Page 198 of 873

17EMISSION CONTROL
2
REPAIR HEATED OXYGEN SENSOR (HO2S)
Service repair no - 19.26.16
CAUTION: The removal of the sensors
from the exhaust system must only be
carried out when the engine is cold.
Remove
1.Disconnect battery negative lead.
2.Disconnect the electrical plugs from the sensors.
3.Unscrew and remove the sensors from the two
exhaust downpipes.
Refit
4.Coat the threads of the sensors with anti-seize
compound.
CAUTION: To ensure that the efficiency of
the sensor is not impaired, DO NOT allow
anti-seize compound to come into contact
with the sensor nose.
5.Screw in the sensor and tighten to the correct
torque using special tool LST134.
6.Connect the electrical plugs and battery lead.PURGE CONTROL VALVE
Service repair no - 17.15.39
Remove
1.Disconnect battery negative lead.
2.Disconnect multiplug from purge control valve.
3.Release clip and disconnect hose from valve.
4.Release valve from charcoal canister.
5.Remove valve.
6.Discard 'O' ring.
Refit
7.Clean valve and valve location.
8.Fit new 'O' ring to purge valve.
9.Position and secure valve to charcoal canister.
10.Connect hose to purge valve and secure with
clip.
11.Connect multiplug to valve.
12.Reconnect battery negative lead.
Page 199 of 873
EMISSION CONTROL
3
REPAIR CHARCOAL CANISTER
Service repair no - 17.15.13
Remove
1.Disconnect battery negative lead.
2.Pry out purge valve.
3.Disconnect pipe.
4.Loosen bolt.
5.Remove charcoal canister.
Refit
6.Reverse removal procedure.
Page 202 of 873
17EMISSION CONTROL
6
REPAIR CATALYTIC CONVERTER/FRONT PIPE - 4.0 V8
Service repair no - 17.50.09
WARNING: The removal of the exhaust
system must only be carried out when the
engine is cold.
Remove
1.Disconnect battery negative lead.
2.Raise vehicle on ramp.
3.Remove oxygen sensors
See Heated Oxygen
Sensor (HO2S) - 4.0 V8
4.Remove 4 nuts/bolts securing front anti-roll bar
brackets.
5.Remove 6 nuts securing front pipe flanges to
manifolds.
6.Remove 2 nuts securing front pipe to
intermediate pipe.
7.With assistance, release front pipe from manifold
flanges.8.With assistance, release front pipe from
intermediate pipe.
9.With assistance, lower anti-roll bar.
10.With assistance, remove exhaust front pipe.
11.Remove flange gaskets and discard.
Refit
12.Reverse removal procedure.
Page 203 of 873
EMISSION CONTROL
7
REPAIR EVAP CANISTER AND PURGE VALVE - 4.0 V8
Service repair no - 17.15.13
Remove
1.Disconnect battery negative lead.
2.Disconnect multiplug from EVAP purge valve.
3.Release purge valve rubber mounting from
bracket.
4.Release clip and remove hose from EAVP
canister.
5.Loosen bolt.
6.Remove EVAP canister and purge valve
complete.
Refit
7.Reverse removal procedure.
Page 204 of 873

17EMISSION CONTROL
8
REPAIRADD: 09/95 EVAP CANISTER - ADVANCED EVAPS
Service repair no - 17.15.13
Remove
1.Disconnect battery negative lead.
2.Release clip securing vent solenoid hose to
canister and disconnect hose.
3.Release vent and purge line quickfit connections
from canister.
4.Remove nut and bolt securing canister to
mounting bracket, collect fixture clamp.
5.Remove canister.
Refit
6.Fit canister to mounting bracket.
7.Position fixture clamp and secure canister to
mounting bracket with nut and bolt.
8.Connect vent and purge line quickfit connections
to canister.
9.Connect vent solenoid hose to canister and
secure with clip.
10.Reconnect battery negative lead.EVAP CANISTER PURGE VALVE - ADVANCED
EVAPS
Service repair no - 17.15.39
Remove
1.Disconnect battery negative lead.
2.Disconnect multiplug from purge valve.
3.Release purge valve rubber mounting from
bracket.
4.Release quickfit hose connections from throttle
body plenum and EVAP canister.
5.Remove purge valve assembly.
Refit
6.Locate purge valve adjacent to bracket.
7.Connect quickfit hose connections to throttle
body plenum and EVAP canister.
8.Conmnect multiplug to purge valve and secure
purge valve rubber mounting to bracket.
9.Reconnect battery negative lead.
Page 205 of 873
EMISSION CONTROL
9
REPAIR ADD: 09/95 EVAP CANISTER VENT SOLENOID - ADVANCED
EVAPS
Service repair no - 17.15.43
Remove
1.Disconnect battery negative lead.
2.Release clip securing hose to vent solenoid and
disconnect hose.
3.Disconnect multiplug from vent solenoid.
4.Remove vent solenoid from mounting bracket.
Refit
5.Fit vent solenoid to mounting bracket.
6.Connect multiplug to vent solenoid.
7.Connect hose to vent solenoid and secure with
clip.
8.Reconnect battery negative lead.
Page 218 of 873

Tdi
1
REPAIR TANK SENDER UNIT
Service repair no - 88.25.32
WARNING: Ensure that the WARNINGS
and FUEL HANDLING PRECAUTIONS
given in Section 01 are adhered to before
carrying out the following operations.
Special tool - LST131
Remove
1.Disconnect battery negative lead.
2.Remove the rear carpet retainer.
3.Ease the carpet from under the lower trim panels
at the rear of the fold down seats.
4.Raise the carpet to expose the sound insulation.
5.Fold back the sound insulation to reveal the
access panel.
6.Remove the securing screws and detach the
access panel from the floor.
7.Disconnect the multi-plug from sender unit.8.Disconnect the fuel pipes from the sender unit.
9.Using special tool LST131 remove the locking
ring and withdraw the sender unit from the fuel
tank.
Refit
10.Fit the sender unit to the fuel tank and secure
with the locking ring. Tighten to
45to50 Nm.
11.Connect the fuel pipes to the sender unit.
12.Connect multi-plug to sender unit.
13.Inspect the access panel seal to ensure that it is
satisfactory for further use, renew as necessary.
14.Fit the access panel to the aperture in the floor
and secure with the screws.
15.Reverse removal procedure. 1 to 5. Refit the
sound insulation and carpet.
Page 219 of 873
19FUEL SYSTEM
2
REPAIR THROTTLE CABLE
Service repair no - 19.20.06
Remove
1.Disconnect battery negative lead.
2.Remove pin and clevis pin securing throttle
cable to throttle lever.
3.Pull ferrule from abutment bracket and withdraw
throttle cable.
4.Release throttle cable from clip on bulkhead.
5.Remove pin and clevis pin securing throttle
cable to throttle lever.
6.Release grommet from bulkhead.
7.Withdraw throttle cable from engine
compartment.
Refit
8.Reverse removal procedure. Use new pins to
secure clevis pins.
9.Adjust throttle cable.
See Adjustment,
Throttle Cable
INTAKE HOSE TURBOCHARGER
Service repair no - 19.42.11
Remove
1.Disconnect battery negative lead.
2.Loosen clip and disconnect intake hose from
turbocharger.
3.Loosen clip and disconnect breather hose from
intake hose.
4.Remove clip and disconnect hose from air
cleaner, discard clip.
5.Remove intake hose
Refit
6.Reverse removal procedure. Use a new clip to
secure intake hose to air cleaner.