Contents
Issue 5, January 2010 Workshop Manual 0-0-5
Introduction
Contents ................................................................. 0-3
Welcome................................................................ 0-0-6 Chapters ................................................................. 0-6Chapter Navigation ................................................ 0-6
Page Numbering ..................................................... 0-6
Systems Classification Coding ................................ 0-6
Special Tools.......................................................... 0-0-6 Location References................................................ 0-6
Warnings, Cautions and Notes .............................. 0-0-6 Repairs and Replacements ..................................... 0-6
Safety Precautions ................................................. 0-0-7 Battery Disconnection ............................................ 0-7
Air Conditioning (A/C) System ................................ 0-7
Chemical Handling and Storage ............................. 0-7
Electrical Equipment .............................................. 0-0-7 Exhaust Fumes ........................................................ 0-7
Fire Precautions ...................................................... 0-7
Tools and Equipment............................................. 0-0-8 Used Engine Oil...................................................... 0-8
Health protection precautions................................ 0-8
Environmental Protection ....................................... 0-8
Lifting and Jacking ................................................. 0-0-9 Safety ...................................................................... 0-9
Jacking Points ........................................................ 0-0-9
Lifting ..................................................................... 0-0-9 Workshop Hoist ..................................................... 0-9
Workshop Jack....................................................... 0-9
Stands .................................................................... 0-9
Vehicle Recovery.................................................. 0-0-10 General ................................................................. 0-10
Transporting ......................................................... 0-10Suspended Towing............................................... 0-10
Adhere to Towing Regulations.............................. 0-10
Towing by Another Vehicle .................................. 0-10
Vehicle Identification Number ............................ 0-0-11
VIN Number Location .......................................... 0-11
Engine Number..................................................... 0-12
Gearbox Number .................................................. 0-12
Lifting and Jacking
Issue 5, January 2010 Workshop Manual 0-0-9
Lifting and Jacking
Safety
•Recommended procedures for lifting, jacking and
towing must be strictly ob served to ensure personal
safety.
• Always use a vehicle hoist, ramp or pit for working
beneath the vehicle in preference to jacking.
• Never rely on a jack to supp ort a car independently, use
axle stands or blocks carefu lly placed at jacking points
to provide rigid support.
• When working beneath a vehicle, chock wheels as well
as applying handbrake.
• Ensure vehicle is standing on firm, level ground before
jacking or lifting.
• Check lifting equipment has adequate capacity for load
being lifted and is in full working order.
Jacking Points
This vehicle jacking points are at positions shown.
May also be jacked on the front subframe front crossmember
Always use a jack with a rubber contact pad. Avoid use of
jacks with sharp contact pads which would damage floor
pan Always chock the opposite road wheels as well as
applying the handbrake when using a hydraulic jack.
To prevent body distortion, av oid single point or one side
jacking with the tunnel shear panel removed.
Lifting
Workshop Hoist
Use of a workshop hoist is recommended for all operations
where vehicles must be raised. Follow manufacturers
instructions. If using an adjustable arm type, ensure lifting
pads are correctly positioned at the four jacking points
before lifting.
Workshop Jack
To avoid any danger of bodywork damage when using a
hydraulic jack, the vehicle must only be lifted at the jacking
points.
Stands
When carrying out work (other than a wheel change) which
requires a wheel to be raised, a stand must be used, located
at the jacking point, to provide a secure support for the
vehicle.
00-00-001
Vehicle Recovery
0-0-10 Workshop Manual Issue 5, January 2010
Vehicle Recovery
General
Preferred method of vehicle recovery is by flat bed
transporter.
The towing eye is primarily for emergency use when towing
for short distances, e.g. removing vehicle if it is causing an
obstruction or winching vehicl e onto a flatbed transporter.
If moving this vehicle in such a situation, install the towing
eye to the bracket in the lower grille aperture.
Transporting
If vehicle is to be transported on a trailer or flat bed
transporter the handbrake must be applied and the road
wheels must be chocked.
Suspended Towing
Take care when using 'spectacle frame' type towing
equipment that the towing device is well clear of front or
rear apron. Body damage may occur if vehicle passes over
uneven road surfaces.
Front Suspended Tow
1. Remove the ignition key from the ignition.
2. Raise the vehicle using a ‘spectacle frame’ type lifting device with a cradle positioned under each front wheel
as indicated below.
Rear Suspended Tow
1. Set the steering in the ‘straight ahead’ position.
Remove the ignition key from the ignition. Ensure the
steering is locked in the straight ahead position.
2. Raise the vehicle using a 'spectacle frame' style lifting device where a cradle is positioned under each rear
wheel as indicated below.
Adhere to Towing Regulations
In certain countries the regi stration number of towing
vehicle and an ‘ON TOW’ sign or warning triangle must be
displayed in a prominent position at the rear of vehicle being
towed.
To w i n g b y A n o t h e r V e h i c l e
This vehicle may be towed short distances by another
vehicle provided that a speed of 48 km/h (30 mph) is not
exceeded. Ensure the towed vehicle gear selection is in
‘Neutral’ with ignition key turned to position ‘II’ to release
steering lock and to render hor n, indicators and brake lights
operational.
Caution
Take care to protect the paint work when installing the towing eye. Ensure the towing eye is tight.
Caution
Do not tow with ‘sling’ type equipment as this
could result in damage to the bodywork.
WAR NI NG
WHEN THE ENGINE IS NOT RUNNING, THE STEERING WILL NO LONGER BE POWER-ASSISTED AND THE
BRAKE BOOSTER WILL BECOME INEFFECTIVE AFTER A FEW APPLICATIONS OF TH E BRAKES. BE PREPARED
FOR RELATIVELY HEAVY STEERING AND THE NEED
FOR GREATLY INCREASED BRAKE PEDAL PRESSURE.
Interior Trim (01.05)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-4-1
Body System (01.00)
Interior Trim (01.05)
This section covers removal and installation of the interior mouldings and trim panels. In many instances, one component
overlaps another component. If this co ndition is found, it will be necessary to loosen or remove the overlapping
component before removal, to prevent damage to either component.
Maintenance
Rear Centre Console - Renew
Removal
1. Battery isolation switch ‘OFF’.
1. Remove storage compartment door.
2. Remove bolt and screws (x5) from support rail to body and remove support rail.
3. Remove screw (x1) centre arm rest to rear console panel assembly and remove arm rest (see Figure 1).
4. Remove nuts (x3), screws (x4) from panel assembly rear console (see Figure 2).
5. Remove screws (x2) ashtra y console panel assembly to
floor. 6. Remove rear console panel assembly.
Installation
1. Position rear console panel, install and tighten nuts (x3)
and screws (x4).
2. Install screws (x2) ashtray console panel to floor.
3. Install centre arm rest.
4. Install support rail, install and tighten screws (x5) and
bolt.
5. Install stowage compartment door.
Headlining - Renew (Roadster Only)
Removal
1. Remove header trim (see Workshop Manual procedure 01.05.BB Panel Assembly - Header - Renew).
2. Remove screws (x28) securing rear seal to tension bow, release seal and springs, collect brackets and rest seal on
tonneau (see Figure 1).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Instrument Panel (IP) (01.12)
Body System (01.00)1-9-12 Workshop Manual Issue 5, January 2010
2. Disconnect multiplug (x1) starter button and remove panel assembly (see Figure 1).
3. Remove starter button from instrument panel bezel
assembly (see Figure 2). 4. Remove screws (x6) air vent
s (x2) to bezel assembly and
remove air vents (s ee Figure 3).
Installation
1. Install air vents (x2).
2. Install starter button.
3. Position panel assembly, connect multiplug (x1) starter
button.
4. Install panel and secure in clips (x4).
Rear Console Panel Assembly - Renew
Removal
1. Battery isolation switch ‘OFF’
2. Remove stowage compartment door.
3. Remove bolt and screws (x5), support rail to body. Remove support rail.
4. Remove screw (x1) centre arm rest to rear console panel assembly.
5. Release/remove centre arm rest.
6. Remove nuts (x3), screws (x4), panel assembly rear console.
7. Remove screws (x2) ashtray console panel assembly to floor.
8. Remove rear console panel assembly.
Figure 1
Figure 2
A0112218
A0112217
Figure 3
Repair Operation Time (ROT)
ItemCode
Rear Console Panel Assembly-Renew 01.12.CA
A0112217A
Instrument Panel (IP) (01.12)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-9-13
Installation
1. Position rear console panel, install and tighten nuts (x3) and screws (x4).
2. Install screws (x2) ashtray console panel to floor.
3. Install centre arm rest.
4. Install support rail, install and tighten screws (x5) and bolt.
5. Install stowage compartment door.
6. Battery isolation switch ‘ON’.
Armrest Pad Assembly - Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Remove stowage compartment door.
3. Remove bolt (x1) and screws (x5) support rail to body.
4. Remove screw (x1) centre arm rest to rear console panel assembly.
5. Release and remove arm rest
Installation
1. Install arm rest assembly.
2. Install rear support rail
3. Install stowage compartment door.
4. Battery isolation switch ‘ON’.
Console Panel Assembly - Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Remove stowage compartment door.
3. Remove bolt (x1) and screws (x5) support rail to body.
4. Remove screw (x1) centre arm rest to rear console panel assembly.
5. Release and remove arm rest
6. Release gear lever gaiter.
7. Remove screws (x2) ashtra y console panel assembly to
floor.
8. Release switch panel and disconnect multiplugs (x6) and Lucar connectors (x2).
9. Remove switch panel.
10. Remove boot release and central locking switch.
11. Remove switches below ashtray (x4)
12. Remove Ashtray from panel assembly. (Allen screws x4)
Installation
1. Install ashtray to panel 2. Install switches (x4)
3. Install switch panel screws (x2).
4. Install boot release and central locking switch to panel
assembly console.
5. Position switch panel and connect multiplugs and Lucar connectors.
6. Install gear lever gaiter.
7. Install arm rest assembly.
8. Install rear support rail
9. Install stowage compartment door.
10. Battery isolation switch ’ON’.
RH/LH Rear Console Panel Assembly -
Renew (Roadster Only)
Removal
1. Remove panel assembly ce ntre (see Workshop Manual
procedure 01.05.FR/01.05.FS Panel Assembly - Centre -
Rear Bulkhead - LH/RH - Renew).
2. Remove screw (x1) trim to body lower (see Figure 1).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Instrument Panel (IP) (01.12)
Body System (01.00)1-9-14 Workshop Manual Issue 5, January 2010
3. Remove nut securing consol e panel to body side trim
(see Figure 2).
4. Remove wind stop hook (see Workshop Manual procedure 01.05.CZ Hook - Windstop - Renew).
5. Remove accessory socket cover and cubby box liner (see Figure 3). 6. Remove stowage cover (see Figure 4).
7. Prise top of cubby box side trim aside and remove
securing screw (see Figure 5).
8. Remove screws (x2) securing trim to tunnel and remove trim.
Installation
1. Install trim and securing screws (x2).
2. Prise top of cubby box side trim aside and install securing screw.
3. Install stowage cover.
4. Install accessory socket cover and cubby box liner.
5. Install wind stop hook (see Workshop Manual procedure 01.05.CZ Hook - Windstop - Renew).
6. Install nut securing consol e panel to body side trim.
7. Install screw (x1) trim to body lower.
Figure 2
Figure 3
Figure 4
Figure 5
Instrument Panel (IP) (01.12)
Body System (01.00)1-9-20 Workshop Manual Issue 5, January 2010
3. Fully open the tonneau cover to get access to the hood compartment.
C-01-12-DA-20
4. Use the special tool to hold the tonneau cover.
C-01-12-DA-21
5. Remove the left side infill panel.
C-01-12-DA-24
6. Remove the screw that attaches the left side rear bulkhead cover to the body.
C-01-12-DA-22
7. Remove the left side rear bulkhead cover.
C-01-12-DA-23
8. Remove the stowage box cover and the rubber mat.
C-01-12-DA-25