ENGINE - V8
12-2-40 REPAIRS
6.Remove 2 bolts securing radiator LH and RH
upper mounting brackets to body panel and
remove brackets.
7.Remove 4 screws securing air conditioning
condenser LH and RH upper mounting
brackets to condenser.
8.Remove condenser upper mounting brackets
with rubber mounts from radiator extension
brackets.
9.Remove 2 bolts securing LH and RH extension
brackets to radiator and remove brackets.
10.Position absorbent cloth under each oil cooler
hose connection to collect oil spillage. 11.Push against coupling release rings and
disconnect both hoses from oil cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
12.Remove screw securing oil cooler to radiator.
13.Release cooler from its location on radiator.
14.Release radiator lower mountings from
location in chassis and carefully move radiator
towards engine sufficiently only to release
engine oil cooler from radiator.
15.Remove engine oil cooler.
Refit
1.Fit engine oil cooler to radiator, engage in
location and secure with screw.
2.Fit radiator to location in chassis.
3.Ensure connections are clean, then secure
hoses to oil cooler.
4.Fit extension brackets to radiator and secure
with bolts.
5.Fit brackets with rubber mounts to extension
brackets and secure to air conditioning
condenser with screws.
6.Fit radiator upper mounting brackets and
secure to body with bolts.
7.Fit LH horn and secure with nut.
8.Fit LH and RH air deflectors to front panel and
secure with scrivets.
9.Fit front grille.
+ EXTERIOR FITTINGS, REPAIRS,
Grille - front - up to 03MY..
10.Fit cooling fan cowl and secure with fixings.
11.Fit battery cover and secure with fixings.
12.Top up engine oil.
ENGINE MANAGEMENT SYSTEM - V8
REPAIRS 18-2-81
Engine control module (ECM)
$% 18.30.01
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery earth lead.
3.Remove fixings securing fascia RH closing
panel, release diagnostic socket RH drive
models, and remove panel.
4.Remove 2 fixings and remove 'A' post lower
trim. 5.Remove 2 nuts and release ECM from studs
and location on 'A' post lower panel.
6.Lower ECM into footwell and disconnect 5
multiplugs.
7.Remove ECM.
Refit
1.Position new ECM and connect multiplugs.
2.Fit ECM and secure with nuts.
3.Fit lower trim panel to 'A' post and secure with
fixings.
4.Fit diagnostic socket to closing panel, fit closing
panel and secure with fixings.
5.Connect battery earth lead.
6.Fit battery cover and secure with fixings.
7.Programme ECM and reset adaptions using
TestBook.
ENGINE MANAGEMENT SYSTEM - V8
REPAIRS 18-2-97
Switch - cruise control (set/resume)
$% 19.75.33
Remove
1.Remove the key from the starter switch.
Disconnect both battery leads, negative lead
first. Wait ten minutes before starting work.
2.Remove driver's airbag module.
+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
3.Release remote control switches multiplug and
leads from steering wheel base.
4.Disconnect remote control switches multiplug
from harness.
5.Remove 2 screws securing remote control
switches to steering wheel base.
6.Release and remove remote control switches
from steering wheel.
Refit
1.Fit remote control switches to steering wheel
and secure with screws.
2.Connect remote control switches multiplug to
harness.
3.Secure leads and multiplug to base of steering
wheel.
4.Fit driver's airbag module.
+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
Switch - clutch pedal - cruise control
$% 19.75.34
Remove
1.Remove 3 fasteners and move driver's side
lower closing panel aside.
2.Disconnect multiplug from clutch pedal switch.
3.Remove switch from pedal bracket.
Refit
1.Engage switch fully into pedal bracket location
and connect multiplug.
2.Position lower closing panel and secure with
fasteners.
CORROSION PREVENTION AND SEALING
77-4-22 SEALING
Water leaks
Where water leakage is involved, always adopt a logical approach to the problem using a combination of skill,
experience and intuition. Do not reach a conclusion based only on visual evidence, such as assuming that a wet
footwell is caused by a leak emanating from the windscreen. It will often be found that the source of the leak is
elsewhere. Use of the correct procedure will increase the chance of locating a leak, however obscure it may seem.
Tools and equipment
The following tools and equipment are recommended for the purpose of detection and rectification of water leaks:
1Garden sprayer (hand-operated)
2Wet/dry vacuum cleaner
3Dry, absorbent cloths
4Battery torch
5Small mirror
6Weatherstrip locating tool
7Trim panel remover
8Small wooden or plastic wedges
9Dry compressed air supply
10Hot air blower
11Sealer applicators
12Ultrasonic leak detector
During leak detection, the vehicle should be considered in three basic sections:
lThe front interior space;
lThe rear passenger space;
lThe loadspace or boot.
Testing
From the information supplied by the customer it should be possible for the bodyshop operator to locate the starting
point from which the leak may be detected. After the area of the leak has been identified, find the actual point of entry
into the vehicle.
A simple and effective means in the first instance is an ordinary garden spray with provision for pressure and jet
adjustment, which will allow water to be directed in a jet or turned into a fine spray. Use a mirror and a battery-powered
torch (NOT a mains voltage inspection lamp) to see into dark corners.
The sequence of testing is particularly important. Start at the lowest point and work slowly upwards, to avoid testing
in one area while masking the leak in another. For example, if testing started at the level of the windscreen, any water
cascading into the plenum chamber could leak through a bulkhead grommet and into the footwells. Even at this point
it could still be wrongly assumed that the windscreen seal was at fault.
Another important part of identifying a water leak is by visual examination of door aperture seals, grommets and
weatherstrips for damage, deterioration or misalignment, together with the fit of the door itself against the seals.
Sealing
When the point of the leak has been detected, it will then be necessary to rectify it using the following procedure:
1Renew all door aperture seals and weatherstrips which have suffered damage, misalignment or deterioration
2Check all body seals to ensure that they are correctly located on their mounting flanges/faces using a lipping
tool if necessary
3Dry out body seams to be treated using compressed air and/or a hot air blower as necessary
4Apply sealant on the outside of the joint wherever possible to ensure the exclusion of water
5When rectifying leaks between a screen glass and it's weatherstrip (or in the case of direct glazing, between the
glass and bodywork), avoid removing the glass if possible. Apply the approved material at the appropriate
location (i.e. glass to weatherstrip or glass to body)
LIGHTING
REPAIRS 86-2-13
Switch - hazard warning
$% 86.65.50
Remove
1.Carefully remove switch.
2.Disconnect multiplug from switch.
3.Remove switch.
Refit
1.Connect multiplug switch.
2.Position switch and push to secure.
Switch - indicator and exterior lighting -
combined
$% 86.65.55
WARNING: Always remove the key from the
starter switch, disconnect the vehicle battery and
wait 10 minutes before commencing work on the
SRS system.
Remove
1.Remove rotary coupler.
+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
2.Remove 2 screws securing switch.
3.Carefully raise edge of switch bracket to clear
location peg and release switch from bracket.
4.Disconnect 2 multiplugs and remove switch.
Refit
1.Position switch and connect multiplugs.
2.Fit switch to bracket and secure with screws.
3.Fit rotary coupler.
+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler.
IN CAR ENTERTAINMENT
86-6-28 DESCRIPTION AND OPERATION
Fault Finding
The following table details potential faults, possible causes and rectification suggestions.
Fault Possible Cause Rectification
System fails to power up Missing or blown fuse Check both fuses in passenger compartment fusebox
Battery voltage too low or too high Voltage protection system may be active. Check battery
voltage output
Faulty connections Check all DVD harness connections for security and
correct location of pins
Faulty overhead console Replace overhead console
Damaged DVD harness Check all DVD harnesses for damage and repair or
replace as required
Faulty noise filter connection Check power supply wires into and out of the noise filter
on the CD switch box
No picture or sound Missing or blown fuse Check both fuses in passenger compartment fusebox
Low or high battery voltage Check battery voltage output
Vehicle interior is too hot or too
coldAllow vehicle interior to warm up or cool down before
switching on the system
DVD parental rating system is
preventing DVD playRefer to DVD System Owner's Manual and check the
parental control rating setting
LCD monitor is pushed too far
forwardReturn LCD monitor to an angle for normal viewing
Good picture, no sound Volume setting on audio head unit
too lowCheck and adjust head unit volume control
Headphone not connected, faulty
headphone or headphone volume
control incorrectly setEnsure headphone is correctly connected.
Check headphone for correct operation.
check headphone remote volume control setting.
Faulty connections Check all DVD harness connections for security and
correct location of pins
CD switch box or harness fault Check all harnesses to and from the CD switch box. If
harnesses OK, replace CD switch
Faulty overhead console Replace overhead console
Good sound, poor or no
pictureVehicle interior is too cold Allow the vehicle interior to warm up before switching on
the system
Source mode set incorrectly Press the 'Source' button on the remote handset to set
the correct operating mode
Faulty overhead console Replace overhead console
Remote control handset
does not functionCheck batteries in remote control
handsetReplace batteries with new batteries
Ensure that infra-red sensor on
overhead console is not
obstructedLower LCD monitor and check that sensor is not
obstructed or dirty
Status LED on overhead
console is flashingVehicle interior is too hot allow vehicle interior to cool down before switching on
the system
Audio through vehicle
speakers but not through
wired headphonesFaulty headphones Check headphone for correct operation.
Faulty overhead console Replace overhead console
Audio through vehicle
speakers but not through
wireless headphonesFaulty batteries in wireless
headphonesReplace batteries
Faulty headphones Test with known operational headphones and replace
headphones if necessary
Faulty RF transmitter or connector Replace overhead console
Faulty overhead console Replace overhead console
NAVIGATION SYSTEM
DESCRIPTION AND OPERATION 87-27
Sensor Check Menu
TestBook/T4 Diagnostics
No serial diagnostic link is provided with the CARiN III navigation system, so TestBook/T4 cannot interact with the
system.
Vehicle Position
If the vehicle’s battery has been disconnected, or if the vehicle has been transported to a new location on another
vehicle (e.g. by trailer or train), the navigation system will require up to 15 minutes to identify the new position. Entering
the vehicle’s position manually, reduces this delay. To enter the vehicle's position manually:
1Highlight and select Information.
2From the information menu, scroll down to the next screen and highlight and select Vehicle position.
NOTE: If the correct CD is in the navigation computer, the country is automatically entered. If you have travelled
to a new country, a new CD may be needed.
3From the vehicle position menu, highlight and select City, then use the typewriter menu to enter the vehicle’s
position (town, road, etc.) in the same way that you would enter a destination.
4Once the town and road names are entered, the navigation computer asks for a junction. This is the name of the
road that forms the next junction ahead of the vehicle.
5Highlight and select Junction, then enter the name using the typewriter, or select the correct road name if a list
of names is displayed. Crossing the junction will be highlighted. Drive the vehicle in the direction of the junction
and press the rotary controller when you reach the junction.
NOTE: The vehicle position menu provides a street map facility which enables you to check your vehicle’s current
position and assists in identifying the name of the next road junction.
Provided that the information entered into the computer is correct, the navigation system requires approximately 1
minute to determine the vehicle's position.
Navigation and Trafficmaster
Road navigation and off-road navigation are accessed from the main menu by highlighting and selecting the
appropriate title with the rotary controller. In both modes of navigation, this brings up a safety notice on the display
unit. Pushing the rotary controller again accepts the safety notice and replaces it with a menu screen, which is the
entry point for operation of the navigation function. The Trafficmaster function only operates in the road navigation
mode, and is activated and de-activated by pushing and holding the menu switch for more than 0.5 second. When
activating the Trafficmaster function, the system returns to the navigation mode if the menu switch is not released
within 1.5 seconds.
Refer to the Owner Handbook: Navigation, CARiN III & Traffic Master, Publication Part No. LRL 0586ENG for full
details of how to operate the road navigation, off-road navigation and Trafficmaster functions.
M86 6074
Sensor Check
Wheel Sensors
GPS Satellites
GPS Status
GYRO
Direction of Travel
< Return0
0
08
Position known
0285
Forward