Page 1497 of 3039
5. CAUTION: Make sure the torque converter is fully
located into the oil pump drive.
6. CAUTION: Make sure that the torque converter
remains in the transmission.
NOTE: Some variation in the illustrations may occur,
but the essential information is always correct.
Raise the powertrain assembly jack and transmission
assembly. www.JagDocs.com
Page 1517 of 3039
Transmission fluid ATF Shell M 1375.4 Vehicles with 3.0L diesel engine
Description Nm lb-ft Transmission fluid cooler tube to transmission housing bolt 23 17 Transmission fluid cooler tube bracket to engine oil pan retaining bolt 23 17 Vehicles with 5.0L engine
Description Nm lb-ft Transmission fluid cooler tube to transmission housing bolt 23 17 Transmission fluid cooler tube bracket to engine oil pan retaining bolt 11 8
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Transmission Cooling (Description and Operation), Transmission Cooling (Description and Operation).
Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of damage and system integrity.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.
Symptom Chart
Condition Possible Causes Action Over heating of the
automatic
transmission Obstruction in the automatic
transmission fluid cooler Flush out the automatic transmission fluid cooler with new
automatic transmission fluid. If the flushing is unsuccessful,
install a new transmission fluid cooler. Over heating of the
automatic
transmission Obstruction in the automatic
transmission fluid tubes Flush out the automatic transmission fluid cooler tubes with new
automatic transmission fluid. If the flushing is unsuccessful install
new automatic transmission fluid cooler tubes. Loss of automatic
transmission fluid Connections to the automatic
transmission and the automatic
transmission fluid cooler Check the integrity of the tubes, connections and seals. Check the
torque of the tube fixings. Loss of automatic
transmission fluid Leak at oil cooler
Check the integrity of tubes, connections and seals. Check the torque of the tube fixings. Mechanical
Feed and return tubes
Connections to the automatic transmission and the automatic transmission fluid cooler
Automatic transmission fluid level Visual Inspection
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Page 1590 of 3039
1 Fuel level sensor 2 Fuel level sensor float arm 3 Fuel level sensor float Two fuel level sensors are installed in either side of the saddle tank. One is mounted on the fuel pump module, the other is
mounted on the carrier in the LH side of the fuel tank. The sensors are a float operated MAPPS (magnetic passive position sensor) which provide a variable resistance to ground for the output from the fuel gauge. The sensor is sealed from the fuel
preventing contamination of the contacts, increasing reliability. The fuel level sensors are connected to the external electrical
connector on the flange via the connector on the underside of the fuel pump module flange.
The sensor comprises a series of 51 film resistors mounted in an arc on a ceramic surface. The resistors are wired in series
with individual contacts. A soft magnetic foil with 51 flexible contacts is mounted a small distance above the film resistors. A
magnet, located below the ceramic surface, is attached to the sender unit float arm. As the float arm moves, the magnet
follows the same arc as the film resistors. The magnet pulls the flexible contacts onto the opposite film resistor contacts
forming an electrical circuit.
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1 Magnetic foil 2 Spacer 3 Ceramic surface 4 Magnet 5 Resistance film The film resistors are arranged in a linear arc with resistance ranging from 51.2 to 992.11 Ohms. The electrical output signal is
proportional to the amount of fuel in the tank and the position of the float arm. The measured resistance is processed by the
instrument cluster to implement an anti-slosh function. This monitors the signal and updates the fuel gauge pointer position
at regular intervals, preventing constant pointer movement caused by fuel movement in the tank due to cornering or braking.
A warning lamp is incorporated in the instrument cluster and illuminates when the fuel level is low.
The fuel level sender signal is converted into a CAN message by the instrument cluster as a direct interpretation of the fuel tank contents in liters. The ECM uses the CAN message to store additional OBD (on-board diagnostic) 'P' Codes for misfire detection when the fuel level is below a predetermined capacity.
JET PUMP
The fuel system incorporates two jet pumps. One jet pump is integrated into the fuel pump and draws fuel from the RH side of the fuel tank. The other jet pump is located on the fuel delivery module on the RH side of the tank. There is a pipe that is located in the LH side of the tank that allows fuel to be drawn over from the LH side of the tank, delivering fuel into the swirl pot. The jet pumps operate on a venturi effect created by the fuel at pump output pressure passing through the jet pump. This
draws additional fuel from the LH side of the tank through ports in the jet pump body, delivering additional fuel to the swirl pot.
FUEL VENT VALVE
The fuel level vent valve is located in the upper half of the tank and is connected into a separator which is connected to the
Roll Over Valve (ROV) tank breather. The main purpose of the fuel level vent valve is to control the fill volume of the tank.
During filling, air trapped inside the tank and a small amount of vapor is passed via the fuel level vent valve to the tank
breather. The air and vapor mix then vents to atmosphere through the breather. During filling, when the tank reaches its full
level, the fuel level vent valve closes and prevents air/vapor passing through to the tank breather. The resulting back pressure
causes refueling to stop automatically.
The fuel level vent valve is always open when the fuel tank is below full, providing an unrestricted air/vapor outlet to the tank
breather.
www.JagDocs.com
Page 1663 of 3039
Climate Control System - General Information -
Lubricants, Fluids, Sealers and Adhesives
NOTE: NAS vehicles. Published: 29-Jan-2014
Description Specification Air conditioning (A/C) refrigerant R-1234yf A/C compressor oil SPA2
NOTE: ROW vehicles.
Description Specification Air conditioning (A/C) refrigerant R-134a A/C compressor oil SPA2
NOTE: EU vehicles.
Description Specification Air conditioning (A/C) refrigerant R-1234yf A/C compressor oil SPA2 Capacities
Description Grammes A/C refrigerant - all engine variants 700 Refrigerant Oil Adding Capacities
NOTE: Rotate the A/C compressor shaft at least 6 to 8 turns when draining the refrigerant oil.
Item Milliliters A/C condenser core and desiccant bag Add 25ml oil A/C evaporator Add 30ml oil A/C compressor
1. Drain old A/C compressor. With drain plug removed and ports uncapped, rotate
shaft to remove A/C compressor oil and measure the amount of oil captured. 2. Drain
new A/C compressor into a clean vessel. With drain plug removed and ports
uncapped, rotate shaft to remove oil. Then add back a quantity of the new oil that is
identical to the quantity of oil removed from the old A/C compressor. However, if this quantity is less than 30ml, then make it up to 30ml. A/C lines - if air conditioning has been operational. Add 5ml oil per A/C line A/C system after flushing - with new compressor installed No oil should be used- new oil in new compressor is sufficient A/C system after flushing - without a
new compressor installed - remaining
A/C compressor oil is to be drained.
Compressor and expansion valve must
not be flushed (removed from the circuit) Add 80ml oil A/C compressor drain plug Torque 12Nm www.JagDocs.com
Page 1669 of 3039
8. WARNING: Refrigerant must always be recycled before re-use to ensure
that the purity of the refrigerantis high enough for safe use in the air
conditioning system. Recycling should always be carried out with
equipment which is design certified by Underwriter Laboratory Inc. for
compliance with SEA J1991. Other equipment may not recycle refrigerant
to the required level of purity. R143a Refrigerant Recover Recycling
Recharging station must not be used with any other type of
refrigerant.Refrigerant R134a from domestic and comercial sources must
not be used in motor vehicles air conditioning systems.
Allow the system to recover the refrigerant from the system.
9. Close the valves on the refrigerant station.
10. Turn the main switch 'OFF'.
11. Close the valves on the connections.
12. Disconnect the high and low pressure connections.
13. Install the dust covers to the connectors.
14. Open the tap at the rear of the station to drain the refrigerant oil.
15. Measure and record the quantity of refrigerant oil recovered from the
system.
16. Close the tap at the rear of the station.
17. Evacuation.
18. Remove the dust covers from the high and low pressure connections.
19. Connect the high and low pressure lines to the appropriate connections.
20. Open the valves on the connections.
21. Turn the valves on the station to the correct positions.
22. Turn the process switch to the correct position.
23. Turn the main switch to 'ON'.
24. Allow the station to evacuate the A/C system.
25. CAUTION: The system must be evacuated immediatley before
recharging commences. Delay between evacuation and recharging is not
permitted
Recharging
26. Close the valves on the refrigerant station.
Page 1670 of 3039
27. Close the valve on the oil charger.
28. Disconnect the yellow line from the refrigerant station.
29. Remove the cover from the oil charger.
30. Pour the correct quantity of refrigerant oil into the oil charger.
31. Install the cover to the oil charger.
32. Connect the yellow line to the refrigerant station.
33. Open the valve on the oil charger.
34. Move the pointer on the refrigerant gauge to mark the position of the
refrigerant drop.
35. Slowly open the correct valve on the refrigerant to allow the vacuum to
pull the refrigerant into the system.
36. Close the valve on the refrigerant station when the correct amount of
refrigerant has been drawn into the air conditioning system.
37. Turn the main switch 'OFF'.
38. Close the valves on the connections.
39. Disconnect the high and low pressure connections.
