Page 171 of 1007

MAINTENANCE
10-24 MAINTENANCE
Engine Oil and Filter – KV6
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.
+ ENGINE - K SERIES KV6, REPAIRS,
Filter - engine oil.Refill
1.Fill canister of replacement oil filter with clean
engine oil.
2.Lubricate sealing ring of new filter with clean
engine oil.
3.Fit new filter and tighten by hand until it seats,
then tighten a further half turn.
4.Clean sump drain plug and fit new sealing
washer.
5.Fit sump drain plug and tighten to 25 Nm (18
lbf.ft).
6.Remove engine oil filler cap and fill engine with
oil to correct level.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
7.Fit oil filler cap.
8.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
9.Lower vehicle.
10.Start engine. Run at 2500 rev/min until oil
pressure warning light extinguishes.
11.Stop engine. Recheck engine oil level.
12.Check for signs of leakage.
Page 551 of 1007

BRAKES
70-2 ADJUSTMENTS
Cable - handbrake - check and adjust
$% 70.35.10
Check
1.Release ash tray panel from rear console,
disconnect multiplug from power socket and
remove ash tray panel.
2.Fully release handbrake lever.
3.With engine running, apply footbrake a
minimum of thirty times, to ensure full
adjustment of rear brake shoes.
4.Switch off engine.
5.Apply handbrake lever one notch at a time and
count the number of notches required to apply
the brakes firmly, equivalent to a pull of 20 kgf.
applied at mid point of handbrake lever grip.
Handbrake lever travel = 4 to 7 notches.
6.Adjust handbrake cable tension if travel is
outside limits.
CAUTION: Hand brake travel must be within
the limits given or the automatic adjusters
may not work.Adjust
1.If carrying out handbrake adjustment after
brake drum installation, apply brake pedal a
min. of 30 times, to ensure full adjustment of
rear brake shoes.
2.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Check handbrake cable connections for free
movement in handbrake equalizer.
4.Apply handbrake lever one notch.
5.Tighten equalizer adjusting nut until rear
wheels drag slightly when turned.
6.Release handbrake lever and check that rear
wheels do not drag when turned. Adjust if
necessary.
7.Apply handbrake one notch at a time and count
the number of notches until both rear wheels
lock. This should be a minimum of 4 and a
maximum of 7 clicks. Adjust if necessary.
8.Release handbrake
9.Fit ash tray panel and cigar lighter to rear
console.
10.Remove stands and lower vehicle.
Page 560 of 1007
BRAKES
REPAIRS 70-11
Cable - handbrake
$% 70.35.25
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Release rear ash tray, disconnect connector
from cigar lighter and remove ash tray.
4.Remove cable adjusting nut.
5.Remove 2 bolts securing cable retaining plate
to body and remove plate.
6.Release equalizer from adjusting rod.
7.Release cable from equalizer plate.
8.Remove 2 bolts securing cable to body and
subframe.
9.Release cable from chassis clip.10.Release cable grommet from floor and pull
cable from interior.
11.Remove rear brake shoes.
+ BRAKES, REPAIRS, Brake Shoes -
rear set.
12.Using tool LRT-70-007 release cable retainer
from backplate and withdraw cable from
vehicle.
Page 561 of 1007

BRAKES
70-12 REPAIRS
Refit
1.Manoeuvre cable into position and secure floor
grommet.
2.Fit and secure handbrake cable to backplate.
3.Fit brake shoes.
+ BRAKES, REPAIRS, Brake Shoes -
rear set.
4.Align cable clips, fit bolts and tighten to 22 Nm
(16 lbf.ft).
5.Secure cable in chassis clip.
6.Connect handbrake cable to equalizer.
7.Ensure spring is in place and fit equalizer to
adjusting rod.
8.Fit cable adjusting nut.
9.Fit cable retaining plate, fit bolts and tighten to
22 Nm (16 lbf.ft).
10.Adjust handbrake cable.
+ BRAKES, ADJUSTMENTS, Cable -
handbrake - check and adjust.
11.Fit ash tray and cigar lighter to rear console.
12.Fit road wheel(s).
13.Remove stands and lower vehicle.
Switch - handbrake warning
$% 70.35.40
Remove
1.Remove rear console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
2.Disconnect Lucar from handbrake warning
switch.
3.Release switch from handbrake.
Refit
1.Fit switch to handbrake and connect Lucar.
2.Fit rear console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
Page 715 of 1007

SUNROOF
76-6-2 REPAIRS
11.Using suitable cutting wire, cut through PU
sealer securing sun roof to roof.
NOTE: If multi-strand cutting wire is used, a
sawing action can be used to cut through heavy
sealant deposits around corners.
12.Remove sun roof.
Refit
1.Clean surrounding area with solvent.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
2.Use a vacuum cleaner to clear away any waste.
3.Cut sealer on roof flange down to a smooth
even finish.
4.Etch prime and paint any damaged areas.
5.Apply primer over etch primer on flange.
6.Apply activator over old sealer on flange.
7.Allow activator to cure.
8.Fit pre-cut nozzle to sealer cartridge, remove
lid, shake out crystals and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.
9.Apply a continuous bead of sealer around roof
flange. Make bead slightly thicker at the
corners.
10.Check for breaks and air bubbles in sealer.
11.With assistance position sunroof and align to
roof aperture.
12.Fit sunroof tray seal.
+ SUNROOF, REPAIRS, Seal - tray -
sun /sliding roof - front.
13.Position sunroof clamping plates, fit and tighten
screws.
14.Connect drain tubes and secure with new cable
ties.
15.Remove body and trim protection.
16.Position wind deflectors, fit and tighten screws.
17.Fit 'T' bar and glass panels.
18.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
Wind deflector - sun/sliding roof - 3 door
$% 76.83.28
Remove
1.Release and remove sun roof glass panel.
2.Remove 4 screws securing hinges, remove
wind deflector and collect hinges.
Refit
1.Locate hinges to wind deflector, position wind
deflector, fit and tighten screws.
2.Position glass panel and secure catch.
Page 941 of 1007

LIGHTING
86-2-10 REPAIRS
Switch - hazard warning
$% 86.65.50
Remove
1.Remove radio.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
2.Remove selector knobs from heater controls.
3.Remove 2 screws securing heater control
finisher to heater controls and remove finisher.
4.Release hazard warning switch from heater
controls.
5.Disconnect multiplug and remove hazard
warning switch.
Refit
1.Position hazard warning switch and connect
multiplug.
2.Fit hazard warning switch to heater controls.
3.Fit heater control finisher to heater controls and
secure with screws.
4.Fit heater control knobs.
5.Fit radio.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
Switch - combined direction indicator/
headlight/horn
$% 86.65.55
Remove
1.Remove steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
2.Disconnect 2 multiplugs from indicator and light
switch.
3.Rotate steering wheel to access switch screws.
4.Remove 2 screws securing switch.
5.Depress retaining tag and remove switch.
Refit
1.Fit indicator and light switch and secure with
screws.
2.Connect multiplugs to switch.
3.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
Page 995 of 1007
DRIVER CONTROLS
86-8-4 REPAIRS
Switch - hazard warning - from 04MY
$% 86.65.50
Remove
1.Remove fascia cup holder.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Cup holder - fascia - from 04MY.
2.Release hazard switch from fascia carrier.
3.Disconnect multiplug and remove hazard
warning switch.
Refit
1.Position hazard warning switch and connect
multiplug.
2.Fit switch to fascia carrier.
3.Fit fascia cup holder.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Cup holder - fascia - from 04MY.
Cigar lighter - front
$% 86.65.60
Remove
1.Remove front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Remove cigar lighter element.
3.Remove bulb holder from lighter.
4.Release cigar lighter body from console and
remove.
Refit
1.Fit and secure cigar lighter body to console.
2.Fit bulb holder to lighter.
3.Fit lighter element.
4.Fit front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.