Mazda 2 Demio DY 2002 2007 Factory Service Manual

Page 1 of 2
REMOVAL AND INSTALLATION 2003.50 Mazda2

POWER STEERING PUMP BELT —
1.25L/1.4L/1.6L, VEHICLES WITH:
AIR CONDITIONING
UID=G100708
General Equipment
Knife
Removal
CAUTION: The power steering pump belt must not be reused as it is designed to be
stretched onto the pulleys only once. Failure to follow this instruction may lead to
premature failure of the belt.
1. Raise and support the vehicle. For additional
information, refer to Section 100-02.
2. Detach the power steering line and remove the
crankshaft pulley splash shield.
3. Using a suitable knife, cut the power steering

pump belt and remove.
Installation
NOTE: Install a new power steering pump belt.
1. Wipe clean both of the pulleys to make sure
that the power steering pump belt does not
slip during installation.
2. Install the installation tool (supplied in the
parts kit) to the crankshaft pulley at the 12
o'clock position.
3. Install the power steering pump belt.

1. Install the belt around the power steering
pump pulley.
2. Install the belt around the installation tool.
Page 2 of 2
4. Make sure that the power steering pump belt

is correctly positioned in the grooves of the
pulleys.
5. NOTE: Only turn the engine in the normal
direction of rotation.
NOTE: Guide the power steering pump belt
onto the pulleys as the engine is rotated.
Turn the engine until the installation tool is at the
9 o'clock position.
6. Remove the installation tool from the

crankshaft pulley.
Turn the engine through 360 degrees.
8. Check that the power steering pump belt is
correctly positioned in the grooves of the
pulleys.
 Repeat the installation procedure if the power

steering pump belt is misaligned.
 Discard the installation tool.

9. Install the crankshaft pulley splash shield.
10. Lower the vehicle.

Page 1 of 1
SPECIFICATIONS 2003.50 Mazda2

SPECIFICATIONS
UID=G100716
Torque Specifications
Description Nm lb-ft lb-in

Glow plug 8 - 71
Glow plug electrical connector retaining nut 2 - 18
Glow plug wire electrical connector retaining nut 4 - 35
Page 1 of 1
DIAGNOSIS AND TESTING 2003.50 Mazda2

GLOW PLUG SYSTEM
UID=G100718
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
Visual Inspection Chart
Electrical
- Fuse(s)
- Relay
- Wiring harness
- Electrical connector(s)
- Glow plug(s)
- Glow plug wire
- Powertrain control module (PCM)

3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to WDS to diagnose the
system.
Page 1 of 1

GLOW PLUG
UID=G100719
Removal
1. Remove the air cleaner. For additional
2. Disconnect the glow plug electrical connectors
(intake manifold assembly shown removed for
clarity).
3. Remove the glow plug(s).
Installation
1. To install, reverse the removal procedure.
Page 1 of 1

GLOW PLUG WIRE
UID=G100720
Removal
1. Disconnect the glow plug wire electrical
connector.

3. Disconnect the glow plug electrical connectors
(intake manifold assembly shown removed for
clarity).
4. Remove the glow plug wire.
Installation
Page 1 of 2

AIR CLEANER — 1.4L DIESEL
UID=G100733
Removal and Installation

1. Remove the air cleaner intake pipe retaining
bolt and detach the pipe at the rear.
2. Disconnect the mass air flow (MAF) sensor

electrical connector.
3. Disconnect the air cleaner outlet pipe from the

MAF sensor.
4. Detach the fuel system hand primer from the

air cleaner (if equipped).
5. Remove the air cleaner.
 Pull the air cleaner at the rear to remove.

Page 2 of 2
Installation
Page 1 of 1

FUEL LEVEL SENSOR
UID=G100818
Removal
1. Remove the fuel level sensor.
Installation
Page 1 of 1

SPECIFICATIONS
UID=G105649

Tie-rod to steering gear 110 81 -
Tie-rod end locknut 63 46 -
Tie-rod end retaining nut 48 35 -
Page 1 of 1

SPECIFICATIONS
UID=G105652

Steering wheel retaining bolt 45 33 -
Steering column retaining nuts 24 18 -
Steering column shaft to steering gear pinion retaining bolt 28 21 -
Page 1 of 3

CLUTCH AND CLUTCH FIELD COIL
UID=G105784
General Equipment
Two-legged puller
Bolt M6 x 30 mm
Washer
Removal
1. Remove the auxiliary drive belt. For additional
2. Disconnect the electrical connector for the A/C
compressor clutch.
NOTE: Mark the installed position of the A/C compressor clutch electrical connector in
relation to the compressor housing.
3. Remove the A/C compressor drive plate (A/C
compressor shown removed for clarity).
4. Remove the A/C compressor pulley.
 Remove the spacer washers.
5. Remove the magnetic coil using a suitable two-

legged puller.
Page 2 of 3
Installation
NOTE: Do not skew the magnetic coil when installing it in the A/C compressor.
1. Install the magnetic coil with an M6 x 30 mm
bolt, suitable washer and the compressor drive
plate (A/C compressor shown removed for
clarity).
2. Remove the M6 x 30 mm bolt, washer and

compressor drive plate.
 Install the spacer washers.

3. NOTE: Install a new A/C compressor pulley
snap ring.
Install the A/C compressor pulley.
 Fit the snap-ring.

Page 3 of 3
4. Install the A/C compressor drive plate.
5. Check the compressor clutch gap. For

additional information, refer to Section 412-
00.
6. Connect the electrical connector for the A/C
compressor clutch.
7. Install the auxiliary drive belt. For additional

Page 1 of 1

LOW-PRESSURE CUTOFF SWITCH
UID=G105788
Removal
1. Remove the right-hand headlamp. For
01.
2. Disconnect the low pressure switch connector.
3. Start the engine and switch on the air

conditioning.
4. NOTE: Make certain that the A/C
compressor is running during removal of the
low pressure switch.
Connect a fused bridging cable (20 A fuse)
between pin 1 and pin 4 of the low pressure
switch connector on the wiring harness side.
5. WARNING: Make certain that the valve

of the low pressure switch is completely
closed after removal of the low pressure
switch, to prevent refrigerant from escaping.
Failure to observe this instruction can lead to
injury.
Remove the low pressure switch.
 Discard the O-rings.
Installation
1. NOTE: Install new O-rings on the low
pressure switch.
NOTE: Coat the low pressure switch O-rings
with clean refrigerant oil before installation.
Reinstall the components in reverse order.
Page 1 of 1

IGNITION COIL PACK — 1.3L
UID=G109170
Removal
1. Disconnect the spark plug wires from the
ignition coil pack.
2. Disconnect the ignition coil pack electrical

connector.
3. Remove the ignition coil pack.
Installation
1. CAUTION: The ignition coil pack and

spark plug wires are numbered. Make sure
the spark plug wires are correctly installed to
the ignition coil pack. Failure to follow this
instruction may result in damage to the
engine.
To install, reverse the removal procedure.
Page 1 of 2

REAR CENTER SAFETY BELT
RETRACTOR
UID=G112964
Removal
1. Fold the rear seat cushion forwards.
2. Detach the center safety belt and buckle lower
anchor from the floor pan.
3. Remove the center safety belt retractor cover.
4. Remove the center safety belt webbing trim

panel.
1. Raise the front of the trim panel.
2. Detach the trim panel from the seat
backrest.
 Feed the safety belt webbing through the trim

panel.
5. Detach the center safety belt retractor from

the rear seat backrest.
6. NOTE: Note the backrest latch cable

position on the safety belt retractor to aid
installation.
Remove the rear center safety belt retractor.
1. Slide the backrest latch outer cable to the
side to detach it from the safety belt
retractor.
Page 2 of 2
2. Detach the backrest latch inner cable from

the safety belt retractor.
Installation
1. WARNING: If the safety belt webbing

retracts further than the stop on the webbing,
a new safety belt must be installed. Failure to
follow this instruction may result in personal
injury.
CAUTIONS:
Make sure a webbing retainer is fitted at

least 200 mm towards the safety belt
retractor from the webbing stop.
Check the backrest latch cable routing,

and the operation of the safety belt retractor
and interlock.
Page 1 of 1

SPECIFICATIONS
UID=G113195
Item Nm lb-ft lb-in

Clutch pressure plate retaining bolts 29 21 -
Page 1 of 2
GENERAL PROCEDURES 2003.50 Mazda2

COOLING SYSTEM DRAINING,
FILLING AND BLEEDING
UID=G146259
Draining
1. WARNING: When releasing the cooling

system pressure, cover the coolant expansion
tank cap with a thick cloth to prevent the
possibility of scalding. Failure to follow this
instruction may result in personal injury.
Release the cooling system pressure by slowly
turning the coolant expansion tank cap a
quarter of a turn.
2. Remove the coolant expansion tank cap.

3. Raise and support the vehicle.
4. Drain the cooling system.
 Allow the coolant to drain into a suitable

container.
5. Install the radiator drain plug.

Filling and Bleeding

1. Remove the radiator bleed plug (if equipped).
2. Fill the coolant expansion tank until coolant is

expelled from the radiator bleed point or
stabilizes at the MAX mark (whichever occurs
first).
3. Install the radiator bleed plug (if equipped).
4. Fill the coolant expansion tank to the MAX
mark (if necessary).
Page 2 of 2
5. Start and run the engine at 3000 revolutions

per minute (RPM) for two minutes.
6. Fill the coolant expansion tank completely.
7. Install the coolant expansion tank cap.
8. Start and run the engine at 3000 RPM for
another two minutes.
9. Switch the engine off.
Page 1 of 1

WATER PUMP
UID=G146264
Removal
1. Remove the timing belt. For additional
information, refer to Section 303-01A / 303-
01B.
2. Remove the water pump.
Installation
1. Install the water pump.
 Tighten the water pump retaining bolts in 2

stages and in the sequence shown.
 Stage 1: Tighten the bolts - 3 Nm.
 Stage 2: Tighten the bolts - 10 Nm.
2. Install the timing belt. For additional

01B.
Page 1 of 1

SPECIFICATIONS
UID=G146265
General Specifications
Condition Specification
Regulated fuel pressure 380 kpa (55 psi)
Maximum idle increase for high generator load 100 rpm
Air conditioning idle upspeed at low ambient temperatures 100 rpm
Air conditioning idle upspeed at high ambient temperatures 150 rpm
Power steering idle speed upspeed 50 rpm

Throttle body retaining bolts 10 - 89
Fuel pressure regulator retaining bolts 10 - 89
Fuel injection supply manifold retaining bolts 15 11 -
Page 1 of 1

THROTTLE BODY
UID=G146266
Removal
1. Disconnect the air cleaner outlet pipe from the
throttle body.
2. Remove the throttle body retaining bolts.
3. Disconnect the throttle body electrical

connector and remove the throttle body.
Installation
2. Turn the ignition key to position II for 5
seconds and return the ignition key to position
0 to initialize the throttle body.
Page 1 of 1

SPECIFICATIONS
UID=G146267

Glow plug electrical connector retaining nut 2 - 18
Fuel injector clamp retaining bolt 30 22 -
Exhaust gas recirculation (EGR) tube retaining bolt 10 - 89
Fuel injection pump rear support bracket to fuel injection pump retaining bolt 10 - 89
Fuel injection pump rear support bracket to cylinder block retaining bolt 10 - 89
Fuel injection pump pulley retaining nut 50 37 -
Fuel injection pump retaining bolts 22 16 -
High-pressure fuel supply lines a - -
a) refer to the relevant procedure(s) in this section.
Page 1 of 6

TURBOCHARGER
UID=G146272
Removal
1. NOTE: Make note of the position of the
retaining clamp to make sure that it is
positioned in exactly the same position when
installing.
Remove the bolts from the turbocharger to intake
air resonator and disconnect the intake air
pipe.
2. Remove the intake air resonator

1. Rotate the resonator.
2. Push the resonator to remove.
3. Remove the turbocharger heat shield upper

retaining screws.
CAUTION: Do not remove the two screws either side of the circular cut-outs. Failure
to follow this instruction may cause damage to the heat shield.
4. Remove the turbocharger heat shield (shown
removed for clarity).
 Remove the retaining bolts through the

circular cut-outs.
5. Remove the exhaust manifold heat shield.

Page 2 of 6
6. Remove the air cleaner outlet pipe.
7. Disconnect the oil supply tube from the

turbocharger.
 Discard the sealing washers.
8. Disconnect the oil return tube from the

turbocharger.
9. Detach the turbocharger from the catalytic

converter.
10. Remove the turbocharger.

Page 3 of 6
Installation
1. Install the turbocharger.
2. Attach the turbocharger to the catalytic

converter.
3. Connect the oil return tube to the

turbocharger.
4. Loosen the oil supply tube at the

cylinder block.
Page 4 of 6
5. Position the oil supply tube so that the

clearance between the tube and the wastegate
body is 65 mm.
6. CAUTION: Make sure that the

clearance between the oil supply tube and the
wastegate body is 65 mm when the tube is
tightened.
Tighten the oil supply tube at the cylinder block.

clearance between the oil supply tube and the
turbocharger body is 15 mm when the tube is
tightened.
NOTE: Install new sealing washers.
Connect the oil supply tube to the turbocharger.
8. Install the air cleaner outlet pipe.

Page 5 of 6
9. Install the exhaust manifold heat shield.
10. Install the turbocharger heat shield (shown

 Install the retaining bolts through the circular

cut-outs.
11. Install the turbocharger heat shield upper

retaining screws.
12. Install the intake air resonator

1. Install the resonator to the turbocharger.
2. Rotate the resonator.
13. NOTE: Make sure that the retaining

clamp is positioned in exactly the same
position as removed.
Install the intake air resonator and connect the
intake air pipe.
Page 6 of 6
Page 1 of 4

ACCESSORY DRIVE BELT —
1.25L/1.4L/1.6L, VEHICLES WITH:
AIR CONDITIONING
UID=G146274
General Equipment
Knife
Removal
CAUTION: The accessory drive belt must not be reused as it is designed to be

3. Using a suitable knife, cut both accessory drive

belts and remove.
Installation
NOTE: Install a new accessory drive belt and power steering pump belt.
1. Wipe clean all of the pulleys to make sure that
the accessory drive belt does not slip during
installation.
2. Using paint or typing correction fluid, mark the
crankshaft pulley at the 6 o'clock position.

o'clock position.
Page 2 of 4
4. Install the accessory drive belt.

1. Install the belt around the generator pulley.
2. Install the belt around the air conditioning
compressor pulley.
3. Install the belt around the water pump
pulley.
5. Make sure that the accessory drive belt is

pulleys.
NOTE: Guide the accessory drive belt onto
the pulleys as the engine is rotated.
Turn the engine until the paint mark is at the 8
o'clock position.
7. NOTE: The curved end of the tool fits

around the belt and the cranked end of the
tool fits around the generator mounting
bracket.
Install the belt guide tool (supplied in the parts
kit) to the accessory drive belt (shown from
above for clarity).
8. Install the belt guide tool to the generator

mounting bracket.

o'clock position

crankshaft pulley.
Page 3 of 4

12. Check that the accessory drive belt is
pulleys.
 Repeat the installation procedure if the

accessory drive belt is misaligned.
13. Remove the belt guide tool from the
accessory drive belt.
 Discard the belt guide tool.

14. Install the installation tool to the crankshaft
pulley at the 12 o'clock position.
15. Install the power steering pump belt.

1. Install the power steering pump belt around
the power steering pump pulley.
2. Install the power steering pump belt around
the installation tool.
16. Make sure that the power steering pump belt

is correctly positioned in the grooves of the
pulleys.
NOTE: Guide the power steering pump belt
onto the pulleys as the engine is rotated.
Turn the engine until the tool is at the 9 o'clock
position.

crankshaft pulley.
20. Check that the power steering pump belt is
pulleys.
Page 4 of 4
 Repeat the installation procedure if the power

steering pump belt is misaligned.

21. Install the crankshaft pulley splash shield.

Page 1 of 1

SPECIFICATIONS
UID=G148219

Crankcase vent oil separator retaining bolts 10 - 89
Page 1 of 1

ENGINE EMISSION CONTROL
UID=G148220
2. Visually inspect for obvious signs of mechanical damage.
Mechanical
Positive crankcase ventilation (PCV) valve
PCV separator
Hose(s)/hose joints
Gasket(s)
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Condition Possible Sources Action

Excessive *Blocked PCV *CLEAN or INSTALL new PCV components as necessary.
crankcase valve. TEST the system for normal operation. If the concern
pressure *Blocked PCV persists, REFER to Section 303-00.
separator.
*Blocked PCV
hose.
Oil in the air *Restriction in *CLEAN or INSTALL a new PCV separator. TEST the
intake system PCV separator. system for normal operation.
*PCV valve *INSTALL a new PCV valve. TEST the system for normal
permanently operation.
open.
Page 1 of 1

SPECIFICATIONS
UID=G148221

Exhaust gas recirculation (EGR) valve retaining bolts 10 - 89
Electronic exhaust gas recirculation (EGR) valve retaining bolts 11 8 -
EGR cooler retaining bolt 10 - 89
EGR tube retaining bolt 10 - 89
Page 1 of 1

EXHAUST GAS RECIRCULATION (EGR)
VALVE
UID=G148223
Removal
2. Remove the fuel filter. For additional information,
refer to Section 414-01.
3. Disconnect the vacuum line from the EGR valve.
4. Remove the EGR tube elbow retaining screws.
5. Remove the EGR tube clamp and the EGR tube.
6. Remove the EGR valve.
 Discard the gasket.
Installation
1. NOTE: Install a new EGR valve gasket.
Page 1 of 1

SPECIFICATIONS
UID=G148224
lb- lb-
Description Nm ft in
Air cleaner intake pipe retaining bolt - vehicles with 1.4L Duratorq-TDCi (DV) 4 - 35
diesel engine
Air cleaner retaining screws - vehicles with 1.4L Duratorq-TDCi (DV) diesel 5 - 44
engine
Air cleaner outlet hose retaining clip - vehicles with 1.6L Duratorq-TDCi (DV) 4 - 35
diesel engine
Air cleaner intake pipe duct retaining bolts - vehicles with 1.6L Duratorq-TDCi 5 - 44
(DV) diesel engine
Charge air cooler hose retaining clamps - 1.6L Duratorq-TDCi (DV) diesel engine 5 - 44
Charge air cooler retaining bolts - 1.6L Duratorq-TDCi (DV) diesel engine 10 - 89
Radiator support bracket retaining bolts - 1.6L Duratorq-TDCi (DV) diesel engine 25 18 -
Page 1 of 1

INTAKE AIR DISTRIBUTION AND
FILTERING
UID=G148225
Mechanical
Air cleaner intake pipe
Air cleaner outlet pipe
Air cleaner
Air cleaner element
Intake air resonator
Symptom Chart
Symptom Chart

Excessive *Detached air *CHECK the pipe(s) for security and leaks to
intake air cleaner intake pipe. atmosphere. INSTALL new intake air system
noise *Detached air components as necessary. TEST the system for normal
cleaner outlet pipe. operation.
*Air leak in the *INSTALL new intake air system components as
intake air system. necessary. TEST the system for normal operation.
Oil in the air *Positive crankcase *REFER to Section 303-08A / 303-08B.
cleaner ventilation (PCV)
valve.
*PCV separator.
Water in the *Detached air *CHECK the air cleaner intake pipe for security. INSTALL
air cleaner cleaner intake pipe. new intake air system components as necessary. TEST
the system for normal operation.
*Blocked air cleaner * CLEAN the air cleaner drain. TEST the system for
drain. normal operation.
Page 1 of 1

SPECIFICATIONS
UID=G148228

Fuel tank support strap retaining bolts 25 18 -
Fuel tank filler pipe retaining bolts 9 - 80
Fuel pump module locking ring - All except vehicles with diesel engine 85 63 -
Fuel level sensor locking ring - Vehicles with diesel engine 85 63 -
Floor panel crossmember 4 - 35
Page 1 of 3

ACCESSORY DRIVE BELT —
1.25L/1.4L/1.6L, VEHICLES
WITHOUT: AIR CONDITIONING
UID=G149874
General Equipment
Knife
Removal
CAUTION: The accessory drive belt must not be reused as it is designed to be

3. Using a suitable knife, cut the accessory drive

belt and remove.
Installation
NOTE: Install a new accessory drive belt.
1. Wipe clean all of the pulleys to make sure that
the accessory drive belt does not slip during
installation.
2. Using paint or typing correction fluid, mark the
crankshaft pulley at the 6 o'clock position.

o'clock position.
Page 2 of 3
4. Install the accessory drive belt.

1. Install the belt around the generator pulley.
2. Install the belt around the power steering
pump pulley.
3. Install the belt around the water pump
pulley.
5. Make sure that the accessory drive belt is

pulleys.
o'clock position.
7. NOTE: The curved end of the tool fits

around the belt and the cranked end of the
tool fits around the generator mounting
bracket.
Install the belt guide tool (supplied in the parts
kit) to the accessory drive belt (shown from
above for clarity).
8. Install the belt guide tool to the generator

mounting bracket.

o'clock position

crankshaft pulley.
Page 3 of 3

12. Check that the accessory drive belt is
pulleys.
 Repeat the installation procedure if the

accessory drive belt is misaligned.

13. Remove the belt guide tool from the
accessory drive belt.
 Discard the belt guide tool.

14. Install the crankshaft pulley splash shield and
attach the power steering line.

Page 1 of 1

ACCESSORY DRIVE BELT — 1.4L
DIESEL
UID=G149875
Removal
splash shield.
3. Rotate the accessory drive belt tensioner

clockwise and remove the accessory drive belt.
Installation
Page 1 of 1

SPECIFICATIONS
UID=G149910
Item Nm lb-ft lb-in

Door check strap to door retaining bolts 6 - 53
Door check strap to door pillar retaining bolts 23 17 -
Door striker plate retaining bolts 14 10 -
Door hinge retaining bolts 25 18 -
Liftgate striker plate retaining bolts 11 8 -
Liftgate hinge retaining nuts 18 13 -
Liftgate hinge retaining bolts 11 8 -
Hood hinge retaining bolts 23 17 -
Page 1 of 1

SPECIFICATIONS
UID=G149922
Item Nm lb-ft lb-in

Safety belt upper anchor retaining bolts 40 30 -
Safety belt lower anchor retaining bolts 40 30 -
Front safety belt retractor retaining bolts 35 26 -
Rear safety belt retractor retaining bolts 40 30 -
Rear center safety belt retaining nut 47 35 -
Safety belt buckle retaining bolt 47 35 -
Safety belt buckle and pretensioner retaining bolt 47 35 -
Safety belt shoulder height adjuster retaining bolts 40 30 -
Rear safety belt buckle retaining bolts 55 41 -
Rear seat backrest latch bracket retaining nuts 23 17 -
Page 1 of 1

STARTER MOTOR — 1.4L DIESEL
UID=G151302
Removal
1. Remove the battery tray. For additional
2. Remove the starter motor upper retaining
bolts.

4. Remove the starter motor lower retaining bolt.
5. Disconnect the electrical connectors and

remove the starter motor.
Installation
1. To install reverse the removal procedure.
Page 1 of 1

AIR CONDITIONING (A/C)
COMPRESSOR — 1.4L DIESEL
UID=G152348
Removal
1. Drain the air conditioning system. For
00.
3. Disconnect the compressor clutch connector.
4. CAUTION: Close off the refrigerant

lines and the A/C compressor to prevent
contamination.
Detach the refrigerant lines from the A/C
compressor.
 Discard the O-rings.
5. CAUTION: Support the A/C

compressor before unscrewing the bolts on
the A/C compressor.
Remove the A/C compressor.
Installation
1. NOTE: Install new O-rings on the
refrigerant lines.
NOTE: Coat the O-rings for the refrigerant
lines with clean refrigerant oil prior to
installation.
Refit the components in reverse order.
Page 1 of 1

SPECIFICATIONS
UID=G152539
Item Nm lb-ft lb-in

Top mount retaining nuts 25 18 -
Thrust bearing retaining nut 48 35 -
Stabilizer bar connecting link to strut and spring retaining nut 48 35 -
Wheel knuckle to suspension strut pinch bolt 85 63 -
Brake caliper anchor plate retaining bolts 70 52 -
Lower arm ball joint to wheel knuckle retaining nut 48 35 -
Stabilizer bar clamp retaining bolts 55 41 -
Stabilizer bar to connecting link retaining nut 55 41 -
Steering gear retaining bolts 48 35 -
Lower arm front retaining bolt a) - -
Lower arm rear clamp retaining bolts 55 41 -
Crossmember front retaining bolts 70 52 -
Crossmember rear retaining bolts 115 85 -
Crossmember inner and outer retaining bolts 175 129 -
Wheel hub retaining nut 290 214 -
Engine support insulator center bolt 48 35 -
Wheel speed sensor retaining nut 9 - 80
a) Refer to the procedure in this section.
Page 1 of 1

SPECIFICATIONS
UID=G152540
Item Nm lb-ft lb-in

Shock absorber lower mount retaining bolt 115 85 -
Shock absorber upper mount retaining bolts 25 18 -
Trailing arm bushing retaining bolts 125 92 -
Beam axle retaining bolts 115 85 -
Wheel spindle retaining bolts - Vehicles with rear drum brakes 70 52 -
Wheel spindle retaining bolts - Vehicles with rear disc brakes 66 49 -
Brake hose to brake caliper union 15 11 -
Brake tube to brake hose union 15 11 -
Wheel speed sensor retaining bolt 9 - 80
Page 1 of 2

GEARSHIFT CABLE ADJUSTMENT
UID=G152562
2. Remove the gearshift cables cover.
3. Release the selector cable adjuster locking

insert (gearshift cable box shown removed for
clarity).
 Press the orange colored insert into the

adjuster body.
4. NOTE: Measure the selector cable between

the two positions shown.
Adjust the length of the selector cable.
 XX mm = 138 ± 2.0 mm.
5. Shift the transaxle into third or fourth gear.
 Move the gearshift lever to its right-hand or

left-hand stop position.
Page 2 of 2
6. NOTE: Make sure that the orange colored

insert returns to the locked position.
Lock the selector cable adjuster.
 Press down the clip on the adjuster.
7. Install the gearshift cables cover.

Page 1 of 1

SPECIFICATIONS
UID=G152578
Item Nm lb-ft lb-in

Hood hinge to hood retaining bolts 23 17 -
Hood hinge to fender retaining bolts 23 17 -
Windshield wiper arm retaining nuts 20 15 -
Cowl panel grille retaining bolts 10 - -
Fender splash shield retaining bolts 5 - 44
Fender retaining bolts 7 - 62
Washer reservoir to radiator grille opening panel retaining bolt 3 - 27
Power steering fluid cooler to radiator grille opening panel retaining bolts 3 - 27
Radiator lower retaining bolts 3 - 27
Front bumper retaining bolts 25 18 -
Radiator grille opening panel retaining bolts 25 18 -
Page 1 of 1

SPECIFICATIONS
UID=G152587
Item Nm lb-ft lb-in

Front bumper retaining bolts 25 18 -
Radiator grille opening panel reinforcement retaining bolts 10 7 -
Rear bumper retaining bolts 20 15 -
Fender splash shield retaining screws 3 - 27
Bumper cover to fender retaining screws 3 - 27
Radiator support panel retaining bolts 20 15 -
Page 1 of 1

SPECIFICATIONS
UID=G152599
lb- lb-
Item Nm ft in
Stabilizer bar connecting link to stabilizer bar 55 41 -
Lower arm ball joint to wheel knuckle 48 35 -
Engine support insulator retaining bolts 80 59 -
Steering gear retaining bolts 48 35 -
Crossmember front retaining bolts 70 52 -
Crossmember rear retaining bolts 175 129 -
Exhaust flexible pipe to catalytic converter retaining nuts - Vehicles with 1.25L, 44 32 -
1.4L or 1.6L engine
Exhaust flexible pipe to muffler and tailpipe assembly retaining nuts - Vehicles 47 35 -
with diesel engine
Exhaust flexible pipe to catalytic converter retaining nuts - Vehicles with 2.0L 47 35 -
engine
Page 1 of 4

CLUTCH MASTER CYLINDER
UID=G152706
Removal
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be
immediately washed down with cold water.
All vehicles
1. Using a suitable syringe, remove brake fluid
from the brake fluid reservoir until the brake
fluid level is at the MIN mark.
Right-hand drive vehicles

information, refer to Section 303-12.[Intake
Air Distribution and Filtering, REMOVAL AND
INSTALLATION, Air Cleaner - 1.25L/1.4L/1.6L]
For additional information, refer to
Section 303-12.[Intake Air Distribution and
Filtering, REMOVAL AND INSTALLATION, Air
Cleaner - 1.4L Diesel]
Left-hand drive vehicles

3. Disconnect the two vacuum hoses.
 Detach the vacuum hoses from the battery

clamp clip.
4. Remove the battery tray.
All vehicles
5. NOTE: Plug the brake fluid reservoir to
prevent fluid loss or dirt ingress.
Disconnect the clutch master cylinder supply hose
from the brake fluid reservoir.
 Push the clip to release the clutch master

cylinder supply hose.
6. Remove the clutch master cylinder supply

hose.
 Release the clutch master cylinder supply

hose retaining clip.
Page 2 of 4
 Allow the fluid to drain into a suitable

container.
7. NOTE: Plug the clutch slave cylinder supply

line to prevent fluid loss or dirt ingress.
Disconnect the clutch slave cylinder supply line
from the clutch master cylinder and position it
to one side.
 Release the clutch slave cylinder supply line

retaining clip.
8. Remove the clutch master cylinder retaining

bolts.
9. NOTE: Remove the clutch master cylinder

and the clutch pedal as an assembly.
Remove the clutch master cylinder and the clutch
pedal assembly.
 Remove the pedal pivot shaft retaining nut

and remove the pivot shaft.
 Rotate the clutch master cylinder and clutch

pedal assembly counterclockwise.
10. Remove the clutch master cylinder.
1. Remove the clutch pedal return spring.
2. Detach the clutch master cylinder actuating
rod from the clutch pedal.
Installation
All vehicles
1. NOTE: Using suitable tape, secure the
clutch pedal return spring in position.
Page 3 of 4
Install the clutch master cylinder.

1. Attach the clutch master cylinder actuating
rod to the clutch pedal.
2. Install the clutch pedal return spring.
2. NOTE: Install the clutch master cylinder

and the clutch pedal as an assembly.
Install the clutch master cylinder and the clutch
pedal assembly.
 Rotate the clutch master cylinder and the

clutch pedal assembly clockwise.
 Install the pedal pivot shaft.
3. Install the clutch master cylinder retaining

bolts.
4. Connect the clutch slave cylinder supply line to

the clutch master cylinder.
 Install the clutch slave cylinder supply line

retaining clip.
5. Connect the clutch master cylinder supply hose

to the clutch master cylinder.
 Install the clutch master cylinder supply hose

retaining clip.
6. Connect the clutch master cylinder supply hose

to the brake fluid reservoir.
Page 4 of 4
7. Bleed the clutch system.

8. Install the battery tray.
9. Connect the two vacuum hoses.
 Attach the vacuum hoses to the battery

clamp clip.

10. Install the air cleaner. For additional
Filtering, REMOVAL AND INSTALLATION, Air
Cleaner - 1.4L Diesel]
Page 1 of 4
DESCRIPTION AND OPERATION 2003.50 Mazda2

BRAKE BOOSTER
UID=G163289
Emergency brake assistant (EBA)
As ABS braking systems have become widespread, it has emerged that because of incorrect
use of the brakes, many drivers are losing the safety benefit which ABS provides.
Drivers are applying the brakes too timidly. Because of this, the Anti-lock Braking System
(ABS) does not engage, and the maximum braking effect is not achieved.
The EBA recognises from the driver's manner of braking that an emergency situation is
occurring, and automatically applies full braking power.
This occurs in a matter of milliseconds, which is faster than the driver could do it.
Furthermore, it was observed that after the first heavy application of the brake pedal, the
driver releases the pressure on the pedal too early.
The EBA ensures that the ABS effect still continues when the pedal pressure would normally
lie below the ABS range of control. The system is available as an option depending on market
and vehicle variant.
Depending on driving manner, EBA results in a reduction in braking distance of 15% for
experienced drivers, to over 40% for average drivers.
Because EBA decelerates the vehicle up to the wheel locking limit, emergency brake assist is
only used in vehicles with ABS.
Components
Item Part Number Description

1 - EBA
EBA operates purely mechanically, and is completely integral with the brake servo.
Brake servo units with and without EBA are externally identical. For identification purposes,
brake servo units with EBA carry a white sticker showing a large letter "A".
The tandem master cylinder is the same for vehicles with or without EBA.
Function
In normal braking situations, the brake servo with EBA operates in the same way as a
Page 2 of 4
conventional brake servo unit. This means that the driver can always modulate the brakes.
If an activation threshold defined by a characteristic curve is exceeded during braking, the

EBA operates.
Determination of the activation threshold is based on the pedal movement parameters, which
are a function of the pressure on the brake pedal and the speed of movement of the pedal.
The characteristic curve is separately defined for each vehicle model.
The mechanical EBA uses the fact that in a brake servo unit, the valve piston moves ahead of
the control housing when a braking operation starts.
Because of this, there is a relative travel distance between the control housing and the valve
piston which can vary depending on the force applied to the brake pedal and the pedal speed.
The relative travel distance is small when the pedal moves slowly with low force applied to it.
The relative travel distance is larger when the pedal moves faster with higher force applied to
it.

1 - Relative travel distance
2 - Control housing
3 - Valve piston
Normal braking
Page 3 of 4

1 - Ball sleeve
2 - Control housing
3 - Valve piston
4 - Ball
5 - Lock sleeve
6 - Ball cage
In a normal braking operation, pedal operation causes the relative travel distance to remain
so small that the distance required for engagement is not exceeded.
The lock sleeve is held in its rest position by the force applied by the spring, the ball cage
remains free to move axially and the balls remain free to move radially.
Active brake assistant

1 - Relative travel distance
2 - Disc valve
3 - Key
If the activation threshold level is exceeded because of an emergency braking situation, i.e.
the relative travel distance of the valve piston is so great that the balls are moved in over the
slope of the ball sleeve, then the lock sleeve can move completely to its end position.
The balls are now locked, and the ball sleeve can no longer be moved in the closing direction
of the disc valve.
The EBA is now active, the brake pressure is increased up to the wheel locking limit, and the
brake pedal can be moved to its maximum pressure point without effort.
The brake pressure remains at the ABS control limit until the EBA is completely released
again.
Release of the brake assistant

Page 4 of 4

1 - Lock sleeve
2 - Key
3 - Vacuum cylinder
To release EBA, the brake pedal must be fully released, i.e. it must be returned to its rest
position.
When this occurs, the control housing together with the valve piston move back into the rest
position. The key is pressed against the stop on the vacuum cylinder and by this the lock
sleeve is slid back into its rest position.
The balls can again be moved outward by the ball sleeve, and the ball cage is again free to
move axially and the balls free to move radially.
Service
It is not possible to repair the EBA. A new brake servo unit must be installed.
Page 1 of 2

ANTI-LOCK CONTROL
UID=G163290
Overview

1 - Anti-lock brake system (ABS) hydraulic unit with integrated control unit
2 - Data Link Connector (DLC)
3 - Wheel speed sensors
4 - Ignition lock
5 - Stoplamp switch
6 - ABS warning lamp in the instrument cluster
In addition to the conventional brake system with two diagonally split brake circuits, the ABS
consists of an ABS hydraulic unit with integrated control unit, four wheel sensors and the ABS
warning lamp in the instrument cluster.
Electronic brake force distribution is integrated in the software of the ABS control unit, which
electronically regulates and optimises the pressure applied to the wheel brakes on the front
and rear axles in accordance with the operating conditions.
Function
The ABS is a closed loop control system in the brake system which prevents the wheels from
locking up under braking and therefore maintains steerability and driving stability in extreme
situations.
ABS control unit
The ABS control unit continuously compares stored physical deceleration values with those
detected by the wheel sensors. This allows the lock-up tendency of each wheel to be detected
separately.
If the ABS control unit detects that a wheel is threatening to lock up, then the corresponding
hydraulic valves in the valve block are either closed or opened.
Page 2 of 2
The ABS control unit then also passes on the vehicle speed signal obtained from the wheel
sensors to the Powertrain Control Module (PCM).
The warning lamp in the instrument cluster is actuated by the ABS control unit after switching
on the ignition. It remains on up to the end of the ABS self-test, and is also actuated in the
event of system errors.
It continuously monitors the system for possible faults and stores these as and when they
occur. The corresponding trouble codes can be interrogated with the aid of WDS via the DLC .
The ABS control unit is directly connected via a diagnostic data link to the DLC.
Valve block
The valve block contains four inlet valves and four outlet valves. There is one inlet valve and
one outlet valve for each wheel.
When there is no electrical supply the inlet valves are open and the outlet valves are closed.
The valve block also contains the low-pressure reservoir and sound damping chambers.
Pump motor
In the event of an ABS intervention the pump motor ensures that the pressure can be
provided to the regulating channels independently of the brake master cylinder.
ABS regulating cycle
An ABS regulating cycle has three phases:
Phase 1 - holding pressure
* The inlet valve is closed, and the brake pressure to the wheel brake cannot be
increased any further, even if the actuation pressure (brake pedal) is increased
further.
Phase 2 - pressure reduction
* The outlet valve is temporarily opened, and the brake pressure to the wheel
brake is reduced in a controlled manner.
Phase 3 - pressure build-up
* The inlet valve is opened in stages, and the brake pressure is increased in a
controlled manner to achieve the greatest possible deceleration.
Page 1 of 3

ANTI-LOCK CONTROL
UID=G163291
MK70 Anti-lock Brake System (ABS)
The MK70 ABS is similar to the MK60 in construction and design. The main differences are:
* New ABS control unit
* New hydraulic lines through a revised valve block
* New wiring harness and electrical connector (fewer occupied pins)
The MK70 ABS system will be installed from 05/2004 in vehicles which only have one ABS
function.
Vehicles with ESP/Brake Traction Control System (BTCS) will continue to be equipped with the
MK60.
MK60 ABS

1 - Pump motor
2 - Valve block
3 - ABS control unit
The MK60 ABS has been designed specifically for small to medium size vehicles. Compared to
the MK20 ABS system, it has been possible to reduce the size of the hydraulic and electric
components (e.g. hydraulic valves and solenoids) and the housing.
As a result, the overall weight of the ABS hydraulic unit has been significantly reduced.
The hydraulic unit consists of the pump motor, the valve block with 8 hydraulic valves and
the electronic control unit.
Page 2 of 3
The ABS control unit actuates the ABS warning lamp in the instrument cluster via the CAN
databus.
The MK60 ABS is a 4/3 system. This means that the wheel speed is measured individually for
each wheel (4 wheel speed sensors).
ABS controlled braking is provided individually for the front wheels and jointly for the two rear
wheels (3 control channels; select-low control), i.e. the ABS control for the rear wheels is
governed by the wheel closest to locking up.
Wheel speed sensors

1 - Sensor
2 - Installation position.
NOTE: The wheel speed sensors must not be checked for voltage with an ohmmeter.
The wheel speed sensors are active sensors. They are supplied with a voltage from the ABS
control unit after the ignition is switched on.
The pulses are picked up from a mechanically encoded ring, which is built into the wheel
bearings on the front wheels while for the rear wheels it is a metal ring which is mounted on
the stub axle.
The registered wheel speed is converted into a digital (square-wave) signal by the electronics
integrated in the sensor and is then transmitted to the ABS control unit.
Data transmissions to the ABS control unit take place via a 2-stranded connecting cable.
It also supplies the vehicle speed signal, which is calculated from the wheel speed sensor
signals. This is transmitted via the CAN bus to the Powertrain Control Module (PCM)
The ABS control unit can be diagnosed via the Data Link Connector (DLC).
The hydraulic unit is pre-filled for service.

Page 3 of 3
Page 1 of 1

ACCESSORY DRIVE — 1.25L/1.4L/1.6L
UID=G163301
Overview

A - Vehicles without air conditioning
B - Vehicles with air conditioning
1 - Crankshaft pulley
2 - Coolant pump
3 - Generator
4 - Power steering pump
5 - Air conditioning compressor
Vehicles without air conditioning have one drive belt, which drives the generator, the coolant
pump and the power steering pump.
Vehicles with air conditioning have two drive belts, the longer of which drives the generator,
the coolant pump and the air conditioning compressor. The shorter drive belt drives only the
power steering pump.
Both versions are elastic multi-ribbed belts and do not need a tensioning pulley. Re-
tensioning is not required.
Page 1 of 1

STARTING SYSTEM
UID=G163308
Starting system

1 - Ignition/starter switch
2 - Starter relay
3 - Electric starter motor
4 - Powertrain control module (PCM)
5 - Sensor,- crankshaft position ( CKP)
The purpose of the starting system is to turn the engine crankshaft at a speed which enables the
engine to start.
The engine is started as follows:
* Ignition/starter switch in position III.
* The starter relay is activated by the PCM .
* The solenoid is supplied with voltage.
* The solenoid engages the starter motor pinion with the flywheel ring gear.
* The solenoid applies battery current to the starter.
* The starter turns the crankshaft until the engine starts. The key can then be released and
it automatically returns to position II.
The system incorporates the "Smart Starting"strategy. This makes starting faster and protects the
starter.
If the driver fails to release the key immediately after the engine starts, the PCM interrupts activation
of the starter relay and thus switches off the electric starter motor.
The speed signal provided by the CKP sensor is used for monitoring the starting procedure.
Page 1 of 1

GLOW PLUG SYSTEM
UID=G163310
General
The purpose of the glow system is to heat the combustion chamber before engine starting and during
cold engine running.
The glow system consists of one pencil-type glow plug per combustion chamber, a glow control unit,
a glow indicator light and the corresponding electrical connections.
The glow control unit and the glow indicator light are controlled by the ( PCM) .
The PCM controls the pre-heating time and the post-heating time as a function of the coolant
temperature and the engine speed.
The lower the coolant temperature, the longer the pre-heating time. At coolant temperatures below -
20°C, the maximum pre-heating time is 8 seconds. There is no pre-heating at coolant temperatures
above 80°C.
Post-heating occurs after a cold engine has been started, to improve combustion. This improves cold
idling and reduces hydrocarbon emissions during the cold-running phase.
At coolant temperatures below -20°C, the post-heating phase can last up to 30 seconds. There is no
post-heating at temperatures above 50°C.
Post-heating is stopped at engine speeds above 2,500 rpm, to protect the pencil-type glow plugs
against excessive temperatures.

1 - Pencil type glow plug
2 - Electrical connection
3 - Glow control unit on the bulkhead
Page 1 of 1

SPECIFICATIONS
UID=G164710

Safety belt lower anchor retaining bolts 40 30 -
Page 1 of 3

ABOUT THIS MANUAL
UID=G17371
Introduction
This manual has been written in a format that is designed to meet the needs of technicians
worldwide. The objective is to use common formats and include similar content in each
manual.
This manual provides general descriptions for accomplishing diagnosis and testing, service
and repair work with tested, effective techniques. Following them will help assure reliability.
Special Tools
The special tool(s) table provided at the beginning of each procedure shows all special tools
required to carry out a repair. Where possible, illustrations are provided to assist in
identifying the special tool required.
Important Safety Instructions
Appropriate service methods and correct repair procedures are essential for the safe, reliable
operation of all motor vehicles as well as the personal safety of the individual carrying out the
work.
This manual cannot possibly anticipate all such variations and provide advice or cautions as to
each. Anyone who departs from the instructions provided in this manual must first establish
that he compromises neither his personal safety nor the vehicle integrity by his choice of
methods, tools or components.
Warnings, Cautions and Notes in This Manual
WARNING: Warnings are used to indicate that failure to follow a procedure correctly
may result in personal injury.
CAUTION: Cautions are used to indicate that failure to follow a procedure correctly
may result in damage to the vehicle or equipment being used.
NOTE: Notes are used to provide additional essential information required to carry out a
complete and satisfactory repair.
As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES.
A warning, caution or note is placed at the beginning of a series of steps if it applies to

multiple steps. If the warning, caution or note only applies to one step, it is placed at the
beginning of the specific step (after the step number).
How to Use This Manual
This manual covers diagnosis and testing, service and repair procedures.
This manual is structured into groups and sections, with specific system sections collected
together under their relevant group.
A group covers a specific portion of the vehicle. The manual is divided into five groups,
General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the
group is the first number of a section number.
Page 2 of 3
Pages at the start of the manual list all sections available. Each section has a contents list
detailing Specifications, Description and Operation, Diagnosis and Testing, In Vehicle Repairs,
Disassembly and Assembly, Removal and Installation.
If components need to be removed or disassembled in sequence, the sequence will be

identified numerically in a graphic and the corresponding text will be numbered accordingly.
All left and right-hand references to the vehicle are taken from a position sitting in the driver
seat looking forward.
All left and right-hand references to the engine are taken from a position at the flywheel
looking towards the front camshaft pulley.
Where appropriate, instructions will be given for the use of the diagnostic tool.
Overview Procedures
Overview procedures contain an exploded view illustration(s). The numbered sequence within
the illustration(s) indicate the order to be followed when removing/disassembling or when
installing/assembling a component. Additional information, symbol(s) or a torque figure, may
also be shown alongside the component.
There are ten symbols used to give additional information when removing/disassembling or
when installing/assembling a component.
Item Designation Description

1 Special tool A special tool is required for this component. There will also be a
removal or installation symbol alongside the special tool symbol.
2 Install new Discard the old component and install a new component.
component
3 Inspect Check the component for damage.
4 Apply sealant Apply sealant to the component as specified in the mate-rials
table.
5 Apply petroleum Apply petroleum jelly to the component as specified in the
jelly materials table.
6 Apply oil Apply oil to the component as specified in the materials table.
7 Apply fluid Apply fluid to the component as specified in the materials table.
8 Apply grease Apply grease to the component as specified in the mate-rials table.
9 Removal or Go to the removal or disassembly detail for additional information
Disassembly detail to remove or disassemble a component
10 Installation or Go to the installation or assembly detail for additional information
Assembly detail to install or assemble a component
Visual Inspection Charts, Symptom Charts and other information charts (such as diagnostic
routines) or supplement test procedures with technical specifications will navigate the user to
a specific test procedure.
Page 3 of 3
Symptom Chart
The symptom chart indicates symptoms, sources and actions to address a condition.
Pinpoint Tests
For electrical systems, pinpoint test steps are used to identify the source of a concern in a
logical, step-by-step manner. pinpoint tests have two columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is used exclusively for graphics and icons (with or without captions)
and the DETAILS/RESULTS/ACTIONS column provides direction to another test step or
specific corrective actions.
The boxed numbers indicate the order in which the described action is to be performed.
Component Tests
A component test is used when a component is tested in multiple pinpoint tests, or if a

procedure is too complicated to be formatted within a single page of the pinpoint test.
Graphics
Test graphics show the measurement or test to be performed in a test step.
A representative tester graphic is used for voltmeters and ohmmeters.
If multiple measurements are made in a single graphic, the test leads are drawn with a solid
line until the test lead splits to indicate the multiple measurements, at which point dashed
lines are used.
Breakout box-type testers are represented by a double circle test pin. Test pins are labeled
with the pin number.
Special Tools and Torque Figures
Any requirement for special tools will picture the tool, showing it in use and with its tool
number shown. Torque settings will be given at the relevant point in the procedure.
Page 1 of 20

HEALTH AND SAFETY PRECAUTIONS
UID=G17372
Introduction
Many of the procedures associated with vehicle maintenance and repair involve physical
hazards or other risks to health. This subsection lists, alphabetically, some of these hazardous
operations and the materials and equipment associated with them. Precautions necessary to
avoid these hazards are identified.
The list is not exhaustive and all operations and procedures, and the handling of materials,
should be carried out with health and safety in mind.
Before using any product the Materials Safety Data Sheet supplied by the manufacturer or
supplier should be consulted.
Acids and Alkalis
See also Battery Acids.
For example caustic soda, sulphuric acid.
Used in batteries and cleaning materials.
Irritant and corrosive to the skin, eyes, nose and throat. Cause burns. Can destroy ordinary
protective clothing.
Avoid splashes to the skin, eyes and clothing. Wear suitable protective impervious apron,
gloves and goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing
accidents.
Display Eye Hazard sign.
Air Bags
See also Fire, Chemical Materials.
Highly flammable, explosive – observe No Smoking policy.
Used as a safety restraint system mounted in the steering wheel and passenger side of the
instrument panel.
The inflator contains a high-energetic propellant which, when ignited, produces a VERY HOT
GAS (2500°C).
The gas generant used in air bags is Sodium Azide. This material is hermetically sealed in the
module and is completely consumed during deployment. No attempt should be made to open
an air bag inflator as this will lead to the risk of exposure to Sodium Azide. If a gas generator
is ruptured, full protective clothing should be worn when dealing with the spillage.
After normal deployment, gloves and safety goggles must be worn during the handling
process.
Page 2 of 20
Deployed air bags should be disposed of in a plastic bag in accordance with local regulations
at an approved chemical waste site.
Following any direct contact with gas generant.
- wash affected areas thoroughly with water.
- seek medical assistance if necessary.
Air Bags - Do's
- Do store modules in an upright position.
- Do keep modules dry.
- Do carry modules with the cover side pointing away from the body.
- Do place modules with their cover side upwards.
- Do carefully inspect modules for damage.
- Do stand to one side when connecting modules.
- Do make sure all test equipment is properly calibrated and maintained.
- Do wash hands after handling deployed air bags.
Air Bags - Do Nots
- Do not store highly flammable material together with modules or gas

generators.
- Do not store gas generators at temperatures exceeding 80°C.
- Do not store modules upside down.
- Do not attempt to open a gas generator housing.
- Do not expose gas generators to open flame or sources of heat.
- Do not place anything on top of a module cover.
- Do not use damaged modules.
- Do not touch a fired module or gas generator for at least 10 minutes.
- Do not use any electrical probes on the wiring circuit.
Air Conditioning Refrigerant
See also Chlorofluorocarbon, Chemical Materials
Highly flammable, combustible – observe No Smoking policy.
Skin contact may result in frostbite.

Page 3 of 20
Instructions given by the manufacturer must be followed. Avoid naked lights, wear suitable
protective gloves and goggles.
If refrigerant comes into contact with the skin or eyes, immediately rinse the affected areas
with water. Eyes should also be rinsed with an appropriate irrigation solution and should not
be rubbed. SEEK MEDICAL ASSISTANCE IF NECESSARY.
Air Conditioning Refrigerant - Do Nots
- Do not expose refrigerant bottles to sunlight or heat.
- Do not stand refrigerant bottles upright; when filling, hold them with the valve
downwards.
- Do not expose refrigerant bottles to frost.
- Do not drop refrigerant bottles.
- Do not vent refrigerant to atmosphere under any circumstance.
- Do not mix refrigerants, for example R12 (Freon) and R134a.
Adhesives and Sealers
See also Fire, Chemical Materials.
Highly flammable, flammable, combustible – observe No Smoking policy.
Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be
observed, for example disposable paper covering benches; should be dispensed from
applicators where possible; containers, including secondary containers, should be labeled
appropriately.
Solvent-based Adhesives/Sealers - See Solvents
Follow manufacturers instructions.
Water-based Adhesives/Sealers
Those based on polymer emulsions and rubber latexes may contain small amounts of volatile
toxic and harmful chemicals. Skin and eye contact should be avoided and adequate
ventilation provided during use.
Hot Melt Adhesives
In the solid state, they are safe. In the molten state they may cause burns and health
hazards may arise from the inhalation of toxic fumes.
Use appropriate protective clothing and a thermostatically controlled heater with a thermal
cut-out and adequate extraction.
Resin-based Adhesives/Sealers, for example Epoxide and Formaldehyde Resin-based
Mixing should be carried out in well ventilated areas, as harmful or toxic volatile chemicals
may be released.
Page 4 of 20
Skin contact with uncured resins and hardeners can result in irritation, dermatitis, and
absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes.
Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives
Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye
irritants.
Skin and eye contact should be avoided and the manufacturers instructions followed.
Cyanoacrylate adhesives (super-glues) MUST NOT contact the skin or eyes. If skin or eye
tissue is bonded, cover with a clean moist pad and SEEK IMMEDIATE MEDICAL ATTENTION.
Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause irritation
to the nose and eyes.
For two-pack systems see Resin-based and Isocyanate Adhesives/Sealers.
Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives.
Individuals suffering from asthma or respiratory allergies should not work with or near these
materials as sensitivity reactions can occur.
Over exposure is irritating to the eyes and respiratory system. Excessive concentrations may
produce effects on the nervous system including drowsiness. In extreme cases, loss of
consciousness may result. Long term exposure to vapor concentrations may result in adverse
health effects.
Prolonged contact with the skin may have a defatting effect which may lead to skin irritation
and in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage.
Any spraying should preferably be carried out in exhaust ventilated booths, removing vapors
and spray droplets from the breathing zone.
Wear appropriate gloves, eye and respiratory protection.
Antifreeze
See also Fire, Solvents.
For example isopropanol, ethylene glycol, methanol.
Highly flammable, flammable, combustible.
Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these
vapors.
Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if
swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY.
Page 5 of 20
These products must not be used in any cooling or industrial water system that is connected
or linked to general, food preparation or drinking water supplies.
Asbestos
See also Warning Symbols on Vehicles at the end of this subsection.
Breathing asbestos dust may cause lung damage or, in some cases, cancer.
Used in brake and clutch linings, transmission brake bands and gaskets.
The use of drum cleaning units, vacuum cleaning or damp wiping is preferred.
Asbestos dust waste should be dampened, placed in a sealed container and marked for safe
disposal. If any cutting or drilling is attempted on materials containing asbestos the item
should be dampened and only hand tools or low speed power tools used.
Battery Acids
See also Acids and Alkalis.
Gases released during charging are explosive. Never use naked flames or allow sparks near
charging or recently charged batteries.
Make sure there is adequate ventilation.
Brake and Clutch Linings and Pads
See Asbestos.
Brake Fluids (Polyalkylene Glycols)
See also Fire.
Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as
possible. Inhalation vapor hazards do not arise at ambient temperatures because of the very
low vapor pressure.
Brazing
See Welding.
Chemical Materials
See also Legal Aspects.
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids,
antifreeze, brake fluids, fuels, oils and grease should always be used with caution and stored
and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable
and give rise to hazardous fumes and dusts.
The effects of excessive exposure to chemicals may be immediate or delayed; briefly

experienced or permanent; cumulative; superficial; life threatening; or may reduce life
expectancy.
Page 6 of 20
Chemical Materials - Do's
- Do carefully read and observe hazard and precaution warnings given on material
containers (labels) and in any accompanying leaflets, posters or other
instructions. Material health and safety data sheets can be obtained from
manufacturers.
- Do remove chemical materials from the skin and clothing as soon as practicable
after soiling. Change heavily soiled clothing and have it cleaned.
- Do organize work practices and protective clothing to avoid soiling of the skin
and eyes; breathing vapors, aerosols, dusts or fumes; inadequate container
labeling; fire and explosion hazards.
- Do wash before job breaks, before eating, smoking, drinking or using toilet
facilities when handling chemical materials.
- Do keep work areas clean, uncluttered and free of spills.
- Do store chemical materials according to national and local regulations.
- Do keep chemical materials out of the reach of children.
Chemical Materials - Do Nots
- Do not mix chemical materials except under the manufacturers instructions;

some chemicals can form other toxic or harmful chemicals, give off toxic or
harmful fumes or become explosive when mixed together.
- Do not spray chemical materials, particularly those based on solvents, in

confined spaces, for example when people are inside a vehicle.
- Do not apply heat or flame to chemical materials except under the

manufacturers instructions. Some are highly flammable and some may release
toxic or harmful fumes.
- Do not leave containers open. Fumes given off can build up to toxic, harmful or
explosive concentrations. Some fumes are heavier than air and will accumulate in
confined areas such as pits.
- Do not transfer chemical materials to unlabelled containers.
- Do not clean hands or clothing with chemicals. Chemicals, particularly solvents

and fuels, will dry the skin and may cause irritation leading to dermatitis or be
absorbed through the skin in toxic or harmful quantities.
- Do not use emptied containers for other materials except when they have been
cleaned under supervised conditions.
- Do not sniff or smell chemical materials. Brief exposure to high concentrations

of fumes can be toxic or harmful.
Chlorofluorocarbons (CFC)
There is concern in the scientific community that CFCs and Halons are depleting the upper
ozone layer which filters out harmful ultraviolet radiation. Decreased filtration of ultraviolet
Page 7 of 20
radiation may result in increases in skin cancer, cataracts and immune system suppression in
humans, as well as decreased productivity of crops and aquatic systems.
CFCs are used primarily as refrigerants in vehicle air conditioning systems and as aerosol
propellants. Halons are used as fire extinguishants.
Clutch Fluids
See Brake fluids.
Clutch Linings and Pads
See Asbestos.
Corrosion Protection Materials
See also Solvents, Fire.
Highly flammable, flammable – observe No Smoking policy.
These materials are varied and the manufacturers instructions must be followed. They may
contain solvents, resins or petroleum products. Skin and eye contact should be avoided. They
should only be sprayed in conditions of adequate ventilation and not in confined spaces.
Cutting
See Welding.
Dewaxing
See Solvents and Fuels (Kerosene).
Dusts
Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery
chemical materials or those arising from dry abrasion operations. Wear respiratory protection
if ventilation is inadequate.
Fine dusts of combustible material can present an explosion hazard. Avoid explosive limits
and sources of ignition.
Electric Shock
Electric shock can result from the use of faulty electrical equipment or from the misuse of
equipment in good condition.
Make sure that electrical equipment is maintained in good condition and frequently tested.
Faulty equipment should be labeled and preferably removed from the workstation.
Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or
otherwise damaged.
Make sure that electrical equipment and flexes do not come into contact with water.
Make sure that electrical equipment is protected by the correct rated fuse.
Page 8 of 20
Never misuse electrical equipment and never use equipment that is in any way faulty. The
results could be fatal.
Make sure that the cables of mobile electrical equipment cannot get trapped and damaged,
such as in a vehicle hoist.
Make sure that the designated electrical workers are trained in basic First Aid.
In cases of electrocution:
- switch off the power supply before approaching the victim.
- if this is not possible push or drag the victim from the source of electricity using
dry non-conductive material.
- commence resuscitation if trained to do so.
- SUMMON MEDICAL ASSISTANCE.
Engine Oils
See Lubricants and Grease.
Exhaust Fumes
These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides,
nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only
under conditions of adequate exhaust extraction or general ventilation and not in confined
spaces.
Gasoline (petrol) engine
There may not be adequate warning of odor or of irritation before toxic or harmful effects
arise. These may be immediate or delayed.
Diesel engine
Soot, discomfort and irritation usually give adequate warning of hazardous fume
concentrations.
Fibre Insulation
See also Dusts.
Used in noise and sound insulation.
The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a
physical and not a chemical effect.
Precautions should be taken to avoid excessive skin contact through careful organization of
work practices and the use of gloves.
Fire
See also Welding, Foams, Legal Aspects.

Page 9 of 20
Many of the materials found on or associated with the repair of vehicles are highly flammable.
Some give off toxic or harmful fumes if burnt.
Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes.
Make sure, before using electrical or welding equipment, that there is no fire hazard present.
Have a suitable fire extinguisher available when using welding or heating equipment.
First Aid
Apart from meeting any legal requirements it is desirable for someone in the workshop to be
trained in First Aid procedures.
Splashes in the eye should be flushed carefully with clean water for at least ten minutes.
Soiled skin should be washed with soap and water.
In case of cold burns, from alternative fuels, place affected area in cool to cold water.
Individuals affected by inhalation of gases and fumes should be removed to fresh air
immediately. If effects persist, consult a doctor.
If liquids are swallowed inadvertently, consult a doctor giving him the information on the
container or label. Do not induce vomiting unless this action is indicated on the label.
Fluoroelastomer
See Viton.
Foams - Polyurethane
See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning.
Follow manufacturers instructions.
Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves
and goggles.
Individuals with chronic respiratory diseases, asthma, bronchial medical problems, or

histories of allergic diseases should not work in or near uncured materials.
The components, vapors or spray mists can cause direct irritation, sensitivity reactions and
may be toxic or harmful.
Vapors and spray mists must not be inhaled. These materials must be applied with adequate
ventilation and respiratory protection. Do not remove the respirator immediately after
spraying; wait until the vapors/mists have cleared.
Burning of the uncured components and the cured foams can generate toxic and harmful
fumes. Smoking, naked flames or the use of electrical equipment during foaming operations
and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams
or partially cured foams should be conducted with extraction ventilation. See also the vehicle
Page 10 of 20
Body Repair Manual.
Freon
See Air Conditioning Refrigerant.
Fuels
See also, Fire, Legal Aspects, Chemicals and Solvents.
Avoid skin contact with fuel where possible. Should contact occur, wash the affected skin with
soap and water.
Gasoline (Petrol)
Highly flammable - observe No Smoking policy.
Swallowing can result in mouth and throat irritation and absorption from the stomach can
result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration
of liquid into the lungs, through vomiting, is a very serious hazard.
Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated
contact. Liquid in the eye causes severe smarting.
Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation,
and the concentration of gasoline vapors must be kept very low. High concentrations will
cause eye, nose and throat irritation, nausea, headache, depression and symptoms of
drunkenness. Very high concentrations will result in rapid loss of consciousness.
Make sure there is adequate ventilation when handling and using gasoline. Great care must
be taken to avoid the serious consequences of inhalation in the event of vapor build up arising
from spillages in confined spaces.
Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.
Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth. See First
Aid.
Gas-oil (Diesel Fuel)
Combustible.
Gross or prolonged skin contact with high boiling point gas oils may also cause serious skin
disorders including skin cancer.
Kerosene (Paraffin)
Used also as heating fuel, solvent and cleaning agent.
Flammable - observe No Smoking policy.
Irritation of the mouth and throat may result from swallowing. The main hazard from
swallowing arises if liquid aspiration into the lungs occurs.
Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may
Page 11 of 20
be slightly irritating.
In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to
mists and vapors from kerosene at elevated temperature should be avoided (mists may arise
in dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation.
Alternative Fuel
Highly flammable. Observe ``NO SMOKING" signs.
Make sure there is adequate ventilation when working on alternative fuelled vehicles. Great
care must be taken to avoid the serious consequences of inhalation in the event of vapor
build up in confined spaces.
Inhalation in high concentrations may cause dizziness, headache, nausea and loss of co-
ordination. Very high concentrations may result in loss of consciousness.
Contact with liquefied petroleum gas (LPG) or compressed natural gas (CNG) to the skin may
cause cold burns and frost bite.
Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves
should be worn during removal and installation of LPG/CNG fuel system components.
LPG/CNG fuel leaks could cause a fire and be a hazard to health that can lead to personal
injury, illness or even death.
If a leak is detected, under no circumstances attempt to seal the leak by tightening the
union/connection until the fuel in the system or component is depressurized. Once tightened
the system should be checked for integrity following the specified procedures.
If the fuel tank is to be removed for service or repair the fuel must be evacuated using
dedicated equipment and following the specified procedures.
Gas Cylinders
See also Fire.
Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at
pressures of up to 138 bar (2000 psi) and great care should be taken in handling these
cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of
each cylinder should be clearly identified by appropriate markings.
Cylinders should be stored in well-ventilated enclosures, and protected from ice and snow, or
direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in close
proximity to oxygen cylinders.
Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources
of ignition.
Only trained personnel should undertake work involving gas cylinders.
Gases
See Gas Cylinders.
Gaskets (Fluoroelastomer)
Page 12 of 20
See Viton.
General Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition and that the
correct safety equipment is used where required.
Never use tools or equipment for any purpose other than that for which they were designed.
Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings.
Damage caused by overloading is not always immediately apparent and may result in a fatal
failure the next time that the equipment is used.
Do not use damaged or defective tools or equipment, particularly high-speed equipment such
as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause
serious injury.
Wear suitable eye protection when using grinding, chiseling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with
asbestos-based materials or using spraying equipment.
Make sure there is adequate ventilation to control dusts, mists and fumes.
High Pressure Air, Lubrication and Oil Test Equipment
See also Lubricants and Greases.
Always keep high-pressure equipment in good condition, and regularly maintained,

particularly at joints and unions.
Never direct a high-pressure nozzle, for example diesel injector, at the skin as the fluid may
penetrate to the underlying tissue, and cause serious injury.
Halon
See CFCs.
Legal Aspects
There are many laws and regulations relating to health and safety in the use and disposal of
materials and equipment in a workshop.
For a safe working environment and to avoid environmental pollution, workshops should be
familiar, in detail, with the many health and safety laws and regulations within their country,
published by both national and local authorities.
Lubricants and Greases
Avoid all prolonged and repeated contact with mineral oils. All lubricants and greases may be
irritating to the eyes and skin.
Transmission Fluids
Safety instructions
Page 13 of 20
Certain Transmission and Power Steering fluids supplied to Ford may contain additives which
have the potential to cause skin disease (dermatitis) to exposed persons. The dermatitis may
be irritant or allergic in nature. Risks are higher where prolonged or repeated skin contact
with a fluid may occur. These fluids are used for vehicle initial fill and service purposes. This
sub-section is to:
* Inform Service personnel who may come into contact with these vehicle fluids
(hazard communication).
* Summarise appropriate workplace control measures and personal protective

equipment requirements.
* Draw attention to the existence of Material Safety Datasheets (MSDS's) for the
fluids (available from Ford Customer Service Division). These MSDS's contain
detailed information on hazards and appropriate controls.
Control measures
Workplace risk assessments made under national chemical control regulations should identify
operations involving the fluids as potentially hazardous and specify workplace control and
worker awareness measures. In such circumstances, the relevant Material Safety Datasheet
(see the details specified below) which specifies hazards and control measures in detail should
be made available for guidance.
Avoid unprotected skin contact with the fluids, and in particular, avoid prolonged or repeated
skin contact. Work practices should be organised so as to minimise the potential for skin
contact. This may include the use of drip trays, absorbents, correct fluid handling equipment
(funnels etc), and workplace housekeeping measures such as the cleaning of contaminated
surfaces.
Personnel engaged in operations where skin contact could occur (such as fluid draining or
filling) should wear impervious gloves made from nitrile rubber, certified to a chemical
protection standard, e.g. Europe Standard EN374. This glove type is widely available from
reputable suppliers of gloves for chemical protection [including the manufacturers Ansell-
Admont (Solvex Range), North Safety products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves become torn or contaminated on the inside
they should be replaced. Eye protection with safety glasses is appropriate. Use of an
impervious apron and arm protectors may be necessary if more extensive exposure is
possible. Use of skin barrier creams suitable for work with mineral oil products may offer
some supplementary protection, but such barrier creams should not be used in place of
protective clothing.
If accidental skin contact occurs with the fluids, wash the area thoroughly with soap or skin
cleanser and water.
Accidental eye contact should be dealt with as per normal first aid practices, by flushing the
eyes with an eye wash or clean cool water for 10 minutes, after which medical attention
should be obtained.
Remove and launder clothing which becomes contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly after completing operations where skin exposure may have occurred.
It is important that personnel do not smoke, eat or drink whilst handling the fluids or affected
transmissions. These measures are designed to limit the risk from accidental ingestion.
Page 14 of 20
Label any decanted fluid properly/use an equivalent label to that on original product
containers.
Clean up any spills promptly using an inert absorbent and wash down contaminated surfaces
with detergent and water.
Dispose of any waste fluids safely as hazardous waste.
Safety Data Sheets
Safety Data Sheets, which detail specific material handling instructions and precautions are
available from the respective national sales company, and via internet www.msds.ford.com.
Used Engine Oil
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from
the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains
potentially harmful contaminants, which may cause skin cancer. Adequate means of skin
protection and washing facilities must be provided.
Do not employ used engine oils as lubricants or for any application where appreciable skin
contact is likely to occur.
Environmental Precautions
Burning used engine oil in small space heaters or boilers can be recommended only for units
of approved design. If in doubt check with the appropriate local authority and manufacturer of
approved appliances.
Dispose of used oil and used oil filters through authorized waste disposal contractors or
licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the
relevant local authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or drains, or into watercourses.
Noise
Some operations may produce high noise levels, which could, in time, damage hearing. In
these cases, suitable ear protection must be worn.
Noise Insulation Materials
See Foams, Fibre Insulation.
O-Rings (Fluoroelastomer)
See Viton.
Paints
See also Solvents, Chemical Materials.
Highly flammable, flammable - observe No Smoking policy
One Pack
Page 15 of 20
Can contain harmful or toxic pigments, driers and other components as well as solvents.
Spraying should be carried out only with adequate ventilation.
Two Pack
Can also contain harmful and toxic unreacted resins and resin hardening agents. The
manufacturers instructions should be followed. See also Resin-based Adhesives and
Isocyanate Adhesives and Sealers under Adhesives and Sealers.
Spraying should preferably be carried out in exhausted ventilated booths removing vapor and
spray mists from the breathing zone. Individuals working in booths should wear appropriate
respiratory protection. Those doing small-scale repair work in the open workshop should wear
air-fed respirators.
Pressurized Equipment
See High Pressure Air, Lubrication and Oil Test Equipment.
Solder
Solders are mixtures of metals such that the melting point of the mixture is below that of the
constituent metals (normally lead and tin). Solder application does not normally give rise to
toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not be used,
as they are much hotter and will cause lead fumes to be produced.
Some fumes may be produced by the application of any flame to surfaces coated with grease,
and inhalation of these should be avoided.
Removal of excess solder should be undertaken with care, to make sure that fine lead dust is
not produced, which can give toxic effects if inhaled. Respiratory protection may be
necessary.
Solder spillage and filings should be collected and removed promptly to prevent general air
contamination by lead.
High standards of personal hygiene are necessary in order to avoid ingestion of lead or
inhalation of solder dust from clothing.
Solvents
See also Chemical Materials, Fuels (Kerosene), Fire.
For example acetone, white spirit, toluene, xylene, trichloroethane.
Used in cleaning and dewaxing materials, paints, plastics, resins and thinners.
Some may be highly flammable or flammable.
Skin contact will degrease the skin and may result in irritation and dermatitis following
repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful
quantities.
Splashes in the eye may cause severe irritation and could lead to loss of vision.
Brief exposure of high concentrations of vapors or mists will cause eye and throat irritation,
drowsiness, dizziness, headaches and, in the worst circumstances, unconsciousness.
Page 16 of 20
Repeated or prolonged exposure to excessive but lower concentrations of vapors or mists, for
which there might not be adequate warning indications, can cause more serious toxic or
harmful effects.
Aspiration into the lungs, for example through vomiting, is the most serious consequence of
swallowing.
Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if
necessary.
Make sure there is good ventilation when in use, avoid breathing fumes, vapors and spray
mists and keep containers tightly sealed. Do not use in confined spaces.
When spraying materials containing solvents, for example paints, adhesive, coatings, use
extraction ventilation or personal respiratory protection in the absence of adequate general
ventilation.
Do not apply heat or flame except under specific and detailed manufacturers instructions.
Sound Insulation
See Fibre Insulation, Foams.
Suspended Loads
CAUTION: Never improvise lifting tackle.

There is always a danger when loads are lifted or suspended. Never work under an
unsupported, suspended or raised load, for example a suspended engine.
Always make sure that lifting equipment such as jacks, hoists, axle stands and slings are
adequate and suitable for the job, in good condition and regularly maintained.
Transmission Brake Bands
See Asbestos.
Underseal
See Corrosion Protection.
Viton
In common with many other manufacturers vehicles, some components have O-rings, seals
or gaskets, which contain a material known as `Viton'.
Viton is a fluoroelastomer, that is a synthetic rubber type material, which contains Fluorine. It
is commonly used for O-rings, gaskets and seals of all types. Although Viton is the most well
known fluoroelastomer, there are others, including Fluorel and Tecmoflon.
When used under design conditions fluoroelastomers are perfectly safe. If, however, they are
exposed to temperatures in excess of 400°C, the material will not burn, but will decompose,
and one of the products formed is hydrofluoric acid.
This acid is extremely corrosive and may be absorbed directly, through contact, into the
general body system.
Page 17 of 20
O-rings, seals or gaskets which have been exposed to very high temperatures will appear
charred or as a black sticky substance.
DO NOT; under any circumstances touch them or the attached components.
Enquiries should be made to determine whether Viton or any other fluoroelastomer has been
used in the affected O-ring, seal or gasket. If they are of natural rubber or nitrile there is no
hazard. If in doubt, be cautious, as the material may be Viton or any fluoroelastomer.
If Viton or any other fluoroelastomers have been used, the affected area should be
decontaminated before the commencement of work.
Disposable heavy duty plastic gloves should be worn at all times, and the affected area
washed down using wire wool and a limewater (calcium hydroxide) solution to neutralize the
acid before disposing of the decomposed Viton residue and final cleaning of the area. After
use, the plastic gloves should be discarded carefully and safely.
Welding
See also Fire, Electric Shock, Gas Cylinders.
Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding.
Resistance Welding
This process may cause particles of molten metal to be emitted at a high velocity, and the
eyes and skin must be protected.
Arc Welding
This process emits a high level of ultra-violet radiation, which may cause arc-eye, and skin
burns to the operator and to other persons nearby. Gas-shielded welding processes are
particularly hazardous in this respect. Personal protection must be worn, and screens used to
shield other people.
CONTACT LENS WEARERS ARE ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC
WELDING as the arc spectrum is believed to emit microwaves which dry out the fluid between
the lens and the eye. This may result in blindness when the lens is removed from the eye.
Metal spatter will also occur, and appropriate eye and skin protection is necessary.
The heat of the welding arc will produce fumes and gases from the metals being welded, the
rods and from any applied coatings or contamination on the surfaces being worked on. These
gases and fumes may be toxic and inhalation of these should be avoided. The use of
extraction ventilation to remove the fumes from the working area may be necessary
particularly in cases where the general ventilation is poor, or where considerable welding
work is anticipated. In extreme cases or confined spaces where adequate ventilation cannot
be provided, air-fed respirators may be necessary.
Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken
to prevent leakage of these gases, with consequent risk of fire and explosion.
The process will produce metal spatter and eye and skin protection is necessary.
Page 18 of 20
The flame is bright, and eye protection should be used, but the ultra-violet emission is much
less than that from arc welding, and lighter filters may be used.
The process itself produces few toxic fumes, but such fumes and gases may be produced from
coatings on the work, particularly during cutting away of damaged body parts, and inhalation
of the fumes should be avoided.
In brazing, toxic fumes may be produced from the metals in the brazing rod, and a severe
hazard may arise if brazing rods containing cadmium are used. In this event particular care
must be taken to avoid inhalation of fumes and expert advice may be required.
SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE
ON VESSELS, WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING
OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles
Decals showing warning symbols will be found on various vehicle components.
These decals must not be removed. The warnings are for the attention of owners/operators
and persons carrying out service or repair operations on the vehicle.
The most commonly found decals are reproduced below together with an explanation of the
warnings.
1. Components or assemblies displaying the caution triangle and open book symbol advise
consultation of the relevant section of the owner literature before touching or attempting
adjustments of any kind.
2. Components or assemblies displaying the warning triangle with the `electrified' arrow and
open book symbol give warning of inherent high voltages. Never touch these with the
engine running or the ignition switched on. See Electric Shock in this subsection.
Page 19 of 20
3. Vehicles and replacement components which contain asbestos are identified by this
symbol. See Asbestos in this subsection.
4. Components or assemblies displaying this symbol give warning that the component
contains a corrosive substance. See Acids and Alkalis in this subsection.
5. Displaying the caution circle with a deleted lighted match symbol, caution against the use
of naked lights or flames within the immediate vicinity due to the presence of highly
flammable or explosive liquids or vapors. See Fire in this subsection.
6. Displaying this symbol (normally in conjunction with 5 above) warn of the presence of
potentially explosive matter within the immediate vicinity.
Page 20 of 20
7. Displaying this symbol warn that children should not be allowed in the immediate vicinity
unsupervised.
White Spirit
See Solvents.
Page 1 of 5

STANDARD WORKSHOP PRACTICES
UID=G17373
Vehicle in Workshop
When working on a vehicle in the workshop always make sure that:
- the parking brake is applied or the wheels are securely chocked to prevent the
vehicle moving forwards or backwards.
- the key is removed from key operated hood locks before any work is carried out
around the front of the vehicle.
- if the engine is to be run, there is adequate ventilation, or an extraction hose to

remove exhaust fumes.
- there is adequate room to raise the vehicle and remove the wheels, if
necessary.
- fender covers are always fitted if any work is to be carried out in the engine
compartment.
- the battery is disconnected if working on the engine, underneath the vehicle, or

if the vehicle is raised.
CAUTION: When electric arc welding on a vehicle, always disconnect the generator
wiring to prevent the possibility of a surge of current causing damage to the internal
components of the generator.
- If using welding equipment on the vehicle, a suitable fire extinguisher is readily

available.
Alternative Fuel
WARNING: When servicing the fuel system always follow the recommended
procedures. Failure to follow these instructions may result in personal injury.
If the odor of liquefied petroleum gas (LPG) or compressed natural gas (CNG) is present in
the air in the workshop, warn all persons in the area to:
- extinguish all flames and lighted tobacco.
- shut off electrical and air powered equipment.
- evacuate the area.
- ventilate the area.
- contact the fire control authorities.
- remove the vehicle to a dedicated, ventilated area.
Alternative Fuel — Do's

Page 2 of 5
- Do work on the vehicle in a designated area that is well ventilated and with
access restricted to qualified personnel only.
- Install new warning labels to their original locations.
- If possible always isolate the alternative fuel tank, and run the vehicle on the
alternative fuel until it automatically switches to its normal fuel prior to taking the
vehicle into the workshop/service area.
- Only use tested and approved components and pipes when repairing or servicing
LPG and CNG systems.
Alternative Fuel — Do Nots
- Do not vent off LPG fuel.
- Do not use shop air pressure to force LPG fuel from the fuel tank.
- Do not use paint drying ovens above 40°C for any alternative fuel vehicles. LPG
and CNG fuel tanks must be removed from the vehicles prior to being put into
paint drying ovens above 40°C.
- Do not modify the system or install new components that are not designed for
gas vehicles.
- Do not evacuate fuel tanks unless there is repair that requires the removal of
the fuel tank.
- Do not work on the fuel lines or system components unless the alternative fuel
has been evacuated and the pressure in the system reduced to atmospheric or
less.
- Do not use anything other than the specified leak detector fluid to trace fuel
leaks.
Be aware of situations that may cause the LPG or CNG fuel system to vent off fuel, such as:
- extremely hot days.
- parking by a space heater.
- hoisting a vehicle up near a ceiling heater.
Only fully trained personnel, who are conversant with local standards, are to work on
alternative fuel vehicles.
Towing the Vehicle
WARNING: When the vehicle is being towed the ignition switch must be in position II
(steering lock released and warning lamps illuminated). Only then will the steering, turn
signal lamps, horn and stop lamps be operational. Failure to follow these instructions may
result in personal injury.
NOTE: The removable towing eye (if equipped), has a left-hand thread and must be fully
tightened before towing can commence.
When towing is necessary, the vehicle towing eyes should be used. The rope must be
Page 3 of 5
securely fastened to the towing eyes and must also be attached to the other vehicle such that
the rope will not foul the bodywork.
When a vehicle with automatic transmission is towed, the gear selector must be in position N
(Neutral). Never tow a vehicle with automatic transmission at a speed greater than 30 mph
(50 km/h) or for a distance greater than 30 miles (50 km). If it is necessary to tow the
vehicle a greater distance, the drive wheels must be lifted clear off the ground.
Alternatively the vehicle can be transported on a low loader or a trailer.
Connecting a Slave Battery Using Jumper Cables
WARNING: If the slave battery has recently been charged and is gassing, cover the
vent plugs or covers with a damp cloth to reduce the risk of explosion should arcing occur
when connecting the jumper cables. Failure to follow these instructions may result in
personal injury.
CAUTIONS:
A discharged battery condition may have been caused by an electrical short circuit. If
this condition exists there will be an apparently live circuit on the vehicle even when all
normal circuits are switched off. This can cause arcing when the jumper cables are
connected.
While it is not recommended that the vehicle is jump started, it is recognized that
this may occasionally be the only practical way to mobilize a vehicle. In such an instance,
the discharged battery must be recharged immediately after jump starting to avoid
permanent damage.
- Always make sure that the jumper cables are adequate for the task. Heavy duty
cables must be used.
- Always make sure that the slave battery is of the same voltage as the vehicle
battery. The batteries must be connected in parallel.
- Always make sure that switched electric circuits are switched off before
connecting jumper cables. This reduces the risk of arcing occurring when the final
connection is made.
WARNING: Make sure that the ends of the jumper cables do not touch each other or
ground against the vehicle body at any time while the cables are attached to the battery.
A fully charged battery, if shorted through jumper cables, can discharge at a rate well
above 1000 amps causing violent arcing and very rapid heating of the jumper cables and
terminals, and can even cause the battery to explode. Failure to follow these instructions
Page 4 of 5
Always connect the jumper cables in the following sequence:
- Slave battery positive first and then vehicle battery positive.
- Slave battery negative next and then vehicle ground at least 12 inches (300
mm) from the battery terminal, for example engine lifting eye.
Always reduce the engine speed to idle before disconnecting the jumper cables.
Before removing the jumper cables from the vehicle that had the discharged battery, switch
on the heater blower (high) or the heated rear window, to reduce the voltage peak when the
cables are removed.
Always disconnect the jumper cables in the reverse order to the connecting sequence and do
not short the ends of the cables.
Do not rely on the generator to restore a discharged battery. For a generator to recharge a
battery, it would take in excess of eight hours continuous driving with no additional loads
placed on the battery.
Component Cleaning
To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed
before disconnecting or dismantling components or assemblies.
Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods:
- Dry cleaning.
- Removal of loose dirt with soft or cable brushes.
- Scraping dirt off with a piece of metal or wood.
- Wiping off with a rag.
CAUTION: Compressed air is sometimes 'wet' so use with caution, especially on

hydraulic systems.
- Blowing dirt off with compressed air. Eye protection must be worn when using
this method.
- Removal of dry dust using vacuum equipment. This method should always be
used to remove friction lining material dust (asbestos particles).
- Steam cleaning.
WARNING: Most solvents require careful handling and some are harmful. Refer to
Health and Safety Precautions and to the manufacturers literature for safety precautions.
Failure to follow these instructions may result in personal injury.
Various solvents are available which are suitable for component cleaning. Some components
such as brake hydraulic parts and electrical assemblies should be cleaned only with
recommended solvents — refer to Solvents, Sealers and Adhesives or to the section of the
Page 5 of 5
manual relevant to the component.
Calibration of Essential Measuring Equipment
WARNING: Failure to follow these instructions may result in personal injury or

damage to components.
It is of fundamental importance that certain essential equipment, for example torque
wrenches, multimeters, exhaust gas analyzers or rolling roads, are regularly calibrated in
accordance with the manufacturers instructions.
Page 1 of 1

SOLVENTS, SEALANTS AND
ADHESIVES
UID=G17374
Introduction
WARNING: Always handle all solvents, sealers and adhesives with extreme care.
Some contain chemicals or give off fumes which can be dangerous to health. Always
follow the manufacturers instructions. If in doubt about any substance, particularly a
solvent, DO NOT use it.
CAUTION: If in doubt about the suitability of any proprietary solvent or sealer for a
particular application, contact the manufacturer of the product for information regarding
storage, handling and application.
The Health and Safety Precautions subsection refers to some commonly used chemicals and
materials, hazards associated with their use, and safety measures to be taken.
Page 1 of 3

ROAD/ROLLER TESTING
UID=G17375
Road or roller testing may be carried out for various reasons and a procedure detailing pre-
test checks, engine starting and stopping, pre-driving checks, on-test checks and final checks
to be completed on completion of the test is given below.
Unless complete vehicle performance is being checked, the full road test procedure need not
be carried out. Instead, those items particularly relevant to the system(s) being checked can
be extracted.
Pre-Test Checks
WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt to road test the vehicle until the reason for
the low fluid level, excessive pedal travel or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional tests of those systems and circuits which
affect the safe and legal operations of the vehicle, such as brakes, lights and steering, should
always be carried out before the road or roller test.
With the ignition switched off, check:
- the engine oil level.
- the engine coolant level.
- the tires, for correct pressure, compatible types and tread patterns, and wear
within limits.
- that there is sufficient fuel in the tank to complete the test.
- all around the engine, transmission and under the vehicle for oil, coolant,
hydraulic and fuel leaks. Make a note of any apparent leaks and wipe off the
surrounding areas to make it easier to identify the extent of the leak on
completion of the test.
Starting the Engine
NOTE: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress
the accelerator pedal beyond half travel until the vehicle has attained a minimum speed
of 25 km/h (15 miles/h). Never operate at high engine speed or with the accelerator
pedal at full travel whilst the engine is cold.
With the ignition switched off, check:
- that the parking brake is applied.
- that the gear lever is in the neutral position.
- that all instrument gauges (except fuel gauge) read zero.
With the ignition switched on, check:
- that the ignition controlled warning lamps are illuminated.

Page 2 of 3
- that the engine temperature gauge registers a reading compatible with the
engine temperature.
- that the fuel gauge registers a reading appropriate to the fuel level in the tank.
- the operation of the parking brake warning lamp and fluid level warning
indicator.
Road or Roller Testing
CAUTION: If road testing, check the brake operation while still traveling at low speed
before continuing with the test. If the brakes pull to one side, or appear to be otherwise
faulty, do not continue with the road test until the fault has been found and rectified.
During the road or roller test, check:
- that the clutch pedal operation is not stiff or heavy.
- that the initial gear engagement is smooth and there is no evidence of clutch
drag.
- that the parking brake control operates smoothly and releases quickly and
completely.
- that the clutch takes up the drive smoothly, without slip or judder.
- that gear changing is smooth with no abnormal noises or vibrations from the
transmission.
- the engine power output is satisfactory, full power is achieved, acceleration is

smooth and pedal operation is not stiff or heavy, and engine speed returns to idle
correctly.
- there is no excessive or abnormally colored smoke from the engine under

normal driving, heavy load or overrun conditions.
- that steering operation, including power steering (if equipped), is smooth,

accurate, not excessively heavy or with excessive free play or vibration.
- that the steering does not pull to one side and self centers smoothly after
cornering.
- that the speedometer, coolant temperature gauge and tachometer (if equipped)
register the correct readings and operate correctly.
- that the switches and controls operate smoothly and positively, warning and
indicator lamps operate correctly and the direction indicator control self cancels
when the steering is returned to the straight ahead position.
- that the heating and ventilation systems operate correctly and effectively.
- the brake operation and efficiency.
Brake Testing
Page 3 of 3
WARNING: When brake testing, avoid breathing the fumes from hot brakes, this may
contain asbestos dust which is hazardous to health. Failure to follow this instruction may
result in personal injury. For additional information, refer to Health and Safety
Precautions in this section.
CAUTIONS:
Avoid brake testing on busy roads where it may cause inconvenience or danger to
other road users.
Brake testing which includes heavy brake applications should not be carried out with
new brake pads/discs or linings/drums until the components have bedded-in. New brake
friction components will not reach full efficiency until the bedding-in process is complete.
Test the brakes at several speeds within the normal operating range using both light and
heavy pedal pressure. Note any tendency to snatch, pull or drag, and any undue delay in
application or release.
Allow the vehicle to coast and note any tendency to pull to one side, or evidence that the
brakes are binding.
After stopping the vehicle (not immediately after a period of heavy braking), carefully check
the brake temperature. A brake disc or brake drum that feels hot or is appreciably hotter than
the others, indicates that the brake is binding.
After completion of the test, check for:
- oil, coolant, hydraulic, air and fuel leaks.
- abnormal temperature of any moving components or assemblies, for example

wheel hubs, transmission and axle, which might indicate over tightness or lack of
lubrication.
Page 1 of 2

FRONT TOE ADJUSTMENT
UID=G17387
NOTE: The checking and subsequent adjustment of the front toe setting should be carried
out on a flat surface and in accordance with the manufacturers instructions for the wheel
alignment equipment used.
1. Centralize the steering and lock it in position.
2. Loosen the tie-rod end locknuts.
3. Remove the steering gear boot outer clamps.
4. Rotate the tie-rods an equal amount in either a

clockwise or a counterclockwise direction to
adjust the toe setting.
5. Tighten the tie-rod end locknuts. For additional

Page 2 of 2
6. Install the steering gear boot outer clamps.
7. Check the toe setting.

Page 1 of 1

FRONT SUSPENSION
UID=G17395
REFER to Section 204-00.
Page 1 of 1

REAR SUSPENSION
UID=G17411
Page 1 of 1

SPECIFICATIONS
UID=G17434

Wheel nuts 85 63 -
Page 1 of 1

WHEEL AND TIRE
UID=G17437
Removal
CAUTION: Do not use heat to loosen a seized wheel nut. Heat may damage the wheel
and wheel hub.
1. Loosen the wheel nuts.
3. Remove the wheel and tire assembly.
Installation
1. WARNING: Remove the corrosion or

dirt from the mounting surfaces of the wheel,
wheel hub, brake drum or brake disc, as this
may cause the wheel nuts to loosen and the
wheel to come off while the vehicle is in
motion. Failure to follow this instruction may
Clean the wheel hub and mounting surfaces.
2. Install the wheel and tire assembly.
4. Tighten the wheel nuts in a diagonally opposed
pattern.
Page 1 of 1

DRUM BRAKE
UID=G17465
Page 1 of 1

FRONT DISC BRAKE
UID=G17475
Page 1 of 1

HYDRAULIC BRAKE ACTUATION
UID=G17506
Page 1 of 1

POWER BRAKE SYSTEM
UID=G17519
Page 1 of 1

ANTI-LOCK CONTROL - TRACTION
CONTROL
UID=G17539
REFER to Section 206-09A / 206-09B / 206-09C.
Page 1 of 1

REAR WHEEL SPEED SENSOR
UID=G17542
Removal
1. For additional information, refer to
Section 206-09A / 206-09B / 206-09C.
Page 1 of 1

POWER STEERING
UID=G17571
Page 1 of 1

STEERING LINKAGE
UID=G17594
Page 1 of 1

CAMSHAFT BEARING JOURNAL
DIAMETER
UID=G17620
1. Determine the diameter of the camshaft
journals.
 Using a micrometer measure the diameter at

90 degrees intervals to determine if the
journals are out-of-round.
 Measure at two different points on the journal

to determine if there is any tapering.
 If the measurements are out of the specified

range, install a new camshaft.
Page 1 of 1

CAMSHAFT BEARING JOURNAL
CLEARANCE
UID=G17621
1. NOTE: Make sure that the following stages
are followed exactly. The tappets or followers
must be removed to carry out this
measurement.
NOTE: Make sure that the camshaft is to
specification.
NOTE: The bearing caps and journals should
be free from engine oil and dirt.
Position on a width of plastigage on the bearing
cap.
 Insert the camshaft, without lubrication, into

the cylinder head.
 Position a plastigage strip, which should be

equal to the width of the bearing cap, on the
bearing journal.
2. Following the tightening specification, install
the camshaft bearing caps. Refer to the
corresponding Section 303-01.
3. NOTE: Do not strike the bearing caps.
Remove the camshaft bearing caps, refer to the
corresponding Section 303-01.
4. Using the Plastigage, read off the
measurement.
 Compare the width of plastigage with the

plastigage scale.
 The value that is read off is the bearing

clearance.
Page 1 of 1

CAMSHAFT END PLAY
UID=G17622
1. NOTE: Make sure that the camshaft is to
specification.
Using a Dial Indicator Gauge, measure the end
play.
 Slide the camshaft in both directions. Read

and note the maximum and minimum values
on the Dial Indicator Gauge.
* End play = maximum value minus minimum value
 If the measurement is out of specification,

install new components.
Page 1 of 1

CAMSHAFT SURFACE INSPECTION
UID=G17623
1. Inspect the camshaft lobes for pitting or
damage in the active area. Minor pitting is
acceptable outside the active area.
Page 1 of 1

CAMSHAFT LOBE LIFT
UID=G17624
1. Determine the cam lift.
 Using a micrometer measure the cam in two

directions.
 The difference between the two

measurements is the cam lift.
Page 1 of 1

CRANKSHAFT MAIN BEARING
JOURNAL CLEARANCE
UID=G17626
1. Information not available at time of going to
press.
Page 1 of 1

CYLINDER BORE TAPER
UID=G17628
1. NOTE: The main bearing caps or lower
crankcase must be in place and tightened to
the specified torque; however, the bearing
shells should not be installed.
Measure the cylinder bore with an internal
micrometer.
 Carry out the measurements in different

directions and at different heights to
determine if there is any out-of-roundness or
tapering.
 If the measurement is out of the specified

range, install a new block or hone out the
cylinder block (if aplicable/allowed).
Page 1 of 1

PISTON INSPECTION
UID=G17629
1. CAUTION: Do not use any aggressive

cleaning fluid or a wire brush to clean the
piston.
Carry out a visual inspection.
 Clean the piston skirt, pin bush, ring grooves

and crown and check for wear or cracks.
 If there are signs of wear on the piston skirt,

check whether the connecting rod is twisted
or bent.
Page 1 of 1

PISTON PIN TO BORE DIAMETER
UID=G17630
1. NOTE: The piston and piston pin form a
matched pair. Do not mix up the components.
Measure the diameter of the piston pin bore.
 Measure the diameter in two directions.
 If the values are not to specification, install

both a new piston and a new piston pin.
Page 1 of 1

PISTON DIAMETER
UID=G17631
General Equipment
Micrometer
1. NOTE: Mark the piston to make sure the
piston is installed correctly.
Using a Micrometer measure the piston diameter.
Page 1 of 1

PISTON RING END GAP
UID=G17632
1. CAUTION: Do not mix up the piston

rings. Install the piston rings in the same
position and location.
Take the piston ring and use a piston without
rings to push the piston ring about 30 mm into
the cylinder bore.
2. Using the Feeler Gauge, measure the piston

ring gap.
Page 1 of 1

PISTON RING-TO-GROOVE
CLEARANCE
UID=G17633
General Equipment
Feeler Gauge
1. NOTE: The piston ring must protrude from
the piston groove. To determine the piston
ring clearance, insert the Feeler Gauge right
to the back of the groove, behind the wear
ridge.
Using the Feeler Gauge , measure the piston ring
clearance.
Page 1 of 1

PISTON PIN DIAMETER
UID=G17634
1. NOTE: The piston and piston pin are a
matched pair. Do not mix up the components.
Measure the piston pin diameter.
 Measure the diameter in two directions.
 If the values are not to specification, install a

new piston and a new piston pin.
Page 1 of 1

CONNECTING ROD LARGE END BORE
UID=G17635
1. Measure the bearing bore in two directions.
The difference is the connecting rod bore out-
of-round. Verify the out-of-round and the
bearing bore is within specification.
Page 1 of 1

VALVE STEM DIAMETER
UID=G17636
1. Using a micrometer measure the diameter of
the valve stems.
 If the measurements are not to specification,

install a new valve.
Page 1 of 1

FLYWHEEL INSPECTION
UID=G17637
1. Inspect the flywheel for:
1. Any cracks.
2. Worn ring gear teeth.
3. Chipped or cracked ring gear teeth.
Page 1 of 1

CYLINDER BLOCK DISTORTION
UID=G17639
1. Using a Straight Edge and a Feeler Gauge,
measure the cylinder block/cylinder head
distortion.
 Measure the mating face distortion.
 If the value is not to specification rework the

mating face (if allowed).
Page 1 of 1

EXHAUST MANIFOLD CLEANING AND
INSPECTION
UID=G17640
1. Inspect the cylinder head joining flanges of the
exhaust manifold for evidence of exhaust gas
leaks.
2. Inspect the exhaust manifold for cracks,
damaged gasket surfaces, or other damage
that would make it unfit for further use.
Page 1 of 1

BEARING INSPECTION
UID=G17641
1. Inspect bearings for the following defects.
1. Cratering - fatigue failure
2. Spot polishing - incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching - dirty engine oil.
5. Base exposed - poor lubrication.
6. Both edges worn - journal damaged.
7. One edge worn - journal tapered or bearing
not seated.
Page 1 of 1

VALVE SEAT INSPECTION
UID=G17642
General Equipment
Valve seat width scale
1. Measure the width of the valve seat.
 Measure the valve seat width using the Valve

seat width scale.

valve seat.
Page 1 of 1

ENGINE
UID=G17645
Page 1 of 4

ENGINE COOLING — 1.25L/1.4L/1.6L
UID=G179022
Overview

1 - Coolant pump
2 - Engine
3 - Water outlet housing
4 - Heater heat exchanger
5 - Thermostat housing
6 - Coolant expansion tank
7 - Radiator
Components
Coolant pump
Page 2 of 4

1 - Coolant pump
2 - Coolant pump gasket
The coolant pump is secured to the engine block at the timing gear end.
It is driven through a pulley by the accessory drive belt.
The gasket for the coolant pump must not be reused.
Thermostat and thermostat housing

Page 3 of 4

2 - Thermostat
3 - Venting pin
The thermostat and thermostat housing are located on the side of the engine block.
When installing the thermostat, make sure that the venting pin is at the top.
Water outlet housing

1 - Gasket
2 - Water outlet housing
Page 4 of 4
3 - Engine Coolant Temperature (ECT) sensor

The water outlet housing is located on the cylinder head nearest the transmission.
Among other things, it is used to mount the Electronic Ignition (EI) coil.
In addition, the ECT sensor is located in the housing.

Page 1 of 2

ENGINE COOLING
UID=G179024
Coolant circuit

1 - Radiator
2 - Coolant expansion tank
3 - Coolant pump
4 - Cylinder block heater (not for all markets)
5 - Cylinder block
6 - Heating system heat exchanger
Components
Coolant pump
Page 2 of 2
The coolant pump is mounted on the cylinder block at the timing gear end of the engine.
It is driven by the timing belt and has a plastic housing.
Thermostat housing

The thermostat housing is flange-mounted to the cylinder head on the transmission side of
the engine.
It houses the coolant thermostat valve and the ECT sensor.
The coolant thermostat valve is of conventional design and opens the flow to the radiator at a
coolant temperature of 83°C.
The thermostat housing is made of plastic and cannot be disassembled when the vehicle is
serviced. The ECT sensor can be replaced separately.
Page 1 of 1

TURBOCHARGER
UID=G179027

1 - Steel gasket
2 - Exhaust gas recirculation (EGR ) flange on the exhaust manifold
3 - Turbocharger
The exhaust manifold is made of cast iron. It has flanges for the turbocharger and the EGR .
The turbocharger comprises of the parts for the turbine and the impeller, which are mounted
together on a shared shaft.
The bearings of the turbocharger are lubricated with engine oil.
The turbine uses the flow of exhaust gases as a source of energy to drive the impeller. The
impeller draws in air via the air intake system and supplies it under pressure to the intake
manifold.
The turbocharger operates with fixed turbine geometry and generates a boost pressure of up
to 1.0 bar.
Page 1 of 1

ACCESSORY DRIVE — 1.4L DIESEL
UID=G179031
All accessories are driven by a multi-groove drive belt.
The illustration shows the variants with and without air conditioning.
A self-adjusting belt tensioner is used to tension the belt.

1 - Power steering pump
2 - Generator
3 - Idler pulley
4 - A/C compressor
5 - Crankshaft
6 - Belt tensioner
Page 1 of 1

INTAKE AIR DISTRIBUTION AND
FILTERING — 1.25L/1.4L/1.6L
UID=G179057
Intake manifold
The 1.4l and 1.6l versions feature a revised intake manifold. The overall length of the intake
pipes has been increased, but the pipes are of equal length on all cylinders. This has resulted
in increased torque in the lower engine speed range and a reduction in noise levels.

1 - Mounting for the throttle valve unit
2 - T-MAP sensor
The mounting for the electronic throttle valve is located inside the intake manifold between
the intake pipes of cylinders 1 and 2. The T-MAP sensor, which is used on both the 1.4l and
1.6l versions, is situated next to the throttle valve unit.
Page 1 of 1

CLUTCH
UID=G18068
Page 1 of 1

CLUTCH CONTROLS
UID=G18080
Page 1 of 1

MANUAL TRANSAXLE
UID=G18097
Page 1 of 1
IN-VEHICLE REPAIR 2003.50 Mazda2

VEHICLE SPEED SENSOR (VSS)
UID=G18104
Removal
2. Disconnect the vehicle speed sensor (VSS)
3. Remove the VSS.

1. Remove the retaining pin.
2. Remove the VSS.
Installation
1. Install VSS.
1. Insert the VSS.
2. Insert the retaining pin.
2. Install VSS connector.

Page 1 of 2
DISASSEMBLY AND ASSEMBLY OF 2003.50 Mazda2

SUBASSEMBLIES
SELECTOR PLATE
UID=G18111
Overview, selector mechanism

1 - Fifth and reverse gear selector shaft guide sleeve
2 - Selector plate
3 - Shift lock
4 - Selector shaft interlock mechanism
5 - Selector shaft
6 - Reverse gear selector lever return spring
7 - Reverse gear selector lever
8 - Snap-ring
9 - Fifth and reverse gear selector shaft
Disassembly
1. Remove the selector mechanism.
1. Fifth and reverse gear selector shaft.
2. Selector shaft.
3. Reverse gear selector lever .
4. Selector plate.
5. Fifth and reverse gear selector shaft guide
sleeve.
Assembly
1. Install the selector mechanism.
Page 2 of 2
1. Selector shaft.
2. Reverse gear selector lever.
3. Fifth and reverse gear selector shaft guide
sleeve.
4. Selector plate.
Page 1 of 1

SPECIFICATIONS
UID=G18149

Shift and selector cable bushing. 9 80
Gearshift mechanism to floor assembly 9 80
Exhaust flange bolts 47 35
Gearshift lever 5 44
Page 1 of 1

FUEL SYSTEM PRESSURE RELEASE
UID=G18191
Release
WARNINGS:
1. Do not smoke or carry lighted tobacco

or open flame of any type when working on
or near any fuel related components. Highly
flammable vapors are always present and
may ignite. Failure to follow these instructions
The fuel system remains pressurized for

a long time after the ignition is switched off.
The fuel pressure must be released before
attempting any repairs. Failure to follow this
Remove the fuel pump fuse.
2. Start the engine and allow to idle until the
engine stalls.
3. Crank the engine for approximately five
seconds to make sure the fuel injection supply
manifold pressure has been released.
4. Install the fuel pump fuse.
Page 1 of 5

QUICK RELEASE COUPLING
UID=G18192
General Equipment
Flat-bladed screwdriver
Disconnection
WARNINGS:
Do not carry lighted tobacco or open flame of any type when working on or near any
fuel related components. Highly flammable vapors are always present and can ignite.
This procedure involves fuel handling. Be prepared for fuel spillage at all times and
always observe fuel handling precautions. Failure to follow these instructions may result
in personal injury.
CAUTION: Fuel injection equipment is manufactured to very precise tolerances and

fine clearances. It is therefore essential that absolute cleanliness is observed when
working with these components. Always install blanking plugs to any open orifices or
lines.
NOTE: Fuel supply line connectors are white or are identified by a white band. Fuel return
line connectors are red or are identified by a red band.
1. Release the fuel system pressure. For
additional information, refer to Fuel System
Pressure Release in this section.
2. Disconnect the fuel line quick release coupling.
1. Press the fuel line quick release coupling
locking tangs.
2. Disconnect the fuel line quick release
coupling.

1. Pull the fuel line quick release coupling
locking tang.
2. Push the clip through the fuel line quick
release coupling to release the fuel line.

locking tangs.
2. Disconnect the fuel line quick release
coupling.
Page 2 of 5
 Press the fuel line quick release coupling

buttons and pull the fuel line to disconnect.
6. Release the fuel tank vent line quick release

coupling.
 Press the fuel tank vent line quick release

coupling locking release collar.
7. Disconnect the fuel tank vent line quick release

coupling.
8. Release the fuel line quick release coupling.
 Press the fuel line quick release coupling

locking release collar.

Page 3 of 5
10. Using a suitable Flat-bladed screwdriver

release the fuel line quick release coupling
secondary locking tang.
11. Operate the fuel line quick release coupling

primary locking tang.
 Push the fuel line quick release coupling

primary locking tang into from the fuel line
quick release coupling.
12. Disconnect the fuel line from the fuel line

13. Disconnect the fuel line from the fuel filter.

1. Press the collar into the connector body.
2. Disconnect the fuel line from the fuel filter.
Connect
WARNINGS:
Do not carry lighted tobacco or open flame of any type when working on or near any
fuel related components. Highly flammable vapors are always present and can ignite.
Page 4 of 5
in personal injury.
CAUTION: Fuel injection equipment is manufactured to very precise tolerances and

fine clearances. It is therefore essential that absolute cleanliness is observed when
working with these components. Always install blanking plugs to any open orifices or
lines.
NOTE: Fuel supply line connectors are white or are identified by a white band. Fuel return
line connectors are red or are identified by a red band.
1. Push the connector on to the fuel filter.
2. Install the fuel line to the fuel line quick

release coupling.
3. CAUTION: Make sure the quick release

coupling primary locking tang clicks into place
when installing.
Insert the fuel line quick release coupling
secondary locking tang into the fuel line quick
release coupling.
4. CAUTION: After installation, to make

sure that the fuel line is fully seated, pull on
the line.
Install the fuel line quick release coupling.
5. CAUTION: After installation , to make

sure that the vent line is fully seated, pull on
the line.
Install the fuel tank vent line quick release
coupling.
Page 5 of 5
6. CAUTION: Make sure the fuel line

clicks into place when installing the line. To
make sure that the fuel line is fully seated,
pull on the line.
7. NOTE: Make sure the collar on the fuel line

is inserted fully into the fuel line quick release
coupling.

coupling before the locking tang is locked.
1. Install the fuel line quick release coupling
locking tang.
2. Rotate the fuel line quick release coupling
locking tang into position.

coupling before the locking tang is locked.
1. Install the fuel line quick release coupling.
locking tang into position.
Page 1 of 2

SPRING LOCK COUPLING
UID=G18266
1. NOTE: Select special tool to suit the line
diameter.
Fit the special tool.
 Fit the special tool so that the inner collar can

be guided into the clamping spring.
2. Press the special tool into the clamping spring.
3. Disconnect the refrigerant line.
 Discard the O-ring seals.
4. Connect the refrigerant line.
 Check the clamping spring for damage.
 Carefully pull out any damaged clamping

springs using a thin piece of wire and install
new one.
5. NOTE: Clean the connections using

refrigerant oil and a lint-free cloth.
Press the indicator ring into the clamping spring.
6. NOTE: Install new refrigerant line O-ring

Page 2 of 2
seals.
NOTE: Coat the refrigerant line O-ring seals
in clean refrigerant oil prior to installation.
Connect the refrigerant lines.
 Check that the clamping spring engages

correctly.
Page 1 of 1

AIR CONDITIONING (A/C) CLUTCH
AIR GAP ADJUSTMENT
UID=G18268
Name Specification
Spacer washer set
1. Measurement for recessed pulley
Check the air gap A between the drive plate and
the pulley at 60 degree intervals around the
circumferance of the pulley, while operating
the A/C clutch several times by means of a 5A
fused jumper wire connected between the
battery positive terminal, A/C clutch and
battery ground. For additional information,
refer to Specifications in this section.
1. Belt pulley
2. Drive plate
 Air gap A (the difference measured between

the A/C clutch engaged and disengaged)
2. Measurement for non recessed pulley
Check the air gap A between the drive plate and
the pulley at 60 degrees intervals around the
circumference. For additional information, refer
to Specifications in this section.
1. Belt pulley
2. Spacer washer
3. Drive plate
 Air gap A
3. Remove the drive plate.
4. Correct air gap A as necessary using spacer

washers.
5. Install the drive plate. For additional
information, refer to Specifications in this
section.
6. Check air gap A as described in step 1 or step
2. Repeat steps 3-5 if necessary.
Page 1 of 1

CONTAMINATED REFRIGERANT
HANDLING
UID=G18273
CAUTION: Any R134a or R12 refrigerant which is contaminated with unsuitable

refrigerant should be extracted only by means of a suitable servicing unit designed for the
purpose of collecting and storing contaminated refrigerant, so that the spread to other
vehicles can be prevented.
1. Use refrigerant identification equipment to
check that there is contaminated refrigerant in
the air conditioning system.
2. Inform the customer about the additional cost
to repairing the system caused by the
contamination.
3. Extract the contaminated refrigerant.
Page 1 of 1

VACUUM LEAK DETECTION
UID=G18275
1. Drain the air conditioning (A/C) system. For
additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging in this section.
Page 1 of 1

CONTROL COMPONENTS
UID=G18315
Page 1 of 3

BATTERY CHARGING
UID=G18345
WARNINGS:
1. Keep batteries out of reach of

children. Batteries contain sulphuric acid,
avoid contact with skin, eyes or clothing.
Shield your eyes when working near the
battery to protect against possible splashing
of the acid solution. In case of acid contact
with the skin or the eyes, flush immediately
with water for a minimum of 15 minutes and
seek prompt medical attention. If acid is
swallowed, call a physician immediately.
Failure to follow these instructions may result
in personal injury.
Batteries normally produce explosive

gases which can cause personal injury,
therefore do not allow flames, sparks or
lighted substances to come near the battery.
When charging or working near the battery
always shield your face and protect your
eyes. Always provide adequate ventilation.
in personal injury.
Always observe all manufacturers

instructions when using any charging
equipment. Failure to follow this instruction
Connect the charger to the battery

before switching the charger on. Failure to
injury.
Switch the charger off before

disconnecting the charger from the battery.
Failure to follow this instruction may result in
personal injury.
CAUTIONS:
Batteries should not be charged in the

vehicle.
Do not rely on the generator to recharge

a discharged battery as it would take in
excess of eight hours of continuous driving
with no additional loads placed on the
charging system.
NOTE: The maximum level mark is
approximately 40mm below the top of the
battery.
Place the battery on a level surface and check the
electrolyte level through the casing, reaches
Page 2 of 3
the indicated maximum mark.
WARNING: It is important not to overfill a battery, as this can cause acid leakage and
corrosion damage to the vehicle. Failure to follow this instruction may result in personal
injury.
2. If the level is below the maximum mark,
remove the vent covers and top up the cell(s)
to the correct level.
3. Cold batteries will not readily accept a charge.
Therefore batteries should be allowed to warm
up to approximately 5°C. (41°F.) before
charging. This may require four to eight hours
at room temperature depending on the initial
temperature and the battery size.
4. A battery which has been completely
discharged may be slow to accept a charge
initially, and in some cases may not accept a
charge at the normal charger setting. When
batteries are in this condition, charging can be
started by use of the dead battery switch on
chargers that have this facility equipped.
5. To determine whether a battery is accepting a
charge, follow the manufacturer's instructions
for the charger, for use of the dead battery
switch. If the switch is the spring-loaded type,
it should be held in the ON position for up to
three minutes.
6. After releasing the dead battery switch and
with the charger still on, measure the battery
voltage. If it shows 12 volts or higher, the
battery is accepting a charge and is capable of
being recharged. However, it may require up
to two hour of charging with batteries colder
than 5°C (41°F) before the charge rate is high
enough to show a charge on an ammeter. It
has been found that all non-damaged batteries
can be charged by this procedure. If a battery
cannot be charged by this procedure, a new
one should be installed.
7. A rapid recharger procedure has been
developed for recharging batteries that have
passed the Load Test and only need a
recharge. This can be due to in-service no-
start battery failures (vehicle will not crank
due to low battery state of charge) or battery
discharged in vehicle due to key-off loads.
8. With the cables then disconnected, the battery
can be rapidly recharged by using either of the
following methods:
 Carry out a two hour charge using 20A

constant current (manual setting on charger).
 Carry out a two hour charge using a constant

potential (automatic setting on charger).
Page 3 of 3
Page 1 of 1

GENERATOR
UID=G18359
Page 1 of 1

AUDIO SYSTEM
UID=G18370
Page 1 of 2

LOWER ARM
UID=G183757
Removal
1. Remove the wheel and tire. For additional
2. CAUTION: Protect the ball joint seal

using a soft cloth to prevent damage.
Detach the lower arm ball joint from the wheel
knuckle.
 Remove the heat shield.
3. Remove the crossmember outer retaining bolt.
4. Remove the lower arm.
Installation
1. NOTE: Do not fully tighten the lower arm
to crossmember retaining bolts at this stage.
Install the lower arm.
2. Install the crossmember outer retaining bolt.

Page 2 of 2
3. CAUTION: Make sure the heat shield is

installed to prevent damage to the ball joint.
Install the heat shield.
4. CAUTION: The lower arm pinch bolt

must be installed from the rear of the wheel
knuckle.
Attach the lower arm ball joint to the wheel
knuckle.
5. Install the wheel and tire. For additional

6. NOTE: The lower arm to crossmember
retaining bolts must be tightened with the
vehicle weight on the road wheels.
Tighten the lower arm to crossmember retaining
bolts.
1. Tighten the bolt in two stages.
* Stage 1: 80 Nm.
* Stage 2: 55 degrees.
2. Tighten the bolts.

7. Check the toe setting and adjust as necessary.
Section 204-00.
Page 1 of 1

ANTENNA
UID=G18376
Page 1 of 6

BEAM AXLE
UID=G183767
General Equipment
Transmission jack
Securing strap
Electric hand drill
Blind rivet gun
Removal
Vehicles with rear drum brakes
1. Release the parking brake.
2. Remove the rear wheels and tires. For
04.[Wheels and Tires, REMOVAL AND
INSTALLATION, Wheel and Tire]
3. Detach the rear wheel speed sensor and brake
hose retaining bracket from the beam axle on
both sides.
 Remove the retaining bolt.
4. Disconnect the parking brake cable on both

sides.
5. Detach the parking brake cable from the beam

axle bracket on both sides.
6. Remove the brake drum and wheel spindle

assembly on both sides.
Page 2 of 6
7. CAUTION: Suspend the brake backing

plate, wheel cylinder and brake shoes
assembly to prevent load being placed on the
brake hose.
Detach the brake backing plate, wheel cylinder
and brake shoes assembly from the beam axle
on both sides.
 Using a suitable electric hand drill, remove

the rivets.
Vehicles with rear disc brakes

8. Remove the brake disc shield.
All vehicles
10. Detach the parking brake cable from the
beam axle on both sides.
11. Remove the rear wheel speed sensor. For

09A.[Anti-Lock Control, REMOVAL AND
INSTALLATION, Rear Wheel Speed Sensor]
12. WARNING: Make sure that the beam

axle is secured to the transmission jack.
personal injury.
Using a suitable securing strap, secure the beam
Page 3 of 6
axle to a transmission jack.

13. Detach the shock absorber from the beam
axle on both sides.
14. Detach the spring from the lower spring seat

on both sides.
15. Remove the beam axle.
 Remove the beam axle retaining bolts on

both sides.
Installation
All vehicles
NOTE: Final tightening of the beam axle components should be carried out when the
vehicle weight is on the road wheels.
1. Using a suitable transmission jack, locate the
beam axle.
2. NOTE: Do not fully tighten the beam axle
retaining bolts at this stage.
Install the beam axle.
 Install the beam axle retaining bolts on both

sides.
3. Attach the spring to the lower spring seat on

both sides.
Page 4 of 6
4. NOTE: Do not fully tighten the shock

absorber retaining bolts at this stage.
Attach the shock absorber to the beam axle on
both sides.
5. Remove the securing strap.

6. Lower and remove the transmission jack.
7. Install the rear wheel speed sensor. For
09A.[Anti-Lock Control, REMOVAL AND
INSTALLATION, Rear Wheel Speed Sensor]
8. Attach the parking brake cable to the beam
axle on both sides.

10. Install the brake disc shield.

11. Attach the brake backing plate, wheel
cylinder and brake shoes assembly to the
beam axle on both sides.
Page 5 of 6
 Using a suitable blind rivet gun, install new

rivets.
12. Install the brake drum and wheel spindle

assembly on both sides.

14. Connect the parking brake cable on both

sides.
15. Attach the rear wheel speed sensor and

brake hose retaining bracket to the beam axle
on both sides.
 Install the retaining bolt.
16. Install the rear wheels and tires. For

All vehicles
Page 6 of 6
17. Tighten the beam axle retaining bolts on both

sides.
18. Tighten the shock absorber lower mounting

bolt on both sides.
19. Adjust the parking brake cable. For additional

information, refer to Section 206-05.[Parking
Brake and Actuation, GENERAL PROCEDURES,
Parking Brake Cable Adjustment]
Page 1 of 2

WHEEL SPINDLE
UID=G183768
Removal
All vehicles
1. Remove the dust cap.

2. Remove the brake drum.
3. Detach the wheel speed sensor from the wheel
spindle.
4. Remove the wheel spindle.

5. Remove the brake disc.
6. Remove the wheel hub.
 Remove and discard the wheel hub retaining

nut.

spindle.
Page 2 of 2
8. Remove the wheel spindle.
Installation
NOTE: Install a new wheel hub retaining nut.
Page 1 of 3

HYDRAULIC CONTROL UNIT (HCU) —
VEHICLES BUILT UP TO: 07/2004
UID=G183774
Name Specification
Super DOT 4 brake fluid ESD-M6C57-A
Removal
1. Remove the brake master cylinder. For
06.
2. Detach the engine wiring harness electrical
connector from the wheelhouse assembly.
CAUTIONS:
3. Cap the brake tubes to prevent fluid

loss or dirt ingress.
Plug the hydraulic control unit (HCU)

ports to prevent fluid loss or dirt ingress.
NOTE: Make a note of the position of the
brake tubes, to aid installation.
Remove the brake master cylinder to hydraulic
control unit (HCU) brake tubes.
CAUTIONS:

Plug the HCU ports to prevent fluid loss

or dirt ingress.
Disconnect the brake tubes from the HCU.
5. Detach the brake tubes from the bulkhead.
Page 2 of 3
6. Disconnect the anti-lock brake system (ABS)

module electrical connector.

8. Remove the HCU and ABS module support
bracket lower retaining bolt.

10. Remove the HCU and ABS module assembly
and the support bracket.
11. Detach the HCU and ABS module assembly

from the support bracket.
12. Remove the HCU to ABS module retaining

bolts.
Page 3 of 3
13. Remove the HCU.
Installation
2. Bleed the brake system. For additional
Page 1 of 2

REAR WHEEL SPEED SENSOR
UID=G183775
Removal
2. Detach the wheel speed sensor from the brake
backing plate on both sides.
3. Disconnect the wheel speed sensor electrical

connector.
4. Detach the wheel speed sensor support

bracket and harness from the beam axle.
 Discard the retaining clips.
5. Detach the wheel speed sensor wiring harness

 Discard the retaining clips.
6. Detach the wheel speed sensor wiring harness

from the beam axle on both sides.
Page 2 of 2
7. Remove the rear wheel speed sensor.
Installation
Page 1 of 1

REAR WHEEL SPEED SENSOR RING
UID=G183776
General Equipment
Hydraulic press
Removal
1. Remove the brake drum. For additional
2. Remove and discard the wheel speed sensor
ring.
Installation
CAUTIONS:
1. Make sure the wheel speed sensor

ring is not knocked, damaged and kept free
from metal fragments.
Protect the face of the wheel speed

sensor ring with a suitable non-ferrous flat
block to prevent damage.
Make sure the brake drum is adequately

supported and do not allow it to rest on the
wheel studs.
Make sure the wheel speed sensor ring is

pressed on slowly and squarely until fully
seated.
Do not exceed a maximum load of 10 kN.

Using a suitable hydraulic press, install a new
wheel speed sensor ring.
2. Install the brake drum. For additional
Page 1 of 1

DEPLOYED AIR BAG DISPOSAL
UID=G18618
WARNING: After deployment, the air bag module surface may contain deposits of
sodium hydroxide, a product of the gas generate combustion, that is irritating to the skin.
Use protective gloves when handling any deployed air bag module. Failure to follow this
1. Remove the deployed air bag module(s). For
additional information, refer to the relevant
procedure in this section.
2. Seal the deployed air bag module(s) in the
packaging from the new air bag module(s) or a
suitable polythene bag, and then dispose of in
accordance with local contaminated waste
regulations.
Page 1 of 2

CAMSHAFT POSITION (CMP) SENSOR
— 1.4L DIESEL
UID=G187201
Removal
1. Disconnect the CMP sensor electrical
connector.
2. Remove the CMP sensor.
 Discard the CMP sensor.
Installation
NOTE: Install a new CMP sensor.
Turn the engine until one of the three webs on
the back of the camshaft pulley is visible
through the CMP sensor housing (timing belt
upper cover shown removed for clarity).
2. CAUTION: The CMP sensor tip must

rest on one of the three webs on the back of
the camshaft pulley. Incorrect installation
may result in the CMP sensor being damaged.
Install the CMP sensor until the tip of the sensor
touches the back of the camshaft pulley
(timing belt upper cover shown removed for
clarity).
3. Tighten the CMP sensor retaining bolt.

Page 2 of 2
4. Connect the CMP sensor electrical connector.

Page 1 of 1

FUEL PUMP MODULE
UID=G189085
Removal
1. Remove the fuel pump module.
Installation
Page 1 of 4

SUBASSEMBLIES
CYLINDER HEAD
UID=G202085
Disassembly
1. Disconnect the temperature and manifold
absolute pressure (T-MAP) sensor electrical
connector.
2. Disconnect the throttle plate control motor

(DC-ISC) electrical connector.
3. Disconnect the fuel injector electrical

connectors.
4. Remove the engine wiring harness.

5. Remove the fuel supply manifold.
6. Remove the intake manifold.
 Discard the gaskets.

Page 2 of 4
7. Remove the engine rear lifting eye.
8. Remove the coolant distribution housing and

the ignition coil (EI).
9. Remove the camshaft position (CMP) sensor.
 Discard the O-ring seal.
Assembly
1. NOTE: A new cylinder head is supplied
without exhaust manifold studs.
Install the exhaust manifold studs if necessary.
2. NOTE: Install a new camshaft position

(CMP) O-ring seal.
Install the CMP sensor.
Page 3 of 4
3. NOTE: Install a new coolant distribution

housing gasket.
Install the coolant distribution housing and the
ignition coil (EI).
4. Install the engine rear lifting eye.
5. NOTE: Install new intake manifold gaskets.

Install the intake manifold.
6. NOTE: Install new fuel supply manifold O-

ring seals.
Install the fuel supply manifold.
7. Install the engine wiring harness.

8. Connect the fuel injector electrical connectors.
Page 4 of 4
9. Connect the throttle plate control motor (DC-

ISC) electrical connector.
10. Connect the temperature and manifold

connector.
Page 1 of 1

FRONT DRIVE HALFSHAFTS
UID=G202088
Driveshafts
Conventional driveshafts are used on the front axle. For servicing purposes it is important to
note that the inner tripod joints are pressed onto the shaft. This has made it possible to
reduce noise levels when the vehicle is pulling away from standing.
The outer joint has not been approved for service repairs, so in the event of a fault it is
necessary to replace the complete shaft and outer joint assembly. The inner joints are
dismantled with the aid of a puller. The driveshaft needs to be removed first.
In order to install a new boot on the outer joint, it is first necessary to remove the driveshaft
and then disassemble the inner joint. A special service kit is available in service for this
purpose, consisting of the inner and outer boot and the necessary small parts.
The same amount of grease is used to pack the inner and outer joints.
The PAC nut used for securing the driveshaft to the wheel hub must not be reused.

1 - Securing clip for bearings
2 - Heat shield (only for vehicles with a petrol engine)
3 - Securing pin
It should also be noted that vehicles with a petrol engine have an additional heat shield on
the bearing of the intermediate shaft of the right-hand driveshaft. This is required to prevent
the grease in the bearing from overheating as a result of the closeness to the catalytic
converter.
Page 1 of 2

FRONT SIDE MEMBER AND FENDER
APRON PANEL LH
UID=G204059
General Equipment
Measurement or alignment angle system
Name Specification
Side member with apron panel
Apron panel reinforcement
Removal
1. General Notes.
 Fenders, hood, doors and apron panel

reinforcement are already removed before
repair work starts.
2. Side member with apron panel
1. Separating cut.
2. Mill out the spot welds (two panel
thicknesses).
3. Mill out the spot welds.
3. Bulkhead reinforcement
 Mill out the spot welds (two panel

thicknesses).

2. Grind out the spot welds.
Installation
NOTE: The instructions concerning welding equipment given in Section 501-25A must be
observed before resistance spot welding body panels with a total thickness of 3 mm and
greater.
1. Drill holes for puddle welding.
Page 2 of 2
2. Mill out spot welds (diameter: 10 mm)

1. Mill out spot welds (diameter: 10 mm).
2. Drill holes for puddle welding.
 Puddle welding
 Puddle welding
 Puddle welding
Page 1 of 2

ROCKER PANEL INNER
REINFORCEMENT
UID=G204076
General Equipment
Name Specification
Rocker panel inner reinforcement
Removal
1. General Instructions
 The A-pillar outer panel, A-pillar

reinforcement, B-pillar with reinforcement,
side panel, wheel house with reinforcement
and inner side panel are already removed
before the repair starts.
 Sectional replacement is possible, depending

on the damage.
2. Rocker panel inner reinforcement
1. Front separation area (only for sectional
replacement).
2. Rear separation area (only for sectional
replacement).
 Mill out the spot welds.
 Grind out the spot welds.
Installation
observed before resistance spot welding body panels with a total thickness of 3 mm and
Page 2 of 2
greater.
 Drill holes for puddle welding.
 Resistance spot welding.
 Puddle weld.
Page 1 of 3

QUARTER PANEL RH
UID=G204078
Name Specification
Quarter panel
Removal
1. General Notes
 The doors and tailgate are already removed

before repair work starts.
 Required disassembly operations: Bumper,

rear lamp, weatherstrip, inner trims and side
window.
 Depending on the extent of the damage, the

forced air extraction gusset should also be
replaced.
2. Quarter panel
1. Cut location.
4. Grind down one panel thickness at the
wheel arch edge.
5. Heat the area (approx. 170° C) and release
the NVH elements.
3. Quarter panel

Page 2 of 3
Installation
NOTE: Before resistance spot welding of body panels with a total panel thickness of 3 mm
and greater, the welding equipment instructions contained in chapter 501-25A must be
followed.
1. Quarter panel
2. Quarter panel
1. Apply two-component metal adhesive to the
clinched flange and clinch the wheel arch
flange.
2. Apply clinched flange protection to the NVH
element.
3. Continuous MIG weld seam.
4. Resistance spot weld.
5. Puddle welding.
Page 3 of 3
3. Quarter panel
 Puddle welding.
Page 1 of 2

FRONT SIDE MEMBER SECTION
UID=G204141
General Equipment
Name Specification
Outer side member
Inner side member
Crossmember retaining flange
Removal
1. General Notes.
1. Right-hand side cut line.
2. Left-hand side cut line.
 The fine cut lines are not the same on the

right-hand and left-hand sides.
Hood lock panel, front crash element, hood,

and fender are already removed before repair
work starts.
NOTE: Separate the side member completely on the inside along the fine cut line.
2. Inner side member
 Separating cut.
3. Outer side member

1. Separating cut.
Installation
1. Inner side member
 Continuous MIG weld seam.

Page 2 of 2
2. Outer side member

1. Resistance spot weld
NOTE: : Before welding, secure the retaining flange for the cross member using the
measurement or alignment angle system and the installed hood closing panel.
3. Inner crossmember retaining flange
 Intermittent MIG weld seam.
4. Outer crossmember retaining flange

Page 1 of 8

ELECTRONIC ENGINE CONTROLS —
1.4L DIESEL
UID=G204197
Overview

1 - Mass Air Flow (MAF) sensor
2 - Fuel pressure sensor
3 - Fuel temperature sensor
5 - Camshaft Position (CMP) sensor
6 - Crankshaft Position (CKP) sensor
Page 2 of 8
7 - Vehicle Speed Sensor (VSS)

8 - Accelerator Pedal Position (APP) sensor
9 - Brake Pedal Position (BPP) switch
10 - Clutch Pedal Position (CPP) switch
11 - Generator
12 - Start inhibit relay
13 - Ignition switch
14 - Vehicle battery
16 - Powertrain Control Module (PCM)
17 - Injectors
18 - Exhaust Gas Recirculation (EGR) solenoid valve
19 - Glow control unit
20 - High pressure pump with fuel metering valve and fuel pressure regulator
21 - A/C compressor solenoid clutch and cooling fan
22 - Electric PTC booster heater (not all markets)
23 - PCM relay
24 - Instrument Cluster
Sensors
( CPP) switch
The CPP switch is located directly on the pedal box.
The engine management recognises gearshifts through the CPP switch and thus improves
engine running characteristics.
The CPP switch passes a ground signal to the ( PCM) , when the clutch pedal is depressed
(disengaged).
( Brake Pedal Position) BPP switch
There are two brake pedal switches at the pedal box:

Page 3 of 8
* the brake lamp switch and
* the Brake Pedal Position BPP switch
The brake lamp switch only serves to switch on the brake lamps.
The ( BPP) is used for engine management purposes. It provides the PCM with the
information that the vehicle will be decelerated.
The BPP switch is closed in the rest state (brake pedal not depressed) and sends a ground
signal to the PCM .
( APP) sensor
The APP sensor measures the engine load, that is to say the acceleration desired by the
driver, and transmits that to the PCM .
The APP sensor contains two potentiometers as a safety measure against failure.
( CKP) sensor
WARNING: When working on the crankshaft timing pulley, make sure that the
magnetic disc does not become damaged by contamination or the effects of force. Do not
use any sharp or magnetic tool.
The CKP sensor is located behind the crankshaft timing pulley, on the oil pump housing.
Page 4 of 8
The CKP sensor operates using the Hall effect principle and senses a magnetic disc on the
crankshaft timing pulley. This magnetic disc has 60 magnetic pole pairs, which are arranged
around its circumference.
Through the electronic sensing of the magnetic poles, the engine management calculates the
engine speed.
( CMP) sensor
The CMP sensor is located on the cylinder head, behind the camshaft timing pulley.
The CMP sensor operates using the Hall effect principle and uses the camshaft timing pulley
as reference for the recognition of cylinder number one. For this purpose, integral with the
camshaft pulley there is a reference ring made of material which can be magnetised.
( ECT) sensor
The ECT sensor is located in the thermostat housing on the cylinder head.
The ECT sensor is a resistor with a negative temperature coefficient (NTC resistor).
Using the voltage drop across the ECT sensor, the PCM calculates the coolant temperature.
Fuel temperature sensor
The fuel temperature sensor is located in the collector pipe for fuel return, above the high
Page 5 of 8
pressure pump.
The fuel temperature sensor is a resistor with a negative temperature coefficient (NTC
resistor).
Using the voltage drop across the fuel temperature sensor, the PCM calculates the fuel
temperature, which is needed for fine tuning the injection quantity.
Fuel pressure sensor
The fuel pressure sensor is located in the common rail, which is on the right-hand rear side of
the engine on the cylinder block.
Based on the measured fuel pressure, the PCM calculates the injection time for the required
injection quantity.
The fuel pressure sensor is a piezoelectric sensor that passes to the PCM a voltage signal
which varies depending on the fuel pressure.
( MAF) sensor
The MAF sensor is located on the outlet of the air cleaner housing.
The MAF sensor measures the quantity of fresh air taken in by the engine.
The MAF sensor signal is used to control the ( EGR) . Using the value for the fresh air taken
in, the engine management system can calculate the recirculated exhaust quantity and
control it.
( VSS)
Page 6 of 8
Vehicles without Anti-lock Braking System ( ABS) need the VSS to determine the vehicle
speed.
The VSS is located on the transmission and operates according to the Hall effect principle.
Vehicles with ABS use the wheel sensor signals to determine the vehicle speed.
PCM
The PCM is located in the engine compartment between the left-hand headlamp and the
vehicle battery.
The PCM has three electrical connectors with 112 contacts in total.
The PCM monitors and processes the signals from the sensors.
Using this information and depending on the operating conditions of the engine, the PCM
calculates the opening of the fuel metering valve, the system pressure and the timing and
quantity of the injections.
The PCM can be diagnosed through the ( DLC) using WDS.
Actuators
High-pressure pump
The fuel metering valve and the fuel pressure regulator are located on the high-pressure
pump.
Both components are solenoid valves, used to control the fuel pressure in the common rail.
Both solenoid valves are controlled by the PCM on the ground side.
Page 7 of 8

1 - Fuel metering valve
2 - Inlet (from filter)
3 - Drive shaft
4 - Fuel pressure regulator
5 - Outlet (high pressure)
6 - Return
Injectors

1 - Wiring harness electrical connector
2 - High pressure line union
Page 8 of 8
3 - Seal
4 - Injector nozzle
5 - Fuel leak off line connection with clip
Start of injection and injection quantity are achieved by electrically controllable injectors.
Control of the injectors is performed directly by the PCM .
Electromechanical operation is achieved using piezoelectric elements, which have a

particularly fast switching time of approximately 0.2 milliseconds.
Glow control unit
The glow control unit is located in the engine compartment, at the PCM near the vehicle
battery.
The glow control unit switches the pencil-type glow plugs. It contains a relay and an
electronic control unit, which communicates with the PCM .
The PCM sends data to the glow control unit giving the time for which the glow plugs should
be switched on. In addition, it monitors the function of the glow control unit.
EGR solenoid valve
The EGR solenoid valve is located in the engine compartment, behind the left-hand headlamp
and in front of the left-hand suspension strut turret.
The EGR solenoid valve switches the vacuum feed which operates the EGR valve.
The EGR solenoid valve is controlled on the ground side by the PCM depending on the
quantity of exhaust gas to be recirculated.
Page 1 of 6

ELECTRONIC ENGINE CONTROLS —
1.25L/1.4L/1.6L
UID=G204204
Overview
Item Part Description

Number
1 - Temperature and Manifold Absolute Pressure (T-MAP) sensor
2 - Throttle Position (TP) sensor
3 - Knock Sensor (KS)
4 - Sensor - Engine Coolant Temperature (ECT)
5 - Crankshaft Position (CKP) sensor
Page 2 of 6
6 - Camshaft Position (CMP) sensor

7 - Heated Oxygen Sensor (HO2S)
8 - Power Steering Pressure (PSP) sensor
9 - Vehicle Speed Sensor (VSS) (only on vehicles without Anti-lock Braking
System (ABS))
10 - Brake Pedal Position (BPP) switch
11 - Accelerator Pedal Position (APP) sensor
12 - Clutch Pedal Position (CPP) switch
13 - Generator
14 - Current supply relay
15 - Ignition key
16 - Battery
17 - Powertrain Control Module (PCM)
19 - Fuel Pump (FP) relay
20 - Inertia fuel shut-off switch
21 - Fuel Pump Driver Module (FPDM)
22 - Fuel injectors
23 - Evaporative emissions (EVAP) solenoid valve
24 - Idle Air Control (IAC) valve
25 - Throttle Control Unit (TCU)
26 - Air Conditioning (A/C) compressor clutch / blower switch
27 - Injector Driver Module (IDM)
28 - Start inhibit relay
29 - Instrument cluster
Throttle Control Unit (TCU)
Components

1 - TP sensor
2 - Electric motor
Page 3 of 6
The electronically controlled throttle control unit (TCU) consists of the following components:
* Housing
* Throttle flap
* Throttle flap spindle
* Gear set
* Electric motor with pinion
* TP sensor
* Stop screw
* Throttle flap return spring
Function
CAUTION: The throttle control unit (TCU) must not be dismantled. No adjustments or
repairs can be made to the TCU.

1 - Stop screw
2 - Toothed segment
3 - Throttle flap spindle
4 - Throttle flap return spring
5 - Intermediate shaft with gear
6 - Electric motor with pinion
The APP sensor sends the data containing the driver's acceleration requirement to the PCM.
This information depends directly on the movement of the accelerator pedal.
Page 4 of 6
The PCM processes this information and converts it into an output signal for the throttle
control unit (TCU). This output signal is the control for the electric motor.
The electric motor moves the throttle flap spindle by means of the gear set.
The throttle flap position is adjusted and monitored in a closed control loop. The TP sensor
provides the PCM with the information on the actual position of the throttle flap.
Standby function
If a fault develops in the throttle control unit (TCU), a standby function is carried out. This
standby function allows a slight opening of the throttle flap, so that enough air passes
through to allow limited engine operation.
For this purpose, there is an throttle flap adjustment screw on the throttle housing. The
return spring closes the throttle flap until the stop of the toothed segment touches the stop
screw. In this way a defined throttle flap gap is formed for limp home mode.
The stop screw has a spring loaded pin, which holds the throttle flap open for limp home
mode. In normal operating mode, this spring loaded pin is pushed in by the force of the
electric motor when the throttle flap must be closed past the limp home position (e.g. for idle
speed control or overrun shutoff).
CPP switch
The CPP switch is located directly on the pedal box.
The engine management recognises gearshifts through the CPP switch and thus improves
engine running characteristics.
The CPP switch passes a ground signal to the PCM when the clutch pedal is depressed
(disengaged).
(Brake Pedal Position) BPP switch

Page 5 of 6
There are two brake pedal switches at the pedal box: the brake lamp switch and the BPP
switch. The brake lamp switch only serves to switch on the brake lamps. The BPP switch is
used for engine management purposes.
The BPP switch provides the PCM with the information that the vehicle will be decelerated.
The BPP switch is closed in the rest state (brake pedal not depressed) and sends a ground
signal to the PCM.
If when the APP sensor has failed, the BPP is operated, the engine will be controlled to run at
idle speed by the PCM.
APP sensor
In order that the engine power output can be matched to that required by the driver, the PCM
needs to know the position of the APP sensor.
The APP sensor is a variable resistor whose resistance varies with the accelerator position. It
is a sliding contact potentiometer (2 potentiometers in total).
If a fault occurs in the APP sensor or the throttle control unit (TCU) during vehicle operation,
then this will be briefly indicated by a digital display in the instrument cluster after the
ignition is switched on, and a trouble code will be stored in the PCM.
If one potentiometer fails, the engine will run with reduced power (maximum torque 80 Nm),
Page 6 of 6
if both potentiometers fail, the engine will run with reduced power (maximum torque 55 Nm).
This warning may also be indicated if the engine does not start. The cause may be a poor
state of charge of the battery.
The warning indication normally disappears once the battery is re-charged.

Page 1 of 3

HYDRAULIC BRAKE ACTUATION
UID=G205541
Brake pedal

1 - U-shaped profile of the brake pedal
2 - Latch
3 - Carrier plate
The brake pedal is equipped with a safety device which uncouples the brake pedal from the
brake master cylinder in the event of a severe frontal collision to reduce injuries to the feet of
the driver.
As a result, the pressure acting from the brake master cylinder on the brake pedal is
interrupted and the brake pedal can be pushed to the floor.
The brake pedal is divided into 3 parts: a U-shaped profile, a latch and a carrier plate within
the brake pedal.
Function
Page 2 of 3

A - Fascia/crash padding mounting
1 - Connection point between the latch and the pedal
2 - Retaining pin (plastic)
3 - Mounting bore
4 - Mounting for the brake servo actuation rod
The complete pedal unit is mounted via a bore in the carrier plate.
The U-shaped profile of the brake pedal is held in position by the latch at a connection point.
In the event of a severe impact the entire pedal box is pushed into the footwell. As the pedal
box is pushed into the footwell, the latch on the upper side of the brake pedal is pushed
against the mounting of the fascia/crash padding.
Page 3 of 3

A - Direction of motion of the latch
B - Direction of motion of the pedal
1 - Sheared off retaining pin
The latch is twisted around the mounting axis of the pedal, and in the process the retaining
pin is cut through.
The connection point of the brake pedal is released, and no more force can be transmitted.
The carrier plate of the pedal is uncoupled from the U-shaped pedal and the pedal is left to
swing free.
It is very important not to damage the retaining pin when working on the pedal box.
Page 1 of 2

FUEL TANK AND LINES — 1.4L DIESEL
UID=G205545
Fuel tank and lines

1 - Fuel return line
2 - Tank retaining straps
3 - Tank breather pipe
4 - Tank filler neck
5 - Fuel tank
6 - Fuel feed line
Fuel supply unit

1 - Fuel feed
Page 2 of 2
2 - Electrical connection for the fuel gauge sender unit

3 - Fuel return
The fuel supply unit contains an integral venturi pump. In this way, the returning fuel sucks
up additional fuel into the housing. Because of this, the fuel volume of the tank is used in the
most optimal way.
Page 1 of 2

FUEL TANK AND LINES —
1.25L/1.4L/1.6L
UID=G207055
Overview

1 - Fuel return line
2 - Non-return valve, Evaporative Emission (EVAP) system
3 - Fuel pump unit
4 - Tank breather pipe
5 - Tank filler neck
6 - Activated charcoal canister
7 - Fuel filter
8 - Fuel feed line
The fuel tank holds 45 litres.
The fuel pump unit is located in the fuel tank. It consists of the fuel pump and the sender for
the fuel gauge.
The fuel pump is electrically controlled through the fuel cut-off safety switch.
In the event of an accident, the fuel cut-off safety switch interrupts the power supply so that
no more fuel can be supplied.
It is located behind a cover on the right-hand A-pillar in the footwell next to the central
junction box.
Page 2 of 2
The fuel tank must be removed before the fuel pump unit can be removed.
Care must be taken on installation, that the arrows on the fuel tank and the fuel pump unit
point at each other.
If the alignment is wrong, then the fuel level shown may be incorrect.
Page 1 of 2

FRONT DOOR SKIN PANEL
UID=G207179
Name Specification
Door skin panel
Removal
1. General Notes.
 Necessary removal work: door trim, exterior

mirror, door window glass, door outer handle
and door hinges already removed
2. NOTE: Before opening the door outer skin
seam, remove the clinched flange protection
using a plaited wire brush.
Door skin panel
1. Open the clinched seam.
2. Detach the adhesive bonds.
Installation
1. Door skin panel
 Apply clinched flange protection in the joint

area.
2. Door skin panel
 Apply clinched flange protection.

Page 2 of 2
3. Door skin panel
 Clinch the seam and apply clinched flange

protection.
Page 1 of 1

CRANKCASE VENT OIL SEPARATOR
UID=G210048
Removal
2. Remove the intake manifold. For additional
01B.
3. Remove the crankcase vent oil separater.
Installation
1. NOTE: Install a new crankcase vent oil
separator gasket.
Page 1 of 1

AIR CLEANER — 1.25L/1.4L/1.6L
UID=G210049
Removal
1. Disconnect the air cleaner outlet pipe and the
positive crankcase ventilation (PCV) hose from
the air cleaner.
2. Disconnect the air intake hose from the air

cleaner.
 Remove the retaining bolts and lift the air

cleaner up at the rear to remove.
Installation
1. NOTE: Locate the rear isolators onto the
rear mounting pegs and push down.
Page 1 of 3

EVAPORATIVE EMISSION CANISTER —
1.25L/1.4L/1.6L
UID=G210050
General Equipment
Transmission jack
Removal
WARNINGS:
Do not smoke or carry lighted tobacco or open flame of any type when working on or
near fuel related components. Highly flammable vapors are always present and may
ignite. Failure to follow these instructions may result in personal injury.
in personal injury.
2. Remove the floor panel crossmember.
3. Detach the exhaust system from the center

exhaust hanger insulator.
4. NOTE: When detaching the exhaust

system allow the system to be supported by
the rear suspension assembly.
Detach the exhaust system from the rear exhaust
hanger insulator.
5. Remove the exhaust system heat shield.

Page 2 of 3
6. CAUTION: Use a suitable packing

material to prevent damage to the underside
of the fuel tank.
Using a suitable transmission jack , support the
fuel tank.
7. Remove the fuel tank support strap rear

retaining bolts.
8. NOTE: Make note of the positions of the

support straps to make sure they are
positioned in exactly the same positions when
installing (left-hand over right-hand).
Remove the fuel tank support straps.
9. CAUTION: When lowering the fuel

tank, make sure that excessive strain is not
placed on the fuel lines and electrical
connectors.
Partially lower the fuel tank.
10. Disconnect the fuel tank vent pipe from the

evaporative emission canister. For additional
Page 3 of 3
11. Disconnect the back pressure valve from the

evaporative emission canister.
 Hold the cap against the canister and pull the

back pressure valve.
12. Remove the evaporative emissions canister

from the fuel tank.
Installation
WARNINGS:

or near fuel related components. Highly
flammable vapors are always present and
This procedure involves fuel handling. Be

prepared for fuel spillage at all times and
always observe fuel handling precautions.
in personal injury.
NOTE: When installing the fuel tank make
sure the fuel lines do not get kinked or
trapped.
Page 1 of 1

CRANKSHAFT MAIN BEARING
JOURNAL DIAMETER
UID=G21023
General Equipment
Micrometer
1. Measure the diameter of the main bearing
journals and the big-end bearing journals.
 Repeat the measurement with the

micrometer offset by 90°, in order to
determine any eccentricity which may be
present.
 Measure the journal at two different positions

to determine any conicity which may be
present.
Page 1 of 2

BEARING CHECK
UID=G21559
1. NOTE: Establish the cause of the damage
and resolve it.
Check whether the bearing cage is damaged at
the top, side or at the openings is damaged
because of the unprofessional use of a special
tool or of the wrong tool.
 Install a new bearing if necessary.
2. Check whether the ends of the taper rollers are

discoloured as a result of inadequate
lubrication or overheating, possibly through
excessive pre-load.
 Install a new bearing and new seals if

necessary.
 Check the bearing is correctly lubricated.
3. Check whether the ends of the taper rollers are

worn away due to incorrect installation,
excessive pre-load or faulty bearing seating.

necessary.
4. Check whether the bearing surfaces are grey

or grey/black with deposits between the
rollers.

necessary.
5. Check whether the bearing ring surfaces are

grooved caused by static impact.
 Install a new bearing if its surface is rough, or

if it is noisy.
6. NOTE: Overheating can cause loss of

Page 2 of 2
surface hardness.
Check for a dark blue colour caused by
overheating (yellow or brown is normal) due to
excessive pre-load or inadequate lubrication.
 Install a new bearing, new seals and check

other components as necessary.
7. Check the surfaces for abrasion due to metal

fatigue.
 Install a new bearing and clean all other

affected components as necessary.
Page 1 of 8

FUEL CHARGING AND CONTROLS
UID=G215855
WARNINGS:
Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
This procedure involves fuel handling. Be prepared for fuel spillage at all times.
Failure to follow this instruction may result in personal injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances

and fine clearances. The fuel injection pump is a fully electronic and has no linkages or
cables. Do not grease any of the fuel injection pump terminals or connectors. It is
therefore essential that absolute cleanliness is observed when working with these
components. Always fit blanking plugs to any open orifices or lines.
NOTE: As well as carrying out its normal function the glow plug lamp also acts as an
engine check lamp which will flash continuously when a hard diagnostic trouble code
(DTC) is detected by the powertrain control module (PCM). Soft DTCs are also stored by
the PCM but will only be known if the system is checked for DTCs using WDS.
NOTE: If a DTC is detected, all DTCs must be cleared after the cause is repaired. Failure
to clear all DTCs may cause driveability concerns.
NOTE: If the fuel level in the fuel tank drops below approximately 4 liters, rough running
will occur. This is to signal to the driver that the vehicle requires refuelling in order to
prevent the fuel system from running dry.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Mechanical Electrical
- Fuel leak(s) - Fuse(s)
- Fuel filter - Relay(s)
- Air cleaner element - Wiring harness
- Vacuum line(s)/vacuum - Electrical connector(s)

connections
- Passive anti-theft system (PATS)
- Hose(s)/hose connections LED operation
- Pipe(s)/pipe connections - Sensor(s)
- Contaminated fuel - Glow plug indicator
- High-pressure fuel supply - Battery

line(s)
- Fuel injectors
Page 2 of 8
- Fuel injection pump

4. If the cause is not visually evident, verify the symptom and refer to WDS to retrieve the
diagnostic trouble codes (DTCs).
5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart below to
continue diagnostics.
Symptom Chart
Symptom Chart

Engine does not *DTC detected. *REFER to WDS.
crank and glow
plug indicator is
flashing
Engine does not *Battery *CHECK the condition of the battery. REFER to
crank WDS.
*Starter motor. *Check the condition of the starting system.
*PATS. *CHECK the PATS LED extinguishes within 3
seconds when the ignition is turned on. REFER to
Section 419-01A / 419-01B.
*Starter inhibit relay. *CARRY OUT the Relay Component Test. REFER to
*Power relay. the Wiring Diagrams.
*Ignition switch. *REFER to Section 211-05.
*PCM. *REFER to WDS.
Engine cranks but *DTC detected. *REFER to WDS.
does not start and
glow plug indicator
is flashing
Engine cranks but *Inertia fuel shutoff *RESET the IFS switch.
does not start (IFS) switch.
*Fuel filter blocked. *INSTALL a new fuel filter. REFER to Section 310-
01.
*Damaged or blocked *INSTALL new fuel lines as necessary.
fuel lines.
*Air ingress into the *REFER to Section 310-00.
fuel lines.
*Crankshaft position *REFER to WDS.
(CKP) sensor.
*PCM.
*Incorrect valve *CHECK the valve timing. REFER to Section 303-
timing. 01A / 303-01B.
*Fuel injection pump. *REFER to WDS.
*Fuel injection supply *REFER to WDS.
manifold.
*Low cylinder *REFER to Section 303-00.
compression.
Poor starting and *DTC detected. *REFER to WDS.
glow plug indicator
Page 3 of 8
is flashing
Poor starting *Fuel filter blocked. *INSTALL a new fuel filter. REFER to Section 310-
01.
fuel lines.
*Air cleaner element *INSTALL a new air cleaner element.
blocked.
*Glow plug relay. *CARRY OUT the Relay Component Test. REFER to
Wiring Diagrams.
*Glow plug(s). *REFER to WDS.
*Fuel system leak(s). *CHECK the system for fuel leak(s). REPAIR the
system as necessary.
*CKP sensor. *REFER to WDS.
*Manifold absolute
pressure (MAP)
sensor.
*Incorrect engine oil. *INSTALL a new engine oil filter and designated
engine oil.
*Fuel injector(s). *REFER to WDS.
*Fuel injection pump. *INSTALL a new fuel injection pump.
manifold.
Engine starts but *DTC detected. *REFER to WDS.
immediately stops
and glow plug
indicator is flashing
Engine starts but *Air cleaner element *INSTALL a new air cleaner element.
immediately stops blocked.
fuel lines.
*MAP sensor.
*PCM relay. *CARRY OUT the relay component test. REFER to
Wiring Diagrams.
Poor idling and *DTC detected. *REFER to WDS.
glow plug indicator
is flashing
Poor idling *Low fuel tank fuel *CHECK the fuel tank fuel level is greater than
level. four liters. If the fuel tank fuel level is less than
four liters, FILL with fuel.
blocked.
01.
fuel lines.
*Incorrect or *CHECK for signs of contamination such as
contaminated fuel. strange odors from the fuel tank.
*CHECK for signs of water or petrol in the diesel.
*If contaminated fuel is found, DRAIN the
complete fuel system. FLUSH the fuel system
through with clean diesel. REFER to Section 310-
00. INSTALL a new fuel filter. REFER to
Page 4 of 8
Section 310-01. INSTALL a new fuel injection

pump, fuel injectors, fuel injection supply
manifold and high-pressure fuel supply lines.
*MAP sensor.
manifold.
Engine stumbling *DTC detected. *REFER to WDS.
and glow plug
Engine stumbling *Low fuel tank fuel *CHECK the fuel tank fuel level is greater than
*Accelerator pedal *REFER to WDS.
position (APP)
sensor.
manifold.
Engine lacks power *DTC detected. *REFER to WDS.
and glow plug
Engine lacks power *Air cleaner element *INSTALL a new air cleaner element.
blocked.
01.
*APP sensor. *REFER to WDS.
*MAP sensor.
fuel lines.
*Catalytic converter *CHECK if the catalytic converter rattles if gently
blocked. tapped. If noise is present, REMOVE and visually
INSPECT the catalytic convertor for damage.
INSTALL a new catalytic converter as necessary.
*Exhaust gas *REFER to Section 303-08A / 303-08B.
recirculation (EGR)
valve.
*Turbocharger. *REFER to Section 303-04A / 303-04B / 303-
04C.
timing. 01A / 303-01B.
Page 5 of 8

manifold.
Black smoke at idle *DTC detected. *REFER to WDS.
and glow plug
Black smoke at idle *Air cleaner element *INSTALL a new air cleaner element.
blocked.
*MAP sensor. *REFER to WDS.
timing. 01A / 303-01B.
manifold.
Excessive black *DTC detected. *REFER to WDS.
smoke during
acceleration and
glow plug indicator
is flashing
Excessive black *APP sensor. *REFER to WDS.
smoke during *CKP sensor.
acceleration *Incorrect or *CHECK for signs of contamination such as
manifold.
Black smoke at *DTC detected. *REFER to WDS.
cruising speeds
and glow plug
Black smoke at *Air cleaner element *INSTALL a new air cleaner element. REFER to
cruising speeds blocked. Section 303-12.
*Vacuum lines. *CHECK all vacuum lines are correctly installed
and no signs of air leaks are present. REPAIR or
INSTALL new vacuum line(s) as necessary.
*EGR valve sticking *REFER to WDS.
open.
*EGR vacuum
switching valve.
Page 6 of 8

04C.
manifold.
Blue smoke and *DTC detected. *REFER to WDS.
glow plug indicator
is flashing
Blue smoke *Engine burning oil. *CARRY OUT a controlled oil consumption test
over 1000 km (600 miles). CONFIRM that the oil
consumption is less than 0.1 liters per 1000 km
(600 miles). REFER to Section 303-01A / 303-
01B.
*Worn or damaged *REMOVE and inspect the cylinder head, pistons
valve guides, piston and cylinder bores for signs of wear. REFER to
rings, cylinder bores, Section 303-01A / 303-01B.
cylinder head or
gasket.
*Positive crankcase *CHECK the PCV pipes for signs of restriction or
ventilation (PCV) blockage. REPAIR as necessary.
system.
*Turbocharger oil *REFER to Section 303-04A / 303-04B / 303-
seals leaking. 04C.
*Turbocharger oil
return tube blocked
or damaged.
White smoke and *DTC detected. *REFER to WDS.
glow plug indicator
is flashing
White smoke *Water in fuel. *DRAIN the fuel filter of water until clear fuel is
present. If contaminated fuel is still found, DRAIN
the complete fuel system. FLUSH the fuel system
timing. 01A / 303-01B.
*Coolant in the *CARRY OUT a cooling system pressure test.
combustion REFER to Section 303-03A / 303-03B. REMOVE
chamber. and INSPECT the cylinder head, cylinder head
gasket and cylinder bores for wear or damage.
Engine misfire and *DTC detected. *REFER to WDS.
glow plug indicator
Page 7 of 8
is flashing
Engine misfire *Low fuel tank fuel *CHECK the fuel tank fuel level is greater than
* high-pressure fuel *CHECK the high-pressure fuel supply lines for
supply line(s). signs of damage. INSTALL new high-pressure fuel
supply lines as necessary.
fuel lines.
compression.
*Worn or damaged *REMOVE the cylinder head and visually INSPECT
valve, camshaft for signs of wear or damage. REFER to
followers or Section 303-01A / 303-01B.
camshafts.
*Damaged cylinder *REMOVE and INSPECT the cylinder head gasket
head gasket. and cylinder bores for wear or damage. REFER to
Section 303-01A / 303-01B.
*Engine operating *REFER to Section 303-03A / 303-03B.
temperature too
high.
manifold.
Engine knock at *DTC detected. *REFER to WDS.
idle and glow plug
Engine knock at *Low engine oil level. *CHECK the engine oil level. REFILL as necessary.
idle *Incorrect or *CHECK for signs of contamination such as
timing. 01A / 303-01B.
*Excessive carbon *REMOVE and INSPECT the cylinder head for signs
build up. of carbon build up. INSPECT the pistons for signs
carbon build up. REFER to Section 303-01A /
Page 8 of 8
303-01B.
*Worn or damaged oil *REFER to Section 303-01A / 303-01B.
pump.
*Worn or damaged
timing chain or
sprocket.
*Major mechanical
engine failure.
Engine knock *DTC detected. *REFER to WDS.
during acceleration
and glow plug
Engine knock *Fuel injector(s). *REFER to WDS.
during acceleration *PCM. *REFER to WDS.
*Major mechanical *REFER to Section 303-01A / 303-01B.
engine failure.
Excessive fuel *DTC detected. *REFER to WDS.
consumption and
glow plug indicator
Excessive fuel *Brakes binding. *CHECK the braking system. REFER to
consumption Section 206-00.
*Vehicle overloaded, *ADVISE the customer about the effects of
or excessive wind overloading the vehicle and wind resistance on
resistance (roof the fuel consumption.
racks, towing etc).
blocked.
*Fuel system leak(s).*CHECK the system for fuel leak(s). REPAIR the
system as necessary.
*Incorrect engine oil. *INSTALL a new oil filter and designated engine
oil.
*Generator. *REFER to Section 414-00.
*EGR valve stuck *REFER to WDS.
open.
fuel lines.
timing. 01A / 303-01B.
*Turbocharger 04C.
wastegate actutator.
compression.
Page 1 of 1

REFRIGERANT OIL ADDING
UID=G21702
CAUTION: Store the refrigerant oil in a closed, sealed container to prevent the
ingress of moisture.
NOTE: Collect the refrigerant oil in a clean measuring cylinder when replacing the A/C
compressor, the suction accumulator or refrigerant lines.
1. NOTE: This step only needs to be carried
out when removing the A/C compressor.
Drain the refrigerant oil from the A/C compressor.
 Rotate the compressor shaft at least 6 to 8

turns when draining the refrigerant oil.
out when removing the suction accumulator.
Drain the refrigerant oil from the suction
accumulator.
out when removing refrigerant lines.
Drain the refrigerant oil from the refrigerant lines.
4. NOTE: If more than one air conditioning
system component is being renewed, the oil
quantity to be added is the sum of each
individual quantity.
NOTE: In addition, add the same quantity of
new refrigerant oil as was collected in the oil
separator of the servicing unit when the air
conditioning was drained.
Add the calculated quantity of new refrigerant oil.
For additional information, see Specifications in
this subsection.
Page 1 of 3

AIR CONDITIONING (A/C) SYSTEM
RECOVERY, EVACUATION AND
CHARGING
UID=G21707
General Equipment
Refrigerant centre
Refrigerant identification equipment
1. CAUTION: The refrigerant

identification equipment must be used before
the system is emptied, otherwise the
refrigerant centre may become contaminated.
Contaminated refrigerant must be disposed of
as hazardous waste. Always follow the
manufacturer's instructions when using the
refrigerant centre and the refrigerant
identification equipment.
Unscrew and remove the protective caps from the
A/C charging connections.
2. Pull back the catches of the quick-fit unions on
the refrigerant centre lines.
3. NOTE: Larger inner diameter for high-

pressure side. Smaller inner diameter for low-
pressure side.
Connect the refrigerant centre lines to the A/C
charging connections.
4. WARNING: When recovering the

refrigerant do not allow it to enter the
atmosphere under any circumstances.
NOTE: When removing components of the air
conditioning system, calculate the residual
quantity of refrigerant oil. For additional
information, refer to Refilling refrigerant oil in
this section.
Empty the air conditioning system through the
low-pressure connection according to the
refrigerant centre manufacturer's instructions.
CAUTIONS:
5. The air conditioning system must be

evacuated for about 30 minutes before
recharging it, to ensure that it operates
correctly.
Page 2 of 3
If moisture was able to enter an open

system over an extended period (several
hours), install a new accumulator/dehydrator
and increase the evacuation time to 2-3
hours.
Evacuate the air conditioning system according to
the refrigerant centre manufacturer's
instructions.
6. NOTE: If an air conditioning system that
was filled with refrigerant is being evacuated,
then some refrigerant will still be in the
refrigerant oil in the compressor. This
remaining refrigerant may evaporate, causing
a slight increase (max. two marks) in the
reading on the pressure gauge during the
leak test. However, despite this pressure
increase the air conditioning system is free of
leaks.
NOTE: If the gauge reading increases by
more than 20 mbar (2 kPa or 0.29 psi), the
system is leaking.
Perform the leak test.
1. For the leak test, close the hand valves on
the gauge set, switch off the refrigerant
centre vacuum pump and observe the low
pressure gauge.
2. Locate any leaks in the A/C refrigerant
circuit using a leak tester.
7. Top up with refrigerant oil. For additional
information, refer to Refrigerant Oil Adding in
this section.
CAUTION: The air conditioning system must always be evacuated before charging.
8. NOTE: Depending on the type of
refrigerant centre and the equipment (with or
without heated filling cylinder), the air
conditioning system is either charged with
liquid through the high-pressure connection
or with gas through the low-pressure
connection,
NOTE: Charge quantity on sticker in the
engine compartment.
Charging the air conditioning system (with liquid)
through the high-pressure connection.
1. Open the shut-off valve on the high-
pressure side.
2. Switch the refrigerant centre to "Fill" mode
and fill with the prescribed quantity of liquid
refrigerant (R134a).
9. CAUTION: Only gaseous charging of

the air conditioning system is performed
through the low-pressure connection.
Charging the air conditioning system through the
low-pressure connection.
1. Open the shut-off valve on the low-pressure
Page 3 of 3
side.
2. Switch the refrigerant centre to "Fill" mode
and charge with gaseous refrigerant.
3. Top up with the remaining amount of
refrigerant whilst the air conditioning is
switched on. Let the engine run at about
1200-1500 rpm for this purpose. Switch the
air conditioning to maximum cooling power
and fresh air mode. Set the blower to full
power. Fill with the remainder of the
prescribed fill capacity.
10. WARNING: Do not detach the high-

pressure hose when the air conditioning is
switched on.
Disconnecting the refrigerant centre.
1. Close the shut-off valves.
2. Switch off the refrigerant centre.
3. Disconnect the refrigerant centre lines from
the A/C charging connections.
4. Screw the protective caps onto the filler
valves.
Page 1 of 1

AIR DISTRIBUTION AND FILTERING
UID=G21711
Page 1 of 1

HEATING AND VENTILATION
UID=G21715
Page 1 of 1

AIR CONDITIONING
UID=G21730
Page 1 of 4

REAR SEAT BACKREST COVER
UID=G240077
1. Remove the components in the order indicated in the following illustration(s) and table(s).

1 - Safety belt lower anchor and buckle retaining bolt
See Removal Detail
See Installation Detail
2 - Safety belt lower anchor and buckle
3 - Backrest retaining bolts
4 - Backrest
5 - Head restraints (if equipped)
6 - Backrest release lever trim panel
7 - Center safety belt webbing trim panel (if equipped)
See Removal Detail
8 - Head restraint guides (if equipped)
See Removal Detail
9 - Backrest cover and pad
See Removal Detail
Page 2 of 4
Removal Details
Item 1 : Safety belt lower anchor and buckle retaining bolt
WARNING: If the safety belt webbing retracts further than the stop on the webbing, a
new safety belt retractor must be installed.
CAUTION: Make sure the webbing retainer is fitted at least 200 mm from the
webbing stop towards the retractor.
Item 7 : Center safety belt webbing trim panel (if equipped)
CAUTION: Make sure the webbing retainer is fitted at least 200 mm from the
webbing stop towards the retractor.
Item 8 : Head restraint guides (if equipped)
CAUTION: When detaching the retaining strip take care not to damage the backrest
carpet.
1. Locally detach the backrest cover and pad to
gain access to the head restraint guides.
 Detach the retaining strip
2. Remove the head restraint guides (if

equipped).
1. From the underside of the backrest pad
depress the locking tangs.
2. Slide the head restraint guides upwards
through the backrest cover.
Item 9 : Backrest cover and pad

Page 3 of 4
1. CAUTION: When removing the

backrest cover take care not to detach the
safety belt webbing retainer.
Remove the backrest cover and pad.
 Feed the safety belt webbing through the

backrest cover and pad.
2. Remove the backrest cover.

1. Roll the backrest cover inwards to access
the pleating hog rings.
2. Cut the hog rings.
Installation Details
Item 9 : Backrest cover and pad
CAUTIONS:
Make sure the webbing retainer is fitted at least 200 mm from the webbing stop
towards the retractor.
When installing the backrest cover take care not to detach the safety belt webbing
retainer.
Check the backrest latch cable routing, and the operation of the safety belt retractor
and interlock before fully installing the rear seat backrest cover.
After installation check for correct operation of the center safety belt retractor.
NOTE: If a replacement backrest pad is to be installed, cut out a hole for the center safety
belt webbing trim panel. Use the existing backrest pad as a template.
NOTE: If a replacement backrest cover is to be installed, cut out holes for the head
restraint guide and center safety belt webbing trim panel. Use the existing backrest cover
as a template.
NOTE: Use hog ring pliers to close the hog rings. Do not use any other tool. The hog rings
must be closed to overlap as illustrated.
Page 4 of 4
Item 6 : Backrest release lever trim panel
NOTE: When installed, the trim panel may not have the original retaining force.
Item 1 : Safety belt lower anchor and buckle retaining bolt
CAUTION: After installation check for correct operation of the center safety belt
retractor.
Page 1 of 1

DRUM BRAKE
UID=G250944
Overview

1 - Brake shoe
2 - Brake cylinder
3 - Automatic adjuster
4 - Bi-metallic strip
5 - Return spring
The drum brake is equipped with an automatic adjuster which adjusts the brake shoes towards the
brake drum when lining wear occurs.
The adjustment mechanism is equipped with a bi-metallic strip which prevents undesired
adjustment of the brake shoes when the brakes are run hot.
The heat generated during braking is passed to the bi-metallic strip. If the heat exceeds a critical
point, the bi-metallic strip bends upwards into the corresponding nib and prevents further
adjustment.
After the brake has cooled again, the bi-metallic strip returns to the initial position. Adjustment is
now possible again.
Page 1 of 1

FRONT DISC BRAKE
UID=G250945
Overview

1 - Brake disc
2 - Brake back plate assembly
3 - Retaining spring clip
4 - Brake pads
5 - Brake caliper
The front brake system has internally ventilated brake discs and a single-piston floating
caliper.
The front disc brakes are the same on all vehicles, irrespective of the vehicle specifications.
Please refer to the "General Specifications" section for the dimensions of the brake discs.
The piston of the brake caliper has a diameter of 54 mm.

Page 1 of 2

PARKING BRAKE
UID=G250946
Overview

1 - Handbrake lever
2 - Handbrake adjusting nut
3 - Front handbrake cable
4 - Equaliser
5 - Handbrake cables
6 - Sleeve connection
7 - Rear handbrake cable
Layout
The handbrake cable mechanism consists of three sections: the front handbrake cable, the
two handbrake cables underneath the vehicle and the two rear handbrake cables leading to
the brakes.
The front handbrake cable is connected to the handbrake lever via a threaded piece and a
nut. This nut is used to adjust the handbrake cable.
Page 2 of 2
The two handbrake cables underneath the vehicle are both connected via a threaded piece
and a nut to the equaliser and therefore the front handbrake cable. They are connected to the
rear handbrake cables via a sleeve connection.
The rear handbrake cables in turn link into the lever mechanism of the rear brakes.
Function
When the handbrake lever is operated, the front handbrake cable acts via the equaliser onto
the two handbrake cables underneath the vehicle. Via the sleeve connection pieces these then
act onto the rear handbrake cables and, via the lever mechanism, onto the brake.
Page 1 of 3

CLUTCH
UID=G251010
Self-adjusting clutch
Advantages of the self-adjusting clutch

A - Release force in kN
B - Release travel in mm
1 - Conventional clutch - condition when new
2 - Conventional clutch - after wear
3 - Self-adjusting clutch
The self-adjusting clutch has the following advantages over conventionally designed clutches:
* lower release forces, which remain constant over the service life and thus
ensure high driving comfort throughout the entire service life
* increased wear reserve and therefore greater service life due to the automatic
wear adjustment
Function
Page 2 of 3

1 - Cover
2 - Adjusting ring (ramp ring)
3 - Spring
4 - Sensing Belleville washer
5 - Main Belleville washer
A conventional clutch responds to clutch wear with an increase in the release force, which
ultimately has to be delivered by the driver to press down the clutch pedal.
This increase in the release force after clutch wear is used on the self-adjusting clutch as the
key indicator for adjusting the clutch.
The main distinction to a conventional clutch is that the main Belleville washer is not riveted
in a fixed manner to the cover, but instead is supported by a so-called sensing Belleville
washer. In addition an adjusting ring (ramp ring) is used to compensate the wear of the
clutch lining.
The sensing Belleville washer is hooked into the clutch cover at the outside and, with the
inner tongues, forms the bearing for the main Belleville washer.
The sensing Belleville washer is designed to deliver a slightly greater opposing force under
normal conditions than the maximum required release force.

1 - Air gap
If when the clutch is operated the release force is less than the opposing force of the sensing
Belleville washer, then the pivot bearing point of the main Belleville washer remains in the
same position.
If however the release force increases due to lining wear, then the opposing force of the
sensing Belleville washer is exceeded.
If the opposing force of the sensing Belleville washer is exceeded, the sensing Belleville
washer and therefore also the main Belleville washer are displaced towards the flywheel.
This displacement towards the flywheel has the effect that the release force is reduced again.
Once the release force has dropped to the level of the opposing force of the sensing Belleville
Page 3 of 3
washer again (equilibrium of forces), the displacement of the components towards the
flywheel stops.
When the sensing Belleville washer is displaced this results in an air gap between the main
Belleville washer and the clutch cover.
The adjusting ring (ramp ring) arranged around the circumference immediately compensates
for the air gap. To do this, springs press the adjusting ring and therefore the ramp against
the main Belleville washer.
This results in a balancing of the clutch actuation mechanism, which keeps the forces required
to operate the clutch constant throughout the entire service life of the clutch.
Page 1 of 4

WHEELS AND TIRES
UID=G25362
To maximize tire performance, inspect the tires for signs of incorrect inflation and uneven
wear which may indicate a need for balancing, rotation or suspension alignment. Tires should
also be checked frequently for cuts, stone bruises, abrasions, blisters, and for objects that
may have become embedded in the tread. More frequent inspections are recommended when
rapid or extreme temperature changes occur or when road surfaces are rough or occasionally
littered with foreign material.
As a further visible check of tire condition, tread wear indicators are molded into the bottom
of the tread grooves. When these indicator bands become visible, new tires must be installed.
Tire Wear Diagnosis
Uneven wear is usually caused by either excessive camber or excessive toe on tires.
Sometimes incorrect toe settings or worn struts will cause severe `cupping' or `scalloped' tire
wear on non-driven wheels.
Severely incorrect toe settings will also cause other unusual wear patterns.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure always begins with a road test. The road test and
customer interview (if available) will provide much of the information needed to find the
source of a vibration.
During the road test, drive the vehicle on a road that is smooth and free of undulations. If
vibration is apparent, note and record the following:
- the speed at which the vibration occurs.
- what type of vibration occurs in each speed range.
 mechanical or audible
- how the vibration is affected by changes in the following:
 engine torque
 vehicle speed
 engine speed
- type of vibration - sensitivity: torque sensitive, vehicle speed sensitive or engine

speed sensitive.
The following explanations help isolate the source of the vibration.
Torque Sensitive
Page 2 of 4
This means that the condition can be improved or made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or applying engine torque.
Vehicle Speed Sensitive
This means that the vibration always occurs at the same vehicle speed and is not affected by
engine torque, engine speed or the transmission gear selected.
Engine Speed Sensitive
This means that the vibration occurs at varying vehicle speeds when a different transmission
gear is selected. It can sometimes be isolated by increasing or decreasing engine speed with
the transmission in NEUTRAL or by stall testing with the transmission in gear. If the condition
is engine speed sensitive, the cause is probably not related to the tires.
If the road test indicates that there is tire whine, but no shake or vibration, the noise
originates with the contact between the tire and the road surface.
A thumping noise usually means that the tire is flat or has soft spots making a noise as they
slap the roadway. Tire whine can be distinguished from axle noise. Tire whine remains the
same over a range of speeds.
A complete road test procedure is described in Section 100-04.
Symptom Chart
Symptom Chart

Tires show *Tires under-inflated. *ADJUST the tire pressure.
excess wear on *Vehicle overloaded. *CORRECT as necessary.
edge of tread *Incorrect wheel *ADJUST the wheel alignment.
alignment.
Tires show *Tires over-inflated. *ADJUST the tire pressure.
excess wear in
center of tread
Other *Incorrect tire *ADJUST the tire pressure.
excessive tire pressure.
wear concerns *Tires need rotating. *ROTATE the tires.
*Incorrect wheel *ADJUST the wheel alignment.
alignment.
*Vehicle overloaded. *CORRECT as necessary.
*Loose or leaking *TIGHTEN or INSTALL new suspension components as
front strut and necessary. REFER to Section 204-01.
spring assembly.
*Wheel bearings *INSTALL new wheel bearings as necessary. REFER to
worn. Section 204-01 / 204-02.
*Suspension *CHECK or INSTALL new suspension components as
components, necessary.
bushings and ball
joints.
*Excessive lateral or *CHECK the wheel and tire radial runout. REFER to
radial runout of Section 204-00.
wheel or tire.
Wheel *Incorrect application *FOLLOW manufacturers specifications.
Page 3 of 4
mounting is or mismatched parts,

difficult including wheel
studs and nuts.
Wheel rust or *Poor maintenance. *CLEAN and PROTECT with paint.
corrosion
Wobble or *Damaged wheel. *INSPECT wheel rims for damage. INSTALL new parts
shimmy as necessary.
affecting wheel *Front wheel bearing. *CHECK or INSTALL new wheel bearings as necessary.
runout REFER to Section 204-01.
Excessive *Suspension *CHECK or INSTALL new parts. REFER to Section 204-
vehicle components. 00.
vibration,
rough steering
Vehicle *Incorrect tire *ADJUST the tire pressure.
vibrations from pressure.
wheels and *Wheel or tire *BALANCE the tire and wheel assembly.
tires imbalance.
*Uneven tire wear. *INSTALL a new tire(s) as necessary.
*Brake disc *CHECK the brake disc for foreign material.
imbalance.
*Water in tires. *REMOVE the water.
*Bent wheel. *INSTALL a new wheel. Attempts to straighten a wheel
can cause fractures in the wheel and weaken the
wheels strength.
*Incorrectly seated *SPIN the wheel on the vehicle. EXAMINE the area
tire bead. where the tire and the wheel meet. If that section of
the tire appears to waver while being rotated, the tire
bead may not be correctly seated on the wheel.
REMOVE the tire and CLEAN the bead seat areas on
both wheel and tire.
*Radial runout of *Using a suitable dial indicator gauge and holding
wheel or tire. fixture, CHECK the radial runout of both the wheel
and the tire. REFER to Section 204-00.
*Wheel stud, wheel *CHECK or INSTALL new parts as necessary.
nut or enlarged stud
holes.
*Foreign material *CLEAN mounting surfaces.
between wheel
mounting face and
hub mounting
surface.
*Lateral runout of *Using a suitable dial indicator gauge and holding
wheel or tire. fixture, CHECK the radial runout of both the wheel
and the tire. REFER to Section 204-00.
*Front wheel bearing. *CHECK or INSTALL a new wheel bearing as
necessary. REFER to Section 204-01.
Cracks develop *Overloading or *INSTALL a new wheel. CHECK loading and operating
in rim base abusive use. conditions. AVOID over inflation of tires. CHECK the
back (rim bead specifications for the rim load capacity, working load,
seat) tire size, ply rating and tire construction.
*Incorrect use of *CHECK mounting, demounting, and maintenance
tools. procedures.
Damaged *Sliding wheel across *INSTALL new wheel studs as necessary. INSTALL a
wheel studs wheel studs during new wheel as necessary.
assembly.
Loose brake *Wheel studs too *INSTALL new wheel studs of the correct length as
Page 4 of 4
drum long. necessary.

Broken wheel *Loose wheel nuts. *INSTALL new wheel studs and nuts. TIGHTEN to
studs specification.
*Overloading. *INSTALL new wheel studs. TIGHTEN to specification.
Compare actual load against vehicle load ratings.
Stripped wheel *Excessive tightening. *INSTALL new wheel studs and nuts. TIGHTEN to
stud threads specification.
Rust streaks *Wheel nuts. *CHECK complete assembly. If parts are damaged
from the wheel INSTALL new parts. TIGHTEN to specification.
stud holes in
the wheel
Damaged *Wheel assembly. *INSTALL new wheel nuts. TIGHTEN to specification.
wheel nuts *Over tightened *FOLLOW correct tightening procedure.
wheel nuts.
Seized wheel *Corrosion. *CAUTION: Do not permit lubricant to get on cone sets
nuts of stud holes or on cone angle of wheel nuts. If
corrosion is slight, wire brush away. If corrosion is
excessive, INSTALL new wheel studs and nuts. If the
condition persists, LUBRICATE the first three threads
of each wheel stud with a graphite-based lubricant.
*Overloading *REDUCE weight.
Page 1 of 1

FUEL TANK AND LINES
UID=G25711
Page 1 of 2

DRIVER AIR BAG MODULE WIRING
HARNESS
UID=G278614
Removal
WARNINGS:
Always wear safety glasses when working on an air bag equipped vehicle and when
handling an air bag module. Failure to follow this instruction may result in personal injury.
To minimize the possibility of injury in the event of premature deployment, always

carry a live air bag module with the bag and trim cover pointed away from the body.
To minimize the possibility of premature deployment, live air bag modules must only
be placed on work benches which have been ground bonded and with the trim cover
facing up. Failure to follow these instructions may result in personal injury.
Never probe the electrical connectors of air bag modules or any other supplemental
restraint system component. Failure to follow this instruction may result in personal
injury.
Do not work on the air bag with the trim cover facing downwards. Support the air
bag vertically and work to the side of the air bag. Failure to follow these instructions may
1. Remove the driver air bag module. For
additional information, refer to Driver Air Bag
Module in this section.
2. CAUTION: Note the position and

routing of the wiring harness, to aid
assembly. An incorrectly routed wiring
harness may become damaged when the
steering wheel is rotated.
Remove the driver air bag module wiring harness.
1. Detach the elastic band from the air bag
module.
2. Using a suitable screwdriver, release the
locking tangs.
Installation
WARNINGS:

Page 2 of 2
injury.
CAUTIONS:
1. Make sure the driver air bag module

electrical connectors are free from fragments.
CAUTION: Make sure the driver air bag

module wiring harness is correctly routed and
is secure with the elastic band. An incorrectly
routed wiring harness may become damaged
when the steering wheel is rotated.
Page 1 of 1

BRAKE SYSTEM
UID=G281357
Overview

A - Brake system without Anti-lock Brake System (ABS)
B - Brake system with ABS
1 - Brake master cylinder
2 - Reservoir
3 - Brake servo
4 - Brake pedal
5 - Brake pressure reduction valve
6 - Rear drum brake
7 - Front disk brake
8 - ABS hydraulic unit with integrated control unit
9 - Wheel speed sensors
Vehicles without ABS are equipped with brake pressure reduction valves for the rear wheel
brakes. They are located in the corresponding brake circuits at the brake master cylinder.
Vehicles with ABS do not need brake pressure reduction valves because they are equipped
with electronic brake distribution (EBD).
The handbrake is cable operated on the rear brakes.
On vehicles with a petrol engine the necessary vacuum for the brake booster is generated by
the intake manifold.
On vehicles with a diesel engine, a vacuum pump driven by the engine provides the
necessary vacuum for the brake booster.
Page 1 of 1

EVAPORATIVE EMISSIONS
UID=G281359
Overview

1 - From activated charcoal canister
2 - From fuel tank
3 - Non-return valve
4 - Carbon canister
5 - Evaporative Emission (EVAP) solenoid valve
6 - To the intake manifold
The EVAP collection system prevents fuel vapours from reaching the atmosphere.
To achieve this, the fuel vapours are led from the fuel tank into the activated charcoal
canister, and temporarily stored there.
Under part load the Powertrain Control Module (PCM) activates the EVAP solenoid valve. This
causes the fuel vapours to be passed on to the intake system of the engine.
Page 1 of 2

CLUTCH CONTROLS
UID=G281360
Overview

1 - Brake fluid reservoir
2 - Supply line
3 - Clutch Pedal
4 - Master cylinder
5 - Pressure line
6 - Slave cylinder with choke assembly
The hydraulic clutch is supplied from a separate chamber in the brake fluid reservoir.
Because of this separate chamber, the braking system remains operational if a leak occurs in
the hydraulic clutch system.
Function
Pressure is created in the master cylinder when the clutch pedal is operated.
The hydraulic fluid in the master cylinder is put under pressure and fed through the pressure
pipe to the slave cylinder.
Page 2 of 2
The displaced hydraulic fluid moves the piston in the slave cylinder and this in turn slides the
release bearing axially.
The release bearing pushes the bearing inner ring against the tongues of the diaphragm
spring.
The spring induced grip between the clutch disc and the flywheel is broken.
When the clutch pedal is released the diaphragm spring presses the piston in the slave
cylinder back to its starting position. The spring induced grip between the clutch disc and the
flywheel is created again.
A spring in the slave cylinder ensures preload on the release bearing.
The release bearing is always touching the pressure plate because of this preload. The extra
travel caused by clutch lining wear is compensated for by the preload.
There is a choke assembly in the slave cylinder which helps to increase smoothness when
pulling away.
Because of the choke assembly, the pressure drop of the fluid leaving the slave cylinder and
returning to the reservoir is delayed.
Because of this, the clutch closing time is delayed when the clutch pedal is released suddenly,
and a soft and comfortable clutch engagement is achieved.
Choking does not occur during clutch disengagement.
CAUTION: Vehicles with an automated shift manual (ASM) transmission have a slave
cylinder without a choke assembly. The slave cylinders must not be exchanged for one
another.
NOTE: The clutch pedal travel cannot be adjusted.
The release bearing is an interference fit in the slave cylinder and cannot be renewed
separately.
Page 1 of 11

MANUAL TRANSAXLE
UID=G281365
General
The iB5 manual transmission is a two shaft transmission.
All gear wheels are helical toothed, synchronised (except reverse gear) and run in plain
bearings.
1st and 2nd gears are double synchronised.
There is no need to change the oil.
Transmission construction
Page 2 of 11

1 - 5th gear housing
2 - Transmission side housing halves
3 - Breather
4 - Hydraulic clutch connection
5 - Clutch side housing halves
6 - Slave cylinder with integral release bearing
7 - Input shaft
8 - Output shaft
9 - Differential assembly
Input shaft
Page 3 of 11

1 - Ball bearing
2 - Input shaft
3 - Reverse gear idler
4 - 1st gear wheel
5 - Reverse gear wheel
6 - 2nd gear wheel
7 - 3rd gear wheel
8 - 4th gear wheel
9 - Snap ring
10 - 5th gear wheel
11 - Snap ring
Output shaft
Page 4 of 11

1 - Open cylinder roller bearing
2 - Output shaft with differential drive wheel
3 - 1st gear wheel
4 - 1st gear double synchronisation
5 - Synchroniser - 1st/2nd gear with reverse gear wheel
6 - 2nd gear double synchronisation
7 - 2nd gear wheel
8 - 3rd gear wheel
9 - 3rd gear simple synchronisation
10 - Synchroniser assembly - 3rd/4th gear
11 - 4th gear simple synchronisation
12 - 4th gear wheel
13 - Ball bearing (closed both sides)
14 - Snap ring
15 - 5th gear wheel
16 - 5th gear simple synchronisation
17 - 5th gear synchroniser assembly
18 - Retaining plate
19 - Snap ring
Double synchronisation
Page 5 of 11

1 - Gearwheel
2 - Inner synchroniser ring
3 - Conical ring
4 - Outer synchroniser ring
5 - Synchroniser hub
1st and 2nd gears are double synchronised.
The effective synchronisation surface for double synchronisation is almost twice that of simple
synchronisation. Because of this, the speeds of the gearwheels are equalised much faster,
which considerably improves gearshifting comfort.
Differential assembly

1 - Bearing
2 - Crown wheel
3 - Differential assembly
4 - Sender wheel - Vehicle Speed Sensor (VSS)
5 - Crown wheel bolts
Page 6 of 11
The differential assembly is built into the transmission housing.
The drive torque is transmitted to the differential by the crown wheel which is bolted to it.
The differential assembly contains differential pinion gears mounted on a spindle and the axle
halfshaft pinion gears which connect to the front wheel axle halfshafts through helical
gearing.
The axle halfshaft pinion gears can revolve around the differential pinion gears when the road
wheel speeds are different (e.g when cornering).
On vehicles without Anti-lock Brake System (ABS) a VSS detects the speed of the differential
assembly at the VSS sender wheel.
On vehicles with ABS the VSS sender wheel is also installed. The VSS is however not installed
in this case. A plug with an O-ring closes the corresponding bore instead.
Internal shift mechanism
Layout

1 - Selector gate
2 - Shift locking bush
3 - Return spring from reverse gear position
4 - Reverse gear selector shaft
5 - Snap ring
6 - Shift rod - 5th gear/reverse gear
7 - Selector interlock
8 - Selector shaft
9 - Guide sleeve
The shift locking bush prevents two gears from being engaged at the same time.
The selector interlock maintains engagement of the selected gear.

Page 7 of 11
Both the shift and the select process is performed through the selector shaft.
Select movement

2 - Selector shaft
3 - Selector boss
4 - Selector gate
The axial movement of the selector cable is transferred at the transmission to the selector
shaft which can turn in its bearing.
If the gearshift lever is moved to the left or right, the selector shaft and the selector boss
both turn together in the corresponding direction.
As this happens, the selector shaft is guided by a pin in the selector gate.
The selector boss selects the required selector fork.
At the same time the shift locking bush prevents access to other gear combinations.
Shift movement
Page 8 of 11

2 - Selector shaft
3 - Selector boss
4 - Selector gate
After the gear pair to be shifted has been selected, the shift movement takes place.
Here the axial movement of the shift cable at the transmission produces an axial movement
of the selector shaft.
If the gearshift lever is moved forwards or backwards, the selector shaft and the selector boss
both move vertically together.
As this happens, the selector shaft is guided by a pin in the selector gate.
The selector boss shifts the required selector fork.
Engage reverse gear

Page 9 of 11

2 - Reverse gear selector shaft
3 - Shift rod - 5th gear/reverse gear
4 - Selector shaft
5 - Selector boss
6 - Selector gate
In order to select reverse gear, the gearshift lever must be moved to the right over and past
the reverse gear inhibit device. As this occurs the axial movement of the selector cable is
transferred to the selector shaft which can turn in its bearing.
When shifting into reverse gear, the gearshift lever is moved backwards. The selector boss
engages in the 5th gear/reverse gear shift rod, which in turn engages through a pin in the
reverse gear selector shaft.
During the select and shift process the selector shaft is guided through the selector gate by a
pin.
The reverse gear idler is slid by the reverse gear selector shaft and reverse gear is engaged.
Power transmission in the individual gears

Page 10 of 11
Page 11 of 11
Page 1 of 1

GEARSHIFT HYDRAULIC FLUID LINES
UID=G281388
Removal
1. CAUTION: If brake fluid comes into

contact with the paintwork, rinse off the
affected areas with cold water without delay.
Completely drain the brake fluid from the brake
fluid reservoir.
2. Detach the clutch slave cylinder line from the

clutch slave cylinder.
 Pull out the clutch slave cylinder line clip.
3. Detach the clutch slave cylinder line from the

clutch actuator.
 Pull out the clutch slave cylinder line clip.
 Unclip the clutch slave cylinder line.
Installation
1. Install the components in the reverse order.
2. CAUTION: The gearshift actuator

bleeding procedure of the Worldwide
Diagnostic System (WDS) must be performed
if parts of the hydraulic clutch system have
been opened or new components have been
installed.
NOTE: The clutch parameters for the
transmission control unit are automatically
adapted when the gearshift actuator bleeding
procedure of the WDS is performed.
Bleed the clutch system. For additional
Page 1 of 15

BRAKE SYSTEM
UID=G28494
The brakes system operates by transferring effort applied to the brake pedal by the driver to
the brakes at each wheel.
The braking effort is distributed to each wheel, using a hydraulic system. The system is
assisted using a vacuum brake booster that reduces pedal effort and increases hydraulic
pressure.
The parking brake operates on the rear wheels and is applied using a hand operated control.
NOTE: Before carrying out any diagnosis, make sure that the brake system warning
indicator is functional.
Mechanical
- Tire pressure
- Wheels and tires
- Fluid leak from brake line(s)

3. If an obvious cause for an observed or reported concern is found, correct the case (if
4. If the cause if not visually evident, verify the symptom and refer to the Symptom Chart.
Road Test
Perform a road test to compare actual vehicle braking performance with the performance
standards expected by the driver. The ability of the test driver to make valid comparisons and
detect performance deficiencies will depend on experience.
The driver should have a thorough knowledge of the brake system operation and accepted
general performance guidelines to make good comparisons and detect performance concerns.
An experienced technician will always establish a route that will be used for all brake
diagnosis road tests. The road selected will be reasonably smooth and level. Gravel or bumpy
roads are not suitable because the surface does not allow the tires to grip the road equally.
Crowned roads should be avoided because of the large amount of weight shifted to the low
set of wheels on this type of road. Once the route is established and consistently used, the
road surface variable can be eliminated from the test results.
Before a road test, get a complete description of the customer concerns or suspected
condition. From the description, the technician will be able to match possible causes with
symptoms. Certain components will be identified as possible sources while others will be
eliminated by the evidence. More importantly, the customer description can reveal unsafe
conditions which should be checked or corrected before a road test. The description will also
help form the basic approach to the road test by narrowing the concern to specific
Page 2 of 15
components, vehicle speed or conditions.
Begin the road test with a general brake performance check. Using the description of the
concern, test the brakes at different vehicle speeds using both light and heavy pedal
pressure. Determine if the concern is in the front or rear braking system. First use the foot
brake and then the parking brake. If the condition (i.e. pull, vibration, pulsation) occurs only
on operation of the parking brake, the concern is in the rear brake system. If the condition
occurs when the foot brake is depressed, the concern is in the front brake system.
Avoid locking the brakes and sliding the tires. This condition will not indicate brake efficiency.
A heavily braked but turning wheel will stop the vehicle in a shorter distance than locked
wheels.
If the concern becomes evident during this check, make sure it fits the description given
before the road test. If the concern is not evident, attempt to duplicate the condition using
the information from the description.
If a concern exists, use the Brake System Symptom Chart in order to isolate it to a specific
sub-system and condition description. From this description, a list of possible sources can be
used to further narrow the cause to a specific component or condition.
Symptom Chart

Brakes pull or *Worn or damaged brake shoes or *INSTALL new brake shoes or brake
drift brake pads and linings. pads.
*Abnormal wear or distortion of brake *INSTALL a new brake discs.
discs.
*Incorrect rear brake adjustment. *PERFORM a parking brake cable
adjustment.
*Incorrect wheel alignment *PERFORM a wheel alignment
adjustment. adjustment. REFER to Section 204-
00.[Suspension System - General
Information, GENERAL PROCEDURES,
Front Toe Adjustment]
*Incorrect wheel bearing preload *ADJUST or INSTALL a new wheel
adjustment. bearing.
*Unequal air pressure in the tires. *INFLATE the tires to the correct
pressure.
*Grease or fluid on the brake shoes or *INSTALL new brake shoes or brake
brake pads; glazed linings. pads.
*Stuck or seized calipers. *GO to Pinpoint Test A.
Brake warning *Low brake fluid level. *FILL the reservoir. CHECK the brake
indicator and clutch system for leaks including
always on brake fluid in the brake booster.
*Leaking brake master cylinder *INSTALL a new brake master
primary piston cup. cylinder.
*Parking brake control not fully *FREE UP and ADJUST the parking
released. brake cable. INSTALL new
components as necessary.
*Shorted indicator circuit. *GO to Pinpoint Test B.
Vibration when *Grease or fluid on the brake shoes or *INSTALL new brake shoes or brake
the brakes are brake pads; glazed linings. pads.
applied *Worn or damaged brake shoes or *INSTALL new brake shoes or brake
brake pads. pads.
*Loose caliper mounting bolt(s). *TIGHTEN the caliper mounting bolt
Page 3 of 15
(s).
*Insufficient grease on sliding parts.*APPLY grease where necessary.
*Damaged brake drum contact *INSTALL a new brake drum.
surface.
*Loose or missing rear wheel spindle *TIGHTEN or INSTALL new rear wheel
bolts. spindle bolts. REFER to Section 204-
02.[Rear Suspension,
SPECIFICATIONS, Specifications]
*Go to Pinpoint Test C.
Pedal goes *Leak in the hydraulic system. *REPAIR the leak. CHECK the entire
down fast hydraulic system. FILL and BLEED
the brake system.
*Air in the system. *CHECK for leaks. BLEED the brake
system.
*Worn brake master cylinder piston *INSTALL a new brake master
cups or scored cylinder bore. cylinder.
*Brake disc brake `knock *Install a new brake disc.
back' (Brake pads push the brake
caliper piston back into brake
caliper. Caused by excessive brake
disc lateral runout or loose wheel
bearings.)
*Worn brake shoes or brake pads. *INSTALL new brake shoes or brake
pads.
*GO to Pinpoint Test D.
Pedal eases *Air in the system. *BLEED the brake system.
down slowly *Malfunctioning brake master *GO to Pinpoint Test E.
cylinder.
Pedal is low or *Worn brake shoes or brake pads. *INSTALL new brake shoes or brake
feels spongy pads.
*Hydraulic system. *GO to Pinpoint Test F.
Brake lockup *Incorrect tire pressures. *INFLATE the tires to the correct
during light pressure.
brake pedal *Tires worn. *INSTALL new tires.
force *Glazed or worn brake shoes or brake *INSTALL new brake shoes or brake
pads. pads.
*Brake booster. *GO to Pinpoint Test G.
Excessive or *Worn brake shoes or brake pads. *INSTALL new brake shoes or brake
erratic pedal pads.
travel *Brake discs. *GO to Pinpoint Test H.
Brake drag *Brake booster. *GO to Pinpoint Test I.
*Incorrectly adjusted brake light *ADJUST the brake light switch.
switch.
*Brake pressure control valve.
*Seized brake caliper or wheel
cylinder.
*Parking brake applied or
malfunction.
*Seized parking brake cables.
*Seized brake caliper slide pins.
Excessive *Brake booster inoperative. *PERFORM a brake booster functional
brake pedal test REFER to the component tests.
effort *Worn or contaminated brake shoes *INSTALL new brake shoes or brake
or brake pads. pads.
Page 4 of 15
*GO to Pinpoint Test J.

Brake noise *Worn brake shoes or brake pads. *INSTALL new brake shoes or brake
pads.
*Brake booster. *GO to Pinpoint Test K.
Slow or *Brake booster. *GO to Pinpoint Test L.
incomplete *Brake master cylinder.
brake pedal
return
Pinpoint Tests
PINPOINT TEST A : BRAKES PULL OR DRIFT

CONDITIONS DETAILS/RESULTS/ACTIONS
A1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brake pedal.
Does the vehicle pull or drift?
Yes
GO to A2.
No
Vehicle OK.
A2: TIRE INSPECTION
1 Check for excessive wear or incorrect tire pressures.
Are the tires in good condition?
Yes
GO to A3.
No
INFLATE the tires to the correct pressure. INSTALL new tires if excessively
worn. TEST the system for normal operation.
A3: BRAKE SHOE OR BRAKE PADS AND LINING INSPECTION
1 Inspect the brake shoes or brake pads for grease or fluid on the linings and
or wear concerns.
Are any concerns present?
Yes
INSTALL new brake shoes or brake pads. TEST the system for normal
operation.
No
GO to A4.
A4: CHECK PRESSURE CONTROL VALVE–RIGHT-HAND REAR
1 Install pressure gauges in the left-hand front and right-hand rear bleed
nipples. Apply the brake to read 6895 kPa (1000 psi) at the left-hand
front wheel.
 Read the pressure at right-hand rear wheel.

Does the pressure gauge read between 4692-5164 kPa (680-750 psi) at the
right-hand rear wheel?
Yes
INSPECT the brake calipers and INSTALL new components as required. GO to
A5.
No
INSTALL a new right-hand rear brake pressure control valve. BLEED the brake
system. TEST the system for normal operation.
A5: CHECK PRESSURE CONTROL VALVE–LEFT-HAND REAR
Install pressure gauges in the right-hand front and left-hand rear bleed
Page 5 of 15
1 nipples. Apply the brake to read 6895 kPa (1000 psi) at the right-hand front
wheel.
 Read the pressure at left-hand rear wheel.

left-hand rear wheel?
Yes
INSPECT the brake calipers and INSTALL new components as required. TEST
No
INSTALL a new left-hand rear brake pressure control valve. BLEED the brake
PINPOINT TEST B : BRAKE WARNING INDICATOR ALWAYS ON
B1: CHECK BRAKE WARNING INDICATOR
NOTE: The brake warning indicator should only illuminate when the ignition switch is in
the START or RUN position and the parking brake is applied.
1 Key in ON position.
2 Release the parking brake.
 Check the fluid level in the reservoir is at the MAX mark.

Does the brake warning indicator illuminate?
Yes
No
GO to B2.
B2: CHECK BRAKE SYSTEM FOR LEAKAGE
1 Check the brake master cylinder reservoir sealing points and external brake
and clutch system for leaks. Refer to the brake master cylinder
component tests in this section.
Does the system leak?
Yes
REPAIR as necessary. ADD fluid and BLEED the brake system. TEST the system
for normal operation.
No
GO to B3.
B3: CHECK BRAKE WARNING SWITCH OR WIRING
2 Remove the brake master cylinder reservoir filler cap or switch. Allow the
float to rest at its lowest point.
Does the brake warning indicator illuminate?
Yes
The switch or wiring is OK. TEST the system for normal operation.
No
PINPOINT TEST C : VIBRATION WHEN BRAKES ARE APPLIED
C1: ROAD TEST THE VEHICLE
1 Road test the vehicle without applying the brakes at 40-80 km/h (25-50
mph).
Is a vibration present?
Yes
Page 6 of 15
After servicing, TEST the system for normal operation.

No
GO to C2.
C2: CHECK FOR REAR BRAKE VIBRATION
NOTE: With a manual release parking brake control, hold the parking brake control
release button in the release position during parking brake control application.
1 Road test the vehicle at 40-80 km/h (25-50 mph) with a medium
application on the parking brake control.
Yes
CHECK the rear brake drums or discs for excessive wear. INSTALL new
components as necessary. TEST the system for normal operation.
No
GO to C3.
C3: CHECK FOR FRONT BRAKE VIBRATION
1 Road test the vehicle at 40-80 km/h (25-50 mph) with light and medium
application of the foot brake.
Yes
CHECK the front brake discs for excessive wear or cracks. INSTALL new
No
Vehicle OK.
PINPOINT TEST D : PEDAL GOES DOWN FAST
D1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the foot brake.
Was the brake pedal effort normal?
Yes
Vehicle OK.
No
GO to D2.
D2: CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid level.
Is the fluid level acceptable?
Yes
GO to D3.
No
CHECK the brake master cylinder reservoir sealing points for leaks. REFER to
the brake master cylinder component tests in this section. ADD fluid and BLEED
the brake system. TEST the system for normal operation.
D3: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
Does the brake pedal height build up and then hold?
Yes
CHECK parking brake adjustment and ADJUST as necessary. If the condition
still exists. BLEED the brake system. TEST the system for normal operation.
No
GO to D4.
D4: CHECK FOR BRAKE SYSTEM LEAKS
Page 7 of 15
1 Check for external brake and clutch system leaks. REFER to the component
tests.
Are any leaks found?
Yes
No
GO to D5.
D5: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION CHECK
1 Test for a brake master cylinder bypass. REFER to the component tests.
Was a concern found?
Yes
INSTALL a new brake master cylinder. ADD fluid and BLEED the brake system.
TEST the system for normal operation.
No
System OK.
PINPOINT TEST E : PEDAL EASES DOWN SLOWLY
E1: CHECK BRAKE PEDAL OPERATION
1 Check if the condition occurs when applying the brake pedal while the
vehicle is moving.
Does the condition occur with the vehicle stationary?
Yes
GO to E2.
No
REFER to the component tests.
E2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks. Refer to the component tests.
Are any leaks found?
Yes
No
GO to E3.
E3: PERFORM A BRAKE MASTER CYLINDER BYPASS TEST
1 Test for a brake master cylinder bypass. Refer to the component tests.
Yes
INSTALL a new brake master cylinder. ADD fluid and BLEED the bake system.
No
System OK. TEST the system for normal operation.
PINPOINT TEST F : PEDAL IS LOW OR FEELS SPONGY
F1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the foot brake.
Did the brake pedal feel spongy?
Yes
GO to F2.
No
Page 8 of 15
Vehicle OK.
F2: CHECK BRAKE FLUID LEVEL
1 Check the brake master cylinder reservoir fluid level.
Is the fluid level OK?
Yes
GO to F3.
No
CHECK the brake master cylinder reservoir sealing points. REFER to the
component tests. ADD fluid and BLEED the brake system. TEST the system for
normal operation.
F3: CHECK FILLER CAP VENT
1 Check if the filler cap vent holes are clogged or dirty.
Yes
CLEAN as necessary. TEST the system for normal operation.
No
GO to F4.
F4: BLEED THE BRAKE SYSTEM
1 Check for air in the brake system. Bleed the brake system.
Is the condition still present?
Yes
GO to F5.
No
Vehicle OK.
F5: CHECK FRONT WHEEL HUB RETAINING NUT
1 Check the front wheel hub retaining nut for looseness.
Is the front wheel hub retaining nut loose?
Yes
INSTALL a new front wheel hub retaining nut. REFER to Section 204-01.[Front
Suspension, SPECIFICATIONS, Specifications]Do not reuse the front wheel hub
retaining nut. TEST the system for normal operation.
No
CHECK the parking bake adjustment.
PINPOINT TEST G : BRAKE LOCK UP DURING LIGHT BRAKE PEDAL FORCE
G1: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brake pedal lightly.
Do the rear brakes lock up?
Yes
GO to G2. GO to Pinpoint Test G.
No
Vehicle OK.
G2: TIRE INSPECTION
1 Check for excessive tire wear or incorrect tire pressures.
Are the tires in good order?
Yes
No
SUBSTITUTE known good tires. INFLATE to the correct pressure. TEST the
Page 9 of 15
system for normal operation.

G3: BRAKE SHOES OR BRAKE PADS INSPECTION
1 Inspect the brake shoes or brake pads are correctly fitted and for grease or
fluid contamination or wear concerns.
Are there any concerns?
Yes
REPAIR or INSTALL new components as necessary. TEST the system for normal
operation.
No
G4: CHECK PRESSURE CONSCIOUS REDUCING VALVE–RIGHT-HAND REAR
1 Install pressure gauges in the left-hand front and right-hand rear bleed
nipples. Apply the brake to read 6895 kPa (1000 psi) at the left-hand
front wheel.
 Read the pressure at the right-hand rear wheel.

right-hand rear wheel?
Yes
TEST the brake booster. Go to Pinpoint Test I.
No
INSTALL a new right-hand rear brake pressure control valve. BLEED the brake
system. TEST the system normal operation.
G5: CHECK PRESSURE CONSCIOUS REDUCING VALVE–LEFT-HAND REAR
1 Install pressure gauges in the right-hand front and left-hand rear bleed
nipples. Apply the brake to read 6895 kPa (1000 psi) at the right-hand
front wheel.
 Read the pressure at the left-hand rear wheel.

left-hand rear wheel?
Yes
TEST the brake booster. Go to Pinpoint Test I.
No
INSTALL a new left-hand rear brake pressure control valve. BLEED the brake
PINPOINT TEST H : EXCESSIVE OR ERRATIC BRAKE PEDAL TRAVEL
H1: ROAD TEST THE VEHICLE
1 Road test the vehicle under rough road conditions. Apply the brakes slowly.
Is the pedal travel OK?
Yes
Vehicle OK.
No
GO to H2.
H2: CHECK WHEEL BEARING
1 Check for loose front wheel bearings.
Are the front wheel bearings loose?
Yes
CHECK the front wheel hub retaining nut. INSTALL a new front wheel bearing(s)
if worn or damaged, TEST the system for normal operation.
Page 10 of 15
No
CHECK the front brake disc(s) for thickness variances. INSTALL new
PINPOINT TEST I : BRAKES DRAG
I1: CHECK BRAKE BOOSTER
1 Check the brake booster push rod alignment and pedal travel.
Is the push rod and pedal travel OK?
Yes
GO to I2.
No
INSTALL a new brake booster. TEST the system for normal operation.
I2: ROAD TEST THE VEHICLE
1 Road test the vehicle and apply the brakes.
Are the brakes functioning correctly?
Yes
Vehicle OK.
No
INSPECT individual wheel cylinders or calipers for binding or sticking
components. INSTALL new components as necessary. BLEED the brake system.
PINPOINT TEST J : EXCESSIVE BRAKE PEDAL EFFORT
J1: CHECK BRAKE APPLICATION
1 With the engine off, apply and release the brake pedal five times to deplete
all vacuum from the brake booster. Apply the brake pedal, hold with light
pressure. Start the engine.
Does the brake pedal hold?
Yes
GO to J2.
No
GO to J6.
J2: CHECK BRAKE BOOSTER FOR LEAKS
1 Run the engine at medium idle, release the accelerator pedal and turn the
engine off. Wait 90 seconds and apply the brakes. Two or more brake
applications should be power assisted.
Does the brake booster work?
Yes
Vehicle OK.
No
GO to J3.
J3: CHECK BRAKE BOOSTER CHECK VALVE
1 Disconnect the vacuum hose, for the brake booster check valve at the
intake manifold. Blow into the hose attached to the brake booster check
valve.
Does air pass through the valve?
Yes
INSTALL a new brake booster check valve. TEST the system for normal
operation.
No
GO to J4.
Page 11 of 15
J4: CHECK BRAKE BOOSTER CHECK VALVE VACUUM

1 Disconnect the vacuum hose from the brake booster check valve. Run the
engine at idle. Check the supply with a vacuum gauge.
Is the vacuum pressure above 40.5 kPa (12 in-Hg) with the brake booster non-
operational?
Yes
GO to J5.
No
REPAIR or INSTALL a new vacuum hose and fittings. TEST the system for
normal operation.
J5: CHECK BRAKE BOOSTER
1 Check the brake booster. GO to the component test procedure in this
section.
Is the brake booster OK?
Yes
GO to J6.
No
J6: CHECK BRAKE PEDAL LINKAGE
1 Disconnect the actuator rod from the pedal pin and apply the brake pedal
fully.
Did the pedal move freely?
Yes
GO to J7.
No
REPAIR or INSTALL new brake pedal bushings. TEST the system for normal
operation.
J7: CHECK BRAKE PRESSURE CONTROL VALVE
1 Check the brake pressure control valve for contamination.
Is the brake fluid contaminated?
Yes
INSTALL a new brake pressure control valve. FILL the brake master cylinder
reservoir. BLEED the brake system. TEST the system for normal operation.
No
Vehicle OK.
PINPOINT TEST K : BRAKE NOISE
K1: CHECK FOR PEDAL NOISE
1 Inspect the brake pads and brake shoes for excessive wear.
Run the engine at idle for 10 seconds or longer. Apply the brake pedal and
listen for noise. Compare results with a known good system.
Was a noise present?
Yes
GO to K2.
No
Vehicle OK.
K2: CHECK PUSH ROD ALIGNMENT
1 Check the brake booster push rod alignment and travel.
Is the push rod OK?
Yes
Page 12 of 15
BLEED the brake system. TEST the system for normal operation.
No
PINPOINT TEST L : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
L1: CHECK FOR BRAKE PEDAL RETURN
1 Run the engine at fast idle while making several brake applications. Pull the
brake pedal rearward with approximately 44.5 N (10 lbs) force. Release
the brake pedal and measure the distance to the floor pan. Make a hard
brake application. Release the brake pedal and measure the brake pedal
to floor pan distance. The brake pedal should return to its original
position.
Did the brake pedal return to its original position?
Yes
Vehicle OK.
No
GO to L2.
L2: CHECK FOR BRAKE PEDAL BINDING
1 Check the brake pedal for free operation.
Is the brake pedal operating freely?
Yes
No
REPAIR or INSTALL new brake pedal bushings. TEST the system for normal
operation.
Component Tests
Hydraulic Leak Check
NOTE: There is a common clutch and brake fluid reservoir, therefore it is possible that a
clutch leak can lead to reduction in the reservoir level.
It is possible that all evidence of fluid leakage may have washed off if the vehicle has been
operated in rain or snow, as brake fluid is water-soluble. Refill the system, bleed then apply
the brakes several times. Examine the system to verify that the reservoir fluid level is actually
dropping. Locate and repair the external leak. If the fluid level drops and no external leak can
be found, check for a brake master cylinder bore end seal leak.
Brake System Check
Brake Pedal Reserve Check
Where a low brake pedal or the feel of a bottomed-out condition exists, check for brake pedal
reserve.
1. Operate the engine at idle with the transaxle in NEUTRAL.
2. Apply the brake pedal lightly three or four times.
3. Allow 15 seconds for vacuum to replenish the brake booster.
NOTE: This increased resistance may feel like something has bottomed out.
4. Apply the brake pedal until it stops moving downward or an increased resistance to the
pedal travel occurs.
Page 13 of 15
5. Hold the brake pedal in the applied position and raise the engine speed to approximately
2000 rpm.
NOTE: The additional movement of the brake pedal is the result of the increased engine
intake manifold vacuum which exerts more force on the brake booster during engine
rundown. This means that additional stroke is available in the brake master cylinder and
the brake system is not bottoming out.
6. Release the accelerator pedal and observe that the brake pedal moves downward as the
engine returns to idle speed.
Brake Booster Functional Test
Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses
and their connections should be correctly secured and in good condition with no holes and no
collapsed areas. Inspect the check valve on the brake booster for damage.
Brake Booster Operation Check
1. Check the hydraulic brake system for leaks or low fluid.
2. With the transaxle in NEUTRAL, stop the engine and apply the parking brake. Apply the
brake pedal several times to exhaust all vacuum in the system.
3. With the engine turned off and all vacuum in the system exhausted, apply the brake pedal
and hold it down. Start the engine. If the vacuum system is operating, the brake pedal will
tend to move downward under constant foot pressure. If no motion is felt, the vacuum
booster system is not functioning.
4. Remove the vacuum hose from the brake booster. Intake manifold vacuum should be
available at the brake booster end of the hose with the engine at idle speed and the
transaxle in NEUTRAL. Make sure that all unused vacuum outlets are correctly capped, hose
connectors are correctly secured and vacuum hoses are in good condition. When it is
established that manifold vacuum is available to the brake booster, connector the vacuum
hose to the brake booster and repeat Step 3. If no downward movement of the brake pedal
is felt, install a new brake booster.
5. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine and let the
vehicle stand for 10 minutes. Then, apply the brake pedal with approximately 89 N (20 lb)
force. The pedal feel (brake application) should be the same as that noted with the engine
operating. If the brake pedal feels hard (no power assist), install a new vacuum check valve
and then repeat the test. If the brake pedal still feels hard, install a new brake booster. If
the brake pedal movement feels spongy, bleed the brake system.
Brake Master Cylinder
Usually, the first and strongest indicator of anything wrong with the braking system is a
feeling through the brake pedal. In diagnosing the condition of the brake master cylinder,
check pedal feel as evidence of a brake concern. Check for the brake warning indicator
illumination and the fluid level in the master cylinder reservoir.
Normal Conditions
The following conditions are considered normal and are not indications that the brake master
cylinder is in need of service.
- Modern brake systems are not designed to produce as hard a pedal effort as in
Page 14 of 15
the past. Complaints of light pedal efforts should be compared to pedal efforts of
another vehicle, of the same model and year.
- During normal operation of the brake the fluid level in the reservoir will rise
during brake application and fall during release. The net fluid level (i.e., after
brake application and release) will remain unchanged.
- A trace of brake fluid will exists on the brake booster shell below the master
cylinder mounting flange. This results from the normal lubricating action of the
master cylinder bore end seal.
- The fluid level will fall with brake shoe and lining wear.
Abnormal Conditions
NOTE: Prior to performing any diagnosis, make sure the brake system warning indicator
is functional.
Changes in brake pedal feel or travel are indicators that something could be wrong with the
braking system. The diagnostic procedure and techniques use brake pedal feel, warning
indicator illumination and low brake fluid level as indicators in diagnosing braking system
concerns. The following conditions are considered abnormal and indicate that the brake
master cylinder is in need of service.
- The brake pedal goes down fast. This could be caused by an external or internal
leak.
- The brake pedal eases down slowly. This could be caused by an external or
internal leak.
- The brake pedal is low and or feels spongy. This condition may be caused by no
fluid in the brake master cylinder reservoir, reservoir cap vent holes clogged or air
in the hydraulic system.
- The brake pedal effort is excessive. This may be caused by a bind or obstruction
in the pedal or linkage, clogged fluid control valve or insufficient booster vacuum.
- The rear brakes lock up during light pedal force. This may be caused by
incorrect tire pressures, grease or fluid on the brake shoes and linings, damaged
brake shoes and linings, incorrectly adjusted parking brake, or damaged or
contaminated brake pressure control valves.
- The brake pedal effort is erratic. This condition could be caused by a brake
booster malfunction, extreme caliper piston knock back or incorrectly installed
brake shoes and linings.
- The brake warning indicator is ON. This may be caused by low fluid level,
ignition wire routing too close to the fluid level indicator assembly, or float
assembly damage.
Bypass Condition Test
1. Check the fluid in brake master cylinder. Fill the brake master cylinder reservoir if low or
empty.
2. Observe the fluid level in the brake master cylinder reservoir. If after several brake
applications, the fluid level remains the same, measure the wheel turning torque required to
rotate the wheels with the brakes applied as follows:
Page 15 of 15
Place the transaxle in NEUTRAL and raise and support the vehicle.
Apply the brakes with a minimum of 445 N (100 lb) and hold for approximately 15 seconds.
With the brakes still applied, exert a torque on the front wheels of 10.1 Nm (75 lb.ft). If
either wheel rotates, install a new brake master cylinder.
Non-Pressure Leaks
Any empty brake master cylinder reservoir condition may be caused by two types of non-
pressure external leaks.
Type 1: An external leak may occur at the master cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the cap and gasket.
Type 2: An external leak may occur at the reservoir mounting seals. Service such a leak by
installing new seals.
Page 1 of 1

BRAKE VACUUM PUMP
UID=G28530
Removal
INSTALLATION, Air Cleaner - 1.4L Diesel]
2. Disconnect the brake vacuum hose from the
brake vacuum pump.
 Depress the locking tangs.
3. NOTE: Note the position of the drive

coupling, to aid installation.
Remove the brake vacuum pump.
Installation
1. CAUTION: Make sure the drive

coupling is aligned with the camshaft
coupling.
NOTE: Install new O-ring seals.
Page 1 of 1

SPECIFICATIONS
UID=G28531

Brake booster retaining nuts 25 18 -
Brake master cylinder retaining nuts 25 18 -
Page 1 of 1

UID=G28679
Principles Of Operation
- Fuel leak(s) - Wiring harness
- Blocked or contaminated fuel filter - Electrical connector(s)
- Fuel rail - Fuel injector(s)
- Vacuum line(s) - Throttle body
- Throttle body
4. If the cause is not visually evident, verify the symptom and refer to WDS.
Page 1 of 1

ENGINE IGNITION
UID=G28729
- Spark plug wire(s) - Wiring harness
- Spark plug(s) - Electrical connector(s)
- Ignition coil pack

4. If the concern remains after visual inspection, use WDS to diagnose the system.
Page 1 of 1

EVAPORATIVE EMISSIONS
UID=G28748
- Vacuum line(s) - Fuse(s)
- Evaporative emission (EVAP) system - Wiring harness

canister
- Electrical connector
- EVAP system hose(s) (s)
- EVAP system canister purge valve

system.
Page 1 of 1

SPECIFICATIONS
UID=G28929

Horn retaining nut 26 19 -
Page 1 of 1

BATTERY
UID=G28937
Page 1 of 6

AUTOMATED GEARSHIFT
UID=G289653
iB5 transmission
CAUTION: The automated iB5 transmission must not be replaced by a standard iB5
transmission, as the automated iB5 transmission is precisely adapted to the gear ratio
steps, particularly with regard to the calibration of the transmission control unit.
The iB5 transmission has revised gear ratio steps.
In particular the shift forks of the transmission have to meet stricter tolerance specifications
to allow the transmission to meet the requirements of an automatic gearshift mechanism.
The transmission housing has three additional threaded bores which are used to secure the
shift actuator.
These bores are also present on a conventional iB5 transmission, although they serve no
purpose there.
Self-adjusting clutch
The use of a self-adjusting clutch is a pre-requirement on vehicles with an automated manual

transmission, as this type of clutch keeps the forces required for actuation low and virtually
Page 2 of 6
constant throughout the service life of the clutch.
Clutch slave cylinder
CAUTION: Clutch slave cylinders from normal vehicles must not be interchanged with
those from a vehicle with an automated iB5 manual transmission.
Vehicles with a normal iB5 transmission have a throttle fixture in the clutch slave cylinder
which improves driving comfort during engagement of the clutch.
On vehicles with an automated iB5 transmission the engagement of the clutch is electronically
controlled, so the clutch slave cylinder must not have a throttle fixture.
The clutch slave cylinder is connected via a pressurised hydraulic line to the clutch actuator.
If a pressure is created in the clutch actuator, then the displaced hydraulic fluid moves the
piston in the slave cylinder and thus displaces the clutch release bearing in an axial direction.
The release bearing presses with the bearing inner race onto the tongues of the main
Belleville washer, which enables it to interrupt the positive engagement between the flywheel
and the clutch plate.
If the clutch actuator decreases the pressure then the main Belleville washer pushes the
piston in the clutch slave cylinder back into its starting position. The positive engagement
between the clutch plate and the flywheel is then re-established.
The thrust bearing is secured on the clutch slave cylinder via a press fit and cannot be
renewed separately.
Clutch actuator with integrated transmission control unit

Page 3 of 6
The clutch actuator consists of a DC motor, a gearing mechanism for actuation of the
integrated clutch master cylinder and an integrated distance sensor which measures the
actuation travel.
Operation of the clutch is performed hydraulically. For this purpose, the clutch master
cylinder which is integrated in the clutch actuator is connected on the one hand to the brake
fluid reservoir and on the other via a high-pressure line to the clutch slave cylinder.
The transmission control unit is integrated into the clutch actuator housing. It evaluates the
incoming signals and actuates the corresponding components.
The clutch actuator performs tasks that would otherwise be performed by the driver with the
aid of the clutch pedal on a vehicle with a conventional clutch operating mechanism:
* Disengagement of the clutch
* Measured engagement of the clutch for pulling away from standing
* Disengagement and engagement of the clutch for gear changes while driving
* Disengagement of the clutch for stopping with a gear engaged
* Engagement of the clutch with a gear engaged for parking with the engine
switched off
Shift actuator
Page 4 of 6

1 - Shift motor in the shift actuator
2 - Selector motor in the shift actuator
The shift actuator has two electric motors (selector motor and shift motor) which are
mounted directly on the transmission on a shared mounting plate with the corresponding
actuating mechanisms.
The selector motor is used to select the relevant shift slot in the transmission.
The shift motor is used to engage the correct gear.
Electronic selector lever
The electronic selector lever has no mechanical link to the transmission.

Page 5 of 6
It is connected electrically via the CAN databus to the transmission control unit.
Every operation of the selector lever is sensed by Hall sensors and then processed by the
internal electronics and made available to the transmission control unit.
The Hall sensors and the electronics are mounted on a printed circuit board underneath the
selector lever cover.
The following positions and operations of the selector lever are detected:
Selector
lever
position Description
N The transmission is put into neutral.The selector lever stays in this position.
R Reverse gear is engaged.The selector lever stays in this position.
D One of the five forward gears is engaged.The selector lever stays in this
position.Depending on the selected driving mode, the transmission control is
either in automatic mode or manual mode.
A The control changes between manual and automatic mode when the selector
lever is moved to A.The selector lever then jumps back to D when released.
+ The transmission shifts up a gear.If the transmission control was previously in
automatic driving mode, then it changes with this gearshift operation into
manual mode and shifts up a gear.The selector lever then jumps back to D when
released.
- The transmission shifts down a gear.If the transmission control was previously in
automatic driving mode, then it changes with this gearshift operation into
manual mode and shifts down a gear.The selector lever then jumps back to D
when released.
Instrument panel display

1 - Gear display
2 - MIL warning lamp
The instrument cluster contains a display showing the currently engaged gear.
Page 6 of 6
When the transmission is in automatic driving mode the display also shows "Auto".
The following displays can appear on the instrument cluster:
* N (transmission in neutral)
* R (transmission in reverse)
* 1 (transmission in 1st gear)
* 2 (transmission in 2nd gear)
* 3 (transmission in 3rd gear)
* 4 (transmission in 4th gear)
* 5 (transmission in 5th gear)
* -- (communications error to the transmission control unit)
All of the display elements are activated for approx. 3 seconds when the ignition is switched
on to indicate to the driver that the system is ready.
A flashing gear display indicates that the gear has been preselected but has not yet been
engaged.
The MIL warning lamp serves to warn the driver of serious operational faults.
Page 1 of 18

AUTOMATED GEARSHIFT CONTROL
UID=G289654
Overview
Item Part Description

Number
1 - Transmission control unit
3 - Powertrain Control Module (PCM) (version shown taken from a 1.4L
Duratec 16V engine)
4 - Anti-lock Brake System (ABS) control unit
6 - Generic Electronic Module (GEM)
7 - Electronic selector lever
Page 2 of 18
8 - Distance sensor in the clutch actuator

9 - Distance sensor in the selector motor
10 - Distance sensor in the shift motor
11 - Stoplamp switch
12 - Driver's side door contact switch
13 - Power supply relay
14 - Ignition switch
15 - Battery
16 - Parking brake switch
17 - Clutch actuator
18 - Selector motor
19 - Shift motor
Transmission control unit
Installation position.
The transmission control unit is integrated into the clutch actuator.
The assembly is located in the engine compartment in front of the transmission and is
attached to the left-hand front longitudinal member.
The transmission control unit is connected to the vehicle wiring harness via two encoded
connectors.
Function
The transmission control unit is responsible for detecting the incoming signals from the
individual sensors and control units. It must then evaluate these signals and perform the
necessary gearshifts.
In the process the transmission control unit controls every aspect of the gearshift.
* Engine torque reduction

Page 3 of 18
* Disengagement of the clutch
* Selection of the target gear
* Synchronisation
* Engagement of the target gear
* Engagement of the clutch
* Engine torque increase
The transmission control must perform the gearshift in a way that does not adversely affect
the long-term durability of the transmission.
Diagnosis
The transmission control can be diagnosed with WDS via the DLC.
The DLC is located in the passenger compartment underneath the steering wheel.
The transmission control unit can be reprogrammed with WDS if a new calibration becomes
necessary.
Gearshift strategies
Park
The clutch is engaged when the engine is switched off.
If the selector lever is not in N, then a gear is engaged to prevent the vehicle from rolling
away.
Engine start release
The engine start is only permitted if the PCM has received a start release from the
transmission control unit via the CAN databus.
The following conditions must be satisfied for this to happen:
* Transmission in neutral
* Selector lever in neutral
* Brake pedal depressed

Page 4 of 18
Adaptation of the clutch touch point
NOTE: If a new clutch actuator with integrated transmission control unit is installed then
the touch point of the clutch needs to be relearned with the aid of WDS.
The term 'clutch touch point' describes the point at which the pressure plate and the clutch
plate touch and transmit a low torque (approx. 4 Nm).
The transmission control unit needs this information to be able to always engage the clutch in
the best possible way, i.e. smoothly without judder and without excessive slip.
In the factory the clutch touch point is stored in the non-volatile memory of the transmission
control unit.
The adaptation of the clutch touch point is performed repeatedly while driving with the engine
idling, with a gear engaged and with the brake depressed.
In addition, the current clutch touch point is checked by the transmission control unit during a
gearshift and then adapted as required.
This means that the various tolerances in the clutch operating mechanism, which arise for
example due to variations in operating temperatures, are continuously adapted and optimised
for the current operating conditions.
Creep
The system offers a creep function similar to that found on an automatic transmission
whenever the selector lever is in position D or R and neither the accelerator pedal or the
brake pedal are depressed.
The creep function means that when first gear or reverse gear is engaged the clutch is
partially engaged (i.e. with slip) and a noticeable amount of torque is transmitted.
The creep quality depends greatly on the smoothness of the engine when idling.
The creep function is suspended if there is not enough torque available to move the vehicle
(e.g. when climbing hills) or if the torque signal transmitted by the PCM is not precise
enough.
Stalling of the engine is prevented in all cases.
NOTE: If the engine does stall then this indicates a fault. This type of fault could be
caused by a problem in the engine management as well as a problem in the transmission
control.
If the driver's door is open while the creep function is active then a warning sounds and the
current gear is flashed on the instrument cluster display.
The creep function is switched off when the parking brake is applied.
Torque tracking
Page 5 of 18

A - Torque
B - Time
1 - Declutching duration
2 - Shift request signal
3 - Clutch torque
4 - Engine torque
The clutch is only operated as far as is required by the current torque which is to be
transmitted.
The clutch torque is a function of engine torque, engine speed and transmission input speed
(calculated back from the rotational speeds of the wheels).
The advantage of torque tracking is that the time required to operate the clutch during
gearshifts is significantly reduced.
Another advantage of torque tracking is that the clutch can temporarily slip whenever there
are torque peaks.
This effect places no particular strain on the clutch because there is only a small difference in
rotational speeds at this point. However, it offers the advantage of smoother ride comfort, as
any judder in the powertrain is absorbed by the clutch slip.
Clutch overheating protection
In order to protect the clutch against overheating, it is necessary to deduce the current clutch
temperature.
The transmission control unit can use the current clutch temperature to identify faults, enable
warnings to be given out and modify the control strategy if the clutch temperatures are too
high.
No separate temperature sensor is installed for measuring the clutch temperature. Instead,
the clutch temperature is calculated by the transmission control unit.
To do this it uses the following factors:
* Ambient temperature (from the engine management),
* Time since engine start,
* Previous clutch slip,
* Torque to be transmitted.
Page 6 of 18
The calculated clutch temperature is compared to the characteristic clutch temperature

capacity stored in the control unit, which is taken as the limit value.
If the driver attempts to hold the vehicle with clutch slip (e.g. when climbing a hill), then this
will result in a risk of the clutch overheating.
In situations like this the transmission control deliberately encourages judder by varying the
amount of clutch torque to be transmitted (more or less clutch slip).
This warns the driver about the imminent risk of overheating.
The driver's response to this will either be to release the accelerator pedal (and therefore
disengage the clutch) or to depress the accelerator pedal (and therefore ensure slip-free
engagement of the clutch).
If however the driver fails to react to this then it may lead to destruction of the clutch disc.
In order to protect the clutch against overheating while driving, torque tracking is no longer
performed above a certain temperature.
In these cases this means that the clutch is always fully engaged (which results in longer
gearshift times).
If the vehicle stops while the risk of the clutch overheating is still present then the creep
function is disabled.
Pulling away from standing
CAUTION: It is possible to depress both the accelerator pedal and the brake pedal at
the same time. If this happens then the clutch is subjected to severe strain and can be
destroyed.
NOTE: The driver controls pulling away with the accelerator pedal alone.
In principle, it is possible to pull away in 1st, 2nd and reverse gear.
In automatic driving mode the vehicle will only pull away from standing in 1st gear.
If the driver specifically wishes to pull away in 2nd gear, then the 2nd gear can be selected in
manual driving mode.
If the vehicle is already rolling, then the corresponding gear is automatically selected by the
transmission control in both driving modes.
In order to ensure that the vehicle does not pull way inadvertently, the selected gear is only
engaged if the brake is depressed when the selector lever is moved from N to D or R.
The gear is also not engaged if the accelerator pedal is not depressed within approx. 26
seconds of shifting the selector lever (from N to D or R).
Driving down a steep descent
The transmission control detects that the vehicle is driving down a steep descent by
comparing the current data for vehicle acceleration and engine load.
If the transmission control detects that the vehicle is driving down a steep descent then it
prevents upshifts below a certain engine speed to maximise the benefits of engine braking.
Page 7 of 18
In addition, the transmission control shifts down a gear when the brake pedal is depressed
provided this is permitted by the engine speed.
Detection of driving resistance
The transmission control detects a driving resistance (e.g. climbing a hill or towing a trailer)
by comparing the current data for vehicle acceleration and engine load.
The transmission control selects the gearshift timing according to the magnitude of the
driving resistance.
The aim is to avoid frequent gearshifts back and forth between the gears.
Detection of fast off mode
A 'fast off' situation is recognised when the accelerator pedal is suddenly released.
In this case the system suppresses an immediate upshift to the next higher gear in order to
give the driver a more direct driving experience and to maximise the benefits of engine
braking.
Cornering detection
The transmission control system detects cornering by comparing the wheel speed sensor
signals from the two non-driven wheels.
Depending on the detected difference in speed, upshifts are prevented during cornering in
order to avoid tip in/tip out reactions.
Engagement of reverse gear
For safety reasons it must not be possible to accidentally engage reverse gear by
inadvertently moving the selector lever to the "R" position.
Therefore reverse gear will only be engaged under the following conditions:
* Electronic selector lever in position "R"
* Vehicle speed below 2 km/h
* Time-delayed to ensure that the differences in rotational speeds are not too
high
One exception is fast changes between D » N » R and R » N » D, for example when

attempting to unstick the vehicle in snow. In this case the transmission control will accept the
gear change to R without depressing the brake pedal in between.
Manual driving mode
In manual driving mode the driver can decide when to change gear.
However, the transmission control checks first whether the engine speed would be too high or
low after the gear change before carrying out the gear change.
Page 8 of 18
The system also changes gear automatically in manual driving mode if the engine speed
becomes too low for the selected gear (when the vehicle is decelerating).
If the driver operates the selector lever several times in quick succession then the target gear
is engaged without the intermediate gears being engaged.
If the expected engine speed (too high or too low) prevents the target gear from being
engaged, then the transmission control shifts up to the next available and appropriate gear.
It is possible at any time to change between automatic and manual driving modes.
Towing
The vehicle can be towed with the transmission in neutral.
NOTE: Battery voltage must be present at the transmission control unit to ensure that the
transmission control releases the clutch to shift into neutral.
If the engine is not running then the following requirements must be met for the shift into
neutral to take place:
* Ignition key in position II
* Selector lever in position "N"
Signal transmission on the CAN databus

1 - Transmission control unit (integrated into the clutch actuator)
2 - PCM (version shown taken from a 1.4L Duratec 16V engine)
3 - ABS control unit
4 - Electronic selector lever
6 - DLC
Page 9 of 18
Engine start release
The PCM receives an engine start release signal from the transmission control unit if the
transmission and the selector lever are in neutral and the brake pedal is depressed.
Engine speed
The engine speed is detected by the Crankshaft Position (CKP) sensor and passed on to the
PCM.
The engine speed is transmitted from the PCM via the CAN databus to the transmission
control unit.
The transmission control unit uses this signal for:
* Engagement and disengagement of the clutch
* Adaptation of the clutch touch point
* Torque tracking
* Creep function
* Clutch overheating protection
* Determination of the target gear
Engine load
The PCM determines a load signal, which is transmitted via the CAN databus to the
transmission control unit.
The transmission control unit uses this signal for the following functions:
* Determination of the gearshift timing
* Torque tracking
* Creep function
* Clutch overheating protection
* Detection of hill descent
* Detection of driving resistance
Signal for torque increase/decrease
Before the transmission control unit disengages the clutch, it sends a signal to the PCM to
reduce the torque.
After the PCM has reduced the engine torque, the transmission control unit disengages the
clutch, disengages the selected gear, shifts into the target gear and re-engages the clutch
again.
Page 10 of 18
Afterwards the transmission control unit sends the PCM a signal to increase the torque.
The PCM then increases the engine torque.
Wheel speed signals
The ABS wheel sensors supply a separate wheel speed signal for each wheel to the ABS
control unit.
These wheel speed signals are transmitted via the CAN databus to the transmission control
unit.
The transmission control unit uses the wheel speed signals for:
* Determining the vehicle speed
* Determining the vehicle acceleration
* Cornering detection
Selector lever position and operation
Printed circuit board in the electronic selector lever

1 - Hall sensors
2 - Printed circuit board
The current selector lever position or the current selector lever operation is detected by the
electronic selector lever by means of six Hall sensors with integrated electronic circuitry and is
transmitted via the CAN databus to the transmission control unit.
The transmission control unit uses the current selector lever position or the current selector
lever operation for determination of the gearshift timing in manual or automatic driving
mode.
Brake pedal position signal
The PCM receives a signal from the brake pedal switch which indicates whether or not the
brake pedal is currently depressed.
This signal is transmitted by the PCM via the CAN databus to the transmission control unit.
The transmission control unit uses the brake pedal actuation signal for:
* Engine start release

Page 11 of 18
* Hill descent mode
* Engagement of reverse gear
Parking brake actuation signal
The signal from the parking brake lever switch is detected by the instrument cluster and
transmitted via the CAN databus to the transmission control unit.
The signal is used by the transmission control unit for switching off the creep function when
the parking brake is activated.
It is possible to pull away on a hill with the parking brake applied if the accelerator pedal is
depressed in addition to the applied parking brake.
Gear display

A - Automatic driving mode - 2nd gear
B - Manual driving mode - 2nd gear
The transmission control unit sends the information about the currently engaged gear and the
current driving mode (automatic or manual) on to the instrument cluster.
The instrument cluster displays both the engaged gear and the automatic driving mode
(Auto) for the driver.
During a gearshift the last engaged gear remains displayed until the gearshift is complete.
If the gear display flashes while the vehicle is stationary, then this means that the selected
gear has not yet been engaged, as not all of the required conditions (e. g.: R selected, brake
pedal not yet depressed) are satisfied.
If the gear display flashes and a warning tone sounds at the same time, then this is warning
the driver that the creep function is active while the driver's door is open.
Page 12 of 18
If the gear display flashes while driving and the MIL warning lamp comes on at the same
time, then this indicates a fault in the transmission control system.
If "--" is displayed while driving and the MIL warning lamp is on, then there is a
communications fault to the transmission control unit.
Actuation of the MIL warning lamp
The MIL warning lamp is actuated by the instrument cluster in the event of a serious fault
with the transmission. The information required to actuate the MIL warning lamp is sent by
the transmission control unit to the instrument cluster.
Warning tone request
The transmission control unit sends a warning tone request to the instrument cluster if the
following conditions are met:
* Engine running
* Transmission control in creep function
* Driver's door open
The instrument cluster passes on the warning tone request to the GEM. The GEM generates
the warning tone.
Clutch actuator distance sensor.

Page 13 of 18
Schematic diagram

1 - Clutch actuator worm gear
2 - Plastic surround moulding with gate guide
3 - Ferrite core
4 - Multi-chamber coil
5 - Measurement tap
6 - Connecting bolt to the clutch actuator worm gear
The clutch actuator distance sensor is integrated into the clutch actuator.
It is designed as a solenoid plunger sensor.
The rotary motion of the worm gear is initially converted via the connecting bolt to a linear
motion of the ferrite core.
The movement of the ferrite core is detected by the multi-chamber coil of the distance sensor
and passed on as a signal to the transmission control unit.
With the distance signal of the clutch actuator, the transmission control unit can determine
the exact position of the clutch and thus realise the engagement and disengagement of the
clutch, as well as the torque tracking and the creep function of the clutch.
Selector motor distance sensor and shift motor distance sensor

Page 14 of 18
Schematic diagram

1 - Electric motor
2 - 1st Hall sensor
3 - 2nd Hall sensor
N - Magnetic north pole
S - Magnetic south pole
The distance sensors of the selector motor and shift motor are integrated into the motors.
The electric motors are each equipped with ten pairs of magnetic poles.
Two Hall sensors with integrated electronic circuitry are arranged above each of these pairs of
poles.
The integrated electronic circuitry of the Hall sensors is capable of using the signals from the
two Hall sensors to determine the rotational speed, the rotary angle and the direction of
rotation of each electric motor.
The transmission control unit needs the signals to be able to carry out the selection and shift
processes precisely.
Brake pedal switch and stoplamp switch

1 - Brake pedal switch
2 - Stoplamp switch
The brake pedal switch and the stoplamp switch are located on the brake pedal.
For safety reasons the transmission control unit receives two signals about the brake pedal
position.
When the brakes are operated the stoplamp switch does two things. Firstly it switches on the
stoplamps, and secondly it passes the signal directly on to the transmission control unit.
Page 15 of 18
The brake pedal switch opens in the same moment as when the stoplamp switch closes, and
in doing so interrupts a ground connection to the PCM.
The signal from the brake pedal switch is transmitted by the PCM via the CAN databus to the
transmission control unit.
The transmission control unit needs the information regarding the operation of the brake
pedal for:
* Engine start release
* Downshifts during hill descents
* Engagement of forwards and reverse gears when pulling away from standing
* Switching off the creep function
* For adaptation of the clutch touch point
Driver's side door contact switch
The door contact switch is located in the door lock on the driver's side.
When the door is closed a ground connection is signalled to the transmission control unit.
When the door is opened this ground connection is interrupted.
The transmission control unit uses the signal from the driver's side door contact switch to
warn the driver if the engine is running, the transmission is in creep mode (no operation of
the brake) and the driver's door is open.
In this case the transmission control unit transmits the warning tone request via the CAN
databus to the instrument cluster. The instrument cluster forwards this request on to the
GEM , and a warning tone is generated by the GEM .
Clutch actuator
Page 16 of 18

1 - DC motor
2 - Integrated transmission control unit
3 - Drive worm gear
4 - Worm gear
5 - Piston rod connecting bolt
6 - Distance sensor
7 - Compensation spring
8 - Piston rod
9 - Afterrun connection (from the brake fluid reservoir)
10 - Clutch master cylinder piston
11 - Clutch master cylinder
12 - High-pressure connection (to the clutch slave cylinder)
The clutch actuator with integrated transmission control unit is located in the engine
compartment in front of the transmission and is secured on the left-hand front longitudinal
member.
The transmission control unit controls the DC motor in the clutch actuator as required.
The DC motor drives the worm gear via the drive worm gear.
The worm gearing is a self-locking device, as a result of which the piston of the clutch master
cylinder will remain naturally in any position without any energy needing to be expended to
Page 17 of 18
keep it there.
The worm gear is connected to the piston rod via the piston rod connecting bolt.
Pressure is built up in the clutch master cylinder via the piston rod and the piston.
Brake fluid is used as the hydraulic fluid.
The system does not have its own separate reservoir, but instead is also connected to the
reservoir for the brake system.
The afterrun connection serves to supply the clutch actuator with brake fluid and to
compensate for the heat-induced expansion of the brake fluid.
The pressure is passed on via the high-pressure line to the clutch slave cylinder in the
transmission and the currently requested clutch position is adopted.
Selector motor and shift motor in the shift actuator

1 - Selector motor
2 - Shift motor
3 - Carrier plate
4 - Selector shaft (in the transmission)
A - Selection movement
Page 18 of 18
B - Shift movement
The selector motor is actuated by the transmission control unit to select the desired shift
slot.
The shift motor is actuated by the transmission control unit to engage the desired gear.
For this purpose the two motors are mechanically connected to the selector shaft of the
transmission via relay levers and connecting linkage.
Both motors act via a worm gear to allow the high forces which are required for the gearshift
operation to be applied.
The gearing of the shift motor also has an additional elastic module which has the task of
making the gearshift as smooth and judder-free as possible and is also designed to keep the
gearshift time as short as possible.
Both electric motors are DC motors with two Hall sensors and integrated electronic circuitry
each.
The transmission control unit actuates the motors electrically via pulse-width modulated
(PWM) signals.
The motors are connected to the wiring harness via coded connectors to prevent any
confusion.
Page 1 of 1

STEERING WHEEL ROTATION SENSOR
UID=G289888
Removal
1. NOTE: The steering wheel rotation sensor
and the clockspring cannot be separated.
Remove the clockspring. For additional
20B.
Installation
1. WARNING: The stability assist

program must be re-configured following
installation. Failure to follow this instruction
Install the clockspring. For additional information,
refer to Section 501-20A / 501-20B.
Page 1 of 5

SUSPENSION SYSTEM
UID=G289891
Mechanical
Tire pressure(s)
Wheels and tires
Wheel knuckles
Tie-rod ends
Front suspension lower arm ball joints
Front suspension lower arm bushings
Front strut and spring assemblies
Front stabilizer bar and connecting links
Rear springs
Rear shock absorbers
Rear suspension beam axle and bushings
Symptom Chart
Symptom Chart

Drift left or *Vehicle attitude incorrect (front *CHECK for abnormal loading, coil spring
right or rear is high or low). sag or non-standard springs.
*Steering gear or linkage worn *CHECK the steering system. REFER to
or damaged. Section 211-00.
*Brake system. *CHECK the brake system. REFER to
Section 206-00.
*Incorrect wheel alignment. *ADJUST the wheel alignment.
*Incorrect front crossmember *CHECK the front crossmember alignment.
alignment.
*Worn front wheel bearings. *CHECK the wheel bearings. REFER to Wheel
Bearing Inspection in this section.
*Wheels and tires. *GO to Pinpoint Test A.
Steering wheel *Vehicle attitude incorrect (front *CHECK for abnormal loading, coil spring
off-center or rear is high or low). sag or non-standard springs.
*Suspension lower arm ball *CARRY OUT the Ball Joint Component Test
joint. in this procedure.
Tracks *Incorrect front suspension toe, *CHECK the wheel alignment. INSTALL new
Page 2 of 5
incorrectly castor or camber angles. suspension components as necessary.

*Incorrect rear suspension toe *CHECK the wheel alignment. INSTALL new
or camber angles. suspension components as necessary.
*Front or rear suspension *CHECK and INSTALL new suspension
damage. components as necessary. REFER to
Section 204-01 / 204-02.
Rough ride *Front strut and spring *CHECK and INSTALL new suspension
assemblies. components as necessary. REFER to
Section 204-01.
*Front stabilizer bar, connecting *CHECK and INSTALL new suspension
links or bushings. components as necessary. REFER to
Section 204-01.
*Front suspension lower arm *CHECK and INSTALL new suspension
bushings. components as necessary. REFER to
Section 204-01.
*Rear suspension bushings. *CHECK and INSTALL new components as
necessary. REFER to Section 204-02.
*Rear shock absorbers. *CHECK and INSTALL new suspension
components as necessary. REFER to
Section 204-02.
Excessive *Front strut and spring *CHECK and INSTALL new suspension
noise assembly upper mounting bolts components as necessary. REFER to
loose or broken. Section 204-01.
*Front strut and spring *CHECK and INSTALL new suspension
Section 204-01.
*Worn front wheel bearings. *CHECK the wheel bearings. REFER to Wheel
Bearing Inspection in this section.
*Front suspension lower arm *CHECK and INSTALL new suspension
bushings. components as necessary. REFER to
Section 204-01.
*Suspension lower arm ball *CARRY OUT the Ball Joint Component Test
joint. in this procedure.
*Wheels and tires. *CHECK the tires. BALANCE or INSTALL new
tires as necessary. REFER to Section 204-
04.
Incorrect tire *Front or rear suspension *· CHECK and INSTALL new suspension
wear damage. components as necessary. REFER to
Section 204-01 / 204-02.
Vibration *Damaged or worn front wheel *CHECK the front wheel bearings. REFER to
bearings. Wheel Bearing Inspection in this section.
*Wheels and tires. *CHECK the tires. BALANCE or INSTALL new
tires as necessary. REFER to Section 204-
04.
*Front strut and spring *CHECK and INSTALL new suspension
Section 204-01.
*Damaged front suspension *CHECK and INSTALL new suspension
lower arm(s). components as necessary. REFER to
Section 204-01.
Page 3 of 5
Pinpoint Tests
WARNING: To avoid personal injury due to the loss of vehicle control, the inspection
should be carried out by two people to maintain safe driving conditions. Adequate grip should
always be maintained on the steering wheel. Failure to follow these instructions may result in
personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
PINPOINT TEST A : DRIFT LEFT OR RIGHT
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to Section 100-02.
 Swap the front left-hand wheel and tire assembly with the front right-hand
wheel and tire assembly.
Road test the vehicle.


Does the vehicle drift?
Yes
GO to A2.
No
The concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
 Swap the rear left-hand wheel and tire assembly with the rear right-hand


Yes
GO to A3.
No
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
 Swap the front left-hand wheel and tire assembly with the rear left-hand


Yes
GO to A4.
No
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
 Swap the front right-hand wheel and tire assembly with the rear right-hand
Page 4 of 5
 Road test the vehicle.

Yes
GO to A5.
No
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
 Swap the front left-hand wheel and tire assembly with the rear right-hand


Yes
GO to A6.
No
A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
 Swap the front right-hand wheel and tire assembly with the rear left-hand


Yes
GO to A7.
No
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1 Install new tires to the four road wheels. TEST the system for normal
operation.
Yes
Verify possible sources, refer to the Symptom Chart.
No
Component Tests
Ball Joint Inspection
1. Raise and support the vehicle. REFER to Section 100-02.
2. Firmly grasp the outer end of the suspension lower arm and try to move it up and down,
watching and feeling for any movement. Free movement will usually be accompanied by an
audible "click''. There should be no free movement.
3. If there is any free movement install a new lower arm. REFER to Section 204-01.
4. If a new lower arm is installed it will be necessary to check and adjust the front wheel
Page 5 of 5
alignment. REFER to in this section.

Page 1 of 1

WHEEL BEARING INSPECTION
UID=G289892
Check
2. Check for worn front wheel bearings by rocking
the wheels at the top and bottom.
3. Spin the wheel quickly by hand and make sure

the wheel turns smoothly without noise from
the wheel bearings.
4. Install new wheel bearings if necessary. For
01 / 204-02.
Page 1 of 5

STABILIZER BAR
UID=G289893
Special Tool(s)
Separator, Ball Joint
49 T028 3A0
General Equipment
Transmission jack
Wooden block
Removal
1. NOTE: Make sure the road wheels are in
the straight ahead position.
Centralize the steering and lock it in position.
2. Detach the steering column shaft from the

steering gear pinion.
 Discard the retaining bolt.

4. CAUTION: Leave the tie-rod end

retaining nuts in place to protect the ball joint
studs
NOTE: Use a 5 mm Allen key to prevent the
ball joint from rotating.
Loosen the tie-rod end retaining nut on both
sides.
5. CAUTION: Protect the ball joint seals

Using the special tool, detach the tie-rod end
from the wheel knuckle on both sides.
1. Release the tie-rod end.
2. Remove and discard the tie-rod end
retaining nut.
Page 2 of 5
6. NOTE: Use a 5 mm Allen key to prevent

the ball joint from rotating.
Detach the stabilizer bar connecting link from the
stabilizer bar on both sides.
7. Remove the engine support insulator.
8. Detach the exhaust system from the exhaust

hanger insulator.
9. Using a suitable transmission jack and a

wooden block, support the crossmember.
10. Remove the crossmember retaining bolts on
both sides.
11. Lower the crossmember to gain access to the

stabilizer bar.
12. Remove the stabilizer bar clamp on both
sides.
Page 3 of 5
13. Remove the stabilizer bar.

14. Remove the stabilizer bar bushings. For
additional information, refer to Stabilizer Bar
Bushing in this section.
Installation
1. Install the stabilizer bar bushings. For
additional information, refer to Stabilizer Bar
Bushing in this section.
2. Position the stabilizer bar on the crossmember.
3. NOTE: Do not fully tighten the stabilizer
bar clamp retaining bolts at this stage.
Install the stabilizer bar clamp on both sides.
4. WARNING: When installing the

stabilizer bar, the measurement must be
taken in a vertical plane between the
crossmember and the stabilizer bar. Failure to
injury.
Set the stabilizer bar to the installation setting.
 Using cable ties, support the stabilizer bar on

both sides.
5. Install the stabilizer bar.
 Tighten the bolts in two stages.
 Stage 1: 10 Nm.
 Stage 2: 55 Nm.
6. Remove the cable ties.

7. Using the transmission jack and the wooden
block, position the crossmember.
Page 4 of 5
8. CAUTION: While tightening the

crossmember retaining bolts, make sure the
crossmember does not move.
Install the crossmember retaining bolts on both
sides.
9. Install the crossmember inner retaining bolts

on both sides.
10. Remove the transmission jack and wooden

block.
11. Attach the exhaust system to the exhaust
hanger insulator.
12. Install the engine support insulator.

Attach the stabilizer bar connecting link to the
14. WARNING: Install new tie-rod end

retaining nuts. Failure to follow this
Page 5 of 5

ball joint from rotating.
Attach the tie-rod end to the wheel knuckle on
both sides.
16. WARNING: Install a new steering

column to steering gear pinion retaining bolt.
personal injury.
Attach the steering column shaft to the steering
gear pinion.
17. Check the toe setting and adjust as

necessary. For additional information, refer to
Section 204-00.
Page 1 of 6

WHEEL KNUCKLE
UID=G289894
Special Tool(s)
Lever, Wheel Knuckle
49 JE01 007
Installer, Halfshaft
49 JE01 009
49 T028 3A0
General Equipment
Three leg puller
Removal
All vehicles
1. Loosen the wheel hub retaining nut.
2. Loosen the strut and spring assembly top

mount retaining nuts by five turns.
3. Remove the wheel and tire.For additional

information, refer to Section 204-04.[Wheels
and Tires, REMOVAL AND INSTALLATION,
Wheel and Tire]
4. NOTE: Make a note of the position of the
brake hose, to aid installation.
Detach the brake hose from the brake hose
support bracket.
 Remove the retaining clip.

Page 2 of 6
5. CAUTION: Suspend the brake caliper

and anchor plate to prevent load being placed
on the brake hose.
Detach the brake caliper and anchor plate from
the wheel knuckle.
 Remove and discard the retaining washer (if

equipped).
Vehicles with anti-lock brakes

knuckle.
All vehicles

retaining nut in place to protect the ball joint
stud.
ball joint stud from rotating.
Loosen the tie-rod end retaining nut.

Page 3 of 6

from the wheel knuckle.
2. Remove and discard the tie rod end
retaining nut.

knuckle.
11. Remove and discard the wheel hub retaining

nut.
12. Remove the wheel knuckle to suspension

strut pinch bolt.
13. NOTE: Support the halfshaft. The inner

joint must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
Using a suitable three leg puller, detach the
wheel hub from the halfshaft.
14. Using the special tool, remove the wheel

knuckle.
Page 4 of 6
Installation
All vehicles
1. Install the wheel knuckle.
2. CAUTION: Make sure the halfshaft is

completely installed into the wheel hub.
Using the special tool, attach the wheel hub to
the halfshaft.


knuckle.
knuckle.
5. WARNING: Install a new tie-rod end

retaining nut. Failure to follow this instruction
Page 5 of 6

Attach the tie-rod end to the wheel knuckle.

6. Attach the wheel speed sensor to the wheel
knuckle.
All vehicles
7. Install the brake disc.
8. CAUTION: Do not twist the brake hose

when attaching the brake caliper to prevent
damage to the brake hose.
Attach the brake caliper and anchor plate to the
wheel knuckle.
CAUTIONS:
9. Make sure the brake hose is correctly

located in the brake hose support bracket to
prevent damage to the brake hose.
Make sure the brake hose retaining clip is

located on the underside of the brake hose
support bracket to prevent damage to the
brake hose.
Attach the brake hose to the brake hose support
bracket.
10. WARNING: Install a new wheel hub

With the aid of another technician, apply the
brakes and pre-load the wheel bearing by
installing the wheel hub retaining nut.
Page 6 of 6

Wheel and Tire]
12. Tighten the wheel hub retaining nut.
13. Tighten the strut and spring assembly top

mount retaining nuts.

Section 204-00.[Suspension System - General
Information, SPECIFICATIONS, Specifications]
Page 1 of 3

STRUT AND SPRING ASSEMBLY
UID=G289895
Special Tool(s)
Lever, Wheel Knuckle
49 JE01 007
Removal
support bracket.

strut and spring assembly.

and anchor plate to prevent load being placed
on the brake hose.
Detach the brake caliper and anchor plate from
the wheel knuckle.
 Remove and discard the retaining washer (if

equipped).
Page 2 of 3

knuckle.
7. Remove the wheel knuckle to strut and spring

assembly pinch bolt.
8. NOTE: Support the halfshaft. The inner

joint must not be bent more than 18 degrees.
The outer joint must not be bent more than
45 degrees.
Using the special tool, detach the wheel knuckle
from the strut and spring assembly.
9. CAUTION: With the aid of another

technician, support the strut and spring
assembly.
Remove the strut and spring assembly.
Installation
CAUTIONS:
Make sure the heat shield is installed to prevent damage to the ball joint.
The lower arm pinch bolt must be installed from the rear of the wheel knuckle.
Do not twist the brake hose when installing the brake caliper to prevent damage to
the brake hose.
Make sure the brake hose is correctly located in the brake hose support bracket to
Make sure the brake hose retaining clip is located on the underside of the brake hose
support bracket to prevent damage to the brake hose.
Page 3 of 3
Page 1 of 2

WHEEL BEARING
UID=G289896
Special Tool(s)
Collet for 49 JE01 015
49 JE01 005
Adapter for 49 JE01 005 (Thrust

Pad)
49 JE01 006
Installer, Front Wheel Bearing
49 JE01 008
Adapter for 49 JE01 011
49 W034 301
Installer, Rear Hub Oil Seal
49 JE01 011
Remover, Bearing (Main Tool)
49 JE01 015
Installer/Aligner, Crankshaft Rear

Oil Seal
49 W017 101
Name Specification
Engine Grade: ACEA A1/B1 or ACEA A3/B3.
oil Viscosity: 5W30, 10W40, 5W40.
Recommended oil: Mazda genuine
DEXELIA oil
Removal
1. Remove the wheel knuckle. For additional
information, refer to Wheel Knuckle in this
section.
2. NOTE: When removing the wheel hub from
the wheel knuckle the bearing will be
destroyed. The bearing inner ring will be on
the wheel hub and the bearing outer ring will
be in the wheel knuckle.
Using the special tool, remove the wheel hub.
CAUTIONS:
3. The special tools must be used to

Page 2 of 2
prevent damage to the wheel hub. If the

wheel hub is damaged a new wheel hub must
be installed.
Do not use heat to remove the bearing

inner ring.
Using the special tools, remove the bearing inner
ring.
4. Using the special tools, remove the bearing

outer ring and speed sensor ring.
Installation
CAUTIONS:
Avoid any impact on the wheel speed sensor ring.
Make sure the wheel speed sensor ring is clean.
Avoid any contact between the wheel speed sensor ring and a magnetic surface.
CAUTIONS:
1. Make sure the wheel bearing is

installed into the wheel knuckle with the
wheel speed sensor ring, colored black,
towards the inner face of the wheel knuckle.
Make sure the wheel bearing is

completely installed in the wheel knuckle.
NOTE: Lubricate the bore of the wheel
knuckle with clean engine oil.
Using the special tool, install the new wheel
bearing.
2. Using the special tools, install the wheel hub.
3. Install the wheel knuckle. For additional

information, refer to Wheel Knuckle in this
section.
Page 1 of 2
DISASSEMBLY AND ASSEMBLY 2003.50 Mazda2

STRUT AND SPRING ASSEMBLY
UID=G289897
Special Tool(s)
Compressor, Coil Spring
49 T034 101
Disassembly
1. WARNING: The spring is under

extreme tension; care must be taken at all
times. Failure to follow this instruction may
Using the special tools, compress the spring.
2. CAUTION: Use an Allen key to prevent

the piston rod from rotating.
Loosen the thrust bearing retaining nut.
3. NOTE: When access to the strut or spring

only is required, remove items two through
five as a complete assembly.
Disassemble the strut and spring assembly.
1. Remove the thrust bearing retaining nut.
2. Remove the top mount.
3. Remove the thrust bearing and spring seat
assembly.
4. Remove the boot.
5. Remove the bump stop.
6. Remove the spring.
Assembly
1. CAUTION: The ends of the spring

Page 2 of 2
must locate correctly in the spring seats.

To assemble, reverse the disassembly procedure.
Page 1 of 2

SPRING
UID=G289898
General Equipment
Spring compressor
Removal
2. WARNING: As the spring is under

extreme tension care must be taken at all
Using a suitable spring compressor, compress the
spring.

axle.
4. WARNING: As the spring is under

extreme tension care must be taken at all
Remove the spring.
Installation
1. NOTE: Make sure the top seat mounting is
installed, and the spring ends butt correctly
against the upper and lower spring seats.
Install the spring.
absorber lower mounting bolt at this stage.
Attach the shock absorber to the beam axle.

4. NOTE: The final tightening of the shock
absorber lower mounting bolt should be
Page 2 of 2
carried out when the vehicle weight is on the

road wheels.
Tighten the shock absorber lower mounting bolt.
Page 1 of 3

WHEEL BEARING
UID=G289899
Special Tool(s)
Installer, Input Shaft Oil Seal
49 JE01 033
Removal
All vehicles
1. CAUTION: The brake drum and hub

assembly removal in this procedure is for
installing a new wheel bearing, not for access
to brake system components.
Remove the wheel and tire. For additional
2. Remove the dust cap.

4. Remove the brake drum and hub assembly.
 Remove and discard the wheel hub retaining

nut.

5. Remove and discard the wheel speed sensor
ring.
All vehicles
Page 2 of 3
6. Remove the circlip.
7. Using a suitable drift, remove the wheel

bearing.
Installation
All vehicles
1. CAUTION: Support the brake drum

and hub assembly on the wheel mounting
face and not on the wheel nut studs.
Using the special tool, install the new wheel
bearing.
2. Install the circlip.

CAUTIONS:
3. Avoid impact on the wheel speed

sensor ring.
Make sure the wheel speed sensor ring is

clean.
Avoid any contact between the wheel

speed sensor ring and a magnetic surface.
Install a new wheel speed sensor ring.
Page 3 of 3
All vehicles
4. CAUTION: Rotate the drum and hub

assembly 10 times in the opposite direction
when tightening the wheel hub retaining nut
to prevent damage to the bearing.
Install the brake drum and hub assembly.
5. Apply the parking brake.

6. NOTE: If the dust cap is damaged a new
dust cap must be installed.
Install the dust cap.

Page 1 of 4

HALFSHAFT LH
UID=G289900
Special Tool(s)
49 JE01 009
Remover, Halfshaft
49 JE02 027
Driveshaft Oil Seal Protector
49 JE02 053
General Equipment
Four leg puller
Name Specification
Manual transmission fluid
SAE 75W90 or transmission oil
meeting WSD-M2C200-C
Removal
mount retaining nuts by three turns.
2. CAUTION: Use a socket to loosen the

wheel hub retaining nut to prevent damage.
Remove the wheel hub retaining nut.
 Discard the wheel hub retaining nut.

Wheel and Tire]

knuckle.
Page 2 of 4
5. CAUTION: Support the halfshaft. The

inner joint must not be bent more than 18
degrees. The outer joint must not be bent
more than 45 degrees.
Using a suitable four leg puller, detach the
halfshaft from the wheel hub.
 Secure the halfshaft to one side.
CAUTIONS:
6. Support the halfshaft. The inner joint

must not be bent more than 18 degrees. The
outer joint must not be bent more than 45
degrees.
Do not damage the halfshaft oil seal.

NOTE: Plug the transaxle to prevent oil loss
or dirt ingress.
Using the special tool, remove the halfshaft.
 Discard the snap ring.
 Allow the oil to drain into a suitable container.
Installation
CAUTIONS:

degrees.
Make sure the snap ring is correctly

seated.
NOTE: Install a new snap ring.
Using the special tool to protect the oil seal,
attach the left-hand halfshaft to the transaxle.
 Remove the special tool before fully installing

the halfshaft.

Page 3 of 4

Using the special tool, install the halfshaft.
3. NOTE: Install a new wheel hub retaining

nut.
NOTE: Do not fully tighten the wheel hub
retaining nut at this stage.
Install the wheel hub retaining nut.
4. CAUTION: Make sure that the heat

shield is installed to prevent damage to the
ball joint.

knuckle.
knuckle.

Wheel and Tire]
7. CAUTION: Use a socket to tighten the

Tighten the wheel hub retaining nut.

Page 4 of 4
9. With the vehicle on a level surface, check the

transmission fluid level and top up with manual
transmission oil if necessary, until the level is
just below the filler hole.
Page 1 of 4

HALFSHAFT RH
UID=G289901
Special Tool(s)
49 JE01 009
General Equipment
Four leg puller
Name Specification
CV Joint Molybdenum disulfined CV Joint
Grease Grease
Removal
2. CAUTION: Use a socket to loosen the

Remove the wheel hub retaining nut.
 Discard the wheel hub retaining nut.


knuckle.

Using a suitable four leg puller, detach the
halfshaft from the wheel hub.
Page 2 of 4
 Secure the halfshaft to one side.

NOTE: Do not damage the inner constant
velocity (CV) joint boot.
NOTE: Discard the grease.
Remove the halfshaft.
 Remove and discard the constant velocity

(CV) joint boot clamp.
Installation
1. CAUTION: The total amount of grease

must not exceed 100 grams.
Apply grease to the intermediate shaft.

Attach the halfshaft to the intermediate shaft.
3. NOTE: Do not damage the inner constant

velocity (CV) joint boot.
NOTE: Make sure that the intermediate shaft
mating surface for the joint boot is clean.
Install the inner constant velocity (CV) joint boot
(halfshaft shown removed for clarity).
1. Slide a small screwdriver under the boot
seat to allow the air to escape.
2. Insert the constant velocity (CV) joint in as
far as it will go, then pull it back
approximately 20 mm.
4. NOTE: Install a new CV joint boot clamp.
Using a suitable grip wrench, install the inner CV
joint boot clamp.
Page 3 of 4

Using the special tool, install the halfshaft.
6. NOTE: Install a new wheel hub retaining

nut.
NOTE: Do not fully tighten the wheel hub
retaining nut at this stage.
Install the wheel hub retaining nut.

ball joint.

knuckle.
knuckle.

10. CAUTION: Use a socket to tighten

the wheel hub retaining nut to prevent
damage.
Page 4 of 4
Tighten the wheel hub retaining nut.

Page 1 of 4

INNER CONSTANT VELOCITY (CV)
JOINT BOOT
UID=G289902
Special Tool(s)
Clamping Tool, Boot Retaining
Clamp
49 T025 001
Remover, Bearing/Gear, Part I
49 0710 520
Remover, Bearing/Gear, Part II
49 0710 520
Installer, Extension Housing

Bushing/Oil Seal
49 F401 331/49 H025 003

Name Specification
Grease Molybdenum disulfined CV Joint
Grease
Removal
1. Remove the right-hand halfshaft. For
additional information, refer to Halfshaft RH in
this section.
2. Remove the left-hand halfshaft. For additional
information, refer to Halfshaft LH in this
section.
CAUTIONS:
3. Do not bent the inner constant

velocity (CV) joint more than 18 degrees and
the outer CV joint more than 45 degrees.
Use vise jaw protectors for all operations

in a vise.
NOTE: Secure the halfshaft in a vise.
Detach the inner CV joint housing from the
halfshaft.
1. Remove and discard the CV joint boot
retaining clamps.
2. Remove the CV joint housing and discard
the grease.
4. Remove and discard the spider circlip.
Page 2 of 4
5. Using the special tool, remove the spider.
6. Remove the inner CV joint boot.
 Mark the halfshaft were the CV joint boot is

located.
Installation
1. NOTE: Make sure that the inner constant
velocity (CV) joint boot is installed to the
marks on the halfshaft.
Install the inner CV joint boot.
2. NOTE: Install a new CV joint boot retaining

clamp.
Using the special tool, install the CV joint boot
retaining clamp.
3. NOTE: Install the spider with the chamfer

facing towards the halfshaft.
Using the special tools, install the spider.
Page 3 of 4
4. NOTE: Install a new spider circlip.

Install the spider circlip.

in the inner CV joint must not exceed 85
grams.
Apply grease to the inner CV joint boot.
6. Attach the inner CV joint housing to the

halfshaft (left hand side shown for clarity).
1. Use a suitable screwdriver under the CV
joint boot to allow air to escape.
2. Install the CV joint boot housing and pull it
backwards 20 mm.
7. NOTE: Install a new CV joint boot retaining

clamp.
NOTE: Make sure that the CV joint boot is
clamped at the measured position.
Using a special tool, install the CV joint boot
retaining clamp.
8. Install the right-hand halfshaft. For additional

information, refer to Halfshaft RH in this
section.
9. Install the left-hand halfshaft. For additional
information, refer to Halfshaft LH in this
section.
Page 4 of 4
Page 1 of 2

OUTER CONSTANT VELOCITY (CV)
JOINT BOOT
UID=G289903
Special Tool(s)
Clamping Tool, Boot Retaining
Clamp
49 T025 001
Name Specification
Grease Molybdenum disulfined CV Joint
Grease.
Removal
1. CAUTION: The outer constant velocity

(CV) joint is a press fit. Do not disassemble.
damage to the outer CV joint.
Remove the inner CV joint boot. For additional
information, refer to Inner Constant Velocity
(CV) Joint Boot in this section.
CAUTIONS:
2. Do not bend the inner CV joint more

than 18 degrees and the outer CV joint more
than 45 degrees.
Use vise jaw protectors for all operations

in a vise.
NOTE: Secure the halfshaft in a vise.
NOTE: Mark the halfshaft were the CV joint
boot is located.
Remove the outer CV joint boot.
 Remove and discard the CV joint boot

retaining clamps.
 Remove and discard the grease.
Installation

in the inner constant velocity (CV) joint must
not exceed 85 grams.
Apply grease to the outer CV joint boot.
2. Install the outer CV joint boot.

Page 2 of 2
 Use a suitable screwdriver under the boot to

allow air to escape.
3. NOTE: Make sure that the outer CV joint

boot is installed to the marks on the
halfshaft.
NOTE: Install a new inner CV joint boot
retaining clamp.
Using the special tool, install the inner CV joint
boot retaining clamp.
4. NOTE: Install a new outer CV joint boot

retaining clamp.
Using the special tool, install the outer CV joint
boot retaining clamp.
5. Install the inner CV joint boot. For additional

information, refer to Inner Constant Velocity
(CV) Joint Boot in this section.
Page 1 of 2

BRAKE PADS
UID=G289904
Special Tool(s)
Retractor, Caliper Piston
49 0221 600C
Name Specification
Super DOT 4 brake fluid
Molybdenum disulfined grease
Removal
2. Remove the brake caliper retaining clip.

support bracket.

to prevent load being placed on the brake
hose.
Detach the brake caliper from the brake caliper
anchor plate.
1. Remove the bolt covers (if equipped).
2. Remove the retaining bolts.
5. Remove the brake pads.

Page 2 of 2
Installation
1. CAUTION: When the brake caliper

piston is retracted into the piston housing,
brake fluid will be displaced into the brake
fluid reservoir.
Using the special tool, retract the brake caliper
piston.
CAUTIONS:
2. Do not twist the brake hose when

installing the brake caliper to prevent damage
to the brake hose.
Make sure the brake hose is correctly


brake hose.
 Apply molybdenum disulfined grease to the

brake pad contact points.
3. Depress the brake pedal, check the fluid level
in the brake fluid reservoir and top up if
necessary with brake fluid.
Page 1 of 1

POWER STEERING SYSTEM FILLING
UID=G289905
Special Tool(s)
Adaptor, Power Steering Bleeding
49 JE01 001
Name Specification
Power Power steering fluid meeting
steering fluid specification WSA-M2C195-A
Refill
1. Using a suitable hand vacuum pump/pressure
pump and the special tool, apply a vacuum of
62cm-75cm-Hg for 30 seconds.
2. Observe the vacuum gauge reading.
 If the vacuum decreases by more than 5cm-

Hg in 5 minutes, the system should be
checked for leaks.
3. Remove the hand vacuum pump/pressure
pump and special tool. Fill the reservoir with
clean power steering fluid to the MAX mark if
necessary.
Page 1 of 2

POWER STEERING SYSTEM BLEEDING
UID=G289906
Special Tool(s)
Adaptor, Power Steering Bleeding
49 JE01 001
1. NOTE: When filling the reservoir, make
sure the power steering fluid is clean and not
agitated prior to use. The fluid should be
poured slowly into the reservoir to minimize
the possibility of aeration. The fluid level
should be checked with the fluid cold.
Fill the reservoir to the MAX mark.
2. NOTE: Make sure that the fluid in the
reservoir does not fall below the MIN mark,
as air could enter the system.
Start the engine and slowly turn the steering
wheel from lock to lock.
3. Switch OFF the engine and examine the hose
connections, steering gear boots, valve body
and pump for external leaks.
4. Check the fluid level. Top up as necessary.
5. NOTE: When bleeding the system the
vacuum will decrease. Maintain a sufficient
vacuum of 38 cm Hg, using the hand
vacuum/pressure pump. If the vacuum
decreases by more than 75 cm Hg in 5
minutes, the system should be checked for
leaks.
Using a suitable hand vacuum pump/pressure
pump and the adaptor, bleed the system.
 Start the engine and slowly turn the steering

wheel from lock to lock once; then turn the
steering wheel to the right, just off the stop.
 Switch OFF the engine and using the hand

vacuum/pressure pump apply a vacuum of 38
cm Hg. Maintain the vacuum until the air is
evacuated from the system (minimum of five
minutes).
 Release the vacuum at the hand vacuum

pump/pressure pump.
 Repeat the bleed procedure, turning the

steering wheel to the left, just off the stop.
6. Remove the hand vacuum pump/pressure
pump and adaptor. Fill the reservoir if
necessary.
7. Start the engine, turn the steering wheel from
lock to lock. If excessive noise is apparent,
repeat the bleed procedure.
Page 2 of 2
8. If the noise level is still unacceptable, leave

the vehicle standing overnight then repeat the
bleed procedure.
Page 1 of 4

POWER STEERING SYSTEM FLUSHING
— 1.25L/1.4L/1.6L
UID=G289907
Special Tool(s)
Socket, Spark Plug
49 JE01 087
Name Specification
2. Disconnect the crankshaft position (CKP)
sensor electrical connector.
3. NOTE: Using a suitable blanking cap, cap

the end of the hose from the power steering
fluid reservoir.
Disconnect the power steering fluid reservoir
return hose quick release coupling.
1. Press the power steering fluid reservoir
return hose quick release coupling locking
tangs.
2. Disconnect the power steering fluid
reservoir return hose quick release coupling.

container.
4. Place the end of the power steering gear
return line into a suitable container.
5. Lower the vehicle until the wheels are clear of
the floor to allow the steering wheel to be
rotated from lock to lock.
1. Disconnect the air cleaner outlet pipe.
2. Disconnect the air cleaner inlet pipe.
3. Disconnect the breather pipe.
7. Disconnect the spark plug wires.

Page 2 of 4
8. Using the special tool remove the spark plugs.
9. NOTE: When filling the power steering fluid

reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The
fluid should be poured slowly into the
reservoir to minimize the possibility of
aeration. The fluid level should be checked
with the fluid cold.
Fill the power steering fluid reservoir to the MAX
mark with Power Steering Fluid.
10. CAUTION: Do not continuously crank

the engine for more than 30 seconds, as
damage to the starter motor may result.
NOTE: When flushing the power steering
system, make sure that the power steering
fluid in the reservoir does not fall below the
minimum mark.
While cranking the engine for no more than 30
seconds turn the steering wheel from lock to
lock.
 With the aid of another technician add 1 liter

of clean Power Steering Fluid.
11. Wait 60 seconds to allow the starter motor to
cool.

minimum mark.
While cranking the engine for a further 30
seconds turn the steering wheel from lock to
lock.
Page 3 of 4
 With the aid of another technician add a

further 1 liter of clean Power Steering Fluid.
13. When all the fluid has been used, turn the
ignition switch to the OFF position.
14. Using the special tool install the spark plugs.
15. Connect the spark plug wires.
16. Install the air cleaner.

1. Install the retaining bolts.
2. Connect the air cleaner inlet pipe.
3. Connect the air cleaner outlet pipe.
4. Connect the breather pipe.

18. NOTE: Make sure the collar on the hose is
inserted fully into the quick release coupling.
Remove the blanking cap and connect the power
steering fluid reservoir return hose quick
release coupling.
19. Connect the CKP sensor electrical connector.

Page 4 of 4
21. Fill and bleed the power steering system. For

additional information, refer to Power Steering
System Bleeding in this section.
Page 1 of 2

POWER STEERING PUMP —
1.25L/1.4L/1.6L
UID=G289908
Special Tool(s)
Expander, Teflon Seal
49 JE02 005
Removal
1. Detach the power steering line from the power
steering pump mounting bracket.
2. Remove the accessory drive belt. For

05.[Accessory Drive, REMOVAL AND
INSTALLATION, Power Steering Pump Belt -
1.25L/1.4L/1.6L, Vehicles With: Air
Conditioning] For additional information, refer
to Section 303-05.[Accessory Drive, REMOVAL
AND INSTALLATION, Accessory Drive Belt -
1.25L/1.4L/1.6L, Vehicles Without: Air
Conditioning]
3. Disconnect the power steering fluid reservoir
tangs.

container.
4. Detach the power steering hose from the
engine block.
5. Disconnect the power steering hose from the


Page 2 of 2
container.
6. Disconnect the power steering line from the


container.
7. Remove the power steering pump.
Installation
1. NOTE: If installing a new power steering
pump, the unions supplied with the new
pump should be removed and retained for
further use.
NOTE: Make sure the collar on the hose is
Using the special tool, install a new O-ring seal
onto the power steering line to power steering
pump union.
1. Push the O-ring seal onto the special tool.
2. Locate the special tool onto the union and
install the O-ring seal.
00.[Steering System - General Information,
GENERAL PROCEDURES, Power Steering
System Filling] For additional information,
refer to Section 211-00.[Steering System -
General Information, GENERAL PROCEDURES,
Power Steering System Bleeding]
Page 1 of 4

POWER STEERING PUMP — 1.4L
DIESEL
UID=G289909
Special Tool(s)
49 JE02 005
Removal
All vehicles
INSTALLATION, Accessory Drive Belt - 1.4L
Diesel]
Vehicles with air conditioning

2. Detach the power steering line support bracket
from the air conditioning (A/C) compressor.
Vehicles without air conditioning

3. Detach the power steering line bracket from
the engine block.
All vehicles
5. Remove the right-hand headlamp assembly.
Section 417-01.[Exterior Lighting, REMOVAL
AND INSTALLATION, Headlamp Assembly]
6. Detach the wiring harness from the power
steering pump.
Page 2 of 4

from the power steering pump.
CAUTIONS:
8. Cover the generator with a suitable

cloth to prevent the ingress of power steering
fluid.
Do not disconnect the power steering

pump pressure adapter from the power
steering pump.
Cap the power steering line to prevent

fluid loss or dirt ingress.
Cap the power steering pump pressure

adapter to prevent fluid loss or dirt ingress.
Disconnect the power steering line from the
1. Using a suitable wrench, hold the power
steering pump pressure adapter.
2. Disconnect the union.

container.
 Discard the Teflon seal.

9. Remove the power steering pump rear
retaining bolt.
10. Detach the power steering fluid reservoir

from the radiator grille opening panel
reinforcement and position to one side.
Page 3 of 4
CAUTIONS:
11. Cap the power steering fluid supply

hose to prevent fluid loss or dirt ingress.
Cap the power steering pump connection

to prevent fluid loss or dirt ingress.
Disconnect the power steering fluid supply hose

container.
12. Remove the power steering pump front
retaining bolts.
Installation
CAUTIONS:
1. Do not remove the power steering

steering pump.
Cap the power steering pump pressure

adapter to prevent dirt ingress.
NOTE: If installing a new power steering line
to the power steering pump, do not remove
the power steering line union.
NOTE: If installing the original power steering
line to the power steering pump, remove the
power steering line union.
Remove the power steering line union from the
power steering pump, if necessary.
2. Remove the union.
2. CAUTION: Care must be taken to

Page 4 of 4
prevent dirt ingress.

line to the power steering pump, install a new
Teflon seal.
Using the special tool, install a new Teflon seal
onto the power steering pump to steering gear
line union, if necessary.
1. Push the Teflon seal onto the special tool.
install the Teflon seal.
Page 1 of 3

POWER STEERING PUMP TO
STEERING GEAR PRESSURE LINE —
1.25L/1.4L/1.6L
UID=G289910
Special Tool(s)
49 JE02 005
Removal
2. Detach the power steering line from the power
steering pump mounting bracket.
3. Detach the power steering line from the

cylinder head.
4. Disconnect the power steering pressure (PSP)

switch electrical connector.
5. Remove the front wheel and tire. For additional

Wheel and Tire]

container.
Page 2 of 3
7. Detach the exhaust hanger insulator from the

crossmember.
8. Detach the exhaust heat shield from the floor

panel.
steering gear.
10. Disconnect the power steering lines from the

steering gear valve body.
1. Remove the retaining bolt.
2. Rotate the clamp plate.

container.
11. Remove the power steering pump to steering

gear pressure line.
12. Remove the PSP switch.
Installation
1. If a new fluid line is being installed, push the
new line into the new union until it clips into
place.
Page 3 of 3
2. Using the special tool, install a new O-ring seal

pump union.
1. Push the new O-ring seal onto the special
tool.
install the O-ring seal.
3. Install new O-ring seals onto the power

steering lines.

Page 1 of 4

POWER STEERING PUMP TO
STEERING GEAR PRESSURE LINE —
1.4L DIESEL
UID=G289911
Special Tool(s)
49 JE02 005
Removal
All vehicles
information, refer to Section 414-01.[Battery,
Mounting and Cables, REMOVAL AND
INSTALLATION, Battery Tray]
steering pump.

CAUTIONS:

fluid.

steering pump.
Cap the power steering fluid supply hose


Page 2 of 4

2. Disconnect the union

container.
 Discard the Teflon seal.

5. NOTE: Note the position of the power
steering line to aid installation.
Detach the power steering line from the
transaxle.

information, refer to Section 100-02.[Jacking
and Lifting, DESCRIPTION AND OPERATION,
Jacking] For additional information, refer to
Section 100-02.[Jacking and Lifting,
DESCRIPTION AND OPERATION, Lifting]

Detach the power steering line support bracket
from the air conditioning (A/C) compressor.
Vehicles without air conditioning

8. Detach the power steering line bracket from
the engine block.
All vehicles
Detach the power steering line from the steering
gear (steering column shown removed for
clarity).
Page 3 of 4
CAUTIONS:
10. Cap the power steering lines to

Cap the steering gear valve body to

Disconnect the power steering lines from the

container.
 Discard the Teflon seals .

Remove the power steering pump to steering
gear pressure line.
Installation
Push the new line into the new union until it clips
into place.

pump union.
install the Teflon seal.
3. Install new Teflon seals onto the power
steering gear lines.
Page 4 of 4

Page 1 of 8

STEERING GEAR
UID=G289912
Special Tool(s)
49 T028 3A0
General Equipment
Transmission jack
Wooden block
Removal

3. Remove the wheels and tires. For additional

Wheel and Tire]
4. Disconnect the power steering reservoir return
hose quick release coupling.
tangs.

container.

retaining nuts in place to protect the ball joint
studs.
Page 2 of 8
Loosen the tie-rod end retaining nut on both

sides.
6. CAUTION: Protect the ball joint seals

from the wheel knuckle on both sides.
retaining nut.

the ball joint stud from rotating.
9. Detach the exhaust system from the

crossmember exhaust hanger insulator.
10. Using a suitable transmission jack and

wooden block, support the crossmember.
both sides.
Page 3 of 8
12. Lower the crossmember to gain access to the

steering gear.
steering gear (left-hand drive shown).
 Remove the retaining bolt.
14. Detach the steering gear return hose from

the steering gear.
 Release the clips.

panel.
16. Detach the power steering lines from the

steering gear (left-hand drive shown).

Page 4 of 8

container.
18. Remove the steering gear.
19. Remove the steering gear bulkhead floor

seal.
20. Remove the exhaust heat shield.
Installation
1. Install the exhaust heat shield.
2. Install the steering gear bulkhead floor seal.

Page 5 of 8
3. Install the steering gear.
4. NOTE: Check the power steering lines to

steering gear valve body O-ring seals for
damage or fatigue. Install new O-ring seals
as necessary.
Connect the power steering lines to the steering
gear valve body.
2. Install the retaining bolt.
5. Attach the power steering lines to the steering

gear.
6. Attach the exhaust heat shield to the floor

panel.
7. Attach the steering gear return hose to the

steering gear.
Page 6 of 8
8. Attach the power steering line to the steering

gear (left-hand drive shown).

sides.

on both sides.

block.
12. Attach the exhaust system to the

Page 7 of 8
14. WARNING: Install new tie-rod end

retaining nuts. Failure to follow this
Attach the tie-rod end to the wheel knuckle on
both sides.

the ball joint stud from rotating.
Attach the stabilizer connecting link to the

Connect the power steering reservoir return hose
17. Install the wheels and tires. For additional

Wheel and Tire]
18. WARNING: Install a new steering

column to steering gear pinion retaining bolt.
personal injury.
gear pinion.

Page 8 of 8
GENERAL PROCEDURES, Power Steering System

Filling] For additional information, refer to
Section 211-00.[Steering System - General
Information, GENERAL PROCEDURES, Power
Steering System Bleeding]
Information, GENERAL PROCEDURES, Front
Toe Adjustment]
Page 1 of 1

STEERING GEAR BUSHING
UID=G289913
Special Tool(s)
Installer, Wheel Hub
49 JE02 001
Remover/Installer, Pivot Bushing
49 JE02 004
Name Specification
Rubber grease
Removal
1. Remove the steering gear. For additional
information, refer to Steering Gear in this section.
CAUTIONS:
2. Make sure vise jaw protectors are used.
Clamp the steering gear reinforcement boss.

Do not clamp the steering gear body.
Secure the steering gear in a vise.
3. Using the special tools remove the steering gear

insulator bushing on both sides.
Installation
1. Lubricate the steering bushing with Rubber grease
prior to installation.
2. Using the special tools install the steering gear
insulator bushing on both sides.
3. Install the steering gear. For additional

information, refer to Steering Gear in this section.
Page 1 of 2

TIE-ROD END
UID=G289914
Special Tool(s)
49 T028 3A0
Removal
Wheel and Tire]

retaining nut in place to protect the ball joint
stud.
Loosen the tie-rod end locknut and the tie-rod
end retaining nut.
1. Loosen the locknut.
2. Loosen the retaining nut.

from the wheel knuckle.
retaining nut.
4. NOTE: Make a note of the number of turns

used to remove the tie-rod end.
Remove the tie-rod end.
Installation
1. NOTE: Install the tie-rod end using the
same number of turns used to remove it.
Install the tie-rod end.
Page 2 of 2
2. WARNING: Install a new tie-rod end

Attach the tie-rod end to the wheel knuckle.
1. Tighten the retaining nut.
2. Tighten the locknut.

Wheel and Tire]
4. Check the toe setting and adjust as necessary.
Toe Adjustment]
Page 1 of 3

TIE-ROD
UID=G289915
General Equipment
Pipe wrench
Vise jaw protectors
Pincers
Name Specification
Lithium based grease (NLGI No1)
Removal
1. Remove the steering gear. For additional
2. NOTE: Make a note of the number of turns
used to remove the tie-rod end.
Remove the tie-rod end and the tie-rod end
locknut.
1. Remove the tie-rod end.
2. Remove the tie-rod end locknut.
3. Remove and discard the steering gear boot

clamps.
4. Remove and discard the steering gear boot.
5. Rotate the steering gear pinion to expose the

rack.
Page 2 of 3
CAUTIONS:
6. Do not clamp the steering rack on

exposed hydraulic sealing surfaces.
Make sure vise jaw protectors are used.
To counter the extensive torque forces

required to remove the tie-rod, clamp the
steering rack teeth in a suitable vise. Do not
clamp the steering gear body.
Secure the steering rack in a vise and using a
suitable pipe wrench remove the tie-rod.
Installation
1. Install the tie-rod.
2. NOTE: Lubricate the steering gear boot.

Install a new steering gear boot.
3. Using a suitable pair of pincers, install a new

steering gear boot inner clamp.
4. NOTE: Make sure the steering gear boot

outer clamp is located over the recess in the
tie-rod.
Using a suitable pair of pincers, install a new
steering gear boot outer clamp.
5. NOTE: Install the tie-rod end using the

Page 3 of 3
same number of turns used to remove it.

Install the tie-rod end locknut and the tie tie-rod
end.
6. Install the steering gear. For additional

Page 1 of 16

ENGINE
UID=G289916
Special Tool(s)
Adapter for 49 S010 1A0A
49 D013 101
Socket, Spark Plug
49 JE01 087
Adapter for 49 S010 1A0A
49 JE02 05
Compression Gauge Set
49 S010 1A0A
General Equipment
Worldwide diagnostic system (WDS)
Name Specification
Sealant - Loctite 243
1. Verify the customer concern by operating the system.
- Coolant leaks - Fuse(s)
- Oil leaks - Loose or corroded connector(s)
- Fuel system leaks - Powertrain control module
- Visibly damaged or worn parts - Damaged or worn switch(es)
- Loose or missing nuts or bolts

Symptom Chart

Loss of oil *Oil leaks on components *CHECK for evidence of oil leaks on
that are either coated in components. Use an ultraviolet (UV) leak
oil themselves or on tester if an oil leak is not evident. INSTALL
components local to them. new gaskets or components as required.
*Internal or external leak *CHECK the coolant expansion tank for a film
Page 2 of 16
at the oil cooler. of oil on the coolant surface. INSTALL a new oil
cooler or oil cooler gasket.
*Leak at the crankshaft oil *INSTALL a new oil seal.
seal.
*Leaks from oil carrying *CHECK for cracks in oil-carrying components
components or basic of the basic engine by means of a UV leak
engine. test. INSTALL new components or seals as
necessary.
Oil consumption *Use of the wrong type of *DETERMINE the last type of engine oil used
engine oil. and compare with the specification. Change
the engine oil to the specification. REFER to
Section 303-01B.[Engine - 1.4L Diesel,
*Faulty positive crankcase *CHECK if the PCV system is operating
ventilation (PCV) system. correctly and repair as necessary. Engine -
-Hoses or ventilation or 1.25L, 1.4L and 1.6L - REFER to Section 303-
breather valves are 08A.[Engine Emission Control -
blocked. This causes 1.25L/1.4L/1.6L, DIAGNOSIS AND TESTING,
excessive pressure in the Engine Emission Control] Engine - 1.4L Diesel
crankcase which causes - REFER to Section 303-08B.[Engine
more oil to enter the Emission Control - 1.4L Diesel, DIAGNOSIS
combustion chamber. AND TESTING, Engine Emission Control]
-PCV oil separator is faulty
and engine oil can enter
the combustion chamber
through the intake
manifold.
*Turbocharger seals (only *INSTALL a new turbocharger. REFER to
diesel engine). Section 303-04C.[Fuel Charging and Controls
- Turbocharger - 1.4L Diesel, REMOVAL AND
INSTALLATION, Turbocharger]
*Damaged gaskets or *CHECK the gaskets and mating surfaces for
mating surfaces. damage.
-Cylinder head gasket is -Remove the cylinder head. CHECK the mating
damaged or mating face faces, cylinder head gasket and the
are warped. evenness of the cylinder head and engine
-Valve stem oil seals are block mating faces.
worn and engine oil can -INSTALL new valve stem oil seals. Engine -
enter the combustion 1.25L, 1.4L and 1.6L - REFER to
chamber between the Section 303-01A.[Engine - 1.25L/1.4L/1.6L,
valve stem and the valve IN-VEHICLE REPAIR, Valve Seals] Engine -
stem guide. 1.4L Diesel - REFER to Section 303-01B.
[Engine - 1.4L Diesel, IN-VEHICLE REPAIR,
Valve Seals]
*Piston ring or cylinder *INSTALL new components as necessary.
liner wear. REFER to Section 303-01B.[Engine - 1.4L
Diesel, SPECIFICATIONS, Specifications]
*Damaged cylinder liners *CHECK the running surfaces and clearances
or excessive clearance of of the individual engine components. INSTALL
engine components. new components as necessary. REFER to
-Pistons Section 303-01B.[Engine - 1.4L Diesel,
SPECIFICATIONS, Specifications] INSTALL a
-Piston rings (clearance in
new cylinder block if necessary.
groove and end gap)
-Cylinder liners
Coolant *Cooling system *Engine - 1.25, 1.4L and 1.6L - REFER to
consumption components. Section 303-03A.[Engine Cooling -
Page 3 of 16
1.25L/1.4L/1.6L, DIAGNOSIS AND TESTING,

Engine Cooling] Engine - 1.4L Diesel - REFER
to Section 303-03B.[Engine Cooling - 1.4L
Diesel, DIAGNOSIS AND TESTING, Engine
Cooling]
*Oil cooler. *INSTALL a new oil cooler.
*Damaged gaskets or *CHECK the cylinder head gasket for damage.
warped mating faces. CHECK the cylinder head for distortion. REFER
to Section 303-01B.[Engine - 1.4L Diesel,
*Cracks or fractures in *DETERMINE the damaged engine component
engine components (s) and install new component(s) as
surrounded by coolant, necessary.
such as cylinder liners and
cylinder head combustion
chamber.
Engine will not *Battery or cables. *CHECK the battery, bracket and cables.
crank REFER to Section 414-00.[Charging System -
General Information, DIAGNOSIS AND
TESTING, Charging System]
*Starter motor or cables. *CHECK the starting system. REFER to
Section 303-06.[Starting System,
DIAGNOSIS AND TESTING, Starting System]
Engine cranks but *Fuel tank is empty. *CHECK the fuel level.
will not start *Water in fuel (only diesel *Drain the water from the fuel system.
engine).
*Fuel filter blocked. *INSTALL a new fuel filter. REFER to
Section 310-01.[Fuel Tank and Lines,
REMOVAL AND INSTALLATION, Fuel Filter -
1.4L Diesel]
*Engine intake air system. *CHECK the intake air system. REFER to
Filtering, DIAGNOSIS AND TESTING, Intake
Air Distribution and Filtering]
*Glow plug faulty (only *CHECK the glow plugs. INSTALL new glow
diesel engine). plugs as necessary. REFER to Section 303-
07B.[Glow Plug System, REMOVAL AND
INSTALLATION, Glow Plug]
*Engine management *CHECK the engine management system.
system. REFER to Section 303-14.[Electronic Engine
Controls, DIAGNOSIS AND TESTING,
Electronic Engine Controls]
*Ignition system (only *CHECK the ignition system. REFER to
petrol engines). Section 303-07A.[Engine Ignition,
DIAGNOSIS AND TESTING, Engine Ignition]
*Incorrect valve timing. *CHECK and adjust the valve timing. Engine -
1.25L, 1.4L and 1.6L - REFER to Section 303-
01A.[Engine - 1.25L/1.4L/1.6L, IN-VEHICLE
REPAIR, Timing Belt] Engine - 1.4L Diesel -
REFER to Section 303-01B.[Engine - 1.4L
Diesel, IN-VEHICLE REPAIR, Timing Belt]
*Broken or damaged *CHECK the timing belt/timing chain and
timing belt/timing chain sprockets/pulleys. INSTALL new components
or pulley/sprocket. as necessary. Engine - 1.25L, 1.4L and 1.6L -
REFER to Section 303-01A.[Engine -
1.25L/1.4L/1.6L, IN-VEHICLE REPAIR, Timing
Belt] Engine - 1.4L Diesel - REFER to
Page 4 of 16
Section 303-01B.[Engine - 1.4L Diesel, IN-

VEHICLE REPAIR, Timing Belt]
Very poor power *Fuel system. *CHECK the fuel system. Engine - 1.25L, 1.4L
output or fuel and 1.6L - REFER to Section 303-04A.[Fuel
consumption too Charging and Controls - 1.25L/1.4L/1.6L,
high or engine DIAGNOSIS AND TESTING, Fuel Charging and
running rough Controls] Engine - 1.4L Diesel - REFER to
Section 303-04B.[Fuel Charging and Controls
- 1.4L Diesel, DIAGNOSIS AND TESTING, Fuel
Charging and Controls]
*Engine intake air system. *CHECK the intake air system. REFER to
Filtering, DIAGNOSIS AND TESTING, Intake
Air Distribution and Filtering]
*Exhaust system blocked. *CHECK the exhaust system.
*Engine management *CHECK the engine management system.
system. REFER to Section 303-14.[Electronic Engine
*Fault in ignition system *CHECK the ignition system. - Engine 1.25L,
(only petrol engines). 1.4L and 1.6L - REFER to Section 303-07A.
[Engine Ignition, DIAGNOSIS AND TESTING,
Engine Ignition]
*Turbocharger (only diesel *CHECK the turbocharger. REFER to
engine). Section 303-04C.[Fuel Charging and Controls
- Turbocharger - 1.4L Diesel, DIAGNOSIS
AND TESTING, Turbocharger]
*Incorrect valve timing. *CHECK and adjust valve timing. INSTALL new
Timing belt/timing components as necessary. Engine - 1.25L,
sprocket or 1.4L and 1.6L - REFER to Section 303-01A.
pulley/sprocket damaged. [Engine - 1.25L/1.4L/1.6L, IN-VEHICLE
*Ignition timing incorrect *CHECK the electronic engine controls. REFER
(only petrol engines). to Section 303-14.[Electronic Engine
Noisy running *Engine auxiliary *CHECK engine auxiliary components for
components loose or damage or looseness. CHECK and adjust
damaged. valve timing. INSTALL new components as
necessary. Engine - 1.25L, 1.4L and 1.6L -
REFER to Section 303-01A.[Engine -
1.25L/1.4L/1.6L, IN-VEHICLE REPAIR, Timing
Belt] Engine - 1.4L Diesel - REFER to
Section 303-01B.[Engine - 1.4L Diesel, IN-
VEHICLE REPAIR, Timing Belt]
Noisy running, *Incorrect fuel *DETERMINE which type of fuel was last put in
misfiring, the tank (note the country specific fuel
backfiring or specifications).
knocking *Water in fuel or fuel *CHECK the fuel system for water or other
contaminated. contamination.
*Valve timing incorrect, *CHECK and adjust valve timing. INSTALL new
timing belt/chain or components as necessary. Engine - 1.25L,
pulley/sprocket damaged. 1.4L and 1.6L - REFER to Section 303-01A.
[Engine - 1.25L/1.4L/1.6L, IN-VEHICLE
Page 5 of 16

Noisy running or *Valve clearance too large *INSTALL new hydraulic lash adjusters or
valve train noise due to faulty valve adjust the valve clearance. Engine - 1.25L,
tappets or worn valve 1.4L and 1.6L - REFER to Section 303-01A.
train components. [Engine - 1.25L/1.4L/1.6L, GENERAL
PROCEDURES, Valve Clearance Adjustment]
*Timing belt or timing *INSTALL a new timing belt or timing chain.
chain damaged. Engine - 1.25L, 1.4L and 1.6L - REFER to
Section 303-01A.[Engine - 1.25L/1.4L/1.6L,
IN-VEHICLE REPAIR, Timing Belt] Engine -
1.4L Diesel - REFER to Section 303-01B.
[Engine - 1.4L Diesel, IN-VEHICLE REPAIR,
Timing Belt]
*Timing belt or timing *CHECK the timing belt tension. INSTALL a
chain incorrectly new timing belt, as necessary. Engine -
tensioned. 1.25L, 1.4L and 1.6L - REFER to Section 303-
01A.[Engine - 1.25L/1.4L/1.6L, IN-VEHICLE
Noisy running or *Engine components *CHECK the engine components for wear or
engine noise -Pistons damage. Make sure all components are within
specification. INSTALL new components as
-Piston rings
necessary. Engine - 1.25L, 1.4L and 1.6L -
-Connecting rod big end, REFER to Section 303-01A.[Engine -
main bearing or thrust 1.25L/1.4L/1.6L, SPECIFICATIONS,
bearing journals Specifications] Engine - 1.4L Diesel - REFER
-Connecting rods bent or to Section 303-01B.[Engine - 1.4L Diesel,
damaged. SPECIFICATIONS, Specifications]
Engine - Oil Leaks
NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly
established.
If the oil leak cannot be identified clearly by a visual inspection, carry out an ultraviolet (UV)
test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a suitable cleaning fluid.
2. Pour the UV-test fluid in accordance with the quantity specified by the manufacturer
through the oil filler neck into the engine and install the oil filler cap.
WARNING: Vehicles with manual transaxle, shift the transaxle into Neutral. Failure to
follow this instruction may result in personal injury.
3. Start the engine and let it run for about five minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the vehicle under various loads and check the
engine for leaks again.
5. Check the engine for oil leaks using a suitable UV lamp.
6. Rectify any leaks found and check the engine for oil leaks.
Page 6 of 16
Measure the compression pressure
NOTE: The powertrain control module (PCM) receives an error message when the fuel
pump relay is removed or electrical components are disconnected. This error message
must be deleted from the fault memory using worldwide diagnostic system (WDS) after
completing the compression test.
NOTE: Valve clearance must be set correctly before performing a compression test. Make
sure the engine is at the normal operating temperature.
NOTE: The varying design of compression checking devices and fluctuating starter motor
speeds normally only allows for a comparison to be made of the compression pressures in
all cylinders.
Measure the compression pressure (Engine - 1.25L, 1.4L and 1.6L)
1. Open the central junction box (CJB) and remove the fuel pump relay.
NOTE: The engine will start, run for a few seconds and then stop.
2. Start the engine.
3. Remove the air cleaner. REFER to Section 303-12.[Intake Air Distribution and Filtering,
REMOVAL AND INSTALLATION, Air Cleaner - 1.25L/1.4L/1.6L]
4. Disconnect the electronic ignition (EI) coil connector from the EI coil.
NOTE: Twist the spark plug connectors slightly before disconnecting them. Pull on the
Page 7 of 16
connector and not on the cable.

5. Remove the spark plug connectors.
6. Using the special tool, remove the spark plugs.
NOTE: Operate the starter motor with wide open throttle until the reading on the
compression tester stops rising.
7. Using the special tool, carry out the compression test in accordance with the
manufacturers instructions and note the recordings.
8. Using the special tool, install the spark plugs.
9. Install the spark plug connectors.

Page 8 of 16
10. Connect the EI coil connector to the EI coil.
11. Install the fuel pump relay.
12. Using WDS, clear the fault codes from the PCM.
Measure the compression pressure (Engine - 1.4L Diesel)
1. Remove the air cleaner. REFER to Section 303-12.[Intake Air Distribution and Filtering,
REMOVAL AND INSTALLATION, Air Cleaner - 1.4L Diesel]
2. Disconnect the fuel injector wiring harness main connector.

Page 9 of 16
3. Disconnect the glow plug relay electrical connector.
4. Detach the exhaust gas recirculation (EGR) tube from the cylinder block and the EGR
valve.
5. Remove the EGR tube from the intake manifold assembly.
6. Disconnect the glow plug electrical connectors from the glow plugs.
7. Remove the glow plugs.

Page 10 of 16
8. Install the special tools.
NOTE: Operate the starter motor until the reading on the compression tester stops rising.
9. Carry out the compression test in accordance with the manufacturers instructions and note
the recordings.
10. Remove the special tools.
11. Install the glow plugs.
12. Connect the glow plug electrical connectors to the glow plugs.
Page 11 of 16
NOTE: Check the exhaust gas recirculation (EGR) tube O-ring seal. Install a new seal if
necessary.
13. Install the EGR tube to the intake manifold assembly.
14. Attach the EGR tube to the cylinder block and to the EGR valve.
15. Connect the glow plug relay electrical connector.
16. Connect the fuel injector wiring harness main connector.
17. Install the air cleaner. REFER to Section 303-12.[Intake Air Distribution and Filtering,
REMOVAL AND INSTALLATION, Air Cleaner - 1.4L Diesel]
Page 12 of 16
18. Using WDS, clear the fault codes from the PCM.
Measure the oil pressure (Engine - 1.25L, 1.4L and 1.6L)
NOTE: The oil pressure depends on various factors (engine speed, oil temperature, oil
viscosity, extent of oil filter contamination).
NOTE: Measure the oil pressure at the specified engine speed.
1. Raise and support the vehicle. REFER to Section 100-02.[Jacking and Lifting,
DESCRIPTION AND OPERATION, Jacking] REFER to Section 100-02.[Jacking and Lifting,
2. Disconnect the oil pressure switch electrical connector from the oil pressure switch.
3. Remove the oil pressure switch.
4. Attach the oil pressure gauge with the oil pressure gauge connector to the oil pressure
switch bore, and position it to allow reading from above.

Page 13 of 16
NOTE: Measure the oil pressure at an oil temperature of 80°C.

NOTE: Oil pressure at 2000 rpm: 3.5 bar.
6. Measure the oil pressure.
8. Detach the oil pressure gauge and connector from the oil pressure switch bore.
9. Coat the oil pressure switch with sealant.
10. Install the oil pressure switch.

Page 14 of 16
11. Connect the oil pressure switch electrical connector to the oil pressure switch.
Measure the oil pressure (Engine - 1.4L Diesel)
NOTE: The oil pressure depends on various factors (engine speed, oil temperature, oil
viscosity, extent of oil filter contamination).
NOTE: Measure the oil pressure at the specified engine speed.
2. Disconnect the oil pressure switch electrical connector from the oil pressure switch.
 Discard the washer.
4. Attach the oil pressure gauge with the oil pressure gauge connector, and position it to
allow reading from above.

Page 15 of 16
NOTE: Measure the oil pressure at an oil temperature of 110°C.

NOTE: Oil pressure at 2000 rpm: 2.3 to 3.7 bar.
6. Measure the oil pressure.
8. Remove the oil pressure gauge and the oil pressure gauge connector.
NOTE: Install a new oil pressure switch washer.

Page 16 of 16
10. Connect the oil pressure switch electrical connector to the oil pressure switch.
Valve train analysis - static (engine off)
Remove the valve cover.
Check all components of the valve train for damage and wear. Make sure that only original
components are installed and that all nuts and bolts are tightened to the specified torque.
Page 1 of 2

CRANKSHAFT FRONT SEAL
UID=G289917
Special Tool(s)
Remover, Crankshaft Oil Seal
49 JE01 084
Installer, Crankshaft Oil Seal
49 JE01 058
Name Specification
Engine Grade: ACEA A1/B1 or ACEA A3/B3
Oil Viscosity: 5W30, 10W40, 5W40
DEXELIA oil
Removal
information, refer to Timing Belt in this
section.
2. Remove the crankshaft timing pulley.
3. Using the special tool, remove the crankshaft

front oil seal.
Installation
1. Coat the crankshaft front oil seal lip with clean
engine oil.
2. Using the special tool, install the crankshaft
front oil seal.
Page 2 of 2
3. Install the crankshaft timing pulley.

section.
Page 1 of 2

VALVES
UID=G289918
Special Tool(s)
Compressor, Valve Spring
49 JE02 0A2
Pliers, Valve Stem Seals
49 JE01 088
Name Specification
Oil Viscosity: 5W30, 10W40, 5W40
DEXELIA oil
Removal
1. Remove the cylinder head. For additional
information, refer to Cylinder Head in this
section.
2. CAUTION: Keep the valve tappets in

order for reassembly.
Remove the valve tappets.
3. NOTE: Install wooden wedges in the
combustion chamber recesses in the cylinder
head so that the valves are held in place for
removal.
Using the special tool, remove the valve springs.
 Compress the valve springs.
 Remove the valve collets.
 Remove the valve spring retainers and the

valve springs.
4. Using the special tool, remove the valve seals.
 Discard the valve seals.
5. Remove the valves.
Installation
1. Coat the valve stem with clean engine oil.
2. Install the valves.
Page 2 of 2
3. Install a valve stem mounting sleeve over the

valve collet groove (valve shown removed for
clarity).
4. CAUTION: The valve seal for the

intake valve is green. The valve seal for the
exhaust valve is brown.
NOTE: Insert wooden wedges in the
combustion chamber recesses in the cylinder
head so that the valves are held in place for
installation.
NOTE: Install new valves seals.
NOTE: Coat the valve seal lip and the valve
stem with clean engine oil.
Using the special tool, install the valve seals.
5. Using the special tool, install the valve springs.
 Install the valve spring retainers and the

valve springs.
 Compress the valve springs.
 Install the valve collets.
7. CAUTION: The valve tappets must be

installed in their original locations.
Install the valve tappets.
8. Install the cylinder head. For additional
information, refer to Cylinder Head in this
section.
Page 1 of 2

VALVE SEALS
UID=G289919
Special Tool(s)
Universal Valve Tool
49 JE02 0A2
Pliers, Valve Stem Oil
49 JE01 088
Name Specification
oil Viscosity: 5W30, 10W40, 5W40
DEXELIA oil
Removal
1. Remove the camshafts. For additional
information, refer to Camshafts in this section.
2. CAUTION: Keep the valve tappets in

order for reassembly.
Remove the valve tappets.
3. Using the special tool, remove the valve
springs.
 Apply 7 to 10 bar of compressed air into the

cylinder.
 Compress the valve spring.
 Remove the valve collets.
 Remove the valve spring retainer and the

valve springs.
4. Using the special tool, remove the valve seals.
 Discard the valve seals.
Installation
1. Cover the valve collet groove on the valve
stem with a protective sleeve (valve shown
Page 2 of 2
2. CAUTION: The intake valve seals are

colored green, and the exhaust valve seals
are colored brown.
NOTE: Install new valve seals.
NOTE: Coat the valve seal lip and the valve
stem with clean engine oil.
Using the special tool, install the valve seal.
3. Remove the protective sleeve.

4. Using the special tool, install the valve springs.
 Install the valve spring retainer and the valve

springs.
 Compress the valve spring.
 Install the valve collets.
6. CAUTION: The valve tappets must be

installed in their original locations.
Install the valve tappets.
7. Install the camshafts. For additional
Page 1 of 2

CAMSHAFTS
UID=G289920
Special Tool(s)
Universal Flange Holding Wrench
49 UN205 072
49 JE01 058
Name Specification
Silicone
rubber
sealant (Gel
type)
Engine Oil Grade: ACEA A1/B1 or ACEA
A3/B3 Viscosity: 5W30, 10W40,
5W40 Recommended oil: Mazda
genuine DEXELIA oil
Removal
section.
2. CAUTION: Install a suitable piece of

hose to the special tool studs, to prevent
damage to the camshaft sprockets.
Remove the camshaft timing sprockets.
3. CAUTION: Keep the camshaft bearing

caps in order for installation.
Remove the camshafts.
 Slacken each camshaft bearing cap retaining

bolt in the sequence shown by one turn until
the camshaft is released.
 Remove the camshaft bearing caps.
 Remove and discard the camshaft oil seals.
Installation
1. Turn the crankshaft to approximately 25 mm
before top dead center (BTDC) on cylinder
number 1.
2. Apply silicone rubber sealant (Gel type) to the
points indicated on the camshaft bearing cap
Page 2 of 2
number 1 and to the mating surface of the

cylinder head.
3. Coat the camshafts and the camshaft bearing

caps with clean engine oil.
4. CAUTION: Position the camshafts in

place so that none of the cams are at full lift.
NOTE: The camshaft bearing cap numbering
starts at the timing belt end with E1 on the
exhaust side and with I1 on the intake side.
NOTE: The exhaust camshaft has an
additional cam for the camshaft position
(CMP) sensor.
Install the camshafts and camshaft bearing caps.
 Tighten the camshaft bearing cap retaining

bolts in the sequence shown in three stages.
 Stage 1: One half turn on each bolt until all of

the camshaft bearing caps are in contact with
the cylinder head.
 Stage 2: 7 Nm.
 Stage 3: 45 degrees.
5. Adjust the valve clearances. For additional
information, refer to Valve Clearance
Adjustment in this section.
6. NOTE: Install new camshaft oil seals.
NOTE: Coat the camshaft journals and
camshaft oil seal lip with clean engine oil.
Using the special tool, install the camshaft oil
seals.
7. NOTE: Do not fully tighten the camshaft

timing sprocket retaining bolts at this stage.
Make sure the camshaft sprockets turn on the
camshafts.
Install the camshaft timing sprockets.
section.
Page 1 of 2

CAMSHAFT SEAL
UID=G289921
Special Tool(s)
Flange Holding Wrench,
Universal
49 UN205 072
49 JE01 084
49 JE01 058
Name Specification
Engine Oil ACEA A1/B1 or ACEA A3/B3
Removal
section.
2. CAUTION: Install a suitable plastic

damage to the camshaft sprockets.
Remove the camshaft timing sprockets.
3. Using the special tool, remove the camshaft oil

seal.
 Discard the oil seal.
Installation
1. NOTE: Install a new camshaft oil seal.
NOTE: Coat the camshaft journals and
camshaft oil seal with clean engine oil.
seal.
Page 2 of 2

timing sprocket retaining bolts at this stage.
Make sure the camshaft sprockets turn on the
camshafts.
Install the camshaft timing sprockets.
section.
Page 1 of 10

TIMING BELT
UID=G289922
Special Tool(s)
Flange Holding Wrench Universal
49 UN205 072
Angle Gauge, Bolt Tightening
49 DO32 316
Alignment Tool, Camshaft
Alignment
49 JE01 054
Socket, Spark Plug
49 JE01 087
Timing Peg, Crankshaft TDC
49 JE01 061
Locking Tool, Crankshaft
49 JE02 024
General Equipment
Trolley jack
Name Specification
Silicone grease
Removal
All vehicles
1. Disconnect the battery ground cable. For
01.
2. Detach the power steering fluid reservoir from
the bracket and position it to one side.
3. Detach the coolant expansion tank from the

bracket and position it to one side.
Page 2 of 10
4. Loosen the water pump pulley retaining bolts.

05.
6. Remove the water pump pulley.
7. Remove the crankshaft pulley.
8. Remove the timing belt cover retaining bolts.

1. Remove the timing belt upper cover
retaining bolts.
2. Remove the timing belt lower cover
retaining bolts.
 Remove the lower cover.

10. Disconnect the generator electrical connector.
Page 3 of 10
11. Detach the generator from the engine.

1. Remove the bolts.
2. Remove the nut and the stud.
12. CAUTION: Do not support the engine

directly on the oil pan.
Place the trolley jack with a wooden block under
the engine and raise it slightly until the front
engine mount is free from strain.
13. Disconnect the ground cable from the engine
mount.
14. Remove the engine front mount.
 Discard the nuts.
15. Remove the valve cover. For additional

information, refer to Valve Cover in this
section.
16. Remove the timing belt upper cover retaining
bolts.
Page 4 of 10
17. Remove the engine front mount bracket

together with the timing belt upper cover.
18. Using the special tool, remove the spark

plugs.
Engines with eccentric cam timing belt tensioner

19. Slacken the timing belt tensioner and remove
the timing belt.
 Discard the timing belt.
20. Remove the timing belt tensioner.
Engines with slotted bracket timing belt tensioner

21. Remove the timing belt tensioner and the
timing belt.
Page 5 of 10
Installation
All vehicles
1. Turn the camshafts to TDC on cylinder number
1 and install the special tool.
2. CAUTION: Install a suitable plastic

damage to the camshaft pulleys.
NOTE: The camshaft pulleys must be free to
turn on the camshafts.
Loosen the camshaft pulley retaining bolts.
3. NOTE: Install a new timing belt.

NOTE: Install the timing belt, beginning with
the crankshaft timing pulley and work
counterclockwise.
Install the timing belt.
4. Install the timing belt lower cover.
5. Remove the blanking plug and install the

special tool.
 Carefully turn the crankshaft against the

special tool.
Page 6 of 10
6. NOTE: Install a new crankshaft pulley

retaining bolt.
Install the crankshaft pulley.
 Tighten the crankshaft pulley retaining bolt in

two stages.
 Stage 1: 40 Nm.

7. Install the timing belt tensioner.
8. Tension the timing belt.
 Tension the timing belt by turning the

tensioner counterclockwise until the arrow
points at the mark and tighten the bolt.

9. Install the timing belt tensioner and tension
the timing belt.
 Screw in the bolts finger tight.

tensioner clockwise until the arrow points in
line with the center of the rectangular hole
and tighten the bolt.
All vehicles
Page 7 of 10
CAUTIONS:
10. Install a suitable plastic hose to the

special tool studs, to prevent damage to the
camshaft pulleys.
Do not tighten the camshaft pulley bolts

against the timing plate.
NOTE: The camshafts must remain at TDC.
Using the special tool, tighten the camshaft
pulleys.
11. Remove special tool.
12. Remove the special tool.
13. NOTE: Only turn the engine in its normal

Turn the engine two revolutions.
14. Install the special tool.
 Carefully turn the crankshaft against the

special tool.
15. Check the valve timing.
 If necessary loosen the camshaft pulleys and

correct the camshaft alignment.
 Remove the special tool.
16. Remove the special tool from the cylinder

block.
17. Install the blanking plug.
Page 8 of 10
18. Using the special tool, install the spark plugs.
19. Install the timing belt upper cover retaining

bolts.
20. Install the front engine mount bracket.
 Position the timing belt upper cover.

bolts.
22. NOTE: Install new engine front mount

retaining nuts.
Install the engine front mount.
Page 9 of 10
23. Connect the ground cable to the engine front

mount.
24. Remove the trolley jack.

25. Install the valve cover. For additional
section.
26. Attach the generator.
1. Install the stud and nut.
2. Install the bolt.
27. Connect the generator electrical connector.

bolts.
Page 10 of 10
30. NOTE: Do not tighten the water pump

pulley retaining bolts at this stage.
Install the water pump pulley.
31. Install the accessory drive belt. For additional

32. Tighten the the water pump pulley retaining
bolts.
33. Attach the power steering fluid reservoir to

the bracket.
34. Attach the coolant expansion tank to the

bracket.
35. Connect the battery ground cable. For

01.
Vehicles with power windows

36. Initialize the driver door window motor. For
11.
Page 1 of 9

EXHAUST MANIFOLD
UID=G289923
General Equipment
Trolley jack
Exhaust wrap
Removal
01.
4. CAUTION: Over bending of the

exhaust flexible pipe may cause damage
resulting in failure.
Support the exhaust flexible pipe with a support
wrap or suitable splint.
5. Detach the exhaust flexible pipe from the

catalytic converter.
 Discard the gasket and the nuts.
6. Disconnect the catalyst monitor sensor

7. Remove the engine support insulator retaining

bolt.
Page 2 of 9
8. Detach the right-hand lower arm from the

wheel knuckle.
CAUTIONS:
9. Secure the halfshaft to prevent

damage to the constant velocity (CV) joints.
The inner CV joint must not be bent more
than 18 degrees. The outer CV joint must not
be bent more than 45 degrees.
Make sure that the halfshaft seal is not

damaged.
Cap the transaxle to prevent oil loss or

dirt ingress.
Detach the right-hand halfshaft together with the
intermediate shaft from the transaxle and
secure it to one side.
 Discard the center bearing cap and locknuts.

10. Remove the exhaust manifold lower heat
shield left-hand retaining bolts.

shield right-hand retaining bolts.
 Remove the lower heat shield.

Page 3 of 9

13. Disconnect the heated oxygen (HO2S) sensor
14. Detach the power steering line support

bracket from the cylinder head.

bracket from the power steering pump
bracket.

from the bracket and position it to one side.

Page 4 of 9

Using a trolley jackand a suitable wooden block
under the oil pan raise the engine so that the
engine front mount is free from load.
 Detach the ground cable from the engine

mount.
20. Using the trolley jack and lower the vehicle.

21. Remove the air cleaner support brackets.
22. Remove the exhaust manifold upper heat

shield.
23. Using a trolley jack positioned under the

engine crossmember, raise the engine.
24. NOTE: Do not tighten the engine front
mount retaining bolts and nuts at this stage.
Page 5 of 9
25. Remove the exhaust manifold retaining bolts

and the nuts.

27. Remove the exhaust manifold.
Installation
All vehicles
1. NOTE: Install a new exhaust manifold
gasket.
Attach the exhaust manifold to the cylinder head.
3. NOTE: Install new exhaust manifold
retaining nuts.
Install the exhaust manifold retaining bolts and
the nuts.

Using a trolley jackand a suitable wooden block
under the oil pan, raise the engine so that the
engine front mount is free from load.

Page 6 of 9
6. Using a trolley jack, lower the vehicle.

7. Install the exhaust manifold upper heat shield.
8. Using the trolley jack, raise the engine.

retaining nuts.
10. Attach the ground cable to the engine mount.
11. Remove the trolley jack.

bracket.

the bracket.
Page 7 of 9
14. Attach the power steering line bracket to the

cylinder head.
15. Attach the power steering line support

bracket to the power steering pump bracket.
16. Connect the heated oxygen (HO2S) sensor

electrical connector
17. Connect the HO2S electrical connector.

19. Position the exhaust manifold lower heat
shield and install the right-hand retaining bolt.
Page 8 of 9
20. Install the exhaust manifold lower heat shield

left-hand retaining bolts.
21. Install the engine support insulator retaining

bolt.
22. Connect the catalyst monitor sensor electrical

connector.

gasket and new nuts.
Attach the exhaust flexible pipe to the catalytic
converter.
CAUTIONS:

Page 9 of 9
Make sure that the halfshaft seal is not

damaged.
NOTE: Make sure that the center bearing heat
shield is correctly seated.
NOTE: Install a new center bearing cap and
locknuts.
Detach the right-hand halfshaft together with the
intermediate shaft to the transaxle.
25. Attach the right-hand lower arm to the wheel

knuckle.
26. Remove the exhaust flexible pipe support

wrap or splint.
01.

11.
Page 1 of 14

CYLINDER HEAD
UID=G289924
Special Tool(s)
Socket, Cylinder Head Bolts
49 JE01 057
Name Specification
oil Viscosity: 5W30, 10W40, 5W40
DEXELIA oil
Removal
1. Drain the cooling system. For additional
03B.
00.
01.
6. Using a suitable splint or wrap support the
exhaust flexible pipe.

8. Remove the engine support insulator retaining

bolt.
Page 2 of 14
9. Detach the lower arm from the wheel knuckle

on both sides (right-hand side shown).
CAUTIONS:

degrees.

or dirt ingress.
Detach the right-hand halfshaft and the

shield left-hand retaining bolts.

shield right-hand retaining bolts.
 Remove the lower heat shield.

Page 3 of 14

connector.
15. Detach the wiring harness and the coolant

hose from the intake manifold.
16. Detach the wiring harness from the intake

manifold.
17. Remove the intake manifold retaining bolt.
18. Detach the oil level indicator tube from the

intake manifold.
Page 4 of 14
19. Disconnect the brake booster vacuum line

from the intake manifold.
20. Disconnect the positive crankcase ventilation

(PCV) hose from the PCV.
21. Disconnect the evaporative emissions (EVAP)

hose from the EVAP valve.
22. Disconnect the engine wiring harness

23. Disconnect the EVAP valve electrical

connector.
Page 5 of 14
24. Disconnect the fuel supply line quick release

coupling. For additional information, refer to
Section 310-00.
25. Disconnect the fuel return line quick release

Section 310-00.
26. Detach the fuel line from the intake manifold

and position it to one side.
 Remove the cable tie.
27. Disconnect the coolant hose from the coolant

distribution assembly.

Page 6 of 14
29. Disconnect the degas hose from the cylinder

head.
30. Disconnect the electronic ignition (EI) coil


32. Detach the power steering line brackets from

the cylinder head.
33. Remove the camshafts. For additional

34. Using a trolley jack, lower the engine.
shield
Page 7 of 14
36. Detach the exhaust manifold and position it

to one side.
 Discard the nuts and the exhaust manifold

gasket.
37. Using a trolley jack, raise the engine.

38. Remove the timing belt rear cover (engine
shown removed for clarity).
CAUTIONS:
39. The cylinder head must have cooled

to below 30°C before removal.
Remove the cylinder head bolts in the

sequence shown.
Position the cylinder head on a soft

surface.
Using the special tool, remove the cylinder head
bolts.
 Remove the cylinder head bolts in the

sequence shown.
 Discard the cylinder head gasket.
Installation
All vehicles
Page 8 of 14
1. CAUTION: The thickness of the new

cylinder head gasket must be the same as
that of the old one (hole marked).
NOTE: Install a new cylinder head gasket.
NOTE: Position the cylinder head into the two
guide sleeves.
Using the special tool, install the cylinder head.
 Tighten the cylinder head bolts in the

sequence shown in tree stages.
 Stage 1: 15 Nm.
 Stage 2: 30 Nm.
2. Install the timing belt rear cover (engine

3. Install the camshafts. For additional

gasket and new exhaust manifold retaining
nuts.
Install the exhaust manifold.
5. Using a trolley jack, lower the engine.

6. Install the exhaust manifold upper heat shield.
7. Using a trolley jack, raise the engine.

8. Attach the power steering line bracket to the
cylinder head.
Page 9 of 14

 Attach the electrical connector to the bracket.
10. Connect the electronic ignition (EI) coil

11. Connect the degas hose to the cylinder head.
12. Connect the coolant hose to the coolant

13. Connect the coolant hose to the coolant

Page 10 of 14
14. Connect the fuel return line quick release

Section 310-00.
15. Connect the fuel supply line quick release

Section 310-00.
16. Attach the fuel line to the intake manifold.
 Install the cable tie.
17. Connect the evaporate emission (EVAP) valve

18. Connect the engine wiring harness electrical

connector.
Page 11 of 14
19. Connect the EVAP hose to the EVAP valve.
20. Connect the positive crankcase ventilation

(PCV) hose to the PCV.
21. Connect the brake booster vacuum line to the

intake manifold.
22. Attach the oil level indicator tube to the

intake manifold.
23. Install the intake manifold retaining bolt.

Page 12 of 14
24. Attach the wiring harness to the intake

manifold.
25. Attach the wiring harness and the coolant

hose to the intake manifold.

connector.

28. Position the exhaust manifold lower heat
shield and install the right-hand retaining
bolts.

left-hand retaining bolts.
Page 13 of 14
30. Install the engine support insulator retaining

bolt.

connector.

gasket and new exhaust manifold retaining
nuts.
converter.
33. Remove the exhaust flexible pipe support.

CAUTIONS:

degrees.

NOTE: Install a new center bearing cap and
locknuts.
NOTE: Make sure that the center bearing heat
shield is correctly seated.
Attach the right-hand halfshaft together with the
35. Attach the lower arm to the wheel knuckle on
both sides (right-hand side shown).
Page 14 of 14
 Install the heat shield.
36. NOTE: Install a new oil filter.

Change the engine oil.
01.
38. Fill and bleed the cooling system. For
03A / 303-03B.

11.
Page 1 of 2

OIL PAN
UID=G289925
General Equipment
Five M8 x 20 mm studs
Name Specification
Engine oil Engine oil Grade: ACEA A1/B1
or ACEA A3/B3 Viscosity:
5W30, 10W40, 5W40
Recommended oil: Mazda
genuine DEXELIA oil
Sealant (e.g.
Loctite 7070)
Silicone
rubber
sealant (low
viscosity)
Removal
2. Drain the engine and remove the oil pan.
1. Remove the oil drain plug.
2. Remove the oil pan retaining bolts.
Installation
CAUTIONS:
1. The oil pump gasket projects over the

cylinder block sealing surface and must not
be damaged.
Do not damage the rubber sealing

surface of the crankshaft rear oil seal carrier.
Clean the engine cylinder block and oil pan
mating faces.
2. CAUTION: The crankcase may be

damaged if sealant enters the blind holes.
Install five M8 x 20 mm studs into the blind holes
where shown.
3. NOTE: Install the oil pan within ten

Page 2 of 2
minutes of applying sealant and tighten the

bolts within a further 5 minutes.
Apply a 3-4 mm diameter bead of silicone rubber
sealant (low viscosity) to the oil pan flange.
4. NOTE: Align the oil pan flush with the

cylinder block at the transaxle end.
Install the oil pan.
 Tighten the oil pan retaining bolts in the

sequence shown in two stages.
 Stage 1: 10 Nm.
 Stage 2: 20 Nm.
 Remove the studs and install retaining bolts.
5. NOTE: Check the oil drain plug seal for

damage and install a new drain plug if
necessary.
Install the oil drain plug.
6. Fill the engine with engine oil.

Page 1 of 3

OIL PUMP
UID=G289926
Special Tool(s)
Installer, Crankshaft Seal
49 JE01 058
Removal
section.
2. Remove the crankshaft timing belt pulley.
3. Detach the air conditioning (A/C) compressor

from the cylinder block and position it to one
side.
4. Remove the oil pan. For additional information,

refer to Oil Pan in this section.
5. Remove the oil pump intake pipe.
6. Remove the oil pump.
 Remove and discard the crankshaft front seal.

Page 2 of 3
Installation
1. NOTE: Install a new oil pump gasket.
Install the oil pump.
2. NOTE: Install a new oil pump intake pipe

gasket.
Install the oil pump intake pipe.
3. NOTE: Install a new crankshaft front oil

seal.
Using the special tool, install the crankshaft front
oil seal.
4. Install the oil pan. For additional information,

5. Attach the air conditioning (A/C) compressor
to the cylinder block.
6. Install the crankshaft timing belt pulley.

section.
Page 3 of 3
Page 1 of 2

CRANKSHAFT REAR SEAL
UID=G289927
Special Tool(s)
Locking Tool, Flywheel
49 E011 1A0
Name Specification
Sealant (e.g. Loctite 7070)
Removal
1. Remove the clutch disc and pressure plate. For
01.
2. Using the special tool, remove the flywheel.
 Discard the bolts.
3. Remove the crankshaft rear oil seal carrier.
 Discard the crankshaft rear oil seal carrier.
Installation
1. Clean the crankshaft journal with sealant (e.g.
Loctite 7070).
2. NOTE: Install a new crankshaft rear oil
seal carrier.
NOTE: A new crankshaft rear oil seal carrier is
supplied with an alignment sleeve which must
be removed following installation.
NOTE: Do not lubricate the oil seal or
crankshaft journal.
Install the crankshaft rear oil seal carrier.
3. NOTE: Install new flywheel retaining bolts.

Using the special tool, install the flywheel.
 Tighten the bolts in the sequence shown in

two stages:
Page 2 of 2
 Stage 1: 30 Nm.
4. Install the clutch disc and pressure plate. For

01.
Page 1 of 14
REMOVAL 2003.50 Mazda2

ENGINE
UID=G289928
Special Tool(s)
Remover, Halfshaft
49 JE02 027
General Equipment
Engine hoist
Retaining straps
Workshop table
Removal
All vehicles
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always
present and may ignite. Failure to follow these instructions may result in personal injury.
00.
mount nuts by three turns on both sides.

03B.
6. Disconnect the degas hose from the coolant
expansion tank.

Page 2 of 14


Section 310-00.

Section 310-00.
11. Detach the fuel line and the degas line from
12. Disconnect the low pressure evaporate

emission (EVAP) hose from the EVAP valve.
Page 3 of 14
13. Detach the brake booster vacuum line from

14. Install the protective cap and disconnect the

generator electrical connectors.

connector.
16. Disconnect the coolant hoses from the heater

core.

connecting pipe.
Page 4 of 14

19. Disconnect the engine wiring harness

20. Disconnect the EVAP electrical connector.

22. Disconnect the knock sensor (KS) electrical
connector.

manifold.
Page 5 of 14

manifold.
25. Disconnect the A/C compressor electrical

connector.
26. Disconnect the oil pressure switch electrical

connector.

28. Disconnect the reversing lamp switch

electrical connector and detach the wiring
harness from the transaxle.
Page 6 of 14
29. Disconnect the starter motor electrical

connector.

 Discard the nuts and the gasket.
31. Disconnect the catalyst monitor sensor

32. Disconnect the cooling fan motor and cooling

fan resistor electrical connectors.
33. Remove the cooling fan motor and shroud.

1. Release the cooling fan motor and shroud
from the retaining brackets.
2. Push the cooling fan motor and shroud
upwards and then downwards to remove.
Page 7 of 14

36. Disconnect the engine ground cable.
37. Detach the engine wiring harness support

bracket.
38. Disconnect the electronic ignition (EI) coil


brackets from the cylinder head.
Page 8 of 14

brackets from the power steering pump
bracket.
41. Remove the oil level indicator and oil level

indicator tube.

05.
43. Disconnect the coolant hose from the
radiator.
44. Disconnect the coolant hose from the

distribution pipe.
45. Detach the A/C compressor from the cylinder

block and position it to one side.
Page 9 of 14
46. Detach the lower arm from the wheel knuckle

on both sides (right-hand side shown).
CAUTIONS:

degrees.

or dirt ingress.

CAUTIONS:

degrees.

or dirt ingress.
Using the special tool, detach the left-hand
halfshaft from the transaxle and secure it to
one side.

49. Detach the power steering hose from the
cylinder block.
Page 10 of 14


container.


container.
Vehicles with automated gearshift

52. Remove the gearshift actuator cover.
53. Disconnect the gearshift actuator electrical

connector (colored black).

connector (colored grey).
Page 11 of 14
55. CAUTION: If brake fluid is spilt on

the paintwork the affected area must be
Disconnect the clutch slave cylinder supply line.
 Remove the spring clip.
Vehicles without automated gearshift

57. Detach the gearshift cables from the

transaxle.
 Detach the gearshift cables and the selector

cable from the selector levers.
 Turn the abutment sleeve clockwise and

detach the cables from the bracket.
All vehicles

the paintwork the affected area must be

Page 12 of 14

Support the exhaust flexible pipe with a suitable
support wrap or suitable splint.
60. Remove the engine rear support insulator.
 Detach the catalyst monitor sensor retaining

bracket.

NOTE: Using suitable retaining straps, secure
the engine and the transaxle on a workshop
table.
Using suitable wooden blocks support the engine
and transaxle assembly.
62. Remove the battery tray support bracket.
63. Remove the engine rear mount.
64. Disconnect the ground cable from the engine

rear mount.
Page 13 of 14
66. Raise the vehicle and remove the engine and

transaxle assembly.
67. Attach the engine and transaxle assembly to
the engine hoist.
68. Remove the starter motor and the transaxle

left-hand retaining bolt.
69. Remove the transaxle right-hand retaining

bolt.
70. Remove the transaxle lower retaining bolts.

Page 14 of 14
71. Remove the transaxle from the engine.

Page 1 of 11
DISASSEMBLY 2003.50 Mazda2

ENGINE
UID=G289929
Special Tool(s)
Universal
Flange
Holding
Wrench
49
UN205
072
Locking
Tool,
Flywheel
49 E011
1A0
Socket,
Cylinder
Head
Bolt
49 JE01
057
Mounting
Stand
49 0107
680A
Mounting
Bracket
for 49
0107
680A
49 LO10
1A0
Socket,
Spark
Plug
49 JE01
087
General Equipment
Page 2 of 11
Retaining straps
Engine hoist
Oil filter strap wrench
Disassembly
All vehicles
01.
2. Loosen the crankshaft pulley retaining bolt.
3. Remove the flywheel.
4. Remove the crankshaft rear seal carrier.
 Discard the crankshaft rear seal carrier.
5. Remove the crankshaft position (CKP) sensor.
6. Remove the CKP sensor bracket.

Page 3 of 11
7. Using the special tool, mount the engine on

the mounting stand.
8. Remove the engine wiring harness.

9. Remove the exhaust manifold heat shield left-
hand retaining bolts.
10. Remove the exhaust manifold heat shield

right-hand retaining bolts.

shield.
12. Remove the catalytic converter.

Page 4 of 11
13. Drain the engine.
14. Using a suitable oil filter strap wrench,

remove the oil filter.
 Discard the oil filter.
16. Remove the generator.


Page 5 of 11
18. Remove the engine mount bracket stud.
19. Remove the timing belt upper cover retaining

bolts.
20. Remove the engine front mount bracket.
 Remove the timing belt upper cover.
21. Remove the fuel supply line and the fuel

return line.
Page 6 of 11
22. Disconnect the spark plug electrical

connectors and detach the wires from the
valve cover.
23. Remove the air cleaner retaining bracket.

24. Remove the valve cover.
25. Using the special tool, remove the spark

plugs.
 Discard the bolt.
27. Remove the timing belt lower cover.

Page 7 of 11

28. Slacken the timing belt tensioner.
29. Remove the timing belt tensioner and remove

the timing belt.

30. Remove the timing belt tensioner and remove
the timing belt.
All vehicles
31. CAUTION: Install a suitable piece of

damage to the camshaft pulleys.
Remove the camshaft pulleys.
32. Remove the crankshaft timing belt pulley.

Page 8 of 11
33. Remove the timing belt rear cover.
34. CAUTION: Keep the camshaft

bearing caps and the camshafts in order for
installation.
Remove the camshafts.
 Slacken each camshaft bearing cap retaining

bolt in the sequence shown by one turn until
the camshaft is released.
 Remove the camshaft bearing caps.
 Remove and discard the camshaft seals.

(PCV) hose from the PCV cover.
36. Remove the oil level indicator and oil level

indicator tube.
37. Remove the intake manifold lower bolts.

Page 9 of 11
CAUTIONS:
38. Place the cylinder head on a suitable

soft surface.
Remove the cylinder head bolts in the

sequence shown.
Using the special tool, remove the cylinder head.
40. Remove the thermostat housing.
41. Remove the knock sensor (KS).

Page 10 of 11
42. Remove the the PCV cover.
43. Remove the oil pan.
44. Remove the oil pump screen and pickup tube.
46. Attach the engine to an engine hoist.

Page 11 of 11

Page 1 of 15
ASSEMBLY 2003.50 Mazda2

ENGINE
UID=G289930
Special Tool(s)
Universal
Flange
Holding
Wrench
49 UN205
072
Angle
Gauge,
Bolt
Tightening
49 DO32
360
Locking
Tool,
Flywheel
49 E011
1A0
Timing
Plate,
Camshaft
Alignment
49 JE01
054
Socket,
Cylinder
Head Bolt
49 JE01
057
Installer,
Crankshaft
Oil Seal
49 JE01
058
Mounting
Stand
49 0107
680A
Mounting
Bracket
for 49
0107
680A
49 L010
Page 2 of 15
1A0
Socket,
Spark Plug
49 JE01
087
Timing
Peg,
Crankshaft
TDC
49 JE01
061
Locking
Tool,
Crankshaft
49 JE02
024
General Equipment
Five M8 x 20 mm studs
Engine hoist
Name Specification
Engine Oil ACEA A1/B1 or ACEA
A3/B3
Silicone rubber sealant
(Gel type)
Silicone rubber sealant
(Low viscosity)
Sealant
Silicone grease
All vehicles
11. Using the special tools, attach the cylinder
block (short block) to the mounting stand.
Page 3 of 15
12. NOTE: Install a new oil pump gasket.

13. NOTE: Install a new oil pump screen and

pickup tube gasket.
Install the oil pump screen and pickup tube.
14. Using the special tool, install the crankshaft

front oil seal.
15. CAUTION: The crankcase may be

damaged if sealant enters the blind holes.
Install five M8 x 20 mm studs into the blind holes
as shown.
16. NOTE: Attach the oil pan within ten

minutes of applying sealant and tighten the
bolts within a further five minutes.
Apply a 3-4 mm diameter thick bead of silicone
rubber sealant (Gel type) to the oil pan flange.
Page 4 of 15
17. NOTE: Align the oil pan so that the

cylinder block is flush with the oil pan on the
flywheel side.
Install the oil pan, loosely install the retaining
bolts.
 Remove the studs and install retaining bolts.
 Tighten the oil pan retaining bolts in the

sequence shown in two stages.
 Stage 1: 10 Nm.
 Stage 2: 20 Nm.
18. Install the positive crankcase ventilation
(PCV) cover.
19. CAUTION: The knock sensor (KS)

cable must not touch the cylinder head or the
PCV cover (approximately 10/11 o'clock
position).
Install the KS.
20. NOTE: Install a new thermostat housing

gasket.
Install the thermostat housing.
21. NOTE: Apply sealant to the oil pressure

switch threads.
Page 5 of 15
Install the oil pressure switch.
22. NOTE: Install a new water pump gasket.

Install the water pump.
23. Rotate the crankshaft to approximately 25

mm before top dead center (TDC) on cylinder
number 1.

that of the old one (hole marked).
NOTE: Position the cylinder head into the two
guide sleeves.

sequence shown in three stages.
 Stage 1: 15 Nm.
 Stage 2: 30 Nm.
25. Install the intake manifold lower retaining

bolts.
26. Install the oil level indicator and oil level

indicator tube.
Page 6 of 15
27. Connect the PCV hose to the PCV cover.
28. NOTE: Identification numbers are

provided on the outer face of the camshaft
bearing caps.
Apply silicone rubber sealant (Gel type) to the
points indicated on the camshaft bearing cap
no. 1 and to the mating surface of the cylinder
head.
29. Coat the camshafts and the camshaft bearing

caps with clean engine oil.
30. CAUTION: Position the camshafts in

place so that none of the cams are at full lift.
NOTE: The camshaft bearing cap numbering
starts at the timing belt end with E1 on the
exhaust side and with I1 on the intake side.
NOTE: The exhaust camshaft has an
additional cam for the camshaft position
(CMP) sensor.
Install the camshafts and camshaft bearing caps.
 Tighten the camshaft bearing cap retaining

bolts in the sequence shown in three stages.
 Stage 1: One half turn on each bolt until all of

the camshaft bearing caps are in contact with
the cylinder head.
 Stage 2: 7 Nm.
31. Coat the camshaft journals and camshaft seal
lips with clean engine oil.
Page 7 of 15
32. NOTE: Install new camshaft seals.

Using the special tool, install the camshaft seals.
33. Install the timing belt rear cover.
34. Rotate the camshafts to TDC on cylinder

number 1 and install the special tool.

timing pulley retaining bolts at this stage.
Make sure the camshaft pulleys turn on the
camshafts.
Install the camshaft timing pulleys.
36. Install the crankshaft timing belt pulley.
37. NOTE: Install a new timing belt.

NOTE: Install the timing belt, beginning with
the crankshaft timing pulley working
counterclockwise.
Page 8 of 15
39. Remove the blanking plug and install the

special tool.
 Carefully rotate the crankshaft against the

special tool.

retaining bolt.
 Tighten the crankshaft pulley retaining bolt in

two stages.
 Stage 1: 40 Nm.

special tool.

43. Install the timing belt tensioner.
Page 9 of 15


 Install the bolts finger tight.

All vehicles
CAUTIONS:
46. Install a suitable plastic hose to the

special tool studs.
Do not tighten the camshaft pulley bolts

against the timing plate.
Using the special tool, tighten the camshaft
pulleys.

Page 10 of 15
49. NOTE: Only rotate the crankshaft in its

normal direction of rotation.
Rotate the crankshaft two revolutions.

special tool.
51. Check the valve timing.
 If necessary loosen the camshaft pulleys and

correct the camshaft alignment.
54. Install the blanking plug.

Page 11 of 15
55. Adjust the valve clearances. For additional

information, refer to Valve Clearance
56. Using the special tool, install the spark plug.
57. Install the valve cover.

three stages.
 Stage 1: Tighten bolt 1 by 3 to 4 turns.
 Stage 2: Tighten bolts 1 through 13 to 3 Nm.

58. Install the air cleaner bracket.
59. CAUTION: Use a suitable blunt

object to avoid damage to the spark plug
connector gasket. Coat the inside of the spark
plug connector with silicone grease to a depth
of 5-10 mm.
Connect the spark plug electrical connectors and
attach the wires to the valve cover.
60. Install the engine front mount bracket.
 Position the timing belt upper cover.

Page 12 of 15

bolts.
62. Install the stud.
63. Install the water pump pulley.
64. Install the generator.

1. Install the nut and the stud.
2. Install the bolts.
Page 13 of 15
65. NOTE: Install a new oil filter.

Install the oil filter.
66. NOTE: Install a new catalytic converter

gasket and new catalytic converter.
Install the catalytic converter.
67. Install the exhaust manifold upper heat

shield.


Page 14 of 15
70. Install the engine wiring harness.

71. Attach the engine to an engine hoist.
73. Install the crankshaft position (CKP) sensor

bracket.
74. NOTE: Install a new crankshaft rear seal

carrier.
NOTE: A new crankshaft rear seal carrier is
supplied with an alignment sleeve which must
be removed following installation.
NOTE: Do not lubricate the crankshaft rear
seal lip.
Install the crankshaft rear seal carrier.
75. Install the CKP sensor.

Page 15 of 15
76. NOTE: Install new flywheel retaining

bolts.
Using the special tool, install the flywheel.

two stages.
 Stage 1: 30 Nm.

01.
Page 1 of 15
INSTALLATION 2003.50 Mazda2

ENGINE
UID=G289931
Special Tool(s)
49 JE02 053
General Equipment
Retaining straps
Workshop table
Engine hoist
Installation
All vehicles
1. Install the transaxle to the engine.
2. Install the transaxle lower retaining bolts.
3. WARNING: Support the engine and

transaxle assembly on wooden blocks and
secure it with suitable retaining straps.
in personal injury.
Using a engine hoist and suitable wooden blocks,
position the engine and transaxle assembly on
the workshop table.
4. Install the transaxle right-hand retaining bolt.
5. Install the starter motor and the transaxle left-

hand retaining bolt.
Page 2 of 15

7. Position the engine and transaxle assembly in
the engine compartment.
 Carefully lower the vehicle.

retaining nuts.
NOTE: Do not tighten the engine front mount
retaining bolts and nuts at this stage.
9. NOTE: Install new engine rear mount

retaining nuts.
NOTE: Do not tighten the engine rear mount
center retaining nut at this stage.
Install the engine rear mount.
10. Install the battery tray support bracket.

the paintwork, the affected area must be
NOTE: Make sure the spring clip is correctly
seated.
Page 3 of 15
Connect the clutch slave cylinder supply line.
 Install the spring clip.
12. Install the engine rear support insulator.
 Install the catalyst monitor sensor retaining

bracket.

connector.

14. Attach the gearshift cables to the bracket and
turn the abutment sleeves counterclockwise.

15. Connect the gearshift actuator electrical

Page 4 of 15
17. Install the gearshift actuator cover.
18. Connect the clutch slave cylinder supply line.
 Install the clip.
All vehicles
19. Connect the power steering pressure line to
the power steering pump.
20. Connect the power steering feed hose to the

21. Attach the power steering hose to the

cylinder block.
Page 5 of 15
CAUTIONS:

degrees.

seated.

the halfshaft.
CAUTIONS:

degrees.

attach the right-hand halfshaft and
intermediate shaft assembly to the transaxle.

the intermediate shaft.
24. NOTE: Install a new intermediate shaft
center bearing cap and locknuts.
Install the intermediate shaft center bearing cap.
1. Install the center bearing cap.
2. Attach the heat shield to the bearing cap (if
equipped).
3. Install the locknuts.
25. Attach the lower arm to the wheel knuckle on

both sides (right-hand side shown).
 Install the heat shield.

Page 6 of 15

to the cylinder block.
27. Install the cooling fan motor and shroud.

upwards and then downwards to install.
2. Install the cooling fan motor and shroud to
the retaining brackets.
28. Connect the cooling fan motor and cooling

29. Connect the coolant hose to the radiator.
30. Connect the coolant hose to the distribution

pipe.
Page 7 of 15
31. NOTE: Install new exhaust flange nuts

and a new exhaust flange gasket.
converter.

33. Connect the starter motor electrical
connector.
34. Connect the reversing lamp switch electrical

connector.
35. Connect the crankshaft position (CKP) sensor

36. Connect the oil pressure switch electrical

connector.
Page 8 of 15
37. Connect the knock sensor (KS) electrical

connector.
38. Connect the A/C compressor electrical

connector.

manifold.

manifold.

[Accessory Drive, REMOVAL AND
INSTALLATION, Accessory Drive Belt -
1.25L/1.4L/1.6L, Vehicles With: Air
Conditioning] For additional information, refer
to Section 303-05.[Accessory Drive, REMOVAL
Page 9 of 15
AND INSTALLATION, Accessory Drive Belt -

1.25L/1.4L/1.6L, Vehicles Without: Air
Conditioning]
42. Tighten the engine front mount retaining nuts
and bolts.
43. Attach the ground cable to the engine mount.
44. NOTE: Install a new engine rear mount

center retaining nut.
Tighten the engine rear mount center retaining
nut.

brackets to the cylinder head.

bracket to the power steering pump bracket.
47. Install the oil level indicator and oil level

indicator tube.
Page 10 of 15
48. Install the engine wiring harness support

bracket.
49. Connect the engine ground cable.
50. Install the cable ties.
51. Connect the electronic ignition (EI) coil

52. Connect the generator electrical connectors

and install the protective cap.
Page 11 of 15

connector.
54. Connect the evaporative emission (EVAP)


connector.

57. Connect the coolant hoses to the heater core.

Page 12 of 15
58. Using the special tool, connect the coolant

hose to the coolant distribution housing.
59. Attach the brake booster vacuum line to the

intake manifold.
60. Connect the low-pressure EVAP hose to the

EVAP valve.

Section 310-00.[Fuel System - General
Information, GENERAL PROCEDURES, Quick
Release Coupling]

coupling.For additional information, refer to
Release Coupling]
Page 13 of 15

bracket.

the bracket.
65. Connect the degas hose to the coolant

expansion tank.
66. Attach the fuel line and the degas line to the
intake manifold.

mount nuts on both sides.
Page 14 of 15
69. Install the battery tray. For additional

70. Fill the engine cooling system. For additional
information, refer to Section 303-03A.[Engine
Cooling - 1.25L/1.4L/1.6L, GENERAL
PROCEDURES, Cooling System Draining, Filling
and Bleeding]

72. Adjust the gearshift cables. For additional
information, refer to Section 308-00.[Manual
Transmission/Transaxle and Clutch - General
Gearshift Cable Adjustment]
73. Fill and bleed the clutch system. For
00.[Manual Transmission/Transaxle and Clutch
- General Information, GENERAL
PROCEDURES, Clutch System Bleeding]
74. CAUTION: The worldwide diagnostic

system (WDS) gearshift actuator bleed option
must be carried out if any part of the clutch
hydraulic system is opened or any new
components are installed.
NOTE: When the WDS gearshift actuator
bleed option is selected, the learn
transmission and learn clutch parameter
options will automatically be completed.
Information, GENERAL PROCEDURES, Clutch
System Bleeding - Vehicles With: Automated
Page 15 of 15
Gearshift]
All vehicles
11.[Glass, Frames and Mechanisms, GENERAL
PROCEDURES, Door Window Motor
Initialization]
Page 1 of 4

SPECIFICATIONS
UID=G289932
Engine Data
Description
Code F6JA
Firing order 1-3-4-2
Bore diameter 73.7 mm
Stroke 82 mm
Displacement 1399 cc
Compression ratio 18:1
Power output at 4000 rpm 50 kW (68 PS)
Torque at 2000 rpm 160 Nm
Idle speed 750 rpm
Lubricants, Fluids, Sealers and Adhesives
Item Specification
Engine Engine oil Grade: ACEA A1/B1 or ACEA A3/B3 Viscosity: 5W30, 10W40,
oil 5W40Recommended oil:Mazda genuine DEXELIA oil
Coolant Mazda genuine coolant (orange color) or a coolant meeting specification WSS-
M97B44-D
Sealer Silicone rubber sealant (Low viscosity)
Engine Oil Capacity
Description Liters
Initial fill including oil filter 4.20
Service fill including oil filter 3.80
Service fill without oil filter 3.40
Cylinder Block
Description mm
Cylinder bore diameter 73.700 - 73.716
Main bearings parent bore diameter 53.655 - 53.674
Main bearing clearance - radial 0.017 - 0.043
Main bearing clearance - axial 0.050 - 0.322
Pistons
Description mm
Piston diameter 73.520 - 73.536
Piston clearance in cylinder 0.164 - 0.196
Piston ring end gaps
— upper compression ring 0.200 - 0.350
— lower compression ring 0.200 - 0.400
— oil control ring 0.800 - 1.000
Piston ring gap position: The piston ring gaps must be distributed evenly around the
circumference of the piston. This also applies to the oil control ring elements. Align the piston
ring gaps at 120 degrees to each other.
Crankshaft
Page 2 of 4
Description mm
Main bearing journal end float 0.100 - 0.300
Main bearing journal diameter 49.962 - 49.981
Connecting rod bearing journal diameter 44.975 - 44.991
Connecting Rod
Description mm
Big end bore diameter 48.655 - 48.671
Small end bore diameter 25.000
Connecting rod bearing clearance 0.024-0.070
Piston Pin
Description mm
Piston pin length 59.700 - 60.000
Piston pin diameter 24.995 - 25.000
Camshaft
Description mm
Camshaft end float 0.195 - 0.300
Camshaft bearing journal diameter 23.959 - 23.980
Valves
Description mm
Valve stem to valve guide clearance — intake valve 0.103 - 0.118
Valve stem to valve guide clearance — exhaust valve 0.113 - 0.128
Cylinder Head
Description mm
Thickness of cylinder head gasket with piston protrusion of 0.618 - 1.252 (two notches)
0.725
Thickness of cylinder head gasket with piston protrusion of 0.726 - 1.303 (three
0.775 notches)
Thickness of cylinder head gasket with piston protrusion of 0.776 - 1.351 (one notch)
0.825
Thickness of cylinder head gasket with piston protrusion of 0.826 - 1.404 (four notches)
0.875
Thickness of cylinder head gasket with piston protrusion of 0.876 - 1.455 (five notches)
0.983
Maximum distortion — measured longitudinally and diagonally 0.025
Oil Pressure Specifications
Description bar
Oil pressure at idle speed 1.0 - 2.0
Oil pressure at 2000 rpm 2.3 - 3.7

Transaxle retaining bolts 47 35 -
Engine rear mount retaining bolts (M10) 48 35 -
Engine front mount retaining bolts 48 35 -
Engine roll restrictor to transaxle bolts 48 35 -
Page 3 of 4
Engine rear mount center nut (M12) 90 66 -

Engine roll restrictor to front axle crossmember bolts 48 35 -
Lower arm ball joint retaining nuts 52 38 -
Intermediate shaft centre bearing cap locknuts 25 18 -
Thermostat housing retaining bolts 7 - 62
Crankshaft pulley retaining bolt a) - -
Flywheel retaining bolts a) - -
Lower crankcase to cylinder block (Crankshaft main bearing cap retaining bolts) a) - -
Lower crankcase to cylinder block (M6) a) - -
Connecting rod bearing cap retaining bolts a) - -
Piston cooling oil spray nozzles 20 15 -
Fuel pump retaining bolts 22 16 -
Fuel pump support bracket retaining bolts 20 15 -
Fuel pump rear support bracket retaining bolts 10 - 89
Fuel pump pulley retaining nut 50 33 -
Noise vibration and harshness (NVH) shield retaining bolts 20 15 -
Fuel injector retaining forks 30 22 -
High pressure fuel supply line nuts to fuel injectors a) - -
High-pressure fuel supply line nuts to fuel injection supply manifold a) - -
Clutch disc and pressure plate retaining bolts 29 21 -
Fuel filter shield 2 - 18
Camshaft upper housing retaining bolts a) - -
Camshaft lower housing retaining bolts a) - -
Camshaft position sensor (CMP) retaining bolt 5 - 45
Timing belt idler pulley stud 7 - 72
Timing belt idler pulley nut 35 26 -
Timing belt tensioner retaining bolt 30 22 -
Brake vacuum pump retaining bolts 20 15 -
Camshaft pulley retaining bolt 43 31 -
Accessory drive belt tensioner retaining bolt 20 15 -
Accessory drive belt idler pulley 45 33 -
Power steering pump support bracket 19 14 -
Water pump retaining bolts 10 - 89
Oil pump pickup tube retaining bolts 7 - 62
Oil cooler retaining bolts 10 - 89
Oil pump retaining bolts 10 - 89
Oil pan drain plug 22 16 -
Oil pan studs 7 - 62
Oil pan retaining bolts and nuts 10 - 89
Oil pressure switch 30 22 -
Oil cooler 10 - 89
Cylinder head bolts a) - -
Timing belt upper cover 4 - 36
Timing belt lower cover 5 - 45
Exhaust manifold studs 8 - 72
Exhaust manifold retaining nuts 25 19 -
Glow plugs 8 - 72
Glow plug wiring loom 2 - 18
Generator front retaining bolts 40 30 -
Generator rear retaining bolts 39 29 -
Generator mounting bracket retaining bolts 19 14 -
Air conditioning compressor retaining bolt
Page 4 of 4
25 17 -
Air conditioning compressor bracket retaining bolt 19 14 -
Intake manifold assembly retaining bolts a) - -
Turbocharger retaining nuts 25 19 -
Turbocharger studs to exhaust manifold 10 - 89
Turbocharger oil return tube retaining bolts 10 - 89
Turbocharger oil supply line union bolt to turbocharger 27 19 -
Exhaust manifold heat shield retaining bolts 12 9 -
Crankshaft speed sensor retaining bolt 8 - 72
Starter motor retaining bolts 35 26 -
Exhaust flexible pipe to muffler and tailpipe assembly nuts 47 35 -
Exhaust flexible pipe clamp nut 47 35 -
Catalytic converter to turbocharger nuts 25 18 -
Turbocharger heat shield upper retaining bolts 3 - 27
Turbocharger heat shield lower retaining bolts 12 9 -
a) Refer to the procedure in this section.
Page 1 of 3

CRANKSHAFT FRONT SEAL
UID=G289933
Special Tool(s)
49 JE01 084
49 JE02 019
General Equipment
Trolley Jack
Wooden Blocks
Removal
section.
2. Install the engine front mount support bracket.
 Install the retaining bolts finger tight.
3. Install the engine front mount.

5. Remove the crankshaft pulley Woodruff key.

Page 2 of 3
front oil seal.
Installation
1. NOTE: A new crankshaft front oil seal is
supplied with an alignment and protection
sleeve that must be removed following
installation.
Using the special tool and the old crankshaft
pulley bolt, install the crankshaft front oil seal.
2. Install the crankshaft pulley Woodruff key.

Using a trolley jack and suitable wooden blocks,
support the engine.
6. Remove the engine front mount support

bracket.
Page 3 of 3

section.
Page 1 of 4

CAMSHAFT
UID=G289934
Special Tool(s)
49 UN20 5072
Guide Studs, Cylinder Head
49 JE02 007
Installer, Crankshaft Front Seal
49 B010 001
Name Specification
Engine Engine oil Grade: ACEA A1/B1 or
oil ACEA A3/B3 Viscosity: 5W30, 10W40,
5W40 Recommended oil: Mazda
genuine DEXELIA oil"
Removal
01.
03B.
3. Remove the intake manifold assembly. For
additional information, refer to Intake Manifold
in this section.
section.
5. Remove the brake vacuum pump. For
07.
6. CAUTION: Protect the generator with

lint-free material to prevent contamination.
Remove the coolant expansion tank.
Page 2 of 4
7. Using the special tool, remove the camshaft

pulley.
8. Remove the camshaft upper housing.
9. Remove the camshaft.
 Discard the seal.
Installation
1. NOTE: Do not damage the mating faces.
Using a suitable metal surface cleaner, clean the
mating faces of the camshaft upper and lower
housing.
CAUTIONS:
2. Make sure that the sealer does not

enter the camshaft lower housing blind holes.
damage to the camshaft lower housing.
Install the camshaft upper housing within

four minutes of applying the sealer.
Apply a 4 mm diameter bead of sealer to the
camshaft lower housing mating face.
Page 3 of 4
3. Coat the camshaft and the camshaft bearings

with clean engine oil.
4. CAUTION: Make sure that no piston is

at top dead centre (TDC).
NOTE: Only turn the engine in the normal
Install the camshaft.
5. Using the special tools, install the camshaft

upper housing.

two stages.
 Stage 1: 5 Nm.
 Stage 2: 10 Nm.
6. NOTE: A new camshaft oil seal is supplied

with an alignment and protection sleeve that
must be removed following installation.
seal.
 Remove and discard the alignment and

protection sleeve.
7. Using the special tool, install the camshaft

pulley.
8. Loosen the camshaft position (CMP) sensor.
9. NOTE: Turn the camshaft to align the

camshaft pulley position indicator with the
CMP sensor if necessary.
Using a feeler gauge, install and adjust the CMP
sensor.
Page 4 of 4
 XX = 1.2 mm between the CMP sensor and

the camshaft pulley postion indicator.

the camshaft pulley postion indicator, when a
new CMP sensor is installed.
10. Install the coolant expansion tank.
11. Install the brake vacuum pump. For

07.
section.
13. Install the intake manifold assembly. For
in this section.
03A / 303-03B.
01.
11.
Page 1 of 2

CAMSHAFT SEAL
UID=G289935
Special Tool(s)
49 UN20 5072
49 JE01 084
Installer, Camshaft Oil Seal
49 B010 001
Removal
section.
2. Using the special tool, remove the camshaft
pulley.
3. Using the special tool, remove the camshaft oil

seal.
Installation
1. NOTE: A new camshaft oil seal is supplied
with an alignment and protection sleeve that
must be removed following installation.
seal.
 Remove and discard the alignment sleeve.
2. Using the special tool, install the camshaft

pulley.
Page 2 of 2

section.
Page 1 of 12

TIMING BELT
UID=G289936
Special Tool(s)
Alignment Peg, Crankshaft
49 JE02 018
49 JE02 020
Alignment Peg, Camshaft
49 JE02 021
General Equipment
Trolley jack
Wooden blocks
Removal
CAUTIONS:
Never install a used timing belt.
Only install the timing belt after the engine has cooled to workshop temperature.
01.
03B.
4. Disconnect the coolant degas hose from the
coolant expansion tank.

coolant expansion tank bracket and secure it
to one side.
 Disconnect the coolant hose.
6. Disconnect the fuel temperature sensor

Page 2 of 12
7. Detach the wiring harness from the timing belt

upper cover.
8. Remove the timing belt upper cover.

05.
10. CAUTION: Make sure that the special

tool engages correctly.
Using the special tool, lock the flywheel.
 Turn the engine until the special tool fits into

one of the slots in the flywheel.

Page 3 of 12
13. Detach the crankshaft speed sensor wiring

harness from the timing belt lower cover.
15. CAUTION: Do not touch the outer

sensor ring.
Install the crankshaft pulley retaining bolt.

Using the special tool, align the camshaft.
 Turn the engine until the alignment hole in

the camshaft pulley is at the 2 o'clock
position.

19. Remove the timing belt guide.
Page 4 of 12

sensor ring.
Remove the crankshaft timing belt pulley.

Using a trolley jack with suitable wooden blocks
support the engine.

from the radiator grille opening panel and
position it to one side.

Page 5 of 12
27. Remove the engine front mount bracket.
28. Remove the timing belt.
Installation
1. NOTE: Do not tighten the timing belt
tensioner retaining bolt at this stage.
Install the timing belt tensioner.
CAUTIONS:
2. Never install a used timing belt.
Install the timing belt with the direction

arrows in the direction of engine rotation.
Only install the timing belt after the

engine has cooled to workshop temperature.
NOTE: Install a new timing belt.
Page 6 of 12
3. Install the engine front mount bracket.

retaining nuts.
5. Attach the power steering fluid reservoir to the

radiator grille opening panel.
6. Using the special tool, align the high pressure

fuel pump pulley (engine shown removed for
clarity) .
7. Make sure the high pressure fuel pump

alignment holes are in line (engine shown
8. Remove the special tool from the high

pressure fuel pump pulley (engine shown
Page 7 of 12
9. Make sure the camshaft alignment holes are in

line.

11. Check the correct position of the crankshaft
timing belt pulley Woodruff key.

sensor ring.
NOTE: Install the old crankshaft pulley bolt.
NOTE: Do not tighten the crankshaft pulley
bolt at this stage.
Install the crankshaft timing belt pulley.

sensor ring.
Using the special tool, align the crankshaft.

15. NOTE: Using an allen key, maintain
tension until the timing belt tensioner bolt is
tightened.
Page 8 of 12
Tension the timing belt (engine shown removed

for clarity).
1. Turn the timing belt tensioner adjustment
arm counterclockwise to tension the timing
belt slightly.
2. The pointer must be positioned between the
sides of the window.
3. Tighten the timing belt tensioner retaining
bolt.


sensor ring.
Remove the special tool from the crankshaft
timing belt pulley.
18. Install the timing belt guide.

Turn the engine ten revolutions.

sensor ring.

22. NOTE: If the special tools cannot be
installed repeat the engine timing steps.
Page 9 of 12
Install the special tool.

sensor ring.
timing belt pulley.

Install the special tool (engine shown removed for
clarity) .
25. Check that the high pressure fuel pump

alignment holes are in line (engine shown
 If the alignment holes are not in line, repeat

the engine timing steps.
26. Remove the special tool (engine shown


Page 10 of 12


sensor ring.
Remove the crankshaft pulley retaining bolt.
31. Attach the crankshaft speed sensor wiring

harness to the timing belt lower cover.
32. CAUTION: Make sure the special tool

engages correctly.
 Turn the engine until the special tool aligns

with one of the slots in the flywheel.

retaining bolt.
Page 11 of 12
 Tighten the crankshaft pulley bolt in two

stages.
 Stage 1: 30 Nm.
34. Remove the special tool from the flywheel.

36. Install the timing belt upper cover.
37. Attach the wiring harness to the timing belt

upper cover.
38. Connect the fuel temperature sensor


coolant expansion tank bracket.
 Connect the coolant hose.

Page 12 of 12
40. Connect the coolant degas hose to the


03A / 303-03B.
01.
11.
Page 1 of 11

CYLINDER HEAD
UID=G289937
Special Tool(s)
Gauge, Bolt Angle
49 D032 316
Mounting Plate for 49 0107 680A
49 L010 1A0
General Equipment
Name Specification
Sealer Silicone rubber sealant (low viscosity)
Removal
WARNINGS:
near any fuel related components. Highly flammable vapors are always present and may
in personal injury.
Do not carry out any repairs to the fuel injection system with the engine running. The
fuel pressure within the system is approximately 1600 bar. Failure to follow this
Wait at least one minute after the engine stops before commencing any repair to the
fuel injection system. Failure to follow this instruction may result in personal injury.
CAUTIONS:
Diesel fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working
with these components. Always install blanking plugs to any open orifices or lines.
Always carry out the cleaning process before carrying out any repairs to the fuel
injection system components to prevent foreign material entering the components.
1. Using datalogger in worldwide diagnostic
system (WDS), check that the fuel pressure
has dropped to zero and that the fuel
temperature is below 30°C.
01.
03B.
in this section.
Page 2 of 11

section.
6. Disconnect the brake booster vacuum line from
the brake vacuum pump.

8. Disconnect the camshaft position (CMP) sensor

10. CAUTION: Do not remove the two

screws either side of the circular cut-outs.
Failure to follow this instruction may cause
damage to the heat shield.
Remove the turbocharger heat shield (engine

circular cut-outs.
11. Remove the exhaust manifold
heat shield.
Page 3 of 11
12. Remove the camshaft housing assembly.
13. CAUTION: Keep the camshaft roller

followers in order for installation.
Remove the camshaft roller followers.
14. Detach the fuel pump rear bracket from the

cylinder head.
15. Detach the fuel pump bracket from the

cylinder head.
Page 4 of 11
16. Disconnect the exhaust gas recirculation

(EGR) vacuum hose from the EGR valve.
17. Detach the thermostat housing from the

cylinder head.
18. Remove the power steering pump rear

retaining bolt.
19. Detach the power steering pump from the

power steering pump support bracket.
20. Detach the power steering pump support

bracket from the cylinder head.
Page 5 of 11
21. Disconnect the oil supply line from the

turbocharger.
22. Disconnect the oil return tube from the

turbocharger.
23. Detach the turbocharger from the catalytic

converter.
24. Remove the fuel injectors. For additional

04B / 303-04C.
25. CAUTION: Remove the cylinder head

bolts in the sequence shown.
Remove the cylinder head.
 Discard the bolts and the gasket.
Installation
WARNINGS:
Page 6 of 11
near any fuel related components. Highly flammable mixtures are always present and
may ignite. Failure to follow these instructions may result in personal injury.
in personal injury.
CAUTIONS:
1. Using a suitable metal surface cleaner, clean
the mating faces of the cylinder head and
cylinder block.
2. Check the cylinder head for distortion. For
00.

that of the old one (hole/tooth marked).
Install a new cylinder head gasket.
4. CAUTION: Install new cylinder head

bolts.
Using the special tools, install the cylinder head.

three stages.
 Stage 1: 20 Nm.
 Stage 2: 40 Nm.

5. Install the fuel injectors. For additional
04B / 303-04C.
6. Attach the turbocharger to the catalytic
converter.
Page 7 of 11
7. Connect the oil return tube to the

turbocharger.
8. NOTE: Install new oil supply line sealing

washers.
Connect the oil supply line to the turbocharger
and measure the distance to the turbocharger
housing.
 XX = 15 mm
9. Attach the power steering pump support

bracket to the cylinder head.
10. Attach the power steering pump to the power

steering pump support bracket.
11. Install the power steering pump rear

retaining bolt.
Page 8 of 11
12. Attach the thermostat housing to the cylinder

head.
 Stage 1: 4 Nm.
 Stage 2: 7 Nm.
13. Connect the exhaust gas recirculation (EGR)

vacuum hose to the EGR valve.
14. Attach the fuel pump bracket to the cylinder

head.
15. Attach the fuel pump rear bracket to the

cylinder head.

cylinder head upper mating face and the
camshaft housing assembly lower mating face.
Page 9 of 11
17. Install the camshaft roller followers.
CAUTIONS:

enter the cylinder head blind holes. Failure to
follow this instruction may result in damage
to the cylinder head.
Install the camshaft housing assembly

within four minutes of applying the sealer.
Apply a 1.5 mm diameter bead of sealer to the
cylinder head upper mating face.
19. CAUTION: Make sure that no piston

is at top dead center (TDC).
Install the camshaft housing assembly.

two stages.
 Stage 1: 5 Nm.
 Stage 2: 10 Nm.

retaining screws.
Page 10 of 11
22. Install the turbocharger heat shield lower

retaining bolts (engine shown removed for
clarity).

cut-outs.

camshaft position (CMP) sensor if necessary.
Install and adjust the camshaft position (CMP)
sensor.

the camshaft pulley position indicator.

the camshaft pulley position indicator, when a

brake vacuum pump.
Page 11 of 11

section.
in this section.
03A / 303-03B.
01.
11.
Page 1 of 5

CRANKSHAFT REAR SEAL
UID=G289938
Special Tool(s)
Adapter
49 JE02 009
30317 Adapter
202A
49 JE02 010
Adapters
49 JE02 011
Gauge, Bolt Angle
49 D032 316
Remover, Crankshaft Seal
49 JE01 084
49 JE02 020
Installer, Crankshaft Rear Seal
49 JE02 023
Removal
All vehicles
01.


Vehicles with dual mass flywheel


Page 2 of 5
Vehicles without dual mass flywheel

All vehicles

rear oil seal.
Installation
All vehicles
Page 3 of 5

seal.
Position the crankshaft rear oil seal on the special
tool.
3. NOTE: A new crankshaft rear oil seal is

installation.
Using the special tools, install the crankshaft rear
oil seal.

protection sleeve.

4. NOTE: Install new flywheel bolts.
NOTE: Do not fully tighten the flywheel bolts
at this stage.
Install the flywheel.

at this stage.
All vehicles



Page 4 of 5
7. Using the special tool, tighten the flywheel

bolts.
 Tighten the bolts in the sequence shown, in

two stages.
 Stage 1: 30 Nm.

bolts.

two stages.
 Stage 1: 17 Nm.
All vehicles

Page 5 of 5
01.
Page 1 of 7

VALVE SEALS
UID=G289939
Special Tool(s)
Installer, Valve Stem Seal
49 JE01 041
49 JE01 043
49 JE01 047
49 JE01 046
Installer, Valve Stem Collets
49 JE01 053
Pliers, Valve Stem Seal
49 JE01 088
Name Specification
Hypoid Hypoid oil
oil
Sealer Silicone rubber sealant (Low
viscosity)
Removal
01.
03B.
in this section.
section.
5. Disconnect the vacuum hose from the brake
vacuum pump.
Page 2 of 7



Remove the turbocharger heat shield.
 Remove the retaining the bolts through the

circular cut-outs.
10. Remove the exhaust manifold heat shield.

Page 3 of 7

13. Position the appropriate piston at top dead

center (TDC).
14. Using the special tools, remove the valve
collets.
15. CAUTION: Keep the valve spring

retainers and the valve springs in order for
installation.
Remove the valve springs and the valve spring
retainers.
16. Using the special tool, remove the valve stem
seals.
 Discard the seals.

Page 4 of 7
Installation
1. Coat the valves with clean hypoid oil.
2. Install a valve stem protective sleeve over the
clarity).
3. NOTE: Only remove the valve stem

protective sleeve after the valve seals have
been installed.
NOTE: Install new valve seals.
Using the special tool, install the valve seals.
4. Remove the valve stem protective sleeves.

5. Install the valve springs and the valve spring
retainers.
6. Using the special tools, install the valve collets.

Page 5 of 7
CAUTIONS:


Apply a 4 mm diameter bead of sealer to the
cylinder head upper mating face.

is at top dead centre (TDC).

two stages.
 First stage: 5 Nm.
 Second stage: 10 Nm.


retaining screws.
Page 6 of 7

retaining bolts (engine shown removed for
clarity).

cut-outs.
14. NOTE: Do not tighten the camshaft

position (CMP) sensor at this stage.
Install the CMP sensor.

CMP sensor if necessary.
Using a feeler gauge, install and adjust the CMP
sensor.

the camshaft pulley position indicator.

the camshaft pulley position indicator, when a
Page 7 of 7
18. Connect the vacuum hose to the brake

vacuum pump.
19. Install the timing belt.

in this section.
03A / 303-03B.
01.
11.
Page 1 of 8

INTAKE MANIFOLD
UID=G289940
General Equipment
Removal
WARNINGS:
in personal injury.
fuel pressure within the system is approximately 1600 bars. Failure to follow this
CAUTIONS:
1. Using datalogger in worldwide diagnostic
01.
4. Detach the intake air resonator outlet pipe
from the intake manifold assembly.
5. Remove the intake air resonator outlet pipe

retaining bolt from the intake manifold
assembly.
Page 2 of 8
6. Remove the intake air resonator.
7. Disconnect the fuel injector wiring harness


from the fuel injectors.
9. Detach the glow plug wiring harness from the

fuel filter housing.
10. Detach the fuel filter housing from the intake

manifold assembly.
Page 3 of 8
11. Detach the fuel filter housing and position it

to one side.
12. Detach the positive crankcase ventilation

(PCV) hose from the intake manifold assembly.

14. Detach the exhaust gas recirculation (EGR)

tube from the cylinder block and the EGR
valve.
15. Remove the EGR tube.

Page 4 of 8
16. Detach the fuel temperature sensor manifold

17. Disconnect the fuel return line from the fuel

injector.
18. Detach the intake manifold assembly from

the cylinder head.
19. Remove the intake manifold assembly.
Installation
WARNINGS:
Page 5 of 8
in personal injury.
CAUTIONS:
1. CAUTION: Install the intake manifold

assembly bolts in the sequence shown.
NOTE: Install new intake manifold assembly
O-ring seals.
NOTE: Check the intake manifold assembly
seal for damage. Install a new seal if
necessary.
Install the intake manifold assembly.
 Tighten the bolts in the sequence shown.

2. Attach the intake manifold assembly to the
cylinder head.
3. Connect the fuel return line to the fuel injector.
4. Attach the fuel temperature sensor manifold to

the intake manifold assembly.
5. NOTE: Check the exhaust gas recirculation

(EGR) tube O-ring seal for damage. Install a
Page 6 of 8
new seal if necessary.

Install the EGR tube.
6. Attach the EGR tube to the cylinder block and

the EGR valve.
7. Connect the fuel temperature sensor electrical

connector.
8. Attach the positive crankcase ventilation (PCV)

hose to the intake manifold assembly.
9. Attach the fuel filter housing to the intake

manifold assembly.
10. Attach the fuel filter housing to the intake

manifold assembly.
Page 7 of 8
11. Attach the glow plug wiring harness to the

fuel filter housing.
12. Connect the fuel injector wiring harness to

the fuel injectors.
13. Connect the fuel injector wiring harness

14. Install the intake air resonator.
15. Install the intake air resonator outlet pipe

retaining bolt to the intake manifold assembly.
Page 8 of 8
16. NOTE: Make sure the intake air resonator

outlet pipe clamp is correctly seated.
Attach the intake air resonator outlet pipe to the
intake manifold assembly.

01.
11.
Page 1 of 14

ENGINE
UID=G289941
Special Tool(s)
Remover, Halfshaft
49 JE02 027
General Equipment
Securing straps
Workshop table
Engine hoist
Engine lifting bracket
All vehicles
WARNINGS:
in personal injury.
1. Using the datalogger in worldwide diagnostic
information, refer to Section 303-03B.[Engine
Cooling - 1.4L Diesel, GENERAL PROCEDURES,
Cooling System Draining, Filling and Bleeding]
4. Disconnect the exhaust gas recirculation (EGR)
control valve electrical connector.
5. Detach the EGR control valve from the battery

tray bracket and position it to one side.
Page 2 of 14
6. Detach the ground cable from the inner fender.
7. Disconnect the battery junction box electrical

connectors.
8. Disconnect the powertrain control module

(PCM) electrical connectors.
9. Disconnect the glow plug relay electrical

connector.
10. Detach the glow plug relay power supply

cables.
Page 3 of 14
11. Remove the battery tray bracket.

mount retaining nuts by three turns on both
sides.



Page 4 of 14
16. Remove the coolant expansion tank.
 Disconnect the coolant hoses.

thermostat housing.
19. Disconnect the rear coolant hose from the

thermostat housing.
20. Disconnect the lower front coolant hose from

the thermostat housing.
21. Using a suitable syringe, remove the power

steering fluid from the power steering fluid
reservoir.
Page 5 of 14

from the radiator grille opening panel.
23. Remove the power steering fluid reservoir.
 Disconnect the power steering line from the

reservoir.

steering pump.

bracket from the power steering pump.
CAUTIONS:

fluid.

Page 6 of 14

steering pump.
Cap the power steering fluid supply hose


2. Disconnect the union.
* Allow the fluid to drain into a suitable container.
* Discard the Teflon seal.
27. Detach the engine wiring harness from the

engine wiring harness bracket.
28. Disconnect the vacuum hose from the brake

vacuum pump.
29. Disconnect the EGR valve vacuum hose.
30. Disconnect the heater core return hose.
31. Disconnect the electric booster heater

Page 7 of 14

32. Detach the air conditioning (A/C) pressure
pipe bracket from the transaxle housing.
33. Disconnect the A/C dryer pressure switch

electrical connector (headlamp shown removed
for clarity).
All vehicles
34. Disconnect the fuel pump to fuel tank return
line quick release coupling. For additional
information, refer to Section 310-00.[Fuel
System - General Information, GENERAL
PROCEDURES, Quick Release Coupling]
35. Remove the fuel filter shield.
36. Clean the area around the fuel filter

connections and fuel lines. For additional
Page 8 of 14
information, refer to Section 303-04B.[Fuel

Charging and Controls - 1.4L Diesel, GENERAL
PROCEDURES, Fuel Injection Component
Cleaning]
37. Disconnect the fuel supply line from the fuel
filter. For additional information, refer to
Release Coupling]


40. Disconnect the power steering pressure


 Discard the gasket and nuts.

Page 9 of 14
43. Detach the exhaust front pipe from the


Diesel]

45. Disconnect the A/C compressor electrical
connector.
46. Detach the A/C compressor from the

mounting bracket and secure it to one side.

Page 10 of 14

transaxle.
1. Detach the gearshift cable and the selector
2. Turn the abutment sleeves clockwise and




Page 11 of 14
All vehicles
54. CAUTION: Protect the ball joint seal,

knuckle on both sides.
CAUTIONS:


or dirt ingress.
 Remove and discard the center bearing cap

and locknuts.

CAUTIONS:

damage to the CV joints. The inner CV joint
Page 12 of 14
outer CV joint must not be bent more than 45

degrees.

or dirt ingress.
one side.

57. Position a suitable workshop table under the
engine and transaxle assembly.

secure it with a suitable securing strap.
CAUTION: Do not support the engine

Carefully lower the vehicle until the engine and
transaxle assembly is supported by the
workshop table.
60. Detach the engine front mount from the

engine front mount bracket.

Page 13 of 14
62. Raise the vehicle and remove the engine and

transaxle assembly.
63. Using a suitable engine lifting bracket, attach
the engine and transaxle assembly to the
engine hoist.
 Remove the securing strap.
64. Disconnect the starter motor electrical

connectors.
65. Remove the starter motor lower retaining

bolt.
66. Remove the starter motor.
67. Remove the transaxle upper retaining bolts.
 Detach the engine wiring harness bracket

from the transaxle.

bolts.
Page 14 of 14
69. Remove the transaxle left-hand retaining

bolts.
70. CAUTION: Make sure that the fuel

pressure sensor electrical connector is not
damaged while moving the transaxle.
Remove the transaxle from the engine.
Page 1 of 24

ENGINE
UID=G289942
Special Tool(s)
Universal Flange Holding
Wrench
49 UN20 5072
Adapter
49 UN20 507202
Remover, Crankshaft Timing

Pulley
49 S120 215B
Remover, Crankshaft Seal
49 JE01 084
Mounting Stand
49 0107 680A
Mounting Bracket for 49 0107

680A
49 L010 1A0
30343 Mounting Plate
513A
49 L010 1A0
49 JE02 020
General Equipment
Engine hoist
Engine Lifting Bracket
Engine vacuum cleaner
Spatula
All vehicles
WARNINGS:
in personal injury.
CAUTIONS:
Page 2 of 24
Diesel fuel injection equipment is manufactured to very precise tolerances. It is

components. Always install blanking plugs to any open orifices or lines.
1. Drain the engine oil.

2. NOTE: The accessory drive belt idler pulley
is retained by the generator lower retaining
bolt.
Remove the generator lower retaining bolts and
the accessory drive belt idler pulley.
4. Remove the air conditioning (A/C) compressor

bracket.

Remove the turbocharger heat shield.

circular cut-outs.
6. Detach the catalytic converter from the

catalytic converter retaining brackets.
Page 3 of 24
8. Remove the catalytic converter retaining

brackets.
9. Remove the oil level indicator tube.
11. Using the special tools, secure the engine to

the mounting stand.
Page 4 of 24
12. Remove the engine lifting bracket from the

engine.
13. Remove the power steering

pump rear retaining bolt.
15. Remove the power steering

pump bracket.
Page 5 of 24
16. Detach the intake air resonator

outlet pipe from the intake
manifold assembly.
17. Remove the intake air resonator outlet pipe

retaining bolt from the intake manifold
assembly.
18. Remove the intake air resonator.
19. Remove the exhaust manifold

Page 6 of 24
heat shield.

from the fuel injectors.
21. Detach the fuel injector wiring

harness from the fuel filter
housing.
22. Detach the positive crankcase ventilation

(PCV) hose from the intake manifold assembly.

Page 7 of 24
injector.
24. Detach the fuel temperature sensor manifold

25. Disconnect the fuel supply line

quick release coupling from the
fuel filter. For additional
information, refer to
Section 310-00.
26. Disconnect the fuel supply line

quick release coupling from the
fuel pump. For additional
information, refer to
Section 310-00.
27. Detach the glow plug wiring

Page 8 of 24
harness from the fuel filter housing.
28. Detach the fuel filter housing

from the intake manifold
assembly.
29. Remove the fuel filter housing.

tube from the cylinder head and the EGR
valve.
31. Remove the EGR tube.

Page 9 of 24
32. Detach the intake manifold assembly from

the cylinder head.
33. Remove the intake manifold assembly.



Page 10 of 24
37. Remove the engine front mount

bracket.
38. Remove the timing belt upper

cover.
39. Remove the timing belt lower

Page 11 of 24
cover.
40. Remove the crankshaft speed sensor.
41. Remove the timing belt guide.

sensor ring.
Remove the crankshaft timing pulley.
Page 12 of 24
44. Remove the crankshaft timing pulley

Woodruff key.
45. Remove the timing belt idler

pulley.
46. Remove the camshaft position (CMP) sensor.

Page 13 of 24
48. Detach the coolant pipe assembly from the

thermostat housing.
49. Remove the coolant pipe

assembly.
50. Remove the noise vibration and harshness

(NVH) shield of the fuel supply manifold.
51. Using the engine vacuum cleaner , vacuum

foreign material from the high-pressure fuel
supply lines, the high-pressure fuel pump, the
fuel injectors and the fuel injection supply
manifold.
52. Clean the high-pressure fuel supply lines, the
fuel pump, the fuel injectors, the fuel injection
supply manifold and surrounding areas. For
Page 14 of 24

04A / 303-04B / 303-04C.
53. CAUTION: Make sure that the high-

pressure fuel supply line remains in contact
with both the fuel pump and the fuel injection
supply manifold until both unions have been
detached and cleaned.
Remove the high-pressure fuel supply line.
 Discard the high-pressure fuel supply lines.

with both the fuel injector and the fuel
injection supply manifold until both unions
have been detached and cleaned.
Detach the high-pressure fuel supply line unions
from the fuel injector and the fuel injection
supply manifold.

have been detached and cleaned.
Using the engine vacuum cleaner , vacuum
supply lines, the fuel injectors and the fuel
injection supply manifold.
56. Remove the high-pressure fuel supply lines.
 Discard the high-pressure fuel supply lines.

57. Install blanking plugs to the open threaded
ports on the fuel pump, the fuel injection
supply manifold and the fuel injectors.
injectors.
1. Remove the locking clip.
2. Pull the fuel return line out of the injector.
59. Clean the area around the fuel injector. For

04A / 303-04B / 303-04C.
60. Remove the fuel injectors and the clamps.

Page 15 of 24
61. Using the special tool, remove the high-

pressure fuel pump pulley retaining nut.
62. Using the special tool and suitable M7 bolts,

remove the high-pressure fuel pump pulley.
63. Detach the high-pressure fuel

pump from the cylinder head.
64. Remove the fuel pump.

Page 16 of 24
65. Remove the fuel pump support bracket.
66. Remove the thermostat

housing.

68. Disconnect the oil supply line from the

turbocharger.

Page 17 of 24
69. Remove the turbocharger oil

supply line.
70. Remove the turbocharger oil return tube.
71. CAUTION: Remove the cylinder head

Remove the cylinder head.
 Discard the bolts and the gasket.


Page 18 of 24
the slot in the flywheel.
73. CAUTION: Remove the clutch disc

and pressure plate bolts in the sequence
shown.
Remove the clutch disc and pressure plate.


All vehicles
77. Remove the turbocharger oil return tube.

Page 19 of 24
78. Remove the oil filter housing.
80. Remove the intermediate shaft center

bearing retaining bracket.
81. Remove the clutch housing cover.
82. Remove the oil pan retaining bolts and nuts.

Page 20 of 24
83. CAUTION: Do not distort the oil pan.

NOTE: Do not damage the mating faces.
Using a suitable spatula, remove the oil pan.
 Slide the spatula around the profile of the oil

pan.
84. Remove the oil pick up pipe.
85. Remove the oil level indicator tube.

front oil seal.

Page 21 of 24
89. Remove the main bearing bolt caps.
 Discard the caps.
90. Remove the engine bed plate rear retaining

bolts.
91. CAUTION: Remove the engine bed

plate outer retaining bolts in the sequence
shown.
Remove the engine bed plate outer retaining
bolts.
Page 22 of 24
92. CAUTION: Remove the main bearing

retaining bolts in the sequence shown.
Remove the engine bed plate.
93. CAUTION: Keep the main bearing

lower shells in order for installation.
Remove the main bearing lower shells.
94. Remove the crankshaft thrust half washers.

Page 23 of 24
95. CAUTION: Keep the connecting rod

bearing caps in order for installation.
Remove the connecting rod bearing caps.
96. CAUTION: Keep the connecting rod

bearing shells and connecting rod bearing cap
shells in order for installation.
Remove the connecting rod bearing shells and
connecting rod bearing cap shells.
97. Remove the crankshaft.
98. CAUTION: Keep the main bearing

upper shells in order for installation.
Remove the main bearing upper shells.
99. CAUTION: Keep the pistons in order

for installation.
Remove the pistons and connecting rods.
100. Remove the piston cooling jets.
Page 24 of 24
Page 1 of 8

SUBASSEMBLIES
CYLINDER HEAD
UID=G289943
Special Tool(s)
Installer, Valve Stem Oil Seal
49 JE01 041
49 JE01 043
49 JE01 046
49 JE01 047
Installer, Valve Stem Collets
49 JE01 053
Pliers, Valve Stem Oil Seal
49 JE01 088
General Equipment
Workshop table
Wooden blocks
Name Specification
oil ACEA A3/B3. Viscosity: 5W30, 10W40,
5W40. Recommended oil: Mazda
genuine DEXELIA oil
Hypoid Hypoid oil
oil
Disassembly
1. Using suitable wooden blocks, position the
cylinder head on a workshop table.
2. Remove the turbocharger lower retaining nuts.

Page 2 of 8
3. Remove the turbocharger.
4. Remove the exhaust manifold.
 Discard the nuts and the gasket.
5. Remove the exhaust manifold studs.
 Discard the studs.
6. Remove the engine rear lifting eye.
7. Remove the fuel pump rear support bracket.

Page 3 of 8
8. Remove the glow plug wiring harness.
9. Remove the glow plugs.
10. Remove the exhaust gas recirculation (EGR)

valve.
11. Remove the oil pressure relief valve.
12. Remove the fuel filter support nut.

Page 4 of 8
13. CAUTION: Keep the hydraulic lash

adjusters in order for installation.
Remove the hydraulic lash adjusters.
14. Using the special tools, remove the valve

collets.
15. CAUTION: Keep the valve spring

retainers and the valve springs in order for
installation.
Remove the valve springs and the valve spring
retainers.
16. Using the special tool, remove the valve stem

seals.
 Discard the seals.
17. CAUTION: Keep the valves in order

for installation.
Remove the valves.
Page 5 of 8
Assembly
2. Grind in the valves.
3. Using a suitable metal surface cleaner, clean
the valves.
5. Install the valves.
6. Install a valve stem protective sleeve over the

clarity).
7. NOTE: Install new valve stem seals.

NOTE: Only remove the valve stem protective
sleeve after the valve stem seals have been
installed.
NOTE: Coat the valve seals with clean engine
oil.
Using the special tool, install the valve stem
seals.
8. Remove the valve stem protective sleeves.

9. Install the valve springs and the valve spring
retainers.
Page 6 of 8
10. Using the special tools, install the valve

collets.
11. Install the hydraulic lash adjusters.
12. Install the fuel filter support nut.
13. Install the oil pressure relief valve.
14. NOTE: Install a new exhaust gas

recirculation (EGR) valve gasket.
Install the EGR valve.
Page 7 of 8
15. Install the glow plugs.
16. Install the glow plug wiring harness.
17. Install the fuel pump rear support bracket.
18. Install the engine rear lifting eye.

studs.
Install the exhaust manifold studs.
Page 8 of 8

retaining nuts.
NOTE: Install a new exhaust manifold gasket.
Install the exhaust manifold.
21. NOTE: Install new turbocharger upper

retaining nuts.
Install the turbocharger.
22. NOTE: Install new turbocharger lower

retaining nuts.
Install the turbocharger lower retaining nuts.
Page 1 of 35

ENGINE
UID=G289944
Special Tool(s)
Universal Flange Holding
Wrench
49 UN20 5072
Adapter for 49 UN20 5072
49 UN20 507202
Adapter
49 JE02 009
30317 Adapter
202A
49 JE02 010
49 JE02 011
Gauge, Bolt Angle
49 D032 316
Alignment Pins, Cylinder Head
49 JE02 012
Mounting Stand
49 0107 680A
Mounting Bracket for 49 0107

680A
49 L010 1A0
30343 Mounting Plate
513A
49 L010 1A0
Alignment Peg, Crankshaft
49 JE02 018
Installer, Crankshaft Front Seal
49 JE02 019
49 JE02 020
Alignment Peg, Camshaft

Page 2 of 35
49 JE02 021
Aligner, Connecting Rod

Bushing
49 JE02 033
Guide, Crankshaft Bearing
49 JE02 022
Installer, Crankshaft Rear Seal
49 JE02 023
Aligner, Clutch Disc
49 JE02 026
General Equipment
Drift
Engine hoist
Engine vacuum cleaner
Piston ring compressor
Workshop table
Name Specification
oil ACEA A3/B3 Viscosity: 5W30, 10W40,
genuine DEXELIA oil.
Hypoid Hypoid oil
oil
Sealer Silicone rubber sealant (Low
viscosity).
All vehicles
WARNINGS:
in personal injury.
CAUTIONS:
Diesel fuel injection equipment is manufactured to very precise tolerances. It is

components. Always install blanking plugs to any open orifices or lines.
Page 3 of 35

cylinder block lower mating face and the
engine bed plate upper mating face.
24. NOTE: Make sure the piston cooling jets

do not rotate during installation.
Install the piston cooling jets.
25. Coat the cylinder bores with clean engine oil.

26. NOTE: Install the pistons with the arrows
pointing to the front of the engine.
NOTE: The piston ring gaps and the oil supply
ring elements must be distributed evenly
around the circumference.
Using a suitable piston ring compressor, install
the pistons and connecting rods.
27. CAUTION: Install the connecting rod

shells in the correct order.
Using the special tools, install the connecting rod
shells.
28. Coat the main bearing journals, bearing

shells and thrust half washers with clean
engine oil.
29. Install the main bearing upper shells.
30. Position the crankshaft in the cylinder block.

Page 4 of 35
31. NOTE: The grooves in the thrust half

washers must face outwards.
Install the crankshaft thrust half washers into the
fourth main bearing with the oil grooves facing
outwards.
32. CAUTION: The mark of the

connecting rod and the connecting rod
bearing cap must be on the same side.
NOTE: Install new connecting rod bearing cap
bolts.
Install the connecting rod bearing caps.
 Tighten the bolts in four stages.
 Stage 1: 10 Nm.
 Stage 2: Loosen the bolts by 180 degrees.
 Stage 3: 10 Nm.
 After installation lubricate the main bearing

journals with clean engine oil.
33. CAUTION: Do not damage the engine

bed plate.
Using a suitable drift, press the 10 engine bed
plate dowels flush into the engine bed plate.
34. CAUTION: Install the main bearing

lower shells in the correct order.
Using the special tool, install the main bearing
lower shells to the engine bed plate.
CAUTIONS:

enter the cylinder block and the engine bed
plate blind holes. Failure to follow this
Page 5 of 35
engine.
Install the engine bed plate within four

minutes of applying the sealer.
Apply a 4 mm bead of sealer to the cylinder block
lower mating face.
36. CAUTION: Do not install the

crankshaft main bearing dowels of main
bearing number five.
Position the engine bed plate on the cylinder
block and using a suitable drift, press the
dowels into the cylinder block.
37. NOTE: Install new main bearing bolts.

Install the main bearing bolts.
38. Install the engine bed plate retaining bolts.

Page 6 of 35
39. Install the engine bed plate rear retaining

bolts.
40. Tighten the main bearing bolts.

three stages.
 Stage 1: Loosen the main bearing bolts by

180 degrees.
 Stage 2: 30 Nm.

Page 7 of 35
41. Tighten the engine bed plate outer retaining

42. Tighten the engine bed plate rear retaining

bolts.
Page 8 of 35
43. NOTE: Install new main bearing bolt

caps.
Install the main bearing bolt caps.

oil pump mating faces of the engine bed plate
and the cylinder block.
CAUTIONS:

enter the cylinder block and the engine bed
plate blind holes. Failure to follow this
engine.
Install the oil pump within four minutes

of applying the sealer.
Page 9 of 35
Apply a 4 mm bead of sealer to the mating faces

of the engine bed plate and the cylinder block.
46. Install the oil pump.

installation.
Using the special tool and the crankshaft pulley
bolt, install the crankshaft front oil seal.

protection sleeve.
48. Install the water pump.

two stages.
 Stage 1: 3 Nm.
 Stage 2: 10 Nm.
49. Install the oil level indicator tube.
50. NOTE: Install a new oil pump pick-up

tube gasket.
Install the oil pump pick-up tube.

Using a suitable metal surface cleaner , clean the
mating faces of the oil pan and the engine bed
plate.
Page 10 of 35
52. CAUTION: Install the oil pan within

Apply a 3 mm bead of sealer to the mating face
of the oil pan.
53. Install the oil pan (16 bolts, 2 nuts).
54. NOTE: Install a new oil drain plug seal.

55. Install the clutch housing cover.
56. Install the intermediate shaft center bearing

retaining bracket.
Page 11 of 35
57. Install the fuel supply manifold.
58. NOTE: Install a new oil filter housing

gasket.
Install the oil filter housing.
59. Install the turbocharger oil return tube.

seal.
Position the crankshaft rear oil seal on the special
tool.
Page 12 of 35

installation.
Using the special tools, install the crankshaft rear
oil seal.

protection sleeve.

at this stage.

at this stage.
All vehicles

Page 13 of 35



bolts.

two stages.
 Stage 1: 30 Nm.

bolts.

two stages.
 Stage 1: 17 Nm.
All vehicles
Page 14 of 35
69. NOTE: Check the correct orientation of

the clutch disc.
Using the special tool, centralize the clutch disc
on the clutch pressure plate.
70. CAUTION: Tighten the clutch

pressure plate retaining bolts finger tight and
then evenly by two turns at a time in the
sequence shown to the specified torque.
NOTE: Install new clutch pressure plate
retaining bolts.
Using the special tool, install the clutch disc and
pressure plate.

that of the old one (hole/tooth marked).
Install the cylinder head gasket.
74. NOTE: Install new cylinder head bolts.


sequence shown, in three stages.
 Stage 1: 20 Nm.
Page 15 of 35
 Stage 2: 40 Nm.
75. Install the turbocharger oil return tube.
76. NOTE: Install new oil supply tube sealing

washers.
Install the turbocharger oil supply tube.
77. NOTE: Install new oil supply line sealing

washers.
Connect the oil supply line to the turbocharger
and measure the distance to the turbocharger
housing.
 XX = 15 mm.
79. NOTE: Check the

thermostat housing seal for
damage. Install a new seal if
necessary.
Install the thermostat housing.
Page 16 of 35
 Stage 1: 4 Nm.
 Stage 2: 7 Nm.
80. Install the fuel pump support bracket.
81. NOTE: Support the high-pressure fuel

pump.
NOTE: Do not tighten the high-pressure fuel
pump retaining bolts at this stage.
Install the high-pressure fuel pump.
82. Attach the high-pressure fuel

pump to the cylinder head.
83. Tighten the high-pressure fuel pump

Page 17 of 35
retaining bolts.
84. Using the special tools, install the fuel pump

pulley.
85. Clean the area around the fuel injectors. For

04A / 303-04B / 303-04C.
86. NOTE: Install new fuel injector clamp
retaining bolts.
Remove the blanking plugs from the fuel injector
nozzles and install the fuel injectors and the
clamps.
 Discard the blanking plugs.
87. Connect the fuel return line to the fuel

injectors.
1. Push the fuel return line into the injector.
2. Install the locking clip.
88. Remove the blanking plugs from the open

threaded ports on the fuel injectors and the
fuel injection supply manifold.
CAUTIONS:
89. Do not allow the unions to hit the

ends of the high-pressure fuel supply line.
Remove the blanking plugs from the

high-pressure fuel supply line, the fuel
injector and the fuel injection supply manifold
at the last possible moment to prevent
foreign material entering the components.
Page 18 of 35
Make sure the tool used to tighten the

high-pressure fuel supply line unions is used
at the top of the unions as this is where there
is most material.
NOTE: Install the new high-pressure fuel
supply lines.
NOTE: Maintain pressure on the high-
pressure fuel supply line to keep the line in
contact with the fuel injector cone and fuel
injection supply manifold while installing the
unions.
NOTE: If it is not possible to correctly install
the new high-pressure fuel supply line, it will
be necessary to remove the remaining high-
pressure fuel supply lines and to loosen the
fuel injection supply manifold to allow correct
alignment.
Install the high-pressure fuel supply lines.
 Tighten the unions in two stages.
 Stage 1: 17 Nm.
 Stage 2: 22 Nm.

CAUTIONS:
90. Do not allow the unions to hit the

ends of the high-pressure fuel supply line.

high-pressure fuel supply line, the fuel pump
and the fuel injection supply manifold at the
last possible moment to prevent foreign
material entering the components.

is most material.
NOTE: Install new high-pressure fuel supply
line.
contact with the fuel injector pump and the
fuel injection supply manifold while installing
the unions.
alignment.
Install the high-pressure fuel supply line.
Page 19 of 35
 Tighten the unions in two stages.
 Stage 1: 17 Nm.
 Stage 2: 22 Nm.

91. Install the noise, vibration and harshness
(NVH) shield of the fuel supply manifold.
92. Install the coolant pipe

assembly.
93. Attach the coolant pipe assembly to the

thermostat housing.

CAUTIONS:
Page 20 of 35


Apply a 1.5 mm bead of sealer to the cylinder
head upper mating face.

is at top dead center (TDC).

two stages.
 Stage 1: 5 Nm.
 Stage 2: 10 Nm.
97. Install and adjust the camshaft position
(CMP) sensor.

the camshaft pulley flag.

the camshaft pulley flag, if a new CMP sensor
is installed.
98. Install the timing belt idler

pulley.
99. NOTE: Do not tighten the

timing belt tensioner retaining
bolt at this stage.
Install the timing belt tensioner.
Page 21 of 35
100. Using the special tool, align the high

pressure fuel pump pulley.
101. Make sure the high pressure pump

alignment holes are in line.
102. Make sure the camshaft alignment holes are

in line.
103. Install the crankshaft timing pulley

Woodruff key.
Page 22 of 35

sensor ring.
NOTE: Install the old crankshaft pulley bolt.
NOTE: Do not tighten the crankshaft pulley
bolt at this stage.
Install the crankshaft timing belt pulley.

sensor ring.
CAUTIONS:
106. Never install a used timing belt.
Install the timing belt with the direction

arrows in the direction of engine rotation.
NOTE: Install a new timing belt.
107. NOTE: Use an Allen key, maintain
tension until timing belt tensioner bolt is
tightened.
Tension the timing belt.
1. Turn the timing belt tensioner adjustment
arm counterclockwise to tension the timing
belt slightly.
2. The pointer must be positioned between the
sides of the window.
3. Tighten the timing belt tensioner retaining
bolt.

sensor ring.
timing belt pulley.
Page 23 of 35
109. Install the timing belt guide.
110. NOTE: Only turn the engine in the

Turn the engine ten revolutions.

sensor ring.


sensor ring.
timing belt pulley.
Page 24 of 35

115. Check that the high-pressure fuel pump

alignment holes are in line.
 If the high-pressure fuel pump alignment

holes are not in line, repeat the engine timing
steps.

sensor ring.
Remove the crankshaft pulley retaining bolt.

Page 25 of 35
119. Install the crankshaft speed sensor.
121. Install the timing belt upper

cover.
Page 26 of 35
122. Install the engine front mount

bracket.

special tool engages correctly.


retaining bolt.
 Tighten the bolt in two stages.
 Stage 1: 30 Nm.

Page 27 of 35
126. NOTE: Install new intake manifold

assembly O-ring seals.
NOTE: Check the intake manifold assembly
seal for damage. Install a new seal if
necessary.
Install the intake manifold assembly.
127. Attach the intake manifold assembly to the

cylinder head.
128. NOTE: Check the exhaust

gas recirculation (EGR) tube O-
ring seal for damage. Install a
new seal if necessary.
Install the EGR tube.
129. Attach the EGR tube to the cylinder block

and the EGR valve.
Page 28 of 35
130. Install the fuel filter housing.
131. Attach the fuel filter housing to

the intake manifold assembly.
132. Attach the glow plug wiring

harness to the fuel filter housing.
133. Connect the fuel supply line

Page 29 of 35
quick release coupling to the high-

pressure fuel pump. For
additional information, refer to
Section 310-00.
134. Connect the fuel supply line

quick release coupling to the fuel
filter. For additional information,
135. Attach the fuel temperature sensor manifold

to the intake manifold assembly.
136. Connect the fuel return line to the fuel

injector.
137. Attach the positive crankcase ventilation

Page 30 of 35
(PCV) hose to the intake manifold assembly.
138. Attach the fuel injector wiring harness to

the fuel filter housing.
139. Connect the fuel injector wiring harness to

the fuel injectors.
140. NOTE: Check the intake air resonator O-

ring seal for damage. Install a new O-ring
seal if necessary.
Install the intake air resonator.
141. Install the intake air resonator outlet pipe

retaining bolt.
142. NOTE: Make sure the

intake air resonator outlet pipe
clamp is correctly seated.
Attach the intake air resonator
outlet pipe to the intake manifold
assembly.
Page 31 of 35
143. Install the power steering

pump bracket.
144. Install the power steering pump.
145. Install the power steering

pump rear retaining bolt.
Page 32 of 35
146. Attach the engine lifting bracket to the

engine hoist and the engine.
147. Remove the engine from the mounting

stand.
149. NOTE: Install a new oil level indicator

tube O-ring seal.
Install the oil level indicator tube.
Page 33 of 35
150. Install the catalytic converter retaining

brackets.
151. Install the catalytic converter.
152. Attach the catalytic converter to the

catalytic converter retaining brackets.

retaining screws.
Page 34 of 35

retaining bolts.

cut-outs.
156. Install the air conditioning

(A/C) compressor bracket.
157. Install the generator.
158. NOTE: The accessory drive

Page 35 of 35
belt idler pulley is retained by

the generator lower retaining
bolt.
Install the generator lower retaining
bolts and the accessory drive belt
idler pulley.

Page 1 of 15

ENGINE
UID=G289945
Special Tool(s)
49 JE02 005
49 JE02 053
General Equipment
Workshop table
Engine hoist
Securing strap
Name Specification
Manual Manual transmission oil SAE
transmission 75W90 or transmission oil
oil meeting WSD-M2C200-C
specification.
All vehicles
WARNINGS:
in personal injury.
CAUTIONS:
1. Make sure that the fuel pressure

sensor electrical connector is not damaged
while moving the transaxle.
Make sure that the two locating dowels

are installed.
Install the transaxle to the engine.
2. Install the transaxle left-hand retaining bolts.
3. Install the transaxle right-hand retaining bolts.

Page 2 of 15
4. Install the transaxle upper retaining bolts.
 Attach the engine wiring harness bracket to

the transaxle.
5. Install the starter motor.
6. Install the starter motor lower retaining bolt.
7. Connect the starter motor electrical

connectors.

secure it with a suitable securing strap.
CAUTION: Do not support the engine

Page 3 of 15

Position the engine and transaxle assembly on
the workshop table.
9. Detach the engine lifting bracket from the

engine hoist and the engine and transaxle
assembly.
10. Position the workshop table under the

vehicle.
11. Carefully lower the vehicle until the engine
and transaxle assembly is in the position to
install the engine mounts.
retaining nuts.
NOTE: Do not tighten the engine front mount
retaining bolts and nuts at this stage.
13. NOTE: Do not tighten the engine rear

mount retaining nuts at this stage.
NOTE: Install new engine rear mount
retaining nuts.
14. Detach the engine and transaxle assembly

from the workshop table.
 Remove the securing strap.

Page 4 of 15

16. Remove the workshop table.
CAUTIONS:

degrees.

seated.

the halfshaft.
CAUTIONS:

degrees.


equipped).
20. CAUTION: Make sure the heat shield

is installed to prevent damage to the ball
joint.
NOTE: The lower arm pinch bolt must be
installed from the rear of the wheel knuckle.
Page 5 of 15




Page 6 of 15

to the A/C compressor bracket.
28. Connect the A/C compressor electrical

connector.
All vehicles
[Accessory Drive, REMOVAL AND
Diesel]
converter.
Page 7 of 15
31. Attach the exhaust front pipe to the exhaust

hanger insulator.
33. Connect the power steering pressure switch


seated.
36. Tighten the engine front mount retaining nuts

and bolts.
Page 8 of 15
37. Tighten the engine rear mount outer

retaining nuts.
38. Tighten the engine rear mount center

retaining nut.
39. Connect the fuel supply line to the fuel filter.

Release Coupling]
40. Install the fuel filter shield.
41. Connect the fuel pump to fuel tank return

line. For additional information, refer to
Release Coupling]
Page 9 of 15

42. Connect the A/C dryer pressure switch
for clarity).
43. Attach the A/C pressure pipe bracket to the

transaxle housing.
All vehicles
44. Connect the electric booster heater electrical
connector.
45. Connect the heater core return hose.
46. Connect the exhaust gas recirculation (EGR)

valve vacuum hose.
Page 10 of 15
47. Connect the vacuum hose to the brake

vacuum pump.
48. Attach the engine wiring harness to the

engine wiring harness bracket.

pump to steering gear pressure line, install a
new Teflon seal.
onto the power steering pump to steering gear
pressure line union, if necessary.
install the new Teflon seal.
50. CAUTION: Cover the generator with

a suitable cloth to prevent the ingress of
power steering fluid.
Connect the power steering line to the power
steering pump.
2. Connect the union.

bracket to the power steering pump.
Page 11 of 15
52. Attach the wiring harness to the power

steering pump.
53. Connect the power steering line to the power

steering fluid reservoir.

the radiator grille opening panel.
55. Connect the lower front coolant hose to the

thermostat housing.
56. Connect the rear coolant hose to the

thermostat housing.
Page 12 of 15

thermostat housing.

 Connect the coolant hoses.

61. NOTE: Install the cooling fan motor and

shroud from the underside of the vehicle.
Install the cooling fan motor and shroud.

Page 13 of 15

mount retaining nuts on both sides.
65. Attach the glow plug relay power supply

cables.
66. Connect the glow plug relay electrical

connector.
67. Connect the powertrain control module (PCM)

electrical connectors.
Page 14 of 15
68. Connect the battery junction box electrical

connectors.
69. Attach the ground cable to the inner fender.
70. Attach the EGR control valve to the battery

tray bracket.
71. Connect the EGR control valve electrical

connector.


Page 15 of 15


Gearshift]
All vehicles
03B.[Engine Cooling - 1.4L Diesel, GENERAL
and Bleeding]
78. With the vehicle on a level surface, fill the
transaxle with manual transmission oil until
the level is just below the filler hole.
Initialization]
Page 1 of 4

ENGINE COOLING
UID=G289946
- Coolant leak(s) - Fuse(s)
- Coolant level - Relay(s)
- Air in system - Wiring harness
- Gaskets/seals - Electrical connector(s)
- Hose(s)/hose joints - Cooling fan motor
- Coolant expansion tank pressure - Engine coolant temperature

cap and seal (ECT) sensor
- Coolant expansion tank - Powertrain control module

(PCM)
- Radiator
- Water pump
- Thermostat
- Thermostat housing
- Accessory drive belt

Symptom Chart
Symptom Chart

Loss of coolant *Hose(s)/hose joint *INSPECT the hoses and hose joints. INSTALL a
(s). new hose(s) as necessary.
*Radiator. *INSPECT the radiator for leaks. CARRY OUT the
Pressure Test Component Test in this section.
INSTALL a new radiator as necessary. REFER to
Radiator in this section.
*Water pump. *INSPECT the water pump for leaks. CARRY OUT
the Pressure Test Component Test in this section.
Page 2 of 4
INSTALL a new water pump or water pump gasket

as necessary.
*Thermostat *INSPECT the thermostat housing for leaks.
housing. CARRY OUT the Pressure Test Component Test in
this section. INSTALL a new thermostat housing
or thermostat housing gasket as necessary.
REFER to Thermostat in this section.
*Coolant expansion *CHECK the coolant expansion tank pressure cap
tank pressure cap for tightness. If OK, CARRY OUT the Coolant
or seal. Expansion Tank Pressure Cap Pressure Test
Component Test in this section.
*Coolant expansion *INSPECT the seal face on the coolant expansion
tank. tank for damage. INSTALL a new coolant
expansion tank as necessary.
*Heater core. *CHECK the heater core for leaks. REFER to
Section 412-02A / 412-02B.
*Engine. *INSPECT the engine, cylinder head, cylinder block
and cylinder head gasket. REFER to Section 303-
00.
The engine *Coolant *CHECK the coolant level. REFILL the cooling
overheats (signs of level/condition. system as necessary. REFER to Cooling System
coolant boiling) Draining, Filling and Bleeding in this section.
*CHECK the coolant condition. If the coolant is in
poor condition drain and refill with new coolant.
REFER to Cooling System Draining, Filling and
Bleeding in this section.
*Coolant *REFER to Specification - in this section.
concentration.
*Cooling system *CARRY OUT the Coolant Expansion Tank Pressure
does not hold Cap Pressure Test Component Test in this
pressure. section.
-INSPECT the coolant expansion tank for damage.
INSTALL a new coolant expansion tank as
necessary.
-INSPECT the water pump or water pump gasket
for damage. INSTALL a new water pump or
water pump gasket as necessary.
-INSPECT the engine, cylinder head, cylinder block
and cylinder head gasket. REFER to
Section 303-00.
*Radiator. *INSPECT the radiator for blockage or damage.
CARRY OUT the Pressure Test Component Test in
this section. INSTALL a new radiator as
necessary. REFER to Radiator in this section.
*Air in system. *BLEED the cooling system. REFER to Cooling
System Draining, Filling and Bleeding in this
section.
*Radiator grille. *INSPECT the radiator grille for air restrictions or
damage. REPAIR or INSTALL new parts as
Page 3 of 4
necessary.
*Water pump. *CARRY OUT the Pressure Test Component Test in
this section. INSPECT the water pump for leaks.
INSTALL a new water pump or water pump
gasket as necessary.
*Thermostat. *CARRY OUT the Thermostat Test Component Test
in this section. INSTALL a new thermostat as
necessary. REFER to Thermostat in this section.
*Accessory drive *CHECK the accessory drive belt for correct
belt. operation. REFER to Section 303-05.
*Cooling fan motor. *CHECK the operation of the cooling fan motor.
REFER to WDS.
00.
The engine does not *Thermostat. *CARRY OUT the Thermostat Test Component Test
reach normal in this section. INSTALL a new thermostat as
operating necessary. REFER to Thermostat in this section.
temperature. *Engine coolant *CHECK the operation of the ECT. REFER to WDS.
temperature (ECT)
sensor.
Component Tests
Pressure Test
WARNING: When releasing the system pressure, cover the expansion tank cap with a
thick cloth to prevent the possibility of coolant scalding, Failure to follow this instruction
2. Install the pressure tester to the coolant expansion tank.
3. Pressurize the system to the coolant expansion tank cap release pressure. REFER to
Specification - in this section.
4. Observe the cooling system pressure tester gauge reading for approximately two minutes.
The pressure should not drop during this time. If the system holds pressure, proceed to step
6. If the system does not hold pressure, check it thoroughly for coolant leaks.
5. Check the engine for coolant leaks REFER to Section 303-00. Drain the cooling system,
repair any coolant leaks found and fill and bleed the cooling system as necessary. REFER to
Cooling System Draining, Filling and Bleeding in this section.
6. Recheck the system by repeating steps 3 and 4 at least twice.
Thermostat
Remove the thermostat and immerse it in water. Heat the water until it reaches 88 ºC (190
ºF). At this temperature the thermostat should begin to open. If it does not begin to open,
install a new thermostat. REFER to Thermostat in this section.
Radiator Leak Test, Removed From Vehicle
CAUTION: Radiator internal pressure must not exceed 130 kpa (20 psi) or damage
Page 4 of 4
may result.
Clean the radiator thoroughly before leak testing it, to prevent contamination of the water in
the test tank. Leak test the radiator in clean water with 138 kpa (20 psi) air pressure. Check
it thoroughly for air leaks. Install a new radiator if necessary. REFER to Radiator in this
section.
Cap
2. Use water to clean the area of the rubber seal and pressure relief valve. Install the
pressure tester and adapter and immerse the coolant expansion tank pressure cap in
water .
NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure reading
will result.
3. Slowly depress the plunger of the pressure tester until the pressure gauge reading stops
increasing, and note the highest pressure reading obtained.
4. Release pressure by turning the pressure relief screw counterclockwise. Tighten the
pressure relief screw and repeat step 3 at least twice to make sure the pressure test
reading is repeatable and within acceptable gauge reading limits of the coolant expansion
tank cap.
5. If the pressure test gauge readings are not within the acceptable gauge reading limits,
install a new coolant expansion tank cap.
Page 1 of 2

THERMOSTAT
UID=G289947
Removal
information, refer to Cooling System Draining,
Filling and Bleeding in this section.
2. Remove the generator. For additional
3. Using the tool, disconnect the radiator lower
hose from the thermostat housing.
4. Disconnect the heater hose from the

thermostat housing.
6. NOTE: The thermostat is installed with the

jiggle pin at the top.
Remove the thermostat.
Installation
Page 2 of 2
 Make sure the rubber seal is located

correctly.
Page 1 of 2

RADIATOR
UID=G289948
Removal
01.

5. Using the tool, disconnect the radiator upper

hose.

hose.
7. Remove the radiator retainers.

1. Remove the radiator retainer locking
screws.
Page 2 of 2
2. Remove the radiator retainers and

grommets.
8. Detach the radiator and the air conditioning

(A/C) condenser from the support panel.
9. CAUTION: Support the condenser by

positioning it on the support panel.
Slide the A/C condenser to detach it from the
radiator
10. Remove the radiator.
Installation
All vehicles

11.
Page 1 of 4

ENGINE COOLING
UID=G289949
- Coolant leak(s) - Fuse(s)
- Coolant level - Relay(s)
- Air in system - Wiring harness
- Gaskets/seals - Electrical connector(s)
- Hose(s)/hose joints - Cooling fan motor
- Coolant expansion tank pressure - Engine coolant temperature

cap and seal (ECT) sensor
- Coolant expansion tank - Powertrain control module

(PCM)
- Radiator
- Water pump
- Thermostat
- Thermostat housing
- Accessory drive belt

Symptom Chart
Symptom Chart

Loss of coolant *Hose(s)/hose joint *INSPECT the hoses and hose joints. INSTALL a
(s). new hose(s) as necessary.
*Radiator. *INSPECT the radiator for leaks. CARRY OUT the
Pressure Test Component Test in this section.
INSTALL a new radiator as necessary. REFER to
Radiator in this section.
*Water pump. *INSPECT the water pump for leaks. CARRY OUT
the Pressure Test Component Test in this section.
Page 2 of 4

as necessary. REFER to Water Pump in this
section.
*Thermostat *INSPECT the thermostat housing for leaks. CARRY
housing. OUT the Pressure Test Component Test in this
section. INSTALL a new thermostat housing or
thermostat housing gasket as necessary. REFER to
Thermostat Housing in this section.
*Heater core. *CHECK the heater core for leaks. REFER to
Section 412-02A / 412-02B.
00.
The engine *Coolant *CHECK the coolant level. REFILL the cooling
overheats (signs of level/condition. system as necessary. REFER to Section 303-03A.
coolant boiling) [Engine Cooling - 1.25L/1.4L/1.6L, GENERAL
and Bleeding]
*CHECK the coolant condition. If the coolant is in
poor condition drain and refill with new coolant.
REFER to Section 303-03A.[Engine Cooling -
1.25L/1.4L/1.6L, GENERAL PROCEDURES, Cooling
System Draining, Filling and Bleeding]
*Coolant *REFER to Specification - in this section.
concentration.
*Cooling system *CARRY OUT the Coolant Expansion Tank Pressure
does not hold Cap Pressure Test Component Test in this section.
pressure. -INSPECT the coolant expansion tank for damage.
INSTALL a new coolant expansion tank as
necessary.
-INSPECT the water pump or water pump gasket
for damage. INSTALL a new water pump or water
pump gasket as necessary. REFER to Water Pump
in this section.
-INSPECT the engine, cylinder head, cylinder block
00.
*Radiator. *INSPECT the radiator for blockage or damage.
CARRY OUT the Pressure Test Component Test in
this section. INSTALL a new radiator as necessary.
REFER to Radiator in this section.
*Air in system. *BLEED the cooling system. REFER to Section 303-
03A.[Engine Cooling - 1.25L/1.4L/1.6L, GENERAL
and Bleeding]
Page 3 of 4

*Radiator grille. *INSPECT the radiator grille for air restrictions or
damage. REPAIR or INSTALL new parts as
necessary.
*Water pump. *CARRY OUT the Pressure Test Component Test in
this section. INSPECT the water pump for leaks.
as necessary. REFER to Water Pump in this
section.
*Thermostat. *CARRY OUT the Thermostat Test Component Test
in this section. INSTALL a new thermostat as
necessary. REFER to Thermostat Housing in this
section.
*Accessory drive *CHECK the accessory drive belt for correct
belt operation. REFER to Section 303-05.
*Cooling fan motor. *CHECK the operation of the cooling fan motor.
REFER to WDS.
00.
The engine does not *Thermostat. *CARRY OUT the Thermostat Test Component Test
reach normal in this section. INSTALL a new thermostat as
operating necessary. REFER to Thermostat Housing in this
temperature. section.
*Engine coolant *CHECK the operation of the ECT. REFER to WDS.
temperature (ECT)
sensor.
Component Tests
Pressure Test
2. Install the pressure tester to the coolant expansion tank.
3. Pressurize the system to the coolant expansion tank cap release pressure. REFER to
Specification - in this section.
4. Observe the cooling system pressure tester gauge reading for approximately two minutes.
The pressure should not drop during this time. If the system holds pressure, proceed to step
6. If the system does not hold pressure, check it thoroughly for coolant leaks.
5. Check the engine for coolant leaks REFER to Section 303-00. Drain the cooling system,
repair any coolant leaks found and fill and bleed the cooling system as necessary. REFER to
Section 303-03A.[Engine Cooling - 1.25L/1.4L/1.6L, GENERAL PROCEDURES, Cooling
System Draining, Filling and Bleeding]
6. Recheck the system by repeating steps 3 and 4 at least twice.
Thermostat
Page 4 of 4
Remove the thermostat and immerse it in water. Heat the water until it reaches 88 ºC (190
ºF). At this temperature the thermostat should begin to open. If it does not begin to open,
install a new thermostat housing. REFER to Thermostat Housing in this section.
Radiator Leak Test, Removed From Vehicle
CAUTION: Radiator internal pressure must not exceed 130 kpa (20 psi) or damage
may result.
Clean the radiator thoroughly before leak testing it, to prevent contamination of the water in
the test tank. Leak test the radiator in clean water with 138 kpa (20 psi) air pressure. Check
it thoroughly for air leaks. Install a new radiator if necessary. REFER to Radiator in this
section.
Cap
2. Use water to clean the area of the rubber seal and pressure relief valve. Install the
pressure tester and adapter and immerse the coolant expansion tank pressure cap in
water .
NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure reading
will result.
3. Slowly depress the plunger of the pressure tester until the pressure gauge reading stops
increasing, and note the highest pressure reading obtained.
4. Release pressure by turning the pressure relief screw counterclockwise. Tighten the
pressure relief screw and repeat step 3 at least twice to make sure the pressure test
reading is repeatable and within acceptable gauge reading limits of the coolant expansion
tank cap.
5. If the pressure test gauge readings are not within the acceptable gauge reading limits,
install a new coolant expansion tank cap.
Page 1 of 2

THERMOSTAT HOUSING
UID=G289950
Removal
3. Remove the air cleaner intake tube.

5. Disconnect the engine coolant temperature
(ECT) sensor electrical connector.
6. Disconnect the coolant degas hose.

1. Remove the clip.
2. Pull the hose to disconnect.
7. Using the tool, disconnect the radiator coolant

hose from the thermostat housing.
8. Using the tool, disconnect the heater hose

from the thermostat housing.
Page 2 of 2
9. Disconnect the water pump intake hose from

the thermostat housing.
10. Loosen the screw and detach the by-pass

tube bracket.
Installation
Page 1 of 2

RADIATOR
UID=G289951
Removal
01.
information, refer to Section 303-03A.[Engine
Cooling - 1.25L/1.4L/1.6L, GENERAL
and Bleeding]

5. Using the tool, disconnect the radiator upper

hose.

hose.
7. Remove the radiator retainers.

Page 2 of 2
1. Remove the radiator retainer locking

screws.
2. Remove the radiator retainers and
grommets.
8. Detach the radiator and the air conditioning

(A/C) condenser from the support panel.
9. CAUTION: Support the condenser by

positioning it on the support panel.
Slide the A/C condenser to detach it from the
radiator
10. Remove the radiator.
Installation
All vehicles

11.
Page 1 of 10

FUEL INJECTION PUMP
UID=G289953
Special Tool(s)
Flange Holding Wrench,
Universal
49 UN20 5072
Adaptors for 49 UN20 5072
49 UN20 507202
Remover, Crankshaft Timing

Sprocket
49 S120 215B
Hand Pressure Pump With
Adapter Kit
49 JE02 050
General Equipment
Pneumatic vacuum gun
Two 13 mm nuts
Two M7x55 mm long bolts
Removal
WARNINGS:

or near any fuel related components. Highly
flammable mixtures are always present and
This procedure involves fuel handling. Be

prepared for fuel spillage at all times and
in personal injury.
Do not carry out any repairs to the fuel

injection system with the engine running. The
fuel pressure within the system can be as
high as 1600 bar. Failure to follow these
instructions may result in personal injury.
Wait at least one minute after the engine

stops before commencing any repair to the
fuel injection system. Failure to follow these
CAUTIONS:
Diesel fuel injection equipment is

manufactured to very precise tolerances and
Page 2 of 10
fine clearances. It is therefore essential that

absolute cleanliness is observed when
working with these components. Always
install blanking plugs to any open orifices or
lines.
Do not disassemble or clean inside the

fuel pump, even with an ultrasonic cleaner.
Always install a new fuel pump when
required.
Always carry out the cleaning process

before carrying out any repairs to the fuel
injection system components. Failure to
follow this instruction may result in foreign
matter ingress to the fuel injection system.
Disconnect the battery ground cable. For
01.
01B.
4. Remove the exhaust gas recirculation (EGR)
tube elbow retaining screws.
5. Remove the EGR tube clamp and the EGR

tube.

electrical connector, the fuel pump fuel supply
and fuel return lines and secure them to one
side.
 Install blanking plugs to the fuel pump fuel

supply and fuel return line female connectors
and the fuel pump.
7. Disconnect the fuel flow control valve electrical

connector.
Page 3 of 10
8. Disconnect the fuel pressure control valve

electrical connector and detach the wiring loom
(shown from below for clarity).
9. Remove the fuel pump support bracket.
10. Clean the fuel pump, high-pressure fuel

supply line and surrounding areas. For
additional information, refer to Fuel Injection
Component Cleaning in this section.

have been detached and cleaned. Failure to
Using the pneumatic vacuum gun, vacuum
supply line, the fuel pump and the fuel

detached and cleaned. Failure to follow this
instruction may result in foreign matter
ingress to the fuel injection system.
Remove and discard the high-pressure fuel supply
line.
Page 4 of 10
13. Using the pneumatic vacuum gun, vacuum

foreign material from the fuel pump and the
ports on the fuel pump and the fuel injection
supply manifold.
15. Assemble the flange holding wrench (49
UN20 5072) and the adaptors (49 UN20
507202) using two 13 mm nuts.
16. Using the special tools, hold the fuel pump
pulley and remove the retaining nut.
17. Using the special tool with two M7x55 mm

long bolts, remove the fuel pump pulley.
18. NOTE: Support the fuel pump.

Remove the fuel pump retaining bolts.
19. Remove the fuel pump.
Installation
All vehicles
WARNINGS:
Page 5 of 10
in personal injury.
CAUTIONS:
Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner.
Always install a new fuel pump when required.
injection system components. Failure to follow this instruction may result in foreign
NOTE: Install a new high-pressure fuel supply line.
1. NOTE: Do not tighten the fuel pump
retaining bolts at this stage.
Install the fuel pump.
2. Install the fuel pump support bracket
3. Tighten the fuel pump retaining bolts.
4. Install the fuel pump pulley.

5. Using the special tools, tighten the fuel pump
pulley retaining nut.
Page 6 of 10
CAUTIONS:
Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure
to follow this instruction may result in damage to the ends of the line and allow foreign
Remove the blanking plugs from the high-pressure fuel supply line, the fuel injection
supply manifold and the fuel pump at the last possible moment. Failure to follow this
instruction may result in foreign matter ingress to the fuel injection system.
Make sure the tool used to tighten the high-pressure fuel supply line unions is used
at the top of the unions as this is where there is most material. Failure to follow this
instruction may result in damage to the unions.
NOTE: Maintain pressure on the high-pressure fuel supply line to keep the line in contact
with the fuel injector cone and fuel injection supply manifold while installing the unions.
6. Install a new high-pressure fuel supply line.
 Tighten the unions in 2 stages.
 Stage 1: Tighten the unions - 17 Nm.
7. Connect the fuel pressure control valve

electrical connector and install the wiring loom
(shown from below for clarity).
8. Connect the fuel flow control valve electrical

connector.
9. Connect the fuel temperature sensor electrical

Page 7 of 10
connector, the fuel pump fuel supply and fuel

return lines.
10. Install the EGR tube and the EGR tube clamp.
11. Install the EGR tube elbow retaining screws.

01B.
13. Disconnect the fuel pump fuel return line
from the fuel tank fuel return line. For
00.

Page 8 of 10
16. Connect the fuel pump fuel return line to the

fuel tank fuel return line. For additional
17. Disconnect the fuel tank to fuel filter fuel

supply line from the fuel filter. For additional
18. Install the hand pressure pump special tool

adaptor to the fuel filter.

adaptor to the fuel tank to fuel filter fuel
supply line.
20. NOTE: Make sure the hand primer special

tool arrow indicating the direction of fuel flow
is pointing towards the fuel filter.
Install the hand pressure pump special tool to the
hand pressure pump special tool adaptors.
21. Operate the hand pressure pump special tool

until fuel starts to flow through the fuel filter.
22. Disconnect the hand pressure pump special
tool adaptor from the fuel tank to fuel filter
fuel supply line.
Page 9 of 10

tool adaptor from the fuel filter.
24. Connect the fuel tank to fuel filter fuel supply

line to the fuel filter. For additional

00.

Page 10 of 10

01.

11.
Page 1 of 4

TURBOCHARGER
UID=G289954
Special Tool(s)
Boost Pressure Gauge
49 1011 130A
NOTE: It is normal for a small amount of combustion gas to pass into the crankcase. This
gas is scavenged into the air intake system through the positive crankcase ventilation
(PCV) system, which incorporates an oil separator. Some engine oil, in the form of a
vapor is carried into the air intake system with the blow-by gases (this engine oil also
contributes to valve seat durability). This means that oil will collect inside the air intake
components and the turbocharger. This is not an indication that the turbocharger oil seal
has failed. The turbocharger oil seal will not fail unless the bearings fail first, which will
cause the turbocharger to become noisy or seize. Do not install a new turbocharger due
to oil inside the turbocharger or the air intake components. If a leak is detected in the oil
supply or return tubes or connections, locate and rectify the source. Do not install a new
turbocharger due to an oil leak.
Mechanical
Oil leak(s)
Air cleaner element
Turbocharger intake tube
Air cleaner intake pipe
Turbocharger oil supply or oil return tube
Wastegate control valve
Turbocharger housing
Wastegate control pipe
Catalytic converter
Symptom Chart
Symptom Chart

Blue smoke with *Turbocharger *GO to Pinpoint Test A. .
excessive compressor
turbocharger rubbing on
noise housing walls.
*Turbocharger
bearings and oil
Page 2 of 4
seal(s).
*Turbocharger oil
supply tube
blocked or
damaged.
Blue smoke *Turbocharger oil *GO to Pinpoint Test B. .
without excessive return tube
turbocharger blocked or
noise damaged.
Poor engine *Wastegate control *CHECK the wastegate control valve actuator rod
performance valve actuator rod. moves freely, If the wastegate control valve actuator
rod does not move freely. CHECK for signs of
damage or signs of foreign material. INSTALL a new
turbocharger. REFER to Turbocharger in this section.
*Turbocharger *The boost pressure is factory set and must not be
boost pressure adjusted. CHECK the paint seal on the actuator rod
incorrect. has not been broken. If the paint seal has been
broken, INSTALL a new turbocharger. REFER to
Turbocharger in this section. TEST the system for
normal operation.
*If the paint seal has not been broken, GO to Pinpoint
Test C.
Pinpoint Tests
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE

A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
1 Remove the air cleaner outlet pipe.
2 Inspect the turbocharger rotor vanes for damage.
Is there visible damage to the rotor vanes?

Yes
GO to A2. .
No
GO to A3. .
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
1
Check the intake air system components for signs of
Page 3 of 4
foreign material.
Are there any signs of foreign material?
Yes
CLEAN the intake air system components. INSTALL a
new turbocharger. REFER to Turbocharger in this
section. TEST the system for normal operation.
No
GO to A4. .
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE: A small amount of movement in the bearings is normal.
1 Make sure the turbocharger rotor spins freely within
the housing.
 1. With the turbocharger stationary, gently lift the

shaft (the shaft will naturally lay in the bottom of
the bearings).
 2. Make sure the rotor spins freely within the

housing.
Does the rotor spin freely within the housing with no
excessive movement?
Yes
GO to A4. .
No
INSTALL a new turbocharger. REFER to Turbocharger in
this section. TEST the system for normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
1 Disconnect the oil supply tube from the
turbocharger.
2 Attach a small piece of known good hose to the oil

supply tube and gently blow down the hose.
Are there any signs of blockage?
Yes
INSTALL a new turbocharger oil supply tube. TEST the
No
INSTALL a new turbocharger. REFER to Turbocharger in
this section. TEST the system for normal operation.
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
B1: CHECK THE TURBOCHARGER OIL RETURN TUBE
1 Remove the turbocharger oil return tube (catalytic
converter shown removed for clarity).
Page 4 of 4
2 Check the turbocharger oil return tube for a

blockage or signs of damage.
Is the turbocharger oil return tube OK?
Yes
GO to Fuel Charging and Controls for further
diagnostics. REFER to Section 303-04A / 303-04B /
303-04C.
No
INSTALL a new turbocharger oil return tube. TEST the
PINPOINT TEST C : POOR ENGINE PERFORMANCE
C1: CHECK THE BOOST PRESSURE
NOTE: The boost pressure is factory set and must not be adjusted.
1 Using the boost pressure gauge and a T connector, connect the gauge
between the wastegate control actuator and the turbocharger.
2 Start and run the engine until the cooling fan has operated.
3 Raise the engine speed to 3000 rpm and observe the reading.
Is the boost pressure 0.5 bar?
Yes
GO to Fuel Charging and Controls for further diagnostics. REFER to
Section 303-04A / 303-04B / 303-04C.
No
INSTALL a new turbocharger. REFER to Turbocharger in this section. TEST the
Page 1 of 3

UID=G289956
General Equipment
Hand Vacuum/Pressure Pump
Mechanical
Exhaust gas recirculation (EGR) valve
EGR tube
EGR tube clamps
Gaskets/seals
EGR vacuum regulator valve
Symptom Chart
Symptom Chart

Excessive exhaust black smoke *EGR valve. *GO to Pinpoint Test A.
*EGR vacuum regulator valve.
Pinpoint Tests
PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE

A1: CHECK VACUUM TO THE EGR VALVE
1 Disconnect the vacuum line from the EGR valve.
2 Connect the vacuum pump to the disconnected

vacuum line.
3 START the engine.
4 Using the vacuum pump, measure the vacuum at

the EGR vacuum line.
Page 2 of 3
With the engine at idle, is no vacuum indicated on the

vacuum gauge?
Yes
GO to A2.
No
Using WDS, CHECK the OPEN and CLOSE input signal to
the EGR vacuum regulator valve. If the result is CLOSE,
INSTALL a new vacuum regulator valve. TEST the
system for normal operation. If the result is OPEN
continue the diagnostic with WDS.
A2: CHECK THE EGR VALVE CONTROL ROD
1 Connect the vacuum pump to the EGR valve.
2 Using the vacuum pump, apply a vacuum to the

EGR valve.
3 Release the vacuum and observe the movement of

the EGR valve control rod.
Does the EGR valve open and return to the fully closed
position?
Yes
GO to A3.
No
INSTALL a new EGR valve. REFER to Exhaust Gas
Recirculation (EGR) Valve in this section. TEST the
A3: CHECK THE EGR VALVE
1 Remove the EGR valve. REFER to Exhaust Gas
Recirculation (EGR) Valve in this section.
2 Inspect the EGR valve for damage.
Is the EGR valve OK?
Yes
No
INSTALL a new EGR valve. REFER to Exhaust Gas
Recirculation (EGR) Valve in this section. TEST the
Page 3 of 3
Page 1 of 5

CRANKSHAFT POSITION (CKP)
SENSOR — 1.4L DIESEL
UID=G289958
Special Tool(s)
Locking Tool - Crankshaft
49 JE02 020
Removal
01.
expansion tank.
3. Detach the coolant expansion tank and secure

it to one side.
4. Detach the wiring harness from the timing belt

upper cover.
5. Remove the timing belt upper cover.

Page 2 of 5

05.

Rotate the engine until the special tool fits into
the hole in the flywheel.
9. Using the special tool, lock the flywheel.
 Discard the crankshaft pulley retaining bolt.
12. Remove the CKP sensor.

Page 3 of 5
Installation
All vehicles
1. Install the CKP sensor.

retaining bolt.
 Tighten the crankshaft pulley bolt in the

sequence shown in 2 stages.
* Stage 1 : Tighten the bolt - 30 Nm.
* Stage 2 : Tighten the bolt - 180 degrees.
4. Remove the special tool from the flywheel.
5. Connect the CKP electrical connector.

Page 4 of 5

8. Install the timing belt upper cover.
9. Attach the wiring harness to the timing belt

upper cover.
11. Connect the degas hose to the coolant

expansion tank.

Page 5 of 5
01.

11.
Page 1 of 4

POWERTRAIN CONTROL MODULE
(PCM) — 1.25L/1.4L/1.6L
UID=G289959
Special Tool(s)
Drill Bush, Powertrain Control
Module
49 JE02 032
Worldwide Diagnostic System
(WDS) or equivalent
General Equipment
6mm drill bit
Removal
NOTE: Before commencing this procedure, make sure that two ignition keys are available
because two keys will be required to initialize the PCM to the passive anti-theft system
(PATS).
NOTE: If a new PCM is to be installed, upload the instrument cluster configuration
information with WDS or equivalent, prior to commencing the removal of the PCM (this is
carried out by WDS or equivalent during the vehicle identification process).
1. Connect WDS or equivalent to the data link
connector (DLC) and carry out the vehicle
identification process.

3. Position the PCM on the battery tray support
panel.
4. Insert the special tool into the PCM electrical

connector.
Page 2 of 4
5. CAUTION: Make sure the special tool

is used to guide the drill bit. Failure to follow
this instruction may result in damage to the
Using the special tool as a guide, drill into the
shear bolt using a 6mm drill bit, until the head
is removed.
6. Remove the special tool from the PCM
electrical connector and clean all foreign
material from the electrical connector.
7. Disconnect the PCM electrical connector and
remove the PCM.
8. Remove the remains of the shear bolt from the

PCM using grips.
Installation
1. Install a new shear bolt and securing clip,
using the special tool to push the clip onto the
shank of the bolt.
Page 3 of 4
2. Install the PCM electrical connector to the PCM.
 Tighten the bolt until the head shears off.

connector (DLC).
5. Input the vehicle information following the

directions on the screen.
6. Select "Module Programming".
7. Select "Programmable Module Installation".
8. Select "PCM" and carry out the procedures
according to directions on the screen.
9. Using WDS or equivalent, verify that there are
no DTCs present.
 If any DTCs are present, diagnose the

instrument cluster. For additional information,
refer to Section 413-01.[Instrument Cluster,
Page 4 of 4
DIAGNOSIS AND TESTING, Instrument

Cluster]
10. NOTE: Incode inquiry will be required for
this step.
Initialize PATS, using WDS or equivalent by:
11. From the main menu select "Body".
12. Select "Security".
13. Select "PATS Functions".
14. Follow the directions on the screen.
this step.
Select "PATS Functions".
16. Select "Parameter Reset"
17. Select "PCM".
Page 1 of 1

HEATED OXYGEN SENSOR (HO2S)
UID=G289960
Special Tool(s)
Socket, Fuel Injector (22mm)
49 T018 001
Removal
2. Disconnect the HO2S electrical connector.
3. Using the special tool, remove the HO2S.
Installation
CAUTION: When installing a new HO2S, it is possible that the new component will be
supplied with a longer cable than the one removed. It is important that the cable is
routed and secured in such a way that it cannot be damaged by heat or moving
components and will not cause a noise, vibration or harshness (NVH) issue.
Page 1 of 1

CLUTCH SYSTEM BLEEDING
UID=G289961
Name Specification
Super DOT 4 Brake fluid
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately
washed down with cold water.
1. Remove the air cleaner. For additional information,
2. Using a suitable syringe, remove brake fluid from
the brake fluid reservoir until the brake fluid level
is at the MIN mark.
3. Using a suitable hand operated vacuum pump, fill

the reservoir with approximately 100 ml of new
brake fluid.
4. NOTE: Make sure that the reservoir is
positioned lower than the bleed nipple and that
the suction pipe is connected to the bleed nipple.
Open the clutch system bleed nipple and using the
vacuum pump bleed the clutch system.
 Pump approximately 80 ml of brake fluid into the

clutch system.
5. Close the bleed nipple.

6. Remove the fluid reservoir.
7. NOTE: The clutch pedal must be fully
depressed and released on each application.
Remove small air bubbles from the system by fully
depressing the clutch pedal several times (four or
five times maximum).
 Wait 30 seconds and fully depressing the clutch

pedal several times.
8. Test the clutch control system for normal
operation.
 Start the engine, depress the clutch pedal, wait

two seconds, then carefully engage reverse gear.
If there are abnormal noises, or reverse gear is
difficult to engage, repeat the clutch system
bleeding procedure.
9. Check the fluid level in the brake fluid reservoir and
top up to the MAX mark with brake fluid if
necessary.
10. Install the air cleaner. For additional information,
Page 1 of 2

CLUTCH DISC AND PRESSURE PLATE
UID=G289962
Special Tool(s)
Locking Tool, Flywheel
49 E011 1A0
Aligner, Clutch Plate
49 JE02 026
Removal
1. Remove the transaxle. For additional
2. CAUTION: Loosen the clutch pressure

plate retaining bolts evenly, by two turns at a
time.
Using the special tool, lock the flywheel and
remove the clutch disc and pressure plate.
Installation
1. Using the special tool, centralize the clutch disc
on the clutch pressure plate.
2. CAUTION: Tighten the clutch pressure

plate retaining bolts finger tight and then
evenly by two turns at a time to the specified
torque.
NOTE: Install new clutch pressure plate
retaining bolts.
Using the special tool, install the clutch disc and
pressure plate.
Page 2 of 2

4. Install the transaxle. For additional
Page 1 of 3

HALFSHAFT SEAL LH
UID=G289963
Special Tool(s)
Remover, Halfshaft
49 JE02 027
Installer, Drive Pinion Oil Seal
49 JE02 002
Remover, Halfshaft Oil Seal
49 JE01 075
Removal


knuckle.

Using the special tools, detach the left-hand side
one side.
 Remove and discard the snap ring.

5. Using the special tool, remove the halfshaft oil
seal.
Page 2 of 3
Installation
1. Using the special tool, install the halfshaft oil
seal.
CAUTIONS:

degrees.

seated.
Attach the halfshaft to the transaxle.

ball joint.
knuckle.

Page 3 of 3

transaxle until the oil level is just below the
bottom of the filler hole.
Page 1 of 3

HALFSHAFT SEAL RH
UID=G289964
Special Tool(s)
Remover Drive Pinion Oil Seal
49 JE01 014
Installer Halfshaft Oil Seal
49 JE01 021
Removal


knuckle
4. Remove the intermediate shaft center bearing

cap.
1. Remove and discard the locknuts.
2. Detach the heat shield from the bearing
cap.
3. Remove and discard the center bearing cap.

Page 2 of 3
6. Using the special tool, remove the halfshaft oil

seal.
Installation
1. Using the special tool, install the halfshaft oil
seal.
CAUTIONS:

degrees.

Attach the right-hand halfshaft and the
2. Attach the heat shield to the bearing cap.

knuckle.
Page 3 of 3


transaxle until the oil level is just below the
bottom of the filler hole.
Page 1 of 7

TRANSAXLE — 1.25L/1.4L/1.6L
UID=G289965
Special Tool(s)
Support Bar, Engine
49 E017 5A0
Remover, Halfshaft
49 JE02 027
General Equipment
Retaining strap
Transmission jack
Removal
All vehicles
(PCM) electrical connector.


Page 2 of 7

from the transaxle.
 Detach the ground cable from the transaxle.
7. Remove the front wheels and tires. For

04.
8. Remove the starter motor.
 Detach the starter motor electrical connector

from the starter motor.
9. Disconnect the reversing lamp switch electrical

connector.



Page 3 of 7



transaxle.
1. Detach the gearshift cables and the selector
2. Turn the abutment sleeve clockwise and
All vehicles
electrical connector (if equipped).
17. Remove the accessory drive belt cover.

Page 4 of 7

Detach the lower arm from the wheel knuckle on
both sides.
CAUTIONS:

degrees.

or dirt ingress.
one side.

21. NOTE: Discard the intermediate shaft
Remove the intermediate shaft center bearing
cap.
1. Remove the locknuts.
2. Detach the heat shield.
3. Remove the center bearing cap.
Page 5 of 7
CAUTIONS:

degrees.

or dirt ingress.
Detach the halfshaft and the intermediate shaft
from the transaxle and secure it to one side.



27. Remove the engine and transaxle rear

Page 6 of 7
mount.
28. Using the special tool, lower the engine and

transaxle assembly.
29. Remove the engine and transaxle rear mount

retaining bracket.

31. Remove the transaxle lower retaining bolts.
32. NOTE: Secure the transaxle with a

retaining strap on the transmission jack.
Using a suitable transmission jack, support the
transaxle.

bolts.
Page 7 of 7

bolt.
35. Using a suitable transmission jack, remove

the transaxle.
Page 1 of 9

TRANSAXLE — 1.4L DIESEL
UID=G289966
Special Tool(s)
Support Bar, Engine
49 E017 5A0
Remover, Halfshaft
49 JE02 027
General Equipment
Transmission jack
Retaining strap
Removal
All vehicles
(PCM) electrical connector.
4. Disconnect the glow plug relay electrical

connector.
5. Detach the glow plug relay power supply

cables.
Page 2 of 9

7. Remove the turbocharger intake air pipe.
8. Remove the intake air pipe.
 Unclip the hood latch release cable.

control valve from the battery tray bracket and
position it to on side.

from the transaxle.
 Detach the ground cable from the transaxle.

Page 3 of 9
14. Remove the engine and transaxle rear mount

retaining bracket.


16. Detach the air conditioning (A/C) pressure
pipe bracket from the transaxle.
Page 4 of 9
All vehicles
01.





Page 5 of 9


transaxle.
All vehicles
Section 303-03A / 303-03B.
26. Remove the accessory drive belt cover.

Page 6 of 9



Detach the lower arm from the wheel knuckle on
both sides.
CAUTIONS:

degrees.
Page 7 of 9

or dirt ingress.
one side.

CAUTIONS:

degrees.

or dirt ingress.
Using the special tool, detach the right-hand
halfshaft and the intermediate shaft from the
transaxle and secure it to one side.

33. Disconnect the reversing lamp switch

35. Using the special tool, lower the engine and
transaxle assembly.

37. Detach the starter motor lower retaining bolt.
Page 8 of 9
38. NOTE: Do not disconnect the starter

motor electrical connector.
Detach the starter motor and secure it to one
side.
39. CAUTION: Secure the transaxle with

retaining straps on the transmission jack.
Using a suitable transmission jack, support the
transaxle.

bolts.

bolts.
42. Using a suitable transmission jack, remove

the transaxle.
Page 9 of 9
Page 1 of 7

TRANSAXLE
UID=G289967
Special Tool(s)
Remover, Drive Pinion Seal
49 JE01 014

Bushing/Seal
49 JE01 020
Remover, Input Shaft Fifth Gear
49 JE01 025
Remover, Differential Bearing

Cone
49 JE02 003
Mounting Bracket,
Engine/Differential
49 G019 0A0
Mounting Stand
49 0107 680A
Mounting Bracket for 303-435
49 L010 1A0
CAUTIONS:
Use vise protectors.
Use a copper or plastic mallet to prevent damage.

1. Using the special tools, mount the transaxle on
the mounting stand.
2. Clean any grease and foreign material from

the input shaft.
CAUTIONS:
3. If brake fluid is spilt on the paintwork,

the affected area must be immediately
Page 2 of 7
Using suitable adhesive tape, cover the

input shaft splines to prevent damage to the
clutch slave cylinder seal.
Remove the clutch slave cylinder.
4. Remove the adhesive tape from the input shaft

splines.
5. Remove the vehicle speed sensor (VSS) (if
equipped).
1. Remove the retaining pin.
2. Pull out the VSS.
6. Remove the selector mechanism cover.
7. Remove the gear shift lever.

1. Remove the protective cap.
2. Remove and discard the snap ring.
8. Remove the shift cable bracket.
9. Remove the selector lever.
 Remove the bellows.

Page 3 of 7
10. Remove the selector interlock mechanism.
11. Remove the fifth gear housing cover retaining

bolts.
12. Using a suitable spatula, remove the fifth

gear housing cover.
13. Remove the fifth gear synchroniser assembly,

the selector fork and the fifth gear wheel.
2. Remove and discard the retaining pin.
14. NOTE: To aid assembly mark the position

of the fifth gear synchroniser assembly.
Disassemble the fifth gear synchroniser.
2. Remove the retaining plate.
3. Remove the synchroniser assembly.
4. Remove the synchroniser ring.
Page 4 of 7
5. Remove the fifth gear wheel.
15. Remove the fifth gear wheel snap ring.
16. Using the special tool, remove the fifth gear

wheel.
17. CAUTION: Do not strike the mating

face.
Remove the fifth gear housing.
18. CAUTION: Do not strike the mating

face.
Remove the snap rings.
1. Remove and discard the gasket.
2. Remove and discard the output shaft snap
Page 5 of 7
ring.
3. Remove and discard the input shaft snap
ring.
4. Pull out the auxiliary plug.
19. Using the special tool, remove both halfshaft

oil seals (left-hand side shown).
 Only remove the reversing lamp switch if

there is evidence of leakage.
20. NOTE: To prevent damage raise the

transaxle housing and turn it slightly.
Separate the two halves of the transaxle housing
(13 bolts).
 Carefully separate the transaxle housing.
 Clean the mating face.
21. Remove the selector shaft guide sleeve upper

snap ring.
1. Remove and discard the upper snap ring.
2. Slide the selector shaft guide sleeve
downwards.
22. Remove the selector shaft guide sleeve.

1. Remove and discard the selector shaft guide
sleeve lower snap ring.
2. Remove the selector shaft guide sleeve.
23. NOTE: Install a rubber band to the

second selector shaft to aid assembly.
Remove the input shaft, the output shaft and the
selector forks.
Page 6 of 7
24. Remove and discard the input shaft oil seal.

25. Remove the differential assembly and the
permanent magnet.
26. Remove the reverse gear idler.
27. Remove the selector shaft and the shift lock

bush.
1. Remove the shift lock bushing.
2. Remove the fifth and reverse gear selector
shaft.
28. Remove the output shaft taper roller bearing.
 Detach the bearing from the bearing case and

remove the bearing case.
29. CAUTION: Use the special tool as

shown, to prevent damage to the blanking
plugs.
Using the special tool, remove the output shaft
Page 7 of 7
bearing cup.
 Remove the oil funnel.
30. Using the special tool, remove the differential

bearing cup.
31. NOTE: Install the special tool in the

transaxle housing grooves.
Using the special tool, remove the differential
bearing cup.
Page 1 of 6

SUBASSEMBLIES
OUTPUT SHAFT
UID=G289968
Special Tool(s)
49 JE01 015

Bushing Oil Seal
49 JE01 020
49 JE01 040
General Equipment
Two-leg puller
Press
Snap ring
Name Specification
fluid meeting WSD-M2C200-C
Disassembly
1. Remove the roller bearing and the fourth gear
wheel.
1. Remove and discard the small snap ring.
2. Install a suitable snap ring.
3. Using a suitable two-leg puller, remove the
roller bearing.
4. Remove the fourth gear wheel and the
synchronizer ring.
2. Remove the third and fourth gear synchronizer

assembly.
2. Remove the gear synchronizer, third and
fourth gear synchronizer assembly and the
third gear wheel.
Page 2 of 6
3. Remove the third gear synchronizer ring from

the third gear wheel.
1. Outer synchronizer ring.
2. Synchronizer cone.
3. Third gear wheel.
4. NOTE: The double synchronizer shown, is a

service replacement component.
Disassemble the third gear synchronizer
assembly.
3. Inner synchronizer ring.
5. Remove the second gear wheel and the

synchronizer assembly
1. Retaining ring.
2. Snap rings.
3. Second gear wheel.
6. NOTE: Remove the synchronizer assembly

and the first gear wheel together.
Remove the first and reverse gear wheel, the
gear synchronizer and synchronizer assembly.
Page 3 of 6
2. Remove the first and second gear

synchronizer and the reverse gear wheel.
6. First gear wheel.
7. CAUTION: To aid assembly mark the

position of the selector ring in relation to the
synchronizer hub.
Disassemble the synchronizer hub.
1. Selector ring.
2. Synchronizer spring.
3. Synchronizer lock.
4. Synchronizer hub.
8. NOTE: Position the anvil-piece in the oil-

funnel bore.
Using the special tools, remove the output shaft
bearing cone.
2. Install the special tools underneath the
bearing cone.
Assembly
CAUTION: Immerse the double synchronizer assembly in clean manual transmission

fluid before assembly.
Page 4 of 6
1. Carefully clean and check all running surfaces

and coat them with clean manual transmission
fluid before assembly.
2. NOTE: Install a new output shaft bearing
cone snap ring.
Install the output shaft bearing cone.
 Evenly heat the bearing cone to

approximately 80°C and install it onto the
output shaft.
 Install the snap ring.
3. NOTE: Assemble the synchronizer hub to

the marks.
Assemble the synchronizer hub.
1. Synchronizer hub.
2. Install the selector ring onto gear
synchronizer hub.
3. Install the synchronizer lock.
4. Install the synchronizer spring.
4. NOTE: Use a new first and reverse gear

wheel snap ring.
Install the first and reverse gear wheel, the gear
synchronizer and synchronizer assembly.
1. First gear wheel.
5. Install the first and second gear
synchronizer and the reverse gear wheel.
6. Install the snap ring.
5. NOTE: Assemble the synchronizer

assembly before installation on the output
shaft.
Install the second gear wheel with the
synchronizer assembly.
4. Second gear wheel.
5. Snap rings.
6. Retaining ring.
Page 5 of 6
6. NOTE: The double synchronizer shown, is a

service replacement component.
Assemble the third gear synchronizer unit
assembly.
7. Attach the third gear synchronizer ring to the

third gear wheel.
8. NOTE: Install a new third and fourth gear

synchronizer assembly snap ring.
NOTE: Install the selector ring with the
annular groove facing downwards and the
small hub collar facing upwards.
Install the third and fourth gear synchronizer
assembly.
1. Install the gear synchronizer, third and
fourth gear synchronizer assembly and the
third gear wheel.
9. NOTE: Install a new roller bearing snap
ring.
NOTE: Install the roller bearing with the
annular groove facing outwards.
Page 6 of 6
Using the special tool and a suitable press, install

the fourth gear wheel and the roller bearing.
1. Install the synchronizer ring and the fourth
gear wheel.
2. Using a suitable press , install the roller
bearing.

Page 1 of 2

SUBASSEMBLIES
INPUT SHAFT
UID=G289969
Special Tool(s)
Bushing Oil Seal
49 JE01 020
General Equipment
Two-leg puller
Press
Name Specification
Disassembly
1. Using a suitable two-leg puller, remove the
inner roller bearing.
2. Remove the inner roller bearing.
2. Remove the outer roller bearing.
Assembly
NOTE: Coat all components with clean manual transmission fluid before assembly.
1. Using the special tool and a suitable press ,
install the outer roller bearing.
2. NOTE: The roller bearing groove must face

outwards.
NOTE: Install a new input shaft snap ring.
Page 2 of 2
Using the special tool, install the inner roller

bearing.

Page 1 of 2

SUBASSEMBLIES
DIFFERENTIAL
UID=G289970
Special Tool(s)
Adapter for 49 JE01 005 (Thrust
Pad)
49 JE01 006
Installer, Differential Bearing
49 JE01 010
49 JE01 015
49 JE02 025
General Equipment
Press
Drift
Name Specification
Disassembly
1. Using the special tools, remove the differential
bearings.
2. Remove the differential bearings.
3. Remove the vehicle speed sensor (VSS)
sensor ring.
2. Remove the differential pinions and the ring

gear.
1. Rotate the differential pinions about 90
degrees in the differential case and remove
Page 2 of 2
them.
2. Remove and discard the snap ring and using
a suitable drift, drive out the pin.
* Remove the two differential pinions and plastic thrust
elements.
3. Detach the ring gear from the differential

case.
Assembly
1. NOTE: Do not lubricate the differential
bearing.
Carefully clean and check all components and
coat them with cleanmanual transmission fluid
before assembly.
2. NOTE: Install a new ring gear and
differential pinion snap ring.
Install the ring gear and the differential pinions.
1. Using the old bolts, carefully attach the ring
gear to the differential case.
* Install the two differential pinions and plastic thrust
elements.
2. Using a suitable drift, install the pin and

install the snap ring.
3. Install the differential pinions and rotate
them 90 degrees in the differential case.
3. NOTE: Install new ring gear retaining
bolts.
NOTE: Do not rest on the lower differential
bearing.
Using the special tools, tighten the ring gear and
install the differential bearings.
1. Install new ring gear retaining bolts and
tighten the bolts working diagonally.
2. Install the vehicle speed sensor (VSS)
sensor ring.
3. Using the special tools, install the
differential bearings.
Page 1 of 10

TRANSAXLE
UID=G289971
Special Tool(s)
Installer, Wheel Hub Bearing
Cone/Seal
49 JE01 018
Bushing/Seal
49 JE01 020
Installer, Halfshaft Seal
49 JE01 021
Installer, Input Shaft Bearing

Cone
49 JE01 023
Installer, Input Shaft Snap Ring
49 JE01 024
49 JE01 043
49 JE01 045
49 JE01 047
Mounting Stand
49 0107 680A
General Equipment
Press
Dial indicator gauge
Magnetic stand for dial indicator gauge
Auxiliary plugs
Name Specification
Sealant Silicone rubber sealant (Low
viscosity)
Sealant Silicone rubber sealant (Gel
type)
High- Molybdenum disulfined grease
temperature
Page 2 of 10
grease
2. Clean and check all parts carefully before
reassembly.
 Apply clean manual transmission fluid to all

running surfaces.
3. Using the special tool, install the output shaft
taper roller bearing and the output shaft
bearing cup.
1. Install the oil funnel.
2. Install the taper roller bearing.
4. Using the special tool, install the differential

bearing cup.
5. Install the fifth and reverse gear selector shaft,

and the shift locking bush.
1. Install the bush.
2. Install the selector shaft.
6. Install the reverse idler gear.
7. Install the differential assembly and the

permanent magnet.
8. Prepare the input and output shaft for

Page 3 of 10
installation.
1. Engage the input shaft and output shaft.
2. Move the first and second gear shift forks to
the installation position.
3. Move the third and fourth gear shift forks to
the installation position.
9. NOTE: Install a rubber band to the second

selector shaft to aid installation.
Install the input shaft and the output shaft.
 Insert the input shaft to a depth of

approximately 50 mm and move it slightly to
one side.
 Insert the output shaft to the level of the

input shaft and engage the gear wheels.
 Install the input shaft and the output shaft.

10. NOTE: Install a new snap ring.
Install the selector shaft guide sleeve lower snap
ring.
1. Install the guide sleeve.

Install the selector shaft guide sleeve upper snap
ring.
1. Lift the guide sleeve.
12. NOTE: The shift lever finger surface must

face the reverse gear idler lever surface.
Move the inner gearshift linkage to the fifth gear.
 Before pressing it downwards, turn the

selector shaft clockwise until it reaches the
reverse and fifth gear passage.
13. Install the 3.8 mm thick measuring shim and

secure it with a punch mark.
1. Transaxle housing.
2. Measuring shim.
Page 4 of 10
3. Bearing cup.
14. NOTE: Make sure that the transaxle

housing mating surfaces are clean.
Assemble the transaxle housing.
 Install the special tool.
 Install the auxiliary plugs.
 Install the bolts.
 Turn the transaxle 180 degrees.

 Remove the auxiliary plugs.
16. Using a suitable dial indicator gauge take a

reference measurement from the face of the
transaxle housing.
 Turn the differential assembly approximately

ten times to settle the bearings.
 Position the dial indicator gauge and magnetic

stand and set the dial indicator gauge to zero.
17. NOTE: Carry out the measuring

procedure three times and calculate the
average value.
NOTE: The adjusting shims are available from
0.1 mm to 1.1 mm in steps of 0.1 mm.
Measure the differential end float.
1. Using the special tool, lift the differential
assembly.
2. Note the resulting measurement (e.g. 0.73
mm).
 Example: 0.73 mm + 0.74 mm + 0.72 mm

divided by three = 0.73 mm.
* The value of the thickness of the shim should be
rounded down to the nearest tenth of a millimeter
below if the value ends in 0.05 mm and below, and
Page 5 of 10
rounded up to the nearest tenth of a millimeter if the

value ends in 0.06 mm and above.
18. Calculate the required adjusting shim

thickness.
 Thickness of adjusting shim = measuring

shim (3.80 mm) + average value (0.73 mm)
+ bearing pre-load (0.14 mm) – thickness of
the Belleville washers (4.42 mm).
* Example: Adjusting shim = 3.80 mm + 0.73 mm +
0.14 mm – 4.42 mm = 0.25 mm.
 The thickness of the adjusting shim becomes

0.2 mm (rounded down from 0.25 mm).
19. Separate the transaxle housing.
 Install the upper auxiliary plugs.
 Turn the transmission approximately 180

degrees.
 Remove the dial indicator gauge, the

magnetic stand and the special tools.
20. Using the special tool, remove the differential

bearing cup and the measuring shim.
21. CAUTION: The Belleville washers

must be installed with the inner raised
sections of both washers touching.
Install the measured adjusting shim.
Page 6 of 10
1. Install the Belleville washers.

2. Install the measured adjusting shim.
3. Install the bearing cone.
 Using a suitable punch, secure the bearing

cone.
22. Apply sealant on the inside edge of the

transaxle housing mating face.
23. Assemble the transaxle housing and tighten

the bolts.
24. NOTE: Install new input and output shaft

snap rings.
Raise the input and output shafts slightly and
install the snap rings.
25. CAUTION: Make sure the snap rings

are in the correct position. Failure to follow
this instruction may cause damage to the fifth
gear housing.
Turn the snap rings to the position shown.
26. NOTE: Install a new fifth gear housing

gasket.
Install the fifth gear housing gasket.
Page 7 of 10
27. NOTE: Install new fifth gear housing

retaining bolts.
Install the fifth gear housing.
28. Remove the transaxle from the mounting

stand.
29. NOTE: The transaxle housing must not
contact the press table. Support the input
shaft splines.
Using the special tool and a suitablepress, install
the fifth gear wheel.
30. Mount the transaxle on the mounting stand.

31. NOTE: Install a new fifth gear wheel snap
ring.
Install the fifth gear wheel snap ring.
1. Install the snap ring onto the special tool.
2. Install the special tool and push on the snap
ring.
32. NOTE: Align the gear synchronizer to the

marks.
Assemble the fifth gear synchronizer.
1. Install the fifth gear wheel.
2. Install the synchronizer ring.
3. Install the synchronizer assembly.
4. Install the retaining plate.
33. NOTE: Install a new fifth gear

synchronizer assembly snap ring.
NOTE: Use a new selector fork retaining pin.
Install the fifth gear synchronizer assembly and
Page 8 of 10
the selector fork.
 Install the retaining pin.
34. Apply sealant evenly to the inside edge of the

fifth gear housing mating face.
35. Install the fifth gear housing cover.
36. NOTE: Make sure that the selector shaft

is in the neutral position.
Correct installation position for the selector shaft
interlock mechanism shown.
37. NOTE: Make sure that the selector shaft

is in the neutral position.
Install the selector shaft interlock mechanism.
 Apply sealant to the thread.
38. Install the selector lever.
 Install the bellows.

Page 9 of 10
39. Engage the fifth gear.
 Turn the selector shaft clockwise as far as

possible and push the shaft in.
40. NOTE: Install new halfshaft oil seals.

Using the special tools, install both halfshaft oil
seals (left-hand side shown).
41. Install the gearshift cable support bracket.

Install the gearshift lever.
2. Install the protective cap.
43. Install the selector mechanism cover.

Page 10 of 10
44. Install the vehicle speed sensor (VSS) (if

equipped).
1. Push in the VSS.
2. Install the retaining pin.
45. CAUTION: Using suitable adhesive

tape, cover the input shaft splines to prevent
damage to the input shaft oil seal.
Install the input shaft oil seal.
CAUTIONS:
46. If brake fluid is spilt on the

paintwork, the affected area must be
Do not apply grease on any parts of the

Install the clutch slave cylinder.
47. Remove the adhesive tape from the input

shaft splines.
48. Coat the input shaft splines with a thin layer
of high-temperature grease.
Page 1 of 8

TRANSAXLE — 1.25L/1.4L/1.6L
UID=G289972
Special Tool(s)
Support Bar, Engine
49 E017 5A0
49 JE02 053
General Equipment
Retaining strap
Transmission jack
Name Specification
Installation
All vehicles
CAUTIONS:
1. Use suitable retaining straps to secure

the transaxle on the transmission jack.

are installed.
Using a suitable transmission jack, install the
transaxle.
3. Install the transaxle lower retaining bolts.

Page 2 of 8
4. Install the transaxle left-hand retaining bolt.
5. Remove the retaining strap .

6. Remove the transmission jack.
8. Install the engine and transaxle rear mount
retaining bracket.
9. Using the special tool, raise the engine and

transaxle assembly.
10. NOTE: Do not tighten the engine rear

mount retaining nuts at this stage.
NOTE: Install new engine rear mount
retaining nuts.

Page 3 of 8

converter.

seated.

CAUTIONS:

degrees.

seated.

the halfshaft.
CAUTIONS:

Page 4 of 8

degrees.


equipped).

ball joint.
Attach the lower arm to the wheel knuckle on
both sides.
20. Attach the bracket to the heated oxygen

sensor.
21. Install the accessory drive belt cover.
22. Connect the vehicle speed sensor (VSS)

Page 5 of 8




Page 6 of 8
All vehicles
connector.
29. Install the starter motor.
 Attach the starter motor electrical connector

to the starter motor.

31. Tighten the strut spring assembly top mount
nuts on both sides.

the transaxle.

retaining nuts.
Page 7 of 8

retaining nut.

electrical connector to the PCM.

38. Install the front wheels and tires. For

Page 8 of 8


Gearshift]
All vehicles
Initialization]
Page 1 of 10

TRANSAXLE — 1.4L DIESEL
UID=G289973
Special Tool(s)
Support Bar, Engine
49 E017 5A0
49 JE02 053
General Equipment
Transmission jack
Retaining strap
Name Specification
Installation
All vehicles
CAUTIONS:
1. Use suitable retaining straps to secure

the transaxle on the transmission jack.

are installed.
Using a suitable transmission jack, install the
transaxle.
3. Remove the retaining strap.

4. Remove the transmission jack.
5. Install the transaxle left-hand retaining bolts.
Page 2 of 10
6. Attach the starter motor to the transaxle.
7. Install the starter motor lower retaining bolts.

9. Install the engine rear mount retaining
bracket.

the transaxle.
11. Using the special tool, raise the engine and

transaxle assembly.
Page 3 of 10
12. NOTE: Install new engine rear mount

retaining nuts.
NOTE: Do not tighten the engine rear mount
retaining nuts at this stage.

connector.
CAUTIONS:

degrees.

seated.
Page 4 of 10


the halfshaft.
CAUTIONS:

degrees.


equipped).

ball joint.
Attach the lower arm to the wheel knuckle on
both sides.

converter.

Page 5 of 10
23. Install the accessory drive belt cover.
24. NOTE: Install the cooling fan motor and

shroud from the underside of the vehicle.
Install the cooling fan motor and shroud.


Page 6 of 10


All vehicles
Page 7 of 10
retaining nuts.

retaining nut.

34. Install the air conditioning (A/C) pressure
pipe bracket to the transaxle housing.
All vehicles

NOTE: Make sure that the spring clip is
correctly seated.
Connect the clutch slave cylinder supply line to
the transaxle.

36. Connect the vehicle speed sensor (VSS)

Page 8 of 10
38. Attach the exhaust gas recirculation (EGR)

control valve to the battery tray bracket.
39. Install the intake air pipe.
40. Install the turbocharger intake air pipe.

mount nuts on both sides.
42. Attach the glow plug power supply cables.

Page 9 of 10
43. Connect the glow plug relay electrical

connector.




Page 10 of 10

Gearshift]
All vehicles
transaxle with manual transmission oil until
the level is just below the filler hole.
Initialization]
Page 1 of 7

FUEL TANK
UID=G289980
Special Tool(s)
Wrench, Sender Unit, Fuel Tank
49 T042 001
General Equipment
Transmission jack
Removal
All vehicles
WARNINGS:
near fuel related components. Highly flammable vapors are always present and may ignite.
always observe fuel handling precautions. Failure to follow these instructions may result in
personal injury.
1. Release the fuel system pressure. For additional
2. Drain the fuel tank. For additional information,
4. Remove the floor panel crossmember.
5. Detach the exhaust system from the center

6. NOTE: When detaching the exhaust system

allow the system to be supported by the rear
suspension assembly.
Detach the exhaust system from the rear exhaust
hanger insulator.
Page 2 of 7
7. Remove the exhaust system heat shield.
8. CAUTION: When removing the fuel tank

vent and filler pipes, do not use any sharp
edge tools to lever off the pipes. Failure to
follow this instruction may cause damage to
the pipes.
NOTE: Make note of the positions of the
retaining clamps to make sure they are
installing.
Disconnect the fuel tank filler pipe and the fuel
tank vent pipe from the fuel tank.
 Discard the retaining clamps.
9. CAUTION: Use a suitable packing

material to prevent damage to the underside
of the fuel tank.
Using a suitable transmission jack, support the fuel
tank.
10. Remove the fuel tank support strap rear

retaining bolts.
11. NOTE: Make note of the positions of the

support straps to make sure they are
Page 3 of 7
installing (left-hand over right-hand).

Remove the fuel tank support straps.
All except vehicles with diesel engine

12. Disconnect the fuel tank vent pipe from the
evaporative emission canister. For additional
All vehicles
13. CAUTION: When lowering the fuel

tank, make sure that excessive strain is not
placed on the fuel lines and electrical
connectors.
Partially lower the fuel tank.

14. Disconnect the fuel pump module electrical
connector.
Vehicles with diesel engine

15. Disconnect the fuel level sensor electrical
connector.
Page 4 of 7
All vehicles
16. NOTE: Make note of the color of the fuel
lines to make sure they are connected in
exactly the same positions when installing.
Fuel supply line connectors are white or are
identified by a white band. Fuel return line
connectors are red or are identified by a red
band.
Disconnect the fuel supply and fuel return lines
from the fuel tank. For additional information,

17. Disconnect the evaporative emissions canister
pipe.
 Squeeze the clip to release the pipe.
18. Remove the evaporative emissions canister

from the fuel tank.
All vehicles
19. Remove the fuel tank assembly.
All except vehicle with diesel engine

20. Using the special tool, loosen the fuel pump
module locking ring.
Page 5 of 7
21.
CAUTION:
Make
sure that
the float or
arm are
not
damaged
while
removing
or
installing
the fuel
pump
module.
Remove the
fuel pump
module.
1. Remove
the
locking
ring.
2. Remove
the O-
ring seal.
* Discard the
O-ring seal.
3. Lift the
module
from the
fuel tank.
Vehicles with diesel engine

22. Using the special tool, loosen the fuel level
sensor locking ring.
23.
CAUTION:
Make
Page 6 of 7
sure that
the float or
arm are
not
damaged
while
removing
or
installing
the fuel
level
sensor.
Remove the
fuel level
sensor.
1. Remove
the
locking
ring.
2. Remove
the O-
ring seal.
* Discard the
O-ring seal.
3. Lift the
sensor
from the
fuel tank.
Installation
WARNINGS:
near fuel related components. Highly flammable vapors are always present and may ignite.
personal injury.
CAUTIONS:
Make sure the fuel lines are connected in the correct fuel-flow direction. Fuel supply
line connectors are white or are identified by a white band. Fuel return line connectors are
red or are identified by a red band.
Make sure that the fuel supply and fuel return lines click into place when installing the
lines. To make sure that the fuel lines are fully seated, pull on the lines.
NOTE: Install a new O-ring seal.
NOTE: When installing the fuel tank make sure the fuel lines do not get kinked or trapped.
NOTE: Install new fuel filler and vent pipe retaining clamps.
NOTE: The fuel filler and vent pipe retaining clamps must be installed in the same position
as removed.
1. NOTE: Make sure that the arrows on the
fuel tank and the fuel pump module or fuel
level sensor are aligned correctly.
Page 7 of 7
Page 1 of 1

ELECTRONIC LEAK DETECTION
UID=G289981
Special Tool(s)
R-134a refrigerant station / Digital
multimeter / Refrigerant indentifier
49 C061 0A0A
WARNING: Good ventilation before leak detection is necessary in the area where it is
to be performed. If the surrounding air is contaminated with refrigerant gas, the leak
detector will indicate this gas all the time. Odors from other chemicals such as antifreeze,
diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem.
While leak detection air movement must be prevented.
1. CAUTION: The refrigerant

identification equipment must be used before
the manifold gauge set is installed, otherwise
the manifold gauge may become
contaminated. Contaminated refrigerant must
be disposed of as special waste. The
manufacturer's instructions must be followed
when working with the service unit.
NOTE: Both manifold gauges should indicate
4,1-5,5 bar at 24°C with the engine off.
Attach the R-134a refrigerant station to the
service gauge port valves.
1. For the leak test, close the manual valves
on the gauge set.
2. If little or no pressure is indicated, charge
the system with approx. 300g of refrigerant.
For additional information, refer to Air
Conditioning (A/C) System Recovery,
Evacuation and Charging in this section.
2. Use R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant
system. Follow the instructions included with
leak detector for handling and operation
techniques.
3. If a leak is found, recover the A/C system. For
additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging in this section.
Page 1 of 1

FLUORESCENT DYE LEAK DETECTION
UID=G289982
Special Tool(s)
R-134a refrigerant station /
Digital multimeter / Refrigerant
indentifier
49 C061 0A0A
120 Watt UV Spot Lamp or
equivalent
NOTE: Some vehicles may have signs of refrigerant oil at the spring lock couplers. This
may be caused from the assembly process which applies to the fittings before installation
to aid in assembly. When a spring lock coupler is suspected of leaking, always wipe the
fitting clean and verify the leak with R-134a Automatic Calibration Halogen Leak Detector.
NOTE: The exact location of leaks can be pinpointed by the bright yellow - green glow of
the tracer dye. Since more than one leak may exist, always inspect each component.
1. Check for leaks using a 120 Watt UV Spot
Lamp. Always scan all components, fittings
and lines of the A/C system.
2. After the leak is found and repaired, remove
any traces of dye with a general purpose oil
solvent.
3. Verify the repair by operating the system for
some minutes and inspecting with the UV lamp
again.
Page 1 of 3

INSTRUMENT CLUSTER
UID=G289987
General Equipment
Worldwide Diagnostic System (WDS) or
equivalent
Removal
NOTE: If a new instrument cluster is to be installed, upload the instrument cluster
configuration information with WDS or equivalent, prior to commencing the removal of
the instrument cluster (this is carried out by WDS or equivalent during the vehicle
identification process).

01.
3. Release the steering column locking lever and
lower the steering column.
4. Remove the instrument cluster finish panel.
(Steering wheel shown removed for clarity).
5. CAUTION: To prevent damage to the

instrument cluster lens or the the steering
column upper shroud, cover the steering
column upper shroud with a suitable cloth
before moving the instrument cluster
Detach the instrument cluster from the
instrument panel.
6. Remove the instrument cluster.
 Disconnect the electrical connectors and

detach the wiring harness.
Page 2 of 3
Installation
All vehicles

11.
All vehicles
connector (DLC).

7. Select "IC" and carry out the procedures
including the installation of the instrument
cluster according to directions on the screen.
8. Using WDS or equivalent, verify that there are
no DTCs present.

refer to Instrument Cluster in this section.
this step.
Page 3 of 3
this step.
16. Select "HEC". Do not select "IC".
Page 1 of 1

FRONT BUMPER
UID=G290000
General Equipment
Transmission jack
Wooden block
Removal
1. Remove the front bumper cover. For additional
information, refer to Front Bumper Cover in this
section.
2. Detach the fog lamp wiring harness from the
bumper (if equipped).
3. Using a suitable transmission jack and wooden

block, support the radiator.
4. Detach the radiator grille opening panel from the

bumper (left-hand side shown).
5. Remove the bumper.
Installation
Page 1 of 1

SPECIFICATIONS
UID=G290001
Special Tool Usage
Description Simulator Test and Deployment Lead

Driver air bag module 49 JE02 029 49 L066 00249 G066 003
Passenger air bag module 49 JE02 029 49 L066 00249 G066 003
Side air bag module 49 JE02 031 49 D066 004
Side air curtain 49 JE02 029 49 L066 002
Safety belt retractor and pretensioner 49 JE02 029 49 L066 002
Item Nm lb-ft lb-in

Restraints control module retaining nuts 9 - 80
Crash sensor retaining bolt 9 - 80
Passenger air bag module bracket to cross-vehicle beam retaining bolts 10 - 89
Driver air bag module 10 - 89
Side air bag module retaining screws 9 - 80
Side air curtain module retaining bolts 9 - 80
Side air curtain module front tether retaining screw 2 - 18
Side air curtain module center retaining screws 2 - 18
Side impact sensor retaining bolt 9 - 80
Page 1 of 5

AIR BAG AND SAFETY BELT
PRETENSIONER SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)
UID=G290002
Special Tool(s)
Test and Deployment Lead,
Driver and Passenger Air Bag
Modules; Side Air Curtain
Modules; Safety Belt Retractor
Pretensioners
49 L066 002
Test and Deployment Lead,
Driver and Passenger Air Bag
Modules
49 G066 003
Test and Deployment Lead, Side
Air Bag Module
49 D066 004
Simulator, Driver and Passenger

Air Bag Modules; Side Air Curtain
Modules; Safety Belt Retractor
Pretensioners
49 JE02 029
Simulator, Occupant Restraint
Systems
49 JE02 031
General Equipment
Refer to the Wiring Diagrams Section for schematic and connector information.
Diagnosing Customer Concerns Without Hard DTCs/LFCs
WARNING: The battery back up power supply must be depleted before any work is
carried out on the supplemental restraint system. Wait at least one minute after
disconnecting the battery ground cable. Failure to follow this instruction may result in
personal injury.
NOTE: Following the pinpoint tests when a diagnostic trouble code/lamp fault code
(DTC/LFC) is not present, will result in needless replacement of air bag system
components and repeat repairs.
Speak with the customer to determine if a particular set of conditions must be met in order
for a fault to occur. If a LFC is reported by the customer but is not present when the vehicle
comes in for repair, pinpoint test diagnostics cannot be used. Instruct the customer on how to
count a LFC.
Diagnosing Customer Concerns with Hard DTCs/LFCs

Page 2 of 5
WARNING: Do not use substitute air bag simulators when working on the
supplemental restraint system. Use only the appropriate tool. Failure to follow this
Most air bag system diagnostic procedures require the use of system deactivation and system
reactivation procedures. These procedures require the air bag module(s) and safety belt
buckle pretensioners to be disconnected from the SRS, thereby removing the risk of the air
bag deployment while diagnostics are carried out.
Air bag simulators are required to carry out diagnosis and testing of the air bag system. The
simulator contains a resistor, used to simulate an air bag module connection to the system. It
is not acceptable to short-circuit the air bag module connections with a 0 ohm jumper wire. If
a 0 ohm jumper wire is used to short-circuit the air bag module connections, a LFC will be
displayed and a DTC logged by the restraints control module.
Deactivation
WARNING: The back up power supply must be depleted, before any work is carried
out on the supplemental restraint system. Wait at least one minute after disconnecting
the battery ground cable. Failure to follow this instruction may result in personal injury.
1. Disconnect the battery ground cable. REFER to Section 414-01.
2. Wait at least one minute for the backup power supply in the restraints control module to
deplete its stored energy.
WARNING: Place the air bag module on a ground wired bench, with the trim cover
facing up to avoid accidental deployment. Failure to follow this instruction may result in
personal injury.
3. Remove the driver air bag module from the vehicle. REFER to Driver Air Bag Module in this
section.
4. Connect the air bag simulators to the sub-harnesses in place of the driver air bag module
at the top of the steering column.
5. Disconnect the passenger air bag module electrical connectors. REFER to Passenger Air
Bag Module in this section.
6. Connect the air bag simulators to the wiring harnesses in place of the passenger air bag
module.
7. Disconnect both the side air curtain module electrical connectors. REFER to Side Air Curtain
Module in this section.
8. Connect the air bag simulators to the wiring harnesses in place of the side air curtain
modules.
9. Disconnect the driver underseat air bag electrical connector.
10. Connect the driver underseat air bag simulator to the floor harness.
11. Disconnect the driver safety belt retractor and pretensioner at the base of the B-pillar.
Remove the B-pillar trim panel. REFER to Section 501-05.
12. Connect the driver safety belt retractor and pretensioner simulator to the wiring
harnesses in place of the driver safety belt retractor and pretensioner module.
Page 3 of 5
13. Disconnect the passenger underseat air bag electrical connectors.
14. Connect the passenger underseat air bag simulator to the floor harness.
15. Disconnect the passenger safety belt retractor and pretensioner at the base of the B-
pillar. Remove the B-pillar trim panel. REFER to Section 501-05.
16. Connect the passenger safety belt retractor and pretensioner simulator to the wiring
harnesses in place of the passenger safety belt retractor and pretensioner module.
17. Connect the battery ground cable. REFER to Section 414-01.
Reactivation
WARNING: The air bag simulators must be removed and the air bag modules
reconnected when reactivated to avoid non-deployment in a collision. Failure to follow this
1. Disconnect the battery ground cable. REFER to Section 414-01.
2. Wait at least one minute for the backup power supply in the restraints control module to
deplete its stored energy.
3. Remove the driver air bag simulators from the sub-harnesses at the top of the steering
column.
4. Connect and install the driver air bag module. REFER to Driver Air Bag Module in this
section.
5. Remove the passenger air bag simulators from the passenger air bag module harnesses.
6. Connect and install the passenger air bag module. REFER to Passenger Air Bag Module in
this section.
7. Remove the side air curtain simulators from the side air curtain module wiring harnesses.
8. Connect and install the side air curtain modules. REFER to Side Air Curtain Module in this
section.
9. Remove the driver underseat air bag simulator.
10. Connect the driver underseat air bag electrical connector.
11. Remove the driver safety belt retractor and pretensioner simulator.
12. Connect the driver safety belt retractor and pretensioner electrical connector. Install the
B-pillar trim panel. REFER to Section 501-05.
13. Remove the passenger underseat air bag simulator.
14. Connect the passenger underseat air bag electrical connector.
15. Remove the passenger safety belt retractor and pretensioner simulator.
16. Connect the passenger safety belt retractor and pretensioner electrical connector. Install
the B-pillar trim panel. REFER to Section 501-05.
Page 4 of 5
17. Connect the battery ground cable. REFER to Section 414-01.
18. Prove out the system.
19. Initialize the driver door window motor. REFER to Section 501-11.
Glossary
Air Bag Simulator
Air bag simulators are used to simulate air bag module connections to the system.
Deactivate The System
Deactivate the system means to carry out deactivation. REFER to Deactivation in this
procedure.
Prove Out The System
The air bag warning indicator will illuminate for three seconds.
Reactivate The System
Reactivate the system means to carry out reactivation. REFER to Reactivation in this
procedure.
Principles of Operation
Supplemental Restraint System (SRS) Operation
The supplemental restraint system is DC fired. All vehicles are equipped with front crash
sensors. Vehicles equipped with side air bags and side air curtains are also equipped with side
impact sensors.
In the event of a severe frontal or three-quarter frontal impact, in excess of a predetermined

limit, the driver and passenger (if equipped) front air bag(s) will deploy.
In the event of a severe full side impact, in excess of a predetermined limit, either the driver
or passenger side air bags (if equipped) and side air curtains (if equipped) will deploy.
Air bag deployment will only occur, in the event of a severe collision when the ignition key is
in the RUN position.
Restraints Control Module
The restraints control module is mounted horizontally to the crossmember beneath the floor
console, to facilitate impact sensing along the longitudinal axis. The restraints control module
retains full control of the whole system, providing continual system checks and full diagnostic
capabilities. The non-volatile memory stores the fault codes, which are down loaded through
the diagnostic link connector to WDS. A visual warning indicator that is housed within the
instrument cluster, is illuminated when the ignition is switched ON for approximately three
seconds then goes out. If a fault occurs the warning indicator, depending on the nature of the
fault, begins to flash or illuminates continuously after five seconds.
In the event of a failure in the vehicle power supply during an accident, the restraints control
module provides an auxiliary power supply, sufficient to deploy the front air bag(s) for a
Page 5 of 5
minimum of 150 mS. The auxiliary power supply is discharged by the restraints control
module within 60 seconds of the battery ground cable being disconnected. Thus making sure
the supplemental restraint system remains operational.
The restraints control module contains a micro-controller to evaluate and process impact
data. In the event of a frontal impact, in excess of a predetermined limit, the restraints
control module will evaluate the signal received from the crash sensor against stored data
and deploy the front air bags and safety belt buckle pretensioners.
Crash Sensor and Side Impact Sensors
Both the crash sensor and the side impact sensors contain an acceleration sensor, filter,
amplifier and an application specific integrated circuit for signal transmitting.
The crash sensor sends a signal at a level determined by the crash severity to the restraints
control module. The restraints control module will evaluate the signal against stored data and
deploy the front air bags and safety belt buckle pretensioners if required.
The side impact sensor processes the impact data against stored data. In the event of a side
impact, in excess of a predetermined limit, the side impact sensor will send a signal to deploy
the side air bags and side air curtains (if equipped). A signal is also sent to the restraints
control module.
Air Bag Warning Indicator
The air bag warning indicator is incorporated into the instrument cluster, together with the
automatic detach detect (ADD) circuit. The air bag warning indicator illuminates for three
seconds at key ON. If the system self-tests OK the indicator extinguishes, if a fault is
detected the indicator will flash after five seconds, illuminate continually from key ON or not
illuminate at all, depending on the nature of the fault.
The ADD circuit is designed to illuminate the air bag warning indicator continuously, if the
restraints control module circuit is broken, either by loss of power or ground supply or
electrical connector disconnection.
Diagnostic evaluation of the supplemental restraints system can be made through the data
link connector (DLC) and WDS to establish the nature of the concern. Once the diagnostic
trouble code (DTC) is known the appropriate course of action can be selected from the
Symptom Chart. REFER to Diagnostic Instructions - Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in this section.
Page 1 of 69

PINPOINT TESTS - AIR BAG AND
SAFETY BELT PRETENSIONER
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)
UID=G290003
WARNING: Wait at least one minute after disconnecting the battery ground cable before
disconnecting any supplemental restraint system electrical connector. Failure to follow this
PINPOINT TEST A : NO COMMUNICATION WITH THE MODULE
A1: CHECK THE WDS IS COMMUNICATING THROUGH THE DATA LINK CONNECTOR
(DLC)
1 Select an alternative system to check the DLC.
Is WDS able to communicate with the selected system?
Yes
GO to A2.
No
CHECK the DLC. For additional information, refer to the
Wiring Diagrams.
A2: CHECK THE AIR BAG WARNING INDICATOR
2 The air bag warning indicator should illuminate

when the ignition is in the ON position for three
seconds and then go out. If a fault is present, the
air bag warning light will then begin to flash.
Is the warning indicator operating?
Yes
GO to A3.
No
CHECK the instrument cluster. For additional
information, refer to the Wiring Diagrams.
A3: CHECK THE DLC CIRCUIT
1 Key in OFF position.
2 Deactivate the supplemental restraint system.

REFER to Air Bag and Safety Belt Pretensioner
Supplemental Restraint System (SRS) in this
section.
3 Disconnect Restraints Control Module S1-01.
4 Measure the resistance between the DLC U-01 pin

7, circuit LG (I) and the restraints control module
S1-01 pin 2G, circuit LG (I), harness side.
Page 2 of 69
Is the resistance less than 5 ohms?

Yes
INSTALL a new restraints control module. REFER to
Restraints Control Module (RCM) in this section.
REACTIVATE the system. REFER to Air Bag and Safety
Belt Pretensioner Supplemental Restraint System (SRS)
in this section. If the air bag warning indicator is
flashing, count the lamp flash code and refer to the
Symptom Chart in this section.
No
REPAIR circuit LG (I). REPEAT the self-test, CLEAR the
DTCs. REACTIVATE the system. REFER to Air Bag and
Safety Belt Pretensioner Supplemental Restraint
System (SRS) in this section.
PINPOINT TEST B : DTC B1318: BATTERY VOLTAGE LOW
B1: CHECK THE IGNITION SUPPLY CIRCUIT FOR AN OPEN CIRCUIT
3 Measure the voltage between the restraints control

module S1-01 pin 2U, circuit BK/RD (I), harness
side and ground.
Is the voltage between 9 and 16 volts?

Yes
GO to B2.
No
REPAIR circuit BK/RD (I). REPEAT the self-test, CLEAR
the DTCs. REACTIVATE the system. REFER to Air Bag
and Safety Belt Pretensioner Supplemental Restraint
B2: CHECK THE RESTRAINTS CONTROL MODULE GROUND CIRCUIT
2 Measure the resistance between the restraints

control module S1-01 pin 2T, circuit BK (I),
harness side and ground.

Page 3 of 69
Yes
REPEAT the self-test, CLEAR the DTCs. REACTIVATE the
system. REFER to Air Bag and Safety Belt Pretensioner
No
REPAIR circuit BK (I). REPEAT the self-test, CLEAR the
PINPOINT TEST C : DTC B1869: AIR BAG WARNING INDICATOR OPEN
CIRCUIT OR SHORT TO GROUND
C1: CHECK THE AIR BAG WARNING INDICATOR
2 Check the air bag warning indicator.

Is the air bag warning indicator illuminated
continuously?
Yes
GO to C2.
No
GO to C5.
C2: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
WARNING: Wait at least one minute after disconnecting the battery ground cable
before disconnecting any supplemental restraint system electrical connector. Failure to

section.
4 Disconnect Instrument Cluster C-01.
5 Measure the resistance between the instrument

cluster C-01 pin 10, circuit BR/YE (I), harness side
and the restraints control module S1-01 pin 2F,
circuit BR/YE (I), harness side.

Yes
GO to C3.
No
REPAIR circuit BR/YE (I). REPEAT the self-test, CLEAR
Page 4 of 69

C3: CHECK THE AIR BAG WARNING INDICATOR FUNCTION
1 Connect Instrument Cluster C-01.
2 Install a fused (7.5A) jumper wire between the

restraints control module S1-01 pin 2F, circuit
BR/YE (I), harness side and ground.
 Turn the ignition to the ON position.
Is the air bag warning indicator illuminated?

Yes
INSTALL a new instrument cluster. REFER to
Section 413-01.[Instrument Cluster, REMOVAL AND
INSTALLATION, Instrument Cluster] REPEAT the self-
test, CLEAR the DTCs. REACTIVATE the system. REFER
to Air Bag and Safety Belt Pretensioner Supplemental
Restraint System (SRS) in this section.
No
GO to C4.
C4: CHECK THE AIR BAG WARNING INDICATOR FUNCTION
1 With the fused (7.5A) jumper wire between the
restraints control module S1-01 pin 2F, circuit
BR/YE (I), harness side and ground.
 Disconnect the fused jumper wire from the ground.
Is the air bag warning indicator illuminated?

Yes
No
C5: CHECK THE INSTRUMENT CLUSTER WARNING INDICATORS
WARNING: Wait at least one minute after disconnecting the battery ground cable
before disconnecting any supplemental restraint system electrical connector. Failure to
2
Deactivate the supplemental restraint system.
Page 5 of 69
section.
4 Check the instrument cluster warning indicators.

Are the warning indicators illuminated when the ignition
is switched to the ON position?
Yes
GO to C6.
No
CHECK the instrument cluster. For additional
information, refer to Wiring Diagrams.
C6: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT

control module S1-01 pin 2F, circuit BR/YE (I),
Is the resistance greater than 10,000 ohms?

Yes
CHECK the air bag warning indicator LED. REPEAT the
self-test, CLEAR the DTCs. REACTIVATE the system.
No
REPAIR circuit BR/YE (I). REPEAT the self-test, CLEAR
PINPOINT TEST D : DTC B1870: AIR BAG WARNING INDICATOR SHORT TO
BATTERY
D1: CHECK THE AIR BAG WARNING INDICATOR CIRCUIT
section.

Page 6 of 69
module S1-01 pin 2F, circuit BR/YE (I), harness side

and ground.
Is any voltage present?

Yes
REPAIR the air bag wiring harness. For additional
information, refer to the Wiring Diagrams. REPEAT the
No
CHECK the instrument cluster. REFER to Section 413-
01.[Instrument Cluster, REMOVAL AND INSTALLATION,
Instrument Cluster] REPEAT the self-test, CLEAR the
PINPOINT TEST E : DTC B1877: DRIVER SAFETY BELT PRETENSIONER OPEN
CIRCUIT
E1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
section.
3 Carry out the self-test with the simulators installed.

Does the system prove out correctly?
Yes
GO to E2.
No
GO to E3.
E2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
Disconnect Driver Safety Belt Pretensioner
2
Simulator.
Connect Driver Safety Belt Pretensioner Connector
3
S1-05.
5 Carry out the self-test.

Page 7 of 69

Yes
REPEAT the self-test, CLEAR the DTCs. REATIVATE the
No
INSTALL a new driver safety belt retractor and
pretensioner. REFER to Section 501-20A.[Safety Belt
System, REMOVAL AND INSTALLATION, Safety Belt
Retractor and Pretensioner] REPEAT the self-test,
CLEAR the DTCs. REACTIVATE the system. REFER to Air
Bag and Safety Belt Pretensioner Supplemental
E3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR HIGH
RESISTANCE

3
Simulator S1-05.
4 Measure the resistance between:
 the restraints control module S1-01 pin 1E, circuit

BU (F), harness side and the driver safety belt
pretensioner S1-05 pin 2, circuit BU (F), harness
side; and
 the restraints control module S1-01 pin 5, circuit

WH (F), harness side and the driver safety belt
pretensioner S1-05 pin 1, circuit WH (F), harness
side.
Are the resistances less than 5 ohms?
Yes
No
REPAIR circuit BU (F) or circuit WH (F). REPEAT the
PINPOINT TEST F : DTC B1878 DRIVER SAFETY BELT PRETENSIONER SHORT
TO BATTERY
F1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
section.
Page 8 of 69

Yes
GO to F2.
No
GO to F3.
F2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
2
Simulator.
3
S1-05.

Yes
No
Retractor and Pretensioner]REPEAT the self-test, CLEAR
F3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO BATTERY

3
Simulator S1-05.
5 Measure the voltage between:

BU (F), harness side and ground; and

WH (F), harness side and ground.

Yes
No
Page 9 of 69

PINPOINT TEST G : DTC B1879: DRIVER SAFETY BELT PRETENSIONER
SHORT TO GROUND
G1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
section.

Yes
GO to G2.
No
GO to G3.
G2: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
2
Simulator.
3
S1-05.

Yes
REPEAT the self-test, CLEAR the DTCs. REFER to Air
No
G3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND
2 Disconnect Restraints Control Module S1-01 .

3
Simulator S1-05.
Page 10 of 69

BU (F), harness side and the restraints control
module S1-01 pin 20, circuit BK (I) harness side;
and

BU (F), harness side and ground; and

WH (F), harness side and the restraints control
module S1-01 pin 20, circuit BK (I), harness side;
and

WH (F), harness side and ground.
Are the resistance greater than 10,000 ohms?

Yes
No
PINPOINT TEST H : DTC B1881 PASSENGER SAFETY BELT PRETENSIONER
OPEN CIRCUIT
H1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
section.

Yes
GO to H2.
No
GO to H3.
H2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
Disconnect Passenger Safety Belt Pretensioner
2
Simulator.
Connect Passenger Safety Belt Pretensioner
3
Connector S1-06.
Page 11 of 69

Yes
No
INSTALL a new passenger safety belt retractor and
H3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR OPEN CIRCUIT OR
HIGH RESISTANCE
3 Disconnect Passenger Underseat Air Bag Simulator.
 the restraints control module S1-01 pin 1A, circuit

PK (F), harness side and the passenger safety belt
pretensioner S1-06 pin 1A, circuit PK (F) harness
side; and
 the restraints control module S1-01 pin 1B, circuit

BU/YE (F), harness side and the passenger safety
belt pretensioner S1-06 pin 2, circuit BU/YE (F)
harness side.
Yes
No
REPAIR circuits PK (F) and BU/YE (F). REPEAT the self-
PINPOINT TEST I : DTC B1882 PASSENGER SAFETY BELT PRETENSIONER
SHORT TO BATTERY
I1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
section.
Page 12 of 69

Yes
GO to I2.
No
GO to I3.
I2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
2
Simulator.
3
Connector S1-06.

Yes
No
I3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO
BATTERY

3
Simulator S1-06.
 the restraints control module S1-01 pin 6, circuit PK

(F), harness side and ground; and
 the restraints control module S1-01 pin 1B, circuit

BU/YE (F), harness side and ground.

Yes
REPAIR circuit PK (F) or circuit BU/YE (F). REPEAT the
Page 13 of 69

No
PINPOINT TEST J : DTC B1883PASSENGER SAFETY BELT PRETENSIONER
SHORT TO GROUND
J1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
section.

Yes
GO to J2.
No
GO to J3.
J2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
2
Simulator.
3
Connector S1-06.

Yes
No
J3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR A SHORT TO GROUND

Page 14 of 69
3 Disconnect Passenger Safety Belt Pretensioner

Simulator.
 the restraints control module S1-01 pin 6, circuit PK

(F), harness side and ground; and
 the restraints control module S1-01 pin 1B, BU/YE

(F), harness side and ground.
Are the resistances greater than 10,000 ohms?

Yes
No
REPAIR circuit PK (F) or circuit BU/YE (F). REPEAT the
PINPOINT TEST K : DTC B1885 DRIVER SAFETY BELT PRETENSIONER
CIRCUIT LOW RESISTANCE
K1: CHECK THE DRIVER SAFETY BELT PRETENSIONER CIRCUIT
section.

Yes
GO to K2.
No
GO to K3.
K2: PROVE OUT THE DRIVER SAFETY BELT PRETENSIONER
2
Simulator.
3
S1-05.

Yes
Page 15 of 69

No
K3: CHECK THE DRIVER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE

3
Simulator.
control module S1-01 pin 1I, circuit WH (F),
harness side and pin 1E, circuit BU (F), harness
side.

Yes
No
REPAIR circuits BU (F) and WH (F). REPEAT the self-
PINPOINT TEST L : DTC B1886 PASSENGER SAFETY BELT PRETENSIONER
L1: CHECK THE PASSENGER SAFETY BELT PRETENSIONER CIRCUIT
section.

Yes
Page 16 of 69
GO to L2.
No
GO to L3.
L2: PROVE OUT THE PASSENGER SAFETY BELT PRETENSIONER
2
Simulator.
3
Connector S1-06.

Yes
No
L3: CHECK THE PASSENGER SAFETY BELT PRETENSIONER FOR LOW RESISTANCE

3
Simulator.
control module S1-01 pin 1A, circuit PK (F),
harness side and pin 1B, circuit BU/YE (F),
harness side.

Yes
No
REPAIR circuits PK (F) and BU/YE (F). REPEAT the self-
Page 17 of 69

PINPOINT TEST M : DTC B1916 DRIVER AIR BAG FIRST STAGE SHORT TO
BATTERY
M1: CHECK THE DRIVER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
section.
Disconnect Driver Air Bag Module First Stage
2
Simulator.
 the restraints control module S1-01 pin 2N, circuit

YE/BK (I), harness side and ground; and
 the restraints control module S1-01 pin 2J, circuit

YE/RD (I), harness side and ground.

Yes
GO to M2.
No
CONNECT the driver air bag module first stage
simulator and the restraints control module. REPEAT
the self-test, CLEAR the DTCs. REACTIVATE the system.
M2: CHECK THE CLOCKSPRING FOR A SHORT TO BATTERY OR IGNITION
2 Disconnect Clockspring F3-04.



Yes
REPAIR circuits YE/BK (I) and YE/RD (I). REPEAT the
Page 18 of 69

No
INSTALL a new Clockspring. REFER to Clockspring in
this section. REPEAT the self-test, CLEAR the DTCs.
in this section.
PINPOINT TEST N : DTC B1925 PASSENGER AIR BAG FIRST STAGE SHORT
TO BATTERY
N1: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT
TO BATTERY OR IGNITION
section.
Disconnect Passenger Air Bag Module First Stage
2
Simulator.
 the restraints control module S1-01 pin 2R, circuit

YE/GN (I), harness side and ground; and
 the restraints control module S1-01 pin 2V, circuit

YE (I), harness side and ground.

Yes
REPAIR circuits YE (I) and YE/GN (I). REPEAT the self-
No
CONNECT the passenger air bag module first stage
PINPOINT TEST O : DTC B1932 DRIVER AIR BAG FIRST STAGE OPEN
CIRCUIT
O1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
Page 19 of 69

section.

Yes
GO to O2.
No
GO to O3.
O2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
WARNING: Do not proceed with this test unless using WDS. Failure to follow this
NOTE: Using a suitable non-conducting tool, disable the shorting bar in the test and
deployment lead connector.
1 Connect the Test and Deployment Lead to the driver
air bag module - first stage.
2 Select DMM specific on WDS.
3 Connect the Test and Deployment Lead to WDS.

air bag module - second stage.
5 Measure the resistance of the air bag module squib.
Are the resistances between 2 and 3 ohms?

Yes
No
INSTALL a new driver air bag module. REFER to Driver
Air Bag Module in this section. REPEAT the self-test,
O3: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE

Page 20 of 69
* the restraints control module S1-01 pin

2N, circuit YE/BK (I), harness side and the
clockspring F3-04 pin 10, circuit YE/BK (I),
harness side; and
* the restraints control module S1-01 pin

2J, circuit YE/BK (I), harness side and the
Clockspring F3-04 pin 12, circuit YE/BK (I),
harness side; and

Yes
INSTALL a new clockspring. REFER to Clockspring in
in this section.
No
PINPOINT TEST P : DTC B1933 PASSENGER AIR BAG FIRST STAGE OPEN
CIRCUIT
P1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
section.

Yes
GO to P2.
No
GO to P3.
P2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
1 Connect the Test and Deployment Lead to the
passenger air bag module - first stage.

Page 21 of 69

passenger air bag module - second stage.

Yes
No
INSTALL a new passenger air bag module. REFER to
Passenger Air Bag Module in this section. REPEAT the
P3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR OPEN
CIRCUIT OR HIGH RESISTANCE
3 Disconnect Passenger Air Bag First Stage Simulator.

YE/GN (I), harness side and the passenger air bag
module GN pin 1, circuit YE/GN (I), harness side;
and
 the restraints control module S1-01 pin 2V, circuit

YE (I), harness side and the passenger air bag
module S1-02 pin 2, circuit YE (I), harness side.
Yes
No
PINPOINT TEST Q : DTC B1934 DRIVER AIR BAG FIRST STAGE CIRCUIT
LOW RESISTANCE
Page 22 of 69
Q1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
section.

Yes
GO to Q2.
No
GO to Q3.
Q2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE


Yes
No
Q3: CHECK THE CLOCKSPRING FOR LOW RESISTANCE

Page 23 of 69

control module S1-01 pin 2N, circuit YE/BK (I),
harness side and pin 2J, circuit YE/RD (I), harness
side.

Yes
in this section.
No
PINPOINT TEST R : DTC B1935 PASSENGER AIR BAG FIRST STAGE CIRCUIT
LOW RESISTANCE
R1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
section.

Yes
GO to R2.
No
GO to R3.
R2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
WARNING: Do not proceed with the test unless using WDS. Failure to follow this

Page 24 of 69


Yes
No
R3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR LOW
RESISTANCE
2 Disconnect Passenger Air Bag First Stage Simulator.

control module S1-01 pin 2R, circuit YE/GN (I),
harness side and pin 2V, circuit YE (I), harness
side.

Yes
No
PINPOINT TEST S : DTC B1936 DRIVER AIR BAG FIRST STAGE SHORT TO
Page 25 of 69
GROUND
S1: CHECK THE DRIVER AIR BAG FIRST STAGE CIRCUIT
section.

Yes
GO to S2.
No
GO to S3.
S2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE
4 Measure the resistance between each of the

terminals and the air bag module casing.

Yes
No
S3: CHECK THE DRIVER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT TO
GROUND
Page 26 of 69

Disconnect Driver Air Bag Module First Stage
3
Simulator.


5 Turn the steering wheel from lock to lock and note

the resistance readings.
Yes
No
GO to S4.
S4: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND



Yes
in this section.
No
PINPOINT TEST T : DTC B1938 PASSENGER AIR BAG FIRST STAGE SHORT
TO GROUND
Page 27 of 69
T1: CHECK THE PASSENGER AIR BAG FIRST STAGE CIRCUIT RESISTANCE
1 Deactivate the supplemental restraint system. REFER
to Air Bag and Safety Belt Pretensioner
section.

Yes
GO to T2.
No
GO to T3.
T2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
4 Measure the resistance between each of the terminals

and the air bag module casing.
6 Measure the resistance between each of the terminals
and the air bag module casing.

Yes
No
T3: CHECK THE PASSENGER AIR BAG FIRST STAGE WIRING HARNESS FOR A SHORT
TO GROUND

Page 28 of 69
Disconnect Passenger Air Bag Module First Stage

3
Simulator.

YE/GN (I), harness side and ground; and
 the restraints control module S1-01 pin 2V, circuit YE

(I), harness side and ground.
Yes
No
test CLEAR the DTCs. REACTIVATE the system. REFER to
Air Bag and Safety Belt Pretensioner Supplemental
PINPOINT TEST U : DTC B1992 DRIVER SIDE AIR BAG CIRCUIT SHORT TO
BATTERY
U1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
section.

Yes
No
GO to U2.
U2: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY

YE/BK (F), harness side and ground; and

Page 29 of 69
YE/RD (F), harness side and ground.

Yes
REPAIR circuits YE/BK (F) and YE/RD (F). REPEAT the
No
PINPOINT TEST V : DTC B1993 DRIVER SIDE AIR BAG CIRCUIT SHORT TO
GROUND
V1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
section.

Yes
GO to V2.
No
GO to V3.
V2: CHECK THE DRIVER SIDE AIR BAG MODULE SQUIB RESISTANCE
side air bag module.

terminals and the side air bag module casing.
Page 30 of 69

Yes
No
INSTALL a new driver side air bag module. REFER to
Side Air Bag Module in this section. REPEAT the self-
V3: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
3 Disconnect Driver Underseat Air Bag Simulator.
 the restraints control module S1-01 pin 1M, circuit

YE/BK (F), harness side and ground; and
 the restraints control module S1-01 pin 1Q, circuit

YE/RD (F), harness side and ground.

Yes
No
PINPOINT TEST W : DTC B1994 DRIVER SIDE AIR BAG CIRCUIT OPEN
CIRCUIT
W1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
1
Page 31 of 69

section.

Yes
GO to W2.
No
GO to W3.
W2: CHECK THE DRIVER SIDE AIR BAG MODULE SQUIB RESISTANCE
Is the resistance between 2 and 3 ohms?

Yes
No
W3: CHECK THE DRIVER SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT OR
HIGH RESISTANCE
3 Disconnect Driver Side Air Bag Module Simulator.

YE/BK (F), harness side and the driver side air bag
module connector P-01 pin 1I, circuit YE/BK (F),
harness side; and
Page 32 of 69

YE/RD (F), harness side and the driver side air bag
module connector P-01 pin 1, circuit YE/RD (F),
harness side.

Yes
No
PINPOINT TEST X : DTC B1995 DRIVER SIDE AIR BAG CIRCUIT LOW
RESISTANCE ON SQUIB
X1: CHECK THE DRIVER SIDE AIR BAG CIRCUIT
section.

Yes
GO to X2.
No
GO to X3.
X2: CHECK THE DRIVER SIDE AIR BAG MODULE SQUIB RESISTANCE

Page 33 of 69

Yes
No
X3: CHECK THE DRIVER SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE
3 Disconnect Driver Side Air Bag Simulator.

control module S1-01 pin 1M, circuit YE/BK (F),
harness side and pin 1Q, circuit YE/RD (F),
harness side.

Yes
No
PINPOINT TEST Y : DTC B1996 PASSENGER SIDE AIR BAG CIRCUIT SHORT
TO BATTERY
Y1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
Page 34 of 69

section.

Yes
No
GO to Y2.
Y2: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO BATTERY
 the restraints control module S1-01 pin 1P, circuit

OR/BK (F), harness side and ground; and
 the restraints control module S1-01 pin 1T, circuit

PK/BK (F), harness side and ground.

Yes
REPAIR circuits OR/BK (F) and PK/BK (F). REPEAT the
No
PINPOINT TEST Z : DTC B1997 PASSENGER SIDE AIR BAG CIRCUIT SHORT
TO GROUND
Z1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
section.

Page 35 of 69
Yes
GO to Z2.
No
GO to Z3.
Z2: CHECK THE PASSENGER SIDE AIR BAG MODULE SQUIB RESISTANCE
passenger side air bag module.

terminals and the side air bag module casing.

Yes
No
INSTALL a new passenger side air bag module. REFER
to Side Air Bag Module in this section. REPEAT the self-
Z3: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR A SHORT TO GROUND
3 Disconnect Passenger Side Air Bag Simulator.

OR/BK (F), harness side and ground; and

PK/BK (F), harness side and ground.

Yes
Page 36 of 69
No
PINPOINT TEST AA : DTC B1998 PASSENGER SIDE AIR BAG CIRCUIT OPEN
CIRCUIT
AA1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
section.

Yes
GO to AA2.
No
GO to AA3.
AA2: CHECK THE PASSENGER SIDE AIR BAG MODULE SQUIB RESISTANCE

Yes
No
Page 37 of 69

AA3: CHECK THE PASSENGER SIDE AIR BAG WIRING HARNESS FOR OPEN CIRCUIT
OR HIGH RESISTANCE

OR/BK (F), harness side and the passenger side air
bag module connector S1-06 pin 2, circuit OR/BK
(F), harness side; and

PK/BK (F), harness side and the passenger side air
bag module connector S1-06 pin 1, circuit PK/BK
(F), harness side.
Yes
No
PINPOINT TEST AB : DTC B1999 PASSENGER SIDE AIR BAG CIRCUIT LOW
RESISTANCE ON SQUIB
AB1: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT
section.

Yes
GO to AB2.
No
GO to AB3.
AB2: CHECK THE PASSENGER SIDE AIR BAG MODULE SQUIB RESISTANCE
Page 38 of 69


Yes
No
test, CLEAR the DTCs. REACTIVATE the system.
AB3: CHECK THE PASSENGER SIDE AIR BAG CIRCUIT FOR LOW RESISTANCE

control module S1-01 pin 1T, circuit OR/BK (F),
harness side and pin 1P, circuit PK/BK (F),
harness side.

Yes
No
PINPOINT TEST AC : DTC B2227 CRASH SENSOR COMMUNICATIONS FAULT
Page 39 of 69
AC1: CHECK THE CRASH SENSOR CIRCUIT

section.
2 Disconnect Crash Sensor S1-16.
 the restraints control module S1-01 pin 1K, circuit

BR (F), harness side and the crash sensor S1-16
pin B, circuit BR (F), harness side; and

BR/WH (F), harness side and the crash sensor S1-
16 pin A, circuit BR/WH (F), harness side.
Yes
GO to AC2.
No
REPAIR circuits BR (F) and BR/WH (F). REPEAT the self-
AC2: CHECK THE CRASH SENSOR FOR A SHORT CIRCUIT TO BATTERY

BR (F), harness side and ground; and

BR/WH (F), harness side and ground.

Yes
No
GO to AC3.
AC3: CHECK THE CRASH SENSOR FOR A SHORT CIRCUIT TO GROUND

BR (F) harness side and ground; and
Page 40 of 69

BR/WH (F) harness side and ground.
Are the resistance greater than 10,000 ohms?

Yes
No
PINPOINT TEST AD : DTC B2228 DRIVER AIR BAG SECOND STAGE SHORT
TO GROUND
AD1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
section.

Yes
GO to AD2.
No
GO to AD3.
AD2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE

Page 41 of 69


Yes
No
AD3: CHECK THE DRIVER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT
TO GROUND

Disconnect Driver Air Bag Module Second Stage
3
Simulator.

BU/Or (I), harness side and ground; and
 the restraints control module S1-01 pin 2I, circuit

VT (I), harness side and ground.

Yes
No
GO to AD4.
AD4: CHECK THE CLOCKSPRING FOR A SHORT TO GROUND
1 Disconnect Clockspring F3-04 .

BU/OR (I), harness side and ground; and
Page 42 of 69


Yes
in this section.
No
REPAIR circuits VT (I) and BU/OR (I). REPEAT the self-
PINPOINT TEST AE : DTC B2229 ERROR VALUE 19: PASSENGER AIR BAG
SECOND STAGE SHORT TO GROUND
AE1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
section.

Yes
GO to AE2.
No
GO to AE3.
AE2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
Page 43 of 69


Yes
No
AE3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR A
SHORT TO GROUND

Disconnect Passenger Air Bag Module Second Stage
3
Simulator.

GN/OR (I), harness side and ground; and

GN/YE (I), harness side and ground.

Yes
No
REPAIR circuits GN (I) and GN/OR (I). REPEAT the self-
Page 44 of 69

PINPOINT TEST AF : DTC B2230 DRIVER AIR BAG SECOND STAGE SHORT TO
BATTERY
AF1: CHECK THE DRIVER AIR BAG SECOND STAGE WIRING HARNESS FOR A SHORT
section.
Disconnect Driver Air Bag Module Second Stage
2
Simulator.



Yes
GO to AF2.
No
CONNECT the driver air bag module second stage
AF2: CHECK THE CLOCKSPRING FOR A SHORT TO BATTERY OR IGNITION



Yes
REPAIR circuits BU/OR (I) and VT (I). REPEAT the self-
Page 45 of 69

No
in this section.
PINPOINT TEST AG : DTC B2231 PASSENGER AIR BAG SECOND STAGE
SHORT TO BATTERY
AG1: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR A
SHORT TO BATTERY OR IGNITION
section.
2
Simulator.

GN (I), harness side and ground; and

GN/YE (I), harness side and ground.

Yes
REPAIR circuits GN (I) and GN/YE (I). REPEAT the self-
No
CONNECT the passenger air bag module second stage
PINPOINT TEST AH : DTC B2232 DRIVER AIR BAG SECOND STAGE OPEN
CIRCUIT
AH1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
Page 46 of 69

section.

Yes
GO to AH2.
No
GO to AH3.
AH2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE


Yes
No
AH3: CHECK THE CLOCKSPRING FOR OPEN CIRCUIT OR HIGH RESISTANCE
3 Disconnect Clockspring F3-04 .

Page 47 of 69

BU/OR (I), harness side and the clockspring F3-04
pin 8, circuit BU/OR (I), harness side; and

VT (I), harness side and the clockspring F3-04 pin
2, circuit VT (I), harness side.

Yes
in this section.
No
PINPOINT TEST AI : DTC B2233 PASSENGER AIR BAG SECOND STAGE OPEN
CIRCUIT
AI1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
section.

Yes
GO to AI2.
No
GO to AI3.
AI2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE

Page 48 of 69


Yes
No
AI3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR OPEN

3
Simulator.

GN/OR (I), harness side and the passenger air bag
module C503 pin 1, circuit GN/OR (I), harness side;
and

GN (I), harness side and the passenger air bag
module S1-02 pin 2, circuit GN/YE (I), harness
side.
Yes
No
REPAIR circuits GN/OR (I) and GN/YE (I). REPEAT the
Page 49 of 69
PINPOINT TEST AJ : DTC B2234 DRIVER AIR BAG SECOND STAGE CIRCUIT
LOW RESISTANCE
AJ1: CHECK THE DRIVER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
section.

Yes
GO to AJ2.
No
GO to AJ3.
AJ2: CHECK THE DRIVER AIR BAG MODULE SQUIB RESISTANCE


Yes
No
AJ3: CHECK THE CLOCKSPRING FOR LOW RESISTANCE
Page 50 of 69

control module S1-01 pin 2E, circuit BU/OR (I),
harness side and pin 2I, circuit VT (I), harness
side.

Yes
in this section.
No
PINPOINT TEST AK : DTC B2235 PASSENGER AIR BAG SECOND STAGE
AK1: CHECK THE PASSENGER AIR BAG SECOND STAGE CIRCUIT RESISTANCE
section.

Yes
GO to AK2.
No
GO to AK3.
AK2: CHECK THE PASSENGER AIR BAG MODULE SQUIB RESISTANCE
Page 51 of 69


Yes
No
AK3: CHECK THE PASSENGER AIR BAG SECOND STAGE WIRING HARNESS FOR LOW
RESISTANCE
2
Simulator.

control module S1-01 pin 2M, circuit GN/OR (I),
harness side and pin 2Q, circuit GN (I), harness
side.

Yes
No
REPAIR circuits GN (I) and GN/OR (I). REPEAT the self-
Page 52 of 69

PINPOINT TEST AL : DTC B2294 DRIVER SIDE AIR CURTAIN CIRCUIT LOW
RESISTANCE ON SQUIB
AL1: CHECK THE DRIVER SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
section.

Yes
GO to AL2.
No
GO to AL3.
AL2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
side air curtain module.

Yes
No
INSTALL a new driver side air curtain module. REFER to
Side Air Curtain Module in this section. REPEAT the self-
AL3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR LOW
RESISTANCE
2 Disconnect Driver Side Air Curtain Simulator.

Page 53 of 69

control module S1-01 pin 1G, circuit WH/BU (F),
harness side and pin 1C, circuit RD/WH (F),
harness side.

Yes
No
REPAIR circuits RD/WH (F) and WH/BU (F). REPEAT the
PINPOINT TEST AM : DTC B2294 DRIVER SIDE AIR CURTAIN CIRCUIT OPEN
CIRCUIT
AM1: CHECK THE DRIVER SIDE AIR CURTAIN CIRCUIT RESISTANCE
section.

Yes
GO to AM2.
No
GO to AM3.
AM2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
4
Measure the resistance of the side air curtain
Page 54 of 69
module squib.

Yes
No
AM3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR OPEN CIRCUIT
OR HIGH RESISTANCE
3 Disconnect Driver Side Air Curtain Simulator.
 the restraints control module S1-01 pin 1G, circuit

WH/BU (F), harness side and the driver side air
curtain module S1-13 pin 1, circuit WH/BU (F),
harness side; and
 the restraints control module S1-01 pin 1C, circuit

RD/WH (F), harness side and the driver side air
curtain module S1-13 pin 2, circuit RD/WH (F),
harness side.
Yes
No
PINPOINT TEST AN : DTC B2294 DRIVER SIDE AIR CURTAIN CIRCUIT
SHORT TO GROUND
Page 55 of 69
AN1: CHECK THE DRIVER SIDE AIR CURTAIN CIRCUIT

section.

Yes
GO to AN2.
No
GO to AN3.
AN2: CHECK THE DRIVER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE

terminals and the side air curtain module casing.

Yes
No
AN3: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
GROUND

Disconnect Driver Side Air Curtain Module
3
Simulator.

Page 56 of 69
WH/BU (F), harness side and ground; and

RD/WH (F), harness side and ground.

Yes
No
self-test CLEAR the DTCs. REACTIVATE the system.
PINPOINT TEST AO : TC B2294 DRIVER SIDE AIR CURTAIN CIRCUIT SHORT
TO BATTERY
AO1: CHECK THE DRIVER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT TO
BATTERY OR IGNITION
section.
Disconnect Driver Side Air Curtain Module
2
Simulator.

WH/BU (F), harness side and ground; and

RD/WH (F), harness side and ground.

Yes
No
Page 57 of 69
CONNECT the driver side air curtain module simulator

and the restraints control module. REPEAT the self-test,
PINPOINT TEST AP : DTC B2294 PASSENGER SIDE AIR CURTAIN CIRCUIT
LOW RESISTANCE ON SQUIB
AP1: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE CIRCUIT RESISTANCE
section.

Yes
GO to AP2.
No
GO to AP3.
AP2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
passenger side air curtain module.
4 Measure the resistance of the side air curtain

module squib.

Yes
No
INSTALL a new passenger side air curtain module.
REFER to Side Air Curtain Module in this section.
Page 58 of 69

AP3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR LOW
RESISTANCE
Disconnect Passenger Side Air Curtain Module
2
Simulator.

control module S1-01 pin 1D, circuit YE/GN (F),
harness side and pin 1H, circuit YE (F), harness
side.

Yes
No
REPAIR circuits YE (F) and YE/GN (F). REPEAT the self-
PINPOINT TEST AQ : DTC B2294 PASSENGER SIDE AIR CURTAIN CIRCUIT
OPEN CIRCUIT
AQ1: CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUIT RESISTANCE
section.

Yes
GO to AQ2.
No
GO to AQ3.
AQ2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE
Page 59 of 69

4 Measure the resistance of the side air curtain

module squib.

Yes
No
AQ3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR OPEN

3
Simulator.
 the restraints control module S1-01 pin 1D, circuit

YE/GN (F), harness side and the passenger side air
curtain module S1-14 pin 1, circuit YE/GN (F),
harness side; and
 the restraints control module S1-01 pin 1H, circuit

YE (F), harness side and the passenger side air
curtain module S1-14 pin 2, circuit YE (F), harness
side.
Yes
No
Page 60 of 69
PINPOINT TEST AR : DTC B2294 PASSENGER SIDE AIR CURTAIN CIRCUIT
SHORT TO GROUND
AR1: CHECK THE PASSENGER SIDE AIR CURTAIN CIRCUIT
section.

Yes
GO to AR2.
No
GO to AR3.
AR2: CHECK THE PASSENGER SIDE AIR CURTAIN MODULE SQUIB RESISTANCE

terminals and the side air curtain module casing.

Yes
No
AR3: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT
TO GROUND
Page 61 of 69

3
Simulator.

YE/GN (F), harness side and ground ; and

YE (F), harness side and ground.

Yes
No
PINPOINT TEST AS : DTC B2294 PASSENGER SIDE AIR CURTAIN CIRCUIT
SHORT TO BATTERY
AS1: CHECK THE PASSENGER SIDE AIR CURTAIN WIRING HARNESS FOR A SHORT
section.
2
Simulator.

YE/GN (F), harness side and ground; and

YE (F), harness side and ground.

Yes
Page 62 of 69

No
CONNECT the passenger side air curtain module
PINPOINT TEST AT : DTC B2791 AIR BAG CUT-OFF SWITCH OUT OF RANGE
AT1: CHECK THE VOLTAGE TO THE PASSENGER AIR BAG DISABLE (PAD) CONTROL
SWITCH
2 Operate the PAD control switch to the OFF position.

Does the pad indicator LED illuminate?
Yes
GO to AT2.
No
GO to AT3.
AT2: CHECK FOR CONTINUITY BETWEEN THE RESTRAINTS CONTROL MODULE AND
THE PAD CONTROL SWITCH
section.
3 Operate the PAD control switch to the ON position.

control module S1-01 pin 2P, circuit BU/WH (I),

Yes
No
REPAIR circuit BU/WH (I). REPEAT the self-test, CLEAR
Page 63 of 69

AT3: CHECK THE PAD CONTROL SWITCH GROUND CIRCUIT
section.
2 Disconnect PAD Control Switch S1-19.
3 Measure the resistance between the PAD control

switch S1-19 pin 3, circuit BK (I), harness side
and ground.

Yes
GO to AT4.
No
AT4: CHECK FOR CONTINUITY BETWEEN THE PAD INDICATOR AND THE PAD
CONTROL SWITCH
1 Disconnect PAD Indicator S1-18.
2 Measure the resistance between the PAD indicator

S1-18 pin 4, circuit OG, harness side and the PAD
control switch S1-19 pin 1E, circuit OG, harness
side.

Yes
GO to AT5.
No
REPAIR circuit. REPEAT the self-test, CLEAR the DTCs.
in this section.
AT5: CHECK FOR CONTINUITY BETWEEN THE RESTRAINTS CONTROL MODULE AND
THE PAD INDICATOR

control module S1-01 pin 2S, circuit YE/GN (I),
harness side and the PAD indicator S1-18 pin 2,
circuit YE/GN (I), harness side.
Page 64 of 69

Yes
INSTALL a new PAD indicator. REPEAT the self-test,
No
REPAIR circuit YE/GN (I). REPEAT the self-test, CLEAR
PINPOINT TEST AU : DTC B2791 AIR BAG CUT-OFF SWITCH IN MIDDLE
POSITION
AU1: CHECK THE PASSENGER AIR BAG DISABLE (PAD) LED OPERATION

Yes
GO to AU2.
No
GO to AU3.
AU2: CHECK FOR CONTINUITY BETWEEN THE PAD LED AND GROUND
section.
2 Disconnect PAD control switch S1-19.

Yes
REPAIR circuit OG (I). REPEAT the self-test, CLEAR the
No
GO to AU3.
AU3: CHECK THE PAD CONTROL SWITCH GROUND CIRCUIT
Page 65 of 69

control module S1-01 pin 2P, circuit BU/WH (I),

Yes
INSTALL a new PAD switch. REFER to Passenger Air Bag
Deactivation (PAD) Switch in this section. REPEAT the
No
REPAIR circuit BU/WH (I). REPEAT the self-test, CLEAR
PINPOINT TEST AV : DTC U2017 DRIVER SIDE IMPACT SENSOR
COMMUNICATIONS FAULT
AV1: CHECK THE DRIVER SIDE IMPACT SENSOR CIRCUIT
section.
2 Disconnect Driver Side Impact Sensor S1-09.

PK/BU (F), harness side and the driver side impact
sensor S1-09 pin A, circuit LG (F), harness side;
and
 the restraints control module S1-01 pin 1S, circuit

LG (F), harness side and the driver side impact
sensor S1-09 pin A, circuit LG (F), harness side.
Yes
GO to AV2.
No
Page 66 of 69
REPAIR circuits LG (F) and PK/BU (F). REPEAT the self-

AV2: CHECK THE DRIVER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO BATTERY

PK/BU (F), harness side and ground; and

LG (F), harness side and ground.

Yes
No
GO to AV3.
AV3: CHECK THE DRIVER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO GROUND

PK/BU (F), harness side and ground; and

LG (F), harness side and ground.
Are the resistance greater than 10,000 Ohms?

Yes
No
PINPOINT TEST AW : DTC U2018 PASSENGER SIDE IMPACT SENSOR
COMMUNICATIONS FAULT
AW1: CHECK THE PASSENGER SIDE IMPACT SENSOR CIRCUIT
1
Page 67 of 69

section.
2 Disconnect Passenger Side Impact Sensor S1-10.

GN (F), harness side and the passenger side impact
sensor S1-10 pin B, circuit GN (F), harness side;
and
the restraints control module S1-01 pin 10, circuit


GN/RD (F), harness side and the passenger side
impact sensor S1-10 pin 2, circuit GN/RD (F),
harness side.
Yes
GO to AW2.
No
REPAIR circuits GN (F) and GN/RD (F). REPEAT the self-
AW2: CHECK THE PASSENGER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO
BATTERY

GN (F), harness side and ground; and

GN/RD (F), harness side and ground.

Yes
No
GO to AW3.
AW3: CHECK THE PASSENGER SIDE IMPACT SENSOR FOR A SHORT CIRCUIT TO
GROUND

Page 68 of 69
GN (F), harness side and ground; and

GN/RD (O), harness side and ground.
Are the resistance greater than 10,000 Ohms?

Yes
No
PINPOINT TEST AX : RESTRAINTS CONTROL MODULE DISCONNECTED OR
INOPERATIVE
AX1: CHECK THE RESTRAINTS CONTROL MODULE ELECTRICAL CONNECTORS
section.
2 Check the restraints control module electrical
connectors.
Are the restraints control module electrical connectors
fully engaged?
Yes
GO to AX2.
No
CONNECT the restraints control module electrical
connectors. REPEAT the self-test, CLEAR the DTCs.
in this section.
AX2: CHECK THE IGNITION SUPPLY CIRCUIT FOR AN OPEN CIRCUIT

side and ground.
Page 69 of 69
Is the voltage between 9 and 16 volts?

Yes
GO to AX3.
No
GO to AX4.
AX3: CHECK THE RESTRAINTS CONTROL MODULE GROUND CIRCUIT

control module S1-01 pin 2T, circuit BK (I),

Yes
No
AX4: CHECK THE IGNITION SUPPLY CIRCUIT
side and ground.

Yes
CHECK the charging circuit. REFER to Section 414-00.
[Charging System - General Information, DIAGNOSIS
AND TESTING, Charging System] REPEAT the self-test,
No
REPAIR circuit BK/RD (I). REPEAT the self-test, CLEAR
Page 1 of 3

SAFETY BELT PRETENSIONER
DISPOSAL
UID=G290004
Special Tool(s)
Deployment Lead, Air
Bag/Pyrotechnic Safety Belt
49 H066 002
Test and Deployment Lead, Driver

Air Bag, Passenger Air Bag, Side
Air Bag, Pyrotechnic Safety Belt
49 L066 002
General Equipment
12v Battery
Wooden blocks
Deploy
WARNINGS:
Before a vehicle equipped with air bag module(s) and safety belt pretensioners is
scrapped, the air bag module(s) and safety belt pretensioners must be deployed. Failure
to follow this instruction may result in personal injury.
Air bag modules and safety belt pretensioners must be deployed in well ventilated
areas. Failure to follow this instruction may result in personal injury.
Before deploying the air bag module or safety belt pretensioner, make sure that all
personnel in the vicinity are aware that a loud noise (bang) is about to occur. Do not let
anybody approach closer than six meters. Failure to follow this instruction may result in
personal injury.
The air bag module or the safety belt pretensioner should not be handled
immediately following deployment as the air bag module or safety belt pretensioner will
be very hot. Failure to follow this instruction may result in personal injury.
After deployment the inflator(s) become inert, direct contact with the skin or eyes of
any free pyrotechnic residues should be avoided. Failure to follow this instruction may
Always wear gloves and safety glasses when handling deployed air bag modules and
safety belt pretensioners. Failure to follow this instruction may result in personal injury.
If the air bag module or the safety belt pretensioner pyrotechnic residue should
contact the eyes, immediately wash the eyes thoroughly with clean water and seek
medical assistance. Failure to follow this instruction may result in personal injury.
WARNING: If a large amount of air bag module or the safety belt pretensioner
pyrotechnic residue is inhaled, seek medical assistance. Failure to follow this instruction
1. WARNING: Do not use the deployment

tool if it fails the normal operation check.
Page 2 of 3

personal injury.
Check the deployment tool for normal operation.
1. Connect the deployment tool to a 12 volt
battery. Green light on, red light off.
2. Connect the electrical connectors. Green
light off, red light on.
3. Depress the switch. Green light on, red light
off.
2. Remove the safety belt retractor and

pretensioners to be deployed. For additional
information, refer to Section 501-20A.[Safety
Belt System, REMOVAL AND INSTALLATION,
Safety Belt Retractor and Pretensioner]
3. Connect the test lead to the safety belt
retractor and pretensioner.
 Place the safety belt retractor and

pretensioner inside a suitable rigid wire cage.
4. Connect the test lead to the deployment lead.
5. Move as far away as possible from the safety

belt retractor and pretensioner and depress
the switch to deploy the safety belt retractor
and pretensioner.
6. WARNING: Under no circumstances is

an unserviceable air bag module or safety
belt retractor and pretensioner to be returned
through the local mailing system. Failure to
injury.
If a safety belt and retractor pretensioner fails to
deploy, seal the unserviceable safety belt and
retractor pretensioner in suitable packaging
and return to the Exchange Plan Center, as
appointed through the local National Sales
Company.
7. Deployed safety belt retractor and
Page 3 of 3
pretensioners should be sealed in suitable bags

and then disposed of in accordance with local
contaminated waste regulations.
Page 1 of 3

SCRAPPED VEHICLE UNDEPLOYED AIR
BAG DISPOSAL
UID=G290005
Special Tool(s)
Deployment Lead, Air
Bag/Pyrotechnic Safety Belt
49 H066 002

Air bag, Passenger Air Bag, Side
Air Curtain, Pyrotechnic Safety
Belt
49 L066 002
Air bag, Passenger Air Bag
49 G066 003
Test and Deployment Lead, Side

Air Bag
49 D066 004
General Equipment
12v Battery
Wooden blocks
All vehicles
WARNINGS:

be placed on work benches which have been ground bonded. Failure to follow this
Air bag modules and safety belt pretensioners must be deployed in well ventilated
areas. Failure to follow this instruction may result in personal injury.
Before deploying the air bag module or safety belt pretensioner, make sure that all
personnel in the vicinity are aware that a loud noise (bang) is about to occur. Do not let
anybody approach closer than six meters. Failure to follow these instructions may result
in personal injury.
The air bag module or the safety belt pretensioner should not be handled
immediately following deployment as the air bag module or safety belt pretensioner will
be hot. Failure to follow this instruction may result in personal injury.
After deployment the inflator(s) become inert, direct contact with the skin or eyes of
any free pyrotechnic residues should be avoided. Failure to follow this instruction may
Page 2 of 3
Always wear gloves and safety glasses when handling deployed air bag modules and
safety belt pretensioners. Failure to follow this instruction may result in personal injury.
If the air bag module or the safety belt pretensioner pyrotechnic residue should
contact the eyes, immediately wash the eyes thoroughly with clean water and seek
medical assistance. Failure to follow this instruction may result in personal injury.
If a large amount of air bag module or the safety belt pretensioner pyrotechnic
residue is inhaled, seek medical assistance. Failure to follow this instruction may result in
personal injury.
1. WARNING: Do not use the deployment

tool if it fails the normal operation check.
personal injury.
Check the deployment tool for normal operation.
1. Connect the deployment tool to a 12 volt
battery. Green light on, red light off.
2. Connect the electrical connectors A and B.
Green light off, red light on.
3. Depress the switch. Green light on, red light
off.
2. Remove the air bag module(s) to be deployed.
For additional information, refer to the relevant
procedure(s) in this section.
Single stage air bag modules

3. Connect the test lead to the air bag module.
Two stage air bag modules

4. Connect the test leads to the air bag module.
All air bag modules
5. CAUTION: To protect the test lead

electrical connector(s) from damage during
deployment, raise the air bag module off the
ground on two wooden blocks.
Page 3 of 3
Place the air bag module inside a suitable rigid

wire cage with the air bag module cover
uppermost (driver air bag shown).
 Connect a test lead to the deployment lead.
6. Move as far away as possible from the air bag

module and connect the deployment lead to
the battery.
module and depress the switch to deploy the
air bag module.
Two stage air bag modules

8. Connect the second test lead to the
deployment lead.

module and depress the switch to deploy the
air bag module.
All air bag modules

10. Deployed air bag module(s) should be sealed
in a suitable bag and then disposed of in
accordance with local contaminated waste
regulations.
Page 1 of 2

FRONT SIDE MEMBER EXTENSION
UID=G290007
General Equipment
Name Specification
Side member front extension
Bulkhead reinforcement
Removal
1. General Notes.
 The front side member with apron panel and

apron panel reinforcement are already
removed before the repair work starts.
 Necessary removal work: Facia crash padding

and seats.
 Fold back the carpets and move the wiring

back away from the working area.
2. Side member
thicknesses).
thicknesses).
Installation
Page 2 of 2
1. Side member
 Drill holes for puddle welding (10 mm

diameter).
NOTE: : before welding, secure the side member using the measurement or alignment
angle system.
2. Side member
 Puddle welding

diameter).
 Puddle welding
5. Side member
 Puddle welding
Page 1 of 4

CROSSMEMBER
UID=G290011
General Equipment
Transmission jack
5 mm Allen key
Wooden block
Securing strap
Removal
Detach the stabilizer bar link from the stabilizer
bar on both sides.

5. Detach the exhaust system from the exhaust

hanger insulator.
Page 2 of 4
6. Detach the steering gear from the

crossmember.
 Using cable ties, support the steering gear on

both sides.
7. Using a suitable transmission jack and a

wooden block, support the crossmember and
lower arm assembly.
8. Secure the crossmember and lower arm
assembly to the transmission jack using a
suitable securing strap.
both sides.

block, remove the crossmember and lower arm
assembly.
11. NOTE: If a new crossmember is to be
installed remove the lower arms.
Remove the lower arms.
Installation
1. NOTE: If installing a new crossmember,
install the lower arms.
NOTE: Do not fully tighten the lower arm to
crossmember retaining bolts at this stage.
Install the lower arms.

block position the crossmember and lower arm
assembly.
Page 3 of 4

sides.

on both sides.

block.
6. Attach the steering gear to the crossmember.
7. Attach the exhaust system to the exhaust

hanger insulator.

Attach the heat shield to the wheel knuckle on
Page 4 of 4
both sides.

knuckle.

Attach the stabilizer bar link to the stabilizer bar
on both sides.
12. Install the front wheels and tires. For

13. NOTE: The lower arm to crossmember
retaining bolts must be tightened with the
vehicle weight on the road wheels.
Tighten the lower arm to crossmember retaining
bolts.
1. Tighten the bolts in two stages.
* Stage 1: 80 Nm
* Stage 2: 55 degrees.
2. Tighten the bolts.

Toe Adjustment]
Page 1 of 1

INTERIOR TRIM
UID=G29003
This section covers removal and installation of the interior mouldings and trim panels. In
most instances, one component overlaps another component. If this condition is found, it will
be necessary to loosen or remove the overlapping component before removal of the desired
component.
The headliner is a one-piece design covering the entire interior roof and is made of a moulded
composite with a cloth covering.
The vehicle is carpeted throughout.

Page 1 of 12

ANTI-LOCK CONTROL
UID=G290108
General Equipment
Refer to the Wiring Diagram Sections for schematic and connector information.
Electrical
* Fuse(s)
* Electrical connector(s)
* Wiring harness(s)
ABS On-Board Diagnosis
On-Board Diagnostic (OBD) Test Description
* The OBD test inspects the integrity and function of the ABS and outputs the results
when requested by the specific tests.
* The OBD diagnostic test also:
 Provides a quick inspection of the ABS usually performed at the start of each
diagnostic procedure.
 Provides verification after repairs to make sure that no other faults occurred
during service.
* The OBD test is divided into 3 tests:
 Read/Clear diagnostic results, PID monitor and record and active command
modes.
Read/Clear diagnostic results
This function allows you to read or clear DTCs in the ABS HU/CM memory.
PID/data monitor and record
This function allows you to access certain data values, input signals, calculated values, and
system status information.
Page 2 of 12
Active command modes
This function allows you to control devices through the WDS.
Reading DTCs Procedure
1. Connect WDS to the vehicle DLC.
2. Retrieve DTC by WDS.
Clearing DTCs Procedure
1. After repairs have been made, perform the DTCs reading procedure.
2. Erase DTC by WDS.
3. Make sure that the customer concern has been resolved.
PID/Data Monitor and Record Procedure
2. Access and monitor PIDs by WDS.
Active Command Modes Procedure

Page 3 of 12
2. Turn the ignition switch to ON (engine OFF) or start the engine.
3. Activate active command modes using WDS.
Terminal Voltage Table (reference value)
All vehicles built up to 07/2004 and vehicles with stability assist built 07/2004 onwards (Mk60
ABS system)
Measured
terminal
Measured (measured
Terminal Signal name Connected to item condition) Standard Inspection item(s)
A Ground Ground point Continuity A— Ground Continuity Related wiring harness
(system) point
B Ground (ABS Ground point Continuity B—Ground Continuity Related wiring harness
motor) point
C - - - - - -
D CAN_L Data link Continuity D—Data link Continuity Related wiring harness
connector-2 connector-2
(CAN_L) CAN_L
terminal
E LF wheel LF wheel Continuity E—LF wheel Continuity Related wiring harness
speed speed sensor speed sensor
(ground) connector O-
02 (R/B)
terminal
F - - - - - -
G - - - - - -
H LF wheel LF wheel Continuity H—LF wheel Continuity Related wiring harness
(signal) connector O-
02 (G)
terminal
I Yaw rate Yaw rate Continuity I—Yaw rate Continuity Related wiring harness
sensor and sensor and sensor and
accelerometer accelerometer accelerometer
(signal) connector B
terminal
J - - - - - -
K - - - - - -
L - - - - - -
M - - - - - -
N RR wheel RR wheel Continuity N—RR wheel Continuity Related wiring harness
04 (L/W)
terminal
O - - - - - -
P CAN_H Data link Continuity P—Data link Continuity Related wiring harness
(CAN_H) CAN_H
terminal
Q RR wheel RR wheel Continuity Q—RR wheel Continuity Related wiring harness
04 (L)
terminal
R - - - - - -
Page 4 of 12
S - - - - - -
T Stoplamp Stoplamp Voltage T—A (When V batt * Related
switch switch depressing wiring
the brake harness
pedal with
ignition * Brake
switch at the switch
ON position)
T—A (When 1 V or less
releasing the
brake pedal
with ignition
switch at the
ON position)
U Yaw rate Yaw rate Continuity U—Yaw rate Continuity Related wiring harness
sensor and sensor and sensor and
accelerometer accelerometer accelerometer
(ground) connector A
terminal
V - - - - - -
W - - - - - -
X - - - - - -
Y - - - - - -
Z - - - - - -
AA - - - - - -
AB Steering Steering Continuity AB—Steering Continuity Related wiring harness
wheel wheel wheel
rotation rotation rotation
sensor sensor sensor
(signal) connector A
terminal
AC Stability Stability Continuity AC—A (With Continuity * Related
assist assist the stability wiring
deactivation deactivation assist harness
switch switch deactivation
switch in the * Stability
ON position) assist
AC—A (With Resistance deactivation
the stability greater switch
assist than
deactivation 10,000
switch in the ohms
OFF position)
AD - - - - - -
AE Steering Steering Continuity AE—Steering Continuity Related wiring harness
wheel wheel wheel
(ground) connector B
terminal
AF LR wheel LR wheel Continuity AF—LR wheel Continuity Related wiring harness
04 (G/W)
terminal
AG - - - - - -
AH Steering Steering Continuity AH—Steering Continuity Related wiring harness
wheel wheel wheel
Page 5 of 12

(ground) connector C
terminal
AI LR wheel LR wheel Continuity AI—LR wheel Continuity Related wiring harness
04 (V/W)
terminal
AJ Power Power Continuity AJ—Power Continuity Related wiring harness
steering steering steering
pressure pressure pressure
connector B
terminal
AK Power supply Ignition Voltage Ignition ON V batt Related wiring harness
(system) switch Ignition OFF 1 V or less
AL - - - - - -
AM Power Power Continuity AM—Power Continuity Related wiring harness
connector A
terminal
AN Steering Steering Continuity AN—Steering Continuity Related wiring harness
wheel wheel wheel
(signal) connector D
terminal
AO RF wheel RF wheel Continuity AO—RF wheel Continuity Related wiring harness
03 (V)
terminal
AP Power Power Continuity AP—Power Continuity Related wiring harness
connector C
terminal
AQ KLN Data link Continuity AQ—Data link Continuity Related wiring harness
(KLN) KLN terminal
AR RF wheel RF wheel Continuity AR—RF wheel Continuity Related wiring harness
03 (W/B)
terminal
AS - - - - - -
AT Power supply Battery Voltage Under any V batt Related wiring harness
(ABS motor) voltage condition
AU Power supply Battery Voltage Under any V batt Related wiring harness
(solenoid) voltage condition
Vehicles without stability assist built 07/2004 onwards (Mk70 ABS system)
Measured terminal
Signal Measured (measured
Terminal name Connected to item condition) Standard Inspection item(s)
A - - - - - -
Page 6 of 12
B Ground Ground point Continuity B—Ground point Continuity Related wiring

harness
C RR wheel RR wheel Continuity C—RR wheel speed Continuity Related wiring
speed speed sensor sensor connector harness
(ground) O-04 (L) terminal
D - - - - - -
E RR wheel RR wheel Continuity E—RR wheel speed Continuity Related wiring
(signal) O-04 (L/W)
terminal
F - - - - - -
G - - - - - -
H CAN_H Data link Continuity H—Data link Continuity Related wiring
connector-2 connector-2 harness
(CAN_H) CAN_H terminal
I LF wheel LF wheel Continuity I—LF wheel speed Continuity Related wiring
(signal) O-02 (G) terminal
J - - - - - -
K LF wheel LF wheel Continuity K—LF wheel speed Continuity Related wiring
(ground) O-02 (R/B)
terminal
L CAN_L Data link Continuity L—Data link Continuity Related wiring
connector-2 connector-2 CAN_L harness
(CAN_L) terminal
M - - - - - -
N Power Ignition Voltage Ignition ON V batt Related wiring
supply switch Ignition OFF 1 V or harness
(System) less
O RF wheel RF wheel Continuity O—RF wheel speed Continuity Related wiring
(ground) O-03 (W/B)
terminal
P - - - - - -
Q RF wheel RF wheel Continuity Q—RF wheel speed Continuity Related wiring
(signal) O-03 (V) terminal
R KLN Data link Continuity R—Data link Continuity Related wiring
connector-2 connector-2 KLN harness
(KLN) terminal
S - - - - - -
T - - - - - -
U LR wheel LR wheel Continuity U—LR wheel speed Continuity Related wiring
(signal) O-04 (V/W)
terminal
V Stoplamp Stoplamp Voltage V—B (When V batt * Related
switch switch depressing the wiring
brake pedal with harness
ignition switch at
the ON position) * Brake
V—B (When 1 V or switch
releasing the brake less
pedal with ignition
switch at the ON
position)
W LR wheel LR wheel Continuity W—LR wheel Continuity Related wiring
Page 7 of 12
speed speed sensor speed sensor harness

(ground) connector O-04
(G/W) terminal
X - - - - - -
Y Power Battery Voltage Under any V batt Related wiring
supply voltage condition harness
(solenoid)
Z Power Battery Voltage Under any V batt Related wiring
supply voltage condition harness
(ABS
motor)
Symptom Chart

No communication with the *DLC. *REFER to network check pinpoint menu on
module *Circuit(s). WDS.
*ABS control
module.
DTC B1317: Battery *Charging system. *CHECK the charging system. REFER to
voltage high Section 414-00.[Charging System - General
Information, DIAGNOSIS AND TESTING,
Charging System] REPEAT the self-test, CLEAR
the DTCs.
DTC B1318: Battery *Charging system. *Check the charging system and battery. REFER
voltage low *Battery to Section 414-00.[Charging System - General
Charging System] REPEAT the self-test, CLEAR
the DTCs.
DTC B1342: ABS control *ABS control *INSTALL a new ABS control module. REFER to
module is defective module internal Section 206-09C.[Anti-Lock Control - Stability
failure. Assist, REMOVAL AND INSTALLATION,
Hydraulic Control Unit (HCU)] REPEAT the self-
test, CLEAR the DTCs.
DTC B2741: Yaw rate *Yaw rate sensor *INSTALL a new yaw rate sensor and
sensor and accelerometer and accelerometer accelerometer. REFER to Section 206-09C.
internal failure cluster. [Anti-Lock Control - Stability Assist, REMOVAL
AND INSTALLATION, Yaw Rate Sensor and
Accelerometer] REPEAT the self-test, CLEAR the
DTCs.
DTC C1093: Traction *Switch. *PERFORM ESP/TCS switch test on WDS.
control disable switch *Circuit.
circuit failure
DTC C1095: ABS hydraulic *Motor. *INSTALL a new ABS control module. REFER to
pump motor circuit failure *Circuit. Section 206-09C.[Anti-Lock Control - Stability
Assist, REMOVAL AND INSTALLATION,
Hydraulic Control Unit (HCU)] REPEAT the self-
DTC C1141: Wheel speed *Wheel speed *INSTALL a new front wheel bearing. REFER to
sensor LEFT FRONT tone sensor ring. Section 204-01.[Front Suspension, REMOVAL
ring tooth missing fault AND INSTALLATION, Wheel Bearing] REPEAT
the self-test, CLEAR the DTCs.
DTC C1142: Wheel speed *Wheel speed *INSTALL a new front wheel bearing. REFER to
sensor RIGHT FRONT tone sensor ring. Section 204-01.[Front Suspension, REMOVAL
ring tooth missing fault AND INSTALLATION, Wheel Bearing] REPEAT
DTC C1143: Wheel speed *Wheel speed *INSTALL a new wheel speed sensor ring. REFER
sensor LEFT REAR tone ring sensor ring. to Section 206-09C.[Anti-Lock Control -
tooth missing fault Stability Assist, REMOVAL AND INSTALLATION,
Page 8 of 12
Rear Wheel Speed Sensor Ring] REPEAT the self-

DTC C1144: Wheel speed *Wheel speed *INSTALL a new wheel speed sensor ring. REFER
sensor RIGHT REAR tone sensor ring to Section 206-09C.[Anti-Lock Control -
ring tooth missing fault Stability Assist, REMOVAL AND INSTALLATION,
Rear Wheel Speed Sensor Ring] REPEAT the
self-test, CLEAR the DTCs.
DTC C1145: Wheel speed *Wheel speed *REFER to DTC C1145 pinpoint menu on WDS.
RIGHT FRONT input circuit sensor.
failure *Circuit.
LEFT FRONT input circuit sensor.
failure *Circuit.
RIGHT REAR input circuit sensor.
failure *Circuit.
LEFT REAR input circuit sensor.
failure *Circuit.
DTC C1233: LEFT FRONT *Air gap too large. *REFER to DTC C1233 pinpoint menu on WDS.
wheel speed input signal *Wheel speed
missing sensor.
DTC C1234: RIGHT FRONT *Air gap too large. *REFER to DTC C1234 pinpoint menu on WDS.
missing sensor.
DTC C1235: RIGHT REAR *Air gap too large. *REFER to DTC C1235 pinpoint menu on WDS.
missing sensor.
DTC C1236: LEFT REAR *Air gap too large. *REFER to DTC C1236 pinpoint menu on WDS.
missing sensor.
DTC C1267: ABS control *ABS control *REFER to DTC C1267 pinpoint menu on WDS.
module internal fault module.
*Circuit(s).
DTC C1277: Steering wheel *ABS control *REFER to DTC C1277 pinpoint menu on WDS.
angle sensor offset failure module.
*Steering wheel
position sensor.
*Circuit(s).
DTC C1279: Yaw rate *ABS control *REFER to DTC C1279 pinpoint menu on WDS.
sensor circuit failure module.
*Yaw rate sensor
and
accelerometer.
*Circuit(s).
DTC C1280: Yaw rate *Yaw rate sensor. *REFER to DTC C1280 pinpoint menu on WDS.
sensor signal fault *ABS control
module.
DTC C1281: Lateral *ABS control *REFER to DTC C1281 pinpoint menu on WDS.
accelerometer circuit module.
failure *Yaw rate sensor.
*Circuit(s).
DTC C1282: Lateral *Yaw rate sensor. *REFER to DTC C1282 pinpoint menu on WDS.
accelerometer signal failure *ABS control
module.
Page 9 of 12
DTC C1288: Pressure *ABS control *REFER to DTC C1288 pinpoint menu on WDS.
transducer main/primary module.
input circuit failure *Primary brake
pressure sensor.
*Circuit(s).
DTC C1295: Steering wheel *Steering wheel *REFER to DTC C1295 pinpoint menu on WDS.
rotation sensor electrical rotation sensor.
fault *Circuit(s).
DTC C1306: Steering wheel *Clockspring. *REFER to DTC C1306 pinpoint menu on WDS.
rotation sensor – No center
found during initialization
DTC C1307: Steering wheel *Clockspring. *INSTALL a new clockspring. REFER to
rotation sensor encoder Section 501-20B.[Supplemental Restraint
ring defective System, REMOVAL AND INSTALLATION,
Clockspring] REPEAT the self-test, CLEAR the
DTCs.
DTC C1440: Brake *ABS control *REFER to DTC C1440 pinpoint menu on WDS.
pressure sensor signal module.
failure
DTC C1446: Brake lamp *Brake lamp *REFER to DTC C1446 pinpoint menu on WDS.
switch plausibility error switch.
*Circuit(s).
DTC C1540: TCS functions *Wheel *REFER to Section 206-00.[Brake System -
temporarily disabled temperature General Information, DIAGNOSIS AND
overheating. TESTING, Brake System] REPEAT the self-test,
CLEAR the DTCs.
DTC C1730: Reference *ABS control *REFER to DTC C1730 pinpoint menu on WDS.
voltage out of range (+5v) module.
*Circuit(s).
DTC C1805: PCM to *ABS control *CONFIGURE the ABS/ESP control module.
ABS/ESP unit mismatch module. REFER to Section 418-01.[Module
Configuration, DIAGNOSIS AND TESTING,
Module Configuration] REPEAT the self-test,
CLEAR the DTCs.
DTC C1994: ESP *ABS control *REFER to DTC C1994 description on WDS.
continuous operation module.
DTC C2778: Sensor- *Circuit(s). *REFER to DTC C2778 description on WDS.
cluster: Voltage supply
failure
DTC C2782: Temperature- * *CHECK for binding brakes. REFER to
sensor failure Section 206-00.[Brake System - General
Information, DIAGNOSIS AND TESTING, Brake
System] REPEAT the self-test, CLEAR the DTCs.
DTC C2783: Yaw rate *Yaw rate sensor *INSTALL a new yaw rate sensor and
sensor and accelerometer: and accelerometer. REFER to Section 206-09C.
Wrong Yaw rate sensor and accelerometer . [Anti-Lock Control - Stability Assist, REMOVAL
accelerometer AND INSTALLATION, Yaw Rate Sensor and
Accelerometer] REPEAT the self-test, CLEAR the
DTCs.
DTC C2785: Sensor offset *Calibration. *CONFIGURE the ABS control module. REFER to
check Section 418-01.[Module Configuration,
DIAGNOSIS AND TESTING, Module
Configuration] REPEAT the self-test, CLEAR the
DTCs.
DTC U1900: CAN *CAN *REFER to DTC U1900 pinpoint menu on WDS.
instrument cluster timeout communication
error.
DTC U1901: CAN 2: *CAN *REFER to DTC U1901 description on WDS.
Page 10 of 12
Sensor-cluster message- communication

timeout error.
DTC U2012: CAN failure *CAN *REFER to DTC U2012 pinpoint menu on WDS.
communication
error.
DTC U2522: *CAN *CHECK CAN circuits between ABS and TCM.
Communication fault communication
between the ABS control error.
module and the TCM.
DTC U2523: *CAN *REFER to DTC U2523 pinpoint menu on WDS.
Communication fault communication
between the ABS control error.
module and the PCM.
DTC U2527: CAN *CAN *REFER to DTC U2527 description on WDS.
communication bus fault communication
error.
PID Table
PID PID Name (WDS

Type display) Unit/Condition Description (WDS display)
Common PID Monitor BOO_ABS On / Off Brake ON/OFF
CCNTABS (Unitless) Continuous codes
LF_WSPD KPH / MPH Left front wheel speed sensor
LR_WSPD KPH / MPH Left rear wheel speed sensor
RF_WSPD KPH / MPH Right front wheel speed sensor
RR_WSPD KPH / MPH Right rear wheel speed sensor
Active PMP_MOTOR On / Off Hydraulic pump motor
Command
LF_INLET On / Off Left front inlet valve
LF_OUTLET On / Off Left front outlet valve
LR_INLET On / Off Left rear inlet valve
LR_OUTLET On / Off Left rear outlet valve
RF_INLET On / Off Right front inlet valve
RF_OUTLET On / Off Right front outlet valve
RR_INLET On / Off Right rear inlet valve
RR_OUTLET On / Off Right rear outlet valve
DSC PID Monitor EPS_VOLT V IVD/DSC sensors supply
only voltage
LAT_ACCL G ABS lateral acceleration rate
MPRETDR KPa-MPa / mBar-Bar ABS main brake pressure
SWA POS Degree Steering wheel angle
TCYC_FS On / Off Traction control system
TCYC_SW Not Depressed / Traction control switch status
Depressed
YAW_RATE degree / second ABS yaw rate value
Active LATACCEL TRUE / FALSE Lateral acceleration sensor
Command initialization start
LF_DSC_V On / Off Left front DSC valve
LF_TC_VLV On / Off Left front traction control valve
MCYL_S_CAL TRUE / FALSE Calibrate master cylinder
pressure sensor
RF_DSC_V On / Off Right front DSC valve
RF_TC_VLV On / Off Right front traction control
valve
YAWRATE On / Off Yaw rate sensor initialization
start
Component Tests
Page 11 of 12
Wheel Speed Sensor Inspection
1. Inspect the wheel speed sensors for the following damage.
 Excess free play of the wheel speed sensor.
 External damage to the wheel speed sensor.
 External damage to the wheel speed sensor ring.
2. Install a new sensor, if required. REFER to Rear Wheel Speed Sensor in this section.
Clearance Inspection - Front Wheel Speed Sensors
NOTE: If the clearance exceeds specification, install a new wheel speed sensor.
1. Check the clearance between the front wheel speed sensor and the front wheel speed sensor
ring.
1. Front wheel speed sensor.

2. Front wheel speed sensor ring.
 XX = 1.8 mm.
Clearance Inspection - Rear Wheel Speed Sensors
NOTE: If the clearance exceeds specification, install a new wheel speed sensor.
1. Check the clearance between the rear wheel speed sensor and the rear wheel speed sensor
ring.
1. Rear wheel speed sensor.

2. Rear wheel speed sensor ring.
 XX = 1.9 mm.
Wheel Speed Sensor Output Value Inspection
CAUTION: Only use WDS to check the wheel speed sensors. Failure to follow this
Page 12 of 12
instruction may result in damage to the wheel speed sensor.

1. Turn the ignition switch off.
2. Connect WDS to DLC.
3. Select the following PIDs.
 LF_WSPD (left front wheel speed sensor).
 RF_WSPD (right front wheel speed sensor).
 LR_WSPD (left rear wheel speed sensor).
 RR_WSPD (right rear wheel speed sensor).
4. Start the engine and drive the vehicle.
5. Check that the WDS display is the same as the speedometer.
6. Install new wheel speed sensor(s), if required. REFER to Rear Wheel Speed Sensor in this
section.
Page 1 of 1

REAR VIEW MIRRORS
UID=G29019
There are two levels of exterior rear view mirror available depending upon market options. All
models have a manual day/night interior rear view mirror. Low series models have manually
operated remote exterior rear view mirrors. High series models have electrically operated
power mirrors controlled by a multi-function switch mounted on the drivers door panel.
Models equipped with power exterior rear view mirrors and heated rear window incorporate
heated exterior rear view mirrors, which are controlled by the heated rear window switch.
Replacement mirror glasses are available for both power and manually operated exterior rear
view mirrors.
The interior rear view mirror is attached to a specially treated area of the front windshield by
an adhesive patch. The adhesive patch is available as a service part.
Page 1 of 1

HANDLES, LOCKS, LATCHES AND
ENTRY SYSTEMS
UID=G29059
The passenger compartment doors are of a conventional lock to striker plate design with the
strikers located on the body pillars.
The tailgate also utilises a conventional lock to striker plate design, with the striker located
centrally on the edge of the load space floor.
The door locks are operated by a conventional actuating rod system connected to the lock
barrels and outer handles, combined with a cable release to the interior remote control levers.
These are supplemented by locking motors. The power motors for the central and double
locking mechanisms are mounted directly onto the individual lock assemblies, and are
operated via sensors in the motor. The locks and key barrels also incorporate the door ajar
and alarm set/reset switches where these systems are fitted.
All the lock mechanisms are shielded to make theft or interference much more difficult.
The interior door handles have a single lever to lock/unlock or open the doors from the
interior (there are no separate locking buttons or levers) and when the doors are `dead
locked' these are rendered inoperative. This makes it impossible for a would be thief to gain
entry by breaking a window and opening the doors using the interior door handles.
A lock may be overhauled using the lockset service kit. The lockset service kit consists of a
lock housing, tumbler magazine, tumbler set, barrel return spring and the appropriate
operating levers.
A fuel resistant grease is recommended in the assembly of a new or overhauled locksets 97SX
M1C253 AA (WSS M7C253A).
This grease will be made available as part of the overhaul kit.

Page 1 of 4

IDENTIFICATION CODES
UID=G295910
The model plate is located on the right-hand B-pillar. The codes are stamped on during
production and can be used to establish precise details regarding the vehicle specification.
The Vehicle Identification Number (VIN) can be checked on the suspension strut top mount in
the engine compartment.

1 - VIN on the suspension strut top mount
2 - Vehicle identification plate

1 - VIN Position 1, 2 and 3 - World manufacturer's code
2 - VIN Position 5 - Engine type
3 - VIN Position 6 - Transaxle codes
4 - VIN Position 7 and 8 - Product source company and assembly plant
5 - VIN Position 9 - Model
Page 2 of 4
6 - VIN Position 11 - Year of manufacture

7 - VIN Position 12 - Month of manufacture
8 - VIN Position 13 to 17 - Vehicle serial number
9 - VIN Position 4 and 10 - Body type (All markets except Israel)
NOTE: VIN Position 10 - Year of manufacture (Israel only)
VIN Position 1, 2 and 3 - World Manufacturer Identifier
Code Manufacturer
JMZ Mazda Motor Corporation
VIN Position 4 and 10 - Body Type
Code Body Type

N 5-door wagon
VIN Position 5 - Engine Type
Code Engine Type

B MZI 1.25 - 75PS
C MZI 1.4 - 80PS
D MZI 1.6 - 100PS
E MZ-CD 1.4 DI Turbo - 68PS
VIN Position 6 - Transaxle Codes
Code Transaxle Codes

A Automatic Shift Manual Transmission
Z 5MT
VIN Position 7 and 8 - Product Source Company and Assembly
Code Product Source Company and Assembly

WP Mazda Spain/Valencia
VIN Position 9 - Model
Code Model
J Mazda2
VIN Position 10 - Year of Manufacture (Israel only)
Code Year of Manufacture

2 2002
3 2003
4 2004
5 2005
6 2006
7 2007
VIN Position 11 - Year of Manufacture
Code Year of Manufacture

2 2002
3 2003
4 2004
5 2005
6 2006
Page 3 of 4
7 2007
VIN Position 12 - Month of Manufacture
Month 2002 2003 2004 2005 2006 2007

January L C B J L C
February Y K R U Y K
March S D A M S D
April T E G P T E
May J L C B J L
June U Y K R U Y
July M S D A M S
August P T E G P T
September B J L C B J
October R U Y K R U
November A M S D A M
December G P T E G P
VIN Position 13 to 17 - 5-digit vehicle serial number
VIN sticker (example) or model plate

1 - Type approval codes
2 - Vehicle identification number (VIN)
3 - Gross vehicle mass (GVM)
4 - Gross train mass (GTM)
5 - Maximum permissible front axle load
6 - Maximum permissible rear axle load
7 - Smoke value (diesel only)
Positions 1 to 6: Vehicle Certification Number
Position Description
Item 1: Type Approval Codes A unique code required by legislation in certain
territories.
Item 2: Vehicle Identification Vehicle identification number.
Page 4 of 4
Number (VIN)
Item 3: Gross Vehicle Mass Indicates the maximum legal mass, in territories where
this is required.
Item 4: Gross Train Mass Indicates the maximum combined mass of vehicle and
trailer or caravan.
Item 5: Maximum Permissible Front Maximum permissible loading on the front wheels of the
Axle Mass vehicle.
Item 6: Maximum Permissible Rear Maximum permissible loading on the rear wheels of the
Axle Mass vehicle.
Item 7: Smoke Value (diesel only)
Code Smoke value

- -
Page 1 of 1

SPECIFICATIONS
UID=G297173
Description Specification
Mazda genuine coolant (orange color) or a coolant meeting the requirement WSS-M97B44-
of the engine supplier D
Antifreeze
Specific gravity (providing no other Approximate percentage of Remains Solidifies

additive is in the coolant) antifreeze (by volume) fluid to at
1.061 at +15°C 50% -25°C (-13° -30°C (-
F) 22°F)
Cooling System Refill Capacities
Description Liters
Cooling system, including heater system and coolant expansion tank (all except 5.0
vehicles with diesel engine)
Cooling System Pressure Specification
Description Pressure kpa (psi)

Radiator pressure test 138 (20)
Coolant expansion tank cap release pressure 120 to 150 (17-21)
Torque Specifications - vehicles with 1.25L/1.4L/1.6L engine

Radiator retaining nut 10 - 89
Water pump pulley retaining bolts 24 18 -
Generator retaining bolts 45 33 -
Generator electrical connector retaining nut 8 - 71
Timing belt lower cover retaining bolts 9 - 80
Page 1 of 1

SPECIFICATIONS
UID=G297174
Mazda genuine coolant (orange color) or a coolant meeting the requirement WSS-M97B44-
of the engine supplier D
Antifreeze
Specific gravity (providing no other Approximate percentage of Remains Solidifies

additive is in the coolant) antifreeze (by volume) fluid to at
1.061 at +15°C 50% -25°C (-13° -30°C (-
F) 22°F)
Cooling System Refill Capacities
Description Liters
Cooling system, including heater system and coolant expansion tank 5.5
Cooling System Pressure Specification
Description Pressure kpa (psi)

Radiator pressure test 138 (20)
Coolant expansion tank cap release pressure 120 to 150 (17-21)

Radiator retaining nut 10 - 89
Crankshaft position (CKP) sensor retaining bolt 8 - 71
Thermostat housing retaining bolts a - -
Water pump retaining bolts b - -
Crankshaft pulley retaining bolt c - -
a) refer to the Thermostat Housing procedure in this section
b) refer to the Water Pump procedure in this section
c) refer to the Water Pump procedure in this section

Page 1 of 2

FUEL CHARGING WIRING HARNESS
UID=G297175
Removal

4. NOTE: It is necessary to lift the red locking

tab before the electrical connector can be
disconnected.
Disconnect the throttle body electrical connector.
5. Disconnect the fuel charging wiring harness

6. Remove the positive crankcase ventilation

(PCV) hose.
Page 2 of 2

connectors and remove the fuel charging
wiring harness.
Installation
Page 1 of 1

FUEL INJECTION COMPONENT
CLEANING
UID=G297176
General Equipment
New brush that will not lose its bristles
Name Specification
Parts cleaning solvent
WARNINGS:
near any fuel related components. Highly flammable mixtures are always present and may
fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction
Eye protection must be worn at all times when working on or near any fuel related
components. Failure to follow this instruction may result in personal injury.
CAUTIONS:
Make sure that the workshop area in which the vehicle is being worked on is as clean and
dust-free as possible. Areas in which work on clutches, brakes or where welding or machining
are carried out are not suitable in view of the risk of contamination to the fuel system.
Make sure that clean non-plated tools are used. Clean tools using a new brush that will
not lose its bristles and fresh parts cleaning solvent, prior to starting work on the vehicle.
Use a steel topped workbench and cover it with clean, lint-free non-flocking material.
Make sure that all parts removed from the vehicle are placed on the lint-free non-flocking
material.
Make sure that any protective clothing worn is clean and made from lint-free non-flocking
material.
Make sure that any protective gloves worn are new and are of the non-powdered latex
type.
Before using the parts cleaning solvent, protect all electrical components and connectors
with lint-free non-flocking material.
1. Using a new brush that will not lose its bristles,
brush parts cleaning solvent onto the
components being removed and onto the
surrounding area.
2. Using the pneumatic vacuum gun, remove all
traces of parts cleaning solvent and foreign
material.
3. Dispose of any unused parts cleaning solvent and
the brush after completing the repair.
Page 1 of 6

ACCESSORY DRIVE
UID=G297177
Mechanical
- Damaged or contaminated accessory drive belt
- Incorrect accessory drive belt
- Accessory drive belt tensioner
- Accessory drive belt idler pulley
- Generator
- Power steering pump
- Air conditioning (A/C) compressor
- Pulley(s)
- Loose hardware
CAUTION: Do not lubricate the accessory drive belt, accessory drive belt tensioner or
idler pulley(s) as potential damage to the accessory drive belt material construction,
accessory drive belt tensioner damping mechanism, accessory drive belt tensioner pulley
bearing and idler pulley(s) bearing may occur.
NOTE: Up to 15 cracks in a belt rib over a distance of 100 mm may be considered
acceptable. If the cracks exceed the acceptable limit or any chunks are found to be
missing, INSTALL a new accessory drive belt.
Page 2 of 6
4. The condition of the accessory drive belt should be compared against the illustration and
appropriate action taken.
1. Small scattered deposits of rubber debris is not a concern and therefore a new
accessory drive belt should not be installed.
2. Longer deposits of rubber debris building up to 50% of the accessory drive belt rib
height is not a concern but may result in excessive noise. If excessive noise is apparent,
INSTALL a new accessory drive belt. Vehicles with diesel engine. REFER to Accessory
Drive Belt - 1.4L Diesel in this section. Vehicles without accessory drive belt tensioner.
REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles With: Air Conditioning in this
section. or REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles Without: Air
Conditioning in this section.
3. Large deposits of rubber debris building up along the grooves are a concern and may
result in excessive noise and a accessory drive belt stability concern. If large deposits or
excessive accessory drive belt noise is apparent, INSTALL a new accessory drive belt.
Vehicles with diesel engine. REFER to Accessory Drive Belt - 1.4L Diesel in this section.
Vehicles without accessory drive belt tensioner. REFER to Accessory Drive Belt -
1.25L/1.4L/1.6L, Vehicles With: Air Conditioning in this section. or REFER to Accessory
Drive Belt - 1.25L/1.4L/1.6L, Vehicles Without: Air Conditioning in this section.
5. Check the accessory drive belt for cracks. If the damage exceeds the acceptable limit,
install a new accessory drive belt. Vehicles with diesel engine. REFER to Accessory Drive
Belt - 1.4L Diesel in this section. Vehicles without accessory drive belt tensioner. REFER to
Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles With: Air Conditioning in this section. or
Page 3 of 6
REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles Without: Air Conditioning in this
section.
6. Check the accessory drive belt for damage. If any chunks are found to be missing,
INSTALL a new accessory drive belt. Vehicles with diesel engine. REFER to Accessory Drive
Belt - 1.4L Diesel in this section. Vehicles without accessory drive belt tensioner. REFER to
Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles With: Air Conditioning in this section. or
REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles Without: Air Conditioning in this
section.
7. Check the accessory drive belt for fraying. The condition of the accessory drive belt should
be compared against the illustrations. For levels 1 to 3, the accessory drive belt DOES NOT
require changing. For levels 4 and 5 INSTALL a new accessory drive belt. Vehicles with
diesel engine. REFER to Accessory Drive Belt - 1.4L Diesel in this section. Vehicles without
accessory drive belt tensioner. REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles
With: Air Conditioning in this section. or REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L,
Vehicles Without: Air Conditioning in this section.
1. No fraying (new belt)

2. Fraying just starting
3. Slight fraying
4. High amount of fraying without cord cuts
5. High amount of fraying with cord cuts
Page 4 of 6
Symptom Chart
Symptom Chart

Accessory *Accessory drive *CHECK the system with the engine running and the accessory
drive belt components drive belt removed (only run the engine for a very short
noise or worn or period). If a noise is apparent, the cause is not the accessory
squeal damaged. drive system. If a noise is not apparent, the cause is the
accessory drive system. CHECK where the noise is coming
from and INSTALL new components as necessary. TEST the
*Accessory drive *CHECK the accessory drive components are correctly
components installed. REPAIR as necessary.
incorrectly
installed.
*Accessory drive *CHECK the accessory drive belt is correctly installed in the
belt incorrectly pulley grooves. INSTALL a new accessory drive belt as
installed. necessary. Vehicles with diesel engine. REFER to Accessory
Drive Belt - 1.4L Diesel in this section. Vehicles without
accessory drive belt tensioner. REFER to Accessory Drive Belt
- 1.25L/1.4L/1.6L, Vehicles With: Air Conditioning in this
section. or REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L,
Vehicles Without: Air Conditioning in this section. TEST the
*Pulley(s). *CHECK the pulley(s) for damage, freedom of rotation and
alignment. INSTALL new components as necessary.
*Lubricant or *CHECK the accessory drive belt for contamination or damage.
other REMOVE the accessory drive belt and wash with detergent
contamination. and water. If the accessory drive belt will not clean or is
damaged, INSTALL a new accessory drive belt. Vehicles with
diesel engine. REFER to Accessory Drive Belt - 1.4L Diesel in
this section. Vehicles without accessory drive belt tensioner.
Page 5 of 6
REFER to Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles

With: Air Conditioning in this section. or REFER to Accessory
Drive Belt - 1.25L/1.4L/1.6L, Vehicles Without: Air
Conditioning in this section. TEST the system for normal
operation.
*Accessory drive *CHECK the accessory drive belt for correct application.
belt. INSTALL a new accessory drive belt. TEST the system for
normal operation. Vehicles with diesel engine. REFER to
Accessory Drive Belt - 1.4L Diesel in this section. Vehicles
without accessory drive belt tensioner. REFER to Accessory
Drive Belt - 1.25L/1.4L/1.6L, Vehicles With: Air Conditioning
in this section. or REFER to Accessory Drive Belt -
1.25L/1.4L/1.6L, Vehicles Without: Air Conditioning in this
Accessory *Accessory drive *CHECK the pulley(s) for damage, freedom of rotation and
drive belt belt. alignment. INSTALL new components as necessary. TEST the
fraying *Pulley(s). system for normal operation.
*Generator.
*Power steering
pump.
*A/C
compressor.
Accessory *Accessory drive *INSPECT the accessory drive belt for cracks or damage. If
drive belt belt cracked or the cracks are within the acceptable limit, the accessory drive
does not damaged. belt is OK. If the cracks exceed the acceptable limit, INSTALL
hold tension a new accessory drive belt. Vehicles with diesel engine.
REFER to Accessory Drive Belt - 1.4L Diesel in this section.
Vehicles without accessory drive belt tensioner. REFER to
Accessory Drive Belt - 1.25L/1.4L/1.6L, Vehicles With: Air
Conditioning in this section. or REFER to Accessory Drive Belt
- 1.25L/1.4L/1.6L, Vehicles Without: Air Conditioning in this
section.TEST the system for normal operation.
*Accessory drive *CHECK the accessory drive belt tensioner for correct
belt tensioner operation or damage. INSTALL a new accessory drive belt
worn or tensioner as necessary. TEST the system for normal
damaged. operation.
Component Tests
Accessory Drive Belt Tensioner - Static Check
The accessory drive belt tensioner may be checked statically as follows:
1. Detach the accessory drive belt in the area of the accessory drive belt tensioner.
2. Using the correct tool, move the accessory drive belt tensioner from its relaxed position
through its full stroke and back to the relaxed position to make sure there is no stick, grab
or bind, and to make sure there is tension on the accessory drive belt tensioner spring.
3. Rotate the accessory drive belt tensioner pulley and check for damage, freedom of rotation
and alignment. INSTALL a new accessory drive belt tensioner as necessary.
4. Inspect the area surrounding the accessory drive belt tensioner for lubricant or other
contamination. Rectify any leaks before installing a new accessory drive belt tensioner. If
the accessory drive belt tensioner is contaminated, do not attempt to clean it as the
damping mechanism inside may be damaged. INSTALL a new accessory drive belt tensioner
as necessary.
Page 6 of 6
5. If the accessory drive belt tensioner meets the above criteria proceed to test the accessory
drive belt tensioner dynamically. If the accessory drive belt tensioner does not meet the
above criteria install a new accessory drive belt tensioner.
Accessory Drive Belt Tensioner - Dynamic Check
The accessory drive belt tensioner may be checked dynamically as follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The
accessory drive belt tensioner should move (respond) when the engine is accelerated
rapidly or when the A/C clutch cycles. If the accessory drive belt tensioner movement is not
constant without engine acceleration or A/C clutch cycling, a pulley or shaft is possibly bent,
out of round, or the damping mechanism inside the accessory drive belt tensioner may be
damaged. Excessive accessory drive belt rideout (uneven depth of grooves in the accessory
drive belt) may cause excessive accessory drive belt tensioner movement. Check the
condition by installing a new accessory drive belt. Vehicles with diesel engine. REFER to
Accessory Drive Belt - 1.4L Diesel in this section. TEST the system for normal operation.
Page 1 of 10

STARTING SYSTEM
UID=G297178
Electrical
Fuse(s)
Wiring harness
Electrical connector(s)
Starter relay
Powertrain control module (PCM)
Switch(es)
Battery
Starter motor
Symptom Chart
Symptom Chart

The engine does not *Battery. *REFER to Section 414-01.
crank/the relay does *Fuse(s). *GO to Pinpoint Test A.
click *Circuit(s).
*Relay.
*Starter motor.
The engine does not *Battery. *REFER to Section 414-00.
crank/the relay does *Fuse(s). *INSTALL a new fuse as necessary. If the fuse fails
not click again check for short to ground.
*Passive anti- *REFER to Section 419-01A / 419-01B.
theft system
(PATS).
*Circuit(s). *GO to Pinpoint Test B.
*Relay.
*PCM.
*Ignition switch.
*Starter motor.
The engine cranks *Battery. *REFER to Section 414-00.
slowly *Fuse(s). *GO to Pinpoint Test C.
*Circuit(s).
Page 2 of 10
*Starter motor.
Unusual starter *Starter motor. *REMOVE the starter motor. REFER to Starter Motor -
noise 1.4L Diesel in this section. INSPECT the starter motor
gear for damage. INSTALL a new starter motor as
necessary.
*Flywheel ring *INSPECT the flywheel for damage. REFER to
gear. Section 303-00.
The starter spins *Starter motor. *REMOVE the starter motor. REFER to Starter Motor -
but the engine does 1.4L Diesel in this section. INSPECT the starter motor
not crank gear for damage. INSTALL a new starter motor as
necessary.
*Flywheel ring *INSPECT the flywheel for damage. REFER to
gear. Section 303-00.
Pinpoint Tests
NOTE: Use a digital multimeter for all electrical measurements.

PINPOINT TEST A : THE ENGINE DOES NOT CRANK/THE RELAY DOES CLICK
A1: CHECK THE ENGINE VARIANT
1 Check the engine variant.
Is the vehicle equipped with a diesel engine?
Yes
GO to A2.
No
GO to A6.
A2: CHECK VOLTAGE TO STARTER SOLENOID
1 Key in START position.
2 Measure the voltage between the starter motor

connector A2-01, (WHITE), harness side and
ground.
Is the voltage greater than 10 volts?

Yes
GO to A3.
No
GO to A4.
A3: CHECK THE VOLTAGE DROP
connector A2-01, (BLACK/YELLOW), component
side and the battery positive terminal.
Is the voltage less than 0.5 volts?

Page 3 of 10
Yes
GO to A5.
No
CLEAN and TIGHTEN all battery positive cable
connections. TEST the system for normal operation. If
the concern persists, INSTALL a new starter motor to
battery cable. REFER to Section 414-01. TEST the
A4: CHECK STARTER RELAY TO STARTER MOTOR FOR OPEN
2 Disconnect Starter Relay A2-03.
3 Disconnect Starter Motor A2-01.
4 Measure the resistance between the starter relay

connector A2-03, (BLACK/YELLOW), harness side
and the starter motor connector A2-01,
(BLACK/YELLOW), harness side.

Yes
INSTALL a new starter motor. REFER to Starter Motor -
1.4L Diesel in this section. TEST the system for normal
operation.
No
REPAIR the circuit (BLACK/YELLOW). TEST the system
A5: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN
1 Measure the resistance between the starter motor
casing and the battery ground terminal.
Is the resistance less than 0.5 ohms?

Yes
operation.
No
CLEAN and TIGHTEN all battery and engine ground
cable connections. TEST the system for normal
operation.
A6: CHECK VOLTAGE TO STARTER SOLENOID

Page 4 of 10

ground.

Yes
GO to A7.
No
GO to A9.
A7: CHECK THE VOLTAGE DROP
connector A1-01, (BLACK/YELLOW), component
side and the battery positive terminal.

Yes
GO to A8.
No
the concern persists, INSTALL a new starter motor to
battery cable. REFER to Section 414-01. TEST the
A8: CHECK STARTER RELAY TO STARTER MOTOR FOR OPEN


Yes
INSTALL a new starter motor. TEST the system for
normal operation.
No
Page 5 of 10

A9: CHECK THE STARTER MOTOR GROUND CIRCUIT FOR OPEN
1 Measure the resistance between the starter motor
casing and the battery ground terminal.
Is the resistance less than 0.5 ohms?

Yes
normal operation.
No
CLEAN and TIGHTEN all battery and engine ground
cable connections. TEST the system for normal
operation.
PINPOINT TEST B : THE ENGINE DOES NOT CRANK/RELAY DOES NOT CLICK
B1: CHECK THE ENGINE VARIANT
1 Check the engine variant.
Is the vehicle equipped with a diesel engine?
Yes
GO to B2.
No
GO to B7.
B2: CHECK THE SWITCHED POWER TO THE STARTER RELAY

relay connector A2-03, (BLACK/WHITE), harness
side and ground.

Yes
GO to B3.
No
REPAIR the circuit (BLACK/WHITE). TEST the system
B3: CHECK STARTER RELAY FOR SWITCHED VOLTAGE
2 Measure the voltage between the starter relay

Page 6 of 10

ground.

Yes
GO to B5.
No
GO to B4.
B4: CHECK STARTER RELAY TO IGNITION SWITCH FOR OPEN
2 Disconnect Ignition Switch X-03.

connector A2-03, (WHITE), harness side and the
ignition switch connector X-03, (RED), harness
side.

Yes
INSTALL a new ignition switch. REFER to Section 211-
05. TEST the system for normal operation.
No
REPAIR the circuit(s) (WHITE). TEST the system for
normal operation.
B5: CHECK STARTER RELAY TO STARTER MOTOR FOR OPEN


Yes
GO to B6.
No
Page 7 of 10

B6: CHECK STARTER RELAY TO PCM FOR OPEN
1 Disconnect PCM B2-01.

connector A2-03, (BLACK/RED), harness side and
the PCM connector B2-01 pin 3J, (BLACK/RED),
harness side.

Yes
operation. If the concern persists, INSTALL a new PCM.
REFER to Section 303-14. TEST the system for normal
operation.
No
REPAIR the circuit (BLACK/RED). TEST the system for
normal operation.
B7: CHECK THE SWITCHED POWER TO THE STARTER RELAY

relay connector A1-04, (BLACK/WHITE), harness
side and ground.

Yes
GO to B8.
No
B8: CHECK STARTER RELAY FOR SWITCHED VOLTAGE
2 Measure the voltage between the starter relay

ground.
Page 8 of 10

Yes
GO to B10.
No
GO to B9.
B9: CHECK STARTER RELAY TO IGNITION SWITCH FOR OPEN
2 Disconnect Ignition Switch X-03.

connector A1-04, (WHITE), harness side and the
ignition switch connector X-03, (RED), harness
side.

Yes
INSTALL a new ignition switch. REFER to Section 211-
No
REPAIR the circuit(s) (WHITE). TEST the system for
normal operation.
B10: CHECK STARTER RELAY TO STARTER MOTOR FOR OPEN


Yes
GO to B11.
No
Page 9 of 10

B11: CHECK STARTER RELAY TO PCM FOR OPEN
1 Disconnect PCM B1-01.

connector A1-04, (BLACK/RED), harness side and
the PCM connector B1-01 pin L, (BLACK/RED),
harness side.

Yes
normal operation. If the concern persists, INSTALL a
new PCM. REFER to Section 303-14. TEST the system
No
normal operation.
PINPOINT TEST C : THE ENGINE CRANKS SLOWLY
C1: CHECK FOR VOLTAGE DROP

terminal 30, component side and the battery
positive terminal.

Yes
GO to C2.
No
the concern persists, INSTALL a new battery to starter
motor solenoid cable. REFER to Section 414-01. Test
C2: CHECK FOR GROUND CONNECTION
2 Measure the voltage between the starter motor case

and the battery ground terminal.
Page 10 of 10

Yes
CHECK the battery. REFER to Section 414-00. TEST the
No
CLEAN and TIGHTEN all battery ground cable
connections, starter motor mounting and body to
ground straps. TEST the system for normal operation.
If the concern persists, INSTALL a new battery ground
cable. Test the system for normal operation.
Page 1 of 1

SPECIFICATIONS
UID=G297179
Torque Specifications - vehicles with 1.25L, 1.4L or 1.6L engine

Powertrain control module (PCM) retaining bolts 3 - 27
Knock sensor (KS) retaining bolt 20 15 -
Camshaft position (CMP) sensor retaining bolt 10 - 89
Engine coolant temperature (ECT) sensor 20 15 -
Idle air control (IAC) valve 10 - 89
Heated oxygen sensor (HO2S) 47 35 -
Catalyst monitor sensor (CMS) 47 35 -
Torque Specifications - vehicles with 1.4L diesel engine

Powertrain control module (PCM) retaining nuts and retaining bolts 10 - 89
Timing belt upper cover retaining bolts 4 - 35
Camshaft position (CMP) sensor retaining bolt 5 - 44
Crankshaft pulley retaining bolt a - -
a) refer to the CKP procedure in this section
General Specifications
Condition Specification
Maximum idle increase for high generator load 100 rpm
Air conditioning idle upspeed at low ambient temperatures 100 rpm
Air conditioning idle upspeed at high ambient temperatures 150 rpm
Power steering idle speed upspeed 50 rpm
Page 1 of 36

ELECTRONIC ENGINE CONTROLS
UID=G297180
General Equipment
Worldwide Diagnostic System (WDS)
European On-Board Diagnostics (EOBD)
EOBD is a diagnostic system integrated into the powertrain control module (PCM). This
system continuously monitors vehicle emission components. The system includes a
malfunction indicator lamp (MIL) which indicates when there is a concern that can affect
emissions or the system malfunctions. Data stored within the module DTC memory can be
accessed using a generic scan tool or WDS.
EOBD is mandated within European Union regulations from the year 2000 for passenger
vehicles with petrol engines and from 2003 onwards for passenger vehicles with diesel
engines.
EOBD Functions:
* Establishes when and how emissions control faults must be indicated.
* Actuates emission control malfunction indicator lamp (MIL) and fault memory.
* Indicates operating conditions in which the concern occurred (freeze frame

data).
* Standardized output of operating data such as engine speed, engine coolant

temperature etc.
* Standardized names and abbreviations for components and systems.
* Standardized DTCs for all manufacturers.
* Standardized communication with the diagnostic equipment.
* Standardized 16-pin data link connector (DLC) in area of the instrument panel.
* Concern display must be possible using a generic scan tool.
EOBD consists of the following elements:
Warm-up Cycle
The warm-up cycle is an operation that consists of key on, engine start and a coolant
temperature increase of 22°C, exceeding 71°C on completion.
Drive Cycle
A drive cycle commences when the engine is started (cold or warm) and ends when the
engine is switched off.
Page 2 of 36
Trip
A trip begins when the engine is started and is complete when all the EOBD monitors have
completed a self-test. This may take place over a number of drive cycles. On diesel variants,
the information gathered from one drive cycle is not carried over to a subsequent cycle or
cycles.
P1000
When a concern has been rectified, particularly after electronic engine control components
have been changed, the DTC memory, which is part of the EEPROM must be cleared of all
trouble codes. When the DTC memory has been cleared, the code P1000 (known as the
readiness code) is set in the PCM memory, which indicates that since the EEPROM has been
cleared, not all of the monitoring systems have completed their tests. WDS will display "On-
Board Diagnostic (OBD) Systems Readiness Test Not Complete." P1000 can not be cleared by
using WDS, as it can only be cleared by carrying out a trip, which involves driving the vehicle
under variable conditions of speed, load and time so that all of the monitors are completed.
As P1000 will not illuminate the MIL, it is not necessary to carry out the trip before returning
the vehicle to the customer.
Freeze Frame Data
When a concern is detected, various data is stored depending on application including:
* Diagnostic trouble code.
* Vehicle speed.
* Engine coolant temperature.
* Engine speed.
* Engine load.
* Mixture formation trim value (trim value for engine wear) (All except vehicles
with diesel engine).
* State of oxygen sensor control (open and closed loop) (All except vehicles with
diesel engine).
* Distance covered since the concern was first registered.
Monitors
The purpose of the monitors is to continuously check the operation of the emission related
sensors and actuators. It then establishes if they are operating within specified tolerances. All
monitors carry out their functions in such a way as to be unnoticeable by the driver of the
vehicle. Each one is carried out under specific conditions of load, speed and engine
temperature. The Comprehensive Component Monitor, Combustion Misfire Monitor and
Air/Fuel Ratio Monitor operate continuously. The remaining monitors are only invoked under
certain operating conditions. On diesel variants, all of the monitors operate under normal
driving conditions: There are no monitors which intervene and cause special operating modes
to enable the monitors to work. Some diesel monitors are non-continuous. This means that in
a drive cycle, monitoring is done as and when suitable driving conditions exist and potential
faults are accumulated and compared with acceptance criteria. Examples of this type are the
turbocharger boost pressure and exhaust gas recirculation (EGR) monitors on vehicles with
common rail fuel injection.
Page 3 of 36
Comprehensive Component Monitor (CCM)
When the CCM detects a component operating out of tolerance, it sets a Diagnostic Trouble
Code (DTC), which is stored in the EEPROM. If the same concern is confirmed during the next
trip the MIL will be switched on. The CCM monitors many components, sub-systems and
signals. The following is a list of those that can effect emissions depending on application:
* Electronic Ignition (EI) System.
* Crankshaft Position (CKP) Sensor.
* Ignition Coil.
* Electronic Throttle Control Unit.
* Camshaft Position (CMP) Sensor.
* Air Conditioning (A/C) Clutch.
* Idle Air Control (IAC) Valve.
* Mass Air Flow (MAF) Sensor.
* Manifold Absolute Pressure (MAP) Sensor.
* Intake Air Temperature (IAT) Sensor.
* Engine Coolant Temperature (ECT) Sensor.
* Cylinder Head Temperature (CHT) Sensor.
* Heated Oxygen Sensor (HO2S).
* Catalyst Monitor Sensor.
* Charge Air Temperature Sensor.
* Knock Sensor (KS).
* Throttle Position (TP) Sensor.
* Vehicle Speed Sensor (VSS).
* Boost Pressure Sensor.
* Cam-Crank Phasing Sensor.
* EEPROM.
* High Pressure Fuel Injection Pump.
* Exhaust Gas Recirculation (EGR) Valve Monitor.
* Fuel Injectors.
Page 4 of 36
* Turbocharger.
* Combustion Noise Monitor.
* Barometric Pressure (BARO) Sensor.
Combustion Misfire Monitor (All except vehicles with diesel engine)
The combustion misfire monitor operates independently of the others, and can detect misfires
caused by the ignition system, fuel system or mechanical engine components. As each
cylinder fires, a characteristic crankshaft acceleration is produced. The monitor detects
irregularities in the acceleration pattern using the crankshaft position (CKP) sensor, thus
detecting the misfire. It can also detect which cylinder has misfired. Combustion misfires can
be categorized as follows:
Type A: These can cause catalytic converter damage due to excessive internal temperatures.
If a certain number of misfires occur over a pre-determined number of engine revolutions, the
MIL will be switched on to alert the driver of the concern.
Type B: These can lead to an increase in emissions to a point above the EOBD threshold. If
the misfire is detected during a second trip, over a pre-determined number of engine
revolutions, the MIL will be switched on. If the misfire does not occur over the next three
trips, the MIL will be extinguished
Air/Fuel Ratio (AFR) Monitor (All except vehicles with diesel engine)
The HO2S fitted before the catalytic converter (upstream) measures the oxygen content of
the exhaust gas and the variations in it. This then enables the PCM to adjust the opening
times of the fuel injectors to maintain the correct AFR. This is known as Short Term Fuel Trim
(STFT). If the same variation is registered a pre-determined number of times, a permanent
correction factor is applied. This is known as Long Term Fuel Trim (LTFT), which is stored in
the EEPROM. When the correction factors exceed pre-determined limits a DTC will be set in
the EEPROM. If a concern is detected in either the STFT or LTFT, and it is still present on a
second trip, the MIL will be switched on.
Heated Oxygen Sensor (HO2S) Monitor (All except vehicles with diesel engine)
This monitors the operation of the pre (upstream) and post (downstream) catalytic converter
HO2S sensors. It will detect deviations in air/fuel ratios (AFR) and sensor faults.
The HO2S will cause emission increase when its response time increases too much. To
diagnose a sensor a period is measured and the number of lean/rich transitions are counted.
The sum of valid periods is then calculated. To avoid non-representative measurements, the
period is valid only if the HO2S has been below a low threshold and above a high threshold
between 2 consecutive lean/rich transitions. A failure is declared when the sum of the
measured periods exceeds the sum of the corresponding limit (held within the PCM) and the
MIL is illuminated.
Catalytic Converter Efficiency Monitor (All except vehicles with diesel engine)
The efficiency of a catalytic converter is measured by its ability to store and later release
oxygen to convert harmful gases. The efficiency is reduced if the converter becomes
contaminated as it ages, and at high gas flow rates, because the exhaust gas does not remain
in the converter long enough to complete the conversion process.
This monitor checks for the oxygen storage capacity (OSC) of the catalytic converter. During
a controlled period, the catalyst monitor sensor signal is analyzed to evaluate the OSC of the
Page 5 of 36
catalyst. It represents the quantity of oxygen that is really used for the oxidation-reduction
reaction by the catalytic converter If a fault has occurred with the catalyst monitor sensor
during the catalyst diagnosis, a sensor diagnosis is carried out. During the controlled
diagnosis phase, the catalyst monitor sensor activity is measured and is compared to the OSC
of the catalyst. If this activity is high (low OSC) the MIL will be illuminated. If throughout the
controlled phase, repeated several times, the downstream sensor output has not moved, the
closed loop mode is delayed in order to test the sensor. If the catalyst monitor sensor is set
to rich, the injection time is forced to lean and conversely if the downstream sensor is set to
lean, the injection time is forced to rich until the sensor switches over or until the end of a
delay. If this delay expires or the sensor does not switch, the sensor is treated as failed.
Combustion Noise Monitor (Vehicles with common rail fuel injection)
In diesel variants, the Combustion Noise Monitor is used to trim the fuel injection pulse
lengths. Each fuel injector has an associated set of correction data that is determined during
a production end of line test. The Combustion Noise Monitor is used to determine how the fuel
injector characteristic changes from this initial calibration over the life of the fuel injector.
EGR Monitor (Vehicles with diesel engine)
The functionality of the EGR system is checked by comparing either the MAP sensor output or
EGR valve lift potentiometer output (depending upon application) with expected values.
Diagnostic Requirements
Vehicles equipped with EOBD, can be diagnosed using the Worldwide Diagnostic System
(WDS). In order for the EOBD system to be invoked, a number of criteria must be met. After
any repair, which could affect emissions, a trip must be carried out on the vehicle, to make
sure that engine management system operates correctly.
Malfunction Indicator Lamp (MIL)
The MIL is located in the instrument cluster and is fitted to alert the driver to the fact that an
abnormal condition has developed in the engine management system, that is having an
adverse effect on emissions. In cases of misfires which are likely to cause catalytic converter
damage, it is switched on immediately. With all other faults it will illuminate continuously
from the second trip after the condition occurred. Under normal operation it should illuminate
at key-on and go out almost as soon as the engine is started.
Diagnostic Trouble Codes (DTCs)
The DTCs given by the PCM are standardized, which means that generic scan tools can read
results from all vehicles.
* The DTC is always a 5 digit alphanumerical code, for example ”P0100".
* The first digit of a code (letter) identifies the system which has set the code.
Provision has been made for a total of four systems to be identified although only
the 'P' code is required for EOBD.
 'B' for the body
 'C' for the chassis
 'P' for the powertrain
 'U' for the network communications systems

Page 6 of 36
* All of the ”x0xxx" codes are standardized codes. However, any manufacturer
can use additional codes over and above the standardized codes. These will be
labelled ”x1xxx"
* The third digit of a code (numeric) identifies the sub-system which has set the
code.
 'Px1xx' for metering of fuel and air supply
 'Px2xx' for metering of fuel and air supply
 'Px3xx' for ignition system – combustion misfires
 'Px4xx' for auxiliary emission control equipment
 'Px5xx' for vehicle speed, idle setting and other related inputs
 'Px6xx' for trip computer and other related outputs
 'Px7xx' for transmission.
 'Px8xx' for transmission.
 'Px9xx' category to be determined
 'Px0xx' category to be determined
* When a concern occurs, the actions taken include storage of the relevant
information and actuation of the MIL occurs in line with the relevant legislation.
MIL Code List
MIL Code Description

P0030 Heated oxygen sensor (HO2S) heater open circuit
P0031 HO2S heater low voltage
P0032 HO2S heater high voltage
P0036 Catalyst monitor sensor heater open circuit
P0037 Catalyst monitor sensor heater low voltage
P0038 Catalyst monitor sensor heater high voltage
P0053 HO2S heater resistance out of limits
P0054 Catalyst monitor sensor heater resistance out of limits
P0106 Manifold absolute pressure (MAP) sensor plausibility malfunction
P0107 MAP sensor circuit low input
P0108 MAP sensor circuit high input
P0109 MAP sensor temporary malfunction
P0112 Intake air temperature (IAT) circuit low input
P0113 IAT circuit high input
P0114 IAT intermittent failure
P0116 Engine coolant temperature (ECT) signal stuck at low level
P0117 ECT circuit low input
P0118 ECT circuit high input
P0119 ECT intermittent failure
P0122 Throttle position (TP) sensor circuit 1 low input
P0123 TP sensor circuit 1 high input
Page 7 of 36
P0130 HO2S circuit open circuit

P0131 HO2S circuit low voltage
P0132 HO2S circuit high voltage
P0133 HO2S circuit slow response
P0134 HO2S low amplitude
P0136 Catalyst monitor sensor circuit open circuit
P0137 Catalyst monitor sensor circuit low voltage
P0138 Catalyst monitor sensor circuit high voltage
P0139 Catalyst monitor sensor circuit slow response
P0171 Fuel system error, lean limit
P0171 Fuel system error , NOx emissions
P0172 Fuel system error , rich limit
P0172 Fuel system error, HC/CO emissions
P0201 Cylinder No. 1 - injector circuit open circuit
P0222 TP sensor circuit 2 low input
P0223 TP sensor circuit 2 high input
P0231 Fuel pump input low voltage
P0232 Fuel pump input high voltage
P0261 Cylinder No. 1 - injector circuit low voltage
P0262 Cylinder No. 1 - injector circuit high voltage
P0300 Random misfire detected
P0301 Cylinder No. 1 misfire detected
P0315 Flywheel segment adaptation at the Limit
P0324 Knock sensor (KS) communication error or implausible signal
P0325 KS implausible signal
P0335 Crankshaft position (CKP) sensor implausible signal
P0336 CKP sensor missing teeth
P0336 CKP sensor loss of synchronization
P0336 CKP sensor no signal
P0340 Camshaft position (CMP) sensor no signal
P0341 CMP sensor implausible signal
P0351 Ignition coil A primary malfunction
P0352 Ignition coil B primary malfunction
P0420 Catalyst system efficiency below threshold
P0444 EVAP emission control purge control valve open circuit
P0458 EVAP emission control purge control valve low voltage
P0459 EVAP emission control purge control valve high voltage
P0460 Fuel tank level malfunction from instrument cluster
P0500 Vehicle speed sensor (VSS) signal malfunction
P0500 Vehicle speed via CAN (VS CAN) implausible signal
P0503
Page 8 of 36
VSS signal too high

P0511 Idle air control (IAC) valve circuit malfunction
P0560 Battery system voltage malfunction high voltage
P0562 Battery system voltage malfunction open circuit
P0571 Brake switch plausibility error
P0603 Powertrain control module (PCM) error NVMY or EEPROM error
P0604 PCM error RAM error
P0605 PCM error checksum error
P0610 VID block checksum not correct or not programmed
P0617 Starter relay malfunction
P0620 Generator circuit malfunction
P0625 Generator low voltage
P0626 Generator high voltage
P0628 Fuel pump primary circuit low voltage
P0629 Fuel pump primary circuit high voltage
P0641 Transmission sensor power supply 1 noisy signal
P0642 Transmission sensor power supply 1 low voltage
P0643 Transmission sensor power supply 1 high voltage
P0646 A/C clutch relay circuit low voltage
P0647 A/C clutch relay circuit high voltage
P0651 Transmission sensor power supply 2 noisy signal
P0652 Transmission sensor power supply 2 low voltage
P0653 Transmission sensor power supply 2 high voltage
P0654 Engine run output circuit malfunction
P0686 Main relay malfunction low voltage
P0687 Main relay malfunction high voltage
P0691 Cooling fan 1 control circuit low voltage
P0692 Cooling fan 1 control circuit high voltage
P0693 Cooling fan 2 control circuit low voltage
P0694 Cooling fan 2 control circuit high voltage
P0704 Clutch switch implausible signal
P1000 EOBD system readiness test not complete
P1500 Vehicle speed sensor (VSS) output circuit malfunction
P1632 Generator command malfunction
P1794 Battery voltage malfunction too high or too low
P2100 Engine throttle body H-bridge malfunction
P2107 Safety failure level 3
P2108 Safety failure level 2 error
P2119 Engine throttle body throttle flap malfunction
P2122 Accelerator pedal position (APP) sensor circuit 1 low input
P2123 APP sensor circuit 1 high input
P2127 APP sensor circuit 2 low input
P2128 APP sensor circuit 2 high input
P2128 APP sensor circuits 1 and 2 plausibility error
P2135 TP sensor circuits 1 and 2 plausibility error
P2176 Engine throttle body adaptive algorithm failed
P2280 Air cleaner obstruction or leakage
P2282 Air leakage between throttle and inlet valves
U0001 Control Area Network (CAN) bus-off or mute
U0101 CAN missing frame from TCU
U0121 CAN missing frame from ABS
U0122 CAN missing frame from ESP
U0155
Page 9 of 36
CAN missing frame from HEC

B1213 Anti-theft number of programmed keys is below minimum
B1600 Passive Anti-Theft System (PATS) ignition key transponder signal is not received
B1601 PATS received incorrect key-code from ignition key transponder
B1602 PATS received invalid format of key-code from ignition key transponder
B1681 PATS transceiver module signal is not received
B2103 Immobilizer antenna not connected
B2139 Immobilizer challenge response doesn't match
B2141 Immobilizer no PCM-ID transferred
B2431 Immobilizer transponder programming failure
U2510 Immobilizer problem with messages on data link
Electrical
- Fuse(s)
- Wiring harness
- Relay(s)
- Sensor(s)
- Actuators
- Switch(es)

4. If the cause is not visually evident, verify the symptom and refer to the PID/DATA Monitor
and Record Procedure.
PID/DATA Monitor and Record Procedure
1. Connect WDS or equivalent to the data link connector (DLC).

Page 10 of 36
2. Turn the ignition key to position II.
3. Access and monitor PIDs according to the following table:
PID/DATA MONITOR Table
PID PID Name Unit/Condition Condition/Specification Action

1340 Accelerator pedal position (APP) % open * Minimum: 0 REFER
sensor - vehicles with diesel to WDS.
engine * Maximum: 100
114A Intake air temperature Volts * Minimum: 0 REFER
to WDS.
* Maximum: 5
1172 Battery Volts 10-16 volts REFER
to WDS.
114D Coolant temperature Volts * Minimum: 0 REFER
to WDS.
* Maximum: 5
0200 DTC Number of * Minimum: 0 REFER
DTCs to WDS.
* Maximum: 255
005 Engine coolant temperature °C (°F) * Minimum: -40 REFER
(ECT) sensor (-104) to WDS.
* Maximum: 215
(419)
1410 Fuel injector pulse width Seconds * Minimum: 0 REFER
to WDS.
* Maximum:
0.524
1135 Engine Idle Speed RPM * Minimum: 0 REFER
to WDS.
* Maximum:
4080
000E Ignition timing advance for °C (°F) * Minimum: -64 REFER
number 1 cylinder - all except (-147) to WDS.
vehicles with diesel engine
* Maximum:
63.5 (146)
000F Intake air temperature (IAT) °C (°F) * Minimum: -40 REFER
sensor (-104) to WDS.
* Maximum: 215
(419)
0010 Mass air flow (MAF) sensor g/sec * Ignition key in REFER
position II: 0 to WDS.
* Maximum:
655.35
1126 Starter Motor - time before PCM Seconds * Minimum: 0 REFER
disables starter motor signal to WDS.
* Maximum: 255
0011 Throttle position (TP) sensor % * Minimum: 0 REFER
to WDS.
* Maximum: 100
Page 11 of 36
11C1 Vehicle speed kph (mph) * Minimum: 0 REFER

(0) to WDS.
* Maximum: 206
(128)
4. If the concern is still evident, refer to the Reading DTCs Procedure.
3. Retrieve DTCs by using WDS or equivalent.
4. If DTCs are retrieved, go to the Diagnostic Trouble Code (DTC) Chart.
Diagnostic Trouble Code (DTC) Chart - All except vehicles with diesel engine
DTC Description Source Action

B1213 Number of passive anti-theft PCM Program additional key(s).
system (PATS) programmed keys
is below minimum
B1600 PATS key transponder signal not PCM REFER to WDS.
received
B1601 PATS received incorrect code PCM REFER to WDS.
B1602 PATS received invalid code from PCM REFER to WDS.
PATS transponder
B1681 PATS transceiver signal not PCM REFER to WDS.
received
B2103 PATS antenna not connected PCM REFER to Section 419-01B.[Anti-Theft -
Passive, REMOVAL AND INSTALLATION,
Passive Anti-Theft System (PATS)
Transceiver]
B2139 PATS does not match with PCM REFER to WDS.
instrument cluster
B2141 No powertrain control module PCM REFER to WDS.
(PCM) ID transferred
B2431 PATS transponder programming PCM REFER to WDS.
failure
P0030 Heated oxygen sensor (H02S) PCM REFER to WDS.
open circuit
P0031 H02S short to ground PCM REFER to WDS.
P0032 H02S short to battery PCM REFER to WDS.
Page 12 of 36
P0036 Catalyst monitor sensor open PCM REFER to WDS.

circuit
P0037 Catalyst monitor sensor short to PCM REFER to WDS.
ground
P0038 Catalyst monitor sensor short to PCM REFER to WDS.
battery
P0053 H02S resistance out of PCM REFER to WDS.
specification
P0054 Catalyst monitor sensor resistance PCM REFER to WDS.
out of specification
P0105 Manifold absolute pressure (MAP) PCM REFER to WDS.
sensor open circuit
P0106 MAP sensor out of specification PCM REFER to WDS.
P0107 MAP sensor short to ground PCM REFER to WDS.
P0108 MAP sensor short to battery PCM REFER to WDS.
P0112 Intake air temperature (IAT) PCM REFER to WDS.
sensor short to ground
P0113 IAT sensor short to battery PCM REFER to WDS.
P0114 IAT sensor intermittent operation PCM REFER to WDS.
P0115 Engine coolant temperature (ECT) PCM REFER to WDS.
sensor open circuit
P0116 ECT sensor stuck in low reading PCM REFER to WDS.
P0117 ECT sensor short to ground PCM REFER to WDS.
P0118 ECT sensor short to battery PCM REFER to WDS.
P0119 ECT sensor intermittent operation PCM REFER to WDS.
P0122 Throttle position (TP) sensor short PCM REFER to WDS.
to ground
P0122 Accelerator pedal position (APP) 1 PCM REFER to WDS.
sensor signal short to ground
P0123 TP sensor short to battery or open PCM REFER to WDS.
circuit
P0123 APP 1 sensor signal short to PCM REFER to WDS.
battery
P0130 H02S signal open circuit PCM REFER to WDS.
P0131 H02S signal short to ground PCM REFER to WDS.
P0132 H02S signal short to battery PCM REFER to WDS.
P0133 H02S internal failure PCM REFER to WDS.
P0134 H02S signal implausible - low PCM REFER to WDS.
amplitude
P0136 Catalyst monitor sensor signal PCM REFER to WDS.
open circuit
short to ground
short to battery
P0139 Catalyst monitor sensor internal PCM REFER to WDS.
failure
P0171 H02S switch signal (lean) out of PCM REFER to WDS.
specification
P0172 H02S switch signal (rich) out of PCM REFER to WDS.
specification
P0201 Cylinder number 1 injector circuit PCM REFER to WDS.
open circuit/implausible signal
Page 13 of 36

P0222 TP sensor short to ground or open PCM REFER to WDS.
circuit
P0223 TP sensor short to battery PCM REFER to WDS.
P0231 Fuel pump input signal short to PCM REFER to WDS.
ground or open circuit
P0232 Fuel pump input signal short to PCM REFER to WDS.
battery
short to ground
short to battery
short to ground
short to battery
short to ground
short to battery
short to ground
short to battery
P0300 Multiple cylinder misfire PCM REFER to WDS.
P0301 Cylinder 1 misfire PCM REFER to WDS.
P0315 Crankshaft position (CKP) sensor PCM REFER to WDS.
signal out of specification
P0324 Communication failure with knock PCM REFER to WDS.
sensor (KS)
P0325 KS short to battery, short to PCM REFER to WDS.
ground or open circuit
P0335 CKP sensor open or short circuit PCM REFER to WDS.
P0336 CKP sensor signal not plausible PCM REFER to WDS.
P0340 Camshaft position (CMP) sensor PCM REFER to WDS.
no signal
P0341 CMP sensor signal not plausible PCM REFER to WDS.
P0351 Ignition coil A short to battery, PCM REFER to WDS.
short to ground or open circuit
P0352 Ignition coil B short to battery, PCM REFER to WDS.
short to ground or open circuit
P0420 Catalytic converter failure PCM REFER to WDS.
P0444 Evaporative emissions canister PCM REFER to WDS.
purge valve open circuit
purge valve short to ground
purge valve short to battery
P0460 Invalid fuel tank level - message PCM REFER to WDS.
Page 14 of 36
from instrument cluster

P0480 Cooling fan (low speed) motor PCM REFER to WDS.
output signal open circuit
P0481 Cooling fan (high speed) motor PCM REFER to WDS.
output signal open circuit
P0500 Vehicle speed sensor (VSS) no PCM REFER to WDS.
signal
P0503 VSS implausible signal (too high) PCM REFER to WDS.
P0571 Brake pedal position (BPP) switch PCM REFER to WDS.
implausible signal
P0603 EEPROM error PCM REFER to WDS.
P0604 RAM error PCM REFER to WDS.
P0605 CHKSUM error PCM REFER to WDS.
P0610 CHKSUM error (VID block) PCM REFER to WDS.
P0617 Starter motor relay short to PCM REFER to WDS.
battery
P0620 Generator circuit open circuit, PCM REFER to WDS.
short to battery or short to ground
P0625 Generator voltage low PCM REFER to WDS.
P0626 Generator voltage high PCM REFER to WDS.
P0627 Fuel pump relay open circuit PCM REFER to WDS.
P0628 Fuel pump relay short to ground PCM REFER to WDS.
P0629 Fuel pump relay short to battery PCM REFER to WDS.
P0645 Air conditioning (A/C) compressor PCM REFER to WDS.
open circuit
P0646 A/C compressor short to ground PCM REFER to WDS.
P0647 A/C compressor short to battery PCM REFER to WDS.
output signal short to ground
output signal short to battery
output signal short to ground
P0704 Clutch pedal position (CPP) switch PCM REFER to WDS.
implausible signal
output signal short to battery
P1000 EOBD system readiness test not PCM REFER to Principles of Operation
complete
P1794 Battery voltage out of PCM REFER to WDS.
specification
P2108 Automated gearshift system signal PCM REFER to WDS.
not plausible (if equipped)
P2108 Mass air flow (MAF) sensor lower PCM REFER to WDS.
than expected
P2119 Throttle body flap failure PCM REFER to WDS.
P2127 Accelerator pedal position (APP) 2 PCM REFER to WDS.
sensor signal short to ground
P2128 APP 2 sensor signal short to PCM REFER to WDS.
battery
P2135 TP plausibility error PCM REFER to WDS.
P2138 APP 1 and 2 sensor(s) plausibility PCM REFER to WDS.
error
P2282 Air leak between the throttle body PCM REFER to WDS.
and intake manifold
Page 15 of 36
U0001 CAN BUS error PCM REFER to WDS.

U0101 CAN missing frame from traction PCM REFER to WDS.
control
U0121 CAN missing frame from anti-lock PCM REFER to WDS.
braking system (ABS)
U0122 CAN missing frame from stability PCM REFER to WDS.
assist
U0155 CAN missing frame from PCM REFER to WDS.
instrument cluster
U2510 PCM unable to read messages PCM REFER to WDS.
from instrument cluster
Diagnostic Trouble Code (DTC) Chart - Vehicles with diesel engine

B1213 Number of passive anti-theft system (PATS) PCM REFER to WDS.
programmed keys is below minimum
B1600 PATS key transponder signal not received PCM REFER to WDS.
B1602 PATS received invalid code from PATS transponder PCM REFER to WDS.
B1681 PATS transceiver signal not received PCM REFER to WDS.
B2103 PATS antenna not connected PCM REFER to WDS.
B2139 PATS does not match with instrument cluster PCM REFER to WDS.
B2141 No powertrain control module (PCM) ID transferred PCM REFER to WDS.
B2431 PATS transponder programming failure PCM REFER to WDS.
P0087 Fuel injection supply manifold pressure sensor short to PCM REFER to WDS.
battery
P0088 Fuel injection supply manifold pressure sensor short to PCM REFER to WDS.
ground
P0089 Fuel injection supply manifold pressure sensor open PCM REFER to WDS.
circuit
P0102 Mass air flow (MAF) sensor short to ground PCM REFER to WDS.
P0103 MAF sensor short to battery PCM REFER to WDS.
P0107 Manifold absolute pressure (MAP) sensor short to PCM REFER to WDS.
ground
P0108 MAP sensor short to battery PCM REFER to WDS.
P0112 Intake air temperature (IAT) sensor short to ground PCM REFER to WDS.
P0113 IAT sensor short to battery PCM REFER to WDS.
P0115 Engine coolant temperature (ECT) sensor open circuit PCM REFER to WDS.
P0116 ECT sensor stuck in low reading PCM REFER to WDS.
P0117 ECT sensor short to ground PCM REFER to WDS.
P0118 ECT sensor short to battery PCM REFER to WDS.
P0119 ECT sensor intermittent operation PCM REFER to WDS.
P0181 Fuel temperature sensor signal out of specification PCM REFER to WDS.
P0182 Fuel temperature sensor signal short to battery PCM REFER to WDS.
P0183 Fuel temperature sensor signal short to ground PCM REFER to WDS.
P0191 Fuel pressure sensor plausibility error PCM REFER to WDS.
P0192 Fuel pressure sensor short to battery PCM REFER to WDS.
P0193 Fuel pressure sensor short to ground PCM REFER to WDS.
P0197 Oil temperature sensor short to ground PCM REFER to WDS.
P0198 Oil temperature sensor short to battery PCM REFER to WDS.
P0201 Cylinder number 1 injector circuit open PCM REFER to WDS.
circuit/implausible signal
Page 16 of 36
P0231 Fuel pump input signal short to ground or open circuit PCM REFER to WDS.
P0232 Fuel pump input signal short to battery PCM REFER to WDS.
P0263 Cylinder number 1 injector plausibility error PCM REFER to WDS.
P0315 Crankshaft position (CKP) sensor signal out of PCM REFER to WDS.
specification
P0336 CKP sensor signal not plausible PCM REFER to WDS.
P0337 CKP sensor open or short circuit PCM REFER to WDS.
P0341 Camshaft position (CMP) sensor signal not plausible PCM REFER to WDS.
P0342 CMP sensor no signal PCM REFER to WDS.
P0380 Glow plug relay open circuit PCM REFER to WDS.
P0401 Exhaust gas recirculation (EGR) controller short to PCM REFER to WDS.
ground
P0402 EGR controller short to battery PCM REFER to WDS.
P0403 EGR valve circuit open circuit, short to battery or short PCM REFER to WDS.
to ground
P0460 Invalid fuel tank level - message from instrument PCM REFER to WDS.
cluster
P0480 Cooling fan (low speed) motor output signal open circuit PCM REFER to WDS.
P0481 Cooling fan (high speed) motor output signal open PCM REFER to WDS.
circuit
P0500 Vehicle speed sensor (VSS) no signal PCM REFER to WDS.
P0562 Battery voltage low PCM REFER to WDS.
P0563 Battery voltage high PCM REFER to WDS.
P0603 EEPROM error PCM REFER to WDS.
P0604 RAM error PCM REFER to WDS.
P0605 CHKSUM error PCM REFER to WDS.
P0615 Starter motor relay short to battery PCM REFER to WDS.
P0627 Fuel pump relay open circuit PCM REFER to WDS.
P0628 Fuel pump relay short to ground PCM REFER to WDS.
P0629 Fuel pump relay short to battery PCM REFER to WDS.
P0645 Air conditioning (A/C) compressor open circuit PCM REFER to WDS.
P0684 Glow plug relay plausibility error PCM REFER to WDS.
P0703 Brake pedal position (BPP) switch implausible signal PCM REFER to WDS.
P0704 Clutch pedal position (CPP) switch implausible signal PCM REFER to WDS.
P0812 Reverse lamp switch plausibility error PCM REFER to WDS.
P1000 EOBD system readiness test not complete PCM REFER to Principles of
Operation
P1244 Generator voltage high PCM REFER to WDS.
P1245 Generator voltage low PCM REFER to WDS.
P1632 Generator circuit open circuit, short to battery or short PCM REFER to WDS.
to ground
P2122 Accelerator pedal position (APP) 1 sensor signal short to PCM REFER to WDS.
ground
P2123 APP 1 sensor signal short to battery PCM REFER to WDS.
P2127 APP 2 sensor signal short to ground PCM REFER to WDS.
Page 17 of 36
P2128 APP 2 sensor signal short to battery PCM REFER to WDS.

P2138 APP 1 and 2 sensor(s) plausibility error PCM REFER to WDS.
U2510 PCM unable to read messages from instrument cluster PCM REFER to WDS.
NOTE: P1000 cannot be cleared using this procedure.

1. After repairs have been carried out, carry out the DTCs Reading Procedure.
2. Clear the DTCs by using WDS or equivalent. TEST the system for normal operation.
3. If the concern is still evident, refer to WDS for further diagnostics.
3. Activate the Active Command Modes by using WDS or equivalent
Active Command Mode
Command Name Definition Operation

Starter Control Command Starter motor relay control Disable(d)/Enable
(d)
Cooling Fan Control High speed cooling fan control Off/On
Cooling Fan Control Low speed cooling fan control Off/On
Air Conditioning (A/C) Control A/C relay control Inactive/Active
Heater Control Electric coolant heater relay 1 Inactive/Active
Heater Control Electric coolant heater relay 2 Inactive/Active
Glow Plug Control Glow plug relay control Inactive/Active
Heated Oxygen Sensor (HO2S) Heater HO2S heater control Off/On
Control
Page 18 of 36
Catalyst Monitor Sensor Heater Control Catalyst monitor sensor heater Off/On
control
Terminal Voltage Table (reference value) - Vehicles with diesel engine
Vehicles with automated gearshift system
Inspection
Terminal Signal Name Connected to Test Condition Standard Item
1A Transmission control TCM - 1 V or Related
module (TCM) input less wiring
signal harness
1B TCM output signal TCM - 1 V or Related
less wiring
harness
1C Dual pressure switch Dual pressure Switch open 10.56 V Related
power signal switch wiring
harness
1D Immobilizer coil input Immobilizer coil - 1 V or Related
signal less wiring
harness
1E - - - - -
1F - - - - -
1G - - - - -
1H Positive temperature Positive - 1 V or Related
coefficient heater relay temperature less wiring
1 power signal coefficient heater harness
relay 1
1I - - - - -
1J Ignition switch power PCM Ignition key in the V batt Related
signal IGN II position wiring
harness
1K APP sensor signal APP sensor - 1 V or Related
less wiring
harness
Page 19 of 36
1L Positive temperature Positive - 1 V or Related

coefficient heater relay temperature less wiring
2 power signal coefficient heater harness
relay 2
1M - - - - -
1N - - - - -
1O Immobilizer coil Immobilizer coil - 1 V or Related
output signal less wiring
harness
1P - - - - -
1Q BPP switch ground BPP switch Switch closed 1 V or Related
signal less wiring
harness
1R CPP switch ground CPP switch Switch closed 1 V or Related
signal less wiring
harness
1S - - - - -
1T - - - - -
1U APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1V - - - - -
1W APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1X - - - - -
1Y PCM ground signal Ground - 1 V or Related
less wiring
harness
1Z APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1AA APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1AB - - - - -
1AC PCM ground signal Ground - 1 V or Related
less wiring
harness
1AD APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1AE - - - - -
1AF - - - - -
2A - - - - -
2B - - - - -
2C - - - - -
2D Dual pressure switch Dual pressure Switch open 1 V or Related
ground signal switch less wiring
harness
2E - - - - -
2F CKP sensor signal CKP sensor - 1 V or Related
less wiring
harness
2G - - - - -
Page 20 of 36
2H - - - - -
2I - - - - -
2J - - - - -
2K CMP sensor signal CMP signal - 1 V or Related
less wiring
harness
2L - - - - -
2M Glow plug relay signal Glow plug relay - 1 V or Related
less wiring
harness
2N - - - - -
2O Stop lamp input signal BPP switch Brake pedal V batt Related
depressed with wiring
ignition ON harness
Brake pedal 1 V or
released with less
ignition ON
2P Fuel rail pressure Fuel rail pressure - 1 V or Related
sensor supply sensor less wiring
harness
2Q CKP sensor signal CKP sensor - 1 V or Related
less wiring
harness
2R CKP sensor signal CKP sensor - 1 V or Related
less wiring
harness
2S CMP sensor signal CMP signal - 1 V or Related
less wiring
harness
2T - - - - -
2U - - - - -
2V - - - - -
2W - - - - -
2X - - - - -
2Y PCM battery power Battery - V batt Related
signal wiring
harness
2Z - - - - -
2AA - - - - -
2AB - - - - -
2AC - - - - -
2AD - - - - -
2AE MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
2AF - - - - -
2AG MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
2AH - - - - -
2AI Fuel temperature Fuel temperature Vehicle at normal 1 V or Related
sensor signal sensor operating less wiring
temperature harness
2AJ - - - - -
2AK - - - - -
Page 21 of 36
2AL - - - - -
2AM PCM ground signal Ground - 1 V or Related
less wiring
harness
2AN ECT sensor signal ECT sensor Vehicle at normal 1 V or Related
operating less wiring
temperature harness
2AO Fuel pressure solenoid Fuel pressure - 1 V or Related
valve input signal solenoid valve less wiring
harness
2AP - - - - -
2AQ - - - - -
2AR - - - - -
2AS Fuel metering valve Fuel metering - 1 V or Related
input signal valve less wiring
harness
2AT - - - - -
2AU EGR vacuum regulator EGR vacuum - 1 V or Related
solenoid signal regulator solenoid less wiring
harness
2AV - - - - -
3A Reversing lamp switch Reversing lamp Reverse gear V batt Related
input signal switch selected with wiring
ignition ON harness
3B Fuel temperature Fuel temperature Vehicle at normal 1 V or Related
sensor signal sensor operating less wiring
temperature harness
3C ECT sensor signal ECT sensor Vehicle at normal 1 V or Related
operating less wiring
temperature harness
3D MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
3E MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
3F Fuel rail pressure Fuel rail pressure - 1 V or Related
sensor ground sensor less wiring
harness
3G Fuel rail pressure Fuel rail pressure - 1 V or Related
sensor signal sensor less wiring
harness
3H - - - - -
3I PCM ground signal Ground - 1 V or Related
less wiring
harness
3J Starter relay input Starter relay Ignition key in the V batt Related
signal START position wiring
harness
3K VSS input signal VSS - 1 V or Related
less wiring
harness
3L CMP sensor signal CMP sensor - 1 V or Related
less wiring
harness
3M - - - - -
Page 22 of 36
3N Cooling fan relay 1 Cooling fan relay 1 Vehicle at normal V batt Related
signal operating wiring
temperature harness
3O Main relay signal Main relay - 1 V or Related
less wiring
harness
3P Cooling fan relay 2 Cooling fan relay 2 Vehicle at normal 1 V or Related
input signal (A/C only) operating less wiring
temperature harness
3Q Glow plug relay signal Glow plug relay - 1 V or Related
less wiring
harness
3R PCM switched power Main relay - V batt Related
wiring
harness
3S - - - - -
3T Generator output Generator - 0.15 V Related
signal wiring
harness
3U A/C wide open throttle A/C wide open - 1 V or Related
relay input signal (A/C throttle relay less wiring
only) harness
3V PCM switched power Main relay - V batt Related
wiring
harness
3W PCM switched power Main relay - 1 V or Related
less wiring
harness
3X Generator input signal Generator - 1 V or Related
less wiring
harness
3Y Fuel injector signal Fuel injector 1 - 1 V or Related
installed in cylinder less wiring
1 harness
3Z Fuel injector signal Fuel injector 4 - 1 V or Related
2 harness
3AA Fuel injector signal Fuel injector 3 - 1 V or Related
4 harness
3AB Fuel injector signal Fuel injector 2 - 1 V or Related
3 harness
3AC Fuel injector signal Fuel injector 3 - 1 V or Related
4 harness
3AD Fuel injector signal Fuel injector 4 - 1 V or Related
2 harness
3AE Fuel injector signal Fuel injector 2 - 1 V or Related
3 harness
3AF Fuel injector signal Fuel injector 1 - 1 V or Related
1 harness
Vehicles with manual transaxle
Page 23 of 36
Test Inspection
Terminal Signal Name Connected to Condition Standard Item
1A * * - 2.45 V Related
Instrument Instrument wiring
cluster cluster harness
signal
* DLC
* DLC signal
1B * * - 2.45 V Related
signal
* DLC
* DLC signal
1C Dual pressure switch Dual pressure switch Switch open 10.56 V Related
power signal wiring
harness
1D Immobilizer coil input Immobilizer coil - 1 V or Related
signal less wiring
harness
1E - - - - -
1F - - - - -
1G - - - - -
1H Positive temperature Positive temperature - 1 V or Related
coefficient heater relay 1 coefficient heater relay less wiring
power signal 1 harness
1I - - - - -
1J Ignition switch power PCM Ignition key V batt Related
signal in the IGN II wiring
position harness
1K APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1L Positive temperature Positive temperature - 1 V or Related
coefficient heater relay 2 coefficient heater relay less wiring
power signal 2 harness
1M - - - - -
1N - - - - -
1O Immobilizer coil output Immobilizer coil - 1 V or Related
signal less wiring
harness
1P - - - - -
1Q BPP switch ground signal BPP switch Switch closed 1 V or Related
less wiring
harness
1R CPP switch ground signal CPP switch Switch closed 1 V or Related
less wiring
harness
1S - - - - -
1T - - - - -
1U APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1V - - - - -
1W APP sensor signal APP sensor - 1 V or Related
less wiring
Page 24 of 36
harness
1X - - - - -
1Y PCM ground signal Ground - 1 V or Related
less wiring
harness
1Z APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1AA APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1AB - - - - -
1AC PCM ground signal Ground - 1 V or Related
less wiring
harness
1AD APP sensor signal APP sensor - 1 V or Related
less wiring
harness
1AE - - - - -
1AF - - - - -
2A - - - - -
2B - - - - -
2C - - - - -
2D Dual pressure switch Dual pressure switch Switch open 1 V or Related
ground signal less wiring
harness
2E - - - - -
2F CKP sensor signal CKP sensor - 1 V or Related
less wiring
harness
2G - - - - -
2H - - - - -
2I - - - - -
2J - - - - -
2K CMP sensor signal CMP signal - 1 V or Related
less wiring
harness
2L - - - - -
2M Glow plug relay signal Glow plug relay - 1 V or Related
less wiring
harness
2N - - - - -
2O Stop lamp input signal BPP switch Brake pedal V batt Related
depressed wiring
with ignition harness
ON
Brake pedal 1 V or
released with less
ignition ON
2P Fuel rail pressure sensor Fuel rail pressure - 1 V or Related
supply sensor less wiring
harness
2Q CKP sensor signal CKP sensor - 1 V or Related
less wiring
harness
Page 25 of 36
2R CKP sensor signal CKP sensor - 1 V or Related

less wiring
harness
2S CMP sensor signal CMP signal - 1 V or Related
less wiring
harness
2T - - - - -
2U - - - - -
2V - - - - -
2W - - - - -
2X - - - - -
2Y PCM battery power Battery - V batt Related
signal wiring
harness
2Z - - - - -
2AA - - - - -
2AB - - - - -
2AC - - - - -
2AD - - - - -
2AE MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
2AF - - - - -
2AG MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
2AH - - - - -
2AI Fuel temperature sensor Fuel temperature Vehicle at 1 V or Related
signal sensor normal less wiring
operating harness
temperature
2AJ - - - - -
2AK - - - - -
2AL - - - - -
2AM PCM ground signal Ground - 1 V or Related
less wiring
harness
2AN ECT sensor signal ECT sensor Vehicle at 1 V or Related
normal less wiring
operating harness
temperature
2AO Fuel pressure solenoid Fuel pressure solenoid - 1 V or Related
valve input signal valve less wiring
harness
2AP - - - - -
2AQ - - - - -
2AR - - - - -
2AS Fuel metering valve Fuel metering valve - 1 V or Related
input signal less wiring
harness
2AT - - - - -
2AU EGR vacuum regulator EGR vacuum regulator - 1 V or Related
solenoid signal solenoid less wiring
harness
2AV - - - - -
Page 26 of 36
3A Reversing lamp switch Reversing lamp switch Reverse gear V batt Related
input signal selected with wiring
ignition ON harness
3B Fuel temperature sensor Fuel temperature Vehicle at 1 V or Related
signal sensor normal less wiring
operating harness
temperature
3C ECT sensor signal ECT sensor Vehicle at 1 V or Related
normal less wiring
operating harness
temperature
3D MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
3E MAF sensor signal MAF sensor - 1 V or Related
less wiring
harness
3F Fuel rail pressure sensor Fuel rail pressure - 1 V or Related
ground sensor less wiring
harness
3G Fuel rail pressure sensor Fuel rail pressure - 1 V or Related
signal sensor less wiring
harness
3H - - - - -
3I PCM ground signal Ground - 1 V or Related
less wiring
harness
3J Starter relay input signal Starter relay Ignition key V batt Related
in the START wiring
position harness
3K VSS input signal VSS - 1 V or Related
less wiring
harness
3L CMP sensor signal CMP sensor - 1 V or Related
less wiring
harness
3M - - - - -
3N Cooling fan relay 1 Cooling fan relay 1 Vehicle at V batt Related
signal normal wiring
operating harness
temperature
3O Main relay signal Main relay - 1 V or Related
less wiring
harness
3P Cooling fan relay 2 input Cooling fan relay 2 Vehicle at 1 V or Related
signal (A/C only) normal less wiring
operating harness
temperature
3Q Glow plug relay signal Glow plug relay - 1 V or Related
less wiring
harness
3R PCM switched power Main relay - V batt Related
wiring
harness
3S - - - - -
3T Generator output signal Generator - 0.15 V Related
Page 27 of 36
wiring
harness
3U A/C wide open throttle A/C wide open throttle - 1 V or Related
relay input signal (A/C relay less wiring
only) harness
3V PCM switched power Main relay - V batt Related
wiring
harness
3W PCM switched power Main relay - 1 V or Related
less wiring
harness
3X Generator input signal Generator - 1 V or Related
less wiring
harness
3Y Fuel injector signal Fuel injector 1 installed - 1 V or Related
in cylinder 1 less wiring
harness
3Z Fuel injector signal Fuel injector 4 installed - 1 V or Related
harness
3AA Fuel injector signal Fuel injector 3 installed - 1 V or Related
harness
3AB Fuel injector signal Fuel injector 2 installed - 1 V or Related
harness
3AC Fuel injector signal Fuel injector 3 installed - 1 V or Related
harness
3AD Fuel injector signal Fuel injector 4 installed - 1 V or Related
harness
3AE Fuel injector signal Fuel injector 2 installed - 1 V or Related
harness
3AF Fuel injector signal Fuel injector 1 installed - 1 V or Related
harness
Terminal Voltage Table (reference value) - All except vehicles with diesel
engine
Page 28 of 36
Vehicles with automated gearshift system
Terminal Signal Name Connected to Test Condition Standard Inspection Item

A PCM battery power Battery - V batt Related wiring
signal harness
B TP sensor signal TP sensor - 1 V or Related wiring
less harness
C Ignition switch PCM Ignition key in V batt Related wiring
power signal the IGN II harness
position
D - - - - -
E - - - - -
F - - - - -
G PCM switched Main relay - 1 V or Related wiring
power less harness
H TP sensor signal TP sensor signal 1 V or Related wiring
less harness
I TCM input signal TCM - 1 V or Related wiring
less harness
J TCM output signal TCM - 1 V or Related wiring
less harness
K - - - - -
L Starter relay input Starter relay Ignition key in V batt Related wiring
signal the START harness
position
M PCM ground signal Ground - 1 V or Related wiring
less harness
N PCM ground signal Ground - 1 V or Related wiring
less harness
O Immobilizer coil Immobilizer coil - 1 V or Related wiring
input signal less harness
P Immobilizer coil Immobilizer coil - 1 V or Related wiring
output signal less harness
Q Evaporative Evaporative - V batt Related wiring
Page 29 of 36
emission canister emission harness

vent solenoid canister vent
output signal solenoid
R Immobilizer coil Immobilizer coil - 1 V or Related wiring
S HO2S output signal HO2S Vehicle at 1 V or Related wiring
normal operating less harness
temperature
T Catalyst monitor Catalyst monitor Vehicle at 1 V or Related wiring
sensor output sensor normal operating less harness
signal temperature
U - - - - -
V CMP sensor signal CMP sensor - 1 V or Related wiring
less harness
W - - - - -
X - - - - -
Y CKP sensor signal CKP sensor - 1 V or Related wiring
less harness
Z CMP sensor signal CMP sensor - 1 V or Related wiring
less harness
AA - - - - -
AB ECT sensor signal ECT sensor Vehicle at 1 V or Related wiring
temperature
AC - - - - -
AD CKP sensor signal CKP sensor - 1 V or Related wiring
less harness
AE IAT sensor signal IAT sensor - 1 V or Related wiring
less harness
AF - - - - -
AG - - - - -
AH ECT sensor signal ECT sensor Vehicle at 1 V or Related wiring
temperature
AI HO2S input signal HO2S Vehicle at 1 V or Related wiring
temperature
AJ - - - - -
AK VSS signal VSS - 1 V or Related wiring
less harness
AL Ignition coil pack Ignition coil pack - 1 V or Related wiring
AM Catalyst monitor Catalyst monitor Vehicle at 1 V or Related wiring
sensor output sensor normal operating less harness
signal temperature
AN - - - - -
AO Dual pressure Dual pressure Switch open 1 V or Related wiring
switch power switch less harness
signal
AP Dual pressure Dual pressure Switch open 1 V or Related wiring
switch ground switch less harness
signal
AQ Cooling fan relay 2 Cooling fan relay Vehicle at 1 V or Related wiring
input signal (A/C 2 normal operating less harness
only) temperature
Page 30 of 36
AR A/C wide open A/C wide open - 1 V or Related wiring

throttle relay input throttle relay less harness
signal (A/C only)
AS BPP switch ground BPP switch Switch closed 1 V or Related wiring
signal less harness
AT IAT sensor signal IAT sensor - 1 V or Related wiring
less harness
AU - - - - -
AV - - - - -
AW Stop lamp input BPP switch Brake pedal V batt Related wiring
signal depressed with harness
ignition ON
Brake pedal 1 V or
released with less
ignition ON
AX APP sensor signal APP sensor - 1 V or Related wiring
less harnessRelated
wiring harness
AY Cooling fan relay 1 Cooling fan relay Vehicle at 1 V or Related wiring
input signal 1 normal operating less harness
temperature
AZ Fuel pump relay Fuel pump relay - V batt Related wiring
input signal harness
BA CPP switch ground CPP switch Switch closed 1 V or Related wiring
signal less harness
BB Power steering PSP switch No load applied 1 V or Related wiring
pressure (PSP) to the steering less harness
switch signal
BC Main relay signal Main relay - V batt Related wiring
harness
BD - - - - -
BE Catalyst monitor Catalyst monitor Vehicle at 1 V or Related wiring
sensor ground sensor normal operating less harness
signal temperature
BF HO2S ground HO2S Vehicle at 1 V or Related wiring
signal normal operating less harness
temperature
BG Generator input Generator - V batt Related wiring
signal harness
BH TP sensor signal TP sensor - 1 V or Related wiring
less harness
BI APP sensor signal APP sensor - 1 V or Related wiring
less harness
BJ TP sensor signal TP sensor - 1 V or Related wiring
less harness
BK TP sensor signal TP sensor - 1 V or Related wiring
less harness
BL - - - - -
BM TP sensor signal TP sensor - 1 V or Related wiring
less harness
BN APP sensor signal APP sensor - 1 V or Related wiring
less harness
BO IAT sensor signal IAT sensor - 1 V or Related wiring
less harness
BP IAT sensor signal IAT sensor - 1 V or Related wiring
less harness
Page 31 of 36
BQ PCM ground signal Ground - 1 V or Related wiring

less harness
BR APP sensor signal APP sensor - 1 V or Related wiring
less harness
BS APP sensor signal APP sensor - 1 V or Related wiring
less harness
BT - - - - -
BU VSS signal VSS - 1 V or Related wiring
less harness
BV Generator output Generator - 1 V or Related wiring
signal less harness
BW - - - - -
BX APP sensor signal APP sensor - 1 V or Related wiring
less harness
BY - - - - -
BZ KS signal KS - 1 V or Related wiring
less harness
CA KS ground signal KS - 1 V or Related wiring
less harness
CB KS signal KS - 1 V or Related wiring
less harness
CC Ignition coil pack Ignition coil pack - 1 V or Related wiring
signal less harness
CD - - - - -
CE - - - - -
CF - - - - -
CG - - - - -
CH - - - - -
CI - - - - -
CJ - - - - -
CK Fuel injector 2 Fuel injector 2 - 1 V or Related wiring
CL Fuel injector 3 Fuel injector 3 - 1 V or Related wiring
CM Fuel injector 4 Fuel injector 4 - 1 V or Related wiring
CN Fuel injector 1 Fuel injector 1 - - Related wiring
output signal harness
CO Ignition coil pack Ignition coil pack - 1 V or Related wiring
signal less harness
CP PCM ground signal Ground - 1 V or Related wiring
less harness
Vehicles with manual transaxle
Test Inspection
Terminal Signal Name Connected to Condition Standard Item
A PCM battery power Battery - V batt Related
signal wiring
harness
B TP sensor signal TP sensor - 1 V or Related
less wiring
harness
C Ignition switch power PCM Ignition key V batt Related
signal in the IGN II wiring
position harness
Page 32 of 36
D - - - - -
E - - - - -
F - - - - -
G PCM switched power Main relay - 1 V or Related
less wiring
harness
H TP sensor signal TP sensor signal - 1 V or Related
less wiring
harness
I * * - 2.45 V Related
signal
* DLC
* DLC signal
J * * - 2.45 V Related
signal
* DLC
* DLC signal
K - - - - -
L Starter relay input signal Starter relay Ignition key V batt Related
in the START wiring
position harness
M PCM ground signal Ground - 1 V or Related
less wiring
harness
N PCM ground signal Ground - 1 V or Related
less wiring
harness
O Immobilizer coil input Immobilizer coil - 1 V or Related
signal less wiring
harness
P Immobilizer coil output Immobilizer coil - 1 V or Related
signal less wiring
harness
Q Evaporative emission Evaporative emission - V batt Related
canister vent solenoid canister vent solenoid wiring
output signal harness
R Immobilizer coil input Immobilizer coil - 1 V or Related
signal less wiring
harness
S HO2S output signal HO2S Vehicle at 1 V or Related
normal less wiring
operating harness
temperature
T Catalyst monitor sensor Catalyst monitor sensor Vehicle at 1 V or Related
output signal normal less wiring
operating harness
temperature
U - - - - -
V CMP sensor signal CMP sensor - 1 V or Related
less wiring
harness
W - - - - -
Page 33 of 36
X - - - - -
Y CKP sensor signal CKP sensor - 1 V or Related
less wiring
harness
Z CMP sensor signal CMP sensor - 1 V or Related
less wiring
harness
AA - - - - -
AB ECT sensor signal ECT sensor Vehicle at 1 V or Related
normal less wiring
operating harness
temperature
AC - - - - -
AD CKP sensor signal CKP sensor - 1 V or Related
less wiring
harness
AE IAT sensor signal IAT sensor - 1 V or Related
less wiring
harness
AF - - - - -
AG - - - - -
AH ECT sensor signal ECT sensor Vehicle at 1 V or Related
normal less wiring
operating harness
temperature
AI HO2S input signal HO2S Vehicle at 1 V or Related
normal less wiring
operating harness
temperature
AJ - - - - -
AK VSS signal VSS - 1 V or Related
less wiring
harness
AL Ignition coil pack input Ignition coil pack - 1 V or Related
signal less wiring
harness
AM Catalyst monitor sensor Catalyst monitor sensor Vehicle at 1 V or Related
output signal normal less wiring
operating harness
temperature
AN - - - - -
AO Dual pressure switch Dual pressure switch Switch open 1 V or Related
power signal less wiring
harness
AP Dual pressure switch Dual pressure switch Switch open 1 V or Related
ground signal less wiring
harness
AQ Cooling fan relay 2 input Cooling fan relay 2 Vehicle at 1 V or Related
signal (A/C only) normal less wiring
operating harness
temperature
AR A/C wide open throttle A/C wide open throttle - 1 V or Related
relay input signal (A/C relay less wiring
only) harness
AS BPP switch ground signal BPP switch Switch closed 1 V or Related
less wiring
Page 34 of 36
harness
AT IAT sensor signal IAT sensor - 1 V or Related
less wiring
harness
AU - - - - -
AV - - - - -
AW Stop lamp input signal BPP switch Brake pedal V batt Related
depressed wiring
with ignition harness
ON
Brake pedal 1 V or
released with less
ignition ON
AX APP sensor signal APP sensor - 1 V or Related
less wiring
harness
AY Cooling fan relay 1 input Cooling fan relay 1 Vehicle at 1 V or Related
signal normal less wiring
operating harness
temperature
AZ Fuel pump relay input Fuel pump relay - V batt Related
signal wiring
harness
BA CPP switch ground CPP switch Switch closed 1 V or Related
signal less wiring
harness
BB Power steering pressure PSP switch No load 1 V or Related
(PSP) switch signal applied to the less wiring
steering harness
BC Main relay signal Main relay - V batt Related
wiring
harness
BD - - - - -
BE Catalyst monitor sensor Catalyst monitor sensor Vehicle at 1 V or Related
ground signal normal less wiring
operating harness
temperature
BF HO2S ground signal HO2S Vehicle at 1 V or Related
normal less wiring
operating harness
temperature
BG Generator input signal Generator - V batt Related
wiring
harness
BH TP sensor signal TP sensor - 1 V or Related
less wiring
harness
BI APP sensor signal APP sensor - 1 V or Related
less wiring
harness
BJ TP sensor signal TP sensor - 1 V or Related
less wiring
harness
BK TP sensor signal TP sensor - 1 V or Related
less wiring
harness
Page 35 of 36
BL - - - - -
BM TP sensor signal TP sensor - 1 V or Related
less wiring
harness
BN APP sensor signal APP sensor - 1 V or Related
less wiring
harness
BO IAT sensor signal IAT sensor - 1 V or Related
less wiring
harness
BP IAT sensor signal IAT sensor - 1 V or Related
less wiring
harness
BQ PCM ground signal Ground - 1 V or Related
less wiring
harness
BR APP sensor signal APP sensor - 1 V or Related
less wiring
harness
BS APP sensor signal APP sensor - 1 V or Related
less wiring
harness
BT - - - - -
BU VSS signal VSS - 1 V or Related
less wiring
harness
BV Generator output signal Generator - 1 V or Related
less wiring
harness
BW - - - - -
BX APP sensor signal APP sensor - 1 V or Related
less wiring
harness
BY - - - - -
BZ KS signal KS - 1 V or Related
less wiring
harness
CA KS ground signal KS - 1 V or Related
less wiring
harness
CB KS signal KS - 1 V or Related
less wiring
harness
CC Ignition coil pack signal Ignition coil pack - 1 V or Related
less wiring
harness
CD - - - - -
CE - - - - -
CF - - - - -
CG - - - - -
CH - - - - -
CI - - - - -
CJ - - - - -
CK Fuel injector 2 output Fuel injector 2 - 1 V or Related
signal less wiring
harness
Page 36 of 36
CL Fuel injector 3 output Fuel injector 3 - 1 V or Related

signal less wiring
harness
CM Fuel injector 4 output Fuel injector 4 - 1 V or Related
signal less wiring
harness
CN Fuel injector 1 output Fuel injector 1 - - Related
signal wiring
harness
CO Ignition coil pack signal Ignition coil pack - 1 V or Related
less wiring
harness
CP PCM ground signal Ground - 1 V or Related
less wiring
harness
Page 1 of 4

POWERTRAIN CONTROL MODULE
(PCM) — 1.4L DIESEL
UID=G297181
General Equipment
Worldwide Diagnostic System (WDS) or
equivalent
Removal
All vehicles
NOTE: Before commencing this procedure, make sure that two ignition keys are available
because two keys will be required to initialize the PCM to the passive anti-theft system
(PATS).
NOTE: If a new PCM is to be installed, upload the instrument cluster configuration
information with WDS or equivalent, prior to commencing the removal of the PCM (this is
carried out by WDS or equivalent during the vehicle identification process).
2. Disconnect the battery ground cable.

3. Remove the left-hand side headlamp
assembly. For additional information, refer to
Vehicles built up to 09/2003

4. Remove the PCM retaining bolt and nuts.
5. NOTE: Disconnect the electrical connector

shown on the right-hand side of the graphic
first.
Remove the PCM.
1. Depress the PCM electrical connector locking
tangs.
2. Rotate the levers and pull off the electrical
connectors.
Page 2 of 4
Vehicles built 09/2003 onwards

6. Using a 6mm drill bit, drill into the shear bolt
until the head is removed.
7. Detach the PCM and the security shield from

the PCM retaining bracket.
8. Detach the PCM from the security shield.

9. NOTE: Disconnect the electrical connector
first.
Remove the PCM.
1. Depress the PCM electrical connector locking
tangs.
2. Rotate the levers and pull off the electrical
connectors.
 Remove the security shield.

10. Remove the remains of the shear bolt from
the PCM retaining bracket using a stud
remover.
Installation
Vehicles built up to 09/2003
1. NOTE: Connect the electrical connector
last.
Connect the PCM electrical connectors.
2. Install the PCM to the PCM retaining bracket.

Page 3 of 4
Vehicles built 09/2003 onwards

3. Slide the security shield onto the wiring
harness.
4. NOTE: Connect the electrical connector
last.
Connect the PCM electrical connectors.
5. Install the PCM into the security shield.

6. NOTE: To aid installation, it is necessary to
manouver the PCM and security shield into
the headlamp aperture to allow the electrical
connectors to clear the engine.
Install the PCM and security shield to the PCM
retaining bracket.
7. Install a new shear bolt.
 Tighten the bolt until the head shears off.
All vehicles
8. Install the left-hand side headlamp assembly.
9. Connect the battery ground cable.
connector (DLC).
Page 4 of 4

14. Select "PCM" and carry out the procedures
according to directions on the screen.
15. Using WDS or equivalent, verify that there
are no DTCs present.

refer to Section 413-01.[Instrument Cluster,
DIAGNOSIS AND TESTING, Instrument
Cluster]
this step.
this step.
23. Select "PCM".

Initialization]
Page 1 of 3

FUEL SYSTEM
UID=G297182
- Fuel level - Fuse(s)
- Fuel filter - Wiring harness
- Fuel tank - Electrical connector(s)
- Fuel line(s) - Fuel pump relay
- Fuel connector(s) - Inertia fuel shutoff switch (IFS)
- Fuel filler cap
- Fuel tank filler pipe
- Gasket(s)
- Seal(s)
system (all except vehicles with diesel engine).
5. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart
(vehicles with diesel engine).
Symptom Chart
Symptom Chart

Engine cranks but does *Fuel charging and *REFER to Section 303-04A / 303-04B / 303-
not start controls. 04C. – vehicles with 1.4L diesel engine.
*Air ingress into *GO to Pinpoint Test A.
the fuel lines.
Poor starting *Fuel charging and *REFER to Section 303-04A / 303-04B / 303-
controls. 04C. – vehicles with 1.4L diesel engine.
the fuel lines.
Engine starts but *Fuel charging and *REFER to Section 303-04A / 303-04B / 303-
immediately stops controls. 04C. – vehicles with 1.4L diesel engine.
Page 2 of 3

the fuel lines.
Poor idling *Fuel charging and *REFER to Section 303-04A / 303-04B / 303-
the fuel lines.
Engine lacks power *Fuel charging and *REFER to Section 303-04A / 303-04B / 303-
the fuel lines.
Engine misfire *Fuel charging and *REFER to Section 303-04A / 303-04B / 303-
the fuel lines.
Excessive fuel *Fuel charging and *REFER to Section 303-04A / 303-04B / 303-
consumption controls. 04C. – vehicles with 1.4L diesel engine.
the fuel lines.
Pinpoint Tests
WARNINGS:
Do not smoke or carry lighted tobacco of any type when working on or near any fuel
related components. Highly flammable mixtures are always present and may ignite.
personal injury.
CAUTIONS:
clearances. it is therefore essential that absolute cleanliness is observed when working
with these components.
Always carry out the cleaning process before carrying out any repairs to the fuel injection
system components. Failure to follow this instruction may result in foreign matter ingress to
the fuel injection system.
PINPOINT TEST A : AIR INGRESS INTO THE FUEL LINES – VEHICLES WITH
1.4L DIESEL ENGINE
A1: CHECK FOR AIR INGRESS INTO THE FUEL SYSTEM
1 Remove the air cleaner. REFER to Section 303-12.
2 Start the engine, wait a few minutes and then

visually observe the clear plastic pipe of the fuel
return line for signs of air ingress.
Page 3 of 3
Are there any signs of air present in the fuel return

line?
Yes
GO to A2.
No
For additional diagnostics for Fuel Charging and
Controls. REFER to Section 303-04A / 303-04B / 303-
04C.
A2: CHECK WHERE AIR IS ENTERING THE SYSTEM
1 Using suitable clean engine oil, apply the oil to each
of the fuel supply line and fuel return line
connections, unions and joints in turn and observe
the clear plastic pipe for visible signs of air after
each oil application.
Did the amount of air in the fuel return line decrease
when any of the connectors, unions or joints were
oiled?
Yes
INSTALL a new fuel line(s) as necessary. Test the
No
For additional diagnostics for Fuel Charging and
Controls. REFER to Section 303-04A / 303-04B / 303-
04C.
Page 1 of 1

ACCELERATION CONTROL
UID=G297183
- Accelerator pedal * Fuse(s)
- Throttle body * Relay(s)
* Wiring harness
* Powertrain control module (PCM)

Page 1 of 11

INSTRUMENT CLUSTER AND PANEL
ILLUMINATION
UID=G297184
Electrical
Fuse(s)
Wiring harness
Light emitting diodes (LED)s
Instrument cluster
Audio unit
Clock
Switch(es)
Symptom Chart
Symptom Chart

The instrument panel illumination dimmer *Fuse(s) *GO to Pinpoint
illumination is inoperative *Circuit(s). Test A.
*Instrument panel
illumination dimmer.
The instrument cluster illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test B.
*Instrument cluster.
The air conditioning switch illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test C.
*Air conditioning switch.
The blower motor switch illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test D.
*Blower motor switch.
The audio unit illumination is inoperative *Fuse(s) *GO to Pinpoint
*Circuit(s). Test E.
*Audio unit.
The hazard flasher switch illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test F.
Page 2 of 11
*Hazard flasher switch.

Heated rear window switch illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test G.
*Heated rear window switch.
Headlamp levelling switch illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test H.
*Headlamp levelling switch.
ESP deactivation switch illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test I.
*ESP deactivation switch.
Gearshift lever illumination is inoperative *Fuse(s) *GO to Pinpoint
*Circuit(s). Test J.
*Gearshift lever illumination.
Audio control switch illumination is *Fuse(s) *GO to Pinpoint
inoperative *Circuit(s). Test K.
*Audio control switch
Pinpoint Tests

PINPOINT TEST A : THE INSTRUMENT PANEL ILLUMINATION DIMMER
ILLUMINATION IS INOPERATIVE
A1: CHECK THE INSTRUMENT PANEL ILLUMINATION DIMMER FOR POWER
Disconnect Instrument Panel Illumination Dimmer
1
12-01.
2 Turn the headlamp switch to the ON position.
3 Measure the voltage between the instrument panel

illumination dimmer connector I2-01 (LIGHT
GREEN/BLACK), harness side and ground.

Yes
GO to A2.
No
REPAIR the circuit (LIGHT GREEN/BLACK). TEST the
A2: CHECK THE INSTRUMENT PANEL ILLUMINATION DIMMER FOR GROUND
1 Measure the resistance between the instrument
panel illumination dimmer connector I2-01
(WHITE/RED), harness side and ground.
Page 3 of 11

Yes
INSTALL a new instrument panel illumination dimmer.
No
REPAIR the circuit (WHITE/RED). TEST the system for
normal operation.
PINPOINT TEST B : THE INSTRUMENT CLUSTER ILLUMINATION IS
INOPERATIVE
B1: CHECK THE INSTRUMENT CLUSTER ILLUMINATION FOR POWER
3 Measure the voltage between the instrument cluster

connector C-01 pin 2K, (LIGHT GREEN/BLACK),

Yes
GO to B2.
No
B2: CHECK THE INSTRUMENT CLUSTER ILLUMINATION FOR GROUND
1 Measure the resistance between instrument the
instrument cluster connector C-01 pin 2I,

Yes
INSTALL a new instrument cluster. REFER to
Section 413-01. TEST the system for normal operation.
No
Page 4 of 11

normal operation.
PINPOINT TEST C : THE AIR CONDITIONING SWITCH ILLUMINATION IS
INOPERATIVE
C1: CHECK AIR CONDITIONING SWITCH ILLUMINATION FOR POWER
1 Disconnect Air Conditioning Switch G2-01.
3 Measure the voltage between the air conditioning

switch illumination connector G2-01 (LIGHT

Yes
GO to C2.
No
C2: CHECK AIR CONDITIONING SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the air conditioning
switch illumination connector G2-01

Yes
INSTALL a new air conditioning switch. TEST the
No
normal operation.
PINPOINT TEST D : THE BLOWER MOTOR SWITCH ILLUMINATION IS
INOPERATIVE
D1: CHECK BLOWER MOTOR SWITCH ILLUMINATION FOR POWER
1 Disconnect Blower Motor Switch I2-02.
3 Measure the voltage between the blower motor

switch connector I2-02 (LIGHT GREEN/BLACK),
Page 5 of 11

Yes
GO to D2.
No
D2: CHECK BLOWER MOTOR SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the blower motor
switch connector I2-02 (WHITE/RED), harness
side and ground.

Yes
INSTALL a new blower motor switch. TEST the system
No
normal operation.
PINPOINT TEST E : THE AUDIO UNIT ILLUMINATION IS INOPERATIVE
E1: CHECK AUDIO UNIT ILLUMINATION FOR POWER
1 Disconnect Audio Unit J-01.
3 Measure the voltage between the audio unit

connector J-01 (LIGHT GREEN/BLACK), harness
side and ground.

Yes
GO to E2.
No
Page 6 of 11

E2: CHECK AUDIO UNIT ILLUMINATION FOR GROUND
1 Measure the resistance between the audio unit
connector J-01 (WHITE/RED), harness side and
ground.

Yes
INSTALL a new audio unit. REFER to Section 415-01.
No
normal operation.
PINPOINT TEST F : THE HAZARD FLASHER SWITCH ILLUMINATION IS
INOPERATIVE
F1: CHECK HAZARD FLASHER SWITCH ILLUMINATION FOR POWER
1 Disconnect Hazard Flasher Switch F1-06.
3 Measure the voltage between the hazard flasher

switch connector F1-06 (LIGHT GREEN/BLACK),

Yes
GO to F2.
No
F2: CHECK HAZARD FLASHER SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the hazard flasher
switch connector F1-06 pin 5 (WHITE/RED),

Yes
Page 7 of 11
INSTALL a new hazard flasher switch. TEST the system

No
normal operation.
PINPOINT TEST G : HEATED REAR WINDOW SWITCH ILLUMINATION IS
INOPERATIVE
G1: CHECK HEATED REAR WINDOW SWITCH ILLUMINATION FOR POWER
1 Disconnect Heated Rear Window Switch I1-04.
3 Measure the voltage between the heated rear

window switch connector I1-04 (LIGHT

Yes
GO to G2.
No
G2: CHECK HEATED REAR WINDOW SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the heated rear
window switch connector I1-04 (WHITE/RED),

Yes
INSTALL a new heated rear window switch. TEST the
No
normal operation.
PINPOINT TEST H : HEADLAMP LEVELLING SWITCH ILLUMINATION IS
INOPERATIVE
H1: CHECK HEADLAMP LEVELLING SWITCH ILLUMINATION FOR POWER
1 Disconnect Heated Levelling Switch Switch E4-01.
3 Measure the voltage between the headlamp levelling

Page 8 of 11
switch connector E4-01 (LIGHT GREEN/BLACK),


Yes
GO to H2.
No
H2: CHECK HEADLAMP LEVELLING SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the headlamp
levelling switch connector E4-01 (WHITE/RED),

Yes
INSTALL a new headlamp levelling switch. TEST the
No
normal operation.
PINPOINT TEST I : DYNAMIC STABILITY CONTROL (DSC) DEACTIVATION
SWITCH ILLUMINATION IS INOPERATIVE
I1: DSC DEACTIVATION SWITCH ILLUMINATION FOR POWER
1 Disconnect DSC Deactivation Switch O-06.
3 Measure the voltage between the DSC deactivation

switch connector O-06 (LIGHT GREEN/BLACK),

Yes
GO to I2.
No
Page 9 of 11

I2: CHECK DSC DEACTIVATION SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the DSC
deactivation switch connector O-06 (WHITE/RED),

Yes
INSTALL a new DSC deactivation switch. TEST the
No
normal operation.
PINPOINT TEST J : GEARSHIFT LEVER ILLUMINATION IS INOPERATIVE
J1: CHECK GEARSHIFT LEVER ILLUMINATION FOR POWER
1 Disconnect Gearshift Lever H-04.
3 Measure the voltage between the gearshift lever

illumination connector H-04 (LIGHT

Yes
GO to J2.
No
J2: CHECK GEARSHIFT LEVER ILLUMINATION FOR GROUND
1 Measure the resistance between the gearshift lever
illumination connector H-04 (WHITE/RED),

Yes
Page 10 of 11
INSTALL a new gearshift lever illumination. TEST the

No
normal operation.
PINPOINT TEST K : AUDIO CONTROL SWITCH ILLUMINATION IS
INOPERATIVE
K1: CHECK AUDIO CONTROL SWITCH ILLUMINATION FOR POWER
WARNING: To deactivate the driver air bag

module, refer to the driver air bag module
procedure in Section 501-20B for the correct air
bag module deactivation procedure. Failure to
1 Remove the driver air bag module. REFER to
Section 501-20A / 501-20B.
2 Disconnect Audio Control Switch I2-04.
4 Measure the voltage between the audio control

switch connector I2-04 pin 3 (LIGHT

Yes
GO to K2.
No
GO to K3.
K2: CHECK AUDIO CONTROL SWITCH ILLUMINATION FOR GROUND
1 Measure the resistance between the audio control
switch connector I2-04 pin 1 (WHITE/RED),

Yes
INSTALL a new audio control switch. TEST the system
No
GO to K4.
K3: CHECK CLOCKSPRING CIRCUIT FOR POWER
Page 11 of 11
2 Measure the voltage between the clockspring

connector F3-04 (LIGHT GREEN/BLACK), harness
side and ground.

Yes
INSTALL a new clockspring. REFER to Section 501-
20A / 501-20B. TEST the system for normal operation.
No
K4: CHECK CLOCKSPRING CIRCUIT FOR GROUND
2 Measure the resistance between the clockspring

connector F3-04 (WHITE/RED), harness side and
ground.

Yes
No
normal operation.
Page 1 of 11

INSTRUMENT CLUSTER
UID=G297185
General Equipment
- Engine oil level - Fuse(s)
- Engine coolant temperature (ECT) - Wiring harness

sensor
- Engine coolant level
- Instrument cluster
- Thermostat
- Light emitting diode(s) (LED)
- Collapsed or damaged fuel tank (s)
- Door adjustment - Powertrain control module

(PCM)
4. Verify the following warning indicators are working correctly:
* Charging.
* Turn signals.
* Headlamps.
5. If the cause is not visually evident, verify the symptom and enter the instrument cluster Self-
Diagnostic Mode.
Self-Diagnostic Mode
1. To enter the instrument cluster Self-Diagnostic Mode simultaneously press and hold the
tripmeter RESET button and turn the ignition switch to position II.
2. When TEST is displayed in the LCD, release the tripmeter reset button.
3. To navigate through or skip any of the instrument cluster Self-Diagnostic Mode tests press the
tripmeter RESET button. If the RESET button is depressed for more than 3 seconds between
tests, the instrument cluster will exit the Self-Diagnostic Mode.
4. The Self-Diagnostic Mode is deactivated when the ignition switch is turned to the OFF
Page 2 of 11
position.
5. If the Self-Diagnostic Mode cannot be accessed, use WDS to diagnose the instrument cluster.
Check Code Table
Check Code Number Checked Item

04 Door switch
08 TNS relay
12 Speedometer
13 Tachometer
14 Buzzer
16 Fuel level warning indicator
22 Fuel tank module
23 Fuel gauge
25 Engine coolant temperature gauge
26 LCD display
Check code 04 - Door switch on/off signal
Step Condition Display Action

1 Open the driver side on Close the driver door GO TO the next Step
front door (the door
switch is on)
1 Open the driver side oFF Verify the voltage at instrument cluster connector C-01 pin
front door (the door 1J, (BLACK/RED) is 1.0 volts or less
switch is on)
* If the voltage is as specified. INSTALL a new
instrument cluster REFER to Instrument Cluster in
this section. TEST the system for normal
operation
* If the voltage is out of specification CHECK the

following items:
 Door switch
Wiring harness
2 Close the driver side on Verify the voltage at instrument cluster connector C-01 pin
front door (the door 1J, (BLACK/RED) is greater than 10 volts.
switch is off)
instrument cluster REFER to Instrument Cluster in
this section. TEST the system for normal
operation
* If the voltage is out of specification CHECK the

following items:
 Door switch
 Wiring harness
2 Close the driver side oFF Input signal to the instrument cluster is normal
front door (the door
switch is off)
Page 3 of 11
Check code 08 - TNS relay on/off signal
Step Condition Display Action

1 Turn the headlamp on GO TO the next Step
switch to the TNS
position (the TNS relay
is on)
1 Turn the headlamp oFF Verify the voltage at instrument cluster connector C-01 pin
switch to the TNS 2K, (LIGHT GREEN/BLACK) is greater than 10 volts
position (the TNS relay
is on) * If the voltage is as specified. INSTALL a new
instrument cluster REFER to Instrument Cluster
in this section. TEST the system for normal
operation
* If the voltage is out of specification CHECK

the following items:
 TNS relay
 Wiring harness
2 Turn the headlamp on Verify the voltage at instrument cluster connector C-01 pin
switch off (the TNS 2K, (LIGHT GREEN/BLACK) is 1.0 volts or less
relay is off)
instrument cluster REFER to Instrument Cluster
in this section. TEST the system for normal
operation
* If the voltage is out of specification CHECK

the following items:
 TNS relay
 Wiring harness
2 Turn the headlamp oFF Input signal to the instrument cluster is normal
switch off (the TNS
relay is off)
Check code 12 - Speedometer operation
Inspection Condition Display Operation State Action

Wait for oo The speedometer needle * The speedometer is normal
approximately 2 moves beyond full scale if the needle returns to the
seconds after then returns to desired setting.
selecting the check approximately 60 kph
code 12 (37 mph) * If the speedometer needle
does not return to the desired
setting INSTALL a new
instrument cluster REFER to
Instrument Cluster in this
section. TEST the system for
normal operation
Wait for Err - INSTALL a new instrument cluster REFER
approximately 2 to Instrument Cluster in this section.
seconds after TEST the system for normal operation
selecting the check
code 12
Page 4 of 11
Check code 13 - Tachometer operation

Wait for oo The tachometer needle * The tachometer is normal if
approximately 2 moves beyond full scale the needle returns to the
seconds after then returns to desired setting
selecting the check approximately 3000
code 13 rpm * If the tachometer needle
does not return to the desired
setting INSTALL a new
normal operation
selecting the check
code 13
Check code 14 - Buzzer operation
Operation
Inspection Condition Display State Action
Wait for approximately 2 on The buzzer The buzzer is normal
seconds after selecting the (fixed) sounds
check code 14
Wait for approximately 2 on The buzzer INSTALL a new instrument cluster REFER
seconds after selecting the (fixed) does not to Instrument Cluster in this section.
check code 14 sound TEST the system for normal operation
Check code 16 - Fuel level warning indicator flashing signal

Wait for approximately 2 on The fuel level warning The fuel level warning indicator is
seconds after selecting the (flashing) indicator turns on and normal
check code 16 off three times
Wait for approximately 2 on The fuel level warning INSTALL a new instrument cluster
seconds after selecting the (flashing) indicator does not turn REFER to Instrument Cluster in
check code 16 on and off three times this section. TEST the system for
normal operation
Check code 22 - Fuel level signal
Step Inspection Condition Display Action

1 Select check code 22 with the fuel 124 - * If the display is within the
sender unit electrical connector 127 specification GO TO the next
disconnected Step
* If the display is not within the

specification INSTALL a new
normal operation
2 Using a fused jumper wire between the 000 - * If the display is within the
instrument cluster connector C-01 pin 003 specification GO TO the next
2D (BROWN/YELLOW) and pin 2M Step
(BROWN/WHITE)
Page 5 of 11
* If the display is not within the

specification INSTALL a new
instrument cluster. REFER to
normal operation
3 Using the SST (Fuel and thermometer 017 - * If the display is within the
checker) or resistor, input 20 ohms 023 specification GO TO the next
between the instrument cluster Step
connector C-01 pin 2D
(BROWN/YELLOW) and pin 2M * If the display is not within the
(BROWN/WHITE) specification INSTALL a new
normal operation
checker) or resistor, input 60 ohms 063 specification. GO TO the next
between the instrument cluster Step
normal operation
checker) or resistor, input 100 ohms 103 specification. CHECK the fuel
between the instrument cluster sender unit
normal operation
Check code 23 - Operation signal to fuel gauge

Wait for oo The fuel gauge indicates * The fuel gauge is normal if
approximately 2 status in the following the status is indicated in the
seconds after order approximately desired order
selecting the check every 2 seconds
code 23 * If the fuel gauge does not
* F-½-E-F display the status indicated
(fixed) in the desired order INSTALL
a new instrument cluster.
REFER to Instrument Cluster
in this section. TEST the
system for normal operation
selecting the check
code 23
Check code 25 - Operation signal to water temperature gauge
Inspection
Page 6 of 11
Condition Display Operation State Action

Wait for oo The water temperature * The water temperature
approximately 2 gauge indicates status in gauge is normal if the status
seconds after the following order is indicated in the desired
selecting the check approximately every 2 order
code 25 seconds
* If the water temperature
* H-Center-C- gauge does not display the
H (fixed) status indicated in the
desired order INSTALL a new
normal operation
selecting the check
code 25
Check code 26 - LCD display
Inspection Operation
Condition Display State Action
Select the All characters All LCD * The LCD display is normal if all the
check code on LCD display segments segments are on
26 are displayed are on
* If the LCD display does not display all
the segments INSTALL a new
instrument cluster REFER to Instrument
Cluster in this section. TEST the system
for normal operation
1. If the cause is not visually evident, verify the symptom and refer to the PID/DATA Monitor
and Record Procedure.
PID/DATA Monitor and Record Procedure
3. Access and monitor PIDs according to the following table:
PID/DATA MONITOR Table
PID PID Name Unit/Condition Condition/Specification Action

0200 DTC Number of * Minimum: 0 REFER to
DTCs WDS.
Page 7 of 11
* Maximum: 255
6196 Speedometer gauge pointer KPH * Minimum: 0 REFER to
placement WDS.
* Maximum:
511.99
6197 Tachometer gauge pointer RPM * Minimum: 0 REFER to
placement WDS.
* Maximum:
16383.5
6198 Engine temperature gauge °C (°F) * Minimum: -40 (- REFER to
pointer placement 38) WDS.
* Maximum: 214
(417)
Diagnostic Trouble Code (DTC) Chart

B1342 Instrument cluster defective Instrument Cluster REFER to
WDS.
B2141 No PCM ID transferred PCM or instrument REFER to
cluster WDS.
B2477 Instrument cluster configuration failure PCM or instrument REFER to
cluster WDS.
U1900 CAN missing frame from instrument cluster PCM or instrument REFER to
cluster WDS.
U2510 PCM unable to read messages from instrument PCM or instrument REFER to
cluster cluster WDS.
U2516 CAN BUS no signal - REFER to
WDS.

Page 8 of 11
Terminal Signal Name Connected to Test Condition Standard Inspection Item

1A - - - - -
1B - - - - -
IC - - - - -
1D - - - - -
1E - - - - -
1F - - - - -
1G Door locking Door locking - Continuity * Related
module module wiring
signal harness
* Door
locking
module
1H Front fog Front fog Front fog lamp Continuity * Related
lamp signal lamp relay switch in the wiring
ON position harness
Page 9 of 11
* Front fog
lamp relay
1I Automated Transmission - Continuity * Related

gearshift control wiring
system module harness
signal
*
Transmission
control
module
1J Ground Door ajar Door closed Continuity * Related
switch wiring
harness
* Door ajar
switch
1K - - - - -
1L Ground Brake fluid Brake fluid level Continuity * Related
level switch above minimum wiring
harness
* Brake fluid
level switch
1M Ground Oil pressure Engine running Continuity * Related
switch wiring
harness
* Oil
pressure
switch
1N Ground Parking Parking brake Continuity * Related
brake switch applied wiring
harness
* Parking
brake switch
1O Restraints Restraints - Continuity * Related
control control wiring
signal
* Restraints
control
module
1P - - - - -
2A - - - - -
2B - - - - -
2C - - - - -
2D Fuel pump Fuel pump - Continuity * Related
signal harness
* Fuel pump
module
2E Ground Ground point - Continuity Related wiring harness
2F Ground Ground point Tripmeter reset Continuity Related wiring harness
button pressed
2G Ground Safety belt Safety belt Continuity * Related
Page 10 of 11
buckle installed into wiring

switch the safety belt harness
buckle
* Safety belt
buckle
2H Power Fuse 3 in the - V batt * Related
supply fuse block wiring
harness
* Fuse
* Fuse block
2I - - - - -
2J - - - - -
2K - - - - -
2L Rear fog Rear fog Rear fog lamp Continuity * Related
lamp signal lamp relay switch in the wiring
ON position harness
* Rear fog
lamp relay
2M Fuel pump Fuel pump - Continuity * Related
signal harness
* Fuel pump
module
2N Flasher unit Flasher unit Direction Continuity * Related
signal indicator switch wiring
in the RIGHT harness
TURN position
* Flasher
unit
* Direction
indicator
switch
2O - - - - -
2P High beam High beam Main beam Continuity * Related
signal relay switch in the wiring
HIGH BEAM
position *
Multifunction
switch
2Q - - - - -
2R Flasher unit Flasher unit Direction - * Related
signal indicator switch wiring
in the LEFT harness
TURN position
* Flasher
unit
* Direction
indicator
switch
2S - - - - -
2T - - - - -
Page 11 of 11
2U - - - - -
2V Power Fuse 7 in the * * No * Related
supply fuse block IGN voltage wiring
OFF harness
*V
* batt * Fuse
IGN
ON * Fuse block
2W Automated Transmission - Continuity * Related
signal
*
Transmission
control
module
2W Manual Powertrain - Continuity * Related
transmission control wiring
module harness
(PCM)
* Powertrain
control
module
(PCM)
2X Automated Transmission - Continuity * Related
signal
*
Transmission
control
module
2X Manual Powertrain - Continuity * Related
transmission control wiring
module harness
(PCM)
* Powertrain
control
module
(PCM)
Configuration of Instrument Cluster
The instrument cluster is a programmable module, which must be configured by selecting the
Programmable Module Installation Routine on WDS.
The following features will need to be configured when a new instrument cluster is installed:
* Malfunction Indicator Lamp (MIL)
* Anti-lock Brake System (ABS) warning indicator
* Dynamic Stability Assist (DSC) indicator
* Automated Gearshift System indicator (if equipped)
* Passive Anti-Theft System (PATS) indicator

Page 1 of 5

HORN
UID=G297186
Electrical
Fuse(s)
Wiring harness
Horn switch (part of driver air bag)
Horn relay
Horn
Clockspring
Symptom Chart
Symptom Chart

The horn is inoperative *Fuse(s). *GO to Pinpoint Test A.
*Circuit(s).
*Horn switch (part of driver air bag).
*Horn relay.
*Horn.
*Clockspring.
The horn is always on *Horn switch (part of driver air bag). *GO to Pinpoint Test B.
*Clockspring.
*Circuit(s).
Pinpoint Tests

PINPOINT TEST A : THE HORN IS INOPERATIVE
A1: CHECK HORN FOR POWER
1 Disconnect Horn F3-03.
2 Measure the voltage between the horn connector

F3-03 (GREEN/YELLOW), harness side and ground
while pressing the horn switch.
Page 2 of 5

Yes
INSTALL a new horn. TEST the system for normal
operation.
No
GO to A2.
A2: CHECK THE HORN RELAY
1 Remove the horn relay.
2 Using a jumper wire, connect one end to Terminal

85 of the relay. Connect the other end to ground.
3 Using a second jumper wire, connect one end to
Terminal 86 of the relay.
4 Connect one lead of an ohmmeter to Terminal 30 of
the relay. Connect the second lead to Terminal 87
of the relay. Observe the resistance.
5 Momentarily tap the unconnected end of the
Terminal 86 jumper wire to the positive battery
power. An audible click should be heard and the
resistance on the ohmmeter should drop to zero.
Is the relay OK?
Yes
GO to A3.
No
INSTALL a new horn relay. TEST the system for normal
operation.
A3: CHECK FOR VOLTAGE AT HORN RELAY
1 Measure the voltage between the horn relay
connector JB-02 pin L and ground.

Yes
GO to A4.
No
INSTALL a new joint box. TEST the system for normal
operation.
A4: CHECK OPERATION OF HORN SWITCH
Page 3 of 5
1 Measure the resistance between the horn switch F3-

05 pin 2 and pin 4 component side while pressing
the horn switch.

Yes
GO to A5.
No
INSTALL a new driver air bag module. REFER to
Section 501-20A / 501-20B. TEST the system for
normal operation.
A5: CHECK CIRCUIT BETWEEN THE HORN RELAY AND THE HORN (GREEN/YELLOW)
FOR OPEN
1 Measure the resistance between the horn connector
F3-03 and the horn relay connector JB-01 pin J
(GREEN/YELLOW), harness side.

Yes
GO to A6.
No
REPAIR the circuit (GREEN/YELLOW). TEST the system
A6: CHECK CIRCUIT BETWEEN THE HORN RELAY AND THE CLOCKSPRING
(BLACK/RED) FOR OPEN
1 Disconnect Horn Relay JB-02.
3 Measure the resistance between the horn relay

connector JB-02 pin L (BLACK/RED), harness side
and the clockspring connector F3-04 pin 4,
(BLACK/RED), harness side.

Yes
GO to A7.
No
Page 4 of 5
normal operation.
A7: CHECK THE CLOCKSPRING GROUND CIRCUIT
1 Measure the resistance between the clockspring
connector F3-04 pin 2 (BLACK), harness side and
ground.

Yes
No
REPAIR the ground circuit (BLACK). TEST the system
PINPOINT TEST B : THE HORN IS ALWAYS ON
B1: CHECK HORN SWITCH GROUND CIRCUIT
Does the horn stop sounding with F3-04 disconnected?
Yes
GO to B2.
No
REPAIR the circuit between the clockspring F3-04 pin 4
(BLACK/RED) and the horn relay JB-02 pin L
(BLACK/RED). TEST the system for normal operation.
B2: CHECK CLOCKSPRING FOR SHORT TO GROUND
WARNING: To deactivate the driver air bag, refer to the procedure in section 501-
20B for the correct air bag deactivation procedure. Failure to follow this instruction, may
1 Remove the driver air bag module REFER to
Section 501-20A / 501-20B.
2 Disconnect Horn Switch F3-05.
3 Measure the resistance between the horn switch

F3-05 pin 2 component side and ground and
between pin 4 component side and ground.
Is the resistance less than 5 ohms at either pin?

Yes
No
Page 5 of 5
INSTALL a new driver air bag module. REFER to

Section 501-20A / 501-20B. TEST the system for
normal operation.
Page 1 of 2

CLOCK
UID=G297187
Electrical
- Fuse(s)
- Wiring Harness
- Electrical connectors(s)
- Clock
Symptom Chart
Symptom Chart

The clock operation is *Fuse(s). *GO to Pinpoint Test A.
erratic/inoperative *Circuit(s).
*Clock.
The clock illumination is inoperative. *Fuse(s). *REFER to Section 413-
*Circuit(s). 00.
*Light emitting diode
(LED).
Pinpoint Tests

PINPOINT TEST A : THE CLOCK OPERATION IS ERRATIC/INOPERATIVE
A1: CHECK CLOCK POWER CIRCUIT (BLUE/RED) FOR VOLTAGE
2 Disconnect Clock 12-03.
3 Measure the voltage between the clock connector

12-03 pin A (BLUE/RED), harness side and
ground.
Page 2 of 2

Yes
GO to A2.
No
REPAIR the circuit (BLUE/RED). TEST the system for
normal operation.
A2: CHECK CLOCK GROUND CIRCUIT (BLACK) FOR OPEN
1 Measure the resistance between the clock connector
12-03 pin B (BLACK), harness side and ground.

Yes
INSTALL a new clock. TEST the system for normal
operation.
No
REPAIR the circuit (BLACK). TEST the system for
normal operation.
Page 1 of 3

BATTERY TRAY
UID=G297192
Removal
All vehicles
1. Remove the left-hand headlamp assembly. For
01.
additional information, refer to Battery
Disconnect in this section.
3. Open the battery positive terminal cover.
4. Disconnect the battery positive cable and


5. Remove the powertrain control module (PCM)
retaining screws.
6. Detach the PCM from the retaining bracket.

Page 2 of 3
All vehicles
7. Detach the battery clamp from the battery tray
1. Remove the battery clamp front retaining
nut.
2. Remove the battery clamp rear retaining
nut.
3. Unhook the battery clamp.
8. Remove the battery.
9. Detach the battery junction box (BJB) from the

battery tray and position it to one side.
Installation
All vehicles
1. CAUTION: When installing the battery

clamp, make sure that the rear retaining nut
is tightened first. Failure to follow this
battery.

Page 3 of 3
additional information, refer to Section 501-11.

Page 1 of 4

GENERATOR — 1.25L/1.4L/1.6L
UID=G297193
Removal
01.
2. Remove the right-hand headlamp assembly.
Section 417-01.
05.
5. Remove the protective cap and disconnect the
6. Detach the power steering reservoir and

7. NOTE: It is not possible to fully remove the

retaining bolt from the generator at this
stage.
Remove the generator upper retaining nut, bolt
and stud.
8. Remove the generator lower retaining bolt.

Page 2 of 4
9. Remove the generator through the headlamp

aperture.
Installation
All vehicles
1. NOTE: Install the generator upper
retaining bolt into the generator prior to
installing the generator.
Install the generator through the headlamp
aperture.
2. NOTE: Do not tighten the generator lower

retaining bolt at this stage.
Install the generator lower retaining bolt.
3. NOTE: Do not tighten the generator upper

retaining nut and bolt at this stage.
Install the generator upper retaining nut, bolt and
stud.
4. Tighten the generator lower retaining bolt.

Page 3 of 4
5. Tighten the generator upper retaining nut and

bolt.
6. Install the power steering reservoir.
7. Connect the generator electrical connectors

and install the protective cap.

9. Install a new accessory drive belt. For
05.
10. Install the right-hand headlamp assembly.
Section 417-01.
01.

Page 4 of 4
11.
Page 1 of 15

AUDIO SYSTEM
UID=G297194
- Audio unit - Fuse(s)
- Cassette player - Wiring harness
- Antenna mast - Electrical connector(s)
- Antenna base - Speaker(s)
- Audio unit
- Cassette player
- Antenna cable
- Remote audio control

4. If the cause is not visually evident, verify the symptom and refer to the Self-Test Mode.
Self-Test Mode
Liquid Crystal Display (LCD) Inspection
1. To enter the audio unit Self-Test Mode (LCD inspection), turn the ignition key to position
II.
2. With the audio unit ON, press the POWER button and the SEEK button (upper) together for
approximately 1 second.
Page 2 of 15
3. Inspect according to the following table:
Self-Test Mode - LCD Inspection
Inspection Display Action

LCD on audio The characters on the LCD The audio unit is normal. No action required
unit are not faint or stop short
LCD on audio The characters on the LCD INSTALL a new audio unit. REFER to
unit are faint or stop short Section 415-01. TEST the system for normal
operation
4. To exit the audio unit Self-Test Mode, turn the audio unit OFF or turn the ignition key to
position 0.
Button Inspection
5. To enter the audio unit Self-Test Mode (button inspection), turn the ignition key to position
II.
6. With the audio unit ON, press the POWER button and the CLOCK button together for
Self-Test Mode - Button Inspection
Inspection Display Action

All button(s) on The buzzer The audio unit is normal. No action required
audio unit sounds
All button(s) on The buzzer does INSTALL a new audio unit. REFER to Section 415-01.
audio unit not sound TEST the system for normal operation
8. To exit the audio unit Self-Test Mode, turn the audio unit off or turn the ignition key to
position 0.
Speaker Inspection
Page 3 of 15
9. To enter the audio unit Self-Test Mode (speaker inspection), turn the ignition key to
position II.
10. With the audio unit ON, press the POWER button and the AUTO-M button together for
Self-Test Mode - Speaker Inspection
Inspection Sound Action

All speaker(s) sound in the The speaker(s) all The speaker(s) and wiring are
following order: sound when tested operating correctly. No action
required
* Front left-hand
door speaker
* Front right-hand
door speaker
* Rear right-hand
door speaker
* Rear left-hand
door speaker
All speaker(s) sound in the The speaker(s) do not GO to Pinpoint Test D.
following order: sound when tested
* Front left-hand
door speaker
* Front right-hand
door speaker
* Rear right-hand
door speaker
* Rear left-hand
door speaker
position 0.
Antenna Inspection
13. To enter the audio unit Self-Test Mode (antenna inspection), turn the ignition key to
Page 4 of 15
position II.
NOTE: Make sure the audio unit is in the radio mode.

14. With the audio unit ON, press the POWER button and the preset button 2 together for
15. The audio unit display will show the radio reception condition in 10 levels (0-9) to
determine the condition of the antenna system.
position 0.
17. If the concern is still evident after the Self-Test Mode, refer to the Self-Diagnostic Mode.
1. To enter the audio unit Self-Diagnostic Mode, turn the ignition key to position II.
2. With the audio unit ON, press the POWER button, then press the AM/FM and CLOCK
buttons together for at least 2 seconds.
3. Release the the AM/FM and CLOCK buttons and the audio unit will enter the Self-Diagnostic
Mode. On entering the Self-Diagnostic Mode, the audio unit will display diagnostic trouble
codes (DTCs).
NOTE: If several DTCs are in the memory of the audio unit. Press the SEEK button to
navigate through the DTCs.
DTC
Displayed Description Source Action
09: Er22 Audio unit Audio Unit INSTALL a new audio unit. REFER to
Section 415-01. TEST the system for normal
operation.
09: Er20 Audio unit power supply Audio Unit GO to Pinpoint Test A.
00: Er10 Tape player Audio Unit INSTALL a new audio unit. REFER to
communication Section 415-01. TEST the system for normal
operation.
03: Er10 Compact disc (CD) Audio Unit INSTALL a new audio unit. REFER to
player communication Section 415-01. TEST the system for normal
operation.
06: Er10 CD changer Audio Unit INSTALL a new audio unit. REFER to
communication with Section 415-01. TEST the system for normal
Page 5 of 15
audio unit - upper operation.

module
07: Er10 Mini Disc player Audio Unit INSTALL a new audio unit. REFER to
communication with Section 415-01. TEST the system for normal
audio unit operation.
03: Er01 CD player Audio Unit INSTALL a new audio unit. REFER to
operation.
03: Er02 CD player Audio Unit CHECK playing surface of CD for damage,
scratches or foreign objects. INSTALL a new
audio unit. REFER to Section 415-01. TEST
03: Er07 CD player Audio Unit CHECK playing surface of CD for damage,
scratches or foreign objects. INSTALL a new
00: Er01 Cassette player Audio Unit CHECK tape cassette for distortion or internal
damage. INSTALL a new audio unit. REFER
to Section 415-01. TEST the system for
normal operation.
00: Er03 Cassette player Audio Unit CHECK tape cassette for distortion or internal
damage. INSTALL a new audio unit. REFER
to Section 415-01. TEST the system for
normal operation.
00: Er04 Tape cassette Tape CHECK tape cassette for distortion or internal
Cassette or damage. INSTALL a new audio unit. REFER
Audio Unit to Section 415-01. TEST the system for
normal operation.
06: Er01 CD changer - upper Audio Unit CHECK playing surface of CD for damage,
module scratches or foreign objects. INSTALL a new
07: Er01 Mini Disc (MD) player Audio Unit CHECK the MD for damage, scratches or
foreign objects. INSTALL a new audio unit.
REFER to Section 415-01. TEST the system
07: Er02 MD player Audio Unit CHECK the MD for damage, scratches or
07: Er07 MD player Audio Unit CHECK the MD for damage, scratches or
07: Er08 MD player MD No recorded data on MD. Using a know good
MD, TEST the system for normal operation.
10: Er01 MP3/CD player Audio Unit CHECK playing surface of MP3 CD for
damage, scratches or foreign objects.
INSTALL a new audio unit. REFER to
Page 6 of 15

operation.
10: Er02 MP3/CD player Audio Unit CHECK playing surface of MP3 CD for
damage, scratches or foreign objects.
INSTALL a new audio unit. REFER to
operation.
no Err No DTCs stored Audio Unit -
DTC Clearing Procedure
5. With the audio unit ON, press the POWER button and then the AUDIO CONT button
together for for at least 2 seconds.
6. To exit the audio unit Self-Diagnostic Mode, turn the audio unit OFF or turn the ignition key
to position 0.
7. If the concern is still evident after the self-diagnostic mode, refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Condition Possible Action

Sources
The audio unit is inoperative/does not *Fuse(s). *GO to Pinpoint Test A.
operate correctly *Circuit(s).
*Audio unit.
The display is blank - radio and cassette *Audio unit. *INSTALL a new audio unit.
player or CD player operate REFER to Section 415-01.
Poor reception *Antenna. *GO to Pinpoint Test B.
*Antenna cable.
*Audio unit.
Poor quality/distorted sound from one or *Speaker(s). *GO to Pinpoint Test C.
more speakers (not all speakers) *Circuit(s).
*Audio unit.
No sound from all speakers *Audio unit. *GO to Pinpoint Test D.
*Circuit(s).
*Speaker(s).
The CD player is inoperative/does not *Audio unit. *INSTALL a new audio unit.
operate correctly REFER to Section 415-01.
No sound from one or more of the speakers *Circuit(s). *GO to Pinpoint Test E.
(not all speakers) *Speaker(s).
*Audio unit.
Page 7 of 15
The audio remote control is *Circuit(s). *GO to Pinpoint Test F.

inoperative/does not operate correctly *Audio remote
control.
*Audio unit.
Pinpoint Tests

PINPOINT TEST A : THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
A1: CHECK AUDIO UNIT (BLACK/ORANGE) FOR SWITCHED POWER

connector J-01 pin 1R (BLACK/ORANGE), harness
side and ground.

Yes
GO to A2.
No
REPAIR the circuit (BLACK/ORANGE). TEST the system
A2: CHECK AUDIO UNIT (BLUE/RED) FOR POWER

connector J-01 pin 1B (BLUE/RED), harness side
and ground

Yes
GO to A3.
No
normal operation.
A3: CHECK AUDIO UNIT (BLACK/RED) FOR GROUND

connector J-01 pin 1W (BLACK/RED), harness side
and ground.
Page 8 of 15

Yes
No
normal operation.
PINPOINT TEST B : POOR RECEPTION
B1: CHECK THE ANTENNA CABLE SHIELD
2 Disconnect Audio Unit Antenna Connector.
3 Measure the resistance between the antenna cable

ground connector (shield) and ground.
Is the resistance less than 1 ohm?

Yes
GO to B2.
No
CLEAN and TIGHTEN the antenna mast base connection
to the body. If the concern persists, INSTALL a new
antenna cable. REFER to Section 415-02. TEST the
B2: CHECK THE ANTENNA CENTER CONDUCTOR FOR OPEN
1 Remove the antenna mast.
2 Measure the resistance of the center conductor,

between the ends of the antenna cable.
Is the resistance less than 1 ohm?

Yes
Page 9 of 15
GO to B3.
No
INSTALL a new antenna cable. REFER to Section 415-
B3: CHECK ANTENNA CABLE FOR SHORT
1 Measure the resistance between the antenna center
conductor and the antenna ground (shield).

Yes
CLEAN and TIGHTEN the ground connections at the
base of the antenna and battery ground cable to body.
If the concern persists, INSTALL a new audio unit.
REFER to Section 415-01. TEST the system for normal
operation.
No
INSTALL a new antenna cable. REFER to Section 415-
PINPOINT TEST C : POOR QUALITY/DISTORTED SOUND FROM ONE OR
MORE SPEAKERS (NOT ALL SPEAKERS)
C1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inoperative

speaker pin 1 and pin 2, component side.
Is the resistance approximately 4 ohms?

Yes
GO to C2.
No
INSTALL a new speaker. TEST the system for normal
operation.
C2: CHECK SPEAKER INPUT FOR SHORT TO GROUND
1 Connect Inoperative Speaker.
3 Measure the resistance between the following

inoperative speaker:
 Front left speaker connector J-03 (VIOLET), harness

Page 10 of 15
side and ground.
 Front right speaker connector J-04 (GREY/BLUE),

 Front left tweeter speaker connector J-02 (VIOLET),

 Front right tweeter speaker connector J-05

(GREY/BLUE), harness side and ground.
 Rear left speaker connector J-06 (GREEN/BLACK),

Rear right speaker connector J-07 (YELLOW),


Yes
GO to C3.
No
REPAIR the inoperative speaker input circuit. TEST the
C3: CHECK SPEAKER RETURN FOR SHORT TO GROUND
 Front left speaker connector J-03 (BLUE/ORANGE),

 Front right speaker connector J-04 (YELLOW),

 Front left tweeter speaker connector J-02

(BLUE/ORANGE), harness side and ground.

(YELLOW), harness side and ground.
 Rear left speaker connector J-06 (GREEN/ORANGE),

Rear right speaker connector J-07


(YELLOW/BLACK), harness side and ground.
Yes
GO to C4.
No
REPAIR the inoperative speaker input circuit. TEST the
C4: CHECK SPEAKER CIRCUIT FOR SHORT
 Front left speaker connector J-03 (VIOLET), and

Page 11 of 15
(BLUE/ORANGE), harness side.
 Front right speaker connector J-04 (GREY/BLUE),

and (YELLOW), harness side.
 Front left tweeter speaker connector J-02 (VIOLET),

and (BLUE/ORANGE), harness side.

(GREY/BLUE), and (YELLOW), harness side.
 Rear left speaker connector J-06 (GREEN/BLACK),

and (GREEN/ORANGE), harness side.
 Rear right speaker connector J-07 (YELLOW), and

(YELLOW/BLACK), harness side.
Yes
operation. If the concern persists, INSTALL a new audio
unit. REFER to Section 415-01. TEST the system for
normal operation.
No
REPAIR the inoperative speaker circuit. TEST the
PINPOINT TEST D : NO SOUND FROM ALL SPEAKERS
D1: CHECK SPEAKER INPUT CIRCUIT FOR SHORT TO GROUND
3 Measure the resistance between the following audio

unit connector:
 (Front left speaker) J-01 pin 1A (VIOLET), harness

side and ground.
 (Front right speaker) J-01 pin 1D (GREY/BLUE),

 (Rear left speaker) J-01 pin 1S (GREEN/BLACK),

(Rear right speaker) J-01 pin 1V (YELLOW),


Yes
GO to D2.
No
D2: CHECK SPEAKER RETURN CIRCUIT FOR SHORT TO GROUND
1 Measure the resistance between the following audio
connector:
Page 12 of 15
 (Front left speaker) J-01 pin 1C (BLUE/ORANGE),

 (Front right speaker) J-01 pin 1F (YELLOW),

 (Rear left speaker) J-01 pin 1U (GREEN/ORANGE),

 (Rear right speaker) J-01 pin 1X (YELLOW/BLACK),

Yes
No
PINPOINT TEST E : NO SOUND FROM ONE OR MORE OF THE SPEAKERS
E1: CHECK THE SPEAKER RESISTANCE
1 Disconnect Inoperative Speaker.
2 Measure the resistance between the inoperative

speaker pin 1 and pin 2, component side.
Is the resistance approximately 4 ohms?

Yes
Left-hand side speaker(s), GO to E2. .
Right-hand side speaker(s), GO to E3. .
No
INSTALL a new speaker(s). TEST the system for normal
operation.
E2: CHECK THE LEFT-HAND SPEAKER(S) CIRCUIT RESISTANCE

connector J-01 and the inoperative speaker(s)
connector pins:
 (Front left speaker) J-01 pin 1A (VIOLET), harness

side and speaker J-03 (VIOLET), harness side.
 (Front left speaker) J-01 pin 1C (BLUE/ORANGE),

harness side and speaker J-03 BLUE/ORANGE),
harness side.
 (Front left tweeter speaker) J-01 pin 1A (VIOLET),

Page 13 of 15
harness side and speaker J-02 (VIOLET), harness

side.
 (Front left tweeter speaker) J-01 pin 1C

(BLUE/ORANGE), harness side and speaker J-02
BLUE/ORANGE), harness side.
 (Rear left speaker) J-01 pin 1U (GREEN/ORANGE),

harness side and speaker J-06 (GREEN/ORANGE),
harness side.
(Rear left speaker) J-01 pin 1S (GREEN/BLACK),


harness side and speaker J-06 (GREEN/BLACK),
harness side.
Yes
unit. REFER to Section 415-01. Test the system for
normal operation.
No
E3: CHECK THE RIGHT-HAND SPEAKER(S) CIRCUIT RESISTANCE

connector J-01 and the inoperative speaker(s)
connector pins:
 (Front right speaker) J-01 pin 1D (GREY/BLUE),

harness side and speaker J-04 (GREY/BLUE),
harness side.
 (Front right speaker) J-01 pin 1F (YELLOW),

harness side and speaker J-04 (YELLOW), harness
side.
 (Front right tweeter speaker) J-01 pin 1D

(GREY/BLUE), harness side and speaker J-05
(GREY/BLUE), harness side.
 (Front right tweeter speaker) J-01 pin 1F

(YELLOW), harness side and speaker J-05
(YELLOW), harness side.
 (Rear right speaker) J-01 pin 1X (YELLOW/BLACK),

harness side and speaker J-07 (YELLOW/BLACK),
harness side.
 (Rear right speaker) J-01 pin 1V (YELLOW),

harness side and speaker J-07 (YELLOW), harness
side.
Yes
Page 14 of 15

unit. REFER to Section 415-01. Test the system for
normal operation.
No
PINPOINT TEST F : THE AUDIO REMOTE CONTROL IS INOPERATIVE/DOES
NOT OPERATE CORRECTLY
F1: CHECK THE CIRCUIT(BLUE/BLACK) FOR OPEN
REFER to Section 501-20A / 501-20B.
2 Disconnect Audio Unit CJ-01.
3 Disconnect Audio Remote Control I2-04.
4 Measure the resistance between the audio unit J-01

pin 1N (BLUE/BLACK), harness side and the audio
remote control I2-04 pin 7, harness side.

Yes
GO to F2.
No
REPAIR the circuit (BLUE/BLACK). TEST the system for
new clockspring. REFER to Section 501-20A / 501-
20B. TEST the system for normal operation.
F2: CHECK CIRCUIT (BLUE/WHITE) FOR OPEN
1 Measure the resistance between the audio unit J-01
pin 1P (BLUE/WHITE), harness side and the audio
remote control I2-04 pin 5, harness side.

Yes
INSTALL a new audio remote control. If the concern
persists, INSTALL a new audio unit. REFER to
Section 415-01. TEST the system for normal operation.
No
REPAIR the circuit. TEST the system for normal
operation. If the concern persists, INSTALL a new
clockspring. REFER to Section 501-20A / 501-20B.
Page 15 of 15
Page 1 of 2

AUDIO UNIT
UID=G297195
Removal
1. Remove the climate control and air
recirculation slider control knobs.
2. Remove the retaining screws in the outer

climate control knob recesses.
3. Remove the steering column lower shroud.
4. Remove the audio unit retaining bolt from the

left-hand side of the audio unit.
 Access the retaining bolt from below the

steering column.
5. Open the stowage compartment and remove it

by pressing the sides towards the center.
Page 2 of 2
6. Push the audio unit from the rear while

carefully pulling the facia at the front.

remove the audio unit.
8. Remove the facia from the audio unit.
Installation
Page 1 of 4

ANTENNA CABLE
UID=G297196
General Equipment
Suitable draw cord, with a minimum length of
one meter
Removal
All vehicles
1. Remove the audio unit. For additional
2. Detach both front door opening weatherstrips.
3. Remove both A-pillar trim panels.
Vehicles without roof opening panel

4. Detach the interior lamp.

remove the interior lamp.
Page 2 of 4
Vehicles with manual roof opening panel

6. Remove the roof opening panel regulator
handle.
Vehicles with overhead console

7. Remove the overhead console. For additional
8. Detach the headliner at the rear of the
overhead console opening.
All vehicles
9. Remove the sun visors.
10. Remove the sun visor retaining clips.
11. Remove the front and rear right-hand side

passenger assist handles.
1. Lever open the screw covers.
2. Remove the retaining screws.
Page 3 of 4
12. Remove the right-hand rear door

weatherstrip.
13. Remove the right-hand B-pillar trim panel.

Section 501-05.
14. Carefully detach the front edge of the
headliner to allow access to the antenna cable.
15. Disconnect the antenna cable from the
antenna base.
16. Detach the antenna cable from the roof

(headliner shown removed for clarity).
17. Detach the antenna cable from the A-pillar

trim panel.
Page 4 of 4
18. Remove the passenger Airbag assembly. For

20A / 501-20B.
19. Detach the antenna cable from the back of
the cross-vehicle beam.
20. Detach the antenna cable from the retaining

clip at the right-hand end of the cross-vehicle
beam (instrument panel shown removed for
clarity.
21. Route the antenna cable from the back of the

audio unit area up to the cross-vehicle beam.
22. Attach a suitable draw cord to the audio unit
end of the antenna cable and pull the antenna
cable from behind the instrument panel to
expose the draw cord.
23. Detach the suitable draw cord and remove

the antenna cable.
Installation
Page 1 of 5

INTERIOR LIGHTING
UID=G297197
Electrical
Fuse(s)
Wiring harness
Lamp(s)
Switch(es)
Symptom Chart
Symptom Chart

The map reading lamp is inoperative *Fuse(s). *GO to Pinpoint
* Bulb(s). Test A.
*Circuit(s).
*Door ajar switch(es).
*Map reading lamp.
The luggage compartment lamp is *Fuse(s). *GO to Pinpoint
inoperative *Bulb(s). Test B.
*Circuit(s).
*Luggage compartment lamp
switch.
*Luggage compartment lamp.
Pinpoint Tests

PINPOINT TEST A : THE MAP READING LAMP IS INOPERATIVE
A1: CHECK THE OPERATION OF THE MAP READING LAMP
1 Check the operation of the map reading lamp in
both the ON and ILLUMINATED ENTRY positions.
Is the map reading lamp inoperative in both positions?
Yes
GO to A2.
Page 2 of 5
No
If inoperative in the ON position, GO to A3.
If inoperative in the ILLUMINATED ENTRY position, GO

to A4.
A2: CHECK THE MAP READING LAMP FOR POWER
1 Disconnect Map Reading Lamp I3-01.
2 Measure the voltage between the map reading lamp

connector I3-01 (BLUE/RED), harness side and
ground.

Yes
INSTALL a new map reading lamp. TEST the system for
normal operation.
No
normal operation.
A3: CHECK THE MAP READING LAMP FOR GROUND
2 Measure the resistance between the map reading

lamp connector I3-01 (BLACK), harness side and
ground.

Yes
INSTALL a new map reading lamp. TEST the system for
normal operation.
No
normal operation.
A4: CHECK THE MAP READING LAMP FOR GROUND WITH THE DRIVER DOOR OPEN
2 Open the driver door.
3 Measure the resistance between the interior lamp

connector I3-01 (BLACK/RED), harness side and
ground.
Page 3 of 5

Yes
INSTALL a new map reading lamp lamp. TEST the
No
GO to A5.
A5: CHECK DOOR AJAR CIRCUIT (BLACK/RED) FOR OPEN
Disconnect Door Ajar Switch (C-06 RHF, C-07 LHF,
1
C-08 RHR, C-09 LHR).
2 Measure the resistance between the map reading
lamp connector I3-01 (BLACK/RED), harness side
and the applicable door ajar switch connector C-
06 RHF, C-07 LHF, C-08 RHR, C-09 LHR
(BLACK/RED), harness side.

Yes
INSTALL a new door ajar switch. TEST the system for
normal operation.
No
normal operation.
PINPOINT TEST B : THE LUGGAGE COMPARTMENT LAMP IS INOPERATIVE
B1: CHECK THE OPERATION OF THE LUGGAGE COMPARTMENT LAMP
1 Check the operation of the luggage compartment
lamp in both the ON and ILLUMINATED ENTRY
positions.
Is the luggage compartment lamp inoperative in both
positions?
Yes
GO to B2.
No
If inoperative in the ON position, GO to B3.
If inoperative in the ILLUMINATED ENTRY position, GO

to B4.
B2: CHECK THE LUGGAGE COMPARTMENT LAMP FOR POWER
1 Disconnect Luggage Compartment Lamp I3-02.
Page 4 of 5
2 Measure the voltage between the luggage

compartment lamp connector I3-02 (BLUE/RED),

Yes
INSTALL a new luggage compartment lamp. TEST the
system for normal operation..
No
normal operation.
B3: CHECK THE LUGGAGE COMPARTMENT LAMP FOR GROUND
1 Disconnect Luggage Compartment Lamp I3-02.
2 Measure the resistance between the luggage

compartment lamp connector I3-02 (BLACK),

Yes
No
normal operation.
B4: CHECK THE LUGGAGE COMPARTMENT LAMP FOR GROUND WITH THE LIFTGATE
OPEN
1 Open the liftgate.

compartment lamp connector I3-02 (BLACK/RED),

Yes
No
Page 5 of 5
GO to B3.
B5: CHECK LUGGAGE COMPARTMENT AJAR CIRCUIT (BLACK/RED) FOR OPEN
Disconnect Luggage Compartment Lamp Switch C-
1
10.
compartment lamp connector I3-02 (BLACK/RED),
harness side and the luggage compartment lamp
switch connector C-10 (BLACK/RED), harness
side.

Yes
INSTALL a new luggage compartment lamp switch.
No
normal operation.
Page 1 of 10

ANTI-THEFT - ACTIVE
UID=G297198
Misaligned door(s), hood or liftgate Fuse(s)
Latch(es) Wiring harness
Cable(s) Electrical connector(s)
Switch(es) Relay(s)
Lock cylinder(s) Anti-theft alarm horn
Linkage(s) Anti-theft module
Symptom Chart
Symptom Chart

The alarm system does not operate *Fuse(s). *GO to Pinpoint Test
correctly *Circuit(s). A.
*Anti-theft module.
*Anti-theft alarm horn.
*Anti-theft alarm horn
relay.
*Hood switch.
*Door switch(es).
*Turn signal lamp(s).
*Instrument cluster.
*Door lock timer unit.
Pinpoint Tests

PINPOINT TEST A : THE ALARM SYSTEM DOES NOT OPERATE CORRECTLY
A1: DOES THE TURN SIGNAL INDICATORS OPERATE CORRECTLY
1 CHECK the operation of the turn signals.
Are the turn signal indicators operating correctly?
Yes
Check the anti-theft module, GO to A2.
Page 2 of 10
If the anti-theft alarm horn is inoperative, GO to A5.
If the alarm system does not sound when the hood is

opened, GO to A8.
If the alarm system does not sound when a door is

opened, GO to A10.
If the anti-theft warning indicator does not illuminate,

GO to A11.
If the alarm system does not sound when a door lock

switch is operated, GO to A12.
The alarm system does not activate when the driver

side door lock cylinder is turned to the lock (set)
position, GO to A20.
The alarm system does not sound when using the

remote key entry, GO to A21.
No
A2: CHECK THE ANTI-THEFT MODULE FOR BATTERY VOLTAGE
1 Disconnect Anti-Theft Module T2-01.
2 Measure the voltage between the anti-theft module

connector T2-01 pin X (BLUE/RED), harness side
and ground.

Yes
GO to A3.
No
normal operation.
A3: CHECK THE ANTI-THEFT MODULE FOR SWITCHED VOLTAGE
2 Measure the voltage between the anti-theft module

connector T2-01 pin W (BLACK/WHITE), harness
side and ground.

Yes
Page 3 of 10
GO to A4.
No
A4: CHECK THE ANTI-THEFT MODULE FOR GROUND
2 Measure the resistance between the anti-theft

module connector T2-01 pin B (BLACK), harness
side and ground.

Yes
INSTALL a new anti-theft module. TEST the system for
normal operation.
No
normal operation.
A5: CHECK THE ANTI-THEFT ALARM HORN RELAY FOR VOLTAGE
1 Disconnect Anti-Theft Alarm Horn Relay T2-02.
2 Measure the voltages between the anti-theft alarm

horn relay connector T2-02 pin B (WHITE/BLACK),
harness side and ground and between the anti-
theft alarm horn relay connector T2-02 pin C
(WHITE/BLACK), harness side and ground.
Are the voltages greater than 10 volts?

Yes
GO to A6.
No
REPAIR the circuit(s) (WHITE/BLACK) as necessary.
A6: CHECK THE ANTI-THEFT MODULE TO ANTI-THEFT ALARM HORN RELAY SIGNAL
FOR OPEN

module connector T2-01 pin E (GREY), harness
side and the anti-theft alarm horn relay connector
T2-02 (GREY), harness side.
Page 4 of 10

Yes
INSTALL a new anti-theft alarm horn relay. TEST the
system for normal operation. If the concern persists,
GO to A7.
No
REPAIR the circuit (GREY). TEST the system for normal
operation.
A7: CHECK THE ANTI-THEFT ALARM HORN RELAY TO ANTI-THEFT ALARM HORN
SIGNAL FOR OPEN
1 Connect Anti-Theft Module T2-01.
2 Disconnect Anti-Theft Alarm Horn T2-03.
3 Measure the resistance between the anti-theft alarm

horn relay connector T2-02 (GREY), harness side
and the anti-theft alarm horn connector T2-03
(GREY), harness side.

Yes
CLEAN the anti-theft alarm horn ground connection.
TEST the system for normal operation. If the concern
persists, INSTALL a new anti-theft alarm horn. TEST
No
REPAIR the circuit (GREY). TEST the system for normal
operation.
A8: CHECK THE ANTI-THEFT MODULE TO HOOD SWITCH FOR OPEN
2 Disconnect Hood Switch T2-04.

module connector T2-01 pin P (PINK), harness
side and hood switch connector T2-04 (PINK),
harness side.

Yes
GO to A9.
No
REPAIR the circuit (PINK). TEST the system for normal
operation.
A9: CHECK THE HOOD SWITCH FOR GROUND
1 Connect Anti-Theft Module T2-01.
Page 5 of 10
2 Measure the resistance between the hood switch

connector T2-04 (BLACK), harness side and
ground.

Yes
INSTALL a new hood switch. TEST the system for
new anti-theft module. TEST the system for normal
operation.
No
normal operation.
A10: CHECK THE ANTI-THEFT MODULE TO DOOR SWITCH(ES) FOR OPEN
Disconnect Door Switch(es) (front left-hand) C-07,
2 (front right-hand) C-06, (rear left-hand) C-09, (rear
right-hand) C-08 .
module connector T2-01 pin T (BLACK/RED),
harness side and the following door switch(es):
 (front left-hand) connector C-07, (BLACK/RED),

harness side.
 (front right-hand) connector C-06, (BLACK/RED),

harness side.
 (rear left-hand) connector C-09, (BLACK/RED),

harness side.
(rear right-hand) connector C-08, (BLACK/RED),


harness side.
Yes
INSTALL a new door switch as necessary. TEST the
normal operation.
No
REPAIR the circuit (BLACK/RED) in question. TEST the
A11: CHECK THE ANTI-THEFT MODULE TO INSTRUMENT CLUSTER FOR OPEN

module connector T2-01 pin S (BROWN), harness
Page 6 of 10
side and the instrument cluster connector C-01 pin

1G (BROWN), harness side.

Yes
normal operation. If the concern persists, REFER to
Section 413-01.
No
REPAIR the circuit (BROWN). TEST the system for
normal operation.
A12: CHECK THE OPERATION OF EACH DOOR LOCK SWITCH
1 Operate all door lock switch(es) in turn with the
anti-theft alarm system active.
Does the driver side door lock switch operate correctly?
Yes
Passenger side door lock switch, GO to A14.
Rear left-hand door lock switch, GO to A16.
Rear right-hand door lock switch, GO to A18.

No
GO to A13.
A13: CHECK THE ANTI-THEFT MODULE TO THE DRIVER SIDE DOOR LOCK SWITCH
FOR OPEN
2 Disconnect Driver Side Door Lock Switch K2-03.

module connector T2-01 pin N (WHITE/BLACK),
harness side and the driver side door lock switch
connector K2-03 (GREY), harness side.

Yes
REFER to Section 501-14. If the concern persists,
normal operation.
No
REPAIR the circuit(s) (WHITE/BLACK) or (GREY) as
necessary. TEST the system for normal operation.
A14: CHECK THE ANTI-THEFT MODULE TO THE PASSENGER SIDE DOOR LOCK
SWITCH FOR OPEN
Page 7 of 10
2 Disconnect Passenger Side Door Lock Switch K2-02.

module connector T2-01 pin O (ORANGE), harness
side and the passenger side door lock switch
connector K2-02 (ORANGE), harness side.

Yes
GO to A15.
No
REPAIR the circuit (ORANGE). TEST the system for
normal operation.
A15: CHECK THE PASSENGER SIDE DOOR LOCK SWITCH FOR GROUND
1 Measure the resistance between the passenger side
door lock switch connector K2-02 (BLACK),

Yes
INSTALL a new passenger side door lock switch. TEST
the system for normal operation. If the concern
persists, INSTALL a new anti-theft module. TEST the
No
normal operation.
A16: CHECK THE ANTI-THEFT MODULE TO THE REAR LEFT-HAND SIDE DOOR LOCK
SWITCH FOR OPEN
Disconnect Rear Left-Hand Side Door Lock Switch
2
K2-07.
side and the rear left-hand side door lock switch

Page 8 of 10
Yes
GO to A17.
No
normal operation.
A17: CHECK THE REAR LEFT-HAND SIDE DOOR LOCK SWITCH FOR GROUND
1 Measure the resistance between the rear left-hand
side door lock switch connector K2-07 (BLACK),

Yes
INSTALL a new rear left-hand side door lock switch.
No
normal operation.
A18: CHECK THE ANTI-THEFT MODULE TO THE REAR RIGHT-HAND SIDE DOOR LOCK
SWITCH FOR OPEN
Disconnect Rear Right-Hand Side Door Lock Switch
2
K2-06.
side and the rear right-hand side door lock switch

Yes
GO to A19.
No
normal operation.
A19: CHECK THE REAR RIGHT-HAND SIDE DOOR LOCK SWITCH FOR GROUND
1 Measure the resistance between the rear right-hand
side door lock switch connector K2-06 (BLACK),
Page 9 of 10

Yes
INSTALL a new rear right-hand side door lock switch.
No
normal operation.
A20: CHECK THE ANTI-THEFT MODULE TO THE DRIVER SIDE DOOR LOCK CYLINDER
(SET) FOR OPEN
2 Disconnect Driver Side Door Lock Cylinder K2-05.

module connector T2-01 pin Q (LIGHT GREEN),
harness side and the driver side door lock cylinder
connector K2-05 (LIGHT GREEN), harness side.

Yes
normal operation.
No
REPAIR the circuit (LIGHT GREEN). TEST the system for
normal operation.
A21: CHECK THE ANTI-THEFT MODULE TO THE DOOR LOCK MODULE FOR OPEN
2 Disconnect Door Locking Module K2-01.

module connector T2-01 pin V (BROWN/RED),
harness side and the door locking module
connector K2-01 (BROWN/RED), harness side.
Page 10 of 10

Yes
normal operation.
No
REPAIR the circuit (BROWN/RED). TEST the system for
normal operation.
Page 1 of 2

ANTI-THEFT - PASSIVE
UID=G297199
General Equipment
Ignition lock cylinder Fuse(s)
Passive anti-theft system (PATS) ignition key Wiring harness
Non-PATS ignition key Electrical connector(s)
Use of a non-programmed PATS ignition key Relay(s)
Use of a non-encoded PATS ignition key PATS transceiver
More than one PATS key in close proximity of the PATS Ignition switch
transceiver
Powertrain control module
(PCM)
Instrument cluster

Page 2 of 2

B1213 Number of passive anti-theft system PCM Program additional key(s).
(PATS) programmed keys is below
minimum
B1600 PATS key transponder signal not received PCM REFER to WDS.
B1602 PATS received invalid code from PATS PCM REFER to WDS.
transponder
B1681 PATS transceiver signal not received PCM REFER to WDS.
B2103 PATS antenna not connected PCM REFER to Passive Anti-Theft System
(PATS) Transceiver in this section.
B2139 PATS does not match with instrument PCM REFER to WDS.
cluster
B2141 No PCM ID transferred PCM REFER to WDS.
B2431 PATS transponder programming failure PCM REFER to WDS.

Page 1 of 2

PASSIVE ANTI-THEFT SYSTEM (PATS)
TRANSCEIVER
UID=G297200
Removal
01.
2. Remove the steering column upper shroud.
4. Disconnect the PATS transceiver electrical

connector.
5. Remove the PATS transceiver.

1. Release the outside clip.
2. Slide the PATS transceiver to the side to
unhook the shielded clip and remove.
Installation
All vehicles
Page 2 of 2

11.
Page 1 of 3

FRONT DOOR TRIM PANEL
UID=G297204
Removal
All vehicles
1. Remove the door pull handle insert .
2. Remove the door pull handle retaining screw.
3. Remove the front door latch remote control

handle bezel.
1. Open the screw cover.
2. Remove the retaining screw.
3. Remove the front door latch remote control
handle bezel.
4. Detach the exterior mirror trim panel.
5. Disconnect the tweeter electrical connector

and remove the exterior mirror trim panel.
Page 2 of 3
6. Remove the front door trim panel retaining

clip.
Vehicles with manual windows

7. Remove the window regulator handle.
 Use a suitable piece of hooked metal or

similar
All vehicles
8. Detach the front door trim panel.
9. Disconnect the electrical connectors (if

equipped) and remove the front door trim
panel.
Page 3 of 3
Installation
Page 1 of 2

REAR DOOR TRIM PANEL
UID=G297205
Removal
All vehicles
1. Remove the door pull handle insert.
2. Remove the door pull handle retaining screw.
3. Remove the rear door latch remote control

handle bezel.
1. Open the screw cover.
3. Remove the rear door latch remote control
handle bezel.

 Use a suitable piece of hooked wire or similar.
All vehicles
5. Detach the rear door trim panel.
Page 2 of 2
6. Disconnect the electrical connector (if

equipped) and remove the rear door trim
panel.
Installation
Page 1 of 4

HEADLINER
UID=G297206
Removal
1. Detach the front door opening weatherstrips.
2. Remove the A-pillar trim panels.
3. Disconnect the washer tube at the top of the

A-pillar.
NOTE: The next step is only necessary if a new headliner is being installed.
remove the interior lamp
Page 2 of 4
6. Remove the interior lamp bezel.
8. Remove the sun visor retaining clips.
9. Detach the rear door opening weatherstrips.
10. Remove the B-pillar trim panel. For additional

information, refer to B-Pillar Trim Panel in this
section.
11. Remove the passenger assist handles.
1. Lever open the screw covers.
Page 3 of 4
NOTE: The next two steps are only necessary if a new headliner is being installed.
12. Detach the rear interior lamp.

remove the interior lamp.
14. Detach the liftgate opening weatherstrip.
15. Remove the C-pillar trim panel. For additional

information, refer to C-Pillar Trim Panel in this
section.
16. Remove the headliner rear retaining clips.
17. Disconnect the rear washer tube from the

headliner.
Page 4 of 4
18. Disconnect the interior lamp wiring harness

electrical connector at the D-pillar.
19. Remove the headliner through the liftgate

opening.
Installation
Page 1 of 1

B-PILLAR TRIM PANEL
UID=G297207
1. Detach the door opening weatherstrips from the B-
pillar (front seat shown removed for clarity).
2. Remove the safety belt upper anchor point cover.
3. CAUTION: The bolt securing the safety

belt anchor is held captive by a paper washer.
The bolt, spacer and paper washer must remain
on the safety belt anchor at all times when the
safety belt is detached or removed.
Detach the safety belt upper anchor from the safety
belt shoulder height adjuster.
4. Remove the B-pillar lower trim panel.

1. Detach the door scuff plates.
2. Pull off the B-pillar lower trim panel.
5. Remove the B-pillar upper trim panel.

1. Remove the screw cover.
3. Pull off the B-pillar upper trim panel.
Installation
Page 1 of 2

C-PILLAR TRIM PANEL
UID=G297208
Removal
1. Remove the loadspace cover (if equipped).
2. Lower the rear seat backrest.
3. Detach the liftgate opening weatherstrip.
4. Detach the loadspace trim panel along the top

edge.
5. Remove the safety belt upper anchor from the

C-pillar.
1. Detach the upper anchor cover.
6. Detach the rear door opening weatherstrip.
7. Detach the C-pillar lower trim panel.

Page 2 of 2
8. Remove the C-pillar trim panel.

1. Remove the screw cover.
3. Pull off the C-pillar trim panel
Installation
Page 1 of 1

SPECIFICATIONS
UID=G297209

Door inner panel retaining bolts 5 - 44
Door latch retaining screws 5 - 44
Door window glass clamp retaining bolts 7 - 62
Hood latch retaining bolts 20 15 -
Liftgate latch retaining bolts 8 - 71
Page 1 of 1

REMOTE TRANSMITTER
PROGRAMMING
UID=G297210
1. NOTE: A maximum of three remote
transmitters can be programmed to the
vehicle. Programming must be done at the
same time for all the remote transmitters.
NOTE: To enter programming mode, first
make sure that the vehicle battery is fully
charged and the anti-theft system is not
armed or triggered (if equipped).
Close all doors and open the driver door only.
NOTE: The following two steps must be completed within 30 seconds.
2. Turn the ignition key from position OFF to ON
to OFF to ON to OFF to ON to OFF, leaving the
key in the ignition switch.
3. Push the driver side interior lamp switch
located on the B-pillar three times.
4. If the previous two steps are successful, the
door lock will lock and unlock once
automatically, indicating that the learning
mode has been initiated and that the remote
transmitters can now be programmed.
5. Press any one of the buttons on the remote
transmitter. The door lock will lock and unlock
which indicates a new transmitter code has
been successfully received.
6. To program additional remote transmitters,
repeat step 5 with each remote transmitter.
7. NOTE: An incorrect programming
procedure does not affect the stored codes.
After successful programming, only the new
programmed transmitters will be accepted.
8. Test all the programmed transmitters, by
activating and deactivating the
locking/unlocking functions.
Page 1 of 4

FRONT DOOR LATCH
UID=G297211
Removal
1. Remove the front door trim panel. For
05.
2. Remove the grommets.
3. Lower the front door window glass, until the

door window glass retaining bolts are visible
through both holes.
4. Loosen the front door window glass retaining
bolts.
5. CAUTION: Make sure the front door

window glass is adequately supported at the
top of the window opening.
Raise the front door window glass by hand and
secure using a suitable wedge or tape.
6. Disconnect the exterior mirror and front door
window regulator motor electrical connectors
and detach the wiring harness (if equipped)
from the door inner panel .
7. Disconnect the front door latch electrical

connectors and detach the wiring harness (if
equipped) from the front door inner panel.
Page 2 of 4
8. Detach the front door speaker and wiring

harness.
9. Remove the front door latch access panel.
10. Remove the grommet.
11. Remove the door lock security shield

retaining bolt.
12. Disconnect the exterior front door handle

actuator rod.
Page 3 of 4
13. Disconnect the door lock security shield

retaining clip and remove the door lock
security shield.
14. Disconnect the front door lock cylinder rod.
15. Remove the front door latch retaining screws.
16. Remove the front door inner panel retaining

bolts.
17. Remove the front door inner panel.

1. Pull the front door inner panel out at the
bottom.
2. Lower the front door inner panel on the
right-hand side and then slide it towards the
front of the car.
Page 4 of 4
18. Remove the front door latch retaining screw

from the door inner panel.
19. Detach the front door latch cables from the

door inner panel.
20. Detach the interior door handle from the door

inner panel.
21. Disconnect the front door latch cables from

the interior door handle and remove the front
door latch from the door inner panel.
Installation
Page 1 of 4

REAR DOOR LATCH
UID=G297212
Removal
All vehicles
1. Remove the rear door trim panel. For
05.

2. Remove the right-hand grommet.
3. Lower the rear door window glass, until the

door window glass retaining bolt is visible
through the right-hand hole.
4. Loosen the rear door window glass retaining
bolt.

5. Remove the left-hand grommet.
6. Lower the rear door window glass, until the

door window glass retaining bolt is visible
through the left-hand hole.
7. Loosen the rear door window glass retaining
bolt.
Page 2 of 4
All vehicles
8. CAUTION: Make sure the rear door

window glass is adequately supported at the
top of the window opening.
Raise the rear door window glass by hand and
9. Disconnect the rear door latch electrical
connectors and the rear door window regulator
motor electrical connectors and detach the
wiring harness (if equipped) from the rear door
inner panel.
10. Detach the rear door speaker and wiring

harness (if equipped) from the door inner
panel.
11. Remove the rear door latch retaining screws
12. Remove the rear door inner panel retaining

bolts.
Page 3 of 4
13. Remove the rear door inner panel.
 Pull the rear door inner panel out at the

bottom.
14. Remove the rear door latch retaining screw

from the door inner panel.
15. Detach the rear door latch cables from the

door inner panel.
16. Detach the interior door handle from the door

inner panel.
17. Disconnect the rear door latch cables from

the interior door handle and remove the rear
door latch from the door inner panel.
Page 4 of 4
Installation
Page 1 of 1

IGNITION LOCK CYLINDER
UID=G297213
Removal
1. Remove the passive anti-theft system (PATS)
transceiver. For additional information, refer to
Section 419-01A / 419-01B.
2. Disconnect the right-hand multifunction switch
3. Remove the right-hand multifunction switch.
4. Turn the ignition key to the ACC position.

5. Depress the detent to release the ignition lock
cylinder.
6. Remove the ignition lock cylinder.
Installation
NOTE: When installing the ignition lock cylinder make sure the ignition key is in the ACC
position.
Page 1 of 2

DOOR LOCK CYLINDER
UID=G297215
Removal
05.
2. Remove the front door latch access panel.
3. Remove the grommet.
4. Remove the door lock security shield retaining

bolt.
5. Disconnect the exterior front door handle

actuator rod.
6. Disconnect the door lock security shield

retaining clip and remove the door lock
security shield.
Page 2 of 2
7. Disconnect the front door lock cylinder rod.
8. Remove the door lock cylinder retaining bolt.
9. Rotate the door lock cylinder clockwise to

remove (exterior front door handle shown
Installation
Page 1 of 1

LIFTGATE LATCH
UID=G297216
Removal
1. Remove the liftgate trim panel.
2. Disconnect the liftgate latch actuator electrical

connectors.
3. Disconnect the liftgate release handle

connecting rod.
4. Remove the liftgate latch.
Installation
Page 1 of 2

LIFTGATE RELEASE HANDLE
UID=G297217
Removal
2. Remove the license plate lamp cover retaining

nuts.
3. Remove the license plate lamp cover.
 Pull downwards to remove.
4. Disconnect the liftgate release handle

connecting rod.
5. Remove the liftgate release handle.

Page 2 of 2
Installation
Page 1 of 1

EXTERIOR FRONT DOOR HANDLE
UID=G297218
Removal
1. Remove the door lock cylinder. For additional
information, refer to Door Lock Cylinder in this
section.
2. Remove the exterior front door handle
retaining bolt.
3. Detach the exterior front door handle.

1. Hold the door lock cylinder cover against the
door.
2. While holding the door lock cylinder cover
against the door, pull out the exterior front
door handle.
3. Detach the exterior door handle and door
lock cylinder cover from the door.
4. Remove the exterior front door handle.
Installation
Page 1 of 1

EXTERIOR REAR DOOR HANDLE
UID=G297222
Removal
1. Remove the rear door latch. For additional
information, refer to Rear Door Latch in this
section.
2. Remove the exterior rear door handle retaining
bolt.
3. Detach the exterior rear door handle.

1. Hold the exterior rear door handle cover
against the door.
2. While holding the exterior rear door handle
cover against the door, pull out the exterior
rear door handle.
3. Detach the exterior rear door handle and
cover from the door.
4. Remove the exterior rear door handle.
Installation
Page 1 of 2

BRAKE CALIPER
UID=G297246
General Equipment
Brake hose clamp
Name Specification
Removal
support bracket.
3. Remove the brake caliper retaining clip.
4. CAUTION: Cap the brake hose to

NOTE: Use a suitable wrench to prevent the
brake hose from rotating.
Disconnect the brake hose from the brake caliper.
1. Using a suitable brake hose clamp, clamp
the brake hose.
2. Disconnect the hose.
5. Remove the brake caliper.

1. Remove the bolt covers (if equipped).
Page 2 of 2
6. Remove the brake pads.
Installation
CAUTIONS:
1. To prevent damage to the brake hose,

do not twist the brake hose when connecting
the brake hose to the brake caliper.
Make sure the brake hose is correctly


brake hose.
 Apply molybdenum disulfined grease to the

brake pad contact points.
Page 1 of 3

PARKING BRAKE CABLE ADJUSTMENT
UID=G297247
1. Remove the parking brake control trim panel.
2. Loosen the parking brake cable adjustment nut

to the end of the thread.
 Discard the retaining clip.

4. Make sure the parking brake cable is correctly
located.
5. NOTE: Prior to carrying out adjustment to
a new or relocated parking brake cable, settle
the parking brake system.
Settle the parking brake system in five stages.
 Stage 1: Raise the parking brake control four

notches.
 Stage 2: Tighten the adjustment nut until

increased torque is detected.
 Stage 3: Operate the parking brake control

firmly ten times.
 Stage 4: Loosen the adjustment nut to the

end of the thread.
 Stage 5: Depress the brake pedal firmly

fifteen times.
7. Remove the brake backing plate inspection
cover on both sides (left-hand side shown).
Page 2 of 3
8. NOTE: Make sure the parking brake control

is fully released.
Adjust the parking brake cable in two stages .
 Stage 1: With the aid of another technician,

tighten the parking brake cable adjustment
nut until the parking brake levers operate
(left-hand side shown).
 Stage 2: When movement is observed on

both levers, tighten the parking brake cable
adjustment nut two full turns.
9. Install the brake backing plate inspection cover
on both sides (left-hand side shown).
10. Check the parking brake cable adjustment in

two stages.
 Stage 1: Raise and release the parking brake

control and check that it returns to the fully
released position. If the parking brake control
does not fully release, repeat the adjustment
procedure.
 Stage 2: Rotate the rear wheels and check for

brake drag. If brake drag is felt, loosen the
parking brake cable adjustment nut two full
turns and repeat the adjustment procedure.
11. Install a new parking brake cable adjustment
nut retaining clip.
Page 3 of 3
12. Install the parking brake control trim panel.

Page 1 of 2

PARKING BRAKE CABLE
UID=G297248
Name Specification
Rubber grease
Removal
3. Detach the exhaust rear muffler from the
exhaust hanger insulators.
4. Detach the centre section of the exhaust

system heat shield from the floor panel.
5. Disconnect the parking brake cable.

axle bracket.

parking brake equalizer.
1. Detach the cables from the bracket.
Page 2 of 2
2. Detach the cables from the equalizer.

axle.
9. Remove the parking brake cable.
Installation
1. NOTE: Check the exhaust hanger
insulators for damage and fatigue. Install new
exhaust hanger insulators as required, using
a suitable lubricant.
2. Adjust the parking brake. For additional
information, refer to Parking Brake Cable
Page 1 of 1

PARKING BRAKE CONTROL
UID=G297249
Removal
1. Remove the center floor console. For additional
2. Disconnect the parking brake warning indicator
3. Disconnect the parking brake cable from the

parking brake control.

5. Remove the parking brake control.
Installation
2. Adjust the parking brake. For additional
information, refer to Parking Brake Cable
Page 1 of 3

BRAKE MASTER CYLINDER — LHD
UID=G297250
Removal
All vehicles
1. CAUTION: The brake fluid reservoir

cap must not become contaminated.
Remove the brake fluid reservoir cap.
2. NOTE: It will be necessary to carry out this
step on both sides in order to completely
drain the brake fluid reservoir.
Drain the brake fluid reservoir.
1. Connect one end of a suitable piece of clear
plastic pipe to the bleed nipple and place the
other end into a suitable container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the fluid is
drained from the brake fluid reservoir.
4. Tighten the bleed nipple.
3. Install the brake fluid reservoir cap.
Vehicles without anti-lock brakes
5. CAUTION: Cap the brake tubes to

Disconnect the brake tubes from the brake
master cylinder.
1. Disconnect the brake tubes.
2. Disconnect the pressure conscious reducing
valves.

master cylinder.
All vehicles
Page 2 of 3
7. CAUTION: Cap the clutch master

cylinder feed hose to prevent fluid loss or dirt
ingress.
Disconnect the clutch master cylinder feed hose

container.
8. Detach the brake vacuum hose from the brake

fluid reservoir.
9. Detach the brake master cylinder from the

brake booster.
10. Disconnect the low brake fluid warning

indicator switch electrical connector.
Vehicles with stability assist

11. Disconnect the stability assist electrical
connector.
All vehicles
12. Remove the brake master cylinder and brake
fluid reservoir assembly.
Page 3 of 3
Installation
1. CAUTION: Make sure the brake

master cylinder vacuum seal is correctly
positioned before installation.
Page 1 of 3

BRAKE BOOSTER — LHD
UID=G297251
Removal
All vehicles
06.
2. Disconnect the brake vacuum pipe from the
brake booster.

3. Remove the windshield wiper motor. For
16.

control unit (HCU) tubes.
5. CAUTION: Cap the brake tube to

Detach the left-hand front brake tube from the
fender.
1. Disconnect the brake tube union.
2. Detach the brake tube.
All vehicles
Page 2 of 3

steering gear.
8. Remove the brake booster retaining nuts.
9. Detach the brake booster actuating rod from

the brake pedal.
1. Depress the clip.
2. Remove the brake booster actuating rod
pin.
10. Remove the brake booster.
Installation
WARNINGS:
1. Do not install an Emergency Brake

Assist (EBA) brake booster to a vehicle that is
not equipped with the Anti-lock Brake System
(ABS). Failure to follow this instruction may
cause personal injury.
Do not use a damaged brake pedal.

personal injury.
Page 3 of 3
Install a new steering column to steering

gear retaining bolt. Failure to follow this
CAUTIONS:
Make sure the brake booster gasket is

correctly positioned on the brake booster
before installation.
Do not drop or knock the brake pedal.

Failure to follow this instruction will cause
damage to the brake pedal decoupler
mechanism.
NOTE: On vehicles equipped with EBA the
brake booster is identified by a white sticker
showing a large letter "A".
NOTE: Install a new brake booster gasket.
Page 1 of 1

POWER STEERING FLUID COOLER
UID=G297253
Removal
2. Disconnect the power steering fluid cooler
quick release couplings.
1. Press the power steering fluid cooler hose
quick release coupling locking tangs.

container.
3. Remove the power steering fluid cooler.
Installation
00.
Page 1 of 1

STEERING WHEEL
UID=G297254
Removal
20A / 501-20B.
3. Remove the steering wheel.

1. Disconnect the electrical connector.
Installation
Page 1 of 3

STEERING COLUMN
UID=G297255
Removal
20A / 501-20B.
2. NOTE: Turn the steering wheel to access to
the steering column upper shroud retaining
clips.
Detach the steering column upper shroud from
the steering column lower shroud (steering
wheel shown removed for clarity).
1. Using a thin bladed screwdriver, release the
two clips, (one each side).
2. Detach the shroud.
3. Remove the steering column lower shroud

(steering wheel shown removed for clarity).
2. Release the steering column locking lever.


6. Disconnect the ignition switch, turn signal,

clockspring, multifunction switches and the
stability assist (if equipped) electrical
connectors.
Page 2 of 3
7. Disconnect the passive anti-theft system

(PATS) transceiver and key in ignition switch
warning electrical connectors.
8. Detach the wiring harness from the steering

column.
9. Remove the steering column.
 Discard the retaining nuts.
Installation
WARNINGS:
1. Install a new steering column shaft to

steering gear pinion retaining bolt. Failure to
injury.
Make sure the steering column locking

lever is in the locked position. Failure to
injury.
Install new steering column retaining

nuts. Failure to follow this instruction may
Page 3 of 3
Page 1 of 2

STEERING COLUMN
UID=G297256
Disassembly
1. Remove the steering wheel.
1. Disconnect the audio control electrical
connector.
2. CAUTION: Make sure the clockspring

is not allowed to rotate. Secure in the central
position with a piece of suitable tape.
Remove the clockspring and multifunction
switches.
 Release the locking tangs.
3. Remove the ignition switch.
 Remove the retaining screw.
4. Remove the passive anti-theft system (PATS)

transceiver.
1. Release the outer clip.
2. Slide the PATS transceiver to the side to
unhook the shielded clip.
5. Remove the key in ignition warning switch.
6. Depress the detent to release the ignition lock

cylinder.
Page 2 of 2
7. Remove the ignition lock cylinder.
Assembly
1. To assemble, reverse the disassembly
procedure.
Page 1 of 2

IGNITION SWITCH
UID=G297257
Removal
01.
2. NOTE: Turn the steering wheel to access
clips.
two clips (one each side).

4. Disconnect the ignition switch, clockspring and

stability assist (if equipped) electrical
connectors.
5. Remove the ignition switch.
 Remove the retaining screw.
Installation
All vehicles

Page 2 of 2

11.
Page 1 of 1

EXTERIOR MIRROR
UID=G297258
Removal
1. Detach the exterior mirror trim panel.
2. Disconnect the tweeter electrical connector

and remove the exterior mirror trim panel (if
equipped).
3. Disconnect the power mirror electrical

connector (if equipped).
4. Remove the exterior mirror.
Installation
Page 1 of 5

FRONT SEAT BACKREST COVER
UID=G297259
WARNING: Note the position of the wiring harnesses, to aid installation. An

incorrectly routed wiring harness could become damaged when the seat is moved. Failure
to follow this instruction may result in personal injury.
1. Remove the Front Seat.

1 - Cushion heater wiring harness electrical connector (if equipped)
See Removal Detail
2 - Cushion retaining screws
3 - Cushion
4 - Backrest recliner handwheel
See Removal Detail
5 - Seat track inner upper trim panel
See Removal Detail
6 - Seat track outer upper trim panel
See Removal Detail
7 - Head restraint
Page 2 of 5
8 - Head restraint guides

See Removal Detail
9 - Backrest cover
See Removal Detail
10 - Backrest cover tension rods
See Removal Detail
Removal Details
Item 1 : Cushion heater wiring harness electrical connector (if equipped)
1. Detach the heated seat electrical harness from

the seat frame.
1. Disconnect the heated seat cushion
2. Disconnect the heated seat backrest electrical

connector.
Item 4 : Backrest recliner handwheel
CAUTION: To avoid damage to the backrest recliner handwheel, even pressure must
be applied to the opposite sides of the handwheel.
Item 5 : Seat track inner upper trim panel
1. Remove the seat track inner upper trim panel.

1. Detach the front retaining clip.
2. Detach the rear retaining tang.
Item 6 : Seat track outer upper trim panel
1. Remove the seat track outer upper trim panel.

Page 3 of 5
Item 8 : Head restraint guides
1. Remove the head restraint guides.

1. Using a suitable screwdriver, depress the
locking tang.
2. Pull the guide upwards.
Item 9 : Backrest cover
1. Detach the backrest cover from the underside

of the backrest.
 Detach the retaining strip.
2. Roll the backrest cover up the backrest to

access the lower ends of the tensioning rods.
3. Detach the lower ends of the tensioning rods
from the backrest.

access the upper ends of the tensioning rods.
5. Detach the upper ends of the tensioning rods
from the backrest.
Page 4 of 5

access the upper end of the spring frame.
7. Detach the backrest cover from the front of
the backrest pad.
 Cut the hog rings.
8. Detach the side air bag deployment sleeve

from the backrest frame.
1. Locally detach the side air bag deployment
sleeve.
2. Detach the retaining strip.

1. Detach the retaining strip.
Item 10 : Backrest cover tension rods
1. NOTE: If installing a new backrest cover,

remove the tensioning rods from the original
backrest cover.
Remove the tensioning rods.
Item 10 : Backrest cover tension rods
1. NOTE: If installing a new backrest cover,

instal the original tensioning rods to the new
backrest cover.
Page 5 of 5
Install the tensioning rods.

Item 9 : Backrest cover
NOTE: If a replacement backrest cover is to be installed, cut the holes for the head
restraint guides. Use the existing backrest cover as a template.
1. Use hog ring pliers to close the hog rings. Do
not use any other tool. The hog rings must be
closed to overlap as illustrated.
Page 1 of 7

WINDSHIELD GLASS
UID=G297262
General Equipment
Hot air gun
Direct glazing cutter for bonded glass
Direct glazing adhesive kit
Direct glazing adhesive oven
Glazing suction cups
Removal
1. Remove the polyurethane (PU) adhesive cap
and heat the PU adhesive for a minimum of 30
minutes.
2. Raise the hood.

3. NOTE: Make sure that the windshield wiper
motor is in the park position.
Remove the windshield wiper arms.
4. Remove the cowl panel grilles.
 Remove the retaining screws.
5. Lower the hood.

6. Detach the front door opening weatherstrip
from the A-pillar on both sides.
7. Remove the A-pillar trim panels.

Page 2 of 7
9. Disconnect the interior lamp electrical

connectors and remove the interior lamp.
10. Remove the interior mirror.
 Release the interior mirror retaining clip.
12. Lever open the covers to expose the screws

and remove the sun visor retaining clips.
Page 3 of 7
13. Detach the leading edge of the headliner and

place two blocks of suitable material between
the headliner and the roof panel to act as
spacers.
14. WARNING: Wear gloves and eye

protection when working with the glass
cutting tool as the cutting operation may
produce splinters. When using the cutter wear
ear protectors. Failure to follow these
instructions may result in personal injury..
CAUTION: Make sure the cutting blades

are changed where the cutting depth changes
to avoid damage to the body and trim panels.
NOTE: Care must be taken when cutting in
the area of the locating blocks along the
lower edge of the windshield glass.
From inside the vehicle, using a suitable direct
glazing cutter, cut the PU adhesive to the
given depth.
1. 23 mm.
2. 75 mm.
3. 160 mm.
15. With the aid of another technician, use
glazing suction cups to remove the windshield
glass.
16. Remove the windshield glass locating blocks.
 Discard the locating blocks.

Page 4 of 7
Installation
1. CAUTION: Do not touch the adhesive

surface as re-bonding will be impaired.
Carefully trim the remaining polyurethane (PU)
adhesive from the windshield glass flange to
leave approximately 1 mm of trimmed PU
adhesive adhered to the flange.
2. Install new windshield glass locating blocks.
3. Check the windshield glass flange for damaged

sheet metal, rust or foreign material which
may have caused, or may cause, glass
breakage.
4. CAUTION: To make sure that the PU

adhesive cures, it is essential that all bonding
surfaces are free of moisture.
Using a hot air gun, apply warm air (25°C) to the
windshield glass flange and glass bond line to
remove all traces of moisture.
5. Prepare the glass, windshield glass flange and
trimmed PU adhesive in accordance with the
instructions supplied with the PU adhesive kit.
6. NOTE: Discard the first 100 mm of PU
adhesive as this may have a reduced working
time.
NOTE: To avoid water leaks, any breakage in
the continuous bead must be overlapped by
20 mm.
Apply the PU adhesive in a continuous bead of
between 8 and 10 mm in height to the
windshield glass flange along the bond line.
Page 5 of 7
7. With the aid of another technician, use glazing

suction cups to install the windshield glass.
 Press firmly and evenly into position.
8. CAUTION: During the curing period of

the PU adhesive, the door windows must be
left open to avoid a build up of pressure when
the doors are opened and closed.
Using suitable tape, secure the windshield glass
in the correct position until the PU adhesive
has cured.
9. If the ambient temperature falls below 10°C,
use a hot air gun and apply warm air (25°C)
continuously for 15 minutes (inside or outside
the vehicle).
10. Remove the spacers and attach the leading

edge of the headliner to the roof panel.
11. Install the sun visor retaining clips.
12. Install the sun visors.

Page 6 of 7
13. Install the interior mirror.
14. Connect the interior lamp electrical

connectors.
15. Install the interior lamp.
16. Install the A-pillar trim panels.
17. Attach the front door opening weatherstrip to

the A-pillar on both sides.
Page 7 of 7
18. Raise the hood.

19. NOTE: Make sure the cowl panel grilles
are located correctly.
Install the cowl panel grilles.
 Install the retaining screws.
20. Install the windshield wiper arms.
21. Lower the hood.

Page 1 of 5

LIFTGATE WINDOW GLASS
UID=G297263
General Equipment
Hot air gun
Removal
minutes.
2. Remove the liftgate window wiper arm.
3. Remove the central high mounted stoplamp

(CHMSL) cover.
4. Detach the CHMSL from the liftgate.

Page 2 of 5
6. Disconnect the heated liftgate window glass


instructions may result in a personal injury.

NOTE: Some resistance may be encountered
when cutting through the glass locating pegs
in the corners of the glass.
From inside the vehicle using a suitable direct
given maximum depths.
1. 22 mm.
2. 51 mm.
3. 130 mm.
4. 170 mm.
5. 25 mm.
6. 170 mm.
7. 130 mm.
8. 125 mm.
suction cups to remove the liftgate window
glass.
Installation
1. Carefully remove the remaining part of the
locating pegs from the liftgate window glass
flange.
Page 3 of 5

Carefully trim the remaining polyurethane (PU)
adhesive from the liftgate window glass flange
to leave approximately 1 mm of trimmed PU
adhesive adhered to the flange.
3. Check the liftgate window glass flange for

damaged sheet metal, rust or foreign material
which may have caused, or may cause, glass
breakage.

adhesive cures, it is essential that all the
bonding surfaces are free of moisture.
liftgate window glass flange and glass bond
line to remove all traces of moisture.
5. Prepare the glass, liftgate window glass flange
and trimmed PU adhesive in accordance with
the instructions supplied with the PU adhesive
kit.
time.
the continuous bead must be overlapped by
20 mm.
between 8 and 10 mm in height to the liftgate
window glass flange along the bond line.

suction cups to install the liftgate window
glass.

Using suitable tape, secure the liftgate window
glass in the correct position until the PU
adhesive has cured.
the vehicle).
Page 4 of 5
10. Connect the heated liftgate window glass

11. Attach the CHMSL to the liftgate.
12. Install the the CHMSL cover.
13. Install the liftgate trim panel.
14. Install the liftgate window wiper arm.

Page 5 of 5
Page 1 of 2

FRONT DOOR WINDOW GLASS
UID=G297264
Removal
All vehicles
05.

2. Connect the power window control switch

3. Install the window regulator handle.
All vehicles
4. Remove the grommets.
5. Loosen the front door window glass clamp

bolts.
 Align the window glass clamp bolts with the

access holes.
Page 2 of 2
6. NOTE: The front door window glass must

be removed towards the outside of the
window opening.
Remove the front door window glass.
1. Lift the glass.
2. Tip the glass forwards and remove the glass
from the front door.
Installation
1. NOTE: The front door window glass must
be installed from the outside of the window
opening.
Page 1 of 2

FRONT DOOR WINDOW REGULATOR
UID=G297265
Removal
All vehicles
1. Remove the front door window glass. For
additional information, refer to Front Door
Window Glass in this section.

2. Remove the front door window regulator
motor.
 Disconnect the electrical connector.

4. Remove the window regulator retaining

screws.
All vehicles
5. Remove the front door speaker from the front
door inner panel.

Page 2 of 2
6. Release the front door window regulator drum.
7. Remove the front door window regulator

retaining nuts.
8. Remove the front door window regulator.
Installation
All vehicles

additional information, refer to Door Window
Motor Initialization in this section.
Page 1 of 1

FRONT DOOR WINDOW REGULATOR
MOTOR
UID=G297266
Removal
05.
2. Remove the front door speaker from the front
door inner panel.
3. NOTE: Support the front door window

regulator through the front door inner panel.
Remove the window regulator motor.
Installation
additional information, refer to Door Window
Motor Initialization in this section.
Page 1 of 3

REAR QUARTER WINDOW GLASS
UID=G297267
General Equipment
Hot air gun
Removal
minutes.
2. Remove the C-Pillar trim panel. For additional



NOTE: Some resistance may be encountered
when cutting through the glass locating pegs
in the corners of the glass.
From inside the vehicle, using a suitable direct
given maximum depths.
1. 17 mm.
2. 52 mm.
3. 30 mm.
4. 70 mm.
5. 32 mm.
suction cups to remove the rear quarter
window glass.
Page 2 of 3
Installation
1. Carefully remove the remaining part of the
locating pegs from the rear quarter window
glass flange.

Carefully trim the remaining PU adhesive from
the rear quarter window glass flange to leave
approximately 1 mm of trimmed PU adhesive
adhered to the flange.
3. Check the rear quarter window glass flange for

damaged sheet metal, rust or foreign material
which may have caused, or may cause, glass
breakage.

adhesive cures, it is essential that all bonding
surfaces are free of moisture.
rear quarter window glass flange and glass
bond line to remove all traces of moisture.
5. Prepare the glass, rear quarter window glass
flange and trimmed PU adhesive in accordance
with the instructions supplied with the PU
adhesive kit.
time.
the continuous bead should be overlapped by
20 mm.
between 8 and 10 mm in height to the rear
quarter window glass flange along the bond
line.
7. Use glazing suction cups to install the rear
quarter window glass.

Page 3 of 3
Using suitable tape, secure the rear quarter

window glass in the correct position until the
PU adhesive has cured.
the vehicle).
10. Install the C-Pillar trim panel. For additional

Page 1 of 3

REAR DOOR WINDOW REGULATOR
UID=G297268
Removal
All vehicles
05.
2. Remove the rear door speaker from the rear
door inner panel.

3. Connect the rear door window regulator motor
5. Loosen the rear door window glass clamp bolt.
 Align the window glass clamp bolt with the

access hole.

Page 2 of 3

access hole.
All vehicles
9. CAUTION: Make sure the rear door

window glass is supported at the top of the
window opening.
Raise the rear door window glass by hand and

10. Remove the rear door window regulator
motor.

11. Remove the window regulator retaining
screws.
Page 3 of 3
All vehicles
12. Release the rear door window regulator
drum.
13. Remove the rear door window regulator

retaining nuts.
14. Remove the rear door window regulator.
Installation
Page 1 of 3

REAR DOOR WINDOW GLASS
UID=G297269
Removal
All vehicles
05.

2. Connect the rear door window regulator motor

access hole.


Page 2 of 3

access hole.
All vehicles
8. Lower the rear door window glass to the
bottom of the door.
9. Detach the weatherstrip from the door.
10. Remove the rear door fixed window glass.

3. Slide the dividing bar forward.
12. NOTE: The rear door window glass must

be removed towards the outside of the
window opening.
Page 3 of 3
Remove the rear door window glass.
Installation
1. NOTE: The rear door window glass must be
installed from the outside of the window
opening.
Page 1 of 1

REAR DOOR WINDOW REGULATOR
MOTOR
UID=G297271
Removal
05.
2. Remove the rear door speaker from the rear
door inner panel.
3. NOTE: Support the rear door window

regulator through the rear door inner panel.
Remove the window regulator motor.
Installation
Page 1 of 3

INSTRUMENT PANEL UPPER SECTION
UID=G297304
Removal
CAUTION: When removing or installing the instrument panel, care must be taken not
to scratch or damage the instrument panel surface.
1. Remove the passenger air bag module. For
20A / 501-20B.
2. Remove the steering column. For additional
3. Remove the audio unit. For additional
4. Remove the instrument cluster. For additional
5. Detach the weather strip from the A-pillar on
both sides.
6. Remove the A-pillar trim panel on both sides.
7. Remove the instrument panel side retaining

screw on both sides.
8. Remove the storage compartment retaining

screws.
Page 2 of 3
9. Remove the storage compartment.

1. Release the sides and front retaining clips.
2. Move forwards to release the rear retaining
clips.
10. Remove the instrument panel center

retaining screws.
11. Remove the instrument panel left-hand

retaining nuts.
 Remove the storage compartment left-hand

support bracket.
12. Detach the storage compartment right-hand

support bracket from the cross-vehicle beam.
13. Remove the instrument panel upper section.
 Move the instrument panel rearwards to

release the retaining clips.
Installation
Page 3 of 3
1. NOTE: Make sure the instrument panel

upper section front retaining clips are fully
engaged.
Page 1 of 2

FLOOR CONSOLE
UID=G297305
Removal
1. Remove the parking brake trim panel.
2. Detach the gearshift lever trim panel from the

floor console.
3. Disconnect the passenger air bag deactivation

(PAD) indicator electrical connector (if
equipped).
4. Remove the gearshift lever trim panel.
 Detach the gearshift lever boot from the trim

panel.
5. Remove the floor console front retaining clips

(right-hand side shown).
6. Remove the floor console center retaining

screws.
Page 2 of 2
7. Remove the floor console.
 Remove the rear retaining screw.
Installation
Page 1 of 1

REAR BUMPER COVER
UID=G297306
Removal
1. Remove the bumper cover upper retaining
screws.
2. Remove the spare wheel and tire.

3. Remove the bumper cover retaining nuts.

5. Remove the bumper cover lower retaining
screws.
6. Remove the rear bumper cover.

1. Release the bumper cover from the
retaining clips.
2. Pull the bumper cover rearwards.
Installation
Page 1 of 2

FRONT BUMPER COVER
UID=G297307
Removal
1. Raise the hood.
3. Remove the front registration plate.
4. Detach the bumper cover from the fender on
both sides.
5. Using a suitable screwdriver, remove the

bumper cover front retaining clips.
6. Remove the bumper cover lower retaining

screws (left-hand side shown).
7. Disconnect the fog lamp electrical connector on

both sides (if equipped).
8. Remove the front bumper cover.

1. Release the bumper cover from the fender
retaining clips.
2. Pull the bumper cover forwards.
Page 2 of 2
Installation
1. CAUTION: The front bumper cover

protrusion must be removed to prevent
power steering fluid cooler interference with
the bumper cover.
NOTE: Only carry out this step on initial
power steering fluid cooler installation, or
when installing a new front bumper cover to a
vehicle with a power steering fluid cooler.
Using a suitable knife, remove the front bumper
cover protrusion.
Page 1 of 1

SAFETY BELT SHOULDER HEIGHT
ADJUSTER
UID=G297308
Removal
2. Move the safety belt shoulder height adjuster
to its lowest position.
3. Remove the safety belt shoulder height
adjuster upper bolt.
4. Remove the safety belt shoulder height

adjuster.
1. Move the safety belt height adjuster to its
highest position.
2. Remove the bolt.
Installation
1. NOTE: Make sure the safety belt shoulder
height adjuster locking control is correctly
located on the safety belt shoulder height
adjuster.
Page 1 of 1

REAR SAFETY BELT RETRACTOR
UID=G297310
Removal
1. Remove the loadspace trim panel. For
05.
2. Raise the rear seat cushion.
3. NOTE: Hold the safety belt webbing when
detaching the lower anchor from the floor
panel.
Detach the rear safety belt lower anchor from the
floor panel.
4. Fold the seat backrest forward.
5. CAUTION: The bolt securing the safety

belt anchor is held captive by a paper washer.
The bolt, spacer and paper washer must
remain on the safety belt anchor at all times
when the safety belt is detached or removed.
Detach the safety belt upper anchor from the C-
pillar.
1. Detach the bolt cover.
2. Remove the bolt.
6. Remove the rear safety belt retractor.
1. Remove the bolt.
2. Lift the retractor to detach the locating
tangs.
Installation
1. CAUTION: Make sure the safety belt

retractor locating tangs are correctly located.
Page 1 of 2

SAFETY BELT RETRACTOR AND
PRETENSIONER
UID=G297311
Removal
WARNINGS:
To avoid accidental deployment, the air bag control module backup power supply
must be depleted. Wait at least one minute after disconnecting the battery ground cable
(s) before commencing any repair or adjustment to the supplemental restraint system
(SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these
To minimize the possibility of premature deployment, do not use radio key code
savers when working on the supplemental restraint system. Failure to follow this
injury.
01.
3. NOTE: Hold the safety belt webbing when
detaching the safety belt lower anchor from
the floor panel.
Detach the lower anchor from the floor panel.
1. Detach the bolt cover.
2. Remove the bolt.
4. Detach the safety belt retractor and

pretensioner from the B-pillar.
2. Lift the retractor.
5. Remove the safety belt retractor and

pretensioner.
 Using a suitable screwdriver, release the

locking tang.
Page 2 of 2
Installation
WARNINGS:
injury.
1. NOTE: Make sure the safety belt shoulder
height adjuster locking control is correctly
located on the safety belt shoulder height
adjuster.
11.
Page 1 of 3

SIDE AIR CURTAIN MODULE
UID=G297312
Removal
WARNINGS:
To avoid accidental deployment, the restraints control module backup power supply

injury.
01.
2. Remove the headliner. For additional
3. Disconnect the side air curtain module

locking tang.
4. CAUTION: If a new side air curtain is

to be installed, the lower retaining screw clip
must be removed.
NOTE: Note the routing of the retaining cord,
to aid installation.
Detach the front retaining cord from the A-pillar.
1. Remove the lower retaining screw.
2. Remove the upper retaining clips.
3. Using a suitable pair of pliers, remove the
Page 2 of 3
lower screw clip, if necessary.

5. Remove the side air curtain module front
retaining bolt.
6. CAUTION: If a new side air curtain is

to be installed, the retaining screw clips must
be removed.
Detach the side air curtain from the roof panel.
2. Using a suitable pair of pliers, remove the
screw clips, if necessary.
7. Remove the side air curtain rear retaining

screws.
8. Remove the side air curtain.
 Lift the side air curtain module to release the

locating tangs.
Installation
WARNINGS:
Make sure the air bag electrical connectors are correctly installed and are secure.

Page 3 of 3
injury.
CAUTION: Make sure the side air curtain module locating tangs are correctly located.
11.
Page 1 of 2

DRIVER AIR BAG MODULE
UID=G297313
Removal
WARNINGS:

injury.
Painting over the driver air bag module trim cover or instrument panel could lead to
deterioration of the trim cover and air bags. Do not for any reason attempt to paint
discolored or damaged air bag module trim covers or instrument panel. Install a new
component. Failure to follow this instruction may result in personal injury.
01.
the driver air bag module retaining bolts.
Remove the driver air bag retaining bolts.
3. Remove the driver air bag module.
 Disconnect the driver air bag module

Page 2 of 2
Installation
WARNINGS:

injury.
11.
Page 1 of 3

PASSENGER AIR BAG MODULE
UID=G297314
Removal
WARNINGS:

injury.
01.
2. Fully open the glove compartment.
 Detach the locking tangs.
3. Detach the passenger air bag module bracket

from the cross-vehicle beam.
Page 2 of 3
4. Open the storage compartment.
5. NOTE: If necessary, use a trim tool to aid

the release of the passenger air bag cover
retaining clips from the instrument panel.
Detach the passenger air bag module from the
instrument panel.
 Start at the edge next to the storage

compartment.
6. Disconnect the passenger air bag module


locking tang.
7. Remove the passenger air bag module.
 Using a suitable trim tool, detach the

passenger air bag wiring harness from the
passenger air bag module.
Installation
WARNINGS:
Make sure the air bag electrical connectors are correctly installed and are secure.
Page 3 of 3

injury.
CAUTION: Make sure that all the passenger air bag trim cover retaining clips are
correctly engaged and the trim cover is flush with the instrument panel.
11.
Page 1 of 5

CLOCKSPRING
UID=G297315
Removal
All vehicles
WARNINGS:
injury.
1. Remove the steering wheel. For additional
2. Detach the steering column upper shroud from
the lower shroud.

4. Detach both multifunction switch harnesses

from the clockspring.
5. Disconnect the clockspring electrical connector.

Page 2 of 5

6. Disconnect the steering wheel rotation sensor
All vehicles

to the steering column retaining clips do not
get damaged.
Remove the clockspring.
 Release the retaining clips.

to steering wheel rotation sensor retaining
clip does not get damaged.
Detach the steering wheel rotation sensor from
the clockspring.
 Release the retaining clip.
Installation

to steering wheel rotation sensor retaining
clip does not get damaged
Attach the steering wheel rotation sensor to the
clockspring.
Page 3 of 5
All vehicles
WARNINGS:
injury.
If installing a new clockspring, do not remove the clockspring locking key at this
stage. Failure to follow this instruction may result in personal injury.
If installing the original clockspring, do not remove the adhesive tape at this stage.
CAUTIONS:
2. Make sure the road wheels are in the

straight ahead position.
Make sure the clockspring to the steering

column retaining clips do not get damaged.
NOTE: Make sure the turn signal lamp switch
is the off position.
Install the clockspring.

3. Connect the steering wheel rotation sensor
All vehicles
4. Connect the clockspring electrical connector.
5. Attach both multifunction switch harnesses to

Page 4 of 5
the clockspring.
6. Install the steering column lower shroud.

1. Install the retaining screws.
2. Lock the steering column locking lever.
7. Attach the steering column upper shroud to

the lower shroud.
WARNINGS:
8. If there is a break between installing

the clockspring and installing the steering
wheel, or the vehicle is left unattended by the
technician, the centralizing procedure MUST
be carried out.
Incorrect centralization may result in

premature component failure. If in doubt
when centralizing the clockspring, repeat the
centralizing procedure. Failure to follow this
CAUTIONS:
Make sure the road wheels are in the

straight ahead position.
When carrying out the clockspring

centralizing procedure, the first turns must be
in the counterclockwise direction.
Do not turn the clockspring more than

two and one half turns after it has been
centralized.
Centralize the clockspring.
1. Turn the clockspring in a counterclockwise
direction until resistance is felt
Page 5 of 5
(approximately two and one half turns).

2. Turn the clockspring in a clockwise
direction, approximately two and one half
turns.
3. The arrow marked on the rotor of the
clockspring must be aligned with the raised
'V' section at the 6 o'clock position on the
outer cover of the clockspring
9. Install the steering wheel. For additional
10. Release the clockspring.
 If a new clockspring is installed remove the

locking key.
 If the original clockspring is installed, remove

the adhesive tape.

11.
12. WARNING: The electronic stability

program must be re-configured. Failure to
injury.
Configure the electronic stability program using
WDS.
Page 1 of 2

RESTRAINTS CONTROL MODULE
(RCM)
UID=G297316
Removal
WARNINGS:
injury.
01.
2. Remove the floor console. For additional
3. Disconnect the restraints control module
4. Remove the restraints control module.
Installation
WARNING: Never probe the electrical connectors of air bag modules or any other
supplemental restraint system component. Failure to follow this instruction may result in
personal injury.
2. WARNING: A new restraints control

module must be configured following
Page 2 of 2
installation. Failure to follow this instruction

If installing a new restraints control module,
configure the restraints control module using
WDS.
11.
Page 1 of 2

SIDE IMPACT SENSOR
UID=G297317
Removal
WARNINGS:
injury.
01.
3. Disconnect the side impact sensor electrical
connector.
1. Hold the rear of the connector.
2. Slide the cover of the connector rearwards.
4. Remove the side impact sensor.
Installation
WARNINGS:
Make sure the side impact sensor locating tangs are correctly located into the floor
pan. Failure to follow this instruction may result in personal injury.
injury.
Page 2 of 2

11.
Page 1 of 4

SIDE AIR BAG MODULE
UID=G297318
Removal
WARNINGS:
To avoid accidental deployment, the restraints control module backup power must be
depleted. Wait at least one minute after disconnecting the battery ground cable(s) before
commencing any repair or adjustment to the supplemental restraint system (SRS), or any
component(s) adjacent to the SRS sensors. Failure to follow these instructions may result
in personal injury.

injury.
01.
2. CAUTION: To avoid damage to the

backrest recliner handwheel, even pressure
must be applied to the opposite sides of the
handwheel.
Remove the backrest recliner handwheel.
3. Remove the seat track inner upper trim panel.

4. Remove the seat track outer upper trim panel.

Page 2 of 4
5. Detach the backrest cover from the underside

of the backrest.
 Detach the retaining strip.

access the lower ends of the tensioning rods.
7. Detach the lower ends of the tensioning rods
from the backrest.

access the upper ends of the tensioning rods.
9. Detach the upper ends of the tensioning rods
from the backrest.
10. WARNING: Note the position of the

wiring harness, to aid installation. An
incorrectly routed wiring harness could
become damaged when the seat is moved.
personal injury.
Detach the side air bag module wiring harness
from the seat frame.
 Use a trim tool to carefully release the

retaining clip.
Page 3 of 4
11. Detach the side air bag wiring harness from

the backrest frame.
 Use a trim tool to carefully release the

retaining clips.
12. Detach the side air bag electrical connector

from the multiplug.

locking tang.
13. Remove the side air bag module.
Installation
WARNINGS:
1. Always wear safety glasses when

working on an air bag equipped vehicle and
when handling the air bag module. Failure to
injury.
To minimize the possibility of premature

deployment, do not use radio key code savers
when working on the supplemental restraint
system. Failure to follow this instruction may
To minimize the possibility of injury in

the event of premature deployment, always
carry a live air bag module with the bag and
trim cover pointed away from the body.
personal injury.
To minimize the possibility of premature

deployment, live air bag modules must only
be placed on work benches which have been
ground bonded and with the trim cover facing
up. Failure to follow these instructions may
Page 4 of 4
Never probe the electrical connectors of

air bag modules or any other supplemental
restraint system component. Failure to follow
this instruction may result in personal injury.
NOTE: Install new retaining nuts.
11.
Page 1 of 1

REAR DOOR FIXED WINDOW GLASS
UID=G306326
Removal
1. Lower the rear door window glass to the
bottom of the door.
2. Remove the dividing bar.
3. Tilt the dividing bar forwards.
Installation
Page 1 of 4

WIPERS AND WASHERS
UID=G31075
All functions are initiated by means of a multi-function switch which is operated by the wiper
lever on the right of the steering column.
The circuits of the windshield/rear window wash/wipe system are protected via fuse F12 (20
A, in the central junction box CJB).
The associated wiring diagrams are contained in the Wiring Diagrams Binder, see subsection
501-16.
Precise information relating to the location of the components is contained in the Wiring
Diagrams Binder (component location chart and views of the components, see subsection
501-16).
Windshield wiper
The windshield wiper comprises the following parts:
- Front wiper arm (2)
- Windshield wiper motor on the air cowl grille
- Front wiper linkage
- Front wiper blade (2)
- Wiper delay relay, in the CJB
- Multi-function switch, comprising
 Windshield wiper switch
 Windshield washer switch
Windshield wiper functions
The windshield wiper motor can run at two speeds and incorporates a park position limit
switch. It is controlled by the multi-function switch on the steering column and by the wiper
delay relay.
After switching on the ignition (position II) the following five wiper functions are available:
- Off
- Wipe once
- Intermittent
- Slow
- Fast
Page 2 of 4
Wiper lever in the OFF position
If the wiper lever is moved from any other setting to the OFF position, then the windshield
wiper motor continues to run at slow speed until the wipers reach the park position. This is
effected through a second circuit via the limit switch, which supplies a voltage to the
windshield wiper motor after it has been switched off. The voltage supply remains intact until
the limit switch interrupts the circuit through the wiper delay relay (normally closed contact)
and the multi-function switch to the windshield wiper motor.
Wiper lever in the WIPE ONCE position
Press the wiper lever up until resistance is felt and then release it. The windshield wipers
perform an individual slow wipe. Current is supplied to the windshield wiper motor via the
multi-function switch.
Wiper lever in the INTERMITTENT position
Press the wiper lever down. The windshield wipers perform intermittent slow wipes. The wiper
delay time is set to 9 seconds.
The multi-function switch sends a 12 V signal to the wiper delay relay, which picks up in 9
second intervals and supplies a voltage to the windshield wiper motor. The flow of current is
routed through the wiper delay relay (normally open contact) and the multi-function switch
(connector C65b, pin 8) to the windshield wiper motor.
Wiper lever in the SLOW WIPE position
Press the wiper lever up one notch. The wipers operate at slow speed. Current flows through
the multi-function switch to the windshield wiper motor.
Wiper lever in the FAST WIPE position
Press the wiper lever up two notches. The wipers operate at high speed. Current flows
through the multi-function switch to the windshield wiper motor.
Windshield washer
WARNING: The washer fluid contains methanol, which is poisonous. Follow the safety
guidelines. Failure to observe these instructions could cause personal injury.
CAUTION: Never operate the washer system for more than 10 seconds or when the
washer reservoir is empty.
The windshield washer comprises the following parts:
- Washer reservoir, underneath the right-hand front fender

Page 3 of 4
- Washer pump, on the washer reservoir
- Two washer nozzles on the hood, adjustable.
Two functions are available depending on how the wipers are operating:
Wiper lever in the OFF or INTERMITTENT position
The windshield wiper and washer pump operate as long as the end of the wiper lever is
pressed in. The washer pump stops immediately when the wiper lever is released. The
windshield wipers perform two more wipe cycles before they return to intermittent operation
(INTERMITTENT position) or stop at the park position (OFF position). Current flows from the
multi-function switch (connector C65b, pin 2) via the washer pump back to the multi-function
switch (connector C65b, pin 1). The multi-function switch makes the ground connection when
it is set to WINDSHIELD WASHER ON.
Wiper lever in the position SLOW WIPE or FAST WIPE
The washer system operates together with the windshield wiper as long as the end of the
wiper lever is pressed in. The washer pump stops immediately when the wiper lever is
released. The current flows through the same circuit as described before.
Rear wiper
The rear wiper comprises the following parts:
- Rear wiper motor
- Rear wiper arm
- Wiper blade
- One nozzle
Rear window wiper
Pull the wiper lever one notch towards the steering wheel to switch it on. The wiper operates
continuously at constant speed. Once it is switched off the wiper motor returns to the park
position before stopping. The current flows from the multi-function switch to the rear wiper
motor. A second circuit supplies the wiper motor with voltage via the limit switch after it is
switched off. The voltage supply is interrupted when the limit switch reaches the park position
and breaks the circuit. Both circuits go through the tailgate contact switch. The spring-loaded
pins in the contact switch are pressed onto the contact plate to make the electrical circuit.
Opening the tailgate interrupts both circuits at the contact plate.
Tailgate contact switch

Page 4 of 4
Contact plate
Rear washer system
Pull the wiper lever right to the steering wheel to turn it on. The system operates until the
lever is released, after which the lever automatically returns to its rest position. The rear
washer draws its wash water from the same washer reservoir as the windshield washer (see
windshield washer system), and the water is also pumped by the same washer pump. In this
case the washer pump operates in the opposite direction of rotation to the direction for
washing the windshield. This means that the current flows in the opposite direction to when
washing the windshield: from the multi-function switch (connector C65b, pin 1) via the
washer pump back to the multi-function switch (connector C65b, pin 2). The latter makes the
ground connection when active.
Washer fluid level warning light
This consists of the following components:
- Washer fluid level warning light (in the instrument panel)
- Float-activated switch in the washer reservoir
- Auxiliary warning system module
The warning light comes on when the washer reservoir is only a quarter full. This is sensed by
a switch which is activated by a float in the washer reservoir. When there is sufficient fluid in
the washer reservoir the switch makes a connection to ground with one of the digital inputs
on the auxiliary warning module. It opens when the fluid level drops to a quarter full. This
then prompts the auxiliary warning module to switch on the washer fluid level warning light.
The warning light goes out when the washer fluid level is topped up and the switch in the
reservoir closes again.
Page 1 of 4

INSTRUMENT PANEL LOWER SECTION
UID=G311672
Removal
CAUTION: When removing or installing the instrument panel, care must be taken not
to scratch or damage the instrument panel surface.
1. Remove the instrument panel upper section.
For additional information, refer to Instrument
Panel Upper Section in this section.
2. Remove the climate controls. For additional
3. Remove the front door scuff plate (on both
sides).
4. Remove the front scuff plate (on both sides).
5. Remove the instrument panel side retaining

nut (on both sides).
6. Remove the center console side retaining

screw (on both sides).
7. Remove the center console front retaining nut.

Page 2 of 4
8. Remove the cigar lighter.

1. Detach the cigar lighter from the instrument
panel.
9. Remove the center console upper retaining

screw.
10. Remove the trinket compartment.

1. Release the trinket compartment stops.
2. Pull the trinket compartment rearwards.
11. Remove the instrument panel retaining

screws.
12. Remove the fuse box cover.

Page 3 of 4
13. Detach the fuse box from the instrument

panel.
14. Remove the passenger air bag deactivation

(PAD) switch (if equipped).
1. Detach the switch from the instrument
panel.
 Release the locking tang.

electrical connectors, to aid installation.
Remove the lighting switches.
1. Detach the switches from the instrument
panel.
2. Disconnect the electrical connectors.
16. Detach the diagnostic link connector (DLC)

from the instrument panel.
Page 4 of 4
17. Remove the instrument panel upper retaining

nuts.
18. Slide the instrument panel rearwards to

release the retaining clips.
19. Disconnect the passenger air bag
deactivation switch electrical connector (if
equipped).
20. Remove the instrument panel lower section.
Installation
1. NOTE: Make sure the front retaining clips
are fully engaged.
Page 1 of 1

UID=G314570
Removal
1. For additional information, refer to
Section 206-09A / 206-09B / 206-09C.
Page 1 of 1

SPECIFICATIONS
UID=G315044
Lubricants, sealants and adhesives
Material Specification
Refrigerant (R134a) WSH-M17B19-A
Refrigerant oil (SD6V12 A/C compressor for Diesel engine) WSH-M1C231-B
Refrigerant oil (FVS090 A/C compressor for Petrol engine) SP10
Refrigerant fill quantities
Grams
Air conditioning 650 ± 13
Refrigerant oil fill quantities
millilitres
Air conditioning 207
Addition of refrigerant oil when new components are installed
millilitres
Air conditioning compressor (if the amount of refrigerant oil taken from the add 90.
compressor is less than 90 ml)
Air conditioning compressor (if the amount of refrigerant oil taken from the Add same
compressor is between 90 ml and 120 ml)) quantity + 15.
Air conditioning compressor (if the amount of refrigerant oil taken from the Add the same
compressor is more than 120 ml) quantity.
Air conditioning condenser add 20.
Air conditioning evaporator add 20.
Renewal of all lines Add same
quantity +2.
Renewal of all lines and components add 0.
Always, if refrigerant was drained. Add the same
quantity.
Accumulator/dehydrator Add same
quantity +90.
Air conditioning clutch
mm
Clutch gap, A/C compressor 0,35 - 0,75
Tightening torques
Description Nm lb/ft lb/in

Bolt, A/C compressor drive plate 13 10 -
Page 1 of 3

AIR DISTRIBUTION SYSTEM
CLEANING
UID=G315089
General Equipment
Spray gun with hose
Name Specification
Odour eliminating agent (240
ml) (TOX Number 142040)
All vehicles
1. WARNING: Avoid contact with eyes

and skin; wear gloves and respiratory
protection. Ensure that you perform this
operation in a well ventilated room. Keep all
vehicle doors and windows open for the
duration of the operation. Do not inhale
vapors under any circumstances. Do not
smoke and avoid open fire and unprotected
light sources. Avoid contact with eyes and
skin; wear gloves and respiratory protection.
Ensure that you perform this operation in a
well ventilated room. Keep all vehicle doors
and windows open for the duration of the
operation. Do not inhale vapors under any
circumstances. Do not smoke and avoid open
fire and unprotected light sources. Failure to
observe this instruction can lead to injuries.
NOTE: The odour eliminating agent can
remove deposits in the heater housing but
cannot prevent odours that are distributed by
the ventilation system, for example those
caused by damp carpets.
Precisely locate the musty or damp odour.
2. Disconnect the low pressure switch connector.
3. Turn on the ignition.
4. NOTE: All ventilation nozzles must be
open.
Open all ventilation nozzles.
5. Set the temperature control to maximum
heating power.
6. Set the blower motor control switch to the
highest setting.
7. Set the air distribution control to the fresh air
position.
8. Start the engine and let it warm up to
operating temperature.
9. To dry out the system, switch off the air
conditioning system and ventilate the vehicle
for approx. 15 minutes.
Page 2 of 3
Vehicles with pollen filter

11. Remove the pollen filter. For additional
Vehicles without pollen filter

12. Fully open the glove compartment.
1. Press the sides towards the center to
release the glove compartment.
2. Pull the glove compartment out of the
hinges.
13. Remove the pollen filter housing cover.
All vehicles
14. Fill the spray gun with the odour eliminating
agent (240 ml).
15. WARNING: The maximum pressure

of 13.5 bar must not be exceeded. Failure to
observe this instruction can lead to injuries.
Use the tyre inflator to apply pressure of 5.5 to
10 bar (operating pressure) to the spray gun.
16. Insert the spray gun hose as far as possible
into the opening towards the evaporator.
17. By moving the hose, spray the odour
eliminating agent over the entire surface of the
evaporator.
18. Spray all of the odour eliminating agent into
the opening.
 Allow the odour eliminating agent to take

effect for 10 minutes.
19. Install the components in reverse order.
20. Start the engine, switch off the air
conditioning system and ventilate the vehicle
for approx. 15 minutes.
21. Open all ventilation nozzles.
22. Set the temperature control to maximum
heating power.
23. Set the blower motor control switch to the
Page 3 of 3
highest setting.
24. Set the air distribution control to the fresh air
position.
26. Connect the low pressure switch connector.
27. Ventilate the vehicle with the doors open for
another 30 minutes.
Page 1 of 1

SPECIFICATIONS
UID=G315093
Torque Specifications -

Nut, steering column flexible coupling 28 21 -
Bolts, in-vehicle crossbeam 20 15 -
Bolts, heater core and evaporator core housing to in-vehicle crossbeam 10 - 89
Nuts, heater core and evaporator core housing to in-vehicle crossbeam 10 - 89
Nut, heater core and evaporator core housing 1 - 9
Page 1 of 1

BLOWER MOTOR
UID=G315095
Removal
Vehicles with electric booster heater
1. Detach the electric booster heater wiring
harness bracket from the air inlet housing.

harness from the air inlet housing.
All vehicles
3. Disconnect the blower motor electrical
connector.
4. Remove the blower motor.

1. Remove the blower motor retaining screws.
Installation
Page 1 of 20

HEATER CORE AND EVAPORATOR
CORE HOUSING
UID=G315097
Special Tool(s)
Remover, quick-release coupling
1/2" (blue)
49 UN41 2027
5/8" (black)
49 JE01 069
Removal
All vehicles
03B.
00.
4. Detach the coolant hoses from the heater core.
5. Remove the retaining clips of the quick-release

couplings on the refrigerant lines.
6. Using the special tool, disconnect the left-hand

refrigerant line from the evaporator core.

Page 2 of 20
7. Using the special tool, disconnect the right-

hand refrigerant line from the evaporator core.
8. Unscrew and remove the nut from the heater

core and evaporator core housing.

10. Remove the rear footwell duct.
11. Remove the right-hand and left-hand rocker

panel cover.
12. Partially detach the right-hand and left-hand

door weatherstrip from the rocker panel.
Page 3 of 20
13. Remove the right-hand and left-hand A-pillar

trim panel.
1. Pull the A-pillar trim panel towards the front
door.
2. Pull the A-pillar trim panel upwards.
14. Remove the right-hand and left-hand

instrument panel side bezel.
15. Disconnect the air distribution blend door

actuating cable from the control mechanism at
the heater core and evaporator core housing.
 Detach the outer cable from the bracket.
16. Remove the left-hand footwell trim.
17. Disconnect the instrument panel wiring

harness left-hand electrical connectors (the
footwell trim is shown removed for clarity).
 Unclip the electrical connectors.

Page 4 of 20
18. Remove the left-hand glove compartment.
 Fully open the glove compartment and pull it

out of the hinges.
19. Fully open the right-hand glove

compartment.
2. Pull the glove compartment downwards.
20. Remove the right-hand glove compartment.
 Pull the glove compartment out of the hinges.
21. Remove the right-hand footwell trim.
22. Disconnect the instrument panel wiring

harness right-hand electrical connectors (the
 Unclip the electrical connectors.

Page 5 of 20

23. Disconnect the electric booster heater
All vehicles
24. Detach the fuse box from the in-vehicle
crossbeam.
25. Disconnect the central timer module electrical

connectors.
 Detach the wiring harness from the central

timer module.
26. Disconnect the blower motor and blower

motor resistor electrical connectors.
1. Detach the wiring harness from the heater
27. Disconnect the temperature blend door

Page 6 of 20
28. Disconnect the air inlet blend door actuating

cable from the control mechanism at the
heater core and evaporator core housing.
29. Disconnect the air bag control module

 Detach the wiring harness from the body.
30. Unscrew and remove the ground cable bolt

from the airbag module.
31. Disconnect the handbrake warning lamp

32. Mark the position of the in-vehicle crossbeam

relative to the A-pillars (left-hand side shown).
Page 7 of 20
33. Remove the caps (left side shown).
34. Remove the in-vehicle crossbeam side

retaining bolts.
35. NOTE: Make sure the rod wheels are in


3. Lift the steering column flexible coupling

from the steering gear pinion.
37. CAUTION: Position a suitable pad

under the heater core and evaporator core
housing to prevent damage to the heater core
and evaporator core housing.
Remove the left-hand heater core and evaporator
Page 8 of 20
core housing retaining nut.
38. Remove the blower motor housing retaining

screw.
39. Remove the right-hand heater core and

evaporator core housing retaining nut.
40. Remove the blower motor housing retaining

nut.
41. Remove the heater core and evaporator core

housing side retaining bolts (left side shown).
42. Remove the in-vehicle crossbeam lower

retaining bolts.
Page 9 of 20
43. Remove the right-hand and left-hand in-

vehicle crossbeam bracket.
44. Remove the in-vehicle crossbeam upper

retaining bolts.

instrument panel together with the in-vehicle
crossbeam is held in position with the aid of
another technician.
NOTE: Using a tire lever, lift the heater core
and evaporator core housing from the in-
vehicle crossbeam brackets.
Detach the instrument panel together with the in-
vehicle crossbeam from the body.
1. Lift the instrument panel together with the
in-vehicle crossbeam.
2. Pull the instrument panel together with the
in-vehicle crossbeam rearwards.
46. Detach the antenna cable from the right-
hand upper clip on the in-vehicle crossbeam
(instrument panel shown removed for clarity).
47. Detach the antenna cable from the right-

hand lower clips on the in-vehicle crossbeam.
Page 10 of 20
48. Detach the antenna cable from the central

clips on the in-vehicle crossbeam.

another technician.
Remove the instrument panel together with the
50. CAUTION: Make sure that the water

drain tube is not damaged when laying down
the housing.
Remove the heater core and evaporator core
housing.
Installation
All vehicles
1. CAUTION: Ensure that the adjustment

nut for the heater core and evaporator core
housing is freely accessible.
Screw on the adjustment nut for the heater core
and evaporator core housing (the heater core
and evaporator core housing seal is shown
1. Tighten the adjustment nut to the stop.
2. Undo the adjustment nut one turn.
2. CAUTION: Make certain that the

rubber grommet of the heater core and
evaporator core housing water drain tube is
correctly located in the vehicle floor.
Page 11 of 20
Install the heater core and evaporator core

housing.

another technician.
Install the instrument panel together with the in-
vehicle crossbeam.
4. Attach the antenna cable to the central clips on
the in-vehicle crossbeam.
5. Attach the antenna cable to the right-hand

lower clips on the in-vehicle crossbeam.
6. Attach the antenna cable to the right-hand

upper clip on the in-vehicle crossbeam
(instrument panel shown removed for clarity).
CAUTIONS:
7. Make sure that the instrument panel

together with the in-vehicle crossbeam is held
in position with the aid of another technician.
Make sure that the heater core and

evaporator core housing correctly locates into
the fixing points in the in-vehicle crossbeam.
Page 12 of 20
Attach the instrument panel together with the in-

vehicle crossbeam to the body.
1. Slide the instrument panel together with the
in-vehicle crossbeam forwards.
2. Lower the instrument panel together with
the in-vehicle crossbeam.
8. Align the in-vehicle crossbeam to the A-pillars

(left-hand side shown).
9. Install the the in-vehicle crossbeam upper

retaining bolts.
10. Install the right-hand and left-hand in-vehicle

crossbeam bracket.
11. Install the in-vehicle crossbeam lower

retaining bolts.
12. Install the side retaining bolts to the heater

core and evaporator core housing (left side
shown).
Page 13 of 20
13. Install the blower motor housing retaining

nut.
14. Attach the right-hand heater core and

15. Install the blower motor housing retaining

screw.
16. Install the left-hand heater core and

WARNINGS:
17. Install a new steering column shaft

to steering gear pinion retaining bolt. Failure
to follow this instruction may result in
personal injury.
Page 14 of 20
Make sure the steering column locking

lever is in the locked position. Failure to
injury.
gear pinion.
1. Lower the steering column flexible coupling
to the steering gear pinion.
2. Install the retaining bolt.
18. Install the in-vehicle crossbeam side retaining
bolts.
19. Install the caps (left side shown).
20. Connect the electrical connector to the

handbrake warning lamp switch.
21. Install the airbag module ground cable .
22. Connect the electrical connector to the airbag

module.
 Attach the wiring harness to the body.

Page 15 of 20
23. Connect the temperature blend door

actuating cable to the control mechanism at
 Attach the outer cable to the bracket.
24. Connect the air inlet blend door actuating

cable to the control mechanism at the heater
25. Connect the electrical connectors to the

blower motor and blower motor resistor.
1. Attach the wiring harness to the heater core
and evaporator core housing.
26. Connect the central timer module electrical

connectors.
 Attach the wiring harness to the central timer

module.
27. Attach the fuse box to the in-vehicle

crossbeam.
Page 16 of 20

28. Connect the electric booster heater electrical
connectors.
All vehicles
29. Connect the right-hand electrical connectors
of the instrument panel wiring harness (the
 Clip the electrical connectors.
30. Install the right-hand footwell trim.
31. Install the right-hand glove compartment.
 Push the glove compartment into the hinges.
32. Close the right-hand glove compartment.

1. Push the glove compartment upwards.
Page 17 of 20
2. Press the sides towards the center to attach

the glove compartment.
33. Install the left-hand glove compartment.
 Push the glove compartment into the hinges

and close it.
34. Connect the left-hand electrical connectors of

the instrument panel wiring harness (the
 Clip the electrical connectors.
35. Install the left-hand footwell trim.
36. Connect the air distribution blend door

actuating cable to the control mechanism at
37. Install the right-hand and left-hand

instrument panel side bezel.
Page 18 of 20
38. Install the right-hand and left-hand A-pillar

trim panel.
1. Push the A-pillar trim panel downwards.
2. Push the A-pillar trim panel towards the
windshield.
39. Attach the right-hand and left-hand door

weatherstrip to the rocker panel.
40. Install the right-hand and left-hand rocker

panel cover.
41. Install the rear footwell duct.
42. Install the floor console. For additional

43. Install the nut on the heater core and
evaporator core housing.
Page 19 of 20
44. NOTE: Lubricate the refrigerant line O-

ring seals with clean refrigerant oil before
installation.
Connect the right-hand refrigerant line to the
evaporator core.
 Install new refrigerant line O-ring seals.
45. NOTE: Lubricate the refrigerant line O-

ring seals with clean refrigerant oil before
installation.
Connect the left-hand refrigerant line to the
evaporator core.
 Install new refrigerant line O-ring seals.
46. Install the retaining clips on the quick-release

couplings on the refrigerant lines.
47. Attach the coolant hoses to the heater core.

49. Fill the air conditioning system. For additional
Page 20 of 20

03A / 303-03B.
Page 1 of 1

POLLEN FILTER
UID=G315101
Removal
1. Fully open the right-hand glove compartment.
2. Pull the glove compartment downwards.
2. Detach the central junction box (CJB) from the

3. Remove the pollen filter housing cover.
4. Remove the pollen filter.
Installation
Page 1 of 1

HEATER CORE
UID=G315102
Removal
housing. For additional information, refer to
Heater Core and Evaporator Core Housing in
this section.
housing gasket.
3. Remove the heater core cover.
4. Remove the coolant pipe bracket.
5. Remove the heater core.
Installation
Page 1 of 6

HEATER CORE AND EVAPORATOR
CORE HOUSING
UID=G315105
Disassembly
1. Detach the electric booster heater electrical
connector bracket from the air inlet housing.

harness bracket from the air inlet housing.

harness from the air inlet housing.
All vehicles
4. Remove the duct.
1. Unclip the retaining clips.
5. Remove the air inlet housing retaining screw.

Page 2 of 6
6. Remove the air inlet housing.

housing seal.
8. Remove the coolant pipe bracket.
9. Remove the heater core cover.
10. Remove the heater core.

Page 3 of 6
11. Remove the evaporator core refrigerant lines

bracket.

housing front retaining screws.

housing lower retaining screws.

housing rear retaining screws.
15. Unclip the heater core and evaporator core

housing retaining clips.
 Cut the seal.

Page 4 of 6
16. Separate the heater core and evaporator core

housing.
1. Cut the seal.
2. Separate the housing.
17. Remove the evaporator core refrigerant lines.
 Detach the seal from the refrigerant lines.
18. Remove the evaporator core.
19. Remove the center nozzles and defrost

nozzles air distribution blend doors.
20. Remove the temperature blend door.

Page 5 of 6
21. Remove the foodwell air distribution blend

door.
22. Remove the blower motor resistor.
24. Remove the pollen filter cover.

Page 6 of 6
26. Remove the air inlet housing lower retaining

screws.
27. Remove the air inlet housing upper retaining

screws.
2. Unclip the retaining clip.
28. Separate the air inlet housing.
29. Remove the air inlet blend door.
Assembly
1. To assemble, reverse the disassembly
procedure.
Page 1 of 1

SPECIFICATIONS
UID=G315107
A/C compressor
Type
A/C compressor (vehicles with diesel engine) SD6V12 (Sanden)
A/C compressor (vehicles with petrol engine) FVS 090
Evaporator core orifice
Colour
Evaporator core orifice red
Tightening torques
Description Nm lb.ft lb.in

Bolt, refrigerant line to A/C compressor 20 15 -
Bolt, A/C compressor 20 15 -
Bolt, A/C compressor drive plate 13 10 -
High-pressure cutoff switch 8 - 71
Low-pressure cutoff switch 2.5 - 23
Nut, refrigerant line to condenser core 8 - 71
Bolt, suction accumulator 8 - 71
Page 1 of 3

EVAPORATOR CORE
UID=G315109
Removal
housing. For additional information, refer to
Section 412-02A / 412-02B.
2. Remove the duct.
3. Remove the air inlet housing retaining screw.
4. Remove the air inlet housing.

housing seal.
6. Remove the evaporator core refrigerant lines

bracket.
Page 2 of 3

housing front retaining bolts.

housing lower retaining bolts.

housing rear retaining bolts.
10. Unclip the heater core and evaporator core

housing retaining clips.
 Cut the seal.
11. Separate the heater core and evaporator core

housing.
1. Cut the seal.
2. Separate the housing.
Page 3 of 3
12. Remove the evaporator core refrigerant lines.
 Detach the seal from the refrigerant lines.
13. Remove the evaporator core.
Installation
Page 1 of 2

EVAPORATOR CORE ORIFICE
UID=G315115
Special Tool(s)
Remover, quick-fit connector
1/2" (blue)
49 UN41 2027
Remover/installer, evaporator
core orifice
49 UN41 2034
Remover, faulty evaporator core
orifice
49 UN41 2035
Removal
1. Remove the air cleaner housing. For additional
00.
3. Remove the refrigerant line quick release
coupling retaining clip.
4. CAUTION: Cap the refrigerant line and

the evaporator core to prevent dirt ingress.
Using the special tool, disconnect the refrigerant
line from the evaporator core.
5. Remove the refrigerant line quick release

coupling retaining clip .
Page 2 of 2
6. CAUTION: Cap the refrigerant lines to

Using the special tool, remove the refrigerant line
with the evaporator core orifice.
7. Using the special tool, remove the evaporator

core orifice.
 Hook the special tool into the evaporator core

orifice, turn it clockwise and pull out the
evaporator core orifice.
8. NOTE: This step is only necessary if the

evaporator core orifice is faulty.
Using the special tool, remove the faulty
evaporator core orifice.
Installation
seals.
NOTE: Lubricate the refrigerant line O-ring
seals with clean refrigerant oil before
installation.
Page 1 of 3

CONDENSER CORE
UID=G315118
Removal
1. Connect the upper service unit line to the A/C
charging connection.
3. Detach the right-hand fender splash shield
from the front bumper cover.
4. Remove the right-hand fender splash shield.

00.
6. Disconnect the radiator fan resistor electrical
connector.
7. Disconnect the radiator fan electrical

connector.
8. Unclip the radiator fan from the left-hand clip.

1. Pull back the clip.
Page 2 of 3
2. Press the radiator fan out of the clip.
9. Remove the radiator fan.

1. Pull back the clip.
2. Press the radiator fan out of the clip and
remove it.
10. Remove the radiator bracket bolts (right-

hand side shown).
1. Remove the security bolts.
2. Unscrew the bolts.
11. Remove the radiator rubber insulators.
12. CAUTION: Cap the refrigerant lines

and the condenser core to prevent dirt
ingress.
Detach the refrigerant lines from the condenser
core.
13. Detach the radiator and condenser core from

the front panel.
Page 3 of 3
14. CAUTION: Do not damage the foam

seals of the condenser core.
Remove the condenser core.
Installation
1. CAUTION: Do not damage the foam

seals of the condenser core.
NOTE: Install new refrigerant line O-ring
seals.
installation.
Page 1 of 4

AIR CONDITIONING (A/C)
COMPRESSOR — 1.25L/1.4L/1.6L
UID=G315119
Removal
00.
3. Disconnect the A/C compressor clutch
 Detach the wiring harness from the bracket.

and the A/C compressor to prevent dirt
ingress.
Disconnect the refrigerant lines from the A/C
compressor.
5. Remove the A/C compressor together with the

clutch and clutch field coil.
 Position the power steering line to one side.
6. Remove the A/C compressor drive plate.
7. Remove the A/C compressor pulley.
 Remove the shims.

Page 2 of 4
8. NOTE: Mark the position of the A/C

compressor clutch electrical connector in
relation to the A/C compressor housing.
Remove the A/C compressor.
 Using a two leg puller, remove the clutch field

coil.
Installation
NOTE: Do not skew the clutch field coil when installing it to the A/C compressor seat.
1. Using a M6 x 30 mm bolt, a suitable washer
and the A/C compressor drive plate, install the
clutch field coil.
2. Remove the M6 x 30 mm bolt, washer and A/C

Page 3 of 4
compressor drive plate.
 Install the shims.

3. NOTE: Install a new A/C compressor pulley
snap ring.
Install the A/C compressor pulley.
4. Install the A/C compressor drive plate.
5. Check the A/C clutch air gap. For additional

6. Install the A/C compressor together with the
clutch and clutch field coil.
7. NOTE: Lubricate the refrigerant line O-ring

installation.
NOTE: Install new O-ring seals on the
refrigerant lines.
Connect the refrigerant lines to the A/C
compressor.
8. Connect the A/C compressor clutch electrical

connector.
 Attach the wiring harness to the bracket.

Page 4 of 4
9. Install the auxiliary drive belt. For additional

10. Fill the A/C system. For additional
Page 1 of 2

SUCTION ACCUMULATOR
UID=G315120
Special Tool(s)
3/4" (white)
49 JE02 028
Removal
1. Connect the upper service unit line to the A/C
charging connection.
3. Detach the right-hand fender splash shield
from the front bumper cover.
4. Remove the right-hand fender splash shield.

00.
6. Disconnect the low-pressure cutoff switch
for clarity).
7. Remove the retaining clips from the quick-

release couplings on the refrigerant lines.
Page 2 of 2

and the suction accumulator to prevent dirt
ingress.
Using the special tool, disconnect the upper
refrigerant line from the suction accumulator.

and the suction accumulator to prevent dirt
ingress.
Using the special tool, disconnect the lower
refrigerant line from the suction accumulator.
 Unclip the refrigerant line.

10. Remove the suction accumulator.
Installation
seals.
installation.
Page 1 of 1

HIGH-PRESSURE CUTOFF SWITCH
UID=G315123
Removal
2. Disconnect the high-pressure cutoff switch
3. WARNING: Make sure that the high-

pressure cutoff switch valve closes completely
after removal of the high-pressure cutoff
switch to prevent loss of refrigerant. Failure
personal injury.
Remove the high-pressure cutoff switch.
Installation
1. NOTE: Install new high-pressure cutoff
switch O-ring seals.
NOTE: Lubricate the high-pressure cutoff
switch O-ring seals with clean refrigerant oil
Page 1 of 3

CLIMATE CONTROL ASSEMBLY
UID=G315125
Removal
1. Remove the audio unit side retaining screw.
2. Remove the left-hand glove compartment.
 Fully open the glove compartment and pull it

out of the hinges.
3. Disconnect the air inlet blend door actuating

cable from the control mechanism at the
heater core and evaporator core housing.
4. Disconnect the temperature blend door

5. Disconnect the air distribution blend door


Page 2 of 3
6. Remove the
rotary
switches
and the
recirculation
actuating
switch.
7. Remove the instrument panel console retaining

screws.
8. Detach the instrument panel console from the

instrument panel.
9. Remove the instrument panel console.
10. Disconnect the climate control assembly

11. Remove the climate control assembly.

Page 3 of 3
Installation
Page 1 of 2

BLOWER MOTOR SWITCH
UID=G315126
Removal
1. Remove the audio unit side retaining screw.
2. Remove the
rotary
switches
and the
recirculation
actuating
switch.
3. Remove the instrument panel console retaining

screws.
4. Detach the instrument panel console from the

instrument panel.
5. Remove the instrument panel console.

Page 2 of 2
6. Disconnect the blower motor switch electrical

connector.
Installation
1. CAUTION: Make sure that the blower

motor switch is correctly seated in the fixing.
Page 1 of 2

HEADLAMP ADJUSTMENT
UID=G315129
General Equipment
Beam setting equipment
1. Place the vehicle on a level surface.
2. Check that the tyre pressures meet the
specifications and that the vehicle is not
excessively laden.
3. Switch on the dipped beam.
4. Repeatedly operate the headlamp levelling
switch and then set it to "0".
5. Set up the measuring screen of the beam
setting device to the correct headlamp setting
value.
6. Adjust the dipped beam so that the light/dark
boundary touches the horizontal line.
7. NOTE: A diffused part of the dipped beam

may lie above the 15° line.
Adjust the dipped beam so that the rising line of
the light/dark boundary lies in the intersection
point of the horizontal line and the 15° line
(LHD variant shown).
Page 2 of 2
Page 1 of 6

HEADLAMP MASKING
UID=G315130
All vehicles
NOTE: The templates are different for LHD and RHD vehicles. The templates are different
for the left and right-hand headlamps.
1. Print out the corresponding templates at the
end of this operation.
2. Measure dimension X on the printout of the
template.
3. Calculate the enlargement/reduction factor Y
for the photocopier using the following
formula: Y=Z÷X×100.
 X = measurement on the printout of the

template in mm
 Y = enlargement/reduction factor in %
 Z = original dimension in mm = 25
4. Enlarge/reduce the printout with a photocopier
by the calculated percentage.
 Compare dimension X on the photocopy with

the original dimension.
5. Cut out the prepared template for the
headlamp.
6. Cut out the shaded areas and the center point.
LHD vehicles
7. NOTE: Right-hand headlamp only.
Align the template on the lens of the headlamp.
1. Template
2. Area to be masked
3. Alignment edges on the headlamp lens
4. center point on the headlamp lens
8. NOTE: Left-hand headlamp only.

1. Template
RHD vehicles
Page 2 of 6
9. NOTE: Right-hand headlamp only.

1. Template
10. NOTE: Left-hand headlamp only.

1. Template
All vehicles
11. CAUTION: Do not damage the

surface of the headlamp.
Copy the outline of the template with a suitable
pen onto the headlamp lens.
12. Remove the template.
13. NOTE: Make sure that the marked area is
not exceeded.
Mask the marked area with opaque black
adhesive tape.
14. Repeat steps 11 to 13 for the headlamp on
the other side.
15. Template
for LHD
vehicles,
right-hand
headlamp
1.
Alignment
edge
2. Center
point
3. Template
Page 3 of 6
16. Template
for LHD
vehicles,
left-hand
headlamp
1.
Alignment
edge
2. Center
point
3. Template
Page 4 of 6
17. Template
for RHD
vehicles,
right-hand
headlamp
1.
Alignment
edge
2. Center
point
3. Template
Page 5 of 6
18. Template
for RHD
vehicles,
left-hand
headlamp
1.
Alignment
edge
2. Center
point
3. Template
Page 6 of 6
Page 1 of 1

FRONT FOG LAMP ADJUSTMENT
UID=G315131
General Equipment
Beam setting equipment
1. Place the vehicle on a level surface.
2. Check that the tyre pressures meet the
specifications and that the vehicle is not
excessively laden.
3. Switch on the front fog lamps.
4. Set up the measuring screen of the beam
setting device to the correct setting value for
the front fog lamps.
5. Adjust the front fog lamps so that the
light/dark boundary touches the horizontal
line.
1. Loosen the front fog lamp lower retaining
screw.
2. Adjust the front fog lamp.
6. Thighten the front fog lamp lower retaining

screw.
Page 1 of 1

FRONT FOG LAMP
UID=G315135
Removal
2. NOTE: This step is only necessary for the
removal of the right front fog lamp.
Remove the right-hand fender splash shield lower
retaining screws.
3. Disconnect the front fog lamp electrical

connector.
4. Remove the front fog lamp assembly.
Installation
2. Adjust the front fog lamps.For additional
information, refer to Front Fog Lamp
Page 1 of 2

HEADLAMP ASSEMBLY
UID=G315136
Removal
1. Remove the headlamp assembly upper
retaining screws.
2. Remove the front bumper cover upper

retaining clips.
3. Remove the right-hand and left-hand splash

shield front retaining clips (right-hand side
shown).
4. Detach the front bumper cover from the front

fender (right-hand side shown).
 Pull the front bumper cover forwards and

secure it .
5. Remove the headlamp assembly lower

retaining screws.
Page 2 of 2
6. Remove the headlamp assembly.
 Disconnect the headlamp assembly electrical

connector.
Installation
1. NOTE: Clean the lens with a damp cloth to
prevent the build-up of electrostatic charge,
which could cause dust to stick to the plastic
lens.
2. Adjust the headlamps. For additional
information, refer to Headlamp Adjustment in
this section.
Page 1 of 1

REAR LAMP ASSEMBLY
UID=G315137
Removal
1. Remove the loadspace cover.
2. Lower the rear seat backrest.
3. Remove the loadspace trim panel.
4. Disconnect the rear lamp assembly electrical

connectors.
5. Remove the rear lamp assembly retaining nut.
6. Remove the rear lamp assembly.
 Release the rear lamp assembly from the

retaining clips.
Installation
Page 1 of 2

REVERSING LAMP
UID=G315142
Removal
1. Remove the tailgate trim panel lower retaining
clips.
2. Remove the tailgate trim panel.

3. Disconnect the reversing lamp electrical

connector.
4. Remove the reversing lamp retaining nuts.
5. Remove the reversing lamp.

Page 2 of 2
Installation
Page 1 of 1

WIPER BLADE AND PIVOT ARM
ADJUSTMENT
UID=G315144
Special Tool(s)
Aligner, Wiper Arm
49 JE01 068
Adjustment
1. CAUTION: Make sure that the wiper

motor is in the park position.
Remove the wiper blade.
2. Insert the wiper arm in the special tool and
place the special tool on the windshield.
3. NOTE: All three support points of the
special tool must be in contact with the glass.
Using the special tool, read off the angle between
the wiper arm and the windshield.
4. NOTE: Lift the special tool away from the

glass when correcting the angle, in order to
prevent damage.
Using the special tool, check and adjust the wiper
arm. For additional information, refer to
Specifications in this section.
 Using an open-ended wrench on the special

tool, adjust the angle.

6. Install the wiper blade.
Page 1 of 2

WINDSHIELD WASHER PUMP
UID=G315146
Removal
1. Raise the vehicle. For additional information,
2. Remove the left-hand fender splash shield
lower retaining screws.
3. Remove the left-hand fender splash shield.
4. Disconnect the windshield washer pump

5. Disconnect the windshield washer pump hoses.
6. Remove the windshield washer pump.

Page 2 of 2
Installation
1. NOTE: Lubricate the windshield washer
pump grommet with soapsuds before
installation.
Page 1 of 2

WINDSHIELD WASHER RESERVOIR —
VEHICLES BUILT FROM: 10/2002
UID=G315148
Removal
1. Remove the windshield washer reservoir upper
retaining bolt.
2. Remove the windshield washer reservoir

centre retaining bolt.
3. Disconnect the hoses from the windshield

washer reservoir.

5. Remove the left-hand fender splash shield
lower retaining screws.
6. Remove the left-hand fender splash shield.

Page 2 of 2
7. Disconnect the windshield washer pump

8. Remove the windshield washer reservoir.
Installation
Page 1 of 2

REAR WINDOW WIPER MOTOR —
UID=G315149
Removal
1. CAUTION: Make sure that the rear

window wiper motor is in the park position.
Remove the rear window wiper arm.
2. Remove the tailgate trim panel lower retaining

clips.
3. Remove the tailgate trim panel.

1. Unscrew the retaining screw.
4. Disconnect the rear window wiper motor

 Disconnect the electrical connector from the

bracket.
5. Remove the rear window wiper motor.

Page 2 of 2
Installation
1. CAUTION: Make sure that the rear

window wiper motor is in the park position
before installing the rear window wiper arm.
Page 1 of 1

SPECIFICATIONS
UID=G316378
Angle of wiper arms to windshield
Description Angle
Front wiper arm driver side (left hand drive vehicle) -4.2°
Front wiper arm passenger side (LHD) -3.7°
Front wiper arm driver side (right hand drive vehicle) 4.2°
Front wiper arm passenger side (RHD) 3.7°
Rear wiper arm -4.2°

Windshield wiper arm retaining nut 27 20 -
Water guide retaining screws 6 - 53
Cross brace retaining screws 10 - 89
Windshield wiper motor assembly bracket retaining screws 10 - 89
Windshield wiper motor assembly retaining screws 10 - 89
Rear window wiper arm retaining nut 8 - 71
Rear window wiper motor retaining screws 8 - 71
Page 1 of 2

WINDSHIELD WIPER MOTOR
UID=G316379
Removal

windshield wiper motor is in the park
position.
Remove the windshield wiper arms.
 Remove the blanking caps.
2. Remove the air cowl grille.
3. Remove the water guide.
 Disconnect the windshield washer hose and

detach it from the water guide.
 Remove the windshield wiper grommets.
4. Detach the cross brace from the bracket for

the windshield wiper motor assembly and
5. Detach the windshield wiper motor assembly

with bracket from the water drain panel.
Page 2 of 2
6. Disconnect the windshield wiper motor

electrical connector and remove the windshield
wiper motor assembly with bracket.
 Unclip the wiring harness.
7. Remove the windshield wiper motor assembly.
Installation

windshield wiper motor is in the park position
before installing the wiper arms.
Page 1 of 4

TERMINOLOGY GLOSSARY
UID=G323325
This manual has been developed using Ford global terminology.
The following cross-reference tables list the Mazda term and the equivalent Ford term, to
assist in the use of this manual.
100-00
Mazda Ford
How To Use This Manual About This Manual
204-00
Mazda Ford
Wheel Alignment (includes toe adjustment) Front Toe Adjustment
204-01
Mazda Ford
Shock Absorber and Spring Strut and Spring Assembly
Steering Knuckle Wheel Knuckle
204-02
Mazda Ford
Torsion Beam Axle Beam Axle
205-04
Mazda Ford
Drive Shaft Halfshaft
Drive Shaft Inner Constant Velocity (CV) Joint BootOuter Constant Velocity (CV) Joint
Boot Boot
206-00
Mazda Ford
Air Bleeding Brake System Bleeding
Brake Fluid Pressure Sensor Fluid Pressure Sensor
206-03
Mazda Ford
Disc Pad (Front) Brake Pads
206-05
Mazda Ford
Parking Brake Lever Adjustment Parking Brake Cable Adjustment
206-07
Mazda Ford
Power Brake Unit Brake Booster
Vacuum Pump Brake Vacuum Pump
Page 2 of 4
206-09
Mazda Ford
Anti-Lock Control Antilock Brake System
206-09A
Mazda Ford
ABS HU/CM Hydraulic Control Unit (HCU)
ABS Wheel-speed Sensor (Rear) Rear Wheel Speed Sensor
ABS Wheel-speed Sensor Ring (Rear) Rear Wheel Speed Sensor Ring
206-09B
Mazda Ford
TCS Anti-Lock Control - Traction Control
211-00
Mazda Ford
Air Bleeding Power Steering System Bleeding
211-03
Mazda Ford
Steering Gear and Linkage Steering Gear
211-05
Mazda Ford
Outer Cylinder Ignition Lock Cylinder
303-01
Mazda Ford
Cylinder Head Cover Valve Cover
Front Oil Seal Crankshaft Front Seal
Rear Oil Seal Crankshaft Rear Seal
303-03
Mazda Ford
Cooling System Engine Cooling
303-05
Mazda Ford
Drive Belt Accessory Drive Belt
303-13
Mazda Ford
Charcoal Canister Evaporative Emission Canister
308-00
Mazda Ford
Air Bleeding Clutch System Bleeding
Shift/Select Cable Adjustment Gearshift Cable Adjustment
Page 3 of 4
Shift/Select Cables Gearshift Cables

412-00
Mazda Ford
Evaporator Evaporator Core
Handling Refrigerant Contaminated Refrigerant Handling
Heater and Air Conditioning Climate Control System
System
Oil Leakage Inspection Fluorescent Dye Leak Detection
Refrigerant System Service Air Conditioning (A/C) System Recovery, Evacuation and
Procedures Charging
412-03
Mazda Ford
A/C Air Conditioning
Condenser Condenser Core
414-01
Mazda Ford
Fuse Block Battery Junction BoxCentral Junction Box
Shield Wire Shield
415-02
Mazda Ford
Antenna Cable Antenna Feeder
417-01
Mazda Ford
Back-up Light Reversing Lamp
Brake Lights Stop Lamps
Front Fog Light Aiming Adjustment Front Fog Lamp Adjustment
Headlight Aiming Headlamp Adjustment
Rear Combination Light Rear Lamp Assembly
Tail Number Side Relay Taillamp and Sidelight Relay
417-04
Mazda Ford
Running Light Daytime Running Lamps (DRL)
418-00
Mazda Ford
Multiple Communication System Communications Network
419-01
Mazda Ford
PATS Anti-Theft - Passive
501-02
Mazda Ford
Page 4 of 4
Shroud Panel Radiator Grille Opening Panel

501-09
Mazda Ford
Power Outside Mirror Exterior Mirror
501-11
Mazda Ford
Front Door Power Window Motor Front Door Window Regulator Motor
Manual/Power Window Regulator (Front) Front Door Window Regulator
Manual/Power Window Regulator (Rear) Rear Door Window Regulator
Quarter Window Glass Rear Quarter Window Glass
Rear Door Power Window Motor Rear Door Window Regulator Motor
Rear Door Quarter Glass Rear Door Fixed Window Glass
Rear Window Glass Liftgate Window Glass
501-12
Mazda Ford
Dashboard Instrument Panel
Dash Lower Panel Instrument Panel Lower Section
Dash Upper Panel Instrument Panel Upper Section
501-14
Mazda Ford
Liftgate Latch and Lock Actuator Liftgate Latch
Liftgate Outer Handle Liftgate Release Handle
Outer Handle (Front) Exterior Front Door Handle
Outer Handle (Rear) Exterior Rear Door Handle
Rear Door Latch And Lock Actuator Rear Door Latch
501-16
Mazda Ford
Washer Motor Windshield Washer Pump
501-19
Mazda Ford
Front Bumper Front Bumper Cover
Front Bumper Reinforcement Front Bumper
Rear Bumper Rear Bumper Cover
501-20B
Mazda Ford
Air Bag System Air Bag and Safety Belt Pretensioner Supplemental Restraint System
(SRS)
Crash Zone Crash Sensor
Sensor
SAS Unit Air Bag Control Module
Page 1 of 1

EXHAUST MANIFOLD
UID=G323368
Removal
1. Remove the turbocharger. For additional
04B / 303-04C.
2. Remove the catalytic converter. For additional
3. Remove the exhaust manifold retaining nuts
and spacers.
4. NOTE: It is necessary to remove the

exhaust manifold studs in order to allow for
sufficient space to remove the exhaust
manifold
Remove the exhaust manifold studs and remove
the exhaust manifold.
 Discard the studs and the gasket.
Installation
1. NOTE: Install new exhaust manifold studs,
exhaust manifold retaining nuts and exhaust
manifold gasket.
Page 1 of 2

OIL PAN
UID=G323369
Name Specification
Oil ACEA A3/B3. Viscosity: 5W30, 10W40,
genuine DEXELIA oil
Removal
2. Drain the engine oil.
3. NOTE: Do not install a new oil drain plug
seal at this stage.
4. Remove the oil pan retaining bolts and nuts

(16 bolts, two nuts).
5. CAUTION: Do not distort the oil pan.

Using a suitable spatula, remove the oil pan.
 Slide the spatula around the profile of the oil

pan.
Installation
oil pan and lower crankcase mating faces.
Page 2 of 2
2. CAUTION: Install the oil pan within

of the oil pan.
3. Install the oil pan (16 bolts, two nuts).
4. Remove the oil drain plug.

5. NOTE: Install a new oil drain plug seal.

Page 1 of 5

OIL PUMP
UID=G323370
General Equipment
Trolley jack
Wooden blocks
Name Specification
Removal
section.
2. Install the engine front mount support bracket.
3. Install the engine front mount.
4. Remove the oil pan. For additional information,

5. Disconnect the crankshaft speed sensor
6. Remove the crankshaft speed sensor.

Page 2 of 5
7. Remove the crankshaft pulley Woodruff key.
8. Remove the oil pan stud.
9. Remove the oil pump pickup tube.
Installation
mating faces of the lower crankcase and the
cylinder block.
Page 3 of 5
CAUTIONS:

enter the lower crankcase and the cylinder
block blind holes. Failure to follow this
engine assembly.
Install the oil pump within 4 minutes of

applying the sealer.
of the lower crankcase and the cylinder block.
3. NOTE: A new oil pump is supplied with an
oil seal alignment sleeve that must be
removed following installation.
 Discard the alignment sleeve.
4. NOTE: Install a new oil pump pickup tube

O-ring seal.
Install the oil pump pickup tube.
5. Install the oil pan stud.
6. Install the crankshaft pulley Woodruff key.

Page 4 of 5
7. Install the crankshaft speed sensor.
8. Connect the crankshaft speed sensor electrical

connector.
9. Install the oil pan. For additional information,


Using a trolley jack with suitable wooden blocks,
support the engine.
12. Remove the engine front mount support

bracket.
Page 5 of 5

section.
Page 1 of 1

SPECIFICATIONS
UID=G323371
Specifications
Manual transmission Manual transmission oil SAE 75W90 or transmission oil meeting
fluid WSD-M2C200-C
High melting point Molybdenum disulfined grease
grease
Super DOT4 brake fluid
Capacities
Litres
Manual transmission fluid: 5 - 10 mm below the lower edge of the fluid filler plug 2.3
Clutch Dimensions
Description mm
Pedal travel 135 ± 5
Worn clutch disc discard thickness* 7
Clutch disc diameter: 1.25L 180
Clutch disc diameter: 1.4L Diesel 210
* When the discard thickness has been reached, install a new clutch disc.
Page 1 of 1

CLUTCH SYSTEM BLEEDING —
VEHICLES WITH: AUTOMATED
GEARSHIFT
UID=G323372
General Equipment
Hand vacuum/pressure pump
Name Specification
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush
the eyes for 15 minutes with cold running water. Get medical attention if irritation
persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately. Failure to follow these instructions may result in personal injury.
2. Check the fluid level in the brake fluid
reservoir and top up to the MAX mark with
Super DOT 4 brake fluid, if necessary.
3. NOTE: Make sure that the hand
vacuum/pressure pump reservoir is
positioned lower than the bleed nipple.
Install a suitable hand vacuum/pressure pump to
the clutch bleed nipple.
4. NOTE: When the WDS gearshift actuator
Using the hand vacuum/pressure pump and the
worldwide diagnostic system (WDS), bleed the
clutch system.
5. Check the fluid level in the brake fluid
reservoir and top up to the MAX mark with
Super DOT 4 brake fluid, if necessary.
Page 1 of 2

HYDRAULIC LASH ADJUSTER
UID=G323470
Name Specification
oil ACEA A3/B3. Viscosity: 5W30, 10W40,
genuine DEXELIA oil
Removal
1. Remove the camshaft. For additional
information, refer to Camshaft in this section.

Remove the camshaft roller follower.
3. CAUTION: Keep the hydraulic lash

adjusters in order for installation.
Remove the hydraulic lash adjuster.
Installation
1. Coat the hydraulic lash adjuster with clean
engine oil.
2. Install the hydraulic lash adjuster.
3. Install the camshaft roller follower.

Page 2 of 2
4. Install the camshaft. For additional

information, refer to Camshaft in this section.
Page 1 of 20

CLIMATE CONTROL SYSTEM
UID=G323473
SERVICE WARNINGS
WARNINGS:
Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate
eyes, nose and throat. Also, due to environmental concerns, we urge use of
recovery/recycling/recharging equipment when draining R-134a from the air conditioning
system. If accidental system discharge occurs, ventilate work area before resuming
service.
Do not perform pressure test or leak test for R-134a service equipment and/or
vehicle air conditioning system using compressed air. Some mixtures of air and R-134a
have been shown to be combustible at elevated pressures. These mixtures, if ignited,
may cause injury or property damage. Additional health and safety information may be
obtained from refrigerant manufacturers.
Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas
may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and
heaters. When carrying out any operation that can cause refrigerant leakage, extinguish
or remove the above-mentioned heat sources and maintain adequate ventilation.
Handling liquid refrigerant is dangerous. A drop of it on the skin can result in

localized frostbite. When handling the refrigerant, wear gloves and safety goggles. If
refrigerant splashes into the eyes, immediately wash them with clean water and consult a
doctor.
SERVICE CAUTIONS
CAUTION: If an insufficient refrigerant level is detected at troubleshooting, do not

charge (add) the refrigerant. Because an accurate amount of refrigerant cannot be
determined from the pressure indicated on the manifold gauge, never charge the
refrigerant. If there is too much or too little refrigerant from the refilling, there may be
secondary problems such as damage to the refrigerant cycle parts, or a decrease of
cooling performance. Therefore, if it is determined that the refrigerant level is insufficient,
completely remove refrigerant from the refrigerant cycle and refill with refrigerant to the
specified amount.
REFRIGERANT SYSTEM SERVICE PROCEDURES
REFRIGERANT PRESSURE CHECK
1. Install the SSTs (gas charging set).
2. Warm up the engine and run it at a constant 1,500 rpm.
3. Set the blower motor speed to MAX HI.
4. Turn the A/C switch ON.
5. Set the RECIRCULATE mode.
6. Set the temperature control to MAX COLD.

Page 2 of 20
7. Set the VENT mode.
8. Close all the doors and all the windows.
9. Measure the ambient temperature and the high- and low-pressure side reading of the SST.
10. Verify that the intersection of the pressure reading of the SST and ambient temperature
is in the zone between the lines.
* If there is any malfunction, troubleshoot the refrigerant system. (See

troubleshooting index)
Specified values for high-pressure
Coordinate axis Description

1 High-pressure (bar)
2 Outside temperature (°C)
Specified values for low-pressure
Coordinate axis Description

1 Low-pressure (bar)
2 Outside temperature (°C)
REFRIGERANT SYSTEM PERFORMANCE TEST
1. Perform refrigerant pressure check
* If they are correct, go to next step.
* If there is any malfunction, troubleshoot the refrigerant system.
2. Place a thermometer in the driver-side center ventilator outlet.
3. Warm up the engine and run constant 1,500 rpm.

Page 3 of 20
4. Set the heater blower speed to MAX HI.
5. Turn the A/C switch on.
6. Set the RECIRCULATE mode.
7. Set the temperature control to MAX COLD.
8. Set the VENT mode.
9. Close all the doors and windows.
10. Wait until the air conditioner output temperature stabilizes. (For stabilization let the
engine run with the settings above for approx. 10 min.)
11. Record driver-side center ventilator outlet temperature.
12. Determine and record ambient temperature.
13. Verify that the temperature reading is in the zone between the lines.
* If the performance is not in the zone between the lines, troubleshoot the
refrigerant system. (See TROUBLESHOOTING INDEX.)
BASIC SYSTEM
POLLEN FILTER INSPECTION
2. Inspect the pollen filter.
* If the pollen filter is damaged, excessively dirty or full smelling, replace the
pollen filter.
NOTE: The pollen filter cannot be reused by cleaning it with water or compressed air.
EVAPORATOR CORE INSPECTION
1. Remove the heater core and evaporator core housing.
2. Remove the evaporator from the heater core and evaporator core housing.
3. Inspect for cracks, damage and oil leakage.
* If any problems are found, replace the evaporator.

Page 4 of 20
4. Inspect for bent fins.
* If any are bent, use a flathead screwdriver to straighten them.
HEATER CORE INSPECTION
1. Remove the heater core and evaporator core housing.
2. Remove the heater core from the heater core and evaporator core housing.
3. Inspect for cracks, damage and coolant leakage.
* If any problems are found, replace the heater core.
5. Verify that the heater core inlet and outlet pipe are not distorted or damaged.
* Repair with pliers if necessary.
CONDENSER INSPECTION
1. Inspect for cracks, damage and oil leakage.
* If any are found, replace the condenser.
2. Inspect for fins clogged by dust.
* If any are clogged, remove the dust from the fins.
CONTROL SYSTEM
CLIMATE CONTROL MODULE INSPECTION
(Vehicles with audio system)
1. Connect the all center panel connectors.
2. Turn the ignition switch to ON position.
3. Measure the voltage at each climate control module terminal and refer to the terminal
voltage list.
* If not as specified, inspect the parts listed under "Action" and the related wiring
harness.
* If there is any malfunction, replace the climate control module.

Page 5 of 20
Terminal Voltage List (Reference)
Connected Test Voltage

Terminal Signal Action
to condition (V)
* Inspect for continuity or
short circuit (Climate
Rear
control module — heated
window
V batt rear window relay: B—W/L)
defroster
Rear Heated switch is off
* Inspect heated rear
window rear
B window relay
defroster window
Rear 1 V or * Inspect terminal voltage
SW signal relay
window less of climate control module
defroster (L, K)
switch is on
* Inspect audio switch
panel
D A/C A/C cycling Blower V batt * Inspect for continuity or
switch motor short circuit (Climate
switch OFF control module—A/C cycling
switch: D — R/B) (A/C
cycling switch—dual
pressure switch: B/R —
B/R) (Dual pressure
switch—PCM: R/W — AO
(Vehicles with diesel
engine: R/B — 1C))
* Inspect A/C cycling switch
* Inspect dual pressure

switch
* Inspect refrigerant
amount
* Inspect PCM terminal

voltage (AO (Vehicles with
diesel engine: 1C))
Blower 1 V or * Inspect terminal voltage
motor less of climate control module
switch at (L, K)
1st position,
A/C switch
ON
F Blower Blower Blower V batt * Inspect for continuity or
Page 6 of 20
motor motor motor short circuit (Blower motor

control switch switch OFF switch—resistor: L/Y — L/Y)
signal
* Inspect resistor
* Inspect blower motor

switch

relay
* Inspect A/C 7.5 A fuse

Blower 1 V or * Inspect for continuity or
motor less short circuit (Climate
switch at control module—blower
1st position motor switch: F — L/Y)
(Blower motor switch—
ground: B — GND)

switch
K GND Ground Under any 1 V or * Inspect for continuity
condition less (Climate control module—
ground: K — GND)
L IG2 A/C 7.5 A Ignition V batt * Inspect A/C 7.5 A fuse
fuse switch at
ON position * Inspect for continuity or
short circuit (Climate
control module—fuse: L —
A/C 7.5 A fuse)
Ignition 1 V or * Inspect for short circuit
switch at less (Climate control module—
LOCK fuse: L — A/C 7.5 A fuse)
position (Climate control module—
blower motor relay: L — P)
A/C SWITCH INSPECTION
(Vehicles without audio system)
1. Inspect for continuity between the A/C switch terminals using an ohmmeter.
* If not as specified, replace the A/C switch.
Switch position Terminal

OFF no continuity between terminal L/Y and terminal R/B
ON continuity between terminal L/Y and terminal R/B
Page 7 of 20
BLOWER MOTOR SWITCH INSPECTION
1. Inspect for continuity between the blower motor switch terminals using an ohmmeter.
* If not as specified, replace the blower motor switch.

0 no continuity to any terminal
1 A—C
2 A—E
3 A—F
4 A—D
In switch position X must be continuity between the terminals as specified in the list above.
HEATER BLOWER MOTOR INSPECTION
1. Connect fused battery positive voltage to terminal A and ground to terminal B of the heater
blower motor and verify its operation.
* If not as specified, replace the blower motor.
RESISTOR INSPECTION
Page 8 of 20
Verify that the resistance between the terminals of the resistor is as shown in the table.
* If not as specified, replace the resistor.
Terminal Resistance (ohm)

A—D 0.2—0.3
A—B 0.75—0.86
A—C 2.6—3.0
A/C COMPRESSOR CLUTCH INSPECTION
1. Connect fused battery positive voltage to terminal L/R of A/C compressor clutch and
ground to terminal B of A/C compressor clutch. (Component side)
2. Verify that the magnetic clutch operates.
* If not as specified, replace the stator.
DUAL PRESSURE SWITCH INSPECTION
1. Install the SST (gas charging set).
2. Disconnect the dual pressure switch connector.
3. Verify the high-pressure side reading of the SST (manifold gauge) and continuity between
the terminals of the dual pressure switch.
* If not as specified, replace the dual pressure switch.
Terminal Refrigerant pressure

A—D Below 16 bar: no continuityUpper 16 bar: continuity
C—B Below 30-34 bar: continuityUpper 30-34 bar: no continuity
Page 9 of 20
A/C COMPRESSOR SWITCH INSPECTION
1. Install the SST (gas charging set).
2. Disconnect the A/C compressor switch connector.
3. Verify the low-pressure side reading of the SST (manifold gauge) and continuity between
the terminals of the A/C compressor switch.
* If not as specified, replace the A/C compressor switch.
Terminal Refrigerant pressure

C—B Below 2 bar: no continuityUpper 2 bar: continuity
TROUBLESHOOTING
Foreword
The areas for inspection (steps) are given according to various circuit malfunctions. Use the
following chart to verify the symptoms of the trouble in order to diagnose the appropriate
area.
TROUBLESHOOTING INDEX
No. Troubleshooting item Description

1 Insufficient air (or no air) blown * Problem with each vent and/or duct.
from vents.
2 Amount of air blown from vents * Malfunction in heater blower system.
does not change.
3 Air from vents not cold enough. * A/C compressor clutch operates but A/C
system malfunctions.
4 No cool air. * A/C compressor clutch does not operate.
5 No temperature control with * Malfunction in climate control assembly
climate control assembly. and/or heater core and evaporator core
housing.
Page 10 of 20
No.1 Insufficient air (or no air) blown from vents
1 Insufficient air (or no air) blown from vents.

Description * Problem with each vent and/or duct
Possible cause * Malfunction in VENT mode system (Step 1-3)
* Malfunction in HEAT mode system (Step 4)
* Malfunction in DEFROSTER mode system (Step 5-8)

Diagnostic procedure
Step Inspection Result Inspection item(s)

1 Inspect to see whether malfunction is Yes Go to step 4.
in vent mode or other modes
No Go to next step.
* Does air blow out when in
VENT mode?
2 Inspect vent Yes Remove obstruction, then go to Step
8.
* Is vent clogged? No Go to next step.
3 Verify that duct in dashboard is Yes Inspect duct for clogging, deformity
installed and air leakage, then go to Step 8.
No Install duct securely in the proper
* Is duct in dashboard properly
position, then go to Step 8.
installed?
4 Inspect to see whether malfunction is Yes Go to next step.
in heat mode or defroster mode
No Inspect vent for clogging, then go to
* Does air blow out when in Step 8.
HEAT mode?
5 Inspect defroster mode Yes Operation is normal. Recheck
malfunction symptoms.
* Does air blow out when in
DEFROSTER mode? No Go to next step.
6 Inspect vent Yes Remove obstruction, then go to Step
8.
* Is vent clogged? No Go to next step.
7 Verify that the defroster duct is Yes Inspect duct for clogging, deformity,
installed and air leakage, then go to next step.
No Install duct securely in proper
* Is defroster duct properly
position, then go to next step.
installed?
8 Confirm that malfunction symptoms Yes Troubleshooting completed. Explain
do not recur after repair repairs to customer.
No Recheck malfunction symptoms, then
* Does air blow out? repeat from Step 1 if malfunction
recurs.
No.2 Amount of air blown from vents does not change
2 Amount of air blown from vents does not change

Description * Malfunction in heater blower system
Possible * Heater blower relay, heater blower motor, resistor, blower
cause motor switch malfunction (Step 1)
Page 11 of 20
* Heater blower unit malfunction (Step 2-4)


1 Inspect heater blower system Yes Go to next step.
* Inspect the following

systems and electrical
parts.
 Heater blower relay

No Repair or replace malfunctioning part,
 Heater blower motor then got to Step 5.
 Resistor
 Blower motor switch
 A/C 7.5 A fuse
 Related wiring
harnesses
* Are they normal?

2 Check to see whether malfunction Yes Go to Step 4.
is in blower motor housing or
elsewhere
* Turn ignition switch to

ON position.
* Turn blower motor switch

ON. No Go to next step.
* Recirculate air inside

vehicle.
* Does the heater blower

in blower motor housing
rotate smoothly?
3 Inspect blower motor housing Yes Go to next step.
* Inspect heater blower

motor in blower motor
housing. No Remove obstruction, repair or replace
heater blower motor and blower motor
 Is the heater blower housing, then go to Step 5.
free of interference
from blower motor
housing?
 Is the heater blower

free of foreign material
and obstructions?
Page 12 of 20
* Is heater blower normal?

4 Inspect blower motor housing Yes Remove obstruction, then go to next step.
intake vent No Inspect if there are any obstructions in
passage between blower motor housing
* Is blower motor housing and heater core and evaporator core
intake vent clogged? housing, then go to next step.
5 Confirm that malfunction Yes Troubleshooting completed.Explain repairs
symptoms do not recur after repair to customer.
* Does air blow out? repeat from Step 1 if malfunction recurs.
No.3 Air from vents not cold enough
3 Air from vents not cold enough

Description * A/C compressor clutch operates but A/C system malfunctions.
Possible * Drive belt malfunction (Step 1)
cause
* Malfunction in blower motor housing or condenser (Step 2, 4, 5)
* Malfunction in suction accumulator or A/C evaporator core orifice

(Step 8, 9)
* Malfunction in refrigerant lines (Step 10, 11)
* A/C compressor system malfunction, insufficient compressor oil

(Step 15, 16)
* Overfilling of compressor oil, malfunction in A/C evaporator core

orifice or heater core and evaporator core housing (Step 17, 19)

1 Inspect drive belt Yes Go to next step.
* Inspect drive belt. (See No Adjust or replace drive belt, then go to

DRIVE BELT INSPECTION) Step 20.
* Is it normal?
2 Inspect refrigerant system Yes Operation is normal. (Recheck
performance malfunction symptoms.)
* Perform refrigerant
system performance test.
(See REFRIGERANT SYSTEM
PERFORMANCE TEST) No Go to next step.
* Is operation normal?
3 Check to see whether malfunction Yes Go to next step.
is in blower motor housing intake
and condenser or elsewhere
No Go to Step 6.
* Are refrigerant high-
pressure and low-pressure
values both high?
4 Inspect blower motor housing Yes Remove obstruction, then go to Step 20.
intake (If air does not reach evaporator within
Page 13 of 20
* Is blower motor housing heater core and evaporator core housing,

intake clogged? heat exchange does not occur and
refrigerant pressure becomes high.
Therefore, removal of obstruction is
necessary.)
No Go to next step.
5 Inspect condenser Yes Adjust refrigerant to specified amount,
then go to Step 20.(Excessive amount of
* Inspect condenser. (See refrigerant.)
CONDENSER INSPECTION)
No Replace condenser, or repair and clean
the condenser fins, then go to Step 20.
* Is it normal?
is in A/C evaporator core orifice,
suction accumulator and refrigerant
lines or elsewhere
No Go to Step 13.
* Are refrigerant high-
pressure and low-pressure
values low?
is in A/C evaporator core orifice
and suction accumulator or
elsewhere
* Immediately after A/C

compressor operates, does
Yes Go to Step 10.
refrigerant high-pressure
value momentarily rise to
correct value, then fall and
stay below it? (Is there a
negative pressure on low-
pressure side?)
8 Check to see whether malfunction Yes Replace A/C evaporator core orifice, then
is in A/C evaporator core orifice or go to Step 20.
suction accumulator
* Turn A/C switch of and let No Replace condenser and refrigerant line
air conditioner stop for 10 30 min or more by vacuum pump, add
min. refrigerant to specified level, then go to
Step 20.(Since water has intermixed in
* Start engine. suction accumulator and it is saturated,
replacement is necessary.)
* Turn both A/C switch and
heater blower switch on.
* Does malfunction occur

after A/C compressor turns
on?
9 Inspect refrigerant lines Yes Go to next step.
* Inspect refrigerant lines.
 Is piping free of damage

and cracks?
Page 14 of 20
 Are piping connections No If piping or A/C component(s) are

free of oil grime? damaged or cracked, replace them.Then
(Visual inspection) go to Step 20.If there is no damage, go
to Step 13.
 Are piping connections
free of gas leakage?
 Are piping installation

points on condenser
free of gas leakage?

points on suction
accumulator free of gas
leakage?

points on A/C
compressor free of gas
leakage?

points on heater core
and evaporator core
housing free of gas
leakage?
 Perform gas leak

inspection using gas
leak tester.
* Are above items normal?

10 Inspect evaporator piping Yes Go to next step.
connections in heater core and
evaporator core housing for gas
leakage No If piping is damaged or cracked, replace
it.Then go to Step 20.If there is no
damage, go to next step.
* Are piping connections for
evaporator in heater core
and evaporator core
housing free of gas
leakage?
11 Inspect evaporator piping Yes Replace O-ring on piping, tighten
connections in heater core and connections with specified torque, adjust
evaporator core housing for loose. both compressor oil and refrigerant to
specified amount, then go to Step 20.
* Are piping connections for
evaporator in heater core
and evaporator core No Go to next step.
housing loose?
12 Inspect piping connections for Yes Replace O-ring on piping, tighten
loose. connections with specified torque, adjust
both compressor oil and refrigerant to
* Are piping connections specified amount, then go to Step 20.
loose? No Go to Step 20.
13 Check to see whether malfunction Yes Go to next step. (Pressure hardly
is in A/C evaporator core orifice, increase.)
Page 15 of 20
temperature control blend door and No Go to Step 17.

compressor oil or elsewhere
* Does refrigerant high-

pressure value hardly
increase?
14 Check to see whether the Yes Return to Step 3.
malfunction is in A/C compressor
oil amount, A/C compressor or
elsewhere
No Go to next step.
* When engine is racing,
does high-pressure value
increase?
15 Check to see whether the Yes Go to next step.
malfunction is in compressor oil
amount or A/C compressor
No Replace A/C compressor, then go to Step
* After compressor oil is 20. (Cause is defective A/C compressor)
replenished each 10 ml,
does high-pressure value
increase?
16 Check A/C compressorCarry a road Yes Troubleshooting completed. (Explain to
test of the vehicle with A/C on and customer that cause was insufficient
max. cold. After the road test check compressor oil.)
high-pressure again.
No Replace A/C compressor, then go to Step
* Does high-pressure value 20. (Cause is defective A/C compressor)
increase?
17 Check to see whether malfunction Yes Go to Step 19.
is in A/C evaporator core orifice or
elsewhere
No Go to next step.
* Is only refrigerant low-
pressure value high?
18 Verify that temperature control Yes Set blower motor switch to 4th
blend door is installed securely and position.Turn A/C switch on.Set FRESH
properly mode.Set temperature control to MAX
COLD.Set VENT mode.
* Are heater core and
evaporator core housing a. Start and run the engine
temperature control blend at 1,500 rpm for 10 min.
door cranks, temperature
control blend door rods and b. Run the engine at idle for
bowden cables securely and 1 min.
properly installed?
c. Within 12 s, idle —>
4,000 rpm —> idle. Perform
cycle 5 times.
d. Run the engine at idle for

30 s.
e. Stop the engine. Drain the

compressor oil completely
from the A/C compressor and
verify the amount.
Page 16 of 20
 If there is approx. 90 ml
of compressor oil, go to
Step 20.
 If there is more than 90

ml of compressor oil,
remove surplus oil an fill
A/C compressor with 90
ml of compressor oil.
Repeat Steps (1) to (5).
(Cause is excessive amount of

compressor oil.)
No
Repair or install the faulty part in proper
position, then go to Step 20.
19 Verify that the correct A/C Yes Replace A/C evaporator core orifice, then
evaporator core orifice is build in go to next step. (A/C evaporator core
orifice too much open, replacement is
* Is a green A/C evaporator necessary.)
core orifice build in and in a No Install the correct A/C evaporator core
proper position? orifice, then go to next step.
20 Confirm that malfunction symptoms Yes Troubleshooting completed.Explain
* Does cool air blow out?

(Are results of refrigerant
repeat from Step 1 if malfunction recurs.
system performance test
normal?)
No. 4 No cool air
4 No cool air
Description * A/C compressor clutch does not operate
Possible * Malfunction in PCM A/C cut control system
cause
* Malfunction in A/C control unit (Vehicles without audio system:
A/C switch)
* Malfunction in dual pressure switch
* Malfunction in A/C compressor switch
* Malfunction in A/C compressor clutch
* Malfunction in A/C wide open trottle (WOT) relay
* Malfunction in PCM (A/C signal)


1 Inspect air blown from vents Yes Go to next step.
No Go to Step 1 of troubleshooting index
* Does air blown from vents? No. 1.
2 Inspect A/C compressor operation Yes Go to Step 1 of troubleshooting index
No. 3.
Page 17 of 20
* Start engine. No Go to next step.
* Turn A/C switch and heater

blower switch on.
* Does A/C compressor

operate?
3 Inspect for DTC in PCM Yes Go to appropriate inspection
procedure.
* Inspect for DTC's related to
the PCM onboard diagnostic
system.
No Go to next step.
* Are any DTC's displayed?
4 Inspect to see whether malfunction is Yes Go to Step 8.
in A/C compressor clutch control
system or elsewhere
* Start engine.
* Does A/C compressor clutch No Go to next step.

operate when terminal AR of
PCM connector (94-pin, A/C
cut signal) (Vehicles with
diesel engine: Terminal 3U
(32-pin, A/C cut signal)) is
grounded?
in wiring harness, fuses, A/C WOT No None 12 V at terminal L/O:
relay or elsewhere
- Inspect A/C compressor
* Test voltage at following clutch 7.5 A fuse, if
terminal of A/C WOT relay necessary install a new
socket one, then go to Step 16
 Terminal L/O (Power - Repair wiring harness

supply, A/C compressor between A/C compressor
clutch 7.5 A fuse) clutch 7.5 A fuse and A/C
WOT relay, then go to
* Turn ignition switch ON. Step 16
 Terminal W/R (Power None 12 V at terminal W/R:

supply, main relay)
- Repair wiring harness
* Is voltage on both terminals between A/C WOT relay
approx. 12 V? and main relay, then go to
Step 16
in wiring harness, A/C WOT relay or
elsewhere No Check the A/C WOT relay, if necessary
install a new one, then go to Step
* Test voltage at terminal AR 16.If the A/C WOT relay is OK, repair
of PCM connector (94-pin, A/C wiring harness between A/C WOT
cut signal) (Vehicles with relay and PCM, then go to Step 16.
diesel engine: Terminal 3U
(32-pin, A/C cut signal)).
Page 18 of 20
* Is voltage approx. 12 V?
7 Inspect to see whether malfunction is Yes Replace A/C compressor clutch, then
in wiring harness or A/C compressor go to Step 16.
clutch
* Disconnect the A/C WOT

relay. No Repair the wiring harness between
A/C WOT relay and A/C compressor
 Connect a fused jumper clutch or between A/C compressor
wire (7.5 A) at the A/C clutch and ground, then go to Step
WOT relay socket between 16.
terminal L/O and terminal
L/R.
* Test voltage between

terminal L/R and terminal B of
A/C compressor clutch.
8 Inspect to see whether malfunction is Yes Vehicles with audio system go to Step
in PCM, Dual pressure switch, A/C 13.Vehicles without audio system go
cycling switch or elsewhere to Step 14.
* Start engine.
Vehicles with audio system:
* Does A/C compressor clutch

operate when terminal D of
climate control module
connector (10-pin, A/C signal)
is grounded?
Vehicles without audio system:

No Go to next step.
operate when terminal R/B of
A/C switch connector (6-pin,
A/C signal) is grounded?
9 Inspect to see whether malfunction is Yes Repair wiring harness between A/C
in PCM, Dual pressure switch, A/C cycling switch and climate control
cycling switch or wiring harness module (Vehicles without audio
system: A/C switch), then go to Step
* Start engine. 16.

operate when terminal R/B of
A/C cycling switch connector is No Go to next step.
grounded?
10 Inspect to see whether malfunction is Yes Inspect wiring harness between dual
in PCM, Dual pressure switch, A/C pressure switch and A/C compressor
cycling switch or wiring harness switch. If wiring harness is normal, go
to next step.
* Start engine.

Page 19 of 20
operate when terminal B/R of No Go to Step 12.

dual pressure switch connector
is grounded?
11 Inspect to see whether malfunction is Yes If refrigerant amount is empty,
in A/C compressor switch or replace refrigerant system 30 min or
refrigerant amount more by vacuum pump, and add
refrigerant to specified level, then go
* Inspect A/C compressor to Step 16.
switch.
No Replace A/C compressor switch, then
* Is the A/C compressor switch go to Step 16.
normal?
12 Inspect to see whether malfunction is Yes Inspect wiring harness between PCM
in PCM, Dual pressure switch or wiring and dual pressure switch. If wiring
harness harness is normal, replace dual
pressure switch, then go to Step 16.
* Start engine.

operate when terminal AO
(Vehicles with diesel engine:
3U) of PCM connector is No Inspect PCM, then go to Step 16.
grounded?
in climate control module or wiring
harness
* Turn ignition switch ON. No Repair wiring harness between climate

control module and A/C 7.5 A fuse,
* Test voltage at the following then go to Step 16.
terminal of climate control
module.
 Terminal L (10-pin, power

supply)
14 Inspect to see whether malfunction is Yes Vehicles with audio system go to next
in climate control module or wiring step.Vehicles without audio system go
harness to Step 16.
* Turn ignition switch ON.
* Test voltage at the

following terminal of
climate control module
(Vehicles without audio
system: A/C switch).
 Vehicles with audio

system: Terminal F (10- No Repair wiring harness between climate
pin, heater blower control module (Vehicles without
motor control signal) audio system: A/C switch) and blower
motor switch, then go to Step 16.
 Vehicles without audio
system: Terminal L/Y
Page 20 of 20
(6-pin, heater blower

control signal)
* Turn heater blower

switch OFF and in 1st.
position.
* Is voltage approx. 12 V
(heater blower switch OFF)
and below 1.0 V (heater
blower switch in 1st.
position)?
15 Inspect ground connection of the Yes Replace the climate control module,
climate control module then go to Step 16.
* Turn ignition switch ON.
* Test voltage at the following Yes Repair wiring harness between climate
terminal of climate control control module and ground
module. connection, then go to Step 16.
 Terminal K (10-pin,
ground)
* Is voltage below 1.0 V?

16 Confirm that malfunction symptoms Yes Troubleshooting completed. Explain
* Does A/C compressor clutch Yes Recheck malfunction symptoms, then

operate? (Are the results of repeat from Step 1 if malfunction
refrigerant system recurs.
performance test normal?)
Page 1 of 24

COMMUNICATIONS NETWORK
UID=G323475
Outline
If there is the possibility of an abnormality in the network system, read the DTC´s of the
following modules, using the WDS or equivalent to determine the malfunction of the system.
- ABS HU/CM (Vehicles with the ABS)
- ESP HU/CM (Vehicles with the ESP)
- Instrument cluster (ICL)
- Transmission control module (TCM) - Vehicles with automated gearshift
- Gearshift lever unit - Vehicles with automated gearshift
DTC Table
Diagnosis System
DTC Component Possible Cause Action
U0001 CAN system * Open or short circuit in See DTC U0001,
communication error the wiring harness U1900, U2516,
U2012, U2523,
* Connector malfunction U2522, U0121,
U0155
* PCM malfunction
U1900 CAN system
communication error * ABS (ABS/TCS)
HU/CM / ESP HU/CM
malfunction
* Instrument cluster
U2516 CAN system wiring malfunction
harness open and short
circuit * TCM malfunction -
Vehicles with automated
gearshift
* Gearshift lever unit

malfunction - Vehicles
with automated gearshift
U2012 CAN system wiring short circuit in the wiring harness o See DTC U0001,
harness open and short ABS (ABS/TCS) HU/CM / ESP HU/CM U1900, U2516,
circuit malfunction U2012, U2523,
U2522, U0121,
U0155
U0121 Communication error to * Open in the wiring See DTC U0121,
ABS (ABS/TCS) HU/CM harness U0122
* Connector malfunction
Page 2 of 24
* ABS (ABS/TCS) HU/CM

malfunction
U0122 Communication error to * Open in the wiring
ESP HU/CM harness
* ESP HU/CM malfunction

U0155 Communication error to * Open in the wiring See DTC U0155
instrument cluster harness
malfunction
U0101 Communication error to * Open in the wiring See DTC U0101
TCM - Vehicles with harness
automated gearshift
* TCM - Vehicles with

automated gearshift
PID/DATA MONITOR TABLE
PID name
(definition)
Condition Specification Related module Terminal
ICL_MSG Present Circuit in the * ABS/ESP - ABS/ESP
instrument module module: P, D
cluster is
normal. * TCM - - Instrument
Not Circuit in the Vehicles cluster: 2W,
Present instrument with 2X
cluster is automated
abnormal. gearshift - PCM -
ABS/ESP_MSG Present Circuit in the * vehicles with
ABS is normal. Instrument diesel engine:
cluster (ICL) 1A, 1B
Not Circuit in the * TCM - - PCM -

Present ABS is Vehicles vehicles with
abnormal. with petrol engine:
automated J, I
gearshift
PCM_MSG Present Circuit in the * ABS/ESP - TCM -
PCM is module Vehicles with
normal. automated
* gearshift:
Instrument 1AA, 1S
cluster (ICL)
- Gearshift
Not Circuit in the * TCM - lever unit -
Present PCM is Vehicles Vehicles with
abnormal. with automated
automated gearshift: G,
gearshift H
Page 3 of 24
* DLC - DLC: R, W
TCM_MSG - Present Circuit in the * ABS
Vehicles with TCM is module
automated normal.
gearshift *
Instrument
cluster (ICL)
Not Circuit in the
Present TCM is
* Gearshift
abnormal.
lever
* PCM
Gearshift lever Present Circuit in the * TCM -
unit_MSG - gearshift lever Vehicles
Vehicles with unit is normal. with
automated Not Circuit in the automated
gearshift Present gearshift lever gearshift
unit is
abnormal.
Quick Diagnosis for CAN-Bus
NOTE: In the CAN-Bus Network are two term resistors of 120 ohm. One term resistor is in
the Powertrain Control Module (PCM), the other term resistor is in the Instrument Cluster
(ICL).
NOTE: Shake the wiring harness and connectors while performing the inspection to
discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are
connected correctly and undamaged.
NOTE: The number of modules connected to the CAN bus depends on the equipment level
of the vehicle. Therefore not every vehicle will have all the modules mentioned below.
When the wiring harness of the CAN-Bus will be open failure, then all of the CAN transmission
will be stopped and many of the DTC Uxxxx will be stored on PCM, TCM, ABS/ESP, GLU and
ICL. And then, many of the warning lamp (MIL,ABS, ESP, Brake and so on) will be turn on.
Step Inspect Result Inspection item(s)

1 Inspect wiring harness between Yes The wiring harness between PCM, ICL,
PCM, ICL, TCM and DLC TCM and DLC are OK. Go to next step.
* Turn ignition to 0 position.
* Measure the resistance

between terminal R and
terminal W of the DLC. No See DTC U0001, U1900, U2516
* Is the resistance approx.

60 ohm?
PCM, ICL, TCM and ABS/ESP module TCM and ABS/ESP module are OK. Go
to next step.
* Disconnect the connector
of the ABS/ESP module.

between terminal P and
terminal D of the ABS/ESP
module.
No See DTC U0001, U1900, U2516
Page 4 of 24

60 ohm?
PCM, ICL, TCM and GLU TCM and GLU are OK. See Procedures
for determining the location of a
* Connect the connector of malfunction.
the ABS/ESP module.
* Disconnect the connector

of the GLU.

between terminal ** and
terminal ++ of the GLU.
No See DTC U0001, U1900, U2516
60 ohm?
Procedures for determining the location of a malfunction
Item Description
1 Wiring harness A
2 Wiring harness B
3 Wiring harness C
4 Wiring harness D
NOTE: If you can not establish a communication with the modules the malfunctioning part
is wiring harness A.
PCM
A. Referring to the following table, determine the malfunctioning part of the CAN
system.
Communication status
Module ABS/ESP Instrument cluster Malfunction location
PCM - - * Wiring harness B, C, D
* PCM
X - * Wiring harness B, C, D
Page 5 of 24
- X * Wiring harness B, C, D
* ABS/ESP module
X: Normal
-: Communication error
ABS HU/CM or ESP HU/CM
A. Access and monitor the "PCM MSG" and "ICL MSG" of PID using the SST (WDS
or equivalent).
B. Referring to the PID/DATA MONITOR, confirm the display status of the PID
(See PID/DATA MONITOR TABLE).
C. Referring to the following table, determine the malfunction part of the CAN
system.
Module PCM Instrument cluster Malfunction location
ABS/ESP - - * Wiring harness B, C, D
* ABS/ESP module
* PCM
* PCM
* ABS/ESP module
X: Normal
Instrument Cluster
A. Access and monitor the "PCM MSG" and "ABS MSG/ESP MSG" of PID using the
SST (WDS or equivalent).
system.
Module ABS/ESP PCM Malfunction location
Instrument cluster - - * Wiring harness B, C, D
* PCM
Page 6 of 24
* ABS/ESP module
X: Normal
Procedures for determining the location of a malfunction - vehicles with

automated gearshift
Item Description
1 Wiring harness A
2 Wiring harness B
3 Wiring harness C
4 Wiring harness D
5 Wiring harness E
6 Wiring harness F
NOTE: If you can not establish a communication with the modules the malfunctioning part
is wiring harness A.
PCM
A. Access and monitor the "ABS/ESP MSG", "TCM MSG", "gearshift lever unit
MSG" and "ICL MSG" of PID using the SST (WDS or equivalent).
C. Referring to the following table, determine the malfunctioning part of the CAN
system.
Gearshift lever Instrument
Module ABS/ESP unit cluster TCM Malfunction location
PCM - - - - * Wiring harness B, C, D,
E, F
* PCM
X - X X * Wiring harness B, C, D,
E, F
Page 7 of 24

- X X X * Wiring harness B, C, D,
E, F
* ABS / ESP module

X X X - * TCM
X X - X * Wiring harness B, C, D,
E, F
* ICL
X: Normal
ABS HU/CM or ESP HU/CM
A. Access and monitor the "PCM MSG", "TCM MSG", "gearshift lever unit MSG"
and "ICL MSG" of PID using the SST (WDS or equivalent).
system.
Gearshift lever Instrument
Module unit PCM cluster TCM Malfunction location
ABS/ESP - - - - * Wiring harness B, C, D,
E, F
* ABS/ESP module
E, F
* PCM
X - X - * Wiring harness B, C, D,
E, F
* TCM
E, F

E, F
X: Normal
Instrument Cluster
A. Access and monitor the "PCM MSG" , "TCM MSG", "gearshift lever unit MSG"
Page 8 of 24
and "ABS MSG/ESP MSG" of PID using the SST (WDS or equivalent).
system.
Gearshift lever
Module ABS/ESP PCM unit TCM Malfunction location
Instrument - - - - * Wiring harness B, C, D,
cluster E, F
E, F
* PCM
E, F
* ABS/ESP module
X - X - * Wiring harness B, C, D,
E, F
* TCM
E, F

X: Normal
TCM
A. Access and monitor the "PCM MSG" , "ABS MSG/ESP MSG", "gearshift lever
unit MSG" and "ICL MSG" of PID using the SST (WDS or equivalent).
system.
Instrument Gearshift lever
Module ABS/ESP PCM cluster unit Malfunction location
TCM - - - - * Wiring harness B, C, D,
E, F
* TCM
E, F
Page 9 of 24
* PCM
E, F
* ABS/ESP module
X X X - * Wiring harness B, C, D,
E, F

E, F
X: Normal
Gearshift lever unit
A. Access and monitor the "PCM MSG","ABS MSG/ESP MSG" and "ICL MSG" of PID
using the SST (WDS or equivalent).
system.
Instrument
Module ABS/ESP PCM cluster TCM Malfunction location
Gearshift lever - - - - * Wiring harness B, C, D,
unit E, F

E, F
* PCM
E, F
* ABS/ESP module
X X X - * Wiring harness B, C, D,
E, F
* TCM
E, F
X: Normal
Page 10 of 24
DTC U0001, U1900, U2516, U2012, U2523, U2522, U0121/U0122, U0155
U0001
U1900
U2012 CAN system communication error
U2516
U2522
DTC U2523 CAN system wiring harness open or short circuit
Detection
Condition WARNING: Detection condition are for the DTC outline before
performing an inspection. Performing an inspection with only detection
condition may cause injury due to an operating error, or damage the
system. When performing an inspection, always follow the inspection
procedure.
* CAN system related wiring harness malfunction
* CAN system related module communication error

Possible * Open or short circuit in the wiring harness
Cause
* PCM malfunction
* ABS (ABS/TCS) / ESP HU/CM malfunction
* Instrument cluster malfunction
* TCM malfunction
* Gearshift lever unit malfunction

Communication error to ABS (ABS/TCS) HU/CM / ESP
DTC U0121/U0122 HU/CM
Detection CAN system related wiring harness malfunction
Condition
Possible Cause * Open circuit in the wiring harness
* ABS (ABS/TCS) HU/CM / ESP HU/CM malfunction
* Malfunction in the wiring harness between battery and ABS

(ABS/TCS) HU/CM / ESP HU/CM
* Malfunction in the wiring harness between ground and ABS

(ABS/TCS) HU/CM / ESP HU/CM
Page 11 of 24
DTC U0155 Communication error to instrument cluster

Condition
* Instrument cluster malfunction
* Malfunction in the wiring harness between battery and

instrument cluster
* Malfunction in the wiring harness between ground and

instrument cluster

1 Determine location of a malfunction Yes Go to step 7.
* Determine the malfunctioning part of

the CAN system. (PROCEDURES FOR
DETERMINING THE LOCATION OF A
No Go to next step.
MALFUNCTION)
* Is the malfunctioning part wiring

harness A or the DLC?
Page 12 of 24
* Determine the malfunctioning part of No Go to next step.

MALFUNCTION)

harness B or the ABS/ESP module?

No Go to next step.
MALFUNCTION)

harness C or the PCM?
No * Vehicles with
* Determine the malfunctioning part of automated
the CAN system. (PROCEDURES FOR gearshift: Go to
DETERMINING THE LOCATION OF A next step.
MALFUNCTION)
* Vehicles
* Is the malfunctioning part wiring without
harness D or the instrument cluster? automated
gearshift: Go to
step 45.

No Go to next step.
MALFUNCTION)

harness E or the TCM?

No Go to step 45.
MALFUNCTION)

harness F or the gearshift lever unit?
7 Inspect fuse Yes Go to next step.
* Remove ROOM 15 A fuse and SAS 10A

fuse.
No Replace fuse.
* Inspect ROOM 15 A fuse and SAS 10A
fuse.
* Are the fuses okay?

8 Inspect wiring harness between Fuse ROOM Yes Go to next step.
15A and DLC
Page 13 of 24
* Test voltage at terminal L/R of DLC. No Replace the wiring harness.
9 Inspect wiring harness between Fuse SAS 10A Yes Go to next step.
and DLC
* Turn ignition to II position.

No Replace the wiring harness.
* Test voltage at terminal B/R of DLC.
10 Inspect ground connection of the DLC Yes * Vehicles with
diesel engines:
* Test voltage at terminal B of DLC. go to next step.
* Test voltage at terminal BW of DLC. * Vehicles with

petrol engines:
* Is voltage below 1.0 V? go to step 12.
11 Inspect wiring harness between DLC and PCM Yes Replace the PCM, then go to
NOTE: Initialize the driver door window step 45.
motor.REFER to Section 501-11.
* Disconnect the negative battery cable.
* Disconnect the ABS HU/CM or ESP

HU/CM connector.
* Disconnect the PCM connector.
* Disconnect the ICL connector.
* Disconnect the TCM (Vehicles with

automated gearshift) connector.
* Disconnect the gearshift lever unit

(Vehicles with automated gearshift)
connector.
* Connect the battery ground cable.
* Inspect the wiring harnesses between No Replace the wiring harness.

the DLC terminal W and PCM terminal
1A, DLC terminal R and PCM terminal 1B
for the following:
 Short to ground
 Short to power supply
 Open circuit
* Is the wiring harness normal?

NOTE: Initialize the driver door window motor. step 45.
Page 14 of 24
* Disconnect the negative battery cable. No Replace the wiring harness.

HU/CM connector.


connector.
* Inspect the wiring harnesses between

the DLC terminal W and PCM terminal J,
DLC terminal R and PCM terminal I for
the following:
 Short to ground
 Open circuit

13 Inspect the PCM connector Yes Go to next step.
NOTE: Initialize the driver door window

* Is the PCM connector connected

correctly?
14 Inspect fuse Yes Replace fuse.
No * Vehicles with
diesel engine:
Go to step 19.
* Remove ENGINE 15A fuse and ENG.+B
7.5A fuse.
* Vehicles with
petrol engine:
* ENGINE 15A fuse and ENG.+B 7.5A Go to next step.
fuse.

15 Inspect wiring harness between Fuse ENG.+B Yes Go to next step.
7.5A and PCM
* Test voltage at terminal A of PCM. No Replace the wiring harness.

Page 15 of 24
16 Inspect wiring harness between Fuse ENGINE Yes Go to next step.
15A and PCM

* Test voltage at terminal C of PCM.
17 Inspect ground connection of the PCM Yes Replace the PCM, then go to
step 45.
* Test voltage at terminal BQ of PCM.
* Test voltage at terminal M of PCM.
* Test voltage at terminal N of PCM.

* Test voltage at terminal CP of PCM.


HU/CM connector.


connector.
* Inspect the wiring harnesses between No Replace the wiring harness.

the DLC terminal W and PCM terminal J,
DLC terminal R and PCM terminal I for
the following:
 Short to ground
 Open circuit

19 Inspect wiring harness between Fuse ENG.+B Yes Go to next step.
Page 16 of 24
7.5A and PCM No Replace the wiring harness.
* Test voltage at terminal 2Y of PCM.
20 Inspect wiring harness between Fuse ENGINE Yes Go to next step.
15A and PCM

* Test voltage at terminal 1J of PCM.
21 Inspect ground connection of the PCM Yes Go to next step.
* Test voltage at terminal 2AM of PCM.
* Test voltage at terminal 1Y of PCM.

* Test voltage at terminal 1AC of PCM.
* Test voltage at terminal 3I of PCM.


HU/CM connector.


connector.

the DLC terminal W and PCM terminal No Replace the wiring harness.
1A, DLC terminal R and PCM terminal 1B
for the following:
 Short to ground
 Open circuit
Page 17 of 24

23 Inspect the instrument cluster connector Yes Go to next step.
NOTE: Initialize the driver door window motor.

* Disconnect the instrument cluster
connector.
* Is the instrument cluster connector

connected correctly?
24 Inspect wiring harness between DLC and Yes Go to next step.
instrument cluster

HU/CM connector.


connector.


the DLC terminal R and ICL terminal 2W,
DLC terminal W and ICL terminal 2X for
the following:
 Short to ground
 Open circuit

* Remove ROOM 15 A fuse and METER

10A fuse.
* Inspect ROOM 15 A fuse and METER
10A fuse.

26 Inspect wiring harness between ROOM 15 A Yes Go to next step.
Fuse and instrument cluster
* Test voltage at terminal 2H of

instrument cluster.
Page 18 of 24
27 Inspect wiring harness between METER 10A Yes Go to next step.
Fuse and instrument cluster

* Test voltage at terminal 2V of
instrument cluster.
28 Inspect ground connection of the instrument Yes Go to next step.
cluster
* Test voltage at terminal A of

instrument cluster.
* Test voltage at terminal 2F of
instrument cluster.

29 Inspect wiring harness between instrument Yes Replace the instrument
cluster and DLC cluster, then go to step 45.

the DLC terminal R and instrument
cluster terminal 2W, DLC terminal W and
instrument cluster terminal 2X for open No Replace the wiring harness.
circuit

30 Inspect the ABS/ESP connector Yes Go to next step.
NOTE: Initialize the driver door window

* Disconnect the ABS/ESP connector.
* Is the instrument cluster connector

31 Inspect wiring harness between DLC and Yes Go to next step.
ABS/ESP module
* Disconnect the instrument cluster

connector.


connector.
Page 19 of 24
* Connect the battery ground cable. No Replace the wiring harness.

the DLC terminal R and ABS/ESP terminal
D, DLC terminal W and ABS/ESP terminal
P for the following:
 Short to ground
 Open circuit

* Remove ABS-V 30 A fuse and SAS 10A

fuse.
* Inspect ABS-V 30 A fuse and SAS 10A
fuse.

33 Inspect wiring harness between Fuse ABS - V Yes Go to next step.
30A and ABS/ESP module
* Test voltage at terminal AU of ABS/ESP

module.
and ABS/ESP module

* Test voltage at terminal AK of ABS/ESP
module.
35 Inspect ground connection of the ABS/ESP Yes Go to next step.
module
* Test voltage at terminal A of ABS/ESP

module.
* Test voltage at terminal B of ABS/ESP
module.

36 Inspect wiring harness between ABS/ESP Yes Replace the ABS/ESP
module and DLC module, then go to step 45.

Page 20 of 24
the DLC terminal W and ABS/ESP module No Replace the wiring harness.
terminal P, DLC terminal D and ABS/ESP
module terminal D for open circuit.

37 Inspect the TCM connector. Yes Go to next step.
* Disconnect the negative battery cable. No Replace the wiring harness.
* Is the TCM connector connected

correctly?
38 Inspect wiring harness between DLC and TCM Yes Replace the TCM, then go to
(Vehicles with automated gearshift). step 45.

connector.

the DLC terminal R and TCM (Vehicles
with automated gearshift) terminal 1AD,
DLC terminal W and TCM terminal 1V for
the following:
 Short to ground
 Open circuit

39 Inspect the gearshift lever unit (Vehicles with Yes Go to next step.

connector.
* Is the gearshift lever unit connector


Page 21 of 24
* Remove STOP 15A fuse and A/T 15A No Replace fuse.

fuse.
* Inspect STOP 15 A fuse and A/T 15A

fuse.

41 Inspect wiring harness between Fuse ROOM Yes Go to next step.
15A and gearshift lever unit
* Test voltage at terminal C of gearshift

lever unit.
and gearshift lever unit

* Test voltage at terminal A of gearshift
lever unit.
43 Inspect ground connection of the gearshift Yes Go to next step.
lever unit
* Test voltage at terminal B of gearshift

lever unit.

44 Inspect wiring harness between DLC and Yes Replace the gearshift lever
gearshift lever unit (Vehicles with automated unit, then go to step 45.
gearshift).


the DLC terminal R and gearshift lever
unit (Vehicles with automated gearshift) No Replace the wiring harness.
terminal H, DLC terminal W and gearshift
lever unit terminal G for the following:
 Short to ground
Page 22 of 24
 Open circuit
45 Check DTC indicate Yes Repeat from step 1.
* Connect the disconnected module

connectors.
* Check the display of DTC using the

WDS or equivalent.
No The troubleshooting
* Are any one or all of the following procedures have been
DTC´s displayed? completed.
 U0001
 U1900
 U2516
 U0121/U0122
 U0155
 U2523
 U2522
 U2012
DTC U0101
Communication error to TCM - Vehicles with automated

DTC U0101 gearshift
Condition
* TCM malfunction
* Malfunction in the wiring harness between battery and

TCM
* Malfunction in the wiring harness between ground and

TCM
Page 23 of 24

* Remove ASM 60A fuse and A/T 15A fuse.

No Replace fuse.
* Inspect ASM 60A fuse and A/T 15A fuse.

2 Inspect wiring harness between ASM 60A Fuse Yes Go to next step.
and TCM
No Replace the wiring
* Test voltage at terminal 1D of instrument
harness.
cluster.
3 Inspect wiring harness between Fuse A/T 15A and Yes Go to next step.
TCM
* Turn ignition to II position. No Replace the wiring

harness.
* Test voltage at terminal 1E of instrument
cluster module.
4 Inspect ground connection of the TCM Yes Go to next step.
* Test voltage at terminal 1A of the TCM. No Replace the wiring

harness.
5 Inspect wiring harness between instrument Yes Replace the TCM, then
cluster module and DLC go to step 6.
* Inspect the wiring harnesses between the

No Replace the wiring
DLC terminal R and TCM terminal 1AD, DLC
harness.
terminal W and TCM terminal 1V for open
circuit
Page 24 of 24

6 Check DTC indicate Yes Repeat from step 1.
* Connect the disconnected module

connectors. No The troubleshooting
procedures have been
* Check the display of DTC U0101 using the completed.
WDS or equivalent.
* Are any one or all of the following DTC

displayed?
 U0101
Page 1 of 1

FRONT DRIVE HALFSHAFTS
UID=G323479
Symptom Chart – Front Drive Halfshafts
Symptom Chart

Clicking, Popping or *Inadequate or contaminated *INSPECT, CLEAN and LUBRICATE as
Grinding Noises lubricant in the inner/outer front necessary.
While Turning drive halfshaft constant velocity
(CV) joint.
*Another component contacting *INSPECT and REPAIR as necessary.
front drive halfshaft assembly.
*Wheel bearings, brakes, *INSPECT and REPAIR as necessary.
suspension or steering REFER to Section 204-04 / 206-00 /
components. 211-00.
Vibration at *Out of balance front wheels or *REFER to Section 204-04.
Highway Speeds tires.
*Out-of-round tires. *REFER to Section 204-04.
*Incorrectly seated outer constant *INSTALL a new halfshaft. REFER to
velocity (CV) joint in front wheel Halfshaft LH in this section. or REFER
hub. to Halfshaft RH in this section.
Shudder Vibration *Excessively high CV joint *CHECK the ride height, VERIFY
During operating angles caused by correct spring rate and CHECK items
Acceleration. incorrect ride height. under Halfshaft Joint Pullout. REPAIR
or INSTALL new components as
necessary.
*Excessively worn or damaged *INSPECT and INSTALL new
inner/outer front drive halfshaft components as necessary.
constant velocity (CV) joint.
Halfshaft Joint *Outer front drive halfshaft *INSPECT and REPAIR or INSTALL
Pullout retainer circlip missing or not new components as necessary.
correctly seated differential side.
*Engine/transaxle assembly *CHECK engine mounts for damage or
misalignment. wear. REPAIR or INSTALL new
*Frame rail or strut tower out of *CHECK underbody dimensions.
position or damaged.
*Front suspension components *CHECK for worn bushings or bent
worn or damaged. components (front stabilizer bar,
front suspension lower arm). REPAIR
or INSTALL new components as
necessary.
Page 1 of 2

INTERMEDIATE SHAFT
UID=G323480
Special Tool(s)
49 JE02 053
Name Specification
oil meeting WSD-M2C200-C
Removal
1. Remove the right-hand halfshaft. For
additional information, refer to Halfshaft RH in
this section.
2. Remove the intermediate shaft center bearing
cap.
1. Remove and discard the locknuts.
2. Detach the heat shield from the bearing cap
(if equipped).
3. Remove and discard the center bearing cap.
3. CAUTION: Do not damage the

halfshaft oil seal.
or dirt ingress.
Remove the intermediate shaft.
 Slide the heat shield off the intermediate

shaft.
Installation
CAUTIONS:

degrees.

attach the intermediate shaft to the transaxle.

Page 2 of 2

equipped).
3. Install the right-hand halfshaft. For additional

information, refer to Halfshaft RH in this
section.
Page 1 of 6

MANUAL TRANSAXLE AND CLUTCH
UID=G323481
General Equipment
Ultraviolet fluid leak detection equipment
Mechanical
* Oil leaks.
* Visibly damaged or worn components.
* Loose or missing nuts or bolts.

4. If the cause is not evident, verify the symptom and REFER to Symptom Chart.
The following checks should be carried out before repairing or installing a new transaxle.
The inspection and verification of manual transaxle concerns can be considered in three main
areas.
Gear shifting concerns
1. Check the operation of the clutch: Lay a block of wood approximately 25 mm thick under
the clutch pedal and depress the clutch pedal as far as the stop. If first or second gear can
be selected with the engine running and the parking brake applied, without any concerns,
the clutch is OK.
2. If the gear(s) cannot be selected, REFER to Symptom Chart.
Transaxle noise concerns
1. Check the engine and transaxle support for insufficient gap between the transaxle and the
body.
2. Road test the vehicle. REFER to Section 100-00.
3. If a noise occurs in various gears at the same engine speed, check if the noise also occurs
in the neutral position. If it does, the noise is not caused by the transaxle.
4. REFER to Symptom Chart.
Oil leakage concerns
1. Check the transaxle fluid level. If necessary, drain off any excess fluid.
Page 2 of 6
2. Clean the transaxle and the adjacent areas carefully and road test the vehicle. REFER to
Section 100-00.
3. Using suitable ultraviolet fluid leak detection equipment, locate the leak and check whether
the leaking fluid is transaxle fluid, brake fluid (from the hydraulically operated clutch) or
engine oil.
4. REFER to Symptom Chart.
Symptom Chart

Clutch *Clutch master *GO to Pinpoint Test A.
slippage cylinder.
*Clutch slave cylinder.
*Clutch pressure plate.
*Clutch disc.
*Engine or transaxle
housing oil or fluid
leak(s).
Clutch *Engine and transaxle *
chatter or mounts.
shudder *Clutch pressure plate. *GO to Pinpoint Test B.
*Clutch disc.
*Flywheel.
Clutch drag *Insufficient brake *FILL the brake master cylinder reservoir to the MAX
fluid. mark. INSPECT the brake and clutch hydraulic
systems for leaks. REPAIR as necessary.
*Air in the clutch *BLEED the system. REFER to Clutch System Bleeding
hydraulic system. in this section.
*Clutch pedal free *GO to Pinpoint Test C.
travel.
*Clutch pressure plate.
*Clutch disc.
*Crankshaft end play.
Clutch pedal *Clutch pressure plate. *INSTALL a new clutch disc and pressure plate. Refer
pulsation *Clutch disc. to the appropriate section in Group 308 for the
procedure.
*Crankshaft end play. *CHECK the crankshaft end play. REFER to
Section 303-00.
Hard shifting *Clutch drag. *GO to Pinpoint Test C.
*Gearshift cable *CHECK the gearshift cable adjustment. REFER to
adjustment Gearshift Cable Adjustment in this section.
*External controls. * CHECK the external controls for wear or damage.
Refer to the appropriate section in Group 308 for the
procedure. INSTALL new components as necessary.
*Gear wheels. *DISASSEMBLE the transaxle. Refer to the appropriate
section in Group 308 for the procedure. INSTALL new
*Selector mechanism. *DISASSEMBLE the transaxle. Refer to the appropriate
*Synchronizer(s). *DISASSEMBLE the transaxle. Refer to the appropriate
Page 3 of 6
Excessive *Engine vibrations *
noise inadequately damped.
*Transaxle fluid level *CHECK the transaxle for leaks. TOP UP the
low. transmission fluid. Refer to the appropriate section in
Group 308 for the procedure.
*Engine or transaxle is *
in contact with the
chassis or body.
*Engine and transaxle *
out of alignment.
*External controls. * CHECK the external controls for wear or damage.
Refer to the appropriate section in Group 308 for the
procedure. INSTALL new components as necessary.
*Gear wheels and *DISASSEMBLE the transaxle. Refer to the appropriate
bearings. section in Group 308 for the procedure. INSTALL new
*Clutch pedal. *GO to Pinpoint Test D.
*Clutch release bearing.
Fluid leakage *Clutch master *INSPECT the brake and clutch hydraulic systems for
cylinder. leaks. REPAIR as necessary.
*Clutch slave cylinder.
*Clutch hydraulic lines.
*Halfshaft oil seal. * INSTALL a new halfshaft oil seal. Refer to the
appropriate section in Group 308 for the procedure.
*Fluid leak between the *DISASSEMBLE the transaxle and clean the mating
transaxle housing faces. CHECK the mating faces for damage. SEAL the
sections. transaxle with sealant. Refer to the appropriate
section in Group 308 for the procedure.
PINPOINT TEST A : CLUTCH SLIPPAGE
A1: TEST CLUTCH SLIPPAGE
1 Lock the wheels and apply the parking brake.
2 Start the engine and engage fourth gear.
3 Run the engine at approximately 2000 rpm.
4 Release the clutch pedal slowly.

Does the engine stall when the clutch pedal is fully released?
Yes
Clutch OK.
No
GO to A2.
A2: CHECK THE CLUTCH PEDAL OPERATION
1 Depress clutch pedal and allow it to return.
Does the pedal return to the initial position?
Yes
GO to A3.
No
GO to A4.
A3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Remove the clutch disc and pressure plate. Refer to the appropriate section
in Group 308 for the procedure.
Page 4 of 6
Is the clutch disc or pressure plate contaminated with oil or hydraulic fluid?
Yes
CHECK the engine and transaxle for leaks. INSTALL new components as
No
INSTALL a new clutch disc and pressure plate. Refer to the appropriate section
in Group 308 for the procedure. TEST the system for normal operation.
A4: CHECK THE CLUTCH HYDRAULIC SYSTEM
1 Release the clutch slave cylinder bleed nipple.
Does the pedal return to the initial position?
Yes
INSTALL a new clutch slave cylinder. Refer to the appropriate section in Group
308 for the procedure. TEST the system for normal operation.
No
INSTALL a new clutch master cylinder. Refer to the appropriate section in
Group 308 for the procedure. TEST the system for normal operation.
PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER
B1: TEST FOR CLUTCH SHUDDER
1 Start the engine.
2 Engage the clutch and select fourth gear.
3 Run the engine at approximately 2000 rpm.
4 Release the clutch pedal slowly.

Does the clutch take up the drive smoothly?
Yes
Clutch is OK.
No
GO to B2.
B2: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid?
Yes
No
GO to B3.
B3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Visually check the clutch disc and pressure plate.
Is the clutch disc and pressure plate worn or damaged?
Yes
No
CARRY OUT the flywheel clutch surface inspection. REFER to Section 303-00.
PINPOINT TEST C : CLUTCH DRAG
Page 5 of 6
C1: CHECK THE OPERATION OF THE CLUTCH PEDAL

1 Depress and release the clutch pedal.
Is excessive force required to depress the clutch pedal?
Yes
GO to C2.
No
GO to C3.
C2: CHECK THE CLUTCH HYDRAULIC SYSTEM
1 Release the clutch slave cylinder bleed nipple and depress the clutch pedal.
Does the clutch pedal operate freely?
Yes
INSTALL a new clutch slave cylinder. Refer to the appropriate section in Group
308 for the procedure. TEST the system for normal operation.
No
INSTALL a new clutch master cylinder. Refer to the appropriate section in
Group 308 for the procedure. TEST the system for normal operation.
C3: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid?
Yes
No
GO to C4.
C4: CHECK THE CLUTCH DISC AND PRESSURE PLATE
1 Visually check the clutch disc and pressure plate.
Is the clutch disc and pressure plate worn or damaged?
Yes
No
GO to C5.
C5: CHECK THE INPUT SHAFT SPLINES
1 Check that the clutch disc slides freely on the input shaft splines.
Does the clutch disc stick on the input shaft?
Yes
CHECK the clutch disc and input shaft splines for damage. INSTALL new
No
MEASURE the crankshaft end play. REFER to Section 303-00.
PINPOINT TEST D : EXCESSIVE NOISE
D1: STATIC CHECK
1 Depress and release the clutch pedal.
Is the noise apparent when the clutch is operated?
Yes
LUBRICATE the clutch and brake pedal shaft. TEST the system for normal
operation.
Page 6 of 6
No
GO to D2.
D2: DYNAMIC CHECK
1 Start the engine.
2 Depress the clutch pedal.

Is the noise apparent when the clutch pedal is depressed?
Yes
No
INSTALL a new clutch slave cylinder and release bearing assembly. Refer to the
appropriate section in Group 308 for the procedure. TEST the system for
normal operation.
Page 1 of 4

SPECIFICATIONS
UID=G323577
Engine Data - 1.25L
Description
Code - Stage III FUJB/F8JA
Code - Stage IV FUJA/F8JB
Bore 71.9 mm
Stroke 76.5 mm
Power output at 5700 rpm (Engine codes FUJB/F8JA/F8JB) 51 kW (70 PS)
Power output at 5700 rpm (Engine codes FUJA) 55 kW (75 PS)
Maximum permissible engine speed continuous 5950 rpm
Maximum permissible engine speed intermittent 6175 rpm
Idle speed 750 rpm
Engine Data - 1.4L
Description
Code FXJA/FXJB
Bore 76.0 mm
Stroke 76.5 mm
Idle speed 750 rpm
Engine Data - 1.6L
Description
Engine code FYJA
Bore 79.0 mm
Stroke 81.4 mm
Idle speed 750 rpm
Oil pressure
Description bar
Page 2 of 4
Oil pressure (minimum, oil temperature 80°C) at 800 rpm 1.0

Oil pressure (minimum, oil temperature 80°C) at 2000 rpm 2.5
Pressure relief valve opening pressure 4
Engine Oil Capacity - 1.25L/1.4L
Description Liters
Service fill excluding oil filter 3.50
Engine Oil Capacity - 1.6L
Description Liters
Service fill excluding oil filter 3.75
Valve Clearance - 1.25L/1.4L
Description mm
Valve clearance (engine cold), intake 0.17 - 0.23
Valve clearance (engine cold), exhaust 0.27 - 0.33
Valve Clearance - 1.6L
Description mm
Valve clearance (engine cold), intake 0.17 - 0.23
Valve clearance (engine cold), exhaust 0.31- 0.37
Cylinder block - 1.25L
Description mm
Cylinder bore diameter, class 1 71.900 - 71.910
Crankshaft end float 0.300 - 0.800
Description mm
Description mm
Cylinder head
Description mm
Maximum distortion (mating face) 0.05
Page 3 of 4
Piston - 1.25L
Description mm
Piston diameter, class 1 (uncoated) 71.870 - 71.880
Piston ring gaps, upper 0.170 - 0.270
Piston ring gaps, middle 0.700 - 0.900
Piston ring gaps, lower 0.300 - 0.700
Piston ring end float, upper 0.040 - 0.080
Piston ring end float, middle 0.025 - 0.070
Piston - 1.4L
Description mm
Piston - 1.6L
Description mm
Piston diameter, class 1 (coated) 78.975 - 79.005
Item Specification
Engine oil 5W30 (recommended oil: Mazda genuine DEXELIA) ACEA A1/B1 or ACEA A3/B3
Silicone grease
Silicone rubber sealant (Gel type)
Silicone rubber sealant (low viscosity)
Sealant (e.g. Loctite 243)

Exhaust flexible pipe to catalytic converter retaining nuts 44 33 -
Lower arm to wheel knuckle pinch bolt 47 35 -
Intermediate shaft center bearing bracket to cylinder block retaining bolts 24 18 -
Starter motor cable retaining nut 11 8 -
Exhaust manifold heat shield retaining bolts 25 18 -
Page 4 of 4
Ground cable to transaxle retaining bolt 47 35 -

Coolant expansion tank retaining bolts 8 - 71
Engine front mount bracket to cylinder block retaining bolts 55 41 -
Engine front mount retaining nuts and bolts 48 35 -
Engine rear mount center retaining nut 90 66 -
Engine rear mount outer retaining nuts 48 35 -
Power steering line support bracket retaining bolts 25 18 -
Power steering line to power steering pump 65 48 -
Air conditioning (A/C) compressor to cylinder block retaining bolts 25 18 -
Generator to cylinder block top rear and lower retaining bolts 47 35 -
Generator to engine front mount bracket retaining bolt 42 31 -
Water pump pulley retaining bolts 27 20 -
Oil pump to cylinder block retaining bolts 9 - 80
Oil pan to cylinder block retaining bolts 20 15 -
Oil level indicator tube bracket retaining bolt 4 - 35
Engine oil drain plug 28 21 -
Oil pump pickup pipe to cylinder block retaining bolts 9 - 80
Oil pressure switch 15 11 -
Cylinder head bolts a) - -
Valve cover retaining bolts a) - -
Intake manifold to cylinder head retaining bolts 18 13 -
Exhaust manifold to cylinder head 54 40 -
Camshaft position (CMP) sensor 9 - 80
Timing belt rear cover retaining bolts 9 - 80
Spark plugs 15 11 -
Engine rear lifting eye retaining bolts 20 15 -
Coolant distribution housing retaining bolts 20 15 -
Ignition coil to coolant distribution housing 6 - 53
Camshaft bearing cap retaining bolts a) - -
Timing belt upper cover to cylinder block retaining bolts 9 - 80
Timing belt lower cover to cylinder block retaining bolts 9 - 80
Timing belt tensioner retaining bolts 20 15 -
Camshaft pulley retaining bolt 60 44 -
Crankshaft position (CKP) sensor bracket to cylinder block retaining bolts 9 - 80
Crankshaft rear oil seal carrier retaining bolts 9 - 80
Cylinder block blanking plug 20 15 -
Crankshaft pulley retaining bolt a) - -
Engine coolant temperature (ECT) sensor 18 13 -
Exhaust manifold studs 10 - 89
Fuel rail to intake manifold 15 11 -
Knock sensor (KS) retaining bolt 20 15 -
Positive crankcase ventilation (PCV) cover retaining bolts 9 - 80
Flywheel to crankshaft retaining bolts a) - -
Transaxle retaining bolts 47 35 -
Intermediate shaft center bearing cap retaining nuts 25 18 -
Ground cable to cylinder head retaining bolt 18 13 -
Suspension strut and spring assembly top mount retaining nuts 25 18 -
a) Refer to procedure in this section.
Page 1 of 3

VALVE COVER
UID=G323578
Name Specification
Silicone grease
Removal
01.
3. Disconnect the spark plug electrical connectors
and detach the wires from the valve cover.

5. Remove the air cleaner support brackets.
6. Detach the heated oxygen sensor (HO2S)

bracket from the valve cover.
Page 2 of 3
7. Loosen the engine lifting eye retaining bolts.
8. Remove the valve cover.
Installation
All vehicles
1. NOTE: Check the valve cover gasket for
damage and install a new valve cover gasket
if necessary.
Install the valve cover.

three stages.
 Stage 1: Tighten bolt 1 by 3 to 4 turns.
 Stage 3: Tigthen bolts 1 through 13 to 9 Nm.

2. Tighten the engine lifting eye retaining bolts.
3. Attach the heated oxygen sensor (HO2S)

bracket to the valve cover.
4. Install the air cleaner support brackets.
Page 3 of 3
6. CAUTION: Use a suitable blunt object

to avoid damage to the spark plug connector
gasket. Coat the inside of the spark plug
connector with silicone grease to depth of 5-
10 mm.
Connect the spark plug electrical connectors and
attach the wires to the valve cover.

01.

11.
Page 1 of 2

VALVE CLEARANCE ADJUSTMENT
UID=G323580
General Equipment
Feeler gauges
1. Remove the valve cover. For additional
section.
2. CAUTION: Only turn the engine in the

Turn the engine until piston No. 1 is at top dead
center (TDC).
3. NOTE: Note down each cylinder number
and the valve clearances measured.
Using a suitable set of feeler gauges, measure
the valve clearances.
4. CAUTION: Only turn the engine in the

Turn the engine until each piston is at TDC and
measure the valve clearances.
5. NOTE: Only carry out the following steps
when the valve clearance(s) require
adjustment. For additional information, refer
to Specification - in this section.
Remove the camshafts. For additional
6. NOTE: The number on the tappet indicates
the tappet thickness.
Determine the tappet thickness required:
1. Remove the tappet and read the thickness
from the underside.
2. Tappet thickness required = thickness of
currently installed tappet + the measured
valve clearance - the required valve
clearance. For additional information, refer
to Specification - in this section.
3. Install the correct tappet.
7. NOTE: Do not install the timing belt at this
stage.
Install the camshafts. For additional information,
refer to Camshafts in this section.
8. NOTE: Turn the camshafts to measure the
valve clearances.
Measure the valve clearances and repeat this
procedure as necessary until all valve
clearances are within the specified tolerance.
Page 2 of 2

section.
10. Install the valve cover. For additional
section.
Page 1 of 1

UID=G323662

1 - Crankcase vent oil separator
2 - Positive crankcase ventilation (PCV) valve
The positive crankcase ventilation system recycles crankcase gases back through the engine
where they mix with the incoming air/fuel charge.
The positive crankcase ventilation valve regulates the amount of ventilation air and crankcase
gas supplied to the intake manifold. This also prevents backfiring into the crankcase.
The positive crankcase ventilation valve is connected to the intake manifold by a rubber hose
and the air cleaner is connected to the engine valve cover by a rubber hose.
The positive crankcase ventilation system helps to reduce hydrocarbon emissions from the
engine.
Page 1 of 2

FUEL SYSTEM
UID=G323663

1 - Fuel level sensor - vehicles with 1.4L diesel engine
2 - Fuel filter - vehicles with 1.4L diesel engine
3 - Water drain valve - vehicles with 1.4L diesel engine
4 - Fuel tank filler pipe - all vehicles
5 - Fuel filter - all except vehicles with diesel engine
6 - Fuel tank - all vehicles
7 - Fuel pump module - vehicles with 1.4L diesel engine
Fuel Level Sensor - Vehicles with 1.4L Diesel Engine
Page 2 of 2
The fuel level sensor monitors the quantity of fuel in the tank. Fuel is drawn from the fuel
tank by the fuel injection pump.
Fuel Filter - Vehicles with 1.4L Diesel Engine
The fuel filter cleans the fuel of contaminants. Unused fuel is returned to the fuel tank
through the oil filter.
Water Drain Valve - Vehicles with 1.4L Diesel Engine
The water drain valve is located at the base of the fuel filter and allows water to be drained
periodically or during annual services.
Fuel Filter - All Except Vehicles with Diesel Engine
The fuel filter cleans the fuel of contaminants before the fuel is delivered to the fuel injection
supply manifold, which then supplies high-pressure fuel to the fuel injectors.
Fuel Pump Module - All Except Vehicles with Diesel Engine
The fuel pump module is located inside the fuel tank and pressurizes the fuel. This
pressurized fuel is then delivered through the fuel supply lines to the fuel filter.
Page 1 of 2

INSTRUMENT CLUSTER
UID=G323668

1 - Tachometer
2 - Automated gearshift system mode indicator
3 - Left turn signal indicator
4 - Anti-lock brake system (ABS) warning indicator
5 - Front fog light indicator
6 - Automated gearshift system warning indicator
7 - High beam indicator
8 - Rear fog lamp indicator
9 - Dynamic stability control (DSC) indicator
10 - Right turn signal indicator
11 - Speedometer
12 - Dynamic stability control (DSC) warning light
13 - Fuel gauge
14 - Fuel level warning indicator
15 - Tripmeter reset button
16 - Odometer
17 - Tripmeter
18 - Automated gearshift system selection indicator
19 - Malfunction indicator lamp (MIL)
20 - Parking brake/brake warning indicator
21 - Charge warning indicator
22 - Low oil pressure warning indicator
23 - Air bag/safety belt pretensioner warning indicator
24 - Door ajar warning indicator
25 - Safety belt warning indicator
26 - Engine immobilization indicator
27 - Temperature gauge
Page 2 of 2
The instrument cluster provides the driver with information and warning indicators on the
vehicle systems.
Vehicle options dictate the operational warning indicators, although the legends may be fitted,
not all will be illuminated.
The gauges and warning indicators may use the outputs from common sensors to carry out
their respective functions. This should always be considered when looking at any system
which may not be functioning correctly.
Always consider and check associated systems for operation, as this may save time when
looking for a concern.
Instrument clusters should be changed as an assembly and not dismantled.
Technical Data
Item Details Specification

Speedometer Meter type Stepper motor type
Speedometer Indication range (km/h) 0-200
Speedometer Input signal communication CAN system
system
Speedometer Input signal source Powertrain control module (PCM)
Speedometer Rated voltage (V) DC 12
Tachometer Meter type Stepper motor type
Tachometer Indication range (rpm) 0-8000
Tachometer Red zone (rpm) 6500-8000
Tachometer Input signal communication CAN system
system
Tachometer Input signal source PCM
Tachometer Rated voltage (V) DC 12
Fuel gauge Meter type Stepper motor type (Reset-to-zero type)
Fuel gauge Input signal communication Conventional system
system
Fuel gauge Input signal source Fuel pump module/fuel level sensor
Fuel gauge Rated voltage (V) DC 12
Temperature gauge Meter type Stepper motor type (medium range
stabilized type)
Temperature gauge Input signal communication CAN system
system
Temperature gauge Input signal source PCM
Temperature gauge Rated voltage (V) DC 12
Odometer/Tripmeter Display LCD
Odometer/Tripmeter Indication digits Odometer: 6 digits, Tripmeter: 4 digits
Odometer/Tripmeter Input signal communication CAN system
system
Odometer/Tripmeter Input signal source PCM
Odometer/Tripmeter Rated voltage (V) DC 12
Page 1 of 3

ANTI-THEFT - ACTIVE
UID=G323669

1 - Front door latch
2 - Hood latch
3 - Liftgate latch
4 - Anti-theft horn
5 - Anti-theft module
6 - Data link connector (DLC)
7 - Rear door latch
The anti-theft system provides protection from unauthorized entry into the vehicle and is
controlled by the anti-theft module.
Page 2 of 3
System Arming
The system will be armed by the remote transmitter when the following input sequence is
followed:
1. Turn the ignition switch to the OFF position and remove the ignition key.
2. Close all the doors (unlocked).
3. Press the LOCK button on the remote transmitter to lock the doors. The turn signal
indicators will flash once.
4. If the turn signal indicators do not flash, the system is not armed.
The system will also be armed when the following input sequence is followed:
5. Turn the ignition switch to the OFF position and remove the ignition key.
6. Close all the doors (unlocked).
7. Lock the doors, with the ignition key.
Disarming an Untriggered System
The system can be disarmed by carrying out one of the following procedures.
- Unlock a front door with an ignition key.
- Unlock the front door by pressing the UNLOCK button on the remote
transmitter.
System Triggering
When the system is triggered, the system flashes the turn signal indicators, and sounds the
anti-theft horn.
When armed, unauthorized entry into the vehicle without using an ignition key or remote
transmitter is detected by a switch being triggered in the door latch, liftgate latch or hood
latch. The system will also be triggered if the ignition switch is turned to the ON position or if
the audio unit electrical connectors are disconnected.
The anti-theft system will not activate, if the liftgate is opened using an ignition key or
remote transmitter due to an inhibit switch.
Disarming a Triggered System
Carrying out either of the following steps will disarm the triggered anti-theft system.
- Unlock the driver or passenger front door with an ignition key.
- Pressing the UNLOCK button on a remote transmitter.
When the system has been triggered, the anti-theft horn will shut off automatically after 30
seconds and the turn signal indicators will shut off automatically after 5 minutes. The system
will then reset to an armed state and will trigger again if another intrusion occurs.
Page 3 of 3
Page 1 of 2

UID=G323670

1 - Instrument Cluster
2 - Powertrain control module ( PCM )
3 - PATS transceiver
4 - Data link connector (DLC)
5 - Transponder (within the ignition key)
6 - Passive anti-theft system ( PATS ) warning lamp
7 - Starter motor
8 - Fuel injectors
9 - Electronic ignition ( EI )
Function
PATS is a passive system designed to increase the anti-theft security of a vehicle. It does not
need to be activated or deactivated by the driver.
The PATS system uses specially encoded keys.
Every encoded ignition key contains a transponder which is permanently fitted to the ignition
Page 2 of 2
key. This transponder contains an identification code randomly selected from millions of
possible combinations (crypto-transponder with automatically changing code).
The transceiver is located around the ignition lock cylinder. The transceiver incorporates an
antenna which is connected to an integrated electronics module.
When the ignition key is turned to position II, communications take place initially between the
transceiver and the PCM.
If these communications are free of errors, then the transponder is actuated by the PCM via
the transceiver.
The transponder returns the identification code to the PCM for processing.
PATS warning lamp
Flash code for PATS (example: code 21)

0 - Warning lamp OFF
1 - Warning lamp ON
A - Two flashing signals (1st digit)
B - One flashing signal (2nd digit)
C - Approximately 3-second pause
D - Repetition of the flash code
As an optical signal, the (PATS ) system sends an actuation signal to the PATS warning lamp
approximately every 2 seconds when the ignition lock cylinder is in position 0.
In the event of a system fault, the PATS outputs a corresponding flash code.
Page 1 of 1

UID=G323674
Expanded passive anti-theft system (PATS ) functionality
The PATS is fully passive in operation and requires no special procedures by the driver to arm
or disarm the system. It is invisible to normal scrutiny and is operated by a miniature
transponder within the key body. This communicates with the powertrain control module
(PCM ) through a transceiver mounted around the ignition lock cylinder.
The PATS functionality is incorporated within the PCM but has been expanded to increase
anti-theft security. The new system also uses new keys.
After completion of the usual PATS communications between the transponder, transceiver and
the PCM , the PCM also requests a code from the instrument cluster module via the CAN
databus in order to increase the passive anti-theft security.
As a result, a further component which is not easily removable is required to enable an

engine start.
All of the code requests must be completed successfully before the PCM will start the engine.
NOTE: When renewing the instrument cluster or the PCM an initialization with WDS is
required.
In order to ensure that the engine can be started as quickly as possible, the initial starting
procedure is initiated provided the correct key has been detected and no communications
errors to the instrument cluster have arisen.
However, if the PCM determines within a maximum of three seconds that not all of the PATS
conditions have been satisfied, then the engine is switched back off and cannot be restarted
(no starter signal, no fuel injection signal, no ignition signal).
Page 1 of 1

UID=G323746
1.25L, 1.4L and 1.6L engines

2 - Fuel supply manifold
3 - Fuel injector retaining clip
4 - Fuel injector O-ring seals
5 - Fuel injector
The supply manifold is a one-piece aluminium die casting with machined holes for the fuel
pressure regulator and the fuel injectors. The supply manifold is retained to the engine by two
bolts.
The pressure regulator is fitted directly into the supply manifold and is retained by two bolts.
Sealing is achieved by means of an O-ring seal.
The fuel pressure regulator is of the vacuum operated, spring loaded diaphragm type and is
designed to maintain a constant pressure in the supply manifold with excess fuel being
returned to the fuel tank.
The fuel injectors are fitted directly into the supply manifold and are retained by the supply
manifold when assembled to the intake manifold. Sealing is achieved by means of upper and
lower O-ring seals. The fuel injectors are activated sequentially by the powertrain control
module which modifies fuelling by adjusting fuel injector opening times according to engine
operating conditions.
Page 1 of 1

ENGINE IGNITION
UID=G323747
1.25L, 1.4L and 1.6L engines

1 - Spark plug wires
2 - Ignition coil
3 - Spark plugs
The crankshaft position sensor signal is the basis for ignition timing calculations. The
alternating voltage signal from the crankshaft position sensor is digitized by the powertrain
control module. This digitized signal is then used to position the closing time of the primary
circuit of the ignition coil.
Ignition angle is determined by the powertrain control module in response to engine

operating conditions. Once ignition angle has been determined, the powertrain control module
interrupts the current to the primary circuit of the ignition coil thus triggering the ignition
spark which is supplied to the cylinders through the spark plug wires and spark plugs.
The ignition coils are triggered by the powertrain control module in pairs (cylinders 1 and 4
and cylinders 2 and 3) sending one ignition spark to the firing cylinder and one ignition spark
to the corresponding cylinder on the exhaust stroke.
Page 1 of 1

JACKING
UID=G324301
WARNING: Always position the vehicle on a hard level surface. If the vehicle must be
jacked up on a soft surface use load spreading blocks under the jack. Always chock the
wheel diagonally opposite the jacking point. Failure to follow these instructions may result
in personal injury.
CAUTION: It is important that only the correct jacking points are used at all times.
Page 1 of 1

LIFTING
UID=G324302
CAUTIONS:
When lifting a vehicle with a two-post lift, vehicle leveling pads must be used under
the lifting points.
It is important that only the correct lifting points and support locations are used at all
times.
Page 1 of 11

DIAGNOSTIC INSTRUCTIONS - AIR
BAG AND SAFETY BELT
UID=G325383
Electrical
* Fuse(s)
* Circuit(s)
* Air bag module(s)
* Bulb
4. If the cause is not visually evident, connect the diagnostic tool to the data link connector
and select the vehicle to be tested from the diagnostic tool menu.
5. Retrieve the DTCs and refer to the Symptom Chart.
SRS On-Board Diagnosis
* The OBD test inspects the integrity and function of the SRS and outputs the
results when requested by the specific tests.
 Provides a quick inspection of the SRS usually performed at the start of each
diagnostic procedure.
during service.
modes.

Page 2 of 11
This function allows you to read or clear DTCs in the restraints control module memory.
Active command modes
This function allows you to control devices through the WDS.

Page 3 of 11
2. Turn the ignition switch to ON (engine OFF) or start the engine.
3. Activate active command modes using WDS.
Diagnostic Tables
PID/DATA Monitor Table Numeric PIDs
RCM terminal
PID Name Definition Units Range (s)
CCNT_RCM Number of Continuous Trouble Codes DTC(s) 0 - 255 -
Set (Unitless)
VBATT System Ignition Voltage Volts (V) 0- 2U
19.6
BIT Mapped PIDs
Group Name PID Name Bit Description

Continuous Restraint D_PTENSFLT(Driver side Driver Pretensioner Other:
System - Seatbelt seatbelt pretensioner fault Resistance Low on Squib Normal
Pretensioner Status status) (SQ_LOWERS)
Driver Pretensioner Open
Circuit (OPEN)
Driver Pretensioner Short to
Battery (SHRT_B+)
Ground (SHRT_GND)
P_PTENSFLT(Passenger side Passenger Pretensioner Other:
seatbelt pretensioner fault Resistance Low on Squib Normal
status) (SQ_LOWERS)
Passenger Pretensioner Open
Circuit (OPEN)
Passenger Pretensioner Short
to Battery (SHRT_B+)
to Ground (SHRT_GND)
Continuous Restraint DS1_STAT(driver side no. 1 Driver Air Bag First Stage Other:
System - Airbag loop airbag circuit fault status) Short to Ground (SHRT_GND) Normal
Status Driver Air Bag First Stage
Short to Battery (SHRT_B+)
Driver Air Bag First Stage
Open Circuit (OPEN)
Inflator Resistance Low on
Page 4 of 11
Squib (SQ_LOWERS)
PS1_STAT(Passenger side no. Passenger Air Bag First Stage Other:
1 loop airbag circuit fault Short to Ground (SHRT_GND) Normal
status) Passenger Air Bag First Stage
Passenger Air Bag First Stage
Open Circuit (OPEN)
Squib (SQ_LOWERS)
DS2_STAT(driver side no. 2 Driver Air Bag Second Stage Other:
loop airbag circuit fault status) Short to Ground (SHRT_GND) Normal
Driver Air Bag Second Stage
Open Circuit (OPEN)
Squib (SQ_LOWERS)
PS2_STAT(Passenger side no. Passenger Air Bag Second Other:
2 loop airbag circuit fault Stage Short to Ground Normal
status) (SHRT_GND)
Passenger Air Bag Second
Stage Short to Battery
(SHRT_B+)
Stage Open Circuit (OPEN)
Stage Inflator Resistance Low
on Squib (SQ_LOWERS)
Continuous Restraint DS_CURT_ST(driver side Driver Side Air Curtain Circuit Other:
System - Curtain center pillar curtain status) Short to Battery (SHRT_B+) Normal
Status Driver Side Air Curtain Circuit
Short to Ground (SHRT_GND)
Driver Side Air Curtain Open
Circuit (OPEN)
Driver Side Air Curtain Circuit
Resistance Low on Squib
(SQ_LOWERS)
PS_CURT_ST(passenger side Passenger Side Air Curtain Other:
center pillar curtain status) Circuit Short to Battery Normal
(SHRT_B+)
Passenger Side Air Curtain
Circuit Short to Ground
(SHRT_GND)
Open Circuit (OPEN)
Circuit Resistance Low on
Squib (SQ_LOWERS)
Continuous Restraint DS_AB_ST(driver side; side Driver Side Air Bag Circuit Other:
System - Side Airbag airbag fault status) Short to Battery (SHRT_B+) Normal
Status Driver Side Air Bag Circuit
Driver Side Air Bag Open
Circuit (OPEN)
Page 5 of 11
Driver Side Air Bag Circuit

(SQ_LOWERS)
PS_AB_ST(passenger side; Passenger Side Air Bag Other:
side airbag fault status) Circuit Short to Battery Normal
(SHRT_B+)
Passenger Side Air Bag
(SHRT_GND)
Passenger Side Air Bag Open
Circuit (OPEN)
Squib (SQ_LOWERS)
Continuous Restraint D_CRSH_S(driver side side Driver Side Impact Sensor Other:
System - Impact crash sensor status) Communications Fault Normal
Sensor Status (COMM_FAIL)
Driver Side Impact Sensor
Internal Fault (INT_FAIL)
P_CRSH_S(passenger side; Passenger Side Impact Other:
side crash sensor status) Sensor Communications Fault Normal
(COMM_FAIL)
Passenger Side Impact
Sensor Internal Fault
(INT_FAIL)
FNT_CRSH_SFront Crash Front Crash Sensor Other:
Sensor Communication Status) Communications Fault Normal
(COMM_FAIL)
Front Crash Sensor Internal
Fault (INT_FAIL)
On-Demand Restraint DSB_P_ST(driver seatbelt Driver Pretensioner Other:
System - Seatbelt pretensioner fault status) Resistance Low on Squib Normal
Pretensioner Status (SQ_LOWERS)
Driver Pretensioner Open
Circuit (OPEN)
Battery (SHRT_B+)
Ground (SHRT_GND)
PSB_P_ST(passenger seatbelt Passenger Pretensioner Other:
pretensioner fault status) Resistance Low on Squib Normal
(SQ_LOWERS)
Passenger Pretensioner Open
Circuit (OPEN)
to Battery (SHRT_B+)
to Ground (SHRT_GND)
On-Demand Restraint OD_DAB1_ST(on demand Driver Air Bag First Stage Other:
System - Airbag Fault driver side no. 1 loop airbag Short to Ground (SHRT_GND) Normal
Status circuit fault status) Driver Air Bag First Stage
Open Circuit (OPEN)
Page 6 of 11
Squib (SQ_LOWERS)
OD_PAB1_ST(on demand Passenger Air Bag First Stage Other:
passenger side no. 1 loop Short to Ground (SHRT_GND) Normal
airbag circuit fault status) Passenger Air Bag First Stage
Open Circuit (OPEN)
Squib (SQ_LOWERS)
OD_DAB2_ST(on demand Driver Air Bag Second Stage Other:
driver side no. 2 loop airbag Short to Ground (SHRT_GND) Normal
circuit fault status) Driver Air Bag Second Stage
Open Circuit (OPEN)
Squib (SQ_LOWERS)
OD_PAB2_ST(on demand Passenger Air Bag Second Other:
passenger side no. 2 loop Stage Short to Ground Normal
airbag circuit fault status) (SHRT_GND)
Stage Short to Battery
(SHRT_B+)
Stage Open Circuit (OPEN)
Stage Inflator Resistance Low
on Squib (SQ_LOWERS)
On-Demand Restraint OD_D_CURT(on demand Driver Side Air Curtain Circuit Other:
System - Curtain driver-side A, B, C pillar Short to Battery (SHRT_B+) Normal
Status curtain circuit fault status) Driver Side Air Curtain Circuit
Driver Side Air Curtain Open
Circuit (OPEN)
Driver Side Air Curtain Circuit
(SQ_LOWERS)
OD_P_CURT(on demand Passenger Side Air Curtain Other:
passenger-side A, B, C pillar Circuit Short to Battery Normal
curtain circuit fault status) (SHRT_B+)
(SHRT_GND)
Open Circuit (OPEN)
Squib (SQ_LOWERS)
On-Demand Restraint OD_DSAB_ST(on demand Driver Side Air Bag Circuit Other:
System - Side Airbag driver side; side airbag fault Short to Battery (SHRT_B+) Normal
Fault Status status) Driver Side Air Bag Circuit
Driver Side Air Bag Open
Circuit (OPEN)
Page 7 of 11
Driver Side Air Bag Circuit

(SQ_LOWERS)
OD_PSAB_ST(on demand Passenger Side Air Bag Other:
passenger side; side airbag Circuit Short to Battery Normal
fault status) (SHRT_B+)
(SHRT_GND)
Passenger Side Air Bag Open
Circuit (OPEN)
Squib (SQ_LOWERS)
On-Demand Restraint OD_D_CRSH(on demand driver Driver Side Impact Sensor Other:
System - Impact side; side crash sensor status) Communications Fault Normal
Sensor Fault Status (COMM_FAIL)
Driver Side Impact Sensor
Internal Fault (INT_FAIL)
OD_P_CRSH(on demand Passenger Side Impact Other:
passenger side; side crash Sensor Communications Fault Normal
sensor status) (COMM_FAIL)
Passenger Side Impact
Sensor Internal Fault
(INT_FAIL)
OD_F_CRSH(On Demand Front Front Crash Sensor Other:
Crash Sensor Fault Status) Communications Fault Normal
(COMM_FAIL)
Front Crash Sensor Internal
Fault (INT_FAIL)
Symptom Chart
NOTE: It is only allowed to repair circuits between connectors. If damage has occurred within
a connector a new wiring harness must be installed. Connectors must not be disassembled.
No communication with the *DLC. *GO to Pinpoint Test A.
module *Circuit(s).
*Restraints control
module.
DTC B1231: Longitudinal *Crash data *CLEAR down the data memory using
acceleration threshold memory full. WDS. REPEAT the self-test, CLEAR the
exceeded. Lamp flash code: DTCs.
13. -The data memory can be cleared a
maximum of five times.
DTC B1317: Battery voltage *Charging system. *CHECK the charging system. REFER to
high Section 414-00.[Charging System -
General Information, DIAGNOSIS AND
TESTING, Charging System] REPEAT the
self-test, CLEAR the DTCs.
DTC B1318: Battery voltage *Battery. *GO to Pinpoint Test B.
low *Charging system.
*Circuit.
DTC B1342: Restraints control *Restraints control *INSTALL a new restraints control module.
module is defective. Lamp module. REFER to Restraints Control Module
flash code: 12. (RCM) in this section. REPEAT the self-
Page 8 of 11

DTC B1869: Air bag warning *Circuit(s). *GO to Pinpoint Test C.
indicator open circuit or short *Instrument
to ground. Lamp flash code: cluster.
continuous
*Restraints control
module.
DTC B1870: Air bag warning *Circuit. *GO to Pinpoint Test D.
indicator short to battery. *Instrument
Lamp flash code: No lamp cluster.
DTC B1877: Driver safety belt *Driver safety belt *GO to Pinpoint Test E.
pretensioner open circuit. pretensioner.
Lamp flash code: 33 *Circuit(s).
DTC B1878: Driver safety belt *Driver safety belt *GO to Pinpoint Test F.
pretensioner short to battery. pretensioner.
DTC B1879: Driver safety belt *Driver safety belt *GO to Pinpoint Test G.
pretensioner short to ground. pretensioner.
Lamp flash code: 33 *Circuit.
DTC B1881: Passenger safety *Passenger safety *GO to Pinpoint Test H.
belt pretensioner open circuit. belt pretensioner.
DTC B1882: Passenger safety *Passenger safety *GO to Pinpoint Test I.
belt pretensioner short to belt pretensioner.
battery. Lamp flash code: 34 *Circuit.
DTC B1883: Passenger safety *Passenger safety *GO to Pinpoint Test J.
belt pretensioner short to belt pretensioner.
ground. Lamp flash code: 34 *Circuit.
DTC B1885: Driver safety belt *Driver safety belt *GO to Pinpoint Test K.
pretensioner low resistance. pretensioner.
DTC B1886: Passenger safety *Passenger safety *GO to Pinpoint Test L.
belt pretensioner low belt pretensioner.
resistance. Lamp flash code: *Circuit.
34
DTC B1916: Driver air bag *Clockspring. *GO to Pinpoint Test M.
first stage short to battery. *Circuit.
Lamp flash code: 19
DTC B1921: Air bag *Restraints control *INSTALL a new restraints control module.
diagnostic monitor ground module internal REFER to Restraints Control Module
circuit open circuit. Lamp fault. (RCM) in this section. REPEAT the self-
flash code: 14 test, CLEAR the DTCs.
DTC B1925: Passenger air *Circuit(s). *GO to Pinpoint Test N.
bag first stage short to
battery. Lamp flash code: 21
DTC B1932: Driver air bag *Driver air bag *GO to Pinpoint Test O.
first stage open circuit. Lamp module.
flash code: 19 *Clockspring.
*Circuit(s).
DTC B1933: Passenger air *Passenger air bag *GO to Pinpoint Test P.
bag first stage open circuit. module.
DTC B1934: Driver air bag *Driver air bag *GO to Pinpoint Test Q.
first stage circuit low module.
resistance. Lamp flash code: *Clockspring.
Page 9 of 11
19 *Circuit(s).
DTC B1935: Passenger air *Passenger air bag *GO to Pinpoint Test R.
bag first stage low resistance. module.
DTC B1936: Driver air bag *Driver air bag *GO to Pinpoint Test S.
first stage circuit short to module.
ground. Lamp flash code: 19 *Clockspring.
*Circuit.
DTC B1938: Passenger air *Passenger air bag *GO to Pinpoint Test T.
bag first stage circuit short to module.
DTC B1992: Driver side air *Circuit. *GO to Pinpoint Test U.
bag circuit short to battery.
Lamp flash code: 22
DTC B1993: Driver side air *Driver side air *GO to Pinpoint Test V.
bag circuit short to ground. bag module.
Lamp flash code: 22 *Clockspring.
*Circuit.
DTC B1994: Driver side air *Driver side air *GO to Pinpoint Test W.
bag circuit open circuit. Lamp bag module.
flash code: 22 *Circuit.
DTC B1995: Driver side air *Driver side air *GO to Pinpoint Test X.
bag circuit low resistance on bag module.
squib. Lamp flash code: 22 *Circuit.
DTC B1996: Passenger side *Passenger side *GO to Pinpoint Test Y.
air bag circuit short to air bag module.
battery. Lamp flash code: 23 *Circuit.
DTC B1997: Passenger side *Passenger side *GO to Pinpoint Test Z.
air bag circuit short to air bag module.
DTC B1998: Passenger side *Passenger side *GO to Pinpoint Test AA.
air bag circuit open circuit. air bag module.
DTC B1999: Passenger side *Passenger side *GO to Pinpoint Test AB.
air bag circuit low resistance air bag module.
on squib. Lamp flash code: 23 *Circuit.
DTC B2226: Front crash *Crash sensor. *INSTALL a new crash sensor. REFER to
sensor internal fault. Lamp Crash Sensor in this section. REPEAT the
flash code: 42 self-test, CLEAR the DTCs.
DTC B2227: Front crash *Circuit(s). *GO to Pinpoint Test AC.
sensor communications fault.
Lamp flash code: 42
DTC B2228: Driver air bag *Driver air bag *GO to Pinpoint Test AD.
second stage short to ground. module.
Lamp flash code: 19 *Clockspring.
*Circuit(s).
DTC B2229: Passenger air *Passenger air bag *GO to Pinpoint Test AE.
bag second stage short to module.
ground. Lamp flash code: 21 *Circuit(s).
DTC B2230: Driver air bag *Clockspring. *GO to Pinpoint Test AF.
second stage short to battery. *Circuit(s).
Lamp flash code: 19
DTC B2231: Passenger air *Passenger air bag *GO to Pinpoint Test AG.
Page 10 of 11
bag second stage short to module.

battery. Lamp flash code: 21 *Circuit(s).
DTC B2232: Driver air bag *Driver air bag *GO to Pinpoint Test AH.
second stage circuit open module.
circuit. Lamp flash code: 19 *Circuit.
DTC B2233: Passenger air *Passenger air bag *GO to Pinpoint Test AI.
bag second stage circuit open module.
circuit. Lamp flash code: 21 *Circuit(s).
DTC B2234: Driver air bag *Driver air bag *GO to Pinpoint Test AJ.
second stage circuit low module.
resistance on squib. Lamp *Circuit(s).
flash code: 19
DTC B2235: Passenger air *Passenger air bag *GO to Pinpoint Test AK.
bag second stage circuit low module.
resistance on squib. Lamp *Circuit(s).
flash code: 21
DTC B2444: Driver side *Driver side *INSTALL a new driver side impact sensor.
impact sensor internal fault. impact sensor. REFER to Side Impact Sensor in this
Lamp flash code: 43 section. REPEAT the self-test, CLEAR the
DTCs.
DTC B2445: Passenger side *Passenger side *INSTALL a new passenger side impact
impact sensor internal fault. impact sensor. sensor. REFER to Side Impact Sensor in
Lamp flash code: 44 this section. REPEAT the self-test, CLEAR
the DTCs.
DTC B2477: Restraints control *Restraints control *CONFIGURE the restraints control
module configuration failure. module. module. REFER to Section 418-01.
Lamp flash code: 54 [Module Configuration, DIAGNOSIS AND
TESTING, Module Configuration] REPEAT
DTC B2773: Driver side air *Driver side air *GO to Pinpoint Test AL.
curtain circuit low resistance curtain module.
on squib. Lamp flash code: 24 *Circuit(s).
DTC B2774: Driver side air *Driver side air *GO to Pinpoint Test AM.
curtain circuit open circuit. curtain module.
DTC B2775: Driver side air *Driver side air *GO to Pinpoint Test AN.
curtain circuit short to curtain module.
ground. Lamp flash code: 24 *Circuit(s).
DTC B2776: Driver side air *Circuit(s). *GO to Pinpoint Test AO.
curtain circuit short to
DTC B2777: Passenger side *Passenger side *GO to Pinpoint Test AP.
air curtain circuit low air curtain
resistance on squib. Lamp module.
flash code: 25 *Circuit(s).
DTC B2778: Passenger side *Driver side air *GO to Pinpoint Test AQ.
air curtain circuit open circuit. curtain module
DTC B2779: Passenger side *Passenger side *GO to Pinpoint Test AR.
air curtain circuit short to air curtain
ground. Lamp flash code: 25 module.
*Circuit(s).
DTC B2780: Passenger side *Circuit(s). *GO to Pinpoint Test AS.
air curtain circuit short to
Page 11 of 11
DTC B2791: Air bag cut-off *Circuit(s). *GO to Pinpoint Test AT.
switch out of range. Lamp
flash code: 56
DTC B2791: Air bag cut-off *Passenger air bag *GO to Pinpoint Test AU.
switch user fault. Lamp flash deactivation
code: 56 control switch.
*Circuit
DTC C1414: Incorrect module *Restraints control *INSTALL a new restraints control module.
design level. Lamp flash code: module. REFER to Restraints Control Module
15. (RCM) in this section. REPEAT the self-
DTC U2017: Driver side *Circuit(s). *GO to Pinpoint Test AV.
impact sensor
communications fault. Lamp
flash code: 43
DTC U2018: Passenger side *Circuit(s). *GO to Pinpoint Test AW.
impact sensor
communications fault. Lamp
flash code: 44
Restraints control module *Restraints control *GO to Pinpoint Test AX.
disconnected or inoperative. module
Lamp flash code: continuous *Circuit(s).
Page 1 of 8

REAR VIEW MIRRORS
UID=G325384
2. Visually inspect for obvious signs of mechanical and electrical damage.
* Exterior mirror(s) * Fuse(s)
* Relay
* Switch

The mirrors are *Exterior mirror *CARRY OUT the Exterior Mirror Control
inoperative control switch. Switch Component Test. REFER to the Wiring
Diagrams.
*Circuit(s). *GO to Pinpoint Test A. .
A single mirror is *Exterior mirror *CARRY OUT the Exterior Mirror Control
inoperative control switch. Switch Component Test. REFER to the Wiring
Diagrams.
*Circuit(s). *GO to Pinpoint Test B. .
*Exterior mirror
motor(s).
A single mirror does not *Exterior mirror *CARRY OUT the Exterior Mirror Control
function with switch logic control switch. Switch Component Test. REFER to the Wiring
Diagrams.
*Circuit(s). *GO to Pinpoint Test C. .
*Exterior mirror
motor(s).
The heated exterior *Heated rear *CARRY OUT the Heated Rear Window Control
mirror does not defrost window control Switch Component Test. REFER to the Wiring
switch. Diagrams.
*Relay. *GO to Pinpoint Test D. .
*Circuit(s).
*Heated mirror
element(s).
PINPOINT TEST A : THE MIRRORS ARE INOPERATIVE
Page 2 of 8
A1: CHECK THE VOLTAGE TO THE EXTERIOR MIRROR CONTROL SWITCH

1 Disconnect Exterior Mirror Control Switch L-01.
3 Measure the voltage between the exterior mirror control

switch L-01, circuit BK/OG (DR1), harness side and
ground.

Yes
GO to A2.
No
REPAIR circuit BK/OG (DR1). TEST the system for normal
operation.
A2: CHECK THE EXTERIOR MIRROR CONTROL SWITCH GROUND CIRCUIT FOR
CONTINUITY
2 Measure the resistance between the exterior mirror

control switch L-01, circuit BK (DR1), harness side and
ground.

Yes
VERIFY the customer concern.
No
REPAIR circuit BK (DR1). TEST the system for normal
operation.
PINPOINT TEST B : A SINGLE MIRROR IS INOPERATIVE
B1: CHECK THE EXTERIOR MIRROR MOTOR CIRCUIT FOR CONTINUITY
2 Measure the resistance between the:
 LHD Driver Exterior Mirror
* exterior mirror control switch L-01,

circuit BR (DR1) and circuit LG (DR1),
harness side.
 LHD Passenger Exterior Mirror

circuit BR (DR1) and circuit BU/YE (DR1),
harness side.
Page 3 of 8
 RHD Driver Exterior Mirror

circuit BR (DR1) and circuit BU/YE (DR1),
harness side.
 RHD Passenger Exterior Mirror

circuit BR (DR1) and circuit WH (DR1),
harness side.
Yes
No
GO to B2.
B2: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH
AND THE EXTERIOR MIRROR
Disconnect Driver Exterior Mirror L-03 or Passenger
1
Exterior Mirror L-02.

circuit LG (DR1), harness side and the
driver exterior mirror L-03, circuit LG
(DR1), harness side.

circuit BU/YE (DR1), harness side and the
passenger exterior mirror L-02, circuit
BU/YE (DR2), harness side.

circuit BU/YE (DR1), harness side and the
driver exterior mirror L-03, circuit BU/YE

circuit WH (DR1), harness side and the
passenger exterior mirror L-02, circuit
BU/YE (DR2), harness side.
Yes
INSTALL a new exterior mirror. REFER to Exterior Mirror
in this section. TEST the system for normal operation.
No
REPAIR circuit LG (DR1), BU/YE (DR1), WH (DR1) or
Page 4 of 8
BU/YE (DR2). TEST the system for normal operation.

PINPOINT TEST C : A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH
LOGIC
C1: CHECK THE EXTERIOR MIRROR FUNCTIONS WITH SWITCH LOGIC
2 Operate the exterior mirror control switch.

Does the exterior mirror function with switch logic?
Yes
No
Driver exterior mirror up/down function is inoperative GO
to C2.
Driver exterior mirror left/right function is inoperative GO

to C4.
Passenger exterior mirror up/down function is

inoperative GO to C6.
Passenger exterior mirror left/right function is

inoperative GO to C8.
C2: CHECK THE DRIVER EXTERIOR MIRROR UP/DOWN CIRCUIT

circuit LG (DR1) and circuit BR (DR1),
harness side.

circuit BU/YE (DR1) and circuit BR (DR1),
harness side.
Yes
No
GO to C3.
C3: CHECK FOR CONTINUITY BETWEEN THE EXTERIOR MIRROR CONTROL SWITCH
1 Disconnect Driver Exterior Mirror L-03.

control switch L-01, circuit BR (DR1), harness side
and the driver exterior mirror L-03, circuit BR
Page 5 of 8

Yes
No
REPAIR circuit BR (DR1). TEST the system for normal
operation.
C4: CHECK THE DRIVER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
3 LHD vehicles - Measure the resistance between the

exterior mirror control switch L-01, circuit LG (DR1)
and circuit BR/YE (DR1), harness side.
4 RHD vehicles - Measure the resistance between the

exterior mirror control switch L-01, circuit BU/YE
(DR1) and circuit BR/WH (DR1), harness side.

Yes
No
GO to C5.
1 Disconnect Driver Exterior Mirror L-03.

circuit BR/YE (DR1), harness side and the
driver exterior mirror L-03, circuit BR/YE

Page 6 of 8

circuit BR/WH (DR1), harness side and
the driver exterior mirror L-03, circuit
BR/WH (DR1), harness side.

Yes
No
REPAIR circuit BR/YE (DR1) or BR/WH (DR1). TEST the
C6: CHECK THE PASSENGER EXTERIOR MIRROR UP/DOWN CIRCUIT

circuit BU/YE (DR1) and circuit BR (DR1),
harness side.

circuit WH (DR1) and circuit BR (DR1),
harness side.
Yes
No
GO to C7.
1 Disconnect Passenger Exterior Mirror L-02.

control switch L-01, circuit BR (DR1), harness side
and the passenger exterior mirror L-02, circuit BR

Yes
No
REPAIR circuit BR (DR1) or BR (DR2). TEST the system
C8: CHECK THE PASSENGER EXTERIOR MIRROR LEFT/RIGHT CIRCUIT
Page 7 of 8

exterior mirror control switch L-01, circuit BU/YE
(DR1) and circuit BR/WH (DR1), harness side.

exterior mirror control switch L-01, circuit WH
(DR1) and circuit BR/YE (DR1), harness side.

Yes
No
GO to C9.
1 Disconnect Passenger Exterior Mirror L-02.

circuit BR/WH (DR1), harness side, and
the passenger exterior mirror L-02,
circuit BR/WH (DR2), harness side.

circuit BR/YE (DR1), harness side, and
the passenger exterior mirror L-02,
circuit BR/YE (DR2), harness side.
Yes
No
REPAIR circuit BR/WH (DR1 or DR2) or BR/YE (DR1 or
DR2). TEST the system for normal operation.
PINPOINT TEST D : THE HEATED EXTERIOR MIRROR DOES NOT DEFROST
D1: CHECK THE OPERATION OF THE HEATED REAR WINDOW
Page 8 of 8
2 OPERATE the heated rear window control switch.

Does the heated rear window function correctly?
Yes
GO to D2.
No
REPAIR the heated rear window. REFER to Section 501-11.
D2: CHECK THE VOLTAGE TO THE INOPERATIVE EXTERIOR MIRROR
Disconnect Driver Exterior Mirror L-03 or Passenger
2
Exterior Mirror L-02.
4 Operate the heated rear window control switch.
5 Measure the voltage between the:
* driver exterior mirror L-03, circuit RD/BU

(DR1), harness side and ground.
* passenger exterior mirror L-02, circuit RD/BU

Yes
GO to D3.
No
REPAIR circuit RD/BU (DR1 or DR2). TEST the system for
normal operation.
D3: CHECK THE INOPERATIVE EXTERIOR MIRROR GROUND CIRCUIT FOR
CONTINUITY
* driver exterior mirror L-03, circuit BK (DR1),

* passenger exterior mirror L-02, circuit BK

Yes
INSTALL a new heated exterior mirror glass. TEST the
No
REPAIR circuit BK (DR1 or DR2). TEST the system for
normal operation.
Page 1 of 10

GLASS, FRAMES AND MECHANISMS
UID=G325385
* Window seal * Fuse(s)
* Door window frame * Electrical connector(s)
* Switch(es)
* Circuit(s)
Symptom Chart

All power windows are *Driver power *CARRY OUT the Driver Power Window
inoperative window control Control Switch Component Test. REFER to
switch. the Wiring Diagrams.
*Circuit(s). *GO to Pinpoint Test A.
A single power window is *Driver power *CARRY OUT the Driver Power Window
inoperative - driver side window control Control Switch Component Test. REFER to
switch the Wiring Diagrams.
*Power window *GO to Pinpoint Test B.
motor.
*Circuit(s).
A single power window is *Driver power *CARRY OUT the Driver Power Window
inoperative - passenger window control Control Switch Component Test. REFER to
side switch. the Wiring diagrams.
*Passenger power *CARRY OUT the Passenger Power Window
window control Control Switch Component Test. REFER to
switch. the Wiring Diagrams.
*Power window *GO to Pinpoint Test C.
motor.
*Circuit(s).
The defrost system is *Heated rear window *CARRY OUT the Heated Rear Window
inoperative control switch. Control Switch Component Test. REFER to
the Wiring Diagrams.
*Heated rear window *CARRY OUT the Grid Wire Component Test.
grid wire. REFER to the Heated Rear Window Grid Wire
Test in this procedure.
Page 2 of 10
*Circuit(s). *GO to Pinpoint Test D.

PINPOINT TEST A : ALL POWER WINDOWS ARE INOPERATIVE
A1: CHECK THE DRIVER POWER WINDOW CONTROL SWITCH LEDS
Do the driver power window control switch LEDs
illuminate?
Yes
No
GO to A2.
A2: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL
SWITCH AND GROUND
2 Disconnect Driver Window Control Switch K1-01.

driver power window control switch K1-01, circuit BK

driver power window control switch K1-01, circuit BK

Yes
GO to A3.
No
operation.
A3: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
2 LHD vehicles - Measure the voltage between the driver

power window control switch K1-01, circuit RD/YE
3
RHD vehicles - Measure the voltage between the driver
power window control switch K1-01, circuit RD/YE
Page 3 of 10

Yes
No
REPAIR circuit RD/YE (DR1). TEST the system for normal
operation.
PINPOINT TEST B : A SINGLE POWER WINDOW IS INOPERATIVE - DRIVER
SIDE
B1: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
Does the driver power window control switch LED
illuminate?
Yes
GO to B2.
No
GO to B4.
B2: CHECK FOR CONTINUITY BETWEEN THE DRIVER POWER WINDOW CONTROL
SWITCH AND THE MOTOR DOWN CIRCUIT
Disconnect Driver Power Window Control Switch K1-
2
01.
3 Disconnect Driver Power Window Motor K1-08.

driver power window control switch K1-01, circuit
YE/GN (DR1), harness side and the driver power
window motor K1-08, circuit YE/GN (DR1), harness
side.

YE/GN (DR1), harness side and the driver power
window motor K1-08, circuit YE/GN (DR1), harness
side.

Yes
GO to B3.
Page 4 of 10
No
REPAIR circuit YE/GN (DR1). TEST the system for normal
operation.
SWITCH AND THE MOTOR UP CIRCUIT
RD/BK (DR1), harness side and the passenger
power window motor K1-08, circuit RD/BK (DR1),
harness side.

RD/BK (DR1), harness side and the passenger
power window motor K1-08, circuit RD/BK (DR1),
harness side.

Yes
INSTALL a new window regulator motor. REFER to Front
Door Window Regulator Motor / Rear Door Window
Regulator Motor in this section.TEST the system for
normal operation.
No
REPAIR circuit RD/BK (DR1). TEST the system for normal
operation.
SWITCH AND GROUND
Disconnect Driver Power Window Control Switch K1-
2
01.
BK (DR1), harness side and ground.

BK (DR1), harness side and ground.
Page 5 of 10

Yes
GO to B5.
No
operation.
B5: CHECK FOR VOLTAGE TO THE DRIVER POWER WINDOW CONTROL SWITCH
2 LHD vehicles - Measure the voltage between the

RD/YE (DR1), harness side and ground.
3 RHD vehicles - Measure the voltage between the

RD/YE (DR1), harness side and ground.

Yes
No
REPAIR circuit RD/YE (DR1). TEST the system for normal
operation.
PINPOINT TEST C : A SINGLE POWER WINDOW IS INOPERATIVE -
PASSENGER SIDE
C1: DOES THE PASSENGER WINDOW OPERATE FROM THE DRIVER SIDE POWER
WINDOW CONTROL SWITCH
2 Operate the passenger power window from the driver

power window control switch.
Does the passenger power window operate?
Yes
REPAIR circuit RD/WH (F). TEST the system for normal
operation.
No
GO to C2.
C2: CHECK THE DOWN CIRCUIT VOLTAGE TO THE PASSENGER POWER WINDOW
CONTROL SWITCH
Disconnect Passenger Power Window Control Switch
2
K1-02; K1-03 or K1-04.
Page 6 of 10
4 Operate the driver side passenger power window

control switch to the DOWN position.
 Front passenger power window control switch K1-04,

circuit GN/BK (DR2), harness side and ground; or
 Left-hand rear passenger power window control

switch K1-02, circuit YE/RD (DR3), harness side and
ground; or
Right-hand rear passenger power window control


switch K1-03, circuit GN/RD (DR4), harness side and
ground.
Yes
GO to C3.
No
REPAIR circuit GN/BK (DR2); YE/RD (DR3) or GN/RD
(DR4). TEST the system for normal operation.
C3: CHECK THE UP CIRCUIT VOLTAGE TO THE PASSENGER POWER WINDOW
CONTROL SWITCH
1 Operate the driver side passenger power window
control switch to the UP position.

circuit GN/WH (DR2), harness side and ground; or

switch K1-02, circuit RD/BU (DR3), harness side and
ground; or


switch K1-03, circuit BU/WH (DR4), harness side and
ground.
Yes
GO to C4.
No
REPAIR circuit GN/WH (DR2); RD/BU (DR3) or BU/WH
(DR4). TEST the system for normal operation.
C4: CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW
CONTROL SWITCH DOWN CIRCUIT AND THE PASSENGER POWER WINDOW MOTOR
Disconnect Power Window Motor K1-05; K1-06 or K1-
2
07.

circuit GN (DR2), harness side and the passenger
power window motor K1-07, circuit GN (DR2),
Page 7 of 10
harness side; or

switch K1-02, circuit GN (DR3), harness side and the
passenger power window motor K1-05, circuit GN
(DR3), harness side; or


switch K1-03, circuit GN (DR4), harness side and the
passenger power window motor K1-06, circuit GN
Yes
GO to C5.
No
REPAIR circuit GN (DR2; DR3 or DR4). TEST the system
C5: CHECK FOR CONTINUITY BETWEEN THE PASSENGER POWER WINDOW
CONTROL SWITCH UP CIRCUIT AND THE PASSENGER POWER WINDOW MOTOR
 Driver side front passenger power window control

switch K1-04, circuit RD (DR2), harness side and the
passenger power window motor K1-07, circuit RD

 Right-hand rear passenger power window control

Yes
INSTALL a new window regulator motor. REFER to Front
Door Window Regulator Motor / Rear Door Window
Regulator Motor in this section.TEST the system for
normal operation.
No
REPAIR circuit RD (DR2; DR3 or DR4). TEST the system
PINPOINT TEST D : THE DEFROST SYSTEM IS INOPERATIVE
D1: CHECK THE OPERATION OF THE HEATED EXTERIOR MIRRORS
Do the heated exterior mirrors operate correctly?
Yes
GO to D2.
No
GO to D4.
D2: CHECK THE HEATED REAR WINDOW GRID GROUND CIRCUIT
Page 8 of 10
2 Disconnect Heated Rear Window I1-02.

window I1-02, circuit BK (R3), harness side and
ground.

Yes
GO to D3.
No
REPAIR circuit BK (R3). TEST the system for normal
operation.
D3: CHECK FOR VOLTAGE TO THE HEATED REAR WINDOW GRID WIRE

window I1-02, circuit RD (R3), harness side and
ground.

Yes
No
REPAIR circuit RD (R3). TEST the system for normal
operation.
D4: CHECK THE HEATED REAR WINDOW RELAY GROUND CIRCUIT

window relay I1-01, circuit WH/BU (F), harness
side and ground.

Yes
GO to D5.
No
Page 9 of 10
REPAIR circuit WH/BU (F). TEST the system for normal

operation.
D5: CHECK FOR IGNITION VOLTAGE TO THE HEATED REAR WINDOW RELAY

window relay I1-01, circuit LG (F), harness side
and ground.

Yes
GO to D6.
No
REPAIR circuit LG (F). TEST the system for normal
operation.
D6: CHECK FOR BATTERY VOLTAGE TO THE HEATED REAR WINDOW RELAY
window relay I1-01, circuit GN (F), harness side
and ground.

Yes
GO to D7.
No
REPAIR circuit GN (F). TEST the system for normal
operation.
D7: CHECK FOR CONTINUITY BETWEEN THE HEATED REAR WINDOW RELAY AND
THE HEATED REAR WINDOW

window relay I1-01, circuit RD/BK (F), harness
side and the heated rear window grid I1-02,
circuit RD (R3), harness side.

Yes
INSTALL a new heated rear window relay. TEST the
No
REPAIR circuit RD/BK (F). TEST the system for normal
operation.
Component Tests
Heated Rear Window Grid Wire Test
1. Using a bright lamp inside the vehicle, visually inspect the grid wire from the outside. A
broken grid conductor line will appear as a brown spot.
Page 10 of 10
2. Run the engine at idle. Set the heated rear window control switch and lights to ON. The
heated rear window indicator light should illuminate.
3. Working inside the vehicle with a multimeter, contact the broad red/brown strips on the
heated rear window positive lead to battery side and negative lead to ground side. The
meter should read 10-13 volts. A lower voltage reading indicates a loose heated rear
window ground wire connection at the heated rear window ground wire screw.
4. Contact a ground point with the negative lead of the multimeter. The voltage reading
should not change.
5. With the negative lead of the multimeter grounded, touch each grid line of the heated rear
window at its pinpoint with the positive lead. A reading of approximately six volts indicates
that the line is OK. A reading of zero volts indicates that the line is broken between the
midpoint and the battery side of the grid line. A reading of 12 volts indicates that the circuit
is broken between the midpoint of the grid line and ground.
6. INSTALL a new heated rear window glass. REFER to Liftgate Window Glass in this section.
Page 1 of 1

SPECIFICATIONS
UID=G325386
Specifications
Power steering fluid meeting specification WSA-M2C195-A
Turning Circle
Description Metres
Wall to Wall 10.37
Steering Wheel Alignment
Description Degrees
Maximum allowable steering wheel mis-alignment ± 3.00°
Page 1 of 2

STEERING SYSTEM
UID=G325387
General Equipment
* Tire pressure(s) * Power steering pressure (PSP)
switch
* Accessory drive belt
* Wheels and tires
* Power steering line fluid

leaks

Steering is very *Loose or worn *CHECK the accessory drive belt. REFER to
difficult/very easy accessory drive belt.Section 303-05.
*Power steering hose *CHECK the power steering hoses for damage,
restriction. kinks or restrictions. INSTALL new
components as necessary. REFER to
Section 211-02.
*Fluid contamination. *FLUSH the power steering system. REFER to
Power Steering System Flushing -
1.25L/1.4L/1.6L / Power Steering System
Flushing - 1.4L Diesel in this section.
*Fluid aeration. *BLEED the power steering system. REFER to
Power Steering System Bleeding in this
section.
*Worn steering gear. *INSTALL a new steering gear. REFER to
Section 211-02.
*Worn steering column. *CARRY OUT the steering linkage component
test. REFER to Steering Linkage Component
Test in this procedure.
*Worn power steering *INSTALL a new power steering pump. REFER
pump. to Section 211-02.
Steering does not *Worn tie-rod ends. *INSTALL new components as necessary.
vary with increased REFER to Section 211-03.
wheel rotation *Worn front suspension *CHECK and INSTALL new components as
bushings. necessary. REFER to Section 204-01.
*Worn suspension ball *CARRY OUT the suspension ball joint
joints. inspection component test. REFER to
Page 2 of 2
Section 204-00.
*Steering gear insulator *CHECK and INSTALL new components as
bushings worn or necessary. REFER to Section 211-02.
perished.
*Loose steering gear *CHECK and INSTALL new bolts as necessary.
retaining bolts. REFER to Section 211-02.
*Loose steering column *CHECK and INSTALL new bolts as necessary.
retaining bolts. REFER to Section 211-04.
*Loose steering column *CHECK and INSTALL a new bolt as necessary.
to steering gear pinion REFER to Section 211-04.
retaining bolt.
*Excessive steering *INSTALL a new steering gear. REFER to
gear backlash. Section 211-02.
Steering assist does *Power steering *Refer to WDS.
not vary with vehicle pressure (PSP) switch.
speed *Circuit.
Components Tests
Steering Linkage
Inspect the steering gear boots for cuts, deterioration, twisting or distortion. Make sure the
boots are secure. Install new boots or clamps as necessary.
1. Park the vehicle on a dry, even surface and apply the parking brake. Place the steering in
the straight-ahead position.
2. With the engine OFF, hold the steering wheel firmly with both hands. Attempt to move the
steering wheel up and down and also to the left and right without turning the wheel, to
check the steering column bearing wear, steering column shaft joint play and steering wheel
or steering column looseness. If free play is detected, check the correct torque of the
steering column, coupling shaft and steering wheel retaining bolts. The steering column
cannot be repaired, install a new steering column. REFER to Section 211-04.
3. If the steering linkage is worn, install new components as necessary. REFER to

Section 211-03. The steering column cannot be repaired, install a new steering column.
REFER to Section 211-04.Steering gear backlash cannot be adjusted, install a new steering
gear. REFER to Section 211-02.
Page 1 of 3

POWER STEERING SYSTEM FLUSHING
— 1.4L DIESEL
UID=G325388
Name Specification
2. Disconnect the crankshaft position sensor
(CKP) electrical connector.
3. NOTE: Using a suitable blanking cap, cap

the end of the hose from the power steering
fluid reservoir.
Disconnect the power steering fluid reservoir
tangs.

container.
4. Place the end of the power steering gear
return line into a suitable container.
5. Lower the vehicle until the wheels are clear of
the floor to allow the steering wheel to be
rotated from lock to lock.
6. CAUTION: Isolate the glow plugs to

prevent damage to the glow plug electrical
connectors.
Remove the glow plug relay fuse from the battery
junction box (BJB).
7. Remove the glow plugs. For additional

07B.
8. NOTE: When filling the power steering fluid
reservoir, make sure the power steering fluid
is clean and not agitated prior to use. The
fluid should be poured slowly into the
Page 2 of 3
reservoir to minimize the possibility of

aeration. The fluid level should be checked
with the fluid cold.
Fill the power steering fluid reservoir to the MAX
mark with clean power steering fluid.

minimum mark.
seconds turn the steering from lock to lock.
 With the aid of another technician add 1 liter

of clean power steering fluid.
10. Wait 60 seconds to allow the starter motor to
cool.

minimum mark.
seconds turn the steering from lock to lock.
 With the aid of another technician add a

further 1 liter of clean power steering fluid.
12. When all the fluid has been used, turn the
ignition switch to the OFF position.
13. Install the glow plugs. For additional
07B.
14. Install the glow plug relay fuse.

Remove the blanking cap and connect the power
steering fluid reservoir return hose quick
release coupling.
Page 3 of 3
17. Connect the CKP sensor electrical connector.

additional information, refer to Power Steering
System Bleeding in this section.
Page 1 of 1

SPECIFICATIONS
UID=G325389
Item Specification
Power steering fluid meeting specification WSA-M2C195-A
Capacities
Litres
Power steering fluid 1.2 - 1.3
Power steering fluid cooler 0.1
lb- lb-
Steering gear mounting bolts 48 35 -
Power steering lines to steering gear valve body clamp retaining bolt 18 13 -
Power steering line to cylinder head support bracket retaining bolt 25 18 -
Power steering line to accessory drive support bracket retaining bolt 25 18 -
Power steering line to air conditioning compressor 25 18 -
Power steering supply hose to engine block (rear) 25 18 -
Power steering line to transaxle retaining bolt 30 22 -
Power steering line to power steering pump union - vehicles with 1.4L diesel 40 30 -
engine
Power steering line to power steering pump union - vehicles with 65 48
1.25L/1.4L/1.6L engine
Power steering pump retaining bolts - vehicles with 1.25L/1.4L/1.6L engine 25 18 -
Power steering pump retaining bolts - vehicles with 1.4L diesel engine 23 17 -
Power steering line bracket to power steering pump - vehicles with 1.4L diesel 25 18 -
engine
Power steering lines bracket to steering gear retaining bolt 14 10 -
Steering column shaft to steering gear pinion retaining bolt 28 21 -
Connecting link to stabilizer bar retaining nut 55 41 -
Front crossmember rear retaining bolts 115 85 -
Front crossmember inner and outer retaining bolts 175 129 -
Front crossmember front retaining bolts 70 52 -
Page 1 of 2

STEERING GEAR BOOT
UID=G325390
General Equipment
Pincers
Name Specification
Lithium based grease (NLGI No1)
Removal
1. Remove the tie-rod end. For additional
information, refer to Tie-Rod End in this
section.
2. Remove the tie-rod end locknut.
3. NOTE: Make sure the tie-rod is clean

before removing the steering gear boot.
Remove the steering gear boot.
 Discard the clamps.
Installation
1. NOTE: Lubricate the steering gear boot.
Install the steering gear boot.
2. Using a suitable pair of pincers, install a new

steering gear boot inner clamp.
Page 2 of 2
3. NOTE: Make sure the steering gear boot

outer clamp is located over the recess in the
tie-rod.
Using a suitable pair of pincers, install a new
steering gear boot outer clamp.
4. Install the tie-rod end locknut.
5. Install the tie-rod end. For additional

information, refer to Tie-Rod End in this
section.
Page 1 of 6

FUEL FILTER — 1.4L DIESEL
UID=G325413
Special Tool(s)
Hand Pressure Pump With
Adapter Kit
49 JE02 050
Removal
WARNINGS:
near any fuel related components. Highly flammable mixtures are always present and can
in personal injury.

and fine clearances. It is therefore essential that absolute cleanliness is observed when
working with these components. Always fit blanking plugs to any open orifices or lines.
01.
00.
3. Disconnect the fuel pump fuel return line from
the fuel tank fuel return line. For additional

6. Disconnect the fuel filter to fuel pump fuel
Page 2 of 6
7. Disconnect the fuel tank to fuel filter fuel

8. Detach the air cleaner intake pipe from the air

cleaner.
9. Remove the fuel filter retaining screw.
10. Detach the fuel filter.
 Rotate the fuel filter counterclockwise to

detach.
11. Disconnect the fuel heater electrical

connector and remove the fuel filter.
Page 3 of 6
Installation
All vehicles
WARNINGS:
in personal injury.

and fine clearances. It is therefore essential that absolute cleanliness is observed when
working with these components. Always fit blanking plugs to any open orifices or lines.
1. Connect the fuel heater electrical connector to
the fuel filter.
2. Install the fuel filter.
 Rotate the fuel filter clockwise to install.
3. Install the fuel filter retaining screw.

Page 4 of 6
4. Connect the fuel filter to fuel pump fuel supply



adaptor to the fuel filter.

adaptor to the fuel tank to fuel filter fuel
supply line.
8. NOTE: Make sure the hand primer special

tool arrow indicating the direction of fuel flow
is pointing towards the fuel filter.
Install the hand pressure pump special tool to the
hand pressure pump special tool adaptors.
9. Operate the hand pressure pump special tool

until fuel starts to flow through the fuel filter.
tool adaptor from the fuel tank to fuel filter
fuel supply line.
Page 5 of 6

tool adaptor from the fuel filter.
12. Connect the fuel tank to fuel filter fuel supply


00.

Page 6 of 6
16. Attach the air cleaner intake pipe to the air

cleaner.

01.

11.
Page 1 of 1

HEADLAMPS
UID=G325445
Light Switch Inspection
1. Verify continuity as indicated in the table.
 If there is any malfunction, replace the light switch.

Flash-to-
Light Dimmer B D H J
pass
Off
OFF -
On X X
Off X X
TNS -
On X X X
Off X X X
LO
Headlamp On X X X
HI - X X X 0) OFF1) TNS2) Headlamp3) Lo Beam4) Hi Beam5)

Flash-To-Pass
X X : Continuity
Page 1 of 1

STOPLAMPS
UID=G325446
Stop Lamp Switch Inspection
 If there is any malfunction, replace the stop lamp switch.
Terminal
Switch Position
A C
brake pedal depressed X X
brake pedal not depressed
X X : Continuity
Page 1 of 3

TURN SIGNAL AND HAZARD LAMPS
UID=G325447
Direction Indicator Switch Inspection
 If there is any malfunction, replace the direction indicator switch.

I E G
OFF
Left X X
Right X X
X X : Continuity
Hazard Warning Switch Inspection
Vehicles without Audio System
 If there is any malfunction, replace the hazard warning switch.

C A
OFF
ON X X
X X : Continuity
Vehicles with Audio System
 If there is any malfunction, replace the hazard warning switch.

I H
Page 2 of 3
OFF
ON X X
X X : Continuity
Flasher Unit Inspection
1. Remove the flasher unit with the connector connected.
2. Measure the voltage at each terminal (with the exception of terminal F).
* If the voltage is not as specified in the Terminal Voltage Table (Reference),

inspect the parts under "Inspection item(s)".
3. Disconnect the Flasher Unit connector.
4. Verify that the continuity at terminal F is as indicated in the Terminal Voltage Table
(Reference).
* If there is any malfunction, inspect the parts under "Inspections item(s)".
Terminal Voltage Table (Reference)
Terminal Signal Connected to Test condition Voltage (V) Inspection item(s)

* Hazard
15 A fuse
Power supply Hazard 15 A Under any
A V batt
(input) fuse condition * Related
wiring
harness
* Flasher
unit
Ignition switch
Direction
ON Direction * Direction
D indicator
indicator switch indicator
lamps (LH)
Direction (LH) ON Alternating switch
indicator voltage
(LH) between 1 V or * Hazard
Page 3 of 3
(output) less and V batt flasher

switch
Hazard flasher
switch ON * Related
wiring
harness
F Ground Ground point Under any 1 V or less * Related
11 condition wiring
harness
* Flasher
unit
Ignition switch * Direction

ONDirection indicator
indicator switch switch
Direction Alternating
Direction (RH) ON
indicator voltage
G indicator
(RH) between 1 V or * Hazard
lamps (RH)
(output) less and V batt flasher
switch
Hazard flasher
* Related
switch ON
wiring
harness
* Hazard
flasher
Hazard flasher
1 V or less switch
ON
Hazard
Hazard
flasher * Related
H flasher
switch ON wiring
switch
(input) harness
Hazard flasher
V batt
OFF
* Flasher
unit
* Direction
indicator
Direction Ignition switch
Direction switch
indicator ONDirection
I indicator V batt
switch (RH) indicator switch
switch * Related
ON (input) (RH) ON
wiring
harness
* Direction
indicator
Direction Ignition switch
Direction switch
indicator ONDirection
J indicator V batt
switch (LH) indicator switch
switch * Related
ON (input) (LH) ON
wiring
harness
Page 1 of 1

PARKING, REAR AND LICENSE LAMPS
UID=G325448
 If there is any malfunction, replace the light switch.

Flash-to-
Light Dimmer B D H J
pass
Off
OFF -
On X X
Off X X
TNS -
On X X X
Off X X X
LO
Headlamp On X X X
HI - X X X 0) OFF1) TNS2) Headlamp3) Lo Beam4) Hi Beam5)

Flash-To-Pass
X X : Continuity
Page 1 of 1

FOG LAMPS
UID=G325449
Front And Rear Fog Lamp Switch Inspection
 If there is any malfunction, replace the front and rear fog light switch.
Terminal
Switch Position
B A C
OFF
Front Fog Lamps ON X X
Front and Rear Fog

X X X
Lamps ON
0) OFF1) Front Fog Lamps ON2) Front and Rear Fog
Lamps ON
X X : Continuity
Page 1 of 1

REVERSING LAMPS
UID=G325450
Reversing Lamp Switch Inspection
 If there is any malfunction, replace the reversing lamp switch.
Terminal
Switch Position
C A
Reverse X X
Other
X X : Continuity
Page 1 of 1

HEADLAMP LEVELING
UID=G325451
Headlamp Leveling Switch Inspection
1. Verify the resistance as indicated in the table.
 If there is any malfunction, replace the headlamp leveling switch.
Switch position Terminal Resistance

0, 1, 2, 3 F-H 2,500 Ohm
0 H-J 250 Ohm
1 H-J 890 Ohm
2 H-J 1,120 Ohm
3 H-J 1,500 Ohm

Page 1 of 1

SPECIFICATIONS
UID=G325507
Tightening torques -

Screws, electric booster heater 1 - 9
Nuts, electric booster heater electrical connections 8 - 71
Page 1 of 5

ELECTRIC BOOSTER HEATER
UID=G325508
Basic system
Description of operation
The positive temperature coefficient heater is controlled by the powertrain control module
(PCM), taking the following factors into account:
The positive temperature coefficient heater is only activated at ambient temperatures below
15ºC.
The positive temperature coefficient heater is switched off when the coolant temperature
exceeds 80ºC. The heater is not reactivated until the coolant temperature has fallen back
below 73ºC.
The positive temperature coefficient heater is switched on depending on the generator

capacity still available. Stage 1 is activated first (by positive temperature coefficient heater
relay No. 1). After 15 seconds, stage 1 is switched off and stage 2 is switched on (by positive
temperature coefficient heater relay No. 2). After a further 15 seconds, stage 1 is switched
back on again, meaning that full heating power is then available.
Control system
Positive temperature coefficient heater relay (No. 1 and No. 2) inspection
* If there is any malfunction, replace the respective positive temperature

coefficient heater relay.
Terminal
Step A B C D
1 Resistance between terminal A and terminal B approx. 75 ohm No continuity
2 Fused B+ GND Continuity
Positive temperature coefficient heater inspection
For this measurements the positive temperature coefficient heater needs to be cold (approx.
20°C) and engine off.
1. Verify that the resistance between the terminals of the positive temperature coefficient
heater as is shown in the table.
Page 2 of 5
* If there is any malfunction, replace the positive temperature coefficient heater.
Terminal Resistance (ohm)

W/R — B (3A) 0.7 - 0.8
B (2A) — B (3A) 0.2 - 0.3
Troubleshooting
Foreword
The areas for inspection (steps) are given according to various circuit malfunction. Use the
following chart to verify the symptoms of the trouble in order to diagnose the appropriate
area.
TROUBLESHOOTING INDEX
No. Troubleshooting item Description

1 Positive temperature * Malfunction of positive temperature coefficient
coefficient heater inoperative heater and/or positive temperature coefficient
heater relays
No. 1 Positive temperature coefficient heater inoperative
1 Positive temperature coefficient heater inoperative

Description * Malfunction of positive temperature coefficient heater and/or
positive temperature coefficient heater relays
Possible * Positive temperature coefficient heater
cause
* Positive temperature coefficient heater relay No. 1
* Positive temperature coefficient heater No. 2


1 Inspect cutting in parameters Yes Go to next step.
* Check cutting in parameters
 Ambient temperature
below 15°C. No Make sure that cutting in parameters
are normal, then go to Step 17.
 Coolant temperature is
below 73°C.
 Enough generator capacity

is available.
* Are all cutting in parameters

OK?
2 Inspect voltage at positive Yes Go to next step.
temperature coefficient heater
* Start engine.
No No voltage in both measurements: Go
to Step 4.No voltage in measurement
* Let engine idle for approx. 2
1: Go to Step 5.No voltage in
minutes.
Page 3 of 5
* Test voltages at following measurement 2: Go to Step 10.

terminals of positive
temperature coefficient heater.
 Terminal W/R (stage 1)
 Terminal B (2A) (stage 2)
* Are voltages approx. 12 V?

3 Inspect ground connection of positive Yes Operation is normal. (Recheck
temperature coefficient heater malfunction symptoms.)
* Start engine.
* Let engine idle for approx. 2 No Repair wiring harness between

minutes. positive temperature coefficient
heater and GND, then go to Step 17.
* Test voltage at terminal B
(3A) of positive temperature
coefficient heater.

4 Inspect control voltage at positive Yes Go to next step.
temperature coefficient heater relay
No. 1
No Repair wiring harness between
positive temperature coefficient
* Turn ignition switch ON. heater relay No. 1 and fuse block,
then go to Step 17.
* Test voltage at terminal L/W
of positive temperature
coefficient heater relay No. 1
5 Inspect intake air temperature Yes Inspect PCM, then go to Step 17.
* Test intake air temperature

signal by using WDS. No Inspect electronic engine control, then
go to Step 17.
* Is intake air temperature
normal (the shown
temperature is plausible)?
6 Inspect fuse Yes Go to Step 8.
No Replace fuse, then go to Step 17. If
* Are Glow/PTC 1 fuse normal? fuse burns out immediately or after
the engine is running, go to next step.
7 Inspect positive temperature Yes Locate and repair the short in wiring
coefficient heater harness between fuse block and
* Test positive temperature heater, then go to Step 17.
coefficient heater according
heater inspection in this
Section. No Replace positive temperature
coefficient heater, then go to Step 17.
* Is the positive temperature
Page 4 of 5
coefficient heater normal?

8 Inspect power supply of positive Yes Go to next step.
No. 1 No Repair wiring harness between fuse
block and positive temperature
* Test voltage at terminal W of coefficient heater relay No. 1, then go
positive temperature coefficient to Step 17.
heater relay No. 1.
9 Inspect positive temperature Yes Go to next step.
* Test positive temperature No Replace positive temperature

coefficient heater relay No. 1 coefficient heater relay No. 1, then go
according relay inspection in to Step 17.
this Section.

normal?
10 Inspect wiring harness between Yes Inspect PCM, then go to Step 17.
heater relay No. 1 and PCM for open No Repair wiring harness between
* Turn ignition switch ON. heater relay No. 1 and PCM, then go
to Step 17.
* Test voltage at terminal 1H
of PCM.
11 Inspect fuse Yes Go to Step 13.
No Replace fuse, then go to Step 17. If
* Are PTC HTR 2 fuse normal? fuse burns out immediately or after
engine is running, go to next step.
12 Inspect positive temperature Yes Locate and repair the short in wiring
coefficient heater harness between fuse block and
* Test positive temperature heater, then go to Step 17.
coefficient heater according
heater inspection in this
Section. No Replace the positive temperature
coefficient heater, then go to Step 17.
coefficient heater normal?
13 Inspect power supply of positive Yes Go to next step.
No. 2 No Repair wiring harness between fuse
block and positive temperature
* Test voltage at terminal B of coefficient heater relay No. 2, then go
positive temperature coefficient to Step 17.
heater relay No. 2.
14 Inspect control voltage of positive Yes Go to next step.
Page 5 of 5
temperature coefficient heater relay No Repair wiring harness between

No. 2 positive temperature coefficient
heater relay No. 1 and positive
* Turn ignition switch ON. temperature coefficient heater relay
No. 2, then go to Step 17.
* Test voltage at terminal L/W
of positive temperature
coefficient heater relay No. 2.
15 Inspect positive temperature Yes Go to next step.
* Test positive temperature No Replace positive temperature

coefficient heater relay No. 2 coefficient heater relay No. 2, then go
according the relay inspection to Step 17.
in this Section.

normal?
16 Inspect wiring harness between Yes Inspect PCM, then go to Step 17.
heater relay No. 2 and PCM for open No Repair wiring harness between
* Turn ignition switch ON. heater relay No. 2 and PCM, then go
to Step 17.
* Test voltage at terminal 1L of
the PCM.
17 Verify that malfunction symptoms Yes Troubleshooting completed.Explain
occurs after repair repairs to customer.
* Operate the positive repeat from Step 1 if malfunction
temperature coefficient heater recurs
normal?
Page 1 of 1

ELECTRIC BOOSTER HEATER
UID=G325509
Removal
WARNING: Check that the ignition switch is in the OFF position. Failure to observe
this instruction can lead to injury.
1. Detach the cover from the electric booster
heater.
2. Detach the nuts of the electric booster heater

cable connections.
3. WARNING: Before performing any

work on the electric booster heater, make
certain that the surface of its heating element
has cooled to ambient temperature. Failure to
observe this instruction can lead to injury.
Remove the electric booster heater with bracket.
4. Remove the electric booster heater.
Installation
Page 1 of 4

BRAKE PEDAL — LHD, VEHICLES
WITH: MANUAL TRANSAXLE
UID=G327028
Removal
WARNING: On vehicles built up to 01/2004 that have sustained a frontal impact in

which the front air bag module(s) or safety belt pretensioner(s) are deployed, a new
brake pedal must be installed. Failure to follow this instruction may result in personal
injury.
clips.


4. Detach the steering column from the steering

gear.
5. Disconnect the clutch and brake pedal switch

 Detach the brake pedal switches electrical

Page 2 of 4
harness from the brake pedal bracket.
6. WARNING: The clutch return spring is

under tension, care must be taken when
disconnecting the spring from the clutch
pedal. Failure to follow this instruction may
Disconnect the clutch pedal return spring from
the clutch pedal.
7. Detach the clutch master cylinder from the

clutch pedal and bracket.
1. Detach the actuating rod.
9. Detach the brake pedal bracket from the floor

panel.

the brake pedal.
pin.
Page 3 of 4
11. Remove the brake pedal bracket.

12. NOTE: Do not remove the clutch pedal
and clutch pedal bushing.
Remove the brake pedal.
1. Remove the pivot shaft nut.
2. Slide out the pedal pivot shaft.
3. Remove the brake pedal.
13. Remove the brake pedal bushes.
Installation
WARNINGS:
Page 4 of 4
1. Install a new steering column to

steering gear retaining bolt. Failure to follow

personal injury.
CAUTION: Do not drop or knock the

brake pedal. Failure to follow this instruction
will cause damage to the brake pedal
decoupler mechanism (if equipped).
NOTE: Attach a suitable piece of cord to the
clutch pedal return spring, to aid installation.
Page 1 of 2

BRAKE PEDAL — RHD
UID=G327029
Removal

injury.
the brake pedal (accelerator pedal shown
pin.

Installation
1. WARNING: Do not use a damaged

Page 2 of 2


Page 1 of 2

BRAKE BOOSTER — RHD
UID=G327031
Removal
06.
brake booster.

the brake pedal (accelerator pedal shown
pin.
4. Remove the brake booster.
Installation
WARNINGS:
1. Do not install an Emergency Brake

Assist (EBA) brake booster to a vehicle that is
not equipped with the Anti-lock Brake System
(ABS). Failure to follow this instruction may
cause personal injury.

personal injury.
CAUTIONS:
Make sure the brake booster gasket is

correctly positioned on the brake booster
Page 2 of 2
Do not drop or knock the brake pedal.

Failure to follow this instruction will cause
damage to the brake pedal decoupler
mechanism.
NOTE: On vehicles equipped with EBA the
brake booster is identified by a white sticker
showing a large letter "A".
NOTE: Install a new brake booster gasket.
Page 1 of 3

DAYTIME RUNNING LAMPS (DRL)
UID=G327032
Daytime Running Lamp Unit Inspection
1. Remove the daytime running lamp unit with the connector connected.
2. Measure the voltage at each terminal (with the exception of terminal D).
1. If the voltage is not as specified in the Terminal Voltage Table (Reference), inspect the
parts under "Inspection item(s)".
3. Disconnect the daytime running lamp unit connector.
4. Verify that continuity at terminal D is as indicated in the Terminal Voltage Table

(Reference).
1. If there is any malfunction, inspect the parts under "Inspection item(s)".
Terminal Voltage Table (Reference)
Voltage
Terminal Signal Connected to Test Condition Inspection item(s)
(V)
*
Illumination
7.5 A fuse
* Tailamp
Illumination Light switch: TNS
A TNS ON (input) V batt and sidelight
7.5 A fuse ON
relay
* Related
wiring
harness
*
Light switch: TNS Illumination
V batt 7.5 A fuse
ON
TNS ON Illumination * Tailamp
B
(output) lamps and sidelight
relay
1 V or
Light switch: OFF * Daytime
less
running lamp
unit
Page 2 of 3
* Related
wiring
harness
* Related
Ground point 1 V or
D Ground Under any condition wiring
11 less
harness
* Meter 10 A
fuse
Ignition/Engine Meter 10 A Ignition/Engine
E V batt
ON (input) fuse switch: ON * Related
wiring
harness
* Front and
Front and rear fog
rear fog lamp
lamp switch: OFF
V batt switch
Light switch: TNS
ON
Front fog lamps Front fog * Front fog
F
ON (output) lamp relay lamp relay
Front and rear fog
lamp switch: Front 1 V or
* Related
fog lamps ONLight less
wiring
switch: TNS OFF
harness
* Tailamp
and sidelight
relay
Light switch: TNS 1 V or
ON less
* Daytime
running lamp
Tailamp and
TNS ON unit
G sidelight
(output)
relay
* Light
switch
Light switch: TNS
V batt
OFF
* Related
wiring
harness
* Front and
Front and rear fog rear fog lamp
Front and lamp switch: Front switch
Front fog lamps 1 V or
H rear fog fog lamps ON/Front
ON (input) less
lamp switch and rear fog lamps * Related
ON wiring
harness
* Light
switch
Light switch: TNS 1 V or
I TNS ON (input) Light switch
ON less * Related
wiring
harness
Light switch: Low * Low beam

Low beam ON Low beam V batt relay
K beam OFF
(output) relay
* Daytime
running lamp
unit
Page 3 of 3
* Light
switch
Light switch: Low 1 V or
beam ON less * Related
wiring
harness
* High beam
relay
Light switch: High
V batt * Daytime
beam OFF
running lamp
High beam unit
High beam ON
M relayLight
(input)
switch * Light
switch
Light switch: High 1 V or
wiring
harness
* Low beam
relay
Light switch: Low
V batt * Daytime
beam OFF
running lamp
unit
Low beam ON Low beam
O
(output) relay
* Light
switch
Light switch: Low 1 V or
wiring
harness
* Light
switch
Low beam ON Light switch: Low 1 V or
P Light switch
(input) beam ON less * Related
wiring
harness
Page 1 of 1

SPECIFICATIONS
UID=G327063
Exterior Lighting
Component Design
Headlamps Complex reflector system, aligned by positioning the reflector
Fog lamps Lamp unit adjusting system, aligned by positioning the lamp unit.
Headlamps - Align (both sides)
Component X value
Headlamps X = 10 cm/10 m = 0 34' = 1,0 %
Fog lamps X = 19.9 cm/10 m = 1 14' = 1,99 %

Headlamp assembly lower retaining screws 5 - 44
Page 1 of 14

LOCKS, LATCHES AND ENTRY
SYSTEMS
UID=G327079
2. Visually inspect for obvious signs of mechanical or electrical damage
- Latch(es) - Fuse(s)
- Misaligned door(s) - Wiring harness
- Misaligned liftgate - Electrical connector(s)
- Misaligned hood - Door latch actuator(s)
- Door latch(es) - Remote transmitter battery(s)
- Actuating rod(s) - Keyless entry remote transmitter
- Exterior door handle(s) - Keyless entry remote transceiver
- Door latch remote control(s) - Door lock switch(es)
- Door lock cylinder(s) - Vehicle battery
- Cable(s)
4. If the cause is not visually evident, verify the symptom and refer to Symptom Chart.
Symptom Chart
Symptom Chart

All door locks are inoperative *Fuse(s). *GO to Pinpoint Test A.
*Circuit(s).
*Door locking
module.
*Door lock control
switch.
*Door lock button.
*Door lock
Page 2 of 14
actuator(s).
The liftgate is inoperative *Fuse(s). *GO to Pinpoint Test B.
*Circuit(s).
*Door locking
module.
* Liftgate latch
actuator.
The door open warning indicator is *Fuse(s). *REFER to Section 413-01.
inoperative *Circuit(s).
*Door locking
module.
*Instrument
cluster.
The turn signal indicator(s) are inoperative *Fuse(s). *REFER to Section 417-01.
*Circuit(s).
*Door locking
module.
*Flasher unit.
The door locking module does not *Fuse(s). *REFER to Section 419-
communicate with the anti-theft module *Circuit(s). 01A / 419-01B.
*Door locking
module.
*Anti-theft module.
The interior lighting does not illuminate *Fuse(s). *REFER to Section 417-02.
*Circuit(s).
*Door locking
module.
*Door ajar switch.
Pinpoint Tests

PINPOINT TEST A : ALL DOOR LOCKS ARE INOPERATIVE
A1: CHECK THE VEHICLE FOR DOUBLE LOCKING
1 Operate the central locking system.
Is the vehicle equipped with double locking?
Yes
GO to A2.
No
GO to A16.
A2: CHECK THE DOOR LOCKING MODULE FOR BATTERY VOLTAGE
2 Measure the voltage between the door locking

module connector K2-01 pin 1A, (WHITE/BLACK),
Page 3 of 14

Yes
GO to A3.
No
REPAIR the circuit (WHITE/BLACK). TEST the system
A3: CHECK THE DOOR LOCKING MODULE FOR VOLTAGE
module connector K2-01 pin 2A, (BLUE/RED),

Yes
GO to A4.
No
normal operation.
A4: CHECK THE DOOR LOCKING MODULE FOR SWITCHED VOLTAGE

module connector K2-01 pin 2B,
(BLACK/YELLOW), harness side and ground.

Yes
GO to A5.
No
A5: CHECK THE DOOR LOCKING MODULE FOR GROUND
1 Measure the resistance between the door locking
module connector K2-01 pin 1E, (BLACK), harness
side and ground; and the door locking module K2-
Page 4 of 14
01 pin 2W, (BLACK), harness side and ground.

Yes
GO to A6.
No
REPAIR the circuit(s) (BLACK) as necessary. TEST the
A6: CHECK THE DOOR LOCKING MODULE TO KEY-IN IGNITION WARNING SWITCH
FOR OPEN
1 Disconnect Key-In Ignition Warning Switch K2-04.

module K2-01 pin 2F, (YELLOW), harness side and
the key-in ignition warning switch K2-04,

Yes
GO to A7.
No
REPAIR the circuit (YELLOW). TEST the system for
normal operation.
A7: CHECK THE KEY-IN IGNITION WARNING SWITCH FOR VOLTAGE
1 Measure the voltage between the key-in ignition
warning switch connector K2-04, (BLUE/RED),

Yes
INSTALL a new key-in ignition warning switch. TEST the
GO to A8.
No
normal operation.
A8: CHECK THE DOOR LOCKING MODULE TO THE DOOR LOCK CONTROL SWITCH
Page 5 of 14
FOR OPEN
1 Connect Key-In Ignition Warning Switch K2-04.
2 Disconnect Door Lock Control Switch K2-05.

module connector K2-01 pin 2S, (LIGHT GREEN),
harness side and the door lock control switch
connector K2-05, (LIGHT GREEN), harness side.

Yes
GO to A9.
No
REPAIR the circuit (LIGHT GREEN). TEST the system for
normal operation.
A9: CHECK THE DOOR LOCK CONTROL SWITCH FOR GROUND
1 Measure the resistance between the door lock
control switch connector K2-05, (BLACK), harness
side and ground.

Yes
INSTALL a new door lock control switch. TEST the
GO to A10.
No
normal operation.
A10: CHECK THE DOOR LOCKING MODULE TO DOOR LOCK BUTTON (LOCK) FOR
OPEN
1 Connect Door Lock Control Switch K2-05.
2 Disconnect Door Lock Button K2-03.

module connector K2-01 pin 2Q, (ORANGE),
harness side and the door lock button connector
K2-03, (ORANGE), harness side.

Page 6 of 14
Yes
GO to A11.
No
normal operation.
A11: CHECK THE DOOR LOCKING MODULE TO DOOR LOCK BUTTON (UNLOCK) FOR
OPEN
module connector K2-01 pin 2R, (GREEN),
K2-03, (GREEN), harness side.

Yes
GO to A12.
No
REPAIR the circuit (GREEN). TEST the system for
normal operation.
A12: CHECK THE DOOR LOCK BUTTON FOR GROUND
button connector K2-03, (BLACK), harness side
and ground.

Yes
INSTALL a new door lock button. TEST the system for
normal operation. If the concern persists, GO to A13.
No
normal operation.
A13: CHECK THE DOOR LOCKING MODULE TO DOOR LOCK ACTUATOR(S) FOR OPEN
1 Connect Door Lock Button K2-03.
Disconnect Door Lock Actuator – (Front Driver Side
2 K2-03), (Front Passenger Side K2-02), (Rear Driver
Side K2-06), (Rear Passenger Side K2-07).
module connector K2-01 pin 1F, (RED/WHITE),
harness side and the following door lock actuator
(s):
 Front driver side door lock actuator connector K2-

03, (RED/WHITE), harness side.
Page 7 of 14
 Front passenger side door lock actuator connector

K2-02, (RED/WHITE), harness side.
 Rear driver side door lock actuator connector K2-

06, (RED/WHITE), harness side.
 Rear passenger side door lock actuator connector

K2-07, (RED/WHITE), harness side.
Are the resistance(s) less than 5 ohms?

Yes
GO to A14.
No
REPAIR the circuit(s) (RED/WHITE) as necessary. TEST
A14: CHECK THE DOOR LOCKING MODULE TO THE DOOR LOCK ACTUATOR(S)
(UNLOCK) FOR OPEN
module connector K2-01 pin 1D, (RED), harness
side and the following door lock actuator(s):

03, (RED), harness side.

K2-02, (RED, harness side.

Rear passenger side door lock actuator connector


K2-07, (RED), harness side.
Yes
GO to A15.
No
REPAIR the circuit(s) (RED) as necessary. TEST the
(LOCK) FOR OPEN
module connector K2-01 pin 1C, (RED/BLACK),
(s):

03, (RED/BLACK), harness side.

K2-02, (RED/BLACK), harness side.

Page 8 of 14


Yes
INSTALL a new door latch(es). REFER to Front Door
Latch / Rear Door Latch in this section. TEST the
INSTALL a new door locking module. TEST the system
No
REPAIR the circuit(s) (RED/BLACK) as necessary. TEST
A16: CHECK THE DOOR LOCKING MODULE (WITHOUT DOUBLE LOCKING) FOR
BATTERY VOLTAGE

module K3-01 pin 1A, (WHITE/BLACK), harness
side and ground.

Yes
GO to A17.
No
REPAIR the circuit (WHITE/BLACK). TEST the system
A17: CHECK THE DOOR LOCKING MODULE FOR VOLTAGE
module connector K3-01 pin 2A, (BLUE/RED),

Yes
GO to A18.
No
normal operation.
A18: CHECK THE DOOR LOCKING MODULE FOR SWITCHED VOLTAGE

module connector K3-01 pin 2B,
(BLACK/YELLOW), harness side and ground.
Page 9 of 14

Yes
GO to A19.
No
A19: CHECK THE DOOR LOCKING MODULE FOR GROUND
module connector K2-01 pin 1E, (BLACK), harness
side and ground; and the door locking module K3-
01 pin 2W, (BLACK), harness side and ground.

Yes
GO to A20.
No
REPAIR the circuit(s) (BLACK) as necessary. TEST the
A20: CHECK THE DOOR LOCKING MODULE TO KEY-IN IGNITION WARNING SWITCH
FOR OPEN
1 Disconnect Key-In Ignition Warning Switch K3-04.

module K3-01 pin 2F, (YELLOW), harness side and
the key-in ignition warning switch K3-04,

Yes
GO to A21.
No
REPAIR the circuit (YELLOW). TEST the system for
normal operation.
A21: CHECK THE KEY-IN IGNITION WARNING SWITCH FOR VOLTAGE
1 Measure the voltage between the key-in ignition
warning switch connector K3-04, (BLUE/RED),
Page 10 of 14

Yes
INSTALL a new key-in ignition warning switch. TEST the
GO to A22.
No
normal operation.
A22: CHECK THE DOOR LOCKING MODULE TO DOOR LOCK BUTTON (LOCK) FOR
OPEN
1 Connect Key-In Ignition Warning Switch K3-04.
2 Disconnect Door Lock Button K3-03.

module connector K3-01 pin 2Q, (ORANGE),
K3-03, (ORANGE), harness side.

Yes
GO to A23.
No
normal operation.
A23: CHECK THE DOOR LOCKING MODULE TO DOOR LOCK BUTTON (UNLOCK) FOR
OPEN
module connector K3-01 pin 2R, (GREEN),
K3-03, (GREEN), harness side.

Yes
GO to A24.
No
Page 11 of 14
REPAIR the circuit (GREEN). TEST the system for

normal operation.
A24: CHECK THE DOOR LOCK BUTTON FOR GROUND
button connector K3-03, (BLACK), harness side
and ground.

Yes
INSTALL a new door lock button. TEST the system for
normal operation. If the concern persists, GO to A25.
No
normal operation.
A25: CHECK THE DOOR LOCKING MODULE TO DOOR LOCK ACTUATOR(S) (UNLOCK)
FOR OPEN
1 Connect Door Lock Button K3-03.
Disconnect Door Lock Actuator – (Front Driver Side
2 K3-03), (Front Passenger Side K3-02), (Rear Driver
Side K3-06), (Rear Passenger Side K3-07).
side and the following door lock actuator(s):





Yes
GO to A26.
No
REPAIR the circuit(s) (RED) as necessary. TEST the
(LOCK) FOR OPEN
(s):
Page 12 of 14



 Rear passenger side door lock actuator connector

Yes
INSTALL a new door latch(es). REFER to Front Door
Latch / Rear Door Latch in this section. TEST the
INSTALL a new door locking module. TEST the system
No
REPAIR the circuit(s) (RED/BLACK) as necessary. TEST
PINPOINT TEST B : THE LIFTGATE IS INOPERATIVE
B1: CHECK THE VEHICLE FOR DOUBLE LOCKING
1 Operate the central locking system.
Is the vehicle equipped with double locking?
Yes
GO to B2.
No
GO to B4.
B2: CHECK THE DOOR LOCKING MODULE TO THE LIFTGATE LATCH ACTUATOR
(UNLOCK) FOR OPEN (VEHICLES WITH DOUBLE LOCKING)
2 Disconnect Liftgate Latch Actuator K2-08.

side and the liftgate latch actuator connector K2-

Yes
GO to B3.
No
REPAIR the circuit (RED). TEST the system for normal
operation.
(LOCK) FOR OPEN (VEHICLES WITH DOUBLE LOCKING)
Measure the resistance between the door locking
Page 13 of 14
1 module connector K2-01 pin 1C, (RED/BLACK),

harness side and the liftgate latch actuator
connector K2-08, (RED/BLACK), harness side.

Yes
INSTALL a new liftgate latch. REFER to Liftgate Latch in
this section. TEST the system for normal operation. If
the concern persists, INSTALL a new door locking
module. TEST the system for normal operation.
No
REPAIR the circuit (RED/BLACK). TEST the system for
normal operation.
(UNLOCK) FOR OPEN (VEHICLES WITHOUT DOUBLE LOCKING)
2 Disconnect Liftgate Latch Actuator K3-08.

side and the liftgate latch actuator connector K3-

Yes
GO to B5.
No
REPAIR the circuit (RED). TEST the system for normal
operation.
(LOCK) FOR OPEN (VEHICLES WITHOUT DOUBLE LOCKING)
harness side and the liftgate latch actuator
connector K3-08, (RED/BLACK), harness side.

Yes
INSTALL a new liftgate latch. REFER to Liftgate Latch in
this section. TEST the system for normal operation. If
Page 14 of 14
the concern persists, INSTALL a new door locking

module. TEST the system for normal operation.
No
REPAIR the circuit (RED/BLACK). TEST the system for
normal operation.
Page 1 of 3

SAFETY BELT SYSTEM
UID=G327105
WARNING: All safety belt components including retractors, buckles, child safety seat
tether brackets and attaching hardware in use during a collision must be removed and
new components installed. New safety belt components should also be installed where
safety belts not in use during a collision, are inspected and found to be damaged or
operate incorrectly. Failure to follow these instructions may result in personal injury.
Vehicles equipped with the supplemental restraint system (SRS) are equipped with a driver
safety belt retractor and pretensioner and a passenger safety belt retractor and pretensioner.
The safety belt pretensioners are controlled as part of the SRS. REFER to Section 501-20A /
501-20B. When the ignition is turned on the RUN position the SRS warning indicator will
illuminate for three seconds. If the SRS, including the safety belt electrical system, is
operating correctly the SRS warning indicator will be extinguished. If a fault is detected the
SRS warning indicator will generate a lamp fault code (LFC).
Rear seat safety belt retractors do not use this type of retractor, they are equipped with a
conventional retractor. The rear seat safety belt buckles are mounted directly to the floor pan
underneath the rear seat cushion.
Emergency Locking Retractor (ELR)
The retractors in all seat positions feature ELR. The ELR is part of the safety belt system that
in normal operation allows free movement of the belted occupant. In an emergency the ELR
will lock, preventing webbing payout and hence forward movement of the occupant. Locking
may be achieved by one of two mechanisms:
Vehicle Motion Sensor (VMS)
VMS is operated by sudden deceleration of the vehicle or excessive tilt. Once operated the
VMS causes a locking pawl to be engaged, thus locking the retractor, preventing webbing
payout. When the vehicle is stationary, the VMS stabilizes, causing the pawl to disengage and
unlock the retractor, allowing webbing payout.
Webbing Motion Sensor (WMS)
The ELR WMS is operated by rapid acceleration of the webbing. Once operated, it causes a
locking pawl to be engaged thus locking the retractor. Webbing payout is prevented in the
same manner as VMS.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Mechanical
* Safety belt retractor
* Safety belt buckle

Page 2 of 3
* Safety belt retractor and pretensioner
possible) before proceeding to the next stop.
Symptom Chart

Normal mode - occupant restraint *Safety belt *CARRY OUT the Safety Belt
system inoperative. retractor. Component Test in this section.
Component Test
Poor Retraction
If a safety belt does not retract correctly, check that the anchor covers and trim bezels are
correctly installed and not rubbing against the safety belt webbing. Where necessary, check
that the safety belt webbing is not rubbing at one end of the retractor cover slot and, if so,
correct by loosening the retaining bolt, aligning the retractor to centralize the safety belt
webbing and retighten the bolt.
The safety belts are “dual sensitive” which means that they have:
* a vehicle motion sensor, which locks the safety belt webbing under braking,
cornering, on steep hills and in adverse camber conditions.
* a webbing motion sensor, which locks when the safety belt webbing is quickly
extracted.
Both systems should be fully operational and can be checked by the tests below:
Vehicle Motion Sensor Test
Either of the following two procedures may be used to check correct operation of the vehicle
motion sensor. Both methods require two technicians but note that technicians of larger than
normal build should not be asked to conduct these tests. This is to avoid the possibility of a
fully unrolled safety belt webbing being mistaken for a correctly locked safety belt retractor.
Test Method 1 (braking)
WARNING: It is important that during this test, the driver and passenger allow the
safety belts to provide the restraint and do not attempt to anticipate the sudden
deceleration. The steering wheel should not be used as a brace. However, both driver and
passenger should prepare themselves for the possibility that the safety belt will not lock.
The passenger should hold their hands in front of them, just clear of the instrument panel
or front seat backrest, depending on which safety belt is being tested. Failure to follow
these instructions may result in personal injury.
* Select for this test a quiet or private stretch of road. Make sure that the road is
clear and that full visibility is maintained at all times.
* Both driver and passenger should adopt a normal, comfortable seating position.
Both occupants should wear the safety belts and the safety belt webbing must be
correctly adjusted, with no slack.
Page 3 of 3
* Proceed at a speed of 10 km/h (6 mph). Do not exceed 10 km/h (6 mph) for

this test.
* Apply the foot brake sharply to stop the vehicle. If the vehicle motion sensitive
lock mechanism is operating correctly, the safety belt webbing will lock and
restrain the wearer.
* Conduct the test twice in each front and rear passenger seat position.
* Any safety belt retractor which does not restrain the wearer during this test
must not be reused. A new safety belt must be installed.
Test Method 2 (turning circle)
This method requires a flat open area of private road, sufficient for the vehicle to be driven in
a continuous circle on full steering lock.
* The driver should wear the safety belt provided and the belt webbing must be
correctly adjusted, with no slack.
* The passenger should occupy a rear seat with the safety belt correctly adjusted,
with no slack.
* Start the engine and, with the steering on full right-hand lock, drive the vehicle
in a continuous circle at 16 km/h (10mph). Do not exceed 16 km/h (10 mph) for
this test.
* When the speed is stable, the passenger should attempt to slowly extract the
safety belt webbing from each safety belt retractor in turn. If the vehicle motion
sensitive lock mechanism is operating correctly, it will not be possible to extract
the webbing.
* Any safety belt retractor from which it is possible to extract the webbing during
this test must not be used. A new safety belt must be installed.
Static Test
With the vehicle stationary and on level ground take firm hold of the safety belt webbing (on
the tongue side of the upper safety belt anchor) and pull out quickly. The retractor should
lock within 0.25 meter (10 inches), preventing further webbing payout. Any safety belt
retractor from which it is possible to extract further webbing must not be used. A new safety
belt must be installed.
Page 1 of 1

PASSENGER AIR BAG DEACTIVATION
(PAD) SWITCH
UID=G327106
Removal
WARNINGS:
injury.
01.
2. Remove the passenger air bag deactivation
(PAD) switch.
1. Detach the PAD switch from the instrument
panel.
Installation
WARNING: Never probe the electrical connectors of air bag modules or any other
supplemental restraint system component. Failure to follow this instruction may result in
personal injury.
11.
Page 1 of 5

WIPERS AND WASHERS
UID=G327107
Windshield wiper motor inspection, LHD
NOTE: Pry off the connection between the windshield wiper motor and windshield wiper
link.
1. Disconnect the windshield wiper motor connector.
2. Connect battery positive voltage to terminal E or D and ground to terminal C, and inspect
the operation of the windshield wiper motor as indicated below.
Terminal connected with battery voltage Operation

D High
E Low
3. Disconnect battery positive voltage from terminal E or D of the motor while the wipers are
operating.
4. Verify that the wipers do not stop in the park position.
5. Short between the motor terminals B and E and connect battery positive voltage to the
motor terminal A.
6. Verify that the wipers operate at low speed again, then stop in the park position.
7. If the motor does not work as specified, replace the windshield wiper motor.
Windshield wiper motor inspection, RHD
NOTE: Pry off the connection between the windshield wiper motor and windshield wiper
link.
1. Disconnect the windshield wiper motor connector.
2. Connect battery positive voltage to terminal B or A and ground to terminal C, and inspect
the operation of the windshield wiper motor as indicated below.
Terminal connected with battery voltage Operation

B High
A Low
Page 2 of 5
3. Disconnect battery positive voltage from terminal B or A of the motor while the wipers are
operating.
4. Verify that the wipers do not stop in the park position.
5. Short between the motor terminals D and A and connect battery positive voltage to the
motor terminal E.
6. Verify that the wipers operate at low speed again, then stop in the park position.
7. If the motor does not work as specified, replace the windshield wiper motor.
Rear window wiper motor inspection
1. Disconnect the negative battery cable.
2. Remove the liftgate lower trim.
3. Disconnect the rear window wiper motor connector.
4. Connect battery positive voltage to the rear wiper motor terminal B and the ground to a
bare metal part of the vehicle and the rear wiper motor terminals C and D.
5. Verify that the rear wiper motor operates.
6. Disconnect the ground to the terminal C while the rear wiper is operating.
7. Verify that the rear wiper stops in the park position.
8. If the motor does not work as specified, replace the rear wiper motor.
Washer pump motor, front and rear
1. Disconnect the negative battery cable.

Page 3 of 5
2. Remove the washer tank.
3. Connect battery positive voltage to the motor terminal B and ground to the motor terminal
A.
4. Verify that the windshield washer motor operates.
5. If the motor does not operate, replace the windshield washer motor.
Wiper / washer switch
1. Inspect for continuity between the wiper / washer switch terminals using an ohmmeter.
2. If the results are not as specified, replace the wiper / washer switch.

Wiper switch Washer switch One Touch C E J A H I
OFF - OFF - - - - - -
ON - - O O - -
INT - - - - - - - -
1 - - - - - O - O
2 - - - - O O - O
MIST - - - - - O - O
OFF ON - - - - - O O
O----O: Continuity between these terminals
Page 4 of 5
Rear wiper / washer switch
1. Inspect for continuity between the rear wiper / washer switch terminals using an
ohmmeter.
2. If the results are not as specified, replace the wiper / washer switch.

Wiper switch Washer switch C E J A H I
INT - - - - - - -
ON - O - - - - O
ON ON O O - - - O
OFF ON - O - - - O
O----O: Continuity between these terminals
Page 5 of 5
Ignition switch
1. Inspect for continuity between the blower motor switch terminals using an ohmmeter.
2. If the results are not as specified, replace the ignition switch.
Ignition key position Terminal

E F C B
LOCK - - - -
ACC - - - -
ON O - O -
- O - O
START O - O -
O----O: Continuity between these terminals.
Page 1 of 1

SPECIFICATIONS
UID=G327194
Item Nm lb-ft lb-in

Front seat retaining bolts 35 26 -
Front seat cushion retaining bolts 23 17 -
Front seat backrest retaining bolts 48 35 -
Front seat side air bag module retaining nuts 9 - 80
Rear seat backrest retaining bolts 25 18 -
Rear seat backrest latch retaining bolts 18 13 -
Rear center safety belt retractor retaining nut 47 35 -
Rear seat cushion retaining bolts 25 18 -
Rear center safety belt lower anchor and buckle assembly retaining bolt 55 41 -
Page 1 of 2

REAR SEAT BACKREST LATCH
UID=G327195
1. Remove the rear seat backrest cover. For

additional information, refer to Rear Seat
Backrest Cover in this section.

1 - Backrest latch to center safety belt retractor locking cable (if equipped)
See Removal Detail
2 - Backrest latch retaining bolts
3 - Backrest latch
Removal Details
Item 1 : Backrest latch to center safety belt retractor locking cable (if equipped)
NOTE: To aid installation, note the backrest latch cable position on the safety belt
retractor.
1. Detach the backrest latch cable from the
safety belt retractor.
Page 2 of 2
Item 1 : Backrest latch to center safety belt retractor locking cable (if equipped)
CAUTION: Check the backrest latch cable routing, and the operation of the safety
belt retractor and interlock before fully assembling the rear seat backrest.
Page 1 of 2

FRONT SUSPENSION
UID=G327200
Overview
NOTE: During installation of the front wheel bearing it is important to adhere to the
specified installation position, as the anti-lock brake system ( ABS ) sensor ring is located
in the wheel bearing. A colored rubber ring is provided to indicate the correct installation
position. If the wheel bearing were to be installed incorrectly then this would cause failure
of the ABS .
A newly developed Mc-Pherson front suspension with L-shaped lower arms is used. These
lower suspension arms are linked via large rubber mountings to a reinforced and extremely
rigid front axle crossmember.
The ball head between the lower suspension arm and the suspension strut is secured with
three rivets. Toe-in is adjusted via adjustable track rods. The lower suspension arms can only
be replaced as a complete unit.

1 - Rear rubber mounting
The rear rubber mountings for the lower suspension arms are enclosed in aluminium
brackets. This provides more vibration damping than previously. Both the front and rear
Page 2 of 2
brackets are arranged horizontally.
The suspension strut turret support bearings have two separate routes for independently
deflecting the spring and shock absorber forces into the body. This reduces the level of noise
transmitted from the road surface.
The correct installation position must be observed when installing the suspension strut turret
support bearings. This is indicated by an arrow on the suspension strut turret support
bearing. The shock absorbers are gas shock absorbers.
Page 1 of 1

STABILIZER BAR BUSHING
UID=G327202
Removal
1. Remove the stabilizer bar. For additional
information, refer to Stabilizer Bar in this
section.
2. Remove the stabilizer bar bushings on both
sides.
Installation
CAUTIONS:
1. Do not lubricate the stabilizer bar

bushings.
The stabilizer bar bushings must be

positioned with the slot facing forwards of the
stabilizer bar.
The stabilizer bar bushings must be

positioned as shown.
NOTE: The location of the stabilizer bar
bushings should be measured from the center
mark on the stabilizer bar.
Install the stabilizer bar bushings.
2. Install the stabilizer bar. For additional
information, refer to Stabilizer Bar in this
section.
Page 1 of 1

SPECIFICATIONS
UID=G327203
Specification
Silicon grease
Brake shoe grease
Drum Brake Specification
Description mm
New brake drum nominal diameter 203
Worn brake drum discard diameter * 204
Brake shoe width 36
Worn brake shoe lining discard thickness * 1
* When the discard diameter/thickness has been reached, install a new brake drum/brake
shoes.

Wheel spindle retaining bolts 70 52 -
Wheel cylinder retaining bolts 10 - 89
Brake hose to wheel cylinder union 17 13 -
Page 1 of 1

SPECIFICATIONS
UID=G327204
Specification
Front Disc Brake Specification
Description mm
Brake disc diameter 258
New brake disc nominal thickness 22
Worn brake disc discard thickness * 20
Maximum brake disc thickness variation 0.025
Worn brake pad discard thickness * 1.5
* When the discard thickness has been reached, install a new brake disc/brake pads.

Brake caliper anchor plate retaining bolts 70 52 -
Brake caliper retaining bolts 30 22 -
Brake hose to brake caliper union 17 13 -
Page 1 of 1

SPECIFICATIONS
UID=G327205

Parking brake cable adjusting nut 4 - 35
Parking brake control nuts 24 18 -
Page 1 of 3

PARKING BRAKE
UID=G327206
1. Verify the customer concern by operating the parking brake system.
- Parking brake - Parking brake warning circuit. REFER to
control Section 413-01.
- Parking brake
cable
4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart

The parking brake will not apply *Parking brake control. *GO to Pinpoint Test A.
*Parking brake cable.
The parking brake will not release *Parking brake control. *GO to Pinpoint Test B.
*Parking brake cable.
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY
A1: CHECK FOR MISADJUSTED REAR PARKING BRAKE CABLE
1 Operate the parking brake control several times to adjust the cable.
Does the parking brake now engage correctly?
Yes
Vehicle OK.
No
GO to A2.
A2: CHECK FOR WORN BRAKE SHOES
1 Inspect the brake shoes for excessive wear. REFER to Section 206-00.
Are the brake shoes and linings OK?
Yes
GO to A3.
No
INSTALL new brake shoes. REFER to Section 206-02. TEST the system for
normal operation.
A3: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables for damage, rust or fraying.
Page 2 of 3
Are the parking brake cables OK?

Yes
CHECK for other causes such as loose parking brake control or conventional
brake system components. REFER to Section 206-00.
No
REPAIR or INSTALL the parking brake cables as necessary. TEST the system for
normal operation.
PINPOINT TEST A : THE PARKING BRAKE WILL NOT RELEASE
A1: CHECK PARKING BRAKE CABLES
1 Loosen the parking brake cable tension.
 Rotate the rear wheels by hand.

Did the rear wheel turn freely?
Yes
INSTALL a new parking brake control. REFER to Parking Brake Control in this
No
GO to B3.
A2: CHECK PARKING BRAKE CONTROL
1 Raise and support the vehicle on a lift with the parking brake fully applied.
Release the parking brake by pulling upwards on the control level and
pushing the release button.
Did the parking brake release?
Yes
CHECK for other causes such as conventional brake system components.
REPAIR or INSTALL new components as necessary. REFER to Section 206-00.
No
GO to B1.
A3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the front parking brake cable from the rear parking brake cable
at the equalizer.
 Rotate the rear wheels by hand.

Did the rear wheel turn freely?
Yes
INSTALL a new front parking brake cable. REFER to Parking Brake Cable in this
No
GO to B4.
A4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the rear parking brake cable at the rear brakes, one at a time.
 Rotate the wheel affected by the disconnected parking brake cable.

Did the wheel turn freely?
Yes
INSTALL a new rear parking brake cable. REFER to Parking Brake Cable in this
No
CHECK for other causes such as conventional brake system components.
Page 3 of 3
REPAIR or INSTALL new components as necessary. REFER to Section 206-00.

Page 1 of 1

SPECIFICATIONS
UID=G327207
Specification

Brake master cylinder brake tube unions 17 13 -
Pressure conscious reducing valve unions 26 19 -
Brake master cylinder retaining nuts 25 18 -
Brake pedal cross-shaft mounting bracket nuts 25 18 -
Page 1 of 1

SPECIFICATIONS
UID=G327208
Specifications
Item Nm lb-ft lb-in

Hydraulic control unit (HCU) to support bracket retaining bolts 9 - 80
HCU support bracket retaining bolts 20 15 89
Brake tube to HCU union 18 13 -
Wheel speed sensor retaining bolts 9 - 80
Anti-lock brake system (ABS) module to HCU retaining bolts 5 - 44
Page 1 of 2

GEARSHIFT LEVER
UID=G327209
Removal
1. Detach the gearshift trim panel from the floor
console.
2. Remove the gearshift trim panel.
 Detach the gearshift boot from the trim

panel.
3. Detach the gearshift cables from the gearshift

lever.
4. Detach the gearshift cables from the retaining

bracket.
 Turn the abutment sleeves clockwise.
5. Remove the gearshift lever front retaining

bolts.
Page 2 of 2
6. Remove the gearshift lever.
 Remove the gerashift lever rear retaining

bolts.
Installation
Page 1 of 4

GEARSHIFT CABLES
UID=G327210
Removal
1. Remove the gearshift lever. For additional
information, refer to Gearshift Lever in this
section.
4. Remove the exhaust front hanger insulator.

panel.
 Slide the heat shield backwards.
7. Detach the gearshift cables from the transaxle.

8. Detach the gearshift cables from the retaining

clip.
Page 2 of 4
9. Detach the selector cable from the retaining

clip.

12. Cut the floor covering and the sound
deadening material to gain access to the
gearshift cable bushing.
13. Detach the gearshift cables bushing from the

floor panel and pull the cables through to the
vehicle interior.
Installation
1. NOTE: Do not bend or kink the gearshift
cables.
Feed the gearshift cables through the floor panel
and attach the gearshift cables bushing.
Page 3 of 4
2. Install the floor console. For additional

5. Attach the gearshift cables to the selector

levers.
6. Attach the exhaust heat shield to the floor

panel.
 Slide the heat shield forwards.
7. Install the exhaust front hanger insulator.
8. Attach the gearshift cables to the retaining

clip.
9. Attach the selector cable to the retaining clip.

Page 4 of 4
10. Install the gearshift lever. For additional

information, refer to Gearshift Lever in this
section.
Page 1 of 1

GEARSHIFT LEVER — VEHICLES WITH:
AUTOMATED GEARSHIFT
UID=G327212
Removal
1. Remove the gearshift lever housing cover.
 Disconnect the cigarette lighter connector.
2. Remove the gearshift lever.
 Disconnect the gearshift lever connector.
Installation
2. NOTE: Display on the instrument cluster.
Check the shift function.
Page 1 of 3

FENDER
UID=G327215
Removal
2. Remove the headlamp assembly. For
01.
3. Remove the front wheel and tire. For additional
4. NOTE: Mark the position of the hood hinge
in relation to the hood on both sides to aid
installation.
Remove the hood.
 Remove the bolts on both sides.
5. NOTE: Mark the position of the hood hinge

in relation to the fender on both sides to aid
installation.
Remove the hood hinge.
6. Remove the cowl panel grille.
 Remove the windshield wipers.
 Remove the bolts.
7. Remove the fender splash shield.
8. Remove the fender inner retaining bolt and

disconnect the turn signal electrical connector.
Page 2 of 3
9. Remove the fender lower retaining bolts.
10. Remove the fender front retaining bolts.
11. Remove the fender upper retaining bolt from

the a-pillar.
12. Remove the fender.
Installation
1. NOTE: Align the hood and hood hinge bolts
to the previously marked positions.
Page 3 of 3
Page 1 of 4

RADIATOR GRILLE OPENING PANEL
UID=G327216
General Equipment
Transmission jack
Removal
WARNINGS:
injury.
01.
3. Detach the windshield washer reservoir from
4. Release the hood latch release cable.
5. Detach the air intake hose from the radiator

grille opening panel.
Page 2 of 4
6. Detach the power steering pump (PSP)

reservoir from the radiator grille opening
panel.
7. Disconnect the crash sensor electrical

connector.
8. Detach the coolant expansion tank hose from

9. Remove the air deflectors.
10. Detach the power steering fluid cooler from

the radiator grille opening panel and position it
to one side.
Page 3 of 4
11. Remove the radiator lower retaining bolts.
12. Remove the radiator lower retaining clips.
 Turn the retaining clips counterclockwise.
13. Detach the radiator from the radiator grille

opening panel.
 Using suitable cable ties, secure the radiator

to the exhaust manifold.
14. Remove the front bumper retaining bolts.
15. Remove the radiator grille opening panel.

Page 4 of 4
Installation
CAUTIONS:
1. The radiator grille opening panel must

be installed centrally between the fenders,
the hood and headlamps must engage freely
to prevent damage.
Make sure the crash sensor electrical

connector is fully connected.

operation of the air bag warning lamp is
observed during the first cycle of the ignition
following installation of the radiator grille
opening panel.
Prove out the supplemental restraint system
(SRS) by cycling the ignition and observing the
air bag warning lamp.
 If the air bag warning light begins to flash,

re-check the crash sensor electrical
connector.
 Note the flash code and repair the SRS. For

20A / 501-20B.
Page 1 of 2

REAR SUSPENSION
UID=G327217
Overview

1 - Brake drum
2 - Anti-lock brake system (ABS ) wheel sensor pick-up ring
3 - Stub axle
4 - Brake back plate assembly with brake
5 - Bracket
Page 2 of 2
6 - Spring
7 - Shock absorber
A significant modification is the replacement of the previous Mc-Pherson suspension struts
with separate spring and shock absorber elements. This results in more space in the area of
the suspension strut turrets, thus increasing the volume of the luggage compartment. In
addition, the forces from the spring and shock absorber elements are now dissipated
separately and have been individually optimised.
The shock absorbers are single-tube gas shock absorbers.
It is important that the correct installation orientation is adhered to when assembling the
support bearings, as otherwise the geometry of the rear suspension will not be correct. The
installation orientation of the support bearing is indicated with an arrow.
Page 1 of 1

SPECIFICATIONS
UID=G327218
Polyurethane adhesive (glass)
Item Nm lb-ft lb-in

Front door regulator motor retaining screws 6 - 53
Door module retaining screws 8 - 71
Door window regulator retaining bolts 6 - 53
Windshield wiper arm retaining nut 27 20 -
Page 1 of 13

AUTOMATED GEARSHIFT SYSTEM
UID=G327220
General Equipment
For mechanical concerns, REFER to Section 308-00.[Manual Transmission/Transaxle and

Clutch - General Information, DIAGNOSIS AND TESTING, Manual Transaxle and Clutch]
* Gearshift actuator * Transmission control module
* Clutch actuator * Fuse(s)
* Transaxle fluid leaks * Electrical connector(s)
* Circuit(s)
4. If the cause is not visually evident, connect the diagnostic tool to the data link connector
and select the vehicle to be tested from the diagnostic tool menu.
5. Retrieve the DTCs and refer to the Symptom Chart.
Automated Gearshift System On-Board Diagnosis
* The OBD test inspects the integrity and function of the automated gearshift
system and outputs the results when requested by the specific tests.
 Provides a quick inspection of the automated gearshift system usually

performed at the start of each diagnostic procedure.
during service.
modes.
Page 2 of 13
This function allows you to read or clear DTCs in the transmission control module memory.
Measured
terminal
Measured (measured Inspection item
Page 3 of 13
Terminal Signal name Connected to item condition) Standard (s)

1A Ground Ground point Continuity A - Ground point Continuity Related wiring
(System) harness
1B - - - - - -
1C - - - - - -
1D Power supply Battery Voltage D - Ignition ON V batt Related wiring
(System) D - Ignition OFF 1 V or harness
less
1E Power supply Ignition Voltage D - Ignition ON V batt Related wiring
(System) switch D - Ignition OFF 1 V or harness
less
1F - - - - - -
1G - - - - - -
1H - - - - - -
1I - - - - - -
1J - - - - - -
1K Door ajar Door ajar Voltage K - A (With door V batt Related wiring
switch OPEN) harness /Door
K - A (With door 1 V or ajar switch
CLOSED) less
1L - - - - - -
1M - - - - - -
1N Stop lamp Stop lamp Voltage N - A (When V batt Related wiring
switch switch depressing the harness / Stop
brake pedal with lamp switch
ignition switch at
the ON position)
N - A (When 1 V or
releasing the less
brake pedal with
ignition switch at
the ON position)
1O - - - - - -
1P - - - - - -
1Q - - - - - -
1R - - - - - -
1S CAN_H Data link Continuity S - Data link Continuity Related wiring
connector connector
1T - - - - - -
1U - - - - - -
1V CAN_H Data link Continuity V - Data link Continuity Related wiring
connector connector harness
1W - - - - - -
1X - - - - - -
1Y Starter inhibit Ignition Voltage Y - A (Ignition V batt Related wiring
switch switch at the harness
START position)
Y - A (Ignition 1 V or
switch at the ON less
position)
1Z - - - - - -
1AA CAN_L Data link Continuity AA - Data link Continuity Related wiring
connector connector CAN_L harness
Page 4 of 13
(CAN_L) terminal
1AB - - - - - -
1AC - - - - - -
1AD CAN_L Data link Continuity AD - Data link Continuity Related wiring
connector connector CAN_L harness
(CAN_L) terminal
1AE - - - - - -
1AF - - - - - -
1AG - - - - - -
1AH - - - - - -
1AI - - - - - -
1AJ - - - - - -
1AK - - - - - -
2A Transmission Transmission Continuity A - Transmission Continuity Related wiring
shift motor shift motor - shift motor- B harness
sensor ground B
2B Transmission Transmission Continuity B - Transmission Continuity Related wiring
shift motor shift motor - shift motor- A harness
+ve A
2C Transmission Transmission Continuity C - Transmission Continuity Related wiring
shift motor shift motor - shift motor - C harness
sensor Vcc C
2D Transmission Transmission Continuity D - Transmission Continuity Related wiring
select motor select motor - select motor - B harness
sensor ground B
2E Transmission Transmission Continuity E - Transmission Continuity Related wiring
shift motor -ve shift motor - shift motor - F harness
F
2F Transmission Transmission Continuity F - Transmission Continuity Related wiring
select motor select motor select motor – A harness
+ve –A
2G Transmission Transmission Continuity G - Transmission Continuity Related wiring
select motor select motor select motor – C harness
sensor Vcc –C
2H Transmission Transmission Continuity H - Transmission Continuity Related wiring
select motor - select motor - select motor - F harness
ve F
2I - - - - - -
2J - - - - - -
2K - - - - - -
2L - - - - - -
2M - - - - - -
2N - - - - - -
2O - - - - - -
2P - - - - - -
2Q - - - - - -
2R - - - - - -
2S - - - - - -
2T - - - - - -
2U - - - - - -
2V - - - - - -
2W - - - - - -
2X - - - - - -
2Y Transmission Transmission Continuity Y - Transmission Continuity Related wiring
Page 5 of 13
shift motor shift motor - shift motor - D harness

speed sensor D
2Z - - - - - -
2AA - - - - - -
2AC Transmission Transmission Continuity AC - Continuity Related wiring
shift motor shift motor - Transmission harness
direction E shift motor - E
sensor
2AD - - - - - -
2AE - - - - - -
2AF - - - - - -
2AG Transmission Transmission Continuity AG - Continuity Related wiring
select motor select motor - Transmission harness
speed sensor D select motor - D
2AH - - - - - -
2AI - - - - - -
2AJ - - - - - -
2AK Transmission Transmission Continuity AK - Continuity Related wiring
select motor select motor - Transmission harness
direction E select motor - E
sensor
2AL - - - - - -
2AM - - - - - -
2AM - - - - - -
2AN - - - - - -
Diagnostic Trouble Codes (DTCs)

DTC B2983: Door switch *Driver door *REFER to WDS.
error during on demand self open switch.
test *Circuit(s).
DTC C1222: Speed wheel *Circuit(s). *REFER to WDS.
mismatch
DTC C1296: Wheel speed *Circuit(s). *REFER to WDS.
LEFT FRONT signal fault
RIGHT FRONT signal fault
RIGHT REAR signal fault
LEFT REAR signal fault
DTC P0504: Brake switch *Brake switch. *REFER to WDS.
A/B correlation *Circuit(s).
DTC P0512: Ignition start *Circuit(s). *REFER to WDS.
circuit failure
DTC P0560: System voltage *Transmission *REFER to WDS.
control module.
*Battery.
*Charging
circuit.
DTC P0562: System voltage *Battery. *REFER to WDS.
low *Charging
circuit.
DTC P0563: System voltage *Charging *REFER to Section 414-00.[Charging System -
Page 6 of 13
high circuit. General Information, DIAGNOSIS AND

TESTING, Charging System]
DTC P0571: Brake pedal *Circuit(s). *REFER to WDS.
switch circuit
DTC P0572: Brake circuit *Brake switch. *REFER to WDS.
open *Circuit(s).
DTC P0601: Internal control *Transmission *REPROGRAM the transmission control module
module memory checksum control module. (TCM), REFER to WDS. REPEAT the self-tests,
error CLEAR the DTCs.
DTC P0605: Powertrain *Transmission *REPROGRAM the transmission control module
control module read only control module. (TCM), REFER to WDS. REPEAT the self-tests,
memory (ROM) error CLEAR the DTCs.
DTC P0613: Transmission *Transmission *REPROGRAM the transmission control module
control module (TCM) control module. (TCM), REFER to WDS. REPEAT the self-tests,
Processor CLEAR the DTCs.
DTC P0614: ECM / *Transmission *CHECK the correct module is installed.
transmission control module control module. REPEAT the self-tests, CLEAR the DTCs.
(TCM) Incompatible *Powertrain
control module.
DTC P0641: Sensor *Transmission *REFER to WDS.
reference Voltage A circuit control module.
open *Gearshift
actuator.
*Circuit(s).
reference voltage A circuit control module.
low *Gearshift
actuator.
*Circuit(s).
reference voltage A circuit control module.
high *Gearshift
actuator.
*Circuit(s).
reference voltage B circuit control module.
open *Gearshift
actuator.
*Circuit(s).
low *Gearshift
actuator.
*Circuit(s).
high *Gearshift
actuator.
*Circuit(s).
DTC P0657: Actuator supply *Gearshift *REFER to WDS.
voltage A circuit actuator.
DTC P0805: Clutch position *Transmission *REFER to WDS.
sensor circuit control module.
*Clutch position
Page 7 of 13
sensor.
DTC P0810: Clutch position *Transmission *REFER to WDS.
control error control module.
*Clutch position
sensor.
DTC P0905: Gate select *Transmission *REFER to WDS.
position circuit control module.
range/performance *Gearshift
actuator.
*Circuit(s).
position circuit low control module.
*Gearshift
actuator.
*Circuit(s).
position circuit high control module.
*Gearshift
actuator.
*Circuit(s).
control error control module.
*Gearshift
actuator.
DTC P0915: Gearshift *Transmission *REFER to WDS.
position circuit control module.
range/performance *Gearshift
actuator.
*Circuit(s).
position circuit low control module.
*Gearshift
actuator.
*Circuit(s).
position circuit high control module.
*Gearshift
actuator.
*Circuit(s).
position control error control module.
*Gearshift
actuator.
DTC P0949: Automated *Transmission *CARRY OUT ASM Service functions. REFER to
shift manual (ASM) control module. WDS.
adaptive learning not done
DTC P1145: Calculated *Powertrain *REFER to WDS.
torque error control module.
DTC P1750: Clutch adaptive *Transmission *LEARN the clutch touch-point. REFER to WDS.
learning not done control module.
DTC P1797: CAN Powertrain *CAN error. *REFER to WDS.
control module (PCM) circuit
malfunction
DTC P1799: CAN Powertrain *CAN error. *REFER to WDS.
Page 8 of 13
control module (PCM) /

Anti-lock brake system
(ABS) circuit malfunction
DTC P1913: Sensor ground *Transmission *REFER to WDS.
reference A circuit control module.
*Gearshift
actuator.
*Circuit(s).
reference A circuit low control Module.
*Gearshift
actuator.
*Circuit(s).
reference B circuit low control module.
*Gearshift
actuator.
*Circuit(s).
reference B circuit control module.
*Gearshift
actuator.
*Circuit(s).
DTC P2712: Hydraulic *Clutch. *BLEED the automated gearshift system.
pressure unit leakage REFER to Section 308-00.[Manual
Gearshift]
DTC P2530: Ignition switch *Circuit(s). *REFER to WDS.
run position circuit
DTC P2531: Ignition switch *Circuit(s). *REFER to WDS.
run position circuit low
DTC P2669: Actuator supply *Gearshift *REFER to WDS.
voltage B circuit actuator.
DTC P2785: Clutch actuator *Transmission *REFER to WDS.
temperature too high control module.
DTC P2786: Gearshift *Gearshift *Allow to cool for one hour. REPEAT the self-
actuator temperature too actuator. tests, CLEAR the DTCs. If the fault remains,
high INSTALL a new gearshift actuator. REFER to
Gearshift Actuator in this section.
DTC P2787: Clutch *Clutch. *Allow to cool for one hour. REPEAT the self-
temperature too high tests, CLEAR the DTCs. If the fault remains,
REFER to Section 308-00.[Manual
Manual Transaxle and Clutch]
DTC P2788: Automated *Transmission. *REFER to WDS.
shift manual (ASM)
adaptive learning at limit
DTC P2789: Clutch adaptive *Clutch. *BLEED the automated gearshift system.
learning at limit REFER to Section 308-00.[Manual
Page 9 of 13
Gearshift]
direction circuit control module.
*Gearshift
actuator.
*Circuit(s).
direction circuit low control module.
*Gearshift
actuator.
*Circuit(s).
direction circuit high control module.
*Gearshift
actuator.
*Circuit(s).
direction circuit control module.
*Gearshift
actuator.
*Circuit(s).
direction circuit low control module.
*Gearshift
actuator.
*Circuit(s).
direction circuit high control module.
*Gearshift
actuator.
*Circuit(s).
DTC U0100: Lost *CAN bus error. *REFER to WDS.
communication with
powertrain control module
(PCM)
communication with *Gearshift
gearshift module module.
communication with anti- *ABS control
lock brake system (ABS) module
control module
communication with *Instrument
instrument panel cluster cluster.
DTC U0401: Invalid data *CAN bus error. *REFER to WDS.
received from *Powertrain
engine/powertrain control control module
module (PCM)
received from gearshift *Gearshift
module module.
received from anti-lock
Page 10 of 13
brake system (ABS) control *ABS control

module module
PID Table
PID Definition Units Condition / Actual Measurement (Reference)

ABS_STAT Anti-lock Braking Digital Inactive: Normal condition
System
ACSW Air Conditioning Digital Inactive: Magnet clutch OFF
Switch Active: Magnet clutch ON
APP Accelerator Position Angle 0°: Closed
90°: Fully open
BCAOC Brake Circuit A on CAN Digital OFF: Brake pedal - off
OFF: Brake pedal - middle position
ON: Brake pedal - on
BCBHW Brake Circuit B Hard Digital OFF: Brake pedal - off
Wired ON: Brake pedal - middle position
BCBOC Brake Circuit B on Digital OFF: Brake pedal - off
CAN ON: Brake pedal - middle position
CLTCHSETPNT Clutch Set Point Integer 16 mm: N-range and engine run
10 mm - 15 mm: D-range and engine run
10 mm: Low-speed driving
CLTCH_SLIP Clutch Slip Integer 720 rpm - 780 rpm: D-range, Engine run,
stand still
0 rpm - 20 rpm: at constant driving (during
rapid acceleration: it will increase up to
approximately 2300 rpm)
CLTCH_TEMP Clutch Temperature Integer 64°C: After warm-up and before driving
153°C: After driving and at idle
GLP_D Automatic Gearshift Digital ON: Gearshift lever in position A
Selected OFF: All other conditions
DR_DOOR_SW Driver Door Digital Closed: Driver door closed
Open: Driver door opened
DTC_TCM Number of Continuous Integer 0 - 10: number of DTCs
Trouble Codes Set
ENG_IDLE Engine Idle Target rpm The PCM sends the target engine idle speed to
Speed the TCU -
848 rpm: at idle after warm-up (A/C Off)
944 rpm: at idle after warm-up (A/C On)
ENG_TORQ Engine Torque Actual Integer 0 Nm - 5 Nm: Idle after warm-up
0 Nm - 120 Nm: During driving
FOOTBRAKE Brake Pedal Digital Inactive: Brake OFF
Active: Brake ON
FRIC1 Friction Coefficient 1 Integer Default value: 270
Range: 100 - 650
Range: 100 - 650
Range: 100 - 650
FRIC_GEN Friction Coefficient Integer Default value: 270
General Range: 100 - 650
GRSEL Gear Selected Digital N
Page 11 of 13
R
1
2
3
4
5
HANDBRAKE Handbrake Status Digital ON: Parking brake applied
OFF: Parking brake not applied
IDLE_SW Idle Switch Digital ON: Accelerator closed
OFF: Accelerator opened
IGN_CAN Ignition CAN Digital ON: IGN On
OFF: IGN Off
IGN_SW Ignition Switch Digital ON: IGN On
OFF: IGN Off
KickDown Kick-down Switch Digital Inactive: Not full throttle
Active: Throttle position > 85°
L_CTP1 Learnt Clutch Touch Digital ON: Learnt
Point 1 OFF: Not Learnt
L_ENDPOS1 Learnt End Position Digital ON: Learnt
Gear 1 OFF: Not Learnt
L_ENDPOS_R Learnt End Position Digital ON: Learnt
Gear Reverse OFF: Not Learnt
L_SYNCPOS1 Learnt Synchronizer Digital ON: Learnt
Position Gear 1 OFF: Not Learnt
MANUAL_ASM Manual Gearshift Digital Active: Manual mode
Selected Inactive: Automatic mode
NEUTRAL Gearshift Lever in Digital ON: Gearshift lever in Neutral position
Neutral OFF: Gearshift lever not in Neutral position
PVT Pressure Vacuum - Enables pressure or vacuum to be monitored
Transducer by the PVT contained in the WDS accessories
kit.
REFPOS_SHFT Reference Position mm Measured value: -1 mm
Shift
Page 12 of 13
REF_POS_SEL Reference Position mm Measured value: -18 mm

Select
REVERSE Gearshift Lever in Digital ON: Gearshift lever in Reverse position
Reverse OFF: Gearshift lever not in Reverse position
RPM_TCM Engine Speed rpm Engine speed
SEL_POS1 Select Position Gear 1 mm Default value: -18 mm
Range: ± 3 mm
SEL_POS2 Select Position Gear 2 mm Default value: -18 mm
Range: ± 3 mm
SEL_POS3 Select Position Gear 3 mm Default value: 0 mm
Range: ± 3 mm
Range: ± 3 mm
Range: ± 3 mm
SEL_POS_R Select Position Gear mm Default value: 19 mm
Reverse Range: ± 3 mm
SEL_TRVL1 Select Travel Gear 1 mm Measured value: 4 mm
SEL_TRVL_R Select Travel Gear mm Measured value: 4 mm
Reverse
SHFTMTR_ACT Shift Motor Actual mm Signal shows the actual movement of the shift
actuator
SHFTMTR_REQShift Motor Requested mm Target value for the shift actuator movement
SHFT_POS1 Shift Position Gear 1 mm Default value: 10 mm
SHFT_POS2 Shift Position Gear 2 mm Default value: -10 mm
SHFT_POS4 Shift Position Gear 4 mm Default value: -10 mm
SHFT_POS_R Shift Position Gear mm Default value: -10 mm
Reverse
START_REQ Starter Request Circuit Digital ON: IGN at "START" position
OFF: IGN not at "START" position
START_RLY Starter Relay Digital ON: IGN at "ON" or "START" + Brake pedal ON
+ N-range
OFF: Other than above
SYNC_POS1 Synchronizer Position mm Default value: 4 mm ± 1.5 mm
Gear 1
SYNC_POS2 Synchronizer Position mm Default value: -4 mm ± 1.5 mm
Gear 2
Gear 3
SYNC_POS4 Synchronizer Position mm Default value: -4 mm ± 1.5 mm
Gear 4
Gear 5
TCHPT_LT Touchpoint - Long mm Learnt value: 11 mm
term Range: 7.5 -14.9 mm
TCHPT_MT Touchpoint - Medium mm Learnt value: 11 mm
Page 13 of 13
TCHPT_ST Touchpoint - Short mm Learnt value: 11 mm

TIP+ Gearshift Lever Digital ON: Gearshift lever in TIP+ position
Position OFF: Gearshift lever not in TIP+ position
TIP- Gearshift Lever Digital ON: Gearshift lever in TIP- position
Position OFF: Gearshift lever not in TIP- position
TRANS_GEAR Transmission Actual Digital N
Gear R
1
2
3
4
5
VPWR Power Supply Volts 12.3V
TP Throttle Position Angle 0°: Closed
90°: Fully open
WSPDFL Wheel Speed Front rpm Wheel speed: Range 0 - 2000 rpm
Left
WSPDFR Wheel Speed Front rpm Wheel speed: Range 0 - 2000 rpm
Right
WSPDRL Wheel Speed Rear Left rpm Wheel speed: Range 0 - 2000 rpm
WSPDRR Wheel Speed Rear rpm Wheel speed: Range 0 - 2000 rpm
Right
Page 1 of 2

BRAKE DRUM
UID=G327221
Removal


5. NOTE: If the dust cap is damaged on
removal a new dust cap must be installed
during installation.
Remove the dust cap.

1. Remove and discard the wheel hub retaining
nut.
2. Remove the drum.
Installation
1. CAUTION: Rotate the drum ten times

in the opposite direction when tightening the
wheel hub retaining nut to prevent damage to
Page 2 of 2
the bearing.
NOTE: Install a new parking brake cable
retaining clip.
Page 1 of 3

BRAKE SHOES
UID=G327222
Name Specification
Brake shoe grease
Removal


5. Detach the wheel speed sensor from the
backing plate.
7. Remove the hold down springs.

Page 2 of 3
8. CAUTION: Do not damage the wheel

cylinder boots.
NOTE: Hold the wheel cylinder pistons in
place with a rubber band.
Detach the brake shoes from the wheel cylinder.
9. Remove the brake shoe return springs.
10. Remove the brake shoe adjuster from the

brake shoes.
11. Disconnect the parking brake cable from the

brake shoe.
12. Remove the brake shoes.
Installation
1. NOTE: Make sure that the brake shoe
Page 3 of 3
adjuster is fully released.

NOTE: Install a new parking brake cable
retaining clip.
 Apply brake shoe grease to the brake shoe

adjuster strut.
 Clean the backing plate and apply brake shoe

grease to the brake shoe contact points.
Page 1 of 1

WHEEL CYLINDER
UID=G327223
General Equipment
Brake hose clamp
Removal
1. Remove the brake shoes. For additional
information, refer to Brake Shoes in this
section.
2. CAUTION: Cap the brake tube to

Disconnect the brake tube from the wheel
cylinder.
1. Using a suitable brake hose clamp, clamp
the brake hose.
2. Disconnect the brake tube.
3. Remove the wheel cylinder.
Installation
Page 1 of 1

BRAKE BACKING PLATE
UID=G327224
General Equipment
Electric hand drill
Blind rivet hand-gun
Removal
1. Remove the wheel cylinder.
backing plate.
1. Depress the retaining clip.
2. Detach the cable.
3. Remove the brake backing plate.
 Using a suitable electric hand drill remove the

rivets.
Installation
 Using a suitable blind rivet hand-gun, install

new rivets.
Page 1 of 1

FRONT SEAT
UID=G327225
WARNING: To avoid accidental deployment the air bag control module backup power
supply must be depleted. Wait at least one minute after disconnecting the battery ground
cable(s) before commencing any repair or adjustment to the supplemental restraint
system (SRS), or any component(s) adjacent to the SRS sensors. Failure to follow these
01.

1 - Front seat retaining bolts
2 - Underseat electrical connector
3 - Front seat
All vehicles

11.
Page 1 of 1

SAFETY BELT SYSTEM
UID=G327260
For the driver and front passenger, the vehicle is equipped with safety belt retractor and
pretensioners. For the rear passengers, the vehicle is equipped with safety belt retractors.
Safety belts are life saving devices and therefore should be checked and tested with care at
regular intervals.
WARNINGS:
All safety belt components including retractors, buckles, child safety seat tether
brackets and attaching hardware in use during a collision must be removed and new
components installed. New safety belt components should also be installed where safety
belts not in use during a collision, are inspected and found to be damaged or operate
incorrectly.
Undeployed safety belt retractor pretensioners represent a danger during disposal,

therefore, safety belt retractor pretensioners must be deployed in accordance with the
relevant operation. Refer to the procedure in this section.
The safety belt retractor pretensioner is an integral part of the safety belt retractor. It is
deployed by the air bag control module and, in the event of a frontal impact, which exceeds a
predetermined limit, the charge is initiated which fires the pretensioner.
The safety belt retractor pretensioner is controlled and monitored by the air bag control
module. Should a fault be sensed, the warning indicator within the instrument cluster will
flash. For additional information, refer to Section 501-20A / 501-20B.
WARNINGS:
Failure to follow recommended cleaning instructions or procedures may adversely

affect the durability and performance of components.
Do not bleach or attempt to alter the color of the seat belt webbing. Failure to follow
manufacturers instructions may affect the strength and durability of the safety belt
webbing.
CAUTIONS:
Test a small area of webbing away from normal view before attempting to clean the
main area.
Do not allow the cleaning agent to come into contact with the retractor mechanism.
Use only a recommended upholstery cleaner to clean the safety belt webbing.
Page 1 of 7

AIR BAG AND SAFETY BELT
UID=G327262
Supplemental Restraint System (SRS)
Overview

1 - Passenger air bag module
2 - Side impact sensor
3 - Side air curtain module
4 - Safety belt retractor and pretensioner
5 - Restraints control module
6 - Driver air bag module
7 - Crash sensor
General
The supplemental restraint system (SRS) has been specifically designed to protect the driver
and passengers from sustaining severe facial and upper body injuries in the event of a serious
Page 2 of 7
impact. Optimum protection can only be achieved when used in conjunction with the
conventional three-point safety belts. The safety belts form an integral part of the SRS.
The driver, wearing the safety belt provided, should position the seat as far back as is
practical, so the steering wheel can be reached with arms slightly angled, thereby leaving a
gap between the steering wheel and the driver.
The passenger, wearing the safety belt provided, should not position himself or herself so that
the air bag cover is in direct contact with the occupants' body.
The front air bags and safety belt retractor pretensioners will deploy in the event of a direct
front impact or when the impact angle is up to 30 degrees from the left or right of the vehicle
center line.
The air bag(s) and the safety belt retractor pretensioners will deploy only once. In a collision
in which they deployed at the first impact, the air bag(s) and safety belt retractor
pretensioners will not reduce the risk of injury in a subsequent impact.
In the event of a side impact, in which the side air bags (if equipped) deploy, the front air bag
(s) will still deploy in a subsequent front impact, provided that the front impact exceeds the
triggering threshold.
Under certain circumstances, although the damage sustained by the vehicle may look
extensive, the impact may remain below the triggering threshold of the SRS and the air bags
will not deploy. In such circumstances the safety belts would provide sufficient protection for
the occupants.
Vehicles equipped with side air bags can be identified by an embossed AIRBAG logo on the
seat fabric adjacent to the air bag module. A label is attached to the B-pillar adjacent to the
seat.
Page 3 of 7
WARNING: All vehicles fitted with the passenger air bag from the factory have a
WARNING sticker attached to the instrument panel, PROHIBITING the use of rear facing
child or baby seats.
The Safety Restraint System (SRS ) consists of the following components.
* Restraints control module
* Front two stage air bag modules
* Side air bag modules
* Side air curtain modules
* Safety belt retractor and pretensioner
* Clockspring
* Crash sensor
* Side impact sensors (vehicle equipped with side air bags)
* Air bag warning indicator
* Passenger air bag deactivation indicator
Restraints control module
The restraints control module, located under the floor console, governs the operation of the
whole system and performs continual system diagnostics. Information on the severity of an
impact is received from the crash sensor and, in the event of a side impact, the
corresponding side impact sensor. In the event of a frontal impact, in excess of a
predetermined limit, the restraints control module will evaluate the signal received from the
front crash sensor against stored data and deploy the front air bag modules and the safety
belt retractor pretensioners. In the event of a side impact, in excess of a predetermined limit,
Page 4 of 7
the restraints control module will evaluate the signal received from either of the side impact
sensors against stored data and deploy the corresponding side air bag module and, if
equipped, the side air curtain module. In the event of a failure in the vehicle power supply
during an accident, the restraints control module provides an auxiliary power supply,
sufficient to deploy the air bag(s) for a minimum of 150 mS. The vehicle battery supply
maintains the restraints control module auxiliary supply and supports all other SRS functions
when the ignition is in the 'RUN' position. In the event of a fault being detected by the
restraints control module the air bag warning indicator is illuminated. The behavior of the
warning indicator depends on the type of fault present. The air bag warning lamp comes on if
the air bag module detects a fault in the system. A diagnostic routine can be performed with
WDS.
The air bags and safety belt retractor pretensioners are deployed with a DC signal.
Front two stage air bag modules
The driver air bag module is fitted to the steering wheel, the cover forming the outer surface
of the steering wheel boss. The cover has invisible 'split lines' molded in its surface allowing
the air bag to easily exit through the cover when the system deploys.
The passenger air bag module is located above the glove compartment and is secured to the
cross-vehicle beam. The passenger air bag has a visible air bag door allowing the passenger
air bag to easily exit when the system deploys.
Both the driver and passenger air bag modules contain two inflators. In the event of a frontal
impact, in excess of a predetermined limit, the restraints control module will deploy the first
stage inflator followed by the second stage inflator. The lapse time between the deployment
of the first stage inflator and the second stage inflator is directly related to the accident
severity.
The second stage inflators will deploy 100 mS following the first stage deployment. This
'disposal' deployment has no effect on the air bag pressure, but is a protection measure for
the rescue services.
Side Air Bag Module
The side air bag (if equipped) will deploy on the same side that the restraints control module
Page 5 of 7
received the signal from the side impact sensor. The side air bag modules are integrated into
the front seat backrests providing an unobtrusive appearance. The unique seat cover has
been designed to accommodate air bag deployment. When the side air bag is deployed the
stitched seam of the seat cover adjacent to the side air bag module splits, allowing the air
bag to exit the seat backrest unobstructed.
Side air curtain modules

1 - Side air curtain
2 - Retaining strap
3 - Ignition unit
4 - Electrical connector
The side air curtain modules are located in the roof rail between the A-pillar and D-pillar.
They are secured to the upper part of the quarter panel.
In the event of an impact these air bags inflate to form a type of curtain between the side
windows and the head of the occupant.
The side air curtain modules are deployed simultaneously with the side air bag modules.
Air Bag Module(s)
When the air bag(s) deploy, they remain fully inflated for only a fraction of a second and start
to deflate immediately, cushioning the occupant. The high speed of inflation, along with the
surrounding events and noise from the impact, can give the impression that the air bag(s) did
not deploy to their full extent.
The driver air bag is a one-piece woven item, the passenger and side air bags are sewn
items. The air bags have a silicon coating to provide flame and heat protection in the vicinity
of the inflator. The shape of the passenger and side air bags (if equipped) are tailored to the
vehicles proportions.
In order to prevent the folds of the air bag from sticking together in its tightly stowed
position, the fabric may be treated with talcum powder. When the air bag(s) deploy, some of
the fine powder is blown into the vehicle. This powder is visible as a dust cloud and also has a
Page 6 of 7
characteristic odor. The particles soon settle and do not represent a health risk. The dust
cloud is not a sign of external combustion outside the air bag inflator cartridge.
In certain circumstances slight grazing or minor friction burns can result from an air bag
deployment.
There are two processes which are involved:
* Friction can occur between the fabric of the air bag and unprotected areas of
the skin, either during its very rapid deployment or when the occupant contacts
the air bag.
* Hot gases from the charge used to inflate the air bag vent as it starts to deflate.
Depending on the position of the drivers hands, or how close the occupant is to
the air bag, it is not always possible to exclude the possibility of these gases
contacting the areas of skin unprotected by clothing.
Safety Belt Retractor and Pretensioners
The safety belt retractor and pretensioners are mounted in the base of the B-pillar. In the
event of a front impact the restraints control module will deploy the pretensioners. The safety
belt retractor and pretensioners are triggered simultaneously with the first stage of the front
air bags. The restraints control module receives information on the status of the safety belt
buckle from a switch contained in the buckle.
Clockspring
The clockspring is designed to carry signals between the restraints control module and the
driver air bag module. The clockspring is fitted to the steering column and consists of fixed
and moving parts connected by a coiled Mylar tape with integral conducting tracks. The Mylar
tape is able to 'wind up' and 'unwind' as the steering wheel (to which the moving part is
attached) is turned, maintaining electrical contact at all times between the restraints control
module and the driver air bag module.
Crash Sensor
The crash sensor is located under the radiator grille opening panel to facilitate impact sensing
along the longitudinal axis. The restraints control module processes the crash data sent by
the front crash sensor and deploys the front air bag(s).
The crash sensor can be re-used after an external check for damage and a subsequent self-
test.
Side Impact Sensors
The side impact sensors are located near the floor panel behind a trim panel on the B-pillar.
Their external appearance is very similar to the front crash sensor, but the side impact
sensors have different color markings.
In the event of a side impact the restraints control module compares the value supplied by
the side impact sensor with stored data and deploys the relevant side air bag, both safety belt
retractor pretensioners and (if fitted) the relevant side air curtain.
The side impact sensors can be re-used after an external check for damage and a subsequent
self-test.
Page 7 of 7
Air Bag Warning Indicator
The air bag warning indicator is located in the instrument cluster. In the event of a fault being
detected by the restraints control module the warning indicator flashes a corresponding flash
code five times and then remains illuminated. For additional information, refer to Diagnosis
and Testing in this Section.
Page 1 of 3

ANTI-LOCK BRAKE SYSTEM (ABS)
MODULE — VEHICLES BUILT UP TO:
07/2004
UID=G327317
Name Specification
Removal
06.
CAUTIONS:


CAUTIONS:


or dirt ingress.
Page 2 of 3
6. Disconnect the anti-lock brake system (ABS)

module electrical connector.



12. Remove the HCU to ABS module retaining

bolts.
Page 3 of 3
13. Remove the ABS module.
Installation
Page 1 of 2

YAW RATE SENSOR AND
ACCELEROMETER
UID=G327319
Removal
NOTE: The yaw rate sensor and accelerometer are one assembly and cannot be
seperated.
1. Remove the left-hand front seat. For additional
2. Remove the scuff plate trim panels.

4. Locally detach the carpet.

bolts, to aid installation.
Remove the yaw rate sensor and accelerometer
assembly cover.

bolts, to aid installation.
Remove the yaw rate sensor and accelerometer
assembly.
2. Remove the bracket retaining bolts.
Installation
Page 2 of 2
WARNINGS:
1. Do not use a damaged yaw rate

sensor and accelerometer assembly. Failure
personal injury.
Make sure the yaw rate sensor and

accelerometer assembly is correctly
positioned. Failure to follow this instruction
CAUTIONS:
The yaw rate sensor and accelerometer

assembly will be damaged if dropped.
Make sure the correct bolts are used for

the yaw rate sensor and accelerometer
assembly. Failure to follow this instruction will
result in damaged threads.
Make sure the correct bolts are used for

the yaw rate sensor and accelerometer
assembly cover. Failure to follow this
instruction will result in damaged threads.
Page 1 of 2

ENGINE
UID=G327325
MZI 1.25L/1.4L/1.6L engine
Overview
Engine
Cross-mounted 16-valve DOHC engines with 59 kW (80 PS) and 74 kW (100 PS) respectively.
Valve train with mechanical bucket tappets
Cylinder block and cylinder head made of an aluminium alloy
Auxiliary drive via a self-tensioning belt without a belt tensioner
Engine management
Sequential multi-port fuel injection (SFI)

Page 2 of 2
temperature and manifold absolute pressure (T-MAP) sensor in conjunction with a Siemens
powertrain control module (PCM).
Knock control
PCM with 84 pins and integrated passive anti-theft system (PATS) immobiliser.
Engine emission control
European emissions level IV
European on-board diagnosis (EOBD) for the monitoring of emissions-relevant components.
Diagnosis
WDS diagnosis CD B17.
Instrument cluster (engine indicator lamp)
Torque/power
The MZI 16V engines are characterised by their high level of running refinement, low
emission levels and balanced development of power.

1 - Power curve for the MZI 1.6 16V engine
2 - Power curve for the MZI 1.4 16V engine
3 - Torque curve for the MZI 1.6 16V engine
4 - Torque curve for the MZI 1.4 16V engine
Page 1 of 13

ENGINE
UID=G327339
General
The MZ-CD 1.4L DI Turbo engine operates using the direct injection principle.
The cylinder block and reinforcement frame in the MZ-CD 1.4L DI Turbo engine are made
from aluminium. Therefore the engine only weighs 105 kg.
This engine can be used in place of higher-capacity engines thanks to its relatively high
output for this capacity class, of 50 kW (68 PS).
The valves are actuated by an overhead camshaft and roller cam follower with hydraulic valve
Page 2 of 13
clearance adjustment.
The camshaft is driven by a timing belt, as are the high-pressure pump and the coolant
pump.
Engine identification code
The engine serial number is located on the exhaust side of the cylinder block (between the
1st and 2nd cylinders).
In addition, the Vehicle Identification Number (VIN) and the engine code are located on the
same side on the transmission flange.

1 - Sequential engine serial number
2 - VIN
3 - Engine code
Cylinder head ancillary components
Page 3 of 13

1 - Cylinder head cover
2 - Intake duct sealing ring
3 - Cylinder head cover gasket
4 - Camshaft housing (top part)
5 - Camshaft housing (bottom part)
6 - Cylinder head
Cylinder head cover
The cylinder head cover is made from plastic and forms part of an assembly that also includes
the inlet manifold, positive crankcase ventilation (PCV) valve with oil separator and fuel filter
bracket.
A separate gasket forms the seal between the cylinder head cover and the top part of the
camshaft housing.
The joints between the inlet manifold and the cylinder head inlet ports in the cylinder head
are made by four separate sealing rings.
The gaskets must be checked for damage and, if necessary, renewed before the inlet
manifold is mounted.
Page 4 of 13
NOTE: Refer to the current service literature for precise details of how to assemble the
cylinder head cover and inlet manifold.

1 - Connection flange for charge air ducting
2 - Oil filler cap
3 - Positive crankcase ventilation (PCV) valve
4 - Integral intake manifold
Camshaft
This camshaft is made from steel tube with shrunk-on cams and shaft ends.
It is supported on five bearings in the camshaft housing
A thrust washer controls the axial movement of the camshaft.

1 - Bearing running surfaces
2 - Shrunk-on shaft end with groove for vacuum pump drive
Page 5 of 13
3 - Shrunk-on shaft end with integral thrust washer

Camshaft housing
The camshaft housing is made of aluminium and consists of two parts.
The two housing parts are bolted together and special tools (locating pins) are used to align
them during production.
The two housing parts are sealed using a one-component, silicone-based sealant when they
are joined together.
NOTE: The upper and lower parts of the camshaft housing are matched to each other and
belong together. It is not possible to replace just one part of the housing.
Two locating pins (special tools) are used to position the camshaft housing on the cylinder
head.

1 - Bores for locating pins used to install the camshaft housing
2 - Camshaft housing (top part)
3 - Camshaft housing (bottom part)
4 - Bores for locating pins for mounting on the cylinder head
Cylinder head and valve train
Page 6 of 13
Valve actuation

1 - Roller cam follower
2 - Hydraulic supporting mount
The cylinder head is made of aluminium and has two valves per combustion chamber. The
valve seats and guides are made of sintered steel.
The cylinder head has a passage for the Exhaust Gas Recirculation (EGR) and has inlet ports
which open upwards.
The inlet ports are on the right-hand side of the engine (at the rear when looking towards the
front of the vehicle) and the exhaust ports are on the left-hand side of the engine (at the
front when looking towards the front of the vehicle).
The valves are actuated by roller cam follower and hydraulic supporting mount for valve
clearance adjustment.
The cylinder head mating face can be reworked up to a depth of 0.4 mm by surface grinding.
Cylinder head gasket
The cylinder head gasket is a multi-layer steel gasket.
There is a choice of five different thickness sizes, depending on the degree of piston
protrusion in the engine. The number of notches (one to five) indicates the gasket thickness.
Number of notches Piston protrusion in mm Gasket thickness in mm

1 0.7760 to 0.8250 1.35
2 0.6175 to 0.7250 1.25
3 0.7260 to 0.7750 1.30
4 0.8260 to 0.8750 1.40
5 0.8760 to 0.9830 1.45
Page 7 of 13
Cylinder head gasket identification
Camshaft drive

1 - Camshaft timing belt pulley
2 - Bore for camshaft timing peg
3 - Idler pulley
4 - Crankshaft timing pulley
5 - Bore for crankshaft timing peg
6 - Coolant pump pulley
7 - Tensioning pulley
8 - High pressure pump pulley
The camshaft is driven by a timing belt. The timing belt also drives the fuel injection system
high-pressure pump and the coolant pump.
The timing belt drive has an automatic tensioning pulley. The tensioning pulley is operated by
spring force and is not temperature-dependent.
Page 8 of 13
Cylinder block
The cylinder block is made from aluminium and has cast-in cylinder liners made from cast
iron.
This construction is called an "Open-Deck" cylinder block, i.e. it is a cylinder block with a
coolant jacket open towards the top.
Through passages for coolant in the upper area between the cylinders improve the cooling.
An aluminium reinforcement frame is bolted to the underside of the cylinder block. It forms
the lower halves of the main bearing housing and has cast iron inserts which are cast in
place.
One-component, silicone-based sealant is used for the seal between the cylinder block and
the reinforcement frame.
NOTE: The sealing surface of the cylinder block towards the cylinder head and the
cylinder running surfaces must not be re-machined. Thread repairs using thread inserts in
the areas of the cylinder head bolts and main bearing bolts are also not permitted.

1 - Coolant jacket
2 - Reinforcement frame
Crank mechanism
Crankshaft
The forged steel crankshaft has five main bearings.
Two thrust half-washers on the fourth main bearing limit the axial play. These thrust washers
are only available in one standard size.
NOTE: Refer to the current service literature for the exact procedure.
The shaft seals at each end of the crankshaft are made from Teflon. The service shaft seals
Page 9 of 13
are supplied pre-formed on a holder. This holder also serves to protect the seal against
damage and as an assembly aid.
Connecting rod
Forged connecting rods with fracture separated bearings are used.
Pistons
The pistons are made from a light-metal alloy and each piston incorporates a combustion
chamber in the piston crown.
A cone is located in the middle of the combustion chamber to ensure a high state of air/fuel
mixture swirl.
Each piston crown also contains two recesses for the valve heads.
The piston crown also has an arrow to show the piston installation orientation, and which
must point towards the timing gear end of the engine.
The piston skirt is partially covered with a graphite-based coating in order to ensure the least
friction, especially during the running-in stage.
Pistons are only available in one weight category.
The piston pin is a floating fit and is held in position by two snap rings.
Flywheel
The engine is equipped with a dual-mass flywheel made of cast iron. The friction surface is
210 mm in diameter.
There is no special installation position of the dual-mass flywheel in relation to the crankshaft.
The flywheel has two blind holes for locking the crankshaft in two different positions.
Page 10 of 13
Crank gear

1 - Mark showing piston installation orientation
2 - Thrust washers (axial bearings)
Engine lubrication
Oil pump
The oil pump is located at the timing gear end of the engine. It is driven directly by the
crankshaft and is a rotor-type design.
The oil pump internal rotor has two flats which form a keyed connection with the crankshaft.
A pressure relief valve is integral with the oil pump housing. It opens when the oil pressure
reaches 5 bar.
A second oil pressure relief valve in the cylinder head limits the oil pressure in the upper part
of the engine.
An oil non-return valve is also located in the cylinder head. This prevents the oil from
returning to the sump when the engine is stopped, thus ensuring rapid lubrication of the
Page 11 of 13
valve gear when the engine is restarted.

1 - Oil pressure control valve
2 - Crankshaft
3 - Flats
4 - Internal rotor
5 - External rotor
Oil filter/oil cooler assembly
The oil filter/oil cooler assembly is located on the exhaust side of the engine near the
flywheel.
The oil cooler is an oil/water heat exchanger.
The oil filter/oil cooler assembly consists of a two-piece housing with replaceable filter
element and flange-mounted oil cooler.
There is a blanking plug on the oil filter element for the drain bore in the filter housing. When
a new oil filter element is being installed, the oil can flow out through the housing, so that
there is no contamination caused by escaping oil.
Page 12 of 13

1 - Filter element
2 - O-ring
3 - Oil filter cover
4 - Blanking plug
5 - Oil cooler
Oil pressure switch
The oil pressure switch is located on the left-hand side of the engine on the cylinder block
near number 1 cylinder.
In depressurised state, the oil pressure switch closes a contact so as to connect the relevant
Page 13 of 13
input on the instrument cluster to engine ground. The oil pressure warning light on the
instrument cluster illuminates.
Oil spray tubes
The piston skirts are cooled from below with oil from the oil spray tubes. The oil spray tubes
are secured in the cylinder block with banjo bolts.
The banjo bolts connect the oil spray tubes with the engine lubrication system. The banjo
bolts are equipped with integral valves which ensure that the oil spray tubes do not operate
below a certain oil pressure.
Page 1 of 2

KEY PROGRAMMING USING TWO
PROGRAMMED KEYS
UID=G327342
CAUTION: Do not carry out key registration or start the engine under the following
conditions as doing so could result in a key registration error or the engine not starting
even with a correctly registered key: If a large metal object is close to a key, if an
electrical device is close to a key or if more immobilizer keys are on the same key ring.
NOTE: A maximum of eight ignition keys can be programmed to passive anti-theft system
(PATS) equipped vehicle.
NOTE: If the engine is started during the key programming procedure, the key
programming mode will be cancelled. Therefore do not start the engine until the key
programming procedure for all the necessary keys is finished.
NOTE: When an error occurs during the following procedures, repeat the procedure from
Step 2. If you still cannot program the key(s), confirm how many keys can start the
engine. After that, perform "Additional key programming using the WDS" or "Erasing All
Key Codes and Key Programming" procedure according to the valid programmed key
number. The programming mode will be cancelled if you cannot finish operating within
the limitation time.
1. Cut the new transponder-equipped ignition key
(s).
2. Using the first programmed ignition key, turn
the ignition switch to the ON position.
1. Observe the engine immobilization indicator
in the instrument cluster.
2. After the engine immobilization indicator
turns OFF (approximately 3 seconds after
the ignition switch is turned to the ON
position), turn the ignition key to the LOCK
position within approximately 4 seconds and
remove it from the ignition lock cylinder.
3. Within approximately 5 seconds of turning the
first programmed ignition key to the LOCK
position, insert the second programmed
ignition key and turn the ignition switch to the
ON position.
4. Within approximately 10 seconds of turning
the second programmed ignition key to the
LOCK position, insert the new unprogrammed
ignition key and turn the ignition switch to the
ON position.
Page 2 of 2

5. To program additional keys, repeat the
procedure from step 2.
6. NOTE: When verifying, wait for more than
5 seconds before inserting the next key.
Verify that the engine starts using the new
programmed key(s).
Page 1 of 2

KEY PROGRAMMING USING
DIAGNOSTIC EQUIPMENT
UID=G327343
Special Tool(s)
(WDS) or equivalent
CAUTION: Do not carry out key registration or start the engine under the following
conditions as doing so could result in a key registration error or the engine not starting
even with a correctly registered key: If a large metal object is close to a key, if an
electrical device is close to a key or if more immobilizer keys are on the same key ring.
NOTE: This procedure is used when a customer needs ignition keys programmed into the
system and does not have two programmed ignition keys available.
NOTE: A maximum of 8 keys can be registered for one vehicle. If 8 keys have already
been programmed, this procedure cannot be performed. To program a key under this
condition, it is necessary to erase all the key codes before key addition. For additional
information, refer to Erasing All Key Codes Using Diagnostic Equipment in this section.
Prepare all of keys to be registered before starting Step 1. The programming mode will be
cancelled if you cannot finish operating within the limitation time. When an error occurs
during the following procedures, repeat the procedure from Step 2. If you still cannot
program the key(s), confirm how many keys can start the engine. After that, perform
"Additional key programming using the WDS" or "Erasing All Key Codes and Key
Programming" procedure according to the valid programmed key number.
(s).
connector (DLC).
3. Using the first programmed ignition key, turn

the ignition switch to the ON position.
 The engine immobilization indicator flashes

rapidly for approximately 1 minute and
displays DTC 15 (WDS: DTC B1601).
4. Carry out the Anti-Theft Security Access
procedure. For additional information, refer to
Anti-Theft Security Access in this section.
5. Select "Program Additional Ignition Key".
6. Turn the first programmed ignition key to the
LOCK position and remove it from the ignition
lock cylinder.
Page 2 of 2
7. Within approximately 5 seconds of turning the

first ignition key to the LOCK position, insert
the second ignition key and turn the ignition
switch to the ON position.
8. Select "Program Additional Ignition Key".
9. Turn the second ignition key to the LOCK
position and remove it from the ignition lock
cylinder.
10. To program additional keys, repeat the
procedure from step 7.
11. NOTE: When verifying, wait for more
than 5 seconds before inserting the next key.
Verify that the engine starts using the new
programmed key(s).
Page 1 of 1

KEY PROGRAMMING SWITCH STATE
CONTROL
UID=G327344
Special Tool(s)
(WDS) or equivalent
NOTE: The spare key programming switch is a programmable switch that provides the
capability to enable or disable the normal customer spare key programming procedure
detailed in the Owner's Manual. This programmable switch is provided as a convenience
for rental company fleets or other fleet purchasers who may not want the spare key
programming procedure available to the vehicle driver.
connector (DLC).
2. Using a valid or new ignition key, turn the

ignition switch to the ON position.
4. Select "Customer Spare Key Programming
Enable/Disable".
 If "Enable" is selected (which is the default),

key programming can be carried out using
two valid programmed keys or by using WDS
or equivalent.
 If "Disable" is selected, key programming can

only be carried out by using WDS or
equivalent.
Page 1 of 2

ERASING ALL KEY CODES USING
DIAGNOSTIC EQUIPMENT
UID=G327345
Special Tool(s)
(WDS) or equivalent
NOTE: Do not carry out key registration or start the engine under the following conditions
as doing so could result in a key registration error or the engine not starting even with a
correctly registered key: If a large metal object is close to a key, if an electrical device is
close to a key, or if more immobilizer keys are on the same key ring.
NOTE: When the Anti-Theft Security Access is granted do not turn off WDS, disconnect
the data link connector (DLC), start the engine or turn the ignition switch to the OFF
position and leave for more than 10 seconds as this will exit the Anti-Theft Security
Access mode.
NOTE: Carry out this procedure to erase a previously programmed key code and program
a new ignition key.
NOTE: If an ignition key is programmed by following this procedure, the engine will not
start using any previously programmed keys. The customer should bring all the keys to
the dealer prior to this operation. If it is needed to have an additional key programming
without having to erase the key codes already registered, carry out " key Programming
Using Diagnostic Equipment" or "key Programming Using Two Programmed keys". To
start the engine, two or more keys need to be programmed. A maximum of eight ignition
keys can be programmed to passive anti-theft system (PATS) equipped vehicle. If an
error occurs during the following procedure, repeat the procedure from Step 2. If it is not
possible to program the key(s), confirm how many keys will start the engine, and then
carry out "key Programming Using Diagnostic Equipment" or "Erasing All Key Codes Using
diagnostic Equipment" procedure according to the valid programmed key number(s).
(s).
2. Connect WDS or equivalent to the DLC.
3. Using the first ignition key, turn the ignition

switch to the ON position.
2. For a valid key the engine immobilization
indicator illuminates, then turns OFF after
approximately 3 seconds.
3. For a new key the engine immobilization
indicator flashes rapidly for approximately 1
minute and displays DTC 15 (WDS: DTC
B1601).
Page 2 of 2

5. NOTE: Do not select any other command
from this menu.
Select "Ignition Key Code Erase".
6. Turn the first ignition key to the LOCK position
for more than 15 seconds.
7. Turn the first ignition key to the ON position
for more than 3 seconds. The security indicator
illuminates for approximately 1 minute and
displays DTC 21(WDS: DTC1213).
8. Turn the first programmed ignition key to the
LOCK position and remove it from the ignition
lock cylinder.
9. Insert the second ignition key into the ignition
lock cylinder and turn the ignition switch to the
ON position for more than 3 seconds. The
immobilizer indicator illuminates, then turns
OFF after approximately 3 seconds.
10. Verify that the engine starts with the
programmed key(s). Wait for more than 5
seconds before inserting the next key. If you
want to add an additional key, go to "Key
Programming Using Two Programmed Keys".
Page 1 of 1

ANTI-THEFT SECURITY ACCESS
UID=G327346
Special Tool(s)
(WDS) or equivalent
NOTE: When the Anti-Theft Security Access is granted do not turn off WDS, disconnect
the data link connector (DLC), start the engine or turn the ignition switch to the OFF
position and leave for more than 10 seconds as this will exit the Anti-Theft Security
Access mode.
NOTE: The Anti-Theft Security Access procedure is utilized to obtain passive ant-theft
system (PATS) security access in order to program additional ignition key(s), erase
ignition keys to enable/disable spare key programming or parameter reset.
NOTE: When WDS displays the "outcode", do not turn the ignition switch from the LOCK
position to the ON position more than 5 times and do not disconnect the battery cables.
Otherwise a new outcode will be generated as anti-theft operation. The outcode data is 6
digits, and the incode data is 4 digits.
connector (DLC).
2. Select "Body".
 WDS or equivalent will display an outcode

depending on the designated procedure which
must be noted for use later in this procedure.
5. Access the Mazda official website to obtain the
incode that corresponds to the outcode
obtained in step 4. Refer to Service
Information Ref. No. A001/02 for details of this
procedure.
6. Input the incode to the WDS or equivalent.
7. After the security access procedure has been
completed a new menu will be displayed.
Select only the functions required before
exiting out of this menu.
Page 1 of 1

SPECIFICATIONS
UID=G327518
Specifications
Manual transmission oil Manual transmission oil SAE 75W90 or transmission oil
Grease, outer constant velocity Molybdenum disulfined CV Joint Grease
(CV) joint
Grease, inner constant velocity Molybdenum disulfined CV Joint Grease
(CV) joint
Constant Velocity (CV) Joint Boot Capacities
Description Grams
Outer constant velocity (CV) joint boot 90
Inner constant velocity (CV) joint boot 100
Item Nm lb-ft lb-in

Lower arm ball joint pinch bolt nut 48 35 -
Intermediate shaft center bearing cap retaining nuts 25 18 -
Strut and spring assembly top mount retaining nuts 25 18 -
CV joint boot clamps 21 15 -
Page 1 of 1

SPECIFICATIONS
UID=G327519
Specifications
High-temperature grease Molybdenum disulfined grease
Item Nm lb-ft lb-in

Clutch slave cylinder retaining bolts 10 - 89
Page 1 of 1

CLUTCH SLAVE CYLINDER
UID=G327520
Name Specification
High-temperature Molybdenum disulfined
grease grease
Removal
1. Remove the transaxle. For additional
2. Clean any grease and foreign material from
the input shaft.
CAUTIONS:

Using suitable adhesive tape, cover the

input shaft splines to prevent damage to the
input shaft oil seal.
Remove the clutch slave cylinder.
Installation
CAUTIONS:

Do not apply grease on any area of the

Install the clutch slave cylinder.
2. Remove the adhesive tape from the input shaft

splines.
3. Coat the input shaft splines with a thin layer of
high-temperature grease.
4. Install the transaxle. For additional
Page 1 of 2

SPECIFICATIONS
UID=G327521
Specifications
High-temperature grease Molybdenum disulfined grease
Manual transmission fluid Manual transmission oil SAE 75W90 or transmission oil
Sealer, transaxle housing to Silicone rubber sealant (Gel type)
clutch housing
Sealer, fifth gear end cap Silicone rubber sealant (Low viscosity)
Capacities
Liters
Manual transmission fluid (5 - 10 mm below the level of the fluid filler plug) 2.3
Transaxle ratios
1.4L 1.6L 1.4L Diesel 1.25L

First gear 3.58 3.15 3.58 3.58
Second gear 1.93 1.93 1.93 1.93
Third gear 1.28 1.28 1.28 1.28
Fourth gear 0.95 0.95 0.95 0.95
Fifth gear 0.76 0.76 0.76 0.76
Reverse gear 3.62 3.62 3.62 3.62
Final drive 4.06 4.25 3.37 4.25
Required shim thickness
Description mm
Measuring shim 3.8
Shim availability (in increments of 0.1 mm) 0.1 - 0.7
Required snap ring thickness
Description mm
Snap ring fifth gear 1.48
Item Nm lb-ft lb-in

Clutch slave cylinder retaining bolts 10 - 89
Selector gate retaining bolts 22 16 -
Transaxle housing retaining bolts 25 21 -
Fifth gear housing to transaxle housing retaining bolts 17 13 -
Selector mechanism to transaxle retaining bolts 22 16 -
Reversing lamp switch 12 9 -
Transaxle housing final drive cover retaining bolts 12 9 -
Transaxle to engine retaining bolts 47 35 -
Engine support insulator to engine retaining bolt 48 35 -
Engine support insulator to subframe retaining bolts 48 35 -
Engine rear mount outer retaining nuts 48 35 -
Page 2 of 2
Exhaust flexible pipe retaining nuts 44 32 -

Lower arm ball joint to the wheel knuckle retaining nut 48 35 -
Engine rear mount center retaining nut 90 66 -
Intermediate shaft center bearing retaining nuts 25 18 -
Strut and spring assembly top mount retaining nuts 48 35 -
Transmission fluid filler plug 35 26 -
Page 1 of 1

SPECIFICATIONS
UID=G327523
Specification
Rubber grease
Anti-seize grease
lb- lb-
Catalytic converter to exhaust flexible pipe nuts - Vehicles with 1.25L / 1.4L / 47 35 -
1.6L engine
Catalytic converter to turbocharger nuts - Vehicles with diesel engine 25 18 -
Turbocharger heat shield upper retaining screws 3 - 27
Exhaust flexible pipe to muffler and tailpipe assembly nuts - Vehicles with diesel 47 35 -
engine
Catalytic converter support bracket to engine block nuts - Vehicles with 1.25L / 47 35 -
1.4L / 1.6L engine
Catalytic converter support bracket to engine block nuts - Vehicles with diesel 25 18 -
engine
Catalytic converter to support bracket nuts 25 18 -
Catalytic monitor sensor 47 35 -
Exhaust flexible pipe to front muffler pipe shield retaining bolts – Vehicles with 8 - 71
1.6L engine
Rear muffler clamp nuts – Vehicles with 1.25L / 1.4L / 1.6L engine 47 35 -
Page 1 of 2

CATALYTIC CONVERTER — 1.4L
DIESEL
UID=G327524
Name Specification
Anti-seize grease
Removal
1. Remove the catalytic converter heat shield.

circular cut outs.
2. Detach the catalytic converter from the

turbocharger.


5. Detach the catalytic converter from the front

muffler and tailpipe assembly.

Page 2 of 2
Removal
1. CAUTION: Never use jointing

compound forward of the catalytic converter.
NOTE: Coat the catalytic converter studs with
anti-seize grease.
NOTE: Install new nuts and gasket.
Page 1 of 1

EXHAUST FLEXIBLE PIPE
UID=G327525
Name Specification
Anti-seize grease
Removal
2. CAUTION: Over bending of the exhaust

flexible pipe may cause damage resulting in
failure.
Support the exhaust flexible pipe with a suitable
support wrap or suitable splint.
3. Detach the exhaust flexible pipe from the catalytic

converter.
 Discard the clamp nut.

5. Remove the exhaust flexible pipe.
Installation
1. NOTE: Coat the exhaust flexible pipe studs
with anti-seize grease.
NOTE: Install new nuts.
Page 1 of 3

STABILITY ASSIST MODULE
UID=G327727
Name Specification
Removal
06.
CAUTIONS:


CAUTIONS:


or dirt ingress.
Page 2 of 3
6. Disconnect the stability assist module electrical

connector.

8. Remove the HCU and stability assist module
support bracket lower retaining bolt.

assembly and the support bracket.
11. Detach the HCU and stability assist module

assembly from the support bracket.
12. Remove the HCU to stability assist module

retaining bolts.
13. Remove the stability assist module.
Installation
Page 3 of 3

Page 1 of 3

HYDRAULIC CONTROL UNIT (HCU)
UID=G327728
Name Specification
Removal
06.
CAUTIONS:


CAUTIONS:


or dirt ingress.
Page 2 of 3
6. Disconnect the stability assist module electrical

connector.

support bracket lower retaining bolt.

assembly and the support bracket.
11. Detach the HCU and stability assist module

assembly from the support bracket.
12. Remove the HCU to stability assist module

retaining bolts.
13. Remove the HCU.
Installation
Page 3 of 3

Page 1 of 1

CRANKSHAFT END PLAY
UID=G327731
General Equipment
Dial indicator
Dial indicator fixture
1. Determine the end float
 Place on the dial indicator and bracket .
 Determine the end float by raising the

crankshaft with the aid of a screwdriver.
 If necessary, correct the end float by using

new thrust half washers.
Page 1 of 1

CYLINDER HEAD DISTORTION
UID=G327732
General Equipment
Feeler Gauge
Straight edge
1. Using a straight edge and feeler gauge,
measure the cylinder head distortion.
 Measure the mating face distortion.

mating face.
Page 1 of 7

BODY AND FRAME
UID=G330228
Construction features
The front and rear side members, windshield frames, doors and D-pillar inner reinforcement
are made of thick walled body panels. Because of the shape of the individual components and
the built-in reinforcements, the bodywork is very resistant to torsion. For the first time, body
panels reformed from tailored blanks are integrated into the crash and strength relevant
areas. Because of this, the deformation performance of the chassis and the occupant
protection are distinctly improved.
Overall, the bodywork of the Mazda 2 proves to be very easy to repair. The overall body
structure is made and assembled in such a way that individual body panels can be replaced
without problem. Body components which are prone to deformation (e.g. front side member,
A-pillar inner panel etc.) are made of several individual parts which are joined together. The
majority of the welded joints which may need to be repaired can be re-created using
resistance spot welding.
Other changes relate to the increase in wheel base, overall length and vehicle height,
deformation areas on the front and rear side members and the front and rear crash elements.
Front side member
In contrast to the previous model, the side member is made of several parts, and the inner
sides are made of tailored blanks. If the frontal damage extends past the crash element
(impact above 15 Km/h), the impact energy is absorbed by the side members and dissipated
in the area of the intentional yield points (deformation area). A deformation area has no inner
reinforcement. Sectional replacement is possible if the damage does not extend past the
deformation area (intentional yield points). If there is deformation inside the engine
compartment, the front section can be replaced individually.
Front side member

1 - Side member (multiple part)
2 - Pre-determined folding points
3 - Laser butt weld
4 - Resistance spot weld joint
Rear crossmember
The rear crossmember is secured to the side members by threaded connections. Because the
crossmember is curved, impact energy is more easily converted into deformation energy. For
light impacts this prevents deformation of the side members and therefore of the vehicle body
Page 2 of 7
also.
Rear side member
If a heavier rear impact occurs, in addition to the crossmember, the ends of the side
members are deformed. The remaining energy is dissipated in a controlled manner in the
area of the intentional yield points. Sectional replacement is possible if the damage does not
extend past the deformation areas.
Rear side member

1 - Left-hand side member
2 - Laser butt weld
3 - Pre-determined folding points
4 - Right-hand side member
NVH measures
In order to prevent air conduction of noise to the vehicle interior, three NVH elements are
installed on each side of the vehicle, clipped to the vehicle bodywork. When carrying out
repair work, either the original NVH elements must be put back in position or new ones
installed.
NOTE: Gases harmful to health will be released if the insulation material is heated too
much. Make sure that the insulation material installed in production is not damaged by
cutting or sanding tools when cutting out bodywork parts.
NVH measures
Page 3 of 7

1 - NVH element, B-pillar
2 - NVH element, C-pillar
3 - NVH element, D-pillar
Tailored blanks
By employing a combination of materials with different thicknesses and properties, tailored

blanks make it possible to produce an exact match to the required strength and rigidity in
different areas within one bodywork component. The number of steel panels can be
decreased by installing tailored blanks and so the weight of the bodywork can be reduced.
Tailored blanks with laser welds

Page 4 of 7

1 - Front side member
2 - Front door frame
3 - Roof frame
4 - Rear right-hand side member
5 - Rear left-hand side member
6 - Rocker panel reinforcement
High-strength steel parts
Reinforced high-strength steel parts are used on all Mazda 2 models.
NOTE: The working methods given in Part I of the Body Repair Manual (501-25A) must be
observed in all repair work.
Overview of parts, front end
Page 5 of 7

1 - Galvanised steel panels
2 - High strength and galvanised steel panels
3 - High-strength low alloy steel
Overview of parts, floor pan (5-door version)
Page 6 of 7

Overview of parts, side view (5-door version)
Page 7 of 7

3 - High-strength steel parts
Page 1 of 3

UNDERBODY TOLERANCE CHECK
UID=G330229
1. Body frame
dimensions
 A tolerance of
± 3 mm
applies to all
measurements
given. All
detailed
illustrations
correspond to
the left-hand
side of the
vehicle.
 All
measurements
have been
taken from
production
data and are
the length of
the straight
line between
the
measurement
points. All
measurements
can therefore
be made using
a
symmetrically
adjusted
measuring
gauge.
 The
measurement
points were
measured with
assemblies
removed and
with the
exception of
oval bodywork
holes, refer to
the centre of
the hole.
 The
measurement
points for oval
bodywork
holes relate to
the foremost
position of the
curve (as seen
Page 2 of 3
from the
driver's seat).
2. Body frame
dimensions
 A tolerance of
± 3 mm
applies to all
measurements
given. All
detailed
illustrations
correspond to
the left-hand
side of the
vehicle.
 All
measurements
have been
taken from
production
data and are
the length of
the straight
line between
the
measurement
points. All
measurements
can therefore
be made using
a
symmetrically
adjusted
measuring
gauge.
 The
measurement
points were
measured with
assemblies
removed and
with the
exception of
oval bodywork
holes, refer to
the centre of
the hole.
 The
measurement
points for oval
bodywork
holes relate to
the foremost
position of the
curve (as seen
from the
driver's seat).
Page 3 of 3
Page 1 of 4

FRAME TOLERANCE CHECK
UID=G330230
1. Body
dimensions,
vehicle front
 All dimensions
with tolerance
± 3mm. All
dimensions
were
determined
from the
center of the
hole or panel
edge using a
symmetrically
adjusted
measuring
gauge.
 1- 2 = 1045
mm; 1 - 3 =
1034 mm; 4 -
5 = 1009 mm;
5 - 6 = 932
mm; 5 - 7 =
381 mm; 5 -
11 = 363 mm;
8 - 9 = 1361
mm; 10 - 12
= 792 mm; 10
- 13 = 792
mm.
2. Body
dimensions,
side view
 All dimensions
with tolerance
± 3mm. All
dimensions
were
determined
from the
center of the
hole or panel
edge using a
symmetrically
adjusted
measuring
gauge.
 14 - 18 = 838
mm; 15 - 18
= 637 mm; 16
- 17 = 1305
Page 2 of 4
mm; 16 - 19
= 1092 mm;
16 - 20 =
1086 mm; 17
- 18 = 1496
mm; 18 - 19
= 1105 mm;
19 - 22 = 969
mm; 19 - 23
= 920 mm; 19
- 24 = 796
mm; 19 - 25
= 614 mm; 20
- 25 = 436
mm.
3. Body
dimensions,
rear view
 All dimensions
with tolerance
± 3mm. All
dimensions
were
determined
from the
center of the
hole or panel
edge using a
symmetrically
adjusted
measuring
gauge.
 26 - 27 =
1214 mm; 27
- 28 = 1024
mm; 27 - 35
= 656 mm; 29
- 30 = 1421
mm; 29 - 32
= 1320 mm;
30 - 32 = 116
Page 3 of 4
mm; 31 - 32
= 1217 mm;
32 - 33 =
1218 mm; 33
- 34 = 1010
mm.
4. Passenger
compartment,
body
dimensions
 All dimensions
with tolerance
± 3mm. All
dimensions
were
determined
from the
center of the
hole or panel
edge using a
symmetrically
adjusted
measuring
gauge.
 Left-hand
side: 36 -37 =
763 mm; 36 -
38 = 890 mm;
36 -39 = 1058
mm; 36 -40 =
1100 mm; 36
-41 = 1219
Page 4 of 4
mm; 36 -42 =
1137 mm; 36
-43 = 1134
mm; 36 -44 =
887 mm; 36 -
45 = 675 mm.
 Right-hand
side: 36 -37 =
834 mm; 36 -
38 = 949 mm;
36 -39 = 1102
mm; 36 -40 =
1140 mm; 36
-41 = 1254
mm; 36 -42 =
1161 mm; 36
-43 = 1183
mm; 36 -44 =
949 mm; 36 -
45 = 755 mm.
Page 1 of 1

FENDER APRON PANEL
REINFORCEMENT
UID=G330234
1. Replacement parts
 Apron panel reinforcement
Removal
1. General Notes.
 The hood, windshield, doors and fenders are

already removed before repair work starts.
 Necessary removal work: water trap cover

and wheelhouse cover.
2. Apron panel reinforcement
thicknesses).
3. Grind out the weld seam
Installation
1. NOTE: Partial replacement of the apron
panel is possible, depending on the damage.
The instructions concerning welding
equipment given in Section 501-25A must be
observed when resistance spot welding body
panels with a thickness greater than 3 mm.
Cut lines for partial replacement
1. Front cut line.
2. Rear cut line.
2. Apron panel reinforcement

2. Puddle welding
Page 1 of 2

FENDER APRON PANEL
UID=G330235
 Apron panel
Removal
1. General Notes.
 The hood, windscreen, doors, fenders and

apron panel reinforcement are already
removed before repair work starts.
 Necessary removal work: water trap cover

and wheelhouse cover.
2. Apron panel
3. Apron panel
Installation
observed when resistance spot welding body panels with a thickness greater than 3 mm.
1. Apron panel
 Resistance spot weld
2. Apron panel

Page 2 of 2
Page 1 of 2

ROOF PANEL
UID=G330240
 Roof
Removal
1. General Notes.
 Necessary removal work: windshield, tailgate,

headliner and interior trim.
2. Roof
3. Roof
 Heat the glued areas before removal.

Page 2 of 2
Installation
1. Roof
 Apply clinched flange protection.
2. Roof

Page 1 of 5

A-PILLAR OUTER PANEL SECTION
AND REINFORCEMENT
UID=G330247
General Equipment
Beam compasses
 A-pillar outer panel
 A-pillar reinforcement
 A-pillar inner panel
 Bulkhead reinforcement
Removal
1. General Notes.
 The apron panel reinforcement and inner

reinforcement of the A-pillar are already
removed before the repair starts.
 Necessary removal work: door, hood,

windshield, facia crash padding, A-pillar trim
and rocker panel trim.
NOTE: If the inner and outer A-pillar reinforcements are being completely replaced, drill
out the spot welds on the A-pillar outer panel by two panel thicknesses.
2. A-pillar outer panel
1. Separating cut.
thicknesses).
3. A-pillar inner reinforcement

Page 2 of 5
4. A-pillar inner reinforcement with rocker panel

reinforcement
thicknesses).
4. Separating cut.
5. A-pillar inner reinforcement with rocker panel

reinforcement
 Grind out the weld seams.

Page 3 of 5
Installation
1. Inner A-pillar with rocker panel reinforcement
 Drill a hole for puddle welding (diameter: 10

mm).

2. Puddle welding
Page 4 of 5
 Drill holes for puddle welding (diameter: 10

mm).

1. Puddle welding

1. Separating cut.
2. Drill holes for puddle welding (diameter: 10
mm).
Page 5 of 5

1. Puddle welding
Page 1 of 1

ROCKER PANEL
UID=G330248
General Equipment
Beam compasses
 Rocker panel
Removal
1. General Notes.
 The wings, doors and door hinges are already

removed before repair work starts.
 Necessary removal work: rocker panel trim,

front and rear seats.

harness back away from the working area.
2. Rocker panel
1. Separating cut.
2. Grind out the wheel arch joint.
Installation
1. NOTE: Apply 2-pack metal adhesive only
just immediately before installing the new
part.
Rocker panel
2. Apply 2-pack metal adhesive and clinch the
wheel arch flange.
Page 1 of 7

B-PILLAR AND REINFORCEMENT
UID=G330249
General Equipment
 B-Pillar reinforcement
 B-pillar inner panel
 Safety belt guide loop reinforcement
Removal
1. General Notes.
 The front door, rear door and rear door

hinges are already removed before the repair
starts.
 Necessary removal work: seat and rocker

panel trim.

harness back away from the working area.
 It is not possible to perform a partial

replacement in the upper area of the B-pillar
reinforcement because of the reinforcement
which is inside.
* When the outer and inner reinforcements are being completely replaced, the
spot welds in the region of the door seal must be drilled out (two panel
thicknesses) as far as the inner panel.
* Make the front cut line on the rocker panel far enough forward to allow access
to the B-pillar inner panel (can be seen on the visible weld flange).
2. B-pillar outer panel

1. Cut points.
thicknesses).
Page 2 of 7
3. B-Pillar reinforcement
1. Separating cut.
2. Separating cut.
3. Separating cut (on the right of the laser
weld seam).
4. Separating cut.
4. B-pillar inner panel
 Separating cut.
5. B-pillar inner panel

1. Separating cut.
3. Grind out the weld seam
Page 3 of 7
 Separating cut.
Installation
1. B-pillar inner panel - safety belt guide loop
reinforcement
2. Glue the NVH element in place using 1-pack
PU adhesive.
Page 4 of 7
3. B-pillar outer panel

2. Puddle welding
4. Rocker panel

Page 5 of 7
Page 6 of 7
 Puddle welding

Page 7 of 7
11. B-pillar

diameter).
12. B-pillar
3. Puddle welding
Page 1 of 3

QUARTER PANEL LH
UID=G330250
 Quarter panel, left-hand side
Removal
1. General Notes.
 The doors and tailgate are already removed

before repair work starts.
 Necessary removal work: Bumper, tail lamp,

door seal, inner trims and side window.

replaced.
2. Side panel
1. Separating cut.
3. Warm the area (approx. 170º C).
4. Grind down one panel thickness at the
wheel arch edge.
3. Side panel

Page 2 of 3
Installation
1. Side panel
2. NOTE: Always apply 2-pack metal adhesive

and clinched flange protection just before
installing the new part.
Side panel
1. Apply 2-pack metal adhesive to the clinched
flange and clinch the wheel arch flange.
2. Apply clinched flange protection.
5. Puddle welding
3. Side panel
1. Puddle welding
Page 3 of 3

Page 1 of 2

BACK PANEL
UID=G330252
 Back panel
 Reinforcement, rear panel left-hand side
 Reinforcement, rear panel right-hand side
Removal
1. General Notes.
 Necessary removal work: rear panel trim.

2. Back panel
3. Back panel
 Grind out the weld seams.
4. Back panel
Installation
1. Back panel with reinforcements

Page 2 of 2
2. Back panel
3. Back panel

Page 1 of 3

INNER QUARTER PANEL AND
WHEELHOUSE
UID=G330253
General Equipment
 Inner quarter panel with wheel housing
 Wheelhouse reinforcement
 NVH element
Removal
1. General Notes.
 Quarter panel, back panel and lamp mounting

panel are already removed before the start of
repairs.
 Necessary removal work: side panel trim.

back away from the working area.
NOTE: When separating the side panel, do not exceed the maximum displacement of the
cut line in relation to the roof edge.
2. Inner quarter panel reinforcement
1. Separating cut.
3. Warm the area (approx. 170° C) and
release the NVH elements.
3. Inner side panel with reinforcement

1. Exact separating cut.
Page 2 of 3
Installation
1. Inner side panel
3. Puddle welding
2. Inner quarter panel reinforcement

PU adhesive.
Page 3 of 3
Page 1 of 2

REAR FLOOR PANEL
UID=G330254
General Equipment
 Luggage compartment floor panel
 Spare wheel retainer
Removal
1. General Notes.
 The tailgate and rear panel with gussets are

already removed before the start of repairs.
 Necessary removal work: rear seat, luggage

compartment carpet, side panel trim left and
right.
2. Luggage compartment floor panel
 Preliminary separating cut.

1. Exact separating cut.
Installation
NOTE: The new part overlaps in the connection area at the front by 10 mm. To install it,
Page 2 of 2
because of space limitations, cut the left-hand part panel and re-install separately.
* The instructions concerning welding equipment given in Section 501-25A must

be observed when resistance spot welding body panels with a thickness greater
than 3 mm.

2. Intermittent MIG weld seam.

Page 1 of 3

REAR OUTER WHEELHOUSE HALF
UID=G330255
 Wheelhouse outer half
 Wheelhouse reinforcement
 NVH element
Removal
1. General Notes.
 side panel, back panel, lamp mounting panel

and lamp mounting panel reinforcement are
already removed before the start of repairs.
NOTE: Make the separating cut on the wheel house reinforcement offset from the wheel
house outer halves.
2. Wheelhouse reinforcement
1. Separating cut.
3. Warm the area (approx. 170° C) and
release the NVH elements.
3. Wheelhouse outer half

1. Separating cut.
Page 2 of 3
Installation

3. Puddle welding
Page 3 of 3

PU adhesive.
Page 1 of 2

REAR LAMP MOUNTING PANEL
UID=G330256
 Lamp retaining panel
Removal
1. General Notes.
 The quarter panel and back panel with

reinforcements are already removed before
the start of repairs.
 The cut may vary depending on damage.

2. Lamp retaining panel
1. Separating cut.
Installation
1. NOTE: The instructions concerning welding
equipment given in Section 501-25A must be
observed when resistance spot welding body
panels with a thickness greater than 3 mm.
Lamp retaining panel
3. Puddle welding
Page 2 of 2
Page 1 of 2

QUARTER/SIDE PANEL REAR SECTION
LH
UID=G334017
 Rear quarter panel section
Removal
1. General Notes.
 The tailgate is already removed before

starting the repair.
 Necessary removal work: bumper, tail lights,

interior trim.

replaced.
2. Side panel
1. Heat the area just before removal.
2. Separating cut.
3. Side panel
1. Separating cut.
Installation
Page 2 of 2
1. NOTE: Apply 2-pack metal adhesive only

just immediately before installing the new
part.
Side panel
1. Apply 2-pack metal adhesive.
2. Side panel
Page 1 of 2

REAR FLOOR PANEL SECTION
UID=G334139
Removal
1. Materials
 Luggage compartment floor panel

2. General Notes.
 The tailgate, back panel, rear crossmember,

side panel and lamp mounting panel
reinforcement are already removed before
 Necessary removal work: Inner trims.
 Move the floor coverings away from the work

area.
1. Separating cut.
3. Mill out the spot welds from below.
Installation
 Drill a hole for puddle welding.

Page 2 of 2

1. Puddle welding

Page 1 of 1

SPECIFICATIONS
UID=G334155
Specifications

Hydraulic control unit (HCU) to support bracket retaining bolts 9 - 80
HCU support bracket retaining bolts 20 15 -
Brake tube to HCU unions 18 13 -
Wheel speed sensor retaining bolts 9 - 80
Stability assist module to HCU retaining bolts 5 - 44
Yaw rate sensor and accelerometer assembly retaining bolts 5 - 44
Yaw rate sensor and accelerometer assembly cover retaining bolts 4 - 35
Page 1 of 1

SPECIFICATIONS
UID=G334156
Specifications
Item Nm lb-ft lb-in

Hydraulic control unit (HCU) support bracket retaining bolts 23 17 -
HCU retaining bolts 10 - 89
Brake tube to HCU union 13 10 -
Page 1 of 1

SPECIFICATIONS
UID=G334159
Specifications
Item Nm lb-ft lb-in

Clutch actuator retaining bolts 20 15 -
Gearshift actuator bracket retaining bolts 11 8 -
Gearshift actuator retaining bolts 23 17 -
Gearshift actuator retaining bolt 16 12 -
Page 1 of 2

REAR FLOOR PANEL SECTION LH
UID=G334174
Removal
 Partial renewal, luggage compartment floor

panel
2. General Notes.
 The tailgate and back panel with

1. Separating cut.
Installation

Page 2 of 2
Page 1 of 2

REAR FLOOR PANEL SECTION RH
UID=G334175
Removal
 Partial renewal, luggage compartment floor

panel
2. General Notes.
 The tailgate and back panel with

1. Separating cut.
Installation

Page 2 of 2
Page 1 of 7

UID=G338809
Overview

1 - Injector
2 - Leak off lines
3 - High-pressure pump
4 - Fuel distribution rail (Common rail)
6 - High pressure fuel lines
General
Description
A Siemens Common Rail diesel fuel injection system is introduced in the MZ-CD 1.4L DI Turbo
engine.
Common rail diesel fuel injection systems are pressure storage injection systems. This means
Page 2 of 7
that the fuel pressure is continuously available on these systems, whereas on traditional
systems with distributor injection pumps, the pressure must be newly built up for every
injection.
Creation of pressure and fuel injection are performed separately on common rail diesel fuel
injection systems. Because of this, the build up of injection pressure is largely independent of
engine speed and injection quantity.
An injection pressure of up to 1,500 bar is kept ready in the fuel distribution rail (common
rail).
General operation
An integral transfer pump is found inside the high pressure pump, and this transfers the fuel
from the tank to the high pressure pump.
The high pressure pump supplies fuel through the high pressure system into the common rail
and to the injectors and builds up the injection pressure there.
Injection timing and quantity are calculated by the powertrain control module ( PCM) .
Using various input variables, the PCM controls the piezoelectrically operated injectors, which
inject the required quantity of fuel into the applicable combustion chamber.
The fuel pressure sensor on the common rail provides the PCM with information on the
current fuel pressure. Another variable is the fuel temperature.
Based on these input variables, the PCM controls the fuel metering for the system by using
the fuel metering valve and the fuel pressure regulator, so that the optimum fuel pressure is
available for every operating state.
Excess fuel passes through the fuel return collector pipe, past the fuel temperature sensor,
and back to the fuel tank.
In the tank a venturi pump ensures that the fuel returned helps the filling of the fuel supply
unit in the tank.
High-pressure pump
Fuel supply is carried out through an integral transfer pump. This is a vane cell pump and is
driven by the drive shaft of the high pressure pump.
The fuel passes from the transfer pump to the high pressure pump itself. This is contains
three pump cylinders which are arranged radially.
The fuel metering valve is located in the supply channel between the transfer pump and the
high pressure pump. The fuel metering valve operates electromagnetically and is controlled
by the PCM .
The fuel metering valve affects the fuel flow to the high pressure pump, and thus controls the
amount of fuel destined for the high pressure pump.
The fuel pressure regulator controls the output pressure of the high pressure pump. The fuel
pressure regulator operates electromagnetically and is controlled by the PCM .
Page 3 of 7

1 - Fuel metering valve
2 - Inlet (from filter)
3 - Drive shaft
5 - Outlet (high pressure)
6 - Return
Operation of the high pressure pump
The storage pressure required for the common rail is created in the high pressure pump.
Three pump cylinders are arranged radially around the drive shaft.
Fuel is sucked into the inside of the pump cylinders by the rotating motion of the drive shaft,
and is supplied under pressure to the common rail and also to the high pressure system.
Fuel flow through the high pressure pump during acceleration
During acceleration fuel is passed unrestricted from the transfer pump through the supply
channel to the high pressure pump.
A proportion of the fuel passes through a calibrated return bore, past the fuel temperature
sensor and back to the tank, thus serving to cool and lubricate the pump.
Fuel flow through the high pressure pump during over-run.
In over-run, the fuel metering valve closes the supply channel from the transfer pump to the
high pressure pump. This causes the pressure in the supply channel to increase.
When a given pressure is reached, a pressure control valve opens, which is connected by a
bore to the transfer pump.
The excess fuel partly flows back to the suction side of the transfer pump, partly back into the
Page 4 of 7
tank.
Common rail
The fuel supplied by the high pressure pump passes through a high pressure line into the
common rail.
The common rail is made of forged steel. It stores fuel under high pressure and damps
pressure fluctuations.
The fuel passes to the injectors through four high pressure lines.
Feedback information for pressure control is provided by a fuel pressure sensor located in the
common rail.
NOTE: The fuel pressure sensor in the common rail must not be slackened or removed.

2 - High pressure line connection (from the high pressure pump)
3 - High pressure line connections (to the injectors)
High pressure fuel lines
NOTE: The radii of the bends on the high pressure lines must not be changed.
NOTE: Every time the high pressure lines are undone, new ones must be installed,
otherwise leaks can occur at the line unions because of the particularly high fuel pressure.
Page 5 of 7
The high pressure fuel lines connect the common rail with the high pressure pump and the
injectors.
The high pressure lines which lead to the injectors are all the same length. All the high
pressure lines have bend radii which are matched to the system.
Injectors
CAUTION: Danger of damage to components. Never disconnect the wiring harness

electrical connector from an injector with the engine running.
NOTE: New injectors must be installed if repairs are needed. They cannot be dismantled.

1 - Wiring harness electrical connector
2 - High pressure line union
3 - Seal
4 - Injector nozzle
5 - Fuel leak off line connection with clip
Start of injection and injection quantity are achieved by electrically controlled injectors.
Control of the injectors is performed directly by the PCM .
The injectors consist of three separate functional groups:
* Injector nozzle,
* hydraulic servo system,
* piezoelectric actuator.
Electromechanical operation is achieved using piezoelectric elements, which have a

particularly fast switching time of approximately 0.2 milliseconds.
Low pressure fuel system

Page 6 of 7
Fuel supply unit

1 - Fuel feed
2 - Electrical connection for the fuel gauge sender unit
3 - Fuel return
The fuel supply unit contains an integral venturi pump. In this way, the returning fuel sucks
up additional fuel into the housing. Because of this, the fuel volume of the tank is used in the
most optimal way.
Fuel filter
Page 7 of 7

1 - Water drain screw
2 - Electric fuel pre-heater
The fuel filter is located on the air cleaner housing towards the transmission.
The fuel filter has electric fuel pre-heating for vehicle operation in low ambient temperatures.
The fuel filter forms a single component with the housing and can only be renewed as a
complete unit.
In addition, the fuel filter is equipped with a water separator. This must be regularly drained
in accordance with the service instructions.
To do this, the drain screw on the filter housing must be undone. Then allow approx. 80 ml of
liquid to run out (collect and dispose of this) and then close the water drain screw again.
Low pressure fuel lines in the engine compartment

1 - Return line to tank
2 - Feed from the fuel filter
3 - Manual pump
4 - Lines for leak off fuel from the injectors
5 - Collector pipe for return fuel with fuel temperature sensor
6 - Feed line to the high pressure pump
7 - Return line from the high pressure pump
The low pressure fuel system is equipped with a manual pump. Using the manual pump, fuel
can be supplied from the fuel tank through the fuel filter to just before the inlet to the high
pressure pump, in order to allow the vane cell pump to suck fuel out of the tank itself.
The collector pipe for return fuel brings together the return lines from the high pressure
pump, manual pump and leak off fuel and contains the fuel temperature sensor.
Page 1 of 5

CORROSION PROTECTION
UID=G33914
General
The corrosion protection provided in production must be carefully maintained and/or

reproduced during and after body repair work. It is only then that the long-term warranty
against penetrative rust damage can be assured (refer to the Warranty Booklet/Service
Booklet).
Only Ford original bodywork components and Ford approved repair materials (sealer, paint
etc.), are to be used for bodywork repairs.
All Ford bodywork components have a cathodic base coating. Individual bodywork
components are zinc plated on one or both sides (in different areas depending on vehicle
model).
Together with elastic paint coating, this guarantees an optimum, highly resistant protection
against corrosion caused by the impact of small objects such as gravel.
NOTE: If possible, the individual protective layers (zinc, cathodic base coat) on Ford
bodywork components must not be damaged or destroyed by sanding or other
mechanical operations.
The Ford logo is stamped onto every Ford original bodywork component for identification. This
symbol is a registered trademark and is a requirement for any later warranty claim.
Ford original spare part
If repair work is necessary on vehicle bodywork, the repair instructions given in the model
specific chapters of this manual and the instructions in the paint and corrosion protection
manual must be followed.
If hairline cracks at "bodywork connection areas" appear after reshaping work (e.g. at door
hinges), it must be ensured that the corrosion protection provided in production is recreated.
The complete paint covering must be re-created if necessary. The same applies to reshaping
work on heavily profiled bodywork components (e.g. floor pan). Renew or touch-up the paint
coating, sealing beads and underbody protection as necessary.
After repair, any interior surfaces which are no longer visible or accessible must be primed
before cavity wax is applied. To be certain of an even coating on inner surfaces, careful
application of spray (twice, with drying time in-between) must be carried out throughout the
whole cavity.
If bodywork panels are strongly heated during repair work, this will invariably result in
Page 2 of 5
damage to or even destruction of the applied corrosion protection material. The effectiveness
of the cavity protection material is reduced if heating occurs. Reworking of the affected areas
is therefore vital.
Welded areas should be ground flat before corrosion protection is applied.
The corrosion protection measures to be taken when bodywork components are renewed are
described on the following pages.
Corrosion protection of new components
All new components must be inspected for transport or storage damage such as scratches or
dents. The following operations may be necessary, depending on the extent of damage:
1. Undamaged new component
 Do not grind the cathodic dip primer. Thoroughly clean with silicone remover and rub dry.
2. Slightly damaged new component
 Sand out scratches.
 Finely sand the surrounding surfaces.
 Thoroughly clean with silicone remover and rub dry.
 Apply corrosion protection primer to bare areas.
3. Damaged new component (bumps, dents)
 Beat out the dented area and sand down to bare metal.
 Apply polyester filler (only onto bare metal).
 Apply fine filler.
 Lightly sand the whole component.
 Thoroughly clean with silicone remover and rub dry.
 Apply corrosion protection to bare areas.
Depending on the vehicle, the clinched flanges on the hood, doors, tailgate and trunk lid must
be sealed with clinched flange sealer. The model specific body repair manuals contain detailed
information.
After repair the paint finish must be recreated according to the paint and corrosion protection
manual.
Welded components
Use a rotating tress wire brush to remove the dip coat on the inside and outside of the area
to be welded, taking care not to damage the zinc coating.
NOTE: The area to be ground should be kept as small as possible, the corrosion
Page 3 of 5
protection applied in production (cathodic primer) should be retained as much as is

possible.
NOTE: The welding primer must be stirred well before application.
Clean the repair area thoroughly (silicone remover).
Apply welding primer evenly to all weld flanges (old and new components).
NOTE: The welding primer must be allowed to dry before welding is carried out.
Apply welding primer
All weld beads must be ground down after all welding is completed, taking care not to weaken
the material.
Any unevenness at joints is removed using lead loading.
If necessary, spot weld missing T-pins for trim strip clamps into position. The vehicle must be
completely cleaned of sanding dust and metal swarf because of the danger of corrosion.
Clean and prime all internal areas and those to be sealed.
Seal all welded areas and joints, apply underbody protection.
NOTE: The primer must be dry before sealing mastic or underbody protection is applied.
Do not use thinner when applying sealing mastic (the mastic would not dry).
The noise damping mats and cavity foam applied in production must be re-applied.
After painting, apply cavity protection to all cavities in all parts which have been renewed
(especially at weld seams).
Partial renewal
The procedure to follow when partially renewing components is the same as described in the
section "Welded components".
The main difference when components are partially rather than completely renewed concerns
the preparation of butt or lap joints.
- When bodywork components are cut through, attention must be paid to the
adequate removal of the paint and zinc coatings on inner areas. This specially
applies to areas which are difficult to access internally.
- It is important for the weld quality that the inner area is bare metal. Zinc and
paint residues in the weld area burn and cause serious hole formation during
welding.
Page 4 of 5
- If the zinc layer and the paint coating are not removed, the zinc and paint will
burn during welding. The soot produced prevents satisfactory cavity protection.
Procedure
- The paint layer must be removed for a width of 30mm from the line of the weld
using a rotating tress wire brush.
- This operation must be carried out on both the new and the old parts of the
bodywork.
- Depending on the bodywork component, a 10mm width of the underlying zinc

layer must also be removed along the weld line.
NOTE: A flat scraper or a wire brush can be used instead of the rotating brush if the
cavity is small. Do not use an angle grinder, which would weaken the structure.
Application of cavity protection on a door sill after partial repair.

1 - Weld bead
2 - Spray head
3 - Distance maintainer
4 - Spray gun
A hole may be drilled in a suitable place for areas which are not accessible for the application
of cavity wax. The diameter depends on the size of plugs available. When this is done it is
vital to make sure that no drilling swarf remains in the cavity (rust will be formed if any
remains). The edge of the hole must be treated with cavity wax. Finally close with a plug and
seal with underseal.
Classification of the different corrosion protection measures for dent removal
Corrosion protection Exterior Accessible inner Inaccessible inner

method surfaces surfaces surfaces
Painting X X
Cavity protection X
Classification of different corrosion protection measures for installation of new components
Corrosion Weld flanges before All bare

protection welding in place (contact sanded Weld flange area Weld flange area
method surfaces) areas accessible not accessible
Page 5 of 5
Welding primer X
Painting X X
Clinched flange X
protection
Cavity protection X
Page 1 of 15

PLASTIC REPAIRS
UID=G33917
General
Because of their various constructions, repair work to plastic parts involves various repair
methods:
- Thermoplastic straightening
- Plastic welding technology (PC, PP/EPDM etc.)
- Plastic bonding technology (all plastic parts)
- Plastic laminating technology (GRP parts with polyester resin only)
In repair work, the material characteristics of plastics are highly significant. Two main groups
can be distinguished:
- Thermoplastics (plastomers)
- Duroplastics (duromers)
Thermoplastics (plastomers)
- Heat causes thermoplastics to change from solid state to thermoelastic state

and then to thermoplastic state.
- When thermoplastics are cooled, they return to solid state.
Duroplastics (duromers)
- Duroplastics are much harder and more brittle than thermoplastics.
 Their strength remains largely unchanged when they are heated.
 Duroplastics are destroyed when the critical temperature point is exceeded.
 Cooling down will not restore the original state.
Plastics used by Ford
Abbreviation Description
ABS Acrylonitrile butadiene styrene (polymer)
PA Polyamide
PC Polycarbonate
PP Polypropylene
PP/EPDM Polypropylene/ethylene propylene rubber
PC/PBT Polycarbonate/polybutylene terephthalate
PBT/PC Polybutylene terephthalate/polycarbonate
PUR Polyurethane
GF Glass fiber reinforced
Plastic identification
Page 2 of 15
If a plastic has no identifying marks, the type can be established using two different
procedures/methods:
- Visual Inspection
- Mechanical Check
The identification of a type of plastic is required for the plastic welding process in order to
determine the correct allocation of the respective welding rod.
Visual Inspection
Visual inspections mainly serve to identify PUR and GRP materials. Thermoplastic components
(e.g. bumpers) are often painted and are therefore difficult to identify.
Identification characteristics:
- PUR: if cracks form or similar damage occurs, visible pores of foam.
- GRP: identifiable glass fiber structure on the inside.
Mechanical Check
- Degree of hardness; the higher-pitched the tone, the harder the plastic.
- Elasticity; the more muffled the tone, the higher the elasticity of the plastic.
NOTE: Mechanical checks can identify the plastics group, but not the plastic type.
According to damage statistics, plastic bumper bars are most often subject to repairs.
NOTE: The PUR foam must not be removed for repair purposes if the foam polyurethane
on the inside is bonded to the outer shell of the bumper bar. If there is serious damage
such as cracking or fracturing (splitting) to the outer shell, do not perform any repairs to
the foam area. The rule is this case is: renew the part.
The outer shell of plastic bumper bars is mainly comprised of thermoplastic materials.
Depending on the degree of damage and accessibility, the following repair procedures can be
applied:
- Thermoelastic straightening
- Bonding
- Welding
Thermoelastic straightening
Bumper bars often have deformations which occur in the elastic area. These normally take
the form of dents, indentations and bends. Many of these deformations (e.g. to bumper bars)
correct themselves of their own accord immediately or after a certain period of time. This
self-correction depends on the extent of the damage and the temperature. Most flat
deformations in the elastic area revert to their original form when heated with a hot air
blower.
Flat elastic deformations
-
Page 3 of 15
NOTE: The necessary application of heat varies according to the type of

plastic. The application of heat must not go beyond the elastic area.
Deformation to plastic cannot be reversed. Never use a naked flame!
Flat indentations or dents should be heated evenly to approx. 200°C using a hot
air blower, if possible apply heat to both sides in turn. Provided there is no
overstretching, the deformation reverts to its original form.
- To an extent, the "straightening" can be supported using mechanical tools such

as the handle of a hammer, a plastic wedge, etc.
Stretch cracks and kinks
If there are stretch cracks or even kinks in the damage area, then the possibilities of
thermoelastic straightening are limited. Bonding repairs are most suited to this kind of
damage.
- To prevent tension in the material, cut off the cracked or kinked areas (using a
hacksaw).
- Heat the depression to approx. 200°C (evenly, both outside and inside) and
adjust to the original form using a narrow spatula or hammer handle.
Plastic welding
NOTE: Do not carry out plastic welding in the area of fixed foam backing.
Plastic welding is the most suitable repair method for cracks to plastic bumper bars, where
the rear side of the damaged area is unsuited to repairs by bonding. Examples: Ribbed
section, box section, narrow rounded sections in reinforced areas.
Required tools and materials
- In addition to the tools available in the workshop (such as scrapers, grinders,

etc.) the following tools are required for plastic welding:
 Hot air blower (approx. 1500 W)
 Welding nozzles
 Various welding rods
 Face cutter Ø 5.5 mm for processing the welding groove.
 Scraper (heart-shaped).
Plastic welding gun

Page 4 of 15

1 - Plastic welding gun
2 - Rapid welding nozzle
3 - Wedge nozzle (fixed nozzle)
4 - Face cutter
Preparing the repair location (crack)
Prepare cracking for the welding process in V-formation.
V-groove weld seam

1 - Part to be repaired
2 - Weld additive (shaped)
Preparing the V-groove weld seam:
- Form the welding groove using the scraper (face cutter).
- Keep the angle of the joint at 60° - 70°.
-
NOTE: Boring out the end of the cracked (3mm drill bit) prevents further
cracking. Where the edge alignment is uneven, fix the start of the crack using
clamp pliers before starting welding.
Finally, bore out the end of crack.
Preparing the hot air blower and welding rod
Convert the hot air blower into a plastic welding gun (extension nozzle and rapid welding
nozzle).
- Set the weld temperature (200°C -700°C) according to the prescribed values.
Weld temperature
Two factors determine the weld temperature:
- Plastic material
- Thickness of the welding rod
Values for the most important materials and conventional welding rod thickness (5.7 mm x
3.7 mm)
Page 5 of 15
Weld temperature in °C (guide Potentiometer control setting for plastic

Thermoplastic value) welding gun
Wedge nozzle Rapid welding nozzle 5.7mm
ABS 350 4,5 5,3
PP 300 3,8 4,5
PP/EPDM 300 3,8 4,5
PBT/PC 300 3,8 4,5
PA 400 5,1 5,6
PC 350 4,5 5,3
PC/PBTP 350 4,5 5,3
- Only weld PBT/PC plastic using a PP welding rod.
- Glass fiber reinforced plastics cannot be welded.
- Blue-dyed plastic parts on the Ford Ka cannot be painted and are therefore not
suited to plastic repairs.
Rear side of the plastic welding gun

1 - Air intake opening
2 - Temperature control unit
3 - Rocker switch
4 - Air volume switch
- The temperatures given are air temperatures for the plastic welding gun. The
temperature of the material is much lower.
- Observe the manufacturer's instructions when setting the temperature.
- Preheat the welding equipment to the preselected welding temperature for 3-4
minutes.
- Bevel the welding rod at the front to ensure gradual filling at the start of the
crack groove.
Carrying out the welding
The following requirements must be met for plastic welding:
- Correct temperature setting
- Even welding speed

Page 6 of 15
- Even operating pressure
Push the beveled welding rod through the heated pre-heating chamber of the rapid welding
nozzle until the tip of the welding rod emerges from the underside.
Aligning the rapid welding nozzle
The underside of the rapid welding nozzle must run parallel to the repair surface in a
lengthways direction. Parallel alignment in a lengthways direction is achieved with the welding
equipment at the appropriate inclination.
Position of the plastic welding gun
- Move the plastic welding gun in such a way that the welding rod is exactly
vertical to the welding groove.
- The welding procedure can be started when the welding rod and the plastic to
be welded are in a plastic state.
Weld seam

1 - Bead of weld
Page 7 of 15
2 - Heightening of weld seam

3 - Base of weld seam
-
NOTE: The optimal connection is achieved when a small and even bead of
weld has formed along the edge of the weld seam. It is essential to weld
through the crack seam. Check the weld seam from the rear side and re-weld
if necessary.
The operating pressure when welding is only exerted across the welding rod.
Welding errors
Deformation:
- Repair area was overheated.
- Material tension present when welding parts.
- Plastic material too thin.
Poor welded joint:
- Weld temperature too low.
- Weld speed too fast.
- Welding together differing materials.
Weld seam sinks:
- Crack groove too wide
- Weld temperature too high.
Re-working the weld seam
- After cooling down, the raised part of the weld seam can be sanded down using
an angle sander and abrasive paper of P80 grit.
- Surface grinding is then carried out using the orbital sander and abrasive paper
of P120 - P220 grit.
- Clean the ground repair surface using plastic cleaner.
- Apply plastic primer thinly to the repair surface.
Plastic reciprocal welding
Reciprocal welding is the preferred method for crack damage in hard-to-reach areas.
- The welding rod is moved freely in reciprocal welding.
- The preparation of the crack groove is the same.
Carrying out the welding

Page 8 of 15
- The plastic welding gun is only fitted with the extension nozzle.
- The welding rod and the crack groove are brought into plastic state by means of
vertical reciprocating movements.
- The welding rod is pressed into the crack groove vertically in a plastic state.
Reciprocal welding

1 - Welding rod
2 - Plastic welding gun
3 - Welding groove
4 - Direction of welding
The following requirements must be met for reciprocal welding:
- Equal heating of welding rod and welding groove.
- Even welding speed.
- Vertical positioning and even pressure on the welding rod.
All other repair steps are described in the chapter Plastic Welding - Re-working the Weld
Seam.
Plastic bonding
General
Bonding technology has some advantages over welding technology:
- Within the group of thermoelastics, all semi-rigid ancillary components (such as

bumper bars, front grilles, etc.) can be repaired without identification.
- A two-component adhesive with a polyurethane basis must be used for all

thermoplastic parts.
- Reinforcement strips can be attached to crack grooves (cracks up to max.

100mm) and fractures to ensure the original tensile properties.
Required tools and equipment
Tools and equipment from the paint shop can be used to carry out bonding repairs to
thermoplastic parts. Angle grinders and belt sanders can be used to grind out scratches and
Page 9 of 15
crack damage. Orbital sanders with extractors are used for fine sanding. An infrared heater
ensures fast and effective drying.
Plastic repair set
- Plastic cleaner
- Plastic primer
- Adhesive repair set
 Three double cartridges
 Three emulsion tubes
- Metal reinforcement strips
- Reinforcing fiber
Tools and auxiliary equipment

1 - Angle grinder with speed control
2 - Orbital sander
3 - Plastic stopper
4 - Scraper
5 - Paint spatula
6 - Clamp pliers
Preparing the repair location (scratch)
Before the repair, clean plastic parts on both sides using a high-pressure cleaner, and then
dry.
- Clean the repair surface using plastic cleaner.
Grinding out the scratch

Page 10 of 15

1 - Preparation of the scratch
2 - Preparation of the crack
- Grind out the scratches thoroughly flat using an orbital sander. Abrasive paper,
P80 - P120 grit
- Fine sanding with orbital sander: Abrasive paper, P120 grit
-
NOTE: Wear protective gloves for cleaning.
Thoroughly clean the repair location using plastic cleaner and paper towels.
- Spray plastic primer evenly onto the repair location.
Preparing the repair location (crack)
- Grind out the crack on the front side so that it is flat using an angle grinder or
belt sander. Grinding surface 40-60mm wide
- Regrind with an orbital sander. Abrasive paper: P120 grit.
- Bore out the end of the crack (Ø 3 mm) to prevent further cracking.
- Rub down the rear side along the crack.
- Clean the repair location on both sides using plastic cleaner and paper towels.
- Spray plastic primer evenly onto the repair location.
Preparation for bonding
- The two-component adhesive is applied to the cleaned and primed repair

location using a hand gun.
- Operating the gun lever pushes the resin and hardener components from the
double cartridge into the attached emulsion tube.
Scratch bonding
Even slight depressions such as cracks require preparation. The surface of the repair area
also has to be processed to provide sufficient priming for the adhesive. This also prevents the
repair area from subsequently sinking.
Page 11 of 15
- After cleaning and priming, over-fill the ground out scratch cavity with adhesive.
- Dip the end of the emulsion tube in adhesive during the material application to
prevent the ingress of air.
- Spread and smooth the adhesive using a flexible plastic stopper.
- Set using an infrared heater or in a drying oven.
Crack bonding with reinforcement
The repair location is reinforced to increase torsional strength in the case of cracking and
fracture damage over a large area. To this end, suitable reinforcement materials (metal
strips, reinforcement fibers) are affixed to the rear side.
- Cover the crack on the front side with a PE sheet and with adhesive tape.
- From the rear side, fill the ground out crack groove with plastic adhesive.
- A wide strip of reinforcing fiber is fixed over the crack groove in the bead of
adhesive.
- The ends of the crack are reinforced by affixing a metal strip that is fastened to
the plastic part using pliers.
- Then level out the reinforcement material over the whole surface.
- Dry using an infrared heater or in a drying oven.
- The PE sheet prevents the adhesive from overflowing at the front side of the
crack.
- Pull off the PE sheet after drying the adhesive.
- Spread adhesive over the repair location on the front side.
- Set using an infrared heater or in a drying oven.
- Cool the adhesive to room temperature to prevent the adhesive being pulled off
when sanding, and to prevent the abrasive paper becoming worn.
Sanding
-
NOTE: In the case of dry sanding, use an extraction unit and wear a dust
mask.
Sand down protruding adhesive using an orbital sander. Abrasive paper: P120 -
P220 grit.
- Re-work sags and curved areas manually.
- Use an abrasive pad to roughen painted surfaces.
- Thoroughly clean the plastic part using plastic cleaner and paper towels.
Page 12 of 15
-
NOTE: Thoroughly dry out the plastic primer (matt surface).
Spray plastic primer for the subsequent 2K filler application thinly onto the repair
areas and sanded-through areas.
Two-component filler application
To prevent porosity at the edges and to smooth out uneven areas, it is advisable to apply 2K
filler (MS, HS) with an elasticising additive.
- After drying, cool the 2K filler to room temperature and sand down using an
orbital sander and fine abrasive paper.
- Re-work sags and curved areas manually (wet) using fine abrasive paper.
- Check the contour of the repair location and re-work if the contours are uneven.
- Perform painting in accordance with the manufacturer's instructions.
GRP repairs
General
GRP material is hard and brittle in its tensile properties. Because of these material properties,
cracks and fractures often result in cases of serious damage. The stability and safety of GRP
parts is impaired if the glass fiber reinforcement is cracked. This must be replaced in cases of
serious damage that affect the structure of the part. Minor damage (such as abrasion, cracks
up to 80mm, holes up to approx. 60mm diameter, etc.) can be repaired to a technically and
visually perfect standard, provided that the damage does not occur in heavily used or hard-
to-reach areas. To ensure excellent repairs, observe the following points:
- The room temperature should be at least 15°C and the air should be as dry as
possible.
-
NOTE: Fingerprints leave behind a film that prevents a proper joint.
The repair location must be thoroughly dry and clean.
- Before the repair, the GRP part being repaired must be dried using an infrared
heater or in a drying oven.
- In cases of large cracks and fractures, the strength of the outer skin can be re-
established by backing with a reinforcement material.
Required tools and auxiliary equipment
- Hacksaw (body saw) for separating cracks.
- Axial grinder, angle grinder or belt sander for grinding out repair locations.
- Orbital sander for grinding out and grinding down the repair surface.
- Hand sanding block for grinding small surfaces.
Grinding the repair location

Page 13 of 15
- Grind out the edge of the hole, in a V form and flat, using an angle grinder -
abrasive paper P80 - P120 grit.
- Remove layers of filler and paint.
- If cracks have formed, these are ground out at the base of the crack by 3mm.
This eliminates any tension.
- Careful, flat grinding is important for the subsequent adhesion of the repair
material.
-
NOTE: The surface must be re-ground by hand.
Grinding with the angle grinder creates heat that causes a change in the surface
structure of the resin. This results in reduced adhesive properties.
GRP repair material
GRP repair components

1 - Polyester resin
2 - Hardener
3 - Glass fiber mats
4 - Scissors
5 - Brush
Apply polyester resin
- The polyester resin is mixed with hardener and applied thinly to the clean repair
location with a brush.
Insert the glass fiber mat
- Cut the glass fiber mat to size and insert it into the applied polyester resin.
- Applied more polyester resin over the glass fiber mat, and add a second or third
mat if necessary.
-
NOTE: Completely soak the glass fiber mat in polyester resin. No air may be
trapped in the repair area.
Apply polyester resin using a brush.
- Allow the polyester resin to dry at room temperature.

Page 14 of 15
- Back larger cracks and fractures with reinforcement material to restore the
strength of the outer skin.
Apply stopper
- The depression on the front side is filled with polyester fiber stopper to achieve
a smooth, flat surface.
- Repeat the procedure if necessary.
Apply stopper

1 - GRP part being repaired
2 - Polyester fiber stopper
3 - Glass fiber insert
Final application of stopper
- Re-create the surface contours by applying stopper or polyester filler.
Grinding with the orbital sander
- Sand down protruding polyester material using an orbital sander. Abrasive

paper, P120 - P220 grit.
- The repair surface can be painted after grinding.
Safety measures
- Polyester resin, adhesive, solvents and thinners are inflammable and must be
kept away from naked fire or flames.
- Sawing and grinding operations must only be carried out in rooms equipped with
extraction systems.
- If no rooms with extraction systems are available, only use tools with extraction
systems.
- Protective equipment such as gloves, protective goggles, aprons and breathing

masks are essential.
For additional information, refer to Section 501-25A / 501-25B / 501-25C / 501-25D /

501-25E / 501-25F. It is also important to observe all applicable regulations, accident
prevention legislation, information sheets, safety notices and guidelines for the processing of
Page 15 of 15
adhesives containing isocyanate, polyester resin, adhesives, solvent and thinners.

Page 1 of 20

WATER LEAKS
UID=G33920
General
- If water leaks occur after bodywork repairs, the cause can be established using
the checks described below. A systematic and logical procedure is required to
locate water leaks. Before beginning extensive checks, a thorough visual
inspection must be carried out.
- Visual Inspection
 The following characteristics may indicate existing leaks:
 Check the clearance and accurate fit of ancillary components such as the
hood, tailgate, doors, and so on.
 Check for correct fit and possible damage to sealing elements such as
blanking plugs, rubber door seals, and so on.
 Check water drain holes for unhindered flow.
- Various tests can be used to provide further information on possible leaks:
 Water test
 Washer test
 Road test
 Test with UV lamp
 Special mirror test
 Chalk (powder) test
 Flow tube (smoke) test
Practical execution of tests and checks
Water test
NOTE: Never aim a jet of water directly at a rubber seal.
- Carry out the water test with a second person present (passenger
compartment).
- Use variable washer nozzles (concentrated water jet to fine spray mist).
- Start in the lower section and spray the whole area, working upwards in stages.
- The following are suitable for the water test:
 softened water (liquid soap additive)

Page 2 of 20
 Special mirror
 Test with UV lamp
Washer test
- Further tests can be carried out in the washer system.
- Some leaks originate here, or only occur here.
- The relevant passenger compartment should be checked using a torch during

the wash procedure.
Road test
- If no leaks are located during the tests above, road tests should be carried out
on wet roads.
- Road tests under various conditions:
 At various speeds.
 On various road surfaces (asphalt to cobbles).
 With loaded or unloaded vehicle.
 Driving through puddles (splash water).
Test with UV lamp
- Wet the test area with clear water from the outside.
- Prepare test liquid (see Owner's Handbook) and apply it from the outside using
a suitable water sprayer.
- Illuminate the relevant area from the inside using the UV lamp.
- The test liquid will make the leak visible.
UV lamp
- Benefits of the UV lamp:
 No need to dry out wet areas before the test.

Page 3 of 20
 The ingress of water and its subsequent path can be identified precisely.
 No need to remove most ancillary components from the vehicle.
Special mirror test
The special mirror can be used to see into hard-to-reach areas.
Special mirror
Benefits
- A switchable light is built into the mirror area.
- The angle of inclination of the mirror can be set manually using the handle.
- The connector between the handle and the mirror is flexible.
Chalk test (powder test)
- In this test, the clamping load and the bearing surface of the seal are checked.
- Performing the test:
 Dust the door seal with powder or coat with chalk.
 Coat the bearing surface of the seal with a thin film of grease.
 Slowly close the door and open it again.
 Check the width and continuity of the imprint on the door seal.
Flow tube test (smoke test)
- Test for locating leaks.
 Set the interior ventilation to the highest setting.
 An assistant creates smoke in the test area (interior) using the flow tube.
 A second assistant locates points at which the smoke escapes on the outside.
Other test equipment

Page 4 of 20
- Other equipment such as stethoscopes or ultrasound measuring instruments can

be used to locate leaks.
Rectifying the leak using recommended tools, auxiliary equipment and

materials
- Tools and auxiliary equipment:
 Dry, absorbent cloths
 Variable washer nozzle
 Torch, fluorescent tube
 Mirror
 Compressed air
 Seal lip installer
 Wet/dry vacuum cleaner
 Sealing compound compressor
 Remover for interior trim
 Cutter blade or pocket knife
 Wedge (wood or plastic)
 Hot air blower
 UV lamp
 Special mirror for concealed leaks
 Stethoscope
 Air flow checker
 Ultrasound measuring instrument
- Materials: (refer to spare parts microfiche)
 Sealing compound (tape and plastic compound)
 Multi-purpose sticker
 Clinched flange sealer
 Window sealing compound
 Water shield (PVC)
 Foam watershield
Page 5 of 20
 Double-sided adhesive tape for water shield
 Butyl tape for foam watershield
 Methylated spirit (available from trade outlets)
 PU adhesive
 Silicone remover
 Tar remover
Water leaks according to mileage or running time
Increasing mileage has an effect on the problem of leaks in a vehicle. Possible influencing
factors are:
- Servicing and maintenance of seals:
 No maintenance, lack of maintenance or incorrect maintenance
 Using an incorrect agent
- Damaged seals:
 As a result of aging, wear or incorrect handling/assembly.
- Heavy soiling of the vehicle:
 Heavy soiling of a vehicle can seriously impair the function of water drainage
channels in particular, and also of rubber seals.
- Age-related factors:
 Environmental factors
 UV radiation
 Extreme climatic conditions
- Corrosion can have a serious impact on bodywork, in particular as a result of:
 Lightly or heavily rusted seal carriers
 Rusted body seal welds
 Perforation corrosion
Water leaks after body repairs
If a vehicle develops a leak after body repairs, the following points must be taken into
consideration in particular:
- The correct seating of ancillary components and their seals (e.g. rear lamps,
etc.) must be checked.
Page 6 of 20
- The correct alignment of doors and luggage compartment lids/tailgates must be

checked. The associated seals must not be damaged and must be installed
correctly.
- Check that welded seams are correctly sealed.
- The correct seating of rubber grommets must be checked.
- The seals of windows fitted using rubber seals must be installed precisely and
make contact all the way round.
- Directly-glazed windows must have correct and complete bonding.
Water drainage system
If a vehicle develops water leaks, then areas into which water is routed or drained should be
checked first.
Water drainage systems

1 - Water drainage, front
Page 7 of 20
2 - Water drainage, side and rear

3 - Sliding roof drainage
4 - Drainage water tank
Water leaks, diagnosis and corrective action: Front passenger compartment
Windscreens (rubber fitted)
- Diagnosis:
 Ingress of water into A-pillar area
- Cause:
 An old or incorrectly fitted seal can cause insufficient or irregular clamping

load of the rubber seal on the windscreen or window frame. This results in
water ingress between the rubber seal and the windscreen or between the
rubber seal and the window frame.
- Corrective action:
 Seal the problem area using window sealing compound between the rubber
seal and the windscreen, or between the seal and the window frame. Wipe off
excess sealing compound immediately.
 If a new leak is found after the necessary leak check, then the rubber seal
must be renewed.
Windscreen seal

1 - Window frame seal
2 - Window seal
Windscreens (directly-glazed version)
- Diagnosis:
 Ingress of water into A-pillar area or instrument cluster area
- Cause:
 Breaks in adhesive beads
Page 8 of 20
NOTE: The repair must be carried out in line with approved methods
(service microfiche/TIS CD group 42/501-11).
 The breaks in adhesive beads can be located from inside by using compressed
air. The leak can be identified from outside by the escaping air.
 The second test method is by means of a water test. The outer cover must
also be raised carefully using a plastic wedge. The leak should be located from
inside by a second assistant.
Diagnosis of a water leak

1 - Compressed air test
2 - Water test
Side windows
In the case of fixed side windows (rubber fitted or directly glazed), the same problems can
arise as for a windscreen. The same corrective actions must therefore be used.
Side windows
Door seal
- Diagnosis:
 Water ingress in the lower part of the interior door trim or in the rocker panel
area.
- Cause:
 The water shield or foam watershield fitted behind the interior door trim
exists to drain off water that has entered the door via the drainage holes,
either downwards or outwards. If the water shield or foam watershield is
damaged or has been fitted incorrectly, then water can get into the passenger
Page 9 of 20
compartment.
 In addition to this, the drainage holes can become clogged with leaves, dirt or
excess cavity protection agents. Water gathers in the door and ingresses into
the passenger compartment.
NOTE: If a water shield or foam watershield becomes damaged in any

way, then it must always be renewed.
 Check water shield or foam watershield for damage or correct fitting.
NOTE: When detaching a foam watershield, the butyl tape must be cut
with a knife.
 If the water shield needs to be re-bonded, then double-sided adhesive tape
must be used. Butyl tape is used for the foam watershields.
 Before the water shield or foam watershield is installed, the drainage holes
must be checked for unhindered flow.
NOTE: When installing the butyl tape, do not touch the mating surface
(this impairs the adhesion).
 Detach the interior door trim.
Door seal

1 - Drainage holes
2 - Foam watershield
3 - Interior door trim
Door seals
- Diagnosis:
 Ingress of water into the rocker panel area
- Cause:
 Insufficient clamping load between seal and door.
 Check clamping load:
 The easiest way to check the clamping load of a seal to the respective bearing
Page 10 of 20
surface is by means of a paper strip test. This consists of trapping strips of

paper at various points between the door and the seal, and fully closing the
door. If it is possible to pull out the paper with no great resistance, then the
clamping load is too low.
 Adjust the clamping load:
NOTE: When adjusting the clamping load, the edge alignment of the
relevant components must always be taken into consideration.
 The clamping load is normally adjusted using the striker. When doing so, the
edge alignment from the door to the side panel, or from the front door to the
rear door must be taken into account.
 Another setting method is to realign the panel flange for the seal mounting.
The clamping load is increased by moving the flange towards the door.
NOTE: Do not realign the flange too far in the direction of the door, as
this can reduce the bearing surface of the seal to the door.
 Check the bearing surface:
 Apply chalk evenly to the surface of the seal. Evenly coat the bearing surface
of the door with vaseline.
 Close the door fully, the lock must engage. Open the door. The imprint of the
chalk (bearing surface) can be identified in the film of grease.
 The bearing surface should be at least 5mm across at all points.
Checking the seal

1 - Panel flange bent too far inwards: small bearing surface
2 - Panel flange adjusted correctly: correct bearing surface
3 - Check clamping load with a strip of paper
- Other causes:
 The door seal must completely seal the door where it meets the bodywork.
 Water can ingress directly or indirectly into the interior of the vehicle if the
seal is damaged at any point.
Page 11 of 20
 A damaged or worn door seal must always be renewed in full.
 When renewing the seal, the following must be taken into account:
 Always fit the seal first in the area of the narrow radii (corner points).
 Next, secure the seal to the flange evenly by tapping lightly with a rubber
hammer. The installed seal must not be kinked at any point.
NOTE: The prescribed length of a seal must not be shortened.

Correct installation of the door seal
- Other cause:
 The door seal is attached to the welded flange all the way round. If this
welded flange is uneven or damaged at any point (usually in areas with
narrow radii) then this point could be subject to leaks.
 A stretched seal carrier can also cause a leak.
 In both cases, water gets into the vehicle interior under the seal carrier.
 Align the deformed welded flange using a hammer and anvil block, prevent
and if necessary repair any paint damage.
NOTE: If the seal has a connecting joint, this must always be at the
bottom of the door surround.
 A stretched seal carrier must be realigned by hand. If this is no longer
possible, the seal must be renewed.
Door seal leaks

Page 12 of 20

1 - Correct seal carrier
2 - Stretched seal carrier
3 - Seal on connecting joint
Sliding roof/tilting roof
- Diagnosis:
 Ingress of water at sliding roof aperture
- Cause:
 The sliding roof/tilting roof is installed in a water trap. The water drains off via
the water trap, water drain holes and drain hoses. The drain hoses lead
downwards on both sides via the A-pillar and C-pillar.
 The drain holes or drain hoses can become clogged with leaves, dirt,
underbody protection and so on.
NOTE: In the case of a sliding or tilting roof, the external rubber seal and
the lock actuator or latch mechanism must be checked first of all.
 Check the water trap for leaks.
 Check the drain hoses for leaks and for correct connection to the water trap.
 Check the drainage system for unhindered flow, and blow out with
compressed air if necessary.
 Check the external seal and the correct adjustment of the sliding roof.
Sliding roof/tilting roof

Page 13 of 20

1 - Roof
2 - Roof moulding
3 - Water trap with drainage flow
Apron panel and heating/ventilation
- Diagnosis:
 Ingress of water into the front footwell area
- Cause:
 The apron panel is sealed in several places to adjacent components, such as

at the joints to the A-pillar or to the floor pan. These seals can be broken.
 The heater and ventilation housing is attached to the apron panel. The
through area is sealed with a foam watershield that is fixed to the housing.
 The housing has drain holes to allow the water to drain off.
 If the foam watershield is defective or the drain hole is clogged, water can
ingress into the front footwell area.
Heater and ventilation housing seal

Page 14 of 20
 Seal the broken seal welds.
 If a leak is found in the heater or ventilation housing, the drain holes must be
checked first.
NOTE: Damaged foam watershield must always be renewed.

 The housing may have to be removed to check the foam watershield and its
bearing surface for damage.
Checking foam watershields and water drain holes

1 - Foam watershields
2 - Water drain holes
- Other causes:
 Fastening bolts and routing holes for cables and hoses must be checked for
leaks in the area of the apron panel and instrument cluster (rubber grommets
in particular).
 If the footwell area is wet, then the door hinge seal, the door light switch and
cable routing holes must also be checked.
Door light switch seal

Page 15 of 20
Rear drip rail seal
- Diagnosis:
 Ingress of water into side headlining area
- Cause:
 The roof outer panel is sealed with a seal weld at the connection point to the
side panel. This seal weld can be concealed with a bezel or trim strip.
 In the case of estate and hatchback vehicles, there is an additional seal to the
rear roof crossmember.
 Water can enter here if there is a break in the seal weld.
 Remove trim strip or bezel. Check and re-seal the seal weld.
Drip rail seal
Luggage compartment seal
- Diagnosis:
 Ingress of water into the luggage compartment
- Cause:
 The luggage compartment lid seal corresponds to the door seal.
 If there is a water leak, the seal must be checked for damage and the seal
carrier must be checked for correct seating.
Page 16 of 20
 The clamping load and the bearing surface of the lid must also be checked for
leaks.
 The adjustment of the lid is made using the lock striker or the lock.
 Rubber bump stops are attached to both sides of the luggage compartment
opening. These are normally adjustable, and the clamping load can be
modified.
 The narrow radii of the luggage compartment lid seal are also problem areas.
Check the seal for correct installation position
- Other cause:
 The seal is not attached evenly around the lid because of a deformed or
uneven welded flange.
 Check the seal and bearing surface.
 Re-align a deformed or uneven welded flange.
Uneven welded flange.
- Other cause:
NOTE: The seal carrier covers a defective weld.

 Leaking weld on welded flange (melted through). Water can ingress into the
luggage compartment under the seal carrier.
Page 17 of 20
 Pull the seal from the seal carrier.
 Seal the leaking weld using sealing compound.
Welds melted through
Tailgate
- Diagnosis:
 Ingress of water into rear headlining area
- Cause:
 The leak problems of the tailgate correspond to those of the doors.
 In addition to this, the area to be sealed is much bigger. The routing holes for
cables and hoses must also be sealed.
 The rubber grommets for the routing holes must be checked for damage and
correct seating (fully unhooked).
 The mounting points of the tailgate hinges may leak.
 Check the rubber grommets and renew if necessary.
 Check the hinge mounting points, and re-seal with sealing compound if
necessary.
Check the routing holes for rubber grommets, cables and hoses
Page 18 of 20
Forced air extraction
- Diagnosis:
 Ingress of water into side luggage compartment area
- Cause:
 The forced air extraction for the vehicle interior is often located in the lower
side panel area of the luggage compartment. The ventilation housing is sealed
with a foam watershield on the bodywork side.
 The rubber flap of the forced air extraction must be able to move freely.
 Remove the forced air extraction. Detach the bumper if required.
 Check the seal area between the bodywork and housing, as well as the rubber
flap.
 Renew a damaged foam watershield if necessary.
Check the seal for the forced air extraction.
Rear window
- Diagnosis:
 Ingress of water into the luggage compartment area
- Cause:
 Rear window leaking.
 Check for leak in the same way as for leaking windscreen.
Rear lights
- Diagnosis:
 Ingress of water into rear luggage compartment area
- Cause:
Page 19 of 20
 Rear lights are leaking. There are two sealing methods:
 Sealing with a foam watershield
 Sealing with plastic sealing compound
 If a rear light has a leak, this usually means that the seal was fitted
incorrectly.
 Remove the rear light. Check the housing and glass for damage. Check the
plastic seal for leaks.
NOTE: The sealing compound must always be removed during repair work.
Check the seal for the rear lights
Panel connections with seal welds
- Diagnosis:
 Ingress of water into the luggage compartment area
- Cause:
 Several panel connections must be fitted in production in the wheelhouse and

luggage compartment areas. These connections are sealed with sealing
compound.
 Uneven application of sealing compound can lead to a break in a seal weld.
 Expose the seal weld.
 Locate the leak in the seal weld.
 Re-seal using sealing compound.
Possible water leaks at the panel connections in the luggage compartment

Page 20 of 20
Page 1 of 9

WIND NOISE
UID=G33923
General
Vehicle noises when driving cannot be avoided. The aim of all development efforts is to
reduce wind noise. The quieter that noise producing components such as the engine, drive
train, tyres etc. become, the more the wind noise at high speeds will be heard.
Apart from general wind noise, some noises can arise which are heard as an irritating hissing
or whistling. The causes of these noises may be partly caused by production or repair factors.
They are mostly caused by poorly mounted components, which must be located and installed
in the correct position.
Most noise experienced in the vehicle interior is wind noise. As speed increases, the level of
sound in the vehicle interior increases with it.
Normal air flow noises
At high speed, as air flows past uniform flat surfaces such as the roof, side windows, etc.,
turbulent air layers form, in which air pressure variations occur. Part of this pressure variation
spreads in the form of sound waves and is transferred to the vehicle interior by the side
windows and seals. Here the noise is particularly loud because of the closeness of the side
window to the driver or passenger. The noise experienced is mostly a low roaring, which
becomes louder as speed increases.
Noises caused partly by changes in the direction of air flow and by air flow
around separate components
If air flows over an edge on a vehicle, the air flow cannot fully the contour of the surface, and
it breaks up at the edge. Eddies are formed, which collapse again after a certain time or
distance.
Change in the direction of air flow

1 - Eddy
2 - Sound wave
3 - Flow
The build-up and decay of turbulence and the associated pressure changes lead to creation of
sound waves. A similar effect can be observed at the A-pillar on a vehicle. Here the area
where eddies are usually formed is directly above the side window. This makes it easy for the
noise (roaring) to be passed to the vehicle interior.
Page 2 of 9
Eddy current zone

1 - Air flow
2 - Build up of eddies
Eddy currents are also formed underneath the vehicle, and so associated noise is also
produced. When air flows past smaller components or through smaller gaps (such as the
radiator grill), the roaring noise becomes a whistling, which increases in pitch and becomes
louder as speed increases.
Noise caused by vibrating seals
Seals which are not making firm contact in the window and door areas can also lead to
vibrations caused by pressure variations on the outside of the vehicle which then means
transfer of noise into the vehicle interior. The vibrating part of the seal operates here in the
same way as loudspeaker membrane.
Origin of vibrations (diagram)

1 - Vibrating seal
2 - Radiation into the vehicle interior
Escaping noises
Page 3 of 9
Small leaks in the vehicle interior sealing system allow small currents of air to enter. This
leads to the creation of "free stream noise" (a stream of air mixes with still air and in doing so
causes turbulence). The loudness of free stream noise increases strongly with increasing
escape speed and can be heard as a hissing noise (for example, letting the air out of a tyre).
Cavity noises
If a bodywork cavity is open to the outside of the vehicle, this can cause the air volume in the
cavity to resonate. The note produced depends on the volume of the cavity and the size of
the opening. (For example, making a note by blowing across the top of a bottle).
Wind noise with the sliding roof open
Problem:
- When the sliding roof is open at about 60 km/h a low frequency noise is
produced (drumming).
Cause:
- When the sliding roof is fully open, perceptible air pressure variations occur
inside the vehicle because of the air current over the opening.
Corrective action:
- At speeds above about 60km/h, close the sliding roof slightly until the
drumming noise is no longer heard.
Wind noises from the door seals
- Because of the air currents passing by the sides of the bodywork and over the
roof, the pressure outside is slightly lower. Because of the heating and ventilation
system the pressure inside the vehicle is slightly higher. This pressure difference
causes, for example, the doors to lift away from the seals by several millimetres
at certain speeds. If there is also a side wind affecting the moving vehicle, this
effect is increased.
- The resulting differences in gap are compensated for by the use of flexible door
seals (when the door seals are intact).
Routes by which external sound is transferred to the inside of a vehicle

Page 4 of 9

1 - Interior ventilation
2 - Windscreen seal
3 - Door window seal
4 - Sliding roof seal
5 - Door seals
6 - Boot lid seal
7 - Interior ventilation
8 - Door handles
Wind noises
Overview
Type of wind noise Where do they arise?

Normal Normal air flow noises Roof, side windows
Noises caused partly by changes in the A-pillars, side mirrors,
direction of air flow and by air flow antennas, windscreen
around separate components wipers
Serious Noises caused by vibrations seals Door gaps too wide,
door/window seals not
seated firmly
Air escape and air passage noises Leaks in the bodywork
sealing system
Cavity noises Unsealed bodywork
cavities
The factors listed under
"serious" require
corrective action.
Summary
The creation and intensity of wind noise on a vehicle depends on the fundamental shape and
structure of the different components.
There are two subjective evaluation and service diagnosis methods in which sound levels can
be reduced and sound nature improved in a vehicle interior:
- Reduction in the intensity of the noise sources
- Reduction of the transmission routes

Page 5 of 9
In order to achieve a general improvement in the wind noise situation in the vehicle, both
factors must be taken into account.
The sealing systems of the doors, windows and tailgate have a major influence on the
acoustic comfort in a vehicle.
Problem sources in practice
Seal on driver and passenger door
- Diagnosis:
 Wind noise from the door seal at the top
- Cause:
 The alignment of the door frame to the roof is incorrect
 Re-align the door with the side window open
 Check the door seal to sealing surface contact area. The width of the sealing
area must be at least 5mm.
The correct gap between the door and A-pillar or door and roof
Adjustment of the tailgate
- Diagnosis:
 Wind noise coming from where the roof meets the top edge of the tailgate
- Cause:
 Tailgate is set too high
 Loosen the tailgate where it is attached at the hinges and move the tailgate
further down. When doing so, pay attention to the gaps with adjacent
components.
 Reset the lock if necessary.

Page 6 of 9
Tailgate too high
Sliding roof adjustment
- Diagnosis:
 Wind noise from the sliding roof
- Cause:
 Sliding roof incorrectly adjusted
 Adjust the sliding roof according to the following requirements:
 There must be an equal gap all round the sliding roof.
 The sliding roof must be adjusted to suit the roof contour.
 The front edge of the sliding roof should close flush with the top face of the
roof itself, or slightly lower.
 The seal around the sliding roof must touch it evenly all round.
Correct installation of the sliding roof

Page 7 of 9
Adjustment of the right-hand windscreen wiper arm
- Diagnosis:
 Wind noise from the area of the right-hand windscreen wiper
- Cause:
 Windscreen wiper arm is set too high
 Free the wiper arm from its shaft and adjust it so that it lies below the air
turbulence which exists at the wind guide plate when it is in its rest position.
Adjustment of the wiper arm

1 - Too high
2 - Correct
Sequence for performing a wind noise diagnosis (diagram)
1. Customer concern
Page 8 of 9
 What is the customer concern and what details can he supply about the wind noise?
2. Under which conditions does the wind noise appear?
1. Sequence A: A diagnosis is possible based on the details supplied by the customer.

* Carry out corrective measures to remedy the wind noise.
* Road test the vehicle to check that the concern is resolved. The vehicle must be driven in the exactly same way
as when the wind noise was produced earlier.
* If the corrective measures based on the information supplied by the customer were not successful, further
testing must be carried out in the workshop (see sequence B).
2. Sequence B: A diagnosis based on details supplied by the customer is not possible

* Test for faults in the workshop, referring to any TSB (Technical Service Bulletin) which may be relevant.
* Visually check external seals, check gaps.
* Visual check: Have any components been fitted to the vehicle after manufacture or has the vehicle been
repaired after an accident?
* Perform a diagnosis based on the road test.
* Carry out corrective measures based on the diagnosis.
* Perform another road test. The vehicle must be driven in the exactly same way as when the wind noise was
produced earlier.
* If this road test does not show that the work has been successful, additional techniques such as powder testing,
stethoscope testing or ultrasonic detection must be employed.
Workshop diagnosis
Before repair work is carried out, a visual check of the vehicle must be performed, paying
special attention to the fit of the doors. When the doors are adjusted to fit exactly,
development of wind noise can often be eliminated at high speeds (lifting of doors off the
seals).
Stethoscope testing
- The stethoscope is a simple and appropriate tool for finding bodywork air leaks.
If the blower is turned on at the highest speed and all the doors, windows and
other openings are closed, the air pressure inside the vehicle can be made higher
than that outside. The outside of the vehicle is then checked for streams of
escaping air.
Powder test
- By coating the contact surface of the door seal with white powder, door seals
that do not make close contact can be found. To do this, the door is carefully
closed and re-opened. In this way, the sealing surfaces which do not touch will be
visible.
Ultrasonic detector
- It is also possible to detect leaks using an ultrasonic detector and a tone

generator. To do this, the ultrasonic tone generator is put inside the vehicle and
the outside of the vehicle is tested using the detector tuned to the generator. The
detector will quite easily show any leaks present.
Page 9 of 9
Road tests
- The causes and origins of wind noises can often be located by a road test.
Attention should be paid to the following points:
 Choose a dry, flat and straight road with as little traffic as possible.
 Make sure that the tyres are at the correct pressure, to avoid tyre noise.
Driving technique
- Perform the road test at all speed ranges, using the highest gears (fourth or
fifth).
- The road test should be performed by two persons, and different seating
positions should be tested.
- Prepare the vehicle as necessary (use adhesive tape to blank off areas).
- Pay special attention to door openings and door seals during the road test.
Page 1 of 8

PAINTLESS DENT REMOVAL
UID=G33926
General
Small minor dents can be repaired without damage to paintwork. The dent is worked from the
inside using special levering tools (pressure tools). The pre-conditions are that the diagnosis
is certain, the correct repair method is identified and that the technician has enough
experience in the use of the special tools and knowledge of the working materials.
- This option is limited to those bodywork surfaces which are accessible from both
sides. This repair technique is seldom possible on double skinned bodywork
components or closed bodywork profiles. The same applies to edge areas, beads
and folds in bodywork components which are very rigid.
- Satisfactory results are only possible for minor dents that are shallow and with a
small deformation radius. This method is therefore particularly suitable for
damage arising from hail, parking and transport.
Economic considerations
- Whether it is economically worthwhile to carry out paintless dent removal

depends on:
 The area and depth of the dent.
 Access to the repair area.
 Rigidity of the repair area.
 Suitability of the material
 The number of dents over a particular body panel area.
 Whether there is already any paint damage present
Extent of the damage
The repair method is suitable for dents up to approx. 50 mm diameter.
Damage assessment according to the size of the dent

Page 2 of 8

1 - Centre of the dent
2 - Edge of the dent
Pre-requirement for the repair
The material at the centre of the dent must not have stretched.
Repair procedure
- Diagnose the damaged area.
- Mark the dent.
- Prepare the area to be repaired.
- Put the adjustable lamp in position.
- Reshape the dent.
- Renew the corrosion protection.
- Carry out quality control.
Repair tools/aids
- Special dent removal levering tools
- Adjustable lamp
Repair Procedure
1. Decide on the repair method.

Page 3 of 8
2. Mark the dent
NOTE: Do not use a pen containing solvent (paint damage).

 The dent is marked in the repair area to help recognition.
3. Prepare the repair area
 It must be certain that the inside of the dent is accessible. Repair openings must not be
made.
 Clean the bodywork in the damaged area. Good visual checking is vital to success.
 Polish the repair surface if it is matt. The repair procedure can only be checked exactly if
there is enough reflection of light.
4. Place the adjustable lamp in position.
 The adjustable lamp should be positioned and adjusted so that the dent can be clearly
seen in the reflection on the paintwork (oval shape).
 When pressure on the dent is increased the oval shape changes into lines which cross
over each other. The point where the lines cross is the pressure point for the pressure
tool.
Light reflection when pressing

1 - No pressure on the dent
2 - Pressure applied to the dent
5. Position the pressure tool
 Position the tip of the pressure tool on the edge of the dent.
 By moving back and forth with light pressure applied on the dent with the tip of the tool,
the reflected light shows the position of the pressure tool.
6. Working principle while applying pressure
 The operation concentrates on forming a half circle, working chronologically.
 To restore the surface, all that is needed is to work on one half of the dent.
 The unworked half of the dent restores on its own, through tension produced by the
pressure.
Page 4 of 8
Diagram

1 - Sequence of pressure
2 - Starting position
NOTE: Never begin in the centre of the dent. If a dent is worked from the centre first, the
edge will be lifted up and will remain visible as a high area (material stretching). This
lifted edge can only then be restored by lengthy reworking.
High edge

1 - High edges
2 - Pressure tool
- Exception:
 Sharp edged dents with minimal material stretching are first worked on at the
centre.
 After pressing out the dent, slightly raised areas can be seen. This is caused
by the excess steel in the centre of the dent, caused by material stretching.
 Use a plastic drift to even out the slightly raised area.
Unstable pressure area
If large, relatively weak body areas are worked on, the path of the pressure tool while
pressure is applied is correspondingly larger. The restoration process takes longer.
Large area dent

Page 5 of 8

1 - Reforming path
2 - Pressure tool
Stable pressure area
-
NOTE: Work areas near internal reinforcing with only light pressure, so that
high areas are not formed (material stretching).
Stable pressure bodywork areas with inner braces have a much more stable
surface than weak pressure areas. Only short pressure movements are required
here because the steel of the bodywork is less sprung.
- Particular care must be taken with the pressure procedure if tools with a small
contact face are used.
- Optical check:
 It is only possible completely to remove all remaining unevenness by making

continual visual checks of the surface using the adjustable lamp. In addition,
towards the end of the pressure procedure, the dent must be checked several
times from different directions. To do this, change position by about 90°.
Pressing out a dent near a brace

1 - Roof surface
2 - Pressure tool
3 - Adhesive bead
4 - Roof brace
Accessibility of individual bodywork components
Roof area
Support (pivot) of the pressure tool using an S-shaped hook

Page 6 of 8

1 - Pivoted using an S-hook
2 - Pressure tool
- In order to make it possible to exert force in the roof area, a pivot in the form of
an S-hook must be used.
- Only loosen the headlining locally, depending on the number of dents and their
location.
- Dents near interior components can be reached by removing the component

(interior lamp).
- Check accessibility before starting repair work if the dent is near the sliding roof.
- Repairs near inner braces are worked using the special tools found in the tool
kit.
 Separate the adhesive bead of the brace using a metal spatula, so that the
pressure tool can be put in position.
Special lever for dents near inner braces.

1 - Contact point
2 - Direction of movement
Door area
- Dents in the upper half of the door can usually be worked on without removing
the inner trim.
- When the window is open, access is obtained through the window cavity. A
protective assembly is inserted into the window cavity to prevent damage to the
window.
Page 7 of 8
- The plastic wedge ensures access.
Equipment

1 - Protective assembly
2 - Plastic wedge
- The pressure is applied in this case without use of an additional support by

simply turning the bent pressure tool.
Pressing out a dent through the window channel.
Hood
- The hood is moved into working position using telescopic struts and held in
position using the "rubber cords".
- In the region of the braces the adhesive bead must be partially opened using a
metal spatula to give access to the dent.
Renewal of the corrosion protection.
- All repair inner areas must be reworked, where accessible the paintwork must
be refinished.
 Clean the inner area with silicone remover.
 Prime and paint the inner repair area.
 Finally, spray in cavity protection where the repair is not accessible.
Quality control
Page 8 of 8
- In order to achieve a repair quality that meets production standards, the

following points must be observed:
 Check the repair area for unevenness. Do this optically by looking at the
surface from different angles.
 Paint the repaired surface area, clean it and polish it if necessary.
 Check that the attached components and inner trim are seated correctly and
are not damaged.
Page 1 of 10

NOISE, VIBRATION AND HARSHNESS
UID=G33929
Introduction
This chapter gives an overview of how noise, vibration and harshness (NVH) can be produced
in a vehicle, and which corrective measures are possible.
What is understood by NVH in vehicle technology
N = Noise - Sound, can be heard
V = Vibration - Oscillation, can be felt
H = Harshness - Roughness, can be heard and felt
Types of noise in NVH technology
- Noises in a vehicle are classified by their notes:
 Low notes - growling, droning
 Mid-pitch notes - buzzing, whirring
 High notes - howling, whistling, squeaking
- Loud howling and whistling is painful to the ears.
Where the different notes come from in a vehicle:
- Low notes are mostly produced by the engine.
- Low notes are also caused by the road surface, especially if the surface is rough.
This is a form of droning which can be felt by the vehicle occupants as vibration or
roughness.
- High notes however, which are experienced as howling or whistling noises are
often air currents (wind noise) or come from attached components such as the
generator, power steering pump or drivebelt.
- There are also clattering noises which can occur when driving over an uneven
road. These jerking noises are produced by, for example, the shock absorbers,
chassis components or loose articles inside the vehicle.
Noise transmission through air
Spreading of sound waves in the air

Page 2 of 10

1 - Sound source e.g. Engine
2 - Sound wave
3 - Amplitude
- The sound is spread by longitudinal waves in the form of pressure changes in

the air.
Sound transmission through a body
Sound is passed through liquids or solids e.g. through the car bodywork.
The speed of transmission (speed of sound) in liquids or solids depends on the material, but is
generally faster than that in air (about 5 times faster).
Combination of transmission through air and bodies
NOTE: Sound transmission through both air and bodies is of prime importance in vehicle
technology.
Noise transmission in a vehicle

1 - Sound through air
2 - Sound vibrations
Page 3 of 10
- Example
 The source of the noise is the engine Engine noises are:
 radiated directly through the air
 transmitted as vibrations from the engine to the bodywork and radiated into
the passenger compartment as air borne sound, for instance by the
bulkhead,.
Vibration technology
- Frequencies below 20 Hz (low frequencies) and those above 20,000 Hz (20 kHz;
high frequencies) are not heard by the human ear.
- The engine is made to oscillate vertically in its flexible mountings by unevenness

in the road.
- Engine mountings which are not tuned will transmit oscillations to the bodywork
and hence to the occupants.
- The following basic rules apply:
 In vehicle technology, not only audible frequencies but also inaudible (low)
frequencies must be considered.
 Low frequency oscillations can usually be seen (large amplitudes).
 High frequency vibrations can be heard, but will also be felt as vibrations in
the floor, steering wheel or seat.
Resonance
- Every body has a natural frequency of vibration.
- If a system able to vibrate (a vehicle) is excited at its natural frequency of

vibration, it will start to resonate.
- Uneven engine running appears for instance when the resonant frequency is
reached (critical engine speed).
- Once the engine speed increases above this speed, the engine will very soon run
smoothly again.
Damping
- If a damper is installed parallel to a spring, the damping characteristic acts to

reduce the movement of a body.
- This is also the way in which a shock absorber on a vehicle works.
- Damping affects the resonance of an object or system.
- The mass being moved is damped by a correctly operating shock absorber, so

that shaking of the bodywork stops immediately.
Page 4 of 10
- The shock absorber in a vehicle is an oscillation damper, which allows the

bodywork to oscillate in a damped manner.
Oscillation

1 - Undamped oscillation
2 - Damped oscillation
Isolation
In oscillation technology, the term isolation means decoupling (separation) of components

and systems.
- Example:
 An engine is mounted in sprung elements, so that as little oscillation as

possible is passed to the vehicle.
 In automotive technology, the isolation technique used is nearly always

rubber mounting. The elasticity of the rubber acts like a spring.
 The effectiveness of this type of decoupling depends on the construction of

the component.
Directional loading of a rubber mounting in order to achieve optimum isolation

Page 5 of 10

1 - Engine
2 - Engine mounting
Absorption
- Sound waves are reflected from hard surfaces
- If they meet soft surfaces, they are absorbed. Here both the material and the
material thickness play important roles.

1 - Reflection of sound waves
2 - Absorption of sound waves
- Example:
 All sound deadening components such as door trim, carpets, headlining,

parcel shelves and the seats are removed from a vehicle.
 The result of this is that the sound is directly reflected (the sound level rises),
and a concert hall effect is produced.
Noise and oscillation behaviour in a vehicle
The occupants of a vehicle experience different levels of sound or noise depending on where
Page 6 of 10
they are sitting.
Sound/noise wave (standing wave) in a vehicle

1 - Driver sits in a "wave calm"
2 - Rear passenger sits in a "wave swell"
Noise and oscillation behaviour of intake and exhaust systems
The vehicle intake system as an air borne sound and solid body sound source
The vehicle exhaust system as an air borne sound and solid body sound source
Page 7 of 10
- Ways in which sound is transmitted
 The top illustration shows the ways in which sound can be transmitted from
intake and exhaust systems.
 Apart from air borne sound, solid body sound is predominant in both systems.
In order to keep this proportion as small as possible, it is necessary for these
type of oscillating components to be connected to the body using stiff
connection points.
 The exhaust system especially is an oscillating component and requires

optimal isolation through its connection to the floor and also good routing and
positioning of the fixing points in order to reduce the solid body sound
transmission.
Intake system
Intake system

1 - Intake manifold
2 - Connection hose
3 - Fixing component (rubber mounted)
4 - Air cleaner
5 - Resonator
- The volume and length of intake systems are matched exactly. No changes may
be carried out during service or repair work. When attaching components (hoses
and tubes), pay attention that all connections are air-tight.
- The surfaces of all components affected by the strong pressure variations in the
intake system are especially subject to strong oscillations.
- The effects of temperature, such as warming of the air filter housing can cause
Page 8 of 10
changes in the rigidity of surfaces.
- In order to prevent solid body sound caused by surface oscillations of the intake
system from being transmitted to the vehicle body, the following points must be
observed during service:
 The whole intake system must be isolated from the bodywork and mounted in
rubber bushes without tension.
 The air channels of the intake system must not contact the bodywork
components.
 Insert foam insulation at points of contact with bodywork or other

components.
Exhaust system
Exhaust system construction

1 - Catalytic converter
2 - Decoupling element
3 - Front silencer
4 - Rear silencer
- Exhaust systems must be installed without strain.
-
NOTE: The rubber mountings in which an exhaust system is suspended also
transmit oscillations and under some circumstances can also cause a noise
problem. For this reason it is important that the exhaust system is installed
free of strain.
The rubber mountings must not be over-stretched.
- The exhaust manifold and catalytic converter (if it is mounted directly at the
engine) must have a solid connection to the engine (no splits in brackets).
- Simple problem testing:
 Remove all mountings from which the exhaust system is suspended.

Page 9 of 10
 Support the exhaust system with rope at two positions at the most.
 Check the noise level in the passenger compartment during a road test.
 If this solves the problem, the exhaust mountings are the source of the noise.
 Put back the exhaust supports one at a time, and road test the vehicle after
fitting each one.
 By proceeding in steps in this way, the mounting that is causing the noise in
the passenger compartment can be found.
Bodywork
Function
- Different types of demand are made on the bodywork of a vehicle, particularly

when it is being driven. Predominant here are vibrations caused mainly by other
vehicle components, such as the engine and mountings. The bodywork is
therefore one of the most important vehicle components where NVF is concerned.
- The vehicle components described so far were, according to their function,

individual self-contained noise sources. The bodywork however, connects and
houses all the vehicle components.
- The bodywork is subject to vibration from both air borne sound and solid body
sound.
- The bodywork must absorb all oscillations and impulses from all components
and if possible transmit none of these to the vehicle interior.
- The largest proportion of NVH behaviour of a bodyshell is in the steel panels of

the roof, sides and floor. They are strongly stimulated by the bodyshell structure
and work like a loudspeaker transmitting noise.
Further demands on the bodywork
- Good crash behaviour
- Large interior space
- Corrosion resistance
- Low weight
- Good aerodynamic shape
A compromise must be made on some of these points. One example is between high body
rigidity for good NVH performance and good energy absorption in an accident by the use of
crumple zones.
Example:
- Watertight does not mean sound tight, therefore the following points must be
taken into account:
Page 10 of 10
 Correct installation of the windows.
 Correct installation of the seals.
- Further points
 Openings into the engine compartment
 Door and window sealing
 Heater and ventilation openings
 Sliding roof drainage hoses
- The side- and crossmembers in the body structure are often linking channels
allowing sound transmission. Possible corrective measures are:
 Installation of dividing walls at critical points such as the joint between the
sidemember and the A-pillar in order to ensure good air borne sound
insulation.
NOTE: Foam pieces and foam filling are used in production to seal air
borne sound transmission routes. If wind, tyre, engine or road noise is a
problem, the position of the pieces of foam should be checked.
 Installation of foam plugs in affected areas.
 Filling hollow sections with foam.

Page 1 of 1

SPECIFICATIONS
UID=G354416
Front Wheel Alignment (at kerb weight)
Tolerance Setting or Maximum variance left or

Derivative
Range Nominal right
Caster angle Degrees and 2°18’ to 4°32’ 3°25’ 1°00'
minutes
Camber Degrees and -2°07’ to 0°39’ -0°44’ 1°15'
angle minutes
Toe-in total mm 0.0 ± 2.2 0.0 ± 1.0 -
Degrees and 0°00' ± 0°21' 0°00' ± 0°10' -
minutes
Rear Wheel Alignment (at kerb weight)
Tolerance Setting or Maximum variance left or

Derivative
Range Nominal right
Camber Degrees and -2°24’ to 0°07’ -1°08’ 1°15'
angle minutes
Toe-in total mm 3.2 ± 2.1 - -
Degrees and 0°31' ± 0°20' - -
minutes
Item Nm lb-ft lb-in

Tie-rod end locknut 63 46 -
Page 1 of 2

BRAKE SYSTEM BLEEDING
UID=G354434
Bleeding
01.
All vehicles
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush
the eyes for 15 minutes with cold running water. Get medical attention if irritation
persists. If taken internally, drink water and induce vomiting. Get medical attention
NOTE: Make sure that the vehicle is standing on a level surface.
NOTE: The system consists of separate circuits for each front and diagonally opposite rear
wheel. Each circuit can be bled independently.

must remain full with new, clean brake fluid
at all times during bleeding.
Install the bleed tube to the bleed nipple.
3. Immerse the end of the bleed tube in a bleed
jar containing a small quantity of approved
brake fluid.
4. Position the bleed jar base at least 300 mm
above the bleed nipple to maintain fluid
pressure and prevent air leaking past the
threads of the bleed nipple.
5. Loosen the bleed nipple by one-half turn.
6. Operate the brake pedal fully (pumping brake
fluid and air into the bleed jar) and allow the
brake pedal to return to the rest position.
7. Fill the brake fluid reservoir to the MAX mark.
8. Continue operating the brake pedal until air-
free fluid is being pumped into the bleed jar.
9. With the brake pedal fully depressed tighten
the bleed nipple.
10. CAUTION: Make sure the bleed

nipple cap is installed after bleeding the brake
line(s). This will prevent corrosion to the
bleed nipple. Failure to follow this instruction
may result in the bleed nipple becoming
seized.
Repeat the procedure for the remaining brake
lines.
Page 2 of 2

01.

11.
Page 1 of 1

BRAKE SYSTEM PRESSURE BLEEDING
UID=G354435
Bleeding
All vehicles
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the
eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush the eyes
for 15 minutes with cold running water. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately. Failure to
follow these instructions may result in personal injury.
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately
NOTE: Make sure that the vehicle is standing on a level surface.
NOTE: The system consists of separate circuits for each front and diagonally opposite rear
wheel. Each circuit can be bled independently.
2. Fill the brake fluid reservoir to the MAX mark.
CAUTIONS:
3. Make sure that the pressure within the

brake system does not exceed 1 bar.
Make sure that the pressure bleeding

equipment is filled with new brake fluid to the
correct specification.
Using suitable pressure bleeding equipment,
pressure bleed the system in accordance with
the manufacturer's instructions.
4. CAUTION: Make sure the bleed nipple

cap is installed after bleeding the brake line(s).
This will prevent corrosion to the bleed nipple.
the bleed nipple becoming seized.
Fill the brake fluid reservoir to the MAX mark as
necessary.

5. Connect the battery ground cable. For additional

Page 1 of 3

BRAKE MASTER CYLINDER — RHD
UID=G354436
Removal
All vehicles
brake booster.
1. Unclip the brake vacuum pipe.
2. Disconnect the brake vacuum pipe.

01.
3. Remove the windshield wiper motor assembly.
Section 501-16.

cap must not become contaminated.
Remove the brake fluid reservoir cap.
5. NOTE: It will be necessary to carry out this
step on both sides in order to completely
drain the brake fluid reservoir.
Drain the brake fluid reservoir.
1. Connect one end of a suitable piece of clear
plastic pipe to the bleed nipple and place the
other end into a suitable container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until all the fluid is
drained from the brake fluid reservoir.
4. Tighten the bleed nipple.
6. Install the brake fluid reservoir cap.

master cylinder.

Page 2 of 3

master cylinder.
All vehicles
9. CAUTION: Cap the clutch master

cylinder feed hose to prevent fluid loss or dirt
ingress.
Disconnect the clutch master cylinder feed hose
10. Detach the brake master cylinder from the

brake booster.
11. Disconnect the low brake fluid warning

indicator switch electrical connector.
12. Remove the brake master cylinder and brake

fluid reservoir assembly.
Installation
All vehicles
CAUTION: Make sure the brake master cylinder vacuum seal is correctly positioned

Page 3 of 3

11.
Page 1 of 2

GEARSHIFT ACTUATOR
UID=G354508
Removal
1. Disconnect the battery negative lead. For
01.
3. Remove the shift actuator cover.
4. Disconnect the shift actuator connector

(black).
5. Disconnect the shift actuator connector (grey).
6. Remove the selector shaft bolt.
7. Remove the bolt from the shift actuator

bracket.
Page 2 of 2
8. Remove the shift actuator.
Installation
2. CAUTION: If part of the hydraulic

clutch system has been opened or new
components have been installed, the shift
actuator bleeding process from WDS must be
performed.
NOTE: As the shift actuator bleeding process
from WDS is performed, the clutch
parameters for the transmission control unit
are read in and stored.
3. Initialise the electric window regulator motor
on the driver's side. For additional information,
Page 1 of 2

CLUTCH ACTUATOR
UID=G354509
Removal
1. Disconnect the battery negative lead. For
01.
CAUTIONS:

the affected area must immediately be
Plug the clutch actuator feed line to

prevent fluid loss and to stop dirt entering.
NOTE: Do not use any tools when separating
the quick-release unions and do not pull or
push hard.
Separate the clutch actuator supply line.
 Press the clutch actuator supply line clip into

the removal position.
3. CAUTION: Do not damage the sealing

lips of the clutch actuator electrical connector.
Disconnect the clutch actuator electrical
connector.
 Open the locking tang of the clutch actuator

4. CAUTION: Plug the clutch slave

cylinder line to prevent fluid loss and to stop
dirt entering.
Detach the clutch slave cylinder line from the
clutch actuator.
 Remove the clip.
5. Remove the clutch actuator bolt.
Installation
Page 2 of 2
2. CAUTION: If part of the hydraulic

clutch system has been opened or new
components have been installed, the shift
actuator bleeding process from WDS must be
performed.
NOTE: As the shift actuator bleeding process
from WDS is performed, the clutch
parameters for the transmission control unit
are read in and stored.
3. Initialise the electric window regulator motor
on the driver's side. For additional information,
Page 1 of 10

INTAKE MANIFOLD
UID=G354519
Removal
00.
01.

05.
6. Remove the intake manifold lower retaining
bolt.
7. Disconnect the engine wiring harness electrical

connector.

(PCV) hose from the PCV.
Page 2 of 10
9. Disconnect the brake booster vacuum line from

10. Disconnect the evaporate emission (EVAP)

hose from the EVAP valve.
11. Disconnect the knock sensor (KS) electrical

connector.
12. Detach the oil level indicator tube from the

intake manifold.

connector.
Page 3 of 10
14. Disconnect the throttle plate control motor

(DC-ISC) electrical connector.
15. Disconnect the generator electrical connector.
16. Detach the generator from the engine.


connectors and position it with the engine
wiring harness to one side.
Page 4 of 10


Section 310-00.

Section 310-00.
21. Detach the fuel line from the intake manifold


Page 5 of 10
23. Detach the wiring harness and the coolant

hose from the intake manifold.

manifold.
25. Remove the intake manifold.
Installation
All vehicles
1. NOTE: Install new intake manifold gaskets.
Install the intake manifold.
Page 6 of 10

manifold.
3. Attach the wiring harness and the coolant hose

to the intake manifold.
4. NOTE: Install new injector O-ring seals.

NOTE: Coat the O-ring seals with clean
engine oil.
Install the fuel supply manifold.

Section 310-00.

Section 310-00.
Page 7 of 10
7. Attach the fuel line to the intake manifold.
8. Connect the fuel injector electrical connectors.
9. Connect the engine coolant temperature (ECT)

10. Attach the generator to the engine.

1. Install the stud and nut.
2. Install the bolts.
Page 8 of 10
11. Connect the generator electrical connector.
12. Connect the throttle plate control motor (DC-

ISC) electrical connector.

connector.
14. Attach the oil level indicator tube to the

intake manifold.
15. Connect the knock sensor (KS) electrical

connector.
Page 9 of 10
16. Connect the evaporate emission (EVAP) hose

to the EVAP valve.

intake manifold.
18. Connect the positive crankcase ventilation

(PCV) hose to the PCV.

connector.
20. Install the intake manifold lower retaining

bolt and the generator bracket retaining bolts.
Page 10 of 10

the bracket.

01.

11.
Page 1 of 2

CRASH SENSOR
UID=G354599
Removal
WARNINGS:
injury.
01.
2. Detach the hood latch from the radiator grille
opening panel.
3. Detach the crash sensor from the radiator

grille opening panel.
4. Remove the crash sensor.

1. Hold the rear of the connector.
2. Slide the cover of the connector rearwards.
Installation
Page 2 of 2
WARNINGS:
Make sure the crash sensor locating tang is correctly located in the radiator grille
opening panel. Failure to follow this instruction may result in personal injury.
injury.
11.
Page 1 of 1

DOOR WINDOW MOTOR
INITIALIZATION
UID=G354604
WARNING: The door window anti-trap function will not operate during the door
window motor initialization procedure. Make sure that the door window opening is free of
all foreign material. Failure to follow this instruction may result in personal injury.
NOTE: After the battery has been disconnected it is necessary to initialize the driver door
window motor.
1. Pull the power window control switch until the
door window is fully closed and hold the switch
in the close position for a further two seconds.
2. Release the power window control switch.
3. Press the power window control switch until
the door window is fully open.
4. Briefly pull the power window control switch to
the second detent and release the switch.
 If the door window does not close

automatically, repeat the complete
procedure.
Page 1 of 1

UNSERVICEABLE AIR BAG DISPOSAL
UID=G354631
WARNINGS:
1. To minimise the possibility of injury in

the event of premature deployment, always
carry a live air bag module with the bag and
trim cover pointed away from the body.
personal injury.
To prevent premature deployment, live

air bag modules must only be placed on work
benches which have been ground bonded.
personal injury.
Remove the unserviceable air bag module. For
additional information, refer to the relevant
procedure in this section.
2. WARNING: Under no circumstances is

an unserviceable air bag module(s) to be
returned through the local mailing system.
personal injury.
Seal the unserviceable air bag module(s) in the
packaging from the new air bag module(s) and
return to the Exchange Plan Center, as
appointed through the local National Sales
Company.
Page 1 of 3

WATER PUMP
UID=G354759
Removal
01.[Battery, Mounting and Cables, GENERAL
PROCEDURES, Battery Disconnect]
4. Remove the crankshaft pulley splash shield.
5. WARNING: Do not remove the water

pump pulley retaining bolts at this stage as
the pulley is under tension from the accessory
drive belt. Failure to follow this instruction
Loosen the water pump pulley retaining bolts.

expansion tank.
8. Detach the coolant expansion tank and secure

it to one side.
Page 2 of 3
9. Remove the generator. For additional

[Generator and Regulator, REMOVAL AND
INSTALLATION, Generator - 1.25L/1.4L/1.6L]
11. Remove the timing belt cover (cover shown

12. CAUTION: Protect the timing belt

and lower cover from contamination by the
coolant.
Remove the water pump.
Installation
All vehicles
1. NOTE: Install a new water pump gasket.

Page 3 of 3
Initialization]
Page 1 of 3

FUEL INJECTION SUPPLY MANIFOLD
UID=G354760
Removal
WARNINGS:
near any fuel related components. Highly flammable vapors are always present and can
in personal injury.
00.
01.
4. Remove the positive crankcase ventilation
(PCV) hose.

connectors and position the wiring harness to
one side.
6. Disconnect the vacuum line from the fuel

pressure regulator.
7. NOTE: Fuel supply line connectors are

white or are identified by a white band. Fuel
Page 2 of 3
return line connectors are red or are

identified by a red band.
Disconnect the fuel supply line from the fuel
injection supply manifold. For additional
8. NOTE: Fuel supply line connectors are

white or are identified by a white band. Fuel
return line connectors are red or are
identified by a red band.
Disconnect the fuel return line from the fuel
injection supply manifold. For additional
9. Remove the fuel injection supply manifold.
10. Remove the fuel pressure regulator.
11. Remove and discard the O-ring seal.
12. NOTE: Discard the fuel injector O-ring

seals.
Remove the fuel injectors from the fuel injection
supply manifold.
1. Lift the retaining clip.
2. Slide the retaining clip.
Page 3 of 3
3. Pull the fuel injector.
13. Remove and discard the O-ring seals.
Installation
All vehicles
WARNINGS:
near any fuel related components. Highly flammable vapors are always present and can
in personal injury.
1. NOTE: Install new fuel injector O-ring
seals.
NOTE: Install a new fuel pressure regulator
O-ring seal.
NOTE: Lubricate the O-ring seals with clean
engine oil to aid installation.

11.
Page 1 of 6

FUEL INJECTORS
UID=G354761
General Equipment
Removal
WARNINGS:
in personal injury.
fuel pressure within the system can be as high as 1600 bar. Failure to follow this
CAUTIONS:
Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic
cleaner. Always install new fuel injectors when required.
injection system components to prevent foreign matter ingress to the components.
01.
01A / 303-01B.
3. Disconnect the glow plug electrical connectors.
4. Clean the fuel injection supply manifold, high-

pressure fuel supply line and surrounding
areas.

Page 2 of 6

line.

7. Install blanking caps to the open threaded
supply manifold.
8. Clean the fuel injector, fuel injection supply
manifold, high-pressure fuel supply line and
surrounding areas.

Detach the high-pressure fuel supply line unions
from the fuel injector and the fuel injection
supply manifold.

supply line, the fuel injector and the fuel
11. Remove and discard the high-pressure fuel
supply line.
ports on the fuel injector and the fuel injection
supply manifold.
injector.
1. Release the locking clip.
2. Pull the fuel return line.
Page 3 of 6
14. Clean the area around the fuel injector.

15. Remove the fuel injector and clamp.
Installation
All vehicles
WARNINGS:
CAUTIONS:
with these components. Always fit blanking plugs to any open orifices or lines.
Always carry out the cleaning process before carrying out any repairs to fuel system
components to prevent foreign matter ingress to the components.
NOTE: Install a new fuel injector clamp retaining bolt.
NOTE: Install a new high-pressure fuel supply lines.
1. Remove the blanking plug from the fuel
injector nozzle and install the fuel injector and
clamp.
 Discard the blanking plug.
2. Connect the fuel return line to the fuel injector.

1. Install the fuel return line.
2. Install the locking clip.
Page 4 of 6
CAUTIONS:
3. Do not allow the unions to hit the ends

of the high-pressure fuel supply line. Failure
damage to the ends of the line and allow
foreign material to enter the fuel injection
system.

at the last possible moment. Failure to follow
this instruction may result in foreign matter

is most material. Failure to follow this
unions.
contact with the fuel injector cone and fuel
injection supply manifold while installing the
unions.
alignment.
Install a new high-pressure fuel supply line.

CAUTIONS:
4. Do not allow the unions to hit the ends

of the high-pressure fuel supply line. Failure
Page 5 of 6
damage to the ends of the line and allow

foreign material to enter the fuel injection
system.

last possible moment. Failure to follow this

is most material. Failure to follow this
unions.
contact with the fuel injector pump and the
fuel injection supply manifold while installing
the unions.
alignment.
Install a new high-pressure fuel supply line.

5. Connect the glow plug electrical connectors.

01A / 303-01B.
01.

Page 6 of 6

Page 1 of 5

FUEL INJECTION SUPPLY MANIFOLD
UID=G354762
General Equipment
Removal
WARNINGS:
in personal injury.
fuel pressure within the system can be as high as 1600 bar. Failure to follow these
Do not carry out any repairs to the fuel injection system without checking that the
fuel pressure has dropped to zero and that the fuel temperature is below 30 degrees C.
fuel injection system. Failure to follow these instructions may result in personal injury.
CAUTIONS:
Do not disassemble or clean inside the fuel injection supply manifold, even with an
ultrasonic cleaner. Always install a new fuel injection supply manifold when required.
01.
01A / 303-01B.
3. Disconnect the glow plug wire.
Page 2 of 5
4. Clean the fuel injection supply manifold, high-

pressure fuel supply lines, injectors and
surrounding areas. For additional information,
refer to Fuel Component Cleaning in this
section.

line.
foreign material from the fuel pump and the
supply manifold.


Remove the high-pressure fuel supply lines in the
sequence shown.
 Using the pneumatic vacuum gun, vacuum

 Install blanking plugs to the open threaded

ports on the fuel injector and the fuel
injection supply manifold after removing each
Page 3 of 5
individual high-pressure fuel supply line.

11. Detach the fuel injection supply manifold
from the cylinder head.
12. Disconnect the fuel pressure sensor electrical

connector and remove the fuel injection supply
manifold.
Installation
All vehicles
WARNINGS:
in personal injury.
CAUTIONS:
NOTE: Install new high-pressure fuel supply lines.
1. Connect the fuel pressure sensor electrical
connector.
2. Install the fuel injection supply manifold to the

cylinder head.
Page 4 of 5
CAUTIONS:
3. Do not allow the unions to hit the olive

ends of the high-pressure fuel supply line as
this may damage the ends of the line and
allow foreign matter ingress to the fuel
injection system.

at the last possible moment. Failure to follow
this instruction may result in foreign matter
Maintain pressure on the high pressure

fuel supply line to keep the olive in contact
with both the fuel injector cone and the fuel
injection supply manifold while hand installing
the union. Failure to follow this instruction
may result in foreign matter ingress to the
fuel injection system.
NOTE: Do not tighten the high-pressure line
unions at this stage.
Install the high-pressure fuel supply lines in the
sequence shown.

4. Tighten the high-pressure fuel supply lines.
CAUTIONS:
5. Do not allow the unions to hit the olive

ends of the high-pressure fuel supply line as
this may damage the ends of the line and
allow foreign matter ingress to the fuel
injection system.

Page 5 of 5

last possible moment. Failure to follow this
Maintain pressure on the high pressure

fuel supply line to keep the olive in contact
with both the fuel pump cone and the fuel
injection supply manifold while hand installing
the union. Failure to follow this instruction
may result in foreign matter ingress to the
fuel injection system.
Install the high-pressure fuel supply line.

6. Connect the glow plug wire.

01A / 303-01B.
01.

11.
Page 1 of 1

SPECIFICATIONS
UID=G354763

Starter motor retaining bolts 35 26 -
Starter motor electrical connector retaining nut 14 10 -
Ignition switch to starter motor electrical connector retaining nut 7 - 62
Starter Motor Output
Vehicles with petrol engine Vehicles with diesel engine

1.1KW 1.4KW
Page 1 of 1

STARTER MOTOR — 1.25L/1.4L/1.6L
UID=G354764
Removal
01.
3. Disconnect the ignition switch to starter motor
solenoid and battery to starter motor solenoid
cables (oil filter shown removed for clarity).
4. Remove the starter motor retaining bolts and

remove the starter motor.
Installation
All vehicles

11.
Page 1 of 1

FUEL TANK DRAINING
UID=G354765
General Equipment
Fuel tank draining equipment
Draining
WARNINGS:
The fuel system remains pressurized for a long time after the ignition is switched off.
The fuel pressure must be relieved before attempting any repairs. Failure to follow these
01.
2. Remove the fuel tank filler cap.
3. Using fuel tank draining equipment, drain the
fuel from the fuel tank using a 12.5mm nylon
drain tube.

01.
5. Initialize the driver door window motor
(vehicles with power windows). For additional
Page 1 of 2

FUEL TANK FILLER PIPE
UID=G354766
Removal
WARNINGS:
near any fuel related components. Highly flammable vapours are always present and can
in personal injury.
01.
2. Drain the fuel tank. For additional information,
4. Remove the left-hand rear fender splash shield
(road wheel shown removed for clarity).
5. Remove the fuel tank filler pipe upper retaining

bolt.
6. CAUTION: When disconnecting the

fuel tank vent and fuel tank filler pipes, do
not use any sharp edge tools to lever off the
pipes. Failure to follow this instructions may
cause damage to the pipes.
NOTE: Make note of the positions of the
retaining clamps to make sure they are
installing.
Disconnect the fuel tank filler pipe and the fuel
tank vent pipe from the fuel tank.
Page 2 of 2
 Discard the retaining clamps.

7. Remove the fuel tank filler pipe lower retaining
bolt and remove the fuel tank filler pipe.
Installation
All vehicles
WARNINGS:
near any fuel related components. Highly flammable vapours are always present and can
in personal injury.
NOTE: Install new fuel tank filler pipe and vent pipe retaining clamps.
NOTE: The fuel tank filler pipe and vent pipe retaining clamps must be installed in the
same position as removed.

11.
Page 1 of 1

SPECIFICATIONS
UID=G354767

Battery clamp retaining nuts 8 - 71
Battery positive terminal retaining nut 5 - 44
Battery positive terminal cable retaining nut 12 9 -
Battery ground terminal retaining nut 5 - 44
Battery ground terminal cable retaining nut 8 - 71
Battery tray retaining bolts 12 9 -
Generator positive cable retaining nut - All except vehicles with diesel engine 8 - 71
Generator positive cable retaining nut - Vehicles with diesel engine 15 11 -
Starter motor positive cable retaining nut 12 9 -
Ignition switch to starter motor cable retaining nut 7 - 62
Battery Specifications

12V. 43Ah and 52Ah 12V. 60Ah
Page 1 of 2

BATTERY TO STARTER MOTOR
SOLENOID CABLE — 1.25L/1.4L/1.6L
UID=G354768
Removal
2. Open the battery positive terminal cover.
3. Disconnect the battery positive cables.
4. Detach the battery to starter motor solenoid

cable from the retaining clip on the wiring
harness cover.

generator electrical connector.

cable from the retaining clip.
Page 2 of 2
8. Disconnect the starter motor solenoid cable

9. Disconnect the ignition switch to starter motor

solenoid and battery to starter motor solenoid
cables (oil filter shown removed for clarity).

cable from the retaining clip on the intake
manifold.
11. Remove the battery to starter motor solenoid

cable.
Installation
All vehicles

11.
Page 1 of 1

SPECIFICATIONS
UID=G354769
lb- lb-
Generator retaining bolts 45 33 -
Generator electrical connector retaining nut - All except vehicles with diesel 8 - 71
engine
Generator electrical connector retaining nut - Vehicles with diesel engine 15 11 -
Accessory drive belt idler pulley retaining bolt - Vehicles with diesel engine 45 33 -
Air conditioning (A/C) compressor retaining bolts 25 18 -
Generator Output

70A (all except vehicles with A/C and fog light) 80A (all except vehicles with PTC heater)
90A (vehicles with A/C and fog light) 150A (vehicles with PTC heater)
Page 1 of 2

GENERATOR — 1.4L DIESEL
UID=G354770
Removal
01.
3. Remove the generator rear upper retaining

bolt.

05.
5. Disconnect the air conditioning (A/C)
compressor electrical connector.
6. Detach the A/C compressor and secure it to

one side.
7. NOTE: The accessory drive belt idler pulley

is retained by the generator lower retaining
bolt.
Page 2 of 2
Remove the bolt cover, the generator lower

retaining bolt and the accessory drive belt idler
pulley.
8. Remove the generator front upper retaining

bolt.
Installation
All vehicles

11.
Page 1 of 1

SPECIFICATIONS
UID=G357256
Spark Plug Specifications
Spark Plug Type Spark Plug Electrode Gap

AYFS-22C (Motorcraft) 1.3 mm
Page 1 of 1

BATTERY DISCONNECT
UID=G371115
Disconnect
WARNINGS:
Batteries normally produce explosive gases which may cause personal injury,
therefore do not allow flames, sparks or lighted substances to come near the battery.
When charging or working near the battery always shield your face and protect your eyes.
Always provide adequate ventilation. Failure to follow these instructions may result in
personal injury.
Batteries contain sulphuric acid, avoid contact with skin eyes or clothing. Shield your
eyes when working near the battery to protect against possible splashing of the acid
solution. In case of acid contact with the skin or eyes, flush immediately for a minimum of
15 minutes and seek prompt medical attention. If swallowed, call a physician
Audio unit key code saving devices must not be used when working on supplemental
restraint or fuel systems. When using these devices the vehicle electrical system is still
live but with a reduced current flow. Failure to follow this instruction may result in
personal injury.
CAUTION: Make sure the engine is not running before disconnecting the battery
ground cable to avoid damage to the vehicle electrical system.
NOTE: This procedure should be used to disconnect the battery while carrying out repairs
that refer to the battery being disconnected.
1. Obtain and record the audio unit keycode and
preset radio frequencies.
Connect
WARNINGS:
Batteries normally produce explosive gases which may cause personal injury,
therefore do not allow flames, sparks or lighted substances to come near the battery.
When charging or working near the battery always shield your face and protect your eyes.
Always provide adequate ventilation. Failure to follow these instructions may result in
personal injury.
Batteries contain sulphuric acid, avoid contact with skin eyes or clothing. Shield your
eyes when working near the battery to protect against possible splashing of the acid
solution. In case of acid contact with the skin or eyes, flush immediately for a minimum of
15 minutes and seek prompt medical attention. If swallowed, call a physician
CAUTION: Make sure all electrical systems are switched OFF before connecting the
battery ground cable to avoid damage to the vehicle electrical system.
1. Connect the battery ground cable.
2. Enter the audio unit keycode and preset radio
frequencies.
3. Reset the clock to the correct time.
Page 1 of 1

ANTI-LOCK CONTROL - STABILITY
ASSIST
UID=G37415
Page 1 of 1

EXTERNAL CONTROLS
UID=G37664
3. Make sure that the gearshift cables are correctly routed and not under any tension from
other components.
5. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart

External controls do not operate *Gearshift cables incorrectly *ADJUST the gearshift
freely. adjusted. cables.
*Gearshift lever damaged. *GO to Pinpoint Test A.
*Selector mechanism damaged.
*Gearshift cables damaged.
Pinpoint Tests
PINPOINT TEST A : STIFF GEARSHIFT

A1: CHECK THE GEARSHIFT LEVER
1 Detach the gearshift cables from the gearshift lever.
Is the gearshift lever difficult to operate?
Yes
Install a new gearshift lever.
No
GO to A2.
A2: CHECK THE GEARSHIFT CABLES
1 Attach the gearshift cables to the gearshift lever.
2 Detach the gearshift cables from the transaxle.

Is the gearshift lever difficult to operate?
Yes
Install new gearshift cables.
No
Install a new selector mechanism.
Page 1 of 1

CHARGING SYSTEM
UID=G37742
WARNINGS:
Batteries contain sulphuric acid. Avoid contact with skin, eyes, or clothing. Also,
shield your eyes when working near batteries to protect against possible splashing of the
acid solution. In case of acid contact with skin or eyes, flush immediately with water for a
minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in personal injury.
Batteries normally produce explosive gases which can cause personal injury.
Therefore, do not allow flames, sparks or lighted substances to come near the battery.
When charging or working near a battery, always shield your face and protect your eyes.
Always provide ventilation. Failure to follow these instructions may result in personal
injury.
- Accessory drive belt - Fuse(s)
- Generator - Wiring harness
- Generator decoupler (if - Electrical connector(s)

equipped)
- Battery junction box (BJB)
- Battery
- Battery cables
- Charging system warning

indicator
system.
Page 1 of 1

FLYWHEEL INSPECTION — VEHICLES
WITH: DUAL MASS FLYWHEEL
UID=G381550
CAUTIONS:
Do not rework the flywheel if it is distorted.
Do not clean the dual mass flywheel with any kind of fluid. Clean the flywheel with a
dry cloth only.
Do not clean the gap between the primary and secondary mass. Only clean the bolt
connection surface and the clutch surface.
1. Inspect the flywheel, if there is evidence of the
following install a new flywheel:
 Cracks.
 Worn ring gear teeth.
 Chipped or cracked ring gear teeth.

2. Check the flywheel for lateral movement.
 Rotation movement in either one or both

directions, or rock on its axis up to x = ± 1.5
mm measured at a radius of y = 125 mm in
relation to the primary mass is acceptable.
 A small amount of lateral movement is

permissible.
3. CAUTION: Make sure that the three

locating dowels are installed.
Check if the locating dowels are touching the
primary mass of the flywheel.
 If the height of the locating dowels is less

than 11 mm, install a new flywheel.
4. Inspect the flywheel for grease.
 If more than 2 g or 2 cm³ grease is evident,

install a new flywheel.
Page 1 of 3

BRAKE PEDAL — LHD, VEHICLES
WITH: AUTOMATED GEARSHIFT
UID=G400805
Removal

injury.
clips.


4. Detach the steering column from the steering

gear.
5. Remove the brake pedal switches.

1. Disconnect the brake pedal switch electrical
connectors.
2. Remove the switches.
Page 2 of 3
 Detach the brake pedal switches electrical

harness from the brake pedal bracket.

the brake pedal.
pin.
8. Remove the brake pedal bracket.


Page 3 of 3
Installation
WARNINGS:
1. Install a new steering column to

steering gear retaining bolt. Failure to follow

personal injury.

Page 1 of 3

HYDRAULIC CONTROL UNIT (HCU) —
UID=G406271
Name Specification
Removal
All vehicles

2. Remove the brake master cylinder.
CAUTIONS:


brake tubes to aid installation.
Remove the brake master cylinder to HCU brake
tubes.

CAUTIONS:


Disconnect the brake master cylinder to HCU
brake tubes from the HCU.
All vehicles
CAUTIONS:
Page 2 of 3


or dirt ingress.
 Detach the brake tubes from the bulkhead.
7. CAUTION: Cap the anti-lock brake

system (ABS) module electrical connector and
socket to prevent dirt and fluid ingress.
Disconnect the ABS module electrical connector.
1. Depress the locking tangs.
2. Release the retainer.



13. Remove the HCU.

Page 3 of 3
Installation
2. Bleed the brake system.
Page 1 of 3

MODULE — VEHICLES BUILT FROM:
07/2004
UID=G406272
Name Specification
Removal
All vehicles

2. Remove the brake master cylinder.
CAUTIONS:


Remove the brake master cylinder to HCU brake
tubes.

CAUTIONS:


Disconnect the brake master cylinder to HCU
brake tubes from the HCU.
All vehicles
Page 2 of 3
CAUTIONS:


or dirt ingress.
 Detach the brake tubes from the bulkhead.
7. CAUTION: Cap the anti-lock brake

system (ABS) module electrical connector and
socket to prevent dirt and fluid ingress.
Disconnect the ABS module electrical connector.
1. Depress the locking tangs.
2. Release the retainer.



13. Remove the ABS module.

Page 3 of 3
Installation
2. Bleed the brake system.
Page 1 of 1

HYDRAULIC CONTROL UNIT (HCU)
UID=G410616
Removal
1. NOTE: The traction control function is only
available on vehicles equipped with the MK60
anti-lock brake system (ABS) and the stability
assist program.
For additional information, refer to Section 206-
09C.[Anti-Lock Control - Stability Assist,
REMOVAL AND INSTALLATION, Hydraulic
Control Unit (HCU)]
Page 1 of 1

MODULE
UID=G410617
Removal
1. NOTE: The traction control function is only
available on vehicles equipped with the MK60
anti-lock brake system (ABS) and the stability
assist program.
For additional information, refer to Section 206-
09C.[Anti-Lock Control - Stability Assist,
REMOVAL AND INSTALLATION, Stability Assist
Module]
Page 1 of 2

COOLING SYSTEM DRAINING,
FILLING AND BLEEDING
UID=G420957
Draining
1. WARNING: When releasing the cooling

system pressure, cover the coolant expansion
tank cap with a thick cloth to prevent the
possibility of scalding. Failure to follow this
Release the cooling system pressure by slowly
turning the coolant expansion tank cap a
quarter of a turn.

4. Drain the cooling system.
 Allow the coolant to drain into a suitable

container.
5. Install the radiator drain plug.

Filling and Bleeding

1. Remove the radiator bleed plug.
2. Fill the coolant expansion tank until coolant is

expelled from the radiator bleed point or
stabilizes at the MAX mark (whichever occurs
first).
3. Install the radiator bleed plug.
4. Fill the coolant expansion tank to the MAX
Page 2 of 2
mark (if necessary).
5. Start and run the engine at 3000 revolutions

per minute (RPM) for two minutes.
6. Fill the coolant expansion tank completely.
7. Install the coolant expansion tank cap.
8. Start and run the engine at 3000 RPM for
another two minutes.
9. Switch the engine off.
Page 1 of 2

SHOCK ABSORBER
UID=G89134
General Equipment
Transmission jack
Removal
2. Detach the fender splash shield from the
fender.
3. Using a suitable transmission jack, support the

beam axle.
axle.
5. Remove the shock absorber.
Installation
1. Attach the shock absorber to the body.
Page 2 of 2

absorber lower mounting bolt at this stage.
Install the shock absorber.
3. Attach the fender splash shield to the fender.

5. NOTE: The final tightening of the shock
absorber lower mounting bolt should be
carried out when the vehicle weight is on the
road wheels.
Tighten the shock absorber lower mounting bolt.
Page 1 of 1

UID=G89259
For additional information, refer to Section 206-09A / 206-09B / 206-09C.
Page 1 of 2

STEERING GEAR TO FLUID COOLER
RETURN HOSE
UID=G91967
Removal
All vehicles
1. Remove the front right-hand wheel and tire.
Section 204-04.[Wheels and Tires, REMOVAL
AND INSTALLATION, Wheel and Tire]
2. Disconnect the steering gear to power steering
fluid cooler return hose quick release coupling,
from either the power steering fluid cooler or
the power steering reservoir return hose.
1. Press the power steering fluid cooler hose
quick release coupling locking tangs.

container.
3. NOTE: Note the position of the steering
gear to power steering fluid cooler return
hose to aid installation.
Detach the steering gear to power steering fluid
cooler return hose clips from the crankshaft
pulley splash shield.

cooler return hose bracket from the steering
gear.
5. Detach the steering gear to power steering

fluid cooler return hose clips from the steering
gear.
6. Detach the steering gear to power steering

Page 2 of 2
fluid cooler return hose from the power steering

line.

7. Remove the steering gear heat shield.

cooler return hose bracket from the steering
gear.
All vehicles

container.
10. Remove the steering gear to power steering

fluid cooler return hose.
Installation
1. NOTE: Make sure that the collar on the
hose is fully inserted into the quick release
coupling.
NOTE: Check the power steering lines to
steering gear valve body O-ring seals for
damage or fatigue. Install new O-ring seals
as necessary.
2. Fill and bleed the power steering system.
Page 1 of 1

STEERING COLUMN
UID=G91977
Page 1 of 1

MODULE CONFIGURATION
UID=G98961
Description of operation
Configuration of a new module is performed using WDS. In doing so, the same system
requirements must apply as for the diagnosis of the respective module:
* The BUS connection between the module and WDS must be in order.
* The voltage supply to the module and to WDS must be guaranteed.
For this reason, if there are communication problems which cannot be attributed to the
incorrect software version in WDS, the system test for module communication of the
particular module must be performed. For further information, refer to REFER to Section 418-
00.
Page 1 of 1

SPECIFICATIONS
UID=G99379

Turbocharger heat shield upper retaining screws 3 - 27
Exhaust manifold heat shield retaining bolts 12 9
Oil supply tube union 30 22 -
Turbocharger to catalytic converter retaining bolts 25 18 -
Turbocharger to exhaust manifold retaining nuts 25 18 -

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Page 1 of 2

REMOVAL AND INSTALLATION 2003.50 Mazda2

3. Using a suitable knife, cut the power steering

3. Install the power steering pump belt.

4. Make sure that the power steering pump belt

6. Remove the installation tool from the

 Repeat the installation procedure if the power

 Discard the installation tool.

10. Lower the vehicle.

SPECIFICATIONS 2003.50 Mazda2

Description Nm lb-ft lb-in

DIAGNOSIS AND TESTING 2003.50 Mazda2

1. Verify the customer concern.

2. Visually inspect for obvious signs of electrical damage.

Visual Inspection Chart

- Glow plug wire

- Powertrain control module (PCM)

REMOVAL AND INSTALLATION 2003.50 Mazda2

3. Remove the glow plug(s).

REMOVAL AND INSTALLATION 2003.50 Mazda2

2. Remove the air cleaner. For additional

4. Remove the glow plug wire.

REMOVAL AND INSTALLATION 2003.50 Mazda2

Removal and Installation

2. Disconnect the mass air flow (MAF) sensor

3. Disconnect the air cleaner outlet pipe from the

4. Detach the fuel system hand primer from the

5. Remove the air cleaner.

 Pull the air cleaner at the rear to remove.

REMOVAL AND INSTALLATION 2003.50 Mazda2

SPECIFICATIONS 2003.50 Mazda2

Description Nm lb-ft lb-in

SPECIFICATIONS 2003.50 Mazda2

Description Nm lb-ft lb-in

REMOVAL AND INSTALLATION 2003.50 Mazda2

4. Remove the A/C compressor pulley.

 Remove the spacer washers.

5. Remove the magnetic coil using a suitable two-

2. Remove the M6 x 30 mm bolt, washer and

 Install the spacer washers.

 Fit the snap-ring.

4. Install the A/C compressor drive plate.

5. Check the compressor clutch gap. For

7. Install the auxiliary drive belt. For additional

REMOVAL AND INSTALLATION 2003.50 Mazda2

3. Start the engine and switch on the air

5. WARNING: Make certain that the valve

 Discard the O-rings.

REMOVAL AND INSTALLATION 2003.50 Mazda2

2. Disconnect the ignition coil pack electrical

3. Remove the ignition coil pack.

1. CAUTION: The ignition coil pack and

REMOVAL AND INSTALLATION 2003.50 Mazda2

3. Remove the center safety belt retractor cover.

4. Remove the center safety belt webbing trim

 Feed the safety belt webbing through the trim

5. Detach the center safety belt retractor from

6. NOTE: Note the backrest latch cable

2. Detach the backrest latch inner cable from

1. WARNING: If the safety belt webbing

Make sure a webbing retainer is fitted at

Check the backrest latch cable routing,

SPECIFICATIONS 2003.50 Mazda2

Item Nm lb-ft lb-in