_ Contents REPAIRS & OVERHAUL Engine and associated systems 11.8 and 2.0 lite petol engines in-car repair procedures 2.4 litre petrol engine in-car repair procedures Transmission Clutch Man Automatic transmission Driveshafts transmission Brakes and suspension Braking system _ Poge 9+t Suspension and steering Body equipment Bodywork and fitings Body electrical systems Wiring diagrams Page 10008 REFERENCE Dimensions and weights Page REF+1 Page REF*2 Buying spate pars Vehicle ieniicaton General repair procedures Jacking and vi ‘Toois and working facies ‘MOT test checks Fault finding Glossary of technical termoa Advanced Driving Advanced driving Many people see the words ‘advanced «( ‘ —— Sooo oe [Connect the other end of the red lead to the positive (+) terminal ef the booster io ‘Jump starting will get you out | ‘trouble but you must corect HINT} wnstover mace tno battory 90 tat nthe frat lace. Thee ve three posses ‘he battery hos been drained by repeated attempts to start or by | avin the ights on The charging system isnot working | properly (alternator drivebelt slack ‘or broken, atemator wiring fault or Sternator itso faulty. The battery itself Isat fault | | Brctetos om: or batter wor out | [Connect one end of black jump lead to ine negative (-) terminal of the booster battery [Connect the ether end of the black jump lead to the to the earth terminal on the et-hand front suspension turet in the engine compartment Make sure thatthe jump leads wil not Jcome into contact with the cooing fan rivebetts or other moving parts on the engine Start the engine, then with the engine running at fast idle speed disconnect tne jump leacs in the reverse order ofRoadside repairs os Wheel changing Warning: Do not change 2 whee! in a situation where you risk being hit by other traffic. On busy roads, try to stop in a lay-by or 2 gateway. Be wary of passing traffic while changing the wheel - itis easy to become distracted by the job in hand. Preparation When a puncture occurs, stop as goon as itis sae todo so, Park on frm lovo! ground. it possible, and well out ofthe way of other tac. Use nazard warning ight I necessary. Changing the wheel Ifyou have one, use a warning rangle to ale other crivers of your presence. ‘Apply the handbrake and engage fist ‘or reverse gear (or P on models with ‘automatic transmission CChock the whesls opposite the one being removed ~ a couple of large stones wil 1 for this, Ir tne ground is sot, use a fat piace of wood to spread the aad under the fot ol the jack. 4 The spare, need and. tools ave stored under the floor in the luggage compartment Lit up the cover pane! ‘Slacken each wheel nut by a half turn, sing the whee brace. if he ruts ae too tight. DONT stand an the whee brace to ‘ofthe motoring organeatons Fit the spare whesl, and scrow on the nuts. Lightly tighten the ruts with the ‘wheal Brace then lower the vehicle to the Ground. Securely tighten the whee! nuts, then ret the wheel im or contre cover, as ‘applicable, Note that the wheel nuts shows be slackened and retightened to the specied torque atthe earlest possible opportunity Unscrew the retaining bolt, and lift the ‘spare wheel out. The jack and wheel brace are located beneath the spare weet, The serev-in towing eye slated alongside the spare wheel Where applicable, using the flat ena of the wheel brace, prise of the whee! tin for centre cover for access to the whee! ruts, Models witn alloy wheels may have special locking nuts ~ these are removed with 2 special ool, which should be provided with the whee! brace (ar may be inthe glovebox) Two jacking points are provided on each side ~ use the one nearest the punctured ‘wheal. Locate the jack head in the groove atthe jacking point i te lower sil lange (don't jack tne vehicle at any other point of the sil, nor on a plastic pane). Tun the jack handle clockwise unti the wheel is raised clear ofthe ground. Finally . Remove the wheel chocks Stow the punctured whee! and tools back in the luggage compartment, and secure them in position heck the tye pressure on the tye just fied Hit is tow, rif you dont have a pressure ‘g2u9@ wit yu. cive slowly tothe rext garage and inate the ye fo the correct pressure Inthe case of the narrow space-savr’ spare whoel his pressure s much high ran fora somal ye. Have the punctured wheel repaired as soon as posse or another puncture wl eave you stranded Note: Some models ae supped wth a special ihtweight ‘space-saver snare whee the fe being rarener than stander. The space-saver spare whee rtanded on for temporary Use nd must be replaced witha standard whee! as soon as possi. Orve with parca care with hs whee! ted special through comers ae whan braking: do rot exceed 0 mph Unscrew the wheel nuts. noting which way round they fit apered side Inward land remove the wheeo-10 Roadside repairs Identifying leaks Pudates on the garage tloor or drive, or Waming: Mos automate ots L\ iti aa “is, ESI Te emet of » tid faking from the car may provide 3 isircosgmaaetstace “A Qrocteient cer" | ANT cee nts ak Sne es ee een store tee dame cats ae rfc ast eecany W cera tt may hata fo close tho cer covehdly Bieady.Losking ol or us ean aso be blown and to park It over some clean paper sendy: Leaking. overnight as an aid to locating the | ing 2 Source of the leak. Remember tat some lee may ony | occur while the engine is running. sage of ar under 12 impression of whi Problem hes Sump oil Oil from filter Gearbox oil " i if ts Engine of may leak from the oran plug Gearbox o can leak frm the seals at he inboard ends of the drveshats, Antifreeze Power steering fluid ‘aking antireeze often leaves a crystaline ring at a wheels almost Power steering uid may leak from the pipe epost ike ths. certainly brake fa connectors an tne etsering rack Towing fails, you may find yourselt_is found in the spare whee! wel. The towing _ Make sure that both divers know the route tow home = of of course you eye screws into a threaded hole, accessible before setting of ‘be helping somebody else. Long-distance ater rising outa cover on the righthand side Only drive at moderate speeds, and keep recovery should only pe done by a garage or of the bumnes (see illustration). the distance towed to a minimum. Drive "Y Before being towed. release the handbrake smoothly, and alow plenty of time for slowing 5's ea5y enough, but and make sue the wansmission isin neutral. down at junctions points (On models with automatic transmission ‘ w-rope ~ they are not special precautions apply - do not exceed 50 Vehicle being towed mph or furner than 80 yy an ON TOW sign in its rear must always rl forwards, Note that much greater-than-usual pedal es, and the whee's Always tur the ignition Key to the “on quired to operate the position when the vehicle is being towed, so since the vacuum servo unt i only that the stesring lock is teleased, and thal the operational wth the engine running, rection indicator ight will work, The diver ofthe car Bang towed must Keep Front towing eye is located behind a cover The towing eye is of the Screw type, and the tow-ope tat at al ies to avo snatching, panel nthe front bumperWeekly checks o-11 Introduction There ave some very simple checks when Keeping \nutes to carry out, But pres je on tyre condition and W your ear develops a brake ful leah, the wil pot only help to stop them your te 0ks roquie no great ski or "Many breakdowns are caused by electrical Nd the small amount of time problems. Batery-reatedtauitsatepartculary they take to perform could prove to be very common, anda quick check on a regular bass well spent, for example wil often prevent the majorty ot Underbonnet check points