It is a reciprocating two
-circuit pu
mp in which one brake circuit is as signed to each pump circuit.
It supplies th
e fluid pressure and vo
lume to supply the brake circuits under ABS and Traction control.
The pump is driven by an electri
c motor, with the pump
housing incorporating two lo w pressure accumulators and
damping chambers for each brake circuit.
The ac cu
mulator stores the pressure and smooths out the output pu
lses from the pump.
ABS Warning Lamp
The sys
tem will be set in a fail-safe mode if a problem is de
tected; a warning lamp on the instrument panel will notify the
driver there is a problem.
Anti-Lock Braking Sy
stem (ABS)
The AB
S components are combined with
an hydraulic booster and a tandem master cylinder to provide a two circuit braking
system. The system comprises, four wheel speed sensor s, a brake control modulator and an ABS warning lamp.
Should a wheel start to lock-up during braking a signal tr ansmitted from the wheel speed sensor to the brake control
modulator will start the hydraulic pump. The brake control modula tor will close the input valve of the line connected to the
locked-wheel to stop any increase in fluid pressure to the br ake caliper. If this fails to prevent the wheel locking, the
pressure in the caliper will be decreased by opening the return valve until th e wheel starts accelerating again. The fluid
pressure from the return va lve is directed into the low pressure accumulator, housed in the pump.
From the low pressure accumulator, fl uid is pumped through the damping cham ber to the brake master cylinder. The
pressure to the brake caliper will then be increased in small steps to maintain maximum adhesion between the tire and road
surface. This is achieved by closing the return valve, and opening the input valve and using the hydraulic pump to increase
the pressure.
Although the system senses all four wheels independently, the rear wheels are regulated as a pair. If a sensor on a rear
wheel detects a wheel decelerating rapidly, then the fluid pressure to both wheels is reduced. The fluid pressure is then
dictated by the wheel having the lowe st adhesion with the road surface.
The ABS system will be set in a fail-safe mode if a problem is detected; a warn ing lamp on the instrument panel will notify
the driver there is a problem. The brake system will still operate conventionally and with the same standard of performance
as a vehicle not equipped with ABS.
Automa tic Stability Control (ASC)
Th
e ASC utilizes the ABS sensing arrangement to provide the maximum traction force to propel the vehicle.
The ASC is switched on when the engine is started. The system can be switched off by pressing the 'ASC OFF' (the switched
is marked 'TRAC OFF' on vehicles fitted with traction control). The switch, which is situated in the center console switchpack,
lights up to warn that the system is sw itched off. An 'ASC' amber warning light flashes on the instrument panel when the
system detects a spinning wheel.
The ASC system uses engine intervention to reduce the torque delivered to the drive wheels to prevent them spinning.
Engine torque is re duced in three ways:
The
throttle is moved towards the closed position.
The ignition is retarded. F
u
el is cut-off at the cylinder injectors.
Wheel spin is detected by the wheel sp eed sensors and communicated to the AB S/TCCM. The ABS/TCCM uses information
from the controller area network (CAN) to calculate the torque that the engine should produce to stop the wheel spinning.
Torque reductions are then requested from the engine control module (ECM ) through the CAN. The throttle is then
positioned to provide the target torque, which has been calculated to prevent wheel spin. During the transient phase of
torque reduction the fuel is cut-off and th e ignition retarded Both the fuel cut-off an d ignition retard will be restored to
normal when the throttle is set to its new position.
The ASC uses a brake control modulator with six solenoid va lves: three normally open inlet valves and three normally
E
ngine Management System Components
Electronic Throt
tle
The
electronic throttle assembly, in resp
onse to signals from both the driver and the ECM, adjusts idle speed, sets the
throttle valve to the position requested by the driver's accelerator / throttle pedal, cruise and traction control, power
limitation and catalyst warm-up.
Mass
Air Flow Meter
The sensor i
s located in the air flow mete
r assembly and outputs an analogue voltag e to the ECM. This sensor measures air
flow into the engine inlet system and is calibrated to measure kg / hour.
In
take Air Temperature
Th
e intake air temperature sensor is loca
ted in the air flow meter assembly and outputs an analogue voltage to the ECM.
The ECM will substitute a default value eq ual to 50°C should this sensor fail.
Fuel Injectors
The eigh
t bottom fed fuel injectors are located in the fuel rails. Th
e fuel injectors are electromagnetic solenoid valves
controlled by the ECM. The pulse time for the injector combined with the fuel pr essure determines the volume of fuel
injected to the manifold.
Fue
l Delivery
The fu
el pump provides fuel to the fuel rail where the circulat
ing pressure is controlled by a pressure regulator valve; excess
fuel is returned to the fuel tank.
The pressure regulator valve is controlled by manifold depression so that fuel delivery pressure is maintained at
approximately 3 bar above manifold pressure.
Fuel Pump
Relay
The ECM controls thi
s component for normal
engine running. The security system may disable this relay via communication
with the ECM.
Fuel Lev
el Sensing
The tank fuel
is measured by the fuel le
vel sensor . This signal is used by the ECM as an in put to certain diagnostics.
Eva
porative Valve
Excess vapour
formed in the fuel tank is
absorbed into the evaporative emission pu rge control canister. While the engine is
running, the fuel absorbed in the canister is gradually purged back into the engine. The rate of purging is governed by
engine operating conditions and vapour concentration level. Operating conditions which affect the purge rate are:
2—Purge
valve
3—Engine
torque reduction
4—E
lectronic throttle assembly
5—Coo
ling fans
6—Ignition amplifier driver
7—Engine overspeed
8—Cli
mate control compressor clutch
9—O
BDII information (J1962, CAN, ISO)
10—F
uel pump relay
11—Heat
ed oxygen sensor
12—Vari
able valve timing
13—MIL sw
itching
ECM Out
puts
It
em
Par
t Number
De
scription
1—Exhaus
t gas recirculation
24. Disconnect the fuel return hose.
1. Disconnect the fuel retu rn hose at the Quick Fit
connector, using special tool 310 - 054.
25. Remove the inlet manifold.
1. Remove the ten bolts which secure the inlet manifold.
2. Remove the inlet manifold
26. Remove and discard the eight se als from the inlet manifold
ports.
27. Remove the fuel pressure regulator from the manifold.
1. Remove the two bolts which secure the pressure regulator.
2. Remove the pressure regulator.
Installation
32. Remove and discard the sixt een sealing rings from the
injectors.
33. Remove the throttle induction elbow from the inlet manifold.
1. Remove the seven bolts which secure the throttle induction elbow.
2. Remove the elbow.
3. Remove the induction elbow seal from the manifold.
1. Clean all parts and relevant mating faces.
2. Fit the fuel pressure regulator to the manifold.
1. Lubricate and fit a new O-ri ng seal to the regulator.
2. Fit the pressure regulator to the manifold.
3. Fit the two bolts which secu re the pressure regulator.
3. Fit the fuel feed pipe to the manifold.
1. Lubricate and fit a new O-ri ng seal to the feed pipe.
Engine - Engine
Removal
Removal
Special Tool(s)
Engine Lifting Brackets
303-536
Quick Fit Connector Release Tool
310-044
Quick Fit Connector Release Tool
310-054
Quick Fit Connector Release Tool
303-623
Fuel Injection Pressure Test Equipment
310-058
1. Park the vehicle on a four post ramp, over which, an overhead
lifting crane is available, and set the gear selector to 'N'.
The crane should be rated at a minimum of 500 kg Safe
Working Load and have suffici ent fore and aft movement
to traverse the engine assemb ly clear of the vehicle.
Do not apply the handbrake, but use wedges to chock one
wheel to prevent movement of the vehicle.
2. Open the engine compartment and fit paintwork protection
sheets.
3. Disconnect the batt ery ground cable.
Remove the battery cover.
ENSURE THAT ALL FIRE PREVENTION PROCEDURES ARE ACTIVE.
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION 100-00 (UNDER THE
HEADING 'SAFETY PRECAUTIONS') ARE READ AND UNDERSTOOD.
9. Depressurise the fuel system.
Ensure that the ignition is switched off and remove the
valve cap from the fuel cross-over pipe. Place a cloth
under the valve to collect any spillage.
Place a closed container, su itable for collecting fuel,
adjacent to the vehicle. Remove the lid.
10. Connect the fuel injection pressure test equipment 310 - 058
(or other suitable type). Insert the drain / bleed tube into the
fuel container. Follow the ma nufacturer's instructions and
depressurise the fuel system.
11. Store the drained fuel safely and ensure that the lid is closed
securely. Remove the equipmen t and discard the cloth from
beneath the valve. Refit the valve cap.
12. Disconnect the breather pipe from the A-Bank camshaft
cover.
1. Disconnect the breather pipe from the stub pipe.
2. Remove and discard the O-ring seal from the breather
pipe.
13. Disconnect the air flow meter multi-plug.
14. Cut and remove the strap which secures the vacuum pipe to
the induction elbow.
15. Disconnect the intake tube from the throttle body.
1. Remove the two bolts which secure the intake tube to the throttle body.
2. Disconnect the intake tube from the throttle body.
Engine - Engine
Installation
Installation
Special Tool(s)
Engine Lifting Brackets
303-536
Quick Fit Connector Release Tool
310-044
Quick Fit Connector Release Tool
310-054
Quick Fit Connector Release Tool
303-623
Fuel Injection Pressure Test Equipment
310-058
1. Position the engine into the engine compartment.
Traverse the engine / transmission assembly to the
vehicle and lower the assembly into the engine
compartment and onto front mounting locations.
2. Align the engine front mountings.
Engine Cooling - Engine Cooling
Diagn
osis and Testing
Related Faults / Codes
Adaptive
Fue
ling
Sym
p
tom Chart
Sy
m
ptom Chart
S
p
ecial Tool(s)
D
i
gital multimeter
Generi
c scan tool
Conditi
on
Possib
l
e Source
Acti
o
n
D
T
C P0171 System too lean bank
1 (A)
D T
C P0174 System too lean bank
2 (B)
Fuel delivery blockage Fu
el delivery pressure (low)
F
a
ulty injector (blocked)
Ai
r i
ntake system leak
F
u
el injector electrical fault
ECT sensor
faul
t
MAFM sensor fault IAT se
nsor fault
Thro
tt
le position sensor
fault
Mec hanica
l check
Mec
hanica
l check
Mec
hanica
l check
Mec
hanica
l check
Go t
o DTC P020
1 to 0208
Go t
o
DTC P0116 to 0118, P0125
Go t
o
DTC P0101 to 0103, P1104
Go t
o DTC P011
1 to 0113
Go t
o
DTC P0121 to 0123, P0222,
P0223
D T
C P0172 System too rich bank
1 (A)
D T
C P0175 System too rich bank
2 (B)
F u
el delivery pressure
(high)
F a
ulty injector (leaking)
F
u
el injector continuously
open
Ai r i
ntake system restricted
Fu
el injector electrical fault
ECT sensor
faul
t
MAFM sensor fault IAT sensor fault
Thrott
le position sensor
fault
Mec hanica
l check
Mec
hanica
l check
Mec
hanica
l check
Mec
hanica
l check
Go t
o DTC P020
1 to P0208
Go t
o
DTC P0116 to P0118, P0125
Go t
o
DTC P0101 to P0103, P1104
Go t
o DTC P011
1 to P0113
Go t
o
DTC P0121 to P0123, P0222,
P0223
Sy m
ptom
Possib
l
e Sources
Acti
o
n
D
T
C P0116 ECT circuit range / performance problem
Thermostat
Coo
l
ant level / contamination
Sensor out of range
Harness open circuit
Connector loose or corroded
*
*
*
*
*
GO to Pinpoint
Test A
*
D
T
C P0125 Insufficient coolant temperature for closed
loop fuel control
Thermostat
Coo l
ant level / contamination
Sensor out of range
Harness open circuit
Connector loose or corroded
*
*
*
*
*
GO to Pinpoint
Test A
*
D
T
C P0117 ECT circuit low input
Sensor o
p
en circuit
Harness open circuit
Harness short
*
*
*
GO to Pinpoint
Test B
*