Jaguar X-Type (2001) manuel d'utilisation

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Un bon manuel d’utilisation

Les règles imposent au revendeur l'obligation de fournir à l'acheteur, avec des marchandises, le manuel d’utilisation Jaguar X-Type (2001). Le manque du manuel d’utilisation ou les informations incorrectes fournies au consommateur sont à la base d'une plainte pour non-conformité du dispositif avec le contrat. Conformément à la loi, l’inclusion du manuel d’utilisation sous une forme autre que le papier est autorisée, ce qui est souvent utilisé récemment, en incluant la forme graphique ou électronique du manuel Jaguar X-Type (2001) ou les vidéos d'instruction pour les utilisateurs. La condition est son caractère lisible et compréhensible.

Qu'est ce que le manuel d’utilisation?

Le mot vient du latin "Instructio", à savoir organiser. Ainsi, le manuel d’utilisation Jaguar X-Type (2001) décrit les étapes de la procédure. Le but du manuel d’utilisation est d’instruire, de faciliter le démarrage, l'utilisation de l'équipement ou l'exécution des actions spécifiques. Le manuel d’utilisation est une collection d'informations sur l'objet/service, une indice.

Malheureusement, peu d'utilisateurs prennent le temps de lire le manuel d’utilisation, et un bon manuel permet non seulement d’apprendre à connaître un certain nombre de fonctionnalités supplémentaires du dispositif acheté, mais aussi éviter la majorité des défaillances.

Donc, ce qui devrait contenir le manuel parfait?

Tout d'abord, le manuel d’utilisation Jaguar X-Type (2001) devrait contenir:
- informations sur les caractéristiques techniques du dispositif Jaguar X-Type (2001)
- nom du fabricant et année de fabrication Jaguar X-Type (2001)
- instructions d'utilisation, de réglage et d’entretien de l'équipement Jaguar X-Type (2001)
- signes de sécurité et attestations confirmant la conformité avec les normes pertinentes

Pourquoi nous ne lisons pas les manuels d’utilisation?

Habituellement, cela est dû au manque de temps et de certitude quant à la fonctionnalité spécifique de l'équipement acheté. Malheureusement, la connexion et le démarrage Jaguar X-Type (2001) ne suffisent pas. Le manuel d’utilisation contient un certain nombre de lignes directrices concernant les fonctionnalités spécifiques, la sécurité, les méthodes d'entretien (même les moyens qui doivent être utilisés), les défauts possibles Jaguar X-Type (2001) et les moyens de résoudre des problèmes communs lors de l'utilisation. Enfin, le manuel contient les coordonnées du service Jaguar en l'absence de l'efficacité des solutions proposées. Actuellement, les manuels d’utilisation sous la forme d'animations intéressantes et de vidéos pédagogiques qui sont meilleurs que la brochure, sont très populaires. Ce type de manuel permet à l'utilisateur de voir toute la vidéo d'instruction sans sauter les spécifications et les descriptions techniques compliquées Jaguar X-Type (2001), comme c’est le cas pour la version papier.

Pourquoi lire le manuel d’utilisation?

Tout d'abord, il contient la réponse sur la structure, les possibilités du dispositif Jaguar X-Type (2001), l'utilisation de divers accessoires et une gamme d'informations pour profiter pleinement de toutes les fonctionnalités et commodités.

Après un achat réussi de l’équipement/dispositif, prenez un moment pour vous familiariser avec toutes les parties du manuel d'utilisation Jaguar X-Type (2001). À l'heure actuelle, ils sont soigneusement préparés et traduits pour qu'ils soient non seulement compréhensibles pour les utilisateurs, mais pour qu’ils remplissent leur fonction de base de l'information et d’aide.

Table des matières du manuel d’utilisation

  • Page 1

    Workshop Manual X-TYPE Sedan and Estate (Wagon) 2.0 L , 2.5 L and 3.0 L Gasoline; 2.0 L and 2.2 L, Diesel 2001 to 2009 www.JagDocs.com JagDocs.com[...]

  • Page 2

    TABLE OF CONTENTS 1: General Informa tion 10 0: Service Information 100 -00: General Information Description and Op eration About This Manual Application and Use of Spec ifications General Service Information Health and Safety Precau tions How To Use This Manu al Important Safety Instruc tions Road/Roller Testing Solvents, Sealants and Ad hesives S[...]

  • Page 3

    2: Chassis 20 4: Suspension 204 -00: Suspension System - Gene ral Information Specification Description and Op eration Wheel Alignment Angles Diagnosis and Testing Suspension System General Procedures Front Toe Adjustment (57.65.01) Rear Toe Adjustment ( 57.65.08) Wheel Bearing In spection 204 -01: Front Suspension Specification Description and Op [...]

  • Page 4

    Removal and Installation Damper Front Lower Arm (64.35.51) - 4-Door Front Lower Arm (64.35.51) - Wagon Rear Lower Arm (64.35.52) Spring (64.20.01) Rear Stabilizer Bar (64.35.08) Rear Stabilizer Bar Link (64 .35.24) Upper Arm (64 .25.31) Wheel Hub (64.15.14) Wheel Knuckle ( 64.15.22) Wheel Knuckle Front Bush ing (64.15.28) Wheel Knuckle Rear Bushin [...]

  • Page 5

    Diagnosis and Testing Driveline System 205 -01: Driveshaft Specification Description and Op eration Driveshaft Diagnosis and Testing Driveshaft General Procedures Driveshaft Runout an d Balancing Removal and In stallation Driveshaft (47.15.01) 205 -02: Rear Drive Axle/Differe ntial Specification Description and Op eration Rear Drive Axle and Differ[...]

  • Page 6

    Front Halfshaft RH (47.10.16) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110 kW/150PS) - Puma Inner Constant Velocity ( CV) Joint Boot (47.10.18) Intermediate Shaft Outer Constant Velocity (CV) Joint Boot (47.10.19) 205 -05: Rear Drive Halfshafts Specification Description and Op eration Rear Drive Halfshafts Diagnosis and Testing Rear Drive Halfshaft[...]

  • Page 7

    Brake Pads (70.40.02) 206 -04: Rear Disc Brake Specification Description and Op eration Rear Disc Brake Diagnosis and Testing Rear Disc Brake Removal and In stallation Brake Caliper (70.55.03) (70.55.25) Brake Disc (70.10.11) Brake Disc Shield (7 0.10.19) Brake Pads (70.40.03) 206 -05: Parking Brake and Actuatio n Specification Description and Op e[...]

  • Page 8

    Brake Pedal and Bracket (70.35.03) Brake Pedal Cross-Shaft 206 -07: Power Brake Actuation Specification Description and Op eration Brake Booster Diagnosis and Testing Power Brake System Removal and In stallation Brake Booster (70.50.17) - LHD AWD/LHD FWD Brake Booster (70.50.17) - RHD AWD/RHD FWD Brake Vacuum Pump - 2.0L NA V6 - AJV6 Brake Vacuum P[...]

  • Page 9

    211: S teering System 211 -00: Steering System - General I nformation Specification Description and Op eration Steering System Diagnosis and Testing Steering System General Procedures Power Steering System Filling Power Steering System Flushing ( 57.15.08) 211 -02: Power Steering Specification Description and Op eration Power Steering Diagnosis and[...]

  • Page 10

    211-03 : Steering Linkage Specification Description and Op eration Steering Linkage Diagnosis and Testing Steering Linkage Removal and In stallation Steering Gear Boot (57.10.29) Tie Rod End ( 57.55.02) 211 -04: Steering Column Specification Description and Op eration Steering Column Diagnosis and Testing Steering Column Removal and In stallation I[...]

  • Page 11

    3: Powertrain 30 3: Engine 303 -00: Engine System - General Inform ation Specification Description and Op eration Engine Diagnosis and Testing Engine General Procedures Bearing Inspection Camshaft Bearing Journal Clear ance Camshaft Bearing Journal Diam eter Camshaft End Play Camshaft Lobe Lift Camshaft Surface Inspec tion Connecting Rod Clean ing [...]

  • Page 12

    Leakage Test Using Smoke Test Equipm ent 303 -01A: Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Engine Diagnosis and Testing Engine General Procedures Valve Clearance Adjustment (12.29.48) Valve Clearance Check (12.29.47) In-Vehicle Repair Camshafts LH (12.13.19) Crankshaft Front Seal (12 .[...]

  • Page 13

    Engine (12.41.01) - Veh icles With: 5-Speed Au tomatic Transaxle - JATCO/6-Speed Automatic Transaxle - AWF21 Disassembly Engine Disassembly and Assemb ly of Subassemblies Cylinder Head (12.29.22) Piston (12.17.02) Assembly Engine Installation Engine (12.41.01) - Veh icles With: 5-Speed Manual Transmission - MT75/6- Spe ed Manual Transaxle - MMT6 En[...]

  • Page 14

    Installation Engine (12.41.01) - 2.0L Du ratorq-TDCi Engine (12.41.01) - 2.2L Du ratorq-TDCi (110kW/150P S) – Puma 303 -03A: Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Engine Cooling Diagnosis and Testing Engine Cooling General Procedures Cooling System Backflush ing Cooling Sys[...]

  • Page 15

    Cooling Module (26.40.16) Radiator (26.40.01) Water Pump (26.50.01) 303 -04A: Fuel Charging and Con trols - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Fuel Charging and Controls Diagnosis and Testing Fuel Charging and Controls - 2.0L NA V6 - AJV6 Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L[...]

  • Page 16

    303 -04C: Fuel Charging and Con trols - Turbocharger Specification Description and Op eration Turbocharger Diagnosis and Testing Turbocharger Removal and In stallation Turbocharger 303 -05: Accessory Drive Specification Description and Op eration Accessory Drive Diagnosis and Testing Accessory Drive Removal and In stallation Accessory Drive Belt (1[...]

  • Page 17

    Starting System Diagnosis and Testing Starting System - 2.0L NA V6 - AJV6 Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Removal and In stallation Starter Motor (86.60.01) - 2.0L Du ratorq-TDCi Starter Motor (86.60.01) - 2.2L Du ratorq-TDCi (110kW/150 PS) - Puma Starter Motor (86.60.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 – AJ[...]

  • Page 18

    Removal and In stallation Exhaust Gas Recirculation ( EGR) Cooler Exhaust Gas Recirculation ( EGR) Cooler to EGR Valve Tube Exhaust Gas Recirculation ( EGR) Valve (17 .45.01) 303 -12A: Intake Air Distribution a nd Filtering - 2 .0L NA V6 - AJV6/2. 5L NA V6 – AJV6/3.0L NA V6 - AJ27 Description and Op eration Intake Air Distribution and Filtering D[...]

  • Page 19

    Removal and In stallation Evaporative Emission Canister (17.15.13) - 2.0L NA V6 - AJV6 Evaporative Emission Canister (17.15.13) - 2.5L NA V6 - AJV6/3 .0L NA V6 - AJ27 Evaporative Emission Canister Purge Valve (17.15.30) 303 -14A: Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V 6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op era[...]

  • Page 20

    Description and Op eration Electronic Engine Controls Diagnosis and Testing Electronic Engine Controls Removal and In stallation Camshaft Position (CMP) Sensor (18.30.63) Catalytic Converter Temperatu re Sensor Crankshaft Position (CKP) Sensor (18.30.12) Cylinder Head Temp erature (CHT) Sensor (18 .30.97) Diesel Particulate Filter ( DPF) Temperatur[...]

  • Page 21

    Transmission Control Module (TCM) (44.15.32) Transmission Range (TR) Sensor Removal Transaxle (44.20.01) Disassembly and Assemb ly of Subassemblies Input Shaft Seal (44.32.07) Installation Transaxle (44.20.01) 307 -01B: Automatic Transmission/Tra nsaxle - Vehicles With: 6-Speed Automatic Transaxle - AWF21 Specification Description and Op eration Tr[...]

  • Page 22

    307 -02A: Transmission/Transaxle Cooli ng - Vehicles Wit h: 5-Speed Automati c Transaxle - JATCO Specification Description and Op eration Transmission Cooling - Veh icles With: 5-Speed Automatic Transaxle - JATC O Diagnosis and Testing Transmission Cooling Removal and In stallation Transmission Fluid C ooler (44.24.10) Transmission Fluid C ooler Tu[...]

  • Page 23

    307 -05B: Automatic Transmission/Tra nsaxle External C ontrols - Vehicles Wi th: 6-Speed Automat ic Transaxle - AWF21 Specification Description and Op eration External Controls - Vehicle s With: 6-Spee d Automatic Transaxle - AWF21 Diagnosis and Testing External Controls General Procedures Selector Lever Cable Adjustment ( 44.15.07) Removal and In [...]

  • Page 24

    Clutch Disc and Pressure Plate (12.53.13) (3 3.10.01) 308 -02: Clutch Controls Specification Description and Op eration Clutch Controls Diagnosis and Testing Clutch Controls Removal and In stallation Clutch Master Cylinder (3 3.20.01) Clutch Slave Cylinder (33.35.01) - Vehicles With: 5-Speed Manu al Transmission – MT75 Clutch Slave Cylinder (33.3[...]

  • Page 25

    Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 Installation Transaxle (37.20.01) - 2 .0L Duratorq-TDCi Transaxle (37.20.01) - 2 .2L Duratorq-TDCi (110kW/150PS) - Puma Transaxle (37.20.01) - 2 .0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 308 -06: Manual Transmission/Tr ansaxle External C ontrols Specification [...]

  • Page 26

    30 9: Exhaust System 309 -00: Exhaust System Specification Description and Op eration Exhaust System Diagnosis and Testing Exhaust System Removal and In stallation Catalytic Converter (17.50.05) - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (110kW/1 50PS) - Puma Catalytic Converter LH (17.50.15) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Ca[...]

  • Page 27

    General Procedures Fuel System Pressure C heck Fuel System Pressure Release (19.50.02) Fuel Tank Draining - 2.0L Duratorq-TDCi/2.2L Durato rq-TDCi (110kW/15 0PS) – Pum a Fuel Tank Draining - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Quick Release Couplin g - Push Connect Spring Lock Coup lings 310 -01: Fuel Tank and Lines Specificatio[...]

  • Page 28

    310 -02: Acceleration Control Specification Description and Op eration Acceleration Control Diagnosis and Testing Acceleration Control General Procedures Accelerator Cable Adju stment (12.20.05) - 2.0L NA V6 - AJV6 Removal and In stallation Accelerator Cable ( 19.20.06) - 2.0L NA V6 - AJV6 Accelerator Pedal ( 19.20.01) 310 -03: Speed Control Specif[...]

  • Page 29

    Air Conditioning (A/C) System Flushing Air Conditioning (A/C) System Recovery, Evacuation an d Charging (82 .30.30) Contaminated Refrigerant Han dling Discharging and Recovery (82.30.30) Electronic Leak De tection Inspection and Assembly Requirements Leak Detection Refrigerant Oil Addin g Refrigerant System Tests 412 -01: Air Distribution and Filte[...]

  • Page 30

    412 -02B: Auxiliary Heating Specification Description and Op eration Electric Booster Heater Fuel Fired Booster Heater Diagnosis and Testing Auxiliary Heater Fuel Fired Booster Heater Removal and In stallation Electric Booster Heater Fuel Fired Booster Heater 412 -03: Air Conditioning Specification Description and Op eration Air Conditioning Diagno[...]

  • Page 31

    Air Discharge Temperatu re Sensor (82.20.64) Ambient Air Temperature Sensor (82.20.02) Climate Control Assembly ( 82.20.07) Defrost Vent/Register Blend Door Actuator (82.20.8 4) Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85) Sunload Sensor (82.20.70) Temperature Blend Door Actu ator (82.20.86) 41 3: Instrumentation and Warning System[...]

  • Page 32

    Removal and In stallation Message Center Message Center Switch (86.66.11) 413 -09: Warning Devices Description and Op eration Warning Devices Diagnosis and Testing Warning Devices General Procedures Oil Change In dicator Reset Removal and In stallation Low Washer Fluid Warning I ndicator Switch (84.10.17) 413 -13: Parking Aid Description and Op era[...]

  • Page 33

    Quiescent Drain Diagnosis and Testing Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 Charging System - 2.0L Durato rq-TDCi/2.2L Durator q-TDCi (110 kW/150PS) – Pum a General Procedures Battery Charging 414 -01: Battery, Mounting and Cables Specification Description and Op eration Battery and Cable s Diagnosis and Testing[...]

  • Page 34

    41 5: Information and Entertainmen t Systems 415 -00: Information and Entertai nment System - Gen eral Information Diagnosis and Testing Audio System 415 -01: Audio Unit Description and Op eration Audio System Diagnosis and Testing Audio System Removal and In stallation Audio Unit (86.50.03) Audio Unit Amplifier (8 6.50.10) (86.50.36) - 4-Door Audi[...]

  • Page 35

    Parcel Shelf Speaker (86 .51.06) Rear Door Speaker (86.50.14) Rear Door Tweeter Spe aker (86.50.62) 41 7: Lighting 417 -01: Exterior Lighting Specification Description and Op eration Exterior Lighting Diagnosis and Testing Headlamps General Procedures Headlamp Adjustment (8 6.40.18) Removal and In stallation Ballast (86.41.52) Front Fog Lamp (86 .4[...]

  • Page 36

    417 -04: Daytime Running Lamps ( DRL) Description and Op eration Daytime Running Lamps (DRL) Diagnosis and Testing Daytime Running Lamps (DRL) 41 8: Electrical Distribution 418 -00: Module Communication s Network Description and Op eration Communications Network Diagnosis and Testing Communications Network - V IN Range: E96603->J 28492 Communica[...]

  • Page 37

    419 -01B: Anti-Theft - Passive Description and Op eration Anti-Theft - Passive Diagnosis and Testing Anti-Theft - Passive General Procedures Anti-Theft Security Acce ss Key Programming Using Diagnostic Equip ment Removal and In stallation Passive Anti-Theft System (PATS) Transceiver ( 86.52.30) 419 -02: Remote Convenience Description and Op eration[...]

  • Page 38

    Cellular Phone Cellular Phone - Veh icles With: Bluetooth Removal and In stallation Bluetooth Module Handset Holder (86.51.12) Module - 4-Door Module – Wagon 419 -10: Multifunction Electronic Modul es Specification Description and Op eration Module Controlled Functions Diagnosis and Testing Multifunction Electronic Mod ule Removal and In stallati[...]

  • Page 39

    General Procedures Door Alignmen t Hood Alignment (76 .16.02) Liftgate Alignment (76.19.54.60) Luggage Compartment Lid Alignment (76.19.03) Removal and In stallation Weatherstrip 501 -05: Interior Trim and Ornamentation Specification Description and Op eration Interior Trim Removal and In stallation A-Pillar Trim Panel (76.13.31) B-Pillar Lower Tri[...]

  • Page 40

    Removal and In stallation Door Moulding (76 .43.72) Liftgate Moulding (7 6.43.79) Radiator Grille (76.55.03) Rear Spoiler (76.19.86.60) - Wagon Rocker Panel Moulding (76.11.36) Roof Rail (76.43.86.60) Window Moulding (76 .43.20) 501 -09: Rear View Mirrors Specification Description and Op eration Rear View Mirrors Diagnosis and Testing Rear View Mir[...]

  • Page 41

    Front Seat Track Motor (86.75. 33) Lumbar Assembly (86.75.12) Rear Seat Backrest (76.70.38) - 4-Door Rear Seat Backrest (76.70.38) - 4-Door, Vehicles With : 70/30 Split Seat Rear Seat Backrest (76.70.38) - Wagon, Vehicles With : 70/30 Split Seat Rear Seat Backrest Latch (76.70.62.60) - Wagon Rear Seat Bolster (76.70.67) - 4-Door Rear Seat Bolster ([...]

  • Page 42

    Rear Quarter Window Glass (76.31.31) Rear Window Glass Using Che ese Wire (76.81.41) Rear Window Glass Using Cut ting Tool Window Control Switch ( 86.25.08) Windshield Glass Using C heese Wire (76.81.40) Windshield Glass Using C utting Tool (76.81.01) 501 -12: Instrument Panel and Cons ole Description and Op eration Instrument Pan el Removal and In[...]

  • Page 43

    501 -16: Wipers and Washers Specification Description and Op eration Wipers and Washers Diagnosis and Testing Wipers and Washers Removal and In stallation Headlamp Washer Pum p (84.20.21) Rain Sensor (84.12.10) ( 86.56.62) Rain Sensor Module (86 .56.60) Rear Window Wiper Motor (8 4.15.48.60) (84.35.12) Windshield and Rear Win dow Washer Pum p (84.1[...]

  • Page 44

    501-19: Bumpers Specification Description and Op eration Bumpers Removal and In stallation Front Bumper Cover (7 6.22.78) Front Bumper Cover In sert (76.22.73) Rear Bumper (76.22.27) (76.22.52) - 4-Door Rear Bumper (76.22.27) (76.22.52) - Wagon Rear Bumper Cover (76 .22.74) (76.22.77) - 4-Door Rear Bumper Cover (76 .22.74) (76.22.77) - Wagon Rear B[...]

  • Page 45

    General Procedures Air Bag Disposal Removal and In stallation Clockspring (86.65.92) Crash Sensor (76.73.55) Driver Air Bag Module (7 6.73.39) Driver Lower Air Bag Module (76.73.75) Occupant Classification Senso r (76.73.60) Passenger Air Bag Deactivation (PAD) Indicat or (76.73.58) Passenger Air Bag Module ( 76.73.37) Restraints Control Module (RC[...]

  • Page 46

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - A bout Th is Man ual Des cr ipt i o n a nd O pe r a t i o n Note s, Ca u tions a n d Warn ings Thr oug hout t hi s manua l , i mpor t a nt i nfo rm at i on i s hi ghl i gh te d by t he us e o f no t e s , ca ut i ons a nd wa rning s. NO TES gi v e a ddi t i o nal i nfo r m at i o n on a t o pi [...]

  • Page 47

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - A pplicatio n and U se o f S pecifi cation s Des cr ipt i o n a nd O pe r a t i o n Torque S pecif ica tions To r que s pe ci fi cat i on s a r e s ho wn i n t he t orque s pe cif i ca t i o ns c ha rt l o cat e d a t t he fro nt of t he rel e v a nt s e c t i o n. JagDocs.com[...]

  • Page 48

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - General Service I nform atio n Des cr ipt i o n a nd O pe r a t i o n Repa irs an d Repla cem en ts W he n s e r vi c e pa r t s a r e requi r ed, it i s e s s e nt ia l tha t onl y g e nui ne Ja g uar/ Dai mle r r ep l a ceme nt s a r e us e d. At t e nt i o n i s drawn t o t he fo l lo wi ng [...]

  • Page 49

    Re - e nt e r t he radi o recei ve r /cas s e t t e pl ayer /min i di s c pl a y e r and co mpact d i s c pl a y e r k e yc od e s a nd pr es e t ' f r e que ncie s , i f kno wn. Fol l o wi ng r e conne cti o n o f t he ba t te r y, t he e ngi ne s h oul d be al lo we d t o i dl e unt i l i t ha s reache d no r m al o p e r at i ng t e mpe r a[...]

  • Page 50

    I t is o f f unda ment a l i m po r t ance t ha t c e rta i n e s s e nti a l e qui pme nt e . g. t o r que wren c he s , mult i met e r s , e xhaus t ga s a nal yse r s, r o ll i ng roads e t c., are regul arly cal i br a t e d i n a ccor da nce wi t h t he m a nufa ct ur ers i ns t r u cti ons . U se of C ontr ol Mo du les Cont rol mod ul es m a [...]

  • Page 51

    I n t he i nt e re st o f cla r it y, s i ngl e l i ne s may repr e se nt mul t i pl e wi r es . Re fe r to the col o r code (1s t a l pha ) f ol lo we d by t he wi r e ref e rence (num eric/al pha/n umer ic) t o t r ace o r i g in a nd de s t i n at io n. e .g. B W 647B002. BW (bl a ck wi t h whi t e t r ace) 647 (wi r e r e fe rence ) B002 (s t a[...]

  • Page 52

    T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on Dat a O ut p ut Li ne DOL Ci r cui t th a t s e n ds certa i n i nf orm at i o n f r o m t he ECM to the i ns t ru me nt cl ust e r Deg r ee de g , ° Angle o r t e mpe r a ture Dep a r t ment o f Tr an s p or t a t i o n (US) DOT W h i ch is a f i br e o pt ic ring ne tw ork, can b e d[...]

  • Page 53

    T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on He a t e d O x ygen S e nso r HO2S El e ct rica ll y he at e d o xy ge n s e ns or w hi ch i ndu c e s f ue l i ng c orr e ct i ons He r t z (freq uency) Hz Fr e que ncy, o ne cycle pe r s e cond Hi gh Mount e d Sto pl amp HMS L Hi gh t e ns i o n HT Ho ur ho ur Hydr oca r b o n HC I dl[...]

  • Page 54

    T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on On -Boa rd Dia g nos t i c OB D A s ys t e m t ha t moni t o r s s o me o r a l l comput e r i npu t a nd o ut p ut cont r o l s i gna l s . S ig nal (s ) ou ts i de th e pre -det e rm ine d l i mi t s i mpl y a f a ul t i n t he s ys t e m o r a r el a t e d s ys te m Orig i na l Equi [...]

  • Page 55

    T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on Tr an s mi s s i o n O i l Te mpe r at ur e TO T I ndi cat e s t e mpe rat ur e o f t rans mis s i o n fl ui d Tr an s mi s s i o n Ran ge TR T he range i n whi ch t he t r ans mis s i o n i s op e r at i ng Tur bi ne Sh af t Sp e e d TS S I ndi cat e s r o t a t i ona l s p ee d of t r[...]

  • Page 56

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - H ealth and Safety Pre cautio n s Des cr ipt i o n a nd O pe r a t i o n P r o l onge d a nd repe a t ed c on t a ct wi t h mine ral o i l wi l l res ul t i n t he r e mov a l of na t ural o i ls f r o m t he s kin , l e adi ng t o dr ynes s , i rr i t a t io n a nd de r m a t i t i s . In a dd[...]

  • Page 57

    Hi ghl y fl ammabl e , combus t i bl e – o bs e rv e No Sm oking po l i cy . S kin co nt a ct may res ul t in f r os tb i te . I nst r ucti o ns gi ven b y t he manufa ct ur e r m us t be f o l l owe d. A voi d na ked l i ght s , we ar s u i t a b l e p r o te cti v e g lo ves and gogg l e s . I f r e frige r a nt come s in t o cont a ct wi t h t[...]

  • Page 58

    Do wa s h b e fo re br ea ks , bef ore e a t i ng, s mokin g, d rinking o r us i ng t o i l et fa ci l i t i e s w he n ha ndl i ng che mica l m a t e ria l s . Do ke e p wo r k a r ea s cl e a n, unclut t e r ed a nd f r e e o f s pi l l s . Do s t ore che mica l mat e ria l s acco r d i ng t o na t i o na l and l o cal regul at i o ns . Do ke e p[...]

  • Page 59

    S ee L ubr ica nt s a nd Gr ea se . Exh a ust Fume s The s e c ont a i n a s phyxia t i ng , harm f ul a nd t oxi c chemi ca l s a nd p a r t i cl e s s uch a s ca r bo n o xide s , ni t r oge n o x i d e s , a l dehyde s , l ea d and aromat i c hydr o carbons . Engi ne s s houl d b e r un onl y unde r co ndi t i o ns of ade qua t e e xhaus t e xt [...]

  • Page 60

    Mot or ga s o li ne may cont ai n a pp r e cia b l e qua nt i t i e s o f b e nz e ne , whi ch is t o xic u po n i n hal at i o n, a nd t he concen trat i o n of ga s o l i ne v a po r s mus t be ke p t v e r y lo w. Hi g h conce nt rat i o ns wi ll ca us e eye, no se a nd throa t i r rit a t i o n, na us ea , he a d ache , d epres s i on a nd symp[...]

  • Page 61

    The Fa ct or i e s A ct (1961). The As bes t os Re gul at i o ns (1969). Hi ghl y Fl a mm a b l e Li q ui ds a nd L iq ui f i e d P e t r o l e um Gas e s Re g ul a t i o ns (1972) . Cont rol o f P o l l ut i on A c t (1974). He a l t h a nd S a fe t y a t W o r k Act (1974). The Cl a s s i f i cat i o n, P a c kagi ng a nd La be l l in g o f Dange[...]

  • Page 62

    a voi de d. Re moval o f e xc e s s s o ld e r s houl d be underta ke n wi t h care, t o make s ure t hat f i ne l e ad d ust i s no t p r o d uced, wh ich ca n gi ve t o xic e ff e ct s i f in ha l e d. Re sp i r a t ory prote c t i o n may b e ne ce s s a r y . S ol de r sp i l l age and fi l i ng s s ho ul d be co ll e ct e d a nd r emove d prom[...]

  • Page 63

    S ee a l s o Fi r e , El e ct ric Shoc k, Ga s Cyli nde rs. W e l di ng pr oce s s e s i ncl ude Res i st a nce W e ld i ng (S pot W e l di ng), A r c W e l d in g and Gas W e l d i ng. Resista nce W el ding Thi s proces s may ca use parti cl e s o f mol t e n met a l t o b e emi t t e d a t a hi gh ve lo ci t y , a nd t he e yes a nd s k i n m us [...]

  • Page 64

    3. J ag ua r vehi cle s a nd r e pl a ce ment parts whi ch cont a i n a s be s t os a r e i de nt i fi ed by t hi s s y mbol . S ee A sb e s t o s i n t hi s s ub s e ct i o n. 3. 4. Componen t s o r as s e mbli e s d is pl a yi ng t hi s s ym bol gi ve wa r ni ng t ha t t he compone n t cont a i ns a co r r os ive s ubs t a nce. See Aci ds a nd Al[...]

  • Page 65

    Ensu r e t hat d ry s a nd is a va i l abl e t o s o ak up a ny f ue l s pi l l a ge . Empty fue l us i ng s ui t ab l e fi r e p r oo f e qui pment i nto an a ut ho r i ze d expl o s i on pr oo f c o nt a i ner. Do no t e m pt y fue l whi l e wo r ki ng i n a wo r ksh op o r a pi t . Ensu r e t hat wo rking a r e a i s we l l v e nt il a t e d. En[...]

  • Page 66

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - H o w To Us e T hi s Manua l Des cr ipt i o n a nd O pe r a t i o n C opyrigh t Sta t em en t Cop y r i ght . © Jagu a r Cars Lt d. 1999 Al l right s r es e r ved. No part of t hi s publ i ca t i on may be repr od uced, s t o red i n a r e t r i e val s yst e m or t r ans mit t e d i n a ny f [...]

  • Page 67

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Important Safety Instructio ns Des cr ipt i o n a nd O pe r a t i o n S af e t y N o t i ce App r opr i at e s e r vi ce met ho d s a nd co r r ect repai r pr oced ur es a re e s s e nt i a l fo r t he s a fe , r el i a bl e o pe r at i o n o f a l l mot o r vehi cl e s , a s wel l a s t he s a[...]

  • Page 68

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - R oa d /R oll e r Tes ting Des cr ipt i o n a nd O pe r a t i o n Roa d o r r o l l e r t e s t i ng may b e carr i e d out f o r vario us reas on s an d a proced ur e de t a i l i ng pre - t e s t checks, t h r o ug h e ng i ne s t arti ng a nd s t o pp i ng, p r e - drivi ng c he ck s , o n -[...]

  • Page 69

    Abnorm a l te mperat ur e o f an y movi ng comp one nt s or as s e mbl i e s , e .g. whe e l hubs , t r ans mis s i o n, a xl e e t c., whi ch mi ght i ndi ca t e overti ght ne s s o r l a ck o f l ub r i cat i o n. JagDocs.com[...]

  • Page 70

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Solvents, Sealants and Adh esives Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: A l wa ys ha ndl e a l l s ol ve nt s , s e a l e r s a nd a d he s i ves wi t h e xtre me ca r e . S ome co nt a i n che mical s o r g i ve of f f um e s whi ch ca n be d a nge rous to hea l th . Al wa ys f o [...]

  • Page 71

    P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Sta ndard Works ho p Practices Des cr ipt i o n a nd O pe r a t i o n Protecting th e V eh icl e Al wa ys i ns t a ll cove rs t o pr ot e ct t he fe nd e r s be f ore co mm enci ng wo rk i n th e e ng i ne co mpa r t ment . A l wa ys i ns t a l l t he i nt e rio r pr ot e ct i o n kit , we a r [...]

  • Page 72

    P ubl i s he d: 11-May-2 011 Identifi cation C odes - Ide ntif icatio n C o des Des cr ipt i o n a nd O pe r a t i o n V eh icl e Ide ntifi cation Num be r (VIN) The o ff i ci a l VI N i s s t a mped o n t he right han d s i de o f t he b o ot compart m e nt fl o o r. A n a ddi ti o nal q ui ck r e fe r e nce a nd a nt i f o r ge r y id e nt i fi c[...]

  • Page 73

    Item Par t N u m ber Desc ri pti on 1 — W orld manuf act ur er i de nt i fi e r 2 — Ma r k e t , a i r ba g s pe cif i ca t i on 3 — T r ans mis s i o n a nd s t e e ring co d e 4 — B o dy code 5 — E ngi ne e mis s i on sys te m 6 — Ch eck di gi t 7 — Mo del ye a r 8 — A s s e mbl y p l a nt , mode l l i ne 9 — P r o duct i on se [...]

  • Page 74

    VI N Po si t i o n 8 • NO T E: *1 EU . I ncl ude s t he f ol l o wi ng mar ket s ; Au s t ria , Be lg i um , Cy pru s , Cz e ch Rep , Den m a rk , Es t o ni a , Fi nla nd, France , Ger many, Gr e e ce, Ne t he rla nds , Hunga r y, It a l y, La t vi a , Li t huani a, L uxe mbour g, Mal t a, P o l and, P o r t uga l , Rep. o f I r el a nd , S lo ve[...]

  • Page 75

    VI N Po si t i o n 1 2 throug h 1 7 Seque nce Nu m ber C00001 - C99999 D0000 1 - D99999 E00001 - E 99999 J00001 - J9999 9 K00001 - K99999 S 000 01 - S9 9999 T00001 - T99999 V00001 - V99999 V eh icl e C ertif i cation La bel The vehi cl e ce r t i f i ca ti on l a b e l al s o cont a i ns t he 17 charact e r vehi cl e i den t i f i cat i o n number.[...]

  • Page 76

    It e m Pa rt Nu mb e r Descri pti o n 1 — Maximum perm i t t e d front a xle l o a di ng 2 — Dat e of ma nufa ct ur e 3 — Gr o s s ve hi cle w ei ght 4 — Maximum perm i t t e d r ea r a xle l o a di ng 5 — Ve hi cl e i de nt i f i ca t i on number 6 — Ty pe 7 — Int e r i or t rim code 8 — Pa i nt cod e Ve hi cl e I d e nt i f i ca t[...]

  • Page 77

    It e m Pa rt Nu mb e r Descri pti o n 1 — Maximum perm i t t e d front a xle l o a di ng 2 — Dat e of ma nufa ct ur e 3 — Gr o s s ve hi cle w ei ght 4 — Maximum perm i t t e d r ea r a xle l o a di ng 5 — Ve hi cl e i de nt i f i ca t i on number 6 — Pa i nt cod e 7 — Int e r i or t rim code 8 — Ty pe Automa tic Tran smission Num b[...]

  • Page 78

    P ubl i s he d: 11-May-2 011 Ja cking and L ifti ng - J ackin g Des cr ipt i o n a nd O pe r a t i o n Sa f et y Precau tion s CAU TIO N : Th e j ack prov i de d wi t h t he vehi cl e i s i nt ende d t o b e us e d i n a n e me r ge ncy f o r cha ngi ng a d e fl a t e d t i re . To a v oi d da mage t o t he v e hi c l e , ne ve r us e th e j a c k [...]

  • Page 79

    P ubl i s he d: 11-May-2 011 Ja cking and L ifti ng - Li ftin g Des cr ipt i o n a nd O pe r a t i o n Liftin g Poi nt s—Twi n-Post Hoist an d Floor Ja ck • CAU TI O N S : Do not a l lo w t he ho i s t a d a pt e r s t o co nt a ct t he s t e e r i ng l i nk ag e , s us pe ns i on a r m s , s t ab i l i z e r bar , rear s ub frame s t abi l i z[...]

  • Page 80

    V eh icl e R ecove ry • NO T E: P r i o r t o vehi cl e r e covery , ma k e su r e t hat t he vehi cl e ke ys a r e avai l a bl e a nd t he s e cur it y s y s t e m i s di s a r me d. Ve hi cl e recove r y met ho ds a r e : By f l a t -be d t r ans porte r. By f r ont s us pe nd ed to w. Tran s p orter or Trailer Re c ove ry W he n t he vehi cl e[...]

  • Page 81

    W he n t he vehi cl e i s b e i ng re c ove r e d b y f r ont s us pe nde d t ow : CAU TIO N : Th e dr i ves ha ft mus t be di s c on ne ct e d. The i gni t i on k e y must b e r emove d from t he i gni t i o n s wi t ch t o l o ck th e s t e e r ing. The front whe e l s mus t b e co r r ect l y po s it i o ne d i n t he l i f t i ng cr adl e and s[...]

  • Page 82

    P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - No ise, V ibration and Harsh ness (NV H) Des cr ipt i o n a nd O pe r a t i o n No i s e , vibr a t i o n a n d ha r s hne ss (NVH) i s be comi ng more i mporta nt a s vehi cl e s be come mor e s op hi s t i ca t e d a nd p a s s eng e r comf ort le vel s in cr e a s e . Thi s s e c t[...]

  • Page 83

    P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - No ise, V ibration and Harsh ness (NV H) Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e . 2. 3. If a n obvi o us cau se fo r an ob s e rv e d [...]

  • Page 84

    lo o s e d r i ve ha l f s ha f t j oi nt b oot cl a mps a not h e r compone nt c on t a ct i ng t he d r i ve ha l f s haf t wor n, da mag e d o r in cor r ect ly i ns t a ll ed whee l b e a r i ng, s u s pe ns io n or brake compone nt Vi brat i o n at hi g hway sp e e ds may b e ca us ed by t he f ol l o wi ng: ou t-o f -bal a nce f r o nt o r re[...]

  • Page 85

    * * * * * * * * * * * * * * * * * * * * * * * * 1 Road C ondit ions An e xperie nce d te chni cia n wi l l a l wa ys e s t a b l is h a rout e t ha t wi l l be u se d fo r a l l NV H di a gnos i s roa d t es t s . T he r o a d s e l e ct e d s ho ul d be r e a s o nab l y s moo th , l e ve l a nd f ree o f undula t i o ns (unl e s s a pa r t i cul [...]

  • Page 86

    1 1 1 1 1 1 1 1 Doe s t he vi brat i o n di s ap pe a r dur ing t he ne ut r a l coa s t t e s t ? Ye s CHECK and INSTAL L ne w e ng i ne /ge a r b o x/ t r an s fe r box mount s as nece s sa ry . RE PE AT Ro a d T e s t a s out li ned . No GO t o D1 . PINPOIN T TE ST B : TIP-I N MOA N T EST C ONDI T I ONS DET AI LS/RE SULT S/A CT IONS B1: C HEC K [...]

  • Page 87

    1 1 1 1 1 1 1 Are t he t i r e s O K? Ye s GO t o D2 . No INS P ECT t he whee l s . Fo r a ddi t i o nal i nfo r mat i o n, refe r to REFER t o : W h e e l s a nd Ti r es (204-04 W he e l s and Ti r e s , Di a gno s i s a nd T e s t i ng). D2: IN SPEC T WHEEL BEAR I NG S Ins p ect t he whe el be a r i n gs . Fo r a ddi t i o na l i nf o r m at i o [...]

  • Page 88

    P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - Exh aust S y stem N eutraliz ing Gene ral P r ocedures 1. Loos e n t he muff le r i nl e t pi p e a nd res o na t o r pip e t o e xha us t mani fo l d f as t e ne rs a t t he f l a nge s a nd t he muf fl e r i nl e t conne ct i on. 2. Pl a ce a s t a nd t o s up port t he muffl e r pa[...]

  • Page 89

    P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Gen eral S p ec if ic a t ions It e m Speci fi cati on C l e a r V i si on Cle a r vis i o n (neg a t i ve val ue i s co unt e rc l ockwis e ) 0° ± 3° R i de Hei ght Fr o nt 371 mm ± 15 mm Re a r 370 mm ± 15 mm Bal l Joi nt Ra di a l Pl a y Lo we r bal l jo i nt — m [...]

  • Page 90

    P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Wheel Alignmen t Angles Des cr ipt i o n a nd O pe r a t i o n To e is ad j us t a bl e o n the f r ont a nd rea r s us pe ns io n s ys t e m . The f r ont t oe i s a d j us t e d b y us e o f t he front t i e -r od. The r ea r t oe i s a dj us t e d by t he us e of ca m bo[...]

  • Page 91

    I te m Descri pti on 1 Re a r r ide he i ght m e a s u r e m e nt Whe el Tra ck It e m De sc ri pti on 1 Fr ont t r a ck 2 Re a r t r ack C ra bbing It e m De sc ri pti on 1 Fr ont t r a ck 2 Re a r t r ack cr abbi ng Cr a b bi ng i s t he condi t i on i n whi ch t he i nd epe nde nt r e a r s us pe ns i on (IRS) s y s t em i s n o t sq ua r e to t[...]

  • Page 92

    a s s mal l rot a t io na l os ci l l a t i o ns of t he s t ee r in g whe e l . Poo r Retu rn ability of the Ste e rin g P oor ret urnabi l i t y of t he s t e e r i ng i s use d t o de s cr ibe t he p oo r r et ur n o f t he s t e e r i ng whe e l t o ce nt e r a ft e r a t ur n or t h e s te e ring co r r ect i o n i s compl e t e d. Drift/Pull [...]

  • Page 93

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Suspensio n Sy stem Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer 's conce r n by carr ying o ut a roa d t es t o n a s mo [...]

  • Page 94

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P oo r Ret ur nab il i t y o f t he s te e r i ng. Ba l l jo i nt s. CHECK t he Ba l l Jo i nt (s ). Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o B al l J o i nt ins pe cti o n i n t his s e ct i on . S t e e r i ng compone nts . C HECK a n [...]

  • Page 95

    P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Front To e Adj ustment Gene ral P r ocedures • NO T E: T he checki ng a nd s ubs equ e nt a dj us tme nt o f t he front t o e s e t t ing s ho ul d be ca rr i ed o ut on a f l a t s ur fa ce a nd i n a ccor dance wi t h t he m a nufa ct ures i ns t ruc t i o ns f o r t he[...]

  • Page 96

    6. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Rot at e t he t ie -r o d s a n e q ual a mount i n e i t her a cl ockwis e o r a count e r cl o ckwis e d ire c t i o n to a dj us t t he t o e s e t t i ng. 7. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Ti ght e n t he t i e-rod e nd l ocknut s . Ti ght e n t o 40 Nm. 8. [...]

  • Page 97

    P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - R ear T oe Adjustment Gene ral P r ocedures • NO T E: T he checki ng a nd s ubs equ e nt a dj us tme nt o f t he r e a r to e se t t i ng s houl d be ca r rie d o ut o n a f l a t s ur fa ce a nd in a ccor da nce w it h th e m a nufa ct ures i ns t ruc t i o ns f o r t he[...]

  • Page 98

    7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t he r e a r l o we r a r m cam bo l t nut s . Ti ght e n t o 115 Nm. JagDocs.com[...]

  • Page 99

    P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Wheel B earing Inspecti on Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. NOT E: Make s ure t he whe e l rot a t e s freel y a nd t he brake pa ds are r e[...]

  • Page 100

    P ubl i s he d: 11-May-2 011 Front Su spensio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b- i n Lo we r arm front ret a i nin g b o lt A A A Lo we r arm r e a r r e t a i ni ng nut a nd bo l t A A A Lo we r arm ba l l j o i nt ret a i ni ng nut a nd bol t 83 61 - S t ab i l i z e r bar t o l i nk ba r r e t a in i ng nut s 48 35 -[...]

  • Page 101

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Suspensi on Des cr ipt i o n a nd O pe r a t i o n It e m Par t Nu m ber Descri pti o n 1 — Fr o nt sub f r ame m ount ing b us h 2 — S ta b il i z e r bar 3 — S ta b il i z e r li nk ba r 4 — S u s p e ns i o n s t rut a nt i s l i p f i n 5 — S u s p e ns i o n s t rut s pring 6 ?[...]

  • Page 102

    Item P a rt N um be r Desc ri pti on 1 — S pring a s s embl y 2 — Thru s t b e a r i ng 3 — S t r ut a nd s pr i ng t op mount 4 — S pring i s o l at o r 5 — Bump s t o p 6 — Dampe r pis t o n ga i t er 7 — Dampe r as s e mbl y JagDocs.com[...]

  • Page 103

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Suspensi on Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 4-00 Suspe ns i on S ys t e m - Ge neral Inf orm at i on JagDocs.com[...]

  • Page 104

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Lo w e r Arm Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep a r at o r, Ba l l Joi nt 204-192 (J D-219) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1. Pos it i o n t he f r ont whe e l s i n a s t r ai ght a he a d po s i t i o n a nd cent r al i z e t he[...]

  • Page 105

    6. NOT E: W he n t he t i e-rod e nd i s s e p a r at ed from t he whe e l hub as s e m bl y, th e ba l l j o i nt s e a l sho ul d be pr ot e ct ed t o pr e vent da mage . Us i ng t he s p e ci a l t o ol , d e t a ch t he t i e -r o d e nd . Vehi c le s with high i ntensity dis char ge hea dlam ps 7. D et a ch t he l i nk r od f r om t he hea dl [...]

  • Page 106

    10. Ins t a l l t he s p e cia l t o o l . 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 13. NO TE: L e ft -hand [...]

  • Page 107

    15. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, make s ur e t he s ubf r ame i s l o we r ed be fo re d e t a chi ng t he l owe r a rm ba l l j o i nt . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . Det ach t he l owe r arm f r om t he wh e el knuck l e. 1. Re move t he l [...]

  • Page 108

    Insta llat ion All v e h icle s 1. Ins t a l l the l owe r arm . Ins t al l a ne w l owe r arm r e a r r e t ai n ing b ol t . 2. Repo s i t i on t he l owe r arm . 3. NOT E: Ins t a l l a new r e t a i ni ng bol t . Lo o s e l y i ns t a l l the l owe r arm front ret a i nin g b o lt . 4. NOT E: Ins t a l l a new r e t a i ni ng nut . At t a ch t [...]

  • Page 109

    5. Usi ng t he s pe cia l t oo l rai s e t he f ront s u bframe . 6. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s . 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l [...]

  • Page 110

    10. Remove t he s pe ci a l t o o l . Vehi c le s with autom at ic tra ns m ission 11. At t ach t he s e l e ct o r l eve r cab l e . All v e h icle s 12. At t ach t he s t ee ring ge a r s uppl y pi p e . Vehi c le s with high i ntensity dis char ge hea dlam ps 13. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h ic[...]

  • Page 111

    14. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . At t a ch bo t h t he t ie -r o d end s . Ti ght e n t o 35 Nm. 15. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover. 16. Ins t a l l t he f r ont whe e ls a nd t i r e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a[...]

  • Page 112

    20. CAUT I O N: T he fi nal t ig ht e ni ng of t he l o wer a rm r e a r r e t ai ni ng nut a nd b ol t, must b e carr i e d out wi th th e v e hi cl e o n i t s whe e l s . Fa i l ure t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n d amage t o t he ve hi cl e . • NO T E: Ri ght -ha n d s hown, l ef t -hand s i m i l a r. Ful l y t i gh[...]

  • Page 113

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Sho ck A bsorber a nd Spr ing Assem bly Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep a r at o r, Ba l l Joi nt 204-192 (J D-219) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 W he e l hub pul l er 205-491 Ada p t e r nuts 205-491- 01 For cing s cr e w 204-269 Knuck l e s p li t t er[...]

  • Page 114

    3. D et a ch t he brake ho s e r e t ai ni ng bracket . 4. D et a ch t he s t a bi l i z er l ink b a r. 5. D i s conne ct t he f r ont whe e l sp e e d s e nso r e l e ctrica l conne ct o r . 6. CAU TI O N : S ecur e t he br ake c a l i p e r a nd a nchor pl a t e a s s e m bl y t o one s id e . Re move t h e br a ke ca l ip e r and a nchor pl a t[...]

  • Page 115

    8. NOT E: W he n t he t i e-rod e nd i s s e p a r at ed from t he whe e l hub as s e m bl y, th e ba l l j o i nt s e a l sho ul d be pr ot e ct ed t o pr e vent da mage . Us i ng t he s p e ci a l t o ol , d e t a ch t he t i e -r o d e nd . Vehi c le s with high i ntensity dis char ge hea dlam ps 9. D et a ch t he l i nk r od f r om t he hea dl [...]

  • Page 116

    12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 13. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rea r mount ret a i ni ng b o lt s . 14. Us i ng t he s pe ci a l t o o l , l owe r the f r ont s ubf rame t o a max[...]

  • Page 117

    17. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, make s ur e t he s ubf r ame i s l o we r ed be fo re d e t a chi ng t he l owe r a rm ba l l j o i nt . Det ach t he whe e l knuck l e . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning nut a nd b o lt . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe [...]

  • Page 118

    1. NOT E: Make s ure o r i ent a t i on a r r ow o n t he s trut to p r ubber mount f a ces from fr on t t o r ea r of t he vehi cle . • NO T E: Make s ur e t he ret a i ni ng st ud mark e d wi t h a pa i nt s po t i s corr e ct l y or i e nt a te d. I nst a l l t he s t rut and sp ring a s s embl y. Ti ght e n t o 25 Nm. 2. Usi ng t he s pe cia [...]

  • Page 119

    6. Usi ng t he s pe cia l t oo l rai s e t he f ront s u bframe . 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s . 8. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l [...]

  • Page 120

    11. Remove t he s pe ci a l t o o l . Vehi c le s with high i ntensity dis char ge hea dlam ps 12. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h icle s 13. At t ach t he t i e -r od e nd . Ti ght e n t o 35 Nm. 14. At t ach t he b rak e ca l i per a nd a n chor pl a t e a s s e mbly. Ti ght e n t o 133 Nm. JagDocs[...]

  • Page 121

    15. Conne ct t he f r o nt whe e l s pe e d s e ns or e l e ct rica l c on ne ct or . 16. At t ach t he s t abi l i z e r li nk ba r. Ti ght e n t o 48 Nm. 17. At t ach t he b rak e ho s e ret a i ni ng br acket . Ti ght e n t o 48 Nm. 18. Ins t a l l t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd [...]

  • Page 122

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Stabilizer B a r Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he r oa d whe e ls a re i n t he s t r ai ght a he a d p o si t i o n. Ce nt ral i z e t he s t e e r i ng a n d l o ck it i n po s i t i o n. 2. Remove t he s t ee ring co l umn l o we r r e t a i nin g b [...]

  • Page 123

    4. Tig ht e n t o 26 Nm. JagDocs.com[...]

  • Page 124

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Stabilizer B a r Bus hing Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 02 R em ova l All v e h icle s 1. Cent e r t he s t e ering w hee l . Lock i n po s i ti o n a n d remove t he i gni t i on key. 2. D et a ch t he s t e e r i ng col u[...]

  • Page 125

    5. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Re move t h e whe e l a rc h l i ne r acces s pa ne l . 6. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (501-0 2 Fr ont End Bod y P a nel s , R emoval [...]

  • Page 126

    10. W A RNING: Ro t at e t he s pe ci al t o o l he i ght a dj us t ment val v e s l o wl y. Fa il ure t o f ol lo w thi s i ns truc t i o n ma y r e s ul t i n p e r s o nal i njur y. Us i ng t he s p e ci a l t o ol , l ow er t h e rear o f t he f ront s ubf r a m e t o a m a ximum of 50 mm (1.97 i n c he s ). 11. NO TE: L e ft -hand s h own, r i[...]

  • Page 127

    2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . I nst a l l t he s t a bi l i z e r bar bus h ret a i ni ng br acket . Ti ght e n t he ret a i ni ng bol t s to 4 8 Nm. 3. Usi ng t he s pe cia l t oo l , r ai s e t he re ar of t he front s ubf r a me . 4. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l [...]

  • Page 128

    7. Tig ht e n t he f r ont s ubf r a m e r ei nf or ce ment bol t s . M8 t o 35 N m. M10 t o 70 Nm. 8. Remove t he s p e cia l to o l . Vehi c le s with diese l engine 9. Ins t a l l the a i r def le cto r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) -[...]

  • Page 129

    13. NO TE: I ns t a ll a new r e t a i ni ng bo l t . At t a ch t he s t e e r i ng col umn. Ins t al l a ne w s t ee r i ng co l umn l o we r r et a i ni ng bo l t. Ti ght e n t o 25 Nm. JagDocs.com[...]

  • Page 130

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Wheel Bea ring and Wheel Hub Re moval a n d I ns t a l l a t i on Speci al T ool (s) Fr o nt h ub carr i e r sup po r t 204-310 Hub fl a nge r e m o ver 204-116 -03 Be aring remover 204-262 Hub car r i e r s up po r t 204-309 Be aring s u ppo r t 204-313 Be aring gui de 204-312 Be aring i nst [...]

  • Page 131

    2. NOT E: W he n r emovi ng t he whe e l hu b f r o m t he whe e l k nuckle t he bea ring wi l l be d e s troyed and th e be a r i ng i nne r r i ng wi l l r e m a i n o n t he whe el hub . Us i ng s pe cia l t o o l s , remov e t he w he e l hub. 3. Usi ng a s ui t a bl e t o o l , r emove t he be a r i ng i nne r r i ng. 4. Usi ng s peci a l t oo[...]

  • Page 132

    3. Usi ng s peci a l t ool s , pr e s s b ea ring i n to whee l knuck le . 4. NOT E: Chan ge s pe ci al t o o l 204-312 t o 204-313. Al ig n t he be aring a nd w hee l knuck l e ove r s p eci a l t ool . 5. S l i de w hee l h ub o ver t he gui de a nd a l ig n t o t he b e aring. 6. Usi ng s peci a l t ool s i ns t a l l t he whee l hub . 7. Ins t [...]

  • Page 133

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Wheel K nuck le Re moval a n d I ns t a l l a t i on Speci al T ool (s) Bal l jo i nt s pl i t t e r 204-1 92 W he el hub pu ll e r 205-4 91 Adap t er nut s 205-4 91-01 For c i n g s cr ew 204-2 69 Knuck le s p l i t t e r 204-1 59 R em ova l 1. Loos e n t he whee l hub n ut. 2. Remove t he whe e l [...]

  • Page 134

    4. CAU TI O N : O nl y on e s i de o f t he s ubfra m e ne e ds t o be l o we r ed t o det a ch t he lo we r arm ba l l jo i nt . Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 5. Loos e n t he front s ub frame re ar mount re ta i ni ng bo l t . 6. Loos e n t he front s ub frame f r o nt mount r e t a i ni ng bo l [...]

  • Page 135

    9. Usi ng t he s pe cia l t oo l s, d e t ach t he ha l f s ha f t . 10. Remove t he whe e l k nuckle p i nc h bo l t . 11. Remove t he whe e l k nuckle . 1. Us i ng t h e s pe ci al t o ol , s p r e a d t he whe el knuck l e. 2. Re move t he whe e l knuc kle . Insta llat ion 1. Att a ch t he whe e l knuck le t o t he s t r ut a nd s pring a s s e [...]

  • Page 136

    2. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. At t a ch t he l o we r a r m b a l l jo i nt r et ai ni ng nut a nd bo l t . 4. Ti g ht e n t o 83 N m. 3. Tig ht e n t he f r ont s ubf r a m e front mount ret a i ni ng b ol t . Ti ght e n t o 142 Nm. 4. Loos e l y i nst a l l t he [...]

  • Page 137

    7. Att a ch t he brake cal i pe r and ancho r pl a t e as s e m bl y. 8. Att a ch t he s t ab i l i ze r ba r conne ct i ng l i nk. Ti ght e n t o 48 Nm. 9. Att a ch t he brake hos e re ta i ni ng br a ck et . Ti ght e n t o 48 Nm. 10. Ins t a l l t he ne w w hee l hub nut . 11. Ins t a l l t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m [...]

  • Page 138

    12. Ti g ht e n t he wh e e l hub nut . Ti ght e n t o 270 Nm. 13. Carr y out f r ont s ubfr a me a l i gnm e nt proced ur e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: U nde r b o dy Mis a li g nment Che ck (502-00 U ni -Bo dy, Subframe a nd Mount i ng S y s t e m, Ge neral Proced ur es ). JagDocs.com[...]

  • Page 139

    P ubl i s he d: 11-May-2 011 Front Su spensio n - Sho ck A bsorber a nd Spr ing Assem bly Dis a s s e mbl y a nd As s e mbl y Speci al T ool (s) S pring co i l compr e s s o r 204-112 S pring a d a pt e r s 204-167-0 1 S pring a d a pt e r s 204-112-0 3 D isa ssem bly 1. Remove t he s ho ck abs o r be r a nd s p r i ng a ss e mbly. For a ddi ti ona[...]

  • Page 140

    4. D i s a s s e mble t he sho ck a bs o rb e r and s pr i ng a s s e mbl y. 1. Re move t he t hru s t b e a r i ng nut . 2. Re move t he s pa ce r . 3. Re move t he t o p mount . 4. Re move t he t hru s t b e a r i ng. 5. Re move t he s pring s e a t . 6. Re move t he s pring . 7. Re move t he b ump s t o p. 8. Re move t he g ai te r . 9. Re move [...]

  • Page 141

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Fr o nt l owe r a rm t o whe e l knuck le ret a i ni ng b o l t 124 91 - Fr o nt l owe r a rm t o s ub frame ret a i ni ng b ol t 124 91 - Re a r l o we r a r m t o whe e l knuc kl e r e t a ini ng bol t 124 91 - Re a r l o we r a r m t o[...]

  • Page 142

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Suspensio n Des cr ipt i o n a nd O pe r a t i o n I te m P art N um be r Desc ri pti on 1 — W he e l k nuck l e mount i ng br acket 2 — S ubfr a me mount b us hin g 3 — U ppe r arm 4 — S hock ab s orbe r 5 — S pr ing 6 — Fr ont l o we r a r m 7 — S t a bi l iz e r ba r l i nk 8 —[...]

  • Page 143

    is of a s te e l des i gn a nd ha s cam bo l t s a t the s ubframe mount i ng p o in t s t o a d jus t whe e l a l i g nment . is t he rea r l o we r su ppo r t f o r th e w hee l knu ckle . car r i e s t he r oa d s pr i ng. is us e d t o a dj us t t he r ea r whe e l al i gnme nt Bus hi ngs : a r e a moul de d co ns t r uct i o n wi t h al umini [...]

  • Page 144

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Suspensio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 204-00 S us pe ns i on Sy s t e m - Ge ne r a l I nfo r mat i o n . JagDocs.com[...]

  • Page 145

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Damper Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. D et a ch t he da mpe r. 3. Remove t he da mpe r . Insta l[...]

  • Page 146

    3. Tig ht e n t o 25 Nm. 4. Tig ht e n t o 130 Nm. JagDocs.com[...]

  • Page 147

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Front Lo w e r Arm4-Door Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. D et a ch t he f ront l o we r arm . 3. [...]

  • Page 148

    4. Tig ht e n t o 124 Nm. 5. Tig ht e n t o 124 Nm. JagDocs.com[...]

  • Page 149

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Front Lo w e r ArmWago n Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). Vehi c le s with 2.0L engi[...]

  • Page 150

    5. D et a ch t he f ront l o we r arm . 6. Remove t he f r ont l o we r arm . Insta llat ion All v e h icle s • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l e o n i t s whe e l s . 1. Ins t a l l the f r ont l o we r a rm . 2. Att a ch t he f r ont l o we r arm[...]

  • Page 151

    3. Loos e l y i nst a l l t he f ue l t a nk prot e ct i on br a ck et re ta ini ng bo l t . 4. Usi ng a s ui t a bl e t o r x ada p t o r , 10 mm combi na t i on sp a nne r and 3 /8 dr i ve t orque wr ench, i ns t a l l t he f ue l t a nk pr ot e ct i on br a cket r e t a i ni ng bo l t . 5. Usi ng t he t o rx a dap t o r , 10 mm combina t i o n s[...]

  • Page 152

    6. Usi ng a s ui t a bl e t o r x ada p t o r , 10 mm combi na t i on sp a nne r and 3 /8 dr i ve t orque wr ench, i ns t a l l t he f ue l t a nk pr ot e ct i on br a cket r e t a i ni ng bo l t . 7. Usi ng t he t o rx a dap t o r , 10 mm combina t i o n s pa nne r a nd 3/8 d r i ve t o r que wrench, t i ght e n t he fue l t an k prot e ct i o n b[...]

  • Page 153

    10. Ti g ht e n t o 115 N m. 11. Ti g ht e n t o 115 N m. JagDocs.com[...]

  • Page 154

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Lo we r Arm Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 2. Usi ng s uit ab l e t i e s t r a ps , se cur[...]

  • Page 155

    1. Ins t a l l the rear l o we r arm . 2. Att a ch t he rear l o we r arm . 3. Att a ch t he s t ab i l i ze r ba r l i nk . 4. Ins t a l l the rear whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 5. Tig ht e n t o 124 Nm. JagDo[...]

  • Page 156

    6. Tig ht e n t o 124 Nm. 7. Tig ht e n t o 35 Nm. 8. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n). JagDocs.com[...]

  • Page 157

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Spring Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 2. Usi ng s uit ab l e t i e s t r a ps , se cur e t he s [...]

  • Page 158

    7. Remove t he s p r i ng. Re mov e t he i s ol a t o r. Insta llat ion • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l e o n i t s whe e l s . 1. Ins t a l l the s p r i ng. Ins t al l t he i s ol a t o r. 2. Att a ch t he rear l o we r arm . 3. Att a ch t he a[...]

  • Page 159

    5. Tig ht e n t o 124 Nm. 6. Tig ht e n t o 124 Nm. 7. Tig ht e n t o 35 Nm. 8. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n). JagDocs.com[...]

  • Page 160

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Stabiliz er Bar Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. D et a ch t he s t a bi l i z er ba r l i nks . Rig ht -ha nd s hown , l e f t -ha nd s [...]

  • Page 161

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Stabiliz er Bar L ink Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. D et a ch t he s t a bi l i z er ba r l i nk. 3. Remove t he s t abi l i ze r ba r[...]

  • Page 162

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Upper Arm Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 2. D et a ch t he uppe r a r m. 3. Remove t he uppe r a[...]

  • Page 163

    4. Tig ht e n t o 124 Nm. 5. Tig ht e n t o 124 Nm. 6. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n). JagDocs.com[...]

  • Page 164

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel H ub Re moval a n d I ns t a l l a t i on Speci al T ool (s) Pul l e r , W h e el hub remover 205-49 1 For c i n g Sc r ew, W he e l hub r emove r 204-26 9 Adap t or Nut s , W he e l hub re mover 205-49 1-01 R em ova l All v e h icle s 1. Remove t he rear brak e di s c. For a ddi ti ona l i nf o[...]

  • Page 165

    4. Usi ng t he s pe cia l t oo l s, re move t he whee l hub. Vehi c le s with 2.0L engi n e 5. CAU TI O N : Fai l ure t o fo l l o w t hi s procedu r e may r es ul t i n da mag e t o th e ant i -l ock b r a ke s yst e m (ABS) compon e nt s . Di s conn ect t he a nt i -l ock brak e s ys t e m (ABS ) s e ns or e l ect r i cal conne ct o r. 6. Remove [...]

  • Page 166

    1. Ins t a l l the whe e l hub. Ti ght e n t o 63 Nm. Vehi c le s with 2.5L or 3.0L engine 2. Ins t a l l a ne w rea r hal f s haf t r e t a in in g nut . Ti ght e n t o 270 Nm. Vehi c le s with 2.0L engi n e 3. Ins t a l l the (AB S ) se ns o r . Ti ght e n t o 7 Nm. 4. Reconnect t he (ABS ) s e ns o r el e ct r ica l conne ct o r . All v e h icle[...]

  • Page 167

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l hub. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l H ub (204-02, Re mova l a nd I nst a l l at io n). 2. Remove t he a nt i-l o ck br ake s yst e m (ABS) whe e l s p e ed s ens o r wi ring ha r nes[...]

  • Page 168

    6. D et a ch t he da mpe r. 7. D et a ch t he uppe r a r m. 8. D et a ch t he f ront l o we r arm . 9. CAU TI O N : Make s ur e t h at exces s i ve s t r ai n i s not pl a ced o n t he lo we r a r m. Us i ng a s ui t a b l e t rans mis s io n j ack, s uppo r t the rear l o we r arm . 10. Det a ch t he whee l knu ckle mount i ng br acket . JagDocs.c[...]

  • Page 169

    11. Remove t he whe e l k nuckle . Det a ch t he r ea r l o we r ar m. 12. CAUT I O N: Ma k e s ure co r r ect po s i t i o n o f t he mount i ng b r ack e t i s not e d b e fo re r emoval . Re move t h e whe e l knuc kl e mount i ng br acket . Insta llat ion • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m[...]

  • Page 170

    3. Att a ch t he whe e l knuck le mount i ng b rack e t. 4. Ins t a l l the f r ont l o we r a rm . 5. Att a ch t he upp e r arm . 6. Att a ch t he da mpe r . 7. Att a ch t he pa r ki ng b r ake ca bl e a nd condui t . JagDocs.com[...]

  • Page 171

    8. Att a ch t he pa r ki ng b r ake ca bl e a nd condui t . 9. Att a ch t he ABS whe e l s p ee d s e ns or wi ring ha r ne s s. 10. Ins t a l l a n ew AB S whe e l s pe e d s e ns o r wi r i ng ha r nes s r et ai ni ng s t r ap . 11. Ins t a l l t he whe e l hub. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l H ub (204-02, Re mov[...]

  • Page 172

    13. Ti g ht e n t o 124 N m. 14. Ti g ht e n t o 124 N m. 15. Ti g ht e n t o 115 N m. No t e : I f y ou a re re-us i ng t hi s f ixi ng o n a ve hi cl e bu i l t p r i o r t o VI N J29472, t he n t i gh te n t o 130 N m. If yo u a re r epl a ci ng a fi xi ng o n a ny v e hi cl e, t he n you mus t r e pl a ce b ot h nut and bol t a nd t i g ht e n [...]

  • Page 173

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e F ro nt B ush ing Re moval a n d I ns t a l l a t i on Speci al T ool (s) S upp o r t Cup , Re a r whe e l knuck le front b us h 204-30 0 Remove r , Rea r whe e l knuck l e f r o nt b us h 204-30 1 Ins t a l l e r , Re a r whe e l knuck l e f r ont b ush 204-30 2 R em ova l 1. Remove t [...]

  • Page 174

    P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e Rear Bus hing Re moval a n d I ns t a l l a t i on Speci al T ool (s) For cing S cr e w, Re a r W he e l Knuckle Re a r Bus h 204-246 S upport Cup , Rea r W h e e l Knuckle Rea r Bus h 204-296 Re mover , Re a r W he e l Knuckle Re a r Bus h 204-298 I nst a l l er, Re a r W he el Knuck l[...]

  • Page 175

    4. D et a ch t he r e a r l o we r a r m. 5. CAU TI O N : Ca r ef ul l y l o wer t he t r a ns mis s i o n j a c k. Us i ng t he s p e ci a l t o ol s , r emove t he whe e l knuck le rear bus hi ng. Insta llat ion • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l [...]

  • Page 176

    3. Att a ch t he s t ab i l i ze r ba r l i nk . 4. Ins t a l l the rear whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 5. Tig ht e n t o 124 Nm. 6. Tig ht e n t o 35 Nm. 7. Ch eck t he wh e el a l i gnment and a dj us t as nec[...]

  • Page 177

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - T i re Pres s ur es Whe e l Si ze T i re Si z e T i re Manu f acturer R i m Eng i ne C om for t N orm al Front R e a r F ront Re a r 16" 205/55 R16 91 V Pi r e l li P 6000 6.5Jx 16 2.0L 2. 07 ba r (30 l b f/i n² ) 2.07 bar (30 l b f/i n² ) 2.41 bar (35 l bf /i n² ) 2.21 bar (32 l bf /i n²) 2[...]

  • Page 178

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Safety P recautio ns Des cr ipt i o n a nd O pe r a t i o n • W ARNINGS : Do not mix d i f fe re nt t ype s of t i r e s o n t he s a me ve hi cl e s uch a s radi a l , b i a s or bi a s bel t e d t i re s e xc ep t i n e mer ge nci e s (t e mpor a ry s p are us a ge ). Fai l ure t o fo l l o w t h[...]

  • Page 179

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel s and T ires Des cr ipt i o n a nd O pe r a t i o n It e m Par t N um be r Descri pti on 1 — L ocki ng wh ee l nut a nd wrench s o cket Locking W he e l Nuts Lo ck ing whee l nut s are f i t t e d t o a l l UK a nd Mexico ve hi cl e s wi th a l lo y whe e ls , a nd a r e ava i l a bl e a s a [...]

  • Page 180

    Item Part Nu mber D escri pt i on 1 - T i re va l ve a nd pr e s s ur e s e ns or 2 - T i re f it t i ng/r e mova l t o o l in i t i al s t art po s i t i o n 3 - H i gh t i r e a nd b e a d t e nsi on a r e a 4 - L o w t i re a nd b e ad te ns i o n a re a W he n re m ovi ng t h e t i r e , t he b e ad b r ea ker mu s t no t b e us e d wi t h in 9[...]

  • Page 181

    Tir e Pressur e Monit oring Syste m The TP MS i s a dr i ver as s i s t a nce s yst e m whi ch a s s i s t s t he dr i ver t o mai n ta i n th e t i re pres s ur es a t t he o p t i mum l e vel . The TPM S i s a s t a nda r d fi tme nt o n NA S vehi cl e s a nd a n o pt i o nal f i t ment i n o t her ma r ke t s . The T P MS s yst e m ha s t he f o[...]

  • Page 182

    The i ni t i at o r i s a p a ss i ve LF t rans mi t t e r . I t t rans mi t s s i gna l s whi ch are recei ve d b y t he t ire pr e s s ur e s e n s ors p r o mpt i ng t he m t o mo di fy th e i r m o de s t at us . The TP MS modul e e ne rg i z es ea ch i ni t i a to r i n t ur n us i ng LF drive r s . T he corr e s po ndi n g t ir e pr e s s ure[...]

  • Page 183

    I f a T P MS fa ul t wa r nin g me s s a ge is d et e cte d b y t he i ns t r um e nt cl us t e r a t i gni t i o n on , t he wa r ni ng i ndi ca t o r wi l l f l a s h fo r 72 s e conds a f t e r t he 3 s e cond bul b c he ck pe r i od a nd t he n remai n pe rm a nent l y i l l umina t e d. I f a t i r e pr es s ure wa r ni ng mes s a ge i s d e t[...]

  • Page 184

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel s and T ires Dia gn os i s a nd Te s t i ng G ene r al note s Fa c t o r y i ns t a l l e d t i r es a nd whe e l s are de s i gne d t o o pera te sa t i s fa ct or y whe n i nfl a t e d t o th e r ecommende d i nfl a t i on pr es s ures ; refe r t o t he S peci fi ca t i o ns s ub-s ect i on .[...]

  • Page 185

    * * * * * * * * * * * * * * * * * * * * Mechani cal Bul ge s (b li s t e r ) P ly s e pa r a t io n Embed ded o bj e ct s I m pa ct d a m a ge I nc o r r ect s pe e d rat i ng I nc o r r ect l o a d r at ing I nc o r r ect r ot at i on a l di rect i on 3. If a n obvi o us cau se fo r an ob s e rv e d o r r epo r t e d conce r n i s f o und, co r r [...]

  • Page 186

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * Exces s ive l a t e ral o r radi a l runout of whe e l o r t i r e Che ck , r epa i r or i nst a l l a n e w a s nece s s a ry . Ref e r t o t he pr oce dure in t hi s s ect i on . W he e l mount i ng i s di ff i cul t In c orr e ct a ppl[...]

  • Page 187

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Lo w Pre ssu re Senso rV IN Range: J28 493- >V99999 Re moval a n d I ns t a l l a t i on R em ova l • NO T E: I t i s s t r ong l y r e com me nde d t ha t a ne w t i re l ow p r e s s ur e s e ns o r O-r i ng s e al , wa s he r , nut , va l ve cor e a nd ca p a re i ns t a l l e d e a ch [...]

  • Page 188

    2. CAU TI O N : Make s ur e s o l ve nt s or cl e a ni ng a ge nt s of a ny t ype a r e not use d t o cl e a n t he t ire l o w pr e s s ure s e ns o r. Fa i l ur e t o fo l l ow t his in s t ruc t i o n may r es ul t i n da mag e t o t he ti r e l ow pres s ur e s e ns o r . • NO T E: If t h e t i re l o w pr e s s ur e s e nso r i s r e pl a ce[...]

  • Page 189

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Fro nt AntennaVI N Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Jackin g (100-02 Ja ck i ng a nd Li f t i ng , Des cr ipt i o n [...]

  • Page 190

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Main AntennaVIN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Jackin g (100-02 Ja ck i ng a nd Li f t i ng , Des cr ipt i o n a n[...]

  • Page 191

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 5 Nm. JagDocs.com[...]

  • Page 192

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Mo duleV IN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a[...]

  • Page 193

    6. Repo s i t i on t he t i re p r es s ur e moni t o r i ng s yst e m modul e . Re mov e t he re ta i ni ng nut s . 7. Remove t he t i re pr e s s ur e moni t o ring s ys te m modul e . Dis conne ct t he e xt ernal ant e nna conne ct o r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 5 Nm. JagDocs.com[...]

  • Page 194

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Rear AntennaVIN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Jackin g (100-02 Ja ck i ng a nd Li f t i ng , Des cr ipt i o n a n[...]

  • Page 195

    P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel and T ire Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : Do no t us e hea t t o l o os e n a s e i ze d whe e l nut , e x ce s s i ve he at ma y caus e da ma ge t o t he whe el a nd t he whe e l be a r i ngs . Lo o s e n t he whe e l nut s . 2. Rai s e a nd s uppo r t the ve hi[...]

  • Page 196

    P ubl i s he d: 11-May-2 011 Driveline System - G eneral In fo rm ation - Driv eline System Des cr ipt i o n a nd O pe r a t i o n The dr i vel in e t r ans fe rs e ngi ne t orque t o t he drive whe e l s . O n vehi cl e s wit h 2.0L o r d i e s e l e ngi nes t he po we r is t rans mi t t e d t hr oug h t he t r a nsa xl e t o t he f r ont d r i ve[...]

  • Page 197

    P ubl i s he d: 11-May-2 011 Driveline System - G eneral In fo rm ation - Driv eline System Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on Ce r t a i n drive l i ne condi t i o ns a re a l s o co mm o n t o t h e e ng i ne , t rans a xle , t r a nsf e r cas e , whe el b e a r i ngs , whe e l s a nd t i res a nd o t he r pa r t s o [...]

  • Page 198

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 2 No i s e i s a t co ns t a nt t o ne ove r a na r r ow vehi cl e s p e ed r ange . Us ual l y he a r d o n l i g ht dr ivi ng a nd coa s ti ng condi ti o ns Re a r d r i v e di f f e r ent i a l . Trans f e r cas e . Trans a xle . For a ddi t[...]

  • Page 199

    P ubl i s he d: 11-May-2 011 Driveshaft - T o rque Sp eci f i cat ions Descri pti on Nm l b-ft l b-i n Dr ive s ha f t cent er be a r i ng r et a i ni ng bol t s 25 18 - Dr ive s ha f t front uni versa l j oi nt r e t ai n in g b ol t s 44 32 - Dr ive s ha f t r ea r uni ver s a l j o int r et a i ni ng b ol t s 44 32 - JagDocs.com[...]

  • Page 200

    P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Des cr ipt i o n a nd O pe r a t i o n I te m Pa rt N um be r De sc ri pti on 1 — Li nk was he r 2 — Dr ive s ha f t uni versa l j o i nt ret a i ni ng bol t 3 — Dr ive s ha f t front col l a ps i bl e t ube 4 — Dr ive s ha f t cent e r be a ring 5 — Dr ive s ha f t uni versa l j o i n[...]

  • Page 201

    P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 205-00 Dr i ve l i ne S yst e m - Gene ral I nfo rm at i on . JagDocs.com[...]

  • Page 202

    P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Runo ut and B alanc ing Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t o t he a pproved Ja guar di agno s t i c s yst e m. JagDocs.com[...]

  • Page 203

    P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Re moval o f t he dr i v e s ha f t rear uni versa l j oi nt s hown, removal o f t he dr ive s ha f t front uni vers al j o i nt s i mil a r. 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r [...]

  • Page 204

    7. CAU TI O N : Make s ur e t h e front a nd r e a r d r i ves ha ft s e cti o ns a re s uppo r t e d . Re move t h e dr i ves ha ft . Re mov e dr ive s haf t ce nt e r bea ring ret a i ni ng bo l t s. Insta llat ion 1. CAU TI O N : Make s ur e t h e front a nd r e a r d r i ves ha ft s e cti o ns a re s uppo r t e d . I nst a l l t he d r i v e s [...]

  • Page 205

    P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Gen eral S p ec if ic a t ions I te m Speci fi ca ti on Oi l t ype M2C1 92A synt he t i c Oi l cap a c i t y 1.2 l it e r s T o rque Sp eci f i cat ions Descri pti on Nm l b-f t l b- i n Dr ive s ha f t front uni versa l j oi nt r e t ai n in g b ol t s 40 3 0 - Dr ive s ha f t r ea r [...]

  • Page 206

    P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Re ar Drive A xle a nd Differential Des cr ipt i o n a nd O pe r a t i o n I te m Pa rt Nu mber De sc ri pti on 1 — Vi br at i o n d a m pe r br acket 2 — Ax l e s ha ft o i l s e a l 3 — Ax l e ho us i ng 4 — Ax l e s ha ft o i l s e a l 5 — Dr i v e pi ni o n s e a l 6 — [...]

  • Page 207

    P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Re ar Drive A xle a nd Differential Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n . JagDocs.com[...]

  • Page 208

    P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Ax le Shaf t Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Re mover , Axl e S ha f t O i l S e a l 308-208 I nst a l l er, O i l S e a l 204-264 R em ova l 1. Remove t he rear hal fs haf t . For a dd it i o na l i nfo rm at i on, ref e r t o Sect i on 205-05 Rea r Dr i ve Ha l f s[...]

  • Page 209

    P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - D rive Pinio n Flange I n-v e hi c l e Re pa i r Speci al T ool (s) To r que T o T ur n Ro t a r y T ool 205-518 W r e nch, Fl a ng e 205-053 Re mover , Fl a nge P la t e 204-295 Re mover , Fl a nge Bo s s 204-266 Re mover , Fl a nge S haf t 204-268A I nst a l l e r, O i l Sea l 204-26[...]

  • Page 210

    4. Remove t he vibrat i on d amper ret a i ni ng b o l t . 5. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e f r ont r e t a i ni ng bol t s . Re mov e t he vi br at i o n da m pe r br acket . 6. Remove t he a xle a s s e mbly r ea r r et ai ni ng bo l t . 7. CAU TI O N : Make s ur e CV j o in t s d o no t e xc e e d 18 de gr ee s[...]

  • Page 211

    10. Us i ng t he s pe ci a l t o o l , i ns t a l l a brea ker ba r a nd r e move a nd di sca r d t he dr i ve p i ni on f l a nge ret a i ni ng n ut . 11. NO TE: Mark t he pi ni o n f l a ng e i n r e l a t i on t o t he drive pi ni o n s t e m t o e ns ure corr e ct a l i gnment dur i ng i ns t al l a t i on. Us i ng t he s p e ci a l t o ol s , [...]

  • Page 212

    3. CAU TI O N : Do no t unde r any ci rc ums t a nce, l o o s e n t he p i ni on nut t o r e duce p r el o a d, if prel o a d i s excee de d i nst a l l a ne w col l a p s i b le s pa cer an d pi ni o n nut . Us i ng t he s p e ci a l t o ol , h ol d t he p i nio n f l a nge whi l e t i ght e ni ng t he d r i ve pi ni on r et a i ni ng nut . 4. CAU[...]

  • Page 213

    9. Tig ht e n t he a xle a s s e mbly f r on t ret a i ni ng bo l t s t o 90 N m. 10. Ti g ht e n t he a xl e a s s embl y rear r e t a i nin g b o lt t o 110 Nm a nd t he n s l o wl y ti gh te n t o 135 N m . 11. Ins t a l l t he vibrat i on d amper. Ti ght e n t o 48 Nm. 12. Ins t a l l t he drive sha f t . For a ddi ti ona l i nf o r m a t i o n[...]

  • Page 214

    P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - D rive Pinio n Seal I n-v e hi c l e Re pa i r Speci al T ool (s) To r que T o T ur n Ro t a r y T ool 205-518 W r e nch, Fl a ng e 205-053 Re mover , Fl a nge P la t e 204-295 Re mover , Fl a nge Bo s s 204-266 Re mover , Fl a nge S haf t 204-268A I nst a l l e r, O i l Sea l 204-264 [...]

  • Page 215

    4. Remove t he vibrat i on d amper ret a i ni ng b o l t . 5. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e f r ont r e t a i ni ng bol t s . Re mov e t he vi br at i o n da m pe r br acket . 6. Remove t he a xle a s s e mbly r ea r r et ai ni ng bo l t . 7. CAU TI O N : Make s ur e CV j o in t s d o no t e xc e e d 18 de gr ee s[...]

  • Page 216

    10. Us i ng t he s pe ci a l t o o l , i ns t a l l a brea ker ba r a nd r e move a nd di sca r d t he dr i ve p i ni on f l a nge ret a i ni ng n ut . 11. NO TE: Mark t he pi ni o n f l a ng e i n r e l a t i on t o t he drive pi ni o n s t e m t o e ns ure corr e ct a l i gnment dur i ng i ns t al l a t i on. Us i ng t he s p e ci a l t o ol s , [...]

  • Page 217

    3. CAU TI O N : Do no t unde r any ci rc ums t a nce, l o o s e n t he p i ni on nut t o r e duce p r el o a d, if prel o a d i s excee de d i nst a l l a ne w col l a p s i b le s pa cer an d pi ni o n nut . Us i ng t he s p e ci a l t o ol , h ol d t he p i nio n f l a nge whi l e t i ght e ni ng t he d r i ve pi ni on r et a i ni ng nut . 4. CAU[...]

  • Page 218

    9. Tig ht e n t he a xle a s s e mbly f r on t ret a i ni ng bo l t s t o 90 N m. 10. Ti g ht e n t he a xl e a s s embl y rear r e t a i nin g b o lt t o 110 Nm a nd t he n s l o wl y ti gh te n t o 135 N m . 11. Ins t a l l t he vibrat i on d amper. Ti ght e n t o 48 Nm. 12. Ins t a l l t he drive sha f t . For a ddi ti ona l i nf o r m a t i o n[...]

  • Page 219

    P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Ax le Ass embly Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l e ft -hand rear hal f s haf t. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Hal fs ha ft (205-05 Re a r Dr i v e Ha l f s ha f t s , Re moval a nd I ns t a l l a t i o n). 2. Loos e l y i[...]

  • Page 220

    6. Remove t he vibrat i on d amper. 7. Remove t he vibrat i on d amper bracket r et a i ni ng bo l t . 8. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e a s s embl y f r ont r et a i ni ng bo l t s . Re mov e t he vi br at i o n da m pe r br acket . 9. Remove and di s card t he axl e a s se mbl y r e a r r et a ini ng bol t a nd l[...]

  • Page 221

    Insta llat ion 1. NOT E: S uppo r t t he a xl e a s s embl y. • NO T E: W he n i nst a l l in g t he ha lf s ha ft ma k e s ure t he s pring cl i p i s ful l y e ngag e d i n t he di ff e r e nt i a l . I nst a l l t he a xl e a s s e mbl y. 1. I ns t a l l t he a x l e a s s e mbl y. 2. I ns t a l l t he hal fs h a ft i nt o t he a xl e as s e m[...]

  • Page 222

    6. Tig ht e n t o 150 Nm. 7. CAU TI O N : S lo wl y t i ght e n t he a x l e ret a i ni ng b ol t to f i nal t or que . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . Ti ght e n t o 150 Nm. I f you are refi t t ing a n ol d fi xing (be f o r e V IN J24258), t i g ht e n t o 135 N m. 8. Tig ht e n t[...]

  • Page 223

    11. At t ach t he d rives ha f t r e a r uni ver s al j o int . 1. I ns t a l l a ne w ga s ke t . 2. I ns t a l l ne w drive s ha ft r et a i ni ng bo l t l in k was he r s . 3. I ns t a l l ne w drive s ha ft r et a i ni ng bo l t s . 1. Tight en t o 4 0 Nm . 12. Carr y out t he unde r bod y m i s al i gnment ch e ck. For a ddi ti ona l i nf o r [...]

  • Page 224

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n W he e l hub nut 270 200 - Ti e r o d e n d ret a i ni ng nut 35 26 - Lo we r arm ba l l j o i nt ret a i ni ng nut 83 61 - Fr o nt s ubf rame r e i nfo r cement p l a t e r et a i ni ng bo l t 35 26 - Fr o nt s ubf rame r e a r m [...]

  • Page 225

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Drive Halfsh afts Des cr ipt i o n a nd O pe r a t i o n Front Drive Half sha f ts I te m P ar t N u m ber Descri pti on 1 — O ut e r cons t a nt ve l oci t y (CV) j o i nt 2 — CV jo i nt bo o t r e t a i ni ng cl ip 3 — CV jo i nt bo o t 4 — CV jo i nt bo o t r e t a i ni ng cl [...]

  • Page 226

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Drive Halfsh afts Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n . JagDocs.com[...]

  • Page 227

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft LH Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j oi nt s pl i t te r 204-192 W he e l hub pu ll e r 205-491 Ada pt e r nut s 205-491- 01 For cing s cr e w 204-269 S li de ha mm er 100-012 100-012- 02 S li de ha mm er s ha f t Ha l f s ha f t r emove r fo rk [...]

  • Page 228

    2. Remove t he f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 3. Remove t he t i e r o d e nd ret a i ni ng nut . 4. Usi ng t he s pe cia l t oo l de t a ch t h e t i e rod e nd. 5. Remove t he s ub frame rei nfo rc e[...]

  • Page 229

    7. Loos e n t he s ubf r a me front mount ret a i ni ng b ol t. 8. Remove and di s card t he whee l hub n ut . 9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e . 10. Us i ng t he s pe ci a l t o o l s , d e t ach t he[...]

  • Page 230

    13. Us i ng t he s pe ci a l t o o l s , re m o v e t he hal fs ha ft . 14. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o pr ot ect t he b a r s ha ft . Re move t h e ha l fs ha ft s na p ring. Insta llat ion All v e h icle s 1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. CAU TI O N : Make s ur e t h e CV j o i nt s pl [...]

  • Page 231

    3. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l t he lo we r ar m ba l l j o i n t r e t a i ni ng bo l t . Ti ght e n t o 83 Nm. 4. Tig ht e n t he f r ont s ubf r a m e front mount ret a i ni ng b ol t . Ti ght e n t o 142 Nm. 5. Loos e l y i nst a l l t he s ubf r a [...]

  • Page 232

    8. Ins t a l l the t ie r od e nd. Ti ght e n t o 35 Nm. 9. Loos e l y i nst a l l a ne w whee l hub nut . 10. Ins t a l l t he f r ont r oa d w hee l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). Vehi c le wi th aut om a tic t ra nsmi[...]

  • Page 233

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft RH2. 0L NA V6 - A JV6 /2. 5L N A V 6 - A JV 6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j o i nt s pl i tt e r 204-192 W h ee l hub pul l e r 205-491 Ada p t e r nuts 205-491-0 1 For ci ng s crew 204-269 RH hal fs ha ft s pl i t t e r[...]

  • Page 234

    All v e h icle s 1. Loos e n t he whee l hub n ut. 2. Remove t he f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 3. Remove t he t i e r o d -end ret a i ni ng n ut . 4. Usi ng t he s pe cia l t oo l , de t a ch th e t[...]

  • Page 235

    6. Loos e n t he s ubf r a me r ea r m ou nt bol t . 7. Loos e n t he s ubf r a me front mount bo l t . 8. Remove and di s card t he whee l hub n ut . 9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e . 10. Us i ng t h[...]

  • Page 236

    Vehi c le s with 2.5L or 3.0L engine 11. Remove t he e xhaus t muff l e r i nl e t pi p e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Muff l e r Inl e t Pi p e - 2.0L N A V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ27 (309- 00 Exhaus t S y s t e m, Re moval a n d I ns t a l l a t i o n). 12. Remove t he ha l f s haf t s ea l . 13. R[...]

  • Page 237

    16. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o pr ot ect t he b a r s ha ft . Re move a nd di s ca r d t he ha l f s ha f t s nap r in g. Insta llat ion All v e h icle s 1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. Ins t a l l a ne w ha lf sha f t se a l . Vehi c le s with 2.0L engi n e 3. Ins t a l l the ha l f s [...]

  • Page 238

    4. Remove t he s p e cia l to o l . 1. Re move t he t rans f e r cas e Y brack e t ret a i ni ng bo l t. 2. Re move t he s pe cia l t oo l . 5. CAU TI O N : Make s ur e t h e CV j o i nt s pl i ne s a re l o ca t e d f ul l y . Do not use e x ce s s i v e fo rc e wh en e nga gi ng t he CV jo i nt i nt o t he l i nk s haf t . I nst a l l t he ha l f[...]

  • Page 239

    9. Tig ht e n t he s ubf r ame front mount r e t a i nin g b o lt . Ti ght e n t o 142 Nm. 10. Ins t a l l t he s ub frame r ei nfo r cemen t pl a t e r et a i ni ng bol t s . Ti ght e n t o 35 Nm. 11. Ti g ht e n t o 142 N m. 12. Ins t a l l t he t i e -r od e nd . Ti ght e n t o 35 Nm. 13. Loo s e l y i ns t a l l a ne w whee l hub nut . JagDocs.[...]

  • Page 240

    14. Ins t a l l t he f r ont r oa d w hee l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 15. Ti g ht e n t he wh e e l hub nut . Ti ght e n t o 270 Nm. 16. Check t he s ubframe al i gnmen t. For a ddi ti ona l i nf o r m a t i o n, r [...]

  • Page 241

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft RH2. 0L Duratorq-TDCi / 2.2L Durato rq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j oi nt s pl i t te r 204-192 W he e l hub pu ll e r 205-491 Ada pt e r nut s 205-491- 01 For cing s cr e w 204-269 R em ova l 1. Loos e n t he whee[...]

  • Page 242

    4. Usi ng t he s pe cia l t oo l , de t a ch th e t i e -r od end. 5. Remove t he s ub frame rei nfo rc emen t pl a t e ret a i ni ng bol t s . 6. Loos e n t he s ubf r a me r ea r m ou nt bol t . 7. Loos e n t he s ubf r a me front mount bo l t . 8. Remove and di s card t he whee l hub n ut . JagDocs.com[...]

  • Page 243

    9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e . 10. Us i ng t he s pe ci a l t o o l s , d e t ach t he h a lf sha f t. 11. Remove t he ha l f s haf t. 12. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o[...]

  • Page 244

    1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. Ins t a l l the ha l f s haf t . Ti ght e n t o 25 Nm. 3. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l t he lo we r ar m ba l l j o i n t r e t a i ni ng bo l t . Ti ght e n t o 83 Nm. 4. Tig ht e n t he s u[...]

  • Page 245

    6. Tig ht e n t o 142 Nm. 7. Ins t a l l the t ie -r o d e nd . Ti ght e n t o 35 Nm. 8. Loos e l y i nst a l l a ne w whee l hub nut . 9. Ins t a l l the f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 10. Ti g ht e n[...]

  • Page 246

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Inner C on stant Velo city (CV ) J o in t Bo o t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont ha l f s ha f t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o Ha l f s ha f t L H . For a ddi t i o na l i nfo rm at i o n, ref e r t o H a lf sha f t RH . 2. CA[...]

  • Page 247

    7. Remove t he i nne r CV jo i nt b oo t r e t a in ing cl i p. Re mov e a nd di s c a r d t he r et a i ni ng cli p. 8. Remove t he i nne r CV jo i nt b oo t . Insta llat ion 1. Ins t a l l the i nner CV j oi nt b o ot . 2. NOT E: Ins t a l l a new r e t a i ni ng cl ip . Us i ng a s ui t a b l e t o o l , ins t a l l t he i nne r CV j o i nt bo o[...]

  • Page 248

    3. CAU TI O N : Do no t da mage t he r o l l e r be a rings . I nst a l l t he t ripo d s t a r . 4. Ins t a l l the t r i p od s t a r circ l i p. 5. NOT E: Ins t a l l ne w grea s e . I nst a l l t he t ripo d s t a r hous ing . 6. NOT E: Make s ure e noug h a i r i s pres e n t in t he CV boo t . • NO T E: Ins t al l a ne w re t a i ni ng cl i[...]

  • Page 249

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Intermediate Sh aft Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he right -ha nd ha l fs ha ft . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Ha l fs ha ft RH i n t hi s s e cti o n. Vehi c le s with autom at ic tra ns m ission 2. D r ai n t he a ut om[...]

  • Page 250

    2. CAU TI O N : Be f o r e i ns t a l l i ng t he be a r i n g carr i e r r e t ai n in g b ol t s m a ke s ur e t ha t t he be a r i ng ca r r ie r i s l o cat e d i n t he s a me po s i t i o n t ha t i t wa s r e moved f r om, f ai l ur e t o f ol l ow th i s p r o ced ure wi l l r e s ul t i n d a mage to th e v e hi cl e . I nst a l l t he b r[...]

  • Page 251

    P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Outer C on stant V elo c ity (CV ) J o int B oo t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont ha l f s ha f t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o Ha l f s ha f t L H . For a ddi t i o na l i nfo rm at i o n, ref e r t o H a lf sha f t RH . 2. C[...]

  • Page 252

    1. Ins t a l l the o ut er CV jo i nt b oo t . 2. CAU TI O N : Do no t da mage t he bea ring ret a i ne r . • NO T E: T he o ut e r CV j o in t is r e t a i ne d t o t he s ha ft by a s pr ing cl i p. I nst a l l t he o ut e r CV j o i nt . 3. Att a ch t he o ut e r CV jo i nt bo o t . Ins t al l new gr ea s e . 4. NOT E: Make s ure e noug h a i [...]

  • Page 253

    P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Item S pe ci fi ca ti on Cons t a nt vel o c i t y (CV) gr e a s e Ol i s t amol y L N 584 LO Fi l l C apaci ti es Descri pti on Grams Gr ea s e f o r i nne r CV jo i nt boo t 90 Gr ea s e f o r i nne r CV jo i nt 90 Gr ea s e f o r o ut e r[...]

  • Page 254

    P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Driv e Hal fshafts Des cr ipt i o n a nd O pe r a t i o n Rea r Drive Half sh a fts I te m P ar t N u m ber Descri pti on 1 — O ut e r cons t a nt ve l oci t y (CV) j o i nt 2 — An t i -l o ck br ake s yst e m (ABS) r i ng 3 — O ut e r CV j o i nt boo t 4 — I nne r CV jo i nt bo o [...]

  • Page 255

    P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Driv e Hal fshafts Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n . JagDocs.com[...]

  • Page 256

    P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Halfsh aft Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover , Axl e S ha f t O i l S e a l 308-208 I nst a l l er, O i l S e a l 204-264 R em ova l 1. Remove t he whe e l knuck le . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Knuck le (204- 02 Re a r S [...]

  • Page 257

    2. NOT E: W he n i ns t a l l i ng t he ha l fs haf t make s ur e t he s p r i ng cli p i s f ul l y e ngag e d i n t he di ff e r e nt i a l . I nst a l l t he ha l f s ha f t . 3. Ins t a l l the whe e l knuckle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Knuck le (204- 02 Re a r S us pe ns i o n, Re m o v al a nd I ns t a [...]

  • Page 258

    P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Ou ter Co nst ant Vel oci ty (CV ) J oi nt Bo ot Re moval a n d I ns t a l l a t i on R em ova l • NO T E: O ut er Cons t a nt Ve l o ci t y (C V) Jo i nt B oo t s hown, i nner Co nst a nt V e l o c i t y (CV) Jo in t Bo o t si mil a r . 1. Remove t he ha l f s ha f t . For a ddi ti ona l i n[...]

  • Page 259

    1. Ins t a l l the o ut er CV jo i nt b oo t . Ins t al l a ne w ret a i ni ng cl i p. Us i ng a s u it a b le t oo l , i ns t a ll the r et ai ni ng cli p. 2. Ins t a l l the ne w r e t a i n in g cl i p. Ins t al l a ne w ret a i ni ng cl i p. Us i ng a s u it a b le t oo l , i ns t a ll the r et ai ni ng cli p. 3. CAU TI O N : Make s ur e t h e [...]

  • Page 260

    P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d[...]

  • Page 261

    P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: B r ake fl ui d con ta i ns p ol ygl yc o l e t he rs a nd pol ygl yc ol s. Avoi d cont a ct wi t h t he e yes . W a s h hand s t hor ou ghl y a ft e r handl i ng. I f brak e fl ui d co nt a ct s t he e ye s , f l [...]

  • Page 262

    * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System Dia gn os i s a nd Te s t i ng P r i nci pl e s o f O pe r at i o ns The br ake s yst e m op e rat e s by t r ans fe rr i ng ef f ort a ppl i e d t o t he b r a ke p e da l , by t he dr i ver, t o t he brakes a t e a ch wh e e l . The br[...]

  • Page 263

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 1 1 1 The br ake s pul l o r dr i ft T i re p r e s s ur es /wea r . Ca li pe rs. Br ake p a ds . Br ake d i s cs . W he e l a l i gnme nt a dj us t me nt . W he e l b ea ring. S uspe ns i o n b us he s and ba l l jo i nt s . GO t o Pi npoi nt Te[...]

  • Page 264

    1 1 1 1 1 1 1 1 Is a vib r a t i o n p res e nt ? Ye s CHECK t he br ake cal i pe r mount i ng b ol t s and whee l hub nu ts and TI GHTEN a s ne ces s a r y. CHECK t h e ba l a nce of a l l r oa d whee l s a nd REP AIR a s ne ce s s a ry . CHECK t he b r a ke d i scs f o r exces s i ve we ar, r unout , t h i ckn e s s va r i a t i on or cr ack s . [...]

  • Page 265

    1 1 1 2 3 4 5 6 1 1 1 1 I s t he a l i gnment wi t hi n s peci f i ca t i o n? Ye s Ve hi cl e i s O K. No Adj us t t h e a l i gnment a s ne ce s s a r y. Fo r a ddi t i o nal i nfo r m at i o n, r ef e r t o REFER t o : U nde rb od y Mi s al i gnme nt Che ck (502-00 Uni -Bod y , S ubframe a nd Mount in g Sy st e m, Ge ne r a l P r o ce dures ). .[...]

  • Page 266

    1 1 1 1 1 1 2 3 4 1 2 3 4 1 Check f o r e xt e r nal b r ake s yst e m l e a ks. For add i t i ona l i nf o r m a t i o n, r e f er t o Ma s t er Cyl i nd er i n t hi s s e ct i on. Ar e l e a k s fo un d? Ye s REPAI R a s ne ce ss a r y, ADD fl ui d a n d B LEED b r ake s yst e m. Fo r a ddi t i on a l i nf o r m at i o n, ref e r t o REFER t o : [...]

  • Page 267

    1 1 1 1 1 1 1 2 1 1 T EST C ONDI T IONS DET AI LS/RE S U LT S/ACT IONS H1 : T EST B R AKE LOC KUP Roa d t e s t t he vehi cl e a nd a ppl y t he br a ke pe d al l ig ht l y. Do t he br akes l o ck up? Yes GO t o H2 . No Vehi cl e i s O K. H2 : I NS PE C T B R AKE PADS Ins p e ct brake pa ds f o r cont a mina t i o n, co r r e c t i nst a l l a ti o[...]

  • Page 268

    2 3 4 5 6 1 1 2 3 4 5 1 Appl y t he br ake pe da l l i g ht l y t hr e e o r f o ur t i m e s . W a i t 15 s e con ds fo r t he v a cuum t o repl e ni s h. P ush do wn on th e bra k e ped a l unt i l it s t o ps movi ng downwa r d o r a n i ncr ea s e d res i s t a n c e t o t he brak e p e da l t ravel occur s . Ho ld t he b r ake p e da l i n t h[...]

  • Page 269

    The fo l lo wi ng condi t i on s a r e c o ns i de r e d norm al a nd a r e no t i ndi cat i o ns t ha t t he brak e ma s t e r c yl i nde r i s i n ne ed o f r e pa i r . Ne w b rak e s ys t e ms a r e d e s ig ne d t o pr od uce a p e da l e f fo rt t ha t i s not a s hard a s i n t he pa s t . Compl a i nt s o f l i g ht pe d a l e f f o r t s s[...]

  • Page 270

    P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake Dis c Runo ut C heck Gene ral P r ocedures C heck 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. Remove t he whe e l a nd t i r e [...]

  • Page 271

    P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System B leeding Gene ral P r ocedures W ARNI N G: B r ake Fl ui d cont ai ns po l ygl yc ol e t he r s a nd p o l yglycol s . Avoi d c ont a ct wi t h t he e ye s . W a s h ha nds tho r ou ghl y a f t e r han dl i ng. I f brak e fl ui d co nt a ct s t he e ye s , f l us [...]

  • Page 272

    br ake ci rcu i t s . 6. F i l l up t h e mas t e r cy li nde r r es e r voi r t o t he MAX mar k . 7. Ins t a l l the mas t e r cy li nde r r es e rv oi r cap. JagDocs.com[...]

  • Page 273

    P ubl i s he d: 11-May-2 011 Front Dis c B rake - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d IT T S up e r Do t 4[...]

  • Page 274

    P ubl i s he d: 11-May-2 011 Front Dis c B rake - Front Dis c B rake Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um be r Descri pti on 1 — B r a k e hos e 2 — B r a k e cal ip e r r e t ai n in g b ol t s 3 — B r a k e pad s 4 — B r a k e cal ip e r a ncho r pl a t e 5 — B r a k e di s c 6 — W hee l hub 7 — W hee l knuc kle [...]

  • Page 275

    P ubl i s he d: 11-May-2 011 Front Dis c B rake - Front Dis c B rake Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 206-00 Br ake Sy s t e m - Gene r a l I nfo r mat i on . JagDocs.com[...]

  • Page 276

    P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake C al iper Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Sect i on 204-04 W hee l s a nd T ire s . 2. CAU TI O N : If brak e fl ui d i s[...]

  • Page 277

    1. CA UT I O NS: I f t he pi s t o ns a r e pus he d b a c k i nt o t he ho us i ng , br a ke f l ui d wi l l be fo rc e d o ut o f t he i nl e t po rt of t he b rak e ca l i p er. Make s ur e t ha t the br a k e di s c fa ce s a r e c l e a n be f o r e i ns t a l l a t i o n. • NO T E: Ins t al l n ew br a ke ca li pe r r e ta i ni ng bo l t s.[...]

  • Page 278

    P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake Di sc Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he brake pa ds , r ef e r t o t he p r oce dur e i n t hi s s e c t i o n : P a ds . 2. Remove and di s card t he br a ke cal i p e r a n c hor pl a t e r e t a in in g b ol t s . 3. D et a ch t he brake cal i pe r , brake cal i[...]

  • Page 279

    P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake Pads Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Sect i on 204-04 W hee l s a nd T ire s . 2. Pi vot t he brake cal i pe r upwa r ds . 1. Re move a nd di s car d t he br ake ca l i pe r l o wer r e[...]

  • Page 280

    3. Pi vot t he brake cal i pe r downwa rds . 4. Ins t a l l a ne w b r ake ca l i per l o we r r et a i ni ng bo l t . Ti ght e n t o 30 Nm. 5. Ins t a l l the whe e l . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o Sect io n 204-04 W he e l s a nd Ti r es . JagDocs.com[...]

  • Page 281

    P ubl i s he d: 11-May-2 011 Rear Disc Brake - Lubr i cant s, Flu ids , sea l e rs and Ad hesi ves CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d IT T S up e r Do t 4 ha s[...]

  • Page 282

    P ubl i s he d: 11-May-2 011 Rear Disc Brake - R ear Disc Brak e Des cr ipt i o n a nd O pe r a t i o n Item Pa rt Nu mb e r Descri pti on 1 — Pa r k in g brake cabl e 2 — Hub ca r rie r 3 — Br ake ho s e 4 — Br ake d i s c s hi el d 5 — Br ake ca l i per 6 — Br ake ca l i per a nchor pl a t e 7 — Br ake p a ds 8 — W hee l hu b 9 ?[...]

  • Page 283

    P ubl i s he d: 11-May-2 011 Rear Disc Brake - R ear Disc Brak e Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 206-00 Br ake Sy s t e m - Gene r a l I nfo r mat i on . JagDocs.com[...]

  • Page 284

    P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Cali per Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 Brak e ca l i per pi st o n re t r act o r t oo l 206-080 Cr anks haf t pul l e y/dampe r r emover 303-588 R em ova l 1. Remove t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m a[...]

  • Page 285

    4. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: T o pr e vent the l os s o f brak e fl ui d, a ppl y t he b r ake p e dal ho l d dow n t o o l a nd a dj us t to h ol d t he b r ake pe da l d own 40m m. Ins t a l l a bl [...]

  • Page 286

    3. NOT E: Ins t a l l ne w brake ho s e s e a l i ng wa s hers . At t a ch t he b r a ke h os e. Ti ght e n t o 38 Nm. 4. Remove t he brake pe da l hol d do wn t o o l . 5. Ble e d t he br ake s y s t e m. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke S ys te m Bl e e d i ng (206-00 Brak e Sy s t e m - Gene r a l Inf o r m at i o [...]

  • Page 287

    P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Disc Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he brake pa ds . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P a ds (206-04 Re a r Di s c Br ake , Re moval a n d I ns t a l l a t i o n). Vehi c le s with 2.5L or 3.0L engine 2. D et a ch t he A[...]

  • Page 288

    P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Disc S hield Re moval a n d I ns t a l l a t i on 1. Remove t he rear whe e l hub. Fo r add i t i o nal i nf or ma ti on, re fe r to S ect i o n 204-02 Rea r S usp e ns io n . JagDocs.com[...]

  • Page 289

    P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake P ads Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e ca l i per pi st o n re t r act o r t oo l 206-080 Cr anks haf t pul l e y/dampe r r emover 303-588 R em ova l 1. Remove t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (2[...]

  • Page 290

    5. Remove t he brake pa ds . Insta llat ion 1. CAU TI O N : If t he pi s t o n i s pus he d ba ck i nt o th e ho us i ng, b r a ke fl ui d wi l l be f o r ced ba ck i nt o t he f lui d r es e r voir. • NO T E: T he l e f t -ha nd brake cal ip e r pi s t o n r e t r a ct s co unt e r cl o ck wi s e a n d th e r igh t -ha nd ret ract s cl o ck wi s[...]

  • Page 291

    4. Att a ch t he pa r ki ng b r ake ca bl e ret a i ni ng cl i p. 5. Att a ch t he pa r ki ng b r ake ca bl e . 1. Re l e a s e t he t e ns i o n. 2. At t a ch t he p ark in g b rak e ca bl e . 6. Ins t a l l the whe e l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mo[...]

  • Page 292

    P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - T o rque Sp eci f i cat ions Descri pti o n Nm l b-f t l b- i n P a r ki ng br ake cont r ol ret a i ni ng nut s 20 15 - JagDocs.com[...]

  • Page 293

    P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake Des cr ipt i o n a nd O pe r a t i o n It e m Pa r t Nu m be r D escri pti on 1 — Fr ont ca bl e 2 — Re a r cabl e 3 — Brake cal i pe rs The pa r king brake cont r ol s ys t e m i s cabl e -ope r a t e d a nd cont r ol l e d b y a n i nde pe nde nt ha nd-op e r at ed[...]

  • Page 294

    * * * * * * 1 1 1 1 1 P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m t o dupl i cat e t he co ndi t i on. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o[...]

  • Page 295

    1 1 Dis conne ct t he p a rk i ng br ake f r o nt cabl e f r o m t he rea r br ake cab l e a nd condui t a t t h e e q ual iz e r . Rot a t e t he w hee ls b y hand. Did t he rear whe e l s r ot a t e O K? Ye s INS TA LL a ne w front p a r k i ng b r a ke cabl e . For ad di t i on a l in fo rm at i on, refe r t o t he p r oced ure i n thi s s e ct [...]

  • Page 296

    P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C a bleVehic les W ith: Manuall y Adju sted Par kin g Brake Re moval a n d I ns t a l l a t i on Speci al T ool (s) P a r ki ng b r ake cab l e a dj us t e r s ocket . 206-087 R em ova l 1. Rel e as e t he pa r ki ng br ake . 2. Rai s e a nd s uppo r t the ve hi cle . For [...]

  • Page 297

    6. Remove t he rear pa rk i ng br ake ca b le ret a i ni ng cli p. 7. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 8. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 9. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 10. Remove t he rea r park i ng br ake ca bl e a nd co ndui t . Insta llat ion 1. [...]

  • Page 298

    P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C a bleVehic les W ith: Self-A dj us ting Par kin g Brake Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear r oa d whe e l a nd t i re. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i on 204-04 W he e l s an d T i res . 2. D et a ch t he r [...]

  • Page 299

    7. D et a ch t he pa rk in g b r ake ca bl e a nd co nd ui t . 8. D et a ch t he r e a r p ark ing b r ake cabl e . 9. Remove t he pa r ki ng b r ake rear ca bl e a n d co ndui t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 300

    P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C ontro lV ehicles With: Manuall y A dj usted Par kin g Brake Re moval a n d I ns t a l l a t i on Speci al T ool (s) P a r ki ng b r ake cab l e a dj us t e r s ocket . 206-087 R em ova l All v e h icle s 1. Remove t he ce nt e r cons o le . Fo r a ddi t i o nal i nfo r m[...]

  • Page 301

    7. NOT E: 2.5L o r 3.0L s ho wn, 2. 0L s imi l a r . Det ach t he rear pa rk i ng br ake cabl e s . Vehi c le s with 2.5L or 3.0L engine 8. Remove t he drive sha f t. Fo r a ddi t i ona l i nf o r m at i o n ref e r t o Sect i o n 205-01 Dr i ve s haf t . All v e h icle s 9. Remove t he pa r ki ng b r ake . Insta llat ion 1. To i ns t a l l , rever[...]

  • Page 302

    P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C ontro lV ehicles With: Self-Ad j us ting Par kin g Brake Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he ce nt e r cons o le . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o S ect i o n 501-12 Ins t r ument P a ne l a nd Cons o l e[...]

  • Page 303

    9. Remove t he e xhaus t re ar hea t s hi e l d. 10. Remove t he p a r k i ng b r a ke cont r ol ret a i ni ng nut s . 11. Lowe r t he vehi c l e . 12. Det a ch t he pa r k i ng br a ke cont rol . 1. De ta ch t he pa r king br ake c a bl e g r o mmet . 2. De ta ch t he pa r king br ake c ont r ol . 13. Remove t he p a r k i ng b r a ke cont r ol . [...]

  • Page 304

    1. To i ns t a l l , rever s e t he remov a l procee d ur e. Ti ght e n t o 20 Nm. JagDocs.com[...]

  • Page 305

    P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d IT T S up [...]

  • Page 306

    P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Hy draulic B rake A ctua tio n Des cr ipt i o n a nd O pe r a t i o n I te m Pa r t Nu m be r De scr i pti on 1 — Br a ke mas t e r cyli nder 2 — Br a ke f l ui d r e s e rv oi r 3 — Br a ke bo o s t e r 4 — Rea r brake cal i pe r 5 — Br a ke t ube s 6 — Fr ont b r ake cal i pe[...]

  • Page 307

    P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Hy draulic B rake A ctua tio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 6-00 Br a ke S yst e m - Ge neral I nf orm at i on . JagDocs.com[...]

  • Page 308

    P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Fluid Reservoir Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Make s ur e t he f i l l[...]

  • Page 309

    5. NOT E: Re m o ve a nd d i sca r d t he O -r ing s e a l s f r om t he br ake mas t e r c yl i nde r . Re move t h e br a ke f l ui d r e s e r vo i r. 1. Re l e a s e o ne le g of t h e res e rv oi r from t he r et a i ni ng pi n. 2. Re move t he b r a ke f l uid res ervoir. Insta llat ion All v e h icle s 1. NOT E: Ins t a l l ne w O -r ing s e[...]

  • Page 310

    4. F i l l t he b r a ke f lu id r es e r voi r. 5. Ble e d t he br ake s y s t e m. For a ddi t i o na l i nf orm at i o n, r ef e r t o Sect i on 206-00 Br ake S y s t e m - Ge ne r al I nf o r mat i on . 6. Ins t a l l the brake f l ui d res e r voi r fi l l e r cap. JagDocs.com[...]

  • Page 311

    P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Master C y l inder Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Make s ur e t he f i [...]

  • Page 312

    5. D et a ch t he cl ut ch mas t er cyli nde r f ee d hos e . All v e h icle s 6. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. Re move t he coo l a nt e xpans i o n t a nk ret a i ni ng b ol t . 2. Tur n t he co o l a nt e xpans i o n t a nk count e r clo ckwis e . 3. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 7. D i s conne [...]

  • Page 313

    9. NOT E: Re m o ve a nd d i sca r d t he O -r ing s e a l at t he re ar of t he br a ke m a s t e r cy l i nde r . Re move t h e br a ke mas t er cyli nde r a nd res e rv o i r . 1. Re move t he b r a ke ma s t e r cyli nde r r et a i ni ng nut s . 2. Re move t he b r a ke ma s t e r cyli nde r a nd r es e r v o ir. Insta llat ion All v e h icle s[...]

  • Page 314

    4. Att a ch t he coo l a nt e x pa ns i o n t a nk. 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. Tur n t he co o l a nt e xpans i o n t a nk cl ockwi se . 3. I ns t a l l t he c oo l a nt e xpans i o n t a nk ret a i ni ng bol t . Vehi c le s with ma nual tra nsmission 5. Att a ch t he clu t ch m a s t e r cy l i nde r fe e d ho s [...]

  • Page 315

    8. F i l l t he b r a ke f lu id r es e r voi r. 9. Ble e d t he br ake s y s t e m. For a ddi t i o na l i nf orm at i o n, r ef e r t o Sect i on 206-00 Br ake S y s t e m - Ge ne r al I nf o r mat i on . 10. Ins t a l l t he brake f l ui d r es e r voir f i l le r cap. JagDocs.com[...]

  • Page 316

    P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Pedal and B racket Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with ma nual tra nsmission 1. W ARNING: Bra k e fl ui d co nt a i ns po l ygl ycol et he r s a nd p o l ygl ycols . Av o i d co nt a ct wit h t he e yes . W a s h ha nd s t ho roughl y a f t e r hand l i n[...]

  • Page 317

    4. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Ins t al l s ui t a bl e bl a nk i ng p lug s . • NO T E: Ri ght -ha n d d r i ve s ho wn, l e f t -ha nd d r i v e s i mil a r . Di s conn ect t he cl ut ch mas t e r c[...]

  • Page 318

    9. Remove t he s up port p a nel . Le ft-hand dr ive ve hi c le s 10. Po s i t i o n t he f r o nt whe e l s i n a s t r a ig ht a he a d po s i t i o n a nd ce nt r a l i z e t he s te e r i ng wh e e l . Lock i n po s i ti o n a n d remove t he i gni t i on key. 11. Det a ch t he s t e e r ing c ol umn . Re mov e a nd di s c a r d t he s t e e r [...]

  • Page 319

    15. Repo s i t i o n t he a nt i -c o ll ap s e bracket . R ight-hand driv e v ehi c le s 16. Remove t he b rak e bo o s t e r pus h r o d r et a i ni ng nut . 17. Remove t he a ccel erat o r pe da l mount bracket . Le ft-hand dr ive ve hi c le s 18. Remove t he b rak e bo o s t e r pus h r o d r et a i ni ng cli p. 1. Re l e a s e t he b r ake b o[...]

  • Page 320

    19. Remove t he a ccel erat o r pe da l mount bracket . 20. Remove t he b rak e pe da l a nd br a ck et re ta i ni ng nut s . All v e h icle s 21. Remove t he b rak e pe da l a nd br a ck et re ta i ni ng nut s . 22. NO TE: Ri ght -hand d r i ve s ho wn, l e ft -hand drive s i mi l a r. Re move t h e br a ke pe d al a nd bracket . Dis conne ct t he[...]

  • Page 321

    1. NOT E: Ri g ht -hand drive s h own , l e ft -hand drive s i mil a r. I nst a l l t he b r ake pe dal a nd bracket . Conne ct t he e l e ct r i cal co nnect o r. 2. Ins t a l l the brake pe da l a nd b r ack e t ret a i ni ng n ut s . Ti ght e n t o 25 Nm. Le ft-hand dr ive ve hi c le s 3. Ins t a l l the brake pe da l a nd b r ack e t ret a i ni[...]

  • Page 322

    5. Ins t a l l the brake bo o s t e r pus h r od r et ai ni ng cli p. R ight-hand driv e v ehi c le s 6. Ins t a l l the a ccel e r at o r pe da l mount brack e t . Ti ght e n t o 25 Nm. 7. Ins t a l l the brake bo o s t e r pus h r od r et ai ni ng nut . Ti ght e n t o 3 Nm. All v e h icle s 8. Repo s i t i on t he a nt i -col l a ps e bracket . J[...]

  • Page 323

    9. Ins t a l l the a nt i -c ol l a ps e br acket cl e vis pi n ret a in ing cl i p. 1. I ns t a l l t he a nt i -col l a ps e b r acket cle vi s pi n. 2. I ns t a l l t he a nt i -col l a ps e b r acket cle vi s pi n r e t a i nin g cl i p. 10. At t ach t he wi r i ng harnes s . 11. Ins t a l l t he a cc e l e rat o r pe da l . For a ddi ti ona l [...]

  • Page 324

    15. Ins t a l l t he drive r si de i ns t rum e nt pan e l l o we r t r i m pa ne l . R ight-hand driv e v ehi c le s 16. Ins t a l l t he brake p e da l a nd br a ck e t ret a i ni ng nut s . Ti ght e n t o 25 Nm. Vehi c le s with ma nual tra nsmission 17. CAUT I O N: I f brake fl ui d i s s pi lt o n t he pa i nt wo r k, t he a f fe ct e d a r e [...]

  • Page 325

    19. NO TE: Ve hicl e s wi t h 2.5L o r 3.0L eng i ne o nl y. At t a ch t he e ngi ne wi ring harnes s . Ti ght e n t o 10 Nm. 20. Bl e e d t he hydr aul ic clut ch s ys t em. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Cl ut ch S y s t e m Bl e e di ng - Ve hi c l e s W i t h: 6-S pee d Manual Tr ans axl e - MMT6 (308-00 Manua l Tr an s[...]

  • Page 326

    P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Pedal C ro ss-Shaft Re moval a n d I ns t a l l a t i on Speci al T ool (s) Dis conne ct t o ol , f ue l l i ne . 310-076 Dis conne ct t o ol , f ue l l i ne . 310-D 005 Dis conne ct t o ol , f ue l l i ne . 412-038 5 P o i nt S e c urit y T o r x Bi t . 418-535 R em ova l All v e h [...]

  • Page 327

    5. D et a ch t he wi ring ha r ne s s . 6. D et a ch t he DPF d i ff e r e nt ia l pr es s ur e s e ns o r r et a i ni ng br acket . Re mov e t he re ta i ni ng nut s . 7. D i s conne ct t he DPF di ff e r e nt i al pres s ur e s e ns o r e l e ct rical co nnect or. 8. NOT E: Not e t h e o r i e nt a t i o n o f t he DPF di ff e r e nt i a l pres s[...]

  • Page 328

    10. Dis c o nne ct t he up pe r fue l vap or ho s e from t he e vapo rat i ve e mi s s i o n cani s t e r pur ge va lve . 11. Det a ch t he oxyge n s ens or e l e ct rica l c o nne ct or s . 12. Dis c o nne ct t he e va porat o r s o l e no i d e l ect r i cal conne cto r. 13. Dis c o nne ct t he l ow er f ue l va po r h os e f r om t he e v ap o r[...]

  • Page 329

    14. Det a ch t he wi ring ha r nes s from t he r e t a i ni n g b r ack e t . 15. Remove t he e va porat i ve e mis s i o n ca ni s t e r pur ge v a l ve r e t ai ni ng br acke t . Vehi c le s with 2.0L engi n e 16. Remove t he i nt a ke mani f o l d. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: I nt a ke Ma nif ol d (303-01A Engi n e - [...]

  • Page 330

    19. Remove t he A /C refr i g e r ant l i ne r e t a i ni ng cl i p . 20. NO TE: I ns t a ll b l anking pl ugs to t he e xpo s e d po rts . Us i ng t he s p e ci a l t o ol , d i s co nne ct t he A/C r e frige rant l i ne . Re mov e a nd di s c a r d t he O -r ing s e a l s . All e x cept ve hicles with die s el engine 21. NO TE: T he b ol t r e ma[...]

  • Page 331

    23. Dis c o nne ct t he e n gi ne wi r i ng ha r ne ss e l e ct rical co nnect or. 24. Det a ch t he eng i ne wi ring ha r nes s ret a i ni ng cl i p. 25. Det a ch t he eng i ne wi ring ha r nes s e l e ct rica l c on ne ct or . 26. NO TE: T he b ol t r e mai ns ca pt i ve in t he ECM e l e ct rical conne ct or. Di s conn ect t he ECM ha r nes s e [...]

  • Page 332

    All v e h icle s 28. Remove t he b rak e pe da l cr os s -s haf t s uppo r t bra c ket r e t a in ing bol t . 29. Rot a te t he b r a k e pe da l cr os s-s haf t cl o ck wi s e. 30. Remove t he b rak e pe da l a nd br a ck et . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P e da l a nd B r a cket (206-06 Hydr aul i c Br ake A ct [...]

  • Page 333

    33. Remove t he g l ove co mpa r t ment fi nis her t r im. 34. Remove t he g l ove co mpa r t ment . Re mov e t he g l o ve compa r t m e nt ret a i ni ng screws . 35. Remove t he b l owe r mot or t rim. 36. Remove t he ce nt ral j unct i o n bo x (CJB) ret a i ni ng n ut . 37. Det a ch t he CJB. JagDocs.com[...]

  • Page 334

    38. Repo s i t i o n t he br a ke pe d a l c ross -sh a f t s e cur i ng br acket . 1. Un do b ut do no t r e move t he br a ke pe d a l cross -s ha ft s e cur i ng brack e t r et a i ni ng nut . 2. Re pos i ti on t he br ake ped a l cr o s s -s ha f t s e cur in g b rack et . 39. Remove t he rig ht -ha nd f e nde r sp l a s h shi el d. For a ddi t[...]

  • Page 335

    43. Det a ch t he br a k e l i ne s . 44. Remove t he A /C refr i g e r ant l i ne. Re mov e t he re ta i ni ng cl i p. 45. Remove t he A /C refr i g e r ant l i ne. 46. NO TE: No t e t he po s i t i o n o f th e brake ped a l cr o s s-s haf t s pr i ng. Det ach t he brake p e da l cr os s -s ha f t s pring. JagDocs.com[...]

  • Page 336

    47. Det a ch t he br a k e pe da l cr os s -s ha ft l ef t -ha nd mount i ng br acket . 48. Det a ch t he br a k e pe da l cr os s -s ha ft g r ommet . 49. NO TE: Re move t he b r ake p e da l cr os s -s ha f t sp ring b us h. Re move t h e br a ke pe d al cross -s ha ft . Insta llat ion All v e h icle s 1. NOT E: Make s ure t ha t t he b r ake pe [...]

  • Page 337

    2. Att a ch t he brake pe da l cr os s -s haf t gr ommet . 3. Att a ch t he brake pe da l cr os s -s haf t le f t -hand m o unt i ng brack e t . 4. NOT E: Make s ure t he brake pe da l cr os s -s ha ft s pr i ng i s l ocat e d i n i t s or i gi nal po s i t i o n. At t a ch t he b r a ke p e da l cr os s -s ha ft s pring. 5. Ins t a l l the A/C r e[...]

  • Page 338

    7. Att a ch t he brake l i ne s . 8. NOT E: Re m o ve t he bl a nki ng p l ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 9. NOT E: Re m o ve t he bl a nki ng p l ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 10. Ins t a l l t he A/C ref r i ge r a nt l i ne s r e ta i n[...]

  • Page 339

    12. Repo s i t i o n t he br a ke pe d a l c ross -sh a f t s e cur i ng br acket . 1. Ti g ht e n t he brake pe da l cr os s-s haf t s e cur ing bracket r e t a i ni ng nut . 2. Re pos i ti on t he br ake ped a l cr o s s -s ha f t s e cur in g b rack et . 13. At t ach t he CJB . Ti ght e n t o 6 Nm. 14. Ins t a l l t he CJB ret a i ni ng nut . Ti[...]

  • Page 340

    17. Ins t a l l t he gl o ve compa r t ment f i ni s her t rim. 18. Ins t a l l t he gl o ve compa r t ment hi ng e ret a i ni ng s cr ew s. 19. Ins t a l l t he s o und i ns u lt at i o n. 20. Ins t a l l t he pe d a l bo x. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P e da l a nd B r a cket (206-06 Hydr aul i c Br ake A ct ua[...]

  • Page 341

    22. Ins t a l l t he brake p e da l cr os s -s haf t s uppo r t b rack e t r e t a i ni ng bol t . Ti ght e n t o 25 Nm. All e x cept ve hicles with die s el engine 23. Conne ct t he E CM el e ct r i cal co nnect or. Us i ng s pe c i a l t o o l 418-5 35, t ig ht e n t o 5 Nm. Vehi c le s with diese l engine 24. At t ach t he e ngi ne wi r i ng ha [...]

  • Page 342

    26. At t ach t he e ngi ne wi r i ng ha r ne ss e l e ct rical co nnect or. 27. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 28. Conne ct t he e ngi ne wi r i ng ha r ne s s e l e ct rica l co nnect o r . Ti ght e n t o 10 Nm. 29. NO TE: Re move t he b l a nking pl ugs f r om t he fue l p ump f uel s uppl y a nd r e t ur n l i [...]

  • Page 343

    30. NO TE: Re move t he b l a nking pl ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 31. Ins t a l l t he A/C ref r i ge r a nt l i ne r et a i ni ng cl i p . 32. NO TE: Re move t he b l a nking pl ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 33. Ins t a l l t he r e f[...]

  • Page 344

    35. Ins t a l l t he e vapo rat i ve e m i s s i on ca ni s t e r pur ge val v e r e t a i ni ng br acke t . Ins t al l t he re t a i ni ng nut s . Ti ght e n t o 5 Nm. 36. At t ach t he wi r i ng harnes s t o t he re ta i ni ng br a ck et . 37. Conne ct t he l o wer f ue l vapo r hos e to t he e va porat i v e e mis s i o n cani s t e r pur ge va [...]

  • Page 345

    39. At t ach t he o xygen s e ns o r el e ct r i cal co nnect o rs. 40. Conne ct t he up pe r fue l v ap o r hos e to t he e va porat i ve e mis s i o n cani s t e r pur ge va lve . All v e h icle s 41. Ins t a l l t he brake b oo s t e r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke Bo o s t e r - RHD AW D/R HD FW D (206-07 P o [...]

  • Page 346

    44. At t ach t he DP F d i f f eren ti al p res s ur e s e ns or r et ai ni ng brack e t . Ins t al l t he re t a i ni ng nut s . Ti ght e n t o 5 Nm. 45. At t ach t he wi r i ng harnes s . 46. CAUT I O N: I ns t a l l t he re t a i ni ng cl i p t o t he o rigi na l po s i ti o n. Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n[...]

  • Page 347

    P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - T o rque Sp eci f i cat ions Descri pti o n Nm l b- ft l b- i n Brak e b oo s t e r r et a i ni ng nut s 25 18 - Brak e ma s t e r cyli nd er r e t a i ni ng nut s 25 18 - Coo l a nt e x pa ns i o n t a nk r e t a i ni ng bo l t 3 - 27 S pe ed cont r o l m o dul e re ta i ni ng bo l t - V e [...]

  • Page 348

    P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo oster Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: B r ake fl ui d con ta i ns p ol ygl yc o l e t he rs a nd pol ygl yc ol s. Avoi d cont a ct wi t h e ye s . W a s h ha nds af t e r hand l i ng. I f br ake f l uid cont a ct s t he e yes , f l us h t he e y es f or 15 mi nut [...]

  • Page 349

    P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - P ower Brake S y stem Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 6-00 Br a ke S yst e m - Ge neral I nf orm at i on . JagDocs.com[...]

  • Page 350

    P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo osterLHD A WD/LHD FWD Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he brake boo s t e r pus h r od r e t ai ni ng cl i p . 1. Re l e a s e t he b r ake b oos t e r pus h rod ret a ini ng cl i p. 2. Re move t he b r a ke b o os t e r pus h rod ret a i [...]

  • Page 351

    5. Remove t he coo l a nt e xpa ns i o n t a nk r e t ai ni ng bo l t . 6. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. De ta ch t he co ol a nt expa ns i on t ank. 2. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . Vehi c le s with 2.0L engi n e 7. D et a ch t he cr uis e co nt rol ca b le . 8. D et a ch t he t hrot t l e ca b le[...]

  • Page 352

    9. D et a ch t he i d l e ai r cont r ol (IAC) val ve wi r i ng harnes s . 10. Det a ch t he t hr ot t l e ca bl e r e t a i ni n g b r ack e t . 11. Dis c o nne ct t he s pe e d cont r ol modul e e l e ct r i cal co nnect o r. 12. Remove t he s pe e d cont r ol modul e ret a i ni ng b o l t . 13. Repo s i t i o n t he s p ee d cont r o l mod ul e [...]

  • Page 353

    Vehi c le s with ma nual tra nsmission 14. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Fa i l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . • NO T E: Ins t al l b l a nk i ng pl [...]

  • Page 354

    18. Det a ch t he br a k e boo s t e r v a cuum hos e. 19. Det a ch t he br a k e boo s t e r. Re mov e t he b rak e boo s t e r r et a i ni ng nut s . 20. Remove t he b rak e bo o s t e r s uppo r t br acket . 21. Remove t he b rak e bo o s t e r. Insta llat ion All v e h icle s JagDocs.com[...]

  • Page 355

    1. NOT E: Make s ure t he brake bo os t e r pus h rod i s c orr e ct l y a l i gne d t o t he br ake p e dal . • NO T E: Do no t i ns t al l t he brake boo s t er r e ta i ni ng nut s a t t hi s s t a ge . I nst a l l t he b r ake bo o s t e r . 2. Ins t a l l the brake bo o s t e r s up port b r a cket . Loo s e l y i ns t a l l t h e br a ke bo[...]

  • Page 356

    6. NOT E: Ins t a l l a new br ake mas t er cyli nde r t o b r ake bo o s t e r O-r i ng s e a l . • NO T E: Make s ur e t he b r a ke b o o s t e r pus h r od i s cor r ect ly a l i gne d t o t he br ake mas t e r cyli nde r as s e mbl y. At t a ch t he b r a ke ma s t er cyli nde r a s s e mbl y t o t he b r ake b oos t e r . Ti ght e n t o 25 [...]

  • Page 357

    10. Ins t a l l t he s p e ed c on t r ol m od ul e ret a i ni ng bo l t . Ti ght e n t o 4 Nm. 11. Conne ct t he s pe e d cont r ol modul e el e ct r i cal co nnect o r. 12. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket . 13. At t ach t he I A C va lve wi r i ng harne ss . 14. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t[...]

  • Page 358

    15. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 16. At t ach t he co o l a nt e xpans i o n t a nk . 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. At t a ch t he coo l a nt e xpans i o n t a nk. 17. Ins t a l l t he coo l a nt e xpan s i o n t a nk r et ai ni ng bo l t . Ti ght e n t o 3 Nm. 18. NO TE: Re move t he [...]

  • Page 359

    19. At t ach t he b rak e f l ui d l ow le vel warnin g i ndi cat o r wi ring ha rn e s s t o t he cool a nt expa n si o n t ank. 20. Conne ct t he b rak e fl ui d l ow le vel wa r ni ng i ndi cat o r e le ctrica l conne ct o r . 21. Ins t a l l t he brake b oo s t e r pus h r od r e t a i nin g cl i p. 22. Check a nd t op up t he coo l i ng s yst [...]

  • Page 360

    P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo osterRHD AWD/ RH D FWD Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e pe da l ho l d do wn t o o l JDS 9013 R em ova l All v e h icle s 1. D i s conne ct t he brake f lui d l o w l e ve l wa r n in g i ndi cat o r e l e ctrica l conne ct or. 2. D et a ch t he brake f[...]

  • Page 361

    4. Remove t he coo l a nt e xpa ns i o n t a nk r e t ai ni ng bo l t . 5. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. De ta ch t he co ol a nt expa ns i on t ank. 2. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . Vehi c le s with 2.0L engi n e 6. D et a ch t he cr uis e co nt rol ca b le . 7. D et a ch t he t hrot t l e ca b le[...]

  • Page 362

    8. D et a ch t he i d l e ai r cont r ol (IAC) val ve wi r i ng harnes s . 9. D et a ch t he t hrot t l e ca b le ret a i ni ng br acket . 10. Dis c o nne ct t he s pe e d cont r ol modul e e l e ct r i cal co nnect o r. 11. Remove t he s pe e d cont r ol modul e ret a i ni ng b o l t . 12. Repo s i t i o n t he s p ee d cont r o l mod ul e . JagDo[...]

  • Page 363

    Vehi c le s with ma nual tra nsmission 13. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Fa i l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . • NO T E: Ins t al l b l a nk i ng pl [...]

  • Page 364

    17. Det a ch t he br a k e boo s t e r v a cuum hos e. 18. Det a ch t he br a k e boo s t e r. Re mov e t he b rak e boo s t e r r et a i ni ng nut s . 19. Remove t he b rak e bo o s t e r s uppo r t br acket . 20. Us i ng t he br a ke pe da l ho l d do wn t o o l, a ppl y t he b rak e p e da l unt i l t he br ake b o os t e r pus h r od pi n ca n [...]

  • Page 365

    22. Remove t he b rak e bo o s t e r pus h r o d pi n. 23. Remove t he b rak e bo o s t e r. Insta llat ion All v e h icle s 1. NOT E: Do not i ns ta l l t he br ake b o os t e r r e t a i ni ng nut s a t t hi s s t a ge . I nst a l l t he b r ake bo o s t e r . 2. Ins t a l l the brake bo o s t e r pus h r od pi n. JagDocs.com[...]

  • Page 366

    3. Ins t a l l the brake bo o s t e r pus h r od pi n re t a in i ng cl i p. 4. Remove t he brake pe da l hol d do wn t o o l . 5. Ins t a l l the brake bo o s t e r s up port b r a cket . Loo s e l y i ns t a l l t h e br a ke bo o s t e r s uppo r t brack et r et a i ni ng bo l t . 6. Att a ch t he brake bo os t e r. Ti ght e n t o 25 Nm. 7. Tig [...]

  • Page 367

    9. NOT E: Ins t a l l a new br ake mas t er cyli nde r t o b r ake bo o s t e r O-r i ng s e a l . • NO T E: Make s ur e t he b r a ke b o o s t e r pus h r od i s cor r ect ly a l i gne d t o t he br ake mas t e r cyli nde r as s e mbl y. At t a ch t he b r a ke ma s t er cyli nde r a s s e mbl y t o t he b r ake b oos t e r . Ti ght e n t o 25 [...]

  • Page 368

    13. Ins t a l l t he s p e ed c on t r ol m od ul e ret a i ni ng bo l t . Ti ght e n t o 4 Nm. 14. Conne ct t he s pe e d cont r ol modul e el e ct r i cal co nnect o r. 15. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket . 16. At t ach t he I A C va lve wi r i ng harne ss . 17. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t[...]

  • Page 369

    18. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 19. At t ach t he co o l a nt e xpans i o n t a nk . 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. At t a ch t he coo l a nt e xpans i o n t a nk. 20. Ins t a l l t he coo l a nt e xpan s i o n t a nk r et ai ni ng bo l t . Ti ght e n t o 3 Nm. 21. NO TE: Re move t he [...]

  • Page 370

    22. At t ach t he b rak e f l ui d l ow le vel warnin g i ndi cat o r wi ring ha rn e s s t o t he cool a nt expa n si o n t ank. 23. Conne ct t he b rak e fl ui d l ow le vel wa r ni ng i ndi cat o r e le ctrica l conne ct o r . 24. Check a nd t op up t he coo l i ng s yst e m as r eq ui r ed . Vehi c le s with ma nual tra nsmission 25. Bl e e d t[...]

  • Page 371

    P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Va cuum Pump2.0L N A V6 - AJ V 6 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he vacuum ho se . Re l e a s e t he re t a i ni ng cl i p. 2. D i s conne ct t he e l ect r i cal conne ct o r. 3. Remove t he vacuum pump. Insta llat ion 1. To i ns t a l l , rever s e[...]

  • Page 372

    P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Va cuum Pump2.0L D uratorq- TDC i/2.2L Durato rq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover /Ins t al l , Co o l i ng Ho s e Cl a mp 303-397 R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. [...]

  • Page 373

    6. D i s conne ct t he brake vacuum hos e f rom t he b rak e v a cuum pum p. 7. Remove t he po we r s t e e r i ng ho s e s upp o r t bracket . 8. D et a ch t he cyli n der he a d t e m pe r a ture (CHT) s e ns o r el e c t rical co nne cto r a wa y f r om t he brak e vacuum pump. 9. Usi ng t he s pe cia l t oo l 303-397, d i s conne ct t he coo l [...]

  • Page 374

    11. Us i ng t he s pe ci a l t o o l 303-397, di s conne ct t he cool a nt hos e s . 12. Remove t he b rak e va cuum pu m p. Re mov e a nd di s c a r d t he gas ke t. Insta llat ion 1. CAU TI O N : Make s ur e t h e dr i ve coup l i ng i s al ig ne d wi th t he c a msha f t c o upl i ng. • NO T E: Ins t al l a ne w b rak e vacuum pum p ga s ke t [...]

  • Page 375

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui [...]

  • Page 376

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss ist Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um be r Desc ri pti on 1 — Ins t r ument cl us t e r 2 - D ynamic s t a bi l i t y cont r o l 'O N/O FF' s wi t ch 3 - ABS /Tr act i on c o ntrol h y draul i c uni t 4 - [...]

  • Page 377

    e nabl e s t he sys t e m t o r e cog ni z e th e dr ive r 's i nt e nt i ons . The DS C s yst e m a l s o i nco r por at e s e me r gen c y b r ake a s si s t (EBA), whi c h mea s ures t he r a t e a t wh ich t he br a ke pr e s s ur e i ncr e as e s d ur i ng a br aki ng ma noe uvr e . I f t he s ys t e m d et e ct s a n e me r ge ncy br aki[...]

  • Page 378

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss istVIN R ange: C 00344->J12991 Dia gn os i s a nd Te s t i ng Principle of oper at ion The a nt i - l ock b r a k e s ys t e m (ABS ) modul at e s br ake pres s u r e on e ach w hee l i nd e pe nde nt l y t o mai nt a i n vehi cle s t a [...]

  • Page 379

    1. Vi s ua ll y i ns pe ct f or ob vio us s ig ns o f mecha ni cal o r e l e ct rical da mage . 1. Mechani cal El e ct ri cal Che ck th e t i re s i z e s , condi t i o n, a nd i nf l a t io n Brak e f l ui d l e ve l or l e a k a ge W he e l s pee d s e ns o r fi t me nt W he e l s pee d s e ns o r ai r gap W he e l s pee d s e ns o r to o t he d [...]

  • Page 380

    1 2 3 4 1 1 DT C D escri pti on P oss i bl e Source Act i on C1278 S t e e r i ng a ngl e s e ns or CAN me s s a ge no t pl a us i bl e S te e r in g a ng l e s e ns or no t cal i b r a t e d S te e r in g a ng l e s e ns or po we r s uppl y ci r c ui t ; o pe n circ uit , hi g h r es i s t a nce S te e r in g a ng l e s e ns or f a i l ur e For s [...]

  • Page 381

    1 2 1 1 1 2 3 4 1 1 1 2 1 I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams. CLEAR t he DTC, t e s t t he s y s t e m f o r norm a l ope rat i on. No GO t o A 4 . A4 : CHEC K T HE R IGH T -HAND FRO NT WSS PO WER CIRC UIT FOR HI GH R[...]

  • Page 382

    1 1 2 3 4 1 1 1 2 1 1 1 2 3 4 Mea s ur e t he res i s t a nce b et we e n LF01, p i n 01 (N ) and GROU ND. I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams. CLEAR t he DTC, t e s t t he s y s t e m f o r norm a l ope rat i on. No I[...]

  • Page 383

    1 1 1 2 1 1 1 2 3 4 1 2 3 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C, t e s t t he s ys t e m fo r n or mal o perat i o n. No GO t o D2 . D2: C HECK T H E LEF T - HAN D REAR WSS SENSOR C I[...]

  • Page 384

    1 2 1 2 3 4 1 2 3 1 1 2 1 2 3 4 1 2 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s GO t o E4 . No For CAN circu i t t es t s, REFER t o : Communica t i ons Ne t wo r k - V IN Rang e : E96603->J28492 (418-00 Modul e Co mm u nica t i o ns Ne t wo rk , Di a gnos i s and Te s t in g). E4: CHEC K T HE ST E ER I N G AN GLE S ENSOR GR O UND C[...]

  • Page 385

    3 1 2 1 2 1 2 1 2 3 1 2 3 1 1 2 3 1 2 3 Mea s ur e t he r es i s t a nce be t we en JB89, p in 03 (GB) and JB 185, pi n 42 (GB) . Is t he res i s t a nce g r ea t er t h a n 5 o hms ? Ye s REP AIR t he hi gh r e s i s t ance ci rc ui t . Fo r a d di t i o na l i nf o r mat i o n, refe r to t he wi r i ng di a gr a m s , t e s t t he s yst e m f o r[...]

  • Page 386

    4 1 2 Mea s ur e t he vol t a ge bet we e n JB45/J B185, pi n 06 (R) and GRO UN D. I s e it he r vol t a ge l e s s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n t he AB S / DS C modul e a nd ba t t e r y. Th is ci rcu i t i ncl ude s t he b at t e r y j unct i o n bo x (fu s e 03) a nd ha r ne s s s pl i ce , JBS 27. Fo r addi t i o[...]

  • Page 387

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss istVIN R ange: J1 2992-> V99999 Dia gn os i s a nd Te s t i ng Principles of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he Ant i -Lock Co nt r o l - S ta b i l i t y As si s t sys t ems , ref e r t o t he r e l e vant De[...]

  • Page 388

    DT C D escri pti on P oss i bl e cause Ac ti on C007298 Brak e Te mpe r at ur e Too Hi g h Compo nent o r s yst e m over t e m pe r at ur e . T he HCU ha s de t e ct ed t ha t th e t e mpe r a t ur e i s t oo hi gh f or t he co r r e c t op erat i o n o f compone nt o r s ys t em Ove r he a t i ng o f at le a s t o ne hy draul i c br aki ng ci rcu [...]

  • Page 389

    DT C D escri pti on P oss i bl e cause Ac ti on to bat t e ry Modul e s up pl y vol t a ge gr ea t e r t ha n 16.8 vol t s Ove r v ol t a ge o f t he ba t t e r y cha r gin g s yst e m Ove r v ol t a ge m e a s ur e d b e t we e n m o dul e i gni t i o n a nd gr ound Ove r v ol t a ge m e a s ur e d b e t we e n m o dul e p ump s up pl y a nd mot o[...]

  • Page 390

    DT C D escri pti on P oss i bl e cause Ac ti on P oor W S S s i g na l at hi ghe r freque ncy . At a ppr oxi mat el y 50 kph (31 mph) W S S may no t c ompa re a n d s how a var i a nc e C1A7614 Va l v e Rel a y Ci r cuit Circ ui t s ho rt t o ground or o pen S ol e noi d s up pl y ci r cuit op en S ol e noi d s up pl y ci r cuit s hort t o g r ound[...]

  • Page 391

    DT C D escri pti on P oss i bl e cause Ac ti on op en ci r cuit W S S i nt e rn a l f a i l ure C1A9229 Re a r L e ft W hee l S pe e d S e nso r Ci r cuit S ig na l i nval i d. A fa i lu r e where t h e val ue of t he s i gnal i s no t pl a us i b l e g i ven th e ope r at ing condi t io ns Incor rect s i z e whe e l o r ti r e Ex ces s i ve a ir g[...]

  • Page 392

    DT C D escri pti on P oss i bl e cause Ac ti on cir cuit s ho r t t o ground W S S s upp l y f r ont right cir cuit s ho r t t o po we r W S S s upp l y f r ont right op en ci r cuit W S S i nt e rn a l f a i l ure C1A9429 Fr ont Ri ght W h ee l Spee d S en s or Ci r cuit S ig na l i nval i d. A fa i lu r e where t h e val ue of t he s i gnal i s n[...]

  • Page 393

    DT C D escri pti on P oss i bl e cause Ac ti on Gr o und l i ne t o yaw r a t e s e n so r op e n cir cuit Y a w rat e s e ns or s en di ng i nva l i d CA N m e s s a g e Y a w rat e s e ns or s en di ng i ni t i a l iz a t i on s t a t us fa ul t Y a w rat e s e ns or in t e r na l fa i l ur e C1A9900 P r e s s ur e S ens or Ci r cuit HCU i nte r [...]

  • Page 394

    DT C D escri pti on P oss i bl e cause Ac ti on C1B0271 Re t ur n P ump Ci r cuit Act ua t o r s tuck. Low o r di s cha r ged ba t t e r y Ve hi cl e cha r gi ng s yst e m f a i l ure P ump s uppl y li ne i s op en ci r cuit P ump s uppl y li ne s hort to pow er P ump m ot o r a ct uat i o n fa i lu r e P ump m ot o r r e l a y fa i lu r e HCU f a [...]

  • Page 395

    DT C D escri pti on P oss i bl e cause Ac ti on s t e e r i n g whe e l r o t a t i on s ens o r o pen cir cuit CAN H o pen cir cuit be t we e n yaw rat e s en s o r , s t e ering w hee l r o t a t i on s ens o r a nd m o dul e CAN L o p e n ci rcu i t be t we e n yaw rat e s en s o r , s t e ering w hee l r o t a t i on s ens o r a nd m o dul e S [...]

  • Page 396

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock Brake System (ABS) ModuleVI N Range : C 00001->J12991 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he a nt i-l o ck br a ke s yst e m (ABS) mod ul e e l e ct r ica l conne ct or. 2. D et a ch t he hydr aul ic cont rol u nit (HCU). 3. Remove t[...]

  • Page 397

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Front Whe el Speed Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e as s e mbl y. Fo r addi t i ona l i nf o r m at i o n, r e f er t o S ect i on 204-04 W he e l s an d T i res . 2. D i s conne ct t he f r ont whe e l sp e e d s e nso[...]

  • Page 398

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Hydraulic C on tro l U ni t (HC U)V IN Range: C 00001->J12991 Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nn[...]

  • Page 399

    8. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he ef fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Di s conn ect t he hydr aul i c co nt rol uni t b r a ke t ube s . 9. Remove t he hydr a uli c cont r ol uni t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur[...]

  • Page 400

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Hydraulic C on tro l U ni t (HC U)V IN Range: J1 2992-> V99999 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e [...]

  • Page 401

    8. Remove t he HCU . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 8 Nm. 2. CAU TI O N : Make s ur e t h e br a ke t ubes are i ns t a l l e d to t he co r re c t port s. Fa i l ur e t o f o l l o w t hi s ins t r ucti on may res ul t i n da mag e t o t he vehi cl e . Ti ght e n t o 16 Nm. 3. Ble e d t he[...]

  • Page 402

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Rear Wheel Speed Senso r Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.5L or 3.0L engine 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Di s a s s embl y a nd As s[...]

  • Page 403

    7. D i s conne ct t he ABS whe e l s p ee d s e ns or el e ct r i c a l co nnect o r. 8. Remove t he ABS whe e l s p ee d s e ns o r . Insta llat ion Vehi c le s with 2.5L or 3.0L engine 1. To i ns t a l l , rever s e t he remov a l proced ur e . 1. Ti g ht e n t o 22 N m. Vehi c le s with 2.0L or die sel engine 2. To i ns t a l l r evers e t he r [...]

  • Page 404

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Stability Assi st Mo dule Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: S t a bi l i t y as s is t modul e is a n int e gral co mponen t o f t he A BS m o dul e a n d ca nnot b e s e pa r a t e d. Di s conn ect t he a nt i -l ock brak e s ys t e m (ABS ) modul e e l[...]

  • Page 405

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Steering Wheel Ro t ation Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he s t ee r in g whe e l r ot a ti on s ens o r e l e ct rica l co nnect o r . 2. Remove t he uppe r st e e r i ng col umn. For a ddi ti ona l i nf o r m a t i o n, r e f e r t[...]

  • Page 406

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Yaw Rate Sensor2 .0L Durato rq- TDCi /2. 0L NA V6 - A JV 6/2.5 L NA V 6 - AJV6/3. 0L NA V6 - AJ2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f l o or cons o l e trim p ane l . 2. D i s conne ct t he yaw rat e s e ns or e l e ct rical con nect or . 3. W ARNI[...]

  • Page 407

    P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Yaw Rate Sensor2 .2L Durato rq- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with autom at ic tra ns m ission 1. D et a ch t he J-gat e s ur r ound. Vehi c le s with ma nual tra nsmission 2. D et a ch t he ge a r s e l e ct o r s ur r o[...]

  • Page 408

    5. CAU TI O N : Make s ur e t h e ya w rat e s e ns or i s no t s ubj e c t e d t o a ny fo rm of i mpa ct a nd i s no t d r opp ed or damag e d. Fai l ure t o fo l l o w t hi s in s t ruc t i o n may r es ul t i n f ai l ure o f t he s e ns or. Det ach t he yaw rat e s e ns or . Re mov e t he re ta i ni ng nut s . 6. Remove t he yaw r a t e s e ns[...]

  • Page 409

    P ubl i she d: 20-Jul-2011 Steering System - G eneral Inf orm atio n - Ste eri ng L i nk age Sp ec if i cat io ns St ee r i ng Li nk age Free Pl ay Mea sur e men t (mm ) Me a surem e nt (i n) Fr e e pl a y (meas ur e d at t he s t ee r in g whe e l r i m) 0-6 0-0.24 Pow er Stee ri ng Pump Sp eci fic ati o ns I te m Speci fi cati on P owe r st e e r[...]

  • Page 410

    P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - Stee ring S y stem Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N u mber Des cri pti o n 1 — Flui d cool e r 2 — Lo w p r e s s ur e pi p e - f lui d coo l e r t o res e rv o i r 3 — Flui d res e r voir 4 — Po we r s t e e r i ng pump 5 — He a t s h ie ld 6 ?[...]

  • Page 411

    P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - Stee ring S y stem Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by drivi ng t he ve hi cle . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Mec hani cal I nsp[...]

  • Page 412

    Item Descri pti on 1 St e e r ing t rans ducer ground 2 I g ni t io n f e ed 3 St e e r ing t rans ducer f e ed 4 Ground 5 Spe e d s e ns o r s i gna l 6 Seria l i nt erfa ce Ste e ring Lin ka g e In spect ion an d Ba c kla sh (Fr eep la y) C he ck CAU TIO N : S t e e ring ge a r boo t s mus t b e ha nd l e d ca r e ful l y t o a voi d da mage . U [...]

  • Page 413

    It e m Speci a l T o ol Nu mb e r Desc ri pti on 1 21 1-011 Pres su r e Ga uge Ho s e 2 21 1-011-08 Pump Re t urn Ho s e 3 21 1-011-07 Pump Re t urn Ho s e Co nnect o r 4 211 -011- 03/ 2 Tes t Eq ui pment t o Hi g h P res s ur e Ho s e Ada pt or 5 211 -011- 03/ 1 Pump H ig h P res s ur e O ut l e t t o Hos e A da p t or 6 21 1-011-02 Pump Ad apt o [...]

  • Page 414

    C ondi ti on Possi bl e Sources Acti on Damag e d f l ui d cap . INS TA LL a ne w f l ui d c a p. Loo s e o r d a mage d hos e f i t t i ngs . TIGHT EN or IN S TALL a ne w ho s e a s ne ces s ary. Lea ka ge a t powe r s t e e ring pump . I NS TALL a ne w po we r st e e r i ng pump a s ne ce s s ary . For add i t i o na l i nf o r mat i o n, REFER t[...]

  • Page 415

    C on di ti on Po ss i bl e Sou rces Act i on Lo o s e o r worn rear s us pen s i o n. TIGHT EN l o o se , o r I NS TAL L n e w rea r su s p e ns i on compone nt s . Fo r a ddi t i ona l i nf o r m at i o n, REFER t o Sect i on 204-02 Rea r S us pen s i o n . Ve hi cl e t e nd s t o pul l t o o ne s i de whe n d r i ven o n a l eve l s ur f ace Inco[...]

  • Page 416

    C on di ti on Po ss i bl e Sou rces Act i on Damage d or w orn f r o nt s us pe ns i o n co mpone nt s . INS TA LL ne w f r ont s usp e ns i on co m po nent s a s nece s sa ry . Fo r a ddi t i o nal i nfo r mat i o n, REFER t o Sect i on 204-01 Front S us p e ns i on . Incor rect t o e a dj us t ment . ADJUS T a s nece s s a r y . For a ddi ti o na[...]

  • Page 417

    C on di ti on Po ss i bl e Sou rces Act i on Flu id l o ss a t t he po we r st e e r i ng p ump s haf t s e al . CHECK t he po we r s t e e r i ng pu m p f or s i gns of s t e ering f l ui d l o s s . INS TA LL a ne w powe r s t ee ring p ump as ne ce s s a ry . For a ddi t i o nal i nfo r m at i o n, REFER t o Sect io n 211-02 P owe r S te e r i n[...]

  • Page 418

    C on di ti on Poss i bl e S ources Ac ti on Acces s o r y dr ive bel t s quea l I nc o r r ect a cces so ry d r i ve be l t t e ns i o n or a cces s o r y drive b e l t gl a z e d. CHECK a cces so ry d r i v e be l t cond i t i on a nd IN S TAL L a ne w a cc e s s o r y drive b e l t a s ne ce s s a r y. Fo r a ddi t i o nal i nfo r m at i o n, REF[...]

  • Page 419

    C ondi ti on Possi bl e Sources Acti on CHECK and TI GHTEN t he s te e r i ng col umn ret a i nin g bo l t s /nut s and pi nch bo l ts i f r e qui red. For a dd i t i o na l in f orm a t i o n, REFER t o Sect i on 211-04 S t ee r i ng Co l umn . Ex ces s i ve we a r i n s t ee ring co l umn a s s embl y. CHECK f o r st e e r i ng col umn f or we a [...]

  • Page 420

    Dee p, l o ng, prol o nged s o und l i ke a n a n imal , o r wi nds a nd o cea n wa ves . Rum b le Lo w, he a vy cont i nuo us s o und l i ke t ha t made by wa go ns o r th under. Sc r ap e Gr a t i ng no i s e l i ke one hard p la s t i c ru bbi ng pa rt r ubbi ng a ga i ns t a no t he r . Sq u eak Hi gh-pi t che d s ou nd l i k e r ubbi ng a cl e[...]

  • Page 421

    is a s t ruc t ur e-bo rne n oi s e t r ans mit te d t hrough t he i nt e r medi at e s ha ft a nd co l umn. Ra ck knock ca n a l s o be he a rd a s a "t hump" o r i mpact no is e t hat o ccur s wi t h t he vehi cl e s t a t i ona r y whe n t he s t e e r i ng whe e l i s rel e a se d f rom a l o ad e d po s it i o n a nd a l l owe d t o [...]

  • Page 422

    ba l l j o i nt s a r e worn, t he l o we r s t e e r i ng col umn j oi nt s a re wo r n o r t he ba ckl a s h o f t he s t e ering ge a r is e xces si v e . CAU TIO N : DO NO T a t t e m pt t o a dj us t th e s t e e r i ng gea r yoke. Fa i l ur e t o f ol l ow t hi s i ns t r ucti on wi l l r e s ul t i n t he st e e r in g ge a r wa r ra nty t o[...]

  • Page 423

    P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - P ower Steer ing S y stem Fillin g Gene ral P r ocedures 1. NOT E: W he n fi l l ing t he r e s e r vo i r, make s ur e t ha t t he fl ui d i s cl e an a nd not agi t a t ed p r i or t o us e . T he f l ui d s ho ul d b e p our e d sl o wl y i nt o t he r e s e r voi r t o mi [...]

  • Page 424

    P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - P ower Steer ing S y stem Flushi ng Gene ral P r ocedures • NO T E: I f hea vy s t e e ring o r cont a mina t io n wi t hi n t he powe r s t e e ring s ys t e m i s f o und , i t is ne ces s a r y t o carr y out t he s ys t e m fl us h pr oce dure a s d e t a i l e d b e l o[...]

  • Page 425

    6. NOT E: The s ui t a bl e f unnel s ho ul d ha ve t he a ca pa ci t y o f 4 l it r e s a nd O-ring s e a l • NO T E: T he s ui t a bl e f unne l must be t i g ht l y s e a l e d t o t he po we r s t e e r i ng fl ui d res e rv oi r t o avo id fl ui d l e akag e . I nst a l l a s ui t a bl e f unnel o nt o t he po we r s t e e ring f l ui d res [...]

  • Page 426

    10. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id s . Re move t h e s ui ta bl e fun ne l . 11. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id s . Re move t h e s ui ta bl e pi p e t o t he p o we r s t e e r ing r et ur n ho s e . 12. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id [...]

  • Page 427

    P ubl i s he d: 11-May-2 011 Pow er Steering - Gen eral S p ec if ic a t ions Item Speci f i cati on P owe r a ss i s t e d s te e r i ng f lu id Dexr on 2E T o rque Sp eci f i cat ions Desc ri pti on N m l b- ft l b- i n Ti e r o d e n d ret a i ni ng nut 35 26 - P owe r st e e r i ng p ump r et a in ing bol t s 2 5 18 - Exte ns i o n s ha ft l o [...]

  • Page 428

    P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N u mber Des cri pti o n 1 — Flui d cool e r 2 — Lo w p r e s s ur e pi p e - f lui d coo l e r t o res e rv o i r 3 — Flui d res e r voir 4 — Po we r s t e e r i ng pump s uct i o n hos e 5 — Po we r s t e e r i ng pump 6 ?[...]

  • Page 429

    P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 211-00 S t e e r i ng S y s t em - Gene r a l I nf o r mat i on . JagDocs.com[...]

  • Page 430

    P ubl i s he d: 11-May-2 011 Pow er Steering - Start U p Pr o cedure After P ower Ste ering Pump/Gear O verh aul Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t oS e cti o n 211-00 S t ee r in g Sy s t e m - Gene r a l I nf o r m at i o n . JagDocs.com[...]

  • Page 431

    P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering C o ntrol Va lve Actuato r2.5L N A V6 - AJV6/3. 0L NA V 6 - A J27 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. Remove t he e xhaus t f r o [...]

  • Page 432

    1. To i ns t a l l , rever s e t he remov a l proced ur e . 1. I ns t a l l a ne w f il t e r 2. CAU TI O N : Make s ur e bo l t s a r e t i ght e ne d e venl y . Ti ght e n t o 3 Nm. JagDocs.com[...]

  • Page 433

    P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid C oo ler2 .0L Durato rq- TDCi Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d ia t o r S pl a s h S hie l d (501-0 [...]

  • Page 434

    P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid C oo ler2 .2L Durato rq- TDCi (110kW / 150PS) - Puma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d ia t o r S pl a s h S hie l d (501-0 2 Fr o nt End B o dy P a nel s ,[...]

  • Page 435

    I n s ome ca s e s where t he fl ui d cl ea rly co nt a i ns pa rti c ul a t e ma t t e r , a nd t he s y s t e m cont i nues t o f unct i o n, fl us h t he s ys t e m wi t h f r e s h f l ui d a nd r e pl a ce the res e rv oi r , a s t he r e i s t he p o ss i bi l i t y t ha t t he res e rv oi r i nt e r na l fi lt e r may be d a mage d o r fa ul[...]

  • Page 436

    P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid Reserv o ir Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : If po we r s t e e r i ng f l ui d is s pi l t o n t he pai nt wo r k , t he e ff e ct e d a r e a mus t be i mm e di a t e l y wa s he d d own wi th cold wa t e r. Re move t h e po we r s t e ering f l ui[...]

  • Page 437

    P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Pump2.0L N A V6 - AJV6 / 2.5L N A V6 - AJV6/3. 0L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a cc e s s o r y drive b e l t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Acces s or y Dr ive Be lt - 2.0L N A V 6 - AJV6/2.5L N A V6 - AJV 6/3.0[...]

  • Page 438

    3. Tig ht e n t o 30 Nm. 4. NOT E: If t he s t e e r i ng ge ar, pump o r coo l e r are be ing rep l a ced f o r le a kage or noi s e r e la t e d i s s ue s a nd t he re i s no e vid ence of f l ui d c on t a mina t i o n, t he r e i s no ne e d t o repl a c e t he re se r voi r . I n s ome ca s e s where t he fl ui d cl ea rly co nt a i ns pa rti[...]

  • Page 439

    Name Gr ea s e P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Pump2.0L Durato rq- TDC i/2.2 L D urato rq - T DCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Mate ri a l s Speci fi cati on W S S -M 12 A4-A2 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f [...]

  • Page 440

    7. D et a ch t he po we r s t ee ring hi gh-pr e s s ure pi pe . 8. CAU TI O N : W he ne ver t h e po we r s t e ering pump fe e d ho s e i s di s conne c t e d t he p o we r s t e e r ing pump p or t a nd ho s e s houl d be pl ugg e d t o pr eve nt d i r t i ngres s . Fa i l ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t i n d a mag[...]

  • Page 441

    11. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y. Re move t h e po we r s t e ering pump s ecur i n g b r a cket . 12. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y. Det ach t he po we r s t e e r i ng pump f r om t he co o l a nt pump. 13. Remove t he p o we r s[...]

  • Page 442

    1. Coat t he p o we r s t e e r i ng pump dr i ve s pl i ne s wi t h gr ea s e . 2. Ins t a l l a ne w wa t er pump O -r ing s e a l. 3. Ins t a l l the po we r s t e e r i ng pump. 4. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. At t a ch t he p owe r s t e ering pump t o th e co o la nt pump. JagDocs.co[...]

  • Page 443

    5. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. I nst a l l t he p o wer s t e ering pum p s e cur i ng b r acket . Ti ght e n t o 25 Nm. 6. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. I nst a l l t he p o wer s t e ering pum p r et a i ni ng bo l t s . Ti ght [...]

  • Page 444

    9. NOT E: Re m o ve t he pl ug s f r om t he po we r s t ee ring pump port a nd t he fe e d ho s e . • NO T E: Shown wi t h t he EGR co o l e r t o EGR va l ve t ube r e m ove d fo r cla rit y . Conn ect t he po we r st e e r ing fe e d ho s e. 10. At t ach t he p o we r s t e e r i ng hi gh-pres s ur e pi p e . 11. At t ach t he p o we r s t e e[...]

  • Page 445

    14. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.0L Durat o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150P S ) - P uma, Re moval a nd I ns ta l l a t i on). 15. Ins t a l l t he a ir de f le cto r . For a ddi ti ona l i [...]

  • Page 446

    P ubl i s he d: 11-May-2 011 Pow er Steering - Steering G ear2.0 L D uratorq- TDC i/2.2L Durato rq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Cent e r t he s t e ering w hee l . Lock i n po s i ti o n a n d remove t he i gni t i on key. 2. Remove and di s card t he ext e ns i on s haf t lo we r r e t a i ni ng b[...]

  • Page 447

    7. D et a ch t he s t e e r i ng ge a r coo l e r p ip e . 8. D et a ch t he r i ght -hand s i d e of t he s te e ring g e a r . 9. D et a ch t he l e f t -hand s i de o f t he s t ee ring g e a r . 10. Remove t he b ul k he a d pa ne l s e a l . 1. Re pos i ti on t he st e e r i ng ge a r. 2. Re move t he b ul k he a d pa nel s e a l . 11. Remove [...]

  • Page 448

    Insta llat ion 1. Ins t a l l the s t ee r i ng g e a r . 2. Repo s i t i on t he s t e e ring ge a r . 1. I ns t a l l t he bul k he a d pa ne l s e a l. 2. Re pos i ti on t he st e e r i ng ge a r. 3. Att a ch t he l e ft -hand s i d e o f t he s t e e r i ng ge a r . Ti ght e n t o 133 Nm. 4. Att a ch t he right -ha nd s id e o f t he s te e r i[...]

  • Page 449

    5. Att a ch t he s t ee r in g g e a r coo l er pi p e. 6. Att a ch t he s t ee r in g g e a r coo l er pi p e. 7. Ins t a l l new O -r ing s e a l s . 8. Att a ch t he s t ee r in g g e a r f l ui d l i ne s . Ti ght e n t o 10 Nm. 9. Ins t a l l the a i r def le cto r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.[...]

  • Page 450

    10. NO TE: Ri ght -hand s ho wn, Le f t ha nd s i m i l a r . Conn ect t ie -r o d e nd ba l l j oi nt s . 1. At t a ch bo t h t i e r o d s t o previou s l y not e d p o si t i o ns. 2. Ti g ht e n t he t i e r o d l o c ki ng nut . 11. NO TE: I ns t a ll a new b ol t . At t a ch t he l o we r s t e e ring co l umn. Ti ght e n t o 25 Nm. 12. Carr [...]

  • Page 451

    P ubl i s he d: 11-May-2 011 Pow er Steering - Steering G ear2.0 L N A V6 - AJV6 / 2.5L NA V6 - AJV6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1. Cent e r t he s t e ering w hee l . Lock i n po s i ti o n a n d remove t he i gni t i on key[...]

  • Page 452

    Vehi c le s with high i ntensity dis char ge hea dlam ps 6. D et a ch t he l i nk r od f r om t he hea dl a mp l e ve l in g s e ns o r . All v e h icle s 7. D et a ch t he po we r s t ee ring hi gh p r es su r e p ip e . Vehi c le s with autom at ic tra ns m ission 8. D et a ch t he s e l ect o r l e ver cab l e . All v e h icle s 9. Ins t a l l t[...]

  • Page 453

    10. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move[...]

  • Page 454

    14. Remove t he ret a i ni ng cl ip from t he po we r s t e e r ing hi g h a nd l o w pr es s ur e pi pe s . All v e h icle s 15. CAUT I O N: W h e neve r t he pow er s t e ering pi pe s are d i s co nnect ed, th e s t e e r ing gea r val ve bo d y po r t s a nd po we r st e e r in g pi p e s s houl d b e pl ugg ed to prevent d i r t i ngres s . Fa[...]

  • Page 455

    18. CAUT I O N: W h e neve r t he pow er s t e ering hi gh pr es s ur e pi p e i s di s conne c t e d, t he po we r s t e e ring pump po rt a nd pi pe s houl d be p l ugg e d t o pr eve nt d i r t i ngres s . Fa i l ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t i n d a mage to the ve hi cle . Di s conn ect t he po we r s t e ering h[...]

  • Page 456

    22. NO TE: L e ft -hand drive ve hi cl e s s ho wn, r i ght -ha nd d rive vehi cl e s s i mi l a r . Re move t h e s t e e r i ng ge ar bul k he a d s e a l. 23. NO TE: L e ft -hand drive ve hi cl e s s ho wn, r i ght -ha nd d rive vehi cl e s s i mi l a r . Re move t h e s t e e r i ng ge ar. Rot a t e th e s t e e r i ng gea r. Re mov e t he s t [...]

  • Page 457

    3. NOT E: Le f t -hand drive vehi cl e s s hown , r i ght -hand d r i ve vehi cl e s s imi l a r. At t a ch t he r i g ht -hand s i de o f t he s t e e r i ng g e a r . Loo s e l y i ns t a l l t h e s te e r i ng ge a r r e ta i ni ng bo l t . 4. NOT E: Le f t -hand drive vehi cl e s s hown , r i ght -hand d r i ve vehi cl e s s imi l a r. At t a [...]

  • Page 458

    7. NOT E: Re m o ve t he bl a nki ng p l ug. I nst a l l a ne w O -r ing s e a l . 8. NOT E: Re m o ve t he bl a nki ng p l ug. Conn ect t he po we r st e e r ing hi gh pr e s s ur e pi pe to the po we r s t e e r in g pump. Ti ght e n t o 30 Nm 9. Ins t a l l the po we r s t e e r i ng hi gh pres s ur e pi pe br a cket r e t a i ni ng bo l t . Ti [...]

  • Page 459

    Le ft-hand dr ive ve hi c le s 12. Ins t a l l t he r e t a i ni ng cl i p t o t he po we r s t e e r i ng hi gh a nd l o w p res s ur e pi pe s . All v e h icle s 13. Us i ng t he s pe ci a l t o o l rai s e t he f r ont s u bframe. 14. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r[...]

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    16. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t o 142 Nm. 17. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 18. Remove t he s pe ci a l t o o l . Vehi c le s with autom at ic tra ns m ission 19. At t ach t he s e l e ct o[...]

  • Page 461

    20. At t ach t he p o we r s t e e r i ng hi gh pres s ur e pi pe . Vehi c le s with high i ntensity dis char ge hea dlam ps 21. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h icle s 22. Conne ct t he p o we r s t e e r i ng cont r o l va l ve a ct ua t or e l ect r i cal co nnect o r (if e qu ip pe d). 23. NO TE: [...]

  • Page 462

    24. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover. All v e h icle s 25. Carr y out s t ee ring s ys t e m bl e e d p r o ce d ur e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: P o we r S t e e r i ng S y s t e m Fil l i ng (211-00 Ste e ring S yst e m - Ge neral I nfo rm at i on, Ge ne r al P roced ur es ). 26. CA[...]

  • Page 463

    P ubl i s he d: 11-May-2 011 Steering L inkage - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Ti e -r od e nd ret a i ni ng nut 35 26 - Ti e -r od e nd l o c k nut 40 30 - W he e l nut s - Ve hi cle s wit h s t e e l whe e l s 80 59 - W he e l nut s - Ve hi cle s wit h a lumi ni um whee l s 103 76 - JagDocs.com[...]

  • Page 464

    P ubl i s he d: 11-May-2 011 Steering L inkage - Steering Li nka ge Des cr ipt i o n a nd O pe r a t i o n Item Pa r t Nu m be r D escri pti on 1 — S t e e r i ng g e a r 2 — Ti e-r od end boo t 3 — Ti e-r od 4 — Ti e-r od end 5 — W h ee l hub a s se mbl y 6 — Ti e-r od end r et ai ni ng nut 7 — Ti e-r od end l o ck nut The l e f t a [...]

  • Page 465

    P ubl i s he d: 11-May-2 011 Steering L inkage - Steering Li nka ge Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 211-00 S t e e r i ng S y s t em - Gene r a l I nf o r mat i on . JagDocs.com[...]

  • Page 466

    P ubl i s he d: 11-May-2 011 Steering L inkage - Steering G ear Bo ot Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he t i e -r o d e n d. For a ddi t i o na l i nf orm at i o n, r ef e r t o p r oce dur e i n t hi s s e ct io n: Ti e Ro d En d 2. Remove t he s t ee ring ge a r bo ot . 1. Re move a nd di s car d t he s t e e r in g g [...]

  • Page 467

    P ubl i s he d: 11-May-2 011 Steering L inkage - Ti e Rod End Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep e r at or, B a ll Joi nt 204-192 (JD- 219) R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n re fe r t o Sect i o n 204-04 W hee l s a nd T ire s . 2. Loos e n t he t i e -r od e nd lo ck[...]

  • Page 468

    5. NOT E: Make a not e o f t h e numbe r of t ur n s re qui r ed t o remove t he ti e -r od e nd. Re move t h e t i e -r od e nd. Insta llat ion 1. NOT E: Make s ure t he t i e-rod e nd i s i ns t a l l ed o n t he t i e -r od by t he s a me a m o unt o f t ur ns u s e d t o r emove i t . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure.[...]

  • Page 469

    P ubl i s he d: 11-May-2 011 Steering Co lu mn - T o rque Sp eci f i cat ions Desc ri pti on N m l b- ft l b- i n S t ee r in g whe e l r et a i ni ng bo l t 47 35 - S t ee r in g co l umn l o we r r e t a i ni ng bo l t 25 18 - S t ee r in g co l umn r e t a i ni ng bo l t s 24 18 - S t ee r in g co l umn f l e xi bl e coupl i ng re ta ini ng bo l[...]

  • Page 470

    P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Des cr ipt i o n a nd O pe r a t i o n Item Pa r t Nu m be r Desc ri pti on 1 — S te e r i ng col umn 2 — S te e r i ng wh e e l 3 — S te e r i ng wh e e l a ng l e s e ns or 4 — S te e r i ng col umn f l e xib le coupl i ng The s t e e r i ng co lu m n l o c k i s s e cur[...]

  • Page 471

    P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 21 1-00 Ste e ring S yst e m - Ge neral In fo rm at i on . JagDocs.com[...]

  • Page 472

    P ubl i s he d: 11-May-2 011 Steering Co lu mn - Ignitio n Switch L o ck Cylinder Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l pocke t . 2. Remove t he drive r s s i de i ns t rum ent pa ne l l o we r t r i m pa ne l . 3. Remove t he s t ee ring co l umn l o we r s hr [...]

  • Page 473

    P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he clo cksp ring. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Cl o ckspring (501-20B S uppl e me nt a l Re s t rai nt Sy s t e m, Re moval a nd I nst a l l at io n). Vehi c le s without Dr ive[...]

  • Page 474

    6. D i s conne ct t he s t ee r in g whe e l r ot a ti on s ens o r e l e ct rica l co nnect o r . 7. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 8. Remove t he s t ee ring co l umn. 1. Re move t he s t e e r i ng col umn ret a i ni ng bol ts . 2. Re move t he s t e e r i ng col umn. Insta llat ion 1. To i ns [...]

  • Page 475

    2. Tig ht e n i n t he s eque n c e s ho wn. Ti ght e n t o 24 Nm. 3. Ins t a l l a ne w b o l t . Ti ght e n t o 25 Nm. JagDocs.com[...]

  • Page 476

    P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn C ouplin g Re moval a n d I ns t a l l a t i on R em ova l 1. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 2. Remove t he s t ee ring co l umn coupl i ng. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t [...]

  • Page 477

    P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing W heel Re moval a n d I ns t a l l a t i on R em ova l 1. Pos it i o n t he f r ont whe e l s i n a s t r ai ght a he a d po s i t i o n a nd cent r al i z e s t e e ring whe e l. 2. Remove t he drive r ai r b a g mod ul e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Driver Ai r[...]

  • Page 478

    P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n S wit ches Des cr ipt i o n a nd O pe r a t i o n Ste e ring C olu mn Multif u nction Switch RH The s t e e r i ng co lu m n mul t i funct i on s wi t ch RH cont rol s t he f o l l o wi ng f unct i o ns whe n t h e i g ni t i on s w i t c h i s i n po s i t i o n I I: Fl[...]

  • Page 479

    P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n S wit ches Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage . 2. Vi sual Inspect i on C h art El e ct ri cal W i r i ng ha r ne s[...]

  • Page 480

    P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n Multi func tio n Switch LH Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l pocke t . 2. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l . 3. Remove t he s t ee ring c[...]

  • Page 481

    5. D et a ch t he s t e e r i ng col umn m ul t i funct i o n s wi t ch l e f t -ha nd. Re l e a s e t he re t a i ni ng t ang. 6. Remove t he s t ee ring co l umn mult i f unct i o n s wit ch l e f t-h a nd. Dis conne ct t he e l e ct r i cal co nnect o r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 482

    P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n Multi func tio n Switch RH Re moval a n d I ns t a l l a t i on R em ova l 1. Lowe r t he s t e e r i ng col umn. 2. Remove t he s t ee ring co l umn uppe r s hr ou d. 3. D et a ch t he s t e e r i ng col umn m ul t i funct i o n s wi t ch rig ht -hand. Re l e a s e t he[...]

  • Page 483

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Gen eral sp eci fi cat ions 2.0 l it r e d i es el . I te m Speci fi cati on Cod e FMBA/FMB B Firing o rder 1- 3-4-2 Cyli nder bo r e di a met e r 86 mm S t r oke 86 mm Di s pl ace ment 1998 c c Compr es s i o n ra ti o 19:1 Engi ne we i ght 195 kg (e xcludi ng front end acce s[...]

  • Page 484

    C ranks haft D im ensi o ns 2.0 l i tr e and 2 .2 li t re d i es el . Desc ri pti on m m Mai n be a ring j o ur nal – di a met e r 69·950 - 69·970 Mai n be a ring j o ur nal – e nd fl oa t 0·090 - 0·305 Bi g-e nd b e aring j o ur nal – di a met e r 52·980 - 53·000 Mai n be a ring j o ur nal s 1 t o 4 – di amet e r 64·950 - 64·970 C [...]

  • Page 485

    I te m Sp eci f i cati on Va l ve he a d di a met e r e x ha us t (m m) 3 0.15 - 29.85 I nt a ke val ve f ace a ngl e deg r e e 45.75° Exhaus t va l ve f ace a n gl e d egree 45.25° Va l ve s t e m di amet e r i nt a ke (m m) 5.492 - 5.477 Va l ve s t e m di amet e r e x hau s t (mm ) 5.479 - 5.464 Va l ve s p r i ng f r ee l engt h (mm ) 4 4. 2 [...]

  • Page 486

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Engin e Des cr ipt i o n a nd O pe r a t i o n 2.0 L, 2 .5 L an d 3. 0L Engine s The 2.0L, 2.5L a nd 3. 0L e ngi ne s c o ns i s ts of : A s i x cyl in de r 60 de gree 'V' conf i gur a t i o n l i q ui d coo l e d a l umini um cyli nde r bl o ck wi t h d r y cas t i r[...]

  • Page 487

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Engin e Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on S ince di a gno s i s a nd t es t in g a ct ua l l y be g in s wh e n [...]

  • Page 488

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * Exces s ive cr anks ha ft e n d p la y. I NS TALL a new e ngi ne. Exces s ive conne ct i ng rod b e a r ing oi l cl e arance. I NS T AL L a new e ngi ne. P i s t o n/cy li nde r wor n. I NS TALL a ne w e ngi ne. P i s t o n ring da mag e d. I NS T AL L a new e ngi ne. Conn e cti ng r od be nt [...]

  • Page 489

    a nd r e pe a t the compr es s io n m e a s urement . I f t he r e adi ng gr e a t l y i mpr o ve s t he n t he pi s t o n r i ngs a r e da mag e d. I f t he r e adi ng s ta ys t he s ame t hen t he ca us e i s e i t he r d a mage d val v e se a t s o r val ve s t e m s e a l s . I f t he mea s u r e m e nt s fo r t wo cyli nd e r s next t o e a ch[...]

  • Page 490

    5. I f t he o i l cons umpt i on rate i s un a cc ept abl e go t o S tep 6 . 6. Check t he p o si t i ve cr a n kc as e ve nt i la t i o n (PCV ) s ys t e m. Make s ur e th e s ys t e m i s no t p l ugg e d. 6. 7. Check fo r pl ugge d oi l d r ai n-ba ck hol e s i n t he cy l i nde r hea d and c yli nder bl ock. 7. 8. If t he co ndi t i on s t i l [...]

  • Page 491

    i ndi cat e d. The r e a di ng a t i dl e co ul d be rel a t ive l y s t ea d y. 10. LATE VALVE TI MING: A s t e a dy b ut l o w r ea d in g co ul d be cau s ed by l a t e va l ve t imi ng. 10. 11. IGNIT IO N TIMIN G RETA RDING: Re t a r d e d i gni t i o n ti mi ng wi l l produce a s t e a dy but so mewh a t l o w r ea d i ng. 11. 12. INS UFFI CI [...]

  • Page 492

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Bearin g I nspectio n Gene ral P r ocedures 1. Ins pect b e a r i ngs f o r th e fo l l o wing d e fe ct s . 1. Cr at e r i ng - fa t i gue f a i l ure 2. S po t pol i s hi ng - i ncorr e ct s e a t i ng. 3. I mbedde d d i r t e ngi ne o i l . 4. S cr a t chi ng - di r t y e ng[...]

  • Page 493

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Bea ring J ournal Cl earance Gene ral P r ocedures 1. NOT E: Make s ure t ha t t he f ol l o wi ng s t a ge s a r e f o l l owe d exact l y . The ta p pe t s or f o ll owe rs mus t be remov e d t o car ry o ut t hi s me a s ur e ment . • NO T E: Make s ur e t ha t [...]

  • Page 494

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Bea ring J ournal Diam eter Gene ral P r ocedures 1. D et e r mine t he di a met e r of t he cams haf t jo urn al s . Us i ng a mi cr o met e r mea s ure t he di a met e r a t 90 de gr ee s i nt e r val s to det e r mine i f t he j o ur nal s a re o ut -o f -r o und [...]

  • Page 495

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft E nd Play Gene ral P r ocedures 1. NOT E: Make s ure t ha t t he cams ha f t i s t o s pe ci fi cat io n. Us i ng t he s p e ci a l t o ol , me a s ur e t he e nd pl ay. S li de t he ca ms ha ft i n b o th di r ect i o ns . Re a d a nd not e t he maxi m um a nd mini [...]

  • Page 496

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft L obe L ift Gene ral P r ocedures 1. M e as ur e t he di a met e r (1) and di a met e r (2) wi t h a ve rn i e r cal i p e r . T he di f fe r e nce i n me a s ur e ment s i s t he l obe l i f t . JagDocs.com[...]

  • Page 497

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Surfac e Inspecti on Gene ral P r ocedures 1. Ins pect ca ms haf t l o b e s f or pi t t i ng or da mag e i n t he a c t i ve a rea . Mi nor pi t t i ng i s a c ce pt a bl e out s i de t h e a ct i ve area . JagDocs.com[...]

  • Page 498

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C onn ecting Rod C leani ng Gene ral P r ocedures 1. CAU TI O N : Do no t us e a ca us t i c cle a ni ng s o l ut io n or da mag e t o c on ne ct ing r od s m a y occur . Mark a nd s ep a r at e t he p a r t s a nd cle a n wi th so l vent . Cl e a n t he oi l pa s sa g e s . Ja[...]

  • Page 499

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C onn ecting Rod L arge End B ore Gene ral P r ocedures 1. M e as ur e t he be a ring bo r e i n t wo di r ect i ons . The di f f e rence i s t he conne ct i ng r od bore o ut -of -r ound. Verif y t he o ut -o f -r o und i s wi t hi n s p e cif i c a t i o n. 2. M e as ur e t h[...]

  • Page 500

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft E n d P lay Gene ral P r ocedures 1. Usi ng t he Di a l Indi cat or Gauge wi t h Br ack e t s , me as ure t he e nd pl a y . Mea s ure t he e nd pl a y by l i ft i ng t he crank s haf t us i ng a l e ver. If t he val ue i s o ut o f t he s pe ci fi cat io n, in s t [...]

  • Page 501

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft Main B earing Jo u rnal C lea rance Gene ral P r ocedures 1. The mai n be a ring m a chi ne co de s a r e d is pl a ye d o n t he cr anksha ft (1) a nd t he cyli nde r bl o ck (2) 2. NOT E: Mai n be aring numbe r 1 r e l at e s t o t he f ront of t he e ngi ne . Re [...]

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    3. NOT E: Mai n be aring numbe r 1 r e l at e s t o t he f ront of t he e ngi ne . Re a d t he i d ent i f i ca t i on number s on t he cyli nder bl o ck (2 ). The fi r s t t wo number s r e pres e nt th e code f o r m a i n be a ring number 1. The s e cond pa i r o f number s r e pres e nt s th e code f o r m a i n be a ring number 2. The t hi r d[...]

  • Page 503

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft Main B earing Jo u rnal Di ameter Gene ral P r ocedures Ge nera l Equi pm ent Mi c rom e t e r 1. M e as ur e t he di a met e r of t he mai n be a ring j ournal s a nd t he b i g-end be a r i ng j ou r na l s . Re pea t t he mea s ur emen t wit h t he mi cr omet e r[...]

  • Page 504

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Blo ck Disto rtio n Gene ral P r ocedures 1. Usi ng a St r ai ght Ed ge a nd a Fe e l e r Gaug e, mea s ur e t he cyli nde r bl o ck/ cylind e r he ad di s t o rti o n. Mea s ure t he mat i n g f a ce di s t or t i o n. If t he val ue i s no t t o s pe cif i ca t i [...]

  • Page 505

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Bore O u t- o f- Round Gene ral P r ocedures 1. NOT E: The mai n be a r i ng cap s or l o we r cr ankc a se must be i n pl a ce and ti g ht e ne d t o t he s pe ci f i e d t o r q ue ; ho we ver , t he b e a r ing she ll s s h oul d no t be i ns t al le d. Mea s ur [...]

  • Page 506

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Head Disto r tio n Gene ral P r ocedures 1. M e as ur e t he cyli n der bl ock/ cyli nde r he a d di s t orti o n. Us i ng t he s pe ci a l t o ol , m e a s ur e t he m a t i ng f ace di s t o r t i o n. If t he val ue i s no t t o s pe cif i ca t i on r ewo r k t h[...]

  • Page 507

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Exh aust Manifo ld C leaning a nd Inspectio n Gene ral P r ocedures 1. Ins pect t he cy l i nde r hea d jo i ni ng fl ange s o f t he e xhaus t mani f ol d f or e vid e nce of e xha ust g a s l e aks . 2. Ins pect t he e xh a us t ma nif ol d f o r c rac ks , da ma ged gas ke t[...]

  • Page 508

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Flyw h eel In spectio n Gene ral P r ocedures 1. CA UT I O NS: Do no t rework t he f l ywhee l i f i t is di s t o rte d. Do no t cle a n t he d ual mas s f l ywhee l wit h a ny kind o f f l ui d . Cl e a n th e fl ywhe e l wi t h a dry cl ot h o nly. Do no t cle a n t he g a p[...]

  • Page 509

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Diam eter Gene ral P r ocedures Ge nera l Equi pm ent Mi c rom e t e r 1. NOT E: Mark t he pi s t o n t o mak e s ure t he pi s t o n i s i ns t a ll ed corr e ct l y. Us i ng a Micromet e r me a s ur e t he pi s t on d i a met e r. JagDocs.com[...]

  • Page 510

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ins pection Gene ral P r ocedures 1. CAU TI O N : Do no t us e a ny a ggres s i ve cl ea ni ng fl ui d or a wi r e b r us h to c l e a n t he pi s t o n. Ca r ry out a vis ua l i ns p ect i on. Cle a n t he p i s t o n s ki r t , pi n bu s h, r i ng grooves a nd crown a[...]

  • Page 511

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Pin Dia meter Gene ral P r ocedures 1. NOT E: The pi st o n a nd p is t o n pi n ar e a ma tche d p a i r . Do not mix up t he c ompo ne nt s . Mea s ur e t he pi s t o n pi n d i a me t e r. Mea s ure t he di a met e r i n t wo di rect i o ns . If t he val ue s a r e n[...]

  • Page 512

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Pin to B ore D iam eter Gene ral P r ocedures 1. NOT E: The pi st o n a nd p is t o n pi n fo r m a ma t ched pai r . Do not mi x up th e compone nt s . Mea s ur e t he di a met e r of t he pi st o n p i n bore. Mea s ure t he di a met e r i n t wo di rect i o ns . If t[...]

  • Page 513

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ring En d Ga p Gene ral P r ocedures 1. CAU TI O N : Do no t mi x u p t he pi s t o n r i ngs . Ins t al l t he pi st o n ring s in t he s a me p o s i t i on a nd l o cat i o n. Us i ng t he Fe e l e r Gauge , mea s ur e t he p i s t o n ring ga p . The val ue s g i ve[...]

  • Page 514

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ring- to-G roo ve Clea rance Gene ral P r ocedures 1. NOT E: The pi st o n ring mus t prot r ude f r om t he pi s t o n gr oo ve. T o det e r mine t he pi s t on r i ng cle a r a n c e , i nse r t t he Fe e le r Ga uge r i ght to t h e back o f t he gr oo ve , beh ind t[...]

  • Page 515

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Seat Inspectio n Gene ral P r ocedures Ge nera l Equi pm ent Va l ve s e a t wi dt h s cal e 1. M e as ur e t he wi d t h o f t he val ve s e a t . Mea s ure t he v a l ve s ea t wi dt h usi ng t he Va l v e s e a t wi dt h s ca le . If t he val ue i s no t t o s pe cif[...]

  • Page 516

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Spring Free Length Gene ral P r ocedures 1. Usi ng a ve r ni er ga ug e , mea s ure t he fre e l e ng t h o f e a ch val ve s pr i ng. Ve r i fy t he l e ngt h i s wi t hin s p e ci fi cat io n. JagDocs.com[...]

  • Page 517

    P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Stem Di ameter Gene ral P r ocedures 1. Usi ng a mi cr omet er me as u r e t he di a me t e r of t he v a l ve s t e ms . If t he m e a s u r e m e nt s a r e no t t o s p eci fi ca t i o n, ins t a l l a new val ve . JagDocs.com[...]

  • Page 518

    P ubl i s he d: 02-J un-2011 E ngine System - G eneral I nform atio n - Leaka ge Test U si ng Smo ke Test E quipm ent Gene ral P r ocedures CAU TIO N : Th e co mpr e s s e d a i r li ne s uppl y pr e s s ur e must b e b e t wee n 3.5 a nd 12 ba r (50 a nd 175 ps i ) fo r t h e s moke t e s t e q ui pment t o funct i on corr e ct l y. Do no t e xc e[...]

  • Page 519

    6. NOT E: In s o me c a s e s i t may be ne ces s a ry t o r emove t he a i r c l e a ne r (s ) to a ll o w a cces s t o t he a i r cl e an e r out l e t pi p e s. • NO T E: In s ome cas e s i t wi l l be ne ce s s a ry t o cap one o f t he a i r c l e ane r out l e t pi pes . U s e t he b la n king ca ps s upp li e d i n t he ki t t o cap t h e [...]

  • Page 520

    Publ i s he d: 23-S ep -2011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Descri pti o n Speci fi cati on Engi ne oi l 2. 0L ga s o l i ne , S AE 5W -30 (NAS ) API S L a nd I LS AC GF –3 Engi ne oi l 2. 0L ga s o l i ne , S AE 5W -30 (ROW ) AP I SJ / EC a nd ACEA A1[...]

  • Page 521

    Descri pti o n N m l b-ft l b- i n W i r i ng ha r ne s s t o val ve cover r et a i ni ng nut s 6 - 53 Thr ot t l e ca bl e ret a i ni ng b r ack e t bo l t s 9 - 80 A = ref e r t o th e proced ur e fo r corr e ct t orque s e que nce - - - JagDocs.com[...]

  • Page 522

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Des cr ipt i o n a nd O pe r a t i o n 2.0 Li t re 2.5 and 3.0 Li t re JagDocs.com[...]

  • Page 523

    The 2.0, 2.5 a nd 3.0 l i t r e 24 val ve V6 e n gi ne s ha ve fo ur o ver he ad c a msha f t s a n d a re dr i v e n by t wo t i ming cha in s . A l l t hree e ngi ne s in cor po r at e e l e ct roni c e ng i ne mana ge ment wi t h d i s t r i but o r l e s s i gni t i on s ys t e m , s e que nt i a l e l e ct roni c fue l inj ect i on. Al l t hr [...]

  • Page 524

    The r ot a r y o i l pump d e v e l op s t he o i l pres s ur e: The o il p ump i s l o ca t e d at t he f r on t of t he cr anks ha ft . The o il p ump i s d r i ven by t he cr a nk s ha ft . A f u ll f lo w oi l f il t e r i s e xt e r nal l y mount ed o n t he oi l fi l t e r hous i ng. I f t he f i l t e r e l e ment s ho ul d be come b l ocked[...]

  • Page 525

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 303-00 Engine S ys t em - Gen e r al I nf or mat i o n . JagDocs.com[...]

  • Page 526

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C learanc e A djustment Gene ral P r ocedures 1. Remove t he ca m s haf t s . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o Ca ms ha f t 2. Use com pres s e d a i r to remove t he s hi ms t ha t r e qui r e r e pl a ci ng. Bl o w com [...]

  • Page 527

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C learanc e C heck Gene ral P r ocedures 1. Remove t he l e ft ha nd val ve co ver. For ad di t i o na l i nfo rm at i on, refe r t o Va l ve Co ver — LH 2. Remove t he right ha nd val ve cover . Fo r a ddi t i o nal i nfo r mat i on, ref[...]

  • Page 528

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C amsh afts LH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he t i mi ng chai ns. For a dd it i o nal i nfo r mat i on, ref e r t o Ti mi ng Dr ive Co mpone nt s . 2. Remove t he ca m s haf t be a r in g cap s e venl y. 3. Remove t he ca m s h[...]

  • Page 529

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Fro nt Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Cr a nk s ha f t Front S e a l Remo ver 303-700 Cr a nk s ha f t Front S e a l Ins t a l l e r 303-542 Cr a nk s ha f t Dampe r Ins t a l l e r 303-102 R em ova l 1. Remove t he [...]

  • Page 530

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Pu lley I n-v e hi c l e Re pa i r Speci al T ool (s) W r e nch s t r ap-uni vers al 303-D 055 Cr a n ks haf t Da mper Remove r 303-D 121 Thr us t P ad 303-D 121- 01 Cr a n ks haf t Da mper Ins t a l l e r Dr a w Bol t 303-102 Cr a n ks[...]

  • Page 531

    3. D i s conne ct t he cr a n ks haf t p o si t i on s e ns o r (CKP) e l e ct r ica l conne ct o r . 4. Remove t he CKP s e ns or. 5. D et a ch t he a cces s o r y d r i ve be lt . 1. Us i ng t h e s pe ci al t o ol , r ot a t e t he b e l t te ns i o ne r c o unt e r cl ockwis e . 2. De ta ch t he a cces s ory dr i vebe l t . 6. Usi ng t he s pe [...]

  • Page 532

    8. Usi ng t he s pe cia l t oo l s, re move t he cr anksh a ft vib rat i on dampe r. Insta llat ion 1. NOT E: Coa t t he cr a nks ha ft da mpe r keyway wit h s i l i cone gas ke t s e a l ant W S E- M4G 323-A6 o r equi va l e nt mee t i ng Ja guar s p e ci fi c a t io n. Us i ng t he s p e ci a l t o ol , i ns t a l l t he cr anksh a ft vib rat i o[...]

  • Page 533

    4. Ins t a l l the CKP . Ti ght e n t o 10 Nm. 5. Connect t he CKP el e ct r i cal co nnect o r. 6. Ins t a l l the s p l a s h s hi e ld . 7. Ins t a l l the whe e l a nd t i r e. Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S e cti o n 204-04 W hee l s a nd T ire s . JagDocs.com[...]

  • Page 534

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Re ar Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Cr anks haf t Re a r S ea l Re m over 303-566 Cr anks haf t Re a r S ea l I ns t a l l e r 303-178 Cr anks haf t Re a r S ea l I ns t a l l e r Ada pt e r Bo l t s 303-384 Cr anks[...]

  • Page 535

    3. NOT E: Al t e r nat e bo l t t i ght e ni ng t o corr e ct l y s e a t t he cr anks haf t r e a r oi l s ea l unt i l i t i s fl us h wi t h t he cyl in de r bl o ck . Us i ng t he s p e ci a l t o ol , i ns t a l l t he cr anksh a ft rear oi l s e a l . Vehi c le s With Manual Tra nsmi ss io n 4. Ins t a l l the f l ywhe e l . Fo r ad di t i o [...]

  • Page 536

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C ylinder Head LH I n-v e hi c l e Re pa i r R em ova l Vehi c le s with 2.5L or 3.0L engine 1. D i s conne ct t he e ngi ne co ol a nt t e mperat ur e (ECT) a nd f uel t e mperat ure s e ns o r (F TS) el e ct r ica l conne ct o r s . 2. D i s conn[...]

  • Page 537

    5. D et a ch t he f ue l chargin g wi ring harnes s . 2.5 a nd 3. 0L s hown, 2. 0L s i m i l a r . 6. W ARNING: Fue l m a y s t i l l be pres e nt i n t he f ue l i nj e ct i on s uppl y m a ni f ol d, e xt r eme c a re mus t be t a k en as t his coul d c a us e pe r s o na l i nj ury . Det ach t he f uel i nj e ct i on su ppl y mani fo l d, l o we[...]

  • Page 538

    10. Remove t he co o l a nt bypas s t ube. Re mov e a nd di s c a r d t he cool ant b ypa ss t ub e O -r i ng s e a l s . 11. Remove t he e xhaus t mani f o l d. Re mov e a nd di s c a r d t he e x ha us t m a ni f ol d g a s ket . 12. Remove t he l ef t -han d cams ha f t s . Fo r ad di t i on a l in f orm at io n, r e f er t o Ca m s ha f t . 13.[...]

  • Page 539

    5. Ins t a l l the co ol a nt by pa s s t ube . Ins t al l t he n e w coo la nt bypas s t ub e O -r i ng s ea l s. Ti ght e n t o 10 Nm. 6. Ins t a l l the wa t e r pump out l et p i pe. Ins t al l t he n e w wa t e r pump ou t l e t pi pe O -r i ng s e al s . Ti ght e n t o 10 Nm. 7. Ins t a l l the o i l l e v el i ndi c a t o r t ube . Ins t al [...]

  • Page 540

    10. At t ach t he f uel cha r ging wi ring ha r nes s . 2.5 a nd 3. 0L s hown, 2. 0L s i m i l a r . Vehi c le s with 2.0L engi n e 11. Conne ct t he co o l a nt t e mpe rat ur e (ECT) e l e ct r i cal c onn e cto r . Vehi c le s with 2.5L or 3.0L engine 12. At t ach t he f uel s e nso r vacuum l i ne . 13. Conne ct t he e l e ct r i cal conne ct o[...]

  • Page 541

    14. Conne ct t he e ngi ne co o l a nt t e mpe rat ur e (ECT) a nd f uel t e mperat ure s e ns o r (F TS) el e ct r ica l conne ct o r s . JagDocs.com[...]

  • Page 542

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Front C o ver I n-v e hi c l e Re pa i r R em ova l CAU TIO N : I t i s ne ce s s a r y t o r e move t h e e ngi ne i n o r de r t o r e move t he e ngi ne f r on t c o ve r . All v e h icle s 1. Usi ng a s ui t a bl e co nt a i ne r dr ai [...]

  • Page 543

    6. D i s conne ct t he t hr o t t l e po s i t i o n s e ns o r e l e ct r i cal c onn e cto r . 7. D et a ch t he cr uis e co nt rol ca b le . 8. D et a ch t he t hrot t l e ca b le . 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. De ta ch t he t hr ot t le cabl e . 9. D et a ch t he t hrot t l e ca b le ret [...]

  • Page 544

    11. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 12. Det a ch t he wi ring ha r nes s. Vehi c le s with 2.5L or 3.0L engine 13. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 14. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 15. Det a ch t he wi ring ha r nes s. JagDocs.com[...]

  • Page 545

    16. Det a ch t he vacuum hos e. All v e h icle s 17. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt a k e mani fo l d s uppo rt b r a cket . 18. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt a k e mani fo l d s uppo rt b r a cket . 19. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt [...]

  • Page 546

    20. Dis c o nne ct t he l ef t -han d i g nit i o n coi l e l e ct r i c a l co nnect o rs. 21. Remove t he l ef t -han d i g nit i o n coi l s . 22. Dis c o nne ct t he va r i a bl e ca m s ha f t t i m i ng (VCT) s o l e no i d e l ect r i cal conne ct or. 23. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Di s conn ect t he cams ha f t [...]

  • Page 547

    Vehi c le s with 2.0L engi n e 26. Det a ch t he hea t ed pos i t i ve cr an k cas e vent i l a ti on val v e cool ant h os e s . All v e h icle s 27. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Det ach t he co ol a nt h os e . 28. Remove t he l ef t -han d va l ve cover. Re mov e a nd di s c a r d t he val ve cove r g a ske t s. 29. Dis c o [...]

  • Page 548

    30. Remove t he rig ht -ha nd i g ni t i o n coi l s . 31. Det a ch t he wi ring ha r nes s. 32. Dis c o nne ct a nd repos i t i on the v a r i a bl e ca ms ha ft t i mi ng (VCT) s ol e no i d e l e ct r i cal conne c t o r . 33. Remove t he e n gi ne co ver r e ta i ni ng br a cket . 34. Repo s i t i o n t he right -hand wi ring ha r nes s f or ac[...]

  • Page 549

    35. Remove t he rig ht -ha nd val ve cover . Re mov e a nd di s c a r d t he val ve cove r g a ske t s. 36. Det a ch t he acce s s o r y driveb e l t . 1. Us i ng t h e s pe ci al t o ol , r ot a t e t he b e l t te ns i o ne r c o unt e r- cl ockwis e . 2. De ta ch t he a cces s ory dr i vebe l t . 37. Remove t he a cces s o r y drive be l t t e n[...]

  • Page 550

    40. Dis c o nne ct t he g e ne r at o r po s i t i ve ca bl e e l e ct r i cal conne cto r. 41. Dis c o nne ct t he g e ne r at o r e l e ct r i cal conne cto r. 42. Remove t he g e ne r at o r. 43. Us i ng t he s pe ci a l t o o l , r e move t he cr anksha ft vi br a t i o n da mper r et a i ni ng b ol t . Re mov e a nd di s c a r d t he cr a n k [...]

  • Page 551

    45. Remove t he CKP . 46. Ins t a l l t he s p e cia l t o o l . 47. Us i ng t he s pe ci a l t o o l s , re m o v e t he cr anks ha ft vib rat i o n dampe r. 48. Remove t he a i r cond i t i o ni ng co m pr es s or . 49. Remove t he p o we r s t e e r i ng pump. JagDocs.com[...]

  • Page 552

    50. Remove t he o i l pa n . Re mov e a nd di s c a r d t he o il pa n g a ske t . 51. Remove t he i dl e r pul l e y. 52. Remove t he i dl e r pul l e y. 53. Remove t he e n gi ne f r o nt co ver. Re mov e a nd di s c a r d t he e ngi ne front cove r g as ke t s . Insta llat ion All v e h icle s JagDocs.com[...]

  • Page 553

    1. Ins t a l l the ne w f ront t imi ng co v e r gas ket s . 2. NOT E: Prio r t o a p pl yin g s e a l e r cle a n t he f ront t imi ng co ver t o e ng ine bl o ck a nd cyli nd e r he a d s e a l i ng s urface s wi t h met a l s ur face cle a ne r . • NO T E: Ap pl y a 6 mm di a met er do t o f s i l icone se al a nt W S E-M4G 32 3-A6 o r e qui v[...]

  • Page 554

    5. Ins t a l l the i dl e r p ul l e y. Ti ght e n t o 25 Nm. 6. NOT E: Appl y a 10 mm dia me t e r dot of s i l i co ne s e al a nt W S E-M 4G323- A6 or eq ui val ent mee t i ng Ja gua r s pe ci fi cat io n t o t h e e ng i ne f r on t cover t o th e c yl i nde r bl o ck mat i ng j o i nt s . • NO T E: L oos e l y i ns t a l l t he o i l p a n t[...]

  • Page 555

    10. Us i ng t he s pe ci a l t o o l , t i ght e n t he c r a nk s ha f t vibra ti on d ampe r r et a i ni ng b ol t . Ins t al l a ne w cr anks haf t vib r a t i o n ret a i ni ng bo l t . Compl e t e t he ti ght e ni ng s e que nce. S ta g e 1: T o r que t o 120 N m . S ta g e 2: L o o se n t he b ol t (mi ni mum 1 t ur n) . S ta g e 3: T o r que[...]

  • Page 556

    15. Conne ct t he g e ne r a t or po s i t i ve ca bl e . Ti ght e n t o 12 Nm. 16. At t ach t he g e ne r a to r po s i t i ve ca bl e prot e ct i ve cove r . 17. At t ach t he a cces s or y drive be l t . 18. Ins t a l l t he a cc e s s o r y drive b e l t t e nsi o ner. Ti ght e n t o 47 Nm. 19. At t ach t he a cces s or y drive be l t . 1. Us i[...]

  • Page 557

    20. NO TE: Ap pl y a 5 mm di amet e r b e ad o f s i li cone ga s k et s e a l a nt W S E- M4G 323-A6 o r equi va l e nt mee t i ng Ja guar s p e ci fi c a t io n on t he ha l f r o und g a s ket s a nd a ppl y a n 8 m m di a met e r be a d o f s i l i cone gas ke t s ea l ant o n th e t wo pl ace s whe r e t he cyl i n der he a d a nd f r ont t i [...]

  • Page 558

    Vehi c le s with 2.0L engi n e 25. Ins t a l l t he he a t e d po s it i ve crank ca s e ve nt i l a t i o n val ve cool a nt ho s e s . All v e h icle s 26. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he (CMP) s e mso r s . Ti ght e n t o 7 Nm. 27. NO TE: Ri ght -hand s ho wn, l e ft ha nd s i m i l ar. Conn ect t he cams[...]

  • Page 559

    29. Ins t a l l t he l e f t -hand ig ni t io n c oi l s . Ti ght e n t o 6 Nm. 30. Conne ct t he l e f t -ha nd i g ni ti on coi l s e l ect r i cal conne cto rs. 31. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. • NO T E: T he i nt a k e mani fo l d ret a i ni ng bo l t s num be red 1, 2 a nd 3 a re lo ng e r t ha n t he r e t a i ni ng bo [...]

  • Page 560

    34. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Ti ght e n t o 6 Nm. Vehi c le s with 2.5L or 3.0L engine 35. Conne ct t he va cuum h os e . 36. At t ach t he wi r i ng harnes s . Ti ght e n t o 10 Nm. 37. Conne ct t he e l e ct r i cal conne ct o rs. 38. Conne ct t he e l e ct r i cal conne ct o rs. Vehi c le s with 2.0L engi n e JagDocs.com[...]

  • Page 561

    39. At t ach t he wi r i ng harnes s . 40. Conne ct t he e l e ct r i cal conne ct o rs. 41. Ins t a l l t he coo l a nt hos e s . 42. At t ach t he t hr ot t l e cabl e br acket . Ti ght e n t o 9 Nm. 43. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. At t a ch t he t hrot [...]

  • Page 562

    44. At t ach t he cr ui s e cont r ol cab l e . 45. Conne ct t he t hr ot t l e po s i t i o n s e ns o r e l e ct r i cal c onn e cto r . 46. Conne ct t he i dl e a ct ua t or co ntrol val v e e l e ct rical co nnect or . 47. At t ach t he p o s i t i ve cr a n k cas e veni l a t i on ho se . Vehi c le s with 2.5L or 3.0L engine JagDocs.com[...]

  • Page 563

    48. At t ach t he p o s i t i ve cr a n k cas e vent i l at i o n hos e . All v e h icle s 49. Ins t a l l t he a ut omat i c or manua l t rans mis s io n. For a dd it i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 307-01A Aut omat i c Tr an s mi s s i o n/T r a nsa xl e S e ct i on 307-01B Aut o mat ic Tr an s mi s s i o n/T r a nsa xl e [...]

  • Page 564

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Front Mount I n-v e hi c l e Re pa i r Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-0 2 R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o . For a ddi ti ona l i nf o r[...]

  • Page 565

    4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 5. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 6. D et a ch t he coo l a nt pi p e . 7. Remove t he e ngi ne s up port b r acket . JagDocs.com[...]

  • Page 566

    8. Remove t he e ngi ne mount . 9. Remove t he hydr o mount . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 83 Nm. 2. Tig ht e n t o 80 Nm. JagDocs.com[...]

  • Page 567

    3. Tig ht e n t o 80 Nm. 4. Tig ht e n f ixi ngs t o 40 N m o r 48 Nm a s o ut l ine d b e l o w. • NO T E: I f r e usi ng e xis t i ng f i xi ngs , o n vehi cl es bui l t prio r to V IN J24252, t ig ht e n t o 48 Nm. I f ne w fi x i ng s a r e us e d o n a ny vehi cl e t i ght e n t o 40 N m . 5. Tig ht e n t o 9 Nm. 6. F i l l a nd bl e e d t h[...]

  • Page 568

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Ex haust Manifo ld LH I n-v e hi c l e Re pa i r R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o S e c t i o n 303-03A Engi ne Co o l i ng S ect i o n 303-03B Engi ne Co o li ng . 2. Remove t [...]

  • Page 569

    8. D et a ch t he coo l a nt ho s e. 9. Rai s e t he vehi cl e. 10. Remove t he co o l a nt hos e . 11. Dis c o nne ct t he he a te d o xygen s ens or (HO2S) el e ct r ica l conne ct o r . 12. Remove t he e xhaus t mani f o l d he a t s hie ld r et ai ni ng bo l t . 13. Lowe r t he vehi c l e . JagDocs.com[...]

  • Page 570

    14. Remove t he e xhaus t mani f o l d he a t s hie ld . 15. Det a ch t he cat al yti c conver t e r . Dis car d t he ret a i ni ng nut s . Re mov e a nd di s c a r d t he r et a i ni ng s t uds . 16. Us i ng a s uit a bl e t o ol remove t he HO 2S . 17. Remove t he e xhaus t mani f o l d. Re mov e a nd di s c a r d t he e x ha us t m a ni f ol d g[...]

  • Page 571

    1. Ins t a l l the e xha us t mani fo l d. Ins t al l t he n e w e xhaus t m a ni fo l d g a ske t . Compl e t e t he ti ght e ni ng s e que nce. Ti ght e n t o 20 Nm. 2. Ins t a l l the H02S. Ti ght e n t o 40 Nm. 3. NOT E: Make s ure t ha t t he r e t a ini ng nut s a r e ti ght e ned twi ce i n th e s eq ue nce sho wn. At t a ch t he cat a l yt [...]

  • Page 572

    7. Connect t he he a t e d oxygen s e nso r (HO 2S ) e l ect r i cal co nne cto r. 8. Ins t a l l the co ol a nt hos e . 9. Lowe r t he vehi cl e . 10. At t ach t he co o l a nt hos e . 11. Ins t a l l t he coo l a nt p ip e ret a ini ng br a ck et . Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 573

    12. At t ach t he co o l a nt pi p e . 13. At t ach t he co o l a nt hos e . 14. Ins t a l l t he a ir f i l te r ret a i ni ng br acket . 15. At t ach t he g e ne r a to r wi r i ng ha r ne s s . 16. Ins t a l l t he a ir f i l te r i nt a ke pi pe . JagDocs.com[...]

  • Page 574

    17. Ins t a l l t he coo l i ng fa n mot o r a nd s hroud. For a ddi ti o nal i nfo r mat i o n, r ef e r t o S ect i o n 303-03A Engi ne Coo l i ng S e ct i on 303-03B Engi ne Coo l i ng . 18. Fi ll a n d b l e e d t he co ol i ng s ys t e m. Fo r a d di t i ona l i nfo r mat i o n, refe r to S ect i o n 303-03 A Engi ne Co ol i ng Sect i on 303-0[...]

  • Page 575

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Flexplate I n-v e hi c l e Re pa i r R em ova l 1. Remove t he a ut omat i c t rans mi s s i o n. Fo r a d di t i o nal i nfo r mat i o n, refe r t o S ect i on 307-01A Aut omat i c Tr a nsmi s s i o n/Trans a xle Sect i o n 307-01B Aut o mat ic Tr[...]

  • Page 576

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Ex haust Manifo ld RH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he t hree wa y cat al yti c conver t e r (TW C). For add i t i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 309-00 Exhaus t Sy s t e m . 2. D i s conne ct t he he a t [...]

  • Page 577

    2. Tig ht e n t o 40 Nm. 3. Ins t a l l the t hr ee wa y cat al yti c conve r t e r (TW C). Fo r add it i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 309-00 Exhaus t Sy s t e m . JagDocs.com[...]

  • Page 578

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Flyw he el I n-v e hi c l e Re pa i r R em ova l 1. Remove t he clut ch d i s c a n d p r e s s ur e pl at e . For ad di t i ona l inf o rm a t i o n, r ef e r t o S ect i o n 308-01 Cl ut ch . 2. NOT E: Pre v en t t h e fl ywhee l f r om r ot at i[...]

  • Page 579

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Intake Man ifo ld I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1. Remove t he e ngi ne cover (if e q uip pe d ). 2. Remove t he a i r fi l t e r out l e t pi p e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r Ou[...]

  • Page 580

    6. D et a ch t he cr uis e co nt rol ca b le . 7. D et a ch t he t hrot t l e ca b le . 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. De ta ch t he t hr ot t le cabl e . 8. D et a ch t he t hrot t l e ca b le ret a i ni ng br acket . 9. D i s conne ct t he t hr o t t l e bo dy e l e ct r i cal conne ct or. 10[...]

  • Page 581

    11. Dis c o nne ct t he e l e ct r ica l conne ct o r s . Vehi c le s with 2.5L or 3.0L engine 12. Dis c o nne ct t he t hr ot t l e bo dy el e c t r i cal co nne ct ors . 13. Dis c o nne ct t he e l e ct r ica l conne ct o r s . All v e h icle s 14. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Det ach t he vacuum ho se s . 1. P r es s t he r [...]

  • Page 582

    15. Det a ch t he coo l a nt ho se from t he ret a i ni ng cl i ps . Vehi c le s with 2.5L or 3.0L engine 16. Dis c o nne ct t he va cuum ho s e . All v e h icle s 17. Det a ch t he i nj e cto r ha r nes s e l e ct rica l c on ne ct or from t he i nta ke m a ni f o l d s upp o r t bracket . 18. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re m[...]

  • Page 583

    19. NO TE: 2. 0L s hown , 2.5L a nd 3.0L s i mil a r. Det ach t he e ngi ne wi r i ng ha r ne ss br a ck et . 20. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Det ach t he i nt a ke m a ni f o l d s upp ort br a cket . Vehi c le s with 2.0L engi n e 21. W ARNIN GS : Ne ver r e move t he coo l a nt e xpans i on ta nk pr es s ur e ca p unde r an[...]

  • Page 584

    23. NO TE: Re move a nd di s ca r d the O -ring s e a l . Det ach t he t hr o t t l e b ody. Re mov e t he re ta i ni ng bo l t s. All v e h icle s 24. Remove t he i nt a ke mani f o l d. Re mov e a nd di s c a r d t he i nt a ke m a ni fo l d g a ske t s. Insta llat ion All v e h icle s 1. NOT E: Ins t a l l ne w i nt a ke mani fo l d gas ket s . [...]

  • Page 585

    3. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . • NO T E: Do no t ful l y t i g ht en t he r e ta i ni ng bo l t s . I nst a l l t he i nt a k e mani fo l d s uppo rt b r ack e t . 4. NOT E: The i nt a ke mani fo l d r et ai ni ng bo l t s i n p o si t i o n 1, 4 a nd 5 a re lo ng e r t ha n t he r e t a i ni ng bo l t s i n po s i t i o n 2[...]

  • Page 586

    Vehi c le s with 2.5L or 3.0L engine 8. NOT E: Ins t a l l a new O -r i ng s e a l . At t a ch t he t hrot t le bod y. Ins t al l t he re t a i ni ng b ol t s . 9. Connect t he vacuum ho se . All v e h icle s 10. At t ach t he wi r i ng harnes s . Ti ght e n t o 10 Nm. 11. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. At t a ch t he vacuum hos [...]

  • Page 587

    12. NO TE: Re move t he co ol a nt hos e ca p s. At t a ch t he i nt a k e mani fo l d cool a nt hos e s . 13. At t ach t he co o l a nt hos e t o t he ret ai ni ng cl ip s . 14. Conne ct t he e l e ct r i cal conne ct o rs. Vehi c le s with 2.5L or 3.0L engine 15. Conne ct t he e l e ct r i cal conne ct o rs. JagDocs.com[...]

  • Page 588

    16. Conne ct t he t hr ot t l e bo dy e l e ct r i cal conn ect ors . Vehi c le s with 2.0L engi n e 17. Conne ct t he t hr ot t l e bo dy e l e ct r i cal conn ect or. 18. Conne ct t he t hr ot t l e bo dy e l e ct r i cal conn ect or. 19. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket . JagDocs.com[...]

  • Page 589

    20. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. At t a ch t he t hrot t l e ca b le . 21. At t ach t he cr ui s e cont r ol cab l e . 22. At t ach t he p o s i t i ve cr a n k cas e vent i l at i o n hos e . 23. Fi ll t he cool i ng s ys t e m up t o th e MAX mar k on th [...]

  • Page 590

    25. Ins t a l l t he po s i t i ve cr ankc a s e ve nt i l a t i o n ho s e. All v e h icle s 26. Ins t a l l t he a ir f i l te r o ut l e t pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r Out l e t P i pe (303-12A I nt a ke Ai r Di s t ribut i o n a nd Fi l t e r i ng - 2.0L NA V6 - AJV6/2.5L N A V6 - AJV6/3.0L N A[...]

  • Page 591

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Lo w e r Intak e Manifo ld I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1. Remove t he i nt a ke man if ol d . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: I nt a ke Ma nif ol d (303-01A Engi n e - 2.0L N A V 6 - A JV6/2.5L NA [...]

  • Page 592

    6. Remove t he e ngi ne cover ret a i nin g b r a cket (i f equi p pe d). 7. D i s conne ct t he f uel i nj e ct or ha r nes s e l e ct rica l conne ct or . 8. W ARNING: Fue l m a y s t i l l be pres e nt i n t he f ue l i nj e ct i on s uppl y m a ni f ol d. • NO T E: Re move a nd di s card t he l o we r int a k e mani f ol d O -r i ng s e al s [...]

  • Page 593

    2. Connect t he f ue l i nj e ct o r ha r ne s s e l e ct rica l conne ct o r . 3. Ins t a l l the e ng ine co ver ret a i ni ng br acket (i f e qui pp e d). Vehi c le s with 2.0L engi n e 4. Connect t he e ngi ne co ol a nt t empe rat ure (ECT) e l e ct rica l c o nne ct or . At t a c h t he ha r nes s . Vehi c le s with 2.5L or 3.0L engine 5. Con[...]

  • Page 594

    6. Connect t he e ngi ne co ol a nt t empe rat ure (ECT) a nd f uel t e mpe r at ure s e ns o r e le ctrica l conne ct o r s . 7. Connect t he s p r i ng lo ck co upl i ng. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Spr i ng L ock Co upl i ngs (310-00 Fue l S yst e m - Ge neral I nf o rm a t i o n, Ge ne r a l P roc e dur e s ). 8. Ins[...]

  • Page 595

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il Co o ler I n-v e hi c l e Re pa i r R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o S e c t i o n 303-03A Engi ne Co o l i ng S ect i o n 303-03B Engi ne Co o li ng . 2. D r ai n t he e n[...]

  • Page 596

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il P an I n-v e hi c l e Re pa i r Speci al T ool (s) Acces s o r y Bel t De t e ns i o ner 303-703 R em ova l All v e h icle s 1. D r ai n t he e ngi ne oi l . Vehi c le s with 2.5L or 3.0L engine 2. Remove t he t r a ns f e r cas e . Fo r a ddi[...]

  • Page 597

    6. Remove t he s ump t o t r ans m i s s i on se cur i ng bol t . 7. S l a cken b ut no t r emove t he u ppe r cat a l y s t ret a i ni ng b r acket s u pport s e cur ing b ol t . 8. Repo s i t i on t he ca t a l ys t ret a i ni ng br acket s upport. All v e h icle s 9. D et a ch t he a cces s o r y d r i ve be lt . 1. Us i ng t h e s pe ci al t o [...]

  • Page 598

    10. NO TE: Do not remove t he A /C compr es s o r uppe r r et a i ni ng bol t s . Re po s i t i o n t he a i r condi t i oni ng (A/C) compr es s o r . 1. Re move t he A /C compr es s o r lo we r ret a i ni ng bo l ts . 2. Lo os e n t he A/C co mpr e s s o r upp e r r e t ai ning b ol t s . 11. Remove t he a cces s cover. Vehi c le s with 2.0L engi [...]

  • Page 599

    14. Remove t he o i l pa n . Re mov e a nd di s c a r d t he gas ke t. Cle a n a nd i nsp e ct t he o i l pa n a nd t he cyli nd e r b l ock s e al in g s ur fa ce s us ing met a l s urface cle a ner or e qui va le nt mee t i ng Jagua r s pe ci f i ca ti o n W SE-M 5B392- A. Insta llat ion All v e h icle s 1. NOT E: Appl y a 10 mm dia me t e r dot [...]

  • Page 600

    4. Tig ht e n t o 10 Nm. 5. Tig ht e n t o 25 Nm. Vehi c le s with 2.0L engi n e 6. Tig ht e n t o 25 Nm. 7. Tig ht e n t o 45 Nm. JagDocs.com[...]

  • Page 601

    8. Tig ht e n t o 25 Nm, 9. Tig ht e n t o 55 Nm. 10. Ti g ht e n t o 55 N m. Vehi c le s with 2.5L or 3.0L engine 11. Ins t a l l t he t r a ns f e r cas e . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Sect i on 308-07 Trans f er Cas e . All v e h icle s 12. NO TE: U s e o i l W S E- M2C908- A or eq uiva l e nt mee t i ng Ja gua r s pe [...]

  • Page 602

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il P ressure Sender I n-v e hi c l e Re pa i r R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 100-02 Ja cking a nd L i f t i ng . 2. Remove and di s card t he oi l fi l t e[...]

  • Page 603

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il P um p I n-v e hi c l e Re pa i r R em ova l 1. Remove t he t i mi ng chai ns. For a dd it i o nal i nfo r mat i on, ref e r t o Ti mi ng Dr ive Co mpone nt s . 2. Remove and di s card t he eng i ne o i l fi l t e r . 3. Remove t he oi l p ump[...]

  • Page 604

    2. Ins t a l l the o i l pump t ube . Ins t al l a ne w O -r i ng s e a l . Ti ght e n t o 10 Nm. 3. Tig ht e n t o 5 Nm + 45°. 4. Ins t a l l a ne w e ngi ne o i l f i l t e r. 5. Ins t a l l the t imi ng chai ns . Fo r add i t i o nal i nf or ma ti on, re fe r to T i m i n g Dr ive Co mpone nt s . JagDocs.com[...]

  • Page 605

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Ti mi ng Drive C om ponents I n-v e hi c l e Re pa i r R em ova l 1. Remove t he e ngi ne f r ont co v e r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Eng i ne Fr ont Co ver (303-01A Engi ne - 2. 0L NA V6 - AJV6/2.5L NA V 6 - A JV6/3.0[...]

  • Page 606

    7. NOT E: Ke e p t he t imi ng chai n t ens i o ne r r a t che t rel e a s e d. Re po s i t i o n t he t i ming chai n t e ns i o ne r pl unger. 8. Ret a i n t he t imi ng chai n t e ns i one r plun ge r . 9. Remove t he right -ha nd t i mi ng chai n t e ns i o ne r . 10. Remove t he rig ht -ha nd t i ming c ha i n o ut e r g ui de . 11. Remove t h[...]

  • Page 607

    12. CAUT I O N: I ns p e ct a nd repl a ce the O -r ing s e a l i f ne ces s a r y. Re move t h e r i ght -ha nd t i mi ng cha i n i nner gui de . 13. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e. Rot at e t he cr anksha f t c l o ckwis e unt il t he cr anksha [...]

  • Page 608

    17. Remove t he l ef t -han d t i mi ng cha i n t e ns i o ne r . 18. Remove t he l ef t -han d t i mi ng cha i n i nne r g ui de . 19. Remove t he l ef t -han d t i mi ng cha i n. 20. CAUT I O N: I ns p e ct a nd repl a ce the O -r ing s e a l i f ne ces s a r y. Re move t h e l e f t -han d t i ming cha i n out e r gui de . 21. CAUT I O N: Ma k e[...]

  • Page 609

    22. Remove t he cr anks haf t s pr ocket . Insta llat ion 1. NOT E: Make s ure t he cr anks ha ft s pr ocket t i ming marks a r e f a cing out wa r ds . I nst a l l t he cr an k s ha ft s procket . 2. CAU TI O N : Make s ur e t h e cr anksh a ft k e yway i s a t t he 9 O 'c l ock pos i t i on b ef o r e the ca msha ft po s it i o ns a r e al i[...]

  • Page 610

    4. Rot a t e t he right -hand i nt a k e c a msha f t c l ockwi s e unt i l t he cams ha ft s p r o cket a l i gnment ma r k i s a t t he 5 O' c l o ck pos i t i o n a nd rot a t e t he r i ght -ha nd e xhaus t c a m s ha f t s p r ocket c l o ck wi s e unt il t he camsha f t s p r o cket a l i gnment ma r k i s a t t he 12 O'cl ock po s [...]

  • Page 611

    9. CAU TI O N : Do no t manual l y a dj us t t he t i mi ng chai n t ens i one r . I nst a l l t he l e f t-ha nd t i ming cha in t e ns i o ne r . Ti ght e n t o 25 Nm. 10. CAUT I O N: Do no t manu al l y a d j us t t he t i mi ng cha i n t ens i o ne r . Make s ur e t he l e ft -han d t i mi ng cha i n a l i g nment marks ha ve r ema i ne d cor r[...]

  • Page 612

    14. CAUTI O N S : Make s ur e t he cr anks ha f t keyway i s a t t he 3 O 'c l ock p os i t io n, the a li g nment mark o n t he r i ght -han d i nt a ke ca msh af t s pr ock e t i s a t the 5 O'clo ck po s i t i o n a nd t he a l ig nment mark o n t he r i ght -ha nd e xhaus t c a msha f t sp roc ket is a t t he 12 O 'cl ock po s i [...]

  • Page 613

    19. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e. • NO T E: Ro t a t e t he cr a nk s ha ft u s i ng ha nd t oo l s o nl y Rot at e t he cr anksha f t t wo c ompl et e t ur ns cl o ckwis e t o make s ur e t he val ve s a nd p i s t ons do n ot cl as h. 20. CA[...]

  • Page 614

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C o v er LH I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1. Remove t he i g ni t i o n coi l s . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o S ect i o n 303-07A Engi ne I g ni t io n S ect i o n 303-07B Gl o w P l ug S[...]

  • Page 615

    6. D et a ch t he po s i t i ve cr a nk cas e ve nt i l a t i o n ho se . 7. D et a ch t he he a t e d po si t i v e cr ankc a s e ve nt il a t i on val ve coo l ant p i pe s . All v e h icle s 8. D i s conne ct t he var i a bl e ca ms haf t t i ming (VCT) s o l e no i d e l ect r i cal conne ct or. 2.5 a nd 3. 0L s hown, 2. 0L s i m i l a r . 9. D[...]

  • Page 616

    10. Remove t he va l ve cover. Re mov e a nd di s c a r d t he val ve cove r g a ske t s. 1. 2.5 and 3.0L sh o wn, 2.0L s i m i l a r. Insta llat ion 1. NOT E: Appl y a 5 mm di ame t e r be ad o f si l i c one ga s k e t s e a la n t W S E- M4G 323-A6 o r equi va l e nt mee t i ng Ja guar s p e ci fi c a t io n on t he ha l f r o und g a s ket s, a[...]

  • Page 617

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C o v er RH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he i g ni t i o n coi l s . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o Sect i on 303-07A Engi ne I g ni t io n S ect i o n 303-07B Gl o w P l ug S ys t e m . 2. D et[...]

  • Page 618

    [...]

  • Page 619

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gineVehi cles With: 5-Spee d Manual Transm i ssi on - MT7 5/ 6-Spe ed Manual T ransaxl e - MM T6 Re moval Speci al T ool (s) P owe r t rai n A s s embl y Ja ck HTJ1200-2 5 P oi nt S ecur i t y Torx Bit 418-535 Ba l l j o i nt s pl i tt e r 204-1[...]

  • Page 620

    Ri g ht -hand ha l f s haf t s pl i t t e r 307-442 Ri g ht -hand ha l f s haf t s pl i t t e r ha nd le 307-443 P i ni o n oi l s e a l r e m o ver 308-208 Li nk s ha f t l i mi t i ng t o ol 307-446 Engi ne l i f t i ng kit 303-707 R em ova l All v e h icle s 1. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e n t he f r ont hub[...]

  • Page 621

    For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Co ndi t io ni ng (A/C) S ys t e m Re cover y, Eva cuat i on a nd Cha r ging (412- 00 Cl imat e Co nt r o l S ys t em - Gene r a l I nf o r m at i o n, Ge neral Proced ur e s ). 6. Remove t he f r ont whe e ls a nd t i res . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l[...]

  • Page 622

    12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 13. NO TE: Suppor t t h e br a ke ca l ip e r as s e mbl y us ing t i e s t r a p s . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re po s i t i o n a n d s e cur e t he br a ke cal i p e r a s s e mbl y. 14. NO TE: L e ft -hand s h own, r i g ht -[...]

  • Page 623

    17. Remove t he co o l i ng f a n mot o r a nd s hroud. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Fan Mot o r a nd Shr o ud (303-03 A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V 6 - A JV6/3 .0L NA V6 - AJ27, Remova l a nd I ns t a ll a t i o n). Vehi c le s with 2.5L or 3.0L engine 18. Remove t he d rives ha ft . For[...]

  • Page 624

    25. Det a ch t he coo l a nt ho se . 26. Det a ch t he coo l a nt ho se . 27. Det a ch t he coo l a nt ho se s . Vehi c le s with 2.0L engi n e 28. Det a ch t he cr uis e co nt r ol ca bl e . JagDocs.com[...]

  • Page 625

    29. Det a ch t he acce l e r at o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n. 2. De ta ch t he a ccel e rat o r cabl e . 30. Det a ch t he acce l e r at o r cab l e r et ai ni ng bracket . 31. Det a ch t he coo l a nt ho se s . All v e h icle s 32. Det a ch t he ba t t e ry cab l e s. JagDo[...]

  • Page 626

    33. NO TE: U pp e r s el e ct or cabl e s hown, l ow er s e l e ct o r cab l e s i mil ar. Det ach t he s e le cto r cabl e s. 1. P r es s t he but t o n. 2. De ta ch t he s e l e ct or cabl e s . 34. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps . Det ach t he s e le cto r cabl e s. 35. CAUT I O N: I f brake fl ui d i s s pi lt [...]

  • Page 627

    38. Us i ng s pe ci a l t ool 418-535, di s conne ct th e e ng i ne co nt rol modul e (ECM) e l e c t r i cal co nne ct or. 39. Dis c o nne ct t he g round cab l e . 40. NO TE: Drai n t he f lui d i nt o a s ui t a bl e co nt a i ne r. • NO T E: U s e a s ui t a bl e b l a nking pl ug t o s e a l t h e ho s e . Det ach t he po we r s t e e r i ng[...]

  • Page 628

    43. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he s t r ut a nd s pr ing as s e m bl y. 44. Rai se th e v e hi cl e . 45. Ins t a l l t he s p e cia l t o o l . 46. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 47. NO TE: Ri ght -hand [...]

  • Page 629

    48. Po s i t i o n and adj ust t he s p e ci al t oo l e ngi ne he i ght a d j us t e r s . 49. Remove t he e n gi ne s upp ort br a cket . 50. Remove t he t r ans a x l e mount br a ck et s e cur ing nut . 51. Remove t he cl ut ch mas t e r cyli nd e r t o cl ut ch s l a ve cyli nde r hi gh-pr e s s ure pi pe s u pport b r acket . 52. NO TE: L e f[...]

  • Page 630

    53. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e . 54. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he f r ont s ubf r ame. 55. W A RNING: Ro t at e t he s pe ci al t o o l he i ght a dj us t ment val v e s l o wl y. Fa il ure t o f ol lo w thi s i ns truc t i [...]

  • Page 631

    58. Ins t a l l t he s p e cia l t o o l . 59. Remove t he l ef t -han d e xhaus t mani f o l d he a t s hi e l d. 60. Ins t a l l t he s p e cia l t o o l . 61. Remove t he up pe r exha us t he a t s hie ld . JagDocs.com[...]

  • Page 632

    62. Remove t he ce nt e r e xhaus t he at s hi e l d ret a i ni ng bol t s . 63. Remove t he ce nt e r e xhaus t he at s hi e l d . 64. Ins t a l l t he s p e cia l t o o l . 65. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front wh ee l hub ret a i ni ng nut s . JagDocs.com[...]

  • Page 633

    66. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Us i ng t he s p e ci a l t o ol s , de ta ch t he hal fs ha ft s . 67. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e t i e rod e nd r et a i ni ng nut s. 68. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Us i ng t he s p e ci a l t o ol , d e t a ch t he [...]

  • Page 634

    71. Us i ng t he s pe ci a l t o o l s , re m o v e t he l e ft -han d ha l f s haf t . 72. Remove a nd di s car d t he hal fs ha ft s na p r i ng. 73. Remove t he p o we r s t e e r i ng hi gh-pres s ur e pi p e ret a i ni ng bol t . 74. Dis c o nne ct t he p o we r s t e e r i ng hi gh-pres s ur e pi p e . Re mov e a nd di s c a r d t he O -r ing[...]

  • Page 635

    75. Ins t a l l t he s p e cia l t o o l . 76. Remove t he e n gi ne rol l r e s t r i ct o r r e t ai ni ng bo l t . 77. Remove t he e n gi ne rol l r e s t r i ct o r . JagDocs.com[...]

  • Page 636

    78. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent . Us i ng t he s p e ci a l t o ol , re mov e t he e ng i ne and t rans a xle f r om t he s ub frame. Vehi c le s with 2.0L engi n e 79. Remove t he ha l f s ha[...]

  • Page 637

    81. Remove t he t r ans fe r ca se Y b r acket . 82. Remove t he ha l f s haf t s ea l . 83. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.87 i nches ) from t he t r a ns f e r cas e . Us i ng t he s p e ci a l t o ol s , r em[...]

  • Page 638

    86. Dis c o nne ct t he rig ht -ha nd h ea t e d oxy ge n s e n s or (HO 2S ) e l e ct rical conne ct or. 87. Remove t he rig ht -ha nd cat a l yti c co nver t e r r et a i ni ng b o l t s . 88. Remove t he rig ht -ha nd cat a l yti c co nver t e r . Re mov e a nd di s c a r d t he r et a i ni ng nut s . 89. Remove a nd di s car d t he c a t a l yt[...]

  • Page 639

    91. Us i ng t he s pe ci a l t o o l , det a ch t he t r a ns fe r ca s e l i nk sha f t. 92. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.87 i nches ) from t he t r a ns f e r cas e . Us i ng t he s p e ci a l t o ol , p a r[...]

  • Page 640

    95. Remove t he t r ans fe r ca se . 96. Remove a nd di s car d t he t r ans f er cas e O -r i ng s e a l . 97. Remove a nd di s car d t he li nk s ha ft s na p ring. 98. Remove t he l i nk s ha f t l imi t i ng to o l . 1. Re move t he r e t a i ni ng bo l t . 2. Re move t he l i nk s ha f t l i mi t i ng t o ol . 99. Remove t he l i nk s ha f t .[...]

  • Page 641

    [...]

  • Page 642

    104 . Re move t he t r a ns axl e r et a i ni ng bol t s . 105 . Re move t he t r a ns axl e r et a i ni ng bol t s . 106 . Re move t he t r a ns axl e. JagDocs.com[...]

  • Page 643

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gineVehi cles With: 5-Spee d Autom atic T ransa xle - JATC O / 6-Sp eed Autom atic T r ansaxl e - AWF 21 Re moval Speci al T ool (s) P owe r t rai n A s s embl y Ja ck HTJ1200-2 5 P oi nt S ecur i t y Torx Bit 418-535 Ba l l j o i nt s pl i tt e[...]

  • Page 644

    Ri g ht -hand ha l f s haf t s pl i t t e r 307-442 Ri g ht -hand ha l f s haf t s pl i t t e r ha nd le 307-443 P i ni o n oi l s e a l r e m o ver 308-208 Li nk s ha f t l i mi t i ng t o ol 307-446 Engi ne l i f t i ng kit 303-707 R em ova l All v e h icle s 1. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e n t he f r ont hub[...]

  • Page 645

    For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Co ndi t io ni ng (A/C) S ys t e m Re cover y, Eva cuat i on a nd Cha r ging (412- 00 Cl imat e Co nt r o l S ys t em - Gene r a l I nf o r m at i o n, Ge neral Proced ur e s ). 6. Remove t he f r ont whe e ls a nd t i res . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l[...]

  • Page 646

    12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 13. NO TE: Suppor t t h e br a ke ca l ip e r as s e mbl y us ing t i e s t r a p s . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re po s i t i o n a n d s e cur e t he br a ke cal i p e r a s s e mbl y. 14. NO TE: L e ft -hand s h own, r i g ht -[...]

  • Page 647

    17. Remove t he co o l i ng f a n mot o r a nd s hroud. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Fan Mot o r a nd Shr o ud (303-03 A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V 6 - A JV6/3 .0L NA V6 - AJ27, Remova l a nd I ns t a ll a t i o n). Vehi c le s with 2.5L or 3.0L engine 18. Remove t he d rives ha ft . For[...]

  • Page 648

    24. NO TE: Secur e t he s e le cto r cabl e us i ng t i e s t r aps Di s conn ect t he s el e ct or cabl e. 25. Dis c o nne ct t he a ut o mat i c t rans a xle e l e ct r i cal co nne cto rs. 26. Lowe r t he vehi c l e . 27. Remove t he a i r cl ea n e r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A[...]

  • Page 649

    30. Det a ch t he coo l a nt ho se . 31. Det a ch t he coo l a nt ho se s . Vehi c le s with 2.0L engi n e 32. Det a ch t he cr uis e co nt r ol ca bl e . 33. Det a ch t he acce l e r at o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n. 2. De ta ch t he a ccel e rat o r cabl e . JagDocs.com[...]

  • Page 650

    34. Det a ch t he acce l e r at o r cab l e r et ai ni ng bracket . 35. Det a ch t he coo l a nt ho se s . All v e h icle s 36. Det a ch t he ba t t e ry cab l e s. 37. Dis c o nne ct t he e n gi ne h a r ne s s e l e ct rica l conne ct o r . JagDocs.com[...]

  • Page 651

    38. Us i ng s pe ci a l t ool 418-535 di s conne ct t he e ngi ne cont r ol modul e ( ECM) e l e ct r i cal conne c t o r . 39. Dis c o nne ct t he g round cab l e . 40. NO TE: Drai n t he f lui d i nt o a s ui t a bl e co nt a i ne r. • NO T E: U s e a s ui t a bl e b l a nking pl ug t o s e a l t h e ho s e . Det ach t he po we r s t e e r i ng[...]

  • Page 652

    43. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he s t r ut a nd s pr ing as s e m bl y. 44. Rai se th e v e hi cl e . 45. Ins t a l l t he s p e cia l t o o l . 46. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 47. NO TE: Ri ght -hand [...]

  • Page 653

    48. Po s i t i o n and adj ust t he s p e ci al t oo l e ngi ne he i ght a d j us t e r s . 49. Remove t he e n gi ne s upp ort br a cket . 50. Det a ch t he s upp or t ba r . 51. Remove t he s uppo rt ba r . 52. Remove t he s pa cer. JagDocs.com[...]

  • Page 654

    53. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 54. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e . 55. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he f r ont s ubf r a[...]

  • Page 655

    58. Remove t he t r ans a x l e mount . 59. Ins t a l l t he s p e cia l t o o l . 60. Remove t he l ef t -han d e xhaus t mani f o l d he a t s hi e l d. 61. Ins t a l l t he s p e cia l t o o l . JagDocs.com[...]

  • Page 656

    62. Remove t he up pe r exha us t he a t s hie ld . 63. Remove t he ce nt e r e xhaus t he at s hi e l d ret a i ni ng bol t s . 64. Remove t he ce nt e r e xhaus t he at s hi e l d . 65. Ins t a l l t he s p e cia l t o o l . JagDocs.com[...]

  • Page 657

    66. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front wh ee l hub ret a i ni ng nut s . 67. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Us i ng t he s p e ci a l t o ol s , de ta ch t he hal fs ha ft s . 68. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e t i e rod e nd r et a i ni ng nut [...]

  • Page 658

    71. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he whe e l knuck l e s . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e s . 72. Us i ng t he s pe ci a l t o o l s , re m o v e t he l e ft -han d ha l f s haf t . 73. Remove a nd di[...]

  • Page 659

    76. Ins t a l l t he s p e cia l t o o l . 77. Remove t he e n gi ne rol l r e s t r i ct o r r e t ai ni ng bo l t . 78. Remove t he e n gi ne rol l r e s t r i ct o r . JagDocs.com[...]

  • Page 660

    79. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent . Us i ng t he s p e ci a l t o ol , re mov e t he e ng i ne and t rans a xle f r om t he s ub frame. Vehi c le s with 2.0L engi n e 80. Remove t he ha l f s ha[...]

  • Page 661

    82. Remove t he t r ans fe r ca se Y b r acket . 83. Remove t he ha l f s haf t s ea l . 84. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.87 i nches ) from t he t r a ns f e r cas e . Us i ng t he s p e ci a l t o ol s , r em[...]

  • Page 662

    87. Dis c o nne ct t he rig ht -ha nd h ea t e d oxy ge n s e n s or (HO 2S ) e l e ct rical conne ct or. 88. Remove t he rig ht -ha nd cat a l yti c co nver t e r r et a i ni ng b o l t s . 89. Remove t he rig ht -ha nd cat a l yti c co nver t e r . Re mov e a nd di s c a r d t he r et a i ni ng nut s . 90. Remove a nd di s car d t he c a t a l yt[...]

  • Page 663

    92. Us i ng t he s pe ci a l t o o l , det a ch t he t r a ns fe r ca s e l i nk sha f t. 93. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.87 i nches ) from t he t r a ns f e r cas e . Us i ng t he s p e ci a l t o ol , p a r[...]

  • Page 664

    96. Remove t he t r ans fe r ca se . 97. Remove a nd di s car d t he t r ans f er cas e O -r i ng s e a l . 98. Remove a nd di s car d t he li nk s ha ft s na p ring. 99. Remove t he l i nk s ha f t l imi t i ng to o l . 1. Re move t he r e t a i ni ng bo l t . 2. Re move t he l i nk s ha f t l i mi t i ng t o ol . 100 . Re move t he l in k s haf t[...]

  • Page 665

    101 . Us i ng t he sp e ci a l t oo l , re move a nd d i s card t he l i nk s h af t o i l s e a l. All v e h icle s 102 . Re move t he s ta rte r mot o r . 103 . Re move t he dus t cove r . 104 . Re move t he a cces s co ver. JagDocs.com[...]

  • Page 666

    105 . NO TE: Ro t at e t h e t o r q ue co nver t e r t o gai n a cces s t o t h e r e m a i n ing r e t a i ni ng bo l t s . Re move t h e t o rqu e conve r t e r r et ai ni ng bo l t s . 106 . Re move t he t r a ns axl e r et a i ni ng bol t s . 107 . Re move t he t r a ns axl e r et a i ni ng bol t s . 108 . Re move t he t r a ns axl e r et a i [...]

  • Page 667

    110 . W ARNIN G: Do no t l et t he t o r que converte r dr op out o f t he tra nsa xl e . Fa i l ur e t o f ol lo w t hi s i ns truc t i o n may r e s ul t i n p e r s o nal i njur y. Re move t h e t rans a xle . JagDocs.com[...]

  • Page 668

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Dis a s s e mbl y Speci al T ool (s) W r e nch s t r ap-uni vers al 303-D 055 Cr a n ks haf t P ul l e y Re move r 303-D 121 Cr a n ks haf t P ul l e y I ns t a ll e r 303-102 Tr us t P a d 303-D 121- 01 Cr a n ks haf t p ul le y i ns t a l[...]

  • Page 669

    3. D i s conne ct t he po s it i ve cr ankcas e ve nt i l a t i o n (P CV) hos e . 4. D i s conne ct t he e l ect r i cal conne ct o rs. 5. D i s conne ct t he f uel p res s ur e r eg ul a t or va cu um ho s e . 6. Remove t he f uel p res s ur e r eg ul a t or bracket . 7. D et a ch t he i nt a ke mani fo l d front r e t a i ni ng bracket . JagDocs[...]

  • Page 670

    8. D et a ch t he e ngi ne wiring ha r ne s s f r om t he i nt a ke mani fo l d r e a r r et a i ni ng b r ack e t . 9. D et a ch t he i nt a ke mani fo l d r ea r r et a i ni ng brack e t . 10. NO TE: T he e va porat i ve e mis s i o n ca ni s t er pur ge v al ve t rans f e r pi pe i s a tt a ched t o t he i nd uct i on m a ni f ol d b y a qui ck [...]

  • Page 671

    13. Remove t he e n gi ne b reat he r hos e . 14. Remove t he e va porat i ve e mis s i o n p ur ge v a l ve hos e . 15. Dis c o nne ct t he o i l co o le r cool a nt ho s e s . 16. Remove t he co o l a nt hos e . 17. Remove t he co o l a nt hos e . JagDocs.com[...]

  • Page 672

    18. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 19. Det a ch t he eng i ne harnes s . 20. Det a ch e ngi ne ha r nes s . 21. Remove t he rea r k no c k s e ns o r . 1. De ta ch t he knock s e ns or wi r i ng ha r nes s . 2. Re move t he r e a r knock s e ns o r. 22. Dis c o nne ct t he rig ht -ha nd cams ha f t pos i t i o n s e ns or . J[...]

  • Page 673

    23. Det a ch t he eng i ne harnes s ret a i ni ng br a cket . 24. Det a ch t he eng i ne harnes s . 25. Dis c o nne ct t he rig ht -ha nd i g ni t i o n coi l s . 26. Det a ch t he eng i ne harnes s . 27. Dis c o nne ct t he l ef t -han d cams ha f t p os i t i on s e ns or . JagDocs.com[...]

  • Page 674

    28. Dis c o nne ct t he l ef t -han d i g nit i o n coi l s . 29. Dis c o nne ct t he e n gi ne wi r i ng ha r ne ss e l e ct rical co nnect ors. 30. Remove t he e n gi ne wi r i ng ha r ne ss . 31. Remove t he i gni t i o n coi l s . 32. Remove t he l ow er i nt a ke mani f ol d and in je ct o r s uppl y m a nif ol d . JagDocs.com[...]

  • Page 675

    33. Remove a nd di s car d t he lo we r int ake ma ni f ol d ga s ke t s . 34. Remove t he l ef t -han d knock s e ns o r. 35. Remove t he a cces s o r y drive be l t . 1. Us e a 3/8 i nch drive ba r t o r e l e a s e t h e a cces s ory dr ive be l t t e nsi o ner. 2. Re move t he a cces s ory d r i v e be l t . 36. Remove t he rig ht -ha nd i d l [...]

  • Page 676

    38. Remove t he p o we r s t e e r i ng pump. 39. Remove t he a i r cond i t i o ni ng (A/C) compr es s o r . 40. Remove t he A /C co mpr e s s or mount i ng bracket . 41. Remove t he o i l l e v e l i ndi cat or t ube . 1. Re move a nd di s car d t he O -r i ng s ea l . 42. NO TE: Ri ght -hand s ho wn, Le f t -ha nd s imi l a r . Re move t h e e x[...]

  • Page 677

    43. NO TE: Ri ght -hand s ho wn, Le f t -ha nd s imi l a r . Re move t h e e xhaus t mani f ol ds . 44. Remove t he f l ywhe el . P r e vent t he e ng ine f r om r o t a t i ng. 45. Remove t he e n gi ne re ar ba cking pl a t e . 46. Remove t he o i l f i l t e r hous i ng a s s e mbl y. Re mov e a nd di s c a r d t he O -r ing s e a l . 47. Remove[...]

  • Page 678

    48. Remove t he co o l a nt cr os s o ve r t ub e . Re mov e a nd di s c a r d t he O -r ing s e a l s . 49. Remove t he wa t e r pum p a nd coo l an t ho s e a s s e mbl y. 1. De ta ch t he ho s e . 2. Re move t he wa t e r pump a nd coo l a nt h os e as s e mbly. 50. Remove t he a cces s o r y drive be l t t e ns i one r. 51. Ins t a l l t he s p[...]

  • Page 679

    53. Us i ng t he s pe ci a l t o o l , r e move t he cr anksha ft vi br a t i o n da mper. 54. Remove t he l ef t -han d i d l e r pu l l e y. 55. Remove t he o i l pa n . Re mov e a nd di s c a r d t he o il pa n g a ske t . Cle a n a nd i nsp e ct t he o i l pa n a nd cyli nder bl o ck s e a l i ng s urface s usi ng Met a l s ur fa ce cle ane r o[...]

  • Page 680

    58. Remove t he cr anks haf t p os i t i on (CKP) s e ns o r puls e whe e l . 59. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e. I nst a l l t he cr an k s ha ft p ul le y r et a ini ng bol t a nd wa s he r. 60. CAUT I O N: Do no t r ot a t e t he cr anks haf t [...]

  • Page 681

    63. Remove t he rig ht -ha nd t i ming c ha i n o ut e r g ui de . 64. Remove t he rig ht -ha nd t i ming c ha i n. 65. Remove t he rig ht -ha nd t i ming c ha i n i nne r gui de . 66. Remove t he cr anks haf t o ut e r s proc ket . 67. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi [...]

  • Page 682

    68. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e. Rot at e t he cr anksha f t c l o ckwis e unt il t he cr anksha f t ke yway i s at t he 11 O' c l o ck pos i t i o n, t he a l i gnment mark o n t he l e f t -han d i nt a ke ca ms haf t s p r o cket i s a [...]

  • Page 683

    73. Remove t he l ef t -han d t i mi ng cha i n o ut e r g ui de . 74. Remove t he cr anks haf t i nne r s prock e t. 75. Remove t he RH exha ust cams ha ft b e a r i ng cap b ol ts eve nl y. Re mov e t he e xha us t ca msh a ft be a r i ng caps . 76. Remove t he RH exha ust cams ha ft . 77. Remove t he RH in le t ca m s ha f t be a r i ng cap bo l[...]

  • Page 684

    78. Remove t he RH in le t ca m s ha f t . 79. Remove t he L H e xhaus t ca msh a ft be ar i ng cap bol t s e ve nl y. Re mov e t he e xha us t ca msh a ft be a r i ng caps . 80. Remove t he L H e xhaus t ca msh a ft . 81. Remove t he L H i nl e t ca ms haf t b ea ring ca p b o lt s e ve nl y. Re mov e t he i nl e t ca ms haf t b ea ring ca ps . 82[...]

  • Page 685

    83. NO TE: Re move t he b o l t s i n t he i ndi cat e d s e q uence . Re move t h e RH cyli nder he a d. Dis car d t he ga s ke t . 84. NO TE: Re move t he b o l t s i n t he i ndi cat e d s e q uence . Re move t h e L H cyli nd e r he ad. Dis car d t he ga s ke t . 85. Remove t he e n gi ne co o l a nt hous i ng. Dis car d t he 'O' ring[...]

  • Page 686

    88. Remove t he o i l pump. Re mov e a nd di s c a r d t he O -r ing s e a l . Ins p e ct t he o i l pump fo r da mage a nd we a r . 89. CAUT I O N: P i s t o ns , conne c t i ng r ods a nd conne ct i ng r od be a r i ng s s houl d be number e d t o m a ke s ur e t he y a re r e a s s embl e d i n t he sa me pos i t i on. • NO T E: Mar k t he po [...]

  • Page 687

    94. NO TE: Mark t he pos i t i on o f the upp e r a nd l o we r cr a nks ha ft ma i n bea ring a nd t he cr anks ha f t t hru s t be a r i ng fo r r e as s e mbl y. Re move t h e l o we r cr a nksh a f t be a rings . 1. Re move t he l o we r cr a nks ha ft t hr us t mai n b e aring. 2. Re move t he l o we r cr a nks ha ft ma i n b e a r i ngs . 95.[...]

  • Page 688

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C ylinder Head Dis a s s e mbl y a nd As s e mbl y o f Sub a s s e mbli e s Speci al T ool (s) Va l ve S p r i ng Co mpr es s o r 303-252 D isa ssem bly 1. CAU TI O N : If t he cyli nde r he ad v al v e compone n ts are t o be reus e d, m a r k pos[...]

  • Page 689

    Gene r a l I nf o r m at i o n . 6. Remove t he pi pe pl ugs a nd a l i gnm e nt do we l s a s nece s s ary t o cl e an t he cyli nde r he ad s . A ssemb ly 1. W ARNING: Eye p rot e cti o n i s requi r ed during us e o f compr e s s e d a ir. Fai lu r e t o fo l l o w t he s e i nst ru ct i o ns may res ul t in pe rso na l i nj ur y. CAUTI O N : Th[...]

  • Page 690

    6. Ins t a l l the bucket t a ppe t a nd s hi m a s s e mbl i e s . JagDocs.com[...]

  • Page 691

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Pisto n Dis a s s e mbl y a nd As s e mbl y o f Sub a s s e mbli e s D isa ssem bly 1. NOT E: Mark t he pi s t o ns t o t he o r i gi na l conne ct i ng rods t o make s ur e c orr e ct i ns t a l la t i o n i n t he sa me cy l i nd e r s f r om wh [...]

  • Page 692

    6. W ARNING: T he re ta ini ng r i ngs ha ve a t e nde nc y t o s pr i ng o ut dur ing r emova l . Co v e r t he e nd o f th e pi n bo r e wit h a ha nd o r a rag whe n r e m o ving th e ret a i ni ng r i ng. Eye p r o te cti on s houl d b e wo r n. Fa i l ur e t o fo l lo w t he s e ins t ruc t i o ns m a y r e s ult in pers ona l i nj ur y. Re mo[...]

  • Page 693

    5. Ins t a l l the s e cond oi l cont r o l r i ng. 6. Ins t a l l the o i l cont rol s pa ce r r ing. 7. Ins t a l l the f i rst oi l cont r ol r i ng. 8. Ins t a l l the s e cond compr es s i o n r ing. The t o p of t h e s e cond co mpr e s s io n ring h a s a "0" m arked on i t . P os i t i on t hi s s i de o f t he r i ng t o wa rds [...]

  • Page 694

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine As se mbl y Speci al T ool (s) W r e nch Strap-Uni ve r s a l 303-D 055 Cr anks haf t Re a r S ea l I ns t a l l e r 303-178 Cr anks haf t Re a r S ea l I ns t a l l e r Ada pt e r Bo l t s 303-384 P is t o n Ri ng Compres s o r 303-372 Cyl[...]

  • Page 695

    4. Ins t a l l the upp e r cr anks ha ft mai n b e a r ing s . Lubricat e t he b e a r i ngs and t hru s t wa s he r . 5. CAU TI O N : Avoi d d a mage t o an y c r a nk s ha f t j o ur nal bea ring s ur fa ce s . I nst a l l t he cr an k s ha ft . 6. NOT E: Pus h t he cr a nks ha ft r ea r wa rd prio r t o i nst a l l a ti on o f uppe r thrust bea [...]

  • Page 696

    9. CAU TI O N : Bo l t s 1 t hr o ug h 16 a r e t i g ht e n-t o -y i e l d a nd mus t be r e pl a ce d. • NO T E: T ig ht e n t he bo l t s i n t he i ndi ca t e d s e que nce i n f our s t ag e s . Compl e t e t he t i ght e ning s e que nc e . S ta g e 1: B o lt s 1-8, 25 Nm S ta g e 2: B o lt s 9-16, 40 Nm S ta g e 3: B o lt s 1-16, 90° S ta[...]

  • Page 697

    11. NO TE: Al t e rn a t e bo l t t ig ht eni ng to c orr e ct l y s e at the cr anks ha f t r ea r oi l s e al unt i l i t i s f l us h wi t h t he cyli nd e r b l o ck . Us i ng t he s p e ci a l t o ol s , i ns t al l t he cr anks haf t r ea r oi l s e a l . 12. CAUT I O N: U s e a ppropria t e pr ot e ct i o n t o pre v e nt da mag e t o t he c[...]

  • Page 698

    17. CAUT I O N: O i l p a n ba ff l e nut s a r e t i ght e ned t o yie ld a nd mus t no t be r e us e d. • NO T E: T ig ht e n t he bo l t s i n t he i ndi ca t e d s e que nce i n t wo s ta g e s . I nst a l l t he o i l pa n ba f f l e . S ta g e 1: 5 Nm S ta g e 2: 45° 18. NO TE: Eng in e i nv e rte d f o r cl a r i t y. I nst a l l t he o i[...]

  • Page 699

    22. Ins t a l l a n ew cy l i nd e r h ea d ga s ket (LH s ho wn - RH s i mil a r ). 1. Make s ur e t he cyli nde r he ad dow el s a r e corr e ct l y lo ca t e d . 2. I ns t a l l a ne w cyli nde r he a d g a s ket . 23. NO TE: I ns t a ll t he bo l t s i n th e i ndi cat e d s e quence . I nst a l l t he L H cyl in de r he ad. Ti ght e n t o 30 N[...]

  • Page 700

    27. Ins t a l l t he LH e xhau st ca ms ha ft . 28. CAUT I O N: Do no t i ns t a l l the cyli nde r hea d cams ha f t j o ur n a l th r ust cap s unt i l the ca msh af t j ournal ca ps a r e in s t a l l e d or dama ge t o t he th r ust cap s may occur . • NO T E: L ubr ica t e t he ca msha f t s a n d t he c a msha f t be a r i ng cap s wi t h o[...]

  • Page 701

    32. Ins t a l l t he RH exha us t c a msha f t be a r i n g cap bol t s eve nl y. Ins t al l t he e xhaus t ca ms ha ft be a r i ng caps . 33. Rot a te t he righ t -ha nd i nt a ke cams ha ft cl ockwis e unt i l t he cams ha ft s p r o cket a l i gnment ma r k i s a t t he 5 O' c l o ck pos i t i o n a nd rot a t e t he r i ght -ha nd e xhaus [...]

  • Page 702

    37. Ins t a l l t he l e f t -hand t i mi ng chai n i nne r gui de . 38. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers o n t he vi ce j aws to pr ot ect t he t i mi ng cha in te ns i o ne r . S ecur e t he l e f t -ha nd ti ming c ha i n t e ns i one r in t he vi ce j a ws . 39. CAUT I O N: Dur ing t i m i ng cha i n t e ns i o ner compres[...]

  • Page 703

    42. Ins t a l l t he l e f t -hand t i mi ng chai n t e ns i on e r . Ti ght e n t o 25 Nm. 43. Rel e as e t he t e ns i on i n t he l e ft -hand t imi ng chai n t ens i o ne r . Re mov e t he re ta i ni ng t ool . 44. Mak e s ure t he l e ft -hand t i ming cha i n a l i gnme nt mar ks ha ve remai ne d cor r ect ly p os i t io ne d t o t he cams ha[...]

  • Page 704

    48. Ins t a l l t he cr a nks haf t o ut e r s proc ket . 49. Ins t a l l t he r i ght -ha nd t i m in g chai n i nne r gui de . Ti ght e n t he ret a i ni ng bol t s in t he s e que nce s ho wn i n t wo s t a ge s . S ta g e 1: T i ght en bol t 1 t o 25 N m. S ta g e 2: T i ght en bol t s 2 t o 25 Nm. 50. CAUTI O N S : Make s ur e t he cr anks ha [...]

  • Page 705

    53. CAUT I O N: Dur ing t i m i ng cha i n t e ns i o ner compres s i o n, d o no t r e l e a s e t he rat chet s t e m unt i l t he t i ming cha in t e ns io ne r pi s t on i s f ul ly bot t ome d i n i t s bo r e o r da m a ge t o t he r at chet s t e m wi l l r e s ul t . Us i ng a s ui t a b l e t o o l , hol d t he r i ght -hand t imi ng chai [...]

  • Page 706

    58. CAUT I O N: Ma k e s ure t he r i ght -ha nd t i mi ng cha i n a l i gnment m a r k s ha ve remai ne d corr e ct l y po s i t io ne d t o t he c a m s ha f t s p r ocket and c r a nk s ha f t s p r ocket al i g nment mark s . Make s ur e al l th e t i m i ng cha i n a l i g nment mar ks a re i n th e pos i t i o ns s ho wn. 59. CAUT I O N: Do n[...]

  • Page 707

    63. Carr y out a v a l ve cl e aran c e check. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Va l ve Cl e a r a nce Check i n t hi s s e ct i o n. 64. Ins t a l l ne w front t i mi ng co ver ga s ket s . 65. NO TE: P rio r t o a p pl ying s e a l e r cl e a n t he front cover t o e ngi ne b l ock a nd cyl i nde r hea d s e a li ng s ur f a[...]

  • Page 708

    68. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he val ve covers. Compl e t e t he ti ght e ni ng s e que nce. Ti ght e n t o 10 Nm. 69. Ins t a l l t he l e f t -hand id l er pul l e y. Ti ght e n t o 25 Nm. 70. Us i ng t he s pe ci a l t o o l s , i ns t a ll t he cr anksha f t pul l e y. Coa t t h e cr anks ha f t pul l[...]

  • Page 709

    73. Ins t a l l t he wa t e r pum p a nd cool ant ho s e a s s e mbl y . 1. At t a ch t he hos e . 2. I ns t a l l t he wa t e r pum p a n d co o l a nt hos e as s e mbl y. Ti ght e n t o 25 Nm. 74. NO TE: I ns t a ll n e w coo la n t cr o s s ove r O-r i ng s e a l s . I nst a l l t he coo l ant cross o v e r t ube . Ti ght e n t o 10 Nm, 75. Ins [...]

  • Page 710

    78. Ins t a l l t he e ngi ne rear ba cking pl a t e . 79. Ins t a l l t he f l ywhee l . P r e vent t he e ng ine f r om r o t a t i ng. Ti ght e n t o 80 Nm. 80. NO TE: Ri ght -hand s ho wn, Le f t -ha nd s imi l a r . I nst a l l t he e xhaus t mani f ol ds . Ti ght e n t o 25 Nm. 81. NO TE: Ri ght -hand s ho wn, Le f t -ha nd s imi l a r . I ns[...]

  • Page 711

    83. Ins t a l l t he A/C co mpr e s s or mount i ng b rack e t. Ti ght e n t o 25 Nm. 84. Ins t a l l t he a ir co ndi t io ni ng (A/C) co m pr es s or . Ti ght e n t o 25 Nm. 85. Ins t a l l t he po we r s t e e r i ng pu m p. Ti ght e n t o 25 Nm. 86. Ins t a l l t he ge ne r a t or. Ti ght e n t o 48 Nm. 87. Ins t a l l t he r i ght -ha nd i dl [...]

  • Page 712

    88. Ins t a l l t he a cc e s s o r y drive b e l t . 1. Us e a 3/8 i nch drive ba r t o r e l e a s e t h e a cces s ory dr ive be l t t e nsi o ner. 2. I ns t a l l t he a c ce ss o ry d r i v e be l t . 89. Ins t a l l t he l e f t -hand knock s e ns or. Ti ght e n t o 25 Nm. 90. Ins t a l l ne w l owe r int a ke mani f ol d ga s ke t s . 91. In[...]

  • Page 713

    93. Ins t a l l t he e ngi ne wi r i n g ha r ne s s . Ti ght e n t o 10 Nm. 94. Conne ct t he e ngi ne wi r i ng ha r ne s s e l e ct rica l co nnect o r s . 95. Conne ct t he l e f t -ha nd i g ni ti on coi l s . 96. Conne ct t he l e f t -ha nd ca ms haf t pos i t i on s ens or . 97. At t ach t he e ngi ne h a r n e s s . JagDocs.com[...]

  • Page 714

    98. Conne ct t he rig ht -ha nd ig ni t io n c oi l s . 99. At t ach t he e ngi ne h a r n e s s . 100 . At t ach t h e e ng i ne ha r ne s s ret a i ni ng br a c ket . 101 . Di s conne c t t h e right -ha nd cams ha ft p o s i t i on s e ns or. 102 . In s t a l l t he rea r kno c k s e ns o r . 1. At t a ch t he knock s e ns o r wi r ing harnes s [...]

  • Page 715

    103 . At t ach e ngi ne ha rn es s . 104 . At t ach t h e e ng i ne ha r ne s s . 105 . Conne c t t he e l e ct r ica l conne ct o r s . 106 . In s t a l l t he co ol a nt hos e . 107 . In s t a l l t he co ol a nt hos e . JagDocs.com[...]

  • Page 716

    108 . Conne c t t he o i l coo l e r coo l a nt ho s e s . 109 . In s t a l l t he e va porat i ve emi s s i o n p ur ge v a l ve ho s e . 110 . In s t a l l t he e n gi ne b reat her ho s e . 111 . In s t a l l ne w i nt a ke mani fo l d gas ke ts . 112 . NO TE: The i nta ke m a ni f o l d ret a i ni ng bo l t s in pos i t i on 1,2,3 a nd a r e lo[...]

  • Page 717

    113 . Conne c t t he e va porat i v e e mis s i o n ca ni s t e r pur g e val v e t rans f er pi pe. 114 . At t ach t h e i nt a ke mani f o l d r e ar r e t a i ni ng b r a cket . Ti ght e n t o 10 Nm. 115 . At t ach t h e e ng i ne wi r i ng harnes s from t he in t a ke man if ol d rear r et a i ni ng b r ack e t . 116 . At t ach t h e i nt a ke [...]

  • Page 718

    118 . Ti ght e n t o 7 Nm. 119 . Conne c t t he f ue l pres s ur e r e gul a t o r vacuum ho s e . 120 . Conne c t t he e l e ct r ica l conne ct o r s . 121 . Conne c t t he po s i t i ve cr an kc as e ve nt i la t i o n (P CV) ho s e . 122 . Conne c t t he t hr ot t l e po s i ti o n s ens o r . JagDocs.com[...]

  • Page 719

    123 . Conne c t t he t hr ot t l e mot or e l ect r i cal co nnect o r. JagDocs.com[...]

  • Page 720

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gineVehi cles With: 5-Spee d Manual Transm i ssi on - MT7 5/ 6-Spe ed Manual T ransaxl e - MM T6 I nst a l l a t io n Speci al T ool (s) Ha l f s ha f t o i l s e al i nst a l l er 205-115 Li nk s ha ft l imi t i ng t oo l 307-446 Engi ne l i f [...]

  • Page 721

    3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 47 Nm. 4. Ins t a l l the a cces s co ver. Ti ght e n t o 10 Nm. 5. Ins t a l l the dus t cover . Ti ght e n t o 10 Nm. 6. Ins t a l l the s t art er mot o r . Ti ght e n t o 35 Nm. Vehi c le s with 2.5L or 3.0L engine JagDocs.com[...]

  • Page 722

    7. NOT E: Us i ng a s ui t a bl e s ur f a ce cl ea ne r , W S E- M5B392 -A o r e qui val e n t, m e e t i ng t he Jagua r s pe ci f i cat i on . Cl e a n t he s e a l f a ce o n t he t r a nsf e r cas e bef o r e i ns ta l l i ng t he ne w l i nk s ha ft o i l se a l. Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w l i nk s ha ft o i l se a[...]

  • Page 723

    12. NO TE: Do not t ig ht e n t he engi ne r o l l res t ricto r br acket t o p re ta i ni ng bol t s a t t hi s s t a ge a t t hi s s t a ge . I nst a l l t he e n gi ne r o l l r e s t rict o r br acket . Ins t al l t he e ngi ne r o ll re st r i ct o r br acket t o p ret a i ni ng bol t s . 13. NO TE: Do not t ig ht e n t he engi ne r o l l res [...]

  • Page 724

    17. NO TE: Do not t ig ht e n t he c a t a l yt i c conver t e r r et ai ni ng bo l t s a t t hi s s t a ge . I nst a l l t he cat a l yt i c co nverte r moun t br acket . 18. Ins t a l l t he cat a l yti c converte r mount br acke t r e t ai ni ng bo l t . Ti ght e n t o 25 Nm. 19. Ti g ht e n t he cat a l yt i c co nverte r m ou nt br acket ret a[...]

  • Page 725

    22. CAUT I O N: N e v e r us e j oi nti ng compound f o r war d o f the ca t a l yt i c c on ver t e r . Fa i l ur e t o f ol l ow th i s i ns t r uct io n m a y r e s ul t i n d a mage t o th e c ompo ne nt . • NO T E: Make s ur e t he ret a i ni ng nut s a r e t i ght e ne d tw i ce in t he s e que nc e s hown. I nst a l l t he r i g ht -hand c[...]

  • Page 726

    27. Ins t a l l a n ew ha l f s ha f t s e a l . 28. CAUT I O N: Do no t us e e x ces s i ve f o rc e when e ngag ing t he hal fs h a ft t o t he l i nk s ha f t . Fa i l ur e t o f o l l ow t hi s i ns t r u cti o n may res ul t i n dama ge t o t he co mpon ent . • NO T E: Make s ur e t he ha l f s ha f t i s f u ll y l o cat e d t o t he li nk [...]

  • Page 727

    31. Ins t a l l t he ha l f s ha f t a nd i nt erm ed ia t e s haf t a s s e mbl y. Ti ght e n t o 20 Nm. All v e h icle s 32. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent . Us i ng t he s p e ci a l t o ol , [...]

  • Page 728

    35. Remove t he s pe ci a l t o o l . 36. Conne ct t he p o we r s t e e r i ng hi gh-pres s ur e pi p e . Ins t al l a ne w O -r i ng s e a l . Ti ght e n t o 30 Nm. 37. Ins t a l l t he po we r s t e e r i ng hi gh-pres s ur e pi pe ret a i ni ng b ol t. Ti ght e n t o 25 Nm. 38. Ins t a l l a n ew ha l f s ha f t s na p ring. JagDocs.com[...]

  • Page 729

    39. Ins t a l l t he l e f t -hand ha l f s ha ft . 40. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. • NO T E: Make s ur e t he ha l f s ha f t i s a l i gne d t o t he f r ont whe e l hub. At t a ch t he whe e l knuc kl es . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle s . 3. I ns t a l l t he lo we r ar m[...]

  • Page 730

    44. Remove t he s pe ci a l t o o l . 45. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d. Ti ght e n t o 10 Nm. 46. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d ret a ini ng bol t s . Ti ght e n t o 10 Nm. 47. Ins t a l l t he uppe r exhau st he a t s hi e l d . Ti ght e n t o 6 Nm. JagDocs.com[...]

  • Page 731

    48. Remove t he s pe ci a l t o o l . 49. Ins t a l l t he l e f t -hand e xh a us t m a ni f o l d he a t s hi e l d . Ti ght e n t o 10 Nm. 50. Remove t he s pe ci a l t o o l . 51. Ins t a l l t he t r a ns a xl e mount . Ti ght e n t o 80 Nm. JagDocs.com[...]

  • Page 732

    52. Ins t a l l t he coo l a nt s ys t em t o p ho se . Ins t al l a ne w ga s k e t . Ti ght e n t o 9 Nm. 53. W A RNING: Ra i s e t he s pe ci a l t o o l pl a t f o r m s l o wl y. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n ca n res ul t i n pe r s o na l i nj ury . I nst a l l t he e n gi ne a n d t r ans a xl e a s s e mbl y. Ra is e t[...]

  • Page 733

    57. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 58. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame ret a i ni ng b ol t. Ti ght e n t o 142 Nm. 59. NO TE: L e ft -hand s h own, r i g ht -hand s i mil [...]

  • Page 734

    62. Ti g ht e n t he e ngi ne s uppo rt b r a cket ret a i ni ng bol t s . Ti ght e n t o 40 Nm. • NO T E: I f fi x i ngs can be r e -use d o n ve hi cl e s bui l t pr i o r to VIN J24254, t he n t he ol d t or que must b e us e d (48 Nm). If ne w f i xing s a re us ed on a ny ve hi cle us e t he ne w t or que . 63. Remove t he s pe ci a l t o o [...]

  • Page 735

    68. NO TE: Re move t he b l a nking pl ug from t he ho se . At t a ch t he p owe r s t e ering ho s e . 69. Conne ct t he g round ca bl e . Ti ght e n t o 10 Nm. 70. Conne ct t he e ngi ne co nt rol modul e (ECM ) el e ct r i cal co nnect o r. Us i ng s pe c i a l t o o l 418-5 35, t ig ht e n t o 5 Nm. 71. Conne ct t he e l e ct r i cal conne ct o[...]

  • Page 736

    73. Ins t a l l t he clut ch mas t e r cyl i nde r t o c l ut ch s l a ve cyli nd e r hi g h pre ss ur e pi pe sup po r t b rack e t. 74. CAUT I O N: I f brake fl ui d i s s pi lt o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Re move t he ti e s t raps . • NO T[...]

  • Page 737

    Vehi c le s with 2.0L engi n e 78. At t ach t he co o l a nt hos e s . 79. At t ach t he a ccel erat o r cab l e ret a i ni ng br acket . Ti ght e n t o 9 Nm. 80. At t ach t he a ccel erat o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n. 2. At t a ch t he a ccel e r a t or cabl e . 81. At t ac[...]

  • Page 738

    82. At t ach t he co o l a nt hos e s . 83. At t ach t he co o l a nt hos e . 84. At t ach t he co o l a nt hos e . 85. Ins t a l l t he a ir f i l te r i nt a ke pi pe . 86. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A i r Di s t r i b ut i o n and Fil t e r i ng [...]

  • Page 739

    88. At t ach t he co o l a nt hos e . 89. NO TE: Re move t he t i e s t r ap s . • NO T E: Re move t he bl a nk i ng p lu gs from t he t ube a nd t he A/C c ompres s o r. At t a ch t he A /C compr es s o r s uppl y a nd r et ur n t ube s . Ins t al l new O-r i ng s e a l s . Ti ght e n t o 25 Nm. 90. Ins t a l l t he f r ont muff l e r. For a ddi[...]

  • Page 740

    95. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he A BS whe e l s pe e d s e ns o r. 96. NO TE: Re move t he t i e s t r ap s . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Det ach a nd rep os i t i on t he brake cal i pe r a ss e mbly. 97. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he[...]

  • Page 741

    100 . NO TE: Ri ght -hand s h own, le ft -hand s i mil ar. Re move t h e r e a r ve hi cle t ie down s t rap. 101 . NO TE: Ri ght -hand s h own, le ft -hand s i mil ar. Re move t h e front vehi cl e t i e d o wn s t r a p. 102 . In s t a l l t he f r o nt whe el s a nd t i res . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd [...]

  • Page 742

    109 . NO TE: Le f t -ha nd s ho wn, r i ght -hand s i mi l ar. Ti ght e n t he f r ont hub ret a i nin g nu ts . Ti ght e n t o 290 Nm. 110 . Carr y o ut t he u nderbody mis a l i gnment che ck . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: U nde r b o dy Mis a li g nment Che ck (502-00 U ni -Bo dy, Subframe a nd Mount i ng S y s t e m, [...]

  • Page 743

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gineVehi cles With: 5-Spee d Autom atic T ransa xle - JATC O / 6-Sp eed Autom atic T r ansaxl e - AWF 21 I nst a l l a t io n Speci al T ool (s) Ha l f s ha f t o i l s e al i nst a l l er 205-115 Li nk s ha ft l imi t i ng t oo l 307-446 Engi n[...]

  • Page 744

    4. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 5. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 6. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 7. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 8. NOT E: Rot a t e t [...]

  • Page 745

    9. Ins t a l l the a cces s co ver. Ti ght e n t o 10 Nm. 10. Ins t a l l t he dus t c o ver . Ti ght e n t o 10 Nm. 11. Ins t a l l t he s t arte r mot o r . Ti ght e n t o 35 Nm. Vehi c le s with 2.5L or 3.0L engine 12. NO TE: U s i ng a s ui t abl e s ur face cl e a ne r , W SE -M 5B392-A or e qui va l e nt , m e e t i ng t he Jagua r s pe ci f [...]

  • Page 746

    14. Ins t a l l a n ew l i nk s ha f t s n ap r i ng. 15. Ins t a l l a n ew t r ans fe r cas e O -r i ng s e a l . 16. NO TE: Eng a ge the l i nk s ha f t int o t he t r ans a xle . I nst a l l t he t rans f e r cas e . Ti ght e n t o 90 Nm. 17. NO TE: Do not t ig ht e n t he engi ne r o l l res t ricto r br acket t o p re ta i ni ng bol t s a t t[...]

  • Page 747

    19. Ins t a l l t he e ngi ne roll r e s t r i cto r br acket s i de re t a i ni ng bo l t s . Ti ght e n t o 35 Nm. 20. Ti g ht e n t he e ngi ne r ol l r e s t rict or bracket r et a i ni ng nut s. Ti ght e n t o 35 Nm. 21. Ti g ht e n t he e ngi ne r ol l r e s t rict or bracket t o p r e t ai ni ng bo l t s . Ti ght e n t o 55 Nm. 22. NO TE: Do[...]

  • Page 748

    24. Ti g ht e n t he cat a l yt i c co nverte r m ou nt br acket ret a i ni ng bo l t s. Ti ght e n t o 55 Nm. 25. Ins t a l l a n ew ca t a l yt i c co nv e rte r s e a l i ng r i ng . 26. Ins t a l l ne w c a t al yt i c conver t e r r e t a i ni ng s t uds . Ti ght e n t o 9 Nm. 27. CAUT I O N: N e v e r us e j oi nti ng compound f o r war d o f[...]

  • Page 749

    29. Conne ct t he rig ht -ha nd cat a l ys t m on it o r s e ns o r e l e ct r i cal co nnect o r. 30. Ins t a l l t he r i ght -ha nd cat a lyt i c conver t e r r e t a i ni ng bo l t s . Ti ght e n t o 25 Nm. 31. Ins t a l l a n ew ha l f s ha f t s na p ring. 32. Ins t a l l a n ew ha l f s ha f t s e a l . 33. CAUT I O N: Do no t us e e x ces s[...]

  • Page 750

    34. Ins t a l l t he t r a ns f e r cas e Y br acket . Ti ght e n t o 55 Nm. 35. Ins t a l l t he t r a ns f e r cas e Y br acket r et a i ni ng bo l t s . Ti ght e n t o 25 Nm. Vehi c le s with 2.0L engi n e 36. Ins t a l l t he ha l f s ha f t a nd i nt erm ed ia t e s haf t a s s e mbl y. Ti ght e n t o 20 Nm. All v e h icle s JagDocs.com[...]

  • Page 751

    37. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent . Us i ng t he s p e ci a l t o ol , i ns t a l l t he e ngi ne a nd t rans a xle to t he s ubframe . 38. Ins t a l l t he e ngi ne roll r e s t r i cto r . Ti [...]

  • Page 752

    40. Remove t he s pe ci a l t o o l . 41. Conne ct t he p o we r s t e e r i ng hi gh-pres s ur e pi p e . Ins t al l a ne w O -r i ng s e a l . Ti ght e n t o 30 Nm. 42. Ins t a l l t he po we r s t e e r i ng hi gh-pres s ur e pi pe ret a i ni ng b ol t. Ti ght e n t o 25 Nm. 43. Ins t a l l a n ew ha l f s ha f t s na p ring. JagDocs.com[...]

  • Page 753

    44. Ins t a l l t he l e f t -hand ha l f s ha ft . 45. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. • NO T E: Make s ur e t he ha l f s ha f t i s a l i gne d t o t he f r ont whe e l hub. At t a ch t he whe e l knuc kl es . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle s . 3. I ns t a l l t he lo we r ar m[...]

  • Page 754

    49. Remove t he s pe ci a l t o o l . 50. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d. Ti ght e n t o 10 Nm. 51. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d ret a ini ng bol t s . Ti ght e n t o 10 Nm. 52. Ins t a l l t he uppe r exhau st he a t s hi e l d . Ti ght e n t o 6 Nm. JagDocs.com[...]

  • Page 755

    53. Remove t he s pe ci a l t o o l . 54. Ins t a l l t he l e f t -hand e xh a us t m a ni f o l d he a t s hi e l d . Ti ght e n t o 10 Nm. 55. Remove t he s pe ci a l t o o l . 56. Ins t a l l t he t r a ns a xl e mount . Ti ght e n t o 80 Nm. JagDocs.com[...]

  • Page 756

    57. Ins t a l l t he coo l a nt s ys t em t o p ho se . Ins t al l a ne w ga s k e t . Ti ght e n t o 9 Nm. 58. W A RNING: Ra i s e t he s pe ci a l t o o l pl a t f o r m s l o wl y. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n ca n res ul t i n pe r s o na l i nj ury . I nst a l l t he e n gi ne a n d t r ans a xl e a s s e mbl y. Ra is e t[...]

  • Page 757

    62. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 63. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame ret a i ni ng b ol t. Ti ght e n t o 142 Nm. 64. NO TE: L e ft -hand s h own, r i g ht -hand s i mil [...]

  • Page 758

    67. Ti g ht e n t o t he s uppo r t ba r ret a i ni ng bol t s . Ti ght e n t o 25 Nm. 68. Ins t a l l t he e ngi ne s up port b r acket . Ti ght e n t o 80 Nm. 69. Ti g ht e n t he s uppo rt ba r ret a i ni ng bo l t s . Ti ght e n t o 25 Nm. 70. Remove t he s pe ci a l t o o l . 71. Lowe r t he vehi c l e . 72. NO TE: Ri ght -hand s ho wn, l e ft[...]

  • Page 759

    73. At t ach t he co o l a nt pi p e . Ti ght e n t o 9 Nm. 74. Conne ct t he s pr i ng l o ck coupl in g. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Spr i ng L ock Co upl i ngs (310-00 Fue l S yst e m - Ge neral I nf o rm a t i o n, Ge ne r a l P roc e dur e s ). 75. NO TE: Re move t he b l a nking pl ug from t he ho se . At t a ch t [...]

  • Page 760

    78. Conne ct t he e ngi ne h a r nes s e l e ct r i cal conne cto r . Ti ght e n t o 10 Nm. 79. At t ach t he b a t t e r y cab le s . Ti ght e n t o 10 Nm. Vehi c le s with 2.0L engi n e 80. At t ach t he co o l a nt hos e s . 81. At t ach t he a ccel erat o r cab l e ret a i ni ng br acket . Ti ght e n t o 9 Nm. JagDocs.com[...]

  • Page 761

    82. At t ach t he a ccel erat o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n. 2. At t a ch t he a ccel e r a t or cabl e . 83. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 84. At t ach t he co o l a nt hos e s . 85. At t ach t he co o l a nt hos e . JagDocs.com[...]

  • Page 762

    86. At t ach t he co o l a nt hos e . 87. Ins t a l l t he a ir f i l te r i nt a ke pi pe . 88. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A i r Di s t r i b ut i o n and Fil t e r i ng - 2.0L N A V6 - A JV6/2.5L NA V6 - AJV6/3.0L N A V6 - AJ27, Remova l a nd I ns[...]

  • Page 763

    94. Ins t a l l t he coo l i ng fa n mot o r a nd s hroud. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Fan Mot o r a nd Shr o ud (303-03 A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V 6 - A JV6/3 .0L NA V6 - AJ27, Remova l a nd I ns t a ll a t i o n). 95. NO TE: Re move t he t i e s t r ap s . • NO T E: L ef t -hand s[...]

  • Page 764

    99. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he b r a ke p i pe . 100 . NO TE: Le f t -ha nd s ho wn, r i ght -hand s i mi l ar. • NO T E: Ins t al l n ew br a ke ca li pe r anchor pl at e ret a i ni ng bo l t s. At t a ch t he b r a ke ca l i pe r a s se mbl y. Ti ght e n t o 133 Nm. 101 . NO TE: Ri ght -hand s h own, [...]

  • Page 765

    104 . In s t a l l t he f r o nt whe el s a nd t i res . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 105 . In s t a l l t he b a t t e r y t ray. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Moun[...]

  • Page 766

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Oil C apa ci ty Descri pti on Li ters I nit i a l f i l l i ncl udi ng oi l fi lt er 6·7 S er vice f il l i ncl udi ng o i l f i l te r 6·0 S er vice f il l wi t hout o i l fi l te r 5·8 Lubr i cant s, Seal er s a nd Ad hesi ve s I te [...]

  • Page 767

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Des cr ipt i o n a nd O pe r a t i o n Gene ral Vi e w Item Pa r t Nu m be r De scri pt i on 1 - Int a k e mani f ol d 2 - Fuel i nj e ct i on su ppl y ma ni fo l d 3 - Fuel i nj e ct o r 4 - Va l ve co ver 5 - T ur bochar ge r 6 - Br a k[...]

  • Page 768

    14 - O i l pres s ur e s wi t ch 15 - Fuel i nj e ct i on pum p 16 - O i l l evel ind i ca t or a nd t ub e 17 - Exhaus t gas r eci rc ula t i on (EGR) val ve Engin e Ide nt ifica tion C ode Engi ne code a nd e ngi ne s eria l numbe r The e ngi ne co de (4-di gi t ) a nd t he e ngi ne se ria l nu m be r (consi s t ing of t wo l e t t e r s f o r th[...]

  • Page 769

    Item Pa rt Nu m ber De scr i pti on 1 - Cyli nder he a d 2 - Cyli nder he a d bo l t s 3 - I nt a ke val ve s 4 - Cyli nder he a d ga s ke t 5 - Exh a us t va l ve s 6 - Exh a us t cams ha f t 7 - I nt a ke camsha f t 8 - Ca m s ha f t ca r r ie r 9 - Ca m s ha f t ca r r ie r bea ring bracket s (5 of f ) 10 - S e a li ng s urface 11 - Ro c ker s h[...]

  • Page 770

    I te m Pa rt Nu m ber Desc ri pti on 1 - Rock er s haf t , e xha us t roc ker a r m 2 - Rock er s haf t , i nt a ke rock er arm 3 - S t ud o n r ock e r ar m The val ve s a r e op e r at e d by l i ght we i ght a l umin iu m r ocker arm s , whi ch a r e mount e d o n t wo rocker s haf t s . T he rock e r a r m s a r e o f d if fe rent le ngt hs t o[...]

  • Page 771

    3 - Engi ne f r o nt co ver gas ke t Fr o nt Co ver The t imi ng cover i s of s t e el co nst r uct i o n a nd i s fi tt e d us i ng s e a l i ng compo und. Prio r t o f i t t i ng, t he m a t ing f a ces o n t he t i m i ng ca s e and cover m us t b e cl e a ne d t ho roughly. A sp e ci a l t o ol is us e d t o a l ig n t he cove r t o t he e ngi [...]

  • Page 772

    I te m Pa rt N um be r De s cri pti on 1 - Oi l s pray noz z l e 2 - Ta b The pi s t on a ls o i nco r por a t e s a n o i l ga l l e r y f o r c oo l i ng pur po s e s . T hi s is s uppl ie d b y oi l s pray no z z l e s whi ch a r e l ocat e d i n e ngi ne b l ock o i l ga l l e ry . O pt i mum pi s t o n co ol ing i s e ns ured, w hi c h i s ne [...]

  • Page 773

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - C ranksha ft Front Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Re l e a s e t ool , b el t t ens io ne r 303-676 W r e nch s t rap-unive r s a l 303-D 055 Re mover /Ins t a l l e r , Front O il Seal 303-679 (21- 238) R em ova l 1. Remove t[...]

  • Page 774

    5. Usi ng t he s pe cia l t oo l , r emove t he cr a nk s ha ft f r ont o i l s e a l. Dis car d t he o il s e a l . Insta llat ion 1. NOT E: Ins t a l l a new cr a nks ha ft front oi l s e a l . • NO T E: A ne w cr anks ha ft f r on t oi l s e al i s s uppl i e d wi th a n a l i gnm e nt s l e e ve t ha t wi l l b e pu she d o ut d ur i ng i ns [...]

  • Page 775

    4. Ins t a l l the right -ha nd whe e l a rc h l i ne r acces s pa ne l . 5. Ins t a l l the f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). JagDocs.com[...]

  • Page 776

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - C ranksha ft Rear Seal I n-v e hi c l e Re pa i r R em ova l 1. Remove t he f l ywhe e l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl ywhe e l (303-01B Eng in e - 2. 0L Dur a t o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150PS ) - P[...]

  • Page 777

    4. Tig ht e n t he cr a n ksha f t r e a r o i l s e al ca r r ie r r et a i nin g bo l t s . Ti ght e n t he b ol t s i n t he s e q ue nce s ho wn. Ti ght e n t o 10 Nm. 5. Remove t he cr a nks haf t r e a r o i l s e a l al i g nment s l e e v e . 6. Ins t a l l the f l ywhe e l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl ywhe e[...]

  • Page 778

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Front C o v er I n-v e hi c l e Re pa i r Speci al T ool (s) Al ig ne r , Fr o nt Co ve r 303-682 (21- 241) R em ova l 1. Remove t he e ngi ne f r ont mount . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Eng i ne Fr ont Mo unt [...]

  • Page 779

    6. D et a ch t he ge ne r a t o r pos i t i ve cabl e . 7. D i s conne ct t he ge ne r a t or e l e ct r i cal co nne cto r. 8. Remove t he ge ne r a t or upp e r r e t ai n ing b ol t . 9. D et a ch t he ge ne r a t o r . S li de t he g e ne r at or r e a r ward s a s f a r awa y f r om t he a cces s o r y drive bel t t ens i one r a ss e mbl y a [...]

  • Page 780

    11. Det a ch t he acce s s o r y drive be l t . 12. Remove t he a cces s o r y drive be l t t e ns i one r. 13. Remove t he e n gi ne f r o nt co ver l owe r r e t a i ni ng nut s a nd bo l t s . 14. Lowe r t he vehi c l e . 15. NO TE: Eng in e s ho wn removed f o r cl a r i t y. • NO T E: T he i dl er pul l e y can not be r e m o ved unt i l t h[...]

  • Page 781

    16. NO TE: Eng in e s ho wn removed f o r cl a r i t y. Re move t h e front e ngi ne m ou nt br a c ket a nd i dl e r pul l e y. 17. NO TE: Eng in e s ho wn removed f o r cl a r i t y. Re move t h e e ngi ne f r on t c o ver uppe r r et a i ni ng bol t s . 18. CAUT I O N: A v oi d da mag e t o t he engi ne front co ver mat i ng f a ce on t he e ngi[...]

  • Page 782

    2. CA UT I O NS: A ne w e ngi ne f r ont c o ver must be i ns t a l le d. Fai l ur e to f o ll o w t hi s in s t ruc t i o n may r es ul t i n da mag e t o t he v eh icl e. I ns t a ll t he e ngi ne front cove r wi t hi n f i ve mi nut e s o f a ppl yi ng t he s ea l er. Fa i lu r e t o fo l l o w t hi s ins t ruc t i o n may r es ul t i n da mage [...]

  • Page 783

    7. Tig ht e n t he e ngi ne f r ont cove r l o we r r et a i ni ng nut s a nd bo l t s . Ti ght e n t he e n gi ne f r o nt co ver nuts and bol t s t o 3 Nm. Ti ght e n t he e n gi ne f r o nt co ver nuts and bol t s in t he f ol l o wi ng s eq ue nce: Ti ght e n t he 2 bo l ts i ndi cat e d t o 11 Nm. Ti ght e n t he rema ini ng nut s a nd bo l t [...]

  • Page 784

    10. NO TE: Eng in e s ho wn removed f o r cl a r i t y. I nst a l l t he i d l e r pu ll e y r e t a i ni ng nut . Ti ght e n t o 43 Nm. 11. Ins t a l l t he a cc e s s o r y drive b e l t t e nsi o ner. 12. At t ach t he a cces s or y drive be l t . 13. At t ach t he a cces s or y drive be l t t e ns i one r as s e mbl y. Ti ght e n t o 47 Nm. 14.[...]

  • Page 785

    15. Ins t a l l t he ge ne r a t or upp e r r e t a i ni ng b ol t . Ti ght e n t o 47 Nm. 16. Ti g ht e n t o 47 N m. 17. Conne ct t he g e ne r a t or e l ect r i cal co nne cto r. 18. At t ach t he g e ne r a to r po s i t i ve ca bl e . Ti ght e n t o 8 Nm. 19. Ins t a l l t he cr a nks haf t front s e a l . For a ddi ti ona l i nf o r m a t i [...]

  • Page 786

    20. Ins t a l l t he r e t a i ni ng nut s . 1. I ns t a l l t he r e t a i ni ng bracket . 2. I ns t a l l t he r e t a i ni ng nut s . 21. At t ach t he e ngi ne wi r i ng ha r ne ss . 22. At t ach t he e ngi ne wi r i ng ha r ne ss . 23. Ins t a l l t he e ngi ne f r ont mount . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Eng i ne Fr[...]

  • Page 787

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Front Mou nt I n-v e hi c l e Re pa i r Speci al T ool (s) Engi ne s up po r t b r acke t 303-021 Engi ne l i f t i ng e ye 303-1067 R em ova l All v e h icle s 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r ca[...]

  • Page 788

    4. D et a ch t he wi ring ha r ne s s f r om t he e ng i ne co ve r mount i ng bracket . 5. D et a ch t he e l e c t r i cal co nne ct or f r om t he e ngi ne c ove r mount i ng b r a cket . 6. Remove t he e ngi ne cover mount ing bra c ket . 7. Ins t a l l the s p e ci a l t o ol . Ti ght e n t o 23 Nm. 8. Usi ng t he s pe cia l t oo l , s uppo r [...]

  • Page 789

    Vehi c le s bu ilt up to VI N: E4 386 8 9. D i s conne ct t he f uel p ump f ue l s upp l y an d r e t ur n l i ne s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Ins t al l bl a nki ng pl ugs t o t he f[...]

  • Page 790

    13. S e cur e t he p o we r s t e e r i ng fl ui d r e s e rv oi r to one s id e . 14. Remove t he e n gi ne mount da mpe r . 15. NO TE: Mark t he pos i t i on o f the e ng ine mo unt b e fo re remo v al . Re move t h e e ngi ne mount a nd b r a cket a s s e mbl y. 16. Remove t he e n gi ne mount . Vehi c le s bu ilt from VIN :E4 38 69 JagDocs.com[...]

  • Page 791

    17. Dis c o nne ct t he f uel pump fue l sup pl y and r e t urn l i ne s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Ins t al l bl a nki ng pl ugs t o t he f ue l pu m p f uel s uppl y a nd ret ur n l [...]

  • Page 792

    22. Remove t he e n gi ne mount . Insta llat ion Vehi c le s bu ilt from VIN :E4 38 69 1. NOT E: Cl e an t he front e ngi ne mount mat in g f a c e s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 80 Nm. 2. Tig ht e n t o 80 Nm. 3. Tig ht e n t o 10 Nm. Vehi c le s bu ilt up to VI N: E4 386 8 JagDocs.com[...]

  • Page 793

    4. NOT E: Cl e an t he front e ngi ne mount mat in g f a c e s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 80 Nm. 5. Tig ht e n t o 80 Nm. 6. Tig ht e n t o 10 Nm. All v e h icle s 7. Tig ht e n t o 23 Nm. JagDocs.com[...]

  • Page 794

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Flexplate I n-v e hi c l e Re pa i r R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e [...]

  • Page 795

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Flyw h eel I n-v e hi c l e Re pa i r R em ova l 1. Remove t he clut ch d i s c a n d p r e s s ur e pl at e . For ad di t i ona l inf o rm a t i o n, r ef e r t o : Cl ut ch Dis c a nd P res s u r e P l a t e (308- 01 Cl ut ch, Re mov a l a nd I[...]

  • Page 796

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Intake Manifo ld I n-v e hi c l e Re pa i r R em ova l 1. Remove t he a i r cl ea ne r a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.0L [...]

  • Page 797

    6. Remove t he i nt a ke man if ol d . Re mov e a nd di s c a r d t he i nt a ke m a ni fo l d g a ske t s. Insta llat ion 1. NOT E: Ins t a l l ne w i nt a ke mani fo l d gas ket s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 15 Nm. 2. NOT E: Ins t a l l a new EGR val ve ga s ket . Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 798

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Oi l Pan I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def l e ct o r - 2.2L Di e s el /2.0L Di es e l (501-0 2 Fr ont End Bod y Pa n e l s[...]

  • Page 799

    Insta llat ion All v e h icle s 1. CAU TI O N : Avoi d d a mage t o the oi l pan mat i ng f ace o f t he cy l i nd e r bl o ck . Fa i l ur e t o f o l l ow th i s i ns t r uct i on may ca us e d a mage t o t he ve hi cle . Cl e a n t he cyl i nde r bl o ck m a t i ng f a ces . 2. CA UT I O NS: A ne w o i l pa n must be i ns t al l e d. Fai l ure t [...]

  • Page 800

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - T imin g C hain I n-v e hi c l e Re pa i r Speci al T ool (s) Ti mi ng To o l , Cr anks ha f t 303-698 (2 1-251 ) R em ova l 1. Remove t he e ngi ne f r ont co v e r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Eng i ne Fr ont Co ver [...]

  • Page 801

    7. Usi ng s uit ab l e 6 mm ba r , l o ck t he t i mi ng d rive s p r o cket s . 8. D et e ns i o n a nd lo ck t he t i mi ng cha i n t e ns io ne r . 1. Re t ract t he p a wl . 2. P us h t he l o ck i n. 3. I ns e rt a p in . 9. NOT E: Engi ne r e moved fo r cla rit y . Re move t h e t i ming chai n t e ns i o ne r a nd gui de s . JagDocs.com[...]

  • Page 802

    10. Remove t he t i mi ng cha i n. Insta llat ion 1. CAU TI O N : Make s ur e t h e col or e d l i nks a l i g n t o t he ti ming mark s. Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . I nst a l l t he t i mi ng cha in. JagDocs.com[...]

  • Page 803

    2. CAU TI O N : Make s ur e t h e t i m i ng chai n te ns i o ne r i s f ul l y r e t r a cte d bef o r e i ns ta l l a t i on. Fa i l u r e t o f o l l ow t hi s i ns t r uct i on m a y r es ult i n da mag e to the ve hi cle . • NO T E: Engi ne r emove d f o r cl a r it y. I nst a l l t he t i mi ng cha in t e ns i o ne r a nd gui de s . Ti ght [...]

  • Page 804

    5. Tig ht e n t o 33 Nm. 6. Remove t he s ui t a bl e 6 mm ba r. 7. Remove t he s p e cia l to o l from t h e cr anks ha f t pos i t io n ( CKP ) s e ns o r hol e . 8. NOT E: O nl y t ur n t he e ngi ne i n t he norm a l di rect i o n o f rot a t i o n. Us i ng a s ui t a b l e s c r e wdr ive r, t ur n t he en gi ne cl o ck wis e t wo r e vol ut i[...]

  • Page 805

    9. Ch eck t he cams ha f t ti ming by i ns e rti ng a s ui t a bl e 6 mm b ar t hr oug h t he ho le s i n t he cams ha ft and fue l i nj e ct i on pump s pr ocket s . 10. Check t he t i ming by ins e r t i ng t he s peci a l t o ol i n t he CKP s e ns o r hol e . 11. Remove t he s pe ci a l t o o l and th e s ui t a b l e 6 mm bar. 12. Ins t a l l [...]

  • Page 806

    Name Hi g h p r es s ur e f ue l s u ppl y l i ne uni o n l ubrica nt TBD P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - V alve C over I n-v e hi c l e Re pa i r Speci al T ool (s) Al i gner, Fuel I nj e cto r 303-711 (2 1-258 ) Ge nera l Equi pm ent P ne umat i c vacuum gun Mate ri a l s Spe[...]

  • Page 807

    2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he e ng i ne o i l f i l l e r cap t o pr e vent f o r ei gn mat e ria l e nt e r i ng t he val v e c ove r . Re move t h e e ngi ne cove r. 4. CAU TI O N : P r ot ect t he fu e l i nj e ct o r e l e c t r i cal co nne ct ors wi t h li nt -free mat e ria l t o p r e vent c ont a mi na t i [...]

  • Page 808

    7. NOT E: O ne pi pe s h own o t he r pip e s a re s i mi l a r . Re move a nd di s ca r d t he hig h-pr e s s ure f uel s uppl y li ne . 8. Usi ng t he p neumat i c va cuum g un , va cuum forei g n mat e r i a l from t h e fu e l i nj e ct o r a nd t he f ue l i nj e ct i o n s uppl y mani f o l d. 9. Ins t a l l bl a nk i ng cap s t o t he o pe n[...]

  • Page 809

    13. Dis c o nne ct t he mas s a i r fl o w (MA F) s e ns or e l ect r i cal conne ct o r. 14. Det a ch t he s t ar t e r moto r wi r i ng harne ss . 15. Det a ch t he cy li nde r he a d t e mperat ure (CH T) s e n s or e l e c t r i cal conne ct or. 16. Dis c o nne ct t he CHT s e ns or el e ct r i cal co nnect o r. 17. Dis c o nne ct t he p o s i [...]

  • Page 810

    18. Det a ch t he s t ar t e r moto r a nd i nj e ct o r wiring ha rn e s s . Re pos i t i o n a nd t i e t he wiring ha r ne s s a s i de . 19. NO TE: Ri ght -hand s ho wn l ef t -hand s i m i l a r. Det ach t he mas s a i r fl o w (MA F) s e ns or wi r i n g ha r ne s s . Re pos i t i o n a nd t i e t he wiring ha r ne s s a s i de . 20. Remove t[...]

  • Page 811

    23. Remove t he va l ve cover. Re mov e a nd di s c a r d t he val ve cove r g a ske t . Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t ype whe n wo rk i ng on o r ne ar an y f uel rel a t ed com po ne nt s . Hi ghl y fl a mm a b l e mixt ur e s a r e a l wa ys pr e s e nt and may i g ni[...]

  • Page 812

    3. NOT E: Do not t i ght e n t he r et ai ni ng bo l t s a t t h is s t age . I nst a l l t he f ue l r ai l br a c ket s . 4. NOT E: Do not t i ght e n t he r et ai ni ng bo l t s a t t h is s t age . I nst a l l t he f ue l i nj e c t i o n s upp l y mani f o l d r e t ai ni ng bo l t s . 5. Loos e n t he fue l inj ect i on s u ppl y mani f o l d[...]

  • Page 813

    8. Connect t he po s it i ve cr ankcas e ve nti l a t i o n (P CV) hos e t o t h e va l ve cover. 9. Connect t he CHT se ns o r e l e c t r i cal co nne ct or. 10. At t ach t he (CH T) s e ns o r e l e c t r i cal co nne ct or. 11. At t ach t he s t arte r mot o r wi ring ha rn es s . 12. Conne ct t he MAF s e ns o r el e ct r i cal co nnect o r. J[...]

  • Page 814

    13. NO TE: O ne f ue l i nj e ct or s ho wn o t he r fue l i nje ct o rs a r e s i mil a r . I nst a l l a ne w v a l ve cove r f ue l i nj e c t o r se al . 14. Lubr i cat e t he hi g h-pr e ss ure f ue l s uppl y l i ne u nio n t hr e a ds wi t h cl e a n l ubrica nt . 15. CAUT I O N: Do no t a l l o w t he uni ons t o hi t the ol ive e nds o f t[...]

  • Page 815

    19. NO TE: Hi gh pr e s s ur e f uel s upp ly l i ne s s hown r emove d f o r cl arit y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif o ld ret a i ni ng bo l t s. Ti ght e n t o 23 Nm. 20. NO TE: Hi gh pr e s s ur e f uel s upp ly l i ne s s hown r emove d f o r cl arit y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif o ld ret a [...]

  • Page 816

    24. Conne ct t he f uel i nje ct o r e le ctrica l conne ct o r s . 25. Conne ct t he f uel ret urn l i ne s to t he f ue l i nj e ct o rs. 26. Ins t a l l t he e ngi ne cover. 27. Ins t a l l t he oi l f il l e r cap . 28. Ins t a l l t he oi l l e vel i ndi cat o r . JagDocs.com[...]

  • Page 817

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine2.0L Duratorq-TDCi Re moval Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho s e Cl amp 303-3 97 (24- 003) Bal l jo i nt s pl i t t e r 204-1 92 W he el hub pu ll e r 205-4 91 Adap t or nut s 205-4 91-01 For c i n g s cr ew 204[...]

  • Page 818

    Engine li f t i ng e ye 303-1 067 5 P o i nt S e cur i t y T or x Bi t 418-5 35 R em ova l 1. D et a ch t he l o we r s t e e r i ng col um n s ha ft . 2. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n). [...]

  • Page 819

    7. D i s conne ct t he radi a t o r l owe r coo l a nt hos e . 8. CAU TI O N : To pr eve nt t he veh icl e beco ming uns t ab l e whe n t he e ngi ne a nd tra nsmi s s i o n a s s e mbl y a r e r e m ove d , i ns t a l l t he ve hi cl e ti e -do wn s t r a ps . Fai l ur e t o f ol l o w t hi s i nst r ucti o n may res ul t i n da ma ge t o th e v e[...]

  • Page 820

    14. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake ca l i pe r a nd brake cal i pe r a nchor p l a t e a s s e mbl y. 15. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 16. CAUT I O N: Su ppo r t t he brake ca l i per a s s e mbly us i ng t i e s t raps . Fai l ure t o fo l l o w t hi [...]

  • Page 821

    19. CAUT I O N: Secur e the AB S wh ee l s pe ed s e ns or us i n g t i e s t r aps . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re po s i t i o n a n d a t t a ch t he ABS whe e l s p e ed s e ns o r . 20. NO TE: Re move a nd di s ca [...]

  • Page 822

    24. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps . Det ach t he s e le cto r cabl e s. 1. P r es s t he r et a i ni ng c l i p . 2. De ta ch t he s e l e ct or cabl e s . 25. Remove t he f ront bumpe r s pl i t te r vai n. 26. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front bumpe r s pl i tt e r v a i[...]

  • Page 823

    29. Dis c o nne ct t he b rak e va cuum pum p va cuum hos e . 30. Dis c o nne ct t he e xhaus t ga s recircu l a t i o n (E.G.R) va lve modul e vacuum ho s e. 31. Dis c o nne ct t he e xpa ns i o n t a nk ve nt hos e . 32. Det a ch t he coo l i ng s y s t e m hos e . 33. Dis c o nne ct t he e xpa ns i o n t a nk o ut l e t hos e . JagDocs.com[...]

  • Page 824

    34. NO TE: T he ret a i ni ng bo l t remai ns ca pt i ve i n t he e l e ct r ica l conne c t o r . Di s conn ect t he e ngi ne ha r ne s s e le ctrica l co nnect o r . 35. Dis c o nne ct t he g l ow pl ug ha r nes s e l e ct rical c onn e cto r . 36. Dis c o nne ct t he b a t t e r y cabl e s . 37. Det a ch t he wi ring ha r nes s from t he ba t t [...]

  • Page 825

    39. CAUT I O N: I f f l ui d i s s p il t o n t he pa i nt wo rk , t he a f f e ct e d a rea m us t b e i mmedi a t e l y wa s he d do wn wit h col d wa t e r . Fa i l ure t o f ol lo w t hi s in s t ruc t i o n may r es ul t i n da mag e t o t he v eh icl e. • NO T E: Dr ai n t he f l ui d i nt o a s ui t a bl e cont ai ne r . • NO T E: Ca p t[...]

  • Page 826

    44. Det a ch t he powe r a s si s te d s t e ering ho s e . 45. NO TE: Ca p t he e xpos e d po rts . Di s conn ect t he po we r as s i s t e d s t e e r i ng hos e . 46. NO TE: Ca p t he e xpos e d po rts . Di s conn ect t he E.G. R va lve va cuum p i pe . 47. Loo s e n t he ai r condi t i o ni ng compr e ss o r l i ne r e t a in ing bol t . 48. NO[...]

  • Page 827

    49. Dis c o nne ct t he f uel l ine s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Ins t al l bl a nki ng pl ugs t o t he f ue l pu m p f uel s uppl y a nd f ue l ret ur n li ne mal e and fe mal e c o n[...]

  • Page 828

    53. NO TE: Bo l t r emai ns cap ti ve i n t he e ngi ne cont r ol m od ul e (ECM) e l e ct r i cal conne ct o r . Us i ng t he s p e ci a l t o ol , d i s co nne ct t he ECM ha r n e s s e l e ctrica l conne ct o r . 54. Det a ch t he eng i ne wi ring ha r nes s ret a i ni ng cl i p. 55. Det a ch t he eng i ne wi ring ha r nes s e a r t h l ea d . [...]

  • Page 829

    59. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 60. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 61. Po s i t i o n and adj ust t he s p e ci al t oo l e ngi n[...]

  • Page 830

    63. NO TE: Di s card t he r e t ai ni ng nut s . Re move t h e e ngi ne f r on t mount r et a i ni ng nut s . 64. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 65. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf[...]

  • Page 831

    68. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the co m po ne nt . P la ce t he e ng i ne , s us pe ns i on a nd t ransmi s s i o n a s s e mbl y t o a s ui t a bl e work i ng a r ea . 69. Det a ch t he eng i[...]

  • Page 832

    73. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move a nd di s ca r d t he whe e l hub nut s . 74. CAUT I O N: W h e n t he ti e -r od e nd i s se pa r at e d from t he whe e l hub a ss e mbly, t he b a l l jo i nt s e a l s houl d b e pr o t e c t e d t o pr e ve nt damag e . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r[...]

  • Page 833

    78. Us i ng t he s pe ci a l t o o l s , re m o v e t he drive ha l f s ha f t . 79. Remove a nd di s car d t he dr ive ha l f s haf t s nap r i ng. 80. Remove t he d rive ha l f s ha f t . 81. NO TE: Di s card t he O -r ing s e a l s . • NO T E: Ca p t he e xpos e d po r t s . Di s conn ect t he po we r s t e ering l i ne s . 82. Det a ch t he w[...]

  • Page 834

    83. Remove t he e n gi ne rol l r e s t r i ct o r . 84. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the co m po ne nt . Us i ng a s ui t a b l e hydr aul i c l i f t , remove t he engi ne a nd t rans mi s si [...]

  • Page 835

    88. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 89. Remove t he va cuum r e gul a t o r s o l e no i d val ve. 1. Dis con nect t he e l e c t rical co nnect ors . 2. De ta ch t he va c uum hos e s . 3. Re move t he vacuum r e gul a t o r s o le noi d va lve . 90. Det a ch t he s t ar t e r moto r wi r i ng harne ss . [...]

  • Page 836

    92. Dis c o nne ct t he s t arte r mot o r wi ring ha rn es s e l e ct r i ca l conne cto r . 93. Det a ch t he s t ar t e r moto r wi r i ng harne ss . 1. Dis con nect t he s t a r t e r mot o r e l e ct r i cal conne cto r. 2. Dis con nect t he s t a r t e r mot o r s o l e no i d e l e c t r i cal co nnect o r. 94. Remove t he s t arte r mot o r[...]

  • Page 837

    96. Remove t he t r ans mis s i o n up pe r r e t a i ni ng bo l t s . 97. Remove t he t r ans mis s i o n right -hand ret a i ni ng bol t s . 98. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the co m po ne nt [...]

  • Page 838

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine2.2L Duratorq-TDCi (1 10kW/150P S) - Pu ma Re moval Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho s e Cl amp 303-3 97 (24- 003) Bal l jo i nt s pl i t t e r 204-1 92 W he el hub pu ll e r 205-4 91 Adap t or nut s 205-4 91-01[...]

  • Page 839

    1. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 2. Remove t he s t ee ring co l umn coupl i ng. 3. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n). 4. Recover t he a [...]

  • Page 840

    8. D et a ch t he e l e c t r i c bo o st e r hea t e r el e c t r i cal co nnect or fr om t he s ub frame r e t a i ni ng t a ng. 9. D et a ch t he coo l a nt ho s es from t he r e t a i ni ng cl ip s . 10. Det a ch t he coo l a nt ho se . Dis conne ct t he co o l a nt ho s e . Vehi c le s with f uel fire d boo ster he ate r 11. Dis c o nne ct t h[...]

  • Page 841

    12. Det a ch t he coo l a nt ho se . 13. Dis c o nne ct t he co o l a nt hos e . All v e h icle s 14. Dis c o nne ct t he radi a to r l owe r co o la n t hos e . 15. CAUT I O N: T o p r eve nt t he vehi cl e be co ming uns t abl e whe n t he e ngi ne a nd tra nsmi s s i o n a s s e mbl y a r e r e m ove d , i ns t a l l t he ve hi cl e ti e -do wn [...]

  • Page 842

    16. CAUT I O N: T o p r eve nt t he vehi cl e be co ming uns t abl e whe n t he e ngi ne a nd tra nsmi s s i o n a s s e mbl y a r e r e m ove d , i ns t a l l t he ve hi cl e ti e -do wn s t r a ps . Fai l ur e t o f ol l o w t hi s i nst r ucti o n may res ul t i n da ma ge t o th e v e hi cl e . • NO T E: Ri ght -ha n d s hown, l ef t -hand s [...]

  • Page 843

    22. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 23. CAUT I O N: Su ppo r t t he brake ca l i per a s s e mbly us i ng t i e s t raps . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re po s i t i o n [...]

  • Page 844

    27. NO TE: Re move a nd di s ca r d the O -ring s e a l . • NO T E: Ca p t he e xpos e d po r t s . Di s conn ect t he s uct io n a cc umul a to r pi pe . 28. Dis c o nne ct t he a i r t e m pe r at ur e s e ns or e l ect r i cal co nnect o r. 29. Dis c o nne ct t he hi g h i nt e ns it y di s charge (H.I .D) s e ns or drop a r m . 30. Det a ch t[...]

  • Page 845

    32. NO TE: Drai n t he f lui d i nt o a s ui t a bl e co nt a i ne r. • NO T E: Ca p t he e xpos e d po r t s . • NO T E: U s e care wh e n rep os i t i oni ng p ow er as s i s t e d s t e e r i ng hos e . Di s conn ect t he po we r as s i s t e d s t e e r i ng hos e . Re mov e t he p o we r as si s te d s t ee ring ho s e ret a i ni ng cl i p[...]

  • Page 846

    37. Det a ch t he coo l i ng s y s t e m hos e . 38. Dis c o nne ct t he e xpa ns i o n t a nk o ut l e t hos e . 39. NO TE: T he ret a i ni ng bo l t remai ns ca pt i ve i n t he e l e ct r ica l conne c t o r . Di s conn ect t he e ngi ne ha r ne s s e le ctrica l co nnect o r . 40. Dis c o nne ct t he g l ow pl ug ha r nes s e l e ct rical c onn[...]

  • Page 847

    42. Det a ch t he wi ring ha r nes s from t he ba t t e r y t ray mount . 43. CAUT I O N: I f f l ui d i s s p il t o n t he pa i nt wo rk , t he a f f e ct e d a rea m us t b e i mmedi a t e l y wa s he d do wn wit h col d wa t e r . Fa i l ure t o f ol lo w t hi s in s t ruc t i o n may r es ul t i n da mag e t o t he v eh icl e. • NO T E: Dr a[...]

  • Page 848

    47. Loo s e n t he ai r condi t i o ni ng (A/C) compr e ss o r li ne ret a i ni ng bol t . 48. NO TE: Re move a nd di s ca r d the O -ring s e a l s . • NO T E: Ca p t he e xpos e d po r t s . Di s conn ect t he A/C compr es s or l i ne s. 49. Dis c o nne ct t he f uel l ine s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l[...]

  • Page 849

    52. Det a ch t he eng i ne wi ring ha r nes s e l e ct rica l c on ne ct or . 53. NO TE: Bo l t r emai ns cap ti ve i n t he e ngi ne cont r ol m od ul e (ECM) e l e ct r i cal conne ct o r . Us i ng t he s p e ci a l t o ol , d i s co nne ct t he ECM ha r n e s s e l e ctrica l conne ct o r . 54. Det a ch t he eng i ne wi ring ha r nes s ret a i n[...]

  • Page 850

    57. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps . Det ach t he s e le cto r cabl e s. 58. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he s t r ut a nd s pr ing as s e m bl y. 59. Rai se th e v e hi cl e . 60. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t h[...]

  • Page 851

    62. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 63. Po s i t i o n and adj ust t he s p e ci al t oo l e ngi ne he i ght a d j us t e r s . 64. Remove t he e n gi ne re ar mount re ta i ni ng nut . 65. NO TE: Di s card t he r e t ai ni ng nut s . Re mo[...]

  • Page 852

    66. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 67. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e . 68. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he f r ont s ubf r a[...]

  • Page 853

    71. Remove t he e n gi ne , s us pe ns i o n a nd t r a nsmi s s i o n a s s e mbl y. Rot a t e th e s pe ci a l t o o l he i ght a d ju s t ment va l ve co unt e r cl o ck wi s e . 72. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may[...]

  • Page 854

    76. Ins t a l l t he e ngi ne rear l i f t i ng e ye. 77. Remove a nd di s car d t he r i g ht -hand whe e l hub nut . 78. CAUT I O N: W h e n t he ti e -r od e nd i s se pa r at e d from t he whe e l hub a ss e mbly, t he b a l l jo i nt s e a l s houl d b e pr o t e c t e d t o pr e ve nt damag e . Re move a nd di s ca r d t he r i ght -ha nd t i[...]

  • Page 855

    81. Remove t he rig ht -ha nd wh e el knuck l e a nd s t rut. 1. Re move a nd di s car d t he l owe r a rm ba l l j o i nt r e t a i ni ng nut a nd bo l t. 2. Re pos i ti on t he l owe r a r m s . 3. Re move t he whe e l knuc kle a nd s t ru t . 82. Remove t he rig ht -ha nd d r i v e hal fs ha ft . 83. Remove a nd di s car d t he dr ive ha l f s h[...]

  • Page 856

    [...]

  • Page 857

    91. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 92. Dis c o nne ct t he e mi s s i on c ont r ol s o l e noi d e l e ct r ica l conne ct o r . 93. Dis c o nne ct t he e mi s s i on c ont r ol s o l e noi d ho s e. 94. Remove t he e mi s s i on c ont r ol s o l e noi d a s s e mbl y. 95. Det a ch t he s t ar t e r moto[...]

  • Page 858

    96. Remove t he s t arte r mot o r wi ring ha rn es s ret a i ni ng b r ack e t . 97. Dis c o nne ct t he s t arte r mot o r wi ring ha rn es s e l e ct r i ca l conne cto r . 98. Det a ch t he s t ar t e r moto r wi r i ng harne ss . 1. Dis con nect t he s t a r t e r mot o r e l e ct r i cal conne cto r. 2. Dis con nect t he s t a r t e r mot o r[...]

  • Page 859

    101 . Re move t he t r a ns mis s i o n up pe r r et ai ni ng bo l t s . 102 . Re move t he t r a ns mis s i o n rig ht -ha nd r e t a i ni ng bol t s . 103 . CAU T IO N: Do no t s upp or t t he e ng i ne a nd t r ans a x l e a s s e mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the c[...]

  • Page 860

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Dis a s s e mbl y Speci al T ool (s) Engine st a nd 303-0 11 Uni vers al Fl ange Ho l di ng W r e nch 205-0 53 Adap t er fo r 205-05 3-02 205-0 53-02 Ti ming Too l , Cr anksh a ft 303-6 98 Remove r , Fue l Inj e c t or 303-7 11 Remove r /[...]

  • Page 861

    2. D et a ch t he gl ow pl ug wi r i ng ha r ne s s . Re mov e t he g l o w pl ug wiring ha r ne s s s e cur ing nut . 3. D et a ch t he wi ring ha r ne s s f r om t he i nt a ke mani f o l d. JagDocs.com[...]

  • Page 862

    4. D et a ch t he wi ring ha r ne s s f r om t he a i r cond it i o ni ng (AC) compr e s s o r. 5. D i s conne ct t he AC compr e s s o r e le ctrica l conne ct o r . 6. D et a ch t he wi ring ha r ne s s f r om t he ret a i ni ng s t ud . 7. D et a ch t he mas s a i r f l o w (MAF) se ns o r wiring ha r ne s s . 8. D et a ch t he ge ne r a t o r w[...]

  • Page 863

    9. Remove t he wi r i ng ha r ne s s . 10. Det a ch t he acce s s o r y drive be l t . 1. Re pos i ti on t he acce s s o r y dr ive be l t t e ns io ne r . 2. De ta ch t he a cces s ory dr i ve be lt . 11. Remove t he a cces s o r y drive be l t . 1. Re move t he a cces s ory d r i v e be l t t e n s i o ne r . 2. Re move t he a cces s ory d r i v [...]

  • Page 864

    14. Dis c o nne ct t he g e ne r at o r e l e ct r i cal conne cto r. 15. Remove t he g e ne r at o r. Re mov e t he w i r i ng ha r nes s s uppor t br acket f r om t he ge n e r at or uppe r r et a i ni ng bol t . 16. Remove t he a cces s o r y drive be l t t e ns i one r br acket . Vehi c le s with 2.2L die sel engine 17. Remove t he cha r ge a i[...]

  • Page 865

    18. Remove t he t ur bo o ut le t pi pe ret a i ni ng b o lt . 19. Remove t he t ur bo o ut le t pi pe a nd cha r g e a i r coo l e r i nt a ke p i pe a s s e mbl y. All v e h icle s 20. Remove t he t ur bo c ha rg e r he a t s hi e l d. 21. Remove t he ca t a l y t i c co nverte r r e t a i ni ng b ol t s . Re mov e t he ca t al yti c conve r t e [...]

  • Page 866

    22. Remove t he ca t a l y t i c co nverte r. Re mov e a nd di s c a r d t he r et a i ni ng nut s . 23. Remove t he ca t a l y t i c co nverte r r e t a i ni ng b r a cket . 24. Remove t he ha l f s haf t r e t a i ni ng bracket . 25. Remove t he e xhaus t ga s recircu l a t i o n (EGR) coo l e r coo l ant ho s e . 26. Us i ng t he s pe ci a l t o[...]

  • Page 867

    27. Dis c o nne ct t he t ur bo c ha rg e r va cuum ho s e . 28. Remove t he a i r f i l t e r o ut l e t tu be re t a i ni ng cl i p. 29. Remove t he a i r f i l t e r o ut l e t tu be . 30. Remove t he p o we r a s s i s t e d s t e e ring hi gh -pr es s ure p ip e . Dis car d t he O -r i ng s ea l . 31. Dis c o nne ct t he co o l a nt hos e . Ja[...]

  • Page 868

    32. Remove t he co o l a nt hos e . 33. Remove t he co o l a nt hos e . 34. Remove t he s t arte r mot o r t o ge ne rat o r wi ring ha rn e s s . 35. Remove t he i nt a ke mani f o l d. Re mov e a nd di s c a r d t he i nt a ke m a ni fo l d g a ske t s. 36. Remove t he g l ow pl ug wi r e r et ai ni ng nut s . JagDocs.com[...]

  • Page 869

    37. Remove t he g l ow pl ug wi r i ng ha r ne s s . 38. Remove t he g l ow pl ugs . 39. Remove t he o i l l e v e l i ndi cat or and t ube . 40. Remove t he b rak e va cuum pu m p re ta i ni ng bo l t s . Re mov e t he p o we r s t e e ring pump be l t cove r . 41. Remove t he p o we r s t e e r i ng pump be lt . Rot a t e th e powe r s t e e ring[...]

  • Page 870

    42. Remove t he p o we r a s s i s t e d s t e e ring pu m p b rack e t r e t a i ni ng bo l t s . 43. Dis c o nne ct t he co o l a nt hos e f r om t he wa t e r pump. 44. Remove t he wa t e r pum p a nd pow er a s s i s t e d s t e e r i ng pump a s se mbl y . Re mov e a nd di s c a r d t he gas ke t. 45. Dis c o nne ct t he o i l pre ss ur e sw i[...]

  • Page 871

    47. Dis c o nne ct t he kno ck se n s o r (KS ) e l e ct rica l c o nne ct or . 48. Det a ch t he wi ring ha r nes s. 49. NO TE: P rot e ct t he f ue l met e ring val ve a nd f ue l t e mper a t ur e s e ns o r e l e ct r i cal conne ct o r s wi t h l i nt f r e e cl o t h t o pre v e nt cont a mina t i o n f r o m t he c l e a nin g f l ui d . Di [...]

  • Page 872

    51. Remove t he f l ywhe el . Re mov e a nd di s c a r d t he r et a i ni ng bo l t s . 52. Remove t he i dl e r pul l e y. 53. Remove t he e n gi ne f r o nt mount br acket . 54. Dis c o nne ct t he o i l s uppl y t ube from t he t ur b o c ha rg e r. Re mov e a nd di s c a r d t he s e a l i ng wa s he r s . 55. Det a ch t he oi l su ppl y t ube [...]

  • Page 873

    56. Remove t he o i l s uppl y t ube . 57. Dis c o nne ct t he o i l ret urn t ube from t he t urbocha r ge r . Re mov e a nd di s c a r d t he gas ke t. 58. Remove t he o i l ret urn t ube. Re mov e a nd di s c a r d t he O -r ing s e a l . 59. Remove t he EGR co o l e r m ount b r acket ret a i ni ng b o l t . 60. Remove t he EGR co o l e r m oun[...]

  • Page 874

    61. Remove t he e xhaus t mani f o l d. Re mov e a nd di s c a r d t he r et a i ni ng bo l t s a nd nut s . 62. Det a ch t he cy li nde r he a d t e mperat ure (CH T) s e n s or e l e c t r i cal conne ct or. 63. Dis c o nne ct t he CHT s e ns or el e ct r i cal co nnect o r. 64. Dis c o nne ct t he ca ms haf t p o si t i on (CMP) s e ns or el e c[...]

  • Page 875

    • NO T E: Inj e ct or numb e r 4 s ho wn, i nj e ct or numbers 1, 2 a n d 3 s i mil a r . Lo o s e n t he hi gh-pr e s s ure f uel s uppl y l i ne f r om t he f ue l i nj e ct o r a nd f uel i nj e ct i o n s uppl y mani fo l d. 66. CAUT I O N: Ma k e s ure t hat t he hi gh-pr e s s ure f uel s uppl y li ne r e m a i ns in con ta ct wi t h b o t [...]

  • Page 876

    73. CAUT I O N: Ma k e s ure t hat t he f uel i nj e cto r do es not mo v e when lo o s eni ng th e fue l inj e ct or l o ck ing col l a r . Fa i l ur e t o f o l l o w t hi s ins t r ucti on wil l r e s ul t i n d ama ge t o t he f u e l i nje ct o r an d t he fue l i nj e cto r se a li ng wa she r . • NO T E: Inj e ct or numb e r 4 s ho wn, i n[...]

  • Page 877

    m a ni f ol d unt i l b ot h uni o ns ha ve be e n de ta che d a nd cl e ane d . Fa i l ure t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n f o r ei gn m a t t e r i ngres s t o t he f uel in j ect i o n s yst e m. Us i ng t he pne u m a t i c vacuum gun, va cuum f o rei gn m a t eria l f r om t he hi gh-pr e s s ure f uel s uppl y li ne [...]

  • Page 878

    86. Remove t he f u el i nje ct i on s upp l y mani f o l d ret a i ni ng bol t s . 87. Loo s e n t he fue l i nj e ct io n s up pl y mani f o l d s up po r t br a cket s . 88. Remove t he s o und pr oo f p add i ng. 89. Remove t he f u el i nje ct i on s upp l y mani f o l d . 90. Remove t he va l ve cover. Re mov e a nd di s c a r d t he val ve c[...]

  • Page 879

    91. Us i ng t he s pe ci a l t o o l s , re m o v e t he cr anks ha ft da mpe r . 92. Remove a nd di s car d t he engi ne front co ver. Re mov e t he e n gi ne f ront co ver ret a i ni ng n ut s a nd b ol t s . 93. Tur n t he cr an k s ha ft t o 50 de g r e e s be f ore t o p d e ad c e nt e r (BTDC) a nd i ns e r t the s pe ci a l t o ol 30 3-698,[...]

  • Page 880

    94. Us i ng s ui t a b l e 6 mm ba r , l o ck th e t i ming d r i ve s pr ocket s. 95. Loo s e n t he c a msha f t s p r ocket r e t ai ni ng bo l t s . 96. Loo s e n t he fue l i nj e ct io n pump s p r ocket r e t ai ni ng bo l t s . 97. Us i ng a s uit a bl e t o ol , ret a in t he t i mi ng chai n t e ns i o ne r pi s t on. 1. Re t ract t he p [...]

  • Page 881

    98. Remove t he t i mi ng cha i n t e nsi one r a nd gui de s . 99. Remove t he t i mi ng cha i n. 100 . Re move t he hi gh-pres sure fue l pump ret a i ni ng b o lt s . JagDocs.com[...]

  • Page 882

    101 . Re move t he t imi ng chai n o i l f e e d p i pe . 102 . Re move t he hi gh-pres sure fue l pump. 1. Re move t he r e t a i ni ng bo l t s . 2. Re move t he hi g h-pr es s ur e f ue l pump. 103 . Re move t he KS . 104 . Re move t he rock e r sha f ts . Re mov e a nd di s c a r d t he r et a i ni ng bo l t s . JagDocs.com[...]

  • Page 883

    105 . CAU T IO N: Remove t he ca mshaf t ca r rie r bol ts i n t he s e quence s hown. Re move t h e cams ha f t carr i er. 106 . Re move t he ca msha f t s . Re mov e a nd di s c a r d t he i nt a ke c a m s ha f t rear oi l s e a l . JagDocs.com[...]

  • Page 884

    107 . CAU T IO N: Remove t he cyli nder he a d bo l t s in t he s e que nce s hown. Re move t h e cy l i nd e r he a d. Re mov e a nd di s c a r d t he cy l i nde r hea d ga s ket a nd t he bo l t s . 108 . Re move t he CKP s e ns o r. 109 . Re move t he CKP s e ns o r br acket . JagDocs.com[...]

  • Page 885

    110 . NO TE: Do not d i sca r d t he cranks haf t rea r o i l s e a l c a rr i e r . Re move t h e cr anks ha ft rea r oi l s ea l ca r r i e r . 111 . Re move a nd d i sca r d t he o i l pa n. Re mov e t he o i l pan r et ai ni ng nut s a nd b ol t s . 112 . Re move t he o i l pump pi ck up t ub e. Re mov e a nd di s c a r d t he O -r ing s e a l [...]

  • Page 886

    114 . CAU T IO N: Remove t he l a dde r f r a m e b ol t s i n t he s equ e nce s hown. Re move t h e l a dd e r f rame. Re mov e a nd di s c a r d t he l a dde r frame g a s ket . 115 . NO TE: O ne pi s t o n o i l coo l e r j et s ho wn, o t he r pi s t on oi l coo l er j e t s s i mi l a r . Re move t h e pi s t o n oi l c o ol er j e t s . 116 [...]

  • Page 887

    118 . CAU T IO N: Kee p t he cr a n ks haf t mai n b ea ring ca ps i n orde r f or in s t a l l a t i o n. Re move t h e cr anks ha ft ma i n b e a r i ng caps . 119 . Re move t he cr anksha f t . JagDocs.com[...]

  • Page 888

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine As se mbl y Speci al T ool (s) P is t o n r i ng compr es s or 303-372 Uni ve r s a l Fl a nge Ho l di ng W rench 205-053 Ada p t e r f or 205-053 205-053- 02 Be dp l a t e a l i gnmen t pl a t e 303-1095 Re mover /Ins t a l l e r Cr a nk[...]

  • Page 889

    Re mover /Ins t a l l e r , Co o l i ng Ho s e Cla m p 303-397 Engi ne s t and 303-011 A ssemb ly All v e h icle s • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t ype whe n wo rk i ng on o r ne ar an y f uel rel a t ed com po ne nt s . Hi ghl y fl a mm a b l e mixt ur e s a r e a l wa ys pr e s e nt and[...]

  • Page 890

    4. CA UT I O NS: As se mbl e ca ps wit h a r rows po i nt i ng f o r war d. Ca ps a r e i de nt i fi ed from fr on t t o r ea r, F, 2, 3, 4, R. Cr anks ha f t mai n b ea ring cap b ol t s mus t on ly b e us e d f o ur t i mes . Ti g ht en t he bo l ts i n t hr e e s t a ge s i n t he s eq ue nce s ho wn. • NO T E: L ubr ica t e t he crank s haf t[...]

  • Page 891

    9. Ins t a l l the pi s t o n o il co o l e r je t s . 10. CAUT I O N: Do no t t rim o r da mage pr o t r udi ng f o am p a ds . • NO T E: Ins t al l n ew l a dd e r f rame g a s ket s . • NO T E: Do no t ful l y t i g ht en t he la d der f r ame r et ai ni ng n ut s a nd b ol t s a t th i s s t a ge . I nst a l l t he l a d de r frame. 11. CAU[...]

  • Page 892

    12. Ins t a l l t he ol d cr anksha f t rea r s e a l an d carr i e r . 13. CAUT I O N: T he la dde r f r ame a nd t he cy l i nd er bl ock mu s t be a li g ne d s o t ha t t he rea r c l e arance doe s not e xc ee d 0. 01 m m o v e rla p t o 0. 2 m m gap . Us i ng a s ui t a b l e s trai g ht e dge , a l i gn t he l a dd er f r ame t o t he cyli n[...]

  • Page 893

    15. Remove t he o l d c r a nk s ha f t rea r s e a l a n d carr i e r . Re mov e a nd di s c a r d t he cr a n k s ha ft re a r oi l s e a l . 16. NO TE: I ns t a ll a new cr anks ha ft rea r oi l s ea l car rie r a nd cr anks ha ft rea r oi l s e al ca r r ie r ret a i ni ng bol ts . • NO T E: A ne w cr anks ha ft rea r o i l s e a l c a r r i [...]

  • Page 894

    19. Us i ng a s uit a bl e di a l i ndi cat o r ga uge t a k e a ref e r ence m e a s urement f r om t he f r ont f a ce of t he cr a nksha f t s procket . 1. P o si t i on t he d ia l gauge ho l di ng fi xture o n t he cyl in de r bl o c k. 2. P o si t i on t he d ia l ind i ca to r ga ug e pl un ger on t he cranksha f t s p r ocket a nd s e t t h[...]

  • Page 895

    26. CAUTI O N S : A ne w o i l pa n must be i ns t al l e d I ns t a ll t he o il pa n wi t hi n f ive minut e s of a pp lyi ng t he s e a l e r. App l y a 3 mm be a d of s ea l er W SE- M 4G323- A4 t o t he o i l pa n. 27. NO TE: Do not f ul l y ti g ht e n t he o i l p a n ret a i ni ng bol t s a t thi s s t a ge . I nst a l l t he o i l pa n . 2[...]

  • Page 896

    30. NO TE: T i ght e n t he r e t a i ni ng bo l t s i n t he s equ e nce s ho wn. I nst a l l t he cl ut ch d i s c and pr e s s ure pl a t e. Ti ght e n t o 29 Nm. 31. NO TE: Do not f ul l y ti g ht e n t he cr a nksha f t po s i t i o n s e ns or br acket r e t a i ni ng bo l t s a t t his s t age . I nst a l l t he cr an k s ha ft p o s i t i o[...]

  • Page 897

    35. Mar k t he p o si t i o n o n t he fl ywh e e l pr i mar y mas s . 36. NO TE: Ro t a t e t he cr a nks haf t count erclo ck wi s e . Rot at e t he cr anksha f t unt i l t h e pi s t on numb e r one a chi e ves z e ro o n t h e di a l i ndi cat or gau ge . Mar k t he p o s i t i o n o n t he f l ywhee l primary mas s . 37. Repe a t th e pr e vio[...]

  • Page 898

    41. NO TE: Mark t he c a l cul at e d a mount o n t he fl y whe e l pr i ma r y mas s by m e a s uring f r o m TDC co unt e r clo ckwis e . Mul t i pl y t he cir cumference by 0.1388. 1. Fi rst mar k. 2. S e c o nd mark. 3. De te r mine d TDC. 4. De te r mine d 50 deg rees be f o r e t o p de a d cen t e r ( BT DC). 42. NO TE: Ro t a t e t he cr a [...]

  • Page 899

    46. NO TE: T he l a r ge s t me a su r eme nt d e t e r m i nes t he choi ce of t he cyl in der hea d gas ket . Us i ng a s ui t a b l e t o o l , m e as ur e t he pi s t o n prot ru s i on. 47. Det e r mi ne t h e cy l i nd e r he a d ga s ket t hi cknes s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Speci fi cat i ons (3 03-01B Engi [...]

  • Page 900

    50. Appl y a 2.5 mm di a met er be a d o f s e al e r W SE- M 4G323- A4 t o t he m a t ing f a ce of t he cyli nder he a d. 51. Remove t he ca ms haf t s . Re mov e a nd di s c a r d t he i nt a ke c a m s ha f t rear oi l s e a l . JagDocs.com[...]

  • Page 901

    52. NO TE: T i ght e n t he bol t s i n t h e s e que nce s hown i n t wo s t a ge s . I nst a l l t he cams ha f t carr i er. S ta g e 1: T i ght en bol t s 1 t hrough 22 t o 23 Nm. S ta g e 2: T i ght en bol t s 23 t hrough 25 t o 10 Nm. 53. Us i ng s pe ci a l t ool 308-417, i ns t a l l a ne w ca msha f t r ea r s e a l. 54. NO TE: Do not f ul [...]

  • Page 902

    55. NO TE: I ns t a ll n e w r ock e r s ha ft ret a i ni ng bol t s . • NO T E: L ubr ica t e t he roc ker s h af t s wit h cle a n e ng in e o i l. • NO T E: T he o i l s uppl y ho l e s i n t he r o ck er s ha f t s mus t p oi nt do wn. • NO T E: T ig ht e n t he bo l t s i n t wo s t a g e s . I nst a l l t he r ocker s ha ft s . S ta g e[...]

  • Page 903

    59. Ins t a l l t he hi gh-pr e s s ure f uel p ump r e t a i nin g b o lt s . Ti ght e n t o 22 Nm. 60. CAUTI O N S : Do no t t ig ht e n t he hi gh-pr e s s ure f uel s uppl y l i ne uni o n a t t h is s t a ge . Mai nt a i n p r e s s ur e o n t he hi gh-pr e s s ur e f ue l s upp ly l i ne t o ke e p t he ol i ve i n co nt a ct wi t h t he f ue[...]

  • Page 904

    64. CAUT I O N: Ma k e s ure t he col o r ed l i nks a l i gn t o the t i ming marks. Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . I nst a l l t he t i mi ng cha in. 65. CAUT I O N: Ma k e s ure t he ti mi ng c ha i n t e ns i on e r i s f ul l y r et r act e d bef o r e i ns ta l l a t i on. Fa [...]

  • Page 905

    66. Unl o ck t he t i mi ng chai n t e ns i one r . 67. Ti g ht e n t o 33 N m. 68. Ti g ht e n t o 33 N m. 69. Remove t he l ocking pi ns from t h e t i ming d r i ve s pr ocket s. JagDocs.com[...]

  • Page 906

    70. Remove t he s pe ci a l t o o l 303-69 8. 71. Rot a te t he cranksha f t t wo r evo l ut i o ns . 72. Us i ng s pe ci a l t ool 303-698, check t h e t i ming b y in s e r t i ng t he s pe ci al t o ol i n t he CKP s e ns or ho l e . 73. Check t he cams ha ft t i ming b y i ns e rti ng a s ui t a b l e 6 mm bar t h r o ug h t he ho l e s i n t h[...]

  • Page 907

    75. Remove t he s pe ci a l t o o l . 76. Ins t a l l t he CKP s e ns or. 77. CAUT I O N: I ns t a l l t he e ngi ne f r o nt co ver wi t hi n f i ve mi nut e s o f a ppl yi ng t he s e a l e r. • NO T E: Ins t al l a ne w e ngi ne f r o nt co ver. App l y a 3 mm dia me t e r bea d of s e a l e r W S E-M4G 3 23-A4 t o t he engi ne f r ont cove r.[...]

  • Page 908

    79. Ins t a l l t he f r ont cove r r et a i ni ng nut s a nd bo l t s . Ti ght e n t he b ol t s t o 14 Nm. Ti ght e n t he nut s t o 10 N m. 80. Remove s pe ci a l t o o l. 81. NO TE: I ns t a ll a new cr anks ha ft f r o nt o il s e a l . • NO T E: A ne w cr anks ha ft f r on t oi l s e al i s s uppl i e d wi th a n a l i gnm e nt s l e e ve t[...]

  • Page 909

    82. NO TE: Ne w c rank s ha f t pul l e y bo l t s m us t b e i ns t al l e d. Us i ng t he s p e ci a l t o ol s 205-053 a nd 205-0 53-02, i ns t a l l t he cr a nks ha ft da mpe r . S ta g e 1: 45 Nm. S ta g e 2: 120 de g r ee s . 83. NO TE: I ns t a ll a new val ve cover ga s ket . I nst a l l t he val ve cover. Ti ght e n t o 10 Nm. 84. NO TE: [...]

  • Page 910

    87. At t ach t he s t arte r mot o r a nd i nj ect or w ir i n g ha r ne s s . 88. Ins t a l l t he s o und pr oo f pad di ng. 89. NO TE: Do not f ul l y ti g ht e n t he f uel i nje c t i o n s up pl y ma ni fo l d s uppo r t br acket bo l t s a t t his s t age . I nst a l l t he f ue l i nj e c t i o n s upp l y mani f o l d s upp o r t b rack e [...]

  • Page 911

    bl ue co l o r ed col l a r i s f i t t ed a t t he f ue l i nj e ct i o n s uppl y mani f ol d e nd of t he hi gh p res s ur e fue l sup pl y l ine . • NO T E: T o a i d i d e nt i f i ca t i o n o f t he hi g h pr e s s ur e f ue l s up pl y l i ne s , t he uni on a t t he f ue l pump e nd i s e t ched wi t h t he wo r d P ump . P os i t io n t[...]

  • Page 912

    99. NO TE: Hi gh-pr es s u r e f ue l s up pl y l i ne s s ho wn r e moved f o r c l a r i t y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif o ld s uppo r t br acke t s . Ti ght e n t o 14 Nm. 100 . NO TE: Hi gh-pr e s s ur e f uel s uppl y l i ne s s h own r emove d f o r cl arit y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif [...]

  • Page 913

    104 . CAU T IO N: Make s ure t he t o o l us ed t o t i ght e n t he hi g h-pr es s ur e fue l s uppl y l i ne uni on s i s us e d a t t he t o p of t he uni o n a s t hi s i s whe re th e re i s most mat e r i a l . Fa i l ur e t o f ol l o w t hi s i ns truc t i o n may r e s ul t i n dama ge t o t he u nio n. Ti ght e n t he hi g h-pr e s s ur e[...]

  • Page 914

    109 . CAU T IO N: Make s ure t he t o o l us ed t o t i ght e n t he hi g h pres s ur e fue l s uppl y l i ne uni on i s use d a t t he t o p o f t he uni on a s t hi s is where th e re i s most mat e r i a l . Fa i l ur e t o f ol l o w t hi s i ns truc t i o n may r e s ul t i n dama ge t o t he u nio n. Ti ght e n t he hi g h pr e s s ur e f ue [...]

  • Page 915

    114 . Conne c t t he ca ms haf t po s i t i o n (CMP) s e ns or el e ct r i cal co nnect o r. 115 . Conne c t t he cyli nd e r he ad t e mpe rat ur e (C HT) s e nso r e l e ct r i cal conne ct or. 116 . At t ach t h e CHT s e ns or e l ect r i c a l conne ct o r . 117 . In s t a l l t he e xhaus t mani f o l d. Ti ght e n t o 40 Nm. 118 . In s t a [...]

  • Page 916

    119 . In s t a l l t he EGR co o l e r mount b r ack e t ret a i ni ng bo l t . Ti ght e n t o 10 Nm. 120 . NO TE: I nst a l l a ne w O -r ing se al . I nst a l l t he o i l ret ur n t ube . Ti ght e n t o 10 Nm. 121 . NO TE: I nst a l l a ne w gas ke t . Conn ect t he o i l ret ur n tu be t o t he t ur bo char ge r. Ti ght e n t o 10 Nm. 122 . In [...]

  • Page 917

    124 . NO TE: I nst a l l ne w s e a l i ng wa s he rs. Conn ect t he o i l s u ppl y t ube t o t he t ur bocha rger . Ti ght e n t o 14 Nm. 125 . In s t a l l t he e n gi ne f r o nt mount br acket . Ti ght e n t o 80 Nm. 126 . In s t a l l t he i dl e r pul l e y. Ti ght e n t o 43 Nm. 127 . NO TE: I nst a l l ne w O -r i ng s e a l s . I nst a l [...]

  • Page 918

    129 . NO TE: I nst a l l a ne w wa t e r pump ga s ket . I nst a l l t he wa t e r pump a nd po we r a s s i s t e d s t e e ring p ump as s e mbly. Ti ght e n t o 22 Nm. 130 . Conne c t t he co o la nt hos e t o t h e wa t er pump. 131 . In s t a l l t he p owe r a ss i s t e d s te e r i ng pump bracket r et a i ni ng bo l t s . Ti ght e n t o 22[...]

  • Page 919

    134 . In s t a l l t he o i l l e v e l i ndi cat or a nd t ube . 135 . In s t a l l t he g lo w pl ugs . Ti ght e n t o 13 Nm. 136 . In s t a l l t he g lo w pl ug wi r e . Ti ght e n t o 2 Nm. 137 . NO TE: I nst a l l ne w ma ni fo l d g a ske t s . I nst a l l t he i nt a k e mani fo l d. Ti ght e n t o 15 Nm. 138 . In s t a l l t he s t a rte r[...]

  • Page 920

    139 . In s t a l l t he co ol a nt hos e s . 140 . In s t a l l t he a i r f i l t e r o ut l e t tub e . 141 . NO TE: I nst a l l a ne w a i r fi l t e r o ut l e t t ub e r e t a i ni ng cl ip . I nst a l l t he a i r f i lt e r o ut l e t t ube . 142 . Conne c t t he t ur bocharger vacuum hos e . 143 . Conne c t t he co o la nt hos e s . JagDocs[...]

  • Page 921

    144 . Conne c t t he co o la nt hos e . 145 . NO TE: I nst a l l a ne w pow e r a s s i s te d s t e e r i ng hi gh-pres s ur e O -r ing s ea l . I nst a l l t he p o wer as s i s t ed s t e e r i ng hi gh pres s ur e pi pe. 146 . Us i ng t he sp e ci a l t oo l , i ns t a l l t he wa t e r pump hos e s . 147 . In s t a l l t he EGR co o l e r coo [...]

  • Page 922

    149 . In s t a l l t he ca t a l yt i c co nverte r brack e t. Ti ght e n t o 46 Nm. 150 . NO TE: I nst a l l ne w ret a i nin g nut s . I nst a l l t he cat a l yt i c co nverte r . Ti ght e n t o 46 Nm. 151 . In s t a l l t he ca t a l yt i c co nverte r r e t a in i ng bol t s . Ins t al l t he ca t al yti c conve r t e r s e cur i ng br a ck et[...]

  • Page 923

    153 . NO TE: Do not t i gh t e n t he r e t a i ni ng cl i p. Al ig n t he turbo o ut l et pi p e a nd charge a i r coo l e r i nt ake pi p e a s se mbl y . 154 . In s t a l l t he t ur bo o ut l e t pi pe ret a i ni ng b ol t . 155 . In s t a l l t he charge a i r coo l e r in t a ke p i pe r et a i ni ng b ol t s . 156 . Ti ght e n t he r et a i [...]

  • Page 924

    157 . In s t a l l t he a cces s ory drive be l t t e ns i one r br a cke t . Ti ght e n t o 25 Nm. 158 . NO TE: I nst a l l t he wi ring harnes s s upport b r acket t o t he g e ne r at o r uppe r r et a i ni ng bol t . I nst a l l t he g e nerat o r . Ti ght e n t o 47 Nm. 159 . Conne c t t he ge ne r at o r el ect r i cal conne ct o r. 160 . At [...]

  • Page 925

    162 . In s t a l l t he a cces s ory drive be l t t e ns i one r. 1. I ns t a l l t he a c ce ss o ry d r i v e be l t . 2. I ns t a l l t he a c ce ss o ry d r i v e be l t te ns i o ne r . 163 . At t ach t h e a cces s ory dr ive be l t . 1. Re pos i ti on t he acce s s o r y dr ive be l t t e ns io ne r . 2. At t a ch t he a cces s o r y dr i v [...]

  • Page 926

    167 . At t ach t h e wi r i ng harnes s to t h e ret a i ni ng s t ud . 168 . Conne c t t he AC c ompres s o r e l e ct rical conne ct o r . 169 . At t ach t h e wi r i ng harnes s to t h e AC c ompres s o r . 170 . At t ach t h e gl o w p l ug wi r i ng harne ss . Ti ght e n t o 5 Nm. 171 . At t ach t h e wi r i ng harnes s to t h e i nt a ke mani[...]

  • Page 927

    172 . Re move t he e ng in e f r om th e eng i ne s t a nd. JagDocs.com[...]

  • Page 928

    P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine2.0L Duratorq-TDCi I nst a l l a t io n Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho s e Cl amp 303-3 97 (24- 003) Po we rtrai n a s s emb l y j a ck HTJ120 0-02 Engine li f t i ng e ye 303-1 067 5 P o i nt S e cur i t y T [...]

  • Page 929

    3. Ins t a l l the t r a n s mis s i o n uppe r r et a i ni ng bo l ts . Ti ght e n t o 40 Nm. 4. Connect t he crank s haf t s e ns o r e le ctrica l conne ct o r . 5. Ins t a l l the s t art er mot o r . Ti ght e n t o 25 Nm. 6. Att a ch t he s t art er mot o r wiring ha rn e s s . 1. Ti g ht e n t o 12 N m. 2. Ti g ht e n t o 6 N m. JagDocs.com[...]

  • Page 930

    7. Connect t he s t a r t er mo to r wi ring harnes s e l ect r i cal co nnect o r. 8. Ins t a l l the s t art er mot o r wi ring ha rnes s re ta i ni ng br a ck et . Ti ght e n t o 20 Nm. 9. Att a ch t he s t art er mot o r wiring ha rn e s s . 10. Ins t a l l t he vacuum r e gul a t or s ol eno i d val ve. 1. Co nnect t he e le ct rica l co nnect[...]

  • Page 931

    11. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 12. Ins t a l l t he cha r g e a i r coo l e r pi pe . Ti ght e n t o 4 Nm. 13. At t ach t he re v e r se l a m p s wi t ch wi r i ng ha r ne s s r e t a i ni ng cl i p . 14. Ins t a l l t he cha r g e a i r coo l e r pi pe ret a i nin g nut . Ti ght e n t o 23 Nm. 15.[...]

  • Page 932

    16. Ins t a l l t he e ngi ne roll r e s t r i cto r . Ti ght e n t o 80 Nm. 17. At t ach t he wi r i ng harnes s . 18. NO TE: U n-Ca p th e expo s ed p ort s. • NO T E: Ins t al l n ew O -r i ng s e a l s . Conn ect t he t he p owe r s t ee ring l ine s . Ti ght e n t o 10 Nm. 19. Ins t a l l a n ew dr i ve ha lf s ha f t s n a p ring . 20. CAUT[...]

  • Page 933

    21. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he whe e l knuc kl e. 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l a ne w l o we r a r m bal l j oi nt re t a i ni ng nut a nd b ol t . Ti ght e n t o 83 Nm. 22. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. I nst a l l a[...]

  • Page 934

    26. Ins t a l l t he e ngi ne cover r e a r mount brack e t . Ti ght e n t o 23 Nm. 27. At t ach t he e le ct r ica l conne ct o r . 28. At t ach t he e ngi ne h a r n e s s . 29. W A RNING: Ra i s e t he s pe ci a l t o o l pl a t f o r m s l o wl y. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n ca n res ul t i n pe r s o na l i nj ury . I ns[...]

  • Page 935

    31. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e t ai ni ng bol t s . 32. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. I nst a l l t he f ront sub f r ame rei nf orcement pl at e . Loo s e l y i ns t a l l t h e front s ub f r ame r e ar r et ai ni ng bo l t s . 33. NO TE: L[...]

  • Page 936

    36. NO TE: I ns t a ll n e w r et a i ni ng nut s . I nst a l l t he e n gi ne f ront mount r et a i ni ng nut s . Ti ght e n t o 80 Nm. 37. NO TE: I ns t a ll a new r e t a i ni ng nut . I nst a l l t he e n gi ne r e a r m ount r e t a i ni ng nut . Ti ght e n t o 133 Nm. 38. Remove t he s pe ci a l t o o l . 39. Lowe r t he vehi c l e . 40. At t[...]

  • Page 937

    42. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 43. CAUT I O N: Ma k e s ure t hat t he e l e ct r i cal conne cto r l oca t e s c orr e ctl y i n t he ECM. Do not f o r ce o r o ver t i g ht e n t he e le ct r ica l conne ct o r . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e co mponen [...]

  • Page 938

    47. Conne ct t he f uel l in e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Re mov e t he b l a nki ng pl ug s. 48. NO TE: I ns t a ll n e w O -r ing s e a ls . • NO T E: U n-cap t he e xpos e d p o[...]

  • Page 939

    51. NO TE: U n-cap t he e xpo s e d po rts . I nst a l l t he p o wer as s i s t ed s t e e r i ng hos e . 52. At t ach t he p o we r a s s i s t e d s t e e r in g ho s e. 53. Conne ct t he p o we r a s s i s t e d s t e e r in g ho s e. 54. Ins t a l l t he e xhaus t mani f o l d t o EGR v a l ve t ub e . For a ddi ti ona l i nf o r m a t i o n, [...]

  • Page 940

    56. Conne ct t he radi a t or upp er coo l a nt ho s e . 57. CAUT I O N: I f brake fl ui d i s s pi lt o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: U n-cap t he e xpos e d p o r t s . • NO T E: Re move t he ti e s t rap. At t a ch t he cl ut ch s l a ve cyli n[...]

  • Page 941

    61. Conne ct t he g l ow pl ug ha rn es s e l e ct r i ca l conne ct o r . 62. Conne ct t he e ngi ne h a r nes s e l e ct r i cal conne cto r . Ti ght e n t o 10 Nm. 63. At t ach t he t he e xpans io n t a n k out l et ho s e . 64. Conne ct t he e xpans i on t a nk o ut l e t hos e . 65. Conne ct t he e xhaus t ga s reci r cula t i o n (EGR) val v[...]

  • Page 942

    66. Conne ct t he b rak e v a cuum pump vacuum hos e. 67. Rai se th e v e hi cl e . 68. NO TE: U n-cap t he e xpo s e d po rts . Conn ect t he po we r as s i s t ed s t e e r i ng ho s e . 69. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. I nst a l l t he f ront bumper s pl i t t e r v ai n f i nis he r t r i m s . 70. Ins t a l l t he f [...]

  • Page 943

    71. NO TE: Re move t he s e l e ct o r cab l e s t i e s t rap s. At t a ch t he s el e ct or cabl es . 72. At t ach t he s e l e ct o r cabl e s . 73. Conne ct t he hi gh i nt ens it y di s cha r ge (HID) s e ns or drop a r m. 74. Conne ct t he a i r te m pe r a t ur e s e ns or e l e ct r i cal conne ct o r . 75. NO TE: I ns t a ll a new O -r ing[...]

  • Page 944

    76. NO TE: Re move t he a nti -l o ck braki ng s y s t e m (ABS) whe e l s p e ed s ens o r ti e s t rap s. • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . • NO T E: Re move t he ti e s t rap. Det ach a nd rep os i t i on t he ABS whee l s p e ed s e ns o r . 77. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Conn ect t he AB[...]

  • Page 945

    81. NO TE: I ns t a ll n e w br a k e cal i p e r a nchor pl a t e r e t a i nin g b o lt s . At t a ch t he b r a ke ca l i pe r a nd br a ke cal i pe r anchor pl at e a s s e mbl y. Ti ght e n t o 133 Nm. 82. Ins t a l l t he f r ont br a ke pa d s. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P a ds (206-03 Fr ont Dis c Brak e[...]

  • Page 946

    87. Conne ct t he he a t e r hos es to the he a t e r cor e . 88. Ins t a l l t he e xhaus t f l e xibl e pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Exhaus t Fl e xib le P i pe - 2. 0L Dur a t o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150PS ) - P uma (309-00 Exhaus t Sy st e m, Re moval a nd I ns ta l l a t i on). 89. Ins t a l[...]

  • Page 947

    [...]

  • Page 948

    3. Ins t a l l the t r a n s mis s i o n uppe r r et a i ni ng bo l ts . Ti ght e n t o 40 Nm. 4. Connect t he crank s haf t po si t i o n (CKP) s e ns o r e l e ct r i cal conne ct o r. 5. Ins t a l l the s t art er mot o r . Ti ght e n t o 25 Nm. 6. Att a ch t he s t art er mot o r wiring ha rn e s s . 1. Ti g ht e n t o 12 N m. 2. Ti g ht e n t [...]

  • Page 949

    7. Connect t he s t a r t er mo to r wi ring harnes s e l ect r i cal co nnect o r. 8. Ins t a l l the s t art er mot o r wi ring ha rnes s re ta i ni ng br a ck et . Ti ght e n t o 20 Nm. 9. Att a ch t he s t art er mot o r wiring ha rn e s s . 10. Ins t a l l t he e mi ss i on cont r o l s o l e noi d a s s embl y. Ti ght e n t o 23 Nm. 11. Conne[...]

  • Page 950

    12. Conne ct t he e m i s s i o n cont r o l s o l e no i d e l ect r i cal conne cto r. 13. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 14. Ins t a l l t he cha r g e a i r coo l e r pi pe . Ti ght e n t o 4 Nm. 15. Ins t a l l t he cha r g e a i r coo l e r pi pe ret a i nin g b o lt . Ti ght e n t o 10 Nm. 16. In[...]

  • Page 951

    17. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the co m po ne nt . Us i ng a s ui t a b l e hydr aul i c l i f t , l o we r t he e ngi ne a nd t r a ns mi s s i o n from t he s ubfr a m e . 18. At t ach t he [...]

  • Page 952

    23. NO TE: U n-Ca p th e expo s ed p ort s. • NO T E: Ins t al l n ew O -r i ng s e a l s . Conn ect t he t he p owe r s t ee ring l ine s . Ti ght e n t o 10 Nm. 24. Ins t a l l a n ew dr i ve ha lf s ha f t s n a p ring . 25. CAUTI O N S : Make s ur e t he CV j o i nt s pl i ne s are l oca t ed f ul l y. Do no t us e e x ce s s i ve fo rc e whe[...]

  • Page 953

    28. Ins t a l l a n ew right -ha nd t i e r od -e nd r et ai ni ng nut . Ti ght e n t o 35 Nm. 29. Loo s e l y i ns t a l l a ne w whee l righ t-h and hub nut . 30. Remove t he e n gi ne re ar l i f t i ng e ye. 31. Ins t a l l t he e ngi ne cover r e a r mount brack e t . Ti ght e n t o 23 Nm. 32. At t ach t he e le ct r ica l conne ct o r . JagDo[...]

  • Page 954

    33. At t ach t he e ngi ne h a r n e s s . 34. Rai se th e eng i ne , s usp e ns io n a nd t r a ns mis s i o n a s s e mbly t o a s ui t a bl e he i ght . 35. NO TE: Re move t he t i e s t r ap s . Re po s i t i o n t he a i r condi t i oni ng (A/C) pi pe t o t he e ngi ne , s us p e ns i on a nd t r a ns mis s i o n a s s e mbly. 36. W A RNING: R[...]

  • Page 955

    38. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e t ai ni ng bol t s . 39. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. I nst a l l t he f ront sub f r ame rei nf orcement pl at e . Loo s e l y i ns t a l l t h e front s ub f r ame r e ar r et ai ni ng bo l t s . 40. NO TE: L[...]

  • Page 956

    43. NO TE: I ns t a ll n e w r et a i ni ng nut s . I nst a l l t he e n gi ne f ront mount r et a i ni ng nut s . Ti ght e n t o 80 Nm. 44. NO TE: I ns t a ll a new r e t a i ni ng nut . I nst a l l t he e n gi ne r e a r m ount r e t a i ni ng nut . Ti ght e n t o 133 Nm. 45. Remove t he s pe ci a l t o o l . 46. Lowe r t he vehi c l e . 47. At t[...]

  • Page 957

    49. At t ach t he s e l e ct o r cabl e s . 50. At t ach t he e ngi ne wi r i ng ha r ne ss e arth le a d. Ti ght e n t o 10 Nm. 51. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 52. CAUT I O N: Ma k e s ure t hat t he e l e ct r i cal conne cto r l oca t e s c orr e ctl y i n t he ECM. Do not f o r ce o r o ver t i g ht e n t h[...]

  • Page 958

    54. Ins t a l l t he e ngi ne wi r i n g ha r ne s s t rim p a nel . 55. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 56. Conne ct t he f uel l in e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o[...]

  • Page 959

    59. Conne ct t he p o we r a s s i s t e d s t e e r in g ho s e. 60. Conne ct t he cha r ge a i r cool e r ho s e . Ti ght e n t o 4 Nm. 61. Conne ct t he radi a t or upp er coo l a nt ho s e . 62. CAUT I O N: I f brake fl ui d i s s pi lt o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co l[...]

  • Page 960

    64. Conne ct t he b a t te r y cabl e s . 65. Conne ct t he g l ow pl ug ha rn es s e l e ct r i ca l conne ct o r . 66. Conne ct t he e ngi ne h a r nes s e l e ct r i cal conne cto r . Ti ght e n t o 10 Nm. 67. At t ach t he t he e xpans io n t a n k out l et ho s e . 68. Conne ct t he e xpans i on t a nk o ut l e t hos e . JagDocs.com[...]

  • Page 961

    69. Conne ct t he e xhaus t ga s reci r cula t i o n (EGR) val ve mo dul e va cuum ho s e. 70. Conne ct t he b rak e v a cuum pump vacuum hos e. 71. Rai se th e v e hi cl e . 72. NO TE: U n-cap t he e xpo s e d po rts . • NO T E: U s e care wh e n rep os i t i oni ng p ow er as s i s t e d s t e e r i ng hos e . Conn ect t he po we r as s i s t e[...]

  • Page 962

    74. At t ach t he cha r ge a ir coo l e r o utl e t ho s e t o t h e charge a i r coo l e r . 75. Conne ct t he hi gh i nt ens it y di s cha r ge (HID) s e ns or drop a r m. 76. Conne ct t he a i r te m pe r a t ur e s e ns or e l e ct r i cal conne ct o r . 77. NO TE: I ns t a ll a new O -r ing s e a l . • NO T E: U n-cap t he e xpos e d p o r t[...]

  • Page 963

    79. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Conn ect t he AB S whe e l s pe e d s e ns o r. 80. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he A BS whe e l s pe e d s e ns o r. 81. NO TE: Re move t he b r ake ca l i per a s s embl y t i e s t r a p s . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r[...]

  • Page 964

    84. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. • NO T E: Ins t al l n ew br a ke ca li pe r anchor pl at e ret a i ni ng bo l t s. At t a ch t he b r a ke ca l i pe r a nd br a ke cal i pe r anchor pl at e a s s e mbl y. Ti ght e n t o 133 Nm. 85. Ins t a l l t he f r ont br a ke pa d s. For a ddi ti ona l i nf o r m a t i o n, r e f[...]

  • Page 965

    89. Conne ct t he co o l a nt hos e . 90. At t ach t he co o l a nt hos e . 91. Conne ct t he f uel f i red bo os t e r hea t e r e l e c t r i cal co nne cto r t o t he s ub frame r e t a i ni ng t a ng. Vehi c le s without ele ctri c boo s te r h ea ter 92. At t ach t he co o l a nt hos e . Conne ct t he coo l a nt ho s e . JagDocs.com[...]

  • Page 966

    93. At t ach t he co o l a nt hos e s t o t h e r e t a i ni ng cl ip s . 94. At t ach t he e le ct r ic bo o s t e r he a t e r el e ct r ica l conne ct o r t o t he sub f r ame r et a i ni ng t a ng . Vehi c le s without auxil ia r y h ea ting 95. Conne ct t he he a t e r hos es to the he a t e r cor e . All v e h icle s 96. Ins t a l l t he e xh[...]

  • Page 967

    102 . In s t a l l t he s t e e ring col umn coupl i ng. 103 . At t ach t h e l owe r s t ee ring co lumn s ha f t . Ins t al l a ne w ret a i ni ng b o l t . Ti ght e n t o 25 Nm. 104 . Bl e ed the powe r s t e e r in g s yst e m. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: P o we r S t e e r i ng S y s t e m Fil l i ng (211-00 Ste e r[...]

  • Page 968

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Fl ui d s and Lubr i cant s Desc ri pti on Speci fi cati on Ja guar P r e m i u m Co o l i ng Sy st e m Fl ui d ES E-M97B44- A P r e mium Cool i ng S yst e m Fl us h EGR-M 14P7-A O-R ing L ubr i cant ES E-M9 9B176- A C o o l i ng Sy st em[...]

  • Page 969

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - En gine C oo li ng Des cr ipt i o n a nd O pe r a t i o n C ooli ng M odule Com ponen t s I te m Pa rt Nu mber Descri pt i on 1 — Co o l i ng fa n mot o r cont r ol modul e 2 — Co o l i ng fa n s hr oud 3 — Co o l i ng fa n, R/H 4 ?[...]

  • Page 970

    It e m Pa r t Nu m be r Desc ri pti on 1 — Uppe r cool a nt hos e 2 — W a te r pump 3 — Cool ant e xpa ns i on t a nk 4 — Cool ant p res s ur e cap 5 — Therm os t a t 6 — Engi ne oi l coo l er 7 — Engi ne bl o c k h ea t e r (col d cl i mat e mark et ve hi cl e s o nl y) 8 — Engi ne bl o c k d r ai n pl ug • W ARNINGS : Ne ve r r [...]

  • Page 971

    To a voi d the po s si bi l i t y of pe rsona l inj ur y, do n ot ope rat e t he e ngi ne wi th t he ho o d o p e n un ti l t he f a n b l a de s ha ve b e en e x ami ned fo r cr a cks and s e p a r at i on . Fai lu r e t o fo l l o w t hi s i ns t ru ct i o n may r es ul t i n pe rso nal i nj ury . Re move f us e 37 from t he e ngi ne co m pa r t [...]

  • Page 972

    Coo l a nt e x pa ns i o n d ur i ng wa r m- up. Ai r s e pa r a t i o n dur i ng o perat i on. S yst e m pres s ur i z at i o n by t he co ol a nt p r es s ure ca p. The cool a nt e xpa nsi o n t a nk i s de s i gne d t o have a ppr oxi mat e l y 0.5 t o 1 l it e r o f ai r w he n col d t o a l l ow f or coo l a nt e xpans i o n. Engin e Oil C oo [...]

  • Page 973

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 2 3 1 1 2 P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - En gine C oo li ng Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. If a n obvi o us cau se fo r an ob s e rv e d o r r epo [...]

  • Page 974

    3 4 5 6 7 1 2 3 1 1 1 1 1 1 1 2 Conn e ct t he co ol ing f a n co nt r o l mod ul e e l e ct rical co nnect or JB187 (t o VI N E71957) an d c onn e cto r JB190 (from VIN 71958) and t ur n t he ig ni t io n s wi t ch t o t he RU N po s it i o n. The coo l i ng f a ns wi ll run a t maximum s pe e d . Al lo w t h e co o li ng fa ns t o r un fo r 5 mi [...]

  • Page 975

    1 1 1 1 1 2 1 2 I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he cir cuit b e t we e n t h e e ng i ne co mpar t me nt fus e b o x and t he cool i ng f a n mot or co nt r o l m o dul e . CLEAR t he DTC. T ES T t he sys t e m f or norm al op e rat i o n. No GO t o A 12 . . A1 2: CHEC K T HE CO O LIN G FA N M O T O R C ONT R O L MO DU[...]

  • Page 976

    1 2 3 1 1 1 1 1 1 2 Ar e the drive s pl i nes O K? Ye s I nst a l l a n e w wat e r p ump. For a dd i t i o na l i nf orm a t i o n, r e fe r t o REFER t o : W a t e r P ump (303-03A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V6 - A JV6/3.0L NA V6 - AJ27, Re moval a n d I ns t a l l a t i on). . TEST t he s ys t e m f or norm al op e rat i o n[...]

  • Page 977

    1 1 2 1 1 2 3 1 2 . TEST t he s ys t e m f or norm al op e rat i o n. PINPOIN T TE ST D : THE ENG INE B LOCK HEATER DOES NOT OPERATE T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS D1: C HECK CO NT I N U I T Y OF T HE BLOCK HEAT E R POW ER SUPP LY C ABL E AN D T HE BLO CK H EAT ER Mea s ur e t he res i s t a nce b et we e n t he l i v e s uppl y [...]

  • Page 978

    W ARNI N G: N eve r r emove t he coo l a nt e x pa ns i o n t a nk cap unde r a ny ci r cum s t a nce s whi l e t he e ngi ne i s o pe r at i ng . Fa i l ure t o fo l l o w t he s e i nst r ucti o ns m a y r es ult i n da mag e t o t he coo l i ng s yst e m or e ngi ne and/or pe rso na l inj ur y. To a v oi d ha v i n g s cal di ng hot c oo l ant o[...]

  • Page 979

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing System B ackflu shi ng Gene ral P r ocedures • CAU TI O N S : Th e he a t e r co r e mus t be ba ckfl us he d s e para te l y from t h e e ng i ne co o l i ng s ys t e m t o p r e vent t he e ng i ne co o l i ng s ys t em p a[...]

  • Page 980

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing System Draini ng, Filling and Bl e eding Gene ral P r ocedures • W ARNINGS : Ne ve r r e m ove t he coo l a nt pres s ur e cap unde r a ny ci r cums t a nce s whi l e t he e ngi ne is o pe r at i ng. Fa il ure t o fo l l ow t[...]

  • Page 981

    4. CAU TI O N : Do no t o v e r t i ght en t he drai n p l ug. Fa i l ur e t o f o l lo w thi s in s t ruc t i o n may caus e da mag e t o t he vehi cl e . I nst a l l t he d r ai n pl ug whe n a l l coo l a nt h a s d r ai ne d . Ti ght e n t o 1 Nm. Re mov e t he d rai n t r ay. 5. Ins t a l l the unde r t r ay. For a ddi t i o na l i nfo rm at i[...]

  • Page 982

    13. Loo s e l y i ns t a l l a p i pe cl a mp t o t he he at e r r et ur n ho s e . 14. S T ART a nd RU N t he e ngi ne at 2000 r pm . 15. W i t h t he e ng i ne a t 2000 r p m, f ul l y cl a mp t he he a t e r out l e t hos e a n d t he n ful l y cl a m p t he he a t e r i nl e t hos e . 16. Cont i nu e t o ru n th e e ng i ne fo r a f ur t he r t[...]

  • Page 983

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing System Flus hing Gene ral P r ocedures • NO T E: T o remov e r us t , s l udge a nd ot he r f o r e i gn mat e ria l f r o m t he co o l i ng s ys t e m, u s e P re m iu m Co ol ing Sy s t e m f l us h, me e t ing Ja g uar s [...]

  • Page 984

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Bl o ck Heater Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o Co o l i ng S yst e m Dr a i ni ng, Fi l l i ng a nd Bl e e di ng . 2. D i s conne[...]

  • Page 985

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ant E xpansio n T ank Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Cl a mp t he ho s e t o mini miz e coo l a nt l o s s . Det ach t he co ol a nt e x pa ns i o n t a nk out l e t ho s e f rom t he co o l a nt e xpans [...]

  • Page 986

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 3 Nm. 2. Ch eck a nd t o p up t he coo l i ng s yst e m. JagDocs.com[...]

  • Page 987

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing Fa n Mo dule Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r . For a dd it i o nal i nfo r mat i on, ref e r t o : Ai r Cl e a ne r (303- 12A I nt a ke Ai r Di s t ribu ti o n a nd Fi l t e ring [...]

  • Page 988

    6. D et a ch t he coo l i ng f a n modul e wi r i ng harnes s from t he coo l i ng f a n s hr oud . 7. Remove t he coo l i ng fa n mod ul e . Insta llat ion 1. To i ns t a l l r evers e t he r emova l pr oced ure. Ti ght e n t o 3 Nm. JagDocs.com[...]

  • Page 989

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing Fa n Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he coo l i ng fa n mot o r a nd s hr oud. Fo r a ddi t i o nal i nfo r mat i o n, r ef e r t o Coo l i ng Fa n Mot or and S hroud . 2. D i s conne ct t he[...]

  • Page 990

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing Fa n Mo to r and Shro ud Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A i r Di s [...]

  • Page 991

    8. Repo s i t i on t he co ol a nt hos e f r om t he e ngi ne o i l coo l e r t o t he t he rm o s t a t ho us i ng a nd s e cur e i t t o t he f r on t cr o s s m e mber us i n g a s ui t a bl e ret a i ni ng s t rap. 9. Remove t he radi a t o r s uppo r t bea m. Al l ow t he coo l i ng modu le t o be parti a l ly l o we r e d and s upp or t e d b[...]

  • Page 992

    Insta llat ion 1. CA UT I O NS: Make s ur e t ha t the r adi a t or i s no t d ama ged when in s t a l l in g t he c oo l i ng f an mot o r and s hr oud. Fai l ure t o fo l l ow t his i ns t r uct io n may r e s u lt in damag e t o t he ve hi cl e . Make s ur e t ha t the r et a i ni ng l ugs o f t he r adi at o r a r e not d a mage d whe n i ns t [...]

  • Page 993

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing Module Re moval a n d I ns t a l l a t i on R em ova l All Ve hicles 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A i r Di s t r i b ut i o n and [...]

  • Page 994

    7. Lowe r t he vehi cl e . Vehi c le s bu ilt up to VI N: E7 195 6 8. D et a ch t he r a di a t or v e nt ho s e from t h e radi a t o r . 9. D et a ch t he uppe r cool a nt ho s e f r o m t he r adi a t or. 10. Dis c o nne ct t he co o l i ng f a n mot o r c on t r ol mod ul e e l ect r i cal co nnect o rs. Vehi c le s bu ilt from VIN :E7 19 57 11[...]

  • Page 995

    12. Det a ch t he uppe r cool ant ho s e f r o m t he radi a t o r. 13. Dis c o nne ct t he co o l i ng f a n mot o r c on t r ol mod ul e e l ect r i cal co nnect o r. All v e h icle s 14. Rai se th e v e hi cl e . 15. Remove t he a i r s p li t t e r g r i l le . 16. Remove t he f ront t owi ng e ye t r ims . Vehi c le s With Au tom a tic Transm [...]

  • Page 996

    17. NO TE: L e ft -hand s i de s hown, right -ha nd s i de s i mi l a r . Det ach t he po we r a ss i st e d s te e ring o i l co o l e r i nl et a nd ret urn pi pe s . Al l ow t he powe r a s s i s t e d s t e e r ing fl ui d t o dr ai n i nt o a s ui t a bl e c on t a i ne r . Us i ng s ui t a bl e bl a nking p l ugs , bl a nk t he e xpos e d po [...]

  • Page 997

    21. Lowe r t he coo l i ng modul e and the A/C conde ns e r t o a po s i t i o n whe r e t he a i r condi t i o ni ng pi pe i s f orwa r d of t he f r ont b umper . 22. Remove t he l ef t -han d s i de A/C co nde ns e r r e t ai ni ng bo l t f r om t he r adi a t o r . Vehi c le s With Au tom a tic Transm ission 23. NO TE: L e ft -hand s i de s how[...]

  • Page 998

    25. NO TE: L e ft -hand s i de s hown, right -ha nd s i de s i mi l a r . Det ach t he co ol i ng modul e f r om t he A/C co nde ns e r . 26. CAUT I O N: Ma k e s ure t hat t he r a di a t o r and t he A /C conde n se r a r e not damag e d d ur i ng t he r e m o val o f the co ol i ng modul e . Fai l ur e t o fo l l o w th i s i ns t r uct io n m a[...]

  • Page 999

    3. NOT E: Le f t -hand s i de s hown, rig ht -ha nd s i de s i mi l a r. I nst a l l t he a ut o mat i c t r ans m i s s i on o i l c oo l e r t o t he r ad i a t o r . All Ve hicles 4. Ins t a l l the l e ft -hand s i d e A /C co ndens e r r e t a i ni ng bo l t . Ti ght e n t o 7 Nm. 5. Ins t a l l the right -ha nd s id e A /C co nde ns e r r et [...]

  • Page 1000

    9. Ins t a l l the radi a t o r s uppo rt be a m. Ti ght e n t o 25 Nm. Vehi c le s With Au tom a tic Transm ission 10. NO TE: L e ft -hand s i de s hown, right -ha nd s i de s i mi l a r . Conn ect t he po we r as s i s t ed s t e e r i ng o i l cool e r i nl e t a nd ret ur n p i pe s . Re mov e t he b l a nki ng pl ug s. Vehi c le s With Manual [...]

  • Page 1001

    13. Remove t he ret a i ni ng s t rap from t h e e ng i ne o i l co o le r cool a nt ho s e . 14. Ins t a l l t he f r ont t owi ng e ye t r ims . 15. Ins t a l l t he a ir s p l i t t e r gr i l l e . Re mov e t he p rote cti ve t a pe f r om t he front b umper. 16. Lowe r t he vehi c l e . 17. Remove t he ret a i ni ng s t raps from t he A/C cond[...]

  • Page 1002

    18. Conne ct t he co o l i ng f a n mot o r c o nt r o l m o dul e e l e ct r i cal co nnect o r. 19. Conne ct t he up pe r coo la n t ho s e on to t h e radi a t o r. 20. Conne ct t he radi a t or ve nt hos e o nt o t he r ad i a t o r . Vehi c le s bu ilt up to VI N: E7 195 6 21. Conne ct t he co o l i ng f a n mot o r c o nt r o l m o dul e e l [...]

  • Page 1003

    22. Conne ct t he up pe r coo la n t ho s e on to t h e radi a t o r. 23. Conne ct t he radi a t or ve nt hos e o nt o t he r ad i a t o r . All v e h icle s 24. Ins t a l l t he a ir cl e a ne r i nt a ke duct . 25. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A i r[...]

  • Page 1004

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Radiator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he coo l i ng m o dul e . For a ddi t i o na l i nfo rm at i o n, ref e r t o Coo l i ng Modul e . 2. CAU TI O N : Make s ur e t h at th e ret a i ni ng l ugs o f t he r[...]

  • Page 1005

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - T hermo stat Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng S y s t em Dr ai[...]

  • Page 1006

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Water Pump Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o Co o l i ng S yst e m Dr a i ni ng, Fi l l i ng a nd Bl e e di ng . 2. Lowe r t he veh[...]

  • Page 1007

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Water Pump Ho usi ng Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o Co o l i ng S yst e m Dr a i ni ng, Fi l l i ng a nd Bl e e di ng . 2. Lowe [...]

  • Page 1008

    9. Remove t he wa t e r pump ho us i ng. Re mov e a nd di s c a r d t he gas ke t. 10. Remove t he wa t e r pum p from t he wa t er pump hou s i ng. Re mov e a nd di s c a r d t he gas ke t from t he wa t e r pum p. Insta llat ion 1. NOT E: Ins t a l l a new ga s ket . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 10 N[...]

  • Page 1009

    3. NOT E: Ins t a l l a new ga s ket . Ti ght e n t o 9 Nm. 4. NOT E: Ins t a l l ne w O -r ing s e a l s t o t h e wa t er pump c oo l a nt o ut l e t p ip e . • NO T E: P r i or t o i ns t a ll at i o n of t he wa t e r pump o ut l e t p i pe, l ubricat e t he O-ring s e a l o f th e w at e r p ump o ut l e t pi pe a t t he j o in t wi t h th e[...]

  • Page 1010

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - Fl ui d s and Lubr i cant s Desc ri pti on Speci fi cati on Ja guar P r e m i u m Co o l i ng Sy st e m Fl ui d ES E-M97B44- A P r e mium Cool i ng S yst e m Fl us h EGR-M 14P7-A O-R ing L ubr i cant ES E-M9 9B176- A C o o l i ng Sy st e[...]

  • Page 1011

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - E ngine Co o ling Des cr ipt i o n a nd O pe r a t i o n • W ARNINGS : Ne ve r r e m ove t he coo l a nt pres s ur e cap unde r a ny ci r cums t a nce s whi l e t he e ngi ne is o pe r at i ng. Fa il ure t o fo l l ow t his i ns t r uc[...]

  • Page 1012

    Item Pa r t Nu m be r De sc ri pti o n 1 - Cool i ng modul e 2 - Cool i ng f a n mot o r and s hroud 3 - Cool i ng f a n 4 - Radi a t o r upper i s ol a t or mount i ng 5 - Radi a t o r s i de s e a l 6 - Radi a t o r lo we r i s o l at o r mount i ng 7 - Radi a t o r lo we r s e a l 8 - Radi a t o r s uppo rt bea m 9 - Radi a t o r lo we r i s o l[...]

  • Page 1013

    The t herm os t a t i s l o cat e d i n t he t he r mos t a t hous i ng whi ch i s bol t e d t o t h e cyli nd e r he ad a nd a l l o ws r api d e ng i ne warm -up b y r es t r i ct i ng cool a nt f lo w t hrough t he radi a t o r be l ow 88°C (190°F). The the r mos t a t a l s o a s s i s t s i n kee pi ng t he e ngi ne o pe rat i ng t e mpe rat[...]

  • Page 1014

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng System D raining, Filling and Bl e eding Gene ral P r ocedures 1. W ARNING: W hen r e l e a s i ng t he co o l ing s ys t e m p r e s s ur e, cove r t he e x pa ns io n t a nk cap wi t h a t hi ck cl ot h to p r eve nt t he po[...]

  • Page 1015

    8. Remove t he a i r cl ea ne r mount br acket . 9. Loos e n t he coo li ng s yst e m ai r b le e d s cr ew. 10. Fi ll t he cool ant e xpans i on t a nk unt i l coo l a nt e merges from t he cool i ng s yst e m ai r bl e e d s cr e w. 11. Ti g ht e n t he coo l i ng s ys t e m a ir bl e e d s cr e w. Ti ght e n t o 10 Nm. 12. CAUT I O N: T he e ngi[...]

  • Page 1016

    14. At t ach t he wi r i ng harnes s . 15. Ins t a l l t he a ir cl e a ne r a ss e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.0L Durat o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150P S ) - P uma, Re moval a nd I ns ta l l a t i on). 16. S t a r [...]

  • Page 1017

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng System D raining and V acuum F illi ng Gene ral P r ocedures W ARNI N G: To a voi d ha vi ng s cal di ng ho t coo l a nt o r s te a m bl o wi ng out o f t he coo l i ng s ys t e m, us e e xt reme ca r e when r emovin g t he co[...]

  • Page 1018

    7. Ins t a l l the co ol i ng s ys t e m va c uum r ef il l a d a pt o r t o t he e x pa ns io n t a nk. 8. Ins t a l l the vacuum fi l l e r ga uge t o t h e coo l ing s yst e m vacuum r ef i l l a da pt o r . 9. Ins t a l l the ve nt uri t ube a s s e mbl y t o t he vacuum f i l l e r ga uge . 10. NO TE: Make s ur e th a t bo t h val v es are i n[...]

  • Page 1019

    11. O pen th e a i r s upp l y val v e . 12. NO TE: Make s ur e th e coo la nt s uppl y ho s e i s po s it i o ne d i nt o a c on t a i ne r of f i f t y pe r cent mi xture o f Jag ua r P r e mi um Coo l i ng Sy s t e m Fl ui d or eq ui val ent , mee t i ng Jagua r s pe ci f i cat i o n W SS M97B44- D a nd f i f t y percent wa t e r . Make s ur e n[...]

  • Page 1020

    15. Al l o w o ne minut e t o ch e ck t he vacuum i s he l d. Dis conne ct t he a i r s up pl y. 16. NO TE: Cl o se th e co o l a nt s uppl y val ve whe n t he coo l a nt e xpans i o n t a nk MAX mark i s r e a ch e d or co ol a nt m ove ment has ce a s e d. Op e n t he co ol a nt sup pl y val ve and al l ow t he co o l a nt t o be dr awn int o t h[...]

  • Page 1021

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng Fa n Mo to r and Sh roud Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he coo l i ng m o dul e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Modul e (303-0 3B Engi ne Coo l i ng - 2.0L Dur[...]

  • Page 1022

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng Module Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover /in st a l l e r , co ol in g ho s e cl a mp. 303-397 R em ova l 1. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t [...]

  • Page 1023

    I nst a l l at io n) / Cha r ge Ai r Coo l e r - 2.2L Dur a t o r q-TDCi (110k W /150PS ) - P uma (303- 12B I nt a ke Ai r Di s t ribut i o n a nd Fi l t e r i ng - 2.0L Dur a t orq-TDCi/2.2L Dur a t o r q-TDCi (110k W /150PS ) - P uma, Re m ova l and Ins t a l l a t i o n). 9. D i s conne ct t he radi a t o r l owe r coo l a nt hos e . 10. NO TE: [...]

  • Page 1024

    1. W ARNING: U s ing an a s s i s t a nt , i ns t a l l t he cool i ng modul e . Fa i l ure to fo l l o w t hi s i nst r uct i o n may res ul t i n pe rs ona l i nj ur y. CAUTI O N : Make s ur e t ha t the radi a t o r and t he a ir con di t i o ni ng c on de ns e r are no t da mage d during t he i ns t a l la t i o n o f t he coo l i ng modu le . [...]

  • Page 1025

    6. Connect t he e l ect r i cal co nnect o r. 7. Connect t he radi a t o r uppe r cool a nt ho s e . 8. Connect t he radi a t o r vent hos e . 9. Ins t a l l the ba t t e r y t ray. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n). 10. Ca[...]

  • Page 1026

    P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - Radiator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he coo l i ng fa n mot o r a nd s hr oud. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Fan Mot o r a nd Shr o ud (303-03 B E ngi ne Coo l i ng - [...]

  • Page 1027

    Name Gr ea s e P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - Water Pump Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho s e Cl amp 303-3 97 (24- 003) Mate ri a l s Speci fi cati on W S S -M 12 A4-A2 R em ova l Vehi c le s with 2.2L d[...]

  • Page 1028

    5. NOT E: S hown wi t h t he exha ust g a s reci r cul a t i o n (EGR) coo l e r t o EGR val ve t ube removed f o r cl a rit y. Re move t h e po we r s t e ering pump r e t a i ni ng bo l t s . 6. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. Re move t h e po we r s t e ering pump s ecur i n g b r a cket .[...]

  • Page 1029

    9. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. Det ach t he wi r i ng harnes s . 10. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y. Det ach t he wa t e r pump. Det a ch t he wi ring ha rn es s f r om t he wat e r pump l owe r r et a i ni ng bol t s . 11. Remove [...]

  • Page 1030

    13. Remove t he e n gi ne o i l t e mpe r a t ur e co nt rol t he r mos t a t . Re mov e a nd di s c a r d t he O -r ing s e a l . Insta llat ion All v e h icle s 1. NOT E: Ins t a l l a new e ngi ne o il t e mpe r at ure cont rol t he r mos t a t O -ring s ea l . I nst a l l t he e n gi ne o i l t e mperat ure co nt r ol t herm os t a t . 2. Ins t[...]

  • Page 1031

    4. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. At t a ch t he wa t e r pump. Ti ght e n t he wa t e r pum p r et a i ni ng bo l t s t o 24 Nm. At t a c h t he w i r i ng ha r ne s s t o t he wa t e r pump l owe r ret a i ni ng bo l t s. 5. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube rem[...]

  • Page 1032

    8. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. At t a ch t he p owe r s t e ering pump t o th e w at e r p ump. 9. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. I nst a l l t he p o wer s t e ering pum p s e cur i ng b r acket . Ti ght e n t o 25 Nm. 10. NO TE: [...]

  • Page 1033

    12. At t ach t he p o we r s t e e r i ng pump be lt . Rot a t e th e powe r s t e e ring p ump be l t t e ns i one r c l o ckwis e . 13. At t ach t he p o we r s t e e r i ng fl ui d pi pe. 14. Carr y out t he co ol i ng s ys t e m fi l l ing a nd bl e e di ng procedur e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng S y s t[...]

  • Page 1034

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b-i n Lo we r in ta ke mani f o ld r et a i ni ng bo l t s 10 - 89 Fue l i nje cti o n s uppl y man if ol d ret a i ni ng bol t s 10 - 89 Fue l pre ss ur e s en s o r[...]

  • Page 1035

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols Des cr ipt i o n a nd O pe r a t i o n I te m P ar t Nu m ber Desc ri pti on 1 — Fuel chargin g wi r i ng harnes s 2 — Fuel i nj e c t o r 3 — Fuel pr e s s ur e s e nso r 4 — Thr ot t[...]

  • Page 1036

    CAU TIO N : Th e us e o f s uppl ement a r y oi l or fu e l add i t i ve s i s no t a ppr oved unl es s s pe c i fi e d by Jag ua r Ca r s i n t h e fo rm of a s e rvice comm unica t i on o r di r ect i ve. A f u e l pre ss ur e rel ie f val ve i s fi t t ed to the f ue l r a i l a t t he front of t he ca ms haf t cove r. Thi s val ve a l l ows t h[...]

  • Page 1037

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols 2.0L NA V6 - AJV6 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani[...]

  • Page 1038

    Publ i s he d: 24-No v-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols 2.5L NA V6 - AJV6 / 3.0L NA V 6 - AJ2 7, VIN Range: E 96603->J28492 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis u[...]

  • Page 1039

    DT C C ondi ti o n P oss i bl e Ca uses Ac ti o n P 0112, P 0113 Conce rn wi t h IAT s e ns o r Engi ne fa ul t y l e a di ng t o overhea t i ng Int ake a ir t e mperat ure (IAT ) s ens or fa ul t Ha r nes s fa ul t ECM fa il ure REFER t o: A cce le r a t i o n Co nt rol (310- 02 Accel e r a t i o n Co nt r ol , Di a gnos is a nd Te s t i ng) / El [...]

  • Page 1040

    1 2 3 1 2 1 2 3 1 2 DT C C ondi ti o n P oss i bl e Ca uses Ac ti o n P 1338 Conce r n wi t h fue l pump c o m mands (fue l p ump not a cti vat e d whe n r e que s t e d by ECM) ECM t o f ue l pump co nt rol m o dul e co nt rol and /or fe e d ba ck ci r cui t s ; o pe n cir cuit , s hort ci rc ui t , hi g h r e s i s t a nce Fuel pump co nt rol mod[...]

  • Page 1041

    3 1 1 1 2 3 4 1 2 1 2 1 1 2 Mea s ure t he r es i s t a nce b e t we en the rel e va nt i nje cto r ha r nes s e l e ct rical c onn e cto r (IJ1 t o 6) pi n 1 and EN16 pi ns a s fo l lo ws - Inj e ct o r 1 pi n 1 (NW ) a nd ECM pi n 115. Inj e ct o r Cyl 3 pi n 1 (N) a nd ECM pi n 114. Inj e ct o r Cyl 5 pi n 1 (NR) a nd ECM pi n 113. Inj e ct o r [...]

  • Page 1042

    1 1 1 2 3 1 2 1 2 1 2 1 2 3 1 2 REFER t o: Fue l P ul s e Dampe r - 2.5L NA V 6 - A JV6/3.0L NA V6 - AJ27 (303- 04A Fue l Charging a nd Co ntrol s - 2. 0L NA V6 - AJV6/2.5L NA V 6 - AJV6/3.0L NA V6 - AJ27, Re moval a nd I ns t al l a t i o n). CLEA R t he DTC. TES T t he s yst e m f or no r m al o p e r at i on . B6: C HEC K T HE FUEL R AI L PR E S[...]

  • Page 1043

    1 2 1 2 1 2 3 1 1 2 1 2 3 4 1 2 I s t he r es i s t a nce l e s s t ha n 5 o hms? Ye s GO t o C7 . No REP AIR t he ci r cuit b e t we e n FT3 pi n 1 (W B) a nd I P 10 p i n 8 (W B ). Fo r a ddi t i o na l i nf o r mat io n, r e f e r t o wi ring di a g r ams. CLEA R t he DTC. TES T t he s yst e m f or no r m al o p e r at i on . C 7: C HEC K T HE F[...]

  • Page 1044

    1 2 3 1 2 3 1 2 3 1 1 2 3 1 i nf o r ma t i o n, ref e r t o wi ring di a g rams. CLEA R t he DT C. TES T t he s ys t e m fo r nor mal o p e r a t i o n. PINPOIN T TE ST E : FU EL PUM P FEED BA CK C IRC UI TS. P133 8 T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS E1: CHEC K SI GNA L PO W ER CIRC UIT T O FUEL PUMP MODULE Di s conn ect f uel p ump[...]

  • Page 1045

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols 2.5L NA V6 - AJV6 / 3.0L NA V 6 - AJ2 7, VIN Range: J2 8493-> V99999 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis [...]

  • Page 1046

    DT C C on di ti on Possi bl e C a u ses Acti o n P 0116, P 0117, P 0118, P 0125 Conce r n wi t h e ng i ne c oo l a nt t e mpe r at ure Engine c oo l a nt t e mperat ure s e ns o r Harnes s fa ul t ECM f a i lur e REFER t o : E le ctroni c Eng i ne Co nt rol s - 2.5L NA V6 - AJV6/3.0L N A V6 - A J 27, VI N Ra nge : J28493->V99999 (303-1 4A El e [...]

  • Page 1047

    1 2 3 1 2 1 2 3 1 2 3 1 1 DT C C on di ti on Possi bl e C a u ses Acti o n ope n circu i t , s ho r t ci r cuit , hi gh r e s i s ta n ce Thr ot t l e mo t o r f a i l ur e Thr ot t l e b o dy f a i l ure P 1656 Conce r n wit h TP se n s o r a m pl i f i e r c i r cuit ECM REF ER t o : El e ct roni c Eng i ne Co nt rol s - 2.5L NA V6 - AJV6/3.0L N [...]

  • Page 1048

    1 2 3 4 1 2 1 2 1 1 2 1 1 1 Be fo re repl aci ng a ECM, cont a ct De a l e r t e c hni ca l s uppo r t . PINPOIN T TE ST B : F UEL PU L S E DAM PER SENSOR. P01 90 , P01 9 2, P01 9 3 T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS B1: C HEC K T HE FUEL PU LSE DAM PE R SENS OR SUPPLY VOLT AGE Tur n t he i gni t i o n s wi t ch t o th e O FF po s i [...]

  • Page 1049

    2 3 1 2 1 2 1 2 1 2 3 1 2 1 2 1 2 Tur n t he i gn it i o n s wi t ch t o t he O N po s i t i o n. Mea s ur e t he res i s t a nce b et we e n e l e ctrica l conne c t o r FT2 pi n 3 (B) a nd GROU ND. I s t he r es i s t ance l e s s t ha n 5 o hms? Ye s GO t o C2 . No REP AIR t he cir cuit b e t we e n e l e ctr i cal co nne cto r FT2 pi n 3 (B ) a[...]

  • Page 1050

    1 2 3 1 2 3 1 2 3 1 1 2 3 1 1 2 1 2 3 4 PINPOIN T TE ST D : FU EL P U MP CONTROL MODU LE. P062 7, P0 62 8, P062 9 T EST C ONDI T I ONS DET AI LS/RE SULT S/A CT IONS D1: C HECK S IGN AL P O WER C I RC UIT T O FUEL PUMP MODULE Dis conne ct fue l p ump modul e e l e ct rica l co nnect o r CA105. Tur n t he i gni t i o n s wi t ch t o th e O N p o si t[...]

  • Page 1051

    1 2 1 2 3 1 I s t he v ol t a ge grea t e r tha n 10 vo lt s ? Ye s GO t o E5 . No I NS TALL a ne w fue l p ump modul e . REFER t o: Fue l P ump Modul e - 2. 5L N A V 6 - A JV6/ 3.0L NA V 6 - AJ27 (310-01 Fue l T a nk a nd Li ne s , Re moval a nd I nst a l l at io n). CLEA R t he DTC. TES T t he s yst e m f or no r m al o p e r at i on . E5: CHEC K[...]

  • Page 1052

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging Wiri ng Harness Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.5L or 3.0L engine 1. Remove t he i nt a ke man if ol d . Fo r ad di t i on a l in f orm at i on, r e f er t o Sect i on 303-[...]

  • Page 1053

    7. NOT E: Fue l may s t i l l be pres e nt i n t he fue l i nj e ct i on s uppl y mani f o l d. Det ach t he f uel i nj e ct i on su ppl y mani fo l d a nd l o we r i nt a ke ma nif ol d a nd pl a ce t o o ne s i de . Re mov e a nd di s c a r d t he l owe r in t a ke man if ol d O -r i ng s e a l s . 8. Remove t he f uel i nj e ct i on s uppl y man[...]

  • Page 1054

    12. Dis c o nne ct t he e l e ct r ica l conne ct o r . 13. Remove t he f u el cha r ging wi ring ha r nes s. Insta llat ion Vehi c le s with 2.0L engi n e 1. To i ns t a l l , rever s e t he remov a l proced ur e . Vehi c le s with 2.5L or 3.0L engine 2. NOT E: Ins t a l l ne w f ue l i nje ct or O -r i ng s e a l s . • NO T E: Ins t al l n ew l[...]

  • Page 1055

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel Injecti on S upp ly Manif ol d Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n[...]

  • Page 1056

    7. Remove t he f uel rai l ret a i ni ng bol t s . 8. D i s conne ct t he f uel rai l f r o m t he i nj e ct o r s. 9. Remove t he f uel i nj e ct i on r a i l . 1. Ro t a t e t he fu e l i nj e ct i o n rai l t hr ough 180°. 2. Re move t he f ue l i nj e ct i o n rai l . Vehi c le s with 2.5L or 3.0L engine 10. Remove t he f u el pres s ur e s e [...]

  • Page 1057

    2. NOT E: Ins t a l l a new ga s ket . Ti ght e n t o 10 Nm. Vehi c le s with 2.0L engi n e 3. Tig ht e n t o 10 Nm. 4. Tig ht e n t o 6 Nm. JagDocs.com[...]

  • Page 1058

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel Injecto rs Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.5L or 3.0L engine 1. Remove t he f uel cha r gi ng wi ring ha r ne s s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Fue l Ch ar[...]

  • Page 1059

    6. Remove and di s card t he O -r ing s e a ls . 7. Insta llat ion 1. NOT E: Ins t a l l ne w f ue l i nje ct or O -r i ng s e a l s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Lubricat e t he f u el i nje ct o r O-r i ng s ea l s wit h cl e a n e ngi ne o i l . JagDocs.com[...]

  • Page 1060

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel Pulse D amper2.5L NA V6 - AJV 6/ 3.0L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he t hrot t l e b o dy. Fo r a ddi t i o na l i nf o r m at i o n, r ef e r to Throt t l e Bo dy . 2. D[...]

  • Page 1061

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - Throttl e Bo dy Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s CAU TIO N : Do no t a t te m pt t o cl e a n t he t hr o tt l e bo dy. T he b or e a nd t he t hr ot t l e pl a t e ha s a s p eci al coa ti n[...]

  • Page 1062

    5. D i s conne ct t he e l ect r i cal conne ct o r. Vehi c le s with 2.5L or 3.0L engine 6. D i s conne ct t he e l ect r i cal conne ct o r. 7. D i s conne ct t he e l ect r i cal conne ct o r. 8. Remove t he t hrot t l e b o dy. Vehi c le s with 2.0L engi n e JagDocs.com[...]

  • Page 1063

    9. Remove t he t hrot t l e b o dy. All v e h icle s 10. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move a nd di s ca r d t he O-r i n g s e al . Insta llat ion All v e h icle s CAU TIO N : Do no t a t te m pt t o cl e a n t he t hr o tt l e bo dy. T he b or e a nd t he t hr ot t l e pl a t e ha s a s p eci al coa ti ng a ppl ie d d ur i [...]

  • Page 1064

    3. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1065

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - T o rque Sp eci f i cat ions Descri pti o n Nm l b-f t l b- i n Hi gh-pr e s sure f uel s uppl y l i ne s 40 30 - Hi gh-pr e s sure f uel s uppl y l i ne s up port b r ack e t ret a i ni ng nu t 8 - 71 Fue l i nje cto rs[...]

  • Page 1066

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel C harging and Co ntrols Des cr ipt i o n a nd O pe r a t i o n Hi gh Pre ss ure Fue l I nj e cti on Co mpone nt s I te m Pa rt N um b e r Desc ri pti on 1 - Fue l i nj ect io n s up pl y mani f o l d s up po r t b r[...]

  • Page 1067

    It e m Pa rt N um be r Descri pti on 1 - Fue l pum p r et a i ni ng bo l t 2 - Fue l pum p gas ke t 3 - Fue l pum p fue l r e t ur n l in e 4 - Fue l pum p fue l s uppl y l i ne 5 - Fue l pum p 6 - Fue l pum p s hie ld 7 - Fue l r e tu r n l i ne ve nt ur i 8 - Fue l pum p s pr ock e t ret a i ni ng bo l t 9 - Fue l pum p s pr ock e t Fu el Inj ect[...]

  • Page 1068

    The fue l i nj e ct io n s up pl y mani fo l d i s a r e s e r vo i r fo r the pres s ur i ze d f ue l t ha t i s p r o d uced by t he f ue l pump. I t a l s o i ncor po r at e s a p res s ur e s e ns o r s o t hat t he ECM can moni t o r/ ad jus t t he p r es su r e o f th e fue l to be i nj ect ed i n t o t he cyl in der. The fue l i nj e cti o n[...]

  • Page 1069

    P ubl i she d: 12-Jul-2011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel C harging and Co ntrols Dia gn os i s a nd Te s t i ng Principle of oper at ion Thi s s e cti on cove r s t he f uel s ys t e m from t he f ue l f i l t e r t o t he fu e l i nje ct ors , and incl ud es t he f ue l r [...]

  • Page 1070

    Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Cr anks haf t po si t i o n (CKP) s e ns or f a ul t Cyli nder he a d t e m perat ure (CHT) s e ns o r f aul t Fue l pu m p f a ul t Lo w co mpr e s s io n Va l ve t r a i n f aul t Bl o cked cat a l ys t Engi ne cont rol mod ul e (ECM) f a ul t Di ff i cul t t o s t a rt Di[...]

  • Page 1071

    Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Dual -mas s fl ywh e e l f aul t I dl e s pe e d hi g h o r lo w Accel erat o r pe da l po s i t i o n (AP P ) s e ns or f aul t I nt a ke a i r t e mper a t ur e (IAT ) s e nso r f aul t Check f o r DTCs i nd i cat i ng a n A P P o r IA T se ns o r f a ul t . Re cti f y a s[...]

  • Page 1072

    Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Cyli nder he a d t e m perat ure (CHT) s e ns o r f aul t Ca m s ha f t po s it i o n (CMP) s e ns o r fa ul t Cr anks haf t po si t i o n (CKP) s e ns or f a ul t I nt a ke a i r t e mper a t ur e (IAT ) s e nso r f aul t Mani f o l d a bs o l ut e pr es s ur e (MAP) s e ns[...]

  • Page 1073

    Name Cl e a ni ng Fl ui d P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel In jec tio n C o m ponent C leanin g Gene ral P r ocedures Ge nera l Equi pm ent P ne umat i c vacuum gun Mate ri a l s Speci fi cati on W -M5B411 -A • W ARNINGS : Do not s moke o r car r[...]

  • Page 1074

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel In jec tio n Pump Re moval a n d I ns t a l l a t i on Speci al T ool (s) Adap t e r f or 303-681- 01 303-681 -01 Re mov e r /Ins t a l l e r , Cr a n ks haf t O i l Sea l 303-679 Locking T o ol , Fue l Inj e ct i o[...]

  • Page 1075

    1. Remove t he e xhaus t g a s reci r cul a t i o n (EGR) coo l e r t o EGR va l ve t ube. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Exhaus t Gas Re ci r cula t io n (EGR) Coo l e r t o EGR Va l ve T ube (303-08 Engin e Emi s s i on Cont r ol - 2. 0L Di es e l /2.2L Di e s e l , Remova l a nd I ns t a l l a t i o n). 2. D et a ch t he[...]

  • Page 1076

    6. Remove t he i nt a ke man if ol d . Dis car d t he i nt a ke m a ni f ol d g a s ket s . 7. D i s conne ct t he f uel me t e r i ng val ve a nd f ue l t e mper a tu r e s e ns o r e l e ct r i cal conne c t o r s . 8. D et a ch t he wi ring ha r ne s s . 9. D et a ch t he hi g h-pr e s s ur e f ue l s up pl y l ine s u ppo r t br acke t . 10. Cl[...]

  • Page 1077

    11. CAUTI O N S : Make s ur e t he t o ol us e d t o l o o s e n t he hi g h pres s ur e fue l s upp l y l i ne uni on i s use d a t t he t o p o f t he uni on a s t hi s is where t here i s mos t m a t e ria l . Fa i l u r e t o f o l l ow t hi s i ns t r uct i o n may res ul t i n d a mage t o t he uni on . Mai nt a i n p r e s s ur e o n t he hi[...]

  • Page 1078

    18. Dis c o nne ct t he f uel i nje ct i on pump f ue l s uppl y a nd r et ur n l in e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Ins t al l bl a nki ng pl ugs t o t he f ue l i nj e ct i o n pump f[...]

  • Page 1079

    23. Det a ch t he fue l sup pl y and fue l r e t urn l i ne s uppo rt br acket . 24. Remove t he p o we r s t e e r i ng fl ui d re se r voi r r e t a ini ng nut s . 25. Det a ch t he powe r s te e ring f lui d r es e r voi r . 26. S e cur e t he p o we r s t e e r i ng fl ui d r e s e rv oi r to one s id e . 27. Dis c o nne ct t he hydr a ul i c c[...]

  • Page 1080

    28. Remove t he e n gi ne mount da mpe r . Vehi c le s bu ilt from VIN :E4 38 69 29. Dis c o nne ct t he f uel i nje ct i on pump f ue l s uppl y a nd r et ur n l in e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o c[...]

  • Page 1081

    32. Remove t he f u el s u ppl y a nd ret ur n l i ne s uppo r t brack e t r et a i ni ng nut . 33. Det a ch t he fue l sup pl y and r e turn l in e s. 34. Dis c o nne ct t he HCU e l e c t r i cal co nne ct or. 35. Det a ch t he powe r s te e ring p i pe t o e ngi ne wiring ha r ne s s ret a i ni ng cli p . 36. Remove t he p o we r s t e e r i ng [...]

  • Page 1082

    37. Det a ch t he powe r s te e ring f lui d r es e r voi r . All v e h icle s 38. Us i ng t he s pe ci a l t o o l , r e move t he fue l inj ect i on pump s prock e t a cces s cover. 39. NO TE: T urn t he engi ne in t he no r mal di r e cti on o f r o t at i o n onl y . Tur n t he e n gi ne unt i l t he fue l i nj e cti o n pump sp roc ket ti mi n[...]

  • Page 1083

    42. NO TE: Fo r a d di t i on al i nfo r mat i o n, s e e s te p 41. • NO T E: T he s peci a l t o ol l ocking pi n ho l e s a re o f f s e t . Dur i ng i ns t a l l a t io n o f th e s pe ci a l t o o l , che ck t ha t t he o ff se t p i n ho l e i s l o cat e d a t t he t o p. I nst a l l t he s pe cia l t o ol . 43. NO TE: Fo r a d di t i on a[...]

  • Page 1084

    47. NO TE: Fo r a d di t i on al i nfo r mat i o n, s e e s te p 41. • NO T E: Acces s t he f ue l i nj e ct i o n p ump r e t a i nin g b ol t s t hr ough t he ho l es pr ovid e d i n t he s pe cia l t o o l (To ol n o. 303-11 51 and t o o l no. 303-083A) a nd th e fue l inj e ct i on pump s pr ocket . The f uel i nj e ct i on pum p r e t a i ni[...]

  • Page 1085

    51. Dis c o nne ct t he kno ck se n s o r (KS ) e l e ct rica l c o nne ct or . 52. Det a ch t he eng i ne wi ring ha r nes s . 53. Remove t he f u el i nje ct i on p ump s uppo rt brack et . 54. Remove t he f u el i nje ct i on p ump s uppo rt brack et t o e ngi ne cyl i nde r bl o ck r et a ini ng bol t s . 55. NO TE: W hen r e moving t he f u el[...]

  • Page 1086

    56. Remove t he f u el i nje ct i on p ump s hi e l d from t he fue l i nj e ct io n pump. 57. Det a ch t he fue l r e t ur n l i ne ve nt uri f r o m t he fu e l i nj ect i o n p ump. Dis car d t he f uel ret u r n l i ne v e nt ur i O -r i ng s e a l . 58. Remove t he f u el i nje ct i on p ump fue l s uppl y l i ne a n d f ue l ret ur n li ne a [...]

  • Page 1087

    1. NOT E: Ins t a l l ne w f ue l i nje ct i o n p ump s up pl y l ine O -r i ng s e a l s . I nst a l l t he f ue l i nj e c t i o n p ump fue l s upp l y l i ne and f ue l r et ur n l i ne a s s embl y t o t he f ue l i nj e ct i o n p ump. Ti ght e n 20 Nm. 2. NOT E: Ins t a l l a new O -r i ng s e a l t o t he fu e l r et ur n l i ne ve nt ur i[...]

  • Page 1088

    6. NOT E: Ins t a l l t he f ue l i nje ct i o n pump r e t a ini ng b ol t s e ve nl y i n o r d e r t o pul l t he f ue l i nj e ct i o n pump s q ua r el y i nt o pos i t i on. Lo o s e l y i ns t a l l the f ue l i nj e ct i on pump s uppo r t br acket t o e ng i ne cyli nde r bl o ck r e t a in i ng b ol t s . 7. NOT E: Do not ful l y t ig ht [...]

  • Page 1089

    11. Conne ct t he f uel i nje ct o r t o f ue l i nj e c t i o n pump fue l r e t u r n l ine . At t a c h t he f ue l i nje cto r t o f uel i nje c t i o n pump r e t ur n l i ne ret a i ni ng c l i p (i f e qui ppe d). Re mov e t he b l a nki ng pl ug s f rom t he f uel i nje ct o r t o fue l i nj e c t i o n pump f uel ret ur n l i ne mal e an d[...]

  • Page 1090

    16. Ins t a l l t he f uel i nj e cti on p ump s p r ock e t ret a i ni ng b ol ts . Ti ght e n t o 32 Nm. 17. Remove t he s pe ci a l t o o l s . 18. NO TE: I ns t a ll t he f uel i nj e ct i on pum p r et a i ni ng bo l t s e venl y i n o r de r t o pul l t he f ue l i nj e ct i o n pump s q ua r el y i nt o pos i t i on. • NO T E: U s e a t o [...]

  • Page 1091

    21. Us i ng t he s pe ci a l t o o l , i ns t a l l t he f uel i nje ct i o n pump s pr ocket a cces s cover. Vehi c le s bu ilt from VIN :E4 38 69 22. At t ach t he p o we r s t e e r i ng fl ui d r e s e rv oi r . 23. Ins t a l l t he po we r s t e e r i ng fl ui d res e rv oi r r et a i ni ng n ut s . 24. At t ach t he p o we r s t e e r i ng pi[...]

  • Page 1092

    25. Conne ct t he H CU e le c t rical co nnect or. 26. At t ach t he f uel s uppl y a nd ret ur n li ne s . Ti ght e n t o 23 Nm. 27. Ins t a l l t he f uel s upp ly a nd ret ur n l i ne s sup po r t b rack e t r et ai ni ng n ut . Ti ght e n t o 8 Nm. 28. At t ach t he wi r i ng harnes s r et ai ni ng cli p. 29. Ins t a l l t he f uel s upp ly a n[...]

  • Page 1093

    30. Conne ct t he f uel i nje ct i on p ump f uel s uppl y a nd ret ur n l i ne s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Vehi c le s bu ilt up to VI N: E4 386 8 31. Ins t a l l t he e ngi ne mount[...]

  • Page 1094

    34. At t ach t he p o we r s t e e r i ng fl ui d r e s e rv oi r . 35. Ins t a l l t he po we r s t e e r i ng fl ui d res e rv oi r r et a i ni ng n ut s . 36. At t ach t he f uel s uppl y a nd f uel re t urn l i ne s uppo r t br a ck et . 37. At t ach t he wi r i ng harnes s r et ai ni ng cli p. 38. At t ach t he wi r i ng harnes s r et ai ni ng[...]

  • Page 1095

    39. At t ach t he p o we r s t e e r i ng fl ui d ho s e t o t he fue l r e t ur n l i ne . 40. Ti g ht e n t he f ue l s uppl y a nd r e t ur n l i ne s s up port b r acket ret a i ni ng n ut. Ti ght e n t o 8 Nm. 41. Conne ct t he f uel i nje ct i on p ump f uel s uppl y a nd ret ur n l i ne s . For a ddi ti ona l i nf o r m a t i o n, r e f e r [...]

  • Page 1096

    44. CAUT I O N: Do no t a l l o w t he uni ons t o hi t the ol ive e nds o f t he hi gh-pr es s ur e fue l s up pl y l ine as t hi s may d a mage t he e nds of t he l i ne a nd a ll o w f o r e i gn m a t te r t o e nt e r t he fue l inj e ct i on s ys te m . • NO T E: P o s i t i o n t he hi gh p r es s ur e f ue l s up pl y l in e a s ne a r t [...]

  • Page 1097

    50. At t ach t he wi r i ng harnes s . 51. Conne ct t he f uel met e r i ng val ve a nd f ue l t e mper a tu r e s e ns o r el e ct rica l conne ct ors. 52. NO TE: I ns t a ll n e w i nt a ke mani fo l d g as ke t s . I nst a l l t he i nt a k e mani fo l d. Ti ght e n t o 15 Nm. 53. At t ach t he wi r i ng harnes s ont o t he i nt a k e mani f ol [...]

  • Page 1098

    55. Ins t a l l t he a ir cl e a ne r moun t br acket . 56. At t ach t he wi r i ng harnes s . 57. Ins t a l l t he EGR coo l e r t o E GR val ve t ube. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Exhaus t Gas Re ci r cula t io n (EGR) Coo l e r t o EGR Va l ve T ube (303-08 Engin e Emi s s i on Cont r ol - 2. 0L Di es e l /2.2L Di e s [...]

  • Page 1099

    Name Hi g h p r es s ur e f ue l s u ppl y l i ne uni o n l ubrica nt TBD P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel In jec tio n Su pply Manifo ld Re moval a n d I ns t a l l a t i on Speci al T ool (s) Al i gner, Fuel I nj e cto r 303-711 (2 1-258 ) Ge ner[...]

  • Page 1100

    3. D et a ch t he wi ring ha r ne s s . 4. D et a ch t he hi g h p r e s s ur e f ue l s upp ly l i ne s upp ort br a cket . 5. Cle a n t he fue l p ump, hi gh p r es s ure f ue l s up pl y l in e a nd s ur roundi ng a r e a s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fuel In je ct i o n Co mpone nt Cl e a ni ng (303-04 B Fue l Cha [...]

  • Page 1101

    9. CAU TI O N : Make s ur e t h at th e hi gh pr e s s ure f uel s uppl y l i ne r e m a i ns in con ta ct wi t h b o t h t he f ue l pump a nd t he f ue l i nj e ct i o n s upp l y m a ni f ol d unt i l b ot h uni o ns ha ve be e n de ta che d a nd cl e ane d . Fa i l ure t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n f o r ei gn m a t [...]

  • Page 1102

    17. Remove a nd di s car d t he hi gh p r es s ure f ue l s up pl y l in e . 18. Repe a t s t e p s 14 a nd , 15 t o r emove t he 3 remai ni ng hi gh p r es s ur e f ue l s up pl y l i ne s. 19. Us i ng t he pne umat i c vacuum gun , vacuum f orei gn mat e r i a l f r om t he f uel i nj e cto r a nd t he fue l in je ct i o n s uppl y mani f o l d. [...]

  • Page 1103

    Th is proc e dur e i nvol ve s fue l h a ndl i ng. B e p r ep a r e d f o r fue l s pi l l a ge a t al l t i me s a nd a l wa ys ob s e r ve f uel ha nd li ng pr e caut i ons . Fa i l ur e t o fo l l o w t he s e ins t ruc t i o ns may r e s ul t i n pers o nal i njur y. • CAU TI O N S : Make s ur e the wo rk sho p a rea i n which t he vehi cl e [...]

  • Page 1104

    4. Lubr icat e t he ne w hi gh pr e s s ure f uel s uppl y l i ne uni on t hr ea d s wi t h cle a n l ubr ica nt . 5. CAU TI O N : Do no t a l l ow t he uni o ns t o hi t t he o l i ve e nd s of t he hi gh p res s ur e fue l sup pl y l ine as t hi s may d a mage t he e nds o f t he l i ne a nd a ll o w f o r e i gn m a t te r t o e nt e r t he fue [...]

  • Page 1105

    10. CAUT I O N: Do no t a l l o w t he uni ons t o hi t the ol ive e nds o f t he hi gh p res s ur e fue l sup pl y l ine as t hi s may d a mage t he e nds o f t he l i ne a nd a ll o w f o r e i gn m a t te r t o e nt e r t he fue l inj e ct i on s ys te m . • NO T E: T he yel l ow c o l ored co l l a r i s fi t t e d a t t he fue l i nj e cto r[...]

  • Page 1106

    15. NO TE: Hi gh pr e s s ur e f uel s upp ly l i ne s s hown r emove d f o r cl arit y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif o ld ret a i ni ng bo l t . Ti ght e n t o 23 Nm. 16. NO TE: T wo fue l i nj e ct or s ho wn, o t he r f ue l i nj e ct o r s s i mi l ar. Di s conn ect t he fu e l r et ur n li ne s f r o m the fue l inj e[...]

  • Page 1107

    20. CAUT I O N: Ma k e s ure t he to o l us ed to ti ght e n t he hi g h pres s ur e fue l s uppl y l i ne uni on s i s us e d a t t he t o p of t he uni o n a s t hi s i s whe re th e re i s most mat e r i a l . Fa i l ur e t o f ol l o w t hi s i ns truc t i o n may r e s ul t i n dama ge t o t he u nio n. Ti ght e n t he hi g h pr e s s ur e f u[...]

  • Page 1108

    25. At t ach t he hi g h pr e s s ure fue l s uppl y li ne s uppo rt brack e t . Ti ght e n t o 8 Nm. 26. CAUTI O N S : Make s ur e t he t o ol us e d t o t i ght e n t h e hi gh pr es s ure f ue l s uppl y l i ne uni on i s use d a t t he t o p o f t he uni on a s t hi s is where t here i s mos t m a t e ria l . Fa i l u r e t o f o l l ow t hi s [...]

  • Page 1109

    30. Ins t a l l t he i nt a ke man if ol d . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: I nt a ke Ma nif ol d (303-01B Engi ne - 2.0L Dur at o rq -TDCi /2.2L Dur at o r q-TDCi (110kW /150PS ) - Puma, I n-v e hi cle Re pa i r) . 31. Ins t a l l t he e ngi ne cover. 32. Ins t a l l t he oi l f il l e r cap . 33. Ins t a l l t he oi l l e[...]

  • Page 1110

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel In jec tor Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ock e t , Fue l Inj e ct o r Remove r /Ins t a l l er 303-677 Al i gner, Fuel I nj e cto r 303-711 Ge nera l Equi pm ent P ne umat i c vacuum gun [...]

  • Page 1111

    2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he o i l f i l le r cap a nd o i l l e ve l i ndi ca t o r t o pr e ven t fo r ei gn m a t e ria l e nt e ring t he val ve cover. Re move t h e e ngi ne cove r. 4. CAU TI O N : P r ot ect t he fu e l i nj e ct o r e l e c t r i cal co nne ct ors wi t h li nt -free mat e ria l t o p r e ven[...]

  • Page 1112

    7. Remove and di s card t he hi gh-pr es s ur e f ue l s up pl y l i ne . 8. Usi ng t he p neumat i c va cuum gun, vacuum f orei gn mat e r i a l f r om t he f ue l i nj e ct o r a nd t he f ue l i nj e ct i o n s uppl y mani f o l d. 9. Ins t a l l bl a nk i ng cap s t o t he o pe n th r e ade d p orts o n t he f ue l i nj e ct o r and t he fue l [...]

  • Page 1113

    13. CAUT I O N: Ma k e s ure t hat t he f uel i nj e cto r do es not mo v e when lo o s eni ng th e fue l inj e ct or l o ck ing col l a r . Fa i l ur e t o f o l l o w t hi s ins t r ucti on wil l r e s ul t i n d ama ge t o t he f u e l i nje ct o r an d t he fue l i nj e cto r se a li ng wa she r . Us i ng t he s p e ci a l t o ol , re mov e t h[...]

  • Page 1114

    2. NOT E: Do not t i ght e n t he fue l in j ect or l o ck i ng col la r a t t hi s s t a ge . Us i ng t he s p e ci a l t o ol , i ns t a l l t he fue l in j ect or. 3. D i s conne ct t he f uel i nj e ct or e l e ct rica l c on ne ct or . 4. Usi ng t he s pe cia l t oo l s, t i gh t e n t he f ue l i nj e cto r l o cking col l a r . Ti ght e n t [...]

  • Page 1115

    7. NOT E: Hi g h-pr e s s u r e f ue l s up pl y l i ne s s ho wn removed f o r c l a r i t y. Lo o s e n t he f uel i nje cti on s uppl y ma nif ol d ret a i ni ng bol t s . 8. NOT E: Hi g h-pr e s s u r e f ue l s up pl y l i ne s s ho wn removed f o r c l a r i t y. Lo o s e n t he f uel i nje cti on s uppl y ma nif ol d s upport br acket s . 9.[...]

  • Page 1116

    13. CAUT I O N: Ma i nt a i n pr e s s ur e on t he hi gh-pr es s ure f uel s uppl y l i ne to k ee p t he ol i ves in co nta ct wi t h t he f uel i nj e ct o r s and t he f ue l i nje cti o n s uppl y mani f ol d co ne s whi l e ins t a l l ing t he u nio ns . • NO T E: Ins t al l t he hi gh-pr es s ur e f ue l s up pl y l in e s t o t he fue l [...]

  • Page 1117

    uni on a t t he f ue l i nje ct o r . Ti ght e n t o 40 Nm. 18. Remove t he s pe ci a l t o o l . 19. CAUT I O N: Ma k e s ure t he to o l us ed to ti ght e n t he hi g h-pr e ss ur e fue l s uppl y l i ne uni on s i s us e d a t t he t o p of t he uni o n a s t hi s i s whe re th e re i s most mat e r i a l . Fa i l ur e t o f ol l o w t hi s i ns[...]

  • Page 1118

    22. NO TE: Re move t he o i l f i l l e r cap and oi l le vel i nd i cat o r . I nst a l l t he e n gi ne cove r. 23. Ins t a l l t he oi l f il l e r cap . 24. Ins t a l l t he oi l l e vel i ndi cat o r . 25. Us i ng t he Jag ua r ap prov e d di agno s t i c s yst em, conf i g ur e t he ne w f ue l i nj e ct o r t o t he e ngi ne c o nt r ol m od[...]

  • Page 1119

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel Metering Valve Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t ype whe n wo rk i ng on o r ne ar an y f uel rel a t ed co[...]

  • Page 1120

    4. D i s conne ct t he f uel me t e r i ng val ve a nd f ue l t e mper a tu r e s e ns o r e l e ct r i cal conne c t o r s . 5. CAU TI O N : Al wa ys car ry o ut t he cl e a ni ng proces s b e fo re carr yi ng out any repai r s t o t he f uel i nj e cti on s yst em compone nt s. Fa i l ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t [...]

  • Page 1121

    4. CAU TI O N : The fu e l met ering val ve r et a i ni ng bo l t s m us t be ti g ht e ne d i n t he f ol l owi ng s t a ge s . Fai l ur e t o fo l l o w t hi s i ns t r ucti o n may r e s ul t i n d a mage to the fue l me t e ring va l ve . Ti ght e n t he f ue l met e ring val ve re ta i ni ng bo l t s i n t wo s t a g es . S ta g e 1: 2.5 Nm S [...]

  • Page 1122

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel Return L ine Venturi Re moval a n d I ns t a l l a t i on Ge nera l Equi pm ent P ne umat i c vacuum gun R em ova l 1. W ARN INGS : Do no t s moke o r car r y l i ght e d t ob a cc o or ope n f l a me of a ny t ype [...]

  • Page 1123

    4. NOT E: Prot e ct t he fue l met e r in g va l ve e l ect r i cal conne ct o r wi t h l i nt -fr ee m a t e ria l t o pr e vent cont a mi na t i on from t h e cl e a ni ng f l ui d. Di s conn ect t he fu e l met ering v al v e el e ct r i cal co nnect or. 5. Cle a n t he fue l p ump, fue l r e t ur n l ine s an d s ur r oundi ng a r e a. For a dd[...]

  • Page 1124

    9. Remove t he f uel p ump s hi el d uppe r r e ta i ni ng bo l t s . 10. Us i ng t he pne umat i c vacuum gun, vacuum f orei gn mat e r i a l f r o m t he f uel p ump, f ue l ret ur n l ine v e nt ur i a nd t he fue l p ump fue l ret u r n l ine s . 11. Remove t he f u el pump s hi el d. 12. Remove t he f u el ret urn l i ne vent ur i . Ins t al l[...]

  • Page 1125

    2. Tig ht e n t o 8 Nm. 3. Tig ht e n t o 33 Nm. JagDocs.com[...]

  • Page 1126

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - Turboc harger - T o rque Sp eci f i cat ions Descri pti on Nm l b - f t l b-i n Oi l s upp l y t ub e uni o n ret a i ni n g b o lt 14 10 - Oi l r e t urn t ube t o t urb ocha r ge r r e t ai ni ng bo l t s 10 - 89 Oi l r e t urn t ube t o cy li nde r bl ock ret a i ni ng bo l t 10 - 89 E[...]

  • Page 1127

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - Turboc harger - Turbocha rger Des cr ipt i o n a nd O pe r a t i o n Va r i abl e vane t urbochar ge r - Ve hi cl e s bu il t up t o VIN :E25781 I te m Pa r t Nu m be r Descri pti on 1 - Exhaus t m a ni f o l d g a s ket /hea t s hi e l d 2 - T ur bocharger/ exha us t mani fo l d 3 - O i [...]

  • Page 1128

    It e m Part N u mber Desc ri pti on 1 - Co mpr es s o r c a s i ng 2 - Va r i a b l e va ne a d jus t ment ring 3 - Ro t ary e l e ct r o ni c a ctu a t or 4 - Va r i a b l e va ne 5 - Exhaus t t ur bi ne 6 - Tu r b i ne cas in g 7 - Exhaus t ma nif o ld 8 - O i l sup pl y l ine 9 - O i l dr ai n l i ne The t ur b o c ha r ge r and e xhaus t m a ni[...]

  • Page 1129

    Item Pa r t Nu m ber De sc ri pti o n 1 - V ane a dj us t ment s o l e noi d va l ve 2 - A t mos ph e r ic pr e s s ure 3 - V acuum 4 - A dj us t i ng r i ng 5 - V ane s 6 - V ane s 7 - T ur bi ne 8 - T ur bi ne 9 - V acuum di a phragm uni t 10 - E C M At l o w e ngi ne s pee d s t he ECM a ct ua t es the van e a d jus t me nt s ol en oi d val ve t[...]

  • Page 1130

    Item Pa r t Nu m ber De sc ri pti o n 1 - V ane a dj us t ment s o l e noi d va l ve 2 - A t mos ph e r ic pr e s s ure 3 - V acuum 4 - A dj us t i ng r i ng 5 - V ane s 6 - V ane s 7 - T ur bi ne 8 - T ur bi ne 9 - V acuum di a phragm uni t 10 - E C M As t he e ngi ne s pee d i ncr ea s e s t he i nt a ke cr os s s e ct i o n i n f r o nt o f t he[...]

  • Page 1131

    P ubl i she d: 26-Jul-2011 Fuel Ch arging and C ontro ls - Turboc harger - Turbocha rger Dia gn os i s a nd Te s t i ng Over view For i nfo rm at i o n o n t he ope rat i on o f the t ur bocharger: REFER t o : T ur bo charger (303- 04C Fue l Charging a nd Co nt rol s - Turbocha r ge r , Des cr ipt i o n a nd O pe r at i o n). Insp ection a nd Ve ri[...]

  • Page 1132

    DT C Descri pti on . Thi s DTC may be caus e d b y: . Low bat t ery v o lt a ge . Che ck t he cond it i o n o f t he ba t t e r y. Che ck t he wi r i ng and t he a p pr op r i a te fus e . Hi g h ba t t e r y vol t a g e . Che ck t he bat t e ry charging s ys t e m. P 138D Tur bocha r ge r /Superch arger Boo s t Co nt r o l A Te mperat ur e T oo Hi[...]

  • Page 1133

    Po i nt H ea l th Che ck : 6. C heck for l o os e or brok en turb i ne a nd com pre ss or hous i ng f asteners. I f m oun t i ng fl ange s are dam age d, re pl a ce or ti ghten ( t orque to m a nufa c ture r' s speci fi ca ti on): Le gend - 1. Bo o s t pr e ss ure a ct ua t o r - 2. Act ua t or arm - 3. L ow f l o w adj us t i ng s cr e w - 4.[...]

  • Page 1134

    Po i nt H ea l th Che ck : 8. C heck Vac uu m suppl y s ys te m : Le gend - 1. At mos phe r i c pi pe f r om a i r cle a n e r - 2. Va cuum from brak e boo s t er - 3. Va cuum t o VGT a ctua t o r - 4. T ur bo cha r g e r s o l e noi d va l ve - 5. Va cuum r es e r voi r W ARNI N G: K e ep hands a wa y f r om r o d and mechani s m . Fi nge r i nj u[...]

  • Page 1135

    T urbocharge r T r oubl e sh ooti ng Gui de 1. Le ge n d - 1. Di r t y a i r duct - 2. Ai r Cl e ane r - 3. MAF s e ns or - 4. EGR va lve - 5. T ur bocharger compr es s o r i nt ake a i r p i pe - 6. T ur bocharger - 7. P o s t c ha r ge ai r cool er pi pe - 8. P r e c ha rg e a i r cool e r pi p e - 9. MAP s e ns or - 10. Cha r ge a i r coo l e r [...]

  • Page 1136

    T urbocharge r T r oubl e sh ooti ng Gui de T urboch ar ge r Boos t Ci rc ui t – Check f or: 6. P re Charge Ai r Co ol e r Pi pes: - 1. Spli t hos e - 2. Ba d l y l o cat e d ho se - 3. Ba d l y l o cat e d cla mp - 4. I ncorr e ct cl a mp t o r que - 5. O i l sa t ur a ti o n o f ho s e - 6. Che ck fo r bl o ck ag e – R e mov e pi pe s t o che[...]

  • Page 1137

    P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - Turboc harger - Turbocha rger Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he ca ta l yt ic convert er. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ca t a l y t i c Conve r t e r - 2.0L Dur a t o r q- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S[...]

  • Page 1138

    6. Remove t he oi l s upp l y t ub e. All v e h icle s 7. D et a ch t he oi l r e t ur n t ube from t he t ur b o charger . Dis car d t he ga s ke t . 8. Remove t he oi l re tu r n t ube . Dis car d t he O -r i ng s ea l . 9. D et a ch t he e xhaus t ga s r e ci r cul a t i o n (EGR) coo l e r fr om t he exha us t m a ni f o l d. Dis car d t he ga [...]

  • Page 1139

    10. Det a ch t he coo l a nt pi pe f r om t he EGR cool e r . 11. Remove t he EGR co o l e r m ount b r acket ret a i ni ng b o l t . 12. Remove t he EGR co o l e r m ount b r acket . 13. Remove t he e xhaus t mani f o l d r e t a i nin g b ol t s a nd nut s . Dis car d t he bo l t s a nd nut s . 14. Lowe r t he vehi c l e . 15. Remove t he co wl v[...]

  • Page 1140

    16. Dis c o nne ct t he va cuum ho s e . 17. Det a ch t he pos i t ive crankcas e vent i la t i o n ho s e f r o m t he v al ve cove r . Dis car d t he po s i t i ve cr ankcas e ve nt i l a t i o n ho s e r e t ai ni ng cl i p . 18. Det a ch t he ai r cl e a ne r out l e t pi pe f r om t he t ur bocharge r . Dis car d t he a i r cle a ne r o ut le [...]

  • Page 1141

    20. Det a ch t he pos i t ive crankcas e vent i la t i o n ho s e f r o m t he v al ve cove r . Dis car d t he po s i t i ve cr ankcas e ve nt i l a t i o n ho s e r e t ai ni ng cl i p . 21. Det a ch t he ai r cl e a ne r out l e t pi pe f r om t he t ur bocharge r . Dis car d t he a i r cle a ne r o ut le t pi pe r e t ai ni ng cl i p . All v e h[...]

  • Page 1142

    24. Det a ch t he t ur bocha r ge r from t he cy l i nde r hea d . 25. Remove a nd di s car d t he exha ust ma ni f o l d ga s ke t . 26. Remove t he t ur bo c ha rg e r . Re mov e a nd di s c a r d t he t urbochar ge r r e t a ini ng s t u ds . Vehi c le s bu ilt from VIN :E4 38 69 27. Det a ch t he t ur bocha r ge r from t he cy l i nde r hea d .[...]

  • Page 1143

    28. Remove a nd di s car d t he exha ust ma ni f o l d ga s ke t . 29. Remove t he t ur bo c ha rg e r . Re mov e a nd di s c a r d t he t urbochar ge r r e t a ini ng s t u ds . Insta llat ion Vehi c le s bu ilt from VIN :E4 38 69 1. NOT E: Ins t a l l ne w t urbocha r ger r et ai ni ng s t uds . I nst a l l t he t urbocha r ger . 2. NOT E: Ins t [...]

  • Page 1144

    3. Att a ch t he t u r b o charger t o t he cyli nd e r he a d. Vehi c le s bu ilt up to VI N: E4 386 8 4. NOT E: Ins t a l l ne w t urbocha r ger r et ai ni ng s t uds . I nst a l l t he t urbocha r ger . 5. NOT E: Ins t a l l a new ga s ket . I nst a l l t he e xhaus t mani f ol d ga s k et . 6. Att a ch t he t u r b o charger t o t he cyli nd e [...]

  • Page 1145

    7. NOT E: Ins t a l l ne w e xhaus t mani fo l d r e t a i ni ng nut s a nd bo l t s • NO T E: Ve hicl e s ho wn rai s e d fo r cla rit y. Lo o s e l y i ns t a l l the e xha us t mani fo l d r e t a i ni ng nut s a nd bol t s . 8. Ins t a l l the e xha us t mani fo l d ga s ke t r e t ai ni ng s t uds . Ti ght e n t o 10 Nm. 9. Att a ch t he cha[...]

  • Page 1146

    11. NO TE: I ns t a ll a new p os i t i v e c r a nk cas e vent i l a t i on hos e r et a i ni ng cl i p. At t a ch t he p os i t i ve cr a nk cas e ve nt i l a t i on hos e to t h e va lve co ver. 12. Conne ct t he e l e ct r i cal conne ct o r. Vehi c le s bu ilt up to VI N: E4 386 8 13. NO TE: I ns t a ll a new a i r cle a n e r out l e t pi p e[...]

  • Page 1147

    15. Conne ct t he va cuum h os e . All v e h icle s 16. Ins t a l l t he cowl vent s cr ee n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co wl Ve nt S cr e e n (501-02 Fr ont End Bo dy P a nel s , Re mova l a nd Ins t al l a t io n). 17. Rai se th e v e hi cl e . 18. Ti g ht e n t he e xh au s t mani f ol d ret a i ni ng n ut s a nd b [...]

  • Page 1148

    21. At t ach t he co o l a nt pi p e t o t he E GR cool e r . 22. NO TE: I ns t a ll a new g a ske t . At t a ch t he EGR co ol e r t o t he e xhaus t mani fo l d . Ti ght e n t o 37 Nm. 23. NO TE: I ns t a ll a new O -r ing s e a l . I nst a l l t he o i l ret ur n t ube . Ti ght e n t o 10 Nm. 24. NO TE: I ns t a ll a new g a ske t . At t a ch t [...]

  • Page 1149

    25. CAUT I O N: I f a ne w o i l s uppl y t ube is t o b e i ns t a l l ed , e ns ur e t ha t th e bl a nki ng c a ps ha ve be e n r e moved prio r to ins t a l la t i o n. Fai l ur e to fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he t urb ocha r ge r . I nst a l l t he o i l s uppl y t ube . Ti ght e n t o 14 Nm. 26. At[...]

  • Page 1150

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b- i n Acces s o r y dr ive b e l t t e ns i o ne r ret a i ni ng bol t - ve hi cl e s wi t h 2. 0L, 2. 5L o r 3.0L e ng i ne 47 35 - Be l t i dl e r pul l e y ret a i ni ng b o lt - A b ank pul l e y - ve hi cl e s wi th 2.0L, 2. 5L o r 3.0[...]

  • Page 1151

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e Des cr ipt i o n a nd O pe r a t i o n 2.0 L, 2 .5 L an d 3. 0L e ngin e Item Par t N u m ber Desc ri pti on 1 — P o we r s t e ering pump pul l e y 2 — A cc e s so ry dr i ve b e l t i dl e r pul l e y 3 — A cc e s so ry dr i ve b e l t t ens io ne r 4 — A cc e s so ry [...]

  • Page 1152

    Item Par t N u m ber Desc ri pti on 1 — A cc e s so ry dr i ve b e l t i dl e r pul l e y 2 — A cc e s so ry dr i ve b e l t t ens io ne r 3 — A cc e s so ry dr i ve b e l t i dl e r pul l e y 4 — A i r condi t i o ni ng p ump pul l e y 5 — A cc e s so ry dr i ve b e l t 6 — Cr a nksha f t p ul l e y 7 — Ge ne r a t or pul l ey Cr a n[...]

  • Page 1153

    It e m De sc ri pti on 1 Accep t a bl e Dr i ve Be l t Cracking 2 U na ccept a b le Dr i v e Be l t Da mag e The dr i ve b el t s houl d be i ns p e ct e d a t e ver y r o ut ine s e rv i ce fo r e xc e s s i ve we a r and d a mag e. A dr i v e be l t which di s pl a ys s ym pt o ms o f cr a c king m a y be p e rfe ctl y fi t fo r f ur t her s e r [...]

  • Page 1154

    * * * * * * * * * * P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e . 2. Vi sual Inspect i on C h art Mechani cal Damag e d or cont a m i[...]

  • Page 1155

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt2.0L Durato rq- TDC i/2.2L Durato rq- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re l e a s e t ool , b e l t t ens io ne r 303-676 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i [...]

  • Page 1156

    7. D i s conne ct t he ge ne r a t or e l e ct r i cal co nne cto r. 8. Remove t he ge ne r a t or upp e r r e t ai n ing b ol t . 9. D et a ch t he ge ne r a t o r . S li de t he g e ne r at or r e a r ward s a s f a r awa y f r om t he a cces s o r y drive bel t t ens i one r a ss e mbl y a s po s s ib l e . 10. Det a ch t he acce s s o r y drive[...]

  • Page 1157

    Insta llat ion 1. Ins t a l l the a cces s o r y dr ive b e l t . 2. Att a ch t he a cc e s s o r y drive b e l t t e nsi o ner a s s emb ly. Ti ght e n t o 47 Nm. 3. NOT E: Lo o s el y i ns t a l l t he gene r a t o r r e t ai n in g nut s . At t a ch t he g e nerat o r . 4. Ins t a l l the ge n e r at or r et a i ni ng bo l t . Ti ght e n t o 47 [...]

  • Page 1158

    6. Connect t he ge ne r a t or e l e c t r i cal co nne cto r. 7. Att a ch t he ge ne r a t or po s i t i ve ca bl e . Ti ght e n t o 8 Nm. 8. Usi ng t he s pe cia l t oo l , i ns t a l l t he a cc e s s ory drive be lt . 9. Ins t a l l the right -ha nd whe e l a rc h l i ne r acces s pa ne l . 10. Ins t a l l t he r i ght -ha nd r oa d whe e l . F[...]

  • Page 1159

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt2.0L N A V6 - AJ V6 / 2.5L N A V6 - AJV6/3.0L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Acces s o r y Be l t De -t e ns i one r 303-703 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref[...]

  • Page 1160

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 47 Nm. JagDocs.com[...]

  • Page 1161

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt T ensio n er2.0L Durato rq- TDCi/2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re l e a s e t ool , b e l t t ens io ne r 303-676 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf [...]

  • Page 1162

    7. D i s conne ct t he ge ne r a t or e l e ct r i cal co nne cto r. 8. Remove t he ge ne r a t or upp e r r e t ai n ing b ol t . 9. D et a ch t he ge ne r a t o r . S li de t he g e ne r at or r e a r ward s a s f a r awa y f r om t he a cces s o r y drive bel t t ens i one r a ss e mbl y a s po s s ib l e . 10. Det a ch t he acce s s o r y drive[...]

  • Page 1163

    12. Remove t he a cces s o r y drive be l t t e ns i one r. Insta llat ion 1. Ins t a l l the a cces s o r y dr ive b e l t t e ns i o ne r . 2. Att a ch t he a cc e s s o r y drive b e l t . 3. Att a ch t he a cc e s s o r y drive b e l t t e nsi o ner a s s emb ly. Ti ght e n t o 47 Nm. JagDocs.com[...]

  • Page 1164

    4. NOT E: Lo o s el y i ns t a l l t he gene r a t o r r e t ai n in g nut s . At t a ch t he g e nerat o r . 5. Ins t a l l the ge n e r at or r et a i ni ng bo l t . Ti ght e n t o 47 Nm. 6. Tig ht e n t o 47 Nm. 7. Connect t he ge ne r a t or e l e c t r i cal co nne cto r. 8. Att a ch t he ge ne r a t or po s i t i ve ca bl e . Ti ght e n t o 8[...]

  • Page 1165

    9. Usi ng t he s pe cia l t oo l , i ns t a l l t he a cc e s s ory drive be lt . 10. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s pa nel . 11. Ins t a l l t he r i ght -ha nd r oa d whe e l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t[...]

  • Page 1166

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt T ensio n er2.0L N A V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a cc e s s o r y drive b e l t . For add i t i o na l i nf or m a t io n, r e fe r t o t h e Acces s o r y D rive Be l t . 2. Remove t h[...]

  • Page 1167

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Power Steering P um p Belt2.0L Duratorq-TDCi / 2.2L Durato rq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i[...]

  • Page 1168

    6. Remove t he EGR coo l e r t o EGR val ve t ube s uppo rt brack e t . 7. Remove t he po we r s t e e r i ng pu m p b e l t . Rot a t e t he t e ns i one r c l o ckwis e . Insta llat ion 1. Ins t a l l the po we r s t e e r i ng pump be lt . Rot a t e t he t e ns i one r c l o ckwis e . 2. NOT E: Do not t i ght e n t he EGR coo l e r t o EGR val v[...]

  • Page 1169

    3. Ins t a l l the EGR cool e r t o EGR val ve t ube s u pport brack e t l owe r r et a i ni ng bo l t s . Ti ght e n t o 23 Nm. 4. Tig ht e n t o 10 Nm. 5. Ins t a l l the po we r s t e e r i ng pump b e l t cover. 6. Ins t a l l the po we r s t e e r i ng pump b e l t cover r e t a i nin g nut . Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 1170

    7. Att a ch t he po we r s t e e r i n g f l ui d pi pe . 8. Ins t a l l the a i r c l e a ne r a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.0L Durat o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150P S ) - P uma, Re moval a nd I ns ta l l a t[...]

  • Page 1171

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Power Steering P um p Belt Ten sion er2. 0L Duratorq-TDC i/2. 2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e xhaus t g a s reci r cul a t i o n (EGR) coo l e r t o EGR va l ve t ube. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o:[...]

  • Page 1172

    6. Remove t he po we r s t e e r i ng p ump be l t t e ns i o ne r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 23 Nm. 2. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1173

    P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - W ater Pu mp B elt2.0L N A V6 - AJV6 / 2.5L N A V 6 - AJV6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ba t t e r y t ray . Fo r a d di t i o na l i nf o r mat i on , refe r t o S ect io n 414-01 Bat t e ry , Mount i ng a nd Ca bl e s . 2. Remove t he wa t[...]

  • Page 1174

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  • Page 1175

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  • Page 1176

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  • Page 1177

    I te m P a rt N um ber Descri p ti on 1 — Engi ne cont rol mod ul e (ECM ) 2 — S ta rte r m o t o r 3 — S ta rte r m o t o r r e la y Ve hi cl e s wi th 2.0L a nd 2.2L d i e s e l e ngi ne s JagDocs.com[...]

  • Page 1178

    I te m P a rt N um ber Descri p ti on 1 — Engi ne cont rol mod ul e (ECM ) 2 — S ta rte r m o t o r r e la y 3 — S ta rte r m o t o r JagDocs.com[...]

  • Page 1179

    P ubl i s he d: 11-May-2 011 Starting System - Starting S y stem 2.0L N A V6 - A JV 6 Dia gn os i s a nd Te s t i ng W ARNI N G: B ewa re of r ot a t i ng p a r t s. Fa i l ur e t o f o l l ow t hes e i ns t r ucti o ns may res ul t i n pe r s o na l i nj ury . 1. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l a nd e l e ct r i ca[...]

  • Page 1180

    1 1 1 2 3 P ubl i s he d: 11-May-2 011 Starting System - Starting S y stem 2.5L N A V6 - A JV 6 /3. 0L NA V6 - AJ27 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. 3. M ake s ur e t he [...]

  • Page 1181

    1 2 3 1 1 2 3 1 2 1 2 1 1 1 2 3 1 2 Is t he vol t a ge gr e a t e r t han 10 vol t s? Ye s GO t o A 20 . No GO t o A 4 . A4 : CHEC K F OR C R ANK SUPP LY VO LT AGE T O EC M Dis conne ct t he ECM e l e ct rica l con nect or EN16. Tur n t he i gn i t i on s w i t ch t o t he CRAN K p os i t io n, an d ho l d . Mea s ure t he v ol t a ge be t wee n EN[...]

  • Page 1182

    1 2 1 2 3 1 2 1 2 1 2 3 1 1 1 1 Is t he vol t a ge gr e a t e r t han 10 vol t s? Ye s INS TA LL a ne w ECM . REFER t o Sect io n 303-14A El e ct r oni c Eng i ne Co nt r ol s / 303-14 B El e ct roni c Engi n e Co nt rol s . Be fo r e r ep l a cing a ECM, cont a ct Dea le r t e chnica l s up po r t . No REPAI R t he ci r c ui t bet we e n t he ECM [...]

  • Page 1183

    1 2 1 2 No REPAI R s t art er GROU ND s t rap o r conne ct i o ns . For add i t i o na l i nf o r mat i o n, r e fe r t o wi ri ng d i a gr ams . CL EAR th e DTC. TES T t he s ys t e m f o r no r mal o p e r at i o n. PINPOIN T TE ST B : THE E NG I NE CRANKS S LOWL Y T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I O NS B1: C HEC K F OR VO LT AGE D[...]

  • Page 1184

    P ubl i s he d: 11-May-2 011 Starting System - Starter Moto r2 . 0L Duratorq-TDC i Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ). 2. Rem[...]

  • Page 1185

    7. D et a ch t he wi ring ha r ne s s ret a i ni ng c l i p s f r om t he wiring ha r ne s s s up port b r a cket . 8. Remove t he wi r i ng ha r ne s s s up po r t b r a ck et . 9. D et a ch t he s t a r t e r m o to r. 10. Po s i t i o n t he s t art er mot o r t o p r o vi de a cc e s s t o t he s t a rte r m ot o r cabl e s . 11. Remove t he s [...]

  • Page 1186

    12. Remove t he s t arte r mot o r . Re mov e t he s t a r t e r mot or e l e ct rica l c on ne ct or r et a i ni ng nut . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 12 Nm. 2. Tig ht e n t o 6 Nm. 3. Tig ht e n t o 25 Nm. JagDocs.com[...]

  • Page 1187

    4. Tig ht e n t o 23 Nm. JagDocs.com[...]

  • Page 1188

    P ubl i s he d: 11-May-2 011 Starting System - Starter Moto r2 . 2L Duratorq-TDC i (110k W/150P S) - P uma Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al [...]

  • Page 1189

    7. Remove t he wi r i ng ha r ne s s s up po r t b r a ck et . 8. Remove t he cha r g e a i r c oo l e r i nt a ke pi pe ret a i ni n g b o lt s . Re pos i t i o n t he cha r ge a i r c o ol e r i nta ke p i pe f o r acce s s . 9. D et a ch t he coo l a nt ho s e. 10. Dis c o nne ct t he va cuum s ol e noi d va l ve e l e ct r i ca l conne ct o r .[...]

  • Page 1190

    12. Remove t he va cuum s ol e noi d mount b r acket a s s e mbly. 13. Remove t he s t arte r mot o r . Insta llat ion 1. To i ns t a l l r evers e t he r emova l pr oced ure. Ti ght e n t o 25 Nm. 2. Tig ht e n t o 30 Nm. JagDocs.com[...]

  • Page 1191

    3. Tig ht e n t o 35 Nm. 4. Tig ht e n t o 12 Nm. 5. Tig ht e n t o 6 Nm. JagDocs.com[...]

  • Page 1192

    P ubl i s he d: 11-May-2 011 Starting System - Starter Moto r2 . 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o S [...]

  • Page 1193

    5. Pos it i o n and adj us t t he s pe ci a l t o o l front he i g ht a dj us t er. Rig ht -ha nd s hown , l e f t -ha nd s i mi l a r . 6. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 7. D et a ch t he s up po r t b a r . 8. Remove t he s up port b a r . JagDocs.com[...]

  • Page 1194

    9. D et a ch t he s t a r t e r m o to r s o l e no i d cove r . 10. Dis c o nne ct t he s t arte r mot o r e l e ct rica l co nnect o r . 11. Dis c o nne ct t he s t arte r mot o r s ol e noi d e l e ct rica l conne ct o r . 12. Remove t he s t arte r mot o r r e a r r e t a i ni ng bol t . 13. Remove t he s t arte r mot o r . 1. Re move t he s t [...]

  • Page 1195

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 35 Nm. 2. Tig ht e n t o 35 Nm. 3. Tig ht e n t o 6 Nm. 4. Tig ht e n t o 12 Nm. 5. Tig ht e n t o 133 Nm. JagDocs.com[...]

  • Page 1196

    6. Tig ht e n t o 25 Nm. JagDocs.com[...]

  • Page 1197

    P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - Gen eral S p ec if ic a t ions I te m Speci fi cati on Firing O rde r 1,4, 2,5,3, 6 S pa r k P l ug Ga p mm (in ) 1.3-1.45 (0.051-0.057) S pa r k P l ug T y pe XW 4E-12405 S il i cone Die l e ct r i c Comp ound D7AZ-19A331- A (S par k P l [...]

  • Page 1198

    P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - En gine Ignitio n Des cr ipt i o n a nd O pe r a t i o n Compo nent L o c a t i o ns It e m Pa rt N um b er D escri pt i o n 1 - I gni ti on Co i l 2 - Spar k Pl ug 3 - RH Ba nk 4 - I gni ti on Co i l Re t a i ni ng Bo l t 5 - L H B a nk I[...]

  • Page 1199

    P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - En gine Ignitio n 2.0L N A V 6 - AJV6 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical d[...]

  • Page 1200

    P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - En gine Ignitio n 2.5L N A V 6 - AJV6/3. 0L NA V 6 - A J2 7 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a [...]

  • Page 1201

    E ngine C o ntrol M o du l e (E C M) Ha rness Co n nector Pi n Nu m ber C i rcui t F unc t i on C i rc ui t Col or 61 1 B i gni t io n c oi l t r i gg er Gr een /Bl ue 62 2 B i gni t io n c oi l t r i gg er Gr een /whit e 63 3 B i gni t io n c oi l t r i gg er Gr een /r e d 87 1 A i gni t i on c o il t r i gg er Gr ee n/Bl ue 88 2 A i gni t i on c [...]

  • Page 1202

    1 2 1 2 3 4 5 1 2 3 4 5 1 2 1A, 2A, 3 A, 1B, 2 B , 3B I g nit ion C oil s Pi n N um be r C i rcui t Fu n cti on 1 I gni t i o n coi l v o l t a g e s upp ly 2 I gni t i o n coi l di a g nos t i c s ig na l 3 I gni t i o n coi l gr ou nd s uppl y 4 I gni t i o n coi l t rigg e r PINPOIN T TE ST A : IG NITI ON COILS — P03 5 1 , P03 5 2, P035 3, P03[...]

  • Page 1203

    1 Cy l B 2. EN055 pi n 4, (GW ) a nd EN 016 pi n 62, (GW ) Cy l B 3. EN056 pi n 4, (GR) a nd EN 016 pi n 63, (GR ) Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o A 5 . No REPAI R t he i gni t i on coi l t rig ge r sup pl y cir cuit b e t we e n t he rel e vant i gni t i o n coi l e l e ct rica l co nnect o r (s) a nd t he ECM e l e ct[...]

  • Page 1204

    P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - I g niti on C oi l-On-P lug LH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o S ect i o n 414-01 Ba t t e r y, Mount i ng and Cabl[...]

  • Page 1205

    P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - I g niti on C oi l-On-P lug RH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o S ect i o n 414-01 Ba t t e r y, Mount i ng and Cabl[...]

  • Page 1206

    P ubl i s he d: 11-May-2 011 Gl ow Plug System - T o rque Sp eci f i cat ions Descri pti o n Nm l b-f t l b- i n Gl ow pl ug 13 10 - Gl ow pl ug e l ect r i cal conne ct o r ret a i ni ng nut 2 - 18 Mai n wi ring ha rn es s t o gl o w pl ug wi r i ng harnes s nut 4 - 35 Gl ow pl ug t e r mina l bl o ck r et a i ni ng s cr e w 5 - 44 JagDocs.com[...]

  • Page 1207

    P ubl i s he d: 11-May-2 011 Gl ow Plug System - G lo w Plug System Des cr ipt i o n a nd O pe r a t i o n It e m P a rt N um b er Descri pti on 1 - Glo w pl ug i ndi ca t o r l a mp 2 - Glo w pl ug fus e 3 - Glo w pl ug r el ay 4 - Glo w pl ug wi re 5 - Glo w pl ug The gl o w pl ug s a r e l o cat e d i n t he s i de of t he cyl i nde r he a d a n[...]

  • Page 1208

    of 30 s e conds a t -20° C (-4° F) o r l o we r . A t t e mper a t ures a bo ve 50°C (122° F) t he r e is no a f t e r- gl ow pha s e . JagDocs.com[...]

  • Page 1209

    P ubl i s he d: 11-May-2 011 Gl ow Plug System - G lo w Plug System Dia gn os i s a nd Te s t i ng Principle of oper at ion As comm o n rai l di e s e l en gi ne s ha ve be tt e r col d -s ta rti ng charact e r i s t i cs t ha n t rad it i on a l di e s e l e ng in e s, t he gl o w p lu gs ha ve t wo fun cti ons o n t hi s e ng i ne : P r e -hea t [...]

  • Page 1210

    1 2 3 4 1 2 1 1 2 1 1 2 3 4 E ng i ne control m o d ul e ( E C M) con nect o r C i rcui t P i n Gl o w pl ug - cont r ol 20 Gl ow p l ug r el ay con nect o r C i rcui t Pi n Gl o w pl ug r el a y - cont r ol 02 P e rm a nent 12 vo l t sup pl y 03 ECM r e l ay cont r ol l e d 12 vol t s uppl y 01 Gl o w pl ug r el a y - out p ut 05 Ke y o f f. Gl o [...]

  • Page 1211

    1 2 3 4 1 1 1 2 3 4 1 1 2 3 4 1 2 3 4 1 Ke y o f f. Gl o w pl ug r el a y conne ct o r di s conne ct e d. Ke y o n, e ngi ne o f f. Mea s ur e t he res i s t a nce b e t we e n: G l ow pl ug re l ay c onnect or Vehi cl e battery Gl o w pl ug r el a y - out p ut - P i n 01 N e gat i ve po s t I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s[...]

  • Page 1212

    1 2 3 4 1 2 3 4 1 2 3 I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s S us pe c t : - Glo w pl ug re l a y f aul t No GO t o A15 . A1 5: CHEC K WHET HER T HE SHOR T CIRC UIT T O GR O UND I S I N T HE EC M H ARNESS O R EC U Ke y o f f. ECM conne ct o r d i s conne ct e d . Ke y o n, e ngi ne o f f. Mea s ur e t he res i s t a nce b e t we [...]

  • Page 1213

    P ubl i s he d: 11-May-2 011 Gl ow Plug System - G lo w Plug s Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ). 2. D et [...]

  • Page 1214

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 13 Nm. 2. Tig ht e n t o 2 Nm. 3. Tig ht e n t o 5 Nm. 4. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ). JagDocs.com[...]

  • Page 1215

    P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - T o rque Sp eci f i cat ions Descri pti on Nm l b- f t l b-i n Exhaus t g a s r e circu l a t i on (EGR) val ve t o i nt a ke man if ol d ret a i ni ng bo l t s 10 - 89 EGR val ve t ube t o EGR val ve ret a i ni ng nu[...]

  • Page 1216

    P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - En gine E mis sio n Co ntrol Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um be r Desc ri pti on 1 - EGR val ve 2 - EGR val ve to i nt ake ma ni f ol d r et a i ni ng bo l t 3 - EGR coo l e r t o EGR va lve [...]

  • Page 1217

    P ubl i she d: 12-Jul-2011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - En gine E mis sio n Co ntrol Dia gn os i s a nd Te s t i ng Over view For i nfo rm at i o n o n t he des cr i pt i on a nd o perat i on o f t he e mi s si o n cont r ol s yst e m: REFER t o : E ngi ne E mis s i o n Co n[...]

  • Page 1218

    P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - Ex haust Gas Recircula tio n (EG R ) Co oler Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho s e Cl amp 303-3 97 (24- 003) R em ova l 1. D r ai n t he coo l i ng s yst[...]

  • Page 1219

    8. Remove t he EGR coo l e r m o unt br acket . 9. Remove t he EGR coo l e r. Dis car d t he ga s ke t . 10. Remove t he co o l a nt hos e f r om t he EGR co ol e r . Insta llat ion 1. Ins t a l l the co ol a nt hos e to t he EGR co ol e r. JagDocs.com[...]

  • Page 1220

    2. NOT E: Ins t a l l a new EGR coo l e r gas ket . I nst a l l t he EGR co ol e r . Ti ght e n t o 37 Nm. 3. Ins t a l l the EGR cool e r mount br a cket . Ti ght e n t o 10 Nm. 4. Ins t a l l the EGR cool e r mount br a cket re ta i ni ng bo l t . Ti ght e n t o 10 Nm. 5. Lowe r t he vehi cl e . 6. Usi ng t he s pe cia l t oo l , conne ct t he co[...]

  • Page 1221

    7. Usi ng t he s pe cia l t oo l , conne ct t he EGR co o l e r coo l a nt ho s e t o t he t he rm o s t a t ho us i ng . 8. Ins t a l l the a i r c l e a ne r o ut l et pi p e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r Out l e t P i pe (303-12B I nt a ke Ai r Di s t ribut i o n a nd Fi l t e r i ng - 2.0L Dur a t orq-[...]

  • Page 1222

    P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - Ex haust Gas Recircula tio n (EG R ) Co oler to EGR Va lve Tube Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r[...]

  • Page 1223

    6. Remove t he EGR val v e t ube t o EGR val ve ret a i ni ng s t ud s . Re mov e a nd di s c a r d t he gas ke t. 7. Remove t he EGR coo l e r t o EGR val ve t ube. Insta llat ion 1. CAU TI O N : The t i ght e ni ng s e que nce o f t he EGR cool e r t o EG R val ve tu be re t a i ni ng nut s a nd bo l t s i s cr i t i c a l . Fol l o w t he e xa c[...]

  • Page 1224

    3. Loos e l y i nst a l l t he EGR va l ve t u be t o EGR val ve r et a i ni ng nut s . 4. NOT E: Ins t a l l a new EGR val ve t ube t o EGR cool e r gas ket . Lo o s e l y i ns t a l l the EGR v a l ve t ub e t o EGR co o l e r r et a i ni ng bol t s . 5. Loos e l y i nst a l l t he EGR co ol e r t o EGR val ve t ube mount i ng bracket l o we r r [...]

  • Page 1225

    8. Tig ht e n t he EGR coo l e r t o EGR val ve t ube mount i ng brack e t l owe r r et a i ni ng b ol t . Ti ght e n t o 10 Nm. 9. Tig ht e n t he EGR coo l e r t o EGR val ve t ube mount i ng brack e t upp er r et a i ni ng b ol t . Ti ght e n t o 10 Nm. 10. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t [...]

  • Page 1226

    P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - Ex haust Gas Recircula tio n (EG R ) Va lve Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke [...]

  • Page 1227

    6. D et a ch t he char ge ai r coo l e r ho s e . 7. Loos e n t he EGR coo l e r to EGR val v e t ube mount in g b rack et lo we r r et a i ni ng b ol t . 8. Remove t he EGR val v e t ube t o EGR val ve ret a i ni ng nut s . 9. Remove t he EGR val v e t ube t o EGR val ve ret a i ni ng s t ud s . Re mov e a nd di s c a r d t he gas ke t. 10. Remove[...]

  • Page 1228

    11. Remove t he EGR va l ve. Insta llat ion 1. NOT E: Ins t a l l a new EGR val ve O -r i ng s e al . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 10 Nm. 2. NOT E: Ins t a l l a new EGR val ve ga s ket . Ti ght e n t o 11 Nm. 3. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1229

    4. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1230

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - Intake A i r Distributio n a nd Filtering Des cr ipt i o n a nd O pe r a t i o n I te m P a r t Nu m be r Desc ri pti on 1 — Ai r cl ea ne r out l et pi p e 2 — Ai r cl ea ne r cover 3 — Ai r cl ea ne r e l [...]

  • Page 1231

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - Intake A i r Distributio n a nd Filtering Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mech[...]

  • Page 1232

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - A ir C leaner Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r e l e ment . For ad di t i o na l i nfo rm at i on, refe r t o the pr oce dure i n t hi s s e c t i o n: Ai r Cl e ane [...]

  • Page 1233

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - A ir C leaner E lemen t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e ngi ne cover. 2. D i s conne ct t he mas s a i r fl o w s e ns or el e ct r i cal co nnect o r. 3. D i s conne ct t he a i r[...]

  • Page 1234

    5. Remove t he a i r cl ea ne r cover. 6. Remove t he a i r cl ea ne r e l e ment . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 1235

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - A ir C leaner Ou tlet Pipe Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he po s it i ve cr ankcas e ve nt i l a t i o n ho s e. 2. Remove t he a i r cl ea ne r ou tl et pi pe. Insta llat ion[...]

  • Page 1236

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - T o rque Sp eci f i cat ions Desc ri pti on N m l b-f t l b- i n Cha r ge a i r c oo l e r ret a i ni ng b ol t s 7 – 62 Cha r ge a i r c oo l e r o ut l e t hos e 4 – 35 Cha r ge a i r c oo l e r i nt a ke hos [...]

  • Page 1237

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Inta ke Air Distributio n and Filterin g Des cr ipt i o n a nd O pe r a t i o n V eh icl es wi th 2.0 L diesel eng ine I te m Pa rt N um be r Descri pti on 1 - Ai r cl ea ne r out l et pi pe 2 - Tur bo t o t ur bo o[...]

  • Page 1238

    12 - I nt a ke mani f o l d i nl e t ho s e 13 - Ai r cl ea ne r e l e ment 14 - Ai r cl ea ne r cover V eh icl es wi th 2.2 L diesel eng ine I te m Pa rt N um be r Descri pti on 1 - Ai r cl ea ne r out l et pi pe 2 - Tur bo t o t ur bo out le t pi pe c onn e cti ng ho s e 3 - Tur bo out l e t pi p e 4 - Tur bo out l e t pi p e t o cha r ge a i r c[...]

  • Page 1239

    1 2 3 1 2 1 2 3 1 1 P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Inta ke Air Distributio n and Filterin g Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s[...]

  • Page 1240

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Air Cl eaner Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he o i l f i l le r cap a nd o i [...]

  • Page 1241

    5. D et a ch t he a i r cle a ner out l e t p ip e . Vehi c le s bu ilt up to VI N: E4 386 8 6. D i s conne ct t he e l ect r i cal conne ct o rs. Vehi c le s bu ilt from VIN :E4 38 69 7. D i s conne ct t he e l ect r i cal conne ct o r. All v e h icle s 8. D et a ch t he vacuum pi pe f rom t he a i r cle a ne r . JagDocs.com[...]

  • Page 1242

    9. D et a ch t he a i r cle a ner i nt a ke p ip e . 10. Remove t he a i r cl ea n e r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 1243

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Air Cl eaner E lem ent Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. Remove t he e ngi ne cover. 4. D i s conne ct t he mas s a i [...]

  • Page 1244

    5. D et a ch t he a i r cle a ner out l e t p ip e . 6. D et a ch t he a i r cle a ner cover. 7. Remove t he a i r cl ea ne r cover. Dis conne ct t he b reat he r p i pe . 8. Remove t he a i r cl ea ne r e l e ment . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 1245

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Air Cl eaner O utlet P ipe Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he o i l f i l le r[...]

  • Page 1246

    5. Remove t he po s i t i ve cr ankc a s e ve nt i l a t i o n ho s e. Re mov e a nd di s c a r d t he pos i t i v e cr ankcas e vent il a t i on hos e r e t a i ni ng cl i p s . 6. Remove t he a i r cl ea ne r ou tl et pi pe. Re mov e a nd di s c a r d t he a i r cle a ner ou t l e t p i pe ret a i ni n g cl i p. Vehi c le s bu ilt from VIN :E4 38[...]

  • Page 1247

    9. Remove t he a i r cl ea ne r ou tl et pi pe. Re mov e a nd di s c a r d t he a i r cle a ner ou t l e t p i pe ret a i ni n g cl i p. Insta llat ion 1. NOT E: Ins t a l l ne w po s i t i ve c rank cas e v ent i l at io n hos e ret a i ni ng cl i ps . • NO T E: Ins t al l a ne w a i r c l e ane r out l e t pi p e ret a i ni ng cl ip . To i ns t[...]

  • Page 1248

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - C harge A ir C ooler2.0L D urato rq - T DCi Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d ia t o r S p[...]

  • Page 1249

    6. D et a ch t he char ge ai r coo l e r i nt a ke ho s e from t he cha r ge a i r c oo l e r. 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Re move t h e charge a i r cool e r r e t ai n ing b ol t . 8. Remove t he cha r g e a i r c oo l e r. Insta llat ion 1. NOT E: Make s ure t he char ge a i r cool er ho s e s a r e not s pl i t [...]

  • Page 1250

    3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. 5. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t o 7 Nm. JagDocs.com[...]

  • Page 1251

    P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - C harge A ir C ooler2.2L D urato rq - T DCi (110kW / 150P S) - Puma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont bu m pe r cover . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr[...]

  • Page 1252

    To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. 2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t o 7 Nm. 3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. 5. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t o 7 Nm. JagDocs.com[...]

  • Page 1253

    P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - T o rque Sp eci f i cat ions Descri pti o n Nm l b -f t l b- i n Evapo rat i ve e mis s io n ca nis t e r r et a in i ng nut s a nd bo l t s 5 - 44 Accel erat o r cabl e ret a i ni ng b r ack e t ret a i ni ng b o l t s - vehi cl e s wi t h 2. 0L e ngi ne 9 - 80 Fue l t a nk s u pport s t r[...]

  • Page 1254

    P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on s Des cr ipt i o n a nd O pe r a t i o n I te m P ar t N um be r Desc ri pti on 1 — Evapo r a ti ve e mis s i o n cani s t er - no n fe d e r al mar ket ve hi cl e s 2 — Evapo r a ti ve e mis s i o n cani s t er - f e de r a l mar ket ve hi cl e s • NO T E: 2.5[...]

  • Page 1255

    P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on s2.0L N A V6 - A JV 6 Dia gn os i s a nd Te s t i ng 1. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage , bl o wn f us e s , e t c. 1. 2. If a n obvi o us cau se fo r an ob s e rv e d o r r epo r t e d conce r n i s f o und[...]

  • Page 1256

    P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on s2.5L N A V6 - A JV 6 /3. 0L NA V6 - AJ27 Dia gn os i s a nd Te s t i ng Prelimina ry Inspe ction 1. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage , bl o wn f us e s , e t c. 1. 2. If a n obvi o us cau se fo r an ob s e r[...]

  • Page 1257

    [...]

  • Page 1258

    1 2 3 1 1 I f s uf fi ci ent a d a pt i o ns have o ccu rr e d, t he Ev a po r at i ve val ve s ho ul d no w be o pe rat i ng . Thi s can b e verif i e d manua l l y by e i t her t o uchi ng o r li s t e ni ng t o t he val ve . By t o uchi ng t h e Evapo r at i ve va lve , i t s ho ul d b e po s s i bl e t o fe e l the v a l ve s wi t chin g. L i s[...]

  • Page 1259

    1 2 1 2 1 2 3 1 2 1 1 2 3 1 PINPOIN T TE ST B : P04 42 . L EAK DETECTED. 4 0 THOU T EST C ONDI T IONS DET AI LS/RE S U LT S/ACT IONS B1: C HEC K F UEL F ILLER CAP FI T MENT AN D CO NDI T I ON OF PI PE S AN D C O NN EC T O R S Mak e s ure t hat t he f uel f il l e r c a p i s co r r ect l y ins t a l l e d a n d t i ght e n e d. (Mini mum 3 cli ck s[...]

  • Page 1260

    1 2 3 1 2 1 2 3 1 2 1 2 1 T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I O NS E1: CHEC K EVAPO R AT IV E PU R GE VA LVE S I GNA L WI R E FOR SH OR T T O GR O UND Dis c on ne ct Eva po r at i ve pur ge va l ve e l ect r i cal co nnect o r JB1 70. Dis c on ne ct ECM e le ctrica l co nnect o r , EN 16. Meas ur e t he res is t a nce b e t we e n JB17[...]

  • Page 1261

    1 2 3 1 2 3 1 2 3 4 1 2 3 1 1 H1 : CHEC K CC V SI G NA L WI R E F O R SH OR T T O GR O UND. Dis conne ct CCV e le ct r ica l conne ct o r , FT 5. Dis conne ct ECM e l e ct r i cal conne cto r, EN16. Mea s ur e t he r es i s t a nce be t we en FT5, p i n 2 (O ) a nd gr ound . Is t he res i s t a nce l e s s t han 10,000 Oh m s ? Ye s REP AIR t he s [...]

  • Page 1262

    2 1 2 1 2 1 2 3 1 2 1 2 Mea s ure t he r es i s t ance b e t wee n CA5, p i n 4 (RG) a nd GROU ND. Thi s t e s t wi l l no t che ck t he i nt e gr it y o f t he h arnes s from CA5 t o FT1. I f t he ci rc ui t i s s o und t o CA5, t he f uel t a nk m us t b e r e moved a nd t he ha r ne s s a nd s ens o r c on t i nui t y checke d. Is t he res i s t[...]

  • Page 1263

    P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on C anister2 .0 L N A V6 - AJV6 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. [...]

  • Page 1264

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 5 Nm. JagDocs.com[...]

  • Page 1265

    P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on C anister2 .5 L N A V6 - AJV6/3.0L NA V6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe rtrai n As s e m bl y Ja ck (fe d eral mar ket vehi cle s onl y) HTJ1200 -2 R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or[...]

  • Page 1266

    6. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. De-pres suriz e t he fue l s y s t e m. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o: Fue l S yst e m P r e s s ur e Re l e a s e (310-00 Fuel Sy s t e m - Ge neral Inf or mat io n, Ge ne r a l P rocedur e s ). 7. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. Re move t h e r e a r s e [...]

  • Page 1267

    13. NO TE: Fe d e r al mar ket ve hi cl e s o nly. • NO T E: No t e t he o rie nt a t io n o f t he f ue l t ank fi l le r pi p e t o f ue l ta nk hos e r e t a i ni ng cl i p b e fo re l o o s e ni ng. Det ach t he f uel t a nk fi l l er pi pe hos e f rom t he f ue l t ank. 14. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he e [...]

  • Page 1268

    18. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Us i ng t he s p e ci a l t o ol , s uppo rt t he f ue l t a nk. 19. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Re move t h e fu e l t ank s up po r t s t raps r et a i ni ng bo l t s . 20. NO TE: Fe d e r al mar ket ve hi cl e s o nly. • NO T E: Ri ght -ha n d s hown, l ef t -hand s i m i l [...]

  • Page 1269

    Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl a mm a b l e vapo r s are a l ways pre se nt a nd m a y i g ni t e . Fa i l ur e t o f o l l ow t he s e i nst r uct i ons may res ul t i n p e r s o[...]

  • Page 1270

    5. W ARNING: T he f uel t a nk canno t be dr ai ned i n ve hi cl e . Due t o t he hea vy we i ght , make s ur e t ha t t he f ue l t a nk i s s ecur e l y a t t a ched t o t h e pow ertrai n as s e mbly j a ck when r e m o ving. Fa i lure t o f ol l o w t hi s i ns t ruc t i on m a y r es ult i n pe r s o na l i nj ury . • NO T E: Fed e ral marke[...]

  • Page 1271

    10. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Conn ect t he e vapo rat i ve e mi s si o n ca ni s t e r cl o s e val ve e l e ctrica l conne ct or. 11. NO TE: Fe d e r al mar ket ve hi cl e s o nly. • NO T E: Re move t he bl a nk i ng p lu gs . Conn ect t he fue l f i l t e r li ne qui ck r el ea s e co upl i ng . For a ddi ti o nal i nfo r [...]

  • Page 1272

    15. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Conn ect t he e l e ct rica l conne ct o r . 16. NO TE: Fe d e r al mar ket ve hi cl e s o nly. At t a ch t he e l e ct rica l conne ct o r . 17. NO TE: Fe d e r al mar ket ve hi cl e s o nly. At t a ch t he wi ring ha rn es s gromm et . 18. NO TE: Fe d e r al mar ket ve hi cl e s o nly. I nst a l [...]

  • Page 1273

    P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on C anister Purge Valve Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.0L engi n e 1. D et a ch t he s p e e d cont rol ca b l e . 2. D et a ch t he a ccel e r a t o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e[...]

  • Page 1274

    5. D i s conne ct t he upp e r f ue l v a po ur h os e from t he e v ap o r a t i ve e mi s si o n cani s t e r pur ge va lve . 6. D et a ch t he e vap o r a t i ve e mi s s i on cani s t e r purge val ve f r om t he ret a i ni ng br acke t . 7. Remove t he e vap orat i ve e mis s i on ca ni s t e r pur ge val v e. Dis conne ct t he l o we r f ue l[...]

  • Page 1275

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b-i n Ca m s ha f t po s it i o n s e ns o r r et a i ni ng bol t 7 - 62 He a t e d oxygen s e ns o r 40 3 0 - Ca ta l yst moni t o r s e ns o r 40 30 - Cr anks haf[...]

  • Page 1276

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls Des cr ipt i o n a nd O pe r a t i o n 2.0L E ngi ne I te m P a r t Nu m be r De scri pti on 1 — I nt a ke Mani f ol d Tuni ng (IMT) V a l ve - uppe r 2 — I nt a ke Mani f ol d Tuni ng [...]

  • Page 1277

    I te m P a r t Nu m be r De scri pti on 1 — I nt a ke Mani f ol d Tuni ng (IMT) V a l ve - uppe r 2 — I nt a ke Mani f ol d Tuni ng (IMT) V a l ve - l o we r 3 — Engi ne Coo l a nt T e mperat ure (ECT) S e ns or 4 — Va r i a bl e Ca msh a ft T imi ng O i l Cont r o l S ol e no i d LH 5 — Ca mshaf t P o si t i on (CMP) S ens o r LH 6 — C[...]

  • Page 1278

    Item P a r t Nu m be r De sc ri pti on 1 — Knock S e ns or (KS ) 2 — T hr ot t le P os i t i on (TP ) S e ns or 3 — O i l Te m pe r a t ur e Sens or 4 — O i l P res s ur e S wi t ch JagDocs.com[...]

  • Page 1279

    It e m Pa rt N um be r Descr i pti on 1 — Hea t e d Oxygen S e ns o r (HO2S ) LH 2 — Cat a l ys t Mo ni t or S e ns or RH 3 — Hea t e d Oxygen S e ns o r (HO2S ) RH 4 — Cat a l ys t Mo ni t or S e ns or LH Item P a rt N um be r Desc ri pti on 1 — Mas s A i r fl ow (MAF) S ens o r JagDocs.com[...]

  • Page 1280

    Item P a r t Nu m be r De sc ri pti on 1 — Engi ne Co nt rol Mod ule (ECM ) Engi ne Con trol Modul e (ECM) The e l e ct roni c e ngi ne co nt r ol s ys t e m cons i s t s o f a e ngi ne co nt r ol modul e (ECM ) a nd a num be r of s e nsi ng a nd a ct uat ing de vice s . T he s e ns o r s s uppl y t he ECM wi t h i nput s i gnal s whi ch rel a t [...]

  • Page 1281

    e ngi ne s p ee d . Engi ne Coo l a nt T emp erat ure (ECT) S e nso r The e ngi ne co ol a nt te m pe r at ur e (ECT ) s e ns or i s a t he r mis t or t yp e s ens or t ha t pr ovi de s a n i nput si gna l t o t he ECM whi ch i s pr opo r t i o na l t o t he e ngi ne coo l ant t e mper a t ur e . T he ECT s ens o r i s a nega t i ve t e mpe r a t u[...]

  • Page 1282

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls2.0L N A V6 - AJV6 Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he e ngi ne c on t r ol s yst em, r e f er t o t h e rel e vant De [...]

  • Page 1283

    DT C Desc ri pti on Possi bl e C ause Act i on Ca ta l yst co nversi on f ai lu r e P 0300 Ra nd o m Mis fi r e Det e ct e d I gni t i on s ys t e m compo nent s I gni t i on s ys t e m wi r i ng harne ss Che ck a l l ig ni t io n coi l s f o r s e cur e f i xi ng a nd check wi ring ha rnes s conne ct or f o r da mage a nd cor rect e ng a geme nt .[...]

  • Page 1284

    DT C Desc ri pti on Possi bl e C ause Act i on e ngi ne cont rol modul e f or op e n ci rc ui t s or s ho r t t o g round/powe r. Mini mum s up pl y vol t a ge a t c oi l i s 10.5 vol t s . maximum res i s t a nce i n s i gna l l i ne s i s 5 o hms. Re p a i r wi r i ng us i ng a p pr op r i at e rep ai r kit a s requi r e d. If t he r e a re no wi[...]

  • Page 1285

    DT C Desc ri pti on Possi bl e C ause Act i on W i r i ng b e t we e n ups trea m O 2 s e ns or a nd E CM Fue l i nje cto r f l ow pa r t i a l ly b l ocke d Ca ta l yst e f fi cie ncy de cr ea s e P 0051 HO 2S He at e r Cont r o l Ci r cuit L o w (Ba n k 2, S en s o r 1) Conce r n wi t h ups trea m O 2 s e ns or he a t e r W i r i ng f a ul t be t[...]

  • Page 1286

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls2.5L N A V6 - AJV6 / 3.0L NA V6 - AJ27, VIN Range: E 96603->J28492 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis [...]

  • Page 1287

    DT C De scri pti o n Possi bl e Sour ce A cti on H02S 1/1 s ho r t ci rc ui t t o ground. H02S 1/1 wi r i ng s hi e l d op e n ci rcu i t . H02S 1/1 he a t e r ci r c ui t f a ul t . Exhaus t l e ak. Lo w exha us t t e m pe r at ur e . I nje ct o r f lo w pa rti a l ly bl ocked . Ca t a l ys t e f fi ci e ncy de cr ea s e . H02S 1/1 f a i l ure. a [...]

  • Page 1288

    DT C De scri pti o n Possi bl e Sour ce A cti on f a i l ure. P 0430 Co ncern wi th l e ft -hand ba nk cat a l yt ic converte r s yst e m (Eff i ci e ncy be l o w t hr e s hol d ). HO 2 s ens o r di sco nne ct e d. HO 2 s ens o r t o ECM wi r i ng f au l t . HO 2 s ens o r he at e r to ECM wi ring f a ul t . HO 2 s ens o r he at e r f a i l ure. Up[...]

  • Page 1289

    DT C De scri pti o n Possi bl e Sour ce A cti on P 1215, P 1216, P 1344 Conce r n wi t h a ccel e r at or pe da l po s i t i o n s e ns o r ; T r a ck 3. AP P s e ns or . AP P s e ns or ci r cui t s . GO t o Pi npoi nt T es t AA . P 0480 Co ncern wi th radi a t o r coo l i ng f an mod ule drive . Coo l i ng f an mod ul e . Coo l i ng f an mod ul e [...]

  • Page 1290

    1 2 3 4 1 1 DT C De scri pti o n Possi bl e Sour ce A cti on P 0565, P 0566, P 0567, P 0568, P 0569, P 0570, P 0831, P 0832, P 0834, P 0835, P 1571 Conce r n wi t h ve hi cl e s pe e d cont rol . S wi t chpa ck. S wi t chpa ck ci r cuit s . Cl ut ch can c e l s wi t ch. Cl ut ch s a f e t y s wi t ch. Brak e o n/off s wi t ch. REFER t o : Spe e d C[...]

  • Page 1291

    1 2 1 2 3 1 2 1 1 2 3 1 1 1 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o A 4 . No REPAI R t he ci r c ui t. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o th e wi r i ng di a gr a m s . CL EAR t he DTCs . T ES T t he s yst em f o r no r mal o p e r at i o n. A4 : CHEC K T HE EC T S ENSOR GR O UND C I R CU IT F O R A SHO R T T[...]

  • Page 1292

    1 2 1 2 1 2 1 1 2 3 1 1 1 I s t he res i s t a nce l e s s t ha n 10, 000 ohms? Ye s REPAI R t he s hor t t o GROU ND. For ad di t i on a l in fo rm at i on, r e fe r t o t he wi r i ng d i agrams . Reco nnect a l l co nnect ors. CLEAR t he DT Cs . T ES T t he s ys t e m f or no r m al o pe r a t i o n. No GO t o B 7 . B7: C HEC K T HE C KP S ENS O[...]

  • Page 1293

    1 2 1 2 1 2 1 1 2 3 1 1 1 2 Is t he res i s t a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t t o GROU ND. Fo r ad di t i on a l in f o r m at i on , r ef e r t o t he wi r i ng di a g r a ms . CL EAR t he DTCs . TE S T t he s yst e m f o r norm al ope rat i on. No GO t o C7 . C 7: C HEC K T HE R IGH T -HAND BAN K C MP S ENSOR SI GNAL C[...]

  • Page 1294

    1 2 1 2 1 2 3 1 2 3 1 1 1 1 Is t he res i s t a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t t o GROU ND. Fo r ad di t i on a l in f o r m at i on , r ef e r t o t he wi r i ng di a g r a ms . CL EAR t he DTCs . TE S T t he s yst e m f o r norm al ope rat i on. No GO t o D7 . D7: C HECK T H E LEF T - HAN D BA N K CM P SENS OR SI GN AL [...]

  • Page 1295

    1 2 1 2 3 4 1 1 1 2 3 1 2 3 1 2 3 4 I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR s ho rt t o ground b et we e n t he e ngi ne compartme nt f us e b ox a nd t he right -hand ba nk HO 2S . For ad di t i ona l i nf o r ma t i o n, r e f e r t o th e wi r i ng di a gr ams . CL EAR t he DTC. TEST t he s yst e m fo r norm a l o pe r[...]

  • Page 1296

    1 2 1 1 1 2 3 1 2 3 4 1 2 3 4 1 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s GO t o G2 . No REPAI R t he ci r c ui t. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTCs . T ES T t he sys t em f or norm a l op erat i o n. G2: CHEC K T HE KS SI GNA L WI RE FOR S HOR T T O BAT T ER Y Tur n t h[...]

  • Page 1297

    1 2 3 1 2 3 1 2 3 1 2 3 1 1 2 3 1 2 1 no r mal o p e r at i o n. H3 : CHEC K T HE OIL T EMP ER AT UR E SENS O R GRO U ND C IRC U IT F OR SHOR T T O BAT T ER Y Conne ct ECM e l e ct r i cal conn e cto r , EN16. Tur n t he i gni t i on s wi t ch to the O N p o si t i on. Mea s ure t he vol t a ge be t we e n t he o i l t e mpe r at ur e s e ns o r e [...]

  • Page 1298

    1 2 3 1 2 3 4 1 2 3 1 1 1 1 1 2 3 I6 : CHEC K T HE VAR I A BLE CIRC UIT OF T HE R IGH T - HA ND BAN K HO2S FOR SH OR T T O BA T T ER Y Conne ct t he ECM e l e ct rica l conne ct o r EN16. Tur n t he i gni t i on s wi t ch to the O N p o si t i on. Mea s ure t he vol t a ge be t we e n EN37, pi n 3 (Y ) a nd GROU ND. Is t he vol t a ge gr e a t e r [...]

  • Page 1299

    1 1 1 1 2 3 1 1 2 3 1 2 3 1 1 2 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s INS TA LL a ne w ECM . For a ddi ti o nal i nfo r mat i o n, REFER t o : E ngi ne Co nt rol Modul e (ECM) (303 -14B El e ct roni c Eng in e Co nt rol s - 2.0L Dur a t o r q- TDCi /2.2L Dur at o rq-TDCi (110k W /150P S ) - P uma, Re mo v al a nd I ns t a l la t i o [...]

  • Page 1300

    3 1 2 3 4 1 2 3 1 1 1 1 1 2 3 Mea s ure t he vol t a ge be t we e n EN32 pi n 3 (Y ) a nd GRO UN D. Is t he vol t a ge gr e a t e r t ha n 5 vol t s ? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i o nal i nfo r m a t i o n, r e f e r to the wi r i ng di a g r ams . CL EAR t he DTCs . T ES T t he s y s t em fo r nor mal o p e r at i o n. No [...]

  • Page 1301

    1 1 1 1 2 3 4 1 2 3 1 1 1 1 REPAI R t he ci r cui t . Fo r addi t i o na l i nf orm at i o n, r ef er t o t he wi r ing di a g r ams . CLEAR t he DT Cs . T ES T t he sys t e m fo r norm a l ope rat i on. L8: CHEC K FUSE 42 OF T HE ENGI N E C O MPAR T MENT FUSE BOX Check t h e fus e . Is t he f us e O K? Yes GO t o L 10 . No GO t o L 9 . L9: CHEC K [...]

  • Page 1302

    1 1 2 3 4 1 1 2 3 1 1 2 3 1 2 I s t he res i s t a nce l e s s t ha n 10, 000 ohms? Ye s REPAI R s hort t o g r ound be t we e n t he e ng i ne co mpa r t ment f us e bo x a nd t he MAF s e ns o r . Fo r add i t i o na l i nf o r mat i o n, r e fe r t o wi r i ng di a g r a ms . CL EAR t he DTC. TEST t he s y s t e m fo r norm al o pe rat i on. No [...]

  • Page 1303

    1 2 3 1 1 1 1 1 1 1 1 GO t o O 2 . O2: C HEC K T HE GRO UND CIRC UI T T O T H E LEF T - HAN D BA NK HO 2 S H EAT E R Tur n t he i gni t i o n s wi t ch to the O FF p os i t io n. Dis conne ct t he ECM e l e ct rica l c o nne ct or EN16. Mea s ure t he r es i s t a nce b e t we en the HO 2S e l e ctrical co nne ct or EN32 p i n 1 (GO) a nd t h e ECM[...]

  • Page 1304

    1 1 1 1 2 3 1 1 1 1 2 1 2 1 Mea s ur e t he vol t a ge be t we e n t he ECM co nt rol r e la y e l ect r i cal co nnect o r JB3 4 pi n 132 a n d GRO UN D. I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s Re pa i r t he ci r c ui t from t he e ngi ne compart ment fus e bo x t o th e ECM cont r o l rel a y . CL EAR t he DTC. T ES T t he s ys t e m[...]

  • Page 1305

    2 1 2 1 2 3 4 1 2 3 1 2 3 1 2 1 1 2 1 2 Mea s ure t he v ol t a ge be t wee n t he MAP s e ns o r e l e ctrical co nne ct or EN8 pi n 2 (OY ) a nd GRO UN D. Is t he vol t a ge gr e a t e r t ha n 6 vol t s ? Ye s REPAI R t he s h or t t o ba t t e r y. For ad di t io na l inf or mat io n, r e fe r t o wi r i ng d ia gr ams . C LEAR t he DTC. TE S T[...]

  • Page 1306

    1 2 1 1 2 1 2 1 2 1 2 1 2 3 4 Is t he vol t a ge gr e a t e r t ha n 1 vol t ? Ye s REP AIR t he s h or t circ ui t . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o wi ring di a g r ams. CLEA R t he DTC. T ES T t he s ys t e m f or no r mal o p e r at i o n. No I NS T AL L a ne w r i ght -hand ba nk V VT s o l e no i d . REFER t o : V a r i a [...]

  • Page 1307

    1 1 1 1 1 2 1 2 1 1 2 3 T 4: CHEC K T HE T HR O T T LE MO T O R RELAY SI GN AL W IRE FOR SH OR T T O GR OU ND Mea s ur e t he res i s t a nce be t we e n th e t hrot t le mot o r r el ay bas e p i n 2 a nd GRO UN D. I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t t o GROU ND. Fo r a d di t i ona l i nf o r mat i o n[...]

  • Page 1308

    1 2 1 2 1 1 2 3 1 1 2 3 1 1 2 3 PINPOIN T TE ST V : P15 32 . I MT VA LVE 2 T EST C O NDI T IONS DET AI LS/RE SULT S /ACT IONS V1: C HEC K T HE PO WER SUP PLY CIRC UIT T O T HE I MT VA LVE 2 Tur n t he i gni t i o n s wi t ch to the O N p o si t i on. Mea s ure t he vol t a ge be t we e n IMT val ve 2 e l e ct r i ca l conne cto r EN998 p i n 1 (NG)[...]

  • Page 1309

    1 1 2 3 1 1 2 3 1 1 2 1 1 2 I s t he v ol t a ge grea t e r tha n 4 vol t s ? Ye s GO t o X4 . No REP AIR t he ci r cuit be t we e n t he MAP s e ns or e l ect r i cal co nnect o r EN8 pi n 2 (O Y ) a n d t h e s e ns o r 5 vo l t s u ppl y bu s. CLEA R t he DTC. TEST t he s yst e m f or norm al o pe rat i o n. (T he fa u lt co uld be i n a n y o f[...]

  • Page 1310

    1 1 1 1 1 1 1 1 I s t he v ol t a ge grea t e r tha n 4 vol t s ? Ye s GO t o X12 . No REP AIR t he ci r cuit be t we e n t he ACP s e nso r e l e ct r ica l conne cto r JB106 pi n 2 (O Y ) a nd t he s e ns o r 5 vol t s uppl y bus . CLEAR t he DTC. T ES T t he s ys t e m f o r no r mal o p e r at i on . (T he fa u lt co uld be i n a n y o f the o [...]

  • Page 1311

    1 1 1 1 2 1 2 3 1 2 3 1 2 3 1 2 3 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o Y 8 . No REPAI R t he ci r c ui t bet we e n t he AP P s e ns o r e l e ct rical conne c t o r PA1 p i n 3 (BG) a nd GR O UN D. CL EAR t he DTC. TES T t he s ys t e m f o r no r mal o p e r at i on . ( This circ uit i nclud e s th e EC M. Fo r ad d ition [...]

  • Page 1312

    1 2 1 2 1 2 3 1 2 3 1 2 3 1 1 2 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o Z 6 . No REPAI R t he ci r c ui t bet we e n t he AP P s e ns o r e l e ct rical conne ct o r PA1 pi n 4 (R) a nd t he ECM el e ct r ica l conne ct o r E N16 pi n 102 (R). Fo r ad di t io nal i nf or ma t i on, r e fe r t o wi ring d i a grams . CLEAR t he [...]

  • Page 1313

    1 2 3 1 2 3 1 2 3 4 1 2 1 1 1 1 REFER t o : A cc e l erat o r Pe d al (310-02 Acc e l e r a t i o n Co nt rol , Re moval a nd I ns t a l l a t i on). CLEAR t he DT C. TE S T t he sys t em f or norm al op e rat i o n. PINPOIN T TE ST A B : P0 48 0. RAD IATOR COOLING F AN MODU LE DRI VE T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I O NS AB1 : CHEC[...]

  • Page 1314

    2 1 2 1 2 1 2 3 1 2 1 1 1 2 3 Mea s ure t he r es i s t ance b e t w ee n fus e bo x e l e ct rica l conne ct o r JB34 pi n 79 a nd GROU ND. Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o w iring d ia g r ams . CLE A R t he DT C. TES T t he s yst e m [...]

  • Page 1315

    1 2 3 4 5 1 2 1 2 1 2 1 1 2 1 W ARNI N G: Ma k e s ur e t he s t a rte r m ot o r do e s no t e nga ge i n t he co ur s e o f t he s e t e st s . Fa i lur e t o fo l l o w t hes e i ns tru ct i o ns may res ul t i n pe r s o nal i nj ur y . T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I O NS AE1: CHEC K T HE ST ART I NPUT T O T HE EC M Mov e t he[...]

  • Page 1316

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls2.5L N A V6 - AJV6 / 3.0L NA V6 - AJ27, VIN Range: J2 8493-> V99999 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis[...]

  • Page 1317

    DT C Descri pti on P oss i bl e S ourc e Acti on ground. H02S 1/1 wi r i ng shi e l d op e n ci rc ui t . H02S 1/1 he a t e r ci r c ui t f a ul t . Exhaus t l e ak. Lo w exha us t t e mper a t ur e . I nje ct o r f lo w pa rti a l ly bl ocked . Ca t a l yst e f fi ci e ncy de cr ea s e. H02S 1/1 f ai l ure. AJV6/3.0L N A V6 - AJ27, Di a gno s i s [...]

  • Page 1318

    DT C Descri pti on P oss i bl e S ourc e Acti on Up s t r ea m HO 2 s ens or f a i l ure. Downs t r e a m HO2 s ens o r f a i l ure. HO 2 s e ns o r fa i l e d. Ca t a l yt i c conver t e r f a i l ure. P 0430 Co ncern wi t h l e f t -ha nd ba nk cat a l yti c conve r t er s ys t e m. (Eff i ci e ncy be l o w t hr e s ho l d ). HO 2 s e ns o r di s[...]

  • Page 1319

    DT C Descri pti on P oss i bl e S ourc e Acti on P 0226, P 00227, P 0228 Conce rn wi t h a ccel e r at o r p eda l po s i t i o n s e ns or ; T r a ck 1. AP P s e ns or . AP P s e ns or ci r cui t s . GO t o Pi npoi nt T es t Z. . P 2122, P 2123 Co ncern wi th a ccel e r at o r p eda l po s i t i o n s e ns or ; T r a ck 3. AP P s e ns or . AP P s [...]

  • Page 1320

    DT C Descri pti on P oss i bl e S ourc e Acti on Va po r l i ne s . P 0460 Co ncern wi t h f ue l l e ve l s e ns o r s . Fue l l e vel s e ns ors. Fue l l e ve l s e ns or ci r cuit s . I ns t ru me nt cl ust e r . REFER t o : Fu e l Charging a nd Co nt rols - 2. 5L N A V 6 - AJV6/3.0L N A V6 - AJ27, VI N Ra nge : E96603- >J284 92 (303-04 A Fue[...]

  • Page 1321

    1 2 3 4 1 1 1 2 1 2 3 1 2 1 1 2 DT C Descri pti on P oss i bl e S ourc e Acti on P 0860, P 1637, P 1638. P 1642, P 1643, P 1699 Conce rn wi t h CAN ne t wo rk . CAN ne t wo r k modul e s a n d circu i t s . REFER t o : Co mmu ni cat i o ns Ne t work - V I N Ra ng e : E96603->J 28492 (4 18-00 Mod ul e Co mm uni cat i ons Ne t work , Dia gn os i s[...]

  • Page 1322

    3 1 1 1 1 2 1 2 1 2 1 1 2 3 Meas ur e t he r es i s t a nce be t we e n t he CKP s e ns o r e l e ct r i cal conne ct o r EN12, pi n 1 (Y ) a n d t he ECM el e ct rica l conne ct o r EN16, p i n 37 (Y ). I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s GO t o B 4 . No REPAI R t he ci r cui t . Fo r addi t i o na l i nf orm at i o n, r ef er t o[...]

  • Page 1323

    1 1 1 1 2 1 2 1 2 1 1 2 3 I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s GO t o C4 . No REPAI R t he ci r cui t . For a ddi t i o na l i nf orm at i o n, r ef e r t o t he wiring di a grams. CLEAR the DTCs . TE S T t he s ys t e m f or norm a l ope rat i on. C 4: C HEC K T HE R IGH T -HAND BAN K C MP GRO UND WI RE FO R OP E N C IRC UI T Meas [...]

  • Page 1324

    1 1 1 2 1 2 1 2 1 2 3 1 2 3 1 I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s GO t o D4 . No REPAI R t he ci r cui t . For a ddi t i o na l i nf orm at i o n, r ef e r t o t he wiring di a grams. CLEAR the DTCs . TE S T t he s ys t e m f or norm a l ope rat i on. D4: C HECK T H E LEF T - HAN D BA N K CM P GR O UND WI R E F O R OP EN CI RC U IT[...]

  • Page 1325

    1 1 1 1 2 1 2 3 4 1 1 1 2 3 1 2 3 GO t o E4 . E4: CHEC K T HE R I G HT -HAN D BA N K HO2S GR O UND CIR C UI T FO R SHOR T T O BAT T ER Y Che ck fo r a vol t a ge b e t we e n t he HO 2S el e ct r ica l conne ct o r EN 37, pi n 1 (RU ) a nd GROU N D. I s t he v ol t a ge gr e a t e r th a n 1 vo l t ? Ye s REP AIR t he s h or t t o ba t t e r y. Fo [...]

  • Page 1326

    1 2 3 4 1 2 1 1 1 2 3 1 2 3 4 I s t he v ol t a ge grea t e r tha n 10 vo lt s ? Ye s REP AIR t he sh or t to ba t t e ry . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o t he w i r i ng di a g r a m s . CL EAR t he DTCs . TE S T t he s ys t e m fo r nor m al op e r at i o n. No I NS TALL a ne w f uel t e mperat ure s e nso r. REFER t o: Fue l[...]

  • Page 1327

    1 2 3 4 1 1 2 3 1 2 3 1 2 3 1 2 3 1 1 2 3 PINPOIN T TE ST H : DTC P01 96 , P01 97 , P01 98 . OIL TEMPERATU RE SENS OR T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS H1 : CHEC K T HE OIL T EMP ER AT UR E SENS O R S I GNA L WI R E FOR OP EN CI R C UI T Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Di s conne ct t he o i l t empe[...]

  • Page 1328

    1 2 1 1 2 3 1 2 3 4 1 2 3 1 1 1 Is t he vol t a ge gr e a t e r t han 5 vol t s? Yes REPAI R t he s hor t circ uit . Fo r add i t i ona l i nf o r m a t i o n, r e f er t o t h e wi r i ng di a gr ams . CLEAR t he DTCs . TEST t he s ys t e m fo r nor m al o p e r at i o n. No GO t o I 4 . I4 : CHEC K T HE VAR I A BLE CIRC UIT OF T HE R IGH T - HA N[...]

  • Page 1329

    1 1 2 3 1 1 1 1 2 3 1 1 2 3 No INS TA LL a ne w RH b a nk cat a lys t m o nit or s e ns or. For a ddi t i o na l i nf orm at i o n, REFER t o : Ca t a l yst Mon it o r Sens o r RH (303-14A El e ct roni c Engi ne Co nt rols - 2.0L N A V 6 - A JV6/ 2.5L NA V6 - AJV6/3 .0L N A V 6 - A J27, Re moval a nd I nst a l l a t i on). CLEAR t he DT Cs . T ES T[...]

  • Page 1330

    1 2 3 1 1 2 3 1 2 3 4 1 2 3 1 1 1 K4: C HECK T HE VARIAB LE CI RC U I T OF T HE LEFT - HAN D BA N K H O2S FOR O PE N CIRC UIT Dis conne ct t he HO 2S e l e ct rical co nnect or EN32. Dis conne ct t he ECM e l e ct rica l con nect or EN16. Mea s ure t he r es i s t ance b e t w ee n EN16, p i n 107 (Y ) a nd EN32, p i n 3 (Y ) Is t he res i s t a nc[...]

  • Page 1331

    1 1 2 3 1 1 1 1 2 3 4 1 2 3 1 1 REFER t o : E ngi ne Cont rol Mo dul e (ECM) (30 3-14A El e ct roni c Eng i ne Co nt rol s - 2. 0L NA V6 - AJV6/ 2.5L N A V 6 - AJV6/ 3.0L N A V 6 - A J27, Re moval a nd I nst a l l at io n). Bef o r e r ep l a cing a n ECM, co nt a ct dea l e r t e chni cal s uppo rt. L6: CHEC K T HE L EFT -HAN D BA NK CAT ALYST M O[...]

  • Page 1332

    1 1 1 1 2 3 4 1 1 2 3 1 1 2 3 I s t he res i s t a nce grea t e r t ha n 10,000 o hms? Ye s INS TA LL a ne w MAF se ns o r . For add i ti ona l i nf o r m a t i o n, REFER t o : Ma ss A ir Fl o w (M AF) S e ns o r (30 3-14 A El e ct roni c Engi ne Co nt rol s - 2. 0L NA V6 - AJV6/2.5L NA V 6 - AJV6/ 3. 0L N A V 6 - AJ27, Remo val a nd I nst a l l a[...]

  • Page 1333

    1 2 1 2 3 1 1 1 1 1 1 I s t he v ol t a ge grea t e r tha n 1 vol t ? Ye s REP AIR t he s h or t circu i t . Fo r a ddi t i o nal i nfo r mat i on, ref e r t o t he wiring di a g rams. CL EAR t he DTCs . T ES T t he s ys t e m f or norm al op e rat i o n. No I NS TALL a ne w MAF s e nso r. REFER t o : Ma s s A i r Fl o w (MAF) S e n s o r (303- 14A[...]

  • Page 1334

    1 1 1 1 1 1 2 3 1 1 1 1 2 I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s GO t o P 3 . No REP AI R t he cir cuit f r om t he ECM cont r ol rel a y t o t he ECM. Fo r ad di t io nal i nf or ma t i on , ref e r t o wi ring di agrams . CLEAR t he DTC. T ES T t he sys t e m fo r nor mal op e r at i o n. P3: C HECK F USE 9 I N T HE ENGI NE CO MPAR T[...]

  • Page 1335

    1 2 1 2 1 2 1 2 3 4 1 2 3 1 2 3 1 2 I s t he r es i s t a nce l e s s t ha n 5 ohms? Ye s P os s ib l e i nt e rm it t ent f a ul t . Reche ck DTCs . No I NS TALL a ne w ECM cont rol r e la y di o de . Ma ke s ur e t ha t t he ECM co nt rol rel a y di o de i s i ns t al l e d co r re c t l y. Fo r a ddi t i o na l i nf orm at i o n, r ef e r t o t [...]

  • Page 1336

    1 1 2 1 2 1 2 1 1 2 1 2 1 2 Is t he res i s t a nce l e s s t han 5 ohms ? Ye s GO t o R2 . No REP AIR t he ci r c ui t bet we e n VVT s o l e no i d e l e ct r i cal co nnect o r EN61 pi n 2 (BG) a nd GRO U ND. For ad di t io na l in f o r ma t i o n, r e f er t o wi r i ng d ia g r ams . CLE AR t he DTC. TES T t he s ys t e m fo r n or mal o pe r[...]

  • Page 1337

    1 2 1 2 3 4 1 1 1 1 1 2 1 2 I s t he v ol t a ge gr e a t e r th a n 10 vo l t s ? Ye s GO t o T2 . No REP AIR t he ci r cuit be t we e n pi n 1 of t he t hrot t l e mo t o r r e l a y b as e and t he EMS cont ro l r el a y. Fo r add i t i ona l i nf o r ma t i o n, r e f e r t o th e wi r i ng di a gr ams . CL EAR t he DTC. TEST t he s yst e m fo [...]

  • Page 1338

    1 1 2 3 1 2 1 2 1 1 2 3 1 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s GO t o U 3 . No REPAI R t he ci r c ui t bet we e n t he IMT val v e 1 e l e ct rica l conne ct o r EN 999 pi n 2 (OY ) a nd t he ECM e l ect r i c a l conne ct o r EN16 p i n 38 (OY ). For a dd i t i o na l i nf orm a t i o n, r e fe r t o wi r i ng di a gr ams . CLEAR [...]

  • Page 1339

    1 1 1 1 1 1 1 1 1 Te s t not ap pl i cabl e. PINPOIN T TE ST X : P12 43 . S ENSOR G ROU ND CIRCU ITS . T EST C ONDI T I ONS DET AI LS/RE SULT S /ACT IONS X1: C HEC K T HE GR O UND CIR C UI T T O T HE EC T SEN SOR Mea s ure t he r es i s t ance b e t wee n ECT se n s o r e le c t rical co nnect or EN18 pi n 1 (BG) a nd GRO U ND. Is t he res i s t a [...]

  • Page 1340

    1 1 2 3 1 2 3 1 2 1 2 3 1 2 3 1 2 3 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o X 10 . No REPAI R t he ci r c ui t bet we e n t he AP P s e ns o r e l e ct rical conne c t o r PA1 p i n 6 (BG) a nd GR O UN D. CL EAR t he DTC. TES T t he s ys t e m f o r no r mal o p e r at i on . ( This circ uit i nclud e s th e EC M. Fo r ad d iti[...]

  • Page 1341

    1 2 3 1 2 1 2 1 2 3 1 2 3 1 2 3 1 Is t he vol t a ge gr e a t e r t ha n 1 vol t ? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o w iring d ia g r ams . CLE A R t he DT C. TES T t he s yst e m fo r norm a l op erat i o n. No GO t o Z 5 . Z5: CHEC K CO NT I NUI T Y O F T HE APP SENSOR SI GNA L WI RE T[...]

  • Page 1342

    1 2 1 2 3 4 5 1 2 1 2 1 2 1 1 2 1 AA 6: CHEC K CO NT I NUI T Y O F T HE APP SENSOR PO T E NT IOM ET E R Mea s ure t he r es i s t ance b e t w ee n APP s e ns o r el e ct r i cal co nnect or PA 1 pi ns 1 a nd 3. Op e r at e th e acce l e r at o r pe da l through i t 's f ul l r a nge whil e o bs erv ing t he res i s t a nc e r e a di ng. Does [...]

  • Page 1343

    1 2 3 1 1 2 3 1 1 2 3 1 1 2 3 fo r no r m a l op e r at i o n. If t h e DTC i s r e pe a t e d , I NS TAL L a ne w ECM. REFER t o : E ngi ne Cont rol Mo dul e (ECM) (30 3-14B El e ct roni c Eng in e Co nt rol s - 2. 0L Dur a t orq- TDCi /2.2L Dur at o rq-TDCi (110k W /150PS ) - P uma, Removal a nd Ins t al la t i o n). Bef o r e r ep l a cing a n E[...]

  • Page 1344

    1 1 2 1 1 2 1 1 2 3 1 2 3 4 Mea s ur e t he vol t age bet we e n AP P s e ns o r e le ctrica l conne ct o r P A 1 pi n 5 (OY ) a nd GRO U N D. I s t he v ol t a ge grea t e r tha n 6 vol t s ? Ye s REP AIR t he ci r cuit be t we e n t he AP P s e nso r e l e ctrica l conne ct o r P A 1 p in 5 (O Y ) and th e s e nso r 5 v ol t s upp l y bus . CLEA [...]

  • Page 1345

    1 2 1 1 1 1 2 1 2 1 2 1 2 3 1 2 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s REPAI R t he ci r c ui t bet we e n EN30 p i n 2 (B) a nd GROU ND. Fo r a ddi t i o nal i nfo r mat i on, re fe r t o wi r i ng d i agrams . CLEAR th e DTC. T EST t h e s y s t e m fo r norm al o pe rat i on. No GO t o A E2 . AE2: CHEC K T HE C I RC U I T I N T E G[...]

  • Page 1346

    1 1 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s GO t o A E11 . No REPAI R t he ci r c ui t. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o w i r i ng di a g r a ms . CL EAR t he DTC. TES T t he s yst e m fo r no r mal ope rat i on. AE11 : CHEC K T HE C I R CU IT BET W EE N T HE EC M A N D T HE A C C C RE LAY B ASE FOR SH OR T T O B[...]

  • Page 1347

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Pow ertrain C o ntrol Mo d ule (PCM) Lo ng Drive C y cle Se lf-Test Gene ral P r ocedures W ARNI N G: W here pos s ib l e , a l l roa d te s t s s hou l d be o n we l l s urfaced a nd dr y r oad s . Al wa ys co mply wi t h[...]

  • Page 1348

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Pow ertrain C o ntrol Mo d ule (PCM) Sho rt Drive Cycle Self-Te st Gene ral P r ocedures • NO T E: T hi s p rocedur e i s a n o ve r check onl y . I f fa ul t cod e s a r e f o und, i nt e rr o g a ti o n o f th e rel e [...]

  • Page 1349

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C amsh aft Pos itio n (C M P ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e ngi ne cover. 2. D i s conne ct t he CMP s e ns o r el e ctr i cal co nne ct or. 3. Remove t he CMP s e ns or . Re mov[...]

  • Page 1350

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C atalyst Moni to r Sensor LH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd C[...]

  • Page 1351

    1. CAU TI O N : Make s ur e t h at th e ca t a l y s t moni t or s e nso r cas i ng a nd c a bl e a r e not da ma ge d. To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 40 Nm. 2. NOT E: For NAS v e hi cl e s o nl y. I f r e qui red, ca r r y o ut a l ong dr ive cycle . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o[...]

  • Page 1352

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C atalyst Moni to r Sensor RH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd C[...]

  • Page 1353

    8. CA UT I O NS: Do no t cut t he HO 2S ha r ne s s . Make s ur e t ha t the cat al ys t mo ni to r s e ns o r cas i ng a nd ca bl e a r e not dama ge d. Us i ng S nap -on s o cket Y A8875 re mov e th e ca t al yst moni to r s e ns o r. Insta llat ion 1. CAU TI O N : Make s ur e t h at th e ca t a l y s t moni t or s e nso r cas i ng a nd c a bl e [...]

  • Page 1354

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C rankshaft Pos i tio n (C K P) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he right -ha nd front r oa d whe e l. For a ddi ti ona l i nf o r m a t i o n, r ef e r t o S ect i o n 204-04 W he e l s [...]

  • Page 1355

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E ngine Co n trol Module (E CM ) Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o For a ddi ti ona l i nf o r m a t[...]

  • Page 1356

    6. D et a ch t he ge ne r i c e l e ct r o nic modul e (GEM ) f r om t he ECM . 1. Re l e a s e t he GEM l ocki ng t a ng. 2. De ta ch t he GEM f r o m t he ECM. 7. Remove t he ECM. 1. Re move t he ECM ret a i ni ng nut . 2. Re move t he ECM. 8. Remove t he ECM f r om t he ECM ret a i ni ng br acket . Insta llat ion 1. To i ns t a l l , rever s e t[...]

  • Page 1357

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Fuel Tem perature Senso r2.5L N A V6 - AJV6 / 3.0L N A V6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Qui ck fi t conne ct o r r e l ea s ing t o o l 310-0 45 R em ova l 1. Remove t he e ngi ne cover. 2.[...]

  • Page 1358

    Insta llat ion 1. NOT E: Ins t a l l a new O -r i ng s e a l . I nst a l l t he f ue l t empe r a t ure s ens o r . 2. Connect t he f ue l t e mpe r at ur e s e ns or e l e ct r i cal co nne cto r. 3. Ins t a l l the ret a i ni ng cl i p to the s pr i ng lo ck co upl i ng. 4. Ins t a l l the e ng ine co ver . JagDocs.com[...]

  • Page 1359

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Heated Oxygen Senso r (HO2S) L H Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 414-01 B at t e ry [...]

  • Page 1360

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Heated Oxygen Senso r (HO2S) RH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 414-01 B at t e ry ,[...]

  • Page 1361

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - K no ck Senso r (KS) Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 414-01 B at t [...]

  • Page 1362

    8. NOT E: Fue l may s t i l l be pres e nt i n t he fue l s up pl y m a ni fo l d. Det ach t he f uel i nj e ct i on su ppl y mani fo l d a nd l o we r i nt a ke ma nif ol d a nd pl a ce t o o ne s i de . 9. Remove t he f uel i nj e ct i on s uppl y mani f ol d a nd l owe r i nt a ke mani f o l d . Dis conne ct t he e l e ct r i cal co nnect o r. R[...]

  • Page 1363

    13. Remove t he e n gi ne co o l a nt i nl e t p i pe . Re mov e a nd di s c a r d t he s e a l . 14. Remove t he KS. Insta llat ion All v e h icle s 1. NOT E: Prio r t o i ns t al li ng t he KS , cl e a n t h e e ng i ne b lo ck a nd KS ma t i ng s ur fa ce s wi t h met a l s ur f a ce cl e a ne r (W S W -M5 B392-A). To i ns t a ll , r e ver s e t[...]

  • Page 1364

    3. Ins t a l l a ne w s e a l . Ti ght e n t o 10 Nm. 4. Tig ht e n i n t he s eque n c e s ho wn. Ti ght e n t o 10 Nm. Vehi c le s with 2.0L engi n e 5. Ins t a l l a ne w s e a l . Ti ght e n t o 9 Nm. 6. Tig ht e n t o 6 Nm. JagDocs.com[...]

  • Page 1365

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Mass A ir Flo w (MA F ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ba t t e r y cover . 2. D i s conne ct t he MAF se n s o r e l e c t r i cal co nne cto r. 3. Remove t he MAF s e ns o r . Inst[...]

  • Page 1366

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Oi l T em peratu re Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 100-02 Ja cking a nd L i f t i ng . [...]

  • Page 1367

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - T hrottle Po si tio n (TP) S ensor Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.5L or 3.0L engine 1. F or ad di t i o na l i nfo rm at i on, refe r t o S e ct io n 303-04A Fuel Cha r gi ng a nd Cont r[...]

  • Page 1368

    6. Remove t he t he t hr ot t le pos i t i on (TP ) s e ns o r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n t o 7 Nm. JagDocs.com[...]

  • Page 1369

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - V ariable C amsh aft T im ing ( VC T) Oil C on trol Sol eno id Re moval a n d I ns t a l l a t i on R em ova l R ight-H and Bank 1. Remove t he right -ha nd val ve cove r. For ad di t i o na l i nfo rm at i on, refe r t o [...]

  • Page 1370

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - T o rque Sp eci f i cat ions Descri pti o n N m l b-ft l b- i n Ca m s ha f t po s it i o n s e ns o r r et a i ni ng bol t 9 – 80 Cr anks haf t po si t i o n s e ns or r et a i ni ng bol t 7 – 62 Cyli nder he a d t em[...]

  • Page 1371

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ele ctro nic Engine C o ntro ls Des cr ipt i o n a nd O pe r a t i o n It e m P art N um ber Descri pti on 1 — Camsha f t po s i ti o n (CMP) s e ns or 2 — Eng i ne cont r o l mod ule (ECM ) 3 — Cy li nde r he ad te [...]

  • Page 1372

    id e nt i fi e d. S houl d t he CMP se ns o r fa i l t he e ng i ne wi l l no t s t a r t . Engi ne Con trol Modul e (ECM) The e ngi ne co nt r o l mod ul e (ECM ) i s l o ca t e d i n t he s ame p o si t i on a s t he p e t r ol ve r s i on. T he e ngi ne mana ge m e nt s y s t em (EMS ) us e s s i g na ls from t he var i o us s e ns or s a s i np[...]

  • Page 1373

    P ubl i she d: 12-Jul-2011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ele ctro nic Engine C o ntro ls Dia gn os i s a nd Te s t i ng Over view Thi s s e cti on cove r s t he co mpon ent s of t he e ngi ne ma nage me nt s ys t e m . The change s t o t he e ngi ne mana ge ment f o r th is mode l[...]

  • Page 1374

    Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Engi ne cont rol mod ul e (ECM) f a ul t Di ff i cul t t o s t a rt Di ff i cul t t o s t a r t co l d Gl ow pl ug (s)/circu i t f aul t Cont a mi nat e d f ue l Ai r i ngr e s s Bl o cked a i r cle a ne r Bl o cked fue l fi lt e r Lo w-pr e s s ur e ci r cui t f aul t Fue l[...]

  • Page 1375

    Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Engi ne sp e e d ou t of co nt r ol Engi ne oi l l e vel t o o hi gh Exc es s ive b l o w-by Accel erat o r pe da l po s i t i o n (AP P ) s e ns or f aul t Tur bo charger be a r i ng/s e a l f ai l ure Check/ cor r e ct t he e ng i ne o i l l e v e l . Check t he e ngi ne c[...]

  • Page 1376

    Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Mani f o l d a bs o l ut e pr es s ur e (MAP) s e nso r f aul t Kno c k s e ns o r f a ul t Fue l rai l pr e s s ur e (FRP ) s e ns o r f aul t I nje ct o r (s ) f aul t /pr ogr a mming Ca ta l yst b l ocked Tur bo charger f a ul t Dual -mas s fl ywh e e l f aul t Cyli nder [...]

  • Page 1377

    DT C C ondi ti o n Poss i bl e sourc e Act i o n W he e l s pe e d s e ns o r in put ci r cuit : s ho r t cir cui t to powe r C1155 Le f t -ha nd front whe e l s pee d se n s o r i np ut ci r cuit f a ul t W he e l s pe e d s e ns o r in put ci r cuit : hi gh r e s i s ta n ce W he e l s pe e d s e ns o r in put ci r cuit : s ho r t cir cui t to gr[...]

  • Page 1378

    DT C C ondi ti o n Poss i bl e sourc e Act i o n P 0191 Fue l pr e s s ur e s e nso r A ci r cuit r a n ge/p e r fo r m a nce Pump d e t e r i o r at i o n - Co nt a mina t e d f ue l Lea ki ng f ue l rai l Fuel pr e s s ur e s e nso r c i r cuit f a ul t Fuel pr e s s ur e s e nso r fa ul t Che ck f o r cont a mina t e d fue l . Draw o ff a pp r o[...]

  • Page 1379

    DT C C ondi ti o n Poss i bl e sourc e Act i o n c i r cuit (s i gnal re t urn ) MAPT s ens or fa ul t P 0243 Turbocha r ger a ct ua t o r A c i r cuit Turbochar ge r a ct ua t o r c i r cuit : h ig h res i s t a nce Tur bocha r ge r a ct ua t o r fa ul t Re fe r t o t he a pprov e d d i a gnos ti c s y s t e m f o r a gui d e d d i a gno s t ic r [...]

  • Page 1380

    DT C C ondi ti o n Poss i bl e sourc e Act i o n op en ci r cuit , hi gh res i s t a nce. Fo r furthe r di a gno s t i c i nfo rm at i on REFER t o : T ur bo charger (303- 04C Fue l Charging a nd Co nt rol s - Tur bo charg e r, Dia g no si s a nd T e st i ng). P 0405 Exhaus t ga s r e ci r cul a t i o n (EGR) se n s o r A ci rc ui t l o w EG R val [...]

  • Page 1381

    DT C C ondi ti o n Poss i bl e sourc e Act i o n P 0530 A i r condi t i oni ng r e f r i ge rant pr es s ure s e ns o r ci rc uit Ai r cond i t i oni ng p r es s ure se n s o r ci r cuit : hi g h r e s i s ta n ce Ai r cond i t i oni ng p r es s ure se n s o r ci r cuit : s hort c i r cuit t o g r ound Ai r cond i t i oni ng p r es s ure se n s o r[...]

  • Page 1382

    DT C C ondi ti o n Poss i bl e sourc e Act i o n Engi ne c o nt r ol m od ul e (ECM ) f aul t P 0623 Gene r at or wa r ni ng l a mp ci r cuit W a r ni ng la mp fa i l ur e W a r n i ng l a mp c i r cui t : hi gh res i s t a n c e W a r n i ng l a mp c i r cui t : sho rt ci r cuit t o gr ou nd W a r n i ng l a mp c i r cui t : sho rt ci r cuit t o p[...]

  • Page 1383

    DT C C ondi ti o n Poss i bl e sourc e Act i o n P 132B Turbocha r g e r b o os t s ys t e m perform a nce Memor y check fa i l ur e dur ing i ni t i a l i za t i o n Tur bocha r ge r va nes st i cking Tur bocha r ge r r ot a r y el e ctr o ni c a c t ua t o r in te r nal f a i l ur e Ca r ry o ut vi s ua l i nsp e ct i on of t he r o ta ry e le ct[...]

  • Page 1384

    DT C C ondi ti o n Poss i bl e sourc e Act i o n sho rt t o po we r Fai l ur e o f ECM Fai l ur e o f TCM P 1937 Fue l fi r ed hea t er (FFH) cont r ol c i r cuit FFH s upp l y or ground c i r cuit f a ul t FFH cont r ol ci r cui t : hi g h r e s i s ta n ce FFH cont r ol ci r cui t : s hort c i r cuit t o g r ound FFH cont r ol ci r cui t : s hort[...]

  • Page 1385

    DT C C ondi ti o n Poss i bl e sourc e Act i o n t he DTCs , t e s t f o r norm a l op erat i o n. P 2337 Cyl i nde r 2 a b ove k nock th r es hol d - knock s e ns o r t r im fo r cyli nd e r 2 (i nje ct o r 4) in val i d Nat ur al we a r o f t he in je ct o r Fuel cont a mina t ed Bl o c ked o r dirt y fu e l in je ct o r( s ) Inj ect or ci r cuit[...]

  • Page 1386

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ca msh aft Posi tio n (CMP) Sensor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r [...]

  • Page 1387

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ca talyt ic C on v erter Temperature S ensor Re moval a n d I ns t a l l a t i on Speci al T ool (s) Exhaus t g a s t e mperat ure s e nso r wrench 303-1184 R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove [...]

  • Page 1388

    4. Remove t he t urbocharger hea t s hi e l d. 5. D i s conne ct t he ca t a l yt i c c o nver t e r t e mpe r a t ur e s e ns or e l ect r i cal conne ct or. 6. Remove t he ca ta l yt ic convert er t e m pe r a t ur e s e ns o r . Insta llat ion 1. CAU TI O N : Make s ur e t h e t orque wr ench s e t t i ng procedur e i s fo l lo we d co r r ect l[...]

  • Page 1389

    2. CAU TI O N : Make s ur e t h e t orque wr ench s e t t i ng procedur e i s fo l lo we d co r r ect l y. Fai lure t o fo l l o w t hi s i ns t ru ct i on may r e s ul t i n d amage to the ve hi cle . I nst a l l t he cat a l yt i c co nverte r t empe rat ure s e ns o r . Ti ght e n t o 35 Nm. 3. Connect t he ca t a l yt i c c o nver t e r t e mpe[...]

  • Page 1390

    7. Ins t a l l the o i l l e v el i ndi c a t o r . JagDocs.com[...]

  • Page 1391

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Cra nkshaft Positio n (CKP ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he e l ect r i cal conne ct o r. 2. Remove and di s card t he cr anksh a ft po s i t i o n (CKP) s e ns o r . Insta l[...]

  • Page 1392

    3. Connect t he CKP s e ns or el e ct r i cal con nect o r . JagDocs.com[...]

  • Page 1393

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Cylin der Head Temperature (CH T) Senso r Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ock e t , CHT S e ns o r 303-680 (21 -239) R em ova l 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t [...]

  • Page 1394

    5. D et a ch t he cycli nde r he a d te mperat ur e (CHT) s e ns or e l e ct r i ca l conne ct or. 6. D i s conne ct t he CHT se ns o r e l e c t r i cal co nne cto r. 7. Usi ng t he s pe cia l t oo l 303-680, r e move t he CHT s e ns or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 1395

    2. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1396

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Dies el P articul ate Filter (DPF ) T emperature Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L[...]

  • Page 1397

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - En gine C ontro l Mo dule (EC M) Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o For a ddi ti ona l i nf o r m a t[...]

  • Page 1398

    6. D et a ch t he ge ne r i c e l e ct r o nic modul e (GEM ) f r om t he ECM . 1. Re l e a s e t he GEM l ocki ng t a ng. 2. De ta ch t he GEM f r o m t he ECM. 7. Remove t he ECM. 1. Re move t he ECM ret a i ni ng nut . 2. Re move t he ECM. 8. Remove t he ECM f r om t he ECM ret a i ni ng br acket . Insta llat ion 1. To i ns t a l l , rever s e t[...]

  • Page 1399

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - En gine Oi l Pressu re (EO P) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li[...]

  • Page 1400

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Fuel T emperature Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i [...]

  • Page 1401

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 15 Nm. JagDocs.com[...]

  • Page 1402

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Kn o ck Senso r (KS) Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n a[...]

  • Page 1403

    6. D i s conne ct t he e l ect r i cal conne ct o r. 7. Remove t he knock s e ns o r (KS ). Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 20 Nm. 2. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1404

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Manifo ld Abso lute Pressure and T emperature (MA PT) Sen sor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. Remove t he e ngi ne cover. 4[...]

  • Page 1405

    5. CAU TI O N : Make s ur e t h at th e radi a t o r i s not da mage d whe n in s t a l l in g t he ret a i nin g s t raps . Fit s ui t a bl e re t a i ni ng s t r a ps t o t he r a di a t o r. 6. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Jackin g (100-02 Ja ck i ng a nd Li f t i ng , Des cr ipt[...]

  • Page 1406

    11. Remove t he cha r ge a i r coo l e r ho se s and mani fo l d a bs o l ut e pre ss ur e a nd t e mperat ure (MAPT) s e ns or a s s e mbl y. 12. Remove t he MAP T s e ns or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 4 Nm. 2. Tig ht e n t o 25 Nm. JagDocs.com[...]

  • Page 1407

    3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. JagDocs.com[...]

  • Page 1408

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Manifo ld Abso lute Pressure (MA P) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he o i l f i l le r cap a [...]

  • Page 1409

    5. D i s conne ct t he ho s e . Det a ch t he r et a i ni ng cli p . 6. Remove t he MAP s e ns o r . Re mov e t he re ta i ni ng bo l t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 4 Nm. JagDocs.com[...]

  • Page 1410

    P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Mass Air Flo w (MA F ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. Remove t he e ngi ne cover. 4. D i s conne ct t he mas s a i[...]

  • Page 1411

    5. Remove t he mas s a i r f l ow (MAF ) s e ns or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 1412

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Lubr i cant , Sea le r s and Solve nts Descri pti on Speci f i ca ti on Hi gh-t e mpe rat ur e g r ea s e ES D-M 1 C220-A Met al s ur f a c e cl e a ner W S W -M5 B392- A S ea l a nt W SS -M4G 323 -A6 Fl ui d M a i nte[...]

  • Page 1413

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on D escriptio nV ehicl es Wi th: 5-Speed Auto mati c Tran saxle - JATC O Des cr ipt i o n a nd O pe r a t i o n Automa tic tra nsm ission JF5 06 E - Up To 200 9MY The ne wl y de ve l o pe d JF506E a ut o [...]

  • Page 1414

    t he re i s no p owe r fl o w t hrough t he a ut oma t i c t rans mi s s i o n. t he pa r king pa wl l o cks t he out put s ha ft t o t he cas e . t he e ngi ne may be s t art ed . t he i gni t i o n ke y m a y be r e moved . "R" I n t he REVERSE pos i t io n: t he v e hi c l e may be o pe r at e d i n a rearwar d di r e cti o n, a t a r [...]

  • Page 1415

    It e m Pa rt Nu mb e r De s cri pti on 1 — T o r que co nv e rte r 2 — T e r mina l as s e mbly 3 — P l a t e 4 — Re t ai ni ng bo l t 5 — I nhi b i t o r swi t ch 6 — Ma i n cont r o l va l ve bo dy cove r 7 — Ma i n cont r o l va l ve bo dy 8 — A i r br e a t he r 9 — A ut oma t i c t rans mi s s i o n fl ui d cha r ging pi p e [...]

  • Page 1416

    I te m P a rt Nu m ber Descri pti on 1 — O i l pump 2 — O i l s trai ne r 3 — I np ut s ha ft 4 — Di ff e r e nt i a l gea r 5 — Re duct io n gea r 6 — Re duct io n br ake b a nd 7 — Sun ge a r 8 — Di r e ct clut ch 9 — O ne -wa y cl ut ch i nne r race 10 — Pa rk i ng mechani sm 11 — Ba nd s e r vo 12 — M a nua l s ha f t 13[...]

  • Page 1417

    I te m P a rt N um be r D e s cri pti on 1 — TCM 2 — Ant i -lo ck Br aki ng S yst e m (ABS ) 3 — Engi ne Cont rol Modul e (ECM) 4 — D/4 s wi t ch, (t es t s wi t ch), s po r t s mode s wi t ch 5 — CAN (i nclud i ng t o rq ue down sw i t ch) 6 — Li ne pres s u r e s ol e noi d 7 — Lo ck -up s o l e noi d 8 — S hif t s ol e noi d A 9 [...]

  • Page 1418

    It e m Pa r t Nu m ber Desc ri pti o n 1 — T orque conver t e r 2 — Inp ut s haf t 3 — O ut pu t ge a r 4 — L ow cl ut ch 5 — L ow a nd r eve r s e b rak e 6 — Re a r pl ane t a r y pi ni o n ge ar 7 — L ow o ne-wa y cl ut c h 8 — Re a r i nt e rn al g e a r 9 — Re a r s un ge a r 10 — Fr on t s un gea r 11 — Fr on t in t e rn[...]

  • Page 1419

    23 — D ire c t clut ch 24 — Park ing g e a r 25 — Park ing p a wl 26 — Fina l ge a r 27 — D if fe rent i a l g e ar 28 — D r i ves h a ft Torque C onvert er It e m Pa rt N um be r Descri pti on 1 — Co nve r t er cl ut ch a nd d a mper 2 — Re act o r 3 — T urb i ne da mpe r 4 — I mpe l l e r 5 — Fl ui d mot i o n 6 — T rans m[...]

  • Page 1420

    It e m Pa rt Nu mb e r Desc ri pti on 1 — O i l s e a l 2 — O -r i ng 3 — O i l pump hous i ng 4 — I nne r r ot o r 5 — O ut er r ot o r 6 — O i l pump cove r 7 — Sea l ring 8 — Bo l t s A t r ocho i d o i l pump i s us e d wi t h JF506E a ut o mat i c t r a ns mis s i o n. T he t rochoi d o i l pu mp ha s t he a d v an t ag e of ve[...]

  • Page 1421

    Item Pa r t Nu m be r De s cri pti on 1 — Fr ont s un ge a r 2 — Fr ont p i ni on ge a r 3 — Rea r s un ge a r 4 — Fr ont i nt e r na l ge a r 5 — Rea r pi ni o n ge a r 6 — Rea r i nt e r nal ge a r The r e a re 3 pl ane t ary ge a r s e t s . Fr ont , rear a nd r e duct i o n. C lutch es The r e a re 4 we t t ype mult i d is c cl ut c[...]

  • Page 1422

    I te m P a rt N um be r Descri pti on 1 — H i g h cl ut c h pi s t o n 2 — Ca n ce l f o r ce 3 — H i g h cl ut c h pr e s s ure 4 — L ubr i cat i ng pres s ur e 5 — Ca n ce l f o r ce co ver The JF506E aut o mat i c t rans mis s i on is e qui pp e d wi t h t he ce nt rif uga l oi l p res s ur e canc el room i n l o w cl ut ch a nd hi gh [...]

  • Page 1423

    Item Par t Nu m be r Descri pti on 1 — Brak e b a nd e nga ge ment pres s ur e 2 — P is t o n s te m 3 — Tr an s mi s s i o n cas e 4 — Anchor en d b o lt 5 — Brak e b a nd 6 — Di r ect cl ut ch d r u m 7 — Brak e p i s t o n The br ake b a nd a cts i n res p o nse t o t he s e rv o t o s t o p t he di rect cl ut c h dr um r ot a t i [...]

  • Page 1424

    cam a nd i nne r r ace t he y a r e uni te d t o t r ans mi t to rque. I n t he r e ver s e di rect i on , be c a us e t he r ol l e r s move i n t he di r ect i on whe r e t he cle a r a nce i s l a r ge r , cl ea r a nces o cc ur be twe e n races and t he i nne r and o ut e r r aces ca n rot a t e t o e ach o t he r . Sp r ag - Ty p e One -Wa y C[...]

  • Page 1425

    I te m P a rt N um be r Descri pti on 1 — S ub lo we r body 2 — Br ack e t 3 — Cli p 4 — Li ne pr es s ure d ut y s ol e noi d 5 — Low cl ut ch t i mi ng s o l e no i d 6 — Br ack e t 7 — 2-4 br a k e dut y t i m i n g s o l e noi d 8 — 2-4 br a k e t i ming s ol e n oi d 9 — Pi l o t f i l t e r 10 — S e p a r a t e pl a t e A [...]

  • Page 1426

    21 — S e p a r a t e pl a t e C 22 — Uppe r bo dy 23 — Manual va l ve The r e a re 9 s ol e noi d s whi ch c a n b e cl a ss i f i e d as two t ype s b y t he wa y i n whi ch t he y o pe r a t e . Thr e e o f the m a r e dut y s o l e no i ds , t he o t he r s i x a re o n/of f t ype s . T he s o le no id s a re a ct ua t e d by t he TCM o ut[...]

  • Page 1427

    The TSS us e s a magne ti c coi l . As t he i np ut s ha f t r ot a t e s , th e s e ns or de t e c t s a pul se si g nal a ccor di ng t o t h e ge ar t e e t h on t he o ut si d e o f t he r e ver s e cl ut ch dr um a nd s end s i t to t he TCM. Ve hic le Sp e ed Sen sor The vehi cl e s p e ed s e ns o r (VS S) de t e ct s th e pa rk i ng ge a r r[...]

  • Page 1428

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Diagnos tic Stra te gyVehicles Wi th: 5- Speed A utom atic Trans axle - JAT CO Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the aut o mat i c t ran smi s s i o n/t r a[...]

  • Page 1429

    1 2 CAU TIO N : W hen probi ng conne ct o r s t o t a ke me a s ur e ment s i n t he co ur s e of t he p in po i nt t e s t s , use t he a d a pt o r ki t , part numbe r 3548-135 8-00 . • NO T E: Che ck and r ect i fy ba s i c f a ul t s bef or e be gi nni ng di a gnos t i c rout in e s i n v ol v i n g pi npo i nt t es t s. • NO T E: W he n pe[...]

  • Page 1430

    1 1 2 1 1 2 1 1 2 1 1 2 1 1 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s GO t o A 3 . No GO t o A 2 . A2 : CHEC K T HE LOW C LUT C H T IMI N G SOLENOID RESI ST ANCE. Mea s ur e t he res i s t a nce b et we e n t r a ns mis s i o n e l e ct r i cal conne ct o r JB155 pi n 18 a nd pi n 12 a t t he t rans m i s s i o n. I s t he r es i s t [...]

  • Page 1431

    2 1 1 2 3 1 2 1 2 1 2 1 2 1 2 Mea s ur e t he res i s t a nce b et we e n JB155, p in 18 (B) a nd JB131, p i n 17 (B). I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m fo r n [...]

  • Page 1432

    1 1 2 1 1 1 1 1 1 2 3 1 2 Ca r r y o ut t he a dj us t ment pr o ce dur e f o r t he t r a n s mi s s i o n r a nge s e ns o r . REFER t o T r ans mis s i on Ra nge (TR ) S e ns o r A dj us t me nt i n t hi s s e c t i o n. Re check t he ci rc u i t . I f s t i l l o pe n ci r cui t , INSTAL L a ne w t rans mi ss i on r ang e s e ns o r. REFER t o [...]

  • Page 1433

    1 1 2 3 1 1 2 1 2 1 1 1 2 Is t he res i s t a nce g r ea t er t h a n 5 o hms ? Ye s REP AIR t he hi gh r e s i s t ance ci rc ui t . Fo r a d di t i o na l i nf o r mat i o n, refe r to t he wi r i ng di a gr a m s . CL EAR t he DTC. TES T t he s yst e m f o r norm al op erat i o n. No GO t o E3 . E3: CHEC K D-4 S WI T C H S IGN AL WIRE F O R H I [...]

  • Page 1434

    1 2 1 1 1 2 1 2 1 1 1 2 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m fo r n or mal o perat i o n. No GO t o H3 . H2 : CHEC K T HE OU T PU T SPEED SEN SOR GR O UND CIRC[...]

  • Page 1435

    1 1 1 2 1 1 2 1 1 2 1 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m fo r n or mal o perat i o n. No GO t o J3 . J3: CHEC K T HE OIL T EMP ER AT UR E SEN SOR SI GNAL W I[...]

  • Page 1436

    1 1 2 1 1 2 1 1 2 1 1 2 1 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m fo r n or mal o perat i o n. No Cont a ct d e a l e r t e chn ical s upp ort f or a dvice o n po s s[...]

  • Page 1437

    1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 Cont a ct d e a l e r t e chn ical s upp ort f or a dvice o n po s s i b le modul e f ai lu r e. PINPOIN T TE ST O : P07 48 . LINE PRESS U RE CONTROL SO LENO ID MALFU NC TION T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS O1: C HEC K T HE LI NE PR ESSUR E CO NT R O L S OLE NOID GR O UND C IRC UIT . Di s conn ect t h[...]

  • Page 1438

    2 1 2 3 1 2 1 2 3 1 2 1 2 1 1 1 2 3 Mea s ur e t he res i s t a nce b et we e n JB155, p in 18 (B) a nd JB131, p i n 17 (B). I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m f[...]

  • Page 1439

    1 2 1 2 1 1 1 2 1 2 1 1 Does t he s ys t e m funct i on corr e ct l y? Ye s No f ur t he r act i on require d. No Cont a ct d ea l er t e chni cal s uppo rt fo r ad v i ce on po s s i bl e modul e f a i l u r e . PINPOIN T TE ST S : P07 91 . I NTERMEDIA TE SPEED SENS OR MALFU N CTION (F R OM VI N C7 93 29 ) T EST C ONDI T IONS DET AI LS /R ESULT S/[...]

  • Page 1440

    1 2 1 2 1 1 U1: CHEC K T HE T U R BIN E SPEED S ENSOR GR O UND C I R C UI T . Di s conn ect t he t r ans mi s s i o n e l e ct r ica l conne ct o r , JB155. Mea s ur e t he res i s t a nce b et we e n JB155, p in 01 (B) a nd GROU ND (s hi e l ded cabl e ). I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce [...]

  • Page 1441

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Flu id Drain an d Refill Gene ral P r ocedures D ra in 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o For a ddi ti ona l i nf o r m a t i o n, r e f e r [...]

  • Page 1442

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Flu id Level C heck Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. Connect t he Ja[...]

  • Page 1443

    11. Ins t a l l t he a ut omat i c t rans mi ss i on fl ui d cha r g i ng pi pe cap . 12. Lowe r t he vehi c l e . 13. Dis c o nne ct t he Ja gua r Appr o ved Dia gno st i c S y s t em. JagDocs.com[...]

  • Page 1444

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Range (T R) Senso r Adjustment Gene ral P r ocedures Speci al T ool (s) S e t t i ng p l a t e rot a r y s wi t ch 307-44 5 1. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r[...]

  • Page 1445

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Halfsh aft Seal L H I n-v e hi c l e Re pa i r Speci al T ool (s) Li nk s ha ft o i l s e a l ins t a l le r 205-115 P ini on o i l s ea l remover 308-208 R em ova l 1. D r ai n t he t rans mi s s i on. Fo r a ddi t i [...]

  • Page 1446

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Halfsh aft Seal RH I n-v e hi c l e Re pa i r Speci al T ool (s) Li nks haf t oi l s e al i ns t al l er 205-115 P ini on o i l s e al remover 308-208 1. D r ai n t he t rans mi s s i on. For a ddi ti ona l i nf o r m [...]

  • Page 1447

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Ma in Co ntro l Valve B ody I n-v e hi c l e Re pa i r R em ova l 1. D et a ch t he wi ring ha r ne s s . 2. Remove t he mai n val ve b o dy cover. Dr a i n t he trans mi s si o n f l ui d i nt o a s ui t a bl e cont a[...]

  • Page 1448

    4. D et a ch t he wi ring ha r ne s s . 5. Remove t he mai n co nt r ol val ve b od y. 6. Remove and di s card t he O -r ing s e a ls . Insta llat ion JagDocs.com[...]

  • Page 1449

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ins t al l t he n e w O -r ing s e a ls . 2. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 8 Nm. 3. Tig ht e n t o 8 Nm. JagDocs.com[...]

  • Page 1450

    4. NOT E: Appl y a n e v e n be a d o f s i l i con e ga ske t s e al a nt W S E-M 4G 323-A6 or eq ui val ent mee t i ng Ja gua r s pe ci fi cat io n t o t h e mai n val ve bo dy cove r s ea l i ng s u r f a c e . Ti ght e n t o 8 Nm. 5. Ch eck a nd a dj us t t he t rans mi s s i on fl ui d l e v el . For a ddi t i o na l i nf o r ma t i o n, r e f[...]

  • Page 1451

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Shift Solen oi ds (SS) I n-v e hi c l e Re pa i r R em ova l 1. Remove t he mai n co nt r ol val ve b od y. For add i t i o na l i nf orm a t i o n, r e fe r t o Mai n Co nt r ol Va l ve B od y . 2. D i s conne ct t he[...]

  • Page 1452

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transax le Support In sul ator I n-v e hi c l e Re pa i r Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, [...]

  • Page 1453

    4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 5. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 6. D et a ch t he s up po r t b a r . 7. Remove t he s up port b a r . JagDocs.com[...]

  • Page 1454

    8. Remove t he s p a c e r. 9. Remove t he t r a ns a xl e s uppo rt i ns ul a t o r. Re mov e t he t rans a xle s u pport i ns ul a t or ret a i ni ng nut s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 47 Nm. 2. Tig ht e n t o 133 Nm. JagDocs.com[...]

  • Page 1455

    3. Tig ht e n t o 25 Nm. JagDocs.com[...]

  • Page 1456

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on C ontrol Modul e (TC M) I n-v e hi c l e Re pa i r R em ova l 1. Remove t he rai n s e ns or modul e. Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S ect i o n 501-16 W i pers a nd W as h e r s . [...]

  • Page 1457

    4. Remove t he TCM. 1. Dis con nect t he e l e c t rical co nnect or. 2. Re move t he T CM. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 1458

    2. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1459

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Range (T R) Senso r I n-v e hi c l e Re pa i r R em ova l 1. Remove t he ba t t e r y t ray . Fo r a d di t i o na l i nf o r mat i on , refe r t o S ect io n 414-01 Bat t e ry , Mount i ng a nd Ca bl e[...]

  • Page 1460

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transax le Re moval Speci al T ool (s) S li de ha mm er 100-012 100-012- 02 S li de ha mm er s ha f t Ha l f s ha f t r emove r fo rk 204-226 P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 P ini on o i l s ea l remover[...]

  • Page 1461

    3. Loos e n t he l e ft -hand s ho ck a bs orber an d s pr i ng a s s e m bl y s e cur i ng nut s . 4. Loos e n t he r i ght -ha nd s ho ck abs o r b e r and s pr i ng a s s e mbl y s e cur i ng nut s . 5. Remove t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L NA V 6 - AJV6/2.5L N A V6 - AJV [...]

  • Page 1462

    8. Remove t he s t ee ring ge a r he a t s hi e l d. 9. Remove t he t r a ns f e r cas e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans fe r Cas e (308-0 7 T r ans fe r Ca s e, Re moval ). Vehi c le s with 2.0L engi n e 10. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i c[...]

  • Page 1463

    13. NO TE: P l ug the t rans a xle t o p revent fl ui d l os s o r di r t i n gr es s . Us i ng t he s p e ci a l t o ol s , de ta ch t he l e f t -han d hal fs ha ft . 14. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res u[...]

  • Page 1464

    18. NO TE: Ro t a t e t he t o r que co nverte r t o g a i n a cces s f o r the remai ni ng r e t a i ni ng bo l t s . Re move t h e t o rqu e conve r t e r r et ai ni ng bo l t s . 19. NO TE: L owe r tran sa xl e fl ui d co ol e r t ube s ho wn, uppe r t r ans axl e fl ui d c oo l er t u be s i mi la r. • NO T E: P l ug t h e t r ans axl e fl ui[...]

  • Page 1465

    24. Ins t a l l t he e ngi ne s up port b r acket . 25. Det a ch t he pos i t ive crankcas e vent i la t i o n (P CV ) hos e from t he i nt a k e m a ni f o l d. 26. Det a ch t he el e ct r i cal co nnect o r fr om th e i nt a ke mani fo l d s uppo r t br acke t . 27. Remove t he i nt a ke mani f o l d s up port b r acket . 28. Det a ch t he wi rin[...]

  • Page 1466

    29. Ins t a l l t he e ngi ne s up port b r acket . 30. Ins t a l l t he e ngi ne s up port b r acket . Adj us t th e e ng i ne s upp or t bracket t o s upp or t t he we i g ht o f t he pow ertrai n as s e mbly. 31. Remove t he s uppo rt ba r r et a i ni ng b o l t s . 32. Remove t he s uppo rt i ns ul a t or ba r. 33. Ins t a l l t he s up port i [...]

  • Page 1467

    34. Det a ch t he s t ar t e r moto r s o l e no i d cover. 35. Det a ch t he s t ar t e r moto r e l e ct r i cal c onn e cto r . 36. Det a ch t he s t ar t e r moto r s o l e no i d e l ect r i cal co nne cto r. 37. Remove t he s uppo rt ba r mount bracket /t r ans a xle uppe r r et a i ni ng bol t . 38. Remove t he s uppo rt ba r mount bracket .[...]

  • Page 1468

    39. Remove t he s t arte r mot o r . 40. Det a ch t he t rans a xle ground l e a d. 41. Remove t he t r ans a x l e ret a i ni ng bol ts . 42. Remove t he t r ans a x l e mount br a ck et s e cur ing bol t s . 43. Rai se th e v e hi cl e . 44. NO TE: T he t r ans a x l e ret a i ni ng b ol t r e mai ns cap t i ve t o t he cy l i nde r bl o ck f l a[...]

  • Page 1469

    45. Remove t he t r ans a x l e ret a i ni ng bol ts . 46. Al i gn t he po we r t r a i n a s s e mbl y j a ck t o t he t rans a xle . S ecur e t he t rans a xle t o t h e po we rtr a i n a s s e mbl y j a ck . 47. Remove t he t r ans a x l e ret a i ni ng bol t. 48. NO TE: Ca rr y t his s t e p i f a n ea rly co ndi t i o n t r ans axl e is be i n[...]

  • Page 1470

    50. NO TE: Ca rr y t his s t e p i f a l a t er cond it i o n t r ans axl e i s be i ng r emove d. • NO T E: Ve hicl e s wi t h 2. 5L a nd 3.0L e ngi ne s s ho wn, ve hi cl e s w i t h 2.0L e ngi ne s i mi l a r . Re move t h e t rans a xle r e t a i ni ng bo l t . 51. W A RNING: Do not l e t t he t o r que co nv e rte r dr op out of t he tra nsa[...]

  • Page 1471

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Input Shaft S eal Dis a s s e mbl y a nd As s e mbl y o f Sub a s s e mbli e s Speci al T ool (s) Li nk s haf t o i l s e al i n st a l l er 205-11 5 1. Remove t he t r a ns mis s i o n a s s e mbly. Fo r ad di t i on [...]

  • Page 1472

    6. CAU TI O N : Do no t l e t t he t orque conve r t e r dr op o ut o f t he tra nsmi s si o n. Fai l ur e to fo l l o w t hi s i ns t r ucti o n may res ul t i n p e rson a l in j ur y. • NO T E: T he t o rqu e conve r t e r hub must eng a ge f ul l y i n t he o i l pump drive gea r. I nst a l l t he t o rque conve r t e r . 7. Ins t a l l the t[...]

  • Page 1473

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transax le I nst a l l a t io n Speci al T ool (s) Ha l fs ha ft o i l s e a l ins t a l le r 205-115 P owe r t r ai n a s s embl y j ack HTJ1200-2 Engi ne sup po r t b rack et 303-021 Engi ne sup po r t b rack et s 30[...]

  • Page 1474

    4. W ARNING: Do not l e t t he t o r que co nverte r drop o ut of t he tra nsa xl e . Fa i l ur e t o f ol lo w t hi s i ns truc t i o n may r e s ul t i n p e r s o nal i njur y. I nst a l l t he t rans a xle . 5. NOT E: Carr y o ut t hi s s t ep i f a la t e r co ndi t i on t r a ns a xl e i s be i ng in s t a l l e d. • NO T E: Ve hicl e s wi [...]

  • Page 1475

    9. Remove t he po we r t r ai n a s s e mbl y j a ck. Re mov e t he t rans a xle t o t h e po we r t r ai n a ss e mbly ja ck s ecur i ng s t rap. 10. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 11. Ins t a l l t he t r a ns a xl e ret a i ni ng nut . Ti ght e n t o 48 Nm. 12. Lowe r t he vehi c l e . 13. Ins t a [...]

  • Page 1476

    14. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 15. At t ach t he t r ans a xle gr oun d l ea d . Ti ght e n t o 25 Nm. 16. Ins t a l l t he s t arte r mot o r . Ti ght e n t o 35 Nm. 17. Ins t a l l t he s up port b a r m o unt bracket . Ins t al l t he s t a r t e r mot o r f r o nt r e t a i ni ng bo l t . Ti g[...]

  • Page 1477

    19. At t ach t he s t arte r mot o r s ol e noi d e l e ct rica l conne ct o r . Ti ght e n t o 6 Nm. 20. At t ach t he s t arte r mot o r e l e ct rica l co nnect o r . Ti ght e n t o 12 Nm. 21. At t ach t he s t arte r mot o r s ol e noi d co v e r. 22. Remove t he s uppo rt i ns ul a t or r e t a i ni ng nut . 23. Ins t a l l t he s up port i ns[...]

  • Page 1478

    24. Ins t a l l t he s up port b a r r e ta i ni ng bo l t s . Ti ght e n t o 25 Nm. 25. Remove t he e n gi ne s upp ort br a cket . 26. Remove t he e n gi ne s upp ort br a cket . 27. At t ach t he wi r i ng harnes s from t he camsh a f t cover r et a i ni ng s t ud. Ti ght e n t o 6 Nm. 28. Ins t a l l t he i nt a ke man if ol d s upport br acket[...]

  • Page 1479

    29. At t ach t he e le ct r ica l conne ct o r t o t he i nt a ke mani fo ld s upport bracket . 30. At t ach t he p o s i t i ve cr a n kc as e ve nt i la t i o n (P CV) ho s e t o t he i nt a k e m a ni f o l d. 31. Remove t he e n gi ne s upp ort br a cket . 32. Ins t a l l t he a ir cl e a ne r moun t br acket . Ti ght e n t o 6 Nm. 33. At t ach[...]

  • Page 1480

    34. Rai se th e v e hi cl e . 35. Conne ct t he t r ans a xle e l e ct rica l c o nne ct or s . 36. Conne ct t he t r ans a xle f l ui d c oo l e r t ube s . 37. NO TE: Ro t a t e t he t o r que co nverte r t o g a i n a cces s f o r the remai ni ng r e t a i ni ng bo l t s . I nst a l l t he t o rque conve r t e r r e t ai ni ng b ol t s . Ti ght [...]

  • Page 1481

    40. Ins t a l l a n ew ha l f s ha f t s na p ring. 41. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s . Det ach t he ha l f s haf t . 42. CAUTI O N S : Make s ur e t he ha l f s haf[...]

  • Page 1482

    44. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w ha l f s ha ft s e a l. 45. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s . At [...]

  • Page 1483

    49. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he f e nde r s pl a sh sh i e l d a cces s pa ne l . 50. Ins t a l l t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L NA V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ27 (502- 00 U ni -Bod y, S u bf r a m e a nd Mo unt i[...]

  • Page 1484

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Lubr i cant , Sea le r s, So l vent s and Ad hesi ves Desc ri pti on Speci fi cati on Hi gh-t e mpe rat ur e g r ea s e ES D- M1C220- A Met al s ur f a c e cl e a ner W S W -M5 B392-A S ea l a nt W S K-M4G 320 -A Adhe [...]

  • Page 1485

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Descriptio n Vehicl es With: 6- Speed A uto mati c Tran saxle - A WF21 Des cr ipt i o n a nd O pe r a t i o n C OMPONENT L OC ATION - A W F21 6 SPEED A U T OMATIC TRA NSMIS SIO N 200 9 MY Item Pa r t Nu[...]

  • Page 1486

    Des i gne d t o be mai nt e nance f r ee To r que ca pa cit y o f 450 Nm Tr an s mis s i o n f l ui d i s fi ll f o r l i f e The t or que conver t e r fe a t ure s a co ntrol l e d s l i p f e a t ur e wi t h e l e ct r oni ca l ly r e gul a t ed l o ck -up co nt rol o n g e a r s 2 t o 6 S hif t pr ogr a ms cont rol l ed by t he TCM TCM ha s a n [...]

  • Page 1487

    For add i t i o na l i nf or m a t io n, ref er t o : Tr an s mis s i o n Co o l i ng - Ve hi cl e s W it h: 6-S pe e d Aut o mat i c Tr an s a xl e - A W F 21 (307-02B Tr an s mis s i o n/Trans a xle Coo l i ng - Ve h icl e s W i t h : 6-S p e e d Aut o mat i c Trans a xl e - AW F21, Des cr ipt i o n a nd O pe rat i o n). TORQUE CO NVERTER I te m [...]

  • Page 1488

    Item Par t N u m ber Desc ri pti on 1 - 3-W a y s o le no id - S2 2 - Shif t cont r ol s ol e noi d - SLC2 3 - Shif t cont r ol s ol e noi d - SLC1 4 - V a l ve bl ock 5 - L o c k-up cont r ol s o l e no i d - SLU 6 - Shif t cont r ol s ol e noi d - SLC3 7 - Shif t cont r ol s ol e noi d - SLB1 8 - 3-W a y s o le no id - S1 9 - L i ne p res s ur e [...]

  • Page 1489

    I te m Par t Nu m ber Desc ri pti o n 1 - S p e e d S e ns or (S P) - O ut put s haf t s pe e d 2 - Count er drive ge a r 3 - C2 clut ch drum 4 - S p e e d s e n so r (NIN) Two s pe e d s ens o r s (NIN a nd S P) a r e us e d i n t he t rans mi s s i on a nd a r e l o ca t e d wi thi n t he t rans m i s s i o n ho usi ng. S pe e d s e ns o r (S P )[...]

  • Page 1490

    7 - Di a phragm s pr i ng 8 - O ut put s ha f t 9 - Be a r i ng 10 - Dy na mic pres s ur e e qual i s a t i on chambe r 11 - Pi s t on chambe r 12 - Lubr i cat i o n cha nne l The r e a re t hr e e dr i ve cl ut che s a nd t wo br a ke clu t che s (B 2 i s a mul t i pl a t e br a ke clu t ch & B 1 i s a do ubl e wrap br ake b a nd) us e d i n t[...]

  • Page 1491

    Item Pa rt N um ber Descri pt i on 1 - Cl ut ch C2 2 - B rak e B2 3 - O ne wa y cl ut ch F1 4 - Co unt e r drive g e a r 5 - B rak e B1 6 - Cl ut ch C1 7 - Cl ut ch C3 8 - Fl ui d pump 9 - I n put s ha f t 10 - Di ff e r e nt i a l ge a r a s s e mbl y 11 - Coun te r ge a r a ss e mbly 12 - P i ni o n ge a r s 13 - S un ge a r s 14 - Ri ng g e ar 1[...]

  • Page 1492

    It e m Pa r t Nu m be r De scri pt i o n 1 - Clut ch - C2 2 - Br ake - B2 3 - One -wa y cl ut ch - F1 4 - Br ake - B1 5 - Clut ch - C1 6 - Clut ch - C3 Pow er F low - 1 s t Ge ar Eng in e B raki ng So l enoi d O perat ion T ra ns m i ss i on Sel ector Lever Posi ti on Sol e noi d SLC 1 SLC 2 SLC 3 SLB 1 S1 S2 D Eng in e Brake - X X X X X X = O pe r[...]

  • Page 1493

    The i nput s haf t r ot a t e s i n a cl ockwis e di r e cti on, d riven by t he t o rque conve r t e r . T h e pl a ne ta r y r i ng ge a r r ot a t e s i n a cl o ck wi s e d i r e ct io n a l on g wit h t he pl a ne t a ry pin i on gea r whi ch al s o r ot a t e s cl o ckwis e o n i t s axi s a nd o r bit . T he pl a ne t a ry s un g e ar i s l [...]

  • Page 1494

    wit h t he pl a ne t a ry pin i on gea r whi ch al s o r ot a t e s cl o ckwis e o n i t s axi s a nd o r bit . T he p la n e t a ry s un g e ar i s l o cked by t he fl ui d p ump whi ch caus e s i t t o pr e s s a ga i ns t t h e pl a ne ta ry r i n g g e a r an d orbit t he s un ge a r, r ot a t i ng o n i t s a xis . The front p la n et a r y ca[...]

  • Page 1495

    The i nput s haf t r ot a t e s i n a cl ockwis e di r e cti on, d riven by t he t o rque conve r t e r . T h e pl a ne ta r y r i ng ge a r r ot a t e s i n a cl o ck wi s e d i r e ct io n a l on g wit h t he pl a ne t a ry pin i on gea r whi ch al s o r ot a t e s cl o ckwis e o n i t s axi s a nd o r bit . T he pl a ne t a ry s un g e ar i s l [...]

  • Page 1496

    - I nput : Midd le s un ge a r - Lo cked: Ca r r ie r - O ut put : Ri ng ge a r Fr o nt P l a ne ta ry Ge a r Tr a in The i nput s haf t r ot a t e s i n a cl ockwis e di r e cti on, d riven by t he t o rque conve r t e r . T h e pl a ne ta r y r i ng ge a r r ot a t e s cl ockwi s e wi t h t he i npu t s haf t. The pi ni o n ge a r r ot a t e s cl[...]

  • Page 1497

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on E lectro nic Co ntrol S ystemVe hicl es Wi th: 6-S peed A utom atic T ransaxle - AWF2 1 Des cr ipt i o n a nd O pe r a t i o n C ONTROL DIAGRA M - AW F21 6 SPEED AUTOMATIC TR ANSMIS SION 2 00 9 MY • N[...]

  • Page 1498

    Item Par t N um be r Descri pti on 1 - TCM 2 - ' Ne ut r al 'N' p os i t i o n 3 - Pa r k 'P' po s i t i o n 4 - Po s i ti o n s e ns o r /m anua l sha f t 5 - Ele ct rica l conne ct o r The TCM (t rans mi s s i on co nt r ol modul e ) i s l o ca t e d on t he t o p of t he t rans mi s s i o n ca s i ng a nd i s c o nne ct [...]

  • Page 1499

    For add i t i o na l i nf or m a t io n, ref er t o : Comm uni cat i o ns Ne t wo r k (418- 00 Modul e Co mm unica t i o ns Net wo r k, De s cr ip t i o n a n d O p e rat i on ). I n t he e vent of CAN bu s f ai lure, t he f ol l o wi ng s y mpt o ms may be o bs e r v e d: Tr an s mis s i o n o p e r at e s i n de f a ul t mode To r que co nverte r[...]

  • Page 1500

    Fa st o f f r eco gni t i on mod e a s si s t s ve hi cl e s t a bi l i ty a nd i s us e d i n conj unct i on wi th a l a t e r al a ccel e rat i o n i npu t dur ing co r nering t o mai nt a in t he cur r e nt g e ar unt i l t he c orner i s ne got i a t e d. Up h ill and Trailer Up hi l l a nd t r ai l e r m o de ca n be a cti ve whe n t he t rans[...]

  • Page 1501

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Diagnos tic S trategy Vehic les Wi th: 6-S peed A utom atic T ransaxle - AWF 21 Dia gn os i s a nd Te s t i ng Principles of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he a ut o mat i c t rans mi s s i[...]

  • Page 1502

    DT C D escri pti on P ossi bl e C ause Act i on Tr an s mis s i o n f l ui d l e ve l l ow Tr an s mis s i o n f l ui d cool e r /h o s e s a r e o bs t r u cte d , da mage d, b l ocke d Mechani ca l fa u lt i n t he t r a nsmi s s i o n Engi ne cool i ng s ys t e m fa i l ur e a nd i ns t a l l a new T CM/ t r a ns mis s i o n a s r e qui r ed , r[...]

  • Page 1503

    DT C D escri pti on P ossi bl e C ause Act i on modul e/co mponent i ns t al la t i o n no t e a t the t o p o f t h e DTC I ndex. Re f e r t o s e r v i ce r ou ti ne s a t the t op o f t he DTC I nde x a nd ca r r y out s e rv i ce r out i ne s a s r e qui red us ing t he ma nufa ct urer a ppr o ved di a gnos t i c s yst e m P 071200 Trans mi s s[...]

  • Page 1504

    DT C D escri pti on P ossi bl e C ause Act i on S hor t t o gr ound o n CA N ci r cuit be t we e n ECM a nd TCM P 072900 Gea r 6 I ncorr e ct Ra t i o Incor r e ct ly r e gul a t i ng s o l e no i d Mechani ca l fa i l ur e i n t r a nsmi s s i o n Tr an s mis s i o n co mpone nts wor n caus in g l o w s yst e m fl ui d pr es s ur e a nd s l i p S [...]

  • Page 1505

    DT C D escri pti on P ossi bl e C ause Act i on P 074100 To r que Co nve r t e r Cl ut ch S ol e no i d Ci r cuit P e r fo r mance/S t uck O ff Hi gh cont a ct res i st a nce i n t he conne ct or t erm i nal s Op e n ci rc ui t of S LU ci r cui t o f lo ck up co ntrol s o l e no i d Fa il ure o f SLU lo ck up s o l e no i d S LU l o ck up s ol e no[...]

  • Page 1506

    DT C D escri pti on P ossi bl e C ause Act i on Mechani ca l fa i l ur e i n t r a nsmi s s i o n P 074E00 Un a bl e t o En ga ge Gea r 6 Hi gh cont a ct res i st a nce i n t he conne ct or t erm i nal s C2 pres s ur e cont rol SL C2 s o l e noi d ha s s t uck i n o ff po s i t i o n B1 p r es s ur e cont rol S LB1 s o l e noi d ha s s t uck i n o [...]

  • Page 1507

    DT C D escri pti on P ossi bl e C ause Act i on val ue wa s e xpe ct e d S hor t t o po we r on t he L I N comm unica t i on ci r cuit be t we e n t he T CM and GS M I nt e r nal f a i l ur e i n GS M I nt e r nal f a i l ur e i n T CM r e fe r t o t he new modul e /compone nt ins t a l l a ti o n no t e a t t he t o p o f t he DTC Ind e x. Re f e [...]

  • Page 1508

    DT C D escri pti on P ossi bl e C ause Act i on conne ct or t erm i nal s Op e n ci rc ui t on t he S FL s hi ft l o ck circ ui t b et we e n t he TCM a nd GS M Op e n ci rc ui t on t he gr ound circ uit be t we e n t he GS M a nd gr ound s tud I nt e r nal f a i l ur e i n GS M P 093011 Gea r S hif t Lock S ol e no i d/A ctu a to r Ci r cuit A Low[...]

  • Page 1509

    DT C D escri pti on P ossi bl e C ause Act i on P 096900 P r es s ur e Cont r o l S ol e no i d C Co nt rol Ci r cuit Ra nge /Pe r f or mance Hi gh cont a ct res i st a nce i n t he conne ct or t erm i nal s be t we e n TCM a nd t r a ns mis s i o n op en ci r cuit o f i nt e r na l wiring fo r S L C2 co nt rol s ig na l ci r cuit op en ci r cuit o[...]

  • Page 1510

    DT C D escri pti on P ossi bl e C ause Act i on ob s t r uct e d/dama ge d /bl o c ked Mechani ca l fa i l ur e o f t r a nsmi s s i o n Tr an s mis s i o n ha s b e e n e xpos e d t o e xces s i ve hi gh lo a d a nd hi gh a m bi e nt t e mperat ure gr e a t e r t ha n 150 de gree s C (302 de gree s F) ou t s e r vice rout i nes as r eq ui red usi [...]

  • Page 1511

    DT C D escri pti on P ossi bl e C ause Act i on P 273300 P r es s ur e Cont r o l S ol e no i d F S tu ck On S LC1 pr e s sure cont r ol no t e ngag e d i n dr i ve Mechani ca l fa u lt i n t he t r a nsmi s s i o n S us pe c t t he t r ans m i s s i on, c he ck a nd i ns t al l a ne w t r a ns mi s s i o n a s r e qui r e d, ref e r t o t he ne w [...]

  • Page 1512

    DT C D escri pti on P ossi bl e C ause Act i on pa r t o f t he CAN ne t wo rk I nt e r nal f a i l ur e i n T CM car ry o ut s e r vi ce rout i ne s a s requi r e d us i ng t he manu f act ur e r a ppr oved di a gnos t i c s yst e m U210511 S wi t ch P a ck Signa l "A" Ci rc u i t s hort t o g r o und. T he TCM ha s de t e ct ed a g r ou[...]

  • Page 1513

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Fluid Drain a nd Refill Gene ral P r ocedures W ARNI N G: O b se r v e due care whe n dr a i n ing , as t he f lu i d can b e ve r y hot . 1. E ns ur e t ha t t he a ut o mat i c t r a n s mis s i o n i[...]

  • Page 1514

    11. Remove t he t r ans mis s i o n f l ui d dr ai n p l ug. Al l ow t he t rans mi s s i o n fl ui d t o drai n. 12. NO TE: I ns t a ll a new g a ske t . I nst a l l t he t rans mi s s i o n f l ui d dr ai n pl ug. Ti ght e n t o 47 Nm. 13. Lowe r t he vehi c l e . 14. Fi ll t he t rans mis s i o n wi t h t he co r r ect f l ui d unt i l i t r u n[...]

  • Page 1515

    18. S e cur e t he b a t te r y carr i er brack et . Ti ght e n t o 25 Nm. 19. Ins t a l l t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n). 20. Conne ct t he Ja g uar ap pr ove d di a gn os t i c e qu ip ment . [...]

  • Page 1516

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Fluid L ev el C heck Gene ral P r ocedures W ARNI N G: O b se r v e due care whe n dr a i n ing , as t he f lu i d can b e ve r y hot . 1. E ns ur e t ha t t he a ut o mat i c t r a n s mis s i o n i s [...]

  • Page 1517

    13. S e cur e t he b a t te r y carr i er brack et . Ti ght e n t o 25 Nm. 14. Ins t a l l t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n). 15. Conne ct t he Ja g uar ap pr ove d di a gn os t i c e qu ip ment . [...]

  • Page 1518

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Main Co ntrol Va lve B ody I n-v e hi c l e Re pa i r R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . 2. Remove t he t r a ns mis s i o n f l ui d p a n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T [...]

  • Page 1519

    6. CAU TI O N : Dis card t he bo l t s. Re move t h e s ucti o n cover. Re mov e t he 2 bol ts . Re mov e a nd di s c a r d t he gas ke t. 7. CAU TI O N : Dis card t he bo l t s. • NO T E: W i t h eve ry pas s , un do t he bol ts o ne t ur n a t a t i me al t e rnat e l y. Re l e a s e t he t rans mi s s i o n mai n cont r ol va lve b o dy. Re mo[...]

  • Page 1520

    2. CA UT I O NS: Make s ur e t ha t new b ol t s a r e ins t a l l e d. O nl y ti ght e n t he b ol t s fi nge r- t i ght a t thi s s t a ge . S ecur e t he t r an smi s s i o n mai n co nt r ol va l ve bo dy. 3. CA UT I O NS: Make s ur e t ha t new b ol t s a r e ins t a l l e d. O nl y ti ght e n t he b ol t s fi nge r- t i ght a t thi s s t a ge[...]

  • Page 1521

    5. CAU TI O N : Make s ur e t h at th e s e compone nt s are i n st a l l ed t o t he not e d removal po s i t i o n. S ecur e t he t r an smi s s i o n i nt e r na l wiring harnes s . S ecur e i n t he cl i ps . Conne ct t he e l e ct r i cal co nnect o rs . Ti ght e n t he b ol t t o 10 Nm. 6. Connect t he e l ect r i cal co nnect o r. 7. Ins t a[...]

  • Page 1522

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Selecto r Shaft S eal I n-v e hi c l e Re pa i r R em ova l • NO T E: Re moval s t e ps in t hi s p rocedur e may cont a in i nst a l l a t i on det a i l s. 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For[...]

  • Page 1523

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on C o ntrol Module (TC M) I n-v e hi c l e Re pa i r R em ova l 1. Remove t he cover a nd d i s co nnect t he ba t t e r y ground ca b le . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e[...]

  • Page 1524

    2. Ins t a l l the t r a n s mis s i o n s e l ect or l e v e r and co nnect t he e l e ctrica l conne ct or. Ti ght e n t he nut t o 13 Nm. 3. S e cur e and c onn e ct t he s e l e ct or l e ve r cabl e. 4. Ins t a l l the ba t t e r y t ray. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i n[...]

  • Page 1525

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Internal W i ring Harness I n-v e hi c l e Re pa i r R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . 2. Remove t he t r a ns mis s i o n cont rol modul e (TCM). For a ddi ti ona l i nf o r m a t i[...]

  • Page 1526

    1. CA UT I O NS: Make s ur e t ha t the wi ring ha r ne s s do e s not cat ch. Th e co mponen t must b e a l i gne d wi t h t he i ns t a l l a t i o n mark i ngs . I nst a l l t he t rans mi s s i o n i nt e r nal wi ring ha rn e s s . S ecur e wi t h t he cl i p. 2. CAU TI O N : Make s ur e t h at th e s e compone nt s are i n st a l l ed t o t h[...]

  • Page 1527

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Fluid Pan I n-v e hi c l e Re pa i r R em ova l • NO T E: Re moval s t e ps in t hi s p rocedur e may cont a in i nst a l l a t i on det a i l s. 1. Rai s e a nd s uppo r t the ve hi cle . 2. D r ai n[...]

  • Page 1528

    1. CAU TI O N : Make s ur e t h at th e mat i ng f a ces are cl e a n a nd f r ee of fo rei gn mat e r i a l . App l y s i l ico ne ru bbe r s e al a nt t o t he t r a ns mis s i o n f l ui d p a n. 2. Ins t a l l the t r a n s mis s i o n f lui d pa n. Appl y Lo cti t e 243 t o t he t rans mi s s i on f l ui d pan bo l t th r e ads . Ti ght e n t [...]

  • Page 1529

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - To rque C onverter Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . 2. Remove t he t r a ns mis s i o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans m i s s[...]

  • Page 1530

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - To rque C onverter Seal Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . 2. Remove t he t o r que co nverte r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: To r que [...]

  • Page 1531

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Turbine Sh aft Speed (TSS) S enso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he mai n co nt r ol val ve b od y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Mai n Cont r ol V a l ve Bo dy [...]

  • Page 1532

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Re moval Speci al T ool (s) I m pul s e e xt racto r 100-012( LRT-99-00 4) S l i de Ha mm er S ha ft - 100-012- 02 Ha l fs ha f t Re mover Fork - 204-226 P owe r trai n as s e mbly j a c k HTJ1200-2 Eng[...]

  • Page 1533

    7. Usi ng t he s pe cia l t oo l s, re l e a s e t he LH ha l f s ha f t . 8. CAU TI O N : Make s ur e t h e ha l f s ha ft cons t a nt ve lo ci t y (CV) j o i nt s do not over a r t i cula t e . Fa i l ur e t o f o l l ow t hi s i ns t r ucti o n may res ul t in da mag e to the CV j o i nt s . Us i ng a s ui t a b l e t i e s t r a p, s upp o r t [...]

  • Page 1534

    11. Rel e as e t he e m i s s i on c o nt r ol val ve . Re mov e t he 2 bol ts . P os i t i on a s i d e. 12. Rel e as e co o l a nt pi pe f r om t he e ngi ne . Re mov e t he 2 bol ts . 13. Remove t he f l e xpla t e c ove r . JagDocs.com[...]

  • Page 1535

    14. Rel e as e t he t o r que co nverto r from t he f l e xpl a t e . Re mov e t he 6 bol ts . 15. Dis c o nne ct t he 2 trans mi s s i on f l ui d co o le r tu be s . Re mov e t he 2 Torx bo l t s . P os i t i on a s i d e. 16. Lowe r t he vehi c l e . 17. Dis c o nne ct t he t r ans mis s i o n co nt rol modul e (T CM) el e ct r i cal co nnect or[...]

  • Page 1536

    19. Rel e as e t he t r ans mis s i o n s e l e ct or l e v e r cabl e f r om t he TCM . Re mov e t he nut . Re l e a s e t he s e l e ct or cabl e a nd l e v er. P os i t i on a s i d e. 20. Dis c o nne ct t he b a t t e r y ground cab l e. Re mov e t he b o l t . 21. Us i ng t he s pe ci a l t o o l , sup po r t t he e ngi ne a nd t r a ns mis s [...]

  • Page 1537

    22. Rel e as e t he t r ans mis s i o n mo unt i ng. Re mov e t he nut . 23. Lowe r t he e ngi ne s uffi ci e nt l y a l l owi ng t he t rans mi s s i o n a s se mbl y t o cle a r the mount i ng. 24. Remove t he 3 t rans mi s s i on a s s e mbly uppe r bo lt s . 25. Rai se th e v e hi cl e . 26. Remove t he 2 t rans mi s s i on a s s e mbly r ea r [...]

  • Page 1538

    27. NO TE: Som e varia t i o n i n t he i l l ust rat i o ns may occur , b ut t he e s s e nt i al in f orm a t i o n i s a l wa ys corr e ct . Al ig n t he po wert r ai n as s e mbly ja ck t o t he t rans mi s s i on. S ecur e t he t rans mi ss i on t o t he p o we rtrai n a s s embl y j ack. 28. Remove t he 4 t rans mi s s i on a s s e mbly l o w[...]

  • Page 1539

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on I nst a l l a t io n Speci al T ool (s) P owe r t r ai n a s s e mbl y ja ck HTJ1200 -2 Engi ne s uppo r t b rack e t 303-02 1 Insta llat ion 1. Ins t a l l the t r a n s mis s i o n. Ra is e t he pow e[...]

  • Page 1540

    3. Ins t a l l the t r a n s mis s i o n as s e mbly rea r bo l ts . Ti ght e n t he b ol t s t o 48 Nm. 4. NOT E: S ome varia t io n i n t he i l l us t rat i o ns may o c cur , but t he e ss e nt i a l in f orm a t i o n i s a l wa ys corr e ct . Re move t h e po we rtr a i n as s e mbl y j a ck . 5. Lowe r t he vehi cl e . 6. Ins t a l l the t r[...]

  • Page 1541

    7. Rai s e t he e ngi ne a nd t rans mi s s i o n a s se m bl y o nt o t he mount i ng. Ti ght e n t he nut t o 130 Nm. 8. Remove t he s p e cia l to o l . 9. Att a ch t he ba t t e r y gr oun d cab l e . Ti ght e n t he b ol t t o 25 Nm. 10. At t ach t he t r ans mis s i o n s e l e ct or ca bl e t o t he br a cket . Re l e a s e t he l o ck i ng [...]

  • Page 1542

    11. At t ach t he t r ans mis s i o n s e l e ct or ca bl e a nd l e ver t o t he t r a ns mi s s i o n cont rol mod ul e (TCM). Ti ght e n t he nut t o 13 Nm. 12. Conne ct t he T CM e l e c t r i cal co nne ct or. 13. Rai se th e v e hi cl e . 14. Conne ct t he t r ans mis s i o n fl ui d cool e r t ube s . Ti ght e n t he b ol t s t o 10 Nm. JagD[...]

  • Page 1543

    15. S e cur e t he t o r que co nv e rto r t o t he f l e xpla t e . Ti ght e n t he b ol t s 60 N m. 16. Ins t a l l t he f l e xpl a t e cover . 17. S e cur e t he co o l a nt pi p e t o t he e ngi ne. Ti ght e n t he b ol t s t o 10 Nm. JagDocs.com[...]

  • Page 1544

    18. S e cur e t he e m i s s i o n cont r ol va l ve . Ti ght e n t he b ol t s t o 30 Nm. 19. Rel e as e t he p o we r s t e e r i ng fl ui d pi pe. 20. Ins t a l l t he cha r g e a i r coo l e r int a ke p ip e . Ti ght e n t he ho s e cl i ps . Ti ght e n t he b ol t s t o 35 Nm. 21. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel [...]

  • Page 1545

    22. At t ach t he L H h a l f s haf t t o t he t rans mi s s i on. 23. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s . At t a ch t he RH ha l f s ha f t t o t he t rans mi s s i on.[...]

  • Page 1546

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Aut o mat ic t rans mi s s i on f l ui d W S S - M2C922- A1 T o rque Sp eci f i cat ions Descri pti o n Nm l b- ft l b- i n Aut o mat ic t rans mi s s i on f l ui d[...]

  • Page 1547

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on C ooli ngVeh icles With: 5-Spee d Autom atic T rans axle - JATC O Des cr ipt i o n a nd O pe r a t i o n I te m Pa rt N u mber De scri p ti on 1 — Aut o mat ic t rans mi s s i on 2 — Tr ans mi s s i o[...]

  • Page 1548

    * * * * P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on C ooli ng Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou [...]

  • Page 1549

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on Flu id C oo ler Re moval a n d I ns t a l l a t i on Speci al T ool (s) Qui ck fi t conne ct o r r e l ea s ing t o o l 310-0 44 R em ova l W ARNI N G: W hen eve r r e l e as i ng t he t rans mi ss i on c[...]

  • Page 1550

    1. To i ns t a l l r evers e t he r emova l pr oced ure. 1. Ti g ht e n t o 7 N m. 2. Tig ht e n t o 7 Nm. 3. CAU TI O N : U s e o f a ny t rans mi s s i o n fl ui d o t he r t ha n t he r e comm e nded fl ui d, wil l caus e t r ans mis s i o n da mag e . Ca r ry out a t r a ns mis s i o n fl ui d l e vel c he ck. For a dd it i o na l i nfo rm at i[...]

  • Page 1551

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on Flu id C oo ler T ubes Re moval a n d I ns t a l l a t i on R em ova l W ARNI N G: W hen eve r r e l e as i ng t he t rans mi ss i on cool i ng s ys t e m f l ui d, t a ke care t o preve nt f l ui d s cal[...]

  • Page 1552

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Aut o mat ic t rans mi s s i on f l ui d W S S - M2C922- A1 T o rque Sp eci f i cat ions Descri pti o n Nm l b- ft l b- i n Aut o mat ic t rans mi s s i on f l ui d[...]

  • Page 1553

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on C o ol ingV ehicles W ith: 6-Sp eed Au to ma tic T ransaxl e - A WF21 Des cr ipt i o n a nd O pe r a t i o n COMP O NENT L O CAT IO N - A W F21 6 S PEED AU TO MATI C T RANSM IS S I O N - FROM 2009M Y It e[...]

  • Page 1554

    * * * * P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on C o ol ing Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou[...]

  • Page 1555

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on Fluid C oo ler Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng S y s t em Dr ai ni ng , Fi l l i n[...]

  • Page 1556

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on Fluid C oo ler Return T u be Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d ia t o r S pl a [...]

  • Page 1557

    2. Connect t he t r a ns mi ss i o n fl ui d cool e r r et ur n t u be t o t he t ransmi s s i on f l ui d coo l e r. 3. Connect t he t r a ns mi ss i o n fl ui d cool e r r et ur n t u be t o t he t ransmi s s i on. Ti ght e n t o 10 Nm. 4. Ins t a l l the cha r ge a i r coo l e r i nt a ke pi p e . Ti ght e n t he ho s e cl i ps . Ti ght e n t he[...]

  • Page 1558

    P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on Fluid C oo ler S upply Tube Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d ia t o r S pl a s[...]

  • Page 1559

    2. Connect t he t r a ns mi ss i o n fl ui d cool e r su ppl y t ube t o t h e t rans mi s s i on f l ui d coo l e r. 3. Connect t he t r a ns mi ss i o n fl ui d cool e r su ppl y t ube t o t h e t rans mi s s i on . Ti ght e n t o 10 Nm. 4. Ins t a l l the cha r ge a i r coo l e r i nt a ke pi p e . Ti ght e n t he ho s e cl i ps . Ti ght e n t h[...]

  • Page 1560

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b- i n S el e cto r cabl e s hie ld 10 7 - S el e cto r cabl e ret a i ni ng br acket 10 7 - JagDocs.com[...]

  • Page 1561

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - External C o n trols V ehicles With : 5- Spee d Autom atic T ransaxle - J A T CO Des cr ipt i o n a nd O pe r a t i o n It e m P a rt Nu m be r De sc ri pti on 1 — Tr ans m i s s i on se l e c[...]

  • Page 1562

    is conne ct e d t o t he d r i ve r' s s e l e ct o r m odu le by a cab l e . op erat e s t he man ua l se l e c t o r v al ve, whi ch i s pa r t of t he e l e ct ro-hydr a ul i c cont r o l u ni t . op erat e s t he rot a r y s w i t ch, whi ch i s co nne cte d t o t he ECM. The t r a ns mi s s i o n s e l e ct o r ca bl e provide s t he p o [...]

  • Page 1563

    1 2 3 1 2 1 2 3 P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - External C o n trols Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s [...]

  • Page 1564

    1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 1 Is t he vol t a ge l e s s t han 10 vol t s ? Ye s REPAI R t he ci r c ui t bet we e n I P14, pi n 01 (W R) a nd t he ig ni t i o n s wi t ch (t hi s c i r cuit i ncl ude s t he Ce nt ral Junc t i o n fu s e box, I gni t i on rel a y , a nd i n ert i a s wi t ch). Fo r a ddi t i o nal i nfo r m at i o n, r e f e r [...]

  • Page 1565

    1 1 2 3 Is t he res i s t a nce g r ea t e r t han 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC. TEST t he s yst em f o r norm al ope rat i on. No GO t o C7 . C 7: C HEC K T HE J-G AT E SI GNAL I N PUT WIRES F OR C O NT INUI T Y [...]

  • Page 1566

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - Selector L ever Cable Adju stme nt Gene ral P r ocedures Se ttin g Procedure -All Ve hicle s 1. Appl y t he pa rk ing b r a ke . 2. Appl y t he f o ot b rak e . 3. Tur n t he i gni t io n swi t [...]

  • Page 1567

    1. Usi ng t he corner o f t he gr ey f e a t ur e l i ne t ha t f ol l o ws t h e e d ge of t he 'J' ga t e a s a da t um, us e a r u le a nd m o ve t he ge a r s e l e ct o r f orwar ds o r ba ck t wo mil l i met e rs. All Ve h icles • NO T E: Be f o re s t a rti ng t he 'J ' ga t e s et t i ng proced ur e, m a ke s ur e t he[...]

  • Page 1568

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - Selector L ever Cable and Bracket Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: To mov e t he ge a r s e l e ct o r l e ve r , t he i gni t i on mus t be i n th e RU N pos i t i on, [...]

  • Page 1569

    6. D i s conne ct t he ge a r s e l e c t o r cabl e f rom t he J-ga t e. 7. D et a ch t he ge a r s e l e ct o r cabl e gr omme t. 8. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 9. D et a ch t he e xhaus t he a t s hi e l d . JagDocs.com[...]

  • Page 1570

    10. Remove t he g e a r s e l e ct o r cabl e shi e l d . 11. Det a ch t he ge a r s e l e ct o r cabl e b r a cket . 12. Dis c o nne ct t he g e a r s e l e ct o r cab le . 13. Remove t he g e a r s e l e ct o r cabl e from t he ge a r bo x mount i ng b r a cket . 1. P ul l o ut t he l o ck i ng pi n. 2. Re move t he g ea r s e l e ct o r cabl e f[...]

  • Page 1571

    Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. 2. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1572

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - Selector L ever A ss embly Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: To mov e t he s e l ect or l e ver, t he ig ni t io n m us t b e i n t he RU N pos i t i on, wi t h t he f oo[...]

  • Page 1573

    7. Remove t he a s ht ray r e t a i ni ng s cr e ws . 8. Remove t he a s ht ray. Dis conne ct t he ci gar l i g ht e r el e ct rica l conne ct o r . 9. Remove t he s e l e ct o r l eve r r et a i ni ng s crew. 10. Remove t he s e l e ct o r l eve r . 11. Det a ch t he el e ct r i cal co nnect o r fr om th e s e l ect o r l e ver. JagDocs.com[...]

  • Page 1574

    12. Remove t he s e l e ct o r l eve r f r o m t he s e l e ct o r l eve r br a cket . Re mov e t he s e l e ct or l e v e r r e ta i ni ng s c r e ws . Insta llat ion 1. NOT E: Do not ful l y t ig ht e n t he s e le ct o r le ve r r et a i ni ng s cr ews at t hi s s t a ge . I nst a l l t he ne w s e le cto r le ver t o th e s e l ect or l e v e r[...]

  • Page 1575

    4. Att a ch t he e l ect r i cal conne ct o r t o t he se l e ct o r l e ver. 5. Ins t a l l the s e le cto r l e ver. 6. Ins t a l l the s e le cto r l e ver ret a i ni ng s crew. 7. Ins t a l l the a s htray. Conne ct t he ci gar l ig ht e r el e ct r ica l conne ct o r . 8. Ins t a l l the a s htray r e t a ini ng s cr e ws . JagDocs.com[...]

  • Page 1576

    9. Connect t he s e le cto r l e ver cabl e t o t he s el e ct o r le ver . 10. Ins t a l l t he s e l e ct o r l eve r cabl e l o cking pi n. 11. Ins t a l l t he f l oo r cons o l e brack e t r et a i ni ng scr ews . 12. Conne ct t he s e l e ct o r l eve r el e ct rica l conne ct o r . 13. S e t t he s e l e ct o r le ver c a bl e a d jus t ment[...]

  • Page 1577

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b- i n S el e cto r cabl e s hie ld 10 7 - S el e cto r cabl e ret a i ni ng br acket 10 7 - JagDocs.com[...]

  • Page 1578

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - External C ontrol sV ehicles With : 6- Speed Autom atic T ransaxle - AWF2 1 Des cr ipt i o n a nd O pe r a t i o n C OMPONENT L OC ATION - A W F21 6 SPEED A U T OMATIC TRA NSMIS SIO N FROM 200 9[...]

  • Page 1579

    Item Pa rt N um be r Desc ri pti on 1 - Int erlock s o le no id - E m e rgency r e l e a se l e ve r 2 - Cabl e a d jus t ment /s e t t i ng ape r t ure 3 - S e l ect o r le ver but t o n 4 - Cabl e a t t a chm ent b a l l pi n 5 - Knob 6 - Gai t e r 7 - S e l ect o r pos it i o n LED's 8 - S pring cl i p 9 - S hi ft ho us i ng L e ft H a nd ([...]

  • Page 1580

    M/S (Manual /Spor t Mod e ) - Ini ti al s e l e ct i on o f t hi s po s i ti o n a ct i vat e s t he t r ans m i s s i on 'S po r t ' mo de. Thi s pos i t i o n ha s t h e s a me funct i on a s 'D ' b ut fo rc es t he t r ans mis s i o n t o up s hi f t a t hig her e ngi ne s p e e ds t o i mp r ove accel e r a t i o n + and - ([...]

  • Page 1581

    The s e le c t o r le ver e nd o f t he ca bl e ha s a n a dj ust a bl e e ye e nd whi ch l o cat e s on a b a l l pi n o n t he s e l e c t o r l e ver . An a but me nt o n th e ca bl e ou te r s hea t h l oca t e s in a n ap e rtur e i n th e s e l e ct or l ever s h if t hous i ng . Th e t r ans mi s s io n e nd of t he cab l e a l s o ha s a n [...]

  • Page 1582

    1 2 3 1 2 1 2 3 P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - External C ontrol s Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i[...]

  • Page 1583

    1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 1 Is t he vol t a ge l e s s t han 10 vol t s ? Ye s REPAI R t he ci r c ui t bet we e n I P14, pi n 01 (W R) a nd t he ig ni t i o n s wi t ch (t hi s c i r cuit i ncl ude s t he Ce nt ral Junc t i o n fu s e box, I gni t i on rel a y , a nd i n ert i a s wi t ch). Fo r a ddi t i o nal i nfo r m at i o n, r e f e r [...]

  • Page 1584

    1 1 2 3 Is t he res i s t a nce g r ea t e r t han 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC. TEST t he s yst em f o r norm al ope rat i on. No GO t o C7 . C 7: C HEC K T HE J-G AT E SI GNAL I N PUT WIRES F OR C O NT INUI T Y [...]

  • Page 1585

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - Selector Lever Cable Adjustment Gene ral P r ocedures 1. Ch eck t he o p erat i o n o f t he t r ans mi s s i on se l e ct o r l e ver. 2. Remove t he ce nt e r cons o le LH s i d e f i ni s he [...]

  • Page 1586

    8. Ins t a l l the ce nt e r cons o l e LH s i de f in is he r t r i m pa ne l . JagDocs.com[...]

  • Page 1587

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - Selector Lever A ss embly Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f l o or cons o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- [...]

  • Page 1588

    5. Remove t he s e l e ct o r l eve r a s s e mbl y. Re mov e t he 4 nut s . Insta llat ion 1. NOT E: Ti ght e n t he front 2 bo l t s fi r s t . I nst a l l t he s el e ct o r le ver as s e mbly. Ti ght e n t o 10 Nm. 2. Att a ch t he t r a ns mis s i o n s e l ect or l e ver cab l e . JagDocs.com[...]

  • Page 1589

    3. Connect t he s e le cto r l e ver a s s e mbl y e l e ct rica l conne ct o r . 4. Ins t a l l the f l o o r cons ol e r ei nf orceme nt bracket . Ti ght e n t o 3 Nm. 5. Ins t a l l the f l o o r cons ol e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a nd Co ns o l e , Re mov al a[...]

  • Page 1590

    P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - Selector Lever K nob Re moval a n d I ns t a l l a t i on R em ova l 1. Rel e as e t he s e le cto r l e ver ga i t e r f r om t he s el e ct o r le ver k nob . Rot a t e th e chr ome f i nis he[...]

  • Page 1591

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Lubr i cant s, Flu ids , Seal er s and A dh e si v es It e m Speci fi ca ti on Brak e f l ui d I TT S upe r Dot 4 JagDocs.com[...]

  • Page 1592

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Manual T ransm iss io n and C lutch Des cr ipt i o n a nd O pe r a t i o n The clu tch s ys t e m cons i s t s o f t he f ol l o wi ng co mpone nt s: A f l ywhe e l A cl ut ch di s c A cl ut ch pr e s s ur e pl a t e A cl ut ch mas t e r cy li n[...]

  • Page 1593

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * - - * * * * P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Manual T ransm iss io n and C lutch Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on - C lut ch As f aul t di a g nos i s s ta r t s whe n rep ai r [...]

  • Page 1594

    * * * * * * * * * * * * - * * * * * * * * * * - * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ge a r s The e ngi ne /tr a ns mis s i o n a s s e mbly i s in cont a ct wi t h t he cha s s i s/b o dy. I NS PECT fo r poi nt s o f cont act o r d a [...]

  • Page 1595

    1 2 3 4 1 2 1 1 1 2 3 1 1 1 1 1 2 PINPOIN T TE ST A : CLUTCH S LIPPAG E T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I ONS A1 : T EST CLUT C H SL I PP AGE Lock whe e l s a nd put p a r k in g brak e o n . S t a r t t he e ngi ne a nd e n ga ge 4t h g e a r . Run t he e ngi ne a t a pp r o xi mat e l y 2000 rpm . Rel e as e cl ut ch pe dal s lo wl[...]

  • Page 1596

    1 1 2 3 1 2 1 2 1 2 3 1 1 2 Is t he mea s ur ed di mens i o n wi t hi n 15 mm ? Ye s INS TA LL a ne w clut ch pr e s s ur e pl at e . TE S T t he s ys t e m f o r no r mal o p e r at i on . No GO t o B 3 . PINPOIN T TE ST D : CLUTCH PEDAL PU LSATI ON T EST C ONDI T I O NS DET AI LS/RE SULT S/A CT IONS D1: T EST CLUT C H PEDAL Che ck lu br i cat io [...]

  • Page 1597

    1 2 1 2 3 1 1 1 1 Are t he r e no i s e s whe n t he c l ut ch i s o p erat e d? Ye s GO t o G2 . No S yst e m O K. G2: T E ST CLU T C H PEDAL FREE T R AVEL P r es s t he clu t ch down manua l l y unt i l r es i s t a nce i s f el t, t he n rel e as e i t a g a i n. Mea s ur e p e da l travel . I s t he mea s ured di mens i o n wi t hi n 15 mm? Ye [...]

  • Page 1598

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Cl utch Syste m B leeding V ehicl es Wit h: 5-Speed Manual Trans mi ss io n - MT 75 Gene ral P r ocedures 1. W ARNING: Bra k e fl ui d co nt a i ns po l ygl ycol et he r s a nd p o l ygl ycols . Av o i d co nt a ct wit h t he e yes . W a s h ha [...]

  • Page 1599

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Cl utch Syste m B leeding V ehicl es Wit h: 6-Speed Manual Trans axle - MMT6 Gene ral P r ocedures 1. W ARNING: Bra k e fl ui d co nt a i ns po l ygl ycol et he r s a nd p o l ygl ycols . Av o i d co nt a ct wit h t he e yes . W a s h ha nd s t [...]

  • Page 1600

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - G earshift C ab le A djustment Gene ral P r ocedures Speci al T ool (s) Gea r s hi f t s e l e ct o r s e t t ing t o o l 308-436 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to S ect i o n 204-04 W h[...]

  • Page 1601

    • NO T E: S hi f t cabl e has a bl a ck co v e r t o ca bl e e nd a nd t he s e l e ct o r c a bl e ha s a whi t e cover t o ca b l e e nd . 6. D et a ch t he r e d l o ck i ng t a b o n t he s hi f t cab l e. 7. Att a ch t he s hi f t cabl e t o t he ba l l pi n o n t h e t r ans mis s i on s e le cto r. 8. Pr es s t he r e d l ocking t a b t o [...]

  • Page 1602

    10. Det a ch t he r ed l ocking t a b o n t he s e l e cto r ca bl e . 11. At t ach t he s e l e ct o r cabl e t o t h e ba l l p i n o n t he ge a r bo x mas s d a mper . 12. Pres s t he red l ocking t a b t o s e cur e t he p os i t i on o f t he s e le cto r cab l e . 13. Remove t he g e a r s hi f t s el e cto r se t t i ng t ool . 14. Ins t a [...]

  • Page 1603

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Release Hu b and B earing Check Gene ral P r ocedures 1. Tur n t he clut ch rel e a s e hub a nd be aring i n b ot h di rect i o ns a nd che ck f or a ny bi ndi ng or ab no r mal n oi s e . 2. CAU TI O N : The cl ut ch rel e a s e h ub a nd b ea[...]

  • Page 1604

    P ubl i s he d: 11-May-2 011 C lutch - T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n P r e s s ur e p l a te ret a i ni ng bo l t s 25 18 - JagDocs.com[...]

  • Page 1605

    P ubl i s he d: 11-May-2 011 C lutch - Cl utch Des cr ipt i o n a nd O pe r a t i o n Item Pa rt Nu m be r Descri pt i o n 1 — P r es s ure p la t e ret a i ni ng bo l t 2 — P r es s ure p la t e 3 — Cl ut ch di s c 4 — Fl ywhee l ret a i ni ng b ol t 5 — Fl ywhee l The clu tch t r ans f e rs t he e ngi ne t o rque t o t he t rans mi s s [...]

  • Page 1606

    P ubl i s he d: 11-May-2 011 C lutch - Cl utch Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 30 8-00 Manu al Trans mi s si o n/Tr ans a x l e a nd Cl ut ch - Gene ral Inf orm at i o n . JagDocs.com[...]

  • Page 1607

    P ubl i s he d: 11-May-2 011 C lutch - Cl utch Dis c and Pr ess ure Plate Re moval a n d I ns t a l l a t i on Speci al T ool (s) Cl ut ch a li g nm e nt t o o l 308-441 R em ova l All e x cept ve hicles with die s el engine 1. Remove t he manua l t rans mi s s i on. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans a x l e - 2. 0L NA[...]

  • Page 1608

    2. NOT E: The cl ut ch d i s c i s mar ked "Tr a ns mis s i o n s i de" f o r c o r r ect in s t a l l a t i o n. Lo cat e t he cl ut ch p res s ur e pl a t e on t he f l ywhee l d o wel s a nd t i gh te n t he bo l t s p r ogres s ive l y i n a d i a gona l s e que nce. Ti ght e n t o 25 Nm. Vehi c le s with diese l engine 3. NOT E: Make[...]

  • Page 1609

    P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Gen eral S p ec if ic a t ions I te m Speci fi cati on Brak e f l ui d I TT s uper do t 4 T o rque Sp eci f i cat ions Desc ri pti on N m l b- f t l b- i n Clut ch s l a ve cy l i nd e r r e t a i ni ng b ol t s 10 7 - Clut ch ma s t e r cyli nde r r et a i ni ng nut s a n d b o lt s 10 7 - Clut ch[...]

  • Page 1610

    P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch C on tro ls Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 5-sp ee d manual t r ans mis s i o n I te m P ar t N u m ber Descri pti on 1 — Brake fl uid res e rv oi r 2 — Cl ut ch mas t e r cy li nde r s uppl y l i ne 3 — Cl ut ch mas t e r cy li nde r 4 — T rans m i s s i[...]

  • Page 1611

    Item P ar t N u m ber De s cri pti on 1 - Fl ywhee l 2 - Bl ee d ni ppl e 3 - Cl ut ch mas t e r cyli nde r 4 - Vi br at i o n d a mper 5 - Hydr aul i c l i ne 6 - Cl ut ch s l a ve cyli nd e r 7 - S e lf -adj ust i ng clu t ch Thi s ve hi cle has a hydr aul i ca l l y ope rat e d cl ut ch . Th e bra k e mast e r cy l i nde r r e s e r voi r ha s a[...]

  • Page 1612

    It e m Pa rt Nu mb e r Desc ri pti on 1 - Rel e a s e be aring 2 - Pr ot e c t i ve ca p 3 - Pr es s ur e s pr i ng 4 - Hy dr aul i c channe l 5 - Oi l s e a l 6 - Pl a s t i c ho us i ng The cent r al s la ve cyl i nde r i s f i xed t o t he cl ut ch hous i ng w i t h t hree bo l t s, t o g et he r wi t h a n i nt e g r at e d r e l e a s e be a r[...]

  • Page 1613

    P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch C on tro ls Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 30 8-00 Manu al Trans mi s si o n/Tr ans a x l e a nd Cl ut ch - Gene ral Inf orm at i o n JagDocs.com[...]

  • Page 1614

    P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch Mas te r C ylinder Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. W ARNING: Do not a l l ow brake f l ui d t o co nt a ct th e s kin or e ye s . If br ake f l ui d comes i nto c ont a ct wi t h t he s ki n o r eye s , rins e t he a f f e ct e d pl a ces i mm edi at e l[...]

  • Page 1615

    4. D i s conne ct t he clu t ch m a s t e r cy l i nde r s uppl y l i ne . 5. D i s conne ct t he clu t ch s l a ve cy l i nd e r s up pl y li ne from t he clut ch mas t e r cyli nde r . Re l e a s e t he re t a i ni ng cl i p t o d i s conne ct t he l i ne . 6. Remove t he clut ch p eda l po si t i o n s wit ch. 1. Dis con nect t he e l e c t rica[...]

  • Page 1616

    9. Remove t he clut ch mas t e r cy l i nde r r et a i ni ng nut s a n d b o lt s . 10. Remove t he cl ut ch mas t e r cyli nd e r a nd cl ut ch p e da l . 11. Remove t he cl ut ch mas t e r cyli nd e r f rom t he cl ut ch pe da l . Insta llat ion All v e h icle s 1. Ins t a l l the cl ut ch mas t e r cy l i nde r . Ti ght e n t o 10 Nm. JagDocs.co[...]

  • Page 1617

    2. Ins t a l l the cl ut ch ped a l . 1. At t a ch t he cl ut ch p e da l t o t he cl ut ch mast e r cy l i nde r . 2. At t a ch t he cl ut ch p e da l t o t he s up port b r ack e t . 1. Tight en t o 2 3 Nm . 3. Ins t a l l the cl ut ch ped a l ret ur n sp ring p i n. 1. I ns t a l l t he c l ut ch pe d a l ret urn s pr i ng. 2. I ns t a l l t he [...]

  • Page 1618

    6. NOT E: Re po s i t i o n t he r e t a in in g cl i p. Conn ect t he cl ut ch s l ave cyli n der s up pl y l ine t o t he cl ut ch mas t e r cyli nde r . 7. Connect t he clu t ch mas t e r cyli nde r s uppl y l i ne. All e x cept ve hicles with die s el engine 8. Att a ch t he e ngi ne wi r i ng ha r ne s s t o t he i nt a ke mani fo l d . Ti ght[...]

  • Page 1619

    P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch S lav e C ylinderVehicle s W ith: 5-Sp eed Ma nual Tran smi s sion - MT75 Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: The cl ut ch s l a ve cy l i nd e r a s s e mbly must be r e pl a ce d whe ne ver it is removed . Re move t h e manual t r an s mi s s i o n. For a ddi ti o n[...]

  • Page 1620

    P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch S lav e C ylinderVehicle s W ith: 6-Sp eed Ma nual Tran saxle - MM T6 Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: The cl ut ch s l a ve cy l i nd e r a s s e mbly must be r e pl a ce d whe ne ver it is removed . Re move t h e manual t r an s mi s s i o n. For a ddi ti o nal i[...]

  • Page 1621

    2. Ins t a l l the cl ut ch s l a ve cyli nd e r bl e e d uni o n. Ful ly s e a t t he r e t ai ning cl i p. 3. Ins t a l l the cl ut ch s l a ve cyli nd e r hi g h p r e s s ur e pi pe to t he ret a i ni ng br acke t and clu tch s l a ve cyli nd e r b l e e d uni o n. Ful ly s e a t t he r e t ai ning cl i p. 4. Ins t a l l the manua l t rans mi s[...]

  • Page 1622

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Desc ri pti on Speci f i ca ti on Manua l t rans a xle f l ui d W S D-M 2C200- C C apaci ti es Descri pti o n Qua nti ty Manua l t rans mi ss i on fl ui d 1.75 Li t e rs o r 0 - 5 mm (0 - 0. 20 in ) be l o w t he l owe r edg e o[...]

  • Page 1623

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - M anual T rans axleV ehicles With: 5-Speed Manual T ransm iss io n - MT75 Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um be r Descr i pti on 1 — T r ans a xle h ous i ng - cl ut c h s i d e 2 — I nput s ha ft 3 — Di f f eren ti al 4 — O ut put s ha ft 5 — Re ve [...]

  • Page 1624

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - M anual T rans axleV ehicles With: 6-Speed Manual T ransaxle - MMT6 Des cr ipt i o n a nd O pe r a t i o n Thi s ve hi cle i s e qui pp e d wit h a t rans ver s e l y mount e d manua l t rans a xle , whi ch co mbine s bo t h t he t rans mi s s i on a nd d if f e r e nt i a l i n o [...]

  • Page 1625

    It e m Descri pti on I tem De sc ri pti o n 1 O ut put s haf t — 5 t h /6th a nd rev e rse ge a rs 13 S ync h r oni ze r a s s embl y – 3r d/4t h g e a r 2 Input s ha f t 14 4t h ge ar whee l 3 1st g e a r whee l 15 2nd g e a r wh ee l 4 O ut put s haf t — 1 s t t o 4t h g e ars 16 5t h ge a r w hee l 5 Pi nio n 17 3r d g e ar whe e l 6 Diff [...]

  • Page 1626

    It e m De sc ri pti on 1 S el e c t o r m e chani s m 2 Input s haf t 3 Ou tp ut s haf t — 1s t t o 4t h ge a r s 4 Dif f e rent i a l ho us i ng 5 Ou tp ut s haf t — 5t h/6t h a nd re ver s e ge ars Inp ut S ha f t JagDocs.com[...]

  • Page 1627

    I te m De sc ri pti on I te m De sc ri pti o n 1 Clut ch hous i ng r o l l e r be a ring 6 3r d ge a r whee l 2 Oi l s e a l 7 Be a r i ng r et ai ne r 3 1s t g ea r whee l 8 Be a r i ng r et ai ni ng s cr e w 4 2nd g e a r whe e l 9 4th/6t h gea r whe e l 5 5th gea r whe e l The i nput -s haf t i s a s ol i d uni t , w hi ch r ot a t e s : in a ba[...]

  • Page 1628

    Item Descri pti on I te m Descri pti on 1 T a pe r r ol l e r bea ring , t rans mis s i o n ho usi ng 1 7 Inne r s y nchr oni z e r r i ng 2 4t h g e ar whe e l 18 2n d ge a r s ync hr oni z e r cone 3 Ne e dl e b e a r i ng 19 O ut e r s yn chr o ni z e r ring - 2nd ge a r 4 I nne r s ync hr oni z e r r ing 2 0 S n ap r ing 5 4t h g e ar s ync hr [...]

  • Page 1629

    It e m Descri pti on It em Descri pti on 1 Trans mi s s i on hous i ng ta p e r r o ll e r bea ring 11 Snap ring 2 Ne e d l e be a ring 12 O i l col le cto r r ing 3 6t h ge a r whee l 13 Ta pe r r o l l e r b ea ring , clu tch ho us i ng 4 6t h ge a r s ynch r on iz e r r i ng 14 O ut pu t sha f t 5t h/6t h/r evers e ge ar 5 S na p ring 15 Re ver [...]

  • Page 1630

    Item Desc ri pti on 1 Sli di ng bl ock as s embl y 2 Sy nchr on i z e r hub 3 Sli di ng col l ar The ge ars 1s t , 2nd , 3r d and 4t h ha ve do ubl e co ne s y nchr o ni z e r s , 5t h, 6t h a nd rever s e ge a rs have s i ngl e co ne s ynchr on iz e r s . The de t e n t ba l l s , s pr i ngs and sl i di ng bl o ck s f or m o ne un it , t hi s a r [...]

  • Page 1631

    G ea r Se lection Pow er Flow • NO T E: T he p os i t i o n o f t he trans a xl e s ha ft s ha s be e n a l t e r ed f o r cl a r it y. The fo l lo wi ng di a g r a m s s ho w a sche mat i c repres e nt at io n of t he p o we r -fl o w t hr oug h t ra ns a xle f o r ea ch g ea r s e l e ct i o n. T he p o we r fl o w i s t r a nsmi t t e d t h r [...]

  • Page 1632

    Fif th G ea r The 5t h ge a r- whee l o n t he i npu t sha f t is p o s i t i vel y co nnect e d t o t he 5t h g e a r -whe el on t he o ut put s ha f t by t he 5t h/6th g ea r s ynchr oni ze r . Six th G ear The 4t h/6t h ge a r- whee l on t he i np ut sh a ft i s po s i t i ve ly co nne ct ed t o t he 6t h ge a r -whe e l o n t he out p ut s h a [...]

  • Page 1633

    It e m De sc ri pti on 1 Count e r b a l a nce 2 Re ver s e ge a r s wi t ch 3 S el e ct o r s haf t 4 S el e ct o r f i nger 5 S el e ct o r ga t e The s e le c t o r in t e r l o ck mecha ni s m a nd s e l e cto r f in ge r a r e mount e d o n a s l ee ve i n t he s el e cto r mechani s m ho us i ng. A sp ring-l o ad e d b a l l m a i nt a i ns t[...]

  • Page 1634

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - M anual T rans axle Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 30 8-00 Manu al Trans mi s si o n/Tr ans a x l e a nd Cl ut ch - Gene ral Inf orm at i o n JagDocs.com[...]

  • Page 1635

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle D raini ng and Fillin g V ehicl es Wi th: 5-Spe ed Manual T ransm iss io n - MT7 5 Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i on 100-02 Jacki ng a nd Li ft i ng 2. Remove t he drai n p l ug[...]

  • Page 1636

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle D raini ng and Fillin g V ehicl es Wi th: 6-Spe ed Manual T ransaxl e - M MT6 Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O p[...]

  • Page 1637

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - H alfs haft S eal LH I n-v e hi c l e Re pa i r Speci al T ool (s) Li nk s ha ft o i l s e a l ins t a l le r 205-115 P ini on o i l s ea l remover 308-208 R em ova l 1. D r ai n t he t rans mi s s i on. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans a x l e Dr ai [...]

  • Page 1638

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - H alfs haft S eal RH I n-v e hi c l e Re pa i r Speci al T ool (s) Li nk s ha ft o i l s e a l ins t a l le r 205-115 P ini on o i l s ea l remover 308-208 1. D r ai n t he t rans mi s s i on. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans a x l e Dr ai ni ng a nd [...]

  • Page 1639

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - In put Shaft S eal I n-v e hi c l e Re pa i r R em ova l 1. Remove t he clut ch s l a ve cy l i nd e r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Cl ut ch S l a ve Cyli nde r - Ve hi cl e s W i t h: 5-S pee d Manual Tr ans mis s i o n - M T75 (308- 02 Cl ut ch Cont r[...]

  • Page 1640

    Name Gas ket El i mi na t o r S ea l a nt P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - S electo r Mechani sm Vehi cles With: 5- Speed Manual T ransm iss io n - MT75 I n-v e hi c l e Re pa i r Speci al T ool (s) Engi ne S uppo r t B e a m 303-021 Engi ne S uppo r t B rack e ts 303-1068 Engi ne l i f t i ng e ye 303-1067 Gea r [...]

  • Page 1641

    4. D i s conne ct t he brake f lui d l o w l e ve l wa r n in g i ndi cat o r e l e ctrica l conne ct or. 5. D et a ch t he brake fl ui d l o w l e vel wa r ni ng i ndi ca t o r wi r i ng harnes s from t he coo l a nt e xpa ns i on t a nk. 6. NOT E: Ins t a l l bl anki ng pl u gs t o t he co o l i ng s y s t em ve nt hos e s a nd t he c oo l ant e [...]

  • Page 1642

    All e x cept ve hicles with die s el engine 9. D et a ch t he ge ne r a t o r wi ring ha r ne s s ret ai ni ng cl i p from t h e cams ha f t cover r e t a i ni ng cl i p. 10. Remove t he a i r cl ea n e r mount b r ack e t . 11. Ins t a l l t he s p e cia l t o o l . 12. Det a ch t he pos i t ive crankcas e vent i la t i o n (P CV ) hos e from t he[...]

  • Page 1643

    14. Remove t he i nt a ke mani f o l d s up port b r acket . 15. Det a ch t he wi ring ha r nes s from t he cams haf t cover r et a in i ng s t ud. 16. Ins t a l l t he s p e cia l t o o l . 17. Ins t a l l t he s p e cia l t o o l . Adj us t th e e ng i ne s upp or t bracket t o s upp or t t he we i g ht o f t he pow ertrai n as s e mbly. Vehi c l[...]

  • Page 1644

    18. Det a ch t he eng i ne harnes s . 19. Det a ch t he el e ct r i cal co nnect o r. 20. Remove t he e n gi ne co ver r e a r mount bracket . 21. Ins t a l l t he s p e cia l t o o l . 22. Us i ng t he s pe ci a l t o o l , sup po r t t he e ngi ne a nd t r a ns mis s i o n a s s embl y. JagDocs.com[...]

  • Page 1645

    All v e h icle s 23. Remove t he t r ans a x l e mount br a ck et s e cur ing nut . 24. Remove t he t r ans a x l e s u pport i ns ul a t o r. 25. Det a ch t he cl ut ch mas te r cyli nde r t o cl ut ch s l ave cyli n der hi gh p r es sure pi pe from t he s uppo r t brack et . All e x cept ve hicles with die s el engine 26. Remove t he cl ut ch mas[...]

  • Page 1646

    27. Remove t he cha r ge a i r coo l e r pi pe ret a i ni ng nu t. 28. Remove t he cl ut ch mas t e r cyli nd e r t o cl ut ch s l a ve cyli nde r hig h pr es s ur e pi pe s uppo r t br ack e t . All v e h icle s 29. Remove t he t r ans a x l e mount br a ck et . 30. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. JagDocs[...]

  • Page 1647

    31. NO TE: Shown f r om th e unde r s i de of t he vehi cle f or cl arit y. • NO T E: L owe r s hi f t cabl e s how n, uppe r shi ft ca b l e s i mil ar. Di s conn ect t he s hi ft ca bl e s f r om t he t rans a xle s e le ct ors . 32. Det a ch t he uppe r s hi f t ca bl e f r om t he r e t a i ni ng bra c ket . 33. NO TE: Cl e an t he s e le ct [...]

  • Page 1648

    3. Att a ch t he upp e r s hi ft ca bl e t o t h e r et a i ni ng br acket . 4. NOT E: Li ft t he r e ver s e ge a r s e le c t o r t o fi t s pe ci a l t ool . Us i ng t he s p e ci a l t o ol , ma ke s ur e t he ge a rshi ft l eve r is i n t he ne ut ral po s i t i o n. 5. M ake s ure t he t rans mi s s i o n s e l e cto r i s i n t h e f ourth g[...]

  • Page 1649

    8. NOT E: S hown f r o m t he unde r s i de of t he ve hi cl e f o r c l a r i t y. P r es s t he red l ocki ng t ab t o s e cur e t he po s it i o n o f t h e s hi ft cabl e . 9. Pl a ce t he t rans mi s s i on s e l e ct o r i nt o t he ne ut r al po s i t i o n. 10. NO TE: Shown f r om th e unde r s i de of t he vehi cle f or cl arit y. Det ach [...]

  • Page 1650

    13. Remove t he s pe ci a l t o o l . 14. At t ach t he g e a r s hi f t l e ve r s urr o und. 15. Check f or cor r e c t o pe r at i o n o f ge a r cont r ol s . 16. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 17. Ins t a l l t he t r a ns a xl e mount b r ack e t . Ti ght e n t o 80 Nm. Vehi c le s with diese l en[...]

  • Page 1651

    18. Ins t a l l t he clut ch mas t e r cyl i nde r t o c l ut ch s l a ve cyli nd e r hi g h pre ss ur e pi pe sup po r t . 19. Ins t a l l t he cha r g e a i r coo l e r pi pe ret a i nin g nut . All e x cept ve hicles with die s el engine 20. Ins t a l l t he clut ch mas t e r cyl i nde r t o c l ut ch s l a ve cyli nd e r hi g h pre ss ur e pi p[...]

  • Page 1652

    22. Ins t a l l t he t r a ns a xl e s uppo rt i ns ul a t o r. Ti ght e n t o 47 Nm. 23. Ins t a l l t he t r a ns a xl e mount b r ack e t s e cur i ng nut . Ti ght e n t o 133 Nm. Vehi c le s with diese l engine 24. Remove t he s pe ci a l t o o l . 25. Remove t he s pe ci a l t o o l . JagDocs.com[...]

  • Page 1653

    26. Ins t a l l t he e ngi ne cover r e a r mount brack e t . Ti ght e n t o 23 Nm. 27. At t ach t he e le ct r ica l conne ct o r . 28. At t ach t he e ngi ne h a r n e s s . All v e h icle s 29. Remove t he s pe ci a l t o o l . JagDocs.com[...]

  • Page 1654

    30. Remove t he s pe ci a l t o o l . 31. At t ach t he wi r i ng harnes s t o t he ca ms haf t co ver r et a i ni ng s t u d. Ti ght e n t o 6 Nm. 32. Ins t a l l t he i nt a ke man if ol d s upport br acket . Ti ght e n t o 10 Nm. 33. At t ach t he e le ct r ica l conne ct o r t o t he i nt a ke mani fo ld s upport bracket . 34. At t ach t he P C[...]

  • Page 1655

    35. Remove t he s pe ci a l t o o l . 36. Ins t a l l t he a ir cl e a ne r moun t br acket . Ti ght e n t o 6 Nm. 37. At t ach t he g e ne r a to r wi r i ng ha r ne s s r e t ai ni ng cl i p t o t he cams ha f t cover r e t a i ni ng cl i p. 38. At t ach t he co o l a nt e xpans i o n t a nk . 1. Re pos i ti on t he cool a nt e xp a ns i o n t a [...]

  • Page 1656

    40. NO TE: Re move t he b l a nking pl ugs f r om t he c oo l i ng s yst e m v en t ho se s a nd t he cool a nt e xp a ns i o n t a nk. At t a ch t he coo l ing s yst e m vent ho s es to the co o la nt e x pa ns io n t a nk. 41. At t ach t he b rak e f l ui d l ow le vel warnin g i ndi cat o r wi ring ha rn e s s t o t he cool a nt expa n si o n t [...]

  • Page 1657

    Name Gas ket El i mi na t o r S ea l a nt P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - S electo r Mechani sm Vehi cles With: 6- Speed Manual T ransaxle - MMT6 I n-v e hi c l e Re pa i r Mate ri a l s Speci fi cati on W S K-M2G 34 8-A5 R em ova l 1. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e [...]

  • Page 1658

    6. D i s conne ct t he rev e rse l a mp swi t ch e l e ct r i cal co nnect o r. 7. Remove t he ba t t e r y t ray r et a i ni ng brack e t r et a i ni ng bol ts . 8. Remove t he ba t t e r y t ray r et a i ni ng brack e t r et a i ni ng bol ts . Re pos i t i o n t he ba t t e r y t ray 9. NOT E: Cl e an t he s e l ect or me chani s m mat i ng s ur [...]

  • Page 1659

    2. Ins t a l l the s e le cto r m e cha ni s m. Ti ght e n t o 20 Nm. 3. Loos l y i ns t a l l t he ba tt e r y t r ay r e ta i ni ng br a cket r e t a i ni ng b ol t s . Re pos i t i o n t he ba t t e r y t ray . 4. Ins t a l l the ba t t e r y t ray r et a i ni ng brack e t r et a i ni ng bol t s . 5. F ul l y t ig ht en t he ba t t e ry t ray re[...]

  • Page 1660

    6. Connect t he rev e rs e l a mp sw i t ch el e ct r i cal co nnect o r. 7. Att a ch t he s e l e cto r cab l e s . 8. Att a ch t he f us e b ox. 9. Att a ch t he wi r i n g ha r ne s s e s . 10. At t ach t he wi r i ng harnes s e s . 11. Ins t a l l t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tra[...]

  • Page 1661

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - S upport In sul ator I n-v e hi c l e Re pa i r Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t[...]

  • Page 1662

    4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 5. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 6. Remove t he ret a i ni n g nut . Vehi c le s with 5- spee d m anual transa x le JagDocs.com[...]

  • Page 1663

    7. D et a ch t he s up po r t b a r . 8. Remove t he s up port b a r . 9. Remove t he s p a c e r. All v e h icle s 10. Remove t he t r ans mis s i o n mo unt . Re mov e t he t rans mi ss i on mount r e ta i ni ng nut s . Insta llat ion All v e h icle s JagDocs.com[...]

  • Page 1664

    1. Ins t a l l the t r a n s mis s i o n mount . Ti ght e n t o 47 Nm. Vehi c le s with 5- spee d m anual transa x le 2. Ins t a l l the s p a cer. 3. Ins t a l l the s u pport b a r . 4. Tig ht e n t o 25 Nm. All v e h icle s JagDocs.com[...]

  • Page 1665

    5. Tig ht e n t o 133 Nm. 6. Remove t he s p e cia l to o l . 7. Lowe r t he vehi cl e . JagDocs.com[...]

  • Page 1666

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L D uratorq- TDC i Re moval Speci al T ool (s) S li de ha mm er 100-012 100-012- 02 S li de ha mm er s ha f t Ha l f s ha f t r emove r fo rk 204-226 P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 P ini on o i l s ea l remover 308-208 Engi ne s up port b r a cket 303-[...]

  • Page 1667

    3. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e n t he s ho ck abs o r be r a nd s p r i ng a ss e mbly s e cur i ng nut s . 4. Remove t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L Dur at o rq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (502-0 0 U ni -Body, [...]

  • Page 1668

    8. Remove t he vacuum s o l e noi ds a nd va cuum r e s e r voi r m ount br ack e t a s s e mbl y. 9. D et a ch t he coo l a nt pi p e from t he e ngi ne. 10. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama g[...]

  • Page 1669

    13. CAUT I O N: Ma k e s ure t he ha l fs h a ft CV j o i nt s do no t o ve r a r t i cul a t e . Fa i l ur e t o f o ll o w t hi s i ns t r ucti on may res ul t i n d a mage t o t he CV jo i nt s . S upport t he le ft -hand ha l fs ha f t . 14. Remove a nd di s car d t he le ft -hand ha l f s haf t s nap r i ng. 15. S up po r t t he p o we r s t e[...]

  • Page 1670

    18. Det a ch t he ge a rshi f t ca bl e s uppo rt br a ck et f r o m t he t rans a xle . 19. Remove t he t r ans a x l e mount br a ck et r e t a i nin g b o lt . 20. Lowe r t he vehi c l e . 21. Det ach t he ge n erat o r and s t arte r mot o r pos i t i ve cabl e from t he e ngi ne cover mount i ng b r a ck et . 22. Remove t he e n gi ne co ver r[...]

  • Page 1671

    23. Ins t a l l t he s p e cia l t o o l . 24. Us i ng t he s pe ci a l t o o l , sup po r t t he e ngi ne a nd t r a ns mis s i o n a s s embl y. 25. Det a ch t he char ge ai r coo l er pi pe . 26. Det a ch t he t rans a xle ground cabl e . 27. Remove t he t r ans a x l e upp er r e t a i ni ng b ol t s . JagDocs.com[...]

  • Page 1672

    28. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 29. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r. Fai l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . Det [...]

  • Page 1673

    33. Us i ng t he eng i ne s upp o r t b rack e t l owe r t he p ow ertrai n as s e m bl y a ppr oxi mat e l y 60 mm (2.36 i nches ) b e t we e n t h e t r ans axl e a nd t rans a xl e m o unt br acket . 34. Rai se th e v e hi cl e . 35. Al i gn t he po we r t r a i n a s s e mbl y j a ck t o t he t rans a xle . S ecur e t he t rans a xle t o t h e [...]

  • Page 1674

    38. Remove t he t r ans a x l e . Det a ch t he t rans a xle from t he cl ut ch p l a te . Lowe r t h e po we r t r a i n a s s e mbl y j a ck a nd t r a ns a xl e a s s e m bl y. JagDocs.com[...]

  • Page 1675

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .2 L D uratorq- TDC i (110kW / 150PS) - Puma Re moval Speci al T ool (s) S li de ha mm er 100-012 100-012- 02 S li de ha mm er s ha f t Ha l f s ha f t r emove r fo rk 204-226 P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 P ini on o i l s ea l remover 308-208 Engi ne s [...]

  • Page 1676

    4. CAU TI O N : Make s ur e t h e ha l f s ha ft cons t a nt ve lo ci t y (CV) j o i nt s do not over a r t i cula t e . Fa i l ur e t o f o l l ow t hi s i ns t r ucti o n may res ul t in da mag e to the CV j o i nt s . Det ach t he right -ha nd hal fs ha ft . Dis e ngag e t he right -ha nd hal fs ha ft f r om t he t rans a xle . S ecur e t he r i[...]

  • Page 1677

    9. NOT E: Pl ug t he t rans a xle t o prevent f lui d l o s s o r di r t i ngr e s s . Us i ng t he s p e ci a l t o ol , re mov e t he l e ft -hand ha l f s haf t s ea l . 10. NO TE: Secur e t he po we r st e e r i ng fl ui d p i pe u si ng t i e s t r ap s . S upport t he powe r s t ee ring f l ui d pi pe . 11. Det a ch t he vacuum s o le noi d v[...]

  • Page 1678

    14. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r. Fai l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . Di s conn ect t he cl ut ch mas t e r c yli nder t o clut ch s l a ve cy l i nd e r[...]

  • Page 1679

    19. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps . Det ach t he s e le cto r cabl e s. 20. Dis c o nne ct t he cr an ks haf t p os i t i on (CKP) s e ns o r el e ct rica l conne ct o r . 21. Remove t he t r ans a x l e upp er r e t a i ni ng b ol t s . 22. Remove t he t r ans a x l e mount br a ck et r e t a i nin g b o lt s . 2[...]

  • Page 1680

    24. Us i ng t he s pe ci a l t o o l , l owe r the po we rtrai n a s s embl y a p pr oximat e l y 60 mm (2.36 i nche s ) b et we e n t h e t rans a xle a nd t rans a xl e mount br acke t . 25. Rai se th e v e hi cl e . 26. Al i gn t he s p e ci a l t o ol t o t he t r a n s a xl e . S ecur e t he t rans a xle t o t h e po we rtr a i n a s s e mbl y[...]

  • Page 1681

    29. NO TE: Shown wi t h t he s pe ci a l t o o l r emove d f o r cl arit y. Re move t h e t rans a xle r e t a i ni ng bo l t s . 30. Us i ng t he s pe ci a l t o o l , r e move t he t rans a xle . Det a ch t he t rans a xle from t he cl ut ch p l a te . Lowe r t h e po we r t r a i n a s s e mbl y j a ck a nd t r a ns a xl e a s s e m bl y. JagDoc[...]

  • Page 1682

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L N A V6 - AJV6/2.5L NA V6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval Speci al T ool (s) S li de ha mm er 100-012 100-012- 02 S li de ha mm er s ha f t Ha l f s ha f t r emove r fo rk 204-226 P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 P ini on o i l s ea l remover 308-[...]

  • Page 1683

    3. Loos e n t he l e ft -hand s ho ck a bs orber an d s pr i ng a s s e m bl y s e cur i ng nut s . 4. Loos e n t he r i ght -ha nd s ho ck abs o r b e r and s pr i ng a s s e mbl y s e cur i ng nut s . 5. Remove t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L NA V 6 - AJV6/2.5L N A V6 - AJV [...]

  • Page 1684

    8. Remove t he s t ee ring ge a r he a t s hi e l d. 9. Remove t he t r a ns f e r cas e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans fe r Cas e (308-0 7 T r ans fe r Ca s e, Re moval ). Vehi c le s with 2.0L engi n e 10. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i c[...]

  • Page 1685

    13. Us i ng t he s pe ci a l t o o l s , d e t ach t he l ef t-h a nd ha lf s ha f t . 14. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s . S upport t he hal fs ha ft . 15. Remove a [...]

  • Page 1686

    18. Det a ch t he ge a rshi f t ca bl e s uppo rt br a ck et f r o m t he t rans a xle . 19. Remove t he t r ans a x l e mount br a ck et r e t a i nin g b o lt . 20. Lowe r t he vehi c l e . 21. Det a ch t he ge ne r at o r wi ring ha r nes s ret a i ni ng c l i p f r om t he c a msha f t cover r e t a i ni ng cl i p. 22. Remove t he a i r cl ea n[...]

  • Page 1687

    24. Det a ch t he pos i t ive crankcas e vent i la t i o n (P CV ) hos e from t he i nt a k e m a ni f o l d. 25. Det a ch t he el e ct r i cal co nnect o r fr om th e i nt a ke mani fo l d s uppo r t br acke t . 26. Remove t he i nt a ke mani f o l d s up port b r acket . 27. Det a ch t he wi ring ha r nes s from t he cams haf t cover r et a in i [...]

  • Page 1688

    29. Ins t a l l t he e ngi ne s up port b r acket . Adj us t th e e ng i ne s upp or t bracket t o s upp or t t he we i g ht o f t he pow ertrai n as s e mbly. 30. Det a ch t he s t ar t e r moto r s o l e no i d cover. 31. Det a ch t he s t ar t e r moto r e l e ct r i cal c onn e cto r . 32. Det a ch t he s t ar t e r moto r s o l e no i d e l ec[...]

  • Page 1689

    34. Remove t he t r ans a x l e ret a i ni ng bol t. 35. Remove t he t r ans a x l e ret a i ni ng bol ts . 36. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 37. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r.[...]

  • Page 1690

    39. Remove t he cl ut ch mas t e r cyli nd e r t o cl ut ch s l a ve cyli nde r hig h pr es s ur e pi pe s uppo r t . 40. Remove t he t r ans a x l e mount br a ck et s e cur ing s t uds . 41. Us i ng t he eng i ne s upp o r t b rack e t l owe r t he p ow ertrai n as s e m bl y a ppr oxi mat e l y 60 mm be t we en t he trans a xl e a nd t r ans a x[...]

  • Page 1691

    45. Al i gn t he po we r t r a i n a s s e mbl y j a ck t o t he t rans a xle . S ecur e t he t rans a xle t o t h e po we rtr a i n a s s e mbl y j a ck . 46. Remove t he t r ans a x l e ret a i ni ng bol t. 47. NO TE: Ve hicl e s wi t h 2.5L a nd 3. 0L e ngi ne s s ho wn, ve hi cl e s wi t h 2. 0L e ngi ne s i mi l a r . Re move t h e t rans a xl[...]

  • Page 1692

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L D uratorq- TDC i I nst a l l a t io n Speci al T ool (s) Ha l fs ha ft o i l s e a l ins t a l le r 205-115 P owe r t r ai n a s s embl y j ack HTJ1200-2 Engi ne sup po r t b rack et 303-021 Engi ne li f t i ng e ye 303-1067 Insta llat ion 1. Ins t a l l the t r a n[...]

  • Page 1693

    3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 4. Remove t he po we r t r ai n a s s e mbl y j a ck. Re mov e t he t rans a xle t o t h e po we r t r ai n a ss e mbly ja ck s ecur i ng s t rap. 5. Lowe r t he vehi cl e . 6. Usi ng t he e ngi ne s uppo r t b r a c ket r a i s e t he powe rtrai n a s s e mbl y. Adj [...]

  • Page 1694

    8. Ins t a l l the t r a n s a xl e mount b r acket ret a i ni ng s t uds . Ti ght e n t o 80 Nm. 9. Ins t a l l the cl ut ch mas t e r cy l i nde r to c l ut ch s l a ve cyli nde r high pres s ur e pi pe sup po r t b rack e t. 10. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o w[...]

  • Page 1695

    13. Ins t a l l t he t r a ns a xl e up per ret a i ni ng b o lt s . Ti ght e n t o 48 Nm. 14. At t ach t he t r ans a xle gr oun d ca b le . 15. At t ach t he cha r ge a ir coo l e r pi pe ret a i ni ng nu t. 16. Remove t he e n gi ne s upp ort br a cket . 17. Remove t he s pe ci a l t o o l . JagDocs.com[...]

  • Page 1696

    18. Ins t a l l t he e ngi ne cover r e a r mount brack e t . Ti ght e n t o 23 Nm. 19. At t a ch t he g ene rat o r a nd s t a rte r mot or po s i t i ve cab l e f r o m t he e ngi ne cover mount i ng b r a ck et . 20. Rai se th e v e hi cl e . 21. Ti g ht e n t he t r an sa xl e mount brack e t ret a i ni ng b ol t . Ti ght e n t o 80 Nm. 22. At [...]

  • Page 1697

    23. At t ach t he g e a r s hi f t cabl es t o t he t r a ns a xl e . 24. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w r i ght -hand ha l f s ha f t s e a l . 25. Ins t a l l a n ew right -ha nd ha l f s ha f t s na p r i ng . 26. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci[...]

  • Page 1698

    28. CAUTI O N S : Make s ur e t he ha l f s haf t CV j oi nt s do not ove r a r t i cul a t e. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n d amage t o t he CV jo i nt s . Make s ur e t he ha l f s haf t s ea l i s not damag e d. Fai l ure t o fo l l ow t his in s t ruc t i o n may r es ul t i n a n t r ans a xle f l ui d l[...]

  • Page 1699

    33. At t ach t he wi r i ng harnes s t o t he va cuum s o l e noi ds a nd vacuum r es e rv o i r mount bracket . 34. Conne ct t he va cuum s o l e noi d va l ve s e le ctrica l conne ct o r s . 35. Conne ct t he va cuum p i pe s t o t he vacuum s o l e no i d val v e s a nd t he vacuum r e s e r voi r. 36. Ins t a l l t he f r ont s ubfr a me. For [...]

  • Page 1700

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .2 L D uratorq- TDC i (110kW / 150PS) - Puma I nst a l l a t io n Speci al T ool (s) Ha l f s ha f t o i l s e al i n st a l l er 205-115 P owe r t r ai n a ss e mbl y ja ck HTJ1200- 2 Engi ne s up port b r a cket 303-021 Insta llat ion 1. Usi ng t he s pe cia l t oo l ,[...]

  • Page 1701

    3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 4. Att a ch t he t u r b o charger o i l fe e d pi p e ret a i ni ng br acket . Ti ght e n t o 22 Nm. 5. Remove t he s p e cia l to o l . Re mov e t he s pe ci a l t o o l s ecur i ng s t rap. 6. Lowe r t he vehi cl e . 7. Usi ng t he s pe cia l t oo l rai s e t he p [...]

  • Page 1702

    8. Loos e l y i nst a l l t he t rans a xle mount bra c ket r e t a in ing bol t s . 9. Ins t a l l the t r a n s a xl e mount b r acket ret a i ni ng b o lt s . Ti ght e n t o 80 Nm. 10. Ti g ht e n t o 80 N m. 11. Ins t a l l t he t r a ns a xl e up per ret a i ni ng b o lt s . Ti ght e n t o 48 Nm. 12. Conne ct t he cr a nks haf t p o si t i on [...]

  • Page 1703

    13. NO TE: Re move t he s e l e ct o r cab l e t ie s t r a ps . At t a ch t he s el e ct or cabl es . 14. At t ach t he s e l e ct o r cabl e s . 15. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 16. At t ach t he b a t t e r y ground c a bl e. 17. At t ach t he b a t t e r y ground c a bl e. JagDocs.com[...]

  • Page 1704

    18. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r. Fai l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . Conn ect t he cl ut ch ma s t e r c yl i nde r t o cl ut ch s l a ve cyl in de r hi[...]

  • Page 1705

    24. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w r i ght -hand ha l f s ha f t s e a l . 25. Ins t a l l a n ew right -ha nd ha l f s ha f t s na p r i ng . 26. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o [...]

  • Page 1706

    28. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w l e ft - ha nd ha l f s ha f t s ea l . 29. CAUT I O N: Ma k e s ure t he ha l fs h a ft CV j o i nt s do no t o ve r a r t i cul a t e . Fa i l ur e t o f o ll o w t hi s i ns t r ucti on may res ul t i n d a mage t o t he CV jo i nt s . At t a ch[...]

  • Page 1707

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L N A V6 - AJV6/2.5L NA V6 - A JV 6/3.0 L NA V 6 - AJ27 I nst a l l a t io n Speci al T ool (s) Ha l fs ha ft o i l s e a l ins t a l le r 205-115 P owe r t r ai n a s s embl y j ack HTJ1200-2 Engi ne sup po r t b rack et 303-021 Engi ne sup po r t b rack et s 303-106[...]

  • Page 1708

    3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t . Ti ght e n t o 48 Nm. 4. Remove t he po we r t r ai n a s s e mbl y j a ck. Re mov e t he t rans a xle t o t h e po we r t r ai n a ss e mbly ja ck s ecur i ng s t rap. 5. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 6. Ins t a l l the t r a n s a xl e ret a[...]

  • Page 1709

    8. Usi ng t he e ngi ne s uppo r t b r a c ket r a i s e t he powe rtrai n a s s e mbl y. Adj us t th e e ng i ne s upp or t bracket t o al i gn t he t r a n s a xl e t o t he tra nsa xl e mount b rack e t . 9. Ins t a l l the t r a n s a xl e mount b r acket s e cur i ng st ud s. Ti ght e n t o 80 Nm. 10. Ins t a l l t he clut ch mas t e r cyl i n[...]

  • Page 1710

    13. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 14. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 15. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t . Ti ght e n t o 48 Nm. 16. Ins t a l l t he s t arte r mot o r . Ti ght e n t o 35 Nm. 17. At t ach t he s t arte r mot o r s ol[...]

  • Page 1711

    18. At t ach t he s t arte r mot o r e l e ct rica l co nnect o r . Ti ght e n t o 12 Nm. 19. At t ach t he s t arte r mot o r s ol e noi d co v e r. 20. Remove t he e n gi ne s upp ort br a cket . 21. Remove t he e n gi ne s upp ort br a cket . 22. At t ach t he wi r i ng harnes s t o t he ca ms haf t co ver r et a i ni ng s t u d. Ti ght e n t o [...]

  • Page 1712

    23. Ins t a l l t he i nt a ke man if ol d s upport br acket . Ti ght e n t o 10 Nm. 24. At t ach t he e le ct r ica l conne ct o r t o t he i nt a ke mani fo ld s upport bracket . 25. At t ach t he p o s i t i ve cr a n kc as e ve nt i la t i o n (P CV) ho s e t o t he i nt a k e m a ni f o l d. 26. Remove t he e n gi ne s upp ort br a cket . 27. [...]

  • Page 1713

    28. At t ach t he g e ne r a to r wi r i ng ha r ne s s r e t ai ni ng cl i p t o t he cams ha f t cover r e t a i ni ng cl i p. 29. Rai se th e v e hi cl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 30. Ins t a l l t he t r a ns a xl e mount b r a[...]

  • Page 1714

    33. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w ha l f s ha ft s e a l. 34. Ins t a l l a n ew ha l f s ha f t s na p ring. 35. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n [...]

  • Page 1715

    Vehi c le s with 2.0L engi n e 38. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w ha l f s ha ft s e a l. 39. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama[...]

  • Page 1716

    43. Ins t a l l t he f e nde r s pl a s h s hie ld acce s s pane l . 44. Ins t a l l t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L NA V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ27 (502- 00 U ni -Bod y, S u bf r a m e a nd Mo unt i ng Sy s t e m , Re moval a nd I nst a l l at io n). 45. T[...]

  • Page 1717

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n S el e cto r cabl e gromm e t - - 60 l b -i n Gea r s hi f t l e ve r mount r et a i ni ng nut s - - 80 l b-i n JagDocs.com[...]

  • Page 1718

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - External C ontro ls Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 5-sp ee d manual t r ans mis s i o n I te m Pa r t N u m ber De scri pt i o n 1 — Gears hi ft l e ver knob 2 — S h i f t ca bl e 3 — S el e c t o r c a bl e 4 — S el e c t o r [...]

  • Page 1719

    It e m De s cri pti o n I tem De s cri pti on 1 Int e r na l shi ft me cha ni s m 8 Sel e ct or ca bl e 2 Count e r b a l a nce 9 Bod y s e a l 3 S el e ct o r cab l e a dj us t m e nt mecha ni s m 10 Shif t ca bl e m o unt i ng 4 S h i f t ca bl e 11 S hif t ca bl e mount i ng po i nt o n t he ge ars hi ft l e ver 5 Gear l e v er ho usi ng 12 Re v[...]

  • Page 1720

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - External C ontro ls Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e . 2. Mechani cal Vi s i bl y d a mage d o r wo r n L[...]

  • Page 1721

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift C ablesVe hic les W ith: 5-Spe ed Manual T ransm iss io n - MT7 5 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l 1. Remove t he ce nt e r cons o le r i ght -han d s i de pa ne l . 2. N[...]

  • Page 1722

    4. Remove t he i ns t r um e nt pa ne l ce nt e r m ount b r acket . 5. Remove t he ce nt e r ai r duct r et ai ni ng s cr ew. 6. Repo s i t i on t he ce nt e r a i r duc t upwards. 7. D et a ch t he ge a rshi ft s e l e ct or ca bl e g romm et . 8. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i[...]

  • Page 1723

    9. D et a ch t he e xhaus t he a t s hi e l d . 10. CAUT I O N: U s i ng t he pow ertrai n a s s e mbly j ack, s uppo r t t he r e a r of t he s ubf rame. • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re move t h e s ubfr a me r e in f o r ce me nt pl a t e r e t ai ni ng bo l t s . 11. NO TE: L e ft -hand s h own, r i g ht -hand s i [...]

  • Page 1724

    13. NO TE: P res s t he b ut t o n t o r e l e a s e t he cab l e fi t t i ng b e fo re di s conne c t i ng t he ca b l e . Re move t h e ge arshi f t s e le ct or cab l e . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n t o 60 l b /i n. 3. Ch eck a nd a dj us t t he ge a rshi f t ca bl e s . For ad di t io[...]

  • Page 1725

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift C ablesVe hic les W ith: 6-Spe ed Manual T ransaxl e - M MT6 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ge a r s hi f t l e ve r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ge a r s hi f t Le ver - V e hi cle s W i t [...]

  • Page 1726

    6. D et a ch t he ge a rshi ft ca bl e s f r o m t he t r ans mi ss i o n r et ai ni ng bracket . 7. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 8. Repo s i t i on t he e xhaus t mount i n g f o r a cces s t o t[...]

  • Page 1727

    10. Repo s i t i o n t he ge a r s hi f t cabl e s f r o m t he s ubf r a m e . 11. CAUT I O N: Ma k e s ure t he ge ars hi ft ca bl e s a re fe d t hrough t he vehi cl e f lo o r pan i nd i vidu a ll y. Fa i l ur e t o f o l l ow t hi s i ns t r uct i on may res ul t in damag e t o t he ve hi cl e . • NO T E: Re move t he gea rshi ft ca bl e s f[...]

  • Page 1728

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift L everVehicles With: 5-Spe ed Manual T ransm iss io n - MT7 5 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ge a r s hi f t l e ve r k nob . 2. D et a ch t he ge a rshi ft l eve r s ur r ound. 3. NOT E: Pre ss t he b ut t on t o rel e[...]

  • Page 1729

    5. D i s conne ct t he ge a r s hi f t s el e ct o r cab l e s . 6. NOT E: Ri g ht -hand s ho wn, l e f t hand s i mil a r . Re move t h e cent e r c o ns o l e r ig ht -ha nd s i d e t r i m pa ne l . 7. Remove t he ge a r s hi f t l e ve r . 1. Re move t he g ea rshi ft l e v e r m ount i ng r et a i ni ng nut s . 2. Re move t he g ea rshi ft l e[...]

  • Page 1730

    P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift L everVehicles With: 6-Spe ed Manual T ransaxl e - M MT6 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ge a r s hi f t l e ve r k nob . Re mov e t he g e a r s hi f t l e ve r s pr ing . 2. Remove t he res t r a i nt s co nt rol modul[...]

  • Page 1731

    6. D et a ch t he ge a rshi ft l eve r as se m bl y t o a ll ow a cces s t o t he ge a rshi f t cabl e s . Re mov e t he re ta i ni ng nut s . 7. D i s conne ct t he ge a r s hi f t cab l es . Re mov e t he g e a r s hi f t l e ve r a s s e mbl y . Insta llat ion 1. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1732

    P ubl i s he d: 11-May-2 011 T ransfer C ase - C apaci ti es Desc ri pti on Li t e rs Tr an s fe r ca s e l ubr i cant , d r ai n and r ef i ll 0.50 T o rque sp e ci fi cat i o ns Descri pti o n Nm Lb - ft Lb - i n M8 pi ni o n ho usi ng s t ud s 35 26 - M8 pi ni o n ho usi ng bo l t s 35 26 - Engi ne a nt i -r o ll res t r i ct o r m o unt i ng b [...]

  • Page 1733

    P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase Des cr ipt i o n a nd O pe r a t i o n It e m P a r t Nu m be r De scri pti o n 1 — Trans f e r cas e 2 — Trans f e r cas e fi l l pl ug 3 — Trans f e r cas e r et a i ni ng bo l t 4 — Trans f e r cas e a i r cool in g d uct 5 — Trans f e r cas e Y brack e t r et a i ni ng bo [...]

  • Page 1734

    P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase D raining and Fil ling Gene ral P r ocedures Speci al T ool (s) Fla nge hol d i ng t o ol 205-05 3 Fla nge r e move r /ins t a l l e r 204-06 8A Fla nge r e move r /ins t a l l e r bos s 204-26 6 Fla nge r e move r /ins t a l l e r 204-29 5 S e a l e xt ract or 308-37 5 S l i de h a m m[...]

  • Page 1735

    2. NOT E: Mark t he po s i t i o n of t he d rives haf t in r e la t i o n t o t he dr i v e pi ni o n fl a nge. Re move t wo o ppos i ng d r i v e s ha f t uni ve r s a l j o i nt r e t a i nin g b o lt s . 3. Loos e n t he r emai ni ng dr i ves ha ft uni ve r s a l jo i nt r e t a i ni ng bo l t s . 4. D et a ch t he e ngi ne r o l l res t ricto [...]

  • Page 1736

    6. Usi ng s uit ab l e t i e s t r a ps , se cur e t he o ut e r cas i ng of t he d r ive s haf t uni ver s a l j o i nt . 7. CAU TI O N : Make s ur e t h at th e drive s ha f t do e s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Us i ng s[...]

  • Page 1737

    10. NO TE: Make a not e o f t he compl e t e number of t ur n s requi red t o r e m o ve t he co m pani o n f l a nge r e t ai ning nut . • NO T E: Make a no t e o f t he numbe r of de gree s p as t t he l a s t compl e t e r o t a t i on r eq ui red to r e m ove t he compani on f l a nge r e t a i n ing nut . Re move t h e compan i on fl ange re[...]

  • Page 1738

    14. Remove t he co mpani o n f l a nge . Rot a t e th e s pe ci a l t o o l count e r -c l o c kwi s e . 15. Us i ng t he s pe ci a l t o o l s r e move t he pi ni on o i l s ea l . 16. NO TE: Make s ur e th e v e hi cl e i s compl e t e l y l e vel whe n drai ni ng t he tra nsf e r cas e . Al lo w t h e o i l t o f ul l y drai n i nt o a s ui t ab[...]

  • Page 1739

    21. Appl y s ea l ant (C2S 1209 9) t o t he a r e a o f t r ans fe r ca s e r ea r o ut put f l a nge whe r e s e cur in g nut s e a t s . 22. Ins t a l l t he s p e cia l t o o l t o t he compa ni o n f l a ng e. 23. Appl y s ea l ant (C2S 1209 9) t o t he mat i ng f a ce of t he t r ans fe r cas e r e a r ou tp ut f l a ng e s ecur i ng nut . 24.[...]

  • Page 1740

    25. CAUT I O N: Ma k e s ure t hat t he drive sha f t doe s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Cut a nd r emove t he t i e s t r aps s e cur ing t he o ut er cas i ng of t he d r i v e s ha f t uni ver s a l j o i nt . 26. Cut a [...]

  • Page 1741

    29. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm. 30. W A RNING: Do not wo rk o n or unde r a vehi cl e s uppo r t e d o nl y by a ja ck. Al wa ys s uppo r t t he vehi cl e o n sa f e t y s t a nds . • NO T E: T he l o we r li p o f t he s i l l mus t be 540m m from t he f l o o r . Ra is e a nd s upp o r t t he l e f t [...]

  • Page 1742

    P ubl i s he d: 11-May-2 011 T ransfer C ase - Hal fshaft Seal RH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he right -ha nd ha l fs ha ft s e a l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o T rans f e r Ca s e i n t hi s s e ct i o n. JagDocs.com[...]

  • Page 1743

    P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase Rear O utput Shaft S eal I n-v e hi c l e Re pa i r Speci al T ool (s) Fla nge hol d i ng t o ol 205-05 3 Fla nge r e move r /ins t a l l e r 204-06 8A Fla nge r e move r /ins t a l l e r bos s 204-26 6 Fla nge r e move r /ins t a l l e r 204-29 5 S e a l e xt ract or 308-37 5 S l i de [...]

  • Page 1744

    2. NOT E: Mark t he po s i t i o n of t he d rives haf t in r e la t i o n t o t he dr i v e pi ni o n fl a nge. Re move t wo o ppos i ng d r i v e s ha f t uni ve r s a l j o i nt r e t a i nin g b o lt s . 3. Loos e n t he r emai ni ng dr i ves ha ft uni ve r s a l jo i nt r e t a i ni ng bo l t s . 4. D et a ch t he e ngi ne r o l l res t ricto [...]

  • Page 1745

    6. Usi ng s uit ab l e t i e s t r a ps , se cur e t he o ut e r cas i ng of t he d r ive s haf t uni ver s a l j o i nt . 7. CAU TI O N : Make s ur e t h at th e drive s ha f t do e s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Us i ng s[...]

  • Page 1746

    10. NO TE: Make a not e o f t he compl e t e number of t ur n s requi red t o r e m o ve t he co m pani o n f l a nge r e t ai ning nut . • NO T E: Make a no t e o f t he numbe r of de gree s p as t t he l a s t compl e t e r o t a t i on r eq ui red to r e m ove t he compani on f l a nge r e t a i n ing nut . Re move t h e compan i on fl ange re[...]

  • Page 1747

    14. Remove t he co mpani o n f l a nge . Rot a t e th e s pe ci a l t o o l a nt i - clo ckwis e . 15. Us i ng t he s pe ci a l t o o l s r e move t he pi ni on o i l s ea l . 16. NO TE: Make s ur e th e v e hi cl e i s compl e t e l y l e vel whe n drai ni ng t he tra nsf e r cas e . Al lo w t h e o i l t o f ul l y drai n i nt o a s ui t abl e co[...]

  • Page 1748

    5. Appl y s ea l a nt (C2S 12099) t o t he a r ea of t r a n s fe r ca s e r ea r o ut put f l a nge whe r e s e cur in g nut s e a t s . 6. Ins t a l l the s p e ci a l t o ol to t he co m pa ni o n f la ng e. 7. Appl y s ea l a nt (C2S 12099) t o t he mat i ng f a ce of t he t r a ns f e r cas e r e a r ou tp ut f l a ng e s ecur i ng nut . 8. In[...]

  • Page 1749

    9. CAU TI O N : Make s ur e t h at th e drive s ha f t do e s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Cut a nd r emove t he t i e s t r aps s e cur ing t he o ut er cas i ng of t he d r i v e s ha f t uni ver s a l j o i nt . 10. Cut [...]

  • Page 1750

    13. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm. 14. W A RNING: Do not wo rk o n or unde r a vehi cl e s uppo r t e d o nl y by a ja ck. Al wa ys s uppo r t t he vehi cl e o n sa f e t y s t a nds . • NO T E: T he l o we r li p o f t he s i l l mus t be 540m m from t he f l o o r . Ra is e a nd s upp o r t t he l e f t [...]

  • Page 1751

    P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase Re moval Speci al T ool (s) S l i de ha mm er a da pt e r 100-012-0 3 S l i de ha mm er 100-012 100-012-0 2 S l i de ha mm er s ha f t Ri g ht -hand ha l f s haf t s pl i t t e r 307-442 Ri g ht -hand ha l f s haf t s pl i t t e r ha nd le 307-443 Li nk s ha f t l i mi t e r br a c ket [...]

  • Page 1752

    2. D et a ch t he s t e e r i ng col umn. Re mov e a nd di s c a r d t he s t e e r i ng col u m n l ow er r e t a i ni ng b ol t . 3. Loos e n t he s ho ck ab so rber and s pring a s s e mbl y s e cur ing nut s . 4. Remove t he right -ha nd front whe e l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204[...]

  • Page 1753

    8. Remove t he s e l e ct o r l eve r cabl e s hi e l d. 9. D et a ch t he s e l ect o r l e ver cab l e bracket . 10. Dis c o nne ct t he s e l e ct o r l eve r cab l e . 11. Dr a i n t he t r a n s mi s s i o n f l ui d . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans m i s s i on Fl ui d Drai n a nd Re f il l (307-01 B A ut o ma[...]

  • Page 1754

    14. Loo s e n t he r e m a i ni ng d r i ves ha ft uni ve r s a l jo i nt r et a i ni ng bo l t s . 15. Det a ch t he eng i ne r ol l res t r i cto r . Re mov e t he e n gi ne r ol l res t r i ct or r et a i ni ng bo l t . 16. Remove t he e n gi ne rol l r e s t r i ct o r . Re mov e t he e n gi ne r ol l res t r i ct or r et a i ni ng bo l t . 17.[...]

  • Page 1755

    18. Us i ng s ui t a b l e t i e s t r ap s , s e cur e t he o ut e r cas i ng of t he drives haf t uni ver s a l j o i nt . 19. CAUT I O N: Ma k e s ure t hat t he drive sha f t doe s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Us i ng s[...]

  • Page 1756

    22. Loo s e n t he le ft -hand f r ont s ubframe r ea r mount r et a i ni ng bol t . 23. CAUT I O N: Ma k e s ure t he cons t ant ve l oci t y (CV) j o i nt bo o t i s pr ot ect ed. Fa il ur e t o f o l l ow th i s i ns t r uct i on m a y r es ult i n da mag e t o t he CV jo i nt bo o t . Det ach t he l owe r arm f r om t he wh e el knuck l e. 1. R[...]

  • Page 1757

    27. Remove t he t r ans fe r ca se sup po r t b rack e t . 28. Remove t he ca t a l y t i c co nverte r mount br acke t r et ai ni ng bo l t s . 29. Remove t he ca t a l y t i c co nverte r mount br acke t t o t rans f er cas e r et a i ni ng b ol t . 30. Remove t he ca t a l y t i c co nverte r mount br acke t r et ai ni ng bo l t . 31. Us i ng t [...]

  • Page 1758

    32. Remove t he ca t a l y t i c co nverte r mount br acke t . 33. Remove t he e n gi ne a n t i -r ol l res t r i cto r br acket ret a i ni ng bo l t s. 34. Remove t he e n gi ne a n t i -r ol l res t r i cto r br acket ret a i ni ng nut s . 35. Remove t he e n gi ne a n t i -r ol l res t r i cto r br acket . 36. CAUT I O N: T o p r eve nt da m a [...]

  • Page 1759

    37. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r bo x i nt e r nal s e a l , m a ke s ur e t ha t t he l i nk s ha ft i s no t r et r act e d f ur t he r t ha n 200 mm (7.87 in ches ) f r om t he trans f er cas e. Us i ng t he s p e ci a l t o ol , re t r act t he t r ans f e r cas e l ink s ha ft . 38. CAUT I O N: Ma k e s ure t her[...]

  • Page 1760

    42. CAUT I O N: Ma k e s ure t here i s no l os s o f f l ui d from t he t r a n sf e r c a s e . Fai l ure t o fo l l ow t his i ns t ru ct io n may r e s ul t i n d ama ge t o the tra nsf e r cas e . Re move t h e l i nk s ha f t from t he t r a n s fe r cas e . 43. CAUT I O N: Ma k e s ure t here i s no l os s o f f l ui d from t he t r a n sf e[...]

  • Page 1761

    P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase I nst a l l a t io n Speci al T ool (s) Li nk s ha ft l i mit er bracket 307-446 To r que a d a pt e r 303-1069 Li nk s ha ft oi l se a l ins t al le r 205-115 Insta llat ion All v e h icle s 1. CAU TI O N : Make s ur e t h ere i s no l os s o f f l ui d f rom t he t r ans fe r c a s e [...]

  • Page 1762

    4. CAU TI O N : Make s ur e t h ere i s no l os s o f f l ui d f rom t he t r ans fe r c a s e . Fai l ure t o fo l l ow t his i ns t ru ct io n may r e s ul t i n d ama ge t o the tra nsf e r cas e . I nst a l l a ne w O -r ing s e a l . 5. CAU TI O N : Make s ur e t h ere i s no l os s o f f l ui d f rom t he t r ans fe r c a s e . Fai l ure t o [...]

  • Page 1763

    9. NOT E: Do not t i ght e n t he e ngi ne a nt i -rol l r es t rict or brack e t r et a i ni ng nut s a t t his s t age . I nst a l l t he e n gi ne a n ti -r ol l r e s t r ict or br a c ket ret ai ni ng nut s . 10. NO TE: Do not t ig ht e n t he engi ne a nt i-r o l l r e s t rict o r br acket r e t a in in g bol t s a t t hi s s t a ge . I nst [...]

  • Page 1764

    14. Ti g ht e n t he cat a l yt i c co nverte r m ou nt br acket ret a i ni ng bo l t s. Ti ght e n t o 55 Nm. 15. Ti g ht e n t he cat a l yt i c co nverte r m ou nt br acket ret a i ni ng bo l t . Ti ght e n t o 55 Nm. 16. Ins t a l l t he cat a l yti c converte r mount br acke t t o t rans f er ca s e r e t a i ni ng bo l t . Ti ght e n t o 25 N[...]

  • Page 1765

    19. Ti g ht e n t he e ngi ne a nt i -r ol l r e s t r i ct o r brack et s i de ret a i ni ng b o l t s . Ti ght e n t o 35 Nm. 20. Ins t a l l t he cat a l yti c converte r t o cat a l yti c converte r mount br acke t r et a i ni ng b ol t s . Ti ght e n t o 25 Nm. 21. NO TE: Al t e rn a t o r c o ol i ng duct s ho wn removed fo r cl a r i t y. I [...]

  • Page 1766

    24. Ins t a l l a n ew ha l f s ha f t s e a l . 25. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s . Re move t h e ha l fs ha ft s upp o r t s tra p. 26. CAUT I O N: Ma k e s ure t [...]

  • Page 1767

    29. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l a t e r et a i ni ng bo l t s . 30. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t o 142 Nm. 31. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo[...]

  • Page 1768

    33. Cut a nd remove t he t i e s t raps s e cur i ng t he out e r c a s i ng of t he dr i ves ha f t uni v e rsal j oi nt. 34. Conne ct t he d rives ha f t to t he t r a n s fe r cas e . 35. At t ach t he d rives ha f t uni v ersa l j oi nt . 1. At t a ch t he d r ive s haf t uni ver s a l j o i nt . 2. I ns t a l l ne w drive s ha ft r et a i ni n[...]

  • Page 1769

    37. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm 38. Ti g ht e n t o 80 N m. Vehi c le s with ma nual tra nsmission 39. Fi ll t he manual t r ans mis s i o n t o t he co r r ect oi l l e vel . For ad di t io na l i nf o r ma t i o n, r e f e r t o: (308-03 Ma nual T r ans m i s s i on/T r ans axl e ) Tr an sa xl e Dr ai ni[...]

  • Page 1770

    Aut o mat ic Trans a xle - JATCO , Ge ne r a l P r o ced ures ). 43. Ins t a l l t he s e l e ct o r l eve r cabl e s hi e l d. Ti ght e n t o 10 Nm. All v e h icle s 44. Ins t a l l t he m uf fl e r in le t pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Muff l e r Inl e t Pi p e - 2.0L N A V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6[...]

  • Page 1771

    49. NO TE: I ns t a ll a new s t e e r i ng col u m n l o wer r e ta i ni ng bo l t . At t a ch t he s t e e r i ng col umn. JagDocs.com[...]

  • Page 1772

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - T o rque Sp eci f i cat ions Descri pti o n N m l b- ft l b- i n Ca ta l yt ic c onve r t er ret a i ni ng s t uds - vehi cl e s wi t hou t di e s e l eng i ne s 9 - 80 Ca ta l yt ic c onve r t er t o e xha ust man i f o ld r et ai ni ng nut s - vehi c l e s wi t ho ut di e se l e ng i ne s A - - Ca t[...]

  • Page 1773

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - E xhaust System Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 2.0L pe t rol e ng i ne I te m P a rt N um be r Des cri pti o n 1 - E xhaus t ha ng er 2 - E xhaus t ha ng er i s ol a t o r 3 - E xhaus t ha ng er i s ol a t o r 4 - E xhaus t ha ng er 5 - E xhaus t ha ng er 6 - E xhaus t ha ng[...]

  • Page 1774

    Item Par t N um be r Desc ri pti on 1 — Exhaus t mani f o l d - R/H 2 — Muf fl e r a nd t a i l pi p e a s se m bl y 3 — Exhaus t ha nge r 4 — Exhaus t ha nge r i s o l at o r 5 — Exhaus t ha nge r i s o l at o r 6 — Exhaus t ha nge r 7 — Fr on t muffl er 8 — Exhaus t ha nge r i s o l at o r 9 — Exhaus t ha nge r i s o l at o r 10[...]

  • Page 1775

    I te m P a rt Nu mb e r De sc ri pti o n 1 — Cat a l yt ic converte r 2 — Ex hau s t f l e xi bl e pi pe 3 — Ex hau s t han ge r is o l a t or 4 — Fr o nt muff l e r 5 — Ex hau s t han ge r is o l a t or 6 — Muffl e r a nd t ai l p ip e 7 — Ex hau s t han ge r is o l a t or 8 — Ex hau s t han ge r is o l a t or 9 — Ex hau s t han [...]

  • Page 1776

    I te m P a rt Nu mb e r De sc ri pti o n 1 — Cat a l yt ic converte r 2 — Ex hau s t han ge r 3 — DPF 4 — Ex hau s t han ge r is o l a t or 5 — Re ar pi pe 6 — Ex hau s t han ge r is o l a t or 7 — Muffl e r 8 — Ex hau s t han ge r is o l a t or 9 — Ex hau s t f l e xi bl e pi pe Al l pe t rol vehi cle s a r e f i t t e d wi t h a[...]

  • Page 1777

    DPF co nt r ol s o ft wa r e i ncorporat e d i nt o t he engi ne c o nt r o l m o dul e (ECM) Dif f e rent i a l pr e s s ur e s e n s or The DPF reduce s t he pol l ut i o n ge ne rat e d by di e s e l ve hi cle s b y f i l te r i ng s o ot pa rti cl e s o ut of t he e xhaus t g a s e s . The DPF i s l o cat e d i n t he e xhaus t s ys t e m, down[...]

  • Page 1778

    The fi r s t po s t-i nj ect io n o f f ue l bur ns i ns i de t he cy l i nd er, whi ch i ncr ea s e s t he t e mp e rat ure o f t he e xha us t ga s The s e c ond p os t -i nj e ct i o n o f f uel i s i nj e ct e d l a t e i n the po we r s t roke cy cle . The f ue l p a r t l y combus t s i n t he cyl i nde r , but s o m e un-bur nt f uel a l so [...]

  • Page 1779

    It e m Pa r t Nu m be r Descri pti o n 1 - H ig h p r es s ur e co nnect i o n 2 - Lo w p r e s s ure co nne cti o n 3 - El e c t r i cal co nne cto r The di f f e rent i a l pr e s s ur e s e nso r i s l o ca t e d i n t h e e ngi ne co mpar t me nt , o n t he l o we r RH si d e o f t he bul khea d. The se ns o r is l o cat ed o n 2 s t ud s a nd [...]

  • Page 1780

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - E xhaust System Dia gn os i s a nd Te s t i ng Over view For i nfo rm at i o n o n t he des cr i pt i on a nd o perat i on o f t he d i e s e l pa r t i cul a t e fi l t e r (DPF) a nd c a t al yt i c conver t e r s y s t e ms: REFER t o : E xhaus t Sy st e m (309- 00 Exha us t S yst e m , De s cr i p[...]

  • Page 1781

    DT C Descri pti on P ossi bl e cause Act i on s en s o r f a ul t P 0546 Exhaus t ga s t e mpe r a t ur e s e ns o r c i r cuit h ig h, right -ha nd ba nk, ups t r e a m s e ns or Ex ha us t g as t e mperat ur e s en s o r ci r cuit : s hort ci rc ui t to pow er Ex ha us t g as t e mperat ur e s en s o r f a ul t Ref e r t o t he a p pr ove d d i a[...]

  • Page 1782

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Catalytic C o n verte r2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he o i l f i l le r cap a nd o i l l e ve l i ndi ca t o r t o[...]

  • Page 1783

    5. Remove t he ca ta l yt ic convert er t o t ur bo charger r et a i ni ng nut s . Re mov e a nd di s c a r d t he r et a i ni ng nut s . 6. D i s conne ct t he ca t a l yt i c c o nver t e r t e mpe r a t ur e s e ns or e l ect r i cal conne ct or. 7. Remove t he e xhaus t f le xibl e pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o:[...]

  • Page 1784

    10. Remove t he ca t a l y t i c co nverte r. Re mov e t he s e cur ing bol t . Re mov e a nd di s c a r d t he gas ke t. Insta llat ion 1. CAU TI O N : Ne ver us e j oi nt i ng compou nd f or wa rd of t he ca t al yti c c on ver t e r . • NO T E: Co at t he ca t a l y t i c convert er s t uds wi t h a nt i -s e i z e grea s e . I nst a l l t he [...]

  • Page 1785

    6. Att a ch t he t u r b o charger o ut le t pi pe . 1. Re pos i ti on t he pi pe . 2. Ti g ht e n t he r e t a i nin g cl i p. Ti ght e n t o 4 Nm. 7. Ins t a l l the t ur bocharger out l e t p ip e ret a i ni ng bo l t . Ti ght e n t o 46 Nm. 8. Ins t a l l the e xha us t f l e xib l e pi p e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t[...]

  • Page 1786

    11. NO TE: Re move t he o i l f i l l e r cap and oi l le vel i nd i cat o r . I nst a l l t he e n gi ne cove r. 12. Ins t a l l t he oi l f il l e r cap . 13. Ins t a l l t he oi l l e vel i ndi cat o r . JagDocs.com[...]

  • Page 1787

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Catalytic C o n verte r LH 2.0L N A V 6 - AJV6 / 2.5L NA V6 - AJV6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: B[...]

  • Page 1788

    7. Remove t he f r ont pi p e . 8. Remove t he t he r mos t a t ho us ing t o o i l co ol e r coo l an t pi pe. 9. Remove t he ca ta l yt ic convert er he a t s hi e l d l o we r r e t ai ni ng bo l t . 10. Lowe r t he vehi c l e . 11. Det a ch a nd r e po s i t i o n t he wi ring ha rnes s e s . 12. Remove t he a i r cl ea n e r r e t a i ni ng br[...]

  • Page 1789

    13. Det a ch a nd r e po s i t i o n t he r adi a t o r i nl e t co o l a nt pi p e . 14. Remove t he ca t a l y t i c co nverte r he a t s hi e ld . 15. Remove t he ca t a l y t i c co nverte r. Dis car d t he ret a i ni ng nut s . 16. Remove t he HO 2S. 17. Remove a nd di s car d t he c a t a l yt i c conver t e r r e t ai ni ng s t uds . JagDocs[...]

  • Page 1790

    18. Remove a nd di s car d t he se a li ng r i ng. Insta llat ion 1. CAU TI O N : Ne ver us e j oi nt i ng compou nd f or wa rd of t he ca t al yti c c on ver t e r . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ins t al l a ne w s e a li ng r i ng. 2. Ins t a l l new cat a l yti c co nv e r t e r r e t a ini ng s t u ds . Ti ght e [...]

  • Page 1791

    5. Tig ht e n t o 10 Nm. 6. Tig ht e n t o 6 Nm. 7. Tig ht e n t o 10 Nm. 8. Tig ht e n t o 55 Nm. 9. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Ti ght e n t o 55 Nm. JagDocs.com[...]

  • Page 1792

    10. Ti g ht e n t o 25 N m. 11. NO TE: Fo r N AS ve hi cle s o nl y. I f r e qui red, ca r r y o ut a l ong dr ive cycle . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o: P o we r t r ai n Co nt rol Mo dul e (PCM) Lo ng Dr i ve Cyc l e S e l f -Te s t ( 303-14A El e c t r on ic Engi ne Cont r ol s - 2.0L NA V6 - AJV6/2.5L NA V 6 - AJV6/3.0L [...]

  • Page 1793

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Catalytic C o n verte r RH2.0L NA V 6 - AJV 6/ 2.5L N A V6 - AJV6 / 3.0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s ubfr a me. Fo r a d di t i o nal i nfo r mat i o n, refe r to For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L[...]

  • Page 1794

    6. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Re move a nd di s ca r d t he r e t a i ni ng nut s . 7. Remove and di s card t he r et ai ni ng s t uds . 8. Remove t he HO 2S . 9. Remove and di s card t he s e a l i ng ring . Insta llat ion 1. CAU TI O N : Ne ver us e j oi nt i ng compou nd f or wa rd of t he ca t al yti c c on ver t e r . To[...]

  • Page 1795

    2. Tig ht e n t o 40 Nm. 3. Ins t a l l new r et a i ni ng s t uds . Ti ght e n t o 9 Nm. 4. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . • NO T E: Make s ur e t ha t t he ret a i ni ng nut s a re t i ght e ne d t wi ce i n t he s eq ue nce sho wn. Ti ght e n i n t he s e q uence s ho wn t o 25 Nm. 5. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i [...]

  • Page 1796

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Diesel Particul ate Filter (DPF ) Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. D i s conne ct t he di es e l p[...]

  • Page 1797

    6. Remove t he di es e l pa r t i cul a t e f i l t er t o f l e xib l e pi pe ret a i ni ng n ut s . Re mov e a nd di s c a r d t he gas ke t a nd n uts . 7. Remove t he di es e l pa r t i cul a t e f i l t er. Re mov e a nd di s c a r d t he gas ke t a nd n uts . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e [...]

  • Page 1798

    2. Tig ht e n t o 46 Nm. Ins t al l a ne w ga s k e t a nd nut s. www.JagDocs.com JagDocs.com[...]

  • Page 1799

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Diesel Particul ate Filter (DPF ) Diff erential Pressu re Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r ou tl et pi pe. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r Out l e t P i pe (303-12B I nt a ke Ai r Di s t ribut i o n a nd Fi [...]

  • Page 1800

    6. NOT E: Not e t h e o r i e nt a t i o n o f t he DPF di ff e r e nt i a l pres su r e hi gh-pr es s ur e and lo w-pres s ure ho s e s a nd make sure t hey a re i ns t a l le d i n th e s a me p os i t i on . Di s conn ect t he DP F di f fe rent i a l p r e s s ur e s e ns o r hi gh-pr es s ure a nd l ow -pr es s ur e ho s e s . 7. Remove t he DP[...]

  • Page 1801

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - E xhaust Flexible Pipe2.0L Durato rq- TDCi /2 .2L Durato r q- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k[...]

  • Page 1802

    2. Tig ht e n t o 46 Nm. Ins t al l a ne w e xha us t f l e xib l e pi p e ga s ket a nd nut s . JagDocs.com[...]

  • Page 1803

    [...]

  • Page 1804

    1. CAU TI O N : The e xhaus t hange r is o l a t or s a r e cons t r uct e d o f a s pe ci a l mat e r ia l . Us e onl y t he cor r e ct s pe cif ica t i o n e xhaus t ha nge r is o l a t or s . • NO T E: Check t he e xhaus t ha nge r i s o l a t o r s f or da mag e o r fa t i gue . In s t a l l new e xhaus t ha nge r i s ol at o r s i f r e qui [...]

  • Page 1805

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Front Muffl er2. 0L NA V6 - A JV6 /2. 5L NA V 6 - A JV 6/3.0 L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 100-01 Id e nt i fi cat i o n Cod e s . 2. Loos [...]

  • Page 1806

    6. D et a ch t he f ront muff l e r hange r i s o l a t o r s . 7. Remove t he f r ont muff l e r. Loo s e n t he f ront muffl e r cla mp ret a i ni ng nut s . Insta llat ion Vehi c le s with 2.5L or 3.0L engine 1. CAU TI O N : The e xhaus t hange r is o l a t or s a r e cons t r uct e d o f a s pe ci a l mat e r ia l . Us e onl y t he cor r e ct s[...]

  • Page 1807

    3. CAU TI O N : The e xhaus t hange r is o l a t or s a r e cons t r uct e d o f a s pe ci a l mat e r ia l . Us e onl y t he cor r e ct s pe cif ica t i o n e xhaus t ha nge r is o l a t or s . • NO T E: Check t he e xhaus t ha nge r i s o l a t o r s f or da mag e o r fa t i gue . In s t a l l new e xhaus t ha nge r i s ol at o r s i f r e qui [...]

  • Page 1808

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler and T ailpipe2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma, 2.0L Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a n[...]

  • Page 1809

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler and T ailpipe2.5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. NOT[...]

  • Page 1810

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler In let Pipe2. 0L NA V6 - A JV6 /2. 5L NA V 6 - A JV 6/3.0 L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he f r ont whe e l and t i r e. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i o n 204-04 W he e l s a nd Ti r e s . Vehi c l[...]

  • Page 1811

    6. D et a ch t he muff l e r . S la cken t he m uf fl e r r et a i ni ng cl a mp nut s . All v e h icle s 7. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Re move t h e muff l e r i nl e t p ip e . 8. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Re move t h e e xhaus t hea t s hi e l d. Insta llat ion All v e h icle s 1. NOT E: 2.5L a nd 3[...]

  • Page 1812

    2. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Ti ght e n t o 55 Nm. Vehi c le s with 2.0L engi n e 3. Tig ht e n t o 55 Nm. 4. Tig ht e n t o 55 Nm. Vehi c le s with 2.5L or 3.0L engine 5. NOT E: Ins t a l l a new ga s ket . Ti ght e n t o 55 Nm. JagDocs.com[...]

  • Page 1813

    6. Tig ht e n t o 55 Nm. 7. Tig ht e n t o 10 Nm. JagDocs.com[...]

  • Page 1814

    P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler In let PipeVehicles With : Diesel Particula te Filter (DPF ) Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).[...]

  • Page 1815

    2. Tig ht e n t o 55 Nm. JagDocs.com[...]

  • Page 1816

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Gen eral S p ec if ic a t ions I te m Speci fi cati on Fue l t a nk capa ci t y 61.5 l trs T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b-i n Fue l t a nk s e nder uni t l ock r ing s 70 52 - JagDocs.com[...]

  • Page 1817

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 2.0L e ngi ne I te m P art Nu mber De sc ri pti on 1 — Fuel t a nk fi l l er pi pe 2 — I nerti a f ue l s hut of f (I FS ) s wi t ch 3 — Fuel p ump 4 — Fuel f il t e r 5 — Fuel t a nk The mechani ca[...]

  • Page 1818

    The e l e ct ric t ur b i ne fu e l pump, whi ch o pe rat e s i n a f u e l r es ervoir , ha s a n i nt e g r al t o p pl a t e f or t he e xte rn al p i pe wor k an d e l ect r i cal conne ct ors. T he pump is s e cur ed t o t he f ue l t a nk by a s crew-on pl a s t i c cl o s u r e r ing. Two rol l o ver val ves a r e conne ct e d by a hos e whi[...]

  • Page 1819

    6 — Fue l t rans f e r pu m p (j e t p ump ) modul e The e l e ct roni c ret ur nl es s f ue l s ys t e m u ti l i ze d ha s t he f ol l o wi ng a dvant a ge s : r e duced fue l t a nk va po r . r e qui res l e s s e l e ct r ica l p o wer. do es not req ui r e a f ue l ret ur n l i ne. The i nt e ll i ge nc e o f t hi s s ys t e m i s co nt a i [...]

  • Page 1820

    It e m Pa r t Nu m be r De scr i pti on 1 - Fuel t a nk f i l l e r p i pe 2 - Fuel f i l t er 3 - S e n der uni t 4 - Fuel t a nk The fue l t ank i s co nst r ucte d of h i g h de nsi t y po l yt hyl e ne a nd i s l o c a t e d un dernea t h t he ve hi c l e be l o w t he rea r pa s s e nge r s e a t . T he t a nk i s r e t a i ne d b y t wo s upp[...]

  • Page 1821

    * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. 3. If a n obvi o us cau se fo r an ob s e rv e d o r r epo[...]

  • Page 1822

    1 2 3 4 1 2 1 2 1 1 2 3 4 1 1 2 1 1 Pi n Nu m be r C i r cu i t F u nc ti on C i r cui t Col or 2 Gr ound Bl a ck 3 Fue l pump ground Y e l l ow 4 T hr ot t l e s c reen Bl a ck/ gr ee n 5 Fue l pump s cr e e n W h i t e 7 E CM m oni t o r o ut put W hi t e 9 B a t t e r y p o s i t i ve Br o wn/gr ee n 10 Fue l pump po s it i ve Re d PINPOIN T TE [...]

  • Page 1823

    2 1 2 3 4 1 2 3 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2 3 4 Meas ur e t he res is t a nce b e t we e n t h e f ue l pump co nt roll e r CA105 p i n 2, and GRO UN D. I s t he r es i s t a nce l e s s t ha n 0. 5 O hm? Ye s REPAI R t he ci r cui t b e t we en t he f ue l pump c o nt r ol l e r CA105 pi n 2, (B) and GR O U ND. CLEA R DTC. TEST t he s ys t em [...]

  • Page 1824

    1 2 1 2 3 4 1 2 3 1 2 Is t he vol t a ge gr e a t e r t han 10.5 Vo l t s ? Yes GO t o B 2 . No GO t o B 3 . B2: C HEC K T HE GR O UND SUPP LY T O T HE F UEL T ANK ELECT R IC AL CO NNECT OR S wit ch t he i g ni t i o n t o t he O FF p os i t i on. Meas ure t he r es is t a nce a t t he fue l ta nk e l ect r i cal co nnect o r be t we e n CA 005 pi [...]

  • Page 1825

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Pressure C heck Gene ral P r ocedures • NO T E: T hi s p rocedur e i s f o r t he i nst a l l at io n of t he a d a pt o r i nt o t he fue l l i ne d ue t o t he r e m ova l o f t he s c hr a ede r va lve f r o m th e fue l li ne . 1. W ARN INGS : P l a ce t he ve[...]

  • Page 1826

    6. Ins t a l l the f uel p res s ur e g auge . 7. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ). 8. Car r y out t he f ue l s yst e m pr e s s ure check. For a ddi ti ona l i nf o r m a t i o n, r [...]

  • Page 1827

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Pressure Release Gene ral P r ocedures R el ease 1. W ARN INGS : Do no t s moke , carr y l ig ht e d to b a c co o r an o p e n f l a me o f a ny t ype whe n wo r king on o r nea r an y f uel rel a t e d co mpone nt s . Hi ghl y f l a mmabl e vapors a r e a l wa y s[...]

  • Page 1828

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Tank D raini ng2.0 L D uratorq- TDC i/2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Gene ral P r ocedures Speci al T ool (s) Fuel s uppl y l i ne a da pt o r 310-1 31 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge No Sm ok i ng s i gn s[...]

  • Page 1829

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Tank D raini ng2.0 L N A V6 - AJV6 / 2.5L NA V6 - A JV6 / 3.0L N A V6 - AJ27 Gene ral P r ocedures Speci al T ool (s) Re move/Re fi t fue l p ump/ s e nd er l o ck i ng nut 310-072A 2.0 L veh icle 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd [...]

  • Page 1830

    Af t e r car r yi ng o ut repai r s , t he f ue l s y s t e m mu s t b e che cked vi s ua l l y fo r l ea ks . F a i l ur e t o fo l l o w t he s e i ns truc t i o ns may res ul t i n pe rsona l inj ur y. Di s conn ect t he ba tt e r y ground ca bl e . Fo r a ddi t i ona l i nf o r m at i o n, r ef er t o S ect i on 414-01 Ba t t e r y, Mount i ng [...]

  • Page 1831

    7. Remove t he f uel t r ans fe r pump. Dis conne ct t he cros s o ver pi pe s Re mov e a nd di s c a r d t he O -r ing s e a l . 8. D i s conne ct t he e l ect r i cal conne ct o r. 9. D et a ch t he e l e c t r i cal co nne ct or. 10. Dis c o nne ct t he f uel s u ppl y pi p e . 11. Us i ng t he s pe ci a l t o o l , r e move t he l o ck i ng rin[...]

  • Page 1832

    12. CAUT I O N: Ma k e s ure t he fl oa t or a rm are no t da ma ged whi l e r e m o ving th e f ue l pump modul e . Guide t he f u e l pump modul e t hr o ug h t he a perture. 13. CAUT I O N: Ma k e s ure d a mage t o t he fue l c r o s s o v e r pip e s do e s not occur . Guide t he cros s ove r pi pe s t hr ough t he a pe r t ur e . 14. Remove t[...]

  • Page 1833

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Quic k Releas e Co upli ng - Push C o nnect Gene ral P r ocedures Disc onn e ct 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Fue l Va p or s " s i gns a b ou t th e ve hi cle . Be f o r e a ny wo r k i s ca r r i[...]

  • Page 1834

    5. D i s conne ct t he f uel l i ne q ui ck r e l e a s e coupl i ng. 1. P r es s t he fue l li ne qui ck rel e as e coupl i ng l o ck i ng t a ngs . 2. Dis con nect t he f ue l l i ne q ui ck r e l e a s e co upl i ng. 6. D i s conne ct t he f uel l i ne q ui ck r e l e a s e coupl i ng. P r e s s t he f ue l l i ne q ui ck r e l ea s e co upl i n[...]

  • Page 1835

    9. Rel e as e t he f uel l i ne qui ck rel e a s e coupl i ng. P r e s s t he f ue l l i ne q ui ck r e l ea s e co upl i ng l o cking r e l e a s e co ll ar. 10. Dis c o nne ct t he f uel l ine qui ck rel e a s e coup li ng. 11. Us i ng a s uit a bl e Fl a t -bl ad e d s cr ewd river r el e a s e t he fue l l i ne q ui ck r el e a s e coupl i ng s[...]

  • Page 1836

    C onne ct • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t ype whe n wo rk i ng on o r ne ar an y f uel rel a t ed com po ne nt s . Hi ghl y fl a mm a b l e vapo r s are a l ways pre se nt a nd m a y i g ni t e . Fa i l ur e t o f o l l ow t he s e i nst r uct i ons may res ul t i n p e r s o na l i njur[...]

  • Page 1837

    5. CAU TI O N : Make s ur e t h e fue l l i ne cl i cks i nt o pl ace w hen i ns t a l l i ng th e l i ne . T o make s ur e t ha t t he f ue l l i ne i s ful l y s e at e d , pul l o n t he l i ne . I nst a l l t he f ue l l i ne q uick r e l e as e cou pl i ng. 6. NOT E: Make s ure t he col l a r o n t he fue l l i ne is i ns e rte d ful l y int o[...]

  • Page 1838

    P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Spring Loc k C ou plin g s Gene ral P r ocedures Speci al T ool (s) S pr ing Lo ck Co upl e r Too l o r E qui val e nt 23-040 D isco nn e ction 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Pe t rol Fum e s " s i [...]

  • Page 1839

    4. Ins t a l l the s p r i ng l ock co upl i ng t oo l . P la ce s ui t a b l e a bs o rb e nt mat e r i al be lo w t he pi pe t o col l e ct f ue l s pi l l ag e 5. Clo s e a nd pus h t he s p r i ng l o ck coupl i ng t o o l in to t he o pe n s i d e of t he cage . 6. S e pa r at e t he fi t t ing . 7. Remove t he s p r i ng l o ck coupl i ng t o[...]

  • Page 1840

    1. Ins pect a nd cl e a n bo t h coupl i ng e nds . I ns t a l l ne w O -r ing s an d g a r t e r s p r i ngs if ne ces s a r y. 2. F i t t he ma le f i t t i ng i nt o t he f e mal e e nd a nd pus h unt i l t he ga r t e r s pring s na ps over t he fl a r e d e n d o f t he mal e f i t t i ng. 3. M ake s ure t he coupl i ng i s e nga g e d by pul [...]

  • Page 1841

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b-i n Fue l t a nk s u pport s t r ap r et ai ni ng b o l t s 25 18 - Fue l pu m p modul e l ocking ring - v e hicl es wi t h 2.5L o r 3.0L e ngi ne (non f e de ral mar k e t vehi cl e s ) 70 52 - Fue l pu m p modul e l ocking ring - v e hi[...]

  • Page 1842

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank a nd Lin es Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 2.0L e ngi ne It e m P a rt N um be r De scri pt i on 1 - Fue l pump modul e 2 - Fue l t a n k 3 - L o we r fu e l t a nk f i l le r pi pe ret a i ni n g nut 4 - U pp e r f ue l t a nk f i l le r pi pe ret a i ni ng [...]

  • Page 1843

    Item Pa rt Nu m ber De scr i pti on 1 - Fue l l e ve l se n s o r 2 - Fue l t a nk 3 - Fue l t a nk f i l l e r pi p e 4 - Fue l t a nk f i l l e r pi p e brea t he r hos e 5 - Fue l t a nk he a t s hi e l d 6 - Fue l t a nk s up port s t raps 7 - Fue l t a nk s up port s t rap i ns ul a t or 8 - Fue l fi l t e r Ve hi cl e s wi th 2.5L or 3.0L e n[...]

  • Page 1844

    I te m P a r t Nu m be r Des cri pti o n 1 — Fue l f i l le r ca p 2 — Fue l t a nk f i ll e r pi pe 3 — Fue l t rans f e r pump 4 — Fue l t a nk 5 — Fue l t a nk s uppo rt s t raps 6 — Fue l f i l te r 7 — Fue l pump modul e 8 — Fue l t a nk p r es s ure s e ns o r (Fed e ral market vehi cl e s onl y) Fu el Tan k The fue l t ank i [...]

  • Page 1845

    Fu el Tan k Filler Pi pe The fue l t ank fi l l e r pi pe i s o f a s t e e l con st r uct i o n a nd i s r e t a i ne d t o t he vehi cl e by mea n s of t hree r e t a i ni ng nut s, o ne ret a i ni ng t he fi l l er ne ck t o t h e bo d y a nd t wo nut s re t a i ni ng t he f i ll er pi pe t o th e ve hi cle chas s i s . The f ue l t a nk f i l l[...]

  • Page 1846

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank a nd Lin es Dia gn os i s a nd Te s t i ng Insp ection a nd verif ica tion 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual i ns pecti o n, vehi cl es wit h petrol engi nes Mecha[...]

  • Page 1847

    Ve hi cl e s wi th di ese l engi ne onl y. Do no t i nt e r change fue l i nj e ct ors . Improper i n je ct o r i ns t al l a t i o n ca n caus e mi s fi r e s , po or r unni ng a nd s e vere e ngi ne da mag e. Make s ur e tha t a ny pr ot ect i ve clo t hi ng worn i s c l e a n and made from l i nt -fr e e no n-fl o cking mat e r i a l . Fa i l ur[...]

  • Page 1848

    Sym ptom P ossi bl e s ource Acti on Di ff i cul t t o s t a rt hot Inj ect or l e a k Fuel t empe rat ure s ens o r IAT s e ns or MAF s e ns o r Engi ne c o ol a nt te m pe r a t ur e (ECT) s ens o r Purge val ve Fuel pu m p Igni t i on s ys te m EG R val ve s t uck op e n For fue l inj e ct o r te s t s , REFER t o: Fue l Charging a nd Co nt r o [...]

  • Page 1849

    Sym ptom P ossi bl e s ource Acti on c a ni s t e r S no w o r i ce pa ck around th e ca ni s te r o ut le t or fi l t er Fue l s m e l ls i n/around t he vehi c l e Fil l er ca p i ncorr e ct l y f i t t e d Lea ks f r om j o i nt s Lea ks f r om mod ul e s e a l s Lea k f r o m i nl et /out l e t pi pe s a t p ur ge va l ve Ino pe r at i ve pu r [...]

  • Page 1850

    1 2 3 DT C C ondi ti on Possi bl e s ource Ac ti on P 0441 Evapo r at i ve e mi s s i o ns s ys t e m, in c orr e ct p ur ge f l o w Ca ni s t er purg e pi p e ; r e s t rict ed, l e aki ng o r di sco nne ct ed Ca ni s t er vent r e s t r i ct e d Ca ni s t er purg e pi p e s t o e ngi ne ; r es t ricte d, l e aki ng o r di s conne c t e d Ca ni s [...]

  • Page 1851

    1 2 1 1 1 FT06, p i n 02 (B ) and GROU ND. FT06, p i n 04 (B ) and GROU ND. Ve hi cl e s wi th 2.0 L pet r ol ; CA415, p i n 04 (B) a nd GROU ND. Ve hi cl e s wi th 2.0 /2.2 L di e s el e ngi ne s ; CA415, p i n 04 (B) a nd GROU ND. I s t he r es i s t a nce gr ea t e r t ha n 5 oh m s ? Ye s REP AIR t he hi gh r e s i s t a nce ci rcu i t . Fo r a[...]

  • Page 1852

    1 1 1 2 3 1 1 2 F06, pi n 05 (W B) a nd GRO UN D. I s t he r es i s t a nce l e s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t ci r cuit . For a ddi t i o na l i nfo rm at i on, ref e r t o t he wiring di a g rams. CL EAR t h e DTC, t e s t t he s yst em f o r no r mal o p e r at i o n. No GO t o A 6 . A6 : CHEC K T HE FUEL LEVEL SEN SOR RAN G[...]

  • Page 1853

    1 2 3 4 1 2 1 2 3 4 5 6 7 8 1 No GO t o B4 . B4: C HEC K T HE PO WER SUP PLY CIRC UIT T O T HE F UEL PUMP Re conne ct t he f uel pump modul e conne ct o r , CA105. Dis conne ct t he fu e l pump co nnect o r: Ve hi cl e s wi th 2.5/3.0 L e ng ine , RO W ; FT02. Ve hi cl e s wi th 2.5/3.0 L e ng ine , U S A; FT06. Tur n t he i gni t i o n s wi t ch t[...]

  • Page 1854

    2 3 4 1 2 3 4 5 1 2 Mak e s ure t he gea r s e le ct o r i s i n t he NEUT R AL pos i t i on f or ve hi cle s f i t t e d wi th manual t r ans mis s i on , P AR K po s i t i o n fo r vehi cle s fi tt e d wi t h aut o mat i c tran smi s s i o n. S t a r t t he e ngi ne a nd a l l o w t o i dl e . W hi l e t he e ngi ne i s i dl i ng, d i s co nnect [...]

  • Page 1855

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Filter2.0L Du rat o rq-TDCi/2. 2L Duratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ha nd P r e s s ur e Pu m p wi t h A da pt e r Kit 310-110 R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t yp[...]

  • Page 1856

    4. D i s conne ct t he f uel f il t e r t o f uel pump f u e l s uppl y l i ne f r om t he fu e l f i l t e r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Ins t al l a b l a nking pl ug t o t he f u e l[...]

  • Page 1857

    3. NOT E: Make s ure t ha t t he ha nd p r i mer arr o w i ndi ca t i ng t he fue l f l o w i s poi nt i ng t o wa rds t he fue l f i l t er. I nst a l l t he ha nd p r e s s ure pump s p e ci a l t oo l b et we e n t he fue l fi lt e r and t he fue l f i l t e r fue l s uppl y l i ne . 4. NOT E: O nce t he ha nd pr e s s ur e pump s pe ci a l t o [...]

  • Page 1858

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Filter2.0L N A V6 - AJV6/2.5L NA V 6 - A JV6/3.0L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Pe t rol Fum e s " s i gn s a bo ut t he ve hi cl e . Do no t s m[...]

  • Page 1859

    Insta llat ion 1. W ARN INGS : Do no t s moke o r car r y l i ght e d t ob a cc o or ope n f l a me of a ny t ype whe n wo r king on o r nea r an y f uel rel a t e d co mpone nt s . Hi ghl y f l a mmabl e vapors a r e a l wa y s pr es ent a nd may i gni t e . Fai l ur e t o fo l l o w t he s e in s t ruc t i o ns may r e s ult i n pers o nal i njur[...]

  • Page 1860

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender2 .0L NA V 6 - A JV 6 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl a mm a b l e vapo r s [...]

  • Page 1861

    5. Remove t he f uel l e vel s e nder. Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl a mm a b l e vapo r s are a l ways pre se nt a nd m a y i g ni t e . Fa i l ur e t o f o l l ow t he s e i nst[...]

  • Page 1862

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender2 .0L Duratorq-TDC i/2. 2L Duratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne [...]

  • Page 1863

    Do not ca r ry or o perat e c e l l ul a r pho nes w he n work ing o n o r ne a r a ny f ue l r e l at e d co mpo nent s . Hi ghl y f l a mm abl e vapo rs a r e a l wa y s pr es e nt an d may i gni t e . Fa i l ure t o fo l lo w t he se in s t ruc t i o ns may r e s ul t i n p ers ona l i nj ur y. Th is proc e dur e i nvol ve s fue l h a ndl i ng. [...]

  • Page 1864

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender LH2.5L NA V6 - AJV6 / 3.0L NA V6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl a m[...]

  • Page 1865

    5. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. Re move t h e fu e l l e ve l se n de r a nd h arnes s . Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl a mm a b l e vapo r s are a l ways pre s[...]

  • Page 1866

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender R H2.5L N A V6 - A JV 6/3. 0L NA V6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl [...]

  • Page 1867

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Senso r2.0L Durato rq- TDCi/2.2L D uratorq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re move/In st a l l f ue l pump/trans f e r pum p l o ck i ng r i ng 310-127 R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or[...]

  • Page 1868

    4. D et a ch t he t o p o f t he fue l l e ve l s ens or . 5. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e r e m o ving th e f ue l l e v e l s e ns o r. Re move t h e fu e l l e ve l se n s o r . 1. Ro t a t e t he l o we r pa r t o f t he fue l le vel s e ns o r . 2. Re move t he f ue l l e ve l se ns o r . Re mov e a[...]

  • Page 1869

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Pump Mo dule2.0L N A V6 - AJV6 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re move/In st a l l f ue l pump/trans f e r pum p l o ck i ng r i ng 310-072A R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i [...]

  • Page 1870

    5. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e r e m o ving th e f ue l pump modul e . Re move t h e fu e l pump modul e . 1. Ro t a t e t he l o we r pa r t o f t he fue l pump modul e . 2. Re move t he f ue l pump modu le . Re mov e a nd di s c a r d t he s e a l . Insta llat ion 1. W ARN INGS : Do no t s moke o r ca[...]

  • Page 1871

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Pump Mo dule2.5L N A V6 - AJV6 / 3.0L NA V6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove /Ins t a l l f ue l pum p/t r a ns f e r p ump lo cking r i ng (Non fe d e r al mar ket ve hi cl e s onl y) 310-0 72A Remove /Ins t a l l f ue l pum p/t r a ns f e r p ump lo cki[...]

  • Page 1872

    3. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Det ach t he e l e ct r i ca l conne cto r . 4. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Di s conn ect t he fu e l s uppl y pi p e . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o: Q ui ck Re l ea s e Co upl i ng - P us h Conn ect (310-00 Fuel S ys te m - Ge neral I nf orm at [...]

  • Page 1873

    8. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Re move t h e fu e l pump modul e a nd cr os s ove r pi pe s . Re mov e a nd di s c a r d t he O -r ing s e a l . 9. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. Re move t h e fu e l t ank. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o: Fue l Ta nk - 2. 5L NA V6 - AJV 6/3.0L NA V 6 [...]

  • Page 1874

    13. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Det ach t he f uel p ump m o dul e f la n ge f rom t he f uel pump mo dul e ba s e . 14. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he e l e ct rica l conne ct o r . 15. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he e l e ct rica l conne ct o r . 16. Det a ch[...]

  • Page 1875

    18. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he fu e l cr o s s ove r pi pe f r om t he fue l p ump modul e b a s e . 19. CAUT I O N: Ma k e s ure t he fl oa t or a rm are no t da ma ged whi l e r e m o ving th e f ue l pump modul e . • NO T E: Fed e ral market vehi cl e s onl y. Re move t h e fu e l pump modul e . Re mov e [...]

  • Page 1876

    1. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e in s t a l l in g t he f ue l p ump mod ul e . • NO T E: Fed e ral market vehi cl e s onl y. • NO T E: Make s ur e t he f ue l pump modul e is corr e ct l y o r i en t a t e d . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ins t al l a ne w O -r i ng s [...]

  • Page 1877

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank2.0L N A V6 - A JV 6 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : P l a ce t he ve hi cl e i n a we l l v e nt il a t e d, quarant i ne d a rea a nd a r r ange No S m ok i ng/P e trol Fu mes s i gn s a bo ut t he ve hi cl e . Be f o r e a ny wo r k i s ca r r ie d o u[...]

  • Page 1878

    7. D i s conne ct t he f uel f il t e r l i ne qui ck rel e a s e coupl i ng. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). 8. D i s conne ct t he f uel f il t e r l i ne qui ck rel e a s e coupl i ng. For[...]

  • Page 1879

    12. NO TE: An as s i s t a nt w i l l be req uir e d to r e move t he fu e l t a nk. Re move t h e fu e l t ank. Re mov e t he f ue l t a nk s uppo rt s t raps . Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s .[...]

  • Page 1880

    4. Connect t he e va porat i ve e mis s i on ca ni s t er ho s e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). 5. Connect t he f ue l f il t e r l i ne qui ck rel e a s e coupl i ng. For a ddi ti ona l i[...]

  • Page 1881

    10. At t ach t he wi r i ng harnes s gr omm e t . 11. Ins t a l l t he r e ar s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t i o n). 12. Conne ct t he b a t te r y g r o und cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t[...]

  • Page 1882

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank2.0L D urato rq - T DCi/2. 2L Duratorq-TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : P l a ce t he ve hi cl e i n a we l l v e nt il a t e d, quarant i ne d a rea a nd a r r ange No S m ok i ng s i gns abo ut t he v e hi cl e. Do not s moke [...]

  • Page 1883

    6. D et a ch t he brea t he r ho se from t he fue l t ank. 7. NOT E: Not e t h e o r i e nt a t i o n o f t he fue l t a nk f il l e r pi pe t o f uel t a nk hos e r e t a i ni ng cl i p b e fo re l o o s e ni ng. Lo o s e n t he f uel t a nk fi l l er pi p e t o fu e l t a nk ho s e ret a i ni ng cl i p. 8. NOT E: An a s s i s t a nt wi ll b e r e[...]

  • Page 1884

    1. NOT E: An a s s i s t a nt wi ll b e r e qui r ed t o i ns ta l l t he f uel t a nk. • NO T E: Make s ur e t he f ue l f i l l e r pi pe ho s e i s conne c t e d t o t he fue l t a nk a s it i s i ns t al l e d. I nst a l l t he f ue l t ank. Ins t al l t he f ue l t a nk s u pport s t raps . Ti ght e n t o 25 Nm. 2. NOT E: Make s ure t he f u[...]

  • Page 1885

    6. Lowe r t he vehi cl e . 7. F i l l t he fu e l t ank w it h fue l . 8. Connect t he e l ect r i cal co nnect o r. 9. Att a ch t he wi r i n g ha r ne s s g r omm et . 10. Ins t a l l t he r e ar s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Di s a s s embl y a nd As s e m[...]

  • Page 1886

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank2.5L N A V6 - A JV 6/3.0 L N A V6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l • W ARNINGS : P l a ce t he ve hi cl e i n a we l l v e nt il a t e d, quarant i ne d a rea a nd a r r ange No S m ok i ng/P e tro[...]

  • Page 1887

    6. D et a ch t he e l e c t r i cal co nne ct or. 7. D i s conne ct t he e l ect r i cal conne ct o r. 8. Usi ng a s ui t a bl e s uct i on devi c e dr a i n t he f uel t a nk fi l l e r pi pe . 9. NOT E: To pr e vent t he ve hi cl e be coming uns t a bl e whe n t he f ue l t a nk ha s bee n r emove d, i ns t a l l t h e ve hi cle t ie down s t r a[...]

  • Page 1888

    13. Remove t he a xl e as s e m bl y rea r r e t ai n in g b ol t . 14. Remove t he a xl e as s e m bl y f r ont ret a i ni ng bol t s . 15. Us i ng t he s pe ci a l t o o l , l owe r the a xle a ss e mbly a pproximat e l y 75 mm (2.95 i nches ) . 16. Ins t a l l t he cha in s u ppl i e d wi t h t he s pe cia l t oo l HT J1200- 2 t o t he a xle a s[...]

  • Page 1889

    18. At t ach t he s e cur ing s t r a p s upp li e d wi t h t he s pe cia l t oo l HT J1200-2 t o t he r ea r t owi ng e ye t hr e a d a nd s uppo r t t he rea r of t he a xl e a s s e m bl y. 19. Remove t he s pe ci a l t o o l . 20. NO TE: No t e t he or i e nt a t i o n of t he f ue l t a nk f i l l e r pi p e t o f ue l t ank hos e r e ta i ni [...]

  • Page 1890

    23. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he e vapo r at i ve e mi s si o n cani s t e r cl o s e val ve e l e ctrica l conne ct or. 24. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Det ach t he e va porat i v e e mis s i o n ca ni s te r pur ge ho s e f r om t he fue l t a nk r e t a i ni ng cl i ps . 25. CAUT I O N: U s[...]

  • Page 1891

    28. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Us i ng t he s p e ci a l t o ol , l ow er t h e f ue l t a nk a ppr o x i mat e l y 100 mm (3.94 i nche s ). Det a ch t he fue l fi ll er pi pe ho se from t he fue l t ank. Ins t al l bl a nki ng pl ugs t o t he f ue l t a nk a nd f ue l f il l e r pi pe ho s e . 29. NO TE: No n f e de r a l ma r [...]

  • Page 1892

    33. W A RNING: T he f u el t a nk c a nno t be dr ai ne d i n ve hi cl e . Due t o t he hea vy we i ght , make s ur e t ha t t he f ue l t a nk i s s ecur e l y a t t a ched t o t h e pow ertrai n as s e mbly j a ck when r e m o ving. Fa i lure t o f ol l o w t hi s i ns t ruc t i on m a y r es ult i n pe r s o na l i nj ury . • NO T E: Al l ve h[...]

  • Page 1893

    3. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Conn ect t he e vapo rat i ve e mi s si o n ca ni s t e r ho s e t o t he e vap orat i ve e mi ss i on cani st e r . 4. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. Conn ect t he e vapo rat i ve e mi s si o n ca ni s t e r ho s e t o t he e vap orat i ve e mi ss i on cani st e r . 5. NOT E:[...]

  • Page 1894

    8. Ins t a l l the f uel t a nk s uppo r t s t r aps re ta i ni ng bo l t s. Ti ght e n t o 25 Nm. 9. Remove t he s p e cia l to o l . 10. NO TE: Fe d e r al mar ket ve hi cl e s o nly. At t a ch t he e vapo r a t i ve e mi s si o n cani s t e r p ur ge ho s e t o t he f ue l t a nk r e t a i ni ng cl i ps . 11. NO TE: Fe d e r al mar ket ve hi cl [...]

  • Page 1895

    13. Conne ct t he e vapora ti ve e mis s i o n ca ni s t e r pur ge hos e qui ck rel e a s e coupl in g. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). 14. NO TE: Make s ur e th e fue l ta n k f il l e r pi[...]

  • Page 1896

    18. Remove a nd di s car d t he axl e a ss e mbl y wa s he r. 19. Ins t a l l a n ew a xl e a s s e mbl y wa s he r . 20. Remove t he cha i n f r om t he a xl e a s s e mbl y front s upp o r t bracket . 21. Us i ng t he s pe ci a l t o o l , i ns t a l l t he a xl e a s s e m bl y. 22. Loo s e l y i ns t a l l t he a xl e a s se m bl y front r et a[...]

  • Page 1897

    23. Loo s e l y i ns t a l l a ne w axl e a ss e mbl y r ea r r et a i ni ng bol t. 24. Ti g ht e n t o 90 N m. 25. Ti g ht e n t o 110 N m. 26. Remove t he s pe ci a l t o o l . 27. Ins t a l l t he f r ont muff l e r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Muff l e r - 2. 0L NA V6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ[...]

  • Page 1898

    30. Conne ct t he e l e ct r i cal conne ct o r. 31. At t ach t he e le ct r ica l conne ct o r . 32. At t ach t he wi r i ng harnes s gr omm e t . 33. Ins t a l l t he r e ar s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t i o n). 34. Fi ll t h[...]

  • Page 1899

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank Fill er Pipe Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Pe t rol Fum e s " s i gn s a bo ut t he ve hi cl e . Do no t s moke o r car r y l i ght e d t ob a cc o or ope [...]

  • Page 1900

    7. Remove t he f uel t a nk fi l l er pi p e a nd ho s e . 1. Re move t he r e t a i ni ng nut s . 2. Re move t he f ue l t a nk f i l le r pi pe a nd hos e . Insta llat ion 1. W ARN INGS : Do no t s moke o r car r y l i ght e d t ob a cc o or ope n f l a me of a ny t ype whe n wo r king on o r nea r an y f uel rel a t e d co mpone nt s . Hi ghl y [...]

  • Page 1901

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - G as F uel T ank Pre ss ure Senso r Re moval a n d I ns t a l l a t i on R em ova l • NO T E: T he f ue l t a nk pr e s s ure s e ns o r i s fi t t e d t o f e de r a l mark et ve hi cl e s o nl y. 1. W ARN INGS : Do no t s moke o r car r y l i ght e d t ob a cc o or an op e n f la m e o f a ny[...]

  • Page 1902

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ransfe r Pump Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove /Ins t a l l f ue l pum p/t r a ns f e r p ump lo cking r i ng (Non fe d e r al mar ket ve hi cl e s onl y) 310-0 72A Remove /Ins t a l l f ue l pum p/t r a ns f e r p ump lo cking r i ng (Fed e r al mark et ve hi[...]

  • Page 1903

    3. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Det ach t he e l e ct r i ca l conne cto r . 4. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. • NO T E: No t e t he o rie nt a t io n o f t he f ue l t r ans fe r pump be f o r e r e moval . Us i ng t he s p e ci a l t o ol , re mov e t he l o c ki ng r i ng. 5. CAU TI O N : Make s ur e[...]

  • Page 1904

    8. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. • NO T E: No t e t he o rie nt a t io n o f t he f ue l t r ans fe r pump be f o r e r e moval . Us i ng t he s p e ci a l t o ol , re mov e t he l o c ki ng r i ng. 9. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e r e m o ving th e f ue l t r a ns f e r pump. • NO [...]

  • Page 1905

    • NO T E: Fe de ral mar ket vehi cle s, re fe r t o s t e p 1. • NO T E: No n f e de ral ma r k e t vehi c l e s , re fe r t o s t e p 2. 1. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e in s t a l l in g t he f ue l p ump mod ul e . • NO T E: Fed e ral market vehi cl e s onl y. • NO T E: Make s ur e t he f ue l [...]

  • Page 1906

    P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Ine rtia Fuel Shuto ff (IF S) S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cowl s i de t rim pa ne l . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on . 2. D i s conne ct t he e l ect r i cal conne c[...]

  • Page 1907

    P ubl i s he d: 24-Ma r -2 011 Fuel Tan k and Li nes - Fuel T ank Fill er Pipe Hos e Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Pe t rol Fum e s " s i gn s a bo ut t he ve hi cl e . Do no t s moke o r car r y l i ght e d t ob a cc o[...]

  • Page 1908

    a nd may i gni t e . Fa i lu r e t o f ol l o w t he s e i ns t r ucti ons ma y r es ul t i n pe r s o nal in j ur y. Th is p roc e dur e i nvol ves fue l ha ndl i ng. Be p r e pa r ed f o r fue l s pi l l age a t a l l ti mes a nd a l w ays o b s e r ve f uel ha n dl i ng precaut i o ns . F a i l ur e t o fo l l o w th e s e i nst r ucti o ns m a [...]

  • Page 1909

    P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b-i n Accel erat o r pe da l 9 - 80 JagDocs.com[...]

  • Page 1910

    P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele ratio n Co n trol Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um b e r Desc ri pti on 1 — E ngi ne cont r ol modul e (ECM) 2 — Ac cel e r a t or ped a l (l e ft -hand d r ive vehi cl e s ) 3 — Thr ot t l e body 4 — Ac cel e r a t or ped a l (r igh t -ha nd d r i ve [...]

  • Page 1911

    * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele ratio n Co n trol Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. 3. If a n obvi o us cau se[...]

  • Page 1912

    1 2 3 1 2 3 4 1 2 Pi n N um be r C i r cu i t Fun cti on Ci r c ui t Col or 12 Out put (5 v ol t s ) O range /Y e ll o w 13 Out put (5 v ol t s ) Y e l l o w 19 G r o und Bl a ck /Gr e e n 20 G r o und Bl a ck /Gr e e n 52 T hr o tt l e Re l ay Gr ound Gree n/Re d 75 Input P urp l e 76 Input Y e l l o w 80 T hr o tt l e mot o r Gr e e n 102 Input R[...]

  • Page 1913

    1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 I s t he r es i s t ance great e r t ha n 10,000 o hms ? Ye s DIA GNOSE t he e l e ct r o ni c e ngi ne co nt r o l s yst e m. Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Sect i o n 303-14A El e ct r oni c Engi ne Cont r ol s S e c t i o n 3 03-14B El e c t roni c Engi ne Co nt rol s . No REP AIR t he [...]

  • Page 1914

    1 2 3 1 2 1 2 1 2 1 2 1 1 1 2 3 1 1 2 Turn t he i gn it i o n s wi tch t o t he O FF p o si t i on. Di s c onn e ct t he t hr ot t le pos i t i on s e ns o r e l e ct rical co nnect or EN13. Mea s ur e t he res i s t a nce b et we e n EN13-1 and ground. I s t he r es i s t ance l e s s t ha n 5 o hms? Ye s GO t o C6 . . No GO t o C5 . . C 5: C HEC [...]

  • Page 1915

    1 1 1 2 1 2 1 1 2 1 2 1 2 3 I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he t hrott l e mot o r r e l ay po we r s uppl y ci rc ui t . CL EAR t he DTC. TES T t he s ys t e m f o r no r mal o p e r at i o n. No I NS TALL a ne w t hr o t t l e mot o r r el a y. CLEAR t he DTC. T ES T t he sys t e m fo r nor mal op e r at io n. D6: C [...]

  • Page 1916

    P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele rator Cable Adj ustme nt2. 0L NA V 6 - A JV 6 Gene ral P r ocedures 1. Remove t he primary cabl e r et a i ni ng cli p . 2. NOT E: Make s ure t he acce l e r a t o r cabl e i s s e a t e d ful l y i n the ret a i ni ng br acket . Ful l y d e pr e ss t he a ccel e r a t or pe d a l a n[...]

  • Page 1917

    P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele rator Cable2.0L N A V6 - AJV 6 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 414-01 B at t e ry , Mount i ng a nd Ca b l e s . 2. D et a ch t he a ccel e r a t o[...]

  • Page 1918

    6. Remove t he a cc e l e r a to r cab l e . Det a ch t he a ccel e rat o r cab l e gr ommet . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n t o 5 Nm. 3. Adjus t t he a cc e l e r a t o r cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Acce l e r a t o r Cabl e A dj us t me nt -2.0L in t h[...]

  • Page 1919

    P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele rator P ed al Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.0L engi n e 1. D et a ch t he a ccel e r a t o r cab l e . 1. P o si t i on t he a ccel e rat o r a c t ua t o r t o t he ful l y o pe n po s i t i o n. 2. De ta ch t he a ccel e rat o r cabl e . 2. D et [...]

  • Page 1920

    5. Remove t he a cc e l e r a to r pe da l. Insta llat ion 1. NOT E: Ve hi cl e s wit h 2.5L , 3.0L o r di e s e l e ngi ne s hown, 2.0L s i mil a r . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 9 Nm. JagDocs.com[...]

  • Page 1921

    P ubl i s he d: 11-May-2 011 Speed C o ntrol - T o rque Sp eci f i cat ions Descri pti o n Nm l b- f t l b- i n Cr ui s e cont r o l s wi t ch r e t a i ni ng s cr e ws 3 - 27 JagDocs.com[...]

  • Page 1922

    P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Des cr ipt i o n a nd O pe r a t i o n 2.0L ve hi cl e s It e m Pa rt Nu mb e r Descri pt i on 1 — Engi ne cont r o l modu le (ECM ) 2 — Cr ui s e cont r o l s wi t ch 3 — Ha ndbrake s wi tch 4 — Cr ui s e cont r o l mod ul e 5 — Thr o tt l e b ody 6 — Ins t r um e nt cl us [...]

  • Page 1923

    It e m Pa rt Nu mb e r Descri pt i on 1 — Engi ne cont r o l modu le (ECM ) 2 — Cr ui s e cont r o l s wi t ch 3 — Thr o tt l e b ody 4 — Ins t r um e nt cl us t e r (IC) 5 — S pee d cont rol dea ct i vat o r s wi t ch (br ake ped a l pos i t i on s eco nda r y s wi t ch, gre en) 6 — S pee d cont rol dea ct i vat o r s wi t ch (br ake p[...]

  • Page 1924

    Actua tor Switche s ON Sw itc h W he n t he O N s w it ch i s o pe r a t ed t he s p e e d cont rol s ys t e m i s a ct i vat e d a nd providi ng t he v eh i cl e i s t ravel li ng at a s pe e d great e r t ha n 40k m/ h (25m il e /h), t he s p e e d cont rol s yst e m wil l a ccep t t he s pe e d i npu ts . T he i ns t r u ment clus t e r (IC) wi [...]

  • Page 1925

    P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol2 .0L NA V6 - AJV 6 Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the v e hi cle s pe e d co nt rol sys t e m a nd t he commun i cat i o n ne t wo r k whi ch i s co nnect ed t o t he s yst e m, pr ecl ud e t he us e of wo r k s hop ge ne [...]

  • Page 1926

    P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol2 .5L NA V6 - AJV 6/3 .0L N A V6 - A J2 7 Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the v e hi cle s pe e d co nt rol sys t e m a nd t he commun i cat i o n ne t wo r k whi ch i s co nnect ed t o t he s yst e m, pr ecl ud e t he us e [...]

  • Page 1927

    1 2 3 1 1 2 3 1 2 1 2 1 1 2 1 DT C De sc ri pti o n Poss i bl e Sour ce Acti on t o ground, hi gh re si s t a nce. Brak e cance l s wi tch po we r s uppl y ci r cui t o pe n ci rc ui t . Brak e cance l s wi tch f a i l ure. Pinpoint Test s PINPOIN T TE ST A : P056 8 . CHECK SPEED CONTROL INPU T WIRE F OR OPEN CIRCU I T/HIG H RESI S TANC E T EST C O[...]

  • Page 1928

    1 2 1 2 1 2 1 2 1 2 3 1 2 3 I s t he r es i s t a nce 0 o hms? Ye s No el e ct r i cal f a ul t i n s wi t chpa ck . RECHECK DTCs. No I NS TALL a ne w s wi t chpack. REFER t o Spee d Cont r ol Swit ch i n t hi s se ct i o n. CLEA R t he DTC. TES T t he s yst e m f or no r m al o p e r at i on . PINPOIN T TE ST C : P0 56 6 . S PEED CONTROL CANCEL SW[...]

  • Page 1929

    1 2 1 2 3 4 5 1 2 3 1 2 3 1 2 3 1 2 1 2 3 4 5 1 2 3 Conne ct a n o hmm e t e r bet we e n pi ns 1 and 3 o f t he cl ut ch cance l s w i t c h. Op e r at e t he cl ut ch pe d a l up and do wn, whi l e o b s e r ving t he res i st a nce r e a di ng. Doe s t he r e s i s ta nce s wi t ch b e t we e n o p e n a nd cl o s e d ci r cuit a s t he p e da l[...]

  • Page 1930

    1 2 3 1 2 1 2 1 1 1 2 3 1 2 3 1 2 1 EN16, pi n 31 (B). Fo r add i t i o nal i nf or ma ti on, re fe r t o wiring di ag rams. CLEAR t he DT C. T ES T t he s ys t e m f o r no r mal op e r at i o n. PINPOIN T TE ST I : P157 1. B RAKE ON/OF F SW ITCH / BRA KE CANCEL SWI TCH MALFU N CTION T EST C ONDI T IONS DET AI LS/R ESULT S/AC T I O NS I1 : CHEC K [...]

  • Page 1931

    1 Is t he s wi t ch o p e n ci rc uit ? Ye s GO t o I 10 . No INS TA LL a ne w br ake can ce l swi t ch. CL EAR t he DTC. T ES T t he s y s t e m fo r norm al o pe r a t i on. I1 0: CHECK T HE S WI T C H A C T ION O F T HE BR AK E C AN C EL S WI T C H Mea s ure t he r es i s t ance b e t wee n pi ns 1 a nd 2 of t he brake ca nc e l s wi t ch, wi t [...]

  • Page 1932

    P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Deactivato r Switch Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he s p e e d cont r o l d e a ct iva t o r s wi t ch e l e ct r i cal c onn e cto r . 2. Remove t he s p e e d cont r o l de a ct i vat o r s wi t ch. Tur n t he s pee d cont r ol de a ct i va t or s[...]

  • Page 1933

    P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Module Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s p e e d cont r o l modul e cab le r et ai ni ng t i e st r ap . 2. D et a ch t he i nne r c a bl e . 3. D et a ch t he ou t e r cabl e . 4. D et a ch t he coo l a nt e xpans i o n t a nk. 1. Re move t he coo l a nt [...]

  • Page 1934

    5. D i s conne ct t he e l ect r i cal conne ct o r. 6. Remove t he modul e r e t a ini ng bo l t . 7. Remove t he modul e . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n t o 4 Nm. JagDocs.com[...]

  • Page 1935

    3. Tig ht e n t o 3 Nm. JagDocs.com[...]

  • Page 1936

    P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Switch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s t ee ring whe e l. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ste e ring W h e e l (211-04 S te e r i ng Col umn, Re moval a nd Ins t a l la t i o n). 2. Remove t he s t ee ring whe e l fi nis her t r i[...]

  • Page 1937

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Re frige r a nt HFC 134a Compr es s o r oi l P ol yal ky l e ne gl y col S yst e m oi l quant i t y Tot a l s ys t e m o i l qua nt i t y = 160ml. Ne w c ompres s o r s uppl i e d wi t h 90ml, pl us a dd i t o [...]

  • Page 1938

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Cli m ate Co ntro l System Des cr ipt i o n a nd O pe r a t i o n The pur po s e o f t he a i r di s t ribu ti o n s yst e m i s t o rout e a i r t o t he de s i gnat e d regi st e r s . T his i s a ccom pl i s he d whe n a i r ent e rs t he pl e num t hr o ugh t he[...]

  • Page 1939

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Cli m ate Co ntro l System Dia gn os i s a nd Te s t i ng Principle of Ope ra tion REFER t o : Cl i mat e Co nt rol Sy s t e m (412-00 Cl i ma te Co nt r o l Sy s t e m - Gene r a l I nfo r mat i on, De s cr ip t i o n a nd O p e rat i o n). Insp ection a nd Ve rifi[...]

  • Page 1940

    DT C De s cri pti o n Poss i bl e Cause A c ti o n B1253 A i r Te mpe r at ure Int ernal S e ns o r Cir cuit Shor t t o Gr o und I n ca r t e mp s e ns or fe e d s ho r t t o g r ound Re fe r t o t he r el e va nt ci r cuit di ag r a m and che ck t he i nt e g r i t y of t he wi r i ng be t we e n t he a i r t e mpe r at ur e i nte r n a l s e ns o[...]

  • Page 1941

    DT C De s cri pti o n Poss i bl e Cause A c ti o n B1946 Cl i mat e Co nt r ol A /C Po s t Eva porat o r S e ns o r Ci rc uit Fai l ur e Evapo rat or t empe r a t ure s e ns o r f ee d ope n ci r cuit Re fe r t o t he r el e va nt ci r cuit di ag r a m and che ck t he i nt e g r i t y of t he wi r i ng be t we e n t he Cl i mat e Co nt r ol A/C P o[...]

  • Page 1942

    DT C Descri pti on Poss i bl e Ca use Ac ti on B1318 Ba t t e r y Vol ta ge L o w Bat t ery di s char ge d W iring harnes s f a u lt Charging s ys t e m fa ul t Check ba t t e r y i s f ul l y charged . U s i ng t he a p pr opr i a t e ci r cuit di a gr ams : Che ck p o wer sup pl y cir cuit s from front po we r di s t ribu t i o n b o x t o t he f[...]

  • Page 1943

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Air Co nditio nin g (A /C) C o mpress or Leak Detectio n Gene ral P r ocedures 1. Remove t he A/C co mpr e s s or f r om t he vehi c l e . For add i t i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 412-03 Ai r Condi t io ni ng . 2. Ins t a l l A/C pres s ur[...]

  • Page 1944

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Air Co nditio nin g (A /C) System Flushin g Gene ral P r ocedures 1. W ARNING: U s e e xt r e me ca r e a nd o bs e rv e al l s af e t y precaut i o ns r e l at e d t o t he us e of r ef r i ge r an t s . W a r ning : Due t o ref r i ge r ant ha za rds, a lwa ys we [...]

  • Page 1945

    9. Ins t a l l new r ef r i gerant l i ne s i f clo gge d wi t h de bris . 10. Reco nnect t he h ea t e xchange r be i ng f l us hed . 11. Add ad di t i ona l r e f r i gerant oi l a s r e qui red. Fo r ad di t io na l i nf o r mat i on , r ef e r t o Ref r i g e r ant O i l A ddi ng . 12. Ev a cuat e , charg e a nd l e a k t es t A /C s yst e m. 1[...]

  • Page 1946

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Air Co nditio nin g (A /C) System Reco v ery, Evacuation an d Charging Gene ral P r ocedures 1. W ARN INGS : A/C r e f r i geran t c a n be ext r e mel y ha za rdous a nd f a i l ur e t o f ol l ow th e e qui p m e nt manuf a c t u r e r s ins t ruc t i o ns may r e[...]

  • Page 1947

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Co ntam inated Refrigerant Handli ng Gene ral P r ocedures 1. If cont a mi nat e d ref r i ge rant i s de t ect e d DO NO T r eco v e r t he ref r i ge rant i nt o your R-134a O R R-12 recover y/ r e c ycli ng e qui pme nt . Ta ke t he fo l l o w a cti ons : 1. Re p[...]

  • Page 1948

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Dischargin g and Recovery Gene ral P r ocedures 1. W ARNING: U s e e xt r e me ca r e a nd o bs e rv e al l s af e t y precaut i o ns r e l at e d t o t he us e of r ef r i ge r an t s . Fa i l ur e to f o ll ow t hi s i nst r ucti o n may r e s ul t i n p e r s o n[...]

  • Page 1949

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - El ectroni c L eak Detectio n Gene ral P r ocedures 1. W ARNING: Go od ve nt i la t i o n i s nece s s a r y in t he area whe r e A/C le a k t e s t i ng i s t o be ca r r ie d o ut . If t he s ur r o und i ng a i r is co nt a mi nat e d wit h r e frige r a n t ga s[...]

  • Page 1950

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Inspectio n a nd Assembly Requ i re me nts Gene ral P r ocedures 1. NOT E: Any t i me a ho s e o r comp one nt conne ct i on l e a k i s obs e r v e d, t he c ompo ne nt a nd fi t t i ng mus t b e s e pa r a t e d, cl e a ne d a nd a ne w O -r ing a nd c on ne ct or[...]

  • Page 1951

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Leak Dete cti on Gene ral P r ocedures 1. NOT E: O n vehi cl e s wi t h R-134a Le a k T race Dye i ncorpor at e d i nt o t he A/C s ys t em. The e xact l o ca t i on o f l e a ks c a n b e pi np oi n te d b y t he brigh t yel l o w-gr e e n g l ow of t he t r ace r [...]

  • Page 1952

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Refrige rant Oi l Ad ding Gene ral P r ocedures 1. A ne w repl a cement A /C co m pr es s or co nt a i ns 1 50 ml (5 o z . ) r ef r i ge rant oi l . If t he a mount o f oi l dr ai ne d f r om t he r emove d A/C comp r e s s o r i s be t we e n 90 and 150 ml (3 t o 5[...]

  • Page 1953

    P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Refrige rant System Tests Gene ral P r ocedures 1. W ARNING: U s e e xt r e me ca r e a nd o bs e rv e al l s af e t y precaut i o ns r e l at e d t o t he us e of r ef r i ge r an t s . T he A /C ref r i ge r an t a na l yze r mu s t b e use d be f o r e t he recov[...]

  • Page 1954

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - A ir Dis tributio n and Filterin g Des cr ipt i o n a nd O pe r a t i o n It e m Pa r t Nu m be r De sc ri pti on 1 — Le f t -hand s i de regi s t e r 2 — Ce nt e r r e gi st e r 3 — Ri ght -hand s id e regi s t e r 4 — Ri ght -hand s id e f r o nt f l o o r duct 5 — Ri ght[...]

  • Page 1955

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - A ir Dis tributio n and Filterin g Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 412-00 Cli mat e Con trol Sy s t em - Ge ne r a l I nfo r mat i o n JagDocs.com[...]

  • Page 1956

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - Center Registers Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i ns t r um e nt pa ne l vene e r t rim. 2. Remove t he ce nt e r r egi st e r s . Re mov e t he ce nt e r regi s t e r r e t a in in g s cr ews . Insta llat ion 1. To i ns t a l l , rever s e t he remov [...]

  • Page 1957

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - Driver Sid e Register Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i ns t r um e nt pa ne l vene e r t rim. 2. Remove t he i ns t r um e nt pa ne l s urr o und. Re mov e t he i ns t r ument p a ne l s urr o und ret a ini ng s cr ews . 3. Remove t he drive r si de r [...]

  • Page 1958

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - F ron t Foo tw ell Duct L H Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f o ot we l l l a mp. 2. D et a ch t he f l oo r regi s t e r . Re mov e t he f lo o r r egi s t e r r e t a i ni ng s cr e ws 3. D et a ch t he f ront o f t he cent e r cons ul s i d e t ri[...]

  • Page 1959

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - F ron t Foo tw ell Duct RH Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f o ot we l l l a mp. 2. D et a ch t he f l oo r regi s t e r . Re mov e t he f lo o r r egi s t e r r e t a i ni ng s cr e ws . 3. D et a ch t he f ront o f t he cent e r cons ul s i d e t r[...]

  • Page 1960

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - P assen ger Side Register Re moval a n d I ns t a l l a t i on R em ova l 1. W ARNING: T o a voi d acci de nt a l d e pl o ym e nt and pos s i b le pers ona l in j ur y, t he ba ck up po we r s up pl y must be d epl et e d be fo re repa i ring or r e pl a ci ng a ny a i r ba g s uppl[...]

  • Page 1961

    P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - P o llen Filter Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cowl vent s cr ee n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co wl Ve nt S cr e e n (501-02 Fr ont End Bo dy P a nel s , Re mova l a nd Ins t al l a t io n). 2. Remove t he po l l e n fi l [...]

  • Page 1962

    P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Speci fi ca ti on I n ve hi cle cr os s b e a m bon di ng W SKM 2G37 9-A1 I n ve hi cle cr os s b e a m s o l vent wi pe W S KM14J 251- A1 T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n Evapo rat or core ho us i ng t o i n [...]

  • Page 1963

    P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Heating a nd Ventil atio n Des cr ipt i o n a nd O pe r a t i o n The he at i ng a nd de f r os t i n g s yst e m i s a b l e nded a i r s ys t e m a n d co ns i st s o f a he a t e r co r e, a bl ow er mot o r , d i s t r i but i on d oors a n d a n e vapo rat or core. Ai r i s di rect e d t[...]

  • Page 1964

    P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Heating a nd Ventil atio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 41 2-00 Cl i m a t e Co nt r ol S ys t e m - Ge ne r a l Info rm at i o n . JagDocs.com[...]

  • Page 1965

    P ubl i s he d: 11-May-2 011 Heating and V entilatio n - B lo we r Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he bl owe r mot o r l o we r cover. 2. D i s conne ct t he e l ect r i cal conne ct o r. 3. Remove t he bl owe r mot o r . Re mov e t he b l o we r mo t o r r e t a i ni ng s cr e ws . Insta llat ion 1. To i ns t a l[...]

  • Page 1966

    P ubl i s he d: 11-May-2 011 Heating and V entilatio n - E va po rator C o re Ho usin g Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . 2. Recover t he r e frige r a n t. Fo r a ddi t i o nal i nfo r mat i o n, refe r to S ect i o n 412-00 Cl i mat e Co nt rol S ys t e m - Gen e r al Inf or m a[...]

  • Page 1967

    9. Usi ng a s ui t a bl e t o o l di s con nect t he r e f r i geran t li ne . 10. Remove t he ref rige r a nt l i ne r et a i ni ng cl i p . 11. Us i ng a s uit a bl e t o ol di sco nne ct t he r ef r i ge rant l i ne . 12. Remove t he e va porat o r cor e ho us in g l ow er s e cur ing nut . 13. Remove t he i ns t r ume nt pa ne l . For a dd i t [...]

  • Page 1968

    14. Remove t he ce nt e r r eg i s t e r a ir duct . 15. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 1. O n ma nual A /C o nl y. 2. Al l ve hi cle s . 16. Dis c o nne ct t he e l e ct r ica l conne ct o r . 17. Remove t he g l ove b o x mount i ng f r a m e . Re mov e t he re ta i ni ng bo l t s. 18. Dis c o nne ct t he e l e ct r ica l c[...]

  • Page 1969

    19. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 20. Det a ch t he wi ring ha r nes s. 21. Det a ch t he wi ring ha r nes s. 22. Det a ch t he wi ring ha r nes s. Re mov e t he e a r th l e a d r e t a i ni ng bol t . Det a ch t he wi ring ha rn es s . 23. Us i ng a s uit a bl e t o ol cut t he bond i ng on t he i n ve hi cl e cr os s bea [...]

  • Page 1970

    24. Det a ch t he cent e r o f t he i n v ehi cl e cr os s be a m. 25. Remove t he i n ve hi cl e cr os s be a m ret a i nin g b o lt s . Lef t-h a nd s i de s ho wn, r i g ht -ha nd s i de s i mil a r . 26. Remove t he i n ve hi cl e cr os s be a m a nd t he e va porat o r cor e ho us i ng . Insta llat ion 1. NOT E: Re m o ve t he P U bo nd i ng f[...]

  • Page 1971

    3. Tig ht e n t o 25 Nm. JagDocs.com[...]

  • Page 1972

    P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Heater C ore Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: If a l e ak i s s us pe ct e d, t he h e a t e r core must b e l e ak t e s t e d i n t h e vehi cl e b e fo re r emova l. For a ddi ti o nal i nfo r mat i o n, ref e r to S e ct io n 412-00 Cli mat e Cont r ol Sy st e m -[...]

  • Page 1973

    7. Remove t he he a t e r cor e ai r duct ho us i ng. 1. Re move t he he a t e r c ore a i r duct hous i ng ret a i ni ng s cr e ws . 2. Re move t he he a t e r c ore a i r duct hous i ng . Re l e a s e t he re t a i ni ng t abs . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . 8. Remove t he he a t e r cor e hous ing ret a i ni ng[...]

  • Page 1974

    12. Remove t he he a te r co r e. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 1975

    P ubl i s he d: 11-May-2 011 Heating and V entilatio n - E va po rator C o re Ho usin g Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he e vap orat o r co r e h ou s i ng. For add i t i o na l i nf orm a t i o n, r e fe r t o Evapo rat or Co r e H ous i ng . 2. D et a ch t he bl owe r moto r f r om t he i n ve hicl e cr os s b e a [...]

  • Page 1976

    5. Rel e as e t he he a t e r cor e hous in g ret a i ni ng t abs . 6. Remove t he he a t e r cor e hous ing . 7. Remove t he rub be r s e a l . 8. Remove t he he a t e r cor e r et a i ni ng bo l t . 9. Remove t he he a t e r cor e . JagDocs.com[...]

  • Page 1977

    10. Remove t he b l owe r mot or . Re mov e t he b l o we r mo t o r r e t a i ni ng s cr e ws . 11. Remove t he manu a l c on t r ol bl o we r mot or r es i s t o r. Re mov e t he ma nua l cont r ol b l o we r m ot o r r e s i s to r ret a i ni n g s cr ew. 12. Remove t he rubber s e al . 13. Remove t he e va porat o r cor e ret a i ni ng s cr e w[...]

  • Page 1978

    14. Remove t he e va porat o r cor e up pe r hous i ng . 15. Remove t he e va porat o r cor e . A ssemb ly 1. To a s s e mbl e , reverse t he di s as s e mbly proced ur e. 2. Tig ht e n t o 7 Nm. JagDocs.com[...]

  • Page 1979

    3. Tig ht e n t o 5 Nm. JagDocs.com[...]

  • Page 1980

    P ubl i s he d: 11-May-2 011 A uxil iary Heating - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n El e ctric bo o s t e r he a t e r r et a in i ng nut s 10 - 89 He a t i ng e le m e nt e l e ct rica l conne ct or r et a i ni ng nut s 4 - 35 JagDocs.com[...]

  • Page 1981

    P ubl i s he d: 11-May-2 011 A uxil iary Heating - E lectric B o os ter Heater Des cr ipt i o n a nd O pe r a t i o n Due t o t he hi gh -ef fi ci ency o f t he di e s el e ngi ne , t here i s i ns uff i ci e nt wa s t e -hea t a v ai l a b l e t o t he h e a t e r cor e. An a uxi l ia r y e l e c t r i cal b o os t e r he at e r i s i ns ta l l e [...]

  • Page 1982

    5 - TMAP s e ns or 6 - CHT s ens o r 7 - Gene rat o r P r o vi de d t he t emp erat ure cond i ti ons a re s a t i sf ie d and de pe nd i ng o n t he l o a d cond i t i o n o f t he ge ne rat o r , t he P CM w i l l ca use o ne o f th e fo l lo wi ng t o occur : a c t i va t io n o f rel a y 1 a c t i va t io n o f rel a y 2 a c t i va t io n o f b[...]

  • Page 1983

    P ubl i s he d: 11-May-2 011 A uxil iary Heating - Fuel Fired Bo os ter Heater Des cr ipt i o n a nd O pe r a t i o n For mar ket s th a t e x pe rie nce e x t r e mel y l o w t e m pe rat ur e s , a f uel f ire d b o os t e r hea t e r i s i nst a l l e d in pl ace o f t he e l e ct rica l boo s t e r hea t e r . The fue l f ir e d bo o s t e r he[...]

  • Page 1984

    It e m Pa r t Nu m be r Descri pti o n 1 - Combus t i o n a i r f a n 2 - Burner ho us i ng 3 - El e c t r on ic c ont r ol mod ul e 4 - H ea t e xchange r 5 - Burner i nse rt 6 - Exhaus t 7 - Coo l ant i nl e t 8 - Gl o w pl ug / f l a me s e nso r 9 - Evap o r a t or 10 - Fue l i nl e t 11 - Coo l ant o ut l e t 12 - Ai r int a ke Comb u s tion A[...]

  • Page 1985

    Over he at Protec tion Ove r he a t pr ot e ct i o n i s cont r ol l e d by a t e m pe r at ur e res i s t o r lo ca t e d in t he he a t excha nge r. Thi s p r ot ect s a g ai nst e xces s i ve op e rat i ng t e mperat ures . O ve r he a t pr ot ect i on res po nds a t a co ol a nt te m pe rat ur e i n e xces s o f 125 ° C a nd s wi t che s t he [...]

  • Page 1986

    P ubl i s he d: 11-May-2 011 A uxil iary Heating - Auxilia ry Heater Dia gn os i s a nd Te s t i ng Principle of oper at ion The r e a re t wo t ype s of a uxil i a r y hea t e r , t he e l e ctri c boost er hea ter , whi ch i s f i t t e d a s s t a nda rd, a nd t h e f ue l f i re d boost er hea ter , wh i ch is an opt i on. Fo r a ddi t i ona l [...]

  • Page 1987

    1 2 3 1 2 Auxi l iary heat er 1 f use connect or C i r cu i t Pi n Auxil i a ry hea t e r r e l a y 1 o ut put 01 Auxil i a ry hea t e r 1 cont r ol 02 Auxi l iary heat er 1 co nnect o r C i r cui t P i n Auxil i a ry hea t e r r e l a y 1 cont r o l 01 Ju ncti o n b o x connector C i r cui t P i n Auxil i a ry hea t e r r e l a y 1 cont r o l 38 E[...]

  • Page 1988

    1 2 1 2 3 4 1 1 2 3 4 1 1 2 3 4 5 6 7 1 I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s S US P ECT:- Auxi l i a r y he a t er 1 a s s e mbly No REP AI R t he sh ort c i r cuit . For a ddi t i o na l i nfo rm at i o n, r ef e r t o t he wiring di a gr ams . A3 : CHEC K T HE AUXI L I ARY HEAT ER 1 CIRC UIT C ONT IN UI T Y Auxil i a ry hea t[...]

  • Page 1989

    1 2 3 4 1 2 3 4 1 1 2 3 4 1 2 3 I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s GO t o A14 . No GO t o A13 . A1 0: CHEC K T HE AUXI LIA RY HEA T E R 1 CO NT R O L LI NE 'O F F' S T AT E • NO T E: I t i s as s umed t he i g ni t i o n i s s t i l l o n f r o m t he pr e vio us s t e p, i f n ot , p l e a s e make s ur e t he i [...]

  • Page 1990

    1 2 3 4 5 6 7 1 2 3 4 1 Auxi l iary heat er connector C i r cu i t Pi ns Auxil i a ry hea t e r cont r ol 03/05 Auxi l iary heat er rel a y 2 conn ec tor C i r cui t P i n Auxil i a ry hea t e r r e l a y 2 cont r o l 02 I gni t io n s up pl y 01 P e rm a nent 12 vo l t sup pl y 03 Auxil i a ry hea t e r 2 cont r ol 05 E ng i ne control m o d ul e [...]

  • Page 1991

    1 2 3 4 1 2 3 4 1 1 2 3 4 1 2 3 4 1 1 2 I s t he r es i s t a nce l e s s t ha n 10 o hms? Ye s GO t o B4 . No REP AI R t he o pen c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di a gr ams . B4: C HEC K T HE SUPP LI ES T O T HE AUXI LIA R Y HEA T ER 2 R ELAY Ke y o f f. Mea s ur e t he vol t a ge be t we e n : Au xi l[...]

  • Page 1992

    3 4 1 2 3 4 1 2 3 Ke y o n, e ngi ne o f f. Mea s ur e t he res i s t a nce b e t we e n: Au xi l i ary hea ter rel ay 2 conn e c tor, harne s s s i de Ve hi cl e ba ttery Auxil i a ry hea t e r 2 cont r ol , p i n 02 Ne g at i ve po s t I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s S US P ECT:- ECM No REP AI R t he sh ort c i r cuit . [...]

  • Page 1993

    1 2 3 4 1 2 1 1 2 1 Auxi l iary heat er connector C i rcui t P i n Auxil i a ry hea t e r cont r ol 01 Auxi l iary heat er rel a y co nnector C i rcui t P i n Auxil i a ry hea t e r r e l a y cont rol 02 P e rm a nent 12 vo l t sup pl y 03 ECM r e l ay cont r ol l e d 12 vol t s uppl y 01 Auxil i a ry hea t e r r e l a y out p ut 05 Ke y o f f. Aux[...]

  • Page 1994

    1 2 3 4 1 2 3 4 1 1 1 2 3 4 1 1 2 3 4 di a gr ams . C 6: C HEC K T HE AUXI L IA RY HEAT ER C ONT R O L LI NE ' ON' ST AT E S can t o ol co nnect ed . Acce s s t he ECM a nd cont r ol t he a uxil i a r y hea t e r cont r ol P ID. Act iva t e t he a uxil i a r y hea t er. Mea s ur e t he vol t a ge be t we e n : Au xi l i a r y heate r fuse[...]

  • Page 1995

    1 2 3 4 1 1 2 3 4 1 2 3 4 1 2 3 Ke y o f f. Auxil i a ry hea t e r r e l a y conne c t o r di s conne c t e d. Ke y o n, e ngi ne o f f. Mea s ur e t he res i s t a nce b e t we e n: Au xi l i a r y heate r fuse c on nector, harness s i de Vehi cl e battery Auxil i a ry hea t e r r e l a y out p ut , pi n 01 P os i t ive p o s t I s t he r es i s t[...]

  • Page 1996

    P ubl i s he d: 11-May-2 011 A uxil iary Heating - Fuel Fired Bo os ter Heater Dia gn os i s a nd Te s t i ng Principle of oper at ion The fue l f ir e d bo o s t e r he a t e r i s a vai la b l e as an o pt io n in pl ace o f t he e l e ct ric ve rsi o n, a nd i s l i kel y t o be m o r e co mm on i n e xtreme cli mat e s . The s ys t e m pe r fo [...]

  • Page 1997

    1 2 3 1 1 2 3 4 Fuel fi red h e ate r modul e con nect or C i r cu i t P i n Fue l fi r ed he a t e r modul e g r ound 02 Fue l fi r ed he a t e r modul e i g ni t i o n s up pl y 04 Fue l fi r ed he a t e r modul e p ow er 01 Fue l fi r ed he a t e r modul e s i gnal 05 Fuel fi red h e ate r modul e rel ay connect or C i rcui t P i n Fue l fi r ed[...]

  • Page 1998

    1 1 2 3 4 1 1 2 3 4 1 1 2 3 4 1 2 3 4 1 Mea s ur e t he res i s t a nce b e t we e n: Fuel fi r e d hea te r rel ay co nn e ctor, h ar ness si de Ve hi cl e batter y Fue l fi r ed he a t e r modul e r e l ay s i gna l , p i n 01 P os i t i ve p o st I s t he r es i s t a nce great e r t ha n 100 K ohms ? Ye s GO t o A6 . No GO t o A5 . A5 : CHEC K [...]

  • Page 1999

    1 2 1 1 2 I s t he vol t a ge be t we e n 9 vo lt s a nd 15 vo l t s ? Ye s GO t o A12 . No NO s uppl y t o t he f ue l fi r ed he a t e r modul e c i r cuit . REP AI R t he circ ui t as ne ce s s a r y. Fo r a ddi t i o nal i nfo r m at i o n, r ef e r t o t he wi r i ng d ia gr ams . A1 2: CHEC K T HE I GNI T ION S U P P LY T O T HE FUEL F I RED [...]

  • Page 2000

    P ubl i s he d: 11-May-2 011 A uxil iary Heating - E lectric B o os ter Heater Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (501-0 2 Fr ont End Bod y P a nel s ,[...]

  • Page 2001

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. 2. Tig ht e n t o 4 Nm. 3. Ch eck a nd t o p up t he coo l ant i f ne ce s s a ry . JagDocs.com[...]

  • Page 2002

    P ubl i s he d: 11-May-2 011 A uxil iary Heating - Fuel Fired Bo os ter Heater Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (501-0 2 Fr ont End Bod y P a nel s ,[...]

  • Page 2003

    6. NOT E: Cl a mp t he ho s e t o mini miz e coo l a nt l o s s . Di s conn ect t he coo l ant ho s e . 7. Remove t he ret a i ni n g b o lt s . 8. Remove t he f uel f i re d b o os t e r he a t e r . Re mov e t he re ta i ni ng bo l t s. Insta llat ion 1. Ins t a l l the f uel f ire d b o os t e r hea t e r . Ins t al l t he re t a i ni ng b ol t [...]

  • Page 2004

    2. Ins t a l l the ret a i ni ng b o l t s . 3. Connect t he coo l a nt h os e . Re mov e t he ho s e cl a mp. 4. Connect t he coo l a nt h os e . Re mov e t he ho s e cl a mp. 5. Att a ch t he coo l a nt hos e . 6. Connect t he f ue l f ire d b o os t e r hea t e r f ue l l i ne. JagDocs.com[...]

  • Page 2005

    7. Connect t he f ue l f ire d b o os t e r hea t e r e l e c t r i cal co nne ct or. 8. Ins t a l l the a i r def le cto r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (501-0 2 Fr ont End Bod y P a nel s , R emoval a nd I ns t a l l a t i o n).[...]

  • Page 2006

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b-i n Ai r condi t i o ni ng (A /C) clut ch r et a i ni ng nut 26 19 - A/C co mpr e s s or ret a i ni ng b o l t s 25 18 - A/C co mpr e s s or mani fo l d a nd t ub e ret a i ni ng bo l t 20 15 - A/C co nde ns e r cor e r e t a in ing b ol t[...]

  • Page 2007

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing Des cr ipt i o n a nd O pe r a t i o n The a i r condi t i o ni ng (A /C) s yst e m i s a cl ut ch cy cl i ng , fi x e d o rif i ce t ube t ype . The A/C compres so r i s dr i ven by t he e n gi ne . T he A/C compr e ss o r pr i mes t he g a s e o us ref r i ge r a nt o ut o f[...]

  • Page 2008

    Fixe d orifi ce tub e The fi xed o r i fi ce t ub e s yst e m al l o ws t he co mpr e s se d l i qui d t o e xpand , by met e ring t he l iq ui d i nt o t he l ow pr es s ur e a re a o f t he eva po r at or. The l ow pr es s ure b e i ng cr ea t e d by t he r e s t rict io n of t he f i xed orif i ce t ube a nd t he suct i o n o f the s cr ol l t y[...]

  • Page 2009

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n refe r t o S ect i on 412-00 Cl i ma te Co nt r o l Sy s t e m - Ge neral Inf orm a t i o n . JagDocs.com[...]

  • Page 2010

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing (A/C) Co mpre ss o r2. 0L NA V 6 - A JV 6/2.5 L N A V6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Recla i m t he re frige r a nt . Fo r a d di t i ona l i nf o r mat i on , refe r t o S e cti on 412-00 Cl i mat e Co nt rol S ys t e m - Gen [...]

  • Page 2011

    7. Remove t he compr es s o r . Insta llat ion 1. NOT E: Ins t a l l ne w O -r ing s e a l s . • NO T E: Co at t he re frige r a nt l i ne O -r i ng s e a l s i n c l e a n r ef rige rant oi l p rior to ins t a l la t i o n. • NO T E: 5o z o f oi l a r e cont a i ned i n t he ne w co mpr e s s or . The a i r c on di t io ni ng s ys t e m requi [...]

  • Page 2012

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing (A/C) Co mpre ss o r2. 0L Duratorq-TDC i/ 2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re l e a s e t ool , b e l t t ens io ne r 303-676 R em ova l 1. Recover t he a ir co ndi t io ni ng (A/C) refrig e r ant . For a ddi ti[...]

  • Page 2013

    7. NOT E: Roa d whe e l s hown r e moved f or cla rit y. Re move t h e r i ght -ha nd whe e l a r ch l i ne r a c ce s s p ane l s. 8. Usi ng t he s pe cia l t oo l , de t a ch th e a cces s o r y drive be l t . 9. D et a ch t he e xhaus t fl e xi bl e p i pe s up po r t i s o l at o r . 10. CAUT I O N: Ma k e s ure t hat t he e xhaus t f l e xibl [...]

  • Page 2014

    11. CAUT I O N: Ca r e mus t be t a ken t o avoi d dama gi ng compone nts whe n p o si t i oni ng t he bl o c k. Di s pl ace t he e ngi ne a ppr o ximat e l y 40mm rearwar ds . Re mov e t he rol l res t r i c t o r r ea r r et a i ni ng bo l t. W i t h as s i s t ance di sp l a ce t he e n gi ne a n d s uppo rt i n an a ppropria t e pos i t i on us[...]

  • Page 2015

    2. NOT E: If i ns t al l i ng t he ol d A/C compr es s or, in s t a l l new O -r i ng s e a l s . • NO T E: If i n st a l l ing a ne w A/C compr es s or, mak e s ure t hat ne w O -r i ng s ea l s a r e al r e a dy i ns t al l e d. • NO T E: Co at t he A /C co mpr e s s or O - ring s e a l s i n cl e a n ref r i ge r a nt o i l pr i o r to ins t[...]

  • Page 2016

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing (A/C) Pressure T ransducer Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont whe e l and t i r e. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i o n 204-04 W he e l s a nd Ti r e s . 2. D et a ch t he wh ee l a r ch l i ne r . 3. D i s conn[...]

  • Page 2017

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Cl utch a nd Clu tch F ield C o il2.0L NA V6 - A JV 6/2.5 L N A V6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P ull e y Re pl a c e r 412-109 W r e nch Strap-Uni ve r s a l 303-D 055 Cr a nk s ha f t Dampe r Re m o v er 303-D 121 R em ova l 1. Remove t he a[...]

  • Page 2018

    4. Remove t he A/C cl ut ch s hi m . 5. Remove t he A/C cl ut ch pul l e y ci rcli p. 6. CAU TI O N : Do no t us e a i r t oo l s. Fa i l ur e t o f o l l ow t hi s i ns t r u cti o n m a y r es ult i n da mag e t o t he compon e nt . Us i ng t he s p e ci a l t o ol , re mov e t he A/C clu t ch pul l e y. 7. Remove t he A/C s e ns o r r et a i ni [...]

  • Page 2019

    9. Remove t he A/C cl ut ch a nd cl ut ch f i e l d c oi l ci r cli p. 10. Remove t he A /C cl ut c h and c l ut ch f i e l d coi l . Insta llat ion 1. Ins t a l l the A/C clut ch a nd cl ut ch f i e l d coi l . 2. CAU TI O N : Make s ur e t h e ci rc l i p i s i ns t al l e d a nd s e a t e d corr e ct l y . Fai l ure t o fo l l o w t hi s i ns t [...]

  • Page 2020

    3. Att a ch t he A/C t e mpe r at ure s e n so r. 4. Ins t a l l the A/C t e mpe r at ure s e nso r r et a i ni ng p l a te . Ti ght e n t o 6 Nm. 5. NOT E: The A/C cl ut ch be aring a nd p ul l e y i s a s l i p fi t o n t he compr e s s o r. If co r r ect l y al ig ne d i t sho ul d sl i p on e as i ly. If di ff i cul t y is e xpe r i ence d o n [...]

  • Page 2021

    8. Ins t a l l the A/C clut ch. Ins t al l t he A /C cl ut ch r et a i ni ng nut . 9. Usi ng t he s pe cia l t oo l , t i ght e n t he A/C cl ut ch re ta i ni ng nut . Ti ght e n t o 26 Nm. 10. Meas ur e a nd a dj us t t he A/C cl ut ch a i r g a p by remov i ng o r ins t a l l ing A/C cl ut ch s hi m s . A/C cl ut ch a i r ga p t o be s e t b e t [...]

  • Page 2022

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Co n den ser C ore Re moval a n d I ns t a l l a t i on R em ova l 1. Recla i m t he re frige r a nt . Fo r a d di t i ona l i nf o r mat i on , refe r t o S ect io n 412-00 Cl i mat e Co nt rol S ys t e m - Gen e r al Inf or m a t i o n . 2. Remove t he f r ont bu m pe r cover . For a ddi ti o nal[...]

  • Page 2023

    1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n 7 Nm. 3. NOT E: Coa t t he r e f r i gerant li ne O -r ing s e a l s i n cl e a n refrige r a n t oi l p r i o r to ins t a l la t i o n. I nst a l l a ne w O -r ing s e a l . 4. NOT E: Coa t t he r e f r i gerant li ne O -r ing s e a l s i n cl e a n refrige r a n t oi l p r[...]

  • Page 2024

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Evaporato r Co re Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i n ve hicl e cr o s s be a m and e vap o r a t or cor e hous in g. Fo r a ddi t i o na l i nfo rm at i on, ref e r t o Sect io n 412-02A Hea t i ng a nd Ve nt i l a t i o n S ect i o n 412-02B Auxi l i a r y He a t in[...]

  • Page 2025

    6. Remove t he e vap orat o r co r e s up po r t br a cket . Re mov e t he re ta i ni ng s c r e w. 7. Remove t he e vap orat o r co r e h ou s i ng. 8. Remove t he e vap orat o r co r e. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2026

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Evaporato r Co re Orific e Re moval a n d I ns t a l l a t i on R em ova l 1. Recla i m t he re frige r a nt . Fo r a d di t i ona l i nf o r mat i on , refe r t o S e cti on 412-00 Cl i mat e Co nt rol S ys t e m - Gen e r al Inf or m a t i o n . 2. D et a ch t he e vap o r a t or cor e o r i fi c[...]

  • Page 2027

    P ubl i s he d: 11-May-2 011 A ir C onditio ning - Suctio n Accumu lato r Re moval a n d I ns t a l l a t i on R em ova l 1. Recla i m t he re frige r a nt . Fo r a d di t i ona l i nf o r mat i on , refe r t o S e cti on 412-00 Cl i mat e Co nt rol S ys t e m - Gen e r al Inf or m a t i o n . 2. Remove t he wa s he r r e s e voi r. Fo r ad di t i [...]

  • Page 2028

    7. Remove t he s uct i on a ccum ula t or. Re mov e t he re ta i ni ng bo l t s. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. NOT E: Coa t t he r e f r i gerant li ne O -r ing s e a l s i n cl e a n refrige r a n t oi l p r i o r to ins t a l la t i o n. I nst a l l a ne w O -r ing s e a l . 3. NOT E: Coa t t he r e[...]

  • Page 2029

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - C ontro l C o mp o nents Des cr ipt i o n a nd O pe r a t i o n I te m P a rt Nu m ber Descri pti o n 1 — A ir i n le t bl e nd do o r a ct ua t o r 2 — A ir di s char ge t e m pe r at ur e s e ns or 3 — De fros t v e nt /r e gi s t e r bl e nd do o r a ct uat o r 4 — T e mpe r a t ur [...]

  • Page 2030

    Item Pa r t Nu m be r De sc ri pti o n 1 — Touch s cr e e n s wi t ch 2 — Re ci r cula t e d a i r s wi t ch 3 — Incr ea s e s e t t e mpe rat ur e s w i t c h 4 — De c r e as e s e t t e mper a t ure s wi t ch 5 — Te mperat ure/clo ck di s pl a y 6 — Aut o mat i c o pe r at i o n s wi t ch 7 — Fan s pe e d s wi tch 8 — Cl i mat e c[...]

  • Page 2031

    Item Pa r t Nu m be r De sc ri pti o n 1 — Fan s pe e d a nd O N/O FF s wi t ch 2 — Re ci r cula t e d a i r s wi t ch 3 — S c r e en d i s p l a y 4 — Ce l s i us /Fahr e nhe i t s e le ct s wi t ch 5 — Aut o mat i c o pe r at i o n s wi t ch 6 — Ai r di s t r i but i o n s wi t che s 7 — Incr ea s e s e t t e mpe rat ur e s w i t c [...]

  • Page 2032

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - C ontro l C o mp o nents Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 41 2-00 Cl i m a t e Co nt r ol S ys t e m - Ge ne r a l Info rm at i o n . JagDocs.com[...]

  • Page 2033

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Air Disc harg e T em p erature Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2. D i s conne ct t he a i r di s char ge t e m pe r at ur e s e ns or e l e ctr i cal co nne cto r. 3. Remove[...]

  • Page 2034

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Ambient Air T emperature Sens or Re moval a n d I ns t a l l a t i on R em ova l CAU TIO N : Make s ur e t he i gni t i on s wi t ch i s i n t he o f f p os i t io n be f ore di s conne ct i n g t he a mbie nt a i r t empe r a t ure s e ns o r . 1. D et a ch t he a mbi e nt a i r t empe rat ur[...]

  • Page 2035

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - C lima te C ontro l A ssem bly Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with autom at ic tra ns ax l e 1. NOT E: To ai d r e mov a l of t he cl i mat e co nt rol a s s e mbl y pl ace t he J-ga t e s el e ct o r i n t h e ne ut ral po s i t i o n. Re move t h e J-ga t e s urr[...]

  • Page 2036

    6. Remove t he cli mat e cont r ol a s se m bl y mount i ng b r a ck et up pe r r et ai ni ng s cr ews co ver. 7. Remove t he cli mat e cont r ol a s se m bl y mount i ng b r a ck et up pe r r et ai ni ng s cr ews . 8. Remove t he cli mat e cont r ol a s se m bl y mount i ng b r a ck et l o wer r e t a i ni n g s cr ews . 9. D i s conne ct t he ha [...]

  • Page 2037

    11. Dis c o nne ct t he cl i mat e cont r o l a s s e mbl y e l e ct rica l co nnect or s . 12. Remove t he cl i mat e cont r o l a s s e mbl y r et a i ni ng s cr e ws . 13. Remove t he cl i mat e cont r o l a s s e mbl y. 1. Re move t he r e t a i ni ng s cr e ws . 2. Re move t he cl i mat e co nt rol a s s e mbly. Insta llat ion 1. NOT E: Make s[...]

  • Page 2038

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Defros t V ent/R eg ist er Blen d Doo r Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2. D i s conne ct t he de f ros t vent /r egi s t e r bl e nd do o r a ct uat o r e le ctrica l conn[...]

  • Page 2039

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Foo tw ell Vent/Duct Blen d Doo r Actuato r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2. D i s conne ct t he f o ot we l l vent /d uct bl end doo r a ctua t o r e l e ct r ica l conne ct or. [...]

  • Page 2040

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Sunlo ad Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i ns t r um e nt clu s t e r a nd ve nt f i ni s h p a nel . 2. Remove t he i ns t r um e nt clu s t e r f i ni s h pa ne l . 3. Remove t he s i de ai r vent . 4. D i s conne ct t he s un lo a d s e ns or e l e ct [...]

  • Page 2041

    5. Remove t he s unl o a d s e nso r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2042

    P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - T emperature Blend Do o r Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2. D i s conne ct t he t e mper a t ur e b le nd d o or a ct ua t o r e l e ct rica l conne ct o r . 3. Remove t h[...]

  • Page 2043

    P ubl i s he d: 11-May-2 011 Instrum ent Cl uster and Panel Il lumi natio n - Instrument Cl uster an d Panel Illu min atio n Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the i ns t ru me nt cl ust e r pr e c l ude t he us e o f wo rk s ho p g e ne r al e le ctrica l t e s t e qui pme nt . The r e f[...]

  • Page 2044

    P ubl i s he d: 11-May-2 011 Instrum ent Cl uster - Instrumen t C luster Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s W it h 2.0L , 2.5L An d 3. 0L Engi ne s It e m Pa r t N u m ber Desc ri pti on 1 — Engi ne t e m pe r at ur e gau ge 2 — Le f t hand di r e cti o n i nd i cat or 3 — Doo r aj ar warning 4 — Lo w e xt e r i or t e mpe [...]

  • Page 2045

    It e m Pa r t N u m ber Desc ri pti on 1 — Engi ne t e m pe r at ur e gau ge 2 — Le f t hand di r e cti o n i nd i cat or 3 — Doo r aj ar warning 4 — Lo w e xt e r i or t e mpe r at ur e wa rning 5 — Ta cho met e r 6 — Po we rtrai n mal funct i on 7 — Engi ne mal f uncti o n 8 — Fr ont fo g l amp s 9 — Mai n be a m 10 — S i de ([...]

  • Page 2046

    It e m Pa r t N u m ber Desc ri pti on 1 — Engi ne t e m pe r at ur e gau ge 2 — Le f t hand di r e cti o n i nd i cat or 3 — Doo r aj ar warning 4 — Gl o w pl ug wa r ning la m p 5 — Lo w e xt e r i or t e mpe r at ur e wa rning 6 — Ta cho met e r 7 — Engi ne mal f uncti o n 8 — Fr ont fo g l amp s 9 — Mai n be a m 10 — S i de [...]

  • Page 2047

    P ubl i s he d: 11-May-2 011 Instrum ent Cl uster - Instrumen t C luster Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he i ns t ru ment cl us t e r , ref e r to the rel e va nt De s cr i pt i o n and O pe r a t i o n s e ct i o ns i n t he worksho p ma nua l. REFER t o: I ns t rum e nt Cl u[...]

  • Page 2048

    P ubl i s he d: 11-May-2 011 Instrum ent Cl uster - Instrumen t C luster Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : Do no t l e a ve t he i ns t r ument cl us t e r fa ce d o wn f o r any le ngt h of t ime . Lo we r a nd e x t e nd t he st e e r i ng col umn t o i t s m a ximum r e arwar d po s i t i o n. 2. D i s conne ct t he[...]

  • Page 2049

    P ubl i s he d: 11-May-2 011 Ho rn - Horn Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s W it h 2.0L , 2.5L An d 3. 0L e ngi nes It e m P ar t N u m ber De scr i pti on 1 — Ho rn s wi t c h 2 — P o we r d i s t ribut i o n b o x 3 — Ho rn The ho r n s ys t e m cons i s t s o f t he fo l l owi ng : P owe r di s t rib ut i o n bo x fus e 3[...]

  • Page 2050

    It e m P a r t Nu m be r De s cri pti on 1 — Hor n s wit ch 2 — Hor n r el ay 3 — Hor n The ho r n s ys t e m cons i s t s o f t he fo l l owi ng : P owe r di s t rib ut i o n bo x fus e 3 (20A) P owe r di s t rib ut i o n bo x r el ay 2 Ho r n Ai r ba g s l i d i ng co nt a ct W i r i ng ha r ne s s Ho r n swi t ch Gene ric el e ctr o ni c m[...]

  • Page 2051

    P ubl i s he d: 11-May-2 011 Ho rn - Horn Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspect i on C h art Mechani cal El e ct ri cal S wit ch Ho r n Re l a y( s ) Fuse (s) El e ctrica l conne ct o r (s ) D[...]

  • Page 2052

    P ubl i s he d: 11-May-2 011 Ho rn - Horn Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i on 100-02 Jacki ng a nd Li ft i ng . 2. D et a ch t he ho r n. 3. Remove t he ho r n . 1. Dis con nect t he horn e l e ct r i ca l conne cto r . 2. Re move [...]

  • Page 2053

    P ubl i s he d: 11-May-2 011 Ho rn - Horn Switch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r ai r ba g modul e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Driver Ai r B a g Modul e (501-20B S uppl e men ta l Re st rai nt Sy s t e m, Remo val a nd I nst a l l a t i on). 2. D i s conne ct t he ho r n s wi t ch[...]

  • Page 2054

    P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Inform atio n and Message Cen ter Des cr ipt i o n a nd O pe r a t i o n It e m Par t N u m ber De scri pt i o n 1 — Ins t rum ent Cl us t e r 2 — Red W a r ni ng L amp 3 — A m ber W ar ni ng La mp 4 — Dr i v e r' s I nfo r mat i on/Me ss a ge Ce nt e r The dr i ver&apos[...]

  • Page 2055

    P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Inform atio n and Message Cen ter Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage . 2. Vi sual Inspect i on C h art El e ct ri cal Fuse (s ) [...]

  • Page 2056

    P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Message Cen ter Re moval a n d I ns t a l l a t i on 1. The i nfo rm a ti o n a n d mes s age ce nt e r i s bui l t i nt e gral t o t he s p e edo met e r . Fo r ad di t i ona l inf or mat i o n, r e f er t o Sect i on 413-01 I nst r um e nt Cl ust e r . JagDocs.com[...]

  • Page 2057

    P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Message Cen ter Sw itch Re moval a n d I ns t a l l a t i on 1. The t rip comput e r s wi tch i s b ui l t i n te gr al t o t he h ea dl amp s wi t ch. Fo r a ddi t i o na l i nfo rm at i on, ref e r t o Sect io n 417-01 Ext e r i or Li ght i ng . JagDocs.com[...]

  • Page 2058

    P ubl i s he d: 11-May-2 011 Warning Devices - Warning Dev ic es Des cr ipt i o n a nd O pe r a t i o n 4-doo r I te m P a r t Nu m be r Des cri pti on 1 — Do or a ct ua t or 2 — Safe t y be l t b uck l e 3 — I ns t r um ent cl us t e r 4 — J Ga t e (Aut omat i c o nl y) 5 — Eng i ne co mpar t me nt s wi t ch - v i s ual wa rn i ng o nl y[...]

  • Page 2059

    It e m Par t Nu m ber De scri pt i on 1 — Doo r act ua t o r 2 — S af et y be l t buckl e 3 — I ns t rum e nt cl ust e r 4 — J Gat e (Aut o mat i c o nl y) 5 — Engi ne c ompa r t ment s wi t ch - vis ua l w arning o nl y 6 — He a dl a mp s wit ch 7 — I gni t i on s wi t ch 8 — Li ft gat e s wi t ch - vi s ua l wa r ni ng onl y 9 —[...]

  • Page 2060

    The i ns t r um e nt cl us t e r a ct s a s a sys t em monit o r fo r t he vi s u a l w arnings . It recei ve s i nput s f r om s wi t che s a nd s e ns o rs di rect l y o r t hr oug h t he m ul t i p l e x l i nk from a no th e r m odu le and trig ge r s t he ne ces s a r y vis ua l wa r ni ng Ign ition Switch Lock C ylin der (North America Only )[...]

  • Page 2061

    P ubl i s he d: 11-May-2 011 Warning Devices - Warning Dev ic es Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the i ns t ru me nt cl ust e r and gene r a l e l e ct roni c modul e (GEM ), o f whi ch t he mes s a g e ce nt e r i s a pa r t , a nd t he mult i p l e xe d co mm unica t i on ne t wo rk [...]

  • Page 2062

    P ubl i s he d: 11-May-2 011 Warning Devices - Oil Chan ge Indicato r Reset Gene ral P r ocedures 1. NOT E: S t e ps 2 t o 5 mus t be compl e t e d wi t hi n 3 s e cond s f or s ucces s ful s ervice mod e res e t t i n g. • NO T E: Ig ni t i on key i n t he OFF po s i t i o n. P r es s a n d ho l d dow n t he t r i p co mpute r R E SET but to n. [...]

  • Page 2063

    P ubl i s he d: 11-May-2 011 Warning Devices - Low Washer Fluid W arni ng Indicato r Switch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to S ect i o n 204-04 W hee l s a nd T ire s . 2. D et a ch t he wh ee l a r ch l i ne r . 3. Remove t he res e rv o i r[...]

  • Page 2064

    P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Des cr ipt i o n a nd O pe r a t i o n Item P ar t N um be r Descri pt i o n 1 — P a r king a i d s wi t c h 2 — Fr o nt pa r king a i d s pea ke r 3 — Fr o nt pa r king a i d s e ns o r 4 — Re ar out e r pa rk i ng a i d s e ns o r 5 — Re ar cent re pa r ki ng a i d s e ns or 6 ?[...]

  • Page 2065

    (2 ft ), at t he vehi cl e cor ne rs. The ve r t i ca l r ang e i s a de qua t e t o p r ot e ct t he hi gh e s t a nd l o we s t po i nt s o f t he front o f t he ve hicl e . The s ys t e m wil l d et e ct cur bs wi t h he i ght s o f a t l e a st 18 c m (7.1 i nches ). O bs t a cl e s , s uch a s c urbs, t h at a re l ow e n ough t o p a s s und [...]

  • Page 2066

    P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he pa rk i ng a i d, ref e r to the rel e va nt Des cr i p t i on a nd O pe rat i o n s e ct i o ns i n t he wo r ks hop manua l . REFER t o : P a r ki ng Ai d (413-13 P a r king A i d, D[...]

  • Page 2067

    DT C Descri pti on Pos si bl e Ca use A ct i on C1714 Ri ght Fr on t S e ns o r Cir cuit Shor t t o V ba t W i r in g harnes s co ncern Re fe r t o e le ctrica l ci r cuit di a gr a ms. Che ck if da t a li ne is s ho r t ci r cuit t o pow er. Re pai r wi ring ha r nes s us i ng a p pr ove d me t h ods a nd ma t e r i a l s , c l e a r DTC a nd r et[...]

  • Page 2068

    P ubl i s he d: 11-May-2 011 Par kin g A id - F ron t Parking Aid Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont bu m pe r cover . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont B umper Cover (501-19 Bumpe r s , Re moval a nd I ns t a l l a t i on). 2. D i s conne ct t he e l ect r i cal conne ct o r.[...]

  • Page 2069

    P ubl i s he d: 11-May-2 011 Par kin g A id - F ron t Parking Aid Speaker Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r a[...]

  • Page 2070

    5. Remove t he a s ht ray Dis conne ct t he e l e ct r i cal co nnect o rs. Re mov e t he a s ht ray. 6. Remove t he s wi t ch pa ck t rim cove r. 7. Remove t he ret a i ni n g s cr ew co ver pl a t e . 8. Remove t he di sp l ay mount i ng br a c ket up pe r ret a i ni ng s cr ews . 9. Remove t he di sp l ay mount i ng br a c ket l o we r ret a i n[...]

  • Page 2071

    10. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 11. Remove t he d i s p la y modul e a nd a udi o uni t . 1. Dis con nect t he e l e c t rical co nnect ors a nd t h e fi br e op t i c conne ct o r . 2. Re move t he d is pl a y modu le and audi o uni t . 12. Dis c o nne ct t he f r o nt p a r k in g a i d s p ea ke r e l e ct rica l conne [...]

  • Page 2072

    P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Mo d ule4 -D oo r Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o S ect i o n 414-01 Ba t t e r y, Mount i ng and Cabl es . 2. Remove t he s p a r e whe e l . 3. D i s conne ct t he e[...]

  • Page 2073

    P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Mo d uleW agon Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e t he l o a ds p a ce fl o o r cove r i ng. 2. Remove t he l o ad s p a ce fl oo r covering. 3. Remove t he ce nt re l o a ds pace s t o wage compartment . 4. D i s conne ct t he e l ect r i cal conne ct o r. JagDocs.c[...]

  • Page 2074

    5. D i s conne ct t he e l ect r i cal conne ct o r. 6. D i s conne ct t he e l ect r i cal conne ct o r. 7. Remove t he pa r ki ng a i d modul e. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2075

    P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he bumpe r l ow er bl a ck out p a nel . 2. D i s conne ct t he e l ect r i cal conne ct o r. 3. CAU TI O N : Make s ur e e xc e s s i ve pres s ur e or t o o ls a re no t us e d whe n r e moving th e s e ns or f r [...]

  • Page 2076

    P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid Speaker4-D o or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear pa rc e l s he l f . Fo r a d di t i ona l i nf o r mat i on , refe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on . 2. D i s conne ct t he e l ect r i cal conne ct o r. 3. Remove t[...]

  • Page 2077

    P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid SpeakerWagon, VIN R ange: D86655 - >E43419 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e t he l o a ds p a ce fl o o r cove r i ng. 2. Remove t he l o ad s p a ce s t owa g e compa rtment t r i m pan e l . 3. Remove t he l o ad s p a ce s t owa g e compa rtment . 4. D i[...]

  • Page 2078

    5. Remove t he rear pa rk i ng a i d s pe a ker. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2079

    P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid SpeakerWagon, VIN R ange: E4 3420-> V 99999 Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: The l i f t g a t e we a t he r s t r i p must b e repl a ced on ce removed. Re move a nd di s ca r d t he l i f t g a t e o pe ni ng we a t he r s t rip. 2. Remove bo t h C-pi l l [...]

  • Page 2080

    8. D i s conne ct r e a r p ark ing a i d s pe a ke r el e c t r i cal co nne ct or. 9. Remove t he rear pa rk i ng a i d s pe a ker. Re mov e t he 2 s cr ews . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ins t al l a ne w l if tg a t e o pe ni ng we at he r s t r ip. JagDocs.com[...]

  • Page 2081

    P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Cha rg i ng Sy stem Des cr ipt i o n a nd O pe r a t i o n V eh icl es wi th 2.0 L, 2 .5L or 3. 0L en gin es The charging s yst e m cons i s t s o f a 120 a mp out put ge ne r a t or a nd re gul a t o r as se m bl y whi ch g e ne r a t e s c ur r ent t o s uppl y[...]

  • Page 2082

    P ubl i she d: 14-Jul-2011 B attery and Chargin g Syste m - General Info rm atio n - Battery C are Des cr ipt i o n a nd O pe r a t i o n 12 V LEAD ACID BAT TER Y CARE MANUAL FOR DE AL ER / RE T AILE R US E 1. INTRODU CTION 2. GENERAL RU LES FO R BA TTERY CA RE 3. EQ U IP MENT (MI NIMU M S TANDAR D) 4. HEAL TH AN D SA F ETY PRECA UTI ONS 5. DETE R [...]

  • Page 2083

    s uppo rte d wi th a po we r sup pl y / char ge r / vehi cl e ma i nt a i ner ca pab l e o f d e l ive r i ng 5 0 Amps or more. Ju mp Sta rting Ne w v ehic le s Bef ore They Hav e B een Delive re d to the Cus tom er. I t is t he de a l e r / r e t a i l e rs res p ons i bi l i t y t o e ns ur e t he b a t te r y i s not a l l o we d t o go f l a t [...]

  • Page 2084

    Digi t a l Mult i -Met e r o r Digi ta l Vo l t -Oh m Met er (DVOM) Midt r oni cs GR-1 Di agno s t i c Charge r JagDocs.com[...]

  • Page 2085

    4. HE ALTH A ND S A FETY PR ECAUTION S • W ARNINGS : BA TT ERY CELLS CO NT AI N S UL P HUR IC ACID AND EXP LO S IV E MIX TURES O F H Y DRO GEN AND O XY GEN GAS ES . I T I S THEREFORE ES S ENT I AL T HAT T HE FO L LO W I N G S AFETY PRECAU T IO NS ARE O BSERVED . Ba t t e r i e s e mit hi ghl y e xplo s ive hydr o g en a t a l l t i mes , parti cu[...]

  • Page 2086

    Sc e nar io 1 - Dea lers hi p / Retailer ( Res p ons ib ility: De aler / Retailer ) 1. W i t hi n 24 ho ur s o f a r r iva l a t t he d e a l e r / ret a i l e r pr ocee d as fo l l o ws: P e r form a Mi dt r oni cs ba t t e ry t e s t (S ee A ppe ndi x A. ) Ca r ry o ut t he recommende d a ct i o ns a ccor d i ngl y . 2. If t he Mi dt roni cs r es[...]

  • Page 2087

    I t is e s s ent i a l t ha t a s ui ta b l y vent i l a t e d d e fi ned area e xis t s in e a ch d e a l e r s hi p / r e t a i l e r f o r bat t e ry ch a rging. Li kew i s e , an a r ea s ho ul d be a ll ot t ed f o r s cr a p ba t t e r i e s , a nd cl e a rly i ndi cat e d a s s uch. I t i s r ecommende d t ha t de al e r s / ret a i l e r s [...]

  • Page 2088

    CAU TIO N : DO NO T conne ct t he t e s t e r t o a ny o t he r circ ui t o r c ha s s i s po i nt . 1. Att a ch t he Mi dt roni cs Te s t e r t o t he ba t t e ry . 2. Fol l ow th e i ns t r uct i o ns o n t he te s t er t o t e st t he ba t t e r y . Ens ur e t he corr e ct ba t t e ry type a nd s i z e i s s e l e ct e d . 3. Perform t he a ct i[...]

  • Page 2089

    • NO T E: O n ve hi cl e s f i t t e d wi t h a Ba t t e ry Mon it o r ing S ys t em (BMS ) , t he di a gnos t ic ro ut i ne fo r qui e s c e nt dr a i n t e s t i ng i n t he a p pr oved di a gno s t ic s ys t e m s houl d be ut i li z e d. • NO T E: I f a cus t o mer compl a i ns o f a ve hi cl e b a t te r y th a t di s char ge s cont i nuo [...]

  • Page 2090

    1. If 24 hours have pa s s e d s i nce th e l a s t ti me t h e e ng i ne wa s run o r th e ba t t e ry charge d, p rocee d t o `P a r t 2 - Bat t e ry Te st '. 2. Tur n on t he i gni t i on. S wi t ch o n t he he a d l a mps o n hi gh be a m fo r a mini mum 3 minut es . 3. S wi t ch o ff t he he a dl amps . Fo r vehi cl e s t e s t ed a ft er[...]

  • Page 2091

    Publ i s he d: 28-S ep -2011 B attery and Chargin g Syste m - General Info rm atio n - Qu iescen t Drain Des cr ipt i o n a nd O pe r a t i o n QUIES C ENT D RA IN - TYP ICAL VALUES • NO T E: T he q ui e s cen t dr ai n a f t e r t he ini t i a l s hut do wn p e r i od s houl d not excee d t he val ue s ho wn i n t h e t abl e . Jaguar Q ui es ce[...]

  • Page 2092

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Cha rg i ng Sy stem 2.0L N A V6 - A JV 6/2.5 L NA V 6 - AJV6/3. 0L NA V6 - AJ2 7 Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o [...]

  • Page 2093

    1 2 1 1 2 1 1 Pi n Num be r C i r cu i t F u nc ti on Ci rcui t Col or 4 Ge ne r at o r Cha rge W a rning I n di cat or La mp O ut pu t S ig na l t o ECM Bl ue E ngine C o ntrol M o du l e (E C M) E l ectri c al C o nnect or ( E N 1 6, Harnes s Side ) Pi n Num be r C i rcui t F unc ti o n C i r cu i t Col or 53 Vol t a ge Re qu e st O ut p ut S i g[...]

  • Page 2094

    2 1 1 2 1 2 1 1 1 1 2 1 2 1 Mea s ur e t he res i s t a nce be t we e n e l e ct r i cal c onn e cto r EN49-1 a nd t he gen e rat o r ba t t e r y po s i t i ve ca bl e . I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR s ho rt t o t he ge ne r a t or ba t t e ry p os i t i ve cab l e . CL EAR t he DTC. TES T t he s yst e m fo r n[...]

  • Page 2095

    1 1 1 1 1 2 1 1 1 1 1 I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR s ho rt t o t he ge ne r a t or ba t t e ry p os i t i ve cab l e . CL EAR t he DTC. TES T t he s yst e m fo r no r m a l o pe r at i o n. No GO t o D3 . . D3: C HECK T H E S I G NA L WI RE FOR A SH O R T T O GR O UND Mea s ur e t he res i s t a nce be t we e n[...]

  • Page 2096

    1 1 2 1 1 1 1 1 2 1 1 1 1 ope rat i o n. E10: CHEC K FUSE 8 2 OF T HE PASSEN GER C O MPAR T M ENT FUSE BOX FOR A S HOR T T O GR O UND Meas ur e t he res is t a nce b e t we e n e l ect r i cal conn e cto r JB51-14 of t he pa s s e nge r compart ment f us e bo x a nd gr oun d. I s t he r es i s t a nce l e s s t ha n 10,000 o hms? Ye s REPAI R s hor[...]

  • Page 2097

    1 2 1 1 1 1 1 2 1 1 2 1 2 I s t he v ol t a ge l es s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n t he pa s s e nge r c ompa rtment f us e box a nd t he i gni t i on r el ay. TEST t he s y s t em f o r norm al op e r at i o n. No REP AIR t he ci r cuit b e t we e n t he pa s s e nge r c ompa rtment f us e box a nd t he ge n e r at [...]

  • Page 2098

    1 2 1 2 3 1 2 3 T EST C ONDI T IONS DET AI L S/R ESULT S/ACT IONS H1 : CHEC K T HE GENER AT OR FO R T HE CAUSE OF RADIO I NT ER FER ENC E S TART a nd RU N t he e ngi ne a t 1500 RP M. TU RN t he radi o s wi t c h t o t he O N po s i t i o n. Is r a di o i nt e rfe rence p res e nt ? Ye s GO t o H3 . . No GO t o H2 . . H2 : CHEC K T HE GENER AT OR F[...]

  • Page 2099

    P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Cha rg i ng Sy stem 2.0L Durato rq- T DCi/2. 2L Duratorq-TDC i (110k W/1 50PS) - P uma Dia gn os i s a nd Te s t i ng Principle of oper at ion The di e s e l char gi ng s y s t em d i f fe rs f r o m t ha t us ed i n p e t r o l -e ng i ne d var ia n t s i n t ha[...]

  • Page 2100

    1 2 3 1 1 1 2 3 4 1 2 3 1 DT C Co ndi ti on Pos si bl e Sour ce Act i on No ne The ba t t e ry kee ps di s cha r g i ng Ba t t e r y f a ul t Ba t t e r y cabl e s Ba t t e r y qui e s ce nt d r ai n Acces s o r y dr ive b e l t t e ns i o n Gene r a t or f a i l ur e Gene r a t or pul le y f aul t Che ck t he ba t t e ry condi t i on a nd s t a t [...]

  • Page 2101

    2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 1 1 2 3 4 5 1 2 1 Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Di s conn ect t he ge nerat o r t hr e e -way con nect or . Conn ect a vol t met e r bet we e n t he g ene rat o r , p i n 01 a nd GRO UN D. S t art t he e ngi ne . Tur n t he he a dl i ght s a nd he a t e d rea r wi nd o w t o t he ON p[...]

  • Page 2102

    1 1 1 1 1 1 2 1 2 T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I O NS E1: CHEC K T HE GENER AT O R FOR SECU R IT Y Ins p ect t he g e nerat o r f ixi ngs . I s t he ge ne rat o r s e cur e? Ye s GO t o E2 . No S ECU RE t he ge ne r a t o r . REFER t o : Ge nerat o r. TES T t he s yst e m f or no r m al o p e r at i on . E2: CHEC K T HE ACC ESS O [...]

  • Page 2103

    1 2 1 2 3 1 2 3 1 2 3 T EST C O NDI T IONS DET AI LS/RE SULT S/ACT IONS F1: C HEC K IF T HE GENERAT O R I S T HE CAUSE OF T HE RADI O I N T ER FER E NCE S ta rt an d r un t he e n gi ne a t 1500 r pm . Tur n t he radi o t o t he O N po s i t i o n, a nd s e l e c t t he a f f e ct e d s t at io n. Is t he radi o i nt e r f e r ence pr e s e nt ? Ye[...]

  • Page 2104

    P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Battery C harging Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t o t he b at t e ry car e ma nua l (BCM ). JagDocs.com[...]

  • Page 2105

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Ba t t e r y Capa ci t y Ve hi cl e s W it h P e t rol Engi ne s 80 Ah Ba t t e r y Capa ci t y Ve hi cl e s W it h Die s e l Engi nes 80 Ah Ba t t e r y Col d Cranking Vehi cl es W i t h P e t r o l E ngi ne s 680 Amps Ba t t e r[...]

  • Page 2106

    [...]

  • Page 2107

    I te m P a rt N um be r De scr i pti on 1 — B at t e r y t o g e nerat o r a nd s t arte r mot o r p os i t i v e c a bl e 2 — B at t e r y cover 3 — B at t e r y 4 — B at t e r y t r a y 5 — B at t e r y ground ca bl e 6 — B at t e r y cla mp r et ai ni ng bo l t 7 — B at t e r y cla mp 8 — B at t e r y cla mp r et ai ni ng nut The[...]

  • Page 2108

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o t h e ba t t e r y car e manual . JagDocs.com[...]

  • Page 2109

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Co nnec t Gene ral P r ocedures • W ARNINGS : Ba t t e r i e s no r m al l y produce e xpl o s ive g a s e s which may ca use pers ona l i nj ur y, t he ref o r e do not a l l o w l i g ht e d s ubs t ance s t o come ne a r t he ba t t ery. W he n charging o r work i ng ne ar[...]

  • Page 2110

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Disco n nect and Co nnect Gene ral P r ocedures Disc onn e ct • W ARNINGS : Ba t t e r i e s no r m al l y produce e xpl o s ive g a s e s which may ca use pers ona l i nj ur y, t he ref o r e do not a l l o w l i g ht e d s ubs t ance s t o come ne a r t he ba t t ery. W he [...]

  • Page 2111

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ).[...]

  • Page 2112

    6. NOT E: Pe t r ol e ngi ne s how n, d i es e l e ngi ne s i mi l a r. Re move t h e ba tt e r y he a t s hi e ld . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2113

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Cables2 .0L NA V6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nt[...]

  • Page 2114

    7. D et a ch t he ba t t e ry t o s t a rte r mot o r so l eno i d c a bl e cove r . 8. Remove t he ba t t e r y t o s t a r t e r m o to r s o l e no i d ca bl e . Re mov e t he re ta i ni ng nut . 9. Remove t he a i r cl ea ne r a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A i r Di s t[...]

  • Page 2115

    12. Remove t he a i r f i l t e r ret a i ni ng b r ack e t . Re mov e t he re ta i ni ng nut s . 13. Det a ch t he ge ne r at o r ba t te r y po s i t i ve cabl e p r ot e ct ive co ver. 14. Remove t he b a t t e r y pos i t ive cab l e . Det a ch t he ge ne rat o r b a t t e r y po s i t i ve ca bl e e l e ct r i cal conne cto r. Re mov e t he re[...]

  • Page 2116

    2. Tig ht e n t o 6 Nm. 3. Tig ht e n t o 12 Nm. 4. Tig ht e n t o 25 Nm. 5. Tig ht e n t o 25 Nm. 6. Tig ht e n t o 4 Nm. JagDocs.com[...]

  • Page 2117

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Cables2 .0L Durato rq- TDCi / 2.2L Du ratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s[...]

  • Page 2118

    7. D et a ch t he ge ne r a t o r a nd st a r t e r mot or po s it i ve ca bl e f r om t he st a r t e r m o t o r . 8. D et a ch t he ge ne r a t o r a nd st a r t e r mot or po s it i ve ca bl e f r om t he ai r cle a ne r mount i ng bracket . 9. D et a ch t he ge ne r a t o r a nd st a r t e r mot or po s it i ve ca bl e f r om t he powe r s t e[...]

  • Page 2119

    12. Det ach t he ge n erat o r and s t arte r mot o r pos i t i ve cabl e from t he e ngi ne cover mount i ng b r a ck et . 13. Dis c o nne ct t he g e ne r at o r wi r i ng ha r ne ss e l e ct rical co nnect or. 14. Det a ch t he ge ne r at o r an d s t a r t e r mot or po s it i ve ca bl e f r om t he ge ne r a t or ca bl e moun t i ng bracket . [...]

  • Page 2120

    16. Dis c o nne ct t he g e ne r at o r e l e ct r i cal conne cto r. 17. Det a ch t he ba t t e ry g r ound ca bl e f r o m th e t rans mis s i on r et a i ni ng br acke t and bat t e ry br a cket . 18. Det a ch t he ba t t e ry g r ound ca bl e f r o m th e t rans mis s i on . 19. Remove t he b a t t e r y ground cab l e. Insta llat ion JagDocs.c[...]

  • Page 2121

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 25 Nm. 2. Tig ht e n t o 25 Nm. 3. Tig ht e n t o 8 Nm. 4. Tig ht e n t o 8 Nm. JagDocs.com[...]

  • Page 2122

    P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Tray Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ba t t e r y . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y (414- 01 Ba t t e ry , Mount i ng a nd Ca b l e s , Remo v al a nd I ns t a l l a t i o n). 2. NOT E: Pe t r ol e ngi ne s how[...]

  • Page 2123

    P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - T o rque Sp eci f i cat ions Descri pti on Nm l b -f t l b- i n Gene r a t or uppe r r et ai ni ng bo l t 4 7 35 - Gene r a t or l o we r r et a i ni ng b o l t s - vehi cl e s wi t h 2.0L, 2. 5L o r 3.0L e ngi ne 25 18 - Gene r a t or l o we r mount i ng s t uds - vehi cl e s wi t h 2. 0L di[...]

  • Page 2124

    P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator Des cr ipt i o n a nd O pe r a t i o n C ha r ging syste m componen ts Ve hi cl e s wi th 2.0L, 2. 5L o r 3.0L e ngi ne Item P a r t Nu m be r De sc ri pti on 1 — Engi ne Co nt rol Mod ule (ECM ) 2 — Ge nerat o r Ve hi cl e s wi th 2.0L di e s e l eng ine JagDocs.com[...]

  • Page 2125

    Item P a r t Nu m be r De sc ri pti on 1 — Engi ne Co nt rol Mod ule (ECM ) 2 — Ge nerat o r • NO T E: Ge ne r at o rs s houl d b e s e r v ice d a s a uni t a nd no t di s mant l ed fo r overhaul . JagDocs.com[...]

  • Page 2126

    P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator Dia gn os i s a nd Te s t i ng 2.0L/2.5L/3.0L Ve hi cl e s REFER t o : Cha r g i ng Sy s t em - 2. 0L NA V6 - AJV 6/2.5L NA V6 - AJV6/3.0L N A V 6 - A J27 (414-00 B a t t e r y a nd Cha rging Sy st e m - Gene ral I nfo r m at i o n, Dia gno si s a nd Te s t i ng). 2.0L Di e s e l V[...]

  • Page 2127

    P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator2.0L N A V6 - A JV 6/ 2.5L NA V6 - AJV6 / 3.0L NA V6 - A J27 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o S ect i o n 414-01 Ba t t e r y, Mount i ng and Cabl es . 2. Remov[...]

  • Page 2128

    7. Remove t he ge ne r a t or . Re mov e t he g e ne r at o r uppe r r e t a i ni ng bo l t s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 47 Nm. 2. Tig ht e n t o 25 Nm. 3. Tig ht e n t o 12 Nm. JagDocs.com[...]

  • Page 2129

    P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator2.0L Durato r q -TDCi/2.2L Duratorq-TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) S epa rat o r, ba l l j o i nt 204-192 Re l e a s e t o o l , bel t t e ns i on e r 303-676 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a[...]

  • Page 2130

    7. D et a ch t he r i ght -hand s t ab i l i z e r ba r li nk. Re pos i t i o n t he a nt i -lo ck br a ke s yst e m (ABS) wi ring ha r ne s s m o unt i ng b r a cket . 8. Usi ng t he s pe cia l t oo l , de t a ch th e a cces s o r y drive be l t . 9. Remove t he ge ne r a t or co ol i ng duct f r o m th e ge ne r at o r . 10. Det a ch t he ge ne r[...]

  • Page 2131

    12. Remove t he g e ne r at o r uppe r r e t ai ni ng bo l t . 13. Remove t he g e ne r at o r r e t a i ni n g nut s . 14. Remove t he g e ne r at o r mount i ng s t uds . 15. Remove t he g e ne r at o r. Insta llat ion JagDocs.com[...]

  • Page 2132

    1. Ins t a l l the ge n e r at or. 2. Ins t a l l the ge n e r at or mount i ng s t uds . Ti ght e n t o 15 Nm. 3. Loos e l y i nst a l l t he g ene rat o r r e t a i nin g nut s . 4. Ins t a l l the ge n e r at or uppe r r e t ai ni ng bo l t . 1. Ti g ht e n t o 47 N m. 5. Tig ht e n t o 47 Nm. JagDocs.com[...]

  • Page 2133

    6. Connect t he ge ne r a t or e l e c t r i cal co nne cto r. 7. Att a ch t he ge ne r a t or po s i t i ve ca bl e . Ti ght e n t o 12 Nm. 8. Ins t a l l the ge n e r at or coo li ng duct t o t he ge ne rat o r . Ti ght e n t o 4 Nm. 9. Usi ng t he s pe cia l t oo l , at t a ch t he a cces s o r y drive be l t . 10. At t ach t he rig ht -ha nd s [...]

  • Page 2134

    11. Ins t a l l t he t i e -r od e nd a nd t he t i e -r od e nd ret a i ni ng nut . Ti ght e n t o 35 Nm. 12. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover. 13. Ins t a l l t he f r ont , right -hand whe e l and t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti r[...]

  • Page 2135

    P ubl i s he d: 11-May-2 011 Info rma tio n and E ntertainm ent System - G eneral In fo rmati on - Audio System Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he Audi o Sy s t e m and co mponent s , r ef e r t o t he r e l e v an t De s c ript io n a nd O pe r at i o n s e ct i o n i n t he w[...]

  • Page 2136

    DT C Descri pti on Poss i bl e Ca uses Ac ti on U0194 Los t Comm uni ca t i o n wi t h Digi t a l Audi o Co nt rol Modul e B Di gi t a l Aud io Broa dcas t Modul e Gat e wa y modul e - l o s t c ommunicat i o n wi t h d ig i t a l a udi o b r o a d cas t mod ul e Ca r ry out a ny p i npoi nt t e s t s a s s oci a t e d wi t h t hi s DT C us in g t [...]

  • Page 2137

    DT C De scr i pti on Poss i bl e Ca uses Act i on C1977 Audi o S t e e ring W h e e l S w i t c h Ci r cui t Shor t T o Gr o und Ra di o hea d uni t , a ud io s t ee ring whe e l s wi t c h ci r cuit - s h or t t o ground Re fe r t o e l e ct rical c i r cuit d i a grams, no t es sus pe c t t h e a ud io s t e ering whe el s wi t ch che ck f o r ci[...]

  • Page 2138

    DT C De s cri pti o n P ossi bl e Ca uses Act i on B11A413 L -Band a nt e nna DAB L -Band a nt enna Ci r cuit - ope n ci r cuit Re f e r t o e l e ctr i cal ci rc ui t d ia g r ams a nd che ck DAB L -ba nd a nt e nna ci rc ui t fo r op e n ci rcu i t B11-A511 Ba nd 3 a nt e nna DAB b a nd 3 a nt e nna ci rcu i t - sho rt t o ground Re f e r t o e l[...]

  • Page 2139

    P ubl i s he d: 11-May-2 011 A udio U nit - A udio System Des cr ipt i o n a nd O pe r a t i o n Ba s e cas s e t t e I te m Pa rt N um ber De sc ri pti o n 1 — Dol b y n oi s e reduct i on but t o n 2 — Rep e a t CD but t o n 3 — Audi o s yst e m di s pl ay 4 - S e e k a st o r ed numbe r fr om t he p hon e s m e mor y 5 — Radi o s t a t i[...]

  • Page 2140

    I te m Pa rt N um ber De sc ri pti o n 1 - Mu t e s a ud i o 2 - Repe a t CD but t o n 3 - Audi o s yst e m di sp l ay 4 - S e e k a st o r ed numbe r fr om t he p hon e s m e mor y 5 - Radi o s t a t i o n pre-s e t but to ns 6 - S e e k a st o r ed numbe r fr om t he p hon e s m e mor y 7 - Mix CDs o r CD/M D t r acks but t o n 8 - Eje c t CD or [...]

  • Page 2141

    I te m Pa rt N um ber De sc ri pti o n 1 - O n/Of f pus h f o r t ou ch -s cr e e n cont r ol s 2 - Touch-s cr ee n di s pl a y 3 - Pres s to a cce ss t o uch-s c r e e n o p t i ons 4 - CD t r a ck mix but t on 5 - Prio r i t y p r o g r amme t ype but t o n 6 - Tr a ff i c a nno unce ment but t on 7 - Aut o me mor y but t on 8 - S e l ect CD chan[...]

  • Page 2142

    3 - Pres s to a cce ss t o uch-s c r e e n o p t i ons 4 - Eje c t CD or MD 5 - Mix CDs o r CD/M D t r acks but t o n 6 - Prio r i t y p r o g r amme t ype but t o n 7 - Tr a ff i c a nno unce ment but t on 8 - Aut o me mor y but t on 9 - S e l ect CD chang er 10 - S e l ect co mpact d i sc whe n i n o t her a udi o mode , o r CD pau s e 11 - Audi [...]

  • Page 2143

    P ubl i s he d: 11-May-2 011 A udio U nit - A udio System Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 415-00 Info rm at i o n a nd Ent e rta i nment Sy s t e m - Ge neral Inf or m a t io n . JagDocs.com[...]

  • Page 2144

    P ubl i s he d: 11-May-2 011 A udio U nit - A udio Un it Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cli mat e cont r ol p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 412-04 Cont r ol Co mpone nt s . 2. Remove t he na vig a ti o n s y s t e m s cr ee n (whe r e f i t t ed). For a ddi ti ona l i nf o[...]

  • Page 2145

    P ubl i s he d: 11-May-2 011 A udio U nit - A udio Un it A mplifi er4-D o o r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l ugga g e co mpar t me nt front f lo o r car pe t . 2. Remove t he l ugga g e co mpar t me nt r ea r fl o or car pe t . 3. Remove t he l ugga g e co mpar t me nt i nt erio r t r i m. 4. D i s conne ct t he a [...]

  • Page 2146

    5. Remove t he a udi o uni t a mpl if ie r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 9 Nm. 2. Usi ng t he Jag ua r a pproved di agno s t i c s yst e m con fi gur e t he a udi o uni t a m pl i fi e r . JagDocs.com[...]

  • Page 2147

    P ubl i s he d: 11-May-2 011 A udio U nit - A udio Un it A mplifi erWagon Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he au di o uni t pi n cod e i s a vai l a bl e bef or e di s conne c t i ng t he b a t te r y gr ound cabl e . Di s conn ect t he ba tt e r y ground ca bl e . For a ddi ti o nal i nfo r m a t i o n, r e f [...]

  • Page 2148

    6. Remove t he l e ft -hand lo a d s p ace s i de t rim p a nel ret a i ni ng s cr e w. 7. D i s conne ct t he pa r ki ng a id s pe a ker e le ct r ica l conne cto r . 8. Remove t he pa r ki ng a i d s pe a ker. 9. Remove t he a udi o uni t a mpl if ie r ret a i ni ng bol t . 10. Remove t he a ud i o uni t ampl i f i e r r et a i ni ng b ol t s . J[...]

  • Page 2149

    11. Remove t he a ud i o uni t ampl i f i e r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 9 Nm. 2. Tig ht e n t o 9 Nm. 3. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a[...]

  • Page 2150

    P ubl i s he d: 11-May-2 011 A udio U nit - Com pact Disc (C D ) Ch anger4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he ICE pi n co de i s a vai l abl e be fo re di s conne ct i ng t he bat t ery ground ca bl e . Di s conn ect t he ba tt e r y ground ca bl e . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o[...]

  • Page 2151

    7. D i s conne ct t he e l ect r i cal conne ct o rs. 8. Remove t he compa ct di s c (CD ) pl a ye r r e t a ini ng bo l t s . 9. Remove t he CD p l a yer . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 1 Nm. JagDocs.com[...]

  • Page 2152

    2. Tig ht e n t o 1 Nm. 3. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ). JagDocs.com[...]

  • Page 2153

    P ubl i s he d: 11-May-2 011 A udio U nit - Com pact Disc (C D ) Ch angerWagon Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he au di o uni t pi n cod e i s a vai l a bl e bef or e di s conne c t i ng t he b a t te r y gr ound cabl e . Di s conn ect t he ba tt e r y ground ca bl e . For a ddi ti o nal i nfo r m a t i o n, r[...]

  • Page 2154

    6. Remove t he l o ad s p a ce s t owa g e compa rtment . 7. Remove t he l o ad s p a ce fl oo r covering r e t a i nin g s cr ews . 8. D et a ch t he l o a d sp a ce fl o o r cove r i ng upwards. 9. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt ret a i ni ng screw. 10. Remove t he l ef t -han d l o a ds pa ce s t ow ag e comp[...]

  • Page 2155

    11. Det a ch t he modul e ret a i ni ng brack e t . 12. Dis c o nne ct t he na vi ga t i o n s y s t e m module e l e ct rica l con nect or s . 13. Dis c o nne ct t he co mpact d i sc (CD) change r e l e ct r i cal c onn e cto r s . 14. Dis c o nne ct t he mul t i funct i on v o i ce a c t i va t e d m odul e e l e ctrica l conne ct ors. 15. Dis c [...]

  • Page 2156

    16. Remove t he CD pl a yer r e t a i ni ng b o lt s . 17. Remove t he CD pl a yer. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 1 Nm. 2. Tig ht e n t o 1 Nm. JagDocs.com[...]

  • Page 2157

    3. Tig ht e n t he modul e r e t a i n in g b r a cke t uppe r a nd l owe r f i xin gs . Ti ght e n t he l ow er r e t a i ni n g nut s t o 4 N m . Ti ght e n t he up pe r r et a i ni ng bo l t t o 9 Nm. 4. Connect t he ba t t e ry gr ound cabl e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , M[...]

  • Page 2158

    P ubl i s he d: 11-May-2 011 A udio U nit - Steering Wheel Audio C ontro ls Re moval a n d I ns t a l l a t i on 1. Remove t he s t ee ring whe e l. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ste e ring W h e e l (211-04 S te e r i ng Col umn, Re moval a nd Ins t a l la t i o n). 2. Remove t he s t ee ring whe e l fi nis her t r im pan[...]

  • Page 2159

    P ubl i s he d: 11-May-2 011 A ntenna - T o rque Sp eci f i cat ions Descri pti o n Nm l b- f t l b-i n Modul e r e t a i nin g b o lt - 4 Door 9 – 80 Ant e nna ret a i ni n g nut - W a go n 7 – 62 JagDocs.com[...]

  • Page 2160

    P ubl i s he d: 11-May-2 011 A ntenna - Antenna Des cr ipt i o n a nd O pe r a t i o n ANT ENNA - 4 DOOR I te m Pa rt N u mber De sc ri pti on 1 — Roof pod ant e nna modul e (vehi cl es from 2009MY ) 2 — FM an t e nna 3 — AM Ant e nna 4 - Digi t a l Aud io Broadca s t (D AB)/Ve hi cl e Inf orm a t i o n a nd Co mm unica t i o n Sy st e m (VI [...]

  • Page 2161

    The DAB s ys t e m us e s t he a nt e nna i n t he r oo f p od a nt e n na modul e a nd a l s o t he r e a r win do w he a t e r e l e ment s f or DAB r ece pt i on . The a nt e nna mod ul e r ece i ves L ba nd s i g nal s whi ch a re p a s s e d di r e ctl y t o t he DAB modul e i n t he lu gga ge compa r t ment . The r ea r wind o w e l e ment s [...]

  • Page 2162

    Wag on - V eh icle s fr om 20 0 9MY Ve hi cl e s f r om 2009MY a r e f i t t e d w i t h a roof po d a nt e nna mo dul e . Th e mo dul e i s s e cur e d t o t he ve hi cl e roof pa ne l wi t h 2 l o ck nut s a nd wa s he rs s cr ewe d o nt o cap t i ve s t uds i n t he mod ul e . T he mod ule ca n co nt a i n t he f o l l owi ng a nt e n na e d e p[...]

  • Page 2163

    P ubl i s he d: 11-May-2 011 A ntenna - Antenna Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage . 2. Vi sual Inspect i on C h art El e ct ri cal Modul e FM annt ena AM a nt e nna W i r i ng ha r ne s s f o r[...]

  • Page 2164

    P ubl i s he d: 11-May-2 011 A ntenna - AntennaWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: O ve r hea d Co ns ol e (501-1 2 I nst r um e nt P a ne l a nd Co ns ol e , Re mov a l a nd I n st a l l at i o n). 2. Remove t he bo t h s un vis o r[...]

  • Page 2165

    8. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he B-pi l l a r uppe r t r im pa ne l f r om t he B -pi l l a r t r i m l o we r t rim pa ne l . 9. Remove bo t h C-pi l l a r trim pane l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: C-Pi l l a r Tr i m P a nel - W ago n (501- 05 I nt e r i o r Tr im a nd O rname n[...]

  • Page 2166

    14. Det a ch t he hea d l i n er. 15. CAUT I O N: T he hea dl i ne r must no t be cr ea s e d o r fo l ded dur ing r e m o val o r i ns t a l l at i on. Fa i l ur e t o f o l lo w thi s i ns t r ucti on may res ul t i n dama ge t o t he co mpon ent . Lo we r th e he a d l i ne r. Re mov e t he s unr oo f op e ni ng pa ne l we a t herst r ip . 16. D[...]

  • Page 2167

    19. Det a ch t he ant e nna harnes s . 20. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 21. Remove t he a nt e n na . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 7 Nm. 2. NOT E: The l i f t g a t e we a t he r s t r i p must b e repl a ced on ce removed. I nst a l l a ne w l i f t ga t e o p e [...]

  • Page 2168

    P ubl i s he d: 11-May-2 011 A ntenna - Modul e Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he C-pi l l a r t rim. Fo r add i t i o nal i nf or ma ti on, re fe r t oSect i on 501-05 Int e rio r T r i m and O r namen ta t i o n . 2. D i s conne ct t he a nt enna ca b l e e l e ct r i cal co nnect o r. 3. D et a ch t he mod ul e . 1. [...]

  • Page 2169

    P ubl i s he d: 11-May-2 011 Speakers - Speakers Des cr ipt i o n a nd O pe r a t i o n Al l Ve hi cl e s Op t i m um a cous t i c d et a il i s a chi eve d t hr o ugh moun ti ng t he s pea ker s hi gh o n e a ch doo r pa ne l . The pr e m i u m s oun d s y s t e m s pe a k e r s a r e powe re d b y a s e pa r at e , remot e ampl i f i e r. For add[...]

  • Page 2170

    P ubl i s he d: 11-May-2 011 Speakers - Speakers Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage . 2. Vi sual Inspect i on C h art El e ct ri cal W i r i ng f or da mag e a nd co r ros i o n El e ctrica l co[...]

  • Page 2171

    P ubl i s he d: 11-May-2 011 Speakers - F ro nt Do or Speaker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n . 2. Remove t he f r ont s pea ke r . 1. Dis con nect t he e l e c t rical co nnect or[...]

  • Page 2172

    P ubl i s he d: 11-May-2 011 Speakers - F ro nt Do or Tweete r Speaker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n . 2. Remove t he f r ont t we et e r s pe a ke r . Insta llat ion 1. To i ns [...]

  • Page 2173

    P ubl i s he d: 11-May-2 011 Speakers - Parc el Shelf Speaker Re moval a n d I ns t a l l a t i on 1. Remove t he pa r cel s hel f. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: P a r cel S he l f (501- 05 I nt e rio r Tr i m a nd O rnament a t i o n, Re moval a nd Ins t a l la t i o n). 2. D i s conne ct t he e l ect r i cal conne ct o r[...]

  • Page 2174

    P ubl i s he d: 11-May-2 011 Speakers - Re ar Doo r Spe aker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n . 2. Remove t he rear s pe aker. 1. Dis con nect t he e l e c t rical co nnect or. 2. R[...]

  • Page 2175

    P ubl i s he d: 11-May-2 011 Speakers - Re ar Doo r Twee ter Speaker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n . 2. Remove t he rear t we e t e r s pe ake r. 1. Dis con nect t he e l e c t r[...]

  • Page 2176

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Gen eral S p ec if ic a t ions It e m Speci fi cati on Fr o nt t ur n s i gna l l a mp b ul b PY 21W Fr o nt f og l a mp bul b H1-55W P a r ki ng/Side l a mp b ul b W 5W Lo w b e a m l a mp bul b H1-55W Hi gh b ea m l a mp bul b H1-55W Hi gh i nt ens i t y di s cha r ge (HI D) l a mp bu lb D2 s -3[...]

  • Page 2177

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Exterior L igh ting Des cr ipt i o n a nd O pe r a t i o n The he ad l a mp s wit ch is l o cat e d o n t he dr i ver s i de o f t he i n st r um e nt pa ne l. It al s o o perat e s t he s i d e l a mps , f og la mps , "Aut o Mod e ", he adl a mp l eve ll i ng a nd t he t r i p s wi t ch[...]

  • Page 2178

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamps Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he l i g ht i ng s yst e m, ref e r t o t he rel e vant Des cr i pt i on a nd O perat i o n s e ct i on s i n th e wo r k s hop manual . REFER t o: Ext erio r Li ght i ng (417-01 Exte[...]

  • Page 2179

    DT C De sc ri pti o n P os si bl e Ca use Acti on B2615 Fr ont or rea r axl e vehi cl e le vel s e ns o r s upp l y circ ui t fa i l ur e W i ring ha r ne s s concern Re fe r t o e l e ct r i cal cir cuit d i a grams , check l e ve l se ns o r powe r s up pl y circ ui t f o r s ho r t t o p o we r . Re p a i r wi r ing harnes s us i ng ap prov e d [...]

  • Page 2180

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp Adjustment Gene ral P r ocedures 1. NOT E: He a dl a mp a dj us t men t s ho ul d be made at roo m t e mper a t ur e . P r epa re t he vehi cl e fo r he a dl a mp a dj us t me nt . 1. P l a ce t he vehi cl e o n a le vel s ur f a c e . 2. Be f ore a dj us ti ng t he he a dl a mps , che c[...]

  • Page 2181

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Ballast Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl a mp a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o He a d l a mp A ss e mbl y - i n t hi s se ct i o n. 2. Remove t he bul b c ove r . 3. D i s conne ct t he ba l l a st mo dul e e l e ct rica l [...]

  • Page 2182

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - F ront Fo g Lam p Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o S ect i on 501-02 Fr ont End Bo dy P a nel s . 2. D i s conne ct t he f o g la mp e l e ct rica l co nnect o r . 3. Remove t he[...]

  • Page 2183

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp Ass embly Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he f r ont bu m pe r cover . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont B umper Cover (501-19 Bumpe r s , Re moval a nd I ns t [...]

  • Page 2184

    Vehi c le s with headla m p w asher s 6. Remove t he he a dl a mp w as he r mot o r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Ch eck t he h e adl amp a dj us t me nt , r e f e r t o For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: He a dl a mp Adj ust ment (417- 01 Exte rio r L i ght i ng, Gene r a l P r [...]

  • Page 2185

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp B u lbV ehicles With: High Intensi ty Dis charge Headlam ps Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl a mp a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o He a d l a mp A ss e mbl y - i n t hi s se ct i o n. 2. Remove t he bul b c ove r [...]

  • Page 2186

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp L eveling Mo d ule Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl a mp a s s e mbl y. For a ddi t i o na l i nf orm at i o n, r e fe r t o He a dl a mp As s e m bl y 2. Remove t he he a dl a mp bul b cover . 3. D i s conne ct t he he a dl a mp a dj us t me nt modu[...]

  • Page 2187

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp L eveling Sens or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e as s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 204-04 W h e e l s a nd Ti r es . 2. D et a ch t he l i nk r od f r om t he hea dl a mp l e ve l in g s e[...]

  • Page 2188

    6. Remove t he he a dl a mp l e v e l ing s e ns or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2189

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp S witch Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he he a dl a mp s wi t ch. 1. Re l e a s e t he r e t ai n in g t a ng. 2. De ta ch t he he a dl a mp s wi t ch. 2. Remove t he he a dl a mp s wi t ch. 1. Dis con nect t he he a dl a mp s wi t ch e l e ct rical co nne[...]

  • Page 2190

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - High Mounted Sto plam p4- Door Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl i ne r, fo r a d di t i ona l i n fo r mat i on , refe r t o S e cti on 501-05 I nt e r i o r Tr im a nd O rname nt a ti o n . 2. Remove t he hi gh mount e d s t op l amp ret a i ni ng s cr ews . [...]

  • Page 2191

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - High Mounted Sto plam pWag o n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s po i l e r For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S p o i l e r - W a g on (501-08 Exte rio r T r i m an d O rname nt a t i o n, Re moval a nd I ns t a l la t i o n). 2. Rem[...]

  • Page 2192

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - R ear Lamp As sembl y4- D o o r Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch a nd r ep o s i t i on t he r e a r qua r t e r t rim pane l . 2. D i s conne ct t he rear l a mp a s s emb l y e le ct r ica l conne cto r . 3. Remove t he rear l a mp a s s emb ly re ta i ni ng nut s . 4[...]

  • Page 2193

    P ubl i s he d: 11-May-2 011 E xterior L i ghting - R ear Lamp As sembl yW agon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce t rim p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L o ads pa ce T r im P a ne l (501-05 I nt e r i o r Tr im a nd O rname nt a ti o n, Re m o val a nd Ins t al l a t i o[...]

  • Page 2194

    P ubl i s he d: 11-May-2 011 Interio r Li ghting - Interior Li ghting Des cr ipt i o n a nd O pe r a t i o n The i nt e r i or l i gh ti ng s yst e m cons i s t s of t he f ol l o wi ng compo ne nt s : On e f r ont int e r i or l a m p. Two map r ea d i ng l amp s. Two f r o nt f o ot we l l l a mps On e rear i nte r i or l a mp. Two f r o nt d o o[...]

  • Page 2195

    P ubl i s he d: 11-May-2 011 Interio r Li ghting - Interior Li ghting Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspect i on C h art Mechani cal El e ct ri ca l Doo r s wi t c h(s) I nt e r i o r la mp s [...]

  • Page 2196

    P ubl i s he d: 11-May-2 011 Interio r Li ghting - Front Interio r Lam p Re moval a n d I ns t a l l a t i on 1. Remove t he ove r he a d co ns o l e . Fo r a ddi t i ona l i nfo r m at i o n, r ef e r t o S ect i o n 501-12 Ins t r ument P a nel a nd Co ns ol e . JagDocs.com[...]

  • Page 2197

    P ubl i s he d: 11-May-2 011 Interio r Li ghting - Rear Interior Lam p Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he i nt e rio r la mp. 2. Remove t he i nt e r i o r l a mp. Dis conne ct t he e l e ct r i cal co nnect o rs. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2198

    P ubl i s he d: 11-May-2 011 Daytime Runni ng Lamps (DRL ) - D aytime Runni ng L amps (DRL ) Des cr ipt i o n a nd O pe r a t i o n DRL us e t he ful l i nte ns i t y l o w bea m he a dl a mps whi ch a re p e r m ane nt l y i l l umina t e d whe n t he ve hi c l e i s b e i ng dr i ven. DRL a re us e d i n a number of market s a nd t h e r e a r e [...]

  • Page 2199

    P ubl i s he d: 11-May-2 011 Daytime Runni ng Lamps (DRL ) - D aytime Runni ng L amps (DRL ) Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspect i on C h art Mechani cal El [...]

  • Page 2200

    P ubl i s he d: 11-May-2 011 Module C o mm un icatio ns N etw ork - C o mmu nic ation s N e tw ork Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um be r D e s cri pti on 1 — Ant i -lo ck br a ke cont r ol mod ul e 2 — In ca r e nt e r t a i nment (I CE) modul e 3 — Dual a ut o mat i c t e mperat ure co nt r ol (DAT C) 4 — J Gat e m[...]

  • Page 2201

    P ubl i s he d: 11-May-2 011 Module C o mm un icatio ns N etw ork - C o mmu nic ation s N e tw orkV IN Range: E 96603->J28492 Dia gn os i s a nd Te s t i ng Principles of Ope ra tion The vehi cl e ha s f our modul e commun i cat io n net wo r ks . O nl y t hr e e o f whi ch are co nne cte d to t he di agn os t i c conne ct o r . The standard cor[...]

  • Page 2202

    REFER t o : Ai r Bag S up pl e ment a l Re s t r ai nt S ys t e m (S RS ) (501-2 0B S u ppl e ment a l Res t r ai nt Sy s t e m, Di a gnos i s a nd Te s t i ng). The voi ce a ct i va t e d cont r ol modul e (VACM) i s c o nne ct e d t o t he D2B communica t i on net wo r k. T hi s a l l o ws t he us er t o s e l e ct f unct i o ns b y gi ving a voi[...]

  • Page 2203

    fo r one e rr or , o r, a s i n t he ca s e of a n o p en ci r cuit , no DTC be i ng s e t . DT C Desc ri pti on Possi bl e S ource Ac ti on P 1573 CAN t hr ot tl e a ngl e e rr or TP s ens or fa ul t (a d di t io nal DTCs lo g ged ) ECM CA N me s s a ge e r r or For TP s e n so r circ ui t t e s t s, REFER t o : El e ct roni c Engi ne Co nt rol s [...]

  • Page 2204

    DT C Desc ri pti on Possi bl e S ource Ac ti on P 1699 CAN ECM t o EATCM ne t w ork m a l funct i on Modul e po we r s up pl y o r gr ound i nt err upt i o n CAN op en ci r cuit f a ul t ; EATCM t o ECM CAN s hort ci rc uit fa ul t ; EATCM t o ECM EATCM f a il ur e ECM f a i lur e Re f e r t o po we r a nd g r ound t e st f or s us p e ct modul e .[...]

  • Page 2205

    DT C Desc ri pti on Possi bl e S ource Ac ti on U2196 I ns t r ument cl us t er CAN e ngi ne s p e e d mes sa g e i nval i d Verif y i nt e gr it y o f e ngi ne m a nage m e nt s yst e m CAN ne t wo r k fa ul t For i ns t r um e nt cl us t e r CAN ne t wor k t e st s , GO t o P i npoi nt T e s t D. U2197 I ns t r ument cl us t er CAN e ngi ne s p e[...]

  • Page 2206

    DT C Desc ri pti on Possi bl e S ource Ac ti on sup pl y fa ul t Modul e ig ni t io n s wi t che d sup pl y fa ul t U2614 Ampl i f i e r not r es pond i ng on D2B net wo r k D2 B ne t wo rk 'wake-up' c i r cuit ; s hort ci r cuit t o B+, sho rt ci r cuit t o gr ou nd D2 B ne t wo rk fa ul t For D2B 'wa ke-up' ci rc ui t t e s t [...]

  • Page 2207

    1 2 Descri pti o n Possi bl e s ource Acti on fa i lu r e TCM s up pl y o r gr ound f a ul t (16 b it ) B+ s upp l y f a i l ure Ig n + s uppl y f a i lur e GR O UND f ai l ure For 16 b it TCM ci r cuit t es t s , GO t o P i npo i nt T e s t AD. TCM s up pl y o r gr ound f a ul t (32 b it ) B+ s upp l y f a i l ure Ig n + s uppl y f a i lur e GR O [...]

  • Page 2208

    1 2 1 2 1 1 2 1 1 2 1 1 2 1 1 2 Is t he res i s t a nce b e t we e n 50 a nd 70 ohms ? Ye s GO t o A 3 . No GO t o A 2 . A2 : CHEC K T HE C AN N ET W O R K FOR SHOR T CIRC UIT Tur n t he i gni t i o n s wi t ch to the O F F p os i t i on. Mea s ure t he r es i s t a nce b e t we en pi ns 06 (Y ) a nd 14 (G) of t he di a gno s t i c conne ct or . Is[...]

  • Page 2209

    1 1 1 1 1 1 1 1 Is t he res i s t a nce g r ea t e r t ha n 5 o hms ? Ye s REP AIR t he hi gh r e s is t a nce ci rc ui t . Fo r a ddi t i o na l i nf o r m at i o n, r ef e r t o t he wi r i ng di a gr a ms. Cle a r a ny DTCs , t e s t th e s yst e m f o r norm al op erat i o n. No GO t o A 12 . A1 2: CHEC K T HE CAN - CIRC U IT BET W EEN T HE D I[...]

  • Page 2210

    1 1 1 1 1 2 1 GO t o C5 . C 5: C HEC K CAN - FOR SHOR T C IRC UIT T O BAT T ER Y Mea s ur e t he res i s t a nce b et we e n t he di a g nos t i c co nnect or, pi n 14 (G ) a nd pi n 16 (O Y ). I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring[...]

  • Page 2211

    1 1 1 1 1 2 1 1 1 Mea s ur e t he res i s t a nce b et we e n: Ve hi cl e s wi th 2.5 a nd 3. 0L e ngi ne - EN16, pi n 123 (G) a nd IP 10, p in 18 (G). Ve hi cl e s wi th 2.0L p e t rol eng i ne - EN65, pi n 88 (G) a nd I P10, pi n 18 (G ). Ve hi cl e s wi th 2.0L d i e s e l e ngi ne - DL01, pi n 73 (G) a nd I P10, pi n 18 (G ). I s t he r es i s [...]

  • Page 2212

    1 2 1 2 1 1 2 1 1 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n. No GO t o D6 . D6: C HECK F O R SH OR T CI RC U IT BET W EE N CAN + A ND CAN - Dis c[...]

  • Page 2213

    1 1 1 1 1 1 1 1 1 Mea s ure t he r es i s t ance b e t w ee n: Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - pi ns 123 a nd 124 o f t he ECM. Vehi cl e s wi t h 2. 0L pet r ol e ng i ne - pi ns 88 a nd 89 o f t he ECM. Vehi cl e s wi t h 2. 0L di e s e l e ng in e - pi ns 54 a nd 73 o f t he ECM. Is t he res i st a nce b et we e n 110 a nd 140 o hms[...]

  • Page 2214

    1 1 2 1 1 1 Meas ur e t he r es i s t a nce be t we e n I P 22 p in 06 (Y ) a nd EN65, p in 89 (Y ). Vehi cl e s wi t h 2. 0L di e s e l e ng in e - Dis c on ne ct t he ECM conne ct o r , DL01. Meas ur e t he r es i s t a nce be t we e n t he d ia g no st i c conne ct o r , p i n 06 (Y ) and DL01, p in 54 (Y ). Is t he res i st a nce g r ea t e r t[...]

  • Page 2215

    1 1 1 1 2 1 1 1 2 1 2 Vehi cl e s wi t h 2. 0L pet r ol e ng i ne - pi ns 88 a nd 89 o f t he ECM. Vehi cl e s wi t h 2. 0L di e s e l e ng in e - pi ns 54 a nd 73 o f t he ECM. Is t he res i st a nce b et we e n 110 a nd 140 o hms ? Ye s GO t o E13 . No P le a se c he ck pa r t i s no t o n a n y f o rm o f p r i or a ut ho r i s a t i o n b e f o[...]

  • Page 2216

    1 1 2 1 1 1 1 GO t o F8 . F8: C HEC K FOR O PE N C IR C UIT ON CAN - BET W EEN T HE DI AGNOST I C C O NN EC T O R AN D T HE EAT C M ODU LE Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 14 (G) a nd IP 101, pi n 23 (G). Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a n[...]

  • Page 2217

    1 1 2 1 1 1 1 2 1 2 1 1 2 CLEAR t he DT C, t e st t he s ys t e m fo r n or mal o pe r a ti o n. PINPOIN T TE ST G : P17 9 9: CAN NET WORK MALF UNCTI ON, ANTI- LOCK B RAK E (A BS ) /DYNAMI C STA B ILITY CONTROL (DS C) CONTROL MODU LE T EST C O NDI T IONS DET AI LS/RE SULT S /ACT IONS G1: CHEC K T HE AB S OR DSC MO DULE F OR DAMA GE Ins p e ct t he [...]

  • Page 2218

    1 1 1 1 1 1 To t es t : Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - Dis conne ct t he ECM conne ct o r , EN16, a nd t he I C conne ct or , I P 10. Meas ure t he r es is t a nce b e t we e n EN16, p i n 124 (Y ) a nd I P 10, pi n 17 (Y ). Vehi cl e s wi t h 2. 0L pet r ol e ng i ne - Dis conne ct t he ECM conne ct o r , EN65, a nd t he I C conne ct[...]

  • Page 2219

    1 1 1 1 1 2 3 4 1 1 2 3 1 2 3 1 2 1 2 GO t o H3 . H3 : CHEC K T HE SCP + FOR SH OR T C IRC U I T T O BA T T ER Y Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi ns 02 (Y ) a n d 16 ( O Y ). Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t[...]

  • Page 2220

    1 1 1 1 1 1 1 1 2 3 4 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on. No GO t o H13 . H1 3: CHEC K FOR LO SS O F S CP + T ER M I N AT ION[...]

  • Page 2221

    1 2 3 1 2 3 4 1 2 1 2 1 1 2 3 4 5 6 1 Re conne ct t he I CE conne ct o r , I P 65. Re conne ct t he b a t t e r y ne g a t i ve te r mina l . Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 02 (Y ) a nd GROU ND. Is t he res i st a nce 150 t o 210 ohms ? Ye s INS TA LL a ne w ICE he a d uni t . REFER t o : A udi[...]

  • Page 2222

    1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 1 1 2 3 4 5 6 K1: C HECK T HE ' WAKE-UP ' SI GNA L T O T HE CD CHAN GER Di s c onn e ct t he CD cha nge r connect or, CA301. Turn t he i gn it i o n s wi tch t o t he AC C po s i t i o n. Mea s ur e t he vol t a ge be t we e n CA301, pi n 03 (O ) a nd GRO U ND, us i ng a n os ci ll o s cop e (s e [...]

  • Page 2223

    1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 2 3 4 5 6 I s U 2019 se t ? Ye s CHECK t he 'wake-up' s i gna l t o t h e modul e . No GO t o M2 . M2: C HEC K F O R DT C U260 2 O R U 2 603 Che ck DTCs . Ar e c od e s U 2602 o r U 2603 l o gg ed? Ye s CHECK f o r br e a k in opt i ca l harnes s . No RECHECK DT Cs. N o br e a k in opt i cal ha [...]

  • Page 2224

    [...]

  • Page 2225

    1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 1 2 1 2 Q1: C HEC K F IBRE OP T I C LEA D BET WE EN LUGGAGE CO M P ART MENT JOIN T AND AMPLIFI ER Dis c on ne ct t he f i b r e o pt i c conne c t o r , CD06. Dis c on ne ct t he f i b r e o pt i c conne c t o r , CD07. Conne ct t he O p t i ca l B us Tes t er t o CD07. S e t t he Op t ical B us Te s t e [...]

  • Page 2226

    1 2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 No CHECK t he m o dul e f or GROU ND. IN S TAL L a ne w 'phone m o dul e . REFER t o: M odul e - 4-D oo r (419-0 8 Ce l l ul ar Ph one , Remova l a nd I ns t a l l a t io n). CLEA R t he DTC, te s t t he sys t e m fo r nor mal o pe r at i o n. GO t o R4 . R 4: CHEC K T HE PER MANEN T SUPPLY T O T HE NA V[...]

  • Page 2227

    1 2 1 2 1 2 1 1 2 3 1 2 3 1 2 1 2 3 Is t he vol t a ge l e s s t han 10 vol t s ? Ye s REPAI R t he ci r c ui t bet we e n t he 'pho ne mod ul e co nnect o r, P H01, pi n 29 a n d t he c e nt r a l j unct i o n fus e bo x, fus e 78. For a ddi t i o nal i nfo r m at i o n, r e f e r t o t he wi r i ng di a g r a ms . CL EAR t he DTC, t e s t t [...]

  • Page 2228

    1 2 3 1 1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 I s t he v ol t a ge l e ss t ha n 4 vol t s ? Ye s GO t o W 2 . No GO t o W 3 . W2: C H ECK T HE MO DULE SUPPLY CIRC UIT T O T HE YAW R AT E S ENS O R FOR HI GH R ESI ST ANCE Tur n t he i gn it i o n s wi t ch t o t he O FF po s i t i o n. Di s conn ect t he DS C modul e conne c t o r , JB185. Mea s ur e t he [...]

  • Page 2229

    1 2 1 2 1 1 2 3 1 1 2 3 1 1 2 I s t he v ol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n JB185, p i n 02 a nd ba t t e r y. T hi s circu i t i ncl ud e s t he front powe r di s t r i but i o n bo x, fus e 41. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o th e wi r i ng di a gr a m s . No GO t o Y 3 . Y3: CHEC K[...]

  • Page 2230

    1 2 1 2 1 1 2 1 1 2 1 2 1 1 1 2 Turn t he i gni t i o n s wi t ch t o t he O N pos i t i o n. Mea s ur e t he vol t a ge be t we e n I P 101, p in 02 (W R) a nd GRO U ND. I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s REP AI R t he cir cuit be t wee n IP 101, pi n 02 a nd ba t t e r y. Th is ci r cuit i nclude s t he p r i mar y j unct i o n b[...]

  • Page 2231

    1 2 1 2 1 2 1 1 2 1 2 1 2 1 2 1 I s t he vol t age le s s t ha n 10 v ol t s ? Ye s REPAI R t he ci r cui t b e t we en JB131, pi n 06 and bat t e ry . Thi s ci r cui t i ncl ude s t he f r on t po we r di s t rib uti o n b o x , f us e 32. For a dd i t i o na l i nf o r mat i o n, refe r t o t he wi ring di agrams . No GO t o A D2 . AD2 : CHEC K T[...]

  • Page 2232

    1 2 3 1 2 1 2 1 1 2 3 1 2 1 2 1 1 2 3 PINPOIN T TE ST A F : ECM S U PPLY OR G ROU ND F A U LT (V EHIC LES WITH 2 . 0 L PETROL ENG I NE) T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I ONS AF1 : CHEC K T HE B+ SUPP LY T O T HE ECM Turn t he i gn it i o n s wi tch t o t he O FF po s it i o n. Di s c onn e ct t he ECM con nect or , EN65. Mea s ur e t[...]

  • Page 2233

    1 2 1 2 1 1 1 1 1 2 3 1 2 1 2 I s t he vol t age le s s t ha n 10 v ol t s ? Ye s REPAI R t he ci r cui t b e t we en DL 01, pi n 03 a nd ba t t e r y. Th is ci rc ui t i ncl ude s t he front po we r di s t r ib ut io n bo x, fus e 21, and t he EMS cont r ol r el ay. Fo r a ddi t i on a l i nf o r m at i o n, r ef e r t o t h e wi r i ng di a gr a [...]

  • Page 2234

    1 2 3 1 1 2 3 1 2 1 2 1 2 3 1 2 1 2 1 AJ1: CHEC K T HE B+ SUPPLY T O T HE C D CHAN GER Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Di s conne ct t he CD cha nge r connect o r, CA301. Mea s ur e t he vol t age bet we e n CA301, pi n 02 (O Y ) a nd GROU ND. I s t he v ol t a ge l es s t ha n 10 vol t s ? Ye s REP AIR t he ci r cu[...]

  • Page 2235

    2 3 4 1 2 1 2 3 4 1 2 1 2 1 1 1 Di s conn ect t he pa r k a i d modul e co nne ct or, CA 418. Tur n t he i gni t i o n s wi t ch t o th e O N po s i t i o n. Mea s ur e t he vol t a ge bet we e n CA418, p i n 01 (N ) a nd GROU ND. I s t he v ol t a ge l es s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n CA418, p i n 01 a nd b a t t e[...]

  • Page 2236

    1 2 3 4 1 1 1 1 2 1 1 1 1 2 3 AP4: CHEC K FOR O PE N C IR C UIT O N K- LI N E BET WEE N DI A GNOST I C C O NNECT O R A ND RC M Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Di s conn ect t he ba tt e r y ne ga t i v e t e rm ina l . Di s conn ect t he RCM con nect or , IP 74. Mea s ur e t he res i s t a nce be t we e n di a gno s[...]

  • Page 2237

    4 1 1 1 1 2 3 4 1 1 1 Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 07 (W ) a nd : Vehi cl e s wi t h l ow-l i ne cons o l e - RC23, pi n 08 (W ). Vehi cl e s wi t h hi gh-l i ne cons o l e - RC33, pi n 03 (W ). Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci [...]

  • Page 2238

    1 2 1 1 1 1 2 3 4 1 2 3 4 1 2 3 Tur n t he i gn i t i on s w i t ch t o t he O FF pos it i o n. Dis conne ct t he b a t t e r y ne gat i ve t e r m i na l . Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - Dis c on ne ct t he ECM conne ct o r , EN16. Meas ur e t he r es i s t a nce be t we e n t he d ia g no st i c conne ct o r , p i n 07 (W ) a nd E N[...]

  • Page 2239

    P ubl i s he d: 11-May-2 011 Module C o mm un icatio ns N etw ork - C o mmu nic ation s N e tw orkV IN Range: J2 8493-> V99999 Dia gn os i s a nd Te s t i ng Principles of Ope ra tion The vehi cl e ha s f our modul e commun i cat io n net wo r ks . O nl y t hr e e o f whi ch are co nne cte d to t he di agn os t i c conne ct o r . The standard co[...]

  • Page 2240

    REFER t o : Ai r Bag S up pl e ment a l Re s t r ai nt S ys t e m (S RS ) (501-2 0B S u ppl e ment a l Res t r ai nt Sy s t e m, Di a gnos i s a nd Te s t i ng). The voi ce a ct i va t e d cont r ol modul e (VACM) i s c o nne ct e d t o t he D2B communica t i on net wo r k. T hi s a l l o ws t he us er t o s e l e ct f unct i o ns b y gi ving a voi[...]

  • Page 2241

    DT C Desc ri pti on Possi bl e S ource Ac ti on CAN s hort ci rc uit fa ul t JG M fa i l ur e ECM f a i lur e P 1573 CAN t hr ot tl e a ngl e e rr or TP s ens or fa ul t (a d di t io nal DTCs lo g ged ) ECM CA N me s s a ge e r r or For TP s e n so r circ ui t t e s t s, REFER t o : El e ct roni c Engi ne Co nt rol s - 2.5L NA V6 - AJV 6/3.0L N A V[...]

  • Page 2242

    DT C Desc ri pti on Possi bl e S ource Ac ti on P 1656 TP s e ns or a mpl i f i e r ci r cuit m a l f unct i on ECM f a i lur e P l e as e che ck part is not o n a ny f o r m o f pr i or a ut horiz a t i o n be fo re r e pl a ceme nt . P 1699 CAN ECM t o EATCM ne t w ork m a l funct i on Modul e po we r s up pl y o r gr ound i nt err upt i o n CAN [...]

  • Page 2243

    DT C Desc ri pti on Possi bl e S ource Ac ti on U2019 VACM not res po nd i ng o n D2B ne t wo r k D2 B ne t wo rk 'wake-up' c i r cuit ; s hort ci r cuit t o B+, sho rt ci r cuit t o gr ou nd D2 B ne t wo rk fa ul t For D2B 'wa ke-up' ci rc ui t t e s t s, GO t o P i npo i nt T e s t K. Fo r VACM D2B net wo r k t e s t s , GO to[...]

  • Page 2244

    DT C Desc ri pti on Possi bl e S ource Ac ti on U2613 Na vig a t i on cont r o l m o dul e not re s po ndi ng on D2B net wo r k D2 B ne t wo rk 'wake-up' c i r cuit ; s hort ci r cuit t o B+, sho rt ci r cuit t o gr ou nd D2 B ne t wo rk fa ul t Modul e pe r m an e nt s upply fa ul t Modul e a c ce s s o ry s wi t ched sup pl y fa ul t Mo[...]

  • Page 2245

    Descri pti o n Possi bl e s ource Acti on Memory s ea t mod ul e s uppl y o r ground fa ul t B+ 1 s uppl y f a i l ur e B+ 2 s uppl y f a i l ur e Ig n + s uppl y f a i lur e El e ctroni c GR O UND fa i lu r e P owe r GR O UND fa i lu r e S ig na l GR O UND fa i lu r e For memor y s e a t modul e c i r cuit t e s t s , GO t o P i npo i nt T e s t A[...]

  • Page 2246

    1 2 1 2 1 2 1 1 2 1 1 2 1 1 2 1 • NO T E: T he f o l l o wi ng t e s t i s bas e d on t he maxi m um num be r o f modul e s i n t he net wo r k. Re fe r t o t he wi ring di agra m s f or i nfo r mat i on o n ne t wo r ks wi t h f e wer modul e s . T EST C ONDI T IONS DET AI L S/R ESULT S/ACT IONS A1 : CHEC K T HE R ESI S T AN C E O F T HE C AN NE[...]

  • Page 2247

    1 2 1 1 1 1 1 1 1 Is t he res i s t a nce g r ea t e r t ha n 5 o hms ? Ye s REP AIR t he hi gh r e s is t a nce ci rc ui t . Fo r a ddi t i o na l i nf o r m at i o n, r ef e r t o t he wi r i ng di a gr a ms. Cle a r a ny DTCs , t e s t th e s yst e m f o r norm al op erat i o n. No GO t o A 11 . A1 1: CHEC K T HE CAN + CI RC U I T BET WEEN T HE [...]

  • Page 2248

    1 1 1 1 1 1 2 1 I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams. CLEAR t he DTC, t e s t t he s y s t e m f or no r ma l op e r at i o n. No GO t o C4 . C 4: C HEC K CAN - FOR SHOR T C IRC UIT T O GR O UND Mea s ur e t he res i s [...]

  • Page 2249

    1 1 1 1 1 2 1 1 Di s conne ct t he ECM co nnect o r, DL01, a n d t he IC conne ct o r , I P 10. Mea s ur e t he res i s t a nce be t we e n DL01, pi n 54 (Y ) and I P 10, pi n 17 (Y ). I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he CAN + ci r cui t . For ad di t i o na l i nfo rm at i on, refe r t o t he wi ring d i a grams. C[...]

  • Page 2250

    1 1 2 1 2 1 1 2 1 1 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n. No GO t o D5 . D5: C HECK CAN - FOR S HO R T CIRC UIT T O BAT T ER Y Mea s ure t h[...]

  • Page 2251

    1 1 1 1 1 1 1 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on. No GO t o D12 . D12 : CHEC K FOR LO SS OF T ER MI N AT I ON WI T HI N T HE [...]

  • Page 2252

    1 1 1 2 1 1 Dis conne ct t he b a t t e r y ne gat i ve t e r m i na l . Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - Dis c on ne ct t he ECM conne ct o r , EN16. Meas ur e t he r es i s t a nce be t we e n I P 22 p in 06 (Y ) a nd EN16, p in 124 (Y ) . Vehi cl e s wi t h 2. 0L pet r ol e ng i ne - Dis c on ne ct t he ECM conne ct o r , EN65. Meas [...]

  • Page 2253

    1 1 1 1 1 2 1 1 1 2 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on. No GO t o E12 . E12: CHEC K FOR LOSS OF T E R MI NA T ION WI T HI N T H[...]

  • Page 2254

    1 2 1 1 2 1 1 1 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n. No GO t o F7 . F7: C HEC K FOR O PE N C IR C UIT ON CAN + BET WE EN T HE D IA GNOST IC[...]

  • Page 2255

    1 1 1 2 1 1 1 1 2 1 2 1 pi ns 54 a nd 73 o f t he ECM. Is t he res i st a nce b et we e n 110 a nd 140 o hms ? Ye s GO t o F13 . No P le a se c he ck pa r t i s no t o n a n y f o rm o f p r i or a ut ho r i za t i o n b e f ore repl a cemen t . F13 : CHEC K FOR LO SS OF T ER M I N AT ION W IT HI N T HE I C Mea s ure t he r es i s t ance b e t w ee[...]

  • Page 2256

    1 2 1 1 1 1 Is t he res i s t a nce g r ea t e r t han 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc ui t . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o t h e wi r i ng d i a gr ams . CL EAR t he DTC, t e s t t he s yst e m f o r norm al ope rat i on. No GO t o G9 . G9: CHEC K FOR CO R R EC T BUS T ER MIN AT ION Re conne ct t [...]

  • Page 2257

    1 1 1 1 1 1 1 2 3 4 1 1 2 3 1 2 3 T EST C O NDI T IONS DET AI LS/RE SULT S/ACT IONS H1 : CHEC K GEM F OR DAMA GE Ins p e ct t he GEM f o r da mage . Does t he GEM i ndi ca t e any s i gns of da mage ? Ye s INS TA LL a ne w GE M. REFER t o : Ge ne r ic El e c t r o ni c Modul e (GEM) (419-10 Mu l t i funct i on El e ct roni c Mod ul e s, Re moval a [...]

  • Page 2258

    1 2 1 2 1 1 1 1 1 1 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on. No GO t o H11 . H1 1: CHEC K FOR LO SS O F S CP + T ER M I N AT ION W[...]

  • Page 2259

    1 2 3 4 1 1 2 3 1 2 3 4 1 2 1 2 1 1 2 3 4 5 Tur n t he i gn i t i on s w i t ch t o t he O FF pos it i o n. Dis conne ct t he b a t t e r y ne gat i ve t e r m i na l . Dis conne ct t he I CE conne ct or, IP 65. Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 02 (Y ) a nd IP 65, pi n 09 (Y ). Is t he res i st a[...]

  • Page 2260

    6 1 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 Che ck f o r 'not r e s po ndi ng' DTCs . Is U 2003 s e t ? Ye s CHECK t he 'wake-up' si gna l t o t he modul e . No GO t o J2 . J2: CHEC K F OR DT C U2 602 OR U26 03 Che ck DTCs . Ar e c od e s U 2602 o r U 2603 l o g ged ? Ye s CHECK f or brea k i n op t ica l h a r nes s . No Re c[...]

  • Page 2261

    1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 1 2 3 4 5 L2: CHEC K FOR DT C U260 2 O R U2603 Che ck DTCs . Ar e c od e s U 2602 o r U 2603 l o gg ed? Ye s CHECK f o r br e a k in opt i ca l harnes s . No RECHECK DT Cs. N o br e a k in opt i cal ha r n e ss . PINPOIN T TE ST M : U20 1 9: V OI CE CONTROL MODU LE NOT RES PONDING T EST C ONDI T I O NS DE[...]

  • Page 2262

    6 1 2 3 4 5 6 1 2 3 4 5 1 2 3 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 6 1 2 Check f or l i ght p ul s e s a t the r ecei ver pi n o f d is conne ct e d D2B co nnect o r , CD02. Are l i ght pul s e s v i s ib l e ? Ye s GO t o P 2 . No INS TA LL a ne w t e l e mat ic ha r nes s be t we e n CD06 a nd CD02. Fo r add i t i ona l i nf o r m a t i o n, re f er t[...]

  • Page 2263

    3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 1 2 Conne ct t he O p t i ca l B us Tes t er t o CD05. S e t t he Op t ical B us Te s t e r t o T X . S e t t he Op t ical B us Te s t e r t o O N . Check f or l i ght p ul s e s a t the t rans m i t t e r pi n o f di s conne cte d D2B conne c t o r , CD07. Are l i ght pul s e s v i s ib l e ? Ye [...]

  • Page 2264

    1 2 1 2 1 2 3 1 2 3 1 2 3 1 2 3 I s t he v ol t a ge l es s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n t he voi ce a cti vat e d cont r ol modu le conne ct o r , P H02, pi n 22, a n d f us e 71 of t he ce nt ral j unct i o n f us e box. For add i ti ona l i nf o r m a t i o n, ref er t o t h e wi r i ng di a gr ams . CL EAR t he D[...]

  • Page 2265

    1 2 3 1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 3 1 2 T 1: CHEC K T HE I G NI T ION SWI T C HED SUPP LY T O T HE VO I CE AC T I VA T ED C ONT R O L MO DULE Dis conne ct t he vo ice a ct i va t e d cont rol mo dul e conne ct o r, PH02. Tur n t he i gn i t i on s w i t ch t o t he O N po s i t i o n. Mea s ure t he v ol t a ge be t wee n PH02, p i n 06 (W R) a n[...]

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    1 2 3 1 2 3 1 1 2 3 1 2 1 2 1 2 1 1 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . No No fa ul t f o und wi t h p o we r or ground sup pl i e s . Che ck fo r DTCs i ndi c a t i ng a mod ul e f a ul t . PINPOIN T T[...]

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    2 3 1 2 1 2 1 2 1 1 2 3 1 1 2 3 1 Tur n t he i gni t i o n s wi t ch t o th e O N po s i t i o n. Mea s ur e t he vol t a ge bet we e n JB185, p i n 23 (GW ) a nd GRO UN D. I s t he v ol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n JB45, pi n 23 a nd ba t t e r y. T hi s c i r cuit i nclude s t he front powe r di s t r[...]

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    1 2 1 2 1 2 1 1 2 1 1 2 1 2 1 1 T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I ONS AB1 : CHEC K T HE B+ SUPPLY T O T HE EA T C MODULE Di s c onn e ct t he EA TC mod ul e conne ct o r , I P 101. Mea s ur e t he vol t a ge be t we e n I P 101, p in 14 (O G) a nd GROU ND. I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s REP AI R t he cir cuit be [...]

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    1 2 1 2 1 2 1 2 1 1 2 1 2 1 2 1 2 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . No No fa ul t f o und wi t h p o we r o r ground s uppl i e s . Che ck fo r DTCs i ndi c a t ing a mod ul e f a ul t . PINPOIN T TE [...]

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    1 1 2 3 1 2 1 2 1 1 2 3 1 2 1 2 1 I s t he res i s t a nce grea t e r t ha n 5 o hms ? Ye s REPAI R t he hi gh res i s t a nce ci r cuit . For ad di t io na l inf or mat io n, r e fe r t o t h e wi ring di a grams . No GO t o A E5 . AE5: CHEC K T HE GR O UND 2 T O T HE T CM Meas ur e t he r es i s t a nce be t we e n JB231, p i n 38 (B ) a nd GROU [...]

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    1 2 3 1 2 1 2 1 1 1 1 1 2 3 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh res i s t a nc e ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . No No fa ul t f o und wi t h p o we r o r ground su ppl i e s . Che ck fo r DTCs i ndi c a t i ng a mod ul e f a ul t . PINPOIN T TE ST [...]

  • Page 2272

    1 2 1 2 3 1 1 2 3 1 2 1 2 1 2 3 1 2 GO t o A I 3 . AI 3: C HEC K T HE G R O UND T O T HE I C E Tur n t he i gni t i o n s wi t ch to the O F F p os i t i on. Mea s ure t he r es i s t a nce b e t we en IP 65, pi n 01 (B) and GRO UN D. Is t he res i s t a nce g r ea t e r t ha n 5 o hms ? Ye s REP AIR t he hi gh r e s is t a nce ci rc ui t . Fo r a [...]

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    1 2 1 2 3 4 1 2 1 2 3 4 1 2 1 2 1 1 Tur n t he i gni t i o n s wi t ch t o th e O FF pos i t i on. Mea s ur e t he r es i s t a nce be t we en JB232, p in 02 (B) a nd GROU ND. Is t he res i s t a nce g r ea t er t h a n 5 o hms ? Ye s REP AIR t he hi gh r e s i s t ance ci rc ui t . Fo r a d di t i o na l i nf o r mat i o n, refe r to t he wi r i n[...]

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    1 1 2 3 4 1 1 1 1 2 1 1 I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t ci r cuit . For a ddi t i o na l i nfo rm at i on, ref e r t o t he wiring di a g rams. CL EAR t h e DTC, t e s t t he s yst e m fo r no r m a l op e r at i o n. No GO t o A P3 . AP3: CHEC K K-LIN E F OR SH O R T CIRC U IT T O BAT T E R Y Mea s [...]

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    1 1 2 3 4 1 1 1 1 2 3 4 1 1 GO t o A R3 . AR3: CHEC K K -LINE FOR S HOR T CIRC U IT T O BAT T E R Y Mea s ure t he r es i s t ance b e t w ee n di a gnos t i c conne ct or, pi n 07 (W ) a nd pi n 16 (O Y ). Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t[...]

  • Page 2276

    1 1 2 1 1 1 1 2 3 4 1 2 3 4 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n. No GO t o A T3 . AT 3: C HECK K - LIN E FOR S HO R T CIRC UIT T O BAT T ER[...]

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    1 1 1 1 1 2 3 4 Is t he res i st a nce b et we e n 50 a nd 70 o hms ? Ye s P le a se c he ck pa r t i s no t o n a n y f o rm o f p r i or a ut ho r i za t i o n b e f ore repl a cemen t . No GO t o A W 10 . AW10 : C HEC K C ONT IN UI T Y OF T HE CAN + C I R C UI T To t es t : Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - Dis c on ne ct t he ECM con[...]

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    1 2 No GO t o A X2 . AX2 : CHEC K T HE GR O UND T O T HE JGM Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Mea s ur e t he res i s t a nce be t we e n I P14, pi n 2 (B) a nd GRO UN D. I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci rcu i t . Fo r ad di t io nal i nf or ma t i on, r [...]

  • Page 2280

    P ubl i s he d: 11-May-2 011 Module C o nfi guratio n - Mo dule C onfi guration Dia gn os i s a nd Te s t i ng Principles of Ope ra tion • NO T E: Ne wl y r el e a s e d modul e s wi l l requi r e co nfi gur a t i on a ft er be i ng i ns t a l le d o n t he vehi cl e . A l l conf i gur ab l e modul e s wi l l be pa ckage d i n a kit whi ch cont a[...]

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    P ubl i s he d: 11-May-2 011 Module C o nfi guratio n - Mo dule C onfi guration Gene ral P r ocedures 1. The compl exi t y of t he e l e ct roni cs in vol ve d wi t h mo dul e conf i gur a t i o n, o f whi ch t he GEM and i ns trum e nt cl us t e r are a pa rt, a nd t he mul t i pl e xed comm unica t i o n ne two rk whi ch a r e conne ct e d t o t [...]

  • Page 2282

    P ubl i s he d: 11-May-2 011 Wiring Harnesse s - Wiring Harn ess Des cr ipt i o n a nd O pe r a t i o n Introd uction CAU TIO N : Do not us e a ny o t her he a t s hrink s l ee ve o t her t ha n t he a pproved gl ue l i ned hea t s hr i nk s l e e ve me nt i o ne d i n t he repa i r pr oce dure. The pur po s e o f t hi s document is t o pr o m o te[...]

  • Page 2283

    The i l l us t rat i o n s hows : The pr e -te r mina t e d wi ring ha r ne s s (s) whi ch a re in clud e d i n t he wi ring ha r nes s repa i r ki t The pa r t number o f t he pre-t e r m i n at e d wi r i ng harnes s The l e t te r s howi ng t he e xtract o r t i p whi ch mus t be us e d t o remove t hi s t ype o f e l e ct rica l conne ct o r t [...]

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    The P r e-T erm i nat e d W i r i ng Ha r ne s s (s ) i l lus t rat i on sh ows t he e l e ct r i cal conne cto r t er m i na l t y pe , t he p a r t numbe r o f t he p r e-t erm i nat e d wi r i ng ha r nes s a nd t he l e t t e r of t he e xt r act o r t i p whi ch must be us e d t o e xt r a ct t he e l ect r i cal co nnect o r t e r m i n al f [...]

  • Page 2285

    By pr e s s i ng t he ou te r e d ge s o f the wi r i ng ha r ne s s cabl e le ngt h s t o p t o ge t he r th e a dj us t e r ca n b e s l id up or down t he j aw. Thi s d e cr e as e s o r in cr e a s e s t he l e ngt h b y whi ch t he wi ring ha r nes s ca bl e i ns ul a t io n wi l l b e s t r i ppe d f r om t he p r e-t e r mina t e d wi ring h[...]

  • Page 2286

    The cr i mpin g p li e r s ha ve a mov i ng j a w a nd a s t at i o na r y j a w, wi t h t hr ee di ff e r e nt s i z e d cr i mping e ncl o s ures . Ea ch o f t he e nclo s ur e s i s id e nt i fi e d by a red , bl ue o r yel l ow c ol oured d ot which cor r es po nds t o t he t hr e e co l o ur s o f th e pre-t erm i nat e d wi r ing harnes s (s [...]

  • Page 2287

    CAU TIO N : Se vera l di f fe re nt t y pe s and si ze s of ter m i nal m ay b e found i n a s i ngl e e l e ct ri cal con nector hous i ng. I t is ne ces s a r y t o i de nt i f y: The conduct o r (wire) si z e o f t he a f fe cte d w i r i ng ha r nes s The e l e ct rica l c on ne cto r r ang e f r om whi ch t he d amage d w i r i ng ha r nes s i[...]

  • Page 2288

    JagDocs.com[...]

  • Page 2289

    JagDocs.com[...]

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    • NO T E: T he chart s hows t he e l e ct r i cal co nnect o r t ypes , t erm i nal p ins /s o cket s , e xtr a ct o r t i p a nd ant i -ba ckout t i p. El e c tri cal con nector termi na l t ype P i n or soc k et E xtr actor t i p Ant i -ba ck out t i p Muli tl o ck 040 s e rie s D A Muli tl o ck 040 s e rie s B A Muli tl o ck 070 s e rie s B B [...]

  • Page 2291

    CAU TIO N : : A numb e r of e l e ct r i cal conne c t o r t e rm ina l s a r e go l d pl a t e d or go l d fl a she d . W he n d e fe ct i ve , t he y mus t be i ns t a l l e d wit h a gol d pr e-t e rm in a t e d wi ring ha rn es s (s) f r om t he wiring ha r ne s s r e pa i r ki t. I t i s no t a l w ays e a s y t o i de n ti fy t he f e mal e a[...]

  • Page 2292

    S pi ce Co r r ect l y Loca t e d JagDocs.com[...]

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    P ubl i s he d: 11-May-2 011 Wiring Harnesse s - Wiring Harn ess Repair Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t o: W i ring Ha rnes s (418-02 W i ring Ha r nes s e s , Des cr ipt i o n a nd O pe rat i o n). JagDocs.com[...]

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    P ATS s yst e m whe n t he i gni t i on is s wi tche d t o p os i t i o n II . W he n t h e i gni t i o n i s swi t c he d in t he of f po s i ti o n, t he LED wi l l f l a s h e very f our s e cond s whe n t he s ecur i t y s ys t e m i s i n t he p re-ar m or a r m ed s t a te . The s e c urit y L ED wi l l i l l umin at e f o r t hree s e co nds[...]

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    P ubl i s he d: 11-May-2 011 A nti-Th eft - Activ e - A nti- Th eft - Ac tive Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspect i on C h art Mechani cal El e ct ri cal Doo[...]

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    P ubl i s he d: 11-May-2 011 A nti-Th eft - Activ e - A nti- Th eft Alarm Ho rn Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l e ft -hand f r ont fe nde r sp l as h shi el d. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fe nde r S pla s h Shie l d (501- 02 Fr ont End B o dy P a nel s , Re mova l a nd I ns t al l a t i o[...]

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    P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Anti- T heft - Pass ive Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um be r Des cri pti o n 1 — P AT S t r a ns cei ver modul e The pa s s i ve ant i t he f t sys t e m (PAT S ) i s a f ea t ur e t o prevent t he vehi cl e f r o m bei ng dr i v e n aw ay by a n unaut horiz e d p e [...]

  • Page 2299

    P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Anti- T heft - Pass ive Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspect i on C h art Mech a ni c al El e ctri cal [...]

  • Page 2300

    P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Anti- T heft Security Access Gene ral P r ocedures 1. The compl exi t y of t he e l e ct roni cs in vol ve d wi t h t he a nt i t h e ft , o f whi ch t he s ecur i t y a cces s i s a part, a nd t he m ul ti pl e xed commun i cat io n ne t wo r k whi ch a re co nne cte d t o i t pr e clud e t he[...]

  • Page 2301

    P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Key P ro g ram min g Us ing Diagno s tic E quipment Gene ral P r ocedures 1. The compl exi t y of t he e l e ct roni cs in vol ve d wi t h t he a nt i t h e ft , o f whi ch t he key pr ogr a mm i ng i s a p a r t , a nd t he mult i pl e xe d comm uni cat i o n ne t wo r k whi ch a re co nne cte[...]

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    P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Passi v e Anti-Theft Sy stem (PATS) Tra nsceiver Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s without driv e r low e r a ir bag 1. Remove t he i ns t r um e nt pa ne l l o we r t rim pa ne l . Vehi c le s with driv er lo we r ai r ba g 2. Remove t he drive r lo we r ai rbag m odu[...]

  • Page 2303

    P ubl i s he d: 11-May-2 011 Remo te Co n v enience - U niversal T rans mitter Des cr ipt i o n a nd O pe r a t i o n The Ho meL ink unive r s a l t rans mi t t e r pr ovi de s a conve ni e nt wa y t o r e pl a ce up t o t hr ee h a nd-hel d t rans mit t e r s w i t h a s i ng le bui l t -i n de vice . The uni ve r s a l t rans mi tt e r : wil l o [...]

  • Page 2304

    1 1 P ubl i s he d: 11-May-2 011 Remo te Co n v enience - U niversal T rans mitter Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e . 2. Vi sual Inspect i on Mechani cal Damag [...]

  • Page 2305

    P ubl i s he d: 11-May-2 011 Remo te Co n v enience - U niversal T rans mitter Program m ing Gene ral P r ocedures W ARNI N G: A g a r a g e d o or o pen in g s ys t e m t hat ca nnot s t o p o r r e ver s e i t s e l f a f te r de te ct i ng a n o bj e ct i n i t s pa t h d o e s no t mee t cur r e n t fe de r a l s a fe t y s t a nda r ds . To d [...]

  • Page 2306

    a s t he uni ve r s a l t r ans mi t t e r red l i ght f l a s he s (1-2 s e conds ). Re l ea s e t he b ut t o n a nd re-pr e s s t he b ut t o n t o conf i rm t ha t t he uni versa l t r ans mit t e r i s t r ai ne d t o t he r e ce i ver . 5. The ga r a ge d o o r ope ne r s ho ul d r e cog ni z e th e uni versa l t rans mi t t e r . Erasing Ch [...]

  • Page 2307

    P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Des cr ipt i o n a nd O pe r a t i o n 4-D oo r I te m P a rt Nu m ber Descri pti o n 1 — Ro o f p od a nt e nna modu le (from 2009MY ) 2 — Na vi ga t i o n GP S a nt e nna (u p t o 2009M Y ) 3 — Na vi ga t i o n comput e r 4 - Na vig a t i o n s ys t e m di s pl ay W a go n J[...]

  • Page 2308

    I te m P a rt Nu m ber Descri pti o n 1 - Roo f pod a nt e nna modul e (f rom 2009MY ) 2 - Na vig a t i o n GPS ant e nna (up t o 2009M Y ) 3 - Na vig a t i o n comput e r 4 - Na vig a t i o n s ys t e m di s pl ay The na v i g at io n sys t e m ut i l i z e s the f o l l o wi ng fu ncti o ns . Vo i ce gui d a nce vol u m e co nt rol l e d vi a a u[...]

  • Page 2309

    P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he na vig a t i o n s yst e m, ref e r to t he rel e va nt Des cr i p t i on a nd O pe rat i o n s e c t i o ns i n t he wo r ks hop manua l . REFER t o: Na vig a t io n S ys te m[...]

  • Page 2310

    DT C De s cri pti o n Po ssi bl e C ause Ac ti on B2205 GPS r ece i ve r f a ul t S at e l l i t e na vi ga t i on s ys t e m modul e - gl o ba l p os i t i o ni ng s a t e l l i t e rece i ver fa ul t Ca r ry out a ny p i npo i nt t es t s a s s oci a t ed wi t h t his DT C us i ng t he m a nufa ct ur er a pprov e d d i a gno s ti c s y s t e m. R[...]

  • Page 2311

    P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Antenna4-Doo r, VIN R ange : E96603 -> J39905 Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r d oo r o pe n in g we a t he r -st r i ps . Lef t-h a nd s hown, rig ht -ha nd s i mi l a r . 2. Remove t he rear s e a t s i de bo l s t e r s . For a ddi t i [...]

  • Page 2312

    7. Remove t he GPS ant e nna. 1. Dis con nect t he GP S a n te nna e l e ct rica l conne ct o r . 2. Re move t he GP S a nt e nna. 1. Remove th e po p ri ve t. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

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    P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Antenna4-Doo r, VIN R ange : J399 06- >V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. F ol d d o wn t he r e a r s e at b a ckr e s t s . 2. D et a ch t he r e a r s ea t b a ck r e st bo l s t e r s . P r e s s t he t a ng s . 3. Remove t he rear s e a t b a ck r es t[...]

  • Page 2314

    6. Remove t he C-pi l l a r t rim pa ne l s . 7. D et a ch t he cove r s t o e xpo s e t he s cr ews and r emove t he r ea r pa s s e nger a s s i s t ha ndl e s . 8. NOT E: S ome varia t io n i n t he i l l us t rat i o ns may o c cur , but t he e ss e nt i a l in f orm a t i o n i s a l wa ys corr e ct . Det ach t he rear of t he he a dl i ne r .[...]

  • Page 2315

    P ubl i s he d: 11-May-2 011 Navigation System - Navigation System AntennaWagon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s po i l e r For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S p o i l e r - W a g on (501-08 Exte rio r T r i m an d O rname nt a t i o n, Re moval a nd I ns t a l la t i o n). 2. D et a[...]

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    P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Di splay Module Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with autom at ic tra ns m ission 1. NOT E: To ai d r e mov a l of t he na vi gat i o n mod ul e a nd a udi o un it p l ace t he J-gat e i n t h e 'D' po s i t i on . Re move t h e J-ga t e s urr ou[...]

  • Page 2317

    6. Remove t he s wi t ch pa ck t rim cove r. 7. Remove t he ret a i ni n g s cr ew co ver pl a t e . 8. Remove t he di sp l ay mount i ng br a c ket up pe r ret a i ni ng s cr ews . 9. Remove t he di sp l ay mount i ng br a c ket l o we r ret a i ni ng s cr ews . 10. Dis c o nne ct t he e l e ct r ica l conne ct o r s . JagDocs.com[...]

  • Page 2318

    11. Remove t he d i s p la y modul e a nd a udi o uni t . 1. Dis con nect t he e l e c t rical co nnect ors a nd t h e fi br e op t i c conne ct o r . 2. Re move t he d is pl a y modu le and audi o uni t . 12. Remove t he na vi ga t i o n s y s t e m di s pl ay modul e . 1. Re move t he navi gat i o n s ys t e m di s pl a y ret a i ni ng screws . 2[...]

  • Page 2319

    [...]

  • Page 2320

    6. Remove t he a udi o uni t a mpl if ie r . 7. D et a ch t he mod ul e ret a i ni ng br acket . 8. D i s conne ct t he e l ect r i cal conne ct o rs. 9. Remove t he na vig a ti o n mod ul e ret a i ni ng bo l t s. 10. Remove t he na vi ga t i o n modul e . JagDocs.com[...]

  • Page 2321

    Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 3 Nm. 2. Tig ht e n t o 3 Nm. 3. Tig ht e n t o 9 Nm. 4. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ). Jag[...]

  • Page 2322

    P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Mo duleWago n Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he na viga t i o n DVD di s c ha s be e n r e m o ved a nd t he a udi o uni t p in code i s a va il a b l e be f o r e di s conne ct i ng t he ba tt e r y ground c a bl e. Di s conn ect t he ba tt e[...]

  • Page 2323

    6. Remove t he l o ad s p a ce s t owa g e compa rtment . 7. Remove t he l o ad s p a ce fl oo r covering r e t a i nin g s cr ews . 8. D et a ch t he l o a d sp a ce fl o o r cove r i ng upwards. 9. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt ret a i ni ng screw. 10. Remove t he l ef t -han d l o a ds pa ce s t ow ag e comp[...]

  • Page 2324

    11. Det a ch t he modul e ret a i ni ng brack e t . 12. Dis c o nne ct t he na vi ga t i o n s y s t e m module e l e ct rica l con nect or s . 13. Dis c o nne ct t he co mpact d i sc (CD) change r e l e ct r i cal c onn e cto r s . 14. Dis c o nne ct t he vo i ce a ct i vat e d cont r o l modul e (VACM) e l e ct r i ca l conne ct ors. 15. Dis c o [...]

  • Page 2325

    16. Remove t he na vi ga t i o n s y s t e m module r et a i ni ng bo l t s . 17. Remove t he s yst e m navi ga t i o n modu le . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 3 Nm. 2. Tig ht e n t o 3 Nm. JagDocs.com[...]

  • Page 2326

    3. Tig ht e n t he modul e r e t a i n in g b r a cke t uppe r a nd l owe r f i xin gs . Ti ght e n t he l ow er r e t a i ni n g nut s t o 4 N m . Ti ght e n t he up pe r r et a i ni ng bo l t t o 9 Nm. 4. Connect t he ba t t e ry gr ound cabl e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , M[...]

  • Page 2327

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - T o rque Sp eci f i cat ions Descri pti on N m l b- ft l b-i n Ce l l ul a r phone mo dul e 5 - 44 JagDocs.com[...]

  • Page 2328

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Cellu lar Pho ne Des cr ipt i o n a nd O pe r a t i o n C ELLULA R PHONE - UP TO 2 006 M Y The po r t a bl e ce l l ul a r phone s ys t e m cons i s t s o f : Ce l l ul a r phone ha nds e t (GS M) . Cr a d l e (GS M). Ce l l ul a r porta b le (US On ly). Ha nds e t b a t t e r y (US O nl y) . Ha ng [...]

  • Page 2329

    it ma y b e ne ce s s ary t o reduce t he s y s t e m vol ume s l ig ht ly whe n us ing ce r t a i n mob i le p hone s . P hone r e la t e d mes s a ge s a re s hown on t he a udi o uni t pa ne l di sp l ay o r t o uc h-s cr e en whe n the phone s ys te m i s a cti ve. T he B l ue t oo t h™ t e l e phone s ys t e m c a n be us e d i n co njunct i[...]

  • Page 2330

    Item P a rt N um ber Descri pt i on 1 - Rot a r y Vol ume cont r ol 2 - Rot a r y cont rol Te l e pho ne m o de - s cr ol l t hr oug h s t ore d numbe r s 3 - Pho ne mode s e l e ct b ut t on 4 - S t a r t vo ice mode but t o n, a ns w er t e l e p ho ne o r se n d/end i n p hone mode The t el e phone s wi t ches a r e l o cat e d o n t he LH s id [...]

  • Page 2331

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Cellu lar Pho ne Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he pho ne s yst e m, ref e r t o th e rel e va nt Des cr i pt i on a nd O perat i o n s e ct io ns i n t he wo r ks hop manua l . REFER t o : Ce l l ul a r Pho ne (419-08 Cel l ul[...]

  • Page 2332

    • NO T E: W he n pe rfo r mi ng vol t a ge o r r e s i s t a nce t e s t s , a l wa ys use a di g i t a l mult i me t e r (DMM ) a c cur a t e t o t hree d e ci m a l pl a ces and wi t h a cur r e nt ca l i brat i on certi fi c a t e . W he n t e st i ng r e s i s t a nce, a l wa ys t a ke t he r es i s t a nce o f t he DMM l e a d s in t o a c c[...]

  • Page 2333

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Cellu lar Pho neVe hicles W i th: Bl ueto oth Dia gn os i s a nd Te s t i ng Over view Thi s s e cti on cove r s t he co mpon ent s of t he B l ue t o ot h c e l lul a r pho ne s yst e m. For i nfo rm at i o n o n t he des cr i pt i on a nd o perat i on o f t he B l ue t o o t h cel l ul a r p hone [...]

  • Page 2334

    1 1 1 1 1 1 1 1 1 • NO T E: I ns pe ct conne c t o r s f or s i g ns of wa t e r ing res s , a nd p i ns f o r damag e and /or co r ros i o n. • NO T E: I f a cont r o l modu le or compone nt i s s us pe ct a nd t he vehi cl e r e mai n s under manuf a ct urer wa r rant y, r e fe r t o t h e W a rr a nt y Po l i cy a nd P r o ce dures manual (s[...]

  • Page 2335

    1 1 1 1 1 1 1 1 1 1 1 Is t he co nnect i on be t w ee n t he B l ue t oo t h upgr a de modul e a nd t he p hone h a rn es s l oo s e ? Ye s Re conne ct t he B l ue t oot h u pgr a de mod ul e a nd check f or norm a l ope rat i o n. No GO t o B 5 . B4: Ar e any of t he B lue t oo t h up gr a de mod ul e pi ns d a maged ? Ye s Re fe r t o t he wa r r[...]

  • Page 2336

    1 1 1 1 1 1 1 1 1 1 1 Ha s t he hand s e t pai r ed wi th t he s ys t e m s ucces s f u ll y ("Phone con nect e d" di sp l a yed (t ouch s cr ee n) o r "S IG* " di s pl a y e d (audi o he a d un i t di s pl a y))? Ye s P r o b l e m may ha ve be e n d ue t o a f aul ty Bl ue to o t h conne c t i o n. No P a ir a nd conne ct a d [...]

  • Page 2337

    1 1 1 1 1 1 1 1 1 1 Che ck al l c onn e cti o ns /connect i vit y t o a nd f r o m t he p o rta bl e s upp o r t e l e ct r oni cs (PS E) mod ul e a nd t he B l uet oo t h upgrade m o dul e . A re a ny o f the ha rn e s s co nnect i o ns lo o s e o r d ama ge d? Ye s Re ct i f y as ne ce ss a r y. Re fe r t o t he e l e ct rica l gui d es . No Re f[...]

  • Page 2338

    1 1 1 1 1 1 1 1 1 1 I n t he ha nds e t Bl ue t o o t h menu, is "Jag ua r " l i s t e d a s a p a i red de vi c e ? Ye s GO t o F3 . No Fol l ow p a iring p r oce s s f or t he s peci f i c han ds et . GO to F6 . F3: I s t he hand s e t 'conne ct e d' t o ano t h er Bl ue t o o t h de vice (i .e . not "Jagua r ")? Ye [...]

  • Page 2339

    1 1 1 1 1 1 1 1 1 1 1 1 Che ck th e ha nd se t menu. Ha s a ut o conne c t bee n t ur ne d o n? Ye s GO t o G4 . No S wi t ch a ut o conne ct o n and che ck f o r nor mal o p e r at i on . G4: Ha s t h e us er t r i e d t o t r ans f e r a ca l l from ha nds f r ee t o ha nds e t ? Ye s Che ck th e ha nd s e t gui de i nfo , s o m e ha nd s e t s w[...]

  • Page 2340

    1 1 1 1 1 1 1 1 1 1 Ha s t he us e r f ol l o we d ve hi cle and hands e t i ns truc t i o ns f or do wnl o a di ng phone b oo k? Ye s GO t o H4 . No Re fe r t o t he vehi c l e ha ndbo o ks/ha nds e t 'quick gui d e i nfo rm at i o n' r e gardin g p ho nebo o k do wnl o a d. Che ck f or no rm al op e r at i o n. H4 : Aft e r " Downl[...]

  • Page 2341

    1 1 1 1 1 1 1 1 1 1 1 1 I5 : I s t he r e a ny 3r d p a r t y au di o ? Ye s End. No Dis conne ct t he Bl ue to o t h l i nk be t we e n t he ha nds e t a nd vehi cl e pho ne s yst em a nd re -t r y t he ca ll . GO t o I6 . I6 : Doe s t he 3 rd pa r t y ca ll a udi o wo rk wi th t he mobi l e pho ne d i s conne cte d f r om t he vehi cl e? Ye s Re [...]

  • Page 2342

    1 1 1 1 1 1 1 1 1 1 Ar e the mi cr o p ho ne harne ss conne ct i o ns da mag e d? Ye s Re cti f y as ne ces s a r y . Re fe r t o t he e l e ct rica l g ui de s . No Re pl a ce t he micr o p ho ne a nd r e-t ry t he cal l . GO t o I17 . I1 7: Doe s t he 3 rd pa r t y ca ll a udi o wo rk wi th t he B l ue t o ot h s ys t e m? Ye s P r o b l e m may [...]

  • Page 2343

    1 1 1 1 1 1 1 1 1 1 1 W he n t he r e i s no ca l l i n pr og r es s , a nd t he a udi o s o urc e i s cha nge d, i s any aud i o hea rd e .g. f r om r adi o ? Ye s GO t o K3 . No Che ck D2 B conne ct i ons a re no t l o o s e a nd t hat a l l node s a r e conne ct e d on t he D2B ring . Re cti f y as ne ces s a r y . GO t o K2 . K2: Ar e a ny of t[...]

  • Page 2344

    1 1 1 1 1 1 1 1 1 1 1 1 Ca n a ny r i ngi ng be he a r d t hrough t he ve hi cl e s pe a kers? Ye s P r o b l e m due t o a f a ul t y Bl ue t o o t h l i nk . No GO t o K4 . K14 : Ha s t he hand s e t " profi l e " b ee n s e t t o "s i le nt "? Ye s Cha nge se t t i ngs wi t hi n p r o fi le , make a n i ncomi ng c a l l a nd [...]

  • Page 2345

    1 1 1 1 1 1 1 1 1 1 1 1 I s ca l l vo lu m e s t il l l o w whe n ca l l t r a ns f e rr e d t o 'hands et ' mod e ? Ye s GO t o L 6 . No Key of f i g ni t i o n a nd wai t 6 minu te s f or t he p o r t a bl e s upp o r t e l e ct r oni cs (PS E) modul e t o s hut d own. Key o n i gni t i o n and r e -t ry t he c a l l . GO t o L 16 . L6:[...]

  • Page 2346

    1 1 1 1 1 1 1 1 1 1 I s vo l ume s t i l l l o w? Ye s Ref e r t o t he wa rr a nt y pol i cy a nd p r oce dur e s manua l i f a modul e i s s us p ect . No Low a udi o i s s ue ca us e d by t he ha nds e t , cons ult t he hand s e t s uppl i e r . PINPOIN T TE ST M : CANNOT D IA L OUT F ROM AU DI O HEAD U NI T/TO U CH- S CREEN/STEERING WHEEL CONTR[...]

  • Page 2347

    1 1 1 1 1 1 1 1 1 1 1 1 Ca nnot di a l us i ng voi c e cont r o l ? Ye s GO t o N8 . No GO t o N6 . N6 : Ca nnot t ur n phone o n/of f? Ye s GO t o N8 . No GO t o N10 . N7 : I s t he hand s e t o n t he ap prov e d pho ne li s t ? Ye s Ca ll T e chni cal He l p l i ne . No On l y han ds e t s s pe cif i e d i n t he app r oved l i s t wi t h t he c[...]

  • Page 2348

    1 1 1 1 1 1 1 1 1 1 Is t he ca l l droppe d a ga i n? Ye s P a ir a nd conne ct a d if fe rent known 'goo d' hands e t t o t he vehi cl e p hone s ys t e m a nd ma ke a n i ncomi ng cal l. GO t o O 7 . No S wit ch o ff t he ha nds e t, remove t he b at t ery f r o m the ba ck o f t he hand s e t . Re pl a ce t he b at t e r y i nt o t he [...]

  • Page 2349

    1 1 Ca n t he cal l be t rans f e r r e d b e t we e n ha nds f r e e a nd ha nds e t ? Ye s P r obl em may have b e e n caus e d b y t he Bl uet o ot h l in k be i ng di s conne ct e d. No Ke y o f f i g ni t i o n f or 6 mi nut e s f or t he po r t a bl e s uppo r t e l e ct roni c s (P S E) modul e t o s hut down. Ke y o n i gni t i o n a nd r e[...]

  • Page 2350

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Blu etoo th Mo dule Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f l o or cons o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a nd Co ns o l e , Re mov al a nd I ns t a l l at i o n). 2. Remove t he Bl uet o ot h[...]

  • Page 2351

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Handset Ho lde r Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he f l o or cons o l e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a nd Co ns o l e , Re mov al a nd I ns t a l l at i o n). 2. NOT E: US mod[...]

  • Page 2352

    6. Remove t he a rm r e s t . 7. Remove t he no n s li p mat . 8. Remove t he ha nds e t ha ng up cup. Insta llat ion Vehi c le s with c or de d cellular phone 1. Ins t a l l the ha nds e t h a ng up cup. JagDocs.com[...]

  • Page 2353

    2. Ins t a l l the no n s l i p mat . 3. Ins t a l l the a rm r e s t . Vehi c le s with c or dle ss cell ular phone 4. Ins t a l l the a rm r e s t . 5. Att a ch t he ha nds e t ho l de r . 1. I ns t a l l t he hands e t hol de r . 2. At t a ch t he ha nds e t hol der. JagDocs.com[...]

  • Page 2354

    6. Ins t a l l the ce l l ula r phone . All v e h icle s 7. NOT E: US mode l s o nl y have a n a d di t i on a l a nt e nna conne cto r . Conn ect t he cel l ul ar phone e l e ct rica l conne ct or . 8. Ins t a l l the f l o o r cons ol e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a [...]

  • Page 2355

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Module4-Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he compa ct di s c (CD ) cha nge r For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co mpact Di s c (CD) Cha nger - 4-Door (415-01 A udi o U ni t, Re moval a nd I ns t a l l a t i o n). 2. Remove t he modul e . Insta ll[...]

  • Page 2356

    P ubl i s he d: 11-May-2 011 C ellula r P ho ne - ModuleWago n Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ). 2. Remove [...]

  • Page 2357

    P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - T o rque Sp eci f i cat ions Descri pti o n N m l b- ft l b- i n Vo i ce a ct i vat e d co nt r ol modul e 5 - 44 JagDocs.com[...]

  • Page 2358

    P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M o dule C o ntrol led Functio ns Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um be r Descri pti on 1 — V oi ce a cti vat e d co nt rol mod ul e (VACM) 2 — Ge ne r i c e le ctroni c modu le (GEM) V oic e Activa te d Cont rol Comp one n t Loc at ion JagDocs.com[...]

  • Page 2359

    I te m P a rt N um be r Descri pti o n 1 — Micr opho ne 2 — Vi s ua l fe e d back mes s a ge cent er di sp l a y 3 — Audi b l e f e e dba ck (incorpor a te d i n a u di o s ys t e m) 4 — S te e r i ng whe e l cont rol s G ene r ic Electronic Module (GEM) The GEM modul e is l o cat e d o n t he r i gh t hand s i de , be l o w t he i ns t ru [...]

  • Page 2360

    P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M ulti functio n Ele ctronic Modul e Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he mult i f uncti o n e l e ct roni c mod ule s , r e f e r t o t he rel e vant De s cr ipt i o n a nd O pe rat i on se ct i o ns i n t he [...]

  • Page 2361

    cur r e nt ca l i brat i on certi fi c a t e . W he n t e st i ng r e s i s t a nce, a l wa ys t a ke t he r es i s t a nce o f t he DM M l e a d s i nt o a ccount . • NO T E: Che ck and r ect i fy ba s i c f a ul t s fi r s t be fo r e be gi nni ng di a gno s t i c rout i ne s th a t i nvo l ve pi npo i nt t e s t s . • NO T E: I ns pe ct conn[...]

  • Page 2362

    DT C D escri pti on Possi bl e Ca us es Ac ti o n B2282 Le f t turn s wi t ch s hort to gr ound Tur n s wi t ch f a ul t y W i ring ha r ne s s co ncer n Che ck le ft t ur n s w i t c h ope rat i o n f o r s t i ck ing . Re pl a ce s wi t ch a s r eq ui red. Re fe r t o e l e ct r i cal c i r cuit wi r i ng di a g r a ms . Che ck l e f t tur n s wi[...]

  • Page 2363

    P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - Generic E lectron ic Module (G E M) Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : El e ct roni c modul e s a r e s e ns i t i ve t o s t a t i c e l e ct rical c ha rg e s . I f expo s ed t o t he s e charges , d a m a ge may r e s ul t . Di s conn ect t he ba t[...]

  • Page 2364

    P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M ulti functio n Vo ice Activated Module4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : El e ct roni c modul e s a r e s e ns i t i ve t o s t a t i c e l e ct rical c ha rg e s . I f expo s ed t o t he s e charges , d a m a ge may r e s ul t . Di s conn [...]

  • Page 2365

    6. Remove t he VACM. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 6 Nm. 2. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ). 3. Confi gu r e t he vo i ce a[...]

  • Page 2366

    P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M ulti functio n Vo ice Activated ModuleWago n Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a[...]

  • Page 2367

    P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Front E nd B ody P anel s Des cr ipt i o n a nd O pe r a t i o n Fr o nt B umper As s e mbly and Unde rtray The front b ody s t r ucture i s d es i gne d t o s a ti s fy bumpe r i mpa ct r equi re m e nt s and primaril y compr is e s t he f r ont bumper as s e mbl y whi ch i s ful l y de s c r[...]

  • Page 2368

    P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Air Deflector2 .0L Durato rq- TDCi / 2.2L Duratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des [...]

  • Page 2369

    P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Co w l Vent Screen Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he wi p er arm s a nd b l ade s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W i pe r Pi vot A rm (501- 16 W i p e r s a nd W a s he r s , Re moval a nd I ns t a l l a t i on ). Vehi c [...]

  • Page 2370

    P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Fen der Splash Shield Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e as s e mbl y. Fo r addi t i ona l i nf o r m at i o n, r e f er t o S ect i on 204-04 W he e l s an d T i res . 2. Remove t he whe e l a r ch l i ne r acce ss cove r . 3. Remove whe e l a [...]

  • Page 2371

    P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Radiator S p las h Shi eld Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i on 100-02 Jacki ng a nd Li ft i ng . 2. Remove unde r t r ay as s e m bl y. Insta llat ion 1. To i ns t a l l , rev[...]

  • Page 2372

    P ubl i s he d: 11-May-2 011 B ody Cl osures - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-ft l b-i n Doo r hi ng e b o lt - hi nge to bo dy 35 26 – Doo r hi ng e b o lt - hi nge to do o r 47 35 – Doo r hi ng e g r ub scr e w 18 13 – Doo r che ckst r a p t o b o dy 35 26 – Doo r che ckst r a p t o d o or 6 – 53 Doo r s t riker pl a[...]

  • Page 2373

    P ubl i s he d: 11-May-2 011 B ody Cl osures - Body Cl os ures Des cr ipt i o n a nd O pe r a t i o n Doo r s The pa s s e nger compa r t ment d o or s e a ch compr is e o f a n i nner a nd ou t e r pane l, cli nched a nd b o nded t o ge t he r t o fo rm a do or as s e mbly. Bo t h pa nel s i nco r por at e e xte n s i o ns s p ot wel de d t o ge t[...]

  • Page 2374

    P ubl i s he d: 11-May-2 011 B ody Cl osures - D o o r A l ignment Gene ral P r ocedures 1. NOT E: Re a r do o r sho wn, front doo r s i mi l a r. Re move t h e r e a r do o r ape rtur e s ea l . 2. Remove t he s t r i k e r pla t e . 3. Loos e n t he doo r hin ge b o l t s . 4. NOT E: Ini t i a l do o r f i t t i ng, se t t he f r ont d o or 4 mm [...]

  • Page 2375

    6. Ins t a l l the s t r i ker pl a t e . Ti ght e n t o 25 Nm. 7. Ins t a l l the rear do o r a p ert ur e s e a l . JagDocs.com[...]

  • Page 2376

    P ubl i s he d: 11-May-2 011 B ody Cl osures - Hoo d Alignment Gene ral P r ocedures 1. Remove t he ho od l at ch. Fo r ad di t io na l i nf o r ma t i on, ref e r t o Sect i on 501-14 Hand l e s , Locks , La t c he s a nd Ent r y Sy s t e ms . 2. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar. Re move t h e A-pi l la r e xte r io r t r i m. 3.[...]

  • Page 2377

    7. Tig ht e n t he ho o d hi ng e s cr e ws t o 20 Nm. 8. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar. I nst a l l t he l o we r A-pi l l ar dr a i na ge channe l . 9. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar. I nst a l l t he A -pi l l a r ext e rio r t r i m. 10. Ins t a l l t he ho od l a t ch. Fo r a d di t i on al i n fo r mat[...]

  • Page 2378

    P ubl i s he d: 11-May-2 011 B ody Cl osures - Liftgate Alignment Gene ral P r ocedures 1. Ope n t he l i f t ga t e. 2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Adj us t bo t h l i ft gat e b ump s t o ps count e r- clo ckwis e t o t hei r f ul ly s e a t e d po s i t i o n. 3. Remove t he l o ad s p a ce s cuff pl at e t r i m pa[...]

  • Page 2379

    9. Tig ht e n t he l i f t g a t e s t r i ker r e t a i ni ng b ol t s . Ti ght e n t o 25 Nm. 10. Loo s e n t he uppe r l i ft ga t e hi n ge r e t ai n in g b ol t s . 11. NO TE: Make s ur e th e ga p be t we e n t he l if t ga t e a nd t he r e a r qua r t er pane l s , rear l a mp a s s e mbl i e s a nd rea r bumpe r co v e r are e qual . S et[...]

  • Page 2380

    15. NO TE: Make s ur e th e ga ps be t wee n t he l i f t ga t e a nd r e a r la mp a ss e mbli e s a r e equ a l on bo t h s i des . S et t he l i ft gat e g a ps t o t he r e a r l a mp as s e mbl i e s . 16. Ti g ht e n t he l o we r l i f t g a t e hi ng e r e t a i ni ng bo l t s . Ti ght e n t o 14 Nm. 17. NO TE: L e ft -hand s h own, r i g h[...]

  • Page 2381

    22. Mak e s ure t he r ea r wi pe r pi vot a r m i s i n t h e pa r ke d po s it i o n. 23. O pen th e l i f t ga t e wi nd o w gl a s s . 24. O pen th e l i f t ga t e. 25. Remove t he l i f t ga t e trim pa nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t ga t e T r i m Pa ne l (501- 05 Int e r io r Tr i m a nd O r na m e nt [...]

  • Page 2382

    P ubl i s he d: 11-May-2 011 B ody Cl osures - Lugg age Co m partment L id Alignm ent Gene ral P r ocedures 1. Remove t he l ugga g e co mpar t me nt l i d a p erture s e a l . 2. Remove t he s t r i k e r pla t e . 3. NOT E: Le f t ha nd s ho wn, r i g ht ha nd s i mi l ar. Re move t h e ga s s t ru t . 4. NOT E: Le f t ha nd s ho wn, r i g ht ha [...]

  • Page 2383

    5. Pul l up/pus h down o n l ugg a ge compartment l i d. 6. NOT E: S et t he a li gnment t o 2 mm lo we r t ha n no mi nal . S et t he l ugg age c ompa rtment l i d a l i gnme nt . 7. Tig ht e n t he l ugga g e comp artme nt l i d hi ng e b ol t s . Ti ght e n t o 25 Nm. 8. Adjus t t he l ugga g e co mpar t me nt l i d s t op s cr e w. 9. Ins t a l[...]

  • Page 2384

    10. Ins t a l l t he s t r ike r pla t e . Ti ght e n t o 10 Nm. 11. Ins t a l l t he l ugga g e co mpar t me nt l i d a pe rture s e al . JagDocs.com[...]

  • Page 2385

    P ubl i s he d: 11-May-2 011 B ody Cl osures - We atherstri p Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Fr ont do o r s hown, rear do o r s i mi la r. Det ach t he do o r che ck s t r a p . 2. Remove t he wi ndo w a pe rture t r i m. 3. Remove t he f r ame se a l . 4. NOT E: A s ta rt poi nt lo cat o r can be fo und on e a ch we at [...]

  • Page 2386

    6. Usi ng a s ui t a bl e t o o l remove a ny r es i dua l a dhe s i ve f r om t he doo r. Insta llat ion 1. NOT E: Doo r wea t he rst r i ps a r e i de nt i fi e d by a col o r cod e d do t whi ch i s a ls o t he s t a rt poi nt . T he r i ght hand front do o r i s r ed , t he l e ft ha nd f r o nt doo r i s ye ll o w, t he right hand r ea r doo r[...]

  • Page 2387

    6. Ins t a l l the do o r che ck s t rap. Ti ght e n t o 35 Nm. JagDocs.com[...]

  • Page 2388

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b-i n S ea t bel t a nchor i ng bo l t 5 5 41 – Lo a ds p a c e r et a i ni ng ho o k - W ago n 8 – 71 JagDocs.com[...]

  • Page 2389

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Interior T r im Des cr ipt i o n a nd O pe r a t i o n Thi s s e cti on cove r s r emova l a nd i nst a l l a t i on of t he i nt e r i o r mold i ngs a nd t r i m pa ne l s . I n many i nst a nces , o ne c ompo ne nt o v e rla ps a not he r compone nt . I f t hi s co ndi t i o n i[...]

  • Page 2390

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - A - Pillar Trim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f ront do o r op eni ng we a t he r -s t rip. 2. NOT E: The A-pi l l a r t rim p a nel i s s e cur ed t o t he t op o f t he A-pi ll a r by a r e t a i ni ng s t r a p. T he r e t a ini ng s t r[...]

  • Page 2391

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - B- Pilla r Lo w er T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s c uf f p l a t e t rim pa nel . For ad di t io na l i nf o r mat i o n, r ef e r t o S c uf f Pl a t e Tr im Pa nel —Fr o nt . 2. Remove t he rear s cuff pl a t e t r i m pa ne[...]

  • Page 2392

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - B- Pilla r Upper Trim P anel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r d oo r o pe n in g we a t he r -st r i p. 2. D et a ch t he f ront do o r op eni ng we a t he r -s t rip. 3. D et a ch t he B -Pi l l a r upp er t r i m pa ne l . 4. D et a ch t h[...]

  • Page 2393

    5. D et a ch t he s a f e ty b e l t lo we r a nc ho r from t he unders i de o f t he s ea t . 6. Remove t he B-pi l l a r uppe r t r i m pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 55 Nm. JagDocs.com[...]

  • Page 2394

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Co wl Side T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f ront do o r op eni ng we a t he r -s t rip. 2. Remove t he f r ont s c uf f p l a t e t rim pa nel . For ad di t io na l i nf o r mat i o n, r ef e r t o S c uf f Pl a t e Tr im Pa nel —Fr [...]

  • Page 2395

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - C-P illa r T rim Panel4 -D o or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t s i de bo l s t e r . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 501-10 S e at in g . 2. NOT E: The C-pi l l a r t rim pa ne l i s s e cur ed t o t he t[...]

  • Page 2396

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - C-P illa r T rim PanelW agon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce cove r . 2. F ol d d o wn t he r e a r s e at b a ckr e s t . 3. D e t a ch t he l o a d s p ace co ver ret a i ni ng br acket fi ni s he r t r i m. 4. Repo s i t i on t he r[...]

  • Page 2397

    7. D et a ch t he r e a r d oo r o pe n in g we a t he r st rip. 8. Remove t he C-pi l l a r t rim pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2398

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - D- Pillar Tri m P anel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he l i f t ga t e o pe ni ng we a t he rst r i p. 2. D et a ch t he D-Pi l l a r t r i m pa ne l . 3. Remove t he D-Pi l l a r t rim p a nel . Insta llat ion 1. Att a ch t he D-Pi l l a r t rim p [...]

  • Page 2399

    3. Ins t a l l the D-Pi l l a r t rim p a nel . 4. Att a ch t he l i f tg a t e o pe ni ng we at he r s t r ip. JagDocs.com[...]

  • Page 2400

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Front Doo r Trim Pa nel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ret a i ni n g s cr ew co ver. 2. Remove t he ret a i ni n g s cr ew. 3. Remove t he ret a i ni n g s cr ews . 4. D et a ch t he f ront do o r trim pa nel . JagDocs.com[...]

  • Page 2401

    5. D et a ch t he do o r handl e ca bl e . 6. Remove t he do o r han dl e cabl e. 7. Remove t he f r ont do o r t r i m pane l . Dis conne ct t he e l e ct r i cal co nnect o rs a nd de t a ch t he wi r i ng ha r nes s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2402

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Front Scuff Plate Trim P anel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s cuff pl a t e t r i m pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2403

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Headliner4-Door Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: O ve r hea d Co ns ol e (501-1 2 I nst r um e nt P a ne l a nd Co ns ol e , Re mov a l a nd I n st a l l at i o n). 2. R[...]

  • Page 2404

    8. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he rear do o r op eni ng we a t he r -s t rip. 9. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he B-pi l l a r uppe r t r im pa ne l . 10. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he B-pi l l a r l o we r t rim pa ne l . 11. NO TE:[...]

  • Page 2405

    13. Remove t he C-p il l a r trim pa nel s . 14. Det a ch t he cove r s t o e xpo s e t he s cr e ws a nd re m o ve t he dr ive r a nd pa s se n ge r as s i s t ha n dl e s . 15. Remove t he rea r s e a t cus hi on . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t [...]

  • Page 2406

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - HeadlinerWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: O ve r hea d Co ns ol e (501-1 2 I nst r um e nt P a ne l a nd Co ns ol e , Re mov a l a nd I n st a l l at i o n). 2. R[...]

  • Page 2407

    8. D i s conne ct t he right -ha nd e l e ct rica l conne ct or and det a ch t he w i r i ng ha r nes s. 9. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he B-pi l l a r uppe r t r im pa ne l . 10. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he B-pi l l a r l o we r t rim pa ne l . 11. NO TE: Ri ght -hand[...]

  • Page 2408

    13. Remove bo t h C-pi ll ar t rim p ane l s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: C-Pi l l a r Tr i m P a nel - W ago n (501- 05 I nt e r i o r Tr im a nd O rname nt a ti o n, Re m o val a nd Ins t al l a t i o n). 14. Remove bo t h D-pi l l a r t rim p ane l s. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: D-Pi ll a [...]

  • Page 2409

    19. Dis c o nne ct t he roof o pe ni ng pa ne l m o to r e l e ct rical conne c t o r . 20. Dis c o nne ct t he rea r was he r hos e co nne ct o r . 21. NO TE: He a d l i n er s ho wn removed fo r cl a r i t y. Us i ng a s ui t a b l e a dhe s i ve t a pe , pr ot e ct b o th f r ont co r ne r s of t h e he a dl i ne r. 22. NO TE: He a d l i n er s [...]

  • Page 2410

    Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. NOT E: The l i f t g a t e we a t he r s t r i p must b e repl a ced on ce removed. I nst a l l a ne w l i f t ga t e o p e ni ng we a t he rst r i p . JagDocs.com[...]

  • Page 2411

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Liftgate Trim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he l i f t ga t e wi ndow g la s s we a t he r s t r i p. 2. Remove t he l i f t g a t e wi ndo w gl as s l a t ch a ct ua t or fi ni s he r t r i m pa ne l . 3. Remove t he l i f t g a t e t rim pa [...]

  • Page 2412

    5. Remove t he l i f t g a t e fi ni s her t r i m pa ne l . 6. D ea t ch t he l i f t ga t e t r i m pa ne l . 7. Remove t he l i f t g a t e t rim pa nel . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2413

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Loa dspace Scuf f Plate Tri m P anel Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e t he l o a ds p a ce fl o o r cove r i ng. 2. Remove t he l o ad s p a ce fl oo r covering. 3. Remove t he ce nt re l o a ds pace s t o wage compartment . 4. D et a ch t he l o a d sp a [...]

  • Page 2414

    5. D et a ch t he l o a d sp a ce s c uf f p l a t e t rim pa nel . 6. Remove t he l o ad s p a ce s cuff pl at e t r i m pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2415

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Loa dspace Trim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce s cuff pl at e t r i m pa ne l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L o ads pa ce Sc uff Pl a t e Trim P a nel (501-05 I nt e r i o r Tr im a nd O rn a ment a t[...]

  • Page 2416

    8. Remove t he ret a i ni n g ho ok. 9. Remove t he l o ad s p a ce t rim p a nel ret a i ni ng screws . 10. Det a ch t he l o a ds pa ce t r im pa ne l rea r r e t a i n ing cl i ps . 11. Det a ch t he l o a ds pa ce t r im pa ne l f r ont ret a i ni ng c l i p s . 12. Remove t he l oa ds pa ce t r im pane l . JagDocs.com[...]

  • Page 2417

    Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 8 Nm. JagDocs.com[...]

  • Page 2418

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - P arcel Shelf Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with s plit r ea r se at back r est 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t[...]

  • Page 2419

    6. Remove t he pa r cel s hel f. P as s t he re ar cent re s a f e t y be l t t hr ough t he pa rc el s he l f. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 55 Nm. JagDocs.com[...]

  • Page 2420

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Rear Doo r T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ret a i ni n g s cr ew co ver. 2. Remove t he ret a i ni n g s cr ew. 3. Remove t he ret a i ni n g s cr ew. 4. D et a ch t he r e a r d oo r t r i m pa ne l . 5. D et a ch t he do o r handl e ca [...]

  • Page 2421

    6. Remove t he do o r han dl e cabl e. 7. Remove t he rear do or t r i m pa ne l . Dis conne ct t he e l e ct r i cal co nnect o rs a nd de t a ch t he wi r i ng ha r nes s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2422

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Rear Scuff P late T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he s cuff pl at e t r i m pa ne l . 2. Remove t he s cuff pl a t e t r i m pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2423

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Rear Window Bli nd Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r d oo r o pe n in g we a t he r -st r i ps . 2. Remove t he rear s e a t s i de bo l s t e r . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 501-10 S e at in g . 3. Remove[...]

  • Page 2424

    7. Remove t he rear wi nd ow bl i nd r e t a i ni ng cl ip s . 8. Remove t he rear wi nd ow bl i nd. P r e s s t he s i de s o f t he rea r wi ndo w b l i nd i nwa rds. 9. Remove t he rear wi nd ow bl i nd r o o f f i xing . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2425

    P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Sun Vi s or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s un vis o r r e t a i ni ng s cr e w cover . 2. D et a ch t he s un v i s o r . 3. Remove t he s un vis o r . Dis conne ct t he e l e ct r i cal co nnect o r. Insta llat ion 1. NOT E: Us i ng a s ui t a bl [...]

  • Page 2426

    [...]

  • Page 2427

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Ex terio r Trim Des cr ipt i o n a nd O pe r a t i o n 4-Do or I te m Pa r t Nu m be r Descri pti on 1 — Ra d ia t o r g r il le 2 — Front b umper i ns e r t mo ul di ng 3 — Front d o or l o we r m oul di ng 4 — Front d o or gl a s s m o ul di ng 5 — Re a r do o r l o we r[...]

  • Page 2428

    It e m Pa r t Nu m be r Descri pti on 1 - Roo f r ai l 2 - Re a r s po i l e r 3 - Li f t ga t e m o uld i ng 4 - Rocker pa nel moul di ng JagDocs.com[...]

  • Page 2429

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Do or Mouldin g Re moval a n d I ns t a l l a t i on R em ova l 1. Appl y s uit a b l e pr ot ect i ve t a pe to adj a c e nt a r ea s o f pa i nt wo r ks . 2. Usi ng a ha n d-hel d hea t g un, a ppl y he at uni fo r mly a l ong t he moul di ng l e ngt h. 3. Appl y i n g l o ca l he[...]

  • Page 2430

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Li ftgate Moul ding Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l i f t g a t e t rim pa nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t ga t e T r i m Pa ne l (501- 05 Int e r io r Tr i m a nd O r na m e nt a t io n, Re mov al a n d I ns t a[...]

  • Page 2431

    6. Remove t he l i f t g a t e moul di ng r et a i ni ng s cr e ws . 7. D et a ch t he gromm et . 8. Remove t he l i f t g a t e moul di ng . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 3 Nm. JagDocs.com[...]

  • Page 2432

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Radiator G rille Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r gr i l l e . Re mov e t he rad i a t or gril l e ret a i ni ng bol t s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 7 Nm. JagDocs.com[...]

  • Page 2433

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Rear Spo ilerWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove and di s card t he t a i l ga t e o p e ni ng wi nd ow fi ni s he r t rim p ane l . 2. Remove t he rear s po i l e r r e t a i n in g nut s . 3. D et a ch t he r e a r s poi l e r . 4. Remove t he rear s p[...]

  • Page 2434

    1. NOT E: A ne w t a i l ga t e op eni ng wi ndo w f ini s he r t r i m pa ne l must b e in s t a l l e d. To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 5 Nm. JagDocs.com[...]

  • Page 2435

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Ro cker Panel Mou lding Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roc ker pa ne l mould i ng r e t a ini ng s cr e ws . 2. NOT E: Bot h do o r s wi ll n e e d t o be o p e n t o r e move t he rock e r pane l m o uld i ng. Re move t h e r ocker pa ne l moul di ng[...]

  • Page 2436

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Ro of Rail Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Us i ng a s ui t a bl e t i e s t r ap remove t he r o o f r a i l f r ont t r i m. Re move t h e r oo f r ai l front t rim. 2. Remove t he roof rai l f r ont r e t a i nin g b o l t s . 3. NOT E: Us i ng a s ui t [...]

  • Page 2437

    1. NOT E: Ins t a l l ne w s e a l s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 14 Nm. 2. Tig ht e n t o 14 Nm. JagDocs.com[...]

  • Page 2438

    P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Wi ndow Moul ding Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he do o r wi ndow g l a s s a pe rture s e a l . 2. Remove t he wi ndo w moul di ng . Re mov e a nd di s c a r d t he r i v e t s . Insta llat ion 1. NOT E: Ins t a l l ne w r i vet s . To i ns t a ll ,[...]

  • Page 2439

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b- i n Exte rio r mi r r or r et a i ni ng nut 12 9 - JagDocs.com[...]

  • Page 2440

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Rea r Vie w Mirro rs Des cr ipt i o n a nd O pe r a t i o n The manua l d i p pi ng i nt e r i or mirr o r is a pr i s mat i c uni t wi t h mi r r or di p pi ng a chie ved b y pul l i ng th e l e ver fo r wa r d. W he re f i t t e d a n e l e ct r ochr omic i nt e rio r m i r r o r wil l a ut oma t [...]

  • Page 2441

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Rea r Vie w Mirro rs Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage . 2. Vi sual Inspect i on C h art El e ct ri cal El e ctrica l conne ct o r (s ) W i r i[...]

  • Page 2442

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - A uto-Dimm in g Interio r Mirror Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he i nt e rio r m i r ror trim pane l . 2. D et a ch t he i nt e rio r m i r ror . 3. Remove t he i nt e r i o r mirr o r. Dis conne ct t he i nt e rio r mi r r or e l ect r i cal co nnect o r. Insta llat[...]

  • Page 2443

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on . 2. Remove t he wi ndo w s ur r o und t r i m pane l . 3. D i s conne ct [...]

  • Page 2444

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 12 Nm. JagDocs.com[...]

  • Page 2445

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror C ontrol S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on . 2. Remove t he e xte rio r m i r ror c ont rol s w i t[...]

  • Page 2446

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror C ov er Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e xte rio r m i r ror gl a s s . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Exte rio r Mi rr or Gl as s . 2. Appl y l i ght p r e s s ur e t o t he i nne r e d ge of t he e xt e r i o r mirr o r cov e[...]

  • Page 2447

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror G lass Re moval a n d I ns t a l l a t i on R em ova l 1. Appl y l i ght p r e s s ur e t o t he mi rr o r g l a s s . 2. D et a ch t he mirr o r gl a s s . 1. App l y l i g ht pr e s s ur e t o t he i nne r e dge of t h e mi r r or gl a s s . 2. P ul l t he o ut e r e dge o f the m[...]

  • Page 2448

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e xte rio r m i r ror gl a s s . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Exte rio r Mi rr or Gl as s . 2. D et a ch t he e xt e r i or mirr o r m ot or. 1. Re move t he e xt e r i or mirr o r mot o[...]

  • Page 2449

    P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Interior Mi rror Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i nt e r i o r mirr o r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2450

    P ubl i s he d: 11-May-2 011 Seating - T o rque Sp eci f i cat ions Desc ri pti on N m l b-f t l b-i n Fr o nt s e a t r e t a i ni ng b ol t s 20 15 - Fr o nt s e a t ba ckr e s t r et a i ni ng bo l t s 25 18 - Fr o nt s e a t cus hi o n ret a i ni ng nut s 15 11 - Fr o nt s e a t t rack mot o r r e t a i ni ng bol t 10 7 - Fr o nt s e a t cus hi[...]

  • Page 2451

    P ubl i s he d: 11-May-2 011 Seating - Seats Des cr ipt i o n a nd O pe r a t i o n Fr o nt Seat - Hi gh S pe ci fi c a t i o n, V e hi cl e s wi tho ut Seat P o s i t i o n Memory It e m Pa rt Nu mber Desc ri pti o n 1 — Fr ont s ea t 2 — Fr ont s ea t t r a ck a nd cus hi o n front /r ea r he i gh t a dj ust ment s wi t ch 3 — Fr ont s ea t[...]

  • Page 2452

    It e m Pa rt Nu mber Desc ri pti o n 1 — Fr ont s ea t memo r y s t ore s wi t ch 2 — Fr ont s ea t memo r y s wi t ch 3 — Fr ont s ea t ba ckr es t r ecl i ne r s wi t ch 4 — Fr ont s ea t l umbar sup po r t s wi t ch 5 — Fr ont s ea t t r a ck a nd cus hi o n front /r ea r he i gh t a dj ust ment s wi t ch Fr o nt Seat - Low Sp e ci f i[...]

  • Page 2453

    I te m Pa r t N u m ber Descri pti on 1 — Fr o nt s e a t t rack a dj us t me nt l o ck i ng ba r 2 — Fr o nt s e a t ba ckr e s t r ecl i ner ha nd whe e l 3 — Fr o nt s e a t cus hi o n he i g ht a dj us t me nt s wi t ch (Dr i ver s i de o nl y) 4-D oo r, Ve hi cl es wit h 70/30 S p l i t Sea t JagDocs.com[...]

  • Page 2454

    Item P a rt N um be r De sc ri pti on 1 — Re a r s ea t b a ck r e s t bol st e r - RH 2 — Re a r s ea t b a ck r e s t 3 — Re a r s ea t h e a d r es t r a i nt s (Ce nt e r r e a r s e at h e a d re st r ai nt i s o pt i o nal ) 4 — Re a r s ea t b a ck r e s t 5 — Re a r s ea t b a ck r e s t bol st e r - LH 6 — Re a r s ea t cus hi [...]

  • Page 2455

    Item P a rt N um be r De sc ri pti on 1 — Re a r s ea t b a ck r e s t bol st e r - RH 2 — Re a r s ea t b a ck r e s t 3 — Re a r s ea t h e a d r es t r a i nt s (Ce nt e r r e a r s e at h e a d re st r ai nt i s o pt i o nal ) 4 — Re a r s ea t b a ck r e s t 5 — Re a r s ea t b a ck r e s t bol st e r - LH 6 — Re a r s ea t cus hi [...]

  • Page 2456

    It e m Pa rt Nu mber Des cri pti o n 1 — Fr ont s e a t b ackr e s t r ecl i ner mot o r 2 — Fr ont s e a t cus hi o n f r o nt he i ght a d ju s t ment mot o r 3 — Fr ont s e a t t rack mot o r 4 — Fr ont s e a t cus hi o n rea r hei ght a dj ust ment mot o r P a ss e nge r Fr ont Sea t - Hi gh Sp e cif ica t i o n It e m Pa rt Nu mber Des[...]

  • Page 2457

    I te m P a r t Nu m be r De s cri pti on 1 — Fr ont s e at l umba r s upp o r t b a g 2 — Fr ont s e at l umba r mot o r P a ss e nge r Fr ont Sea t W e i g ht S e ns ing s ys t e m I te m Pa rt Nu m ber Desc ri pti on 1 — Fr on t s e a t we i ght s e ns or 2 — Fr on t s e a t we i ght s e ns or modul e He a t e d S e a t Modul e - Hi gh S [...]

  • Page 2458

    s e ns o r a nd t he pas s e n ger s e a t has a we i ght s e ns i ng s y s t em. I n bot h i ns t a nces t he comp one nt s fo rm a n i nt e gr a l pa r t o f t he o ccupant r e s t r ai nt s ys t e m. For add i t i o na l i nf or m a t io n, ref er t o : S e at P o s i t i o n Sens or (501- 20B S upp le m e nt a l Re s t r a i nt S y s t e m, Re [...]

  • Page 2459

    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 1 2 3 4 1 1 P ubl i s he d: 11-May-2 011 Seating - Seats Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspec[...]

  • Page 2460

    2 3 4 1 1 1 2 1 1 2 3 1 2 1 2 1 1 2 Dis c on ne ct t he s e a t cont r ol s wi t ch e l e ct rical co nnect or RS 1. S wi t ch t he i gni t i o n s wit ch t o t he O N p os i t i on. Meas ur e t he vol t a ge be t we e n t he s e a t cont r ol s wit ch e l e c t r i cal co nnect or RS 1 pi n 6, (O Y ), a n d g r o un d. I s t he vol t age gr ea t e[...]

  • Page 2461

    1 1 2 3 1 2 1 2 1 1 1 2 3 1 2 1 2 1 2 Mea s ure t he r es i s t ance b e t wee n the s e a t cont r o l s wi t ch e l e ct rical conne c t o r RS 16 pi n 3, (B), a n d g r o un d a nd be t we e n RS 16 pi n 6, (B), and ground. Ar e t h e res i st a nces l e s s th a n 5 ohms ? Ye s GO t o B 10 . . No REPAI R t he ci r c ui t. TEST t he s y s t em f[...]

  • Page 2462

    1 2 3 1 2 1 2 1 2 1 1 1 2 3 1 2 1 2 1 2 C 6: C HEC K T HE R H FRO NT S EAT T R ACK MOT O R C I R C UI T Di s c onn e ct t he s e a t t rack mo to r e l e ct rica l c on ne ct or RS 4. O pe rat e t he s e a t cont r ol s wi t c h t o t he R EARW ARD t rack pos i t i o n. Mea s ur e t he vol t a ge be t we e n t he s e at t rack mot or e l e ct rica [...]

  • Page 2463

    1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 1 2 1 2 Is t he res i s t a nce l e s s t han 5 ohms ? Ye s I NS T AL L a ne w s e a t co nt rol s wi tch. For a dd i t i o na l i nfo rm a ti o n, re fe r t o Sea t Cont r ol S wit ch . No REP AIR t he ci r c ui t. TEST t he s y s t e m fo r norm al o pe rat i on. D7: C HECK T H E LH FRO NT SEAT C USHI ON R EAR H EIGH[...]

  • Page 2464

    1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 1 2 1 2 REP AIR t he ci r c ui t. TEST t he s y s t e m fo r norm al o pe rat i on. D16 : CHEC K T HE RH F R ONT SEAT CUSHI ON RE AR H EIGHT A DJUST MENT MO T OR CIRC U I T S Dis conne ct t he s e a t cus hi on r ea r he i ght a dju s t ment mot o r e l e ct r i cal co nnect or RS 2. Op e r at e t he s e a t co nt r ol[...]

  • Page 2465

    1 2 3 1 2 1 2 1 2 1 1 2 1 1 2 3 1 2 1 2 Dis conne ct t he s e a t b a c kr es t mot o r e l e ct r i cal conn ect or RS 6. Op e r at e th e s e a t co nt r o l s wi t ch t o t he REARW ARD RECLI NE p os i t io n. Mea s ure t he v ol t a ge be t wee n t he s e a t b a c kr e s t mot o r el e ct r i cal co nnect or RS 6 pi n 2, (Y R), a n d RS6 p i n[...]

  • Page 2466

    1 2 1 1 2 1 2 1 1 2 3 1 2 1 2 1 2 1 1 2 REPAI R t he ci r cui t . T ES T t he s ys t e m fo r nor mal op e r at i o n. F7: C HEC K T HE L H S EAT LUMBAR AS SEMBLY I N FLA T E CIRC UI T Ope rat e the s e a t l umbar cont r ol s wi t ch t o t he IN FLATE p os i t i on. Meas ur e t he vol t a ge be t we e n t he s e a t l umba r m o to r e l ect r i c[...]

  • Page 2467

    I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s INS TA LL a ne w s e a t l umbar cont r ol s wi t ch. TE S T t he s yst e m f o r norm a l op erat i o n. No REPAI R t he ci r cui t . T ES T t he s ys t e m fo r nor mal op e r at i o n. JagDocs.com[...]

  • Page 2468

    P ubl i s he d: 11-May-2 011 Seating - Front Seat Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : An RCM modu le o nl y r e qui res r e pl a ce ment i f t he s y s t em ha s i ncur red f i ve s e parat e de pl o ym e nt s. At no t i me chang e a n RCM f o r l e s s t ha n fi ve s e pa r a t e de p l o ym ent s . Al ways we a r s a f[...]

  • Page 2469

    5. D et a ch t he s a f e ty b e l t lo we r a nc ho r from t he unders i de o f t he s ea t . 6. Remove t he s e a t r e a r r e t a i ni ng bol t covers. 7. Remove t he s e a t . Re mov e t he re ta i ni ng bo l t s. 8. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o For a ddi ti ona l i nf[...]

  • Page 2470

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 20 Nm. 2. Tig ht e n t o 55 Nm. 3. Tig ht e n t o 20 Nm. JagDocs.com[...]

  • Page 2471

    P ubl i s he d: 11-May-2 011 Seating - Front Seat Ba ckrest Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n). 2. D et a ch t he ou t e r s i d e t r i m pa ne l . 3. D et a ch t he ou t e [...]

  • Page 2472

    6. D et a ch t he i nne r si de t rim pa ne l . 7. Remove t he i nne r s i de t rim p ane l . 8. Remove and di s card t he cabl e ti e . 9. D et a ch t he r e cl in e r m ot o r el e ctr i cal co nne ct or. 10. Dis c o nne ct t he recl i ne r mot or e l e ct r i ca l conne ct o r . JagDocs.com[...]

  • Page 2473

    11. Det a ch t he r ecl i ne r mot o r wiring ha r ne s s . Re mov e a nd di s c a r d t he r et a i ni ng cli p. 12. Det a ch t he s e a t ha r ne s s e l e ct rica l conne ct o r . 13. Dis c o nne ct t he s i de a i r bag modul e e l ect rical conne cto r. 14. Det a ch t he s i d e a i rbag mod ul e wi r i ng harnes s . Re mov e a nd di s c a r d[...]

  • Page 2474

    16. Remove t he f ront s e a t ba ckr e s t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e Ti ght e n t o 25 Nm. 2. Tig ht e n t o 25 Nm. JagDocs.com[...]

  • Page 2475

    P ubl i s he d: 11-May-2 011 Seating - Front Seat C ushi on Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : The front se a t cus hi on i s ca l i b r at e d t o t he o ccupant c l a s s i f i cat i o n s e ns o r, a nd can onl y be repl ace d a s pa rt of t he s e r vice ki t . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o S[...]

  • Page 2476

    P ubl i s he d: 11-May-2 011 Seating - Front Seat Fron t Height Adj ustm ent Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n). 2. Cu t a n d d i s ca r d t he cab le t i e . 3. D et[...]

  • Page 2477

    6. Remove t he f r ont s e at front h e i ght a dj us t me nt mo t o r . Re mov e t he re ta i ni ng bo l t s. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 2478

    P ubl i s he d: 11-May-2 011 Seating - Front Seat Rear Height Adjustment Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n). 2. Remove and di s card t he cabl e ti e . 3. D et a ch t[...]

  • Page 2479

    6. Remove t he t r i m fi ni she r . 7. Remove t he f r ont s e at r ea r hei ght a dj u st ment mot or. Re mov e t he re ta i ni ng bo l t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 2480

    P ubl i s he d: 11-May-2 011 Seating - Front Seat Reclin er Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at backr es t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t B ackr e s t (501-1 0 S ea t i ng, Re mova l and In s t a l l a t i o n). 2. Remove t he f r ont s e at hea d res t rai nt [...]

  • Page 2481

    6. D i s conne ct t he f r ont s e at ba ckr e s t m o to r e l ect r i cal conne cto r. 7. D et a ch t he f ront s e a t ba ckr e s t recl i ne r bar f r om t he moto r. 1. Re move t he r e cli ner ba r r et a i ni ng cl i p. 2. De ta ch t he f r ont s ea t b a ck r e s t r e cli ne r ba r from t he mot o r . 8. Remove t he f r ont s e at r ecl i [...]

  • Page 2482

    P ubl i s he d: 11-May-2 011 Seating - Front Seat T rack Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n). 2. Remove and di s card t he cabl e ti e . 3. D et a ch t he f ront s e a[...]

  • Page 2483

    1. NOT E: Make s ure t he f ront s e a t t r a c k mot o r cont rol rods a r e co r r ect l y lo ca t e d . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 10 Nm. JagDocs.com[...]

  • Page 2484

    P ubl i s he d: 11-May-2 011 Seating - Lu mbar Assem bly Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at backr es t . Fo r a d di t i ona l i nf o r mat i o n, refe r to Fr o nt Sea t B ackr e s t . 2. Remove t he he a d res t r a i nt . P r e s s t he t a ng s . 3. D et a ch t he ba ckr e s t cove r . Det a ch t he r [...]

  • Page 2485

    6. D et a ch t he ba ckr e s t cove r . Cut t he ho g rings . 7. D et a ch t he ba ckr e s t cove r . Cut t he ho g rings . 8. Rol l t he b a ckr e s t cover up t he ba ckr e s t. 9. D et a ch t he l umba r mot o r fr o m t he s e a t b a c kr e st f r a me . Cut t he ca b le t ie s . 10. Remove t he l umbar as s e mbl y. Cut t he ca b le t ie s . [...]

  • Page 2486

    Insta llat ion 1. NOT E: Ins t a l l ne w cab l e t i e s a nd h og r i ngs . Us e ho g ring pl i e r s t o cl os e th e hog r i ng s . Do no t us e an y ot he r to o l . The hog r ing s mus t b e cl os e d t o overla p a s i ll us t r a t e d. To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. JagDocs.com[...]

  • Page 2487

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n. Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Re a r S ea t Cushi o n . 2. Remove t he rear cent e r s af e t y be l t a nd buckl e. Re mov e t he re ta i ni ng bo l t . 3. Remove t he r[...]

  • Page 2488

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest4- Doo r, Vehi cles Wi th: 70/3 0 Split Seat Re moval a n d I ns t a l l a t i on R em ova l 1. F ol d d o wn t he r e a r s e at b a ckr e s t . 2. Remove t he rear s e a t b a ck r es t . 1. De ta ch t he rear s e a t backr e s t . 2. Re move t he r e a r s ea t ba ckr es t . Insta llat io[...]

  • Page 2489

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krestWago n, Ve hicle s W ith: 70/3 0 Spl it Seat Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t i o n). 2. F ol d d o wn t[...]

  • Page 2490

    1. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 55 Nm. 2. Tig ht e n t o 55 Nm. 3. Tig ht e n t o 23 Nm. 4. Tig ht e n t o 23 Nm. JagDocs.com[...]

  • Page 2491

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest La tchWagon Re moval a n d I ns t a l l a t i on R em ova l 1. D i s a s s e mble t he r e a r se a t ba ck res t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Ba ck r e st - W a go n, Ve hi cl e s W it h: 70/30 S pl i t S e a t (501-10 S e a ti ng, Di s a s s e m[...]

  • Page 2492

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bo ls ter4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. F ol d d o wn t he r e a r s e at b a ckr e s t . 2. D et a ch t he r e a r s ea t b a ck r e st bo l s t e r . P r e s s t he t a ng . 3. Remove t he rear s e a t b a ck r es t b o ls t er. Insta llat ion 1. To i ns t a l l , rever[...]

  • Page 2493

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bo ls terWagon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce cove r . 2. F ol d d o wn t he r e a r s e at b a ckr e s t . 3. D e t a ch t he l o a d s p ace co ver ret a i ni ng br acket fi ni s he r t r i m. 4. D et a ch t he r e a r s ea t b ol s t e r . 1. P r es [...]

  • Page 2494

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Cu shi on Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Re m o ve a nd d i sca r d o l d re ta ini ng cl ip s . Re move t h e r e a r s e at cush io n. 1. De ta ch t he rear s e a t c us hi o n f r ont ret a i ni ng c l i p s . 2. S li de t he r e a r s ea t cus hi on o ut o f t he ret a [...]

  • Page 2495

    P ubl i s he d: 11-May-2 011 Seating - Seat Ba se Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at backr es t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t B ackr e s t (501-1 0 S ea t i ng, Re mova l and In s t a l l a t i o n). 2. D et a ch t he e l e c t r i cal co nne ct ors . 3. Remove t he[...]

  • Page 2496

    1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 15 Nm. JagDocs.com[...]

  • Page 2497

    P ubl i s he d: 11-May-2 011 Seating - Seat Co n trol S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n). 2. D et a ch t he ou t e r s i d e t r i m pa ne l . 3. D et a ch t he ou t[...]

  • Page 2498

    6. Remove t he s e a t c ont r ol s wi t c h. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2499

    P ubl i s he d: 11-May-2 011 Seating - Front Seat Ba ckrest Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he f r ont s e at backr es t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t B ackr e s t (501-1 0 S ea t i ng, Re mova l and In s t a l l a t i o n). 2. Remove t he f r ont s e at hea d res t rai nt . P [...]

  • Page 2500

    6. D et a ch t he f ront s e a t ba ckr e s t co ver r e ta ini ng hoo k. 7. D et a ch t he f ront s e a t ba ckr e s t co ver. Re mov e a nd di s c a r d t he hog r i ngs . 8. D et a ch t he f ront s e a t ba ckr e s t co ver. Re mov e a nd di s c a r d t he hog r i ngs . 9. D et a ch t he ba ckr e s t cove r . Re mov e a nd di s c a r d t he hog [...]

  • Page 2501

    11. Remove t he f ront s e a t he a d res t r a i n t gui de s . Us i ng a s u it a b le t oo l , p r es s t he l o cking t a ngs . 12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he f r ont s e at b a ckr e s t cover t e ns i o n cor ds f r om t he front s e a t ba ck r e s t . 13. Remove t he f ront s e a t ba ckr e s t cove[...]

  • Page 2502

    P ubl i s he d: 11-May-2 011 Seating - Front Seat C ushi on Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he f r ont s e at cush io n. For a dd i t i o na l i nf o r mat i o n, refe r t o Fr ont S ea t Cushi o n . 2. Remove t he s e a t c us hi o n co ve r . Uncl i p t h e s e a t cus hio n f r om t he se a t ba s e. Cut t he ho g [...]

  • Page 2503

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest4- Doo r, Vehi cles Wi th: 70/3 0 Split Seat Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t b a ck r es t - f o l di ng. For add i t i o na l i nf orm a t i o n, r ef e r t o Rea r S e a t Ba ck r es t —Fo l di ng . 2. Remove t he he a d res t r a i nt (s ).[...]

  • Page 2504

    1. NOT E: Ins t a l l ne w hog r i ngs . U s e ho g ring pl i e r s t o clo s e t he ho g ring s. Do no t u se a ny o th e r t o o l . Th e ho g rings mus t be clo s e d t o ove r la p as il l us tra te d. To a s s e mble , r e ver s e t he d is a s se mbl y pr oce dur e . JagDocs.com[...]

  • Page 2505

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krestWago n, Ve hicle s W ith: 70/3 0 Spl it Seat Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t b a ck r es t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Ba ck r e st - W a go n, Ve hi cl e s W it h: 70/30 S pl i t S e a t (501-10 S e [...]

  • Page 2506

    7. D et a ch t he r e a r cen t r e s a f et y be l t g ui de f i nis her. 8. Remove t he rear cent re s a fe t y be l t g uid e f ini s he r . 9. D et a ch t he r e a r s ea t b a ck r e st cove r . Re mov e a nd di s c a r d t he hog r i ngs . 10. Det a ch t he r ea r s e a t ba ckr es t co ver . 11. Det a ch t he r ea r s e a t ba ckr es t co ve[...]

  • Page 2507

    12. Det a ch t he r ea r s e a t ba ckr es t co ver . Re mov e a nd di s c a r d t he hog r i ngs . 13. Det a ch t he r ea r s e a t ba ckr es t co ver . Re mov e a nd di s c a r d t he hog r i ngs . 14. Det a ch t he r ea r s e a t ba ckr es t co ver . Re mov e a nd di s c a r d t he hog r i ngs . 15. Det a ch t he r ea r s e a t ba ckr es t co ve[...]

  • Page 2508

    17. Remove t he rea r s e a t ba ckr e s t co ver. P as s t he ce ntre s a fe t y bel t t hrough t he re a r s e a t ba c kr es t co ver. A ssemb ly 1. NOT E: Ins t a l l ne w hog r i ngs . U s e ho g ring pl i e r s t o clo s e t he ho g ring s. Do no t u se a ny o th e r t o o l . Th e ho g rings mus t be clo s e d t o ove r la p as il l us tra t[...]

  • Page 2509

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t b a ck r es t - f i xed . For ad di t i on a l in fo rm at i on, refe r t o Re a r S ea t B a ck r e st —Fi x e d . 2. Remove t he he a d res t r a i nt s . 3. D et a ch t he ba ckr e s t cove r . Cut t he ho g[...]

  • Page 2510

    5. Remove t he he a d res t r a i nt gui de s . 1. Us i ng a s ui ta b l e s cr ew dr ive r , pres s th e l o c king t a ng. 2. Re move t he he a d r e s t rai nt g ui de . 6. Remove t he ba ck res t frame f rom t he b a ck r e st cus hi o n a nd co v e r. 7. D et a ch t he ba ckr e s t cove r from t he cus hi o n. Cut t he ho g rings . 8. Remove t[...]

  • Page 2511

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bo ls ter Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t b a ck r es t - bo l s t e r . Fo r addi t i ona l i nf o r m at i o n, r ef e r t o Rea r S e a t Ba ck r es t —B ol s t er . 2. Remove t he ba ck res t bol st e r c o ver . Cut t he ho g rings . A ssemb ly 1.[...]

  • Page 2512

    P ubl i s he d: 11-May-2 011 Seating - Rear Seat Cu shi on Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t cus hi o n. Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Re a r S ea t Cushi o n . 2. D et a ch t he s e a t cus hi on cove r . Cut t he ho g rings . 3. Cu t t he s e a t c us hi o n co ver t e ns i o n[...]

  • Page 2513

    7. Remove t he s e a t c us hi o n co ve r . Cut t he ho g rings . A ssemb ly 1. NOT E: Ins t a l l ne w hog r i ngs . U s e ho g ring pl i e r s t o clo s e t he ho g ring s. Do no t u se a ny o th e r t o o l . Th e ho g rings mus t be clo s e d t o ove r la p as il l us tra te d. To a s s e mble , r e ver s e t he d is a s se mbl y pr oce dur e [...]

  • Page 2514

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Ad hesi ve Desc ri pti on Speci fi cati on W i nd s hi e l d A dhe s i ve W S S -M2G 379- A6A T o rque Sp eci f i cat ions Desc ri pti on N m l b-f t l b-i n Fr o nt wi ndo w gl a s s r e t a i ni ng bo l t s 8 - 71 Re a r q uarte r l i ght r e t ai ni ng s cr e ws 7 - 62 Re a r wi nd o[...]

  • Page 2515

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Gl ass, Frames and Mechani sms Des cr ipt i o n a nd O pe r a t i o n Thi s ve hi cle has a ful l y bo nd ed, l ami na t e d front wi nds hi e l d gl a s s gl a z e d d ire c t l y t o t he b od y. The front wi nds hi e l d gl a s s i s a vai l a bl e i n s i x ver s i o ns : S ta nd a [...]

  • Page 2516

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Gl ass, Frames and Mechani sms Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l a nd e l e ct r i cal dama ge . 2. Vi sual[...]

  • Page 2517

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Doo r W indow Moto r In itiali zati on Gene ral P r ocedures 1. NOT E: Af t e r t he ba t t e r y has be e n d is co nnect e d it i s nece s s a ry t o in it i a l i z e e a ch do or wi nd ow mot or s e pa r a t e l y t o o pe r a t e th e "one -t o uch" up f unct i o n. Op e [...]

  • Page 2518

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Liftgate Windo w Glass Adj ustm ent Gene ral P r ocedures 1. M ake s ure t he r e a r wip e r m oun ti ng a r m i s i n t he pa r ked po s it i o n. 2. Ope n t he l i f t ga t e win do w gl a s s . 3. Ope n t he l i f t ga t e. 4. Remove t he l i f t g a t e t rim pa nel . For a ddi ti [...]

  • Page 2519

    Tr i m a nd O r na m e nt a t io n, Re mov al a n d I ns t a l l a t i o n). JagDocs.com[...]

  • Page 2520

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Front Doo r Win dow Gla ss Re moval a n d I ns t a l l a t i on R em ova l 1. Lowe r t he f ront doo r wi ndo w gl a s s a ppr oxi mat e l y 290 mm (11.41 i n). 2. Remove t he f r ont do o r t r i m pane l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Do o r T r im P [...]

  • Page 2521

    4. Tig ht e n t o 8 Nm. 5. CAU TI O N : Do no t t ou ch t he a d hes ive s urface a s r eb on di ng wi l l b e impa i r e d. At t a ch t he front doo r wea t he rshi el d. 6. Ins t a l l the f r ont d o or t rim pan e l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Do o r T r im P a ne l (501-05 I nt e r i o r Tr im a nd O rname [...]

  • Page 2522

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Front Doo r Win dow Reg ulato r and Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r win do w g la s s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Do o r W i ndow Gla s s (501-1 1 Gl as s , Fr a m e s a nd Mecha ni s m s , R e mo[...]

  • Page 2523

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Liftgate Windo w Glass Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s po i l e r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S p o i l e r - W a g on (501-08 Exte rio r T r i m an d O rname nt a t i o n, Re moval a nd I ns t a l la t i o n). 2[...]

  • Page 2524

    6. D et a ch t he l i f t ga t e wi ndow g la s s r el ea s e s wi t ch e l e ct rica l c o nne ct or . 7. D i s conne ct t he l i f tg a t e wi ndo w gl as s re le a s e s wi t ch e l e ct rica l co nnect o r . 8. D et a ch t he l i f t ga t e wi ndow g la s s wi ring ha rn es s ret a i ni ng cl i ps . 9. D et a ch t he l i f t ga t e wi ndow g la[...]

  • Page 2525

    Insta llat ion 1. CAU TI O N : Make s ur e t h e l i ft ga t e w i nd ow gl a s s do e s no t cont act th e v e hi cl e bod y work whe n t he l i ft ga t e win do w gl a s s i s cl o s ed. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n d amage t o t he ve hi cl e . • NO T E: Al i gn t he l i f t ga t e wi ndo w gl a s s r e[...]

  • Page 2526

    6. Connect t he de f r o s t gr id wi re e le ct rica l conne ct o r . 7. Att a ch t he de f r o s t grid wi re e l e ct rical c onn e cto r . 8. Connect t he na vig a t i o n s yst e m a nt e nna e l e c t r i cal co nnect o r. 9. Att a ch t he na vig a t i o n s yst e m a nt enna e l e ct r i cal co nnect o r. 10. Loo s e n t he li f t ga t e wi [...]

  • Page 2527

    11. Al i gn t he l if tg a t e wi nd ow gl as s t o t he li ft g a t e wi ndo w g l a s s a p e r t ur e. 12. Ti g ht e n t he l i ft ga t e w i ndow g la s s ret a i ni ng bol ts . Ti ght e n t o 9 Nm. 13. CAUT I O N: Ma k e s ure t he r e a r s poi le r do e s no t cont act t he vehi cl e r o o f pa nel wh e n t he l i ft ga t e wi ndo w g la s s[...]

  • Page 2528

    21. Loo s e n t he r e a r wip e r mot or r e t a i ni ng nut s . 22. Clo s e t he l i f t ga t e . 23. NO TE: T he a i d o f a n a s s i st a nt i n t he l oa ds pa ce wi l l be r eq uired t o a li g n t he r e a r wi p e r mot o r t o t he l i ft ga t e wi ndow g la s s . Make s ur e t he l i f t ga t e gl a s s l a t ch a nd r ea r wi pe r mount[...]

  • Page 2529

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Fixed Window G las s Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear do or t r i m pa ne l . Fo r add it i o na l i nf orm at i o n, r e f er t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on . 2. CAU TI O N : Do no t t ou ch t he a d hes[...]

  • Page 2530

    6. D et a ch t he wi nd o w gl a s s a pe r t ur e s e a l . 7. Remove and di s card t he r i vet s. 8. D et a ch t he r e a r q uarte r wi ndo w gl a s s gui de rai l r et a i ni ng brack e t . 9. Remove t he ret a i ni n g s cr ews . 10. CAUT I O N: U s e care whe n r e mov i ng t he r e a r q uarte r wi ndo w gl a s s . Fa i l ur e t o f o l l o[...]

  • Page 2531

    Insta llat ion 1. CAU TI O N : U s e care whe n i nst a l l i ng t he r e a r qu a r t er w i ndow g la s s . Fai l ure t o fo l l o w t he s e i ns t ruc t i o ns may r es ul t i n da mage t o t he wi ndow gl a s s a n d t he ext e r i or t r i m. • NO T E: W he n refi t t in g t he or i g i na l r ea r quarte r gl a s s , a ppl y ne w be a d o [...]

  • Page 2532

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Win dow Gla ss Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear qua r t e r wind o w gl a s s . For add i ti ona l i nf o r m a t i o n, r e f er t o W i nd ow Gla s s —Re a r Q uarte r . 2. Lowe r t he d o or wi ndow g l a s s unt i l t he pi n i s v i[...]

  • Page 2533

    1. CAU TI O N : U s e care whe n i nst a l l i ng t he s l e e ve a nd t he pi n i nt o t he win do w gl as s . Fa il ure t o fo l l o w t he s e i ns truc t i o ns may r es ul t i n da mage t o th e wi ndo w g l a s s . I nst a l l t he p i n. 1. CAU TI O N : Make s ur e t h e s le e ve i s f i t t ed cent r al i n t he win do w gl as s . 1. I ns [...]

  • Page 2534

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Win dow Re gulator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 501-05 In t e r i o r Trim a nd Ornament a t i o n . 2. Remove t he rear s pe aker. For a ddi ti ona l[...]

  • Page 2535

    7. Remove t he rear do or wi ndo w r e gul a t o r. Insta llat ion 1. Ins t a l l the rear do o r wi ndo w r e gul a t o r . Ti ght e n t o 7 Nm. 2. CAU TI O N : S uppor t t he wi ndow g l a s s p r i o r to removal o f t he pr ot ect ive t a pe . Re move t h e pr o t e ct i ve t a pe from t he t op o f the w i ndow g l a s s . 3. CAU TI O N : U s [...]

  • Page 2536

    4. NOT E: Ins ert t he gl a s s i nt o t he r e gul a t or gl a s s c l a mp a nd f i r mly pus hed dow n. Che ck b ot h s i de s of t he cl a mp have s na ppe d ove r t he s pace r br acket pi n. At t a ch t he wi ndo w gl a ss i nt o t he regul a t o r cla mp. 5. CAU TI O N : Do no t t ou ch t he a d hes ive s urface a s r eb on di ng wi l l b e [...]

  • Page 2537

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Win dow Re gulator and Mo tor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear do or wi ndo w gl a ss . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Door W ind ow Gl as s (501-11 Gl as s , Fr a m e s a nd Mecha ni s m s , R e moval a nd [...]

  • Page 2538

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Q uarter Wi ndow Gl ass Re moval a n d I ns t a l l a t i on Speci al T ool (s) S pray B ot t l e W K9 Lubr i cant Co ncent r at e W K9L Po we r Cutt i ng To o l W K10HD Cut ti ng Bl a de - Si de W K4ZS Adhe s i ve Re mova l Bl a d e - B o dy W K6 Bet a gun a ppl ica t i on g un B[...]

  • Page 2539

    2. Remove t he rear qua r t e r wind o w gl a s s fi ni she r t r i m. 3. Remove t he l o ad s p a ce t rim p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L o ads pa ce T r im P a ne l (501-05 I nt e r i o r Tr im a nd O rname nt a ti o n, Re m o val a nd Ins t al l a t i o n). 4. Appl y a s ui t a bl e p rot e cti ve t a p e t o[...]

  • Page 2540

    2. If t he o r i gi na l r e a r q uarte r wi ndo w gl a s s i s t o b e i ns t a l l e d r emove a ny r es i dua l a dhe s i ve from t h e r ea r qua r t e r wind o w gl a s s us ing t he s pe c i al t o ol . 3. Thoroughly cl e an r e a r quarte r wi n dow g la s s s u r f ace us i ng Be t a wi pe s p irit . 4. Thoroughly cl e an t he ma ti ng fa [...]

  • Page 2541

    7. Cu t t he no z z l e o f t he JLM 20452 gl a s s bo ndi ng a dhe s ive t o a chi e ve a t r i an gul a r s e ct i o n be a d 8 m m (0.32 i n) wi d e b y 10 mm (0.4 i n) hi gh. 8. Usi ng t he s pe cia l t oo l , app l y a uni f o r m b ea d of a d he s ive t o t he r e a r qua r t e r wi ndo w g l a s s e d ge co mm e nc i ng a t t he bot t o m c[...]

  • Page 2542

    14. NO TE: Make s ur e th e r ea r qua r t e r wi ndow gl a s s a dhe s i ve ha s s e t bef o r e i ns ta l l i ng t he rear qua r t e r wi ndo w g l a s s e xt erio r we a t herst rip. I nst a l l t he r e a r qua r t er w i ndow g l a s s we a t he rst r i p. JagDocs.com[...]

  • Page 2543

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Wi ndow G las s U sin g Che ese Wire Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he hi gh l e ve l s t op l a mp. For a ddi ti o nal i nfo r mat i o n, ref e r t o S ect i o n 417-01 Ex t e r i o r Li ght i ng . 2. D et a ch t he s e a t b e l t reel t r i m pa ne [...]

  • Page 2544

    6. D i s conne ct t he e l ect r i cal conne ct o rs. 7. D i s conne ct t he e l ect r i cal conne ct o r. 8. D i s conne ct t he e l ect r i cal conne ct o r. 9. Appl y s uit a b l e pr ot ect i ve t a pe a r o und t he wind s hi e ld gl a s s ape rtur e . 10. Pl a c e a p r ot e c t i ve s he e t ove r t he parcel s he lf a nd pl a ce a pr ot e c[...]

  • Page 2545

    12. Prepare t he che e s e wi r e and the cut t ing hand l e . P os i t i on t he cut t i ng ha ndl e cen t r a l t ube f ul l y up wa r ds i n t he handl e. Cut a s ui t a bl e l e ng t h o f chee s e wire a nd pa s s o ne e nd t hrough t he handl e t ub e a nd t he l oca t i ng a pe r t ur e . Mov e t he cut t i ng h andl e ce nt r a l t ube do w[...]

  • Page 2546

    19. Appl y s ui t a bl e pr ot ect i ve t a pe t o t he wi nds hi e l d g la s s a pe r t u r e . 20. NO TE: T o ai d b on di ng of a ne w w i nds hi el d g l a s s , make s ur e a t l e a s t 1 m m (0.3 i n) of res i dual a d hes i ve r e mai ns on t he bo dy f l a nge . Us i ng a s ui t a b l e t o o l remov e r es i dua l a d he s ive f r om t h[...]

  • Page 2547

    3. Appl y gl a s s pr i mer t o th e ma t i ng f a ce o f the bod y f la nge . 4. Cu t t he a dhe s i v e noz z l e t o achi e ve a tria ng ul a r s e ct i on be a d 8 mm (0.31in ) wi de b y 13 mm (0.51 i n) hi gh. 5. NOT E: Appl y wi nds hi e l d a dhe s i ve W S S -M 2G3 79-A6A o r e qui val ent m e e t i ng Ja gua r s pe ci f i ca ti o n a r o u[...]

  • Page 2548

    7. CAU TI O N : Make s ur e t h e wi nds hi e l d gl a s s d oe s not move o ut o f pos i t i on i n t he wi nds hi e l d g la s s a pe r t ur e . App l y s ui t a bl e p rot e ct i ve t a p e t o t he t op o f t he wi nd sh i e l d gl a s s . 8. Remove t he t a p e f rom t he i nne r e d ge o f t he r oo f pane l. 9. Remove t he prot e ct i ve she[...]

  • Page 2549

    13. CAUT I O N: Do no t conne ct t he e l ect r i cal conne ct o rs fo r at le a s t 1 hour af t e r i ns t al l a t io n of t he wi nd s hi e l d gl a s s . Fa i l ur e t o f o l l o w t he s e in s t ruc t i o ns may r e s ult i n dama ge t o t he wi nd shi el d gl a s s a dhe s i v e. Conn ect t he e l e ct rica l conne ct o r s . 14. CAUT I O N[...]

  • Page 2550

    19. CAUT I O N: Ma k e s ure t he wind s h ie ld gl a s s a dhe s i ve i s s e t bef o r e r e m o ving th e prot e ct i v e t a pe . Re move t h e pr o t e ct i ve t a pe from t he t op o f the w i nds hi el d g l a s s . JagDocs.com[...]

  • Page 2551

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Wi ndow G las s U sin g Cuttin g T oo l Re moval a n d I ns t a l l a t i on Speci al T ool (s) Lub r i cant conce nt rat e BTB -W K9L S pr ay bo t t l e BTB -W K9 Cut t i ng t o ol BTB -W K10HD S er rat e d ge ne r a l pur po s e 'Z' cut t i ng bl ad e BTB -W K24ZS C Cu[...]

  • Page 2552

    3. Remove t he rear s e a t b a ck r es t l at ch co v e rs. 4. D et a ch t he pa rc el s he l f t r i m pa ne l . 5. D i s conne ct t he e l ect r i cal conne ct o rs. 6. D i s conne ct t he e l ect r i cal conne ct o rs. 7. D i s conne ct t he e l ect r i cal conne ct o r. JagDocs.com[...]

  • Page 2553

    8. D i s conne ct t he e l ect r i cal conne ct o r. 9. Appl y s uit a b l e pr ot ect i ve t a pe a r o und t he wind s hi e ld gl a s s ape rtur e . 10. Pl a c e a p r ot e c t i ve s he e t ove r t he parcel s he lf a nd pl a ce a pr ot e ct i ve bo a r d o ver t he s he e t . 11. Appl y s ui t a bl e pr ot ect i ve t a pe t o i nne r edg e o f [...]

  • Page 2554

    16. Appl y c ut t i ng l ubrica nt t o b ot h s i de s o f t he i nne r C -pi l la r wi nds hi e l d gl a s s a d he s i ve. 17. Ins t a l l t he cutt i ng t oo l cont r ol l e r arm BTB-W K11B t o t h e cut t in g t o ol BTB -W K10HD. S et the cut t ing cont rol l e r a rm t o 45 mm . 18. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. •[...]

  • Page 2555

    24. Remove t he wi nds hi e l d gl a s s . At t a c h l i ft ing ha nd l e s t o t he wi nds hi e l d gl a s s . 25. NO TE: T o ai d b on di ng of a ne w w i nds hi el d g l a s s , make s ur e a t l e a s t 1 m m (0.3 i n) of res i dual a d hes i ve r e mai ns on t he bo dy f l a nge . Us i ng t he s p e ci a l t o ol r e move t he r e s i du a l [...]

  • Page 2556

    4. Cu t t he a dhe s i v e noz z l e t o achi e ve a tria ng ul a r s e ct i on be a d 8 mm (0.31in ) wi de b y 13 mm (0.51 i n) hi gh. 5. NOT E: Appl y wi nds hi e l d a dhe s i ve W S S -M 2G3 79-A6A o r e qui val ent m e e t i ng Ja gua r s pe ci f i ca ti o n a r o und t he wi nd s hi e l d gl a s s edg e . Us i ng a s ui t a b l e pne umat ic [...]

  • Page 2557

    8. Remove t he t a p e f rom t he i nne r e d ge o f t he r oo f pane l. 9. Remove t he prot e ct i ve she e t a nd t he pr ot e ct i ve bo a r d f r om t he pa r cel s he l f . 10. Remove t he p rote c t i ve t a p e f r om a r o un d t he win ds hie ld gl as s a pe r t ur e . 11. CAUT I O N: Do no t conne ct t he e l ect r i cal conne ct o r f or[...]

  • Page 2558

    14. CAUT I O N: Do no t conne ct t he e l ect r i cal conne ct o rs fo r at le a s t 1 hour af t e r i ns t al l a t io n of t he wi nd s hi e l d gl a s s . Fa i l ur e t o f o l l o w t he s e in s t ruc t i o ns may r e s ult i n dama ge t o t he wi nd shi el d gl a s s a dhe s i v e. Conn ect t he e l e ct rica l conne ct o r s . 15. At t ach t[...]

  • Page 2559

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Windo w C ontro l S wit ch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on . 2. Remove t he wi ndo w cont r ol s wi t ch. Inst[...]

  • Page 2560

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Windshi eld Gl ass U s ing Ch eese Wire Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s un vis o r s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 501-05 In t e r i o r Trim a nd Ornament a t i o n . 2. Remove t he cowl vent s cr ee n cover. For a[...]

  • Page 2561

    handl e. Cut a s ui t a bl e l e ng t h o f chee s e wire a nd pa s s o ne e nd t hrough t he handl e t ub e a nd t he l oca t i ng a pe r t ur e . Mov e t he cut t i ng h andl e ce nt r a l t ube do wnwa rd s t o s e cur e t he c he e s e wi r e. 10. Us i ng a s uit a bl e l ong bl a ded t o ol , pe ne t rat e th e wi nds hi e l d g l a s s a dhes[...]

  • Page 2562

    16. NO TE: T o ai d b on di ng of a ne w w i nds hi el d g l a s s , make s ur e a t l e a s t 1 m m (0.3 i n) of res i dual a d hes i ve r e mai ns on t he bo dy f l a nge . Us i ng a s ui t a b l e t o o l remov e t he re si dua l a dhe s i v e from t he bo dy f l a nge . Insta llat ion 1. M ake s ure t he ne w wi nds hi e l d g la s s s ur f a c[...]

  • Page 2563

    5. NOT E: Appl y wi nds hi e l d a dhe s i ve W S S -M 2G3 79-A6A o r e qui val ent m e e t i ng Ja gua r s pe ci f i ca ti o n a r o und t he wi nd s hi e l d gl a s s edg e . Us i ng a s ui t a b l e pne umat ic a ppl i cat io n gun, a ppl y a un i f o r m be a d o f a dhe s i v e t o t he w i nds hi el d gl a s s e dge comm e nci ng a t t he bot[...]

  • Page 2564

    10. Remove t he p rote c t i ve t a p e f r om th e w i nds hi el d g l a s s a p e r t ur e. 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Conn ect t he t he h ea t e d wi nd s h ie ld gl a s s e l e ct rical conn ect o r s . 12. Ins t a l l t he A-pi l l a r ext e r i or t r i m. 13. Ins t a l l t he r e ar vi ew mi r r or . For a d[...]

  • Page 2565

    P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Windshi eld Gl ass U s ing Cu tting To o l Re moval a n d I ns t a l l a t i on Speci al T ool (s) Lubr i cant co nc e nt r at e BTB-W K9L S pray b ot t l e BTB-W K9 Cut ti ng t ool BTB-W K10HD S e rr a t ed e x t r a l o ng f la t cut t i ng bl ade BTB-W K1S C S e rr a t ed gene r al p[...]

  • Page 2566

    4. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Di s conn ect t he he a t e d wi nds hi e l d gl a s s e le ctrica l conne ct o r s . 5. Remove t he A-pi l l a r e xt e r i or t rim. 6. Appl y s uit a b l e pr ot ect i ve t a pe a r o und t he wind s hi e ld gl a s s ape rtur e t o pr ot e ct t he p a i nt wo r k. 7. Pl a ce a s ui t a[...]

  • Page 2567

    12. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Us i ng t he cut t i ng t o o l, cut t hrough t he l owe r wi nds hi el d g l a s s a d he s i ve a nd a p pr oxi mat e l y 150 mm (5.9 i n) u p t he A-pi l l a r. 13. Appl y c ut t i ng l ubrica nt t o b ot h s i de s o f t he i nne r A-pil l a r wi nd s hi e l d gl a s s a d he s i ve. 1[...]

  • Page 2568

    19. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Us i ng t he s p e ci a l t o ol cut t hr o ugh a ny r e mai ni ng wi nds hi e l d gl a s s a dhe s i v e o n t he A -pil l a rs. 20. W i t h a s s i s t a nce remov e t he wi nds hie l d gl a s s . At t a c h t he l i f t i ng ha ndl e s t o t he w ind s hi e l d g la s s . 21. Remove t h[...]

  • Page 2569

    3. Appl y gl a s s pr i mer t o th e ma t i ng f a ce o f the bod y f la nge . 4. Cu t t he a dhe s i v e noz z l e t o achi e ve a tria ng ul a r s e ct i on be a d 8 mm (0.31in ) wi de b y 13 mm (0.51 i n) hi gh. 5. NOT E: Appl y wi nds hi e l d a dhe s i ve W S S -M 2G3 79-A6A o r e qui val ent m e e t i ng Ja gua r s pe ci f i ca ti o n a r o u[...]

  • Page 2570

    7. CAU TI O N : Make s ur e t h e wi nds hi e l d gl a s s d oe s not move o ut o f pos i t i on i n t he wi nds hi e l d g la s s a pe r t ur e . App l y s ui t a bl e p rot e ct i ve t a p e t o t he t op o f t he wi nd sh i e l d gl a s s . 8. Remove t he prot e ct i ve ta p e f r o m t he i nner l e a di ng e dge o f t he roof pa nel . 9. Remov[...]

  • Page 2571

    For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 501-09 Re a r Vi e w Mi r r or s . 14. Ins t a l l t he cowl vent s cr ee n. For a dd i t i o na l i nf o r mat i o n, refe r t o S ect i o n 501-02 Fr ont End Bo dy P a ne l s . 15. Ins t a l l t he s un vis or s . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S e cti o [...]

  • Page 2572

    P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Instrum ent Panel Des cr ipt i o n a nd O pe r a t i o n I te m Pa r t Nu m be r Descri pti o n 1 — Le f t h a nd s i de regi s t e r 2 — Ins t rum ent cl us t e r 3 — Ce nt e r r e gi s t er 4 — P as s e nger a i r bag mo dul e 5 — Gl ove bo x 6 — Ri g ht hand si de r eg[...]

  • Page 2573

    P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Floor Co n so le Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D et a ch t he e l e c t r o ni c p as s i ve a nt i -t he ft s ys t e m (PA TS) l i ght . 2. Remove t he P AT S l i g ht . Dis conne ct t he e l e ct r i cal co nnect o r. 3. Remove t he ha nd br ak[...]

  • Page 2574

    5. Remove t he ret a i ni n g s cr ews . 6. Remove t he ce nt e r cons o le t rim pa ne l . 7. Remove t he ce nt e r cons o le t rim pa ne l . 8. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar. Re move t h e r e t a i ni ng s cr e ws . Vehi c le s with autom at ic tra ns m ission JagDocs.com[...]

  • Page 2575

    9. Remove t he J-gat e s ur r ound. Vehi c le s with ma nual tra nsmission 10. Det a ch t he ge a r s e l e ct o r s ur r ound. All v e h icle s 11. Remove t he ret a i ni ng s cr e ws. Vehi c le s with c or dle ss cell ular phone 12. Dis c o nne ct t he b l ue t oot h upgr a de modul e e l e ct rica l co nnect o r . All v e h icle s JagDocs.com[...]

  • Page 2576

    13. Remove t he f l o o r c on s o l e . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2577

    P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Instrum ent Panel Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he cons o l e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a nd Co ns o l e , Re mov al a nd I ns t a l l at i o n). 2. Remo[...]

  • Page 2578

    All v e h icle s 11. Remove t he rig ht ha nd e nd pane l. 1. De ta ch t he f r ont doo r ope nin g we a t he r s t r ip . 2. Re move t he r i ght ha nd e nd pa ne l . 12. Remove s uppo r t pa nel . 13. Remove t he l ow er vent . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 14. Remove t he i ns t r ume nt pa ne l ret a i nin g s[...]

  • Page 2579

    16. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ew. 17. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ews . 18. Remove t he l ef t ha nd e nd p a nel . 1. De ta ch t he f r ont doo r ope nin g we a t he r s t r ip . 2. Re move t he l e f t hand e nd pa ne l . 19. Remove t he l ow er vent . 1. De ta ch t he bu lb ho l der. 2. Re [...]

  • Page 2580

    21. Det a ch t he el e ct r i cal ha r nes s . 22. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ew. 23. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ews . 24. Remove a nd di s car d t he pop r i ve t s. 25. Remove t he i ns t r ume nt pa ne l . Insta llat ion JagDocs.com[...]

  • Page 2581

    1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2582

    P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Overhea d C o nso le Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r o of cons o l e . 2. Remove t he roof co ns ol e . Dis conne ct t he e l e ct r i cal co nnect o r( s ). Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2583

    P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Overhea d C o nso le S w itch Mo ulding Re moval a n d I ns t a l l a t i on R em ova l • NO T E: S o m e va r i a t i on i n t he i l l ust r at i o ns may o cc ur, but the e s s e nt i a l i nf o r m a t i o n i s a l wa ys co r r ect . 1. Remove t he ove r he a d co ns o l e . F[...]

  • Page 2584

    4. CAU TI O N : Make s ur e t h at onl y t he hea d o f t he f i xing i s r e moved . Do no t d r i l l a ny de e pe r t ha n nece s s a ry . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on m a y r es ult i n da mag e t o t he compon e nt . Re move t h e pr i nt e d ci rc ui t boa rd (P CB) co ver . Us i ng a 5mm dr il l b i t, car e f ul l y dr[...]

  • Page 2585

    7. Remove t he f o am pa d. 8. Car ef ul l y remove s unroof roc ker s wi t ch f or r eus e i n t he new r e a r s wit ch m o uld i ng. Insta llat ion 1. S e l e c t t he co r rect s wi t ch moul di ng fo r t he vehi c l e f r om t he pa rts ki t . 2. Remove any unne c e s s a r y s wi t ch but t o ns from t he re ar moul di ng us in g a s ui t a b[...]

  • Page 2586

    8. Ins t a l l the co ver . Ins t al l t he 4 Torx s cr e ws Ti ght e n t o 1. 5 Nm. 9. Ins t a l l the ga r a ge d o o r op ene r modul e . 10. Ins t a l l t he f r ont i nt r us i on s e ns or. 11. Ins t a l l t he ove r he a d cons o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: O ve r hea d Co ns ol e (501-1 2 I nst r um e nt P [...]

  • Page 2587

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - T o rque Sp eci f i cat ions Descri pti o n Nm l b- ft l b- i n Doo r l a t ch act uat o r r e t a i ni ng s cr e ws 7 - 62 Doo r l a t ch s t r i ker r e t a i ni ng bo l t s 25 18 - Doo r e x t e r i o r ha ndl e r e t ai ning s cr e ws 5 - 44 Lug gag e co mpar t men t li[...]

  • Page 2588

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Handles, L ock s, Latc hes and E ntry Systems Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um b e r Desc ri pti on 1 — Rear do o r e xt e r i or ha ndl e 2 — D oo r i nt e r i o r han dl e 3 — G ene ric e l e ct r oni cs modul e (GEM ) 4 — Hood la t ch rel[...]

  • Page 2589

    Item Pa rt N um be r Desc ri pti on 1 - L i f t g at e wi ndow gl a s s r e l e as e s wi t ch 2 - L i f t g at e wi ndow la t ch a ct uat o r 3 - L i f t g at e l a t ch a ct ua t o r 4 - L i f t g at e rel e a s e s wi t ch For most mar ket s e xcl udi ng No rth Ame r i ca a nd Jap a n, t he r e mot e cent ral l o ck i ng s y s t e m i nc o r por[...]

  • Page 2590

    K ey less Entry The i nt e gr at e d k e y remot e t rans mi t t e r op erat e s t he f ol l o wi ng f unct i on s : unl ocki ng th e dr ive r do or unl ocki ng/lo cking a l l do o r s r e l e a s i ng t he l ugga ge co m pa r t ment l i d a c t i va t e/de a ct i va te t he d o ubl e l o ck i ng a r ms /di s a r m s t he a nt i -t he ft al a r m s[...]

  • Page 2591

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Lo cks, Latches and En try Sy stem s Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspect i on C h[...]

  • Page 2592

    1 1 1 1 2 1 1 2 1 Sym tom ( Ge ner a l ) Sym ptom (Speci f i c) P os si bl e S ourc e A c ti on Doo r (s ) fa i l t o op e n An i ndi vi dua l d o o r f ai ls t o o p e n f r om t he e xt e r i o r handl e Exte r i o r r e le a s e ha ndl e fa i lu r e Op e r at i ng rod di s conne cte d /dama ge d P a wl st i cking Check t he pa wl f o r cor r ect[...]

  • Page 2593

    Are a n y of t he cab le s d i sco nnect e d o r d amage d ? Ye s RECTI FY a s nece s s a ry . For a dd i t i o na l i nfo rm at i on, re fe r t o r e mova l a nd i ns t a l l a t i on i n th i s s ect io n. No CARRY OU T fun cti o nal t e s t s us i ng t h e Ja gua r ap pr oved d i a gnos t i c s ys t e m. JagDocs.com[...]

  • Page 2594

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Remote T r ansm itter Programm in g Gene ral P r ocedures 1. NOT E: Al l r e mot e t r a ns mit t e rs a r e pr ogr a mm abl e an d mus t b e pr ogr a mmed a t t he s a me t i me. • NO T E: If a n at t empt i s made t o program a f i f t h remot e t rans mi t t e r a ft e[...]

  • Page 2595

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Exterio r F ront Do o r Handle Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r win do w g la s s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Do o r W i ndow Gla s s (501-1 1 Gl as s , Fr a m e s a nd Mecha ni s m s , R e mo[...]

  • Page 2596

    6. Remove t he f r ont do o r ext e r i or ha ndl e . Insta llat ion 1. NOT E: Ins t a l l ne w f ront do o r s ecur i t y s hi e ld ret a i ni ng cli p s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 5 Nm. 2. Tig ht e n t o 7 Nm. JagDocs.com[...]

  • Page 2597

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F ro nt Do or Lo ck A ctuato r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i on 501-05 Int e r io r Tr i m a nd Orna ment a t io n . 2. CAU TI O N : Do no t t ou ch [...]

  • Page 2598

    6. D i s conne ct t he f r ont d oo r l a t ch a ct ua t o r el e ct r i c a l co nnect o rs. 7. Remove t he f r ont do o r la tch a ctua t o r . 1. De ta ch t he f r ont doo r l a t ch a ct ua t o r r el e a s e c a bl e. 2. Dis con nect t he f ront do o r l a t ch a ct ua t o r r e l e as e ca bl e . 3. Re move t he f r o nt do o r l a t ch a ct [...]

  • Page 2599

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F ro nt Do or Lo ck C y lin der Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r ext e r i or ha ndl e . For a dd i t i o na l i nf or m a t io n, r e fe r t o Ha ndl e —Fr on t Doo r E x t e r i o r . 2. Remove t he do o r l o ck cy l i nde r[...]

  • Page 2600

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F uel Fill er Do or Release Handl e and C able4- Doo r Re moval a n d I ns t a l l a t i on R em ova l • NO T E: T he p r o ce d ur e s ho wn is f or LHD ve hi cl e s . The pr oce dure is s i m i l a r fo r RHD ve hi cl e s . All v e h icle s 1. Remove t he rear s e a t c[...]

  • Page 2601

    8. Repo s i t i on t he f l o o r cove r i ng t o o ne s i de . 9. D et a ch t he r e a r d oo r o pe n in g we a t he r st rip a nd po s i t i o n t o o ne s i de . 10. Repo s i t i o n t he wi r i ng harnes s t o o ne s i de. Loo s e n t he r e t a in ing s cr e ws . 11. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . 12. Det a ch t [...]

  • Page 2602

    Vehi c le s bu ilt up to VI N: J38 978 13. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . 14. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . Vehi c le s bu ilt from VIN :J38 97 9 15. Remove t he l ugga ge co m pa r t ment fl oor covering . 16. Det a ch a nd r e po s i t i o n t he LH rear qua r t e d t r i m pan e l . 17[...]

  • Page 2603

    18. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . 19. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . All v e h icle s 20. Det a ch a nd r e po s i t i o n t he RH re ar qua r t e r t rim pa ne l . 21. Remove t he f u el f i l l e r d oor rel e a s e cabl e. 1. Ro t a t e t he fu e l fi l l e r doo r r el e as e c a bl e[...]

  • Page 2604

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F uel Fill er Do or Release Handl e and C ableWagon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t i[...]

  • Page 2605

    9. D i s conne ct t he s ub wo of e r e ncl os ur e e l e ct rica l co nnect or (i f e qui pp e d). 10. Remove t he s ubwo of e r e nclos ur e (i f e qui ppe d). 11. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . 1. Ro t a t e t he fu e l fi l l e r doo r r el e as e c a bl e cl o ck wis e . 2. De ta ch t he f ue l f i l l e r doo r r[...]

  • Page 2606

    14. Repo s i t i o n t he ca bl e t hr o ugh t he boo t . 15. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he f ue l f i l l e r doo r r e l e a s e ca bl e . Det ach f ue l fi l l e r do or r el e a s e ca bl e . 16. Det a ch fue l f i l l er do o r r e l e a s e ca bl e . 17. Repo s i t i o n t he f l o o r cove r i ng t o o n[...]

  • Page 2607

    19. Remove t he f u el f i l l e r d oor rel e a s e ha ndl e. 1. De ta ch t he f ue l f i l l e r doo r r el e a se c a bl e f rom t he ha ndl e . 2. Re move t he f ue l fi l l er doo r r el ea s e ha nd l e . 20. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he f ue l f i l l e r doo r r e l e a s e ca bl e . Re move t h e fu e[...]

  • Page 2608

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Li ftgate Latch Actuato r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he t a i l ga t e t r i m pa ne l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t ga t e T r i m Pa ne l (501- 05 Int e r io r Tr i m a nd O r na m e nt a t io n, Re mov [...]

  • Page 2609

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Li ftgate Window G las s Release S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear wi nd ow wi per pi vot a r m ret a i ni ng nut c ove r . 2. Remove t he rear wi nd ow wi per pi vot a r m. 3. Remove t he l i f t g a t e wi ndo w gl as s rel e a s[...]

  • Page 2610

    5. Remove t he rear wi pe r m o unt i ng arm cover . 6. Remove t he rear wi pe r m o unt i ng arm . 7. Remove t he l i f t g a t e wi ndo w gl as s rel e a s e s wi t ch. Dis conne ct t he l i f t ga t e wind o w gl a s s r el e a s e s wi t ch e l e ct rical c on ne ct or . Insta llat ion 1. Ins t a l l the l if tg a t e wi nd ow gl as s re le a s[...]

  • Page 2611

    2. Ins t a l l the rear wi p e r mount i ng arm . Ti ght e n t o 8 Nm. 3. Ins t a l l the rear wi p e r mount i ng arm cove r . 4. Ins t a l l the rear wi p e r mount i ng arm cove r r e t ai ni ng nut t r i m covers . 5. Ins t a l l the l if tg a t e wi nd ow gl as s re le a s e s wi t ch r e t a i ni ng nut . Ti ght e n t o 9 Nm. 6. M ake s ure t[...]

  • Page 2612

    7. Ins t a l l the rear wi nd ow wi per pi vot a r m ret a i ni ng nut . Ti ght e n t o 7 Nm. 8. Ins t a l l the rear wi nd ow wi per pi vot a r m ret a i ni ng nut cover . 9. Remove t he l i f t g a t e t rim pa nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t ga t e T r i m Pa ne l (501- 05 Int e r io r Tr i m a nd O r na m e[...]

  • Page 2613

    14. CAUTI O N S : W i t h t he ai d o f a n a s s i s t a nt i n the l oa ds pa ce, f u ll y t i ght e n t he r ea r wip e r mot or r e t a i ni ng nut s . Fa i l ure t o f ol l o w t hi s i ns t ruc t i o n ma y r es ul t i n dama ge t o t he ve hi cl e . Make s ur e t he rear wi p e r mot o r do e s not mov e whi l s t t i ght eni ng t he r e t a[...]

  • Page 2614

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Luggage Com partm ent Lid L atc h Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l ugga g e co mpar t me nt l i d l a t ch a ct uat o r trim pa nel . 2. D i s conne ct t he l u gga ge co mpa r t ment li d l a t ch a ctu at o r e l e ct rica l conne [...]

  • Page 2615

    P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Rear Door Lo c k Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear do or t r i m pa ne l . Fo r add it i o na l i nf orm at i o n, r e f er t o S ect i on 501-05 Int e r io r Tr i m a nd Orna ment a t io n . 2. CAU TI O N : Do no t t ou ch t he a [...]

  • Page 2616

    6. D i s conne ct t he e l ect r i cal conne ct o rs. 7. Remove t he rear do or l a t c h a ct ua t or . 1. De ta ch t he rear do o r l a t ch act uat o r r e le a s e ca bl e . 2. Dis con nect t he r e a r d oor l a tch a ctu a t or rel e a s e cabl e. 3. Re move t he r e a r d oor l a tch a ctua t or. Insta llat ion 1. To i ns t a l l , rever s e[...]

  • Page 2617

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b- i n Fr o nt mount i ng a r m and p ivo t s h af t ret a i ni ng bol t s 8 - 7 1 Fr o nt wi pe r mot o r r e t a i ni ng s cr e ws 8 - 71 Fr o nt wi pe r mot o r s haf t r e t a ini ng nut 18 13 - Fr o nt wi pe r arm ret a i nin g nut s 17[...]

  • Page 2618

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p ers and W ashers Des cr ipt i o n a nd O pe r a t i o n Al l ve hicl e s Item Par t N um be r Desc ri pti on 1 — Mo is t ur e s e ns or 2 — W i pe r pi vot arm s /wip e r bl a des 3 — Mo unt i ng a r m a nd pi vot s haf t 4 — W i nds creen was h e r j e t s 5 — Re s ervoi r 6 — Re [...]

  • Page 2619

    Item P a rt N um ber D e scr i pti on 1 - Re a r wi ndo w wa s he r je t 2 - Re s e r voi r 3 - W i nds he i l d a nd rea r w i ndow wa s her mot o r 4 - Re a r wi ndo w wi pe r m ot o r 5 - Re a r wi pe r mount i ng a r m 6 - Re a r wi ndo w wi pe r pi vot a rm /wip e r b l a de The r ea r wi pe r an d wa s he r sys t e m cons i s t o f t he f o l[...]

  • Page 2620

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p ers and W ashers Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Vi sual Inspect i on C h art Mech a ni c al El ectri cal W i p e[...]

  • Page 2621

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Headlam p Wash er P um p Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to S ect i o n 204-04 W hee l s a nd T ire s . 2. D et a ch t he wh ee l a r ch l i ne r . 3. Remove t he unde r t r a y. For a dd it i [...]

  • Page 2622

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Rain S ensor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i nt e r i o r r e a r vi e w mi rr o r . Fo r ad di t i ona l i n fo r mat i on, refe r t o S ect i o n 501-09 Re ar Vi e w Mi r r or s . 2. Remove t he moi s t ur e s ens o r . 1. Dis con nect t he moi s t ur e s e ns o r[...]

  • Page 2623

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Rain S ensor Module Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cowl s i de t rim pa ne l . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S ect i on 501-05 Int e r io r Tr i m a nd Orna ment a t io n . 2. Remove t he rai n s e ns or modul e. 1. Dis con nect t he r a in[...]

  • Page 2624

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Rear Windo w Wiper Motor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l i f t g a t e t rim pa nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t ga t e T r i m Pa ne l (501- 05 Int e r io r Tr i m a nd O r na m e nt a t io n, Re mov al a n d I ns t a l l a t i [...]

  • Page 2625

    1. NOT E: Do not t i ght e n t he r ea r wind o w w i pe r mot or ret a i ni ng nut s a t th i s s t a ge . I nst a l l t he r e a r wi ndow wip e r mot o r. 2. Connect t he rea r wi nd o w wi per mot o r e l e ct rical conn ect o r . 3. NOT E: Do not t i ght e n t he l i ft gat e wi ndo w gl a s s a c t ua t o r r et a i ni ng bo l t s a t t hi s [...]

  • Page 2626

    6. M ake s ure t he r e a r wip e r m oun ti ng a r m i s i n t he pa r ked po s it i o n. 7. NOT E: The a i d o f a n a s si s t a nt in t he l o ads pa ce wi l l be r eq ui red t o a l ig n th e r ea r wi pe r mot or t o t h e l i ft ga t e wi nd o w gl a s s . Make s ur e t ha t t he l i ft gat e gl a s s l a t ch a nd rear wi per mount i ng a r[...]

  • Page 2627

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d and Rear Wi ndow Washer Pump Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he right -ha nd front whe e l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 2. D et[...]

  • Page 2628

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d Was her Pump Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to S ect i o n 204-04 W hee l s a nd T ire s . 2. D et a ch t he wh ee l a r ch l i ne r . 3. Remove t he wa s he r pump . 1. Dis con n[...]

  • Page 2629

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d Was her Reservoir Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ABS e l e ct r i cal co nnect o r. 2. D et a ch t he A BS modul e . 3. Remove t he ABS modul e s u pport brack e t ret a i ni ng b ol ts . 4. Remove t he ABS modul e s u pport brack e t . JagDocs.c[...]

  • Page 2630

    5. Remove t he res e rv o i r fi l l e r ne ck . 6. Remove t he f r ont bu m pe r cover . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o S ect i o n 501-19 Bumpe r s . 7. D i s conne ct t he he a dl a mp w as he r s uppl y hos e . 8. Remove t he res e rv o i r . 1. Dis con nect t he wa s he r pump, hea d l amp wa s her pump and f l ui d l e [...]

  • Page 2631

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d Wi per M o to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he mount i ng a rm a nd pi v ot s ha ft a s s e mbl y. For add i t i o na l i nf o r ma t i o n, r e f e r t o Mount i ng Arm an d P i v o t S haf t . 2. Remove t he wi p er mot o r . Insta llat ion 1. To i ns [...]

  • Page 2632

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p er Mou nting Arm a nd Pivot Shaft Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he pl enum cove r . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S e ct i on 501-02 Fr ont En d B od y P a ne l s . 2. D et a ch t he mount i ng arm a nd pi vot s ha ft as s e m bl y. 3. Remove[...]

  • Page 2633

    P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p er Pivot Arm Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover - wi nd s cr ee n wi pe r 501-065 R em ova l 1. Remove t he wi p er arm nut co vers 2. Remove t he wi p er arm nut s . 3. Usi ng t he s pe cia l t oo l , de t a ch th e w i pe r arm s . 4. Remove t he wi p er arm s J[...]

  • Page 2634

    Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 17 Nm. JagDocs.com[...]

  • Page 2635

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b- i n Roo f o pen ing pa ne l frame ret a i ni ng bo l t s 9 - 80 Roo f o pen ing pa ne l br a ck et re t a i ni ng b ol t s 9 - 80 Roo f o pen ing pa ne l mot or ret a i ni ng bo l t s 3 - 27 Roo f o pen ing pa ne l gl a s s r et a i ni [...]

  • Page 2636

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Des cr ipt i o n a nd O pe r a t i o n Item Pa rt Nu mb e r Descri pti on 1 — Roof o pe ni ng pa ne l s hi e l d 2 — Lif t e r a rm s 3 — Air de f l e ct o r 4 — Roof o pe ni ng pa ne l fra m e 5 — Roof o pe ni ng pa ne l mot or 6 — Roof o pe ni ng pa ne l g la [...]

  • Page 2637

    - Th e roof op e ni ng gl a s s wi l l cl o s e unt i l the roo f op e ni ng pa ne l s wi t ch i s pres s e d i n a ny di rect i o n o r t he r oo f o p eni ng gl a s s r ea che s t he f ul l cl os e d po s i ti o n. P r e s s t he r e a r of the swi t ch t o t he f i rst d e t ent wi t h t he r o of o pe nin g gl a s s i n a ve nt up p os i t io n[...]

  • Page 2638

    * * * * * * * P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Dia gn os i s a nd Te s t i ng Principles of Ope ra tion Roof Op en ing Pan el Control Modu le Ba t t e r y po we r i s cont i nuo us l y s uppl i e d t o t he r o o f op eni ng pane l co nt r ol mod ul e . Ho w e ve r , t he r oo f o p eni ng pa nel wi l l o [...]

  • Page 2639

    * * * * * * * * * * * * * * * * * * * * * * * 1 2 1 1 1 1 1 1 The roof o pe ni ng p a ne l i s no i s y du r i ng o pera ti o n Ro o f ope ni ng p a ne l gl a s s . Roo f ope n ing p a ne l . Roo f ope n ing p a ne l mot o r . GO t o Pi npoi nt T es t C. The roof o pe ni ng p a ne l d oe s n ot op en o r c l o s e Ro o f op e ni ng pa ne l . Roo f [...]

  • Page 2640

    1 1 1 1 No GO t o C3 . C 3: C HEC K T HE R O OF O PE NI NG PAN EL MO T O R Cycle t he r o of o pe nin g g l a s s f r om t he ful l -ope n t o t he ful l -cl o se d pos i t io n. Doe s t he r o of o pe ni ng pa n el mot or make e xc e s s i ve no i s e ? Ye s CHECK t he r o of o pe n in g p a ne l mot o r for cor r e ct mo unt i ng. If ne ce s s a [...]

  • Page 2641

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Mot or Synchroniz atio n Gene ral P r ocedures Ne w R oof Ope n ing Pan e l Motor Synch roniza tion Procedure • NO T E: T he roof op e ni ng pa ne l a nd r o of ope ning p a ne l mot o r m us t be i n st a l l ed a nd t h e roof ope n in g pa ne l a l i gnmen t checked p r i o r t o s ynchr o [...]

  • Page 2642

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel A li gnment Gene ral P r ocedures 1. Pl a ce a s ui t abl e 1.0 - 1.2 mm t h ick p la s t i c s p a cer be t we e n t he roof op e ni ng pa ne l a nd t he roof p a ne l . 2. Adjus t t he r e ar e dge o f t he r o o f op e ni ng pa ne l . 1. Lo os e n t he r ea r s cr ews o [...]

  • Page 2643

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Air Deflec to r Re moval a n d I ns t a l l a t i on R em ova l 1. M ove t he roof ope nin g p a ne l gl a s s ful l y rearwar d. 2. D et a ch t he a i r de f l e ct or. 3. Remove t he a i r de f l e ct or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2644

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Li fter Arms Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roof o pe n in g p a ne l gl a s s . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o Roo f O pen i ng P ane l Gla s s . 2. D et a ch t he cont r ol a r m . 3. Remove t he l i f t e r a r m r et a in i ng p la t e [...]

  • Page 2645

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel C ontro l S wit ch Re moval a n d I ns t a l l a t i on 1. Remove t he ove r he a d co ns o l e . Fo r a ddi t i ona l i nfo r m at i o n, r ef e r t o S ect i o n 501-12 Ins t r ument P a nel a nd Co ns ol e . JagDocs.com[...]

  • Page 2646

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Drain H os e Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r q uarte r t r i m pa ne l . 2. D et a ch t he drai n hos e f r o m t he r et ai ni ng cl i p. 3. D et a ch t he drai n hos e f r o m t he gr omm e t . 4. Remove t he he a dl i ne r. For a[...]

  • Page 2647

    6. Remove t he drai n ho s e. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

  • Page 2648

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Fra me Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roof o pe n in g p a ne l gl a s s . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o Roo f O pen i ng P ane l Gla s s . 2. D et a ch t he r o of o pen i ng p ane l s hi e l d. 1. P o si t i on t he[...]

  • Page 2649

    7. D et a ch t he r o of o pen i ng p ane l r ea r dr a i n ho se s . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . 8. D et a ch t he r o of o pen i ng p ane l frame . 9. Remove t he roof o pe n in g p a ne l frame ret a i ni ng br acket s. Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . 10. CAUT I O N: T ake ca [...]

  • Page 2650

    12. Remove t he roof o pe ni ng pa ne l m o to r. 13. Remove t he a i r de f l e ct o r . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . 14. Det a ch t he cont rol a r m s . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . 15. Remove t he l i f t e r a r m ret a i ni ng pl a te s . Rig ht -ha nd s i d e s ho wn, l [...]

  • Page 2651

    17. Remove t he l i f t e r a r ms . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 9 Nm. 2. Tig ht e n t o 9 Nm. 3. Tig ht e n t o 9 Nm. 4. Tig ht e n t o 3 Nm. JagDocs.com[...]

  • Page 2652

    5. CAU TI O N : If mot o r os ci ll a t i o n i s de t e ct e d , l o o s e n t he mot o r s cr ews , o p e r at e t he r o o f op e ni ng pa ne l , th e n ret i ght e n t he mot o r s cr ews . If ne ce ss a r y r ep e at t hi s pr ocedu r e . S ync r oni z e t he r oo f o peni ng pan e l mot o r . Re fe r t o Mot or S y nchr oni z at i o n —Ca l[...]

  • Page 2653

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Gl ass Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Make s ur e t he roof o p e ni ng pa ne l gl a ss i s i n t he cl o s e d po s i t i o n. 1. Remove t he roof o pe n in g p a ne l gl a s s s cr ew s. 2. Remove t he roof o pe n in g p a ne l gl a s s . Inst[...]

  • Page 2654

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . Fo r a ddi t i ona l i nfo r m at i o n, r ef e r t o S ect i o n 501-12 Ins t r ument P a nel a nd Co ns ol e . 2. D et a ch t he r o of o pen i ng p ane l mot or. 3. Remove t [...]

  • Page 2655

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Shi eld Re moval a n d I ns t a l l a t i on R em ova l 1. Parti a l ly o pe n t he r o of o pe nin g p a ne l . 2. D et a ch t he f ront o f t he r o o f o pe ni ng pa ne l s hi e l d. 1. P o si t i on t he cent e r of t he roof o pe n in g p a ne l s hi e l d do wnwa r ds[...]

  • Page 2656

    P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Weatherstrip Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roof o pe n in g p a ne l gl a s s . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o Roo f O pen i ng P ane l Gla s s . 2. Remove t he roof o pe n in g p a ne l gl a s s s e a l . Insta llat [...]

  • Page 2657

    P ubl i s he d: 11-May-2 011 B umpers - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Fr o nt b umper cover uppe r s e cur ing bo l t s 7 5 - Fr o nt b umper cover s i d e s e cur ing bo l t s 7 5 - Re a r b ump e r cover s i de s e cur i ng nut s 7 5 - Re a r b ump e r cover s e cur i ng nut s 7 5 - Re a r b ump e r s e cur ing b[...]

  • Page 2658

    P ubl i s he d: 11-May-2 011 B umpers - Bum pers Des cr ipt i o n a nd O pe r a t i o n Thi s ve hi cle i s f it t e d w i t h a cha s s is mount e d a l umi ni um be a m a nd i s c ove r ed b y a on e pi e ce col o r co-o r di na t e d f ront bum pe r cover whi ch in cor po r at e s t he en e rg y a bs o r bi ng f o a m . Th e bu m pe r cons t r u[...]

  • Page 2659

    P ubl i s he d: 11-May-2 011 B umpers - F ron t B umper Co v er Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he radi a t o r s pl a s h s hie ld r et ai ni ng bo l t s . 2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Det ach t he whe e l a r ch l i ne r . 3. D i s conne ct t he bumpe r wi ring ha rn es [...]

  • Page 2660

    5. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . App l y s ui t a bl e t a p e t o t he b ump e r cover t o prevent da mage t o t he bumpe r c o ver . 6. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Re po s i t i o n t he hea d la mp wa s hers t o t he f ul l y o pe n po s i t i o n. 7. NOT E: Le f t -hand s ho wn, r i ght [...]

  • Page 2661

    9. CAU TI O N : Make s ur e t h e bu m pe r c o ver i s s up porte d bef or e r e m o ving th e s e cur ing bo l ts . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re move t h e bu m per cove r . Re mov e t he b umper cover s e cur ing b ol t s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o[...]

  • Page 2662

    P ubl i s he d: 11-May-2 011 B umpers - F ron t B umper Co v er Insert Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont bu m pe r cover . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o S ect i on 501-19 Bumper s . 2. Remove t he e ne r gy a bs or bi ng fo a m. 1. Re move t he e ne rgy a bs o rbi ng f o a m r et a i ni n[...]

  • Page 2663

    P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per4- Door Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a dd i t i o na l i nf orm a t i o n, r e fe r t o Bumpe r Cover—Rea r . 2. Remove t he bumpe r i ns ul a t or. 3. Remove t he rear bumper. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l p[...]

  • Page 2664

    P ubl i s he d: 11-May-2 011 B umpers - Rear Bum perWag o n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Bumper Cove r - W a go n (501-1 9 Bumpe r s , Re moval a nd I ns t a l l a t i on). 2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . [...]

  • Page 2665

    P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co ver4- Door Re moval a n d I ns t a l l a t i on R em ova l All Ve hicles 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. D et a ch t he r e a r whe el a rc h l i ne r. Rig ht -ha nd s i d e s ho wn[...]

  • Page 2666

    7. D i s conne ct t he e l ect r i cal conne ct o r. All v e h icle s 8. D i s conne ct t he e l ect r i cal conne ct o r. 9. D et a ch t he gromm et . 10. Det a ch t he s i d e o f t he b umper cover. JagDocs.com[...]

  • Page 2667

    11. Det a ch t he s i d e o f t he b umper cover. 12. CAUT I O N: Ma k e s ure t he bumper cover i s s up porte d be f o r e r e m o ving th e s e cur ing nut s. Re move t h e bu m per cove r se cur i ng nut s . 13. Remove t he b umper cover . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n t o 7 Nm. 3. Tig [...]

  • Page 2668

    4. Tig ht e n t o 7 Nm. 5. Tig ht e n t o 7 Nm. JagDocs.com[...]

  • Page 2669

    P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co verWa go n Re moval a n d I ns t a l l a t i on R em ova l All Ve hicles 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. NOT E: Ri g ht -hand s ho wn, l [...]

  • Page 2670

    7. D et a ch t he l o a d s p ace f lo o r covering. 8. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt ret a i ni ng screw. 9. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt . 10. Det a ch t he modul e ret a i ni ng brack e t . 11. Dis c o nne ct t he na vi ga t i o n s y s t e m module e l e ct rica l con [...]

  • Page 2671

    12. Dis c o nne ct t he co mpact d i sc (CD) change r e l e ct r i cal c onn e cto r s (i f e qui pp e d). 13. Dis c o nne ct t he vo i ce a ct i vat e d cont r o l (VACM) modul e e l e ct r i ca l conne ct ors (i f e qui p ped ). 14. Dis c o nne ct t he ce l l ul a r pho ne mod ul e e l e ct rica l co nnect o r s (i f e qui pp e d). 15. Det a ch t[...]

  • Page 2672

    17. Det a ch t he r igh t -ha nd l oa d s p ace s i de t rim p a nel . 18. Remove t he rig ht -ha nd l o a d sp a ce s i de t rim p ane l . 19. Dis c o nne ct t he s ubwo of e r e nclos ur e e l e ct rical conn ect or (i f e q ui pp e d) . 20. Remove t he s ubwo of e r e nclos ur e (i f e qui ppe d). 21. Det a ch t he bumper cover. JagDocs.com[...]

  • Page 2673

    22. CAUT I O N: Ma k e s ure t he bumper cover i s s up porte d be f o r e r e m o ving th e ret a i ni ng nut s . Re move t h e bu m per cove r r e ta i ni ng nut s . Vehi c le s with park ing aid 23. Dis c o nne ct t he e l e ct r ica l conne ct o r . 24. Det a ch t he gr o m met . All v e h icle s 25. Remove t he b umper cover . Insta llat ion 1[...]

  • Page 2674

    2. Tig ht e n t o 4 Nm. 3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. 5. Tig ht e n t o 4 Nm. 6. Tig ht e n t o 4 Nm. JagDocs.com[...]

  • Page 2675

    7. Tig ht e n t o 8 Nm. JagDocs.com[...]

  • Page 2676

    P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co ver Insert4-D oo r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i on 501-19 Bumper s . 2. Remove t he e ne r gy a bs or bi ng fo a m. 1. Re move t he e ne rgy a bs o rbi ng f o a m r et a i ni ng [...]

  • Page 2677

    P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co ver InsertWagon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Bumper Cove r - W a go n (501-1 9 Bumpe r s , Re moval a nd I ns t a l l a t i on). 2. D et a ch t he bumpe r cov e r i ns e rt. 3. U[...]

  • Page 2678

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - T o rque Sp eci f i cat ions Desc ri pti on N m l b- f t l b -i n Fr o nt s a fe t y be lt b uck l e a nd pr et en s i o ne r r e t a i ni ng bol t 50 37 - Fr o nt s a fe t y be lt l o we r a nchor r et a i ni ng bol t 55 41 - Fr o nt s a fe t y be lt u ppe r r et a i ni ng bo l t 25 18 - Fr o nt [...]

  • Page 2679

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Safety Be lt System Des cr ipt i o n a nd O pe r a t i o n • W ARNINGS : To a voi d accid e nt a l de pl o y ment a nd po s s i bl e pe rs ona l i nj ur y, t he backup pow er s up pl y mus t be de p l e t e d b e fo r e r ep a i r i ng o r r epl aci ng a ny a i r ba g o ccupant r e s trai nt s s[...]

  • Page 2680

    (gene r i c e l e ct roni c modu le ) ) o f an i nt erm i t t e nt t one wi ll s t a rt or r e s ume a ccompani e d by t he s e a t be l t wa r ning la mp f l a s hi ng i n t he in s t r um en t clus t e r . T he i nt e r mit t e nt t o ne a nd f l a shi ng l a mp wi l l l a s t f o r 10 s e cond s , f o l l ow ed by a 10 s e cond pe riod wi t h no[...]

  • Page 2681

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Safety Be lt System Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e . 2. Vi sual i ns pecti on Damag e d/f r a ye d we b bi ng Damag e d buck l e s Damag e [...]

  • Page 2682

    cor r e ct b y l oo s e ni ng t he r e t a i ni ng bol t , a l i gni ng t he r et r act o r t o ce nt ral i z e t he s a fe t y bel t we b bi ng a nd ret i ght e n t he bol t . The vehi cl e i s e qui ppe d wit h t wo f r o nt a nd t hree r ea r i ne rti a r ee l s a fe t y b el ts . T he se s a f e t y bel t s a re dual s ensi ti ve w hi c h mea n[...]

  • Page 2683

    1 2 3 4 5 6 7 8 DT C C ondi ti o n Poss i bl e s ource Ac ti on pr et e ns i one r circ ui t fa u lt s qu i b t e s t s , GO t o P i npo i nt T e s t E. Fla s h co d e 38 - dr i ver s i de P I D $595 4/5961 (bit 7) B2292 Safe t y be lt r ee l pr et e ns i one r circ ui t fa u lt Ret r act or pret e ns i o ne r c i r cuit ; ope n c i r cuit For dr i[...]

  • Page 2684

    1 2 3 4 5 6 1 1 1 1 1 1 2 3 Ar e t h e r e a ny DTCs a nd/or f la s h co de s se t wi t h t he s i mula t o r( s ) i n p la ce ? Ye s GO t o A 2 . No INS TA LL a ne w pr e t e ns i o ne r . REFER t o : Safe t y Be lt B uck l e a nd P r e t e ns i one r (501-20 A S a fe t y Bel t Sy st e m, Re moval a nd I ns t a l l a t i on). CLEAR t he DT C, t e [...]

  • Page 2685

    4 5 6 7 8 1 2 3 4 5 6 1 1 1 1 1 1 Conne ct t he s i mula t or i n pl a ce of t he p r e t e ns i o ne r . Re conne ct t he b a t t e r y ne g a t i ve te r mina l . Cle a r th e DTC. Tur n t he i gn i t i on s w i t ch t o t he O N po s i t i o n. Re check t he DTCs an d fl a s h co de s. Ar e t h e r e a ny DTCs a nd/or f la s h co de s se t wi t [...]

  • Page 2686

    2 3 4 5 1 1 1 1 1 2 3 4 5 1 W a it o ne mi nut e f o r t he ba cku p pow er s u ppl y t o de p l e t e. Di s c onn e ct t he RCM c on ne ct or , For ve hi c l e s wi t h 2. 0L e ngi ne; CA165. For ve hi c l e s wi t h 2. 5/3.0L en gi ne ; CA450. Di s c onn e ct t he dr i ver s a f e t y be l t s wi t ch co nnect o r, CA 65. Mea s ur e t he res i s [...]

  • Page 2687

    1 1 1 1 2 3 4 5 6 7 8 1 2 3 4 5 1 I s t he r es i s t a nce l e s s t ha n 10,000 o hms? Ye s REP AI R t he sh ort c i r cuit . For a ddi t i o na l i nfo rm at i o n, r ef e r t o t he wiring di a grams. Cl e a r t he DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n. No GO t o D3 . D3: C HECK T H E PAS SENGER SA FET Y BELT SWIT C H S UPP[...]

  • Page 2688

    1 1 1 1 1 2 3 4 5 6 7 8 1 2 3 4 5 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . Cl e a r t he DTC, t e s t t he s ys t e m fo r n or mal o pe r a t i o n. No GO t o E4 . E4: CHEC K T HE R ET R AC T O R PR ET ENSI[...]

  • Page 2689

    1 1 1 1 1 1 2 3 1 1 1 1 No GO t o F3 . F3: C HEC K T HE RE T R ACT OR PR ET E NS IONER GR O UND CI RC UIT F O R H IGH RE SI ST AN CE Mea s ur e t he res i s t a nce b e t we e n CA422, pi n 03 (B R) a nd t he RCM conne ct o r, pi n 38 (BR). I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For[...]

  • Page 2690

    1 1 1 1 GO t o G6 . G6: CHEC K T HE BELT T ENSI ON SEN SOR GR O UND CI R C UI T FOR S HOR T C IRC UI T T O BA T T ER Y Meas ur e t he res is t a nce b e t we e n W S 1 9, p i n 03 (G) and t he ba t t e ry p os i t i v e t e rm ina l . I s t he res i s t a nce l e s s t ha n 10, 000 ohms? Ye s REPAI R t he s hor t cir cui t . For a dd i t i o na l i[...]

  • Page 2691

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - F ront Safety Bel t Retractor Re moval a n d I ns t a l l a t i on R em ova l • NO T E: T he f r o nt s e a t be l t s , whi ch i ncor po r at e t he s e at be l t r e t r a cto r s a nd p r e te ns i o ne r s are s up pl i e d a s an a s s e m bl y and no t s e r vi cea bl e compone nt s . • [...]

  • Page 2692

    Insta llat ion • NO T E: T he f r o nt s e a t be l t s , whi ch i ncor po r at e t he s e at be l t r e t r a cto r s a nd p r e te ns i o ne r s are s up pl i e d a s an a s s e m bl y and no t s e r vi cea bl e compone nt s . • NO T E: Re p ai r is made by r e pl a ce ment o nl y. If a part is rep l a ced and t he ne w p art d o es not co r [...]

  • Page 2693

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - F ront Safety Bel t Sho ulder Hei g ht Adj uster Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he uppe r B-pil l a r t r i m pa ne l fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on . 2. D et a ch t he s a f e ty b e l [...]

  • Page 2694

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r C enter Safety Belt Retra cto r4-Door Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Re p ai r is made by r e pl a ce ment o nl y. If a part is rep l a ced and t he ne w p art d o es not co r r ect t he con di t i on, ins t a l l t he o r i gi na l pa rt a nd carr y o ut t he di[...]

  • Page 2695

    2. Tig ht e n t o 55 Nm. 3. NOT E: Make s ure t he an t i r ot a t i on pi ns o n t he bo dy a nd s a f e t y b e l t a nchor pl a t e a r e l o c a t e d corr e ct l y be fo re t ig ht e ni ng the bo l t . Ti ght e n t o 55 Nm. JagDocs.com[...]

  • Page 2696

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r C enter Safety Belt Retra cto rWago n Re moval a n d I ns t a l l a t i on R em ova l 1. D i s a s s e mble t he r e a r se a t ba ck res t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Ba ck r e st - W a go n, Ve hi cl e s W it h: 70/30 S pl i t S e a t (501-10 S [...]

  • Page 2697

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r Safe ty Belt Bu ckle Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S ect i o n 501-10 S e at in g . 2. Remove t he l e ft -hand rear s a fe t y be lt b uck l e s . Re mov e t he re ta i ni ng bo l t [...]

  • Page 2698

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r Safe ty Belt Retractor4-Door Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Re p ai r is made by r e pl a ce ment o nl y. If a part is rep l a ced and t he ne w p art d o es not co r r ect t he con di t i on, ins t a l l t he o r i gi na l pa rt a nd carr y o ut t he di a gno s [...]

  • Page 2699

    1. To i ns t a l l r evers e t he r emova l pr oced ure. Ti ght e n t o 55 Nm. 2. Tig ht e n t o 55 Nm. JagDocs.com[...]

  • Page 2700

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r Safe ty Belt RetractorWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce t rim p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L o ads pa ce T r im P a ne l (501-05 I nt e r i o r Tr im a nd O rname nt a ti o n, Re m o val a nd Ins t al l [...]

  • Page 2701

    2. Tig ht e n t o 55 Nm. JagDocs.com[...]

  • Page 2702

    P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Safety Be lt Bu ckl e and Pr etensio n er Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : To a voi d accid e nt a l de pl o y ment a nd po s s i bl e pe rs ona l i nj ur y, t he backup pow er s up pl y mus t be de p l e t e d b e fo r e r ep a i r i ng o r r epl aci ng a ny a i r b[...]

  • Page 2703

    6. Remove t he s a f e t y be l t buckl e a nd pr e t e nsi one r. Re mov e t he re ta i ni ng bo l t . Insta llat ion • W ARNINGS : To a voi d accid e nt a l de pl o y ment a nd po s s i bl e pe rs ona l i nj ur y, t he backup pow er s up pl y mus t be de p l e t e d b e fo r e r ep a i r i ng o r r epl aci ng a ny a i r ba g O RS compone nt s .[...]

  • Page 2704

    [...]

  • Page 2705

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Air Ba g Supplemental Restrain t System (SRS) Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: A l l pyr ot e chni c de vi ces a r e da nge r o us . B e f o r e pe rfor ming a ny p r o ce d ur es o n a ny pyr ot echni c de vice , r e a d a l l i nfo r mat i on cont a i ne d wi t hi n [...]

  • Page 2706

    The pr i mar y purpos e o f t h e res t r ai nt s cont rol s ys t e m i s t o di s cr i mina t e be t we e n a n e vent t hat wa r r a n ts s upp l e ment a l res t rai nt s s yst e m de p lo yment a nd a n e vent t ha t doe s no t . T he a i r ba g cont r o l modu le , l oca t e d unde r t he f l oo r cons o l e, g ove r ns t he o pe r at i o n of[...]

  • Page 2707

    The s e at t r ack po s i t i o n s e ns or: The s e at t r ack po s i t i o n s e ns or i s l o ca t e d o n t he d river s e a t t r a ck. The s e a t p o si t i o n s e ns o r de t e rm ine s t he po si t i o n o f t he dr ive r s e a t , which i s t hen com muni c a t e d t o t he r es t r a i nt s cont r ol modul e . If t he dr i ver s e a t i[...]

  • Page 2708

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Air Ba g Supplemental Restrain t System (SRS) Dia gn os i s a nd Te s t i ng Principle of oper at ion The S RS is a n in t e ll i ge nt s ys te m , i n t hat i t de pl o ys t he a p pr op r i a te a i r bag mo dul e f o r any i mpact e ve nt , b a s e d o n i nf or mat io n prov i de d [...]

  • Page 2709

    W a rning l i ght ON s o l i d f o r s i x s e conds . W a rning l i ght goe s o f f fo r t wo s e c o nds . W a rning l i ght fl as he s t he a ppr o pr ia t e numbe r of t i m e s fo r t he f aul t l o gge d (s e e be l o w). W a rning l i ght goe s o f f fo r t wo s e c o nds . The s e quence i s r e pe a t e d f i ve t i mes . W a rning l i ght[...]

  • Page 2710

    DT C / Fl a sh cod e C o ndi ti on Poss i bl e s ource Acti on B2294 Cur t a i n ai r bag circ ui t s t a t us fa ul t Pa s s e nge r cur t a i n ai r ba g ci r cui t; st a t us fa ul t For cur ta i n a i rb a g ci r cuit t e s t s , GO t o P i npo i nt T e s t D. Fla s h co d e 25 - pa s se nge r B2295 S id e ai r ba g ci rcu i t s t at us f aul t[...]

  • Page 2711

    1 2 3 4 5 1 2 1 2 1 2 1 2 1 2 DT C Co ndi ti on P ossi bl e sou rce Act i on B2290 O cc upant cl a s s i f i ca t i on se n s o r (O CS ) s yst e m f a ul t OCS modul e communicat io ns f aul t For communica ti on ci r cuit t e s t s , GO t o P i npoi nt T e s t N. For more d e t a i l e d CA N ci rcu i t t e s t s , REFER t o : Communicat i o ns N[...]

  • Page 2712

    1 1 2 3 4 5 6 7 1 2 3 4 5 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . Cle ar t he DTC, t e s t t he s yst em f o r norm al ope rat i on. No GO t o B 5 . B5: C HEC K T HE PAD LAM P T R IGGER CIRC U I[...]

  • Page 2713

    1 2 1 1 2 3 4 5 6 7 1 2 3 4 I P 37, pi n 01 (RW ) a nd t he RCM co nnect or , pi n 13 (RW ) I P 37, pi n 02 (BW ) a nd t he R CM connect or, pi n 14 (BW ) Are a n y of t he r e s i s t a nce s gr ea t e r t ha n 5 o hms ? Ye s GO t o C4 . No I NS TALL a ne w RCM. REFER t o : Re s t r ai nt s Co nt rol Modul e (RC M) (501-20B S uppl e ment a l Re s [...]

  • Page 2714

    5 1 2 3 4 5 6 7 1 2 3 4 5 CA450. Mea s ur e t he res i s t a nce b e t we e n: For fl a s h code 24 The RCM conne ct o r , p i n 03 (RW ) a nd CA 144, p i n 01 (RW ) The RCM conne ct o r , p i n 04 (B W ) a nd CA144, p i n 02 (B W ) For fl a s h code 25 The RCM conne ct o r , p i n 05 (RW ) a nd CA 145, p i n 01 (RW ) The RCM conne ct o r , p i n 0[...]

  • Page 2715

    1 2 3 4 5 6 1 2 3 4 1 1 2 3 4 5 6 1 2 3 I NS TALL a ne w RCM. REFER t o : Re s t r ai nt s Co nt rol Modul e (RC M) (501-20B S uppl e ment a l Re s t rai nt S y s t e m, Re moval a nd I ns t a l l a t i o n). Cl e a r t he DT C, t es t t he s ys t e m f o r n or mal o perat i o n. PINPOIN T TE ST F : B 22 96 (F LASH COD E 42) : FRO NT IMPAC T SENSO[...]

  • Page 2716

    4 1 1 2 3 4 5 6 1 2 3 4 1 For ve hi c l e s wi t h 2. 5/3.0L en gi ne ; CA450. Mea s ur e t he res i s t a nce b e t we e n CA215, pi n 02 (W ) a nd t he RCM conne ct o r , p i n 27 (W ). I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he [...]

  • Page 2717

    1 2 3 4 5 6 1 2 3 4 1 1 2 3 4 5 6 1 2 3 W ARNI N G: T o a voi d a cci den t a l de p lo yment a nd po s s i bl e pe r s o na l i nju r y , t he ba ckup po w e r s uppl y mus t b e de pl e t e d be f or e repa i r i ng or r ep l a cing any ai r b ag SRS compone nt s . To de p le t e t he b ackup po we r s uppl y e ne r g y, di s conne ct t he ba t t[...]

  • Page 2718

    1 2 3 4 5 6 7 8 1 2 3 4 5 1 1 1 2 3 4 5 W ARNI N G: T o a voi d a cci den t a l de p lo yment a nd po s s i bl e pe r s o na l i nju r y , t he ba ckup po w e r s uppl y mus t b e de pl e t e d be f or e repa i r i ng or r ep l a cing any ai r b ag SRS compone nt s . To de p le t e t he b ackup po we r s uppl y e ne r g y, di s conne ct t he ba t t[...]

  • Page 2719

    1 1 1 1 1 2 3 4 5 1 1 1 No GO t o L 2 . L2: CHEC K T HE DRI VER SEAT T R ACK PO SI T ION SEN SOR S UP PLY CIRC UIT FOR SHOR T CI R C UIT T O BA T T ER Y Mea s ur e t he res i s t a nce b e t we e n CA65, p in 20 (U ) a nd t he b a t t e r y p o s i t i ve t e r mi nal . I s t he r es i s t a nce l e s s t ha n 10,000 o hms? Ye s REP AI R t he sh or[...]

  • Page 2720

    1 1 2 3 4 5 1 1 2 1 1 1 1 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . Cl e a r t he DTC, t e s t t he s ys t e m fo r n or mal o pe r a t i o n. No GO t o M5 . M5: C HEC K T HE PASSEN GER SEA T T R ACK POSIT IO[...]

  • Page 2721

    1 1 1 1 1 2 1 No GO t o N8 . N8 : CHEC K T HE 5V C IRC U IT BET W EEN T HE OC S A ND T HE SEAT T R ANS DUCE R FOR S HOR T C IRC UI T T O GR O UND Mea s ur e t he res i s t a nce be t we e n W S 17, pi n J (W ) and GROU ND. I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t ci r cuit . For a ddi t i o na l i nfo rm at i[...]

  • Page 2722

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Air Ba g Dispos al Gene ral P r ocedures Deployed A ir Ba g 1. W ARNING: A l wa ys wea r s a fe t y g la s s es when r e pa i ring a n a i r b ag s uppl e men t a l r e s t rai nt s y s t e m (S RS ) v e hi cl e a nd whe n ha ndl i ng a n a i r ba g m o dul e . Fai l ure to fo l l o w t[...]

  • Page 2723

    8. W ARNING: Be f ore p roc e e di ng , make s ur e precaut i o ns have be e n ta ke n t o wa r n pers o nnel of a p os s i b l e l o ud noi s e upon a ct i vat i o n. Do not a ll o w a n y bo dy t o a pproa c h cl os e r t o res t r a in t de vi ce t han s i x m e t e r s . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n p ers[...]

  • Page 2724

    3. W ARNING: Make s ur e t ha t t he t yre s t a ck is s t ab l e b e f ore a nd a f te r dep l o yment . Fai l ure t o f o l l o w t hi s i nst ru ct i o n my r es ul t i n p e r s ona l i njur y. S t ack s cr a p t yr e s o f a suf fi c i e nt he i ght t o mas k t he s i de cur t a i n a i r bag m o dul e , s e cur ing t og et he r wi t h h e a v[...]

  • Page 2725

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - C lo cksprin g Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : Al wa ys we a r s a fe t y gl a s se s w he n r e pa i r i ng a n a i r ba g s upp l e ment a l r e s t rai nt s s yst e m (S RS ) vehi cl e a nd whe n ha ndl i ng a n a i r ba g m od ul e . Ca r r y a l i ve[...]

  • Page 2726

    3. Remove t he s t ee ring co l umn uppe r s hr ou d. 4. D i s conne ct t he mul t i f unct i on s wi t c h el e ct r i cal co nnect ors. 1. Re move t he mult i f unct i o n s wit ch s pr i ng. 2. Dis con nect t he mult i f unct i o n s wi t ch e l e ct r i cal c onn e cto r s . 5. Remove t he mul ti fu ncti on s wi t c he s . 6. Remove t he a i r [...]

  • Page 2727

    pers o nal i njur y. • NO T E: A repai r is mad e by r e pl a ce men t onl y. I f a pa r t is re pl a ced and th e new part d oe s n ot c orr e ct t he co ndi t io n, in s t a l l t he o r i gi na l part a nd c a rr y out t he di a gno s t i c pr oced ur e a ga i n. • NO T E: T he a i r ba g s l i di ng co nt a ct has a s e rv ice l ock t ha t [...]

  • Page 2728

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - C rash S enso r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y, t he backup p o we r s upp l y must b e de pl et e d be f ore r ep a i ring o r r e pl a ci ng a ny a i r bag or any ot he [...]

  • Page 2729

    Ne ve r pr obe t he e l e c t rical co nnect ors o f a i r ba g modul e s or any o t her s up pl e ment a l res t r a i nt s ys te m (S RS) compone nt . Fai lur e t o fo l lo w t hi s i ns truc t i o n may r e s ul t i n p e r s o nal i njur y. • NO T E: Re p ai r is made by r e pl a ce ment o nl y. If a part is rep l a ced and t he ne w p art d [...]

  • Page 2730

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Driver Air Bag Mo d ule Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : An RCM modul e o nl y r e qui r e s r e pl a ceme nt i f t he s ys t e m ha s incur red fi v e s e pa rat e de pl o yment s . At no t i me chang e a n RCM f or l e s s t ha n fi ve s ep a rat e d e p[...]

  • Page 2731

    3. D i s conne ct t he drive r ai r b a g modul e e l e ct r i cal co nnect o r. 4. Remove t he drive r ai r ba g modul e . Dis conne ct t he d river a i r ba g modu le el e ct r i cal co nnect o r. Insta llat ion 1. W ARN INGS : An RCM modul e o nl y r e qui r e s r e pl a ceme nt i f t he s ys t e m ha s incur red fi v e s e pa rat e de pl o ymen[...]

  • Page 2732

    3. NOT E: Make s ure t he driver a i r ba g mod ule s na p f it co nne ct o r s a re ful l y s ea t e d. I nst a l l t he d r i v e r a i r ba g mo dul e. 4. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur[...]

  • Page 2733

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Driver Lo wer Air B ag M o dule Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt s cont rol (RCM ) modul e o nl y requi r e s repl a cement i f t h e s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s. A t no t i me chang e a n RCM fo r l es s[...]

  • Page 2734

    3. D et a ch t he r i ght -hand drive r l o we r a ir ba g modul e ret a i ni ng cl i p. 4. D et a ch t he l e f t -hand drive r lo we r a i r ba g mod ul e r et ai ni ng cli p. 5. Remove t he drive r lo we r ai r ba g modul e . Dis conne ct t he d river l owe r a ir ba g modul e e l e ctrical co nnect or. Insta llat ion 1. W ARN INGS : An RCM modu[...]

  • Page 2735

    2. NOT E: Make s ure t he driver l o we r ai r ba g mod ul e r et a i ni ng cl i p s a r e f ul l y s ea t e d. I nst a l l t he d r i v e r l ow er ai r ba g m o dul e . Ti ght e n t o 11 Nm. 3. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng[...]

  • Page 2736

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - O ccupant C las si ficatio n Sen sor Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y, t he backup p o we r s upp l y must b e de pl et e d be f ore r ep a i ring o r r e pl a ci ng a ny a [...]

  • Page 2737

    5. Remove t he e l ect r o nic cont rol uni t (ECU). 1. Re move t he t wo cl i ps . 1. Remove th e ECU. 6. D i s conne ct t he e l ect r i cal conne ct o r fr o m t he s e ns or. 7. D et a ch t he wi ring ha r ne s s f r om t he s e a t ba s e by cut t i ng a nd r emovi ng t he cabl e t i e s . If a pl a s t ic ha rn es s con nect or pl at e i s f [...]

  • Page 2738

    10. Remove t he s e a t b as e ret a i ni ng nu ts . 11. Det a ch t he pa s s e nge r wei gh t s e n so r e l e ctrica l conne ct o r f rom t he r et a i ni ng cl i p. 12. Remove t he s e a t cove r . Uncl i p t h e s e a t cover from t he s e a t bas e . 13. Remove t he s e a t cus hi o n bl ad de r from t he s e a t bas e . Re mov e t he t wo f i[...]

  • Page 2739

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Passenger Air B ag Deactiva tio n (PA D) Indica tor Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y, t he backup p o we r s upp l y must b e de pl et e d be f ore r ep a i ring o r r e pl [...]

  • Page 2740

    6. Remove t he P AD i ndi ca t o r . Dis conne ct t he e l e ct r i cal co nnect o r. Insta llat ion 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y, t he backup p o we r s upp l y must b e de pl et e d be f ore r ep a i ring o r r e pl a ci ng a ny a i r bag s uppl e men t a l r e s trai nt s s ys[...]

  • Page 2741

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Passenger Air B ag Module Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt s cont rol modul e (RCM) o nl y requi r e s repl a cement i f t h e s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s. A t no t i me chang e a n RCM fo r l es s t ha n[...]

  • Page 2742

    4. D et a ch t he pa s s e nge r f i nis h p a ne l . 5. Remove t he pa s se n ge r a i r ve nt . 6. W ARNING: Di sco nnect t he pa s s e n ger a i r bag modul e right -ha nd e l e ct r i cal conne ct o r bef or e t he l e f t -ha nd e l e ct rical conne c t o r . Fa i l ur e t o fo l lo w t he s e ins t ruc t i o ns m a y r e s ult in pers ona l i[...]

  • Page 2743

    9. Remove t he pa s se n ge r c o mpartment f i ni s he r trim. 10. Remove t he p a s s e ng e r compa r t m e nt . Re mov e t he p a s s eng e r compa r t me nt ret a i ni ng s cr ews . 11. Dis c o nne ct t he p a s s e ng e r compa r t m e nt l amp e le ctrica l conne ct o r . 12. NO TE: U nde r no ci rc um s t ance s s ho ul d t he a i r ba g be[...]

  • Page 2744

    Ca r r y a l i ve a i r ba g modul e wi t h t he a i r ba g a nd de p lo yment d oor poi nt e d a wa y f r om your bod y. T hi s wi ll r e duce th e r i s k of i njur y i n t he e v e nt o f a n a cc i d ent a l de pl o ym e nt . Ne ver probe t he conne ct o r s o n t he a i r bag modul e . Doi ng s o m a y r e s ul t i n a i r ba g de p lo yment .[...]

  • Page 2745

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Restraints C ontro l M odule (RCM) Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y, t he backup p o we r s upp l y must b e de pl et e d be f ore r ep a i ring o r r e pl a ci ng a ny a i [...]

  • Page 2746

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Seat P os itio n Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y, t he backup p o we r s upp l y must b e de pl et e d be f ore r ep a i ring o r r e pl a ci ng a ny a i r bag S RS[...]

  • Page 2747

    Ne ver probe t he el e ct r i cal co nnect o rs o f a i r ba g mod ul e s o r any ot he r s uppl ement a l r e s t rai nt s y s t e m compone nt . Fai lu r e t o fo l l o w t hi s r e s t rai nt s yst e m compone nt . Fa il ure t o f ol l ow th is i ns t r ucti o n ma y r e s ul t i n pers o nal i njur y. • NO T E: Re pa i r is mad e by r e pl a [...]

  • Page 2748

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Side Air C urtain Module4-Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt cont r ol mod ule (RCM) onl y req ui r es rep l a c e ment i f t he s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s. A t no t i me chang e a n RCM fo r l es s [...]

  • Page 2749

    4. NOT E: To ai d i ns t a l l a t i o n, n ot e t he rout i ng of t he re ta ini ng cord. Det ach t he s i d e ai r cur ta i n m o dul e co r d from t he ret a i ni ng cl i p. 5. D i s conne ct t he s i d e ai r cur ta i n m od ul e e l e ct r i cal co nnect o r. 6. NOT E: To ai d i ns t a l l a t i o n, n ot e t he rout i ng of t he re ta ini ng [...]

  • Page 2750

    1. W ARN INGS : An res t r a i nt c on t r ol mod ul e (RCM) o nl y r e qui r e s repl a cemen t i f t he s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s. A t no t i me chang e a n RCM fo r l es s t ha n fi ve s e parat e de p l oyment s . Al wa ys we a r s a fe t y gl a s se s w he n r e pa i r i ng a n a i r ba g s upp l e ment a l[...]

  • Page 2751

    5. Ins t a l l the s i d e ai r cur t a i n modul e cord r et a i ni ng bo l t. Ti ght e n t o 9 Nm. 6. Ins t a l l the he a d li ne r . For ad di t io na l inf o r mat i o n, refe r t o S e c t i o n 501-05 I nt e r i o r Tr im a nd O rname nt a ti o n . 7. Connect t he ba t t e ry gr ound cabl e . For a dd it i o na l i nfo rm at i on, ref e r t [...]

  • Page 2752

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Side Air C urtain ModuleWago n Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt cont r ol mod ule (RCM) onl y req ui r es rep l a c e ment i f t he s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s. A t no t i me chang e a n RCM fo r l es s t[...]

  • Page 2753

    4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he f r ont d o or o pe n ing we a t he r s t rips . 5. Remove t he A-pi l l a r t rim p a nel s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: A-P i l l ar Trim P a nel (501-05 Int e r i o r Tr i m a nd O r na m e nt a t io n, Re mov al a n d I ns t a l l a t i o n). [...]

  • Page 2754

    10. Le ver o pen the co ver s t o e xpos e t he s cr e ws a nd remove t he drive r a nd pa s se n ge r as s i s t ha n dl e s . 11. Remove t he D-pi l l a r t rim p a nel s. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: D-Pi ll a r Tr im P a nel (501-05 Int e r i o r Tr i m a nd O r na m e nt a t io n, Re mov al a n d I ns t a l l a t i o[...]

  • Page 2755

    16. Dis c o nne ct t he rea r was he r hos e co nne ct o r . 17. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he ret a i ni ng c ord. Re move t h e s id e a i r cur t a i n mod ul e f r on t cor d ret a i ni ng bol t . 18. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he ret a i ni ng c ord. Det ach t he s i d[...]

  • Page 2756

    21. Remove t he s i de a i r cur ta i n modul e . 1. Re move t he r e t a i ni ng bo l t s . 2. De ta ch t he ret a i ni ng c l i p . Insta llat ion • W ARNINGS : An res t rai nt cont r ol mod ule (RCM) onl y req ui r es rep l a c e ment i f t he s ys te m ha s i ncurr e d f i ve s e p a r at e d e pl o ym e nt s . At no t i me chang e a n RCM fo[...]

  • Page 2757

    3. Tig ht e n t o 9 Nm. JagDocs.com[...]

  • Page 2758

    P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Side I mpact Sens o r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y, t he backup p o we r s upp l y must b e de pl et e d be f ore r ep a i ring o r r e pl a ci ng a ny a i r bag s uppl [...]

  • Page 2759

    P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Speci fi ca ti on Bus h i ns t al l a t i on l ubr ica t i on S hel l gr avex o i l 973 T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Fr o nt s ubf rame f ront mount r et a i ni ng bo l t s 142 105 - F[...]

  • Page 2760

    P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Frame Ass embly Des cr ipt i o n a nd O pe r a t i o n FRONT SU B-FRAM E A SS EMBLY The front s ub-f rame i s bol t e d to the bo d y an d a i d s i n s t ruc t ur al s uppo rt. Th e f r ont s ub-f r ame prov i d es t he mo unt i ng s ur f a ce f or t he s t e e r i ng ge [...]

  • Page 2761

    P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - U nderbody Mis alignm ent Ch eck Gene ral P r ocedures Speci al T ool (s) Al ig nment e qui pment 501-081 1. Rai s e a nd s uppo r t the ve hi cle on a t wo p os t r amp. Fo r ad di t i on a l i nf o r ma t i o n, r e f e r t o S e ct i on 100-02 Ja c ki ng a nd Li ft i ng[...]

  • Page 2762

    5. CAU TI O N : Make s ur e t h e mea s ur ing equi p ment i s us e d t he right wa y up a s s ho wn i n t he i ll us t r a t i o n. The Z me a sureme nt i s s e t on t he s pe ci a l t oo l be f o r e t he X mea s ur eme nt i s t a ke n o n t he ve hi cle . 6. CAU TI O N : Make s ur e t h e mea s ur ing equi p ment i s us e d t he right wa y up a [...]

  • Page 2763

    8. NOT E: The s mal l e s t di a met er pi n a nd br acket (D) i s fi t t e d t o ve hi cl e s wit h a ut omat i c t rans mi ss i on. Th e l a r ge r di a met e r pi n a nd br a ck et (D) i s fi tt e d t o ve hi cle s wi t h man ua l t rans mis s i o n. • NO T E: Cl e a n a ll t he s p e ci al t oo l mount i ng s urfaces be f o r e i ns t a l l i[...]

  • Page 2764

    9. CAU TI O N : W he n i ns t a l l i n g o r r e m ovi ng the s pe ci a l t o ol m a ke s ur e th e br a k e pi pe s a r e not da mag e d or de t a che d f r o m t he ret a i ni ng cl i ps . Adj us t t he s te a dy s c r e w t o t he f ront o f t he whe e l knuck le t o s t ab i l i ze t he s peci a l t o ol t o t he unde rsi d e o f t he vehi c l[...]

  • Page 2765

    Underbod y Di m en si o ns X-Di mens i on Mi l l i meter In c h 1-Al l v e hi cl e s 674.00 26.28 2-Al l v e hi cl e s 977.00 38.10 3-M anua l t rans mi s si o n 877.00 34.20 4-M anua l t rans mi s si o n 708.00 27.61 3-Aut o mat i c t r a nsmi s s i o n 92 4.00 36.04 4-Aut o mat i c t r a nsmi s s i o n 73 6.00 28.70 5-Al l v e hi cl e s 799.00 31[...]

  • Page 2766

    P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe2.0L N A V 6 - AJV6 / 2.5L NA V 6 - A JV 6/3.0 L N A V 6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1. Remove t he f r ont whe e ls a nd t i res . For a ddi ti ona [...]

  • Page 2767

    7. D et a ch t he e ngi ne r o l l res t ricto r. Re mov e t he e n gi ne r ol l res t r i ct or r et a i ni ng bo l t . 8. Remove t he e ngi ne roll r es t r i ct o r . Re mov e t he e n gi ne r ol l res t r i ct or r et a i ni ng bo l t . 9. NOT E: If i ns t al l e d, r e move a n d d i s ca r d t he ga s ke t . Det ach t he drive s ha ft from dr[...]

  • Page 2768

    11. CAUT I O N: Ma k e s ure t hat t he drive sha f t doe s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Us i ng s ui t a bl e t i e s t raps , s e cur e t he dr i ves ha ft t o t he front exha us t ha nger . 12. NO TE: Ri ght -hand s ho w[...]

  • Page 2769

    15. Det a ch t he front of t he s t e e r i ng ge a r co o li ng pi p e . 16. Det a ch t he r ea r o f t he s t ee r i ng g e a r coo l i ng p i pe . Vehi c le s with autom at ic tra ns m ission 17. Remove t he s e l e ct o r cabl e s hi e l d . 18. Det a ch t he s e l ect or ca bl e . JagDocs.com[...]

  • Page 2770

    19. Dis c o nne ct t he s e l e ct o r cabl e . 20. NO TE: Secur e t he s e le cto r cabl e us i ng t i e s t r aps . Det ach t he s e le cto r cabl e . All v e h icle s 21. Ins t a l l t he s p e cia l t o o l . 22. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t[...]

  • Page 2771

    23. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 24. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 25. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re [...]

  • Page 2772

    27. Det a ch t he s t e e r ing gea r s up pl y pi pe f r om t he s t e e r i ng ge ar hea t s hi e l d mount br a c ket . 28. Det a ch t he s t e e r ing gea r he a t s hi e l d mount b r acke t . 29. Det a ch t he r igh t -ha nd s i de o f t he s t e e ring ge ar . 30. Det a ch t he l e ft -hand s i de of t he s t e e ring ge a r . 31. Us i ng s [...]

  • Page 2773

    32. Remove t he s t ee ring ge a r hea t s hi e l d l o we r r et a i ni ng b ol t s . 33. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, d et a ch th e l o we r a r m bal l j o i nt a s th e s ubframe i s bei ng l owe r e d. Fa il ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .[...]

  • Page 2774

    2. CAU TI O N : To pr eve nt da mage t o t he l ow er arm bus hi ng, a tt a ch th e l o we r a r m bal l j o i nt a s th e s ubframe i s bei ng rai s ed . Fa i l ur e t o f ol l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . • NO T E: Ri ght -ha n d s hown, l ef t -hand s i m i l a r. At t a ch t he l o we r ar m[...]

  • Page 2775

    7. Att a ch t he right -ha nd s id e o f t he s te e r i ng ge ar. Ti ght e n t o 133 Nm. 8. Att a ch t he s t ee r in g g e a r he at s hi e l d mount br a ck et . 9. Att a ch t he s t ee r in g g e a r s uppl y p i pe t o t he s te e r i ng ge ar he a t s hie ld m o unt br acket . 10. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Lo o s[...]

  • Page 2776

    12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l a t e r et a i ni ng bo l t s . 13. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Ti ght e n t o 142 Nm. 14. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t o 142 Nm. 15. NO TE: L e ft -[...]

  • Page 2777

    17. At t ach t he s e l e ct o r cabl e . 18. Conne ct t he s e l e ct o r cabl e . Ti ght e n t o 10 Nm. 19. At t ach t he s e l e ct o r cabl e . 20. Ins t a l l t he s e l e ct o r cabl e s hie ld . Ti ght e n t o 10 Nm. All v e h icle s JagDocs.com[...]

  • Page 2778

    21. At t ach t he re ar of t he s t e e r i ng ge ar coo li ng pi p e . Ti ght e n t o 7 Nm. 22. At t ach t he f r o nt o f t he s t e e r ing ge a r co ol i ng p i p e. Ti ght e n t o 7 Nm. Vehi c le s with high i ntensity dis char ge hea dlam ps 23. Conne ct t he hi gh i nt ens it y di s cha r ge (H.I .D) s e ns or drop a r m. All v e h icle s 24[...]

  • Page 2779

    25. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he l o we r a r m ba l l j oi nt r e t ai ni ng nut a nd b ol t . Ti ght e n t o 83 Nm. 26. Ins t a l l t he m uf fl e r in le t pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Muff l e r Inl e t Pi p e - 2.0L N A V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ[...]

  • Page 2780

    30. Ins t a l l t he e ngi ne roll r e s t r i cto r . Ins t al l t he e ngi ne r o ll re st r i ct o r r e t a i ni ng bo l t . 31. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm 32. Ti g ht e n t o 80 N m. 33. Ins t a l l t he r a di a t o r s pl a s h s hie ld . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d[...]

  • Page 2781

    P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe2.0L D uratorq- TDC i/2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1. Remove t he whe e l s and ti r es . For a ddi ti ona l i nf [...]

  • Page 2782

    7. D i s conne ct t he hi gh i nt ens i t y di s cha r ge (H.I .D) s e ns or dr op a r m. All v e h icle s 8. D et a ch t he f ront o f t he s t e e r i n g g e a r coo l i ng p i pe . 9. D et a ch t he r e a r o f t he s t e ering ge a r cool i ng pi pe . Vehi c le s with ele ctric booste r he ate r 10. Det a ch t he el e ct r i c bo os t e r he a[...]

  • Page 2783

    11. Det a ch t he coo l a nt ho se s f rom t he r e t a ini ng cl i ps . 12. NO TE: Cl a mp t he ho se t o mini miz e co o l a nt l o s s . Det ach t he co ol a nt h os e . Dis conne ct t he co o l a nt ho s e . Vehi c le s with f uel fire d boo ster he ate r 13. Det a ch t he fue l fi r e d b o os t e r h e at e r e l e ct rica l co nnect o r f r [...]

  • Page 2784

    15. Det a ch t he wi ring ha r nes s. 16. Ins t a l l t he s p e cia l t o o l . 17. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 18. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i g[...]

  • Page 2785

    19. Det a ch t he eng i ne r ol l res t r i cto r . 20. Remove t he e n gi ne rol l r e s t r i ct o r . Re mov e t he rol l res t r i c t o r r et a i ni ng bo l t . 21. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 22. NO TE: L e ft -hand s h own, r i g ht [...]

  • Page 2786

    24. Det a ch t he r igh t -ha nd s i de o f t he s t e e ring ge ar . 25. Det a ch t he l e ft -hand s i de of t he s t e e ring ge a r . 26. Us i ng s ui t a b l e s e cur i ng s trap s , s e cu re t he s t e e r i ng ge a r t o t he ve hi cle bo dy. 27. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, d et a ch th e l o we r a[...]

  • Page 2787

    1. W ARNING: Ra i s e t he s p e cia l to o l p la t f or m s lo wl y. Fa i l ure t o f o l l o w th i s i ns t r uct io n c a n res ul t i n pe rsona l inj ur y. I nst a l l t he s ubf r ame. Ra is e t he s peci a l t oo l pl a t fo rm . 2. CAU TI O N : To pr eve nt da mage t o t he l ow er arm bus hi ng, a tt a ch th e l o we r a r m bal l j o i [...]

  • Page 2788

    7. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame f ront mount r et a i ni ng bo l t . 8. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s . 9. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mi[...]

  • Page 2789

    12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 13. Ins t a l l t he e ngi ne roll r e s t r i cto r . Ti ght e n t o 80 Nm. 14. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm. 15. Remove t he s pe ci a l t o o l . 16. A[...]

  • Page 2790

    Vehi c le s with f uel fire d boo ster he ate r 17. At t ach t he co o l a nt hos e . 18. At t ach t he f uel f i red bo os t e r hea t er e l e c t r i cal co nne cto r t o t he s ub frame r e t a i ni ng t a ng. Vehi c le s with ele ctric booste r he ate r 19. At t ach t he co o l a nt hos e . Re mov e t he ho s e cl a mp. 20. At t ach t he co o [...]

  • Page 2791

    21. At t ach t he e le ct r ic bo o s t e r he a t e r el e ct r ica l conne ct o r t o t he sub f r ame r et a i ni ng t a ng . All v e h icle s 22. At t ach t he re ar of t he s t e e r i ng ge ar coo li ng pi p e . Ti ght e n t o 7 Nm. 23. At t ach t he f r o nt o f t he s t e e r ing ge a r co ol i ng p i p e. Ti ght e n t o 7 Nm. Vehi c le s w[...]

  • Page 2792

    25. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he s t a bi l iz e r b ar l i nk a rm s . Ti ght e n t o 48 Nm. 26. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he l o we r a r m ba l l j oi nt r e t ai ni ng nut a nd b ol t . Ti ght e n t o 83 Nm. 27. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mi[...]

  • Page 2793

    P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe Front B u shing Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ada p t or nut 204-274 For cing s cr e w 204-275 S upport 204-305 I nst a l l er gui de 204-306 Re cei ver cup 204-307 Bus h r emove r /ins t a l l e r 204-308 Bus h r emove r /ins t a l[...]

  • Page 2794

    2. NOT E: Not e t h e o r i e nt a t i o n o f t he bus hi ng be f or e removal . Us i ng t he s p e ci a l t o ol s , r emove t he f r ont s ubf r a me mount i ng b us hi ng. Insta llat ion 1. F i t t he bus hi ng t o t he s p e cia l t o o l . 2. NOT E: Appl y a s ui t abl e a mount of S he ll g rav e x o i l 973 t o t he bu s hi ng bef o r e i n[...]

  • Page 2795

    4. Usi ng t he s pe cia l t oo l s, f ul l y e nga ge t he b ushi ng i nt o t he s ubf r a me . 5. Ins t a l l the f r ont s ubf r ame For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L Dur at o rq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (502-0 0 U ni -Body, S ubframe a nd Mount i ng Sy s t e m, Re moval a[...]

  • Page 2796

    P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe Rear B ushin g Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ada p t or nut 204-274 For cing s cr e w 204-275 S upport 204-305 I nst a l l er gui de 204-306 Re cei ver cup 204-307 Bus h r emove r 204-308 Bus h i ns t al l e r 204-315 I nst a l l er[...]

  • Page 2797

    Thr us t b e aring JAG- 061 R em ova l 1. Remove t he f r ont s ubfr a me For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L Dur at o rq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (502-0 0 U ni -Body, S ubframe a nd Mount i ng Sy s t e m, Re moval a nd I nst a l l at io n). 2. NOT E: Not e t h e o r i e nt a [...]

  • Page 2798

    4. Usi ng t he s pe cia l t oo l s, f ul l y s ea t t he b us hi n g. 5. Ins t a l l the f r ont s ubf r ame For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L Dur at o rq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (502-0 0 U ni -Body, S ubframe a nd Mount i ng Sy s t e m, Re moval a nd I nst a l l at io n). [...]

  • Page 2799

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