Valve
Co
ver
LH (12.29.43)
Valve
Cover RH (12.29.44)
Valve
Cover Gasket LH (12.29.40)
Valve
Cover Gasket RH (12.29.41)
Valve
Springs LH
Valve
Springs RH
Variable
Camshaft Timing Oil Con
trol Unit LH (12.65.71)
Variable
Camshaft Timing Oil Control Unit RH (12.65.70)
Variable
Camshaft Timing Oil Control Unit Housing LH (12.65.52)
Variable
Camshaft Timing Oil Control Unit Housing RH (12.65.51)
303‐03A : Engine Cooling
Descriptio
n and Operation
Engine Cooling
Diagnosis and Testing
Engine Cooling
Related Faults / Codes
DTC P0116 ECT circuit range / performance problem
DTC P0125 Insufficient coolant temperature for closed loop fuel control
DTC P0117 ECT circuit low input
DTC P0118 ECT circuit high input
DTC P1474 Intercooler coolant pum
p relay malfunction
Pinpoint test A: P0116, P0125
Pinpoint test B: P0117
Pinpoint test C: P0118
Pinpoint test D: P1474
General Procedures
Cooling System Draining, Filling and Bleeding ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 –
AJ27
Cooling System Draining, Filling and Bleeding ‐ 4.0L SC V8 ‐ AJ26
Cooling Sy
stem Draining and Vacuum Filling
Removal and Installation
Removal
Engine ‐ Re m
oval
(12.41.01)
Installation
Engine ‐ Installation (12.41.01)
Coolant E x
pansion
Tank (26.15.01)
Coolant Outlet Pipe (26.31.08)
Cooling Fan Motor (26.25.24)
Cooling Fan Motor and Shroud (26.25.25)
Cooling Fan Motors (26.25.25)
Cooling Fan Shroud (26.25.30)
Engine Coolant Level Switch (26.40.11)
Radiator (26.40.01) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Radiator (26.40.01) ‐ 4.0L SC V8 ‐ AJ26
Radiator Lower Hose (26.30.07) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Radiator Lower Hose (26.30.07) ‐ 4.0L SC V8 ‐ AJ26
Radiator Upper Ho
se (26.30.01) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Radiator Upper Hose (26.30.01) ‐ 4.0L SC V8 ‐ AJ26
Thermostat (26.45.07) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Thermostat (26.45.07) ‐ 4.0L SC V8 ‐ AJ26
Thermostat Housing Cover (26.
45.22) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Thermostat Housing Cover (26.45.22) ‐ 4.0L SC V8 ‐ AJ26
Thermostat Housing Cover Seal (26.45.20) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Thermostat Housing Cover Seal (26.45.20) ‐ 4.0L SC V8 ‐ AJ26
Water Pump (26.50.
01) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Water Pump (26.50.01) ‐ 4.0L SC V8 ‐ AJ26
Water Pump Pulley (26.50.05) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Water Pump Pulley (26.50.05) ‐ 4.0L SC V8 ‐ AJ26
303‐03B : Supercharger Cooling
Removal and Installation
Water Pump
303‐04: Fu
el Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
Inspection and Verification
Driver Information Chart
Default mode Definitions
Diagnostic Trouble Code (DTC) index
Pinpoint Tests
Removal and Installation
Fuel Injection Supply Manifo ld LH
(19.60.05)
Fuel Injection Supply Manifold RH (19.60.04)
Fuel Injection Supply Manifold Pipe (19.41.04)
Fuel Injector Vehicles Without: Supercharger (18.10.01)
Fuel Injector Vehicles With: Supercharger (18.10.01)
Fuel Injectors Vehicles With: Supercharger (18.10.02)
Throttle Body (19.70.04)
Throttle Body Gasket (19.70.07)
303‐05: Accessory Drive
Descriptio
n and Operation
Accessory Drive
Removal and Installation
Accessory Drive Belt (12.10.40) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Accessory Drive Belt (12.10.40) ‐ 4.0L SC V8 ‐ AJ26
Accessory Drive Belt Idler Pulley (12.10.43) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Accessory Drive Belt Idler Pulle
y (12.10.43) ‐ 4.0L SC V8 ‐ AJ26
Accessory Drive Belt Tensioner (12.10.41) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Accessory Drive Belt Tensioner (12.10.41) ‐ 4.0L SC V8 ‐ AJ26
Supercharger Belt (18.50.08)
Supercharger Belt Idler Pulley (18.50.09)
Supercharger Belt Tensioner (18.50.24)
303‐06: Starting System
Description and Operati
on
Starting System
Diagnosis and Testing
Starting System
Inspection and Verification
Diagnostic Trouble Code (DTC) Index
Pinpoint Tests
Removal and Installation
Starter Motor (86.60.01)
Superchar
ger
Outlet Pipe (18.50.16)
Supercharger Outlet Pipe Gasket (18.50.17)
Throttle Body Elbow (19.70.28)
Throttle Body Elbow Gasket (19.70.29)
303‐13: Evaporative Emissions
Diagnosis and Testing
Evaporative Emissions
Preliminary
Inspection
Diagnostic
Drive Cycles
Diagnostic
Trouble Code (DTC) index/Symptom Chart
Pinpoint
Tests
Removal
and Installation
Evaporative
Emission Canister (17.15.13)
Evaporative
Emission Canister Purge Valve (17.15.30)
Fuel
Tank Press
ure Sensor (19.55.31)
Fuel
Vapor Vent Valve Housing (19.55.24)
Fuel
Vapor Vent Valve Housing Seal (19.55.25)
303
‐14: Electronic Engine Controls
Description
and
Diagnosis
and Testing
Electronic
Engine Con
trols
Inspection
and Verification
Driver
Information Chart
Default
mode Definitions
Diagnostic
Trouble Code (DTC) Index
Pinpoint
Tests
Removal
and Installation
Catalyst
Monitor Sensor LH (18.30.81)
Catalyst
Monitor Sensor RH (18.30.80)
Heated Oxygen Sensor (HO2S) LH (18.30.79)
Heated Oxygen Sensor (HO2S) RH (18.30.78)
Camshaft
Position
Sen s
or
ECM
Position
Sensor
Crankshaft
Removal
Engine
Coolant Temperature
Sensor
Operation
Intake Air Temperature (IAT) Sensor (18.
30.52)
309: Exhaust Syst
em
309‐00: Exhaust System
Specification
Description and Operation
Exhaust System
Diagnosis and Testing
Exhaust System
Removal and Installation
Catalytic Converter LH (17.50.15) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Catalytic Converter LH (17.50.15) ‐ 4.0L SC V8 ‐ AJ26, Vehicles With:
Supercharger
Catalytic Converter RH (17.50.16) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Catalyt
ic Converter RH (17.50.16) ‐ 4.0L SC V8 ‐ AJ26, Vehicles With:
Supercharger
Catalytic Converter Gasket LH (17.50.06) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Catalytic Converter Gasket LH (17.50.06) ‐ 4.0L SC V8 ‐ AJ26
Catalytic Converter Gasket RH (17.50.07) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Catalyt
ic Converter Gasket RH (17.50.07) ‐ 4.0L SC V8 ‐ AJ26
Front Muffler (30.10.18) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Front Muffler (30.10.18) ‐ 4.0L SC V8 ‐ AJ26
Intermediate Muffler LH (30.10.15) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Intermediate Muffler LH (30.10.15) ‐ 4.0L SC V8 ‐ AJ
26
Intermediate Muffler RH (30.10.16) ‐ 3.2L NA V8 ‐ AJ26/4.0L NA V8 ‐ AJ27
Intermediate Muffler RH (30.10.16) ‐ 4.0L SC V8 ‐ AJ26
Muffler and Tailpipe LH (30.10.22)
Muffler and Tailpipe RH (30.10.52)
310: Fuel System
310‐00: Fuel System ‐ General Information
General Procedures
Fuel System Pressure Check
Fuel Tank Draining
Fuel Sy stem Pres
sure
Release
310‐01: Fu el Tank and Lines
Removal and Installation
Fuel Level Sensor (88.25.32)
Fuel Pump (19.45.08)
Fuel Tank (19.55.01)
310‐02
:
Acceleration Control
General Procedures
Accelerator Cable Adjustment (12.20.05)
Removal and Installation
Accelerator Cable (19.20.06)
310‐03: Speed Control
Diagnosis and Testing
Speed Con
trol
4: Electrical
412: Climate Control System
412‐00: Climate Control System ‐ General Information
Specification
Description and Operation
Climate Control System
Diagnosis and Testing
Climate Control System
General Procedures
Air Conditioning (A/C) System Check ‐ Retail Procedure
Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)
Contaminated Refrigerant Ha
ndling
Manifold Gauge Set Connection
Refrigerant Adding (82.30.02)
Refrigerant Oil Adding
Refrigerant System Tests
412‐01: Air Distribution and Filtering
Description and Operation
Removal and Installation
Door (76. 28.04)
Front Doo
r
Opening Weatherstrip (76.40.01)
Fuel Filler Door (76.10.25)
Hood (76.16.01)
Hood Hinge (76.16.12)
Hood Striker (76.16.24)
Hood Strut (76.16.15)
Luggage Compartment Lid Hinge (76.19.28)
Luggage Compartment Lid Opening Weatherstrip (76.19.06)
Luggage Compartment Lid Striker (76.19.12)
Luggage Compartment Lid Strut (76.19.27)
Rear Door Opening Weathe
rstrip (76.40.02)
501‐05: Interior Trim and Ornamentation
Description and Operation
Interior Trim
Removal and Installation
A‐Pillar Trim Panel (76.13.31)
B‐Pillar Trim Panel (76.13.28)
Cowl Side Trim Panel (76.13.30)
C‐Pillar Trim Panel (76.13.73)
Door Window Control Switch Finish Pane
l (76.47.33)
Engine Cover (76.11.35)
Floor Covering (76.49.08)
Folding Tray (76.47.31)
Folding Tray Finish Panel (76.47.32)
Front Door Armrest (76.34.22)
Front Door Trim Panel Finish Panel (76.47.11)
Front Door Stowage Compartment (76.34.27)
Front Door Trim Panel (76.34.01)
Headliner (76.64.01)
Luggage Compartment Front Trim Panel (76.19.31)
Luggage Compart
ment Lid Trim Panel (76.19.05)
Luggage Compartment Rear Trim Panel (76.19.44)
Luggage Compartment Side Trim Panel (76.19.22)
Overhead Console Finish Panel (76.47.41)
Torque Specifications
Torque sp
ecifications are shown in maintenance procedure illustra
tions and also in the torque specifications chart located at
the front of the relevant section.
Disconnecting/Connecting the Battery
Ow ing t
o the electronic components used on the vehicle, it is important that the battery is disconnected when specified in a
maintenance procedure.
When the battery is connected, the specified procedure must be followed, to ensure the correct operation of all vehicle
systems; refer to Section 414-01.
Use of Control Modules
Control modu les may
only be used on the ve
hicle to which they were originally fitted. Do not attempt to use or test a control
module on any other vehicle.
Function
al Test
On
completion of a maintenance procedure, a thorough test should be carried out, to ensu
re that the relevant vehicle
systems are working correctly.
Protecting the Vehicle
Al ways
fit covers to protect
the fenders before commencing work in the engi ne compartment. Cover the seats and carpets,
wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid,
antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water imme diately. Use polythene sheets
in the trunk to protect carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified.
Protect temporarily exposed screw thread s by replacing nuts or fitting caps.
Preparation
Before disassembly, clean the surrounding ar ea
as thoroughly as possible. When co
mponents have been removed, blank off
any exposed openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when
separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oilways, exposed
by component removal, with tapered hardw ood plugs or readily visible plastic plugs. Immediately a component is removed,
place it in a suitable container; use a se parate container for each component and its associated pa rts. Before dismantling a
component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the
materials within the component. Clean the bench and obtain ma rking materials, labels, containers and locking wire before
dismantling a component.
Dismantling
O b
serve scrupulous cleanliness when dismantling components,
particularly when parts of the brake, fuel or hydraulic
systems are being worked on. A particle of dirt or a fragment of cloth could caus e a dangerous malfunction if trapped in
these systems. Clean all tapped holes, crev ices, oilways and fluid passages with compressed air. Do not permit compressed
air to enter an open wound. Always use ey e protection when using compressed air.
Ensure that any O-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to ensure that
they are replaced as dismantled. Whenever possible use markin g materials which avoid the possibilities of causing distortion
or the initiation of cracks, which could occur if a center pu nch or scriber were used. Wire together mating parts where
necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to
parts requiring further inspection before being passed fo r reassembly. Place labelled parts and other parts for rebuild in
separate containers. Do not disc ard a part which is due for renewal until it ha s been compared with the new part, to ensure
that the correct part has been obtained.