SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ‘This model has an SRS which includes a driver's airbag located in the steering wheel hub and 2 passenger's airbag located in the dashboard above the glove box and seat belt tensioner located in the seat belt retractor. Information necessary to safely service the SRS is included in the Shop Manual, P/N 62S1E00. items marked with an asterisk (*) on the contents page include, or are located near, SAS components. Servicing, dis- assembling or replacing these items will require special precautions and tools, and should therefore be done by an authorized Honda dealer. AWARNING + To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal collision, all SRS service work must be performed by an authorized Honda dealer. + Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deploy- ‘ment of the airbags. + Do nat bump the SRS unit. Otherwise, the system may fail in case of a collision, or the airbags may doploy when the ignition switch is ON (I). + AIL SRS electrical wiring hamesses are covered with yellow insulation. Related components are located in the steering column, front console, dashboard, dashboard lower panel, and in the dashboard above the glove box. Do not use electrical test equipment on these circuits, + Before trying to remove the seat belt tensioner, first the sensor lock pin to LOCK position.Civic Aerodeck DIESEL SHOP MANUAL SUPPLEMENT 98 ‘This Repair Manual Supplement contains informa: tlon on the components and systems unique to ‘98 Civic Aerodeck Diesel models. This supplement should be used in conjunetion with the following manual: INTRODUCTION GENERAL INFORMATION INFORMATION MAINTENANCE ENGINE ELECTRICAL Nene MANIFOLD AND EXHAUST coouna FUEL AND EMISSIONS cLUTCH MANUAL GEARBOX DRIVE SHAFTS Description Code No, HONDA Civic Aerodeck MAINTENANCE, REPAIR AND CONSTRUCTION 98 6281E00 First Edition 3/98 540 pages HONDAMOTOR CO.,LTD. All Rights Reserved ‘Service Publication Office “HEATING AND VENTILATION ‘AIR CONDITIONING WIPERS AND WASHERS “BODY ELECTRICAL INSTRUMENTS:INTRODUCTION ra CONTENTS Page INTRODUCTION INTRODUCTION .... cnatan enone 1 REPAIRS AND REPLACEMENTS... 2 SPECIFICATION 2 3 ABBREVIATIONS AND SYMBOLSINTRODUCTION ra INTRODUCTION How to use this Manual To assist in the use of this Manual the section ttle is given at the top and the relevant sub-section is given at the bottom each page. Each major section starts with a contents page, listing the information contained in the relevant sub-sections. To assist filing of revised information ‘each sub-section is numbered from page 1. ‘The individual items comprising repair operations. are to be followed in the sequence in which they ‘appear. Items numbers in the ilustration are relerred tointhe text. ‘Adjustment and repair operations include reference to Service tool numbers and the associated ilustration depicts the tool. Where usage is not ‘obvious the too! Is shown in use. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, and specialist information and useful assembly details. Each adjustment or repair operation is given its Repair Operation Time number. WARNINGS, CAUTIONS and NOTES have the following meanings: WARNING: Procedures which must be followed precisely to avoid the possibility of injury. CAUTION: Calls attention to procedures which must be followed to avoid damage to components. NOTE: Gives helpful information. a References References to the LH or RH side given in this, Manual are made when viewing the vehicle from the ‘ear. With the engine and gearbox assembly removed, the crankshaft pulley end of the engine is referred to as the front. Operations covered in this Manual do not include reference to testing the vehicle after repair. It is ‘essential that work is inspected and tested after ‘completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concemed. ‘The dimensions quoted are to design engineering specification with Service limits where applicable. INTRODUCTION 1INTRODUCTION REPAIRS AND REPLACEMENTS When replacement parts are required itis essential that only HONDA recommended parts are used. Attention is particularly drawn to the following points concerning repairs and the fiting of replacement parts and accessories. Safety features and corrosion prevention treatments ‘embodied in the vehicle may be impaired if other than HONDA recommended parts are fitted. In certain terri- tories, legislation prohibits the fiting of parts not to the manufacturer's specification. Torque wrench set- ting figures given in this Manual must be used. Locking devices, where specified, must be fitted. I the efficiency of a locking device is impaired during removal it must be renewed. ‘Owners purchasing accessories while travolling abroad should ensure that the accessory and its fitted location ‘on the vehicle conform to legal requirements. ‘The Terms of the vehicle Warranty may be invalidated by the fitting of other than HONDA recommended parts. All HONDA recommended parts have the full backing of the vehicle Warranty. HONDA Dealers are obliged to supply only HONDA rec- ‘ommended parts, SPECIFICATION HONDA are constantly seeking to improve the speci cation, design and production of their vehicles and alterations take place accordingly. While every effort thas been made to ensure the accuracy of this Manu: ‘should not be regarded as an infallible guide to current specifications of any particular vehicle. ‘This Manual does not constitute an offer for sale of any particular vehicle. HONDA Dealers are not agents of HONDA and have no authority to bind the manufactur: er by any expressed or implied undertaking or repre- ——— 2 INTRODUCTIONINTRODUCTION ra ‘ABBREVIATIONS AND SYMBOLS ‘After Bottom Dead Centre ‘ABDC Manifold absolute pressure Map ‘After Top Dead Centre AOC Mass air flow MAF ‘ir conditioning AC Maximum max. Ar fuel ratio AFR Hg Aitemating current ac ™m Amperes A mph Antilock brake system ABS mm min Betore Bottom Dead Centre BDC Betore Top Dead Centre BTDC Mowe erg ; Bottom Dead Centre BDC mana {ena uw Briish Standards BS Mael Year ww Carbon monoxide co Mui-funetion unit MFU Gees (Centigrade c Muit-point injection MPI Gentimetre on Chiorofuorocarbons orcs Negative (electrical) 2 Cubic centimetres on enon qe Crankshaft position KP Degree (angie) eg or* Outside diameter odia Degree (temperature) 9, or Percentage % Dial test indicator on Plus of minus : Diameter da, Pus (tolerance) : Direct current dc Positive (electrical) + Positive crankcase ventiation Pov Electronic Control Unit ecu Exhaust gas recirculation EGR postive temperature coetfiient Pas Electronic air control valve EACV wer asst ma s Engine Contro! Module ECM Radius ' Electronic Diese! Control e0c Ratio Engine coolant temperature ECT Reference ret ' Revolutions per minute revimin Fuel injection Pump FIP rayaluions rin Gramma (ress) ° Right-hand drive RHD Second {angle} : igen fe inal overhead camshaft sone Specific s.r Hour 6 Square centimetres cm? Intake air temperature aT Standard std. intemal diameter iia Sun Root sim Intemational Organisation for 180 ‘Supplementary Restraint System SRS Standardization Synchronizer/synchromesh synchro Kilometre ton Thousand x Kiiogramme Kg Top deed centre Toc Left-hand un ‘Throttle position 7 eer iB United Kingdom uk {ight emiting ciode tsp United States us ‘Low Compression iG Vehicle identification number vn volt v Watt w INTRODUCTION = 3.GENERAL INFORMATION CONTENTS Page VEHICLE IDENTIFICATION NUMBER ‘VEHICLE IDENTIFICATION NUMBER so 42 IDENTIFICATION NUMBER LOCATIONS «0 . . 12 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS IGNITION SYSTEM SAFETY PRECAUTIONS .. . 13 DANGEROUS SUBSTANCES ENVIRONMENTAL PROTECTION PRECAUTIONS .. SAFETY INSTRUCTIONS. FUEL HANDLING PRECAUTIONS FUEL HANDLING PRECAUTIONS. ELECTRICAL PRECAUTIONS ELECTRICAL PRECAUTIONS.GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER Location ‘The Vehicle Identification Number (VIN) is stamped on a plate attached to lower corner of the windscreen. Example given below: Vehicle ident ication number SHHMC3730WU000001 SHH: Type of Vehicle HONDA OF THE U.K. MEG., LTD. England. HONDA Passenger car MC3: Line, Body and Engine Type CIVIC §-door/20T2N, 20T2R 7: Body and Transmission Type S-door Wagon/ S-speed Manual Factory Code Honda of the U.K. Manufacturing in England, ‘Model Year 1998 5 figures: Serial number IDENTIFICATION NUMBER LOCATIONS Engine number 2.0 Engine: Stamped on the front face of the oylinder block adjacent to the alternator. Goarbox number ‘Manual Gearbox: Stamped on a label attached to the {front face of the clutch housing. 1.2 VEHICLE IDENTIFICATION NUMBERGENERAL INFORMATION a | GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS Ignition system safety precautions WARNING: Betore commencing work on By anignition system, al! high tension terminals, adapters and dlagnostic ‘equipment for testing should be inspected to fenoure that they are adequately inaulated and shielded to prevent accldental personal contacts and minimise te risk of shock: Wearers of surgically Implanted pacemaker devices should not be in close proximity to ignition circuits or diagnostic equipment. Dangerous substances WARNING: Many liquids and other ‘substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far 28 possible, be kept from contact with the skin. ‘These substances among others include acid, ‘anti freeze, asbestos, brake fluid, fue windscreen washer additives, lubricants, refrigerant and various adhesives. ‘Always read carefully the instructions printed on labels or stamped on components and obey ‘them implicitly, Such instructions are included for reasons of your health and personal safety. Never disregard them. Used engine olls: Prolonged exposure to used ‘engine olls can cause serious skin disorders, avoid excessive skin contact and always adhere to the following recommendations: Engine oils. Prolonged and repeated contact with mineral oil will result in the removal of natural fats trom the skin, leading to dryness, iritation and dermatitis. in addition, used engine oi contains potentially harmful ‘contaminants which may cause skin cancer. ‘Adequate means of skin protection and washing facilties must be provided. Health Protection Precautions + Avoid prolonged and repeated contact with oils, patticularly used engine oils. + Wear protective clothing, including impervious gloves where practicable, + Do not put oly rags in pockets. + Avoid contaminating clothes, particularly underpants, with ol. + Overalls must be cleaned regularty. Discard heavily soiled clothing and oil impregnated footwear. + First aid treatment should be obtained immediately for open cuts and wounds. + Use barrier creams, applying before each work period, to help the removal of ol from the skin. + Wash with soap and water to ensure ail ol is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. + Do not use petrol, Kerosene, diesel fuel, gas oi thinners or solvents for cleaning skin. + It skin disorders develop, obtain medical advice without delay. + Where practicable, degrease components prior to handling. + Where there isa risk of eye contact, eye protection should be wom, for example, chemical ‘goggles or face shields; in addition an eye wash faciity should be provided. Environmental Protection Precautions Its illegal to pour used oil on to the ground, down ‘sewers or drains, or into water courses. Buming of used engine oil in small space heaters or boilers can be recommended only for units of approved design. The heating system must meet the regulatory standards of HMIP for small burners of less than 0.6 MV. If in doubt check with the ‘appropriate local authority and/or manufacturer of ‘approved appliance. Dispose of used oil and used fiters through authorised waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. ifn doubt, contact the Local Authority for advice on disposal facilites, (GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1.3GENERAL INFORMATION ‘SAFETY INSTRUCTIONS Jacking The recommended jacking points are given in LIFTING AND TOWING, always ensure that any liting apparatus has adequate load and safety capacity for the weight to be ited. Ensure the vehicle is standing on level ground prior to iting or jacking. Apply the handbrake and chock the wheels. Never rely on a jack as the sole means of support ‘when working beneath the vehicle. Use additional ‘safety supports beneath the vehicie. Do not leave tools, lifting equipment, spilt oll, etc. around or on the work bench area. Precautions against damage Always fit wing and seat covers before commencing ‘work. Avoid spilling brake fluid or battery acid on paintwork. Wash off with water immediately f this occurs. Disconnect the battery earth lead before starting work, see ELECTRICAL PRECAUTIONS. ‘Always use the recommended service tool or a satisfactory equivalent where specified. Protect exposed bearing and sealing surfaces and ‘screw threads from damage. Brake shoes and pads WARNING: Always fit the correct grade ind specification of brake linings and renew brake pads and brake shoes in axle sets only. Brake hydraulics WARNING: itis imperative that the correct brake fittings are used and that threads of components are compatible. Always use two spanners when slackening or tightening brake pipe or hose connections. Ensure that hoses run in a natural curve and are not kinked or twisted. Fit brake pipes securely in their retaining lips and ensure that the pipe run cannot contact a potential chafing point. Containers used for hydraulic fluid must be kept absolutely clean. Do not store hydraulic fluid in an unsealed container, it will absorb water and in this ‘condition would be dangerous to use. Do not allow hydraulic uid to be contaminated with mineral ol, or Use a container which has previously contained mineral oil. Do not re-use fluid from the system. Always use clean brake fluid or a recommended alternative to clean hydraulic components. Fit a ‘blanking cap to an hydraulic union and a plug to its ‘socket after removal to prevent the ingress of dit. ‘Absolute cleanliness must be observed with hydraulic components. Engine coolant caps and plugs Extreme care is necessary when removing engine coolant caps and plugs when the engine is hot and ‘especialy it it is overheated. To avoid the possibilty of scalding allow the engine to coo! before: attempting coolant cap or plug removal. Cleaning components Always use the recommended cleaning agent or equivalent. Do not use degreasing equipment for components. ‘containing items which could be damaged by the use of this process. Whenever possible clean ‘Components and the area surrounding them before removal. Always observe scrupulous cleanliness when cleaning dismantled components. 1-4 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS.GENERAL INFORMATION ve Joints and joint faces, Bolt identification Fit joints dry unless otherwise specified in this, Manual. It gaskets andjor jointing compound is recommended {or use; remove al traces of old joining material prior to reassembly. Do not use a tool which will damage the joint faces and smooth out any scratches or burrs on the joint faces using an oil ‘stone. Do not allow dit or jointing material to enter any tapped holes. Prior to reassembly, blow through any pipes, ‘channels or crevices with compressed alr. ‘An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of ‘Screw threads the symbols ISO M or M embossed or indented on top of the head. ‘Metric threads to ISO standards are used. In addition to marks to identity the manufacturer, the Damaged nuts, bolts and screws must always be head is also marked with symbols to indicate the discarded. strength grade, e.g. 8.8; 10.9; 12.9; 14.8, As an alternative, some bolts and screws have the M and Cleaning up damaged threads with a die or tap strength grade symbol on the flats of the hexagon. impairs the strength and closeness of fit of the threads and is not recommended. Castellated nuts must not be slackened back to ‘accept a split-pin, except in those recommended ‘cases when this forms part of an adjustment. Do not allow oil or grease to enter blind threaded holes. The hydraulic action on screwing in the bolt or ‘stud could spit the housing. ‘Always tighten a nut or bolt to the recommended torque figure, Damaged or corroded threads can affect the torque reading. To check or re-tighten a bolt or screw to a specified torque figure, fist slacken a quarter of a turn, then retighton to the correct torque figure. GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS — 1.5GENERAL INFORMATION Nut identification +4mo0s6 ‘Arnut with an ISO metric thread is marked on one face or on one ofthe flats of the hexagon with the strength grade symbol 8, 12, of 14. Some nuts with a strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the flat opposite the strength grade marking. ‘A clock face system is used as an alternative ‘method of indicating the strength grade. The external ‘chambers or a face of the nut is marked in a position relative to the appropriate hour mark on a clock face to indicate the strength grade. ‘A dot is used to locate the 12 o'clock position and a dash to indicate the strength grade. If the grade is above 12, two dots identify the 12 o'clock position. Locking devices Always release locking tabs and fit new locking washers, do not re-use locking tabs. Always use a backing spanner when slackening or tightening brake and fuel pipe unions. Fitting a split pin x on 1M0057 ‘Always fit new split-pins of the correct size for the hole in the bolt or stud. Do not slacken back nut to center spli-pin. ‘Always fit new roll pins of an interference fit in the hole. ‘Always fit new circlips of the correct size for the groove. © © a a ‘moss Selt-locking nuts, i.e. nylon insert or metal stif nuts ‘can be re-used providing resistance can be felt when the locking portion of the nut passes over the thread ‘ofthe bolt or stud, — 1-6 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS.GENERAL INFORMATION ra ‘Selt-locking bolts and screws 1M0059 Selt-locking bolts and screws, ie. nylon patched or trilobular thread can be re-used providing resistance ccan be felt when the locking portion enters the female thread. Nylon patched bolts and screws have a focking agent pre-applied to the threads. They are identified by the presence of a coloured section of thread which extends for up to 180° around the thread. ‘Trilobular i.e, Powerlok bolts have a special thread form which creates a slight interference in the tapped hole or threads of the nut into which itis screwed. 00 NOT re-use self-locking fasteners in critical locations eg engine bearings. Always use the correct replacement self-locking nut, bolt or screw. DO NOT fit non self-locking fasteners in applications where a self-locking nut, bolt or screw is specified. Encapsulated bolts and screws 1M0062 Encapsulated bots and screws have a rmicro-encapsulated locking agent pre-applied to the thread. They are identified by the presence of a coloured section of thread which extends completely ‘around the thread - 360°. The locking agent is released and activated by the assembly process and is then chemically cured to provide the locking action. Unless a specific repair procedure states otherwise, encapsulated bolts may be re-used providing the threads are undamaged and the following procedure is adopted. Remove loose adhesive from the bolt and housing threads, ensure threads are clean and tree of oll and, grease. Apply an approved adhesive. Fit a new encapsulated bot, or if not available a bolt of equivalent specification treated with an approved adhesive. ‘GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1.7GENERAL INFORMATION ee Oil eeale ‘Aiways renew oil seals which have been removed {rom their working location either as an individual ‘component or as part of an assembly. Ensure the surface on which the new seal sto unis tree of burs or scratches. Renew the component i the original sealing surface cannot be completely restored. Protect the seal from any surtace which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surtace. Lubricate the sealing lips with a recommended lubricant before use to prevent damage in initial use. ‘On dual lipped seats, smear the area between the lips with grease. Use the recommended service too! to fit an oil seal Ifthe correct service too! is not available, use a suitable tube approximately 0.4 mm smalier than the ‘outside diameter of the seal. Press or drift the seal in to the depth of its housing, with the sealing lip facing the lubricant to be retained if the housing is shouldered, or flush with the face of the housing where no shoulder is provided. Service tools and garage equipment Special service tools have been developed to faciitate removal, dismanting and assembly of mechanical components in a cost effective and practical manner without causing damage. Some operations in this Manuel cannot be carried out wehout the aid of the relevant service tools. Body repairs ‘Any damage found, that would affect the corrosion resistance of the vehicle during the Warranty period ‘must be rectified by an authorised Rover Dealer to the standards, and by the methods, detailed in the Body Repair Manual. Replacement body panels ‘Body panels are supplied coated in cathodic electrocoat primer. ‘Synthetic rubber Many 0’ rings, seais, hoses, flexible pipes and other similar items which appear to be natural rubber, are in fac, made of synthetic materials called Fiuoroelastomers. Under normal operating Conditions this material is safe and does not present a heath hazard. However, ifthe material is damaged by fir or excessive heating, it can break down and produce highly corrosive Hydrofluoric acid which can cause serious burns on contact with skin. If skin contact does occur: + Remove any contaminated clothing immediately. + Irigate ettected area with a copious amount of cold water or limewater for 15 to 60 minutes. *+ Obtain medical assistance immediately ‘Should the material be in a bumt or over-heated ‘condition handle only with seamless industrial gloves. Decontaminate and dispose of gloves ‘immediately after use. 1-8 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSGENERAL INFORMATION 4 | FUEL HANDLING PRECAUTIONS: General The following information provides basic precautions ‘which must be observed if petrol (gasoline) isto be handled safely it also outlines other areas of risk Which must not be ignored. This information is issued for basic guidance only, and if in doubt appropriate enquiries should be made of your local Fire Officer. Petrol - Gasoline Petrolgasoline vapour is highly flammable and in Confined spaces is also explosive and toxic. When petrol/gasoline evaporates it produces 150 times its own volume in vapour which when diluted with air becomes a readily ignitable mixture. The vapour is heavier than air and will always fall to the lowest level. It can readily be distributed throughout ‘a workshop by air currents; consequently, even @ ‘small spillage of petrol/ gasoline is potentially very dangerous. ‘Always have a fire extinguisher containing FOAM, (C02, GAS or POWDER close at hand when ‘handling or draining fuel or when dismantiing fuel ‘systems and in other areas where fuel containers are stored. ‘Always disconnect the vehicle battery before carrying out dismanting or draining work on a fuel system. ‘Whenever petrol/gasoline is being handled, drained (or stored or when fuel systems are being dismantied, all forms of ignition must be extinguished or removed; any leadiamps must be flameproof and kept clear of spillage. WARNING: No one should be permitted to repair components associated with petrol/gasoline without first having specialist training. Fuel tank draining WARNING: Petroligasoline must not be extracted or drained from any vehicle whilst itis standing over a pit. Draining or extraction of petrol/gasoline from a vehicle fuel tank must be carried out in a well ventilated area. ‘The receptacle used to containthe petrolgasoline must be more than adequate for the full amount of fuel to be extracted or drained. The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations. CAUTION: When petrol/gasoline has been extracted or drained from a fuel tank the precautions governing naked lights and Ignition sources should be maintained. Fuel tank removal When the fuel tine is secured to the fue! tank outlet by a spring stee! clip, the clip must be released ‘before the fuel line is disconnected or the fuel tank is removed. This procedure will avoid the possibilty of residual petrol fumes in the fuel tank being ignited when the clip is released. ‘As an added precaution fuel tanks should have a "PETROL (GASOLINE) VAPOUR’ waming label attached to them as soon as they are removed from the vehicie, FUEL HANDLING PRECAUTIONS 1.9GENERAL INFORMATION Fuel tank repairs Under no circumstances should a repair to any fuel tank involving heat treatment be carried out without first rendering the tank SAFE, by using one of the following methods: ‘a. STEAMING: With the filer cap and tank unit removed, empty the tank, Steam the tank for at least ‘two hours with law pressure steam. Position the tank 0 that condensation can drain away freely, ensuring that any sediment and sludge not volatized by the steam is washed out during the steaming process. b. BOILING: With the filer cap and tank unit removed, empty the tank. Immerse the tank ‘completely in boiling water containing an effective alkaline degreasing agent or a detergent, with the ‘water filing and also surrounding the tank for at least two hours. ‘After steaming or boiling, a signed and dated label to this effect should be attached to the tank. Body and chassis repairs ‘When a body or chassis repairs involve the use of heat, al fuel pipes which run in the vicinity ofthe repair area must be removed, and the tank outlet plugged, BEFORE HEAT IS APPLIED. If the repair the vicinity ofthe fuel tank, the tank must be removed. Fuel lines or tanks must not be removed whilst the vehicle is over an inspection pit. —_— 4-10 FUEL HANDLING PRECAUTIONS.GENERAL INFORMATION re ELECTRICAL PRECAUTIONS: General ‘The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the vehicle. Where necessary specific precautions are detailed in the relevant sections ofthis Manual which ‘should be referred to prior to commencing repair ‘operations. Equipment - Prior to commencing any test procedure (on the vehicle ensure that the relevant test ‘equipment is working correctly and any hamess or connectors are in good condition, this particularly applies to mains lead and plugs. {an ignition system all high tension terminals, adapters and diagnost ‘equipment for teating should be inspected to ‘ensure that they are adequately insulated and shielded to prevent accidental personal contacts and minimise the risk of shock. Wearers of surgically implanted pacemaker devices should ‘not be in close proximity to ignition circuits or diagnostic equipment. A WARNING: Before commencing work on Polarity - Never reverse connect the vehicle battery ‘and always observe the correct polarity when connecting test equipment. High Voltage Circuits - Whenever disconnecting live ht circuits always use insulated pliers and never allow the open end of the ht lead to come into ‘contact with other components particularly ECU's. Exercise caution when measuring the voltage on the coil terminals while the engine is running, high voltage spikes can occur on these terminals. Connectors and Hamess - The engine compartment of a vehicle isa particularly hostile environment for electrical components and connectors. Always: ‘ensure these items are dry and ol ree before disconnecting and connecting test equipment. Never force connectors apart either by using tools or by pulling on the wiring harness. Always ensure locking tabs are disengaged before removal and not crientation to enable correct reconnection. Ensure that any protective covers and substances are replaced i disturbed. Having confirmed a component to be faulty switch oft the ignition and disconnect the battery. Remove the ‘component and support the disconnected hamess. When repiacing the component keep oily hands away from electrical connection areas and push ‘connectors home until any locking tabs fully engage. Battery disconnecting Before disconnecting the battery, switch off all ‘electrical equipment. If the radio is to be serviced, ensure the security code has been deactivated. CAUTION: To prevent damage to electrical components ALWAYS disconnect the battery when working on the vehicle electrical system. The earth lead must be disconnected first and reconnected last. Always ensure that battery leads are routed correctly and are not close to any potential chafing points. Battery charging Recharge the battery out of the vehicle and keep the top well ventilated. While being charged or discharged, and for approximately fifteen minutes afterwards, batteries emit hydrogen gas. This gas is inflammable. : Always ensure any battery charging area is well ventilated and that every precautions is taken to ‘avoid naked flames and sparks. ss ELECTRICAL PRECAUTIONS 1-11GENERAL INFORMATION Disciplines ‘Switch off ignition prior to making any connection or disconnection in the system as electrical surge caused by disconnecting lve’ connections can damage electronic components. . Ensure hands and work surfaces are ciean and free of grease, swart, etc. as grease collects dirt which ‘can cause tracking or high-resistance contacts. When handling printed circuit boards, treat them as you would a disc - hold by the edges only; note that ‘some electronic components are susceptible to body static. Connectors should never be subjected to forced removal or refit, especialy inter-board connectors, damaged contacts will cause short-circuit and open-circuit conditions. Prior to commencing test, and periodically during test, touch a good earth, .. cigar lighter socket, to discharge body static as some electronic ‘components are vulnerable to static electricity, 1-12 ELECTRICAL PRECAUTIONSINFORMATION CONTENTS Page LIFTING AND TOWING JACKING, SUPPORTING AND TOWING WORKSHOP JACK WHEEL-FREE LIFT RECOVERY TOWING GENERAL DATA ENGINE .. FUEL SYSTEM COOLING SYSTEM CLUTCH... . MANUAL GEARBOX - PGI... FINAL DRIVE STEERING ... ‘SUSPENSION BRAKES .. WHEELS ... TYRE ver ‘TYRE PRESSURES ELECTRICAL, DIMENSIONS .. wn vn WEIGHTS. ve ' . 28 ENGINE TUNING DATAINFORMATION CONTENTS Page TORQUE WRENCH SETTINGS: ENGINE EMISSION CONTROL... ENGINE MANAGEMENT SYSTEM-EDC FUEL DELIVERY SYSTEM FUEL DELIVERY SYSTEM - EDC COOLING .... MANIFOLD AND EXHAUST . cLuTcH MANUAL GEARBOX - PG1 DRIVE SHAFTS. STEERING ‘SUSPENSION BRAKES SUPPLEMENTARY RESTRAINT SYSTEM BODY .. so HEATING AND VENTILATION AIR CONDITIONING WIPERS AND WASHERS .. ELECTRICAL INSTRUMENTS os. CAPACITIES, FLUIDS AND LUBRICANTS: ‘CAPACITIES FLUIDS LUBRICATIONINFORMATION ra JACKING, SUPPORTING AND TOWING 4. Central jacking point - front 2. LH sill re-inforced bracket front 3. RH sill re-inforced bracket front 4. LH sill re-inforced bracket rear 5. RH sill re-inforced bracket rear WARNING: In accordance with normal ‘workshop practice, and to avoid the possibility of damage or personal injury, work must not be carried out on or under a vehicle when It is supported solely on a jack. Place safety supports under the sill reinforced jacking areas (2, 3, 4 or 5). Central jacking point and lashing/towing eye - rear Longitudinal members «front Longitudinal members - rear Lashingytowing eyes - front WARNING: Do not position a jack, jack stand or wheel free support under the ‘suspension attachment points. LIFTING AND TOWING 2.3INFORMATION WORKSHOP JACK Front: Locate the jack head under the central location bracket (1). Position safety supports under both front sil reinforced brackets (2 and 3) Rear, Locate the jack head under the rear towing eye (6). Position safety supports under both rear sill reinforced brackets (4 and 5). Side: Locate the jack head pad under the reinforced bracket (2 of 3) of the front sill and position safety ‘support under front longitudinals (7), jack under reinforced area (4 of 5) of the rear sill then position safety support under rear longitudinals (8). WARNING: Do not attempt to jack under A ‘suspension attachment points. WHEEL-FREE LIFT It crossbeams are available, locate the pads under the sill reinforced jacking brackets (2, 3) and (4,8) It only longitudinal beams are available, locate the beams under the floor fongitudinals with the lifting pads at the front and rear positions (7) and (8). Raise the lif a few inches and ensure the vehicle is firmly supported. Raise the tit to full height and inspect the iting points for security. RECOVERY, Itis recommended that a recovery trailer or two Wheel vehiole ambulance be used. In an emergency, the vehicle may be towed on its own wheels using the front lashing/towing eyes (9). SUSPENDED TOW: Cannot be carried out without incurring damage. If additional damage is immaterial because of existing crash damage, lifting chains can be attached to the towing eyes. Before towing commences release the handbrake, place the gear lever in neutral and the ignition switch at". Do not tow at a greater speed than 30 mph, $0 kan/h. On no account should the vehicle be towed with the front wheels on the ground if the transmission is faulty, the transmission fluid level is low, or the towing distance exceeds 30 miles or 50 ken, TOWING ‘The rear lashingftowing eye (6), must only be used for towing a light vehicle. Use the front lashingftowing eyes (8) for towing the Vehicle on all four wheels from the front. WARNING: To ensure that the steering does not lock when the vehicle is being towed, itis essential that the ignition key Is turned to position '', and remains there while the vehicle is moving. Ensure the following precautions are observed: Do not tow if the gearbox or a drive shatt is faulty. Do not tow if a wheel or drive shafts are touching the body or frame. Ensure the gear lever is in neutral and the handbrake is released. Remember that greater effort than normal will be necessary to apply the brakes if the vehicle is being towed without the engine running. 2-4 LIFTING AND TOWINGINFORMATION ENGINE Type. .. 20T2N, 20T2R/8 valve SOHC Cylinder arrangement. "inline - transverse smn 845 mm (3.33 in} “88.9 mm (3.50 in) “1,994 erm (122 cu-in} Firing order... 1-3-4-2 Rotation.. Clockwise, viewed from the front of the engine Lubrication ‘System Type. cman Wet Sump, crankshaft driven eccentric rotor pump Pressure at idle. . SIL 0.7 bar (0.7 kgffem?) il pressure warning light switch OPENS vrcecrnewn 0.40.7 bar (0.4. 0.7 kgt/em?) Ol fier. Full flow with disposable canister FUEL SYSTEM .. Bosch rotary pump s80 Bosch 0450 906172 Bosch two spring, needle lift on number one cylinder Fue! injection Pump. type. Fuel filter Fuel injectors. COOLING SYSTEM 11-1 bar (1.1 kaffem=) "ac e5C Pressure cap opens . ‘Thermostat fully open. Cooling fan switch Models without intercooler ‘non air conditioning. with air conditioning... On- 104°C, Off - 94°C "slow fan: On - 98°C, Off - 94°C fast fan: On - 112°C, Off - 104°C cuuTcH Tye snr Cluteh plate diamet Friction material wear limit. vn Diaphragm spring, hydraulic operation III. 228 mm (8.98 in) 4.5 mm (0.06 in} MANUAL GEARBOX - PG1 GENERAL DATA 2-5INFORMATION = 420031 Road speed at 1000 revimin in top gear: with 185/60 R14 tyres. 38.4km/h (23.9 mph) STEERING Front wheel alignment : oP s0°12 Front wheel camber : Ost? Front wheel caster cons 1928" King pin inclination 10° 41" Steering angle of outer whee! with inner wheel at 20° ....... seo cee 18°33" Tums - lock to lock cittttecrreeereen, 8:48 Rear wheel camber : 0° 55° negative Rear wheel alignment : : Toe-in 0° 11" + 0°6' per side A NOTE: Steering and Suspension geometry settings are for a vehicle at unladen weight. 2-6 GENERAL DATAINFORMATION SUSPENSION Front Te Independent. double wishbone with coll spring, damper and anti-roll bar Nominal height to wheel arch from hub centre... 365 mm (14.4 in} Rear Type.. ay smmineensntennnnn Independent, trailing arm with damper and coil spring. Nominal height to wheel arch from hub centre. 373 mm (147 in) BRAKES, Front brakes Dise diameter. a 1 262 mm (10:3 in) Dise wear limit ae : 11.0 mm (0.43 in} "2 19.0 mm (0.75 in) Pad minimum thickness. 3.0 mm {0.12 in) dise by Dise diam a seve 239 men (9.41 in) Disc wear limit (minimum thickness). "8.0 mm (0.31 in) Pad minimum thickness. 3 mm (0.1 in} Rear drum brakes Drum inside diameter <20-o 203.2 mm (8.00 in) Drum wear limit (maximum diameter! 204 erm (8.03 in) Lining minimum thickness... 7 2mm (0.08 in) Master cylinder Bore diameter: Non ABS. 1 22.21 mm (0.87 in) ABS. 23.81 mmm (0.94 in} Brake servo ‘Servo boost ratio: Bosch ABSS: suxts 185/65 R14 GENERAL DATA = 2.7INFORMATION ‘TYRE PRESSURES Pressure (cold): Front 2.2 bar (32 Ibffin‘) Rear 2.1 bar (31 Ibffin’) ELECTRICAL ‘System, ._ 12 volt, negative earth .- 78 amp hour at 20 hour rate Without A/C With a/c DENsO DENSO - 80 amp 90 amp Starter motor Type/power DENSO RA/2.0 kW 2-8 GENERAL DATAINFORMATION DIMENSIONS (Overall length. 4425 mm ‘Overall width .. 1695 mm Overall height woman ¥440 mam Ground clearance (at unladen weight . 150 mm 2620 min 1475 mm 1470 mm + Atunladen weight WEIGHTS Unladen (fuel tank full, excluding options) 2.017. semaine 280 KG Maximum permissible vehicle weight . 1740 kg Maximum permissible rar axte weight (must not be exceeded) When towing. ~ ‘B70kg When not towing.. “820 kg, Maximum towing weight - braked trailer {restart on 12% grant with to occupants 1000 kg Towing hitch downward load, sane 5OKG ats 4fetgi afin 6in 8ft7 in 4ft10in At in 2822 1b 3836 Ib 1918 1808 Ib 2200 Ib ‘ole GENERAL DATA 2.9INFORMATION Engine ‘Type/Capacity Models without intercool 20T2N, 2072R/1,994 em Firing ord 13-42 Compression ratio. Idle speed: ‘Models without intercooler 19531 805+ 60 rev/min Electronic Diesel Control Fuel injection pump - make/type: Bosch electronic rotary/1-580 Bosch 2 stage Type. DSLATASP446, Opening pressure. 2000/3200 Glow plugs ‘Make. - BERV Type. (0100226 184 2.10 ENGINE TUNING DATAINFORMATION eter to appropriate section heading for component torque figures, e.g, Road wheel nuts - refer to SUSPENSION Exhaust front pipe to manifold - refer to MANIFOLD AND EXHAUST ENGINE Camshaft cover Camshaft gear centre bolt Camshatt gear bolts Crankshaft pulley bolt Cylinder head botts| First stage’ ‘Second stage’ Third stage’ . Fourth stage’ Engine LH mounting to body bolts Engine LH mounting to gearbox bolts Engine LH mounting to arm . Engine RH mounting to body bolts Engine RH mounting to engine bolts Engine RH mounting to bracket, nut Engine RH mounting plate, nuts and bolts Flywheel bolts’ Inecion pump dive gear rear of camehat) Ol fiter Oil pressure switch. Snubber nuts Steady bar bolts - lower Steady bar bolts - upper Steady bar bracket bolt ‘Sump bolts’ ‘Sump to gearbox suppor bracket Timing belt cover : Timing belt tensioner pulley "Tighten in diagonal sequence EMISSION CONTROL Catalytic converter heat shield botts Catalytic converter to intermediate pipe nuts Catalytic converter to front pipe nuts Heated oxygen sensor to exhaust manifold « 91Nhm (0.9 kgm, 7 IBF) 20 Nem (2.0 kgfm, 15 IbfAt) + 90° 25 Nan (2.5 kgfm, 18 IbFfe) {63 Nem (6.4 kgfm, 46 bfft) + 90° 30 Nem (3.1 kgfm, 22 bt) 65 Nem (6.6 kgm, 48 IbFt) 90° 90° +45 Nm (4.6 kgfm, 33 Ibft) {60 Nem (6.1 kgfim, 44 IbFt) 45 Nem (4.6 kgfm, 33 bt) 45 Nem (4.6 kgm, 33 bf) 105 Nem (10.7 kgtm, 77 Tot) 80 Nem (8.2 kgm, 59 Ibf‘t) 230 Nem (3.1 kgtim, 22 bFft) + 90° 85 Nem (8.7 kgf, 63 IDE) {60 Nien (6.1 kgm, 44 Tht 17Nem (1.7 kgm, 12 lof) 12.Nem (1.2 kof, 8.7 Ibtt) 10. (1.0 kgtm, 72 IbF) £80 Nem (8.2 kgf, 59 Ibt 100 Nem (10.2 kgm, 73.8 Ibfft) £80 Nem (8.2 kgf, 59 IbFt) 25 Nem (2.5 kgm, 18 IbFt) + 25 Nm (2.5 kgfm, 18 bf) 5.Nem (0.5 kofim, 4 IbF 44. Nem (45 kgf, 32 bf) 8.Nmm (0.8 kgf, 6 IbFt) 34Nm (3.5 kgtm, 25 IbFft) + 22 Nem (2.2 kgfm, 16 ibftt) 155 Nem (6.6 kgfm, 41 IbFAt) TORQUE WRENCH SETTINGS 2-11INFORMATION ENGINE MANAGEMENT SYSTEM - EDC ‘CKP sensor ECM to bracket . EGA pipe to plenum chamber EGR valve to manifold EGR valve to recirculation pipe Glow piug Glow plug lead... IAT sensor to intake manifold . MAP sensor FUEL DELIVERY SYSTEM Fuel tank heat shield bolts FUEL DELIVERY SYSTEM - EDC. Fue! injection pump, gear boit Fuel shut off solenoid : Fuel injection pump to mountings : Fuel injection pump, tensioner allen bolt. . Fuel injection pump, tensioner plate . Fuel injection pump camshaft Injector clamp bolt Injector pipes Plenum chamber to camshaft cover bolt Plenum chamber to inlet manifold . ‘Turbocharger oil drain pipe bolts... ‘Turbocharger oil feed pipes COOLING Coolant outlet elbow to cylinder head nuts . Coolant pump to bracket bolts . ‘Cooling fan to housing Cooling fan housing to radiator bots Expansion tank to body bolts... Radiator to bonnet lock platform, bolts MANIFOLD AND EXHAUST Catalytic converter to intermediate pipe, nuts .... Exhaust manifold to cylinder head, nuts and bolts Front pipe to manifold Intermediate pipe to tail pipe 6Nm (0.6 kgf-m, 4 bt) 91m (0.9 kgf, 7 Int) + 9Nm (0.9 kgm, 7 bt) 25 Nem (2.5 kgm, 18 tof) 25 Nem (2.5 kgf, 18 lbttt) 20 Nem (2.0 kgfm, 15 bt) ++ 25 Nm (03 kgm, 22 Ibfft) 12.Nem (1.2 kgtm, 87 IbFA) 9.Nm (0.9 kgf, 7 Ibtt) 9.Nm (0.9 kgm, 7 IbEFt) 20 Nem (2.0 kgfm, 15 Ibft) + 90° 20 Nem (2.0 kgm, 15 thf) 25 Nm (2.5 kgtm, 18 Ibtt) 44 Nem (4.5 kgm, 32 IDF) Nem (0.6 kfm, 4 Ibt 25 Nem (25 kgf'm, 18 bff) 25 Nem (2.5 kgf, 18 thf) 20 Nem (2.0 kgm, 15 tb) 9.Nim (0.9 kgm, 7 thE) + 9Nkm (0.9 kgm, 7 Ibe) 25 Nem (25 kgf, 18 bE) 20 Nem (2.0 kgm, 15 Ibt#t) 25 Nm (25 kgm, 18 lott) 10.Nm (1.0 kat, 7.2 bet) 9Nem (0.9 kgm, 7 tht) 9.Nem (0.9 ktm, 7 tbe) 9.Nem (0.9 kgm, 7 tht) 9m (0.9 kgm, 7 thee 34 Nem (3.5 kgtm, 25 tht) 25 Nem (2.5 kgtm, 18 beet) 45 Nem (4.6 kgtm, 33 IDF 45 Nim (4.6 kgfm, 33 Ibtt) 2:12 TORQUE WRENCH SETTINGSINFORMATION CLUTCH Clutch release fork to shaft 29 Nm (3.0 kgf, 22 bt) Prossure plate to flywheel bolts"... 26 Nem (2.7 kgfm, 20 IDF) {latch seve cinder mounting basket to geubox bolts. a 70 Nem (7.1 kgm, 51 thf) "Tighten in diagonal sequence MANUAL GEARBOX - PGT Gearbox to mounting plate bolts ........ 70 Nem (7.1 kgf, 51 EE) Gearbox iting eye bot « : 25 Nem (25 kgf, 18 Ibtt) Gearbox mounting bracket 2+ 60 Nim (6.1 kgf, 44 IBF) Gearbox drain plug me +45 Rem (48 kgm, 33 ER) Gearbox level plug. === 40 Nem (4.1 kgfm, 30 Ibfft) Gearchange steady bar to gearbox + 10 Nem (1.0 kgf, 7.2 Ibfft) Earth lead to gearbox bolt . . ss +++ 36.Nem (3.6 kgm, 26 Ibf#t) DRIVE SHAFTS: Drive shaft NEW nut, stake to shaft 181 Ne (1855 kgm, 134 bt) STEERING Rear trailing arm compensator adjustment bolt... 45 nkm (4.6 kgtm, 33 IbFft) Steering wheel nut 49 Nm (5.0 kgtm, 36 loft) ‘Steering column tower clamp bolts 22.Nm (22 kgtm, 16 Ibftt) Steering column upper bracket nuts 16 Nam (1.6 kof, 12 IF) Steering column universal oint bolts 28a (29 kgf, 21 Ibe) ‘ie-rod ball pin nut - align to next hole 39 Nm (4.0 kgtm, 29 Ibe) Steering rack clamp bolts : seers 38 Nem (3.9 kgfm, 28 bet) Steering rack pinion fange bolts _- 58 Nm (5.9 kgtm, 43 IDFA Steering rack fed pipe union 37 Nem (3.8 kgf-m, 27 Ibt ft) ‘Steering rack retum pipe union <2. a8 Renn (29 kgf, 21 It ‘Steering pipe clip .. 9 Nim (0.9 kaf'm, 7 Ibfft) High pressure hose to PAS pump _ 55 Nem (5.6 kgfm, 41 IbFft) PAS pump pulley bolts ..... ceeeeeeese 9 Nhe (0.9 kgm, 7 Ibf#t) PAS pump to coolant pump bolts. cesses 25 Nem (25 kgfm, 18 IDE) ‘TORQUE WRENCH SETTINGS 2-13INFORMATION ‘SUSPENSION Front Suspension Anti-rllbar link nuts... 22m (22 kote, 16 tet) ‘Anti-roll bar lamp to rear beam bots ....-....... 22 Nam (22 kgf, 16 ott Damper fork to lower arm bow? «2s... se. + 65:Nem (6.6 ktm, 48 Itt Lower arm front pivot bol? 65 Nem (6.6 kat, 48 bt) Lower arm rear pivot nut? Ssecesescs 85 Nem (8.7 kgm, 68 If) load wheel nuts’... pecesses 110m (11.2 kgfen, 61.0 IBF) Lower arm ball joint nut, align to next hole 49. Nm (5.0 kgfm, 36 htt) Upper arm ball joint nut, align to next hole ‘Steering arm bail joint nut, align to next hole + 39.Nem (4.0 kgtm, 29 IbF#t) + 39.Nim (4.0 kgm, 29 Ibf-ft) [ABS sensor adaptor screw . : 9 Nm (0.9 kgf, 7 Ib ABS sensor bracket to hub screw . ++ 10 Nem (1.0 kgf-m, 7.2 Ibfft) Brake nose bracket bolts . 30 Nm (1.0 kgm, 7.2 IDF) Upper arm bracket to body nuts 65 Nem (6.6 kat, 48 oft) Damper top mounting nuts... 40 Nem (4.1 kgf, 30 Ib) Damper to mounting pate nuts 30 Nem (3.1 kgm, 22 Ib) ‘Damper fork to damper bol 45 Nm (6.8 kgf, 33 Ib) Rear Suspension Lower arm mounting to Body Bots? 2+ 47 am 14.8 kgf, 35 ett) Upper arm to trailing arm bot. . eee a nan ae anse ee Upper arm to body bots .- TaN (8.0 kgtm, $8 tft) Compensator arm to trailing arm bolt” 45 Nem (4.6 kgfm, 33 Ibfft) Damper to mounting plate, self locking nut ........ 29 Nim (3.0 kgfm, 22 Ibfft) Damper mounting plate nuts? eos esses. sss 38. Nem (2.9 kgf, 28 Fe) Lower arm to trailing arm bots : 47 Nem (4.8 kgf, 29 tt) Road wheel nuts’ 190 Nem (11.2 kgf, 81.0 Ib) Hub shaft NEW nut- stake to shat. +5 181 Nem (185 kgf, 134 bff) Trailing arm mounting to body bolts 781m (8.0 kot, 58 loft) Handbrake cable bracket to trailing arm bons 22.Nm (22 kgtm, 16 bt) "Tighten in diagonal sequence Tighten with weight of vehicle on suspension 2.14 TORQUE WRENCH SETTINGSINFORMATION BRAKES Bleed screw - calipers Bleed screw - rear wheel cylinder Front caliper to mounting bots Front disc to drive lange screws Front caliper guide pin boks Front caliper shield bolts Front caliper banjo bolt |ABS front sensor to hub screw 'ABS front sensor hamess brackets bolts Rear caliper shield, bots Handbrake lever to body bolts Handbrake cable brackets bolts Handbrake cable retaining plate to back plate bolts ‘ABS ECU to modulator screws Modulator mounting spigot Modulator mounting nuts ‘ABS ECU pipe unions Master cylinder to servo nuts Pipe unions to master cylinder’. Brake servo to bulkhead nuts Brake proportioning valve bracket nuts Brake proportioning valve pipe unions. Front disc to drive flange screws Rear disc to hub screws Rear caliper banjo bolt [ABS rear sensérto adaptor screw [ABS rear sensor cover to hub bolts ‘ABS rear sensor hares brackets bolts 10 Nem (1.0 kgf, 7.2 bf) 71Nem (0.7 kgm, 5 Itt) 108 Nm (11.0 kgfm, 79.6 Ibf ft) 10.Nim (1.0 kgm, 7.2 bE) 27 Nem (2.8 kgm, 20 tht) 10 Nem (1.0 kgtm, 7.2 bf) 34 Nem (3.5 kgm, 25 thf) Nm (0.6 kgm, 4 1bF4t) 10.Nm (1.0 kgm, 7.2 bt) 10. Nem (1.0 kgf, 7.2 bt) + 22.Nm (2.2 kgfm, 16 IF tt) 22.Nm (22 kgtm, 16 tt) 22.Nem (22 kgf, 16 IFA) 8 Nm (0.8 kgm, 6 (bF4t) 15m (1.5 kgtm, 11 Bott) 10.Nm (1.0 kgm, 7.2 bet) 14Nem (14 kgf, 10 loft) 15. Nem (1.5 kgtm, 11 fof ft) 19m (1.9 kgtm, 14 1bEFt) 13.1Nm (13 kgtm, 9.4 Ibttt) 10Nem (1.0 kgm, 72 Ibtt) 19.Nem (1.9 kgf, 14 IF) 10Nm (1.0 kgtm, 7.2 Ibttt) 10Nem (1.0 kgm, 72 IbFt) 34 Nem (38 kgm, 25 lott) Nm (0.6 kgf, 4 IDF) 10 Nem (1.0 kgtm, 7.2 ttt) 10 Nem (1.0 kgm, 7.2 IDE) TORQUE WRENCH SETTINGS 2.15INFORMATION SUPPLEMENTARY RESTRAINT SYSTEM Driver's airbag module Torx screws 9.Nmm (0.9 kofm, 7 tht‘) Passenger’s airbag module to fascia nuts. . 4.Nim (0.4 kofim, 3 bt) Passenger’s airbag module to lower mounting ruts. 9m (0.9 kom, 7 tht) ‘Airbag hamess earth wire Torx screw 10m (1.0 kgm, 7.2 IbFt) ‘Airbag control unit to steering wheel Torx screws... 3 Nim (0.3 kat m, 2 lb-ft) BODY Doors Door lock striker to body screws... 18 Nem (1.8 kgtem, 19 latte) “Taildoor lock striker to body screws Secess 91Nhen (0.9 kgm, 7 Ibe) Door glass regulator to door bolts... 1.1.2... 1. 9 Rem (0.9 kgm, 7 bE Door glass regulator to motor screws 216 Tien (0.7 kgm, 5 Ib) Door glass regulator roller guide fos 8 Nem (0.8 kgm, 6 IbFft Door outside handle bolts : 9Nim (0.9 kgtm, 7 bt Door latch to door Torx screws... 2. nvm (0.6 kgfm, 4 bE) Front door glass rear channel bolt 8 Nim (0.8 kot, 6 bt) Rear door glass rear channel nut... s+ Nk (0.4 kgtim, 3 bff) Rear door glass rear channel bolts... -. anim (08 kgtm,6 bt) Rear door latch and cover screws... 7 Nem (0.7 kgf, 5 IDE Taldoor hinges to body nuts... eevee sess 22.Nhen (22 kgf, 16 IFA) Exterior Fitting Exterior mirror to door Tork Screws... ++ 4 Rm (O4kgfm, 3 bts) Bonnet hinge, bolts .... fosees ees 9 Nh (09 kgh, 7 IE) Front bumper to bonnet platform screws .......... 9 Nem (0.9 kgfm,7 ott) Interior Trim Components Fascia mounting Bolts ....... e225 9.Nem (0.9 kgtm, 7 Ibe) Seats and Seat Belts Seat belt stalk bolt - cece ses es 95 Nhe (26 kgf, 26 Ib) ‘Seat belt mountings bolt =<... 222.2... c 22.22, 32 Nh (8.3 kgm, 24 Ib) ‘Seat belt reet bracket to body bolt... 22.2... 9 km (0.9 kgtm, 7 HFE) Front seat runner to body Bolts... ss ++++. 38 Nem (35 kgm, 25 bff) Front seat runner to frame Torx screws .......... 22Nhm (22 kgm, 16 IbFft) Rear squab hinge to body bolts...» YO Nm (1.0 kgm, 7.2 bt) Screens ‘Sun root mountings screws wee 2 Nim (0.3 kgfen, 2 Ib ‘Sun foot to body bolts .... fosteseess 8 Nhe (09 kgf, 7 IDEA ee 2.16 TORQUE WRENCH SETTINGSINFORMATION HEATING AND VENTILATION Heater unit to bulkhead: 6 mm nuts 8 mmnuts ~~ ‘AIR CONDITIONING ‘Compressor to mounting bracket bolts Pipe union to compressor Cooling fan to housing nuts Pipe bracket to condenser bots Condenser to fan housing bolts Condenser pipe to compressor Trinary switch Receiver/ier to body bots Pipes to receiver/drier bolts Battery tray mounting bracket bolts Expansion valve ‘Adaptor to expansion valve Evaporator casing screws Lower rail to fascia screws Giovebox to fascia screws Pipe flange to evaporator bot Pipe bracket screws (LH) ‘Compressor mounting bolts . Condenser cooling fan to housing bolts Condenser cooling fan housing to condenser Pipe to condenser union ....... 2.2.22 Pipe to pipe unions Pipe to compressor unions Pipe to receiver drier Pressure switch to receiver drier Receiver drier to body 10m (1.0 kgtm, 7.2 Ibftt) 22 Nem (2.2 kgf, 16 bt) 45 Nem (4.6 kgm, 33 tof) 45 Nem (4.6 kgfm, 33 IbfAt) 91m (0.9 kgm, 7 tht) 5m (0.5 kgm, 4 Ibtt) Nm (0.9 kgm, 7 IDE) 25 Nem (2.5 kgf, 18 Ibtt) 12.Nem (1.2 kgm, 8.7 bf) 9.Nm (0.9 kgtm, 7 Ibtt) Nm (0.5 kgm, 4 tbe) 9Nim (0.9 kgf, 7 tht) 81Nm (0.9 kgf, 7 thf) 81Nm (0.9 kgf, 7 thf 10.Nem (1.0 kgm, 7.2 IbFAt) 10.Nem (1.0 kgm, 7.2 IbF) 101m (1.0 kgm, 7.2 thE) 101m (1.0 kgm, 7.2 IbFAt 10m (1.0 kgm, 7.2 IbFt) 45 Nem (4.6 kgm, 33 IbFft) 9.Nem (0.9 kgm, 7 IDF) 91Nem (0.9 kgf-m, 7 thf) 51Nm (0.5 kgf, 4 IbF ft) 25 Nem (25 kgfm, 18 IbFft) 45 Nem (4.6 kgtm, 33 IbFft) 5.Nem (0.5 kfm, 4 thf) 12. Nem (1.2 kam, 8.7 IbF ft) 9.Nm (0.9 kgf-m, 7 IDF TORQUE WRENCH SETTINGS 2.17INFORMATION WIPERS AND WASHERS Windscreen wiper motor linkage bolts Windscreen wiper motor botts Windscreen wiper arm nut . 8.Nem (0.8 kgm, 6 Ibf-ft) 9.Nim (0.9 kgm, 7 Ibe) 18.Nem (1.8 kgf, 13 1bFft) Rear wiper arm nut seers +14 Nem (1.4 kgf, 10 bf) Rear wiper motor bolts . 81m (0.8 kgfm, 6 bf‘) Rear wiper motor spindle nut. . 2Nem (0.2 kgm, 1 Mbt) ELECTRICAL Alternator upper fixing bolt . 25 Nem (2.5 kgm, 18 IbFtt) ‘Alternator lower fixing bolt veo 45. Nem (4.6 kghm, 33 bt) Alternator drive belt tensioner bolt. : + 45 Nm (6.6 kgm, 33 bt) Battery cable to alternator stud : sees 4m (0.4 kgm, 3 IBF Starter motor bolts - Horn bracket to body bolt Front bumper: Impact can to front panel bolts: 55 Nem (5.6 kgfm, 41 IbFft) 22.Nem (2.2 kgm, 16 IDF) + 22.Nm (2.2 kgtm, 16 IE) INSTRUMENTS Engine coolant temperature sensor. ............. Nm (0.8 kgm, 4 bf) ‘Speedometer pinion housing to gearbox... . Nm (0.8 kgm, 6 bt) eo 2.18 TORQUE WRENCH SETTINGSINFORMATION CAPACITIES nk oll refill and filter change. Engine oil refil from dry Manual gearbox -PG1 Refill. es From dry Power steering, Cooling system from dry* Washer reservoir 56 litres 5.0 litres 65 litres 20 litres 22 litres 335 m3 (20.4 cu-in) to max. level 7.0 litres 65 litres ‘Refill capacity is approx. 0.7 litres less than the from dry figures (which is approx. 2.94 litres). FLUIDS Brake Fluid Use only DOT 3 or DOT 4 brake fluid. 00 NOT use any other type of fluid. Antifreeze solutions properties of the coolant are maintained. Antifreeze concentrations greater than 60% are not recommended as cooling efficiency will be Use Genuine HONDA Anti “The cooling system should be drained. flushed and refiled with the correct amount of anti-freeze solution al the intervals given on the Service Maintenance Check Sheet. CAUTION: No other ‘universal’ anti-freeze should be used with Genuine HONDA Anti- Freeze Coolant. After filing with antifreeze solution, attach a warning bel to a prominent position on the vehicle stating the ‘ype of anti-freeze contained in the cooling system to ensure that the correct type is used for topping up. ‘The recommended quantities of anti-freeze for different degrees of frost protection are: Solution Amount of anti-freeze Commences freezing Frozen solid 50% 35 Litres 36°C 39°F arc 33°F ‘CAPACITIES, FLUIDS AND LUBRICANTS 2-19.INFORMATION LUBRICATION ‘The engine and other lubricating systems are filled with high- performance lubricants giving prolonged lite, CAUTION: You should always use a high quality oll of the correct viscosity range in the engine and gearbox during maintenance and when topping-up. The use of oil not to the correct specification can lead to high oil and fuel consumption and uttimately to damaged components. Oil to the correct specification contains additives ‘which disperse the corrosive acids formed by ‘combustion and prevent the formation of sludge which can block the oil ways. Additional oil additives should not be used. Always adhere to the recommended servicing intervals. Manual gearbox - PG1 Use a transmission oil of API service SG or SH viscosity SAE 10W/40 for refill or topping-up. Power Steering Use @ PSF-V, lor S Sw/20 Sa/30 ‘swi4 SwiS0 ¥Ow'30 owe ow/50 w/a tow /0 | 2ow/40 20w/0- “C -30" 20° 0" ow" 20" 30" 40" a M0060 ing specification RES.22.06.PD2 Gea inkage Use grease containing 3% Molybdenum Disulphide. 1 Greasing Use Multipurpose Lithium Base Grease N.L.G.l consis- ‘tency No. 2. Bonnet latch Lubricate cable and latch with multi-purpose grease. Locks, Latches and Hinges Use Door Lock and Latch Lubri grease, nt, multi-purpose 2.20 CAPACITIES, FLUIDS AND LUBRICANTS.MAINTENANCE CONTENTS Page (MAINTENANCE UNDERBONNET LOCATIONS .. . CHECK ENGINE AND TRANSMISSION .. ‘CAMSHAFT TIMING BELT ENGINE OIL AND FILTER . ‘GRANKCASE PRESSURE LIMITER VALVE . FUEL SYSTEM HOSES, PIPES AND UNIONS. FUEL FILTER AIR CLEANER ELEMENT . INJECTION PUMP - TIMING BELT .. GEARBOX OIL. - MANUAL GEARBOX COOLING SYSTEM EXHAUST SYSTEM CLUTCH ... DRIVE SHAFT GAITERS, STEERING SUSPENSION DAMPERS, BALL JOINTS, FIXINGS AND GAITERS . ROAD WHEELS AND FASTENINGS ‘TYRE PRESSURES AND CONDITION FOOTBRAKE ... ns HANDBRAKE BRAKE FLUID BRAKE HOSES AND PIPES FRONT BRAKES-HYDRAULICS, PADS, DISCS AND CALIPERS REAR DISC BRAKES BODY .... DRIVERS AIR BAG MODULE PASSENGER AIR BAG MODULE ‘SCREEN WIPERS AND BLADES WINDSCREEN AND REAR SCREEN WASHERS - LAMPS, HORNS AND WARNING INDICATORS . BATTERY CONNECTIONS '. FUSEBOX ROAD TEST ENMAINTENANCE 3.2 MAINTENANCEMAINTENANCE CHECK ENGINE AND TRANSMISSION 4. Visually inspect for oil leaks trom engine and transmission, pay particular attention to areas of gaskets and seals. CAMSHAFT TIMING BELT ‘See ENGINE, Adjustments section. ENGINE OIL AND FILTER Oil level check Always check oll level and drain oil with vehicle standing on level ground and use engine oil of specification 10w/40 for topping up and refiling 10M 0315 1. Withdraw dipstick and wipe blade. Re-insert dipstick fuly, withdraw it and check oil level ‘which must be maintained between minimum ‘and maximum marks on dipstick. lf required, remove filler cap and top-up with new engine oil to specification 10w/40. See INFORMATION, Capacities, fluids and lubricants section. MAINTENANCE 3.3,MAINTENANCE drain and refill Oil should always be drained when engine is warm. WARNING: Observe duo care when engine oll as the oil can be very hot. Prolonged and repeated contact with used engine oil may cause serious skin disorders, wash thor- ‘oughly after contact. Keep out of reach of chil- 1. Raise front of vehicle. fy, WARNING: Support on anfoty stands 2. Remove oil drain plug access caver from RH. under belly panel Place a container beneath sump. Remove drain plug and sealing washer, allow ofl to drain; discard sealing washer. 5. Clean drain plug, fit new sealing washer and refit drain plug. Tighten drain plug to 45 Nm (4.6 kgfm, 33 bt). 6 Remove ol filer cap, refill engine with oil to "specification SAE 15W/40 nti! rect CAUTION: Do not raise oll level above the ‘MAX’ mark on dipstick. 7. Fit oil filer cap. 3. Remove container from beneath sump. 9. Fit olf drain plug access cover to RH under belly panel. 10. Remove standis) and lower vel CAUTION: Ensure oil does not drop onto ‘the alternator when extracting the dipstick. 3-4 MAINTENANCEMAINTENANCE fat Oil filter renewal no - 12.60.04 Service rep: Remove 1. Raise tront of vehicle, 2. Remove oil fiter access cover trom RH under belly panel 3. Clean area around fiter head and place 2 ‘container beneath engine. Using a strap wrench, unscrew and discard fier. 3. Clean mating face of fiter head. Lubricate sealing ring of new fiter with engine oil Screw filter on to filter head by hand until it seats then tighten one complete turn or 17 Nem (1.7 kgm, 13 IDF). 8. Fit fiter access cover to RH under belly panel. 9, Remove stand{s) and lower vehicle 10. Top-up engine with engine oil to specification SAE 16W/40 until evel is correct. ~ ome 1. Clean mating face of fiter head. 2. Lubricate sealing ring of new fiter with engine oil 3. Fitfilter until it seats against filter head then tight- en one complete turn or to 17 Nem (1.7 kgfm, 12 wf) 4, Fit access panel to underbelly panel and secure with screws. ‘6. Top-up engine with engine oil to specification 10W/40 unt level is correct. CAUTION: Do not raise oil level above the DY Tia mask on pack 7. Start and run engine and check for oil leaks. 8. Stop engine, wait a few minutes, then check oi level and top up if necessary, CAUTION: Ensure of doesnot drop onto AX Se atemtor when exracing the eat MAINTENANCE 3.5MAINTENANCE CRANKCASE |ESSURE LIMITER VALVE Service Repair No. 17.10.25 som aa 1. Slacken clip and release valve from air Intake hose. 2. Slacken clip and remove valve from breather hose. Refit 1. Fit valve to breather hose and tighten clip, 2 Connect vaive ta air intake hose and tighten ci. 3.6 MAINTENANCEMAINTENANCE FUEL SYSTEM HOSES, PIPES AND UNIONS 1. Check fuel pipes and connections for chafing and leakage. 2. Check pipas are securely clipped. 3. Check fue! tank connections for security. 4. Check fue! tank is free from leaks and corrosion. 5. Check fuel tank for security of fixings. FUEL FILTER ‘AIR CLEANER ELEMENT. ‘See FUEL DELIVERY SYSTEM, Repairs. ‘See ENGINE MANAGEMENT SYSTEM - EDC, Repairs. INJECTION PUMP - TIM See ENGINE, Adjustments MAINTENANCE 3-7MAINTENANCE GEARBOX OIL - MANUAL Service repair no - 37.24.01 Oil level check and top-up 1. Ensure vehicle is standing on a level surface. 2. Remove underbelly panel. See BODY, Exterior 100433, 4, Remove fllerfievel plug. 5. Check that oil is tevel with bottom of filerlevel plug hole. CAUTION: Oil lodged behind fillerflevel plug will trickle out when plug is removed and can give the impression that level is. correct. 6. Top-up, if required, until oil just runs from filerflevel hole. Allow sutficient time for oll to flow until it reaches a common level in the gearbox. Use the correct specification oil. See INFORMATION, Capacities, fluids and lubricants. 7. Fit filler/level plug and tighten to 40 Nem (4.1 kgm, 30 IbFt) 3:8 MAINTENANCECOOLING SYSTEM WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove pressure relief cap from expansion tank while system is hot. Wait until system has cooled, use a cloth or glove to protect hands from escaping steam. Check level and top-up CAUTION: The coolant level should only be checked when the system is cold. 1. Visually check that coolant level is between the MAX’ and ’MIN’ marks on expansion tank. If {evel is appreciably low, suspect leakage or ‘overheating. CAUTION: If coolant is not visible in expansion tank system must be refilled in accordance with Refilling procedure. 2. If required, remove coolant expansion tank cap and top-up with anti-reeze mixture. See INFORMATION, Capacities, fluids and lubricants. CAUTION: The coolant must ot exceed AX, Semaimum coe ndiaton ae MAINTENANCE Check specific gravity of coolant. The overall anti-freeze concentration must not be below 50% by volume and must nol exceed 60% by volume. Refit expansion tank cap. For cooling system drain and refil. See COOLING, Adjustments. MAINTENANCE 3.9MAINTENANCE EXHAUST SYSTEM STEERING Check and top-up power steering fluid 1. Check for damage and signs of leakage 2. Check security of system. Carry out fuid level check when engine is stopped Check mountings and correet alignment. ‘Check security of heat shields. be CLUTCH 4. Check operation of cluteh, and free movement of pedai and release lever. 2. Check fiuid level in clutch master cylinder and top-up with clutch fluid. See INFORMATION, Capacities, fluids and lubricants, DRIVE SHAFT GAITERS 10M0346 4. Check that drive shatt gaiters are not twisted, split or damaged, 2. Check clips are secure, and system is cold. NOTE: It is essential that power steering jstem should not have been operated since engine was stopped. 4 Clean reservoir around filler cap and level! indicators. 2. Visually check fluid level is between level indicators. 3. required, remove filler cap and top-up with PSF- V, lor S. Do not overfill CAUTION: Ensure no dirt is allowed to Ay Chetretivcitunen captsemoved. 4, Refit filer cap, — 3-10 MAINTENANCEMAINTENANCE Steering column, rack, joints and gaiters Check security of 4 steering rack fixing bolts, tight- ‘en to 58 Nem (5.9 kgtm, 43 Ibft) MAINTENANCE 3.11MAINTENANCE SUSPENSION DAMPERS, BALL JOINTS, FIXINGS AND GAITERS Front suspension romose1 9 1 jon dampers for oll leaks. 2 {op mounting nuts - 40 Nem (4.1 kgm, 30 bt) 3. Check upper arm to body boots - 65 Nem (6.6 kgfm, 48 tbFtt) 4. Check upper arm to swivel hub - 45 Nem (4.6 kgfm, 33 bt) 5, Check damper to damper fork - 45 Nm (4.6 kgf, 33 itt) 6, Check lower arm to rear beam -55 Nem (5.6 kgm, 41 Ibe) 7. Check anti-roll bar to link and link to lower arm - 15 Nem (15 kgm, 11 IbFft) 8, Check damper fork to lower arm - 65 Nem (6.6. kgm, 48 bff) ‘9. Check lower arm to swivel hub -55 Nem (6.6 kgm, a1 ibe) 410. Check anti-roll bracket to rear beam -22 Nem (2.2 kgm, 16 Ft) 11. Check bush to lower arm nuts - 85 Nem (8.7 kgm, 63 Ibt) 12, Check bush to rear beam bolts - 90 Nem (8.2 kgtm, Wot) 3.12 MAINTENANCEMAINTENANCE Rear suspension 1. Check suspension dampers for oil 2. Check damper top mounting nuts «40 Nem (4.1 kgf, 30 Ibf th 3. Cheek bet 5. Check damper te lower arm bolt - 45 Nem (4.6 kgm, 33 bff 6. Cheek lower arm to body botts - 45 Nem (4.6 kgfm, 23 Ifo. 7. Check compensating arm to trailing arm - 45 Nem {4.6 kgfm, 33 bff 8. Check trailing arm to body bolts - 80 N-m (8.2 kgf, 59 IbFt). 8. Check upper arm to. kgtm, 33 Ibtfe). 10. Check compensating arm to body bolts - 45 Nem (46 kgm, 33 IbFft) 11. Check upper arm to bedy bolts -30 Nem (3.1 kgm, 22 Wott. 12.Cheek condi 19 arm bolt - 45 Nm (4.6 n of suspension bushes. MAINTENANCE 3.13MAINTENANCE ROAD WHEELS AND FASTENINGS TYRE PRESSURES AND CONDITION 1. Remove wheel trim. +0Mo333 2. Check condition of road wheels including spare for signs of buckling and rim damage. 3. Working jonal sequence slacken each nut 1/2 turn and then tighten to 110 Nem (11.2 kgm, 810 IbFt) 10Mo348 4. Fit key socket over locking wheel nut, then fit wheel nut spanner over key socket and unscrew. 5. Refit wheel trim, ensuring valve stem locates between stem guides. Use firm pressure around ‘edge to push trim securely into position. 1. Check for signs of tyre wear indicator in tread patter. 2. Check all tyres including spare for uneven wear, external cuts in fabric, exposure of ply or cord structure, lumps and bulges 3. Check and adjust tyre pressures. See INFORMATION, General data section. FOOTBRAKE es 10Mo238 1. Press brake pedal and check for firm resistance after short pedal movement. 3.14 MAINTENANCEMAINTENANCE iz. HANDBRAKE Check 1. Apply handbrake lever one notch at a time and ‘count number of notches to apply the brakes firm ly, equivalent to 180N (18 kgf, 40 Ibf) pull applied at the first finger contour from end of level. Handbrake level travel = 6 to 10 notches at 180N (18 kgf, 40 Ibf) pull. 2. Adjust handbrake cable tension if travel is outside limits. CAUTION: Handbrake travel must not be Ay tatmonetnncnes 3. Ifthe handbrake requires adjustment. See BRAKES, Adjustments. BRAKE FLUID WARNING: Do not allow dirt or foreign liquids to enter reservoir when topping-up. Use only DOT 3 or DOT 4 brake fluid from airtight containers. CAUTION: Do not allow brake fluid to contact paint finished surfaces as paint may be damaged. If spilled, remove fluid and clean area with clean warm water. Level check 10M0350 1. Wipe reservoir body and filer cap clean and check level visually. 2. Remove filler cap and top-up to MAX’ mark, if required, MAINTENANCE 3-15MAINTENANCE Renew fluid 1. Ralse vehicle. 4 WARNING: Support on safety stands. CAUTION: Never re-use fluid that has been LY bied trom system. 10M0331 2. Attach a bleed tube to LH front bleed screw. Insert tree end of tube into bottle containing fuid 3. Open bleed screw and use an assistant to Bleed sequence press brake pedal to floor and release. 4, Repeat operation unti clean fluid flows from CAUTION: Baking eiioncy may be Reveal operate can seriously impaired if wrong bleed 5. When clear, bubble free fluid flows, hold pedal to ‘sequence is used. floor and tighten bleed screw to 10 Nm (1.0 kgtm, 7.2 IbFft) on calipers and 7 Nem (0.7 kgtm, 5 Ibt¢t) ‘on wheel cylinders. CAUTION: Ensure that fluid level in reservoir is maintained during the complete operational sequence using new brake fluid. 6. Repeat foregoing procedure at each wheel in. sequence illustrated, until clean, bubble free fluid flows from bleed screw at each sequence stage. 7. Check for a firm footbrake atter complete operation, 3.16 MAINTENANCE5 MAINTENANCE BRAKE HOSES AND PIPES 1. Visually check all brake fluid pipes, hoses and ‘connections for correct routing and security. 2. Check for signs of chafing, leakage or corrosion. sess MAINTENANCE 3.17MAINTENANCE Renew brake hose NOTE: Disconnect hose at end nearest to JA hesereyinget tees 1 axe 10, 1". 12. Release brake pipe union from hose using ‘correct union spanner. 9. Fit plug to pipe end to prevent undue fluid loss. 3. Withdraw brake hose clip from upper bracket. |. Remove bolt and release hose from bracket, front brake hose only. Release banjo bolt at other end of hose and discard 2 sealing washers. Remove hose and discard. Position new hose through bracket Fit banjo end to ealiper or wheel eylinder with banjo bolt and 2 new sealing washers and tighten 1034 Nem (3.5 kgm, 25 IDF). 9. Fit brake hose clip to bracket and tap home with hide mallet. Remove plug from pipe end, connect brake pipe to hose and tighten union, ‘Secure hose to bracket with bolt and tighten. Front brake only. Bleed brake system, See BRAKES, Adjustments section. FRONT BRAKES-HYDRAULICS, PADS, DISCS AND CALIPERS Check 1, Raise tront of vehicle, Q WARNING: Support on safety stands. 2. Remove both front road wheels, 3. Check brake pads visually and assess lining thickness. 10M0374 Minimum brake pad thickness: Dimension A= 3 mm (0.1 in). NOTE: Measurement does not include pad backing thickness. 4, Ifthe brake pads need to be renewed. See BRAKES, Repairs section. 5. Fit road wheel and tighten nuts to 110 Nm (11.2 kgfm, 81.0 lott) 6. Rem id(s) and lower vehicle, 7. Depress footbrake several times in order to give correct pad to disc clearance before road testing, 3.18 MAINTENANCEMAINTENANCE fe] REAR DISC BRAKES Check 1. Raise rear of vehicle. A WARNING: Support on safety stands. 2, Remove road wheel(s). 410M0351 3. Check brake pads visually and assess pad thickness. 10Mo374 Minimum pad thickness Dimension A = 3 mm (0.1 in) NOTE: Messureent does not inde pad LX beating etree 4, Ifthe brake pads need to be renewed. See BRAKES, Repairs section. 5, Fitroad wheel and tighten nuts to 110 Nim (11.2 kgfm, 81.0 Ibfft). 6, Remove stand(s) and lower vehicle. MAINTENANCE 3.19MAINTENANCE BODY Locks, hinges and latch mechanism (not steering lock) +1. Functionally check operation of all locks. 2. Operate front door lock and check that electric central door locking operates. 3, Ensure that all locks, hinges and latch mechanisms are lubricated using multi-purpose gresse. Clean off any surplus grease. DO NOT lubricate the steering lock. Exterior paintwork and body panels 4. Visually check paintwork and body panels for damage and corrosion. Underbody sealer 1. Visually check underbody sealer for damage and continuity. 3-20 MAINTENANCEaS MAINTENANCE DRIVERS AIRBAG MODULE 1. Visually check for signs of damage. 2. To renew an air bag. See SUPPLEMENTARY RESTRAINT SYSTEM, Repairs. PASSENGER AIRBAG MODULE 1. Visually check for signs of damage. 2. To renew an air bag. See SUPPLEMENTARY RESTRAINT SYSTEM, Repairs. SCREEN WIPERS AND BLADES Operate tront screen wiper. Check that blades wipe screen without smearing. ‘Check that wipers park correctly. ‘Operate wiper switch in all modes. Check that wipers operate at speeds selected. ‘Operate rear screen wiper and check that blade wipes screen without smearing. Renew blade ft wiper arm. Press retaining lever. Slide blade down arm. Withdraw blade assembly from arm. Position new blade to wiper arm, Push blade into engagement with arm. (Check that it is retained. MAINTENANCE 3.21MAINTENANCE WINDSCREEN AND REAR SCREEN WASHERS yomos41 5 1. Visually check mixture level in reservoir. 4, Operate windscreen washer and check that 2. Top-up by removing filler cap and adding jets strike top and centre of area to be wiped. required concentration mixture of water and 5. Adjust jet by inserting a needle into jet hole and ‘Screenwash’ tepositioning. 3. Clean windscreen washer jets using thin wire as a probe. 3-22 MAINTENANCEMAINTENANCE fey 10. 1" Clean rear screen washer jets using thin wire asa probe. ‘Operate rear screen washer and check that jet strikes centre of area to be wiped. ‘Adjust jet by inserting a needle into jet hole and repositioning, Check operation of programmed washiwipe by ‘switching on ignition and operating washer lever. Observe that washer and wiper operate for as long as lever is operated and wiper operates for a further 5 seconds after lever is released |. Recheck level in reservoir after adjustments. LAMPS, HORNS AND WARNING INDICATORS 1. ‘Switch on sidelamps and check that sidelamps, headlamps in the dipped mode, tail lamps, rear umber plate lamps, panel illumination lamps and panel sidelamp indicators iluminate. 2. Switch on headlamps and check that headlamps, tail lamps and rear number plate lamps iluminate. 3. Operate dip switch and check that headlamp dip and main beams and panel main beam indicators illuminate. 4, Operate flash switch and check that headlamps flash ‘Switch on ignition. ‘Open doors and luggage compartment and ccheck that interior and lights illuminate. 7. Press horn and check that horn operates. 8. Operate direction waming indicator switch to right and left and check that warning indicators flash at front and rear. 9. Operate hazard warning switch and check that all warning indicators flash. MAINTENANCE 3-23MAINTENANCE BATTERY CONNECTIONS 1. Pull back flexible protector on terminal. 2. Wipe battery top clean and dry, smear terminal Posts with petroleum jell. 3, Ensure terminals are tight. 4. Replace protector. 3.24 MAINTENANCEMAINTENANCE FUSEBOX nninann Uu UUU eppee " I) na ooouwgwu car 16 Engine compartment fuse box |. Release and lif off cover Check security of fusible ink and power lead pe ‘connections. . Refit cover and secure. MAINTENANCE 3:25MAINTENANCE ROAD TEST Engine start and fast idle speed 41. Start engine from cold and check that fast engine idle speed is maintained until normal ‘engine temperature is reached. Engine performance and throttle operation 1. Start engine and check that it starts easily. 2. Check that ‘oil pressure’ and 'no charge’ ‘warning lamps extinguish 3. Check that throttle pedal movement is free and. unrestricted. 4. Check that engine is responsive to throttle movement, Clutch and gear selection - manus driving conditions Normal 1. Check that clutch engages smoothly without judder, slipping or noise. 2. Check for abnormal transmission noise. 3, Check for smooth quiet gear change and that gear selected engages easily. Steering 14. Check for noise, effort required, free play and sett-centralism. Suspension 41. Check for noise, irregularity in ride (e.g dampers) and wheel imbalance. Footbrake 1. Check tor pedal effort, travel, braking efficiency, pulling and binding, Instruments 1. Check that all instruments operate. 2. Check speedometer for steady operation, noise and operation of distance recorder. Body 1. Check for abnormal body noise. Seat belts 1. Check for operation of inertia reels and Condition of belt webbing Handbrake 1. Apply handbrake firmly, check travel and fatchet hold and release 3.26 MAINTENANCEEngine Electrical Starting System Circuit Diagram Battery - ‘L’ Series Starter Motor - ‘L’ Series ... Charging System Circuit Diagram . Alternator - ‘L’ Series Auxiliary Drive Belt ‘L’ St Drive Belt Tensioner ‘L’ Series ... Outline of Model Change [ +_20T2N engine (turbocharger with intercooler) has been added.Starting System Circuit Diagram oa UNDERH20 FUSERELAY BOX @-~= SP wr om N38 a) UNDER OAS Henan Boe BS Reo Pun eugi erwRen aca wycaen COREL 42BATTERY - ’L’ SERIES Service repair no - 86.15.01 Remove 1. Disconnect both battery leads, earth lead first. ‘86M3616 2, Remove bolt securing battery clamp to battery tray, 3. Remove battery clamp. 4, Release and remove battery from vehicle. Retit 1. Clean battery terminals and coat with petroteum jelly 2. Position battery to battery tray. 3. Fit battery clamp and secure with bolt. 44, Position and connect battery leads, earth lead last ‘STARTER MOTOR -'L’ SERIES Service repair no - 86.60.01 Remove 41. Disconnect battery earth lead. 2. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs. 863043, Disconnect Lucar from starter solenoid. |. Remove nut and disconnect battery lead from starter solenoid. Remove lower bolt securing starter motor. Remove upper bolt securing starter motor. Remove starter motor. yee Refit Clean mating faces of starter motor and gearbox. Fit starter motor and fit lower bolt but do not tighten, Fit upper retaining bolt Tighten both retaining bolts to 85 Nem (8.7 kgfim, 63 Wwe. 5, Connect battery cable to starter solenoid, ft nut and tighten to 4 Nem (0.4 kgf, 3 IDF 6. Connect Lucarto solencid. 7. Fitair cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Ropairs. & Connect battery earth lead. 43Charging System Circuit Diagram UNDER HOO FUSEELAY BOX Sure Neato) N03 604) Oo WHEL eo WHT aE nose | Auxuiany (3a) | a, Hotben a unre sue, Buk Fc i wire TLFEROATOR 44ALTERNATOR - ‘L’ SERIES Service repair no - 86.10.02 Remove 1. Disconnect battery earth lead. 2. Raise front of vehicle. Q WARNING: Support on safety stands. 3. Remove auxiliary drive belt. See this section. 4, Remove engine acoustic cover. See BODY, Exterior fittings section. 86M3939 5. Disconnect muttiplug from alternator. 6. Release cover, remove nut and disconnect battery cable from alternator. Models with Air Conditioning fitted. 7. Remove bolt securing brake servo vacuum, Pipe to camshatt cover. All Models. 8, Release clip and disconnect vacuum hose from vacuum pump. 9. Position drain tin to collect oi! spillage. BeM3940 10. Disconnect vacuum pump oil return pipe from sump, 11, Disconnect vacuum pump oil feed pipe union from cylinder block.Charging System e Ae i 86M3042 12, Remove 2 bolts securing altemator to mounting bracket, 13. Disconnect oil feed pipe from vacuum pump. 14. Remove alternator from vehicle. CAUTION lug the connections. Do not carry out further dismantling if ‘component is removed for access only. 15, Fit vacuum pump to new altemator. Se BRAKES, Repairs section. 46 Refit Remove plugs from connections. Clean all pipe connections. Position alternator to mounting bracket. Connect oil feed pipe to cylinder block and tighten 5. Fit bolts securing alternator to mounting bracket and tighten the lower bolt to 45 Nem (4.6 kgtm, 33 IDF) and the upper bolt to 25 Nem (2.5 kgfm, 18 IbF 6, Tighten oil feed pipe union to vacuum pump. 7. Connect vacuurn hase to vacuum pump and secure: hose with clip. ‘Models with Air Conditioning fitted. 8. Align vacuum pipe bracket to camshaft cover and tighten bolt. All Models. 8. Connect cil return pipe to sump. 10. Remove drain tin from beneath vehicle, 11. Remove standis) and lower vehicle 12. Connect battery cable to alternator stud tighten nut, to 41Nm, and position cover. 13. Connect multilug to alternator. 14, Fit auxiliary drive belt. See this section. 18. Fit engine acoustic cover. See BODY, Exterior fit- 198 section. 16. Connect battery earth lead.‘AUXILIARY DRIVE BELT 'L’ SERIES DRIVE BELT TENSIONER ‘L’ SERIES Service repair no - 86.10.03 Remove 1, Remove underbelly panel. See BODY, Exterior fittings section. 8eM3949 2. Using a 15 mm ring spanner on drive belt tensioner pulley bol, rotate pulley fully clockwise and hold. 3. With assistance, release drive belt from alternator pulley. 4, Remove drive belt trom remaining pulleys and remove from vehicle. Refit 1. Clean ative bett pulley grooves and ensure grooves are not damaged. 2. Fitnew drive belt around pulleys, except alternator pulley, ensure belt is correctly aligned in pulley grooves. 3. Hold tensioner pulley fully clockwise, with assistance fit drive belt around alteriator pulley 4. Fitunderbelly panel. See BODY, Exterior fitings section. Service repair no - 86.10.06 Remove 1. Remove altemator drive belt, See this section. 863950 2. Remove bolt and remove drive belt tensioner. Refit 1. Clean tensioner and mating face. 2. Fittensioner locate with dowel and tighten retaining bolt to 45 Nm (4.6 kgf, 33 bff 3. Fit drive belt, See this section. a7ENGINE Engine Repairs Page ADJUSTMENTS: CAMSHAFT TIMING BELT CHECK... INJECTION PUMP TIMING BELT CHECK REPAIRS CAMSHAFT FRONT OIL SEAL CAMSHAFT REAR OIL SEAL (CRANKSHAFT PULLEY x ‘CRANKSHAFT FRONT OIL SEAL .. CRANKSHAFT REAR OIL SEAL CYLINDER HEAD GASKET .. CAMSHAFT COVER GASKET ..... ENGINE AND GEARBOX : INTERCOOLER - NON AIR CONDITIONING MODELS INTERCOOLER - AIR CONDITIONING MODELS ..... ENGINE MOUNTING - LH . ' ENGINE MOUNTING - RH ENGINE STEADY BAR - UPPER ENGINE STEADY BAR - LOWER FLYWHEEL... FLYWHEEL STARTER RING GEAR SUMP GASKET OIL PRESSURE SWITCH ‘CAMSHAFT TIMING BELT ...... : CAMSHAFT TIMING BELT UPPER COVER ‘CAMSHAFT TIMING BELT LOWER COVER. INJECTION PUMP TIMING BELT INJECTION PUMP TIMING BELT COVER... 5.33 5.33 5.34 535 541 542 (. Outline of Model Change 20T2N engine (turbocharger with intercooler! has been added.ENGINE CAMSHAFT TIMING BELT CHECK Service repair no - 12.65.17 Check CAUTION: This check must be carried out at the service intervals specified in the service maintenance Check Sheet and whenever carrying out a repair that requires the timing belt to be disturbed. Pay particular attention for signs of belt splitting at base of teeth. 1. Remove underbelly panel for access to crankshaft pulley bolt. See BODY, Exterior fittings . 2, Remove timing belt upper cover. See Repairs 3. Use a socket on the crankshaft pulley bolt to rotate the engine. CAUTION: Do not use camshaft gears or retaining bolts to rotate engine. 12M1856 4, Check timing bet for condition and renew any belt showing signs of oil contamination, ‘cracking, fraying or spliting at the base of the teeth. CAUTION: Cause ofl contamination, AN, Srosem muat be recites 5. Fit timing belt upper cover. See Repairs . 6. Fit underbelly panel. See BODY, Exterior fittings . ‘ADJUSTMENTS 5-1ENGINE INJECTION PUMP TIMING BELT CHECK Service repair no - 12.65.52 CAUTION: This check must be carried out ‘at the service intervals specified on the service maintenance check sheet and whenever carrying out any repair which requires the timing belt to be disturbed. Pay particular attention for signs of the belt splitting at the base of teeth. 1. Disconnect battery earth lead 2, Remove belt cover. See Repairs. 3. Remove underbelly panel for access to crankshaft pulley bolt. See BODY, Exterior fittings . 4. Using a socket and an extension bar on the crankshaft pulley bot, rotate the engine and inspect the injection pump timing bet. CAUTION: Never use the camshatt gear, gear retaining bolt or timing belt to rotate the engine. ia r2tase Renew a timing belt that shows signs of splits at base of teetn, fraying, oil contamination or uneven wear. See Repairs. WARNING: Cause of oil contamination must be rectified. 6. Fit underbelly panel. See BODY, Exterior fittings . 7. Fitinjection pump timing belt cover. See Repairs. 8. Connect battery earth lead. 5-2 ADJUSTMENTSENGINE CAMSHAFT FRONT OIL SEAL Service repair no - 12.13.05 Remove 1, Remove underbelly panel, See BODY, Exterior fittings . 2. Remove RH front road wheel 13. Disconnect battery earth lead. 4. Remove camshaft timing belt upper cover. See this section . 121863 7. Remove tensioner access plug from camshaft timing belt lower cover. Slacken Allen bolt securing tensioner pulley. ‘9. Remove tensioner access plug trom rear cover. 10. Fit oo! 18G 1719 to tensioner. 11. Pull back tensioner plunger using tool 186 1719. 12, Tighten tensioner pulley Allen bolt. " 12M 1862 186 1528 5. Using a socket and extension baron the Stockist align ming marks on camshat 13. Remove 2 bots securing RH engine mounting pully to back cover to body and remove salty bar ‘CAUTION: Never use the camshaft gear, gear retaining bolt or timing belt to rotate the camshatt. 6. Insert timing pin tool 18G 1523 through hole in ‘gearbox mounting back plate and into hole in flywheel REPAIRS 5.3ENGINE 14, Raise RH side of engine on a jack sutticientiy only to give access to fit seal removal tool 18G 1476. Dy Samet pee came 3. Restrain camshaft gear using tool 18G 1521. . Remove camshatt gear retaining bolt Remove tool 18G 1521. Release camshaft gear from camshaft and remove from belt. CAUTION: he siete geare have been AN Sinjcteste poiorgedo contamination, trey nt be outed ina seven bath and snorougn washed wit coven betes rete secsust tne porous conection ofthe aries materi olimpregrted nthe gear wl aiurge nd contaminate anew be CAUTION: I! camshatt timing belt shows any sign of oll contamination renew camshaft timing belt. See MAINTENANCE 19, 20. a1. 22. |. Remove and discard seal from seal remover, 24. 18G 1476 121866 Fit but do not tighten the old camshaft gear retaining bot. Fit and tighten seal remover tool 18G 1476 to camshaft seal Tighten seal remover centre screw to remove camshatt seal Remove seal remover 186 1476. tool Remove and discard camshaft gear retaining bolt 5.4 REPAIRSENGINE fpyeeee]] Refit 10, n 2 13, “ 5, 6. 18, 19, 20. |. Clean seal recess and camshatt Grease outer edge of new seal Lubricate the inner lip of the seal with clean engine ol 186 1716 a ie 12M1867 Ensure seal fitting tool 18G 1716 is clean. Fit camshaft oil seal using 18G 1716 . Clean camshaft gear and mating face. - Fit camshaft gear to belt and position gear to camshatt CAUTION: Ensure timing marks on ‘camshatt gear and rear cover are aligned. 3. Restrain camshaft gear using tool 18G 1521 Apply clean engine oll to threads of new bolt. Fit camshaft gear bolt and tighten to 20 Nem (2.0 kgm, 14 thf) + 90° Remove tool 186 1521. Lower RH side of engine to body. Fit 2 bolts securing RH engine mounting Fit 2 bolts securing RH engine mounting and safety bar to body. Tighten 2 bolts to 45 Nem (4.6 kgf, 33 Ib. Remove jack. Slacken tensioner pulley Allen bot. Release cambelt tensioner plunger using tool 186 1719. Remove tool 186 1719 from camshaft timing belt tensioner. Remove timing pin tool 18G 1523 from flywheel. Using a socket and extension bar on the crankshaft pulley bolt, rotate crankshaft two turns clockwise Until the flywheel timing pin can be refitted, 21. Check the camshaft gear timing mark is correctly aligned with the back cover timing mark. 22, Slacken Allen bott securing belt tensioner pulley, to allow the tensioner to react and tighten to 44 Nem (45 kgfm, 33 IbFt) CAUTION: Do not exceed the specified torque figure. 23. Fit access plugs to lower cover and rear cover. 24, Fit underbelly panel. See BODY, Exterior fittings. 25. Fit camshaft timing belt upper cover. See this section. 26. Fit road wheel and tighten nuts to 110 Nem (11.2 kgf, 81 Ibft) 27, Connect battery earth lead. REPAIRS 5.5,ENGINE CAMSHAFT REAR OIL SEAL Service repair no - 12.13.06 Remove 1. Remove fuel injection pump (FIP) timing belt See this section . 2. Restrain camshaft gear using tool 18G 1521. 3. Remove FIP belt drive gear bot. 4, Remove FIP belt drive gear. CAUTION the seed yer Pave boon DN Sean te tee etre Se a thoroughly washed with solvent before refitment. Se Se ea tml a a CAUTION: If FIP belt shows any sign of oil contamination renew camshaft timing belt. ‘See MAINTENANCE . 5. Remove Allen bott securing FIP drive and remove tensioner. 12M1869 6. Remove 3 bolts securing FIP drive belt rear cover. 7. Remove rear cover and acoustic cover bracket. ‘8. Fit but do not tighten the old FIP gear retaining bolt. 186 1476 12M1870 9. Fit and tighten seal remover tool 18G 1476 to camshaft seal. 10, Tighten seal remover centre screw to remove ‘camshaft seal 11. Remove seal remover 18G 1476. 42, Remove and discard seal from seal remover tool. 13, Remove and discard FIP gear retaining bolt —— 5.6 REPAIRSENGINE [B22] Refit 1. Clean seal recess and camshaft. 2. Grease outer edge of new seal. 3. Lubricate the inner lip of the seal with clean engine oil 186 1716 co ramie7i 4. Ensure seal iting tool 186 1716 is clean 5. Fitcamshat oil seal using 18G 1718 6. Fit rear cover and acoustic cover bracket 7. Fit3 bolts securing FIP drive belt rear cover. 8. Fit drive bett tensioner, ft Allen bot. 8. Clean camshaft gear and mating face 410. Fit FIP gear to camshaft 11. Restrain camshaft gear using too! 18G 1521. 12. Apply clean engine oil to threads of new bolt. it FIP gear bolt and tighten to 20 Nim (2.0 kgm, 14 bt) + 90° 18. Romove too! 186 1521 14, Fit injection pump timing belt. See this section. CRANKSHAFT PULLEY, Service repair no - 12.21.01 Remove 1. Disconnect battery earth lead 2. Raise tront of vehicie. Q WARNING: Support on safety stands. 3. Remove auxiliary drive belt. S ELECTRICAL, Repairs 4. Remove RH front road wheel semi7a7 5. Using a socket and extension bar on the crankshaft pulley bol, rotate crankshaft until 18G 1853 can be fitted through gearbox adaptor plate to fock flywheel. CAUTION: Never use the camshaft timing ‘gear, gear retaining bolt, or timing belt to rotate the engine. 6. Remove bolt securing crankshatt pulley. 7. Remove crankshaft pulley, REPAIRS 5-7ENGINE Refit 1. Clean and fit pulley to crankshaft, tighten crank- ‘shaft pulley bott to 63 Nim (6.4 kaf-m, 46 Ibfft) + 90° 2. Fit auxiliary drive belt. See ELECTRICAL, Repairs. 3. Remove timing pin 18G 1523 from gearbox adaptor plate, 4, Fit road wheel and tighten nuts to 110 Nem (11.2 kgm, 81 beth 5, Remove standis} and lower vehicle. 8. Connect battery earth lead. CRANKSHAFT FRONT OIL SEAL Service repair no = 12.21.14 Remove 1. Remove camshaft timing belt. See this section. 12M1858 2. Remove timing gear trom crankshatt 186 1718 TO & 12M1859 3. Ensure bore of tool 18G 1716 is burr tree, screw tool into crankshatt front oil seal 4, Remove oil seal by tightening centre bolt of tool. 5-8 REPAIRSENGINE my2se2]] Retit 1. Use lint free cloth and thoroughly clean seal recess in oil pump and running surface on ‘crankshaft 186 1909 186 1810-1 18 1810 12M 1860, 2. Fit guide tools 186 1510 and 18G 1810-1 onto crankshatt. 3. Lubricate oil pump seal recess and guide tools with clean engine oil 4, Using guide tools position new oil seal on crankshaft journal and against oil pump, drift into place Using tool 18G 1509, 5. Remove guide tools from crankshaft. 6. Clean crankshaft timing gear and slide onto crankshaft 7. Fit camshatt timing bel. See this section . CRANKSHAFT REAR OIL SEAL Service repair no - 12.21.20 Remove 1. Remove flywheel. See this section. 122058 Remove 2 bolts securing PAS pipe clips to ‘sump and beaming bracket Lower PAS pipe. Drain engine oll, See MAINTENANCE . Fit oll drain plug using NEW sealing washer and tighten to 25 Nem (2.6 kgfim, 19 Ib REPAIRS 6.9ENGINE Retit 1. Clean seal seating area of block and accessible area of sump gasket. 6 ‘The sump gasket must be replaced if damaged. See this section. 2. Lubricate oil seal and sealing surfaces with clean engine oil, 48G 1108 s2Mesi 6. Loosen 17 sump bolts by approximately 3 tums, allowing sump to drop away from rear oll seal housing, 7. Remove § bolts securing oil seal housing housing. 8, Remove seal and housing, 12M1852 3. Fit tool 18G 1108 over crankshaft boss and fit ail seal. 4, Remove tool 186 1108, 5. Fit and tighten seal housing bolts to 10 Nm in ‘sequence shown, ET 5-10 REPAIRS121853 Tighten engine sump bolts progressively in the sequence shown to 25 Nim (2.6 kgf, 19 Ib ‘Align PAS pipe to sump and secure with bolts. Fit flywheel. See this section. Fill engine with oil. See MAINTENANCE. ENGINE [Pyeeee]] CYLINDER HEAD GASKET rvice repair no - 12.29.02 Remove 1. Drain cooling system. See COOLING, Adjust- ments. 2, Remove camshaft timing belt lower caver. See this section. 3, Remove fuel injection pump (FIP) timing belt. See this section. 186 1719, s2Me17 4, Remove camshaft timing belt tensioner access plug trom bel rear cover. 5, Slacken Allen bolt securing belt tensioner pulley. 6. Fit 18G 1719 to tensioner. 7. Pull back camshaft timing bet tensioner plunger using 18G 1718. 8. Tighten tensioner pulley Allen bolt 8. Release timing belt from camshaft gear CAUTION: Ease timing belt from gears using fingers only. Metal levers may damage the belt and gears, Do not rotate ‘engine with timing belt removed and cylinder head fitted. REPAIRS 5-11ENGINE 12M1818 10. Stacken clip and disconnect breather hose from camshaft cover. 11, Disconnect muttiplug from mass air flow (MAF) sensor. 12, Stacken clip and disconnect air intake pipe trom turbocharger, remove air intake pipe assembly. 13. 14, 15, 16. 17. 18. samira Slacken hose clip at turbocharger outlet. Slacken hose clip at intercooler inlet. Remove 2 bolts securing turbocharger outlet pipe to cylinder head and engine lifting eye bracket, Remove pipe and hose assembly. Slacken hose clips at intercooler outlet and plenum chamber. Remove intercooler outlet hose. 5-12 REPAIRSENGINE All models reM1940 49, Remove 3 nuts securing exhaust front pipe t0 manifold 20. Release exhaust front pipe from manifold , remove and discard gasket, 21. Remove banjo bolt securing oil feed pipe to turbocharger, collect 2 sealing washers. 22, Disconnect boost pressure sensing pipe from turbocharger. 23. Disconnect vacuum pipe from EGR valve. 24, Remove 2 bolts securing oil drain pipe flange to turbocharger. 25. Remove and discard gasket. 26. Remove 2 bolts securing exhaust manifold to mounting bracket seMigay 27. Remove 6 bolts securing exhaust manifold to cylinder head. 28. Remove 6 nuts securing exhaust manifold to cylinder head, 28. Release and rémove manifolds and turbocharger assembly. 30. Remove and discard manifold gasket. s2M1822 31. Use 18G 1821 to hold camshatt drive gear. remove and discard fuel injection pump (FIP) belt drive gear bolt. 32, Remove FIP belt drive gear. 33. Remove Allen bolt securing FIP drive belt tensioner and remove tensioner. REPAIRS 5-13ENGINE sei824 34. Remove 3 bolts securing FIP drive belt rear cover. 35. Remove rear cover and acoustic cover bracket, 36. Remove 2 bolts securing RH engine mounting and safety bar to body. 37. Raise RH side of engine on a jack sufficiently only to give access to camshaft drive gear bolt. CAUTION: lace suitable plece of wood AY Shura proce cane 38. Use 186 1521 to hold camshaft drive gear, remove and discard retaining bolt 38. Remove camshaft drive gear. 5-14 REPAIRS1aM1823 40. Release engine hamess clips from camshaft drive belt rear cover. 41, Remove 5 bolts and remove camshatt timing belt rear cover. 12M1825 42, Remove bolt securing brake servo vacuum pipe to camshaft cover. 43. Release clip and disconnect brake servo vacuum hose from vacuum pump. CAUTION: Plug hose and pump. 44, Move vacuum pipe aside ENGINE Models with air conditioning 48, Remove altemator upper fixing bott. 12M1827, 46, Disconnect multiplug from coolant temperature sensor and coolant temperature transmitter lead from engine harness, 47. Slacken top hose clip and disconnect hose from engine. 48, Remove fuel injection pipes. 49. Remove nut and disconnect feed lead trom glow plug, REPAIRS 5-15ENGINE 12M1831 50. Remove 12 bolts securing camshatt cover. 51. Remove camshaft cover. T2M1816 82 52. Release gasket from fixings on camshaft cover and discard gasket 12M1832 ‘53. Working in the sequence shown, progressively loosen and remove 10 cylinder head bolts. NOTE: Store cylinder head bolts in their LA original positions for retitment. 84, Remove cylinder head assembly and place on ‘wooden blocks or stands. CAUTION: The tips of the injectors and glow plugs protrude below the face of the cylinder head and could be damaged if the cylinder head is placed face down on a work bench. 12M1833 55. Remove cylinder head gasket. CAUTION: Note the gasket thickness indicator and ensure the same thickness gasket is used on refit ment of cylinder head. 5-16 REPAIRS1. Clean mating face of cylinder head and block. 2. Ensure oil and coolant passages are clean. 3. Clean dowels and dowel holes. 4. Clean and dry cylinder head botts. 5. Measure length of cylinder head bolts. If any bolt exceeds the maximum length of 243.41 mm (9.5831 ); then all bolts must be renewed. 6. Ensure dowels are fitted to cylinder block and fit new cylinder head gasket, dry, over the dowels. 7. Use clean engine oll o lubricate the thread and. under side of each cylinder head bolt head. CAUTION: Do not lubricate under side of 8. Fit cylinder head onto cylinder block, carefully locating onto dowes. seMna34 9. Fit and tighten the cylinder head bolts progressive Iy in the sequence shown, using the following pro- ‘codure, 1. Tighten all botts to 30 Nim (3.1 kfm, 22 bff). 8 bff) 3. Tighten each bolt through 90°. 4, Tighten each bolt through a further 90°, 10. Clean camshatt cover and mating face on ccarnshaft carer. 11. Fit new gasket to camshaft cover. ENGINE [Pyee2*] s2M1835 12, Fit camshaft cover and tighten bolts in sequence shown to 9 Nim (0.9 kgfm, 6.5 IbFft), 13, Connect glow plug feed lead and tighten nut to 25, Nem (0.26 kgtm, 1.9 thf) 14, Fit injector pipes. 15. Connect top hose to engine and tighten hose clip. Models with air conditioning 16. Fit alternator upper fixing bolt and tighten to 25 Nm (2.6 kgf, 19 bff) All models: 17, Connect multiplug to coolant temperature sensor and coolant temperature transmitter lead to engine harness. 18. Connect brake servo vacuum hose to vacuum ‘pump and secure with clip. 19. Align brake servo vacuum pipe to camshaft cover ‘and secure with bolt. 20, Fit FIP drive belt rear cover and acoustic cover sup- port bracket. 21, Secure cover and bracket with bolts. 22. Clean FIP drive belt tensioner. 23. Hold tensioner off and fit Allen bol. 24, Fit camshaft drive belt rear cover and secure with bolts. 25, Align engine harness to belt cover and secure with clips. Clean camshaft drive gear and mating face. Fit camshaft drive gear and tighten new bott to 20 Nem (2.0 kgfm, 14 bf). 8B REPAIRS 5-17ENGINE 28. Clean FIP belt drive gear and mating face. 29, Fit FIP belt drive gear and tighten new bolt to 20 Nm (2.0 kgm, 14 IDEA). 30. Lower RH side of engine on jack 31. Fit safety bar to mounting. 32. Fit bolts securing RH engine mounting to body and tighten to 45 Nem (4.6 kgf, 33 bf 33, Clean mating faces of manifold and cylinder head, 34. Fit new manifold 35. Clean mating fa exhaust front pipe. Fit manifold flange gasket. Manoeuvre manifold and turbocharger assembly into position and align to cylinder head. 38. Fit nuts, bolts and washers securing manifold to cylinder head. 39, Working in the sequence illustrated tighten mani fold nuts and bolts to 25 Nem (2.6 kgfm, 19 IbFft). 40, Fit2 bolts securing exhaust manifold to mounting bracket 41. Clean mating faces of oll drain pipe and turbo- charger. 42. Fit new gasket to turbocharger oll drain pipe. ‘Align pipe to turbocharger, fit bolts and tighten to 25 Nem (2.6 kgfm, 19 IbfAt). 43. Align exhaust front pipe to exhaust manifold. Fit 3 nuts and tighten to 45 Nim (4.6 kgtim, 33 tote). ‘44, Connect vacuum pipe from EGR solenoid to EGR valve. 45. Connect boost pressure sensing pipe to tur- bocharger. 46, Clean turbocharger oil feed pipe union and banjo bolt. 47. Fit new sealing washers to banjo bolt. 48. Connect oil feed pipe to turbocharger and tighten tunion to 20 Nem (2.0 kgfm, 16 bff). 49. Connect intercooler outlet hose to intercooler out- let and plenum chamber. 50. Tighten hose clips at inter cooler outlet and, plenum chamber 51. Fit turbocharger outlet pipe to cylinder head and engine lifting eye bracket. ‘52. Fit2 bolts and tighten to 25 Nm (2.6 kgf'm, 19 tet 52. Tighten hose clips at turbocharger inlet and outlet. se ‘54. Position air intake pipe and connect to turbocharger, tighten clip. Connect multiplug to MAF sensor. Connect breather hose to camshaft cover and tighten clip. 157. Check for correct alignment of camshaft g Using fingers only, fit timing belt to gears. ‘58. Ensure the belt run between the crankshaft gear and camshaft gear is kept taut during the fitting Procedure. 8s CAUTION: if original bolt Isto be refitted LY ensure diection of rotation eorect. 59. Slacken Allen bolt securing bett tensioner pulley. 60. Release camshaft timing belt tensioner plunger using 186 1719. 61. Remove 186 1719 from tensioner. 62. Nip up tensioner pulley Allen bolt. 63, Fit tensioner access plug to camshaft timing bett 64. Fit camshaft timing belt lower cover. See thie section. 65, Remove timing pin 18G 1523 from flywheel. 66. Using a socket and extension bar on the crankshaft pulley bolt, rotate crankshaft two turns clockwise Luntil the flywheel timing pin can be refitted, 67. Check the camshaft gear timing mark is correctly aligned with the back cover timing mark, 68. Slacken Allen bolt securing bett tensioner pulley, to allow the tensioner to react and then tighten to 44 Nem (45 kgfm, 33 Ibf th 69. Remove timing pin 18G 1523 from flywheel. 70. Fit Allen bolt access plug to lower cove 71. Fit FIP drive bolt. Soe this section. 72. Connect battery earth lead, 73. Refill cooling system. See COOLING, Adjustments. 5-18 REPAIRSENGINE yee] CAMSHAFT COVER GASKET Service repair no - 12.28.40 Remove 4. Remove engine acoustic cover, See BODY, Exterior fittings . saMe74 2. Slacken clip and disconnect engine breather hose from camshaft cover. 3, Remove bolt securing brake servo vacuum pipe to camshatt cover. 12M1875 4, Remove 12 bolts securing camshaft cover. 12Mia76 5, Remove camshatt cover. 6. Release gasket from fixings on camshaft cover and discard gasket. Rett Clean camshaft cover and mating face on camshaft camer. Fit new gasket to camshatt cover. Fit camshaft cover and tighten bolts in sequence shown to 9 Nm (0.9 kgfm, 6.5 IbFt), Align brake servo vacuum pipe bracket to camshaft ‘cover and secure with bolt, Connect engine breather hose to camshaft cover, Fit engine acoustic cover. See BODY, Exterior fittings. REPAIRS 5-19ENGINE ENGINE AND GEARBOX Service repair no - 12.37.01.99 Remove 41. Raise front of vehicle. Q WARNING: Support on safety stands. 2. Drain cooling system. See COOLING, Adjustments. 3. Drain gearbox ol. See MANUAL GEARBOX - G1, Adjustments . 4. necessary, drain engine oll, See MAINTENANCE . 5. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs. 6, Remove acoustic cover. See BODY, Exterior fittings . Models with Air Conditioning fitted. 7, Recover retrigerant from air conditioning system. See AIR CONDITIONING, Adjustments . 8, Remove intercooler hoses (see page 5-3). 5-20 REPAIRSENGINE All Models: 9. Disconnect mutipug from MAF sensor. 10. Loosen clip and remove air hose from turbocharger. 11. Disconnect dim dip resistor muitiplug from engine harness. 12, Remove 4 bolts and a nut securing battery tray 13. Remove battery tray y—18G 1593 14 12M1967 14, Use 18G 1593 to release, then disconnect Clutch fluid hose. 15, Remove LH front and RH tront road wheels 5. Remove LH and RH drive shafts. See DRIVE SHAFTS, Repairs . 12M1968 17. Remove bolt and disconnect gear change steady bar from gear box, collect 2 washers. 18, Remove clip retaining selector rod roll pin 19. Using a suitable punch, drive out roll pin and release selector rod from shaft. 20. Tie selector rod and steady bar aside. REPAIRS 5.21ENGINE s2M1969 21. Loosen bolt securing steady bar to bracket on rear cross member. 22. Remove bolt securing steady bar to bracket on. ‘engine and lower steady bar. All Models jewng72! 23. Remove cable tie securing engine harness at oil pump. 24. Disconnect multiplugs from engine oll temperature ‘and oil pressure sensors. 25. Disconnect multiplug from EGR solenoid. 28. Release 3 clips securing engine harness to ‘camshaft drive belt cover 42M1973 27. Disconnect multiplug from coolant temperature 28, Disconnect coolant temperature sender unit Lucar connection at harness. 29, Release harness clip from dipstick bracket. 5-22 REPAIRSENGINE 38. Disconnect additional multiplug from FIP. All Models 38. Disconnect reverse lamp switch leads. 40. Disconnect lucar from starter solenoid. 41. Remove bolt and disconnect earth leads from gear- 12977 42, Disconnect multiplug from vehicle speed sensor. 3 Release injector lift sensor multiplug from FIP bracket and disconnect multiplug from harness. 32, Disconnect multiplug from air conditioning com- pressor. 33, Disconnect cooling fan multiplug. 34, Remove cover from alternator terminal, remove ‘aut and disconnect lead. 35, Disconnect multiplug from alternator. 36. Release harness clip from throttle cable bracket at FIP. 37. Disconnect multiplug from FIP REPAIRS 5.23ENGINE 0) 0 8 121980 43. Disconnect multiplug from CKP sensor. 44, Release 4 harness clips from cool 45, Release harness from engine and lay aside. 46, Remove nut and disconnect lead from starter sole- noid. A CAUTION: Plug the connections. 41. Position cloth to collect fuel spillage. 48. Release clips and disconnect fuel hoses from pipes saMig83, 51, Release clip and disconnect coolant hose from 152, Release clip and disconnect brake servo vacuum, hose from pipe at camshaft cover. 53. Disconnect vacuum pipe from EGR valve. 5-24 REPAIRSENGINE ‘Models with Air Conditioning fitted. 54. Release clip and disconnect outlet hose from PAS reservoir. '56. Loosen union and disconnect condenter pipe from compressor pipe. 57, Remove and discard ‘0’ ring seal 121985 55. Disconnect PAS high pressure union bulkhead. 12M1948 A CAUTION: Plug the connections. 558. Loosen union and disconnect compressor pipe from expansion vaive pipe. 59. Remove and discard ‘0’ ring seal. CAUTION: To prevent damage to air conditioning pipes or components use two backing spanners when loosening or tightening unions. CAUTION: Immediately cap all air conditioning pipes to prevent ingress of dirt and moisture into the system. REPAIRS 5.25ENGINE All Models 63, Remove 2 bolts and move PAS fluid reservoir aside {fot access to tie bar through bolt. 64, Remove through bolt securing tie bar to body. 60. Fit 18G 1598 to suitable engine lifting equipment 65. Remove through bolt securing tie bar to engine and connect to engine lifting eyes. ‘mounting, 61. Take weight of engine and gearbox. 66. Remove tie bar. 167. Remove nut securing bracket to RH engine mount- ing. (68. Remove 3 bolts securing mouting bracket to ‘engine and remove bracket. 69. Collect special washer. 122089 62. Release fuel filter from bracket and move aside. ee 5.26 REPAIRSn n. 73, ms 7. 2, 73 4. 5, 6. 1 a 9, 10, n 2 3, 4. 18. Remove 2 bolts securing LH engine mounting to 1 bracket on gearbox. ” Lower engine and gearbox assembly for access and remove 2 bolts securing mounting bracket to 1 gearbox. Remove bracket from gearbox. 9 Remove 4 bolts securing LH engine mounting to body and remove mounting. 20. Adjust engine lifter as necessary and with assis- tance raise engine and gearbox assembly from a vehicle engine bay. Move engine and gearbox away from vehicle and 2 ower onto work bench. 23. 24, 26, 26. . Fit washers to gear change steady b: ENGINE [yceee]| Raise engine and gearbox from workbench posi tion over vehicle and lower into engine bay. Use ‘engine lifter to level unit when in position. Fit LH engine mounting to body and tighten bolts t0 45 Nem (4.6 kgm, 33 bf, Fit mounting bracket to gearbox and tighten bolts to 60 Nem (61 kof¢m, 44 IDF ft). Raise unit to align LH mounting to bracket on gea ‘box and tighten bolts to 45 Nim (4.6 kgf=m, 33. tote. Fit engine mounting bracket to mounting, fit spe- 1 washer and start but do not tighten nut ign engine to mounting bracket and engage dowels. Fit bolts securing mounting bracket to engine and, tighten to 105 Nem (10.7 kgm, 77.4 Ibft Tighten nut securing bracket to mounting to 80 Nim (8.2 kgm, 59 IbFfE. Fit steady bar to RH engine mounting and align to body. Fit but do not tighten through bolts. Remove engine lifting equipment. Fit fuel filter into its bracket ‘Align lower steady bar to bracket on engine. Fit bolt steady bar to bracket on engine tighten both steady bar bolts to 80 Nim (8.2 kgfm, 59 tote, Clean mating faces of gear change selector and steady bars. Connect selector rod to shaft and align holes. Fit new roll pin securing selector rod to shaft and fit oll pin retaining and connect bar to gearbox. Fit steady bar ret (1.0 kgm, 7.2 bff). Fit LH and RH drive shafts. See DRIVE SHAFTS, Repairs. Fit both front road wheels and tighten nuts to 110 Nim (11.2 kghm, 81 IbF Align PAS reservoir and secure with bolts, Connect PAS pump feed hose to reservoir and secure hose with cli Clean PAS high pressure pipe connections at bulk: head. Lubricate new '0" ring seal with PAS fluid and fit to male connection. Connect PAS high pressure union at bulkhead and tighten. ng bolt and tighten to 10m. CAUTION: To prevent damage to PAS pes or components use 2 backing span- ‘nors when loosening or tightening unions. REPAIRS 5.27ENGINE Models with Air Conditioning fitted. 27. Clean sir conditioning pipe connections. 28. Lubricate new ‘O' ring seals with refrigerant oi fit to air conditioning pipes. 29, Connect unions and tighten to 25 Nim (2.6 kgm, 19 tote) CAUTION: To prevent damage to air conditioning pipes or components use 2 spanners when loosening or tightening unions. All Models 30. Connect vacuum pipe to EGR valve. 31. Connect brake servo vacuum hose to pipe at camshaft cover and secure with clip. 32. Connect coolant hose to heater valve and secure hose with clip. 33, Connect top hose to radiator and tighten hose clip. 34. Connect heater hose to coolant rail and tighten, hose clip 35. Connect fuel feed and return hoses to pipes and secure hoses with clips. 36. Connect battery negative lead to starter solenoid and secure with nut 37. Position harness to engine and secure clips at coolant rail. 38, Connect multiplugs to vehicle speed sensor and CKP sensor. 39. Fit earth leads to gearbox and secure with bott 40, Connect Lucar to starter solenoid, |. Connect reverse lamp switch leads. Connect muttialug to FIP. 43, Connect additional multiplug to FIP. All Models 44, Fit harness clip to throttle cable bracket. 45, Connect muttipug to alternator. 46, Connect lead to alternator terminal, fit and tighten nut and reposition terminal cover. 47. Connect multiplugs to cooling fan and air condi tioning compressor. Connect injector fit sensor muttiplug and secure multiplug to FIP bracket. 49. Connect feod lead to glow plugs and tighten nut to 2.5 Nem (0.10 kgfim, 0.72 bff. 50. Secure harness clip to dipstick, 51. Connect coolant temperature sender Lucar and ‘mubtiplug to coolant temperature sensor. 52. Secure harness clips to camshat drive belt cover. ‘53. Connect multipiug to EGR solenoid. 54. Connect multiplugs to engine oil temperature and pressure switches. 85. Align and Mt cable tie securing harness at oil pump, All Models 56. Connect clutch fluid hoses. 57. Fit battery tray and secure with 4 bolts and a nut. 58. Connect dim dip resistor multiplug. 59. Fit air hose to turbocharger and tighten hose clip. 60. Connect multiplug to MAF sensor. ‘Models with Air Conditioning fitted. 61. Recharge air conditioning system. See AIR CONDI- TIONING, Adjustments. 62. Fit intercooler hoses. All Modals (63. Fit engine acoustic cover. See BODY, Exterior ft- tings. 64, Fit air cleaner. Soe ENGINE MANAGEMENT SYS- TEM - EDC, Repairs. 65. drained, refill engine with oil. See MAINTE- NANCE, 66. Fill gearbox with oll. See MANUAL GEARBOX PGI, Adjustments. 67. Fill cooling system. See COOLING, Adjustments. 68. Remove standis) and lower vehicle. 5-28 REPAIRSENGINE INTERCOOLER - NON AIR CONDITIONING MODELS. Remove 1. Disconnect battery earth lead. 2, Raise front of vehicle. WARNING: Support on safety stands. ‘2, Remove under belly panel, 4. Slacken hose clip and release hose from top of intercooler. 8. Slacken clip and release air hose from bottom of intercooler. . Remove 2 bolts securing intercooler support ‘bracket to bonnet lock plateform: 7. Remove 2 Tx40 Torx bolts and nuts ‘securing intercooler to radiator. Release and remove intercooler. Retain rubber mounting, Ensure rubber mounting is fitted correctly. Fit and tighten nuts and Torx bolts securing intercooler and radiator. 3. Fit intercooler into position Fit intercooler support bracket to bonnet lock plateform, fit bolts and tighten bolts 10.9 Nem (0.9 kgfm, 7 Ibfft) . Fit hoses to top and bottom of intercooler land and secure with clips. Fit under belly panel, see BODY - Repairs. . Remove stand(s) and lower vehicle. Connect battery earth lead, REPAIRS 5.29ENGINE INTERCOOLER - AIR CONDITIONING MODELS Remove 1. Remove air cleaner assembly. see Air cleaner. 10M 0727 2. Remove 3 bolts securing sound deadening pad to engine. 3. Remove sound deadening pad. 4. Remove under belly panel, see BODY - Repairs. 5. Drain cooling system, see MAINTENANCE. om ore 6. Slacken clip and disconnect top hose from intercooler. 7. Slacken clip and disconnect bottom hose {rom intercooler. 8. Slacken clip and disconnect expansion tank return pipe trom radiator. 8. Remove bolt securing air conditioning pipe to LH cooling tan cow! 10. Disconnect LH cooling fan motor muttiplug, 11. Release harness from clip on LH cooling fan cowl 12, Slacken clip and disconnect coolant hose from radiator inlet pipe. 13. Disconnect radiator high temperature sensor multiplug 14, Disconnect 2 lucars from radiator low temperature sensor. 15, Disconnect multipug from alternator. 16. Release cover and remove nut securing lead to alternator. 17. Release harness trom 2 clips on RH cooling fan cow! Remove bolt securing air conditioning pipe to bonnet lock platform, 19 19 19M 0744 19. Remove 4 bolts secunng radiator top ‘mounting brackets to bonnet platform, 20. Remove 2 mounting brackets 21. Remove 4 bolts securing condenser to radiator. 5-30 REPAIRSENGINE [y22221] ENGINE MOUNTING - LH eee Service repair no - 12.45.11 Remove 1 2 Remove underbelly panel. See BODY, Exterior fittings . Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs. 12M1877 |. Disconnect dim dip resistor multiplug from engine harness. |. Remove 4 bolts and a nut securing battery tray Remove battery tray. Fit wooden block to jack and position jack to support gearbox. somne7e Remove 2 bolts securing engine mounting to bracket on gearbox. . Lower gearbox on jack suliciently only for access to mounting bolts. ‘9. Remove 4 bolts securing engine mounting to body. 10. Remove engine mounting. Refit 1. Fit engine mounting to body and tighten bolts to 45 Nm. 2. Raise unit on jack and align bracket on gearbox with engine mounting Fit bolts securing mounting to bracket and tighten. 10 45 Nem (4.6 kgm, 33 IDFA). Remove jack. Fit battery tray assembly. Fit 4 bolts and 1 nut securing battery tray Connect dim dip resistor multiplug, Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs. Fit underbelly panel. See BODY, Exterior fittings. exoge REPAIRS 5.31ENGINE ENGINE MOUNTING - RH Service repair no - 12.45.12 Remove 1. Remove underbelly panel. See BODY, Exterior fittings . 2. Fit wooden block to jack and position jack to support engine. semie72, 3. Remove 2 bolts trom PAS fluid reservoir bracket and move aside for access to steady bar to body through bott 4, Slacken through bolt steady bar to body. 5. Remove through bolt securing steady bar to engine mounting bracket. . Pivot steady bar for access. . Remove nut engine bracket to mounting, Remove 2 bolts securing safety bar and engine ‘mounting to body. 9. Remove satety bar. 10. Remove 3 bolts securing engine mounting bracket to engine. 11, Remove RH engine mounting bracket, 12. Remove RH mounting, Retit 1. Glean engine mounting bracket, dowels and dowel holes. 2. Fit engine mounting and engine bracket. 3. Tighten bolts bracket to engine to 105 Nim (10.7, kgm, 77 bt) 4. Fit nut mounting to engine bracket but do not tighten, ‘5. Fit safety bar to mounting and align mounting to body. Tighten bolts to 45 Nm (4.6 kaf-m, 33 IDE, 6. Remove supporting jack. 7. Tighten nut mounting to engine bracket to 80 Nm (8.2 kgm, 59 Ib) 8. Align steady bar to engine mounting fit through bolt but do not tighten. 9. Tighten steady bar bolts to 80 Nim (8.2 kgm, 59 TbFtt). Through bolt to body first 10. Align PAS fluid reservoir mounting bracket and fit bolts. 11. Fit underbelly panel. See BODY, Exterior fittings, 5-32 REPAIRSENGINE [py2eee]] ENGINE STEADY BAR - UPPER ENGINE STEADY BAR - LOWER Service repair no - 12.45.16 Remove 1. Remove 2 bolts and move PAS fluid reservoir aside for access to steady bar through bolt securing steady bar to body. 2. Remove through bolt securing steady bar to body. 3, Remove through bolt securing steady bar 10 engine mounting, 4, Remove steady bar. 1, Align steady bar to body fit through bott and tight- fen to 80 Nem (8.2 kgm, 59 IDF). 2. Align steady bar to engine mounting fit bolt and tighten to 80 Nm (8.2 kfm, 59 IDF). 3, Align PAS mounting bracket and secure with 2 bolts. no - 12.45.17 1, Remove underbelly panel. See BODY, Exterior fittings . 2. Remove through bolt securing steady bar to engine bracket 3, Remove through bolt securing steady bar to subframe. 4, Remove steady bar 1, Clean area of subframe whore engine steady bi fitted. 2. Align steady bar to subframe fit through bolt and. tighten to 80 Nem (8.2 kgf, 59 bt). 3. Align steady bar to engine bracket, fit bolt and tighten to 60 Nm (8.2 kgf, 59 bff) 4. Fit underbelly panel. See BODY, Exterior fittings. REPAIRS 5.33ENGINE FLYWHEEL Service repair no - 12.53.07 Remove 1. Remove clutch assembly. See CLUTCH, Repairs. 18G 1823 12M1873 2. Remove bolt securing CKP sensor and release: ssensor from gearbox mounting plate. 3. Remove and discard 6 bolts securing flywheel! to crankshaft ‘4, Remove flywheel locking pin tool 18G 1823. 5. Remove flywheel from crankshaft. Refit 1. Using an old flywheel retaining bolt with saw cuts at 45 °to bolt shank, clean old adhesive from thread of flywheel bolt holes in crankshatt .Clean flywheel and mating face of crankshatt. clean dowel and dowel hole. Fit flywheel to crankshaft . Fit flywheel locking pin tool 18G 1523. 6. Fit NEW bolts securing flywheel to crankshaft and ‘working in a diagonal sequence tighten bolts to 15 Nem (1.5 kgm, 11 IF) + 90°. Clean CKP sensor and mating face. Fit CKP sensor and secure with bolt. Fit clutch assembly. See CLUTCH, Repairs. 5-34 REPAIRSENGINE FLYWHEEL STARTER RING GEAR SUMP GASKET Service repair no - 12.53.19 Remove 1. Remove engine flywheel. See this section. 12M1480 2. Apply a cold chisel in root of one of ring gear teeth, strike chisel with hammer to break ring gear. 3. Remove starter ring gear. Refit 1. Clean flywheel and starter ring gear. 2. Heat neat starter ring gear evenly to 350°C (662°F), indicated when the ring is a light blue colour. 3. Locate ring gear on flywheel and press ring gear hard against flange on flywheel. 4. Ensure ring gear is correctly seated around the complete circumference of flywheel and allow to cool. 5. Fit flywheel. See this section. Service repair no- 12.60.38, Remove 1, Raise ont of vehicle By NE servo ey stands. 2. Drain engine oil. See MAINTENANCE . 3. Remove oil fiter. See MAINTENANCE . yom il 12M2084 4, Slacken bolt engine lower tie rod to sub frame. 8, Remove bolt engine lower tie rod to bracket on sump. Release rod from bracket. 12M2085 6. Remove 2 bolts securing PAS pipes to sump ‘and gearbox to engine support bracket. REPAIRS 5.35ENGINE 12M2086 7. Remove 3 bolts securing support bracket to gearbox and sump. 8. Remove bracket 8. Position container to collect spillage trom vacuum pump and oil cooler pipe unions. 12m2088 10, Release vacuum pump oil return pipe from adaptor on sump. 11. Remove bolt securing oll cooler pipe ciip to bracket on coolant purnp mounting 12, Remove oil cooler pipe union nut from oil pump and release pipe from pump. 13, Remove and discard 'O' ring seal A CAUTION: Plug the connections. 14, Remove 2 bolts securing ol cooler pipe to sump, 122090 5 15. Remove 17 bolts securing sump to cylinder block. 16. Remove sump. 17. Remove gasket trom sump. 5-36 REPAIRSENGINE Refit 1. Clean sump and cylinder block mating faces. 2. Fit gasket to sump. s2Mias3 3. Fit sump to block and tighten bolts in sequence shown to 25 Nim (2.6 kgf'm, 19 bff 4. Fit2 bolts securing oil cooler pipe clips to sump. 5, Clean oll cooler pipe union. 6. Fitnew 0’ ring seal to 7. Connect pipe to oll pump and tighten union nut to 25 Nem (2.6 kgf, 19 Ibf ft) 8. Fit bolt securing oll cooler pipe clip to coolant pump mounting. 9. Connect vacuum return pipe to sump. 10. Fit support bracket and tighten bolts, bracket to adaptor plate to 70 Nem (7.1 kgm, 52 Ibfft) and bolt bracket to sump to 25 Nem (2.6 kgm, 19 bf) 11. Fit2 bolts securing PAS pipe to sump and engine to gearbox support bracket. 12. Align lower tie rod to bracket on sump and tighten bolts to 80 Nm (8.2 kgtm, 59 IDEA). 13, Fitooil filter. See MAINTENANCE. 14, Fill with engine oll. See MAINTENANCE, 15. Remove standis) and lower vel OL PRESSURE SWITCH Service repair no - 12.60.50 Remove 1. Disconnect battery earth lead 2. Raise front of vehicle. A WARNING: Support on safety stands. 3, Remove underbelly panel. See BODY, Exterior fittings 4, Position drain tin below engine oil fier. 12M 1855 5. Disconnect muttiplug from oil pressure switch. 6. Remove oil pressure switch. REPAIRS 5.37ENGINE Refit CAMSHAFT TIMING BELT 1 ids. Service repair no - 12.65.18 2. Fit oil pressure switch and tighten to 12 Nem (1.2 kgtm, 8.8 bff). Remove Connect multiplug to oil pressure switch. Fit underbelly panel. See BODY, Exterior fittings. Remove stand(s) and lower vehicle. ‘Top up engine oil. See MAINTENANCE. Connect battery earth lead. 1. Remove camshatt timing belt lower cover. See this section raM1e848 2, Remove 2 bolts and move PAS fluid reservoir aside for access to upper steady bar through bot, steady bar to body. 3, Remove through bolt steady bar to body. 44, Slacken through bolt steady bar to engine ‘mounting 5. Pivot steady bar forwards for access, 12M1850 6, Remove 6 nuts from RH engine mounting plate 7. Remove RH engine mounting plate. 5.38 REPAIRS{8 It timing belt is to be refited, mark direction of rotation, sega? 9. Remove timing belt tensioner access plug trom belt cover. 10, Slacken Allen bolt securing belt tensioner pulley 11, Fit 186 1718 to tensioner. 12. Pull back camshatt timing belt tensioner plunger using 186 1719. 13. Tighten tensioner pulley Allen bot 14. Remove timing belt CAUTION: Ease timing belt from gears using fingers only. Metal levers may damage the belt and gears. Do not rotate ‘engine with timing belt removed and cylinder head fitted. Timing belts must be stored and han- dled with care. Store a belt on its edge with a radius greater than 50mm (2.0 in). Do not use o belt which has been twisted or bent double az this can fracture reinforcing fibres, Do not u: ‘an oil contaminated belt. Although the belt has a service life of 84,000 miles, (135,000 km) an existing bolt should only be refitted if it has com- pleted less than 42,000 miles (65,000 km). ENGINE [Pyeeee]] Refit 1. Clean timing belt gears and pulleys. CAUTION: If the sintered gears have been subjected to prolonged oil contamination, they must be soaked in a solvent bath and thoroughly clean and dry before reuse. the cause of oil contamination must be rectified. 2. Using fingers only, fit timing belt to gears. Ensure the belt run between the crankshaft {gear and camshaft gear is kept taut during the fitting procedure. CAUTION: If original bett is to be refitted ensure direction of rotation is facing the correct way. 3. Clean mounting plate faces. 4. Fit engine mounting plate and secure with 6 nuts, Tighten to 30 Nem (3.1 kgfm, 22 IbFft) + 120°. 5. Align steady bar to body, ft and tighten bolt to 80, Nem (8.2 kofm, 58 IbF#t. 6. Tighten bolt securing steady bar to engine mount. ing to 80 Nem (8.2 kgfm, 59 Ibft) 7. Align PAS mounting bracket and secure with 2 bolts, Slacken Allen bolt securing belt tensioner pulley. 8. Release camshaft timing belt tensioner plunger using 186 1719. 10. Remove 186 1718 from tensioner. 11. Nip up tensioner pulley Allen bolt. 12. Fit timing belt tensioner access plug to belt cover. 13. Remove Allen bott access plug from lower cover. 14. Fit camshaft timing belt lower cover. See this sec- 6 Socket and extension bar on the crankshaft pulley bolt, rotate crankshaft two turns clockwise until the flywheel timing pin can be refitted. 16. Check the camshatt gear timing mark is correctly aligned with the back cover timing mark. 17. Slacken Allen bolt securing belt tensioner pulley, to allow the tensioner to react and then tighten to 44 Nim (6.5 kgf, 33 bf 18, Remove timing pin 18G 1523 from flywhet 19, Fit Allen bolt access plug to lower cover. REPAIRS 5.39ENGINE CAMSHAFT TIMING BELT UPPER COVER Service repair no - 12.65.41 Remove 1. Remove 4 bolts securing timing belt upper ‘cover to rear cover. 2. Remove timing belt upper cover. Refit 1, Fit timing belt upper cover and tighten bolts to 5Nm (05 kghm, 3.5 Ibf ft CAMSHAFT TIMING BELT LOWER COVER Service repair no - 12.65.43 Remove 1. Disconnect battery earth lead. 2. Raise front of vehicle Q WARNING: Support on safety stands. 3, Remove timing belt upper cover. See this section . 4, Remove crankshat pulley. See this section 12M1857 '5, Remove 6 bolts securing lower caver. 6. Remove lower cover. 5-40 REPAIRSENGINE [P2222] Refit Fit lower cover to engine and tighten bolts to 5 Nm (05 kotm, 3.5 Ibf‘t). Fit crankshaft pulley. See this section Fit timing belt upper cover. See this section. Remove standis) and lower vehicle Connect battery earth lead, INJECTION PUMP TIMING BELT Service repair no - 12.65.51 Remove 1. Remove injection pump timing belt cover. See this section . 2. Remove camshatt timing belt upper cover. See this section . 3. Remove underbelly panel for access to crankshaft pulley bok. See BODY, Exterior fittings . 42M1839 4. Using a socket with extension bar on the crankshaft pulley bolt, rotate crankshaft ‘Clockwise to align timing marks on camshatt pulley and back cover. ‘CAUTION: Never use the camshaft gear, gear retaining bolt or timing belt to rotate the camshatt. 5, Fit timing pin 18G 1523 through hole in ‘gearbox adaptor plate and flywheel! REPAIRS 5.41ENGINE 12M1939 6. Fit locking pin 18G 1717 through injection pump drive gear and into hole in mounting plate. 7. Restrain camshatt drive gear using 18G 1521. 8. Slacken 4 bolts securing FIP drive belt gear to hub on camshaft CAUTION: tive bat ito be atts, AN Sanson st raaen on bot 9. Slacken Allen bolt securing tensioner pulley, move tensioner away from belt and tighten Allen bolt. 10, Remove injection pump timing bett. CAUTION: Ease timing belt from gear using fingers only. Metal levers may damage the belt and gears. Timing belts must be stored and handled with care. Store a belt on its edge with a radius greater than 50 mm |. Do not use a belt which has been can fracture reinforcing Although the belt has a service life of 84,000 mites, (135,000 km) an existing belt should only bbe refitted if it has completed less than 42,000 6-42 REPAIRS Refit 11 Clean timing ben gears. CAUTION: I the sintered gears have been subjected to prolonged oil contamination, they must be soaked in a solvent bath and thoroughly clean and dry before reuse. the cause of oll contamination must be rectified. 2. Leave the 4 bolts securing the FIP belt drive gear to hub just loose enough for the gear to rotate within slots without tipping. 3. Fit timing belt using fingers only rotating the FIP belt drive gear fully clockwise within the ‘lots. and then anti-clockwise until the drive belt locates in the gear teeth. fiting the belt in the other possible position will not allow for correct bett adjustment. CAUTION: If the original belt is to be refitted, ensure direction of rotation is, correct. 4. Slacken tensioner pulley Allen bolt. 5. Using a torque wrench fitted to the tensioner plate, tension the belt to 6 Nm (0.6 kgtm, 5.2 let 6. Tighten the Allen bolt. 7. Restrain camshaft gar using 18G 1521 and tighten ‘4 bolts securing FIP drive belt gear. 8. Remove injection pump gear locking pin and engine timing pin, 9. Rotate crankshatt 2 complete turns clockwise and fit flywhoe! timing pin. 10. Slacken 4 bolts securing FIP belt drive g and fit FIP gear locking pin. 111. Slacken timing belt tensioner Allen bolt. 12, Using a torque wrench fitted to the tensioner plate ‘set the tension to 6 Nem (0.6 kgm, 5.2 IbFft) and tighten the tensioner Allen bolt to 44 Nem (45 kgm, 33 IDE). 12. Fita torque wrench to FIP drive bolt gear and. apply an anti-clockwise torque of 25 Nem (2.6 kgm, 19 IDEN, 14, Tighten 4 camshaft gear bolts to 25 Nm (2.6 kgm, 19 bt 15, Remove injection pump gear locking pin and engine timing pin. 16. Fit injection pump timing belt cover. See this sec- ton. 17. Fittiming belt upper cover. See this section. 18. Fit underbelly panel. See BODY, Exterior fittings. 9 hubENGINE INJECTION PUMP TIMING BELT COVER Service repair no - 12.65.53 Remove 1. Remove engine acoustic cover, See BODY, Exterior fittings . 2. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - EDC, Repairs 12M1e5¢ 3, Remove 6 bolts and remove injection pump timing belt cover. 1. Fit timing belt cover and tighten bolts to 5 Nem (0.5 2. Fit air cleaner. See ENGINE MANAGEMENT ‘SYSTEM - EDC, Repairs. 3. Fit engine acoustic cover. See BODY, Exterior fittings. REPAIRS: 5.43ENGINE Engine Overhaul Page DESCRIPTION AND OPERATION ‘CYLINDER BLOCK COMPONENTS: CYLINDER HEAD COMPONENTS .... CAMSHAFT TIMING BELT COMPONENTS ‘OPERATION ‘OVERHAUL CAMSHAFT TIMING BELT AND TENSIONER Tensioner - remove Camshaft timing belt and tensioner - inspection Tensioner «refit... vs Camshaft timing belt- refit and adjust CYLINDER HEAD ASSEMBLY ‘Camshaft - check end-float ‘Camshaft - remove Valves and springs - remove Cylinder head - inspection .. Tappets - inspection Camshaft and bearings - inspection ~. Camshaft bearings - check clearance Valve springs - inspection Valves and valve guides - inspection Valve guides - renew 556 558 558 559 570 Valve seat inserts and valves - rofacing and lapping-in ei Valve head stand down . 872 Valve seat inserts - replace .. a3 Cylinder head bolts - inspection .. Cylinder head and camshaft carrier - cleaning .. Valves - assembling . ‘Tappets and camshafts - assembling . Cylinder head gasket selection Gylinder head - refit FLYWHEEL AND STARTER RING GEAR ..... ‘GEARBOX ADAPTOR PLATE SUMP AND OIL STRAINER 573 576 om - 578 576 578 il pump and oll pressure relief valve - inspection (CRANKSHAFT, MAIN AND BIG-END BEARINGS . snd bearings - remove Crankshaft end-float - check .. Crankshaft - remove . PISTONS, CONNECTING RODS AND CYLINDER BORES ... Piston 1 Pistons. Outline of Model ChangeENGINE CONTENTS Pistons and connecting rods - inspection Pistons - refit ns iston rings - refit ona Cylinder bores - inspection Cylinder block Pistons and connecting rods - refit DATA, TORQUE & TOOLS ENGINE DATA ... TORQUE FIGURES . TOOL NUMBERSENGINE 12M4170 5-48 DESCRIPTION AND OPERATIONCYLINDER BLOCK COMPONENTS 1. Oylinder block 2. Foam pad 3. Gearbox adaptor plate 4. Circip - gudgeon pin 5. Gudgeon pin 6. Piston 7. Connecting rod 8. Bolt - connecting rod 9. Nut 10. Big-end bearing shells, 11. Big-end bearing cap 42, Crankshaft rear oil seal and housing 13. Top compression ring 14. 2nd compression ring 18. Oil control ring 16. Crankshaft 17. Woodruff key 18. Dipstick 19. Dipstick tube 20. Main bearing cap 21. Thrust washer 22. Upper main bearing shell - grooved ENGINE [acee?]] 23, Lower main bearing shell - plain 24. Bolt - main bearing cap 25. Gasket - sump 26. Sump 27. 'O'ring 28. Oil strainer and pick-up pipe 29. Bolt - sump 30. Drain plug 31. Sealing washer 32. Oil squirt jet 33. Banjo bolt 34. Gasket - oll pump 35. Oil pump 36. Bolt - M6 37. Bolt - M10 38. Crankshaft front oil seal 39. Sealing ring 40. Oil fter element 41. Timing gear 42. Crankshatt pulley 43. Bolt - crankshaft pulley 444, Bolt - connecting rod” * Type 8’ engines DESCRIPTION AND OPERATION 5.49ENGINE 5.50 DESCRIPTION AND OPERATIONCYLINDER HEAD COMPONENTS Oil filer cap ‘Camshatt cover Gasket - camshatt cover ‘Camshaft carrier Drive pin Camshatt Camshaft rear oil seal Camshaft front oll seat Fuel injection pump drive belt rear cover Bolt - fuel injection pump drive gear Fuel injection pump drive gear Allen screw Fuel injection pump drive belt tensioner . Gasket - cylinder head 18, 16. 17. 18. 19. 20. 21 22. 23. 24 25. 26. 27. ENGINE #22221] Cylinder head Bolt - cylinder head Tappet Colles Spring cap Valve spring Spring seat and valve stem oil seal Valve guide - exhaust Valve seat insert - exhaust Valve guide - inlet Valve seat inser - inlet Exhaust valve Inlet valve Coolant outle elbow DESCRIPTION AND OPERATION 5.51ENGINE ~ “be CAMSHAFT TIMING BELT COMPONENTS |. Bolt - timing belt gear . Washer . Timing belt gear Camshatt timing belt 5. Tensioner housing Bolt - tensioner pulley ”. Tensioner pulley Allen screw - tensioner pulley ‘Timing belt upper rear cover ts 10. n 12, 13, 14, 15, 5. Timing belt lower rear cover 7. Tensioner plunger 18, ‘Timing belt upper front cover Timing bett ower front cover Engine front mounting cover plate Nut - idler pulley Idler pulley Stud and adaptor - idler pulley Tensioner spring 5-52 DESCRIPTION AND OPERATIONENGINE [P2222] DESCRIPTION The 'L’ Series 2.0 litre engine is a 4 cylinder, inne, direct injection diesel engine having 2 valves per cylinder operated by a single overhead camshaft. ‘A cast iron cylinder block incorporates direct bored cylinders, each pair of cylinders being strategically positioned to reduce engine length and give good structural rigidity ‘An alloy camshaft carrier is bolted directly to the alloy cylinder head, the camshaft bearing journals are line bored between the two components. The camshaft operates the valves via hydraulic tappets and is driven from a gear on the crankshaft by an intemalty toothed belt. Bel tension is by means of a semi-automatic tensioner and an idler pulley is also fied. A gear on the rear end of the camshaft drives the fuel injection pump bel, ‘A single spring is fited to each valve, the valve stem oil seals are moulded on to a metal base which also forms the valve spring seat on the cylinder head. The valve stems run in guides pressed into the cylinder head. The aluminium alloy, graphite coated pistons are fitted with two compression and an oil control ring, the top ring is located in a steel insert which helps to provide a minimal reaction to compression forces. The piston crowns are domed in the centre, the ‘combustion chamber being formed ina bowl around the dome. Fully floating gudgeon pins retain the pistons to the connecting rods, the pins are offset towards the thrust side of the pistons and are secured in the pistons by circlips. Oil squit jets, located in the cylinder block provide additional piston ‘cooling and gudgeon pin lubrication, Plain big-end bearing shells are fitted, the connecting rod caps boing retained by dowel bolls and nuts, ‘A new process in the manufacture ofthe connecting rods has been introduced, known as ‘Fracture Split connecting rods, where the bearing cap is fractured from the connecting rod. Plain big-end shells without location tags are fitted, with flange headed bolts retaining the bearing cap to the connecting rod. To prevent incorrect fitment of the bearing cap to the Connecting rod, the retaining bolt threads in the connecting rod are machined off-set by tren, ‘The crankshatt runs in 5 main bearings, grooved bearing shells are fited in the cylinder block with plain bearing shells it each main bearing cap. Positive location of each main bearing cap is by means of hollow dowels. Crankshaft end/loat is controled by single size thrust washers, located each side ofthe centre - Number 3 main bearing in the cylinder block. The crankshaft front ol seal is located in the oil pump body whilst the rear ol sealis integral with a housing bolted to the rear of the ylinder block. Additional ol sealing is provided by RTV sealant injected into grooves and along the joint tines ofthe front main - Number 1 bearing cap and the crankshatt rear oil seal ‘A rotor type oil pump is driven from the front of the crankshaft the pump is sealed to the cylinder block with a gasket. The cast alloy sump is bolted tothe cylinder block and rear main bearing cap and is sealed tothe block with a rubber gasket which incorporates location lugs forthe block and sump. Compression limiters in the bolt holes prevent distortion of the gasket DESCRIPTION AND OPERATION 5.53ENGINE 12M2131A Lubrication il is drawn through @ gauze strainer (1) and through 9 passage in the cylinder block to the oil pump (22. Pressurised oil flows via the full flow filter (3) to the ‘main oll gallery in the cylinder block. Drilings from the main oil gallory direct oi to the crank- shaft main bearings (4) and cross drillings in the crank: shaft direct oil to the big-end bearings (6). Additional drilings in the cylinder block supply oil at reduced pres sure to the oil squirt jets (7) for piston cooling and gue: gen pin lubrication and via a restrictor (8) in the top of the cylinder block to the rear of the cylinder head. A full length drilling in the cylinder head directs oil to the camshaft journals (9) and tappets (10). ‘An oil pressure relief valve (11) is located in the oil pump body which also carries the oil filter adapter and, the return union for the externally mounted oll cooler A thermostatic valve (12), comprising a valve, spring and diverter plug is located in the oil pump body. The oil flow union to the oil cooler is screwed into the ‘end of the diverter plug. The valve is closed during ‘engine warm-up thereby preventing oil low to the oil ‘cooler. As soon as the oil reaches a pre-determined temperature, the valve opens and allows cil to flow to the cooler. Crankcase ventilation {A positive crankcase ventilation system is used to vent crankcase gases to the air induction system. ‘The gases are drawn from the camshaft cover, through a depression limiting valve and into the turbocharger intake, ‘As engine speed increases, the depression limiting valve progressively closes thereby limiting the depression in the crankcase, 5.54 DESCRIPTION AND OPERATIONEngine number location ‘The engine number will be found on the side of the cylinder block adjacent to No.2 cylinder. ENGINE DESCRIPTION AND OPERATION 5.55ENGINE CAMSHAFT TIMING BELT AND TENSIONER Camshaft timing belt - remove 12M1680 4. Remove 4 screws securing camshaft timing belt upper front cover, remove cover. 186 1523 somige 2. Using crankshaft pulley bolt, rotate crankshaft Until camshaft gear timing mark is aligned with, pointer on timing belt top backplate and drive pin is at 2 o'clock position. CAUTION: Do not use camshatt timing belt gear or fuel injection pump drive belt gear to rotate crankshatt. 3, Insert timing pin 1861823 into flywheel soMie82 4, Remove crankshatt pulley bolt, withdraw pulley. 5. Noting fitted position of 3 longest screws, remove 6 screws securing camshaft timing belt lower front cover. Remove cover. 5.56 OVERHAULENGINE 12M1883 6. Remove 4 nuts and 2 bolts securing engine front mounting cover plate, remove plate. NOTE: Six nuts are fitted on certain ZL tontestons 12. Using the fingers only, ease timing belt from gears, CAUTION: Do not rotate camshatt or crankshaft with timing belt removed and cylinder head fitted, 7. Remove access plug from camshatt timing belt lower rear cover, 8. Siacken but do not remove Allen screw securing timing belt tensioner pulley, 8. Screw timing belt tensioner retractor tool 18G1719 into timing belt tensioner plunger. 10. Tighten nut on too! 181719 unti timing belt tension is released. 11, Iforiginal timing belt is to be refited, mark direction of rotation on belt OVERHAUL 5.57ENGINE Tensioner- remove 1. Remove Allen screw and bolt securing timing belt tensioner, remove tensioner. 2. Remove tensioner spring and plunger. ‘Camshatt timing belt and tensioner - inspection 1. Inspect timing belt for signs of splits at base of ination or uneven wear. ng belt if t falls inspection or if it h bbeen used for more than 48,000 miles, 80,000 km. CAUTION: If timing belt is contaminated with oll, cause of oil contamination must be rectified. Timing bolts must be stored and handled with care. Always st ‘edge with a bend radius greator than 30 mm ( in). Do not u or twisted as fibros. Do not use a belt that has been contami- nated with oil 12M 1886 2. Cheek tensioner spring for distortion, check spring {ree length. Free length = 65 mm (2.6 in} 3. Cheek tensioner plunger and bore of housing for wear and corrosion. CAUTION: Do not attempt to remove corrosion by means of emery cloth, ‘components must be replaced. 4, Check that tensioner and idler pulleys rotate smoothly and belt surfaces are smooth and clean, 5. Check that sealing strips in upper and lower covers are not split or damaged, replace as necessary. 5.58 OVERHAULENGINE Tensioner - refit Camshatt timing belt - refit and adjust 1. Ensure that bore of plunger housing is clean. 41. Clean tensioner and idler pulleys and timing belt gears. 2. Check that camshatt timing belt upper and lower cover sealing strips are correctly located 2. Smear tensioner plunger with molybdenum disulphide based grease, locate spring and plunger in housing. 3. Position tensioner on cylinder block, fit bott and tighten to 45 Nem (4.6 kgf, 33 bff}, fit but do not fully tighton Allen screw. /r8c 1523 12M1888 3, Ensure that timing pin 1861523 is inserted in flywheel, camshaft gear timing mark is aligned exactly with pointer on timing belt backplate land that drive pin is at 2 o'clock position, OVERHAUL 5.59ENGINE 186 1719 124889 4. Screw timing belt tensioner retractor too! 18G1719 into tensioner plunger, tighten nut on ‘ool and fully retract tensioner. '8. Using the fingers only, ease timing belt over crankshaft and camshaft gears keeping it as taut as possible on the idler pulley side. CAUTION: Original belt - ensure that fection of rotation mark is facing the correct way. 6. Siacken Allen scrow until tonsioner pulley moves ‘easily without tipping. 7. Slacken nut on tool 18G1719 until tension« released; tighten Allon scrow to 55 Nim (5.6 kgfm, 41 IbFét) and remove tool. 8, Insert access plug in lower rear cover. CAUTION: If engine front mounting bracket is removed, clean all traces of oi and old Loctite from bracket and cylinder block. Reseal bracket to cylinder block using Loctite 638. 12M1930, 9. Fit engine front mounting cover plate, fit 4 nuts ‘and 2 bolts and tighten bolts to 45 Nem (4.6 kgkm, 33 Ibfft) and nuts to 35 Nem (3.6 kgfm, 26 lbf th CAUTION: When 6 nuts are fitted, the nuts securing the engine mounting must be tightened to 35 Nim (3.6 kgm, 26 Ibft). T 196 18 12M1890_ 8 2s 10, Locate crankshaft pulley on crankshaft, fit bott and tighten to 63 Nem (6.4 kgf, 46 IbF ft). Do not en bolt further at this n. 1 ‘turns in a clockwise: 1261523. 5.60 OVERHAULCAUTION: Do not use camshaft timing belt gear or fuel injection pump drive belt gear to rotate crankshaft. 1. Check that camshaft gear timing mark is. aligned with pointer on timing belt top backplate and that drive pin is at 2 o'clock position, 2N1982 14, Slackon Allen serew until tonsioner pulley moves to tension belt then tighten screw to 55 Nm (6.6 kgm, 41 Ibf th 15, Remove crankshaft pulley bolt, pulley and ti pin 1861523. 16. Position camshaft timing belt lower front cover to timing belt lower rear cover. ENGINE 117. Fit lower front cover securing screws ensuring that 3 longest screws are in correct fitted position, hton all screws to § Nem (0.5 kgm, 3.7 IbFft). 18, Fit crankshaft pulley and bolt, tighten bolt to 60 Nem (6.1 kgf, 44 ibFft). ©) soMig33 19. Position camshaft timing belt upper front cover to rear cover, fit and tighten screws to 5 Nem (0.5 kgfm, 3.7 bt. OVERHAUL 5-61ENGINE CYLINDER HEAD ASSEMBLY Remove 1. Remove camshaft timing belt. See this section. 3, Restrain camshaft timing belt gear using tool 18G1521 and remove bolt securing camshatt timing belt gear, remove gear, discard bolt CAUTION: Ensure camshatt does not rotate when removing bolt and do not rotate crankshaft or camshaft with timing belt removed and cylinder head fitted. 2, Restrain camshaft timing belt gear using tool 18G1521 and remove bolt securing fuel injection pump drive belt gear to camshaft, remove gear, discard bolt. CAUTION: Ensure camshatt does not rotate when removing bolt and do not rotate crankshaft or camshaft with timing belt removed and cylinder head fitted. 4. Remove 5 screws securing camshaft timing belt upper rear cover, remove cover, recover sealing strip. 6-62 OVERHAUL12M189¢ 5. Remove Allen screw securing fuel injection pump drive belt tensioner, remove tensioner. 6. Remove 3 screws securing fuel injection pump drive belt rear cover, remove cover, recover bracket 12M1895 7. Using sequence shown, progressively slacken then remove 12 bolts securing camshaft cover. '& Remove camshaft cover, remiove and discard gasket, ENGINE Jeceee] 12M1896 9. Using sequence shown, progressively slacken then remove 10 cylinder head Torx bolts and washers. CAUTION: Keep bolts in their fitted order, do not attempt to remove washers from bolts. 10. Remove cylinder head assembly and support ‘each end of cylinder head on blocks of wood to protect valves which, when open, protrude below face of cylinder head, CAUTION: Cylinder head is dowel located, do not tap it sideways to free it from cylinder block. 11, Remove and discard cylinder head gasket. OVERHAUL 5.63ENGINE Camshaft - check end-float NOTE: Prior to removing the camshaft, LA Sreccensioa s2Mi8o7 11. Attach a magnetic base DTI* to front of cylinder block, move camshaft rearwards, position stylus of DTIon end of camshaft and zero DTI. Move camshaft forwards and measure end-fioat, End-float (maximum) = 0.51 mm (0,02 in). CAUTION: Camshaft end-float is controlled by the width of No.1 bearing in the camshaft carrier. f end-tloat exceeds the above dimension, remove the camshaft and repeat the end-float check using a new camshatt. It end-float still exceeds the maximum, a new cylinder head and camshaft carrier asssembly must be fitted. Camshatt - remove 121898 1. Using sequence shown, slacken the 10 ‘camshatt carrier retaining bolts 2 to 3 turns. CAUTION: Do not fully remove bolts at this, stage. 2. Gently tap the camshaft carrier upwards to break the sealant bond. CAUTION: Camshaft carrier is dowel located, do not tap it sideways, 3. Using the same sequence, continue to progressively slacken the carrier retaining bolts Until all loading is removed trom the carrier. CAUTION: If bolts are removed completely before loading is removed trom the ‘camshaft carrier, the carrier may be suddenly released and damage caused as a result. 4, Remove retaining bolts, remove camshaft carrier. 5. Remove camshaft, remove and discard front and rear oil seals. 5-64 OVERHAUL6. Using a stick magnet, remove 8 tappets from the cylinder nead. CAUTION: Keep tappets in their fitted AX, Stierana store inverted to prevent fase. Do not squeeze tappet chambers together. ENGINE Valves and springs - remove 1. Support cylinder head clear of valves, use a hollow drift and tap each spring cap to free collets. 18G 1519 semi90 2. Using tool 1861519, compress valve spring, 3, Remove 2 collets from valve stem using a stick magnet. 4, Remove tool 1861519. 5, Remove spring cap and valve spring, remove valve. OVERHAUL 5-65ENGINE saMs902 6. Using tool 1861577, remove valve stem oil seal; discard seal. 7. Repeat above operations to remove remaining valves, CAUTION: Keep component parts of ach AA Cave sovniy intron ted acer Cylinder head - inspection 1284190 ‘across contre and 1. Check eylinder head for warp: from corner to comer: ‘Maximum warpage - 0.010 mm (0.00039 in). CAUTION: Cylinder head may not be refaced, replace head assembly if warpage exceeds figure given. 2. Check tappet bores for scoring and signs of wear or damage. Siight scoring or burting may bbe removed using fine emery cloth 5-66 OVERHAUL‘Tappets - inspection 1. Check tappets for signs of wear, scoring and overheating, replace as necessary. 2. Ensure oil hole in each tappet is clear. 3. Check outside diameter of each tappet Diameter = 34.959 to 34.975 mm (1.3763 to 1.370 in. {: Keep tappets in their fitted order and store inverted to prevent oil loss. Do not squeeze tappet chambers together ENGINE [,ce2?] Camshaft and bearings - inspection 1. Check camshaft cams and bearing journals for signs of scoring and excessive wear. ORY seMigod 2. Check camshaft timing belt gear and fuel injection pump drive belt gear drive pins for ‘damage and wear. replace if necessary ensuring that split in pin faces towards centre of camshatt 3. Check bearing journals in cylinder head and camshaft carrier for signs of scoring and excessive wear. CAUTION: Cylinder head and camshaft carrier are machined together as an ‘assembly. If bearing journals in either ‘component are found to be damaged, complete assembly must be replaced. OVERHAUL 5.67ENGINE ‘Camshatt bearings - check cl ance 1. Clean all traces of oil from camshatt, cylinder head and camshaf carrier. 2. Using sealant remover from sealant kit, Part No. LW10002B, remove all traces of sealant ‘rom cylinder head and camshaft carrier 121905 3. Position camshaft in cylinder head. 4, Place a piece of Plastigage along the centre line of each camshaft journal. '5. Support each end of cylinder head on blocks of 12M1908 6. Carefully fit the camshaft carrer, fit 10 retaining bbolts and tighten in sequence shown to & Nem (0.8. kgm, 5.9 IbFft) CAUTION: Do not rotate camshatt. 12M1898 7. Using sequence shown, progressively slacken, then remove 10 retaining bolts. 8. Carefully remove camshaft cartier 12M1907 9. Measure and record widest portion of Plastigage on each camshaft journal. 10. Compare figures obtained with camshaft bearing clearance. Bearing clearance = 0,043 to 0.094 mm (0.0017 to 1.0037 in) 11. tfany bearing clearance is found to be excessive, at the above procedure using a new camshatt. CAUTION: If, ater repeating the bearing clearance check with a new camshaft the clearances are still excessive, a new cylinder head and camshaft carrier assembly must be fitted. 12, Remove Piastigage using an oily rag, do not use a scraper. 6-68 OVERHAULENGINE fPy2e2*]] Valve springs - inspection 12M1908 | 1. Check valve springs: Free length = 37.0 mm (1.46 in) CAUTION: Valve springs must be replaced A asaset. Valves and valve guides - inspection 1. Clean carbon from valves, check valves for ‘burning, pitting or cracking; replace as necessary 2 4 XA 12M 1909, 2. Check and record diameter of each valve stem. Inlet = 6.907 to 6.923 mm (0.2719 to 0.2726 in) Exhaust = 6.897 to 6.913 mm (0.2715 to 0.2722 in) 3, Renew any valve if stem diameter is less than spec- ified. 4. Insert each valve into its respective guide, check ‘and record valve stem to quide clearance. {alet valve = 0.056 mm (0.0022 in). Exhaust valve = 0.066 mm (0.0026 in). 5, Renew any guide and its associated valve i cl ‘OVERHAUL 5.69ENGINE Valve guides - renew 1. Check area on camshatt side of cylinder head around valve guide to be replaced for marks denoting previous vaive guide replacement: + denotes 1st replacement - denotes 2nd replacement CAUTION: Valve guides may only be replaced twice. 2. Heat cylinder hes 120°C (248"F uniformly to a temperature of 3, Using a suitable pilotted mandrel, press valve guide out of cylinder head from combustion face side; discard guide. NOTE: Only one size of replacement guide is available. 4, Reheat cylinder head to 120°C (248°F) a) S33 f=P? C '. Using the pllotted mandrel, press replacement valve guide into cylinder head from camshaft side of head until fitted height of guide from combus- tion face side of cylinder head to top of guide is 61.1 to 61.7 mm (2.41 to 2.43 in). 6. Allow cylinder head to air cool. 7. Ream bores of replacement valve guide ensuring ‘that reamer is kept perpendicular to and concentric with valve ses Valve guide bore diameter = 6.950 to 6.963 mm (0.2736 to 0.2741 in} CAUTION: If valve seat insert has also been replaced, guide and insert must be machined together. 8. Suitably mark cylinder head on camshatt side of head to denote that guide has been replaced. 1st replacement guide + 2nd replacement valve guide - CAUTION: A new valve must always be fitted whenever a guide is replaced. 5-70 OVERHAULValve seat inserts and valves - refacing and lapping-in Refacing vaive seat inserts 1. Check valve seat inserts for pitting and burning, if necessary, valve seats may be recut providing valve head stand down is within limits after recutting 2Migi2 2. Using a suitable pilotted cutter, cut valve seat insen to correct angle and width. Inlet valve seat insert: ‘Seat width A = 35.697 mm (1.4054 in} ‘Seat angle B = 60° Exhaust valve insert ‘Seat width A = 31.05 to 31.55 mm (1.222 to 1.242 in) ‘Seat angle B = 58° to 62° ENGINE fee? 12M1913 . Check face angle A of each valve, renew any valve with incorrect face angles, do not attempt to recut Valve face angle - Inlet and exhaust = 45%o 45°30" OVERHAUL 5.77ENGINE Lapping: 1. Lap each valve to its seat using grinding paste, 2. Apply Prussian Blue to valve seat, insert valve into guide and press it firmly, without rotating, on to seat, samigta 3. Remove valve and check that a continuous, even line of Prussian Blue has been transferred on to valve face: continue lapping-in valve as necessary. OTE: Line one nathav 0 be cron AA tae with ove ace 4. On completion of lapping-in, check vaive head stand down. See this section. Valve head stand down . Insert each valve into its respective guide. 2. Using a straight-edge and feeler gauges, check land record stand down of each valve head. 1. Compare figures obtained with figures given below. If any valve has a stand down greater than specified, valve seat insert and valve must be replaced. Valve head stand down: Inlet valve A = 1.45 mm (0.0571 in) Exhaust valve B = 1.35 mm (0.0531 in) 5.72 OVERHAULENGINE myeeee]] Valve seat inserts - replace 1. Taking care not to damage cylinder head, grind a crescent into insert to reduce wall thickness. Break insert at thin section, remove inser. A CAUTION: Do not damage counterbore. 2, Heat eylinder head to 120°C (248 °F) and using a piloted mandrel, press valve seat insert into head insert is kept sequare to counterbore. WARNING: Take care when handling hot A culinder head 3. Allow cylinder head to ait cool. 44. Lap valve to its seat and check valve head stand down. See this section. Cylinder head bolts - inspection 1. Keeping bolts in their fitted order, clean bolts and washers, lightly oil threads 12Mi916 2. Check bott heads and threads for damage, replace individual bolts as necessary. 3. Cheek length of bolt from top of bolt head to end of bolt. any bolt exceeds 243.41 mm (9.5831 in) length, all 10 bolts and washers must be replaced. CAUTION: Do not attempt to remove ‘washers from bolts. OVERHAUL 5.73ENGINE Cylinder head and camshaft carrier - cleaning Valves - assembling CAUTION LW 100028 which contains sealant remover and liquid sealant. 1. Clean mating surfaces of cylinder head and camshaft carrier, remove any deposits from camshaft oil seal recesses using a plastic soraper. 2. Clean gasket material from cylinder head and block using gasket removal spray and plastic scraper, DO NOT USE A METAL SCRAPER. 3, Clean all traces of carbon from combustion face areas. 4, Blow out all cilways and waterways. 5. Ensure threaded holes in cylinder block and ‘camshaft carrier are clean and dry. 6. Check core plugs for corrosion and signs of leakage and replace if necessary; use Loctite 57210 seal replacement plugs. ise Liquid Sealant Kit, Part No. 41. Using too! 1861577, fit new valve stem oll seals. 2. Lubricate valve stem oil seals, valve guides, valve stems, spring caps and springs with engine ol. 3. Assemble valves, springs and spring caps ‘ensuring that they are in their correct fitted order. Compress vaive springs using tool 1861518, fit collets, remove tool 5. Using a wooden dowel and mallet, tap each spring cap lightly to seat collet. 5.74 OVERHAULTappets and camshafts - assembling Lubricate tappets and tappet bores with engine oil 2. Fit tappets ensuring they are in their correct fitted order. 3, Lubricate cams and bearing journals on camshaf., cylinder head and camshaft carrier with engine oil 4, Position camshatt in cylinder head with timing belt gear drive pin at approximately 2 o'clock position. '5. Support ends of cylinder head on blocks of wood. Li [oO oo seman 6. Using sealant from kit, Part No. LVV100028, apply an even tim of sealant to cylinder head; spread sealant to an even film using a brush or roller. CAUTION: Ensure sealant does not block Iways or is spread on to bearing journals. ENGINE 7. Fit camshatt carrier, ft and finger tighten bolts, 12M1908 CAUTION: With camshaft carrier bolted down, some valves will protrude below face of cylinder head; support each end of cylinder head on blocks of wood. 8 Using sequence shown, progressively tighten ‘camshaft carrier bolts to 11 Nem (1.1 kgm, 8 Ibft). CAUTION: Botts must be tightened to AN, Soret torque niin 20 minutes ot sealant 9. Lubricate a new camshaft front oil seal with engine oll. 10. Fit oil seal using using tool 1861716. OVERHAUL 5.75ENGINE 186 1716 i: oS 7 12M1922 11. Lubricate a new camshaft rear oll seal with engine oil 12, Fitoll seal using tool 1861716. \der head gasket selection NOTE: There are three thicknesses of cylinder head gasket available and in order that the correct gasket is fitted, itis necessary to determine the stand proud (protrusion) of each piston above the top face of the cylinder block. sawe123 NOTE: Gaskets have either 1, 2 or 3 Identification holes and the following procedure must be followed in order that the correct gasket is selected. 1. Temporarily assemble pulley to crankshaft, fit and finger tighten bolt 2. Remove timing pin 18G1523 (i fited). 5.76 OVERHAUL3, Assemble a magnetic base DTI* to cylinder block top face, zero DTI with stylus touching block top fa 4, Rotate crankshaft in @ clockwise direction until No. 1 piston is at TDC" 5. Position stylus near edge of piston crown, measure and record No. 1 piston protrusion. ANTON: Messen mn be hen DB ee eer 6. Repeat above procedure for rem: ing pistons, DTI: Dial Test Indicator “*TOC: Top Dead Center ENGINE From readings obtained, determine highest piston protrusion figure and select the appropriate eylin- der head gasket: Protrusion 0.10 to 0.25 mm (0.0039 to 0.0098 in) - Select gasket with one identification hole. Protrusion 0.25 to 0.40 mm (0.0098 to 0.016 in} - Select gasket with two identification holes. Protrusion 0.40 to 0.55 mm (0,016 to 0.022 in} - Select gasket with three identification holes. OVERHAUL 5.77ENGINE Cylinder head - refi 1. Fit crankshaft pulley bolt and washer and tighten bolt to 63 Nem (6.4 kgfm, 46 IbFt). Do not tighten bolt further at this stage. 2. Remove timing pin 18G 1523. 3. Ensure than cylinder block end head faces are clean and dry and that al traces of gasket material hhave been removed. Check that cylinder head location dowels are fitted in eylinder block. 4, Check that oil feed restrictor in cylinder block is clear and that restrictor is below biock face. 5. Ensure that cylinder head bolt holes in cylinder block are clean and dry. 6. Using crankshaft pulley bolt, rotate crankshaft ant clockwise until Nos. 1 and 4 pistons are approxi- ‘mately 25 m (0.98 in) below cylinder block top face. 7. Position camshaft timing gear drive pin at 2 ofelock. 8. Position selected cylinder head gasket on cylinder block ensuring that itis the correct way round. CAUTION: Gasket must be fitted dry. one CAUTION: Do not i undersides of QA Sasnere 11. Carefully enter cylinder head bolts in their fied order. DO NOT DROP BOLTS INTO CYLINDER BLOCK. 12. Using sequence shown, tighten cylinder head bolts to: Stage 1-30 Nem (3.1 kgtm, 22 Ibf ft) Stage 2 - 65 Nem (6.6 kgfm, 48 IDF). Stage 3- Further 90° Stage 4 - Further 90° CAUTION: Ensure that correct tightening sequence is followed for all four tightening stages. 13. Fit fuel injection pump drive belt rear cover and. mounting bracket, fit 3 serews and tighten to 8 Nim (0.8 kfm, 6 IDF) 44. Fit fuel injection pump drive belt tensioner, ft but do not fully tighten Allen screw. 15. Ensure sealing strip is correctly located on ‘camshaft timing belt upper rear cover. 16. Fit upper rear cover ensuring that2 shortest ‘screws are fitted in camshaft carrier. 17. Tighten screws to 8 Nim (0.8 kgf, 6 lof) 6.78 OVERHAULENGINE 20. 2 22. ramei2e TeMToaT Fit camshaft timing belt gear. fit a new bolt. 23. Using crankshaft pulley bolt, carefully rotate Restrain camshaft timing belt gear using tool ‘rankshatt clockwise unti timing pin 1861523 1861521 and tighten bolt to 20 Nem (2.0 kgm, 14 can be inserted in hole in flywheel. thf) then a further 90°. Fit fuel pump drive belt gear to camshaft, use a CAUTION: Do not rotate crankshatt too far, new bolt. pistons may contact the valves. Restrain camshaft timing belt gear using too! 18G1521 and tighten fuel pump drive belt gear bott 24, Remove crankshatt pulley bolt and washer. 10.20 Nem (2.0 kgf, 14 iff) then a further 90°. 25. Fit timing belt and adjust tension. See this section. CAUTION: Ensure camshaft does not 26. Fit a new gasket to camshaft cover ensuring rotate as bolts aro tightened. that raised holes in gasket are towards the cover and are located on the two spigots Enaure that camshaft timing geae drive pin is still at 2 o‘clock position and camshaft gear timing mark is aligned with pointer on timing belt rear A CAUTION: Gasket must be fitted dry. OVERHAUL 5.79ENGINE 121928 27. Fit camshatt cover bolts and tighten in sequence ‘shown to 12 Nem (1.2 kgm, 8.9 IDF) FLYWHEEL AND STARTER RING GEAR Flywheel - remove rawigse 1. Remove bolt securing camshat sensor to ‘gearbox adapior plate, remove sensor. 5-80 OVERHAULENGINE 12M1935 2. Insert timing pin 1861523 into flywheel. 3. Remove and discard 6 bolts securing tlywhee! to crankshaft, 4, Remove timing pin 1861523. 5. Using assistance, remove flywhedl. A NOTE: Dowel located. Starter ring gear - remove M196 6 f 1. Apply a cold chisel to root of tooth, break ring {gear and remove from flywheel. WARNING: Suitable eye protection must be worn, Starter ring gear - refit 1. Heat ring gear evenly to 350°C (662°F) indicated by light blue colour. Locate ring gear on flywheel and press on to flange. Q WARNING: Handle hot ring gear with care. 2. Allow ring gear to air cool OVERHAUL 5.81ENGINE Flywheel - refit 1 |. Clean threads in crankshaft using an old flywheel bolt having 2 saw cuts at 45°along thread of bolt. DO NOT USE A TAP TO CLEAN THREADS. Clean flywheel faces. Using assistance, position flywheel on crankshaff, fit and finger tighten new Patchlok bolts Inger timing pin 1861823 into fywheet. Tighten bolts to 15 Nem (1.5 kof¢m, 11 Ibf#t) then @ further 90°. Position crankshaft sensor to gf plate, fit and tighten bolt to 8 N-m ( ott). GEARBOX ADAPTOR PLATE Remove s2Miga7 1. Remove 4 Torx screws securing adaptor plate to cylinder block, remove plate. Refit 1. Check condition of foam rubber pad, replace if necessary. 2. Remove all races of Loctite from Torx screws. 3. Ensure tapped holes in cylinder block are clean and dry. 4. Apply Loctite 275 to threads of Torx screws. 5. Position adaptor plate to cylinder block, ft and. tighten Torx serews to 45 Nem (8.6 kfm, 33 Ibt4) 5-82 OVERHAULENGINE ‘SUMP AND OIL STRAINER Sump - remove 1. Remove dipstick 2. Remove and discard oil fiter element, 42 8. Using sequence shown, remove 17 bolts securing Sump to cylinder block. 4. Remove sump, remove and discard gasket. Oil strainer - remove 121939 1. Remove 3 bolts securing oil strainer to cylinder block and main bearing cap noting fitted position of shortest bolt. 2. Remove oil strainer, remove and discard 'O ring OVERHAUL 5.83ENGINE Oil strainer- refit Sump -retit 1. Clean strainer and pick-up pipe. 2. Ensure bolt holes in cylinder block and main bearing cap are clean and dry. 3. Lubricate a new O'ring with engine oll and fit 10 pick-up pipe flange. 4. Position strainer to cylinder block and main bear- 19 cap. ‘5. Fit bolts noting that shortest bolt is fitted into ‘main bearing cap. Tighten bolts to 8 Nem (0.8 kgtm, 6 ibttt) NOTE: Patchlok bolts may be re-used pro- vided threads are undamaged. 1. Clean sump flange and mating surfaces of cylinder block, ensure bolt holes in cylinder block and main bearing cap are clean and ary. 2. Using sealant trom kit, Part No. LVV100028, fill ‘grooves on each side of front - No.1 main bearing cap and apply a bead of sealant to joint line of main bearing cap and cylinder block. 3. Using a brush or roller, spread sealant to an. even fim. 121943 4, Position new gasket to sump ensuring that locating lugs are inserted in holes in sump. ) NOTE: Gasket must be fitted dry. 5. Position sump to cylinder block ensuring that locating lugs are inserted in holes in block 5-84 OVERHAULsemigea Fit and finger tighten 17 bolts. Using sequence shown, tighten bolts to 25 Nem (2.5 kgf, 18 Ff). Using the same sequence, recheck that all bolts are torqued to 25 Nem (2.5 kgfim, 18 Ibf ft) Fit dipstick. Fit anew oil filter element. ENGINE OW PUMP: Remove 1. Remove camshatt timing belt. See this section. ramiges 2. Slide timing gear off crankshaft NOTE: The Woodrutt key is an integral part of the gear. 3. Remove nut securing camshatt timing belt idler pulley, remove pulley NOTE: Idler pulley mounting stud may be unscrewed as nut is removed. 4, Remove 2 bolts securing camshaft timing belt lower rear cover, remove cover and sealing strips. OVERHAUL 5.85ENGINE il pump and oil pressure relief valve - inspection il pump CAUTION: Overhaul procedures for the ol! ZA, bump are limited to carrying out dimensional checks. In the event of wear or damage being found, a replacement pump must be fitted. 1. Make suitable alignment mark between pump backplate and body, 2. Remove 4 Torx screws securing backplate to body, remove backplate. 12M 1946 5. Using sequence shown, remove 1 M10 and 9 (M6 bolts securing oil pump to cylinder block, NOTE: Longest M6 bolt is fitted at position 8 6. Remove oil pump. 7. Remove and discard gasket 8. Recover Woodruff key from crankshaft 9, Remove and discard crankshatt front oll seal from oll pump body. 122120 3. Using a felt tipped pen, make suitable alignment marks between inner and outer rotors and pump body. 4, Remove inner and outer rotors. 5. Check rotors and pump body for signs of scoring and wear. 6. Fit rotors into pump body ensuring that reference marks are aligned and outer rotor identification mark faces outwards. 6-86 OVERHAULENGINE 7. Using feeler gauges, check pump body to rotor clearance. 98. Using fecler gauges, check clearance between nce = 0.05 to 0.10 mm (0.002 to 0.0039 in). inner and outer rotor lobes. Clearance = 0.025 to 0.12 mm (0.0010 to 0.0047 in} 10. Renew oil pump assembly if scoring exists or clearances are excessive. 8, Place a straight edge across pump body and fooler gauges, measure end-float of outer rotor. End-float = 0.03 to 0.08 mm (0.001 to 0.003 in) OVERHAUL 5.87ENGINE il pressure relief valve ——_ 12M1955A 1. Remove and discard plug, 2. Remove spring and relief valve plunger. 3. Check plunger and bore for wear, corrosion and scoring NOTE: Light scoring may ba removed ZX ting erate 600 omer cath soaked nol. Check spring free length Free length = 38.9 mn (1.531 in). 5. Renew relief valve as an assembly 6. Remove all traces of sealant from plug threads init pump body, 7. Lubricate spring, relief valve plunger and bore with engine oil 8, Fit plunger and spring, fit and tighten a new plug. CAUTION: Do not attempt to re-sel and fi AN thecal pis. 9. Check oil pressure switch - if fited for damage, replace as necessary. Apply Loctite 577 to threads of replacement switch and tighten to 16Nm, Thermostatic valve 12M33938, 1, Remove diverter plug, remove and discard Dowty washer. 2. Withdraw spring and vaive from oil pump body. CAUTION: Do not separate spring from valve. 3. Check spring for distortion and corrosion 4. Check valve for corrosion, seating faces of valve and diverter plug for damage and pitting: replace valve as an assembly 5. Check valve bore for corrosion NOTE: Light corrosion may be removed from valve bore using grade 600 emery cloth soaked in oil. 6. Remove all traces of Loctite from threads of diverter valve plug and oil pump body. 5-88 OVERHAULENGINE CAUTION: Do not remove blanking plug from oil gallery below thermostatic valve bore. 7. Lubricate valve, spring and bore with engine oil 8. Secure oll pump body ina soft jawed vice with thermostatic valve bore facing upwards. CAUTION: Valve bore must be as nes Ay senaniee posse 9. Insert valve and spring in bore ensuring that it is positioned centrally in bore. CAUTION: Valve will not seat correctly in diverter plug if itis not positioned centrally. 10. Fita new Dowty washer to diverter plug. 11. Apply Loctite 577 to threads of diverter plug. 12, Fit diverter plug, carefully tighten plug by hand ensuring that valve is not displaced as plug is tightened, 13, When diverter plug is seewed fully down, tighten 10 35 Nem (3.8 kgm, 26 Ib). il pump - assembling 1. Using gasket romoval spray and plastic scraper, remove all races of gasket material {rom oil pump body 2. Use a suitable cleaning solvent, remove all traces of sealant from oll pump body and backplate. 3. Remove all races of Loctite from Torx screws and holes in oil pump body, ensure holes are clean and dry, CAUTION: Do not use a tap. A 4. Ensure all components are clean, lubricate rotors and housing with engine oil 5. Fitrotors ensuring that reference marks are aligned and chamfered side of outer rotor carrying a square identification mark is facing ‘away from backplate side of pump body. © O 6. Apply a1 mm bead of Loctite §73 to pump backplate as shown, 7. Fit pump backplate ensuring reference marks ‘on backplate and pump body are aligned. 8. Apply Loctite 222 to threads of Torx screws, fit and tighten screws. ‘9. Check that pump rotates freely 12M3391 OVERHAUL 5.89ENGINE Oil pump - refit 1. Using gasket removal spray and plastic ‘scraper, remove all races of gasket from cylinder block 2, Remove all races of sealant from joint faces of front - No.1 main bearing cap ‘3. Lubricate oil seal running surtace on crankshaft with engine oil 4, Fit Woodrulf key to crankshaft, G +— 181509 12M2126" 5. Lubricate a new crankshatt front oil seal with engine oil 6, Fit oll seal using tool 1861509. 12M1956 7. Using sealant from kit, Part No. LVV10002B, apply a bead of sealant to joint line of front - No.1 main bearing cap. CAUTION: Do not fill grooves on either side of main bearing cap until immediately before sump is fitted. 8. Position a new gasket to cylinder block. a NOTE: Gasket must be fitted dry. 186 1510-1 oe 12M 1957, 9. Align Woodruff key slots in oil pump inner rotor with Woodrutt key. 10. insert oil seal protector 1861510 and adapior sleeve 18G1510.-1 into oil pump inner rotor. NOTE: Thi wi asin locating ol pump JD Menrvoton wena ice 5.90 OVERHAUL16. Fit camshaft timing belt idler pulley ensuring that recessed side of centre boss faces away from ‘engine. 17, Apply Loctite 275 to threads of idler pulley nut, fit and tighten nut to 45 Nem (4.6 kgf, 33 lb If stud was unscrewed during nut n old Loctite from threads of stud and ensure hole in cylinder block is clean and dry. Apply Loctite 275 to threads of stud and screw it into block, tighten stud to 12, Nm (1.2 kgfm, 8.9 Ibfft). 1B. Slide timing gear on to crankshaft. 19. Fit camshaft timing belt and adjust tension, See this section, 11. Slide olt pump over crankshaft ensuring Woodruff key is located in keyway in inner rotor. NOTE: Tools 1861510 and 18618104 wil ZA, beauplnced a pu otis 12. Fit bolts ensuring that longest M6 bolt is fitted at position 1 13, Tighten bolts in sequence shown to: M10 bolts - 45 Nem (4.6 kafim, 33 Ibf#t). M6 bolts - 10.Nimn (1.0 kgm, 7 IbFft). NOTE: Patchlok bolts may be re-used pro- Sided threads are undamaged. 14. Ensure sealing strips are fitted to camshaft timing belt lower rear cover. 15. Fit lower rear cover, fit and tighten screws to 8 Nem (0.8 kgfm, 6 IbFt. OVERHAUL 5.91ENGINE CRANKSHAFT, MAIN AND BIG-END BEARINGS. ‘Big-end bearings - remove Crankshatt rear oil seal - remove 1. Remove 5 bolts securing rear oil seal housing to cylinder block, remove and discard housing and oil seal NOTE: Dowel located, ensure dowels are retained in cylinder block. 1. Suitably mark cylinder reference number on each big-end bearing cap, noting that tapered portion of machined fiat on each cap faces towards front of engine. 2. Remove 2 nuts securing each big-end bearing ‘cap, remove caps and recover big-end bearing shells CAUTION: Keep nuts and bearing caps in their fitted order. Big-end bearing shells should always be replaced whenev crankshaft is removed. 3. Slide suitable lengths of plastic tubing over threads of connecting rod bolts. 4. Push each connecting rod up cylinder bore Lunt connecting rod bolts are clear of ‘crankshaft journals. CAUTION: Ensure connecting rods do not contact oil squirt jets or cylinder bores. 5-92 OVERHAULENGINE Crankshaft end-float - check 12M1962 1. Attach a magneti block, move crankshaft rearwards, po ‘on end of crankshaft and zero OTT 2, Move crankshaft forwards, measure and record ‘end float figure obtained. End-float = 0.03 to 0.26 mm (0.001 to 0.010 in). 3. Mend-flost exceeds above dimension, new thrust washers must be fitted. ‘Thrust washer thickness = 2.31 to 2.36 mm (0.0909 10 0.0929 in). *DTE: Dial Test Indicator Crankshaft - remove 1. Check that identification marks are etched on. ‘each main bearing cap, it necessary, number Caps 1 to § from front of engine and indicate fitted direction. 2. Starting at centre main - No. 3 main bearing cap and working outwards, progressively slacken, then remove 2 bolts securing each cap. CAUTION: Keep bolts in their fitted order. A 3. Using fingers only, rock each main bearing cap until itis released from locating dowels. A CAUTION: Do not tap caps sideways. 4, Remove main bearing caps and plain bearing shells. 5. Using assistance, remove crankshaft 6. Recover upper, grooved main bearing shells and 2 thrust washers, 7. Remove sealant from front - No.1 main bearing cap and cylinder block. OVERHAUL 5.93ENGINE Crankshaft - inspection 1. Clean crankshaft, ensure all oilways are clear. ravere7 2. Check crankshaft journals for wear and ovality, make three checks at 120° intervals in centre of journals. Crankshaft bearing journal diameters: Main bearings = 60.703 to 60.719 mm (2.3899 to 2.3905 in. Big-end bearings = 57.683 to 57.696 mm (2.2710 to 22718 in) Clearance in bearings = + 0.005 min (0.0002 in} CAUTION: Crankehatt journals may not be Dy Same Seana oanas may et water besa se ne ere aint oe Sreekd cheers be saced eee ne sgl alway be 3. Check thrust washers for wear and scoring, replace as necessary. ‘Thrust washer thickness: 0 0.0928 in} 21 to 2:36 mm (0.0908 Crankshatt - refit CAUTION: If crankshaft end-float exceed- ed 0.26 mm (0.010 in), now thrust washers must be fitted. 1. Clean main bearing shell locations in cylinder block, clean main bearing caps. 2. Check that ring dowels are fitted in main bearing cap locations and that bolt holes are ‘clean and dry. 3. Check threads of main bearing cap bolts for damage, renew bolts in pairs, 4. Lubricate new upper main bearing shells with engine oil and ensuring that they are centrally Positioned, fit to their locations in cylinder block. NOTE: These bearing shells are grooved. Lubricate thrust washers with engine oil and fi. il groove side outwards to each side of centre = No. 3 main bearing in cylinder block 6. Lubricate crankshaft journals with engine oil and using assistance, position crankshaft in cylinder block. CAUTION: Ensure thrust washers are not displaced as crankshaft is fitted, 7. Lubricate new main bearing shells with engine oil and fit to main bearing caps. shelis are plain. NOTE: These be: 8. Fit main bearing caps ensuring that they are the correct way round and in their fitted order. CAUTION: Do not apply sealant to grooves in front - No.1 main bearing cap until immediately before sump is fitted. 5.94 OVERHAUL9, Lubricate threads of main bearing cap bolts with ‘engine oil fit and finger tighten bolts. 10. Starting from the centre - No. 3 main bearing cap and working outwards, tighten bolts to 112 Nm (11.4 kgtim, 82.5 tet 11. Check that crankshaft rotates smoothly. 12, Recheck crankshatt end-float. See this section. CALTION: Hf xia hr sbors hve AN, Soonvated and cnation oroseds 00 Cera essmruerasrnees ann nen tn neces Wa stn ne Gum wachors tes on ton eV ancesive, Seer nen cree ENGINE Crankshaft rear oil seal - refit CAUTION: Rear oil seal and housing must be fitted prior to fitting sump. 1. Ensure oil seal running surfaces on crankshaft and cil seal housing mating surface on cylinder block are clean and oil free and that bolt and dowel holes are clean and dry, CAUTION: The oil seal is pre-lubricated at ‘manufacture. Do not lubricate oil seal or running surface on crankshaft. Do not ‘separate protector sleeve from oil seal and do not touch lip of seal. If seal is inadvertently handled it must not be fitted as the coating applied to the seal during manufacture will be destroyed and oil leakage can result. 2. Slide oll seal protector sleeve, oil seal and housing over end of crankshaft 3. Position oil seal and housing on cylinder block. NOTE: Oil seal protector will be displaced Z\, as soat and housing aro fitted. 4, Fit bolts and working in sequence shown, tighten to 8Nem (0.8 kam, 6 IDF OVERHAUL 5.95ENGINE oy 123390 5 5. Apply a 1 mm (0.039 in) thick bead of sealant from kit, Part Number GUG 705548 GM along joint fine of seal housing, rear main bearing cap and cylin der block CAUTION: Do not apply sealant until immediately prior to fitting sump. Do not spread sealant bead. |. Rotate crankshaft unt big-end bearing journals are correctly positioned, . Lubricate crankshaft big-end journals with engine oil 3. Fit new big-end bearing shells to connecting rods, lubricate shells with engine oil Taking care not to damage oil squit jets or to displace bearing shells, pull connecting rods on, to crankshaft journals, 3. Type ’A’ engine: Remove plastic sleeves from connecting rod bolts, Check that new big-end bearing shells are correctly located on big-end bearing caps, lubricate shells with engine oi. Fit big-end bearing caps ensuring that they are in their correct fitted order, and that on Type ‘A engines, the tapered portion of machined fat ‘on each cap is facing towards front of engine. For the Type B’ engine ensure the identification marks on the connecting rod and bearing cap are on the same side. Type ‘A’ engine: Lubricate threads of connecting rod bolts with engine oil. Fit nuts to their respoc- tive connecting rods and tighten to 48 Nem (4.9 kom, 35 IDF. Type ’B” engine: Lubricate threads and fit bolts to their respective connecting rods and tighten to 20 ‘Nem (2.0 kgm, 14 tbEtt) then a further 85°, 5-96 OVERHAULENGINE yee2e]] PISTONS, CONNECTING RODS AND CYLINDER Piston rings - remove BORES 1. Using a suitable expander, remove old piston Pistons and connecting rods - remove rings. 2. Use a squared off end of a broken piston ring to clean groove in piston 1. Remove crankshatt. See this section. CAUTION: Do not use a wire brush or By Seay etn 12Mi968 2. Remove banjo bolts securing oil squirt jets to cylinder block, remove jets. 12M1966 NOTE: Each jet is located by means of a roll pin. 3. Check new ring to groove clearance. 3, ‘Suitably identity each piston and comecting ‘Top compression = 0.115 to 0.135 mm (0.00453 to rod assembly to its respective cylinder bore. 0.00531 inh 4, Using assistance, lay cylinder block on its side. Beal psmpenaslon 1 0.065 to 0,602 (6.0020 to 0.0002 '5. Check that plastic tubes are still on connecting in rod bolts. Oil control = 0.050 to 0.082 mm (0.0020 to 0.0032 6. Push each piston and connecting rod up cylinder bore taking care to keep connecting rod clear of bore walls; remove pistons and connecting rods. 7. Recover big-end bearing shells from ‘connecting rods, 12M2108 4. Check new ring fitted gap 30 mm from top of oylin- der bore, ensure rings are kept square to bore when checking gaps. Fitted gap: Top compressio 0.011 in) 2nd compression = 0.40 to 0.42 mm (0.016 to 0.017 in) il contro! rai in. 0.25 10 0.27 mm (0.0098 to 0.30 t0 0.32 mm (0.012 to 0.013, OVERHAUL 5.97ENGINE Pistons-remove 1. Type ‘A’ engine: Suitably identity each piston to its connecting rod, note position of bearing shell tag recess in connecting rod relative to arrow on piston crown. Type 8 engine: Suitably identity each piston to its connecting rod nating the position of the cast boss on the connecting rod relative to the arrow on piston crown, 12Maie7 2. Remove and discard circlips securing gudgeon pin, 3, Push qudgeon pin out of piston and connecting rod. CAUTION: Keep gudgeon pins with their respective pistons. Pistons and connecting rods - inspection 41. Clean carbon from pistons using fine emery cloth, do not use a wire brush oF scraper 2. Check pistons for cracks, distortion and damage, 12M2140 3, Measure and record piston diameter at right angles to gudgeon pin hole and 48 mm (7.73 in) from bottom of skirt Diameter ~ 84.262 mm (3.3174 in) CAUTION: Measurement point must be on the ungraphited area of the piston. 5.98 OVERHAUL12M21294, 4, Starting with Number 1 piston, invert piston and with arrow on piston crown pointing towards REAR of cylinder block, insert piston into top of Number 1 cylinder bore. 5, Position piston with bottom of skirt 25 mm (0.98 in) from top of cylinder bore. 6, Using feeler gauges, measure and record clear- ance betwoen piston skirt and left hand side of ‘evlinder bore 70 mm (2.75 in} from top of bore (viewed from front of cylinder block) Piston to cylinder bore clearance = 0.18 to 0.2 mm {0.0071 to 0.008 in), 7. Repeat procedures for remaining pistons. CAUTION: Oversize pistons are not available, if clearaces are excessive, measure diameter of cylinder bore before proceeding further. If, after inspection, cylinder bores are found to be the correct size, pistons must be replaced. ENGINE [y2ee?]) 8, Check ft of each gudgeon pin in its respective piston, pin must be a tight, sliding fit with no perceptible side play. ¥ ¥ s t s2wat12 9. Measure gudgeon pin diameter at each end and contre of pin: Diameter = 29.995 to 30.000 mm (1.1809 to 1.1811 in) 10, Renew gudgeon pins and pistons as an assembly if diameters are loss than specified or if excessive pin to piston side play is evident. 11. Check connecting rods for alignment, reject any connecting rod which is bent, 12, Check small-ond bushes for wear, check that gud geon pin isa close, sliding fit in the bush with no perceptible side play. CAUTION: Small-end bushes may not be repalced, a new connecting rod must he fitted 13, Type ‘A’ engine: Using fingers only, check that each big-end bearing cap nut runs freely on the. threads of its respective dowel bolt. any nut is tight, then both bolts and nuts from that connect ing cod must be replaced. Retain nuts with their respective bolts. Type ‘8’ engine: Check that each big-end bearing cap bolt turns freely in the connecting rod, if there is any sign of binding on the threads, the bolts ‘must be repalced. OVERHAUL 5.99ENGINE Pistons - refit 1. Lubricate gudgeon pin and smail-end bush with engine oil. 2. Position piston to its respective connecting rod ‘ensuring that bearing shell tag recess in connecting rod is to the left of the arrow on the piston crown when piston is viewed from the rear, 3. Fit gudgeon pin, fit new circlips ensuring they are fully seated in their grooves. 4, Repeat above procedures for remaining pistons. Piston rings - refit vers Fit oil controt rails and spring . Fit 2nd compression ring with "TOP" marking upwards. 3. Fit top compression ring with TOP’ marking upwards. |. Check that rings are free to rotate, position ring {gaps at 120 “to each other and away from thrust side of piston, Check ring fitted gaps: 0.30 to 0.50 (0.012 to 0.020 in). 40 to 0.60 mm (0.016 to 0.024 il control = 0.25 to 0.50 mm (0.0088 10 0.020 in} 6-100 OVERHAULENGINE joa) Cylinder bores - inspection 1. Check cylinder bores for scoring 2. Check cylinder bores for wear, measure and record diameter of each bore, 30 mm (0.12 in) from top of. bor CAUTION: Measurements must be taken LY from side to side and front to rear of bore. Bore amet in) CAUTION: No rebori busting of cylinder bores is permi cylinder block must be replaced. 84.442 to 84.460 mm (3.3245 to 3.3252 1 honing or glaze te; Cylinder block 1. Check that all oilways are clear and that oil restrictor located in oilway to cylinder head is fitted below face of cylinder block. 2. Check that main bearing cap, crankshaft rear oil seal housing and cylinder head locating dowels are fitted 3. Check core plugs for leakage and corrosion, replace as necessary. NOTE: Seal replacement core plugs and main oil gallery plug on rear of cylinder block with Loctite 572, tighten main oil gallery plug to 8 Nem (0.8 kgfm, 6 Ibft). OVERHAUL 5-101ENGINE Pistons and connecting rods - refit 1. Lubricate cylinder bores, pistons, rings and crankshaft big-end journals with engine oil 2. Lubricate new big-end bearing shells with ‘engine oil and fit to connecting rods and, bearing caps. 3. Ensure arrows on big-end bolts are facing away from connecting rods. 4, Slide suitable lengths of plastic tubing over threads of connecting rod bolts. 5. Check that piston ring gaps are positioned at 120 “to each other and away from thrust side of piston. 6, Fitring clamp 18GSSA to each piston in turn and ensuring that pistons are in their correct fitted order and that arrow on piston crown is facing towards front of engine, push pistons into their respective cylinder bores. 10. " 2 CAUTION: Ensure that connecting rods do not contact cylinder bores. . Do not pull connecting rods fully down cylinder bores at this stage. Check that cut-out in each piston skirt is positioned above oil squirt jet location Ensure oil squir jets are clear and that roll pins are inserted in jet housings. Clean all traces of Loctite trom threads of banjo bolts Position oil squir jets in cylinder block ensuring that roll pins are inserted in locating holes. Apply Loctite 275 to threads of banjo bolts. CAUTION: Do not allow Loctite to enter oll ZN fein anyone 14, Fit banjo bolts and tighten to 12 Nem (1.2 kgm, 87 Ite Fit crankshaft and big-end bearings. See this sec- tion, 5-102 OVERHAULENGINE [picese] ENGINE DATA. it pump Outer rotor to body clearance Rotor lobe clearance .. Outer rotor end float. Relief valve spring free length 0.05 t0 0.10 mm (0.002 to 0,0039 in} (0.025 to 0.12 mm (0.0010 to 0.0047 in) 0.03 to 0.08 mm {0,001 to 0.003 in) 41.83 mm (1,649 in) Camshaft Camshaft end-float 0.51 mm (0.020 in) - max. Camshaft bearing clearance 0.043 to 0.094 mm (0.0017 to 0.0037 i Camshaft timing bolt tensioner spring free length 65 mm i26 in) Tappets Tappet outside diame 34.959 to 34.975 mm (1.3763 to 1.3770 in) Cylinder head Cylinder head maximum warpage 0.010 mm (0.00039 in) Cylinder head bolt length noes 243.41 mm (8.5831 in) Valve springs Free length 37.9 mmm (1.48 in} Valves Valve stem diameter: Inlet « 6.907 to 6.823 mm (0.2719 to 0.2726 in) Exhaust 6.897 to 6.913 mm (0.2718 t0 0.2722 in) Valve stem to guide clearance: Inlet Exhaust Valve face angie. 0.056 mm (0.0022 in) 0.066 mm (0.0026 in) 45° to 45°30" Inlet... 1.48 men (0.0571 in) Exhaust 1.35 mm (0.0531 in) Valve guides: Inside diameter after reaming smn: 6.960 t0 6.963 min {0.2736 to 0.2741 in) Fitted length above cylinder head ean. 61.1 10 61.7 mm (2.41 to 2.48 in) Valve seat inserts: Seat angle Inlet 60° Exhaust 58° to 62" Insert diameter Inlet se sone, 98,687 men (1.4054 in} Exhaust 31.05 to 31.55 mm (1.222 to 1.242 in) DATA,TORQUE & TOOLS 5.103ENGINE Crankshaft End-float Thrust washer halves Main journal diameter Clearance in bearings Big-end journal diameter Clearance in bearings 0.03 to 0.26 mm (0.001 to 0.010 in) 2.31 to 2.36 mm {0.0808 to 0.0929 in) {60.703 to 60.719 mm (2.3899 to 2.3905 in) 0.005 mm (0.0002 in) 57.683 to 57.696 mm (2.2710 to 2.2718 in) +£ 0.005 mm (0.0002 in) Piston rings New ring to groove clearance: Top compression . 2nd compression ... Oil control ... ).11 to 0.135 mm (0.00453 to 0.00531 in} 0.050 to 0.082 mm (0,0020 to 0.0032 in) 0.080 to 0.082 mm (0.0020 to 0.0032 in) Ring fed gap 30 mm (1.2 in} from top of cylinder bor: ‘Top compression 0.25 to 0.27 mm (0.0098 to 0.011 in) 2nd compression ... 0.40 to 0.42 mm (0.016 to 0.017 in) Oil contro! rails 0.30 to 0.32 mm (0.012 to 0.013 in} Pistons Piston diameter Clearance in bore 84.262 mm (3.3174 in) 0.18 to 0.2 mm (0.0071 to 0.008 in) Cylinder block Cylinder bore... . 84,442 to 84.460 mm {3.3245 to 3.3252 in) 5-104 DATA, TORQUE & TOOLSENGINE presse} ‘TORQUE FIGURES 5Nm (0.5 kgm, 4 IbFft) 5 Nm (0.5 kgtm, 4 bff) 8Nm (0.8 kgf, 6 Ibf fe) BN (0.8 kafim, 6 IbFft) 45 Nem (4.6 kgm, 33 IDF) 55 Nom (5.6 kgtm, 41 loft) 1 45 Nem (4.6 kgf, 33 bf) 12.Nem (1.2 kgf, 8.9 IDF) 35 Nem (3.6 kgtm, 26 IDF ft) ~ 45 Nem (4.6 kgm, 33 IbFft) 63 Nem (6.4 kgm, 46 Ibfft) + 90° Camshaft timing bolt top cover screws ‘Camshaft timing belt bottom cover screws Camshaft timing belt top backplate screws Camshaft timing belt bottom backplate screws. ‘Camshaft timing belt tensioner bolt ‘Camshaft timing belt Allen screw ... Camshaft timing belt idler pulley nut Idler pulley stud Engine front mounting cover plate nuts Engine front mounting cover pat ots Crankshaft pulley bolt i! pump bolts - Patchlok Ms se wo Thermostat valve veer ug il pressure switch Oil pick-up pipe bolts - Patchiok Fuel injection pump drive belt backplate screws Camshaft timing belt gear bolt Fue! injection pump drive belt gear bolt Camshaft cover bolts Camshaft carrier to cylinder head bolts Cylinder head Torx bolts, +: 8 Nem (0.8 kom, 6 bff) - 45 Nm (4.6 kgf, 33 bff) 35 Nem (3.6 kgm, 26 Ibt) 16 Nem (1.6 kgf, 12 loft) 8m (0.8 kgm, 6 IDF) 81Nim (0.8 kgm, 6 bff) 20 Nem (2.0 kgm, 14 IDFA) + 90° v= 20 Nem (2.0 kgfim, 14 IbFft) + 90° 12Nam (1.2 kghm, 89 bff) vw 11/Nem (1.1 kgf, 8 bf) Stage 1 1 30 Nem (3.1 kgm, 22 lbFft) Stage 2 85 Nem (6.6 kgf, 48 Ibe) Stage 3 Further 80° Stage 4 « ~- Then further 80° Flywheel bolts - Petchtok w= 15 Nem (1.5 kgfem, 11 IDF) + 90° Gearbox adaptor plate Torx s¢T@WS -nrvnnnarnenenen 45 Nem (4.6 kgf, 33 bE Crankshaft sensor to adaptor plate screws BN (0.8 kgm, 6 loth) Oil sump bolts ss 25 Nem (2.5 kgtm, 18 IDF) il sump drain plug - “25 Nem (2.5 kgm, 18 IDF) Main bearing cap bolts sous 112.Nem (11.4 kghem, 82 Ib) Connecting rod cap nuts vo 48 Nem (4.9 kgf, 35 IDEA) Connecting rod bots .. 20 Nem (2.0 kgm, 14 IDE) + 85° Crankshaft ear oil seal housing screws. 1 8 Nem (0.8 kgm, 6 IbFft) Oil squirt jet banjo bolts n 1 12.Nem (1.2 kgm, 8.9 IDFA) Main oil gallery plug... 12 Nm (1.2 kgf, 89 Ib) DATA, TORQUE & TOOLS 5-105ENGINE TOOL NUMBERS: 186 55A Piston Ring Clamp 18G 1503 Replacer - Crankshaft Oil Seal 18G 1510 it Seal Protection Sleeve 18G 1510-1 ‘Adaptor Sleeve 18G 1519 Valve Spring Compressor 18G 1521 Timing Gear Holding Too! 18G 1523 Timing Pin 186 1577 Valve Stem Oil Seal Remover/replacer 18G 1716 Replacer - Camshaft Oil Seals 18G 1719 Camshaft Timing Belt Tensioner Retractor — 5-106 DATA, TORQUE & TOOLSMANIFOLD AND EXHAUST CONTENTS. Page DESCRIPTION AND OPERATION INLET MANIFOLD EXHAUST MANIFOLD EXHAUST SYSTEM EXHAUST PIPE INLET AND EXHAUST MANIFOLD REPAIRS, FRONT PIPE . o INTERMEDIATE PIPE TAIL PIPE FRONT PIPE TO MANIFOLD GASKET. FUEL TANK HEAT SHIELD ewnsvnrsnnnses INLET AND EXHAUST MANIFOLD GASKET...... ‘Outline of Model ChangeMANIFOLD AND EXHAUST Pali INLET MANIFOLD. ‘The inlet manifold is manufactured from aluminium, alloy and the gasket is @ multi-leaf type which also seals the exhaust manifold. On vehicles fitted with an intercooler, an intake air tem- perature sensor is located at the timing belt end to ‘measure the temperature of the boosted air supply. EXHAUST MANIFOLD The cast iron exhaust manifold carries an EGR valve and a variable wastegate Garrett turbocharger. ‘There are two tappings on the compressor housing; the 'N’ port to the wastegate and the ‘J’ port to the boost pressure sensor on the bulkhead. NOTE: Gaskets are NOT fitted between the manifold to turbocharger joint or between the turbocharger to exhaust outlet pipe joint. EXHAUST SYSTEM ‘The exhaust system consists ofa front pipe, catalytic converter, intermediate pipe and tail pipe assembly which contains a large capacity silencer. ‘The front pipe consists of a single constant diameter pipe with integral flexible joint. {All the silencers contain a series of expansion cham- bers, resonators and baffles designed to give an improved exhaust system, which reduces condensation increases the life of the system. DESCRIPTION AND OPERATION 9-1MANIFOLD AND EXHAUST EXHAUST PIPE 30Mogas 1. Bolt, heat shield - 4 off 6. Catalytic converter 2. Heat shield 7. Flange nut - 12 oH 3. Mounting rubber - § off 8. Exhaust front pipe 4. Exhaust tail pipe 9. Exhaust intermediate pipe 5. Gasket - 3 off - pipe flange 9-2 DESCRIPTION AND OPERATIONMANIFOLD AND EXHAUST INLET AND EXHAUST MANIFOLD Flange nut, inlevexhaust manifold Inlet manifold Gasket, inlet manifold to turbocharger adaptor Bolt, inlet manifold to turbocharger adaptor Inlet manifold to turbocharger adaptor 5. Bolt, exhaust manifold to EGR pipe 7. Stud, inlevexnaust manifold to cylinder head 8. Exhaust manifold 9. Gasket, inleexhaust manifold }0. Flange bolt and piain washer, inleexhaust manifold DESCRIPTION AND OPERATION 9.3.MANIFOLD AND EXHAUST —_ FRONT PIPE INTERMEDIATE PIPE Service repair no - 30.10.09 Remove 1. Raise vehicle on 4 post ramp. 2, Remove underbelly panel. See BODY, Exterior fittings section. 30M0348 3, Remove 3 flange nuts securing front pipe to catalytic converter 4, Release mounting rubber from pipe bracket 5. Remove 3 flange nuts securing front pipe to manifold 6, Release front pipe trom manifold and remove {om catalytic converter. 7. Remove flange gaskets. Refit 41. Clean pipe flanges. 2. Fit new gasket to catalytic converter flange. 3. Fit front pipe to catalytic converter, fit nuts but DO NOT tighten. 4, Fit new gasket to manifold flange. 5. Raise tront pipe and engage flange. 8. Fit manifold to front pipe flange nuts and tighten to 45 Nm (4.6 kgfm, 33 Ibftt), 7, Tighten flange nuts securing front pipe to catalytic converter to 22 Nem (2.2 kgfm, 16 Ibfft) 8. Connect rubber mounting to front pipe bracket. 9. Fit underbelly panel. See BODY, Exterior fittings section. 10, Lower vehicle. Service repair no - 30.10.11 Remove 1. Raise vehicle on 4 post ramp. ae 2. Remove 3 nuts securing tail pipe to intermediate pipe. 3, Remove 3 nuts securing intermediate pipe to catalytic converter. 4, Release intermediate pipe from catalytic converter. Remove and discard gasket 5. Release 2 rubber mountings from intermediate pipe. 6, Release and remove intermediate pipe. 7. Remove and discard gasket from tail pipe flange end of intermediate pipe. REPAIRS 9.5MANIFOLD AND EXHAUST Retit 1. Clean mating faces of intermediate pipe, catalytic converter and tail pipe. 2, Fit new gaskets to tail pipe flange end of intermediate pipe and catalytic converter flange. 3. Fit intermediate pipe to tail pipe, align and connect to catalytic converter flange. Fit nuts and tighten intermediate pipe flange nuts to 34 Nem (3.5 kgm, 25 Ibtt) and tall pipe flange nuts to 45 Nem (4.6 kgf, 33 Ibft). 4. Connect mounting rubbers. 5. Lower vehicle, TAIL PIPE Service repair no - 30.10.22 Remove 1. Raise vehicle on 4 post ramp. 3oMo3s0 2 2. Remove 3 nuts securing intermediate pipe to tail pipe. 3. Release 3 rubber mountings from tail pipe. 4, Remove tal pipe. 5. Remove and discard gasket. Clean intermediate pipe and. 1 ipe mating faces. 2. Fitnew gasket to intermediate pipe flange studs. 3. Fit tail pipe and connect rubber mountings. 4. Fit nuts to flange and tighten to 45 Nem (4.6 kgtm, 33 Ib) 5. Lower vehicle 9.6 REPAIRSMANIFOLD AND EXHAUST FRONT PIPE TO MANIFOLD GASKET FUEL TANK HEAT SHIELD Service repair no - 30.10.26 Service repair no - 30.10.63 Remove 1. Raise vehicle on 4 post ramp. 41, Raise vehicle on 4 post ramp. 2. Remove underbelly panel. See BODY, Exterior fittings section. 30M0351 3. Remove 3 flange nuts securing front pipe to manifold ‘4, Release front pipe from manifold 5. Remove gasket from manifold flange. Refit 1. Clean manifold and front pipe flanges. 2. Fit new gasket to manifold flange. 3. Position front pipe to manifold and fit and tighten bolts to 45 Nem (4.6 kgm, 33 IbFtt). 4. Fit underbelly panel. See BODY, Exteric tings section. fit. somoas2 2 2. Release exhaust tail pipe and intermediate pipe from mounting rubbers. 3. Remove 4 bolts securing exhaust heat shield to body. 4, Remove heat shield 1. Fitheat shield and tighten bolts to 10 Nem (1.0 kgtm, 7.2 bt. 2. Raise exhaust pipe into position and connect rub- ber mountings. 3. Lower vehicle. REPAIRS 9-7MANIFOLD AND EXHAUST INLET AND EXHAUST MANIFOLD GASKET Service repair no - 30.15.15 Remove 1. Disconnect battery earth lead. 2. Remove underbelly panel, See BODY, Exterior fittings section. 3. Remove engine acoustic cover. See BODY, Exterior fittings section. ‘4. Remove ait cleaner, See ENGINE MANAGEMENT SYSTEM - EDC, Repairs section. 30M0353, 5. Slacken clip and disconnect breather hose {rom camshaft cover. 6. Disconnect muttiplug from MAF sensor. 7. Stacken clip and disconnect air intake pipe from turbocharger, remove air intake pipe assembly. soMo3s¢ ‘8. Remove banjo bolt securing oil feed pipe to turbocharger, collect 2 sealing washers, 9. Disconnect boost pressure sensing pipe from turbocharger. 10 30M0355 10. Disconnect vacuum pipe from EGR valve, 11. Remove 2 Allen screws securing EGR valve to inlet manifol. 12. Remove 2 bolts securing EGR vaive recirculation pipe to exhaust manifold 13. Release and remove EGR valve, 14. Remove and discard 2 gaskets. 9-8 REPAIRSMANIFOLD AND EXHAUST 15, 16. 7. 18. 18, s0Mo3s6 Remove 3 nuts securing exhaust front pipe to exhaust manifold Release exhaust front pipe from exhaust manifold, remove and discard manifold flange gasket Remove 2 bolts securing oil drain pipe flange to turbocharger. Remove and discard gasket Remove 2 bolts securing exhaust manifold to ‘mounting bracket 20. 21. 2. 23. 24. 30M03S7 Slacken the 6 bolts and 6 nuts securing inlet manifold and the exhaust manifold to cylinder head, Remove 6 bolts securing exhaust manifold to oylinder head, collect 4 washers. Remove 6 nuts securing exhaust manifold to cylinder head. Release and remove manifolds and turbocharger assembly. Remove and discard manifold gasket, REPAIRS 9.9MANIFOLD AND EXHAUST Refit Clean mating faces of manifold and cylinder head. 2. Fit new manifold gasket. 0. 1" 2 Clean mating faces of exhaust manifold and exhaust front pipe. Fit manifold flange gasket. ‘Manoeuvre manifold and turbocharger assembly into position and align to eylinder head. Fit nuts, bolts and washers securing manifold to cylinder head. Working in the sequence illustrated tighten mai fold nuts and bolts to 25 Nem (2.6 kgm, 19 [bt Fit2 bolts securing exhaust manifold to mounting bracket. Clean mating faces of oll drain pips bocharger. Fit new gasket to turbocharger oil drain pipe. ‘Align pipe to turbocharger, fit bolts and tighten to 25 Nm (2.6 kgm, 19 IbFt) 7p exhaust front pipe to exhaust manifold. Fit 3 nuts and tighten to 45 Nem (4.6 kgf, 33 Ife. Clean mating faces of EGR valve, inlot manifold ‘and exhaust manifold, ‘new gaskets to EGR valve and recirculation pipe. ind tur 1“ 6 6 W. 19 20. a. 2. 23, 28 25, Align EGR valve and recirculation pipe to inlet and exhaust manifolds. Fit2 bolts securing EGR valve recirculation pipe to exhaust manifold and tighten to 9 Nem (0.9 kgtm, es wtf. Fit2 Allen bolts securing EGR valve to inlet mani- fold and tighten to 25 Nem (2.6 kgtm, 19 Ibf-ft). Connect vacuum pipe from EGR solenoid to EGR valve. Connect boost pressure sensing pipe to tur- bocharger. Clean turbocharger oil feed pipe union and banjo bot. Fit new sealing washers to banjo bolt. Connect oil feed pipe to turbocharger and tighten union to 20 Nem (2.0 kgm, 14 IbFt) Position air intake pipe and connect to turboct er, tighten clip to secure. Connect muttiplug to MAF sensor. Connect breather hose to camshaft cover and, tighten clip Fit ale cleaner. See ENGINE MANAGEMENT SYS- TEM - EDC, Repairs section. Fit engine acoustic cover. See BODY, Exterior fit- tings section. Fit underbelly par ‘section. Connect battery earth lead. |. See BODY, Exterior fittings 9-10 REPAIRSCOOLING CONTENTS Page DESCRIPTION AND OPERATION COOLING SYSTEM COMPONENTS 10-41 COOLING SYSTEM OPERATION 102 ADJUSTMENTS. DRAIN AND REFILL 105 REPAIRS. RADIATOR COOLING FAN 10-7 FAN AND MOTOR UNIT RH - WITH AIR CONDITIONING 107 RADIATOR. - 108 RADIATOR WITH AIR CONDITIONING .. 109 ‘THERMOSTAT yo-10 COOLANT PUMP. 10-10 COOLANT PUMP WITH AIR CONDITIONING ... 10-12 Outline of Model ChangeCOOLING SYSTEM COMPONENTS 41. Expansion tank 2. Expansion tank to coolant rail 3. Hose - heater valve to heater 4. Coolant rail 8. Bottom hose 8. Radiator 7. Cooling fan and cow! 8. Hose - coolant pump to thermostat housing COOLING 9. Coolant pump 1. Cootant expansion pipe 14, Heater temperature control valve 12, Hose - engine to heater valve 13. Hose - oll cooler to thermostat housing 14, Thermostat housing 15, Pipe - expansion pipe to radiator 16. Top hose DESCRIPTION AND OPERATION 10-1COOLING COOLING SYSTEM OPERATION 260297 ‘The cooling system employed is the bypass type. When the engine is cold the thermostat closes off the coolant feed from the radiator bottom hose (). Coolant is drawn via the heater matrix (2) from the top of the cylinder block, this allows some heat transfer to the radiator via the top hose by ‘convection while retaining the majority of the heat within the cylinder block ‘The siting of the thermostat (3) nthe inlet rather than the outlet side of the system provides a reduced warm up time by circulating a smat! amount of coolant around a shorter tract, this also prevents temperature build up within the cylinder head prior to the thermostat opening A=HOT = B=COLD ‘As temperature increases the thermostat gradually ‘opens, bleeding coo! fluid into the cylinder block and allowing hot coolant to flow to the radiator via the top hose (4), balancing the flow of hot and cold fluid to maintain temperature. As the thermostat opens further so the full flow of coolant is drawn through the radiator. Any excess coolant created by heat expansion is. returned to the expansion tank (5) via hose (6). ‘The radiator (7) s a copperibrass cross-flow type with moulded plastic end tanks which incorporate ‘sensor mountings and is mounted on rubber bushes directly into the front body member. The top of the radiator is supported by means of mounting brackets bolted to the radiator and bonnet locking platform. 10-2 DESCRIPTION AND OPERATIONFor additional airflow, at times when the vehicle is st tionary, an electric cooling fan is fitted. This is tri ‘gered by the Engine Contra! Module (ECM). ‘The coolant pump (8) is @ rotor type pump which draws coolant directly from the thermostat. The pump is dri: ‘ven by a geared pulley from the camshatt timing belt. COOLING DESCRIPTION AND OPERATION 10.3COOLING MEMO 10-4 ADJUSTMENTSDRAIN AND REFILL Service repair no - 26.10.01 WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the pressure reliet cap from the expansion tank while system is hot. ait until system has cooled, use a cloth or gloves to protect hands from escaping steam. Drain, 1. Visually check engine and cooling system for signs of coolant leaks. 2. Examine hoses for signs of cracking, distortion and security of connections. 3. Remove underbelly panel. See BODY, Exterior fittings section. 4, Position heater temperature control to ‘maximum hot position. 26M0295 5. Remove expansion tank filler cap. 8. Position drain tin to collect coolant COOLING ‘26M0296 7. Loosen clip and disconnect bottom hose from radiator. 8. Allow cooling system to drain. Refill 1, Flush system with water under low pressure. CAUTION: High pressure water could damage the radiator. 2. Connect bottom hose to radiator and tighten, ip. 3. Prepare coolant to required concentration. capacities, fluids and lubricants 4. Position heater temperature control to ‘maximum hot position 5. Fill system siowly through coolant expansion tank, until the coolant reaches the ‘MAX’ mark (on expansion tank 6. Fit expansion tank filler cap. 7. Fit underbelly panel. See BODY, Exterior fittings section. ‘8, Start and run engine until radiator cooling fan operates. If fitted DO NOT operate air conditioning. 8. Switch off engine and allow to cool 10, Check for leaks and top-up coolant to 'MAX’ ‘mark on expansion tank. ADJUSTMENTS 10.5COOLING MEMO. 10-6 ADJUSTMENTSRADIATOR COOLING FAN Service repair no - 26.25.22 Remove 1. Disconnect battery earth lead. 26M0301 2. Disconnect mutiplug from radiator cooting fan 3, Remove 2 nuts securing top of cooling fan housing to radiator. 4, Release cooling fan housing from stud on radiator. 5. Manoeuvre cooling fan housing around radiator top hose and remove from vehicle Refit 11. Manoeuvre cooling fan housing around radiator top hose and into position on radiator stud. 2. Fitts securing cooling fan housing to radiator ‘and tighten to 9 Nm (0.9 kgfm, 6.6 Ib. ‘8. Connect multiplug to radiator cooling fan. 4. Connect battery earth lead. COOLING FAN AND MOTOR UNIT RH- WITH AIR CONDITIONING Service repair no - 26.25.34 Remove 1. Disconnect battery earth lead. 2. Remove condenser. See AIR CONDITIONING, Repairs section. 3. Remove tront bumper. See BODY, Exterior fittings section. M0300 4. Disconnect mutpug from radiator cooling fan. 5. Release multplug from cooling fan housing. 6. Remove 3 nuts and washers securing cooling fan to cooling fan housing 7. Remove radiator cooling fan. Refit 1. Fit radiator cooling fan to cooling fan housing, 2. Fit3 nuts securing cooling fan to cooling fan hous ing ond tighten to 9 Nm (0.9 kgf, 6.6 Ibt ft 3. Connect mutiplug to cooling fan housing 4, Connect mutipug to radiator cooling fan 5. Fit ont bumper. See BODY, Exterior fitings section. Fit condenser. See AIR CONDITIONING, Repairs section. 7. Connect battery earth lead REPAIRS 10.7COOLING RADIATOR Service repair no - 26.40.01 Remove 1. Drain cooling system, See Adjustments section, 2. Remove radiator cooling fan. See this section. 26M0302 3. Loosen clip securing top hose to radiator. 4, Release top hose from radiator. 5. Remove 2 bolts securing radiator top mounting, brackets to bonnet platform. 6. Remove 2 radiator top mounting brackets. 7. Release radiator from 2 lower mountings. 8. Remove radiator trom vehicle. Do not carry out further dismantling if ‘component is removed for access only. 9. Remove 2 lower mounting rubbers from old radiator. 10. Fit lower mounting rubbers to new radiator. Manoeuvre radiator into position and locate on lower mountings. . Fit top mountings to radiator and align to body . Fit bolts securing radiator to bonnet platform and tighten 9 Nem (0.9 kgfm, 6.6 IbFf). . Connect top hose to radiator and secure with lip, . Fit radiator cooling fan. See this section, Fill cooling system. See Adjustments section. 10-8 REPAIRSRADIATOR WITH AIR CONDITIONING Service repair no - 26.40.01.20 Remove 1. Drain cooling system. See Adjustments section. 2, Remove screws from bonnet platform closing panel and remove panel. ‘3. Loosen clip and disconnect coolant expansion tank. hose from radiator. Loosen clip a Position expansion tank ar Remove 2 bolts securing radiator top mounting rackets to bonnet platform. Remove 2 radiator top mounting brackets. Release radiator from 2 lower mountings. Flemove radiator from vehicle. Do not carry out further dismantling if com- ponent is removed for access only. 10. Remove 2 lower mounting rubbers from old ra tor. 111, Fit lower mounting rubbers to new radiator. disconnect top hose from radiator. 1d top hoses to one side. COOLING ‘Manoeuvre radiator into position and locate on lower mountings. Fit top mountings to radiator and align to body. Fit bolts securing radiator top mountings to bonnet platform Connect top hose to radiator and tighten clip, Connect coolant expansion tank hose to radiator and tighten clip. Fit bonnet platform closing panel and secure with screws, Refill cooling system. See Adjustments section. REPAIRS 10-9COOLING THERMOSTAT Service repair no - 26.45.09 Remove 1, Remove engine acoustic cover. See BODY, Exterior fittings section. 2. Drain cooling system. See Adjustments section. 26M0303 3. Loosen 3 clips and disconnect hoses from thermostat housing Refit 1. Fit thermostat housing 2. Connect hoses to thermostat housing and tighten clips 3, Refi cooling system. See Adjustments section. 4, Fit engine acoustic cover. See BODY, Exterior fittings section. COOLANT PUMP Service repair no - 26.50.01 Remove 1. Remove altemator. See ELECTRICAL, Repairs section. 2. Drain cooling system. See Adjustments section. 3. Slacken clips and release radiator top hose from engine, radiator and thermostat housing. 4, Remove radiator top hose from engine, 10-10 REPAIRSCOOLING Refit |. Clean coolant pump housing and mating faces, 2. Fit’ ring to coolant pump and coolant pump cover. 3, Fit coolant pump and cover. 4 Fit S bolts and tighten to 45 Nim (4.6 kgf-m, 33 let 5. Connect hose to coolant pump housing and tighten clip. 6. Fit top hose to engine and tighten clip 7. Connect top hose to radiator and thermostat hous- ing and tighten clips. 8. Refill cooling system. See Adjustments section. 8. Fit alternator. See ELECTRICAL, Repairs section. 26M0310 '8. Slacken clip and release coolant hose trom pump housing. 6. Remove § bolts securing cover to coolant pump. 7. Remove cover and discard ‘0’ ring 8. Remove coolant pump from housing and discard 'O' ring REPAIRS 10.11COOLING COOLANT PUMP WITH AIR CONDITIONING Service repair no - 26.50.01.20 Remove 1. Remove alternator. See ELECTRICAL, Repairs section. 2, Drain cooling system. See Adjustments section. 3. Slacken clips and release radiator top hose from engine, radiator and thermostat housing, 4, Remove radiator top hose trom engine. 260318 5. Remove 4 bolts 3 nuts and 2 washers from AJC ‘compressor and pivot forwards. 26M0310 . Slacken clip and release coolant hose from ‘pump housing . Remove 5 bolts securing cover to coolant pump. |. Remove cover and discard 0’ ring . Remove coolant pump from housing and discard 'O" ring, Refit 1, Clean coolant pump housing and mating faces. 2. Lubricate new ‘0’ rings with Loctite 405 and fit to coolant pump and cover. 3. Fit coolant pump and cover. 44. Fit 5 bolts and tighten to 45 Nem (4.6 kgfm, 33 Ee) 5. Connect hose to coolant pump housing and tighten lip. 6. Position A/C compressor, fit 4 bolts 3 nuts and 2 to secure. iator top hose to engine and tighten clip. jor top hose to radiator and thermo- stat housing and tighten clips. 9. Refill cooling system. See Adjustmonts section. 10. Fit alternator. See ELECTRICAL, Repairs section. 10-12 REPAIRSFuel and Emis: Special Tools 12 Component Locations Index . se 13 ‘System Description Electrical Connections .. 116 Troubleshooting Troubleshooting Guide 11-10 Troubleshooting Procedures nn... 11-12 How to Read Flowcharts .. 11-17 Diesel Engine Management System System Description ve WB Main Relay 11-20 Engine Control Module Engine Coolant Temperature 1-22 Sensor 11-26 Crankshaft Position Sensor 11-32 Throttle Pedal Position Sensor 11:38 Vehicle Speed Sensor 11-50 Brake Light Switch 11-52 Boost Pressure Sensor .. 11-56 Low Battery Voltage .. Needle Lift Sensor . Fuel Supply System ‘System Troubleshooting Guide ........ 11-76 System Descri 77 Fuel Lines 14-81 Fuel Injectors + 19-82 [ Outline of Model Change 20T2N engine (turbocharger 11-85 11-86 \jection Pump Assembly .. Glow Plug Relay Glow Plugs . Fuel Temperature Sensor Fuel Timing Solenoid 11-98 Fuel Shut-off Solenoid .. 11-100 Fuel Quantity Feedback Sensor 11-104. Fuel Quantity Solenoid 14-112 Intake Air System ‘System Troubleshooting Guide ... ‘System Description oe WANG 19-115, Air Cleaner ... 11-116 Intake Manifold .. W417 Turbocharger 11-118 Mass Air Flow Sensor Intake Air Temperature Sensor 11-120 11-132 Emission Control System System Troubleshooting Guide ‘System Desc! Exhaust Gas Recircul: Solenoid Valve Exhaust Gas Recirculation Valve Oxidation Catalytic Converter Exhaust Gas Recirculation System . Idle Speed Setting 11-138 11-139 we 11-140 11-140 1181 19-142 11-148 th intercooler) has been added.Special Tools netine, | __ Toolamba oesstion | ew | rons ® HO 10042 ‘Test Harness 1 ‘VL-Churchill S| Beco | Rater eSinecor | 11.2Component Locations Index Gtow PLUG RELAY Testing, page 1188 ENGINE CONTROL MODULE (ECM) MAIN RELAY ‘Troubleshooting Procedure, page 11-12 ‘Tosting, page 11-20 ‘Troubleshooting, page 11-22 BOOST PRESSURE SENSOR EXHAUST GAS RECIRCULATION Troubleshooting, page 11-56 (EGR) VALVE Troubleshooting, page 11-142 ‘CRANK RELAY ‘THROTTLE CABLE INTAKE AIR TEMPERATURE (UAT) SENSOR Troubleshooting, page 11-122 ‘CRANKCASE PRESSURE LIMITING VALVE EXHAUST GAS RECIRCULATION. (EGRI CONTROL SOLENOID VALVE ‘Troubleshooting, page 11-142 [MASS AIR FLOW [MAF] SENSOR Troubleshooting, page 11-120, ‘THROTTLE PEDAL, POSITION SENSOR: ‘Troubleshooting, page 11-38 [ENGINE COOLANT TEMPERATURE (ECT) SENSOR Troubleshooting, page 11-26 RADIATOR FAN RELAY UNIT ‘AIR CLEANER (ACL) Replacement, page 11-116 INTERCOOLER (CRANKSHAFT POSITION (CKP) ‘SENSOR Troubleshooting, page 1136 NEEDLE LIFT SENSOR ‘Troubleshooting, page 1-88 ‘TURBOCHARGER Inspection, page 11-118 VEHICLE SPEED SENSOR (VSS), Replacement page 11-118 Troubleshooting, page 11-50 FUEL SHUT.OFF FUELINJECTION PUMP ASSEMBLY SOLENOID VALVE Troubleshooting, page 11-100, Testing, page 1188 Replacement, page 17-87 FUEL TIMING SOLENOID VALVE Troubleshooting, page 17-68 (contd) 13Component Locations Index (cont'd) WNTAKE MANIFOLD IST GAS RECIRCULATION 1OM EXHAUST ALTERNATOR DRIVEN. MANIFOLD EXHAUST GAS RECIRCU- Vacuum PUMP LATION (EGR) CONTROL ‘SOLENOID VALVE ‘Troubleshooting, WwreRcooLeR page 11-142 ToeNawe ess team Scars > Reseonert, bese 8 exaust cas an race TeGNE —MASSAMFLOW BHAUST FECIMCULATION (20m WARNES (Mar enson Wave Mosteshctra Treuesoating, pooe hn VentWeROM —toonaKe oe ie? Scher" Tere Sune5System Description Electrical Connections MASS AIRFLOW CRANKSHAFT ewicte speED. (MAF) SENSOR POSITION SENSOR vss) (cKP) SENSOR NEEDLELIFTSENSOR [| i =) cite ENGINE COOLANT ~ TEMPERATURE - {ecT) SENSOR = —GYD->| - INTAKE AIR af ‘TEMPERATURE f THROTTLE POSITION (TP) SELECTOR LEVER SENSOR A cures Conaxe roa.(Y, | | [Micro LAMP (ML) en Wa) (oe ||, soe ene Teena URE fpeete| MVP | trum wrcaTon EXHAUST GAS [E REGRCULATION exnaueroas (EGR) CONTROL RECIRCULATION (EGR) MECHANICAL FUEL Sclonoid operated valve SOLENOID VALVE Low luc INJECTION PUMP energization itiming device) RELAY VALVESystem Description Electrical Connections 0) EGR CONTROL SOLENOID VALVE -FUELINJECTION PUMP ASSEMBLY FueL TING SOLENOID — 4 SOLENOID ruses: @ Acoarrenv con ® mestowmonvo 200 ® weeew sare @ No. 24 FUEL PUMP) (15) © No.rsBAcKUP LIGHTS (08) © FawrenI0%) (sone ® e100) (sone ® rusenorven (30) @® wrervon vce (75) nthe under-hood fusarlay box ___p Te we swrcn P nivenrennevayobese DATA UNK ‘CONNECTOR FUEL TEMPERATURE SENSOR pone / ECM-A (55°) \ wl” | GOLEGCEL Tare [3s | a6 | 57 TERMINAL LOCATIONSTroubleshooting Troubleshooting Guide £.£$-—A£—$-______________ NOTE: Across each row in the char, the systems that could be sources of a symptom ere ranked in the order they should be inspected starting with @. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column. If inspection shows the system is OK, try the next most likely system @, etc. Pace [sub | ENGNE MANAGEMENT SYSTEN. [__FUEL SUPPLY SYSTEM svsrem ENGR] cranng_| TAROT T T na | NAN coouanr) Saye | TueveD- | venicue | snake | soost | necour | woes rey | ccm | tem. | ,Shnfa,,| ALPost | speeD | uowT leessune) “urr | FUE | ‘Tow ay renacunc| RUG | “Ton | sensoa | swe [senson | senson | UES | sump | censor | 5%" | senson [asemmy SYMETOM waa |i [as [ise | nas [ise aame | ese | eee) a) tne. wRrNCTOR i teoeaTon ce | tomorumson || masrncron | coments | auc SMOKE tL __ | | — — ENGINE! EMITS } WONT | WATE | | START | SMOKE hea bisa) © woar ar ONCE | || oss ronen @/o/® ® |e! ® Toesarronea anor ~ | Gucci | | | | le ssa : an ao | | seine, uneven | | ® ) @ ann en | ® |@ MAXIMUM REVI | TOO HGH T COMPRESSED AIR | LenxeLowns) agen | | | ® 11-10SOP TE RESET eco TT 7 — | OW | ace | [oaausr as] EXRAUST wom | ote | rat, [roe fee ame, | Si | ms | MEST | sey | uno. [momen |e sec | tm fours nmore| EER | Sooo’ | AR) | AR | Tumba | Sian [encod rumen | "ops |soceno1o|sotenow |=] souenono| ATU |sranma} en | Towra | ta | | eon enon stngon | {ee | senson | OLN] senson [Sere | SENSO eed et Teas ee | ee [eae | ino [omar [see [tee [rene | ae | reve | ae 14.41Troubleshooting [- Troubleshooting Proeedyres); Ama a |L_When the Matfunction indicator Lamp (MIL) has been reported on, do the following: a} Procedure with Honda PGM-Tester: Connect the Honda PGM-Tester with the SP Data Link Connector (DLC) located under the dash on the passenger's side of the vehicle. ‘The Honda PGM-Tester will display the Diagnostic Trouble Code (DTC). b) Procedure without Honda PGM-Taster: Connect the Data Link Connector terminal 3 (L-Line) to terminal 1 {GND} with a jumper wire es shown or with ABS short-Connector {the Data Link Connector (SP) is located under the dash on the passenger's side of the vehic the ignition switch ON (lh. Turn (Line) LTGRN/RED WARNING: DO NOT CONNECT PIN 2 (eno) TOGROUND eecausE ‘THIS PIN IS BATTERY +. Data Link Connector (SP) 1, Note the Diagnostic Trouble Code (DTC): the Mil ie code by @ number of blinks until the jumper wire is removed from the DLC (SP). Each blink code is indicated three times in succession, beginning with blink code 12 (initial- ‘sation code-OK). (MALFUNCTION INDICATOR LAM ML) 1a. blink code 16 W412C' Ui, Engine Control Module (ECM) Reset Procedure 1, Turn the ignition switch off. Reset Procedure: If the Honda PGM-Tester is available please use the Honda PGM-Tester and follow the instructions in its manual for resetting the ECM, Ifthe Honda PGM-Tester is not available please follow the instructions below: Reset the ECM by switching on and off the ignition switch approximately 50 times. IV. Final Procedure (this procedure must be done after any troubleshooting) 1, Remove the jumper wire. NOTE: Ifthe service check connactor is jumped the MIL will stay on, 2. Do the ECM Reset Procedure. V. Known-Good ECM Substitution ‘The ECM is part of the immobilizer system. If you substitute @ known-good ECM, the ECM will have a different immobi- lizer code. In order for the engine to start, you must rewrite the immobilizer code with the Honda PGM Tester. cont'd) 11.13Troubleshooting [- Troubleshooting Procedures (cont'd) DIAGNOSTIC ] TROUBLE SYSTEM INDICATED Page CODE (OTC) I 2 INITIALISATION CODE-OK_ = 14 ____| ENGINE COOLANT TEMPERATURE SENSOR-BELOW SETPOINT 1126 | 6 ENGINE COOLANT TEMPERATURE SENSOR-ABOVE SETPOINT 17-30 6 FUEL TEMPERATURE SENSOR-BELOW SETPOINT 1192 7 FUEL TEMPERATURE SENSOR ABOVE SETPOINT | 1¥86 1° CRANKSHAFT POSITION SENSOR-IMPLAUSIBLE 14-32 a [THROTTLE PEDAL POSITION SENSOR-ABOVE SETPOINT 11a 2 ‘THROTTLE PEDAL POSITION SENSOR-BELOW SETPOINT [re 2 THROTTLE PEDAL POSITION SENSOR IMPLAUSIBLE WITH LOW IDLE SWITCH 1146 28 VEHICLE SPEED SENSOR-IMPLAUSIBLE 1780 2 MASS AIR FLOW SENSOR BELOW SETPOINT 11-120 28 [MASS AIR FLOW SENSOR-ABOVE SETPOINT aa 23 MASS AIR FLOW SENSOR-NOT PLAUSIBLE 1128 a (CRANKSHAFT POSITION SENSOR-NO SIGNAL 1136 38 EGR-SETPOINT NOT ACHIEVABLE 1142 36 FUEL TIMING SOLENOID-SETPOINT NOT ACHIEVABLE 1198 7 BRAKE LIGHT SWITCHIMPLAUSIBLE 1152 a ‘BOOST PRESSURE-BELOW SETPOINT [186 2 BOOST PRESSURE-ABOVE SETPOINT [__1¥60 a | BOOST PRESSURE-IMPLAUSIBLE WITH ATHMOSPHERIC PRESSURE 1164 8 | BATTERY VOLTAGE Too LOW - 11-68 =a [ FUEL SHUT-OFF SOLENOID DEFECTIVE 11-100 5 ECM FAULT PRESENT ~ 1125 61 FUEL QUANTITY FEEDBACK SENSOR-ABOVE OR BELOW SETPOINT 11-104 62___| FUEL QUANTITY FEEDBACK SENSOR IMPLAUSIBLE WITH NEEDLE LIFT SENSOR 11-108 64 _ | FUEL QUANTITY SOLENOID-SETPOINT NOT ACHIEVABLE ia n _ INTAKE AIR TEMPERATURE SENSOR-BELOW SETPOINT 1-132 | 2 INTAKE AIR TEMPERATURE SENSOR-ABOVE SETPOINT [6 81 [ NEEDLE LIFT SENSOR-NO SIGNAL 11-68 2 [NEEDLE LIFT SENSOR-IMPLAUSIBLE WITH ENGINE SPEED SENSOR ee er ‘© Ifcodes other than those listed above are indicated, verity the code. Ifthe code indicated is not listed above, replace the ECM, (The only exception is DTC 39 for a defective Theft Alarm.) ‘© The Malfunction Indicator Lamp (MIL) may come on, indicating a system problem when, in fact, there is a poor or inter- mittent electrical connection. First, check the electrical connections, clean or repair connections if necessary, W814Troubleshooting [- Troubleshooting Procedures (cont'd) (NOTICE) For testing at connectors bring the tester probe into contact with the terminal from the connector side of wire harness connectors in the engine compartment. For female connectors, just touch lightly with the tester probe and do not fore® insert the probe. Puncturing the insulation on a wire can cause poor or intermittent electrical connections, RUBBER SEAL TESTER PROBE WIRE HARNESS TERMINAL W168- How to Read Flowcharts {A flowchart is designed to be used from start to final repair. t's like a map showing you the shortest distance. But beware: if you go off the “map” anywhere but a “stop” symbol, you can easily get lost. TART) Describes the conditions or situation to start a troubleshooting flowchart. (bold type) [ACTION] ‘Asks you to do something; perform a test, set up a condition etc. BECTON —_Asks you about the result ofan action, then sends you in the appropriate troubleshooting direction. SIGE] _—_The ond ofa series of actions and decisions, describes final repair atan and sometimes crete Faroe ey Youtoan earl por ofthe flowchart confim your cepa NOTE: © The term “Intermittent Failure” is used in these charts. It simply means a system may have had a failure, but it checks ‘out OK at this time. Ifthe Malfunction Indicator Lamp (MIL) on the dash does not come on, check for poor connections oF loose wires at all connectors related to the circuit that you are troubleshooting (soe illustration below). ‘© Most of the troubleshooting flowcharts have you reset the Engine Control Module (ECM) and try to duplicate the Diagnostic Trouble Code (OTC). f the problem is intermittent and you can't duplicate the code, do not continue through the flowchart. To do go will only cesult in confusion, and possibly, a needlessly replaced ECM. © “Open” and “Short” are common electrical terms. An open is a break in a wire or at a connection. A short is an acci dental connection of a wire to ground or to another wire. In simple electronics, this usually means something won't work at al In complex electronics (ike ECM's), this can sometimes mean something works, but not the way it’s supposed to. ‘© Ifthe electrical readings are not 2s specified when using the test harness, check the test harness connections before proceeding, W.47Diesel Engine Management System ‘- System Description wars 1 [ emers | conta Postion Seer } Needle Litt Sensor | Erie Gv Tempe Sr | inca tomer Sos Giow Pug Rey tiers Se Cokes ve | Vehicle Speed Sensor Fuel Shut-off Solenoid Tote PadalPosnonsansor = |_—__[ ec |__| Glow Pgs tame Breve Peal Sich Malfunction indicator Lamp ‘Mass Air Flow Sensor | | Data Link Connector Fuel Temperature Sensor Injection Timing Device Fuel Quantity Feedback Sensor | Fue! Quantity Solenoid Diagnostic Connector Battery Supply | Starter Signal Earth Supply | Diesel Engine Management System Electronie diesel control operation is necessary in order to achieve optimum combustion of fuel in the cylinder using sen. sors located at strategic points around the engine. The signals from these sensors are used to adjust the fuel injection {quantity and timing according to performance conditions. ‘The ECM therefore contains control maps for each sensor related to performance conditions which are updated during driving. The ECM incorporates short-circuit protection and can store intermittent faults on certain inputs. In case of system failure the ECM implements a back-up facility to continue functioning, although at a reduced level of performance. A seporate Data Link Connector is used to read out the diagnostic trouble codes without disconnecting the ECM. Fuel Injector Timing and Duration Fuel injection timing and quantity control is done with the ECM comparing the actual values of performance with the ones stored in so-called control maps in the ECM and then adjusting the solenoids and actuators as necessary. WagEi Idle Control System Idie Speed is controlled from the ECM only with the amount of fuel being injected into the cylinders. Fuel Supply System ‘Aclose “cooperation” between ECM and Fuel Injection Pump is necessary to achieve oss. Therefore the Fuel Injection Pump Assembly contains different devices controlling the actual fuel injection quantity and timing. In case of any major fault or any problem in the electric supply circuit to the Fuel injection Pump, the Fuel Shut-off Solenoid cuts off the fuel supply immediately. 9 optimum in the combustion pro- Intake Air System ‘The Intake Air System contains Air Cleaner, Turbocharger, the Intake Manifold, intercooler and Mass Air Flow Sensor. Emission Control System Effective Emission Control is done by use of an Exhaust Gas Recirculation (EGR) Solenoid Valve, Exhaust Gas Recizculation (EGR) Valve, Crankcase Emission Control and Fuel Vapour Evaporative Loss Control. When EGR is required for control of oxides of nitrogen (NOx) emissions, the ECM supplies ground to EGR Control Solenoid Valve which then supplies regulated vacuum to the EGR Valve and exhaust gas is drawn back into the Intake Manifold to decrease combus- tion temperatures and therefore emissions of NOx ECM Fall-safe/Back-up Functions 1. Fail-safe Function When an abnormality occurs in a signal from a sensor, the ECM ignores that signal and assumes a pre-programmed value for that sensor that allows the engine to continue to run, although at ¢ reduced level of performance. 2. Back-up Function ‘When an abnormality occurs in the ECM itself, the ECM implements back-up to allow the engine running although at 3 reduced level of performance. 3 Self-diagnosis Function [Malfunction indicator Lamp (MIL) ‘When an abnormality occurs in a signal from a sensor, the ECM lights the MIL and stores the Diagnostic Trouble Code (OTC) in erasable memory. When the ignition is initially turned on, the ECM supplies ground for the MIL for two sec- fonds to check MIL bulb condition. 11.19Main Relay Main Relay ‘The Main Relay is energised by the ECM as soon as the ECM recieves the signal from the ignition switch, The Main Relay supplied battery voltage to the ECM and varying other sensors and actuators enabling the engine to start. Main Relay Testing 1. Remove the Main Relay from the engine compartment fuse relay box. 2. Attache the battery positive terminal to the No. 1 terminal and the battery negative terminal to the No. 3 terminal of the Main Relay. Then check for continuity between the No. 4 terminal and No. 2 terminal of the Main Relay. ‘If there is no continuity, replace the Main Relay and retest. © If there is continuity, the Main Relay is ok. No. 26 Hiecm (FUELPUMP) (15) (5A)tuse fuse, I 1 lL. main RELAY 3 2 p-e--——-4-- em Tas Ae ay \ ! I I L-------------4 11.20Diesel Engine Management System “The Malfunction Indiator Lamp | ier cameron ine ro wo seconds) ater ignition | termed ON a. - | ves [tor tne ‘Connect he breakout box between aon] - Troubleshooting Flowchart — Engine Control Module (ECM) inspect fuse No. 18 BAKE UP TReete daw we unaeraaah | fuselelay box Connect Aé (-} terminal at the ‘boxe body ground. ee | check for continuity at 1s | GUase terminal ana pos ‘ground. and recheck (see page 11-13 for immobilizer Information). symptom/indiestion goes away, Feplace the original ECM, Substitute @ known-good ECM Disconnect ECM connector ze | fuse No. 18 BACK UP LIGHT (20, | Aland the gauge assembly. ‘Replace the MIL bu = Repair ‘wire between ECM (A4) and | Jn wirels) between ‘body ground that had ‘0 continuity. no {replace the use, 11-22Ti Matneton nator Lamp | (MIL) stays on or comes on after [_twoseeonts, Connect the Data Link Connector terminale 1 (GND) and 3 LT GRN! FRED (L-Line) with 2 jumper wire (see page 11-12) or connect the Honda PGM-Tester to the Data Link Connector. | [turn the ignition switch ON t ‘oes the MIL indicate any. Diagnostic Trouble Code (OTC) No Remove the jum Honda PGM Testor from the Data Link Connector [Remove and inspect use No. 24 | Eee er ae a fuselrelay box. —— Is the fuse OX? | Replace the fuse. ves Remove and inspect fuse No. H (ECM) (15 A) in the under-hood Tuseielay box. emma | ves (To page 11-24) Replace the fuse, (cont'd) 11-23