Manual Control System (07.06)
Transmission (07.00)
May 2007 Workshop Manual 7-6-1
Transmission (07.00)
Manual Control System (07.06)
Maintenance
Gearshift Assembly Mechanism-Renew
Removal
1. Remove panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console -
Renew).
2. Using tool (308 - 642), release selector cable ball joints (x2) from gear lever mechanism.
3. Remove screws (x6), securi ng gear lever mechanism to
housing.
4. Remove gearshift assembly mechanism.
5. Remove gear knob, collect gaiter.
Installation
1. Clean gearshift mechanism.
2. Lubricate gearshift mechanism with recommended grease.
3. Install gearshift mechanism, install and tighten screws
(x6).
4. Install selector cables to gearshift mechanism.
5. Install panel assembly - console (see Workshop Manual procedure 01.12.DB Panel Assembly Console - Renew).
6. Install gear lever gaiter, install gear knob.
Transmission Gearshift Cable Assembly-
Renew
Removal
1. Disconnect vehicle battery.
2. Remove panel assembly - console.
3. Using tool 308 - 642, release selector cable ball joint from gear lever mechanism.
4. Remove horseshoe clip secu ring selector to bracket.
5. Raise vehicle on ramp and secure with straps. 6. Remove road wheel(s).
7. Remove rear exhaust muffl
er (see Workshop Manual
procedure 09.00.KA Silencer and Bypass Valve
Assembly - Re move for Access and Refit
8. Remove bolts (x4), subframe cross brace.
9. Loosen clamp nuts (x2), release centre pipe from both catalysts.
10. Remove centre pipe and rear exhaust pipes as an
assembly.
11. Remove bolts (x4), centre heatshield to body, remove heatshield.
12. Remove bolts (x8), shear plate to body, remove shear plate.
13. Remove bolt securing earth lead to transaxle.
14. Mark drive shaft to differential flanges for assembly purposes.
15. Remove and discard Allen bolts (x12), collect plates (x6), drive shaft flanges to transaxle.
16. Release drive shafts from transaxle and position aside.
17. Position drain container to collect oil spillage.
18. Loosen unions and disconnect oil cooler pipes (x2) from
transaxle interconnecting pipes. Plug pipe connections
(x4).
19. Remove drain container.
20. Remove nuts (x2), hydra mounts to subframe mountings.
21. Position hydraulic lifter to support transaxle.
22. Remove and discard bolts (x8 (4 each side), mounting brackets to transaxle. Remove mounting brackets with
hydra mounts.
23. Release reverse lamp switch multiplug from bracket, disconnect multiplug.
24. Lower transaxle sufficiently and use tool (308 - 642) to release selector cable ball joint from selector lever.
25. Remove horse shoe clip securing selector cable to mounting bracket, remove selector cable assembly.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
WA R N I N G
TO AVOID PERSONAL INJURY, I.E. SEVERE BURNS TO
THE SKIN, ALLOW EXHAUST SYSTEM TO COOL DOWN BEFORE REMOVING EXHAUST SYSTEM COMPONENTS.
WA R N I N G
OBSERVE ALL TRANSAXLE OIL MANUFACTURERS SAFETY INSTRUCTIONS WHEN HANDLING
COMPONENTS THAT HAVE BEEN IN CONTACT WITH
TRANSAXLE OIL.
Caution
Plug oil cooler connections to prevent ingress of dirt or moisture into the system.
Caution
Ensure that the service tool No. 0308 - 642 is used to
release selector cable ball joints from selector levers.
Air Conditioning (A/C) System (12.03)
Climate Control (12.00)
12-3-10 Workshop Manual May 2007
1. Connect an R-134a Recovery / Recycling / Recharging
unit to the vehicle A/C system.
2. Follow the Recovery / Recycling / Recharging unit manufacturer’s instructions to evacuate the A/C system.
Evacuation
The removal of unwanted air and moisture, is critical to the
correct operation of the A/C system. Moisture in the system
can be highly destructive and may cause internal blockages
due to freezing; water suspended in the lubricating oil will
damage the compressor. Once the A/C system has been
dismantled, or the refrigerant charge recovered, all traces of
moisture must be removed before charging.
Read manufacture’s instruct ions and warnings before
completing any Recovery / Recycling / Recharging
operation.
1. Connect an R-134a Recovery / Recycling / Recharging unit to the vehicle A/C system.
2. Follow the Recovery / Recycling / Recharging unit manufacturer’s instructions to evacuate the A/C system.
Charging
Read manufacture’s instruct ions and warnings before
completing any Recovery / Recycling / Recharging
operation.
1. Connect an R-134a Recovery / Recycling / Recharging unit to the vehicle A/C system.
2. Follow the Recovery / Recycling / Recharging unit manufacturer’s instructions to charge the A/C system.
Compressor oil may be drawn ou
t during this process, take
note of the quantity recovered so that it may be replaced.
It is recommended that initiall y only the high-side valve be
opened at the start of the pr ocedure. After a short time a
small depression should be seen on the low-side, at which
point the low-side valve may be opened and the evacuation
process completed. If a vacuum is not registered on the
low-side, it may indicate that the expansion valve is
permanently closed or that th e system is blocked. This
simple check may save time and effort when the system is
recharged.
Caution
Do not exceed the specificat ion when charging the A/C
system with refrigerant. Doing so will decrease the
efficiency of the A/C unit or damage the refrigeration cycle parts.
Caution
Always start the charging of refrigerant from the high-
pressure side. If charging st arts from the low-pressure
side, vanes of the A/C compressor will not be released and abnormal noise may result.
Fluids/Capacities
Appendix & Glossary
May 2007 Workshop Manual 20-1-3
Fluids/Capacities
Terms
Frequently used alternative names or spellings for vehicle
components mentioned in this Workshop Manual.
Capacities
Europe UK USA
Engine sump (incl. filter) 9 .5 litres 16.7 pints 10.0 Qts
Engine sump (excl. filter) 8 .5 litres 15.0 pints 9.0 Qts
Engine cooling system 12 litres 21 pints 14.4 Qts
Screen washer reservoir 2.0 litres 3.5 pints 2.2 Qts
Gearbox & Cooler 4.7 litres 7.9 pints 5.6 Qts
Final drive 2.0 litres 3.5 pints 2.2 Qts
Fuel tank 80.0 litres 17.6 galls 88.0 Qts
Recommended Fluids
Engine oil (Initial fill) Castrol Edge Sport 10w60
Do not mix Engine oil with any mineral oils.
Engine coolant 50% water, 50% OAT Coolant (Arteco Havoline XLC only)
Do not mix OAT coolant with any glycol based anti-freeze.
Gearbox oil Shell Transaxle Oil 75w90
Final drive oil Mobil 1 80w140
Brake fluid Castrol Super Response DOT4
Power steering fluid Esso Power steering Fluid
A/C Refrigerant R134A (HFC134A)
A/C Compressor oil ND8
UK EnglishUS English
Bonnet Hood
Boot Trunk
Brake Disc Rotor
Handbrake Parking Brake
Petrol Gasoline
Tyre Tire
Wing Fender
Windscreen Windshield
Sill Rocker Panel
