Service Manual 2011 MG6

Service Manual 2011
MG6
cardiagn.com
Version 2.0
This manual provides information on the specifications, the system introduction, the service procedures and the
adjustments for the 2011 series MG6 Vehicle.
The technicians, worked for the servicing station authorized by MG Motor, can provide better service for the owners of
MG6 vehicle based on a profound understanding this manual and related updated Service Bulletins.
You are suggested that please contact MG Motor. if you want to obtain related information mentioned in this manual
about the brand, the parts number, and special tools etc.
MG Motor.
Copy Right Reserved
All information received cutoff date is August 2011
Any information contained in this manual are the property of the MG Motor. No part of this manual may be copied,
stored in any retrieval system, or spread by any means (including but not limited in electronic, mechanical, photocopying
and recording) without written MG Motor authorization. This applies to all text, illustrations, and tables (not limited in
above) mentioned in this manual.
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How To Use This Manual NOTE statements emphasize a necessary characteristic of
General a diagnostic or repair procedure. NOTE statements are
designed to do the following:
To assist in the use of this Manual, it is divided into sections
and sub-sections. The relevant sub-section title is given at the • Clarify a procedure.
header of each page. • Present additional information for accomplishing a
procedure.
There is a single Contents section at the front of the Manual,
which is divided by section and sub-section. The book is • Give insight into the reason or reasons for performing a
numbered from page 1. The page number is given at the procedure in the manner recommended.
bottom of each page. • Present information that will help to accomplish a
procedure in a more effective manner.
The individual actions of the repair operations must be
followed in the sequence in which they appear. Item numbers • Present information that gives the technician the benefit
in the illustrations refer to the relevant numbered text under of past experience in accomplishing a procedure with
the illustration. greater ease.
Adjustment and repair operations include reference to Service TIP: Gives helpful information.
tool numbers and the associated illustration depicts the tool in References
use. Adjustment and repair operations also include reference
References to the LH or RH side given in this Manual are made
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to wear limits, relevant data, torque figures, and specialist
when viewing the vehicle from the rear. With the engine and
information and useful assembly details. Each adjustment or
gearbox assembly removed, the crankshaft pulley end of the
repair operation is given a unique Repair Operation number.
engine is referred to as the front.
WARNINGS, CAUTIONS, NOTES and TIPS have the
Operations covered in this Manual do not include reference
following meanings:
to testing the vehicle after repair. It is essential that work
When encountering a WARNING, you will be asked to take is inspected and tested after completion and if necessary a
a necessary action or not to take a prohibited action. If a road test of the vehicle is carried out. This is of particular
WARNING is not heeded, the following consequences may importance where safety related items are concerned.
occur: Dimensions
• Serious bodily injury or death to the technician.
The dimensions quoted are to design engineering specification.
• Serious bodily injury or death to other technicians in the Service limits are included where applicable.
workplace area.
Our company are constantly seeking to improve the
• Serious bodily injury to the driver and/or passenger(s) of
specification, design and production of their vehicles and
the vehicle, if the vehicle has been improperly repaired.
alterations take place accordingly. While every effort has been
CAUTION call special attention to a necessary action or to a made to ensure the accuracy of this Manual, it should not be
prohibited action. If a CAUTION is not heeded, the following regarded as an infallible guide to current specifications of any
consequences may occur: particular vehicle.
• Damage to the vehicle.
• Unnecessary vehicle repairs.
• Unnecessary component replacement.
• Improper operation or performance of the system or
component under repair.
• Damage to any systems or components which are
dependent upon the proper operation of the system or
component under repair.
• Improper operation or performance of any systems
or components which are dependent upon the proper
operation or performance of the system or component
under repair.
• Damage to fasteners, basic tools, or special tools.
• The leakage of coolant, lubricant, or other vital fluids.
Version 2.0 1
Repairs and Replacements
Parts
When replacement parts are required it is essential that only
our company’s 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 vehicle may be impaired if other than
SMC recommended parts are fitted.
• 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.
• The terms of the vehicle warranty may be invalidated by
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the fitting of parts other than SMC recommended parts.
All SMC recommended parts have the full backing of the vehicle
warranty.
SMC Dealers are obliged to supply only SMC recommended
parts.
Special tools
Special tools have been developed to facilitate removal,
dismantling and assembly of mechanical components in a cost
effective and time efficient manner. The use of special tools
also helps prevent the potential for damage to components.
Some operations in the manual cannot be carried out properly
without the aid of the relevant special tools.
Special tools can be obtained from the following supplier.
Shanghai Xiangzhi Industrial Development Co., Ltd
Address: 17F, Building C, No.900, Yishan Road, Shanghai
Post Code: 200233
Tel: 021-54234810
Version 2.0 2
Contents
General Information ........................... 1 Connecting Rod Bearings Overhaul ............... 65
General Information .............................................1 Pistons & Liners............................................ 67
General Precautions ........................................... 1 Crankshaft Rear Oil Seal ............................... 70
Safety Instructions .............................................. 2 Crankshaft Front Oil Seal.............................. 71
Environmental Precautions.................................. 3 Flywheel - Manual Transmission..................... 72
General Fitting Instructions................................. 5 Torque Converter Drive Plate - Automatic
Transmission ................................................ 72
Ball and Roller Bearings ...................................... 6
Cylinder Head Gasket Overhaul - with
Oil Seals ............................................................ 7 Engine Removed ........................................... 73
Joints and Joint Faces .......................................... 8 Camshaft Cover Gasket ................................ 77
Locking Devices ................................................. 8 Valves .......................................................... 78
Screw Threads ................................................... 9 Hydraulic Tappets ......................................... 82
Fasteners Identification....................................... 9 Camshafts - Inlet or Exhaust ......................... 82
Flexible Pipes and Hoses................................... 11 Intake Manifold Gasket.................................. 84
Fuel Handling Precautions................................. 12 Exhaust Manifold Gasket ............................... 86
Electrical Precautions ....................................... 13 Oil Pump ..................................................... 89
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Supplementary Restraint System Engine Oil and Oil Filter................................ 90
Precautions...................................................... 14
Engine Oil Pressure Check............................ 91
SRS Component Replacement Policy................. 20
Oil Pick - Up Strainer ................................... 92
Air Conditioning System Precautions ................ 21
Engine Sump................................................. 92
Air Conditioning Compressor
Replacement .................................................... 23 Camshaft Drive Belt Cover - Front
Upper .......................................................... 93
Vehicle Identification Number ...........................24
Camshaft Drive Belt Cover - Rear
Vehicle Identification ........................................ 24 Upper .......................................................... 94
Other Identification Plate Locations .................. 25 Crankshaft Pulley.......................................... 95
Lifting & Towing...................................................26 Engine Mounting - RH................................... 96
Lifting .............................................................. 26 Engine Mounting Lower Tie Rod ................... 96
Vehicle Recovery.............................................. 27 Camshaft Front Oil Seal - Exhaust ................. 97
Lubrication & Maintenance ................................29 Camshaft Front Oil Seal - Inlet ...................... 98
Capacities ........................................................ 29 Camshaft Drive Belt ..................................... 99
Fluids............................................................... 29 Engine and Manual Transmission .................. 102
Lubrication ...................................................... 30 Engine and Automatic Transmission............. 110
Engine................................................. 31 Cylinder Head Gasket................................. 119
Turbocharger ............................................. 123
Engine Mechanical-1.8T ......................................31
Hose - Coolant Drain - Turbocharger........... 126
Specifications ................................................... 31
Hose - Coolant Intake - Turbocharger........... 126
Torque ......................................................... 31
Pipe - Oil Return - Turbocharger................. 127
Reference..................................................... 32
Hose - Air Intake - Turbocharger ................ 127
Description and Operation............................... 39
Pipe - Oil Feed - Turbocharger .................... 128
Engine Component Layout ............................ 39
Hose - Air Intake - Electronic
Description .................................................. 52 Throttle ..................................................... 128
Operation .................................................... 54 Intercooler................................................. 129
Service Procedures........................................... 56 Hose - Air Intake - Intercooler.................... 130
Cylinder Head Overhaul - with Cylinder Special Tools .................................................. 131
Head Removed............................................. 56
Engine Mechanical-1.8 VCT .............................134
Crankshaft Overhaul - with Engine
Removed...................................................... 61 Specifications ................................................. 134
Torque ....................................................... 134
Version 2.0 1
Contents
Reference................................................... 135 1.8VCT Solenoid - Inlet Camshaft ............... 205
Description and Operation............................. 136 1.8VCT Solenoid Housing - Exhaust
Component Layout..................................... 136 Camshaft.................................................... 206
Description ................................................ 147 1.8VCT Solenoid Housing - Inlet
Camshaft.................................................... 206
Operation .................................................. 149
1.8VCT Cylinder Head GasketNew ............ 207
Service Procedures......................................... 152
Special Tools .................................................. 210
Cylinder Head Overhaul - with Cylinder
Head Removed........................................... 152 Engine Cooling System .....................................213
Crankshaft Overhaul - with Engine Specifications ................................................. 213
Removed.................................................... 157 Torque ....................................................... 213
Connecting Rod Bearings Overhaul ............. 161 Reference................................................... 214
Pistons & Liners.......................................... 163 Description and Operation............................. 215
Crankshaft Rear Oil Seal ............................. 166 System Component Layout ......................... 215
Crankshaft Front Oil Seal............................ 167 Description ................................................ 218
Flywheel - Manual Transmission................... 168 Operation .................................................. 220
Torque Converter Drive Plate - Automatic Service Procedures......................................... 223
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Transmission .............................................. 168 Coolant - Drain and Refill ........................... 223
Cylinder Head Gasket Overhaul - with Expansion Tank Cap- Pressure Test.............. 224
Engine Removed ......................................... 169
System - Pressure Test ................................ 225
Camshaft Cover Gasket .............................. 173
Coolant Expansion Tank.............................. 226
Valves ........................................................ 174
Fan Assembly ............................................. 227
Hydraulic Tappets ....................................... 178
Cooling Fan Resistor .................................. 229
Camshafts - Inlet or Exhaust ....................... 178
Radiator Assembly...................................... 229
Intake Manifold Gasket................................ 180
Supply Fluid Cooler Hose - Automatic
1.8VCT Exhaust Manifold Gasket ................ 182 Transmission .............................................. 231
Oil Pump ................................................... 184 Return Fluid Cooler Hose - Automatic
Engine Oil and Oil Filter.............................. 185 Transmission .............................................. 232
Engine Oil Pressure Check.......................... 186 Thermostat ................................................ 233
Oil Pick - Up Strainer ................................. 186 Pump-Coolant ............................................ 233
Engine Sump............................................... 187 Special Tools .................................................. 234
Camshaft Drive Belt Cover - Front Engine Manifold & Exhaust System .................235
Upper ........................................................ 188 Specifications ................................................. 235
Camshaft Drive Belt Cover - Rear Torque ....................................................... 235
Upper ........................................................ 188
Description and Operation............................. 236
Crankshaft Pulley........................................ 189
System Component Layout-1.8T Inlet and
Engine Mounting - RH................................. 190 Exhaust System .......................................... 236
Engine Mounting Lower Tie Rod ................. 191 System Component Layout-1.8VCT Inlet
1.8VCT Camshaft Front Oil Seal - and Exhaust System .................................... 242
Exhaust ...................................................... 191 Description-1.8T Inlet and Exhuast
1.8VCT Camshaft Front Oil Seal - System ....................................................... 247
Inlet ........................................................... 192 Description-1.8VCT Inlet and Exhuast
1.8VCT Camshaft Drive Belt (New) ............ 192 System ....................................................... 248
1.8VCT Camshaft Phaser Unit..................... 195 Operation-1.8T Inlet and Exhuast
1.8VCT Engine and Manual System ....................................................... 249
Transmission .............................................. 196 Operation-1.8VCT Inlet and Exhaust
1.8VCT Engine and Automatic System ....................................................... 250
Transmission .............................................. 200 Service Procedures......................................... 251
1.8VCT Solenoid - Exhaust Camshaft........... 205 Air Cleaner ................................................ 251
2 Version 2.0
Contents
Element - Air Cleaner................................. 252 Solenoid - Boost Control -
Tail Pipe and Silencer .................................. 252 Turbocharger ............................................. 322
Intermediate Pipe ....................................... 253 Fuel Rail ..................................................... 322
Front Pipe - Turbocharger........................... 254 Injectors .................................................... 323
Heat Shield - Alternator.............................. 255 Charcoal Canister ...................................... 324
Heat Shield - Rear Silencer.......................... 256 Purge Control Valve ................................... 324
Heat Shield - Exhaust Pipe and Fuel Pipe Assembly - Body Underfloor Fuel
Tank........................................................... 256 Lines .......................................................... 325
Electric Throttle - Includes Tuning ............... 257 Tank - Fuel ................................................. 326
Engine Fuel & Management System................258 Fuel Pump .................................................. 328
Specifications ................................................. 258 Fuel System - Depressurise ......................... 329
Torque ....................................................... 258 Fuel System - Pressure Test......................... 330
Description and Operation-1.8T ..................... 259 Tank-Drain & Refill ..................................... 331
System Component Layout ......................... 259 Fuel Filter................................................... 331
Control Diagram-1.8T ................................ 261 Filler Neck ................................................. 332
Description ................................................ 264 Switch - Inertia - Fuel Cut Off ..................... 333
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Operation .................................................. 275 Special Tools .................................................. 334
Cruise Control-1.8T ................................... 288 Engine Electrical System ..................................335
Description and Operation-1.8 VCT ............... 289 Specifications ................................................. 335
System Component Layout-1.8VCT ............ 289 Torque ....................................................... 335
Control Diagram-1.8 VCT .......................... 291 Description and Operation............................. 336
Description ................................................ 293 Component Layout..................................... 336
Operation .................................................. 302 Control Diagram ........................................ 337
Cruise Control-1.8VCT .............................. 314 Description ................................................ 338
Service Procedures......................................... 315 Operation .................................................. 340
Spark Plugs................................................. 315 Service Procedures......................................... 341
Ignition Coils.............................................. 315 Belt - PAS Pump ......................................... 341
Engine Control Module (ECM) .................... 316 Alternator.................................................. 341
Sensor - Engine Coolant Temperature Bracket - Alternator - Upper ...................... 342
(ECT) ........................................................ 316 Bracket - Alternator - Lower ...................... 343
Switch - Oil Pressure .................................. 317 Drive Belt .................................................. 344
Sensor - Crankshaft Position (CKP)............. 317 Starter Motor ............................................ 344
Sensor - camshaft position (CMP) - Battery Tray and Support Bracket................ 345
VCT .......................................................... 318 Tensioner - Alternator Drive Belt................ 346
Sensor - inlet camshaft position (CMP) -
VCT .......................................................... 318 Transmission .................................... 347
Sensor - Exhaust Camshaft Position (CMP) Shift Lock Control-AT.......................................347
- VCT ........................................................ 319
Specifications ................................................. 347
Sensor - temperature and manifold absolute
pressure (TMAP) ........................................ 319 Torque ....................................................... 347
Sensor - manifold absolute pressure Description and Operation............................. 348
(MAP) ........................................................ 320 Description ................................................ 348
Sensor - Knock (KS) ................................... 320 Service Procedures......................................... 349
Sensor - Heated Oxygen (HO2S) - Front - Knob–Selector Lever–Automatic................. 349
Turbocharger ............................................. 321 Rod/Cable
Sensor - Heated Oxygen (H02S) - Rear - Assembly–Selector–Automatic .................... 349
Turbocharger ............................................. 321 Lever–Gearshift Selector
Assembly–Automatic .................................. 350
Version 2.0 3
Contents
Shift Lock Control-MT......................................351 Oil Seal–Gear Change Rod ......................... 411
Specifications ................................................. 351 Lubrication System–Drain & Refill ............... 412
Torque ....................................................... 351 Manual Transmission Assembly.................... 412
Service Procedures......................................... 352 Lamp Switch–Reverse ................................. 416
Knob–Gear Lever–Manual........................... 352 Cover–Reverse Access–Reseal .................... 416
Remote Control–Gear Lubrication System–Manual
Change–Manual .......................................... 352 Transmission–Top up .................................. 417
Transmission-AT................................................353 Oil Seal–Differential–LH ............................. 417
Specifications ................................................. 353 Oil Seal–Differential–RH ............................. 418
Torque ....................................................... 353 Manual Transmission Dismantling ................ 418
Specifications.............................................. 354 Input Shaft Assembly................................... 420
Description and Operation............................. 356 Output Shaft Assembly ............................... 423
System Component Layout ......................... 356 Reverse Idler Gear ..................................... 425
System Control System............................... 361 Differential Assembly .................................. 426
Description ................................................ 364 Control Assembly....................................... 427
Operation .................................................. 370 Fittings and Release Mechanism................... 428
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Service Procedures......................................... 386 Special Tools .................................................. 430
Automatic transmission–Pressure Clutch .................................................................432
Test ........................................................... 386 Specifications ................................................. 432
Neutral start (inhibitor)–Switch .................. 386 Torque ....................................................... 432
Neutral Start (Inhibitor)–Switch–Check Specifications.............................................. 433
and Adjust.................................................. 388
Transmission and Converter ....................... 388
System Component Layout ......................... 434
Automatic Transmission Fluid–Drain and
Refill .......................................................... 389 Description ................................................ 437
Automatic Transmission–Top Up ................. 390 Operation .................................................. 439
Control Unit–Automatic Service Procedures......................................... 440
Transmission .............................................. 391 Clutch Assembly......................................... 440
Harness–Automatic Transmission................ 392 Clutch Release Bearing ............................... 442
Sensor–Speed Input .................................... 393 Clutch Master Cylinder (A)......................... 442
Sensor–Speed Output................................. 393 Clutch Master Cylinder (B) ......................... 443
Dipstick–Oil Level ...................................... 394 Clutch Slave Cylinder (A)............................ 444
Oil Seal–Differential–LH ............................. 394 Clutch Slave Cylinder (B) ............................ 445
Oil Seal–Differential–RH ............................. 395 Clutch System Bleeding............................... 445
Torque Converter ...................................... 396 Special Tools .................................................. 446
Side Cover ................................................. 397
HVAC System.................................. 447
Oil Seal–Oil Pump ...................................... 398
Special Tools .................................................. 399 HVAC Structure ................................................447
Transmission-MT ...............................................400 Specifications ................................................. 447
Specifications ................................................. 400 Torque ....................................................... 447
Torque ....................................................... 400 Specifications.............................................. 448
Specifications.............................................. 401 Description and Operation............................. 449
Description and Operation............................. 402 System Component Layout ......................... 449
System Component Layout ......................... 402 Description ................................................ 451
Description ................................................ 409 Operation .................................................. 466
Operation .................................................. 410 Service Procedures......................................... 470
4 Version 2.0
Contents
Refrigerant Recovery, Recycling and Left Blend Flap - Servo Motor ..................... 509
Recharging ................................................. 470 Heater Coolant Temperature Sensor........... 510
If Recharging is Completed Right Blend Flap - Servo Motor ................... 510
Successfully/Unsuccessfully: ......................... 472
Fresh Recirculated Air Flap - Servo
Compressor............................................... 472 Motor ........................................................ 511
Evaporator ................................................. 473 Distribution Flap - Servo Mmotor .............. 511
Thermostatic Expansion Valve ..................... 475
Condenser ................................................. 475 Steering System .............................. 513
Drier Desiccant Bag ................................... 477 Front Wheel Steering .......................................513
Pressure Sensor - Air Conditioning ............. 478 Specifications ................................................. 513
Hose - Compressor to Condenser .............. 478 Torque ....................................................... 513
A/C Pipe - Evaporator to Compressor Specifications.............................................. 514
A-Evaporator to Connection....................... 479 Description and Operation............................. 515
A/C Pipe - Evaporator to Compressor B - System Component Layout ......................... 515
Compressor to Connection ........................ 480
Description ................................................ 518
A/C Pipe - Condenser to Evaporator A -
Condenser to Connection .......................... 480 Operation .................................................. 520
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A/C Pipe - Condenser to Evaporator B - Service Procedures......................................... 524
Connection to Evaporator .......................... 481 Pressure Sensor.......................................... 524
Filter Housing - Fresh Air Intake.................. 481 Power Assisted Steering System - Pressure
Fresh Air Filter ........................................... 482 Test ........................................................... 524
Heater Assembly ........................................ 482 Power Assisted Steering System
Bleeding ..................................................... 525
Blower Assembly........................................ 483
Power Assisted Steering Pump .................... 526
Heater Core .............................................. 484
PAS Pump Tensioner................................... 527
Power Controller ....................................... 485
Power Assisted Steering Rack ..................... 527
HVAC-ETC.........................................................486
Track Rod Ball Joint .................................... 529
Specifications ................................................. 486
Pipe - PAS Pump to Steering Rack ............... 530
Torque ....................................................... 486
Pipe - Steering Rack To Oil Cooler.............. 531
Oil Cooler - Steering .................................. 532
Special Tools .................................................. 533
System Control Diagram............................. 488
Steering Wheel and Column ...........................534
Description ................................................ 490
Specifications ................................................. 534
Torque ....................................................... 534
Control Assembly ...................................... 492
HVAC-ATC ........................................................493
Specifications ................................................. 493
Description ................................................ 537
Torque ....................................................... 493
Steering Wheel Alignment -
System Component Layout ......................... 494 Adjustment ................................................ 538
System Control Diagram............................. 496 Switch - Cruise Control.............................. 538
Description ................................................ 499 Steering Column Cover .............................. 539
Operation .................................................. 504 Steering Wheel .......................................... 540
Service Procedures......................................... 507 Steering Column ........................................ 541
Control Assembly ...................................... 507 Switch Assembly - Steering Column ............ 542
Evaporator Temperature Sensor.................. 508
Solar Light Sensor....................................... 508
Suspension System.......................... 543
Ambient Temperature Sensor-ATC.............. 509 Wheel Alignment ..............................................543
Version 2.0 5
Contents
Specifications ................................................. 543 Tyres and Wheels ..............................................587
Torque ....................................................... 543 Specifications ................................................. 587
Specifications.............................................. 544 Torque ....................................................... 587
Service Procedures......................................... 545 Specifications.............................................. 588
Wheel Alignment ....................................... 545 Service Procedures......................................... 589
Front Suspension ...............................................546 Wheel........................................................ 589
Specifications ................................................. 546
Brake System................................... 591
Torque ....................................................... 546
Specifications.............................................. 547 Brake ..................................................................591
Description and Operation............................. 548 Specifications ................................................. 591
System Component Layout ......................... 548 Torque ....................................................... 591
Description ................................................ 551 Description and Operation............................. 592
Service Procedures......................................... 553 System Component Layout ......................... 592
Lower Arm-Front....................................... 553 Description ................................................ 598
Outer Ball Joint Boot-Front Lower Operation .................................................. 602
Arm........................................................... 554 Service Procedures......................................... 608
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Bush and Bracket-Front Lower Arm ............ 555 Brake Pad-Front ......................................... 608
Damper-Front ............................................ 556 Brake Disc-Front ........................................ 609
Subframe-Front .......................................... 558 Caliper Housing - Front .............................. 610
Brace-Front Subframe................................. 560 Brake Pad-Rear........................................... 611
Bush-Front Subframe .................................. 560 Brake Disc-Rear ......................................... 612
Anti Roll Bar-Front ..................................... 561 Backplate-Rear Brake Disc .......................... 613
Mounting Rubbers-Anti Roll Bar-Set ............ 563 Brake Shoe-Rear......................................... 613
Link-Anti Roll Bar....................................... 564 Caliper Housing-Rear ................................. 614
Hub-Front.................................................. 564 Thickness and Run-Out Check-Rear Brake
Bearings-Front Hub .................................... 566 Disc ........................................................... 615
Special Tools .................................................. 568 Thickness and Run-Out Check-Front Brake
Disc ........................................................... 616
Rear Suspension ................................................571
Pedal Box-Automatic Transmission .............. 617
Specifications ................................................. 571
Pedal Box-Manual Transmission ................... 618
Torque ....................................................... 571
Vacuum Servo-Brake................................... 620
Rear Suspension ......................................... 572
Switch-Brake .............................................. 621
Brake System Bleeding ................................ 622
Low Level Indicator Switch-Brake
Description ................................................ 576 Fluid .......................................................... 623
Service Procedures......................................... 578 Master Cylinder and Fluid Reservoir............ 623
Upper Arm-Rear ........................................ 578 Special Tools .................................................. 625
Bush Set-Rear-Upper Arm .......................... 579 Park Brake .........................................................626
Lower Arm-Rear ........................................ 580 Specifications ................................................. 626
Bush Set-Rear Lower Arm .......................... 581 Torque ....................................................... 626
Damper-Rear ............................................. 582 Description and Operation............................. 627
Spring-Rear Suspension............................... 582 System Component Layout ......................... 627
Anti-Roll Bar-Rear ...................................... 583 Description ................................................ 628
Rubbers-Anti-Roll Bar................................. 583 Service Procedures......................................... 629
Link-Anti Roll Bar....................................... 584 Cable-Handbrake........................................ 629
Hub Bearing-Rear ....................................... 584 Handbrake-Adjustment ............................... 630
Special Tools .................................................. 586
6 Version 2.0
Contents
Handbrake Lever ........................................ 631 Specifications ................................................. 662
Handbrake Front Cable............................... 632 Torque ....................................................... 662
Brake Module.....................................................634 Description and Operation............................. 663
Specifications ................................................. 634 System Component Layout ......................... 663
Torque ....................................................... 634 System Control Diagram............................. 666
Description and Operation............................. 635 Description ................................................ 667
System Component Layout ......................... 635 Operation .................................................. 669
Description ................................................ 637 Service Procedures......................................... 671
Service Procedures......................................... 640 Seat Complete - Passenger.......................... 671
ABS ........................................................... 640 Squab Foam - Passenger - Front .................. 672
Cover - Passenger Squab - Front ................. 672
Driveline/Axle.................................. 641
Cushion - Rear Seat.................................... 674
Drive Axle ..........................................................641 Cover - Cushion - Rear Seat ....................... 674
Specifications ................................................. 641 Squab - Rear Seat ....................................... 675
Torque ....................................................... 641 Cover - Squab - Rear Seat........................... 675
Description and Operation............................. 642 Striker - Squab - Rear Seat .......................... 676
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System Component Layout ......................... 642 Side Board Outer - Power Seat ................... 677
Description ................................................ 644 Lumbar support assembly - front seat........... 677
Operation .................................................. 645 Switch pack assembly - driver seat............... 678
Service Procedures......................................... 646 Cover - driver cushion - front ..................... 678
RH Shaft & Both Joints................................ 646 Seat complete - driver ................................ 679
LH Shaft & Both Joints ................................ 647 Foam - driver squab - front ......................... 680
Outer CV Joint........................................... 649 Cover - driver squab - front ........................ 681
Outer CV Joint Gaiter ................................ 649 Door Trim ..........................................................683
Inner Joint .................................................. 650 Service Procedures......................................... 683
Inner Joint Gaiter ....................................... 650 Plastic Sheet - Rear Door ........................... 683
Special Tools .................................................. 651 Trim Casing - Rear Door ............................ 683
Interior Fitting................................. 653 Plastic Sheet - Front Door .......................... 684
Trim Casing - Front Door ........................... 685
Instrument Panel and Console.........................653
Interior Trim and Paneling ...............................686
Specifications ................................................. 653
Specifications ................................................. 686
Torque ....................................................... 653
Torque ....................................................... 686
Switch - Cruise Control.............................. 654
Trim Finisher - 'A' Post - Upper - Each........... 687
Panel Assembly - Fascia Closing Panel
Driver Side................................................. 655 Trim Finisher - 'A' Post - Lower - Each........... 687
Wood Trim - Centre Console - Rear........... 655 Trim Finisher - 'BC' Post - Upper -
Each........................................................... 688
Glove Box Assembly................................... 656
Trim Finisher - 'BC' Post - Lower -
Fascia......................................................... 657
Each........................................................... 689
Ventilator - RH........................................... 659
Trim Finisher - 'D' Post - Upper - Each -
Console Assembly ...................................... 659 Saloon........................................................ 689
Centre Bezel Assembly ............................... 660 Trim Finisher - 'D' Post - Lower - Each -
Panel Assembly - Steering Column Lower Saloon........................................................ 690
Cover - Base .............................................. 661 Handle - Grab - Each .................................. 690
Ventilator - LH ........................................... 661 Headlining - Sunshine/Sliding Roof -
Seats ...................................................................662 Saloon........................................................ 691
Carpet - Main Floor.................................... 693
Version 2.0 7
Contents
Parcel Tray - Rear - Saloon .......................... 694 Description and Operation............................. 720
Parcel Tray - Rear - Sun Blind Fitted ............ 694 System Component Layout ......................... 720
Spectacles Box - Driver .............................. 696 System Control System............................... 721
Trim Casing - Luggage Compartment - Description ................................................ 722
Sill ............................................................. 696 Operation .................................................. 723
Trim Finisher - Luggage Service Procedures......................................... 724
Compartment ............................................ 697
Sun/sliding Roof Assembly........................... 724
Exterior Fitting................................ 699 Glass Panel - Sun/Sliding Roof...................... 724
Fixed Windows ..................................................699 Sunshade Assembly - Sun/Sliding Roof........... 725
Service Procedures......................................... 699 Wipers and Washer ..........................................726
Glass - Rear Quarter Light.......................... 699 Specifications ................................................. 726
Windscreen ............................................... 699 Torque ....................................................... 726
Backlight .................................................... 700 Description and Operation............................. 727
Bumpers, Fascias and Grille .............................701 System Component Layout ......................... 727
Specifications ................................................. 701 System Control Diagram............................. 729
Description ................................................ 730
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Torque ....................................................... 701
Service Procedures......................................... 702 Operation .................................................. 732
Bumper Assembly - Front ........................... 702 Service Procedures......................................... 735
Bumper Assembly - Rear ........................... 703 Arm - Wiper - Each.................................... 735
Bumper Assembly - Rear - With Park Motor and Linkage - Wiper......................... 735
Distance Control Fitted .............................. 704 Blade - Wiper - Each .................................. 736
Exterior Trim and Paneling ..............................705 Reservoir - Washer .................................... 736
Service Procedures......................................... 705 Pump - Washer .......................................... 737
Undertray - Assembly ................................. 705 Sensor - Rain.............................................. 737
Liner - Rear Wheel Arch - Each .................. 705
Lighting Systems ............................. 739
Plenum - Air Intake..................................... 706
Liner - Front Wheel Arch - Front - Lighting...............................................................739
Each........................................................... 707 Description and Operation............................. 739
Mirrors................................................................708 System Component Layout ......................... 739
Specifications ................................................. 708 System Control Diagram............................. 740
Torque ....................................................... 708 Description ................................................ 741
Description and Operation............................. 709 Operation .................................................. 743
System Component Layout ......................... 709 Service Procedures......................................... 745
System Control Diagram............................. 710 Main Light Switch (MLS).............................. 745
Description ................................................ 711 Lamp Assembly - CHMSL............................ 745
Operation .................................................. 712 Lamp Assembly - Interior Courtesy -
System Component Layout ......................... 713 Rear........................................................... 746
System Control Diagram............................. 714 Lamp Assembly - Interior Courtesy -
Front ......................................................... 746
Description ................................................ 715
Lamps .................................................................747
Operation .................................................. 717
Mirror - Exterior - Electric.......................... 718
Mirror - Interior - Dipping .......................... 718
Description ................................................ 749
Roof.....................................................................719
Operation .................................................. 751
Specifications ................................................. 719
Torque ....................................................... 719
8 Version 2.0
Contents
Bulb - Directional - Indicator....................... 756 Glass/Glass Cassette Unit - Rear Door -
Bulb - Reverse Lamp- Saloon....................... 756 Adjust ........................................................ 784
Bulb - Number Plate Lamp .......................... 757 Glass - Rear Door - Each ............................ 785
Bulb - Rear Fog Lamp ................................. 757 Switch - Electric Window Lift - Rear Door
- Each ........................................................ 786
Bulb - Rear DI ............................................ 758
Motor and Control Unit - Rear Door -
Bulb - Dip Beam ......................................... 758 Each........................................................... 787
Cover Assembly- Front Fog Lamp ............... 759 Release Handle - Interior - Rear Door -
Lamp Assembly - Front Fog......................... 759 Each........................................................... 788
Headlamps - Dip Beam, High Beam ............. 760 Trim Casing - Front Door ........................... 788
Headlamp Assembly.................................... 760 Trim Casing - Rear Door ............................ 789
Bulb - Front Directional Indicator................ 761 Switch Pack - Electric Window Lift Driver
Bulb - Side Lamp......................................... 761 Door ......................................................... 790
Lamp Assembly - Tail .................................. 762 Rubber/Felt - Glass Channel - Front Door -
Each........................................................... 790
Bulb - Main Beam ....................................... 762
Seal - Waist Inner - Front Door -
Body Systems .................................. 763 Each........................................................... 791
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Seal - Waist Outer - Front Door -
Doors ..................................................................763 Each........................................................... 792
Specifications ................................................. 763 Glass/Glass Cassette Unit - Front Door -
Torque ....................................................... 763 Adjust ........................................................ 792
Description and Operation............................. 764 Glass - Front Door - Each ........................... 793
System Component Layout ........................ 764 Motor and Control Unit - Front Door -
System Control Diagram............................. 765 Each........................................................... 794
Description ................................................ 766 Release Handle - Interior - Front
Door ......................................................... 795
Operation .................................................. 772
Switch - Electric Window Lift - Front Door
Service Procedures......................................... 773 - Passenger................................................. 795
Handle - Outside - Front Door ................... 773 Front Closures ...................................................796
Door Assembly - Front............................... 773 Specifications ................................................. 796
Hinge - Front Door - Upper........................ 774 Torque ....................................................... 796
Hinge - Front Door - Lower ....................... 775 Service Procedures......................................... 797
Door - Front - Align on Hinges ................... 775 Fender - Front - Each.................................. 797
Private Lock - Front Door .......................... 776 Member Front End Panel ............................ 798
Latch - Front Door..................................... 776 Bonnet – Alignment – Check and
Door - Front - Adjust on Striker ................. 777 Adjust ........................................................ 799
Handle - Outside - Rear Door .................... 778 Bonnet....................................................... 800
Door Assembly - Rear ................................ 778 Safety Catch – Bonnet ................................ 801
Hinge - Rear Door - Upper......................... 779 Lock – Bonnet............................................ 801
Hinge - Rear Door - Lower......................... 780 Control Cables Assembly – Bonnet ............. 802
Door - Rear - Align on Hinges .................... 780 Rear Closures.....................................................803
Latch - Rear Door ...................................... 781 Specifications ................................................. 803
Door - Rear - Adjust on Striker .................. 781 Torque ....................................................... 803
Division Bar - Quarter Light - Rear ............. 782 Service Procedures......................................... 804
Rubber/Felt - Glass Channel - Rear Door - Solenoid/Motor - Fuel Filler Flap
Each........................................................... 783 Release ...................................................... 804
Seal - Waist Inner - Rear Door - Each........... 783 Boot Lid..................................................... 804
Seal - Waist Outer - Rear Door - Boot Lid – Align on Hinges ......................... 805
Each........................................................... 784 Boot Lid – Align on Striker ......................... 806
Version 2.0 9
Contents
Trim Casing - Boot Lid................................ 806 Corrosion Prevention ................................. 862
Latch - Boot Lid ......................................... 807 Diagnostic...................................................... 868
Horns ..................................................................808 Water Leaks............................................... 868
Specifications ................................................. 808 Service Procedures......................................... 869
Torque ....................................................... 808 Front End Panel .......................................... 870
Service Procedures......................................... 809 Door Panel ................................................ 872
Horn - each................................................ 809 Rear Floor Panel......................................... 873
Body Control Module........................................810 Roof Panel ................................................. 874
Specifications ................................................. 810 Bodyside Panel ........................................... 876
Torque ....................................................... 810 Front Floor Panel ....................................... 878
Description and Operation............................. 811 Wheel Arch Panel ...................................... 879
Body Control Module (BCM) Component
Location..................................................... 811 Safety and Restraints ...................... 881
Body Control Module (BCM) Component Vehicle Access....................................................881
Location..................................................... 812 Description and Operation............................. 881
Description ................................................ 814 Alarm and Locking System Component
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Operation .................................................. 816 Layout........................................................ 881
Service Procedures......................................... 817 Alarm and Locking System Control
Body Control Module (BCM) ...................... 817 Diagram ..................................................... 882
Immobilisation System Control
Body Repair ..................................... 819 Diagram ..................................................... 884
Body Dimension ................................................819 Description ................................................ 885
Service Procedures......................................... 819 Seat Belts ...........................................................889
Basic Information........................................ 819 Specifications ................................................. 889
Floor Information........................................... 820 Torque ....................................................... 889
Front End Information .................................... 821 Description and Operation............................. 890
Side Information............................................. 822 System Component Layout ......................... 890
Point to Point Dimensional System Control Diagram............................. 893
Information ................................................ 823 Description ................................................ 895
Side and Roof Information .............................. 824 Operation .................................................. 903
Internal Information ....................................... 825 Service Procedures......................................... 905
Front End Information .................................... 826 Adjustable Mounting - Seat Belt - BC Pillar
Rear End Information ..................................... 827 - Each ........................................................ 905
Under Body Information................................. 828 Seat Belt Assembly - Front - Each ................ 905
Gap Information ......................................... 829 Supplemental Inatable Restraints....................906
Side Information ......................................... 829 Specifications ................................................. 906
Front End Information ................................ 831 Torque ....................................................... 906
Rear End Information.................................. 832 Service Procedures......................................... 907
Fuel Flap Information .................................. 833 Airbag - Fascia - Passenger .......................... 907
Paint and Coatings ............................................834 Airbag - Steering Wheel - Driver................. 908
Description and Operation............................. 834 SRS Electronic Control Unit SRS ................ 908
General...................................................... 834 Curtain Airbag - Head ................................ 909

Collision Repair .................................................837 Park Assistant System ......................................910
Description and Operation............................. 837 Description and Operation............................. 910
General Welding Precautions ...................... 837 System Component Layout ......................... 910
Body Sealing ............................................... 842 System Control Diagram............................. 911
Description ................................................ 912
10 Version 2.0
Contents
Operation .................................................. 913
Control Unit (ECU) - PDC ......................... 914
................................................................. 914
Information and
Entertainment ................................. 915
Entertainment and Navigation ........................915
ICE Component Layout .............................. 915
ICE -Control Diagram ................................ 916
IN CAR ENTERTAINMENT
ICE -Description......................................... 917
IN CAR ENTERTAINMENT
(ICE)-Operation......................................... 921
Navigation System Component
Layout........................................................ 922
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Navigation System Control Diagram............ 923
Navigation System-Description.................... 924
Navigation System - Operation.................... 926
Woofer - Rear Door .................................. 927
Woofer - Front Door ................................. 927
Speaker - Tweeter - Front ........................... 928
Displays and Gages ............................................929
Description ................................................ 932
Operation .................................................. 941
Instrument Pack ......................................... 942
Glossary List ......................................................943
Version 2.0 11
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General Information
General Information Health Protection Precautions
General Precautions The following precautions should be observed at all times.
Dangerous Substances
• Wear protective clothing, including impervious gloves
Modern vehicles contain many materials and liquids which if not where practicable.
handled with care can be hazardous to both personal health • Avoid prolonged and repeated contact with oils,
and the environment. particularly used engine oils.
Warning: Many liquids and other substances used in • Do not put oily rags in pockets.
vehicles are poisonous and should under no circumstances • Avoid contaminating clothes (particularly those next to
be consumed and should, as far as possible, be kept the skin) with oil.
from contact with the skin. These liquids and substances
• Overalls must be cleaned regularly. Discard heavily soiled
include acid, antifreeze, brake fluid, fuel, windscreen
clothing and oil impregnated footwear.
washer additives, lubricants, refrigerants and various
adhesives. • First aid treatment should be obtained immediately for
open cuts and wounds.
Warning: Always read carefully the instructions printed
• Apply barrier creams before each work period to help
on labels or stamped on components and obey them
prevent lubricating oil from contaminating the skin.
implicitly. Such instructions are included for reasons of
your health and personal safety. Never disregard them. • Wash with soap and water to ensure all oil is removed
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(proprietary skin cleansers and nail brushes will help).
Synthetic Rubber
• Use moisturisers after cleaning; preparations containing
Many O-rings, seals, hoses, flexible pipes and other similar lanolin help replace the skin's natural oils which have been
items which appear to be natural rubber, are in fact, made removed.
of synthetic materials called Fluoroelastomers. Under normal
• Do not use petrol/gasoline, kerosene, diesel fuel, oil,
operating conditions this material is safe and does not present
thinners or solvents for cleaning skin.
a health hazard. However, if the material is damaged by fire
or excessive heating, it can break down and produce highly • Where practicable, degrease components prior to
corrosive Hydrofluoric acid. handling.
• If skin disorders develop, obtain medical advice without
Contact with Hydrofluoric acid can cause serious burns on
delay.
contact with skin. If skin contact does occur
• Wear eye protection (e.g. goggles or face shield) if there
• Remove any contaminated clothing immediately. is a risk of eye contamination. Eye wash facilities should
• Irrigate affected area of skin with a copious amount of be provided in close vicinity to the work area.
cold water or limewater for 15 to 60 minutes.
• Obtain 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.
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.
Version 2.0 1
General Information
Safety Instructions • Observe absolute cleanliness when working with
Jacking hydraulic components.
Caution: It is best to use the lift when working under the Cooling System Caps and Plugs
vehicle. Be sure to hold the wheels with chocks and apply expansion tank caps and coolant drain or bleed screws when
parking brake. the engine is hot, especially if it is overheated. To avoid
Always use the recommended jacking points. the possibility of scalding, allow the engine to cool before
attempting removal.
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 parking brake 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
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on the work bench area. Always keep a clean and tidy work
area.
Brake Shoes and Pads
Always fit the correct grade and specification of brake linings.
When renewing brake pads and brake shoes, always replace as
complete axle sets.
Brake Hydraulics
Observe the following recommendations when working on the
brake system:
• Ensure that hoses run in a natural curve and are not
kinked or twisted.
• Ensure that hoses run in a natural curve and are not
kinked or twisted.
• Fit brake pipes securely in their retaining clips and ensure
that the pipe cannot contact a potential chafing point.
• Containers used for brake fluid must be kept absolutely
clean.
• Do not store 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.
• Do not allow brake fluid to be contaminated with mineral
oil, or put new brake fluid in a container which has
previously contained mineral oil.
• Do not re-use brake fluid removed from the system.
• Always use clean brake fluid or a recommended
alternative to clean hydraulic components.
• After disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to prevent
the ingress of dirt.
• Only use the correct brake fittings with compatible
threads.
Version 2.0 2
General Information
Environmental Precautions Discharges to Water
General Oil, petrol, solvent, acids, hydraulic oil, antifreeze and other
This section provides general information which can help to such substances should never be poured down the drain and
reduce the environmental impacts from the activities carried every precaution must be taken to prevent spillage reaching
out in workshops. the drains.
Emissions to Air Handling of such materials must take place well away from the
Many of the activities that are carried out in workshops emit drains and preferably in an area with a kerb or wall around it, to
gases and fumes which contribute to global warming, depletion prevent discharge into the drain. If a spillage occurs it should
of the ozone layer and/or the formation of photochemical be soaked up immediately. Having a spill kit available will make
smog at ground level. By considering how the workshop this easier.
activities are carried out, these gases and fumes can be Checklist
minimised, thus reducing the impact on the environment.
Always adhere to the following disposal and spillage prevention
Exhaust Fumes instructions.
Running car engines is an essential part of workshop activities • Never pour anything down a drain without first checking
and exhaust fumes need to be ventilated to atmosphere. that it is environmentally safe to do so, and that it does
However, the amount of time engines are running and the not contravene any local regulations.
position of the vehicle should be carefully considered at all
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• Store liquids in a walled area;
times, to reduce the release of poisonous gases and minimise
• Protect bulk storage tanks from vandalism by locking the
the inconvenience to people living nearby.
valves;
Solvents
• Transfer liquids from one container to another in an area
Some of the cleaning agents used are solvent based and will away from open drains;
evaporate to atmosphere if used carelessly, or if cans are left
• Ensure lids are replaced securely on containers;
unsealed. All solvent containers should be firmly closed when
• Make sure that taps on liquid containers are secure and
not needed and solvent should be used sparingly. Suitable
cannot be accidentally turned on;
alternative materials may be available to replace some of the
commonly used solvents. Similarly, many paints are solvent • Have spill kits available near to points of storage and
based and the spray should be minimised to reduce solvent handling of liquids.
emissions. Spill Kits
Refrigerant Special materials are available to absorb a number of different
Discharge and replacement of these materials from air substances. They can be in granular form, ready to use and
conditioning units should only be carried out using the correct bought in convenient containers for storage. Disposal of used
equipment. spill-absorbing material is dealt with in 'Waste Management'
section.
Engines:
Land Contamination
Always adhere to the following.
Oils, fuels and solvents etc. can contaminate any soil that
• Don't leave engines running unnecessarily; they are allowed to contact. Such materials should never be
• Minimise testing times and check where the exhaust disposed of by pouring onto soil and every precaution must be
fumes are being blown. taken to prevent spillage reaching soil. Waste materials stored
Materials: on open ground could also leak, or have polluting substances
washed off them that would contaminate the land. Always
• Keep lids on containers of solvents;
store these materials in suitable robust containers.
• Only use the minimum quantity;
Checklist
• Consider alternative materials;
Always adhere to the following.
• Minimise over-spray when painting.
Gases: • Don't pour or spill anything onto the soil or bare ground;
• Use the correct equipment for collecting refrigerants; • Don't store waste materials on bare ground, see 'Spillage
prevention' list.
• Don't burn rubbish on site.
Version 2.0 3
General Information
Local Issues Dispose of waste in accordance with the following guidelines.
A number of environmental issues will be of particular concern • Fuel, hydraulic fluid, anti-freeze and oil: keep separate
to residents and other neighbours close to the site. The and dispose of to specialist contractor.
sensitivity of these issues will depend on the proximity of the • Refrigerant: collect in specialist equipment and reuse.
site and the layout and amount of activity carried on at the site.
• Detergents: safe to pour down the foul drain if diluted.
Car alarm testing, panel beating, hammering and other such • Paint, thinners: keep separate and dispose of to specialist
noisy activities should, whenever possible, be carried out contractor.
indoors with doors and windows shut or as far away from
• Components: send back to supplier for refurbishment,
houses as possible.
or disassemble and reuse any suitable parts. Dispose of
Be sensitive to the time of day when these activities are carried the remainder in ordinary waste.
out and minimise the time of the noisy operation, particularly • Small parts: reuse any suitable parts, dispose of the
in the early morning and late evening. remainder in ordinary waste.
Another local concern will be the smell from the various • Metals: can be sold if kept separate from general waste.
materials used. Using less solvent, paint and petrol could help • Tyres: keep separate and dispose of to specialist
prevent this annoyance. contractor.
Local residents and other business users will also be concerned • Packaging: compact as much as possible and dispose of
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about traffic congestion, noise and exhaust fumes, be sensitive in ordinary waste.
to these concerns and try to minimise inconvenience from • asbestos material keep separate and dispose of to
deliveries, customers and servicing operations. specialist contractor.
Checklist • Oily and fuel wastes (e.g. rags, used spill kit material):
Always adhere to the following. keep separate and dispose of to specialist contractor.
• Air filters: keep separate and dispose of to specialist
• Identify where the neighbours who are likely to be
contractor.
affected are situated;
• Rubber/plastics: dispose of in ordinary waste.
• Minimise noise, smells and traffic nuisance;
• Hoses: dispose of in ordinary waste.
• Prevent litter by disposing of waste in the correct
manner; • Batteries: keep separate and dispose of to specialist
contractor.
• Have waste containers emptied regularly.
Waste Management • Airbags - explosives: keep separate and dispose of to
specialist contractor.
One of the major ways that pollution can be reduced is by the
• Electrical components: send back to supplier for
careful handling, storage and disposal of all waste materials that
refurbishment, or disassemble and reuse any suitable
occur on sites. This means that it is necessary to not only know
parts. Dispose of the remainder in ordinary waste.
what the waste materials are, but also to have the necessary
documentation and to know local regulations that apply. • Catalysts: can be sold if kept separate from general waste
• Used spill-absorbing material: keep separate and dispose
Handling and Storage of Waste
of to specialist contractor.
They should be stored in such a way as to prevent the escape
of the material to land, water or air.
They must also be segregated into different types of waste
e.g. oil, metals, batteries, used vehicle components. This will
prevent any reaction between different materials and assist in
disposal.
Disposal of Waste
Disposal of waste materials must only be to waste carriers who
are authorised to carry those particular waste materials and
have all the necessary documentation. The waste carrier is
responsible for ensuring that the waste is taken to the correct
disposal sites.
Version 2.0 4
General Information
General Fitting Instructions • Never inspect a component for wear or dimensional
Component Removal check unless it is absolutely clean; a slight smear of grease
can conceal an incipient failure.
Whenever possible, clean components and surrounding area
before removal. • When a component is to be checked dimensionally
against recommended values, use the appropriate
• Blank off openings exposed by component removal. measuring equipment (surface plates, micrometers,
• Immediately seal fuel, oil or hydraulic lines when dial gauges etc.). Ensure the measuring equipment is
apertures are exposed; use plastic caps or plugs to calibrated and in good serviceable condition.
prevent loss of fluid and ingress of dirt. • Reject a component if its dimensions are outside the
• Close the open ends of oilways exposed by component specified tolerances, or if it appears to be damaged.
removal with tapered hardwood plugs or conspicuous • A part may be refitted if its critical dimension is exactly
plastic plugs. to its tolerance limit and it appears to be in satisfactory
• Immediately a component is removed, place it in a condition. Use 'Plastigauge' for checking bearing surface
suitable container; use a separate container for each clearances.
component and its associated parts.
• Clean bench and provide marking materials, labels and
containers before dismantling a component.
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Dismantling
Observe scrupulous cleanliness when dismantling components,
particularly when brake, fuel or hydraulic system parts are
being worked on. A particle of dirt or a cloth fragment could
cause a serious malfunction if trapped in these systems.
• Blow out all tapped holes, crevices, oilways and fluid
passages with an air line. Ensure that any O-rings used
for sealing are correctly replaced or renewed, if disturbed
during the process.
• Use marking ink to identify mating parts and ensure
correct reassembly. Do not use a centre punch or
scriber to mark parts, they could initiate cracks or
distortion in marked components.
• Wire together mating parts where necessary to prevent
accidental interchange (e.g. roller bearing components).
• Attach labels to all parts which are to be renewed, and
to parts requiring further inspection before being passed
for reassembly; place these parts in separate containers
from those containing parts for rebuild.
• Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its correct
replacement has been obtained.
Cleaning Components
Always use the recommended cleaning agent or equivalent.
Ensure that adequate ventilation is provided when volatile
degreasing agents are being used. Do not use degreasing
equipment for components containing items which could be
damaged by the use of this process.
General Inspection
All components should be inspected for wear or damage
before being reassembled.
Version 2.0 5
General Information
Ball and Roller Bearings • In the case of grease lubricated bearings (e.g. hub
General bearings) fill the space between bearing and outer seal
with the recommended grade of grease before fitting
When removing and installing bearings, ensure that the
seal.
following practices are observed to ensure component
serviceability. • Always mark components of separable bearings (e.g.
taper roller bearings) when dismantling, to ensure
• Remove all traces of lubricant from bearing under
correct reassembly. Never fit new rollers in a used outer
inspection by cleaning with a suitable degreasant;
ring; always fit a complete new bearing assembly.
maintain absolute cleanliness throughout operations.
• Hold inner race of bearing between finger and thumb of
one hand and spin outer race to check that it revolves
absolutely smoothly. Repeat, holding outer race and
spinning inner race.
• Rotate outer ring gently with a reciprocating motion,
while holding inner ring; feel for any check or obstruction
to rotation. Reject bearing if action is not perfectly
smooth.
• Lubricate bearing with generous amounts of lubricant
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appropriate to installation.
• Inspect shaft and bearing housing for discoloration or
other markings which indicate movement between
bearing and housing.
• Ensure that shaft and housing are clean and free from
burrs before fitting bearing.
• If one bearing of a pair shows an imperfection, it
is advisable to replace both with new bearings; an
exception could be if the faulty bearing had covered a
low mileage, and it can be established that damage is
confined to only one bearing.
• Never refit a ball or roller bearing without first ensuring
that it is in a fully serviceable condition.
• When hub bearings are removed or displaced, new
bearings must be fitted; do not attempt to refit the old
hub bearings.
• When fitting a bearing to a shaft, only apply force to the
inner ring of the bearing. When fitting a bearing into a
housing, only apply force to the outer ring of the bearing.
Version 2.0 6
General Information
Oil Seals
General
Always renew oil seals which have been removed from their
working location (whether as an individual component or
as part of an assembly). NEVER use a seal which has been
improperly stored or handled, such as hung on a hook or nail.
• Carefully examine seal before fitting to ensure that it is
clean and undamaged.
• Ensure the surface on which the new seal is to run is
free of burrs or scratches. Renew the component if the
original sealing surface cannot be completely restored.
• Protect the seal from any surface which it has to pass
• Use the recommended service tool to fit an oil seal. If
when being fitted. Use a protective sleeve or tape to
the correct service tool is not available, use a suitable
cover the relevant surface.
tube approximately 0.4 mm (0.015 in.) smaller than
• Lubricate the sealing lips with a recommended lubricant the outside diameter of the seal. Use a hammer VERY
before use to prevent damage during initial use. On dual GENTLY on drift if a suitable press is not available.
lipped seals, smear the area between the lips with grease.
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• Use the recommended service tool to fit an oil seal. If
• If a seal spring is provided, ensure that it is fitted correctly. the correct service tool is not available, use a suitable
Place lip of seal towards fluid to be sealed and slide into tube approximately 0.4 mm (0.015 in.) smaller than
position on shaft. Use fitting sleeve where possible to the outside diameter of the seal. Use a hammer VERY
protect sealing lip from damage by sharp corners, threads GENTLY on drift if a suitable press is not available.
or splines. If a fitting sleeve is not available, use plastic
tube or tape to prevent damage to the sealing lip.
• Grease outside diameter of seal, place square to housing

recess and press into position using great care, and if
possible a 'bell piece' to ensure that seal is not tilted. In
some cases it may be preferable to fit seal to housing
before fitting to shaft. Never let weight of unsupported
shaft rest in seal.
Version 2.0 7
General Information
Joints and Joint Faces Locking Devices
General General
Fit joints dry unless specified otherwise. Always replace locking devices with one of the same design.
• Always use the correct gaskets as specified. Tab Washers
• When sealing compound is used, apply in a thin uniform Always release locking tabs and fit new locking washers. Do
film to metal surfaces; take care to prevent sealing not re-use locking tabs.
compound from entering oilways, pipes or blind tapped Locking Nuts
holes.
Always use a backing spanner when loosening or tightening
• If gaskets and/or sealing compound is recommended for
locking nuts, brake and fuel pipe unions.
use; remove all traces of old sealing compound prior to
reassembly. Do not use a tool which will damage the Roll Pins
joint faces and smooth out any scratches or burrs using Always fit new roll pins of an interference fit in the hole.
an oil stone. Circlips
• Prior to reassembly, blow through any pipes, channels or
Always fit new circlips of the correct size for the groove.
crevices with compressed air.
Keys and Keyways
Remove burrs from edges of keyways with a fine file and clean
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thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for refitting only
if indistinguishable from new, as any indentation may indicate
the onset of wear.
Split Pins
Always fit new split-pins of the correct size for the hole in the
bolt or stud.
Version 2.0 8
General Information
Screw Threads Fasteners Identification
General Bolt Identification
Metric threads to ISO standards are used.
Damaged nuts, bolts and screws must always be discarded.
Cleaning damaged threads with a die or tap impairs the
strength and fit of the threads and is not recommended.
Always ensure that replacement bolts are at least equal in
strength to those replaced.
Castellated nuts must not be loosened to accept a split-pin,
except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind threaded holes. The
hydraulic action on screwing in the bolt or stud could split the
housing. An ISO metric bolt or screw made of steel and larger than 6
mm in diameter can be identified by either of the symbols ISO
Always tighten a nut or bolt to the recommended torque
M or M embossed or indented on top of the bolt head.
figure. Damaged or corroded threads can affect the torque
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reading. In addition to marks identifying the manufacturer, the top of the
bolt head is also marked with symbols indicating the strength
To check or re-tighten a bolt or screw to a specified torque
grade, e.g. 8.8; 10.9; 12.9; 14.9. As an alternative, some bolts
figure, first loosen a quarter of a turn, then re-tighten to the
and screws have the M and strength grade symbol stamped on
correct torque figure.
the flats of the hexagon.
Oil thread lightly before tightening to ensure a free Encapsulated Bolts and Screws
running thread, except in the case of threads treated with
sealant/lubricant, and selflocking nuts.
Encapsulated bolts and screws have a microencapsulated

locking agent pre-applied to the thread. They are identified
by a coloured section which extends 360° around the thread.
The locking agent is released and activated by the assembly
process and is then chemically cured to provide the locking
action.
Unless a specific repair procedure states otherwise,
encapsulated bolts may be reused providing the threads are
undamaged and the following procedure is adopted:
• Remove loose adhesive from the bolt and housing
threads.
• Ensure threads are clean and free of oil and grease.
• Apply an approved locking agent.
Version 2.0 9
General Information
An encapsulated bolt may be replaced with a bolt of equivalent also marked and some have the metric symbol M on the flat
specification provided it is treated with an approved locking opposite the strength grade marking.
agent.
When tightening a slotted or castellated nut, never loosen it
Self-locking Bolts and Screws to insert a split pin except where recommended as part of an
adjustment. If difficulty is experienced, alternative washers or
nuts should be selected, or the washer thickness reduced.
Where bearing preload is involved, nuts should be tightened in
accordance with special instructions.
Self-locking Nuts
Self-locking bolts and screws, i.e. nylon patched or trilobular
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thread can be reused providing resistance can be felt when the
locking portion enters the female thread.
Nylon patched bolts and screws have a locking agent
pre-applied to the threads. They are identified by the presence
of a coloured section of thread which extends for up to 180°
Self-locking nuts, e.g. nylon insert or deferred thread nuts, can
around the thread.
be reused providing resistance can be felt when the locking
Trilobular bolts (i.e. Powerlok) have a special thread form portion of the nut passes over the thread of the bolt or stud.
which creates a slight interference with the thread of the hole
Where self-locking nuts have been removed, it is advisable to
or nut into which it is screwed.
replace them with new ones of the same type.
DO NOT reuse self-locking fasteners in critical locations (e.g.
Don't use non self-lock nuts in the area where self-lock nuts
engine bearings, flywheel). Always use the correct replacement
must be used.
self-locking nut, bolt or screw.
DO NOT fit non self-locking fasteners in applications where a
self-locking nut, bolt or screw is specified.
Nut Identification A
A nut with an ISO metric thread is marked on one face or on

one of the flats of the hexagon with the strength grade symbol
8, 12, or 14. Some nuts with a strength grade 4, 5 or 6 are
Version 2.0 10
General Information
Flexible Pipes and Hoses Hose Orientation and Connection
General
When removing and installing flexible hydraulic pipes and
hoses, ensure that the following practices are observed to
ensure component serviceability.
• Clean end fittings and the area surrounding them as
thoroughly as possible.
• Obtain appropriate plugs or caps before detaching hose
end fittings, so that the ports can be immediately covered
to prevent the ingress of dirt.
Clean hose externally and blow through with airline.
Examine carefully for cracks, separation of plies, security
of end fittings and external damage. Reject any faulty
Correct orientation of cooling hoses is important in ensuring
hoses.
that the hose does not become fatigued or damaged through
• When refitting a hose, ensure that no unnecessary bends contact with adjacent components. Where 'timing' marks (1)
are introduced, and that hose is not twisted before or are provided on the hose and corresponding connection, these
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during tightening of union nuts. must be used to ensure correct orientation. Hoses must be
• Fit a cap to seal a hydraulic union and a plug to its socket pushed fully onto their connection points. Usually, a moulded
after removal to prevent ingress of dirt. form (2) on the stub pipe provides a positive indicator.
• Absolute cleanliness must be observed with hydraulic Hose Clip

components at all times.
After any work on hydraulic systems, carefully inspect
for leaks underneath the vehicle while a second operator
applies maximum brake pressure to the brakes (engine
running) and operates the steering.
Fuel System Hoses
Markings (1) are usually provided on the hose to indicate the

correct clip position. If no markings are provided, position the
clip directly behind the retaining lip at the end of the stub as
shown. Worm drive clips should be oriented with the crimped
side of the drive housing (2) facing towards the end of the hose,
or the hose may become pinched between the clip and the stub
pipe retaining lip. Worm drive clips should be tightened to 3
All fuel hoses are made up of two laminations, an armoured Nm unless otherwise stated. Ensure that hose clips do not foul
rubber outer sleeve and an inner viton core. If any of the fuel adjacent components.
system hoses have been disconnected, it is imperative that the
Heat Protection
internal bore is inspected to ensure that the viton lining has
not become separated from the armoured outer sleeve. A Always ensure that heatshields and protective sheathing are
new hose must be fitted if separation is evident. in good condition. Replace if damage is evident. Particular
care must be taken when routing hoses close to hot engine
Cooling System Hoses
components, such as the exhaust manifold and the Exhaust Gas
The following precautions MUST be followed to ensure that Recirculation (EGR) pipe. Hoses will relax and deflect slightly
integrity of cooling hoses and their connections to system
components are maintained.
Version 2.0 11
General Information
when hot; ensure this movement is taken into account when Fuel Handling Precautions
routing and securing hoses. General
Fuel vapour is highly flammable and in confined spaces is
also explosive and toxic. The vapour is heavier than air
and will always fall to the lowest level. The vapour can be
easily distributed throughout a workshop by air currents;
consequently, even a small spillage of fuel is potentially very
dangerous.
The following information provides basic precautions which
must be observed if fuel is to be handled safely. It also
outlines other areas of risk which must not be ignored. This
information is issued for basic guidance only, if in doubt consult
your local Fire Officer.
Always have a fire extinguisher containing FOAM, CO2, GAS
or POWDER close at hand when handling or draining fuel or
when dismantling fuel systems. Fire extinguishers should also
be located in areas where fuel containers are stored.
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Always disconnect the vehicle battery before carrying out
dismantling or draining work on a fuel system.
Whenever fuel is being handled, drained or stored, or when
fuel systems are being dismantled, all forms of ignition must be
extinguished or removed; any lead lamps must be flameproof
and kept clear of spillage.
Warning: No one should be permitted to repair
components associated with fuel without first having
specialist training.
Warning: Do not remove fuel system components while
the vehicle is over a pit.
Fuel Tank Draining
Fuel tank draining should be carried out in accordance with
the procedure outlined in the FUEL DELIVERY section of this
manual and observing the following precautions
Warning: Do not remove fuel system components while
the vehicle is over a pit. Extraction or draining of fuel
must be carried out in a well ventilated area.
The capacity of containers must be more than adequate for
the amount of fuel to be extracted or drained. The container
should be clearly marked with its contents and placed in a safe
storage area which meets the requirements of local authority
regulations.
Fuel Tank Removal
When the fuel line is secured to the fuel tank outlet by a
spring steel clip, the clip must be released before the fuel line
is disconnected or the fuel tank is removed. This procedure
will avoid the possibility of fumes in the fuel tank being ignited
when the clip is released.
Version 2.0 12
General Information
As an added precaution, fuel tanks should have a 'FUEL Electrical Precautions
VAPOUR' warning label attached to them as soon as they are General
removed from the vehicle.
The following guidelines are intended to ensure the safety of
Fuel Tank Repairs the operator while preventing damage to the electrical and
No attempt should be made to repair a plastic fuel tank. If the electronic components fitted to the vehicle. Where necessary,
structure of the tank is damaged, a new tank must be fitted. specific precautions are detailed in the individual procedures of
this manual.
Body Repairs
Equipment
Plastic fuel pipes are particularly susceptible to heat, even
at relatively low temperature, and can be melted by heat Prior to commencing any test procedure on the vehicle ensure
conducted from some distance away. that the relevant test equipment is working correctly and any
harness or connectors are in good condition. It is particularly
When body repairs involve the use of heat, all fuel pipes which
important to check the condition of the lead and plugs of mains
run in the vicinity of the repair area must be removed, and the
operated equipment.
tank outlet plugged.
Polarity
Warning: If welding is to be carried out in the vicinity of
Never reverse connect the vehicle battery and always ensure
the fuel tank, the fuel system must be drained and the tank
the correct polarity when connecting test equipment.
removed before welding commences.
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High Voltage Circuits
Whenever disconnecting live HT circuits always use insulated
pliers and never allow the open end of the HT lead to contact
other components, particularly ECUs. Exercise caution when
measuring the voltage on the coil terminals while the engine is
running, high voltage spikes can occur on these terminals.
Connectors and Harnesses
The engine compartment of a vehicle is a particularly hostile
environment for electrical components and connectors:
• Always ensure electrically related items are dry and oil
free before disconnecting and connecting test equipment.
• Ensure disconnected multiplugs and sensors are
protected from being contaminated with oil, coolant
or other solutions. Contamination could impair
performance or result in catastrophic failure.
• Never force connectors apart using tools to prise apart
or by pulling on the wiring harness.
• Always ensure locking tabs are disengaged before
disconnection, and match orientation to enable correct
reconnection.
• Ensure that any protection (covers, insulation etc.) is
replaced if disturbed.
Having confirmed a component to be faulty:
• Switch off the ignition and disconnect the battery.
• Remove the component and support the disconnected
harness.
• When replacing the component keep oily hands away
from electrical connection areas and push connectors
home until any locking tabs fully engage.
Version 2.0 13
General Information
Battery Disconnection Supplementary Restraint System Precautions
Before disconnecting the battery, disable the alarm system and General Precautions
switch off all electrical equipment. The SRS system contains components which could be
potentially hazardous to the service engineer if not serviced
Caution: To prevent damage to electrical components,
and handled correctly. The following guidelines are intended
always disconnect the battery when working on the
to alert the service engineer to potential sources of danger
vehicle's electrical system. The ground lead must be
and emphasise the importance of ensuring the integrity ofSRS
disconnected first and reconnected last.
components fitted to the vehicle.
Caution: Always ensure that battery leads are routed
Warning: Always follow the 'SRS Precautions' and the
correctly and are not close to any potential chafing
correct procedures for working on SRS components.
points.
Persons working on SRS systems must be fully trained and
Battery Charging
have been issued with copies of the Safety guidelines.
Always ensure any battery charging area is well ventilated and
Warning: It is imperative that before any work
that every precaution is taken to avoid naked flames and sparks.
is undertaken on the SRS system the appropriate
Disciplines information is read thoroughly.
Remove the handset prior to making any connection or Warning: The airbag module contains sodium azide which
disconnection in the system to prevent electrical surges is poisonous and extremely flammable. Contact with
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caused by disconnecting ‘live' connections damaging electronic water, acid or heavy metals may produce harmful or
components. explosive compounds. Do not dismantle, incinerate or
Ensure hands and work surfaces are clean and free of grease, bring into contact with electricity, before the unit has
swarf, etc. Grease collects dirt which can cause electrical been deployed.
tracking (shortcircuits) or high resistance contacts. Warning: Always replace a seat belt assembly that has
When handling printed circuit boards, treat with care and hold withstood the strain of a severe vehicle impact, or if the
by the edges only; note that some electronic components are webbing shows signs of fraying.
susceptible to body static. Warning: Always disconnect the vehicle battery before
Connectors should never be subjected to forced removal or carrying out any electric welding on a vehicle fitted with
refit, especially inter-board connectors. Damaged contacts can an SRS system.
cause short-circuit and open-circuit fault conditions. Caution: Do not expose an airbag module or seat belt
Prior to commencing test, and periodically during a test, touch pre-tensioner to heat exceeding 85° C.
a good vehicle body earth to discharge static charge. Some It should be noted that these precautions are not restricted
electronic components are vulnerable to the static electricity to operations performed when servicing theSRS system,
that may be generated by the operator. the same care must be exercised when working on ancillary
Electrical Multiplugs Lubricate systems and components located in the vicinity of theSRS
components; these include, but are not limited to:
In order to prevent corrosion, Some multiplugs under bonnet
and carpet is wiped special lubricate in factory. If these is • Steering system steering wheel airbag, rotary coupler.
destroyed in maintaining, repair and replacing process, special • Front fascia passenger front airbag.
lubricate should be newly wiped
• Interior trimICS Head Curtain Airbags (‘A'-post trim,
‘B'-post upper trim, grab handles, headlining above front
doors ;SRS Electronic Control Unit (ECU) (beneath
centre console); side impact crash sensors (under carpet
beneath front seats)
• Seats side (thorax) airbags.
• Electrical system–SRS harnesses, link leads and
connectors.
Version 2.0 14
General Information
Making the System Safe • Never apply electrical power to an SRS component
Before working on, or in the vicinity ofSRS components, unless instructed to doSRS so as part of an approved
ensure the system is rendered safe by performing the following test procedure.
procedures: • Ensure the bolts are tightened to the correct torque.
Always use new fixingsSRS when replacing SRS
components.
• Ensure the ECU is always installed correctly.SRS
ECU.SRSECU There must not be any gap between the
ECU and the bracket to which it is mounted.SRSECU
An incorrectly mounted ECU could cause the system to
malfunction.
• Do not supply power to the ECU are connected.SRS
before all SRS componentsSRSECU before all SRS
components.
Caution: Ensure SRS components are not contaminated
with oil, grease, detergent or water.
Caution: Torque wrenches should be regularly checked for
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• Remove the handset from the docking station.
accuracy to ensure that all fixings are tightened to the
• Disconnect both battery leads, earth lead first.
correct torque.
• Wait 10 minutes forSRSECU the SRS ECU back-up
power circuit to discharge. Caution: Following seat belt pretensioner deployment,
the seat belts can still be used as conventional seat
TheSRS system uses energy reserve capacitors to keep the belts, but will need to be replaced as soon as possible to
system active in the event of electrical supply failure under re-establish full SRS protection.
crash conditions. It is necessary to allow the capacitor
sufficient time to discharge (10 minutes) in order to avoid the Caution: If the SRS component is to be replaced, the bar
risk of accidental deployment. code of the new unit must be recorded.
SRS Component Testing Precautions
Caution: Disconnect the battery before starting the SRS
operation. Disconnect the battery negative terminal first.
DO NOT disconnect the battery in the reverse order.
Installation
In order to ensure system integrity, it is essential that the
SRS system is regularly checked and maintainedSRS so that
it is ready for effective operation in the event of a collision.
Carefully inspect SRS components before installation.SRS
Do not install a part that shows signs of being dropped or
improperly handled, such as dents, cracks or deformation.
Warning: The integrity of the SRS system is critical for
safety reasons.
Ensure the following precautions are always adhered to:
TheSRS components are triggered using relatively low
• Never install used SRS components from another operating currents, always adhere to the following precautions:
vehicleSRS or attempt to repair anSRS component.
Warning: Do not use a multimeter or other general
• Never use the SRS parts without a clear
purpose test equipment on SRS system components
identificationSRS label.
or accidental deployment may occur. Only use the
• Never use an airbag orSRS ECU that has been dropped. recommended diagnostic equipment to diagnose system
• When repairing an SRS system only useSRS genuine new faults.
parts.
Version 2.0 15
General Information
Warning: Do not use electrical test equipment on the SRS Caution: Do not apply grease or cleaning solvents to seat
harness while it is connected to any of the SRS system belt pretensioner units, component failure could result.
components. It may cause accidental deployment and
personal injury.
Handling and Storage
Warning: Store the airbag module with the deployment

side uppermost. If it is stored deployment side down,
accidental deployment will propel the airbag module with
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Always comply with the following handling precautions. enough force to cause serious injury.
Warning: The SRS components are sensitive and Warning: Airbag modules and seat belt pre-tensioners are
potentially hazardous if not handled correctly; always classed as explosive devices. For overnight and longer
comply with the following handling precautions: term storage, they must be stored in a secure steel cabinet
• ECU and airbag must be stored in a cabinet in a dry which has been approved as suitable for the purpose and
room at normal room temperatures not exceeding has been registered by the local authority.
85° C. Ensure that heating, fire, water and other Warning: When recovering the seat belt pretensioner, DO
chemical corrosive substances cannot contaminate NOT aim the piston pipe at yourself or others. Keep the
the stored SRS components. pistons facing the ground. Hold the case instead of the
• For safety reasons, do not store inflammable goods seat belt.
close to the area where the SRS components are
Warning: Store the airbag module or seat belt
stored.
pre-tensioners in a designated storage area.
• Keep new airbag module in the original packaging,
Caution: Improper handling or storage can internally
until just before fitting.
damage the airbag module, making it inoperative. If you
• The storage area must comply with all legal
suspect the airbag module has been damaged, install
requirements. It must have suitable fire extinguishers
a new module and refer to theDeployment/Disposal
or other fire extinguishing equipment.
Procedures for disposal of the damaged module.
• Never drop an SRS component. The airbag
SRS Harnesses and Connectors
diagnostic control unit is a particularly shock
sensitive device and must be handled with extreme
care.
• Never wrap your arms around an airbag module. If
an airbag module has to be carried, hold it by the
cover, with the cover uppermost and the base away
from your body.
• Never transport airbag modules or seat belt
pre-tensioners in the cabin of a vehicle.
Warning: Never attach anything to an airbag cover or any
trim componentcovering an airbag module. Do not allow
anything to rest on top of an airbag module.
Version 2.0 16
General Information
Always observe the following precautionsSRS with regards to Do not place any object on the steering wheel or instrument
SRS system electrical wiring: panel that could penetrate an inflating airbag or be a thrown
item likely to cause injury.
• Never attempt to modify, splice or repairSRS wiring.
• Never install electronic equipment (such as a mobile Never fit cover on seat which fitting side airbag.
telephone, two-way radio or in-car entertainment Children under 12 years old should not sit in the front seat.
system) in such a way that it could generate electrical
Only genuine accessory parts are allowed to be installed.
interference in the airbag harness. Seek specialist advice
when installing such equipment. Only authorised people can remove airbag modules, ECU,
SRS system wiring harness and connectors.SRSECU andSRS
Note: SRS system wiring can be identified by a special
system wiring harness and connectors.
yellow outer sleeve protecting the wires (black with yellow
stripe protective coverings are sometimes used). If the airbag and seat belt pre-tensioner are deployed during an
accident,SRSECU must be replaced and discarded.
Every SRS system on every carSRS has been paired and
identified,SRS illegally adding or modifying the SRS system
and the wiring harness could injure people.
Modifying the vehicle structure or SRS system is strictly not
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allowedSRS and may cause wrong airbag deployment or failure
to deploy when required.
Rotary Coupler Precautions
Caution: Always follow the procedure for fitting and
checking the rotary coupler as instructed in the SRS
repairs section. Comply with all safety and installation
procedures to ensure the system functions correctly.
Warning: Always ensure SRS wiring is routed correctly.
Be careful to avoidtrapping or pinching the SRS wiring. Observe the following precautions:
Do not leave the connectors hanging loose or allow SRS • Do not unlock and rotate the rotary coupler when it is
components to hang from their harnesses. Look for removed from the vehicle.
possible points of chafing.
• Do not turn the road wheels when the rotary coupler is
removed from the vehicle.
• Always ensure the rotary coupler is removed and
installed in its centred position and with the front road
wheels in the straight ahead position - procedure.SRS
refer to the SRS repair section for the correct removal
and installation
• If a new rotary coupler is being installed, ensure the
locking tab holding the coupler's rotational position is
not broken; units with a broken locking tab should not
be used.
Warning Labels
Warning symbols are displayed at various positions in the
Precautions for Vehicle Owners vehicle.SRS components have additional warning labels
For the airbag to work effectively and protect vehicle owners, displayed on them to indicate that particular care is needed
follow the precautions listed below. when handling them. These include airbag modules,SRS
ECU, seat belt pre-tensioners and the rotary coupler.
Driver and passengers must use seat belts correctly. Correctly
using the seat belts can protect the body and reduce injuries The following warning symbols may be displayed at various
in the event of an accident. locations on the vehicle:
Never fit any accessory that obstructs or impairs the operation

of the seat belt pretensioners or airbags.
Version 2.0 17
General Information
4. Bar code. The code number must be recorded if the
rotary coupler is to be replaced.
A The need for caution when working in close proximity to

SRS components.SRS in close proximity to SRS components.
Bar Codes
B Refer to the publication where the procedures,SRS
instructions and advice can be found (usually Workshop Bar codesSRS are fitted to SRS system components and
Manual or Owner's Handbook) for working on the SRS componentsSRS which are critically related to SRS operation.
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system. The code number(s) must be recorded if the component is to
be replaced.
C Do not use rear facing child seats in the front passenger seat
if the vehicle is fitted with a passenger airbag. Components featuring bar codes include the following:
Warning: It is imperative that before any work • Driver's front airbag module – label attached to rear of
is undertaken on the SRS system the appropriate module housing
information is read thoroughly. • Passenger front airbag module – label attached at side of
module housing
The following list indicates possible locations and content
for warning labels. Exact positions and content may vary • SRSECU IncludedSRSECU on label on top of ECU
dependent on model year, legislation and market trends. • Rotary coupler – several labels on front face
Vehicle Recovery
TowingSRS Components Not Deployed
Normal towing procedures are unlikely to cause an airbag to
deploy. However, as a precaution, remove the handset from
the docking station and then disconnect both battery leads.
Disconnect the negative ‘-’ lead first.
TowingSRS Components Not Deployed
Once the driver s airbag has been deployed, the vehicle must
have a suspended tow. However, as a precaution remove the
handset from the docking station and then disconnect both
battery leads. Disconnect the negative - lead first.
SRS Components Deployed
Do not use rear facing child seat in front passenger seat of
vehicles fitted with passenger airbag. If a vehicle is to be scrapped and contains an undeployed airbag
module, the module must be manually deployed.
Rotary Coupler
Always observe the following precautions:
1. The need for caution when workingSRS in close
proximity to SRS components. Warning: Only personnel who have undergone the
2. Refer to Workshop Manual for detailed instructions. appropriate training should undertake deployment of
airbag and seat belt pre-tensioner modules.
3. Ensure the wheels are in the straight ahead position
before removal and refitting. Warning: A deployed airbag or seat belt pre-tensioner is
very hot, DO NOT return to a deployed airbag module
until at least 30 minutes have elapsed since deployment.
Version 2.0 18
General Information
Warning: Only use approved deployment equipment, Warning: Compliance with the following precautions
and only deploy SRS components in a well-ventilated MUST be ensured:
designated area. Ensure SRS components are not • Only use deployment equipment approved for the
damaged or ruptured before deployment. intended purpose.
Warning: Contact with chemicals from deployed and • Before commencing deployment procedure, ensure
damaged SRS components could present a health hazard, the deployment tool functions properly.
wear protective clothing when handling. DO NOT eat, • Deployment of airbag/pre-tensioner modules should
drink or smoke when handling SRS components. be performed in a well ventilated area which has
Warning: Deployment of airbag modules and seat belt been designated for the purpose.
pre-tensioners can cause injury to personnel in the close • Ensure airbag/pre-tensioner modules are not
vicinity of the deploying unit. In case of injury seek urgent damaged or ruptured before attempting to deploy.
medical advice. Possible sources of injury include: • Notify the relevant authorities of intention to deploy
• impact - due to inflating airbag or pretensioner airbag and pretensioner units.
operation causing component 'kick'. • When deploying airbag and seat belt pre-tensioner
• hearing - due to noise produced by deploying airbags units, ensure that all personnel are at least 15 metres
and seat belt pretensioner units. away from the deployment zone.
• burns - hot component parts and gases. • When deploying seat belt pretensioners in the
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• irritation to eyes and lungs - from deploying gases or vehicle, ensure the pre-tensioner unit is fully secured
combustion residue. to its fixing point.
• When removing deployed airbag and seat belt
Warning: Ensure the SRS component to be deployed is
pre-tensioner modules, wear protective clothing.
securely fastened to its mounting.
Use gloves and seal deployed units in a plastic bag.
• Following deployment of any component of the SRS
system within the vehicle, all SRS components must
be replaced. DO NOT re-use or salvage any parts of
the SRS system.
• Do not lean over airbag modules or seat belt
pre-tensioner units when connecting deployment
equipment.
Version 2.0 19
General Information
SRS Component Replacement Policy • SRS ECU
Impacts Which Do Not Deploy the Airbags or • Side impact crash sensors (both sides of vehicle)
Pre-tensioners
In addition, the following should be inspected for damage and
Check for structural damage in the area of the impact, paying
replaced as necessary:
particular attention to bumper armatures, longitudinals, crash
cans and bracketry. • Front seat belts (retractors, webbing, tongue latching, 'D'
loop and body anchorage points)
Impacts Which Deploy the Airbags or
Pre-tensioners • Rear seat belt buckles (webbing, buckle covers, tongue
latching and body anchorage)
The replacement and inspection policy is dependent on the
type and severity of the crash condition. SRS. The following • Front seat frame (if there is evidence of external or airbag
guidelines are the minimum that should be exercised as a result deployment damage to seat frame)
of the deployment of specific SRS components: • 'BC' post internal finishers and fixings
Front Airbag Deployment (driver and passenger) • Door casings
If the front airbags are deployed, the following parts must be • Seat belt automatic height adjusters on 'B' post
replaced: • Rear seat belt escutcheons in parcel shelf trim
• Driver airbag module Inflatable Curtain Structure (ICS) Airbags
Modules
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• Passenger airbag module
If the Inflatable Curtain Structure airbag modules are deployed,
• Flyleads (where applicable) connectingSRS front airbag
the following parts must be replaced, (ICS) on the side of the
modules to SRS harness
vehicle for which deployment occurred:
• Seat belt pre-tensioners
• ICS airbag module
• Driver's seat belt retractor
• Link lead between airbag gas generatorSRS and SRS
• Rotary coupler
harness
• SRS ECU
• Airbag retaining clips above window aperture
In addition, the following should be inspected for damage and • 'A' post internal finisher
• Front seat belt pre-tensioners
• Front passenger's seat belt retractor (webbing, tongue • SRS ECU
latching, 'D' loop, body anchorage point)
• Side impact crash sensors (both sides of vehicle)
• Rear seat belt buckles (webbing, buckle covers, body
anchorage and tongue latching function) In addition, the following should be inspected for damage and
• Fascia moulding adjacent to passenger airbag module
• Steering wheel (if damage is evident) • Headlining
• Front seat frames and head restraints (if there is evidence • ICS mounting brackets
of damage to the seat frame or cushion pan) • Alarm sensor
• Steering column (if adjustment is lost or there are signs • Front seat belts (retractors, webbing, tongue latching, ‘D'
of collapse) loop and body anchorage points)
• Seat belt automatic height adjusters on 'BC' posts • Rear seat belt buckles (webbing, buckle covers, tongue
• Rear seat belt escutcheons in parcel shelf trim latching and body anchorage)
Side (Thorax) Airbags • 'BC' post upper finisher and fixings
If the side (thorax) airbags are deployed, the following parts • Door casing
must be replaced, on the side of the vehicle on which the • Seat belt automatic height adjusters on ‘B' post
deployment occurred: • Rear seat belt escutcheons in parcel shelf trim
• Seat (thorax) airbag module Rear Impacts
• Seat squab foam Rear impacts may cause the seat belt pretensioners to deploy.
• Seat squab cover If this occurs, all pretensioner units must be replaced. In
addition, the following components should be inspected for
• Front seat belt buckle pre-tensioners
damage and replaced as necessary:
Version 2.0 20
General Information
• Front seat frames Air Conditioning System Precautions
• Seat belt automatic height adjusters on ‘B'- post General
• Front seat belts (retractors, webbing, tongue latching, 'D' The air conditioning system contains fluids and components
loop and body anchorage points) which could be potentially hazardous to the service engineer
• Rear seat belt buckles (webbing, buckle covers, tongue or the environment if not serviced and handled correctly. The
latching and body anchorage) following guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the importance
• Rear seat belt escutcheons in parcel shelf trim
of ensuring the integrity of the air conditioning operating
• SRS ECU
conditions and components fitted to the vehicle.
Periodic Replacement of SRS Components
Where necessary, additional specific precautions are detailed
The performance of the propellants within airbags and in the relevant sections of this Manual which should be referred
pre-tensioners will deteriorate over a period of time. As a to prior to commencing repair operations.
result, it is essential that the airbags and pre-tensioners are
periodically replaced to maintain occupant safety. Airbags, The refrigerant used in the air conditioning system is HFC-134a
seat belt pre-tensioners and the rotary coupler should be (Hydrofluorocarbon) R134a.
replaced at 12 year intervals. Warning: Servicing must only be carried out by personnel
familiar with both the vehicle system and the charging and
testing equipment. All operations must be carried out in
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a well ventilated area away from open flame and heat
sources.
Warning: R134a is a hazardous liquid and when handled
incorrectly can cause serious injury. Suitable protective
clothing, consisting of face protection, heat-proof gloves,
rubber boots and rubber apron or waterproof overalls,
must be worn when carrying out operations on the air
conditioning system.
Remedial Actions
If an accident involving R134a should occur, conduct the
following remedial actions:
• If liquid R134a enters the eye, do not rub it. Gently run
large quantities of eye wash over affected eye to raise the
temperature. If an eye wash is not available, cool, clean
water may be used to flush the eye. After rinsing, cover
the eye with a clean pad and seek immediate medical
attention.
• If liquid R134a is splashed onto the skin, run large
quantities of water over the affected area to raise the
temperature. Implement the same action if the skin
comes in contact with discharging cylinders. Wrap
the contaminated body parts in blankets (or similar
materials) and seek immediate medical attention.
• If the debilitating effects of inhalation of R134a vapour
is suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated
area to fresh air and apply artificial respiration and/ or
oxygen and seek immediate medical attention.
Version 2.0 21
General Information
Warning: Due to its low evaporating temperature, R134a • Whenever the refrigerant system is opened, the
must be handled with care. R134a splashed on any part receiver/drier must be renewed immediately before
of the body will cause immediate freezing of that area. evacuating and recharging the system.
Also, refrigerant cylinders and replenishment trolleys • Use alcohol and a clean lint-free cloth to clean dirty
when discharging will freeze skin to them if contact is connections.
made.
• Ensure that all new parts fitted are marked for use with
Service Precautions R134a.
Observe the following precautions when handling components Refrigerant Oil
used in the air conditioning system: Refrigerant oil easily absorbs water and must not be stored for
• Air conditioning units must not be lifted by their hoses, long periods. Do not pour unused refrigerant oil back into the
pipes or capillary lines. container. Always use an approved refrigerant oil.
• Hoses and lines must not be subjected to any twist or When replacing components in the A/C system, drain the
stress; the efficiency of the system will be impaired by refrigerant oil from the component being replaced into
kinks or restrictions. Ensure that hoses are correctly a graduated container. On assembly, add the quantity of
positioned before tightening couplings, and ensure that refrigerant oil drained to the new component.
all clips and supports are utilised.
Compressor
• Flexible hoses should not be positioned close to the
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A new compressor is sealed and pressurised with Nitrogen gas.
exhaust manifold (less than 100 mm) unless protected
When fitting a new compressor, slowly release the sealing cap;
by heat shielding.
gas pressure should be heard to vent as the seal is broken.
• Completed assemblies must be checked for refrigeration
lines touching metal panels. Any direct contact of Caution: Do not remove the cap(s) until immediately
components and panels may transmit noise and so must prior to connecting the air conditioning pipes to the
be eliminated. compressor.
• The appropriate torque wrench must be used when Rapid Refrigerant Discharge
tightening refrigerant connections to the stipulated If the air conditioning system is involved in accident damage and
value. An additional spanner must be used to hold the the system is punctured, the refrigerant will discharge rapidly.
union to prevent twisting of the pipe when tightening The rapid discharge of refrigerant will also result in the loss
connections. of most of the oil from the system. The compressor must be
• Before connecting any hose or pipe, ensure that removed and all the remaining oil in the compressor drained
refrigerant oil is applied to the seat of the new O-rings, and refilled as instructed in the air conditioning section of this
BUT NOT to the threads of the connection. manual.
• All protective plugs must remain in place to seal the Precautions for Refrigerant Recovery, Recycling
component until immediately prior to connection. and Recharging
• Ensure components are at room temperature before When the air conditioning system is recharged, any existing
uncapping, to prevent condensation of moisture from refrigerant is first recovered from the system and recycled.
the air that enters it. The system is then charged with the required weight of
• Components must not remain uncapped for longer than refrigerant and volume of refrigerant oil.
15 minutes. In the event of a delay, the caps must be Warning: Refrigerant must always be recycled before
fitted. re-use to ensure that the purity of the refrigerant is high
• When disconnecting, immediately cap all air conditioning enough for safe use in the air conditioning system.
pipes to prevent ingress of dirt and moisture into the
Warning: Recycling should always be carried out with
system.
equipment which is design certified by Underwriter
• The receiver/drier contains desiccant which absorbs Laboratory Inc. for compliance with SAE J1991. Other
moisture. It must be positively sealed at all times. A equipment may not recycle refrigerant to the required
receiver/drier that has been left uncapped must not be level of purity.
used, fit a new unit.
Warning: A R134a Refrigerant Recovery Recycling
• The receiver/drier should be the last component
Recharging Station must not be used with any other type
connected to the system to ensure optimum dehydration
of refrigerant.
and maximum moisture protection of the system.
Version 2.0 22
General Information
Warning: Refrigerant R134a from domestic and Air Conditioning Compressor Replacement
commercial sources must not be used in motor vehicle air Replacement Instructions
conditioning systems.
A new compressor is supplied filled with a full charge of
Caution: The system must be evacuated immediately refrigerant oil. The new compressor must be drained and a
before recharging commences. Delay between evacuation calculated quantity of oil added before fitting. To calculate the
and recharging is not permitted. quantity of oil to be added, carry out the following procedure:
1. Remove the filler/drain plug from the old compressor.
2. Invert the compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotate the compressor
clutch to ensure the compressor is completely drained.
3. Record the quantity of oil drained, discard the oil.
4. Remove the filler/drain plug from the new compressor.
5. Invert the compressor and gravity drain the oil into a
calibrated measuring cylinder. Rotate the compressor
clutch to ensure the compressor is completely drained.
6. Add the same amount of oil drained from the old
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compressor to the new compressor.
7. Discard the remaining oil drained from the new
compressor.
8. Fit and tighten the compressor filler/drain plug.
Version 2.0 23

Service Manual 2011 MG6

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Service Manual 2011

General...................................................... 834 Curtain Airbag - Head ................................ 909

• Grease outside diameter of seal, place square to housing

Encapsulated bolts and screws have a microencapsulated

Self-locking bolts and screws, i.e. nylon patched or trilobular

A nut with an ISO metric thread is marked on one face or on

• Absolute cleanliness must be observed with hydraulic Hose Clip

Markings (1) are usually provided on the hose to indicate the

Warning: Store the airbag module with the deployment

Never fit any accessory that obstructs or impairs the operation

A The need for caution when working in close proximity to

Side (Thorax) Airbags • 'BC' post upper finisher and fixings

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