200 SERIES Workshop Manual Werkplaatshandboek Manuel D’Atelier Werkstatthandbuch Manuale D’Officina Manual De Taller Manual de OficinaAMENDMENT INSTRUCTION SHEET Cay NEW ROVER 200 SERIES WORKSHOP MANUAL Publication Number RCLOO64ENG (8th Edition) Amendment Number: RF-005/99ENG Date: 06/99 To ensure that this manual is kept up to date and that a record of amendments to this manual s available, an ‘Amendment instruction Sheet will be issued with each set of revised pages. + The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the Contents pages, all revised and new pages have the issue date at the foot of each page, together with an indication of whether the pages are revised or new. + This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment has been incorporated. Do not discard previous Amendment Instruction sheets. + Your manual s only complete to this issue providing all prior Amendments are included, + The filing instructions give section and page numbers affected. Additional pages or complete new sections may be issued, insert the pages as instructed FILING INSTRUCTIONS Section Discard Existing ] Insert New Pages | Reason for Amendment Pages TITLE PAGE, Title page Title page Publication part number raised to 9th Edition, GENERAL General General Information on wax coated oil seals added. Precautions and | Precautions and INFORMATION Fitting Instructions | Fitting Instuctions pages 5&6 pages 5&6 INFORMATION General Data General Data BRM steering geometry data amended pages 5&6 pages 9&6 General Data General Data BRM brake master cylinder and brake servo pages 7&8 pages 7&8 data added. Torque Wrench | Torque Wrench | Amendments to existing information and Settings pages 1 | Settngs pages 1 & | addon of new torque figure. ENGINE -'K8! Repairs pages 1 to | Repairs pages 1 to | Introduction of new camshatt gear holdin popes Pea sepa Peg took Instruction te lubricate camshaft an Crankshaft front ll seals deleted, Fequirement to ft oi seals dry added. Repairs pages 11 | Repairs pages 11. | Introduction of new carnshatt gear holdin EER Pest Ege eS tool Camshaft Cover Gasket Remove ahd Rofit- Revised procedure issued herowith, Repairs pages 27 | Repairs pages 27 | Oil Pump - Remove and Refit- Revised age ag procedufe issued herewith Repairs pages 29 | Repairs pages 29 | Sump Gasket - Remove and Refit - Revised as aso procedure issued herewith ContinuedSection Discard Existing ] Insert New Pages | Reason for Amendment Pages ENGINE -'K16 Contents Page | Contents Page —_| Contents amended. Repairs pages 1 to Repairs pag Repairs pages 7 & Repairs pags Repairs pages 9 & 10 3 Repairs pages 13 wie Repairs pages 21 &22 3 Repairs pages 72 Repairs pages 1 to Repairs pag Repairs pages 7 & Repairs pag: Repairs pages 9 & 10 s Repairs pages 13 bie Repairs pages 21 &22 s Repairs pages 79 Introduction of new camshaft gear holding 09), Instruction to lubricate camshatt ol! seals deleted, requirement to fit oll seals dry added. Instruction to lubricate crankshaft front oll Seal deleted, requirement to fit oll seal dry added. Introduction of new camshaft gear holding toa Introduction of new camshaft gear holding Introduction of new camshaft gear holding tol Oil Pump - Remove and Refit, Sump Gasket 1.4 Models - Remove and Refit ang Sump 116 and 1.8 Models - Remove and Ref Revised procedures issued herewith, ENGINE -'K16 WITH we Contents Page Repairs pages 1 to Repairs pag Repairs pages 7 & Repairs pags Repairs pages 15 Repairs pages 23 Repairs pages 49 Repairs pages 51 Repairs pages 59 Contents Page Repairs pages 1 to Repairs pag Repairs pages 7 & Repairs pag: Repairs pages 15 epais pages 23 Repairs pages 49 Repairs pages 51 Repairs pages 59 Contents amended. Introduction of new camshaft gear holding 09), Instruction to lubricate camshatt ol! seals deleted, requirement to fit oll seals dry added. Instruction to lubricate crankshaft front oll seal deleted, requirement to fi oll seal dry ‘added. Introduction of new camshaft gear holding tool Introduction of new camshaft gear holding Introduction of new camshaft gear holding Oil Pump - Remove and Refit - Revised procedure issued herewith. Engine Sump - Remove and Refit- Revised procedure issued herewith, ‘Amendment to existing caution. Introduction fnew camshaft gear holding tool ENGINE -'L’ SERIES Repairs pages 3 & B 9 Repairs pages 7 & Repairs pags Repairs pages 13, aie 3 Repairs pages 71 Repairs pages 3 & 4 Repairs pages 7 & Repairs pag: Repairs pages 13 aia s Repgirs pages 71 Instruction to lubricate camshaft front oll seal deleted, requirement to fi ol seal dry added Instruction to lubricate camshaft rear oll seal deleted, requirement to i ol seal dry added Instruction to lubricate crankshaft front oll seal deleted, requirement to fit oll seal dry added. Amendment to existing information. ll Pump - Remove and Refit - Revised procedute issued herewith. ENGINE MANAGEMENT SYSTEM - MEMS Repairs pages 15 &16 3 Repairs pages 15 &16 s Note added regarding fing of HO2S ContinuedSection Discard Existing Pages Insert New Pages Reason for Amendment COOLING SYSTEM - Description and Description and Cooling system operation amended. $ Operation pages 1 | Operation pages 1 L'SERIES Ons ages 1 | Ope 9 cLuTcH Repairs pages 9 & | Repairs pages 9 & | Introduction of new clutch alignment tool for forans Pest gran Pas ‘T'Seres engine. s AUTOMATIC Ilustration showing fluid cooler feed/hase GEARBOX.- ‘CVT Repairs pages 19 &20 3 Repairs pages 19 &20 s pipe removal amended. STEERING Adjustments pages Adjustments pages BRM steering geometry data amended ELECTRICAL Contents Page ‘Adjustments pages a2 * Repairs pages 1& 8 96 Repairs pages 7 & Repairs pags Repairs pages 9 & Repairs pag Contents Page Adjustments pages neo * Repairs pages 1 & 8 9 Repairs pages 7 & Repairs pag: Repairs pages 9 & Repairs pag Page numbers amended Auxliary Drive Belt-'K’ Series Without Air Conditioning = Check and Adjust « Cautions regarding dive belt adjusting bol added ‘Alternator 'K’ Series Without Air Conditoning = Remove and Ref - Cautions regarding drive bel adjusting bolt added Avalay Drive Bel’ Series Without Potter Mcerng-Removeand Rehan ions regarding drive belt adjusting bot added. * $ 8 Auxiliary Drive Belt -'K’ Series With Power Steering - Remove and Refi: Catone regarding drive bel adjusting bolt addedAMENDMENT INSTRUCTION SHEET Cay NEW ROVER 200 WORKSHOP MANUAL Publication Number: RCL 0064ENG - 7th Edition Amendment Number: RF-002/99ENG Date:02/99 To ensure that this manual is kept up to date and that a record of amendments to this manual s available, an ‘Amendment instruction Sheet will be issued with each set of revised pages. ‘+ This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment has been incorporated. Do not discard previous Amendment Instruction sheets. + Your manual s only complete to this issue providing all prior Amendments are included, + The filing instructions give section and page numbers affected. Additional pages or complete new sections may be issued, insert the pages as instructed FILING INSTRUCTIONS Section Discard Existing ] Insert New Pages | Reason for Amendment Pages TITLE PAGE, Title Page Title Page Publication part number raised to &th Edition INFORMATION Contents Page | Contents Page _| Contents and page numbers changed, General Data General Data Data for BRM model added together with pages 3to 15 ages 3t0 17 additional steering geometry data Engine Tuning | Engine Tuning | Maximum no-load engine speed for 2.0 Daiapages 5&6 |Daiapages 5&6 | Series engine added, Torque Wrench | Torque Wrench, _ | Amendments to existing information and Settings pages 1 & | Settings pages 1 & | addition of new torque figures. 2 2 Torque Wrench _ | Torque Wrench, Settings pages 5 & | Settngs pages 5 & Torque Wrench | Torque Wrench Settings pages 11 | Settings pages 11 iis Pes iota Pas Capacities, Fluids | Capacities, Fluids | Data for BRM model included. and Lubreants | and Lubricants, pages 1&2 pages 1&2 MAINTENANCE, Maintenance Maintenance ‘Amendments to existing information, pages 7&8 pages 7&8 Maintenance Maintenance ‘Automatic gearbox oil top-up procedure pages 13814 [pages 12814 | revised.” ENGINE 'K8" Repairs pages 5 & | Repairs pages 5 & | Addition of sealant bead to crankshaft rear 6 6 all seal ENGINE ‘16! Repairs pages 7 & | Repairs pages 7 & | Addition of sealant bead to crankshaft rear Repairs pages 87 | Repairs pages 87 | Requirement o replace automatic timin age ae Delf tensioner at specific intervals deleted ENGINE 'K16 WITH | Repairs pages 7 & | Repairs pages 7 & | Addition of sealant bead to crankshaft rear we: 8 8 ail seal. Continued‘Section Discard Existing Pages Insert New Pages Reason for Amendment ENGINE 'L’ SERIES Contents Page ‘Adjustments pages tape Pes Repairs SubSection pages 1 to 69 se Contents Page Repairs Sub-section pages teas Contents and page numbers amended. Requirement to inspect camshaft and FIP timing belts delete Method for removing, refitting and tensioning camshatt and FIP timing belts amended. Revisions to camshaft all seals and cylinder head remove and refit procedures. Sump refit procedure amended nd sealant part number changed. MANIFOLD AND. EXHAUST SYSTEMS Description and ation pages 3 gipraion Pes Repairs pages 19 &20 3 Beserpton and eration pages 3 Qperation pag Repairs pages 19 &20 s Key to illustration amended. “16 inlet manifold fixings torque figure amended. ns s STEERING ‘Adjustments pages | Adjustments pages | Data for BRM model included together with Hag mers POGeS | Hazen P20°* | adaltional steering geometry data BODY Contents Page | Contents Page __| Contents and page numbers changed, Doors pages 11 & | Doors pages 11 & | Front door trim casing remove and refit 1a Pes a Pe procedure amended. Exterig Fitiggs | Exterior Fitings | BRM mode included in front bumper pages 5 to 1 pages 5 to Femove and rei Interior Tim Interior Trim BRM mode! included in front console Components Components Femove and refit. BRM front console tim pages 11020 | pages 11021 __| pad remove and refit operation added ELECTRICAL, Contents Pages | Contents Pages | Contents and page numbers changed Repairs pages 31 Repairs pages 31 ‘Tweeter - front door and GD Player remove and refit operations added.AMENDMENT INSTRUCTION SHEET Cay NEW ROVER 200 SERIES WORKSHOP MANUAL Publication Number: RCL 0064ENG - 6th Edition Amendment Number: RF-003/98ENG Date:11/98 To ensure that this manual is kept up to date and that a record of amendments to this manual s available, an ‘Amendment instruction Sheet will be issued with each set of revised pages. ‘+ This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment has been incorporated. Do not discard previous Amendment Instruction sheets. + Your manual s only complete to this issue providing all prior Amendments are included, + The filing instructions give section and page numbers affected. Additional pages or complete new sections may be issued, insert the pages as instructed FILING INSTRUCTIONS Section Discard Existing ] Insert New Pages | Reason for Amendment Pages TITLE PAGE, Title Page Title Page Publication part number raised to 7th Edition INTRODUCTION Contents Page | Contents Page _| Contents and page numbers changed Introduction page| Inosucton pages | Model change identiying VIN Nos. added ' age | Inyosucton pag 98 ientying INFORMATION Torque Wrench | Torque Wrench | Amendments to existing information and Setings pages 1.8 | Settngs pages 1 & | addon of new torque figure ENGINE -K8 Contents page | Contents page —_| Contents and page numbers changed Adjustments page | - Camshaft timing belt inspection deleted 1 Repairs pages 1 to | Repairs pages 1 to | Introduction of new camshatt oll seals and apes Pas sepa peg modified service tool Repairs pages 29 | Repairs pages 29. | General updating of camshaft timing belt tos tou ° ° information ENGINE -'K16' Contents page | Contents page _| Contents and page numbers changed Adjustments page | - Gamshatt timing bett inspection deleted SaPS6tiion pages | Sub gestion pages | moaiied sonics tool Revisions to eye He 85 Host ead remove and refit procedures Iniroduction of camshaft iming Bet automate tensioner fogatner wth jeneral updating of camshaft ting be {fformation. Camshaft iming bek remove ang ref procedures combined. General Epdating’of information ENGINE-’K16 WITH | Contents page | Contents page —_| Contents and page numbers changed we Adjustments pages | - Camshaft timing belt inspection deleted, 182 adjustment procedure included in Repairs Sub-section Repairs Repairs Introduction of new camshaft oll seals and sub-section pages | sub-section pages | modified service tool, Camshaft timing belt To 62 11060 adjustment included in remove and refit ‘ogether with updating of camehatt front and rear timing bel information. General Updating otinformation ContinuedSection Discard Existin Pages 8 Insert New Pages Reason for Amendment AUTOMATIC GEARBOX.- ‘CVT Contents page Repairs pages 23 Contents page Repairs pages 23 ‘Additional operation added. Primary bearing remove and refit added BRAKES Adjustments pages Adjustments pages Handbrake cable check - data amendedAMENDMENT INSTRUCTION SHEET (Goa NEW ROVER 200 SERIES WORKSHOP MANUAL Publication Number RCLOO64ENG - Sth Edi Amendment Number: RF-001/98ENG Date: 01/98 To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an ‘Amendment Instruction Sheet will be issued with each set of revised pages. + The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the Contents pages, all revised and new pages have the issue date at the foot of each page, together with an. indication of whether the pages are revised or new. + This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment has been incorporated. Do not discard previous Amendment Instruction sheets. + Your manual is only complete to this issue providing all prior Amendments are included, + The filing instructions give section and page numbers affected. Additional pages or complete new sections may be issued, insert the pages as instructed, FILING INSTRUCTIONS Section insert Now Pages | Reason for Amendment TITLE PAGE, Tile page Title page Part number raised to 6th Edition GENERAL Venice Venice Introduction of 1.1 KB! engine. Identication Identification INFORMATION Numberpage 1__| Number page 1 INFORMATION Contents page | Contents page —_| Contents amended, General Data _| General Data pages 1 108 pages 1108 General Data. | General Data, _| Introduction of 1.1 ‘K8! engine. pages 3875 | pages 13 8 15, Engine Tuning, | Engine Tuning | Inttaduction of 1.1 KS" engine. Bafa sub-section | Batasub-section | Secton content revised Torque Wrench | Torque Wrench __ | Introduction of 1.1 'K8' engine and Settings pages 5 & | Settings pages 5 & | drum ABS. Capacities, Fluids | Capacities, Fluids | Introduction of 1.1 ‘K8! engine. ‘and Lubricants | Snd Lubricants ° page t page + ENGINE - 16 Repairs page 69 _| Repairs page 69 _ | Torque figure corrected. STEERING Contents page | Contents page _| Contents amended, ‘Adjustments page| Adjustments page | Text correction. 1 1 Repairs pages 9 & | Repairs pages 9& | Introduction of PAS drive belt automatic it it tensioner. ik series PAS pump repair procedure revised Repairs pages 15 | Repairs pages 15. | Introduction of PAS drive belt automatic too or tensioner ‘ot Intredueton of passive col for friendh re-mobiisation® ¥ Continued,Section Discard Existing Pages 3 Insert New Pages Reason for Amendment FRONT SUSPENSION Repairs page 11 Repairs page 11 Front beam repair procedure revised. REAR SUSPENSION Contents page Bescription and jeration pages 1 Qperation pag Repairs pages 3 to 19 “ Contents page Description and Operation pages 1 Qperation pag Repairs pages 3 to 25 3 Contents amended. Introduction of drum ABS. Introduction of drum ABS. Stub axle bolt torque figure amended. BRAKES Contents page | Contents page _| Contents amended, Description and_ | Description and __| Introduction of ABS 5... Operation page 7 | Operation page 7 Repairs pages 3, | Repairs pages 3, | Ilustration correction, 5oa20 9 5,028 9 Iniroductos of ABS 8.3 Repairs pages 31 age RESTRAINT Contents page | Contents page _| Contents amended SYSTEMS Precautions page | Service replacement policy. it ELECTRICAL, Contents page | Contents page _| Contents amended, ‘Repairs pages 39 Repairs pages 38, asst Headlamp levelling motor repair procedure Headlamp levelling pair pr Introduction of friendly re-mobilisationF2@ Technical Information Review While every attempt is made to ensure that the technical information we supply is as accurate and up to date as. possible, from time to time, errors do occur. There may also be instances where the style or content of our publications do not meet your exact needs. We would value your assistance in helping us to improve the quality of our publications and invite you to submit details of any technical errors, or improvements you would like to see, in the space below. Publication part number and edition Publication title Section andlor pages affected ‘Technical information errors: Other improvements/changes you would like us to consider: Service manager's signature ae tm Date .. Please return to: Technical Communication, Rover Group After Sales, PO BOX 29, Cowley, Oxford, OX4 SNLNEW ROVER 200 SERIES WORKSHOP MANUAL This manual should be used in conjunction with the following overhaul manuals, RCL0053. R65 Manual Gearbox RCL00S7 _'K' Series Engine RCL0085 —‘L' Series Engine RCL0124 PGI Manual Gearbox Publication Part No. RCL 0064ENG (8th Edition) Published by Rover Technical Communication © 1999 Rover Group Limited INTRODUCTION GENERAL INFORMATION INFORMATION MAINTENANCE ENGINE-ke ENGINE -Ki6 ENGINE -k16 WITH WC ENGINE L SERIES EMISSION CONTROL ENGINE MANAGEMENT SYSTEM: MEMS EDC ¢ FUEL DELIVERY SYSTEM COOLING SYSTEM- k’ SERIES COOLING SYSTEM. "L SERIES twoirovo genus vere A cwureH MANUAL GEAREOX-’RES MANUAL GEAREOX -PGt AUTOMATIC GEAREOX- ‘CVT DRIVE SHAFTS. STEERING FRONT SUSPENSION REAR SUSPENSION BRAKES RESTRAINT SYSTEMS BooY HEATING & VENTILATION AIR CONDITIONNNG WIPERS & WASHERS ELECTRICAL INSTRUMENTSINTRODUCTION CONTENTS Page INTRODUCTION INTRODUCTION REPAIRS AND REPLACEMENTS SPECIFICATION MODEL CHANGE IDENTIFICATION ABBREVIATIONS AND SYMBOLSINTRODUCTION. How to use this Manual To assist in the use of this Manual the section title is given at the top and the relevant sub-section is given at the bottom of each page. Each major section starts with a contents page, listing the information contained in the relevant ‘sub-sections. To assist fling of revised information ‘each sub-section is numbered from page 1 ‘The individual items comprising repair operations are to be followed in the sequence in which they ‘appear. Items numbers in the illustration are referred toin the text. ‘Adjustment and repair operations include reference to Service tool numbers and the associated ilustration depicts the tool. Where usage is not ‘obvious the tool is shown in use. Adjustment and repair operations also include reference to wear limits, relevant data, torque figures, and specialist information and useful assembly details. Each adjustment or repair operation is given its Repair Operation Time number. WARNINGS, CAUTIONS and NOTES have the following meanings: WARNING: Procedures which must be followed precisely to avoid the possit of injury. CAUTION: Calls attention to procedures which must be followed to avoid damage to components. A NOTE: Gives helpful information. INTRODUCTION References References to the LH or RH side given in this Manual are made when viewing the vehicle from the rear. With the engine and gearbox assembly removed, the crankshaft pulley end of the engine is referred to as the front Operations covered in this Manual do not include reference to testing the vehicle after repair. It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned, Dimensions The dimensions quoted are to design engineering specification with Service limits where applicable. INTRODUCTION 1INTRODUCTION REPAIRS AND REPLACEMENTS When replacement parts are required itis essential that only Rover recommended parts are used. Attention is particularly drawn to the following points ‘concerning repairs and the fiting of replacement parts and accessories. Safety features and corrosion prevention treatments ‘embodied in the car may be impaired if other than Rover recommended parts are fitted. In certain teritories, legislation prohibits the fiting of parts not to the manufacturer's specification. Torque wrench setting figures given in this Manual must be used. Locking devices, where specified, must be fitted. If the efficiency of a locking device is impaired during removal it must be renewed. ‘Owners purchasing accessories while travelling ‘abroad should ensure that the accessory and its, fitted location on the car conform to legal requirements, ‘The Terms of the vehicle Warranty may be invalidated by the iting of other than Rover recommended parts All Rover recommended parts have the full backing of the vehicle Warranty. Rover Dealers are obliged to supply only Rover recommended parts ‘SPECIFICATION Rover are constantly seeking to improve the specification, design and production of their vehicles, and alterations take place accordingly. While every effort has been made to ensure the accuracy of this Manual, it should not be regarded as an infallible guide to current specifications of any particular vehicle. This Manual does not constitute an offer for sale of any particular vehicle, Rover Dealers are not agents of Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation 2 INTRODUCTIONMODEL CHANGE IDENTIFICATION Model year feature changes are identified from the following VIN's: 97.5MY from VIN 186624 All models except 200vi badged as 200 1.8'K16' engine Headlamp levelling 98MY from VIN 267264 1.1'K8' engine Bosch ABSS.3 Drum ABS Friendly re-mobilisation INTRODUCTION INTRODUCTION 3INTRODUCTION ABBREVIATIONS AND SYMBOLS ‘ter Bottom Dead Centre ABDC ‘ter Top Dead Centre ATDG Air conditioning AG ‘rue ratio AFR ‘Aerating current ac “Amperes A ‘Anti-lock brake system ABs Before Bottom Dead Centre BDC Before Top Dead Centre BTDC Bottom Dead Centre BDC British Standards BS Carbon monoxide co Celcius (Centigrade) c Centimetre Chlorofuarocarbons Crankshaft position Cubic centimetres Degree (angle) Degree (temperature) Dial test indicator Diameter Direct current Double Overhead Camshaft DOHC Electronic Control Unit ECU Exhaust gas recirculation EGR Electronic air control valve EACV Engine Control Module ECM Electronic Diesel Control EDC Engine coolant temperature ECT Fuel Injection Pump FIP Gramme (mass) 9 Heated oxygen sensor Ho2s High compression he High tension bt. Hour h Idle air control valve lacy Intake air temperature IAT Internal diameter iia International Organisation for Iso Standardization Kilometre km Kilogramme kg Lefthand LH Left-hand drive LHD Light emitting diode LeD Litre 1 Low Compression le Manifold absolute pressure Mass air flow Mercury Metre Miles per hour Milimetre Minimum Minus (of tolerance) Minute (angle) Model Year ‘Multi-function unit “Mutt-point injection Negative (electrical) Newton metre Number Outside diameter Percentage lus or minus Plus (tolerance) Positive (electrical) Positive crankcase ventilation Positive temperature coefficient Power assisted steering Radius Ratio Reference Revolutions per minute Right-hand Right-hand drive Rover Engineering Standards ‘Second (angle) Single overhead camshaft Specific gravity Square centimetres Standard Supplementary Restraint System Synchronizerlsynchromesh Thousand Top dead centre Throttle position United Kingdom United States Vehicle identification number Volt Watt MAP MAF Hg mph My MFU MPi ref revimin RH RHD RES SOHC sp.gr std, SRS synchro k ToC P uK us VIN v w 4 INTRODUCTIONGENERAL INFORMATION CONTENTS Page VEHICLE IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER 1 IDENTIFICATION NUMBER LOCATIONS 1 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS Dangerous substances Engine cils Health Protection Precautions Environmental Protection Precautions SAFETY INSTRUCTIONS FUEL HANDLING PRECAUTIONS FUEL HANDLING PRECAUTIONS. 1 ELECTRICAL PRECAUTIONS ELECTRICAL PRECAUTIONS 1VEHICLE IDENTIFICATION NUMBER Location ‘The Vehicle Identification Number (VIN) plate is attached to the LH 'B’ post. The VIN is also stamped in the followinng locations: On the centre top of the engine bulkhead. Ona plate behind the LH lower comer of the windscreen, Vehicle identification number Example: S AR RF MWX GAD 000400 S= Geographic area ‘Az Country R= Manufacturer RF= Marque!Model M= Class W= Body X= Engine C= Transmission and Steering ‘A= Model change: D= Assembly plant 6 figures= Serial number GENERAL INFORMATION Paint and Trim colour codes S:letter codes identifying the original Paint and Trim colours are stamped on the VIN plate. Paint Example: HAM He Basie colour ‘A= Mark identifier Mz ColouriShade name Trim Example: LPR Basic colour P= Mark identifier R= ColouriShade name IDENTIFICATION NUMBER LOCATIONS Engine number i’ Series Engine: Stamped on the front face of the cylinder block adjacent to the gearbox. L Series Engine: Stamped on the front face of the cylinder block at top centre. Gearbox number Manual Gearbox - R65 and PG1: Stamped on a label attached to the front face of the clutch housing, ‘Automatic Gearbox: Stamped on a plate attached to the rear top face of the gearbox. Body number The body number is stamped on a plate fixed to the fioor to the LH side of the spare wheel compartment. ‘VEHICLE IDENTIFICATION NUMBER 1‘GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS Ignition system safety precautions WARNING: Before commencing work on 1n ignition system, all high tension terminals, adapters and diagnostic ‘equipment for testing should be inspected to ‘ensure that they are adequately insulated and shielded to prevent accidental personal contacts, and minimise the risk of shock. Wearers of surgically implanted pacemaker devices should not be in close proximity to ignition circuits or diagnostic equipment. Dangerous substances WARNING: Many liquids and other substances used in motor vehicles are poisonous and should under no circumstances be consumed and should, as far as possible, be kept from contact with the skin. ‘These substances among others include acid, anti-freeze, asbestos, brake fluid, fuel, windscreen washer additives, lubricants, refrigerant and various adhesiv Always read carefully the instructions printed on labels or stamped on components and obey them implicitly. Such instructions are included for reasons of your health and personal safety. Never disregard them. Used engine oils: Prolonged exposure to used ‘engine oils can cause serious skin disorder avoid excessive skin contact and always adhere to the following recommendations: Engine oil Prolonged and repeated contact with mineral ol wil result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. in addition, used engine oil contains potentially harmful ‘contaminants which may cause skin cancer. ‘Adequate means of skin protection and washing faclities must be provided, GENERAL INFORMATION Health Protection Precautions + Avoid prolonged and repeated contact with ols particulary used engine oils. + Wear protective clothing, including impervious gloves where practicable. + Do not put ily rags in pockets, + Avoid contaminating clothes, particularly underpants, with ci + Overalls must be cleaned regulary. Discard heavily soiled clothing and oil impregnated footweer. + First aid treatment should be obtained immediately for open cuts and wounds. + Use barrier creams, applying before each work period, to help the removal of ol from the skin. + Wash with soap and water to ensure all lis removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. + Do not use petrol, kerosene, diesel ful, gas ol, thinners or solvents for cleaning skin. + If skin disorders develop, obtain medical advice without delay + Where practicable, degrease components prior to handing, + Where theres a risk of eye contact, eye protection should be wom, for example, chemical {goggles or face shields; in addition an eye wash facilty should be provided. Environmental Protection Precautions Itis illegal to pour used oil on to the ground, down sewers or drains, or into water courses. Burning of used engine oi in small space heaters or boilers can be recommended only for units of approved design. The heating system must meet the regulatory standards for small burners(s) with a net rated thermal input of less than 3 MW.The use of waste oil burners must be licensed by the local author Dispose of used oil and used filters through authorised waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. Ifin doubt, contact the Local Authority for advice on disposal facilites. GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1GENERAL INFORMATION SAFETY INSTRUCTIONS Jacking ‘The recommended jacking points are given in LIFTING AND TOWING, always ensure that any lifing apparatus has adequate load and safety capacity for the weight to be lifted. Ensure the vehicle is standing on level ground prior to lifting or jacking. Apply the handbrake and chock the wheels. Never rely on a jack as the sole means of support when working beneath the vehicle. Use additional safety supports beneath the vehicle. Do not leave tools, lifting equipment, spit oil, ete. ‘around or on the work bench area, Pro tions against damage Always fit wing and seat covers before commencing ‘work. Avoid spilling brake fluid or battery acid on paintwork. Wash off with water immediately if this Disconnect the battery earth lead before starting work, see ELECTRICAL PRECAUTIONS. Always use the recommended service tool or a satisfactory equivalent where specified Protect exposed bearing and sealing surfaces and screw threads from damage. Brake shoes and pads WARNING: Always fit the correct grade ind specification of brake linings and renew brake pads and brake shoes in axle sets only. hydraulics WARNING: Itis imperative that the correct brake fittings are used and that threads of components are compatible. Always use two spanners when slackening or tightening brake pipe or hose connections. Ensure that hoses run in a natural curve and are not kinked or twisted. Fit brake pipes securely in their retaining clips and ensure that the pipe run cannot contact a potential chafing point. Containers used for hydraulic fluid must be kept absolutely clean, Do not store hydraulic fluid in an Unsealed container, itwill absorb water and in this condition would be dangerous to use. Do not allow hydraulic fluid to be contaminated with mineral oil, or use a container which has previously contained ‘mineral ol, Do not re-use fluid from the system. Always use clean brake fluid or a recommended alternative to clean hydraulic components. Fit blanking cap to an hydraulic union and a plug to its socket after removal fo prevent the ingress of dirt. Absolute cleanliness must be observed with hydraulic components. Engine coolant caps and plugs Extreme care is necessary when removing engine coolant caps and plugs when the engine is hot and especially ifit is overheated. To avoid the possibilty of scalding allow the engine to cool before attempting coolant cap or plug removal. Cleaning components ‘Always use the recommended cleaning agent or equivalent, Do not use degreasing equipment for components Containing items which could be damaged by the se of this process. Whenever possible clean ‘components and the area surrounding them before removal. Always observe scrupulous cleanliness when cleaning dismantled components 2 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS.Joints and joint faces Fit joints dry unless otherwise specified in this Manual. If gaskets andior jointing compound is recommended for use; remove all traces of old jointing material prior to reassembly. Do not use a tool which will damage the joint faces and smooth ‘out any scratches or burrs on the joint faces using an il stone. Do not allow dirt or jointing material to center any tapped holes. Prior to reassembly, blow through any pipes, ‘channels or crevices with compressed air. Screw threads Metric threads to ISO standards are used. Damaged nuts, bolts and screws must always be discarded, Cleaning up damaged threads with a die or tap impairs the strength and closeness of ft of the threads and is not recommended. Castellated nuts must not be slackened back to ‘accept a split-pin, except in those recommended ‘cases when this forms part of an adjustment. Do not allow oil or grease to enter blind threaded holes. The hydraulic action on screwing in the bolt or ‘stud could split the housing, ‘Always tighten a nut or bolt to the recommended torque figure. Damaged or corroded threads can affect the torque reading ‘To check or re-tighten a bolt or screw to a specified torque figure, first slacken a quarter of a tum, then retighten to the correct torque figure. GENERAL INFORMATION Bolt identification amonss, ‘An ISO metric bolt or screw made of steel and larger than 6 mm in diameter can be identified by either of the symbols ISO M or M embossed or indented on top of the head. In addition to marks to identify the manufacturer, the head is also marked with symbols to indicate the strength grade, e.g. 8.8; 10.9; 12.9; 14.9. As an alternative, some bolts and screws have the M and strength grade symbol on the flats of the hexagon. GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 3GENERAL INFORMATION Nut identification 1Maoss ‘Annut with an ISO metric thread is marked on one face or on one of the fats of the hexagon with the strength grade symbol 8, 12, or 14. Some nuts with a strength grade 4, 5 or 6 are also marked and some have the metric symbol M on the flat opposite the strength grade marking, ‘A clock face systems used as an alternative method of indicating the strength grade. The ‘external chambers or a face of the nut is marked in a Position relative to the appropriate hour mark on a ‘lock face to indicate the strength grade. ‘A dotis used to locate the 12 o'clock position and a dash to indicate the strength grade. Ifthe grade is ‘above 12, two dots identify the 12 o'clock position. Locking devices Always release locking tabs and fit new locking washers, do not re-use locking tabs. Always use a backing spanner when slackening or tightening brake and fuel pipe unions. Fitting a split pin A 1nto0s7 Always fit new split-pins of the correct size for the hole in the bolt or stud. Do not slacken back nut to enter split-pin. Always ft new roll pins of an interference fit in the hole. Always ft new circlips of the correct size for the groove. & 1mio0se fom Solfocking nuts, i.e. nylon insert or metal stiff nuts can be re-used providing resistance can be felt when the locking portion of the nut passes over the thread of the bolt or stud. 4 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS.Solf-locking bolts and screws Fn Ca, iMoose Sel-docking bolts and screws, ie. nylon patched or trilobular thread can be re-used providing resistance ‘can be felt when the locking portion enters the female thread, Nylon patched bolts and screws have a locking ‘agent pre-applied to the threads. They are identified by the presence of a coloured section of thread which extends for up to 180° around the thread. Trlobular Le. Powerlok bolts have a special thread form which creates a slight interference in the tapped hole or threads of the nut into which itis screwed, DO NOT re-use self-locking fasteners in critical locations eg engine bearings flywheel. Always use the correct replacement self-locking nut, bolt or DO NOT fitnon setflocking fasteners in applications where a self-locking nut, bolt or screw is specified. GENERAL INFORMATION Encapsulated bolts and screws 1mo062 Encapsulated bolts and screws have a rmicro-encapsulated locking agent pre-applied to the thread. They are identified by the presence of a coloured section of thread which extends completely around the thread - 360°. The locking agent is released and activated by the assembly pracess and is then chemically cured to provide the locking action. Unless a specific repair procedure states otherwise, encapsulated bolts may be re-used providing the threads are undamaged and the following procedure is adopted, Remove loose adhesive from the bolt and housing threads, ensure threads are clean and free of oil and grease. Apply an approved adhesive. Fit a new encapsulated bolt, or if not available a bolt of equivalent specification treated with an approved adhesive, GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 5GENERAL INFORMATION Oil seals Always renew oil seals which have been removed {rom their working location either as an individual ‘component or as part of an assembly. Ensure the surface on which the new seal is to run is {ree of burrs or scratches. Renew the component if the original sealing surface cannat be completely restored, Protect the seal from any surface which it has to pass when being fitted. Use a protective sleeve or tape to cover the relevant surface. Certain oil seals are coated with a protective wax ‘and must be fitted dry unless stated otherwise. Where an oll seal needs to be lubricated prior to fitment, lubricate the sealing lips with a recommended lubricant before use to prevent ‘damage in initial use. On dual lipped seals, smear the area between the lips with grease. Use the recommended service tool to fit an oil seal Ifthe correct service tool is not available, use a suitable tube approximately 0.4 mm smaller than the ‘outside diameter of the seal. Press or drift the seal in to the depth of its housing, with the sealing lip facing the lubricant to be retained ifthe housing is shouldered, or flush with the face of the housing where no shoulder is provided. Service tools and garage equipment Special service tools have been developed to facilitate removal, dismantling and assembly of mechanical components in a cost effective and practical manner without causing damage. Some ‘operations in this Manual cannot be carried out, without the aid of the relevant service tools. Where specific garage equipment is required for diagnosis and repair, reference should be made to the Service Tools and Equipment Programme where details of the equipment recommended by Rover Service may be found. ‘Synthetic rubber Many ‘0’ rings, seals, hoses, flexible pipes and other similar items which appear to be natural rubber, are in fact, made of synthetic materials called Fluoroelastomers. Under normal operating conditions this material is safe and does not present a health hazard. However, if the material is, damaged by fire or excessive heating, it can break down and produce highly corrosive Hydrofluoric acid Which can cause serious bums on contact with skin. If skin contact does occur: + Remove any contaminated clothing immediately + Irrigate effected area with a copious amount of ccold water or imewater for 15 to 60 minutes. + Obtain medical assistance immediately ‘Should the material be in a burnt or over-heated condition handle only with seamless industrial gloves. Decontaminate and dispose of gloves immediately after use. 6 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS.FUEL HANDLING PRECAUTIONS General ‘The following information provides basic precautions which must be observed if petrol (gasoline) is to be handled safely. It also outlines other areas of risk which must not be ignored. This information is issued for basic guidance only, and if in doubt ‘appropriate enquiries should be made of your local Fire Officer, Petrol - Gasoline Petroligasoline vapour is highly flammable and in confined spaces is also explosive and toxic. ‘When petroligasoline evaporates it produces 150 times its own volume in vapour which when diluted with air becomes a readily ignitable mixture. The ‘vapour is heavier than air and will aways fall to the lowest level. It can readily be distributed throughout, ‘a workshop by air currents; consequently, even a ‘small spillage of petrol/ gasoline is potentially very dangerous. Always have a fire extinguisher containing FOAM, C02, GAS or POWDER close at hand when handling or draining fuel or when dismantling fuel systems and in other areas where fuel containers are stored. Always disconnect the vehicle battery before carrying out dismantling or draining work on a fuel system. Whenever petroligasoline is being handled, drained cr stored or when fuel systems are being dismantled, all forms of ignition must be ‘extinguished or removed; any leadlamps must be flameproof and kept clear of spillage. WARNING: No one should be permitted to repair components associated with petrol/gasoline without first having specialist training. GENERAL INFORMATION Fuel tank drainage WARNING: Petrol/gasoline must not be extracted or drained from any vehicle whilst itis standing over a pit. Draining or extraction of petroligasoline from a vehicle fuel tank must be carried out in a well ventilated a The receptacle used to contain the petrol/gasoline must be more than adequate for the full amount of fuel to be extracted or draine The receptacle should be clearly marked with its contents, and placed in a safe storage area which meets the requirements of local authority regulations. CAUTION: When petrol/gasoline has been extracted or drained from a fuel tank the precautions governing naked lights and ignition sources should be maintaine Fuel tank removal When the fuel line is secured to the fuel tank outlet by a spring stee! clip, the clip must be released before the fuel line is disconnected or the fuel tank is removed. This procedure will avoid the possibilty of residual petrol fumes in the fuel tank being ignited when the clip is released. ‘As an added precaution fuel tanks should have a PETROL (GASOLINE) VAPOUR warning label attached to them as soon as they are removed from the vehicle. FUEL HANDLING PRECAUTIONS. 1GENERAL INFORMATION Fuel tank repairs Under no circumstances should a repair to any fuel tank involving heat treatment be carried out without first rendering the tank SAFE, by using one of the following methods: a. STEAMING: With the filer cap and tank unit removed, empty the tank. Steam the tank for atleast ‘wo hours with low pressure steam. Position the tank ‘0 that condensation can drain away freely, ensuring that any sediment and sludge not volatized by the ‘steam is washed out during the steaming process. b. BOILING: With the filer cap and tank unit removed, empty the tank. Immerse the tank ‘completely in boiling water containing an effective alkaline degreasing agent or a detergent, with the water filing and also surrounding the tank for at least two hours, ‘After steaming or boiling, a signed and dated label to this effect should be attached to the tank. Body and underbody repairs When a body or underbody repairs involve the use ‘of heat, all fuel pipes which run in the vicinity of the repair area must be removed, and the tank outlet plugged, BEFORE HEAT IS APPLIED. Ifthe repair is in the vicinity of the fuel tank, the tank must be removed. Plastic fuel pipes are particularly susceptible to heat, ‘even at relatively low temperature, and can be melted by heat conducted from some distance away. Fuel lines or tanks must not be removed whilst the vehicle is over an inspection pit. 2 FUEL HANDLING PRECAUTIONS:ELECTRICAL PRECAUTIONS: General ‘The following guidelines are intended to ensure the safely of the operator whilst preventing damage to the electrical and electronic components fitted to the vehicle. Where necessary specific precautions are detailed in the relevant sections of this Manual which should be referred to prior to commencing repair operations. Equipment - Prior to commencing any test procedure on the vehicle ensure that the relevant test equipment is working correctly and any hamess ‘or connectors are in good conaition, this particularly ‘applies to mains lead and plugs. WARNING: Before commencing work on 1n ignition system all high tension terminals, adapters and diagnostic ‘equipment for testing should be inspected to ‘ensure that they are adequately insulated and shielded to prevent accidental personal contacts, and minimise the risk of shock. Wearers of surgically implanted pacemaker devices should not be in close proximity to ignition circuits or diagnostic equipment. Polarity - Never reverse connect the vehicle battery land always observe the correct polarity when connecting test equipment. High Voltage Circuits - Whenever disconnecting live ht circuits always use insulated pliers and never allow the open end of the ht lead to come into ‘contact with other components particularly ECU's. Exercise caution when measuring the voltage on the coil terminals while the engine is running, high voltage spikes can occur on these terminals. Connectors and Harness - The engine compartment ofa vehicle is a particularly hostile environment for electrical components and connectors. Always censure these items are dry and oil free before disconnecting and connecting test equipment. Never force connectors apart either by using tools or by pulling on the wiring harness. Always ensure locking tabs are disengaged before removal and not ‘orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed. GENERAL INFORMATION Having confirmed a component to be faulty switch off the ignition and disconnect the battery. Remove the component and support the disconnected hamess. When replacing the component keep cily hands away from electrical connection areas and push connectors home until any locking tabs fully engage. Battery disconnection Before disconnecting the battery, switch off all electrical equipment. Ifthe radio is to be serviced, ensure the security code has been deactivated, CAUTION: To prevent damage to electrical ‘components ALWAYS disconnect the battery when working on the vehicle electrical system. The earth lead must be disconnected first and reconnected last. Always ensure that battery leads are routed correctly and are not close to any potential chafing point Battery charging Recharge the battery out of the vehicle and keep the top well ventilated. While being charged or discharged, and for approximately fiteen minutes afterwards, batteries emit hydrogen gas. This gas is, inflammable. Always ensure any battery charging area is well ventilated and that every precautions is taken to avoid naked flames and sparks. ELECTRICAL PRECAUTIONS 1GENERAL INFORMATION Disciplines ‘Switch off ignition prior to making any connection or disconnection in the system as electrical surge ‘caused by disconnecting live’ connections can damage electronic components. Ensure hands and work surfaces are clean and free of grease, swarl, etc. as grease collects dirt which can cause tracking or high-resistance contacts. When handling printed circuit boards, treat them as you would a disc - hold by the edges only; note that ‘some electronic components are susceptible to body static. ‘Connectors should never be subjected to forced removal or refit, especially inter-board connectors, damaged contacts will cause short-circuit and ‘open-circuit conditions. Prior to commencing test, and periodically during test, touch a good earth, i.e. cigar lighter socket, to discharge body static as some electronic components are vulnerable to static electricity. Grease for electrical connectors ‘All under bonnet and under body connectors are protected against corrasion by the application of a ‘special grease on production, Should connectors be disturbed in service or repaired or replaced, a ‘grease of this type, available in 150 gm tubes under Part No. BAU 5811, should again be applied. NOTE: The use of greases other than BAU 5811 must be avoided as they can migrate into relays, switches etc. contaminating the contacts and leading to intermittent operation or failure. 2 ELECTRICAL PRECAUTIONSINFORMATION CONTENTS Page LIFTING AND TOWING JACKING, SUPPORTING AND TOWING WORKSHOP JACK WHEEL-FREE LIFT RECOVERY TOWING GENERAL DATA ENGINE -'k SERIES 1 ENGINE -'k’ SERIES WITH VVC. 1 ENGINE -'L’ SERIES 2 FUEL SYSTEM - 'k’ SERIES 2 FUEL SYSTEM 'L’ SERIES 2 COOLING SYSTEM -'K’ SERIES 3 COOLING SYSTEM -'L' SERIES 3 CLUTCH 3 MANUAL GEARBOX- R65 4 MANUAL GEARBOX - PG1 4 AUTOMATIC GEARBOX 4 FINAL DRIVE 5 STEERING - EXCEPT BRM 5 STEERING - BRM. 6 SUSPENSION - EXCEPT BRM 6 SUSPENSION - BRM 7 BRAKES 8 WHEELS 9 TYRE SIZES. 10 TYRE PRESSURES - 1.1, 1.4 & 1.6 «SERIES WITH MANUAL GEARBOX..... 11 TYRE PRESSURES - 1.6K’ SERIES WITH AUTOMATIC GEARBOX 12 TYRE PRESSURES - 1.8'K’ SERIES & 1.8 ’ SERIES WITH WC - EXCEPT BRM 13 TYRE PRESSURES - 1.8 'K’ SERIES WITH VVC - BRM 13 TYRE PRESSURES - 2.0'L' SERIES 14 ELECTRICAL - 'K’ SERIES. 15 ELECTRICAL-'L’ SERIES 15 DIMENSIONS 16 WEIGHTS 7 ENGINE TUNING DATA 4.1. K8 with MPi 41.4 K8 with MPi 4.4 and 1.6 K16 with MPi 4.8 K16 with WC 2.0-'L' Series 4.8 K16 with MPi TORQUE WRENCH SETTINGS ENGINE -'k’ SERIES. ENGINE -'L’ SERIES EMISSION CONTROL ENGINE MANAGEMENT SYSTEM - MEMSINFORMATION CONTENTS ENGINE MANAGEMENT SYSTEM - EDC. FUEL DELIVERY SYSTEM COOLING MANIFOLD AND EXHAUST CLUTCH MANUAL GEARBOX - R65 MANUAL GEARBOX - PG1 AUTOMATIC GEARBOX - CVT DRIVE SHAFTS STEERING SUSPENSION. BRAKES RESTRAINT SYSTEMS, BODY HEATING AND VENTILATION AIR CONDITIONING WIPERS AND WASHERS ELECTRICAL INSTRUMENTS CAPACITIES, FLUIDS AND LUBRICANTS CAPACITIES. FLUIDS LUBRICATIONINFORMATION ra This page is intentionally left blank LIFTING AND TOWING 1INFORMATION JACKING, SUPPORTING AND TOWING Jacking and support points Front jacking point, lashing/towing eye - front Rear jacking point, lashingitowing eye - rear LH sill re-inforced bracket front RH sil re-inforced bracket front Pepe WARNING: In accordance with normal ‘workshop practice and to avoid the possibility of damage or personal injury, ‘work must not be carried out on or under a vehicle when it is supported solely on a jack. Place safety supports under the floor longitudinal members (3, 4, 5 and 7). 5. LH sill re-inforced bracket rear 5. Longitudinal members - front "RH sill reinforced bracket rear . Longitudinal members - rear WARNING: Do not position a jack, jack stand or wheel free support under the suspension attachment points or the rear suspension’! frame. 2 LIFTING AND TOWINGINFORMATION WORKSHOP JACK WARNING: Do not attempt to jack under suspension attachment points or the rear suspension 'H’ frame. Front Locate the jack head under the central towing bracket (1), Position safety supports under both front longitudinal members (6). Rear Locate the jack head under the rear towing eye (2) Position safely supports under both rear longitudinal members (8). Side CAUTION: The side jacking points are designed to accomodate the vehicle jack only. Front: Locate the jack head pad under the front reinforced bracket between the two protrusions on the sill (3 or 4). Position a safety support under the appropriate front longitudinal member (8). Rear: Locate the jack head pad under the reinforced. bracket between the two protrusions on the rear sil (Sor7), Position a safety support under the appropriate rear longitudinal member (8) WHEEL-FREE LIFT ‘Two-post ift and crossbeams: Locate the pads Under the sill reinforced jacking brackets atthe front (3,4) and rear (5, 7). Longitudinal beams: Locate the beams under the floor longitudinals with the lifting pads at the front ‘and rear positions (6) and (8). Raise the lit a few inches and ensure the vehicle is firmly supported. Raise the lift to full height and inspect the liting points for security RECOVERY Itis recommended that a recovery trailer or two wheel car ambulance be used. In an emergency, the car may be towed on its own wheels using the front lashing/towing eye (1). ‘Suspended tow ‘front whee lft should be used with a crass beam and body protection. Before towing commences release the handbrake, place the gear lever in neutral and the ignition switch at’. Do not tow at a speed greater than 30 mph, 50 kev CAUTION: On no acount hou the AN Ghiante ued waite feet aes on ie roundif ta taamtnsion tet LIFTING AND TOWING 3INFORMATION TOWING CAUTION: The rear lashingitowing eye (2), must only be used for towing a light vehicle. Manual gearbox models Use the front lashing/towing eye (1) for towing the vehicle on all four wheels from the front. WARNING: To ensure that the steering does not lock when the vehicle is being towed, itis essential that the starter key is turned to position ', and remains there while the vehicle is moving. Ensure the following precautions are observed: Do not tow if the gearbox or a drive shaft faulty. Do not tow if a wheel or drive shafts are touching the body or fram« Ensure the gear lever is in neutral and the handbrake is released. Remember that greater effort than normal will be necessary to apply the brakes if the vehicle is being towed without the engine running. ‘Automatic gearbox models When a car with an automatic gearbox is to be towed, a suspended tow must be used because the gearbox is not adequately lubricated without the engine running. The following precautions must be observed: ‘The selector must be at’N’ CAUTION: A rear suspended tow must not LA be attempted as serious damage will be caused to the automatic transmission. NOTE: A voici ited wth an automati LA satoor connate Started by toning 4 LIFTING AND TOWINGENGINE -'K” SERIES ‘Type: ka. K16 Cylinder arrangement Bore: 11814 1681.8 Stroke 14 14816 18 Capacity 4.1 14 16 18 Firing order Rotation Lubrication System Type Pressure at idle Relief valve opening pressure Maximum pressure at 6500 revimin Oil pressure waming light switch opens, Oilfiter ENGINE -'K’ SERIES WITH VVC Type Cylinder arrangement Bore Stroke Capacity Firing order Rotation Lubrication System Type Pressure at idle Relief valve opening pressure Maximum pressure at 6500 revimin Oil pressure waming light switch opens, Oilfiter INFORMATION 8 valve SOHC 16 valve DOHC 4 inline - transverse 75.00 mm 80.00 mm 63.25 mm 79.00 mm 89.30 mm 1120 om? 1396 cm? 1589 cm? 1796 cm? 1-3-4-2 Clockwise, viewed from front of engine Wet sump, crankshaft driven eccentric rotor pump 1.7 to3.5 bar 4.4 bar 7.0 bar (below 40°C) 0.310 0.5 bar Full low with disposable canister 16 valve DOHC with Variable Valve Control on inlet valves 4 inline - transverse 80.00 mm 89.30 mm 1796 cm? 1-3-4-2 Clockwise, viewed from front of engine Wet sump, crankshaft driven eccentric rotor pump 1.7 to3.5 bar 4.4 bar 7.0 bar (below 40°C) 0.310 0.5 bar Full low with disposable canister GENERAL DATA 1INFORMATION ENGINE -'L’ SERIES Type Cylinder arrangement Bore Stroke Capacity Firing order Rotation Cylinder head warp - maximum Lubrication System Type Pressure at idle Relief valve opening pressure Pressure at 3000 revimin hot Oil pressure waming light switch opens Oilfiter FUEL SYSTEM SERIES, Electronic fuel injection data Fuel Pump Type Pump maximum pressure at 13.5V Regulated injection pressure range FUEL SYSTEM ‘SERIES Fuel fiter Fuel injection pump Mechanical Electronic Fuel injectors 8 valve SOHC 4 inline - transverse 84mm 89mm 1994 cm? 1-3-4-2 Clockwise, viewed from the front of the engine 0.10 mm Wet sump, crankshaft driven eccentric rotor pump 07 bar 455 bar 38 bar 04 to 0.7 bar Full low with disposable canister See Engine tuning data. Electric immersible 4.4 bar 3.0 £0.2bar Bosch 0450 906172 Bosch rotary ve2t vp37 Bosch two spring, needle lift sensing on number one injector 2 GENERAL DATAINFORMATION COOLING SYSTEM - Pressure cap opens 0.910 1.2 bar ‘Thermostat starts to open a°22°C ‘Thermostat fully open 100° =2°C Cooling fan operation: Heater cars On- 104°C, Off - 98°C. Air conditioned cars: Siow speed On - 104°C, Off 98°C Fast speed On- 112°C, Off - 106°C NOTE: With air conditioning operating, fans will run at slow speed. Fans may run on for up to 8 minutes if temperature exceeds 112°C at switch off. COOLING SYSTEM-'L’ SERIES Pressure cap opens 0.910 1.2 bar ‘Thermostat fully open a2 25°C Cooling fan switch Models without intercooler: Without air conditioning On- 108°C, off 94°C. With air conditioning: Siow speed (On - 98°C, Off - 94" Fast speed On- 112°C, Off - 104°C Models with intercooler: Without air conditioning On- 105°, off 94°C. With air conditioning: Siow speed On - 105°C, off 94°C Fast speed On- 112°C, Off - 103°C cLuTcH Type Diaphragm spring, hydraulic operation Clutch plate diameter: 41.1, 1.4 and 1.6 K' Series 200 mm 1.8°K' Series 215 mm 2.0'L' Series: Without intercooler 215 mm With intercooler 228 mm Friction material wear limit 1.5 mm GENERAL DATA 3INFORMATION MANUAL GEARBOX.- R65 Gearbox code: 4.1K’ series 5c 42 WUR, 114°’ series 5C 39 WUR, 1.6K’ series 5C 37 WUC Gear ratios: Fifth 0.88421 Fourth 1.0844 Third 4.33311 Second 119471 First 3at7:1 Reverse 3.5831 MANUAL GEARBOX - PG1 Gearbox code 1.8K’ series cess 1.8K’ series with VVC ~ Except BRM caps - BRM BeBsT 2.0'L' series: Without intercooler s6Bs. With intercooler ‘S6BSU Gear ratios: caBsicess SeBS/S6BSU Fifth 0.765 :1 0.648: 1 Fourth 1.0334 0.848: 1 Third 4.308 1 1:22:41 Second 1.8421 1.895 1 First 3.46721 3.250: 1 Reverse 3.000: 1 3.000: 1 BeBST Fifth 0.848:1 Fourth 1.033:1 Third 1.308:1 Second 1:750:1 First 2.9231 Reverse 3.000:1 AUTOMATIC GEARBOX Type Constantly Variable Transmission (CVT) Gearbox code viet Ratio range 24731 100.445: 1 4 GENERAL DATAINFORMATION FINAL DRIVE Ratios: 1.1K’ series 4.200:1 1.4'K’ series 393721 1.6'K' series 3.76521 1.8'K' series 3.938: 1 1.8K’ series with VVC - Except BRM 4.200:1 - BRM 3.938:1 2.0'L' series 3.938: 1 Road speed at 1000 revimin in top gear: 4.1K’ series 29.3 kmih 18.2 mph 114°’ series 31.8 kmh 19.8 mph 1.6 K ' series: Manual gearbox 33.3 kmh 20.7 mph ‘Automatic gearbox 44.7 kmih 25.9 mph 1.8'K' series 355 kmh 22.1 mph 1.8'K’ series with VVC. - Except BRM 33.3 km/h 20.7 mph - BRM 32.3 kmh 20.1 mph 2.0'L' series 41.8 km/h 26.0 mph STEERING - EXCEPT BRM NOTE: The following steering geometry settings are given in degrees and minutes, decimal parts of a dogree and millimetres. Steering and Suspension geometry settings are for a vehicle at unladen weight. Front whee! alignment - toe-out - per side: os 2078 0.10" £0.12" 5J x 14 wheel 0.53 mm £0.80 mm Sil J x 15 wheel 0.60 mm + 0.84 mm Front wheel camber - negative: 0° 20' 20°10" 0.33: 5J x 14 wheel 240mm + 1.03 mm 5'ipJx 15 wheel 2.20 mm = 1.10mm Front wheel caster: 2 20°30" 2° 5J x 14 wheel 42.41 mm £3.10mm Sif, Jx 15 wheel 13.30 mm =3.31 mm king pin inclination: 12°7' +0" 30" 12.127 £0.5° 5J x 14 wheel 76.34 mm £3.10 mm 5'%pJ wheel 81.80 mm £3.31 mm ‘Tums - lock to lock: Manual 40 PAS. 34 Rear wheel alignment - toe-in - per side: oe +0°10 0.19 20.21° 5J x 14 wheel 0.82 mm + 1.03 mm 51/2 Jx 15 wheel 0.88 mm = 1.10 mm Rear wheel camber - negative: 0° 20' 20°10" 0.33" 20.21° 5J x 14 wheel 240mm + 1.03 mm 5'%pJ wheel 2.20 mm = 1.10mm GENERAL DATA 5INFORMATION STEERING - BRM NOTE: The following steering geometry settings are given in degrees and minut , decimal parts of a dogree and millimetres. Steering and Suspension geometry settings are for a vehicle at unladen weight. Front whee! alignment -toe-out - per sie: Front wheel camber - negative: Front wheel caster: King pin inclination ‘Tums - lock to lock: Rear whee! alignment - toe-in - per side: Rear wheel camber - negative: SUSPENSION - EXCEPT BRM Front Type Nominal height to wheel arch from hub centre * ‘All models except 1.8 'K’ series & 1.8K’ series with WC 1.8K’ series & 1.8 'K’ series with VVC. Road spring identification (colour code): 1.1, 1.4 & 1.6'K' series: Manual gearbox Air conditioning andlor Automatic 1.8K’ series and 1.8 K' series with VVC 2.0'L' series Anti-rll bar: 4.1, 1.48 1.6'K' series: 1.8°K' series and 1.8 K’ series with VC. 2.0'L' series os +078 0.10" £0.12" 0.61 mm £0.85 mm ost 20°45" 0.85" =0.75° 6.11 mm +5.32mm wars 161 21° 11.50 mm £7.11 mm 10°48 + 1° 10.8 21° 77.54 mm £7.11 mm 32 oe s078 0.19" 20.12 0.93 mm +£0.85 mm 0° 20' 20°45" 0.33" 20.75" 2.41 mm +5.32mm Independent, MacPherson strut damper with coil spring and anti-all bar. 386 mm = 10mm 366mm = 10mm PINK GREY BLUE BROWN 19mm diameter 25mm diameter 23mm diameter 6 GENERAL DATA REVISE! 6/99Rear Type Nominal height to wheel arch from hub centre * All models except 1.8 'K’ series & 1.8 «’ series with VVC. 1.8 K' series and 1.8 K’ series with VVC Road spring identification (colour code}: ‘All models except 1.8 'K’ series and 1.8 'K’ series with VVC 1.8K’ series and 1.8 K’ series with VW Anti-rll bar: 1.8 K' series and 1.8 K’ series with VVC - All models 2.0'L' series * Atunladen weight SUSPENSION - BRM Front Type Nominal height to wheel arch from hub centre * Road spring identification (colour code} Anti-rll bar: Rear Type Nominal height to wheel arch from hub centre * Road spring identification (colour code} Anti-rll bar: * Atunladen weight INFORMATION Independent, torsion beam 'H' frame with dampers, coil springs and anti-roll bar - if fitted. 387 mm = 10mm 367mm = 10mm WHITE ORANGE, 18mm diameter 16mm diameter Independent, MacPherson strut damper with coil spring and anti-roll bar. 346 mm = 10mm WHITE 25mm diameter Independent, torsion beam 'H' frame with dampers, coil springs and anti-roll bar. 347 mm = 10mm WHITE 18mm diameter GENERAL DATA 7INFORMATION BRAKES: Front disc brake Disc diameter: Disc wear limit (minimum thickness) Solid disc Ventilated dise Pad minimum thickness Rear disc brakes Disc diameter Disc wear limit (minimum thickness) Pad minimum thickness Rear drum brakes Drum inside diameter Drum wear limit (maximum diameter) Lining minimum thickness Master cylinder Bore diameter: Except BRM BRM Brake servo Servo boost ratio: Except BRM BRM Anti-lock braking system System type: Up to 98MY 98MY on. 262 mm 11.0 mm 19.0 mm 3.0mm 239 mm 80mm 3.0mm 203.2 mm 204mm, 2.0mm 22.21 mm 23.83 mm Bosch ABSS electronic Bosch ABSS.3 electronic 8 GENERAL DATA REVISE! 6/99INFORMATION WHEELS. Wheel type and size: 1.1'K' series 5Jx 14 steo! 1.4'K’ series Standard 5Jx 14 steel Option Sif, Jx 15 alloy" 1.6'K' series Standard 5Jx 14 steel Option Sil, Jx 15 alloy" 1.8K’ series & 1.8K’ series with VVC ~ Except BRM Sif Jx 15 alloy" -BRM 61, Jx 16 alloy" 2.0'L' series Standard 5Jx 14 steel Option Silex 15 alloy" * These cars fitted with alloy road wheels are equipped with a 5'/, Jx 15 temporary use, steel spare wheel fitted with 2 185/55-R15 81V tyre, * BRM models are equipped with a SJ x 14 temporary use, steel spare wheel fitted with 2 175/65.R14 827 tyre. WARNING: The steel spare wheel supplied with cars fitted with alloy wheels is for temporary use only 3nd must be changed as soon as possible after fitting. The car MUST be driven with caution and ‘speed MUST NOT exceed 50 mph (80 km/h) with the spare wheal fitted. No more than one temporary spare wheel may be fitted at any one time. Replacement tyres fitted to the temporary use spare wheel must be of the same make and specification as those originally fitted. GENERAL DATA 9INFORMATION TYRE SIZES 1.1K’ series 1.4'K’ series Steel wheel Alloy wheel 1.8'K' series Steel wheel Alloy wheel 1.8'K’ series and 1.8 K' series with WC ~ Except BRM = BRM Stee! spare wheel 2.0'L’ series (without intercooler) Steel wheel Alloy wheel 2.0'L’ series (with intercooler) Steel wheel Alloy wheel * Replacement tyres must be of the same make ‘and specification as those originally fitted. 175/65 - R14 82T 175/65 - R14 827 185/55 - R15 B1V 175/65 - R14 82H 185/55 - R15 B1V 185/55 - R15 81V Dunlop 205/45 ZR16 - Directional" Dunlop 175/65 R14" 175/65 - R14 82T 185/55 - R15 B1V 175/65 - R14 82H 10 GENERAL DATAINFORMATION ‘TYRE PRESSURES - 1.1, 1.48 1.67’ SERIES WITH MANUAL GEARBOX Pressures (cold) Loading conditions bar. Ibffin? Normal driving conditions 175/65 R14 827 tyres Front and rear 2a 30 175/65 R14 82H tyres Front and rear 2a 30 185/55 R15 81V tyres Front and rear 2a 30 Max. load conditions 175165 R14 827 tyres Front and rear 2a 30 175/65 R14 82H tyres Front and rear 2a 30 185/55 R15 81V tyres Front and rear 2a 30 ‘Speeds over 100 mph (160 km/h) 175165 R14 827 tyres Front and rear 23 33 175/65 R14 82H tyres Front and rear 24 34 185/55 R15 81V tyres Front and rear 24 34 Towing 175165 R14 827 tyres Front 24 30 Rear 24 34 175/65 R14 82H tyres Front 24 30 Rear 24 34 185/55 R15 81V tyres Front 24 30 Rear 24 34 GENERALDATA 11INFORMATION TYRE PRESSURES - 1.6°K’ SERIES WITH AUTOMATIC GEARBOX Pressures (cold) Loading conditions bar. Ibffin? Normal driving conditions 175/65 R14 827 tyres Front 22 32 Rear 24 30 185/55 R15 81V tyres Front 23 33 Rear 24 30 Max. load conditions 175/65 R14 827 tyres Front 22 32 Rear 24 30 185/55 R15 81V tyres Front 23 33 Rear 24 30 ‘Speeds over 100 mph (160 km/h) 175165 R14 82T tyres automatic. Front 25 36 Rear 24 34 185/55 R15 81V tyres Front 25 37 Rear 24 34 Towing 175165 R14 827 tyres Front 22 32 Rear 24 34 185/55 R15 81V tyres Front 23 33 Rear 24 34 12° GENERAL DATA‘TYRE PRESSURES - 1.8 °K’ SERIES & 1.8 SERIES WITH VVC - EXCEPT BRM Pressures (cold): INFORMATION Loading conditions: bar lbtlin? Normal driving conditions Front and rear 22 32 Max. load conditions Front and rear 22 32 Speeds over 100 mph (160 knvh) automatic automatic Front and rear 26 38 Towing Front 22 32 Rear 25 36 TYRE PRESSURES - 1.8: SERIES WITH WG - BRM Pressures (cold): Loading conditions: bar lbtlin® Normal driving conditions* Front 19 28 Rear 24 30 Max. load conditions" Front 22 32 Rear 24 30 ‘Speeds over 100 mph (160 km/h) automatic Front and rear 26 38 Towing Front 22 32 Rear 25 36 Steel spare wheel Front and rear 24 30 * Up to 4 passengers and luggage ** Up to maximum gross vehicle weight GENERAL DATA 13INFORMATION TYRE PRESSURES - 2.0 1 ‘SERIES Pressures (cold): Loading conditions bar, Ibi? Normal driving conditions 175/65 R14 827 tyres Front 22 32 Rear 24 30 175/65 R14 82H tyres Front 22 32 Rear 24 30 185/55 R15 81V tyres Front 23 33 Rear 24 30 Max. load conditions 175/65 R14 827 tyres Front 24 35 Rear 24 30 175/65 R14 82H tyres Front 25 35 Rear 24 30 185/55 R15 81V tyres Front 25 36 Rear 24 30 ‘Speeds over 100 mph (160 km/h) 175165 R14 827 tyres Front 24 35 Rear 23 33 175/65 R14 82H tyres Front 25 35 Rear 23 33 185/55 R15 81V tyres Front 25 36 Rear 23 33 Towing 175165 R14 827 tyres Front 22 32 Rear 24 34 175/65 R14 82H tyres Front 22 32 Rear 24 34 185/55 R15 81V tyres Front 23 33 Rear 24 34 14 GENERAL DATAELECTRICAL -'K’ SERIES System Battery Capacity Alternator Type Maximum output Regulator Starter motor Type Power 41,14 16 18 ELECTRICAL - System Battery Capacity Alternator Type Maximum output Without air conditioning With air conditioning Starter motor Type Power INFORMATION 12 volt, negative earth 45 amp hour at 20 hour rate Magnetti Marelli 115-654 65 Amps 2iTR Magnetti Marelli E80E or M79 og kw ogkw 1.0 KW 12 volt, negative earth 75 amp hour at 20 hour rate Nippon Denso 80.amp 90 amp Nippon Denso RA 11P 15 1.8 KW GENERALDATA 15,INFORMATION DIMENSIONS Overall length Overall width: Including mirrors Excluding mirrors Overall height” ~ Except BRM - BRM Ground clearance: ‘All models except 1.8 'K’ series & 1.8K’ series with WC" 1.8 K' series & 1.8 'K’ series with VVC * ~ Except BRM - BRM * Wheelbase ‘Tuming circle (kerb to kerb) ~ Except BRM -BRM Track: Front Rear * At unladen weight ** Atunladen weight but including driver 3.973m 1.894 _m 1.688 m 1.419 4.39 m 120 mm 410 mm 114 mm 2.502 m 10.31m 11.39m 1473mm 1461 mm 16 © GENERAL DATAINFORMATION WEIGHTS Approximate unladen (fuel tank full, excluding options) Petrol models (manual gearbox) ~ Except BRM 1000- 1060kg 2205 - 2836 Ib - BRM 1100 kg 2424 Ib Petrol models (automatic gearbox) 1045-1085kg 2305 - 2390 Ib Diesel models 1105-1165kg 2435 - 2570 Ib Maximum gross vehicle weight: 4.18 1.4 models 1460 - 1480 kg 3220 - 3265 lb 1.6 manual models, 1480 - 1510 kg 3265 - 3330 lb 1.6 automatic models, 1500 - 1550 kg 3310 - 3415 lb 1.8 models 1520kg 3350 Ib Diesel models 1580 - 1620 kg 3485 - 3570 lb Maximum rear axle load (must NOT be exceeded) 750 kg 1655 Ib ‘Maximum rear axle load when towing lat speeds up to 62 mph (100 km/h) 860 kg 1875 1b Maximum towing weight - braked trailer (estart on 12% gradient with two occupants): 41.1 models 800 kg 4765 ib 1.4 models 900 kg 1985 ib Allother models 1000 kg 2200 Ib ‘Towing hitch downward load 70kg 154 Ib Coupling device maximum overhang: Fixed coupling 749 mm 295in Removable coupling 779 mm 30.7 in Maximum roof rack load (includes weight of rack)... 65 kg 143 Ib GENERALDATA 17Model: 4.1 K@ with MPi Engine ‘TypelCapacity Firing order Compression ratio Idle speed controlled by ECM Exhaust gas CO content at idle" Ignition timing at idle speed:* vacuum connected" Programmed ignition Distributor rotor arm Rotation Ignition Coil Type Primary resistance at 20° Spark Plugs Type Gap Engine Management System Type Fuel pressure Fuel grade INFORMATION Year: 1998 on 11K8 / 1119 om? 1-3-4-2 75:1 875 £50 revimin less than 0.5% hot 10 =5°BTDC Resistive type Anti-clockwise (front of engine - clockwise) F type, dry. (0.63 to 0.77 ohm Unipart GSP 6662 085 mm Indirect multi-port fue! injection. 3.0 +0.2 bar constant 95 RON minimum - UNLEADED fuel CAUTION: Serious damage to the engine may occur if a lower octane number fuel than recommended QA is used. Serious damage to the catalyst will occur if LEADED fuel is used. * Ignition timing in Crankshaft degrees. ** No electrical load present ENGINE TUNING DATA 1INFORMATION Model: 4.4 K8 with MPi Engine ‘TypelCapacity Firing order Compression ratio Idle speed controlled by ECM Exhaust gas CO content at idle" Ignition timing at idle speed:* vacuum connected" Programmed ignition Distributor rotor arm Rotation Ignition Coil Type Primary resistance at 21 Spark Plugs Type Gap Engine Management System Type Fuel pressure Fuel grade Year: 1995 on 414K8 / 1396 cm? 123-422 east 875 £50 revimin less than 0.5% hot 10 5° BTDC Resistive type Anti-clockwise (front of engine - clockwise) F type, dry. (0.63 to 0.77 ohm Unipart GSP 6662 085 mm Indirect multi-port fue! injection. 3.0 +0.2 bar constant 95 RON minimum - UNLEADED fuel CAUTION: Serious damage to the engine may occur if a lower octane number fuel than recommended is used. Serious damage to the catalyst will occur if LEADED fuel is u: * Ignition timing in Crankshaft degrees. ** No electrical load present d. 2 ENGINE TUNING DATAModel: 4.4 and 1.6 K16 with MPi Engine ‘TypelCapacity 14 16 Firing order Compression ratio: 1.4K16 1.6 K16 Idle speed controlled by ECM Exhaust gas CO content at idle" Ignition timing at idle speed:* vacuum connected" Programmed ignition Distributor rotor arm Rotation Ignition Coil Type Primary resistance at 21 Spark Plugs Type Gap Engine Management System Type Fuel pressure Fuel grade INFORMATION Year: 1995 on 14K 16 / 1396 om? 46K 16 / 1589 om? 1-3-4-2 10.4:1 10.5:1 875 £50 revimin less than 0.5% hot 10 BTC Resistive type Anti-clockwise (front of engine - clockwise) F type, dry. (0.63 to 0.77 ohm Unipart GSP 6662 085 mm Indirect multi-port fue! injection. 3.0 +0.2 bar constant 95 RON minimum - UNLEADED fuel CAUTION: Serious damage tothe engine may occur fa lower octane number fuel than recommended QBS is used. Serious damage to the catalyst will occur if LEADED fuel is used. * Ignition timing in Crankshaft degrees. ** No electrical load present ENGINE TUNING DATA 3INFORMATION Model: 4.8 K16 with VVC. Engine ‘TypelCapacity Firing order Compression ratio Exhaust gas CO content at idle Idle speed controlled by ECM Ignition timing at idle speed:* Vacuum connected ** Ignition Coil Type Primary resistance at 20°C Spark Plugs ‘Type - Double Platinum Gap Engine Management System Type Fuel pressure Fuel grade Year: 1995 on 18K 16 / 1796 om* 1-3-4-2 10.5:1 less than 0.5%. 875 £50 revimin 10 =5°BTDC H type twin coil (04 t0 0.61 ohm Unipart GSP 9652 or Champion RC8 PYP 085 mm Indirect multi-port fue! injection. 3.0 +0.2 bar constant 95 RON minimum - UNLEADED fuel CAUTION: sutous damage tothe aging may occu fa ower octane number fel thn recommended Dy wenn Setoue damages tu celpn tl Seer LEASED eli aned * Ignition timing in Crankshaft degrees. ** No electrical load present 4 ENGINE TUNING DATAModel: 2.0 Engine ‘Type/Capacity Models without intercooler Models with intercooler Firing order Compression ratio Idle speed Models without intercooler Models with intercooler Max. no load engine speed Engine Management System ECM - make: ‘Models without intercooler Models with intercooler Fuel injection pump - makeltype: Models without intercooler Models with intercooler Injectors: Make Type Opening pressure Glow plugs: Make Type INFORMATION Year: 1995 on 20T2R | 1994 cm* 2OT2N | 1994 cm? 4-3-4-2 105:1 850 +50 revimin 805 +50 revimin 15300 revimin Rover Bosch Bosch electronic rotary / VP 21 Bosch electronic rotary / VP 37 Bosch 2-stage needle lift injectors 2000/3200 kPa BERU 0100226 184 ENGINE TUNING DATA 5INFORMATION Model: 4.8 K16 with MPi Engine ‘Typelcapacity Firing order Compression ratio Idle speed controlled by ECM Exhaust gas CO content at idle “* Ignition timing at idle * vacuum connected ** Programmed ignition Distributor rotor arm Rotation Ignition Coil Type Primary resistance at 21 Spark Plugs ‘Type - Double Platinum Gap Engine Management System Type Fuel pressure Fuel grade Year: 1997.5 on 18K 16 / 1796 om® 134.2 10.5:1 875 +50 revimin 0.5 %- maximum 12° BTDC Resistive type Anti-clockwise (front of engine - clockwise) H type twin coil (0.410 0.61 ohm Champion RC8 PYP or Unipart GSP 9652 085 mm Indirect multi-port fue! injection. 3.0 +0.2 bar constant 95 RON minimum - UNLEADED fuel CAUTION: Serious damage othe engine may occu if lower otane number ful than recommended AA itisua Sorous demage te the cosy wil oceurf LEADED fais ured. * Ignition timing in crankshaft degrees. ** No electrical load present 6 ENGINE TUNING DATAINFORMATION Refer to appropriate section heading for component torque figures, e.g. Road wheel nuts - refer to SUSPENSION, Exhaust front pipe to manifold - refer to MANIFOLD AND EXHAUST ENGINE -'K” SERIES ‘Timing bett cover bolts 10Nm Tensioner pulley backplate bolt - Manual timing belt tensioner 10Nm ‘Timing bett pulley Allen bolt - Manual timing belt tensioner 45.Nm ‘Timing belt tensioner bolt - Automatic timing belt tensioner * 25.Nm Camshaft gear bolts: Me 35.Nm Mio 65 Nm ‘Timing belt tensioner pulley Allen bolt 45.Nm Rear camshaft cover plate bolts 25.Nm Tensioner backplate screw 45.Nm Camshaft timing belt rear cover bolts 10Nm Drive belt tensioner to steering pump bracket 25Nm Crankshaft pulley bolt 463 Nm Engine RH mounting to engine nuts 400 Nm Engine RH mounting to body through bolt 80.Nm ‘Torque mounting RH bracket to engine bolts 60.Nm Engine LH mounting to body bolts 55.Nm Engine LH mounting bracket to body bolts, 55Nm Steady bar to engine 45.Nm Steady bar to subframe 80.Nm Oi pressure switch 15Nm Cylinder head bolts, tighten progressively ‘ist stage + 20Nm 2nd stage + a further 180° 3rd stage + a final 180° ‘Alternator top mounting bracket nutibolt 25.Nm Camshaft cover to carrier bolts + 10Nm Spark plug cover screws 2Nm Engine lifting bracket bolts Nm Flywheel to crankshaft NEW bolts, 85.Nm Flywheel lower cover bolts ONm Dipstick tube to block 10Nm Oil pump to black bolts + * 10Nm Pressed steel sump to bearing ladder: MBIMB bolts + * 10Nm Alloy sump to bearing ladder bolts + 25Nm Engine sump drain plug Steel sump 42Nm Alloy sump 25Nm + Tighten in sequence * New Patchlok bolts must be fitted REVISED: 06/99 TORQUE WRENCH SETTINGS: 1INFORMATION ENGINE -'L’ SERIES Camshaft cover bolts Camshaft gear centre bolt Camshaft gear hub bolts Camshaft timing belt upper rear cover bolts FIP timing belt tensioner pulley Allen bolt FIP timing belt backplate bolts ‘Timing belt lower rear cover bolts ‘Timing belt tensioner pulley Allen bolt Timing cover bolts Crankshaft pulley bolt Crankshaft rear ol seal housing bolts + Cylinder head bolts First stage + ‘Second stage + Third stage + Fourth stage + Manifold nuts + Manifold bolts + Manifold intake pipe bolts EGR recirculation pipe bolts Engine LH mounting to body bolts Engine LH mounting to gearbox bolts Engine RH mounting to body bolts Engine RH mounting to engine bolts, Engine RH mounting to bracket, nut Engine RH mounting to steady bar bolts Snubber nuts Steady bar through bolt to body Steady bar through bolt to engine Steady bar bracket bolt il pump to block: M10 bolts + M6 bolts + i pipe to oll pipe union ii pipes to pump Sump bolts + Sump drain plug Sump to gearbox support bracket Oilfilter Dipstick tube bracket bolt Oi pressure switch Oil cooler to block: M10 bolts M8 bolts Oi cooler pipe unions Fuel injection pipe union nuts Spill return pipes to injectors Flywheel to crankshaft NEW bolts, ‘Turbocharger: Oil drain pipe bolts Oil feed pipe banjo bolt Vacuum pipe banjo bolt + Tighten in sequence 12Nm 20.Nm + 90° 25Nm &Nm 44Nm Nm Nm 55 .Nm 5Nm 63 Nm + 90° 8Nm 30Nm 65Nm a further 90° a final 90° 25.Nm 33 Nm 25.Nm 40Nm 85Nm 400 Nm 45.Nm 400 Nm 85.Nm 80Nm 10Nm 60.Nm 85.Nm 80Nm 45Nm 10Nm 410Nm 25.Nm 25.Nm 25 Nm 25.Nm 47 Nm 25.Nm 16Nm 45Nm 25Nm 25 Nm 28Nm 40Nm 15 Nm then further 90° Nm 18Nm 25Nm 2 TORQUE WRENCH SETTINGSINFORMATION EMISSION CONTROL Catalytic converter heat shield bolts Nm ENGINE MANAGEMENT SYSTEM - MEMS Air cleaner to battery tray bolts ONm Intake resonator to battery tray bolts Nm Expansion tank to body bolts Nm ‘Throttle body to inlet manifold bolts 7Nm Spark plugs to cylinder head 27/Nm Ht lead cover bolts 2Nm Rotor arm to camshaft, NEW patchlock screw Nm Ignition coil to engine: M10 bolts, 45Nm M6 bolts Nm ECM to bracket nuts 4Nm Idle air control valve to manifold Torx screws Nm Intake air temperature sensor to manifold 7Nm Engine coolant temperature sensor to housing 15Nm Crankshaft position sensor to housing bolt 6Nm ‘Throttle position sensor to housing Torx screws .... 1.5 Nm Oxygen sensor to exhaust manifold 55.Nm Fuel rail to manifold bolts 10Nm Fuel feed pipe to fuel ral bolts 5Nm Variable Valve Control (VVC): Hydraulic control unit solenoid nut 12Nm Oil temperature sensor 15Nm Manifold absolute pressure sensor bolts 10Nm Camshaft position sensor bolt 6Nm TORQUE WRENCH SETTINGS: 3INFORMATION ENGINE MANAGEMENT SYSTEM - EDC Crankshaft position sensor ECM to bracket Exhaust gas recirculation EGR pipe to plenum chamber EGR valve to manifold EGR valve to recirculation pipe Glow plug Glow plug lead terminal nut Air temperature sensor to intake manifold Mean atmospheric pressure sensor Injector clamp plate bolt Coolant temperature sensor (ECT) ‘Throttle position sensor to bracket nuts Injection pump gear nut Injection pump spacer bolt Injection pump adaptor bracket Allen screws Injection pump feediretum pipe banjo bolt Injector pipe union Fuel shut-off solenoid Exhaust manifold elbow to turbocharger bolts ‘Turbocharger to manifold nuts Exhaust manifold to mounting bracket bolts, ll drain tube to turbocharger nuts Oli feediretum pipe to turbocharger nuts, ‘Turbocharger air pipe to cylinder head bolts Intercooler to radiator bolts Nm 4Nm 10Nm 25Nm 25Nm 20.Nm 2.5Nm 42Nm ONm 25Nm 15Nm 4Nm 60.Nm 10Nm 10Nm 25Nm 20.Nm 20Nm 25Nm 25Nm 25Nm 40Nm 20Nm 10Nm 25Nm 4 TORQUE WRENCH SETTINGSINFORMATION FUEL DELIVERY SYSTEM Fuel tank heat shield bolts ONm °K Seri Fuel fiter union, inletoutlet 30Nm Fuel fiter bracket to bulkhead 10Nm Inertia fuel shut-off switch 2Nm Fuel pump to tank nuts Nm 'L’ Series Injector pipes 20.Nm Plenum chamber to camshaft cover bolt ONm Plenum chamber to inlet manifold ONm COOLING 1K Seri Cooling fan housing to radiator ONm Radiator mountings to bonnet locking platform Nm Expansion tank to body bolts, 5Nm ‘Thermostat housing cover bolts Nm. ‘Thermostat housing to block bolts 10Nm Coolant ral to block bolts Nm ‘Thermostatic switch 25 Nm Coolant pump to cylinder block bolts 40Nm Rear cover to coolant pump bolt 10Nm 'L’ Series Coolant outlet elbow to cylinder head nuts 25Nm Coolant pumpicover to bracket bolts, 40Nm Support bracket to pump 25Nm Cooling fan to housing Nm Cooling fan housing to radiator bots Nm Expansion tank to body bolts 5Nm Radiator to bonnet locking platform bolts Nm TORQUE WRENCH SETTINGS: 5INFORMATION MANIFOLD AND EXHAUST Exhaust front pipe to catalyst nuts, Catalyst to intermediate pipe nuts Intermediate pipe to tal pipe nuts °K Seri KB’ - Inlet manifold to cylinder head rut and bolts’ 'K8'- Inlet manifold chamber to manifold bolts 'K16' Non VVC - Inlet manifold to cylinder head rut and bolts! K16 WC’ - Inlet manifold to cylinder head rut and bolts! Inlet manifold to support bracket bolt Exhaust manifold to cylinder head nus" ‘Aternator heat shield, bolts Support bracket to exhaust manifold nuts Exhaust front pipe to manifold nuts "L’ Series Inlet manifold to cylinder head bolts" Exhaust manifold to cylinder head: Nuts" Bolts! Exhaust manifold support bracket bolt ‘Turbocharger to exhaust manifold nuts ‘Turbocharger pipe to cylinder head bolts, CLUTCH °K Seri Pressure plate to flywheel Torx bolts:' 4.1, 1.4 and 1.6 18 'L’ Series Pressure plate to flywheel Torx bolts’ Clutch release fork to shaft “Tighten in diagonal sequence 50.Nm 50.Nm 50.Nm 25.Nm 25Nm 17Nm 25.Nm 25Nm 45.Nm 10Nm 25Nm 50.Nm 25.Nm 25.Nm 33 Nm 25Nm 25.Nm 40Nm 18Nm 26Nm 26 Nm 29Nm 6 TORQUE WRENCH SETTINGSINFORMATION MANUAL GEARBOX.- R65 Reverse light switch 25.Nm Fillerlevel plug 25.Nm Drain plug 25.Nm Gearbox to engine balts' 85 .Nm LH engine mounting to body bolts 55m Mounting bracket to gearbox bolts 60.Nm Gearbox mounting through bolt 85Nm Engine rear mounting to engine bolts 60Nm Engine steady bar to gearbox bolts 400 Nm Flywheel front caver plate bolts Nm Flywheel lower cover plate bolts Nm Gear selector to body bolts 22.Nm Gearchange linkage to rear beam bolts 24.Nm MANUAL GEARBOX - PG1 Reverse light switch 25.Nm Drain plug 45.Nm Fillerlevel plug 40.Nm Gearbox lifting eye boit 27 Nm Gearbox to mounting plate bolts' 85 Nm Gearbox mounting bracket 60.Nm LH mounting to body bracket bolts 85.Nm LH engine mounting to gearbox bolts, 400 Nm Gearchange steady bar to gearbox 410Nm Earth lead to gearbox bolt 35.Nm “Tighten in sequence TORQUE WRENCH SETTINGS: 7INFORMATION ‘AUTOMATIC GEARBOX - CVT Inhibitorreverse light switch Drain plug Fluid pan bolts’ Pitot chamber bolts Pitot tube Fluid cooler union nut Gearbox fuid hose adaptors Dipstick tube retaining bolt Primary cover ots Secondary cover bolts Selector shaft nut Flywheel cover plate bolts Engine to gearbox bolts’ Mounting bracket to gearbox Gearbox mounting bracket to engine bolts Steady bar to engine through bolt Steady bar to body through bolt Gear selector lever nut Gearchange linkage to rear beam bolts "Tighten in sequence DRIVE SHAFTS: Drive shaft NEW nut 12Nm 30 Nm 10Nm 12Nm 10Nm 15Nm 37Nm 25Nm 40Nm 10Nm 15Nm 8Nm 85 Nm 80.Nm 45.Nm 45.Nm 80Nm 7Nm 24Nm 180 Nm 8 TORQUE WRENCH SETTINGSINFORMATION STEERING Steering whee! nut 50 Nm Steering column lower clamp boltinut 22Nm Steering column upper bracket nuts 42Nm Steering column upper bracket bolts, 22Nm Steering column universal joint bolts 28.Nm ‘Track-rod ball pin Nyloc nut 45.Nm Steering rack clamp bolts 38Nm Steering rack pinion flange bolts 58.Nm Steering rack feed pipe union 37Nm Steering rack return pipe union 28Nm Steering pipe clip 9Nm Steering arm ball joint Nyloc nut 45.Nm 1K Seri Steering pump adjuster clamp bolt 25Nm Steering pump mounting bracket bolts 25Nm Steering pump pulley bolts ONm Steering pump outlet hose union 55Nm 'L’ Series High pressure hose union to PAS pump 20Nm PAS pump pulley screws 10Nm PAS pump fo coolant pump bolts 25Nm TORQUE WRENCH SETTINGS: 9INFORMATION SUSPENSION Road wheel nuts! Front Suspension Anti-rll bar link to lower arm bolt Anti-roll bar to link bolt ‘Anti-rol bar clamp to rear beam bolts Damper shaft nut Damper top mounting nuts? Damper to hub pinch bolt” Lower arm front pivot bolt? Lower arm ball joint nut Upper arm ball joint nut Tie-rod to lower arm bolts Tie-rod to front beam nut Front beam to body bolts Rear beam to body bolts Rear Suspension Damper to mounting plate, self locking nut Damper mounting plate nuts, Damper to’ frame bolt? Hub shaft NEW nut 'H' frame to body bolts 'H' frame pivot bush bolt Anti-roll bar to 'H' frame nuts Stub axle to'H' frame bolts ‘Tighten in diagonal sequence Tighten with weight of vehicle on suspension. 110Nm 60Nm 45.Nm 22Nm 40.Nm 30 Nm 80 Nm 45.Nm 55.Nm 30Nm 80.Nm 45.Nm 400 Nm 400 Nm 30Nm 38 Nm 80 Nm 185 Nm 400 Nm 400 Nm 80Nm 45.Nm 10 TORQUE WRENCH SETTINGSINFORMATION BRAKES: Bleed screw - calipers 10Nm Front caliper to mounting bolts 408 Nm Front disc to drive flange screws 10Nm Front caliper shield bolts 10Nm Front caliper guide pin bolts 27Nm Front caliper banjo bolt 34.Nm Brake hose bracket bolts 10Nm [ABS front sensor to hub screw 6Nm ‘ABS front sensor harness bracket bolts 10Nm Rear disc to hub screws 10Nm Rear caliper shield, bolts 10Nm Rear caliper guide pin bolts 27 Nm Rear caliper banjo bolt 34.Nm ABS rear sensor to adaptor screw 6Nm ‘ABS rear sensor caver to hub bolts 10Nm ‘ABS rear sensor harness bracket bolts, 10Nm Master cylinder to servo nuts 15Nm Pipe unions to master cylinder 19Nm Brake servo to bulkhead nuts 13Nm 'L’ Series: Brake servo pipe bolt 25Nm Vacuum adaptor to pump 25.Nm \Vacuum feed pipe to pump union 18Nm Vacuum pump to alternator Nm ABS ECU to modulator screws Nm ‘ABS modulator mounting spigot 15Nm ‘ABS modulator mounting nuts 10Nm ‘ABS ECU pipe unions 14Nm Brake proportioning vaive bracket nuts 10Nm Brake proportioning valve pipe unions 19Nm Handbrake lever to body bolts 22Nm Handbrake switch to handbrake screw 5Nm Handbrake cable brackets bolts 22Nm Handbrake cable retaining plate to back plate bolts 22.Nm Rear drum brakes: Bleed screw - rear wheel cylinder 7Nm Rear brake drum to hub screws, 7/Nm Rear wheel cylinder to backplate bolts Nm Rear whee! cylinder pipe union 19Nm Back plate to trailing arm bolts 64Nm Brake hose bracket to traling arm bolt 22Nm ABS rear sensor adaptor clamp screw 0.5Nm RESTRAINT SYSTEMS: Driver's airbag module Torx screws ONm Passenger's airbag module to fascia screws Nm Passenger's airbag madule to lower mounting ruts ONm SRS earth strap bolt Nm TORQUE WRENCH SETTINGS 11INFORMATION BODY Doors Door lack striker to body screws Door glass regulator to door bolts Door glass regulator to motor screws Door glass regulator roller guide Door glass rear channel bolt Door outside handle bolts Door latch to door Torx screws Front door glass rear channel bolt Rear door glass rear channel nut Rear door glass rear channel bolts Rear door latch and caver screws Tailgate lock striker to body screws Tailgate latch to tailgate screws Tailgate hinges to body nuts, Exterior Fitting Exterior mirror to door Torx screws, Bonnet hinge, bolts Bonnet lock to body bolts Bumper to body bolts Front bumper: Impact cans to front panel bolts Bumper to bonnet platform screws Under tray to beam bolts, Splash shield to body screws/bolts Tailgate spoiler to tailgate bolts Interior Trim Components Fascia mounting bolts Glovebox to fascia screws Lower rail to fascia M8 bolts M6 bolts Front console screws Rear console screws Gear lever gaiter finisher sel-locking nuts - BRM only Sun visor screws Bonnet release handle screws Seats and Seat Belts Seat belt pretensioner to seat bolt Seat belt mounting bolt Seat belt reel bracket to body bait Seat belt bracket M6 bolt Rear seat belt stalk bolt Front seat runner to body bolts Front seat runner to frame Torx screws Rear squab hinge to body bolts Rear seat to floor 18Nm ONm 7Nm Nm Nm ONm 6Nm Nm 4Nm aNm 7Nm ONm 7Nm 22Nm 4Nm ONm 10Nm 6Nm 22Nm 5.Nm ONm 5Nm 6Nm Nm 10Nm 20Nm 10Nm 2Nm 3Nm 3Nm 25Nm ONm 30Nm 50.Nm 30.Nm Nm 50 Nm 34Nm 22Nm 40Nm 10Nm 12 TORQUE WRENCH SETTINGSScreens Sun roof mountings screws Sun roof to body bolts Rear quarter glass nuts - 3 door HEATING AND VENTILATION Heater unit to bulkhead: 6 mmnutsibolts 8 mmnutsibolts Blower motor screws ‘AIR CONDITIONING Pipe bracket to condenser bolts Condenser to fan housing bolts Trinary switch Receiveridrier to body bolts Pipes to receiveridrier bolts Pipe to pipe unions Pipe bracket to gearbox bracket bolt Relay module to body bolts Expansion valve ‘Adaptor to expansion valve Evaporator casing screws Pipe flange to evaporator bolt Pipe bracket screw (LH Drive) °K Seri Compressor to mounting bracket bolts Pipe union to compressor Evaporator pipe to compressor Condenser pipe to compressor 'L’ Series Compressor mounting bolts Pipe unions to compressor Engine overheat sensor 5Nm ONm Nm 10Nm 22Nm ONm 6Nm Nm 12Nm ONm 5.Nm 25.Nm ONm Nm ONm Nm. 10Nm 10Nm 10Nm 45.Nm 35.Nm 45.Nm 25Nm 45.Nm 45.Nm 15Nm INFORMATION TORQUE WRENCH SETTINGS 13INFORMATION WIPERS AND WASHERS Windscreen wiper motor linkage bolts Windscreen wiper motor bolts Windscreen wiper arm nut Rear wiper arm nut Rear wiper motor bolts Rear wiper motor spindle nut ELECTRICAL Battery tray to body bolts Earth lead to body bolt Horn bracket to body nut Homs to bracket nut Headlamp to body bolts Dim dip resistor bolt Engine compartment fusebox to body bolts Passenger compartment fusebox to body bolts Starter switch: Lower clamp bolts Top bracket nuts °K Seri Drive bett tensioner bolt ‘Alternator to mounting bolts ‘Alternator top mounting bracket to engine nutibolt ‘Alternator through bolts nut ‘Alternator pulley nut Battery cable to alternator nut Starter motor support bracket nuts, Starter motor to engine bolts, "L’ Series Alternator drive belt tensioner bolt ‘Alternator upper fixing bott ‘Alternator lover fixing bolt Battery cable to alternator stud Starter motor bolts INSTRUMENTS: 1K Seri Coolant temperature gauge sensor Speedometer pinion housing to gearbox 'L’ Series Engine coolant temperature sensor Speedometer pinion housing to gearbox 10Nm 5Nm 10Nm 10Nm Nm 2Nm ONm Nm 5Nm 5Nm 5Nm Nm 10Nm 10Nm 22Nm 16Nm 25Nm 25Nm 25Nm 45Nm 25Nm 4Nm 25.Nm 45.Nm 45Nm 25Nm 45.Nm 4Nm 55.Nm 10'Nm Nm 5Nm Nm 14 TORQUE WRENCH SETTINGSCAPACITIES Fuel tank Engine oil refill and fiter change: 1.1, 1.4, 1.6 8 1.8K’ Series 20'L' Series Engine oil refill from dry: 1.1, 1.4, 1.6 8 1.8K’ Series 20'L' Series Manual gearbox - R6S Refill From dry Manual gearbox - PG1 ~ Except BRM Refill From dry -BRM Refill From dry CVT- Automatic Power steering Cooling system from dry: * 1.1, 1.4, 1.68 1.8K’ Series 2.0L Series Washer reservoir 50 litres 45 litres 438 litres 48 litres 5.2iitres 1.8 litres 20litres 2.01itres 22 litres 23itres 24 litres 45 litres 03 litre 5.5litres 7.0litres 65 litres * Refil capacity is approx. 0.7 litre less than the from dry figures. INFORMATION ‘CAPACITIES, FLUIDS AND LUBRICANTS: 1INFORMATION FLUIDS. Brake Fluid Use only AP New Premium Super DOT 4 brake fluid ‘or Castrol Girling Universal DOT 4 brake/clutch fui. DO NOT use any other type of fluid Anti-freeze solutions ‘The overall anti-freeze concentration should not fal by volume, below 50% to ensure that the anti-corrosion properties ofthe coolant are maintained. Antifreeze concentrations greater than 60% are not recommended as cooling efficiency will be impaired, Use UNIPART Superplus 3 Anti-freeze and ‘Summer Coolant to protect the cooling system. ‘The cooling system should be drained, flushed and refilled with the correct amount of anti-freeze ‘solution at the intervals given on the Service Maintenance Check Sheet CAUTION: No other ‘universal’ anti-freeze should be used with UNIPART Superplus 3 Anti-freeze and Summer Coolant. IfUNIPART Superplus 3 Anti-reeze and Summer Coolant is not available, use an ethylene glycol based anti-freeze containing no methanol with rnon-phosphate corrosion inhibitors which meet specifications BS6580 and BS5117 suitable for use in mixed metal engines. To ensure the protection of the cooling system against corrosion, these ant-freezes must be renewed every 12 months Aer filing with anti-freeze solution, attach a warning label to a prominent position on the vehicle stating the type of anti-freeze contained in the cooling system to ensure that the correct type is used for topping-up. The recommended quantities of anti-freeze for different degrees of frost protection are: Solution Amount of anti-freeze | Commences freezing | Frozen solid 50% Litres °c of &c oF °K Series models 27 26 23 48 53 “L’ Series models 35 26 23 48 53 2 CAPACITIES, FLUIDS AND LUBRICANTSLUBRICATION ‘The engine and other lubricating systems are filled with high- performance lubricants giving prolonged life, CAUTION: You should always use a high quality oil of the correct viscosity range in the engine and gearbox during maintenance and when topping-up. The use of oil not to the correct specification can lead to high oil and fuel consumption and ultimately to damaged component: Oil to the correct specification contains additives which disperse the corrosive acids formed by ‘combustion and prevent the formation of sludge which can block the oil ways. Additional oil additives should not be used. ‘Always adhere to the recommended servicing intervals. INFORMATION Engine oil ‘swi20 w/30 540 5Wi50 10/30 tow'40 FEE E—F+ 10w'50 vwao 15/50 2ow/a0. 20w/50 °C __-50"-20" 10" OF 10" 20° 30° 40° =F 20" 0" 20" _a0® 6d? 80° 100" + M00608, Petrol vehicles Use oil meeting specification RES.22.0L.G4 or the requirements of CCMC G4, and having a viscosity band recommended for the temperature range of your locality. Where oils to these Rover and European specifications are not available, well known brands of olis meeting API SG, SH or SGICD. quality should be used. Diesel vehicles Use oll meeting specification RES.22.08.PD2 or CMC PD2 and having a viscosity band recommended for the temperature range of your locality. ‘CAPACITIES, FLUIDS AND LUBRICANTS: 3INFORMATION Manual gearbox - R65 Use the following oils for refill or topping-up ESSO Gear oil BV 75w/80 MOBIL Mobilube 1 SHC SHELL SF5288 75w/80w UNIPART Gear oil BV 75wi80w ‘The following olls may be used for topping-up only: BP Hypogear TL 75wi80w CASTROL EPX 75w/80w DUCKHAMS Hypoid PT 75w/80w Manual gearbox - PG1 Use the following oils for refill or topping-up ‘TEXACO MTF 94 UNIPART MTF 94 ‘The following olls may be used for topping-up only: Use oil meeting the requirments of RES.22.0L.G4 or CCMC G4 and a viscosity of 10/40 ‘Automatic gearbox - CVT Use the following oils for refill or topping-up: ESSO CVT Fluid UNIPART CVT Fluid ‘The following oll may be used for topping-up only: ‘Automatic Transmission Fluid meeting Dexron II D specification. Power Steoring TOPPING-UP: Use Unipart Power Steering Fluid or an Automatic Transmission Fluid meeting Dexron I D specification COMPLETE FILL: Use Unipart Power Steering Fluid or a fluid meeting PSF-V specification Gear linkage - Manual Use grease Part No. AFU 1500 containing 39% Molybdenum Disulphide. General Greasing Use Multipurpose Lithium Base Grease N.L.G.L consistency No. 2. Bonnet latch Lubricate cable and latch with oil Locks, Latches and Hinges Use Door Lock and Latch Lubricant, Part No. VWN 10075. 4 CAPACITIES, FLUIDS AND LUBRICANTSMAINTENANCE CONTENTS MAINTENANCE UNDERBONNET LOCATIONS - 'K8! UNDERBONNET LOCATIONS -'K16" UNDERBONNET LOCATIONS - 'K16 1.8 and K16 WITH WC" UNDERBONNET LOCATIONS -'L’ SERIES CHECK ENGINE AND TRANSMISSION ENGINE OIL AND FILTER -'k’ SERIES ENGINE OIL AND FILTER -'L’ SERIES CAMSHAFT TIMING BELT - 'k’ SERIES CAMSHAFT TIMING BELT - 'L' SERIES INJECTION PUMP TIMING BELT - 'L’ SERIES CRANKCASE VENT HOSES - 'K’ SERIES CRANKCASE PRESSURE LIMITER VALVE - 'L’ SERIES FUEL SYSTEM HOSES, PIPES AND UNIONS FUEL FILTER ENGINE TUNING. AIR CLEANER ELEMENT - 'k’ SERIES AIR CLEANER ELEMENT - 'L’ SERIES DISTRIBUTOR CAP, H.T. CABLES AND COIL TOWER -'k’ SERIES SPARK PLUGS - 'K” SERIES. COOLING SYSTEM EXHAUST SYSTEM CLUTCH GEARBOX OIL - ‘R65’ GEARBOX OIL - 'PGt AUTOMATIC GEARBOX OIL ‘CVT" DRIVE SHAFT GAITERS STEERING SUSPENSION DAMPERS, BALL JOINTS, ROAD WHEELS AND FASTENINGS TYRE PRESSURES AND CONDITION FOOTBRAKE HANDBRAKE BRAKE FLUID BRAKE HOSES AND PIPES FRONT BRAKES-HYDRAULICS, PADS, DISCS AND CALIPERS, REAR DRUM BRAKES REAR DISC BRAKES. BODY DRIVER AIR BAG MODULE PASSENGER AIR BAG MODULE ROTARY COUPLER SCREEN WIPERS AND BLADES WINDSCREEN AND REAR SCREEN WASHERS LAMPS, HORNS AND WARNING INDICATORS. BATTERY CONNECTIONS FUSEBOX ROAD TEST Page enUNDERBONNET LOCATION: ppaene Brake fluid reservoir Fuel fter Distributor Coolant expansion tank Engine compartment fusebox Battery 2, MAINTENANCE Air cleaner Crankcase ventilation hoses Spark plugs ). Engine oll filer cap |. Windscreen and rear screen washers reservoir Engine oll dipstick MAINTENANCE 1MAINTENANCE UNDERBONNET LOCATIONS - 'K16" Noga eNe Brake fluid reservoir Fuel fter Distributor Coolant expansion tank Engine compartment fusebox 10. 1. 2, Engine ol filer cap Spark plugs Crankcase ventilation hoses Windscreen and rear screen washers reservoir Power steering reservoir Battery 13. Engine oil dipstick Air cleaner 14. Automatic gearbox oll dipstick (If fitted) MAINTENANCEUNDERBONNET LOCATIONS - K16 1.8 and K16 WITH wc" WE engine illustrated Pp aeNs Brake fluid reservoir Fuel fiter Coolant expansion tank Engine compartment fusebox Battery Air cleaner 10. 1. 2, MAINTENANCE /. Engine ol filer cap Spark plugs Crankcase ventilation hoses Windscreen and rear screen washers reservoir Power steering reservoir Engine oll dipstick MAINTENANCE 3MAINTENANCE UNDERBONNET LOCATIONS -'L’ SERIES 1oMoass Non - intercooler illustrated Brake fluid reservoir Fuel fter Coolant expansion tank and cap Engine compartment fusebox Battery Air cleaner peas Crankcase pressure limiter valve Engine oll dipstick Engine oil filer cap ). Windscreen and rear screen washer reservoir Power steering reservoir 4 MAINTENANCEMAINTENANCE CHECK ENGINE AND TRANSMISSION 41. Visually inspect for oil leaks from engine and transmission, pay particular attention to areas of gaskets and seals. ENGINE OIL AND FILTER - ‘SERIES Oil level check Always check cil level and drain oil wth vehicle standing on level ground and use engine oil of specification 10w/40 for topping up and refiling § roweses 41. Withdraw dipstick and wipe blade. Re-insert dipstick fully, withdraw it and check oil level which must be maintained between minimum mark "LO and maximum mark 'HI' on dipstick. 2. If required, remove filler cap and top-up with ‘new engine oil to specification 10wi40. See INFORMATION, Capacities, fluids and lubricants. MAINTENANCE 5MAINTENANCE il drain and refill ‘The oll should be drained when engine is warm. The oll iter can be renewed while oil is being drained. WARNING: Observe due care when draining engine oil as the oil can be very hot. Prolonged and repeated contact with used ‘engine oil may cause serious skin disorders, wash thoroughly after contact. Keep out of reach 41. Place a container under sump. 2. Remove drain plug and sealing washer, allow oll to drain 3. Clean the drain plug, fit new sealing washer and refit drain plug. Tighten to 42 Nm. 4. Remove filer cap, refil with new engine oil to specification 10w/40. Re-check oil level. OIL FILTER RENEWAL Service repair no - 12.60.04 For information on replacement ofthe oil fiter refer {0 one of the following engine sections: \K8' models: See ENGINE - 'K8', Repairs. K16' models: See ENGINE. 'K16', Repairs. ‘K16 with VVC' models: See ENGINE - 'K16 WITH WC", Repairs. ENGINE OIL AND FILTER -'L’ SERIES Oil level check Always check cil level and drain oil wth vehicle standing on level ground and use engine oil of specification 10w/40 for topping up and refiling 41. Withdraw dipstick and wipe blade. Re-insert dipstick fully, withdraw it and check oil level which must be maintained between minimum ‘and maximum marks on dipstick. 2. If required, remove filler cap and top-up with ‘new engine oil to specification 10wi40. See INFORMATION, Capacities, fluids and lubricants. 6 MAINTENANCEil drain and refill ‘The oll should be drained when engine is warm. The oll iter can be renewed while oil is being drained. WARNING: Observe due care when draining engine oil as the oil can be very hot. Prolonged and repeated contact with used ‘engine oil may cause serious skin disorders, wash thoroughly after contact. Keep out of reach of children. 1. Raise front of vehicle. Q WARNING: Support on safety stands. MAINTENANCE 9. Fitnuts securing undertray to rear beam and tighten to 10 Nm, 10. Fitbolts securing undertray to front beam and tighten to 10 Nm, 11. Remove stand(s) and lower vehicle. 12. Remove filler cap, refill with new engine oil to. specification 10w/40. Re-check oil level CAUTION: Do not raise oi level above the LY ‘Max mark on dipstick. 13, Start and run engine and check for oil leaks. 14. Stop engine, wait afew minutes, then check oil level and top up if necessary. CAUTION: Ensure oil does not drop onto the alternator when extracting the dipstick, OIL FILTER RENEWAL Service repair no - 12.60.04 For information on replacement of the oil fter refer to the engine section. See ENGINE. * SERIES, Repairs. 2. Remove 2 bolts securing undertray to front beam. 3. Remove 2 nuts securing undertray to rear beam. 44, Release and remove undertray. 5. Place a container under sump. 6. Remove drain plug and sealing washer, allow oll to drain 7. Clean drain plug, fit new sealing washer and refit drain plug. Tighten to 45 Nm. 8. Position undertray and locate on studs on rear beam. CAMSHAFT TIMING BELT -'K’ SERIES K8' models: See ENGINE - 'K8’, Repairs. K16 models:See ENGINE - 'K16', Repairs. K16 with VVC’ models: See ENGINE - 'K16 WITH We", Repairs. ‘CAMSHAFT TIMING BELT -'L’ SERIES See ENGINE. * SERIES, Repairs. INJECTION PUMP TIMING BELT - ‘SERIES See ENGINE. 'L’ SERIES, Repairs. MAINTENANCE 78 MAINTENANCE CRANKGASE VENT HOSE: ‘CRANKCASE PRESSURE LIMITER VALVE -'L” SERIES sonore 1. Check crankcase ventilation hases for signs of splitting and general condition. 2. Check hoses are routed correctly, secure and serviceable. 41. Check hoses for signs of spliting and general condition, 2. Check valve connections are secure. 3. Check hoses are routed correctly, secure and serviceable. MAINTENANCEMAINTENANCE FUEL SYSTEM HOSES, PIPES AND UNIONS 'K series 1oMo447 'L’ series Check fuel pipes and connections for chafing and leakage. Check pipes are securely clipped. Check fuel tank connections for security Check fuel tank is free from leaks and Check fuel tank for security of fixings. Ben MAINTENANCE 9MAINTENANCE FUEL FILTER See FUEL DELIVERY SYSTEM, Repairs. ENGINE TUNING. Engine tuning must be carried out using TestB0ok. AIR CLEANER ELEMENT - SERIES See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. AIR CLEANER ELEMENT -'L’ SERIES See ENGINE MANAGEMENT SYSTEM - EDC, Repairs. DISTRIBUTOR CAP, H.T. CABLES AND COIL TOWER -'K’ SERIES Check soMoa97: Release 2 screws, Lift off distributor cap. (Check cap for cracks, warping and bums. Check rotor for damage. Clean interior and exterior of distributor cap. Check that hi. cables are free from damage, routed correctly and all connections are tight Clean ignition coil tower. Refit distributor cap. Tighten distributor cap screws to 2 Nm. ‘SPARK PLUGS-'K’ SERIES See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 10 = MAINTENANCECOOLING SYSTEM WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove pressure relief cap from expansion tank while system is hot. Wait until system has cooled, use a cloth or glove to protect hands from escaping steam. Check level and top-up CAUTION: The coolant level should only bbe checked when the system is cold. nomad? 41. Visually check that coolant level is between the ‘MAX’ and ‘MIN’ marks on expansion tank. If level is appreciably low, suspect leakage or overheating CAUTION: If coolant is not visible in expansion tank, system must be refilled in accordance with refilling procedure. K series models: See COOLING SYSTEM - 'K" SERIES, Adjustments. LU seties models: See COOLING SYSTEM - 'L’ SERIES, Adjustments. MAINTENANCE 2. If required, remove coolant expansion tank cap and top-up with antifreeze mixture. See INFORMATION, Capacities, fluids and lubricants. CAUTION: The coolant must not exceed LY the maximum level indication. 3. Check specific gravity of coolant. The overall anti-freeze concentration must not be below 80% by volume and must not exceed 60% by volume. 4. Refit expansion tank cap. EXHAUST SYSTEM |. Check for damage and signs of leakage. . Check security of system, . Check mountings and correct alignment. |. Check security of heat shields. CLUTCH | Check operation of the clutch and free movement of the pedal 2. Check the cable for fraying. MAINTENANCE 11MAINTENANCE ‘GEARBOX OIL - "R65" Oil level check and top-up 10M 41. Ensure vehicle is standing on level surface. 2. Wipe clean area around fillerievel plug and remove plug and sealing washer. Discard ‘sealing washer. 3. Check that oils level with bottom of level plug hole. CAUTION: Oil lodged behind level plug will trickle out when plug is removed and can give impression that level is correct. 4. Top-up, ifrequired, until oil ust runs from hole. Allow sufficient time for cil to flow and reach a ‘common level within gearbox. Use a BV 75wi80w transmission oil. See INFORMATION, Capacities, fluids and lubricants. 5. Refi fillerevel plug and new sealing washer land tighten to 25 Nm GEARBOX OIL - 'PGT" Oil level check and top-up 4. Ensure vehicle is standing on a level surface. 2. LU’ sertes modes: Remove underbelly panel. See BODY, Exterior fittings. 3. Clean area around fillerflevel plug. roMo433. 4, Remove filerlevel plug, '5. Check that oil is level with bottom of filerlevel plug hole. CAUTION: Oil lodged behind fillerlevel plug will trickle out when plug is removed and can give the impression that level is correct. 6. Top-up, if required, until il just runs from fillerievel hole. Allow sufficient time for oil flow until it reaches a common level in the gearbox. Use the correct specification oil. See INFORMATION, Capacities, fluids and lubricants. 7. Fitfillerlevel plug and tighten to 40 Nm. 8. L’series models: Fit underbelly panel. See BODY, Exterior fittings. 12 MAINTENANCEMAINTENANCE AUTOMATIC GEARBOX OIL - ‘CVT" Oil level check and top-up NOTE: Always check fluid level with vehicle standing on level ground and gearbox at operating temperature. soma SW With engine running at idle speed and handbrake applied, select '°" or ’N’. Withdraw dipstick and wipe blade with clean cloth. 2. Revinsert dipstick fully, withdraw and check fluid level which must be maintained between minimum and maximum marks on dipstick. 3. Switch off engine and top-up to maximum mark ifrequired. See AUTOMATIC GEARBOX - CVT’, Adjustments, Refit dipstick » DRIVE SHAFT GAITERS towoss mf 4. Check that drive shaft galters are not twisted, split or damaged. 2. Check clips are secure. MAINTENANCE 13MAINTENANCE STEERING Check and top-up power steering fluid Carry out fluid level check when engine is stopped and system is cold NOTE: It is essential that power steering system should not have been operated since engine was stopped, 41. Clean reservoir around filler cap and level indicators. 2. Visually check fluid level is between level indicators. 3. Ifrequired, remove filer cap and top-up with DEXRON IID specification fuid. Do not overfill CAUTION: Ensure no dt is allowed to QR enter reservoir when cap is removed. 4, Refit filler cap. 14° MAINTENANCEMAINTENANCE Steering column, rack, joints and gaiters 1. Check security of pinion flange bolts, tighten to Check that ball joint nuts are tightened to 45, 58 Nm. Nm. Check security of steering rack clamp bolt, Visually check that the rack sealing gaiters are tighten to 38 Nm not twisted or damaged and clips are secure. Restrain ball joint movement and check that 5. Check for signs of lubricant leakage. steering track rod locknuts are tightened to 45 Nm. MAINTENANCE 15MAINTENANCE SUSPENSION DAMPERS, BALL JOINTS, FIXINGS AND GAITERS. Front suspension rowmoass Check suspension dampers for oil leaks. Check tie rod front mounting nuts - 45 Nm. Check tie rod to lower arm bolts - 80 Nm. Check damper top mounting nuts - 30 Nm Check front hub damper bolts - 80 Nm Check lower arm to body bolts - 60 Nm. Check anti-roll bar to link bolts- 45 Nm. Nog aeNs Check anti-roll bar link to lower arm bolts - 60 Nm. . Check anti-roll bar clamp bolts - 22 Nm. |. Check condition of tie rod bushes. 10. 1, 2, Check condition of anti-rall bar bushes. Check condition of lower arm bushes. Check that a spit pin is fited to lower arm ball joint nuts 16 9 MAINTENANCERear suspension > MAINTENANCE Check damper top mounting nuts - 30 Nm Check anti-roll bar fxing nuts - 80 Nm Check damper assembly to 'H'frame fixing bolts - 80 Nm. Check condition of pivot bushes. Check condition of body bracket bolts - 100 Nm. Check pivot bush fixing bolts - 100 Nm. Check suspension dampers for oil leaks. . Check stub axle fixing bolts - 45 Nm. MAINTENANCE 17MAINTENANCE ROAD WHEELS AND FASTENINGS 1. Stee! whee Remove wheel trim. 100333 2. Check condition of road wheels including spare for signs of buckling and rim damage. 3. Working ina diagonal sequence loosen each nut '/; turn and then tighten to 110 Nm. cose SF 4, Alloy wheel-Push extractor tool over head of nut cover and pull to remove. 5. Fitkey socket over locking wheel nut, then fit ‘wheel nut spanner over key socket and 6. Sica! wheet:Refit wheel trim, ensuring valve stem locates between stem guides. Use firm pressure around edge to push trim securely into position TYRE PRESSURES AND CONDITION |. Check for signs of tyre wear indicator in tread pattern. 2. Check all tyres including spare for uneven wear, external cuts in fabric, exposure of ply or cord structure, lumps and bulges. 3. Check and adjust tyre pressures. See INFORMATION, General data. FOOTBRAKE SS eo -_- 1010338 41. Press brake pedal and check for firm resistance after short pedal movement. 18 = MAINTENANCEMAINTENANCE HANDBRAKE Check 1. Apply handbrake lever one notch at a time and ‘count number of notches to apply the brakes firmly, equivalent to 21.5 Nm applied perpendicular at a point 50 mm from the end of the handbrake grip. DATA: Handbrake lever travel = 10 +2 notches at 21.5 Nm for drum brakes; 42 £2 notches at 21.5 Nm for disc brakes. 2. Adjust handbrake cable tension if travel is outside mts. See BRAKES, Adjustments. BRAKE FLUID WARNING: Do not allow dirt or foreign liquids to enter reservoir when topping-up. Use only new AP New Premium Super DOT 4 or Castrol Girling Universal DOT 4 brake fluid from airtight containers, CAUTION: Do not allow brake fluid to contact paint finished surfaces as paint may be damaged. If spilled, remove fluid and clean area with clean warm water. Level check &S Sa 41. Wipe reservoir body and filler cap clean and ccheck level visually. 2. Remove filer cap and top-up to "MAX’ mark, if required. 1on0472 MAINTENANCE 19MAINTENANCE Renew fluid 41. Raise vehicle. Q WARNING: Support on safety stands. CAUTION: Never re-use fluid that has been AN Sieatvom syste Bleed sequence CAUTION: Braking efficiency may be seriously impaired if wrong bleed rum 2. Attach a bleed tube to LH front bleed screw. Insert free end of tube into battle containing fluid 3. Open bleed screw and use an assistant to press brake pedal to floor and release. 4. Repeat operation until lean fluid flows from bleed screw. '5. When clear, bubble free fluid flows, hold pedal to floor and tighten bleed screw to 10 Nm on calipers and 7 Nm on whee! cylinders, CAUTION: Ensure that fluid level in reservoir is maintained during the complete operational sequence using new brake fluid. 6. Remove bleed tube. 7. Repeat foregoing procedure for each whee! in sequence illustrated, 8. Apply brakes and check for fluid leakage. 9. Remove stand(s) and lower vehicle. 10. After completion of bleed sequence, check pedal for short firm travel when brakes are applied. 20 = MAINTENANCEMAINTENANCE BRAKE HOSES AND PIPES Visually check all brake fluid pipes, hoses and connections for correct routing and security Check for signs of chafing, leakage or MAINTENANCE 21MAINTENANCE Renew brake hose NOTE: Disconnect hose at end nearest to LA nostereyincer tse 1. Release brake pipe union from hose using ‘correct union spanner. 1om0¢69 2. Fitpplug to pipe end to prevent undue fluid loss. 3. Withdraw brake hose clip from upper bracket, 10. 1, 2, rowoa7e J. Remove bolt and release hose from bracket, front brake hose only. . Release banjo bolt at other end of hose and discard 2 sealing washers. . Remove hose and discard, ”. Position new hose through bracket . Fit banjo end to caliper or wheel cylinder with banjo bolt and 2 new sealing washers and tighten to 34 Nm, ). Fit brake hose clip to bracket and tap home with hide mallet. Remove plug from pipe end, connect brake pipe to hose and tighten union. ‘Secure hose to bracket with bolt and tighten. Front brake only. Bleed brake system. See BRAKES, Adjustments. 22° MAINTENANCEFRONT BRAKES-HYDRAULICS, PADS, DISCS AND CALIPERS. Check 1. Raise front of vehicle. ‘owoses 3. Check brake pads visually and assess lining thickness. MAINTENANCE 10Mo374 Minimum brake pad thickness: Dimension A = $ mm, NOTE: Measurement does not include pad backing thickness. |. Renew brake pads if thickness is less than ‘minimum dimension. See BRAKES, Repairs. 5. Fitroad wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings. 3. Remove stand(s) and lower vehicle. . Depress footbrake several times in order to ive correct pad to disc clearance before road testing, MAINTENANCE 23MAINTENANCE REAR DRUM BRAKES: Check 41. Raise rear of vehicle. Q WARNING: Support on safety stands. 2. Remove inspection grommet from brake backplate. 3. Check brake linings for contamination and Minimum lining thickness = 2.0 mm Inspect 4. Remove road wheels). 2. Release handbrake. 3. Remove 2 screws retaining brake drum. 4. Remove brake drum. Ease drum from hub using 2 screws, 10. 1, 2, If drum cannot be removed due toa wearlcorrosion lip, proceed as follows. Slacken hand brake cable. Remove rubber grommet from rear of brake backplate. Disengage handbrake lever stop fram behind lever with a screwdriver to increase shoe to drum clearance, and then remove drum. If the brake shoes need to be renewed. See BRAKES, Repairs. Clean down backplate with Giring cleaning fluid Ensure handbrake lever and quadrant lever are free to rotate. Lubricate contact faces of strut, handbrake lever and quadrant lever with Girling brake grease. Apply Molycote 3-111 Grease to shoe platforms on backplate and contact areas of adjuster strut and backplate. (24° MAINTENANCEs0Mo372 13. Apply Molycote 3-111 Grease to shoe steady platforms and tips of shoes as shown. CAUTION: Keep grease away from shoe linings and all hydraulic parts. 414, Inspect drum for cracks, score marks and corrosion. If serviceable, remove any loose rust with a wire brush and wipe inside of drum with damp cloth, 415. Check quadrant is in minimum adjustment position, 16. Reset adjustment by placing a piece of wood between hub and trailing brake shoe to prevent itfrom moving forward. Lever leading shoe ‘away from wheel cylinder with a screwdriver. Move quadrant in required direction, ease shoe back into position and remove wood. 417, Refit brake drum and 2 screws and tighten to 7 Nm. 418. Repeat brake assembly inspection and cleaning procedure for the remaining rear brake assembly. 419. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings. 20. Apply footbrake 3 times to set shoe to drum clearance. 21. Adjust handbrake cable. See BRAKES, Adjustments. 22. Remove stand(s) and lower vehicle. MAINTENANCE REAR DISC BRAKES. Check 4. Raise rear of vehicle. Q WARNING: Support on safety stands. 2. Remove road wheel(s). 3. Check brake pads visually and assess pad thickness A wf oo G3 = toMmoazs Minimum pad thickness Dimension A = 3 mm. NOTE: Measurement does not include pad backing thickness. 4. Renew brake pads if thickness is less than ‘minimum dimension. See BRAKES, Repairs. 55. Fitroad wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings. 6. Remove stand(s) and lower vehicle. MAINTENANCE 25MAINTENANCE BODY Locks, hinges and latch mechanism (not steering lock) soMoaea Functionally check operation ofall locks. Operate front door lock and check that electric central door locking operates. Ensure that all locks, hinges and latch mechanisms are lubricated using Door Lock land Latch Lubricant, Part No. VWN 10075. Inject grease sparingly into lock barrels. Clean off any surplus grease. DO NOT lubricate the steering lock. ‘4. Lubricate sunroof lid seal very sparingly using Non-Staining Grease BAU 5812 (Corning No. 7. Exterior paintwork and body panels 41. Visually check paintwork and body panels for damage and corrosion. Underbody sealer 1. Visually check underbody sealer for damage land continuity. 26 = = MAINTENANCEMAINTENANCE DRIVER AIR BAG MODULE 41. Visually check for signs of damage. 2. To renew an airbag. See RESTRAINT SYSTEMS, Repairs. PASSENGER AIR BAG MODULE 41. Visually check for signs of damage. 2. To renew an airbag. See RESTRAINT SYSTEMS, Repairs. ROTARY COUPLER 1. Rotate steering wheel one half turn in each direction and check for noise from the rotary coupler. 2. To renew the rotary coupler. See ELECTRICAL, Repairs. ‘SCREEN WIPERS AND BLADES 4. Operate front screen wiper. Check that blades wipe screen without smearing Check that wipers park correctly. Operate wiper switch in all modes, Check that wipers operate at speeds selected Operate rear screen wiper and check that blade wipes screen without smearing Renew blade Lit wiper arm. Press retaining lever. Slide blade down arm. Withdraw blade assembly from arm. Position new blade to wiper arm. Push blade into engagement with arm. Check that itis retained MAINTENANCE 27MAINTENANCE WINDSCREEN AND REAR SCREEN WASHERS. 41. Visually check mixture level in reservoir. 2. Top-up by removing filler cap and adding required concentration mixture of water and 'Screenwash’ 3. Clean windscreen washer jets using thin wire as a probe. ONOAES 4. Operate windscreen washer and check that jets stike top and centre of area to be wiped. 5. Adjust et by inserting a needle into jet hole and repositioning, 6. Clean rear screen washer jets using thin wire as a probe. 7. Operate rear screen washer and check that jet strikes centre of area to be wiped. 8. Adjust jet by inserting a needle into jet hole and repositioning. 9. Check operation of programmed washiwipe by switching on ignition and operating washer lever. 10. Observe that washer and wiper operate for as long as lever is operated and wiper operates. for a further 5 seconds after lever is released. 14. Recheck level in reservoir after adjustments. 28 = MAINTENANCEMAINTENANCE LAMPS, HORNS AND WARNING INDICATORS FUSEBOX 41. Check for correct operation of all lamps, warning lamps, switches and horn, BATTERY CONNECTIONS: Engine compartment fuse box 4. Wipe batery top clean and dy 4: Release andi offcover, 2. Pull back protector to expose terminal posts . Release 2 clips and remove fuse box inner ‘and smear with petroleum jelly. cover. a, Salmon wh poole 2. Check securiy of fusible lnk and power lead connections, |. Refit inner caver. 5. Refit cover and secure. 4, Replace protector. 4 5. MAINTENANCE 29MAINTENANCE ROAD TEST. Starter inhibitor switch - automatic 1. Select D’ gear lever position 2. Check that engine will not start. 3. Select'R’ gear lever position and repeat start check. 4, Check that engine will startin 'P’ and 'N' positions. Selector and kick-down cables - automatic 41. Check for correct setting of gear selector cable and kick-down overcheck. Engine start and fast idle speed 41. Start engine from cold and check that fast engine idle speed is maintained until normal ‘engine temperature is reached. Engine performance and throttle operation 41. Start engine and check that it starts easily. 2. Check that ‘ol pressure’ and ‘no charge’ warning lamps extinguish 3. Check that throttle pedal movement is free and unrestricted, ‘4, Check that engine is responsive to throttle movement. Clutch and gear selection - manual. Normal driving conditions 1. Check that clutch engages smoothly without judder, slipping or noise. 2. Check for abnormal transmission noise. 3. Check for smooth quiet gear change and that gear selected engages easily Gear change and parking paw! engagement - automatic. Normal driving conditions |. Select 'R’ and check for smooth take up. 2. Select 'D' and check for smooth up-changes of ralio from rest. 3. Check operation of kick-down by driving vehicle at approximately 30 mph (50 km/h) and pressing throttle pedal quickly and firmly to the floor. Automatic down-change should operate. 4. Slow down vehicle and check for smooth down-changes of ratio. '5. Stop vehicle on a slope. Select 'P’ and release handbrake. Check that vehicle does not move and that selector does not slip out of 8. Carry outa similar check with vehicle facing in the opposite direction. 30 = MAINTENANCESteering 1. Check for noise, effort required, free play and self centralism, Suspension 41. Check for noise, irregularity in ride (e.g dampers) and wheel imbalance. Footbrake 41. Check for pedal effort, travel, braking efficiency, pulling and binding, Instruments 4. Check that all instruments operate. 2. Check speedometer for steady operation, noise and operation of distance recorder. Body 4. Check for abnormal body noise. Seat belts 1. Check for operation of inertia reels and condition of belt webbing, Handbrake 41. Apply handbrake firmly, check travel and ratchet hold and release. MAINTENANCE MAINTENANCE 31ENGINE “KB? CONTENTS REPAIRS CAMSHAFT FRONT OIL SEAL CAMSHAFT REAR OIL SEAL CRANKSHAFT FRONT PULLEY CRANKSHAFT FRONT OIL SEAL CRANKSHAFT REAR OIL SEAL CYLINDER HEAD GASKET CAMSHAFT COVER GASKET VALVE STEM OIL SEAL ENGINE AND GEARBOX ENGINE STEADY BAR ENGINE LH MOUNTING ENGINE RH MOUNTING FLYWHEEL FLYWHEEL STARTER RING GEAR OIL FILTER DIPSTICK TUBE lL PUMP. SUMP GASKET OIL PRESSURE SWITCH CAMSHAFT TIMING BELT CAMSHAFT TIMING BELT UPPER COVER CAMSHAFT TIMING BELT LOWER COVERCAMSHAFT FRONT OIL SEAL Service repair no - 12.13.05 Remove 1. Remove and discard camshaft timing belt. See this section. WES 12 50208 2. Using tool 12-182, hold camshaft gear against rotation and loosen centre bolt. 3. Remove centre bolt and plain washer from camshaft gear. 4, Remove camshaft gear. 186 12098 186 12004 MU pennies OF 5. Fitcamshaft gear centre bolt to camshaft. 6. Fittool 186 1299A into camshaft seal 7. Remove ol seal by tightening centre bolt 186 1299-1 8. Remove centre bolt from camshaft. ENGINE -'ks’ [pyseee]] Refit |. Clean sealing area of cylinder head and camshaft, ensuring al races of rubber are removed. DO NOT use a scraper as this may damage sealing surfaces. 4eNHaS6B. : 2. Using tool 186 1769A fit new camshaft oll Aa CAUTION: Ci nal must be ad ry. Do Dy countess NOTE: This oil seal is coloured BLACK. 3. Align timing mark and fit camshaft gear. 4. Fit centre bolt and plain washer to camshaft gear. REVISED: 06/99 REPAIRS 1ENGINE - ’K8’ 2 Using too! 12-182 hold camshaft gear against rotation and tighten centre bolt to: Mg Bolt - 35 Nm M10 Bolt - 65 Nm Check camshaft gear timing mark alignment. Fitnew camshaft timing belt. See this section. CAMSHAFT REAR OIL SEAL Service repair no - 12.13.06 Remove 4. Disconnect battery earth lead 2. Remove air cleaner assembly. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 3. Remove distributor cap. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 18G 12098 | 186 12998-1 ype in) A Wh a 1aNIASS J 4, Screw tool 186 129A. into camshaft rear oil seal 5. Tighten centre bolt, ool 18G 1299-1, to remove seal 6. Remove camshaft oll seal REPAIRS REVISE! 6/99Refit 41. Clean sealing area of cylinder head and camshaft carrier, ensuring all traces of rubber are removed. DO NOT use a scraper as this may damage sealing surfaces. 18G 17098 jeMta568, 2. Using tool 186 1769A fit new camshaft oil seal. A NOTE: This oil seal is coloured RED. CAUTION: Oil seal must be fitted dry. Do LX notuse tool 186 1769. 3. Fitdistributor cap. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 4, Fitair cleaner assembly. See ENGINE ‘MANAGEMENT SYSTEM - MEMS, Repairs. 5. Connect battery earth lead. ENGINE -'ks’ [pyseee]] CRANKSHAFT FRONT PULLEY Service repair no - 12.21.01 Remove 4. Disconnect battery earth lead 2. Raise front of vehicle. Q WARNING: Support on safety stands. 3. Remove auxiliary dive belt. See ELECTRICAL, Repairs. 4, Remove starter motor. See ELECTRICAL, Repairs. 18 1571 5. Fit flywheel locking tool 18G 1871 to flywheel housing and secure with 2 bolts REVISED: 06/99 REPAIRS 3ENGINE - ’K8’ Refit t2NN713, 1212356 6. Remove bolt securing pulley to crankshaft and collect washer. 7. Remove crankshaft pulley. 4. Fitcrankshatt pulley to crankshaft gear ensuring that indent on pulley locates over lug (on gear (arrowed in illustration). 2. Fit washer and bolt securing crankshaft pulley to crankshaft and tighten to 205 Nm. 3. Remove 2 bolts securing tool 186 1571 to flywheel housing and remove tool 186 1571. 4, Fitstarter motor. See ELECTRICAL, Repairs. 5. Fit auxiliary drive bet. See ELECTRICAL, Repairs. 6. Connect battery earth lead. 4 REPAIRSCRANKSHAFT FRONT OIL SEAL Service repair no - 12.21.14 Remove 1. Remove camshaft timing belt. See this section. 2. Remove crankshaft gear. 18G 1566 sansea7 3. Fittool 186 705-1/3 to end of crankshaft. 4. Ensure bore of tool 186 1566 is free from burrs. 5. Screw tool 18G 1566 into crankshaft front oil seal. 6, Tighten centre bolt of ool 186 1566 to remove seal 7. Discard crankshaft front oil seal 8. Remove 186 705-1A/3 from crankshaft. ENGINE -'ks’ [pyseee]] Refit |. Using a lint free cloth, thoroughly clean oil seal recess in oil pump and running surface on crankshaft | L ves 1587, 12M 10988 2. Fitoll seal guide, from seal kit, over end of crankshaft 3. Position new seal on crankshaft up against oll ump housing. Drift seal into place using too! 186 1587. CAUTION: Oil sal must be fitted dry. 5. Clean crankshaft gear. . Fit crankshaft gear to crankshaft. 4, Remove tool 186 1587 and oil seal guide. 5. 6. 7. Fit camshaft timing belt. See this section. REVISED: 06/99 REPAIRS 5ENGINE - ’K8’ CRANKSHAFT REAR OIL SEAL Servi repair no - 12.21.20 Remove 1. Remove flywheel. See this section 124s 2. Using a burr free flat ended screwdriver, ease crankshaft rear oll seal from cylinder block and remove. Discard oil seal CAUTION: Do not mak sealing surace on Refit 4. Remove all traces of oll and sealant from cylinder block, oil seal recess and running surface on crankshaft. 2. Apply al5 mm continuous bead of sealant, Part No. GAC 8000 to replacement oil seal as shown, CAUTION: Do not apply oil or grease to iny part of oil seal or running surfac crankshaft. Seal must be fitted ately after application of sealant. 18G 1574 3,4 . Position ol seal to cylinder block and fit oll seal replacer tool 18G 1574, retain tool using 3 slave bolts, . Evenly tighten oll seal replacer bolts to press oil seal squarely into cylinder block 3. Leave oil seal replacer tool and oil seal in clamped position for one minute. 3. Remove oil seal replacer tool ” Allow sealant to cure for a minimum of 30 minutes before topping-up oil or rotating crankshaft . Fit flywheel. See this section. 6 REPAIRSCYLINDER HEAD GASKET Service repair no - 12.29.02 Remove 1 2 3. 10, 1 12. Disconnect battery earth lead, Drain cooling system. See COOLING SYSTEM - ’k’ SERIES, Repairs. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Remove exhaust manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs. Remove and discard camshaft timing belt. See this section. 12M 22008 Restrain camshaft gear using tool 12-182 and remove bolt and washer securing camshaft gear to camshaft Remove camshaft gear. Remove camshaft timing belt tensioner spring. Remove timing belt tensioner centre Allen bolt land backplate screw. Remove camshaft timing belt tensioner. Remove 3 bolts securing camshaft timing belt Remove camshaft timing belt rear cover. ENGINE - ’K8’ 13. Remove clips securing coolant hoses to coolant outlet elbow. |. Release coolant pipes from outlet elbow. . Disconnect multiplugs from coolant sensors on outlet elbow. 16. Release throttle cable agjustment nut from abutment bracket. 17. Release throttle cable from throttle cam. REVISED: 06/99 REPAIRS 7ENGINE - ’K8’ 18. Release clip securing evaporative emission canister vacuum pipe to inlet manifold and disconnect pipe. 49. Disconnect ECM vacuum pipe from inlet manifold, 20. Depress plastic collar on quick release ‘connector and disconnect brake servo vacuum hose from inlet manifold 21. Release clip securing coolant pipe to inlet manifold and disconnect pipe. . Position absorbent cloth around fuel fiter outlet 23. Loosen fuel filter outlet union to relieve fuel pressure. 24, Re-tighten union to 28 Nm. CAUTION: To prevent damage to fuel 5, use two 1n loosening or tightening 8 REPAIRSENGINE - ’K8’ 25. Release clip securing fuel return pipe to fuel rail and disconnect pipe. CAUTION: Plug ua sytem hoses and Dy Somes 26. Release fuel return pipe from 2 clips on underside of inlet manifold. 29, Release injector harness multiplug from bracket on throttle body. 30. Disconnect multipug from injector hamess. 31. Disconnect multilug from IAT sensor. 32. Disconnect multiplug from TP sensor. 33. Disconnect multiplug from IACV. 34, Disconnect coil ht lead from distributor. 27. Remove 2 bolts securing fuel feed pipe to fuel rail 28. Remove fuel feed pipe from fuel rail and discard 'O' ring. REPAIRS 9ENGINE - ’K8’ bracket. 36. Remove 3 bolts securing both h.. lead guide brackets to cylinder head and collect brackets. 37. Remove camshaft cover. See this section, 38. Remove 10 cylinder head bolts in sequence shown, Remove bolts and store in fitted order. 39. Using assistance, remove cylinder head assembly from cylinder block. 40. Remove cylinder head gasket from cylinder block and discard, 41. Remove 2 location dowels from cylinder block. 42. Fit cylinder liner clamps 18 1736/1 to cylinder block and secure with cylinder head bolts CAUTION: Do not tan ranahat wh AN, Shiner nd removes Face yaa eton ecs cfucodte seal damaging aves 10 REPAIRSRefit 1. Remove bolts securing cylinder liner clamps to cylinder block and remove clamps. 2. Clean joint surfaces of cylinder head and cylinder block. Clean oil and coolant passages. If necessary, de-carbonise piston crowns and cylinder head, 3. Clean cylinder head bolts with a wire brush. Inspect cylinder head bolts for signs of damage. ‘4, Wash cylinder head bolts and wipe dry. apply a light film of oil to bolt threads and underside of head bolts, 5. Clean location dowels and fit to cylinder block. 6. Fitnew cylinder head gasket, dry, to cylinder block 7. Using assistance, fit cylinder head onto cylinder block, carefully locating dowels. 8. Carefully enter cylinder head bolts. DO NOT DROP. Screw botts into place by hand. 9. Working in the sequence shown, progressively tighten the cylinder head bolts using the following procedure: Allbolts to 20 Nm. Use a felt tip pen and mark position of radial mark on each bolt head. ‘Tum all bolts through 180°. . Turn al bolts through another 180° and align radial mark. If bolt is overtightened, back off then realign radial marks. 10. Fit camshaft cover. See this section, 1, 2, 1B. 14, 15, 16. 17. 18, 19, 20. at. 2, 23, 24, 25. 26. 27. 28, 29, 30. ENGINE -'ks’ [pyseee]] Fith.t lead guide brackets and secure with bolts Connect coil ht lead to distributor. Fitbolt securing inlet manifold to support bracket and tighten to 25 Nm. Connect muttiplug to IACV. Connect multiplug to TP sensor. Connect multiplug to IAT sensor. Connect injector hamess multiplug and secure con throttle body mounting bracket. Fitnew ‘0’ ring to fuel feed pipe Fit fuel feed pipe to fuel rail and tighten bolts to 5Nm. Fit fuel return hose to fuel rail and secure with clip. ‘Secure fuel return pipe to clips on underside of inlet manifold Fit coolant pipe to inlet manifold and secure with clip. Connect brake servo pipe to inlet manifold Connect ECM vacuum pipe to inlet manifold. Fit evaporative emission canister vacuum pipe to inlet manifold and secure with clip. Connect throttle cable to throttle cam. Locate throttle cable adjusting nut in abutment bracket. Connect coolant pipes to outlet elbow on cylinder head and secure with clips. Connect multiplugs to coolant sensors on outlet elbow. Fit camshaft timing belt rear cover and tighten bolts to 10 Nm. REPAIRS 11ENGINE - ’K8’ at. 32, 33, 35, 36. 37. 38, 39. 40. 12 Position camshaft timing belt tensioner to ‘engine and ft centre bolt and backplate screw. Fit camshaft timing belt tensioner spring, Fit camshaft gear to camshaft ensuring timing marks on camshaft gear and rear cover are aligned. Fitbolt and washer securing camshaft gear to camshaft, Using tool 12-182 restrain camshaft {gear and tighten bolt to: Mg Bolt 35 Nm M10 Bolt - 65 Nm Fit new camshaft timing belt. See this section. Fit exhaust manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs. Fitair cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Connect battery earth lead. Refill engine cooling system. See COOLING SYSTEM - ’k’ SERIES, Repairs. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments, ‘CAMSHAFT COVER GASKET Service repair no - 12.29.40 Remove 41. Disconnect battery earth lead 2. Release 2 clips and disconnect 2 breather hoses from camshaft cover. 12M1716 3. Using sequence shown, progressively loosen. and remove 12 bolts securing camshaft cover. 4, Remove camshaft cover. NOTE: The gasket is re-usable and should LA remain attached to camshaft cover. '5. Check condition of sealing path. It should be complete and attached to gasket. Remove gasket from camshaft cover only f sealing path is damaged or detached from gasket. REPAIRS REVISE! 6/99Refit 41. Clean mating surfaces of camshaft cover and 2. Clean inside of camshaft cover. If necessary, wash oil separator elements in solvent and blow dry. CAUTION: If camshaft cover gasket is to be renewed, fit new gasket to camshaft 10 seMt7 ~ 3. Fitcamshaft cover to camshaft carrier. Fit bolts ‘and working in sequence illustrated, tighten progressively to 10 Nm ‘4, Connect breather hoses to cover and secure with clips. 5. Connect battery earth lead. ENGINE -'ks’ [ysece]| VALVE STEM OIL SEAL Service repair no - 12.30.26 Remove 4. Disconnect battery earth lead 2. Remove camshaft cover. See this section, 3. Remove camshaft. See 'K’ Series Engine Overhaul Manual - Overhaul. 4. Remove spark plug from cylinder head. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. SS na ‘5. Screw airline adaptor MS 1567 into spark plug hole. 6. Connect airline to adaptor. 7. Remove hydraulic tappet from valve. CAUTION: Store tappets inverted to prevent oil loss, REPAIRS 13ENGINE - ’K8’ 10. 14 12Mi1806, 3. Position tool MS 1567/7 to valve spring cap. 11. Use tool 186 1577 to remove valve stem oil 1. Strike tool firmly with hammer to release spring seal cap calles. Remove collets, spring cap, and valve spring. REPAIRSRefit 1. Lubricate new valve stem oll seal with engine ol 2. Use tool 186 1577 to fit oil seal to valve stem. 121807 Position valve spring, spring cap, and collets. Position tool MS 1567/1 to valve spring cap. Strike tool with hammer to secure spring cap to valve with collets. Ensure spring cap collets are correctly seated 6. Fithydraulic tappet to valve. 7. Disconnect airline, and remove adaptor from cylinder head, 8. Fitspark plug. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 9. Fitcamshaft. See 'k’ Series Engine Overhaul Manual - Overhaul 10. Remove camshaft cover. See this section. 4114. Connect battery earth lead, gaye ENGINE -'ks’ [ysece]| ENGINE AND GEARBOX Service repair no - 12.37.01.99 Remove 41. Raise front of vehicle. Q WARNING: Support on safety stands. 2. Remove road wheel(s). 3. ifrequired: Drain engine oil. See MAINTENANCE. 4, Drain cooling system. See COOLING SYSTEM - ’K’ SERIES, Adjustments. 5. Drain gearbox oil. See MANUAL GEARBOX - 'R6S', Adjustments. 6. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 7. Remove ECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 8. Remove engine management relay module. Seo ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 9. Remove 2 bolts securing resonator to battery tray. 10. Remove resonator. 11. Remove engine compartment fuse box. See ELECTRICAL, Repairs. REPAIRS 15ENGINE - ’K8’ SWAY _ AvyA\ 15. Loosen clip and disconnect radiator top hose from coolant outlet elbow. 16. Loosen clip and disconnect coolant hose from. coolant ral 17. Loosen clip and disconnect heater hose from coolant outlet elbow, position hose aside. 12. Remove 4 bolts securing battery tray to body. 413. Loosen 3 bolts securing battery tray to body. 414, Remove battery tray. 18. Disconnect clutch cable from clutch release lever. 19. Release cable from abutment bracket. 16 REPAIRSZo LOA 4 xs oN 4. -\ ramest |) KY / 20. Remove bolt securing engine harness earth lead to bonnet lacking platform, 21. Disconnect multiplug from radiator cooling fan. ENGINE - ’K8’ 22, Disconnect engine harness multiplug from ‘main harness, REPAIRS 17ENGINE - ’K8’ 23. Disconnect muitiplug from HO2S. 24. Disconnect front pipe from manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 28. Depress collar and release brake servo vacuum hose from inlet manifold. 29. Release ECM vacuum pipe from inlet manifold 30. Loosen clip and disconnect coolant hose from. inlet manifold 31. Loosen clip and disconnect hose from thermostat housing, 25. Release throttle cable adjusting nut from ‘abutment bracket. 26. Disconnect throttle cable from throttle cam, 27. Remove evaporative emission canister. See EMISSION CONTROL, Repairs. 18 REPAIRSENGINE - ’Kt 34. Loosen clip and disconnect hose from coolant rail Position absorbent cloth around fuel fer outlet 35, 32. Disconnect 3 engine harness multiplugs from main hares. 36. Loosen union to relieve fuel pressure then 33. Disconnect inertia switch muliplug and release re-tighten to 28 Nm. harness clip from bracket CAUTION: To prevent damage to fuel LAY system pipes or components use two spanners when loosening or tightening 37. Position an absorbent cloth around fue! rail feed pipe REPAIRS 19ENGINE - ’K8’ coupes 44, Using tool 18G 1592 release gear selector linkage ball oint from gear selector lever. 445. Using tool 18G 1592 release gear change linkage ball joint from gear change lever. 38. Remove 2 bolts securing fuel feed pipe to fuel rail 39. Disconnect fuel feed pipe from fuel rail 40. Remove and discard ‘0’ ring 1ew2286 46, Fitlifting bracket 186 1872/2 to cylinder head and tighten bolt to 9 Nm. 41. Release clip and disconnect fuel retum hose from fuel ral A CAUTION: Plug the connections. 42, Release fuel return hose from clips on Underside of inlet manifold and position aside. 43, Release both drive shafts from gearbox, as, detailed in Differential cil seal. See MANUAL GEARBOX - 'R65', Repairs. 20 REPAIRSENGINE - ’K8’ 47. Fit second lifting bracket 186 1572/2 to cylinder head and tighten bolt to 9 Nm. 48, Connect adjustable iting bracket 186 1598 to ‘engine lifting brackets. Connect hoist to engine lifting bracket and raise to take weight of engine without exerting load on engine mounting bots. 49. |. Loosen through bolt securing engine steady bar to subframe, |. Remove through bolt securing engine steady bar to bracket on gearbox. 2. Remove engine LH mounting. See this section. . Remove through bolt securing engine RH ‘mounting to body. |. Using adjustable ling bracket tool 18G 1598, tit engine with the gearbox as low as possible, 5. Using assistance, manoeuvre engine and gearbox from vehicle. . Lower engine and gearbox assembly and disconnect hoist from adjustable lifting bracket, REPAIRS 21ENGINE - ’K8’ Refit 1 2. 3. 4 10. 1. 12. 13. 14, 22 Connect hoist to tool 186 1598, Using assistance, raise engine and manoeuvre into position in vehicle ‘Adjust tool 18G 1598 so engine is horizontal in ‘engine compartment. Fitengine RH mounting through bolt but do not tighten. Fit engine LH mounting. See this section. Connect steady bar to engine, ft through bolt land tighten bolt to 45 Nm. ‘Tighten through bolt securing engine steady bar to subframe to 80 Nm. Tighten engine RH mounting through bolt to 80 Nm. Lower hoist and disconnect tool 186 1598 from ‘engine lifting brackets. Remove lifting brackets 186 1592 from engine. Clean gear selector linkage and gear selector linkage ball joints, 1aye239 Using too! 186 1594 connect gear selector linkage ball joint to gear selector lever. Using too! 186 1594 connect gear change linkage ball joint to gear change lever. Connect drive shafts to gearbox, as detailed in Differential oil seal. See MANUAL GEARBOX ~'R65;, Repairs. 45. 16. 17. 18, 19, 20. at. 2, 23, 24, 25, 26. 27. 28. 29. 30. at 32. 33. 34. 35. 36. 37. 38, 39, 5. Position fuel return hose through clips under inlet manifold and connect to fuel rail, secure with clip. Lubricate new ‘©’ ring with slicone grease and fit to fuel feed pipe. Connect feed pipe to fuel rail and tighten bolts to5Nm. Connect hase to coolant rail and tighten clip. Connect hase to thermostat housing and tighten clip Connect coolant hose to inlet manifold and. tighten clip Connect muttiplug to inertia switch and secure clip on hamess to bracket. Connect engine harness multiplugs to main hares. Connect ECM vacuum pipe to inlet manifold. Connect brake servo vacuum pipe to inlet manifold Fit evaporative emission canister. See EMISSION CONTROL, Repairs. Connect throttle cable to throttle cam. ‘Secure throttle cable adjusting nut to abutment bracket. Connect front pipe to manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs. Connect multiplug to HO2S. Connect multipug to radiator cooling fan. Connect engine harness multiplug to main hares. Position engine hamess earth lead to bonnet platform and tighten bolt to 9 Nm. Feed clutch cable through abutment bracket and connect to clutch release lever. Connect heater hose to coolant outlet elbow and tighten clip. Connect radiator bottom hose to coolant rail and tighten clip. Connect radiator top hose to coolant outlet elbow and tighten clip. Position battery tray in vehicle. Tighten 3 bolts securing battery tray to body, to 10 Nm. Fit engine compartment fuse box. See ELECTRICAL, Repairs. Fit4 bolts Securing battery tray to body and tighten to 10 Nm, REPAIRSat, 42, 43, 45, 46, 47. 48, 49. 50. st. Fit resonator to air intake pipe. Fit bolts securing resonator to battery tray and tighten to 10 Nm Fit engine management relay module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. FItECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Fit road wheel(s) and tighten nuts to correct, torque. See INFORMATION, Torque wrench settings. Remove stand{s) and lower vehicle. Refil gearbox with ol. See MANUAL GEARBOX - 'R65', Adjustments. Refill cooling system. See COOLING SYSTEM - ’K’ SERIES, Adjustments. i required! Refill engine with oil. See MAINTENANCE. ‘Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments. ENGINE -'ks’ [ysece]| ENGINE STEADY BAR Service repair no - 12.45.08 Remove 41. Raise front of vehicle. Q WARNING: Support on safety stands. 1eMii47 2. Remove through bolt securing engine steady bar to subframe, ‘3, Remove through bolt securing engine steady bar to bracket on gearbox. 4, Remove engine steady bar. 41. Position engine steady bar to subframe and fit through bolt 2. Fitand tighten through bolt securing steady bar to bracket on gearbox to 45 Nm. 3, Tighten through bolt securing steady bar to subframe, to 80 Nm, 4, Remove stand(s) and lower vehicle. REPAIRS 23ENGINE - ’K8’ ENGINE LH MOUNTING Servi repair no - 12.45.30 Remove 1. Raise front of vehicle. Q WARNING: Support on safety stands. 2. Fitblock to jack and position jack to support engine. 3. Remove air cleaner. See ENGINE ‘MANAGEMENT SYSTEM - MEMS, Repairs. 12M1746, 44, Disconnect clutch cable from clutch release lever. 5. Release clutch cable from abutment bracket on {gearbox and position aside. 6. Remove 2 bolts securing engine mounting to ‘gearbox mounting bracket. 7. Remove 2 bolts securing engine mounting to body. 8. Remove 2 bolts securing engine mounting to ‘mounting bracket 9. Loosen 2 bolts securing engine mounting bracket to body. 10. Carefully lower engine and remove engine ‘mounting Refit 4. Postion engine mounting and raise engine and gearbox assombly, 2. Filbots securing engine mounting to boty and tighten to 85 Nm 2. Fitbots securing engine mounting to bracket on body and tighten fo 55 Nm 4. Allgn gearbox mounting bracket to engine mounting, bots and tighten fo 60 Nm. 5. Tighten bolts securing bracket to body, o 55 Nm 6. Lower jack supporting engine, and remove from beneath vehicle 7, Feed clutch cable through abutment bracket and connect io cutch release lever 8. Fitaircloaner. See ENGINE MANAGEMENT SYSTEM- MEMS, Repair, 9. Fitroad wheels) and then nus to correct torque. See INFORMATION, Torque wrench settings 410. Remove stand() and lower vehicle 24 REPAIRSENGINE -'ks’ [ysece]| ENGINE RH MOUNTING Service repair no - 12.45.31 Remove 41. Disconnect battery earth lead. 2. Fitwooden block to jack and position jack to ‘support engine. 3. Remove and discard 2 nuts securing engine mounting to engine. ‘4, Remove through bolt securing engine mounting to bady. 5. Remove engine mounting. 6. Remove 2 rubber washers from mounting, 41. Fitrubber washers to engine mounting, 2. Fitengine mounting to body and engine. 3. Fitthrough bolt securing engine mounting to body, but do not tighten. 44, Fit2 new nuts securing engine mounting to ‘engine and tighten to 100 Nm 5. Tighten through bolt securing engine mounting to body, to 75 Nm. 6. Lower jack supporting engine and remove from beneath vehicle. 7. Connect battery earth lead. FLYWHEEL. Service repair no - 12.53.07 Remove 41. Remove clutch assembly. See CLUTCH, Repairs. 2. Leave tool 186 1571 attached to cylinder block. 3. Remove crankshaft position sensor. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 4, Remove and discard 6 bolts securing flywheel to crankshaft, '5. Remove flywheel from crankshaft Refit |. Using a tap, clean adhesive from threads of flywhee! bolt holes in crankshaft Clean flywheel and mating face of crankshatt. Fit flywhee! to crankshaft Fit NEW bolts securing flywheel to crankshaft ‘and working in a diagonal sequence tighten bolts to 85 Nm. ‘5. Fit crankshaft position sensor. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 6. Fitclutch assembly. See CLUTCH, Repairs REPAIRS 25ENGINE - ’K8’ FLYWHEEL STARTER RING GEAR Service repair no - 12.53.19 Remove 1. Remove flywheel. See this section 12M1460 2. Apply a cold chisel in root of ane of ring gear teeth, strike chisel with hammer to break ring gear. 3. Remove starter ring gear. Refit |. Clean flywheel and starter ring gear. Heat new starter ring gear evenly to @350°C, indicated when the ring is a ight blue colour. 3. Locate ring gear on flywheel and press ring gear hard against flange on flywheel ‘4, Ensure ring gear is correctly seated around the complete circumference of flywheel and allow to cool 5. Fitflywheel. See this section. OIL FILTER Service repair no - 12.60.04 Remove 41. Raise front of vehicle. Q WARNING: Support on safety stands. ami7ie 2. Clean area around fiter head and place a container beneath engine 3. Using a strap wrench, unscrew and discard filter. Refit |. Clean mating face of filter head. 2. Lubricate sealing ring of new filter with clean engine oil 3. Fitnew filer and tighten by hand until it seats then tighten a further half tur, 4. Remove stand(s) and lower vehicle. ‘5. Top up engine with oil to specification 10w/40 until level is correct. 6. Start and run engine and check for leaks. 7. Stop engine, wait a few minutes, then check cil level. Top up if necessary. 26 REPAIRSENGINE -'ks’ [pyseee]] DIPSTICK TUBE Service repair no - 12.60.09 Remove 4. Remove dipstick. 2. Remove bolt securing thermostat housing and dipstick tube to cylinder block 3. Remove 2 bolts securing dipstick tube to cylinder block. 4, Remove dipstick tube and collect gasket 1. Fitnew gasket and dipstick tube to cylinder block 2. Fitbolts securing dipstick tube to cylinder block land tighten to 10 Nm 3. Fitbolt securing dipstick tube and thermostat housing to cylinder block and tighten to 10 Nm. 4. Fit dipstick. O1L PUMP Service repair no - 12.60.26 Remove 4. Remove camshaft timing belt. See this section. 2. Remove crankshaft gear. 3. Remove 2 bolts securing engine harness to oil pump. 4, Remove and discard 9 bolts securing oil pump to cylinder block. romn7ny ‘5. Remove oil pump and discard gasket. REVISED: 06/99 REPAIRS 27ENGINE - ’K8’ Refit 1 2. 3. 28 Clean oil pump bolt holes in cylinder block. Clean mating surfaces of oil pump and cylinder block Clean oil seal running surface on crankshat Fit new oil pump gasket to cylinder block and position oil pump. CAUTION: Do not lubricate crankshaft front oil seal or running surface of crankshaft. 7 121769 . Fit new Patchlok bolts and tighten in sequence shown to 10 Nm. . Align engine harness to oil pump, ft bolts and tighten to 10 Nm. 7. Clean crankshaft gear. Fit gear to crankshaft Fit camshaft timing belt. See this section. ‘SUMP GASKET Service repair no - 12.60.38 Remove 4. Disconnect battery earth lead 2. Raise front of vehicle. Q WARNING: Support on safety stands. 3. Drain engine oil. See MAINTENANCE. 4, Fitnew sealing washer to engine oil drain plug Fitdrain plug and tighten to 42 Nm. '5. Remove exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 12Mt461 6. Remove 3 bolts securing flywheel lower cover plate to flywhee! housing. 7. Remove flywheel lower cover plate. REPAIRS REVISE! 6/9910M1462 8 8. Remove and discard 14 bolts securing sump to ‘engine bearing ladder. 9. Release gasket from bearing ladder and remove sump. 10. Remove gasket from sump. ENGINE -'ks’ [pyseee]] Refit |. Clean inside of sump and mating faces of sump and bearing ladder. 2. Check condition of sump gasket, renew gasket ifit shows signs of damage or deterioration 3. Fit gasket to sump ensuring its 7 pegs are located in holes on sump. 4. Position sump to engine bearing ladder, ft and lightly tighten new Patchiok bolts. 10M463 '5. Working in the sequence shown, progressively tighten sump bolts to: MB/MB bolts - 10 Nm. 6. Fit flywheel lower cover plate and tighten 3 bolts to 9 Nm. 7. Fitexhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 8. Remove stand(s) and lower vehicle. 9. Fill engine with oil. See MAINTENANCE. 10. Connect battery earth lead. REVISED: 06/99 REPAIRS 29ENGINE - ’K8’ OIL PRESSURE SWITCH Service repair no - 12.60.50 Remove 41. Disconnect battery earth lead. 2. Raise front of vehicle. 3. Position container below engine ol fiter to collect spillage. 12M1305 4. Disconnect multplug from oil pressure switch. 5. Remove oll pressure switch Refit Clean oil pressure switch threads. Fit oil pressure switch and tighten to 15 Nm. Connect muttiplug to oil pressure switch. Remove stand{s) and lower vehicle. Top-up engine oll. See MAINTENANCE. Connect battery earth lead. ppaene CAMSHAFT TIMING BELT Service repair no - 12.65.18 Remove CAUTION: Timing belt must be replaced if cylinder head is to be removed or new timing gears, tensioner or coolant pump are to be fitted. Timing belts must be stored and handled with care. Always store a timing belt on its edge with a bend redius greater than 50 mm. Do not use a timing belt that has been twisted or bent double as this can damage the reinforcing fibres. Do not use a timing belt if debris other than belt dust is found in timing cove Do not use a timing belt if partial engine seizure has occurred. Do not use a timing belt if belt mileage exceods. 48,000 miles (77,000 km). Do not use an oil or coolant contaminated belt. NOTE: The cause of contamination MUST LN be rectified. 4. Disconnect battery earth lead 2. Raise front of vehicle. Q WARNING: Support on safety stands. 3, Remove RH front road wheel 4. Remove timing belt upper cover. See this section. 1eMi719 '5. Rotate crankshaft to align camshaft gear timing ‘marks with top face of cylinder head - 90° BTOC. 30 REPAIRS6. Remove starter motor. See ELECTRICAL, Repairs. 186 1971 7. Position flywheel lacking tool 186 1571 to flywheel and secure with 2 starter motor bolts 8. Remove auxiliary drive belt. See ELECTRICAL, Repairs. 9. Remove engine RH mounting. See this section. 40, Remove 3 bolts securing engine RH mounting bracket to engine. 11. Carefully raise engine slightly to remove ‘engine mounting bracket. 42. Remove crankshaft pulley bolt and washer. 43. Remove crankshatt pulley. 414. Remove 3 bolts securing timing belt lower 415. Remove lower cover and rubber seal ENGINE - ’K8’ 12M 7280 16. If camshaft timing belt is to be re-used, mark position of tensioner backplate to cylinder head for belt tensioning reference. Mark direction of rotation of belt using chalk. 17. Loosen tensioner pulley Allen bolt turn. 18. Loosen tensioner backplate screw '/, tur. 19. Push tensioner pulley down to fully OFF position 20. Tighten backplate bolt to 10 Nm. 21. Ease timing belt from gears and remove. CAUTION: Ease timing belt off gears using fingers only. Metal levers may damage the bolt and gears. 22. Slacken tensioner backplate bolt and ensure tensioner moves freely through its adjustment range and returns under spring tension. 23. Push tensioner down to OFF position and tighten backplate bolt to 10 Nm. REPAIRS 31ENGINE - ’K8’ Refit 4. Clean timing gears and pulleys. CAUTION: If the sintered gears have been subjected to prolonged oll contamination, they must be soaked in a solvent bath and then thoroughly washed in clean solvent before refitment. Because of the porous construction of sintered material, oil impregnated in the gear will ‘emerge and contaminate a new bolt. 2. Check correct alignment of timing marks for ‘90° BTDC. NOTE: Ensure dots on crankshaft gear a aligned with flange onoil pump and camshaft gear aligns with mark on rear 3. Fittiming belt over crankshaft gear and then ‘over camshaft gear, keeping belt taut from crankshaft to camshaft gears CAUTION: Existing timing bolts - ensure direction of rotation mark is facing correct. 4. Using fingers only, ease timing belt over tensioner pulley and coolant pump drive gear, ‘ensuring belt is positioned centrally around {gears and pulley. 5. Fittiming belt lower cover, ensuring correct position of seal. 6. Fitbolts securing lower cover and tighten to 10, Nm. 122526 7. Fit crankshaft pulley to crankshaft gear, ensuring indent on pulley locates over gear lug, 8. Fit crankshaft pulley bolt and washer and tighten bolt to 205 Nm. 9. Remove tool 186 1571 from flywheel 10. Position starter motor to flywheel housing 11. Fitstarter motor. See ELECTRICAL, Repairs. 12, Fitengine RH mounting bracket to engine and tighten bolts to 60 Nm. 13. Fitengine RH mounting. See this section. 14. Remove jack. Existing timing belts 15. Unhook tensioner spring from pillar bolt. 16. Position tensioner to align mark on backplate with mark on cylinder head, 17. Tighten tensioner backplate bolt to 10 Nm, 18, Tighten tensioner pulley Allen bolt to 45 Nm. 19. Connect tensioner spring to pillar bolt 32. REPAIRSENGINE -'ks’ [ysece]| Replacement timing belts 20. Loosen tensioner backplate bolt and tension timing belt by applying finger pressure to backplate and pushing tensioner pulley against belt 21. Hold tensioner in this position and tighten backplate bolt to 10 Nm. 22. Rotate crankshaft clockwise 2 complete revolutions and align camshaft timing gear mark with top face of cylinder head. 23. Slacken backplate bolt and check that belt tension is being applied by tensioner spring. 24, Tighten tensioner backplate bolt to 10 Nm. 25. Tighten tensioner pulley Allen bolt to 45 Nm, 26. Fittiming belt upper cover. See this section. 27. Fitauxiliary drive belt. See ELECTRICAL, Repairs. 28. Connect battery earth lead. 29. Fitroad wheel(s) and tighten nuts to correct, torque. See INFORMATION, Torque wrench settings. 30. Lower vehicle, CAMSHAFT TIMING BELT UPPER COVER Service repair no - 12.65.41 Remove s2Mi1728 41. Loosen lower bolt securing camshaft timing belt upper cover to engine. 2. Remove 6 bolts securing camshaft timing belt upper cover to rear cover. 3, Remove camshaft timing belt upper cover and rubber seal. Refit Clean camshaft timing belt upper cover. 2. Position timing belt upper cover, ensuring correct position of rubber seal 43. Fit bolts securing camshaft timing belt upper cover to rear cover and tighten to 5 Nm, 4, Tighten bolt securing camshaft timing belt upper cover to engine to 5 Nm. '5. Connect battery earth lead. REPAIRS 33ENGINE - ’K8’ CAMSHAFT TIMING BELT LOWER COVER Servi repair no - 12.65.43 Remove 41. Disconnect battery earth lead. 2. Raise front of vehicle. Q WARNING: Support on safety stands. semi726 Remove crankshaft front pulley. See this section. Remove 3 bolts securing timing belt lower cover to engine. Remove timing belt lower cover. |. Fit timing belt ower cover to engine. Fitbolts securing cover to engine and tighten to5Nm. Fit crankshaft front pulley. See this section. Remove stand(s) and lower vehicle. Connect battery earth lead, 34 REPAIRSENGINE - ’K16" CONTENTS Page REPAIRS EXHAUST CAMSHAFT FRONT OIL SEAL 1 EXHAUST CAMSHAFT REAR OIL SEAL 2 INLET CAMSHAFT FRONT OIL SEAL 3 INLET CAMSHAFT REAR OIL SEAL 4 CRANKSHAFT FRONT PULLEY - 1.4 & 1.6 MODELS 5 CRANKSHAFT FRONT OIL SEAL 6 CRANKSHAFT REAR OIL SEAL 7 CYLINDER HEAD GASKET - MODELS WITHOUT AIR CONDITIONING 8 CYLINDER HEAD GASKET - MODELS WITH AIR CONDITIONING 15 CAMSHAFT COVER GASKET 22 VALVE STEM OIL SEAL 23 ENGINE AND GEARBOX - MODELS WITH AIR CONDITIONING 25 ENGINE AND GEARBOX - MODELS WITHOUT AIR CONDITIONING 37 ENGINE AND AUTOMATIC GEARBOX - MODELS WITH AIR CONDITIONING . 48 ENGINE AND AUTOMATIC GEARBOX - MODELS WITHOUT AIR CONDITIONING 59 ENGINE STEADY BAR - 1.4 MODELS 69 ENGINE STEADY BAR - 1.6 & 1.8 MODELS 69 ENGINE LH MOUNTING - 1.4 MODELS. 70 ENGINE LH MOUNTING - 1.6 & 1.8 MODELS. n ENGINE LH MOUNTING - AUTOMATIC GEARBOX MODELS WITHOUT ABS. 71 ENGINE LH MOUNTING - AUTOMATIC GEARBOX MODELS WITH ABS. 3 ENGINE RH MOUNTING - 1.4 MODELS 74 ENGINE RH MOUNTING - 1.6 & 1.8 MODELS 75 FLYWHEEL - 1.4 & 1.6 MODELS WITH MANUAL GEARBOX 76 FLYWHEEL - MODELS WITH AUTOMATIC GEARBOX 76 TORSION DAMPER 7 FLYWHEEL STARTER RING GEAR 78 OIL FILTER 78 DIPSTICK TUBE, 79 lL PUMP. 79 SUMP GASKET - 1.4 MODELS 80 SUMP - 1.6 & 1.8 MODELS 82 OIL PRESSURE SWITCH a4 CAMSHAFT TIMING BELT 34 CAMSHAFT TIMING BELT UPPER COVER at CAMSHAFT TIMING BELT LOWER COVER a1 CRANKSHAFT FRONT PULLEY - 1.8 MODELS 92 FLYWHEEL - 1.8 MODELS. 94EXHAUST CAMSHAFT FRONT OIL SEAL Service repair no - 12.13.07 Remove 1. Remove and discard camshaft timing belt. See ENGINE - 'K’ SERIES, Repairs. 12-182 186 1570 Mx250198 2. Restrain camshaft gear using tool 12-182 and remove bolt and washer securing camshaft gear to camshaft 3. Remove camshaft gear locking tool 18G 1570. 4. Remove camshaft gear. — | 180 12990, | 186 17998-4 5. Fitcamshaft gear retaining bolt to camshaft 6. Screw oil seal removal tool 186 1299A into camshaft oil seal 7. Remove oll seal by tightening centre bol, tool 186 1298-1 8. Discard camshaft oil seal 9. Remove bolt from camshaft ENGINE -"k16’ yeeee] Refit |. Clean sealing area of cylinder head and camshaft carrer, ensuring all traces of rubber are removed. DO NOT use a scraper as this may damage sealing surfaces. 166 17608 seMnasza, 2. Using tool 186 1769A fit new camshaft oil seal A NOTE: This oil seal is coloured BLACK. CAUTION: Ci nal must be ad ry. Do Dy causes es 3. Clean camshaft gear. CAUTION: If the sintered gears have been subjected to prolonged oil contamination, they must be soaked in a solvent bath and thoroughly washed in clean solvent before refitment. Because of the porous construction of sintered material, oil impregnated in the gear will ‘emerge and contaminate a new timing bel REVISED: 06/99 REPAIRS 1ENGINE - ’K16" Noge 12-182 186 1570 Align camshaft gear timing marks. 5. Fit camshaft gear to camshaft . Fit camshatt gear locking tool 186 1570. "Fit bolt and washer securing camshaft gear to camshaft, restrain gear using tool 12-182 and tighten bott to: MB bolt 35 Nm M10 bolt 65 Nm. 1. Fit new camshaft timing belt. See ENGINE - 'K” SERIES, Repairs. EXHAUST CAMSHAFT REAR OIL SEAL Service repair no - 12.13.08 Remove 4. Disconnect battery earth lead 2. Remove air cleaner assembly. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 3, Remove 2 bolts securing rear cover plate and remove plate, f— 186 12004 18G 1299-1 > 12M1810 W 4, Screw tool 186 129A. into camshaft rear oil seal '5, Tighten centre bolt of tool 186 1299-1 to remove seal 6. Discard camshaft oil seal REPAIRS REVISED: 06/99Refit 41. Clean sealing area of cylinder head and camshaft carrier, ensuring all traces of rubber are removed. DO NOT use a scraper as this may damage sealing surfaces. 18G 17098 jeMta568, 2. Using tool 186 17694, fit new camshaft oil seal. A NOTE: This oil seal is coloured RED. CAUTION: Oil seal must be fitted dry. Do LX notuse tool 186 1769. 3. Clean camshaft rear cover plate. 4. Position cover plate, fit bolts and tighten to 25, Nm. 5. Fitair cleaner assembly. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 6. Connect battery earth lead. ENGINE -"k16’ yeeee] INLET CAMSHAFT FRONT OIL SEAL Service repair no - 12.13.09 The procedure for renewing the inlet camshaft front oil seal is identical to the procedure for renewing the exhaust camshaft front oll seal except that the inlet camshaft gear not the exhaust camshaft gear must, be removed. See this section. REVISED: 06/99 REPAIRS 3ENGINE - ’K16" INLET CAMSHAFT REAR OIL SEAL Service repair no - 12.13.10 Remove 41. Disconnect battery earth lead. 2. Remove air cleaner assembly. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 3. Remove distributor cap. See ENGINE ‘MANAGEMENT SYSTEM - MEMS, Repairs. i 18G 12994 | 1aM1455 4, Screw tool 186 1299 into camshaft rear oil seal. 5, Tighten centre bolt, tool 186 1299A-1, to remove seal 6. Remove camshaft il seal Refit |. Clean sealing area of cylinder head and camshaft carrer, ensuring all traces of rubber are removed. DO NOT use a scraper as this may damage sealing surfaces. 18G 17698 1214568 2. Using tool 186 1769A, fit new camshaft oil seal A NOTE: This oil seal is coloured RED. CAUTION: Ci nal must be ad ry. Do Dy causes es 3. Fitdistributor cap. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 4. Fitair cleaner assembly. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. '5. Connect battery earth lead. 4 REPAIRS REVISE! 6/99ENGINE - ’K16’ CRANKSHAFT FRONT PULLEY - 1.48 1.6 MODELS Service repair no - 12.21.01 Remove 41. Disconnect battery earth lead. 2. Raise front of vehicle. ) WARNING: Support on safety stands. 3. Remove auxiliary drive belt. See ELECTRICAL, Repairs. 4, Remove starter motor. See ELECTRICAL, Repairs. 186 571 1eN1719, 6. Remove bolt securing pulley to crankshaft and collect washer. 7. Remove crankshaft pulley. seMi712 5. Fittool 18G 1571 to flywheel housing and secure with 2 bolts. REPAIRS 5ENGINE - ’K16" Refit 1212356 1. Fit crankshaft pulley to crankshaft gear ‘ensuring that indent on pulley locates over lug ‘on gear (arrowed in illustration). 2. Fitwasher and bolt securing crankshaft pulley to crankshaft and tighten to 205 Nm. 3. Remove 2 bolts securing tool 186 1571 to flywheel housing and remove tool 186 1571. 4, Fit starter motor. See ELECTRICAL, Repairs. 5. Fitauxilary drive belt. See ELECTRICAL, Repairs. 6. Connect battery earth lead. CRANKSHAFT FRONT OIL SEAL Service repair no - 12.21.14 Remove 4. Remove camshaft timing belt. See this section. 12M1696 2. Remove crankshaft gear. i te 168 Te Ga ceen 4 ao T0818 Ls, s2M1637 3. Fit thrust button, tool 18G 705-1A/3 to end of crankshaft. 4, Ensure bore of tool 18G 1566 is free from burrs. '5. Screw tool 18G 1566 into crankshaft frant oll seal 6. Tighten centre bolt of tool 186 1566 to remove seal 7. Discard crankshaft front ol seal 8. Remove tool 18G 705-1A/3. 6 REPAIRSRefit 41. Using a lint free cloth, thoroughly clean oil seal recess in oil pump and running surface on crankshatf 186 1887 aval | 2. Fitoil seal guide, from seal kit, over end of ccrankshaf 3. Position new seal on crankshaft up against oil pump housing. Drift seal into place using tool 186 1587. CAUTION: Oil seal must be fitted dry. 4, Remove tool 186 1587 and oil seal guide. . Clean crankshaft gear. 6. Fitcrankshaft gear to crankshaft. 7. Fitcamshaft timing belt. See this section. ENGINE -"k16’ yeeee] CRANKSHAFT REAR OIL SEAL Service repair no - 12.21.20 Remove 41. Remove engine flywheel. See this section. 2. Using a burr free flat ended screwdriver, ease crankshaft rear ol seal from cylinder block and remove. Discard oil seal CAUTION: Do not mark naling surface on DY Sania eSpace Refit |. Remove all traces of oil and sealant from cylinder block, oll seal recess and running surface on crankshaft. 2. Apply a5 mm continuous bead of sealant, Part No. GAC 8000 to replacement oil seal as shown, CAUTION: Do not apply oil or grease to any part of oll seal or running surface of crankshaft. Seal must be fitted immediately ater applying sealant. REVISED: 06/99 REPAIRS 7ENGINE - ’K16" 18G 1574 eM aaBA, 3. Position oil seal to cylinder block and ft ol seal replacer tool 186 1574, retain tool using 3 slave bolts. 4. Evenly tighten oil seal replacer bolts to press. oil seal squarely into cylinder block 5. Leave oil seal replacer tool and oil seal in ‘clamped position for one minute. 6. Remove oil seal replacer tool 7. Allow sealant to cure for a minimum of 30 minutes before topping-up oil or rotating crankshaff 8. Fitflywheel. See this section. CYLINDER HEAD GASKET - MODELS WITHOUT AIR CONDITIONING. Service repair no - 12.29.02 Remove 4. Disconnect battery earth lead 2. Raise front of vehicle. Q WARNING: Support on safety stands. 3. Remove and discard camshaft timing belt. See this section. 4, Drain cooling system. See COOLING SYSTEM - ’K’ SERIES, Adjustments. Engines fitted with manual timing belt tensioner M1532 '5. Remove bolt securing camshaft timing belt tensioner backplate to cylinder head. 6. Disconnect camshaft timing belt tensioner spring from stud on cylinder head. 7. Remove Allen bolt securing camshaft timing belt tensioner pulley to cylinder head. 8, Remove camshaft timing belt tensioner. 8 REPAIRSAltengines 12M 15998 9. Restrain camshaft gears using 12-182 and remove bolts and washers securing camshaft {gears to camshafts. 40, Remove camshaft gear lacking tool 186 1570. 11. Mark camshaft gears for identification when refitting. 12. Remove 2 camshaft gears. 18M1566.— 413. Remove 4 bolts securing camshaft timing belt rear cover to cylinder head and block. 414, Remove camshaft timing belt rear cover. 15, 16. 17. 18, 19, 20. 21. ENGINE - ’K16" Remove 4 nuts securing exhaust front pipe to exhaust manifold, Release exhaust front pipe from exhaust manifold Remove and discard exhaust manifold flange gasket, Loosen clip and disconnect radiator top hose from coolant outlet elbow. Loosen clip and disconnect coolant hose from coolant outlet elbow. Disconnect multiplug from ECT sensor. Disconnect multiplug from engine coolant temperature gauge sensor. REVISED: 06/99 REPAIRS 9ENGINE - ’K16" 22. 23. 24, 25. 26. 27. 28. 29. 10 Disconnect coil h.t. lead from distributor. 30. Disconnect multipug from TP sensor. Disconnect multipug from injector harness. 31. Release coil h.t lead from clip on bracket. Disconnect multiplug from IAT sensor. Disconnect HO2S multiplug from engine harness Release HO2S multiplug from clip on bracket. Disconnect multipug from IACV. Release clip and disconnect air intake pipe from throttle body. Position absorbent cloth around fuel fer outlet REPAIRSENGINE - ’K16" 34, Remove 2 bolts securing fuel feed pipe to fuel rail 35. Release pipe from fuel rail and remove and discard'0’ ring. 32. Loosen fue! fiter outlet union to relieve fuel pressure. CAUTION: To prevent damage to fuel LM systom F components use two spanners when loosening or tightening 33. Tighten fue! filter union to 28 Nm. 2N219% 36. Release clip and disconnect fuel return hose from fuel rail A CAUTION: Plug the connections. REPAIRS 11ENGINE - ’K16" 37. Release clip and disconnect purge hose from throttle housing. 38. Release throttle cable adjusting nut from abutment bracket. 39. Release throttle cable from thrattle cam. 40, Depress plastic collar on quick release connector and disconnect brake servo vacuum hose from inlet manifold 41. Release throttle cable from clip on inlet manifold 442. Disconnect vacuum hose from inlet manifold 43. Loosen clip and disconnect expansion tank hose from inlet manifold 44, Remove camshaft cover. See this section. ‘45. Disconnect ht. leads from distributor cap, 46. Remove hi. leads, 12 REPAIRSENGINE - ’K16" 47. Working in the sequence shown, loosen 10 cylinder head to al rail bolts. 48, Remove cylinder head bolts and store in fitted order. 49. Using assistance, remove cylinder head ‘assembly fram cylinder block. 52. Fitcylinder liner clamps 186 1736/1 to cylinder block and secure with cylinder head bolts. CAUTION: Tete car ntio damage 02s. AUTON: eat ea rants win ‘when removing cylinder head. yl . Refit 41. Remove bolts securing cylinder liner clamps to cylinder block and remove clamps. 2. Clean joint surfaces of cylinder head and cylinder block, Clean oil and coolant passages. Clean mating face of exhaust manifold and exhaust front pipe. Hf necessary, de-carbonise piston crowns and cylinder head. 3. Clean cylinder head bolts with a wire brush. Inspect cylinder head bolts for signs of damage. 4. Wash cylinder head bolts and wipe dry. Apply alight film of oil to bolt threads and underside of bolt heads. '5. Clean location dowels and ft to cylinder block. 6. Fitnew cylinder head gasket, dry, to cylinder ‘50. Remove and discard cylinder head gasket from block. cylinder block. 7. Using assistance, ft cylinder head onto '51. Remove 2 location dowels from cylinder block. cylinder block carefully locating on dowels. CAUTION: Take care not to damage HO2S when refitting cylinder head. 8. Carefully enter cylinder head bolts. DO NOT DROP. Screw bolts into place by hand. REPAIRS 13ENGINE - ’K16" sPMIBad 9. Working in the sequence shown, progressively tighten the cylinder head bolts using the following procedure: Allbolts to 20 Nm. Use a felt tip pen and mark position of radial mark on each bolt head. ‘Tum all bolts through 180°. Turn all bolts through another 180° and align radial mark, CAUTION: If bolt is overtightened, back off 90° then realign radial marks. 10. Fit camshaft cover. See this section, 414. Connect ht. leads to distributor cap. 12. Connect expansion tank hose to inlet manifold land tighten clip 43. Connect vacuum hose to inlet manifold. 44, Secure throttle cable to clip on inlet manifold, ‘ensure throttle cable is correctly routed. 415. Connect brake servo vacuum hose to inlet manifold, 46. Connect throttle cable to throttle cam. 17. Locate throttle cable adjusting nut in abutment bracket. 18. Connect purge hose to throttle housing and secure with clip. 19. Connect air intake pipe to throttle body and secure with clip. 20. Remove plugs from fuel system hoses and ‘components. 21. Connect fuel return pipe to fuel rail and secure with clip, 22. Fitnew 0’ ring to fuel feed pipe. 23. Connect fuel feed pipe to fuel rail and secure with bolts. Tighten bolts to 5 Nm. 24. Connect multiplug to IACV. 25. Connect HO2S multiplug to engine hamess land secure to clip on bracket. 26. Secure coil ht. lead to clip on bracket and connect to distributor cap. 33, 34, 35, 36. 37. 38, 39, ™. Connect muttiplug to IAT sensor. 3. Connect muttiplug to injector harness, |. Connect muttiplug to TP sensor. Connect muttiplugs to ECT sensors. |. Connect coolant hose to coolant outlet elbow and tighten clip. . Connect radiator top hose to coolant outlet elbow and tighten clip. Fitnew gasket to exhaust manifold flange and connect exhaust front pipe. Fit nuts securing exhaust front pipe to exhaust manifold and tighten to 45 Nm. Fit camshaft timing belt rear cover to cylinder head and cylinder block. Fit4 bolts securing camshaft timing belt rear cover to cylinder head and cylinder block and tighten bolts to 10 Nm. Fit2 camshaft gears to their respective camshafts, 38 12M 21998 Fitbolts and washers securing camshaft gears to camshafts. Using tool 12-182 restrain camshaft gears and tighten bolts to: Ma Bolts - 35 Nm M10 Bolts - 65 Nm Using tool 12-182 align camshaft gear timing ‘marks and fit camshaft gear locking tool 186 1570. 14 REPAIRSEngines fitted with manual timing belt tensioner 40. Fit camshaft timing belt tensioner to cylinder head 41. Fittensioner pulley Allen bot 42. Connect tensioner spring to tensioner and to stud on cylinder head, 43. Push tensioner pulley down to fully OFF position, fit and tighten backplate bolt to 10, Nm. Altengines 44, Fitnew camshaft timing belt. See this section. 45. Remove stand(s) and lower vehicle. 46. Refi cooling system. See COOLING SYSTEM -’K’ SERIES, Adjustments. 47. Connect battery earth lead. 48. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments, ENGINE -"k16’ yeeee] CYLINDER HEAD GASKET - MODELS WITH AIR CONDITIONING Service repair no - 12.29.02.20 Remove 4. Disconnect battery earth lead 2. Raise front of vehicle. Q WARNING: Support on safety stands. 3. Remove and discard camshaft timing belt. See this section. 4, Drain cooling system. See COOLING SYSTEM - ’K’ SERIES, Adjustments. Engines fitted with manual timing belt tensioner '5. Remove bolt securing camshaft timing belt tensioner backplate to cylinder head. 6. Disconnect camshaft timing belt tensioner spring from stud on cylinder head. 7. Remove Allen bolt securing camshft timing belt tensioner pulley to cylinder head. 8. Remove camshaft timing belt tensioner. REPAIRS 15ENGINE - ’K16" Altengines 12M 15998 9. Restrain camshaft gears using tool 12-182 and remove bolts and washers securing camshaft {gears to camshafts. 40, Remove tool 186 1870 from camshaft gears. 11. Mark camshaft gears for identification when refitting. 12. Remove 2 camshaft gears. 413. Remove 4 bolts securing camshaft timing belt rear cover to cylinder head and block. 44, Remove camshaft timing belt rear cover. 15, Remove 2 nuts and bolts securing alternator to engine, 16, Release alternator from mounting brackets. ”. Remove nut and bolt securing alternator top ‘mounting bracket to cylinder head. 18. Pivot alternator top mounting bracket out of the way, 19. Loosen 2 nuts securing cables to alternator. 20. Disconnect 2 cables from alternator. |. Remove alternator from vehicle. 16 REPAIRS REVISED: 06/9922. 23. 24, 25. 26. 27. Remove bolt securing altemator heatshield to mounting bracket. Release alternator heatshield from stud on cylinder head, Remove alternator top mounting bracket Remove 4 nuts securing exhaust front pipe to ‘exhaust manifold Release exhaust front pipe from exhaust manifold, Remove and discard exhaust manifold flange gasket. 28, 29, 30. 31. 32, 33, 34, 35. 36. 37. 38, ENGINE - ’K16" 1222134, Loosen clip and disconnect radiator top hose from coolant outlet elbow. Loosen clip and disconnect coolant hose from coolant outlet elbow. Disconnect multiplug from ECT sensor. Disconnect multiplug from engine coolant temperature gauge sensor. Disconnect coil ht. lead from distributor. Disconnect multiplug from TP sensor. Disconnect multiplug from injector harness. Release coil h.t. lead from clip on bracket. Disconnect multiplug from IAT sensor. Disconnect HO2S multiplug from engine hares. Release HO2S multplug from clip on bracket REPAIRS 17ENGINE - ’K16" 39. Disconnect multiplug from IACV, 40. Position absorbent cloth around fuel filer outlet |. Loosen fuel iter outlet union to relieve fuel pressure. 4 CAUTION: To prevent da AN Stata pipes oreompon Sporworton loosening o tightening 42. Disconnect fuel outlet pipe from fuel fter and position aside. 43. Release clip and disconnect hose from fuel retum pipe. A CAUTION: Plug the connections. 44, Release clip and disconnect purge hose fram throttle housing. 45. Release throttle cable adjusting nut from abutment bracket. 46. Release throttle cable from throttle cam, 18 REPAIRS47. Depress plastic collar on quick release ‘connector and disconnect brake servo vacuum hose from inlet manifold Release throttle cable fram clip on inlet manifold, 49. Disconnect vacuum hose from inlet manifold. ‘50. Loosen clip and disconnect expansion tank hose from inlet manifold Remove camshaft cover. See this section. 48, st. '52. Disconnect ht. leads from distributor cap. 53. Remove hit. leads. ENGINE - ’K16’ 54, Working in the sequence shown, loosen 10 cylinder head to cil rail bolts. 55. Remove cylinder head bolts and store in fitted order. 56. Using assistance, remove cylinder head assembly from cylinder block. CAUTION: Take care not to damage HO2S when removing cylinder head. 57. Remove and discard cylinder head gasket from cylinder block, 58. Remove 2 location dowels from cylinder block. REPAIRS 19ENGINE - ’K16" '59. Fit cylinder liner clamps 18G 1736/1 to cylinder block and secure with cylinder head bolts. CAUTION: Do not rotate crankshaft with LY crlinder head removed. Refit 1. Remove bolts securing cylinder liner clamps to cylinder block and remove clamps. 2. Clean joint surfaces of cylinder head and cylinder block. Clean oil and coolant passages. Clean mating face of exhaust manifold and ‘exhaust front pipe. Ifnecessary, de-carbonise piston crowns and cylinder head, 3. Clean cylinder head bolts with a wire brush. Inspect cylinder head bolts for signs of damage. ‘4, Wash cylinder head bolts and wipe dry. Apply a light film of ol to bolt threads and underside of bolt heads. 5. Clean location dowels and fit to oylinder block. 6. Fitnew cylinder head gasket, dry, to cylinder block 7. Using assistance, fit cylinder head onto cylinder block carefully locating on dowels. CAUTION: Take care not to damage HO2S ‘when refitting cylinder head. 8. Carefully enter cylinder head bolts, DO NOT DROP. Screw botts into place by hand. 10. 1. 2, 13, 14, 15, 16, 17. 18, 19, 20. at. tented ). Working in the sequence shown, progressively tighten the cylinder head bolts using the following procedure: i. Allbolts to 20 Nm, Use a felt tip pen and ‘mark position of radial mark on each bolt head. fi, Turn al bolts through 180°. {ii.Turn all bolts through another 180° and align radial mark, CAUTION: If bolt is overtightened, back off Fit camshaft cover. See this section. Connect ht. leads to distributor cap. Connect expansion tank hose to inlet manifold and tighten clip. Connect vacuum hose to inlet manifold, Secure throttle cable to clip on inlet manifold, ensure throttle cable is correctly routed. Connect brake servo vacuum hose to inlet manifold Connect throttle cable to throttle cam. Locate throttle cable adjusting nut in abutment bracket. Connect purge hose to throttle housing and secure with clip. Remove plugs from fuel system hoses and ‘components. Connect hase to fuel retum pipe and secure with clip. Clean union of fuel fiter and fue! outlet pipe. 20 REPAIRS22. Connect fuel outlet pipe to fue! fter and tighten Union to 28 Nm. 23. Connect multiplug to IACV. 24. Connect HO2S multiplug to engine hamess land secure to clip on bracket. 25. Secure coil ht. lead to clip on bracket and ‘connect to distributor cap. 26. Connect multiplug to IAT sensor. 27. Connect multipug to injector harness. 28. Connect multiplug to TP sensor. 29. Connect multiplugs to ECT sensors. 30. Connect coolant hose to coolant outlet elbow land tighten clip 31. Connect radiator top hose to coolant outlet elbow and tighten clip. 32. Fitnew gasket to exhaust manifold flange and ‘connect exhaust front pipe. 33. Fit4 nuts securing exhaust front pipe to ‘exhaust manifold and tighten to 45 Nm. 34, Fitalternator top mounting bracket to stud on. cylinder head, 36. Connect alternator heatshield to stud on cylinder head, 36. Fitand tighten bolt securing alternator heatshield to mounting bracket. 37. Position altemator in vehicle. 38. Connect 2 cables to alternator and secure with nuts. 39. Fitbolt securing alternator top mounting bracket to cylinder head and tighten to 25 Nm. 40. Fitnut securing alternator top mounting bracket to cylinder head and tighten to 25 Nm 41. Manoeuvre alternator onto mounting brackets. 42, Fit2 through bolts securing alternator to mounting brackets, fit nuts and tighten to 45 Nm. 43, Fitcamshaft timing belt rear cover to cylinder head and cylinder block 44, Fit4 bolts securing camshaft timing belt rear ccover to cylinder head and cylinder block and tighten bolts to 10 Nm. 45, Fit2 camshaft gears to their respective camshafts, ENGINE -"k16’ yeeee] 12M 22230 ‘46. Fitbolts and washers securing camshaft gears to camshafts, Using tool 12-182 restrain camshaft gears and tighten bolts to: Ma Bolts - 35 Nm M10 Bolts - 65 Nm 47. Using tool 12-182 align camshaft gear timing ‘marks and fit tool 186 1570 to camshaft gears. Engines fitted with manual timing belt tensioner ‘48. Fit camshaft timing belt tensioner to cylinder head, 49. Fit tensioner pulley Allen bolt 50. Connect tensioner spring to tensioner and to stud on cylinder head 51. Push tensioner pulley down to fully OFF position, fit and tighten backplate bolt to 10, Nm. All engines 52, Fitnew camshaft timing belt. See this section 583. Remove stand(s) and lower vehicle. 54. Refill cooling system. See COOLING SYSTEM -'K’ SERIES, Adjustments. 55. Connect battery earth lead. 56. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments. REVISED: 06/99 REPAIRS 21ENGINE - ’K16" CAMSHAFT COVER GASKET Service repair no - 12.29.40 Remove 1. Disconnect battery earth lead. 12M1474 3 2. Release 2 clips and disconnect 2 breather hoses from camshaft cover. 3. Remove 2 screws securing spark plug cover land remove cover. 4. Disconnect h.t leads from spark plugs, release ‘mounting rubbers and place leads aside. 5. Progressively loosen and remove 15 bolts ‘securing camshaft cover. 6. Remove camshaft cover. NOTE: The gasket is re-usable and should romain attached to camshaft cover. 7. Check condition of sealing path. it should be complete and attached to gasket. Remove gasket from camshaft cover only if sealing path is damaged o detached from gasket. Refit 41. Clean mating surfaces of camshaft cover and 2. Clean inside of camshaft cover. If necessary, wash oil separator elements in solvent and blow dry. CAUTION: If camshaft cover gasket is to be renewed, fit new gasket with EXHAUST MAN SIDE’ mark towards exhaust manifold 12Mi475 3, Fit camshaft cover to camshaft carrer. Fit bolts ‘and working in sequence illustrated, tighten progressively to 10 Nm. 4. Connect ht. leads to spark plugs and secure ‘mounting rubbers in camshaft caver. 5. Fit spark plug cover, fit screws and tighten to 8 Nm 6. Connect breather hoses and secure with clips. 7. Connect battery earth lead. 22 REPAIRSVALVE STEM OIL SEAL Service repair no - 12.30.26 Remove 41. Disconnect battery earth lead. 2. Remove camshaft cover. See this section, 3. Remove inlet and exhaust camshafts. See 'K’ Series Engine Overhaul Manual - Overhaul. 12M 4. Using a 16 mm spark plug socket, remove spark plug ENGINE -"k16’ Jyeeeey] taisa2 '5. Fitand tighten air ine adaptor tool MS 1567 into spark plug hole. 6. Connect an aire to adaptor and apply air pressure. 7. Remove hydraulic tappet from exhaust valve. CAUTION: Store tappet inverted to prevent LN, cilloss. REPAIRS 23ENGINE - ’K16" Ms 1567/7 Ms 1567/18 8, Fittool MS 1657/18 and tool MS 1567/7 to valve spring cap. 9. Strike head of tool firmly with hammer to release valve spring collets, 40, Remove collats from magnetic end of tool 11. Remove valve spring cap and spring, 186 1877 9. Use tool 186 1577 to remove valve stem cil . Repeat operations to remove second exhaust 24 REPAIRSENGINE -"k16’ Jyeeeey] Refit 1. Lubricate new valve stem oll seal with engine ol 2. Use tool 186 1577 to fit new oil seals. 3. Fitvaive spring and spring cap to each valve. MS 1657, saw23s@ Ms 1657/13 ‘4, Assemble too! MS 1657 in over exhaust valve. 5. Locate valve spring cap with compressor tool MS 1657/13. 6. Screw down valve spring compressor until valve stem collet groove is level with top face of spring cap, 7. Attach collets to end of a small lat screwdriver with grease and locate collets in valve stem groove. 8. Unscrew valve spring compressor ensuring collets are correctly located in valve spring cap. 9. Repeat refit operations on second valve. 10. Remove valve spring compressor tool MS 1657. 411. Lubricate tappet with clean engine oil and refit. 42. Disconnect air line from adaptor tool MS 1567. 13. Remove airline adaptor tool MS 1567. 44, Clean spark plug and set gap to 0.85 mm. 415. Fit spark plug and tighten to 27 Nm. 416. Fit inlet and exhaust camshafts. See 'K’ Series Engine Overhaul Manual - Overhaul. 417. Fit camshaft cover. See this section, 48. Connect battery earth lead. ENGINE AND GEARBOX - MODELS WITH AIR. CONDITIONING Service repair no - 12.37.01.20 Remove 4. Disconnect battery earth lead 2. required: Drain engine cil. See MAINTENANCE. 3, Fitnew sealing washer to drain plug, fit drain plug and tighten to 42 Nm. 4. Drain cooling system. See COOLING SYSTEM - 'K’ SERIES, Adjustments. 5. Drain gearbox ol 1.4 & 5.6 models: See MANUAL GEARBOX - "R65, Adjustments. 1.8 models: See MANUAL GEARBOX- PGT’, Adjustments. 6. Recover refrigerant from air conditioning system. See AIR CONDITIONING, Adjustments. 7. Raise front of vehicle. Q WARNING: Support on safety stands. 8. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 9. Remove ECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 10. Remove engine management relay module, See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 11. Release ABS fuse holder from battery tray. 12, Remove 2 bolts securing resonator to battery tray. 13, Remove resonator. REPAIRS 25ENGINE - ’K16" 14, 15. 16. 17. 18. 26 Remove bolt securing engine compartment fuse box to battery tray. Remove 4 bolts securing battery tray to body. Remove bolt securing engine compartment {use box to body and position fuse box aside. Loosen 3 bolts securing battery tray to body. Remove battery tray from vehicle. 19. 20. at. 1.48 1.6 models itustrated ). Disconnect clutch cable from clutch release lever. Release clutch cable from abutment bracket on gearbox and position aside, Release both drive shafts from gearbox as detailed in Differential oil seal 1.4 & 5.6 models; See MANUAL GEARBOX - "ROS", Repairs. 1.8 models: See MANUAL GEARBOX- PGT’, Repairs. REPAIRSENGINE - ’K16’ 26. Remove bolt securing earth lead to bonnet locking platform, 22. Loosen clip and disconnect radiator top hose from coolant outlet elbow. 23. Loosen clip and disconnnect radiator bottom hose from coolant rail 24. Loosen clip and disconnect heater hose from coolant outlet elbow. 27. Disconnect multiplug from radiator cooling fan. 25. Release heater hose from clip on coolant rail land position aside. REPAIRS 27ENGINE - ’K16" ® 12M 28. Release clip and remove fuse box cover. 29. Depress 2 clips and remove fuse box inner 30. Remove 2 screws securing positive leads to fuse box. 31. Disconnect multiplug from fuse box. 28 REPAIRS32, 33, 38, 36. ENGINE - ’K16" 37. Loosen fuel filter outlet union to relieve fuel | pressure. Disconnect engine harness to main hamess ‘connector. 38. Disconnect fuel outlet pipe from fuel fter and Lay engine hamess across engine to avoid it position aside, being caught when the engine is removed, Remove evaporative emission canister. See EMISSION CONTROL, Repairs. Remove exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. Position absorbent cloth around fuel fier outlet 39. Release clip and disconnect hose from fuel retum pipe. REPAIRS 29ENGINE - ’K16" 30 1. Release throttle cable adjusting nut from abutment bracket. |. Release throttle cable from throttle cam, .. Depress plastic collar on quick release ‘connector and disconnect brake servo vacuum pipe from inlet manifold. . Release throttle cable from clip on inlet manifold, Disconnect ECM vacuum pipe from inlet manifold, 3. Loosen clip and disconnect expansion tank hose from inlet manifold 3. Loosen clip and disconnect coolant hose from thermostat housing, 47. 48. Disconnect multiplug from inertia switch. Release clip securing inertia switch harness to ‘mounting bracket. Release 4 multiplugs from mounting bracket on. bulkhead. |. Disconnect engine hamess multiplugs from ‘main harness, |. Loosen clip and disconnect coolant feed hose from coolant expansion tank. . Position container to catch fluid loss from power steering system. REPAIRS53, Loosen clip securing fluid inlet hose to power steering pump. ‘54, Disconnect fluid inlet hose from power steering pump. Remove bolt securing fluid outlet hose clamp to bracket. '56. Loosen union and disconnect fluid outlet hase from power steering pump. 55, CAUTION: To prevent damage to pipes ind components use two spanners when loosening or tightening unions. 57. Remove and discard ‘0’ ring from fluid outlet hose. '58. Plug hose and power steering pump ‘connections to prevent excess fluid loss and the ingress of dit into the system, '59. Remove bolt securing air conditioning pipe to bracket on flywheel housing ENGINE - ’K16" 60. Loosen union and disconnect compressor pipe from evaporator pipe. CAUTION: To prevent damage to air conditioning pipes and componer two spanners when loosening or tightening unions. 61. Remove and discard 'O' ring from compressor pipe. 62. Position evaporator pipe aside. Remove bolt securing compressor pipe to condenser pipe. Release compressor pipe from condenser pipe and discard 'O’ ring. REPAIRS 31ENGINE - ’K16" 65. Remove bolt securing air conditioning pipe union to compressor. 66. Release air conditioning pipe union fram ‘compressor. 67. Remove air conditioning pipes. 68. Remove and discard 2 0' rings from ‘compressor. CAUTION: Immediately cap all air conditioning pipes and compressor to prevent ingress of dirt and moisture into the system. 1.48 1.6 Models, 69. Using tool 186 1592 release gear selector linkage ball joint from gear selector lever. 70. Using tool 18G 1592 release gear change linkage ball joint from gear change lever. 1.8 Models 71. Remove bolt and disconnect gear change steady bar from gearbox. Collect 2 washers. 72. Remove clip retaining selector rod rol pin. 73. Using a suitable punch, drive out rol pin securing selector rad to selector shaft 74, Release selector rod from selector shaft and tie aside. All models 1.4 model 75. Loosen through bolt securing engine steady bar to subframe, 76. Remove through bolt securing engine steady bar to bracket on gearboxisump. 32. REPAIRS77. Remove 2 bolts securing camshaft rear cover plate to cylinder head. 78. Remove camshaft rear cover plate. 79. Fitliting bracket too! 186 1572/1 to cylinder head. Fit bolts and tighten to 9 Nm. 80. Fitltting bracket tool 186 1572/2 to cylinder head. Fit bolt and tighten to 9 Nm. at 82, 83. ENGINE - ’K16" O\ 18G 1598 121808 Connect adjustable iting bracket tool 186 1598 to lifting brackets. Connect a hoist to tool 186 1598 and raise hoist to take weight of engine without exerting load on engine mounting bots. Remove engine RH mounting. See this section. REPAIRS 33ENGINE - ’K16" 1.4 models 84, 85, 86. a7. 34 Remove 2 bolts securing engine LH mounting to gearbox mounting bracket. Remove 2 bolts securing engine LH mounting to body. Remove 2 bolts securing engine LH mounting ‘to mounting bracket. Remove engine LH mounting, 1.6 8 1.8 models rewesien \ 88. Remove through bolt securing engine LH ‘mounting to bracket on body. 89. Remove 2 bolts securing engine LH mounting to mounting bracket on gearbox. 90. Remove engine LH mounting, All models 91. Adjust tool 186 1598 to tlt engine with the gearbox as low as possible. 92. Using assistance, manoeuvre engine and gearbox from vehicle. CAUTION: Take care not to damage the ABS modulator or brake pipes when removing the engine. 93. Lower engine and gearbox assembly and disconnect hoist from adjustable lifting bracket, REPAIRSRefit 4. Connect hoist to adjustable lifting bracket tool 186 1598. 2. Using assistance, raise engine and manoeuvre into position in vehicle 3. Adjust lifing bracket tool so engine is horizontal in engine compartment. 1.68 1.8 models ‘4, Position engine LH mounting to mounting bracket on gearbox, fit bolts and tighten to 100 Nm. 5. Align engine LH mounting to bracket on body, fit through bolt and tighten to 85 Nm, 1.4 models 6. Position engine LH mounting, 7. Fitbolts securing engine LH mounting to mounting bracket and tighten to 55 Nm 8. Fitbolts securing engine LH mounting to body land tighten to 55 Nm 8. Align gearbox mounting bracket to engine mounting ft bolts and tighten to 60 Nm. All models 10. Fit engine RH mounting. See this section 11. Lower hoist and disconnect lifting bracket too! 18G 1598 from fing brackets. 42. Remove bolt securing iting bracket tool 186 157212 to cylinder head and remove lifting bracket. 43. Remove 2 bolts securing lifting bracket tool 18G 1572/1 to cylinder head and remove lifting bracket. 44, Clean camshaft rear cover plate. 415. Position camshaft rear cover plate to cylinder head, fit bolts and tighten to 25 Nm. 16. 1,68 1.8 models: Connect engine steady bar to bracket on sump, fit through bolt and tighten to 80 Nm. 17. 1,4 models: Connect engine steady bar to bracket on gearbox, ft through bolt and tighten to 45 Nm. 18. Tighten through bolt, engine steady bar to subframe, to 80 Nm. 49. Clean gear selector linkage and gear change linkage ball joints, ENGINE -"k16’ Jyeeeey] 1.4 8 1.6 Models 20. Using tool 186 1594 connect gear selector linkage ball joint to gear selector lever. 21. Using tool 186 1594 connect gear change linkage ball joint to gear change lever. 1.8 Models 22. Connect selector rod to selector shaft and align holes. 23. Fit NEW roll pin securing selector rod to shaft and fit rol pin retaining clip. 24, Fit washers to steady bar and connect to gearbox. 25, Fit bolt securing steady bar to gearbox and tighten to 60 Nm, All models 26. Remove caps from air conditioning pipes and compressor. 27. Clean mating faces of air conditioning pipe union and compressor. 28. Lubricate 2 new ‘O' rings with refrigerant oll and fit to compressor. 29. Position air conditioning pipe union to ‘compressor, fit bolt and tighten to 35 Nm. 30. Clean condenser pipe and compressor pipe 31. Lubricate new ‘©’ ring with refrigerant oll and ft to condenser pipe. 32. Connect condenser pipe to compressor pipe, fit bolt and tighten to 6 Nm. REPAIRS 35,ENGINE - ’K16" 33. Clean compressor pipe and evaporator pipe 34, Lubricate new 'O' ring with refrigerant ol and fit to compressor pipe. 36. Connect evaporator pipe to compressor pipe and tighten union to 45 Nm. CAUTION: To prevent damage to air conditioning pipes and components use two spanners when loosening or tightening unions. 36. Align air conditioning pipe to bracket on flywheel housing, fit bolt and tighten to 6 Nm 37. Remove plugs from power steering pump and. hose connections. 38. Lubricate new 'O’ ring with clean power steering fluid and fit to fluid outlet hose. 39. Connect fluid outlet hose to power steering pump and tighten union to 55 Nm. CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions. 40. Align fluid outlet hose clamp to bracket and ‘secure with bolt 41. Connect fluid inlet hose to power steering pump and tighten clip. 42, Connect coolant feed hose to expansion tank and tighten clip 43. Connect 4 engine harness muitiplugs to main harness and secure to mounting bracket on bulkhead, 44. Connect multiplug to inertia switch and secure harness clip to mounting bracket. 48, Connect coolant hose to thermostat housing land tighten clip 46. Connect expansion tank hose to inlet manifold and tighten clip 47. Connect ECM vacuum pipe to inlet manifold. Connect throttle cable to throttle cam. Locate throttle cable adjusting nut in abutment bracket. Ensure throttle cable is correctly routed and secure to clip on inlet manifold. |. Connect brake servo vacuum pipe to inlet manifold Connect hase to fuel retum pipe and secure with clip. Clean union of fue! outlet pipe and fuel fiter. Connect fuel outlet pipe to fuel filter and tighten union to 28 Nm. 2 8 88 CAUTION: To prevent damage to fuel system pipes and components use two spanners when loosening or tightening 55. Fit exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 56. Fit evaporative emission canister. See EMISSION CONTROL, Repairs. 57. Connect the engine harness to main hamess connector. 58. Connect multiplug to fuse box. 59. Fit positive leads to fuse box and secure with 60. Fit fuse box inner cover. 61. Fit fuse box cover. 62. Connect multiplug to radiator cooling fan. 63. Position earth lead to bonnet locking platform, fit bolt and tighten to 9 Nm. 64. Connect heater hose to coolant outlet elbow and tighten clip. 65. Secure heater hose to clip on coolant rail 66. Connect radiator bottom hose to coolant rail and tighten clip. 67. Connect radiator top hose to coolant outlet elbow and tighten clip. 68. Connect drive shafts to gearbox as detailed in Differential oil seal 1.4 & 5.6 models; See MANUAL GEARBOX - "R65", Repairs. 1.8 models: See MANUAL GEARBOX- PGT’, Repairs. 69. Feed clutch cable through abutment bracket ‘and connect to clutch release lever. 70. Position battery tray in vehicle. 71. Tighten 3 bolts securing battery tray to body, to 10 Nm. 72, Position engine compartment fuse box to body, fit bolt and tighten to 10 Nm. 36 REPAIRS73. 74, 75. 76. 7. 78. 79. 80. at. 82. 83, 85, 86. a7. 88, Fit4 bolts securing battery tray to body and tighten to 10 Nm Fit and tighten bolt securing engine compartment fuse box to battery tray. Fit resonator to air intake pipe. Fit and tighten bolts securing resonator to battery tray, Secure ABS fuse holder to battery tray. Fit engine management relay module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. FitECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Fitair cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Replace receiveridryer. See AIR CONDITIONING, Repairs. Remove stand{s) and lower vehicle. Recharge air conditioning system. See AIR CONDITIONING, Adjustments. Refill gearbox with ol 1.4 & 1,6 models See MANUAL GEARBOX - "R65", Adjustments. 1.8 models: See MANUAL GEARBOX PGT’, Adjustments. Refill cooling system. See COOLING SYSTEM - ’k’ SERIES, Adjustments. Hf requirad: Refill engine with oil. See MAINTENANCE. Bleed power steering system. See STEERING, Adjustments. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments, ENGINE -"k16’ Jyeeeey] ENGINE AND GEARBOX - MODELS WITHOUT AIR CONDITIONING. Service repair no - 12.37.01.99 Remove 4. Disconnect battery earth lead 2. required: Drain engine cil. See MAINTENANCE. 3 Fitnew sealing washer to drain plug. 4. Fit drain plug and tighten to 42 Nm. 5. Drain cooling system. See COOLING SYSTEM - 'K’ SERIES, Adjustments. 6. Drain gearbox ol 1.4 & 5.6 models: See MANUAL GEARBOX - "R65, Adjustments. 1.8 models: See MANUAL GEARBOX- PGT’, Adjustments, 7. Raise front of vehicle. Q WARNING: Support on safety stands. 8. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 9. Remove ECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 10. Remove engine management relay module, See ENGINE MANAGEMENT SYSTEM - ‘MEMS, Repairs. 11. Release ABS fuse holder from battery tray. 12, Remove 2 bolts securing resonator to battery tray. 13, Remove resonator. REPAIRS 37ENGINE - ’K16" 14, 15. 16. 17. 18. 38 Remove bolt securing engine compartment fuse box to battery tray. Remove 4 bolts securing battery tray to body. Remove bolt securing engine compartment {use box to body and position fuse box aside. Loosen 3 bolts securing battery tray to body. Remove battery tray from vehicle. 19. 20. at. 1.48 1.6 models itustrated ). Disconnect clutch cable from clutch release lever. Release clutch cable from abutment bracket on gearbox and position aside, Release both drive shafts from gearbox as detailed in Differential oil seal 1.4 & 5.6 models; See MANUAL GEARBOX - "ROS", Repairs. 1.8 models: See MANUAL GEARBOX- PGT’, Repairs. REPAIRSENGINE - ’K16’ 26. Remove bolt securing earth lead to bonnet locking platform, 22. Loosen clip and disconnect radiator top hose from coolant outlet elbow. 23. Loosen clip and disconnnect radiator bottom hose from coolant rail 24. Loosen clip and disconnect heater hose from coolant outlet elbow. 27. Disconnect multiplug from radiator cooling fan. 25. Release heater hose from clip on coolant rail land position aside. REPAIRS 39ENGINE - ’K16" ® 12M 28. Release clip and remove fuse box cover. 29. Depress 2 clips and remove fuse box inner 30. Remove 2 screws securing positive leads to fuse box. 31. Disconnect multiplug from fuse box. 40 REPAIRS32, 33, 38, 36. ENGINE - ’K16" 37. Loosen fuel filter outlet union to relieve fuel | pressure. spanner: Disconnect engine harness to main harness 38. Disconnect fuel outlet pipe from fuel fter and connector. position aside. Lay engine hamess across engine to avoid it being caught when the engine is removed, Remove evaporative emission canister. See EMISSION CONTROL, Repairs. Remove exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. Position absorbent cloth around fuel fier outlet 39. Release clip and disconnect hose from fuel retum pipe. REPAIRS 41ENGINE - ’K16" 42 1. Release throttle cable adjusting nut from abutment bracket. |. Release throttle cable from throttle cam, .. Depress plastic collar on quick release ‘connector and disconnect brake servo vacuum pipe from inlet manifold. . Release throttle cable from clip on inlet manifold, Disconnect ECM vacuum pipe from inlet manifold, 3. Loosen clip and disconnect expansion tank hose from inlet manifold 3. Loosen clip and disconnect coolant hose from thermostat housing, 47. 48. Disconnect multiplug from inertia switch. Release clip securing inertia switch harness to ‘mounting bracket. Release 4 multiplugs from mounting bracket on. bulkhead. |. Disconnect engine hamess multiplugs from ‘main harness, |. Loosen clip and disconnect coolant feed hose from coolant expansion tank. . Position container to catch fluid loss from power steering system. REPAIRSENGINE - ’K16" 1.8 Models sewaoeT '53. Loosen clip securing fluid inlet hose to power steering pump. ‘54, Disconnect fluid inlet hose from power steering pump. '55, Remove bolt securing fluid outlet hose clamp to bracket. '56. Loosen union and disconnect fluid outlet hase from power steering pump. CAUTION: To prevent damage to pipes and components use two spanners when loosening or tightening unions. 57. Remove and discard ‘0’ ring from fluid outlet hose. '58. Plug hose and power steering pump ‘connections to prevent excess fluid loss and the ingress of dit into the system, 1.48 1.6 models 121228 '59. Using tool 186 1592 release gear selector linkage ball joint from gear selector lever. 60. Using tool 186 1592 release gear change linkage ball joint from gear change lever. 61. Remove bolt and disconnect gear change steady bar from gearbox. Collect 2 washers. 62. Remove clip retaining selector rod rol pin. 63. Using a suitable punch, drive out roll pin securing selector rad to selector shaft 64, Release selector rod from selector shaft and tie aside. All models 1.4 model 65. Loosen through bolt securing engine steady bar to subframe, 66. Remove through bolt securing engine steady bar to bracket on gearboxisump. REPAIRS 43.ENGINE - ’K16" 67. Remove 2 bolts securing camshaft rear cover plate to cylinder head. 68, Remove camshaft rear cover plate. 69. Fitltting bracket tool 186 1572/1 to cylinder head. Fit bolts and tighten to 9 Nm. ramzeasa | 70. Fitliting bracket tool 186 1572/2 to cylinder head. Fit bolt and tighten to 9 Nm. O\ 18G 1598 121808 71. Connect adjustable lifting bracket tool 186 1598 to lifting brackets. 72. Connect a hoist to tool 186 1598 and raise hoist to take weight of engine without exerting load on engine mounting bots. 73. Remove engine RH mounting. See this section. 44 REPAIRS1.4 models raMazeea 74, Remove 2 bolts securing engine LH mounting to gearbox mounting bracket. 75. Remove 2 bolts securing engine LH mounting to body. 76. Remove 2 bolts securing engine LH mounting ‘to mounting bracket. 77. Remove engine LH mounting ENGINE - ’K16" 1.6 8 1.8 models ‘asion \ 78. Remove through bolt securing engine LH ‘mounting to bracket on body. 79. Remove 2 bolts securing engine LH mounting to mounting bracket on gearbox. 80. Remove engine LH mounting, All models 81. Adjust tool 186 1598 to tlt engine with the gearbox as low as possible. 82, Using assistance, manoouvre engine and gearbox from vehicle. CAUTION: Take care not to damage the ABS modulator or brake pipes when removing the engine. 83. Lower engine and gearbox assembly and disconnect hoist from adjustable lifting bracket, REPAIRS 45,ENGINE - ’K16" Refit 4. Connect hoist to adjustable lifting bracket tool 186 1598. 2. Using assistance, raise engine and manoeuvre into position in vehicle 3. Adjust lifing bracket tool so engine is horizontal in engine compartment. 1.68 1.8 models ‘4, Position engine LH mounting to mounting bracket on gearbox, fit bolts and tighten to 100 Nm. 5. Align engine LH mounting to bracket on body, fit through bolt and tighten to 85 Nm, 1.4 models 6. Position engine LH mounting, 7. Fitbolts securing engine LH mounting to mounting bracket and tighten to 55 Nm 8. Fitbolts securing engine LH mounting to body land tighten to 55 Nm 8. Align gearbox mounting bracket to engine mounting ft bolts and tighten to 60 Nm. All models 10. Fit engine RH mounting. See this section 11. Lower hoist and disconnect lifting bracket too! 18G 1598 from engine lifting brackets. 42. Remove bolt securing iting bracket tool 186 157212 to cylinder head and remove lifting bracket. 43. Remove 2 bolts securing lifting bracket tool 18G 1572/1 to cylinder head and remove lifting bracket. 44, Clean camshaft rear cover plate. 415. Position camshaft rear cover plate to cylinder head, fit bolts and tighten to 25 Nm. 16. 1,68 1.8 models: Connect engine steady bar to bracket on sump, fit through bolt and tighten to 80 Nm. 17. 1,4 models: Connect engine steady bar to bracket on gearbox, ft through bolt and tighten to 45 Nm. 18. Tighten through bolt, engine steady bar to subframe, to 80 Nm. 1.48 1.6 models 19. Clean gear selector linkage and gear change linkage ball joints 20. Using tool 186 1594 connect gear selector linkage ball joint to gear selector lever. 21. Using tool 186 1594 connect gear change linkage ball joint to gear change lever. 1.8 Models 22. Connect selector rod to selector shaft and align holes. 23. Fit NEW roll pin securing selector rod to shaft and fit rol pin retaining clip. 24, Fit washers to steady bar and connect to gearbox. 25, Fit bolt securing steady bar to gearbox and tighten to 60 Nm, 46 REPAIRSAll models 26. Remove plugs from power steering pump and. hose connections. 27. Lubricate new ‘0’ ring with clean power steering fluid and fit to fluid outlet hose. 28. Connect fluid outlet hose to power steering pump and tighten union to 55 Nm. CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions. 28. Align fluid outlet hose clamp to bracket and ‘secure with bolt 30. Connect fluid inlet hose to power steering pump and tighten clip. 31. Connect coolant feed hose to expansion tank land tighten clip 32. Connect 4 engine harness muitiplugs to main harness and secure to mounting bracket on bulkhead, 33. Connect multipug to inertia switch and secure harness clip to mounting bracket. 34, Connect coolant hose to thermostat housing land tighten clip 36. Connect expansion tank hose to inlet manifold and tighten clip 36. Connect ECM vacuum pipe to inlet manifold. 37. Connect throttle cable to throttle cam, 38. Locate throttle cable adjusting nut in abutment bracket. 39, Ensure throttle cable is correctly routed and ‘secure to clip on inlet manifold 40. Connect brake servo vacuum pipe to inlet manifold, 41. Connect hose to fuel return pipe and secure with clip, ENGINE -"k16’ Jyeeeey] ‘42. Clean union of fue! outlet pipe and fuel fiter. 43. Connect fuel outlet pipe to fue! filter and tighten union to 28 Nm. CAUTION: To prevent damage to fuel system pipes and components use two spanners when loosening or tightening 44, Fitexhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 45. Fit evaporative emission canister. See EMISSION CONTROL, Repairs. ‘46. Connect the engine harness to main harness connector. 47. Connect mutiplug to fuse box. 48. Fit positive leads to fuse box and secure with 449. Fit fuse box inner cover. 50. Fit fuse box cover. 51. Connect multipug to radiator cooling fan. 52. Position earth lead to bonnet locking platform, fit bolt and tighten to 9 Nm. 53. Connect heater hose to coolant outlet elbow and tighten clip. 54, Secure heater hose to clip on coolant rail 55. Connect radiator bottom hose to coolant rail and tighten clip. 56. Connect radiator top hose to coolant outlet elbow and tighten clip. 57. Connect drive shafts to gearbox as detailed in Differential oil seal 1.4 & 5.6 models; See MANUAL GEARBOX - "R65", Repairs. 1.8 models, See MANUAL GEARBOX- PGT’, Repairs. 58. Feed clutch cable through abutment bracket ‘and connect to clutch release lever. REPAIRS 47ENGINE - ’K16" 59. 60. et. 62. 63, 66. 67. 68 69. 70. nm. rR. 73. 74, 75. 48 Position battery tray in vehicle. Tighten 3 bolts securing battery tray to body, to 10Nm. Position engine compartment fuse box to body, fit bolt and tighten to 10 Nm. Fit4 bolts securing battery tray to body and tighten to 10 Nm Fit and tighten bolt securing engine compartment fuse box to battery tray. 1. Fit resonator to air intake pipe. 65. Fit and tighten bolts securing resonator to battery tray, Secure ABS fuse holder to battery tray. Fit engine management relay module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. FitECM. See ENGINE MANAGEMENT ‘SYSTEM - MEMS, Repairs. Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Remove stand{s) and lower vehicle. Refill gearbox with ol 1.4 & 1,6 models See MANUAL GEARBOX - "RES", Adjustments. 1.8 models See MANUAL GEARBOX- PGT’, Adjustments. Refill cooling system. See COOLING SYSTEM - ’k’ SERIES, Adjustments. Hf requirad: Refill engine with oil. See MAINTENANCE. Bleed power steering system. See STEERING, Adjustments. Adjust throttle cable. See ENGINE MANAGEMENT SYSTEM - MEMS, Adjustments, ENGINE AND AUTOMATIC GEARBOX - MODELS WITH AIR CONDITIONING Service repair no - 12.37.01.20 Remove 4. Disconnect battery earth lead 2. required: Drain engine cil. See MAINTENANCE. 3, Fitnew sealing washer to drain plug, fit drain plug and tighten to 42 Nm. 4. Drain cooling system. See COOLING SYSTEM - 'K’ SERIES, Adjustments. 5. Drain gearbox fluid. See AUTOMATIC GEARBOX.- ‘CVT’, Adjustments. 6. Recover refrigerant from air conditioning system. See AIR CONDITIONING, Adjustments. 7. Raise front of vehicle. Q WARNING: Support on safety stands. 8. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 9. Remove ECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 10. Remove engine management relay module, See ENGINE MANAGEMENT SYSTEM - ‘MEMS, Repairs. 11. Release ABS fuse holder from battery tray. REPAIRS13. 14. 15. 16. 17. . Se Remove bolt securing engine compartment fuse box to battery tray. Remove 4 bolts securing battery tray to body. Remove bolt securing engine compartment {use box to body and position fuse box aside. Loosen 3 bolts securing battery tray to body. Remove battery tray from vehicle. Release both drive shafts from gearbox as detailed in Differential cil seal. See AUTOMATIC GEARBOX - ‘CVT’, Repairs. ENGINE - ’K16" 1242782 A 18. Loosen clip and disconnect radiator top hose from coolant outlet elbow. 19. Loosen clip and disconnnect radiator bottom hose from coolant ral 20. Loosen clip and disconnect heater hose from coolant outlet elbow. 21. Release heater hose from clip on coolant rail and position aside. REPAIRS 49ENGINE - ’K16" saw27e3 22. Remove bolt securing earth lead to bonnet, locking platform, 23. Disconnect multiplug from radiator cooling fan. TONED fe 2 ® ®@ ® 255— \‘* pews 24, Release cp and remove fuse box cover. 25. Depress 2 clips and remove fuse box inner 50 REPAIRS26. Remove 2 screws securing positive leads to fuse box. 27. Disconnect multiplug from fuse box. ENGINE - ’K16’ 122787 . Disconnect engine hamess to main harness connector. 1. Lay engine harness across engine to avoid it being caught when the engine is removed. }. Remove evaporative emission canister. See EMISSION CONTROL, Repairs. |. Remove exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 2. Position absorbent cloth around fuel fiter outlet REPAIRS = 51ENGINE - ’K16" 1302768 33. Loosen fue! fier outlet union to relieve fuel pressure. CAUTION: To prevent damage to fuel LX syst0m pipes and comp Se two. spanners when loosening or tightening 34. Disconnect fuel outlet pipe from fuel fter and position aside. 36. Release clip and disconnect hose from fuel return pipe. 36. Release throttle cable adjusting nut fram abutment bracket. 37. Release throttle cable from throttle cam. 38. Depress plastic collar on quick release connector and disconnect brake servo vacuum pipe from inlet manifold 39, Release throttle cable from clip on inlet manifold ‘40. Disconnect ECM vacuum pipe from inlet manifold 41. Loosen clip and disconnect expansion tank hose from inlet manifold 42. Loosen clip and disconnect coolant hose from thermostat housing, 52 REPAIRS1. Disconnect multplug from inertia switch Release clip securing inertia switch hamess to mounting bracket. 3. Release 4 multiplugs from mounting bracket on bulkhead, 3. Disconnect engine harness multiplugs from main harness. /. Loosen clip and disconnect coolant feed hose from coolant expansion tank. 3. Position container to catch fluid loss from power steering system. ENGINE - ’K16’ reva7ge SS 49. Loosen clip securing fluid inlet hose to power steering pump. ). Disconnect fluid inlet hose from power steering pump. Remove bolt securing fluid outlet hose clamp to bracket. 52. Loosen union and disconnect fluid outlet hose from power steering pump. 5 51. CAUTION: To prevent damage to pipes and components use two spanners when loosening or tightening unions. 53. Remove and discard 'O' ring from fluid outlet hose. 54, Plug hose and power steering pump connections to prevent excess fluid loss and the ingress of dit into the system. 122795 55. Remove bolt securing air conditioning pipe to bracket on flywheel housing, REPAIRS 53.ENGINE - ’K16" '56. Loosen union and disconnect compressor pipe {rom evaporator pipe. CAUTION: To prevent damage to air conditioning pipes and components use two spanners when loosening or tightening unions. '57. Remove and discard ‘0’ ring from compressor Pipe. ‘58. Position evaporator pipe aside. 59 ©) . oe POS nr | u2797 '59. Remove bolt securing compressor pipe to ‘condenser pipe. Release compressor pipe from condenser pipe and discard '‘O'ring 60. 54 REPAIRS 1212798 61. Remove bolt securing air conditioning pipe union to compressor. Release air conditioning pipe union from compressor. 63. Remove air conditioning pipes. 64. Remove and discard 2'O’ rings from compressor. 62, CAUTION: Immediately cap all air conditioning pipes and compressor to prevent ingress of dirt and moisture into the system.ENGINE - ’K16" 3. Remove nut securing selector cable rod to selector lever. . Release selector cable rod from selector lever. "Slide rubber sleeving back fram lock nut on 72. Loosen through bolt securing engine steady selector cable rod, bar to subframe. 3. Loosen lock nut securing selector cable to 73. Remove through bolt securing engine steady ‘abutment bracket. bar to bracket on sump. 1. Seperate ant-vibration rubbers and release cable from abutment bracket. 74, Remove 2 bolts securing camshaft rear cover plate to cylinder head 1. Loosen unions and disconnect 2 fluid cooler 75. Remove camshaft rear cover plate hoses from gearbox. |. Remove and discard 'O' rings from fluid cooler hose unions. A CAUTION: Plug the connections. REPAIRS 55,ENGINE - ’K16" O\ 18G 1598 76. Fitliting bracket tool 186 1572/1 to cylinder 412M1808 head. Fit bolts and tighten to 9 Nm. 78. Connect adjustable lifting bracket tool 186 1598 to lifting brackets. 79. Connect a hoist to tool 186 1598 and raise hoist to take weight of engine without exerting load on engine mounting bots. TT. Fitlifting bracket tool 186 1572/2 to cylinder head. Fit bolt and tighten to 9 Nm. 12M2805, \\ 80. Remove bolt securing RH steady bar to engine ‘mounting 81. Remove 2 bolts securing mounting bracket to engine, 82, Remove nut securing mounting bracket to engine mounting. 83. Loosen 2 nuts securing engine mounting restraint bar to body. 84, Remove RH engine mounting bracket. 56 REPAIRS85. Remove and discard nut securing gearbox mounting bracket to engine LH mounting. 86, Adjust tool 18G 1598 to tilt engine with the ‘gearbox as low as possible. 87. Using assistance, manoeuvre engine and gearbox from vehicle CAUTION: Take care not to damage the ABS modulator or brake pipes when removing the engine. 88. Lower engine and gearbox assembly and disconnect hoist from adjustable lifting bracket. ENGINE -"k16’ Jyeeeey] Refit | Connect hoist to adjustable lifting bracket tool 186 1598. 2. Using assistance, raise engine and manoeuvre into position in vehicle. 3. Adjust lifting bracket tool so engine is horizontal in engine compartment. 4, Locate gearbox mounting bracket on engine LH mounting. '5. Fitnnew Nyloc nut securing bracket to engine ‘mounting and tighten to 160 Nm. 6. Fit engine RH mounting bracket to engine ‘mounting, steady bar and engine. 7. Align mounting bracket to engine, ft bolts and tighten to 160 Nm. 8. Fitnut securing mounting bracket to engine ‘mounting and tighten to 85 Nm 9. Tighten nuts securing engine mounting to body, to 45 Nm. 10. Fit bolt securing RH steady bar to mounting bracket and tighten to 80 Nm. 14. Lower hoist and disconnect lifting bracket tool 186 1598 from ling brackets. 12, Remove bolt securing ling bracket tool 186 1872/2 to cylinder head and remove lifting bracket. 13. Remove 2 bolts securing lifting bracket tool 418G 1572/1 to cylinder head and remove lifting bracket. 14, Clean camshaft rear cover plate. 15. Position camshaft rear cover plate to cylinder head, fit bolts and tighten to 25 Nm. 16. Connect engine steady bar to bracket on sump, fit through bolt and tighten to 80 Nm. 17. Tighten through bolt, engine steady bar to subframe, to 80 Nm, 18. Remove plugs from fluid cooler hose unions, lubricate new °O’ rings with gearbox and fit to 19. Connect fuid cooler hoses to gearbox and tighten unions to 37 Nm. 20. Fit selector cable to abutment bracket and push anti-vibration rubbers into position. 21, Tighten selector cable lock nut fo abutment bracket. 22, Slide selector cable rod sleeving into position 23. Connect selector cable rad to selector rod, DO NOT tighten nut REPAIRS 57.ENGINE - ’K16" 24. Remove caps from air conditioning pipes and ‘compressor. 25. Clean mating faces of air conditioning pipe union and compressor. 26. Lubricate 2 new 'O' rings with refrigerant oil and fit to compressor. 27. Position air conditioning pipe union to ‘compressor, ft bolt and tighten to 35 Nm. 28. Clean condenser pipe and compressor pipe 29. Lubricate new 'O' ring with reftigerant ol and fit to condenser pipe. 30. Connect condenser pipe to compressor pipe, ft bolt and tighten to 6 Nm. 31. Clean compressor pipe and evaporator pipe 32. Lubricate new ‘0’ ring with reftigerant ol and fit to compressor pipe. 33. Connect evaporator pipe to compressor pipe and tighten union to 45 Nm. CAUTION: To prevent damage to air conditioning pipes and components use two spanners when loosening or tightening unions. 34, Align air conditioning pipe to bracket on flywheel housing, fit bolt and tighten to 6 Nm 36. Remove plugs from power steering pump and. hose connections. 36. Lubricate new ‘0’ ring with clean power steering fluid and fit to fluid outlet hose. 37. Connect fluid outlet hose to power steering pump and tighten union to 55 Nm. CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions. 38. Align fluid outlet hose clamp to bracket and ‘secure with bolt 39. Connect fluid inlet hose to power steering pump and tighten clip. 8 Connect coolant feed hose to expansion tank and tighten clip. 41. Connect 4 engine hares multiplugs to main hamess and secure to mounting bracket on bulkhead. Connect multiplug to inertia switch and secure hhamess clip to mounting bracket. Connect coolant hose to thermostat housing and tighten clip. Connect expansion tank hose to inlet manifold and tighten clip. Connect ECM vacuum pipe to inlet manifold. Connect throttle cable to throttle cam. Locate throttle cable agjusting nut in abutment bracket. Ensure throttle cable is correctly routed and secure to clip on inlet manifold. 149. Connect brake servo vacuum pipe to inlet manifold 50. Connect hose to fuel retum pipe and secure with clip. 51. Clean union of fuel outlet pipe and fuel filter. 52. Connect fuel outlet pipe to fue fiter and tighten. union to 28 Nm. ase 8 8 8 8 CAUTION: To prevent damage to fuel system pipes and components use two spanners when loosening or tightening 53. Fitexhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 54, Fit evaporative emission cansiter. See EMISSION CONTROL, Repairs. 55. Connect the engine hares to main hamess connector. 56. Connect multiplug to fuse box. ST. Fit positive leads to fuse box and secure with 8. Fit fuse box inner cover. 59. Fit fuse box cover. 60. Connect multipug to radiator cooling fan. 61. Position earth lead to bonnet locking platform, fit bolt and tighten to 9 Nm. 58 REPAIRS62. 63, 65. 66. 67. 68, 69. 70. nm. 2. 73. 74, 75. 76. 7. 78. 79. 80. at. 82. 83, Connect heater hase to coolant outlet elbow land tighten clip Secure heater hose to clip on coolant ral 1. Connect radiator bottom hose to coolant rail and tighten clip Connect radiator top hose to coolant outlet elbow and tighten clip. Connect drive shafts to gearbox as detailed in Differential oil seal. See AUTOMATIC GEARBOX - ‘CVT’, Repairs. Position battery tray in vehicle. Tighten 3 bolts securing battery tray to body, to 10Nm. Position engine compartment fuse box to body, fit bolt and tighten to 10 Nm. Fit4 bolts securing battery tray to body and tighten to 10 Nm Fit and tighten bolt securing engine ‘compartment fuse box to battery tray. Secure ABS fuse holder to battery tray. Fit engine management relay module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. FItECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. Replace receiveridryer. See AIR CONDITIONING, Repairs. Adjust selector cable. See AUTOMATIC GEARBOX - ‘CVT’, Adjustments. Remove stand{s) and lower vehicle. Recharge air conditioning system. See AIR CONDITIONING, Adjustments. Refill gearbox with fluid. See AUTOMATIC GEARBOX - ‘CVT’, Adjustments. Refill cooling system. See COOLING SYSTEM - 'K’ SERIES, Adjustments. H required: Refill engine with oil. See MAINTENANCE. Bleed power steering system. See STEERING, Adjustments. 1. Adjust throttle and kickdown cable. See AUTOMATIC GEARBOX - ‘CVT’ Adjustments, ENGINE -"k16’ Jyeeeey] ENGINE AND AUTOMATIC GEARBOX - MODELS WITHOUT AIR CONDITIONING Service repair no - 12.37.01.99 Remove 4. Disconnect battery earth lead 2. required: Drain engine cil. See MAINTENANCE. 3, Fitnew sealing washer to drain plug, fit drain plug and tighten to 42 Nm. 4. Drain cooling system. See COOLING SYSTEM - 'K’ SERIES, Adjustments. 5. Drain gearbox fluid. See AUTOMATIC GEARBOX.- ‘CVT’, Adjustments. 6. Raise front of vehicle. Q WARNING: Support on safety stands. 7. Remove air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 8. Remove ECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 9. Remove engine management relay module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs. 10. Release ABS fuse holder from battery tray. REPAIRS 59.ENGINE - ’K16" 14. Remove bolt securing engine compartment fuse box to battery tray. 12. Remove 4 bolts securing battery tray to body. 413. Remove bolt securing engine compartment {use box to body and position fuse box aside. 414, Loosen 3 bolts securing battery tray to body. 415. Remove battery tray from vehicle. 16. Release both drive shafts from gearbox as detailed in Differential cil seal. See AUTOMATIC GEARBOX - ‘CVT’, Repairs. 17. Loosen clip and disconnect radiator top hose from coolant outlet elbow. 18. Loosen clip and disconnnect radiator bottom hose from coolant ral 19. Loosen clip and disconnect heater hose from coolant outlet elbow. 20. Release heater hose from clip on coolant rail and position aside. 60 REPAIRS21. Remove bolt securing earth lead to bonnet, locking platform, 22. Disconnect multiplug from radiator cooling fan. ENGINE - ’K16" TONED @ fio] @ ® fio] @ @ pod @ Q oO | ye teiet ‘* © 12102812 @ 23. Release clip and remove fuse box cover. 24. Depress 2 clips and remove fuse box inner REPAIRS 61ENGINE - ’K16" ARLE: 128s SY 25. Remove 2 screws securing positive leads to fuse box. 26. Disconnect multiplug from fuse box. 122814 /. Disconnect engine hamess to main harness connector. . Lay engine harness across engine to avoid it being caught when the engine is removed. |. Remove evaporative emission canister. See EMISSION CONTROL, Repairs. |. Remove exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs. |. Position absorbent cloth around fuel fiter outlet 62 REPAIRSENGINE - ’K16’ 35, Release throttle cable adjusting nut from abutment bracket. 36. Release throttle cable from throttle cam. avneis, 32. Loosen fue! fiter outlet union to relieve fuel pressure CAUTION: To prevent damage to fuel LX syst0m pipes and comp Se two. spanners when loosening or tightening 33. Disconnect fuel outlet pipe from fuel fter and position aside. 37. Depress plastic collar on quick release connector and disconnect brake servo vacuum pipe from inlet manifold 38. Release throttle cable from clip on inlet manifold 39. Disconnect ECM vacuum pipe from inlet manifold 40. Loosen clip and disconnect expansion tank hose from inlet manifold 41. Loosen clip and disconnect coolant hose from thermostat housing, 34. Release clip and disconnect hose from fuel return pipe. REPAIRS 63ENGINE - ’K16" 64 2. Disconnect multplug from inertia switch |. Release clip securing inertia switch harness to mounting bracket. Release 4 multiplugs from mounting bracket on bulkhead, 3. Disconnect engine harness multiplugs from main harness. 3. Loosen clip and disconnect coolant feed hose from coolant expansion tank. 7. Position container to catch fluid loss from power steering system. 48. Loosen clip securing fluid inlet hose to power steering pump. 449. Disconnect fluid inlet hose from power steering pump. 50. Remove bolt securing fluid outlet hose clamp to bracket. 1. Loosen union and disconnect fluid outlet hose from power steering pump. CAUTION: To prevent damage to pipes and components use two spanners when loosening or tightening unions. 52, Remove and discard 'O' ring from fluid outlet hose. 53. Plug hose and power steering pump connections to prevent excess fluid loss and the ingress of dit into the system. REPAIRSENGINE - ’K16" REPAIRS 3ENGINE MANAGEMENT SYSTEM - MEMS SPARK PLUGS- Ka" Refit Service repair no - 18.20.02 4. Fit terminals to new spark plugs. Remove St IER 14 1 18Mo097 ssmoa95 2. Set gap of each spark plug to 0.85 mm. 3. Fit spark plugs and tighten to 27 Nm 4. Connect ht. leads to spark plugs. 41. Disconnect ht. leads from spark plugs. 18§M0096 2. Using a 16 mm spark plug socket, remove 4 ‘spark plugs. 4 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS SPARK PLUGS - 'K16" Servi repair no - 18.20.02 Remove t8Mo042 2 4. Remove 2 screws retaining hit. lead cover. 2. Remove hit lead cover. 1eMo043 3. Disconnect ht. leads from spark plugs. 44. Release h.t. leads mounting rubbers fram ‘camshaft cover and place ht. leads aside. revocsa '5. Using a 16 mm spark plug socket remove 4 spark plugs. Refit 4. Fit terminals to new spark plugs. ¥ revo ‘Set gap of each spark plug to 0.85 mm. Fit spark plugs and tighten to 27 Nm. Connect hit leads to spark plugs. Locate h.t lead mounting rubbers in camshaft Fith.t lead cover and tighten screws to 2 Nm. REPAIRS 5ENGINE MANAGEMENT SYSTEM - MEMS DISTRIBUTOR CAP AND ROTOR ARM Service repair no - 18.20.23 Remove 41. Noting their fitted positions, disconnect hit leads from distributor cap, 2. Loosen 2 screws securing distributor cap to engine. 3. Remove distributor cap. 4. Rotate engine to gain access to rotor arm 5. Remove and discard screw securing rotor arm to camshaft Remove rotor arm. Remove distributor flash shield Refit 41. Clean distributor cap, rotor arm and flash shield. 2. Examine distributor cap and rotor arm for signs ‘of damage or tracking; renew if necessary 3. Fitflash shield 4. Clean rotor arm screw thread in camshaft with thread tap. 5. Position rotor arm on camshaft. 6. Fitnew patchlock screw to secure rotor arm to ‘camshaft and tighten to 8 Nm. 7. Fitdistributor cap and align holes in cap and flash shield with those in engine. 8. Fit2 screws securing distributor cap to engine. 9. Connect hit leads to distributor cap. IGNITION COIL Service repair no - 18.20.43 Remove 4. Disconnect battery earth lead 2. Raise front of vehicle. Q WARNING: Support on safety stands. 180028 - Disconnect multiplug from ignition col |. Disconnect ht. lead from ignition col 5. Remove 3 bolts securing igntion coil to engine. . Remove ignition coil Refit |. Position ignition coil to engine. . Fit bolts securing ignition coil to engine, tighten 2.x M10 bolts to 45 Nm and ME bolt to 9 Nm. Connect ht. lead to ignition coil Connect mutiplug to ignition coil Connect battery earth lead. . Remove stand(s) and lower vehicle. 6 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS OO Do not carry out further dismantling if IGNITION COIL -°K16 WITH VVC" ‘component is removed for access only. Service repair no - 18.20.43 Remove 1. Raise front of vehicle. Q WARNING: Support on safety stands. 2. Disconnect battery earth lead. 7. Centre punch top of 3 rivets securing coll to ‘mounting bracket. 8. Drill out 3 rivets securing coll to mounting bracket. 9. Remove ignition coil Disconnect 4 ht. leads from ignition coils. Disconnect 2 multiplugs from ignition coils From beneath vehicle; remove 2 bolts securing ignition coil mounting bracket to cylinder block. 6. Remove ignition calls and collect spacer. gee REPAIRS 7ENGINE MANAGEMENT SYSTEM - MEMS Refit 1 2. 3. 8 ENGINE CONTROL MODULE (ECM) Position ignition coil to mounting bracket and Service repair no - 18.30.01 ‘secure with nuts and bolts. Position ignition coil mounting bracket and Remove ‘spacer to cylinder block Fit bolts securing ignition coil mounting bracket 41. Disconnect battery earth lead to cylinder block and tighten to 45 Nm Connect htt. leads to ignition coils in the order eos shown Connect mutiplug with 3 pins to ignition coll 1 2. Disconnect multiplug rom ECM. Connect mutiplug with 2 pins to ignition cll 3. Disconnect vacuum hose from ECM. 23 4. Loosen bolls securing ECM to mounting Remove stand(s) and lower vehicle. bracket. Connect battery earth ead 5. Release and remove ECM Refit 4. FILECM to mounting bracket 2: Tighten bolts securing ECM to mounting bracket to4 Nm. 3. Connect vacuum hose to ECM. 4 Connect mutiplug to ECM. 5. Connect battery earth lead NOTE: Ifa new ECM has been fitted, the L) ECM will need to be programmed with the code from the anti-theft security unt using TestBook, before the engine can be started. REPAIRSENGINE MANAGEMENT SYSTEM - MEMS *\} ra ENGINE CONTROL MODULE (ECM) - 16 WITH we" Service repair no - 18.30.01 Remove 41. Disconnect battery earth lead. Loosen bolt securing ECM to battery tray. Release ECM from battery tray. Disconnect 2 multiplugs from ECM. Remove ECM. paen Refit 41. Position ECM and connect 2 multiplugs. Locate ECM on battery tray 3. Tighten bolt securing ECM to battery tray, to 4 Nm. 4, Connect battery earth lead. NOTE: If a new ECM has been fitted, the ECM will need to be programmed with the code from the anti-theft security unit using ‘TestBook, before the engine can be started. IDLE AIR CONTROL VALVE (IAGV) Service repair no - 18.30.05 Remove 41. Disconnect battery earth lead °§ TaMOuaa 2. Disconnect multiplug from IACV. 3, Remove 2 X20 Tor screws securing |ACV to inlet manifold 4, Remove IACV from inlet manifold. 5. Remove and discard ‘0’ ring from IACV. Refit |. Clean mating faces of [ACV and inlet manifold 2. Lubricate new °O' ring with silicone grease and fitto IACV. 3. Fit ACV to inlet manifold, Fit Torx screws and tighten to 8 Nm. 4. Connect muttiplug to IACV. '5. Connect battery earth lead. REPAIRS 9ENGINE MANAGEMENT SYSTEM - MEMS INTAKE AIR TEMPERATURE (IAT) SENSOR Service repair no - 18.30.09 Remove 41. Disconnect battery earth lead. remorse 2. Disconnect multiplug from IAT sensor. 3. Remove IAT sensor. Refit 4. Clean threads of IAT sensor. 2. Clean mating faces of IAT sensor and inlet manifold, 3. FILIAT sensor to inlet manifold and tighten to 7 Nm, 4. Connect multiplug to IAT sensor. 5. Connect battery earth lead. ENGINE COOLANT TEMPERATURE (ECT) SENSOR Service repair no - 18.30.10 Remove 41. Disconnect battery earth lead telocao 2. Disconnect multiplug from ECT sensor. 3. Position container to collect spillage. 4, Remove ECT sensor. Refit 4. Clean threads of ECT sensor. . Apply Loctite 577 to threads of ECT sensor. Fit ECT sensor and tighten to 15 Nm. Connect multiplug to ECT sensor. Connect battery earth lead. Top-up coolant. See MAINTENANCE, 10 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS CRANKSHAFT POSITION (KP) SENSOR Servi repair no - 18.30.12 Remove spMons3 4. Disconnect muitiplug from CKP sensor. 2. Remove bolt securing CKP sensor to flywheel housing. 3. Remove CKP sensor. 1. Clean CKP sensor and mating face on flywhee! housing. 2. Position CKP sensor, fit bolt and tighten to 6 Nm. 3. Connect multiplug to CKP sensor. CRANKSHAFT POSITION (CKP) SENSOR - K16 4.8 & K16 WITH WC" Service repair no - 18.30.12 Remove 41. Raise front of vehicle. rensor7s 2. Disconnect multiplug from CKP sensor. 3, Remove bolt securing CKP sensor to flywhee! housing 4, Remove CKP sensor. 4. Clean CKP sensor and mating face on flywhee! housing 2. Position CKP sensor, fit bolt and tighten to 6 Nm. 3. Connect muttiplug to CKP sensor. 4. Remove stand(s) and lower vehicle. REPAIRS 11ENGINE MANAGEMENT SYSTEM - MEMS THROTTLE POSITION (TP) SENSOR’ Service repair no - 18.30.17 Remove 41. Disconnect battery earth lead. ‘rettocs0 2. Disconnect multiplug from TP sensor. 3. Remove and discard 2 TX20 Torx screws and wave washers securing TP sensor to throttle. housing. ‘4, Remove TP sensor specification plate. 5. Pull TP sensor from throttle spindle. CAUTION: Do not twist or apply leverage to TP sensor. Refit 41. Clean mating faces of throttle housing and TP 2. Fit TP sensor to throttle spindle. Ensure that during fting, the machined flat on the throttle spindle is aligned with the mating portion of the TP sensor. 18M0058 CAUTION: The TP sensor can be easily damaged during fitting. When pressing the sensor onto the throttle spindle, ust fingers only, and only apply pressure to the area shown shaded in the illustration. 3. Rotate TP sensor in an anti-clockwise direction to align fixing holes. CAUTION: Do not rotate sensor in a clockwise direction, and ensure that it is not rotated beyond its internal stops. 4. Fit TP sensor specification plate. 5. Fitnew Torx screws and wave washers, and tighten to 1.5 Nm. CAUTION: Do not exceed specified torque QL figure. 6. Connect multiplug to TP sensor. 7. Operate throttle cable cam 2 or 3 times and ensure that full travel to the throttle open and the throttle closed positions is available. 8. Connect battery earth lead. 12 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS HYDRAULIC CONTROL UNIT (HCU) SOLENOIDS (OIL TEMPERATURE SENSOR - 'K16 WITH Wi 16 WITH VVC" Service repair no - 18.30.41 Service repair no - 18.30.39 Remove Remove jeuor73, 41. Disconnect multiplug from oil temperature 2. Remove temperature sensor from HCU. 3. Remove and discard seal tewor72 1 4. Disconnect 2 multiplugs from HCU solenoids. Refit 2. Remove nut securing solenoids to HCU. 3. Remove 2 solenoids. |. Clean sealing faces of sensor and HCU. 9. Fit new seal to sensor. . Fit sensor and tighten to 15 Nm. |. Connect multiplug to sensor. Refit 41. Clean solenoids and fit to HOU. 2. Position solenoids and tighten securing nut to 12.Nm. 3. Connect multiplugs to solenoids. REPAIRS 13ENGINE MANAGEMENT SYSTEM - MEMS MANIFOLD ABSOLUTE PRESSURE (MAP) ENGINE MANAGEMENT RELAY MODULE. SENSOR -'K16 WITH VVC" Service repair no - 18.30.71 Service repair no - 18.30.56 The engine management relay module contains the Remove following relays: Main relay Starter relay Fuel pump relay HO2S relay Remove 4. Disconnect multiplug from MAP sensor. 2. Remove 2 bolts securing MAP sensor to manifold chamber. 3. Remove MAP sensor. ‘4. Remove and discard ‘0’ ring from MAP sensor. Refit 41. Release relay module from mounting bracket. 2. Disconnect 2 multiplugs from relay module. 41. Clean sealing faces of sensor and manifold 3. Remove relay module, chamber. 2. Lubricate and fit new ‘0’ ring to MAP sensor. Refit 3. Fitsensor to manifold chamber and tighten bolts to 10 Nm, 41. Position relay module and connect 2 ‘4. Connect multiplug to sensor. ‘multplugs. Ensure multiplugs are correctly engaged. 2. Secure relay module to mounting bracket. 14 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS CAMSHAFT POSITION (CMP) SENSOR - 'K16 WITH we" Service repair no - 19.22.07 Remove je 18017. 4. Disconnect muitiplug from CMP sensor. 2. Remove bolt securing CMP sensor to cylinder head 3. Remove CMP sensor. ‘4. Remove 'O’ ring from CMP sensor. 41. Clean sealing faces of sensor and cylinder head 2. Lubricate and fit'0' ring to CMP sensor. 3. Fitsensor to cylinder head and tighten bolt to 6 Nm, 4. Connect multiplug to CMP sensor. HEATED OXYGEN (HO2S) SENSOR Service repair no - 19.22.16 Remove 4. Disconnect battery earth lead 2. Disconnect HO2S multiplug from harness. fl ‘19M0910 3. Release multiplug from bracket on coolant rail seMoort 4, Using a 22 mm open ended spanner remove HO2S and collect sealing washer. Refit NOTE: Any sensor that has been dropped must not be fitted to vehicle. 4. Fit sealing washer to HO2S. Fit HO2S and tighten to 55 Nm. ‘Secure multiplug to bracket on coolant rail Connect HO2S multiplug to hamess, Connect battery earth lead. REVISED: 06/99 REPAIRS 15ENGINE MANAGEMENT SYSTEM - MEMS HEATED OXYGEN (HO2S) SENSOR - 'K16" Servi repair no - 19.22.16 Remove 4. Remove exhaust manifold. See MANIFOLD & EXHAUST SYSTEMS, Repairs. s9Moasza 2. Using a 22 mm open ended spanner remove HO2S and collect sealing washer. Refit 41. Fitsealing washer to HO2S 2. Fit HO2S and tighten to 55 Nm. 3. Fitexhaust manifold See MANIFOLD & EXHAUST SYSTEMS, Repairs. THROTTLE HOUSING Service repair no - 19.22.45 Remove 41. Disconnect battery earth lead 1960915 2. Release clip securing air intake hose to throttle housing 3, Disconnect air intake hose from throttle housing 4. Disconnect hose from IACV. 5. Disconnect multiplug from TP sensor. 6. Release clip and disconnect breather hose from throttle housing, 7. Release throttle cable adjusting nut from abutment bracket 8. Disconnect throttle cable from throttle cam. 9. Remove 4 bolts securing throttle housing to inlet manifold 10. Remove throttle housing. 11. Remove and discard 'O' ring from throttle housing 16 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS *\} ra Refit 41. Clean mating faces of throttle housing and inlet manifold, 2. Lubricate new 'O' ring with silicone grease and fitto throttle housing. 3. Position throttle housing to inlet manifold and. align injector harness multiplug bracket. 44, Fit bolts securing throttle housing to inlet manifold and tighten to 7 Nm 5. Connect throttle cable to throttle cam. 6. Locate throttle cable adjusting nut in abutment bracket. 7. Connect breather hose to inlet manifold and secure with clip. 8. Connect multiplug to TP sensor. 9. Connect hose from IACV to throttle housing, 40. Connect ir intake hose to throttle housing and secure with clip. 44. Connect battery earth lead. ECM FUEL TRAP Service repair no - 19.25.10 Remove 19M2041 41. Release fuel trap from mounting bracket. 2. Disconnect two vacuum pipes from fuel trap. Refit 4. Connect vacuum pipes to fuel trap, 2. Fit fuel trap to mounting bracket, REPAIRS 17ENGINE MANAGEMENT SYSTEM - MEMS FUEL RAIL- "Ke" Service repair no - 19.60.04 Remove 41. Disconnect battery earth lead. 2. Position absorbent cloth around fuel filter outlet 5. Release clip and remove vacuum pipe from fuel pressure regulator. 6. Release clip and disconnect fuel return hose from fuel rail CAUTION: Plug the connections. 7. Position an absorbent cloth around fuel feed connection. 3. Loosen union to relieve fuel pressure, then re-tighten to 28 Nm. CAUTION: To prevent damage to fuel system pipes or components, use two spanners when loosening or tightening 4, Remove inlet manifold chamber. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 8. Remove 2 bolts securing fuel feed pipe to fuel rail 9. Release fuel feed pipe from fuel rail and discard'0’ ring. A CAUTION: Plug the connections. 18 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS 10. Release clips securing injectors to fuel rail 11. Remove 2 bolts securing fuel rail to inlet manifold. 42. Release fuel rail from injectors and remove, 413. Remove and discard 'O' ring from each injector. 414, Fit protective caps to each injector. Refit 41. Clean injector recesses in fuel ral 2. Lubricate new 'O' rings with silicone grease land fit to injectors, 3. Fitfuel railto injectors and secure with spring clips. 44, Fit bolts securing fuel ral to inlet manifold and tighten to 10 Nm. 5. Lubricate new 'O' ring with silicone grease. Fit ‘0’ ring to fuel feed pipe. 6. Position fuel feed pipe to fuel rail and secure with bolts. Tighten to 5 Nm 7. Connect fuel retum hose to fuel rail and secure with clip, 8. Connect vacuum pipe to fuel pressure regulator and secure with clip. 9. Fitinlet manifold chamber. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 40, Connect battery earth lead. FUEL RAIL- 'K16" Service repair no - 19.60.04 Remove 41. Disconnect battery earth lead r9ni2092 2. Position absorbent cloth around fuel fiter outlet 3. Loosen union to relieve fuel pressure then re-tighten. CAUTION: To prevent damage to fuel system pipes or components use two spanners when loosening or tightening REPAIRS 19ENGINE MANAGEMENT SYSTEM - MEMS ey B s9M0824 semones, 4, Release clips and disconnect breather hoses from camshaft cover. 5. Remove 2 breather hoses from inlet manifold 6. Disconnect multiplug from IACV. 12, Remove 2 bolts securing fuel feed pipe to fuel 7. Release clip and disconnect vacuum pipe from rail fuel pressure regulator. 13. Release fuel feed pipe from fuel ral 8. Release clip and disconnect fuel retum hose 14. Remove and discard 'O' ring. from fuel ral A CAUTION: Plug the connections. CAUTION: Plug the connections. 15, Remove engine oil dipstick. 9. Remove bolt securing injector hamess ‘muliplug bracket to inlet manifold 40. Disconnect injector harness multiplug and remove bracket. 411. Position an absorbent cloth around fuel rail fuel feed connection 16. Release spring clips securing injectors to fuel rail 17. Remove 2 bolts securing fuel ral to inlet manifold 18, Release fuel ral from injectors and remove. 19. Remove and discard 'O' rings from injectors. 20 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS *\} ra Refit 1. Lubricate new ‘0’ rings with silicone grease and fit injectors. 2. Position fuel rail and ft to injectors. 3. Fitbolts securing fuel rail to inlet manifold and tighten to 10 Nm. 4, Remove plugs from fuel feed pipe and fuel ral. 5. Lubricate new 'O' ring with silicone grease and fitto fuel feed pipe. 6. Fitfuel feed pipe to fuel rail, fit bolts and tighten to5.Nm 7. Fitengine oil dipstick. 8. Position injector harness multiplug bracket to inlet manifold and secure with bolt. 9. Connect injector harness multiplug to engine harness and secure to bracket. 10. Remove plugs from fuel return hose and fuel rail 114. Connect fuel return hose to fuel rail and secure with clip, 12. Connect vacuum pipe to fuel pressure regulator and secure with clip 43. Fit breather hoses to inlet manifold, 14. Connect multiplug to ACV. 415. Connect breather hoses to camshaft cover and secure with clips. 46. Connect battery earth lead. FUEL RAIL - 'K16 WITH VVC" Service repair no - 19.60.04 Remove 4. Disconnect battery earth lead 2. Remove inlet manifold chamber. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 3. Position absorbent cloth around fuel fiter outlet union. Loosen union to relieve fuel pressure. Retighten union to 28 Nm. CAUTION: To prevent damage to fuel system pipes and components, use two spanners when loosening or tightening 4, Remove clip and release fuel return pipe from fuel rail REPAIRS 21ENGINE MANAGEMENT SYSTEM - MEMS Refit 41. Lubricate new ‘©’ rings with silicone grease and fit to injectors. . Position fuel ral and fi to injectors. 3. Fit spring clips securing fuel rail to injectors. 4, Fitbolts securing fuel ral to inlet manifold and tighten to 10 Nm, '5. Connect fuel retum pipe to fuel rail secure with, clip. 6. Remove plugs from fuel feed pipe and fuel rail 7. Lubricate new ‘0’ ring with silicone grease and. fitto fuel feed pipe. 8. Connect fuel feed pipe to fuel ral and tighten bolts to 5 Nm. 9 Fitinlet manifold chamber. See MANIFOLD & EXHAUST SYSTEMS, Repairs. 10. Connect baitery earth lead. 5. Remove 2 bolts securing fuel feed pipe to fuel rail 6. Release fuel feed pipe from fuel rail 7. Remove and discard ‘0’ ring CAUTION: Plug the connections. 8. Remove 2 bolts securing fuel ral to inlet manifold, 9. Remove spring clips securing injectors to fuel rail 40, Release fuel rail from injectors and remove. 11. Remove and discard 'O' rings from injectors. 22 REPAIRSENGINE MANAGEMENT SYSTEM - MEMS FUEL INJECTORS - 'K3" Servi repair no - 19.60.12 Remove 41. Disconnect battery earth lead. 2. Remove fuel rail. See this section. Disconnect multiplugs from injectors, Remove injectors from inlet manifold Remove and discard 'O' rings from injectors. Fit protective caps to each end of injectors. pane Refit Clean injectors and recesses in inlet manifold Lubricate new 'O' rings with silicone grease and fitto injectors, Fit injectors to inlet manifold, Connect multiplugs to injectors, Fit fuel rail. See this section. Connect battery earth lead. pane FUEL INJECTORS -'K16" Service repair no - 19.60.12 Remove 1. 2 Refit Disconnect battery earth lead. Remove fuel rail. See this section. a . SL Se VO we Disconnect multiplugs from injectors. Remove injectors, Remove and discard ‘0’ rings from injectors. Fit protective caps to each end of injectors. 41. Clean injectors and recesses in inlet manifold. Lubricate new ‘0’ ring seals with silicone grease and ft to injectors. Fitinjectors to inlet manifold Connect multiplugs to injectors. Fit fuel rail. See this section. Connect battery earth lead. REPAIRS 23ENGINE MANAGEMENT SYSTEM - MEMS —— 2. Remove 2 bolts securing resonator to battery AIR INTAKE RESONATOR tray. — 3, Release resonator from air intake pipe and Servi remove. Remove Refit 4. Remove air cleaner. See this section, 4. Fitresonator and connect to air intake pipe. 2. Fitbolts securing resonator to battery tray and tighten to 9 Nm. 3, Fitair cleaner. See this section. 24 REPAIRSENGINE MANAGEMENT SYSTEM - EDC CONTENTS DESCRIPTION AND OPERATION ENGINE COMPARTMENT COMPONENT LOCATIONS - WITHOUT INTERCOOLER ENGINE COMPARTMENT COMPONENT LOCATIONS - WITH INTERCOOLER PASSENGER COMPARTMENT COMPONENT LOCATIONS ELECTRONIC DIESEL CONTROL OPERATION ADJUSTMENTS THROTTLE CABLE - MODELS WITHOUT INTERCOOLER, THROTTLE CABLE - MODELS WITH INTERCOOLER. REPAIRS ‘AIR CLEANER, AIR CLEANER ELEMENT THROTTLE CABLE - MODELS WITHOUT INTERCOOLER: THROTTLE CABLE - MODELS WITH INTERCOOLER: MASS AIR FLOW (MAF) SENSOR AIR INTAKE PIPE, ENGINE CONTROL MODULE (ECM) - ROVER ENGINE CONTROL MODULE (ECM) - BOSCH FUEL SHUT-OFF SOLENOID INTAKE AIR TEMPERATURE (IAT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR CRANKSHAFT POSITION (CP) SENSOR. THROTTLE POSITION (TP) SENSOR - MODELS WITH INTERCOOLER MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ENGINE MANAGEMENT RELAY MODULE INJECTOR NEEDLE LIFT SENSOR FUEL INJECTION PUMP (FIP) - MODELS WITHOUT INTERCOOLER FUEL INJECTION PUMP (FIP) - MODELS WITH INTERCOOLER TURBOCHARGER - MODELS WITHOUT INTERCOOLER, TURBOCHARGER - MODELS WITH INTERCOOLER INTERCOOLER - MODELS WITHOUT AIR CONDITIONING. INTERCOOLER - MODELS WITH AIR CONDITIONING INJECTOR - MODELS WITHOUT INTERCOOLER INJECTOR - MODELS WITH INTERCOOLER. GLOW PLUGS PageENGINE MANAGEMENT SYSTEM - EDC ENGINE COMPARTMENT COMPONENT LOCATIONS - WITHOUT INTERCOOLER Beenowaens EGR solenoid EGR valve ‘Turbocharger Crankshaft position sensor Fuel fiter Vehicle speed sensor Mass air flow sensor Glow plug relay ECM Engine coolant temperature sensor 1. 2, 8. 14, 15, 16. 17. Glow plugs Injectors Needle lift sensor Fuel shut-off solenoid Fuel injection pump (mechanical) Air cleaner Relay module ~main relay + starter relay = fuel shut-off relay DESCRIPTION AND OPERATION 1ENGINE MANAGEMENT SYSTEM - EDC ENGINE COMPARTMENT COMPONENT LOCATIONS - WITH INTERCOOLER 4. Throttle position sensor 13. Relay module 2. Intake air temperature sensor + starter relay 3. EGR solenoid + fuel shut-off relay 4, Manifold absolute pressure sensor 14. ECM 5. EGR valve 45. Aircleaner 6. Turbocharger 16. Intercooler 7. Crankshaft position sensor 17. Fuel injection pump (electronic) 8. Fuel fter 18. Fuel shutoff solenoid 9. Vehicle speed sensor 19. Needle lift sensor 40. Mass air flow sensor 20. Injectors 11. Glow plug relay 21. Glow plugs 42. Main relay 22. Coolant temperature sensor 2 DESCRIPTION AND OPERATIONENGINE MANAGEMENT SYSTEM - EDC PASSENGER COMPARTMENT COMPONENT LOCATIONS to¥vo0a) Glow plug warning lamp Malfunction indicator lamp Brake pedal switch (intercooler model) Diagnostic connector pepe DESCRIPTION AND OPERATION 3ENGINE MANAGEMENT SYSTEM - EDC ELECTRONIC DIESEL CONTROL OPERATION Diesel engines operate by compression ignition. The rapid compression of air in the cylinder during the ‘compression cycle heats the injected fuel causing it to self ignite. During cold starting, automatically controlled glow plugs assist in raising the temperature of the compressed air to ignition point. ‘The Engine Control Module (ECM) monitors the conditions required for optimum combustion of fuel in the cylinder through sensors located at strategic. points around the engine. Dependent on the inputs from these sensors, the engine control module can agjust the fuel quantity and timing of the fuel being delivered to the cylinder. NOTE: Models ted wh an arcooar LA recog pape Een nd isda uatourte neconer se ‘The main features are as follows: + The ECM controls the fuel injection quantity and timing of the fuel delivered to the cylinder based Con inputs from sensors located around the engine. The ECM incorporates short circuit protection and can store intermittent faults on certain inputs. TestBook can interrogate the ECM for these stored faults. + The engine management system is a ‘Drive by Wire’ system for models fited with an intercooler. ‘The throttle pedal is not physically connected to the fuel injection pump, but instead connected by a linkage to a remotely mounted throttle position ‘sensor which provides the ECM with a signal proportional to throttle pedal movement. The ECM then adjusts the fue! injection pump to deliver the required amount of fuel + In conjunction with the throttle position sensor the ECM uses the speedidensity method of air flow measurement to calculate fuel delivery. This method measures the inlet air temperature and inlet manifold pressure and assumes that the engine is a calibrated vacuum pump, with its characteristics stored in the ECM, it can determine the correct amount of fuel to be injected. + If certain system inputs fail, the ECM implements a back-up facilty to enable the system to Continue functioning, although at a reduced level of performance, + Asseparate diagnostic connector allows engine tuning oF fault diagnosis to be carried out using TestBook without disconnecting the ECM hamess muttiplug. + The ECM hamess muttiplug incorporates specially plated pins to minimise oxidation and give improved reliability ECU inputs and outputs are shown in the following table. INPUTS Crankshaft position sensor * Manifold absolute pressure sensor Coolant temperature sensor * Intake air temperature sensor Fuel temperature sensor Mass air flow sensor ‘OUTPUTS: Glowplug relay EGR modulator valve Injector needle lift sensor Fuel quantity servo - position Vehicle speed sensor ecm Fuel shut off solenoid | Glow plug warning lamp Engine warning lamp * Throttle position sensor * Brake pedal switch Diagnostic input Battery supply Starter signal Earth supply Diagnostic connector Injection timing device Fuel quantity servo - control actuator * Intercooler models 4 DESCRIPTION AND OPERATIONENGINE MANAGEMENT SYSTEM - EDC *\} ra Fuel injection timing ‘The engine control module determines the optimum {uel injection timing for the injection pump based on the signals it receives from the following sensors: 41. Crankshaft position sensor - Engine speed and ‘crankshaft position 2. Needle lit sensor - Start of injection 3. Coolant temperature sensor - Engine temperature ‘Manifold absolute pressure - Engine load “Intake air temperature sensor oe * Intercooler models Basic fuel injection timing Crankshaft position sensor ‘The speed and position of the engine is detected by the crankshaft position sensor (CKP) which is bolted. to, and projects through, the gearbox adaptor plate adjacent to the flywheel. The CKP is an inductive sensor consisting of a bracket mounted body containing a coil and a permanent magnet which provides a magnetic field The sensor is situated such that an air gap exists, between it and the flywheel. Air gap distance is critical for correct operation. The flywhee! has four poles positioned equally around the crankshaft circumference at 90 degree intervals. When the flywheel rotates, as a pole passes the sensor it disturbs the magnetic field inducing a voltage pulse in the coil. This pulse is transmitted to the engine control module. Four pulses are transmitted to the engine control ‘module for each revolution of the flywheel. By calculating the number of pulses that occur within a given time, the engine control module can determine the engine speed. The output from this sensor when sed in conjunction with that from the needle lft ‘sensor is used for idle stabilisation and reference for injection timing. DESCRIPTION AND OPERATION 5ENGINE MANAGEMENT SYSTEM - EDC Needle lift sensor ‘The needle lift sensor consists of a coil which surrounds the shaft of an extended injection needle. ‘The coil is fed a DC supply from the control unit which produces a magnetic field. When the needle is moved under the influence of fuel pressure, the magnetic field is disturbed which induces an ac voltage in the coil. The induced voltage is registered in the engine control module as, a reference point for the start of the injection ‘sequence, ‘The engine control module uses the input signals from the needle lift sensor, together with the signal from the CKP sensor, to detect the actual start of injection. The engine control module, using inputs. from the other sensors, calculates then adjusts the injection timing of the fuel pump to achieve optimum fuelling of the engine. Fuel injection timing compensation Engine coolant temperature sensor The engine coolant temperature sensor is a ‘thermistor’ (a temperature dependent resistor, ie the voltage output varies in proportion to temperature. The sensor is located in the top of the coolant outlet elbow. The engine control module constantly monitors the signal and uses the information to correct the quantity of fuel injected and the injection timing especially during cold starting. During starting, output from the sensor determines how long the glow plugs are on. Imake air temperature sensor - Bosch ECM only ‘The intake air temperature sensors located in the side ofthe inlet manifold. This sensor is of the negative temperature coefficient (NTC) type, designed to reduce its resistance with increasing temperature. The engine control module receives a signal proportional to the temperature ofthe intake air. When used in conjunction with the signal from the manifold absolute pressure sensor the engine control module can calculate the volume of oxygen in the air and adjust the quantity of fuel being injected to achieve optimum fuelling of the engine. 6 DESCRIPTION AND OPERATIONENGINE MANAGEMENT SYSTEM - EDC *\} ra ‘Manifold absolute pressure sensor ~ Bosch ECM only ‘The pressure of the intake air is monitored by a strain gauge type sensor located on the bulkhead ‘and connected, via a pressure tube, to the intake side of the turbocharger. The sensor is connected ‘electrically o the engine control module. ‘The sensor comprises of a plastic body containing a pressure detection chamber. The pressure detection ‘chamber consists of four individual sensors made from glass panels with silicon diaphragms. The silicon diaphragms contain resistors which are bonded to the glass panels forming an enclosed When the intake air pressure changes, pressure in the detection chamber causes the diaphragms to deflect. The deflection of the diaphragms alters the length of each resistor, changing their resistance. ‘This change in resistance is converted into a signal within the pressure sensor. The change in output from the pressure sensor is detected by the engine control module where itis converted into a pressure value. Manifold absolute pressure when used in conjunction with the signal from the intake air temperature sensor allows the engine control module to accurately calculate the volume of oxygen in the air and adjust the quantity of fuel being injected to achieve optimum fuelling ofthe engine. Vehicle speed sensor ‘The vehicle speed sensor is located on the top of the differential housing. The vehicle speed sensors driven by a shaft from the final drive gear where itis, converted into an electrical signal proportional to road speed. The output from the vehicle speed ‘sensor is used to drive the instrument pack speedometer in addition to providing a signal to the engine control module. The engine control module ses this signal to provide active surge damping and adjust idle stabilisation and the quantity of fuel being delivered to injectors, DESCRIPTION AND OPERATION 7ENGINE MANAGEMENT SYSTEM - EDC Throttle position sensor - Bosch ECM only The throttle pedal is not physically connected to the {uel injection pump by a mechanical linkage as in a traditional injection system, but instead the amount ‘of fuel injected is controlled by the control unit. The throttle pedal is connected by a linkage to a throttle position sensor. Movements of the throttle pedal are ‘sensed by the throttle position sensor and a signal sent to the engine control module. The throttle position sensor consists ofa thick film potentiometer together with a sender switch. With the throttle pedal at rest the switch is open. When the throttle pedal has been moved enough to rotate the potentiometer more than 9 degrees the switch closes. The sender switch signal from the potentiometer is used by the engine control module to check the operation ofthe circuit, implement idle ‘speed control and over-run fuel shut-off. ‘When the potentiometer is moved the sender switch signals a logic input to the engine control module. ‘The engine control module then checks the voltage signal from the potentiometer. This voltage is ‘compared with a pre-programmed value to check the potentiometer is working correctly Throttle pedal movement causes voltage across the potentiometer to vary. The control unit calculates the rate of change of the voltage signal in positive (acceleration) or negative (deceleration) directions. From this the engine control module can determine the required engine speed, rate of acceleration or rate of deceleration and apply acceleration enrichment, deceleration fuel metering or over-run fuel cut-oft The engine control module calculates the ‘maximum allowable fuel quantity’ from the input signal according to strategies such as smoke limitation, active surge damping, fuel reduction to calculate the final igure. I the signal fram the throttle potentiometer is smaller than the maximum allowable quantity then the requested quantity will be injected. However, ifthe requested quantity is greater than the maximum allowable quantity, then the maximum allowable quantity will be injected rather than that demanded, Brake pedal switch - Bosch ECM only amt ‘The brake pedal switch informs the engine control ‘module when the vehicle is braking and allows it to implement active surge damping and over-run fuel cutott The engine control module has two brake inputs, each of opposite polarity. Comparison of the two polarity states provides the engine control module with brake sense. If both switches are the same polarity the engine control module senses a fault. NOTE: Failure to correctly adjust the switch could affect the fuel information supplied by the ECM. 8 DESCRIPTION AND OPERATIONENGINE MANAGEMENT SYSTEM - EDC *\} ra Glow plug relay When the starter switch is turned to position Il the ‘engine control module energises the glow plug relay and illuminates the glow plug warning light in the fascia. The glow plug relay supplies a current from the battery to the three glaw plugs (there is no glow plug in No. 4 cylinder) to assist cold starting by raising the temperature of the compressed air in the cylinder to ignition point. Glow plug ‘The length of time the glow plugs will remain ‘operational is dependent upon the initial engine temperature determined by the engine control module from the coolant temperature sensor. Once the glow plugs have operated for their pre-determined time the control unit will remove the ‘supply from the glow plug relay and extinguish the glow plug waming light on the fascia If an attempt to start the engine is made before the glow plugs have finished operating the engine control module will remove the supply from the glow plug relay, switching off the glow plugs. Mass air flow sensor ‘The mass airflow is determined from the cooling effect of inlet air flowing over a hot film sensor. This, signal is fed back to the engine control module where itis used to monitor the recirculation of exhaust gases. Increase in the exhaust gas recirculation reduces the amount of intake air being drawn into the system, thereby reducing the cooling effect of hot fim resistor. DESCRIPTION AND OPERATION 9ENGINE MANAGEMENT SYSTEM - EDC Diagnostic connector Malfunction indicator lamp The engine control module has a builtin self-diagnosis function. Ifa fault is detected the ‘malfunction indicator lamp (MIL) in the instrument ppack will illuminate, and the control module will implement a back-up facility to enable the system to continue functioning, though at a reduced level of performance. Ifa serious fault is detected the warning light wil luminate and the engine management system will shut down preventing the ‘car from being started or driven. The MIL will remain illuminated until the starter switch is tured off. If the faultis stil present when the starter switch is tumed back on the MIL will illuminate. if the fault is not present when the starter switch is tumed on, the ML will remain extinguished but a fault code willbe stored in the memory of the engine control module. ‘The diagnostic connector is located on a bracket behind the centre console and allows engine tuning ‘or fault diagnosis via TestB0ok to be carried out without disturbing the system electrical connections. Itutlises the ability of the engine control module to store certain faults. 10 DESCRIPTION AND OPERATIONENGINE MANAGEMENT SYSTEM - EDC *\} ra FUEL SYSTEM Fuel injection pump (electronic) 19M 0701 6 5 4 '5. Control spool 4. Fuel quantity servo potentiometer 6. Injection timing device 2. Fuel quantity servo control unit 7. Injection pump drive shaft 3. Fuel shut off solenoid 8. Fuel temperature sensor 4. Injection timing device solenoid valve ‘The fuel injection pump is a vane-type pump, which is belt driven from the rear end of the camshaft. Fuel

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