Publi s hed: 11-May-2011
Battery, Mounting and Cables - Battery and Cables
Des cript ion and Operat ion
COMPONENT LOCATION
• NOTE: TD4 s hown, i6 s imil ar
ItemPart NumberDescription1-Batt ery
2-Central Junct ion Box (CJB)
3-Auxili ary Junct ion Box (AJB)4-Batt ery Junct ion Box (BJB)
5-Starter mot or
6-Generator
OVERVIEW
The batt ery i s located behind a cover on t he Left Hand (LH) si de of the engine compart ment . The bat tery s it s in a t ray andis secured i n pos it ion wi th a clamp pl at e and bolt as s embly. The batt ery s upplies elect ri cal power to the s t art er motor,generator and BJB.
The BJB is mount ed adjacent t he LH front s us pens ion t urret. The BJB cont ains fusi ble l inks , bl ade and J-case fus es, andrel ays to di st ribute el ect ri cal power to various vehicle s ys tems and junct ion boxes .
Publ is hed: 11-May-2011
Front End Sheet Metal Repairs - Front Side Member Section
Removal and Installation
Removal
• NOTE: The front side member section is cut from the front side member service panel.
• NOTE: The RH section is slightly shorter than the LH due to the location of the engine mounting.
• NOTE: Due to the combined thickness of the panels, it is recommended that spot welds are replaced with MIG plug welds
in this repair.
1. The front s ide member s ect ion is replaced in conjunct ion wit h:
Front bumper cover
Front bumpe r a rma t ure
Hood lat ch panel
Both front fenders
Front bumpe r mount i ng
• NOTE: It is also necessary to remove the engine and suspension as an assembly.
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Re move t he f ront bumpe r mount i ng.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Bumper Mount ing
(501-27 Front End Sheet Met al Re pai rs , Removal and
Installation).
4. Remove the radiator cooling pack.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Radiator
(303-03A Engi ne
Cooling - I6 3.2L Petrol, Removal and Installation).
5. Remove the engine and front suspension as an assembly.
6. LH Side: Remove the air intake pipe.
7. LH Side: Release the battery junction box and position aside.
8. RH Side: Remove the windshield washer reservoir.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Windshield Washer
Res ervoi r (501-16 W i pers and W as hers , Removal and
Installation).
9. Release and lay aside the wiring harness.
10. Mill out the spot welds.
Publ is hed: 11-May-2011
Roof Sheet Metal Repairs - Roof PanelVehicles Without: Sliding Roof
Opening Panel
Removal and Installation
Removal
• NOTE: The roof is serviced as a separate weld on panel, less its reinforcements.
• NOTE: Along the RH and LH sides of the panel, spot welds should be installed adjacent to the originals and not in the
same locations.
1. The roof panel is replaced in conjunction with:
Liftgate
Windshield
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Disconnect both battery cables.
4. Remove the liftgate.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Liftgate
(501-03 Body
Closures, Removal and Installation).
5. Remove the windshield glass.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Windshield Glass
(501-11
Glass, Frames and Mechanisms, Removal and Installation).
6. Remove both front seats.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Seat
(501-10
Seating, Removal and Installation).
7. Remove the rear seat.
8. Remove bot h side air curt ain modules.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Side Air Bag Module
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
9. Remove both front safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
10. Remove both rear safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
11. Release and lay aside the wiring harness.
Publ is hed: 11-May-2011
Roof Sheet Metal Repairs - Roof Rear PanelVehicles With: Sliding Roof
Opening Panel
Removal and Installation
Removal
• NOTE: The roof rear panel is serviced as a separate weld-on panel, less its reinforcements.
• NOTE: Along the RH and LH sides of the panel, spot welds should be installed adjacent to the originals and not in the
same locations.
1. T he ro o f re a r p a ne l i s re p l a ce d i n co nj unct i o n w i t h:
Liftgate
Roof opening panel
2. Fo r a d d i t i o na l i nf o rma t i o n re l a t i ng t o t hi s re p a i r p ro ce d ure
please see the following:
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Body and Frame
(501-26
Body Repairs - Vehicle Specific Information and Tolerance
Checks, Description and Operation) /
St a nd a rd W o rks ho p P ra ct i ce s
(100-00 Ge ne ra l I nf o rma t i o n,
Description and Operation).
3. Disconnect both battery cables.
4. Remove the liftgate.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Liftgate
(501-03 Body
Closures, Removal and Installation).
5. Remove both front seats.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Seat
(501-10
Seating, Removal and Installation).
6. Remove the rear seat.
7. Remove the roof opening panel.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Roof Opening Panel
(501-17 Roof O peni ng Panel , Removal and Ins t al l at i on).
8. Remove bot h side air curt ain modules.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Side Air Bag Module
(501-20B Suppl ement al Res t rai nt Sys t em, Removal and
Installation).
9. Remove both front safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Front Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
10. Remove both rear safety belt retractors.
Fo r a d d i t i o na l i nf o rma t i o n, re f e r t o : Rear Safety Belt Retractor
(501-20A Safe t y Bel t Sys t em, Removal and Ins t al l at i on).
11. Release and lay aside the wiring harness.
12. Re mo ve 4 21mm he a de d bo l t s , 2 e a ch s i de .
Contents
5
R
ENGINE COOLANT CHECK ............................ 163
BRAKE AND CLUTCH FLUID CHECK ............. 165
POWER STEERING FLUID CHECK ................ 166
WASHER FLUID CHECK ................................ 167
TECHNICAL SPECIFICATIONS ...................... 169
Vehicle battery
BATTERY WARNING SYMBOLS ................... 171
BATTERY CARE ............................................ 171
USING BOOSTER CABLES ............................ 173
CHARGING THE VE HICLE BATTERY ............. 174
CHANGING THE VE HICLE BATTERY ............. 174
Wheels and tyres
GENERAL INFORMATION ............................. 176
TYRE CARE ................................................... 177
USING WINTER TYRES................................. 183
CHANGING A ROAD WHEEL ......................... 183
TYRE REPAIR KIT ......................................... 187
USING SNOW CHAINS.................................. 192
TYRE GLOSSARY.......................................... 193
TECHNICAL SPECIFICATIONS ...................... 194
Fuses
FUSE BOX LOCATIONS ................................. 195
CHANGING A FUSE ....................................... 195
FUSE SPECIFICATION CHART....................... 196
Emergency equipment
HAZARD WARNING FLASHERS .................... 204
WARNING TRIANGLE ................................... 204
Status after a collision
DRIVING AFTER A COLLISION...................... 205
INSPECTING SAFETY SYSTEM COMPONENTS ...
206
Vehicle recovery
TOWING POINTS .......................................... 207
LASHING POINTS ......................................... 208
TRANSPORTING THE VEHICLE..................... 208
TOWING THE VEHICLE ON FOUR WHEELS .. 208
Vehicle identification
VEHICLE IDENTIFICATION PLATE................. 210
VEHICLE IDENTIFI CATION NUMBER (VIN) ... 210
VEHICLE BUILD DATE PLATE ....................... 210
Technical specifications
ENGINE SPECIFICATIONS ............................ 211
WEIGHTS...................................................... 212
DIMENSIONS................................................ 213
Type approval
Declarations of conformity ........................... 215
Audio introduction
RADIO RECEPTION....................................... 218
Audio unit overview
AUDIO UNIT OVERVIEW............................... 219
Audio unit operation
ON OR OFF CONTROL .................................. 223
VOLUME CONTROL ...................................... 223
AUDIO CONTROL ......................................... 223
WAVEBAND BUTTON ................................... 224
AUTOSTORE CONTROL ................................ 225
STATION PRESET BUTTONS ........................ 226
TRAFFIC INFORMATION CONTROL .............. 226
Audio unit menus
RADIO DATA SYSTEM (RDS) ....................... 228
REGIONAL MODE (REG) .............................. 228
ENHANCED OTHER NETWORK (RDS-EON).. 229
ALTERNATIVE FREQUENCIES ...................... 229
NEWS BROADCASTS ................................... 230
PRIORITY PROGRAMME TYPE (PTY) .......... 231
RESETTING THE AUDIO UNIT ...................... 233
Digital audio broadcasting
GENERAL INFORMATION ............................. 234
AUDIO CONTROLS ....................................... 235
DISPLAY OPTIONS ....................................... 236
CHANNEL AUTOMATIC TUNING................... 236
CHANNEL OPTIONS ..................................... 236
PRESET BUTTONS ....................................... 238
SETTINGS..................................................... 240
Compact disc player
LOADING COMPACT DISCS ......................... 245
EJECTING COMPACT DISCS ........................ 246
EJECTING MULTIPLE CO MPACT DISCS....... 246
COMPACT DISC SELECTION ........................ 246
COMPACT DISC PLAYBACK ......................... 246
Index
273
R
Driving after a collision . . . . . . . . . . . . . . 205 Before starting or driving . . . . . . . . . . 205
Resetting the fuel cut-off . . . . . . . . . . 205
When driving . . . . . . . . . . . . . . . . . . . 205
E
Economical driving . . . . . . . . . . . . . . . . . 129
Driving tips for economy . . . . . . . . . . 129
Maintenance and fuel economy . . . . . 129
Ejecting compact discs . . . . . . . . . . . . . . 246
Ejecting multiple compact discs . . . . . . . 246
Electric exterior mirrors . . . . . . . . . . . . . . 95 Adjusting and folding . . . . . . . . . . . . . . 95
Mirror dip when reversing . . . . . . . . . . 96
Electric seats . . . . . . . . . . . . . . . . . . . . . . . 49 Driving position memory . . . . . . . . . . . 50
Electric sunroof . . . . . . . . . . . . . . . . . . . . 105 Anti-trap mechanism . . . . . . . . . . . . . 105
Calibration . . . . . . . . . . . . . . . . . . . . . 106
Operation . . . . . . . . . . . . . . . . . . . . . . 105
Sunroof blinds . . . . . . . . . . . . . . . . . . 106
Electric windows . . . . . . . . . . . . . . . . . . . . 93
One shot operation . . . . . . . . . . . . . . . . 93
Overriding anti-trap protec tion . . . . . . . 93
Window isolator . . . . . . . . . . . . . . . . . . 94
Window reset . . . . . . . . . . . . . . . . . . . . 94
Engine compartment overview . . . . . . . . 161 1. Engine oil filler caps (Black) . . . . . . 161
2. Engine oil dipsticks (Yellow) . . . . . . 161
3. Brake fluid reservoi r cap (Black) . . . 161
4. Coolant reservoir ca p (Black) . . . . . 161
5. Washer fluid reserv oir cap (Blue) . . 161
6. Power steering flui d reservoir cap (Black)
161
Engine coolant check . . . . . . . . . . . . . . . 163 Checking the coolant level . . . . . . . . . 163
Topping up the coolant . . . . . . . . . . . . 164
Engine oil check . . . . . . . . . . . . . . . . . . . 162 Checking the oil level . . . . . . . . . . . . . 162
Engine oil specification . . . . . . . . . . . . 163
Topping up the oil . . . . . . . . . . . . . . . . 163
Engine specifications. . . . . . . . . . . . . . . . 211
Enhanced other network (RDS-EON). . . . 229
Essential towing checks . . . . . . . . . . . . . 151
Event data recording . . . . . . . . . . . . . . . . . 37 Exterior mirrors . . . . . . . . . . . . . . . . . . . . . 94
Proximity mirror (Japan only) . . . . . . . . 94
F
Fast forward/reverse . . . . . . . . . . . . . . . . . 247
Fastening the seat belts . . . . . . . . . . . . . . . 56 Releasing the seat belts . . . . . . . . . . . . . 56
Filling station information . . . . . . . . . . . . . . 33 Engine coolant specification. . . . . . . . . . 34
Engine oil specification . . . . . . . . . . . . . 34
Fuel filler flap . . . . . . . . . . . . . . . . . . . . . 33
Tyre pressures . . . . . . . . . . . . . . . . . . . . 34
Front fog lamps . . . . . . . . . . . . . . . . . . . . . 72
Fuel and refuelling Technical specifications . . . . . . . . . . . . 146
Fuel burning heater. . . . . . . . . . . . . . . . . . 104
Fuel consumption . . . . . . . . . . . . . . . . . . . 146
Fuel cut-off . . . . . . . . . . . . . . . . . . . . . . . . 144 Resetting the fuel cut-off . . . . . . . . . . . 144
Fuel filler flap . . . . . . . . . . . . . . . . . . . . . . 144
Fuel quality . . . . . . . . . . . . . . . . . . . . . . . . 142 Alternative fuels for petrol engines. . . . 143
Diesel engined vehicles . . . . . . . . . . . . 143
Petrol engined vehicles . . . . . . . . . . . . 142
Fuse box locations . . . . . . . . . . . . . . . . . . 195
Fuse specification chart . . . . . . . . . . . . . . 196 Engine compartment fuse box . . . . . . . 196
Luggage compartment fuse box . . . . . 201
Passenger compartment fuse box . . . . 199
G
General driving points . . . . . . . . . . . . . . . 128 Battery charging - red . . . . . . . . . . . . . 128
Low oil pressure - red . . . . . . . . . . . . . 128
General information on ra dio frequencies. . 40
H
Handbrake . . . . . . . . . . . . . . . . . . . . . . . . 124
Hazard warning flashers . . . . . . . . . . . 74, 204
HDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Head restraints . . . . . . . . . . . . . . . . . . . . . . 51
Headlamp adjustment . . . . . . . . . . . . . . . . . 73
Headlamp levelling . . . . . . . . . . . . . . . . . . . 73 Halogen headlamps . . . . . . . . . . . . . . . . 73
Xenon headlamps . . . . . . . . . . . . . . . . . 73
Headlamp washers . . . . . . . . . . . . . . . . . . . 88
Headphones . . . . . . . . . . . . . . . . . . . . . . . 253