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ROVER 25 / MG ZR /
STREETWISE
WORKSHOP MANUAL - SERVICE
PROCEDURES
Publication Part No. RCL 0534(3)ENG Published by MG Rover Group After Sales © MG Rover Group Limited 2004
All right reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic, mechanical, photocopying, recording or other means without prior written permission of MG Rover Group Ltd.
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CONTENTS |
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INTRODUCTION ...................................................................................... |
01-1 |
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INTRODUCTION ............................................................................................................................ |
01-1 |
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REPAIRS AND REPLACEMENTS ................................................................................................. |
01-1 |
||
SPECIFICATION ............................................................................................................................ |
01-2 |
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ABBREVIATIONS AND SYMBOLS ................................................................................................ |
01-3 |
||
GENERAL INFORMATION ...................................................................... |
03-1 |
VEHICLE IDENTIFICATION NUMBER.......................................................................................... |
03-1 |
VIN NUMBER LOCATIONS............................................................................................................ |
03-2 |
COMPONENT IDENTIFICATION NUMBER LOCATIONS............................................................. |
03-3 |
DANGEROUS SUBSTANCES ....................................................................................................... |
03-4 |
SAFETY INSTRUCTIONS .............................................................................................................. |
03-5 |
ENVIRONMENTAL PRECAUTIONS .............................................................................................. |
03-6 |
PRECAUTIONS AGAINST DAMAGE............................................................................................. |
03-10 |
GENERAL FITTING INSTRUCTIONS ............................................................................................ |
03-10 |
BALL AND ROLLER BEARINGS.................................................................................................... |
03-11 |
OIL SEALS...................................................................................................................................... |
03-12 |
JOINTS AND JOINT FACES .......................................................................................................... |
03-13 |
LOCKING DEVICES ....................................................................................................................... |
03-14 |
SCREW THREADS ........................................................................................................................ |
03-15 |
BOLT IDENTIFICATION ................................................................................................................. |
03-15 |
NUT IDENTIFICATION ................................................................................................................... |
03-17 |
FLEXIBLE PIPES AND HOSES ..................................................................................................... |
03-18 |
SERVICE TOOLS ........................................................................................................................... |
03-19 |
DYNAMOMETER TESTING ........................................................................................................... |
03-20 |
FUEL HANDLING PRECAUTIONS ................................................................................................ |
03-20 |
ELECTRICAL PRECAUTIONS ....................................................................................................... |
03-21 |
SUPPLEMENTARY RESTRAINT SYSTEM PRECAUTIONS ........................................................ |
03-23 |
WARNING LABELS ........................................................................................................................ |
03-27 |
VEHICLE RECOVERY ................................................................................................................... |
03-30 |
SRS COMPONENT DEPLOYMENT............................................................................................... |
03-30 |
SRS COMPONENT REPLACEMENT POLICY .............................................................................. |
03-31 |
AIR CONDITIONING SYSTEM PRECAUTIONS............................................................................ |
03-32 |
AIR CONDITIONING COMPRESSOR REPLACEMENT................................................................ |
03-34 |
INFORMATION ........................................................................................ |
04-1 |
LIFTING AND TOWING.................................................................................................................. |
04-1 |
LIFTING .......................................................................................................................................... |
04-2 |
VEHICLE RECOVERY ................................................................................................................... |
04-3 |
GENERAL DATA ..................................................................................... |
05-1 |
ENGINE - 'K' SERIES ..................................................................................................................... |
05-1 |
ENGINE - 'L' SERIES...................................................................................................................... |
05-8 |
FUEL SYSTEM - 'K' SERIES .......................................................................................................... |
05-11 |
FUEL SYSTEM - 'L' SERIES .......................................................................................................... |
05-12 |
COOLING SYSTEM - 'K' SERIES................................................................................................... |
05-13 |
COOLING SYSTEM - 'L' SERIES ................................................................................................... |
05-14 |
CLUTCH ......................................................................................................................................... |
05-15 |
MANUAL GEARBOX - R65 ............................................................................................................ |
05-16 |
MANUAL GEARBOX - PG1............................................................................................................ |
05-17 |
CONTENTS 1
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CONTENTS |
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MANUAL GEARBOX - IB5 ........................................................................................................... |
.. 05-18 |
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AUTOMATIC GEARBOX - EM-CVT............................................................................................... |
05-19 |
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FINAL DRIVE.................................................................................................................... |
.............. 05-20 |
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STEERING ....................................................................................................................... |
.............. 05-21 |
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BRAKES ......................................................................................................................... |
................ 05-22 |
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FRONT SUSPENSION............................................................................................................... |
.... 05-23 |
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REAR SUSPENSION ................................................................................................................ |
..... 05-24 |
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WHEELS......................................................................................................................... |
................ 05-25 |
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TYRE SIZES..................................................................................................................... |
.............. 05-26 |
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TYRE PRESSURES - 1.1, 1.4 & 1.6 'K' SERIES ........................................................................... |
05-27 |
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TYRE PRESSURES - 1.8 'K' SERIES WITH VVC ......................................................................... |
05-29 |
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TYRE PRESSURES - 1.8 'K' SERIES WITH EM-CVT................................................................... |
05-30 |
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TYRE PRESSURES - 2.0 'L' SERIES DIESEL ENGINES ............................................ |
................. 05-31 |
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AIR CONDITIONING ............................................................................................................... |
....... 05-33 |
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ELECTRICAL - 'K' SERIES ........................................................................................................ |
.... 05-34 |
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ELECTRICAL - 'L' SERIES........................................................................................................ |
..... 05-35 |
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DIMENSIONS - Rover 25 .......................................................................................................... |
..... 05-36 |
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DIMENSIONS - MG ZR ............................................................................................................. |
..... 05-37 |
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DIMENSIONS - Streetwise ........................................................................................................ |
..... 05-38 |
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WEIGHTS ........................................................................................................................ |
............... 05-39 |
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TOWING WEIGHTS ................................................................................................................. |
...... 05-40 |
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TORQUE WRENCH SETTINGS .............................................................. |
06-1 |
|
ENGINE - 'K' SERIES............................................................................................................ |
......... 06-1 |
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ENGINE - 'L' SERIES ............................................................................................................ |
......... 06-3 |
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ENGINE MANAGEMENT SYSTEM - MEMS ................................................................ |
................. 06-5 |
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ENGINE MANAGEMENT SYSTEM - EDC................................................................................. |
.... 06-6 |
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FUEL DELIVERY SYSTEM ........................................................................................................... |
. 06-7 |
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COOLING ........................................................................................................................ |
............... 06-8 |
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MANIFOLD AND EXHAUST........................................................................................................... |
06-9 |
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CLUTCH ......................................................................................................................... |
................ 06-10 |
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MANUAL GEARBOX - R65 ........................................................................................................... |
. 06-11 |
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MANUAL GEARBOX - IB5 ........................................................................................................... |
.. 06-12 |
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MANUAL GEARBOX - PG1........................................................................................................... |
. 06-13 |
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AUTOMATIC GEARBOX - EMCVT ................................................................................................ |
06-14 |
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DRIVE SHAFTS................................................................................................................... |
........... 06-15 |
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STEERING ....................................................................................................................... |
.............. 06-16 |
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SUSPENSION ..................................................................................................................... |
........... 06-17 |
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BRAKES ......................................................................................................................... |
................ 06-18 |
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RESTRAINT SYSTEMS .............................................................................................................. |
... 06-19 |
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BODY........................................................................................................................... |
................... 06-20 |
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HEATING AND VENTILATION....................................................................................................... |
06-22 |
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AIR CONDITIONING ............................................................................................................... |
....... 06-23 |
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WIPERS AND WASHERS............................................................................................................. |
. 06-24 |
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ELECTRICAL..................................................................................................................... |
............. 06-25 |
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INSTRUMENTS.................................................................................................................... |
.......... 06-26 |
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2 CONTENTS
CONTENTS
CAPACITIES, FLUIDS AND LUBRICANTS ............................................ |
09-1 |
CAPACITIES................................................................................................................................... |
09-1 |
FUEL REQUIREMENTS ................................................................................................................. |
09-2 |
RECOMMENDED FUEL................................................................................................................. |
09-2 |
FLUIDS ........................................................................................................................................... |
09-3 |
ANTI-FREEZE CONCENTRATION ................................................................................................ |
09-3 |
LUBRICATION................................................................................................................................ |
09-4 |
MAINTENANCE ........................................................................................ |
10-1 |
MAINTENANCE |
|
UNDERBONNET LOCATIONS - 'K16’ (except 1.8 with VVC)........................................................ |
10-1 |
UNDERBONNET LOCATIONS - 'K16 (1.8 with VVC)' .................................................................. |
10-2 |
UNDERBONNET LOCATIONS - 'L’ SERIES.................................................................................. |
10-3 |
CHECK ENGINE AND TRANSMISSION........................................................................................ |
10-4 |
ENGINE OIL AND FILTER - 'K’ SERIES ........................................................................................ |
10-4 |
ENGINE OIL AND FILTER - 'L’ SERIES......................................................................................... |
10-5 |
CRANKCASE VENT HOSES - 'K’ SERIES .................................................................................... |
10-7 |
CRANKCASE PRESSURE LIMITER VALVE - 'L’ SERIES ............................................................ |
10-7 |
FUEL SYSTEM HOSES, PIPES AND UNIONS ............................................................................. |
10-8 |
ENGINE TUNING ........................................................................................................................... |
10-9 |
IGNITION COILS ............................................................................................................................ |
10-9 |
COOLING SYSTEM........................................................................................................................ |
10-10 |
EXHAUST SYSTEM ....................................................................................................................... |
10-10 |
CLUTCH ......................................................................................................................................... |
10-11 |
GEARBOX OIL - 'R65’ .................................................................................................................... |
10-11 |
GEARBOX OIL - 'PG1’.................................................................................................................... |
10-12 |
AUTOMATIC GEARBOX OIL - 'EM-CVT’....................................................................................... |
10-12 |
DRIVE SHAFT GAITERS ............................................................................................................... |
10-13 |
STEERING...................................................................................................................................... |
10-13 |
SUSPENSION DAMPERS, BALL JOINTS, FXINGS AND GAITERS ............................................ |
10-15 |
ROAD WHEELS AND FASTENINGS ............................................................................................. |
10-17 |
TYRE PRESSURES AND CONDITION.......................................................................................... |
10-17 |
FOOTBRAKE.................................................................................................................................. |
10-18 |
HANDBRAKE.................................................................................................................................. |
10-18 |
BRAKE FLUID ................................................................................................................................ |
10-19 |
BRAKE HOSES AND PIPES .......................................................................................................... |
10-21 |
FRONT BRAKES-HYDRAULICS, PADS, DISCS AND CALIPERS................................................ |
10-23 |
REAR DRUM BRAKES................................................................................................................... |
10-23 |
REAR DISC BRAKES..................................................................................................................... |
10-25 |
BODY.............................................................................................................................................. |
10-26 |
DRIVER AIR BAG MODULE .......................................................................................................... |
10-27 |
PASSENGER AIR BAG MODULE.................................................................................................. |
10-27 |
ROTARY COUPLER....................................................................................................................... |
10-28 |
SEATS AND SEAT BELTS............................................................................................................. |
10-28 |
SCREEN WIPERS AND BLADES .................................................................................................. |
10-29 |
WINDSCREEN AND REAR SCREEN WASHERS......................................................................... |
10-29 |
LAMPS, HORNS AND WARNING INDICATORS........................................................................... |
10-30 |
HEATER BLOWER......................................................................................................................... |
10-31 |
BATTERY CONNECTIONS............................................................................................................ |
10-31 |
FUSEBOX....................................................................................................................................... |
10-32 |
AUXILIARY DRIVE BELT ............................................................................................................... |
10-32 |
ANTI-CORROSION CHECK ........................................................................................................... |
10-33 |
ROAD TEST ................................................................................................................................... |
10-33 |
CONTENTS 3
CONTENTS
ENGINE - 'K16' ......................................................................................... |
12-1-1 |
REPAIRS |
|
OIL SEAL - FRONT - EXHAUST CAMSHAFT ............................................................................... |
12-1-1 |
OIL SEAL - REAR - EXHAUST CAMSHAFT.................................................................................. |
12-1-4 |
OIL SEAL - REAR - INLET CAMSHAFT ........................................................................................ |
12-1-5 |
CARRIER - CAMSHAFT - A/C ....................................................................................................... |
12-1-6 |
CRANKSHAFT FRONT PULLEY ................................................................................................... |
12-1-9 |
CRANKSHAFT FRONT OIL SEAL ................................................................................................. |
12-1-11 |
CRANKSHAFT REAR OIL SEAL ................................................................................................... |
12-1-12 |
GASKET - CYLINDER HEAD......................................................................................................... |
12-1-13 |
GASKET - CAMSHAFT COVER .................................................................................................... |
12-1-19 |
VALVE STEM OIL SEAL ................................................................................................................ |
12-1-21 |
ENGINE AND GEARBOX - MODELS WITHOUT A/C ................................................................... |
12-1-23 |
ENGINE AND GEARBOX - MODELS WITH A/C ........................................................................... |
12-1-31 |
ENGINE STEADY - LOWER .......................................................................................................... |
12-1-37 |
HYDRAMOUNT - ENGINE RH....................................................................................................... |
12-1-38 |
MOUNTING - ENGINE LH - 'R65 GEARBOX'................................................................................ |
12-1-39 |
ENGINE LH MOUNTING - 'EM-CVT' GEARBOX MODELS WITH ABS ........................................ |
12-1-40 |
FLYWHEEL - 1.1, 1.4 & 1.6 MODELS WITH MANUAL GEARBOX............................................... |
12-1-42 |
FLYWHEEL - 'EM-CVT' MODELS.................................................................................................. |
12-1-42 |
TORSION DAMPER - 'EM-CVT' MODELS .................................................................................... |
12-1-43 |
FLYWHEEL STARTER RING GEAR ............................................................................................. |
12-1-44 |
OIL FILTER..................................................................................................................................... |
12-1-44 |
DIPSTICK TUBE............................................................................................................................. |
12-1-45 |
OIL PUMP....................................................................................................................................... |
12-1-47 |
SUMP - ENGINE - RESEAL ........................................................................................................... |
12-1-48 |
OIL PRESSURE SWITCH .............................................................................................................. |
12-1-50 |
OIL PRESSURE RELIEF VALVE ................................................................................................... |
12-1-51 |
SENSOR - OIL TEMPERATURE ................................................................................................... |
12-1-52 |
CAMSHAFT TIMING BELT ............................................................................................................ |
12-1-53 |
COVER - UPPER - CAMSHAFT TIMING BELT............................................................................. |
12-1-57 |
COVER - LOWER - CAMSHAFT TIMING BELT ............................................................................ |
12-1-58 |
ENGINE - 'K16 WITH VVC'....................................................................... |
12-2-1 |
REPAIRS |
|
OIL SEAL - EXHAUST CAMSHAFT - FRONT ............................................................................... |
12-2-1 |
OIL SEAL - EXHAUST CAMSHAFT - REAR.................................................................................. |
12-2-4 |
OIL SEAL - INLET CAMSHAFT - FRONT ...................................................................................... |
12-2-5 |
OIL SEAL - INLET CAMSHAFT REAR........................................................................................... |
12-2-9 |
CARRIER - CAMSHAFT................................................................................................................. |
12-2-10 |
CRANKSHAFT FRONT PULLEY ................................................................................................... |
12-2-15 |
CRANKSHAFT FRONT OIL SEAL ................................................................................................. |
12-2-16 |
CRANKSHAFT REAR OIL SEAL ................................................................................................... |
12-2-17 |
GASKET - CYLINDER HEAD......................................................................................................... |
12-2-18 |
GASKET - CAMSHAFT COVER .................................................................................................... |
12-2-24 |
HYDRAULIC CONTROL UNIT ....................................................................................................... |
12-2-25 |
ENGINE AND GEARBOX............................................................................................................... |
12-2-32 |
ENGINE STEADY BAR .................................................................................................................. |
12-2-37 |
HYDRAMOUNT - ENGINE - RH..................................................................................................... |
12-2-37 |
MOUNTING - ENGINE - LH ........................................................................................................... |
12-2-38 |
FLYWHEEL .................................................................................................................................... |
12-2-39 |
FLYWHEEL STARTER RING GEAR ............................................................................................. |
12-2-40 |
4 CONTENTS
|
CONTENTS |
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OIL FILTER..................................................................................................................................... |
12-2-40 |
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DIPSTICK TUBE............................................................................................................................. |
12-2-41 |
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OIL PUMP....................................................................................................................................... |
12-2-41 |
||
SUMP - ENGINE - RESEAL ........................................................................................................... |
12-2-43 |
||
OIL PRESSURE SWITCH .............................................................................................................. |
12-2-45 |
||
OIL PRESSURE RELIEF VALVE ................................................................................................... |
12-2-46 |
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SENSOR - OIL TEMPERATURE.................................................................................................... |
12-2-47 |
||
COOLER - OIL................................................................................................................................ |
12-2-48 |
||
CAMSHAFT TIMING BELT............................................................................................................. |
12-2-49 |
||
COVER - UPPER - CAMSHAFT TIMING BELT ............................................................................. |
12-2-52 |
||
COVER - LOWER - CAMSHAFT TIMING BELT ............................................................................ |
12-2-53 |
||
COVER - CAMSHAFT REAR TIMING BELT.................................................................................. |
12-2-53 |
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CAMSHAFT REAR TIMING BELT.................................................................................................. |
12-2-54 |
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ENGINE - 'L' SERIES................................................................................ |
12-3-1 |
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REPAIRS |
|
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OIL SEAL - CAMSHAFT - FRONT.................................................................................................. |
12-3-1 |
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OIL SEAL - CAMSHAFT - REAR .................................................................................................... |
12-3-2 |
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BEARING CARRIER - RESEAL - CAMSHAFT .............................................................................. |
12-3-4 |
||
PULLEY - CRANKSHAFT - Up to VIN Number RF 545050 ........................................................... |
12-3-9 |
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PULLEY - CRANKSHAFT - From VIN Number RF 545051............................................................ |
12-3-13 |
||
OIL SEAL - CRANKSHAFT - FRONT ............................................................................................. |
12-3-15 |
||
CRANKSHAFT REAR OIL SEAL.................................................................................................... |
12-3-16 |
||
CYLINDER HEAD GASKET ........................................................................................................... |
12-3-17 |
||
GASKET - CAMSHAFT COVER..................................................................................................... |
12-3-27 |
||
COVER - ACOUSTIC - ENGINE..................................................................................................... |
12-3-28 |
||
ENGINE AND GEARBOX............................................................................................................... |
12-3-29 |
||
ENGINE STEADY - LOWER .......................................................................................................... |
12-3-37 |
||
HYDRAMOUNT - ENGINE - RH ..................................................................................................... |
12-3-38 |
||
ENGINE STEADY - UPPER ........................................................................................................... |
12-3-39 |
||
ENGINE MOUNTING - LH .............................................................................................................. |
12-3-39 |
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FLYWHEEL..................................................................................................................................... |
12-3-40 |
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FLYWHEEL STARTER RING GEAR.............................................................................................. |
12-3-41 |
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ENGINE OIL FILTER ...................................................................................................................... |
12-3-41 |
||
DIPSTICK TUBE............................................................................................................................. |
12-3-42 |
||
OIL STRAINER AND PICK-UP PIPE.............................................................................................. |
12-3-42 |
||
OIL PUMP....................................................................................................................................... |
12-3-43 |
||
GASKET - SUMP - ENGINE ........................................................................................................... |
12-3-47 |
||
OIL PRESSURE SWITCH .............................................................................................................. |
12-3-49 |
||
VALVE - OIL PRESSURE RELIEF ................................................................................................. |
12-3-49 |
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OIL COOLER .................................................................................................................................. |
12-3-50 |
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CAMSHAFT TIMING BELT............................................................................................................. |
12-3-51 |
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COVER - CAMSHAFT TIMING BELT - UPPER ............................................................................. |
12-3-55 |
||
COVER - CAMSHAFT TIMING BELT - LOWER ............................................................................ |
12-3-56 |
||
FUEL INJECTION PUMP (FIP) - TIMING BELT - UP TO VIN NUMBER RF 545050 .................... |
12-3-57 |
||
FUEL INJECTION PUMP (FIP) - TIMING BELT - FROM VIN NUMBER RF 545051..................... |
12-3-60 |
||
COVER - FUEL INJECTION PUMP (FIP) - TIMING BELT............................................................. |
12-3-64 |
||
DAMPER - CAMSHAFT GEAR....................................................................................................... |
12-3-64 |
||
EMISSION CONTROL .............................................................................. |
17-1 |
||
REPAIRS |
|
||
CONTENTS 5
CONTENTS
CRANKCASE PRESSURE LIMITER VALVE - 'L' SERIES ............................................................ |
17-1 |
EVAPORATIVE EMISSION CANNISTER - 'K' SERIES................................................................. |
17-1 |
VALVE - EXHAUST GAS RECIRCULATION (EGR) - 'L-SERIES'................................................. |
17-2 |
EXHAUST GAS RECIRCULATION (EGR) SOLENOID - 'L' SERIES ............................................ |
17-2 |
COOLER - EXHAUST GAS RECIRCULATION (EGR) - 'L' SERIES ............................................. |
17-3 |
CATALYTIC CONVERTER - 'L' SERIES........................................................................................ |
17-3 |
ENGINE MANAGEMENT SYSTEM - MEMS ............................................ |
18-1-1 |
ADJUSTMENTS |
|
THROTTLE CABLE ........................................................................................................................ |
18-1-1 |
REPAIRS |
|
THROTTLE CABLE ........................................................................................................................ |
18-1-3 |
AIR CLEANER................................................................................................................................ |
18-1-4 |
AIR CLEANER ELEMENT.............................................................................................................. |
18-1-5 |
SPARK PLUGS - 'K16' ................................................................................................................... |
18-1-5 |
COIL - EACH .................................................................................................................................. |
18-1-6 |
ENGINE CONTROL MODULE (ECM)............................................................................................ |
18-1-6 |
ENGINE CONTROL UNIT (ECM) - WITH SECURITY SHIELD FITTED ....................................... |
18-1-7 |
IDLE AIR CONTROL (IAC) VALVE ................................................................................................ |
18-1-8 |
SENSOR - INTAKE AIR TEMPERATURE (IAT) ............................................................................ |
18-1-8 |
SENSOR - ENGINE COOLANT TEMPERATURE (ECT) .............................................................. |
18-1-9 |
SENSOR - CRANKSHAFT POSITION (CKP) ................................................................................ |
18-1-9 |
SENSOR - THROTTLE POSITION (TP) ........................................................................................ |
18-1-10 |
SENSOR - CAMSHAFT POSITION (CMP) .................................................................................... |
18-1-11 |
HYDRAULIC CONTROL UNIT (HCU) SOLENOIDS - 'K16 WITH VVC' ........................................ |
18-1-11 |
SENSOR - OIL TEMPERATURE - 'K16 WITH VVC'...................................................................... |
18-1-12 |
SENSOR - MANIFOLD ABSOLUTE PRESSURE (MAP) - 'K16 WITH VVC' ................................. |
18-1-13 |
SENSOR - CAMSHAFT POSITION (CMP) - 'K16 WITH VVC' ...................................................... |
18-1-13 |
SENSOR - HEATED OXYGEN (HO2S) - 'K16' .............................................................................. |
18-1-14 |
SENSOR - HEATED OXYGEN (HO2S) - 'K16 WITH VVC'............................................................ |
18-1-15 |
HOUSING - THROTTLE................................................................................................................. |
18-1-16 |
SENSOR - HEATED OXYGEN - (HO2S) - POST CATALYST - 'K16' ........................................... |
18-1-17 |
FUEL RAIL AND INJECTORS - 'K16 WITH VVC' .......................................................................... |
18-1-18 |
FUEL RAIL AND INJECTOR SET - 'K16' ....................................................................................... |
18-1-19 |
AIR INTAKE RESONATOR ............................................................................................................ |
18-1-21 |
ENGINE MANAGEMENT SYSTEM - EDC ............................................... |
18-2-1 |
ADJUSTMENTS |
|
THROTTLE CABLE ........................................................................................................................ |
18-2-1 |
GLOW PLUG TEST........................................................................................................................ |
18-2-1 |
REPAIRS |
|
AIR CLEANER................................................................................................................................ |
18-2-3 |
AIR CLEANER ELEMENT.............................................................................................................. |
18-2-3 |
THROTTLE CABLE ........................................................................................................................ |
18-2-4 |
ENGINE CONTROL MODULE (ECM)............................................................................................ |
18-2-5 |
SENSOR - ENGINE COOLANT TEMPERATURE (ECT) .............................................................. |
18-2-5 |
SENSOR - CRANKSHAFT POSITION (CKP) ................................................................................ |
18-2-6 |
SENSOR - THROTTLE POSITION (TP) ........................................................................................ |
18-2-6 |
SENSOR - MANIFOLD ABSOLUTE PRESSURE (MAP)............................................................... |
18-2-7 |
6 CONTENTS
CONTENTS
INJECTOR - NEEDLE LIFT SENSOR ............................................................................................ |
18-2-7 |
SENSOR - MASS AIR FLOW (MAF) & INTAKE AIR TEMPERATURE (IAT)................................. |
18-2-8 |
PUMP - FUEL INJECTION (FIP) .................................................................................................... |
18-2-9 |
TURBOCHARGER ......................................................................................................................... |
18-2-12 |
PLENUM CHAMBER ...................................................................................................................... |
18-2-13 |
INTERCOOLER .............................................................................................................................. |
18-2-13 |
AIR INTAKE PIPE........................................................................................................................... |
18-2-14 |
INJECTORS - FUEL - SET ............................................................................................................. |
18-2-15 |
GLOW PLUGS................................................................................................................................ |
18-2-16 |
FUEL DELIVERY SYSTEM ...................................................................... |
19-1 |
REPAIRS |
|
FUEL TANK DRAINING - 'K' SERIES............................................................................................. |
19-1 |
FUEL TANK DRAINING - 'L' SERIES ............................................................................................. |
19-1 |
INERTIA FUEL SHUT-OFF (IFS) SWITCH - 'K' SERIES ............................................................... |
19-2 |
FUEL FILTER - 'K' SERIES ............................................................................................................ |
19-2 |
FUEL FILTER - 'L' SERIES............................................................................................................. |
19-3 |
ELECTRIC FUEL PUMP - 'K' SERIES............................................................................................ |
19-4 |
FUEL TANK - 'K' SERIES ............................................................................................................... |
19-5 |
FUEL TANK - 'L' SERIES................................................................................................................ |
19-7 |
FUEL TANK BREATHER VALVE - 'L' SERIES .............................................................................. |
19-10 |
COOLING SYSTEM - 'K' SERIES ............................................................ |
26-1-1 |
ADJUSTMENTS |
|
DRAIN AND REFILL ....................................................................................................................... |
26-1-1 |
COOLANT - VACUUM REFILL SYSTEM - 'K’ SERIES 1800cc ..................................................... |
26-1-2 |
COOLANT - VACUUM REFILL SYSTEM - 'K’ SERIES 1100, 1400 AND 1600cc ......................... |
26-1-4 |
SYSTEM - PRESSURE TEST ........................................................................................................ |
26-1-7 |
CAP - EXPANSION TANK - PRESSURE TEST............................................................................. |
26-1-8 |
REPAIRS |
|
COOLANT EXPANSION TANK ...................................................................................................... |
26-1-9 |
RADIATOR COOLING FAN............................................................................................................ |
26-1-9 |
COOLING FAN - RADIATOR - A/C ................................................................................................ |
26-1-10 |
RADIATOR ..................................................................................................................................... |
26-1-11 |
THERMOSTAT ............................................................................................................................... |
26-1-12 |
COOLANT PUMP ........................................................................................................................... |
26-1-13 |
COOLING SYSTEM - 'L' SERIES............................................................. |
26-2-1 |
ADJUSTMENTS |
|
DRAIN AND REFILL ....................................................................................................................... |
26-2-1 |
COOLANT - VACUUM REFILL SYSTEM ....................................................................................... |
26-2-2 |
SYSTEM - PRESSURE TEST ........................................................................................................ |
26-2-4 |
CAP - EXPANSION TANK - PRESSURE TEST............................................................................. |
26-2-5 |
CONTENTS 7
|
CONTENTS |
|
|
REPAIRS |
|
||
COOLANT EXPANSION TANK...................................................................................................... |
26-2-7 |
||
RADIATOR COOLING FAN ........................................................................................................... |
26-2-7 |
||
RADIATOR ..................................................................................................................................... |
26-2-8 |
||
THERMOSTAT ............................................................................................................................... |
26-2-9 |
||
PUMP - COOLANT......................................................................................................................... |
26-2-10 |
||
COOLANT PUMP - MODELS WITH AIR CONDITIONING............................................................ |
26-2-11 |
||
GASKET - HOUSING - COOLANT PUMP ..................................................................................... |
26-2-13 |
||
GASKET - HOUSING - COOLANT PUMP - WITH A/C.................................................................. |
26-2-14 |
||
MANIFOLD & EXHAUST SYSTEMS........................................................ |
30-1 |
||
REPAIRS |
|
||
FRONT PIPE - 'K' 1.1 / 1.4 / 1.6 ..................................................................................................... |
30-1 |
||
FRONT PIPE - 'L' SERIES ............................................................................................................. |
30-2 |
||
FRONT PIPE - 'K16 WITH VVC'..................................................................................................... |
30-2 |
||
INTERMEDIATE PIPE - 'K' SERIES............................................................................................... |
30-4 |
||
INTERMEDIATE PIPE - 'L' SERIES ............................................................................................... |
30-5 |
||
TAIL PIPE - 'K' SERIES.................................................................................................................. |
30-6 |
||
TAIL PIPE - 'L' SERIES .................................................................................................................. |
30-6 |
||
GASKET - FRONT PIPE TO MANIFOLD 'K' SERIES.................................................................... |
30-7 |
||
GASKET - FRONT PIPE TO MANIFOLD 'K16 WITH VVC' ........................................................... |
30-7 |
||
GASKET - FRONT PIPE TO MANIFOLD - 'L' SERIES .................................................................. |
30-8 |
||
HEAT SHIELD - FRONT PIPE - 'K' SERIES .................................................................................. |
30-8 |
||
TAIL PIPE HEAT SHIELD .............................................................................................................. |
30-9 |
||
HEAT SHIELD - REAR BIB SPOILER............................................................................................ |
30-10 |
||
MODULATOR - VACUUM VALVE - TAIL PIPE - EXHAUST ......................................................... |
30-10 |
||
VACUUM RESERVOIR - VACUUM VALVE - TAIL PIPE - EXHAUST .......................................... |
30-11 |
||
GASKET - INLET MANIFOLD - 'K16' ............................................................................................. |
30-11 |
||
GASKET - INLET MANIFOLD - 'K16 WITH VVC'........................................................................... |
30-13 |
||
HEAT SHIELD - EXHAUST MANIFOLD - 'K-SERIES' ................................................................... |
30-15 |
||
HEAT SHIELD - EXHAUST MANIFOLD - A/C - 'K-SERIES'.......................................................... |
30-15 |
||
HEAT SHIELD - EXHAUST MANIFOLD - 'K16 WITH VVC'........................................................... |
30-17 |
||
MANIFOLD - EXHAUST - 'K16' WITH A/C..................................................................................... |
30-18 |
||
GASKET - EXHAUST MANIFOLD - 'K16' ...................................................................................... |
30-21 |
||
GASKET - EXHAUST MANIFOLD 'K16 WITH VVC' ...................................................................... |
30-22 |
||
GASKET - INLET AND EXHAUST MANIFOLD 'L' SERIES ........................................................... |
30-22 |
||
GASKET - INLET MANIFOLD CHAMBER - 'K16 WITH VVC'........................................................ |
30-25 |
||
PLASTIC MANIFOLD STUB PIPES - RENEW .............................................................................. |
30-26 |
||
CLUTCH .................................................................................................... |
33-1 |
||
REPAIRS |
|
||
CLUTCH ASSEMBLY AND RELEASE BEARING - 'K' SERIES 1.1 / 1.4 / 1.6 R65....................... |
33-1 |
||
CLUTCH ASSEMBLY AND RELEASE BEARING - 'K16 WITH VVC'............................................ |
33-3 |
||
CLUTCH ASSEMBLY AND RELEASE BEARING - 'L' SERIES..................................................... |
33-5 |
||
CLUTCH CABLE - 'R65' GEARBOX .............................................................................................. |
33-7 |
||
CLUTCH CABLE - 'PG1' GEARBOX.............................................................................................. |
33-8 |
||
CLUTCH RELEASE FORK AND BUSHES - 'R65' GEARBOX ...................................................... |
33-10 |
||
CLUTCH RELEASE FORK - 'PG1' GEARBOX .............................................................................. |
33-11 |
||
8 CONTENTS
|
|
C ONTENTS |
|
MANUAL GEARBOX - 'R65' |
....................................................... 37-1-1............. |
||
ADJUSTMENTS |
|
|
|
OIL DRAIN AND REFILL ................................................................................................................ |
37-1-1 |
||
REPAIRS |
|
|
|
GEAR SELECTOR MOUNTING ..................................................................................................... |
37-1-3 |
||
GEARBOX - 'K16' ........................................................................................................................... |
37-1-3 |
||
SEAL - INPUT SHAFT .................................................................................................................... |
37-1-6 |
||
SEAL - SELECTOR SHAFT ........................................................................................................... |
37-1-7 |
||
REVERSE LAMP SWITCH............................................................................................................. |
37-1-8 |
||
DIFFERENTIAL OIL SEAL - R65.................................................................................................... |
37-1-9 |
||
MANUAL GEARBOX - 'PG1'.................................................................... |
37-2-1 |
ADJUSTMENTS |
|
OIL DRAIN AND REFILL ................................................................................................................ |
37-2-1 |
REPAIRS |
|
GEAR SELECTOR MOUNTING ..................................................................................................... |
37-2-3 |
MANUAL GEARBOX - 'K16 WITH VVC'......................................................................................... |
37-2-3 |
MANUAL GEARBOX - 'L' SERIES.................................................................................................. |
37-2-7 |
OIL SEALSELECTOR SHAFT...................................................................................................... |
37-2-12 |
REVERSE LAMP SWITCH............................................................................................................. |
37-2-13 |
DIFFERENTIAL OIL SEAL - LH...................................................................................................... |
37-2-13 |
DIFFERENTIAL OIL SEAL - RH ..................................................................................................... |
37-2-14 |
AUTOMATIC GEARBOX - 'EM-CVT' ....................................................... |
44-1 |
ADJUSTMENTS |
|
DRAIN AND REFILL ....................................................................................................................... |
44-1 |
SELECTOR CABLE........................................................................................................................ |
44-2 |
REPAIRS |
|
LEVER - GEAR CHANGE .............................................................................................................. |
44-3 |
KNOB - GEAR SELECTION ........................................................................................................... |
44-4 |
CABLE - GEAR CHANGE .............................................................................................................. |
44-4 |
SWITCH - STARTER INHIBITOR/REVERSE................................................................................. |
44-5 |
SELECTOR SHAFT SEAL.............................................................................................................. |
44-6 |
SENSOR - SPEED ......................................................................................................................... |
44-7 |
GEARBOX INTERFACE UNIT (GIU).............................................................................................. |
44-8 |
HARNESS - RATIO CONTROL MOTOR........................................................................................ |
44-8 |
MOTOR - RATIO CONTROL.......................................................................................................... |
44-11 |
GEARBOX - ABS - WITH A/C ........................................................................................................ |
44-14 |
INPUT SHAFT SEAL ...................................................................................................................... |
44-17 |
PRIMARY COVER.......................................................................................................................... |
44-18 |
SECONDARY COVER SEALS....................................................................................................... |
44-18 |
DIPSTICK TUBE SEAL................................................................................................................... |
44-22 |
FLUID PAN GASKET...................................................................................................................... |
44-23 |
FILTER - GEARBOX FLUID ........................................................................................................... |
44-24 |
FLUID COOLER ............................................................................................................................. |
44-24 |
HOSE - OIL COOLER - FEED ........................................................................................................ |
44-25 |
HOSE - OIL COOLER - RETURN................................................................................................... |
44-26 |
CONTENTS 9
|
CONTENTS |
|
PIPE - OIL COOLER - FEED....................................................................................................... |
... 44-27 |
|
PIPE - OIL COOLER - RETURN .................................................................................................... |
44-28 |
|
BEARING - PRIMARY .............................................................................................................. |
...... 44-29 |
|
OIL SEAL - DIFFERENTIAL ........................................................................................................ |
... 44-32 |
|
DRIVE SHAFTS ........................................................................................ |
47-1 |
|
REPAIRS |
|
|
DRIVE SHAFT - LH ............................................................................................................... |
......... 47-1 |
|
DRIVE SHAFT - RH............................................................................................................... |
......... 47-3 |
|
DRIVE SHAFT GAITER - OUTER.................................................................................................. |
47-5 |
|
DRIVE SHAFT - OUTER JOINT - EMCVT ..................................................................................... |
47-5 |
|
DRIVE SHAFT GAITER - INNER ................................................................................................... |
47-6 |
|
DRIVE SHAFT AND INNER JOINT................................................................................................ |
47-7 |
|
STEERING ................................................................................................ |
57-1 |
|
ADJUSTMENTS |
|
|
FRONT WHEEL ALIGNMENT........................................................................................................ |
57-1 |
|
REAR WHEEL ALIGNMENT .......................................................................................................... |
57-1 |
|
POWER STEERING SYSTEM BLEED - 'K' SERIES .................................................... |
................. 57-2 |
|
POWER STEERING SYSTEM BLEED - 'L' SERIES .................................................... |
................. 57-2 |
|
POWER STEERING SYSTEM - PRESSURE TEST..................................................... |
................. 57-3 |
|
REPAIRS |
|
|
POWER STEERING RACK............................................................................................................ |
57-5 |
|
BELT - PAS PUMP - 'K' SERIES................................................................................................... |
. 57-8 |
|
PUMP - POWER STEERING - PAS 'K SERIES'........................................................... |
................. 57-9 |
|
PUMP - POWER ASSISTED STEERING - PAS - 'L' SERIES ....................................................... |
57-11 |
|
TENSIONER - PAS PUMP DRIVE BELT 'K' SERIES' ................................................................... |
57-12 |
|
STEERING RACK GAITER ........................................................................................................... |
. 57-13 |
|
STEERING COLUMN ASSEMBLY ........................................................................................ |
........ 57-13 |
|
STEERING COLUMN NACELLE ................................................................................................... |
57-15 |
|
STEERING LOCK.................................................................................................................. |
......... 57-16 |
|
TRACK ROD END .................................................................................................................. |
........ 57-18 |
|
STEERING WHEEL................................................................................................................. |
....... 57-18 |
|
FRONT SUSPENSION.............................................................................. |
60-1 |
|
REPAIRS |
|
|
FRONT DAMPER ................................................................................................................... |
........ 60-1 |
|
FRONT HUB...................................................................................................................... |
............. 60-3 |
|
FRONT HUB BEARING.............................................................................................................. |
.... 60-6 |
|
ANTI-ROLL BAR.................................................................................................................. |
........... 60-7 |
|
ANTI-ROLL BAR LINK............................................................................................................. |
....... 60-8 |
|
ANTI-ROLL BAR BUSHES........................................................................................................... |
.. 60-8 |
|
SUSPENSION LOWER ARM ASSEMBLY.................................................................... |
................. 60-9 |
|
SUSPENSION LOWER ARM BUSH .......................................................................................... |
.... 60-11 |
|
FRONT BEAM ..................................................................................................................... |
........... 60-11 |
|
REAR BEAM - WITH POWER STEERING RACK ........................................................ |
................. 60-12 |
|
TIE ROD ........................................................................................................................ |
................. 60-15 |
|
10 CONTENTS
CONTENTS
REAR SUSPENSION................................................................................ |
64-1 |
REPAIRS |
|
REAR DAMPER.............................................................................................................................. |
64-1 |
REAR HUB AND BEARING - MODELS WITH DISC BRAKES ...................................................... |
64-2 |
REAR HUB AND BEARING - MODELS WITH DRUM BRAKES WITHOUT ABS.......................... |
64-3 |
REAR HUB AND BEARING - MODELS WITH DRUM BRAKES AND ABS ................................... |
64-3 |
REAR STUB AXLE - MODELS WITH DISC BRAKES.................................................................... |
64-5 |
REAR STUB AXLE - MODELS WITH DRUM BRAKES ................................................................. |
64-7 |
'H' FRAME BUSH............................................................................................................................ |
64-11 |
'H' FRAME - MODELS WITH DISC BRAKES................................................................................. |
64-12 |
'H' FRAME - MODELS WITH DRUM BRAKES............................................................................... |
64-16 |
'H' FRAME MOUNTING BRACKET ................................................................................................ |
64-21 |
BRAKES ................................................................................................... |
70-1 |
ADJUSTMENTS |
|
BRAKE SYSTEM BLEEDING......................................................................................................... |
70-1 |
HANDBRAKE CABLE..................................................................................................................... |
70-2 |
BRAKE LIGHT SWITCH - MANUAL ADJUSTING TYPE ONLY .................................................... |
70-3 |
REPAIRS |
|
HANDBRAKE WARNING SWITCH ................................................................................................ |
70-5 |
BRAKE LIGHT SWITCH - MANUAL ADJUSTING TYPE ............................................................... |
70-5 |
BRAKE LIGHT SWITCH - SELF ADJUSTING TYPE ..................................................................... |
70-6 |
FLUID LEVEL SWITCH .................................................................................................................. |
70-7 |
HANDBRAKE LEVER..................................................................................................................... |
70-8 |
ABS SENSOR - FRONT ................................................................................................................. |
70-9 |
ABS SENSOR - REAR - MODELS WITH DISC BRAKES.............................................................. |
70-11 |
BRAKE PROPORTIONING VALVE - ABS ..................................................................................... |
70-12 |
BRAKE PROPORTIONING VALVE - NON ABS ............................................................................ |
70-12 |
BRAKE MASTER CYLINDER......................................................................................................... |
70-13 |
SERVO ASSEMBLY ....................................................................................................................... |
70-13 |
BRAKE SERVO VACUUM PUMP .................................................................................................. |
70-14 |
FRONT BRAKE PADS.................................................................................................................... |
70-15 |
REAR BRAKE SHOES ................................................................................................................... |
70-16 |
REAR BRAKE PADS ...................................................................................................................... |
70-19 |
FRONT BRAKE CALIPER .............................................................................................................. |
70-21 |
REAR BRAKE CALIPER ................................................................................................................ |
70-23 |
REAR WHEEL BRAKE CYLINDER ................................................................................................ |
70-24 |
FRONT BRAKE DISC..................................................................................................................... |
70-26 |
REAR BRAKE DISC ....................................................................................................................... |
70-27 |
REAR BRAKE DRUM ..................................................................................................................... |
70-28 |
ABS HYDRAULIC MODULATOR ................................................................................................... |
70-30 |
ABS SENSOR - REAR - MODELS WITH DRUM BRAKES............................................................ |
70-31 |
CONTENTS 11
CONTENTS
RESTRAINT SYSTEMS ............................................................................ |
75-1 |
REPAIRS |
|
DRIVER AIRBAG............................................................................................................................ |
75-1 |
PASSENGER AIRBAG................................................................................................................... |
75-2 |
AIRBAG CONTROL AND DIAGNOSTIC UNIT .............................................................................. |
75-3 |
SEAT BELT PRE-TENSIONER...................................................................................................... |
75-3 |
FRONT SEAT BELT AND PRE-TENSIONER - 3 DOOR............................................................... |
75-4 |
FRONT SEAT BELT AND PRE-TENSIONER - 5 DOOR............................................................... |
75-5 |
ROTARY COUPLER ...................................................................................................................... |
75-7 |
DOORS...................................................................................................... |
76-1-1 |
REPAIRS |
|
DOOR STRIKER - ADJUST ........................................................................................................... |
76-1-1 |
TAILGATE STRIKER - ADJUST..................................................................................................... |
76-1-1 |
TAILGATE ALIGNMENT ................................................................................................................ |
76-1-2 |
EXTERIOR MIRROR GLASS......................................................................................................... |
76-1-3 |
EXTERIOR MIRROR - MANUAL.................................................................................................... |
76-1-4 |
EXTERIOR MIRROR - ELECTRIC................................................................................................. |
76-1-4 |
FRONT DOOR TRIM CASING ....................................................................................................... |
76-1-5 |
REAR DOOR TRIM CASING ......................................................................................................... |
76-1-6 |
FRONT DOOR PLASTIC SHEET................................................................................................... |
76-1-8 |
REAR DOOR PLASTIC SHEET ..................................................................................................... |
76-1-9 |
FRONT DOOR GLASS................................................................................................................... |
76-1-9 |
REAR DOOR GLASS ..................................................................................................................... |
76-1-10 |
REAR QUARTER GLASS - 5 DOOR MODELS ............................................................................. |
76-1-11 |
FRONT DOOR GLASS REGULATOR ........................................................................................... |
76-1-11 |
REAR DOOR GLASS REGULATOR.............................................................................................. |
76-1-12 |
TAILGATE TRIM CASING.............................................................................................................. |
76-1-13 |
TAILGATE SIDE FINISHER ........................................................................................................... |
76-1-13 |
TAILGATE UPPER FINISHER ....................................................................................................... |
76-1-14 |
TAILGATE LATCH.......................................................................................................................... |
76-1-14 |
LATCH - TAILGATE - EMERGENCY RELEASE ........................................................................... |
76-1-15 |
DRIVERS DOOR LOCK ................................................................................................................. |
76-1-15 |
TAILGATE LOCK............................................................................................................................ |
76-1-16 |
TAILGATE STRUT ......................................................................................................................... |
76-1-16 |
FRONT DOOR OUTSIDE HANDLE ............................................................................................... |
76-1-17 |
REAR DOOR OUTSIDE HANDLE ................................................................................................. |
76-1-17 |
FRONT DOOR INTERIOR HANDLE.............................................................................................. |
76-1-18 |
REAR DOOR INTERIOR HANDLE ................................................................................................ |
76-1-18 |
EXTERIOR FITTINGS ............................................................................... |
76-2-1 |
REPAIRS |
|
BONNET ALIGNMENT................................................................................................................... |
76-2-1 |
WHEEL ARCH LINER .................................................................................................................... |
76-2-1 |
UNDERTRAY - 'L' SERIES............................................................................................................. |
76-2-2 |
SPLASH SHIELD - 'K16' WITH 'VVC'............................................................................................. |
76-2-2 |
BONNET......................................................................................................................................... |
76-2-3 |
LOCK - BONNET............................................................................................................................ |
76-2-4 |
BONNET RELEASE CABLE .......................................................................................................... |
76-2-4 |
12 CONTENTS
|
CONTENTS |
|
FRONT BUMPER ........................................................................................................................... |
76-2-5 |
|
FRONT BUMPER - STREETWISE ................................................................................................ |
76-2-8 |
|
BUMPER VALANCE - FRONT ....................................................................................................... |
76-2-9 |
|
FRONT BUMPER ARMATURE ...................................................................................................... |
76-2-11 |
|
GRILLE - FRONT............................................................................................................................ |
76-2-12 |
|
GRILLE - FRONT - MG................................................................................................................... |
76-2-12 |
|
REAR BUMPER.............................................................................................................................. |
76-2-13 |
|
REAR BUMPER – STREETWISE .................................................................................................. |
76-2-14 |
|
BUMPER VALANCE - REAR.......................................................................................................... |
76-2-15 |
|
SPOILER - BOOT/TAILGATE - TOP - RENEW.............................................................................. |
76-2-17 |
|
EXTREME SPOILER - BOOT/TAILGATE - RENEW...................................................................... |
76-2-18 |
|
BIB SPOILER - FRONT BUMPER - RENEW ................................................................................. |
76-2-19 |
|
BIB SPOILER - REAR BUMPER - RENEW.................................................................................... |
76-2-20 |
|
MOULDING - SILL EXTERIOR - RENEW ...................................................................................... |
76-2-20 |
|
TAILGATE APPLIQUE.................................................................................................................... |
76-2-21 |
|
FRONT DOOR RUBBING STRIP ................................................................................................... |
76-2-22 |
|
REAR DOOR RUBBING STRIP ..................................................................................................... |
76-2-23 |
|
REAR QUARTER RUBBING STRIP............................................................................................... |
76-2-24 |
|
FRONT TREAD PLATE .................................................................................................................. |
76-2-25 |
|
REAR TREAD PLATE .................................................................................................................... |
76-2-25 |
|
INTERIOR TRIM COMPONENTS.................................... |
......................... 76-3-1 |
|
REPAIRS |
|
|
BULKHEAD - LOADSPACE - VAN ................................................................................................. |
76-3-1 |
|
GUARD - LOADSPACE - VAN ....................................................................................................... |
76-3-2 |
|
FLOOR FRAME - LOADSPACE - VAN .......................................................................................... |
76-3-2 |
|
REAR CONSOLE ........................................................................................................................... |
76-3-3 |
|
FRONT CONSOLE ......................................................................................................................... |
76-3-4 |
|
FRONT UPPER CONSOLE - STREETWISE ................................................................................. |
76-3-5 |
|
REAR CUSHION CONSOLE - STREETWISE ............................................................................... |
76-3-6 |
|
CENTRE CONSOLE - STREETWISE ............................................................................................ |
76-3-7 |
|
FASCIA ........................................................................................................................................... |
76-3-8 |
|
FASCIA VENEERED PANEL ......................................................................................................... |
76-3-11 |
|
GLOVE BOX ................................................................................................................................... |
76-3-11 |
|
GLOVE BOX LATCH ...................................................................................................................... |
76-3-12 |
|
FUSE BOX COVER ........................................................................................................................ |
76-3-12 |
|
'A' POST UPPER TRIM CASING.................................................................................................... |
76-3-13 |
|
'A' POST LOWER TRIM CASING................................................................................................... |
76-3-13 |
|
'B' POST LOWER TRIM CASING - 5 DOOR.................................................................................. |
76-3-14 |
|
REAR QUARTER TRIM CASING - 3 DOOR .................................................................................. |
76-3-14 |
|
REAR QUARTER TRIM CASING - 5 DOOR .................................................................................. |
76-3-16 |
|
HEADLINING .................................................................................................................................. |
76-3-17 |
|
PARCEL TRAY SUPPORT PANEL - 3 DOOR MODELS............................................................... |
76-3-18 |
|
PARCEL TRAY SUPPORT PANEL - 5 DOOR MODELS............................................................... |
76-3-20 |
|
REAR QUARTER LOWER TRIM CASING - 3 DOOR.................................................................... |
76-3-21 |
|
REAR QUARTER LOWER TRIM CASING - 5 DOOR.................................................................... |
76-3-21 |
|
LUGGAGE COMPARTMENT SIDE CARPET ................................................................................ |
76-3-22 |
|
LUGGAGE COMPARTMENT TRIM CASING................................................................................. |
76-3-22 |
|
PARCEL TRAY ............................................................................................................................... |
76-3-23 |
|
CONTENTS 13
CONTENTS
SCREENS ................................................................................................. |
76-4-1 |
REPAIRS |
|
WINDSCREEN ............................................................................................................................... |
76-4-1 |
REAR SCREEN.............................................................................................................................. |
76-4-4 |
REAR QUARTER GLASS - 3 DOOR MODELS ............................................................................. |
76-4-7 |
SEATS AND SEAT BELTS....................................................................... |
76-5-1 |
REPAIRS |
|
FRONT SEAT ................................................................................................................................. |
76-5-1 |
FRONT SQUAB COVER ................................................................................................................ |
76-5-2 |
FRONT SEAT AND SQUAB FRAME ............................................................................................. |
76-5-3 |
OUTER VALANCE - FRONT CUSHION ........................................................................................ |
76-5-5 |
INNER VALANCE - FRONT CUSHION.......................................................................................... |
76-5-6 |
SEAT HEIGHT ADJUSTMENT HANDLE ....................................................................................... |
76-5-6 |
ARM REST - REAR SEAT.............................................................................................................. |
76-5-7 |
REAR SEAT CUSHION.................................................................................................................. |
76-5-7 |
REAR SEAT CUSHION - STREETWISE ....................................................................................... |
76-5-8 |
REAR SEAT SQUAB...................................................................................................................... |
76-5-9 |
REAR SEAT SQUAB - STREETWISE .......................................................................................... |
76-5-10 |
COVER - SQUAB - REAR SEAT - SIDE - LH ................................................................................ |
76-5-11 |
COVER - SQUAB - REAR SEAT - RH ........................................................................................... |
76-5-12 |
LEVER ASSEMBLY - REAR SQUAB RELEASE ........................................................................... |
76-5-14 |
CABLE - REAR SQUAB LATCH .................................................................................................... |
76-5-14 |
REAR SQUAB LATCH ................................................................................................................... |
76-5-15 |
REAR SEAT BELT - SIDE - 3 DOOR............................................................................................. |
76-5-16 |
REAR SEAT BELT - SIDE - 5 DOOR............................................................................................. |
76-5-17 |
SEAT BELT - CENTRE - REAR ..................................................................................................... |
76-5-19 |
SUNROOF................................................................................................. |
76-6-1 |
REPAIRS |
|
SUN ROOF GLASS HEIGHT ADJUSTMENT ................................................................................ |
76-6-1 |
SUN ROOF GLASS........................................................................................................................ |
76-6-1 |
SUN ROOF SUNSHADE................................................................................................................ |
76-6-2 |
SUN ROOF SWITCH...................................................................................................................... |
76-6-2 |
SUN ROOF MOTOR ...................................................................................................................... |
76-6-3 |
SUN ROOF DRAIN TUBE .............................................................................................................. |
76-6-3 |
SUN ROOF..................................................................................................................................... |
76-6-5 |
PANEL REPAIRS...................................................................................... |
77-1 |
INTRODUCTION |
|
BODY REPAIRS............................................................................................................................. |
77-1 |
BODY DIMENSIONS |
|
DIMENSIONAL INFORMATION..................................................................................................... |
77-9 |
SEALING AND CORROSION PROTECTION |
|
APPROVED MATERIALS .............................................................................................................. |
77-23 |
14 CONTENTS
|
CONTENTS |
|
REPLACEMENT PANELS |
|
|
SERVICE CONDITION OF PANELS .............................................................................................. |
77-43 |
|
GENERAL WELDING PRECAUTIONS |
|
|
GENERAL WELDING PRECAUTIONS .......................................................................................... |
77-53 |
|
PROCEDURES |
|
|
PANEL REPLACEMENT PROCEDURE ........................................................................................ |
77-55 |
|
REPAIRS |
|
|
RADIATOR LOWER CROSSMEMBER.......................................................................................... |
77-61 |
|
VALANCE ....................................................................................................................................... |
77-61 |
|
FRONT VALANCE ASSEMBLY ..................................................................................................... |
77-62 |
|
VALANCE MEMBER REINFORCEMENT ...................................................................................... |
77-63 |
|
SIDEMEMBER ASSEMBLY ........................................................................................................... |
77-64 |
|
'A’ POST ......................................................................................................................................... |
77-65 |
|
FRONT BODY SIDE ....................................................................................................................... |
77-66 |
|
'BC’ POST - 5-DOOR...................................................................................................................... |
77-67 |
|
BODY SIDE SILL ............................................................................................................................ |
77-68 |
|
BODY SIDE ASSEMBLY - 3-DOOR............................................................................................... |
77-68 |
|
BODY SIDE ASSEMBLY - 5-DOOR............................................................................................... |
77-70 |
|
REAR BODY SIDE - 3-DOOR ........................................................................................................ |
77-72 |
|
REAR BODY SIDE - 5-DOOR ........................................................................................................ |
77-74 |
|
REAR QUARTER ASSEMBLY - 3-DOOR ...................................................................................... |
77-75 |
|
REAR QUARTER ASSEMBLY - 5-DOOR ...................................................................................... |
77-77 |
|
REAR INNER WHEELARCH .......................................................................................................... |
77-79 |
|
SPARE WHEEL WELL ASSEMBLY............................................................................................... |
77-79 |
|
REAR LONGITUDINAL MEMBER.................................................................................................. |
77-80 |
|
ROOF PANEL ASSEMBLY ............................................................................................................ |
77-80 |
|
REAR BODY ASSEMBLY .............................................................................................................. |
77-81 |
|
LOAD FLOOR SIDE ....................................................................................................................... |
77-82 |
|
TIMES |
|
|
PANEL/ ASSEMBLY REPLACEMENT TIMES ............................................................................... |
77-83 |
|
PAINT |
|
|
PAINT ............................................................................................................................................. |
77-87 |
|
PANEL PREPERATION ................................................................................................................. |
77-87 |
|
HEATING & VENTILATION............................................................... |
....... 80-1 |
|
REPAIRS |
|
|
INTAKE AIR FILTER....................................................................................................................... |
80-1 |
|
AIR INTAKE PLENUM .................................................................................................................... |
80-2 |
|
RESISTOR UNIT ............................................................................................................................ |
80-3 |
|
HEATER CONTROLS .................................................................................................................... |
80-3 |
|
CONTROL CABLE - AIR DISTRIBUTION ...................................................................................... |
80-6 |
|
CONTROL CABLE - AIR RECIRCULATION .................................................................................. |
80-7 |
|
HEATER VALVE............................................................................................................................. |
80-7 |
|
HEATER ......................................................................................................................................... |
80-8 |
|
HEATER MATRIX........................................................................................................................... |
80-9 |
|
BLOWER ASSEMBLY .................................................................................................................... |
80-9 |
|
BLOWER ASSEMBLY MOTOR...................................................................................................... |
80-10 |
|
HEATER FAN SWITCH .................................................................................................................. |
80-11 |
|
CONTENTS 15
CONTENTS
AIR CONDITIONING ................................................................................. |
82-1 |
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING |
|
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING................................................ |
82-1 |
REPAIRS |
|
AIR CONDITIONING RELAY MODULE ......................................................................................... |
82-3 |
COMPRESSOR - K-SERIES.......................................................................................................... |
82-3 |
COMPRESSOR - 'L' SERIES ......................................................................................................... |
82-5 |
CONDENSER FAN AND MOTOR.................................................................................................. |
82-6 |
CONDENSER................................................................................................................................. |
82-8 |
RECEIVER/ DRIER ........................................................................................................................ |
82-8 |
AIR CONDITIONING SWITCH ....................................................................................................... |
82-10 |
EVAPORATOR............................................................................................................................... |
82-10 |
WIPERS & WASHERS.............................................................................. |
84-1 |
REPAIRS |
|
WINDSCREEN WASHER RESERVOIR ........................................................................................ |
84-1 |
WASHER JET - WINDSCREEN..................................................................................................... |
84-1 |
WASHER PUMP - WINDSCREEN................................................................................................. |
84-2 |
WINDSCREEN WIPER ARM ......................................................................................................... |
84-2 |
WINDSCREEN WIPER BLADE...................................................................................................... |
84-3 |
WINDSCREEN WIPER MOTOR .................................................................................................... |
84-3 |
WINDSCREEN WIPER LINKAGE.................................................................................................. |
84-4 |
WINDSCREEN WASHER AND WIPER SWITCH.......................................................................... |
84-5 |
REAR SCREEN WASHER JET...................................................................................................... |
84-5 |
REAR SCREEN WIPER ARM ........................................................................................................ |
84-6 |
REAR SCREEN WIPER BLADE .................................................................................................... |
84-6 |
REAR SCREEN WIPER MOTOR................................................................................................... |
84-7 |
ELECTRICAL ............................................................................................ |
86-1 |
ADJUSTMENTS |
|
HEADLAMPS ADJUST................................................................................................................... |
86-1 |
AUXILIARY DRIVE BELT - 'K' SERIES.......................................................................................... |
86-1 |
AUXILIARY DRIVE BELT - 'K' SERIES WITH A/C......................................................................... |
86-2 |
AUXILIARY DRIVE BELT - 'L' SERIES .......................................................................................... |
86-3 |
REPAIRS |
|
ALTERNATOR - 'K' SERIES .......................................................................................................... |
86-5 |
ALTERNATOR - 'K' SERIES WITH A/C ......................................................................................... |
86-6 |
ALTERNATOR - 'L' SERIES........................................................................................................... |
86-6 |
ALTERNATOR - 'L' SERIES WITH A/C.......................................................................................... |
86-8 |
AUXILIARY DRIVE BELT - 'K' SERIES.......................................................................................... |
86-11 |
AUXILIARY DRIVE BELT - 'K' SERIES - WITH A/C ...................................................................... |
86-12 |
AUXILIARY DRIVE BELT - 'L' SERIES .......................................................................................... |
86-13 |
AUXILIARY DRIVE BELT TENSIONER - 'L' SERIES .................................................................... |
86-13 |
BATTERY ....................................................................................................................................... |
86-14 |
FRONT DOOR GLASS MOTOR .................................................................................................... |
86-14 |
ELECTRIC WINDOW SWITCH ...................................................................................................... |
86-15 |
WINDOW LIFT ECU ....................................................................................................................... |
86-16 |
FRONT DOOR LOCK MOTOR ...................................................................................................... |
86-17 |
16 CONTENTS
CONTENTS
REAR DOOR LOCK MOTOR ......................................................................................................... |
86-18 |
HORN SWITCH .............................................................................................................................. |
86-19 |
HORN ............................................................................................................................................. |
86-19 |
LAMP ASSEMBLY - FRONT FLASHER......................................................................................... |
86-20 |
LAMP ASSEMBLY - FRONT FLASHER - 2004 MY ....................................................................... |
86-21 |
HEADLAMP ASSEMBLY................................................................................................................ |
86-22 |
SIDE REPEATER ........................................................................................................................... |
86-23 |
LAMP ASSEMBLY - TAIL ............................................................................................................... |
86-24 |
NUMBER PLATE LAMP ................................................................................................................. |
86-24 |
LAMP - FRONT FOG...................................................................................................................... |
86-25 |
LAMP - FRONT FOG - 2004 MY .................................................................................................... |
86-26 |
LAMP ASSEMBLY - CENTRE HIGH MOUNTED STOP ................................................................ |
86-27 |
INTERIOR LIGHT ........................................................................................................................... |
86-27 |
GLOVEBOX LAMP ......................................................................................................................... |
86-28 |
LUGGAGE COMPARTMENT LAMP .............................................................................................. |
86-28 |
HEATER CONTROL ILLUMINATION BULB .................................................................................. |
86-29 |
INSTRUMENT PACK ILLUMINATION BULB ................................................................................. |
86-30 |
RADIO............................................................................................................................................. |
86-30 |
REAR SPEAKER ............................................................................................................................ |
86-31 |
REMOTE ICE CONTROLS............................................................................................................. |
86-31 |
FRONT SPEAKER.......................................................................................................................... |
86-32 |
AERIAL ........................................................................................................................................... |
86-32 |
COAXIAL CABLE............................................................................................................................ |
86-34 |
TWEETER - FRONT DOOR ........................................................................................................... |
86-36 |
CD PLAYER.................................................................................................................................... |
86-37 |
NAVIGATION SYSTEM - BECKER ................................................................................................ |
86-37 |
CONTROL UNIT (ECU) - PARKING AID........................................................................................ |
86-39 |
SENSOR - PARKING AID .............................................................................................................. |
86-40 |
SOUNDER - PARKING AID............................................................................................................ |
86-41 |
FLASHER UNIT .............................................................................................................................. |
86-42 |
DOOR SWITCH .............................................................................................................................. |
86-42 |
BONNET SWITCH.......................................................................................................................... |
86-43 |
MULTI FUNCTION UNIT (MFU) - MODELS WITH SERVICABLE FUSEBOX............................... |
86-44 |
MULTI FUNCTION UNIT (MFU) - MODELS WITH HARD-WIRED FUSEBOX .............................. |
86-45 |
STARTER MOTOR 1.1, 1.4 AND 1.6 MODELS ............................................................................. |
86-46 |
STARTER MOTOR - 'L' SERIES .................................................................................................... |
86-47 |
STARTER MOTOR - 'EM-CVT' MODELS ...................................................................................... |
86-47 |
STARTER MOTOR - 'K16 WITH VVC' ........................................................................................... |
86-48 |
STARTER SWITCH ........................................................................................................................ |
86-49 |
FRONT FOG LIGHT SWITCH ........................................................................................................ |
86-50 |
HEATED REAR SCREEN SWITCH ............................................................................................... |
86-51 |
HAZARD WARNING LIGHT SWITCH ............................................................................................ |
86-51 |
INDICATOR/HEADLAMP SWITCH ................................................................................................ |
86-52 |
STEERING COLUMN SWITCH ASSEMBLY.................................................................................. |
86-52 |
REAR FOG LIGHT SWITCH .......................................................................................................... |
86-53 |
DOOR MIRROR SWITCH............................................................................................................... |
86-54 |
ENGINE COMPARTMENT FUSE BOX .......................................................................................... |
86-54 |
SWITCH - HEADLAMP LEVELLING .............................................................................................. |
86-55 |
MOTOR - HEADLAMP LEVELLING ............................................................................................... |
86-56 |
ANTI-THEFT ALARM ECU ............................................................................................................. |
86-57 |
SECURITY CONTROL UNIT (SCU)............................................................................................... |
86-58 |
BATTERY BACKED UP SOUNDER - BBUS.................................................................................. |
86-59 |
TRANSPONDER COIL ................................................................................................................... |
86-59 |
ANTI-THEFT ALARM LED.............................................................................................................. |
86-60 |
CONTENTS 17
CONTENTS
INSTRUMENTS......................................................................................... |
88-1 |
REPAIRS |
|
CLOCK ........................................................................................................................................... |
88-1 |
CLOCK - 2004 MY.......................................................................................................................... |
88-2 |
INSTRUMENT PACK ..................................................................................................................... |
88-3 |
INSTRUMENT PANEL WINDOW AND FACE PLATE ................................................................... |
88-4 |
COOLANT TEMPERATURE GAUGE ............................................................................................ |
88-5 |
ENGINE COOLANT TEMPERATURE GAUGE SENSOR - 'K' SERIES ........................................ |
88-5 |
ENGINE COOLANT TEMPERATURE GAUGE SENSOR -'L' SERIES ......................................... |
88-6 |
FUEL GAUGE................................................................................................................................. |
88-6 |
FUEL GAUGE TANK UNIT - 'L' SERIES........................................................................................ |
88-7 |
SPEEDOMETER ............................................................................................................................ |
88-8 |
VEHICLE SPEED SENSOR - 'R65' GEARBOX ............................................................................. |
88-9 |
VEHICLE SPEED SENSOR - 'PG1' GEARBOX ............................................................................ |
88-10 |
TACHOMETER............................................................................................................................... |
88-11 |
18 CONTENTS
INTRODUCTION
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 filing 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. Item numbers in the illustration are referred to in the text.
Adjustment and repair operations include reference to Service tool numbers and the associated illustration 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 possibility of injury.
CAUTION: Calls attention to procedures which must be followed to avoid damage to components.
NOTE: Gives helpful information.
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.
REPAIRS AND REPLACEMENTS
When replacement parts are required, it is essential that only MG Rover recommended parts are used.
Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories.
Safety features and corrosion prevention treatments embodied in the car may be impaired if other than MG Rover recommended parts are fitted. In certain territories, legislation prohibits the fitting 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 fitting of other than MG Rover recommended parts.
All MG Rover recommended parts have the full backing of the vehicle Warranty.
MG Rover Dealers are obliged to supply only MG Rover recommended parts.
01-1
INTRODUCTION
SPECIFICATION
MG 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. MG Rover Dealers are not agents of MG Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation.
01-2
|
|
|
|
INTRODUCTION |
|
|
|
|
|
|
|
ABBREVIATIONS AND SYMBOLS |
|
|
|
||
|
|
|
ERL |
Electrical Reference Library |
|
ABDC |
After Bottom Dead Centre |
||||
ATDC |
After Top Dead Centre |
EACV |
Electronic Air Control Valve |
||
A/C |
Air Conditioning |
EAT |
Electronic Automatic Transmission |
||
AFR |
Air Fuel Ratio |
EBD |
Electronic Brake pressure |
||
ATC |
Air Temperature Control |
|
Distribution |
||
ac |
Alternating Current |
ECU |
Electronic Control Unit |
||
AAP |
Ambient Air Pressure |
EDC |
Electronic Diesel Control |
||
AAT |
Ambient Air Temperature |
EEPROM |
Electronic Erasable Programmable |
||
AP |
Ambient Pressure |
|
Read Only Memory |
||
A |
Amperes |
ETC |
Electronic Traction Control |
||
Ah |
Amperes per hour |
EVR |
Electronic Vacuum Regulator |
||
ABS |
Anti-lock Brake System |
EM-CVT |
Electro Mechanical - Continuously |
||
ASC |
Anti-shunt Control |
|
Variable Transmission |
||
ACEA |
Association of Constructors of |
EKA |
Emergency Key Access |
||
|
European Automobiles |
ELR |
Emergency Locking Retractor |
||
AUX |
Auxiliary |
ECM |
Engine Control Module |
||
ALR |
Automatic Locking Retractor |
ECT |
Engine Coolant Temperature |
||
AVC |
Automatic Volume Control |
EON |
Enhanced Other Network |
||
BBDC |
Before Bottom Dead Centre |
ECD |
European Community Directive |
||
BTDC |
Before Top Dead Centre |
EN |
European Norm |
||
BDC |
Bottom Dead Centre |
EOBD |
European On Board Diagnostics |
||
bhp |
Brake horse power |
EVAP |
Evaporative Emission |
||
BPP |
Brake Pedal Position |
EGR |
Exhaust Gas Recirculation |
||
BS |
British Standards |
F |
Fahrenheit |
||
CMP |
Camshaft Position |
FTC |
Fast Throttle Control |
||
CO2 |
Carbon Dioxide |
ft. |
Feet |
||
CO |
Carbon Monoxide |
FET |
Field effect Transistor |
||
C |
Celcius (Centigrade) |
FIP |
Fuel Injection Pump |
||
cm |
Centimetre |
g |
Gramme (mass) or gravity |
||
cm2 |
Square centimetres |
gal. |
Gallons |
||
cm3 |
Cubic centimetres |
GIU |
Gearbox Interface Unit |
||
CCU |
Central Control Unit |
GTW |
Gross Train Weight |
||
CDL |
Central Door Locking |
GVW |
Gross Vehicle Weight |
||
CHMSL |
Centre High Mounted Stop Lamp |
HO2S |
Heated oxygen sensor |
||
CFCs |
Chlorofluorocarbons |
HRW |
Heated Rear Window |
||
CPP |
Clutch Pedal Position |
hc |
High compression |
||
CR |
Common Rail |
ht |
High tension |
||
CD |
Compact Disc |
h |
Hour |
||
CD-ROM |
Compact Disc - Read Only |
HC |
Hydrocarbons |
||
|
Memory |
IACV |
Idle Air Control Valve |
||
CVT |
Continuously Variable |
ICE |
In Car Entertainment |
||
|
Transmission |
in. |
Inches |
||
CAN |
Controller Area Network |
in2 |
Square inches |
||
CKP |
Crankshaft Position |
in3 |
Cubic inches |
||
dB |
Decibels |
IAT |
Intake Air Temperature |
||
deg. or ° |
Degree (angle or temperature) |
i.dia. |
Internal diameter |
||
DIN |
Deutsche Industrie Normen |
ISO |
International Organisation for |
||
|
(German Industrial Standards) |
|
Standardization |
||
DTI |
Dial Test Indicator |
kg |
Kilogramme |
||
dia. |
Diameter |
kg/h |
Kilogrammes per hour |
||
DSP |
Digital Signal Processing |
km |
Kilometre |
||
dc |
Direct current |
km/h |
Kilometres per hour |
||
DI |
Direct Injection |
kPa |
KiloPascal |
||
DCV |
Directional Control Valve |
KS |
Knock sensor |
||
DOHC |
Double Overhead Camshaft |
l |
Lambda |
||
01-3
INTRODUCTION
LH |
Left-hand |
ROW |
Rest of World |
LHD |
Left-hand drive |
rev/min |
Revolutions per minute |
LED |
Light emitting diode |
RH |
Right-hand |
LCD |
Liquid Crystal Display |
RHD |
Right-hand drive |
l |
Litre |
RES |
MG Rover Engineering Standards |
lc |
Low compression |
" |
Second (angle) |
MIL |
Malfunction Indicator Lamp |
SOHC |
Single Overhead Camshaft |
MAP |
Manifold absolute pressure |
SPE |
Single Point Entry |
MAF |
Mass air flow |
SAE |
Society of Automotive Engineers |
max. |
Maximum |
sp.gr |
Specific gravity |
MPa |
MegaPascal |
cm2 |
Square centimetres |
Hg |
Mercury |
std. |
Standard |
m |
Metre |
SRS |
Supplementary Restraint System |
m |
Micro |
synchro |
Synchronizer/synchromesh |
mph |
Miles per hour |
TMAP |
Temperature, Manifold Absolute |
mm |
Millimetre |
|
Pressure |
min |
Minimum |
TXV |
Thermostatic Expansion Valve |
- |
Minus (of tolerance) |
k |
Thousand |
' |
Minute (angle) |
TWC |
Three Way Catalyst |
MY |
Model Year |
TP |
Throttle Position |
MEMS |
Modular Engine Management |
TDC |
Top Dead Centre |
|
System |
TV |
Torsional Vibration |
MFU |
Multi-function unit |
TA |
Traffic Announcement |
MPi |
Multi-point injection |
UK |
United Kingdom |
-ve |
Negative (electrical) |
US |
United States |
NTC |
Negative Temperature Coefficient |
Var. |
Variable |
Nm |
Newton metre |
VRS |
Variable Reluctance Sensor |
NO2 |
Nitrogen dioxide |
VVC |
Variable Valve Control |
NRV |
Non Return Valve |
VIN |
Vehicle identification number |
No. |
Number |
VSS |
Vehicle Speed Sensor |
W |
Ohms |
V |
Volt |
OBD |
On Board Diagnostics |
W |
Watt |
OAT |
Organic Acid Technology |
|
|
o.dia. |
Outside diameter |
|
|
NOX |
Oxides of Nitrogen |
|
|
% |
Percentage |
|
|
pts. |
Pints |
|
|
± |
Plus or minus |
|
|
+ |
Plus (tolerance) |
|
|
PTFE |
Polytetrafluorethylene |
|
|
+ve |
Positive (electrical) |
|
|
PCV |
Positive Crankcase Ventilation |
|
|
PTC |
Positive Temperature Coefficient |
|
|
lb(s) |
Pounds |
|
|
lbf |
Pounds force |
|
|
lbf.in |
Pounds force inches |
|
|
lbf/in2 |
Pounds per square inch |
|
|
lbf.ft |
Pounds force feet |
|
|
PAS |
Power Assisted Steering |
|
|
PCB |
Printed Circuit Board |
|
|
PPS |
Pulse Per Second |
|
|
PWM |
Pulse Width Modulation |
|
|
RDS |
Radio data Service |
|
|
r |
Radius |
|
|
: |
Ratio |
|
|
ROM |
Read Only Memory |
|
|
ref |
Reference |
|
|
RON |
Research Octane Number |
|
|
01-4
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
VIN plate details
The VIN plate contains the following information:
1Vehicle Identification Number (VIN)
2Gross vehicle weight (GVW)
3Gross train weight (GTW)
4Maximum front axle load
5Maximum rear axle load
6Paint code
7Trim code
VIN code key
Example: S A R R F X N M E 1 D 441071
SAR |
= World Identifier (MG Rover Group) |
|
|
RF |
= Marque/Model |
|
|
X |
= Trim level |
|
|
N |
= Body Style (N = 3 door) |
|
|
M |
= Engine (M = 1.8 160 PS) |
|
|
E |
= Transmission and Steering (E = RHD, |
|
G4 manual gearbox) |
|
|
1 |
= Model year |
|
|
D |
= Assembly plant (D = Longbridge) |
|
|
6 figures |
= Serial number |
|
|
Paint and Trim colour codes
3-letter codes identifying the original Paint and Trim colours are stamped on the VIN plate.
Paint
Example: J R J
J |
= Basic colour |
|
|
R |
= Mark identifier |
|
|
J |
= Colour/Shade name |
|
|
Trim
Example: S C D
S |
= Basic colour |
|
|
C |
= Mark identifier |
|
|
D |
= Colour/Shade name |
|
|
03-1
GENERAL INFORMATION
VIN NUMBER LOCATIONS
The Vehicle Identification Number (VIN) plate is attached to front of the LH ‘B’ post on 3-door models.
The Vehicle Identification Number (VIN) plate is attached on the outside of the LH ‘B’ post on 5-door models.
The VIN is also stamped in the following locations:
At the top centre of the engine bulkhead.
On a plate behind the LH lower corner of the windscreen.
03-2
GENERAL INFORMATION
Gearbox number
COMPONENT IDENTIFICATION NUMBER
LOCATIONS
Engine number
Manual Gearbox - R65 and PG1: Barcode on a label attached to the front face of the clutch housing.
‘K’ Series Engines: Stamped on the rear LH side of the cylinder block.
Automatic Gearbox (EM-CVT): Stamped on a label attached by the gearbox to engine mounting bolt at top RH side of the gearbox.
‘L’ Series Engine: Stamped on the LH side of the cylinder block at top centre.
03-3
GENERAL INFORMATION
Body number
The body number is stamped on a plate fixed to the floor to the LH side of the spare wheel compartment.
DANGEROUS SUBSTANCES
Modern vehicles contain many materials and liquids which if not handled with care can be hazardous to both personal health and the environment.
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 liquids and substances include acid, antifreeze, asbestos, brake fluid, fuel, windscreen washer additives, lubricants, refrigerant and various adhesives.
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.
Synthetic rubber
Many ‘O’ 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.
Contact with Hydrofluoric acid can cause serious burns on contact with skin. If skin contact does occur:
lRemove any contaminated clothing immediately.
lIrrigate affected area of skin with a copious amount of cold water or limewater for 15 to 60 minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or overheated condition, handle with extreme caution and wear protective clothing (seamless industrial gloves, protective apron etc.).
Decontaminate and dispose of gloves immediately after use.
03-4
GENERAL INFORMATION
Lubricating oils
Avoid excessive skin contact with used lubricating oils and always adhere to the health protection precautions.
WARNING: Avoid excessive skin contact with used engine oil. Used engine oil contains potentially harmful contaminants which may cause skin cancer or other serious skin disorders.
WARNING: Avoid excessive skin contact with mineral oil. Mineral oils remove the natural fats from the skin, leading to dryness, irritation and dermatitis.
Health Protection Precautions
The following precautions should be observed at all times:
lAvoid prolonged and repeated contact with oils, particularly used engine oils.
lWear protective clothing, including impervious gloves where practicable.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those next to the skin) with oil.
lOveralls must be cleaned regularly. Discard heavily soiled clothing and oil impregnated footwear.
lFirst aid treatment should be obtained immediately for open cuts and wounds.
lApply barrier creams before each work period to help prevent lubricating oil from contaminating the skin.
lWash with soap and water to ensure all oil is removed (proprietary skin cleansers and nail brushes will help).
lUse moisturisers after cleaning; preparations containing lanolin help replace the skin‘s natural oils which have been removed.
lDo not use petrol/gasoline, kerosene, diesel fuel, oil, thinners or solvents for cleaning skin.
lWhere practicable, degrease components prior to handling.
lIf skin disorders develop, obtain medical advice without delay.
lWear eye protection (e.g. goggles or face shield) if there is a risk of eye contamination. Eye wash facilities should be provided in close vicinity of the work area.
SAFETY INSTRUCTIONS
Whenever possible, use a lift or pit when working beneath vehicle, in preference to jacking. Chock wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points, the recommended jacking points are given in LIFTING
AND TOWING
Always ensure that any lifting apparatus has sufficient load 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.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc. around or on the work bench area. Always keep a clean and tidy work area.
Brake shoes and pads
WARNING: Always fit the correct grade and specification of brake linings and renew brake pads and brake shoes in axle sets only.
03-5
GENERAL INFORMATION
Brake hydraulics
Observe the following recommendations when working on the brake system:
lAlways use two spanners when loosening or tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are not kinked or twisted.
lFit brake pipes securely in their retaining clips and ensure that the pipe cannot contact a potential chafing point.
lContainers used for hydraulic fluid must be kept absolutely clean.
lDo not store hydraulic brake fluid in an unsealed container, it will absorb water and in this condition would be dangerous to use due to a lowering of its boiling point.
lDo not allow hydraulic brake fluid to be contaminated with mineral oil, or put new brake fluid in a container which has previously contained mineral oil.
lDo not re-use brake fluid removed from the system.
lAlways use clean brake fluid or a recommended alternative to clean hydraulic components.
lAfter disconnection of brake pipes and hoses, immediately fit suitable blanking caps or plugs to prevent the ingress of dirt.
lOnly use the correct brake fittings with compatible threads.
lAbsolute cleanliness must be observed when working with hydraulic components.
WARNING: It is imperative that the correct brake fittings are used and that threads of components are compatible.
Cooling system caps and plugs
Extreme care is necessary when removing cooling system expansion tank caps and coolant drain or bleed screws when the engine is hot, and especially if it is overheated. To avoid the possibility of scalding, allow the engine to cool before attempting coolant cap or plug removal.
ENVIRONMENTAL PRECAUTIONS
General
This section provides general information which if observed, can help reduce environmental damage caused by activities carried out in workshops.
Emissions to air
Many of the activities that are carried out in workshops emit gases and fumes which contribute to global warming, depletion of the ozone layer and/or the formation of photochemical smog at ground level. By considering how the workshop activities are carried out, these gases and fumes can be minimised, thus reducing the impact on the environment.
Exhaust fumes
Running car engines is an essential part of workshop activities and exhaust fumes need to be ventilated to atmosphere. However, the amount of time engines are running and the position of the vehicle should be carefully considered at all times, to reduce the release of poisonous gases and minimise the inconvenience to people living nearby.
Solvents
Some of the cleaning agents used are solvent based and will evaporate to atmosphere if used carelessly, or if cans are left unsealed. All solvent containers should be firmly closed when not being used and solvent should be used sparingly. Suitable alternative methods may be available to replace some of the commonly used solvents. Similarly, many paints are solvent based and the spray should be minimised to reduce solvent emissions.
Refrigerant
It is illegal to release any refrigerants into the atmosphere. Discharge and replacement of these materials from air conditioning units should only be carried out using the correct equipment.
Checklist
Always adhere to the following:
Engines:
lDon‘t leave engines running unnecessarily.
lMinimise testing times and check where the exhaust fumes are being blown.
Materials:
lKeep lids on containers of solvents.
lOnly use the minimum quantity.
lConsider alternative materials.
lMinimise over-spray when painting.
03-6
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