Page 149 of 1007
MAINTENANCE
10-2 MAINTENANCE
K1.8 – Petrol Engine – Under Bonnet
View
LHD shown, RHD similar
1Cooling system expansion tank filler cap
2Engine oil dipstick
3Brake/Clutch fluid reservoir cap
4Engine Control Module box
5Engine compartment fusebox
6Battery
7Air cleaner
8Engine oil filler cap
9Windscreen washer reservoir filler cap
10Power steering reservoir
Page 150 of 1007
MAINTENANCE
MAINTENANCE 10-3
KV6 – Petrol Engine – Under Bonnet
View
LHD shown, RHD similar - 03 Model Year illustrated
1Power steering reservoir
2Cooling system expansion tank filler cap
3Brake/Clutch fluid reservoir cap
4Engine Control Module box
5Engine compartment fusebox
6Battery
7Engine oil filler cap
8Engine oil dipstick
9Windscreen washer reservoir filler cap
Page 151 of 1007

MAINTENANCE
10-4 MAINTENANCE
Seats and Seat Belts
Check
1.Check seat frames are secured to floor and
show no signs of movement.
2.Check operation of seat slide and tilt
mechanisms, ensuring there is no excessive
play between seat cushion and seat back.
3.Check tightness of accessible seat fixings.
4.Fully extract seat belt and allow it to return
under its own recoil mechanism.
5.Check entire length of seat belt webbing for
signs of fraying or damage. Repeat for all belts.
6.Check security of seat belt upper mountings.
7.Check for correct operation of seat belt height
adjusters.
8.Check security of seat belt buckle mountings.
9.Connect each belt to the correct buckle, check
seat belt buckle and tongue are secure.
Release seat belt buckle and check for correct
operation.
10.Check tightness of accessible seat belt
mountings.
Lamps, Horns and Warning Indicators
Check
1.Switch on side, head and tail lights and check
operation.
2.Check headlamp dim/dip operation.
3.Check headlamp levelling operation.
4.Check turn signals and hazard warning lights
operation.
5.Press brake pedal and check operation of
brake lights.
6.Check all exterior lamp lenses for clarity and
condition. Pay particular attention to head lamp
lenses for signs of stone chips or damage.
7.Check horn for loud clear sound.
8.Check operation of all instrument pack warning
and indicator lights.
9.Check for correct operation of interior courtesy
lights.
10.Switch on headlamps (with ignition switch at 'O'
position) and check light reminder warning
operates when door is opened.
Page 152 of 1007

MAINTENANCE
MAINTENANCE 10-5
Wipers and Washers
Check
1.Operate screen washer and switch on wipers.
Check washer jets are correctly aimed and
check for smooth smearless operation across
screen of wiper blades at all speeds, including
intermittent.
2.Repeat operation for rear screen wipers/
washers.
3.Check all wiper blades for condition and signs
of splits or damage.
4.Check security of wiper arms.
Handbrake
Check
1.With the vehicle stationary and on a level
surface, apply and release handbrake and
check for correct operation. If required, adjust
handbrake.
+ BRAKES, ADJUSTMENTS, Cable -
handbrake - check and adjust.
NOTE: Any adjustment required as a result of
the checking process will be subject to
additional labour and/or material cost and
should not be carried out without the
authorisation of the customer.
Adjust Handbrake
(First 12,000 miles/12 months only)
1.Adjust handbrake cable.
+ BRAKES, ADJUSTMENTS, Cable -
handbrake - check and adjust.
NOTE: Additional time is built into the first
12,000/12 months service time to allow for
handbrake cable adjustment.
Page 154 of 1007

MAINTENANCE
MAINTENANCE 10-7
Tyres
Check
1.Check for any apparent damage to tyres,
paying particular attention to side walls.
2.Look at tyre treads and check for any unusual
wear patterns which may indicate out of
specification adjustment of steering or
suspension.
NOTE: Any adjustments to steering or
suspension will be subject to additional labour
and/or material cost and should not be carried
out without the authorisation of the customer.
3.Measure the tread depth across the width of the
tyre and around the circumference. Annotate
the maintenance check sheet with the lowest
figure obtained from each tyre.
NOTE: Any requirement to replace tyres should
be advised to the customer before any remedial
work is carried out. This will be subject to
additional labour and/or material cost and
should not be carried out without the
authorisation of the customer.
CAUTION: If new tyres are to be fitted,
ensure that they are fitted to the rear axle
only or to both front and rear axles. DO NOT
fit new tyres to front axle only.
Brake Pads and Calipers
Brake Pads
1.With front road wheels removed, check brake
pad thickness and ensure that both pads are
wearing evenly.
2.Check brake discs for signs of cracking,
excessive scoring or oil contamination.
NOTE: Any requirement to replace brake pads
or brake discs should be advised to the
customer as this will be subject to additional
labour and/or material cost and should not be
carried out without the authorisation of the
customer.
3.Check for any signs of brake fluid leakage from
caliper seals, hoses or unions.
4.Using brake cleaner, remove excessive
deposits of brake dust from pads, calipers and
disc shields.
Page 155 of 1007

MAINTENANCE
10-8 MAINTENANCE
Brake Shoes
1.With the vehicle at a convenient working height,
remove the rubber plugs from the rear of the
back plate.
2.Using a lamp, inspect thickness of rear brake
shoes.
NOTE: Any requirement to replace brake shoes
should be advised to the customer as this will
be subject to additional labour and/or material
cost and should not be carried out without the
authorisation of the customer.
3.Check for any signs of brake fluid
contamination on brake shoes, or evidence of
brake fluid leakage from drum/backplate.
4.Ensure that rubber plug is correctly fitted into
back plate upon completion of check.Brake Drums
1.With vehicle at a convenient working height and
the wheels removed, remove the rear brake
drums.
+ BRAKES, REPAIRS, Drum - rear.
2.Check brake shoe thickness, and condition of
brake shoes for any evidence of contamination
from brake fluid.
3.Check brake drum for signs of cracking,
excessive scoring or oil contamination.
NOTE: Any requirements to replace brake
shoes, wheel cylinders or brake drums should
be advised to the customer as this will be
subject to additional labour and/or material cost
and should not be carried out without the
authorisation of the customer.
4.Using brake cleaner, remove excessive
deposits of brake dust from drums, shoes and
back plate.
5.Refit drums.
+ BRAKES, REPAIRS, Drum - rear.
Page 156 of 1007
MAINTENANCE
MAINTENANCE 10-9
Brake Fluid
Replace
1.Replace brake fluid.
+ BRAKES, ADJUSTMENTS, Brake
bleed.
Road Wheel Speed Sensors
Inspect
Front wheel
1.Check harness is correctly routed and secured.
Ensure harness shows no sign of damage or
chafing.
2.Check speed sensor is fully inserted to the
correct position. Check reluctor ring condition
and ensure it is free from debris.
Rear wheel
3.Check harness is correctly routed and secured.
Ensure harness shows no sign of damage or
chafing.
4.Check speed sensor is fully inserted to the
correct position. Check reluctor ring condition
and ensure it is free from debris.
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.