30MANIFOLD AND EXHAUST SYSTEM
4
REPAIR
7.Remove 4 bolts securing fuel cooler to inlet
manifold.
8.Remove 2 bolts and remove alternator support
bracket and disconnect fuel injector harness
multiplug.
9.Remove bolt securing engine dip stick tube to
camshaft carrier.
10.Remove dip stick tube and discard’O’ring.
11.Remove 2 nuts and 8 bolts securing inlet
manifold to cylinder head.
12.Disconnect multiplugs from turbocharger boost
control soleniod, ECT sensor, ambient air
pressure sensor, MAF sensor, and A/C
compressor.
NOTE: EU3 Model illustrated.
13.Remove 2 bolts securing harness to camshaft
carrier.
14.Release harness from engine and inlet manifold.
15.Remove inlet manifold and gasket.
ProCarManuals.com
PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
The panel repairs shown in this section are all based
on a 110 Station Wagon. Therefore all illustrations
and text relate only to this model. Although certain
areas of the vehicle, such as the front end, are
relevant to all models.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring.
Where this is necessary use the relevant section in
this manual.
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
Front suspension upper damper
mountings.
Front suspension or sub frame mountings.
Engine mountings on RH and LH chassis
longitudinals.
Rear suspension upper damper mountings.
Rear suspension mountings or lower
pivots.
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
Inner holes in crossmember - side - main
floor.
Holes in valance front assembly.
Body to chassis mounting holes.
Holes in rear floor.
Holes in rear lower panels or extension
rear floor.
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can be checked by offering up an undamaged
component as a gauge and also by measuring known
dimensions.See BODY DIMENSIONS section.
ProCarManuals.com
