Page 141 of 1007

LIFTING AND TOWING
08-2
Raising the front of a vehicle
Position the cup of the hydraulic arm under the 
centre of the front body crossmember assembly.
Use jack to raise front road wheels to enable safety 
stands to be  installed under the front end of each 
longitudinal member.
Carefully lower jack until vehicle sits securely on 
safety stands.
Before working on the underside of a vehicle re-
check the stability of the vehicle on the stands.
 Use the reverse procedure when removing a vehicle 
from stands. 
NOTE: For some repair operations it may be 
necessary to use a jack to support the engine under 
the sump. In this case, a block of wood should be 
used on the jack to protect the sump.
Raising the rear of a vehicle
Position cup of hydraulic arm under the centre of the 
rear subframe  crossmember at the position 
identified by the embossed arrows.
Use jack to raise rear road wheels to enable safety 
stands to be  installed under the rear ends of the 
body longitudinal members.
Carefully lower jack until vehicle sits securely on 
safety stands.
Before working on the underside of a vehicle, re-
check the  stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle 
from stands.   
Wheel-free lift
Locate the lifting pads under the ends of the body 
longitudinal members. Raise the ramp to support the 
weight of the vehicle, ensure the vehicle is secure on 
the lifting pads, then raise the ramp to the required 
height.
Towing
General
The vehicle has permanent four wheel drive. The 
following instructions must be adhered to:
Towing the vehicle on all four wheels with driver 
operating steering and brakes
lTurn ignition key to position '1' to release 
steering lock and then to position 'II' to enable 
the brake lights, wipers and direction indicators 
to be operated, if necessary.
l Select neutral in gearbox and ensure HDC (hill 
descent control) is deselected.
lSecure tow rope, chain or cable to towing eye.
lRelease the parking brake.
CAUTION: The brake servo and power assisted 
steering system will not be functional without the 
engine running. Greater pedal pressure will be 
required to apply the brakes and the steering 
system will require greater effort to turn the front 
road wheels. The vehicle tow connection should 
only be used under normal road conditions, 
'snatch' recovery should be avoided.
Suspended tow by breakdown vehicle
Mark propeller shaft drive flanges and mating flanges 
with identification lines to enable the propeller shaft 
to be refitted in its original position.
Remove the propeller shaft fixings then remove the 
shaft from  the vehicle.
CAUTION: To prevent vehicle damage, rear 
propeller shaft MUST BE removed. 
         
        
        
     
        
        Page 145 of 1007

CAPACITIES, FLUIDS, LUBRICANTS AND SEALANTS
09-2
Fluids
Fuel
Always use the following recommended fuels:
Petrol engines
Use unleaded petrol with a minimum octane rating of 
95 RON to ENN 228 specification.
In an emergency (and only if the correct fuel is 
unavailable), lower octane rated fuel can be used for 
very limited periods of moderate, low speed 
motoring, provided engine 'knocking' does not occur.
Fuels of 90 RON is used in certain markets; 90 RON 
fuel can be used regularly ONLY if the engine has 
been tuned specifically to suit low octane fuel.
Certain markets use fuel containing a 23% Ethanol 
additive.
K1.8 and KV6 engines are also available for use with 
a low octane leaded fuel specification in some 
markets.
Diesel engines
Use a good quality diesel fuel or automotive gas oil 
(AGO) conforming to EN 590 specification.
It is important that the sulphur content of diesel fuel 
does not exceed 0.3%.
Ensure the fuel filter element is changed at the 
recommended intervals.
 
 +  MAINTENANCE, MAINTENANCE, Fuel 
Filter - Diesel.
Brake Fluid
Use only DOT 4 brake fluid. DO NOT use brake fluid 
of a different specification.
PAS fluid
Use Texaco 9226 fluid.Anti-freeze solutions
The overall anti-freeze concentration should not fall, 
by volume,  below 50% to ensure that the anti-
corrosion properties of the coolant are  maintained. 
Anti-freeze concentrations greater than 60% are not 
recommended as cooling efficiency will be impaired.
Use Havoline Extended Life Coolant (XLC), or any 
ethylene glycol based anti-freeze (containing no 
methanol) with only Organic Acid Technology (OAT) 
corrosion inhibitors, to protect the cooling system.
CAUTION: No other anti-freeze should be used 
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and 
refilled with  the correct amount of anti-freeze 
solution at the intervals given on the  Service 
Maintenance Check Sheet. 
After filling with anti-freeze solution, attach a warning 
label to a prominent position on the vehicle stating 
the type of  anti-freeze contained in the cooling 
system to ensure that the  correct type is used for 
topping-up.
The following recommended quantities of anti-freeze 
will provide frost protection to -36 °C (-33 °F):
Engine – Td4
Engine – K1.8
Engine – KV6
Concentration 50%
Amount of anti-freeze 3.75 litres 
(6.625 imp. pts)
Concentration 50%
Amount of anti-freeze 2.9 litres 
(5.125 imp. pts)
Concentration 50%
Amount of anti-freeze 3.9 litres 
(6.875 imp. pts, ) 
         
        
        
     
        
        Page 160 of 1007
MAINTENANCE
MAINTENANCE 10-13
Vent filter - turbocharger boost control 
solenoid valve - Td4
Replace
1.Replace turbocharger solenoid valve vent filter. 
 
 +   FUEL DELIVERY SYSTEM - DIESEL, 
REPAIRS, Vent filter - turbocharger boost 
control solenoid valve - Td4.
Spark Plugs – K1.8
Check & Renew
1.Check spark plugs condition and gap. Renew if 
necessary.
 
 +  ENGINE MANAGEMENT SYSTEM - 
MEMS, REPAIRS, Spark plugs.
Spark Plugs – KV6
Check & Renew
1.Check spark plugs condition and gap. Renew if 
necessary.
 
 +  ENGINE MANAGEMENT SYSTEM - 
SIEMENS, REPAIRS, Spark plugs - up to 
03MY.
Air Cleaner – Petrol Models
Replace
1.Replace air cleaner element.
 
 +  FUEL DELIVERY SYSTEM - 
PETROL, REPAIRS, Element - air cleaner - 
KV6.
Clean
1.Clean the drain hole in filter casing. 
         
        
        
     
        
        Page 162 of 1007
MAINTENANCE
MAINTENANCE 10-15
Ancillary Drive Belt – KV6
Check
1.Check ancillary drive belts for tension, signs of 
fraying, damage and for any oil contamination.
Replace
1.Replace ancillary drive belt.
 
 +  CHARGING AND STARTING, 
REPAIRS, Ancillary drive belt - KV6.
Camshaft Timing Belt – K1.8
Check
1.Check camshaft drive belt and renew if 
necessary. 
 
 +  ENGINE - K SERIES 1.8, REPAIRS, 
Camshaft timing belt. 
         
        
        
     
        
        Page 163 of 1007
MAINTENANCE
10-16 MAINTENANCE
Camshaft Timing Belt – KV6
Check
1.Check camshaft drive belt and renew if 
necessary.
 
 +   ENGINE - K SERIES KV6, REPAIRS, 
Camshaft timing belt.
Brake/Clutch Reservoir
Check/Top-up
RHD shown, LHD similar
1.Check fluid level in brake/clutch fluid reservoir.
2.Clean area around filter cap, remove cap.
3.Top-up if necessary to correct level on reservoir 
using recommended fluid.
 
 +  CAPACITIES, FLUIDS, 
LUBRICANTS AND SEALANTS, Fluids.
4.Fit filler cap. 
         
        
        
     
        
        Page 166 of 1007

MAINTENANCE
MAINTENANCE 10-19
Manual Gearbox – GETRAG
Replace Fluid
WARNING: Avoid excessive skin contact 
with mineral oil. Mineral oils remove the 
natural fats from the skin, leading to 
dryness, irritation and dermatitis.
1.Replace gearbox fluid.
 
 +  MANUAL GEARBOX - GETRAG, 
ADJUSTMENTS, Gearbox oil - drain and 
refill.
Automatic Gearbox – JATCO
Check and top-up fluid
WARNING: Avoid excessive skin contact 
with mineral oil. Mineral oils remove the 
natural fats from the skin, leading to 
dryness, irritation and dermatitis.
1.Position vehicle on ramp.
2.Apply handbrake and position chocks under 
front and rear wheels.
3.Remove underbelly panel.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Panel - underbelly.
4.Connect TestBook/T4 to monitor gearbox fluid 
temperature.
CAUTION: The gearbox fluid level must only 
be checked when the temperature of the 
fluid is between 35° and 45°. The reading 
obtained will be incorrect if the fluid is 
outside this temperature range.
5.Start engine, move selector lever from 'P' 
through all gear positions, pausing in each gear 
position for 2-3 seconds and return to 'P' 
position.
6.Clean area around level plug.
7.With the engine still running, remove level plug 
using a 5 mm Allen socket and allow any 
excess fluid to drain off.
CAUTION: There are a number of similar 
fixings/plugs on the underside of the 
gearbox. It is imperative that the correct 
plug is removed prior to checking the level. 
Removing the wrong fixing/plug could 
result in internal damage to the gearbox.
8.If no fluid loss is apparent when level plug is 
removed: 
         
        
        
     
        
        Page 169 of 1007

MAINTENANCE
10-22 MAINTENANCE
Engine Oil and Filter – Td4
Drain 
1.Raise vehicle on ramp.
2.Remove underbelly panel.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Panel - underbelly.
3.Place a suitable container under engine sump 
drain plug, remove drain plug and discard 
sealing washer. Allow oil to drain.
WARNING: Observe due care when draining 
engine oil as the oil can be very hot.
WARNING: Avoid excessive skin contact 
with used engine oil. Used engine oil 
contains potentially harmful contaminants 
which may cause skin cancer or other 
serious skin disorders.
4.Lower vehicle
5.Remove oil filter cap and discard 3 seals.
CAUTION: Care must be taken to ensure 
that oil or fluid does not enter or 
contaminate the alternator.Refill
1.Replace engine oil filter.
 
 +  ENGINE - Td4, REPAIRS, Filter - 
engine oil.
2.Fit new seals and lubricate with clean engine 
oil.
3.Fit oil filter cap and tighten to 25 Nm (18 lbf.ft).
4.Raise vehicle.
5.Clean sump drain plug, fit new sealing washer 
and tighten sump drain plug to 28 Nm (21 lbf.ft).
6.Fit oil filler cap.
7.Fit underbelly panel.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Panel - underbelly.
8.Lower vehicle.
9.Remove engine oil filler cap and fill engine with 
oil to correct level.
 
 +  CAPACITIES, FLUIDS, 
LUBRICANTS AND SEALANTS, 
Lubrication.
10.Start engine. Run at idle until oil pressure 
warning light extinguishes.
11.Stop engine. Recheck engine oil level.
12.Check for signs of leakage. 
         
        
        
     
        
        Page 170 of 1007

MAINTENANCE
MAINTENANCE 10-23
Engine Oil and Filter – K1.8
Drain
1.Raise vehicle on ramp.
2.Remove underbelly panel.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Panel - underbelly.
3.Place a suitable container under engine sump 
drain plug, remove plug and discard sealing 
washer. Allow oil to drain.
WARNING: Observe due care when draining 
engine oil as the oil can be very hot.
WARNING: Avoid excessive skin contact 
with used engine oil. Used engine oil 
contains potentially harmful contaminants 
which may cause skin cancer or other 
serious skin disorders.
4.Remove and discard engine oil filter.Refill
1.Lubricate sealing ring of new filter with clean 
engine oil.
2.Fit new filter and tighten by hand until it seats, 
then tighten a further half a turn.
3.Clean sump drain plug and fit new sealing 
washer.
4.Fit sump drain plug and tighten to 25 Nm (18 
lbf.ft).
5.Remove engine oil filler cap and fill engine with 
oil to correct level.
 
 +  CAPACITIES, FLUIDS, 
LUBRICANTS AND SEALANTS, 
Lubrication.
6.Fit oil filler cap.
7.Fit underbelly panel.
 
 +  EXTERIOR FITTINGS, REPAIRS, 
Panel - underbelly.
8.Lower vehicle.
9.Start engine. Run at idle until oil pressure 
warning light extinguishes.
10.Stop engine. Recheck engine oil level.
11.Check for signs of leakage.