Shock Absorber System (04.03)
Suspension (04.00)
May 2007 Workshop Manual 4-3-7
14. Remove spring and damper assembly (see Fig. 8).
15. Remove nuts (x3) each side from damper to mounting plate (see Fig, 9).
Installation
1. Position mounting plate to damper and torque tighten retaining nuts (x3) each side.
2. Install spring and damper assembly and torque tighten upper bolts (x4) each side.
3. Install damper to lower arm each side and torque tighten nuts and bolts.
4. Position fuel filler pipe to body, install and tighten nut.
5. Position fuel filler pipe, install and tighten bolt.
6. Position toe control arm each side, install and torque tighten nuts/bolts.
7. Position handbrake callipers each side, install bolts (x2) each side and tighten bolts to the correct torque.
8. Connect ABS sensor multiplugs each side.
9. Install clips (x2) each side from sensor harness to toe control arms.
10. Install LH wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew). 11. Install RH wheel arch li
ner (see Workshop Manual
procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew)
12. Install road wheel(s).
13. Lower vehicle on ramp.
14. Install fuel filler cap and close fuel filler lid.
Rear Spring-Pair-Renew
Removal
1. Open fuel filler lid and remove fuel filler cap.
2. Raise vehicle on ramp.
3. Remove road wheel(s).
4. Remove LH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew).
5. Remove RH wheel arch liner (see Workshop Manual procedure01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
6. Remove bolt securing fuel filler pipe bracket to damper
mounting bracket.
7. Remove nut securing fuel fille r pipe to body and tie filler
pipe aside (see Fig. 1).
Fig. 8
Fig. 9
Repair Operation Time (ROT)
Shock Absorber System (04.03)
Suspension (04.00)4-3-8 Workshop Manual May 2007
8. Disconnect ABS sensor multiplug (see Fig. 2).
9. Release sensor harness clips (x2) from toe control arm (see Fig. 3).
10. Remove bolts (x2) each side from handbrake calliper to rear hub and release calliper an d position aside (see Fig.
4)
.
11. Remove nuts and bolts both sides from toe control arms (see Fig. 5).
12. Remove nuts and bolts each side from lower damper mountings (see Fig. 6).
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Shock Absorber System (04.03)
Suspension (04.00)
May 2007 Workshop Manual 4-3-9
13. Remove bolts (x4) each side from damper upper mounting (see Fig. 7).
14. Remove spring and damper assembly (see Fig. 8).
15. Remove nuts (x3) each side from damper to mounting plates and remove mounting plates (see Fig. 9).
16. Position spring compresso r to spring and compress
spring.
17. Hold damper shaft and remove top mounting retaining nut. 18. Remove top mounting and spring assembly.
19. Remove spring compressor from spring.
Installation
1. Clean spring and top mounting .
2. Position spring compressor to new spring and compress
spring.
3. Install spring and top mounting and torque tighten retaining nut.
4. Remove spring compressor.
5. Position mounting plate to damper and torque tighten
retaining nuts (x3) each side.
6. Install spring and damper assembly and torque tighten upper bolts (x4) each side.
7. Install damper assembly to lower arm each side and torque tighten nuts and bolts.
8. Position fuel filler pipe to body and install and tighten nut.
9. Position fuel filler pipe and install and tighten bolt.
10. Position toe control arm each side and install and torque tighten nuts and bolts.
11. Position handbrake callipers each side, install bolts (x2) each side and tighten bolts to the correct torque.
12. Connect ABS sensor multiplugs each side.
13. Install clips (x2) each side from sensor harness to toe control arms.
14. Install LH wheel arch li ner. (see Workshop Manual
procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
15. Install RH wheelwright li ner (see Workshop Manual
procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
16. Install road wheel(s).
17. Lower vehicle on ramp.
18. Fit fuel filler cap and close fuel filler lid.
Rear Damper-Pair-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel(s).
3. Remove LH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew)
4. Remove RH wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew).
5. Remove bolt securing fuel filler pipe bracket to damper
mounting plate.
6. Remove nut securing fuel fille r pipe to body and tie filler
pipe aside.
7. Disconnect ABS sensor multiplug.
Fig. 7
Fig. 8
Fig. 9
Repair Operation Time (ROT)
Shock Absorber System (04.03)
Suspension (04.00)4-3-10 Workshop Manual May 2007
8. Release sensor harness clips (x2) from toe control arm.
9. Remove bolts (x2) each side from handbrake calliper to rear hub.
10. Release calliper and position aside.
11. Remove nuts and bolts both sides from toe control arms.
12. Remove nuts and bolts each side from lower damper mountings.
13. Remove bolts (x4) each side from damper upper mounting.
14. Remove spring and damper assembly.
15. Remove nuts (x3) each side from damper to mounting plates and remove mounting plates.
16. Position spring compressor to spring and compress spring.
17. Hold damper shaft and remove top mounting retaining nut.
18. Remove top mounting and spring assembly.
19. Remove dust shield, rebound bumper and spring seat flange.
Installation
1. Clean spring, spring seat flange, rebound bumper, dust
shield and top mounting .
2. Install spring seat flange, rebound bumper and dust shield onto damper.
3. Install spring and top mounting and fit and tighten retaining nut.
4. Remove spring compressor.
5. Position mounting plate to damper and torque tighten retaining nuts (x3).
6. Install spring and damper assembly and torque tighten upper bolts (x4) each side.
7. Install damper assembly to lower arm each side and torque tighten nuts and bolts.
8. Position fuel filler pipe to body and install and tighten nut.
9. Position fuel filler pipe and install and tighten bolt.
10. Position toe control arm each side and install and torque tighten nuts and bolts.
11. Position handbrake callipers each side, install bolts (x2) each side and tighten bolts to the correct torque.
12. Connect ABS sensor multiplugs each side.
13. Install clips (x2) each side from sensor harness to toe control arms.
14. Install LH wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
15. Install RH wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - LH -
Renew)
16. Install road wheel(s).
17. Lower vehicle on ramp.
Road Wheels and Tyres (04.04)
Suspension (04.00)4-4-10 Workshop Manual May 2007
Display Unit
The display unit provides additional features when correctly
connected to a previously installed ‘Smartire’ system. The
display unit connects directly to the front of the basic
‘Smartire’ receiver and is powered from the vehicle circuits.
The display will be fully illu minated during use but will go
into ‘Energy Saver’ mode when no activity is detected.
Display Panel
Connection and Normal Operation
1. Remove the front bezel of the Pressure Sensor Receiver. Install the extension lead to the display unit and to the
receiver module. Turn on the ignition.
All icons will illuminate briefly and then extinguish
leaving only the vehicle outline.
2. When tyre pressure data is received, (drive the vehicle
or spin the road wheels), all the road wheel icons will
appear. Press the Tyre icon to access the recorded data
for each of the four road wheels.
3. Press the Mode button to scroll through the pressure, temperature and pressure deviation readings for the
selected tyre. 4. If any tyre pressure sensor is defective, the display will
show three dashes to indicate the absence of data for
that tyre.
5. To return to normal mode, press the SET button.
System Programming
The system may be programmed by the user on three
different levels. Enter Progra mming Mode by pressing the
‘Set’ button:
• 2 seconds to enter level 1
• 5 seconds to enter level 2
• 10 seconds to enter level 3
The following parameters ma y be set in each level:
Level 1 Programming
Cold inflation pressure
1. Press ‘Set’ for 2 seconds to enter level 1 programming .
2. Press ‘Tyre’ to select the front or rear axle. Front or rear
tyres will be highlighted.
3. Press ‘Mode’ to show the current value. Press ‘Tyre’ to increase or ‘Mode’ to decrease the current value.
4. Press ‘Set’ to save the new values.
5. Repeat steps 2 - 4 to set the cold inflation pressure for other the axle.
Programmed wheel position No data
Data received
Alarm light Low pressure warning
Alert indicatorLearn mode MODE button
Set button
Tyre rotation program
Cold pressure program
Programming mode
Towing vehicle indicator
Numerical display
Units of pressure or temperature TYRE button
36-5-038
36-5-039
Level 1
• Cold Pressure
• Tyre Rotation
• Low Pressure Warning
• Pressure Deviation
• High Temperature Alert
•Units Selection
Level 2 •Slope
• Learn Transmitter ID
Level 3 • Low Pressure Alert
PSI
36-5-045
Driveshaft (05.01)
Driveline (05.00)5-1-6 Workshop Manual May 2007
8. Manual Only - Open clutch hydraulics bleed nipple
and with suitable container below, press clutch pedal
fully and retain pedal in that position. Tighten bleed
nipple (see Fig. 3).
9. Manual Only - Disconnect the clutch slave cylinder
supply pipe at the flexible pipe union and cap pipes (see
Fig. 4) 10. With assistance, support torque tube and remove bolts
(x16) that secure torque tube to engine (see Fig. 5)
.
11. Remove torque tube (see Fig. 6).
Installation
1. Clean torque tube and mating face on engine.
2. With assistance, install and align torque tube to engine.
3. Install and torque tighten bolts (x16) using a cross-over sequence to ensure even face loading.
4. With assistance, install propshaft into torque tube and install circlip.
5. Manual Only - Remove pipe caps and reconnect clutch
hydraulics (clean up fluid loss).
Fig. 3
Place suitable absorbent material around the affected area to absorb any possible clutch fluid spillage.
Fig. 4
Fig. 5
Fig. 6
Warning
The torque tube is heavy. To avoid personal injury or damage to the torque tube, torque tube removal / installation is a two person operation.
Warning
The torque tube is heavy. To avoid personal injury or damage to the torque tube, torque tube removal /
installation is a two person operation.
Version 6, March 2010 Workshop Manual 6-3-1
Brake System (06.00)
Contents
Front Disc Brake (06.03)........................................ 6-3-2Description ............................................................. 3-2
Specifications.......................................................... 3-2
Maintenance ........................................................... 3-3Front Brake Disc Set - Renew ................................. 3-3
Front Caliper-Renew .............................................. 3-4
Front Pad Kit - Renew ............................................ 3-5
Front Brake Hose Assembly - Renew ...................... 3-5
Rear Disc Brakes (06.04) ....................................... 6-4-1 Description ............................................................. 4-1
Specifications.......................................................... 4-1
Maintenance ........................................................... 4-2Rear Brake Disc Set-Renew .................................... 4-2
RH/LH Rear Caliper-Renew ................................... 4-2
Rear Pad Kit-Renew ............................................... 4-3
Rear Brake Hose Assembly-Renew ......................... 4-4
Hand Brake (06.05) ................ ............................... 6-5-1
Description ............................................................. 5-1
Specifications.......................................................... 5-1
Maintenance ........................................................... 5-2 RH/LH Handbrake Caliper-Re new ......................... 5-2
Handbrake Lever Assembly-Renew ........................ 5-2
Handbrake Pad Set-Renew .................................... 5-2
Handbrake Cable Assembly-Adjust......................... 5-3
Handbrake Cable Assembly-Vehicle Set-Renew ..... 5-3
Brake Actuation System (06.06)............................. 6-6-1 Description ............................................................. 6-1
Tandem Master Cylinder ........................................ 6-1
Specifications.......................................................... 6-1
Maintenance ........................................................... 6-2Pedal Box Assembly - Renew ................................. 6-2
Installation ............................................................. 6-2
RHD-Brake Master Cylinder Assembly-Renew........ 6-2
LHD-Brake Master Cylinder Assembly-Renew ........ 6-3
Clutch Master Cylinder Assembly-Renew ............... 6-3
RH/LH Front Caliper Hose Assembly-Renew .......... 6-4
RH/LH Rear Brake Caliper Tube Assembly-Renew . 6-5
Brake Master Cylinder to Modulator Secondary
Tube Assembly-Renew ........................................... 6-6
Brake Master Cylinder to Modulator Primary
Tube Assembly-Renew ........................................... 6-7
Rear Wheel Brake Front to Rear Tube Assembly
-Renew .................................................................. 6-8
RH Front Caliper to Modulator Tube Assembly
-Renew .................................................................. 6-9
Rear Wheel Brake Tube Assembly-Renew ............ 6-10
Dynamic Stability Control Module-Renew............ 6-11
Power Brake System (06.07) .................................. 6-7-1 Brake Booster ......................................................... 7-1
Emergency Brake Assist .......................................... 7-1
Specifications.......................................................... 7-2
Maintenance ........................................................... 7-2Brake Booster-RHD-Renew.................................... 7-2
Brake Booster-LHD-Renew .................................... 7-2 Brake Fluid Reservoir-Renew ................................. 7-3
Brake Bleeding - AMDS ......................................... 7-3
Brake Master Cylinder and Vacuum Booster
-Renew .................................................................. 7-4
Brake Master Cylinder-Renew ................................ 7-5
Anti-lock Braking System (ABS) (06.09)................. 6-9-1 Dynamic Stability Control ...................................... 9-1Concept ................................................................ 9-1
System Overview ................................................... 9-2
Operation Summary .............................................. 9-2
Traction Control ..................................................... 9-2 Functional Description ........................................... 9-2
Engine Intervention ................................................ 9-3
Brake Intervention ................................................. 9-3
ABS / DSC Circuit .................................................. 9-3
Specifications ......................................................... 9-3 Maintenance ......................................................... 9-4
ABS Modulator - Remove and Install ...................... 9-4
Rear Disc Brakes (06.04)
Brake system (06.00)6-4-2 Workshop Manual May 2007
Maintenance
Rear Brake Disc Set-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s
3. Remove pad wear sensors.
4. Remove bleed nipple dust caps.
5. Fit bleed bottle.
6. Loosen bleed nipples, push pistons into Calipers, tighten bleed nipples.
7. Remove bleed bottle.
8. Fit bleed screw dust caps.
9. Remove brake pad retaining pins and anti-rattle springs.
10. Remove Caliper bolts (x4) and tie Caliper aside.
11. Remove handbrake Caliper bolts (x4) and tie Calipers aside.
12. Remove retaining screws (x4) and discs.
Installation
1. Clean hubs.
2. Install discs and retaining screws.
3. Install Calipers and retaining bolts.
4. Install handbrake Ca lipers (bolts x4).
5. Clean components (Caliper s, pins, shims, springs)6. Apply anti-seize compound to pads, pins and shims.
7. Install pads and shims to Caliper.
8. Install retaining pad pins
and springs to Calipers.
9. Install pad wear sensors.
10. Pump brake pedal.
11. Top-up brake fluid.
12. Install road wheel/s
13. Lower vehicle on ramp.
RH/LH Rear Caliper-Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s
3. Remove pad wear sensor.
4. Ease Caliper pistons to release pads.
5. Remove brake pad retaining pins and anti-rattle spring.
6. Remove pads and shims from Caliper.
7. Remove brake hose (cap and plug open orifices).
8. Remove Caliper bolts (x2) and Caliper.
Repair Operation Time (ROT)
When installing new brake pads, install a new brake pad wear sensor.
WAR NI NG
BEFORE MOVING OFF, PUMP THE FOOT BRAKE 2 OR
3 TIMES TO ENSURE THE FOOT BRAKE WORKS
CORRECTLY. BRAKE CALIPER PISTONS MAY REQUIRE TRAVEL TO CONTACT THE BRAKE PADS AND DISC.
Repair Operation Time (ROT)
ItemCode
Rear Caliper-Renew RH06.04.AB
Rear Caliper-Renew LH06.04.AC
WAR NI NG
AVOID SKIN / EYE CONTACT OR INGESTION OF
BRAKE FLUID. IF SKIN OR EYES ARE SPLASHED WITH BRAKE FLUID, RINSE THE AFFECTED AREA
IMMEDIATELY WITH PLENTY OF WATER AND OBTAIN
MEDICAL ATTENTION. IF BR AKE FLUID IS INGESTED,
OBTAIN IMMEDIATE MEDICAL ATTENTION.
WAR NI NG
BRAKE FLUID IS HYGROSCOPIC. IF KEPT IN OPENED CONTAINERS IT WILL ABSORB WATER VAPOUR. USE ONLY BRAKE FLUID FROM FRESHLY OPENED
CONTAINER.
Caution
Brake fluid must not be allowed to contact the vehicle
paint work. Remove spilt brake fluid from the paint work
by rinsing away with running water.
Place an absorbent cloth around the brake fluid reservoir filler neck to absorb any possible brake fluid spillage.