Engine Sealing (03.10)
Engine (03.00)
Issue 5, Janauary 2010 Workshop Manual 3-10-1
Engine (03.00)
Engine Sealing (03.10)
Specifications
Maintenance
Engine Timing Cover - Renew
1. Remove the front subframe (refer to Workshop Manual procedure 02.01.BA Subframe Assembly - Front -
Remove for Access and Refit).
2. Put an applicable container in position under the engine
to collect drained oil.
3. Remove the sump drain plug and drain the oil from the engine.
4. Remove the oil tank assembly (refer to Workshop Manual procedure 03.02.CA Tank Assembly - Oil
Cooler - Renew).
5. Drain cooling system (refer to Workshop Manual procedure 03.03.AD Coolant - Drain and Refill).
6. Remove the left cam cover (Refer to ’Left Side Cam Cover - Remove and Install’, page 3-10-4) 7. Remove the outer and inner seals from the left cam
cover.
8. Remove the right cam cover (Refer to ’Right Side Cam Cover - Remove and Install’, page 3-10-9).
9. Remove the outer and inner seals from the right cam cover.
10. Release the clips and disconnect the two coolant hoses from the coolant manifold.
11. Release the clip and disconnect the hose from oil the separator.
12. Remove the four M6 Torx screws that attach the coolant manifold to the cylinder heads (Refer to Figure 1).
Figure 1
13. Release the coolant manifold from the coolant pipe.
14. Disconnect the electrical connector for the temperature sensor.
15. Remove the coolant manifold.
16. Remove and discard the two O-rings from the manifold.
17. Loosen the three M6 attachment screws for the water pump pulley (Refer to Figure 2).
Figure 2
18. Turn the auxiliary drive be lt tensioner to release the
tension from the drive belt.
19. Remove the drive belt.
20. Remove the three M6 screws that attach the water pump pulley and remove the pulley.
Torque Figures
DescriptionNm.lb./ft.
Cam cover 10 7
Dipstick tube 6 4
Timing cover:
Bolts 1 to 7, 9 to 18 and 20 to 27
Bolts 8 and 19
12
10
9
7
Crankshaft pulley bolt 320 236
Alternator mounting bracket 21 15.5
Alternator 40 30
Coolant manifold 9 6.5
Coolant pump 12 9
Coolant pump pulley 10 + 45° 7 + 45°
PAS pump 21 15.5
Accessory drive belt idler pulleys 40 30
Accessory drive be lt tensioner 40 30
Heater hose brackets:
M6 Bolts
M5 Nuts
12
5
9
3.7
Harness support brackets:
M5 Nut
M6 Screw
M8 Screw
5
10
25
3.7
7
18.5
Repair Operation Time (ROT)
A030368
A030553A
Power Brake System (06.07)
Brake System (06.00)6-7-2 Workshop Manual May 2007
Specifications
Maintenance
Brake Booster-RHD-Renew
Removal
1. Remove brake master cylind er (see Workshop Manual
procedure 06.06.EB Brake Master Cylinder Assembly
Renew).
2. Remove oil dipstick.
3. Remove vacuum hose.
4. Disconnect multiplugs (x2).
5. Remove pedal cover.
6. Remove clevis pin and clip.
7. Remove servo securing nuts (x4).
8. Remove servo assembly.
9. Remove brake light switch.
Installation
1. Install brake light switch.
2. Install servo assembly.
3. Install servo retaining nuts (x4) (torque).
4. Install clevis pin and clip.
5. Install pedal cover.
6. Connect multiplugs (x2).
7. Install vacuum hose.
8. Install dipstick. 9. Install brake master cylinder (see Workshop Manual
procedure 06.06.EB Brake Master Cylinder Assembly
Renew).
Brake Booster-LHD-Renew
Removal
1. Move drivers seat fully rearward.
2. Remove clevis pin and clip.
3. Remove booster securing nuts (x4).
4. Remove corner cross brace.
5. Move expansion tank aside for access (bolt x1, nut x1,
hose clips x2, multiplug x1).
6. Remove vacuum hose move aside.
7. Remove bolts (x2) from clutch pipe bracket and move aside.
8. Disconnect clutch reservoir feed pipe.
9. Disconnect multiplugs (x4).
10. Disconnect brake pipes from master cylinder (move aside).
11. Remove booster assembly.
12. Split components.
13. Remove reservoir securing screw (for access to securing nut).
14. Remove master cylinder from booster (nuts x2).
15. Re-fit components.
16. Install master cylinder to booster (nuts x2).
17. Install reservoir securing screw.
Torque Figures
DescriptionNm.lb. / ft.
Brake Booster Mount 21-24 15.5-18
Repair Operation Time (ROT)
Repair Operation Time (ROT)
ItemCode
Brake Booster-Renew 06.07.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
CONTAINERS WHEN TOPPING-UP THE BRAKE FLUID RESERVOIR.
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.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
Caution
Always plug pipe ends to prevent ingress of dirt or
moisture into the system.
