Page 466 of 1007
AUTOMATIC GEARBOX - JATCO
REPAIRS 44-31
Fluid cooler - KV6
$% 44.24.10
Remove
1.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
2.Position container to collect fluid spillage.
WARNING: Observe due care when draining
gearbox fluid as the fluid can be very hot.
3.Disconnect 2 fluid cooler hose unions and
discard 'O' rings.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Position container to collect coolant spillage.
5.Release 2 clips and disconnect coolant hoses
from fluid cooler.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 2 bolts securing fluid cooler.
7.Remove fluid cooler.Refit
1.Position fluid cooler to mounting bracket, fit
bolts and tighten to 25 Nm (18 lbf.ft).
2.Connect coolant hoses and secure with clips.
3.Lubricate new 'O' rings with clean transmission
fluid and fit 'O' rings to fluid cooler hoses.
+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
4.Connect hoses to fluid cooler and tighten
unions to 18 Nm (13 lbf.ft).
5.Refill cooling system.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
6.Top-up gearbox fluid level.
+ MAINTENANCE, MAINTENANCE,
Automatic Gearbox – JATCO.
7.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
Page 491 of 1007
REAR AXLE & FINAL DRIVE
51-6 REPAIRS
Refit
1.Fit new collapsible spacer.
2.Fit pinion bearing and oil thrower.
3.Clean pinion flange and oil seal recess.
4.Fit new oil seal using LRT-51-010.
5.Fit pinion flange and washer.
6.Restrain pinion flange using LRT- 51-003.
7.Fit new pinion nut and tighten to 190 Nm (140
lbf.ft).
8.Check for end float on pinion. If end float exists
continue to tighten pinion nut until end float is
removed.
9.Continue to tighten pinion nut until correct
preload is obtained.
10.Pinion preload is 1.7 - 2.8 Nm (1.2 - 2.1 lbf.ft), if
higher replace collapsible spacer.
CAUTION: Do not tighten pinion nut to more
than 373 Nm (275 lbf.ft), or the collapsible
spacer will compress too far.
11.Clean propeller shaft flange and mating face.
12.Position propeller shaft to rear axle and align
reference marks.
13.Tighten propeller shaft nuts and bolts to 65 Nm
(48 lbf.ft).
14.Fit drive shafts.
+ REAR AXLE & FINAL DRIVE,
REPAIRS, Oil seal - differential housing.
15.Check differential oil level.
+ MAINTENANCE, MAINTENANCE,
Rear Axle.
Oil seal - differential housing
$% 51.20.36
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.
3.Remove bolt securing handbrake cable to
subframe.
4.Remove nut and bolt securing trailing link to
rear hub, collect spacer from under bolt head.
5.Remove nut and bolt securing fixed transverse
link to subframe. Collect dynamic damper.
6.Remove nut and bolt securing adjustable
transverse link to subframe.
7.Position drain tin to catch oil spillage.
8.With assistance pull hub assembly outwards.
Page 502 of 1007
STEERING
REPAIRS 57-9
Oil cooler - Td4 & K1.8 models
$% 57.15.11
Remove
1.Disconnect battery earth lead.
2.Remove engine acoustic cover if fitted.
+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
3. Td4 models: Release and remove air intake
duct.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Ducting - intake assembly.
4. Td4 models: Loosen 2 clips and remove
intercooler outlet hose.
5. Td4 models: Remove dipstick for access.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove bolt securing PAS oil cooler pipe lower
mounting bracket to body.
7.Remove bolt securing PAS oil cooler pipe to RH
suspension turret.8.Place a suitable container beneath PAS
reservoir, release clip and disconnect return
hose from mount. Allow fluid to drain.
9.Place container beneath PAS quick release
pipe fitting.
10.Clean area surrounding quick release
connection.
11.Using LRT-57-044, disconnect cooler quick
release hose.
12.Release PAS reservoir from mounting bracket
and move aside.
13.Remove PAS oil cooler from vehicle.
NOTE: Do not carry out further dismantling if
component is removed for access only.
M12 6972
M57 1047
Page 508 of 1007
STEERING
REPAIRS 57-15
Pump - steering - Td4
$% 57.20.14
Remove
1.Disconnect battery earth lead.
2.Remove hydramount.
+ ENGINE - Td4, REPAIRS,
Hydramount - engine - RH.
3.Loosen 3 PAS pump pulley bolts.
4.Remove ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
5.Raise engine on hoist.
6.Remove bolts and remove PAS pump pulley.
7.Cover alternator to prevent PAS oil
contamination.
8.Place container beneath PAS pump, release
clip and remove feed hose to pump. Allow fluid
to drain.
CAUTION: Care must be taken to ensure
that oil or fluid does not enter or
contaminate the alternator.9.Remove banjo bolt securing fluid outlet hose to
PAS pump, release hose, remove and discard
sealing washers.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
10.Remove 4 bolts and remove PAS pump.
11.Remove 5 Torx bolts securing PAS pump to
mounting brackets. Collect mounting brackets.
Refit
1.Position PAS pump to mounting brackets, fit
and tighten Torx bolts to 25 Nm (18 lbf.ft).
2.Position pump to mounting, fit bolts and tighten
M8 bolts to 25 Nm (18 lbf.ft) and M6 bolts to 10
Nm (7.5 lbf.ft).
3.Using new sealing washers, fit PAS outlet hose
to pump and tighten banjo bolt to 25 Nm (18
lbf.ft).
4.Clean PAS pump and mating faces.
5.Fit inlet hose to PAS pump and secure with new
clip.
6.Fit PAS pump pulley to PAS pump and tighten
bolts to finger tight.
7.Fit ancillary drive belt.
+ CHARGING AND STARTING,
REPAIRS, Ancillary drive belt - Td4.
8.Tighten PAS pump pulley bolts to 10 Nm (7.5
lbf.ft).
9.Fit hydramount.
+ ENGINE - Td4, REPAIRS,
Hydramount - engine - RH.
10.Connect battery earth lead.
Page 717 of 1007
SUNROOF
76-6-4 REPAIRS
Sun/sliding roof - complete - front - 5
door
$% 76.84.01
Remove
1.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
2.Disconnect drain tubes from sun roof.
3.Disconnect multiplug from sun roof motor.
4.With assistance, remove 6 nuts and 2 bolts
securing sun roof.
5.Remove sun roof.
Refit
1.Ensure plastic washer and tray seal are in
position.
2.With assistance position sun roof assembly, fit
and tighten nuts and bolts.
3.Connect multiplug to sun roof.
4.Connect drain tubes to sun roof and secure
with cable ties.
5.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 5 door.
Glass panel - sun/sliding roof - front - 5
door
$% 76.84.03
Remove
1.Open sun roof blind.
2.Remove covers from glass securing screws.
3.Remove 6 screws securing glass.
4.Remove glass.
Refit
1.Position glass, fit screws but do not tighten at
this stage.
2.Align glass to roof and tighten screws,
alignment points should be measured 300 mm
either side of the centre line.
3.Set front of glass, flush to roof panel to 1.0 mm
down.
4.Set rear of glass, flush to roof panel to 1.0 mm
up.
5.Fit screw covers.
6.Operate sunroof to check alignment.
7.Close sun roof blind.
Page 872 of 1007
HEATING AND VENTILATION
REPAIRS 80-7
Heater unit
$% 80.20.01
Remove
1.Drain cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - drain & refill.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
2.Release 2 clips securing heater hoses to heater
and disconnect hoses.
3.Remove fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
4.Remove 2 bolts from console support bracket,
release 2 relays and remove bracket. Up to
03MY illustrated.5.Disconnect 4 multiplugs from heater controls.
Up to 04MY illustrated.
6.Disconnect multiplug from heater and release
diagnostic socket.
7. Models with A/C: Disconnect multiplug from
evaporator.
8.Remove bolt from duct of LH outer face level
vent and release duct from heater.
Page 874 of 1007
HEATING AND VENTILATION
REPAIRS 80-9
Refit
1.Position heater controls to replacement heater.
2.Connect air distribution cable to lever and
abutment.
3.Connect air blend cable to lever and abutment.
4.Connect multiplugs to heater controls.
5.Fit heater and secure with nuts and bolt.
6.Position harness and connect to clips on
heater.
7.Fit air inlet connector hose.
8.Fit RH demister vent duct to heater.
9. Models with passenger airbag, fit carrier.Fit
RH outer face level vent duct to heater and
secure to body with bolt.
10.Fit LH demister vent duct to heater.
11.Fit LH outer face level vent duct to heater and
secure to body with bolt.
12. Models with A/C: Connect multiplug to
evaporator.
13.Connect multiplug to heater and secure
diagnostic socket.
14.Connect multiplugs to heater controls.
15.Fit console support bracket and secure with
bolts.
16.Fit relays to console support bracket.
17.Fit fascia.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Fascia - up to 04MY.
18.Connect heater hoses and secure with clips.
19.Refill cooling system.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
+ COOLING SYSTEM - K SERIES 1.8,
ADJUSTMENTS, Coolant - drain & refill.
+ COOLING SYSTEM - K SERIES KV6,
ADJUSTMENTS, Coolant - drain and refill.
Page 883 of 1007
HEATING AND VENTILATION
80-18REPAIRS
Fuel burning heater (FBH)
$% 80.40.01
Remove
1.Disconnect battery earth lead.
2.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
3.Drain coolant.
+ COOLING SYSTEM - Td4,
ADJUSTMENTS, Coolant - drain and refill.
4.Position container to collect coolant spillage.
5.Release clips, disconnect coolant feed and
return hoses from FBH.
CAUTION: Before disconnecting or
removing components, ensure the
immediate area around joint faces and
connections are clean. Plug open
connections to prevent contamination.
6.Position an absorbent cloth, release clip and
remove fuel feed hose from FBH. Plug
connections and move aside.7.Loosen 1 bolt and remove other bolt securing
FBH mounting bracket to body.
8.Release FBH from mounting, disconnect
multiplugs and move assembly aside.
NOTE: Do not carry out further dismantling if
component is removed for access only.
9.Remove 3 bolts securing FBH to mounting
bracket.
10.Remove bracket.
M80 0496
M80 0499
