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Service manual Jaguar xj6 2002

1. 76 22 16 76 21 FRONT QUARTER BUMPER RENEW 76 22 73 76 23 FRONT QUARTER BUMPER LOCATING BRACKET 76 22 20 76 22 FRONT QUARTER BUMPER MOUNTING RUBBER 76 22 19 76 22 FRONT SEA Visisseiscsswecdeodasccckectecscaveasssasavecavnaneneosc RENEW 76 70 01 76 72 FRONT SEAT BELTS 91M Y RENEW 76 73 00 76 116 FRONT SEAT BACK RENEW 76 70 03 76 72 FRONT SEAT BELT RENEW 76 73 12 76 76 FRONT SEAT BELT BUCKLE RENEW 76 73 02 76 73 FRONT SEAT BELT LEFT RENEW 76 73 10 76 73 FRONT SEAT BELT RIGHT RENEW e 76 73 21 76 74 FRONT SEAT CUSHION eren nnn RENEW 76 70 02 76 74 FRONT SEAT CUSHION COWER nnns RENEW 76 70 02 76 74 FRONT SEAT CUSHION SUPPORT RENEW 76 70 19 76 75 FRONT SEAT RENEW 76 70 30 76 75 FRONT SEAT HEAD REST ELECTRICALLY OPERATED SEA
2. RENEW COOLANTVALVE VACUUM SOLENOID RENEW DE FROSTVACUUM SOLENOID RENEW DEMISTER DUGCTS neci ci ire RENEW DEMISTER RENEW DEMISTER FLAP RENEW DRIVERS VENT OUTLET eese RENEW ELECTRONIC CONTROL MODULE RENEW HEATER RENEW HEATER MATRIX 2 202 diae tte innt n ern neon RENEW HEATER MATRIX RENEW HEATER SWITCH CONTROL MODUDLE RENEW HEATING amp VENTILATION esee DESCRIPTION INDEX E ILLUSTRATED IN CAR TEMPERATURE RENEW LOWER SERVO eene RENEW LOWER SERVO MOTOR FEEDBACK POTENTIOMETER RENEW PASSENGER VENT OUTLET eee RENEW RE CIRCULATIONVACUUM SOLENOID RENEW
3. 706 2241 2 2 een 76 51 4 191255 REAR BUMPER CENTREBLADETRIM FINISHER 7622 14 76 52 4 132 REAR CENTRE SEAT BELTSTATIC 76 73 31 76 78 4 1932 REAR 76 34 23 76 39 4 134 REAR DOOR GLASS eese eene 76 31 02 itis 76 38 4 1 35 REAR DOOR GLASS CHANNEL RUBBER 46 915142 76 40 4 136 REAR DOOR GLASS 76 31 61 76 41 4 T9 fines REAR DOOR 76 58 02 76 41 4 0022K 76 11 BODY SECTION 178 177 145 amp 146 138 139 140 142 amp 143 162 163 147 141 164 144 151 152 153 amp 154 165 166 177 168 169 157 150 161 149 470 171 172 173 174 148 179 127 159 158 J76 577 76 12 BODY SECTION ILLUSTRATED INDEX KEY ITEM DESCRIPTION OPERATION PAGE VOLUME No No No 138 REAR DOOR INSIDE HANDLE 76 58 19 7642 4 c AB DOOR MATER MRNA TINTE rana 139 BEAR BOOR LOCK o E FEAR DOOR LOWER TRIM 76 34 06 76 44 4 14277 REAR DOOR OUTER HANDLE OPERATING ROD 76 3741 76 97 cscs 4 14377 REAR DOOR
4. VACUUM VENTILATOR CENTRE FLAP SERVO VENTILATOR n WATER TEMPERATURE SWITCH d WATER VALVE eene AIR CONDITIONING ELECTRONIC CONTROLSYSTEM DESCRIPTION 82 00 00 At the heart of the air conditioning control module is a digital micro processor which receives data signals from driver controlled switches then by comparing this data with the signals received from the various temperature sensors and the feedback devices it calculates the output voltages needed to operate the blower motors at the required speed the flap servo motors to the required positions also the compressor and the vacuum solenoids to acheive the temperature requirements selected for the vehicle Although the control module cannot be repaired in service a complete set of test pins are accessiblefor testing the system Great care must be exercised when connecting the test equipment for the control module will be irreparably damaged should any of the test pins bernomentary shorted together 9 10 11 12 13 Fig 1 Keyto Diagram 1 Control module 2 Differentialtemperature control 3 Temperature control 4 Blower motor switch 5 Ambienttemperature sensor 6 In cartemperature control 7 Evaporatortemperature switch 8 Solarsensor 9 Coolanttemperature switch 10 Flapfeedback potentiometer
5. MAP LAMP MAP LAMP LENS aententia 86 02 Issue 2 ELECTRICAL SYSTEMS OPERATION PAGE No No 86 40 39 86 30 86 40 4 86 30 86 40 40 86 30 86 25 06 86 23 86 40 53 86 31 86 45 52 86 43 86 70 20 86 89 86 45 70 86 46 86 00 00 86 104 86 00 00 86 103 86 00 00 86 105 86 00 00 86 105 44 15 12 86 64 86 55 89 86 67 86 45 08 86 36 86 70 24 86 85 86 45 07 86 36 86 65 77 86 52 86 65 45 86 65 86 70 00 86 68 86 70 00 86 68 86 40 2 86 28 86 40 22 86 28 86 40 19 86 27 86 40 20 86 28 86 45 65 86 45 86 65 55 86 92 86 70 32 86 87 86 45 73 86 42 86 80 14 86 55 86 45 89 86 49 86 30 00 86 26 86 30 09 86 45 64 86 45 86 65 03 86 62 86 65 00 86 62 86 65 00 86 61 86 45 95 86 67 86 00 00 86 04 86 00 00 86 05 86 45 48 86 40 86 80 18 86 56 86 45 00 86 35 86 45 13 86 37 86 45 06 86 37 86 45 1 86 37 86 70 23 86 83 86 45 57 86 44 86 80 05 86 54 86 00 00 86 61 86 45 74 86 46 86 45 16 86 38 86 45 15 86 38 86 65 22 86 52 86 25 49 86 26 86 70 19 86 85 86 45 09 86 36 86 45 18 86 38 DESCRIPTION NUMBER PLATE LAMP amp BULB OIL GAUGE ILLUMINATION BULB OIL PRESSURE INDICATOR BULB PARKING LAMP INDICATOR BULB ELECTR C PASSENGER DOOR HARNESS PASSENGER SEAT MOTOR SWITCH PASSIVE RESTRAINT ECU PASSIVE RESTRAINT SYSTEM POWERED SEATS POWERED SEAT HARNESS
6. cc err tee TEST 86 15 02 86 18 BATTERY CONDITION INDICATOR ILLUMINATION BULB seen RENEW 86 45 56 86 44 BATTERY HEALTH AND SAFETY PRECAUTIONS 86 15 00 86 18 BATTERY 5 4 86 15 17119 86 20 BATTERY DISTRIBUTION 86 15 00 86 21 BOOT OPEN WARNING INDICATOR BULB RENEW 80 45 87 86 49 BOOT RELEASE SWITCH 86 65 25 86 67 BONNET LAMP 86 45 24 86 39 BONNET LAMP LENS amp BULB ne RENEW 86 45 23 86 39 BONNET LAMP LINK HARNESS 86 70 26 86 86 BONNET LAMP SWITCH 86 65 23 86 40 BOOT LID RELEASE MOTOR 86 25 54 86 91 BRAKE WARNING INDICATOR 86 45 69 86 46 CHART 86 00 00 80 12 BULB FAILURE MODULE FRONT CONNECTORS 86 55 00 86 99 BULB FAILURE MODULE REAR CONNECTORS 86 55 00 86 101 BULB F
7. door Removethe passenger side dash liner EX Y Removethe screws securingthe module ETAT Displacethe module from retainingclip V ALS Disconnectthe cable hamess block connector Remove the module 8Fig 1 Fitting a new module is the reversal of the removal procedure 30018 HEATER SWITCH CONTROL MODULE Fig 1 RENEW 86 80 14 Openthe bonnet and disconnect the battery earth lead 1 Openthe car door Removethe gear lever knob 37 1 6 11 Removethe consolefinisher 76 25 1 9 Remove the screws securing the upper console assembly 1 Fig 2 Displacethe upper console assembly for access Slackenthe screws securingthe control module Disconnectthe cable harness block connector 2 Fig 2 Removethe module Fitting a new module is the reversal of the removal procedure 30016 CENTRAL PROCESSOR UNIT Fig2 RENEW 86 80 17 Open the bonnet and disconnect the battery earth lead Open the car door and removethe passenger side dash liner 76 46 1 5 Remove the lower screws securing the processor and remove the spacers Displace the processor upwards to disengage the keyholeslot Disconnectthe cable hamess block connectors Removethe screw securing the earth lead Removethe processor unit 10 Fig Fitting a new central processor is the reversal of the A removal procedure 30018 480 Fig3 86 55 ELECTRICALSYSTEM INSTRUMENTILLUMINATION DIMMER MODULE
8. teet teats 76 70 41 nies 4 oy E ELECTRICALLYOPERATED FRONTSEAT RUNNER AND MOTOR 76 70 08 4 EXTERIOR 76 1 0 52 4 56 us FASCIA BOARD eene 76 46 01 4 57 FASCIA CENTRE VENEER 76 47 06 4 58 FASCIA CLOSING PANEL DRIVERSSIDE 76 46 28 4 59 FASCIA CLOSING PANEL PASSENGERSSIDE 76 46 27 4 60 FRONT BUMPER CENTRE BLADE 70 22 37 ces 4 61 2 FRONT BEAM eene 76 22 26 4 625552128 FRONT BEAM COVER 76 22 28 4 63 FRONT 8 76 1 0 05 4 64 FRONT 76 34 22 4 65 FRONT DOOR 9 5 70 91 01 5 22 4 66 FRONT DOOR GLASS at ae RUBBER 76 31 13 4 67 FRONT DOOR GLASS 76 31 51 4 68 FRONT DOOR HANDLE MENACE 76 58 01 4 FRONT DOOR INSIDE HANDLE 76 58 20 4 70
9. 84 80 1 1 84 08 WIPER MOTOR RENEW 84 15 12 84 07 0196G 84 1 WINDSCREEN WIPERS AND WASHERS ILLUSTRATED INDEX WINDSCREEN WIPERS AND WASHERS ILLUSTRATEDINDEX KEY ITEM DESCRIPTION OPERATION PAGE VOLUME No No No Ue HEADLAMP WASHER JETS e 84 20 08 84 08 4 HEADLAMP WASHER PUMMP 84 20 21 84 09 4 55122226 HEADLAMPWASHER PUMP RELAY 86 55 83 84 09 4 E ONE 84 00 00 84 02 4 WASHER 84 10 03 84 05 4 WASHER RESERVOIR SENSOR 84 10 17 84 06 4 WASHER WIPER SWITCH ee 84 15 34 84 08 4 ques ecd WINDSCREENWASHER JETS 84 10 08 84 05 4 WINDSCREENWASHER 84 10 21 84 06 4 WINDSCREEN WASHER PUMP RELAY 86 55 82 84 06 4 EON WINDSCREEN WIPERS nnne 84 00 00 84 04 4 WIPER ARM nnns 84 15 02 84 07 4 5 WIPER BLADE enn 84 15 05
10. rc LOWER oain FLAPM TEE UPPER EHATER 0 0 00 0000 19 HEATER COOLER UNIT docte 20 HOSE COMPRESSORTO hee HOSE EVAPORATORTOCOMPRESSOR HOSE RECEIVER DRIER EVAPORATOR esta INDEX KEY rr ert ext cM IN CARTEMPERATURESSENSOR LOWER FEED BACK POTENTIOMETER PNE UPPER FEED BACK POTENTIOMETER cedet MANIFOLD GAUGE EMEND 50 26 REARAIR DISTRIBUTION maths Yards SIGHT GLASS oec E a RR tc SOLAR SENSOR A n radere AS SOLAR SENSOR 28 ws SUPER 5 20 2 iios SUPER miii SUPER HEATSWITCH AND THERMAL FUSE 29 su SWITCH CONTROL MODULE see SWITCH CONTROL MODULE ILLUMINATION DUAE SWITCH eon TEMPERATURE DISTRIBUTION SYSTEM mius
11. RENEW 76 70 14 76 71 FRONT SEAT RUNNERS AND ADJUSTER ASSEMBLY RENEW 76 70 24 76 76 FUEL FILLER CAP RETENTION MAGNET 76 10 27 76 116 FUEL FILLER FLAP LATCH POST 91MY RENEW n 76 10 28 76 116 GEARBOX SPORT MODE SWITCH FINISHER RENEW 76 25 09 76 97 GLOVE BOX RENEW 76 52 03 76 87 GLOVEBOX ane RENEW 76 52 02 76 87 GLOVEBOX LID RENEW 76 52 08 76 88 GLOVEBOX LID VENEER RENEW n 76 47 21 76 88 GLOVEBOX MIRROR ASSEMBLY RENEW n 76 52 05 76 89 GUTTER FINISHER eere RENEW 76 43 11 76 53 HANDBRAKE LEVER TRIM nnn RENEW 76 13 63 76 89 HEADLAMP TRIM FINISHER nnn RENEW 76 40 01 76 24 HEADLINING REAR RENEW 76 64 12 76 89 ILLUMINATED SUNVISOR 9 RENEW 76 10 48 76 93 ILLUMINATED SUNVISOR MIRROR ASSY RENEW 76 10 50 76 93 INID S EEIE ILLUSTRATED 76 00 00 76 06 INSTRUMENT PANEL VENEER PA
12. SEALING ds matt d Art uae SEN ME 77 00 00 SIDE REPAIRS COMBINATION 1 17 50 01 SIDE REPAIRS CONMBINATION 2 77 50 02 SIEEPANEESEGTION eie te patietur cepe 74 40 00 77 3 VOLUME BODY REPAIR HEALTH AND SAFETY The Health and Safety at Work Act 1974 places a duty on employers to ensure whenever practicable safe working conditions andthe absence or risksto health in connection with the use handling storage and transport of articles and substances With the introduction in recent years of new materials inthe manufacture of vehicles it isimportantthat the risks are highlighted andthe precautions made known PAINT Most paints contain organic solvents these can cause damage to the liver and kidenys if inhaled over long periods Servere solvent inhalationcan cause dizzinessor loss of consciousness Splashes of solvents paint activators and additives can cause damageto the eyes Solventto the skin can cause dermatitis Spray dust and sanding may cause lung damage Peroxide and acid catalysts may cause burns Isocynates may cause lung sensitisation and development of asthma like symptons will follow on subsequent exposureto very low concentrationsof isocyanates Inhaling paint may cause severe irriation of the mouth throat and digestive tracts THE FOLLOWING PRECAUTIONSWILL ELIMINATE MOST RISKS The inhala
13. 84 20 08 84 08 HEADLAMPWASHER RENEW 84 20 21 84 09 HEADLAMPWASHER PUMP 86 55 83 84 09 INDE cesta et cee ILLUSTRATED 84 00 00 84 02 WASHER RESERVORR cessere nnne RENEW s 84 10 03 84 05 WASHER RESERVOIR 84 10 17 84 06 WASHER WIPER RENEW 84 15 34 84 08 WINDSCREEN WASHER JETS RENEW 84 10 08 84 05 WINDSCREEN WASHER 84 10 21 84 06 WINDSCREEN WASHER PUMP RENEW 86 55 82 84 06 WINDSCREEN WIPERS eere INTRODUCTION 84 00 00 84 04 WINDSCREEN WIPERS eeeeeen eren OPERATION 84 00 00 84 04 55 RENEW 84 15 02 84 07 WIPER BLADE erret ere RENEW 84 15 05 84 07 WIPER LOGIC MODULE crecen RENEW
14. 86 50 13 86 59 FRONT DOOR WINDOW LIFT MOTOR 86 25 04 86 22 86 01 Issue 2 CONTENTS DESCRIPTION OPERATION FRONT FLASHER LAMP FRONT FLASHER LAMP FRONT FLASHER LAMP FRONT PASSENGER WINDOW LIFT SWITCH FRONT REPEATER FUEL GAUGE ILLUMINATION FUEL PUMP LINK FUEL WARNING INDICATOR BULB 2240 LH SIDE BOX FUSE CHART bue d Lo M LR RH SIDE BOX FUSE CHART CENTRE BOX FUSE CHART Ae IN LINE GEAR BOX LINEAR SWITCH GEAR BOX POWER RELAY GLOVE BOX LANP GLOVE BOX LAMP HARNESS GLOVE BOX
15. FRONT DOOR 76 37 128 4 JR FRONT DOOR LOCK 76 37 23 4 a FRONT DOOR OUTER HANDLE OPERATING rS 4 sce dum FRONT DOOR REMOTECONTROL OPERATING x MM e E 4 TA scr FRONT BOO 4 Vis aer FRONT DOOR TRIM PAD VENEER PANEL 4 TO auum FRONT DOOR UPPER TRIM PAD 4 Yu eese FRONT DOOR LOWER TRIM PAD 4 78 FRONT DOOR WAIST RAIL MOULDING 4 79 FRONTENERGY ABSORBING STRUT 4 80 FRONT FLOOR 4 81 FRONT QUARTER 4 82 FRONT QUARTER BUMPER BLADE 4 83 BUMPER LOCATING rH E PEE 4 84 FRONT QUARTER BUMPER MOUNTING FRONT SEAT BACK FRONT SEAT BELTADJUSTER FRONTSEAT BELT BUCKLE UNIT FRONTSEAT BELT LEFT HAND FRONT SEAT BELT RIGHT HAND FRONT SEAT CUSHION COVE FRONTSEAT CUSHION SUPPORT CENTRE FRONT SEAT 5 FRONTSEAT HEAD REST ELECTRICALLY OPERATED SEAT tranne tcn 76 9 BODY SECTION 109 123 98 99 1
16. SOLAR SENSOR erret e nenas RENEW UPPER SERVO MOTOR eese RENEW UPPER SERVO MOTOR FEEDBACK POTENTIOMETER RENEW 0209G 80 1 OPERATION PAGE No No 80 10 53 80 15 80 20 1 1 80 09 80 20 12 80 10 80 10 41 80 10 80 10 42 80 11 80 10 39 80 1 1 80 15 66 80 18 80 15 51 80 13 80 15 48 80 17 80 15 24 80 17 80 10 47 80 14 80 10 51 80 15 80 10 50 80 15 80 10 49 80 14 80 15 02 80 16 80 15 53 80 18 80 15 52 80 13 80 15 49 80 17 80 10 52 80 08 80 10 16 80 09 80 20 29 80 08 80 20 04 80 09 88 80 14 80 08 80 00 00 80 04 80 00 00 64 02 80 10 54 80 16 80 10 46 80 12 80 10 43 80 12 80 15 50 80 18 80 10 48 80 14 80 10 55 80 16 80 10 45 80 11 80 10 44 80 12 HEATING AND VENTILATION PAGE 80 02 RESERVED FOR ILLUSTRATED INDEX J80 80 2 HEATING AND VENTILATION PAGE 80 03 RESERVEDFOR ILLUSTRATED INDEX KEY 30 3 HEATING AND VENTILATION HEATING AND VENTILATION DESCRIPTION 80 00 00 Electronic Control Module The electronic control module is located on the right hand side of the heater box assembly At the heart of the electronic control module is a digital micro processor which receives data signals from driver cont
17. 286 113 Reposition the fuel tank retaining strap lower Fig 2 brackets to the body bolt holes then fit and tighten the body securing bolts Tighten the fuel tank retaining strap to the lower bracket clamping nuts and bolts ensuring that no cables and pipes have been trapped Close the filler flap to check the alignment with the body Open the filler flap Remove the rubber stop from the adjustment screw Adjust the screw up or down as required Refit the rubber stop Close the filler flap Refit the bootfront liner left hand side liner and boot floor carpet Replace spare wheel and jack Close the boot Connect the battery Close the bonnet 86 109 ELECTRICAL SYSTEMS 91MY FUEL PUMP LINK HARNESS RENEW 86 70 20 Open the bonnet Disconnect the battery Open the boot Remove spare wheel and jack Remove the bootfront liner and floor carpet Disconnectthe fuel pump link harnessto side harness block connector Cut and remove the ratchet straps securing the link harnesses Reposition the link harness from behind the fuel tank left hand retaining strap Disconnectand remove the link harness from the fuel tank evaporative loss flange socket 1 Fig 1 Connect the new link harness to the fuel tank Fig 1 evaporative loss flange socket Reposition the link harness behind the fuel tank left hand retaining strap Connect the link harness to the side harness block connector Secure the fuel pump link ha
18. GLOVE BOX HANDBRAKE WARNING SWITCH HARNESS CONNECTOR DESCRIPTION HARNESSES DESCRIPTION HEADLAMP BULB LEFT HEADLAMP BULB RIGHT HAND HEADLAMP UNIT LEFT HEADLAMP UNIT RIGHT HEADLAMP HIGH BEAM INDICATOR BULB HEADLAMP HORN INDICATOR COMBINATION SWITCH a foe HEATED BACKLIGHT EARTH HEATER INDICATOR PANEL HEATER SWITCH CONTROL HIGH COOLANT TEMPERATURE WARNING INDICATOR HORNS er haem IGNITION INDICATOR IGNITION SWITCH s IGNITION SWITCHED EARTH DISTRIBUTION DESCRIPTION IGNITION SWITCHED
19. 76 10 05 76 18 FRONT DOOR ARMREST een nnn RENEW 76 34 22 76 30 FRONT DOOR 59 RENEW 76 31 01 76 31 FRONT DOOR GLASS CHANNEL RUBBER RENEW 76 31 13 76 32 FRONT DOOR GLASS RENEW 76 31 51 76 33 FRONT DOOR nnn RENEW 76 58 01 76 33 FRONT DOOR INSIDE RENEW 76 58 20 76 34 FRONT DOOR LOG e raae earo redai o nnair nada nna RENEW 76 37 12 76 35 FRONT DOOR LOCK STRIKER e RENEW 76 37 23 76 37 FRONT DOOR OUTER HANDLE OPERATING ROD ADJUST 76 37 10 76 98 FRONT DOOR REMOTE CONTROL OPERATING GABLE EEE A E A N EEEE 76 37 67 76 26 FRONT DOOR SEAL enne 76 40 01 76 38 FRONT DOOR TRIM PAD VENEER PANEL 76 47 11 76 36 FRONT DOOR UPPER TRIM 76 34 02 76 38 FRONT DOOR LOWER TRIM 76 34 03 76 36 FRONT DOOR WAIST RAIL MOULDING RENEW 76 43 04 76 37 FRONT ENERGY ABSORBING STRUT RENEW 76 22 31 76 17 FRONT FLOOR CARPET eer nnn nn nnn RENEW 76 49 02 76 72 FRONT QUARTER
20. 76 46 11 76 83 DASH LINER PASSENGERS SIDE n RENEW nnne 76 46 15 76 83 DOOR AIR VENT GROMMET rens RENEW 80 00 00 76 83 ELECTRICALLY OPERATED FRONT RENEW 76 70 10 76 70 ELECTRICALLY OPERATED FRONT SEAT BACK FINISHER MS RM oM RENEW 76 70 09 76 71 ELECTRICALLY OPERATED FRONT SEAT CUSHION RENEW 76 70 11 76 69 ELECTRICALLY OPERATED FRONT SEAT RUNNER AND MOTOR 76 70 08 76 70 EXTERIOR MIRROR 76 10 52 76 52 FASCIA 76 46 01 76 84 FASCIA CENTRE VENEER 76 47 06 76 86 0051G 76 01 issue 2 BODY SECTION CONTENTS DESCRIPTION OPERATION OPERATION PAGE No No FASCIA CLOSING PANEL _DRIVERS SIDE RENEW 76 46 28 76 86 FASCIA CLOSING PANEL PASSENGERS SIDE 76 46 27 76 86 FRONT BUMPER CENTRE RENEW 76 22 31 76 16 FRONT BEAM eene nnne nnn nnn nnn nnn RENEW es 76 22 26 76 95 FRONT BEAM COVER enn nnn nnn nnn nnn RENEW 76 22 20 76 94 FRONT
21. Fig 1 Pin Cable YU RH motor positiveto front B Earthnegative B Earth negative NS RH system 12V OD 49 Pin Cable 10 YR LH belt proximity 11 YO RH beltproximity 12 13 YP RH rear dockswitch 14 YS RH overtravelswitch 15 ORH door switch 16 BK SB Logicearth 17 SU 86 98 ELECTRICALSYSTEM BULB MODULE FRONT CONNECTORS 86 55 00 7 PL 3 PIN COLOUR DIA FUNCTION Yeah 450 4 CONNECTOR PM49 WAY SOCKET Fig 1 6 959 ae 1 Red Orange 0 5 Fog 5 2 0 5 Dip DES 3 Blue Slate 0 5 Main 6 4 Red 05 Side ARS 6 White Pink 0 5 Ignition Fig 1 7 Brown Orange 2 0 Main 8 Brown Pink 2 0 Fog Dip t 9 Brown Gren 2 0 D I Side 3 SKT 7 CONNECTOR 9 WAY PLUG Fig 2 1 Red Orange 2 0 Fog 400 b 2 9 0 5 Side d ES 3 Green 0 5 D I 5 NL KO 4 Yellow Slate 0 5 D I 2 B e T 6 6 Yelow Pink 0 5 Side Repeater iin 7 Pink 0 5 D I Fail Fig2 8 Pink Slate 0 5 General Fail 9 Pink Blue 0 5 Disconnect Earth Loop S BEAM AND H43WAY CONNECTOR Fig3 1 Blue Slate 2 0 Main Beam 3 Black 2 0 Earth S BEAM AND H43 WAY CONNECTOR Fig 4 1 Blue White 2 0 Main Beam 186 837 2 Blue Pink 2 0 Dip Beam Fig3 3 Black 2 0 Earth EYELET RWC 51100351 Fig 5 1 Black 2 0 Earth 2 Black 2 0 Earth ixi FF1 NOTES 1 Cable lengths indicated on diagrams are from breakoutpointto connector mating face 186 838 2 module relays have a resistor diode protection network item
22. the headrest retaining clip from the headrest ube 76 71 BODY SECTION Remove the harness from the headrest and discard the headrest Reverse the removal procedure to fit a replacement headrest 1669B 82 FRONT FLOOR CARPET RENEW 76 49 02 Openthe door Liftoutthe carpet Fig 1 Fitandalign the replacement carpet in position Closethe door 1669B 70 FRONT SEAT RENEW 76 70 01 Open the door Removethe front seat cushion 76 70 02 Disconnect the reading lamp block connector move the seat fully forward Remove the seat runner to floor securing screws move the seat fully rearwardand openthe rear door Remove the remaining seat runner to floor securing screws disconnect the springs from the floor brackets and removethe seat assembly from the vehicle Removethe seat runner assister springs operate the seat runners for access to the rear securing bolts and remove the seat runnerto seat securing bolts Removethe seat runner and discard seat Reverse the removal procedure to refit the replacement Seat 0065b FRONT SEAT BACK FINISHER J7B 331 RENEW 76 70 03 Open the doors Removethe front seat cushion 76 70 02 Removethe front seat 76 70 01 Remove the back finisher and recline handle finishers Fig 2 andsecuring screw Removethe reclinehandle and the outer finishers Displace the top finisher from the headrest area and remove the back finisher from the spring retainers
23. 768227 TN 76 57 4 ME S PANELLIFTING BLOCK AN lA cent een 7682 38 76 58 1714222 SLIDING ROOF PANEL 76 82 18 75 58 ous 4 172 SLIDING ROOF PANEL 768249 76 58 4 i ones SEBING Ror BAERE e A DING REGE RACK VEHIGLESER T ss 7692490 76 60 4 ee SLIDING ROOF WIND DEFLECTOR LOC 76 8207 T 28612 5 1 STEERING COLUMN LOWER 76 46 03 76 92 4 STEERING COLUMN UPPER 76 4602 4 170 5 WEATHER sss 76 4322 76 61 4 1801 WEATHER STRIP GHANNEL 764825 76 62 4 0032K 76 13 BODY SECTION RESERVED FOR DIMENSIONS OF VEHICLE 4 08 2 9 76 14 BODY SECTION FRONT BUMPER RENEW 76 22 08 Remove the side marker lamps and the front side lamp assemblies Remove the two bumper securing bolts pull the bumper forward disconnectthe horn feed wires and remove the screw securingthe horn earthto the front bumper Removethe bumperassembly 1 Fig 1 Liftthe replacement bumper assembly into position Reconnectthe horn feed and earth wires Align fit arid tighten the two securing bolts ensuring that the two quarter bumpers are engaged in the wing side fixings Refit the side marker lamps and front side lamp assemblies DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal Fig 1 23 27Nm Bumper mounting struts to body Federal 23 27Nm Bu
24. POWERED SEAT LINK LEAD REAR AXLE HARNESS LH REAR AXLE HARNESS RH REAR BULB FAILURE MODULE REAR COURTESY LAMP REAR DOOR HARNESS REAR DOOR LOCK MOTOR REAR DOOR SPEAKER REAR FOG LAMP ASSEMBLY REAR FOG LAMP BULB REAR SIDE MARKER LAMP REAR SIDE MARKER LAMP BULB REAR WINDOW LIFT MOTOR REAR WINDOW LIFT SWITCH REPEATER LAMP ASSEMBLY REPEATER LAMP BULB REVERSE INHIBIT RELAY PASSIVE RESTRAINT SCREENWASH HEATER 91MY SEAT BELT BUCKLE SWITCH SEAT BELT WARNING INDICATOR BULB SEAT ENTRY SWITCH LINK HARNESS SEAT PAD SWITCH SIDE STOP REVERSE amp NUMBER PLATE SLIDING ROOF MOTOR LIMIT SWITCH SLIDING ROOF MOTOR SWITC SPEEDOMETER ILLUMINATION BULB SPORT MODE INDICATOR BULI STARTER CIRCUIT STARTER MOTOR STARTER MOTOR LINK LEAD STARTER TO ALTERNATOR LINK LEAD STEERING COLUMN HARNESS STOP LAMP SWITCH SUNROOF AND WINDOWS SWITCH PANEL ILLUMINATION BULB SYMBOLS TACHOMETER ILLUMINATION H B BULB TAIL STOP FLASHER AND REVERSE BULB TAIL STOP FLASHER amp REVERSE BULB HOLDER TAIL STOP FLASHER amp REVERSE LAMP LENS TEMPERATURE GAUGE ILLUMINATION BULB TRIP COMPUTER TRIP COMPUTER ILLUMINATION BULB TRIP COMPUTER amp CRUISE LO WIPE WASH WARNING INDICATOR BULB WIPER LOGIC MODULE Issue 2 GIC MODULE ICAL SYSTEMS ONTENTS OPERATION FAULT DIAGNOSIS DESCRIPTION 86 03 OPERATION PAGE No No 86 40 84 86 34 86 45 50 86 43 86 45 66 86 4
25. 4 5 5 580 4 116 PASSIVE 4 146 5 PASSIVE 4 116 PASSIVE 4 117 PASSIVE RESTRAINT GUIDE RAIL 4 118 PASSIVE RESTRAINT 4 119 PASSIVE RESTRAINT ECU 4 120 PASSIVE RESTRAINT INERTIA REEL 4 12 3 iii PASSIVE RESTRAINTMOTO E RRINE AND INERTIA REELASSEMBLIES 4 122 2 PASSIVE RESTRAINTSYSTEM USA ONLY 73 4 129 PASSIVE RESTRAINTWARNING CIROUIT 76 73 00 76 110 4 124 PETROL FILLER 76 10 25 rises 76 53 4 125 RADIATOR GRILLE SURROUND 76 55 15 76 54 4 126 1 RADIATOR GRILLE VEHICLESET 76 55 07 76 54 4 RADIO 76 255 76 93 4 128 REAR 76 22 27 76 96 4 129 REAR BEAM 76 22 29 76 94 _ 4 130 REAR BUMPER CENTRE BLADE
26. 4 5 LH door switch I P 13 YP RH rear dock switch 5 UR 14 YS RH overtravelswitch 6 GP Inertiaswitch I P 15 O RH door switch 7 YB LH overtravel switch 16 BK SB Logic earth 8 YLG LHreardockswitch 17 SU 9 GB 76 111 BODY SECTION PASSIVERESTRAINT SERVICE CHECKS 76 73 00 The following checks must be carried out at every 15 000 miles 24km service interval the period between services must not exceed six months INERTIASWITCH The inertia switch is located in the driver s footwell Ensure all doors except for the driver s are closed Sit in the driving position and ensurethe gear selctor lever is notinthe reverse postion Close and lock the driver s door by pressingthe door locking buttondawn this will also lockthe other doors Switch the ignition ON position 11 the automatic diagonal seat belts should move to the restaining position Raisethe test rest button which protrudesthrough the top of the inertia switch cover Observe that the doors unlock the automatic diagonal seatbelts remain in the restraining position and the instrumentdisplay is switched OFF Open the front doors the automatic diagonal belts should not movefrom the restraining position Leavethe front doors open and reset the inertia switch by depressing the button Observe that the instrument display is illuminatedandthat the diagonalseat belts moveto the unrestraining parked position Lock and unlockthedoorsto ensurethe central locking system sti
27. Door glass clamping strip to door 7 10 Door glass regulatorand slide channel to door 7 10Nm Set screw front lower frame fixing to door 7 TONm Setscrew front upper frame fixing to door 7 10Nm Set screw rear lower fixing to door 7 10Mm Set screw rear upper frame fixing to door 7 10Nm SPANNER SIZES 10mm Torx bit No 30 0020b FRONT DOOR HANDLE RENEW 76 58 01 Open the door Removethe front door trim padveneer panel 76 47 1 1 Removethe front door uppertrim pad 76 34 02 Removethe front door lowertrim pad76 34 03 76 33 BODY SECTION Removethe door aperture closing plate Displacethe weather shield and remove the door handle to linkage to lock mechanism retaining clip Disconnectthe door handle linkage Cut and remove the ratchet strap securing the switch harness Disconnectthe switch harness multi plug and reposition away from the door locatingtangs Remove the door handle assembly securing nuts and removethe clamp Fig 1 Displace the door handle from the door to provide access to the private lock operating rod Disconnectthe operating rod from the plastic cam and removethe door handle Removethe operating rod Remove the screws securing the central locking micro switch and discard the tape securing the harness to the handle body Removethe micro switch assembly Removethe handleclamp securing studs Discardthe handle Reverse the removal procedure to fit the replacement door handle DAT
28. 1 Depressurizethe system 2 Remove and inspect the condenser for oil clogging Clean and flush the condenser to ensure the free passage refrigerantor renewthe condenser 3 Renewthe receiver drier 4 Evacuatethe system using a vacuum pump 5 Rechargethe systemwith new refrigerant J82 0875 6 Operatethe systemandcheckthe performance Moisture In The System Fig 1 Complaint Cooling is not adequate during the hot part of the day Note Cooling may be satisfactory during the early morning or late evening but is not adequate during the hot partof the day Condition 1 The low side gauge reading normal but may drop into vacuum during testing 2 The high side gauge reading normal but will drop when the low side drops into vacuum 3 Thesight glass may showtiny bubbles 4 The discharge air from the evaporator is cold but becomes warm when the low side gauge drops into vacuum Diagnosis Excessive moisture in the system Desiccant agent saturated with moisture which is released during high temperatures The moisture collects and freezes in the expansion valve which stopsthe refrigerantflow Correction 1 Depressurizethe system 2 Renewthe drier bottle 3 Evacuatethe system usinga vacuum pump 4 Rechargethe systemwith new refrigerant 5 Operatethe system and check the performance 82 23 AIR CONDITIONING A LargeAmount Of Air InThe System Complaint Little or no cooling Condition 1 Thelowside g
29. 76 22 18 4 CANTRAIL CRASH 76 13 10 4 42 76 67 18 4 43 5 76 25 01 4 CONSOLE FINISHER AUTOMATIC 762519 4 45 CONSOLE FINISHER MANUAL sess 76 25 9 4 46 76 25 16 4 T1 uuu CONSOLEGLOVEBOX 76 25 18 4 0032K 76 7 BODY SECTION 75 68 69 70 71 72 amp 73 74 76778 78 54 5286 Xs ch J76 575 76 8 B ODY SECTION ILLUSTRATED INDEX KEY ITEM DESCRIPTION OPERATI ON VOLUME No 0 4248 22 DASH LINER DRIVERS 10 76 46 11 4 49 DASH LINER PASSENGERSSIDE 76 46 15 4 0 76 00 00 4 cR ELECTRICALLY OPERATED FRONT 76 70 1 4 EPEN ELECTRICALLY SEER ATED FRONT SEAT BACK FINISHER eene 76 70 09 4 OBEBATED FRONT SEAT CUSHION
30. 76 78 BODY SECTION Remove the foam pad from the rear shelf and remove the seat belt buckle securing bolt Fig 1 Remove the buckle assembly and collect the two star washers and spacers 5 Fig 1 Remove the side seat belt buckle and the lower anchorage bolt Displacethe belt and collectthe upper spacer Remove the seat belt reel securing bolt 7 Fig 1 and remove the reel 8 Fig 1 Remove the seat belt reel to securing bracket nut and bolt discard the reel and belt assembly Reverse the removal procedure to refit the replacement bely assembly 00770 REAR FLOOR CARPET RENEW 76 49 03 Open the front door Movethe front seat fully forward Open the rear door Remove the screws securing the rear of the seat runners to the floor Carefully ease the rear of the front seat upwardsto allow removal of the rear carpet Remove the carpet Fig 2 lowerthe seat andcollectthe spacers Reverse the removal procedure to refit the replacement carpet DATA TORQUE FIGURES Seatrunnersto floor 36 5Nm SPANNER SIZES No 50 Torx 16698 70 A POST LOWER TRIM PAD RENEW 76 13 30 Open the door Displace the draught welting from the lower A post area Removethe trim pad securing screw and removethe trim pad Turn the fuse label cover retaining peg and remove the fuse label cover Discardthe trim Reverse the removal procedure to refit the replacement trim 16698 76 79 BODY SECTION B C POST C
31. DATA TORQUE FIGURES Bumper quarter blade to quarter bumper 7Nm Bumper side to flexiblemounting block 5 ZNm SPANNER SIZES amm 70mm 7669B 76 21 BODY SECTION RENEW 76 22 19 Removethe front beam 76 22 26 Removethe front quarter bumper 76 22 16 Remove the nuts 1 Fig 1 securing the beam to the flexible mounting rubber and remove the mountingfrom the beam Reverse the removal procedure to fit the replacement rubber DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 22 Bumper mounting struts to body Federal 23 27 Bumper to bumper bracket Non Federal 40 50Nm Bumper to bumperstrut Federal 40 50Nm Guideblock to mounting bracket3 5 4 75Nm Horns to bracket22 28Nm Mounting bracket guide block to body 7 5 10Nm SPANNER SIZES 8mm 10mm 13mm 19mm No20Torx 1669B 66 FRONT QUARTER BUMPER LOCATING 2 RENEW 76 22 20 Removethe front beam 76 22 26 Slacken and remove the screws securing the locating bracketto the body and removethe bracket 1 Fig 2 Fig2 Reverse the removal procedure to refit the replacement bracket DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27Nm Bumper to bumper bracket Non Federal 40 50Nm Bumper to bumper strut Federal 40 bONm Guideblockto mounting bracket3 5 4 75Nm 76 22 BODY SECTION DATA TORQUE FIGURES
32. Fig2 76 70 BODY SECTION Removethe spacer washers from the the seat mountings and discard the assembly Reverse the removal procedure to refit the replacement runner and motor assembly 16698 81 ELECTRICALLY OPERATED FRONT SEAT BACK FINISHER RENEW 76 70 09 Open the door Switch on the ignition Move the seat forward to give access to the outer securing screws Switch off the ignition and open the rear door Remove the finishers and screws securing the back finisher Removethe securing screw aperture finisher Remove and discard the seat back finisher nik the removal procedure to refit the replacement inisher 1669B 82 FRONTSEAT HEAD REST ELECTRICALLY OPERATEDSEAT RENEW 76 70 14 Open the door Switch on the ignition Move the seat forward to give access to the outer securing screws Switch off the ignition and open the reardoor Remove the finishers and screws securing the back finisher Removethe securing screw aperturefinisher Fig 1 Remove and discard the seat back finisher Displace the rear reading lamp from the front seat headrest Note the position of and disconnect the reading lamp feed wires Place the lamp aside Remove the reading lamp finisher securing screws and remove the lamp finisher Removethe grommetfrom the headrest harness Position the harness into the headrest tube Displace the headrest retaining clip Fig T and the headrest from its mounted position
33. NOTE To minimise the risk of damage and contamination all repairs conducted on the Instrument Pack should be performed in a non static dust free environment Remove the appropriate bulb Figs 1 amp 2 check for damage serviceability and replace necessary bayonet fitting twist one eighth of a turn anti clockwiseto release NOTE For access to the gauge and lower pack bulbs releasethe electronics pack retaining clips and pivot the pack upwards Fig 3 Fit the instrument pack assembly into dashboard position re connectthe block connectors Align the assembly fit andtighten the securing screws Return the steering wheel to its original position Refit the dash liner Reconnectthe battery NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored Fig 3 tothe correct value Issue 2 88 21 INSTRUMENTS SPEED SENSOR RENEW 88 30 03 Drive vehicle onto ramp Open bonnetand disconnect battery earth lead Open luggage compartmentand removetrim Disconnectspeed sensor cable harness block connector Raisevehicle on the ramp Cut and removecable straps Remove bolts securingthe speed sensor Displace and removethe sensor Fig 1 On refitting new sensor ensure air gap between sensor probe and toothed wheel is 0 5 to 0 9 mm Fitandtighten the securing bolts Securethe hamess with new cablestraps
34. RENEW 86 80 18 Openthe bonnet and disconnect the battery earth lead Open the car door Removethe steering wheel 57 60 01 Remove lower steering column cowl 76 46 03 Removeupper steering column cowl 76 46 02 Removethe nut securingthe dimmer switch Displacethe switch from the mounting bracket Slide the module upwards to disengage the retaining pegs Disconnectthe black block connector Removethe dimmer module Fig 1 Fitting a new module is the reversal of the removal procedure 30018 FLASHER CANCELLATION MECHANISM RENEW 86 65 85 Openthe bonnetand disconnectthe battery earth lead Openthe car door Removethe steeringwheel 57 60 01 Remove the rheostat control knob and remove the screwssecuringthe lower nacelle securing screws Removethe nacelle Remove the retaining ring securing the steering wheel collets Removethe bolts securingthe cancellationmechanism Removeand discard the mechanism Fitting a new module is the reversal of the removal procedure 3001B 86 56 ELECTRICALSYSTEM AUDIBLE WARNING SPEAKER RENEW 86 80 20 Open the bonnetanddisconnectthe battery earth lead Open the car door Removethe steeringwheel 57 60 01 Remove lower steering column cowl 76 46 03 Remove upper steering column cowl 76 46 02 Removew wiper washer switch 86 65 41 Displace the direction indicator cancellation module from its mounting bracket Remove the nut bolt securing the speaker harness clamp
35. RS aie RENEWYv 77 10 01 77 11 den ET SOLDER 77 10 07 77 314 PANEL L WELD 77 10 06 77 13 REAR END REPAIRS COMBINATION 1 77 50 05 77 31 PEAR DOORS KIN RENEW 77 20 04 77 17 REAR PANEL iodrv acia eara na ance pan cene e eee E ere ever eure RENEW 77 35 01 77 21 REAR 5 40 0 1 1 RENEW 77 45 03 77 23 inis laanAlecmm cT 77 25 02 77 19 SEAIEING 2 2 77 00 00 77 08 SIDE REPAIRS COMBINATION 1 RENEW 77 50 01 77 28 SIDE REPAIRS COMBINATION 2 RENEW 77 50 02 77 30 SILL PANELSEGCQTION 22 iiie eia coc noitana tatadi 77 40 02 77 19 00556 77 01 BODY REPAIR ILLUSTRATED INDEX FR IA LL A E 77 2 BODY REPAIR ILLUSTRATEDINDEX KEY DESCRIPTION OPERATION No 6 1 77 00 00 ASBESTOS Gees 77 00 00 ASSOCIATED
36. Removethe nut securingthe wiper arm 2 Fig 1 Positionthe arm from the screen 3 Fig 1 Displaceand removethe wiper arm Fitting a new arm is the reversal of the removal procedure 0196G WIPER BLADE RENEW 84 15 05 Lift the wiper arm from the windscreen Disengagethe wiper blade retainingclip 1 Fig2 Removethe wiper blade 2 Fig 2 Fitting a new blade is the reversal of the removal procedure 0196G WIPER MOTOR ASSEMBLY RENEW 84 15 12 Open the bonnetand disconnectthe battery earth lead Removethe wiper arm and blade Removethe enginecompartmentrubberseal Removethe windscreen rubber lower finisher Remove th screws securing the valance and reposition the valance for access Removethe wiper drive spindle securing nut and spacer 1 Fig 3 Disconnectthe wiper motor multi plug connector 2 Fig Removethe bolt securingthe earth lead and disconnect the lead Removethe bolts securingthe wiper motor assembly 3 Fig3 releasethe assembly lower securng clips Carefully manoeuverethe wiper motor assembly clear of its location 4 Fig3 Fitting a new motor is the reversal to the removal procedure Ensure that all connections including the earth connectionare clean and secure 0196G 84 7 WINDSCREEN WIPERS AND WASHERS WASHER WIPER SWITCH RENEW 84 15 34 Open the bonnet and disconnectthe battery earth lead Open the car door remove the screws securing the steering column cowl a
37. Route the harness to the passenger side fuse box and connectthe fuse box block connector Connectthe relay basesto mountings Securethe hamesstothe A postwith rachetstraps Connect the engine management ECU block connectors Connectthe earth leadto the CPU mounting bolt Route the hamess around the steering column support bracketto the blower motor Connectthe earth leadsto the terminal Connectthe drivers side blower motor block connector Route the harness through the bracket and secure the hamessto the bulkhead with rachet strap Tightenthe bracket securing bolts Connectthe brake light switch block connector Routethe harnessto the roof consoleviathe A post Connectthe A post block connectors Connectthe door harness block connectors Routethe block connectors into the A post and fit the A postfinisher Routethe lower hamessto the fuse box Connectthe fuse box block connector Connectthe inertia switch block connector Connectthe Apostearth lead Connect the interior light block connector and refit the roof console Refit the A post lower trim pads fascia console switch panel ventilator veneer panel fascia closing panels and dash liners Reconnect the battery earth lead and test the operation of the electrical system of the vehicle 3001B 86 77 ELECTRICALSYSTEM ENGINE HARNESS RENEW 86 70 21 Open the bonnet and disconnectthe battery earth lead Cut and remove the strap securing the mu
38. renew 76 70 03 Cut and remove ratchet straps securing the harness to the seat frame Disconnectthe harness multi plug black Econoseal Repositionthe harnessto the rear of the seat Frontseat headrest Renew Displaceand remove the harnessfrom the seat Position the new hamess through the head rest mounting hole Repositionthe harness to the seat frame andthrough the lower access hole Secure seat harnessto frame with the ratchetstraps Repositionthe harness to seat motors Connect the harness multi plug Repositionthe multi plugto retainingclip Repositionthe harnessto the lower frame Securethe harnesswith ratchet straps Refitthe head rest Refitthe seat backfinisher Refitthe seat cushion andclosethe doors 3001B FRONT AXLE HARNESS RENEW 86 70 15 Openthe bonnet and disconnectthe battery earth lead Cut and remove the rachet strap securing the front axle harness multi plug to the side hamess Disconnectthe harnessto side hamess black multi plug Jack upthe vehicle and placeon 1 stand Removethe road wheel 74 20 01 Cut and remove the rachet strap securing the hamessto the brake hose Fig 1 Displacethe hamessfrom the retaining clip Disconnect and remove the front axle harness from the brake padwarning multi plug Fitting a new harness is the reversal of the removal procedure 3001B 186 41 86 83 ELECTRICALSYSTEM REAR AXLE HARNESS Right Hand RENEW 86 70 16 Open the bonnet and disconne
39. 84 07 4 WIPER LOGIC MODULE Saas 84 80 11 84 08 4 WIPER MOTOR ASSEMBLY nennen 84 15 12 84 07 4 84 3 WINDSCREEN WIPERS AND WASHERS WINDSCREEN WIPER AND WASHERS INTRODUCTION 84 00 00 The windscreen wiper motor operates at slow or fast speed and drives via a rack assembly a single arm and blade The wiper is supplemented by washers which spray jets of fluid into the path of the wiper blade as it moves across the screen Intermittent Flick Wipe operations are both at slow speed and are controlled by the ECU The ECU also controls headlamp washer operation which is permitted only with the headlights switched ON Windscreen Wiper and Washer Switch The switch only operates when ignition is ON and hasthe following positions 1 Wiper switched OFF and parked Normal speed operation of the wiper obtained by pushing the switch lever up one position 2 Highspeed operation of the wiper obtained by pushingthe switch lever fully up 3 Intermittent operation of the wiper obtained by pushing the switch lever down against spring pressure and releasing To cancel the function pushthe switch down again and release To obtain a single sweep of the wiper blade pull the lever towards the steering wheel and release To operate the windscreen washers pressthe end of the switch lever NOTE This switch also controlsthe Headlamp Powerwa
40. BY APPOINTMENT TO MAJESTY QUEEN ELIZABETH tt MANUFACTURERS OF DAIMLER AND JAGUAR CARS JAGUAR CARS LIMITED COVENTRY ENGLAND BY APPOINTMENT TO HER MAJESTY OUBEN ELIZABETH THE OUEEN MOTHER MANUFACTURERS OFDAIMLER AND JAGUAR CARS JAGUAR CARS LIMITED COVENTRY ENGLAND XJ6 SERVICE MANUAL VOLUME 4 Contains Sections 74 WHEELS AND TYRES 76 BODY 77 BODY REPAIR 80 HEATING AND VENTILATION SYSTEM Published by Technical Publications Jaguar Cars limited Publication Part No JJM 10 04 05 40 BY APPOINTMENT TO HISROYAL HIGHNESS THE PRINCE OF WALES MANUFACTURERSOF DAIMLER AND JAGUAR CARS JAGUAR CARS LIMTED COVENTRY WHEELS AND TYRES DESCRIPTION ROAD WHEEL ONE SPARE WHEEL AND TOOL KIT TYRES 90MY TYRES 81MY stie rente WHEELS AND TYRES WHEELS eene 2000C Issue 2 CONTENTS OPERATION ILLUSTRATED e REMOVE AND REFIT STOWAGE DATA PRESSURES DATA PRESSURES DESCRIPTION enne TORQUE FIGURES 74 01 OPERATION No 74 00 00 74 20 01 74 00 00 74 00 00 74 00 00
41. Fitting new vacuum solenoid is the reversal of the removal procedure 02095 COOLANT TEM PERATURESWITCH RENEW 80 10 51 Openthe bonnetand disconnectthe battery earth lead Removethe passengerdash liner Disconnectthe switch supply cables Fig 2 Removethe screws securingthe switch to pipe bracket Removethe switch Fitting a new switch is the reversal of the removal procedure 02096 AMBIENT TEMPERATURESENSOR 192 175 RENEW 80 10 53 Openthe bonnetand disconnectthe battery earth lead Removethe right side dash liner NOTE On LHD vehicles remove the glove box lid and glove box Removethe right hand blower motor assembly 80 20 11 Remove the screws securing the ambient temperature sensor Disconnectthe cable harness multi plug connector Slackenthe nut bolt securing the sensor probe retaining clipto flap je Displace the sensor probe from the retaining clip and removethe sensor Fig Fitting a new sensor is the reversal the removal procedure Fig3 Q209G 80 15 HEATING AND VENTILATION IN CAR TEMPERATURE SENSOR RENEW 80 10 54 Open the bonnet and disconnectthe battery earth lead Removethe passengerdash liner Removethe glove box lid and glove box Removethe screws securingthe sensor 3 Fig 1 Disconnect the cable harness multi plug connector 1 Fig 1 Removethe sensor from the hose 2 Fig 1 Fitting a new sensor is the reversal of the removal procedure 02096 SO
42. tightenthe securing bolt Fig 1 Removethe support block repositionthe seat runner fit andtighten the securing bolts Refitthe front seat DATA TORQUE FIGURES J76 5t Seatrunner bolts 35 Nm 00516 4 276 502 76 115 BODY SECTION 1991 MODEL YEAR MODIFICATIONS FRONT SEAT BELTS RENEW 76 73 00 Front seat belt units incorporating a web locker actuation are fitted in place of the pawl and ratchet system Motion and attitude sensors trigger the retractor and cause engagement of two wedged sets of teeth to clamp the belt webbing Once the wedges have locked onto the webbing the webbing around the spool retains its original tightness therefore no more webbing is released This reduces travel or spool out during impact Web lockers are fitted to the front compartment only The web locker is larger and heavier than the conventional unit and has a higher centre of gravity above the mounting hole The unit is secured to the BC post with a 7 16 UNF bolt atthe base and a screw fitted into a nylon locking socket at the top Withdraw sufficient length of webbing up through the inside of the BC post between the trim panel and body and pass through the aperture inthe trim panel Secure the belt upper anchorage point Secure the unit at the lower sill anchorage point FUEL FILLER CAP RETENTION MAGNET RENEW 76 10 27 Open the fuel filler cap Using a flat bladed screwdriver displace and remove the magnet assembly from the
43. 4 25 ons BOOT LID LOCK 76 19 25 5 ens 4 26 BOOT LID LOCK 5 16 19 12 4 Z1 BOOTLIDSEAL ntt eere temen 76 19 06 4 28 22 76 00 00 4 29 BOOT LID SEALTREAD 76 19 09 4 30 22 5 BONNET LOCK CONTROLCABLE 76 16 29 4 3b zai BONNET LOCKCONTROL CABLEASSEMBLY _ VERIGLE SET tebe teet eme rente 76 16 35 4 32 5 LOCK RELEASE HANDLE 76 16 30 4 33 BOOT LOCK RELEASE TRIGGER HANDLE 76 19 15 4 nes BOOT Lock ii ette es 16 43 31 4 BOOT REAR 76 19 22 4 36 5 BOOT SIDE LINER LEFTHAND sees 76 19 22 4 STi BOOT SIDE LINER RIGHT 76 19 23 4 38 BOOT VENTILATOR 76 15 66 4 39 s BUMPER 76 22 08 4 39 uu BUMPER FRONT ASSEMBLY seen 76 22 09 4 40 BUMPER 76 22 15 4 40 BUMPER 5
44. Avoid nicking or cutting any ofthe wires The splice should be at least 40mm 1 1 2 away from any other splices harness branches or connectors Check the stripped wire for nicks or cut strands If the wire is damaged repeat the procedure on a new section or wire The two stripped wire ends should be equal in length Crimpthe wires Fig 2 Selectthe proper clipto securethe splice To determine the proper clip size for the wire being spliced following the directions included with your clips Selectthe correct anvil on the crimper On most crimpers the choice is limited to either a small or large anvil Overlap the two stripped wire ends and hold them between thumb and forefinger as shown Then center the splice clip under the stripped wires and hold itin place Open the crimping tool to its full width and rest one CM handleon a firm flat surface en Centre the back of the splice clip on the proper anvil UM and close the crimping tool to the point where the former touches the wings of the clip Ensure that the clip and wires are still in the correct position Then apply steady pressure until the crimpingtool closes Before crimping the ends of the clip be sure that Thewires extend beyondthe clip in each direction Nostrands of wire are cut loose and Noinsulationis caught under the clip Crimpthe splice clip again once on each end Do not let the crimping tool extend beyondthe edge of
45. Displace the speaker Removethe speaker grille Disconnectthe brown cable harness block connector Remove the speaker cancellation module assembly Fig 1 Fitting a new audible warning speaker is the reversal of the removal procedure 5 Fig 1 30016 SLIDING ROOF MOTOR RENEW 86 76 01 Open the bonnetand disconnect the battery earth lead Open the car door Releasethe fastener securingthe roof console Lowerthe consolefor access Disconnect the interior lamp cable hamess multi plug connector Removethe roof console assembly Disconnect the roof motor cable hamess block connector Undo the rear bolt securing the motor the bolt will remain in its position Removethe boltsecuringthe front of the motor Remove the motor assembly from its roof position and removethe rear securing bolt Fitting a new sliding roof motor is the reversal of the removal procedure having first fitted the rear securing boltto the motor assembly 3001B 86 57 ELECTRICALSYSTEM SLIDING ROOF MOTOR SWITCH RENEW 86 76 05 Open the bonnet and disconnect the battery earth lead Open the car door Releasethe fastener securingthe roof console Lowerthe console for access Disconnect the cable harness multi plug block connectors Removethe roof console assembly Releasethe tags securing the roof motor switch Remove the switch harness assembly from the roof console Fitting a new sliding roof motor switch is the re
46. GLOVE BOX LAMP HARNESS RENEW 86 70 24 Openthe door Glove box renew 76 52 03 Note and disconnect the glove box lamp and switch Lucar connectors Undo and remove hamess to the glove box P clip securing nut bolt Cutand removethe hamessto glove box ratchetstrap Placethe harness aside Fit and align the new hamessto the glove box Fitand tighten the P clip securingnut bolt Connectthe harness to the lamp switch lucars Securethe hamessto glove box with ratchetstrap Refitthe glove box assembly Fig 1 and close the door 3001B 86 85 ELECTRICALSYSTEM BONNET LAMP LINK HARNESS RENEW 86 70 26 Open the door Undo but do not fully remove the bonnet lamp securing screws Displacethe bonnet lamp assemblies for access Undo and remove the bonnet insulation pad lower securing screws Repositionthe padfor access Disconnect both the bonnet lamp multi plugs black Econoseal Cut and remove the harnessto the bonnet ratchet strap Repositionthe hamess from behindthe bonnet pad Cut and remove the ratchet straps securing the harness and multi plug to front closing panel Disconnectthe multi plug red Econoseal Displacethe grommetfrom the panel Reposition the harness multi plug through the body paneland remove Position the new harness multi plug through the body panel Fullyseatthe grommetto the panel Secure the hamess and multi plug with the ratchet straps Repositionthe hamess behindthe bonnet pad Co
47. Horns to bracket22 28Nm Mounting bracketguide block to body 7 5 70Nm SPANNE RSIZES 8mm 10mm 13mm 79mm No20 Torx 16698 66 FRONTQUARTER BUMPER BLADE RENEW 76 22 73 1 e Removethe front beam 76 22 26 oa DES Remove the nuts and bolts 1 Fig 1 securing the blade 19 2 Fig 1 to the bumper Removeand discard the blade Reverse the removal procedure to refit the replacement blade DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27Nm Bumper front blade tobeam 5 7Nm Bumper side blade to beam 5 7Nm Bumper side to mounting block 5 7Nm Bumper to bumper bracket Non Federal 40 50Nm Bumper to bumperstrut Federal 40 50 Flexiblemounting block to beam 5 7Nm Guideblock to mounting bracket 3 5 4 75Nm Hornsto bracket22 28Nm Mounting bracketguide block to body 7 5 1T0Nm SPANNER SIZES 8mm 138mm 19mm No 20 Torx 16698 76 23 BODY SECTION HEADLAMPTRIM FINISHER RENEW 76 40 01 Removethe radiator grille 76 55 07 Removethe headlamp assembly 86 40 06 7 Remove the four screws 1 Fig 1 securing the trim to the headlamp unit Reverse the removal procedureto refit the finisher 0379b BONNET RENEW 76 16 01 Open the bonnet Remove the right hand insulation pad securing screws and removethe pad Disconnectthe bonnetilluminationlampmulti plugs Apply tape to the forward edge of the bonnet behindthe grille surround
48. LIgIHNI 3SH3A3H MO3HO SI HO10313S5 YVAD HOLIMS SYNSNS SALIgB3dONI LINDHIO AVTSY NOLLIGIHNI 310N NI Q33 00d SNONOL ONITISAVHI HLM 53175390 L1noLnO TWAHAHL HOLOW HONIM SAO dad HONIM LHS SNINHYA 0130 IY3S SSANHVH LON Ji NO NOLLINOI AO GINOHS NOLLINDI NO Z 393HO OL TILS 611381936 8 4l JHL 312IH3A FHL 20 53015 NO W318AS JHL 40 79101 V JO LNSAS NI OL 871 3 HONIM HOLMS 3SH3A3H 124136 A070930 OL 81194 HONIM 38012 NO 59513 MO3HO N3dC 330 NOLLINOI NO GSHOLIMS NOILINDI ONY 835012 Hood ADYHOHONY 180d 28 OL A070930 OL HONIM 1 IN31SAS SISONDVIC ANYA LNIVH IS3H JAISSVd 76 104 BODY SECTION ELECTRICALSYSTEM FAULT DIAGNOSIS LHSYSTEM FORWARD DEPLOYMENT Lv61Sf 330 SI IHL SI ZHL BdHll3 NJHA TIM 1LNa3WAO dad apes XTGWASSY HONIWHOLOI MINIY SNOILOJNNOS ISHJAJY A07d30 OL HONIM HOLMS HY3NIT 123136 Isnray HOLIMS SH
49. NUMBER PLATE LAMPR O W 12v5W FESTOON239 JLM9590 02294 86 12 ELECTRICALSYSTEM SYMBOLS Battery power Motor Solenoid Diode Ignition switched power Fuse Zener diode Lamp O o o e 6 Logic earth Earth connection Transistor Aerial y Ignition switched earth Resistor Signal Potentiometer O WW gt yw Cable connector Capacitor Thermistor Switch e LED Clock Linesplice LOGIC EARTH DISTRIBUTION Logic earths are distributedfrom power earth pointB78 locatedclose to the CPU IGNITIONSWITCHED EARTH DISTRIBUTION Ignition switched earths are distributed from the ignition and inertia switches The ignition switch distributes the earths in all switch position except OFF and the inertia switch distributes the earths when tripped with the ignition ON 30018 WARNING The battery emits combustible gas Hydrogen particularly when charging Avoid sparks and short circuits by switching off the charging current before making or breaking the terminal connections When disconnecting the battery connections always disconnectthe earthterminal first and reconnect it last Avoid contact with the battery acid which is both poisonous and corrosive Acid will cause bums to the skin as well asto the eyes Inthe event of skin or eye contamination drenchthe effectedarea with water and seek urgent medicalattention when eye contact has occured Fuel is extremely flamable All fire precautionsmust be observed therefore when work
50. Open the door andslacken the 1 Fig 2 removethe pinfromthe B post and collect the washer Reverse the removal procedure to fit a replacement striker pin DATA TORQUE FIGURES Strikerpin to B post24 30 Fig2 SPANNER SIZES 7 7mm 16698 53 76 37 BODY SECTION FRONT DOOR SEAL RENEW 76 40 01 Open the door Remove the end panel finishers and pull the top finisher clear of the tread plate Removethe five tread plate securing screws and remove the tread plate Removethe seal andcleanthe channel Fig 1 Apply Kent clear sealer to the C channel buttjoints and Soluminto the section of the seal abovethe sill section Position the replacement seal and locate in the upper corners secure with tape and using soft soap seat the door seal inthe channel Remove the tape and slide the front lower edge and corner of the seal into position Clean off all softsoap and refitthe sill tread plate DATA OILS SEALANTS LUBRICANTS Two C channelbuttjoints Kent clearsealer Seal abovesill section Solumin 1669B 69 FRONT DOOR UPPER TRIM PAD RENEW 76 34 02 Openthe door Removethe front door trim padveneer panel 76 47 1 1 Remove the upper trim pad securing clip Fig 2 and screws Fig 2 Lift the trim pad to release from the door remove the inner waist rail seal Reverse the removal procedureto refit the replacement upper trim pad 0023b REAR DOOR GLASS Fig2 RENEW 76 31 02 Openthe do
51. PMA Connector PM4 Connector Amp Timer Amp Timer Relay Base Relay Base Relay Base 187 Blade Receptable 250 Fastin Faston Receptable 187 Blade Receptable 250 Blade Receptable 250 Fastin Faston Receptable Mic 5 Way Mic 5 Way Bosch25 Way Connector Amp Connector Amp Connector Bosch 25 Way Connector 187 Blade Receptable 250 Fastin Faston Receptable Amp Timer 5 Way TTS Socket TTS Socket TTS Socket Bosch Connector Bosch Connector Kiekert Kiekert Packard Connector ITT Cannon 2 Way Male ITT Cannon 2 Way Female 4 Male ITT Cannon 4 Way Female ELECTRICALSYSTEM BULKHEAD CABLE HARNESS RENEW 86 70 09 Open the bonnet and disconnect the battery earth lead Open the car door Removethe driver side dash liner 76 46 11 Remove passengerdash liner 76 46 15 Remove passenger fascia closing panel 76 46 27 Removedrivers fascia closing panel 76 46 28 Removethe centre veneer panel 76 47 06 Removethe centrevent outlet 76 15 48 Removethe fascia board76 46 01 Removethe right and left hand A post lower trim pads 76 13 30 Removethe sun visor 76 10 47 Removethe interior lamp assembly 86 45 1 2 Displacethe roof lining for accessto the cable hamess Displacethe cable hamessfromthe roof and A post Disconnect the block connectors at the base of the A post A postearth bolt and disconnectthe earth ead 2 R
52. Remove the muffler to evaporator compressor hose securing bolt Remove the compressor pivot bolt securing nut Remove the compressor outlet port retaining plate securing bolt Disconnectthe muffler from the compressor remove and discard the O ring seal and fit a blanking plugto the compressor connection Remove the blanking plug from the muffler Position the muffler on the compressor fit the pivot bolt and securing nut do nottighten the nut Remove the blanking plug from the compressor connection fit a new O ring sealto the connection Connect the muffler to the compressor ensure that the O ring seal is correctly positioned to prevent distortion Positionthe compressor outlet port retaining plate fit and tighten the retaining plate securing bolt Tighten the compressor pivot bolt securing nut Fit and tighten the muffler to evaporator compressor securing bolt Remove the blanking plug from condenser hose and fit a new O ring seal Connect the condenser hose to the muffler tighten the union nut ensuring that the charging valve is upright Remove the wing cover and close the bonnet 82 70 AIR CONDITIONING SANDEN COMPRESSOR 709 FIELD COIL RENEW 82 10 25 Open the bonnet and fit a wing cover Depressurize the air conditioning system Remove the compressor refer to 82 10 20 Remove the compressor drive clutch refer to 82 10 08 Removethe compressor pulley referto 82 10 10 Slacken the field coil wire cl
53. a push button which provided that no fault condition exists park brake and seatbelt excepted permits automatic display sequencing of predetermined ISO symbols At the end of the sequence normal system operationis resumed M C a push button which clears resets the trip computer memory so that new journey information can be entered To perform the reset function the push button must be held depressed for a period in excess of five seconds 100 a push button which permitsthe hundreds digit of the display to be setto the desired value 10 a push button which permits the tens digit of the displayto be set to the desired value 1 a push button which permits the units digit of the displayto besetto the desiredvalue 3001B TRIP COMPUTER AND LOGIC MODULE RENEW 86 80 01 Openthe bonnet and disconnectthe battery earth lead Openthe car door Remove the screw securing the trip computer undertray and remove the undertray Displacethe on off switch Fig 1 Displace the trip computer and release the retaining Clips Disconnectthe cable harness block connector Removethe trip computer assembly Fitting a new assembly is the reversal of the removal procedure 30018 86 53 ELECTRICALSYSTEM DOOR LOCK CONTROL MODULE Open the bonnet and disconnectthe battery earth lead O o 1 car door A Removethe passengerside dash liner 16465 Removethe screws securing the module RUN ISI a Dis
54. diagonalseat belt should deployto the unrestraining position frontdock 76 112 BODY SECTION PASSIVE RESTRAINT MOTOR DRIVE AND INERTIA REELASSEMBLIES RENEW 76 73 27 Removethe front seat 76 70 10 Remove the seat runner to floor securing bolts Lift up the inertia reel side of the runner for access Use a suitable blockfor support Remove the inertia reel securing bolt Fig 1 removethe reel assembly Removethe post upper and lower trim pads Remove the cant rail crash roll Remove the guide rail securing screws and dock assembly securing bolts Displace the B post upper trim pad mounting bracket Displace and remove the guide rail from the dock assembly Move the dock assembly adjustment knob to its lowest position Fit suitable tape to the dock assembly plastic face and B postaperture lower edge for protection Fig4 Remove the anti rattlefoam blocks from the B post Fig 2 Disconnect the motor harness multi plugs Fig 3 Remove the passive motor mounting bracket securing bolts Fig 2 anddisplacethe motor from the B post Turn the dock assembly to face inwards Position the dock assembly into the B postas far as possible Tilt the dock assembly upwards to ease removal Displace and removethe motor dock assembly Fig 4 Fit suitable tape to the dock assembly plastic face for protectionduring installation Fit and align the motor dock assembly to the B post taking care not to damage the adjustment
55. to the front seal ensure that the tangs of the tool engage those on the seal Remove the seal from the compressor using a twisting action Removethe seal from the tool Fit thread protector tool 2 Fig 3 on the compressor shaft Smear the new front seal with clean refrigerant oil and fit the seal intool JD168 1 Fig 2 fit the new seal on the compressor shaft using a twisting action disengage and remove the tool from the front seal Remove the seal protector tool from the compressor shaft Apply clean refrigerant oil to the seal seat O ring fit the O ringto the seal seat Fit tool JD167 to seal seat 1 Fig 1 ensure that the tangs of the tool engage the groove inthe seal seat Fitthe seal seatto the compressor ensuring that itis fully seated Removetool JD 167 from the seal seat Fitthe seal seat retaining snap ring and ensure that it is fully seated Fitthe felt ring and the woodruff key Refitthe compressor and compressor drive clutch 82 68 AIR CONDITIONING SANDEN COMPRESSOR 709 COMPRESSOR ASSEMBLY LESS CLUTCH SANDEN 500 AND 700 SERIES RENEW 82 10 19 Open the bonnet and fit a wing cover Depressurize the air conditioning system Remove the compressor outlet port retaining plate securing bolt detach the plate Disconnect the compressor hose remove and discard the O ring seal Fit a blanking plug to the compressor outlet port Remove the compressor pivot bolt securing nut Carefully
56. 1 Disconnectthe batteryearth lead Open the car door and remove the dash liners and the steering wheel Removethe screws securing the instrument pack Disconnect the instrument pack cable hamess multi plug connectors and removethe pack assembly Removethe glove box andthe glove box lid Remove the screws securing the heater matrix pipe housing and removethe pipe housing halves Removethe foam padfrom the pipes Remove the screws securing the pipes reposition the pipesand removethe pipe gaskets Remove the screws securing the electronic control module and reposition the module for access to the screws securingthe matrix housing Remove the screws securing the heater matrix housing and removethe housing Displaceand removethe matrix Fig 1 Removethe foam strip from the matrix Fitting the new matrix is the reversal of the above procedure Ensureall electricalconnection are clean and secure Refillthe engine cooling systemwith specified coolant 0206G 82 49 AIR CONDITIONING HEATER COOLER UNIT EVAPORATOR RENEW 82 25 20 82 25 21 Open the bonnet and disconnect the battery earth lead Depressurizethe air conditioning system Partially drain the engine coolant into a suitable container Open the car door Removethe right and left hand dash liners Removethe steering wheel Remove the instrument module and control panel assem bly Removethe glove box lid Removethe right and left handfascia end panels Remove
57. 19 wiring diagram Diode value Fig4 600V 1A Resistorvalue 82ohm 0 25W 3 Bulb ratings are shown onthe module cover 4 DIM DIP FUNCTION UK ONLY With the ignition and sidelights ON dip beam headlights will be energised but will only give a maximum of 10 light 320 output This value is maintained over the entire __ ___ _ operating voltage range The module senses correct operation of main beam headlamps without affecting 186 839 circuit resistance used for bulb failure monitoring When main beam is activated the low power feed to Fig5 dip beam is shut off 86 99 ELECTRICALSYSTEM BULB FAIL MODULE FRONT DIAGRAM 86 55 00 Keyto diagram 1 Module 2 General Fail 3 Direction Indicator Fail 4 Fog 5 Dip 6 Main 6A Main 7 Side 8 Direction Indicator 9 Direction Indicator Repeater 10 General Fail 11 Logic 0 12 Direction Indicator Fail 13 Disconnect Earth Loop 14 Dim Dip PulseWidth Modulator UK ONLY 15 Ignition 16 Main 4 17 Fog Dip t 18 Side Direction Indicator 19 ProtectionNetwork Arrow goesto Switch 9 2 3 3 1 zug bo 486 834 89MY a c 86 100 ELECTRICALSYSTEM BULB MODULE REAR CONNECTORS 86 55 00 PIN COLOUR DIA FUNCTION R550 CONNECTOR PMHD 15 eerie 150 1517 1 Red Blue 0 5 A 2 Slate Lt Green 0 5 5 aan d 3 Purple Blue 0 5 stop 4 Red 0 5 Number Plate Tai
58. 3 Fig 1 fit to the boot lid and secure with the nuts and plain washer Refit the number plate lamp assemblies and connec tions Closethe boot annd reconnectthe battery DATA TORQUE FIGURES Finisher toboot lid5 7Nm SPANNER SIZES 8mm 0368b 76 65 BODY SECTION BOOT LID LOCK BARREL RENEW 76 19 19 Removethe boot lock assembly remove the four screws and separate the front platefrom the operating assembly Remove the locking pin and spring 1 Fig 1 and push the barrel 2 Fig 1 out from inside Reverse the procedureto refit the replacement ensuring that the locating hole lines up with the holes in the housing 0372b BOOT LID LOCK STRIKER RENEW 76 19 12 Open the boot remove the 4 screws 1 Fig 2 securing the boottrim and remove the trim and carpet Remove the 2 bolts 2 Fig 2 and spring washers and removethe striker plate 3 Fig 2 Reverse the removal procedure and adjust the striker plate until the boot lid is flush wirh the rear wings when closed DATA TORQUE FIGURES Striker to rear trunk panel 7 10Nm SPANNER SIZES 10mm 0365b BOOT VENTILATOR OUTLET RENEW 80 15 66 Remove the boot side trims and remove the 2 bolts and plain washers 4 Fig 3 securing the boxes 5 Fig 3 to the bootfloor in either side Reverse the removal procedure to refit the boxes ensuring that the two earth wire eyelets are refitted to each rear securing bolt and that the exhaust grommets are alignedwith the apeture
59. 390mm Tyre Type Size Dunlop TD SP Super Sport D7 220 65 VR 390 TD or Michelin TOXV 220 65 VR 390 The TD Teardrop Alloy wheel is an optional item after 91MY for all models and markets except North America Both tyre and road wheel are made to metric dimensions in section width and wheel diameter This isa safety precaution to preventthe fitting of aconventionaltyretothe TD road wheel and conversely of a TD tyre to a conventional wheel It should be noted that a TD tyre cannot be fitted to a normal wheel or a normaltyre to a TD wheel 74 12 Issue 2 WHEELS AND TYRES ROULETTE ALLOY WHEEL Size Tyre Type Size Pirelli 225 65 VR 15 225 65 R 15 99 V Pirelli 205 70 VR 15 USA The Roulette style alloy wheel is a standard fit item for XJ6 Daimler and Vanden Plas derivations in all markets from 91MY The Roulette wheel incorporates a diecast hubcap with a rubber O ring type seal round the outside to ensure an optimum fit The hubcap clips into the wheel recess on one side using the hooks shown on the back of the hubcap in Fig 1 and is locked into position using a bright chrome finished Allen type socket head locking screw 1 Fig 2 To remove the hubcap unscrew the captivated bolt 1 Fig 2 securingthe diecast hubcap 2 Fig 2 using the 6mm Allen key which is clipped to the spare wheel mounting bracket in the luggage compart ment Firmly hold the captivated bolt and pull outwards to remove the hubcap from the whe
60. 4 4 GEARBOXSELECTORTRIM EET 4 B C 4 5t B POSTLOWERTRIM 4 eee RERUM PAD 4 asian tect sis ack 4 colons BONNET HINGE FEDERAL 4 BONNET HINGE NON FED 4 10 BONNETHINGE VEHICLE SET FEDERAL 4 Ile BONNETHINGE VEHICLE SET NON FEDERAL 4 12 2 0000 4 I3 BONNET GAS STRUT VEHICLE SET 4 14 BONNET INSULATION 4 15 4 LEi BONNET SEALING 4 17 BONNETSTRIKER 4 16 4 18222 22120 BOOT FLOOR 76 19 30 4 19 2 BOOT FRONT 76 19 31 4 20 5 BOOT 76 19 01 4 2e BOOT LID ADJUST ON 76 19 04 4 22 BOOT LID GAS 76 19 21 s 4 Z3xsss BOOT LID 76 19 28 4 24 BOOT LID 76 19 19
61. 4 Fig 1 and bolt 5 Fig 1 Displace the alternator from the bracket and remove the spacer washer From above liftand removethe alternator from its location N ov e 186 926 On refitting ensure that the drive belt is adjusted to the correct tension A load of 1 5 kg must give a total belt deflection of 4 5 mm when applied at the mid point of the belt DATA SPECIFICATION Type Bosch N1 14V A0 115 Voltage 12volts Maximumrev min 17500 Maximumoutput 115 amps Regulatedvoltage 13 6 14 4 TORQUE FIGURES Throughbolts 4 5 6 2Nm Pulleyshaft nut 27 2 35 0 Nm Rectifer bolts 3 4 3 96 Nm Bearing plate screws 4 7 5 7Nm Main terminalnut 3 96 5 08 Nm 3001B 86 15 ELECTRICALSYSTEM ALTERNATOR DRIVE BELT RENEW AND ADJUST 86 10 03 Loosen the pivot bolts securing the air conditioning compressor Loosen the adjusting link securing bolt and trunnion block bolt Loosen the adjusting link locknut 1 Fig 1 and adjust the compressor towards the engine until compressor drive belt 3 Fig 1 can be removed Loosenthe alternator pivot nutand bolt 2 Fig 1 Loosen the adjusting link pivot bolt and the trunnion block bolt Loosen the adjusting link locknut 4 Fig 1 and adjust the alternator towards the engine by means of the adjusting nut Remove the trunnion block bolt and push the alternator towards the engine until the drive belt can be removed from the pullies On fitting the new belt ensure that the drive belt i
62. 41 BODY SECTION Removethe door aperture plastic closing panel Carefully displace the door weather shield for access Remove the door handle operating rod to lock retaining clip peg and reposition the rod from the retainingclip Removethe front nut securing the handle clamp bracket 1 Fig 1 and slacken but do not remove the rear securing bolt and removethe clamp bracket Remove the handle assembly and remove the securing stud and bolt Discardthe handle Reverse the removal procedure to refit the replacement handle DATA TORQUE FIGURES Door handle to door 3 5 4 5Nm SPANNER SIZES 8mm 00596 REAR DOOR INSIDE HANDLE RENEW 76 58 19 Open the door Removethe rear door trim padveneer panel 76 47 1 2 Disconnectthe inner cable Fig 2 from the door handle and displace the outer cableto handle assembly securing sleeve Disconnectthe cable from the handle assembly operate the handle for accessremove the screw and bolt securing the handle assembly remove and discard the handle Reversethe removal procedureto refit the repiacewment handle DATA TORQUE FIGURES Door inside handle to door 4 5 4N m SPANNER SIZES 10mm 00600 76 42 BODY SECTION REAR DOOR LOCK RENEW 76 37 13 Open the door Removethe front door trim pad veneer panel 76 47 11 Removethe front door uppertrim pad 76 34 02 Removethe front door lowertrim pad 76 34 03 Remove the rear door glass 76 31 02 Displace the inner lock con
63. 74 00 00 74 00 00 74 00 00 74 00 00 PAGE No 74 02 74 19 74 20 74 04 74 06 74 07 74 10 74 11 74 12 3 Hi HN 28 ZAN s issue 2 ITEM No Issue 2 DESCRIPTION ROAD 4 WHEELS AND TYRES ILLUSTRATED INDEX KEY SPARE WHEEL AND TOOL KIT WHEELS AND TYRES WHEELS AND TYRES WHEELS AND TYRES 74 03 OPERATION No 74 20 01 74 00 00 74 00 00 74 00 00 74 00 00 PAGE No 74 19 74 20 74 04 74 07 74 12 VOLUME AKRAAA WHEELS AND TYRES 90MY TYRES DATA TYRE PRESSURES 74 00 00 North American Vehicles Type Size Pirelli P5 205 70 VR 15 Cinturato Tubeless Cold Inflation Pressure Front 33 Ibf in2 2 32kgf cm 2 228kPa 2 27bar Rear 36 Ibf in2 2 53kgf em2 248kPa 2 48bar Note Pressures may be reduced by 6 Ibf in2 0 42kgf cm2 41kPa 0 41bar on front and rear tyres to obtain maximum comfort provided the speed does not exceed TOOmph 160 km h Rest of the World ROW Vehicles Type Size Dunlop TD SP Super Sport D7 220 65 VR 390 or Michelin TDXV 220 65 VR 390 Tubeless Cold Inflation Pressure Front 34lbf in2 2 39kgf cm 2 235kPa 2 35 Rear 34Ibf in 2 39kgf cm2 235kPa 2 35bar Note Pressures may be reduced by 8 Ibf in2 0 56kgf cm2 55kPa 0 55bar on front and rear tyres to obtain maximum comfort provided the speed does not exc
64. Fault BC postfinisher System inoperative Brushes inner and outer Eventual failure Foulstravelling tongue A post cantrail finisher System inoperative Foulstravelling tongue Dash Liner Brackets loose Armaturefalls off rattles Inadequateretention BODY SECTION Cause Loosefinisher fouls travellingtongue Excessfriction incorrect assy of system dust ingress Inadequate retention of brushstrip carrier Brushes adrift from BC post Structural failure or deformation Trim lifting from moulding Bracketfixings Armature fixings 76 103 Action Check security of finisher fixings Assemblesystem correctly Cleanout system Check security of fixings Check security of fixings Renewfinisher Repair renew finisher Inadequateretention Service loads in excess of design loads BODY SECTION ELECTRICAL SYSTEM FAULT DIAGNOSIS LH SYSTEM REARWARD DEPLOYMENT 9 IST NO Q3HOLIMS IHL ONY 138010 SI HH N3HA TIM LN3INAO3430 WALSAS WiL L3H HOLIMS ALINIXOHd ONIMOOQ MINIY SALIVH3dONI HOLIMS ALIWIXOWd ONIMOOQ HOLIMS ASSIHNOS SH3AIHO MANSY A LIATXOBd ONIMOOQ MINIY SALWHAdONI HOLIMS ALIINIXOBd ONIMOOU NO SNIVIN3H ONINHVAA 1735 3l ANDNOL SNITT3AVHI OL L238NOO3H NI LNASAYd SI LANS W Jv HL SHNSN3 SNOLLOANNGO Av T3H
65. Fig 2 and remove the mirror 476 337 catch spire clip 2 Fig 2 and washer and remove the Fig catch Remove the mirror spring 4 Fig 2 displace the mirror securingclip and remove and discardthe mirror Reverse the removal procedure to refit the replacement mirror Q056b HANDBRAKE LEVER TRIM RENEW 76 13 63 uu Openthe door Releasethe trim assembly upper clip Fig 3 and remove the trim from the handbrake lever Fig2 Reverse the removal procedure to fit the replacement trim 0009b HEADLINING REAR FINISHER RENEW 76 64 12 Open the door Release the trim finisher retaining clips Fig3 Removethe trim finisher 1 Fig 4 and making a note of the position of the retaining clips remove Discardthe finisher Reverse the removal procedure to refit ensuring that the clips are fitted in the exact position on the replacement trim to the one discarded 0062b Fig4 76 89 BODY SECTION INTERIOR MIRROR RENEW 76 10 51 Open the door Release the fastner securing the interior lamp and lower the panel for access Pull to remove the mirror assembly Fig 1 from its mountingplate Removethe mounting plate securing screws and remove the plate Reverse the removal procedure to refit the replacement mirror 16698 7 1 REAR LAMP ASSEMBLY INTERIOR TRIM FINISHER RENEW 76 19 20 Openthe boot Fig 1 Removethe nuts securingthe finisher to the lamp units Removethe finish
66. INSTRUMENT PACK eene 88 20 22 INSTRUMENT CONNECTORS 88 00 00 VERE INSTRUMENT PACK ILLUMINATION BULBS 86 45 49 Bien INSTRUMENT PACK LCD MODULE 88 20 23 INSTRUMENT PACK LENS COWL 88 20 17 1025 52 INSTRUMENT PACK FLEXIBLE PRINTED CIROUIT 88 20 20 LOW COOLANT LEVEL PROBE 26 40 11 OILPRESSURE COOLANT TEMPERATURE GAUGESELT enirn cided 88 25 09 32 22 2 SEAT BELT BUCKLE SWITCH 86 57 25 T4 us SEAT PAD SWITCH cesses 86 57 21 15 SPEED SENSOR 88 30 03 16 SPEEDOMETER TACHOMETER GAUGE SET 88 30 20 SPORT MODE SWITCH nnn 86 65 84 18 TRIP COMPUTER 88 00 00 19 VEHICLE CONDITION MONITOR KEYPAD 88 00 00 20 WASHER RESERVOIR SENSOR 84 10 17 issue 2 88 3 VOLUME INSTRUMENTS INTRODUCTION 83 00 00 The Instrument Pack is a self contained removeable unit that incorporates all the main display gauges and warning indicators that are usedto present vehicle condition inf
67. J82 08714 Complaint Little or no cooling Overheating of the engine may also Fia 1 be noted 9 Condition 1 The low side gauge reading excessively high 2 The highside gauge reading is also excessively high 3 Bubbles may appear occasionally in the sight glass andthe liquid lineto the evaporator is very hot 4 Thedischarge air from the evaporator is warm Diagnosis The condenser not operating correctly through lack of cooling caused by too high a high side pressure The system may have either a normal or overcharge of refrigerant Correction Checkthe Compressordrive beltfor correcttension Check the condenser for clogged air passages preventing air flow through the condenser Inspect the condenser mounting for correct radiator clearance Checkthe correctfan operation Check the coolant pressure cap for correct type and operation After making the above checks operate the system checkthe performance 82 22 AIR CONDITIONING Ifthe Condition is not rectified 1 Inspectthe systemfor overcharge of refrigerantand rectify as follows Discharge the system until a stream of bubbles appear in the sight glass and both gauge readings drop to below normal B Add new refrigerantuntil the bubblesdisappear and the pressures are normal Then add 25 to 5 Ib of additionalrefrigerant 2 Operatethe system and check the performance A If the gauge readingsare still too high
68. MUST BE AVAILABLE TO SOAK UP ANY FUEL SPILLAGE 5 EMPTY THE FUEL FROM THE TANK INTO AN AUTHORISED EXPLOSION PROOF CONTAINER USING SUITABLE FIREPROOF EQUIPMENT 6 FUEL MUST NOT BE EMPTIED INTO A PIT 7 THE WORK AREA MUST WELL VENTILATED 8 THE BATTERY MUST BE DIS CONNECTED BEFORE CARRYING OUT WORK ON THE FUEL SYSTEM 9 THE OLD TANK MUST NOT BE DISPOSED OF UNTIL IT IS RENDERED SAFE FROM EXPLOSION 10 MAINTENANCE PERSONNEL SHOULD HAVE UNDERTAKEN SPECIALIST TRAINING BEFORE BEING ALLOWED TO REPAIR COMPONENTS ASSOCIATED WITH THE FUEL SYSTEM Open the bonnet Disconnectthe battery Open the boot Remove spare wheel and jack Remove the boot floor carpet front liner and left hand side liner Slacken and remove the fuel tank retaining strap to lower bracket clamping nuts and bolts 1 Fig 1 Cut and remove the ratchet strap securing the filler housing solenoid block connector to the harness Disconnect the block connector 1 Fig 2 Reposition the aperture seal to drain tube securing clip 2 Fig 2 Disconnect the drain tube 3 Fig 2 from the aperture seal Open the fuel filler flap 1 Fig 3 and remove the filler cap 2 Fig 3 Remove the aperture seal to filler neck garter spring 3 Fig 3 Fig 3 Ji8 303 86 108 ELECTRICAL SYSTEMS Undo and remove the filler housing to body securing bolts 4 Fig 1 Displace the filler housing from the body filler flap aperture remains captive on the filler nec
69. MUST BE TAKEN WHEN WORK IS CARRIED OUT ON THE FUEL SYSTEM THE FOLLOWING PRECAUTIONS MUST BE STRICTLY ADHERED TO 1 NOSMOKING INTHE WORK AREA 2 NO SMOKING WARNING SIGNS MUST BE POSTED ROUND THE AREA 3 CO FIRE EXTINGUISHER MUST BE CLOSE AT HAND 4 DRY SAND MUST BE AVAILABLE TO SOAK UP ANY FUELSPILLAGE 5 EMPTY THE FUEL FROM THE TANK USING SUITABLE FIREPROOF EQUIPMENT 6 FUEL MUST NOTBE EMPTIED INTOA PIT Fig 1 7 THE WORKING AREA MUST BE WELL VENTILATED 8 THE FUEL MUST BE EMPTIED INTO AN AUTHORISED EXPLOSION PROOF CON TAINER Open bonnet and disconnect battery earth lead Remove luggage compartmentfloor carpet Remove luggagecompartment front liner Disconnecttank unit supply leads Rotate tank unit securing ring Fig 1 using Service Tool 18G1001 Removethe securing ring Removethe tank unit Remove and discard the gasket Ensure new sealing gasket and new locking ring is fitted when replacementtank unit is fitted Tighten locking ring with Service Tool 18G 1001 Reconnectthe tank unit supply leads Refit luggage compartmentfront liner Refit luggage compartmentfloor carpet Reconnectbattery earth lead DATA SERVICETOOLS 78G 1001 Lockingring spanner 0467G issue 2 88 23 INSTRUMENTS AUTOMATIC TRANSMISSION UNIT LINEAR SWITCH RENEW 44 15 12 Open bonnetand disconnect battery earth lead Open car door Remove gear lever knob and consolefinisher Removescrews securing linear swi
70. Openthe boot Removethe rear quarter bumper 76 22 17 Slacken and remove the screws securing the locating bracket 1 Fig 1 to the body Removethe locating bracket Reverse the removal procedure to refit the replacement bracket DATA TORQUE FIGURES Bumper beam to bumper bracket Non Federal 40 50Nm Bumper beam to bumper strut Federal 39 50Nm Bumper quarter blade to quarter bumper 5 7Nm Bumper sideto flexible mounting block 5 7Nm SPANNER SIZES 8mm 79mm 1669B 67 REAR QUARTER BUMPER BLADE RENEW 76 22 75 Open the boot Move the rear boot carpet for access to the rear fog guard lamp harness and position approximately 3 of harness slack through the grommet for each lamp Remove the beam securing bolts and spacers and carefully move the beam assembly rearwards for access to the rear quarter bumper mountings Removethe reflector from the quarter bumper pari Remove the nuts securing the bumper to the mounting Fig2 rubber Carefully reposition the quarter bumper from the studs and remove the quarter bumper assembly Reposition the beam onto the strut and remove the quarter blade to quarter bumper securing nuts and bolts 1 Fig 2 Remove the blade from the bumper and place aside 2 Fig 2 Reverse the removal procedure to refit the replacement bumper blade 76 50 BODY SECTION DATA TORQUE FIGURES Bumper beam to bumper bracket Non Federal 40 50 1 Bumper beam to bumpe
71. Pivot the electronics pack upwards for access to the bulb Removethe bulb 12 Fig 1 from the holder Fittinga new bulb by reversingthe removal procedure 3001B 86 50 ELECTRICALSYSTEM CIRCUIT FAILWARNING INDICATOR BULB RENEW 86 45 93 Open the bonnet and disconnect the battery earth lead Open the car door Removethe driver side dash liner Removethe screws securing the instrument pack Removethe instrument pack 88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for accessto the 1 bulb 2 Removethe bulb I1 Fig 1 fromthe holder 3 4 5 Fita new bulb by reversingthe removal procedure 3001B 6 TL REAR BULB FAILURE MODULE 075 RENEW 86 55 70 Openthe bonnetand disconnect the battery earth lead Open the luggagecompartment Removethe rear lamp interior trim finisher Displacethe side liner for access Remove the module earth bolt and displace the earth lead from the bolt Disconnectthe fog lampcable harness block connector Disconnectthe modulecable hamess block connectors Removethe upper bolt securing the module Remove the module from the bracket Fittingthenew moduleisreversaloftheremovalprocedure 30010 FRONT BULB FAILURE MODULE RENEW 86 55 71 Openthe bonnetanddisconnectthe battery earth lead Removethe relay cover Removerelaysfrom retaining brackets Disconnectthe headlamp blockconnector Cu
72. PlugWeld 7 eod atl la ol Sar oid otro m 8H gH NH BM BM N NH NH Tae Fig 1 77 05 BODY REPAIR DIMENSIONS 77 06 PAINTS SEALANTS AND TRIM PLASTIC PAINT The Jaguar XJ6 2 9 4 0 range is available andfinished inthe following colours Alpine Green Metallic Arctic Blue Metallic Bordeaux Red Metallic Crimson Metallic Dorchester Grey Metallic Grenadier Red Jaguar Racing Green Jet Black Moorland Green Metallic Nimbus White Satin Beige Metallic Silver Birch Metallic Solent Blue Metallic Sovereign Gold Metallic Talisman Silver Metallic Tungsten Metallic Westminster Blue NOTE 1 Numbersshown in bracketsdenote BLVC JBC codings 2 The paintcode isto befound atthe base ofthe LH B post BODY REPAIR HES 709 JFE 337 CEK 340 CEV 714 LDP 342 CEH 332 HEN 701 PDH 333 HET 717 NOJ 700 AVF 711 MDJ 716 JEW 715 GDF 341 MDF 336 JEX 718 JFG 712 PAINT MANUFACTURERSAND SYSTEMS MANUFACTURERS Ault amp Wiborg Berger CIL Dulux Dupont USA Glasurit ICI Inmont PPG Rinshed Mason Sikkens Europe Canada USA Spartan SYSTEM BASECOAT Aultragem 2K Standocryl Metallic Basislack 2K Basecoat Dulux 354 2K Acran Enamel Lucite Cronar Glassomax 54 Glassodur 21 P4222K Basecoat P4202K Acrylic Dia mont Acryline Miracryl 2 Autobase Autocryl Eurobase 131 Eurocr
73. Pluqwelds 4 Flitch reinforcementto flitch Removedwith panel bulkhead Single row of resistancespot welds assembly BRAINS 245A or equivalent 77 25 BODY REPAIR Removethe bonnet assembly 76 16 01 Remove Engine gearbox assembly 12 41 01 2 20 Radiator and oil cooler expansion tank and PAS reservoir Frontcrossmember 76 10 05 PAS rack 57 10 01 Steering column 57 40 02 5 Frontto rearfuel and brake pipes Brake pipes acrossthe bulkhead PAS and air ducting brackets Disconnect Steering column lowerjoint 1 3 Fig 1 Shock absorbers and flexible brake hoses Remove Steering column bracket and UJ assembly 1 4 Fig 2 Brake throttle clutch pedal assemblies Remove Bonnet catches locks and control cable assemblies weatherseals and gas struts Front bumper mounting assembly radiator grille and surrounds LH and RH wheel arch shields lower front spoiler and washer reservoir Front seats lower A and B post trims front door beading and weatherstrip rear seat cushion and insulation andfront seat belt assembly Battery and batterytray vacuumbottle assembly driver s well insulation scuttle panel and jets all blanking grommets inbonnet engine bay area Lay aside Rear carpets wiring at upper A post and wiring at transmissiontunnel Remove Bonnetlamps and wiring horns and wiring LH and RH headlamps LH and RH repeater flashers electric fan andbonnetlampswitch LH and RH dash trimboard in
74. REMOTE CONTROL OPERATING ROLE oe eee 76 37 68 76 43 4 144 REAR DOOR 76 40 02 76 467 4 148 REAR DOOR TRIM PAD VEN EER PANELU 7647 12 76 45 4 146 REAR DOOR UPPER TRIM PAD 76 34 05 76 45 4 1i IN coros 149 REAR LAMP ASSEMBLY INTERIOR TRIM sao lao d E POO PD cesis ZED aac A 150 REAR PA CEL TRAN MS i WO pop 4 ipo REAR QUARTER 76 22 17 76 48 4 182 REAR QUARTER BUMPER BLADE s 76 25 7B ss 76 80 4 22 RACK 9222 ZB ace 4 p E REAR QUARTER BUMPER LOQ SONT ROSBER 27655512 IER 4 BE IL REAR QUARTER JEER TEIM PADL LEET HAND 7611812 76 91 4 cr ARTER UPPER TRIM PADR EU 76 13 43 76 91 4 158 REARSEATASSEMBLY eee 70 4 159 REAR SEAT 2 70 4 160 REARSEATSQUAB EE 70 4 REAR SHELF FINISHER een 67 4 162 REAR SIDE SEAT BELT sss 73 4 101 PLATE FRONT 6 MASS ILL TREAN PLAT BEAR m 76 165 gioia NOOPASSE 82 2 4 166 5 ROOF FLANGE FINISHER 4 SLIDING ROOE MOTOR DRIVE GEAR 1 1685 5 SLIDING ROOF 82 4 169 277 SLIDING ROOF PANELLIFTING BLOCK
75. SECTION PASSIVE RESTRAINT ECU LOGIC 76 73 00 Truth tables have been providedfor information andto aid diagnostic work The following notes are also relevant 1 With ignitionon position 2 and reverse gear selected the drivers door switch input is inhibited 2 The ECU must be capable of detecting an inertiaswitch operation with ignition on AND off 3 The ECU mustbe capable of discriminatingbetweenan inertiaswitch operation and ignition off 4 Where indicatedthus logic input can be either logic 1 or logic 0 i e the output state described is not dependant uponthat particular input This combination of logic can only occur under fault conditions L H CHANNEL RH CHANNEL SEATBELT WARNING TRUTH TABLE SKT 7 SKT 15 SKT 13 SITIS FUNCTION DOOR FRONT INERTIA BELT IGN OUTPUT ee sum E PROX SWITCH LOGIC o LOW sx gp dq TOW lo e x 1 t pe LOWE I Fx o 1 1 a qe up ste RIDE 11 pec RUNTO FRONTTRUTHTABLE SKT8 SKT7 PIN2 PIN3 SKT 15 skr 13 Skr14 SKT6 SKT 10 SKT2 PIN DOOR REAR FRONT INERTIA BELT IGN OUTPUT ud 29 pock sume PROX SWITCH VOLTAGE L H CHANNEL R H CHANN
76. SOLENOID RENEW uissescesessesrseserseeenss 82 20 68 82 51 DEMISTER FLAP SERVO eren enne RENEW eere 82 20 42 82 42 DRIER BOTA SE DESCRIPTION 82 00 00 82 11 DRIER BOT IL RENEW 82 17 01 82 36 ELECTRONIC CONTROL MODULE ssessscessseserseseeeseees RENEW 82 20 65 82 44 ELECTRONIC CONTROL SYSTEM REM DESCRIPTION 82 20 00 82 04 EVAPORATOR ote DESCRIPTION 82 00 00 82 12 EVAPORATOR TEMPERATURE RENEW 82 20 64 82 53 EXPANSION DESCRIPTION 82 00 00 82 13 EXPANSION VALVE ener RENEW 82 25 01 82 46 FLAPMOTOR GEARBOX LOWER RENEW eene 82 20 63 82 43 FLAPMOTOR GEARBOX UPPER RENEW 82 20 62 82 43 HEATER MATRIX eene nnne tnn tnnnnn nnns RENEW erneuten 82 25 19 82 49 HEATER COOLER UNIT RENEW ener 82 25 21 82 50 ac ME e POET MEME 82 00 00 82 26 HOSE COMPRESSOR TO CONDENSER m 82 25 49 82 48 HOSE EVAPORATOR TO COMPRESSOR i 82 25 02 82 47 HOSE RECIEVER DRIER TO 82 25 03 82 48 INDE 82 00 00 82 02 INDEX 82 00 00 82 03 IN CAR TEMPERATURE SENSOR 82 20 03 82 37 LOWER FE
77. Slacken the bonnet securing bolts 1 Fig 2 and disconnectthe bonnet support struts 2 Fig 2 Remove the bonnet securing bolts and remove the bonnet Remove the trim pad securing screws and remove the trim pad Remove the bonnet lamp securing screws remove the tape securing the lamp harness to the bonnet and removethe lamps Remove the bonnet lock spring assemblies remove the bonnet catch securing bolts and removethe catch Removethe bonnet support pivots and placethe bonnet aside Reversethe removal procedureto refit ensuringthat the bonnet is aligned before the bonnet securing bolts are finally tightened DATA SPANNER SIZES 13mm 0070b BONNET INSULATION PAD RENEW 76 16 06 Open the bonnet and removethe ten self tapping screws and plain washers securing the insulationto the bonnet Hold the replacement insulation pad in position and secure with the ten screws and plain washer Close the bonnet 76 24 BODY SECTION BONNETSEALING RUBBER REAR RENEW 76 16 04 Open the bonnet Starting from one side of the vehicle prise the rubber seal Fig 1 from the bulkhead inner wings Discardthe old seal Starting from the centre of the vehicle fit the replacementseal to the bulkhead inner wings gradually working outwards Ensure the seal is firmly pressed down onto the channel edge Cutthe outer edge of the seal as shown Fig 1 Press the remainder of the trim firmly down on each inner wing andtrim off untilth
78. The advantages of the new TD tyres stem from their unique construction which distributes the stresses evenly aroundthe casing The natural flexing curve permits the use oflow aspect ratios without the usual penalty of ride harshness The TD Tyres are manufactured to the very high quality standards expected from all tyres and give the following benefits Superb grip and performance The very wide and distinctive tread patterns put a large area of rubber on the road for maximum grip Because of the unique construction a very bold tread pattern with wide channels can be used without causing rapid and uneven wear often associated with this type of pattern Water clearance is excellent giving safe sure grip in the wet Precise handling The whole TD range with its low wide profile gives improved stability and precise steering control Even Wear The equalized stresses resulting from the naturalflexing curve allied to the TD low profile casing result in remarkably even tread wear giving high mileage Low rolling resistance and fuel economy Extensive research has proved that the combination of the TD construction with its low aspect ratio on the special rim provides the optimum in rolling resistance a vital factor in fuel economy 74 10 Issue 2 WHEELS AND TYRES FITTING AND REMOVAL General Notes The TD is fitted and removed inthe conventional way using the standard fitting machinery The following procedures should be used as a
79. The vacuum supply to the centrevent recirculation fresh air flaps have built restrictors so that the operation of these flaps are slowed down to avoid the risk of the system hunting The recirculationflaps can take upto 30 secondsto changestate 80 7 Fig 1 Fig2 Fig3 48279 182115 180 044 HEATING AND VENTILATION HEATER SWITCH CONTROL MODULE RENEW 86 80 14 Disconnectthe battery earth lead Removethe gear lever knob Removethe console finisher Remove the screws securing the upper console assembly and displacethe console assemblyfor access Slackenthe screwssecuring the control module Fig 1 Disconnectthe cable hamess block connector Removethe control module Fitting a new control module is the reversal of the removal procedure 0209G ELECTRONIC CONTROL MODULE ECM RENEW 80 10 52 Disconnectthe battery earth lead Removethe passengerdash liner Removethe screws securingthe control module Fig 2 Displacethe modulefrom its location Disconnectthe earth lead Note and disconnectthe multi plug connectors Removethe control module Fitting a new control module is the reversal of the removal procedure ensuring the multi plugs are secure andtight 0209G HEATER MATRIX RENEW 80 20 29 Disconnectthe battery earth lead Drainthe coolant Removethe driver and passenger side dash liners Removethe glove box lid and glove box Removethe matrix pipe gaskets Remove the sc
80. Wear All tyres fitted as standard have atread wear indicator Fig 1 moulded into their tread pattern to provide indication when the tread depth remaining is 1 6 mm 0 063 in Each indicator appears on the tread surface as bars which connect the tread pattern across the full width of the tyre Itis illegal inthe UK and certain other countriesto continue usingtyres after the tread has wornto lessthan 1mm 0 039 in over three quarters of the tread width around the entire circumference of the tyre J74 Fig 1 74 07 Issue 2 WHEELS AND TYRES The properties of many tyres alter progressively with wear In particular wet grip and aquaplaning resistance properties are gradually but substantially reduced Extra care and speed restriction should therefore be exercised on wet roads as the effective tread depth diminishes When replacement of tyres is necessary itis preferableto fita complete vehicle set Should either front or rear tyres only show excessive wear new tyres must be fitted 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 Ifthe position is changed after wear has occurred the performance of thetyre will be adversely affected Damage Excessive localised distortion sometimes caused by severe contact with kerbs or stones can cause the tyre casing to fracture and may l
81. a full flow of refrigerant WARNING UNDER NO CIRCUMSTANCES OPEN THE HIGH SIDE HAND VALVE WHILE THE AIR CONDITIONING SYSTEM IS IN OPERATION IF THE HIGH SIDE HAND VALVE SHOULD BE OPENED WHILE THE SYSTEM IS OPERATING HIGH PRESSURE REFRIGERANT WILL BE FORCED THROUGHTHE HIGH SIDE GAUGE AND TO THE REFRIGERANT CONTAINER IF IT IS ATTACHED THIS HIGH PRESSURE MAY RUPTURETHE CONTAINER OR POSSIBLY BURST THE FITTING AT THE SAFETY CONTAINER VALVE RESULTING IN MUCH DAMAGE INCLUDING PERSONAL PHYSICALINJURY With the engine switched off removethe protective caps from the schraeder valves Fitthe accessvalve removaltoolto the schraeder valves Ensure that both the manifold hand valves are inthe closed position Connectthe high pressure manifold gauge hoseto the high pressureside of the air conditioning side of the system high side will always bethe line from the compressorto the condenser Connectthe low pressure or compound gauge hoseto the low pressure side of the air conditioning system Usingthe access valve removaltool loosenand screw outthe valve cores PurgingThe Test Hoses With the manifoldtest set attachedto the system Purge the high pressure test hose by cracking open the high pressure side hand valve on the manifold gauge set for 3to 5seconds This will allow the system refrigerantto purgethe air from the test hose and discharge through the manifold centretest hose Immediately close the high pressure side hand valve Purge the low pressur
82. assembly Remove instrument pack cowl housing screws and remove cowl housing Place pack face down on bench ensuring cowl lens is protectedwith suitable cloth or similar NOTE To minimise the risk of damage and contamination all repairs conducted on the Instrument Pack should be performed in a non static dust free environment Removethe electronics pack cover securing screws and removethe cover Carefully release the flexible printed circuit ribbon ends from the edge connectors by squeezeing grips between thumb and forefinger while sliding out connector latch Fig 1 Releaseelectronics pack retainingclips Fig 2 and pivot pack upwards Displace and remove electronics pack from the instrument pack by lifting off from hinges Displace and remove all warning bulbs bayonetfitting twist 1 8th turn anti clockwise to release NOTE There are two types of coloured bulb holders eachtype mustbe returnedto the correct location Disconnect the flexible printed circuitto LCD multi plug Fig 3 DO NOT remove plug from the outer case of the Instrument Pack Remove the 7 veneer panel securing screws carefully peeling back top corners of the flexible printed circuit to gain accessto 2 of the veneer panelsecuringscrews With the gauges uppermost release the cowl lens securing clips and remove the cowl lens assembly CAUTION With cowl lens removed DO NOT rest pack face down The gauge needles are extremely delicate and are easi
83. assembly from the fascia 180 025 Removethe screws securing the centre vent Reposition the fascia and displacethe vent assembly Noteand disconnectthe vacuum pipes Manouvrethe vent assemblyfrom the fascia Fig 1 Fitting a new centre ventilator is the reversal of the removal procedure 02096 CENTRE FASCIA VENTILATOR OUTLET RENEW 80 15 48 Open the car door and remove the fascia centre veneer pane Displace and remove the ventilator outlet Fig 2 Fittinga new centre ventilator outlet is the reversal of the removal procedure 0209G DRIVER SIDE VENTILATOR OUTLET RENEW 80 15 49 Open the car door and remove the ventilator outlet direction vent Releasethe outlet retaining clips Removethe vent outlet Fig 3 Fitting a new ventilation outlet is the reversal of the removal procedure 02090 Fig3 80 17 HEATINGAND VENTILATION PASSENGER SIDE VENTILATOR OUTLET RENEW 80 15 50 Open the car door Openthe glove box lid Remove the ventilator outlet direction vent Releasethe outlet retaining clips Removethe vent outlet Fig 1 Fitting a new ventilation outlet is the reversal of the removal procedure 0209G DEMISTER DUCTOUTLET RENEW 80 15 53 Openthe car door Carefully prise the solar sensor housing from its position Removethe screws securing the vent outlet 1 Fig 2 Remove the ventfrom the retainingclip 2 2 Fitting a new demister duct outlet is the reversal of the removal pr
84. be removedfrom the anti theft label priorto vehicle handover to the customer NOTE It cannot be stressed too highly that Federal law requires dealers to remove paint masks from anti theft labels after performing painting and rustproofing operations Failure to comply renders manufacturerand dealer liablefor violations of the law listed below Federal Motor Vehicle Theft 51 FR 8831 at8835 March 141986 Prevention Standard Motor Vehicle Information 15 U S C 2027 a 4 B and and Cost Savings Act 2027 b sections 607 a 4 B and607 b 77 10 BODY REPAIR PANEL S RENEW 77 10 01 Jack upvehicle and place on axle stands Removetoadwheels Prepare equipment ensuringthat all tools requiredinthe removal sequence of operations are available and to hand Protect vehicle use an asbestos blanket to protect the interior anda protective cloth for the exterior ASSOCIATED PANELS RENEW 77 10 02 This may involvefor examplethe removal of afront wing to provide accessto the front panel Expose resistance spot welds For those spot welds which are not obviously visible use a rotary wire brush fitted to an airdrill or a hand heldwire brush Fig 1 NOTE In wheelarch areas it may be necessaryto remove underseal prior to exposing spot welds Use a solvent hot knife DO NOT BURNTHE SEALANT OFF Centre punch spot welds ensuring that an adequate centre punch is made to give good centering then cut out the welds us
85. boot Move the spare wheel access flap and remove the bolt securingthe spare wheel in position Liftoutthe spare wheel Removethe floor carpet Releasethe tension from the vehicle jack and removethe jack assembly Removethe front liner Removethe nuts securing the rear lamp assembly inner cover Removethe inner cover Removethe screw securing the upper portion ofthe side liner and removethe liner Fig 1 Reverse the removal procedure to refit the replacement side liner DATA TORQUE FIGURES Clampscrew clamp tospare wheel13 16Nm Jack to mounting bracket 7 74Nm 16698 76 ELECTRICALLY OPERATED FRONT SEAT CUSHION RENEW 76 70 11 Openthe door Removethe bolt securingthe seat cushion Removethe cushion retaining plate Reposition the cushion Fig 2 for access to the block connectors Disconnect the block connectors and remove the seat cushion assembly Displace the seat entry switch harness multiplug from the retainingclip Disconnectthe seat entry switch hamess multi plug remove the seat cushionassy andthe seat entry switch Removethe switch bezel and discardthe cushion Reversethe removal procedureto refitthe seat cushion 16698 76 69 BODY SECTION ELECTRICALLY OPERATED FRONT SEAT RENEW 76 70 10 Open the front door Removethe bolt securingthe seat cushion Removethe cushion retaining plate Reposition the cushion for access to the block connector Disconnect the block connector and rem
86. breather pipe heater relay 6 Tan Instrument pack 7 Violet 3A Anti lock braking system ABS main relay 8 Violet 3A Spare position 9 Violet 3A Spare position NOTE Although not used positions marked needto have fuses presentto avoid a false fuse failure warning beingdisplayed IN LINE FUSES Protected Location Colour Fuse Circuit Code Value Wiper logic Adjacentto wiper logic module below unit the glovecompartment Anti lock Behindthe front door pillarfuse brakingsystem box onthe driver s side ABS ECU Anti lock Behindthe front door pillarfuse Light 30A brakingsystem box onthe driver s side green ABS pump motor Radiowhere Below centreconsole 10 fitted Radio memory Below centreconsole E 1A 86 105 ELECTRICAL SYSTEMS 91MY CONTENTS DESCRIPTION OPERATION BULB FAILURE MODULE FRONT 91MY DESCRIPTION BULB FAILURE MODULE REAR 91MY DESCRIPTION CENTRE CONSOLE PANEL 91MY DESCRIPTION CIGAR LIGHTER eere DESCRIPTION DIMMER MODULE eren DESCRIPTION E POST LAMPS 91 DESCRIPTION FUEL FILLER FLAP SOLENOID DESCRIPTION FUEL FILLER FLAP SOLENOID FUEL PUMP LINK HARNESS 91MY FUEL SYSTEM RELAY 91MY FUEL SYSTEM RELAY 91MY 91MY CHANGES GEAR SELECTION ILLUM
87. bulb Removethe bulbfrom the holder Fita new bulb by reversingthe removal procedure 30016 FUEL GAUGE ILLUMINATION BULB RENEW 86 45 52 Open the bonnetand disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securing the instrument pack Removetheinstrument pack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulb by reversingthe removal procedure 30018 86 43 ELECTRICALSYSTEM BATTERY CONDITION INDICATOR ILLUMINATION BULB RENEW 86 45 56 Open the bonnet and disconnectthe battery earth lead Open the car door Removethe driver side dash liner Removethe screws securingthe instrument pack Removethe instrument pack 88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulbby reversing the removal procedure 3001B L C D ILLUMINATION BULB RENEW 86 45 57 Openthe bonnet and disconnect the battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securing the instrument pack Removethe instrument pack88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for access to the bulb Removethe bulb from the holder Fita new bulb by reversing the removal procedure 30018 FLA
88. bulkheadaperture Refitthe vacuum reservoir and the battery tray Connect the positive lead fit tape to the terminal post andfully seatthe rubber boot Positionthe harnessto the battery tray Connectthe earth leadsto the negativeterminal Fit the negative battery lead to the terminal fit and tighten the securing nut Refitthe battery Fig 1 Routethe harness overthe engine Connectthe starter motor multi plug connector eon the harness to the bulkhead with rachet straps ig1 Route and secure the harnessto the harness carrier with rachetstraps Securethe carrier to brackets with rachet straps Route the breather heater connector to its position and secure with rachet strap Connectthe injector leads Connectthe coolanttemperaturesensor lead Connect the engine breather hose to the cam cover Position andtighten the clip Connectthe idle speed actuator multi plug Connect the earth leads to the harness support bracket Fitandtighten the securing nut Route the hamess to the air flow meter and connect the multi plug Connectthe throttle potentiometermulti plug Connectthe supplementaryair valve multi plug Securethe multi plug and harnessto the manifold with a rachetstraps Connect the air pump relay multi plug at the oil cooler pipe andsecure with a rachetstrap Route the hamess to the front of the cam cover and secure with a rachetstrap Connect the crankshaft sensor and secure with a rachet strap Routethe hamessto the HT coil Conn
89. cable harness block connector Remove the bulkhead earth terminal nut and disconnect the earth lead Cutand removethe hamessto bulkhead rachet securing straps Displace and remove the cable hamess Fitting the new harness Fit and alignthe new harnessto the vehicle bulkhead Securethe hamess with rachetstraps Route the hamess under the heater unit to the tunnel area Route the seat heater and interior light hamesses and connectthe block connectors Refitthe seat cushions Securethe hamessto tunnel with rachetstraps Connectthe tunnel earth leads and tighten the securing bolt Route the hamess to the tunnel and secure with rachet straps Locate the powered seat relay bases to the support brackets Connectthe gearbox linear switch block connector Connectthe gearbox block connector Connectthe earth leads fit andtighten the securing bolt Connectthe passenger blower motor block connector Connect the earth lead to bulkhead fit and tighten the securing nut 86 76 ELECTRICALSYSTEM Fitthe CPU bracket fit the CPU to the bracket and connect the block connectors Routethe harnessto the A postarea Connectleadsto the terminal post Tighten the securing nut and position rubber boot over the terminal post Connectthe passengerdoor harness block connectors Position the door harness block connectors into the postandfitthe A postfinisher Connectthe side harness block connectors Connectthe A postearth lead
90. complete evaporization of the liquid refrigerant within the evaporator This is accomplishedby the expansion valve which is a metering device which changes the pressure of the liquid refrigerant from a high pressure to a low pressure liquid As the refrigerant passes through the metering orifice in the valve the pressure and the temperature of the refrigerant is reduced so the refrigerant leaves the expansion valve as a low pressure cold atomized liquid The temperature of the refrigerantis then lower than the temperature of the air in the vehicle so that a heat exchange from the warm air to the refrigerantcan take placeinthe evaporator As this cold atomized liquid refrigerant passes through the evaporator coils heat will follow its natural tendency and move from the warm air into the cooler refrigerant When the refrigerant reaches a temperature and pressure that will induce a change of state a large quantity of heat will move from the air into the refrigerant The refrigerant will then change from alow pressurecold liquidto alow pressurecold vapour The refrigerantvapour then returns to the low suction side of the compressor SAFETY PRECAUTIONS 82 00 00 The air conditioning system is designed to use only Refrigerant 12 dichlorodifluoromethane Extreme care must be taken NOT to use a methylchloride refrigerant The chemical reaction between methylchloride and the aluminium parts of the compressor will result in the formation of p
91. corners secure with tape and using soft soap Seat the door seal inthe channel Remove the tape and slide the front lower edge and corner of the seal into position Clean off all soft soap and refit the sill tread plate DATA OILS SEALANTS LUB RICANTS Three channel buttjoints Kent clear sealer Seal abovesill section Solumin 1669B 70 76 46 BODY SECTION REAR BUMPER ASSEMBLY RENEW 76 22 15 Remove both rear fog lamp assemblies and rear side marker lamps where fitted Remove the bumper securing bolts and collect the spacers and remove the rear bumper assembly Fig 1 Guide the replacement bumper onto the guides at the sides of the vehicle and fit the securing bolts Tighten the bolts and refitthe rear fog and marker lamps wherefitted DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27 Bumper to bumper bracket Non Federal 40 50Nm Bumper to body inner Federal 23 27Nm Bumper to fixingsbumper beam Federal 39 50Nm Bumperto body inner Non Federal 23 27Mm Bumper to fixings bumper beam Non Federal 39 50Nm Guideblock to mounting bracket3 5 4 75Nm Mounting bracket guide block to body 7 5 70Nm SPANNER SIZES 8mm IOmm 13mm 17mm 19mm No 20 Torx 0375b REAR BUMPER ASSEMBLY OVERHAUL 76 22 18 Fig2 Remove the rear fog guard and marker lamps where fitted Remove the rear bumper securing bolts an
92. driver s passive belt is not located in the restraining position Also operation s a six second audiblewarning OPERATION The system is actuated when the doors are closed and the ignition is turned to position Both seat belt warning lights will remain illuminated until the driver s passive automatic belt is located in the restraining position the audible warning once started will continue for six seconds Both driver and passenger belt should operate simultaneously even when the passenger seat is unoccupied This will ensurethat the passenger door mirror is not obscured by the belt The passive belt deploys automatically to the unrestraining position when the ignition key is turned to position I or OFF or when the adjacent door is opened However with reverse gear selected should the driver s door be opened to aid driver vision the belt is preventedfrom travelling to the unrestraining position thereby avoiding the possibility of entanglingthe leaning driver A further safety feature of the system is its connection with the inertia switch If the inertia switch is tripped with the ignition ON no movementof the passive beltwill occur In addition the doors will be unlocked To prevent the occupant from being trapped in the vehicle in the event of a road accident the buckle at the shoulder end of the belt can be released by operating the red button marked PRESS WARNING IF THE BELT IS RELEASED FOR ANY REASON IT MUS
93. filler flap Exercise care to ensure the surrounding paintwork is not damaged Using a flat bladed screwdriver fit and seat the new magnet assembly to the new filler flap note correct orientation Close fuel filler flap FUEL FILLER FLAP LATCH POST RENEW 76 10 28 Open the fuel filler flap Displace the latch post retaining tag Exercise care to ensure the surrounding paintwork is not damaged Remove the latch post Fit the replacement latch post and secure with the retaining tag Close the fuel filler flap 76 116 DULUY SEU LIVIN SIXTH LIGHT RENEW 76 81 13 Open the rear door Remove the trim pad securing screw and the coat hanger hook Slacken but do not remove the dowager strap securing screws Remove the rear seat belt upper anchorage bolt cover and bolt Displace the upper portion of the seat belt and collect the spacer Undo and remove the rear quarter trim pad lower securing screw Unclip the rear quarter trim pad and remove Displace the weather seal from the D post channel Undo and remove the sixth light finisher securing screws Fig 1 Affix four layers of suitable protective tape on to the post paintwork and under the sixth light finisher Carefully cut through the Betaseal securing sixth light into body aperture using suitable hand cutting tools Fig 2 Note Release of the bottom and D post edge first gives easier access to top corner and post edge Place a suitable w
94. guide only TD tyres must be fitted to the appropriate size of TD rim Removal Deflate the tyre by removing the valve core Unseat inturn bothtyre beads with a pneumatic unseating tool fitted with a broad blade Ensurethatthe edge of the blade is free from any rough edges Keep the blade close to the wheel flange Apply a suitable lubrication to the rim flanges and tyre bead area on both sides of the assembly Clamp the wheel to the fitting machine and roll off the tyre beads in turn following the machine manufacturer s operating instructions Take care not to damage the tyre bead location toe during this process Fitting Confirm that a suitable valve and core are correctly fitted to the wheel rim Apply a suitable lubricant to both bead and flange areas of the wheel and both beads of the tyre Clamp the wheel tothe fitting machine and rollon each bead inturn following the machine manufacturer s operating instructions Take care not to damage the tyre bead location toe during this process The TD tyre can only be fitted tubeless No suitable design of tube is available or foreseen As with other modernrimdesigns incorporating bead retention safety features humps for example itis strongly recommended that a fitting machine is used for all fitting and removal Use of hand levers for removal is NOT recommended Unclamp the wheel and inflate the tyre to 50 Ibf in 3 5 bar 350kPa ensuring that the beads remain parallelto t
95. hamess to the bottem of the door Connectthe multi plug connectors Securethe harnesswith rachet straps Repositionthe water curtain Fitthe lower and uppertrim pads Fitthe veneer panel Reconnectthe battery earth lead Check operationof the relevent components 486 612 3001B 86 81 ELECTRICALSYSTEM POWERED SEAT LINK LEAD RENEW 86 70 12 Openthe front doors and switch on the ignition Motor front sears fully forward Switch off the ignition Console assembly renew 76 25 01 Front seat cushion renew 76 70 02 Reposition rear footwell carpet and insulation from below the drivers seatfor access Fig 1 iy eas powered seat link lead multi plug purple 4 Cut and remove the ratchet straps securing the link lead to the floor transmission tunnel Repositionthe link lead from below the drivers seat Reposition the rear footwell carpet and insulation from below passenger seat for access to the harness multi plug Cut and removethe ratchet strapssecuring the hamess Repositionthe linkleadfrom below the passengerseat Displace and removethe link leadfrom the vehicle Fitandalignthe new harnessto transmissiontunnel Repositionthe lead below the passengerseat Fig 2 Connectthe mutti plugto the passenger seat harness Secure the hamess to the floor transmission tunnel with the ratchetstraps Repositionthe rear footwell carpet Repositionthe link lead belowthe drivers seat Connectthe drivers s
96. heater outlet retainingtangs Removethe outletassembly Placethe console assembly aside Fit and seat the rear heater outlet to the replacement console assembly Reverse the remaining removal procedure to refit the replacementconsole assembly 0011b CONSOLE FINISHER AUTOMATIC RENEW 76 25 19 Openthe door Removethe console ashtray 76 67 18 Using a screwdriver release the gearshift rubber surround locating clips and carefully removethe finisher Movethe selector leverto the rearward position remove the wingnuts securing the rear of the veneer and carefully removethe finisher Fig 1 Reversethe removal procedureto refit 0015b CONSOLE GLOVEBOX J76 351 RENEW 76 25 16 Open the door and remove the console ashtray 76 67 18 Removethe glovebox securing screws 1 Fig 2 andthe fuse box to glove box securing screws Removethe glovebox 2 Fig2 Reversethe removal procedureto refit the glovebox 00136 CONSOLE GLOVEBOX LID RENEW 76 25 18 w Openthe door Open the glovebox lid 4 Fig 2 and removethe securing Fia 2 screws 3 Fig 2 9 Removethe lid assembly Reverse the removal procedure to refit the lid noting to align the lid with the console prior to finally tightening the lid securingscrews 0014b 76 82 BODY SECTION DASH LINER DRIVERS SIDE RENEW 76 46 11 Openthe door Remove the screws securing the dash liner Fig 1 and releasethe liner securing clip Remove the da
97. illustrated Fig 1 The jack and wheel changing tools are located behind the spare wheel To remove the spare wheel remove the carpet cover and unscrew the bolt retaining the spare wheel Lift out the wheel Ensure that the ratchet and wheel brace are correctly positioned in the securing clips prior to positioning and securing of the spare wheel and its cover The tool box wherefitted is locatedatthe top ofthe luggage Compartment adjacentto the spare wheel It contains a selection of tools and spare bulbs To remove hold downthe retaining catch belowthe tool box andslide thetool boxrearwards To replace slide the tool box back into its container until the retaining catch locks Note For Daimler Vanden Plas derivatives a 6mm Allen key is clippedto the jack bracket which is used for removing the hubcap Fig 1 DATA TORQUE FIGURES Spare wheel tool stowage bracket to body 22 28Nm SPANNER SIZES 13mm 74 20 Issue 2 BODY SECTION CONTENTS DESCRIPTION OPERATION OPERATION PAGE No No A POST LOWER TRIM PAD erret RENEW nnn 76 13 30 76 19 PRS RUA DRAN RORIS RCM RENEW 76 67 13 76 93 AUTOMATIC GEARBOX SELECTOR TRIM FINISHER 76 25 07 76 93 B C POST CAPPING eere nnns 76 43 34 76 80 B POST LOWER TRIM PAD eene 76 13 29 76 80 B POST UPPER TRIM PAD center 76 13 28 76 80 BONNET us a e ix
98. in an upward direction 76 72 BODY SECTION Discard seat back Reverse the removal procedure to fit the replacement seat back 00696 FRONTSEAT BELT BUCKLE UNIT RENEW 76 73 02 Disconnect the electrical block connector Fig 1 feeding the buckle unit 3 Fig 1 located under the seat cushion Remove the front seat and buckle unit securing bolt cover Removethe bolt 1 Fig 1 Refit to fit the cover the replacement buckle unit to the seat frame with the securing bolt Refit the seat to the vehicle and reconnect the block connector DATA TORQUE FIGURES Seatbuckle to seat frame 271 Nrn SPANNER SIZES 17mm 0393b FRONT SEAT BELT LEFT HAND RENEW 76 73 10 Open the door Removethe B post lowertrim pad 76 13 29 Remove the seat belt upper anchor securing nut cover and nut Reposition the seat belt for access remove the spacer and wavey washer and disconnectthe block connector Unclipthe post upper trim pad Displacethe uppertrim padfrom ist mounted position Pass the seat belt through the trim pad and remove the upper trim pad Remove the seat belt finisher from the B post aperture and reposition the seat beltthrough the B post Remove the seat belt reel securing bolt and remove the seat belt reel Renewthe seat cushion 76 70 02 Cut and remove the seat belt buckle block connector securing strap and disconnect the seat belt buckle block connector Remove the seat belt buckle mounting br
99. lead Remove the bolt securing the dip stick the the engine manifold Removethe dip stick assembly Raisethe vehicle on a ramp From below Remove the bolt securing the front suspension rear mounting inner bracket Disconnectthe engine earth strap Remove the rear mounting nut and remove the mounting bracket From below Removethe upperstarter securing bolt Removethe lower starter securing bolt Displace the starter motor downwards for access Removethe starter terminal securing nut and disconnect the lead from the terminal Disconnectthe cable harness block connector Removethe starter motor Fig 1 Fitting a new starter motor is the reversal of the removal procedure 30018 GEAR BOX LINEAR SWITCH J88 030 RENEW 44 15 12 Fig2 Openthe bonnet and disconnectthe battery earth lead Openthe car door Removethe gear lever knob 37 1 6 1 1 Removethe consolefinisher 76 25 19 Removethe screws 1 Fig 2 securing the linear switch 2 Fig2 86 64 ELECTRICALSYSTEM Displacethe switch for access Disconnectthe cable harness block connectors Remove the switch assemble On fitting new switch select N neutral Fitthe new 2 Fig 1 switch in position Fitbutdo nottighten the securing screws 1 Fig 1 Positionthe setting gauge JD 127 Fig 1 betweenthe linear switch and side plate Ensure the slot of the setting gauge is fully located onto the pin of the linear switch Tighten the securing screws Removethe
100. lifting off from hinges Displace and remove all warning bulbs bayonet fitting twist 1 8th turn anti clockwiseto release NOTE There are two different types of coloured bulb holders each type must be returned to the correct location Disconnectthe flexible printed circuit to LCD multi plug Fig 3 DO NOT remove plug from the outer case of the Instrument Pack Remove the 7 veneer panel securing screws carefully peeling back top corners of the flexible printed circuit to gain access to 2 of the veneer panelsecuring screws With gauges uppermost releasecowl lens securingclips and removecowi lens assembly CAUTION With cowl lens removed DO NOT rest pack face down The gauge needles are extremely delicate and are easily damaged Also take care to scratch or damage the gauge faces ensure cleanliness when handling the pack Displace and remove the veneer panel The LCD module is attached to the veneer panel but with caution may be removed as a complete assembly CAREFULLY remove oil pressure coolant temperature gauge set gently easing the pins out of the printed Fig3 circuit crimps To prevent widening of the crimp connections gauge pairs should be kept square to the Instrument Pack moulding whilst removing issue 2 88 18 INSTRUMENTS NOTE Individual gauge movements CAN NOT be serviced pointers and can location screws should not be removed Align and fit new fuel battery condition gauge set to In
101. lower frame fixing to door 7 T0Nm Setscrew rear upper frame fixing to door 7 10Nm SPANNER SIZES 10 Torx bit No 0019b 76 40 BODY SECTION REAR DOOR GLASS FRAME RENEW 76 31 61 Open the door Removethe front door trim pad veneer panel 76 47 11 Removethe front door upper trim pad 76 34 02 Removethe front door lower trim pad 76 34 03 Remove the rear door waist rail moulding 76 43 05 Removethe rear door glass 76 31 02 Removethe rear door glass channel rubber 76 31 14 Remove the outer finisher securing screw and remove the outer finisher Removethe upper seal from the frame Apply soft soap to the upper seal fitment area of the replacementframe Starting with the front of the seal atthe rear of the frame slidethe seal into position Reverse the remaining removal procedure to refit the replacementframe DATA TORQUE FIGURES Door glass clampingstrip to door 7 10Nm Doorglass regulatorandslide channel to door8 10Nm Setscrewfront lower frame fixing to door 7 10Nm Setscrewfront upper frame fixing to door 7 10Nm Setscrewrear inboard frame fixing to door 7 10Nm Setscrewrear lower frame fixing to door 7 Setscrew rear upper frame fixing to door 7 10Nm SPANNER SIZES 10mm Torxbit No 30 0022b REAR DOOR HANDLE RENEW 76 58 02 Open the door Removethe rear door trim padveneer panel 76 47 11 Removethe rear door upper trim pad 76 34 05 Remove the rear door lowertrim pad 76 34 06 76
102. new O rings are fitted Ensure the union nuts are tightened to the correcttorque Flush evacuate and rechargethe system DATA TORQUE FIGURES Drier securingnuts 7 10Nm 0206G LOWER FEEDBACK POTENTIOMETER RENEW 82 20 60 NOTE The potentiometer is supplied preset on a mounting plateand mustnot be disturbed Open the bonnetand disconnectthe battery earth lead Removethe left hand dash liner Remove the three screws Fig 2 securing the potentiometer plate Disconnectthe cable connector Withdraw the potentiometer complete with plate from its location Fitting a new potentiometer assembly is the reversal of the removal procedure 82 36 AIR CONDITIONING UPPER FEEDBACK POTENTIOMETER RENEW 82 20 61 NOTE The potentiometer is supplied preset on the 7 p 4 mounting plate and must not be disturbed Openthe bonnetand disconnectthe battery earth lead Removethe left hand dash liner Ifthe vehicle is right hand drive removethe glove box Removethe three screws Fig 1 securing potentiometer fixing plate Disconnectthe cable connector Withdraw the potentiometer complete with platefrom its location Fittinga new potentiometer is the reversal of the removal procedure 0206G INCAR TEMPERATURE SENSOR 282 159 RENEW 82 20 03 Open the bonnet and disconnectthe battery earth lead Open the glove box and removethe platefrom insidethe glove box Disconnectthe temperature sensor cable harness multi
103. nuts securing the bulb holders Displacethe holdersfrom the lens Disconnectthe cable harness block connector Removethebulbsftom holders Fig 2 Fitting a new bulb holders is the reversal of the removal procedure 0037d TAIL STOP FLASHER AND REVERSE LAMP LENS RENEW 86 40 72 Fig 1 Openthe luggage compartment Removethe rear lamp interiortrim finisher Fig 1 Displacethe side liner Remove the bolt securing the bulb faiure module bracket Displacethe modulefrom the bracket Removethe nuts securing the bulb holders Displace the holdersforward Removethe nuts securing the lens Removethe bulb failure bracket Removethe lens assembly Fitting a new lens the reversal of the removal procedure 30018 TAIL STOP FLASHER AND REVERSE LAMP BULB RENEW 86 40 73 Fig2 Openthe luggage copartment Remove lamp assembly interiortrim finisher Fig 1 Removethe nuts securing the bulb holders Displacethe bulb hoders forward Removethe appropriate bulb Fig 2 Fitting a new bulb is the reversal of the removal procedure 30018 86 33 ELECTRICALSYSTEM NUMBER PLATE LAMP AND BULB RENEW 86 40 84 Open the bonnet and removethe battery earth lead Open the luggage compartment Removethe screws securing the number plate lamp N Displacethe lampfrom aperture Disconnectthe electrical supply cables at the lamp lucar connectors Removethe lamp completewith the gasket Fig 1 Remov
104. of upper trim remove the nuts and springs washers 1 Fig 1 and removethe channel 2 Fig 1 Reversethe removal procedureto refit the channel 0356b WINDSCREEN GLASS LOWER FINISHER RENEW 76 43 41 Using a suitable implement under one corner of the seal lift out of its aperture and peel back acrossthe vehicle Coat the replacement seal with a liquid soap solution and starting at one end of the aperture press the seal into position working across the vehicle cut the seal to lengthand finally seat 0395b BOOT LIDSTRIKER ADJUST 76 19 04 Open the boot and remove the rear finisher screws and removethe finisher Slackenthe stricker plate securing bolts I Fig 2 adjust the striker to ensure the boot lid lines up with both rear wings andtighten the securing bolts Fitthe rear finisher and secure with the screws Close the boot DATA SPANNER SIZES Fig2 10mm 13mm 0381b 76 62 BODY SECTION BOOT LID RENEW 76 19 01 Open the bonnet and disconnect the battery open the boot cut the clips securingthe harnessto the bootlid Disconnectthe boot lamp and boot lock multi plugs and disconnectthe number plate lampfeed wires Removethe hingeto boot lid securing bolts Fig 1 hold the bootopen using a suitable prop Disconnect the gas struts from the boot lid pivots and remove the boot lid Remove the two number plate lamp units two screws each and the boot illumination lamp Remove the boot lid lock a
105. pack Remove the instrument pack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulb from the holder Fita new bulb by reversing the removal procedure 30018 86 48 ELECTRICALSYSTEM OPEN WARNING INDICATOR RENEW 86 45 87 Open the bonnet and disconnectthe battery earth lead Open the car door Removethe driver side dash liner Removethe screws securing the instrumentpack Removethe instrumentpack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Remove the bulb 4 Fig 1 from the holder Ke Fit anew bulb by reversingthe removal procedure p 30018 ROR OPEN WARNING INDICATOR Jae 075 RENEW 86 45 88 Openthe bonnet and disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securingthe instrumentpack Removethe instrumentpack88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulb 5 Fig 1 from the holder Fita new bulb by reversingthe removal procedure 3001B HIGH COOLANTTEMPERATURE WARNING INDICATOR BULB RENEW 86 45 89 Openthe bonnet anddisconnectthe battery earth lead Openthe car door Removethe driverside dash liner Removethe screws securingthe instrument pack Removethe instrument pack 88 2
106. pack bulb feed supply There are also different pin numbers assigned to the steering column connector SIDELIGHTS ON POWER RELAY DESCRLPTION 86 00 00 The Radio Illumination Relay is replaced bythe Sidelights On Power Relay which also supplies the cigar lighter illumination CIGAR LIGHTER DESCRIPTION 86 00 00 The cigar lighter receptacle glow ring assembly has 3 Lucar type connectors which plug directly into the bulkhead harness The rear cigar lighter is connected into the circuit via a link lead The cigar lighter illumination is now supplied from the sidelights ON relay FUEL FILLER FLAP SOLENOID DESCRIPTION 86 00 00 The fuel filler flap solenoid is operated from the central locking system and is electrically slaved to the left hand rear door lock Inthe event of failure of the electrical flap release the flap can be opened by a mechanical override lever which is located behind the carpet trim in the left hand side of the boot 86 107 ELECTRICAL SYSTEMS FUEL FILLER FLAP SOLENOID RENEW 865577 WARNING OPERATIONS INVOLVING THE FUEL SYSTEM RESULT IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE ATMOSPHERE FUEL VAPOUR IS HIGHLY FLAM MABLE GREAT CARE MUST BE TAKEN WHEN WORKING ON THE FUEL SYSTEM THE FOLLOWING PRECAUTIONS MUST BE STRICTLY ADHERED TO 1 NO SMOKING IN THE WORK AREA 2 SMOKING WARNING SIGNS MUST BE POSTED ROUND THE AREA A CO2 FIRE EXTINGUISHER MUST BE CLOSE AT HAND 4 DRY SAND
107. represent the tyres ability to stop in wet conditions measured on specified government test surfaces of asphalt and concrete WARNING THE TRACTION GRADE IS BASED ON BRAKING STRAIGHT AHEAD TRACTION TESTS AND DOES NOT INCLUDE CORNERING TURNING TRACTION Temperature A B C The temperature grades are A the highest B and C and they represent the tyre s resistance to the generation of wear and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel Sustained high temperature can cause the material of the tyre to degenerate and reduce tyre life and excessive temperature can leadto sudden tyre failure Grade C corresponds to a levelof performance which all passenger cartyres must meetunder Federal Motor Vehicle Safety Standard 109 Grades and A represent higher levels of performance on the laboratory test wheel than the minimum required by law WARNING THE TEMPERATURE GRADE IS ESTABLISHED FOR A TYRE THAT IS PROPERLY INFLATED AND NOT OVERLOADED EXCESSIVE SPEED UNDERINFLATION OR EXCESSIVE LOADING WHETHER SEPARATELY OR IN COMBINATION CAN CAUSE HEAT BUILD UP AND POSSIBLE TYRE FAILURE 74 09 Issue 2 WHEELS AND TYRES THE TD TYRE where fitted DESCRIPTION 74 00 00 The TD tyre offers the benefits of the radial assembly with the added safety and security of limited run on capability in the event of a deflation This can assist in the control of the vehicle to the ne
108. securing the steering column harness carrier Displacethe carrier for access Disconnectthe block connectord Disconnectthe main cable hamess block connector Removethe harnessfrom the vehicle Remove the clips Fig 2 retaining the harness to the bracket Remove the bolt securing the P clip securing the hamessthe bracket Removethe P clip Removethe bracketfrom the hamess Fitting a new steering column harness is the reversal of the removal procedure Reconnectthe battery earth lead and check operation of all relevant components 30018 86 87 ELECTRICALSYSTEM STARTER TO ALTERNATOR LINK LEAD RENEW 86 70 36 Openthe bonnet and disconnectthe battery earth lead Removethe air pump 17 25 07 Remove the link lead to starter motor securing nut Fig 1 Repositionthe leadfrom the starter motor terminal Removethe link leadto alternatorsecuring nut Displace and remove the hamess from the engine compartment Fitting the new harness is the reversal of the removal procedure 30018 ENGINE EARTH LEAD RENEW 86 70 38 Openthe bonnetanddisconnectthe battery earth lead Jack up and placethe front of the vehicle ontwo stands From below remove the bell housing nut securing the earth lead Removethe rear mounting boltsecuringthe earth leadto the front cross member Displace and removethe earth lead Fig 2 Fitting the new earth lead is the reversal of the removal procedure 30018 A B S EARTH LEAD RE
109. setting gauge Check that the vehicle starts in PARK and NEUTRAL but does not start in other positions Check the bar graph on the instrument pack indicates the correct position of the gear selector DATA SERVICE TOOL JD 127Linear Switch Setting Gauge 30018 STOP LAMP SWITCH RENEW 86 65 51 Openthe bonnetanddisconnectthe battery earth lead Removethe drivers side dash liner 76 46 11 Removethe stop lamp harness ratchetstrap Disconnectthe cable hamess block connector Removethe nuts securingthe switch tothe pedalbox Removethe pedal box grommetfor accessto the switch Removethe switch assembly Fig 2 Fitting a new switch is the reversal of the removal procedure 30018 HANDBRAKEWARNING SWITCH RENEW 86 65 45 Openthe bonnetand disconnectthe battery earth lead Openthe car door Removethe front seat cushion 76 70 02 Release the clip securing the handbrake gaiter and displacethe gaiter Removethe top screw securing the switch 1 Fig 1 Slackenthe bottom securing screw Disconnect the supply cablesfrom the switch Removethe switch Fitting a new switch is the reversal of the removal procedure 30018 86 65 ELECTRICALSYSTEM SEAT PAD SWITCH RENEW 86 57 21 Open the bonnet and disconnect the battery earth lead Open the car door Removethe front seat cushion 76 70 02 Displace the accessiblediaphragm hooks from the frame and reposition the diaphragm for access Cut and remove the ratchet strap s
110. temperature sensors An input voltage is supplied to the sensors from AC4 13 of the control module The temperature sensing signal from the sensor is transmitted into the control module via AC4 4 and AC2 4 respectively The sensors are semi conductor devices which are accurate over a wide temperature range The semi conductor is similar to a zenor diode as much as it allows current to flow in reverse bias but the current flow varies with temperature The sensor assemblies have built in potentiometerswhich are preset and must not be adjusted 80 6 HEATING AND VENTILATION Solar Sensor A solar sensor Fig 1 is fitted to reduce the temperature demand This has the effect of stabilising the in car temperature whilst reducing air outlet temperatures to compensate for increased solar load This sensor is constructed round a photo transistor whose sensing voltage will vary with the ambient light level An input is supplied to the sensor from AC4 13 of the control module The sensing voltage from the sensor is then fed back intothe control modulevia AC4 6 Coolant Temperature Switch A coolant temperature switch Fig 2 is fitted to the lower side of the heater matrix inlet pipe Its contacts are open at temperatures below 40 C this will prevent the fans from operating when heat is required until relatively hot coolant is flowing through the system Blower Motor Speed Control Mounted in the outlet of the blower motor units are heatsi
111. the crimps distortion may occur Press down on the flat tangs set at right angles to the crimps as shown in Fig 3 NOTE Take care not to damage crimps or flexible printedcircuit If damage occurs or problemsarise dueto loose crimp connections renew the flexible printed circuit Fig 1 Repeatfor the battery fuel gauge set Repeatfor the oil water temperature gauge set Before fitting veneer panel carefully return all gauge needlesto STOP PIN position Align and fit veneer panel LCD module assembly Fit andtighten centre securing screw Fitthe cowl lens assembly Fit and tighten the six remaining veneer panel securing screws Fit and fully seat warning bulbs ensuring correct colour type is inserted at correct location the 8 white bulb holders are for gauge illumination the remaining 24 are forwarning indication only Connect the flexible printed circuit multi plug to the LCD unit Carefully fit electronics pack over the flexible printed circuit connections and locate into hinges Pivot pack downwards andfit into securing clips Fig 2 Fit the flexible printed circuit to the edge connectors by positioning holes in flexible printed circuit membrane over the connector latch locating pips and sliding latch to the fully closed position Align and fit the back cover to the electronics pack Fit and tighten the securing screws Fit the cowl housing to the pack Fit and tighten the cowl housing securing sc
112. the dash liners Removethe screws securing the instrument pack Disconnect the instrument pack cable harness multi plugconnectors and removethe pack assembly Remove the centre veneer panel and the centre ventilator Remove the fascia board assembly Remove and disconnectthe solar sensor Removethe fascia ventilator grille trim panel Removethe screws securingthe defrost vent Reposition the fascia for access and disconnect the solenoidvacuumtube Removethe vent assembly 180060 Remove the spire clips securing the servo remove the servo Fig 1 Fig 1 Reversethe above procedurewhen fitting the new servo 0206G 82 42 AIR CONDITIONING FLAP MOTOR GEARBOX ASSEMBLY Upper RENEW 82 20 62 Openthe bonnet and disconnectthe battery earth lead Remove the glove box on left hand drive cars and displacethe relay mounting bracket Removethe right hand side dash liner Remove the screws securing the electronic control module 1 Fig 1 to the air conditioning unit and repositionthe moduleto one side for access Remove the screws securing the flap motor assembly displace the assembly and disconnect the multi plug connector Remove the flap motor assembly 2 Fig 1 Fitting a new assembly is the reversal of the above procedure 02066 FLAPMOTOR GEARBOX ASSEMBLY Lower RENEW 82 20 63 Openthe bonnet and disconnectthe battery earth lead On left hand drive ca
113. the top pivot bolt from above Loosely attach adjustment rod 1 Fig 1 to the compressor with nut and bolt 6 and 7 Fig 1 Loosely attach adjustment plate 3 Fig 1 to the compressor with nut and bolt 4 and 5 Fig 1 Fit bolt 2 Fig 1 through trunnion 6 Fig T and fit nut 9 Fig 1 to the bolt Fit the drive belt over the pulley move the compressor away from the engine to tension the drive belt and lightly tighten the bolts and nuts To obtain the correcttension onthe drive belttighten adjuster nuts 7 Fig 1 The belt is correctly tensioned when a load of 59 63 6 kg 130 140 Ib applied at the centre deflects the belt 4mm 82 69 AIR CONDITIONING SANDEN COMPRESSOR 709 Ensure that all securing bolts and nuts are fully tightened Lower the vehicle to the ground Remove the blanking plate and the blanking plugs from the compressor Fit new O ring seals to the muffler and attach it to the compressor Fit a new O ring seal to the evaporator hose and connect itto the compressor Fitthe retaining plate fit and tighten the screw Fit and tighten the compressor upper pivot bolt securing nut Charge the air conditioning system refer to 82 30 08 Remove the wing cover and close the bonnet MUFFLER RENEW 82 10 24 Open the bonnet and fit a wing cover Unscrew the muffler to hose union nut and disconnect the hose from the muffler Remove and discard the O ring seal Fita blanking plug to the hose union nut
114. tool Check the air gap Removethe compressor from the vice and refit itto the vehicle Remove the wing cover and close the bonnet Fig 2 AIR CONDITIONING SANDEN COMPRESSOR 709 COMPRESSOR PULLEY BEARING RENEW 82 10 10 Open the bonnet and fit a wing cover Depressurizethe air conditioning system Remove the compressor refer to 82 10 20 Remove the compressor drive clutch 82 10 08 Displace and remove the snap ring retaining the pulley assembly on the compressor Fit thread protection tool JD166 5 5 Fig 1 on the compressor shaft This will aid collet to pulley engagement in the following operation Engagethe collets 1 Fig 2 of tool JD 166 5 2Fig 2 with the recess in the pulley internal diameter Assemble tool JD166 1 1 Fig 1 to tool collets JD166 5 6Fig1 fit andtighten the securingscrews 2 Fig 1 Fittool JD 166 3 3 Fig 1 to tool JD166 1 1 Fig 1 fit tommy bar JD166 2 4 Fig 1 through tools JD 166 1 and JD 166 3 Tightenthe centre boltof tool JD 166 1 to removethe pulley assembly Remove the pulley complete with the tool from the compressor Remove the collets from the pulley and the thread protection tool from the compressor shaft Place the pulley on a bench with the pulley uppermost remove the snap ring securing the bearing in the pulley Invertthe pulley andfittool JD166 7 1 Fig3 to abut the bearing face Using a soft face mallet remove the bearing from the pulley Removetool JD 166 7 fromt
115. vehicle is left hand drive removethe battery Undo the union nut securing the lower hose to the expansionvalve and disconnect the hose 1 Fig 1 Fita protective cap to the expansionvalve orifice Remove and discardthe ring seal Undo the union nut connecting the evaporator hose to the compressor inlet pipe and disconnectthe hose 2 Fig Fig 1 1 Removeanddiscardthe O seal Fita protective capthe compressor inlet pipe Fitting a new hose isthe reversalof the above procedure Ensure that new O rigs are fitted and the protective caps are not removed until the last possible moment beforethe new hoseis connected Ensure the union nuts are tightened to the correct torque Flush the system fit new drier bottle evacuate and rechargethe system DATA TORQUE FIGURES Hose union evaporator28 37Mm Hose union condenser28 37Nm 0206G 82 47 AIR CONDITIONING DRIER BOTTLE TO EVAPORATOR HOSE RENEW 82 25 03 Depressurizet he air conditioning system Undo the union nut and disconnect the hose from the drier bottle 1 Fig 1 Remove and discard the O ring seal Fit protective caps to the hoseandto the drier bottle Remove the screw securing the pipe clip to the inner wing valance and remove the clip Undo the upper union nut from the expansion valve and disconnectthe pipe 2 Fig 1 Remove and discardthe O ring seal Fita protective cap to the expansion valve and remove pipe Fittinga new hoseisthe reversal
116. veneer panel Disconnectthe flexible circuit board connectorfrom the LCD unit Remove the screws securing the veneer panel to the LCD unit Removethe remaining screws securing the veneer panel tothe instrument pack Remove the clips securing the panel lens to the instrument pack and removethe lens Carefully remove the veneer panel from the instrument pack NOTE Do not lay the insrtument pack on the gauge faces Reverse the removal procedure to refit the replacement veneer panel 0051G 76 99 BODY SECTION PASSIVE RESTRAINT SYSTEM USA ONLY DESCRIPTION 76 73 00 The passive restraintsystem is similar in design to the type fitted to the XJS The passive belt is a single diagonal belt fed from an inertia reel assembly mounted on the seat slide centre console side to a motorised runner slotted in a guide rail attached to the cantrail A quick release buckle for emergency use is located at the cantrail end of the belt An independent second belt inertia reel lap type to be used in conjunction with the passive belt is fitted and must be manually secured by the occupant The Passivebelt is driven by a motor andwinch assembly mounted inthe BC oneto the LH side and one to the RH side of the vehicle The system is controlled by an ECU mounted abovethe driver s side dash liner The seat belt warning on the VCM and a separate warning light located on the fascia below the hazard warning switch indicate that the
117. washer pump and reservoir level sensor multi plug connectors 1 Fig 1 Disconnectwasher pumptubing from pump 2 Fig 1 Remove bolts and washers securing reservoir 3Fig 1 Remove reservoir from the filler neck Drainthe waterfrom reservoir Removebolt securing washer motor clamp plate remove plate and remove pump from grommet 4 Fig 1 Displace and removefluid level sensor 5 Fig 1 Removethe clamp nut grommet assembly Fitthe new reservoir sensor into position Fitthe clamp nut grommet assembly Fitthe reservoirto the filler neck Fitandtighten the reservoir securing bolts Reconnectthe harness multi plugs Refitthe cooling duct and inner valance Removethe stands and lowerthe vehicle DATA TORQUE FIGURES Reservoir securing bolts nuts 19 24Nm SPANNER SIZES 73mm No 4 Pori SPORT MODE SWITCH RENEW 86 65 84 Carefully displace sport mode switch Fig 2 from the gear selector finisher Disconnectthe harness multi plug Connectthe hamess multi plug to the new switch Fully seatthe switch intothe finisher Issue 2 88 26 INSTRUMENTS 1991 MODEL YEAR MODIFICATIONS WARNING LIGHTS 88 00 00 The sport mode indicator and park brake warning light have changed position with one another on the instrument pack This is only a visual position change there is no change in operation or function The sport mode indicator is illuminated when the gearbox is in sport mode It is wired through the instrument p
118. will cause burnstothe skin as well astothe eyes In the event of skin or eye contact drench the effected area with water and in the case of eye contact seek urgent medicalattention 3001B BATTERY HEAVY DISCHARGE TEST 86 15 02 This test ensures that the battery is capable of supplying the heavy currents required by the starter motor at the momentof startingthe engine A heavy dischargetester should be appliedto the battery terminals with the red leadto the positive terminal and the black leadto the negativeterminal The tester should be set for the ammeter to indicate a discharge of approximately 300 amps New Battery 210 amps Service Battery for 15 seconds Observethe voltmeter during the battery discharge If the voltmeter reading 9 6 volts or above the battery can be consideredserviceable Should the voltage fall below the specified 9 6 volts rechargethe battery and retest OPENCIRCUIT NEWBATTERY SERVICE VOLTAGE TESTCURRENT BATTERY 12 60 and above 260amps 180amps 12 45to 12 59 21 Oamps 130amps 12 21 t012 44 11Oamps 85 amps 12 20andbelow The battery must be charged before beingtested DEGREES C DEGREES F MINIMUM ACCEPTANCE VOLTAGE 21 70 and above 9 6 15 60 9 5 10 50 9 4 4 40 9 3 0 30 91 7 20 89 42 10 87 48 0 8 5 If the voltage is 9 6 or above at room temperature ie 20 C or above throughout the 15 second test period thenthe battery is serviceable 30018 86 18 ELECTRICALSYSTEM If the electrolyt
119. 0 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulb 6 Fig 1 from the holder Fita new bulb by reversingthe removal procedure 30018 86 49 ELECTRICALSYSTEM SPORT MODE INDICATOR BULB RENEW 86 45 90 Open the bonnetand disconnect the battery earth lead Open the car door Removethe driver side dash liner Remove the screws securing the instrumentpack Remove the instrument pack 88 20 01 Releasethe electronics pack retaining clips a the electronics pack upwards for access to the ulb Remove the bulb from the holder Fitting a new bulb by reversingthe removal procedure 30018 CHECK ENGINEWARNING INDICATOR BULB RENEW 86 45 91 Fig 1 Openthe bonnet and disconnectthe battery earth lead Open the car door Removethe driver side dash liner Removethe screws securing the instrumentpack Removethe instrumentpack88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulb 14 Fig 1 from the holder Fittinga new bulb by reversingthe removal procedure 3001B ANTI LOCK BRAKE WARNING INDICATOR BULB RENEW 86 45 92 Open the bonnet and disconnect the battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securingthe instrument pack Removethe instrument pack 88 20 01 Releasethe electronics pack retaining clips
120. 01 amp 102 HH 103 117 116 amp 122 137 4 1 EE cab oo dea eet E RES J76 576 76 10 BODY SECTION ILLUSTRATED INDEX KEY ITEM DESCR PTION OPERATION PAGE VOLUME No No No 96 22 Bay RUNNERSAND ADJUSTER T 4 97 SEEDS ORI MODE SWITCH FINISHER 4 98 due GLOVE BOX MP 4 99 us GLOVEBOX LID ecce 4 100 GLOVEBOX LID 4 10122 GLOVEBOX LID VENEER PANEL 4 102 GLOVEBOX MIRROR ASSEMBLY 4 103 GUTTER eee 4 104 4 105 HEADLAMP TRIM 4 106 HEADLINING REAR FINISHER 4 107 ILLUMINATED SUNVISOR ASSEMBLY 4 108 ILLUMINATED SUNVISOR MIRROR ASSEMBLY 4 INDEX ILLUSTRATED eee 4 AN wae INDEX KEY oer eere cete 4 109 INSTRUMENTPANELVENEER PANEL 4 110 INTERIOR 4 111 LAP BELT INERTIA REEL 4 112 LOWER DOOR TRIM FRON 4 113 LOWER DOORTRIM REAR v 4 114
121. 101 ELECTRICALSYSTEM BULB FAIL MODULE REAR DIAGRAM 86 55 00 Key to diagram Module General Fail Direction Indicator Fail Rear Fog Lamp Reverse Lamp Tail Lamp Number Plate Lamp Side Marker Lamp USAAND CANADAONLY Stop Direction Indicator Lamp 10 General Fail 11 Logic 0 12 Direction Indicator Fail 13 Control Logic and Timer 14 Rear Direction Indicator 15 stop 16 Disconnect Earth Loop 17 NumberPlate Side Marker Tail Lamp 18 Reverse Lamp 19 Rear FogLamp 20 Reverse Stop D l Fog 21 NumberPlate Tail Side Marker 22 Ignition 23 Protection Network Arrow goesto Switch C ES e o b 1 e 9 5 3 q ise Dee B2 22 601 bi B1 21 85 20 3 e 1 488 840 89 MY 86 102 ELECTRICALSYSTEM RIGHT HANDSIDE FUSE BOX Fuse Fuse Circuit No Colour Code Al Grey Ride levelling A2 Yellow 20A Right handair conditioningfan where fitted heater fan A3 Yellow 20A Frontand rear cigar lighters A4 Yellow Spare position A5 Light Coolingfans andair conditioningclutch where blue fitted Natural Headlamp power wash wherefitted White Yellow Heatedrear screen Caravan Trailer B1 Tan 5A Luggage compartment remote release B2 Light 15A Right handfront door window liftand mirror blue mo
122. 11 Flapfeedback potentiometer 12 Blower motorfeedback 13 Blower motor feedback 14 Highspeedrelay 15 Compressor clutch 16 Blower motor 17 Blower motor 18 Flapservo motor 19 Flapservo motor 20 Defrostvacuum solenoid 21 Recirculationvacuum solenoid 22 Centreventvacuum solenoid 23 Water valve vacuum solenoid 82 4 AIR CONDITIONING TEMPERATURE DISTRIBUTIONSYSTEM DESCRIPTION 82 00 00 The air conditioning unit case consists of three parts the rear of which carries the evaporator the front is then split intwo to enable the rotary flaps to be inserted Foot outlet boxes are moulded in plastic and are removable for access The method used to achieve the required air temperature is known as a series parallel system All the air into the unit passes through the evaporator then depending on the position of the flaps either passes through the heater matrix to be heated or bypasses the heater matrix completely or a combination of both to achieve the air temperature required see illustrations The system employstwoflaps that are driven to the required position determined by the control system by servo motors and gear box assemblies The motorscan rotate in either a clockwise ar anti clockwise direction depending on the direction of current flow through the motor The flap positions are monitored by feedback potentiometers which supplies a voltage signal to the control module indicating the flap position Fig 2 Fig 4 82 5 A
123. 2 Check adjust the front wheel alignment57 65 01 Align headlamps 0055G 77 29 BODY REPAIR SIDE REPAIRS COMBINATION 2 RENEW 77 50 02 Disconnectthe battery Jack upthe vehicle and supportwith axle stands Remove Exhaust rear section rear lamp cluster rear lamp relay module and electric aerial Petroltank 19 55 01 Rear screen and mouldings Lay aside Rear screen wiring and rear carpeting Wiring loomto vehicle interior Remove Rear seat cushion seat backand insulation Rear sill treadplate 1 2 Fig 1 rear door beading and weatherseal spare wheel andjack Boot mat Fig 2 petrol tank cover rear paneltrim rear wing carpet and boot lid weatherseal Rear bumper assembly rear wing vent box all insulation rear parcel shelf upper rear wing trim and rear door striker Upper quarter finisher upper seat belt mounting rear inertiareel assembly and rear door trim Remove panels Outer whee arch Rear wing Rear door Panel Replacement Panel removal and replacement isto the method detailed in Section 77 10 01 07 Painting See Section 77 00 00 Replace Parts Replace parts in reverse order of removal Reconnect battery and alternator test those electrical itemsthat havebeen removedand replaced 477 056 77 30 BODY REPAIR REAR END REPAIRS COMBINATION 1 RENEW 77 50 05 Disconnectthe battery alternator and petroltank wiring Jack upthe vehicle and support with a
124. 2 00 00 All the clutch service operations must be performedona bench andthe following proceduresstrictly adheredto The clutch includes a counter weight on the front plate to improve dynamic balance Fitservice tool JD 146to the clutch front plate Fig 1 82 55 AIR CONDITIONING Fit the centre bolt assembly and position the holding shaft into the centre bolt assembly locating hole Fig 1 Align the puller centre bolt to the compressor shaft Finger tighten the three puller bolts into the threaded holes Turn the centre bolt clockwise until the front plate is loosened Fig 2 Remove the plate Remove the shaft key Remove the internal bearing circlip by using pinch type of circlip pliersonly Fig Removethe front housing circlip by using spread type of circlippliers Fig 4 Insert the lip of the puller jaws into the circlip groove Fig 3 82 56 AIR CONDITIONING Placethe rotor shaft protector over the exposed shaft Fig 1 482 211 Align the thumb boltsto the pullerjaws Fig 2 Turn the puller centre bolt fig 3 until the rotor puller is free 82 57 AIR CONDITIONING Loosen the field coil lead from its clip on top of the compressor Fig 1 Using spread type of circlip pliers remove the circlip and field coil Fig 2 Refit the field coil in the reverse order to the removal procedure previously described The coil flange protrusion must matchthe hole infront of hous
125. 3 R H CHANNEL SITE BELT IGN OUTPUT 0 p o ix x 1 d ov 1 m ul H o xe o 86 96 ELECTRICALSYSTEM RUNTO REAR TRUTH TABLE SKT 7 as oe aro oe Ae DA SWITCH DOCK DOCK SWITCH PROX SWITCH ao x Ov o o o 1_ o o So 0 f o o AE 1_ ov ov ae ov 202 2 To i ov o o ov ov i o _1_ o L H CHANNEL SKT 7 R H CHANNEL SKT 14 SKT6 SKT10 SKT2 SKT 1 FUNCTION DOOR REAR FRONT INERTIA BELT IGN OUTPUT SWITCH DOCK DQCK SWITCH PROX SWITCH LOGIC ioe eer o0 Ei o Ce we qp se dp a He s 86 97 ELECTRICALSYSTEM PASSIVE RESTRAINT ECU CONNECTORS Thetwo ECU connectors PM4 the other PMHD are identified with their pin numbersin Fig 1 8 WAY PM4 CONNECTOR Pin Cable O10 NA NS LHsystem t 12V YG LH motor positiveto rear YN LH motor positiveto front Blanked off YU RH motor positiveto rear 24 WAY PMHD CONNECTOR Pin Cable RO Central locking O P KB Ignition negative SLG LH belt warning S LH door switch I P UR GP Inertiaswitch I P YB LH overtravelswitch YLG LH rear dock switch GB 351
126. 3001B 86 37 ELECTRICALSYSTEM LUGGAGE COMPARTMENT LAMP BULB RENEW 86 45 15 Open the luggage Compartment Depressthe luggage compartment lamp lens springclip Displacethe lens and removethe bulb Fit new bulbandrefitthe lens 30018 LUGGAGE COMPARTMENT LAMP ASSEMBLY RENEW 86 45 16 Openthe bonnet and disconnectthe battery earth lead Openthe luggage compartment depress the spring clips anddisplacethe lamp lens Removethe bulb Removethe screws securing the lamp Disconnectthe multi plug cable harness connector Removethelamp assembly Fig 1 JBG 480 Fiting a new lamp is the reversal of the removal procedure 3001B MAP LIGHT LENS RENEW 86 45 18 Openthe bonnetand disconnectthe battery earth lead Open the car door turn and release the roof console retainingcatch Fig 2 Lowerthe consolefor access Removethe map light bulb Note anddisconnect the cable hamess lucar connectors Removeth interior lamp bulbs Removethe map light contact platefrom the housing Near Carefully displace and removethe map light lens Fig2 Fitting a new lens is the reversal d the removal procedure 3001B 86 38 ELECTRICALSYSTEM TRIP COMPUTER PANEL ILLU MINATIO N BULB RENEW 86 45 21 Openthe bonnet and disconnectthe battery earth lead Open the car door Removethe screw securing the switch undertray Removethe undertray Fig 1 Removethe bulb holder Removethe bulbfrom the holde
127. 36 contacts Each connector type housing is injection moulded in one Of a range of insulation material colours to permit rapid connector location in vehicle positions where groups of similar Connector type and size exist In addition each connector is allocated an identification number prefixed by letters to identify the hamess of which the connector forms part 30018 206 508 HARNESS CONNECTORS DESCRIPTION 86 70 00 PMA Fig 1 and PMHD Fig 2 connectors contain polarising positive mate latching and secondary locking features PM4 connectors also have rubber seals which protect the terminals in exterior locations where severe environmental conditions exist The polarising feature comprises a tongue and groove arrangement which must be aligned correctly for the connectors to be united The positive mate locking feature Comprising latching arms and dead locking ramps prevents connector separation which is permitted only when the arms are depressed sufficiently to pass below the ramps as the connectors are parted The secondary locking feature comprises a locking cover which prevents individual terminals emerging from the rear of the connector should the terminal locking lance Fig 2 fail CONNECTOR SEPARATION AND UNION Both PM4 and PMHD type connectors are separated by depressing their latching arms sufficient for the dead lockingrampsto be clearedas the connectors are parted The latching ams of PMHD connectors can be de
128. 3601 DBC 3602 DBC 3603 DBC 3604 DBC 3605 DBC 3606 DBC 3607 DBC 3608 DBC 3612 DBC 3613 DBC 3614 DBC 3617 DBC 3618 DBC 3621 DBC 3622 DBC 3645 JLM 1451 JLM 1452 JLM 1453 JLM 1454 CABLE COLOUR White White Yellow Yellow White Yellow White White White White Blue Blue Yellow Yellow Green Green White Yellow White Yellow Green White White White White White White White White White White Yellow Yellow Yellow Yellow Yellow White Yellow Green White Yellow White Yellow White ELECTRICAL SYSTEM SIZE 2 0 0 5 0 5 0 5 1 0 1 0 2 0 2 0 3 0 3 0 0 5 2 0 0 5 2 0 3 0 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 2 0 2 0 2 0 2 0 2 0 0 5 2 0 3 0 0 5 2 0 0 5 2 0 0 5 TERMI NATION Pin Socket Pin Socket Socket Socket Pin Socket Pin Socket Pin Socket Pin Socket Pin Socket Socket Socket Lucar Lucar Lucar Lucar Brass Fastin Faston Lucar Lucar Fastin Faston Socket Socket Socket Flag Flag Socket Lucar Chrome Fastin Faston Socket Socket Socket Socket Socket Socket Socket Flag Flag Pin 86 74 CONNECTOR APPLICATION Amp Econoseal Series E Amp Econoseal Series E Amp Econoseal Series E Amp Econoseal Series E Amp Econoseal Series J Amp Econoseal Series J PMHD Connector PMHD Connector PM4 Connector PMA4 Connector PMA4 Connector Connector PM4 Connector PMA4 Connector
129. 3AIBO 5A079430 HONIM GSLYNIANTH LON LHO ONINHYM 1138 ivas HOLMS ALIIWIXOHS ONINOOQ MANSY 3ALIVH3dONI HOLIMS OL ALINNILNGD 93H23 LNSLLIAH3ANI SI S318v9 ulvd3H HOLIMS SAO Ild3Q HONIM Hv Tid OL SNYNL Y 3n9NOL NAHM S3ivH3dO 110100 TWAHYSHL YOLOW HONIM AYHA3SSY HONIAVHOLOW MINAH 3ALIVH3dONI HOLIMS DNDIOOQ LNOHZ JALWHACONI HOLIMS NO NOLLINDI MOIHI JHL MANSY SIOIHAA JHL JO 53015 NO IW31SAS dO Y JO LN3A3 AHL NI SION HONIM HOLOIN HOCH JDYHOHONY NI SVSHOLLS 3 Y9NOL 31 OL 61194 HONIM 3EOVHOHONY NI LON SI 319 NOL OL 714 HONIM SS3NBYH MOSHO NAOG SI NOLLNG H241MS 59504 493H9 yood N3dO 440 Q3HOLIMS NOLLINDI N3HM OL OL 51 4 HONIM WALSAS SISONOVIG Linva LNIVHLSAY JAISSVd 76 105 BODY SECTION PASSIVE RESTRAINT ECU OPERATIONAL TEST 76 73 00 The following procedure is designed to test the operation of the passive restraint ECU Carry out each test in sequence in the order given below If the system does not function in the manner described refer to Jaguar Diagnostic Sys
130. 4mm when appliedatthe mid point c the belt Ensure that all the nuts and bolts are fully tightened whenthe belt has been correctly adjusted Ensure new ring seals are fitted and the protective caps are not removed until the last possible moment before connectingthe hoses Ensure all hose union nuts are tightened to the correct torque Fit new receiver drier evacuate and rechargethe system DATA TORQUE FIGURES Muffler boit40 50Nm Mufflerplate bolt 32 37Nm 82 32 AIR CONDITIONING COMPRESSOR DRIVE BELT RENEW 82 10 02 ADJUST 82 10 01 Openthe bonnetand disconnectthe battery earth lead Slackenthe compressor drive belt trunnion securingbolt 1 Fig 1 Slacken the upper drive belt adjusting nut 2 Fig 1 Slackenthe adjusting rod pivot bolt 3 Fig 1 From below slacken the compressorfront and rear pivot bolts From above adjustthe compressortowards the engine Displace and removethe drive belt 4 Fig 1 When fitting the a new drive belt do not fully tighten the compressor securing bolts until the drive belt is adjusted to the correct belt tension of 3 3kg to give deflection of 4 4mm when applied atthe mid point of the belt AIR CONDITIONING SUPERHEAT SWITCH Testing Fig 1 If the refrigerant level is satisfactory and there is not a blockage in air conditioning system butthe thermal fuse persistsin melting Carry outthe following checks Test procedureA For use with a cold engin
131. 5 24 2 2 77 10 02 BONNET MOUNTING 77 15 02 is CUTTING AND 2 77 00 00 DIMENSIONS 77 00 00 FRONT END 5 2 77 50 04 FRONT 77 20 02 FRONT SCREEN veiii iria EEE EEE emen 77 45 02 FRONT WING 0002 77 25 01 GENERAL 77 00 00 HEALTHAND 71 00 00 INDEX e nadine 77 00 00 NEW SURFACES eee ee 77 10 04 OLD SURFACES eee 77 10 03 PAINTS SEALANTSAND TRIM 77 00 00 77 10 00 77 10 05 redeas RAAS 77 10 01 PANELS cete su 77 10 07 77 10 06 REAR END REPAIRS COMBINATION 1 77 50 05 REAR 77 20 04 REAR PANEG timete TERE O REAR SCREEN deaa a erede gas 71 45 08 REAR WING hh yer hes 77 25 02
132. 5 86 45 78 86 48 86 70 08 86 80 86 75 05 86 63 86 55 00 86 98 86 55 00 86 93 86 75 00 86 62 86 70 11 86 82 86 70 12 86 82 86 70 17 86 84 86 70 16 86 84 86 55 70 86 51 86 46 03 86 42 86 70 47 86 8 1 86 25 47 86 25 86 50 14 86 60 86 41 15 86 35 86 41 20 86 35 86 40 64 86 31 86 40 62 86 32 86 25 09 86 23 86 25 10 86 24 86 40 53 86 31 86 40 51 86 31 86 55 84 86 89 84 10 00 86 13 86 57 25 86 66 86 45 75 86 47 86 70 48 86 91 86 57 21 86 66 86 40 00 86 32 86 76 01 86 57 86 76 06 86 58 86 76 05 86 58 86 45 49 86 41 86 45 90 86 50 86 60 00 86 63 86 60 0 1 86 64 86 70 31 86 86 86 70 36 86 88 86 70 34 86 87 86 65 51 86 65 86 25 00 86 21 86 45 36 86 40 86 00 00 86 13 86 45 53 86 42 86 40 73 86 33 86 40 67 86 33 86 40 72 86 33 86 45 51 86 43 86 80 00 86 52 86 45 21 86 39 86 80 01 86 53 86 45 86 86 48 86 80 11 86 55 ELECTRICALSYSTEM RESERVED FOR ILLUSTRATED INDEX 86 04 ELECTRICALSYSTEM RESERVED FOR ILLUSTRATEDINDEX 86 5 ELECTRICALSYSTEM RESERVED FOR ILLUSTRATEDINDEX 86 6 ELECTRICALSYSTEM RESERVED FOR ILLUSTRATEDINDEX KEY 86 7 ELECTRICALSYSTEM RESERVED FOR ILLUSTRATED INDEX ELECTRICALSYSTEM RESERVEDFOR ILLUSTRATEDINDEX 86 9 ELECTRICALSYSTEM RESERVED FOR ILLUSTRATEDINDEX 86 10 ELECTRICAL SYSTEM RESERVED FOR ILLUSTRATED INDEX KEY 86 11 ELECTRICALSYSTEM BULB CHART DESCRIPTION CAPACITY TYP
133. 76 16 01 76 24 BONNET HINGE FEDERAL nnne 76 16 11 76 29 BONNET HINGE NON 0 76 16 11 76 28 BONNET HINGE VEHICLE SET FEDERAL 76 16 12 76 30 BONNET HINGE VEHICLE SET NON FEDERAL 76 16 12 76 28 BONNET GAS STRUT eerenr rtt 76 16 15 76 26 BONNET GAS STRUT VEHICLE 76 16 16 76 26 BONNET INSULATION 76 16 06 76 14 BONNET LOCK 76 00 00 76 25 BONNET SEALING RUBBER REAR 76 16 04 76 25 BONNET STRIKER ASSEMBLY 76 16 24 76 25 BOOT FLOOR entrent nenne 76 19 30 76 68 BOOT FRONT LINER ener tnmen 76 19 31 76 68 BOOT LID ue eer cp ee na LE 76 19 01 76 63 BOOT LID ADJUST ON STRIKER cnn 76 19 04 76 62 BOOT LID GAS STRUT acetic cciam 76 19 27 76 64 BOOT LID HINGE VEHICLE 76 19 28 76 67 BOOT LID LOCK BARREL nennt nnn 76 19 19 76 66 BOOT LID LOCK MECHANISM 76 19 25 76 64 BOOT LID LOCK STRIKER ern 76 19 12 76 66 BOOT LID 76 19 06 76 63 BOOT LID STRUT PIVOT BOLTS eene 76 00 00 76 64 BOOT LID SEAL TREAD 76 19 09 76 67 BONNET LOCK CONTROL 76 16 29 76 26 BONNET LOCK CONTROL
134. 87 Deed Y18 1161 198 0 s 9ca 222698 la 5 eae eee 32 seca aesa c Fos 8 504 91 gt I nu 221 rs A 52 2 TM H E2 EIB E 88H 81 558 4 928 B 25926 pz cca T ee et A ee EOE 5 SCE oto X gu SUO osa orn 5 E So g 5 z OL ge 055 225 zi lI ZrO 4 Driversseat padswitch 5 Audible warning buzzer 6 Ignitionon relay 7 Inertiaswitch 13 Fuelfiller relay 14 Fuelflap intetface 15 Manuallock unlock switch 16 Passenger door switch 17 Driversdoor switch 18 Keyinsertswitch 8 Ignitionswitch 9 Centreconsole 76 110 BODY SECTION PASSIVE ECU CONNECTORS 76 73 00 The two ECUconnectors one PM4 the other PMHD are identifiedwith their pin numbersin Fig 1 JSI 943 8 WAY PM4 CONNECTOR Pin Cable Pin Cable 1 NS LH system 12V 6 YU RH motor positiveto front 2 YG LH motor positiveto rear 7 6 Earth negative 3 YN LH motor positiveto front 8 B Earth negative 4 Blankedoff 9 NS RH system 12 5 YU RH motor positiveto rear 24 WAY PMHD CONNECTOR Pin Cable Pin Cable 1 RO Centrallocking O P 10 YR LH belt proximity 2 KB ignition negative 11 YO RH belt proximity 3 SLG LHbeltwarning 12
135. A TORQUE FIGURES Fig 1 Door handle to door 3 5 4 5Nm SPANNER SIZES 8mm 0058b FRONT DOOR INSIDE HANDLE RENEW 76 58 20 Openthe door Removethe front door trim panelveneer panel76 47 1 1 Reposition the inner cable 1 Fig 2 from the door handle disconnect the outer handle assembly securing sleeve and disconnectthe cable from the handle Operate the handle for access remove the screw 2 Fig 2 andbolt 2 Fig2 securingthe handleassembly Removethe handle and discard Reverse the removal procedure to refit the replacement handle DATA TORQUE FIGURES J76 405 Inner handle to door4 5 4Nm SPANNER SIZES 7 Omm 76 34 BODY SECTION FRONT DOOR LOCK RENEW 76 37 12 Openthe door Removethe front door trim padveneer panel 76 47 11 Removethe front door uppertrim pad 76 34 02 Removethe front door lowertrim pad 76 34 03 Remove the front door glass 76 31 01 Displace the inner lock control rod securing clip and remove the rod knob assembly Remove the remote cable to bracket retaining clip and repositionthe cable from the bracket Reposition the inner cable from the lock release arm and remove the outer handle operating rod retainingclip Reposition the rod from the retaining clip and displace the rod from the private lock Cut and remove the door lock harness to door panel ratchet straps and disconnectthe multi plugs Remove the lock securing screws and remove the lock assembly Removethe
136. AILURE WARNING INDICATOR BULB 86 45 77 86 47 BULKHEAD CABLE HARNESS 86 70 09 86 75 CARAVAN WARNING INDICATOR BULB 86 45 78 86 47 CENTRE CONSOLE SWITCH 4 CLOCK MODULE 86 80 13 86 54 CENTRAL PROCESSOR UNIT 86 80 17 86 55 CENTRAL PROCESSOR UNIT PASSIVE 86 55 85 86 90 CHANGES 91 86 00 00 86 106 CHECK ENGINE WARNING INDICATOR BULB 86 45 91 86 50 CIRCUIT FAIL WARNING INDICATOR BULB 86 45 93 86 51 CONTROL SYSTEM DESCRIPTION 86 80 00 86 14 DIRECTION amp HAZARD INDICATION DESCRIPTION 86 40 00 86 29 DOOR BOOT AND FUEL FILLER LOCKS DESCRIPTION 86 25 00 86 24 DOOR LOCK CONTROL MODULE 86 80 03 86 54 DOOR LOCK MICRO SWITOH 86 25 44 86 24 DOOR OPEN WARNING INDICATOR BULB 86 45 88 86 49 DRIVERS DOOR HARNESS eene 86 70 07 86 80 DR
137. APPING RENEW 76 43 34 Openthe doors Remove the four B post capping screws 1 Fig 1 and removethe trim 2 Fig 1 Removethe lower finisher from the trim Glue the lower finisher Fig 2 to the replacement trim position the trim over the B post and secure with the fixing screws Closethe doors DATA TORQUE FIGURES B postsecuring screws 2 4Nm 0397b B POST LOWER TRIM PAD RENEW 76 13 29 Openthe front door and removethe front seat cushion Movethe seat fully rearward Removethe B post lower trim padfront securing clip and movethe seat fullyforward Openthe rear door and remove the B post lower trim pad rear securing Clip Move the seat belt for access remove trim pad release the trim pad from under the upper trim pad and slide up the B postto remove Fit and align the replacement trim pad and reverse the dus remainingremoval procedureto refit Fig 2 0007b B POST UPPER TRIM PAD RENEW 76 13 28 Openthe doors Remove the seat belt bolt lower anchor bolt finisher and removethe bolt 1 Fig3 Collect the wavy washer 4 Fig 3 spacer 5 Fig 3 and bracket Displace the draught welting from the upper trim pad releasethe trim padflaps from the B postand remove the trim pad Reverse the removal procedure to refit the replacement trim 0006b Fig3 76 80 BODY SECTION CANTRAIL CRASH ROLL RENEW 76 13 10 Open the doors Unclip the crash roll Fig 1 from the cantrail Re
138. AT BELT STATIC RENEW 76 73 31 Openthe door Removethe rear seat cushion 76 70 37 Remove the seat belt buckle securing bolt and remove the buckle assembly Removethe four star washers the two spacers andthe side seat belt buckle 76 76 BODY SECTION Remove the centre lap strap buckle and the seat belt strap securing bolt Removethe strap and buckle assembly Remove the four star washers the two spacers and the side seat belt buckle Reverse the removal procedure to fit the replacement static seat belt 0079b REAR SEATARMREST RENEW 76 70 39 Openthe door Removethe Rear seat cushion 76 70 37 Rear seat squab 76 70 38 Remove the staples and clips securing the rear armrest cover and reposition the cover for access to the armrest securing bolts min Remove the armrest hinge securing bolts 1 Fig 1 and removethe squab securing brackets Fig 1 Reposition the squab and the armrest for access and displace the cover from the seat remove the armrest through the rear of the seat squab and remove the hinge to armrestsecuring screws remove the hinge Discardthe armrest Reverse the removal procedure to fit the replacement armrest 0074b REAR SEATCUSHION RENEW 76 70 37 Openthe door Remove the seat cushion securing screws lift and remove the rear seat cushion Reverse the removal procedureto refitthe replacementcushion 0072b 76 77 BODY SECTION REAR SEATSQUAB RENEW 76 70 38 Open the d
139. CABLE ASSEMBLY VEHICLE SET sceccecceccecsecceccesssccesesaceaceseaseaseases 76 16 35 76 27 BONNET LOCK RELEASE 76 16 30 76 27 BOOT LOCK RELEASE TRIGGER HANDLE 76 19 15 76 65 BOOT LOCK 76 43 31 76 65 BOOT REAR ener 76 19 22 76 67 BOOT SIDE LINER LEFT 76 19 22 76 68 BOOT SIDE LINER RIGHT HAND enne 76 19 23 76 69 BOOT VENTILATOR OUTLET ern 80 15 66 76 66 BUMPER 76 22 08 76 15 BUMPER FRONT ASSEMBLY enne OVERHAUL 76 22 09 76 15 BUMPER REAR ASSEMBLY nnne 76 22 15 76 47 BUMPER REAR ASSEMBLY enne OVERHAUL 76 22 18 76 47 CANTRAIL CRASH ROLL ener 76 13 10 76 81 CONSOLE ASHTRAY cene RENEW 76 67 18 76 81 CONSOLE ASSEMBLY erret nnn RENEW 76 25 01 76 81 CONSOLE FINISHER AUTOMATIC RENEW nnns 76 25 19 76 82 CONSOLE FINISHER 1 76 25 19 76 83 CONSOLE IGLOVEBOX RENEW ne 76 25 16 76 82 CONSOLE GLOVEBOX LID nnns RENEW 76 25 18 76 82 DASH LINER DRIVERS SIDE eene RENEW
140. CHOMETER GAUGE SET SPORT MODE SWITCH nnn RENEW eene VEHICLE CONDITION MONITOR INTRODUCTION VEHICLE CONDITION FAULT CODES WARNING LIGHTS eere REVISIONS WASHER RESERVOIR RENEW eere Issue 3 88 01 OPERATION PAGE No 44 15 12 88 00 00 88 25 20 88 25 33 88 00 00 88 25 32 88 00 00 88 20 22 88 00 00 88 00 00 86 45 49 88 20 23 88 20 17 88 20 20 88 00 00 26 40 1 1 88 00 00 88 25 09 86 57 25 86 57 21 88 30 03 88 30 20 86 65 84 88 00 00 88 00 00 88 00 00 84 10 17 No 88 24 88 06 88 22 88 18 88 27 88 23 88 02 88 13 88 06 88 05 88 21 88 20 88 12 88 10 88 04 88 22 88 06 88 16 88 25 88 24 88 22 88 14 88 26 88 08 88 08 88 27 88 26 INSTRUMENTS 88 02 INSTRUMENTS ILLUSTRATED INDEX KEY ITEM DESCRIPTION OPERATION No No AUTOMATIC TRANSMISSION UNIT LINEAR SWITCH iiie trice dete rece 4415 12 ina COOLANT TEMPERATURETRANSMITTER 88 25 20 FUEL BATTERY CONDITION GAUGE 88 25 33 4 FUEL GAUGETANK 88 25 32
141. CUIT CONTINUITY TO ECU DOCKING PROXIMITY SWITCH INOPERATIVE RENEWDOCKING PROXIMITY SWITCH JSI 947 SISONSVIG L1nv4 00 89 98 INSALSAS LNIVH LSdH JAISSVd WALSAS 1V21IH IL2313 ELECTRICAL SYSTEM PASSIVE RESTRAINT ECU OPERATIONAL TEST The following procedure is designed to test the operation of the passive restraint ECU Carry out each test in sequence in the order given below Ifthe system does not function in the manner described refer to Jaguar Diagnostic System to locate the fault 1 Enter car driversseat Close and lock both front doors Operate inertiaswitch Doorswill remain locked 2 Insertkey into ignition Seatbeltwill A post 3 Turn ignitionon position 2 Seatbelt will remainat A post Turn ignition off position 0 Reset inertia switch Turn ignition on position 2 Both seatbelts will q B post Seatbelt warning will activate until driversseatbelt latches in B post eploy to Open drivers door Drivers seatbeltwill retractto A post Open passenger door Passenger seatbelt will retractto A post Close drivers door Driversseatbelt will deploy to B post Close passenger door Passenger seatbeltwill deploy to B post Turn ignition off position 0 Both seatbelts will retractto A post 10 Turn ignition on position 2 Both seatbelts will deploy to B post Lock doors Operate inertia Switch Doors will unlock NOTE Itis necessaryto detectthe lo
142. Displacethe cable harness body grommet Removethe lamp assembly Fig 1 Fitting a new lamp is the reversal of the removal procedure 3001a INTERIOR LAMPS DESCRIPTION 86 45 00 The interior lights operate either direct from switches or by the CPU from interior map and door switch inputs Interiorlampsincludethe following Two lamp assemblies which form an integral part of the roof console A map lamp installed between the two interior lamp assemblies on roof console Door guard lamps locatedin each door Bonnet lamps secured to the underside of the vehicle bonnet Luggage compartment lamp securedto the underside of the luggagecompartment lid Reading lamps located inthe front seat head restraints Glove box lamp located within the cubby box 30016 86 35 ELECTRICALSYSTEM GLOVE BOX LAMP BULB RENEW 86 45 07 Open the bonnetand disconnectthe battery earth lead Openthe car door andthe glove box lid Depressthe glove box lamp upper retainingclip Repositionthe lampfor access and remove the bulb Fit new bulb by reversing the order of the removal procedure 3001B GLOVE BOXLAMP RENEW 86 45 08 Openthe bonnetand removethe battery earth lead Openthe door and the glove box lid Depress the glove box lamp upper retaining clip and displacethe lampfrom its mounted position Fig 1 Note and disconnectthe lamp electric supply cables Removethe lamp assembly Fitting a new lamp is the reversal of the r
143. E C M andto the control potentiometers is removed buta signal is Sentto the E C M this isto ensurethe flaps are closed preventing outside air from enteringthe system Inthe LOW MED and HIGH positions information regardingthe range of fan speed selected is received by the control modulefrom the control switch Signalsare also received by the E C M from the temperature selector feedback circuits and the various sensors The fan speedisthen electronically controlled by the E C M So by selecting LOW MED or HIGH a levelof speed inthe range selected is received dependenton requirements There are no distinct steps betweenthe fan speeds buta gradual increaseor decrease of speed When DEFROST is selected the fans are electronically controlled to operate at maximumspeed the screen vents open maximum heating is obtained and the lower flaps fully close it can take upto a maximum period of 30 secondsto completethis function Thetemperaturecontrol locatedonthe right hand side of the control panelisturnedfully clockwiseto obtain maximum heating 80 5 HEATING AND VENTILATION When the mode button is set to auto the word AUTO will appear The control system uses all the sensors to maintainthe temperature selected The system automatically adjustthe flapsto achievethe disired results When the button is set inthe manual mode the word MAN will appear The system overrides the sensors and givesthe option of maintainingthe selectedtemperature output ai
144. E PARTNO HEADLAMP FRANCEONLY INNER 12V55w HALOGENYELLOW476 JLM9599 FRANCEONLY OUTER 12V60 55W HALOGENYELLOW 476 JLM9599 USAAND CANADA INNER 12V50W SEALED BEAM USAAND CANADAOUTER 12V35 35 SEALED BEAM JAPAN ONLY INNER 12 5 SEALED BEAM JAPAN ONLY OUTER 12V 60W SEALED BEAM R O W INNER 12w55w HALOGEN472 JLM9598 R O W OUTER 12V60 55W HALOGEN472 LLM9598 FRONT FLASHER amp SIDE LAMP CANADAAND USA 12V5 21W DOUBLE FILAMENT380 JLM9598 R O W SIDE LAMP 12V5W REGULAR 207 JLM9587 R O W FLASHER LAMP 12V 21W REGULAR382 C9126 FOG LAMPS FRONT 12v55w HALOGEN479 REAR m 12V 21W REGULAR 382 C9126 UNDERBONNETLAMP 12V5W REGULAR 989 JLM9601 SIDEMARKER LAMP USAAND CANADA 12V AW REGULAR 233 JLM9589 SIDE REPEATER LAMP 12V4W REGULAR 233 JLM9589 DOOR HAZARD LAMP 12V5W FESTOON 239 JLM9590 INSTRUMENTILLUMINATION 12 2 2 CAPLESS JLM646 GEAR SELECTOR ILLUMINATION 12V1 2W CAPLESS 286 C38966 CUBBY BOX LAMP 12V5W FESTOON 239 JLM9590 CIGAR LIGHTER ILLUMINATION 12V1 2W CAPLESS 286 C3896 ROOF CONSOLE MAP LAMP 12V5W HALOGEN ROOF CONSOLE COURTESY LAMP 12V10W FESTOON INTERIOR LAMP SEAT HEADREST 12V5W FESTOON286 JLM9590 REAR QUARTER LAMP 12V4AW REGULAR 233 JLM9589 HIGH MOUNTED STOP LAMP 12v5W CAPLESS501 JLM9600 LUGGAGECOMPARTMENTLAMP 12V5W FESTOON239 JLM959 STOP LAMP 12V 21W REGULAR382 C9126 REVERSE LAMP 12V 21W REGULAR 382 C9126 REAR FLASHER LAMP 12V 21W REGULAR382 c912 TAIL LAMP 12V 5W REGULAR207 JLM9587 NUMBER PLATE LAMPJAPAN 12V 10W FESTOON265 JLM9591
145. ED AND THE IGNITION SWITCHED ON JSI 946 1 16 Sm REFIT TRIM AND RE TEST WINCH FAILS TO DEPLOY SISONSVIG L1n VJ IN31SAS LNIVHIS3H JAISSVd IN31SAS 1V9IH L9313 WINCH FAILS TO DEPLOY TO SCREEN PILLAR WHEN IGNITION SWITCHED OFF CHECK INERTIA SWITCH BUTTON IS DGWN AND CHECK HARNESS CONNECTIONS WINEH FAILS CHECK TONGUE IS JAMMED IN ANCHORAGE CHECK IGNITION ON WINCH FAILS TO DEPLOY DIT a ae NOTE IN THE UNLIKELY EVENT CF A TOTAL FAILURE OF THE SYSTEM ON BOTH SIDES OF THE VEHICLE RENEW THE ECU gt WINCH MOTOR THERMAL CUTOUT OPERATES WHEN TONGUE RETURNS TO PILLAR LIGHT NOT ILLUMINATED i PASSIVE RESTRAINT FAULT DIAGNOSIS LH SYSTEM FORWARD DEPLOYMENT FRONT DOCKING SWITCH INOPERATIVE RENEW MOTOR WINCH ASSEMBLY RENEW INERTIA SWITCH REPAIR CABLES WINCH DEPLOYS FAULT IS INTERMITTENT SEAT BELT WARNING RENEW DRIVERS DOOR COURTESY SWITCH WINCH DEPLOYS 1 SELECT PARK WINCH FAILS TO DEPLOY ADJUST GEARBOX LINEAR SWITCH LNAWAO1dSd QHVMHOH WALSAS H1 FRONT DOCKING SWITCH INOPERATIVE CHECK REVERSE INHIBIT NOTE RH SYSTEM FORWARD DEPLOYMENT WILL OCCUR WHEN EITHER THE RH DOOR IS OPENED AND OR THE IGNITION IS SWITCHED OFF CHECK CIR
146. ED BACK POTENTIOMETER 82 20 60 82 36 MANIFOLD GUAGE SET 82 00 00 82 16 PRESSURE TEMPERATURE ceeeeenetn rne 82 00 00 82 19 REAR AIR DISTRIBUTION 82 20 34 82 35 RECIRCULATION FRESH AIR VACUUM SOLENOID 82 25 47 82 52 REFRIGERATION CYCLE eeeennn nnne DESCRIPTION 82 00 00 82 13 SANDEN COMPRESSOR 709 erret 82 00 00 82 65 SIGHT GLASS DESCRIPTION 82 00 00 82 12 SOLAR SENSOR DESCRIPTION 82 00 00 82 07 SOLAR RENEW ssscsursersonssneenerneeeees 82 20 70 82 40 SUPER HEAT RENEW 82 10 12 82 34 SUPER HEAT SWITCH eene nennt nnns 82 10 13 82 33 SUPER HEAT SWITCH AND THERMAL FUSE 82 00 00 82 08 SWITCH CONTROL MODULE csceseseseseesereseseesererseees RENEW 4 86 80 15 82 45 SWITCH CONTROL MODULE ILLUMINATION RENEW 86 46 07 82 45 SWITCH CONTROL DESCRIPTION e 86 00 00 82 06 TEMPERATURE DISTRIBUTION SYSTEM DESCRIPTIO
147. EL FUNCTION 76 107 BODY SECTION RUNTO REAR TRUTH TABLE FRONT INERTIA BELT IGN DOCK SWITCH PROX SWITCH L H CHANNEL R H CHANNEL DOOR REAR FUNCTION I SWITCH DOCK 1 1 1 1 1 1 1 CENTRAL LOCKING TRUTH TABLE RU SKT6 SKT10 SKT2 SWITCH DOCK DOCK SWiTCH PROX x o x o x 3 Ha 1 x 1 3 76 108 BODY SECTION PASSIVE RESTRAINTWIRING DIAGRAM 3 22 D 6 Es 8689 DD B35 ice pe 7 po e DS Keyto diagram Passive ECU LH Rear dock switch LH Belt proximity switch LH Frontdock switch RH Beltproximity switch RH Rear dock switch RH Frontdock switch RH Motor LH Motor 10 RH Fuseboxfuse 9 11 LH Fuseboxfuse 9 12 Reverselightinhibitrelay ci 13 14 15 16 17 18 19 20 21 22 23 188 205 89 Seat adjust relay Passenger door panel Frontpassenger door switch Auto gear select switch RH rear bulb fail module LH rear bulb fail module Driversdoor panel Driversdoor switch Passenger door light Driversdoor light To Drivers seat relay 76 109 BODY SECTION PASSIVE RESTRAINTWARNING CIRCUIT WIRING DIAGRAM OS C 01 92 AW 861 FoB 99r q cmi 1 eM 559 65 995 SO OY soe i ze1 998 11
148. Fig 2 securing the lifting blocks 2 Fig 2 and remove Reverse the removal procedureto refit the replacement lifting block ensuring that prior to final tightening of the securing nuts the roof panelalignmentis checked 0086b 76 57 B ODY SECTION SLIDING ROOF PANEL LIFTING BLOCK VEHICLE SET ADJUST 76 82 38 Open the door Open the sliding roof Slacken the nuts Fig 1 securing the lifting blocks 2 Fig 1 and repositionas required Tighten the securing nuts and carefully slide the panel shut to check the alignmentwith the roof 0087b SLIDING ROOF PANELSEAL RENEW 76 82 15 Open the door Open the sliding roof Remove the sliding roof panel securing screws and partially closethe roof Removethe sliding roof panelassembly Remove the lifting block securing nuts and screws and removethe lifting blocks and plates Removethe screws 1 Fig 2 and drill outthe pop rivits Fig 2 securing the roof panel seal front and rear retaining plate Removethe retaining plates 3 Fig 2 Removethe seal 4 Fig 2 Discardthe roof panel Reverse the removal procedure ensuring that prior to final tightening of the securing screws that the roof is centralised with an even 4mm gap all round the aperture 0083b SLIDING ROOF PANEL TRIM ASSEMBLY RENEW 76 82 19 Open the door Removethe sliding roof panel 76 82 05 Fully close the sliding roof remove the trim panel securing clips partially open the sliding roof re
149. Fita protective capto the hose Undo the condenserto receiver drier union nut Disconnect the condenser from the receiver drier removeand discard the O ringseal Fita protectivecap to the receiver drier Removethe nuts securingthe receiver drier and displace the receiver drier for access Removethe condenser complete Fig 2 with the rubber mounting grommets o Ji n 1 On fitting the new condenser stick rubber foam to the top andsides Fit new mounting grommets and ensure the condenser is fully seated inthe correct position Ensure all hose union nuts are tightened to the correct torque Flush the system fit new receiver drier evacuate and rechargethe system DATA TORQUE FIGURES Condensorhose3 4UNF 20 27Nm Condensor hose 7 8UNF 28 37Nm Drier to condenser15 1 7Nm 82 35 AIR CONDITIONING DRIER BOTTLE RENEW 82 17 01 Depressurizethe air conditioning system Undo the union nut and disconnect the expansion valve hosefrom the drier bottle 1 Fig 1 Remove and discard the O ring seal Fit a protective cap to the hose Removethe nuts washers securing the drier bottle 2 Fig T With the aid of a backing spanner undo the condenser pipe union nut 3 Fig 1 Disconnectthe drier bottle from the condenser Remove discard the O ring seal and fit a protectivecap to the condenser outlet Removethe drier bottle On fitting new drier bottle ensure
150. H side 9 resistancespot welds each side 6 resistancespot welds each side Single row of resistancespot welds each side ARO arms or equivalent Single row of resistancespot welds ARO arms 242A or eauivalent Disconnect battery and alternator Remove Front bumper assembly with flasher lamp unit RH and LH Disconnect horns Remove Grille front screenwasher bottle filler neck mounting bracket headlamp unitRH and LH Jack upfront of vehicle and placeon axle stands Drainthe radiator Remove Radiator mounting panel disconnect expansion tank hose upper hose at thermostat housing lower hose power steering hoseat reservoir and radiator Drain power steering system Removeradiatorwith shroud Disconnectair conditioning pump lay aside refridgerant unit remove cooling fan bonnet front edge weatherseal courtesy lamp switch and 1 front wing mounting bolt RH and LH for access only Associated Panel Removethe bonnet 77 15 01 Panel Replacement Panelremoval and replacementisto the method detailed in Section 77 10 01 07 with the following variations During removal the panel is cut at point 1 Fig 1 to gain accesswith a resistancespot weld cutter at 2 Fig 2 In replacement the new panelis welded at 2 3 Fig 2 Holes are then punched in the corner gussets for plug welding at 1 Fig 2 asthere is no accessfor a resistance spot welder atthese points Painting See Section 77 00 00 Associated Panel
151. HD TERMINAL INSERTION PROCEDURE Insertthe terminal through the secondary locking cover into its location in the connector housing ensuring that the terminal is fully home its locking lance engaged Fit the secondary locking cover to the connector housing HARNESS FAULTS Harness faults fall into two distinct categories open circuit faults in which either power or earth cannot reach a device and short circuit faults in which an unwanted connection is made between one part of a circuit and either another circuit or ground Ground short circuits invariably cause either a fuse to blow or device control to be lost OPEN CIRCUIT FAULTS Open circuit faults are normally attributed to dirty or badly non united connectors and these conditions should therefore be checked and eliminated first An open circuit due to a broken wire or terminal locking lance is remote but instances of such are repaired as follows 1 Locate the broken wire using either the JDS or by performing a continuity check between the terminals of the harness connectors Fig 1 2 Examine the connector faces for indented terminals associated with terminal locking lance failure and renew any offending terminal as detailed in the relevantterminal insertion extraction procedure 3 Examine the faulty harness covering for signs of physical damage i e chaffing and or cuts and both investigate and correctthe cause if damage is evident 4 Remove the harness coverin
152. INATION MODULE 91MY IGNITION SWITCH CAR ENTERTAINMENT 91MNY LOAD DUMP MODULE 91MY PASSIVE RESTRAINT 91MY POWERED SEATS 91MY RADIATOR COOLING FAN 91MY SCREENWASH HEATER SIDELIGHTS ON POWER RELAY DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION S M DESCRIPTION 86 106 OPERATION PAGE No 86 112 86 112 86 112 86 107 86 107 86 111 86 107 86 108 86 110 86 110 86 110 86 112 86 111 86 113 86 111 86 112 86 111 86 111 86 111 86 107 ELECTRICAL SYSTEMS 91MY DIMMER MODULE DESCRIPTION 86 50 00 new split output dimmer has been introduced so that the interior lighting will go off and the instrument pack remain illuminated if the ignition is switched off with the sidelights still switched on An audible warning sounds if the door is opened Switching off the sidelights extinguishes the instrument pack illumination and ends the audible warning When the ignition is off andthe sidelights are switched on the instrument pack illurnination can be dimmed using the manual dimmer knob but the display cannot be completely extinguished There is an extra connector 8C7 on the 91MY dimmer module SC7 2 WN is the auxiliary earth connection and SC7 1 RO isthe outputto the instrument
153. IR CONDITIONING AIR CONDITIONING SWITCH CONTROL PANEL DESCR FTION 86 00 00 The switch control panel contains a blower motor control rotary switch auto manua mode switch air switch humidity control switches temperature differential selector and a in car temperature selector The control panel producesdigital outputs which are suppliedto and usedby the electronic control module The airflow of the system from the blower motors is controlled by the rotary switch locatedon the left handside of the control panel The switch has five positions OFF LOW NORM HIGH and DEFROST In the OFF position the system is not operational Power to the electronic control module E C M andto the control potentiometers is removed but a signal is sent to the E C M to ensure the flaps are closed preventing outsideair from enteringthe system Inthe LOW NORMAL and HIGH positions information regarding the range of fan speed selected is received by the control module from the control switch Signals are also received by the E C M from the temperature selector feedback circuits and the various sensors The fan speed is then electronically controlled by the E C M So by selecting LOW NORM or HIGH a level of speed in the range selected is received dependent on the vehicle requirements Should a low fan speed be selected the control module will maintainthe speed of the fan motors within a range of low speeds depending onthe temperature requirementof the vehicle The
154. ITCH RENEW 86 75 05 Openthe bonnet and disconnectthe battery earth lead Openthe car door Removethe consolefinisher 76 25 1 9 Displacethe cables from the rear cf the switch pack for access Disconnectthe cable harness block connector Removethe nuts securingthe switch pack Removethe switch pack Fitting a new switch pack is the reversal of the removal procedure 3001B STARTER CIRCUIT DESCRIPTION 86 60 00 The starter circuit supplies battery power to the starter motor when the ignition switch is set to START The circuit comprises a starter solenoid and relay On vehicles fitted with automatic transmission a start inhibit relay is also incorporated 86 63 ELECTRICALSYSTEM An ignition switched earth energises the starter relay when the ignition switch is set to START On vehicles with automatic transmission this occurs when the start inhibit relay is energised through either neutral or park switches of the linear gearbox selector switch When energised the starter relay connects battery power to the starter solenoid containing pull in and hold on coils The pull in coil is earthed through the starter motor windings and the electrical current passing through the motor is sufficient to start the armature turning When closed the solenoid contacts connect full battery power to the motor andthe armature rotates at full power 3001B STARTER MOTOR RENEW 86 60 01 Open the bonnet and disconnectthe battery earth
155. ITGHB RENEW nennen BULBS n He iubes eee INTRODUCTION COOLANT TEMPERATURE TRANSMITTER FUEL BATTERY CONDITION GAUGE SET FUEL GAUGE REVISIONS FUEL GAUGE TANK RENEW ern INSTRUMENT ELECTRONICS PACK RENEW enne INSTRUMENT GAUGES eene INTRODUCTION INSTRUMENT PACK CONNECTORS PIN LOCATION INSTRUMENT PACK ILLUMINATION BULBS INSTRUMENT PACK LCD MODULE RENEW enne INSTRUMENT PACK LENS COWL RENEW nnne INSTRUMENT PACK PRINTED CIRCUIT RENEW enne INSTRUMENTS eene nnn INTRODUCTION LOW COOLANT LEVEL PROBE RENEW eere ODOMETER INTRODUCTION OIL PRESSURE COOOLANT TEMPERATURE GAUGE SET usse iode an RENEW erre SEAT BELT BUCKLE SWITCH RENEW eren SEAT PAD SWITCH enn RENEW ern SPEED SENSOR 5 RENEW ener SPEEDOMETER TA
156. ITIONING SWITCH CONTROL MODULE RENEW 82 20 72 Open the bonnet and disconnectthe battery earth lead Open the car door and remove the centre console ashtray Removethe centreconsolefinisher Remove the screws securing the radio console and remove the console Loosenthe screws securing the switch control module Displace the control module and disconnect the cable harness multi plug connector Removethe switch modulefrom the console Fig 1 Fitting a new switch control module is the reversal of the above procedure SWITCH CONTROL MODULE NG ILLUMINATION BULB Jao oze RENEW 86 46 07 Fig1 Openthe bonnet and disconnectthe battery earth lead Open the car door and remove the centre console ashtray Removethe centre consolefinisher Remove the screws securing the radio console and remove the console Loosenthe screws securingthe switch control module Displace the control module and disconnect the cable harness multi plug connector Removethe switch modulefrom the console Fig 1 Prisethe face level knob from its lever Removethe control knobs Remove the fascia plate retaining nuts and the screws securing the control panel Removethe fascia plate and the lens Removethe appropriatebulb Fitting a new bulb isthe reversal of the above procedure 02066 82 45 AIR CONDITIONING EXPANSION VALVE RENEW 82 25 01 Depressurizethe air conditioning system On left hand drive vehicles remove the battery for acc
157. IVERS DOOR LOCK 86 25 45 86 25 DRIVERS SEAT MOTOR 86 75 03 86 63 DRIVERS WINDOW SWITCH 86 25 03 86 22 ELECTRICALLY OPERATED AERIAL DESCRIPTION 86 50 00 86 59 ELECTRICALLY OPERATED AERIAL 86 50 21 86 60 ELECTRICALLY OPERATED AERIAL MAST RENEW 86 50 29 86 61 ENGINE EARTH LEAD enne RENEW 86 70 38 86 88 ENGINE HARNESS eene nennen nnn nnns 86 70 21 86 78 EXHAUST TEMPERATURE WARNING INDICATOR BULB enr 86 45 80 86 48 EXTERIOR DESCRIPTION 86 40 00 86 26 FLASHER CANCELLATION MECHANISM 86 65 85 86 56 FLASHER INDICATOR 86 45 63 86 44 EOG LAMEBS DESCRIPTION 86 40 00 86 34 FRONT AXLE HARNESS 86 70 15 86 83 FRONT BULB FAILURE RENEW 86 55 71 86 51 FRONT DOOR SPEAKER
158. LAR SENSOR rig RENEW 80 10 55 Open the car door and carefully prise the solar sensor mounting panelfrom the fascia 1 Fig 2 Disconnectthe sensor multi plug connector Removethe completesolar assembly Removethe spire clips 3 Fig 2 securing the sensor to the mounting panel 2 Fig 2 Removethe sensor Fitting a new sensor is the reversal of the removal procedure 92096 DEMISTER DUCT RENEW 80 15 02 Open the bonnet and disconnect the battery earth lead Remove both dash liners Remove both closing panels Remove the fascia veneer centre panel and centre vent outlet Removethe steeringwheel Remove both demister duct outlets 1 Fig3 Removethe fascia board Removethe screws securing the demister duct 2 Fig 3 Invert the fascia Disconnectthe vacuum pipe Removethe demister duct 3 Fig 3 Fitting a new demister duct is the reversal of the removal procedure 02096 80 16 HEATING AND VENTILATION CENTRE VENTILATOR RENEW 80 15 24 Open the bonnet and disconnectthe battery earth lead Remove both dash liners Remove both closing panels Remove the fascia veneer centre panel and centre vent outlet Remove the steering wheel Remove both demister duct outlets Removethe fascia board Remove the screws securing the glove box lid and remove the lid Remove the screws securing glove box striker and removethe striker and spacer Removethe inner and outer securing screws is Removethe glove box
159. Lower ramp Refitthe hamess block connector Refitthe luggage Compartmenttrim Reconnectbattery earth lead COOLANTTEMPERATURE TRANSMITTER RENEW 88 25 20 NOTE the procedure described below should only be carried out on acold engine Open bonnetand disconnect battery earth lead Slacken coolant reservoir cap to remove any residual pressure Tighten cap Disconnectthe supply cable Undo and removethe transmitter Fig 2 Cleanthe housing Fitandtighten the newtransmitter Reconnect supply cable Reconnect battery earth lead LOW COOLANT LEVEL PROBE RENEW 26 40 11 NOTE The following procedure should only be carried out on a cold engine Open bonnetand disconnect battery earth lead Slacken off coolant reservoir cap to remove any residual pressure Tighten cap Disconnect the hamess multi plug and release the hamess securing clips Slacken off and removethe probe using finger pressure rotate the probe anti clockwise 1 8th turn and remove discard the O ring Fig 3 Fit the new probe complete with new O ring into position Tighten by pressing down and rotating the probe clockwise 1 8th turn Reconnect harness secure with retainingclips Fig 3 Reconnect battery earth lead 072 Issue 2 88 22 INSTRUMENTS FUELGAUGETANK UNIT RENEW 88 25 32 WARNING THIS OPERATION RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE ATMOSPHERE FUEL VAPOUR IS EXTREMELY FLAMMABLE THEREFORE GREAT CARE
160. MBER 10 Status Warning Lights 11 Status Warning Lights 12VCM Trip Computer Keypad WARNING INDICATORS Fig 3 1 Automatic Transmission Failure 2 Low Windscreen Washer Reservoir Level 3 Bulb Failure 4 Circuit Failure 5 Anti lock Braking System Failure 6 Low Fuel Level 7 Engine Management Fault 8 Ignition Light amp Battery Alternator Fault 9 Handbrake ON 10 Caravan Indicator Fault 11 Direction Indicator 12 Direction Indicator 13 Headlamp Main Beam ON 14 Brake System Fault 15 Sport Mode 16 Low Coolant Level 17 High Coolant Temperature 18 Door Open 19 Boot Open 20 Seat Belt Not Fastened 21 Low Oil Pressure 22 Exhaust Temperature issue 2 J epe 10 7 11 6 288 074 Fig 1 CLEAR 100 10 FUEL 1 DIST 9 1 1 12 13 Fig3 14 15 InG tk 76 88 7 INSTRUMENTS VEHICLE CONDITION MONITOR VCM INTRODUCTION 88 00 00 The Vehicle Condition Monitor information is displayed on the Odometer VCM Trip Computer display panel located belowthe tachometer and speedometer The condition of the vehicle is constantly monitored for operating faults which if found are highlighted by the illumination of certain warning lights By pressingthe VCM button located on the trip computer panel the relevant fault message will be displayed Fig 1 amp 2 Page 88 07 Inthe event that more than one fault has occurred the display panel will cycle betweenmes
161. N 82 00 00 82 05 TEMPERATURE SENSORS DESCRIPTION 82 00 00 82 07 UPPER FEED BACK POTENTIOMETER RENEW 82 20 61 82 37 VACUUM 5 5 DESCRIPTION 82 00 00 82 09 VENTILATOR CENTRE FLAP RENEW 82 20 41 82 41 VENTILATOR OUTLETS eere RENEW 82 20 39 82 41 WATER TEMPERATURE SWITCH ener RENEW 82 20 7 1 82 44 WATER RENEW 82 20 33 82 40 WATER VALVE VACUUM SOLENOID RENEW 82 20 69 82 52 0057K 82 01 Issue 2 AIR CONDITIONING ILLUSTRATED INDEX RESERVED FOR ILLUSTRATEDINDEX 82 02 AIR CONDITIONING ILLUSTRATED INDEX KEY ITEM DESCRIPTION OPERATION PAGE VOLUME No No No dine AIR CONDITIONING danke AIR CONDITIONING 5 2 AIR CONDITIONING 5 5 AIR CONDITIONING AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM esee AIR CONDITIONING AIR CONDITIONING AIR CONDITIONING 5 5 AIR CONDITIONING SYSTEM AIR CONDITIONING 5 5 AMBIE
162. NEL RENEW 76 47 24 76 99 INTERIOR MIRROR eene RENEW 76 10 5 76 90 0051G Issue 2 76 02 BODY SECTION CONTENTS DESCRIPTION LAP BELT INERTIA REEL eene LOWER DOOR TRIM LOWER DOOR TRIM NUMBER PLATE TRIM eene PASSIVE EQCU PASSIVE RESTRAINT eene PASSIVE PASSIVE PASSIVE RESTRAINT GUIDE RAIL PASSIVE RESTRAINT PASSIVE RESTRAINT EQCU enn PASSIVE RESTRAINT INERTIA REEL PASSIVE RESTRAINT MOTOR DRIVE AND INERTIA REEL ASSEMBLIES eee PASSIVE RESTRAINT SYSTEM USA ONLY PASSIVE RESTRAINT WARNING CIRCUIT PETROL FILLER FLAP eere RADIATOR GRILLE SURROUND RADIATOR GRILLE VEHICLE SET RADIO CONGSOLE eere REAR BEAM ccena eoe hee eR hcc REAR BEAM REAR BUMPER CENTRE REAR BUMPER CENTRE BLADE TRIM FINISHER REAR CENTRE SEAT BELT STATIC REAR DOOR ARMREST nee REAR DOOR GLA
163. NEW SLIDING ROOF PANEL LIFTING BLOCK VEHICLE dE MET ADJUST SLIDING ROOF PANEL SEAL RENEW SLIDING ROOF SLIDING ROOF PANEL WIND DEFLECTOR ADJUST SLIDING ROOF RACK eene RENEW SLIDING ROOF RACK VEHICLE SET RENEW SLIDING ROOF WIND DEFLECTOR RENEW STEERING COLUMN LOWER COWVL RENEW STEERING COLUMN UPPER COWVL RENEW WEATHER STRIP RENEW WEATHER STRIP CHANNEL ees RENEW WINDSCREEN GLASS LOWER FINISHER RENEW 0051G 76 04 issue 2 OPERATION PAGE No 76 82 01 76 82 23 76 82 44 76 82 05 76 82 27 76 82 38 76 82 15 76 82 19 76 82 39 76 82 42 76 82 43 76 82 07 76 46 03 76 46 02 76 43 22 76 43 25 76 43 41 76 55 76 56 76 57 76 57 76 57 76 58 76 58 76 58 76 59 76 59 76 60 76 61 76 92 76 91 76 61 76 62 76 62 BODY SECTION 76 05 BODY SECTION N lt N 76 06 BODY SECTION ILLUSTRATED INDEX KEY DESCRIPTION E CA UEN VOLUME Ray LOWERTRIM
164. NEW 86 70 39 188 600 Openthe bonnetanddisconnectthe battery earth lead Remove the A B S modulator earth lead securing nut Fig3 Repositionthe lead from the modulator stud Remove the earth lead to mounting bracket securing bolt Displace and removethe earth lead Fitting the new earth lead is the reversal of the removal procedure 3001B 86 88 ELECTRICALSYSTEM FUEL PUMP LINK HARNESS RENEW 86 70 20 Openthe bonnetand disconnect the battery earth lead Jack up left handrear of vehicle and placeon a stand Removethe left hand rear road wheel From the wheel arch displace the insulation boots from the fuel pumpterminals Remove the fuel pump terminal nuts and reposition the harness wires from the fuel pumpterminals Open the rear door and remove the rear seat cushion 76 70 37 Repositionthe seat cushion insulation pad for access to the fuel pump harness multi plugconnector Removethe foam pad grommet Cut and remove harnessto side harness ratchet strap Displacethe harnessto body grommet Repositionthe harnessthrough the body Disconnect the fuel pump harness black multi plug connector Displace and removethe harness Fitting the new hamess is the reversal of the removal procedure 30018 REVERSE INHIBIT RELAY PASSIVE RESTRAINT RENEW 86 55 84 Open the drivers door Removethe drivers side dash liner Displace the relay multi plug assembly from the mounting bracket Fig 1 Remove and di
165. NTTEMPERATURESENSOR BLOWER MOTOR _ BLOWER MOTOR RIGHT HAND BLOWER MOTOR SPEED CONTROL D coe CENTREVENTVACUUM SOLENOID p oso CHARGE VALVE COMPRESSOR E HA COMPRESSOR CLUTCH CONTROL Bins COMPRESSOR DRIVE COMPRESSOR DRIVE nn COMPRESSOR OIL eee IR e COMPRESSOR SHAFT GONDENSER vett tor eps ee Co CONDENSER eens COOLANTTEMPERATURE TOS eius DEFROST DEMIST VACUUM SOLENOID DEMISTER FLAP ei evans DRIERBOTTEE ende eroe DN ER DRIERBOTLLE tte Scene T9 eode ELECTRONIC CONTROL MODULE ILS ELIO CONTROL 5 5 qa EVAPORATORTEMPERATURE SENSOR mute 2 7 Jis 44
166. OLUMN LOWER COWL RENEW 76 46 03 Open the door Centralisethe road wheels and remove the ignition key Removethe padfrom the centre of the roadwheel Slacken the nut 1 Fig 1 securingthe wheel 2 Fig 1 to the shaft do not fully remove Pull steering wheel to release from the shaft remove the securing nut and steering wheel Removethe dimmer knob control Remove the screws securing the lower cowl 4 Fig 1 remove the cowl Refitthe replacement cowl and secure with the screws Refitthe dimmer control knob Remove the screws securing the upper cowl and remove Positionthe cowl andsecure with the screws Apply grease to the split collars and fit to the steering shaft Ensuring that the steering wheel is in the straight ahead position fit to the shaft Fit and tighten the securing nut Refitthe steeringwheel pad Close the door Fig 1 TORQUE FIGURES Steering wheel tosteering shaft 35 457 OILS GREASES Splitcollars toshaft Castrol LM Grease 1669B 78 76 92 B ODY SECTION ILLUMINATED SUNVISOR MIRROR ASSY RENEW 76 10 50 Open the bonnetand disconnectthe battery Lower the sunvisor Raise the sunvisorcover and removethe lenses Remove the screws securing the mirror to the sunvisor and discard the mirror Reverse the removal procedure to fit the replacement mirror 0051G ILLUMINATEDSUNVISOR ASSY RENEW 76 10 48 Open the bonnetand disconnectthe battery Lowerthe sunvisor Remove the s
167. Openthe car door Removethe driverside dash liner Removethe screws securingthe instrument pack Removethe instrument pack 88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for access to the bulb Removethe bulb 2 Fig 1 fromthe holder Fita new bulb by reversingthe removalprocedure 3001B 86 45 ELECTRICALSYSTEM BRAKE WARNING INDICATOR BULB RENEW 86 45 69 Open the bonnetand disconnectthe battery earth lead Open the car door Removethe driver side dash liner Removethe screws securing the instrumentpack Removethe instrument pack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulb by reversingthe removal procedure 30018 FUELWARNING INDICATOR BULB 075 RENEW 86 45 70 Fig 1 Open the bonnet and disconnect the battery earth lead Open the car door Removethe driver side dash liner Removethe screws securingthe instrument pack Removethe instrument pack88 20 01 Releasethe electronicspack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulb 13 Fig 1 fromthe holder Fita new bulb by reversingthe removal procedure 3001B LOW COOLANT WARNING INDICATOR BULB RENEW 86 45 74 Openthe bonnet and disconnectthe battery earth lead Openthe car door Remove
168. POWER DISTRIBUTION DESCRIPTION ILLUMINATED SUN VISOR BULB n I ILLUSTRATED INDEX 0 KEY INSTRUMENT ILLUMINATION INSTRUMENT ILLUMINATION DIMMER MODULE RENEW INTERIOR LAMPS 2 DESCRIPTION INTERIOR LAMP ASSEMBLY INTERIOR LAMP INTERIOR LAMP LENS wessssssssssssssssssssssssssssseessene INTERIOR READING LAMP LINK HARNESS L C D ILLUMINATION BULB LIGHTING LOGIC AND SWITCH MODULE LOGIC EARTH 15 DESCRIPTION LOW COOLANT WARNING INDICATOR BULB LUGGAGE COMPARTMENT LANP ssnsssssseosrer LUGGAGE COMPARTMENT LAMP BULB LUGGAGE COMPARTMENT LAMP SWITCH LUGGAGE COMPARTMENT LOCK MOTOR RENEW ines MANUAL TRANSMISSION SWITCH LINK 8 tte ttt t8
169. R PLATETRIM WHERE FITTED RENEW 76 43 22 Open the boot lid remove the three self tapping screws and prise the trim starting at the upper side edge and work round and releasethe eight locating plugsfrom the lower boot panel and removethe trim Reversethe removal procedureto refitthe trim after new sealant has been appliedto the trim 036 1b PETROL FILLER FLAP j MD JTE Depress flap and list as shown and liftthe corner Open Fig2 flap and remove the two nuts spring and plain washers and removethe flap Fig 2 Slackenthe locknut securing the locking pin and remove the locking pin Reverse the removal procedureto refit the flap ensuring that the locking pin is adjusted to ensure that the flap shutsflush with the wing top RENEW 76 10 25 76 53 BODY SECTION DATA TORQUE FIGURES Latch fixing nut to latching bolt 2 3Nm SPANNER SIZES 8mm 10mm OILS SEALANTS LUBRICANTS Fillerflap hinge leaf Shell Retinax 0363b RADIATOR GRILLE VEHICLE SET RENEW 76 55 07 Remove the two screws 1 Fig 1 securing each front grille 2 Fig 1 and removethe grille Refit the replacement grilles by engaging the lower tag of each grille into its locating slot and securing at the top with the screw 0383b RADIATOR GRILLESURROUND RENEW 76 55 15 Remove the two front grilles and remove the two bolts 1 Fig2 each side securingthe grille support bracketsto the body Remove the grille as
170. RAM DESCRIPTION VA DI EMO DIA WIRING DIAGRAM 76 03 OPERATION PAGE No 76 73 22 76 34 03 76 34 06 76 43 22 76 73 00 76 73 00 76 73 00 76 73 00 76 73 33 76 73 00 76 73 00 76 73 23 76 73 27 76 73 00 76 73 00 76 10 25 76 55 15 76 55 07 76 25 15 76 22 27 76 22 29 76 22 12 76 22 14 76 73 31 76 34 23 76 31 02 76 31 14 76 31 61 76 58 02 76 58 19 76 37 13 76 37 24 76 34 06 76 37 11 76 37 68 76 40 02 76 47 12 76 34 05 76 43 05 76 49 03 76 19 20 76 67 06 76 22 17 76 25 75 76 22 22 76 22 21 76 13 13 76 13 13 76 13 43 76 70 39 76 70 37 76 70 38 76 67 06 76 73 18 76 76 01 76 76 02 76 115 76 53 76 53 76 53 76 111 76 102 76 112 76 109 76 1 14 76 106 76 107 76 114 76 113 76 100 76 110 76 53 76 54 76 54 76 93 76 96 76 94 76 51 76 52 76 76 76 39 76 38 76 40 76 41 76 41 76 42 76 43 76 46 76 44 76 97 76 43 76 46 76 45 76 45 76 45 76 79 76 90 76 90 76 48 76 50 76 50 76 49 76 62 76 91 76 91 76 77 76 77 76 78 76 78 76 78 76 55 76 55 BODY SECTION CONTENTS DESCRIPTION OPERATION SLIDING ROOF 5 RENEW SLIDING ROOF FLANGE FINISHER RENEW SLIDING ROOF MOTOR DRIVE GEAR RENEW SLIDING ROOF PANEL RENEW SLIDING ROOF PANEL LIFTING BLOCK RE
171. RATION OPERATION PAGE No No ANTI THEFT 5 444 71 00 00 77 10 ASBESTOS 77 00 00 77 05 ASSOCIATED PANELS nnn T 10 00 TT 11 BONNET MOUNTING PANEL een 77 15 02 77 15 CUTTING AND 77 00 00 77 05 DIMENSIQONS 5 22 5 77 00 00 77 06 FRONT END 77 50 04 77 25 FRONT 77 20 02 77 16 77 45 02 77 22 a ONIANIN C 77 25 01 77 16 GENERAL 77 00 00 77 05 HEALTH AND 5 77 00 00 77 04 INDE 77 00 00 77 02 NEWSURFAGES 77 10 04 77 12 OLD SURFACES 2 4 1 77 10 03 77 12 PAINTS DESCRIPTION 71 00 00 77 07 PANELS 0 INTRODUCTION 77 1000 77 09 icem OFFER UP 77 10 05 77 13 PANEE S5 M Ir emm eoim e ee n
172. Refit replace bonnet 77 15 01 Replace Parts Replace parts in reverseorder of removal Reconnect battery and alternator test those electrical items that have been removed and replaced Align headlamps 0055G 77 15 o D 4 be NET 9 24 2 6 eS e 1 1 2 Fig 1 BODY REPAIR FRONTWING RENEW 77 25 01 Disconnect battery and side flasher lamp unit RH and LH Remove Frontbumper assembly with flasher lamp units Disconnecthorns Fig 1 Remove Grille front screen washer bottle filler neck bracket headlamp unit front wheelarch splashguard main section and front section battery LHD only radiator expansion tank LHDonly flasher repeater lamp unit front spoiler headlamp front screenwasher bottle RHD only and bumperside mounting Lay aside bonnet front edge weather seal and scuttle weatherseal Remove 13 mounting bolts to body and remove panel from vehicle Offer Up Panel Offer up new panel check alignment and remove for painting Fig 1 Painting See Section 77 00 00 Refit Panel Offer up new panel replace mounting bolts to body check alignmentand tighten bolts Replace Parts Replace parts in reverse order of removal Reconnect battery test those electrical items that have been removed and replaced Align headlamp FRONTDOORSKIN RENEW 77 20 02 Remove Frontdoor Panel Replacement Panel removaland replacementist
173. Removethe front door uppertrim pad 76 34 02 Removethe front door lower trim pad 76 34 03 Fit tape 1 Fig 1 over the door glass 2 Fig 1 and frame 3 Fig 1 to secure the glass Remove the screws securing the window lift motor to the door frame Remove the screws securing the window regulator lift guide Disconnect the exterior mirror and regulator multi plug connectors Disconnect the window lift mechanism from the door glass Lower the window lift motor to the bottom of the door and displace the channel rubber from the front channel for accessto the securing screw Remove the screw Fig 2 securing the door glass frame to the front mounting bracket Remove the screws Fig 2 securing the door glass frame to the door remove the spacer plate and remove the door glass and frame assembly removethe tape from the glass and removethe glass from the frame Reverse the removal procedureto refit the replacement glass 76 31 BODY SECTION DATA TORQUE FIGURES Door glass clampingstrip to door 7 Doorglass regulator andslide channel to door 7 10Nm Setscrewfrontlower frame fixing to door 7 10Nm Setscrewfront upper frame fixing to door 7 Setscrewrear lower frame fixing to door 7 10Nm Setscrew rear upper frame fixing to door 7 10Nm SPANNER SIZES 10mm Torxbit No 30 0016b FRONT DOOR GLASS CHANNEL RUBBER RENEW 76 31 13 Fig 1 Open the door Removethe front door trim padveneer panel76 47 1 1
174. Removethe front door uppertrim pad 76 34 02 Removethe front door lowertrim pad 76 34 03 Removethe exterior mirror 76 10 52 Removethe front door waist rail moulding 76 43 04 Removethe front door glass 76 31 01 Removethe glass channel rubber 1 Fig 1 Refit the replacement rubber to the channel in frame engage corners and then fully seat the remainder of the rubber and reverse the remaining removal procedure to refit DATA TORQUE FIGURES Doorglass clamping strip to door 7 10Nm Door glass regulator andslidechannelto door 7 10Nm Setscrew frontlower frame fixing to door 7 Setscrew front upper frame fixing to door7 Setscre wrear lower frame fixing to door7 Setscrew rear upper frame fixing to door 7 SPANNER SIZES 10mm Torxbit No 30 76 32 BODY SECTION FRONT DOOR GLASS FRAME RENEW 76 31 51 Open the door Remove the front door trim padveneer panel 76 47 11 Removethe front door uppertrim pad 76 34 02 Removethe front door lower trim pad 76 34 03 Removethe exterior mirror 76 10 52 Remove the front door waist rail moulding 76 43 04 Remove the front door glass 76 31 01 Remove the front door glass channel rubber 76 31 13 Remove the upper frame seal from the frame and place the frame aside Apply soft soap to the frame apeture and starting with the rear of the seal at the front of the frame slide the seal into position Reversethe removalprocedureto refit DATA TORQUE FIGURES
175. SHER INDICATOR BULB RENEW 86 45 63 Openthe bonnet and disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securingthe instrument pack Removethe instrument pack88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for access to the bulb Removethe bulb from the holder Fit a new bulb by reversing the removal procedure 30018 86 44 ELECTRICALSYSTEM IGNITION INDICATOR BULB RENEW 86 45 64 Open the bonnet anddisconnectthe battery earth lead Openthe car door Remove the driver side dash liner Removethe screws securing the instrument pack Removethe instrumentpack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethebulbfrom the holder Fita new bulb by reversingthe removal procedure 30016 HEADLAMP HIGH BEAM INDICATOR BULB RENEW 86 45 65 Open the bonnet and disconnectthe battery earth lead Open the car door Removethe driver side dash liner Removethe screws securingthe instrument pack Removethe instrumentpack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulb by reversingthe removal procedure 30018 OIL PRESSUREINDICATOR BULB RENEW 86 45 66 Openthe bonnetanddisconnectthe battery earth lead
176. SIDE STOP REVERSE AND NUMBER PLATE LAMPS DESCRIPTION 86 40 00 The vehicle side and number plate lamps are operated with the ignition switched off through an auxiliary sidelamp relay The stop and reverse lamps however are operated by footbrake and gear selector switches which energise stop and reverse relays in the rear bulb fail modules 3001B SIDE STOP REVERSEAND NUMBER PLATE LAMPS OPERATION 86 40 00 Sidelamp operation is selected by setting the master lighting switch to SIDELIGHTS This connects a logic earth to the lighting logic module which energisesthe auxiliary sidelight relay and sends a signal to the CPU Side tail number plate and side marker relays are also energised which route battery power to respective lampfilamentsthrough the bulb fail modules The SideLAMP signal is usedto control the instrumentillumination intensity Operation of the vehicle footbrake actuatesthe footbrake switch which energises stop relays which route battery power through the rear bulb fail modules to the stop lamp filaments Similarly movementof the gear selector to reverse actuates the reverse switch which energises relays which route battery power to the reverse lamp filaments 3001E 86 32 ELECTRICALSYSTEM TAIL STOP FLASHER AND REVERSE LAMP BULB HOLDER RENEW 86 40 67 Open the bonnet and removethe battery earth lead Open the luggage compartment Removethe lamp interiortrim finisher Fig 1 Removethe
177. SS eese REAR DOOR GLASS CHANNEL RUBBER REAR DOOR GLASS REAR DOOR HANDLE rnm REAR DOOR INSIDE HANDLE REAR DOOR REAR DOOR LOCK REAR DOOR LOWER TRIM REAR DOOR OUTER HANDLE OPERATING ROD REAR DOOR REMOTE CONTROL OPERATING REAR DOOR TRIM PAD VENEER PANEL REAR DOOR UPPER TRIM REAR DOOR WAIST RAIL REAR FLOOR CARPET eere REAR LAMP ASSEMBLY INTERIOR TRIM FINISHER REAR PARCEL TRAY eene REAR QUARTER BUMPER nnn REAR QUARTER BUMPER REAR QUARTER BUMPER LOCATING BRACKET REAR QUARTER BUMPER MOUNTING RUBBER REAR QUARTER TRIM REAR QUARTER UPPER TRIM PAD LEFT HAND REAR QUARTER UPPER TRIM PAD RIGHT HAND REAR SEAT REAR SEAT CUSHION REAR SEAT REAR SHELF 5 44 nnne REAR SIDE SEAT SILL TREAD PLATE BILL TREAD PLATE REAR 0516 Issue 2 1 ib Aue OPERATION CONNECTORS FAULT DIAGNOSIS SERVICE CHECKS WIRING DIAG
178. T BE RECONNECTED BEFORE THE VEHICLE IS DRIVENAGAIN In the unlikely event of a malfunction of the deployment system two emergency tongues with protective covers are stored inthe glovebox to allow temporary use of the vehicle The tongues are right and left handed and marked RH TOP and LH TOP respectively Insert the correct tongue intothe trim finisher channel on the B post sliding it down until itengages with the assembly anchorage at the end of the runner rail Release the diagonal seat belt buckle from the runner tongue assembly by operating the red PRESS button and manually attach the buckleto the emergency tongue Fitthe protective cover to the exposed runner tongue assembly Dueto the sensitivity of the belt inertia reels rapid or jerky seat adjustmentmay causethem to lock preventing the system from deploying completely It is preferableto adjust the seat after the belt has deployedto the restraining position If the inertia reel mechanism is locked slowly adjust the seat forwards and ease the belt from the inertia reel or use the emergency release Ensure the belt is re connectedbefore the vehicle is driven Labels referingto the above are attached to the sunvisor and belt webbing 76 100 BODY SECTION OPTIONS FOR USE ON EARLY VEHICLES Incorporationof the passive restraintsystem necessitates modification atthe body in white stage of construction Fitment of the passive restraint system will not be possible therefore to vehicles ma
179. ack dimmer Reducing the illuminationat night will also dim the sport light to prevent distractions FUEL GAUGE UNIT 88 00 00 The introduction of the in tank fuel pump necessitates fitment of a revised tank sender unit The original 90 model year sender unit causes a foul condition on the pump and must therefore not be used on 91 model year vehicles These alterations cause changes to the fuel tank calibration The resistance of the sender unit has been changed to allow optimum accuracy and linearity of the fuel gauge The result of these modifications mean a 91 model year instrument pack cannot be used with a 90 model year sender Itis important to ensure the gauge and sender unit are compatible Incompatible units will cause the gauge to show false information A 91 model year matched set ie gauge and sender unit can be fitted to a 90 model year vehicle as the physical changes to the sender cause no problems 88 27
180. acket to seat assembly securing bolt and remove the belt buckle assembly from the seat Reverse the removal procedure to refit the replacement belt 00755 76 73 BODY SECTION FRONTSEAT BELT RIGHT HAND RENEW 76 73 21 Open the door Removethe post lowertrim pad 76 13 29 Remove the seat belt upper anchor securing nut cover and nut Reposition the seat belt for access remove the spacer and wavey washer and disconnectthe block connector Unclipthe B post uppertrim pad Displacethe uppertrim padfrom ist mounted position Pass the seat belt through the trim pad and remove the uppertrim pad Removethe seat belt finisher from the B post aperture andrepositionthe seat beltthroughthe B post Removethe seat belt reel securing bolt and remove the seat belt reel Renewthe seat cushion 76 70 32 Cut and remove the seat belt buckle block connector securing strap and disconnectthe seat belt buckle block connector Remove the seat belt buckle mounting bracket to seat assembly securing bolt and remove the belt buckle assembly from the seat Reverse the removal procedure to refit the replacement belt 0078b FRONT SEAT CUSHION RENEW 76 70 02 Open the door Remove the bolt securing the seat cushion and remove the cushion retaining plate Lift cushion for access to the block connector situated below the cushion and disconnect the seat belt pad blockconnector Cut and removethe harness securing ratchet strap Removet
181. ad or reach ground If a curcuit is open active components do not energize A short circuit is an unwanted connection between one part of the circuit and either ground or another part of the circuit A short circuit causes a fuse to blow or a circuit breakerto open Short Circuits Caused by Damaged Wire Insulation Locatethe damagedwire Find and correct the cause of the wire insulation damage For minor damage tape over the wire If damage is more extensive replacethe faulty segment of the wire Refer to the splicing instructions for copper aluminum or shielded cable for the correct splicing procedure SPLICING COPPER WIRE Open the Harness If the harness is taped remove the tape To avoid wire insulation damage use a sewing seam ripper to cut open the hamess availablefrom sewing supply stores If the harness has a plastic conduit simply pull out the desired wire Cutthe Wire Begin by cutting as little wire off the harness as possible You may need the extra length of wire later if you decide to cut more wire off to change the location of a splice You may haveto adjust splice locations to make certain that each splice is at least 40mm 1 1 2 away from other splices hamess branches or connectors 86 71 ELECTRICALSYSTEM Strip the Insulation Fig 1 Ifthe wire size is unknown start with the largest opening in the wire stripper and work down until a clean strip of the insulation is achieved
182. amp screw Fig 1 and release the wire from the clamp Remove the field coil retaining snap ring and detach the field coil Clean the mating face of the compressor with a cloth moistened with an approved cleaning fluid Positionthe new field coil on the compressor and fit the retaining snap ring Route the wire to the compressor and fit the wire clamp tighten the securing screw Fit the compressor pulley refer to 82 10 10 Fit the compressor drive clutch refer to 82 10 08 the compressor refer to 82 10 20 Recharge the air conditioning system refer to 82 30 08 Removethe wing cover and close the bonnet GASKET KIT RENEW 82 10 26 Openthe bonnet and fit a wing cover Depressurize the air conditioning system refer to 82 30 05 Remove the compressor referto 82 10 20 Position the compressor in a vice tighten the vice onto the compressor body lugs Remove the outlet port blanking plate securing bolt and detach the plate Remove and discard the O ring seals from the outlet port Removethe compressor cylinder head securing bolts detach the cylinder head Detach the valve plate from the compressor Removethe gaskets from the compressor Remove all traces of gasket material from the mating surfaces of the cylinder head valve plate and cylinder block Position new gaskets 1 and 3 Fig 2 on the valve plate 2Fig 2 and then place it on the cylinder block Position the cylinder head 1 Fig 3 on the cylinder b
183. and glove box Removethe blower motor assembly 80 20 12 10 With the blower motor assembly on a work bench disconnectthe vacuumservoto flap link arm 1 Fig 1 Openthe flap Displacethe cable harness for access Removethe relay 2 FigI Fitting a new relay is the reversal of the removal procedure 0209G 180 055 BLOWER MOTOR HIGH SPEED RELAY RENEW 80 10 39 Disconnectthe battery earth lead Remove the relevantdash liner Disconnectthe servoto blower flap link arm 1 Fig2 Openthe flap Displace removethe relay 2 Fig 2 Fitting a new relay is the reversal of the removal procedure 02096 UPPER FLAP SERVO MOTOR 2 GEARBOX RENEW 80 10 45 Disconnectthe battery earth lead Removethe driver side dash liner Remove the screws securing the electronic control module 1 Fig3 Displacethe module for access Remove the screws securing the motor assembly 2 Fig 3 Displacethe assemblyfor access Disconnectthe cable hamess multi plug connector Removethe motor assembly Fitting a new motor assembly is the reversal of the removal procedure 0209G j 282 157 80 11 HEATING AND VENTILATION UPPER SERVO MOTOR FEEDBACK POTENTIOMETER RENEW 80 10 44 Disconnectthe battery earth lead Removethe passenger dash liner Remove the screws Fig 1 securing the potentiometer mounting plate Displacethe potentiometerfrom the flap drive shaft Disconnectthe multi plug connector Removethe po
184. and replacement isto the method detailed in Section 77 10 01 07 with the following variations During removal the panel is cut at points 1 Fig 1 and the tail lamp panels removed The rear wings are then moved outwards to assist with removingthe bulk of the panel In replacement holes are made in the new assembly for plug welding at 3 Fig 2 and 7 Fig 2 as there is no access for a resistance spot welder Plug welds are also made at 3 Fig 2 and 9 Fig2 usingthe holes left by the resistance spot weld cutter Metal to metal adhesive is applied at the areas shown in the diagram before offering up 10 Fig 2 Painting See Section 77 00 00 Replace Parts Replace parts in reverseorder c removal 77 21 BODY REPAIR FRONT SCREEN RENEW 77 45 02 Open the bonnet and both front doors Remove both wiper arms Removethe plenum chamber finisher Displace and remove both screen finishers Release the screen seal at both A posts Displace and removethe seal Protect the paint around the windscreen aperture using suitable maskingtape From inside the car displace the flange dam noting that the dam remainscaptive along the lower edge To release the screen from the aperture cut through the Betaseal as follows Carefully pierce an access hole through the Betaseal at thetop of the A post Fita length of cheese wire through the hole Secure both ends of
185. and right hand 76 13 10 Removethe sliding roof motor 86 76 01 Releasethe interior lamp panel securing clip and release the panel assemblyfrom its mounted position Disconnect the block connectors Fig 1 and placethe panelaside Removethe sliding roof motor 86 76 01 Removethe tape and cut the ratchet straps securing the rack tubes together and taking care to ensure that the headlining is not soiled by the rack removethe rack end tube sections Manually slide the roof panel rearwards and remove the relevent mounting bracket securing bolts Removethe bracket Remove the screws securing the rack tube clamp to the sliding roof repeat the procedure for the second side manually close the roof and remove the rack to roof panelcarriersecuring nut Displacethe racktube assembly from its guide open up and repositionthe tube clamp over the rear tube and rack bracket Holding the rear tube in position disconnect the front rack tube from the rear rack tube 76 60 BODY SECTION Release the rack from the rear tube and carefully remove the rack Repeatthe procedurefor the second side Grease the replacement racks fit the rack to the front rack tube reposition the rack into the rear rack tube approximately 12 in ensuring that the clamp is not displacedalong the tube Reposition the front rack tube and connect to the rear rack tube ensure that the rack tube to sliding roof assembly rubber is correctly positioned Position the c
186. and the left hand one from the left side instead of feeding both from the right hand side LOAD DUMP MODULE DESCRIPTION 86 00 00 The load dump module connector is changed to a PM5 type and is now earthed via pin of this connector instead of direct to the body also the fuses have been changed RADIATOR COOLING FAN MOTOR DESCRIPTION 86 00 00 Electrical connection to the radiator cooling fan motor is via a 2 way connector integralto the motor body replacing the flying lead used at 9OMY IGNITION SWITCH DESCRIPTION 86 00 00 The two 6 way PMHD column switchgear harness interface connectors SC5 and SC6 are replaced by one 6 way PMHD connector 8 in order to rationalise the number of connectors in the column switchgear area GEAR SELECTION ILLUMINATION MODULE DESCRIPTION 86 00 00 The gear selector illumination module connector is changed from a 15 way PMHD to a MULTILOCK connector 86 111 ELECTRICAL SYSTEMS 91MY PASSIVE RESTRAINT DESCRIPTION 86 00 00 The following wires to the passive restraint ECU are deleted Ignition ground Connector LB86 Pin 5 Logic earth Connector LB86 Pin 9 Logic earth Connector LB86 Pin 12 These wires are spliced internally inside the ECU and are no longer needed CENTRE CONSOLE PANEL DESCRIPTION 86 00 00 The centre console panel connector is changed from a 15 way PMHOto a 12 way Multilock connector Although 13 wires are used pins 12 and 15 onthe previous connector
187. are clean Torquethe plug to 6 9ft Ibs 0 8 1 2kg m Do not over tighten the plug to stop a leak Removethe plug andfit a new ring seal Mounting Angle Acceptable Oil Level Degrees In Increments 0 2 4 10 4 5 20 5 6 30 6 7 40 7 9 50 9 10 60 10 12 90 12 13 Key to Fig 1 1 Oilfiller hole 2 Rodball 3 Pistonrod 4 Ballsocketon planetplate Keyto Fig2 1 Themounting angle 2 Dipstick 3 Thestop 4 Oilfiller hole 82 54 482 226 AIR CONDITIONING It is not necessary to check the oil level as a routine maintenance However should there be a good reason to suspect an incorrect oil level because of leaks carry out the following procedure 1 Runthe enginefor approximately10 minutes 2 Dischargethe systembeing careful notto lose oil 3 Followthe proceduredescribed onthe previous page NEW COMPRESSOR OIL LEVEL CHECK When replacing a Sanden cornpressor containing uncontaminated oil with a new cornpressor use the following procedure 1 Drainthe oilfrom the new compressor 2 Drainand measuerthe oil from the old compressor 3 Measure the new oil equal to the amount drained from the old compressor and add one fluid ounce 30 cc of new to this amount Use it to refill the compressor FLUSHING The system must be flushed when a new fitted or becomes contaminated When flushing the system with R11 do not allow the R11 to enter the compressor CLUTCH REMOVE 8
188. arest point where the wheel can be fitted in safety As an essential preliminary a new international standard of rim dimensions has been developed and adopted by the European Tyre and Rim Technical Organisation STRTO The rim sizes covered are 290 315 340 365 390 415mm diameter rims incorporating the Denloc groove allowing fitment of TDtyres How it works The TD wheel incorporates two grooves running circumferentially around the bead seats The tyres have specially extended bead toes which fit into these grooves In the event of deflation the reinforced bead toes are held firmly in place by these grooves thereby helping to prevent the tyre from leaving the rim Both tyre and road wheel are made to metric dimensions in section width and wheel diameter This is a safety precautionto preventthe fitting of a conventionaltyretothe TD wheel and conversely of a TD tyre to a conventional wheel It should be noted that a TD tyre cannot be fitted to a normal wheel In a conventional radial tyre the bead is designed to fit inside a vertical rim flange the casing cords are forced to curve outwards above the flange before curving inwards again thus forming an unnatural S shape The secret of the TD principle lies in both the unique radial construction and the rim contour which allow the casing cords to follow a shaped flexing curve The rim flange is inclined outwards at an angle parallel to the natural line of the casing cords
189. asethe clip securingthe B postlowertrim pad and displacethe padfrom its position Undo the seat belt reel lower securing bolt and displace the reelfor access Removethe screws securing the B post inner harness guard and removethe guard Displacethe harnessfrom the B post Disconnectthe multi plugs Openthe front door and closethe rear door Displacethe harness protection sleeve from the B post Displacethe harnessfrom the B post Displace the harness protection sleeve and hamess into the rear door Openthe rear door Displacethe water curtain Removethe hamessto door hinge bolts guide Removethe door upper harnessfinisher Cut and remove the harness to lower door securing straps Fig 1 Disconnectthe black yellow green and blue multi plug connectors Cutand removethe upper harnesssecuringstraps Removethe hamessfrom the door Fitthe new hamesstothe rear door Routethe harness protectorto the door aperture thread the harnessintothe B post andfully seatthe protector Connectthe multi plugs Fitthe hamessinner guard Fitandtighten the securing screws Positionthe seat belt reel Fitandtighten the securing bolt Fitthe boltfinisher Position the B post lower trim pad and engage the securingclips Reclinethe seat to its original position and repositionthe seat Routethe upper door hamess connectors Fitthe harnessfinisher Routethe hamessto the lower hinge guide Fit and secure the guide Routethe
190. ate Remove the muffler securing bolt Remove and discard the O ring seals Fit protective caps to the disconnected hoses anda protection plate to the compressor Place the compressor in a vice tighten the vice onto the body lugs Fit tool JD166 1 1 Fig 1 to the compressor fit and tighten the securing screws 2 Fig 1 Fit tommy bar 3Fig 1 to JD166 1 and remove the drive clutch securing nut NN Fit tool JD 166 3 1 Fig 2 to JD168 1 and 2 Jar 202 reposition the tommy barto engage JD 166 3 Tighten the tool centre bolt 2 Fig 2 to remove the drive clutch Fig 1 Remove the drive clutch complete with the tool attached from the compressor Set the tool centre boltto its original position for future use Remove the screws 2 Fig 1 securing tool JD 166 1 to the drive clutch and remove the tool Remove the drive clutch air gap adjustment shims from the compressor shaft Remove the woodruff key from the shaft Fitthe woodruff key to the shaft Fit the drive clutch air gap adjustment shims on the shaft Align the drive clutch keyway with the woodruff key and then using a suitable piece of tubing push the drive clutch fully home on the compressor shaft Fittool JD166 1 1 Fig 1 to the drive clutch fit and tighten the securing bolts Fittommy bar JD166 2 3Fig 1 to JD166 1 and then fit and tighten the drive clutch securing nut Remove the screws 2 Fig 1 securing the tool to the drive clutch and detach the
191. auge reading istoo high 2 The high side gauge reading istoo high 3 An occasional bubble inthe sight glass 4 The discharge air from the evaporator is notcool Diagnosis Air in the system The refrigerant contaminated by non condensables air and or moisture Correction 1 Depressurizethe system 2 Renewthe receiver drier 3 Evacuatethe system using a vacuum pump 4 Rechargethe system with new refrigerant 5 Operatethe systemand checkthe performance Expansion Valve Malfunction The valve stuck open Complaint Little or no cooling Condition 1 Thelowside gauge reading istoo high 2 The highside gauge reading is normalor slightly low 3 Thedischargeair from the evaporator is warm 4 The suction hose and the evaporator show signs of heavy sweating Diagnosis The expansion valve allowing excessive flow d 462 0877 refrigerantthrough the evaporator coils causing flooding Fia2 ofthe coils 9 Correction 1 Depressurizethe system 2 Renewthe expansionvalve 3 Renewthe drier bottle 4 Evacuatethe system usinga vacuum pump 5 Rechargethe system with new refrigerant 6 Operatethe systemandcheck the performance 82 24 AIR CONDITIONING Expansion Valve Malfunction The valve stuck closed Complaint Cooling is not adequate Condition 1 The low gauge readingistoo low Ooravacuum 2 The high side gauge reading istoo low 3 The discharge air from the evaporator only slightly cool 4 T
192. bolt Refit the compressor refer to 82 10 20 Remove the wing mat and close the bonnet DATA TORQUE FIGURES Cylinder head bolts 29 83 33 9 HOSE COMPRESSOR TO EVAPORATOR RENEW 82 25 02 Open the bonnet and fit a wing cover Depressurize the air conditioning system refer to 82 30 05 Slacken the hose to evaporator valve union nut disconnect the hose from the valve remove and discard the O ring seal Fit a blanking plug to the evaporator valve Remove the muffler to compressor evaporator hose securing bolt Remove the compressor outlet port retaining bolt Disconnect the hose from the compressor discard the hose complete with O ring seals Fit a blanking plug to the compressor connection Remove the blanking plugs from the compressor and the evaporator valve Connect the hose to the evaporator valve tighten the union nut ensuring that the charging valve is upright Route the hose to the compressor fit a new O ring seal and connect itto the compressor Position the outlet port retaining plate on the compressor fit and tighten the securing bolt Fitandtighten the mufflerto compressor evaporator hose securing bolt Charge the air conditioning system refer to 82 30 08 Remove the wing cover and close the bonnet 182 294 82 72 WINDSCREEN WIPERS AND WASHERS CONTENTS DESCRIPTION OPERATION OPERATION PAGE No No HEADLAMPWASHER RENEW
193. bulkhead A A T 840 029 Each post fuseblock contains two vertical banks of seven fuses each bank being identified 1to 7 and 8 to 14 descending order on the left and right respectively Fig 1 Fuse ratings and the circuits are detailed at the front of this Section 0022 SUNROOF AND WINDOWS DESCRIPTION 86 25 00 The sunroof if fitted and windows are driven by motors actuated via relays by two way rocker switches located ondoor Fig 1 and sunroof A B Fig 2 switch panels Each window can be raised and lowered independantly from its respectiveswitch panelor from the driver switch panel which also contains passenger window override and isolate switches A Fig 1 A central locking function also raises each window and closes the sunroof in responseto front door key and central locking switches The sunroof is operational at all times that the battery is connected but window operation is permitted only when the ignition switch is setto ON or AUXILIARY JHB40 035 Fig2 The sunroof and each window circuit contains two relays one relay for the open function and the other for the close function Each relay is supplied with battery power which is routed to the motor when the relay is energisen the other relay completing the motor circuitto earth 86 21 ELECTRICALSYSTEM The sunroof circuit also contains a limit override switch which permits sunroof travel to the fully open position when its contacts are cl
194. ce spot welds at the inturned flange beneath the rear screen panel may then be cut out and the metal remnant removed It is necessary to use a body chisel and pincers when removingthe remnant at the wheel arch as adhesive is used in this area which creates difficulties in removal When removing the resistancespot welds at 1 Fig 2 it is necessary to cut out the welds on the outer face and bend the flange upwards as shown in 1 Fig 3 in order to gain access to the second row of resistance spot welds beneath 4 77 041 During replacement holes are punched inthe new panel for plug welding at 1 Fig 2 and 5 Fig 2 as there is no access for a resistancespot welder atthese points Fig 1 Plug welds are also made at 3 4 6 Fig 2 usingthe holes left bythe resistancespot weld cutter Adhesive is applied to the area shown in the welding diagram before offering the panel upto the vehicle see page 77 04 for sealants chart Painting See Section 77 00 00 Replace Parts Replaceparts in reverse order of removal Reconnect battery and alternator test those electrical items and mechanisms that have been removed and replaced 0055G Fig3 77 20 BODY REPAIR REAR PANELASSEMBLY RENEW Welding Table No Location 1 To inner reinforcementlower flange 2 Tobootfloor rear edge and side extension Remove Factory Joint 20 resistancespotwelds 50 resistancespot welds 77 35 01 Replace RepairJoint 20 MIG plug w
195. cedurefor the other strut Reverse the removal procedure to refit the replacement struts 1669B 72 BONNET LOCK CONTROL CABLE RENEW 76 16 29 Openthe bonnet Slacken the clamp bolt 1 Fig 2 securing the cable 4 Fig 2 to the lock actuator Disconnect the cable from the lock and from the mounting clip 2 Fig 2 Displace the cable from the bulkhead mounting clips and remove the ratchet straps securing the cable to the pipes and harnesses Displace the cable from the remaining large ratchet straps Openthe front door Removethe dash liner Pull the release handle and disconnect the cable 1 Fig 3 fromthe release handle and bracket Pull the cable through the bulkhead grommet and discard Reverse the removal procedure to fit the replacement cable DATA SPANNER SIZES Fig3 8mm I Omm 1669B 72 76 26 BODY SECTION BONNET LOCK CONTROLCABLE ASSE MBLY VEHICLE SET RENEW 76 16 35 Open the bonnet Slacken the clamp bolt 1 Fig 1 securing the cable 4 Fig 1 to the lock actuator Disconnect the cable from the lock and from the mountingclip 2 Fig 1 Displace the cable from the bulkhead mounting clips and removethe cable securing ratchetstraps Displace the cable from the remaining large ratchet straps Open the driving side door Removethe dash liner Pull the release handle and disconnect the cable 1 Fig 2 from the release handle 2 Fig 2 and bracket Pull the cable through the bulkh
196. ch door sill and electrical operation by means of motors installed in the doors and boot Mechanical operation of the boot lock is by means of a key operated mechanism also incorporated at both the driver and front passenger doors 86 24 ELECTRICALSYSTEM Each door plunger is connected to its respective lock mechanism by a linkage which sets the mechanism to the desired condition The front door plungers can be operated with the doors open or closed but inthe open position the external door handle must first be raised Driver and front passenger door plunger movement also operates a microswitch which via a door lock module operates the boot and remainingdoor locks A safety feature operated by the inertia switch unlocks all the doors and locksthe boot and fuel filler should the vehicle be involvedina front or rear collision Each lock can also be locked via the door lock module by a central locking function under CPU control it is operated by front door key or central locking switches 30018 DRIVERS DOOR LOCK MOTOR RENEW 86 25 45 Openthe bonnetand disconnectthe battery earth lead Removethe veneer panel76 47 1 1 Removethe upper trim pad 76 34 02 Removethe lowertrim pad 76 34 03 Removethe door lock 76 37 12 Cut and remove the rachet strap securing the lock hamessto switch hamess Remove the screws securing the lock motor to the door lock 1 Fig 1 Removethe lock motorfrom the lock assembly 2 Fig 1 Fig 1 Fit
197. comprises brushes which engage inner and outer slip rings The slip rings are arranged so that the outer supplies battery power to the slow speed circuit until the park position is reachedand the inner supplies an earth to the motor circuit at the park position to provide dynamic braking These inputs are appliedto the slow speedcircuit through connector B59 5 of the logic module battery power being suppliedto the outer slip ring via B59 6 When windscreen headlamp wash is selected windscreen and headlamp wash relays are energised which connect battery power to respective pumps The windscreen wash relay is energised direct but the headlamp relay is energisedthrough the CPU which permits headlampwash functions only when the headlightsare ON 0196G 84 4 WINDSCREEN WIPERS AND WASHERS WASHER RESERVOIR RENEW 84 10 03 Open the bonnet and disconnectthe battery earth lead Jack up and placethe vehicle ontwo stands Remove the nuts bolts screws and washers securing the inner wing valance Displaceand remove the inner wing valance Removethe brakedisc cooling duct Disconnect the washer pump and the reservoir level sensor multi plug connectors 1 Fig 1 Disconnectthe washer pump tubing from the pump 2 Fig1 Remove the bolt and washers securing the reservoir 3 Fig 1 Removethe reservoir from the filler neck Drainthe water from the reservoir Removethe bolt securing the washer motor clamp plate remove the plate and remo
198. connectors Align assembly fit and tighten the securing screws Returnsteering wheel to original position Refit the dash liner Reconnectthe battery 079 Fig 3 NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored to the correct value Issue 2 88 20 INSTRUMENTS INSTRUMENT PACK ILLUMINATION BULBS RENEW 86 45 49 NOTE The following five instrument pack bulbs located in the lower right hand corner area of the pack are accessible without removingthe pack 1 Seat belt warning bulb 2 Bootopen warning bulb 3 Door open warning bulb 4 Coolanttemperature warning bulb 5 Low coolant warning bulb NOTE There are 8 white bulb holders for gauge illumination the remaining 24 brown bulb hoiders are for warning indication only the two types are not inter changeable x All other warning bulbs proceedas follows Disconnectthe battery Remove the drivers side dash liner securing screws releasethe securing clip and removethe liner Release the steering column clamp fully extend the steering wheel and re tightenthe clamp Removethe instrument pack assembly securing screws Disconnect the block connectors from the rear of the pack Displaceand removethe instrument pack assembly Place the pack face down on the bench ensuring that the cowl lens is protected with a suitable cloth or similar
199. connectthe cable hamess block connector ng vs Removethe module 1 Fig 1 ie hd Fitting a new module is the reversal of the removal WES v lt ewe EE hs 30018 CENTRE CONSOLE SWITCH AND CLOCK MODULE ae Fig 1 RENEW 86 80 13 Openthe bonnet and disconnect the battery earth lead Openthe car door Removethe gear lever knob 37 16 11 Removethe consolefinisher 76 25 19 Remove the screws securing the upper console assembly 1 Fig 2 Displacethe assembly from its location Disconnectthe cable harness block connector 2 Fig 2 Removethe screws securingthe harness clamp Removethe module Fitting a new module is the reversal of the removal procedure 3001B LIGHTING LOGICAND SWITCH MODULE RENEW 86 80 05 Openthe bonnet and disconnectthe battery earth lead Open the car door Removedrivers dash liner 76 46 11 Removethe screw securing the lighting logic undertray andremove the undertray Fig 3 Displacethe master lightingswitch Releasethe clips retainingthe logic board Removethe logic boardfrom the fascia Disconnectthe green cable hamess block connector Removethe logic board mu Hazard Fitting a new logic board is the reversal of the removal procedure JIG 492 30018 Fig3 86 54 ELECTRICALSYSTEM WIPER LOGIC MODULE RENEW 86 80 11 1 23456789 10 Open the bonnet and disconnect the battery earth lead pu E
200. crews Fig 1 securing the sunvisor retaining block Fig1 Carefully displace the connector from behind the headlining and disconnect Remove the screws securing the retaining block and removethe block Reverse the removal procedure to refit the replacement visor 0051G ASHTRAY RENEW 76 67 13 Open the door press the flap to openthe ashtray Lift out the ash receptacle replace the receptacle close the lid and shut the door 0380b RADIO CONSOLE RENEW 76 25 15 Open the door Removethe console ashtray 76 67 18 Removethe console finisher 76 25 19 Remove the radio console to centre console securing screws and carefully removethe radio fascia plate Repositionthe radio console from its mounted position disconnect the block connectors and remove the radio console assembly Remove the air conditioning switch control module 86 80 15 Remove the console switch and clock module 86 80 13 and place the housing aside Reversethe removal procedureto refitthe console 0012b 76 93 BODY SECTION FRONT BEAM COVER RENEW 76 22 28 Removethe front bumper centre section and removethe indicator lamp assemblies Remove the rubber cover securing screws remove the lower cover securing screws and removethe cover Fit the replacement cover to the centre blade and align the lower fixing holes Fit but do not tighten the lower securing screws align the cover to centre blade securing bracket holes and fit and tighten the
201. ct the battery earth lead Open the luggage compartment and remove the spare wheel Removethe jack and racet handle Removethe luggage compartmentfront liner Cut and removethe ratchetstrap securing the multi plug tothefueltankstrap Fig 1 Disconnectthe right hand black multi plug Displacethe grommet through the body to the axle area Reposition the harness and multi plug through the body Jack up and placethe vehicle ontwo stands From below disconnect the harness to brake pad multi plug connector Fig 2 Cut and remove the rachet strap securing the harnessto the lower wishbone Displacethe coverfrom the ride height sensor Disconnectthe multi plug connector Cut and remove the rachet strap securing the ride height sensor harness to suspensionarm Displaceand removethe harness Fitting the new harness is the reversal of the removal procedure 3001B REAR AXLE HARNESS Left Hand RENEW 86 70 17 Openthe bonnet and disconnectthe battery earth cable Open thee luggage compartment and remove the spare wheel Removethe jack and rachet handle Cut and remove the rachet strap securing the multi plug to the fuel tank strap Disconnectthe black econoseal multi plug connector Displacethe grommetthroughtothe axle area Repositionthe harness and mylti plug throughthe body Jack up and placethe vehicle ontwostands From below Disconnectthe hamessto brake pad multi plug connector Cut and removethe rachetstrap securing the
202. ctor Discardthe switch Fitting a new switch is the reversal of the removal procedure 30018 POWERED SEATS DESCRIPTION 86 75 00 The driver and front passenger seats are adjusted electrically by means of four rockertype switches located on the powered seat switch assemblies Each seat contains four motors which enable seat movement as follows Foreward or back Cushionfront raise or lower Cushion rear raise or lower Squab raise or recline Driver and front passenger seat movement is with the ignition switched ON the power being appliedto relays which route battery power to the switch assemblies when energised 86 62 ELECTRICALSYSTEM Each seat motor is connected to the moving contact of its associated switch which is spring biased in the OFF position Two poles of each switch are supplied with battery power while the other two are connected to earth The switches are wired so that each motor can operate in either direction depending on the requirement of the operator DRIVERS SEAT MOTOR SWITCH RENEW 86 75 03 Open the bonnet and disconnectthe battery earth lead Open the car door Removethe consolefinisher 76 25 19 Displace the cables from the rear of the switch pack for access Disconnectthe cable hamess block connector Removethe nuts securing the switch pack Removetheswitch pack Fig 1 Fitting a new switch pack is the reversal of the removal procedure 30018 PASSENGER SEAT MOTOR SW
203. ctor mounting plate Reposition the plate for access to the flasher switch harness multi plug Disconnectthe multi plug Remove the bolt securing the switch and remove the switch Reverse the removal procedure to fit a replacement switch 3001B 86 92 Anne PASSIVE RESTRAINT FAULT DIAGNOSIS LH SYSTEM REARWARD DEPLOYMENT WINCH FAILS TO DEPLOY TOBC POST ANCHORAGE AFTER DOOR CLOSED AND IGNITION SWITCHED ON IGNITION OFF OPEN DOOR CHECK FUSES CLOSE DOOR 3 WINCH FAILS TO DEPLOY SELECTR REVERSE CHECK INERTIA SWITCH JOTE N THE UNLIKELY EVENT OF A TOTAL FAILURE OF THE SYSTEM ON BOTH SIDES OF THE VEHICLE RENEW THE ECU BOTH SEATBELTS STILL FAIL TO EPLOY CHECK PIN 2 ON PMHD IGNITION INPUT HIS SHOULD BE OV WITH IGNITION ON NOT HARNESS FAULT SEAT BELT WARNING ENSURE THAT MAGNET 18 PRESENT IN BUCKLE LIGHT ILLUMINATED END AND RECONNECT TO TRAVELLING TONGUE IF SEAT BELT WARNING LIGHT REMAINS ON DOCKING PROXIMITY SWITCH INOPERATIVE RENEW DOCKING PROXIMITY SWITCH WINCH DEPLOYS RENEW DRIVERS DOOR COURTESY SWITCH WINCH MOTOR THERMAL CUTOUT OPERATES WITH TRAVELLING TONGUE DOCKING PROXIMITY SWITCH INOPERATIVE DOCKED IN BC ANCHORAGE RENEWDOCKING PROXIMITY SWITCH INHIBITION RELAY CIRCUIT INOPERATIVE ENSURE LINEAR SWITCH GEAR SELECTOR IS CPERATIVE ADJUSTED CHECK REVERSE INHIBIT RELAY CONNECTIONS NOTE RH SYSTEM REARWARD DEPLOYMENT WILL OCCUR WHEN THE AH DOOR CLOS
204. d battery power is appliedto the hornsthrough the relay contacts 30018 HORNS RENEW 86 30 09 Open the bonnetand disconnectthe battery earth lead Removethe radiatorgrilles 76 55 07 Removethe screws securing the horn bracket 2 Disconnectthe electrical cables and removethe horns Fig2 Fitting new horns is the reversal of the removal procedure 30018 EXTERIOR LIGHTS DESCRPTION 86 40 00 All exterior lights are operated via relays within bulb fail modules These relays which are wire linked to suit the vehicle in which the module is installed are controlled via a lighting logic module which implementsfunctions selected on master fog and main dip beam lighting switches Circuits within the logic module perform the following control functions 86 26 ELECTRICALSYSTEM Headlight operation only when the ignition is switched is ON Initiate headlight operation in dip beam mode Select main dip beam switch mode of operation i e headlight flash or main dip beam select dependent on the position of the master lighting switch provide inputsto boththe CPU and the instrumentpack to facilitate headlamp wash and main beam indicator operation Headlight operation is by switching the master lighting switchto HEADLIGHTS This applies a logic earth to the lighting logic module which via B49 11 and 5 energises relays that route battery power t
205. d disconnectthe battery Open the door and remove the passengers side dash liner 76 45 15 Slacken the screws securing the relay front mounting panel Removethe screws securingthe mounting panel Displace the relay mounting panel and disengage the mounting panel slots from the slackend front screws Removethe relay Violet Reverse the removal procedureto refit the replacement relay 3001B BOOT RELEASE SWITCH RENEW 86 65 25 Openthe bonnetand disconnectthe battery Removethe passengerside dash liner 76 45 1 5 Open the glove box lid and removethe glovebox light lens Disconnect one connector from the lamp remove the lampand disconnectthe remainingconnector Disconnectthe boot switch harness multi plug and cut the ratchet strap securing the harnessto the gearbox Repositionthe hamess from the self adhesive clip tie a suitable draw string to the hamess Displace the switch from the mounting bracket and withdraw the harness draw string Detach the string from the harness and discard the switch Reverse the removal procedure to refit the replacement switch 30018 86 67 ELECTRICALSYSTEM HARNESSES DESCRIPTION 86 70 00 All connections between the various electrical devices are made through cable harnesses terminated by connectors of which there are two main types Positive Mate Mk4 PM4 which are cylindrical and contain up to 9 contacts and Positive Mate High Density PMHD which arerectangular and contain upto
206. d in in motion The LH front tyre will wear faster Issue 2 74 15 WHEELS AND TYRES ALIGNMENT PRECAUTIONS Wheels and tyres vary laterally within their manufacturing tolerances or as a result of service and alignment figures obtained without moving the car are unreliable The following precautions should therefore be observed 1 The car should have to restfrom a forward movement This ensures as far as possible thatthe wheels are in natural running positions 2 1115 preferable for alignment to be checked with the car laden 3 With a conventional base bar tyre alignment gauge measurements should be taken front of and behindthe wheel centres atthe same position onthetyre and rimflanges This is achieved by marking thetyres where the first readingistaken and movingthe car forwards approximately half a road wheel revolution before taking the second reading at the same points With an optical gauge two or three readings should be taken with the car moved forwards to different positions 180 road wheel turn for two readings and 120 for three readings An average figure should then be calculated TYRE AND WHEEL BALANCE Static Balance For smooth riding precise steering and the avoidance of high speed tramp or wheel hop alltyres are balance checkedto predetermined limits To ensure the best degree of tyre balance the covers are marked with white spots on one bead and these indicate the highest part of the c
207. d in place of JD 133 and the coil springs must be removed prior to crossmember removal operation 60 20 01 JD 133 is for operations where the crossmember is being removedfor access only Lowerthe vehicle andsettle the suspension Open the bonnet Engage the camber tie down bars in the suspension turrets Remove the front shock absorber upper securing nuts washersand buffers Fig 1 Slacken off the road wheel nuts 1 4 of aturn each Jack up the front of the vehicle Support with axle stands Mark the wheel to stud relationship and remove the front road wheels Disconnectthe left hand brake pad wear sensor block connector Remove the lower guide pin bolt from the left hand caliper and pivot the caliper upwards to gain access to the brake pads Fig 2 NOTE Use an open ended spanner to hold the guide pin during removal This will prevent damage to the rubber dust cover Removethe brake pads Remove the upper guide pin bolt remove the caliper and re position the caliper away from the suspension area Disconnect the right hand brake pad wear sensor block connector Removethe right hand brake pads and caliper Turn the steering to the straight ahead position Remove the ignition key Remove the lower column 3 Fig 3 to steering rack securing bolt nut 1 2 Fig3 457 186 76 18 BODY SECTION Disengagethe splines from the rack pinion 4 Fig page 18 NOTE At this point the lower column cannot be co
208. d remove the rear bumper assembly Removethe central plastic finisher 1 Fig 2 removethe centre blade rubber securing screws 2 Fig 2 and removethe rubber Remove the quarter bumper securing nuts and bolts 6 Fig 2 and removethe rear quarter bumper 10 Fig 2 76 47 BODY SECTION Remove the bumper cover blade retaining clip securing screws and remove the clips Reverse the removal procedure reassemble ensuring that any damged componentsare replaced Refitthe bumper assembly to the vehicle DATA TORQUE FIGURES Bumper frontblade tobeam5 7Nm Bumper mounting brackets to body Non Federal 23 27 Bumper mountingstruts to body Federal 23 27Nm Bumper side to flexible mounting block 5 Nm Bumper side blades to beam 5 7Nm Bumper to bumper bracket Non Federal 40 50Nm Bumper to body inner Federal 23 27Nm Bumper to fixings bumper beam Federal 39 50Nm Bumper tobody inner Non Federal 23 27 Bumper to fixings bumper beam Non Federal 39 50Nm Flexiblemounting block to beams 7Nm Guideblack to mounting bracket 3 5 4 75Nm Fig 1 Mounting bracket guide block to body 7 5 10Nm SPANNER SIZES 8mm 10 713mm 17mm 19mm No 20 Torx 0377b REAR QUARTER BUMPER RENEW 76 22 17 Openthe boot Move the rear boot carpet for access to the rear fog guard lamp hamess and position approximately 3 of hamess slack through the grommetfor each lamp Remove the beam securing bolts and spacers and ca
209. d removethe trim finisher 1 Fig 1 taking care notto dislodge the beam assembly from the struts Reversethe removal procedureto refitthe trim finisher DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27Nm Bumper to bumper bracket Non Federal 40 50Nm Bumperto bumper strut Federal 40 50 SPANNER SIZES 8mm 7 Omm 13mm 19mm 16698 78 EXTERIOR MIRROR RENEW 76 10 52 Openthe front door Remove the door trim pad veneer panel and the upper trim pad Removethe screws securing the mirror attachment plate and removethe plate Fig 2 Cutthe ratchetstrap securing the mirror harness Disconnectthe mirror hamess block connectors remove the mirror securing screws and remove the mirror assembly Reversethe removal procedureto refit 0003b 476 350 Fig 1 Fig2 76 52 BODY SECTION GUTTER FINISHER RENEW 76 43 11 Open the front and rear doors one side remove the four screws and remove the B post capping Remove the drip moulding securing screws 1 Fig 1 and remove the moulding to six light trim finisher and remove the drip moulding 2 Fig1 Fitthe replacementdrip moulding into position and align to the body fixing holes Fit andtighten the fixing screws Fitthe six lightto moulding finisher position and tighten the four screws Close the doors DATA TORQUE FIGURES Drip moulding to body 2 4Nm 0398b NUMBE
210. d tread condition is caused by wheel misalignment and results in very rapid tread wear Fig 2 18 on the inside edges of the pattern ribs Particularly on the nearside tyre indicate toe in Fins onthe outside edges particularly onthe offside 8 02 tyre indicate toe out Fig 2 Issue 2 74 17 WHEELS AND TYRES Camber Wear One shoulder more severely worn than the other Fig 1 This type of wear is accentuated by mechanical irregularities of steering or suspension or by high speed cornering Neglected Cut Damage through accidental cuts or penetrations will extend in use due to continued flexing and or ingress of moisture and road matter Irregular Wear Caused by mechanicalirregularity of the vehicle Fig 2 as for example worn bearings steering joints or badly adjusted brakes Age Deterioration Cracking and crazing of the tread and sidewall rubber sometimes accompanied by carcase deformation An indication that the tyres have been in service for a very long time Deflation Damage Breakdown of the tyre casing structure which can arise from under inflation overloading or runningona flat tyre Fig 3 Impact Fracture Resultant damage from impact fractures Fig 4 is not always visible externally and therefore as a safety precaution the tyre should be removed and examined a Casing fracture caused by severe localised impact through driving over kerbs hitting pot holes and or objec
211. dash liner Remove the screws securing the instrumentpack Removethe instrument pack 88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulb by reversing the removal procedure 3001B 86 47 ELECTRICALSYSTEM PARKING LAMP INDICATOR BULB RENEW 86 45 78 Open the bonnet and disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securing the instrumentpack Removethe instrument pack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulb by reversingthe removal procedure 30018 EXHAUSTTEMPERATURE WARNING INDICATOR BULB RENEW 86 45 80 Fig 1 Open the bonnet and disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securing the instrument pack Removethe instrumentpack 88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for access to the bulb Removethe bulb 1 Fig 1 from the holder Fita new bulb by reversing the removal procedure 30018 WIPE WASH WARNING INDICATOR BULB RENEW 86 45 86 Open the bonnetand disconnectthe battery earth lead Open the car door Remove the driver side dash liner Removethe screws securing the instrument
212. doorskin RH and LH 7 Bootfloor corner gusset RH and LH 16 Innersill RH andLH 8 TaillamppanelRH and LH 17 FrontdoorskinRH and LH 9 Taillamppanellowergusset RH and LH 18 SillfrontendcappingRH andLH Inner surface only Outer surface only Bothsurfaces Electro coat thickness 0 008mm on all treated surfaces 77 08 BODY REPAIR PLASTIC EXTERIOR TRIM Plastic materials are usedfor certain exterior trim components the locations of which are shown below 776 446 Fig 1 Headlamp surround RH and LH ABS painted Front bumper cladding E P DM Front grille inserts ABS chromed Frontspoiler Thermoplastic elastomer vistaflex 215B painted Door mirror shell RH and LH Polyamid nylon Bootlid lower moulding ABS painted Rear bumper cladding EPDM Sill moulding RH and LH Glass filled polyurethaneRRIM painted Frontwheelarch splashguardand baffle RH and LH HDPP polypropyleneco polymer PANEL REPLACEMENT W Po INTRODUCTION 77 10 00 The following informationis designedto explain the basic panel removal and replacementmethods The following panelreplacementoperations have beenstandardised andkept as simple as possible The mai rriteria removing and replacement of body panels is that the manufacturers original standard is maintained lor as possible Through experience gained over a period of time a standard method of removal andreplacement for welded pane
213. e Evaporator Hose Evaporator Pipe Evaporator Pipe Positionof Fixing Expansion Valve Lower port ExpansionValve Upper port Compressor Muffler Muffler Condenser Drier Bottle Drier bottle ExpansionValve Inner Lower Port Expansion Valve Inner Upper Port Nm 28 37 20 27 40 50 28 37 28 37 28 37 15 17 15 17 28 37 20 27 82 26 kgf m 2 85 3 78 2 04 2 76 4 08 5 09 2 85 3 78 2 85 3 78 2 85 3 78 1 53 1 73 1 53 1 73 2 85 3 78 2 04 2 76 82 00 00 Ibf ft 20 65 27 30 14 75 20 00 29 50 36 87 20 65 27 87 20 65 27 87 20 65 27 87 11 00 12 50 11 00 12 50 20 65 27 85 14 75 20 00 AIR CONDITIONING AIR CONDITIONING DEPRESSURIZING 82 30 05 Note Observe all safety precautions and do not smoke while carrying out the following procedures With the engineswitched off removethe protectivecaps from the schraeder valves Ensurethe manifold gauge set hand valves are in the closed position then by using the access valve core remover connect the manifold gauge set to the system with the red hoseto the high pressure side and the blue hose to the low pressure side Screw out the valve core to allow the refrigerant to flow Place the centre hose of the manifold set into a suitable container Slowly open the high or low side manifold hand valve and adjustthe valve for a smooth refrigerant flow Watch the refrigerantfor any signs of escaping oil and adjustthe hand valve to prevent any oil escaping If oil is l
214. e and at ambient temperatures below 30 C Connectatest lamp in series with the superheat switch Note With the test lamp connected in the circuit it will prevent the thermal fuse from operating as a safety device therefore great care must be taken when carrying outthe test Connect a manifold gauge set to the air conditioning system Ensure a serviceablethermal fuse is fitted With the ignition and the air conditioning switched on Depressurize and evacuate the air conditioning system then close the manifold hand valves see Fia2 The test lamp SHOULD NOT LIGHT during this 9 operation 186 200 82 33 AIR CONDITIONING NOTE If the test lamp does light then follow test procedure B Test procedureB With test lamp not illuminated connect the centre hose of the manifold gauge set to a refrigerant supply container Start and run the engine at about 2000 rev min After a few minutes the lamp should light As soon as the test lamp lights carefully operate the low pressure hand valve to allow refrigerant to charge the system As soon as the air conditioning system becomes chargedthe lamp should go out If the above lamp functions do not occurr renew the superheat switch After checking removethe test lamp from the circuit and reconnectthe switch lead onto the terminal Operate and check the air conditioning system SUPERHEAT SWITCH RENEW 82 10 08 Fig Openthe bonnet and disconnectthe battery earth
215. e batteryterminal post Removethe bolts securingthe battery clamp plate Removethe clamp plate Ensure the battery is kept in an upright position as it is being removed Fitting a new battery is the reversal of the above procedure Ensurethe terminals are clean andtight Connectthe positiveterminalthen connectthe negative terminal ensuring correct connection are made Ensurethe battery clamp is not overtightened 3001B BATTERY NEGATIVE LEAD RENEW 86 15 19 86 15 17 Note Should the positive lead only need renewing always disconnectthe negativeterminalfirst Displacethe cover from the negativeterminal and loosen the nut securing the terminal Removethe terminal from the battery terminal post Remove the nut securing the cable clamp and remove the clamp From beneath the vehicle remove the bolt securing the leadto the bell housing and removethe lead 86 20 ELECTRICALSYSTEM Displace the cover from the positiveterminal and loosen the nut securingthe terminal Removethe terminal from the batteryterminal post Repositionthe rubber boot cover from the body terminal stud remove the nut securing the lead to the stud and removethe lead Fitting the new leads is the reversal of the above procedure 30018 BATTERY POWER DISTRIBUTION 86 15 00 Fused and unfused battery power is distributedfrom the A post fuseblocks and terminal posts located behind the console on the right and left sides of the engine compartment
216. e condenser Test Conditions 1 Usea largefan to substitutefor normal ram air through the condenser 2 Engineadjustedto fast idle speed 3 All conditions equivalentto 30 mph or 48 kmh Ambient High Pressure Low pressure Evaporator Temp C Gauge Reading Gauge reading bf in2 Ibf in so 95 115 40 subs 16 105 125 RH 14 115 125 1 4 12 130 150 om 10 Py go 150 170 18 8 LL 165 185 20 6 Q2 175 195 22 5 SO neni 185 205 2 sisters 4 210 230 3 230 250 28 4 49 suu 250 270 30 0 46 265 285 35 2 280 310 40 5 45 9 50 11 55 14 60 17 19 TO 21 Normaloperating ambienttemperature rangeis 2410 434 Normaloperating evaporator temperaturerangeis 1210 0 C Under normal running conditions system pressure should be as follows Low side 1 05to 2 10 kgf cm 103 42to 206 84kN m 15to 30Ibf in High side 13 00to 14 40kgf cm2 1275 50to 1434 10 kN m2 185to 205 Ibf in2 82 19 AIR CONDITIONING FAULT FINDING WITH MANIFOLD GAUGE SET Refrigerant Slightly Low Complaint Little or no cooling Condition 1 The low side gauge reading is too low 2 The high side gauge readingistoo low A stream of bubbles evident inthe sight glass 4 The discharge air from the evaporator only slightly cool Diagnosis The system low o
217. e floor carpet Fig 1 Reverse the removal procedure to refit the replacement floor carpet DATA TORQUE FIGURES Clamp screw clamp to spare wheel13 16Nm 16698 BOOT FRONT LINER RENEW 76 19 31 Openthe boot Move the spare wheel access flap and remove the bolt securingthe spare wheel in position Liftoutthe spare wheel Removethe floor carpet n Releasethe tension from the vehiclejack and removethe 7 jack assembly 7 Removethe front liner Fig 2 Reverse the removal procedure to refit the replacement front liner DATA TORQUE FIGURES J76 425 Fig2 Clampscrew clampto spare wheel13 76Nm Jack to mounting bracket 7 14Nm 1669B 75 BOOT SIDE LINER LEFT HAND RENEW 76 19 22 Open the boot Move the spare wheel access flap and remove the bolt securingthe spare wheel in position Lift out the spare wheel Removethe floor carpet Release the tension from the vehicle jack and remove the jack assembly Removethe front liner Fig 3 176 2 03 76 68 BODY SECTION Remove the nuts securing the rear lamp assembly inner cover Remove the inner cover Remove the screw securing the upper portion of the side liner and removethe liner Reverse the removal procedure to refit the replacement side liner DATA TORQUE FIGURES Clampscrew clampto spare wheel13 16Nm Jack to mounting bracket 7 14Nm 16698 75 BOOT SIDE LINER RIGHT HAND RENEW 76 19 23 Openthe
218. e frequency of both visible and audible warning signals to 160 outputs per minute and initiates a DI bulb fail indication on the instrument pack through RB LB14 14 Operation of the hazard warning switch applies a logic earth via RB LB49 15 to the CPU which responds in a similar manner to that of the direction indicator function previously described 3001E 86 29 ELECTRICALSYSTEM FRONT FLASHER LAMP RENEW 86 40 39 Openthe bonnet anddisconnectthe battery earth lead Carefully displace the lamp assembly from its retaining Clips Disconnectthe multi plug cable connector and remove the lamp assembly Fitting a new lamp is the reversal of the removal precedure 30018 FRONT FLASHER LAMP LENS RENEW 86 40 40 Openthe bonnet and disconnect the battery earth lead Remove the screws 1 Fig 1 securing the flasher lamp lens and removethe lens 2 Fig 1 Fitting a new lens is the reversal of the removal procedure 30018 FRONT FLASHER LAMP BULB RENEW 86 40 41 Openthe bonnetand disconnectthe battery earth lead Remove the screws 1 Fig 2 securingthe flasher lamp lens 2 Fig 2 and removethe lens 3 Fig 2 Press turn and removethe bulb Fitting a new bulb is the reversal of the removal procedure 30018 486 470 Fig2 86 30 ELECTRICALSYSTEM FRONT REPEATER LAMPASSEMBLY RENEW 86 40 53 Openthe bonnetand disconnectthe battery earth lead Disconnect the repeater lamp cable harness multi plug con
219. e horn feed wires and removethe screw securingthe horn earthto the front bumper Removethe bumper assembly Cutthe ratchet strap securing the block connectorto the strut mounting bracket Removethe bolt securing the strut 1 Fig 1 and remove the strut assembly Securethe strut in a vice Removethe locknut securing the bracketto the strut Note the number of threads protruding from the bracket and removethe strut Reverse the removal procedure to refit the replacement strutto the vehicle Liftthe replacement bumper assembly into position and connectupthe horn feed and earth wires Align fit and tighten the two securing bolts ensuring that the two quarter bumpers are engaged in the wing sidefixings Refit the side marker lamps and front side lamp assemblies DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27Nm Bumper to bumper bracket Non Federal 40 50Nm Bumper to bumperstrut Federal 40 bONm Guideblock to mounting bracket 3 5 4 75 Horns to bracket22 28Nm Mounting bracket guide block to body 7 5 10 76 17 BODY SECTION DATA SPANNER SIZES 8mm I Omm 13mm 19mm No 20 Torx 16698 77 FRONT CROSSMEMBER RENEW 76 10 05 Jack upthe front of the vehicle Fit camber tie down bars Service Tool JD 133 to the road spring pans NOTE If for any reason the front crossmember is being stripped down Service Tool JD 115 must be use
220. e is observed to boil in one of the cells during the discharge period the battery can be considered unserviceable as shorting is taking place petween the cell separator plates Sulphation is a condition which occurs when a battery remainsin a discharged state for a period of time Itis not readily distinquishable from a battery which has been recently discharged Charging may or may not recover the battery but the test procedure will determine whether it is serviceable or not Specific Gravity Test The electrolyte consists of a mixture of sulphuric acid and water in given proportions The electrolyte becomes weaker as the cell discharges and this weakening effect is directly proportional to the amount of electricity given up by the cell Therefore the specific gravity of the electrolyte gives a direct indication ofthe condition ofthe battery When a tube of a hydrometer is inserted into the electrolyte and the rubber bulb is pressed and releaseda small quantity of electrolyte is drawn up into the hydrometer The specific gravity of the electrolyte determines the level of the float in the liquid With the float ina high position the specific gravity is high the specificgravity is lowthe float sinksto a lower position The specific gravity readings are taken when the liquid level crosses the scale on the float and this gives an accurateindication of the state of charge of the battery The volume of electrolyte and hence its specific gravit
221. e rear reading lamp clear of the headrest assembly disconnectthe feed wires and placethe lamp aside Cut the ratchet straps securing the lamp harness to the seat frame Remove the bolt Fig 2 securing the headrest and carefully pullthe headrestfrom its mounted position Remove the screws and the tree clips securing the housingto the headrest Displace the grommet from the feed wires headrest and removethe headrest Removethe housing Reverse the removal procedure to fit the replacement headrest 0071b 76 75 BODY SECTION FRONT SEAT RUNNERSAND ADJUSTER ASSEMBLY RENEW 76 70 24 Open the door Removethe front seat cushion 76 70 02 Front seat 76 70 01 Remove the seat belt buckle securing bolt cover and bolt Removethe buckle assembly Operate the runnerfor access to the rear securing screws Fig 1 and remove the screws securing the runner adjuster to the seat Removethe runner adjuster assembly and discard Reverse the removal procedure to refit the replacement runner adjuster DATA TORQUE FIGURES Seat runners to floor36 5Nim SPANNER SIZES No 50 Torx 0070b FRONT SEAT BELTADJUSTER RENEW 76 73 12 Ooen the doors Remove the B post upper trim pad ana remove the finisher plate Reposition the adjuster to gain access to the lower securing screw removethe screws Fig 2 Removethe adjuster and spacers Reverse removal procedure to refit the replacement adjuster 0076b REAR CENTRE SE
222. e test hose in the same manner by cracking open the low pressure side hand valve manifold gauge set for 3 to 5 seconds then close the hand valve Stabilizing The System The manifold gauge set is now attachedto the system and the test hoses purged of air With both hand valves closed the system must be operated for a few minutes to stabilize all pressures and temperatures throughout the system in orderto obtain accurate test gauge readings Proceedas follows 1 Place all test hoses gauge set and other equipment away from all engine moving parts Also keep the hoses from touching the hot engine manifold 2 Startthe engine and adjust engine speedto fast idle 3 onthe air conditioning and set for maximumcooling with blower fans on high speed 4 Openthe car doors and or windows to quickly eliminatecar interior heat 5 Operate the system under these conditions for 5 to 10 minutes the system will be stabilized and ready for testing 6 Checkthe systemfor full refrigerantby noting the sight glass indications Some refrigerantloss will occur over a period of time replacing this refrigerantloss will constitute much of the service requiredon the air conditioning system 82 17 AIR CONDITIONING Adding Refrigerant The air conditioning system must contain a full refrigerant charge before an accurate system check can be made An insufficient charge is indicatedinthe sight glass by a stream of bubbles or foam Connectthe manifoldtest set t
223. e the forward and reverse harness multi plugs from the securing clips Disconnectthe rnulti plugs Black Econoseal Removethe screw securing the rnulti plug clip Removethe retaining clip Repositionthe main hamess retaining clamp plate Removethe bolt nut securing the lower retaining plate Repositionthe plate for accessto the hamess Carefully cut the tape securing the seat entry hamess to the main harness Repositionthe seat entry harness under the seat Disconnectthe multi plug and discardthe hamess Reverse the removal procedure to refit the replacement harness 3001B BOOT LID RELEASE MOTOR RENEW 86 25 54 Openthe boot lid Removethe release motor securing bolts Repositionthe release motor from the boot lidfor access Disconnectthe motor harness motor multi plug Removethe motorfrom the link rod Remove the motor mounting securing screws and discardthe motor Reverse the removal procedure to fit a replacement motor 3001B 86 91 ELECTRICALSYSTEM COMBINATION SWITCH RENEW 86 65 55 Openthe door Releasethe steering column adjustment lever Positionthe column in its fully extended condition Lock the column inthis position with the lever Removethe steeringwheel 57 60 01 Remove the rheostat switch knob and remove the screws securingthe column lower nacelle Removethe lower nacelle Remove the screws securing the upper nacelle and removethe nacelle Remove the screws securing the left hand conne
224. ead grommet and discard Repeatthe procedure for the remainingcable Reverse the removal procedure to fit the replacement cables DATA SPANNER SIZES 8mm 10mm 1669B 72 BONNET LOCK RELEASE HANDLE RENEW 76 16 30 Open the bonnet Slacken the clamp bolt securing the cable to the lock actuator Repeatthe procedure for the other side Open the driving side door Removethe dash liner Disconnect the inner cables 1 Fig 2 from the bonnet release handle 2 Fig 2 Removethe bolts securing the bonnet release handle 3 Fig 2 to the body remove the cables from the handle and removefrom the vehicle Reverse the removal procedure to fit the replacement handle DATA TORQUE FIGURES Bonnet lock release handle to body 7 10Nm SPANNER SIZES 8mm 70mm 76 27 BODY SECTION BONNET HINGE NON FEDERAL RENEW 76 16 11 Remove the screw situated at the top securing the front grille and removethe grille Fig 1 Open the bonnet Securethe bonnet with asuitable support Remove the bonnet hinge securing nuts and bolts Fig 2 Removeand discardthe hinge Position the replacement hinge on the front panel locatingthe studs inthe holes Open the hinge and align with the securing holes inthe bonnet Fitandtighten the hingeto bonnet securing bolts Fit butdo notfully tighten the the hing securing nuts Remove the bonnet support and carefully lower the the bonnetto checkthe alignment open the bonnet slacken the
225. ead to premature tyre failure Tyres should therefore be periodically examined and any tyre having distortion cracks and or cuts should be replaced In addition all tread imbedded objects suchas stones and glass shouldbe withdrawn and all contamination i e oil and grease removed using a suitable solvent CAUTION Paraffin kerosene must not be used as a cleansing agent on tyres Heat Tyres should not be subjected to excessive heat such as that inherent of paint drying baking ovens It is recommended therefore that all wheels be removed or at least the tyres be relieved of vehicle body weight Repairs It is recommended that damaged tyres are renewed and not repaired in view of the high performance capability of the vehicle Valves When a new tubeless tyre is fitted the valve should be renewed Tyre Use After Vehicle Storage After along period of vehicle standing tyres may become locally distorted with a area This will cause an uneven ride for afew miles untilthe tyres have warmed up and the flat rounds off Issue 2 74 08 WHEELS AND TYRES WINTER SNOW TYRES Thetyres fitted as original equipment are designed with arubber mixture tread pattern and width specially suited for high speeds in normal road conditions but they are less suitable for winter conditions The use of winter tyres will considerably improve the vehicle s handling Winter tyres must be used in vehicle sets i e fitted on all four whe
226. ealwelds at 2 Fig 2 and 4 Fig2 are dressed and the new weatherseal retainer channel sections then trimmed to fit at 5 Fig 2 The sections are then plug welded into position 1 3 Fig 2 asthere is no accessfor aresistancespot welder atthese points Painting See Section 77 00 00 Associated Panel Replacerear door 77 20 03 Replace Parts Replace parts in reverseorder of removal Reconnect battery and alternator test those electrical items and mechanisms that have been removed and replaced 00556 Fig 2 77 18 BODY REPAIR REAR WING RENEW 77 25 02 Welding Table No Location Remove Factory Joint Replace Repair Joint 1 To rear panel 19resistancespot welds Single row of resistancespotwelds see notes ARO arms 264A or equivalent 1X mm Braze 2 _Torear panel lower corner 2 resistancespot welds 3 resistancespotwelds ARO arms 264A or equivalent 1 MIG plugweld Tobootfloor side extension 15 resistancespot welds Single row of resistancespot welds ARO arms 264A or equivalent 4 Towheelarch 35 resistancespot welds Single row of resistancespot welds see notes ARO arms 105010 ar equivalent 1X mm MIG seam weld 5 Todogleg andsill 30 resistancespot welds Single row of resistance spotwelds ARO arms 264A or equivalent 4 MIG plug welds 1X mm MIG seam weld 6 Torearscreenpanelandupper 24resistancespotwelds Single row of resistances
227. ease securing clip and remove liner Release steering column clamp fully extend steering wheel and re tighten clamp Remove instrument pack assembly securing screws Disconnectblock connectorsfrom rear of pack Displace and remove instrument pack assembly Remove instrument pack cowl housing screws and remove cowl housing Place pack face down on bench ensuring cowl lens is protectedwith a suitable cloth or similar NOTE To minimise risk of damage and contamination all repairs conducted on the Instrument Pack should be performedin a non static dust free environment Removethe electronics pack cover securing screws and removethe cover Carefully release the flexible printed circuit ribbon ends from the edge connectors by squeezeinggrips between thumb and forefinger while sliding out connector latch Fig 1 Release the electronics pack retaining clips Fig 2 and pivot the pack upwards Displace and remove the electronics pack from the instrumentpack by lifting off from hinges Displace and remove all warning bulbs bayonet fitting twist 1 8th turn anti clockwise to release fig 3 NOTE There are two different types of coloured bulb holders each type must be returned to the correct location Disconnectthe flexible printed circuit to LCD multi plug Fig4 DO NOT remove plug from the outer case of the Instrument Pack Removethe 7 veneer panelsecuring screws Fig 1 Page 88 11 carefully peeling backtop corners of
228. eat multi plug Securethe harnessto the floor transmission tunnel with the ratchetstraps Repositionthe rear footwell carpet Refitthe front seat cushions Refitthe console assembly Switch on the ignition and motor seats rearward Switch off the ignitionandclosethe doors 3001B POWERED SEAT HARNESS RENEW 86 70 11 Removethe front seat cushion 76 70 02 Positionthe seat fully forward Openthe bonnet and disconnectthe battery earth lead Reposition the rear footwell carpet and insulation for accessto the harnessconnection Removethe harnessto floor retainingcaps Removethe retaining plate Disconnect the seat hamess to link harness purple red and black multi plugs Removethe harnessto seat bracket securing screw Repositionthe harnessfrom the retain clip Reposition the harness multi plugs from the retaining clips Noteand disconnectthe multi plugs Note and disconnect the red and blue wires from the front riseandfall motor Note and disconnect the yellow and white wires from the rear rise andfall motor 86 82 ELECTRICALSYSTEM Cut and remove the rachet strap securing the seat belt cable to the seat frame Disconnect and remove the harness from the seat belt multi plug Fitting the new harness is thr reversal of the removal procedure 3001B INTERIOR READING LAMP LINK HARNESS SEAT RENEW 86 70 23 Open the front and rear doors Frontseat cushion renew 76 70 02 Front seat back finisher
229. eceives refrigerant from the expansion valve as a low pressure cold atomized liquid As this cold liquid refigerant passes through the evaporator coils heat will follow its natural tendency and move from the warm air intothe cooler refrigerant When the liquid refrigerant reaches a temperature and pressure that will induce a change of state a large quantity of heatwill movefrom the air intothe refrigerant andthe refrigerant will change from a low pressure cold atomized liquidto alow pressurecold vapour 483 Fig2 82 12 AIR CONDITIONING EXPANSION VALVE DESCRIPTION 82 00 00 The expansion valve is the dividing point between the high and low pressure sides of the system and automatically meters the high pressure high temperature liquid refrigerantthrough a small orifice controlled by a metering valve into the low pressure cold temperature side of the evaporator matrix The refrigerant must be controlled to obtain the maximum cooling while assuring complete evaporation of the liquid refrigerant within the evaporator To do this the valve senses the outlet pipe temperature the inlet pipe pressure and increases or decreases the flow of refrigerant liquid to maintainthe outlettemperature constant The expansion valve continually meters the exact amount of refrigerant required to supply some liquid refrigerant throughout the evaporator coil while ensuring that all of the refrigerant will be vapourized at the evaporator
230. ectthe door mirror multi plugs and removethe door harness Fitting a new harness is the reversal of the removal procedure 30016 PASSENGER DOOR HARNESS RENEW 86 70 08 Openthe bonnet and disconnectthe battery earth lead Open the drivers door Removethe veneertrim panel 76 47 11 Removethe upper door trim pad 76 34 02 Removethe lower door trim pad 76 34 03 Removethe postlower trim pad 76 13 30 Removedrivers side dash liner 76 46 11 Cut and remove the strap securing the door harness multi plug Removethe multi plug housing Cut and remove the strap securing the door harness to the lower door frame Fig 2 Disconnect the harness multi plugs LB RB 61 and LB RB 62 From inside the vehicle remove the A post inner blanking plug Manouvre the blak multi plugs into the vehicle from the A post aperture Disconnectthe multi plugs ae the door to A post protection sleeve into the oor Removethe hamess tie strap atthe door hinge Disconnect the door mirror multi plugs and remove the door harness Fitting a new harness is the reversal of the removal procedure 300 18 86 80 ELECTRICAL SYSTEM REAR DOOR HARNESS RENEW 86 70 47 Openthe bonnet and disconnectthe battery earth lead Openthe rear door Removethe veneer trim panel 76 47 12 Removethe upper door trim pad 76 34 05 Removethe lower door trim pad 76 34 06 Move and reclinethe front seatfully forward Turn and rele
231. ectthe ignition amplifier multi plug Connectthe earth lead underthe coil Fitandtighten the securing screw Fully seat coil to its mounting position the capacitor to the coil fit and tighten the securing screws Connect the LT leadsto to the HT coil Fit and tighten the securing nuts Connectthe black andthe yellow multi plugs Secure the multi plugs to the power brake hose with a rachet strap Connectthe king leadto the HT coil Reconnect the battery check the operation of all the relevent components and the engine performance 5520 di 7 is eX J86 6rQ 86 79 ELECTRICAL SYSTEM DRIVERS DOOR HARNESS RENEW 86 70 07 Openthe bonnet and disconnectthe battery earth lead Openthe drivers door Removethe veneertrim panel 76 47 11 Removethe upper doortrim pad 76 34 02 Removethe lower door trim pad 76 34 03 Removethe Apostlower trim pad 76 13 30 Removedrivers side dash liner 76 46 1 1 Cut and remove the strap securing the door hamess multi plug Removethe multi plug housing Cut and remove the strap securing the door hamess to the lower doorframe Fig 1 Disconnect the harness multi plugs LB RB 61 and LB RB 62 From inside the vehicle remove the A post inner blanking plug Manouvrethe blak multi plugs intothe vehicle from the Apost aperture Disconnectthe multi plugs m door to A post protection sleeve into the Fig 1 oor Removethe harnesstie strap atthe door hinge Disconn
232. ecuring the cable hamess Removethe seat belt switch pad Fig 2 Fitting a new switch is the reversal of the removal procedure 30018 SEAT BELT BUCKLE SWITCH RENEW 86 57 25 Openthe bonnetanddisconnectthe battery earth lead Openthe car door Removethe B post lower trim pad 76 13 29 Removethe seat belt upper anchor securing nut cover Removethe upper anchor securing nut Displacethe seat belt Removethe wavy washer and spacer Unclip the B post upper trim pad and displace the pad from its mounted position Repositionthe beltthrough the trim pad and removethe ad the B post aperture Repositionthe seat beltthrough the the B post Removethe nut securing the seat belt reel Removethe reel Disconnectthe cable hamess block connector Remove the seat belt buckle securing nut cover 1 Fig 3 Removethe bolt 2 Fig securing the seat belt buckle Removethe seat belt buckle Notethe position of and remove the buckle spacers Fitting a new assembly is the reversal of the removal procedure 3001B Fig2 86 66 ELECTRICALSYSTEM ILLUMINATED SUN VISOR BULB RENEW 86 45 95 Openthe bonnetand disconnectthe battery Openthe door Positionthe sunvisor downwards Liftthe sunvisor cover Remove the mirror illumination lens and remove the bulb Refitting a replacement bulb is the reversal of the removal procedure 30018 GEARBOX POWER RELAY RENEW 86 55 89 Openthe bonnetan
233. ed andseat heater wherefitted B2 Light 15A Left handfront door window lift and blue mirror motors if driver s door B3 Tan 5A Instrumentpack B4 Yellow 20 Sunroof B5 Light 15A Left handrear window lift andfuel filler blue flap interface B6 Tan 5A Left handfront lamps side side marker where fitted direction indicatorsand repeater B7 Light 15A Windscreenwiper blue B8 Light 15A Left hand main beam headlamp blue C1 Violet Spare position c2 Grey 2A Diagnostic memory automatic transmission XJ6 4 0 litre c3 Red 10A Main fuse automatictransmission XJ6 4 0 litre c4 Violet 3A Spare position c5 Violet 3A Left hand rear lamps tail number plate andside marker where fitted C6 Violet 3A Breather heater 7 Red 10A Left handdip beam headlamp left hand front fog lamp where fitted C8 Violet 3A Spare position NOTE Although not used positions marked need to have fuses presentto avoid a false fuse failure warning being displayed 86 104 ELECTRICAL SYSTEM CENTRE FUSE BOX Fuse Fuse Value Circuit No Colour Code Violet Lamp modules right hand rear and left hand front and alternator control 2 Violet 3A Lamp modules right hand front and left hand rear and radio illumination 3 Tan 5A Speed control where fitted Violet Ride levelling where fitted 5 Violet Cooling fan relay heatedwindscreen washer jets and
234. ederal 23 27Nm Bumper frontblade to beam 5 7 Bumperside blade to beam5 7Nm Bumper side to mounting 8 7Nm Bumper to bumper bracket Non Federal 40 50Nm Bumper to bumper strut Federal 40 50Nm Flexible mounting block to beam5 7Nm Guideblock to mounting bracket3 8 4 75Nm Horns to bracket22 28Nm Mounting bracketguide block to body 7 5 10Nm 378 37 amp SPANNER SIZES amm 7 Omm 73mm 79mm No 20 Torx 0392b FRONT BUMPER CENTRE BLADE RENEW 76 22 37 Removethe trim finisher from its locating lugs Remove the centre section securing screws 2 Fig 2 manoeuvre the blade 1 Fig 2 clear of its locating clips and removethe centresection 3 Fig2 Fitthe replacement bladeto the retainingclips and align the fixing holes fit and tighten the securing screws and refitthe finishertothe centre blade 76 16 BODY SECTION DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 2 Nm Bumper mounting struts to body Federal 23 27Nm Bumper to bumper bracket Non Federal 40 50Nm Bumper to bumper strut Federal 40 bONm Guide block to mounting bracket3 5 4 75bNm Horns to bracket22 28Nm Mounting bracketguide block to body 7 5 10Nm SPANNER SIZES amm Omm 13mm 19mm No 20 Torx 0386b FRONT ENERGY ABSORBING STRUT RENEW 76 22 31 Remove the side marker lamps and the front side lamp assemblies Removethe two bumper securing bolts pull the bumper forward disconnectth
235. eed 100 mph 160 km h Replacement tyres of different specifications and or tread pattern should not be fitted in mixed form 74 04 Issue 2 WHEELS AND TYRES SNOW TYRES North American Vehicles Type Size complete sets only Cold Inflation Pressure maximum speed 100mph 160km h Front Rear Cold Inflation Pressure maximum speed 120mph 190km h Front Rear Rest of the World ROW Vehicles Type Size complete sets only Cold Inflation Pressure maximum speed 100mph 160km h Front Rear Cold Inflation Pressure maximum speed 120mph 190km h Front Rear Note Snow chains may be fitted to rear wheels only Use Jaguar snow chains available from the Jaguar Pirelli M amp S Winter 190 215 65 R 15T 27 Ibf in2 1 90kgf cm 186kPa 1 86bar 30 Ibf in2 2 11kgf cm 2 207kPa 2 07bar 33 Ibf in2 2 32kgf cm 228kPa 2 28bar 36 Ibf in2 2 53kgf cm2 248kPa 2 48bar Dunlop TD SP 88 M amp S Tubeless 26 Ibf in 1 83kgf cm 2 179kPa 1 79bar 28 Ibf in2 1 97kgf cm2 193kPa 1 93bar 34 Ibf in2 2 39kgf cm2 235 2 35bar 34 Ibf in2 2 39kgf cm2 235kPa 2 35bar accessory range Champion 26 12 SM or Shur grip Maximum speed with snow chains 30mph 48km h Tyres may be fitted with studs provided maximum speed does not exceed 90mph 145km h Studs must be of the parallel shank type 10mm long 8mm in diameter single flange The use of studs is not permitted in cer
236. eel with the location peg onthe back of the wheel trim insertedinto the hole adjacent to the tyre valve Pushthe wheel trim firmly into position TEARDROP ALLOY WHEEL Size 7 x 15 Tyre Type Size Pirelli 225 65 VR 15 225 65 R 15 99 V Pirelli 205 70 VR 15 USA The Teardrop alloy wheel is standard fit forthe XJ6 Sovereign inall markets and an optionalfit forthe XJ6 in all markets except North America The alloy wheel is standard fit for the basic XJ6 inthe USA There are two types of wheel nut cover for the Teardrop alloy style wheels a perforated wheel nut cover and a flush wheel nut cover The wheel nut cover be removed using the screwdriver provided inthe vehicle toolbox or similar instrument To refitthe perforated style wheelnut cover alignthe holes with the wheel nuts then pushthe cover firmly into position onthe wheel To refittheflush style wheel nut cover push the cover firmly into position on the wheel The cast alloy road wheels are covered with a protective coating To preventcorrosion itis essential that this coating is not damaged To cleanthe wheels use warm soapy water stubborn stains can be removed using a soft brush or by using a proprietary alloy wheel cleaner When removing or fitting tyres only equipment utilizing spigot or stud hole clamping must be used The equipment must not have any moving parts which contact the wheel andtyre levers must not be used TEARDROP ALLOY WHEEL TD TYPE Size 189mm x
237. efrom the refrigerantwhich would be harmful tothe system if allowedto circulatewith the system Fig2 82 11 AIR CONDITIONING SIGHTGLASS DESCRIPTION 82 00 00 A sight glass Fig 1 is located on the output side of the quie drier bottle through which the refrigerantflows is usedto indicate the condition of the refrigerant charge A clear sight glass normally indicates the system has a correct charge of refrigerant It may also indicatethe system has N a complete lack of refrigerant this will be accompanied Z by a lack of any cooling action by the evaporator Also the system may be overcharged this must be verified with test gauge readings Foam or a constant stream of bubbles indicates the system does not contain sufficient refrigerant Occasional bubbles when the system is first started is normal Foam or a heavy stream of bubbles indicates the refrigerant is very low Oil streaks on the sight glass indicates a complete lack of refrigerant A cloudy sight glass indicates that the desiccant contained in the receiver drier has broken down and is being circulated Fia 1 sar ies throughthe system Ig EVAPORATOR DESCRIPTION 82 00 00 The evaporator Fig 2 consists of a refrigerant coil mounted in a series of thin fins to provide a maximum amount of heattransfer in a minimum amount of space It is mounted in a housing where warm air from the vehicle interior is blown acrossthe coils andfins The evaporator r
238. el 27 ou To replace the hubcap ensure that the rubber O ring type seal is correctly located around the diecast hubcap Position the hubcap on the wheel with the hook located in the slots adjacent to the tyre valve Fig 1 and ensure that the captivated screw is aligned with the threaded hole Pushthe hubcapinto position and secure with the captivated screw using the 6mm Allen key to tighten Replace the Allen key in the clip on the spare wheel mounting bracket after use The locking screw is part of the hubcap assembly and is held captive by a circlip Note The 6mrn Allen key to remove the hubcap locking screw is attached to the jack in the luggage compartment by means of a spring clip If the vehicle is supplied with a toolkit it is recommendedthat the key be kept in the toolkit for convenience 474 Fig 2 Issue 2 74 13 WHEELS AND TYRES Replacement hubcaps are supplied without the centre badge Two different types of centre badge are available fig 1 and must be correctly aligned before push fitting into the centre of the hubcap The cast alloy road wheels are covered with a protective coating To prevent corrosion it is essential that this coating is not damaged To clean the wheels use warm soapy water stubborn stains can be removed using a soft brush or by using a proprietary alloy wheel cleaner When removing or fitting tyres only equipment utilizing spigot or stud hole clamping must be
239. elds Singlerowof resistancespot welds ARO arms 264A or equivalent 3 Torearwingatside oftail lamp aperture RH and LH 11 resistancespot welds 2X mm brazes each side 11 MIG plugwelds 2X mm brazeseach side 4 TaillamppanelRH and LHto 10 resistancespotwelds each Singlerow of resistance spot welds rear panels at lower edge side each side ARO arms 242A or equivalent 5 Taillamp panelRH and LHto 8 resistancespotwelds each Single row of resistancespot welds rear panel at vertical gusset side eachside ARO arms 242A or equivalent 6 Rear panelto drain channel 5 resistancespot welds Single row of resistance spot welds RH and LH 1X1 00mm braze each side ARO arms 242A or equivalent 1X1 00m braze each side 7 Taillamppanelto corner gusset RH and LH 10 resistancespot welds 1X35mm MIG seamweld each side 10 MIG plugwelds 1X35mm MIG seam weld each side 8 Torearwingatdrain channel RH and LH 9 J Cormergussetto rear wing RH and LH 1X60mm MIG seam weld 1X60mm braze each side 5 resistancespotwelds each side 1X60mm MIG seam weld 1X60mm braze each side 5 MIG plugwelds eachside Disconnect battery and alternator Remove Spare wheel and jack boot mat petrol tank cover rear paneltrim section and carpet tail lamp cover RH and LH rear wing carpet section RH and LH tail lamp unit RH and LH Jack up vehicle and placeon axle stands Removeexhaustrear section RH and LH Panel Replacement Panel removal
240. els When fitted with winter tread tyres the vehicle should not be driven at speeds in excess of the tyre speed category symbol as moulded on the tyre SNOW CHAINS Snow chains may be fitted to rear wheels only Remove the snow chains immediately upon the road being clear of snow Maximum speed with snow chains fitted 30mph 48km h Tyres may be fitted with studs provided maximum speed does not exceed 90mph 145km h Studs must be of the paralleltype 1Omm long 8mm diameter single flange the use of studs isnot permitted in certain countries check local legislation Snow chains must only be used with the recommended winter tyres USA 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 Treadwear The treadwear grade is a comparative rating based on the wear rate of the tyre when tested under controlled conditions on a specified government test course For example atyre graded 150 would wear one and a half times less on the government course than a tyre graded 100 The relative performance of the tyres depends uponthe actual conditions of their use and may depart significantly from normal due to variations in driving habits service practices and differences in road characteristics and climate Traction A B C The tractions grades from highest to lowest are A B and C andthey
241. emaining removal procedureto assemblethe door 00516 FRONT DOOR OUTER HANDLE OPERATING ROD ADJUST 76 37 10 Removethe rear door trim panel veneer panel 76 47 1 1 Removethe door uppertrim pad 76 34 02 Removethe front door lowertrim pad 76 34 03 Removethe plastic moulding Reposition the plastic waether shield for access and remove the outer handle operating rod adjuster peg retaining peg and reposition the rod from the retaining clip Depress the latch lever until the release hammer just contacts the release peg reposition the operating rod into the retaining clip whilst still holding the latch lever down Fitandseatthe retainingclip peg andclosethe door Checkthe operationofthe lockand outer handle Openthe door Align and fit the plastic moulding and reverse the remaining removal procedureto assemblethe door 0051G 76 98 BODY SECTION INSTRUMENT PANEL VENEER PANEL RENEW 76 47 24 Disconnect the battery Remove the drivers side dash liner 76 46 1 1 Remove the instrument housing 88 20 13 Place Suitable protection on a bench and position the instrument panelface down onthe protection Release the retaining clips securing the rear half of the instrument pack and pivot down for access Remove the warning lamp bulbs adjacent to the instrument pack hingesfor accessto the screws Carefully reposition the flexible circuit board for access to the upper veneer panel securing screws Removethe upper screws securingthe
242. emoval procedure 30018 MAP LAMP BULB RENEW 86 45 09 Openthe bonnet and disconnectthe battery earth lead Openthe car door Releasethe roof console retainingcatch Fig 2 Lowerthe consolefor access Fig2 Releasethe map lamp contact and removethe bulb Fig 3 Fittingthe new bulb is reversal of the removal procedure 30018 Fig3 86 36 ELECTRICALSYSTEM 3 3 3 33 lt INTERIOR LAMP LENS RENEW 86 45 11 Open the car door turn and release the roof console retainingcatch Lowerthe consolefor access Releasethe catches retainingthe lens Displace and removethe lens Fita new lensinthe reverseorder 30018 INTERIOR LAMP BULB RENEW 86 45 12 Open the car door turn and release the roof console retaining catch Lowerthe consolefor access Releasethe spring contact to the bulb Displace and removethe bulb Fig 1 Fig 1 Fitting a new bulb is the reversal of the removal procedure 30018 INTERIOR LAMPASSEMBLY RENEW 86 45 13 Open the bonnet and disconnectthe battery earth lead Open the car door turn and release the roof console retaining catch Lowerthe panelfor access Disconnect the interior lamp cable harness multi plug connector Remove the panel catch retaining washer and remove the panel catch Displace the lamp assembly retaining spring clips and removethe assembly Fitting a new lamp is the reversal of the removal Procedure
243. emovethe cover of the A postaperture Withdraw and disconnect the door cable hamess block connectors Disconnect the cable harness block connector from the footwell fusebox Displacethe harness from the footwell Cutand removethe harness to bulkhead retainingstrap Undo the bolts securingthe steeringcolumn to bulkhead support bracket Displacethe bracket from the bulkhead Displacethe harnessfrom the bracket Disconnectthe brake switch block connector Displace the harness from the bracket Disconnectthe blower motor block connector Fig 1 Displacethe blowerto heater unittrunking for access Remove the nut securing the earth terminal and disconnectthe earth lead Displacethe hamess from the blower motor area Disconnectthe C P U cable hamess block connectors Remove the screw securing the C P U earth lead and disconnectthe earth lead Remove the hamess to bulkhead earth bolt and disconnectthe earth lead Remove the hamess to A post earth bolt and disconnect the earth lead Cut and removethe rachet straps securing the harnessto A post Removethe A postblanking plug Disconnectthe door harness block connectors Displace the relays from the footwell mounting Disconnect cable harness block connector from the footwell fuse block Displacethe harnessfromthe footwell Displacethe terminal postrubber boot Removethe nut securing the earth lead and remove the lead Removethe footwell vent from the heater unit R
244. emovethe gear lever surround finisher Fig 2 86 75 ELECTRICALSYSTEM Removethe consolefinisher 76 25 19 Remove the screws securing the console ashtray and displace the ashtray for access Disconnect the cigar lighter cable hamess block connector Removethe ashtray assembly Remove the centre console switch and clock module 86 80 13 Removethe console assembly 76 25 01 Align the cable hamess on the transmissiontunnel Displace the seat relay basesfrom their mountings Disconnect the gear selector cable hamess block connector Disconnect the gear linear switch cable harness block connector Removethe bolt securing the earth lead and disconnect the lead Cut and remove the rachet straps securing the cable harness to tunnel Peel back the carpet at the seat belt anchorages Disconnectthe seat belt cable hamess block connectors Remove both the front seat cushions76 70 02 Disconnect the seat heater and interior lamp cable harness block connectors Cut and removethe cable harness securing rachet straps Disconnect the handbrake switch cable harnes block connector Route the hamess from the tunnel area under the heater unit into the passenger footwell Remove the screws securing the central processor and disconnectthe earth lead Slacken the upper screw securing the processor displace and removethe processor Remove the bolts securing the processor mounting bracket and removethe bracket Disconnect the blower motor
245. emovethe screws securing the blower motor assembly Disconnectthe multi plug cable connectors Disconnect the vacuum hose from the blower motor assemblyservo unit Disconnectthe pliabletrunking from the air conditioning unit Displaceand removethe blower motor assembly Fig 1 Removethe rubber gasket from the assembly If the vehicle is left hand drive remove the screws securingthe ambienttemperature sensor and removethe sensor Fitting a new blower motor assembly is the reversal of the above procedure 0206G 82 39 AIR CONDITIONING SOLAR SENSOR RENEW 82 20 20 Open the bonnet and disconnectthe battery earth lead Carefully prise the solar sensor panel from the top of the fascia 1 Fig 1 Disconnectthe multi pin cable harness connector Removethe complete solar sensor assembly 2 Fig 1 Remove the spire clips 3 Fig 1 securing the sensor to the assembly and removethe sensor 4 Fig 1 Fitting a new sensor and spire clips is the reversal of the above procedure 0206G WATER VALVE RENEW 82 20 33 Open the bonnet and drain the engine coolant into a suitable container Disconnectthe water valve vacuum pipe 1 Fig 2 Loosen the heater hose securing clip and remove the hosefromthe heater matrix pipe 2 Fig 2 Repositionthe water valve for access Loosen the heater to water valve hose clip and remove the hose assembly Loosenthe water valve to cylinder head hose clip 3 Fig 2 and removethe water va
246. en the bonnetand disconnectthe battery earth lead Depressurizethe air conditioning system Removethe bolt securingthe muffler plate 1 Fig 1 Removethe muffler securing bolt 2 Fig 1 Removethe O ringseals and discard Fit protective caps to the disconnected hoses and a protection plateto the cornpressor Release the distributor cap retaining clips and displace 24 the cap with the HT leads over the engine 4 Loosenthe compressor drive belt trunnion securing bolt 1 Fig2 andthe adjusting rod pivot bolt 2 Fig2 4 From below slacken the compressor front 3 Fig 2 and rear pivot bolts 3 Fig 1 From above adjust the compressor towards the engine until the drive beltcan be removed s Removethe drive belt trunnion securing nut and bolt 1 182156 Fig 2 E Disconnectthe compressor clutch multi plug connector 2 4 Fig2 andthesuperheatswitch cable 4 Fig1 Remove the bolts securing the exhaust heat shield and removethe shield Remove the compressor rear pivot bolt and spacers 3 FigI Removethe compressor front pivot bolt 3 Fig 2 Carefully remove the compressor with the rear end upwardsto preventoil loss Remove the bolts securing the support brackets and removethe brackets Remove the bolt securing the adjuster rod and remove the rod When fitting the new compressor do not fully tighten the securing bolts until the drive belt is adjusted to the correct belttension of 3 3kg to give deflection of 4
247. en when the wheel alignment is correct In such cases itis better to make sure by checking with an alignment gauge Road camber affects the direction of the car by imposing a side thrust and ifleft to follow it s natural course the car will drifttowards it s nearside This is instinctively corrected by a steering towards the road centre and as a result the car runs crabwise as illustrated in an exaggerated form in Fig 1 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 The front wheels on a moving car 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 wheels the car is still out of line with its direction of movement butthere 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 car and tyre maintenance are satisfactory The more severe the average road camber the more marked this tendency will be Fig 2 shows the wheels toed out in motion The RH front tyre will wear faster Fig 3 shows the wheels toe
248. ene GOOD PRACTICE 82 00 00 82 15 AIR CONDITIONING SYSTEM cernens LEAK 82 30 09 82 18 AIR CONDITIONING SYSTEM vessssssssssssesssessesereseeeenere 82 30 04 82 17 AIR CONDITIONING 5 5 000 STABILIZING 82 30 00 82 17 AMBIENT TEMPERATURE SENSOR a RENEW x 82 20 02 82 38 BLOWER MOTOR LEFT HAND RENEW 82 25 13 82 39 BLOWER MOTOR RIGHT HAND RENEW 82 25 14 82 38 BLOWER MOTOR SPEED CONTROL DESCRIPTION 82 00 00 82 08 CENTRE VENT VACUUM SOLENOID RENEW 82 20 66 82 52 CHARGE VALVE CORE wesssesseseesercessseesessrsersecensererses RENEW 82 30 12 82 53 COMPRESSOR assesseesceesseeseeseeseeseeceeesenseensensaesesennes DESCRIPTION 82 00 00 82 10 COMPRESSOR sssesssescesseeseecereeeceeceeesenseeneeesenseseees RENEW 82 10 20 82 32 COMPRESSOR CLUTCH eene tnnt RENEW 82 10 08 82 55 COMPRESSOR CLUTCH CONTROL enne DESCRIPTION 82 00 00 82 08 COMPRESSOR DRIVE BELT eerte ADJUST 82 10 01 82 33 COMPRESSOR DRIVE BELT RENEW 82 10 02 82 33 COMPRESSOR OIL 82 00 00 82 54 COMPRESSOR SHAFT SEAL RENEW 82 10 11 82 59 CONDENSOR DESCRIPTION 82 00 00 82 11 RENEW 82 15 07 82 35 COOLANT TEMPERATURE SWITCH DESCRIPTION 82 00 00 82 07 DEFROST DEMIST VACUUM
249. ent Disconnectthe vacuum pipe from the servo Removethe spire clips Removethe servo Fig 1 Fitting a new ventilator flap servo is the reversal of the removal procedure 0209G DEMISTER FLAPSERVO RENEW 80 15 52 Disconnectthe battery earth lead Removethe driver and passengerside dash liners Removethe driver and passengerside closing panels Removethe steering wheel Remove the glove box lid and glove box Removethe fascia centre panel Removethe fascia centrevent outlet Removethe fascia boardand demister outlet duct Removethe screwssecuringthe demist vent Invert the fascia for access Disconnectthe vacuum pipe from the servo Removethe spire clips Removethe servo Fig 2 Fitting a new demister flap servo is the reversal of the removal procedure 02096 80 13 HEATING AND VENTILATION CENTREVENTVACUUM SOLENOID RENEW 80 10 47 Disconnectthe battery earth lead Removethe driversdash liner Removethe footwell outlet duct Displacethe cable hamess Remove the bolts securing the vacuum solenoid mounting plate Displacethe solenoid Fig 1 Note anddisconnectthe vacuum hoses Note disconnectthe supply cables removethe solenoid Fitting a new vacuum solenoid is the reversal of the removal procedure 0209G RE CIRCULATION VACUUM SOLENOID RENEW 80 10 48 Disconnectthe battery earth lead Removethe driver and passenger side dash liners Removethe c
250. ent pack by lifting off from hinges Carefully fit the new electronics pack over the printed circuit connectionsand locate into the hinges Pivotthe pack downwards andfit intothe securing clips Fitthe flexible printed circuitto the edge connectors by positioning holes in flexible printed circuit membrane over the connector latch locating pips and sliding latch tothefully closedposition Align and fit the back cover to the electronics pack Fit andtighten the securingscrews Fit the cowl housing to the pack Fit and tighten the cowl housing securing screws Fit the instrument pack assembly into dashboard position re connectthe block connectors Align the assembly fit andtighten the securing screws Return the steering wheel to its original position Refit the dash liner Reconnectthe battery NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored tothe correct value 298 078 Fig 1 z add C3 ATA Fig2 issue 2 88 13 INSTRUMENTS ETER TACHOMETER GAUGE RENEW 88 30 20 Disconnectthe battery Remove driver s side dash liner securing screws release securing clip and remove liner Release steering column clamp fully extend steering wheel andre tightenthe clamp Remove instrument pack assembly securing screws Disconnectblock connectorsfrom rear of pack Displaceand remove instrument pack
251. er Reverse the removal procedure to fit the replacement finisher 16698 74 REAR PARCELTRAY RENEW 76 67 06 Open the door Remove the seat cushion securing screws lift and remove the rear seat cushion Remove the screws securing the rear squab and lift the Squabto releasethe rear retainingclips Reposition the rear seat belts and remove the squab assembly fromthe vehicle Remove the staples and clips securing the rear armrest Cover and reposition the cover for accessto the armrest Securing bolts Remove the armrest hinge securing bolts and removethe Sauab securing brackets Reposition the squab and the armrest for access and displace the cover from the seat remove the armrest through the rear of the seat squab and removethe cover fromthe seat Remove the rear shelf securing screws 1 Fig 2 repositionthe rear seat belts wherefitted Removethe rear parceltray 2 Fig 2 Unclip and remove the air extractionventsfrom the tray Discardthe tray Reversethe removal procedureto refitthe tray 476371 16698 80 76 90 BODY SECTION REAR QUARTER UPPER TRIM PAD LEFT HAND RENEW 76 13 13 Open the door Remove the rear seat belt upper anchorage bolt cover and bolt Displacethe upper portion of the seat belt and collectthe emove the trim pad securing screw and coat hanger hook Slacken but do not remove the dowager strap securing screws Unclip the rear quarter trim pad Fig 1 and re
252. er pumptube 1 2 Fig 1 Placea suitable container in position Drainthe washer fliud intothe container Removethe bolt securing the pump clamp Remove the clamp andthe pump Removethe cover from the pump Fitting a new pump is the reversal of the removal procedure 0196G HEADLAMP WASHER PUMP RELAY RENEW 86 55 83 Openthe bonnetand disconnectthe battery earth lead Removethe relay cover 1 Fig 2 Locate and withdraw the relay from the red cable connector block 2 Fig 2 Fiting a new relay is the reversal of the removal procedure 0196G 84 9 ELECTRICAL SYSTEMS CONTENTS DESCRIPTION OPERATION OPERATION PAGE No No A B S EARTH LEAD 86 70 39 86 88 RENEW 86 10 02 86 15 ALTERNATOR DRIVE BELT RENEW amp ADJUST 86 10 03105 86 16 ALTERNATOR LOAD DUMP MODULE 86 10 06 86 16 ANTI LOCK BRAKE WARNING INDICATOR BULB 86 45 92 86 50 AUDIBLE WARNING 86 80 20 86 57 AVAILABLE TERMINATED CABLES DESCRIPTION 86 00 00 86 74 BAT TERY 2 cs RR DESCRIPTION 86 15 00 86 17 BATTERY MENT RENEW 86 15 01 86 20 BATTERY
253. es Discardthe veneer panel Reverse the removal procedure to fit the replacement veneer 004 1b FRONT DOOR LOWERT RIM PAD RENEW 76 34 03 Open the door Removethe front door trim pad veneer panel 76 47 11 Removethe front door uppertrim pad 76 34 02 Remove the lower trim pad securing screw remove the puddle lamp lens and remove the screw securing the lowertrim pad puddle lamp 76 36 BODY SECTION Displace the trim pad from the retaining clips and disconnectthe door hamess block connectors Removethe lowertrim pad assembly Removethe frontdoor armrest 76 34 22 Remove the door speaker securing nuts and remove the speaker Remove the door pocket to trim pad securing screws Fig 1 and remove the door pocket Remove the locating bracket securing screws and remove the bracket Discardthe trim pad Fit the locating bracket to the replacement trim and reversethe remaining procedureto refit the trim pad 00246 FRONT DOOR WAIST RAIL MOULDING RENEW 76 43 04 Openthe door Removethe front door trim pad veneer panel 76 47 1 1 Removethe front door upper trim pad 76 34 02 Fig 1 Removethe front door lowertrim pad 76 34 03 Carefully removethe mouldingfrom the front door Using a suitable block to prevent damage to the moulding carefully fit and seat the replacement mouldingto the door Reverse the remaining procedure to fit the replacement moulding 0033b FRONT DOOR LOCK STRIKER RENEW 76 37 23
254. ess Remove the clamp securing the receiver drier to expansionvalve pipe Undo the top pipe union nut and disconnect the pipe fromthe expansionvalve 1 Fig 1 Fit aprotectivecapto the pipe Undothe lower hose union nut and disconnectthe hose fromthe expansionvalve 2 Fig 1 Fita protectivecapto the hose Removethe O ringseals and discard Undothe union nuts on the evaporator stub pipes 3 Fig 1 Remove the expansion valve remove and discard the 282 169 O ring seals Fit protectivecapsto the evaporatorstub pipes Onfitting new expansionvalve ensure new O ringsare Fig 1 fitted Ensurethe union nuts aretightenedto the correct torque as detailed below Flush the system fit new receiver drier evacuate and rechargethe system DATA TORQUE FIGURES Evaporatorstub pipe union3 4UNC 20 27Nm Evaporatorstub pipe union 7 8UNC 28 37Nm 0206G 82 46 AIR CONDITIONING EVAPORATOR TO COMPRESSOR HOSE RENEW 82 25 02 NOTE It is essential that a second backing spanner is always used when loosening or tightening all hose joints This will rninirnisedistortion or strain on pipes Before renewing any hose or component ensure that suitable clean dry sealing plugs are to hand The protective sealing plugs or caps must remain on all replacement components until immediately before makingconnection The drier bottle must be renewed whenever the system has been opened Depressurizethe air conditioning system Ifthe
255. et and removethe bracket Displaceand remove the air conditioning unit Fig 1 Fig 1 82 50 AIR CONDITIONING With the unit face down on aworkbench cut and remove the cable hamess securing straps Remove the screws securing the evaporator temperature sensor and carefully removethe sensor Remove the right and left hand vacuum solenoid assemblies Removethe screws securing the earth lead and displace the leadfor access Remove the screws securing the heater matrix pipes guide plateand removethe plate amp Remove the clips securing the evaporator housing assembly and carefully remove the evaporator assembly Fig 1 Removethe foam padfrom the evaporator outlet pipes Removethe evaporator pipe bracket Remove the screws securing the evaporator to the casing and carefully removethe casing Cleanthe sealantfrom the casing Fitting new evaporator or a new heater cooler assembly isthe reversal of the above procedure Ensure all the electrical connections are clean andtight Ensure the union nuts on the air conditioning pipes are Fig 1 tightenedto the correcttorque Flush and fit a new receiver drier Evacuate and recharge the system Refillthe cooling systemwith coolant DEFROST DE MISTVACUUM SOLENOID RENEW 82 25 45 Openthe bonnetand disconnectthe battery earth lead Open the car door removethe right hand side dash liner andthe footwell outlet duct Removethe two screws securing the solenoid
256. ethe bulb Fitting a new lamp or bulb is the reversal of the removal procedure 3001B FOGLIGHTS DESCRIPTION 86 40 00 Fig 1 Rear foglamps and front if fitted are controlled via the lighting logic module and the bulb fail modules from switches which are located on the left hand side of the fascia switch panel The logic module which actuates relays inthe modules contains circuits which allow front foglamps if fitted to operate provided that the sidelamps are switched on or the rear foglamps to operate provided that side or headlamps are switched on With the rear orfront fog lampsswitched on a logic earth is connected to the lighting logic module which energises relays that route battery power through the bulbfail modulestothe respectivefoglarnpfilaments 30018 86 34 ELECTRICALSYSTEM REAR FOG LAMP BULB RENEW 86 41 20 Remove the screws Fig 1 securingthe lamp lens Removethe lens Removethe bulb Reversethe order to fit a new bulb or new lens 30018 REAR FOG LAMPASSEMBLY RENEW 86 41 15 Open the bonnet and disconnectthe battery earth lead Open the luggage Compartment Displacethe floor carpetforward Removethe rear lamp assembly interiortrim finisher Displacethe side liner for access us Displacethe rear linerfor access Fig 1 Cut and remove the rachet strap securing the fog lamp lead Disconnectthe cable harness block connector Displacethe foglamp from bumper
257. etting of the humidity controls When the switch with one teardrop is selected the evaporator temperature is controlled between 3 9 to 4 15 C When the switch with two teardrops is selected the evaporator temperature range is between 7 1 to 7 35 C If neither of the two humidity buttons are selected the evaporator temperature is controlled between O to 0 25 With the application of the econ button the compressor clutch is switched off and the compressor is disengaged rendering the air conditioning inoperative A second application of this button gives maximum air conditioning with the evaporator temperaturecontrolled between Oto 0 25 C The slide control Air Differential Control is usedto alterthe temperature of air being distributedthrough the face level vents To increasethe temperature of air being delivered through the vents the slide control is movedto the right andto decreasethe temperaturethe control is movedto the left O humidity J82 160 Fig 1 82 6 AIR CONDITIONING TEMPERATURE SENSORS DESCRIPTION 82 00 00 There are three temperature sensors fitted into the system the ambient temperature sensor the in car temperature sensor and the evaporator temperature sensor All three sensors are electrically identical but the evaporator temperature sensor is physically different and is not interchangeable with either the ambient or the in car temperature sensors An input voltage is supp
258. ews release securingclip and remove liner Release steering column clamp fully extend steering wheel and re tightenthe clamp 7 Remove instrument pack assembly securing screws 77 Disconnectblock connectorsfrom rear of pack 2 ips Displaceand remove the instrument pack assembly Lif Remove the instrument pack cowl housing screws and Me i removethe cowl housing 2 B Place pack face down on bench ensuring that cowl p lens is protected with a suitable cloth or similar yy 2 No NOTE To minimise the risk of damage and contamination all repairs conducted on the Instrument Pack should be performed in a non static dust free environment 078 Fig 1 Removethe electronics pack cover securing screws and remove the cover Carefully release the flexible printed circuit ribbon ends from the edge connectors squeezeing grips between thumb and forefinger while sliding out connector latch Fig 1 Release electronics pack retaining clips and pivot pack upwards Fig 2 Displace and remove electronics pack from instrument pack by lifting off from hinges Displace and remove all warning bulbs bayonetfitting twist 1 8th turn anti clockwiseto release Fig 3 NOTE There are two different types of coloured bulb holders each type must be returned to the correct location Disconnect flexible printed circuit to LCD multi plug Fig2 Fig 1 Page 88 17 DO NOT remo
259. ey are of equal length Close the bonnet 0394b BONNET STRIKER ASSEMBLY RENEW 76 16 24 Open the bonnet slacken the locknut 1 Fig 2 and unscrewthe striker 2 Fig2 Replaceany damagedcomponentsand reassemble A distance of 62 mm 1 Fig fromthe end of the striker to the locknut is an advisable length to set the assembly to priorto fitment to the vehicle Adjust the assembly until the bonnet is flush with the wing andthe bulkhead m Closethe bonnet 0388b BONNET LOCK RENEW 76 00 00 Open the bonnet and disconnect the lock operating cable 4 Fig 4 from the lock Removethe bolts securingthe lock 5 Fig 4 tothe body and removethe lock Reverse the removal procedureto refit the replacement lockensuring that priorto tightening the lock is aligned with the striker DATA TORQUE FIGURES Bonnetlock to body 7 5 10 25Nm SPANNER SIZES 8mm 10mm 16698 8 76 25 BODY SECTION BONNETGAS STRUT RENE 76 16 15 Openthe bonnet Fita suitable bonnet support Displace the upper strut pivot 1 Fig 1 from the pivot bolt Repeatfor the lower Removeand discard the strut 2 Fig 1 Reverse the removal procedure to refit the replacement strut 1669B 7 1 BONNET GAS STRUT VEHICLE SET RENEW 76 16 16 Open the bonnet Fita suitable bonnet support Displace the upper strut pivot 1 Fig 1 from the pivot bolt Repeatfor the lower Removeand discardthe strut 2 Fig 1 Repeatthe pro
260. g replace it by the following procedure Ensure replacementclean dry valve isto hand beforecommencingthe operation Depressurize the system with a schraeder valve removingtool removethe valvecore Fig 2 NOTE When fitting a new valve core ensure it is not f overtightened CAN Evacuateand rechargethe system y NS 0206G J2 179 82 53 AIR CONDITIONING COMPRESSOR OIL CHECK 82 00 00 Whenever a component has been replaced in the refrigerant system or there is an obvious oil leak the following proceduresshould be carried out 1 2 Determinethe angle the compressor is mounted Remove the oil filler plug look through the oil filler plug hole and rotate the clutch front plate to position the internal components as shown in Fig 1 Centrethe components as they are moving to the rear of the compressor the discharge stroke This is necessaryto allow the dipstick to penetrate fully Insertthe dipstick to its stop position stop is the angle near the top of the dipstick 3 fig 2 The point of the angle must betowards the enginewith the bottom surface of the angle flush with surface of the filler hole fig2 See chart below for correct oil level for the mounting angle of the compressor If the increment indication on the dipstick do not match the table add or subtract oil to the mid point value Refitthe oil filler plug checking that the O ring seal is not twisted Ensure O ring seal and the seat
261. g to expose the broken section in the wire and remake the connection by Fig2 installing an in line connectoras shown in Fig 2 185527 5 Electricallycheck the repairedwire to ensurethe repair is good and re cover the hamess using insulating tape SHORT CIRCUIT FAULTS Short circuit faults may be attributed to connector contamination or damaged wire insulation If no connectorcontaminationis evident proceed as follows 1 Locate the shorted wire using either the ATE or by performing a continuity check between the terminals of the hamess connectors 86 70 ELECTRICALSYSTEM 2 Examine the faulty harness covering for signs of physical damage i e chaffing and or cuts and both investigateand correctthe cause if damage is evident 3 Remove the hamess covering to expose the shorted section inthe wire andtape over the shorted section if minor insulation damage is the cause If insulation damage is extensive remove the damaged section and remake the connections by installing in line connectors Fig 1 4 Electricallycheckthe repaired wire to ensurethe repair is good and re cover the harness using insulating tape ELECTRICALREPAIRS This section providesinstruction inthe following repairs Typical Electrical Repairs Splicing Copper Wire N Splicing Aluminum Wire NV Splicing Twisted Shielded Cable 1 TYPICAL ELECTRICALREPAIRS Fig 1 J86 531 An open circuit is an incomplete circuit Power cannot reach the lo
262. ge crimps or flexible printed circuit If damage occurs or problemsarise due to loose crimp connections renew the flexible printed circuit Before fitting veneer panel carefully return all gauge needlesto STOP PIN position Align and fit the veneer panel and LCD module assembly Fitandtighten centresecuring screw Fitthe cowl lens assembly Fit and tighten the six remaining veneer panel securing Screws Fit and fully seat the warning bulbs ensuring the correct colour type x insertedatthe correct location the 8 white bulb holders are for gauge illumination the remaining 24 arefor warning indication only Connect the flexible printed circuit multi plug to the LCD unit Carefully fit the electronics pack over the flexible printed circuit connections and locate intothe hinges Pivotpack downwards andfit into securing clips Fit the flexible printed circuit to the edge connectors by positioning holes in flexible printed circuit membrane over the connector latch locating pips and sliding latch tothe fully closed position Align and fit the back cover to the electronics pack Fit andtighten the securing screws Fit the cowl housing to the pack Fit and tighten the cowl housing securing screws Fit the instrument pack assembly into dashboard position re connectthe block connectors Align the assembly fit and tighten the securing screws Return the steering wheel to its original position Refit the dash liner Reconnectthe ba
263. ghthand RENEW 86 40 07 Open the bonnet and disconnect the battery earth lead Removethe radiator grilles 76 55 07 Displacethe relaysfrom the mounting brackets Removethe headlampsecuring nuts Remove the lower securing bolt and remove the earth leadsfrom the bolt Reposition the headlamp forward and disconnect the multi plug cable connectorsthen remove the headlamp assembly Fitting a new headlamp assembly is the reversal of the removal procedure 3001B HEADLAMP LIGHT UNIT J86 468 RENEW 86 41 26 Openthe bonnet and disconnect the battery earth lead Remove the screws securing the radiator grille and removethe grille Loosenthe nuts securing the radiator grille surround and displace the surroundoutwards Remove the screws securing the headlamp rim finisher andremovethe finisher 1 Fig 1 Slackenthe light unit rim securingscrews 1 Fig2 Turn and removethe rim 2 Fig 2 Displacethe light unit Disconnect the block connector and remove the light unit Fittinga new unit isthe reversalto the above procedure 30018 86 28 ELECTRICALSYSTEM DIRECTION AND HAZARD INDICATION DESCRIPTION 86 40 00 The direction indicators are operational with the ignition on and movementof the direction indicator stalk located onthe left hand side of the steeringcolumn The indicators under CPU control operate at aflash rate of 80 per minute with a visible and audible warning in time with the indicator flash rate S
264. gic outputfrom pin 1 LB86 Output should be logic 0 1 Open drivers door Driversseatbelt will remain at B post 12 Openpassenger door Passengerseatbeltwill remain at B post 13 Close both doors Turn ignition off position 0 Seatbeltswill remain at B post 14 Reset inertiaswitch Seatbeltswill retractto A post 15 Turnignition on position2 Detachdrivers seatbeltfrom guide rail carrier Seatbelt warning will activate 16 Reconnectseatbeltto carrier Seatbelt warning will de activate 17 Endoftest 86 95 ELECTRICALSYSTEM PASSIVE RESTRAINT ECU LOGIC Truth tables have been providedfor information and to aid diagnostic work The following notes are also relevant 1 With ignition on position 2 and reverse gear selected the drivers door switch input is inhibited 2 The ECU must be capable of detectingan inertiaswitch operationwith ignition on AND off 3 The ECU must becapable of discriminatingbetween an inertia switch operation and ignition off 4 Where indicated thus logic input can be either logic 1 or logic 0 i e the output state described is not dependant upon that particular input This combinationof logiccan only occur underfault conditions SEATBELT WARNING TRUTHTABLE rud ace 7 skr2 Lee s ERR a SWITCH DOCK DOCK swircH PROX SWITCH 0 x x o tow HIGH LOW HIGH LOW HIGH HIGH HIGH L H CHANNEL PIN2 PIN
265. give full air conditioning Check that the recirculationflaps are open Press the ECON button and ensure the compressor clutch disengages the engine revs change and there is an audible click Press the ECON button and ensurethe compressor clutch re engages the engine revs change Switchthe left handcontrolto normalfan speed and check that the fan speed increases Switchthe left hand controlto highfan speed and check that the fan speed increases Switch the left handcontrolto defrost and check that all the air is to the windscreen and no air atthe footwell Switchthe left handcontrolto speed ensure that there is no air to the windscreen but air to the footwell Press the air button ensure that air is to the screen and at the footwell also ensure the air button light illuminates Pressthe air button ensurethat there is no air to the windscreen andthe button lightdoes not illuminate Switch the left hand control to normal fan speed check for very cold air from the centre vent and rear compartmentvent Turnthe right handcontrolto full heating Ensurethe engine is runningat normal operating temperature Ensure the centre vent closes there is warm air from side footwell and rear compartment vents Tumthe righthandcontrolto the minimumred position Ensure cool air bleedfrom the centre vent Turn the right handcontrolto the full cold position Ensurethe centrevent fully opens with cold air Se
266. go to the same PCBtrack on the clock BULB FAIL WARNING SYSTEM REAR BULB FAIL WARNING SYSTEM FRONT DESCRIPTION 86 00 00 New bulb fail modules are completely interchange able with the ones used at 90MY 86 1 12 ELECTRICAL SYSTEMS 91M Y IN CAR ENTERTAINMENT DESCRIPTION Changes are as follows 90 MY World Audio Clarion 3 door speakers 4 bass speakers Hirschmann aerial 86 00 00 91 MY AJ9100 Series Alpine 4 Co axial speakers 5 25 bass speakers CD autochanger option Hirschmann aerial Rewiring work will involve cutting and crimping to connect the 5 25 heelboard loudspeakers as purely bass speakers in parallel across each pair of door speakers for the standard four channel output All 91 MY cars will have a CD link lead taped to the left hand side harness one end is fitted to the Head Unit and the other end is clipped behindthe forward trim panelinthe bootto be connectedto the optional CD autochanger unit There is a new aerial lead taped to the right side harness The unit is now earthed by the earth braid only instead of the earth braid and connector 833 in pin 3 A splice is nowtaken from Radio relay Aux ve feed 87 to the accessory fusebox for radiotelephone use etc Battery ve and Aux feed in line fuses are now replaced by thermal cut out devices within the unit 86 113 INSTRUMENTS CONTENTS DESCRIPTION OPERATION AUTOMATIC TRANSMISSION UNIT LINEAR SWL
267. h for the motor beingthrough aerial down relay When the radio cassette player or the ignition is switched OFF the signal applied to the CPU is removed and a second timer is activated This timer energises the aerial down relay for a periodof 15 seconds after a delay of 10 seconds 3001B FRONT DOOR SPEAKER RENEW 86 50 13 Openthe bonnet anddisconnectthe battery earth lead Removethe veneer panel 76 47 1 1 Removethe uppertrim pad 76 34 02 Removethe lowertrim pad 76 34 03 Removethe armrest 76 34 22 Disconnectthe speaker rnulti plug connector Remove the nuts securing the speaker and Remove the speaker Fig 2 Fitting a new speaker is the reversal of the removal procedure 3001B 86 59 ELECTRICALSYSTEM REAR DOOR SPEAKER RENEW 86 50 14 Open the bonnet and disconnectthe battery earth lead Openthe car door Removethe veneer panel 76 47 12 Removethe upper trim pad76 34 05 Removethe lower trim pad 76 34 06 Remove rear door arm rest72 34 23 Disconnectthe speaker multi plug connector Remove the nuts securing the speaker and remove the speaker Fig 1 Fitting a new speaker is the reversal of the removal procedure 30018 ELECTRIC AERIAL RENEW 86 50 21 Openthe bonnet and disconnectthe battery earth lead Openthe luggage compartment Removethe floor carpet 76 19 30 Removethe front liner 76 19 31 Removethe right handside liner 76 19 23 Removethe bolt seciring the earth strap and disconnect
268. hamessto the suspensionassembly Displace and removethe hamess Fitting the new harness is the reversal the removal procedure 3001 Hai 186 605 86 84 ELECIHICALSYSIEN MANUAL TRANSMISSION SWITCH LINK HARNESS RENEW 86 70 19 Jack upthe vehicle and placeon 2 stands Reposition the link hamess from behind foam pad for access Note and disconnect the gearbox switch multi plugs red and yellow Econoseal red male to yellow female Yellow maleto black female Tie a suitabledraw string to the harness link lead Open the door Undo and removethe gear lever knob and locking nut Displace and remove the gear lever surround veneer panel Displacethe gearbox link hamess grommet Disconnect the link hamess multi plug green P M D H Reposition the harness draw string into the vehicle from the gearbox area Cutthe draw string from the hamess Placethe harness aside Fig 1 Position andtiethe new hamessto draw string Reposition the link hamess multi plug through the gearbox panel From below draw the hamess behind the gearbox pad into position Cutand removethe draw string Connectthe hamess multi plugs Repositionthe multi plugs behindthe foam Lowerthe vehicle from the stands Fitandfullyseatthe link hamess grommet Connectthe link hamess multi plug Fitandfully seatsurround veneer panel Fitandtighten the gear leverknob and lock nut Closethe door 3001B
269. he superheat switch and thermal fuse guards against a low refrigerant charge or blockages causing extreme superheated refrigerant vapour conditions resulting in compressor damage The thermal fuse is a sealed unit containing a heater and a meltable fuse The superheat switch is located the rear of the compressor in contact with the suction side refrigerant vapour With a low refrigerant charge or a blockage the pressure drops and the temperature rises This condition closes the superheat switch contacts which completes the thermal fuse heater circuit meltsthe fuse disconnects the battery supply to the compressor clutch winding and the thermal fuse heater The compressor ceases to operate and damagefrom insufficient lubrication will be avoided The thermal fuse melts at 157to 182 C Timetaken 2 0 minutes 5 5 minutes The heater resistance cold 8 to 10 ohms CAUTION After a thermal fuse melt establish and rectify the cause before replacing the thermal fuse unit complete 82 8 AIR CONDITIONING VACUUM SYSTEM DESCRIPTION 82 00 00 The vacuum supply to four solenoids Fig 1 in the system is from the engine manifold via a reservior and a non return valve The reservior is located under the battery The com ponents operated by the solenoids are 1 Defrost Demist flaps which are held closed by vacuum is identified by a green vacuumsupplytube 2 Recirculation Fresh air flaps which are held closed by vacuum is ide
270. he expansion valve shows signs of heavy sweating or frost Diagnosis The expansionvalve restrictingthe refrigerantflow J82 0878 Correction 1 Depressurizethe system Fig 1 2 Renewthe expansionvalve 3 Renewthe drier bottle 4 Evacuatethe system using a vacuum pump 5 Rechargethe systemwith new refrigerant 6 Operatethe systemand checkthe performance Restrictioninthe High PressureSide Complaint Cooling is not adequate Condition 1 The low side gauge readingis low 2 The high side gauge reading will build up to an excessively high reading 3 The discharge air only slightly cool 4 The high pressurure liquid hosefrom the drier bottle to the evaporator is cool to the touch or shows signs of heavy sweating or frost Diagnosis A restriction in the receiver drier or the high pressure liquid hose from the drier bottle results in the compressor removing refrigerant from the evaporator faster than it can enter This results in a starved evaporator Correction 1 Depressurizethe system 2 Renewthe drier bottle and or the high pressure liquid hosesor other defective parts 3 Evacuatethe system usinga vacuum pump 4 Rechargethe system with new refrigerant 5 Operatethe system and checkthe performance 82 25 AIR CONDITIONING AIR CONDITIONING HOSE CONNECTIONS TORQUE FIGURES Component Evaporator Hose Evaporator Hose Muffler Assembly Evaporator Hose Condenser Hose Muffler Hose Condenser Pip
271. he pulley and discardthe bearing refer to Placethe pulley on a bench and fit the bearing Place tool JD166 7 1 Fig 3 on the bearing and then using a soft face mallet drive the bearingfully home Remove tool JD166 7 from the pulley bearing assembly and fit the bearingto pulley snap ring Fit the pulley to the compressor Position tool JD 166 7 so that it abuts the inner race face of the bearing Using a soft face mallet drive the pulley bearing assembly fully home Fitthe pulley to compressor retaining snap ring Fitthe drive clutch referto 82 10 08 Fit the compressor to the vehicle Recharge the air conditioning refrigerant Remove the wing cover and close the bonnet System with 82 67 1 6 A 4 5 lt y L A 264 J82 264 Fig 3 AIR CONDITIONING SANDEN COMPRESSOR 709 M Jaz 282 COMPRESSOR FRONT OIL SEAL RENEW 82 10 11 Openthe bonnet and fit a wing cover Depressurize the air conditioning system refer to 82 30 05 Removethe compressor refer to 82 10 20 Remove the compressor drive clutch refer to 82 10 08 Remove the woodruff key felt seal and seal seat retaining snap ring from the compressor shaft Fit tool JD167 1 Fig 1 to the seal seat 2 Fig 1 ensurethatthe tangs of the tool engagethe groove of the seal seat Remove the seal seat from the compressor and detach the tool from the seal seat Removethe seal seat ring Fit tool JD168 1 Fig 2
272. he rim groove Should difficulty be experienced in securing location of the beads remove the valve core Re inflatethetyre replacingthe valve core when the beads of the tyre havelocatedagainstthe wheel flanges Check this by confirming that the tyre fitting line is concentric with the wheel flange Finally reset the tyre pressure to the recommended specification and remove any excess tyre lubricant TORQUE FIGURES Screw clamp to spare wheel 13 16Nm Jack to mounting bracket 7 14Nm Spare wheel fixing bracket to body 22 28Nm Valve to wheel 3 5 4 5Nm Wheel nut to wheel stud steel wheel 65 85Nm Wheel nut to wheel stud alloy wheel 88 102 Nm SPANNER SIZES 13mm 22mm 2000C 74 11 Issue 2 WHEELS AND TYRES WHEELS 91MY Standard Fit and Options STEEL WHEEL Size 7 x 15 Tyre Pirelli 225 65 VR 15 225 65 15 99 V 7405 91MY steel wheel is manufactured by Dunlop and incorporates one piece wheel trim wheel is held on with wheel nuts and the wheel trim clips over the top This differs from the 90MY steel wheel manufactured by Michelin which has the wheel trim held on by the wheel nuts and is of a different style The steel wheel is standard fit for the basic model XJ6 for all markets except USA The wheel trim can be removed using the screwdriver provided inthe vehicle toolbox as a lever or similar instrument To refitthe wheel trim positionthe wheel trim onthe wh
273. he seat cushion Reverse the removal procedure to refit the replacement seat cushion 0243b CUSHION COVER FRONTSEAT RENEW 76 70 14 Disconnect the electrical block connectors beneath the seat cushion remove the front securing screw and lift outthe cushion Remove all the clips Fig 1 securing the cushion cover in positionand removethe cover 76 74 BODY SECTION Place the replacement cushion cover in the approximate position over the seat frame and secure one side of the cover to the frame with the clips Tension the cover with hand pressure and secure the side oppositethat which is already clipped and repeat for the remainingtwo sides Ensurethat the clips are inthe position illustrated Fig 1 and fit the cushion back in the seat frame refit the fixing screw and reconnectthe electrical block connections 0390b FRONTSEAT CUSHION SUPPORT CENTRE RENEW 76 70 19 Disconnect the electrical block connectors below the rear of the seat cushion and liftoutthe cushion Turn the cushion over and using pliers or suitable implement release the support from the wire clips Place the replacement support in position and secure Fia1 with the wire clips 9 Fit the seat back in position in the front seat frame and reconnectthe electrical block connectors 039 1b FRONTSEAT HEADREST RENEW 76 70 30 Openthe door Removethe Frontseat cushion 76 70 02 Frontseat 76 70 01 Frontseat back finisher 76 70 03 Pullth
274. hinge securing nuts and position the bonnet as required Fullytighten the securing nuts Closethe bonnet and checkthe alignment Refitthe radiator grille and closethe bonnet DATA SPANNER SIZES 13mm 1669B 83 BONNET HINGE VEHICLE SET NON FEDERAL RENEW 76 16 12 Remove the two screws situated at the top securing each front grille and removethe grille Fig 1 Open the bonnet Securethe bonnet with a suitable support Remove the bonnet hinge securing nuts and bolts Fig Remove and discardthe hinge Position the replacement hinge on the front panel locating the studs inthe holes Open the hinge and align with the securing holes inthe bonnet Fit andtighten the hingeto bonnetsecuring bolts Fit butdo notfully tighten the the hingesecuring nuts Remove the bonnet support and carefully lower the the bonnetto checkthe alignment 76 28 BODY SECTION Open the bonnet slacken the hinge securing nuts and position the bonnetas required Fully tighten the securing nuts Close the bonnet and checkthe alignment Repeat the procedurefor the other hinge Refit the radiator grille and closethe bonnet DATA SPANNER SIZES 13mm 16698 83 BONNET HINGE FEDERAL RENEW 76 16 11 Remove the screw situated at the top securing the front grille and removethe grille Fig 1 Remove the two bolts each side securing the grille support bracketsto the body Remove the grille assembly and remove the grille support b
275. hould an indicator bulb fail the visible and audible warning frequency will increase to 160 per minute whilst the external flash frequency will remain at 80 per minute Cancelling is achieved automically by turning the steering wheel or moving the stalk in the opposite direction to that selected Hazardwarning is operationalwith the ignition switched off or on by depressing the hazard warning switch located on the left hand side of the steering column This will cause all the direction indicators the warning lamp in the switch and the audible warning to operate in unison Should an indicator bulb fail the visible and audble warning frequency will increaseto 160 per minute whilst the external flash frequency will remain at 80 per minute but only if the ignition isswitched ON Operation of the direction indicator stalk applies a logic earth to the CPU which energises relays within the relay bulb fail modules The relays are energised for periods of 1 5 seconds at 1 5 second intervals and both visible and audible warnings are in unison with the relay operation provided that the bulbs on the selected side are intact The visible warning signals are applied to the instrument pack and the audible warning signal is appliedto an audiblewarning module In the event of a bulb failure the associated lamp relay bulb fail module generates a DI bulb fail signal which is applied to the CPU On receivingthe DI bulb fail signal the CPU increases th
276. hrough the bulb fail modules to the dip beam filaments A signal is also applied to the CPU which permits headlamp wash operation Upward movement of the main dip beam stalk appliesa logic earth to the lighting logic module The logic module responds to this input as follows Energises through relays within the bulb fail modules which route battery power to the main beam filaments This occurs each time thestalk is operated with the master lighting switch set to OFF or SIDELIGHT Energises through either main or dip beam relays within Fig 1 the bulb fail modules which route battery power to the lamp assembly main or dip beam filaments Main and dip selection occurs on alternate stalk operations with the master lightingswitch setto HEADLIGHT Initiates main beam indicator illumination by applying a logic earth to the instrument pack each time the main beam relays are energised 3001B HEADLAMP ASSEMBLY Lefthand RENEW 86 40 06 Open the bonnet and disconnectthe battery earth lead Removethe radiator grilles 76 55 07 Remove the nuts and washers securing the rear of headlampassembly Remove the lower bolt securing the headlamp assembly and earth leads Removethe earth leadsfrom the bolt Disconnect the headlamp multi plug cable connectors and remove the headlamp assembly Fig 1 Fitting a new headlamp assembly is the reversal of the removal procedure 3001E 86 27 ELECTRICALSYSTEM HEADLAMP ASSEMBLY Ri
277. icle from the axle stands Settle the suspension Refit the shock absorber upper buffers washers and securing nuts Releasethe tie down bars from the suspension Raise the vehicle Remove the tie down bars from the road spring pans Lower the vehicle Bleedthe P A S system as follows Top upthe P A S reservoir Startthe engine Turn the steering wheel to full left hand lock Turn the steering wheel to full right hand lock Top upthe reservoir Fitthe reservoir cap Close the bonnet 76 20 BODY SECTION DATA SERVICETOOLS JD133 Tie down bars JD 124Rearlifting eye 2 9 ENGINE 18G 1465 Hear lifting eye 3 6ENGINE MS 53B Enginesupportbracket TORQUE FIGURES Caliperto carrier 31 40Nm Wheehut to wheelstud steel wheel 65 85 Wheelnut to wheelstud alloy wheel 88 102Nm Shock absorber to upper mounting 35 43Nm 5 feedpipe to rack 19 23Nm PAS returnpipe torack19 23Nm SPANNER SIZES 13mm 14mm 16mm 77mm Fig 1 19mm 22mm 15 16AF OILS GREASES SEALANTS 5 reservoir DEXRON 2D or TypeG M2C 33G 0051G FRONT QUARTER BUMPER RENEW 76 22 16 Removethe front beam 76 22 26 Remove the quarter bumper assembly to mounting rubber securing nuts 1 Fig 1 Removethe quarter bumper assembly Remove the reflector remove the quarter bumper blade securing nuts and bolts 2 Fig7 and removethe quarter bumper blade 3 Fig 1 Reverse the removal procedure to refit the replacement bumper
278. ide block to body 7 5 10Nm Bumper to fixings bumper beam 39 5ONm SPANNER SIZES amm 138mm 20 Torx RENEW 76 22 27 Openthe boot Removethe rear fog guard lamps Removethe rear beamsecuring bolts Fig 1 Removethe spacers Fig 1 Removethe beam assembly Removethe bladetrim finishers Removethe bladesecuring screws Removethe blade Removethe blade mounting brackets Removethe quarter bumper assemblies Remove the beam cover securing clips Remove the beam cover Fitthe beam cover to the replacementbeam Fitand seat the beam cover securing clips Refitthe quarter bumpers Refitthe bumper blade mounting brackets Refit the bumper blade fit and align the screws and finally tighten all the screws Refitthe bladetrim finisher Fitthe beam assembly to the mounting struts Fit andtightenthe beam assembly securing bolts Refitthe rear fog guard lamps Close the boot DATA TORQUE FIGURES Bumper blade to beam 5 7Nm Bumper mounting brackets to body Non Federal 23 27Nm Bumper to bumper bracket Non Federal 40 50 Bumper to bumper strut 40 Mounting bracketguide block to body 7 5 10Nm Bumper to fixings bumper beam 39 50Nm SPANNER SIZES 8mm 10mm 13mm No 20Torx 76 96 BODY SECTION REAR BLIND RENEW 76 10 19 Open both rear doors Removethe rear seat cushion 76 70 37 Removethe rear seat squab 76 70 38 Removethe rear parcel tra
279. ie bar securing nuts Ensure that the rear heater outlet and control are notdisturbed Removethe fascia tie bar securing nuts and move the tie bar away from the fascia Remove the passenger footwell duct and remove the screws securing the relay panel to the glove box and positionthe panel inthe footwell Remove the bolts securing the fascia outer body bracket to the fascia remove the fascia centre securing bolt access to this bolt is through the instrument housing apeture Remove the fascia outer lower securing bolts disconnect the trip computer and lighting module block connectors remove the screws securing the trip computer lighting module and remove the module from the fascia Manoeuvre the fascia rearwards for access disconnect the solar sensor block connector note the position and disconnect the vacuum hoses disconnectthe glove box lamp block connector and remove the fascia assembly Remove the screws securing the glovebox lid and remove the lid Remove the screws securing the glovebox lid striker remove the striker and collect the spacer 76 84 BODY SECTION Remove the glovebox inner and outer securing screws manoeuvre the glovebox from the fascia Fig 1 Remove the screws securing the glovebox frame and removethe frame Removethe frame upper spacing washers Disconnect and reposition the centre vacuum hose through the grommet Remove the screws securing the centre vent and remove the vent assembly Remove the sc
280. ing a Zipcutter or Roto Bor Fig 2 set to the correctdepth of cut At this point it may be necessary to cut out the bulk of the panel using a pneumatic saw Fig NOTE On some panels before removing bulk of panel with pneumatic saw brazes and MIG seam welds should be removed Separate spot welded joints and remove panel remnants using hammer bolster chisel and pincers Fig 4 u Aw C J77 ou 77 11 i e Sod cate 018 Fig 1 377 097 BODY REPAIR OLD SURFACES PREPARE 77 10 03 NOTE Inwheelarch areas it may be necessaryto remove underseal priorto exposing spot welds Usea solvent or hot knife DO NOT BURN THE SEALANT OFF During welding cutting ensure that a mask is worn and fume extraction equipmentis correctly positioned Removeweld nuggetswith a sander 36 grit disc Clean all flange edges to a bright smooth finish using a grinder if necessary Fig 1 Straighten existing panel joint edges with a Dollyblock and hammer NEWSURFACES PREPARE 77 10 04 Mark off the area of new panel and cut to size leaving Fig 1 approx 2 overlap overthe existing panel Offer up new panel section align with associated panels i e new rear wing alignedwith door boot lid tail gate Clamp into position Fig 2 Where necessary cut new and original panels to form a buttjoint Fig 3 Removeall clamps and new panel Preparenew paneljoint edgesfor weldi
281. ing of expanded foams will also liberate toxic fumes All kinds of nitrogen containing chemicals can be liberated as breakdown products these chemicals will contain isocyanates oxides of nitrogen and hydrogen cyanide Fumes and gases are produced by welding for examplea large volume of ozone gas is created when MIG welding They may be potentiallytoxic or asphyxiant causinga lack ofair by build upof gasin confined spaces PRECAUTIONS Operators engaged in accident repair work should wear face masks fresh air masks when carrying out such operations as sanding flatting body solder or fillers A mask and or fume extractor should be used when welding as well as wearing flameproof protective clothing Safety goggles should be worn when sanding drilling chiselling flatting or resistancespot welding or any other risk which may be identified bythe operator The Healthand Safety at Work Act 1974 places uponthe operator a responsibilityto co operate in reducingthe riskto health 77 04 BODY REPAIR ASBESTOS PRECAUTIONS In line with U K Government policy to reduce the use of asbestos JAGUAR CARS are progressively eliminating their use of this material in vehicle manufacture However body underseal asbestos embedded in black mastic material contains small amounts of permittedwhite asbestos Chrysotile WARNING IF IT IS NECESSARY TO REMOVE UNDERSEAL USE A SOLVENT OR HOT KNIFE DO NOT BURN OFF GENERAL REPAIR NOTES During repai
282. ing on the fuel devices of the Engine Managementsystem CAUTION Never reverse the battery terminal connections and always disconnect both terminals before battery charging or usingarc welding equipment onthe vehicle 3001B 86 13 ELECTRICALSYSTEM CONTROL SYSTEM DESCRIPTION 86 80 00 The Control System contains a Central Processing Unit CPU which processesdata on switched input lines to provide control c the following functions Directionand hazard indication Windscreen wash wipe Headlamp wash Interior lights Instrumentlights Seat heaters Wherefitted Rear backlight and door mirar heaters Centralised locking Aerial extend retract Audible warnings The CPU is of modular construction and is attached to the bulkhead onthe passengerside 86 14 ELECTRICALSYSTEM ALTERNATOR RENEW 86 10 02 3 KY es Open the bonnet and disconnectthe battery earth lead pc AT Remove the air cleaner elementfor access lt Undothe alternator link arm adjusting 1 Fig1 d Loosen but do not remove the alternator link arm trunnion bolt 2 Fig 1 Loosen the link arm pivot bolt and pivot the alternator towardsthe engine Removethe drive belt 3 Fig 1 fromthe alternator pulley gt Remove the trunnion bolt From beneaththe vehicle displace the rubber boots from the alternator cable connectors Note and disconnectthe cablesfrom the alternator Remove the alternator pivot nut
283. ing systems would contain an evaporator The front contains the heater matrix and is in two parts to enable the rotary flaps to be inserted Foot outlet boxes are moulded in plastic and are removable for access Air into the unit either passesthrough the heater matrix bypassesthe matrix completely or a combination of both to achieve the air temperature requiredabove ambient The system employstwo flaps that are driven to the required position determined by the control system by servo motors and gear box assemblies The motors rotate in either a clockwise or anti clockwise direction depending on the direction of current flow throughthe motor The flap positionsare monitored by feedback potentiometers located on the oppositeside of the heater caseto the servo motors which supplies a voltage signalto the control module indicating the flap position Fig2 Control Panel The switch control panel Fig 2 contains a blower motor control rotary switch auto manual modeswitch air switch ram switch temperaturedifferentialselector anda in car temperature selector The control panel produces digital outputs which are supplied to and used by the electronic control module Theairflow fromthe blower motorsis controlledbythe rotary switch locatedonthe left handside of the control panel Theswitch hasfive positions OFF LOW MED HIGH and DEFROST Inthe OFF positionthe system is notoperational Powerto the electronic control module
284. ings bumper beam Non Federal 39 50Nm Guideblock to mounting bracket 3 5 4 7BNm Mounting bracketguide block to body 7 5 10Nm SPANNER SIZES 8mm 10mm S 13mm J76 513 17mm 19mm Fig 1 No 20 Torx 0376b FRONT BEAM RENEW 76 22 26 Removethe front beamsecuring bolts Fig 1 Removethe spacers Displace the beam assembly for access to the lamp assembly block connectors Disconnectthe block connectors Fig 2 Removethe beam assembly Removethe bladetrim finishers Removethe blade securing screws Removethe blade N Removethe blade mounting brackets Removethe side lamp assemblies Removethe quarter bumper assemblies Removethe beam cover securingclips Removethe beam cover Fig2 f 276 510 Fitthe beam covertothe replacementbeam Fitand seat the beamcover securing clips Refitthe quarter bumpers Refitthe side lamp assemblies bumper blade mounting brackets Refit the bumper blade fit and align the screws and finally tighten allthe screws Refitthe bladetrim finisher Fitthe beam assembly to the mounting struts Reconnectthe block connectors Fitandtighten the beam assembly securing bolts 76 95 BODY SECTION DATA TORQUE FIGURES Bumper front blade to beam 5 7Nm Bumper mounting brackets to body Non Federal 23 27Nm Bumper to bumper bracket Non Federal 40 0Nm Bumper to bumperstrut Federal 40 50Nm Mounting bracketgu
285. ingto prevent coil movement Correctly locatethe field coil lead Supportthe compressor on the four mounting ears atthe 2 rear of the compressor If using a vice clamp mounting ears NOT ON THE COMPRESSOR BODY Align the rotor assembly squarely on the front housing hub Using the rotor installer set placethe ring part of the set into the bearing cavity Make certainthe outer edge rests firmly onthe rotor bearing outer race Placethe tool set driver intothe ring Fig 3 82 58 AIR CONDITIONING With a hammer tap the end of the driver while guiding the rotorto prevent binding Tap until the rotor bottoms against the compressor front housing hub Listen for a distinct change of sound during the tapping process Fig 1 2 Refit the internal bearing circlip using pinch type of circlip pliers Refit the external front housing circlip using spread type of circlip pliers Check that the original clutch shims are in place on the compressor shaft Replacethe compressorshaft key Align the front plateto compressor shaft key Usinga shaft protector tap the front plateto shaft it has bottomed to the clutch shims Note distinct change of sound Refit the shaft nut and torque to 23 30 ft lbf 3 4 4 2 kgf m Check the air gap with a 0 016 to 0 031 inchfeeler gauge Fig 2 If the gap is not consistant around the circumference lightly tap down atthe maximumgap and gently prise up atthe mini
286. irstto aid reassembly Reverse the removal procedure to refit the replacement strut NOTE Change only strutat once 0370b BOOT LIDSTRUT PIVOT BOLTS RENEW 76 00 00 Open the boot Remove the strut Fig 1 slacken and removethe upper pivot bolt Fig 1 collectthe spring washer Fig 1 Repeatthe operationfor the lower bolt Reversethe removal procedureto refitthe bolts Closethe boot lid DATA 0369b BOOT LID LOCK MECHANISM RENEW 76 19 25 Open the boot disconnect the operating rod from the remote linkage springclip Removethe two lock assembly securing bolts 2 Fig 2 remove the lock from the boot lid disconnect the multi plug 4 Fig 2 and remove the assembly from the vehicle Reversethe removal procedureto refit DATA TORQUE FIGURES Latch to boot lid 7 10Nm Lock to boot lid 5 7Nm 76 64 BODY SECTION DATA SPANNER SIZES 8mm 1 2 AF OILS SEALANTS LUBRICANTS Lock moving parts ValvoleneTectyl 4008 0371b BOOTLOCK RELEASE TRIGGER HANDLE RENEW 76 19 15 Removethe boot lock assembly removethe roll pin and remove the lever Fia 1 Refitthe replacement and reversethe removal procedure 9 0373b BOOT LOCK FINSIHER RENEW 76 43 31 Open the boot disconnect the number plate lamp connections and remove the lens assemblies Remove the two nuts 1 Fig 1 and plain washers securingthe finisher removethe finisher and gasket Glue the gasket 2 Fig 1 to the replacement finisher
287. isplacethe seat belt Removethe wavy washer and spacer Unclip the B post upper trim pad and displace the pad from its mounted position Reposition beltthrough trim pad and remove pad Removefinisher from the B post aperture Reposition seat beltthrough the B post Removenut securing seat belt reel Removethe reel Disconnectthe cable hamess block connector Remove the seat belt buckle securing nut cover 1 Fig 1 Remove bolt securingseat belt buckle 2 Fig 1 Removethe seat belt buckle 3 Fig 1 Note position of and removethe buckle spacers Fit new buckle assembly ensure that spacers are correctly located Fit and tighten the buckle securing bolt Fit the bolt cover Reconnectthe hamess Refitthe seat belt reel Fitandtighten the securing nut Locatethe seat beltthrough the B post Fitthe finisher Locate seat belt through the upper trim pad Fit the pad to position Fitthe seat belt upper anchor fit andtighten the securing bolt Refitthe post lowertrim pad Reconnectthe battery earth lead DATA TORQUE FIGURES Seat beltanchor bolts 27Nm SPANNER SIZES 17mm 04670 Issue 2 88 25 Fig 1 INSTRUMENTS WASHER RESERVOIR SENSOR RENEW 84 10 17 Open bonnet and disconnect battery earth lead Jack up front of vehicle and supporton two axle stands Remove nuts bolts screws and washers securing inner wing valance Displaceand remove inner wing valance Removebrake disc cooling duct Disconnect
288. ith panel bulk 16MIG plug welds side reinforcement 13 Rearwheelarch assyto boot 3 MIG plug welds 6 MIG plug welds floor crossmember Panel Replacement Panel removal and replacement isto the method detailed in Section 77 10 01 07 Sealingdiagramsare shown below Painting See Section 77 00 00 Replace Parts Replace partsin reverse order of removal Reconnect battery and alternator test those electrical itemsthat have been removed and replaced Bleedthe brakes 70 25 02 SEALING DIAGRAMS 77 33 HEATINGAND VENTILATION CONTENTS DESCRIPTION OPERATION AMBIENTTEMPERATURE RENEW BLOWER MOTOR ASSEMBLY DRIVER SIDE RENEW BLOWER MOTOR ASSEMBLY PASSENGER SSIDE RENEW BLOWER MOTOR ISOLATION RELAY DRIVER SIDE RENEW BLOWER MOTOR ISOLATION RELAY PASSENGER 506 RENEW BLOWER MOTOR HIGH SPEED RELAY RENEW BOOT VENTILATOR OUTLET RENEW CENTREFASCIA VENT FLAP SERVO RENEW CENTRE RENEW GENTREVENTILATOR rere ae tee eec RENEW CENTREVENTVACUUM SOLENOID RENEW
289. k Replace the aperture seal over the filler neck Repositionthe fuel tank filler neck rearwards to assist removal of filler housing solenoid assembly Move the filler housing front left hand corner upwards through the body aperture Fig 2 Reposition the fuel tank filler neck forwards Remove the filler housing assembly Note The fuel filler flap solenoid is an integral part of the filler housing assembly it cannot be replacedas adiscrete item the complete filler housing assembly must be replaced Remove and discard the filler housing gasket Fig 1 Clean the filler housing gasket faces Place the new filler aperture housingto front Remove the backing from the gasket Fitthe new gasketto the filler housing flange From inside the boot fit the filler housing to position the front left hand corner through the body aperture Reposition the fuel tank filler neck rearwards and fit the aperture seal over the filler neck Move the fuel tank filler neck and filler housing to align with the body aperture Fitandtighten the filler housing to the body securing bolts Fit and seat the aperture seal to the filler neck garter spring Connect the drain tubetothe aperture seal 3 Fig 1 Reposition and seat the drain tube to aperture seal securing clip 2Fig 1 Fitthe fuel filler cap Connect the filler housing solenoid harness block connector gt Secure the block connector to the harness with a ratchet strap
290. k Fit and tighten the cowl housing securing screws Fit the instrument pack assembly into dashboard position re connectthe block connectors Align the assembly fit and tighten the securing screws Return the steering wheel to its original position Refit the dash liner Reconnectthe battery NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored tothe correct value EX 488 06 Fig 2 188 065 03 2 INSTRUMENTS INSTRUMENT PACK LCD MODULE RENEW 88 20 23 Disconnectthe battery Remove driver s side dash liner securing screws release securing clip and remove liner Release steering column clamp fully extend steering wheel and re tightenthe clamp Remove Instrument Pack assembly securing screws Disconnectblock connectorsfrom rear of pack Displaceand remove Instrument Pack assembly Remove Instrument Pack cowl housing screws and cowl housing Place pack face down bench ensuring cowl lens is protected with a suitable cloth or similar gt ZA 7 7 1 078 NOTE To minimise risk of contamination and damage repairs to Instrument Pack should be performed in a non static dust free environment Avoid touching connector pins and pcb track components to minimise Fig 1 risk of static damage Remove electronics
291. k and oil the O ring in the high pressure hose 9 Fig 1 from the manifold of the charging station and connect itto the high pressure side ofthe system Check inlet valve 5 Fig 1 and vent valve 7 Fig 1 of the chargecylinder and are closed NOTE If the charge cylinder contains refrigerant close the outlet valve 4 Fig 1 Fully open the low pressure valve 1 Fig 1 the high pressurevalve 2 Fig 1 andthe vacuumvalve Fig 1 Switch the vacuum pump on note the low pressure gauge to make certain that a vacuum is being created in the system by the vacuum pump continue to operate until a vacuum of 13mmHg 17 50 mb obtained If this vacuum cannot be attained check the system for leaks From the time a vacuum of 13 mmHg 17 50 mb is attained run the vacuum pump for at least 6 minutes to besure complete evacuation has been attained Close both gauge hand valves switch off the vacuum 8 pump observethe low pressureside gauge reading The gauge reading should remain stationary at the point where the pump was switched off Should the gauge return towards zero a leak exists in the air conditioning Fig 1 system Ifthe gauge needle remains stationary for 3to 5 minutes close both manifold hand valves and disconnect the hosefrom the vacuum pump The air conditioning system is now ready for charging 182 162 82 29 AIR CONDITIONING AIR CONDITIONING CHARGING 82 30 08 Before attempting the charging operation the system
292. l Yellow Slate 0 5 D 166 841 6 Pink Slate 0 5 General Fail d 7 Pink 0 5 D I Fail Fig 1 8 Black Pink 0 5 Logic o 9 Green Brown 0 5 Reverse 10 Green Purple 05 stop PL 11 Red Green 0 5 Tail 5 1 Rea 12 Yellow 0 5 D I 1516 13 Red Black 0 5 Number Plate 14 Pink Blue 05 DisconnectEarth 6 am m roe Loop DGC 1200 15 5 2 CONNECTOR PM4 4 WAY PLUG Fig 2 er 1 Brown Lt Green 2 0 Number Plate Tail Side Marker USA Fig 2 CANADA ONLY 2 White Pink 0 5 Ignition 3 E ri 4 z _ 5 Brown Red 2 0 Reverse Stop D I REI i kogt 150 3 6 Pink Blue 0 5 Disconnect Earth Loop 6 CONNECTORECONOSEAL2 WAY SOCKET Fig 3 386843 1 E 2 Black 0 5 Earth 3 Red Black 05 Sidemarker USA Fig 3 CANADA ONLY CONNECTOR ECONOSEAL 3 WAY SOCKET Fig 4 Black 0 5 Earth Red Yellow 0 5 Fog 150 NOTE This connector has yellow self adhesive tape around 5 zu the body EYELETRWC 51100327 Fig 5 1 Black 0 5 Earth 2 Black 0 5 Earth NOTES 1 Cablelengthsindicatedondiagramsarefrombr koutp int to connector mating face 2 All module relays have a resistor diode protection network item 23 on wiring diagram Diode value 600V 1A 300 Resistorvalue 820hm0 28W fg 997 cO 3 Bulbratingsare shown on the module cover 186 842 4 CONTROL LOGIC FUNCTION USA AND CANADA Fig5 ONLY 1 Stopon D j off Both bulbs on 11 Stopoff D l on DI flash both bulbs on 111 5top D I on FlashD l both bulbs 86
293. l Refrigerant 12 is the only refrigerantthat can be used in the Sanden compressor Certain refrigerants such as methyl and chloride deteriorate aluminum Others are not compatible with the proper operating temperature and pressures Since many of the compressor parts are made of aluminum alloys exercise great care not to damage machinesurfaces Adhere to the torque specifications inserting cap screws to finger tight Then usea suitable torque wrench Compressor Oils Sunico No 5GS Texaco Capella E Virginia Chemicals 500 Viscosity TORQUE SPECIFICATIONS Donot exceed the upper limit item ft lbs Kg m Clutch retainingnut 25 30 3 4 4 2 Cylinder head cap screws 22 25 3 0 3 4 Service port O ring 9 12 1 2 1 7 Oilfiller plug 6 9 0 8 1 2 High pressure hose 18 22 2 5 3 0 Low pressure hose 22 25 3 0 3 4 Drive belt new 100 13 8 Drive belt after run in 80 90 11 125 Clutch wire clamp screw 26 46 22 38 Field coil cap screws 17 23 15 20 Chargevalve cap 48 68 40 60 Keyto lllustration er OORWON COONDOAAWND Service port Cylinder head Hose connection Anti rotation gear Oilfiller plug Planet plate Clutch bearing Electromatic clutch Valve plateassembly Oylinder amp valve plate gasket Oylinderblock Piston Cam rotor Needlethrust bearing Fronthousing amp O ring Shaft seal 82 10 16 382228 AIR CONDITIONING CONDENSER DESCRIPTION 82 00 00 The condenser Fig 1 consists
294. l deteriorate which will require a replacement The specified maximum leakage rate at each fitting is 0 5 kg of R12 in 40 years anda leak detector capable of operatingt o this accuracy must be provided To check placethe leak detector probe at the lowest point of eachjoint pausefor two seconds Donotwave the probeabout as refrigerantis heavierthan air andwillflow tothe lowest point If a leak is greaterthan 0 5kg inforty years is detected identify the leak point for rectification Check that the leaking fitting has been tightened to the correcttorque If the torque is low rectify and repeat leak test Ifthe torque is satisfactory depressurisethe system dismantlethe leaking connection and check the quality d the fitting Ifthe fitting is satisfactory clean and reassembleafter applying athin film of refrigerantto the seat of a flare fitting or a new oiled ringto ring fitting Tighten to the correcttorque Charge the system with 200g of R12 and leaktest the rectifiedsystem If the system is satisfactory depressurise evacuate and rechargethe system Ifthe system is unsatisfactory i e leakage greater than 0 5 kg in forty years depressurise and replacethe leaking assembly 82 18 AIR CONDITIONING pressureTemperature Relationship Note Pressures shown are under exact conditions see test conditions and are not necessarily true for every car Toros is given as the air surroundingthe condenser and is taken 5 cms infront of th
295. l hasbeen devised placing emphasis on ease of repair by eliminating unnecessary work The replacement details all the operationsthat may needto be carried outby an operator together with detailsof the tools used All repairsshould be carried outto a professionalstandard Providedthis standard Is maintained all r i Ned all repairs includin part panels will resultin the same standards of strength and operational safety being maintainedas that of a ne vehicle Reference should always be madeto the welding diagrams andtablesin the procedure Thecriteria should be that the repairs carried out should restore as near as possiblethe original standardof manufacture 77 09 BODY REPAIR ANTI THEFT LABELS ON REPLACEMENT PARTS Jaguar replacement Parts panels etc are suppliedto the USA in electrocoat primer fitted with anti theft labels CBC 4149 Fig 1 in specific locations A protective mask is used to prevent the label from being damaged or obscured by paintand rustproofing material The wording onthe protective mask is as follows TO COMPLY WITH U S FEDERALLAW REMOVE THIS AFTER PAINT HAS DRIED R DOT JAGUAR JHB 871 Fig 1 Thefollowing procedures precautions must be observedwith anti theft labels when fitting replacement parts to vehicles 1 The protective mask on the anti theft label must not be removed until all preparation painting and rustproofingwork has been carried out 2 Theprotectivemask must
296. l to its original position Refit the dash liner Reconnectthe battery NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored tothe correctvalue 286 011 Fig2 Issue 2 88 12 INSTRUMENTS INSTRUMENT ELECTRONICS PACK RENEW 88 20 22 Disconnectthe battery Remove driver s side dash liner securing screws release the securing clip and remove the liner Release the steering column clamp fully extend the steering wheel and re tightenthe clamp Removethe instrument pack assembly securing screws Disconnect block connectorsfrom rear of pack Displace and removethe instrument pack assembly Removethe instrument pack cowl housing screws and removethe cowl housing Place the pack face down on the bench ensuring that the case lens is protected with a suitable cloth or similar NOTE To minimise the risk of damage and contamination all repairs conducted on the Instrument Pack should be performed in a non static dust free environment Removethe electronics pack cover securing screws and removethe cover Carefully release the flexible printed circuit ribbon ends from the edge connectors by squeezeing grips between thumb and forefinger while sliding out connector latch Fig 1 Release the electronics pack retaining clips Fig 2 and pivotthe pack upwards Displace and remove the electronics pack from the instrum
297. lacethe steering colomn fully rearward Removethe screws securingthe instrument pack Displacethe instrument pack upwardsfor access Turn and removethe bulb holder Removethe bulbfrom the holder Fig 2 Fita new bulb by reversingthe removal procedure dos 496 Fig2 30018 9 86 40 ELECTRICALSYSTEM SPEEDOMETER ILLUMINATION BULB RENEW 86 45 49 Open the bonnet and disconnectthe battery earth lead Open the car door Remove the driver side dash liner Removethe screws securing the instrument pack Removethe instrument pack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulbby reversingthe removal procedure 30015 86 41 ELECTRICALSYSTEM TACHOMETER ILLUMINATION BULB RENEW 86 45 53 Open the bonnet anddisconnectthe battery earth lead Open the car door Remove the driver side dash liner Remove the screws securing the instrument pack Removethe instrumentpack 88 20 01 Releasethe electronicspack retaining clips Pivot the electronics pack upwards for access to the bulb Remove the bulbfrom the holder Fita new bulb by reversingthe removal procedure 3001B REAR COURTESY LAMP RENEW 86 46 03 _ ne Open the bonnetand disconnectthe battery earth lead Open the car door and carefully prisethe lamp assembly from the rear of the front seat head rest Note the position of the electrical suppl
298. lamp becoming a nuisance if the vehicle runs out of fuel Codes 26 and 44 will remain ononly untilthe next ignitionon off cycle Ifthe VOM function is used whilethe lamp is illuminated the code will be displayed After the next ignition on off cycle the code will no longer be available to the driver However the code is still in the ECU memory andcan be accessed by dealer personnel 2 Non USA Catalyst Specification Only the following fault codes will cause the check engine lampto illuminate 11 12 14 16 17 18 19 68 23 26 and 44 The lamp will not remain illuminated after the next ignition on off cycle 3 Non Catalyst Specification As Non USA Catalyst Specificationexceptthat codes 23 26 and44 are not active Issue 2 88 8 INSTRUMENTS CHECK ENGINE FAULT CODES FAULTCODE DESCRIPTION 11 Idle potor associated wiring 12 Air flow meter or associated wiring 14 Coolantthermistor or associated wiring 16 Air thermistor or associated wiring 17 Throttle pot or associated wiring 18 Throttle pot air flow meter calibration 19 Throttle pot airflow meter calibration 22 Fuel pumpdrive 23 Fuelsupply 24 Ignition drive 26 Air leak 29 ECUself check 33 Injector drive fault 34 Injectordrive and associated wiring 37 EGR drive 39 EGR check sensor 44 Lambda sensor or associated wiring 46 Idle speed control coil 1 drive 47 Idle speed control coil 2 drive 48 Idle speed control motor or valve 68 Road speed sen
299. lamp over the union and connect the rack to the carrier Tighten the rack securing nut and repeat the procedure for the secondside Manuallyslide the roof fully rearwards Position the rack tube into the guide close the clamp and align the mounting bracket fit andtighten the clamp securing screws Repeatthe procedurefor the secondside Position the rack tube end sections and secure the tubes with ratchetstraps and tape Position the rack tubes for fitting the motor manually close the roof ensure that the carriers are fully forward refit the roof motor and reverse the remaining removal Fig 1 procedure to refit 0092b SLIDING ROOF WIND DEFLECTOR RENEW 76 82 07 Open the door Open the sliding roof Remove the screws securing the wind deflector Fig 1 and remove the deflector assembly Remove and discard the deflector gaskets Placethe deflector to one side Reverse the removal procedure to refit the deflector ensuring that prior to tightening of the securing screws the sliding roof is carefully closedto check the alignment of the deflector 0082b WEATHER STRIP Fig2 RENEW 76 43 22 Remove the door upper trim pad and slide the weather strip 1 Fig 2 from the channel 2 Fig 2 Reversethe removal procedureto refit 0357b 76 61 BODY SECTION WEATHER STRIP CHANNEL RENEW 76 43 25 Removethe door upper trim pad Remove the heater vent plenum chamber securing screws and pullthe chamber clear
300. le trunking to the heater unit Displacethe pliabletrunking fromthe heater unit Removethe bolts securingthe motor assembly Disconnectthe cable harness multi plug Cut and remove rachet strap securing the brake switch cable harness Disconnectthe vacuum pipe from the servo Removethe blower assembly Fig 3 Removethe gasket and trunking from the blower motor assembly Secure the trunking and new gasket to the new blower motor assembly Smear the gasket with glue and fit the assembly in position Fit but do nottighten the securing bolts Connect the vacuum hoseto the servo Connect the cable harness multi plug connectors Connect and secure with retaining clip the trunking to the heater unit Tighten the blower motor securing bolts Refitthe dash liner 0208 80 9 HEATING AND VENTILATION BLOWER MOTOR ASSEMBLY PASSENGER SIDE RENEW 80 20 12 Disconnectthe battery earth lead Removethe passenger dash liner Removethe glove box lidand glove box Removethe lower screws securing the central processor Displacethe earth lead and removethe spacers Slackenthe upper screws securing the processor Raise the processorto disengagefrom the upper screws and place downwards Remove the screws and bolts securing the processor mounting bracket Removethe bracket Removethe bolts securing the blower motor assembly Disconnectthe cable harness multi plug connector Disconnect the in car sensor hose from the p
301. lead Depressurizethe air conditioning system Remove the bolt securing the muffler plate to the compressor 1 Fig 1 Remove the bolt securing the muffler body assembly to the compressor 2 Fig 1 Removeanddiscardthe O ring seals Fit protective caps to the compressorand hoses Disconnectthe superheat switch cable connector 3 Fig 1 With suitable circlip pliers remove the circlip retaining the superheatswitch and removethe switch On fitting new switch fit new O ring seals and receiver drier Ensure all hose union nuts are tightened to the correct torque Evacuateand rechargethe system 82 34 AIR CONDITIONING REAR AIR DISTRIBUTION BOX RENEW 82 10 33 Remove the centre console ashtray glove box and finisher Removethe fascia centre veneer panel and ventilator Removethe driver and passengersside dash liners Removethe screws securing the centre console Displacethe console rearward and upward Displace and remove the air box Fig 1 from the air tubes Fitting a new air distribution box is the reversal of the above procedure CONDENSER RENEW 82 15 07 Depressurizethe air conditioning system Removethe clips securing the fan cowl Remove the bolts securing the radiator cross member and remove the cross member complete with the mounting rubbers With the aid of a backing spanner undo the union nut and disconnect the compressor hose from the condenser Removeand discard the O ring seal
302. lect auto by pressingthe mode switch until AUTO is illuminated Tum the right handcontrolto the mid point position Runthe vehicle and allowthe system to stabilise Apply heatto the in carsensor using a lamp Ensurethe temperature drops atthe side vents andthe centre vent opens 02796 82 63 AIR CONDITIONING SANDEN COMPRESSOR 709 CONTENTS DESCRIPTION OPERATION OPERATION PAGE No No COMPRESSOR ASSEMBLY LESS CLUTCH SANDEN 500 and 700 SERIES RENEW 2 10 19 82 69 COMPRESSOR DRIVE CLUTCH RENEW 82 10 08 82 66 COMPRESSOR FRONT OIL SEAL RENEW 82 10 11 82 68 CO MPRESSOR PULLEY BEARING RENEW 82 10 10 82 67 GASKET rh og x ro rr nnn RENEW 82 10 26 82 71 HOSE COMPRESSOR TO EVAPORATOR RENEW 82 25 02 82 72 2 RENEW 82 10 24 82 70 FIELD COU Tm RENEW 82 10 25 82 71 VALVE PLATE RENEW 82 10 27 82 72 82 65 AIR CONDITIONING SANDEN COMPRESSOR 709 COMPRESSOR DRIVE CLUTCH RENEW 82 10 08 Open the bonnet and fit a wing cover Depressurize the air conditioning system refer to 82 30 05 Remove the bolt securing the muffler pl
303. lectrical connections To release the screen from the aperture cut through the Betaseal as follows CAUTION IF USING CHEESE WIRE FIRST REMOVE THE REAR QUARTER UPPER TRIM PADS AND PARCELSHELF Carefully pierce an access hole through the Betaseal at thetop of the A post Fita length of cheese wire through the hole Secure both ends of the cheese wire to asuitable pair of handles and carefully cutthe screenfrom the aperture NOTE Extra care must be taken when cutting Betaseal atthe screen corners Alternatively use a suitable vibro knife bonded glass remover DO NOT however use a hot knife which can cause distortion trim damage etc Fit and align lifting handlesto the screen Displace and removethe screen Removethe flange dam Removethe lifting handles and discardthe screen EE 276 492 77 23 BODY REPAIR Clean the aperture flange with a sharp blade taking care notto damage the paintwork NOTE A thin layer of sealant may be lefton the flange Clean the replacement screen edge and aperture flange with spiritwipe Apply glass primerto the screen Apply screen body primer to the flange Fit the flange dam note the flat side of the dam goes to the inside of the car Make two wooden support blocks 8mm thick Position the blocks onto the flange Apply a bead Betaseal to the screen edge Fig 1 Attach the lifting handles to the screen carefully fit and align the screen to the aperture using the w
304. led 9 since last reset TIME TAKEN elapsedtime since last reset TIME TO GO time to journey completion assuming the same average speed is maintained RANGE distance the vehicle can travel on the fuel remaining in the tank assuming that the average speed and fuel consumptionremain constant DISTTRAV distance travelled since last reset DIST TO GO distance to journey completion calculated from the distance travelled and the distance entered at journey commencement AV FUEL average fuel consumption since last reset FUEL USED quantity of fuel usedsince last reset INST FUEL instantaneousfuel consumption calculated over a two second period 86 52 ELECTRICALSYSTEM Trip computer functions can be divided into three categories i e time fuel and distance each category having three functions which are selected in the following sequence by multiple operation of TIME FUEL and DIST push buttons TIME Average speed Time taken and Timeto go FUEL Averagefuel Fuel used and Instantaneousfuel DIST Range Distancetravelled and Distanceto go Other controls on the trip computer keyboard are as follows MPH KPH a two position switch which permits the information presented to be displayed in either imperial or metric values CLEAR a push button which permits fault condition messages to be erased thus allowing trip computer information to be presented This facility is revoked when anotherfault condition occures VCM
305. liable trunking Disconnectthe vacuum pipe from the servo Remove the clip retaining the pliable trunking to the heater unit Displacethe pliabletrunking fromthe heater unit Removethe blower assembly Fig 1 Remove the gasket and trunking from the blower motor assembly Secure the trunking and new gasket to the new blower motor assembly Smear the gasket with glue and fit the assembly in position Fit but do nottighten the securing bolts Connectthe vacuum hoseto the servo Connectthe cable harness multi plug connectors Connectthe in car sensor to the trunking Connect and secure with retaining clip the trunking to the heater unit Tighten the blower motor securing bolts Fit the central processor in the reverse order of the removal procedure Fitthe dash liner 0209G x 280 05 BLOWER MOTOR ISOLATIONRELAY DRIVER SIDE RENEW 80 10 42 Disconnectthe battery earth lead Removethe drivers side dash liner Removethe blower motor assembly 80 20 11 09 With the blower motor assembly on a work bench disconnect the vacuum servo to flap link arm 1 Fig 2 Open the flap Displace the cable harnessfor access Removethe relay 2 Fig 2 Fitting a new relay is the reversal of the removal procedure 0209G 80 10 HEATING AND VENTILATION BLOWER MOTOR ISOLATION RELAY Passenger Side RENEW 80 10 41 Disconnectthe battery earth lead Removethe passenger dash liner Removethe glove box lid
306. liedto the sensors from pin 43 of the control module The temperature sensing signal from the sensors is then fed back into the control module via pin 34 for the ambient temperature pin 4 for the in car temperature sensor and pin 5 for the evaporator temperature sensor The sensors are semi conductor devices which are accurate over a wide range The semi conductor is similar to a zenor diode inas much as it allows current to flow in reverse bias but the current flow varies wth temperature The sensor assembly has a ED 6 built Genel is preset and must not be adjusted Fig 1 SOLAR SENSOR DESCRIPTION 82 00 00 A solar sensor Fig 1 is fitted to reduce the temperature demand by a maximum of 2 C in direct sunlight This has the effect of leaving the in car temperature stable whilst reducing air outlet temperatures to compensate for increased solar load This sensor is constructed round phototransistor whose sensing voltage will vary with the ambient light level An input of 5 volts is suppliedto the sensor from pin 43 of the control module The sensing voltage from the sensor is then fed back into the control modulevia pin 36 COOLANT TEMPERATURE SWITCH DESCRIPTION 82 00 00 18218 A water temperature switch Fig 2 is fitted o the lower Fig2 side of the heater matrix inlet pipe Its contacts are open at temperatures below 40 C this will prevent the fans from operating when heat is required until relative
307. linkage rod Remove the motor securing screws and remove the motor Discardthe lock assembly Reverse the removalprocedureto refitthe lock DATA TORQUE FIGURES 376 569 Door lock to door 7 10Nm SPANNER SIZES 8mm 70mm No30 Torx 0029b 76 35 BODY SECTION FRONT DOOR REMOTECONTROL OPERATING CABLE RENEW 76 37 67 Open the door Removethe front door trim padveneer panel 76 47 11 Removethe front door upper trim 76 34 02 Removethe front door lower trim pad 76 34 03 Removethe clip securing the inner cable to the door lock and disconnectthe cable from the lock assembly Removethe clip 2 Fig 1 securingthe outer cable 3 Fig 1 to the door lock assembly disconnect the cable from the bracket 4 Fig 1 andthe inner cable from the interior door handle securing sleeve Disconnectthe cable from the interior handle assembly removethe securing sleeve from fromthe cable Remove and discard the cable Reverse the removal procedure to refit the replacement cable 0031b 1 m FRONTDOORTRIM PADVENEER PANEL RENEW 76 47 11 Openthe door Position the inner door handle in the open position and remove the inner handle escutcheon plate blank 1 Fig 2 Remove the screw 2 Fig 2 securing the escutcheon plate 3 Fig 2 removethe plate and gasket Carefully pull the veneer panel 4 Fig 2 to release the retainingclips Remove the screws securing the retaining clip and removethe retainingclip assembli
308. ll functions Switchthe ignition OFF SEAT BELTWARNINGS Sit in the driving postion close the drivers door and turn the ignition to position the automatic diagonal seat belt should deploy to the restaining position rear dock The seat belt warning light located on the left handside of the fascia below the hazard warning switch andthe seat beltsymbol on the vehicle condition monitor display should be illuminated untilthe diagonal belt is located inthe restrainingposition Release the seat belt buckle from the travelling mechanism by operating the red PRESS button The seat belt warning light and VCM seat belt symbol should illuminate Re attach the seat belt buckleto the runner tongue assembly with the red PRESS buttonfacing inboard Switchthe ignition OFF to releasethe seat belt During these checks the audible warning continuous low pitched tone should operate for approximately six seconds when the driver s diagonal belt is not in the restaining position REVERSEGEARINHIBIT SWITCH Sit the driving position close the driver s door and turn the ignition key to position II the automatic diagonal seat belt should deployto the restraining position rear dock thus extinguishingthe seat beltwarning lights Select reverse gear position R and open the driver s door The diagonal belt should remain in the restraining position Ensuring that body or limbs are not in the path of the deploying seat belt disengage reverse gear The
309. ll times During tests both the high and low side hand valves are in a closed position turned inward untilthe valve is seated Refrigerant will flow around the valve stems to the gauges and register the system low and high pressures on the respective gauges The hand valves isolate the low and the high sides from the central portion of the manifold Low PressureSide Gauge This gauge has a dial reading from O to 150 Ibf in pressure scale in a clockwise direction and a 0 to 30 inches of mercury vacuum scale in counter clockwise direction This low pressure gauge is called a compound gauge it has a dual purpose which is to register both pressure and vacuum This gauge is usedto measurethe evaporator outlet pressure High PressureSide Gauge This gauge has a dail reading from O to 500 Ibf in2 ina clockwise direction and is a pressure gauge only 82 16 AIR CONDITIONING Connecting The Gauge Set A test hose connected the fitting directly under the low side gauge is used to connect the low side of the test manifoldinto the low side of the system anda similar connectionis found on the highside When connecting the gauge manifold set to the air conditioning system an access valve core removing tool 5 availablefor connecting the test hoses to the high and low sides of the system By using the valve removing tool it will enable the valve core to be removed and held back inside the tool eliminating restrictionsthereby providing
310. lock 2 Fig 3 fit and tighten the securing bolts in the sequence shown in Fig 4 Fit new O ring seals inthe compressor outlet port position the outlet port blanking plate and fit and tighten the securing bolt Refit the compressor refer to 82 10 20 Recharge the air conditioning system refer to 82 30 08 DATA TORQUE FIGURES Cylinder head bolts 29 83 to 33 9Nm 282 292 82 71 AIR CONDITIONING SANDEN COMPRESSOR 709 VALVE PLATE RENEW 82 10 27 Open the bonnet and fit a wing cover Depressurize the air conditioning system refer to 82 30 05 Remove the compressor refer to 82 10 20 Position the compressor in a vice tighten the vice onto the compressor body lugs Remove the outlet port blanking plate securing bolt and detach the plate Removethe O ring seals from the compressor outlet port Remove the cylinder head securing bolts and detach the cylinder head 1 Fig 1 from the cylinder block Remove valve plate 2Fig 1 from the compressor Remove all traces of gasket material from the mating surfaces of the cylinder head and compressor Apply clean refrigerant oil to the gaskets and then position them on the valve plate Position valve plate and gaskets 1and 3 Fig 2 onthe compressor and fit the cylinder head Tighten the cylinder head securing bolts inthe order shown in Fig 3 Fit new O rings to the outlet port blanking plate position the plate on the compressor and fit and tighten the securing
311. lti plug to the power brake hose Disconnectthe multi plug 1 Fig 1 Disconnectthe ignition amplifier multi plug Disconnect the distributorto HT coil king lead Displace the rubber boot from the HT coil LT connectors Disconnectthe LT leadsfrom the HT coil Remove the bolts securing the Ht coil and displace the coil Disconnectthe earth leadfrom the coil Bee 5 Remove the screw securing the earth lead to the crush tube Cut and remove strap securing the crankshaft sensor hamessto the engine hamess Disconnectthe multi plug connector Cut and remove the strap securing harnessto the cam shaft cover Disconnectthe water temperaturesensor Fig 2 Remove the front nut securing the harness support bracket and disconnect the earth lead Removethe strap securing the harnessto the manifold Remove the strap securing the supplementary air valve multi plug Disconnectthe supplementaryair valve multi plug Disconnectthe throttle potentiometermulti plug Remove the nut securing the air flow meter earth lead and disconnectthe lead Disconnectthe air flow meter multi plug connector Routethe hamess under the air flow meter Remove the air pump relay multi plug rachet strap Disconnectthe multi plug Displacethe hamess over the engine Slacken the engine breather pipe to cam cover securing clip Disconnectthe breather pipe Remove the strap securing the breather heater multi plug lead Routethe harnessto the engine Cut and rem
312. lve assembly 4 Fig 2 Fitthe new water valve assembly in the reverse order to the above procedure Refil the engine with coolant J80 036 Fig2 82 40 AIR CONDITIONING VENTILATOR OUTLETS Right or left hand RENEW 82 20 39 82 20 40 Openthe car door Carefully prise the appropriate ventilator outlet direction vent from the housing Release the housing retaining clips and remove the ventilator from the fascia Fig 1 To fitthe new ventilator reversethe above procedure 0206G VENTILATOR CENTRE FLAP SERVO RENEW 82 20 41 Openthe bonnet anddisconnectthe battery earth lead Openthe car door and removethe steering wheel Fig 1 Removethe dash liners Removethe screws securingthe instrument pack Disconnect the instrument pack cable harness multi plug connectors and removethe packassembly Removethe glove box Remove the centre fascia veneer panel and the centre ventilator Removethe fascia board assembly Disconnect the vacuum hose from the solenoid and repositionthe vent assemblyfrom the fascia assembly Removethe spire clips and rubber sealing strips Removethe servo Fig 2 and placeaside Reversethe above procedurewhen fitting the new servo 02066 180 045 0 2 82 41 AIR CONDITIONING DEMISTER FLAPSERVO RENEW 82 20 42 Open the bonnetand disconnectthe battery earth lead Open the car door and removethe steering wheel Removethe screws securing the dash liners and remove
313. ly damaged Also take care notto scratch or damage the gauge faces ensure cleanliness when handling the pack Displace and remove the veneer panel The LCD module 5 attachedto the veneer panel but with caution may be removedas a complete assembly CAREFULLY remove speedometer tachometer gauge set gently easing the piris out of the printed circuit crimps Fig 1 Page 88 15 To prevent widening crimp connections gauge pairs should be kept square to the Instrument Pack moulding whilst removing Issue 2 88 14 gt S LE 186 078 Fig 1 Fig2 INSTRUMENTS NOTE Individual gauge movements CAN NOT be serviced pointers and can location screws should not be removed Align and fit new speedometer tachometer gauge set to the instrument pack Fig 2 Take care not to damage the gauge needles CAREFULLY push the gauge pins through the flexible printed circuit DO NOT press down on the crimps distortion may occur Press down on the flat tangs set at right angles to the crimps as shown in Fig 3 NOTE Take care not to damage crimps or flexible printed circuit If damage occurs or problems arise due to loose crimp connections renew the flexible printed circuit OO AP Before fitting veneer panel carefully return all gauge needlesto STOP PIN position Align andfit veneer panel and LCD module assembly Fit andtighten centresecuringscrew Fig 1 Fitthe cowl lens assembly Fit and
314. ly hot coolantisflowing through the system 82 7 AIR CONDITIONING BLOWER MOTOR SPEED CONTROL DESCRIPTION 82 00 00 Mounted in the outlet of the blower motor units are heatsink assemblies each of which consists of an interferencesuppressor diode a feedback isolation diode and a power transistor The unit is supplied with positive battery voltage via an ignition switch controlled fuse On all fan speed except high speed the negative circuit for the fan motor is via the power transistor and the control module The feedback diode enables the control module to sense the voltage at the negative terminal of the fan motor and so calculate the speed of the blower motor With the fan motor switched to high speed the high speed relay is energised thus closing the relay contacts giving the fan motor negative circuit a direct path to earth via the relay contacts so bypassing the transistor andthe control module COMPRESSOR CLUTCH CONTROL DESCRIPTION 82 00 00 The output from pin 20 of the control module is usedto energise the compressor clutch relay which will result in the relay contactsclosing allowing battery voltageto the clutch winding via a thermal fuse andto the cooling fan relay coil to allow the cooling fan to operate when the air conditioning clutch is engaged SUPERHEAT SWITCH AND THERMAL FUSE DESCRIPTION 82 00 00 A superheat swich is included in the compressor clutch circuit to provide a compressor protection system T
315. lyafter removal 17 Afterthe system has been openedthe receiver drier must be renewed 18 Before testing run the engine until normal running temperature is reached This ensures that sufficient vacuum is available for test For cooling tests the engine must be running for the compressor clutchto operate 1 1 82 15 AIR CONDITIONING MANIFOLD GAUGE SET DESCRIPTION 82 00 00 The manifold gauge set Fig 1 is usedto determine the systems high and low pressures the correct refrigerant charge system diagnosis and operating efficiency Itis designed to read both high and low pressures at the same time because these pressures must be compared to determine correct system operation Referringto the illustration a vertical line drawn through the centre of the centre service hose will divide the manifoldset into its LOW and HIGH side The manifold gauge set consists of a charging manifold fitted with two stop hand valves a compound gauge anda high pressure gauge The compound gauge which should be connected to the suction or low pressure side of the system registers both vacuum and pressure The high pressure gauge is connected to the delivery or high J82 087 pressureside of the system WARNING FOR SAFETY REASONS THE ACCURACY Fig 1 OF BOTH GAUGES MUST BE CHECKED AT FREQUENT INTERVALS Gauge Manifold The manifold is designed to control refrigerant flow when connected into the system pressure is registered on both gauges at a
316. ment veneer 00436 REAR DOOR UPPER TRIM PAD RENEW 76 34 05 Open the door Removethe rear door trim padveneer panel 76 47 12 Remove the upper trim panel securing screws lift the panelto removefrom the door mounting and removethe panel Remove the top channel securing nuts and remove the top channelassembly Discardthe upper trim pad Reverse the removal procedure to refit the replacement panel 0090255 REAR DOOR WAIST RAIL MOULDING RENEW 76 43 05 Openthe door Carefully unclip the moulding 1 Fig 2 from the door flange fig 2 Discardthe moulding Using a suitable block to protect the moulding carefully fitthe replacementmouldingto the door Close the door 0034p 76 45 BODY SECTION REAR DOOR LOCK STRIKER RENEW 76 37 24 Open the door and slacken the pin 1 Fig 1 removethe pinfrom the D postand collect the washer Reverse the removal procedure to fit a replacement striker pin DATA TORQUE FIGURES Striker pin to D post 24 30Nm SPANNER SIZES 17mm 16698 61 REAR DOOR SEAL RENEW 76 40 02 Openthe door Remove the end panel finishers and pull the top finisher clear of the tread plate Remove the five tread plate securing screws and remove the tread plate Removethe seal Fig 2 and clean the channel Apply Kent clear sealer to the C channel buttjoints and Soluminto the section of the seal above the sill section Position the replacement seal and locate in the upper
317. mounting paneland displacethe panelfor access Note then disconnect the vacuum hoses and the supply cables Removethe solenoidassembly Fig 2 Removethe vacuum elbow tube and the green vacuum tube 182 186 Release the solenoid mounting clip and remove the Fig 2 solenoid Fitting new solenoids is the reversal of the removal procedure 02066 82 51 AIR CONDITIONING CENTRE VENTVACUUM SOLENOID RENEW 82 25 46 Openthe bonnetand disconnectthe battery earth lead Open the car door and remove the right hand side dash liner andthe footwell outlet duct Removethe two screws securingthe solenoid mounting paneland displace the panelfor access Note then disconnect the vacuum hoses and supply cables Removethe solenoid assembly Remove the vacuum elbow tube and the black vacuum tube Release the solenoid mounting clips and remove the centrevent solenoid Fitting new solenoid is the reversal of the removal procedure 0206G RECIRCULATION FRESH AIR VACUUM ud SOLENOID Fig 1 RENEW 82 25 47 Openthe bonnetand disconnectthe battery earth lead Qpen the car door and remove the left hand side dash liner andthe footwell outlet duct Remove the screws securing the solenoid mounting panel and displacethe panel for access Note then disconnectthe vacuum hoses and the supply cables Removethe vacuum solenoidassembly Fig 1 Remove the screw securing the solenoid to the mounting plate Disconnect the blue vacuum h
318. move Reversethe removal procedureto refit 0005b REAR QUARTER UPPERTRIM PAD RIGHT HAND RENEW 76 13 43 Openthe door Remove the rear seat belt upper anchorage bolt cover and bolt Displacethe upper portion of the seat belt and collectthe spacer Remove the trim pad securing screw and coat hanger hook Slacken but do not remove the dowager strap securing screws Unclipthe rear quarter trim pad and remove Reversethe removal procedureto refit 0008b STEERING COLUMN UPPER COWL RENEW 76 46 02 door Centralisethe roadwheels and removethe ignition key Removethe pad from the centre of the steering wheel Slacken the nut 1 Fig 2 securing the wheel 2 Fig 2 to Fig2 the shaft do notfully remove Pull steering wheel to release from the shaft remove the securing nut and steering wheel Release the steering column adjuster bar and raise the columnto its uppermost position Remove the screws securing the upper cowl 4 Fig 2 and remove Positionthe cowl and securewith the screws CDD grease to the split collars and fit to the steering shaft Ensuringthat the steering wheel is in the straight ahead positionfit to the shaft Fitandtighten the securing nut Refitthe steering wheel pad Closethe door 76 91 BODY SECTION TORQUE FIGURES Steering wheel to steering shaft 35 45Nm OILS GREASES Split collars toshaft Castrol L M Grease SPANNER SIZES 24mm 1669B 78 STEERING C
319. movethe screws securing the front bridge plate and collect the bridge plate Removethe trim panel and clean the rubbers Reverse the removal procedure to fit the replacement trim 76 58 278 358 BODY SECTION SLIDING ROOF PANELWIND EFLECTOR ADJUST 76 82 39 Open the door Open the sliding roof Slacken the screws securing the wind deflector Fig 1 adjust as required and tighten the deflector securing screws Carefully slide the panel shut to check the alignment with the roof 0089b SLIDING ROOF RACK RENEW 76 82 42 Open the doors Remove the sliding roof panel76 82 05 Removethe sliding roof flange finisher 76 82 23 Fig 1 Removethe sun visor vehicle set 76 10 17 Remove the cantrail crash roll left and right hand 76 13 10 Remove the sliding roof motor 86 76 01 Release the interior lamp panel securing clip and release the panelassembly from its mounted position Disconnect the block connectors Fig 2 and place the panelaside Removethe sliding roof motor 86 76 01 Remove the tape and cut the ratchet straps securing the rack tubes together and taking care to ensure that the headliningis not soiled by the rack removethe rack end tube sections Manually slide the roof panel rearwards and removethe relevent mounting bracketsecuring bolts Removethe bracket Remove the screws securing the rack tube clamp to the sliding roof manually closethe roof and remove the rack to roof panelca
320. movethe crash roll Note the position of the clips and transfer to the replacement roll Align the crash roll clips with the holes in the cantrail and press home Close the doors 0004b CONSOLE ASHTRAY RENEW 76 67 18 Open the door Open the centre console glovebox lid and remove the ashtray assembly securing screws 1 Fig 2 Release the rear of the console finisher for access and removethe ashtray assembly 2 Fig2 Open the ashtray lid remove the inner ashtray and discardthe assembly Reverse the removal procedure to refit the replacement ashtray assembly 0064b CONSOLE ASSEMBLY RENEW 76 25 01 Openthe door Removethe console ashtray 76 67 18 Removethe consolefinisher 76 25 19 Removethe radioconsole 76 25 15 Remove the console glovebox securing screws I Fig and the fuse box to glove box securing screws Removethe console glove box assembly 2Fig3 Remove the centre veneer panel assembly 76 47 06 Removethe centre vent assembly Removethe upper console securing screw 1 Fig4 and carefully displace the console rearwards Note retainthe air box in position Close the glovebox lid Remove the console assembly Remove the spire clips Mee the glove box lid securing screws remove the Id Removethe rear control knob Untape the rear ducts from the console Removethe air directionbox duct assembly Fig 4 s 76 81 BODY SECTION Displacethe rear
321. movethe front door lowertrim pad 76 34 03 Remove the screws securing the armrestto the trim pad Fig2 Disconnectthe speaker block connector and remove the armrestfrom the trim pad Fig2 76 39 BODY SECTION Remove the screws securing the switch panei support bracketto the armrest and remove the bracket Displace the switch panel ashtray for access and disconnectthe puddle lamp feed wires Remove the puddle lamp securing screws and remove the lamp assembiy Remove the switch and harness assembly and discard the armrest Reversethe removal procedureto refit 0028b REAR DOOR GLASS CHANNEL RUBBER RENEW 76 31 14 Open the door Removethe front door trim pad veneer panel 76 47 11 Removethe front door uppertrim pad 76 34 02 Removethe front door lowertrim pad 76 34 03 Removethe rear door waist rail moulding 76 43 05 Remove the rear door glass 76 31 02 Removethe plastic finisher screw and plastic finisher Remove the glass channel rubber Fig 1 Place the replacement rubber in the frame and fit the upper corners of the rubber to the frame first and fully seat the remaining rubber inthe frame Reversethe remaining procedureto refit DATA TORQUE FIGURES Door glass clamping strip to door 7 10Nm Door glass regulator and slide channel to door8 10Nm Set screw front lower frame fixing to door 7 10Nm Setscrew front upper frame fixing to door 7 10Nm Setscrew rear inboard frame fixing to door 7 10Nm Setscrew rear
322. mper to bumper bracket Non Federal 40 50Nm Bumper to bumperstrut Federal 40 50Nm Guideblock to mounting bracket3 5 4 75Nm Horns to bracket22 28Nm Mounting bracketguide block to body 7 5 10Nm SPANNER SIZES 8mm 7 Omm 13mm 79mm No20 Torx 0384b FRONT BUMPER ASSEMBLY 476 378 OVERHAUL 76 22 09 Fig2 Remove the front side and marker lamp assemblies and removethetwo bumper securing bolts Pull the bumper assembly forward and disconnect the horn feed and earth wires Remove the bumper assembly complete from the vehicle Remove the centre blade trim finisher 1 Fig 2 remove the centre blade to bumper securing screws 2 Fig 2 and remove the blade 3 Fig 2 76 15 BODY SECTION Remove both quarter bumper securing bolts 4 Fig 2 page 15 and remove the quarter bumper blades 5 Fig2 page 15 Remove the rubber bumper upper cover securing screws Fig 2 page 15 Remove the centre blade bracket cover retaining clip securing screws 4 Fig 2 page 15 and remove the bracket 5 fig 2 page 15 Remove the nuts securing the quarter bumper to the rubbers Removethe cover to bumper lower securing screws and remove the cover remove the horn bracket securing screw and removethe bracketfrom the bumper beam Replace any damaged component and reverse the removal procedureto reassembleandfit to the vehicle DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body F
323. mpletely disconnected from the pinion Remove the P AS pipe to crossmember retaining clamps and spacing washers Position a drain tray under the front of the vehicle Disconnect the steering rack return pipe and drain the system Fit blanking plugsto the pipe and rack Disconnect the steering rack feed pipe and drain the system Fit blanking plugsto the pipe and rack Re positionthe pipes away from the suspension area Removethe drain tray Removethe engine mounting securing nuts Attach JD 124 rear engine lifting eye fit and align Service Tool MS 53B engine support bracket Fig 1 Engagethe hook to the lifting eye 2 9 ENGINE ONLY Disconnect Nos 1 and 2 plug leads Attach 18G 1465 rear engine lifting eye fit and align Service Tool MS 536 engine support bracket Fig 2 Engagethe hooktothe liftingeye 3 6 ENGINE ONLY Tightenthe hook nuttotakethe weight of the engine Slacken off the crossmember rear mounting bolts nuts Removethe nuts Do not removethe bolts atthis stage Slacken off the mounting clamp platesecuring bolts Fig Take the weight of the crossmember assembly on the jack Finally removethe rear mounting bolts and spacers Remove the crossmember front mounting to chassis securingnuts Fig 4 NOTE The bolts nuts remain captive Carefully lower the assembly from the vehicle Ensure that the calipers pipes and lower column do not foul during removal Change over all ancilliary components to the new cr
324. mumgap NOTE The air gap is determined by the spacer shims When fitting a new clutch assembly try the original shims first Add or subtract shims if the air gap does not meet the above specifications SHAFT SEAL Fig2 RENEW 82 00 00 Removethe clutch as previously described Using circlip pliers insertthe points into the two holes of the felt ring metal retainer and lift outthe felt ring fig 3 82 59 AIR CONDITIONING Removethe clutch shims Use O ring hook anda small screwdriver Fig 1 to prevent shims from binding onthe shaft Remove the shaft seal seat retaining circlip using pinch type circlip pliers Fig 2 Remove the shaft seal seat by usingthe tongs Fig 3 Use the O ring hook to remove the shaft seal O ring Take care notto damage the groove Fig 4 82 60 AIR CONDITIONING Insertthe seal remover and installer tool against against the seal assembly Press down against the seal spring and twist the tool until feeling it engage in the slots of the seal cage Lift out the seal assembly Fig 1 Clean the seal cavity thoroughly with R11 or R12 Blow out with dry pressurized vapour Clean thoroughly with lint free or synthetic cloth and clean refrigerant oil Then blow outwith dry pressurizedvapour Make sure all foreign substances are completely removed Insertthe seal sleeve protector over the compressor shaft Fig 2 Do not touch the new seal lapping surface Dip the mati
325. must be evacuated and if necessary flushed through immediately beforehand No delay between evacuation and charging procedures is permissable The equipment should be fitted with means of accurately weighing the refrigerantduring the charging process Great care must be taken to charge correctly as undercharging will result in very inefficient operation and overcharging will result in very high pressures and possibly damageto components Evacuatethe systemas described previously The supply available in the charge cylinder must be at least 3 3 kg weight To fill the charge cylinder the charge cylinder inlet and outlet valves are closed 4 amp 5 Fig 1 Disconnect the charge cylinder hose from the gauge manifold 10 Fig 1 and connect the charge cylinder hoseto a refrigerant R12 bottle Openthe bottle R12stopcock Open the charge cylinder inlet valve 5 fig 1 and observe the refrigerant in the charging cylinder sight glass When the refrigerant stops rising carefully open the charge cylinder vent valve 7 Fig 1 to release the pressure and allow the refrigerantlevelto continue rising until the desired level is achieved Close the vent valve 7 Fig 1 and the charge cylinder inlet valve 5 Fig 1 Switch on the heater and allow the refrigerant pressure to increaseto 830 kPa 8 40 kgf cm 120 Ibf in2 on the charge cylinder pressure gauge 7 Fig 1 Switch off the heater Rotate the plastic shroud on the refrigerant charge cylinder
326. n refrigerant Dueto slight leak Correction J82 087 1 Testthe system for leaks 2 Depressurizethe system Fig 1 3 Repair the leaks and if necessary renew hoses or units 4 Check the compressor oil level The system may have lost oil due to leakage 5 Evacuatethe system usinga vacuum pump 6 Rechargethe system with new refrigerant 7 Operatethe system and checkthe performance Refrigerant Excessively Low Complaint Cooling is not adequate Condition 1 The low side gauge is reading very low 2 The highside gaugeisreadingvery low 3 Nobubbles or liquid evident inthe sight glass 4 Thedischargeair from the evaporator is warm 182 0871 Diagnosis Fig2 The systemis excessively low of refrigeranta serious leak is indicated Correction 1 Testthe systemfor leaks NOTE Partially rechargethe system beforetesting the System for leaks to ensure that leak detection is obtained 82 20 AIR CONDITIONING 2 Depressurizethe system 3 Repair the leaks and if necessary renew hoses or units 4 Check the compressor oil level the system may lost oil due to leakage 5 Evacuatethe system usinga vacuum pump 6 Rechargethe system with new refrigerant 7 Operate the system and checkthe performance Air InThe System Complaint Cooling is not adequate Condition 1 The low side gauge reading is constant and does not drop The pressure should drop until the compressor cycles thermostat contr
327. nd lower the window lift motor assembly into the bottom of the door Removethe window lift motor Fig 2 assembly from the door Fitting a new motor assembly is the reversal of the removal procedure 30018 86 23 ELECTRICALSYSTEM REAR DOOR WINDOW LIFT SWITCH RENEW 86 25 10 Open the bonnet and disconnectthe battery earth lead Removethe veneer panel 76 47 12 Removethe upper trim pad 76 34 05 Removethe lowertrim pad 76 34 06 Removerheam rest 76 34 23 Removethe screws securing the switch retaining bracket and removethe bracket Disconnectthe door guard block connectors Removethe switch ashtray assembly Displace the switch assembly from the housing and carefully release the locking tabs to removethe switch Fitting a new switch is the reversal of the removal procedure 30018 DOOR LOCK SOLENOID MICRO SWITCH J86 921 Fig 1 RENEW 86 25 44 Openthe bonnet and disconnectthe batteryearth lead Removethe veneer panel 76 47 1 1 Removethe uppertrim pad 76 34 02 Removethe lower trim pad 76 34 03 Removethe door handle 76 58 01 Removethe cable hamess tapes Removethe screws Fig 1 securingthe switch Removethe roller bracket Removethe switch complete with hamess Fitting a new switch is the reversal of the removal procedure 30018 DOOR BOOT AND FUEL FILLER LOCKS DESCRIPTION 86 25 00 Two methods of door and boot lock operation exist mechanical operation by means of a plunger located on ea
328. nd removethe boot lock finisher and collectthe finisher gasket Glue the gasketto the boot lock finisher fitthe finisher to the boot lid and secure with the two plain washers and nuts Refit the number plate lamps and the boot illumination lamp refitthe boot lock mechanism liftthe boot lid back into position andfit butdo nottighten the securing bolts and connectthe strutsto the boot lid pivot bolts Carefullyshut the bootto align with the rearwings open the bootandtighten the four securing bolts S cure the hamess to the boot lid with hamess straps and bootlidclips Connect the boot lamp and lock multi plugs and connectthe number plate lightfeed wires Close the boot Reconnectthe battery and close the bonnet DATA SPANNER SIZES 13mm 0367b BOOT LIDSEAL RENEW 76 19 06 Open the boot and removethe rear trim panel securing screws and remove the rear trim panel and remove the sealfrom the bootflange Clean the seal mounting flange fit the new seal in position 1 Fig 2 startatthe lockstriker and work back 76 63 Fig 1 Fig2 47b 410 BODY SECTION Cutthe seal to the correct length andfinally fit the seal to the flange Refitthe rear trim finisher and secure with the screws Closethe boot lid 0366b BOOT LID GAS STRUT RENEW 76 19 27 Open the boot Insert screwdriver and remove the strut Fig 1 from the top pivot and repeatthe operation for the lower pivot Fitthe strutto the lower pivotf
329. nd removethe cowl Fig 1 Disconnect the washer wiper switch multi plug connector Releasethe switch retainingclips Remove the switch complete with guide wires and connector from the upper column Fitting a new switch is the reversal of the removal procedure 0196G WIPER LOGIC MODULE RENEW 86 80 11 Open the bonnet and disconnect the battery earth lead Open the passenger door Remove the screws securing the passenger dash liner and removethe liner Remove the screws securing the module and displace the module 1 Fig2 Note and disconnect the cable harness multi plug connector Removethe module Fitting a new module is the reversal of the removal procedure 0196G HEADLAMP WASHER JETS RENEW 84 20 08 With a suitable implement turn the jet cover anti clockwiseto release 1 Fig3 Displace the jet and disconnect the tube from the jet assembly 2 Fig3 Disconnectthe cable hamess multi plug connector Removethe jet Fitting a newjet is the reversalof the removal procedure 01965 84 8 m c J TTY TOO Sea UI WINDSCREEN WIPERSAND WASHERS HEADLAMP WASHER PUMP RENEW 84 20 21 Open the bonnetanddisconnectthe battery earth lead Turn the front road wheels to the full lock position for access Remove the nuts bolts and screws securing the inner wing valance Removethe valance and the brake disc cooling duct Disconnect the pump multi plug connector and the wash
330. nector Displacethe body grommet into the inner wing Removethe roadwheel Remove the screws securing the inner wing arch liner and removethe liner Peel backthe repeater lamp insulatorsleeve Removethe repeater lampfrom the wing Carefully displace the adhesive pad and withdraw the cable harness Fitting a new lamp is the reversal of the removal procedureensuring the wing apertureis clean 0030d REPEATER LAMP LENS AND BULB RENEW 86 40 51 Remove the screws securing the lens and remove the lens Fig 1 Remove the bulb filter cover from the retainingclips and removethe bulb To fit a new bulb or a new lens reverse the above procedure 30016 REAR SIDE MARKER LAMP RENEW 86 40 64 Open the bonnetand removethe battery earth lead Open the luggage compartment Removethe spare wheel 74 20 00 Removethe fuel tanktrim panel Removethe rear lamptrim panel Removethe sidetrim panel Disconnect the cable hamess multi plug connector at the bulbfailure module Displacethe carpet and displacethe the body grommet Release the spring clips securing the marker lamp and removethe lampcompletewith cable Fiting a new lamp is the reversal of the removal procedure 30016 86 31 N MG 471 Fig1 ELECTRICALSYSTEM REAR SIDE MARKER LAMP BULB RENEW 86 40 62 Remove the screws securing the marker lamp lens and remove the lens Removethe bulb Fita new bulb and refit the lens 3001B
331. nel Slacken the the glovebox lock securing nut 1 Fig 3 turn lock for access remove the nut and plate and removethe lock assembly 2 Fig 3 Removethe spire clips and discardthe lid Reverse the removal procedureto fit the replacement lid ensuring that the lid is aligned with the apeture prior to final tightening of the lidsecuring screws DATA SPANNER SIZES 24mm J76 337 0045b Fig 1 GLOVEBOX LID LOCK RENEW 76 52 08 Openthe door Open the glovebox lid and remove the screws securing the mirror andtray assembly Lift the mirror assembly for access slacken the lock securing nut 1 Fig3 the nut remains captive turn the lock finally removethe securing nut and mounting plate and removethe lock from the lid 2 Fig 3 Reverse the removal procedure to refit the replacement lock DATA SPANNER SIZES 24mm 0057b GLOVEBOX LID VENEER PANEL RENEW 76 47 21 Open the glovebox Remove the screws securing the mirror and tray assembly Repositionthe mirror andtray assembly to gain accessto the screws securing the veneer 76 88 BODY SECTION Remove the screws securing the veneer panel remove the panel and discard Reverse the removal procedure to refit the replacement panel 00445 GLOVEBOX MIRROR ASSEMBLY RENEW 76 52 05 Open the door Open the glovebox lid and remove the screws 1 Fig 1 securing the mirror and tray assembly Lift the mirror assembly 1
332. nformation such as vehicle speed fuel usageanddistance travelled Issue 2 88 4 INSTRUMENTS INSTRUMENT PACK CONNECTORS PIN LOCATIONS SOCKETA Pin o 10 11 12 SOCKET Pin Issue 2 Circuit Input Fuel Flow 12v ignition feed Ground Ground Battery feed Spare lilumination bulb feed Circuit Input Speed out Brake padfeed Fuse 4 Low brake pressure Brake fluid level Brake lights Fuse 3 Wash fluid level Sport mode Seat belt Boot open Park brake on D I bulb fail Elec supply fail controller Door open LH rear Door open RH rear Check engine fuel fault Catalystwarning Main beam Pin Circuit Input Serial output 1 Serial input 2 Speed sensor input Speed sensor input Ov Speedsensor screen Charge warning Coolanttemperature Fuel level Oil pressure Tachometer input ve Circuit Input Average speed Averagefuel Fuel Range Clear VCM Inst fuel Distance Ground keyboard Brake padsense Fuse 1 Fuse 2 Coolantlevel Side light on Caravan on LeftD l on Right D I on Imp Metric slide switch General bulb fail Gearboxfail Elec supply fail brakes Dooropen LH front Door open RH front Anti lock fail INSTRUMENTS GAUGES There are six analogue style gauges containedin the instrument pack 1 Speedometer 2 Tachometer 3 Battery condition 4 Fuel Level 5 Oil Press
333. ng by cleaningto bright metal Fig 4 This includes interior and exterior edges Apply weld through primer to all surfaces to be resistance spot welded Apply metal to metal adhesive or sealer in accordance with the car manufacturer s instructions Fig2 77 12 BODY REPAIR PANEL S OFFER UP AND ALIGN 77 10 05 Offer up new panel section and re align with associated panels clamp into position using welding clamps or mole grips With certain panels it may be necessaryto fix the panel with tack welds PK screws PANEL S 25 WELD 77 10 06 MIG tack buttjoint s Fig 1 re checking alignmentand panel contours as necessary Select arms for resistance spot welding and clean tips RTT usingthe tip trimmer m It is recommendedthat arms of not morethan 12 inches n in length are used Fig 2 Jaen Fitspot welding arms andtest equipmentfor satisfactory Fig 1 operation usingtest coupons Fig 3 In the absence of monitoring equipment a satisfactory weld can be verified by the pulling of a weld slug on separation of the test coupons Resistance spot weld where necessary Fig 4 Dress MIG tack welds with a sander 36 grit disc Fig2 77 13 BODY REPAIR seam weld buttjoints Fig 1 Dressall welds usinga sander 36 grit disc NOTE brazingrequiredmust be done at this point PANEL S SOLDER 77 10 07 Prepare areas to be soldered by cleaning with a rotary wire brush sande
334. ng screws and dock assembly securing bolts Displace the B post upper trim padmounting bracket Displace and remove the guide rail from the dock assembly Fig 2 Carefully removethe seal from the guide rail Fitandalignthe sealtothe new guide rail Positionthe guide railto the dock assembly Positionthe runner tongue into the guide rail Fully seat the guide rail intothe dock assembly Fit the guide rail to the cant rail fit but do not fully tighten the securingscrews Fitand align the mounting bracket to the dock assembly fitandtightenthe securing bolts Fully tighten the guide screws Refit the cant rail crash roll and uppertrim pad 0051G 76 114 BODY SECTION BELT INERTIA REEL RENEW 76 73 22 Remove the front seat 76 70 10 Removethe seat runnerto floor securing bolts Lift up the passive inertia reel side of the runner for access Use a suitable block for support Remove the passive inertia reel securing bolt Fig 1 remove the reel assembly Displace and remove the lap belt buckle Fit and align a new buckle to the seat runner Fit the passive inertia reel assembly to the seat runner ensure that the reel bracket locates on the peg Fit and tighten the securing bolt Repositionthe seat runner on the block for access to the lap belt inertia reel Remove the lap belt reel securing bolt removethe reel assembly Fig 2 Fit the new reel assembly to the seat runner fit and
335. ng surface in a clean refrigerant oil before proceeding Engage the slots of the seal remover and installer to the new seal cage Insertthe seal assembly firmly into place in the compressor seal cavity Twist the tool in the opposite direction to disengage the tool from the seal cage Fig 3 Removethe tool Coatthe new 07 ring with clean refrigerantoil Carefully place in the seal groove with the ring hook Fig 4 Do notscratch the suface 82 61 AIR CONDITIONING Coat the seal retainer with clean refrigerant oil Use the tongs and press the retainer lightly against the seal Fig 1 482 254 Fig 1 Refit the circlip with the beveled edge outward away from the compressor Flat side towards the compressor Fig 2 It may be necessary to lightly tap the circlip to securely position itin its groove Replacethe clutch spacer shims Tap a new felt ring into place Fig 3 Refitfront clutch plate 0206G 82 62 AIR CONDITIONING AIR CONDITIONING FUNCTIONAL TEST 82 00 00 Start and run engine until normal operating temperature is reached Open the fascia and the rear vents Switch the left handcontrolto low fan speed Select the mid positionof the face level control Tum the right handcontrolto the fully cold position Select manual by pressingthe mode switch until MAN is illuminated Ensurethe buttonis not illuminated Ensure all humidity button lights are not illuminatedto
336. nk assemblies each of which consists of an interferancesuppressor diode a feedback isolation diode and a power transistor The unit is supplied with battery power via an ignition switch controlled fuse and an isolation relay mounted within the blower motor assembly On all fan speed except high speed the negative circuit for the fan motor is via the power transistor and the control module The feedback diode enables the control module to sense the voltage at the negative terminal of the fan motor and so calculate the speed of the blower motor With the fan motor switched to high speed the high speed relay is energised closing the relay contacts giving the fan motor negative circuit a direct path to earth via the relay contacts bypassing the transistor and the control module Vacuum System The vacuum supply to four solenoids in the system is from the engine manifold via a reservior located under the battery anda non returnvalve The vacuum solenoids Fig 3 are located on brackets beneaththe heater assembly Components operated bythe solenoids are Defrost Demist flaps which are held closed by vacuum is identified by a green vacuum supply tube 2 Recirculation Fresh air flaps which are held closed by vacuum is identified by a bluevacuum supply tube Centre vent which is opened by vacuumis identified by a blackvacuum supply tube 4 Coolant valve which is closed by vacuum and is identified by a red vacuum supply tube
337. nnectthe hamesstothe bonnet lampmulti plugs Securethe hamessto the bonnet with ratchetstrap Repositionthe bonnet pad Fitandtighten the padsecuring clips Position and seat lights to the bonnet Tightenthe lightsecuring screws andclose the bonnet 30018 STARTER MOTOR LINK LEAD RENEW 86 70 31 Openthe bonnet Starter motor renew 86 60 01 Undo and remove the link lead to the starter solenoid securing screws Place link lead aside Fitandalignthe new link leadto the starter solenoid Fit andtighten the securing screws Refitthe starter motor Close bonnet 3001B 86 86 ELECTRICALSYSTEM HEATED BACK LIGHT EARTH LEAD RENEW 86 70 32 SS Open the rear door Rear quarter upper trim pad left hand renew 76 13 13 Displace and remove the tape securing earth leadto the body panel Disconnectthe earth leadto the heated back light lucar Undo and removethe earth lead securing screw Fig 1 Displaceand removethe earth lead Fitandalignthe new earth lead Fitandtighten the securing screw Connectthe earth leadto heatedback light lucar Securethe leadwith tape Refitthe rear quartertrim and closethe door 30018 STEERING COLUMN HARNESS 186 615 Open the bonnet and disconnectthe battery earth lead Openthe car door Removethe steeringwheel 57 60 01 Removethe driver side dash liner 76 46 11 Remove upper steering column cowl 76 46 02 Remove lower steering column cowl 76 46 03 Removethe screw
338. nnet Fitandtighten the hingeto bonnet securing bolts Fit butdo notfully tighten the the hingesecuring nuts Remove the bonnet support and carefully lower the the bonnetto check the alignment open the bonnet slacken the hinge securing nuts and position the bonnet as required Fully tightenthe securing nuts Closethe bonnetand check the alignment Repeatthe procedurefor the other hinge Refitthe radiator grille and surround Closethe bonnet DATA SPANNER SIZES 7Ornrn 73mm 1669B 85 FRONT DOOR ARMREST RENEW 76 34 22 Open the door Removethe front door trim pad veneer panel76 47 1 1 Removethe front door uppertrim pad76 34 02 Removethe front door lowertrim pad 76 34 03 Removethe screws securing the armrestto the trim pad Fig 4 disconnectthe speaker block connector Fig 4 and removethe armrestfrom thetrim pad 76 30 BODY SECTION Remove the screws Fig 4 page 30 securing the switch panelsupport bracket Fig4 page 30 to the armrest Fig 4 page 30 and removethe bracket Displacethe switch panel ashtray for access Disconnect the puddle lamp feed wires and the securing screws removethe lamp assembly Remove the switch and harness assembly from the armrestand discard the armrest Reverse the removal procedure to refit the replacement armrest DATA SPANNER SIZES No 4 Pozi FRONT DOOR GLASS RENEW 76 31 01 Open the door Removethe front door trim padveneer panel 76 47 11
339. ntified by a blue vacuum supply tube 3 Centre vent which is opened by vacuum is identified by ablackvacuum supply tube di 4 Water valve which is closed by vacuum and is Fig 1 identified by ared vacuum supply tube The vacuum supply to the centre vent and recirculation fresh air flaps have built restrictors so that the operation of these flaps is slowed down to avoid the risk of the system hunting The recirculationflaps can take upto 30 secondsto change state 82 9 AIR CONDITIONING COMPRESSOR DESCRIPTION 82 00 00 The Sanden709 compressor containsseven cylinders The magnetic clutch is engineered with the compressor as a complete assembly resultingin a relativelysmall unit which is of lightweight construction The compressor may be operated in either a clockwise or anticlock wise rotation and can be mounted up to 90 degreesfrom its upright position The compressor incorporates a lubrication system which reduces the oil circulation ratio to a level of less than 2 at 1800rpm An oil deflector and positive pressure differential lubrication system promotes oiling to the cylinder wall piston rod assemblies main bearingsand shaft seal Oil circulation to the refrigeration circuit is kept to a minimum The compressor is charged with 4 6 fluid ounces 135 cc of Sunico No 5GS oil at the factory Only this oil or the equivalent oils Texaco Capella E or Virginia Chemicals 500 viscosity should be used when adding or changing oi
340. nufactured before 1st June 1988 Additionally the front seat slides have been made narrowerto accommodatethe passive restraintreels and consequentlyseat slides are not interchangeablewith the precedingtype MAIN MECHANICAL COMPONENTS Component Location Rail and seal A postandcantrail Motor cable and anchorage B C post Kit emergency tongue Convenient placee g glove box Passive belt reel and buckle Seat slides Lap belt and buckle matched pair Seat slides MAIN ELECTRICAL ELECTRONIC COMPONENTS Component Location Electroniccontrol unitwith a PM4 Behinddriversdash liner and PMHD conector Reverse inhibit relay green Behinddriver s dash liner attachedto blower casing Warning light Instrument pack LHS Rear dock and proximityswitch B C post fitted to anchorage Front limit dock switch In motor drive assembly in BC post Motor anddriveconnector PM4 Bottom of BC post Door pillar switch OnA postcombined with courtesy light switch Power pick up points two 20 Afuses LH and RH fusebox Fuse9 76 101 FAULT DIAGNOSIS AND MAINTENANCE CHECKS BODY SECTION 76 73 00 WARNING SHOULD THE SEAT OR SEAT SLIDES BE REMOVED FOR ANY REASON UPON REASSEMBLY CHECK FOR CORRECTSEAT BELTOPERATION MECHANICALSYSTEM Fauk Seat belt Installation Belt inoperative Faulty belt operation Webbing wear fray Unableto assemble seats intocar Motor Anchorage Failure of motor system inoperative Rattles customer annoyance B C
341. o the method detailed in Section 77 10 01 07 with the following variations In replacement the window aperture reinforcement position is marked on the new panel and adhesive is appliedto the outer flanges priorto offering upto the frame 1 Fig2 A newanti drum pad is fitted to the new panel before painting Painting See Section 77 00 00 Refit replace the Door Refit replace Parts 005856 Fig2 77 16 BODY REPAIR REAR DOORSKIN RENEW 77 20 04 Remove Rear door Upper and lower hingesfromdoor Panel Replacement Panel removal and replacementis to the method detailed in Section 77 10 01 07 with the following variations In replacement the window aperture reinforcement position is marked on the new paneland adhesive is appliedto the outer flanges priorto offering up to the frame Fig 1 A newanti drum pad is fitted to the new panel before painting Painting See Section 77 00 00 Refit replace rear door 77 20 03 Refit upper and lower hingesto door Replace Parts See rear door method 377 050 Fig 1 SILL PANELSECTION RENEW 77 40 02 WELDING TABLE No Location Remove FactoryJoint Replace RepairJoint 1 To existing panelat rear end 1X270mm MIG seamweld 2 Toinnersill upperflangeat rear 15resistancespot welds Single rowof resistancespot welds door aperture ARO arms 242A or equivalent 3 Toexistingpanelat post 1X380mm seam weld To postclosing panel 6 resistancespot welds 3 MIG plug
342. o the air conditioning system as described on page 82 14 Connectthe centre hose of the manifoldtest setto a supply of refrigerant open the refrigerantsupply valve purge the centre hose by momentarily cracking the connection at the manifold block retightenthe connection Startthe engine and operate the air conditioning With the system operating slowly open the low side manifold hand valve to allow refrigerantto enter the system NOTE The low side of the system is the suction side and the compressor will pull refrigerantfrom the container into the system CAUTION THE HIGH SIDE MANIFOLD HAND VALVE MUST NEVER BE OPENED WHILE THE SYSTEM IS OPERATING THIS WOULD RESULT IN REFRIGERANT BEING PUMPED BACK INTO THE CONTAINER WHICH COULD CAUSEIT TO BURST With the refrigerant container in an upright vapour position add refrigerant until the sight glass clears or the gauge readingsare normal CAUTION Never turn the container into a position where liquid refrigerantwill flow intothe system Closethe low side manifold hand valve and refrigerantcontainer valve Continueto stabilizethe system and check for normalcharge Leak Test A high proportion of all air conditioning work will consist of locating and repairing leaks Many leaks will be located at connections and are caused by vibration They may only require the retightening of a connection or clamp Occasionally a hose will rub on a structural part of the vehicle and create a leak or a hose wil
343. ocedure 02096 BOOT VENTILATOR OUTLET RENEW 80 15 66 Openthe boot Removethe rear quarter bumper Remove the nuts securing the rear lamp interior finisher andremovethefinisher 1 Fig3 Removethe screw securing the side liner Fig2 Carefully displace the side liner for access to the ventilator outlet Displacethe ABS control unitfrom the outlet 2 Fig 3 Cut and remove the ratchet straps securing the cable harness Removethe bolts securing the outlet 4 Removethe outlet assembly 5 Fig3 Fitting a new boot ventilator outlet is the reversal of the removal procedure 0209G 80 18 AIR CONDITIONING CONTENTS DESCRIPTION OPERATION OPERATION PAGE No No AIR CONDITIONING SYSTEM cccssesesssesseseecereseseeeeres ADD REFRIGERANT 82 30 02 82 18 AIR CONDITIONING SYSTEM scssesssssssseseseseesereseeeeeers CHARGING 82 30 08 82 30 AIR CONDITIONING DEPRESSURIZE 82 30 05 82 27 AIR CONDITIONING SYSTEM eene EVACUATE T 82 30 06 82 28 AIR CONDITIONING SYSTEM ccsssseseseseserececececereceees FUNCTIONAL TEST 82 00 00 82 63 AIR CONDITIONING FLUSHING enne 82 30 03 82 27 AIR CONDITIONING SYSTEM eene FULL CHARGE 82 00 00 82 31 AIR CONDITIONING SYSTEM e
344. of a refrigerant coil mounted in a series of thin cooling fins to provide a maximum of heat transfer in the minimum amount of space It is usually mounted directly in front of the car radiator so that it receivesthe full flow of RAMAIR Ram air is the air flow induced by the forward motion of the car and the suction of the cooling fan The condenser receives heat laden high pressure refrigerantvapour from the compressor The refrigerant enters the inlet at the top of the condenser as a high pressurevery hot vapour and as the vapour passes down through the condenser coils Heat will follow its natural tendency and move from hot refrigerant vapour into the cooler ram air as it flows across the condenser coil fins When refrigerant vapour reaches the temperature and pressure that will induce a change of state a large quantity of heat will be transferred to the outside air and the refrigerant will change from high pressure hot vapour to a high pressure warm liquid DRIER BOTTLE DESCRIPTION 82 00 00 The drier bottle Fig 2 has two separate functions First i is a storage tank since the amount of refrigerant required by the evaporator varies under different operating conditions It receivesthe high pressure warm refrigerantliquid from the condenser through its inlet line and delivers the refrigerant to an expansion valve through its outlet line Secondly it contains a filter and desiccantto remove and retain foreign particles as well as moistur
345. of the above procedure Ensure that new rings are fitted and the protective caps are not removed until the last possible moment before connectingthe new hose Ensure the union nuts are tightened to the correct torque Flush the system fit new receiver drier evacuate and rechargethe system DATA TORQUE FIGURES Fig 1 Hose union drier 15 7Nm Hose union evaporator 15 17Nm Pipe clip 7 10Nm 0206G COMPRESSOR TO CONDENSER HOSE RENEW 82 25 49 Depressurizethe air conditioning system Undo the union nut from the condenser stub pipe and removethe hose Removeanddiscardthe ring seal Fig2 Fita protective capto the condenser outlet Undo the union nut connecting the hoseto the muffler and disconnectthe hose Removeand discardthe O ring seal Fita protective capto the muffler outlet pipe and remove the hose Fig 2 Fittinga new hose isthe reversalof the above procedure 82 48 AIR CONDITIONING Ensure that new O rings are fitted and the protective caps are not removed until the last possible moment before connecting the new hose Ensure the union nuts are tightened to the correct torque Flush the system fit new drier bottle Evacuate and rechargethe system DATA TORQUE FIGURES Hose union drier 15 17Nm Pipeclip7 10Nm 0206G HEATER MATRIX RENEW 82 25 19 482 17 Open the bonnet ensure the engine is cold drain the engine coolant into a suitable container Fig
346. ol 2 The high side gauge reading is slightly high or 45 Osmia slightly lower especial if a large fan is used to substitute ram air 3 The sight glass is free of bubbles or only shows an occasionalbubble 4 The discharge air from the evaporator is only slightly cool Diagnosis Non condensables presentinthe system Air or moisture present instead of a full refrigerant charge Correction Test the system for leaks Test the compressor seal area very carefully Depressurizethe system Repair the leaks and if necessary renew hoses or units Renew the drier bottle it is probably saturated with moisture Checkthe compressoroil level Evacuatethe system using a vacuum pump Rechargethe systemwith new refrigerant Fig2 Operatethe systemand checkthe performance J82 087 3 Wh Compressor Malfunction Complaint Cooling is not adequate 1 The low side gauge reading istoo high 82 21 AIR CONDITIONING 2 The high gauge reading istoo low 3 The sight glass is free of bubbles and the system is fully charged 4 The discharge air from the evaporator is not sufficiently cool Diagnosis Internalleak inthe compressor Correction 1 Depressurizethe system 2 Renewthe compressorand the drier bottle 3 Evacuatethe system using a vacuum pump 4 Chargethe system with new refrigerant 5 Operatethe system and checkthe performance Condenser Malfunction Or System Overcharge
347. onds SAE standard Reserve Capacity This is the period during which the battery can supply a constant current of 25 amps down to a voltage 1 75 volts per cell at a temperature of 25 C The current is based on a typical total electrical load of a vehicle such as would be carried by the battery under adverse driving conditions in the event of the failure a the vehicle chargingsystem The time is usually stated in minutes Topping up should be carried out when the electrolyte falls belowthe top of the separators The vent covers should be left in position at all times except during the topping up procedure When battery charging is carried out the vent covers should be left in position to allow gas to escape or flooding of electrolyte may result Also it is advisable to disconnectthe battery from the vehicle 440 Series Battery The rapiddischarge current 420 ampsat 18 The reservecapacity time 75 minutes at 25 amps The rapiddischarge voltage 9 0 volts 86 17 ELECTRICALSYSTEM HEALTH AND SAFETY PRECAUTIONS Nosmoking Avoid sparks short circuits or other sources of ignition Hydrogen which is highly explosive is emitted particularly during charging Switch off current before making or breaking electrical connections Always disconnectthe earth terminal first and reconnect itlast Chargethe battery in a well ventilatedarea Avoid contact with battery acid Battery acid is poisonous and corrosive it
348. onsolefinisher Removethe console ashtray Removethe fascia panel and radio console Removethe console assembly Release the clips retaining the left hand air distribution box and removethe box Displacethe solenoidfrom its mounting bracket Fig 2 Note anddisconnectthe vacuum hoses Note anddisconnectthe supply cables Removethe solenoid Fitting a new vacuum solenoid is the reversal of the 182 187 removal procedure 0209G DE FROSTVACUUM SOLENOID RENEW 80 10 49 Disconnectthe battery earth lead Removethe driversdash liner Removethe footwell outlet duct Displacethe cable hamess Remove the bolts securing the vacuum solenoid mounting plate Displacethe solenoid Note and disconnectthe vacuum hoses Note disconnectthe supply cables Removethe solenoid Fig 3 182 186 Fitting a new vacuum solenoid is the reversal of the Fig3 removal procedure 0209G 80 14 HEATING AND VENTILATION COOLANTVALVE VACUUM SOLENOID RENEW 80 10 50 Disconnectthe battery earth lead Removethe driver and passenger side dash liners Removethe console finisher Removethe console ashtray Removethe fascia panel Removethe radio console Removethe console assembly Release the clips retaining the left hand air distribution box and removethe box Displacethe solenoidfrom its mounting bracket Fig 1 Note anddisconnectthe vacuum hoses Note anddisconnectthe supply cables Removethe solenoid 4821187
349. ooden blocksas support NOTE Ensurethat the gap between screen and E post is equal both sides Fullyseatthe screento the apertureflange Removethe maskingtape from the aperture Apply Solumin solution to the screen seal a suggested methodis shown in Fig 2 Fit and fully seat the sealto the screen body during the operation remove the wooden support blocks Clean and remove all moisture from between the seal and the glass Fig 1 Apply Alphaseal 121 betweenthe screen seal and the screen DOWNTHE E POSTS ONLY Apply Solumin solution to the screen seal outer face and slide the finisher down into the seal Fitthe lower edgefinisher Fitthe finisher clips Remove all excess sealant solution from the screen Secure support the screen with tape Refitthe trim panels if removed Reconnectthe heatedrear screen connections After the screen has bonded approximately 2 hours remove the tape and clean the screen and surrounding area SEALANTS LUBRICANTS Alphaseal 121 Betaseal Screen body primer Screenglass primer Solurnin White Spirit 475 490 77 24 BODY REPAIR FRONT END REPAIRS COMBINATION 2 RENEW ERINA WELDING DIAGRAM WELDING TABLE 1 Chassis leg and out riggerto 94 welds 244 WEG elu welds 2 Flitch assembly to transmission 15 resistance spot welds 15 MIG plugwelds 3 H H Flitch assembly to bulkhead 2 welds
350. ooden chock between partially released sixth light and aperture for easier access Fig 3 Removethe sixth light from the vehicle Removethe cured Betaseal from the aperture Touch up the paintwork around the aperture Wipe Betaseal degreasing agent on to the aperture Apply Betaseal primer onto the aperture Carefully remove excess cured Betaseal from the removed glass Wipe Betaseal degreasing agent on to the sixth light glass edge Carefully apply Betaseal glass primer on to the glass ensuringthatthe primer does not smearthe glass edge fading Apply a continuous bead of Betaseal to the glass periphery keeping clear of the glass fading Carefully fit and fully seatthe glass assembly into Position inthe body aperture Adjust the sixth light position for general fit and alignment of screw holes and upper trim joiner Fit and tighten the screws to secure the finisher to the D post 76 117 BODY SECTION Fully seat the weather seal in to the D post channel Removethe protective tape lamination fromthe E post Placethe rearquartertrim pad in position ensuring thatthe leading edge engages behindthe dowager strap mounting Align and securethe trim pad Fit and tighten the rear quarter trim pad Tighten the dowager strap securing screws Refitthe coat hanger hook Refit the seat belt spacer Reposition and align the seat belt to the upper anchor point 76 118 BODY REPAIR CONTENTS DESCRIPTION OPE
351. oor Removethe rear seat cushion 76 70 37 Remove the screws 1 Fig 1 securing the rear squab and liftthe squab to releasethe rear retainingclips Reposition the rear seat belts and remove the squab assemblyfrom the vehicle Remove the staples and clips securing the rear armrest cover and reposition the cover for access to the armrest securing bolts Remove the armrest hinge securing bolts 1 Fig 2 and removethe squab securing brackets Reposition the squab and the armrest for access and displace the cover from the seat remove the armrest through the rear of the seat squab and removethe cover fromthe seat Discardthe seat squab Reverse the removal procedure to fit the replacement seat squab 0073b REAR SHELF FINISHER RENEW 76 67 06 Open the rear door and removethe rear seat cushion and squab Slacken and remove the rear shelf securing screws 1 Fig 3 and pullthe trim material from the rear body paneland remove the rear shelf finisher 2 Fig 3 and remove the extraction vents fromthe retainingclips Remove the rear seat belt blanking plugs where fitted and refit to the replacementfinisher Fit the air extraction vents to the finisher place the EN finisher in position and secure with the screws Fig2 Refitthe rear seat squab andcushion andclosethe door 0396b REAR SIDE SEAT BELT RENEW 76 73 18 Open the door Removethe Rear seat cushion 76 70 37 Rear seat squab 76 70 38 Rear parcel tray 76 67 06
352. or Removethe rear door trim padveneer panel 76 47 12 Removethe rear door upper trim pad 76 34 05 Removethe rear door lower trim 76 34 06 76 38 BODY SECTION Remove the door aperture plastic closing panels Fit adhesive tape 1 Fig 1 over the door frame to secure the glass Remove the screws and nuts 2 Fig 1 securing the window lift motor to the door glass Remove the screws securing the window lift guide to the door and carefully displace the mechanism 3 Fig 1 from the door glass and position in the bottom of the door Remove the grommet to gain access to the rear frame upper securing screws and remove the screws securing the glass frameto the door Lift the glass and frame assembly from the door remove the adhesive tape securing the glass to the door frame and removethe glass Reverse the removal procedure to refit the replacement glass DATA TORQUE FIGURES 476 327 Doorglass clampingstrip 7 10Nm Doorglass regulator and slide channel to door 8 10Nm Setscrewfront lower frame fixing to door 710Nm Set screw frcnt upper frame fixing to door 7 10Nm Setscrew rear inboard frame fixing todoor 7 10 Setscrewrear lower framefixing to door 7 10Nm Setscrewrear upper frame fixing to door 7 10Nm SPANNER SIZES 10mm Torxbit No 30 0017b REAR DOOR ARMREST RENEW 76 34 23 Openthe door Removethe front door trim padveneer panel 76 47 1 1 Removethe front door uppertrim pad 76 34 02 Re
353. or matrices Any damage must be rectified bythe use of fin combs 7 Beforeassembly c tube and hosejoints usea small amount of clean new refrigerant oil onthe sealingseat 8 9 0 1 N Refrigerantoil for any purpose must be kept very clean and capped at all times This will preventthe oil absorbing moisture Before assembly the condition of joints and flares must be examined Dirt and even minor damage can cause leaks atthe high pressure points encountered inthe system Dirty end fitting can only be cleaned usinga cloth wetted with alcohol After removing sealing plugs and immediately before assembly visually check the bore of pipes and components Where any dirt or moisture is discovered the part must be rejected 12 All components must be allowedto reach roomtemperature before sealing plugs are removed This prevents condensation should the component be cold initially 13 Before finally tightening hose connections ensure that the hose lies in the correct position is not kinked or twisted and will not be trapped by subsequence operations e g refitting or closing bonnet 14 Checkthat hoses are correctlyfitted inclips or straps 15 The compressor must be stored horizontally with the sump down It must not be rotated before fitting and charging Do not removethe shipping plate until immediately before assembly Always use new O ring seals inthose joints that incorporatethem 16 Componentsor hoses removed must be sealed immediate
354. ormation The primary function of the Instrument Display is to provide the driver with information usual to normal driving requirements The secondary function is to display the results of trip computer calculations and information in response to signals received from the trip computer keypad Informationis receivedfrom sensors positioned at various locations about the vehicle via one of the two multi pin sockets located at the rear of the Instrument Pack Fig 1 Page 88 05 Informationconcerningvehicle condition and operation is displayed in one of three ways 1 Informationnecessaryto confirm normal vehicle operation road speed engine speed oil pressure battery condition fuel level coolanttemperature This information is displayed using analogue gauges as shown in Fig 1 Page 88 07 2 Informationindicating the presence of a hazard fault condition low oil pressure door open etc or operational action indicator flashing headlamp full beam ON etc This information is provided by twenty two warning lamps tell tales arranged in four groups two groups of seven atthe left and right sides of the instrument panel andtwo groups of four atthe bottom of the instrument panel Fig 3 Page88 07 3 An LCD Display is located at the bottom centre of the instrument pack and is normally used to display the odometer reading but it can also be used to display vehicle condition messages associated with particular warning lamps andtrip computer i
355. ors with the mylar tape Be careful to avoid wrapping the drain wire inthe tape Next splice the drain wire following the splicing instructions for copper wire Then wrap the drain wire aoundthe conductors and mylar tape 0 W A Tapethe Cable Fig2 Tape over the entire cable using a winding motion This tape will replacethe section of the jacket you removedto Fig2 286526 makethe repair TERMINATED CABLES Terminated cables are now available for repairing electrical wiring connectors When used in conjuction with a proprietary crimp tool and heat gun component hamess replacement can be greatly reduced where termination damage occurs The full range of terminated cables are listedover the page Repair procedure Locatethe faulty harnessconnector usingJDS Remove the faulty terminal from the hamess cable and barethe cable end Insertthe bared cable end in to the crimp connector on the terminated cable 1 Fig 3 Securethe cable with a crimptool 2 Fig3 Shrink the insulation sleeve with the heat gun 3 Fig3 Fig3 Insert the new terminal into the connector block and remakethe connection 86 73 AVAILABLETERMINATED CABLES PART NUMBER DBC 3551 DBC 3552 DBC 3553 DBC 3554 DBC 3557 DBC 3558 DBC 3561 DBC 3562 DBC 3565 DBC 3566 DBC 3567 DBC 3568 DBC 3569 DBC 3570 DBC3571 DBC 3572 DBC 3575 DBC 3576 DBC 3579 DBC 3580 DBC 3581 DBC 3594 DBC 3595 DBC 3596 DBC 3597 DBC 3598 DBC 3599 DBC 3600 DBC
356. ose and remove the solenoid Fitting a new solenoid is the reversal of the removal procedure 0206G WATER VALVEVACUUM SOLENOID RENEW 82 25 48 Openthe bonnet and disconnect the battery earth lead Open the car door remove the left hand side dash liner and the footwell outlet duct Remove the screws securing the solenoid mounting paneland repositionthe panelfor access Note then disconnect the vacuum hose and supply cables Remove the screws securing the solenoid mounting plate Disconnect the red vacuum hose and remove the solenoid Fitting new solenoid is the reversal of the removal procedure 82 52 AIR CONDITIONING EVAPORATOR TEMPERATURE SENSOR RENEW 82 20 64 Open the bonnet and disconnect the battery earth lead Removethe right hand dash liner Displacethe wiring harnessfor access Removethe screws securing the sensor Disconnectthe sensor multi plug connector Carefully withdraw the sensor from its location Fig 1 Remove and discardthe gasket On fitting new sensor ensure a new gasket is fitted Carefully with the aid of service tool No JD 122 insert the sensor probe into the evaporator DATA SERVICE TOOL Installer Air Conditioning Sensor JD 122 0206G CHARGING VALVE CORE RENEW 82 30 12 A possible reason for leakage of refrigerant from the system may be a damaged or bent schraeder valve To ensure that the valve core is the cause of leakage use soap solution if the valve core is leakin
357. osed When the override switch contacts are open sunroof travel is limited to a position determined by a reed switch attached to the sunroof transport FRONT DOOR WINDOW SWITCH DRIVERS SIDE RENEW 86 25 03 Open the bonnet anddisconnectthe battery earth lead Open the car door Removethe veneer trim pad76 47 1 1 Removethe upper trim pad 76 34 02 Removethe lower trim pad 76 34 03 Removethe front armrest 76 34 22 Removethe screws securing the switch retaining bracket and removethe bracket 1 Fig 1 Disconnectthe door guard block connectors Removethe switch assembly Fig 2 Fitting a new switch is the reversal of the removal proecedure 3001B FRONT DOOR WINDOW LIFT MOTOR RENEW 86 25 04 Open the bonnet and disconnectthe battery earth lead Removethe veneer panel 76 47 11 Removethe uppertrim pad 76 34 02 Removethe lower trim pad 76 34 03 Fittape over the door glass and frame to secure the glass Fig 3 Remove the screws securing the window lift motor assemblyto the door panel Remove the rubber cover from the window lift guide securing screws and remove the screws Displace the block connector blanking plate from the door for access Cut and remove the ratchet strap securing the block connector Disconnectthe cable harness block connector Displace the window lift motor from the glass and lower the window lift motor assembly into the bottom of the door Remove the window lift motor assembly from the doo
358. ossmember Position the crossmember assembly on the jack under the vehicle Raise the assembly into position and align the shock absorbers Align the engine mountings 5 pipes lower column and rear mountings Align the front crossmember mounting securing bolt holes Fit andtighten the front mounting securing bolts Fig 4 a second jack align the left hand rear mounting Fig3 76 19 BODY SECTION Fit and align the outer spacer Fitthe bolt through the chassis the outer spacer and the mounting Fitthe inner spacer Pushthe boltfully home fit butdo nottighten the nut Lowerand removethe jack from under the mounting Repeat the above procedure for the right hand rear mounting Lower and removethe jack from under the crossmember Finallytighten the rear mounting securing bolts nuts Tighten the rear mounting clamp plate securing bolts Ensure the steering wheel and rack are in the straight ahead position Re positionthe lower column onto the pinion and align the clamp slot Fitandtighten the clamp bolt nut Remove the blanking plugs from the P A S pipes and rack Fit new O ringsto the pipes Connect the pipes to the rack Tighten the union nuts Refitthe P A S pipe clamps Slacken off the MS 536 hook nut Remove the hook Remove Service Tool MS 53B Remove the lifting eye Fitandtighten the engine mounting securing nuts Refitthe calipers Refitthe brake pads Refitthe road wheels Lower the veh
359. ost during the discharge the compressor oil level will have to be checked and if necessary topped up As the discharge rate slows down open the other manifold hand valve so that refrigerant will flow from both high and low pressuresides of the system Constantly adjustthe handvalvesto ensure that oil does notflow When a zero reading is shown on both high and low pressure gauges the system is discharged Close both manifold hand valves AIR CONDITIONING FLUSHING 82 30 03 Flushing the system is an essential function which must be carried out ifthe system has 1 Suffered component or pipe rupture leading to a refrigerant discharge 2 Suffered component failure leading to the possibility of swarf or other contamination of the system 3 The system has been left in a uncapped condition for longerthan eight hours 4 Ifthe system has remained open for than eight hours the drier bottle must be renewed and a 20 minutes evacuation must be carried out in addition to the flushing procedure WARNING IT IS VITAL THAT ADEQUATE VENTILATION IS PROVIDED DURING ALL FLUSHING AND ALL SAFETY PRECAUTIONS ARETAKEN Refrigerant R11 should always be used as the flushing agent Depressurizethe system Removethe drier bottle andthe compressor Discardthe drier bottle 82 27 AIR CONDITIONING The compressor oil level must be checked Stand the bottle of R11 in a container of warm water approx 50 C to raise itto its opera
360. outlet The refrigerant vapour then returnsto the low suction side of the compressor REFRIGERATION CYCLE DESCRIPTION 82 00 00 The belt driven compressor draws in the refrigerant vapour at low pressure and compresses it The pressurized refrigerant is then forced into the condenser located in front of the engine cooling radiator so that it receivesthe full flow of ram air The refrigerant enters the condenser as a high pressure very hot vapour As this hot vapour passes through the condenser coils heat will follow its naturaltendency and movefrom the hot refrigerantvapour intothe cooler ram air as itflows across the condenser coils When the refrigerant vapour reaches the temperature and pressure that will induce a change of state a large quantity of heat will betransfered to the outside air The refrigerantthen changesfrom a high pressurevapourto a high pressure warm liquid This high pressure warm liquid flows from the outlet of the condenserto the drier bottle 82 13 AIR CONDITIONING The drier bottle is a storage tank which receivesthe high pressure warm refrigerant liquid from the condenser filters and retains any foreign particles or moisture from the refrigerant which would be harmful to the system if allowed to circulate with the refrigerant The clean refrigerant passes through to the expansion valve via the sight glass The refrigerantflow to the evaporator must be controlled to obtain maximum cooling while assuring
361. ove the harness to harness carrier securing straps Fig 3 Disconnectthe starter motor multi plug Disconnectthe idle speed actuator connector Disconnectthe injector leads Fig 4 Displacethe harnessfrom the harness carrier Removethe Battery 86 1 5 01 Remove the nut securing the earth lead and disconnect the leads Removethe bolts securing the battery tray and remove the tray Removethe vacuum reservoir tank Cutand removethe securing the harnessto the bulhead Disconnectthe earth leads Displacethe rubber boot from the positiveterminal post and removethe tape Disconnectthe leadsfrom terminal post Openthe door and removethe passenger side dash liner Removethe mainrelayfrom the red socket andthe pump relay from the yellow socket Displacethe relay basesfrom the mounting panel EAS 86 78 ELECTRICAL SYSTEM Disconnect the yellow multi plug connectors LB28 1827 Cut and remove the strap securing the hamess to body Disconnect the engine management block connectors fromthe ECU From the engine bay displace bulkhead cable harness grommet and removethe cable harness Fit the new hamess to the vehicle and route the hamess throughthe bukhead Connectthe engine management block connectors Connectthe yellow multi plug block connectors Fit the relay bases to the mounting panel and refit the relays Securethe hamess with rachet straps Refitthe dash liner Fromthe engine bay Fully seatthe harness grommetto the
362. ove the seat cushion assembly Cutand removethe hamess securing straps Disconnect the reading lamp and recline block connectors Repositionthe hamess away from the seat runners Removethe screws Fig 1 securing the seat to the seat runners Open the rear door Remove the seat to seat runner securing screws and remove the front seat through the front door Reversethe removal procedureto refitthe front seat 175395 Fig 1 16698 81 ELECTRICALLY OPERATED FRONT SEAT RUNNER AND MOTOR RENEW 76 70 08 Openthe front door Removethe bolt securingthe seat cushion Removethe cushion retaining plate Reposition the cushion for access to the block connector Disconnect the block connector and remove the seat cushionassembly Cut and removethe harness securing straps Disconnect the reading lamp and recline block connectors Repositionthe hamessaway from the seat runners Removethe screws securingthe seatto the seat runners Openthe rear door Remove the seat to seat runner securing screws and removethe front seatthrough the front door Remove the bolts Fig 2 securing the rear motor assembly Motor the seatto the fully rearward position and remove the front securing bolts Remove the front securing bolts and reposition the motor assemblyfor access Reposition the sound deadening material and remove the cableclamp securing nuts Removethe clamp Disconnectthe seat multi plugs Removethe runner and motor assembly
363. over Some tyres are slightly outside standard balance limits and are corrected before issue by attaching special patches to the inside covers at the crown The patches contain no fabric and do not affect the local stiffness of the tyre and should not be mistaken for repair patches They are embossed Balance Adjustment Rubber The original degree of balance is not necessarily maintained and it may be affected by uneventread wear cover and tube repair tyre removal or refitting or by wheel damage or eccentricity The car may also become sensitive to unbalance due to normal wear of moving parts If roughness or high speed steering troubles develop and mechanical investigation fails to disclose a possible cause wheel and tyre balance should be suspected WARNING IF BALANCING EQUIPMENT IS USED TO DYNAMICALLY BALANCE THE ROAD WHEELS ALWAYS JACK BOTH REAR WHEELS OFF THE GROUND WHEN REAR WHEEL BALANCING OTHERWISE DAMAGE MAY BE CAUSED TO THE DIFFERENTIAL THIS IS DOUBLY IMPORTANTINTHE CASE OF CARS FITTEDWITH A POWR LOK DIFFERENTIAL AS IN ADDITION TO POSSIBLE DAMAGE TO THE DIFFERENTIAL THE CAR MAY DRIVE ITSELF OFF THE JACK OR STAND 74 16 Issue 2 WHEELS AND TYRES Dynamic Balance Static unbalance can be measured when the tyre and wheel assembly is stationary There is another form known as dynamic unbalance 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 as
364. pack cover securing screws and removethe cover Carefully release the flexible printed circuit ribbon ends from edge connectors by squeezeing grips between thumb and forefinger while sliding out connector latch Fig 1 Release electronics pack retaining clips and pivot pack upwards Fig 2 Displace and remove electronics pack from instrument pack by lifting off from hinges Displace and remove 6 warning bulbs 2 both sides located adjacentto LCD module andthe 2 bulbs located in module itself bayonet fitting twist 1 8th turn anti clockwise to release Disconnectthe flexible printedcircuitto LCD multi plug Remove LCD unit securing screws and unit Fig 3 Fit new LCD unit into position fit and tighten LCD module securing screws Re fitthe warning bulbs into the ernpty sockets Reconnect the flexible printed circuit multi plug to the LCD unit Carefully fit the electronics pack over flexible printed circuit connections and locate onto hinges Pivot pack downwards andfit into securingclips Fit flexible printed circuit to edge connectors by positioning holes in flexible printed circuit membrane over connector latch locating pips and sliding latch to the fully closed position Align and fit back cover to the electronics pack Fit and tighten the securing screws Fit the cowl housing to the pack Fit and tighten the cowl housing securing screws Fit the instrument pack assembly into dashboard position re connectthe block
365. perture finisher Fig 2 from the aperture ensuring that the headlining trim edges are notdamaged Reversethe removal procedureto refitthe finisher 00856 976 357 76 56 BODY SECTION SLIDING ROOF MOTOR DRIVE GEAR RENEW 76 82 44 Open the doors Remove the sliding roof flange finisher 76 82 23 Removethe sun visor vehicle set 76 10 17 Remove the cantrail crash roll left and right hand 76 13 10 Removethe sliding roof motor 86 76 01 Removethe drive gear from the sliding roof motor Reverse the removal procedure to fit the replacement gear ensuring that prior to assembly the gear is coated with grease 0080b SLIDING ROOF PANEL RENEW 76 82 05 Open the door Fig 1 Open the sliding roof Remove the sliding roof panel securing screws and partiallyclosethe roof Removethe sliding roof panel assembly Remove the lifting block securing nuts and screws and 1 Fig 2 removethe lifting blocks 2 Fig 2 and plates 3 Fis 2 Removethe screws 1 Fig 1 and drill outthe pop rivets 2 Fig 1 securing the roof panel seal front and rear retainingplate Removethe retaining plates Removethe seal Discardthe roof panel Reverse the removal procedure ensuring that prior to final tightening of the securing screws that the roof is centralised with an even 4mm gap all round the aperture 0081b SLIDING ROOF PANEL LIFTING BLOCK RENEW 76 82 27 Open the door Openthe sliding roof Remove the nuts 1
366. plate plastic face Reconnectthe motor harness multi plugs Position the motor to the B post fit and tighten the securing bolts Fitthe foam anti rattle blocks intothe B post Remove the tape from the B post aperture and adjustment plate plastic face Repositionthe dock assembly adjustment knob Refitthe guide rail and cant rail crash roll Refitthe B postupper and lowertrim pads Refitthe inertia reel assembly to the seat runner ensure that the reel bracket locates onthe peg Fitandtighten the securing bolt Remove the support block reposition the seat runner fit and tighten thesecuring bolts Refitthe front seat DATA TORQUE FIGURES Seat runner bolts 35Nm 76 113 BODY SECTION PASSIVE RESTRAINT INERTIA REEL RENEW 76 73 23 Removethe front seat 76 70 10 Removethe seat runner to floor securing bolts Liftup the inertia reel side of the runner for access Use a suitable block for support Removethe inertia reel securing bolt Fig 1 remove the reel assembly Fitthe new reel assembly to the seat runner ensure that the reel bracket locates on the peg Fitandtighten the securing bolt Removethe support block reposition the seat runner fit andtighten the securing bolts Refitthe front seat DATA TORQUE FIGURES Seatrunner bolts 35 Nm 0051G PASSIVE RESTRAINT GUIDE RAIL RENEW Removethe B postuppertrim pad Removethe cant rail crash roll Remove the guide securi
367. plug connector 1 Fig 2 Disconne t the rubbertube from the sensor assembly 2 Fig 2 Remove the screws securing the sensor assembly and removethe assembly 3 Fig 2 Remove the screws securing the sensor to the sensor housing and removethe sensor Fitting a new sensor is the reversal of the above procedure 0206G 482 174 Fig2 82 37 AIR CONDITIONING AMBIENT TEMPERATURE SENSOR RENEW 82 20 02 Open the bonnetand disconnectthe battery earth lead Removethe drivers side dash liner Displace the pliable trunking from the air conditioning unit Removethe bolts securingthe blower motor assembly Disconnectthe multi plug cable harness connectors On right hand drive vehicles disconnectthe in car sensor hose from the pliable trunking Disconnect the vacuum hose from the blower motor assembly servo unit Displace and removethe blower motor assembly Remove the two screws securing the ambient sensor and remove the sensor On left hand drive vehicles the sensor is accessible through the removable plate inthe glove box 1 Fig 1 Fitting a new sensor is the reversal of the removal procedure 02066 BLOWER MOTOR ASSEMBLY Right handside RENEW 82 25 14 Openthe bonnetanddisconnectthe battery earth lead Removethe right hand side dash liner Fig 2 Ifthe vehicle is left hand drive removethe glove box and lid Removethe lower screw securing the central processor displacethe earth lead and removethe space
368. postanchorageunit Warning light inoperative Proximity switch inoperative System inoperative Anchorage loose Rail cantrail to A post Seal sags gap between rail and body System inoperative travelling tongue jammed Cause Damageto reels Loose reel bolt Inadequate kick plate Foulingof webbing on carpet cross member rnounting bracket Incorrectreel slide buckle assy Foulingof webbing on carpet cross member mounting bracket Incorrectreel slide buckle assy or damage to webbing guide Bucklefouling cushion buckle crankedtoo far over towards centre line of car Worn motor casings Motorcasing damaged or boltfailure Inadequatebolt retention orfailure Electricalcable severed Electricalcable severed Brokendrive cable Drivecable kinked or excessive cable length Anchorage bolts loose Loosefixing screws and seal fixings Bendradiustoo tight at BC post Action Renewreels Check security of all bolts kick platesretention Check routing of belt Check renew components Check routing of bett Check renew components Check renew webbing guide Check adjust positionof buckle Check dimensions of bucklesupportarm Check renew casings and bolts Check security of all bolts kick plates fixings Repair renew cable Repair renew cable Renewmotor winch assy Check security of all bolts fixings Check security of all fixings Adjust reposition rail renewif necessary
369. potwelds quarter 1Xmm braze ARO arms 264A or equivalent 1X mm MIGseam weld 1X mm braze Disconnectbattery and alternator Remove Spare wheel and jack boot mat petrol tank cover rear panel section and carpet tail lamp cover and rear wing carpet section Lay aside boot aperture weatherseal Remove Rear bumper assembly with rear foglamp unit RH and LH bumper iron boot aperture mouldings andtail lamp unit Jack up rear of vehicle and placeon axle stands Remove Exhaust rear section radio aerial assembly RH only aerial sealing grommet RH only rear wing extractor vent box bumper side mounting rear seat cushion and backrest rear seat insulation at cushion and backrest rear parcel shelf upper quarter trim section and rear sill treadplate Lay aside rear door aperture weatherseal and beading Remove rear door striker quarterlight inner weatherseal quarterlight glass upper quarter moulding petrol filler flap LH only Lay aside rear wiring loom boot lid wiring loom RH only aerial wiring RH only petrol filler flap wiring LH only braking system microprocessor wiring LH only and petroltank wiring RH only 77 19 BODY REPAIR Removethe petrol tank Panel Replacement Panel removal and replacementisto the method detailed in Section 77 10 01 07 with the following variations During removal the panel is cut at points 1 Fig 1 and 2 Fig 1 inthe welding diagramandthe bulk removed The resistan
370. pressed either by hand or by using a separating tool which also commencesthe parting process Use Service tool JD 121 to separate the connectors Fig 3 Uniting boh PM4 and PMHD connectors is simply a matter of aligning the tongues wiyh thw corresponding grooves and gently pushing the two halves together until the latching arms travel up and over the dead lockingramps Fig3 86 68 ELECTRICALSYSTEM PM4 TERMINAL EXTRACTION PROCEDURE Tools and materials required 1 Terminal extractiontool 2 Terminal extraction aid 3 Silicone oil Releasethe secondary locking cover from the connector housing If a rubber cable seal is fitted lubricate the wires with silicone oil dislodge the seal from the housing and slide it up the wires Whilst applying pressure to the terminal fit the terminal extraction tool Fig 1 over the terminal until the tool abuts the housing and withdraw the terminal from the housing via the cable entry end If any resistance is encountered when withdrawing the terminal ensure that the terminal extraction tool is fitted correctly and repeat the operation Lubricate the angled end of the extraction aid with silicone oil then insert the aid into the hole containing the wire to be removed Withdraw the wire and terminal through the extraction aid and remove the aid PM4 TERMINAL INSERTION PROCEDURE Tools and materials required 1 Terminal insertion aid 2 Silicone oil If necessary release the seconda
371. r Reversethe removal procedureto fit a new bulb 30018 BONNETLAMP BULB AND LENS RENEW 86 45 23 Openthe bonnetand disconnectthe battery earth lead Removethe screws securing the lampto the bonnet Removethe lens Removethe bulb Fig 2 To fit a new bulb or lensreversethe above procedure 3001B BONNET LAMP ASSEMBLY RENEW 86 45 24 Openthe bonnet and disconnectthe batteryearth lead Remove the screws and retaining clips securing the bonnettrim Displacethe trim for access Disconnectthe cable hamess multi plugconnector Remove the screws securing the bonnet lamp and 35 removethe lamp Reversethe above operationto fit a new lamp 30018 86 39 ELECTRICALSYSTEM BONNET LAMP SWITCH RENEW 86 65 23 Openthe bonnet anddisconnectthe battery earth lead Disconnectthe switch lucar cable connector Removethe screws securing the switch and remove the switch Fig 1 Reversethe above operationsto fita new switch 30018 SWITCH PANEL ILLUMINATION BULB RENEW 86 45 36 Openthe bonnet and disconnectthe battery earth lead Openthe car door Remove the screw securing the switch cover from beneaththe lighting logic board Remove the bulb holder from the switch panel then remove the bulb Reversethe above operationsto fit a new bulb 30018 INSTRUMENT ILLUMINATION BULB RENEW 86 45 48 Openthe bonnet and disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Disp
372. r Fig 4 Fitting a new motor assembly is the reversal the removal procedure 3001B 86 22 ELECTRICAL SYSTEM FRONT DOOR WINDOW LIFT SWITCH RENEW 86 25 06 Openthe bonnet and disconnect the battery earth lead Remove veneer panel 76 47 11 Remove the uppertrim pad 76 34 02 Removethe lower trim pad 76 34 03 Removethe armrest 76 34 22 Removethe screws securing the switch retaining bracket and removethe bracket Disconnectthe door guard block connectors Removethe switch ashtray assembly Displace the switch asemmbly from the housing and carefully releasethe lockingtabs to removethe switch Fitting a new switch is the reversal of the removal procedure Ensureallthe electrical connections are clean andtight 3001B REAR WINDOW LIFT MOTOR Fig 1 RENEW 86 25 09 Openthe bonnetand disconnectthe battery earth lead Removethe veneer panel76 47 12 Removethe uppertrim pad 76 34 05 Removethe lower trim pad 76 34 06 Fittape over the door glass and frame Fig 1 to secure the glass Cut and remove the ratchet strap securing the block connector Disconnectthe cable harness block connector Remove the screws securing the window lift motor assembly to the door panel Remove the rubber cover from the window lift guide securing screws and removethe screws Remove the rubber cover from the window lift guide securing screws and removethe screws Displacethe window lift motor from the glass a
373. r 80 grit disc Tin areas to be soldered by applying solder paint and heatingwith a propanegas torch Fig 2 Wipe joint area cleanwith cloth Apply solder Shape solder to joint using a gas torch hardwood block and tallow Fig 3 The solder should be carefully and evenly spread over the whole joint area to achieve as smootha finish as possible Shape and dress soldered areas using body files Fig 4 80 grit production paper anda randomorbit sander Fig 1 Neutralisethe solder by cleaning and wiping the finished area with an ammonia soaked cloth NOTE Health and safety regulations requirethat on completion of solder dressing the dress must be removed from the work area At the end of soldering operators must washtheir hands Apply highlight oil to determine final quality of panel shape Remove protectivecovers and cleanthe car interior Seal all joints with 3M Drip Chek automotive joint seam sealer and apply underseal where necessary Anti drum pads can now befitted The panel replacement is now complete so the road wheels can be replaced and the vehicle lowered to the ground Aram Fig4 Fig3 77 14 BODY REPAIR BONNET MOUNTING PANEL RENEW 77 15 02 Welding Table No Location Remove FactoryJoint Replace RepairJoint 1 Corner gussetto mounting 10resistancespotweldseach 10MIGplugwelds each side panel RH and LH 2 Toheadlamppanelrear flange RH and LH 3 To headlamp panel upper flanae RH and L
374. r all old and new panelsurfacesto be resistancespot welded together havethe primer removed and arethen treated with weld through primerto provide corrosion protection inthe weld area The weld nugget produced bythe resistancespot welding equipment available to the motor vehicle repairtrade is smaller than that produced by production equipment In the welding tables the expression single row of resistance spot welds is used This means that resistance spot welds should be spaced 5 8 16mm to 1 25mm apart which will usually mean that more resistance spot welds will be replaced in the repair joint than were removedfromthe factory joint To removeresistance spot welds a resistancespot weld cutter should be used If the newjoint isto be MIG Plug welded the old resistance spot welds should be cut from the panelthat isto be retained whenever possible and these holes usedfor plug welding Alternatively if necessary holes may be punchedor drilledfor this purpose It must be ernphasisedthat all safety precautions must be observed and protectiveequipment used when carrying out welding and grinding operations etc CUTTING AND WELDING SYMBOLS USED INTHIS SECTION Referringto Fig 1 1 1 Saw Cut 2 Chiesel Cut A A2 3 Cut Out SpotWeld 4 Resistance Spot Weld 6 6 6 6 6 6 63 5 Mig Tack Weld 04 Weld es ei ee 8 Gas Weld PDD D 96 9 Mig
375. r at or above ambient regardless of ambient and in car conditions The MODE button will notfunction when RAM isselected Theair button demist when pressedwill openthe defrost flaps and increasethe amount of airto the screen When the RAM button is pressed the word will appear above the mode button together with abovethe RAM button The system autumaticallygoes intothe MAN mode Air is supplied by the foreward movement of the vehicle and the force of the air is dependent on the vehicle s speed The blower motors are disengaged except when DEFROST is selected Pressingthe button again restores the systemto the previousselected position on the MODE button The slide control Air Differential Control is usedto alter the air temperature being distributed through the face level vents To increase the air temperature being delivered through the vents the slide control is movedto the rightand to decreasethe temperature the control is movedto the left Pressing the AIR button increases the amount of air distributedto the windscreen and improves demisting It is mosteffective under normal operation of the heater unit The centre vent is controlled automatically and only opens when the system is switched to full cooling to supply air at ambienttemperature The vents atthe end of the fascia supply ambient or heatedair Temperature Sensors There are two temperature sensors fitted into the system the ambientandthe in car
376. r strut Federal 39 5ONm 3 Bumper quarter blade toquarter bumper 5 7Nm Bumper side to flexible mounting block 5 7Nm SPANNER SIZES 8mm 70mm 19mm 16698 69 REAR BUMPER CENTRE BLADE RENEW 76 22 12 Prise off the black plastic trim finisher 1 Fig 1 remove Fig 1 the five screws 2 Fig 1 securing the blade 3 Fig 1 release the blade from the securing clips and remove the bumper blade Fit the replacement centre blade to the retaining clips fit m nen the five securing screws and refit the trim inisher DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27Nm Bumper to bumper bracket Non Federal 40 50 Bumper to body inner Federal 23 27Nm Bumper to fixings bumper beam Federal 39 50Nm Bumper to body inner Non Federal 23 27Nm Bumper to fixings bumper beam Non Federal 39 50Nm Guideblock to mounting bracket 5 4 75bNm Mounting bracketguide block to body 7 8 SPANNER SIZES amm I Omm 713mm 7 7mm 79mm No 20 Torx 0374b 76 51 BODY SECTION REAR BUMPER CENTRE BLADETRIM FINISHER RENEW 76 22 14 Openthe boot Move the carpet to gain access to the rear fog guard lamp hamesses Reposition approximately 3 of slack through the grommets for each fog guard lamp Removethe bolts securing the rear beam Removethe spacers Carefully position the beam assembly rearwardsto gain access to the trim finisher Unclip an
377. rackets and four plastic thread inserts Fig 2 Open the bonnet Securethe bonnetwith a suitable support Remove the bonnet hinge securing nuts and bolts Removeand discardthe hinge Position the replacement hinge on the front panel locatingthe studs inthe holes Open the hinge and align with the securing holes inthe bonnet Fit andtighten the hingeto bonnetsecuring bolts Fitbut do notfully tightenthe the hingesecuring nuts Remove the bonnet support and carefully lower the the bonnetto checkthe alignment Open the bonnet slacken the hinge securing nuts and positionthe bonnetas required Fullytighten the securing nuts Close the bonnetand check the alignment Refitthe radiator grille and surround i Closethe bonnet Fig2 ean DATA SPANNER SIZES 10mm 13mm 1669B 84 76 29 BODY SECTION BONNET HINGEVEHICLE SET FEDERAL RENEW 76 16 12 Remove the two screws situated at the top securing each front grille and removethe grille Fig 1 Remove the two bolts each side securing the grille support brackets to the body Remove the grille assembly and remove the grille support brackets and four plasticthread inserts Fig 2 Open the bonnet Secure the bonnet with a suitable support Remove the bonnet hinge securing nuts and bolts Fig 3 Remove and discard the hinge Position the replacement hinge on the front panel locating the studs inthe holes Open the hinge and align with the securing holes in the bo
378. rake throttle clutch pedal assemblies Disconnect Heater hose through the bulkhead Remove Radiator expansiontank 26 15 01 Fig 1 Bonnet weatherseals front bumper mounting assembly radiator grille and surrounds Wheel arch shield lower front spoiler and washer reservoir Front seats lower A and B post trims front door beading and weatherstrip Front sill treadplate 1 2 Fig 2 and front seat belt assembly Battery and batterytray Vacuum bottle assembly driver s well insulation scuttle panelandjets Gutter moulding and retainers Frontscreen and mouldings B post outer finisher andfront doortrim Lay aside Carpeting Remove Headlamp repeaterflasher and dashtrimboard Instrumentpaneland housing88 20 01 13 Centre air vents andfascia board 76 46 01 Fig 2 Processor units heater blower unit and all bulkhead insulation Wiper fascia and fascia relay bracket Lay aside Wiring loomto vehicle interior Remove panels Frontwing Front door Weatherseal panel Inner A post Sillclosing panel Innersill sectioned Bodyside sectioned 77 28 BODY REPAIR Panel Replacement Panel removal and replacement isto the method detailed in Section 77 10 01 07 Painting See Section 77 00 00 Replace Parts Replace parts in reverse order of removal Reconnect battery and alternator test those electrical itemsthat have been removed and replaced Bleedthe brakes 70 25 0
379. re are no distinct steps betweenthe fan speeds buta gradual increase or decrease of speed When DEFROST is selected the fans are electronically controlled to operate at maximum speed the screen vents open maximum heating is obtained and the lower flaps fully close it can take up to a maximum period of 30 secondsto completethis operation The control situated on the right hand side of the control panel is the temperature demand control The temperature requirements of the vehicle within the range of 19 to 29 C can be selected by the setting of this control With the control turned to the fully anti clockwise position maximum cooling is obtained and to obtain maximum heatingturn the control fully clockwise When the mode button s set inthe auto modethe control system use all the temperature sensors in relationto the temperature selected by the temperature demand control The system then automatically adjust the flaps for heating or cooling modes to achieve the disired results Blower fan speeds are also selected to increase or decreasethe volumn of air flow depending upon the differences betweenthe varioustemperaturesensors andthe selectedtemperature When the button is set in the manual mode it overrides the temperature sensors and the system will obtain the temperature selected The air button demist when pressedwill cause the defrostflapsto the screento open The maximum and minimum limits of the evaporator temperature are determined by the s
380. re for primary warnings and illuminate RED The seven left hand warning indicators are for secondary warnings and illuminate AMBER The eight lower lamps are a mixture of status and warning lamps ODOMETER Total distance travelled by the vehicle is displayed on an LCD display located centre bottom of the Instrument Pack The LCD is a single line six digit seven segment display The odometer shares the LCD display with Trip Computer and Vehicle Condition Monitor information When the ignition is switched off the odometer reading is permanently displayed If the ignition is switched on and the odometer reading is not shown it can be displayed by pressing the CLEAR button located on the VCM keypad Fig 2 Page 88 07 either once ortwice Excessive heat in the vicinity of the LCD display will be automatically detected by a thermistor and the backlight will be dimmed to preventopaqueing of the LCD This safety feature may be actioned if driving in hot countries with headlightson full beamfor example IN STRUM ENTS instrument Pack Displays and Keypad 40 7 ba 7 age Hu 4 GAUGES Fig 1 amp 2 1 Tachometer 2 Speedometer 3 Battery Condition 4 Fuel Gauge 5 Oil Pressure 6 Coolant Temperature 7 Odometer VCM Trip Computer Display 8 Primary Warning Indicators RED 9 Secondary Warning indicators A
381. refully move the beam assembly rearwards for access tothe rear quarter bumper mountings Removethe reflectorfrom the quarter bumper 76 48 BODY SECTION Remove the nuts Fig 1 securing the bumper Fig 1 to the mounting rubber Carefully reposition the quarter bumper from the studs and removethe quarter bumper assembly Reposition the beam onto the strut and remove the quarter bladeto quarter bumper securing nuts and bolts Removethe bladefrom the bumper and place aside Reverse the removal procedure to refit the replacement bumper DATA TORQUE FIGURES Bumper beam to bumper bracket Non Federal 40 50Nm Bumper beam to bumper strut Federal 39 50Nm Bumper quarter blade to quarter bumper 5 7Nm Bumper side to flexible mounting block 5 7Nm SPANNER SIZES 8mm 276 350 1 Fig 1 19mm 16698 63 REAR QUARTER BUMPER MOUNTING RUBBER RENEW 76 22 21 Open the boot Removethe rear quarter bumper 76 22 1 7 Removethe nuts securing the mounting rubber 1 Fig 2 to the beam and removethe mounting rubber Reverse the removal procedure to refit the replacement rubber DATA TORQUE FIGURES J76 az Bumper beam to bumper bracket Non Federal Fia2 40 50Nm 9 Bumperbeam to bumperstrut Federal 39 50Nim Bumper quarter blade to quarter bumper 5 7Nm Bumper side to flexible mounting block 5 7Nm SPANNER SIZES 8mm 7 Omm 19mm 76 49 BODY SECTION REAR QUARTER BUMPER LOCATING BRACKET RENEW 76 22 22
382. rews Rj oo SOOO Fit instrument pack assembly into dashboard position re connectthe block connectors Align assembly fit and tighten the securing screws NEU Return steering wheelto original position Refitthe dash liner E Reconnectthe battery NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored to the correct value Fig3 issue 2 88 11 INSTRUMENTS INSTRUMENT PACK LENS COWL RENEW 88 20 17 Disconnectthe battery Remove driver s side dash liner securing screws release the securingclip and removethe liner Release the steering column clamp fully extend the steering wheel and re tightenthe clamp Removethe instrument pack assembly securing screws Disconnectblock connectors from rear of pack Displace and remove the instrument pack assembly Fig 1 Release the cowl lens securing clips and remove the cowl lens assembly 1 Fig 2 CAUTION With the cowl lens removed DO NOT rest the pack face down The gauge needles are extremely delicateand are easily damaged Also take care notto scratch or damage the gaugefaces ensurecleanliness when handlingthe pack Fitthe newcowl lens assemblytothe instrument pack Fit the instrument pack assembly into dashboard position re connectthe block connectors Align the assembly fit and tighten the securing screws Return the steering whee
383. rews securing the electronic control moduleand displacethe modulefor access Fig 2 Remove the screws securing the matrix housing and removethe housing halves Removethe matrix Fig 3 Removethe foam stripfrom the matrix Fitting a new matrix is the reversal of the removal procedure 0209G x 282 177 80 8 HEATINGAND VENTILATION HEATER MATRIX PIPE GASKET RENEW 80 20 04 Disconnectthe battery earth lead Drainthe coolant Removethe passenger dash liner Removethe glove box lid and glove box Disconnect the coolant temperature switch supply cables 1 Fig 1 Remove the screws securing the heater matrix pipe housing 2 Fig 1 Removethe housing halves Displacethe foam pad Removethe screws securing the pipes Displacethe pipes for access 3 Fig 1 Removethe gaskets Clean the surface of the matrix Fitting new gaskets is the reversal d the removal procedure HEATER COOLANTVALVE RENEW 80 10 16 Drainthe coolant Slacken the coolant hose to valve securing clip and disconnectthe hose 3 Fig 2 Slackenthe valveto heaterfeed pipe hoseclip 2 Fig2 Disconnectthe vacuum hoseelbow 1 Fig 2 Removethe valve assembly 4 Fig 2 Slackenthe hoseclip and removethe hose Fitting a new coolant valve isthe reversal of the removal procedure BLOWER MOTOR ASSEMBLY DRIVER SIDE RENEW 80 20 11 Disconnectthe battery earth lead Removethe drivers dash liner Remove the clip retaining the pliab
384. rews securing the instrument housing locating bracket and removethe bracket Remove the solar sensor panel from its mounting position Fig 2 Remove the screws securing the defrost outlet duct and remove the ducts Remove the screws securing the defrostvent disconnect the vacuum hose and remove the vent assembly Carefully displace the solar sensor hamess from its position cut the ratchet strap securing the hamess and vacuum hosesto the fascia Remove the grommet from the fascia and the harness vacuum hose assembly Remove the outer ventilator assemblies and the spire nuts from the fascia Discardthe fascia Reverse the removal procedure to refit the replacement fascia DATA TORQUE FIGURES Fig 1 Fasciabracketscre 7 70 Fasciacentre to air conditioning unitstrut22 28Nm Fasciasupportbracketto post22 28Nm Fasciatoside bracket 15 18Nm Steering wheelto steering shaft 35 45Nm Strutto centre fascia fixing 5 ZNm Strutto fasciaend7 10Nm SPANNER SIZES mm 10mm 713mm 24mm 180 037 OILS GREASES SEALANTS Split collarsto shaft Castrol LM Grease 00356 76 85 BODY SECTION FASCIA CLOSING PANEL DRIVERS SIDE RENEW 76 46 28 Openthe door Remove the screw securing the dash liner to the closing panel Remove the screws securing the closing panel and displace the dash liner from the the spring retainingclips Removethe lower screw spacing washers and spire clip Remove and discard the clo
385. rness with ratchet straps Refit the boot front liner and floor carpet Replace the spare wheel and jack Close the boot Connect the battery Close the bonnet 19 318 FUEL SYSTEM RELAY DESCRIPTION 18 00 00 The fuel pump relay has been re positioned from under the passenger footwell to the underbonnet LHS forward of the bulkhead andthe colour of the relay base has changed from redto yellow FUEL SYSTEM RELAY RENEW 18 30 30 Open the bonnet and disconnect the battery The fuel pump relay is mounted adjacent to the brake pedal box Displace the relay cover and remove the relay from the yellow base connector Fit the new relay to the base connector and replace the relay cover Reconnect the battery and close the bonnet POWERED SEATS DESCRIPTION 86 00 00 The seat adjust relay used on 90MY vehicles is deleted at 91MY Seat position control is now provided via the right and left seat relays which use earth switching instead of ignition positive and the earth switched door ajar switch for control signals 86 110 ELECTRICAL SYSTEMS 91MY E POST LAMPS DESCRIPTION 86 00 00 E post lamps will only come on with the keyswitch in the auxiliary ignition position and the 3 redundant wires that went to the passive ECU have been deleted SCREENWASH HEATER DESCRIPTION 86 00 00 The screenwashheater element wires have been split so that the wire for the right hand heater element is fed from the right hand side
386. roducts which will burn spontaneously on exposure to air or decompose with violence in the presence of moisture The suitable refrigerantis supplied underthe following trade names FREON 12 ARCTON 12 ISCEON 12 Or any refrigerantwith a specification of 12 WARNING GOGGLES AND GLOVES MUST BE WORN WHILE WORKING WITH REFRIGERANT EXTREME CARE SHOULD BE EXERCISED IN HANDLING REFRIGERANT LIQUID REFRIGERANT AT ATMOSPHERIC PRESSURE BOILS AT 29 SERIOUS DAMAGEOR BLINDNESS MAY OCCUR IF REFRIGERANT IS ALLOWED TO COME INTO CONTACT WITH THE EYES 82 14 AIR CONDITIONING FIRSTAID If refrigerantshould come into contact with the eyes or skin splash the eyes or afected area with cold water for several minutes DO NOT RUB As soon as possiblethereafter obtain treatment from a Doctor or an eye specialist GOOD PRACTICE Protectivesealing plugs must be fitted to all disconnected pipes and units The protective sealing plugs must remain in position on all replacement components and pipes until immediately before assembly Any partarrivingfor assembly without sealingplugs in position must be returnedto the supplier as defective 4 essential that a second backing spanner is always used when tightening or loosening all joints This minimisesdistortion or strainon components or connecting hoses 5 Components must not be lifted by connecting pipes hosesor capillary tubes 6 Caremustbetaken notto damagefins onthe condenseror evaporat
387. rolled switches then by comparing this data with the signals received from the various temperature sensors andfeedback devices it calculatesthe output voltages neededto operate the blower motors atthe required speed the flap servo motorsto the required positions andthe vacuum solenoidsto acheivethe temperaturerequirements above ambient selected by the driverforthe vehicle Although the control module cannot be be repairedin service a complete set of test pins are accessible for testing the system Great care must be exercised when connecting the test equipment The control module will be irreparably damaged should any of the test pins be momentaryshortedtogether Keyto Diagram Control module Differentialtemperature control Temperaturecontrol Blower motor switch Ambienttemperature sensor In cartemperature control Solar sensor Coolanttemperature switch Flapfeedback potentiometer Flapfeedback potentiometer 11 Blower motorfeedback 12 Blower motorfeedback 13 Highspeed relay 14 Blowermotor 15 Blowermotor 16 Flapservo motor 17 Flapservo motor 18 Defrostvacuum solenoid 19 Recirculationvacuum solenoid 20 Centreventvacuum solenoid 21 Water valve vacuum solenoid 21 20 19 8 9 10 11 12 SE 447 80 4 HEATING AND VENTILATION Temperature Distribution The heating and ventilation unit case Fig 1 consists of three parts the rear of which in air condition
388. rrier securing nut Displacethe racktube assembly from its guide open up and repositionthe tube clamp overthe reartube and rack bracket Holding the rear tube in position disconnect the front rack tube from the rear racktube Releasethe rack from the rear tube and carefully remove the rack Greasethe replacement rack fit the rackto the front rack tube reposition the rack into the rear rack tube approximately 12 in ensuring that the clamp is not displaced along the tube 76 59 BODY SECTION Reposition the front rack tube and connect to the rear rack tube ensure that the rack tube to sliding roof assembly rubber is correctly positioned Position the clamp over the union and connectthe rack to the carrier Tighten the rack securing nut and manuallyslide the roof fully rearwards Position the rack tube into the guide close the clamp and align the mounting bracket fit andtighten the clamp securing screws Position the rack tube end sections and secure the tube with ratchetstraps andtape Position the rack tubes for fitting the motor manually close the roof ensure that the carriers are fully forward refit the roof motor and reverse the remaining removal procedureto refit 003 1b SLIDING ROOF RACK VEHICLE SET RENEW 76 82 43 Open the doors Removethe sliding roof panel76 82 05 Removethe sliding roofflange finisher 76 82 23 Removethe sun visor vehicle set 76 1 0 1 7 Remove the cantrail crash roll left
389. rs Loosen the upper screw securing the processor raise and disengage the processor from the securing screw Displacethe processor downwards for access Remove the screws securing the processor mounting 7 bracket and removethe bracket Displace the pliable trunking from the air conditioning unit Removethe bolts securing the blower motor assembly Disconnectthe multi plug cable harness connectors Disconnect the in car sensor hose from the pliable trunking Disconnect the vacuum hose from the blower motor assembly servo unit Displace and removethe blower motor assembly Fig2 82 38 AIR CONDITIONING Disconnectthe ambienttemperature sensor Removethe rubber gasket from the assembly Remove the tape securing the trunking to the blower fi a motor assembly and removethe trunking Fitting a new blower motor assembly is the reversal of the above procedure 0206G BLOWER MOTOR ASSEMBLY Left hand side RENEW 82 25 13 Open the bonnet and disconnectthe battery earth lead Removethe left hand side dash liner the vehicle is right hand drive remove the glove box and lid Removethe lower screw securing the central processor displace the earth leadand removethespacers Loosen the upper screw securing the processor raise and disengage the processor from the securing screw Displacethe processor downwards for access Remove the screws securing the processor mounting bracketand removethe bracket R
390. rs remove the glove box and relay mounting bracket Remove the left hand side dash liner Remove the screws sucuring the electronic control module 1 Fig 2 to the air conditioning unit and repositionthe modulefor access Remove the screws securing lower motor assembly displace the assembly and disconnect the multi plug connector Removethe flap motor assembly Fitting a new assembly is the reversal of the above procedure 02066 11 282 61 82 43 AIR CONDITIONING ELECTRONIC CONTROL MODULE E C M RENEW 82 20 65 Open the bonnet and disconnectthe battery earth lead Open the car door and remove the right hand dash liner On left hand drive vehicles remove the glove box assembly Remove the screws securing the control module and displace the modulefrom its location Disconnect the earth lead and the multi plug harness connectors Removethe module Fig 1 Fitting a new module is the reversal of the above procedure Ensurethat all connection are secure and clean 0206G WATER TEMPERATURE SWITCH RENEW 82 20 71 Openthe bonnet and disconnectthe battery earth lead Open the car door and remove the left hand side dash liner Note anddisconnectthe switch supply cables Remove the screws securing the switch and remove the switch Fig 2 Fitting a new switch is the reversal of the above procedureensuring all connection are secure and clean 0206G 182 175 82 44 AIR COND
391. ry locking cover and slide the cable seal back along the wires as described in the first two steps of the terminal extraction proceedure Ensure the wire passes through the secondary locking cover and after lubricating the cable seal with silicone oil insertthe aid into the appropriate hole inthe seal until its open end isjust proud of the surface Installthe end of the terminated wire inthe insertion aid then pass the loaded aid through the seal and removethe aid Insert the terminal into its location in the connector housing ensuring that the terminal is fully home and the locking lance engaged Slide the cable seal along the wires and locate it in the connector housing Install the secondary locking cover in the connector housing PMHD TERMINAL EXTRACTION PROCEDURE Tools and materials required 1 Terminal extractiontool 2 Terminalextraction aid 3 Silicone oil Release the secondary locking cover from the connector housing using a suitable instrument e g a screwdriver and set the cover in the cable assembly mode i e the coverfully extended on itsfour locking arms 86 69 J86 629 ELECTRICAL SYSTEM Whilst applying pressure to the terminal fit the terminal extraction tool Fig 1 over the terminal until the tool abuts the housing and withdraw the terminal from the housing via the cable entry end If any resistance is encountered when withdrawing the terminal from the housing repeatthe operation PM
392. s adjusted to the correct tension A load of 1 5 kg must give a total belt deflection of 4 5 mmwhen applied atthe mid point of the belt 30018 ALTERNATOR DUMP MODULE RENEW 86 10 06 Open the bonnet and disconnectthe battery earth lead Removethe air cleaner assembly Remove the screws nuts and washers securing the module Disconnect the cable to the alternator the earth lead and the multi plugcable connector Removethe module Fitting a new module is the reversal of the above procedure ensuring all the electrical connections are clean andsecure 3001B 86 16 186 925 ELECTRICALSYSTEM BATTERY DESCRIPTION 86 15 00 The declaration of the battery capacity in ampere hours by battery manufacturers is now optional and a more realistic method of declaring the characteristics of a battery is by quoting the RAPID DISCHARGE CURRENT and the RESERVE CAPACITY A battery user will find information about how long a battery will sustain the maximum electrical load in the event of an alternator failure and about the battery s cold start performance is of much greater use than details of battery capacity at the 10a 20 hour rate Cranking Performance This is the assessed performance of the battery under simulated load conditions The cranking current is the currentthe battery will deliver at the initialtemperature of minus 18 C which enables a minimum voltage of 7 2 volts to be obtained at the battery terminals for 30 sec
393. s inthe body side vents DATA TORQUE FIGURES Ventilator box to boot floor6 8Nm SPANNER SIZES I 0362b 76 66 BODY SECTION BOOT LID HINGE VEHICLE SET RENEW 76 19 28 Open the boot cut and remove the boot harness straps and move the harness away from the hinge remove the upper hinge securing bolts 1 Fig 1 disconnect the boot illimination switch wire left hand side removethe two lower hinge securing bolts and removethe hinge 2 Fig1 Ravers the removal procedure to refit the replacement hinge and repeatfor the right hand boot hinge Adjust the alignment of the boot relative to the wings and tighten the securing bolts DATA TORQUE FIGURES SPANNER SIZES 73mm 0378b BOOT LIDSEALTREAD PLATE RENEW 76 19 09 Open the boot Slacken and remove the screws 1 Fig 2 securing the tread plate 2 Fig 2 to the body Removethe tread plate Reverse the removal procedure to refit the replacement tread plate 16698 74 BOOT REAR LINER RENEW 76 19 32 Openthe boot Fig Peel back the floor carpet and sound insulation for 9 access Remove the tread plate securing screws and remove the tread plate Removethe boot rear liner Reversethe procedureto fit the replacementliner 16698 74 76 67 BODY SECTION BOOT FLOOR CARPET RENEW 76 19 30 Open the boot Move the spare wheel access flap and remove the bolt securingthe spare wheel in position Lift out the spare wheel Removeth
394. sages pausing for two seconds at each one To enable the trip computer information to be displayed the button marked CLEAR provides a means of extinguishing any VCM message present on the written display Pressingthe VCM button when a fault exists will override any trip computer messages and re displaythe relevant VCM fault symbol VEHICLE CONDITION MONITOR FAULT CODES CHECK ENGINE 88 00 00 In the event of an engine management fault occurring the Check Engine warning light will be illuminated Additional information can be displayed by pressing the Vehicle Condition Monitor VCM buttonlocated on the trip computer panel When a fault has been signalled the likely area responsiblefor the malfunctioncan be indicated when the vehicle is stationary Switch off the ignition wait at least 5 seconds then turn the ignition switch to position Il do not start the engine Pressthe button this action will cause the VCM trip computer display to illuminatethe applicable fault code All fault codes are when triggered stored in the ECU memory In addition the check engine lampis illuminated and will remain illuminated when the ignition is switched on until the fault is rectified and the ECU memory clearedby 705 or by groundingthe relevent ECU pin seenotesfor exceptions NOTES 1 USA Specification Fault codes 26 and 44 will not remain illuminated at each ignitionon off cycle This is to preventthe check engine
395. scardthe relay Fita new relay to the multi plug Fit the assembly to the mounting bracket Refitthe dash liner Close the door 30018 86 89 ELECTRICALSYSTEM CENTRAL PROCESSOR UNIT PASSIVE 7 RESTRAINT 4 RENEW 86 55 85 Open the drivers door Remove the drivers side dash liner Cut and remove the harness ratchet strap Disconnect the unit multi plugs Remove the unit bracket securing bolts removeand discardthe unit Fig 1 Fita new unit to the instrument pack mounting bracket Fitand tighten the securing bolts Connect the multi plugs Securethe harness with a new ratchetstrap Refitthe dash liner Closethe door 3001B INFRA RED DOOR LOCKING RECEIVER J76 506 RENEW 86 55 35 fig 1 Removethe interior light console Displace the infra red receiver Fig 2 Disconnectthe multi plug Removethe receiver Fitthe new receiver to position connect the multi plug and secure the receiver Refitthe lightconsole 3001B 86 90 ELECTRICALSYSTEM SEAT ENTRY SWITCH LINK HARNESS RENEW 86 70 48 Open the door Switch the ignition on and motor the seat fully forward Switch the ignition off Open the rear door and remove the bolts securing the seat Remove the carpet and the rear footwell front soud deadening insulation pad Displace the seat hamess clamp retaining plate Switch on the ignition and motor the seat rearwards Switch off the ignition Removethe seat cushion 76 70 1 1 Displac
396. sembly and remove the grille supportbracketsandthe four thread inserts Fitthe brackets and thread inserts to the replacement grille surround and securethe surroundto the body with the four bolts Refitthe two front grilles DATA SPANNER SIZES TOrnrn 0382b 76 54 BODY SECTION SILLTREAD PLATE REAR RENEW 76 76 02 Open the door Remove the end panelfinishers and pull the top finisher clear of thetread plate Remove the five tread plate securing screws 1 Fig 1 and removethe tread plate 2 Fig 1 Fit the replacement tread plate into position and secure with the fixing screws fit the new sill finisher and push in the end panel finishers Close the door 16698 56 SILL TREAD PLATE FRONT RENEW 76 76 01 Openthe door Removethe end panel finishers and pull the top finisher clear of the tread plate Remove the five tread plate securing screws 1 Fig 2 and removethe tread plate 2 Fig2 Fitthe replacement tread plate into position and secure with the fixing screws Fit the new sill finisher and push in the end panel finishers Closethe door 0399b SLIDING ROOFASSEMBLY RENEW 76 82 01 Openthe doors Removethe sliding roof panel 76 82 05 Releasethe clip securingthe interior lamp Displace the panel assembly from its mounting position anddisconnectthe blockconnectors Placethe panelto one side Remove the cantrail crash roll left and right hand 76 13 10 Removethe headlining rear fini
397. sembly to rotate about its centre due to gravity butthe weight may be unevenly distributed each side ofthe centre tyre line Laterally the eccentric wheels give the same effect During rotation the offset weight distribution sets up a rotating couple which tends to steer the wheel to the right and left alternatively Dynamic unbalance of the tyre and wheel assemblies can be measured on suitable tyre balancing equipment and corrections implemented Where itis clear that a damaged wheel is the primary cause of severe unbalance it is advisable for the wheelto be replaced TORQUE FIGURES Clamp screw clamp to spare wheel 13 16Nm Jack to mounting bracket 7 14Nm Spare wheel fixing bracket to body 22 28Nm Valve to wheel 3 5 4 5Nm SPANNER SIZES 13mm IRREGULAR WEAR AND TYRE DAMAGE Incorrect Tyre Pressure Under inflation A Fig 1 is a frequent cause of severe tyre damage resulting from the excessive JMB 021 flexing of the tyre Under inflation builds up internal heat which eventually weakens the casing It also causes rapid and irregular tread wear Over inflation C Fig 1 leads to shortened tyre life Fig 1 withtread wear concentrated onthe centre section in contact with the road The cushioning effect of the tyre is impaired resulting ina hard and uncomfortable ride The tyre is also susceptible to impact fracture and casing damage Correctly inflated tyres are shown in B Fig 1 Misalignment Wear Rasped and feathere
398. separate the muffler from the compressor remove and discard the O ring seal Fita blanking plugto the muffler and a blanking plate to the compressor fit and tighten the blanking plate securing bolt Raisethe vehicle to working height on a ramp Slacken the compressor drive belt adjuster rod and adjuster plate securing nuts and bolts 4 5 6 and 7 Fig 1 Slacken adjuster nut 5 Fig 1 Removethe nut and bolt 4and 5 Fig 1 from adjuster plate 3 Fig 1 Slacken trunnion nut and bolt 9 and 2 Fig 1 and remove the adjuster rod 1 Fig 1 Disconnectthe compressor multi plug Fig 1 Remove the compressor drive belt Pivot the compressor away from engine support the compressor and remove the top pivot bolt and liftthe compressor clear of the vehicle Removethe mounting brackets from the compressor Remove the compressor pulley from the compressor shaft refer to 82 10 10 Removethe drive clutch from the compressor referto 82 10 08 Remove the field coil from the compressor refer to 82 10 25 Remove the woodruff key from the compressor shaft 292 293 Position the mounting brackets on the compressor fit and tighten the securing bolts and nuts Fit the woodruff key to the compressor drive shaft the field coilto the compressor refer to 82 10 25 Fit the pulley to the compressor shaft refer to 82 10 10 Fit the drive clutch to the compressor refer to 82 10 08 Lift the compressor up to the engine and fit
399. sh WINDSCREEN WIPER AND WASHERS OPERATION 84 00 00 When the washer wiper switch is in either the slow or fast position a circuit to earth is completed for slow or fast speed relays located in a wiper logic module Provided that the ignition switch is ON the appropriate relay is energised and battery power is applied to fast or slow speed windings of the wiper motor Inputs and outputs of the logic module are as follows 1 Slow alogic earth input at B60 3 results in battery power being appliedto the wiper motorthrough B59 4 2 Fast a logic earth input at B60 1 results in battery power being suppliedto the wiper motor through 59 2 For intermittent wiper operation a logic earth is applied to connector B13 4 of the ECU which responds by energising the slow speed relay for periods of half a second at five second intervals The relay is energised by connector B60 2 Wiper operation in intermittent mode continues until cancelled by either a second application ofthe wiper switch or by selecting another mode For flick wipe operation a logic earth is applied to connector B12 5 of the ECU which again responds by energising the slow speed relay through connector B60 2 The relay is energised for a single period of half a second and wiper motor control is then undertaken by a self parking mechanism which causes the wiper arm to complete one sweep of the screen andthen park The self parking mechanism is installed within the wiper motor assembly and
400. sh liner Reverse the removal procedure to refit the replacement liner Note align the footwell heater duct priorto securing the liner with the screws i 0036b DASH LINER PASSENGERS SIDE RENEW 76 46 15 Openthe door Remove the screws securing the dash liner Fig 2 and releasethe liner securing clip Removethe dash liner Reverse the removal procedure to refit the replacement liner 0037b DOOR AIR VENT GROMMET RENEW 80 00 00 Openthe door Carefully depressthe grommet Fig 3 and remove Reversethe removal procedureto refit 0359b CONSOLE FINISHER MANUAL RENEW 76 25 19 Openthe door Removethe console ashtray 76 67 18 Slacken the gear lever locknut remove the gear lever knob and locknut dissengage the retaining clips from the upper consolearea and removethe finisher Reversethe removal procedureto refit 76 83 BODY SECTION DATA SPANNER SIZES 76mm 0015b FASCIA BOARD RENEW 76 46 01 Openthe door Removethe Dash liner drivers side 76 46 1 1 Dash liner passengerside 76 46 15 Fascia closing panel drivers side 76 46 28 Fascia closing panel passengersside 76 46 27 Fasciacentre veneer panel 76 47 06 Steering the wheel 57 60 01 Removethe screws securing the instrument housing and disconnect the instrumentblock connectors Removethe instrument housing Remove the centre console upper securing screw 1 Fig 1 carefully manoeuvrethe console rearwards for access to the fascia t
401. sher 76 64 12 Remove the rear quarter upper trim pad right hand 76 13 43 Remove the rear quarter upper trim pad left hand 76 13 43 Removethe sun visor vehicle set 76 10 17 Removethe sliding roof flangefinisher 76 82 23 Removethe headlining to sliding roof aperture securing clips 1 Fig 3 76 55 BODY SECTION Reclinethe seats fully for access and release the left hand rear headlining clip 1 Fig 2 reposition the headlining onto the rear parcelshelf for access Disconnectthe sliding roof motor block connector Cut and remove the drain tube to roof assembly securing ratchet straps Disconnect the drain tubes from the sliding roof assembly Removethe bolts securing the support bracket 1 Fig 1 to the sliding roof Remove the bolts securing the left and right hand support bracket Fig 1 tothe roof Remove the right hand support brackets and lower the roof assembly from the left hand support brackets and remove from the vehicle via the front passenger door Removethe spacers and place the roof aside Reverse the removal procedure ensuring that prior to final tightening of the securing bolts that the roof is centralised with an even 4mm gap all round the aperture DATA TORQUE FIGURES Outer sealretainer 2 3Nm Plate andlifting block to bracket2 3 3 4Nm SPANNER SIZES 138mm 0080b SLIDING ROOF FLANGE FINISHER RENEW 76 82 23 Openthe door Open the sliding roof Carefully removethe sliding roof a
402. sing panel Fig 1 Reverse the removal procedure to fit the replacement closing panel 0039b mom Fig 1 POE CLOSING PANEL PASSENGER i D mat RENEW 76 46 27 Openthe door Removethe screw securing the dash liner to the closing panel Remove the screws securing the closing panel and displacethe dash linerfrom the the spring retainingclips Removethe lower screw spacing washers and spire clip Remove and discard the closing panel Fig 2 Reverse the removal procedure to fit the replacement closing panel 0038b FASCIA CENTREVENEER PANEL RENEW 76 47 06 iur ir NN 414 Openthe door Fig2 Openthe glovebox lid Carefully release the veneer panel Fig 3 from the retaining clips and removethe panel Remove the retaining clip securing screws and remove the clips Removethe centrevent and discardthe veneer panel Reverse the removal procedure to fit the replacement veneer panel 0040b Fig 3 479 384 76 86 BODY SECTION GLOVE BOX RENEW 76 52 03 Open the door Remove the dash liner passengerside 76 46 15 Remove the screws 1 Fig 1 securing the the glove box lid lift the lid to disengage the guides and remove the lid assembly Remove the upper screws securing the interior of the glovebox Remove the glovebox striker securing screws 3 Fig 1 and collectthe plate and striker Remove the screws securing the glove box to the fascia rail Displace the relay moun
403. sor or associated wiring 69 Drive neutral switch or wiring 89 Purge valve drive IMPLICATION Suspect idle trim pot out of normal operating range Suspectair flow meter signal out c normal operating range Suspect coolantthermistor resistanceout of range or static during enginewarm up Suspectair thermistor resistance out of range Suspectthrottle pot resistance out of range Suspect low throttle pot signal at high air flow Suspect high throttle pot signalat low airflow Suspect ECU output signalto fuel pump relay Suspect poor feedback control in rich direction SuspectECU output signalto ignition amplifier module Suspect poor feedback control in lean direction Checks microprocessor function Checks for ECU outputto injectors Looksfor injector dribble Looksfor ECU output to EGR switch valve Checkscorrect operation of EGR Looksfor feedback out of control rich or weak Looksfor ECU output to idle speed control stepper motor Looksfor ECU outputto idlespeed control stepper motor Looks for stepper motor being wildly out of position with enginetemperature hot and lessthan 86 F 30 C Looks for road speed indicating less than 5km h at high engine air flow Looksfor cranking in D6r high air flow in N Looks for ECU output to purge valve issue 2 INSTRUMENTS INSTRUMENT PACK FLEXIBLE NTED CIRCUIT RENEW 88 20 20 Disconnectthe battery Remove driver s side dash liner securing screws rel
404. ssembly locking sleeve disconnect the inner cable from the interior handle and repositionthe cable Remove the securing sleeve from the cable and remove the cable Reverse the removal procedure to refit the cable to the door 0032b REAR DOOR LOWER TRIM PAD RENEW 76 34 06 Open the door Removethe front door trim padveneer panel 76 47 1 1 Removethe front door uppertrim pad 76 34 02 Remove the rear door trim finisher remove the trim pad centresecuring screw Remove the puddle lamp lens and the lower trim pad securing screw Displacethe trim padfrom the retainingclips disconnect the door block hamess connectors and remove the trim pad assembly Remove the rear door armrest and the nuts securing the speaker Removethe speaker Remove the screws securing the door pocketto the trim pad and removethe door pocket Discardthe trim pad Reverse the removal procedureto refitthe trim pad 0026b 76 44 BODY SECTION REAR DOOR TRIM PAD VENEER PANEL RENEW 76 47 12 Open the door Position the inner door handle in the open position and remove the inner handle escutcheon plate blank 1 Fig 1 Hans the screw 2 Fig 1 securing the escutcheon plate 3 Fig 1 removethe plate and gasket Carefully pull the veneer panel 4 Fig 1 to relaese the retainingclips Remove the Screws securing the retaining clip and remove the retainingclip assemblies Discardthe veneer panel Reverse the removal procedure to fit the replace
405. strument Pack Fig 2 Take care not to damage gauge needles CAREFULLY push gauge pins through flexible printed circuit DO NOT press down on the crimps distortion may occur Press down on the flat tangs set at right angles to the crimps as shown in Fig3 NOTE Take care not to damage crimps or flexible printed circuit If damage occurs or problems arise due to loose crimp connections renew the flexible printed circuit Before fitting veneer panel carefully return All gauge needlesto STOP PIN position Align and fit veneer panel and LCD module assembly Fit andtighten centre securing screw Fitthe cowl lens assembly Fit and tighten the six remaining veneer panel securing Screws Fit and fully seat the warning bulbs ensuringthe correct colourtype is insertedatthe correct location the 8 white bulb holders are for gauge illumination the remaining 24 arefor warning indication only Connect the flexible printed circuit multi plug to the LCD unit Carefully fit the electronics pack over the flexible printed circuit connections and locate intothe hinges Pivotthe pack downwards andfit intothe securing clips Fitthe flexible printed circuitto the edge connectors by positioning holes in flexible printed circuit membrane over the connector latch locating pips and sliding latch tothe fully closed position Align and fit the back cover to the electronics pack Fit andtighten the securing screws Fit the cowl housing to the pac
406. strument panel and housing 88 20 01 13 centre air vents and fascia board 76 46 01 Processor units heater blower unit LH and RH headlamp relay module centre console heater box and all bulkhead insulation Wiper motor assembly with jets fascia board brackets A post bracket positive earth terminal at bulkhead tunnel carpet and insulation andtunnel wiring loom Lay aside LH wiring loomto interior RH wiring loomto interior Remove panels RH and LHfront wings Radiatorsupport panel Headlamp support panel RH Bonnethinge panel Crossmember closing panel Chassis leg mounting RH Chassis leg RH sectioned Flitchassembly LH Flitchclosing panel RH Flitch extension panel RH Flitch reinforcementpanel RH and LH 71 26 BODY REPAIR Panel Replacement Panel removal and replacement isto the method detailed in Section 77 10 01 07 SEALING DIAGRAMS Painting See Section 77 00 00 Replace Parts Replace parts in reverse order of removal Reconnect battery and alternator test those electrical itemsthat have been removed and replaced Bleedthe brakes 70 25 02 Check adjust the front wheel alignment57 65 01 Align headlamps 0055G 77 27 BODY REPAIR SIDE REPAIRS COMBINATION 1 RENEW 77 50 01 Disconnect the battery alternator and injection wiring loom to the engine Jack upthe vehicle andsupportwith axle stands Remove Road wheels Steeringcolumn and bracket 57 40 02 5 B
407. t and remove the rachet straps securing the cable hamess connectors Disconnectthe cable hamess connectors Removethe moduleearth bolt Remove the bolt securing the module to mounting bracket 2 Fig 2 Removethe module 3 Fig 2 Fittingthe newmoduleisreversalofthe removalprocedure 30010 86 51 ELECTRICALSYSTEM LUGGAGE COMPARTMENT LIGHT SWITCH RENEW 86 65 22 Open the bonnetand disconnectthe battery earth lead Openthe luggage compartment Removethe nut securingthe sound deadening pad and displacethe padfor access Removethe screws securingthe switch Disconnectthe leadsfrom the switch Removethe switch Fig 1 Fitting a new switch is the reversal of the removal procedure 3001B GLOVE BOX SWITCH 459 RENEW 86 65 77 Openthe bonnet anddisconnectthe battery earth lead Openthe passenger door and glove box lid Carefully prisethe switch assemblyfrom its mounting Disconnectthe lucar connectors Removethe switch Fitting a new switch is the reversal of the removal procedure 3001B TRIP COMPUTER SPEED VEM 100 OFF DESCRIPTION 86 80 00 m FUEL po Trip computer functions are operated by a DIST DED microprocessor in the instrument pack Fig 2 The functions which are selected on the trip computer keyboard provide journey information which indicatedbelow the VCM 487 Fig2 AV SPEED average speed for the distance travel
408. tain countries Check with local legislation Issue 2 74 05 WHEELS AND TYRES 91MY TYRES STANDARD FIT AND OPTIONS INTRODUCTION Pirelli 225 65 VR 15 225 65 15 99V are standard fit tyres from 91MY for all models and markets except USA which retains the Pirelli P5 Cinturato Tubeless 205 70 VR 15 as standard fit The Dunlop TD Super Sport D7 220 65 VR 390 tyres can still be supplied as an optional item for vehicles with alloy teardrop wheels See 90MY specification page 74 04 for inflation pressures A new sports option wheel is available from 91MY and is fitted with a Pirelli 225 55 ZR 16P600 DATA TYRE PRESSURES 74 00 00 Rest of the World ROW Vehicles Type Size Pirelli 225 65 VR 15 225 65 R 15 99V Pirelli 225 55 ZR 16P600 Cold Inflation Pressure Front 32 Ibf in2 2 24kgf cm2 220kPa 2 21 bar Rear 34 Ibf in2 2 38kgf cm 234kPa 2 34bar Note Pressures may be reduced by 6 Ibt in2 0 42kgf cm2 41kPa 0 41 on front and rear tyres to obtain maximum comfort provided the speed does not exceed 100mph 160 km h Replacement tyres of different specifications and or tread pattern should not be fitted in mixed form 74 06 Issue 2 WHEELS AND TYRES TYRES DESCRIPTION 74 00 00 General Tyres of the correct type dimensions and at the correct cold inflation pressures are an integral part of the vehicle s design Regular maintenance of tyres is an essential contribution to road safety and correc
409. tch 1 Fig 1 Displacethe switch for access Disconnectcable harness block connectors Removeswitch assembly 2 Fig 1 Onfitting new switch select N neutral Fit new switch into position Fit but do nottighten the securing screws Position Service Tool setting gauge JD 127 Fig 1 between linear switch and side plate Ensure slot of the setting gauge is fully located onto the pin of the linearswitch Tighten the securing screws Removethe setting gauge Check that the vehicle starts in PARK and NEUTRAL butdoes notstart in other positions Check the bar graph on the instrument pack indicates the correct position of the gear selector DATA SERVICETOOLS JD 127 Setting gauge 0467G SEAT PAD SWITCH RENEW 86 57 21 Open bonnetand disconnect battery earth lead Removethe front seat cushion Displacethe accessible diaphragm hooks 1 Fig 2 from the frame and repositionthe diaphragmfor access Cut and remove the ratchet strap securing the cable Fig2 harness Remove the seat belt switch pad Fitthe new switch into position fit a new ratchetstrap to the harness Refit the diaphragm fit the securing hooks Refitthe seat cushion Reconnectthe battery earth lead 0467G Issue 2 88 24 INSTRUMENTS SEAT BELT BUCKLE SWITCH RENEW 86 57 25 Open bonnetand disconnect battery earth lead Remove B post lower trim pad Removeseat belt upper anchor securing nut cover Remove upper anchor securing nut D
410. tch is ON Inthis position a power earth is connected to each fuse monitoring circuit and via the inertia switch and a reverse polarity protection diode to a contact of the ignition on relay coil The centre fuseblock contains a bank of six fuses identified 1 to 6 from leftto right Fuse ratings and the circuit s supplied are detailed under a relevant heading of this Section 3001B LOGIC EARTH DISTRIBUTION Fig2 DESCRIPTION 86 00 00 Logic earths are distributed from power earth point locatedcloseto the CPU 3001E 86 61 ELECTRICALSYSTEM IGNITION SWITCHED EARTH DISTRIBUTION DESCRIPTION 86 65 00 Ignition switched earths are distributedfrom the ignition and inertia switches The ignition switch distributes the earths in all switch position except OFF and the inertia switch distributes the earths when tripped with the ignition ON 3001 IGNITION SWITCH RENEW 86 65 03 Openthe bonnet and disconnectthe battery earth lead Open the car door Removethe steering wheel 57 60 01 Remove the instrument illumination rheostat control knob Remove the screws securing the lower nacelle and removethe nacelle Remove the screws securing the upper nacelle and removethe nacelle Using a suitable punch remove the shear bolts securing the ignitionswitch Displacethe switch Release the ignition switch retaining tags and displace the switch from the lock assembly Disconnectthe cable harness block conne
411. tem to locatethe fault 1 Entercar driversseat Close and lock both front doors Operate inertiaswitch Doorswill remain locked 2 Insertkey into ignition Seatbelt will remainat A post Turnignition on position 2 Seatbeltwill remain at A post 4 Turn ignition off position O Resetinertiaswitch Turn ignition on position 2 Bothseatbelts will deploy to B post Seatbeltnotfitted warning will activate until drivers seatbelt latchesin B post 5 Opendrivers door Drivers seatbelt will retractto A post 6 Openpassengerdoor Passenger seatbelt will retractto A post 7 Closedrivers door Driversseatbeltwill deploy to B post 8 Closepassengerdoor Passenger seatbeltwill deploy to B post 9 Turn ignition o f f position Bothseatbeltswill retractto A post 10 Turn ignition on position 2 Both seatbelts will deploy to B post Lock doors Operate inertia switch Doors will unlock NOTE ft is necessaryto detectthe logic output from pin 1 LB86 Output should belogic 11 Opendrivers door Driversseatbeltwill remainat B post 12 Open passengerdoor Passengerseatbeltwill remainat B post 13 Close both doors Turn ignition off position 0 Seatbelts will remainat B post 14 Resetinertiaswitch Seatbeltswill retractto A post 15 Turnignition on position 2 Detachdriversseatbelt from guide railcarrier Seatbeltwarning will activate 16 Re connectseatbeltto carrier Seatbeltwarning will de activate 17 Endoftest 16 106 BODY
412. the centreveneer paneland ventilator Remove the centre console finisher ashtray radio console rear ventilator outlet and glove box Removethe centreconsole assembly 164 178 Removethe fascia assembly On left hand drive cars removethe battery Disconnect the evaporator pipes from the expansion valve Removeand discard O ring seals Fit protective caps to the expansion valve outlets andto the disconnected pipes Disconnect the coolant hoses from the heater matrix inlet and outlet pipes Fromthe engine compartment remove the nuts securing the air conditioning unit Loosen the upper screw securing the central processor unitand removethe lower screw Displace the earth lead lift and disengage the central processorfrom its mounting bracket Remove the screw securing the mounting bracket and removethe bracketcomplete with spacers Displace the pliable trunking from the air conditioning unit Removethe nut and bolt securing the evaporator outlet pipeguideto the bulkhead Disconnectthe condensate drain tubes Disconnect the recirculation vent vacuum tubes at the lefthand T piece and re routeto side for access Disconnectthe left and right hand blower motor cable harness multi plug connectors Note anddisconnect the vacuum hoses Disconnectthe air conditioning unit main harness multi plug connector Disconnectthe left hand blower motor pliabletrunking Remove the bolts securing the air conditioning unit support brack
413. the cheese wire to a suitable pair of handles and carefully cutthe screenfrom the aperture Fig 1 CAUTION DO NOT CRANK THE SCREEN FORWARDTO GAIN ACCESS TO THE BETASEAL AT THE LOWER EDGEOFTHEAPERTUREFLANGE THE FLANGE WILL DISTORT CAUSING THE SCREENTO FOUL THE WIPER ARM SPRING NOTE Extra care must be taken when cutting Betaseal atthe screen corners Alternatively use a suitable vibro knife bonded glass remover DO NOT however use a hot knife which can cause distortion trim damage etc Fit and align lifting handles to the screen Lower the bonnet Displace and remove the screen Fig 2 Removethe flange dam Removethe lifting handles and discardthe screen Cleanthe apertureflange with a sharp blade taking care notto damagethe paintwork NOTE A thin layer of sealant may be left onthe flange Clean the replacement screen edge and aperture flange with spirit wipe Apply glass primerto the screen Apply screen body primerto the flange Fit the flange dam to the flange note the flat side the dam goesto the inside of the car Fig 3 Make two wooden support blocks 8mm thick Position the blocks onto the flange Fig 4 a beadof Betaseal to the screen edge Fig 1 page Attach the lifting handlesto the screen carefully fit and align the screen to the aperture using the wooden blocks as support LL NOTE Enere thal the gap betweenscreen and postis equal both sides Fully seat
414. the clip or you may damage or nickthe wire Solder Fig 3 Apply 50 50 rosin core soldertothe opening inthe back of the clip as shown Following the manufacturer s Fig 2 instructionsfor the solder equipment you are using 186 912 Tape the Splice Centre and roll the splicing tape The tape should cover the entire splice Roll on enough tape to duplicate the thickness of the insulation on the existing wires Do not flag the tape Flagged tape may not provide enough insulation and the flagged ends will tangle with the other wires inthe harness 4186 514 Fig3 86 72 ELECTRICALSYSTEM if the wire does not belong ina conduit or other harness covering tape the wire again Use a winding motion to cover the first piece of tape SPLICING TWISTED SHIELDED CABLE Twisted shielded cable is sometimes used to protect wiring from electrical noise stray signals Remove Outer Cover Remove the outer jacket and discard it Be careful to avoid cutting intothe drain wire or the mylartape Unwrap the Tape Fig 1 Unwrap the tape but do not remove it The tape will be used to rewrap the twisted conductors after the splices have been made Preparethe Splice Fig 1 Untwist the conductors Then prepare the splice by following the splicing instructions for copper wire presented earlier Remember to stagger splices to avoid shorts Re Assemblethe Cable After you have spliced and taped each wire rewrap the conduct
415. the compressor oil level Reconnectthe expansion valve Ensure where necessary new O rings are fitted smearedwith CAPELLA E oil Evacuate and recharge the system with new R12 refrigerant AIR CONDITION ING EVACUATING 82 30 06 Oncethe system has been opened for repairs it must be fully evacuatedwith avacuum pumpto remove all traces of moisture beforebeing rechargedwith new refrigerant Moisture may collect and freeze in the expansion valve which will block the refrigerant flow and prevent the cooling action Moisture will also react with refrigerant 12 and cause corrosion of the small passages in the System 82 28 AIR CONDITIONING The desiccantin the drier bottle can only absorb a limited amount of moisture before it becomes saturated N 2 x therefore it is most important to prevent moisture from y 6 entering the system also to remove any moisture which 3 inadvertently entered the system through leak Im open connection Se The unwanted moisture or air are removed from the 1 ees system by a vacuum pump ON Remove the protective cap from the low pressure KSA connection on the air conditioning system Check and 10 4 oil the O ring in the low pressure hose 8 Fig 1 from the manifold of the charging station and connect it to the low pressure side of the system 3 Remove the protective cap from the high pressure side of the air conditioning system Chec
416. the driver side dash liner Removethe screws securingthe instrumentpack Removethe instrument pack88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulb 7 Fig 1 fromthe holder Fita new bulb by reversingthe removal procedure 30018 86 46 ELECTRICALSYSTEM SEAT BELT WARNING INDICATOR BULB RENEW 86 45 75 Open the bonnet and disconnectthe battery earth lead Open the car door Removethe driver side dash liner Removethe screws securing the instrument pack Removethe instrument pack 88 20 01 Releasethe electronics pack retainingclips Pivot the electronics pack upwards for access to the bulb Removethe bulb 3 Fig 1 from the holder Fita new bulb by reversingthe removal procedure 3001B BULB FAILURE WARNING INDICATOR BULB Fig 1 RENEW 86 45 77 Openthe bonnet and disconnectthe battery earth lead Open the car door Removethe driver side dash liner Remove the screws securing the instrument pack Remove the instrument pack 88 20 01 Releasethe electronics pack retaining Clips Pivot the electronics pack upwards for access to the bulb Removethe bulb 10 Fig 1 from the holder Fita new bulb by reversing the removal procedure 3001B CARAVAN WARNING INDICATOR BULB RENEW 86 45 78 Open the bonnet anddisconnectthe battery earth lead Open the car door Removethe driver side
417. the earth lead Undothe nutsecuringthe aerial lead and disconnect the lead Cut and removethe rachetstrap securingthe aerial block connector 1 Fig 2 Disconnectthe black cable block connector 2 Fig 2 Slacken the lower nuts bolts securing the aerial assembly 3 Fig 2 Disconnectthe draintube 4 Fig2 Removethe aerial assembly Fitting a new electric aerial isthe reversal of the removal procedure 3001E 86 60 ELECTRICALSYSTEM ELECTRICAERIAL MAST RENEW 86 50 29 Undo the aerial to mast retaining nut Switch the ignition andthe radio on Allow the aerial motorto stop at the fully up position Displace and withdraw the mast note the position of the teeth on cable Fig 1 Switch the ignition off During the 15 seconds delay period before the aerial motor operates to retractthe mast preparethe mast and insertthe mastflexible cable into aerial motor assembly Whilst the aerial motor is operating engage the flexible mast cable with the drive gear and allow the mastto seat into aerial Fig 2 Tighten the the mast retaining nut Switch ignition on and allow the mastto fully extend Switch radio and ignition off 3001B IGNITION SWITCHED POWER DISTRIBUTION DESCRIPTION 86 65 00 Fused and unfused ignition switched power is distributedfrom the centrefusebox and line splices inthe bulkhead hamess The line splices are supplied via contacts of the ignition on relay when the vehicle ignition swi
418. the flexible printed circuit to gain access to 2 of the veneer panel securing screws With the gauges uppermost release the cowl lens securing clips and removethe cowl lens assembly CAUTION With the cowl lens removed DO NOT rest the pack face down The gauge needles are extremely delicate and are easily damaged Also take care notto scratch or damage the gauge faces ensure cleanliness when handlingthe pack Displace and remove the veneer panel The LCD module is attached to the veneer panel and with caution may be removed as a complete assembly CAREFULLY remove oil water temperature gauge set gently easing the pins out of the printed circuit crimps Fig 2 Page 88 11 To preventwidening crimp connections gauge pairs should be kept square to the Instrument Pack moulding whilst removing Repeatfor the battery tuel gauge set Repeatfor the speedometer t chometer gauge set 388 062 issue 2 88 10 INSTRUMENTS Displace and remove the flexible printed circuit NOTE Individual gauge movements CAN NOT be serviced pointers and can location screws should not be removed Gauges should not be placed face down Align new flexible printed circuit to instrument pack Align and fit speedometer tachometer gauge set to instrument pack Take care not to damage gauge needles Ensure gauge set is inserted square to pack and flexible printed circuit and CAREFULLY push the gauge pins through the printed circuit DO NOT press down on
419. the pump 2 Fig 1 Remove the bolts and washers securing the reservoir 3 Fig 1 Removethe reservoir from the filler neck Drainthe water from the reservoir Removethe bolt securing the washer motor clamp plate remove the plate and remove the pump from the grommet 4 Fig I Displaceand removethe fluid level sensor Removethe clamp nut grommet assembly Fitting a new reservoir sensor is the reversal of the removal procedure 01966 WINDSCREEN WASHER PUMP RENEW 84 10 21 Openthe bonnet and disconnect the battery earth lead Turn the front road wheels to the full lock position for access Remove the nuts bolts and screws securing the inner wing valance Removethe valance andthe brake disc cooling duct Disconnect the pump multi plug connectors and the washer pump tube 1 2 Fig2 Placea suitablecontainer in position Remove the bolt securing the pump clamp remove the clamp andthe pump Removethe cover from the pump Fitting a new pump is the reversal 4 the removal procedure 0196G WINDSCREENWASHER PUMP RELAY RENEW 86 55 82 Openthe bonnet and disconnect the battery earth lead Removethe relay cover 1 Fig 3 Locate and withdraw the relay from the yellow cable connector block 2 Fig 3 Fitting a new relay is the reversal of the removal procedure 01966 84 6 WINDSCREEN WIPERS AND WASHERS WIPER ARM RENEW 84 15 01 Open the vehicle bonnet Displacethe wiper arm securing nufcover 1 Fig 1
420. the screen to the apertureflange Open the bonnet Remove the masking tape from the aperture Apply Solumin solution to the screen seal a suggested methodis shown in Fig2 page 23 Fitandfully seat the seal to the screen body during the Operation remove the wooden support blocks 77 22 BODY REPAIR Clean and remove all moisture from between the seal and the glass Apply Alphaseal 127 betweenthe screen seal the screen DOWNTHE A POSTSONLY Apply Solumin solution to the screen seal outer face and starting at the top of the A post slide the finishers down into the seal Fig 3 Seat the top of the finisher with a glazing hook Fitthe finisher clip atthe top of the screen Fig 4 Remove all excess sealant solution from the screen Secure support the screen with tape After the screen has bonded approximately 2 hours remove the tape and clean the screen and surrounding area Refitthe plenum chamber finisher Refitthe wiper arms Closethe bonnet as d7 469 DATA TORQUE FIGURES Wiperarm securing nut 77 19 SPANNER SIZES 17mm SEALANTS LUBRICANTS Alphaseal 121 Betaseal Screenbody primer Screen glass primer Solumin White Spirit REAR SCREEN J76 490 RENEW 77 45 03 Displace and remove the screenfinishers Release the screen seal at the E posts Displace and remove the seal Protect the paint around the screen aperture using suitable masking rape Disconnectthe heatedscreen e
421. tighten the six remaining veneer panel securing Screws Fit and fully seat the warning bulbs ensuring the correct colourtype is inserted atthe correct location the 8 white bulb holders are for gauge illumination the remaining 24 are for warning indication only Connect the flexible printed circuit multi plug to the LCD unit Carefully fit electronics pack over flexible printed circuit connectionsand locate into the hinges Pivot pack downwards andfit into securing clips Fitthe flexible printed circuit to the edge connectors by positioning holes in flexible printed circuit membrane over the connector latch locating pips and sliding latch to the fully closed position Align and fit the back cover to the electronics pack Fit andtighten the securing screws Fit the cowl housing to the pack Fit and tighten the cowl housing securingscrews Fit the instrument pack assembly into dashboard position re connectthe block connectors Align assembly fit and tighten securing screws Return steering wheel to original position Refitthe dash liner Reconnectthe battery NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored to the correct value 386 066 Fig lisie 88 15 mE INSTRUMENTS OILPRESSURE COOLANT TEMPERATURE GAUGE SET RENEW 88 25 09 Disconnect the battery Remove driver s side dash liner securing scr
422. ting a new lock motor is the reversal of the removal procedure 30018 REAR DOOR LOCK MOTOR RENEW 86 25 47 Open the bonnetanddisconnectthe battery earth lead Removethe veneer panel 76 47 1 2 Removethe uppertrim 76 34 05 Removethe lowertrim pad 76 34 06 Removethe door handle 76 37 02 Removethe door lock 76 37 13 Cut and remove the rachet strap securing the lock harnessto switch hamess Remove the screws securing the lock motor to the door lock Removethe lock motor from the lock assembly Fitting a new lock motor is the reversal of the removal procedure 3001B 86 25 ELECTRICALSYSTEM LUGGAGE COMPARTMENT LOCK MOTOR RENEW 86 25 49 Open the bonnet and disconnect the battery earth lead Open the luggage compartment Removethe bolts securing the lock mechanism Displace the lock linkage retaining clip and disconnect the linkage 2 Fig 1 Displacethe lock mechanism Disconnect the cable harness black connector 3 Fig 1 Removethe assembly Displace the peg 4 Fig 1 retaining the lock barrel and removethe barrel Fitting a new lock assembly isthe reversal of the removal procedure 486 920 3001B HORNS T DESCRIPTION 86 30 00 Twin horns are fitted mounted on the front lower cross member behindthe front bumper The horns are operational when the battery is connected power being supplied to a horn relay which is energised by a logic earth when the horn push is pressed When energise
423. ting panel to glovebox rear securing screws and slacken the front securing screws Displace the relay mounting panel and glovebox for access Disconnect the glove box lamp block connector and boot release switch hamess multi plug Removethe glove box assembly Fig 2 Displace the glove box lamp from its mounted position cut and removethe lamp hamess securing ratchet strap Displace the hamess from the self adhesive strip and disconnect the switch feed wires and remove the lamp and hamessassembly Release the lamp switch retaining lugs and remove the Switch Remove the screws securing the boot release switch mountingto the glove box Removethe switch and hamess assembly Removethe spire clips and removethe lid rubber buffers Discardthe glove box Reverse the removal procedure to refit the replacement glovebox DATA TORQUE FIGURES Cruise control module to glove box mounting plate 2 7 6 8 Glovebox mounting plate toglovebox 2 4Nm 0055b GLOVEBOX LID RENEW 76 52 02 Open the door Removethe passenger side dash liner 76 46 15 Remove the screws securing the glovebox lid liftthe lid Upwards to disengage the guides and remove the lid assembly 76 87 BODY SECTION Remove the screws 1 Fig 1 securing the mirror tray assembly and remove Removethe lid guide clevis pin spire clips 1 2 and remove the clevis pins 2 Fig 2 Remove the guides remove the veneer panel securing screws and removethe veneer pa
424. ting pressure Disconnect the two pipes from the expansion valve and connect a bridging pipe to the disconnected pipes to completethe circuit The filter fitted to the inlet port of the expansion valve must be carefully removed washed in a solvent blown dry with air and refittedto the expansion valve Renew any faulty componentsar pipes Connect a flexible hoseto each of the of the two pipes normally fitted to the compressor and position the free ends ina large container Connect a flexible hoseto the R11 bottle Connect the other end of the hose to one of the hoses normally connectedto the drier bottle With the R11 bottle positioned above the level of the engine and positionedto discharge liquid open the R11 bottle stopcocks When R11 starts flowing into the container close the stopcock and allow flushing liquid to drain through the system for two orthree minutes Disconnect the flexible hose from the R11 bottle and connect it to a bottle containing R12 Gently open the stopcockon this bottle and observe the R11 flowing into the container When it stops allow approximately 30 seconds then close the stopcock Inspect the flushing liquid if it dirty repeat the flushing precedure with the R11 bottle reconnected If it is clean repeat the flushing procedure with the flexible hose from the R11 bottle connected to the second of the pipes normally connected to the drier bottle On re assemblingthe system fit a new drier bottle Check
425. tiometer assembly Fittinga new potentiometer isthe reversal of the removal procedure 0209G LOWER FLAP SERVO MOTOR amp GEARBOX RENEW 80 10 46 Disconnectthe battery earth lead Removethe drivers dash liner Remove the screws securing the electronic control module 1 Fig 2 Displacethe modulefor access Removethe screws securingthe motor assembly Displacethe assembly for access Disconnectthe cable hamess multi plug connector Removethe motor assembly 2 Fig 2 Fiting a new motor assembly is the reversal of the removal procedure 0209G LOWER SERVO MOTOR FEEDBACK POTENTIOMETER RENEW 80 10 43 Disconnectthe battery earth lead Removethe passengerdash liner Remove the screws securing the potentiometer mounting plate Fig 1 Displacethe potentiometer from the flap drive shaft Disconnectthe multi plug connector Remove the potiometer assembly Fitting a new potentiometer is the reversal df the removal procedure 02096 80 12 HEATING AND VENTILATION CENTRE FASCIA VENTILATOR FLAP SERVO RENEW 80 15 51 Disconnectthe battery earth lead Removethe driver and passengerside dash liners Removethe driver and passengerside closing panels Removethe steering wheel Removethe glove box lidand glove box Removethe fascia centre panel Removethe fascia centrevent outlet Removethe fascia boardand centre vent Removethe screws securing the servo Removethe nut bolt securing the servoto v
426. tion of fumes dust or sprays either during the application of paint or during sanding processers should always be avoided by ensuring there is efficient general ventilation at all times and where appropriate efficient local ventilation Spraying should be confined as far as possible to spray booths Personnel with a history of asthma should not be engaged in any process which invloves the use of isocynates Whenever an operator whether involved in spraying or not hasto work insidea spray booth where isocyanate material is normally used then compressed airline breathing apparatus must be used Supply to the breathing apparatus should be fitted with an efficient oil water and fume filter to provide breathable air Operators involved in handling mixing or spraying should wear protectiveclothing and glovesto avoid skin contact and goggles or afull face visor to avoid splashes inthe eyes A particle mask or canistertype respiratorshould beworn when sanding PANEL REPLACEMENT The increased use of expanded foam for sound insulation the introduction of special materials in corrosion protection the use of specialised adhesives sealing compounds trim and seat materials in vehicle manufacture paints containing isocyanates can all give off toxic and dangerous fumes when subjected to heat Polyurethane based paints could at a temperature of 300 liberate small quantites of the parent isocyanate This has been established by the Fire Research Station The burn
427. tly inflatedtyres in good condition will assist in retaining optimum road holding steering and braking qualities Tyres of the same type and size have widely varying characteristics depending upon manufacturer Itis strongly recommended that only tyres of the same make and type are fitted to all wheels The radial ply tyres specified are designed to meet the high speed performance of which this car is capable Pressure The tyre inflation pressures specified provide optimum ride and handling characteristics for all normal conditions Tyre pressures should be checked and if necessary adjusted weekly with the tyres cold i e not immediately following use as pressure increases with temperature due to road friction Bleeding a warm tyre to the recommended pressure will result in under inflation which can be both dangerous and depreciate tyre life Pressure loss with time is normal but a thorough investigation should be performed if a pressure loss in excess of 2 Ibf in2 0 14kgf cm2 14kPa 014 bar is encountered during a period of one week or less It is an offence in the UK to use a vehicle on public roads with tyres improperly inflated Furthermore incorrect inflation accelerates wear and causes excessive heating which can result in tyre failure due to blow out CAUTION When inflating a tyre it is important to ensure that a pressure of 40 Ibf in2 2 8 kgf em2 310kPa 3 1 bar is not exceeded otherwise serious tyre damage may result
428. tors if driver s door B3 Violet 3A Spare position 64 Light 15A Doors luggage compartmentand fuel filler blue locks B5 Light 15A Right handrear door window lift blue B6 Tan 5A Windscreen washer B7 Red 10A Right hand rear lamps stop reverse direction indicatorsandfog Jewhere fitted and high mountedstop lamp wherefitted B8 Light 15A Right hand main beam headlamp blue c2 Brown 75A Interior luggage compartment under bonnet and door guard lamps c3 Violet 3A Right handrear lamps tail number plate and side marker where fitted c4 Violet 3A Instrument illumination dimmer and auxiliary side light relay c5 Tan 5A Right handfront lamps side side marker where fitted direction indicators and repeater c7 10A Right hand dip beam headlamp right hand front fog lamp where fitted C8 Tan 5A Door mirror heaters 86 103 ELECTRICAL SYSTEM LEFT HAND SIDE FUSE BOX Fuse Fuse Circuit No Colour Code A1 Light Lefit hand front seat motors where fitted green and seat heater where fitted A2 Yellow Vesicihdmeair Conditioning fan where fitted heater fan A3 Violet Spare position A4 Yellow 20A Spare position 5 Red 10A Horns A6 Natural 25A Accessory fuse box wherefitted White A7 Red 10A Left hand rear lamps stop reverse indicatorsandfog where fitted A8 Violet 3A Spare position B1 Light 30A Right handfront seat motors where green fitt
429. trol rod securing clip and remove the rad knob assembly Remove the remote cable to bracket retaining clip and repositionthe cable from the bracket Repositionthe inner cable from the lock release arm and removethe outer handle operating rod retaining clip Repposition the rod from the retaining clip and displace the rod from the private lock Cut and remove the door lock harness to door panel ratchetstraps and disconnectthe multi plugs Remove the lock securing screws 1 Fig 1 and remove the lock assembly Removethe linkage rod Remove the motor securing screws and remove the motor Discard the lock assembly Reverse the removal procedure to refit the replacement lock DATA TORQUE FIGURES Door lock to door 7 10Nm SPANNER SIZES amp mm I Omm No 30 Torx 0030b REAR DOOR REMOTE CONTROL OPERATING CABLE RENEW 76 37 68 Open the door Removethe front door trim padveneer panel 76 47 11 Removethe front door uppertrim pad 76 34 02 Removethe front door lower trim pad 76 34 03 76 43 BODY SECTION Disconnect the cable from the centre support bracket and remove the clip securing the interior locking rod to the linkage removethe locking rod Release and remove the clip securing the operating rod to the cable and disconnect the cable from the lock Remove the clip securing the outer cable to the lock bracket disconnect the cablefrom the bracket Reposition the inner cable to the interior handle a
430. ts inthe road b A double fracture caused by crushing the sidewall of the tyre between an object and the rim flange Note n both instances such damage can lead to sudden and dangerous tyre deflation some time after the impact occurred JMB 022 JMB 025 JMB 074 4MB L24 Fig 4 74 18 Issue 2 WHEELS AND TYRES ROAD WHEEL ONE REMOVE AND REFIT 74 20 01 Remove hubcap Slacken the road wheel nuts of a turn each Jack up the vehicle and place on one stand Remove one road wheel securing nut 1 Fig 1 mark the road wheel relative to a stud and remove the remaining nuts Remove the road wheel andtyre assembly 2 Fig 1 Liftthe replacement road wheel andtyre assembly up to the hub align the wheel with the marked stud and secure with the nuts Take the weight of the vehicle with a jack remove the axle stand lower the vehicle and recheck the torque of the wheel nuts CAUTION Do not exceed a torque of 85Nm 63 Ibf ft where steel wheels are fitted or 102Nm 75 Ibf ft where alloy wheels are fitted DATA TORQUE FIGURES Whee nut to wheel stud steel wheel 65 85 Nm 48 63bf ft Wheel nut to wheel stud alloy wheel 88 102 Nm 65 75Ibf ft SPANNER SIZES 22 P s Issue 2 WHEELS AND TYRES SPARE WHEEL AND TOOL KIT STOWAGE 74 20 04 The spare wheel jack and tools are stowed in the luggage compartment as
431. ttery NOTE On re connection of the battery it is important that the ignition is cycled and the bulb check is completed The odometer reading will then be restored to the correct value Issue 2 88 17 288 062 4856 06 Fig2 Fig3 INSTRUMENTS EUER BATTERY CONDITION GAUGE RENEW 88 25 33 Disconnectthe battery Remove driver s side dash liner securing screws release securingclip and remove liner Release steering column clamp fully extend steering lt lt gt wheel and re tightenthe clamp LAN Remove instrumentpack assembly securing screws Disconnectblock connectorsfrom rear of pack 7 Displaceand removethe instrument pack assembly Remove the instrument pack cowl housing screws and removethe cowl housing Place pack face down on bench ensuring that cowl lens is protectedwith a suitable cloth or similar 018 NOTE To minimise the risk of damage and contamination all repairs conducted on the Instrument Fig 1 Pack should be performed in a non static dust free environment Remove the electronics pack cover securing screws and remove the cover Carefully release the flexible printed circuit ribbon ends from the edge connectors by squeezeing grips between thumb and forefinger while sliding out connector latch Fig 1 Releasethe electronics pack retainingclips and pivot the pack upwards Fig 2 Displace and remove the electronics pack from the instrument pack by
432. until the pressure reading corrsepondingto the gauge pressure is in line with the refrigerant level Note that readings must be taken within the R12 band on the shroud Close the R12 stopcock and reconnect the charge cylinder 10 Fig 1 hosetothethe gauge manifold Ensuring that the vacuum valve fully closed Openthe charge cylinder valve 4 Fig 1 As the pressure in the charging cylinder falls rotate the plastic shroud on the refrigerant cylinder until the pressure reading correspondingto the gauge pressure 6 Fig 1 isinline withthe refrigerant level Whenthe correct charge has been dispensed Closethe high and low pressurevalves 1 amp 2 Fig 1 Close the charge cylinder outlet valve 4 Fig 1 2 7 6 Y f y ub NC AN em mmm Ne 9 J82 162 Rmo AIR CONDITIONING AIR CONDITIONING FULL CHARGE NOT ACCEPTED 82 00 00 If the full charge is not accepted close the high and low pressurevalves 1 amp 2 Fig 1 Startthe engine and runat 1500rev min Set the air conditioning controls to maximum cooling and slowly open the low pressure valve 1 Fig 1 to bleedinthe remainingrefrigerant NOTE This must be carried out Extremely slowly to prevent liquid refrigerantdamagingthe compressor Close the high and low pressurevalves 18 2 Fig 1 Closethe charge cylinder outlet valve 4 Fig 1 Switch off the engine 82 31 182 162 AIR CONDITIONING COMPRESSOR RENEW 82 10 20 Op
433. upper securing screws Tighten the lower securing screws Refitthe centre blade and indicator lamp assemblies DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27Nm Fig 1 LE Bumper to bumper bracket Non Federal 40 Bumper to bumperstrut Federal 40 50Nm Guide block to mounting bracket 3 5 4 75 Horns tobracket 22 28Nm Mounting bracket guide block to body 7 5 10Nm SPANNER SIZES 8mm 7Omm 13mm 79mm No20 Torx 0385b REAR BEAM COVER RENEW 76 22 29 Remove the rear fog and rear marker lamps where fitted from the rear bumper and removethe rear bumper complete Removethe quarter blade securing bolts and nuts both sides 4 Fig 1 and removethe quarter blades 5 Fig 1 Remove the rubber cover securing screws and remove the cover Fig 2 Fitthe replacement coverto the bumper and secure with the screws Refit the quarter blades and secure with the bolts and nuts refit the rear bumper to the vehicle complete and refitthe rearfog and marker lamps where fitted Fig 2 478 278 76 94 BODY SECTION DATA TORQUE FIGURES Bumper mounting brackets to body Non Federal 23 27Nm Bumper mounting struts to body Federal 23 27Nm Bumper to bumper bracket Non Federal 40 bONm Bumper to body inner Federal 23 27Nm Bumper to fixings bumper beam Federal 39 50Nm Bumper to body inner Non Federal 23 27Nm Bumper to fix
434. ure 6 Coolant Temperature The speedometer and tachometer are true analogue gauges in that the readings indicatedare directly proportional to the parameters being measured However the four minor gauges battery condition fuel level oil pressure and coolanttemperature each havetheir indication ranges resolved into 58 discrete steps Slight gauge flicker may be discernable between individual steps Each gauge is contained in a sealed non serviceable can therefore complete replacement of the gauge can is necessary inthe event of a damagedor faulty gauge Extreme care should be exercised when replacing instrument pack components to avoid damage to the delicate gauge indicator needles The coolant temperature gauge needle will move rapidly up the scale to N when the thermostat opens This is due to the sensitivity cf the gauge and the close proximity of the sensor to the thermostat ie when the thermostat opens a rush of hot coolant from the cylinder block causes the sensor to react accordingly Itis perfectly normal there is nota fault with the gauge BULBS Guage and warning indicator illumination is controlled by a microprocessor located in the electronic instrument pack there are no bulb relays Bulbsare of the long lifetype There aretwo different types of coloured bulb holder cream and brown the two types should not be interchanged and replacementbulbs should be of the same colour type The seven right hand warning indicators a
435. used The equipment must not have any moving parts which contactthe wheel andtyre levers must notbe used 1174 02 Fig 1 LATTICE SPORTS ALLOY WHEEL Size 8 x 16 Tyre Type Size Pirelli 225 55 ZR 16 P600 The Lattice Sports wheel is available from 91MY as part of the Sports suspension package itis an option for all models and markets except North America Itis a forged wheel with lattice design fitted with the Pirelli 225 55 ZR 16 P600 8 x 16 tyre When changing the sports road wheels the centre badge must betransferredto the replacement wheel After removing the road wheel carefully removethe badge and press fit to the replacement wheel 74 14 Issue 2 WHEELS AND TYRES MISALIGNMENT AND ROAD CAMBER EFFECTS important that correct wheel alignment be maintained Misalignment causes tyre tread to be scrubbed off laterally because the natural direction of the wheel differs from that of the car A sharp fin protrusion on the edge of each pattern rib is a sure sign of misalignment and itis possible to determine from the position of the fins whether the wheels are toeing in or toeing out Fins onthe inside edges of the pattern ribs particularly onthe nearside tyre indicate toe in Fins onthe 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 ev
436. usset Rear panel Bootfloor extension panel Bootfloor sectioned Chassis leg 77 31 BODY REPAIR WELDING DIAGRAM J77 055 77 32 WELDING TABLE BODY REPAIR No Location Remove Factory Joint Replace Repair Joint 1 Rear wheelarch assy and chassis legtofloorpan and heelbaard Removedwith panelbulk 47 MIG plug welds 2 Rear wheelarch assyto 3 MIG plug welds 3 MIG plug welds heelboard interior 1X MIG seam welds 3 Rear chassis legto floor and 20 MIG plug welds rear seat crossmember 2X MIG seam welds 4 Rear chassis legto sill lower 9 resistancespotwelds 9 MIG plug welds flange 5 Rear wheelarch assyto inner Removedwith panel bulk Single row of resistancespotwelds wing atvertical gusset ARO arms 242A or equivalent 34 MIG plug welds 6 Rear chassis legto innersill 3 resistancespot welds 3 resistance spot welds ARO arms rear flange 242A or equivalent 7 Rear wheelarchto chassis leg Removedwith panel bulk 22 MIG plugwelds 8 _ Bootfloor side extensionto Removedwith panelbulk 12 plug welds chassis leg 9 Bootfloor sectionto chassis 29 resistancespotwelds each 25 MIG plugwelds eachside legRH and LH side 10 Bootfloor sectionto rear 10resistance spot welds each 10 MIG plugwelds each side bulkheadat endsectionRH side and LH 11 Bootfloor section existing 30 MIG plugwelds panelat rear bulkneadlower 10 MiGitackwelds flange 12 Rearwheelarch assy to boot Removedw
437. ve plug from the outer case of the Instrument Pack Remove the 7 veneer panel securing screws carefully peeling back top corners of the flexible printed circuit to gain accessto 2 of the veneer panelsecuring screws With gauges uppermost releasecowl lens securing clips and remove cowi lens assembly CAUTION With cowl lens removed DO NOT rest pack face down The gauge needles are extremely delicate and are easily damaged Also take care notto scratch or damage the gauge faces ensure cleanliness when handlingthe pack Displace and removethe veneer panel The LCD module is attachedto the veneer panel but with caution may be removedas a complets assembly CAREFULLY remove oil pressure coolant temperature gauge set gently easing the pins out of the printed circuit crimps Fig 2 Page 88 17 To prevent widening of the crimp connections gauge pairs should be kept square to the Instrument Pack moulding whilst removing Issue 2 88 16 INSTRUMENTS NOTE Individual gauge movements CAN NOT be serviced pointers and can location screws should not be removed Align and fit the new oil pressure coolant temperature gauge set to the instrument pack Take great care not to damage the gauge needles CAREFULLY push the gauge pins through the flexible printed circuit DO NOT press down on the crimps distortion may occur Press down on the flat tangs set at right anglesto the crimps as shown in Fig NOTE Take care not to dama
438. ve the pump from the grommet 4 Fig 1 Displace and removethe fluid levelsensor 5 Fig 1 Removethe clamp nut grommet assembly Fitting a new reservoir is the reversal of the removal procedure NOTE To minimise the formation of deposits which affect the operation of the system it is recommended thatthe reservoiris filled with a solution of softwater and a proprietary cleaning fluid mixed in accordance with the manufacturer s specification 0196G WINDSCREENWASHER JETS RENEW 84 10 08 Openthe bonnet anddisconnectthe battery earth lead Removethe wiper arm and blade Displace and removethe windscreen lower seal Displaceand removethe bonnet rear seal Remove the front scuttle securing screws and remove the finisher Remove the screw securing the washer jet and repositionthe jet upwards Disconnectthe tube from the jet Disconnectthe multi plug connector Removethejet assembly Fig 2 Fitting a newjet isthe reversalof the removal procedure 0196G 84 5 WINDSCREEN WIPERS AND WASHERS WASHER RESERVOIR SENSOR RENEW 84 10 17 bonnet and disconnectthebattery earth lead Jack up and place the vehicle on two stands Remove the nuts bolts screws and washers securing the inner wing valance Displace and removethe innerwing valance Removethe brake disc cooling duct Disconnect the washer pump and the reservoir level sensor multi plugconnectors 1 Fig 1 Disconnectthe washer pump tubing from
439. versal of the removal procedure 30016 SLIDING ROOF MOTOR LIMIT SWITCH RENEW 86 76 06 Open the bonnet and disconnect the batteryearth lead Openthe car door Removethe sliding roof flange finisher 76 82 23 Removethe sun visors 76 10 17 Removethe crash roll cantrail 76 13 10 Releasethe fastener securingthe roof console Lowerthe consolefor access Disconnectthe cable hamess multi plug connectors Removethe roof console assembly Disconnect the roof motor cable harness block connector Carefully release the headlining from the front clips for access Mark the position of the limit switch using pieces of tape Qt and remove the ratchet straps securing the limit switch Removethe switch magnet assembly Removethe switch harness assembly Fitting a new sliding roof motor limit switch is the reversal of the removal procedure usiing the marker tape to alignthe switch magnet 30018 86 58 ELECTRICALSYSTEM ELECTRICALLY OPERATED AERIAL DESCRIPTION 86 50 00 An electric aerial Fig 1 is fitted as standard Radio cassette player operation is with the ignition switched to ON or AUXILIARY In these positions the ignition switch energises a radio relay which connects battery power to the radio cassette player When the radio is switched ON a signal is applied to the CPU which activates a 15 second timer This timer in turn energises aerial up relay which connects battery power to the aerial motor the earth return pat
440. welds 5 Toinnersill upperflange at 11 resistancespot welds Single row of resistancespotwelds front door aperture ARO arms 242A or equivalent 6 Toexistingpanelatfront end 1X270mm MIG seam weld 7 Toinnersill atlowerflange 34resistancespotwelds Singlerow of resistancespot welds ARO arms 242A or eauivalent 8 Weathersealretainerto rearof 3resistancespot welds 4 MIG plug welds post 9 Weatherseal retainertofront of resistancespot welds 4 MIG plug welds E post 2222222 10 Weatherseal retainer 4 resistancespot welds 4 MIG plug welds 77 17 BODY REPAIR Disconnectbattery andalternator Remove Front door release lever escutchion upper capping upper and lower door trim sections front seat post and B postlowertrim sections andfront silltreadplate Lay aside front carpet section front door aperture beading and weatherseal Removerear seat cushion and backrest rear seat cushion insulationand rear sill treadplate Lay aside rear door aperture beading and rear door weatherseal Remove seatbelt assembly disconnect rear door wiring and lay aside rear carpet section Associated Panel Remove rear door section 77 20 03 Panel Replacement Panel removal and replacementisto the method detailed in Section 77 10 01 07 with the following varations During removal the panel cut at points 1 Fig 1 and 2 Fig 1 The weatherseal retainers 3 Fig 1 4 Fig 1 are then cut out s
441. xle stands Remove Exhaust rear and middle sections Handbrakecable 70 35 1 6 Rear axle assembly 51 25 13 Rear seat heatshield and bootfloor heatshield Rear shock absorbers bump stops and petrol tank 19 55 01 Rear flexible brake hoses Lay aside i s Frontto rear fuel pipes and pump Rear lamp cluster rear lamp relay module RH and LH j number plate lamps and electric aerial Rear screen and mouldings Lay aside Rear screen wiring Rear carpeting Wiring loomto vehicle interior Remove Rear seat cushion seat back and insulation Rear sill treadplate Rear seat cushion seat back and insulation 2 Rear sill treadplate rear door beading and weatherseal ae spare wheel and jack 22 Boot mat petrol tank cover rear panel trim Fig 1 rear p athl wing carpet Fig 2 and bootlid weatherseal Rear bumper assembly boot lip finishers rear wing vent box all insulation rear parcel shelf upper rear wing trim and rear door striker Remove Rear wing chrome finisher rear seat belt locks arid mountings boot lid damper balljoint and boot lid striker Headlining rear finisher petrol tank and wheel arch insulation boot and rear floor grommets and boot lid trim Lay aside Fig2 RH and LH wiring looms to vehicle interior boot lid wiring loomand rear screen wiring Rear carpeting Remove panels Bootlid Rear wing Wheel arch includingtop box and g
442. y varies with temperature Electrolyte Temperature Correction For every 10 C below 15 C subtract 0 007 from the hydrometer reading and for every 10 C above 15 C add 0 0070 the hydrometerreading Specific Gravity Specific gravity F 1 2595 104 40 1 263 95 35 1 2675 86 30 1 270 78 25 1 2735 68 20 1 277 59 15 1 2805 50 10 1 284 41 5 1 2875 32 0 Example Specific gravity reading 1 250 The temperature 5 The equivalent specific gravity at 15 C 1 250 0 007 1 243 3001B 86 19 ELECTRICALSYSTEM BATTERY RENEW 86 15 01 Health and Safety precautions Nosmoking Avoid sparks short circuits or other sources of ignition Hydrogen which is highly explosive is emitted particularly during charging Switch off current before making or breaking electrical connections Always disconnect the earth terminal first and reconnect itlast Chargethe battery in a well ventilatedarea Avoid contact with battery acid Battery acid is poisonous and corrosive it will cause burnsto the skin aswell asto the eyes In the event of skin or eye contact drench the effected area with water and in the case of eye contact seek urgentmedicalattention Openthe car bonnet Displacethe cover fromthe negativeterminal and loosen the boltsecuringthe terminal Disconnectthe terminal from the batteryterminal post Displacethe cover from the positiveterminal and loosen the bolt securingthe terminal Disconnectthe terminalfrom th
443. y 76 67 06 Removethe nuts securing the rear sunblind to the parcel shelf and discard the blind Reverse the removal procedure refit the replacement rear blind 0051G AUTOMATIC GEARBOX SELECTOR TRIM FINISHER RENEW 76 25 07 Removethe gearbox sport modeswitch 86 65 84 E Remove the gearbox sport mode switch finisher 91 76 25 09 Displaceand removethe trim finisher Fig 1 Reverse the removal procedure to refit the replacement trim finisher 0051G GEARBOX SPORT MODESWITCH FINISHER RENEW 76 25 09 Removethe gearbox sport mode switch 86 65 84 Carefully displace and removethe finisher Reverse the removal procedure to fit the replacement finisher 00516 REAR DOOR OUTER HANDLE OPERATING ROD ADJUST 76 37 11 Removethe rear door trim panelveneer panel 76 47 12 Removethe door upper trim pad 76 34 05 Removethe rear door lower trim pad 76 34 06 76 97 BODY SECTION Removethe plastic moulding Reposition the plastic waether shield for access and remove the outer handle operating rod adjuster peg retaining peg and reposition the rod from the retaining clip Depress the latch lever until the release hammer just contacts the release peg reposition the operating rod into the retaining clip whilst still holding the latch lever down Fit and seat the retainingclip peg and closethe door Check the operationof the lock and outer handle Openthe door Align and fit the plastic moulding and reverse the r
444. y cable connections Disconnectthe cables Removethe lamp assembly Fig 1 J86 4B3 Fitting a new lamp is the reversal of the removal procedure 3001B HEATER INDICATOR PANEL BULB RENEW 86 45 73 Openthe bonnetand disconnectthe battery earth lead Removethe gear lever knob 37 16 11 Removethe consolefinisher 76 25 19 Remove the screws securing the upper console assembly Fig 2 Displacethe assembly for access Fig 2 Removethe contron panel rear cover securingscrews Removethe rear cover Turn and remove bulb Fit a new bulb isthe reversal of the removal procedure 30018 86 42 ELECTRICALSYSTEM te veT O Ne MAN OIL GAUGE ILLUMINATION BULB RENEW 86 45 50 Open the bonnet and disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Remove the screws securing the instrument pack Remove the instrumentpack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the bulb Removethe bulbfrom the holder Fita new bulb by reversing the removal procedure 30018 TEMPERATURE GAUGEILLUMINATION BULB RENEW 86 45 51 Openthe bonnetand disconnectthe battery earth lead Openthe car door Removethe driver side dash liner Removethe screws securing the instrumentpack Removethe instrumentpack 88 20 01 Releasethe electronics pack retaining clips Pivot the electronics pack upwards for access to the
445. yl 77 07 SYSTEM CLEARCOAT Two pack 24375 Two pack Klarjack Two pack Klarjack 2000 6000 Clear 2K Clearcoat 455 30900 5805 Cronar Clear Glassodur MS Top Clear 923 985 Two pack P1 90 435 One pack P1 90 390 Local repair only Oiamontop Two pack Acryline MC1000 Clear Two pack Clear Two pack Clear Eurobase Clear 124 2468 BODY REPAIR CORROSION PROTECTION In production the vehicle is given an under body protection Stone chip primer is also usedon the sill panels while hot wax injection is appliedto all box sections and closed members Materials are supplied under the following descriptions UNIPART PENETRANT UNIPART SEALANT A sealing diagram showing the types and locations of sealed joints used is also included where applicable in each method description section A key explainingthe symbols in the sealing diagrams is shown below SEALING DIAGRAM 1 VISIBLE SEALANT 2 HIDDEN SEALANT 3 BOLTED PANELSEALER h addition certain body panels are zinc electro coated locationsare shown below 17 15 476 445 1 Bonnet hingeshim hinge RH and LH 10 Rearpanel upperreinforcement 2 Inner rear wheelarch RH and LH 11 Rearpanel lower reinforcement 3 Outerrear wheelarch RH and LH 12 Rearpanellowercorner gusset RH and LH 4 Rear wheelarch lower extensionRH and LH 13 Bootlidlower panel 5 Bootfloor side extensionRH and LH 14 Rearwing RH and LH 6 Bootfloor 15 Rear

Service manual Jaguar xj6 2002

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