Only the new caliper has to be bled.Ensure that there is always sufficient brake fluid in the reservoir.

Procedure

8. Connect a bleed bottle tube to the caliper inner bleed screw.

9. Actuate the brake pedal firmly to the floor and hold down. Open the inner bleed screw until pressure is released. Close the inner bleed screw, then release the brake pedal.

Wait 2 seconds between brake pedal actuations for the brake fluid level to settle.

Repeat this procedure till clear, air free brake fluid streams out of the inner bleed screw (10 to 20 times).

Watch the brake fluid level of the reservoir and refill if necessary.

10. Once satisfied that no air is in the brake fluid, push down on the brake pedal, hold down and tighten the inner bleed screw. Remove the bleed bottle tube.

11. Complete the same procedure on the outer bleed screw.

12. Once satisfied that no air is in the brake fluid from the outer bleed screw, check, once more, the inner bleed screw for air.

Disconnection

13. Fill the reservoir to the ‘MAX’ level and install the reservoir cap.

Take note of brake pad wear.

14. Start the engine to generate a vacuum in the booster.

15. Check brake pedal travel and pedal ‘feel’.

If the pedal travel is too long after bleeding, check the brake system for leaks If no leaks, repeat the brake bleed procedure.








Power Brake System (06.09)

Brake Booster



The brake booster comprises a chamber divided by a diaphragm plate and is secured to the brake pedal housing.

As the brake pedal is pressed, a poppet valve opens allowing atmospheric pressure into the drivers side of the diaphragm.

Atmospheric pressure builds up on the drivers side of the diaphragm and pushes against the partial vacuum on the other side. This additional force boosts the applied brake pedal force up to 6.5 times.

When the brake pedal is released, the poppet valve closes. The pressure on the diaphragm reduces and the compression spring returns the diaphragm to the release position.

Panic Brake Assist

In an emergency braking situation, a driver presses down on the brake pedal much faster than in normal braking conditions, but often without sufficient force. The initial application of the brake pedal is a reflex reaction. After the initial application, many drivers do not brake hard enough because of concerns that they might cause the vehicle to skid. To aid the driver, the panic brake assist (PBA) intervenes in bringing the vehicle to a halt, sooner and in a controlled manner, in emergency braking situation. The PBA system monitors the speed of brake pedal activation, and at a calibrated pedal activation speed, the PBA provides maximum brake force and makes full use of the ABS.

PBA is controlled by the ABS / DSC module, which monitors a travel sensor attached to the internal vacuum diaphragm of the brake booster. The sensor determines the position of the diaphragm and the speed of the diaphragm movement. If the sensor's signal indicates an emergency braking situation, the

ABS / DSC module will open an electric solenoid on the brake booster. The solenoid directs atmospheric pressure into the rear of the brake booster, causing the booster diaphragm to move forward to fully apply the brakes. PBA takes full benefit of ABS to stop the vehicle in a controlled manner and in the shortest distance possible. When the brake pedal is released the ABS / DSC module instantly releases the brakes.




Specifications

Torque Figures

Description

Brake Booster Mount

Maintenance

Brake Booster

Nm.

lb. / ft.

21-24 15.5-18


Item

Brake Booster Renew

Removal

Code

RHD 06.07.AB

1. Remove the master cylinder (Refer to ’Master Cylinder’, page 6-4-2).

2. Remove the oil dip sick.

3. Remove the clevis pin.


6. Withdraw the brake booster.

01-6-020

01-6-022

7. Remove and discard the brake light switch (mounted on the brake pedal block).

Installation

1. Install a new brake light switch.

After installing a new brake booster a new brake light switch, mounted on the brake pedal block, must be installed.

2. Place the brake booster through the bulkhead.

3. Secure using bolts (x4). Torque to 21-24 Nm .

4. Install the clevis pin.


6. Install the master cylinder (Refer to ’Master Cylinder’, page 6-4-2).


WDS’, page 6-4-4).

4. Remove nuts (x4).

6-5-2

01-6-021


Anti-lock Braking System (ABS) (06.09)




The anti-lock braking system (ABS) is a four-channel system having independent inputs from all four-wheel speed sensors.

The ABS module, monitors signals from the sensors to calculate, brake slip and the acceleration / deceleration of individual wheels. When the brake pedal is depressed, and the ABS module detects incipient wheel lock-up from the incoming signals, it triggers the re-circulation pump inside the module’s hydraulic modulator, and the solenoid valves for the wheel(s) concerned. Brake pressure, is then modulated to increase / decrease or remain constant at the wheel(s) concerned until wheel lock-up is eliminated. The

ABS provides self-diagnosis and any malfunction within the system will be indicated to the driver by the illumination of the brake warning light and ‘ABS FAULT’ displayed in the message centre right. Should a fault develop within the ABS, the brake system will operate conventionally and with the same standard of performance as a vehicle not equipped with ABS.

Dynamic Stability Control

Dynamic Stability Control (DSC) is a closed-loop system designed to enhance driving safety by improving vehicle handling when the tyres are at the limits of their grip capabilities. This is achieved through instantaneous, electronically controlled, reduction of engine torque and strategic application of the brakes at individual wheels.

By using the principle that by controlling the brakes individually it is possible, to an extent, to steer the vehicle.

This principle can be used to enhance driving safety by correcting the vehicle’s yaw moment (turning force), when the vehicle fails to follow the driver’s steering inputs.

Steering Motion

01-06-032a

Concept

Satisfactory handling is determined according to whether a vehicle maintains a path, which accurately reflects the driver’s input (steering wheel angle) while at the same time remaining stable.

The ABS / DSC module measures the vehicle’s motion using the sensors below and processes the information to maintain vehicle control and stability within its ultimate control limits, which are determined by the physical limits set by the tyre’s grip.

Wheel speed sensors - Longitudinal acceleration.

lateral acceleration sensor - Lateral acceleration.

Yaw rate sensor - Yaw rate, defined as the rotation around the vertical axis.

When there is insufficient tyre grip for the driving situation

(for example, the driver has entered a corner too fast) the

DSC will maintain stability and optimise the cornering and stopping performance, but cannot always prevent the vehicle from running wide.

Driver demand is measured by using the steering wheel angle sensor and vehicle speed to calculate the optimum yaw rate. This is compared to the actual measured yaw-rate and a yaw-rate calculated from the lateral acceleration and the vehicle speed. If the deviation between these measurements is too great, an understeer or oversteer correction is made.

The first step in this process is to determine how the vehicle should respond to driver demand (ideal response) and how it actually does respond (actual response). Hydraulic control valves can then be activated to generate brake pressure and

/ or engine torque reduction can be used to maintain the difference between the ideal and actual response within a tolerance band. This directly influences the forces on the tires to generate a corrective yaw moment to reduce the side forces of the tires where appropriate




System Overview

The DSC system embraces capabilities far beyond that of

ABS, or ABS and traction control combined, while relying on the components of these systems. It also incorporates these additional sensors for measuring the vehicle’s motion and brake system pressure:

• The ignition is retarded and / or the fuel is cut-off at the injectors at selected cylinders.

• Ignition and fuelling are reinstated when the engine torque reaches the requested value

Yaw rate sensor - located centrally on the transmission tunnel.

Lateral acceleration sensor - integrated with the yaw rate sensor.

Operation Summary

• DSC is switched ‘On’ when the engine is started

• When the system is operating, the DSC light in the instrument cluster will flash, at the rate of twice a second

Steering angle sensor - located on the upper steering column.

Pressure transducer - located on master cylinder.

• DSC can be switched ‘Off / On’ by pressing the DSC switch

• The DSC light in the instrument cluster will illuminate continuously when the system is switched ‘Off’.

The ABS / DSC module supports data exchange with other vehicle electronic systems via the CAN network; the module also enables diagnostic interrogation using WDS.

The following components register driver demand and the

ABS / DSC module processes their signals as a basis for defining an ideal response:

PCM - position of accelerator pedal.

Brake master cylinder pressure transducer - driver’s braking effort.

• ‘DSC OFF’ will be displayed in the message centre right to indicate the system has been switched ‘Off’

• A malfunction in the traction control system will be indicated to the driver by the following:

• The DSC light in the instrument cluster will illuminate continuously

• The message ‘DSC NOT AVAILABLE’ will be displayed in the message centre right

• If vehicle speed control is engaged it will automatically disengage when traction control is operating.

Steering angle sensor - position of steering wheel.

There are many supplementary parameters also included in the processing calculations these include the coefficient of friction and vehicle speed. The ABS / DSC module monitors these factors based on signals transmitted by the sensors for:

• Wheel speed

• Lateral acceleration

• Brake pressure

• Yaw rate

Traction Control

Traction control is a function of DSC, and is operated in association with DSC. Traction control prevents excessive wheel-spin at standing starts, or during acceleration. Wheelspin is usually caused by excessive use of the accelerator pedal, or slippery, loose or bumpy road surfaces. To prevent excessive wheel-spin and maintain vehicle stability such situations are overcome by the intervention of the traction control system by:

Using these parameters, the function of the ABS / DSC module is to determine the current vehicle status based on the yaw-rate signal and the slip as estimated by the ABS /

DSC module. It then maintains the vehicle response within a tolerance of the ‘normal’ behaviour, which is easily controlled by the driver.

In order to generate the desired yaw behaviour the ABS /

DSC module controls the selected wheels using the ABS hydraulic system and engine control system. In the event of engine intervention, the ABS / DSC module calculates the torque which should be supplied by the engine to the wheels, and relays this request signal to the PCM which implements the torque request.

The PCM receives signals from the DSC system via the CAN bus and reduces engine torque as follows:

• The throttle is positioned to provide the requested engine target torque.

• Braking the driven-wheel when it starts to slip

• And / or adapting the engine torque to a level corresponding to the traction available on the road surface.

Functional Description

Traction control uses the ABS electronic and mechanical / hydraulic hardware with additional valves to control the braking pressure at the calipers. An engine interface also enables the engine to respond to torque reduction requests from the traction control. As with ABS, the signals from the wheel-speed sensors are supplied to the ABS module, where they are used to calculate the wheel-slip of the individual wheels. Traction control intervention is initiated if the slip at one of the wheels is excessive.

• During the transient phase of torque reduction caused by mechanical and combustion delays, other alternative torque reduction methods are used to provide a quicker response.




Engine Intervention

In the event of wheel-slip the ABS / DSC module calculates the torque, which should be applied by the engine to reduce the wheel-slip (this torque does not exceed driver demand).

Engine torque reduction is then requested from the PCM via the CAN bus. The PCM, in response to these signals, reduces engine torque by controlling the ignition and fuelling. A traction control gearshift pattern is automatically selected within the automatic transmission software whenever traction control is active.

ABS / DSC Circuit

Brake Intervention

This function operates by increasing the pressure in the brake caliper of the slipping wheel, by closing the separation valve and the inlet valve of the non-slipping wheel and running the modulator pump. This takes fluid from the fluid reservoir via the non-actuated master cylinder and pressurizes the brake caliper. The pressure is modulated at the caliper via the inlet and outlet valves to achieve the desired wheel-slip target to maximize traction.

Underbonnet Fusebox

F19

30.0 Amps

F20

30.0 Amps

F28

10.0 Amps

C0573-2

C0571-3

C0573-3

C0578-8

Relay 1

Sheet 61 C2608-1 VBATT

F4

30.0 Amps

DIODE 1

C0576-1

C0577-4

SPL5-VIGN/FOR

C1672-5

VPWR

C1672-8

GND

Sensor

Steering Angle

U,3.0

Module-ABS

C0501-1

BATT FEED R/L/GND

U,3.0

C0501-32

BATT FEED

U,0.5

C0501-4

R/L/SIG

IGN FEED

R/R/GND

C0501-42 YG,05

C0501-43 WG,05

R/R/SIG

C2410-9 YG,05

C2410-10 WG,05

Earth

Steering Angle

Sensor

C0501-37 YU,05

C0501-36 WU,05

C2410-7

C2410-8

YU,05

WU,05

F/R/GND

F/R/SIG

C0501-33

C0501-34

WR,05

NR,05

C0144-1

C0144-2

YU,05

WU,05

C0144-3

C0144-7

YG,05

WG,05

Sensor-Front ABS-RH

C0517-2

-

C0517-1

+

Sensor-Brake Pressure

C2444-1

GND

C2444-2

SIG

C2444-3

SENSP

B,0.5

WG,0.5

GB,0.5

C0501-19

C0501-20

C0501-18

GND

SIG

SENSP

F/L/GND

F/L/SIG

C0501-46

C0501-45

W,05

N,05

Sensor-Front ABS-LH

C0516-2

-

C0516-1

+

Sensor-Rear ABS-LH

C0746-4 YU,05 C0502-2

-

C0746-5 WU,05 C0502-1

+

Sensor-Rear ABS-RH

C0746-6 YG,05 C0503-2

-

C0746-7 WG,05 C0503-1

+

Sensor-Brake Pedal Travel

C2446-1

SENSPT

C2446-2

GND

C2446-3

SIG

BG,0.5

B,0.5

C0501-7

C0501-5

GW,0.5

C0501-3

SENSPT

GND

SIG

CAN HS-

CAN HS+

CLUST_SP

GND

C0501-25

C0501-29

C0501-6

C0501-24

OBD2-Body (B)

C0877-7 P,0.35

K-LINE

P,0.35

SPL50-KL/FA

C1184-18 P,0.35

C2410-6 P,0.5

C0501-2

K-LINE

C0434-1

Earth-Module ABS

C0362-1

Earth-Module ABS

BK,1.0

C0501-47

BK,1.0

C0501-16

GND

GND

SR,05

UR,05

YR,0.5

NR,0.5

C2411-4

C2411-5

C2411-6

C2411-3

SR,05

UR,05

YR,0.5

NR,0.5

SIG

NO

NC

PWR

PWM

C0501-28 W,0.5

C0501-27

C0501-30

C0501-17

U,0.5

R,0.5

Y,0.5

C0501-31 P,0.5

Sensor-Yawrate / Acceleration

C1656-1

CAN HS-

C1656-2

CAN HS+

C1656-3

CLUS_SP

C1656-5

GND

Switch-Brake Boost

C2448-5

C2448-1

C2448-2

C2448-4

C2448-3

011-6-003

Specifications

Oils/Greases

Brake Fluid Castrol Response Super Dot 4

Torque Figures

Description

Modulator to Bracket

Modulator / Bracket to body

Brake hose unions

Nm.

5

9

17

14 lb. / ft.

4

7

13

10.5

17 Nm.

14 Nm.

17 Nm.

14 Nm.

14 Nm.

17 Nm.




Maintenance

ABS Modulator

5. Release bolts (x3) that secure the modulator mounting.


Item

ABS Modulator Renew

Removal

Code

RHD 06.06.CB

Warning


If skin or eyes are splashed with brake fluid, rinse the affected area immediately with plenty of water and obtain medical attention.

If brake fluid is ingested, obtain immediate medical attention.

Caution




3. Remove the passenger side road wheel and road wheel arch liner.

Place suitable absorbent material around the modulator valve block area to catch any spilt brake fluid.

6. Disconnect the modulator wiring harness plug.

4. Remove the brake pipe unions (x6) from the top of the modulator valve block. Cap each pipe and plug each valve block outlet to prevent leakage.

Note pipe locations for installation .

6-6-4

7. Remove bolts (x3) that secure the modulator to its bracket.

The ABS / DSC control module can be renewed separately from the modulator and can be removed from the vehicle without disturbing the hydraulic circuit.


Installation

1. Install the modulator to its mounting bracket. Secure with bolts (x3). Torque to 5 Nm .

9 Nm.



5 Nm.


3. Install the modulator and bracket assembly. Secure using bolts (x3). Torque to 9 Nm .

4. Remove the sealing caps and plugs from the brake pipes and the valve block. Install the brake pipes (x6) to their matching outlets on the valve block.

5. Torque the unions to:

6. Remove any traces of brake fluid from the modulator and surrounding area.

7. Install the road wheel arch liner and road wheel.


WDS’, page 6-4-4).

9. Install the road wheel arches and road wheels (Refer to



17 Nm.

14 Nm.

17 Nm.

14 Nm.

14 Nm.

17 Nm.






Contents

Automatic Transaxle (07.01)..................................7-1-2

Description ............................................................. 1-2

Cooling.................................................................. 1-2

Mechatronik module ............................................. 1-2

Specifications.......................................................... 1-3

Gearbox ................................................................ 1-3

Differential............................................................. 1-3

Maintenance........................................................... 1-4

Transmission Oil Check / Top Up........................... 1-4

Differential Oil Check / Top Up ............................. 1-4

Automatic Transaxle............................................... 1-5

Removal.............................................................. 1-5

Installation .......................................................... 1-5

Mechatronik Unit................................................... 1-6

Removal.............................................................. 1-6

Installation .......................................................... 1-7

Differential ............................................................ 1-8

Removal.............................................................. 1-8

Installation .......................................................... 1-9

Differential Output Seal (LH).................................. 1-9

Removal.............................................................. 1-9

Installation ........................................................ 1-10

Differential Output Seal (RH) ............................... 1-11

Removal............................................................ 1-11

Installation ........................................................ 1-12

Differential Oil Filter ............................................ 1-13

Removal............................................................ 1-13

Installation ........................................................ 1-13

Differential Speed Sensor..................................... 1-13

Removal............................................................ 1-13

Installation ........................................................ 1-13

Transmission Cooling (07.02) ...............................7-2-1

Specifications.......................................................... 2-1

Maintenance........................................................... 2-1

Oil Cooler (Automatic Gearbox)............................. 2-1

Removal.............................................................. 2-1

Installation .......................................................... 2-2

Thermostat (Automatic Gearbox)............................ 2-2

Remove............................................................... 2-2

Installation .......................................................... 2-3

Oil Cooler (Automatic Transaxle Differential) ......... 2-3

Removal.............................................................. 2-3

Installation .......................................................... 2-3

Oil Cooler (Manual Transaxle)................................ 2-4

Removal.............................................................. 2-4

Installation .......................................................... 2-4

Manual Transmission (07.03)................................7-3-1

Description............................................................. 3-1

Cooling.................................................................. 3-1

Specifications ......................................................... 3-2

Maintenance........................................................... 3-2

Oil Check and Top-up ........................................... 3-2

Drain / Fill ............................................................. 3-2

Transaxle ............................................................... 3-3

Removal.............................................................. 3-3

Installation.......................................................... 3-4

Differential Output Seal (LH) ................................. 3-5

Removal.............................................................. 3-5

Installation.......................................................... 3-6

Differential Output Seal (RH) ................................. 3-6

Removal.............................................................. 3-6

Installation.......................................................... 3-7

Differential (Limited Slip) ....................................... 3-8

Removal.............................................................. 3-8

Installation.......................................................... 3-8

Automatic Control System (07.05) ........................7-4-1

Transmission controls ............................................ 4-1

Gearbox Modes ..................................................... 4-1

Overview of Gearshift Procedures ......................... 4-1

Park (P) ............................................................... 4-1

Reverse (R) .......................................................... 4-1

Neutral (N) ......................................................... 4-1

Drive (D)............................................................. 4-1

Drive (D) - Sport ................................................. 4-1

Drive (D) - TouchTronic....................................... 4-1

Drive (D) - TouchTronic-Sport.............................. 4-1

Auto-Park / Auto-Neutral..................................... 4-2

Parking Lock ........................................................... 4-2

Overriding the Park Lock ....................................... 4-2

Hydraulic Shift Control Unit................................... 4-3

Electrostatic Discharge (ESD) ................................. 4-3

Personal Wrist-Band Earthing............................... 4-3

Shoes and Foot Earthing Straps ............................ 4-3

Transmission Control Module (TCM)...................... 4-3

Controller Area Network (CAN) Interface ............... 4-3

TCM Inputs............................................................ 4-4

TCM Monitoring Functions .................................... 4-4

Plausibility Checking............................................ 4-5

Torque Converter Lock-up Control ...................... 4-5

Safety Functions..................................................... 4-6

Limp-home Modes .............................................. 4-6

Torque Converter Operation ................................. 4-6

Torque Converter Clutch ..................................... 4-6

TCM Supply Voltage .............................................. 4-6

Shift by Wire........................................................... 4-7

Transmission Plug Pin Assignment ........................ 4-8


Automatic Transmission (07.01)



Automatic Transaxle (07.01)

Description

The ZF 6HP26 automatic gearbox has the following features:

• Six forward speeds / One reverse

• A torque converter with an integral converter lock-up clutch

• Electronic shift and pressure controls

• A single planetary gear set

• A double planetary gear set

• Two fixed multi-disc brakes

• Three multi-plate clutches

All hydraulic functions are directed by electronic solenoids to control:

• Engagement feel

• Shift feel

• Shift scheduling

• Modulated torque converter clutch (TCC) applications

• Engine braking utilizing the coast clutch

The TCM also provides for legislated transmission diagnostics, which meet the requirements of CARB OBDII legislation, monitoring all components, which may effect vehicle emissions. Additional diagnostic functions are also supported to ensure fast repairs of all failures in the service environment.

Engine power transfers to the transmission by a torque converter with integral converter lock-up clutch. Six forward gears and one reverse gear are obtained from a single planetary set followed by a double planetary set also known as lepelletier-type gear sets, these gear sets make it possible to obtain the six forward gears.

Cooling

The Auto transmission has an external cooling circuit which prevents overheating of the transmission oil. A pump mounted in the gearbox, working on engine speed variation, pumps the transmission oil around the radiator and back to the transmission.

A thermostat (Wax / Poppet type), close to the gearbox inlet

/ outlet, controls the oil temperature, operating at a range of

74°C - 88°C.

The ZF 6HP26 Automatic Transmission is a six speed electronically controlled transmission comprising the basic elements of:

• A Mechatronik module (Transmission Control Module

(TCM) and main control valve body assembly)

• A torque converter

• One solenoid valve and six pressure regulators

Gear selection is achieved by the control of the transmission oil flow to operate various internal clutches. The TCM operates the electrical components and provides for the control of gear selection shift pressure which increases refinement and torque converter slip control.

In the event of a system fault the TCM also provides for

Failure Mode Effect Management (FMEM) to maintain maximum functional operation of the transmission with a minimum reduction in driver, passenger or vehicle safety. In the event of a total loss of control or electrical power the basic transmission functions Park, Reverse, Neutral and

Drive are retained. Also 3rd or 5th gear is retained by the hydraulic system, the gear retained is dependant upon the gear selected at time of the failure.

The transmission also contains turbine and output shaft speed sensors, an internal P, R, N, D selector position sensor, and a transmission oil temperature sensor. The TCM also requires information from the shift selector module to determine when the driver has initiated manual gear selection. The TCM communicates with other electronic control modules by the controller area network (CAN).

Mechatronik module

The Mechatronik module is located in the sump of the automatic gearbox. It contains electrical actuators and sensors as well as hydraulic valves which, acting in conjunction with the TCM, perform gear changes.

The electromechanical components are arranged in such a way that they may be replaced while the automatic gearbox is installed in the vehicle.

(Refer to ’Automatic Control System (07.05)’, page 7-4-1)




Specifications

Gearbox

Type

6 speed ZF 6HP26 automatic transmission and torque converter

Weight

Complete with transmission oil - 89 kg (196.25 lbs) approx.

Control System

Electrohydraulic (Mechatronik)

Controlled on-load shifts

Various shift programs available

Torque Converter

Controlled-slip lock-up clutch in gears 1 - 6 and reverse.

Transmission oil

ATF Shell M1375.4

Transmission Qty.

Coolant system Qty.

10 Ltr (17.06 pt. / 10.57 US qts.)

1.6 Ltr (2.8 pt. / 1.7 US qts.)

The ZF 6HP26 automatic transmission is ‘filled for life’ at manufacturer and will not normally require any servicing.

Gear Ratios

1st 2nd 3rd 4th 5th 6th

4.17:1 2.34:1 1.52:1 1.14:1 0.87:1 0.69:1

Reverse

3.40:1

Maximum Towing Distance

150 km (93 miles) at a maximum speed of 70 km/h (43 mph)

Torque Figures

Description

Transaxle to Mounting Brackets

Mechatronics Unit

Sump

Nm.

20-30

8

7-9 lb. / ft.

15-22.5

6

5.5-7

Gearbox to Differential Adaptor Plate 52-75 38.5-55.5

Subframe cross-member 85 63

Differential

Type

Graziano AM803D

Weight

Complete with differential oil - 47.25 kg (104 lbs) approx

Differential oil

Shell ‘Transaxle’ oil 75W/90

Gearbox Qty.

Coolant system Qty.

1.7 Ltr (3 pt. / 1.8 US qts.)

0.7 Ltr (1.2 pt. / 0.7 US qts.)

The automatic transaxle differential is ‘filled for life’ at manufacturer and will not normally require any servicing.

Torque Figures

Description

Differential Housing Cover (bolts smeared with Loctite 242)

Output Shaft Cover

Sump Plug

Fill Plug

End Cover

Nm.

35

10

49

49

30 lb. / ft.

26

7.5

36.5

36.5

22.5




Maintenance

Transmission Oil Check / Top Up

The ZF 6 HP26 automatic transmission is ‘filled for life’ at manufacturer and will not normally require any servicing.

In the event of a oil leak from the transmission cooling system, the leak must be repaired and then the transmission oil may be replenished as follows:

Warning

Observe all transmission oil manufacturers safety instructions when draining and refilling the automatic transmission.

6. Top up oil level with transmission oil (Refer to

’Specifications’, page 7-1-3), until transmission oil drains out of the bore. Stop topping up.

7. Wait until the out coming transmission oil starts dribbling, but at least 1(one) minute or the oil reached

50°C (122°F).

8. Install the fill plug and make sure that the sump temperature has not exceeded 50°C (122°F).

9. Install the RH exhaust pipe. Install the rear under tray.

10.

To ensure that the gearbox and coolant system has been fully charged , complete a test drive. Ensure that the transmission cooling thermostat fully opens (75°C

(167°F)).

11. Check the transmission oil level.

Before doing any work to the transmission oil level setting make sure that:

• The car is on a horizontal ramp

Differential Oil Check / Top Up

• The rear wheels are standing still for a minimum of 2 minutes before starting the oil level check and during the process, e.g. by applying the hand brake

The Graziano differential is ‘filled for life’ at manufacturer and will not normally require any servicing.

• The transmission sump temperature is between 30°C-

50°C (86°F-122°F) when opening the filling plug and whilst checking oil level

In the event of a oil leak from the differential cooling system, the leak must be repaired and then the differential oil may be replenished as follows:

• Positions Reverse and Drive have been engaged for a minimum of 3 seconds with rear wheels braked before a setting is carried out

Warning

Observe all differential oil manufacturers safety instructions when draining and refilling the differential.

• The TCM is not in limp home mode

Before doing any work to the differential oil level setting make sure that:



Warning

While the engine is running ensure that an exhaust extractor system is attached to the exhaust system.

• The rear wheels are standing still for a minimum of 2 minutes before starting the oil level check and during the process, e.g. by applying the hand brake

Warning

Do not breathe exhaust fumes. Exhaust fumes contain carbon monoxide. Carbon monoxide is a dangerous gas, which is colourless and odourless and can cause unconsciousness and may be fatal.

2. Remove the RH exhaust pipe.

3. Run the engine between 600 and 750 rpm.

4. Place a suitable container to hold any oil that may come from the opening.

5. Remove the fill plug (rear RH side of the transmission) immediately after starting up the engine.

• Ensure the vehicle has run a short distance to ensure that the differential cooling system has been completely filled


2. Place a suitable container to hold any differential oil that may come from the opening.

3. Remove the fill plug.

With the fill plug removed the differential oil should just

‘dribble’ from the opening in the side of the differential.

4. If required fill the differential with the specified oil until oil ‘dribbles from the hole (Refer to ’Specifications’, page 7-1-3).

5. Install the rear under tray.




Automatic Transaxle


Item

Automatic Transaxle Renew

Code

07.01.AB

Removal

1. Remove the rear subframe complete with the transaxle


2. Remove bolts (x6) and washer tabs (x3) from each halfshaft. Discard bolts.

Withdraw the halfshafts.

Installation

1. Using suitable lifting equipment, i.e. hydraulic ramp and sling, place the transaxle to the subframe.

2. Install the transaxle to it’s mounting brackets.

Torque bolts (x4) on each mount to 20-30 Nm .

01-0

3. Using suitable lifting equipment, i.e. hydraulic ramp and sling, support the transaxle from above.

4. Remove the transaxle from it’s mounts.

3. Place the halfshafts up to the differential outputs.

5. Withdraw the transaxle from the subframe.

70 Nm.

01-05-014

4. Install the washer tabs (x3) and new bolts (x6) to each halfshaft. Torque bolts to 70 Nm .

New bolts should have a thread lock coating.

5. If removed. Install the torque converter.

6. Install the rear subframe complete with transaxle to the vehicle (Refer to ’Rear Subframe’, page 2-1-4).

7. Top-up the transmission oil (Refer to ’Transmission Oil

Check / Top Up’, page 7-1-4).

8. Run the engine and place gear selector lever in each position for at least 10 seconds. Stop the engine.

9. Check and, if required, top-up the transmission oil.




Mechatronik Unit


Item

Mechatronik Unit Renew

Removal

1. Remove the rear undertray.

Code

TBA

6. Remove the oil thermostat complete with gearbox side coolant pipes (Refer to ’Thermostat (Automatic

Gearbox)’, page 7-2-2).

Remove Thermostat

01-07-009a

7. Remove the gearbox Capacitor.

The following images are taken from the ZF repair manual.

8. Remove screws (x21) that secure the sump. Withdraw the sump. Discard the ‘O’-ring seal and the gasket.

2. Remove the subframe crossmember.

Remove Exhaust

Remove Crossmember

01-07-008a

3. Drain the gearbox oil.

4. Remove LH rear exhaust pipe.

5. Disconnect the coolant pipes from the gearbox.

9. Remove the electric socket.

10. Remove screws (x10 large head M6) and lift off the

Mechatronik unit.

Disconnect Pipes

01-07-007a


11. Remove the Mechatronik unit seals.



4. Install a new ‘O’-ring seal onto stub pipe of the transmission oil filter. Press the new seal into the sump.

Installation

1. Install new Mechatronik unit seals.

5. Install the gearbox capacitor.

6. Install the sump (screws x21). Torque to 7-9 Nm .

2. Install the Mechatronik unit, press on by hand. Torque bolts, in sequence (detailed below), to 8 Nm.

7. Insert a new drain plug. Torque plug to 9 Nm .

8. Install the oil thermostat complete with gearbox side coolant pipes.

3. Press in the new electric socket with the Mechatronik unit screw plug attached. Secure with the retaining clip.

Install Thermostat




9. Connect the coolant pipes to the gearbox. Torque bolt to 20-25 Nm .

Connect Pipes

Differential


Item

Differential Renew

Code

05.02.AB

Removal

1. Remove the rear subframe complete with the transaxle


2. Using suitable lifting equipment, i.e. hydraulic ramp and sling, support the transaxle from above.

3. Remove the transaxle from it’s mounts. Withdraw the transaxle from the subframe.

10. Install the LH rear exhaust pipe.

11. Install the subframe crossmember. Torque bolts to 85

Nm .

Install Exhaust

85 Nm.

12. Top-up the gearbox oil (Refer to ’Transmission Oil

Check / Top Up’, page 7-1-4).

13. Run the engine and place gear selector lever in each position for at least 10 seconds. Stop the engine.

14. Check and, if required, top-up the gearbox oil.

15. Install the rear undertray.

4. Remove the bolts (x4) that secure the differential to the gearbox. Withdraw the differential.


5. Remove the ‘O’ ring.



4. Install the transaxle to it’s mounting brackets.

Torque bolts (x4) on each mount to 20-30 Nm .

Installation

1. Install a new ‘O’ ring.

Ensure that the ‘O’ ring is not twisted when installed. Look for the line running along the ‘O’ ring for guidance.

2. Install the differential. Torque the bolts to 52-75 Nm .

5. If removed. Install the torque converter.

6. Install the rear subframe complete with transaxle to the vehicle (Refer to ’Rear Subframe’, page 2-1-4).

7. Check / Top-up the differential oil (Refer to ’Differential

Oil Check / Top Up’, page 7-1-4).

8. Check and, if required, top-up the transmission oil.

Differential Output Seal (LH)


Item

Differential Output Seal (LH) Renew

Code

TBA

If replacing both LH and RH seals at the same time, change the LH seal first.

When replacing the RH seal the LH output shaft will hold the differential unit in place.

Removal



3. Remove the LH road wheel and road wheel arch liner.


5. Remove the service brake and handbrake calipers (Refer to ’Brake System (06.00)’, page 6-1-1).

6. Remove the vertical link (Refer to ’Rear Suspension

(04.02)’, page 4-3-1).

7. Drain the differential oil.

3. Using suitable lifting equipment, i.e. hydraulic ramp and sling, place the transaxle to the subframe.




8. Remove the halfshaft bolts (x6) and washers (x3).

Withdraw the halfshaft.


01-05-011

12. Remove the seal.

Installation

1. Install a new seal. Push the seal in until it seats against the lip in the casing. Smear the lip with a small amount of grease.

2. Place the output shaft through the seal casing. Install the bearing and circlip.

10. Attach a slide hammer and withdraw the output shaft cover complete with output shaft and bearing. Discard the ‘O’ ring.

The oil pump impeller ring may come out with the output shaft. Ensure that the oil pump impeller ring is correctly locate on install.

11. Remove the circlip and withdraw the bearing.

3. Install a new ‘O’ ring to the seal casting.

4. Install the output shaft cover complete with output shaft and bearing. Install bolts (x4), torque to 10 Nm .

Insert the output shaft through the inner oil pump ring. Take care to locate the splines of the output shaft through the oil pump inner ring.

5. Install the halfshaft. Torque bolts (x6) to 70.5 Nm .

6. Install the vertical link (Refer to ’Rear Suspension

(04.02)’, page 4-3-1).

7. Install the service brake and handbrake calipers (Refer to

’Brake System (06.00)’, page 6-1-1).




8. Ensure the drain plug is installed (Torque 49 Nm .). Fill the differential with the specified oil (Refer to


9. Install the road wheel arch and road wheel (Refer to


10. Run the vehicle a short distance to ensure that the differential cooling system has been completely filled.

Check / Top if required.


Differential Output Seal (RH)


Item

Differential Output Seal (RH) Renew

Removal

Code

TBA



3. Remove the RH road wheel and road wheel arch liner.


5. Remove the brake and handbrake calipers (Refer to



(04.02)’, page 4-3-1).




9. Remove bolts (x12), attach a slide hammer and withdraw the differential housing cover complete with output shaft. Discard the ‘O’ ring.

10. Remove the circlip. Remove the output shaft complete with bearing.




11. Remove the ‘O’ rings (x2).

3. Install new ‘O’ rings (x2)


4. Install the differential housing cover. Install bolts, smeared with Loctite 242 (x12). Torque bolts to 35 Nm .



Installation

1. Install a new seal. Push the seal in until it seats against the lip in the casting. Smear the lip with a small amount of grease.

2. Place the output shaft through the differential housing cover. Install the bearing circlip.

Place a support under the casting bearing race and press the output shaft to its seat. Ensure that the bearing race does not move - shims may be disturbed.



(04.02)’, page 4-3-1).





10. Run the vehicle a short distance to ensure that the differential cooling system has been completely filled.

Check / Top if required.



Differential Oil Filter


Item

Differential Oil Filter Renew

Removal




Code

TBA

Differential Speed Sensor


Item

Differential Speed Sensor Renew

Removal


Code

TBA


3. Remove bolts (x2). Withdraw the gauze filter.

2. Place a suitable container to hold any differential oil that may come from the opening.

3. Disconnect the speed sensor. Remove the speed sensor.

Installation

1. Install the oil filter complete with a new ‘O’ ring. Torque bolts to 5 Nm .



Run the vehicle a short distance to ensure that the differential cooling system has been completely filled.

Check / Top if required.

Installation

1. Install the speed sensor. Torque bolt to 10 Nm .


3. Check / Top-up the differential oil (Refer to ’Differential

Oil Check / Top Up’, page 7-1-4).







Transmission Cooling (07.02)




Specifications

Thermostat

Oil cooler thermostat range

(Auto only)

°C °F

74°- 88° 165° - 190°

Torque Figures

Description

Cooler Matrix (auto)

Nm.

8-10

Cooler to subframe (manual) 8-10

Maintenance

Oil Cooler (Automatic Gearbox)

lb. / ft.

6-7.5

6-7.5


Item

Oil Cooler (Automatic Gearbox) Renew

Removal

Code

07.02.AB


The air intake for the alternator is located in the front under tray.

2. Remove the front bumper (Refer to ’Front Bumper’, page 1-13-1).


6. Remove the PAS cooler securing bolts. Move the PAS cooler to one side.

7. Remove the cooler matrix air duct.

01-02-007

5.

4. Remove screws (x4) that secure the top of the grill divider.

To gain access to the cooler top hose.

Warning

Ensure that the transmission oil has cooled before removing the cooler matrix pipes. The transmission oil operates at very high temperatures.

8. Disconnect the cooler matrix pipes (x2). Cap the open ends.

Some transmission oil will drain as the pipes are removed.

The air intake pipe will restrict access to the cooler matrix pipes.




9. Remove bolts (x4) that secure the cooler matrix.

Withdraw the cooler matrix.

Thermostat (Automatic Gearbox)


Item

Thermostat (Automatic Gearbox) Renew

Code

TBA

Remove

Warning

Ensure that the transmission oil has cooled before removing the cooler matrix pipes. The transmission oil operates a very high temperatures.

1. Remove the cooling pipes clamp.

Some transmission oil will start to drip.

Installation

1. Install the cooler matrix. Torque bolts (x4) to 8-10 Nm .

2. Connect the cooler matrix pipes (x2).

The air intake pipe will restrict access to the cooler matrix pipes.

Access the top cooler matrix pipe through the grill divider.

Use new ‘Oetiker’ hose clips when reconnecting hoses.

3. Install screws (x4) that secure the top of the grill divider.

4. Install the cooler air duct.

5. Install the PAS cooler.

6. Install the bumper (Refer to ’Front Bumper’, page 1-13-

1).


8. Run the engine to prime the cooling circuit.

9. Check / Top up the transmission oil with the specified transmission oil (Refer to ’Transmission Oil Check / Top

Up’, page 7-1-4).

2. Remove the gearbox cooling pipes. Plug the open ends.

3. Remove the thermostat and bracket assembly from the gearbox.




Installation

1. Install the thermostat and thermostat bracket assembly to the gearbox.

2. Connect the cooling pipes. Ensure that the ‘O’ ring is correctly located in each pipe union.

Torque each union to 20 Nm .

Oil Cooler (Automatic Transaxle

Differential)


Item

Oil Cooler (Automatic Transaxle

Differential) Renew

Removal

1. Disconnect (quick release) the coolant pipes.


Cap the open ends.

Code

TBA

3. Install the pipe clamp. Torque bolt to 20-25 Nm .


5. Check / Top up the transmission oil with the specified transmission oil (Refer to ’Transmission Oil Check / Top

Up’, page 7-1-4).

2. Remove the bolts (x2) securing the coolant pipes brackets. Withdraw the oil cooler.


Installation

1. With the coolant pipes clipped into their brackets, secure the coolant pipe brackets.

2. Connect the coolant pipes.


4. Check / Top up the differential with the specified differential oil (Refer to ’Specifications’, page 7-1-3).




Oil Cooler (Manual Transaxle)


Item

Oil Cooler (Manual Transaxle Renew

Removal

1. Disconnect the coolant pipes.


Cap the open ends.

Code

TBA

Image to Follow

2. Remove bolts (x2) securing the oil cooler to the subframe. Withdraw the oil cooler.

Image to Follow

Installation

1. Install the oil cooler to the subframe.

Torque bolts to 8-10 Nm .

2. Connect the coolant pipes.


4. Check / Top up the transmission oil with the specified transmission oil (Refer to ’Manual Transmission (07.03)’, page 7-3-1).



Manual Transmission (07.03)

Description



The Graziano AM803T transaxle installed to this vehicle incorporates a six speed transmission, with synchromesh on all gears. Gear selection is by a twin cable system (shift and select) operating an integrated bellcrank and H gate.

Cooling

The manual transaxle has an external cooling circuit which operates continuously by a fixed displacement pump driven by the input shaft.

The cooler is mounted at the rear attached to the subframe.




Specifications

Type

Graziano AM803T transaxle with:

• Integrated Bellcrank Assembly

• Integrated Reverse Switch

• Plate Type Limited Slip Differential

Synchronisers

Triple Cone Syncros on 1st and 2nd, double cone on all other gears incl. reverse.

Lubrication

Forced Lubrication system with integral pump and filter

(filter is serviceable item)

Transaxle Oil

Shell Transaxle Oil, Fully Synthetic 75W 90

Transaxle Qty.

Coolant System Qty.

4 ltr. (7 pt. / 4.2 US qts.)

0.5 ltr (0.9 pt. / 0.53 US qts.)

Transaxle + Coolant Qty.

4.5 ltr (7.9 pt. / 4.6 US qts.)

Gear Ratios

1st 2nd 3rd 4th 5th 6th

3.154:1 1.947:1 1.435:1 1.148:1 0.935:1 0.758:1

Reverse

2.385:1

Differential Locking Ratio

20% Drive, 60% Coast

Torque Figures

Description

Speedo sensor to cover plate

Sump plug

LH Output shaft housing

Halfshaft

Differential Cover

Nm.

7

49

10

70

35 lb. / ft.

5.5

36.5

7.5

52

26

Maintenance

Oil Check and Top-up

The transaxle is filled for life and would only require checking and topping-up in the event of a oil leak or strip down of the transaxle cooling system.

In the event of a oil leak from the transaxle cooling system, the leak must be repaired and then the transaxle oil may be replenished as follows:

Warning

Observe all transaxle oil manufacturers safety instructions when draining and refilling the manual transaxle.

Before doing any work to the transaxle oil level setting make sure that:



• The rear wheels are standing still for a minimum of 2 minutes before starting the oil level check and during the process, e.g. by applying the hand brake

1. Place a suitable container to hold any transaxle oil that may come from the opening.

2. Remove the fill plug.

With the fill plug removed transaxle oil should just

‘dribble’ from the opening.

3. If required fill the transaxle with the specified oil until oil

‘dribbles from the hole (Refer to ’Specifications’, page 7-

3-2).

Drain / Fill

1. Place a suitable container to hold the transaxle oil.

2. Remove the drain plug. Allow the oil to drain.

3. Disconnect the oil cooling pipes and allow the oil in the cooling system to drain in to the container.

4. Complete with a new sealing washer, install the drain plug. Torque plug to 49 Nm .

5. Connect the oil cooling system pipes.

6. Fill the transaxle with the correct oil.

7. Run the vehicle a short distance to ensure that the transaxle cooling system has been completely filled.

Check / Top-up.




Transaxle


Item

Manual Transaxle Renew

Code

TBA

Removal

1. Raise vehicle and make safe.

Caution

On a two post ramp ensure vehicle is ‘strapped’ to the lift.

2. Remove both rear road wheels.

3. Remove the silencer and rear LH and RH exhaust pipes.

4. Remove the subframe brace.

6. Disconnect the wiring harness plugs.

5. Remove the halfshafts from the differential.

5.1 Remove bolts (x6) and washer tabs (x3). Discard the bolts.

5.2 Withdraw the halfshafts from final drive.

7. Remove the bolts that secure the oil cooler to the subframe. Withdraw oil cooler.

Remove bolts

01-07-018

8. Disconnect the breather pipe from the transaxle.

The breather pipe should remain in position on the vehicle to avoid being incorrectly route on install.

Image to Follow




9. Using suitable lifting equipment, i.e. hydraulic jack and sling, support the transaxle and remove the bolts (x8 (4 each side)) that secure the transaxle to the mounts (x2).

Discard the bolts.

12. Withdraw the transaxle rearwards and manoeuvre transaxle out from rear subframe.

Image to Follow

10. Lower the transaxle, using the lifting equipment, and disconnect the gear selector cables.


Caution

Ensure that the service tool No. TBA is used. There is a risk of bending the end of the cable. Lever cable from ball joint at a point closest to the ball joint.

Installation

1. Using suitable lifting equipment, i.e. hydraulic jack and sling, place the transaxle up in the subframe.

2. Manoeuvre the transaxle to up to the torque tube. Install bolts (x8). Torque to 43-57 Nm .

43-57 Nm (x8)

Image to Follow

11. Disconnect the torque tube from the gearbox.



Remove Bolts (x8)

3. Connect the gear selector cables.

01-05-020

7-3-4

01-05-019




4. Install the transaxle to it’s mountings. Use new bolts.

Torque bolts (x4 on each mount) to 20-30 Nm .

Remove the support.

20-30 Nm (x4 Each Mount)

01-05-021

Differential Output Seal (LH)


Item

Differential Output Seal (LH) Renew

Code

TBA

If replacing both LH and RH seals at the same time, change the LH seal first.

When replacing the RH seal the LH output shaft will hold the differential unit in place.

Removal



3. Remove the LH road wheel and road wheel arch liner.


5. Remove the service brake and handbrake calipers (Refer to ’Brake System (06.00)’, page 6-1-1).


(04.02)’, page 4-3-1).


5. Install the breather pipe.

6. Install the oil cooler.

7. Install the halfshafts. Torque bolts to 70.5 Nm .

8. Install the subframe brace. Torque bolts to 85 Nm .


Torque Tightening’, page 4-5-7)).

10. Complete a test drive to ensure correct operation.

11. Check gearbox oil level.







Installation

1. Install a new seal. Push the seal in until it seats against the lip in the casing. Smear the lip with a small amount of grease.

2. Place the output shaft through the seal casing. Install the bearing and circlip.

10. Attach a slide hammer and withdraw the output shaft cover complete with output shaft and bearing. Discard the ‘O’ ring.

11. Remove the circlip and withdraw the bearing.

3. Install a new ‘O’ ring to the seal casting.

4. Install the output shaft cover complete with output shaft and bearing. Install bolts (x4), torque to 10 Nm .



(04.02)’, page 4-3-1).






10. Install the road wheel arch and road wheel (Refer to







Differential Output Seal (RH)


Item

Differential Output Seal (RH) Renew

Code

TBA

Removal






8. Remove the ‘O’ rings (x2).



7. Remove bolts (x12), attach a slide hammer and withdraw the differential housing cover complete with output shaft.

9. Remove the circlip. Remove the output shaft complete with bearing.





Installation

Differential (Limited Slip)

1. Install a new seal. Push the seal in until it seats against the lip in the casting. Smear the lip with a small amount of grease.

2. Place the output shaft through the differential housing cover. Install the bearing circlip.

Place a support under the casting bearing race and press the output shaft to its seat. Ensure that the bearing race does not move - shims may be disturbed.

3. Install new ‘O’ rings (x2)


Item

Differential (Limited Slip) Renew

Removal

Code

TBA




4. Remove the shear plate and rear undertray

5. Drain the gearbox oil.

6. Remove the RH rear exhaust pipe (Refer to ’Pipes and

Supports (09.03)’, page 9-2-1).

7. Remove the RH halfshaft.

7.1 Remove the halfshaft nut.

4. Install the differential housing cover. Install bolts, smeared with Loctite 242 (x12). Torque bolts to 35 Nm .



6. Install the halfshaft. Torque bolts (x6) to 70 Nm .


(04.02)’, page 4-3-1).







7.2 Remove bolts (x6) and washers (x3).

7.3 Withdraw the halfshaft.


8. Remove the differential cover.

8.1 Install service tool (No. ) to differential output shaft.




8.3 Withdraw the differential cover.

8.4 Discard the ‘O’ rings (x2).

9. Remove the differential.

The differential may come out with the differential cover or it may remain in the differential housing located on the L/H output shaft.

Installation

1. Insert the differential into the differential housing.

2. Complete with new ‘O’ rings (x2), install the differential cover. Secure with bolts (x12). Torque bolts to 35 Nm .


4. Install the exhaust pipe (Refer to ’Pipes and Supports

(09.03)’, page 9-2-1).

5. Install the undertray and shear panel.







Automatic Control System (07.05)




Transmission controls

Push buttons, mounted on the centre console, are used to select P, R, N and D electrically. The link with the transmission shift console is electric and electronic, via the engine electronics. In addition, gear shifts can be made by using the shift paddles behind the steering wheel

('TouchTronic'). The left paddle is for down-shifts, the right paddle for up-shifts.

Gearbox Modes

Automatic - Button ‘D’ pressed. Standard drive program

(with automatic shifts). Economical use of engine power.

Automatic-Sport - Sport button pressed. Makes full use of the engine power. Moves shifts up to higher engine speeds.

Does not use 6th rear.

Neutral (N)

In neutral, there is no power flow between the engine and the automatic transmission. Apply the handbrake to prevent the vehicle from rolling away when neutral has been selected.

To select ‘N’ from ‘P’, the brake pedal must be pressed down, otherwise the DIM display will show ‘PRESS BRAKE

PEDAL!’. Neutral can be selected from any drive position.

Drive (D)

‘D’ can only be selected after pressing down the brake pedal. If position ‘D’ is selected without applying the foot brake, the DIM display will read ‘PRESS BRAKE PEDAL!’.

From ‘D’, D-Touch can be selected directly by moving one of the paddles behind the steering wheel.

TouchTronic - Paddles behind the steering wheel. Manual shifts between all gears (6, 5, 4, 3, 2 and 1). Will auto shift up when engine revs. reach maximum.

TouchTronic-Sport - Manual shifts between all gears with

Sport button pressed (6, 5, 4, 3, 2 and 1). Does not auto shift up when engine revs. reach maximum.

Overview of Gearshift Procedures

Park (P)

The standard drive program is in use, with automatic shifts from 1 to 6 and 6 to 1.

The actual gear is added to the ‘D’ display, for example ‘D1’

(position D, 1st gear).

If the vehicle speed is less than approx. 5 km/h (3 mph), ‘ D ’ may be selected from ‘ R ’, without pressing the brake pedal.

This enables a vehicle ‘rocking’ motion, i.e. to enable vehicle movement out of mud, snow, etc.

Select ‘P’ only with vehicle standing still or moving very slowly (less than 2 km/h). If ‘P’ is selected without applying the foot brake, the DIM display will read ‘PRESS BRAKE

PEDAL!’

The 'shift by wire' (SBW) system also includes a mechanical emergency release (Park override) so that the vehicle can be towed away in certain circumstances.

Drive (D) - Sport

The Sport program is selected at a separate push button on the centre console and must be re-activated each time the engine is started. This is a program that makes full use of the available engine power and moves the shift points farther up the engine-speed scale.

Drive (D) - TouchTronic

Gears are selected by pulling one of the two paddles behind the steering wheel.

If ‘P’ is selected from drive position D > 2 km/h, the transmission will read ‘CANNOT SELECT PARK AT SPEED’.

Reverse (R)

Left paddle (-)

Down-shift

Right paddle (+)

Up-shift

Select ‘R’ only when the vehicle is stationary and the engine idling. ‘R’ can only be engaged if the foot brake has been applied. If ‘R’ is selected without applying the foot brake, the

DIM display will read ‘PRESS BRAKE PEDAL!’.

If the vehicle speed is less than approx. 5 km/h (3 mph), ‘ R ’ may be selected from ‘ D ’, without pressing the brake pedal, to enable a vehicle ‘rocking’ i.e. to enable vehicle movement out of mud, snow, etc. If 5 km/h (3 mph) is exceeded then the transmission will automatically select

‘ N ’.

The up and down shift points are protected so that the engine cannot over speed. If the ‘ + ’ paddle is not operated in time, however, the transmission shifts up to the next higher gear when maximum engine speed is reached.

Pull back simultaneously on both paddles to select Neutral.

Drive (D) - TouchTronic-Sport

In contrast to ‘D-TouchTronic’, no up-shift takes place in ‘D-

TouchTronic-Sport’ when the maximum engine speed is reached. In this mode (manual program / Sport button operated) no up-shift takes place if the ‘ + ’ paddle is not operated. Engine over speeding will be prevented only by the governed maximum speed limit.




Auto-Park / Auto-Neutral

As safety features, the automatic transmission has ‘Auto-Park’ and ‘Auto-Neutral’ strategies. When certain driving situations are encountered, the automatic transmission shifts to the ‘P’ or ‘N’ positions.

Driving situations:

• If the engine stops while ‘D’ or ‘R’ is selected, but the ignition is on and the vehicle is moving, ‘N’ will be selected.

• If the engine is stopped and the ignition turned off while in ‘D’ or ‘R’, but the vehicle continues to roll, ‘P’ will be selected if the vehicle's speed is below approx. 10 km/h.

• If the engine is stopped and the ignition turned off in position ‘D’ or ‘R’, but the vehicle continues to roll, ‘N’ is selected above approx. 10 km/h.

This assumes that the vehicle's speed does not rise too high. These functions are performed automatically to ensure that no power can pass through the automatic transmission when the engine is restarted.

D

N or

+ and -

D

R N or

+ and D

+ or -

+ or -

P P R R

N or

+ and -

N D

D

Auto

+ve oder

-ve

D

Touch

P R

N or

+ and D

R

R

P

P

N or

+ and -

P

Parking Lock

The parking lock is a device that prevents the vehicle from rolling away out of control. It is engaged when ‘P’ is selected.

The parking lock acts by inserting a pawl into the teeth of the parking lock gearwheel on the transmission output shaft; this prevents the rear road wheels from turning by way of the propeller shaft and final drive.

The parking lock is engaged by a mechanical spring system in the transmission and secured electrically. All drive positions are also selected electrically. The detent disc in the transmission is omitted, and replaced by a parking disc and lock cylinder with solenoid valve (MV3).

Apply the handbrake before operating the park override. There is the danger that the vehicle will roll, depending on the incline of the road.

After stopping the vehicle apply the handbrake and push back the park override lever.

Overriding the Park Lock

Apply the handbrake. Remove the LH rear seat base (A) and unscrew the two screws that secure the park override lever cover. Remove the cover.

Pull the manual park override lever (B) fully up on the ratchet, fully releasing the parking lock.

After towing or moving the vehicle apply the handbrake. Lift the manual park override lever slightly, press the ratchet release (C) and lower the manual park override lever back to the stop. The parking lock is now engaged. Install the cover and the rear seat base.

The message in the instrument pack must disappear and the position display must change from ‘N’ to ‘P’.

Otherwise there is the danger that the vehicle will roll away.




Hydraulic Shift Control Unit

The Hydraulic Shift Control Unit (Mechatronik unit) is a combination of hydraulic and electronic control (TCM) modules, which is located in the transmission, in the oil sump.

This technical principle has the following advantages:

• Minimum tolerances

• Better coordination of gear shifts

• Increased refinement

• Optimised shift quality

• Good reliability, since the number of plug connections and interfaces is reduced

Electrostatic Discharge (ESD)

Caution

When working with the transmission control module

(TCM) and main control valve body, all suitable safety precautions must be taken to protect the component against electrostatic discharge (ESD). Failure to follow these instructions may result in component damage.

Make sure all possible safety precautions are taken to protect the TCM and main control valve body unit against ESD.

Personal Wrist-Band Earthing

Earthing (grounding) by means of a wrist band or strap is the most reliable method of diverting electrostatic charges away from working personnel, and should therefore be used wherever possible, particularly if the person concerned is working while seated. The wrist band earthing (grounding) device consists of a bracelet closely attached to the wrist and a spiral earthing (grounding) cable connecting it to the earthing (grounding) contact point. This system must include a quick-release device so that the wrist can be released in the event of danger.

Shoes and Foot Earthing Straps

Electrically conductive shoes should be worn by persons who mainly work standing up or either standing or sitting in

ESD protection zones, particularly if wrist band earthing

(grounding) is impracticable. The standard calls for ESD shoes to record values between 0 and 35 Megga-ohms

(MOhm) resistance. However, for antistatic working shoes resistance values between 0.1 and 1000 MOhm are called for, and a through-conducting resistance for protective shoes of 0.1 to 100 MOhm. A lower limit value of not less than 0.1

MOhm must be maintained on account of the contact voltage risk. For this reason the minimum value has been set contrary to the standard at the higher figure of 0.75 MOhm.

Transmission Control Module (TCM)

The transmission control module (TCM) and its input / output network control the following transmission operations:

• Shift timing

• Line pressure (shift feel)

• Torque converter clutch

The TCM processes signals from the transmission, the engine and the vehicle.

From the signal inputs and the memorised data the control program computes the correct gear and converter lock-up clutch setting and the optimum pressure settings for gear shift and lock-up clutch control.

By means of special output-side modules (power output stages, current regulator circuits), the TCM controls the solenoid valves and pressure regulators and thus influences the hydraulics of the automatic transmission. In addition, the amount and duration of engine interventions are supplied to the engine management by way of the CAN bus.

Caution

Disconnection of other control modules and / or the vehicle battery, may introduce fault codes (DTCs).

Following rectification and reconnection, ensure that no induced codes exist in the TCM memory.

Caution

Disconnection of other control modules and / or the vehicle battery, will cause shift adaptations to be lost; this may be apparent by slight shift quality degradation.

Shift quality adaptations are made to compensate for changing transmission characteristics over time.

Following reconnection, a period of adaptation will be required as the TCM re-learns the transmissions operating characteristics.

Controller Area Network (CAN) Interface

For the TCM to be able to perform shift point and shift quality management a number of external signals are required. For shift point management alone the TCM requires output speed sensor, throttle pedal position, brake pedal status and virtual gear selector position. The controller area network (CAN) bus is used to share information between control modules. The TCM obtains most of its required data over the CAN bus from the electronic engine controls, EMS, Driver inputs and ABS, Instruments pack and diagnostic tools.




TCM Inputs TCM Monitoring Functions

Input Speed Sensor (ISS)

The input speed sensor provides transmission input shaft speed information. This signal is produced from an inductive pick-up, generating 36 pulses per revolution.

Output Speed Sensor (OSS)

The output speed sensor provides transmission output shaft speed information. This signal is produced from an inductive pick-up, generating 36 pulses per revolution.

Accelerator Pedal Position (APP) Sensor

The accelerator pedal position (APP) sensor is a potentiometer mounted on the accelerator pedal. The APP sensor detects the position of the accelerator pedal and sends this information to the TCM. The APP sensor is used for shift scheduling and TCC lock-up.

Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature (ECT) sensor detects engine coolant temperature and supplies the information to the

TCM. The ECT sensor is used to control the torque converter clutch (TCC) operation.

Transmission oil Temperature (TFT) Sensor

A thermistor provides an electrical indication of the oil temperature. The signal is measured as a voltage with reference to analogue ground in the TCM.

Virtual Kickdown Switch

Kickdown is intended to provide maximum vehicle acceleration, via the appropriate downshift(s), when the operator uses full throttle. The kickdown switch provides an electrical signal when the accelerator pedal is fully pressed down. The TCM detects kickdown using the accelerator pedal position.

Position sensor

The TCM uses the position of this switch, housed on the

TCM and main control valve body, to determine the selected gear range. Gear selections are sent by CAN to the

TCM, which operates the transmission selector shaft between positions Park, Reverse, Neutral and Drive. The

TCM detects the driver´s choice of manual range selection.

Transmission Range Switch (TRS)

The transmission range switch detects the position of the transmission selector shaft. The switch is supplied as part of a new transmission assembly, mounted on the transmission body. The switch is used to indicate positions of the shaft:

Park, Reverse, Neutral, Drive, Fourth, Third and Second.

The TCM monitors all input and outputs to identify possible failures. If a fault is detected the TCM takes the appropriate action to ensure the transmission enters a safe mode of operation, without sacrificing transmission durability or driver safety.

Supply Monitoring

If the battery voltage is either too great or too low, the TCM will detect a fault condition. For the TCM to be able to identify this fault, the engine must be running and the transmission oil temperature sensor must be functioning correctly.

Solenoid Supply Monitoring

While the solenoid operating transistors are being activated, checks are run for open circuits, shorts circuits to ground and short circuits to supply. The monitoring function evaluates the voltage characteristics during the switch on process checking for the above faults. All solenoid outputs are fully protected. The processor and the appropriate fail-safe action taken can quickly identify open and short circuit faults.

Sensor Supply Monitoring

The sensor supply voltage is a stabilized supply. This supply is monitored by the TCM by an Analogue to Digital

Converter (ADC). If the voltage is out of the valid tolerance a diagnostic trouble code (DTC) is set and the appropriate fail-safe action is performed.

Electronically Erasable Programable Read Only Memory

(EEPROM) Monitoring

To diagnose errors with the Electronically Erasable

Programable Read Only Memory (EEPROM) the TCM calculates four checksums continuously: If the processor identifies discrepancies in any of the four checksums the

TCM will engage ‘mechanical’ limp-home mode. Diagnosis is only performed during TCM initialization. There is no failsafe mechanism associated with this function as the

EEPROM is mainly used for the storage of fault codes and transmission calibration adoptions. If a fault occurs the TCM is able to perform default action and inform the driver of the problem, this is by the DIM message centre right.

Watchdog Monitoring

Watchdog monitoring has two functions. Firstly, it checks that it is possible to inhibit output control by the activation of the solenoid supply transistor. Secondly, it checks that the safety circuit is functioning correctly. During initialization the watchdog checks that it is possible to inhibit control of the pressure regulator and solenoid valves by switching the solenoid supply transistor. There is a fault if activation of the solenoids cannot be inhibited by the watchdog.

The supply to the solenoids can still be inhibited by the high side switch responsible for control of each solenoid i.e. One safety path is lost.




Temperature Sensor Monitoring

If the temperature of the Mechatronik unit rises above a predetermined level the TCM will be shut down. Prior to the

TCM shutting down the TCM will log a fault code, during shutdown the transmission will enter ‘mechanical’ limphome mode. Temperature monitoring is performed by a temperature dependent resistor mounted on the in the

TCM.

Transmission oil Temperature Sensor Monitoring

The TCM monitors for faults associated with the transmission oil temperature sensor via open and short circuit fault detection.

The temperature cannot alter by more than a pre-defined differential between any two consecutive measurements.

The transmission oil temperature must rise after the engine has been started provided that the oil temperature was low enough to begin with (The vehicle must be driven and the diagnostic test condition met).

Gear Ratio Monitoring

Gear ratio diagnostic checks that each gear ratio is correctly engaged. Also, following a gear shift the diagnostic checks that the transmission has engaged the target gear within the allowed time.

Torque Converter Monitoring

The TCM checks that the torque converter can be locked correctly. If torque converter lock-up does not occur correctly the TCM performs the appropriate fail-safe action of opening the Torque converter clutch.

Plausibility Checking

The TCM detects a fault if an excessive voltage jump is identified between any two consecutive measurements.

Also, with the engine started from cold the transmission oil temperature will start to rise. Therefore the Mechatronik unit or transmission oil temperature will also start to rise because the TCM is surrounded by transmission oil. If the engine and output shaft speed is higher than a set threshold for a predetermined length of time without the substrate temperature rising above a set threshold a fault will be detected.

Pressure Regulator/Solenoid Monitoring

Each pressure regulator and solenoid is monitored for open circuits and short circuits. The TCM also checks that the current being delivered to each solenoid valve or pressure regulator is within valid limits. When each solenoid is being driven with minimum current the TCM checks that the current is not above a threshold value. If a solenoid is being driven with maximum current, it checks that the current is not below a valid threshold. If either of these two errors occur a plausibility error is logged and the appropriate failsafe action is performed.

Output Speed Monitor

It is possible for the TCM to diagnose electrical errors associated with the output speed sensor while the vehicle is stationary as well as moving. Plausibility monitoring is performed on the sensor output when the vehicle is moving.

Input Speed Monitor

It is possible for the TCM to diagnose electrical errors associated with the input shaft speed sensor while the vehicle is stationary as well as moving. Plausibility monitoring is performed on the sensor output when the vehicle is moving.

Position Sensor Monitoring

The TCM can identify position errors with a position switch located within the transmission. If an unrecognized position code is read by the TCM a plausibility fault will be logged.

Torque Converter Lock-up Control

The TCM controls how the torque converter clutch is engaged as a function of the accelerator pedal position, output speed, transmission oil temperature, gear selected and shift program. Lock-up is possible in all forward gears, but usually it is restricted to fourth, fifth and sixth gears. To make use of the comfort enhancing effect of the torque converter, the converter clutch can be disengaged prior to a downshift or up-shift. The torque converter lock up clutch is always modulated to allow for controlled slip, to further improve the shift quality.




Safety Functions

Safety functions are designed to safeguard against inappropriate actions by the operator as well as against system malfunctions. The system prevents reverse gear from being engaged at high forward speeds and prevents manual down shifting at excessive engine speeds.

The functions are not operational in mechanical ‘limphome’ mode.

Reduced Engine Performance - ‘ Reduced Engine

Perform ’ will display in the message centre right. Engine performance will be restricted.

Mechanical - ‘ Limphome No Gear Change Possible ’ will display in the message centre right and a audible warning will sound. If travelling forwards in ‘ D ’ or ‘ D Touch ’ the vehicle will go into a locked gear (3rd or 5th depending on vehicle speed). If entering mechanical limp home mode in any position other than ‘ D ’ or ‘ D Touch ’ (forward gears) the park lock will engage.

Do not attempt to change position while in mechanical limp home mode, i.e. pressing either P, R, N, D or pulling back on both gear shift paddles simultaneously.

If this request is detected at a speed below approx. 20 km (12.5 mph) the engine will stop and the parking lock will engage.

At a speed above approx. 20 km (12.5 mph) the request and any other transmission request will be rejected and the vehicle will continue in 3rd or 5th.

The TCM constantly monitors the transmission for faults. In the event of a problem the TCM will adopt a ‘limp-home’ mode. If a transmission fault is detected, the PCM generates a DIM warning message.

Safety concept is based on the following:

1. The hydraulic system has 'fail-safe' characteristics regarding its electrical operation, such that should the power supply be lost to the electro-hydraulic actuators, the transmission will initiate a ‘limp-home’ mode.

2. Recognition of critical shift operation by monitoring the last element in the signal path, i.e. the solenoid valve, and checking by means of redundant measured variables, i.e. engine speed, input speed and output speed.

3. Each time the vehicle is started there is a check on the entire safety hardware and the associated program parts and signal paths. A malfunction in this part of the system, or triggering of the safety circuit, is communicated to the operator through the DIM message centre right.

Limp-home Modes

If a fault is detected in the ‘Shift by Wire’ system the vehicle will go into ‘Limp Home’ mode. There are three types of

‘Limp Home’.

There are three operating modes for the converter:

Fully open Torque converter 'disengaged'.

Fully closed Torque converter 'engaged'.

Slip control The TCM monitors slip and may apply sufficient pressure to allow a small degree of slip. This mode maximises economy by reducing slip to a minimum whilst providing isolation from drive-line shunt and vibration.

Torque Converter Clutch

Hydraulic Pressure Regulation

The TCM supplies an internally switched +12V supply to

No.4 pressure regulator. The regulator is operated by switching the other side of the operating winding to ground.

Hydraulic pressure is controlled by 'pulse width modulation'

(PWM) of the ground switching signal i.e. the duty cycle: the time that the pressure regulator is switched on.

Electrical - ‘ Gearbox Fault Reduced Function ’ will be displayed in the message centre right. Touchtronic and Sport modes will be disabled. Gearshifts will still be possible but shift quality will be degraded.

In certain circumstances ‘ D ’ will be restricted to 3rd gear. If travelling at speed 3rd gear will engage when an appropriate speed has been reached.

Torque Converter Operation

The TCM continually monitors the state of the torque converter.

TCM Supply Voltage

The TCM monitors battery and ignition switched supply voltages.

A permanent supply is used to maintain a battery backed

'memory'. Should this supply be cut, due to battery disconnection or power interruption, the shift quality adaptations (made due to the transmission's changing characteristics over time) will be lost. This will result in a small reduction in shift quality for a period until the shift adaptations are re-learned.

The TCM will adopt ‘limp-home’ mode as a result of the supply voltage being greater than 16 V or below 7 V with an engine speed of greater than 1600 rpm.

Should the ignition supply be between 7 and 9 volts, the

TCM will hold the gear that it has currently selected. If after

2.5 seconds, with the engine speed more than 1600 rpm, the voltage remains at this level, 'limp-home' mode will be adopted. The 2.5 second delay is built in to prevent reaction to a momentary voltage fluctuation.




Shift by Wire

In the shift by wire (SBW) system driver intention is transmitted by electrical signals.

The driver request is transmitted over the CAN and the ‘Backup Line PSU’. In general the TCM uses the signal over the

CAN, in case of a CAN failure the signal over the backup line is used. The serial backup line is unidirectional.

The EMS converts the driver input into an electrical signal which is transmitted to the TCM. The TCM then makes a plausibility check of the driver request. If the conditions (ignition, engine speed, vehicle speed etc.) are fulfilled, the target position is transmitted to the DIM over the CAN.

If required by the TCM the DIM also displays messages to warn the driver and messages to recommend driver actions.

The SBW system provides an emergency disengagement mechanism for the park lock system to enable towing the vehicle

(Disengagement of Park in case the engine is not running).

Signal Chain-Basic Example for D-Button operation

1. Driver input - via the SBW interface.

2. The PCM receives the input signal.

3. The PSU performs a diagnostic on the input signal. It then buffers the raw signal from the buttons / paddles and distributes the pressed / no pressed, pulled / no pulled information on CAN.

4. The TCM receives the signal and checks, depending on the current conditions (Transmission state, Engine speed,

Vehicle speed etc.), if a change of position is allowed. If yes, the TCM initiates a position change in the gearbox. At the same time the TCM distributes updated position information on CAN.

5. This position information is received by the DIM and the PCM. The DIM illuminates the actual position distributed from the TCM and the PCM illuminates e. g. in addition the drive button light when Drive is distributed from the TCM.

Driver Input

Center Console

Park (P)

Reverse (R)

Neutral (N)

Drive (D)

SBW Interface

Sport Mode

Switch

Hardwire

Hardwire

Hardwire

Engine

Control

Module including

Hardwired Park / No Park

Serial Position Backup Line

HS_CAN / Volcano

Transmission Control

Module (TCM)

(Mechatronic unit)

Position

Selection

Module

Drive Information

Module

Steering Wheel

Shift Up

(+ ve)

Shift Down

(- ve)

Anti Blocking System

LEDs - PRND S




Transmission Plug Pin Assignment

4

5

2

3

Pin Assigned to

1 Series line

CAN L

8

9

6

7

ISO K

Not in use

Not in use

CAN H

S4

Not in use

Terminal 15

10 P signal

11 S4

12 not in use

13 Terminal 31-1

14 Terminal 30

Notes

Serial Backup Line EMS

CAN low

K line (for example application)

Digital input

Digital input

CAN high

Heartbeat Supply optional input

Wake-up signal, terminal 15 VIGN

P line for starter inhibit

Heartbeat

Earth (ground)

Permanent positive (EGS supply voltage)

15 Not in use

16 Terminal 31-2 Earth (ground) 2


Contents

Clutch Assembly (08.01).......................................8-1-2

Description ............................................................... 1-2

Specifications............................................................ 1-2

Maintenance............................................................. 1-2

Clutch Assembly .................................................... 1-2

Remove............................................................... 1-2

Installation .......................................................... 1-3

Clutch (08.00)


Clutch Assembly (08.01)

Clutch (08.00)


Description

The clutch assembly is a balanced unit consisting of a flywheel, clutch friction plates and clutch cover.

The clutch is a twin plate, diaphragm spring type assembly.

A concentric clutch slave cylinder is mounted around the first motion shaft in the torque tube bell housing.

The clutch master cylinder is mounted on the engine bulkhead and is operated directly by the clutch pedal.

A hydraulic connection from the master cylinder feeds pressurised fluid to the slave cylinder. The slave cylinder has an extension tube and bleed nipple extending from the left side of the bell housing for bleeding the system after any major work.

Specifications




5. Remove the transaxle and the torque tube.

• (Refer to ’Manual Transmission (07.03)’, page 7-3-1)

• (Refer to ’Torque Tube’, page 5-1-2).

Warning

The clutch assembly is heavy. Ensure the clutch assembly is supported before removing final bolts.

6. Install the crankshaft holding tool (Refer to ’303-1047

(Crankshaft Holding)’, page 20-1-6) to prevent crankshaft turning.

Clutch Fluid

Castrol/Girling Universal Brake and Clutch fluid.

Clutch Assembly

Balanced assembly with alignment marks

Clutch Plate

Twin friction plates

Torque Figures

Description

Flywheel Bolts

Tighten the bolts in sequence. Loosen the bolts and then torque, in even stages, in the same sequence.

Clutch Bolts

Tighten x3 equally-spaced bolts, inturn, to pull-down the clutch evenly.

Then torque all bolts in sequence.

Starter Motor Bolts.

Maintenance

Clutch Assembly

Nm lb / ft.

75-81 55.5-60

29-35 21.5-26

30-35 22.5-26


Item

Clutch Renew

Remove

Code

TBA

Note alignment marks on clutch cover.


Warning

If rasing vehicle on a ‘two post’ ramp (vehicle supported by underbody), ensurethat the rear end of the vehicle is securly strapped to the ramp. Faliure to strap the rear of vehicle down may lead to the vehicle falling off the ramp.


7. Remove bolts (x6) and lock washers. Withdraw the clutch cover and plates.

Caution

The clutch is replaced as a complete assembly

(flywheel, clutch plate and clutch cover).

Replacing only the clutch plates will result in clutch non-release.

Image to Follow



8. Remove the flywheel.

Warning

The flywheel is heavy. Ensure flywheel is supported before removing.

8.1 Insert bolts into the bolt holes (x2) provided.


8.3 Using the inserted bolts ‘Jack’ the flywheel off the crankshaft.

8.4 Discard the bolts.

2. Install the crankshaft holding tool (Refer to ’303-1047

(Crankshaft Holding)’, page 20-1-6) to prevent crankshaft turning.

3. Install the flywheel.

3.1 Using a suitable support surface under the flywheel, offer the flywheel to the crankshaft. Locate the flywheel onto the crankshaft dowel.

Installation

• If the new clutch assembly is bolted to the flywheel, remove the new clutch assembly from flywheel. Note position of clutch assembly to flywheel.

• If the new clutch assembly is not assembled - assemble with paint marks in alignment:

3.2 Loosely install new flywheel mounting bolts (x8) and hand tighten.

3.3 Tighten the bolts in the sequence illustrated. Continue until the flywheel face is in full contact with the crankshaft flange.

3.4 Loosen the bolts and then torque, in even stages, to 75-81

Nm in the same sequence.

1. Check that pilot bearing in the rear end of the crankshaft is 0.0-1.0 mm below the crankshaft end face.


0.0 / 1.0 mm



4. Insert the clutch alignment tool (Refer to ’303-667

(Clutch Alignment)’, page 20-1-5) through the clutch assembly. Offer this assembly to the flywheel and insert the alignment tool into the crankshaft pilot bearing.

Caution

The flywheel and pressure plate are a balanced assembly. Ensure alignment marks are aligned.

5. Insert new bolts (x9). Tighten x3 equally-spaced bolts inturn to pull-down the clutch evenly.

Torque all bolts, in sequence, to 29-35 Nm .

6. Visually check that marks between the clutch and the flywheel are correctly aligned. If not, the clutch must be removed and installed correctly.

7. Remove the alignment tool.

8. Remove the crankshaft holding tool.

9. Install the torque tube and the transaxle.


• (Refer to ’Manual Transmission (07.03)’, page 7-3-1)

10. Install the starter motor. Torque the starter motor bolts to 30-35 Nm .






15. Connect vehicle battery.


Contents

Exhaust Overview ..................................................9-1-2

Silencer Assembly (09.01) .....................................9-1-3

Variable Flow Silencer Assembly ............................ 1-3

Pipes and Supports (09.03) ...................................9-2-1

Specifications.......................................................... 2-1

Maintenance........................................................... 2-1

Exhaust System ...................................................... 2-1

Removal.............................................................. 2-1

Installation .......................................................... 2-2

Exhaust (09.00)


Exhaust Overview

Exhaust System (09.00)


Exhaust Overview

The exhaust system consists of two six-branch manifolds, four primary catalytic converters, eight oxygen sensors, two secondary catalytic converters and a single variable flow silencer assembly.

Exhaust gasses flow from the exhaust manifolds, through the primary catalysts, through the secondary catalysts and on to the rear silencer assembly.

Eight oxygen sensors are installed in the exhaust system. The four engine management oxygen sensors are mounted before the primary catalysts. The four catalyst monitor oxygen sensors are mounted between the primary and secondary catalysts.


Silencer Assembly (09.01)

Exhaust (09.00)

Exhaust (09.00)


Variable Flow Silencer Assembly

The rear silencer assembly has a variable flow path controlled by two bypass valves.

The system is intended to enhance top end performance in motor sport applications and will not operate in most normal driving conditions.

By directing exhaust gasses through a modified path at high vehicle speeds, exhaust back pressure is reduced and top end performance is enhanced.

As engine speed increase from idle, the bypass valve is open until the engine speed is 1500 rpm.

From 1500 rpm to 3000 rpm, the valve is closed

Above 3000 rpm the bypass valves state is load dependent (fully open at higher loads).



Exhaust (09.00)


Pipes and Supports (09.03)




Specifications

Torque Figures

Description

Catalyst (nuts / bolts)

Catalyst (clamps)

Nm

25.5-34.5 19-25.5

19-22

Centre pipe to rear pipe (clamp) 39-51 lb. / ft.

14.5-16.5

29-38

Rear Pipe to Silencer (bolt) 28-33 21-24.5

Maintenance

Exhaust System


Item

Exhaust System Renew

Removal

Code

09.03.NB


2. Remove the shear panel and both undertrays.

3. Disconnect the vacuum lines from the bypass valves.

4. Remove the silencer assembly.

4.1 Release bolts (x4) from LH and RH rear pipes.

4.2 Support the silencer and release the front and rear hangers.

4.3 Withdraw the silencer assembly.

5. Remove LH and RH rear pipes.

5.1 Remove subframe cross brace.

5.2 Release clamps (2)

5.3 Release LH and RH pipe hangers from body.

5.4 Withdraw LH and RH rear pipes through the subframe.

6. Remove the center pipes.

6.1 Release clamps (2).

6.2 Push center pipe rearwards to release from rubber mount.




7. Remove the catalysts.

7.1 Release bolts (x3).

7.2 Withdraw catalyst. Repeat for second catalyst.

Installation

Use a proprietary exhaust sealant around all clamp joints prior to securing loosely. Use new manifold flange gaskets.

1. Install, loosely, the LH and RH catalysts.

2. Install, loosely, the center pipes.

3. Install, loosely, LH and RH rear pipes.

4. Install the silencer and the vacuum lines to the bypass valves.

5. Work from the front and set all bodywork clearances.

6. Tighten all the exhaust fixings.

7. Install the subframe cross brace.


Contents

Fuel Tank and Lines (10.01) ................................10-1-2

Description ............................................................. 1-2

Fuel Tank............................................................... 1-3

Fuel Pumps............................................................ 1-4

Jet Pumps .............................................................. 1-4

Filler Neck and Check Valve .................................. 1-5

Valves and Sensors................................................. 1-5

Fuel Limit Vent Valve (FLVV)................................. 1-5

Roll Over Valves .................................................. 1-5

Fuel System Schematic ........................................... 1-6

Evaporative Loss System......................................... 1-6

System Operation .................................................. 1-6

Fuel Tank Vents and Control Valves ....................... 1-6

On-Board Refuelling Vapour Recovery ................. 1-7


Specifications.......................................................... 1-8

Maintenance........................................................... 1-8

Fuel System ........................................................... 1-8

Depressurising..................................................... 1-8

Priming ............................................................... 1-9

Pressure Test ....................................................... 1-9

Fuel Tank............................................................... 1-9

Draining.............................................................. 1-9

Removal.............................................................. 1-9

Installation ........................................................ 1-11

Fuel Filters ........................................................... 1-11

Removal............................................................ 1-11

Installation ........................................................ 1-12

Fuel Pumps.......................................................... 1-12

Removal............................................................ 1-12

Installation ........................................................ 1-13

Fuel (10.00)


Fuel Tank and Lines (10.01)

Fuel (10.00)

Fuel (10.00)


Description

This vehicle uses a return less fuel system in which two fuel pumps, controlled by the fuel pump driver modules, are run to supply fuel through two in-tank filters to the two fuel rails (Refer to ’Fuel Charging System (03.04)’, page 3-5-1). Each fuel rail is installed with six fuel injectors. A pressure sensor and a temperature sensor are fitted on the primary fuel rail.

The secondary fuel rail is installed only with a pressure sensor. The fuel pump speeds are varied as required to regulate the fuel pressure in the fuel rails.

The RH fuel pump feeds the engine LH bank fuel rail.

The LH fuel pump feeds the engine RH bank fuel rail.

10-1-2 Workshop Manual Issue February 2005


Fuel (10.00)

Fuel Tank

The fuel tank incorporates a single filler neck and check valve, internal fuel pumps, internal fuel filters, a sender unit and an ‘on board refuelling vapour recovery’ system.

Roll Over Valve

High Pressure

Feed to the Jet Pump

Fuel Limit Vent Valve

Roll Over Valve

High Pressure

Feed to the Jet Pump

Filler Neck Check Valve

LH Jet Pump Low Pressure

Feed to the RH Swirl Pot

RH Jet Pump Low Pressure

Feed to the LH Swirl Pot

Jet Pump



Fuel (10.00)

Fuel Pumps

Fuel Pumps

The two modular fuel pumps are immersed in the base of the fuel tank. The pumps can deliver up to 150 litres / hour.

The in-tank fuel lines connect to the external lines using two quick-fit connectors in the base of the fuel tank.

During normal running, pressurised fuel from each fuel pump passes from the tank, through an 3 micron in-tank fuel filter to one of the two fuel rails on the engine.

Fuel temperature is measured on the primary fuel rail. If fuel temperature becomes excessive, the fuel pressure is increased to prevent fuel vaporisation (boiling).

Fuel pressure is measured by sensors on each fuel rail. The fuel pressure to each rail is regulated as required by continuously changing the run speed of the associated fuel pump. Maximum pressure in the system is limited to 5.3 bar by in-tank pressure regulators.

A constant head of fuel is maintained in the fuel pump modules to ensure that the pumps cannot run dry in a ‘low fuel’ situation.

Jet Pumps

Fuel feed from the fuel pumps is split three ways:

1. Feed to the fuel rails.

2. Feed to the swirl pot jet pumps (integral to the FDM).

3. Feed to the externally mounted jet pumps.

These pumps ensure that the appropriate pump swirl pot is maintained with fuel under severe dynamic conditions.

Jet Pump Assembly



Fuel (10.00)

Filler Neck and Check Valve

Incoming fuel passes through a check valve at the base of the filler neck. This valve is normally held closed by light spring pressure. The valve opens under the pressure of incoming fuel and closes again when fuel flow ceases. The check valve prevents surging of fuel in the filler neck.

Valves and Sensors

Roll Over Valve

Fill Level Vent Valve

Roll Over Valve

The filler neck also forms part of the on-board refuelling vapour recovery system. Incoming fuel forms a liquid seal in the filler neck. Thus any air displaced during fuel tank filling cannot escape via the filler neck.

Fuel Tank Pressure Sensor

Electrical Connector

Fuel Limit Vent Valve (FLVV)

This valve contains a float which rises to cut off the path for displaced air when the fuel level rises towards maximum during fuel filling. This causes a rapid pressure build up in the tank which triggers the cut-off valve in the fuel delivery nozzle. This discourages overfilling of the fuel tank.

The FLVV also includes an over pressure relief valve set at about 2 psi to vent the tank if all other vents fail.

Roll Over Valves

The roll over valves purpose is to vent the highest point of the tank. If the tank is grossly overfilled (e.g. many clicks over the normal filler nozzle cut-off), the FLVV will suffer a hydraulic lock. The roll over vent valve allows venting of the tank at the highest possible level in this situation.

All three valves allow the tank to breath until it is inverted when they will close to prevent fuel spill. The fuel level vent valve controls the fuel height of the tank by creating a pressure spike inside the tank which shuts of the fill nozzle.

If the vehicle is inverted in an accident, this valve will close to prevent leakage of liquid fuel.



Fuel (10.00)

Fuel System Schematic

It includes the positive crankcase ventilation and vapour recovery systems.

1. Oil separator

2. PCV valve

3. Check valve

4. Relief valve

5. Vapour management valve

6. Fuel tank pressure transducer

7. Carbon canister

8. Canister vent valve

9. Fuel limit vent valve

10.Test port

3

1

3 4

2 2

11 5

8

6

7 9

036-2-009

Evaporative Loss System




Fuel Tank Vents and Control Valves

Vapour Management

Valve

To Carbon Filter


Displaced fuel vapour leaves the fuel tank via the normally open fuel level vent valve and the roll over valves. It passes through the carbon canister where fuel hydrocarbons are absorbed. Clean air leaves the system via the normally open canister vent valve. This valve is only closed during diagnostic pressure testing of the fuel system.

During normal engine running, the single vapour management valve in the engine bay is periodically opened, when negative pressure exists in the intake manifold, allowing fresh air flow into the open canister vent valve, through the carbon canister, through the vapour management valve and into the primary inlet manifold. This fresh air flow progressively purges any absorbed fuel vapour from the carbon canister.

To Fuel

Tank

To Service Port



Fuel (10.00)

To Carbon Filter

Canister Close

Valve

Canister

Close Valve

Carbon Canister

Filter

Clean Air

On-Board Refuelling Vapour Recovery

All of the vapour displaced from the tank by refuelling passes through a series of valves and through a carbon canister. This filters out and stores all the fuel vapour and clean air exits the carbon canister port.

Pressure Transducer

Carbon Canister

Roll Over Vent Valve

Normal Fuel Fill - Air displaced from the fuel tank during filling can only exit via the fuel level vent valve and be forced through the carbon canister. Any fuel vapour in the displaced air is absorbed in the carbon filter material. No fuel vapour can escape to the atmosphere. Clean air then exits the carbon canister, via and additional filter, to atmosphere.

Excessive Fuel Fill - In the event of overfilling of the fuel tank, the fuel level vent valve will close at normal maximum fuel level. Finally the roll over vent valve will close, completely sealing the tank. Any excess pressure in the fuel tank will ‘blow off’ via the Over-pressure vent valve (part of the roll over vent valves) in the Fuel Level vent valve assembly.

Roll Over Vent Valve

Vapour from Tank

Fuel Level

Vent Valve



Fuel (10.00)


Operations on fuel system result in fuel liquid and vapour being present in the working environment. This presents a very serious risk and the following precautions must be strictly observed:

Warning


Warning



Warning


Warning


Warning


Warning


Warning


Warning


Warning


Specifications

Pump Pressure

Nominal pump pressure 40 psi (2.7 bar) above inlet manifold pressure.

Torque Figures

Description

Tank retaining plate bolts

Nm

20-25 lb. / ft.

15-18.5

Maintenance

Fuel System

Warning

Never break into the fuel system of a hot engine.

Catalysts and exhaust systems run at high temperatures and present a serious fire risk if fuel is spilled onto them when hot.

Warning

The fuel system is pressurised when the engine is running. Residual pressure will remain in the fuel system as the ignition is switched off.

Opening a pressurised fuel line will cause a fuel leak and a fire risk.

The fuel system must only be serviced by staff trained in fuel handling.

Depressurising


Item


Code

10.01.EK










Warning




Fuel (10.00)


Priming

Warning

Fire Risk. Do not switch on the ignition until all work on the fuel system is completed and area is cleared of fuel and fuel vapour contamination.

The fuel system is self priming.

There must be a minimum of 5 litres of fuel in the tank.

Pressure Test


• Passenger rear ¼ panel

• Rear top panel

• Both seat belts

• Satellite Navigation (if installed)

4. Remove the access cover over the fuel tank flange.

Warning

Ensure there is adequate ventilation inside the vehicle

(i.e. place the vehicle in a well ventilated area, with the windows open).

Warning

Fire Risk. Depressurise the fuel system before disconnecting pipe work. Use a pan or absorbent cloth to catch fuel spills which may occur due to residual pressure. Clean up spillages immediately and dispose of fuel contaminated materials safely.

1. Set the WDS system to monitor the pressure in each fuel rail.

2. Start the engine and monitor the fuel pressure readings.

• Both fuel rails must show a pressure of more than 40 psi for the engine to function satisfactorily.

• If either fuel rail is lower than 40 psi, check for blocked or restricted fuel filter or fuel lines on the side showing low pressure.

3. If the filter and fuel lines are serviceable, suspect a defective fuel pump.

Fuel Tank


Item

Fuel Tank Renew

Draining

Code

10.01.FB

Warning


Warning

Read and follow all fuel handling instructions given at the start of this chapter and in the bowser manufacturers fuel handling documentation before commencing work on fuel system.

This procedure must only be performed by staff who are fully trained in fuel handling.


For trim, seat belt and seat removal refer to the following:

(Refer to ’Interior Trim (01.05)’, page 1-4-1)

(Refer to ’Seating (01.10)’, page 1-7-1)

(Refer to ’Restraining Devices (01.20)’, page 1-14-1)

• Passenger front seat

• Both rear seats

2. Disconnect the seat belts lower mounts.

5. Remove the tank service cover plate (Refer to ’310-136

(Fuel Tank Drainage Adaptor)’, page 20-1-7).

6. Install the fuel drain cover plate (Refer to ’310-136 (Fuel

Tank Drainage Adaptor)’, page 20-1-7).

7. Connect the external pipe to a fuel recovery unit.

Recover the fuel according to the recovery unit instructions.

Several litres of fuel will remain in the tank sump after draining.

8. After fuel recovery, remove the service tool from the fuel tank. Carry out the intended repair or service procedure.

When installing the service cover plate always use a new seal.

Removal

Warning

Fire Risk. Before starting braking in to the fuel system disconnect the earth (- ve) lead from the vehicle battery .

Warning

Fuel vapour is explosive. During the following procedure, fuel tank and fuel lines will be open. Ensure good ventilation and take all necessary precautions to eliminate fire risks.

Warning

Read and follow the fuel handling instructions given in

Safety Precautions at the start of this section.

Take all necessary precautions to prevent sparks from electrical / electrostatic discharge or from friction.


2. Disconnect the earth lead from the vehicle battery.



Fuel (10.00)

3. Drain the tank.

Several litres of fuel will remain in the tank sump after draining.

4. Remove the rear subframe (Refer to ’Rear Subframe’, page 2-1-4).

5. Disconnect the tank wiring harness plugs and earth cable.

6. Disconnect the wiring harness earths and plugs

9. Disconnect the vapour purge and fuel pipes from the tank (Refer to ’310-040 (Fuel Pipe Disconnect Tool)’, page 20-1-6). Cap the open ends on the tank and on the pipes.

Vapour

Purge Line

Disconnect

Plugs and Earth

Fuel Pipes

7. Remove the filler neck from the tank (Refer to ’310-134

(Filler Neck Disconnect Tool)’, page 20-1-6)

Cap the filler neck on the tank.

10. Place a suitable adjustable support, i.e. a transmission jack, under the fuel tank retaining plate.

Warning

This is a two person operation. The fuel tank is heavy.

Withdraw fuel tank with care.

11. Remove bolts (x18) that secure the fuel tank retaining plate. Allow the fuel tank retaining plate and fuel tank to lower on the adjustable support.

The tank may remain in position after retaining plate is removed. Manoeuvre the tank out from the vehicle body.

Remove Bolts x18

8. Disconnect the On-Board Refuelling Vapour Recovery hose to the filter.

Disconnect Hose



Fuel (10.00)

Installation

Fuel Filters

Warning

Fire Risk. Before starting braking in to the fuel system disconnect the earth lead from the vehicle battery .

Warning

Read and follow the fuel handling instructions given in

Safety Precautions at the start of this section.

1. Place the fuel tank on to it’s retaining plate. Using a suitable adjustable support, raise the fuel tank and retaining plate into position. Secure the tank with the tank retaining plate. Torque bolts (x18) to 20-25 Nm .


When reconnecting the fuel lines at the tank, check for complete engagement of locking clips. Test the fuel system integrity before refitting the shear plate and rear undertray.

3. Remove the cap from the filler neck on the tank. Install the filler neck to the tank.

4. Connect the On-Board Refuelling Vapour Recovery hose to the filter.

5. Connect the tank wiring harness plugs and earth cable.

6. Install the rear subframe (Refer to ’Rear Subframe’, page

2-1-4).

7. Fill the tank.

8. Check and ensure integrity of the fuel system.

Warning

Fire Risk. Do not connect the battery and switch on the ignition until all work on the fuel system is completed and the area is cleared of fuel contamination.

Remove contaminated material, open fuel containers, waste fuel. Fully ventilate vehicle and work area to remove all fuel fumes.

9. Connect the earth lead to the vehicle battery.

Warning

Fire Risk. Do not start the engine until the fuel system integrity is confirmed.


Item

Fuel Filter Renew

Removal

3. Disconnect the earth lead from vehicle battery.

4. Remove the passenger front seat.

5. Remove both rear seat backs and bases.

6. Remove the rear trim.

• Rear ¼ panels

• Rear top panel

• Both seat belts

Caution

Code

(x1) 10.01.AB

(x2) 10.01.BB

The following procedure is completed inside the vehicle cabin area. Extra care must be taken to ensure no fuel or fuel vapours come into contact with the vehicle interior.


2. Drain the fuel tank (Refer to ’Draining’, page 10-1-9).

Warning

Several litres of fuel remain in the tank sump after draining.



7. Remove the access cover over the fuel tank flange.

Warning

Ensure there is adequate ventilation inside the vehicle

(i.e. place the vehicle in a well ventilated area, with the windows open).



10. Switch on the ignition. Confirm there are no fuel leaks.

11. Start the engine and check for correct fuel system operation (i.e. correct engine running).



Fuel (10.00)

The following operation is completed using one hand and without sight of the fuel filter.

9. Remove the fuel filter.

9.1 Release the fuel filter pipe clamp.


7. Install the vehicle seat belts and trim.

For trim, seat belt and seat installation refer to the following:




Fuel Pumps


Item

Fuel Pump Renew

Code

(x1) 10.01.CB

(x2) 10.01.DB

9.2 Release the two fuel filter pipes (quick release unions).

Caution

The following procedure is completed inside the vehicle cabin area. Extra care must be taken to ensure no fuel or fuel vapours come into contact with the vehicle interior.

Removal


2. Drain the fuel tank (Refer to ’Draining’, page 10-1-9).

Warning

Several litres of fuel remain in the tank sump after draining.

3. Disconnect the earth lead from the vehicle battery.






9.3 Remove the fuel filter clamp.

9.4 Withdraw the fuel filter.

10. Repeat for the second fuel filter.

Installation

The following operation is completed using one hand and without sight of the fuel filter.

1. Insert a fuel filter through the fuel tank opening. Secure in position using the fuel filter clamp.

2. Connect the fuel pipes (x2).

Repeat for the second fuel filter.

3. Install the tank service cover plate (Refer to ’310-136



• Passenger front seat

• Both rear seats

5. Disconnect the seat belts lower mounts.


• Passenger rear ¼ panel

• Rear top panel

• Both seat belts

7. Remove the access cover over the tank flange.

Warning

Ensure there is adequate ventilation inside vehicle (i.e. vehicle in a well ventilated area, windows open).


Warning

Fire Risk. Do not start engine until fuel system integrity is confirmed.




Fuel (10.00)



12. Using the service tool (Refer to ’310-140 (Fuel Pump

Install / Remove)’, page 20-1-7), twist the fuel pump anti-clockwise to release it from the mounting bracket.

Withdraw the fuel pump.

The following operation is completed using one hand and without sight of the fuel pump.

9. Disconnect the main fuel pipe from the fuel filter (2).

Disconnect Fuel Pipe

10. Disconnect the cross feed fuel pipes.




Disconnect Wires x2

Installation

1. Place the fuel pump to it’s mounting. Using the service tool twist clockwise to secure (Refer to ’310-140 (Fuel

Pump Install / Remove)’, page 20-1-7).

The fuel pump should ‘click’ into place.

2. Install the main fuel pipe, the cross feed pipes and the wiring harness plug.

3. Install the tank service cover plate (Refer to ’310-136




Warning

Fire Risk. Do not start engine until fuel system integrity is confirmed.



7. Install both seat belts.

8. Install the rear top panel.

9. Install the passenger rear ¼ panel.

10. Connect the seat belts lower mounts.

11. Install the rear seats.

Install the seat backs then the seat bases.

12. Install the passenger front seat.



Fuel (10.00)


Contents

Steering Gear (11.01) ..........................................11-1-2

Diagnostics ............................................................. 1-2

Symptom Chart...................................................... 1-2

Specifications.......................................................... 1-4

Maintenance........................................................... 1-4

Wheel Bearing Inspection ...................................... 1-4

Ball Joint Inspection ............................................... 1-4

Track-Rod Ends...................................................... 1-5

Removal.............................................................. 1-5

Installation .......................................................... 1-5

Steering Rack ......................................................... 1-6

Removal.............................................................. 1-6

Installation .......................................................... 1-6

Power Steering (11.02) ........................................11-2-1

Description ............................................................. 2-1

Specifications.......................................................... 2-2

Maintenance........................................................... 2-2

System Bleeding..................................................... 2-2

Steering Column (11.04)......................................11-3-1

Description ............................................................. 3-1

Specifications.......................................................... 3-1

Maintenance........................................................... 3-1

Steering Column .................................................... 3-1

Removal.............................................................. 3-1

Installation .......................................................... 3-2

Steering Column Switches (11.05).......................11-4-1

Maintenance........................................................... 4-1

Column Controls.................................................... 4-1

Removal.............................................................. 4-1

Installation .......................................................... 4-1

Steering Wheel (11.06) ........................................11-5-1

Specifications.......................................................... 5-1

Maintenance........................................................... 5-1

Steering Wheel ...................................................... 5-1

Removal.............................................................. 5-1

Installation .......................................................... 5-1



Steering Gear (11.01)




Upper C owl

S teering C olumn

S teering A ngle S ens or

B ulkhead S eal

Intermediate Shaft

P res s ure T rans duc er

S witc h G ear A s s ay

P A S Oil R es ervoir

P ower S teering

Module A s s ay

S teering R ac k

C ooling L oop

T rac k R od E nds

Diagnostics

Symptom Chart

Symptom

Vehicle wanders from side to side on the road when driven straight ahead with the steering wheel held firmly.

Possible Cause

Incorrect tyre size or pressure.

Vehicle unevenly loaded or overloaded.

Loose or worn tie-rods or tie-rod ends.

Steering gear bolts loose or damaged.

Loose or worn suspension ball joint(s).

Steering column universal joint pinch bolt loose.

Incorrect toe adjustment.

Loose or worn rear suspension.

Steering gear bushes worn or damaged.

01-11-001

Action

Check for correct tyre size.

Adjust tyre pressures.

Adjust load.

New tie-rod end or steering gear.

Tighten.

New bolts.

New suspension ball joint assembly.

Tighten pinch bolt.

Adjust as required.

Tighten if loose.

New rear suspension components.

New steering gear.




Symptom

Vehicle tends to pull to one side when driven on a level surface.

Possible Cause

Incorrect tyre pressure.

Incorrect tyre size.

Different tyre or tread type.

Vehicle is unevenly or excessively loaded.


Damaged front or rear suspension components.

Steering gear valve effort out of balance.

Action

Adjust tyre pressure.

New tyre as required.

Adjust load evenly.

Adjust as required.

New suspension components.

Shift transmission into neutral while driving at no more than 30 miles/hour (50 km/h) and turn the ignition to position I (engine ‘Off’-coasting).

a. If the vehicle does not pull to one side with the engine off, install a new steering gear.

b. If the vehicle drifts with the engine off, ‘cross switch’ the front wheel assemblies.

Test at low speed due to directional tyres.

a. If the vehicle pulls to the opposite side, switch the wheels that were on the rear to the same side on the front.

Feedback (whining or knocking noises in the steering gear)

Condition where roughness is felt in the steering wheel by the driver when the vehicle is driven over rough surfaces.

Power steering pump or reservoir leaks

Check front and rear brakes for correct operation.

Check for bent rear suspension components and for damaged coil springs in the front suspension.

Check the rear suspension for loose or worn suspension components.

Incorrect underbody alignment.

Loose or worn tie-rods.

Steering gear bolts loose or damaged.

b. If the vehicle pull direction is not changed, check the front suspension components and toe adjustments.

Adjust as required.

New rear suspension components.

Tighten.

New components.

Check underbody alignment.

New steering gear.

Tighten.

New bolts.

Loose suspension bushing, bolts or ball joints. Tighten.

New components.

Damaged steering column.

New steering column.

Poor returnability of the steering

Overfilled system.

Damaged fluid cap.

Loose or damaged hose fittings.

Leakage at power steering pump.

Incorrect tyre pressure.

Incorrect tyre size or type.

Steering column universal joints binding.

Correct fluid level.

New fluid cap.

Tighten.

New hose.

New power steering pump.

Check and adjust tyre pressure.

New tyre as required.

New steering column.

Steering column shaft floor seal may be torn New floor seal as required.

Binding or damaged tie-rods.

New steering gear.

Damaged or worn front suspension components.


New front suspension components as required.

Adjust as required.




Symptom

Excessive steering efforts required to turn corners and during parking manoeuvres

Fluid leakage

Accessory drive belt squeal

‘Chirp’ noise in steering pump

Power steering pump noisy

Possible Cause

Low power steering pump fluid.

Damaged accessory drive belt tensioner.

Hose or oil cooler external leak.

Hose or cooler line restriction.

Fluid aeration.

Overfilled system.

Component leak.

Check accessory drive belt for correct tension or glazing.

Loose or worn accessory drive belt.

Low fluid level.

Power steering pump.

‘Swish’ noise

Action

Fill as required. Check for system leaks.

New accessory drive belt tensioner.

New hose or oil cooler as required.

New hose as required.

Bleed system.

Correct fluid level.

Locate suspect component and repair as required.

New accessory drive belt.

New accessory drive belt.

Top up and check for system leaks.

Check for leaks. Repair as required.

New power steering pump.

Normal noise.

‘Whine’ noise

Fluid flow into bypass valve of the power steering pump valve housing with fluid temperature below 54°C (130°F).

Aerated fluid.

Bleed system.

Specifications

Torque Figures

Description

Ball Joint (nut)

Track-Rod (lock nut)

Steering Rack to Subframe

Steering Rack Pipe Latch Plate

Intermediate Shaft Pinch Bolt

Nm.

70

70

115 lb / ft.

52

52

85

9-12 7-9

21-29 15.5-21.5

Maintenance

The specifications and adjustments for front and rear road wheel alignment are located in Suspension (Refer to ’Road


Wheel Bearing Inspection

1. Raise, support and make the vehicle safe.

2. Ensure the road wheel rotates freely and that the brake pads are sufficiently retracted, allowing free movement of the road wheel.

Have a colleague observe upper and lower ball joints for movement during the following check. This will ensure that the cause of any free play is correctly identified.

3. Firmly grasp the road wheel at top and bottom. Attempt to move the road wheel inward and outward while lifting the weight of the road wheel off the road wheel bearings.

4. If there is any excess movement in the wheel bearing, replace the bearing assembly.

5. Remove the safety stand and lower the vehicle.

Ball Joint Inspection

Prior to carrying out any inspection of ball joints, inspect the front wheel bearings.


2. Position a safety stand to support the suspension lower arm.

3. While an assistant pulls and pushes the bottom of the road wheel, check for any relative movement between the ball joint and the suspension lower arm. Any lateral movement indicates a worn or damaged lower ball joint. Install new components if required.

01-11-002




4. While an assistant pulls and pushes the top of the road wheel, observe the relative movement between the ball joint and the suspension upper arm. Any lateral movement indicates a worn or damaged upper ball joint.

Install new components as required.

5. Remove the safety stand and lower the vehicle.

Track-Rod Ends

Install image


Item

Track-Rod Ends Renew

Removal

Code

TBA


2. Remove the front road wheels.


4. Using service tool (Refer to ’204-523 (Ball Joint Splitter)’, page 20-1-3), remove the track rod-end from the vertical link.

Take care not to cut / damage the track rod end boot when using the ball joint splitter.

2. Install the track-rod end to the vertical link. Torque nut to 70 Nm .

70 Nm

70 Nm

01-11-008

Remove image

5. Loosen the track-rod end lock nut and remove the track-rod end.

Note the number of complete turns to remove the rod end from the track rod.

Installation

1. Install the track-rod end.

Install the rod end the same number of turns it took to remove.

3. Install the road wheel.

4. Lower the vehicle.

5. Check the vehicle Toe (Refer to ’Road Wheel Alignment

(04.00)’, page 4-1-2).

• If the vehicle Toe is within specifications - Tighten the track-rod end lock nut(s) ( 70 Nm.

)

• If the vehicle Toe is not within specifications - Raise the vehicle and adjust the vehicle Toe




Steering Rack


Item

Steering Rack Renew RHD

LHD

Code

11.02.DB

TBA

Removal


Caution

Failure to centre the steering wheel and rack during reassembly may cause damage to the restraint bag clock-spring and also may cause difficulties in attaining correct alignment of the steering wheel in the straight ahead position.

2. Secure the steering wheel in the centred position.

Remove the ignition key and engage the steering lock with the road wheel as accurately centred as possible.

3. Support the enginre from above (Refer to ’303-1080



5. Remove the front road wheels.


7. Disconnect the steering rack from the steering intermediate shaft (RH drive shown).

001-11-005

9.2 Remove the front subframe (Refer to ’Front

Subframe’, page 2-1-2).

9.3 Remove bolts (x3) that secure the steering rack to the subframe. Withdraw the steering rack.

10. LH Drive Only.

10.1 ‘Ty-wrap’ the steering rack in position. Remove bolts

(x3) that secure the steering rack to the subframe.

10.2 Remove the front subframe (Refer to ’Front

Subframe’, page 2-1-2).

10.3 Disconnect the power steering fluid pipes.

Caution

Whenever the steering gear unions are disconnected the steering gear valve body ports should be capped to prevent ingress of foreign objects.

10.4 Remove ‘Ty-wraps’ and withdraw the steering rack.

Installation

Always use new washer seals.

1. RH Drive Only.

1.1 Install the steering rack to the subframe (new nyloc bolts x3). Tighten bolts to 115 Nm .

01-11-004

8. Disconnect the L/H and R/H rod ends from the vertical link.

9. RH Drive Only.

9.1 Disconnect the power steering fluid pipes.

Caution

Whenever the steering gear unions are disconnected the steering gear valve body ports should be capped to prevent ingress of foreign objects.

11-1-6

115 Nm

Workshop Manual

011-11-006




1.2 Install the front subframe (Refer to ’Front Subframe’, page 2-1-2).

1.3 Connect the steering rack pipe work.

3. Install L/H and R/H rod ends to the vertical link.

70 Nm

9-12 Nm

01-11-009

2.

LH Drive Only.

2.1 ‘Ty-wrap the steering rack in position.

2.2 Connect the power steering fluid pipes.

2.3 Install the front subframe (Refer to ’Front Subframe’, page 2-1-2).

2.4 Install the steering rack to the subframe (new nyloc bolts x3). Tighten bolts to 115 Nm .

4. Recheck both the steering wheel and rack are accurately centred.

5. Install the steering rack to the steering intermediate shaft.

21-29 Nm

115 Nm

011-11-006

01-11-010


7. Fill and bleed the power steering system (Refer to

’System Bleeding’, page 11-2-2).

Warning

Do not drive the vehicle until the steering geometry has been set and all fixings have been secured.



9. Check and adjust front wheel alignment (Refer to ’Road







Power Steering (11.02)




The power steering system is hydraulically driven and contains a speed sensitive rack and pinion steering gear (ZF

Servotronic II ®). Power assistance is generated by an engine driven vane pump, operating at a constant flow rate.

The level of assistance is controlled electronically via an ECU, which receives a vehicle speed signal from the speedometer.

The signal is then converted to a controlled electric current, which is then transmitted to an electro-hydraulic transducer

(attached directly to the valve housing). This allows steering efforts to remain lighter at lower speeds to aid parking manoeuvres, whilst at higher speeds, efforts are increased, providing greater directional stability.

Hoses / pipes are used to transmit hydraulic fluid throughout the system. The high-pressure line contains a pressure transducer, which sends an electronic signal to the engine management system. This ensures engine rpm is maintained when the steering system draws higher loads from the engine (i.e. during parking manoeuvres). In order to regulate system temperatures, a wire-wound cooler is incorporated into the return line.

Description

Pressure Transducer

Power Steering

Module Assy

PAS Oil Reservoir

Power Steering Pump

Steering Rack

Cooling Loop

Track Rod Ends

01-11-014

The power steering system uses a rack and pinion type steering gear with servotronic steering assistance. The power steering pump is belt driven and the power steering oil cooler is of a wire bound tube type and is mounted in front of the radiator.

The steering assistance decreases smoothly at a calibrated rate to increase the steering efforts required as vehicle speed increases.

The steering efforts are controlled by the servotronic valve (actuator) position, which in turn is controlled electronically by the servotronic ECU housed in the instrument cluster.

Absolute cleanliness must be observed when replenishing the fluid or dismantling any part of the system. A new power steering reservoir must be installed if the steering gear, pump or fluid cooler is to be replaced. New fluid from a sealed container must be used.




Specifications

Item

Pump Pressure (max)

Turns lock-to-lock

Overall steering ratio

Turning Circle (Kerb

To Kerb)

Fluids

Capacity

Toe Settings

Data

116 +/-4 bar

3

17:1

11.5m

33270 Texaco Cold Climate Power

Steering Fluid 14315G

1.3 ltr.

(Refer to ’Road Wheel Alignment

(04.00)’, page 4-1-2)

Maintenance

System Bleeding

When filling the reservoir, make sure that the fluid is clean and not agitated prior to use. Pour the fluid slowly to minimize aeration.

1. Check that the reservoir level is well above the Min. mark. Add fluid if required and install the reservoir cap loosely to avoid fluid splashes during system bleeding.

2. Start the engine and run for several minutes. Check the returning fluid in reservoir. When the air bubbles cease to flow, top up the reservoir. Move to step 3.

3. Turn the steering hard over on one lock. Run the engine for several minutes. Check the returning fluid in reservoir. When the air bubbles cease to flow, top up the reservoir. Move to step 4.

4. Turn the steering hard over on opposite lock. Run the engine for several minutes. Check the returning fluid in the reservoir. When the air bubbles cease to flow, top up reservoir. Move to step 5.

5. Allow the engine to idle for 5 minutes with the road wheels in the straight ahead position.

6. Briefly turn the steering to one lock and then to the opposite lock. If no air sounds are heard, bleeding was successful.

If air noises are present, repeat the bleeding procedure.

7. Top-up the reservoir to the max. level and secure the reservoir cap.


Steering Column (11.04)




Description

The steering column lock is secured to the upper casting of the steering column and consists of a locking pin. The steering column is locked and unlocked by inserting and removing the ignition key respectively.

The steering column has rake and reach functions. These allow the driver to manually set the steering column position by using the rake / reach lever, located on the underside of the steering column, regardless of the ignition switch position.

The steering intermediate shaft consists of two parts. The lower shaft is attached to both the steering gear and the upper shaft.

4. Remove the steering column cowls.

To remove the rear lower screw unlatch the reach / rake lever and pull the steering column forward.

Specifications

Torque Figures

Description

Steering Column to mounting

U/J securing bolt

Nm.

lb / ft.

21-27 15.5-20

20-25 15-18.5

Maintenance

Steering Column

01-11-015


Item

Steering Column (Upper) Renew

Removal

Code

11.04.CB

1. Power the driver’s seat to it’s lowest and most rearward position.

2. Disconnect the vehicle battery at the negative terminal.

Ensure the ignition key is removed.

Warning

The restraint bag is equipped with a back-up power supply and may be inadvertently deployed. To avoid accidental restraint bag deployment, wait at least one minute before starting work so that any residual power is dissipated.

3. Remove the drivers side underscuttle panel.

Caution

Failure to centre steering wheel and rack may cause damage to restraint bag clock-spring and also may cause difficulties in attaining correct alignment of steering wheel in the straight ahead position.

5. Centre the steering and engage the steering column lock.

6. Pull back the bulkhead seal. Remove the pinch bolt that secures the upper column to the intermediate shaft.

Image to follow




7. Ensure that the vehicle battery is disconnected at the negative terminal and that the ignition key is removed.

Warning


8. Disarm and remove the air bag module (Refer to ’Driver

Airbag’, page 1-14-4).

9. Remove the steering wheel (Refer to ’Steering Wheel’, page 11-5-1).

10. Retain the clockspring rotor in position, i.e. masking tape.

11. Automatic Vehicles Only.

Remove the paddle shift assembly.


Installation

1. Install the upper column.

1.1 Connect the intermediate shaft to the upper column.

1.2 Locate the steering column to it’s mount. Install the mounting bracket bolts. Tighten bolts (x4) to 21 -27

Nm .

13. Remove the mounting securing bolts (x4).

21-27 Nm

01-11-019

01-11-020

2. Install the U/J securing bolt. Torque to 20-25 Nm . Install the bulkhead seal.

01-11-018

14. Withdraw the upper column from the intermediate shaft.

3. Install the steering column switch block (Refer to

’Column Controls’, page 11-4-1).


5. Remove the material holding the clockspring rotor in position.

6. Automatic Vehicles Only.

Install the paddle shift assembly. Connect the wiring harness plug.

7. Install the steering wheel (Refer to ’Steering Wheel’, page 11-5-1).

8. Install the air bag module (Refer to ’Driver Airbag’, page

1-14-4).

9. Install the steering column cowls.

10. Install the underscuttle.



Steering Column Switches (11.05)




Maintenance

Column Controls


Item

Steering Column Controls Renew

Removal

Code

TBA

5.


5.1 Remove screws (x4) and release the paddle shift.

5.2 Disconnect the wiring harness plug and remove paddle shift.

6. Disconnect the column switch wiring harness plugs.

Warning

DO NOT remove the restraint bag without first reading and fully understanding the warnings related to restraint bag removal. Follow step by step the procedure for disarming and removing the restraint bag.

1. Disconnect the vehicle battery at the earth (-ve) terminal and ensure the ignition key is removed.

Warning


2. Remove the restraint bag module (Refer to ’Driver


3. Remove the steering wheel (Refer to ’Steering Wheel’, page 11-5-1).

4. Remove the steering column cowls.

To remove the rear lower screw unlatch the reach / rake lever and pull the steering column forward.

01 11 019

7. Unclip the column controls from the steering column and remove.

Installation

1. Install the column controls.

1.1 Clip the column controls to the steering column.

1.2 Connect the wiring harness plugs.


Connect the wiring harness plug and install the paddle shift.

3. Install the restraint bag module (Refer to ’Driver Airbag’, page 1-14-4).

4. Install the steering column cowls.

Warning

DO NOT install the restraint bag without first reading and fully understanding the warnings related to restraint bag removal. Follow the step by step procedure for refitting the restraint bag.

5. Install and re-arm the restraint bag (Refer to ’Driver


6. Install the steering wheel (Refer to ’Steering Wheel’, page 11-5-1).


01-11-015





Steering Wheel (11.06)




Specifications

Torque Figures

Description

Steering Wheel

Maintenance

Steering Wheel

Nm.

40 lb / ft.

30

Installation

1. Install steering wheel.

1.1 Ensure that the steering is in the straight ahead position.

1.2 Align the steering wheel spokes in the straight ahead position.

1.3 Align the steering wheel and column marks correctly and install the steering wheel to the steering column

1.4 Check that the steering wheel rotation is accurately centred when the road wheels are in the straight ahead position.

1.5 Install and tighten the securing bolt. Torque bolt to

40 Nm .


Item

Steering Wheel Renew

Removal

Code

11.06.AB

Warning

DO NOT remove the restraint bag without first reading and fully understanding the warnings related to restraint bag removal. Follow step by step the procedure for disarming and removing the restraint bag.

1. Disconnect the vehicle battery at the earth (-ve) terminal and ensure the ignition key is removed.

Warning


2. Remove the restraint bag module (Refer to ’Driver


3. Place the steering in the straight ahead position.

Caution

Do not use steering lock to hold wheel whilst releasing securing nut. Steering lock may be irreparably damaged.

4. Undo and remove the steering wheel securing nut.

40 Nm

01-11-012

2. Install the restraint bag (Refer to ’Driver Airbag’, page 1-

14-4).

01-11-000

5. Place marks on the steering wheel and column to indicate the correct spline alignment. Pull the steering wheel from the steering column splines.






Contents

Body Ventilation (12.01).....................................12-1-2

Air Intake & Distribution System............................ 1-2

Maintenance........................................................... 1-3

Actuators ............................................................... 1-3

Removal.............................................................. 1-3

Install.................................................................. 1-3

Air Intake Actuator................................................. 1-3

Inspection........................................................... 1-3

Air Mix Actuator .................................................... 1-4

Inspection........................................................... 1-4

LHD.................................................................... 1-4

RHD ................................................................... 1-4

Airflow Mode Actuator........................................... 1-4

Inspection........................................................... 1-4

Heater System (12.02) ........................................12-2-1

Maintenance........................................................... 2-1

Blower Motor ........................................................ 2-1

Removal.............................................................. 2-1

Installation .......................................................... 2-1

Inspection........................................................... 2-1

Air Conditioning (A/C) System (12.03) ...............12-3-1

Major Components................................................. 3-1

Compressor ........................................................ 3-1

Receiver drier ...................................................... 3-1

Condenser .......................................................... 3-1

Trinary switch...................................................... 3-1

Expansion Valve................................................... 3-2

A/C Unit ............................................................. 3-2

Refrigerant System.................................................. 3-3

Handling Refrigerant .............................................. 3-3

Storing Refrigerant ................................................. 3-3

Handling Insufficient Refrigerant Level ................... 3-3

Handling Compressor Oil....................................... 3-3

Refrigeration Cycle................................................. 3-3

Operation ........................................................... 3-4

Specifications.......................................................... 3-4

Refrigerant and Lubricant....................................... 3-4

Capacities .............................................................. 3-4

Torque Figures....................................................... 3-4

Diagnostics ............................................................. 3-5

Electrical Connectors.............................................. 3-5

DTC Inspection...................................................... 3-6

Using WDS ......................................................... 3-6

DTC Fault Codes ................................................. 3-6

Maintenance........................................................... 3-8

Connections .......................................................... 3-8

Recovery ............................................................... 3-8

Evacuation............................................................. 3-8

Charging................................................................ 3-8

A/C System Testing ................................................ 3-9

Pressure Check.................................................... 3-9

Performance Test ................................................ 3-9

Vacuum Check.................................................... 3-9

Leaks ................................................................... 3-10

Leak Detection.................................................. 3-10

System Pressure Fault Classification...................... 3-10

A/C Unit .............................................................. 3-11

Removal............................................................ 3-11

Installation........................................................ 3-12

Heater Matrix ...................................................... 3-12

Remove ............................................................ 3-12

Installation........................................................ 3-13

Evaporator ........................................................... 3-14

Removal............................................................ 3-14

Installation........................................................ 3-15

A/C Compressor................................................... 3-15

Removal............................................................ 3-15

Installation........................................................ 3-16

Condenser........................................................... 3-17

Removal............................................................ 3-17

Installation........................................................ 3-17

Receiver Drier Assembly ...................................... 3-18

Removal............................................................ 3-18

Installation........................................................ 3-18

Power Transistor .................................................. 3-18

Inspection......................................................... 3-18

Removal............................................................ 3-18

Installation........................................................ 3-19

Evaporator Temperature Sensor ........................... 3-19

Inspection......................................................... 3-19

Removal............................................................ 3-19

Installation........................................................ 3-19

Trinary Switch...................................................... 3-20

Removal............................................................ 3-20

Installation........................................................ 3-20

Expansion Valve................................................... 3-20

Removal............................................................ 3-20

Installation........................................................ 3-21

Troubleshooting ................................................... 3-22


Body Ventilation system (12.01)



Body Ventilation (12.01)

Air Intake & Distribution System

Outside air enters the plenum via inlets at the base of the windscreen.

Fresh mode - Air is drawn in through the plenum and into the blower unit. From the blower unit air enters the A/C unit where it is cooled and dehumidified as it passes through the evaporator. It is then ‘reheated’ to the selected temperature as it passes through the heater matrix,.

Air flows from the cabin into the boot via air vent grilles and through apertures in the rear parcel shelf. The air is exhausted from the vehicle through extraction vent assemblies (incorporating one way flaps) in the lower part of the rear bumpers, concealed by the bumper trim.

Recirculation mode - The air in the passenger compartment is drawn into the A/C system via the recirculation air inlets on the blower unit.

2

3

4

1

6

5

Item Description

1.

Air Intake

2.

Windscreen air outlets

3.

Defrost/Demist Ducting


4.

5.

6.

Cabin Distribution Box

Cabin air vents

Side window air outlets

The A/C unit is linked and sealed to the defrost / demisting and cabin air ducting assemblies. The A/C unit incorporates two actuator operated flaps which regulate airflow to the selected air flow mode and temperature blend.

The centre vent duct incorporates a baffle plate which balances the volume of airflow of the centre and end of dash vents.




Maintenance

Actuators


Item

Actuators Renew

Code

TBA

The A/C and blower unit assembly uses three actuators

• Blower unit

1 Air intake actuator

• A/C unit

2 Air mode actuator

3 Air mix actuator

The lower actuator on the A/C unit requires to be firstly removed from the A/C unit.

1

2

1

3

2

1

2

1

2

The removal procedure is the same for all three actuators.

To remove the blower unit actuator remove the A/C unit from the IP (Refer to ’A/C Unit’, page 12-3-11).

Removal

1. Remove the IP from the vehicle (Refer to ’Instrument

Panel (IP) (01.12)’, page 1-9-1).

To gain access to the Air mode and Air mix actuators remove the A/C control module (screws x3).

2. Disconnect the actuator control rod.

3. Remove the wiring harness plugs and the screws (x3).

Withdraw the actuator.

Install

1. Install the actuator (screws x3). Connect the wiring harness plug.

2. Connect the actuator control rod.

3. Install the A/C control module. Conect the wiring harness plug.

4. If removed, install the A/C unit to the IP (Refer to ’’, page 12-3-10).

5. Install the IP to the vehicle (Refer to ’Instrument Panel

(IP) (01.12)’, page 1-9-1).

Air Intake Actuator

Inspection

1. Connect the battery positive voltage to Intake Actuator terminal 1 (or 3), and ground to terminal 3 (or 1).

2. Verify that the Air Intake Actuator operates as shown.

If the operation condition is not normal, replace the Air

Intake Actuator.

Terminal (C0149) Air Intake Actuator Operation

1 3

Ground B+

B+

Fresh > Recirculate

Ground Recirculate > Fresh




Air Mix Actuator

Inspection

Airflow Mode Actuator

Inspection

1. Connect the battery positive voltage to Air Mix Actuator terminal 6 (or 7), and ground to terminal 7 (or 6). Verify that the Air Mix Actuator operates as shown.

1. Connect the battery positive voltage to the Airflow

Mode Actuator terminal 6 (or 7), and ground to terminal

7 (or 6). Verify that the Airflow Mode Actuator operates as shown.

If the operation condition is not normal, replace the Air Mix

Actuator.

If the operation condition is not normal, replace the Airflow

Mode Actuator.

Terminal (C2130) Air Intake Actuator Operation

1 3

B+ Ground Cold - Hot (LHD)

Hot - Cold (RHD)

Ground B+ Hot - Cold (LHD)

Cold - Hot (RHD)

Terminal

6

B+

7

Ground Defroster - Vent

Ground B+

Airflow Mode Actuator operation

Vent - Defroster

2. Check that the resistance between terminals 3 and 5, and 1 and 5 matches the Air Mix Actuator operation as shown in the graph below.

If the operation condition and resistance are not normal, replace the Air Mix Actuator.

2. Verify that the resistance between terminals 1 and 5, and 3 and 5 matches the Airflow Mode Actuator operation as shown in the graph below.

If the operation condition and resistance are not normal, replace the Airflow Mode Actuator.

VENT

90°

MAX COLD

C0413

7 6 5

*

3

*

1

90°

MAX HOT

7°

C2130

7 6 5

*

3

*

1

32°

DEFROSTER

DEFROSTER VENT

L.H.D.

MAX COLD MAX HOT

R.H.D.

MAX HOT MAX COLD

3 5 1 6 7 3 5 1 6 7

3 5 1

KILOHM

4.7

BETWEEN 3-5

TERMINALS WIRE

6 7

BETWEEN 1-5

TERMINALS WIRE

LHD

1.2

VENT DEFROSTER VENT DEFROSTER

AIRFLOW MODE ACTUATOR POSITION

RHD

KILOHM

5.9

BETWEEN 2-5

TERMINALS WIRE

BETWEEN 1-5

TERMINALS WIRE

2.6

MAX

HOT

MAX

COLD

MAX

HOT

AIR MIX ACTUATOR POSITION

MAX

COLD


Heater System (12.02)



Maintenance

Blower Motor


Item

Blower Motor Renew

Removal



Code

12.02.BB

Inspection

1. Connect the battery positive voltage to blower motor terminal 1, ground to terminal 2, and then verify that the blower motor operates smoothly.

2. If the operation condition is not normal, replace the blower motor.

3. Remove screws (x3). Withdraw the blower motor.

Installation

1. Install the blower motor to the blower unit body.

2. Install bolts (x3). Connect the wiring harness plugs.





Air Conditioning (A/C) System (12.03)




1.

Condenser

2.

3.

4.

Trinary switch

Compressor assembly

High-side charge port

5.

Receiver drier.

Major Components

Compressor


6.

Low-side charge.

7.

8.

Blower Unit.

Switch, A/C Cut-Off.

9.

10.

Expansion valve.

A/C Unit.

Condenser

• Multi-pass fin-over-tube type, mounted in front of the engine cooling pack and directly to the radiator

• Engine mounted, driven by the accessory drive belt

• Variable displacement type

• High-pressure relief valve, to avoid system over-pressure

• ECU controlled clutch energised via a relay

Receiver drier

Trinary switch

Located in the compressor discharge pipe

• Vertically mounted on the right-hand side of the engine bay

• The high-side charge port is installed to the high side entry pipe to the receiver drier

• Provides a signal, via the A/C module, to the PCM, to disengage the compressor clutch should the refrigerant pressure be less than 2 bar or greater than 30 bar

• Provides a hard-wired signal to the PCM, to switch the cooling fans to HIGH speed at 22 bar rising pressure and to LOW speed at 17,5 bar falling pressure

• Provides a hard-wired signal to the PCM, to switch the radiator cooling fans to LOW speed at 12 bar rising pressure and to switch the fans OFF at 8 bar falling pressure




Expansion Valve

The expansion valve is located on the outside of the A/C unit and comprises of a diaphragm, connected by a capillary tube to a temperature sensing bulb, which regulates the valve according to temperature variations at the evaporator outlet pipe. This component is not serviceable.

A/C Unit

12-3-2

The A/C unit houses the evaporator, heater matrix and air flow flaps.

The unit also incorporates two servo motor operated air distribution flaps.

1. Regulates airflow to the cabin vents.

2. Regulates airflow to the defrost / demist air ducting.

When the cabin air flap is open, air is ducted to the cabin via face and foot level air vents.

Condensate (water) which forms on the evaporator fins is drained out of the unit case through a drain hose, located at underneath / rear of the evaporator.




Refrigerant System

Handling Refrigerant

Warning

Avoid breathing A/C refrigerant or lubricant vapor.

Exposure may irritate eyes, nose and throat. Also, due to environmental concerns, Aston Martin recommend the use of a recovery / recycling / recharging unit when draining R-134a from the A/C system.

If accidental A/C system discharge occurs, ventilate work area before resuming service.

Warning

Do not perform a pressure test or leak test for R-134a service equipment and or vehicle A/C using compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures.

These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

Warning

Do not allow refrigerant to leak near a fire or any kind of heat. A poisonous gas may be generated if refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause refrigerant leakage, extinguish or remove the above mentioned heat sources and maintain adequate ventilation.

Warning

Handling liquid refrigerant is dangerous. A drop of refrigerant on the skin can result in localized frostbite.

When handling refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor.

Storing Refrigerant

Warning

The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seriously injure personnel. Store refrigerant at temperatures below 40 o C (104 o F).

Handling Insufficient Refrigerant Level

Caution

If an insufficient refrigerant level is detected while troubleshooting, do not charge (add) the refrigerant.

Because an accurate amount of refrigerant cannot be determined from the pressure indicated on the recovery / recycling / recharging unit, never charge the refrigerant.

Caution

If there is too much or too little refrigerant from the refilling, there may be secondary problems such as damage to the refrigerant cycle parts, or a decrease of cooling performance. Therefore, if it is determined that the refrigerant level is insufficient, completely remove refrigerant from the refrigerant cycle and refill with refrigerant to the specified amount.

Handling Compressor Oil

Caution

Use only ND8 compressor oil for this vehicle. Using a

PAG oil other than DENSO OIL8 compressor oil can damage the A/C compressor.

Caution

Do not spill the ND8 compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can damage the paint work. If oil gets on the vehicle, wipe it off immediately.

Caution

ND8 compressor oil has a high moisture absorption efficiency. If moisture mixes with the compressor oil, the refrigerant system could be damaged. Ensure caps are installed immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption.

Refrigeration Cycle

3

2 High Pressure Hot Vapour

High Pressure Cool Liquid

Low Pressure Cold Vapour

Low Pressure Hot Vapour

6

1

4

1.

2.

3.

4.

5.

6.

Compressor

Condenser

Receiver Drier

Expansion Valve

Evaporator

Trinary Switch

5

036-8-019




Operation

1. The Compressor (1) draws low pressure, low temperature, refrigerant vapour from the evaporator (5) and compresses it, raising the refrigerant pressure and temperature.

2. This high pressure, hot, refrigerant vapour enters the condenser (2), where it is cooled by the flow of ambient air and changes state into a cooler, high pressure liquid.

3. From the condenser, the liquid passes into the receiver drier (3) which has three functions:

• Removes moisture from the refrigerant using a desiccant

• Filters the refrigerant to remove system contaminants

• Stores the refrigerant to cope with varying system refrigerant demands

4. The filtered liquid refrigerant, still at high pressure, then enters the expansion valve (4). Here it passes through a controlled orifice and emerges as an atomised liquid spray. This has the effect of reducing the refrigerant pressure and temperature. The cold refrigerant spray now flows into the evaporator (5).

5. As refrigerant passes through the evaporator core, it cools the incoming airflow. Heat is absorbed by the refrigerant, during this process and it once again changes state, from an atomised cool liquid into a vapour. The refrigerant vapour then returns to the compressor for the cycle to be repeated.

An automatic safety valve is incorporated in the compressor, which will open if the system pressure rises above 41 bar.

The valve will reseat when the pressure drops below 27,6 bar. When the safety valve is open, the compressor will 'free wheel' and the excess pressure will be dissipated through the expansion valve. When the pressure drops below 27.6 bar, the safety valve will close again and the compressor will be operative.

Specifications

Refrigerant and Lubricant

Refrigerant R-134a

Compressor Lubricant ND8 (DENSO)

Capacities

Refrigerant charge Weight 850g (30 oz.)

Compressor Lubricant Sealed volume (approx. quantity) 150 cc (pre-charged)

Torque Figures

Torque Figures

Description

AC unit Mounitng

Compressor Mounting

Trinary switch

A/C pipes to condenser

Nm.

lb. / ft.

20-25 15-18.5

23-27 17-20

8-10 6-7.5

The terms ‘high’ and ‘low’ pressure (or side) refer to the pressure differential between the compressor and expansion valve ports. This differential is critical to system fault diagnosis and efficiency checks.

The high side starts at the compressor and includes the trinary switch, condenser, receiver drier and expansion valve.

The low side starts at the expansion valve outlet and includes the evaporator and all connections back to the compressor.

The trinary switch (6) monitors system pressure between the compressor and condenser. If the pressure rises above 30 bar or falls below 2 bar the compressor clutch is de-energised to prevent damage to system components.




Diagnostics

Electrical Connectors


A/C Module (C0792)

Pin Specification

1 V Battery (from CCM)

2 V Ignition (from comfort relay)

Recirculation acutuator

3 Blank

4 Air flow mode actuator (input)

5 Solar sensor (input)

6 Ambient Temperature sensor

7 Engine coolant temperature (input)

8 Ref. voltage - Solar sensor (output)

Ref. voltage - Temperature actuator (output)

Ref. voltage - Air flow mode actuator (output)

9 Blank

10 Blank

11 Blank

12 Temperature actuator (input)

13 Evaporation sensor (input)

14 In-vehicle temperature sensor (input)

15 Ground

16 Sensor ground (In-vehicle, Evaporator, Air flow mode actuator, Temperature mode actuator)




144

250

260

270

280

355

366

377

DTC

10

20

30

40

111

122

133

5

6

3

4

1

2

A/C Module (C0791)

Pin Specification

Air flow mode actuator (output)

Temperature actuator (output)

Blank

Blank

Blank

A/C On (A/C pressure sensor)

7

8

Blank

Recirculation actuator (output)

9 Blank

10 Blank

11 Temperature level (RHD)

12 Blower speed regulator (Output)

13 Air flow mode actuator (output)

14 Temperature actuator (output)

15 Blank

16 Output

17 HAVAC ECU (input)

18 Blank

19 Blower relay (engine bay fusebox)

20 Recirculation actuator (output)

21 Blank

22 blank

23 Temperature level (LHD)

24 Blower speed regulator input)

DTC Inspection

Using WDS

1. Connect the WDS to the body diagnostic socket (Refer to ’Appendix & Glossary’, page 20-1-2).

2. Select ‘Air-Con’ from the menu.

3. Read the fault codes from the WDS screen.

DTC Fault Codes

Fault Code Definition

Switchpack 1 disconnected.

Switchpack 2 disconnected.

Analogue digital converter 100us timeout.

Serial transmit 10ms timeout.

Temperature control - short circuit to ground on A.

Temperature control - short circuit to 5 volts on A.

Temperature control - short circuit to ground on B.

Temperature control - short circuit to 5 volts on B.

Temperature – bad pair.

Mode control - short circuit to ground.

Mode control - short circuit to 5 volts.

Fan control - short circuit to ground.

Fan control – short circuit to 5 volts.

Bad response data - temperature.

Bad response data - mode.




799

880

881

882

883

884

885

886

791

792

793

794

795

796

797

798

887

888

889

567

578

589

613

624

635

646

790

DTC

388

412

423

434

445

556

Fault Code Definition

Bad response data - fan speed.

Bad response data - recirculation.

Serial communications error – header.

Serial communications error – checksum.

Serial communications error – overrun.

Serial communications error – framing.

Serial communications error – parity.

Electrically erasable programmable read only memory - command 120ms timeout.

Electrically erasable programmable read only memory - access error.

Electrically erasable programmable read only memory - protection error.

Electrically erasable programmable read only memory - not blank on verification.

Dynamic stability control 10 second timeout.

Temperature forced to default.

Blower speed forced to default.

Mode forced to default.

Power switch output - short circuit.

Electrically erasable programmable read only memory - command not ready.

Heating ventilating air conditioning control module – in car sensor - current fault.

Heating ventilating air conditioning control module – in car sensor - past fault.

Heating ventilating air conditioning control module – external air sensor - current fault.

Heating ventilating air conditioning control module – external air sensor - past fault.

Heating ventilating air conditioning control module – post evaporator sensor - current fault.

Heating ventilating air conditioning control module – post evaporator sensor - past fault.

Heating ventilating air conditioning control module – coolant temperature sensor - current fault.

Heating ventilating air conditioning control module – coolant temperature sensor - past fault.

Heating ventilating air conditioning control module – solar radiation sensor - current fault.

Heating ventilating air conditioning control module – air mix actuator cool/hot - current fault.

Heating ventilating air conditioning control module – air mix actuator cool/hot - past fault.

Heating ventilating air conditioning control module – mode actuator face/defrost - current fault.

Heating ventilating air conditioning control module – mode actuator face/defrost - past fault.

Heating ventilating air conditioning control module – air mix actuator fail.

Heating ventilating air conditioning control module – mode actuator fail.

Electrically erasable programmable read only memory - data checksum error.




Maintenance

Assessment of the A/C system operating efficiency and fault classification may be achieved by using the facilities on a

Recovery / Recycling / Recharging unit.

Follow the manufacturer's instructions implicitly and observe all safety considerations.

Connections

Only use hoses with connectors which are dedicated to

HFC 134a charge ports.

Warning

Under no circumstances should connections be made with the A/C system in operation or valves open.

Should valves be open and a vacuum pump or refrigerant container attached, an explosion could occur as a result of high pressure refrigerant being forced back into the vacuum pump or container.

Recovery

Warning

Handling liquid refrigerant is dangerous. A drop of refrigerant on the skin can result in localized frostbite.

When handling refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor.

Caution

Do not attempt to adapt this unit for R-12 as an A/C system failure will result. Recovery / Recycle /

Recharging equipment has special connections to avoid cross contamination with R-12 systems.

The A/C unit’s overfill limitation mechanism has been calibrated specifically for use with the 50 lb. (23 Kg) refillable refrigerant tank.

Run the A/C system for a few minutes before starting the recovery procedure as this will enable more refrigerant to be recovered. Turn the A/C system off before starting the procedure.

Ensure the A/C system has pressure in it before beginning the recovery process; if there is no system pressure there is no refrigerant to recover.

Ensure that the oil drain valve is closed.

Read manufacture’s instructions and warnings before completing any recovery / evacuating and charging operations.

Caution

The Recovery / Recycling / Recharging unit relies on a weighing mechanism to weight the quantity of oil removed. Ensure that the Recovery / Recycle /

Recharging unit is not disturbed during the recovery procedure.

1. Connect an R-134a Recovery / Recycling / Recharging unit to the vehicle A/C system.

2. Follow the Recovery / Recycling / Recharging unit manufacturer’s instructions to evacuate the A/C system.

Compressor oil may be drawn out during this process, take note of the quantity recovered so that it may be replaced.

Evacuation

The removal of unwanted air and moisture, is critical to the correct operation of the A/C system. Moisture in the system can be highly destructive and may cause internal blockages due to freezing; water suspended in the lubricating oil will damage the compressor. Once the A/C system has been dismantled, or the refrigerant charge recovered, all traces of moisture must be removed before charging.

It is recommended that initially only the high-side valve be opened at the start of the procedure. After a short time a small depression should be seen on the low-side, at which point the low-side valve may be opened and the evacuation process completed. If a vacuum is not registered on the low-side, it may indicate that the expansion valve is permanently closed or that the system is blocked. This simple check may save time and effort when the system is recharged.

Read manufacture’s instructions and warnings before completing any Recovery / Recycling / Recharging operation.


2. Follow the Recovery / Recycling / Recharging unit manufacturer’s instructions to evacuate the A/C system.

Charging

Caution

Do not exceed the specification when charging the A/C system with refrigerant. Doing so will decrease the efficiency of the A/C unit or damage the refrigeration cycle parts.

Caution

Always start the charging of refrigerant from the highpressure side. If charging starts from the low-pressure side, vanes of the A/C compressor will not be released and abnormal noise may result.

Read manufacture’s instructions and warnings before completing any Recovery / Recycling / Recharging operation.


2. Follow the Recovery / Recycling / Recharging unit manufacturer’s instructions to charge the A/C system.




A/C System Testing

It is recommended that a free standing air mover is placed in front of the condenser / cooling system.

Pressure Check

7. Close all the doors and windows.

8. Wait until the A/C output temperature stabilizes.

Stabilized condition.

The A/C compressor repeatedly turns on and off at regular intervals.

1. Connect the Recovery / Recycling / Recharging unit.

2. Start the engine. Allow to warm up then run at a constant 1,500 rpm.

3. Set the following A/C controls:

• Air Circulation to ‘Recirculate’

• Temperature to ‘Max’ Cold

• Air Flow to ‘Vent’

4. Close all the vehicle doors and windows.

5. Measure the ambient temperature and high / low pressure side reading of Recovery / Recycling /

Recharging unit gauges.

6. Verify that the intersection of the pressure reading of the

Recovery / Recycling / Recharging unit gauges and the ambient temperature is in the shaded zone.

9. After the blower air is stabilized, read the dry-bulb thermometer.

10. Verify the ambient temperature.

11. Verify the temperature is in the shaded zone.

12 {54}

10 {50}

8 {46}

6 {43}

4 {39}

2 {36}

2.0

{20, 284}

1.5

{15, 213}

1.0

{10, 142}

0.5

{5.1, 73}

0.2

{2.0, 28}

0.15

{1.5, 22}

0.1

{1.0, 14}

0.05

{0.5, 7.3}

HIGH-PRESSURE SIDE

LOW-PRESSURE SIDE

10

{50}

15

{59}

20

{68}

25

{77}

30

{86}

AMBIENT TEMPERATURE

°C {°F}

35

{95}

If there is any fault, inspect the refrigerant system according to the troubleshooting chart.

Performance Test

1. Check the refrigerant pressure.

2. Place a dry-bulb thermometer in the driver-side center ventilator outlet.

3. Start the engine. Allow to warm up then run at a constant 1,500 rpm.

4. Set the A/C unit fan speed to ‘Max Hi’.

5. Turn the A/C system on.

6. Set the following A/C controls:

• Air Circulation to ‘Recirculate’

• Temperature to ‘Max’ Cold

• Air Flow to ‘Vent’

10

{50}

15

{59}

20

{68}

25

{77}

30

{86}

AMBIENT TEMPERATURE

°C (°F)

35

{95}

40

{104}

40

{104}

If there is any fault, inspect the refrigerant system according to the troubleshooting chart.

Vacuum Check

1. Stop the vacuum pump, note the high and low pressure side readings of the Recovery / Recycling / Recharging unit gauges and wait for 5 min.

2. Check the high and low pressure side readings of the

Recovery / Recycling / Recharging unit gauges.

1 If the readings have changed, inspect for leaks and go to Evacuation (Refer to ’Evacuation’, page 12-3-8).

2 If the readings have not changed, go to Charging

(Refer to ’Charging’, page 12-3-8).




Leaks

Faults associated with low refrigerant charge weight and low pressure may be caused by leakage. Leaks traced to mechanical connections may be caused by torque relaxation or joint face contamination. Evidence of oil around such areas is an indicator of leakage.

Leak Detection

Fluorescent Tracer Dye - A fluorescent tracer dye is incorporated into the refrigeration system and can be checked for non-apparent leaks by scanning with a high intensity ultraviolet lamp. The location of leaks can be pinpointed by the bright yellow glow of the tracer dye.

Caution

Observe ALL safety precautions associated with ultraviolet equipment.

Automatic Refrigerant Leak Detector - (various manufacturers) Hand-held, portable, battery operated leak detector.

Place in and around A/C system to detect refrigerant leaks.

System Pressure Fault Classification

If erratic or unusual gauge movements occur, check the equipment against known Recovery / Recycling / Recharging unit gauges.

This table should be used in conjunction with the graphical representations of 'High side' pressure / ambient temperature and 'Low side' pressure / evaporator temperature.

Low side gauge reading

High side gauge reading

Normal Normal

Normal to low Normal

Low

Low

Low

Low

Low

Low

Low

High

High

High

Low

Low

High

High

Fault

Discharge air initially cool then warms up Moisture in system

As above As above

Discharge air slightly cool

Discharge air warm

Discharge air slightly cool or frost build up at expansion valve

Discharge air slightly cool, sweating or frost after point of restriction

Compressor noisy

Discharge air warm and high side pipes hot

Discharge air warm

Sweating or frost at evaporator

Cause

Refrigerant charge low

Refrigerant charge very low

Expansion valve stuck closed

Restriction in High side of system

Defective compressor reed valve

Refrigerant charge high or inefficient condenser cooling due to air flow blockage or engine cooling fans not working

Expansion valve stuck open




A/C Unit


Item

A/C Unit Renew

Code

12.03.EB

Removal

1. Connect the WDS and record any logged fault codes in the A/C system.


3. Recover the refrigerant from the A/C system

(Refer to ’Recovery’, page 12-3-8).


5. Remove the IP (Refer to ’Instrument Panel (IP) (01.12)’, page 1-9-1).

6. Remove the blower unit.

6.1 Disconnect the wiring harness plugs (x2).

6.2 Remove bolts (x3). Withdraw the blower unit.



8. Remove bolt (x1) and nuts (x2). Withdraw the A/C unit.

Image to Follow




9. Unlatch the A/C unit from the defrost air duct (Push the

A/C unit up into the IP). Withdraw the A/C unit.

5. Remove the IP (Refer to ’Instrument Panel (IP) (01.12)’, page 1-9-1).

6. Remove the blower unit assembly.

6.1 Disconnect the wiring harness plug (x1).

6.2 Remove bolts (x3). Withdraw the blower unit.

Installation

1. Install the A/C unit to the IP. Torque bolts to 5.5 Nm .

Ensure the A/C unit interlocks with the defrost duct.

2. Install the blower unit to the IP. Torque bolts to 5.5 Nm .


• (x3) to the A/C unit

• (x2) to the blower unit

4. Install the IP (Refer to ’Instrument Panel (IP) (01.12)’, page 1-9-1).

5. Recharge the A/C system (Refer to ’Charging’, page 12-

3-8).

6. Fill the engine coolant system (Refer to ’Cooling System

(03.03)’, page 3-4-1).


8. Start the engine. Allow the cooling system to come to normal operating temperature.

9. Carry out A/C system actuator check and functional check to ensure correct operation (Refer to ’A/C System

Testing’, page 12-3-9).

Heater Matrix


Item

Heater Matrix Renew

Remove

Code

12.02.CB

1. Connect the WDS and record any logged fault codes in the A/C system (Refer to ’Appendix & Glossary’, page

20-1-2).


3. Recover the refrigerant from the A/C system

(Refer to ’Recovery’, page 12-3-8).

4. Drain the engine coolant (Refer to ’Cooling System

(03.03)’, page 3-4-1).




7. Remove the blower unit to A/C unit adaptor and pipe locator.

7.1 Remove the foam.

8. Remove the pipe clips (x2) that secure the heater pipes.

7.2 Remove the pipe location plate (screws x4). Part the pipe location plate and withdraw.

9. Withdraw the heater matrix.

Note the orientation of the two rubber grommets.

Installation

1. Install the heater matrix into the A/C unit. Ensure the heater matrix is pushed fully in.

2. Install the pipe clips.

3. Install the blower unit to A/C unit adaptor and pipe locator.

Ensure that the two rubber grommets are located correctly.

4. Install the foam aorund the pipes

7.3 Remove the adaptor (screws x2), clip (x1) and disconnect one plastic locator.




5. Install the blower unit. Torque bolts to 10-13 Nm .


7. Recharge the A/C system (Refer to ’Charging’, page 12-

3-8).

8. Fill the engine coolant system (Refer to ’Cooling System

(03.03)’, page 3-4-1).


10. Start the engine. Allow the cooling system to come to normal operating temperature.



5. Remove the expansion valve

5.1 Remove protective material from around the expansion valve.

5.2 Remove screws (x2). Remove the A/C pipes clamp.

Evaporator


Item

Evaporator Renew

Removal

Code

12.03.CB

1. Remove the A/C unit (Refer to ’A/C Unit’, page 12-3-

11).

2. Move the in-vehicle temperature pipe to one side.

3. With a sharp knife cut the filter gauze and foam where the two halves of the A/C unit meet.

5.3 Withdraw the A/C pipes.

4. Remove clip (x1) and screws (x9) that secure the two halves of the A/C unit. Part the two halves of the A/C unit.

5.4 Withdraw the expansion valve. Discard ‘O’ rings.


6. Remove the clips (x2) that secure the evaporator temperature sensor element to the evaporator.



A/C Compressor


Item

A/C Compressor Renew

Code

12.03.AB

Removal


2. Recover the refrigerant from the A/C system (Refer to

’Recovery’, page 12-3-8).

3. Remove the road wheel and road wheel arch liner (for access to the A/C compressor securing bolts).

7. Withdraw the evaporator.

4. Remove the accessory drive belt (Refer to ’Accessory

Drive System (03.05)’, page 3-6-1).


Installation

1. Insert the evaporator (inlet / outlet first) into the half of the A/C unit which houses the expansion valve.

2. Complete with new ‘O’ rings, install the expansion valve.

3. Complete with new ‘O’ rings, install the A/C pipes clamp (screws x2).

4. Install the clips (x2) that secure the evaporator temperature sensor element to the evaporator.

5. Place the two halves of the A/C unit together.

Take care to correctly locate the vent flaps.

6. Install clip (x1) and screws (x9) that secure the two halves of the A/C unit.

7. Connect (glue) the filter gauze and foam where the two halves of the A/C unit meet.

8. Install the in-vehicle temperature pipe to the A/C unit clips.

9. Install the A/C unit to the IP (Refer to ’A/C Unit’, page

12-3-11).







6. Remove the A/C pipes. Discard the O-rings.

Install suitable blanking plugs.

Installation

If replacing a faulty A/C compressor with internal mechanical damage, also replace the receiver drier which could also be contaminated with mechanical debris.

1. Fill the new A/C compressor with the correct amount of oil.

1.1 Remove the blanking plugs from the A/C compressor.

1.2 Fill the A/C compressor with same amount of oil that was recovered from the original A/C compressor, plus the amount recovered from the recovery equipment.

1.3 Install the blanking plugs to the A/C compressor.

2. Install the A/C compressor. Torque bolts (x4) to 23-27

Nm .

7. Remove bolts (x3) and withdraw the A/C compressor.

3. Install both A/C pipes. Use new O-rings. Torque bolts

(x2) to 10-13 Nm .

8. Measure the amount of oil held in the A/C compressor.

This step is not necessary in the case of refrigerant loss.

8.1 Pour oil from the old A/C compressor into a suitable measuring container. Note the amount and discard oil.

8.2 Install blanking plugs to the old A/C compressor.

8.3 Note the volume of oil recovered with the refrigerant.





5. Install the accessory drive belt (Refer to ’Accessory Drive

System (03.05)’, page 3-6-1).


Air

Conditioning

Compressor

036-8-022


7. Install the road wheel arch liner and road wheel (Refer to ’Road Wheel Nut Torque Tightening’, page 4-5-7).

8. Recharge the A/C system.

9. Start the engine. Allow the engine cooling system to rise to normal running temperature.



7. Withdraw the condenser upwards.

Installation

If a new condenser is to be installed ensure the correct amount of A/C system oil is added.

1. Insert the condenser, locate the bottom of the condenser into the anchor points (x2). Install bolts (x2).

Condenser


Item

A/C Condenser Renew

Removal

Code

12.03.BB


2. Recover the A/C refrigerant (Refer to ’Recovery’, page

12-3-8).

3. Drain the engine coolant system (Refer to ’Cooling

System (03.03)’, page 3-4-1).

Caution

Ensure open ends are plugged immediately after disconnecting refrigeration parts. If moist air or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other faults may occur.


5. Disconnect the A/C pipes. Discard the O-rings.

Install suitable blanking plugs.

2. Install both A/C pipes. Use new O-rings. Torque bolts

(x2) to 10-13 Nm .

3. Install the ‘slam’ panel.


(03.03)’, page 3-4-1) and charge the A/C system (Refer to ’Charging’, page 12-3-8).




Receiver Drier Assembly


Item

A/C Receiver Drier Renew



Code

12.03.DB

Power Transistor

Inspection

Removal


2. Recover the refrigerant (Refer to ’Recovery’, page 12-3-

8).

3. Disconnect the A/C pipes from the receiver drier assembly. Remove and discard the ‘O’ rings. Install suitable blanking plugs.

Caution

Ensure open ends are plugged immediately after disconnecting refrigeration parts. If moist air or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other faults may occur.

Q=

O=

P=

N=

`MMSU

O

Q

N

P

1. Verify that the continuity between the power transistor terminals is as indicated in the table below.

If there is any fault, replace the power transistor.

If the blower motor operation is not normal even though no fault can be verified, inspect the A/C module.

2

4

2

2

4

4

3

3

1

3

1

1

Tester lead

+ -

3

2

2

4

4

1

4

1

1

3

3

2

Resistance (kilo hm)

Infinity

11.0

Infinity

Continuity detected

Continuity detected

1.5

11.0

Infinity

Infinity

Continuity detected

1.5

Continuity detected

4. Remove bolts (x2) and withdraw the receiver drier assembly.

5. Recover the spacers and ferrules for reuse.

Installation

1. Install receiver drier assembly.Torque bolts to 2-3 Nm .

2. Connect the refrigerant lines. Torque to 2-3 Nm .

Install new ‘O’ rings to the A/C system connectors.

3. Charge the A/C system (Refer to ’Charging’, page 12-3-

8).

4. Connect the vehicle battery. Start the engine. Allow the engine cooling system to rise to normal running temperature.

Removal


2. Remove the glove box.


4. Remove the power transistor.

1

2




Installation

1. Install the power transistor and connect the wiring harness plug.

2. Install the glove box.


Evaporator Temperature Sensor

Inspection

Inspect the Evaporator Temperature Sensor when it is installed in the A/C unit.

1. Set the fan speed Max. Hi.

2. Set the temperature control to Max. Cold.

3. Set the air intake mode to Recirculate.

4. Turn the A/C switch off.

5. Close all the doors and windows. Wait for 5 minutes.

6. Disconnect the Evaporator Temperature Sensor connector.

7. Measure the temperature at the air intake.

8. Measure the resistance between the Evaporator

Temperature Sensor terminals.

If the characteristics of the Evaporator Temperature Sensor are not as shown in the graph, replace the Evaporator

Temperature Sensor.

14

12

10

8

6

4

2

0

-10

{14}

0

{32}

10

{50}

20

{68}

TEMPERATURE

30

{86}

40

{104}

50

{122}

°C {°F}

Removal


2. Remove the A/C unit (Refer to ’A/C Unit’, page 12-3-

11).

3. Remove the evaporator (Refer to ’Evaporator’, page 12-

3-14).

4. Remove the wiring harness plug from the A/C unit.

5. Remove the evaporator temperature sensor.

Installation

1. Install the evaporator temperature sensor.

2. Insert the evaporator (inlet / outlet first) into the half of the A/C unit which houses the expansion valve.

3. Complete with new ‘O’ rings, install the expansion valve and the A/C pipes clamp (screws x2).

4. Install the clips (x2) that secure the evaporator temperature sensor element to the evaporator.

5. Secure the two halves of the A/C unit together.

Take care to correctly locate the two vent flaps.

6. Connect (glue) the filter gauze and foam where the two halves of the A/C unit meet.


8. Install the A/C unit to the IP (Refer to ’A/C Unit’, page

12-3-11).







Trinary Switch


Item

A/C Trinary Switch Renew

Removal


2. Recover the refrigerant from the A/C system.

3. Remove the foam surround.

Code

TBA

Expansion Valve


Item

A/C Expansion Valve Renew

Code

TBA

Removal


2. Recover the refrigerant from the A/C system.

3. Remove protective material from around the expansion valve.

4. Remove screws (x2). Remove the A/C pipes clamp.


5. Hold the piping block with pliers or a similar tool and loosen the trinary switch using a wrench. Withdraw the trinary switch.

5. Withdraw the A/C pipes. Discard ‘O’ rings.

Installation

1. Install the trinary switch. Torque to TBA Nm .

Apply compressor oil to the O-ring joint.


3. Install the foam surround.

4. Charge the A/C system (Refer to ’Charging’, page 12-3-

8).




6. Withdraw the expansion valve. Discard ‘O’ rings.


Installation

Install new ‘O’ rings.

Apply compressor oil to the ‘O’-ring joints.

1. Install the expansion valve to the A/C unit body.

2. Install the A/C pipes to the expansion valve.

3. Install the A/C pipes clamp.

4. Install sealant around the evaporator pipes.



Testing’, page 12-3-9)









Troubleshooting

The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to verify the symptoms of the trouble in order to diagnose the appropriate area.

Symptom(1)

Insufficient air (or no air) blown from vents.

Description

Problem with each vent / duct or both.

Airflow mode does not change.

Possible Cause

• Fault in Airflow Mode Actuator

• Fault in ‘Vent’ mode system

• Fault in ‘Heat’ mode system

• Fault in ‘Defroster’ mode system

Symptom(2)

Amount of air blown from vents does not change.

Description

Fault in blower system.

Possible Cause

• Blower motor fault

• Blower unit fault

• Power transistor system fault

• Climate control unit fault

Shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.

Symptom(3)

Air intake mode does not change.

Description

Air intake mode does not change when switching REC FRESH mode.

Possible Cause

• Air Intake Actuator fault

• Air intake door fault


Symptom(4)

No temperature control with A/C

Module.

Description

Temperature does not change with operating temperature control dial

Possible Cause

• Air Mix Actuator (5 V signal) system fault

• A/C Module (potentiometer GND signal) system fault

• Air Mix Actuator (potentiometer input signal) system fault

• Air Mix Actuator (potentiometer GND signal, motor drive signal) system fault

• Air Mix Actuator system fault

• A/C unit air mix door fault


Symptom(5)

Windshield fogged.

Description

• A/C compressor does not operate while airflow mode is in DEFROSTER or HEAT DEF modes

• Air intake mode does not change to FRESH while airflow mode is in

DEFROSTER or HEAT DEF modes

Possible Cause

• A/C Module (B+ signal) system fault

• Air intake actuator fault

• A/C Module (RECIRCULATE, FRESH signal) system fault

• Fault in blower unit air intake doors





Symptom(6) Description

Air from vents not cold enough.

Magnetic clutch operates but

A/C system malfunctions.

Possible Cause

• Drive belt fault

• Fault in blower unit or condenser

• Fault in Receiver / Drier or expansion valve

(valve closes too much)

• Fault in refrigerant lines

• A/C compressor system fault, insufficient compressor oil

• Over filling of compressor oil, fault in expansion valve or A/C unit air mix link system


Symptom(7)

No cool air.

Description

Magnetic clutch does not operate.

Possible Cause

• Fault in PCM A/C cut control system

• Fault in A/C Module

• Fault in refrigerant pressure switch

• Fault in PCM (A/C signal)

• Fault in PCM (IG1 signal)

• Fault in A/C compressor

• Fault in A/C relay

• Fault in Evaporator Temperature Sensor


Symptom(8)

Noise while operating A/C system.

Description

Noise from magnetic clutch, A/C compressor, hose or refrigerant line.

Possible Cause

• Magnetic clutch operation noise

• A/C compressor slippage noise

• Hose or refrigerant line interference noise






Contents

Instrument Cluster (13.01) ..................................13-1-2

Description ............................................................. 1-2

Information and Warning Lamps............................ 1-3

DIM display layout................................................. 1-4

Gear Position Indicator Display (GPID)................... 1-4

Message Centre Left............................................... 1-4

Message Centre Right............................................. 1-4

Maintenance........................................................... 1-5

Instrument Pack ..................................................... 1-5

Removal.............................................................. 1-5

Installation .......................................................... 1-5


Instrument Cluster (13.01)



Driver Information Module (DIM) (13.01)

Description

F uel

G auge

Odometer Mes s age

C entre

Left

G P ID

Dis play

Mes s age

C entre

R ight

R ev

C ounter

C oolant

T emperature

G auge

The Driver Information module contains the necessary electronic control units and memories to control, process and present all necessary vehicle information to the driver.

1. Information on vehicle performance is presented in visible form using the instruments and gauges. These devices present such information as Vehicle Speed, Engine Speed, Fuel Level and Coolant Temperature.

2. Information on vehicle status is presented by an array of warning lights.

• Red - indicate immediate danger warnings

• Amber - indicate conditions which are serious but not immediately dangerous

• Green and Blue - indicate normal actuation of items such as turn signals or fog lamps

The message centres and the gear position indicator display (GPID) are used to present information on the distance recorders (trip meters), current gear mode and current gear engaged.

3. The right message centre is used to display any warning / information message text. These text messages may be reinforced in some cases by illumination of the appropriate warning lamps.

The following table defines all information and warning lamps and their significance:




Information and Warning Lamps

Name / Function Description

General Warning

– Amber / Red

SRS (Airbag)

High Engine

Coolant Temp

DSC

Controlled internally by the DIM. It is used in conjunction with several text messages to indicate information to the driver.

Controlled externally by the SRS module and indicates a fault in the SRS module.

This tell tale is controlled internally by the DIM. Activated when the engine coolant temperature signal from the CAN bus reaches a pre defined value. (The actual symbol is not lit, only the red LED.)

Controlled externally by the ABS / DSC module. Indicates when the system is in operation or when it is turned off. The tell tale is triggered by a CAN signal.

ABS Controlled externally by the ABS / DSC module. Indicates a fault in the ABS system. The tell tale is triggered by a CAN signal.

Rear Fog Lights Controlled externally by the SRS module. Indicates that the rear fog lights are turned on. The tell tale is triggered by a CAN signal.

Seat Belts Controlled externally by the CEM. Indicates that the seat belts are not fastened properly. The tell tale is triggered by a CAN signal.

Brake (General) Controlled externally by either the CEM or the ABS / DSC module. It indicates low brake fluid level, brake fault and park brake. The tell tale is triggered by two low side inputs or a CAN signal.

Side Lights

Oil Pressure

Controlled externally by the CEM. Indicates that the side lights are on.

Controlled externally by the PCM. Indicates low oil pressure.

The tell tale is triggered by a CAN signal.

Battery Charge Controlled externally by the CEM. Indicates that the alternator is no longer charging the battery properly. The tell tale is triggered by a CAN signal.

Fuel Level Low Controlled internally by the DIM. Activated when the fuel level drops below a pre defined value. The fuel information is provided from the CAN bus. The symbol is not lit, only the amber LED.

Turn Left / Right Controlled externally by the CEM. The tell tale is triggered by a

CAN signal.

High Beam Controlled externally by the CEM. Indicates that the high beam is switched on. The tell tale is triggered by a CAN signal.

Check Engine

Tyre Pressure

Controlled externally by the PCM. Indicates a fault in the engine management system. The tell tale is not connected to the microprocessor.

Controlled by the DIM. Indicates a low or rapid change in the tyre pressure or a tyre pressure monitoring system fault.

Not Used

Symbol Input Signal Power

On Check

Internal

CAN

CAN

CAN

CAN

CAN

CAN

Low side x 2 and CAN

High side

CAN

CAN

CAN

CAN

CAN

Low side

Low side

Yes (5 Seconds)

Yes (5 Seconds)

Yes (5 Seconds)

Yes (5 Seconds)

Yes (5 Seconds)

Yes (5 Seconds)

Yes (5 Seconds)

Yes (5 Seconds)

Yes (5 Seconds)

PATS Controlled externally by the PCM. Indicates key acceptance status.

Low side




DIM Display layout

The DIM contains two displays, which are used to inform the driver about the vehicles status.

Manual Transmission

On a manual transmisssion vehicle the GPID display informs the driver when the current gear has reached it’s upper rev. limit the GPID will indicate revs increasing. The optimum time to shift gear is when the GPID shows three bars and is red at the top and bottom.

Message Centre Left

The Message Centre left is used to display the odometer (A), the

Cruise control status (B), the

Gear range (C) and the T1 or T2 trip distance (D).

Gear Position Indicator Display (GPID)

Automatic Transmission

On an automatic transmisssion vehicle the

GPID display contains the two gearbox mode

‘tags’ (Auto and Touch), and a segmented character area. This segmented display can show P, R, N, D, 1, 2, 3, 4, 5, 6 depending on the current gear engaged. The display is dual colour.

Green - normal operation

Red - defined situations.

For the first 2000 km (1243 mile) and when ever the engine temperature is below 40°C (104°F) the shift control will indicate early shift changes to protect the engine.

A red ‘R’ will show when the transmission is in reverse.

Message Centre Right

The Message Centre Right is used to display the trip function information and warning / information messages.




Maintenance

Driver Information Module (DIM)


Item


Renew

Removal


2. Remove the following items of trim.

2.1 Remove panel (pull off).



Code

TBA

4. Remove the screws (x4) that secure the DIM. Withdraw the DIM to the extent of the wiring harness.

Ensure the spacers are retained.

5. Disconnect the wiring harness plug. Withdraw the DIM.

3. Remove the screws that secure the DIM bezel (x5).

Withdraw the bezel and lay it on the steering column.

The DIM bezel is attached to the leather trim.




Installation

1. Place the DIM to it’s mounting point. Connect the wiring harness plug.

2. Install the DIM (screws x4).

3. Install the DIM bezel (screws x5).

Ensure that the DIM finishers install on the inside of the cluster bezel.

4. Install the trim panels.



Contents

Battery System (14.01).........................................14-1-2

Description ............................................................. 1-2

Battery Connect Switch.......................................... 1-2

Battery Disconnection and Alarm Activation........... 1-2

Charging Circuit ..................................................... 1-3

+12 Volt Distribution............................................. 1-3

Specifications.......................................................... 1-5

Maintenance........................................................... 1-5

Battery................................................................... 1-5

Removal.............................................................. 1-5

Installation .......................................................... 1-5

Alternator and Regulator System (14.02) ............14-2-1

Description ............................................................. 2-1

Specifications.......................................................... 2-1

Maintenance........................................................... 2-1

Alternator .............................................................. 2-1

Removal.............................................................. 2-1

Installation .......................................................... 2-2



Battery System (14.01)




Description

The 12 volt negative earth (‘-’ ve) battery is located under the drivers side rear seat and is grounded to the vehicle body.

The battery positive (‘+’ ve) terminal is connected to a battery connect switch. The connect switch may be accessed by raising the rear seat cushion.

01-14-001

Battery Connect Switch

When the battery connect switch is in an ‘open’ state it isolates electrical power from all systems except the ‘keep alive memory’ functions in the PCMs, TCU, radio, navigation system and door modules.

After connecting the battery, the radio preset stations and the door window controllers will require to be reset (Adaptive learning data in the PCMs and TCU (Auto transmission) modules will require to be re-learned by driving the vehicle for some miles in a range of driving conditions), driveability may be slightly compromised until the vehicle systems have completed their adaptive learning routines again.

This function isolates electrical power from vehicle circuits under all normal service conditions with the following exceptions:

Battery Disconnection and Alarm

Activation

• Before any welding or other work which may induce high voltages into the electronic control modules

• Before disconnecting any of the control modules with

‘keep alive memory’

The vehicle is installed with an alarm which will be activated if the battery is disconnected. This alarm is driven by a back up battery within the alarm sounder unit.

• Before any major service task (e.g. engine removal)

• Before installing any accessory which involves modification of vehicle wiring

In the above four exceptions the battery earth (‘-’ ve) lead should be disconnected.

To prevent the alarm from sounding when the battery is disconnected (for workshop procedures), disconnect the battery within 10 seconds of switching off the ignition.

Always carry out the following procedures upon connection of the battery.

When the battery earth (‘-’ ve) terminal is disconnected, data held in keep alive memories will be lost.

• Reset the clock

• Reset the radio preset programmes.

• Reset the window maximum up and maximum down settings.




Charging Circuit

Alternator / Generator

Secondary PCM

C0637-38G

ALTMON

UW,0.5

C0226-1

ALTMON

C1893-1

B+

B,50.0

C0192-1

Switch-Battery Disconnect

C0046-A

18 Ohm

Coil

C0046-B electronics

CUT OFF

Hall

Sensor

GND

STARTER

VIGN

BDS Power

C2607-1

BDS Power

Engine Bay

Dirty Feed

Power

B,50.0

B,50.0

C1271-1

C1271-5

C1271-3

C1271-6

DIRTY FEED STUD

ENGINE BAY

SPL - TPIECE

B,50.0

SPL - TPIECE

B,50.0

Terminal-Jump Start

C2307-1

Battery

C0045-1

B,50.0

C1661-1

MOTOR Earth via fixings (E110)

Starter Motor

C1661

EARTH BODY

Electrical power generated at the alternator flows via two ‘T Piece’ connectors to the engine bay ‘Dirty Feed’ stud. It then flows via the Battery Disconnect Switch (BDS) to the battery positive terminal. Both the alternator and the battery are earthed via the vehicle body to complete the charging circuit.

The starter motor and the ‘jump start terminal’ are also fed directly from the charging circuit.

+12 Volt Distribution

The +12 volt supply comes from the battery to the battery disconnect switch (BDS). Assuming that this switch is not activated, 12 volt power is then available from C0046-8 on the BDS to all of the clean feed battery studs.

The following clean feeds are then live:

• Boot fuse box clean feed

• Under bonnet fuse box clean feed

• CEM busbars 1, 2, 3, 4 and 5 clean feeds

12V power to all systems and components is then controlled by the CEM and the under bonnet / boot fuse boxes.




14-1-4

R,50.0

Battery

12.0Volts

B,50.0




Specifications

Torque Figures

Description

Battery Compartment Cover

Battery clamp

Battery Terminals

Maintenance

Battery

9

9

Nm.

9

7

7 lb. / ft.

7


Item

Battery Renew

Code

14.01.AB

Removal

1. Power the drivers seat forward.

2. Remove the RH rear seat to reveal the battery compartment.

The rear trim ¼ panel may need to be removed to gain access to the battery compartment lid bolts.

3. Remove bolts (x10). Remove the battery compartment cover.

5. Remove the battery clamp. Disconnect battery vent tube and pull the battery from the compartment.

Warning

The vehicle battery is heavy and access to the battery is restricted. Take care when lifting the vehicle battery.

4. Disconnect the battery terminals.

Warning

Always disconnect the earth (- ve) terminal first.

Installation

Warning

The vehicle battery is heavy and access to the battery is restricted. Take care when lifting the vehicle battery.

1. Lower the battery into it’s compartment.

Ensure that the battery vent tube is attached to the battery and that it located into the opening provided in the body.

2. Clamp the battery. Torque bolts to 9 Nm .

Ensure that the battery vent tube is not distorted by the battery.

Warning

Always connect the earth (- ve) terminal last.

3. Install the battery terminals. Torque to 9 Nm .

4. Install the battery compartment cover. Torque bolts to

9 Nm .

5. Install the rear seat base.

6. Reposition the drivers seat.





Alternator and Regulator System (14.02)




Description

The alternator installed to this vehicle is a Denso, SC2, 150 amp rating, with a 14.4 volt regulator.

Maintenance

Alternator


Item

Alternator Renew

Code

14.02.AB

Removal


2. Disconnect the wiring harness plug on rear of alternator.

The Alternator has an 'Altmon' signal that goes to and from the secondary PCM via a wire in the 3 way connector.

The ‘Altmon’ signal is monitored by the secondary PCM which adjusts ignition timing and fuelling if necessary to maintain idle speed when the alternator is charging.

The alternator pulley has an in-built mechanical clutch which will slip if there is a rapid change in drive belt speed.

This reduces the ‘snatch’ in the auxiliary drive system during gear changes.

Specifications

Disconnect

3. Raise the vehicle and make safe. Remove the road wheel and road wheel arch liner.


5. Release the polyvee drive belt (Refer to ’Accessory Drive

System (03.05)’, page 3-6-1).

6. Unclip the wiring harness from the cooling cover.

Torque Figures

Description

Alternator mounts

Nm.

lb. / ft.

43-52 32-38.5

Unclip Harness

Disconnect Plug




7. Remove bolts / washers (x3). Withdraw the alternator complete with the cooling shield.

Remove Bolts

Installation

1. Place the alternator complete with the cooling shield to mountings.

Insert bolt (1) as cooling shield is placed to alternator.

2. Secure the alternator and cooling shield assembly to engine block. Tighten bolts (x3) to 43-52 Nm .

43-52 Nm.

Remove Pipe

1

For easier access to bolt, remove air ducting from underside of cooling shield.

3. Install the air ducting to the cooling shield, if removed.

4. Clip the wiring harness to the cooling shield.

5. Connect the wiring harness plug to the alternator.

6. Install the drive belt (Refer to ’Accessory Drive System

(03.05)’, page 3-6-1).


8. Install the road wheels (Two stages (Refer to ’Road

Wheel Nut Torque Tightening’, page 4-5-7)).



Contents

Audio System (15.01)...........................................15-1-2


Audio System (15.01)



Audio System (15.01)

Refer to manufactures literature


Body Vacuum System (16.01)


Details to follow


Description




Contents

Vacuum Distribution (16.01)...............................16-1-2

Description ............................................................. 1-2

Vacuum System (16.00)


Vacuum Distrbution (16.01)




Description


Contents

Front Lights (17.01) .............................................17-1-2

Specifications.......................................................... 1-2

Maintenance........................................................... 1-2

Headlamp Unit...................................................... 1-2

Removal.............................................................. 1-2

Installation .......................................................... 1-2

Headlight Alignment .............................................. 1-3

Continental Conversion.......................................... 1-3

Bulb Renewal ........................................................ 1-4

Dipped Beam...................................................... 1-4

Main Beam ......................................................... 1-5

Indicator and Side Light....................................... 1-5

Side Repeater Unit................................................. 1-6

Renewal.............................................................. 1-6

Side Marker Unit Bulb ........................................... 1-6

Renewal (Front and Rear)..................................... 1-6

Side Marker Unit ................................................... 1-6

Renewal (Front and Rear)..................................... 1-6

Interior Lighting (17.02) ......................................17-2-1

Specifications.......................................................... 2-1

Maintenance........................................................... 2-1

Interior Light Bulb .................................................. 2-1

Renew ................................................................ 2-1

Rear Lights (17.03)...............................................17-3-1

Specifications.......................................................... 3-1

Maintenance........................................................... 3-1

Light Cluster........................................................... 3-1

Remove............................................................... 3-1

Installation .......................................................... 3-1

Side Marker Units .................................................. 3-1

Lighting Mechanisms (17.04) ..............................17-4-1

Headlamp Levelling................................................ 4-1

Maintenance........................................................... 4-1

Front Level Sensor ................................................. 4-1

Removal.............................................................. 4-1

Installation .......................................................... 4-1

Rear Level Sensor................................................... 4-2

Removal.............................................................. 4-2

Installation .......................................................... 4-2



Front Lights (17.01)




Specifications

Bulbs

Headlight dipped beam

Rating

35W

Type

(European)

D1S

Headlight main beam 65W H9

Front Indicators 27W /

29W

PY27W

Front Position Lamp 5W

Side Repeater 5W

Side marker (front and rear)

5W

Type

(Federal)

D1S

H9

3457 AK

W5W (Blue) W5W (Blue)

WY5W

N/A

WY5W

W5W

Headlamp Alignment

Main Beam Alignment

European Federal

1.5% Down 0.7% Down Vol.

Dipped Beam Alignment 1.5% Down 0.7% Down Vol.

Main beam is fixed to the Dipped beam.

Maintenance

Headlamp Unit


Item

Headlamp Unit Renew LH

RH

Code

17.01.AB

17.01.BB

(Including side light and indicator)

Removal



3. Remove the air box (Refer to ’Air Charging (03.12)’, page 3-13-1).

4. Remove bolts (x3) securing the headlamp unit bracket.

5. Disconnect the headlamp unit wiring harness plugs (x3)

6. Withdraw the headlamp unit.

Installation

7. Install the headlamp unit.

8. Install the air box (Refer to ’Air Charging (03.12)’, page

3-13-1).


10. Install the road wheel (Refer to ’Road Wheel Nut


11. Carry out headlamp unit alignment procedure.




Headlight Alignment

Headlight alignment should be carried out with vehicle at design weight, i.e.,

• Vehicle at kerb weight, plus

• All fluids at normal full level, plus

• A 75 kg weight in each front seat

1. Remove the access panel from the road wheel arch liner.

2. Switch the ignition to position ‘II’ then back to position

‘0’.

This will motor the headlight units to their ‘set’ position.

5. Switch the ignition to position ‘II’ then back to position

‘0’ to ensure that the headlight units are at their set position.

6. Check the headlight unit alignment again to confirm correct alignment.

Continental Conversion

(UK Spec only)


2. Gain access to the headlight unit by removing the access panel in the road wheel arch liner.

3. Remove both rubber covers.

Warning

HID bulbs start-up voltage can be as much as 1000v.

Ensure power to HID bulbs has been disconnected before attempting to service them. Failure to do this may result in a severe injury or death.

Warning

HID bulbs get hot during operation.

Allow at least 15 minutes for headlamp assemblies to cool before attempting to service them. Failure to do this may result in burns to skin or clothing.

4. Disconnect the dipped beam bulb unit wiring harness plug. Remove the spring clip and withdraw the bulb unit.

3. ROW Only.

Align the headlamps so that the cut off of the dipped beam is 1.5% below the horizontal.

LHD Headlamps

V

1.5% (0.86° below the horizontal)

H H

RHD Headlamps

V

V

H H


V

4.

Federal Only .

Align the headlamps so that the LH cut off of the dipped beam is 0.7% below the horizontal.

Federal Headlamps

V


H H

V




5. Locate the conversion switch and move up / down until a positive ‘click’ is heard.

Bulb Renewal

LH Headlamp Unit

RH Headlamp Unit

6. Install the dipped beam bulb unit. Connect wiring harness plug.

7. Install both rubber covers.

8. Install the access panel in the road wheel arch liner.


Gain access to the headlight unit by first removing the access panel in the road wheel arch liner.

Dipped Beam


Item

Dipped Beam Renew LH

RH

Code

17.01.CB

17.01.DB

HID Bulb Disposal

Always dispose of HID bulbs in a responsible manner.

Follow your local authorised standards for disposal.

The following precautions must be observed when handling

HID bulbs. Failure to comply may result in exposure to ultra violet rays, severe electric shock, burns or risk of explosion.

Warning



Warning



Warning

Never switch on lamps or test bulbs with the lamp holder detached from headlamp.

Warning

Eye and hand protection must be worn.


2. Remove the rubber cover.




3. Disconnect wiring harness plug. Remove the spring clip and withdraw the bulb unit.

Indicator and Side Light


Item

Indicator Bulb Renew

Side Bulb Renew

LHF

RHF

LHF

RHF

Code

17.01.EB

17.01.FB

17.01.JB

17.01.KB

1. Rotate the bulb holder a quarter turn anti-clockwise and withdraw.

4. Insert a new bulb unit. Secure with the spring clip and connect the wiring harness plug.


Main Beam


Item

Main Beam Renew LH

RH

Code

17.01.GB

17.01.HB

Warning



Warning




2. Twist the bulb holder anti-clockwise and pull out from it’s retainer. Disconnect the wiring harness plug.

3. Connect the wiring harness plug to the new the bulb and insert the bulb unit into it’s retainer. Twist clockwise to secure.

2. Pull the bulb from it’s holder and withdraw the bulb.

3. Install a new bulb and turn push to lock.

4. Install the bulb holder to the headlamp light cluster and install the rear lamp access panel.





Side Repeater Unit


Item

Side Repeater Unit Renew LH

RH

Code

TBA

TBA

Renewal

1. Protect surrounding paint work and rotate the repeater unit clockwise approx. 30°. Withdraw the repeater unit from the vehicle and disconnect the wiring harness plug.

5.

Front Side Marker Unit Only .

Install the road wheel arch liner.

6.

Rear Side Marker Unit Only .

Install the rear light cluster (Refer to ’Light Cluster’, page

17-3-1).

Side Marker Unit


Item

Side Marker Unit Renew LH

RH

Code

TBA

TBA

Federal Markets Only

Renewal (Front and Rear)

1.


Remove part of the road wheel arch liner to gain access to the rear of the side marker unit.

2.


Remove the rear bumper to gain access to the rear of the side marker unit (Refer to ’Rear Bumper’, page 1-

13-3).

3. Remove speed nuts (x2) that secure the side marker unit to the bumper. Withdraw the side marker unit.

2. To change the bulb. Hold the side repeater unit and turn the bulb holder 90° anti-clockwise. Withdraw the bulb and install a new one.

3. To change the side repeater unit. Connect the wiring harness plug to a new side repeater unit and install.

Side Marker Unit Bulb


Item

Side Marker Unit Bulb Renew

Federal Markets Only

Renewal (Front and Rear)

LH

RH

Code

TBA

TBA

1.


Remove part of the road wheel arch liner to gain access to the bulb holder.

2.


Remove the rear light cluster to gain access to the bulb holder (Refer to ’Light Cluster’, page 17-3-1).

3. Twist the side marker unit bulb holder 90° anticlockwise and pull from the side marker unit.

4. Install a new bulb to the bulb holder. Insert the bulb holder to the side marker unit. Twist 90° clockwise to lock in place.

4. Disconnect the wiring harness plug at the rear of the side marker unit and remove the assembly.

5. Connect the wiring harness plug to a new side marker unit and install.

6.


Install the road wheel arch liner.

7.


Install the rear bumper (Refer to ’Rear Bumper’, page 1-

13-3).



Interior Lighting (17.02)

Specifications

Rear Quarter Lamp

Bulbs

Reading lamp

Rear occupant lamp

Boot lamp

Maintenance

Interior Light Bulb

Renew

Rating Type

3W W3W

3W

3W

W3W

W3W


Item

Interior Bulb Renew

Code

17.02.AB

1. Taking care to protect the trim panel, lever the lamp unit from the trim panel.

Lever the lamp unit from the trim panels inline with the locating clips.

Reading Lamp

Boot Lamp




2. Twist the bulb holder approx. 20 ° anti-clockwise and withdraw the bulb holder. Pull the from the bulb holder and install a new bulb.

3. Push the lamp unit back into the recess in the trim panel.






Rear Lights (17.03)

The rear light cluster is a sealed unit. If any light which fails to illuminate is traced back to the rear light cluster, replace the whole unit.

Specifications

Bulbs

Rear light cluster

Rear side marker

Number plate

High Mounted Stop Lamp

Maintenance

Light Cluster

Rating Type

LED

3W

5W

W3W

C5W

LED


Item

Rear Light Cluster Renew LH

RH

Code

17.03.AB

17.03.BB

Remove

1. Open the boot and remove the trim from around the light cluster mounts.

2. Release and remove nuts (x3).

3. Withdraw the rear light cluster unit.


Installation

1. Place the rear light cluster unit to vehicle and connect the wiring harness plug.

2. Insert the rear light cluster unit into position.

Ensure the rubber seal is in position. Tighten nuts (x3).

Ensure that the light cluster profile matches the surrounding panels.

Side Marker Units

Refer to ‘Front Lights (17.01)’ for all information on the rear side marker lights.




17-3-1




Lighting Mechanisms (17.04)




Headlamp Levelling Maintenance

Front Level Sensor


Item

Front Level Sensor Renew

Code

17.04.BB

Removal

1. Disconnect the vehicle ride height sensor from the lower suspension arm.

2. Remove the ride height sensor from the subframe.

The ‘Automatic Dynamic Headlamp Levelling System’ consists of:

• An Automatic Dynamic Headlamp Levelling System ECU

• A level sensor for the front suspension

• A level sensor for the rear suspension

• A bi-polar stepper motor mounted in the housing of each headlamp

The Automatic Dynamic Headlamp Levelling System prevents the dipped beam dazzling oncoming road traffic by varying the angular position of the dipped (and main beam) headlamp units relative to the position of the vehicles suspension.

Static condition - Compensates for boot or occupant load condition.

Dynamic condition - Compensates for suspension movements due to acceleration and deceleration. The sensitivity of the system is dependent on vehicle speed and the rate of change of the vehicle speed.

High amplitude low frequency inputs such as those caused by potholes are filtered out to desensitise the system in constant speed situations.

Installation


Torque to:

• (M8 (subframe)) 22.5 Nm .

• (M8 (lower arm)) 22.5 Nm .




Rear Level Sensor


Item

Rear Level Sensor Renew

Code

17.04.CB

Removal

1. Disconnect the vehicle ride height sensor from the upper suspension arm.

2. Remove the ride height sensor from the subframe.

Installation


Torque to:

• (M5 (subframe)) 5-6 Nm .

• (M8 (upper arm)) 22.5 Nm .



Contents

Wiring and Circuit Protection (18.01) .................18-1-2

Fuse Boxes .............................................................. 1-2

Fuse Listings........................................................... 1-2

Engine Bay Fuse / Relay Box ................................. 1-2

Central Electronics Module Fusebox..................... 1-3

Boot Fusebox ...................................................... 1-4

How to Read the Circuits........................................ 1-4

Wires..................................................................... 1-4

Twisted Wires...................................................... 1-5

Controller Area Network (CAN).............................. 1-5

High Speed CAN wire.......................................... 1-5

Low Speed CAN wire .......................................... 1-5

Media Oriented System Transport (MOST)............. 1-6

Connectors ............................................................. 1-6

Splices ................................................................... 1-7

Tracing Spliced Wires .......................................... 1-7

Splice Origin Page ............................................... 1-7

Relays .................................................................... 1-8

Busbars.................................................................. 1-8

Fuses ..................................................................... 1-8

Resistors................................................................. 1-9

Variable Resistors................................................. 1-9

Lamps.................................................................... 1-9

Switches ................................................................ 1-9

Normally Open Switch ........................................ 1-9

2 Position Switch................................................. 1-9

3 Position Switch................................................. 1-9

Motors and Pumps................................................. 1-9

Pump.................................................................. 1-9

Motor ............................................................... 1-10

Diodes................................................................. 1-10

Light Emitting Diode (LED) ................................. 1-10

Transistor ............................................................. 1-10

Field Effect Transistor (FET)................................. 1-10

Earth / Ground..................................................... 1-10

Component Identification .................................... 1-11

Circuit Diagrams .................................................. 1-17

PCMs................................................................. 1-105

Vehicle Control System (18.08) ...........................18-2-1

Module Configuration ............................................ 2-1

Principles of Operation .......................................... 2-1

Market Configuration ............................................. 2-1

Configuration ...................................................... 2-1

Customer Configuration ......................................... 2-1

Data Buses.............................................................. 2-1

Network Bus ........................................................... 2-1

MOST.................................................................... 2-1

Module Locations (RHD)........................................ 2-2

Module Locations (LHD) ........................................ 2-4


Wiring and Circuit Protection (18.01)




Fuse Boxes

From the clean 12V output terminal of the battery disconnect switch, electrical power is distributed to three fuse boxes:

Fuse Listings

Engine Bay Fuse / Relay Box

RH drive shown . On LH drive vehicles the engine bay fuse box is located on the RH side.

The central electronic module (CEM) fuse box is always located on the passenger side.

Always ensure that the fusebox covers are located correctly to prevent ingress of water / foreign materials

The fuse boxes also contain the switching relays.

Fuse Rating Function

F1 10A Keep alive power PCM (Bank B)

F2 10A Tracker (option) / Clock

F3 10A Cooling fan module

F4 20A Engine management (Bank A) / Module -

ABS, Key Reader and Steering angle sensors

F5 20A Engine management (Bank B)

F6 15A Exhaust Gas Oxygen (HEGO) sensors /

Catalyst monitor sensor (CMS) (Bank B)

F7 15A Coils 7-12 / Suppressor solenoid (Bank B)

F8 10A Engine coolant level sensor (Bank B)

F9 20A Injectors 7-12 / Mass air flow sensor (MAF)

(Bank B)

F10 10A A/C clutch

F11 15A Horn

F12 10A Keep alive power PCM (Bank A)

F13 20A Injectors 1-6 / Mass air flow sensor (MAF)

(Bank A)

F14 10A Vapour Management valve (VMV)

(Bank A)

F15 25A Starter motor

F16 15A Coils 1-6 / Suppressor solenoids (Bank A)

F17 5A Glove box release solenoid

F18 15A Exhaust Gas Oxygen (HEGO) sensors /

Catalyst monitor sensor (CMS) (Bank A)

F19 30A ABS module / Battery feed

F20 30A ABS module / Battery feed

F21 30A Heated front screen

F22 5A Spare

F23

F24 5A

Blank

Alternator warning lamp

F25 5A Spare

F26 20A Headlamp wash pump

F27 25A Spare





F28 10A Module - ABS, Key Reader and Steering

R1

R2

R3

R4

R5

R6

R7

R8

PCM A

PCM B

VMV angle sensors

F29 25A Spare

F30 5A Alternator battery sensing

F31 30A Heated front screen

F32 30A Wiper (slow)

F33 30A

F34 20A

F35 60A

Wiper (fast)

Heater Blower motor

Cooling fan module

Relay Rating Function

Coolant fan pack

Injectors (1-6 (Bank A))

MAF Sensor (1-6 (Bank A))

Ignition coils (1-6 (Bank A))

Front and rear HEGOs and CMS (1-6 (Bank A))

Wiper motor

Injectors (7-12 (Bank B))

Ignition coils (7-12 (Bank B))

MAF Sensor (7-12 (Bank B))

Engine coolant level and VMV

Heater blower moter

Glovebox

Wiper motor

Central Electronics Module Fusebox

Fuse Rating Function

F43 10A Multi media module display / Phone

(option) / GPS tuner (option (not Middle

East)) / Media player

F44 10A Airbag module

F45 15A Accessory socket and illumination

F46 5A

F47 5A

ROPS / Convertible roof switch / Driver

Information / Master light switch / Glove box relay / Master lock switch / Battery Off switch

Interior lamps (front / footwell / rear) / Boot lamps relay

Fuse Rating Function

F48 15A Front windscreen relay and wash pump

F49 10A Airbag module

F50 5A Spare

F51 10A Diagnostic connectors / Centre stack switches

F52 5A Start button

F53 10A Headlamp levelling module / Power steering module

F54 10A Engine fuse box, Boot fuse box

F55 20A Spare

F56 10A Centre console module / Sounder module /

Hazard switch

F57 15A Diagnostic connectors / Brake pedal switch

F58 10A High beam (RH)

F59 10A High beam (LH)

F60 15A Drivers seat heating

F61 15A Passenger seat heating

F62 20A A/C module

F63 20A Spare

F64 5A AM / FM receiver module / Traffic

Monitoring Control module (TMC)

F65 5A Media player / Multi media module and display / Antenna amplifiers / Audio amplifier

F66 10A Centre console module / Infotainment control module

F67 15A Spare

F68 5A Spare

F69 5A Convertible roof module (Volante)

F70 15a Spare

F71

F72

Spare

Spare

F73 5A Spare

F74 15A Fuel pump

F75

F76

Spare

Spare

F77 15A Boot power socket

F78 Blank

F79 5A Reversing lamps / Module - Parking aid

(option)

F80 5A Battery ‘Off’ switch

F81 20A Ignition switch

F82 25A Passenger door module

F83 25A Driver door module

F84 25A Passenger seat power and switch pack

F85 30A Driver seat power and switch pack

F86 5A Start button, Driver and passenger seats




Stand Alone Fuses


F1 40A Cabin Fuse box supply

F2

F3

30A Cabin Fuse box supply

Blank

F4

F5



Boot Fusebox


F1 5A Convertible deck lid lock motors

F2

F3

F4

20A

30A

20A

Spare

Heated rear window

Rear quarter glass motor (LH) (Volante)

Spare (Coupe)

F5

F6

F7

F8

30A Spare

20A Rear quarter glass motor (RH) (Volante)

5A

Spare (Coupe)

Battery disconnect switch (BDS) power

30A Fuel pump module (Bank B) / Tracker

F9 20A Fuel pump module (Bank A)

F10 30A Convertible roof module

F11 20A Spare

F12 20A Transmission control module (Automatic)

F13 10A Tyre pressure monitoring

F14 5A Rear parking assistance module (optional)

F15 5A Transmission control module (Automatic)

F16 30A Convertible roof hydraulic pump

F17 5A Boot lamps / Rear power socket illumination

F18 30A Audio amplifier

F19 5A Spare

F20 10A Canister vent

F21 30A Convertible roof lid lock motors relay

F22 20A Exhaust by-pass and vacuum pump

Relay Rating Function

R1 Fuel pump driver module (7-12 (Bank B))

Tracker (If installed)

R2 Fuel pump driver module (1-6 (Bank A))

R3 Cansiter vent valve

Exhaust bypass valve and vacum pump

R4 TCM (auto only)

Spare

Tyre pressure monitor

Parking aid (if installed)

R5 Rear quarter glass motor (Volante)

Spare (Coupe)

BDS

Rear quarter glass motor (Volante)

Spare (Coupe)

R6 Boot lamps

R7 Heated rear window

How to Read the Circuits

Below is a simple guide to what symbols mean on the circuit diagrams. For some of the symbols there are descriptions as to how they function.

Wires

Wire numbers have been deleted from the original engineering circuits. This allows the type size to be increased for improved legibility of the service circuits.

Wires vary in size to allow different current to be carried. For example a wire with a diameter of 0.50mm (This is the diameter of all the internal copper strands together) will carry 11A (dependant on ambient temperature) whilst a wire with a diameter of 2.00mm will carry 25A.

173 WR 2.0

Wire No.

Colour

Size




Twisted Wires

The ‘figure of 8’ shown on circuits as below denotes a twisted wire and shows the wires that are twisted together.

A wire generates a certain amount of ‘electrical noise’ when a current is passed through it. By twisting the 2 wires together the ‘electrical noise’ is cancelled out on each wire by the opposing wire. This is used more on sensors and audio speakers.

908 GU MAPM 05

Wire No.

Colour

MAP (Defines twisted pair)

Size

Controller Area Network (CAN)

Controller Area Network (CAN) is the wiring between intelligent modules of the vehicle. This wiring carries the electronic data around the vehicle allowing the various modules and components to interrogate the network and read their specific data signals.

There are 2 different speeds of network.

Low speed - Transmits at 125,000 bits per second. Mainly for body controller systems such as seats and doors

High speed - Transmits at 500,000 bits per second. Mainly for engine management and powertrain associated systems such as ABS.

All wiring in the CAN is twisted. The twisted wires always consist of one wire with a black trace in it for the negative side and one with a brown trace in it for the positive.

High Speed CAN wire

Screened and Twisted Screen Wires

The signals through a wire can be affected by externally generated electrical noise. To reduce the external interference the wires are placed inside a conductive sleeve.

One end of the conductive sleeve is always open whilst the other end can be terminated to a ground, to a component, or left open.

The symbol for the screen is an oval with the wires that are to be screened inside it. The letters ‘SCR’ define the screen.

Low Speed CAN wire

205 U MABC 05

The symbol below shows a module or a component connector with the pin numbers that have CAN wires coming from them.

Wire No.

Colour

MAB (Defines Screened)

Size


‘CAN LS+’ - Low speed CAN positive side

‘CAN LS-’ - Low speed CAN Negative Side

This naming convention also applies to the High Speed

CAN network.

To aid identification of the different speed CAN’s in the vehicle different colours of wire have been used, e.g. the

Low Speed Volcano is GB twisted with GN, the High Speed

Volcano is RB twisted with RN.

There is attached on a separate page a list for wire colour abbreviations and what colour they refer to.




Media Oriented System Transport

(MOST)

A fibre optic carries out a similar function to that of a wire in that it transmits data signals. The differences being that where a wire is made up of copper strands in an insulated sleeve a fibre optic is a plastic tube with a highly polished reflective inside surface.

The fibre optic carries the data in the form of a pulse of light, which is sent via an infrared transmitter and picked up at the next component in the loop via an infrared receiver. The light pulse is then converted to an electrical signal that is used by that module or component.

The CAN sends signals around the vehicle where the modules or components remove their specific signals. The fibre optic is in a loop with the module components in that loop, one fibre goes in and one fibre goes out. This is shown below.

1 FO

Fibre optic in harness

Fibre Optic

Connectors

There are 2 types of interconnect shown on the circuits.

Each connector is given a dedicated ‘C’ number. The number after the dash is the pin number, also known as the cavity number. The example below is C0582 that when checked on the attached list refers to the CEM Connector

Cockpit 2 (C3).

The 1st type is shown for a connector that is on a module or component with a mating harness connector attached to it.

C0582 9

Connector C number

Connector pin / cavity number

The 2nd type is shown for a connector on a harness with the mating connector on another harness. This is known as an

Inline . Again the above naming convention applies.




Splices

A splice is used where more than 2 wires that have the same requirement i.e. they need the same signal and meet in the same harness. In the example below the Front Position

Lamp-LH and Front Side marker-LH require the same output signal from the CEM. Therefore the 2 wires for the lamps are spliced into the output wire from the CEM on the

Forward Harness.

SPL1 FLL FOR

Splice No.

Associated name

Harness that the splice is on

The terminals in a connector housing can have a special coating on them. This coating if required is selected using the following criteria.

• A specific coating requested by component / system owner.

Or

• The current passing through the terminal.

• The environment the connector is to be situated with respect to temperature.

• The open circuit voltage passing through the terminal at a given.

Depending on the above criteria the coating, if required, can either be gold, silver, phosphor bronze. Generally tin is the common plating on the terminals but there are some that are gold. These are identified in the circuits with the letter ‘ G ’ which stands for gold after the connector number. An example of this is shown below.

G

Gold plated pin

Tracing Spliced Wires

Some splices appear on pages as a wire that goes to one spot and seems to terminate in space. An example of this is shown below.

Splice Origin Page

(e.g.P9)

Other Page(s) on which the splice occurs .

A separate page is attached containing a list of splice abbreviations and the harness to which they refer.




Relays

Another significant component in the circuits is a relay, this is in simple terms a switch that operates on the principal of electromagnetism. Below is the circuit symbol for a typical relay. The relay shown below is a normally open relay in its inoperative state i.e The arm is in the open position.

The high power current then flows through the high power normally open switch through the lamp and then to an earth.

This can be seen more clearly in the diagram below.Lamp

Illuminates

Relays can have either 4 or 5 terminals on the base. The circuit of the relay is shown on the base or the side of the housing. There are 2 types of numbering convention for the relay terminals, both of which are shown below.

Busbars

A busbar is where a electrical supply is fed into a conductive bar, wire or pcb track and various modules or components

‘tap’ into this busbar to draw their required power. The

Central Electronic Module has 4 of these busbars internally, each of which is supplied from an external power supply, that supply can be a battery feed, ignition feed or a switched supply.

Below is a circuit diagram to show the function and operation of a relay in a simple circuit.

The symbol shown below is the symbol used on the circuits for a busbar, the number inside the box refers to the busbar number in the Central Electronic Module.

The current from a battery for example flows through the wires to the high power normally open switch (The arm between pins 30 & 87A) and the low power coil (The box between pins 85 & 86). As you can see in the example above the lamp is in not illuminated, because the switch is open.

For the relay to operate there needs to be current flow through the low power coil i.e Current in to the coil then through to an earth. The current passes through the relay coil and creates a magnetic field, this magnetic field is strong enough to ‘grab’ the high power normally open switch.

The magnetic field pulls the switch from it’s normally open contact to a normally closed contact. The normally closed contact has a path to an earth, in this case it goes through a lamp.

Fuses

A fuse is a device used to protect a module or component from excessive electrical current which can cause damage or destroy that module or component. In practice the fuse is placed in between the power source and the module or component that is being protected.

The size or ‘Rating’ of the fuse in amps is calculated according to the power requirements of the module or component it is protecting with other factors being taken into consideration. If the rating has been calculated correctly then the fuse will ‘blow’ when excessive current passes through it before any harm or permanent damage occurs to the module or component it is protecting.




In a correctly protected circuit, the fuse is placed ‘ Inline ’ between the power source in this case the battery and the lamp. If the lamp goes ‘short circuit’, a massive current will begin to flow and the fuse will fail causing an open circuit.

The battery and wiring are protected from over current damage.

Lamps

Below is the symbol for a light bulb, shown below the symbol is the power of the bulb in watts.

Below is the fuse symbol as shown on the circuit diagrams.

The number above the fuse symbol is the fuse number; allocated to this fuse. The number below the fuse symbol is the rating.

Switches

There are numerous of types of switch, several of examples are shown below.

Normally Open Switch

Resistors

A resistor is an electronic component that by way of its construction reduces the current flowing through it. A resistors unit of measure is the Ohm.

The diagrams below show a resistor and a variable resistor.

2 Position Switch

Variable Resistors

A variable resistor works in the same manner as a normal resistor but the resistance values can fluctuate. The construction of a variable resistor depends upon its use and environment.

One example is for the fuel tank level sensor. The tank full level is 10 ohms and the tank empty level is 204 ohms, the resistance will vary between 10 and 204 ohms depending on how much fuel is in the tank.

3 Position Switch

Motors and Pumps

The same symbol is used for a pump or a motor, the description differentiates between them.

Pump




Motor

Diodes

The simplest way of describing a diode is ‘a non return valve’. The current will flow through the diode from the anode to the cathode, due to the construction of it though current cannot come back. Diodes are used to reduce the possibilities of ‘back feed’. This is where current comes through the circuit the wrong way for one reason or another.

Below is the circuit symbol for a diode.

Field Effect Transistor (FET)

A field effect transistor (FET) is, in simplistic terms, a switch with no moving parts. The

‘switching’ is controlled by electronics and currents etc. rather than a physical switch being operated. The main difference between this and the type of transistor shown above is this one operates using a magnetic field.

Earth / Ground

For an electrical current to ‘flow’ around a circuit it has to start from a power source and go to an earth / ground. If there are any breaks in this circuit then current will not flow, this is called an ‘Open circuit’

= Anode

Light Emitting Diode (LED)

The light emitting diode (LED) works on the same principal as the diode. The main difference is that in the manufacturing process one of the materials is replaced by another. This replacement material has certain properties that when a certain voltage passes through it glows.

Arrow Symbol indicating light

emission

Anode

LED Colour

Cathode

Cathode

There are 2 types of earth, Signal Earth and Chassis Earth, these are referred to sometimes as a Quiet Earth and Noisy

Earth respectively.

Some sensors for example specify a Signal / Quiet Earth.

While components such as pumps and motors can have a

Chassis / Noisy Earth. The reason behind this is that pumps, motors and the like can generate ‘electrical noise’ by the way of their operation. Some of this ‘electrical noise can be transferred through wires, it is this ‘electrical noise’ that can have an adverse effect on sensor signals and affect the control readings.

Keeping Signal / Quiet and Chassis / Noisy earths separate reduces the effect of ‘electrical noise’ being transferred from component to component.

This symbol is a standard symbol for earths.

On the circuit diagrams some earths are shown as eyelets with the description of Earth-**** next to it, the earths also comply with the 4 digit C number. An example of this is shown below.

Transistor

A transistor in simplistic terms is a switch with no moving parts. The ‘switching’ is controlled by electronics and currents etc. rather than a physical switch being operated.

Below is the circuit symbol for it. The example shown below is one of the most common basic type used called a

‘Bipolar’.




Component Identification

Component

Airbag-Driver

Airbag-Passenger1

Airbag-Passenger2

Airbag-Side-Left

Airbag-Side-Right

Alternator/Generator

Alternator/Generator Battery

Terminal

AM/FM Receiver Module



(MOST)

Amplifier-(Aud Power)

Antenna Amplifer1

Antenna Amplifer1

Antenna Amplifer2

Antenna Amplifer2

Antenna-GPS

Antenna-Phone

Bar-ROPS-LH

Bar-ROPS-RH

Battery Fusebox

Battery Negative Terminal

Battery Positive Terminal

Battery-Backup-Tracker

Boot Fusebox - Conn A

Boot Fusebox - Conn B

Boot Fusebox - Conn C

Boot Fusebox - Conn D

Boot Lamp1

Boot Lamp2

Boot-Boot Lid Harness

Boot-Convertible Roof Inline 1

Boot-Convertible Roof Inline 2

Boot-Transmission Inline 1

Boot-Transmission Inline 2

C1 Engine Bay Fusebox










Cabin-Boot Inline 2

Cabin-Boot Inline 3

Connector Circuit Page

C0257 3

C0251

C0261

3

3

C0948

C0949

C0226

C1893

3

3

60, 69

58

C2538

C2219

C0102

7

7

74, 75

36

36

C0570

C0579

C0571

C0572

C0573

C0574

C0575

C0576

C2013

C0119

C0120

C0384

C0349

C0084

C0746

C0747

C0577

C0578

C0144

C0117

C2673

C0632

C0045

C0192

C0800

C2010

C2011

C2012

C2588

C2510

C0491

C2511

C0492

C1598

C2233

C2672

7

17

17

60

46

7

7

7

60

57

57, 58

57, 58

64

Component

Cabin-Boot Inline 4

Cabin-Boot Inline 7

Cabin-Boot Inline 8

Cabin-Boot MOST Connector

Cabin-Centre Stack Inline 1



C0109

C0607

C0608

C0420

C0083

C1165



Cabin-Centre Stack MOST

Connection

Cabin-Driver Airbag Inline

Cabin-Engine Inline 1



C1185

C1322

C1898


Cabin-Fuel Tank Inline 1

Cabin-Fuel Tank Inline 2

Cabin-Passenger Airbag Inline

Capacitor

CEM Busbar 3 Feed

CEM Busbar 4 Feed

CEM Busbar 5 Feed

CEM Connector Cockpit 1 (C1)

CEM Connector Cockpit 2 (C3)

CEM Connector Floor 1 (C5)

CEM Connector Floor 2 (C8)

CEM Connector Front End 1 (C7) C0586

CEM Connector Front End 2 (C9) C0588

CEM Connector Roof 1 (C6)

CEM Connector Roof 2 (C10)

C0585

C0589

Clock-Analogue

Clutch-Compressor-Air

Conditioning (A/C)

C0232

C0127

C1323

C2509

C2841

C2842

C0580

C0582

C0584

C0587

C0273

C2242

C2243

C2244

C2245

C1187

C0113

C0305

9

57

57

31

6

Coil Suppressor-Bank A

Coil Suppressor-Bank B

Convertible Roof1

Convertible Roof2

Convertible Roof3

Convertible Roof5

Convertible Roof6 (Hydraulic

Pump)

Diagnostic Connector A -

Powertrain

Diagnostic Connector B - Body

Direction Mode Actuator

Door Lock-Drivers Door

Door Lock-Passenger Door

Driver Seat-Conn1

C0997

C2455

Connector-Fuel Tank C0114

Convertible Roof Conn4 (HRW) C2808

C2805

C2806

C2807

C2809

C2810

C0549

C0877

C0413

C1449

C1451

C2378

19

19

19

20

18

47

47

41

42

16, 54

14, 53

5, 6

22

22

61, 61A




Component

Driver Seat-Conn3

Driver Seat-Conn4

Drivers Door Module Conn 1



C0751

C0255

2, 61A

15, 61

C0336 22, 23, 26,

28, 35, 49

C0337 15, 23, 25,

26, 28


Drivers Door-Cabin Inline

Drivers Door-Puddle Lamp

Dual Relay Base-Tonneau Lid

Lock

Earth Eyelet-Aircon Clutch

Earth Eyelet-Amplifier

C0338

C0744

C0978

C0063

23

49

18

6

Earth Eyelet-Bank A Cam/Crank

Screen

Earth Eyelet-Bank B Cam/Crank

Screen

C0560 46

C0808 22, 23, 26,

28, 35, 49

Earth Eyelet-Antenna Amplifiers C2713A/B

Earth Eyelet-Auto Int, Start,

Glove Rel, Red Grd

C2716

C0563

C0561

7

32, 63

65

66

Earth Eyelet-Blower Motor

Earth Eyelet-Body

Earth Eyelet-Body to Battery

Negative

C0564

C2934

C1661

5

41

57, 58

Earth Eyelet-Bonnet Switch

Earth Eyelet-Boot Fusebox

Earth Eyelet-Boot Release Sw,

Batt Condition

Earth Eyelet-Brake Fluid Level

Switch

Earth Eyelet-CCM (Noisy)

Earth Eyelet-CCM (Quiet)

Earth Eyelet-CCMTrip Switches

Earth Eyelet-CEM (Quiet)

Earth Eyelet-CEM Chassis

Earth Eyelet-CHMSL

Earth Eyelet-Convert Roof Sw

Earth Eyelet-Convertible Roof

Module

C1972

C2697

C2694

C2562

C1169

C1170

C1355

C2648

C2570

C2626

C2566

C0810

63

57

36, 69

50

Earth Eyelet-Convertible Roof

Module

C2635 18

Earth Eyelet-Cooling Fan Module C0562

Earth Eyelet-Drivers Door C2600

21

22, 23, 26,

28

Earth Eyelet-Drivers Seat

Earth Eyelet-Drivers Seat

Earth Eyelet-ECU A Caseground

Earth Eyelet-ECU A

Powerground

Earth Eyelet-ECU A

Powerground

C2567

C2568

C2651

C0556

C0557

61

61

56

56

56

56

39

18

18

17

17

30

56

Component

Earth Eyelet-ECU B Caseground

Earth Eyelet-ECU B

Powerground

Earth Eyelet-ECU B

Powerground

Earth Eyelet-FPDMs

Earth Eyelet-Front Brake Pad

Wear Sensors

Earth Eyelet-Fuel Flap Release

Switch

Earth Eyelet-Fuel Flap Release

Switch

Earth Eyelet-Fuel Flap Sol, Bt

Lmps, Mtr-Boot

Earth Eyelet-Fuel Tank


C2650

C0558

C0559

C2727

C2564

C2920

C2921

C2692

56

56

56

41

30

32

32

1, 32, 36

Earth Eyelet-Glovebox Release

Motor

Earth Eyelet-Headlamp Wash

Pump

Earth Eyelet-Heated Rear

Window (Con)

Earth Eyelet-Heated Rear

Window (Coupe)

C2899

C2929

C2603

C2693

C1679

41

32

73

42

42

Earth Eyelet-HFS LH

Earth Eyelet-HFS RH

C2597

C2598

Earth Eyelet-HID Module & DIM C0709

Earth Eyelet-Horn C0018

C2710 Earth Eyelet-Hydraulic Roof

Pump

“Earth Eyelet-ICM,MP &

Switches”

Earth Eyelet-Key Read & Ind

Switch

C0555

C0706

42

42

31, 34

71

18

10, 11, 12,

17, 31

33, 35, 63

Earth Eyelet-LH Front Lights

Earth Eyelet-LH Headlamp DI

Earth Eyelet-LH Rear Lamp

C1626

C1964

33

35

C2605 35, 37, 38,

39, 40

Earth Eyelet-LH Side Repeater

Earth Eyelet-Mass Air Flow

Sensor A

Earth Eyelet-Mass Air Flow

Sensor B

Earth Eyelet-Master Lock & Int

Boot Rel Sw

C1968

C0551

C0552

C2646

35

67

67

25

Earth Eyelet-MMM,GPS,Tyre

Press

Earth Eyelet-Module ABS

Earth Eyelet-Module ABS

Earth Eyelet-Module-Auto

Transmission

Earth Eyelet-OBD Chassis Gnd

Earth Eyelet-OBD Signal Gnd

C2634

C0434

C0362

C2696

C2629

C2628

17, 31, 52

51

51

6

53, 54

53, 54




Component

Earth Eyelet-Passenger Door

Earth Eyelet-Passenger Seat

Earth Eyelet-Passenger Seat

Earth Eyelet-PDC Module

Earth Eyelet-Phone, MMD,

Aircon

Earth Eyelet-Power Socket/Cigar

Lighter

Earth Eyelet-Power Steering

Solenoid

Earth Eyelet-Rear Doors Ajar

Earth Eyelet-Rear Quarter light

Motor-LH

Earth Eyelet-Rear Quarter light

Motor-RH

Earth Eyelet-Remote Receiver

Earth Eyelet-RH Front Lights

Earth Eyelet-RH Headlamp DI

Earth Eyelet-RH Rear Lamp &

Side markers


C2601 22, 24, 27,

29

C0811

C2569

C2630

C1398

C2599

C2565

C2712

C2644

C2645

Earth Eyelet-RH Side Repeater

Earth Eyelet-ROPS Module

Earth Eyelet-Rotary Coupler

Earth Eyelet-Rr Brake Pad Wear

Sensors & Mod-Aut

Earth Eyelet-Screen Wash Level

Sensor

C1971

Earth Eyelet-Screen Wash Pump C2652

Earth Eyelet-Sounder, Vac Pump,

Rear Power

C2602

62

62

55

5, 17, 52

1

59

22

20

20

C0707

C1947

63

33

C1967 35

C2604 35, 37, 38,

39, 40

C1969

C2563

C0017

C2695

35

60

71

9, 30, 38

73

50

1, 63, 68

30

50

Earth Eyelet-Stalk Trip Sw

Earth Eyelet-Steering Angle

Sensor

Earth Eyelet-Switch-Battery

Disconnect

Earth Eyelet-Tonneau Lid Motor

Relays

C0821

C2561

C2647

C2711

Earth Eyelet-Tonneau Lid

Switches

Earth Eyelet-Tracker C0553

Earth Eyelet-UBFB Relay 11 Coil C3002

Earth Eyelet-Under Bonnet

Fusebox

Earth Eyelet-Wash Wipe Switch

Earth Eyelet-Windscreen Wiper

Motor

C2643

C1210

C0554

C0809

ECU A (C-Cowl)

ECU A (E-Engine)

ECU A (T-Trans)

ECU B (C-Cowl)

ECU B (E-Engine)

C0635

C0636

C0634

C0638

C2464

57

18

20

64

70

57

73

73

Component

ECU B (T-Trans)

Eyelet-Battery Feed to Battery

Conditioner

Eyelet-Boot Fusebox Battery

Feed


C0637

C2175

C2609

Eyelet-Boot Fusebox Clean Feed C1890

Eyelet-Cabin Side BDS Feed C1891

Eyelet-Cabin Side Clean Feed

Eyelet-Cabin Side Clean Feed

Stud

C2704

C1627

Eyelet-Engine Dirty Feed Supply C2607

Eyelet-Underbonnet Fusebox

Battery Feed

C2608

Eyelet-Underbonnet Fusebox

Clean Feed

C2705

69

57

57

57

57

57

58

57

57

Facia-Cabin Inline 1











Facia-Cabin Inline MMM

Forward-Cabin Inline 1




C0047

C1167

C1168

C1363

C1184

C0223

C0229

C0231

C0467

C0469

C0765

C2246

C2410

C2411

C2409

C2412

Forward-Engine Inline 1

Forward-Engine Inline 2

FPDM A (1-6)

FPDM B (7-12)

Fresh/Recirc Actuator

Front Position Lamp-LH

Front Position Lamp-RH

Front Side marker-LH

Front Side marker-RH

Fuel Pump-A (LH)

Fuel Pump-B (RH)

Fuel Tank Connector

Fuse-Stand Alone-Battery

Conditioner

Headlamp-HID Auto Level-LH

Headlamp-HID Auto Level-LH

Headlamp-HID Auto Level-RH

Headlamp-HID Auto Level-RH

Heated Front Screen-LH

C2275

C2276

C2203

C2369

C0419

C0538

C0537

C0917

C0916

C0204

C0205

C0115

C0601

C0013

C0009

C0012

C0011

C0247

35

33

35

33

42

41

41, 64

5

33

33

33

33

41

41

41

69




Component

Heated Front Screen-RH

Heated Rear Window (Feed)

Heated Rear Window (Gnd)

Horn

Ignition Coil 1

Ignition Coil 10

Ignition Coil 11

Ignition Coil 12

Ignition Coil 2

Ignition Coil 3

Ignition Coil 4

Ignition Coil 5

Ignition Coil 6

Ignition Coil 7

Ignition Coil 8

Ignition Coil 9

Illumination-Accessory / Cigar

Lighter

Illumination-Rear Power Outlet

Injector 1

Injector 10

Injector 11

Injector 12

Injector 2

Injector 3

Injector 4

Injector 5

Injector 6

Injector 7

Injector 8

Injector 9

Interface-Auto Switches

‘Keep Alive’ Fuse

Lamp-CHMSL

Lamp-Convertible CHMSL

Lamp-Footwell-LH

Lamp-Footwell-RH

M6 Cooling Fan Feed Stud

Map Lamp-LH

Map Lamp-RH

Media Player

Media Player (MOST)

Microphone

Mirror-Door-Driver side

Mirror-Door-Passenger side

Module-ABS

Module-Airbag 1

Module-Airbag 2


C0246

C0381

42

42

C0382

C0003

C0156

C2461

C2462

C2463

C0052

C0276

C1770

C1771

C1772

C2087

C2088

C2460

C0074

42

71

47

47

47

47

47

47

47

47

47

47

47

47

1

C0526

C0527

C0528

C0529

C2456

C2737

C1875

C0613

C0351

C0522

C2457

C2458

C2459

C0523

C0524

C0525

C2623

C0077

C0076

C1641

C0355

C0356

C2111

C2107

39

49

49

21

49

49

17

74, 75

C1303

C0352

46

26, 28

C0353 27, 29

C0501 13, 51, 53,

56

C0256 2, 3, 15

C1649 2, 3, 15, 53

48

8,9

57

39

48

48

48

48

48

48

48

48

1

48

48

48

Component

Module-Aircon-Conn A

Module-Aircon-Conn B


C0791

C0792

5

6

Module-Amplifier (AUD2)

Module-Amplifier (AUD3)

C2589

C2796

Module-Amplifier (MOST) C2102

Module-Automatic Transmission C0932

C0947

C2522

45, 46

45, 46

74, 75

9

17

30

Module-Centre Console (Sim)

Module-Centre Console (Trip

Switches)

Module-Centre Console-Conn1

(Key A)


(Midd)

C0428

C0429


(Key B)

Module-Convertible Roof1

C0430

Module-Convertible Roof2

Module-Cooling Fan Pack

Module-Cooling Fan Pack

Module-Driver Information

C2802 15, 18, 19,

20, 36

C2803

C2471

18, 19, 20

21

C2470 21

C0230 13, 14, 30,

31, 34, 55,

59, 60

C1543

C2115

C2105

34

14, 17

74, 75

Module-HID Lighting

Module-Infotainment Control

Module-Infotainment Control

(MOST)

Module-Parking Aid 1

Module-Parking Aid 3

Module-Phone (Antenna)

Module-Phone (Main)

Module-Phone (SIM)

Module-Power Steering

Module-Remote Receiver

Module-ROPS

Module-Sounder

Module-Tracker

Module-Tyre Pressure Monitor

MOST Phone Link

Motor-Boot Latch

Motor-Electronic Throttle A

Motor-Electronic Throttle B

Motor-Heater Blower

Motor-Rear Quarter light-LH

Motor-Rear Quarter light-RH

Motor-Tonneau Lid Lock-LH

Motor-Tonneau Lid Lock-RH

Motor-Windscreen Wipers

Multi Media Module (MOST)

Multi Media Module (Power)

Multi Media Module (Screen)

C0957

C1457

C2537

C2118

C1644

C0316

C0674

C2792

C0520

C2838

C1537

C1023

C2052

C2465

C2466

C0056

C2592

C2593

C2594

C2874

C0030

C2104

C2113

C2114

30, 53, 55

55

17

14, 17

17

30, 59

63

60

63

64

31

74, 75

1, 36

72

72

5

20

20

18

18

73

74, 75

52

52




Component

Multi Media Module Display

(Power)

Passenger Door Module Conn 2

Passenger Door Module Conn 3

Passenger Door-Cabin Inline

Passenger Door-Puddle Lamp


C2516

C0323

C0324

C0733

C0979

52

Multi Media Module Display

(Screen)

C2515 52

Passenger Door Module Conn 1 C0322 22, 24, 27,

29, 35, 49

15, 24, 25

24

Passenger Seat-Conn1



Phone Link-Centre Stack

C2379

C0752

C0253

C1645

49

62

2

2, 62, 15

Phone Module (MOST)

Pretensioner-Driver

Pretensioner-Passenger

Pump-Headlamp Wash

Pump-Screen Washer Fluid

Pump-Vacuum

C2103

C1497

C0252

C1342

C0828

C1977

REAR BUMPER-BOOT INLINE1 C1914

REAR BUMPER-BOOT INLINE2 C1915

74, 75

2

2

73

73

68

Rear Interior Map Lamp-LH

Rear Interior Map Lamp-RH

Rear Lamp-LH

Rear Lamp-RH

Rear Side marker-LH

Rear Side marker-RH

Regulator-Blower Speed

Seat-Left

Seat-Right

Sensor Heated-Oxygen-Front

Sensor-Aircon Pressure (MID)

Sensor-Aircon Pressure (HI &

LO)

C0919

C0918

C0068

C2363

C2368

C0370

C1465

C1257

C1111

C1112

49

49

C0121 35, 37, 38,

39, 40

C0125 35, 37, 38,

39, 40

40

40

5

3

3

6

6

Sensor-Ambient Temp

Sensor-Barometric Pressure

Sensor-Brake Pad Wear (F/L)

Sensor-Brake Pad Wear (F/R)

Sensor-Brake Pad Wear (R/L)

Sensor-Brake Pad Wear (R/R)

Sensor-Brake Pedal Travel

Sensor-Brake Pressure

Sensor-Cam Position (VRS) A

Sensor-Cam Position (VRS) B

Sensor-Catalyst Monitor-Front

Sensor-Catalyst Monitor-Front

Sensor-Catalyst Monitor-Rear

C0884

C0188

C0050

C0968

C2578

C2579

C2446

C2444

C0176

C1463

C0103

C0643

C0676

50

50

51

51

6

68

50

50

66

44

43

44

Component

Sensor-Catalyst Monitor-Rear

Sensor-Crank Position A

Sensor-Crank Position B

Sensor-Engine Coolant Level

Sensor-Engine Coolant Temp

Sensor-Evap

Sensor-F/L/ABS

Sensor-F/R/ABS

Sensor-Front Impact-Left

Sensor-Front Impact-Right

Sensor-Fuel Level

Sensor-Fuel Rail Temp

Sensor-Fuel Tank Pressure


C0644

C0168

43

65

C0170

C0147

C0169

C0417

66

66

65

6

C0516

C0517

C1652

C1653

C2303

C2251

C0132

Sensor-Hall-Front Header Closed C0497

41

65

68

51

51

3

3

Sensor-Heated Oxygen-Front

Sensor-Heated Oxygen-Rear

Sensor-Heated Oxygen-Rear

Sensor-Hlamp Level-FR

Sensor-Hlamp Level-RR

Sensor-In Car Temp

Sensor-Key Reader

Sensor-Mass Air Flow (1-6)

Sensor-Mass Air Flow (7-12)

Sensor-Mass Movement

Sensor-PDC-RIL

Sensor-PDC-RIR

C2370

C0359

C0964

C0965

Sensor-PDC-ROL

Sensor-PDC-ROR

C0963

C0966

Sensor-Pedal Position A (Primary) C1589

Sensor-Pedal Position B

(Secondary)

C0787

C0164

C0908

C0642

C1574

C1575

C0412

C0672

C0149

55

55

72

72

67

63

55

55

44

44

43

34

34

6

56, 63

67

Sensor-R/L/ABS

Sensor-R/R/ABS

C0502

C0503

Sensor-Screen Wash Fluid Level C0620

Sensor-Side Impact-Left C2345

Sensor-Side Impact-Right

Sensor-Steering Angle

Sensor-Sun

Sensor-Switch Buckle-Driver

Sensor-Vehicle Speed

(Automatic)

C2346

C1672

C0881

C2405

C0195

51

51

73

3

3

13, 50, 56

6

2

68

Sensor-Vehicle Speed (Manual)

Sensor-Yaw rate Acceleration

Side Repeater-LH

Side Repeater-RH

C1561

C1656

C1930

C1931

Socket-Accessory/Cigar Lighter

Socket-Rear Power Outlet

Solenoid-Fuel Flap Release

Solenoid-Glovebox Release

C0089

C1632

C0690

C2833

Solenoid-Power Assisted Steering C2571

1

1

32

32

59

68

51

35

35




Component

Sounder-PDC Rear

Speaker-Dual-Front Centre

Speaker-Dual-Front Left

Speaker-Dual-Front Right

Speaker-Rear Left

Speaker-Rear Right


C0405

C0369

55

45

C0340

C0339

C0310

C0308

45

45

46

46

Starter Motor Terminal

Starter-Motor

Stator-Steering Wheel

Subwoofer-Active

C0178

C0179

C0082

C0656

Switch Pack-Drivers Door C0054

Switch -Window-Passenger Door C0087

Switch-Aircon Request

Switch-Battery Disconnect

Switch-Battery Disconnect

Terminal

C1494

C1271

C0046

58

70

3

46

26, 28

24

4, 11

57, 58

57, 58

Switch-Battery Off

Switch-Bonnet

Switch-Boot Release

Switch-Boot Release (Interior)

Switch-Brake Boost

Switch-Brake Fluid Level

Switch-Brake Pedal

Switch-Buckle-Passenger

Switch-Clutch Bottom Of Travel C0667

Switch-Clutch Top of Travel C1491

Switch-Convertible Roof

Switch-Cruise Control

C2591

C0749

Switch-Direction Indicator

Switch-Drive

Switch-Fuel Flap Release

Switch-Glovebox Release

C0036

C2735

C0748

C0238

C1822

C0007

C0221

C1681

C2448

C0026

C0075

C0262

70

70

18

71

30, 33, 35

9

32

32

51

50

39

2

57

63

36

36

Switch-Hazard

Switch-Heated Front Screen

Switch-Heated Rear Window

Switch-Horn (Steering Wheel)

Switch-Ignition

Switch-IVD

Switch-Manual Handbrake

Switch-Master Light

Switch-Master Light

Switch-Master Locking

Switch-Neutral

Switch-Oil Pressure

Switchpack-Seat-Manual 1





C0041

C0328

C2359

C0187

C0773

C0776

C0774

C2800

C0775

C0096

C0131

C0072

C1908

C0028

C0984

C0648

C1082

10, 33

25

9

65

61

62

61

62

61

11, 35

10, 42

10, 42

71

70

12, 50

39

10

Component


Switch-Park

Switch-PDC Disable

Switch-Rear Fog Lamps

Switch-Recirc

Switch-Reduced Guard

Switch-Reverse

Switch-Reverse (Inline)

Switch-Sport

Switch-Start Button

Switch-Steering Column-Wiper

Switch-Tonneau Lid Closed1

Switch-Tonneau Lid Closed2

Switch-Touchtronic (Paddles)

Temp Actuator

Terminal-Jump Start

TMC Module

TMC Module

TMC Module (MOST)

Transducer-Fuel Rail Pressure

Transducer-Fuel Rail Pressure

Transducer-Power Steering

Pressure

Tuner-GPS

Tuner-GPS

Tuner-GPS (MOST)

Unit-Battery Conditioner

Valve-Canister Vent

Valve-Electric Vapour

Management

Valve-Electric Vapour

Management

Valve-Exhaust Bypass

Window Motor-Drivers Door

Window Motor-Passenger Door


C2801

C2736

62

8

C1541

C0064

C0750

C2787

55

10, 37

4, 11

63

C0166

C0163

C0985

C2453

C0278

C2573

C2962

C0410

8

38

8, 12

70

73

20

C2130

C2307

C0897

C2220

C0899

C2467

C2468

C2469

9

5, 6

58

7

7

74, 75

65

66

65

C1608

C1609

C2517

C2797

C2371

C2472

C2473

C1685

C0740

C0741

17

17

74, 75

69

68

65

66

68

23

24


Circuit Diagrams

OU,0.5

BY,0.5

BY,0.5

C2409-1

B,0.5

B,0.5

B,0.5

U,0.5

BK,2.5

Y,0.5

PROFET

120 Ohms

RB,05

RN,05

SPL37-CAN/EN

120 Ohms

CAN LS+ Sheet 15 CAN LS- Sheet 15

120 Ohms

120 Ohms

SPL38-CAN/CA

120 Ohms

CAN LS- Sheet 14 CAN LS+ Sheet 14

120 Ohms 120 Ohms 120 Ohms 120 Ohms

BU,0.5

BY,0.5

B,4.0

B,4.0

PROFET

B,2.0

Sheet 36 Side Repeater LH

B,0.5

B,1.0

B,1.0

B,0.5

C0384-6 B,0.5

B,1.0

BY,0.5

BY,0.5

B,0.5

B,0.5

OU,0.5

B,0.5

B,0.5

BU,0.5

B,0.5

C0467-1 B,0.5

B,0.5

C2246-12

C2246-4

C2246-6

C2246-2

C2246-1

C2246-8

C2246-9

C2246-7

C2246-10

C2246-3

C2246-5

OY,0.75

U,0.5

R,50.0

Battery

12.0 Volts

B,50.0

B,50.0

B,50.0

12.0 Volts

B,0.5

U,0.5

GY,0.5

Coupe

Convertible

BU,0.5

U,0.5

B,1.5

B,1.5

C2409-29

FO,FO

FO,FO

FO,FO

FO,FO

FO,FO

FO,FO

FO,FO

FO,FO

FO,FO

FO,FO

PCMs

Vehicle Control Modules (18.08)



Vehicle Control System (18.08)

Module Configuration

Principles of Operation

All configurable modules are packaged in a kit which contains a warning label and a multi-language sheet reemphasizing the requirements to configure replacement modules.

Replacement configurable modules must be configured using WDS.

Market Configuration

This data is required so that modules can interact with the vehicle correctly. By using WDS this data will be retrieved in the following ways:

• Indirectly from a mirrored image of the old modules data stored in an ‘As is’ database on DCS

• Indirectly from information stored in WDS

Configuration

The complexity of the electronics involved with module configuration and the multiplex communication network which they are connected to preclude the use of general workshop electrical test equipment.

WDS contains detailed instructions on module configuration.

Install the new module(s) and download the ‘As is’ data using the vehicle configuration software on WDS.

WDS will permanently retain the configuration information

Customer Configuration

There are certain modules / functions that the customer may or may not want reconfigured or enabled. Some of these preferences are accessed through the ‘in-car’ menus, available on the infotainment centre. Others are set in the vehicle configuration or specific software files, these items can be toggled or configured by WDS.

The ‘As is’ database (AML) holds customer original preferences. When a new module is installed to a previously upgraded or reconfigured vehicle these preferences can retrieved and re-applied as required through WDS

Data Buses

The primary data required for control and operation is carried on CAN data buses.

Two Can buses are used:

• High Speed CAN bus operates at 500 k bits / sec and is primarily used to transmit powertrain data

• The Powertrain (high speed) CAN bus operates at 500 k bits / sec and is only used to link the two PCMs

• Low Speed CAN bus operates at 125 k bits / sec and is used to transmit data relevant to the body system.

For data bus circuits - (Refer to ’Circuit Diagrams’, page 18-

1-17).

Network Bus

MOST

The MOST network bus is a fibre optical network used only for the Infotainment System

For the MOST network circuits - (Refer to ’Circuit Diagrams’, page 18-1-17).

Issue 2 November 2004 Workshop Manual 18-2-1



Module Locations (RHD)

18-2-2 Workshop Manual Issue 2 November 2004






Module Locations (LHD)









Contents

Active Anti-Theft System (19.01) .........................19-1-2

Alarm System Overview ......................................... 1-2

Component Descriptions ....................................... 1-2

Battery Backed Sounder....................................... 1-2

Guard Reduction Switch...................................... 1-2

Mass Movement Sensor (optional) ....................... 1-2

Central Electronics Module (CEM)........................ 1-2

Driver Information Module (DIM) ........................ 1-2

Ajar switches (perimeter sensors) ......................... 1-2

Remote Transmitter ............................................. 1-2

Functional Description ........................................... 1-3

Overview – Alarm .................................................. 1-3

General setting....................................................... 1-3

Door open............................................................. 1-3

Disable the Alarm .................................................. 1-3

Reduced guard mode ............................................ 1-3

Alarm Cycle ........................................................... 1-3

Audible output device (Siren)............................... 1-3

Visible output device DI’s .................................... 1-3

Panic Alarm ........................................................... 1-3

Activate Panic Alarm............................................ 1-3

Deactivate Panic Alarm ....................................... 1-3

Panic alarm cycle ................................................ 1-3

Remote Transmitter................................................ 1-4

Key Learning Operations........................................ 1-4

Integrated Passive Anti-Theft System (IPATS) ........ 1-4

Description ............................................................ 1-4

Disarming IPATS .................................................... 1-4

Arming IPATS......................................................... 1-4

IPATS LED ............................................................... 1-4

Key Programming................................................... 1-5

Count Keys ......................................................... 1-5


Active Anti-Theft System (19.01)




Alarm System Overview

All alarm and central locking operations are controlled from within the Central Electronic Module (CEM).

Communications with the Mass Movement Sensor, the Instrument Module, the Remote Key Less Entry Function and the

Battery Backed Sounder are via data buses.

Component Descriptions

Battery Backed Sounder

Ajar switches (perimeter sensors)

The car is equipped with ajar switches to sense unauthorised access to the following areas:

This device produces the audible out-put from the alarm system. The sounder can also house a tilt sensor to detect unauthorised vehicle movement.

• Doors (Cabin area)

• Boot (Luggage compartment)

Guard Reduction Switch

Used to disable the mass movement sensor, double locking and tilt sensor, so that people or animals can be left in the vehicle.

Mass Movement Sensor (optional)

Detects movement within the cabin of the car using microwaves. It is specifically designed to protect the ignition barrel and lock.

Central Electronics Module (CEM)

This module controls the vehicle alarm system. The CEM controls all alarm system inputs and outputs.


Instrument Cluster

• Bonnet (Engine bay)

Remote Transmitter

Remote Key less Entry (RKE)

Controls the vehicle locking functionality (Refer to the vehicles Owner’s Guide for operation).

The message centre right provides text messages displaying alarm information to the user.




Functional Description

Overview – Alarm

The Vehicle Alarm System (VAS) will generate an audible and visual warning if the vehicle doors, bonnet or boot are opened without first disarming the system using an authorised remote transmitter key.

There are two types of alarm system:

• Standard

• High Specification (optional). Includes an interior movement sensor and tilt sensor

The interior movement sensor offers further protection of the ignition barrel and steering wheel lock, the tilt sensor will detect unauthorised angular movement of the vehicle.

A Battery Backup sounder (BBS) is used to protect the sounder from disconnection. The BBS will sound if any attempt is made to disconnect it from the rest of the alarm system when the vehicle is armed.

General setting

The system will be armed on the first press of the remote transmitter ‘Lock’ button. The alarm system will arm and deadlock 25 seconds after receiving the arm request.

Door open

If the alarm system is set when any door, bonnet or boot are left open, then the alarm will be armed on all closed doors only, 25 seconds after the alarm set command has been requested. The open door, bonnet or boot will not be armed. 5 seconds after the open door, bonnet or boot have been closed, the alarm will Arm on that door, bonnet or boot.

Disable the Alarm

The alarm will be disabled following the unlock or boot open commands from the remote transmitter key or by turning the ignition key in the ignition barrel.

Reduced guard mode

When the vehicle is in reduced guard mode the mass movement and tilt sensors are disabled. This allows people or animals to be left in the vehicle.

With doors, boot and bonnet closed, ignition key in position

‘0’ or ‘I’ or within 60 sec after removing the keys the reduced guard button can be activated.

The ignition key must have been in position ‘II’ f

Aston Martin DB9 2005 Workshop Manual 652 Pages

Aston Martin DB9 2005 Workshop Manual

Workshop Manual

Issue 2

DB9 Workshop Manual

Contents

Introduction

Contents

Welcome

Welcome

Chapters

Chapter Navigation

Numbering

Location References

Warnings, Cautions and Notes

Special Tools

Repairs and Replacements

Safety Precautions

Safety Precautions

Battery Disconnection

Air Conditioning (A/C) System

Chemical Handling and Storage

Electrical Equipment

Safety Precautions

Exhaust Fumes

Fire Precautions

Tools and Equipment

Used Engine Oil

Health Protection Precautions

Environmental Protection

Lifting and Jacking

Lifting and Jacking

Safety

Jacking Points

Front Crossmember

Stands

Workshop Hoist

Vehicle Recovery

Vehicle Recovery

General

Rear Suspended Tow

Towing an Automatic Vehicle

Transporting

Suspended Towing

Front Suspended Tow

Towing Regulations

Towing by Another Vehicle

Push-start

Identification Numbers

Identification Numbers

Vehicle Identification Number (VIN)

VIN Number Location

VIN Number

VIN Number

Identification Numbers

Engine Number

Gearbox Number

Automatic Gearbox

Manual Gearbox

Body System (01.00)

Body Structure (01.01)

Front End (01.02)

Specifications

Maintenance

Body Closures (01.03)

Doors

Boot Lid

Bonnet

Doors

New Door Assembly

Boot Lid

Bonnet

Interior Trim (01.05)

IP Trim

Roof Trim

Door Trim

Rear Trim

Boot Trim

Installation

Exterior Trim (01.08)