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)
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.
Before inspecting a component for wear or per
forming a dimensional check,
ensure that it is absolutely clean; a slight smear
of grease can conceal an incipient failure. When a component is to be checked dimensionally against figures quoted for it,
use the correct equipment (surface plates, micrometers, dial gauges etc.) in serviceable condition. The use of makeshift
equipment can be dangerous. Reject a component if its dimensio ns are outside the limits quoted, or if damage is apparent.
A part may be refitted if its critical di mension is exactly to the limit size and it is otherwise satisfactory. Use Plastigauge 12
Type PG-1 for checking bearing surface clearance, e.g. big end bearing shell to crank jour nal. Instructions for the use of
Plastigauge and a scale giving bearing clearances in steps of 0.0025 mm (0.0001 in) are supplied with the package.
Safety
Precautions
• WAR
NINGS:
WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE ATMOSPHERE. FUEL
VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHILST WORKING ON THE FUEL SYSTEM.
ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:
DO
NOT SMOKE IN THE WORK AREA.
DISP
LAY 'NO SMOKING' SIGNS AROUND THE AREA.
DISCONNECT TH
E BATTERY BEFORE WORKING ON THE FUEL SYSTEM.
DO NOT CONNEC
T/DISCONNECT ELECTRICAL CIRCUITS
, USE ELECTRICAL EQUIPMENT OR OTHER TOOLS OR
ENGAGE IN WORKING PRACTICES WHICH IN ANY WAY MAY RESULT IN THE PRODUCTION OF SPARKS.
ENS
URE THAT A CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.
ENS
URE THAT DRY SAND IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
EMP
TY FUEL USING SUITABLE FIRE PROOF EQUIPMENT IN
TO AN AUTHORIZED EXPLOSION PROOF CONTAINER.
DO NOT EMP
TY FUEL WHILE WORKING IN A WORKSHOP OR A PIT.
ENS
URE THAT WORKING AREA IS WELL VENTILATED.
ENS
URE THAT ANY WORK ON THE FUEL SYSTEM IS ON
LY CARRIED OUT BY EXPERIENCED AND WELL QUALIFIED
MAINTENANCE PERSONNEL.
ENS
URE THAT FUME EXTRACTION EQUIPMENT IS USED WHERE APPROPRIATE.
FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE,
WHITE SPIRIT, SBP3, METHYLENE CHLORIDE, PERCHLORETHY LENE. DO NOT SMOKE IN THE VICINITY OF VOLATILE
DEGREASING AGENTS.
General workshop practices:
Disc
onnect the grounded termin
al of the vehicle battery.
D
o not apply heat in an attempt to free seized nuts or fitt
ings; as well as causing damage to protective coatings,
there is a risk of damage from stray heat to electronic equipment and brake lines.
Keep oils and solven
ts away from naked flames and other sour
ces of ignition.
Adhere str
ictly to handling and safety inst
ructions given on containers and labels.
E
nsure that a suitab
le form of fire extinguisher is conveniently located.
Wh
en using electrical tools and equipment, inspect the power
lead for damage and check that it is properly earthed.
D
o not leave tools, equipment, spilt oil etc. around the work area.
Working beneath a vehicle:
Wh
enever possible, use a ramp or
pit in preference to jacking.
Posit
ion chocks at the wheels as we
ll as applying the parking brake.
N
ever rely on a jack alone to support a
vehicle; use axle stands, or blocks care fully placed at the jacking points, to
provide a rigid location.
Ch
eck that any lifting equipment used has adeq
uate capacity and is fully serviceable.
Working on air conditioning systems:
D
o not disconnect any pipes of the refrigeration system
unless you are trained and instructed to do so; a refrigerant
is used which can cause blindness if allowed to come into contact with the eyes.
Health Protection
P
rolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness,
In
spection