Page 420 of 3229
Publi s hed: 11-May-2011
Front Disc Brake -
General SpecificationItemSpecification
Front  dis cVenti lated
Front disc diameter:3.2 Pet rol316 mm (12.4 i n)
2.2 Dies el300 mm (11.8 i n)
Front  dis c t hicknes s  new (All  engines )28 mm (1.10 i n)Service l imit  (All engi nes )26 mm (1.024 i n)
Maximum dis c run-out - dis c ins t al led0.080 mm (0.003 i n)
Pad mi nimum thi cknes s2 mm (0.078 i n)Pis t on diamet er60 mm (2.362 i n)
Torque SpecificationsDescriptionNmlb-ft
Brake cali per bl eed screw86
Brake cali per mount ing pl at e t o wheel knuckle bolt s *200148Brake cali per gui de pin bolt s2821
Brake di sc dus t  s hield bol ts107
Brake di sc Torx s crew3526Brake flexi hose uni on to cal iper3224
Brake hos e retaini ng bracket  t o damper bol t2216
* New  nuts/bolts must be fitted 
     
        
        Page 433 of 3229
Publi s hed: 11-May-2011
Rear Disc Brake -
General SpecificationItemSpecification
Rear disc:
3.2 Pet rol  engineVent il at ed2.2 Dies el engineSol id
Rear disc diameter:
Venti lat ed302 mm (11.9 in)Soli d302 mm (11.9 in)
Rear disc thickness new :
Venti lat ed20 mm (0.79 in)Soli d12 mm (0.47 in)
Service limit:
Venti lat ed18 mmSoli d10 mm
Pad mi nimum thi cknes s2 mm
Maximum dis c run out - Dis c ins t al led0.080 mm
Torque Specifications
DescriptionNmlb-ftBrake cali per bl eed screw107
Brake cali per fixed carrier t o wheel knuckl e bolt s*11081
Brake cali per gui de pin bolt s3022Brake di sc dus t  s hield bol ts1310
Brake di sc Torx s crew3526
Brake flexi hose uni ons  to cali per1511Brake hos e retaini ng bracket  t o wheel knuckle bolt2216
* New  nuts/bolts must be installed 
     
        
        Page 498 of 3229
Publi s hed: 11-May-2011
Anti-Lock Control -
General SpecificationItemSpecification
Syst em make / typeConti nent al Teves  - MK23E1
Wheel speed sensors:MakeConti nent al Teves
Yaw rate sensor:
Make / t ypeConti nent al Teves  - RSC03Locat ionCenter cons ole in front  of gear shi ft
Torque SpecificationsDescriptionNmlb-ft
ABS module to mount ing bracket  nuts107
Accel erometer bolt s65Brake flui d t ube uni ons1511
Front  road wheel  s peed sens or to wheel  knuckle bol t54
Rear road wheel speed s ensor t o wheel knuckle bolt54 
     
        
        Page 570 of 3229
Publi s hed: 11-May-2011
Steering Column -
General SpecificationItemSpecification
Upper columnManual  column wit h t ilt  and reach adjust ment
Torque Specifications
DescriptionNmlb-ft
Heats hiel d lower bolt s  (2) to s t eel  pi ni on t ower3.22.3Heats hiel d upper bolt  (1) t o plas ti c s eal2.41.77
St eering column bol ts2518
St eering wheel bol t4835Univers al joi nt to st eering gear bolt *2518
* New  nuts/bolts must be fitted 
     
        
        Page 604 of 3229

DescriptionNmlb-ft
Cams haft  beari ng hous ing to cyli nder head bolt sAA
Camshaft drive sprocket boltsExhaus t75 + 90°55 + 90°
Inlet11081
Cyli nder head bolt sAACyli nder head wiring harnes s  mount ing bolt s65
Di ps t ick t ube bol t107
Engine i ns ulat or lower bolt s11081Engine i ns ulat or lower heat s hield Torx s crew107
Engine i ns ulat or upper bolt s11081
Engine mount bracket LH:M8*2518
M12*8059
Engine mount LH bolts175129Engine mount RH bolts8059
Engine mount bracket RH bolt:
M10*4533M12*8059
Flywheel flexplat e bolt s45 + 50°33 + 50°
Exhaus t  manifold bol tsAAIntake manifold bol ts1612
Lifti ng bracket  bol ts4835
Lower inlet  mani fold bol ts107Lubricant drain plug3828
Oi l cooler as sembl y t o block ret aining bol ts107
Oi l cooler hos e bolt s107Oi l fil ter2518
Oi l level  s ensor bolt86
Oil pan bolts:M71713
M104533
Oi l pump adjus ter bolt1713Oi l pump lock adjus ter s leeve bolt86
Oi l st rai ner pi ck-up ass embly bol t1713
Oi l squirt jet65Throt tl e body to block support  bolt107
Throt tl e body s crews*86
Timing chain t ensi oner bolt107Timing cover bolt sAA
VVT s olenoid107
VVT unit  retai ni ng boltAA* New  nuts/bolts must be fitted
A = refer to procedure for correct torque sequence 
     
        
        Page 753 of 3229
DescriptionNmlb-ft
Engine mount bracket LH:
M8*2518M12*8059
Engine mount bracket RH:
M12*8059M14*175129
Engine mount  LH bolt175129
Engine mount  RH bol ts8059Flywheel bol tsAA
Fuel i njector wi ri ng harness  bol t107
Fuel fil ter bracket bol ts2518Intake manifold runner control (IMRC) act uat or bol t107
Intake manifold adaptor and t hrot tl e hous i ng bol t65
Intake manifold bol ts97Lifti ng bracket s107
Oi l cooler brackets107
Oi l cooler t o cyl inder block bol ts2015Oi l fil ler t ube97
Oi l pan drain pl ug2015
Oi l pan bol ts97Oil pan extension panel:
St age 1107
St age 21612Oil pump bolts:97
St age 175
St age 297Oi l separat or bol ts75
Oi l level  s ensor86
Pis t on cool ing jet bol t107Timing belt  t ensi oner bolt2518
Timing belt  i dler pulley bol t6044
Timing belt  rear cover64Valve cover bol ts107
Vacuum pump bolt s97
* New  nuts/bolts must be fitted
A = refer to procedure for correct torque sequence 
     
        
        Page 770 of 3229

12-Dual  mas s  flywheel  (manual t rans mi ss i on vehi cl es )
13-Bol t (8 off)
14-Torque convert er flex-pl ate (automat ic trans mi ss i on vehi cl es)15-Mai n beari ng lower half s hel l (4 off)
16-Lower t hrus t washer (2 off)
17-Mai n beari ng hal f cap (5 off)18-Oil pump
19-Oil level gage tube (lower)
20-Bol t21-Locati ng dowel
22-Oil pan hous i ng
23-Oil pan hous i ng bol t (20 off)24-Oil pan capt ive bolt  (21 off)
25-Oil drai n plug s eal
26-Oil drai n plug27-Oil pan
28-Oil t emperature s ens or
29-Screw (2 off)30-Oil level gage tube (upper)
31-Oil level gage
32-Oil pump drive chai n33-Cranks haft  pull ey bolt
34-Pl ain was her
35-Cranks haft  pull ey and t ors ional vi brati on damper36-CKP sens or target  ring
37-W oodruff key (2 off)
Crankshaft and Main Bearings
ItemPart NumberDescription
1-Cranks haft2-Mai n bearing upper half s hel l (4 off)
3-Upper thrust  was her (2 off)
4-No. 1 main beari ng cap locati ng dowel  (2 off)5-Mai n bearing cap bol t (10 off)
6-Mai n bearing hal f cap (5 off)
7-Lower thrust  was her (2 off)8-Mai n bearing lower hal f s hel l (4 off)
9-Counter-balance s haft  dri ve gear
10-Mai n bearing cl ass ificati on marki ngsThe crankshaft  is  manufact ured from st eel and formed wit h 5 main beari ng and 4 connect ing rod big-end journals . Themain bearing journals  l ocat e in the cyli nder bl ock mai n beari ng hous ings , and are clamped by the 5 main bearing half caps.Each main beari ng half cap is  st amped wi th t he corresponding cylinder number for identi fi cat ion. The main bearing half capidenti fi ed wit h '1F' mus t  be pos it ioned at the trans mi ss i on end of the engine (No. 1 end). 
     
        
        Page 1195 of 3229

Publi s hed: 11-May-2011
Electronic Engine Controls - I6 3.2L Petrol -
ItemSpecification
Heated oxygen s ens or (H02S)removal *Apply W D40 or equi val ent
Heated oxygen s ens or (H02S)t hreadsApply s uit abl e high temperat ure ant i-s ei ze compound t o t hreads of sens or (Cas trolOpti mol)
* Apply to area around sensor threads prior to attempting to remove sensor
General SpecificationItemSpecification
Engine management system:
MakeDens oCamshaft position sensor:
MakeDens o
TypeMRE (hal l affect)Crankshaft position sensor:
MakeDens o
TypeVariable reluctance
Torque Specifications
DescriptionNmlb-ftCams haft  pos it ion (CMP) sens or bol t+107
Catal ys t  moni tor s ens or4533
Catal ys t  moni tor s ens or harnes s s upport  bol t65Cranks haft posi ti on (CKP) s ensor Torx bol t107
Engine control  modul e (ECM) bracket bolt s64
Flywheel sens or bol t107Flywheel sens or bracket  s crews107
Fuel rail  pres s ure s ens or65
Heated oxygen s ens or (H02S)++4533Knock sens or ret ai ning bolt2014
Mas s  air flow (MAF) s ens or Torx s crews21
+ Apply clean engine oil to a new CMP sensor O-ring seal
++ Apply anti-seize lubricant to threads of sensor - See Lubricants