Bumpers (01.19)
Body System (01.00)
May 2007 Workshop Manual 1-13-3
9. Install number plate and plinth (see Workshop Manual procedure 01.19.BD Licence Plate - Plinth Assembly -
Front - Renew).
10. Install valance (see Workshop Manual procedure 01.19.AF Panel - Front Valance - Renew).
11. Lower vehicle on ramp.
Rear Bumper Cover - Renew
Removal
1. Raise vehicle on ramp.
2. Remove number plate.
3. Remove LH rear lamp assembly (see Workshop Manual procedure 17.03.AB Lamp Assembly (Rear) - LH
Renew).
4. Remove RH rear lamp assembly (see Workshop Manual procedure 17.03.BB XREF: 280 Lamp Assembly (Rear) -
RH Renew).
5. Remove wheel arch liner LH (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - RH -
Renew).
6. Remove wheel arch liner RH (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - LH -
Renew).
7. Remove tyre mobility kit from the rack.
8. Remove torx bolts located behind carpets to rear wings (x2).
9. Remove bolts (x2) in rear light recess.
10. Remove bolts securing bumper to wheel arch (6).
11. Remove bolts (x4) securing bumper to brackets.
12. With assistance Release bumper from body.
13. Release fir trees securing harness to bumper (x6).
14. Release remaining harness clips from bumper (x6).
15. Disconnect multiplugs to parking aid sensors (x2).
16. Disconnect multiplugs to license plate lamps (x2).
17. Remove nuts (x6) securing exhaust finishers to bumper.
18. Remove number plate light assembly (clips x5).
19. Remove parking aid sensors (x2)
20. Remove screw retaining clips (x13)
Installation
1. Install screw retaining clips x13.
2. Install parking aid sensors x2.
3. Install number pl ate light assembly
4. Install exhaust finishers to bumper.
5. With assistance position bumper to body.
6. Connect multiplugs to license plate lamps X2.
7. Connect multiplug to parking aid sensors.
8. Secure harness to bumper (f ir trees x6 and clips x6)
9. Install bumper bolts to brackets and body (x10). 10. Install tyre mobility kit to rack.
11. Install number plate.
12. Install RH rear lamp asse
mbly (see Workshop Manual
procedure 17.03.BB Lamp Assembly (Rear) - RH
Renew).
13. Install LH rear lamp assembly (see Workshop Manual procedure 17.03.AB Lamp Assembly (Rear) - LH
Renew).
14. Install wheel arch liner LH (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - RH -
Renew).
15. Install RH wheel arch li ner (see Workshop Manual
procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
16. Lower vehicle on ramp.
Repair Operation Time (ROT)
Engine Structure (03.01)
Issue 4, November 2008Workshop Manual 3-1-13
13. Remove bolts (x10), evenly and in stages securing RH
cylinder head to cylinder block (see Figure 3).
Figure 3
14. With assistance, remove RH cylinder head assembly.
15. Remove and discard cylinder head gasket.
Installation
1. Thoroughly clean RH cylind er head face and retaining
bolt pockets.
2. Thoroughly clean RH cylinder block face.
3. Thoroughly clean and dry RH cylinder head retaining
bolts.
4. Install new RH cylinder gasket, locate on dowels.
5. With assistance, install RH cylinder head, locate on dowels.
6. Install and torque tighten cylinder head bolts (x12) in the correct sequence.
7. Lubricate RH exhaust camsha ft journals, camshaft lobes,
bearing surfaces on cylinder head and bearing caps with
clean engine oil.
8. Install RH exhaust camshaft, install bearing caps (x5) in their original positions.
9. Install bolts (x10) and torque tighten in the sequence specified.
10. Install sprocket retaining Torx bolt in camshaft.
11. Rotate camshaft accordingly and check each valve clearance using feeler gauges.
12. Remove sprocket retaining Torx bolt.
13. Install RH/LH intake cams haft (see Workshop Manual
procedure 03.09.AT/03.09.AV Camshaft - Intake - RH/
LH - Renew).
14. Install timing chain tensioni ng tool (303-532) into RH
exhaust camshaft sprocket.
15. Apply a force to the tool (303-532) in an anti-clockwise direction and torque tighten RH sprocket Torx bolts.
Remove special tool.
16. Connect multiplug to cam a haft timing sensor.
17. Connect multiplugs (x2) to knock sensors.
18. Install SAI pump and bracket assembly (see Workshop Manual procedure 03.08.DB/03.08.DJ Pump and
Bracket Assembly - Secondary Air Injection - Renew). 19. Install RH/LH exhaust manifold (see Workshop Manual
procedure 09.00.CC/09.00.CD Gasket - Exhaust
Manifold - RH/LH - Renew).
20. With assistance, position engine support beam (SPX M553D) and secure to engine.
21. Position trolley, support front subframe, remove bolts (x6), raise vehicle, remove trolley.
22. Install and torque tighten engine mounting nuts (x2).
RH/LH Cylinder Head - Overhaul
1. Remove cylinder head gasket - RH (see Workshop Manual procedure 03.01.GU Gasket - Cylinder Head -
RH - Renew).
2. Remove Torx screws (x2) se curing EGR tube to cylinder
head, remove tube.
3. Remove and discard gasket.
4. Remove bolt securing camshaf t timing sensor to cylinder
head, remove sensor.
5. Remove bolts (x2) securing knock sensors (x2) to cylinder head, remove sensors.
6. Remove spark plugs from cylinder head.
7. Remove selective tappet buckets, keep in their fitted order.
8. Position valve spring compressor, compress valve spring (see Figure 1).
Figure 1
9. Remove collets (x2), releas e/remove spring compressor,
collect collar and valve spring.
10. Remove valve from cylinder.
11. Remove valve stem oil seal.
12. Repeat procedure for remaining valve assemblies.
13. Keep valves and springs in their fitted order.
A0310319
Repair Operation Time (ROT)
A0301310
Power Steering (11.02)
Steering (11.00)
Issue 5, January 2010 Workshop Manual 11-2-1
Steering (11.00)
Power Steering (11.02)
Description
The power steering system comprises of a non-speed
sensitive rack and pinion steering gear together with an
engine driven vane pump, operating at a constant flow rate.
The level of assistance is co ntrolled via a rotary hydraulic
valve, integral to the steering gear assembly.
Hoses / pipe are used to transm it hydraulic fluid throughout
the steering system. The high -pressure line contains a
pressure transducer, which sends an electronic signal to the
engine management system. This ensures engine RPM is
maintained when the steering system draws higher loads
from the engine (i.e. during parking manoeuvres.) In order
to regulate system temperatures, a wire-wound cooler is
incorporated into the return line.Specifications
11-01-002Steering Gear
Cooling Loop
Power Steering
Pump
Fluid Reservoir
ItemData
Pump Pressure (max)
Turns lock-to-lock
Overall steering ratio
Turning Circle (Kerb
To K e r b )
Fluids
Toe Settings 116 ±4Bar
3
17:1
11.1m
33270 Texaco Cold Climate Power
Steering Fluid 14315G (to 10 MY)
Pentosin CHF 11S (10MY onwards)
(Refer to ’Road Wheel Alignment
(04.00)
Wiring and Circuit Protection (18.01)
Electric Distribution/E lectronic Control (18.00)
18-1-4 Workshop Manual May 2007
How to Read the Circuits
Below is a simple guide to what symbols mean on the circuit
diagrams. For some of the symbols there are descriptions as
to how they function.
Wires
Wires vary in size to allow diffe rent current to be carried. For
example a wire with a diamet er of 0.50mm (This is the
diameter of all the internal copper strands together) will
carry 11A (dependant on ambient temperature) whilst a wire
with a diameter of 2.00mm will carry 25A.
Twisted Wires
The ‘figure of 8’ shown on circuits as below denotes a
twisted wire and shows the wires that are twisted together.
A wire generates a certain amount of ‘electrical noise’ when
a current is passed through it. By twisting the 2 wires
together the ‘electrical noise’ is cancelled out on each wire
by the opposing wire. This is used more on sensors and
audio speakers.
Screened and Twisted Screen Wires
The signals through a wire can be affected by externally
generated electrical noise. To reduce the external
interference the wires are placed inside a conductive sleeve.
One end of the conductive sleeve is always open whilst the
other end can be terminated to a ground, to a component,
or left open.
Boot Fusebox
Fuse/
RelayRatingFunction
F1 5A Spare
F2 20A Spare
F3 30A Heated rear window
F4 20A Spare
F5 30A Spare
F6 20A Spare
F7 5A Battery disconnect switch (BDS) power
F8 20A Spare
F9 20A Tracker
F10 30A Spare
F11 20A Spare
F12 20A Spare
F13 10A Spare
F14 5A Rear parking assistance module (optional)
F15 5A Spare
F16 30A Spare
F17 5A Spare
F18 30A Audio amplifier
F19 5A Spare
F20 10A Canister vent
F21 30A Spare
F22 20A Exhaust by-pass and vacuum pump
Wire numbers have been deleted from the original
engineering circuits. This al lows the type size to be
increased for improved legibil ity of the service circuits.
173 WR 2.0
Wire No.
Colour
Size
908 GU MAPM 05
Wire No.
Colour
MAP (Defines twisted pair)
Size