2012 Fisker Karma Service Manual Part 1

KARMA 2012
SERVICE MANUAL
Publication number: C1810ASD0054.02

© 2012 Fisker Automotive, Inc.
All rights reserved. This material may not be reproduced or copied, in whole
or in part, without the express prior written permission of Fisker Automotive, Inc.
TABLE OF CONTENTS
Chapter Number
ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
ELECTRIC DRIVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
HEVAC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
FINAL DRIVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
STEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
BRAKES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
WHEELS & TIRES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
CHASSIS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
BODY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
ROOF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
GLAZING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76
EXTERIOR FITTINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
DASH ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80
INTERIOR TRIM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82
RESTRAINT SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
SEATS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
ELECTRICAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90
INFOTAINMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94
1-1
ENGINE
Contents Page
Mounting - LH ........................................................................................................................... 12-2

Mounting - RH........................................................................................................................... 12-3
Engine and Generator - Remove and Refit for Access............................................................. 12-4
Gasket - Cylinder Head........................................................................................................... 12-11
Oil Seal - Crankshaft - Rear .................................................................................................... 12-22
Oil - Drain and Refill ................................................................................................................ 12-23
Filter - Oil................................................................................................................................. 12-24
Gasket - Camshaft Cover ....................................................................................................... 12-25
Gasket - Timing Cover ........................................................................................................... 12-27
Oil Seal - Timing Cover ........................................................................................................... 12-28
Cover - Engine ........................................................................................................................ 12-29
Thermostat.............................................................................................................................. 12-29
Water Pump ............................................................................................................................ 12-31
Module - Engine Control (ECM) .............................................................................................. 12-34
Sensor - Oil Pressure .............................................................................................................. 12-35
Sensor - Turbocharger Boost Pressure and Temperature ..................................................... 12-36
Sensor - Manifold - Mass Air Flow and Temperature (MAFIAT) ............................................ 12-37
Modulator - Turbocharger Boost Pressure ............................................................................. 12-38
Sensor - Coolant Temperature ............................................................................................... 12-39
Sensor - Ambient Air Temperature ......................................................................................... 12-40
Sensor - Crankshaft Position (CKP)........................................................................................ 12-41
Sensor - Inlet - Camshaft Position (CMP)............................................................................... 12-42
Sensor - Knock (KS) - Front.................................................................................................... 12-43
Plug Top Ignition Coil - Each .................................................................................................. 12-44
Plug Top Ignition Coil - Set ..................................................................................................... 12-45
Spark Plugs - Set .................................................................................................................... 12-46
Sensor - Manifold Absolute Pressure (MAP) .......................................................................... 12-46
Solenoid - Camshaft Timing ................................................................................................... 12-47
Sensor - Oxygen - Upstream.................................................................................................. 12-48
Sensor - Oxygen - Downstream ............................................................................................. 12-49
Fuel Tank................................................................................................................................. 12-51
Module - Sender - Fuel level................................................................................................... 12-53
Fuel Rail .................................................................................................................................. 12-54
Injector - Each......................................................................................................................... 12-56
Injector - Set ........................................................................................................................... 12-57
Regulator - Fuel Pressure ....................................................................................................... 12-58
Module - Fuel Tank Pump....................................................................................................... 12-59
Fuel Pump - High Pressure..................................................................................................... 12-61
Purge Valve ............................................................................................................................. 12-62
Air Cleaner Assembly.............................................................................................................. 12-63
Element - Air Cleaner .............................................................................................................. 12-65
Intake Manifold Gasket ........................................................................................................... 12-66
Throttle body........................................................................................................................... 12-70
Intercooler - (Charge Air Cooler) ............................................................................................. 12-71
Muffler Assembly - LH ............................................................................................................ 12-74
Exhaust System Complete - Remove and Refit for Access ................................................... 12-75
Exhaust manifold gasket......................................................................................................... 12-77
Muffler Assembly - Center ...................................................................................................... 12-78
Turbocharger .......................................................................................................................... 12-79
Catalyst - Exhaust................................................................................................................... 12-82
12-1
ENGINE
Mounting - LH WARNING: To avoid serious injury, use

ENGINE
appropriate equipment to carry out this

FRT No.: 12100200 operation.
6. Remove nut securing LH mounting to engine
Remove
bracket. Torque - 55 Nm.
1. Raise and support vehicle
7. Raise engine, LH side, approximately 60 mm
WARNING: Make sure the vehicle is correctly for access.
supported before commencing work.
WARNING: To avoid serious injury, use
operation.
FSM00616
8. Remove LH mounting.
NOTE: Note fitted position of components
before removal.
FSM00830
2. Remove nut securing engine mounting to Installation

subframe. Torque - 55 Nm. 1. Installation procedure is reverse of removal.
3. Lower vehicle. NOTE: Clean component mating faces, prior
4. Remove A/C compressor. Refer to FRT: to installation.
30300100, page 30-9. WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
FSM00615
5. Using suitable lifting equipment, support

weight of engine.
12-2
ENGINE
Mounting - RH WARNING: To avoid serious injury, use

Remove
1. Raise and support vehicle
WARNING: Make sure the vehicle is correctly
operation.
FSM00617
6. Remove nut securing RH mounting to engine

7. Raise engine, RH side, approximately 60 mm
for access.
FSM00832
2. Remove nut securing engine mounting to

subframe. Torque - 55 Nm.
3. Lower vehicle.
4. Remove front cross brace. Refer to FRT:
60500300, page 60-13.
FSM00618
8. Remove RH mounting.
before removal.
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
FSM00831
WARNING: Only use cleaning agents and
5. Using suitable lifting equipment, support solvents in a well ventilated area.
weight of engine. CAUTION: Replace all Nyloc nut(s).
12-3
ENGINE
Engine and Generator - Remove and Refit 11. Repeat previous two steps for RH lower arm.
for Access 12. Raise vehicle.
FRT No.: 12100601

operation.
Remove
1. Remove LH wheel arch liner. Refer to FRT:
78100100, page 78-2.
2. Repeat the above procedure and remove RH
wheel arch liner.
3. Remove high voltage battery assembly. Refer FSM00146
to FRT: 16200200, page 16-7.
13. Turn column for spanner access and remove
4. Drain cooling system. Refer to FRT: clamp bolt securing steering column
20010100, page 20-2. intermediate shaft to rack. Torque - 30 Nm.
5. Evacuate refrigerant from A/C system. Refer NOTE: Note fitted position of components
to FRT: 30010100, page 30-2. before removal.
6. Remove air cleaner assembly. Refer to FRT: 14. Disconnect intermediate shaft from steering
12700200, page 12-63. rack.
7. Remove front sway bar. Refer to FRT:
46500500, page 46-15.
8. Remove exhaust system complete. Refer to
FRT: 12800301, page 12-75.
FSM01012
15. Remove screws (x3) securing lower

suspension arm bush heatshield.
16. Release clips (x2) and remove heatshield.
FSM00039
17. Repeat previous step for RH heat shield.
9. Remove nuts (x2) and bolts (x2) securing LH
lower arm to body. Collect washers (x4). NOTE: Refit component/s using suitable pop
Torque - 165 Nm. rivets at correct installation point during
procedure.
10. Move lower arm assembly away from
subframe and tie aside. 18. Lower vehicle.
12-4
ENGINE
19. Position and support hood in service 26. Release battery coolant hose from clip.
position. 27. Release clip and remove clean air inlet hose
20. Remove engine cover. Refer to FRT: from turbocharger.
12301000, page 12-29. CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
FSM00151
21. Loosen clip securing charge air pipe to FSM00732
intercooler hose. 28. Release clip and disconnect top hose from
22. Release intercooler hose and position aside. high temperature radiator.
CAUTION: Plug all open connections to CAUTION: Plug all open connections to
prevent ingress of moisture and dirt. prevent ingress of moisture and dirt.
23. Remove bolts (x2) securing charge air outlet 29. Tie top hose aside to engine.
flange to turbocharger. Torque - 25 Nm.
24. Remove charge air pipe assembly, collect
and discard gasket.
CAUTION: Plug all open connections to
FSM00726
30. Disconnect boost pressure sensor harness

connector.
31. Disconnect boost pressure pipe.
FSM00731
25. Disconnect PCV pipe from cam cover. 32. Release clips (x2) securing charge air inlet
CAUTION: Plug all open connections to pipe to intercooler and throttle body.
prevent ingress of moisture and dirt. 33. Remove charge air inlet pipe.
12-5
ENGINE

FSM00155
37. Release clips (x2) securing generator harness

FSM00153
to body. Tie to transmission to prevent
34. Disconnect engine harness connectors (x6) snagging.
and harness earth lead bolt. Illustration
shows engine removed for clarity.
35. Release harness clips (x6), position loose
harness to engine and tie aside.
ıııı
ııı
FSM00760
38. Remove power steering pump reservoir cap

and using a syringe remove fluid from
reservoir.
FSM00501
NOTE: Place suitable absorbent material
36. Disconnect fuel line from fuel rail and tie fuel around the affected area to absorb any
line aside. possible fluid spillage.
around the affected area to absorb any
possible fluid spillage.
12-6
ENGINE
43. Remove LH suspension turret cross brace.

Refer to FRT: 60500100, page 60-12.
44. Repeat previous step to remove RH
suspension turret cross brace.
45. Remove plenum cover. Refer to FRT:
78200200, page 78-4.
FSM00727
39. Remove bolt securing high pressure union to

power steering pump. Torque - 25 Nm.
NOTE: Position a suitable container to
contain fluid spillage.
around the affected area to absorb any FSM00729
possible fluid spillage. 46. Disconnect engine harness connectors from

40. Disconnect high pressure line from power engine control module.
steering pump. Remove and discard 'O' ring 47. Remove nut securing engine harness ground
seal. cable.
CAUTION: Plug all open connections to 48. Tie harness to engine.
41. Release clip and disconnect power steering
return hose from pump.
FSM00730
49. Disconnect engine harness connectors (x2)

from body harness.
50. Tie harness to engine.
FSM00728
42. Remove bolt securing power steering hose

clip to pump. Torque - 10 Nm.
12-7
ENGINE

54. Release clip and disconnect inlet hose from
coolant pump.
55. Carefully maneuver both coolant hoses into
engine bay and tie aside.
FSM00500
51. Remove bolts (x2) securing bulkhead wall

cross brace to body. Torque - 25 Nm.
FSM00221
56. Remove nut and disconnect A/C pipes from

TXV valve. Torque - 10 Nm.
FSM00502
CAUTION: Remove and discard 'O' ring
seals.
52. Remove bulkhead cross brace bracket.
NOTE: Lubricate new 'O' ring seals with clean
refrigerant oil.
FSM00219
53. Release clip and disconnect bulkhead heater

hose. Note: Wiper motor has been removed
for clarity.
12-8
ENGINE
61. Remove nut and disconnect A/C high

pressure connector from condenser
mounting block. Torque - 20 Nm.
seals.
refrigerant oil.
FSM00223
57. Remove bolt and disconnect bulkhead A/C

joint. Torque - 10 Nm.
seals.
refrigerant oil.
FSM00735
58. Position disconnected A/C pipe section aside
to avoid clash with hoses and harness in 62. Remove bolt (x1) and disconnect high
engine bay. voltage generator connector plug. Torque - 8
Nm.
59. Raise vehicle.
CAUTION: Take care not to damage
component(s).
63. Remove bolt and release cable tray from
body. Torque - 5 Nm.
64. Carefully lower cable tray and tie high voltage
connector aside for access.
65. Adjust vehicle height on lift to accommodate
powertrain lift table at full extension.
66. Isolate lift and with assistance secure vehicle
to lift front arms with service tool.
FSM00224
operation.
60. Release clips (x2) and remove lower high 67. Position suitable support between subframe
temperature coolant hose from vehicle. and engine to prevent rotation when
CAUTION: Plug all open connections to generator mountings are removed.
prevent ingress of moisture and dirt. 68. Position lift table and support subframe
assembly. FST0013
12-9
ENGINE

2. Carry out four wheel alignment check. Refer
to FRT: 46010100, page 46-2.
FSM00225
69. Remove front bolts (x2) securing subframe to

chassis. Torque - 200 Nm
70. Remove centre bolts (x2) securing subframe
to chassis. Torque - 160 Nm
71. Remove rear bolts (x2) securing subframe to
chassis. Torque - 160 Nm
72. Remove bolts (x2) securing generator
support bracket to chassis. Torque - 160 Nm.
73. With assistance, carefully lower subframe
assembly approximately 50 mm.
74. Check all harness/hose connections are
disconnected and harness clips have been
released.
75. Carefully lower subframe assembly moving
lift table approximately 10 mm forward to
clear generator housing from rear chassis
crossmember.
WARNING: When removing subframe with
drivetrain assembly, the centre of gravity of
vehicle will change dramatically. Ensure the
vehicle is lashed to the lift or supported with
a stand prior to removal.
76. Rotate lift table slightly clockwise to allow A/
C pump to clear forward crossmember.
77. Remove subframe assembly.
Installation
1. Installation procedure is reverse of removal
except for the following.
to installation.
12-10
ENGINE
Gasket - Cylinder Head 6. Remove fuel pump acoustic cover.
FRT No.: 12150100
Remove
1. Raise and support vehicle.
operation.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
3. Remove timing cover gasket. Refer to FRT:
FSM00852
12300300, page 12-27. 7. Disconnect fuel pump unions (x2). Torque -

25 Nm.
WARNING: Eye protection must be worn.
WARNING: Care must be taken during fuel
line disconnection as residual fuel pressure
may be present.
WARNING: Petrol/gasoline vapour is highly
flammable and in confined spaces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2 GAS, or
POWDER close at hand when handling or
draining fuel.
FSM00858 prevent ingress of moisture and dirt.
4. Remove bolts (x3) securing fuel pump NOTE: Place suitable absorbent material
support bracket. Remove bracket. Torque - around the affected area to absorb any
10 Nm. possible fluid spillage.
8. Remove bolts (x2) securing fuel pump to
cylinder head. Torque - 10 Nm.
9. Remove bolts (x2) securing fuel pressure
regulator to intake manifold. Torque - 10 Nm.
FSM00851
5. Disconnect fuel pump harness connector.
12-11
ENGINE
FSM00855 FSM00862
10. Remove fuel pressure regulator. 13. Release harness clip from intake manifold
support bracket stud.
14. Loosen nut securing manifold support
bracket to cylinder block. Torque 50 Nm.
FSM00853
11. Remove fuel pump.

FSM00748
NOTE: Place suitable absorbent material 15. Disconnect manifold absolute pressure
around the affected area to absorb any sensor connector.
12. Remove and discard fuel pump gasket.
12-12
ENGINE
FSM00867 FSM00863
16. Disconnect throttle body harness connector. 19. Remove bolt securing dipstick tube support
bracket to intake manifold. Torque - 25 Nm.
20. Release clip securing engine harness to
intake manifold.
FSM00859
17. Disconnect turbo boost pressure modulator

connector.
18. Release clips (x2) and disconnect hoses (x2)
FSM00865
from modulator. 21. Remove bolt securing manifold support

12-13
ENGINE
FSM00866 FSM00869
22. Evenly and progressively loosen / remove 24. Remove and discard intake manifold gasket.
bolts (x5) and nuts (x2) securing intake NOTE: Note fitted position of components
manifold to cylinder head. Torque - 25 Nm. before removal.
FSM00868
FSM00870
23. Remove intake manifold.

25. Disconnect fuel injector harness connector.
FSM0871
26. Remove fuel rail acoustic cover.
12-14
ENGINE
31. Remove spark plugs.

FSM00875
27. Remove bolts (x4) securing fuel rail to

28. Carefully release injectors and rail from FSM00887
cylinder head. 32. Remove bolts (x2) securing catalyst to engine

mounting bracket. Torque - 37 Nm.
FSM0876
29. Remove fuel rail and injectors. FSM00901
CAUTION: Plug all open connections to 33. Remove bolt securing turbo brace to cylinder
prevent ingress of moisture and dirt. block. Torque - 50 Nm.
CAUTION: Injector seals swell when exposed 34. Remove nut securing turbo support bracket
to atmospheric conditions for more than one to turbo. Torque - 25 Nm.
minute. Ensure protective sleeves are 35. Remove turbo brace.
installed.
36. Release turbo oil return pipe from engine
NOTE: Do not remove protective sleeve from block.
injector until moment of assembly.
NOTE: Injector seals are not available seals.
individually. The injector must be replaced as
a unit.
30. Remove camshaft cover. Refer to FRT:
12300100, page 12-25.
12-15
ENGINE

FSM00899
40. Release oil feed pipe union from turbo.

Disconnect oil feed pipe from turbo and
FSM00883
position aside. Discard washer. Torque - 25
37. Remove bolts (x3) securing turbocharger Nm.
heatshield. Torque - 10 Nm. CAUTION: Plug all open connections to
38. Remove turbocharger heatshield. prevent ingress of moisture and dirt.
FSM00898
39. Release coolant feed and return unions to

turbo. Disconnect coolant pipes from turbo
and position aside. Discard washers. Torque FSM00902
- 25 Nm. 41. Remove nuts (x4) securing turbo to exhaust

CAUTION: Plug all open connections to manifold. Torque - 25 Nm.
prevent ingress of moisture and dirt. 42. Remove catalyst and turbo assembly from
NOTE: Place suitable absorbent material exhaust manifold.
12-16
ENGINE
FSM00904 FSM00946
43. Remove and discard turbo to exhaust 45. Progressively loosen and remove nuts (x10)
manifold flange gasket. securing exhaust manifold to cylinder head.
NOTE: Note fitted position of components Discard nuts. Torque - 25 Nm.
before removal.
FSM00947
FSM00945 46. Remove exhaust manifold.

44. Remove bolts (x3) securing exhaust manifold CAUTION: Plug all open connections to
heatshield. Remove heatshield. Torque - 10 prevent ingress of moisture and dirt.
Nm.
12-17
ENGINE
72mm
FSM00948 FSM00990
47. Remove and discard exhaust manifold 49. Remove timing chain tensioner from cylinder
gasket. head casting and discard sealing washer.
NOTE: Note fitted position of components Torque - 75 Nm.
before removal. CAUTION: Plug all open connections to
NOTE: Check condition of timing chain
tensioner. If tensioner is not in fully
compressed active state (72mm) replace
tensioner.
FSM00989
48. Rotate crankshaft in clockwise direction to

locate timing marks on camshafts.
FSM00991
50. Remove bolt securing timing chain tensioner

guide and remove guide. Torque - 10 Nm.
12-18
ENGINE
FSM00992 FSM00994
51. Remove bolts (x2) securing upper timing 57. Remove fixed timing chain guide access plug
chain guide to cylinder head and remove from cylinder head.
guide. Torque - 10 Nm.
4 8 12 14 10 6
1 5 9 13 11 7
FSM00995
58. Using sequence shown, progressively loosen

FSM00993
52. Hold exhaust camshaft in position using 24 cylinder head bolts (x14). Remove and
mm spanner on hexagonal on camshaft. discard bolts.
53. Remove bolt securing camshaft sprocket to CAUTION: Replace all cylinder head bolts.
camshaft and discard bolt. Torque - 85 Nm.
54. Release timing chain from exhaust camshaft
sprocket. Remove sprocket from camshaft.
55. Repeat previous 3 steps for inlet camshaft
sprocket.
56. Release timing chain clear of cylinder head.
12-19
ENGINE
FSM00996 FSM00998
59. Remove cylinder head from cylinder block. 65. Check cylinder head for warping, across
CAUTION: Plug all open connections to centre and from corner to corner as shown. If
prevent ingress of moisture and dirt. specified maximum tolerance exceeded,
replace cylinder head (Refer to technical
data).
66. Check cylinder head height. If specified
maximum reface tolerance exceeded,
replace cylinder head (Refer to technical
data).
Installation
to installation.
FSM00997
60. Remove and discard cylinder head gasket.
2. Replace all disturbed 'O' ring seals.
before removal. NOTE: Apply a suitable lubricant to all 'O' ring
seals.
61. Clean mating faces of cylinder head and
cylinder block. 3. Fit new cylinder head gasket over cylinder
block locating dowels.
62. Remove debris from all oil and coolant
passages. NOTE: Ensure the cylinder head gasket is
fitted correct way up.
63. Check cylinder head for damage, pay
particular attention to gasket face of cylinder
head.
64. Check cylinder block gasket face for
damage.
12-20
ENGINE
7 3 1 5 9
10 6 2 4 8
FSM00999 FSM01001
4. Working in the sequence shown, 7. Check crankshaft sprocket timing position.

progressively tighten the cylinder head bolts Ensure timing mark at 5 o'clock position.
(x10). Torque 30 Nm. 8. Align colored links on timing chain with timing
5. Using a torque angle gauge, tighten cylinder marks on camshaft and crankshaft sprockets
head bolts in sequence 155°. before installing tensioner.
2 9
1 2 3 4 1
6
8 10
5
3
7 4
FSM01000 FSM00949
6. Fit remaining cylinder head bolts (x4). Torque 9. Tighten exhaust manifold nuts in sequence.
35 Nm.
12-21
ENGINE
Oil Seal - Crankshaft - Rear WARNING: This component is extremely

heavy, to avoid personal injury observe all
FRT No.: 12200300 relevant safety precautions before removal.
6. Remove flywheel from crankshaft.
Remove
operation.
2. Remove generator. Refer to FRT: 16100100,
page 16-2.
FSM00939
7. Remove crankshaft rear oil seal. Discard oil

seal.
Installation
except for following.
FSM00937
CAUTION: Replace all patch bolt(s).
3. Remove bolts (x6) securing damper to NOTE: Clean component mating faces, prior
flywheel. Torque - 45 Nm. to installation.
4. Remove damper from flywheel. 2. Fit new crankshaft rear oil seal.FST1011
3. Evenly and progressively tighten bolts
securing flywheel to crankshaft.
securing damper to flywheel.
FSM00938
5. Remove bolts (x8) securing flywheel to

crankshaft. Torque - 53 Nm + 25°.
12-22
ENGINE
Oil - Drain and Refill WARNING: To avoid serious injury, use

9. Allow oil to drain.
Drain & Refill
10. Remove and discard oil pan drain plug seal.
11. Install new oil pan drain plug seal.
supported before commencing work. 12. Install and tighten oil pan drain plug. Torque -
35 Nm.
2. Open vehicle hood.
13. Lower vehicle.
3. Renew oil filter. Refer to FRT: 12250200,
page 12-24. 14. Refill engine with required volume of
specified oil.
15. With key fob in vehicle press Start/Stop
button.
16. Select Park on electric drive system.
17. Select Sport mode on steering wheel paddle
switch.
18. Fully open accelerator pedal.
19. Hold accelerator pedal in fully open position
for 10 seconds.
20. Allow engine to start.
21. Release accelerator pedal when engine has
FSM00611
started.
4. Clean area surrounding oil filler cap. 22. Allow engine to idle.
5. Remove oil filler cap. 23. Turn engine off by deselecting Sport mode on
6. Raise vehicle. steering wheel paddle switch or pressing
Start/Stop button.
7. Position container to collect fluid.
24. Check for leaks.
25. Check and top-up oil level.
FSM00612
8. Remove oil pan drain plug.
12-23
ENGINE
Filter - Oil
FRT No.: 12250200
Remove
FSM00614
7. Remove and discard filter cartridge from

mounting.
8. Remove and discard 'O' ring seals (x2).
Installation
FSM00613
2. Clean area surrounding oil filter housing.
3. Position fuel line and engine harness aside for to installation.
access.
2. Replace 'O' ring seals.
4. Loosen oil filter housing cap. Torque - 25
Nm.FST1009 NOTE: Lubricate new 'O' ring seals with clean
engine oil.
5. Wait approximately one minute for oil to
return to oil pan.
6. Remove oil filter cap and filter element from
housing.
12-24
ENGINE
Gasket - Camshaft Cover

FRT No.: 12300100
Remove
operation.
FSM00765
5. Remove bolts (x2) securing camshaft inlet

and exhaust solenoids to cam cover and
remove solenoids. Torque - 5 Nm.
FSM00941
2. Release turbo breather pipe from cam cover

ıııı
elbow.
3. Release positive crankcase vent pipe from
cam cover.
FSM00881
4. Remove plug top ignition coils. Refer to FRT:
12401300, page 12-45. 6. Release oxygen sensor connection.
7. Release clip securing oxygen sensor
connector to cam cover.
12-25
ENGINE
FSM00942 FSM00944
8. Progressively loosen and remove bolts (x11) 10. Remove camshaft cover gaskets. Discard
securing camshaft cover. Torque - 10 Nm. gaskets.
before removal.
Installation
to installation.
2. Fit new camshaft cover gaskets.
FSM00943
9. Remove camshaft cover.

12-26
ENGINE
Gasket - Timing Cover

FRT No.: 12300300
Remove
1. Remove engine and generator assembly.
FSM00988
4. Remove timing cover and discard gasket.
FSM00925
2. Remove bolt securing crankshaft pulley and

remove pulley. Discard bolt. Torque - 100 Nm
+ 75º.FST1027
FSM00926
5. Remove timing cover oil seal. Discard seal.
Installation
FSM00924 NOTE: Clean component mating faces, prior
3. Remove bolts (x11) securing timing cover. to installation.
Torque - 18 Nm. 2. Fit new timing cover oil seal.FST1032
NOTE: Note fitted position of components 3. Fit new timing cover gasket.
before removal. 4. Fit new crankshaft pulley bolt.
12-27
ENGINE
Oil Seal - Timing Cover 2. Fit new timing cover oil seal.FST1032
3. Fit new crankshaft pulley bolt.
FRT No.: 12300500
Remove
FSM00925
2. Remove bolt securing crankshaft pulley and

remove pulley. Discard bolt. Torque - 100 Nm
+ 75º.FST1027
FSM00926
3. Remove timing cover oil seal. Discard seal.
Installation
to installation.
12-28
ENGINE
Cover - Engine Thermostat

FRT No.: 12301000 FRT No.: 12350100
Remove Remove
1. Remove front cross brace. Refer to FRT: 1. Remove engine cover. Refer to FRT:
60500300, page 60-13. 12301000, page 12-29.
2. Remove AC/DC Inverter. Refer to FRT:
16400100, page 16-11.
FSM00152
2. Release clips (x4) securing engine cover to

engine. FSM00880
3. Remove engine cover. 3. Depress latches and disconnect ECM

harness connections (x2), remove nut
Installation securing ECM harness connector and
1. Installation procedure is reverse of removal. position harness aside.
FSM00741
4. Disconnect ignition coil connectors (x4),

camshaft solenoid connectors (x2) and
oxygen sensor connector, release clips (x2)
and position harness aside.
5. Release clips (x2) securing hoses to front of
cam cover.
12-29
ENGINE
6. Clean area surrounding oil filler cap and

remove oil filler cap.
7. Remove cam cover sound absorber.
FSM00913
10. Remove bolts (x2) securing thermostat cover

and remove cover. Torque - 10 Nm.
FSM00911
11. Remove thermostat and discard 'O' ring seal.
8. Remove bolts (x2) securing bracket and
position bracket and oxygen sensor harness Installation
aside. Torque - 10 Nm. 1. Installation procedure is reverse of removal
to installation.
2. Replace 'O' ring seal.
3. Refill and bleed Engine and Cabin coolant.
FSM00912
9. Release clips and disconnect thermostat

hoses (x2).
12-30
ENGINE
Water Pump 6. Clean area surrounding oil filler cap and

remove oil filler cap.
FRT No.: 12350200
Remove
1. Remove engine cover. Refer to FRT:
12301000, page 12-29.
2. Remove AC/DC Inverter. Refer to FRT:
16400100, page 16-11.
FSM00911
8. Remove bolts (x2) securing bracket and

position bracket and oxygen sensor harness
aside. Torque - 10 Nm.
FSM00880
3. Depress latches and disconnect ECM

harness connectors (x2), remove nut
securing ECM harness connector and
position harness aside.
FSM00912
9. Release clips and disconnect thermostat

hoses (x2).
FSM00741 around the affected area to absorb any
4. Disconnect ignition coil connectors (x4),
camshaft solenoid connectors (x2) and
oxygen sensor connector, release clips (x2)
and position harness aside.
cam cover.
12-31
ENGINE
FSM00916 FSM00918
10. Release clip and disconnect positive 13. Remove bolts (x4) securing water pump
crankcase ventilation tube. Move tube aside. pulley access cover. Remove cover and
11. Release turbo air intake hose clips and discard gasket. Torque - 10 Nm.
remove intake hose. NOTE: Clean component mating faces, prior
to installation.
14. Remove bolts (x2) securing water pump.
Torque - 18 Nm.
before removal.
FSM00917
12. Release clip and disconnect top hose from

radiator. Move hose aside.
possible fluid spillage. FSM00919
CAUTION: Plug all open connections to 15. Install special tool to restrain water pump
prevent ingress of moisture and dirt. drive sprocket, tighten bolts (x4) securing tool
to timing cover.FST1007
to installation.
16. Tighten tool bolts (x3) to secure tool to water
pump drive sprocket.
17. Remove bolts (x3) securing water pump drive
sprocket to water pump. Torque - 7 Nm.
12-32
ENGINE

to installation.
18. Remove the exhaust catalyst. Refer to FRT:
12800900, page 12-82.
FSM00923
24. Remove water pump inlet pipe and discard

'O' ring seal.
25. Remove bolts (x2) securing water pump.
FSM00920
Remove water pump and discard gasket.
19. Release clips and disconnect thermostat Torque - 18 Nm.
housing hoses (x2). NOTE: Place suitable absorbent material
20. Disconnect coolant temperature sensor around the affected area to absorb any
connector. possible fluid spillage.
NOTE: If component has been removed for
access, do not dismantle beyond this point.
26. Remove bolts (x5) securing water pump
cover to water pump. Remove cover and
discard gasket. Torque - 10 Nm.
Installation
to installation.
2. Fit but do not fully tighten rear bolts (x2)
FSM00922
securing water pump.
21. Release coolant feed union to turbo. 3. Install bolts (x2) securing water pump
Disconnect coolant pipe from thermostat through timing case.
housing and position aside. Discard washers.
Torque - 20 Nm. 4. Torque tighten bolts (x4).
22. Remove bolts (x3) securing thermostat 5. Remove water pump retaining tool.FST1007
housing and discard gasket. Torque - 10 Nm. 6. Replace 'O' ring seals.
23. Remove thermostat housing from water 7. Replace gaskets and seals.
pump inlet pipe. Discard 'O' ring seal.
12-33
ENGINE
Module - Engine Control (ECM)

FRT No.: 12400100
Remove
1. Open hood.
90010100, page 90-2.
3. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
4. Remove RH cross brace. Removal procedure
is similar to LH cross brace. Refer to FRT:
60500100, page 60-12. FSM00677
8. Remove ECM from bracket.
Installation
to installation.
FSM00676

harness connections (x2).
6. Remove bolts (x2) securing ECM locating
clamp to bracket. Torque - 8 Nm.
7. Remove ECM clamp.
12-34
ENGINE
Sensor - Oil Pressure

FRT No.: 12400200
Remove
operation.
90010100, page 90-2. FSM00190
3. Isolate high voltage battery. Refer to FRT: 8. Remove screws (x4), release clips (x3)
16200100, page 16-6. securing central heatshield to subframe and
remove shield. Torque - 10 Nm.
4. Disconnect catalyst upstream oxygen sensor
harness connector. 9. Using a suitable block between generator
and exhaust. Position exhaust aside for
5. Apply suitable release agent to catalyst
access.
manifold nuts and studs.
FSM00849
FSM01006
10. Disconnect oil pressure sensor harness
6. Remove nuts (x2) securing center muffler
connector.
flange to catalyst. Torque - 45 Nm.
7. Release exhaust flange.
12-35
ENGINE
Sensor - Turbocharger Boost Pressure and

Temperature
FRT No.: 12400400
Remove
FSM00752
1. Disconnect turbocharger boost pressure and

temperature sensor connector.
FSM00850 NOTE: Ensure terminal connections are clean
and free of corrosion.
11. Remove oil pressure sensor.
Installation
to installation.
solvents in a well ventilated area. FSM00753
2. Remove screw securing sensor to duct and

remove sensor. Torque - 5 Nm.
Installation
to installation.
12-36
ENGINE
WARNING: Only use cleaning agents and Sensor - Manifold - Mass Air Flow and
solvents in a well ventilated area. Temperature (MAFIAT)
FRT No.: 12400500
Remove
FSM00743
1. Disconnect MAFIAT sensor connector and

2. Clean area around sensor.
FSM00744
3. Remove screws (x2) securing sensor to duct

and remove sensor. Torque - 3 Nm.
Installation
to installation.
12-37
ENGINE
WARNING: Only use cleaning agents and Modulator - Turbocharger Boost Pressure
FRT No.: 12400600
Remove
12301000, page 12-29.
FSM00745
2. Disconnect turbocharger boost pressure

modulator connector.
FSM00746

from modulator.
12-38
ENGINE
Sensor - Coolant Temperature
FRT No.: 12400700
WARNING: To avoid serious injury, ensure

the coolant returns to a safe temperature
before commencing work.
ıııı
Remove
1. Remove upstream oxygen sensor. Refer to
FRT: 12402100, page 12-48.
2. Release heat protective sheathing covering
FSM00747 coolant temperature sensor.
4. Depress clips (x2) and remove modulator
from bracket.
Installation
to installation.
FSM00892
3. Disconnect temperature sensor connector.
FSM00893
4. Remove coolant temperature sensor. Torque

- 15 Nm.
12-39
ENGINE
CAUTION: Plug all open connections to Sensor - Ambient Air Temperature

FRT No.: 12400800
Installation
1. Installation procedure is reverse of removal Remove
except for the following. 1. Remove front bumper cover. Refer to FRT:
NOTE: Clean component mating faces, prior 70202100, page 70-8.
to installation.
2. Check and top up coolant level.
FSM00750
2. Disconnect ambient air temperature sensor

connector.
NOTE: Ensure terminal connections are clean
ıııı
FSM00751
3. Remove screw securing sensor to body and

remove sensor. Torque - 5 Nm.
Installation
12-40
ENGINE
Sensor - Crankshaft Position (CKP)

FRT No.: 12400900
Remove
operation.
90010100, page 90-2. FSM00190
access.
FSM00847
FSM01006
10. Disconnect crankshaft position (CKP) sensor
harness connector.
11. Remove bolt securing CKP sensor to cylinder
block. Torque - 8 Nm.
12-41
ENGINE
Sensor - Inlet - Camshaft Position (CMP)

FRT No.: 12401000
Remove
1. Remove high pressure fuel pump. Refer to
FRT: 12501000, page 12-61.
FSM00848
12. Remove CKP sensor.

prevent ingress of moisture and dirt. FSM00856
Installation 2. Remove bolt securing cam position (CMP)

sensor to cylinder head. Torque - 8 Nm.
except for the following. 3. Remove CMP sensor from cylinder head.
NOTE: Clean component mating faces, prior NOTE: Place suitable absorbent material
to installation. around the affected area to absorb any
solvents in a well ventilated area. CAUTION: Plug all open connections to
2. Apply a suitable lubricant to 'O' ring seal.
4. Disconnect CMP sensor harness connector.
FSM00857
5. Remove CMP sensor.
12-42
ENGINE
Installation Sensor - Knock (KS) - Front

FRT No.: 12401100
NOTE: Clean component mating faces, prior Remove
to installation.
2. Apply a suitable lubricant to 'O' ring seal.
operation.
2. Remove intake manifold. Refer to FRT:
12700500, page 12-66.
FSM00870
3. Disconnect fuel injector harness connector.
FSM0871
4. Remove fuel rail acoustic cover.
12-43
ENGINE
Plug Top Ignition Coil - Each

FRT No.: 12401200
Remove
12301000, page 12-29.
FSM00878
5. Disconnect front knock sensor (KS) harness

connector.
6. Release KS connector from fixing bracket.
7. Remove bolt securing KS to engine
crankcase. Torque - 25 Nm.
FSM00741
2. Disconnect ignition coil connectors (x4) and

camshaft solenoid connectors (x2), release
clips (x2) and position harness aside.
cam cover.
4. Clean area surrounding oil filler cap.
5. Remove oil filler cap.
FSM00879
8. Remove KS.
Installation
to installation.
12-44
ENGINE
Plug Top Ignition Coil - Set

FRT No.: 12401300
Remove
1. Remove ignition coil. Refer to FRT:
12401200, page 12-44.
2. Remove bolts (x3) securing remaining ignition
coils to cam cover and remove coils. Torque
- 5 Nm.
Installation
FSM00742 1. Installation procedure is reverse of removal.
7. Remove bolt securing ignition coil to cam
cover and remove coil. Torque - 5 Nm.
Installation
12-45
ENGINE
Spark Plugs - Set Sensor - Manifold Absolute Pressure (MAP)

FRT No.: 12401400 FRT No.: 12401500
Remove Remove
1. Remove ignition coil. Refer to FRT: 1. Remove engine cover. Refer to FRT:
12401200, page 12-44. 12301000, page 12-29.
2. Remove remaining coils (x3).
3. Using a spark plug socket, remove 4 spark
plugs. Torque - 25 Nm.
Installation
2. Set spark plug gaps to 0.9 mm ± 0.1 mm.
FSM00748
2. Disconnect MAP sensor connector and

3. Clean area around sensor.
FSM00749
4. Remove bolt securing sensor to intake

manifold and remove sensor. Torque - 4 Nm.
Installation
12-46
ENGINE
NOTE: Clean component mating faces, prior Solenoid - Camshaft Timing

to installation.
FRT No.: 12401600
Remove
12301000, page 12-29.
FSM00764
2. Disconnect camshaft solenoid connector and

FSM00765
3. Remove bolt securing camshaft solenoid to

cam cover and remove solenoid. Torque - 5
Nm.
12-47
ENGINE
Installation Sensor - Oxygen - Upstream

FRT No.: 12402100
to installation. Remove
WARNING: Only use cleaning agents and 1. Open hood.
90010100, page 90-2.
16200100, page 16-6.
60500100, page 60-12.
FSM00880

harness connections (x2). Tie ECM harness
aside.
ıııı
FSM00881
6. Disconnect oxygen sensor connector.
12-48
ENGINE
7. Release clip securing sensor connector to Sensor - Oxygen - Downstream

cam cover.
FRT No.: 12402300
Remove
1. Open hood.
90010100, page 90-2.
16200100, page 16-6.
60500100, page 60-12.
FSM00882
8. Remove oxygen sensor from catalyst. Torque

- 30 Nm.
Installation ıııı

to installation.
FSM00881
solvents in a well ventilated area. 5. Disconnect upstream oxygen sensor
2. Apply suitable anti-seize lubricant to oxygen connector.
sensor thread. 6. Release clip securing upstream sensor
connector to cam cover. Move upstream
sensor harness aside for access.
12-49
ENGINE
13. Remove oxygen sensor from center muffler.

Torque - 30 Nm.
FSM00970
7. Disconnect downstream oxygen sensor

connector. Installation
8. Release clip securing downstream sensor 1. Installation procedure is reverse of removal
connector to cam cover. except for the following.
9. Pass connector harness down back of engine NOTE: Clean component mating faces, prior
and engine bay area. to installation.
10. Raise and support vehicle. WARNING: Only use cleaning agents and
2. Apply suitable anti-seize lubricant to oxygen
sensor thread.
FSM01029

12-50
ENGINE
Fuel Tank
FRT No.: 12500100
Remove
operation.
2. Remove rear subframe assembly. Refer to
FRT: 60200200, page 60-2. FSM00648
6. Carefully remove sender module from fuel

tank.
component(s).
7. Remove and discard 'O' ring seal.
FSM00842
3. Disconnect fuel level sender harness

connector.
4. Evenly and progressively loosen and remove
bolts (x4) securing fuel level sender module to
tank. Torque - 8 Nm.
FSM00843
draining fuel.
8. Disconnect fuel tank pump harness
connector.
5. Carefully break joint between sender module
9. Evenly and progressively loosen and remove
and tank.
bolts (x8) securing fuel tank pump module to
NOTE: Note fitted position of components fuel tank. Torque - 8 Nm.
before removal.
10. Lift pump module for access to internal pipe
connection.
12-51
ENGINE

draining fuel.
FSM00840
2 1
FSM00651
11. Disconnect internal fuel pipe from module

cover. Disconnection is a two stage process.
Release blue clip and then depress white clip.
NOTE: Ensure internal fuel pipe two stage clip FSM00844
is returned to closed position before

14. Remove bolts (x2) securing tank straps to
connecting to module cover.
rear subframe. Torque - 55 Nm.
12. Maneuver pump module from fuel tank.
FSM00845
15. Remove fuel tank.
12-52
ENGINE
Installation Module - Sender - Fuel level

FRT No.: 12500200
to installation.
1. Remove LH inverter. Refer to FRT:
WARNING: Only use cleaning agents and 16400200, page 16-14.
2
3
3
FSM00647
2. Disconnect fuel level sender harness

FSM00846 connector.
2. Ensure a minimum clearance of 8 mm is 3. Evenly and progressively loosen and remove
observed between fuel tank seam and upper bolts (x4) securing fuel level sender module to
crossmember prior to torque tightening tank tank. Torque - 8 Nm.
strap bolts.
3. Install new 'O' ring seal to sender module. flammable and in confined spaces is also
4. Install pump module using a new 'O' ring explosive and toxic. Always have a fire
seal. extinguisher containing FOAM, CO2 GAS, or
5. If pump module has been changed due to draining fuel.
failure, inspect interior of fuel tank. Remove
any debris. WARNING: Eye protection must be worn.
4. Carefully break joint between sender module
and tank.
before removal.
12-53
ENGINE
Fuel Rail
FRT No.: 12500300
Remove
operation.
2. Remove fuel injector harness. Refer to FRT:
FSM00648
90101400, page 90-3.
5. Carefully remove sender module from fuel
tank.
component(s).
Installation
FSM00874
except for the following. 3. Release unions (x2) securing high pressure
pump to fuel rail feed pipe. Torque - 25 Nm.
to installation. NOTE: Place suitable absorbent material
WARNING: Only use cleaning agents and possible fluid spillage.
2. Install new 'O' ring seal to module. flammable and in confined spaces is also
draining fuel.
may be present.
4. Remove fuel rail feed pipe.
12-54
ENGINE
FSM00875 FSM00877
5. Remove bolts (x4) securing fuel rail to 8. Release clips (x4) and remove injectors from
cylinder head. Torque - 25 Nm. fuel rail.
6. Carefully release injectors and rail from CAUTION: Plug all open connections to
cylinder head. prevent ingress of moisture and dirt.
CAUTION: Injector seals swell when exposed
to atmospheric conditions for more than one
minute. Ensure protective sleeves are
installed.
Installation
NOTE: Injector seals are not available
a unit.
NOTE: Do not remove protective sleeve from
FSM0876
7. Remove fuel rail and injectors. to installation.
CAUTION: Plug all open connections to WARNING: Only use cleaning agents and
prevent ingress of moisture and dirt. solvents in a well ventilated area.
installed.
12-55
ENGINE
Injector - Each
FRT No.: 12500400
Remove
operation.
2. Remove fuel injector harness. Refer to FRT:
90101400, page 90-3. FSM00875
5. Remove bolts (x4) securing fuel rail to

6. Carefully release injectors and rail from
cylinder head.
FSM00874
3. Release unions (x2) securing high pressure

pump to fuel rail feed pipe. Torque - 25 Nm.
possible fluid spillage. 7. Remove fuel rail and injectors.

WARNING: Eye protection must be worn. CAUTION: Plug all open connections to
WARNING: Petrol/gasoline vapour is highly prevent ingress of moisture and dirt.
flammable and in confined spaces is also CAUTION: Injector seals swell when exposed
explosive and toxic. Always have a fire to atmospheric conditions for more than one
extinguisher containing FOAM, CO2 GAS, or minute. Ensure protective sleeves are
POWDER close at hand when handling or installed.
draining fuel.
may be present.
4. Remove fuel rail feed pipe.
12-56
ENGINE
Injector - Set
FRT No.: 12500500
Remove
1. Remove fuel rail. Refer to FRT: 12500300,
page 12-54.
operation.
FSM00877
Installation
8. Release clip and remove injector from fuel
rail. 1. Installation procedure is reverse of removal.
installed.
Installation
NOTE: Injector seals are not available
a unit.
NOTE: Do not remove protective sleeve from
to installation.
12-57
ENGINE
Regulator - Fuel Pressure NOTE: Place suitable absorbent material

FRT No.: 12500600 possible fluid spillage.
Remove
6. Disconnect fuel pump union. Torque - 25 Nm.
operation.
2. Isolate low voltage battery. Refer to FRT: POWDER close at hand when handling or
90010100, page 90-2. draining fuel.
3. Isolate high voltage battery. Refer to FRT: NOTE: Place suitable absorbent material
16200100, page 16-6. around the affected area to absorb any
4. Remove engine cover. Refer to FRT: possible fluid spillage.
12301000, page 12-29. CAUTION: Plug all open connections to
7. Remove bolts (x2) securing fuel pressure
regulator to intake manifold. Torque - 10 Nm.
FSM00854
5. Release clip and disconnect fuel feed pipe

from pressure regulator.
WARNING: Eye protection must be worn. FSM00855
WARNING: Care must be taken during fuel 8. Remove fuel pressure regulator.
may be present. Installation
WARNING: Petrol/gasoline vapour is highly 1. Installation procedure is reverse of removal.

flammable and in confined spaces is also NOTE: Clean component mating faces, prior
explosive and toxic. Always have a fire to installation.
extinguisher containing FOAM, CO2 GAS, or WARNING: Only use cleaning agents and
POWDER close at hand when handling or solvents in a well ventilated area.
draining fuel.
12-58
ENGINE
Module - Fuel Tank Pump

FRT No.: 12500900
Remove
90010100, page 90-2.
16200100, page 16-6.
3. Remove RH inverter. Removal procedure is
similar to LH inverter. Refer to FRT:
16400200, page 16-14.
FSM00650
6. Evenly and progressively loosen bolts (x8)

securing pump module to fuel tank. Torque -
8 Nm.
7. Lift pump module for access to internal pipe
connection.
FSM00649
2 1
4. Disconnect fuel tank pump harness
connector.
5. Release clip and disconnect fuel feed pipe
from fuel tank pump module.
extinguisher containing FOAM, CO2 GAS, or FSM00651
POWDER close at hand when handling or 8. Disconnect internal fuel pipe from module
draining fuel. cover. Disconnection is a two stage process.
NOTE: Place suitable absorbent material Release blue clip and then depress white clip.
around the affected area to absorb any NOTE: Ensure internal fuel pipe two stage clip
possible fluid spillage. is returned to closed position before
CAUTION: Plug all open connections to connecting to module cover.
12-59
ENGINE
2. Install pump module using a new 'O' ring

seal.
3. If fuel tank pump module has been changed
due to failure, inspect interior of fuel tank.
Remove any debris.
FSM00652
9. Due to limited access, compress pump

extension spring to shorten fuel pump overall
height.
10. Maneuver fuel tank pump module from fuel
tank.
FSM00840
Installation
to installation.
12-60
ENGINE
Fuel Pump - High Pressure

FRT No.: 12501000
Remove
operation.
12301000, page 12-29. FSM00852
6. Disconnect fuel pump unions (x2). Torque -

25 Nm.
may be present.
draining fuel.
FSM00858
3. Remove bolts (x3) securing fuel pump around the affected area to absorb any
support bracket. Remove bracket. Torque - possible fluid spillage.
10 Nm. CAUTION: Plug all open connections to
7. Loosen bolts (x2) securing fuel pressure
regulator brackets. Torque - 10 Nm.
8. Remove bolts (x2) securing fuel pump to
FSM00851
4. Disconnect harness connector.

5. Remove fuel pump acoustic cover.
12-61
ENGINE
Purge Valve
FRT No.: 12600200
Remove
FSM00853
9. Remove fuel pump.

CAUTION: Plug all open connections to FSM00860
2. Disconnect purge valve connector.
10. Remove and discard gasket.
3. Release clip and disconnect purge valve
11. Remove and discard 'O' ring seal. vacuum hose. Tie hose aside.
Installation 4. Remove bolt securing purge valve to intake
manifold. Torque - 4 Nm.
to installation.
2. Lubricate new 'O' ring seal with clean engine
oil.
FSM00861
5. Remove purge valve from intake manifold

and discard 'O' ring seal.
Installation
12-62
ENGINE
NOTE: Clean component mating faces, prior Air Cleaner Assembly

to installation.
FRT No.: 12700200
Remove
2. Replace disturbed 'O' ring seal.
1. Open hood.
NOTE: Apply a suitable lubricant to all 'O' ring
2. Remove road wheel. Refer to FRT:
seals.
54100501, page 54-2.
3. Remove front bumper reinforcement. Refer
to FRT: 70202200, page 70-11.
FSM00107
4. Disconnect Mass Air Flow (MAF) sensor

connector.
5. Loosen jubilee clip securing duct to air
cleaner and release duct.
8 8
7 7
FSM00106
7
6. Release clips (x3) securing engine bay
harness to bumper armature and position
harness aside.
12-63
ENGINE
7. Remove fasteners (x3) securing air cleaner to

body.
8. Remove air cleaner assembly and baffle.
FSM00110
11. Remove screws (x5) securing air cleaner

housing upper to air cleaning housing lower
FSM00108 and remove housing upper. Torque - 3 Nm.
9. Remove screw securing MAF sensor to air 12. Remove air cleaner element.
cleaner and remove sensor. Torque - 3 Nm.
Installation
to installation.
FSM00109
10. Remove screws (x3) securing baffle to air

cleaner and remove baffle. Torque - 3 Nm.
12-64
ENGINE
Element - Air Cleaner 2. Remove any debris from air cleaner

assembly.
FRT No.: 12700300
Remove
1. Open hood.
2
3
FSM00140
2. Disconnect Mass Air Flow (MAF) sensor

connector.
3. Loosen jubilee clip securing duct to air
cleaner and release duct.
4. Remove screws (x4) securing air cleaner
cover to housing. Torque - 3 Nm.
FSM00754
5. Lift cover and remove air cleaner element.

Note cover has been removed from graphic
for clarity.
Installation
12-65
ENGINE
Intake Manifold Gasket

FRT No.: 12700500
Remove
operation.
90010100, page 90-2. FSM00190
access.
FSM00862
FSM01006
10. Release harness clip from intake manifold
support bracket stud. Illustration shows
engine removed for clarity.
11. Loosen nut securing manifold support
bracket to cylinder block. Torque 50 Nm.
12. Lower vehicle to convenient height.
12301000, page 12-29.
14. Remove LH cross brace. Refer to FRT:
60500100, page 60-12.
12-66
ENGINE
FSM00726 FSM00748
15. Disconnect turbocharger boost pressure 18. Disconnect manifold absolute pressure
sensor connector and pipe. sensor connector.
16. Release clips (x2) and remove intercooler to
intake manifold charge hose/pipe.
FSM00859
19. Disconnect turbo boost pressure modulator

connector.
FSM00828 from modulator.
17. Release clip securing charge air pipe elbow 21. Remove purge valve. Refer to FRT:
to throttle body and remove elbow. 12600200, page 12-62.
12-67
ENGINE

FSM00858
22. Remove bolts (x3) securing fuel pump

support bracket. Remove bracket. Torque -
25 Nm.
FSM00863
26. Remove bolt from dipstick tube support

FSM00851
23. Disconnect fuel high pressure pump harness

connector.
24. Remove fuel high pressure pump acoustic
cover. FSM00864
25. Remove fuel pressure regulator. Refer to 27. Release dipstick tube from crankcase. Raise
FRT: 12500600, page 12-58. dipstick tube approximately 30 mm for
access.
WARNING: Petrol/gasoline vapour is highly around the affected area to absorb any
flammable and in confined spaces is also possible fluid spillage.
extinguisher containing FOAM, CO2 GAS, or CAUTION: Plug all open connections to
POWDER close at hand when handling or prevent ingress of moisture and dirt.
draining fuel. 28. Release clip securing engine harness to
intake manifold.
12-68
ENGINE
FSM00865 FSM00867
29. Remove bolt securing manifold support 33. Disconnect throttle body harness connector.
FSM00868
34. With assistance remove intake manifold.

FSM00866
30. Evenly and progressively loosen / remove

bolts (x5) and nuts (x2) securing intake
manifold to cylinder head. Torque - 25 Nm.
31. Release manifold from cylinder head studs.
32. Raise and support intake manifold to access
throttle body harness connector.
FSM00869
35. Remove and discard intake manifold gasket.

before removal.
12-69
ENGINE
Installation Throttle body

FRT No.: 12700700
to installation. Remove
WARNING: Only use cleaning agents and 1. Remove intake manifold. Refer to FRT:
solvents in a well ventilated area. 12700500, page 12-66.
2. Fit new intake manifold gasket.
FSM00889
2. Remove bolts (x4) securing throttle body to

intake manifold. Torque 10 Nm.
FSM00890
3. Remove throttle body.

12-70
ENGINE
Intercooler - (Charge Air Cooler)

FRT No.: 12704000
Remove
90010100, page 90-2.
16200100, page 16-6.
4. Remove air cleaner assembly for access.
FSM00891
4. Remove and discard 'O' ring seal from intake

manifold.
Installation
to installation.
2. Fit new `O' ring seal to intake manifold.
FSM01010
seals. 5. Remove clips (x3) securing bumper
absorption pad to body.
6. Remove bumper absorption pad.
FSM01014
7. Remove bolts (x3) securing low temp battery

chiller assembly to body. Torque - 10 Nm.
8. Carefully reposition low temp battery chiller.
12-71
ENGINE
FSM01015 FSM01016
9. Remove screw securing battery cooling low 14. Remove screws (x2) securing air baffle to
temperature coolant pump bracket. radiator bracket. Torque - 10 Nm.
10. Carefully reposition battery cooling low 15. Raise and support vehicle.
temperature coolant pump.
FSM01017
16. Disconnect alarm sounder connector and

FSM01013
11. Release clips (x2) securing charge air harness.

intercooler feed hose. 17. Remove nut and bolt securing alarm sounder
12. Remove charge air intercooler feed hose to body and remove alarm sounder. Torque -
from intercooler. 10 Nm.
13. Repeat steps above and remove charge air
intercooler return hose.
12-72
ENGINE
2. Fit hoses after installation of intercooler is

complete, position clips for easier access.
to installation.
FSM00669
18. Remove nuts (x2) securing intercooler LH

mounting bracket to chassis rail. Torque - 10
Nm.
19. Repeat step above and remove nuts from RH
20. Release intercooler and brackets from studs.
21. Reposition air inlet duct away from
intercooler assembly and tie aside.
22. Carefully remove intercooler assembly.
component(s).
FSM00670
23. Remove screws (x4) and collect brackets

(x2). Torque - 10 Nm.
Installation
12-73
ENGINE
Muffler Assembly - LH
FRT No.: 12800100
Remove
1. Disconnect post catalyst oxygen sensor
harness connector.
2. Remove LH front wheel arch liner. Refer to
FRT: 78100100, page 78-2.
FSM00969
8. Remove screws (x3) securing muffler rear

heatshield to body. Remove heatshield.
Illustration shows muffler removed for clarity.
9. Apply suitable release agent to exhaust
clamp nut.
FSM00593
4. Remove nuts (x2) securing 'Y' pipe flange to

catalyst. Torque - 45 Nm.
5. Release exhaust 'Y' pipe flange from catalyst.
FSM00590
10. Loosen nut securing LH muffler clamp to 'Y'

pipe. Torque - 25 Nm.
ıııı 11. Release muffler clamp and slide aside.
FSM00968
6. Remove bolts (x2) securing muffler front

hanger bracket to body. Torque - 25 Nm.
7. Tilt exhaust system forward for access to
muffler rear heatshield.
12-74
ENGINE
Exhaust System Complete - Remove and

Refit for Access
FRT No.: 12800301
Remove
1. Disconnect post catalyst oxygen sensor
harness connector.
FSM00591
12. Lubricate muffler rear isolation rubber to aid

release.
13. Rock muffler to break 'Y' pipe bond and
disconnect joint.
14. Slide muffler forward and release rear
isolation rubber from body mounting bracket.
15. Remove muffler assembly
FSM01006

4. Release center muffler flange from catalyst.
5. Position a transmission jack to support
exhaust system.
FRT: 78100100, page 78-2.
7. Remove RH front wheel arch liner.
FSM00592
16. Remove both isolation rubber mountings

from muffler.
Installation
to installation.
12-75
ENGINE
Installation
to installation.
FSM01007
8. Remove bolts (x2) securing LH muffler front

hanger bracket to body. Torque - 25 Nm.
9. Lubricate LH muffler rear isolation rubber to
aid release.
10. Slide LH muffler forward and release rear
isolation rubber from body mounting bracket.
11. Repeat above steps on RH side muffler.
12. Fit retaining straps over exhaust assembly
and secure to transmission jack.
13. Carefully lower transmission jack and
exhaust assembly from vehicle.
operation.
FSM01008
14. With assistance, release retaining straps and

place exhaust assembly aside.
12-76
ENGINE
Exhaust manifold gasket

FRT No.: 12800500
Remove
operation.
2. Remove turbocharger. Refer to FRT:
12800700, page 12-79. FSM00947
5. Remove exhaust manifold.

FSM00945
3. Remove bolts (x3) securing exhaust manifold

heatshield. Remove heatshield. Torque - 10
Nm. FSM00948
6. Remove and discard exhaust manifold

gasket.
before removal.
Installation
to installation.
FSM00946
4. Progressively loosen and remove nuts (x10) CAUTION: Replace all Nyloc nut(s).
securing exhaust manifold to cylinder head. 2. Fit new manifold gasket.
Discard nuts. Torque - 25 Nm.
12-77
ENGINE
NOTE: Note fitted position of components Muffler Assembly - Center

before removal.
FRT No.: 12800600
2 9 Remove
1 1. Remove exhaust system complete. Refer to

FRT: 12800301, page 12-75.
6
8 10
5
3
7 4
FSM00949
3. Tighten manifold nuts in sequence.
FSM01009
2. Remove post catalyst oxygen sensor from

center muffler assembly. Torque - 30 Nm.
3. Loosen nut securing LH muffler clamp.
Torque - 25 Nm.
4. Release LH muffler clamp and slide aside.
5. Rock LH muffler to break center muffler
assembly bond.
6. Remove LH muffler assembly.
7. Remove LH muffler clamp.
8. Repeat above steps and remove RH muffler
assembly.
9. Place center muffler aside.
Installation
to installation.
sensor thread.
12-78
ENGINE
Turbocharger
FRT No.: 12800700
Remove
operation.
2. Drain engine coolant. Refer to FRT:
20010100, page 20-2. FSM00896
3. Remove front cross brace. Refer to FRT: 8. Release turbo air intake hose clip. Release
60500300, page 60-13. intake hose from turbo.
4. Remove exhaust catalyst. Refer to FRT: CAUTION: Plug all open connections to
12800900, page 12-82. prevent ingress of moisture and dirt.
FSM00895 FSM00897
5. Release clip securing turbo outlet flexible 9. Release clip and disconnect vacuum tube
hose to charge air pipe. from turbo. Position hose aside.
6. Remove bolts (x2) securing turbo outlet pipe 10. Disconnect boost pressure regulator
to turbo outlet flange. Torque - 25 Nm. connector. Position harness aside.
7. Remove turbo outlet elbow. Remove and
discard gasket.
12-79
ENGINE

13. Remove bolt securing cam cover to turbo
breather pipe. Release pipe and position
aside. Torque - 10 Nm.
seals.
FSM00898
11. Release coolant feed and return unions to 14. Raise vehicle to convenient height.
turbo. Disconnect coolant pipes from turbo
and position aside. Discard washers. Torque
- ?? Nm.
FSM00900
15. Remove bolts (x2) securing catalyst support

bracket to engine block. Remove bracket.
Torque - 50 Nm.
FSM00899
12. Release oil feed pipe union from turbo.

Disconnect oil feed pipe from turbo and
position aside. Discard washer. Torque - ??
Nm.
12-80
ENGINE
FSM00901 FSM00903
16. Remove nut securing turbo support bracket 22. Maneuver turbo clear of exhaust manifold
to turbo. Torque - 25 Nm. studs and remove.
17. Remove bolt securing turbo brace to cylinder
block. Torque - 50 Nm.
18. Remove turbo brace.
19. Release turbo oil return pipe from engine
block.
seals.
possible fluid spillage. FSM00904
23. Remove and discard turbo to exhaust

manifold flange gasket.
before removal.
FSM00902
20. Remove nuts (x4) securing turbo to exhaust

manifold. Torque - 25 Nm.
21. Lower vehicle to convenient height.
12-81
ENGINE
Catalyst - Exhaust
FRT No.: 12800900
Remove
1. Remove LH front road wheel. Refer to FRT:
54100501, page 54-2.
operation.
FSM00905
2. Remove RH front road wheel. Refer to FRT:
24. Remove bolts (x2) securing oil return pipe to 54100501, page 54-2.
turbo. Remove pipe and discard gasket. 3. Isolate low voltage battery. Refer to FRT:
Torque - 10 Nm. 90010100, page 90-2.
CAUTION: Plug all open connections to 4. Isolate high voltage battery. Refer to FRT:
prevent ingress of moisture and dirt. 16200100, page 16-6.
Installation 5. Remove upstream oxygen sensor. Refer to

FRT: 12402100, page 12-48.
to installation.
2. Replace all disturbed 'O' ring seals.
seals.
FSM00883
6. Remove bolts (x3) securing turbocharger

heatshield. Torque - 10 Nm.
7. Remove turbocharger heatshield.
12-82
ENGINE
FSM00884 FSM01006
8. Remove screw securing catalyst heatshield 14. Remove nuts (x2) securing center muffler
to upper chassis rail. Torque - 8 Nm. flange to catalyst. Torque - 45 Nm.
15. Release flange and remove exhaust pipe.
FSM00885
9. Remove nuts (x4) securing catalyst to FSM00886
turbocharger flange. Torque - 50 Nm. 16. Remove screw securing catalyst heatshield
10. Raise vehicle to convenient height. to subframe. Torque - 8 Nm.
11. Remove RH muffler assembly. Removal 17. Remove catalyst heatshield.
procedure is similar to LH muffler assembly.
12. Disconnect catalyst downstream oxygen
sensor harness connector.
12-83
ENGINE
FSM00887
18. Remove bolts (x2) securing catalyst to

mounting bracket. Torque - 37 Nm.
FSM00888
19. Maneuver catalyst clear of turbocharger

studs, remove through underside aperture.
Installation
to installation.
12-84
ELECTRIC DRIVE
Contents Page
Generator .................................................................................................................................. 16-2

Mounting - Generator to Body.................................................................................................. 16-4
Shaft Coupler - Generator ........................................................................................................ 16-5
Battery - High Voltage - Isolation - Manual Service Disconnect - (MSD) ................................. 16-6
Battery Assembly ...................................................................................................................... 16-7
Fuse - Battery Assembly........................................................................................................... 16-9
Charging Port.......................................................................................................................... 16-10
AC/DC Inverter - From Generator........................................................................................... 16-11
Inverter 3 Phase AC - LH ........................................................................................................ 16-14
DC/DC Converter.................................................................................................................... 16-16
16-1
ELECTRIC DRIVE
Generator
ELECTRIC DRIVE
FRT No.: 16100100
Remove
3. Position subframe assembly at a suitable
working height.
FSM00634
5. Working from generator adaptor side remove

top bolts (x2) securing generator adaptor to
engine. Torque - 70 Nm.
6. Support weight of generator using suitable
lifting equipment.
FSM00633
4. Working from engine side remove flange

bolts (x5) securing generator adaptor to
engine. NOTE: Subframe has been removed
from illustration for clarity. Torque - 70 Nm.
FSM00635
7. With assistance remove generator and

position clear of engine and subframe.
16-2
ELECTRIC DRIVE
2. Apply suitable lubricant sparingly to coupler

splines prior to assembly.
3. Clean dowels and dowel holes.
FSM00637
8. Remove bolts (x9) securing adaptor ring to

generator. Torque - 45 Nm.
9. Remove generator adaptor ring.
FSM00636
10. Remove coupler shaft from flywheel drive or

generator. Note: Short spline to engine at
assembly.
11. Clean coupler and check splines for wear and
damage. Replace if required.
Installation
to installation.
16-3
ELECTRIC DRIVE
Mounting - Generator to Body

FRT No.: 16100200
Remove
operation.
2. Remove high voltage battery. Refer to FRT:
16200200, page 16-7. FSM00632
3. Position support beneath generator. 5. Remove nut securing bushing to mounting

FSM00631
FSM00716
4. Remove concealed nut securing bushing to
generator mounting bracket. Torque - 65 6. Remove bolt securing mounting bracket to
Nm. body. Torque - 125 Nm.
FSM00717
7. Remove bracket and bushing.
16-4
ELECTRIC DRIVE
Installation Shaft Coupler - Generator

FRT No.: 16100300
to installation.
1. Remove generator. Refer to FRT: 16100100,
CAUTION: Replace all patch bolt(s). page 16-2.
2. Ensure flat on bushing is located against
register on brackets. Installation
to installation.
2. Apply suitable lubricant sparingly to coupler
splines prior to assembly.
3. Clean dowels and dowel holes.
16-5
ELECTRIC DRIVE
Battery - High Voltage - Isolation - Manual

Service Disconnect - (MSD)
FRT No.: 16200100
Remove
1. Disconnect 12V battery. Refer to FRT:
90010100, page 90-2.
2. Remove rear LH seat cushion. Refer to FRT:
86100400, page 86-3.
FSM00619
5. Release clip and remove Manual Service

Disconnect (MSD) plug.
CAUTION: Wait 5 minutes for high voltage
capacitors to discharge after removal of the
Manual Service Disconnect (MSD). Although
the battery has been disconnected residual
current may still be present.
Installation
FSM00822
3. Release latch pin from (MSD) latch. NOTE: Clean component mating faces, prior
WARNING: HIGH VOLTAGE battery contains to installation.
lethal voltage.
WARNING: Do not remove the Manual
Service Disconnect (MSD) if the vehicle is
switched on or running.
WARNING: Intentional disconnection of the
Manual Service Disconnect (MSD) under load
could potentially damage the battery pack
and cause injury to the person performing the
act.
4. Lift cover for access to (MSD) plug.
16-6
ELECTRIC DRIVE
Battery Assembly
FRT No.: 16200200
NOTE: Prior to battery removal procedure,

vehicle must be positioned parallel in X and Y
planes on the two post lift. Ensure pads are at
the correct height and arms are evenly
spaced, failure to comply with this
requirement will result in battery clashing with
body during installation.
CAUTION: The use of levers and pry bars
during the removal and installation procedure
FSM00710
is prohibited.
7. Disconnect HV battery charger connectors
Remove (x3) and release harness clips (x2).
1. Raise and support vehicle. 8. Tie charger harness aside for access.
WARNING: Make sure the vehicle is correctly CAUTION: Take care not to damage
supported before commencing work. component(s).
operation.
2. Isolate high voltage battery.
3. Raise vehicle to a safe working height.
4. Remove high voltage closing panel. Refer to
FRT: 60502000, page 60-14.
5. Remove tunnel closing panel. Refer to FRT:
60501500, page 60-13.
before removal.
6. Drain battery low temperature coolant. Refer FSM00623
to FRT: 20010500, page 20-3. 9. Disconnect HV generator harness

NOTE: Position a suitable container to connectors (x3) and remove bolt securing HV
contain fluid spillage. plug to battery. Torque - 8 Nm.
CAUTION: Plug all open connections to 10. Disconnect generator HV plug from battery,
prevent ingress of moisture and dirt. release trunking and tie harness aside.
component(s).
16-7
ELECTRIC DRIVE
FSM00711 FSM00624
11. Remove nuts (x2) and bolt (x1) securing HV 16. Evenly and progressively loosen and remove
cable harness tray to battery. Torque - 3 Nm. bolts (x26) securing battery to body. Torque -
20 Nm.
before removal.
FSM00712
12. Remove bolt and disconnect HV inverter plug

from battery, tie cable tray and cables aside.
Torque - 8 Nm. FSM00625
CAUTION: Take care not to damage 17. With assistance lower battery and remove
component(s). from vehicle.
13. Release lock ring and disconnect lower body WARNING: This component is extremely
harness bayonet connector. heavy, to avoid personal injury observe all
14. Check high voltage cables are clear for relevant safety precautions before removal.
access to battery.
Installation
15. Position tool FST1001to a suitable scissor lift
to support weight of high voltage battery.
to installation.
operation.
16-8
ELECTRIC DRIVE
CAUTION: During removal and installation Fuse - Battery Assembly

the battery must be kept horizontal and
vertical to ensure correct alignment and FRT No.: 16201000
prevent damage to components.
Remove
securing battery to body. 1. Raise and support vehicle.
3. Refill and bleed battery low temperature WARNING: Make sure the vehicle is correctly
coolant. supported before commencing work.
operation.
2. Remove high voltage cable closing panel.
FSM00714
3. Remove screws (x4) securing battery fuse

cover. Torque - 3 Nm.
4. Remove fuse cover.
16-9
ELECTRIC DRIVE
Charging Port
FRT No.: 16250100
Remove
operation.
16200100, page 16-6.
3. Remove LH rear wheel arch liner. Refer to
FRT: 78100300, page 78-3.
FSM00715
5. Remove fuse(s) from holder. Replace with

fuse of the same value as required.
FSM00775
Installation 4. Disconnect charging port harness connector

1. Installation procedure is reverse of removal and release clip (x1).
except for the following. 5. Depress clips (x2) and release charging port
NOTE: Clean component mating faces, prior from body.
to installation. 6. Rotate and carefully remove charging port
and harness from body.
16-10
ELECTRIC DRIVE
AC/DC Inverter - From Generator

FRT No.: 16400100
Remove
90010100, page 90-2.
16200100, page 16-6.
FSM00776
7. Remove nuts (x4) securing plug to charging 60500100, page 60-12.
port. Torque - 6 Nm.
FSM00880
FSM00777
8. Remove socket and harness from charging harness connectors (x2), remove nut
port. securing ECM harness connector and
Installation
to installation.
16-11
ELECTRIC DRIVE
FSM00928 FSM00930
7. Disconnect harness connector from AC/DC 11. Release clip and disconnect AC/DC inverter
inverter, remove bolt securing ECM harness coolant hose.
connector and position harness aside. 12. Release clips (x2) on high voltage
8. Drain and recover low temperature coolant. connectors.
ıııı
FSM00881
13. Release oxygen sensor connection.

FSM00929
9. Release clip and disconnect AC/DC inverter 14. Release clip securing sensor connector to
coolant hose. camshaft cover.
10. Release clips (x2), disconnect and remove
coolant bridging hose.
16-12
ELECTRIC DRIVE
FSM00882 FSM00932
15. Remove oxygen sensor from catalyst. Torque 20. Remove screws (x2) and remove water pump
- 30 Nm. bracket. Position water pump aside.
CAUTION: Plug all open connections to 21. Lower vehicle.
16. Release hood switch and position aside.
17. Remove RH front wheel arch liner. Removal
procedure is similar to LH front wheel arch
liner. Refer to FRT: 78100100, page 78-2.
FSM00933
22. Remove bolt securing AC/DC inverter to

bracket.
23. Remove bolts (x2) securing inverter bracket
to dash wall brace.
24. Remove bolts (x4) securing dash wall brace.
FSM00931
18. Remove bolt securing AC/DC inverter to 25. Remove all brackets, supports and grounds
bracket. mounted to brace.
19. Remove bolts (x2) securing inverter bracket 26. Remove dash wall brace.
to dash wall.
27. Remove inverter bracket.
28. With assistance disconnect inverter from
high voltage connectors (x2) and remove
from vehicle.
16-13
ELECTRIC DRIVE
Installation Inverter 3 Phase AC - LH

FRT No.: 16400200
to installation.
2. Drain low temperature coolant. Refer to FRT:
sensor thread.
20010900, page 20-4.
3. Lower vehicle.
90010100, page 90-2.
16200100, page 16-6.
6. Remove trunk closing panel. Refer to FRT:
70401700, page 70-30.
FSM00640
7. Release clips (x2) and disconnect low

temperature coolant hoses from inverter.
16-14
ELECTRIC DRIVE
FSM00641 FSM00643
8. Disconnect high voltage connections (x2) 13. Remove inverter from bracket.
from inverter.
9. Disconnect low voltage harness connector
from inverter.
FSM00644
14. Remove bolts (x4) securing inverter bracket

to body. Torque - 10 Nm.
15. Remove bracket.
FSM00642
10. Remove bolt securing ground cable to

inverter. Torque - 6 Nm. Installation
11. Position ground cable aside. 1. Installation procedure is reverse of removal
12. Remove remaining bolts (x2) securing
inverter to bracket. Torque - 6 Nm. NOTE: Clean component mating faces, prior
to installation.
2. Ensure both harness grounds are clean when
reconnecting to inverters.
3. Refill and bleed low temperature coolant.
16-15
ELECTRIC DRIVE
DC/DC Converter
FRT No.: 16400400
Remove
90010100, page 90-2.
16200100, page 16-6.
5. Remove suspension turret cross brace. Refer FSM00190
to FRT: 60500300, page 60-13.
11. Remove screws (x4) securing central
6. Remove LH suspension turret cross brace.
heatshield to subframe and remove shield.
Torque - 10 Nm.
7. Raise vehicle.
8. Drain and recover low temperature coolant.
9. Remove exhaust system complete. Refer to
FRT: 12800301, page 12-75.
FSM00784
12. Remove bolt and disconnect generator high

voltage connector. Torque - 10 Nm.
13. Tie high voltage harness aside for access.
FSM00148
10. Drill out rivet (x4) securing LH exhaust

heatshield to brackets (x2) and remove
shield.
NOTE: Refit component/s using suitable pop
rivets at correct installation point during
procedure.
16-16
ELECTRIC DRIVE
19. Tie ground cables aside for access.
FSM00785
14. Release clip and disconnect DC/DC coolant FSM00726
hose. 20. Disconnect boost pressure sensor harness

NOTE: Position a suitable container to connector.
contain fluid spillage. 21. Disconnect boost pressure pipe.
15. Remove nuts (x2) securing rear end of DC/DC CAUTION: Plug all open connections to
converter mounting bracket to body. Torque prevent ingress of moisture and dirt.
- 10 Nm.
22. Release clips (x2) securing charge air inlet
CAUTION: Replace all Nyloc nut(s). pipe to intercooler and throttle body.
16. Lower vehicle. 23. Remove charge air inlet pipe for access.
FSM00680 FSM00786
17. Release clip and disconnect coolant hose 24. Release clip and tie heater hoses aside for
from DC/DC converter. access.
NOTE: Place suitable absorbent material 25. Disconnect harness connectors (x2) from
around the affected area to absorb any DC/DC converter.
18. Remove bolts (x2) securing ground cables to
DC/DC converter. Torque - 10 Nm.
16-17
ELECTRIC DRIVE
FSM00787 FSM00789
26. Working through aperture created by removal 28. Carefully raise DC/DC converter and
of charge air pipe. Remove screws (x2) mounting bracket until the lower harness
securing DC/DC mounting bracket to connection can be accessed.
suspension turret. Torque - 10 Nm. Note: CAUTION: Take care not to damage
Heater hoses have been removed from component(s).
graphic for clarity.
29. Disconnect remaining harness connector.
30. Remove DC/DC converter from vehicle.
31. Remove bolts (x2) and remove bracket from
converter. Torque - 10 Nm.
Installation
to installation.
FSM00788
27. Remove screw securing DC/DC converter

bracket to firewall. Torque - 10 Nm.
16-18
COOLING SYSTEM
Contents Page
Coolant - Engine and Cabin - Drain and Refill .......................................................................... 20-2

Coolant - Battery - Low Temp - Drain - Refill and Bleed.......................................................... 20-3
Coolant - Low Temp - Motors, Generators and Inverters - Drain and Refill............................. 20-4
Pump - Coolant - Auxiliary Heating .......................................................................................... 20-5
Pump - Coolant - Low Temp - Generator and DC/DC - Front ................................................. 20-6
Pump - Low Temp - Coolant - Rear ......................................................................................... 20-7
Pump - Coolant - Low Temperature - Battery Cooling............................................................. 20-9
Radiator Pack ......................................................................................................................... 20-10
Cooling Fan Assembly ............................................................................................................ 20-11
Module - Cooling Fan Speed .................................................................................................. 20-14
Radiator - Low Temp - LH ...................................................................................................... 20-14
Cooling Fan Assembly - Low Temp - LH................................................................................ 20-16
Coolant Reservoir Assembly - High Voltage Battery .............................................................. 20-17
Heater - Electric - PTC............................................................................................................ 20-18
Chiller with TXV - Low Temp Battery Cooling......................................................................... 20-19
20-1
COOLING SYSTEM
Coolant - Engine and Cabin - Drain and

COOLING SYSTEM
Refill
FRT No.: 20010100

Drain & Refill

1. Open hood.
FSM00093
5. Remove coolant drain plug from high

temperature radiator.
6. Allow coolant to drain into container.
Bleed
1. Install drain plug to radiator.
NOTE: Clean component mating faces.
2. Using suitable equipment, fill to upper level
mark with coolant and evacuate system.
FSM00092
CAUTION: To prevent damage, do not allow
2. Remove engine and cabin coolant reservoir electric pumps to run until sufficient coolant
pressure cap. has entered system to facilitate bleeding.
NOTE: Place suitable absorbent material 3. Check and top up coolant reservoir.
around the affected area to absorb any 4. Install reservoir cap.
operation.
4. Position container to collect coolant.
20-2
COOLING SYSTEM
Coolant - Battery - Low Temp - Drain -

Refill and Bleed
FRT No.: 20010500
Drain & Refill

operation.
FSM00736
4. Remove cap from battery low temperature

reservoir.
5. Using suitable equipment, fill to upper level
mark with coolant and evacuate system.
electric pumps to run until sufficient coolant
has entered system to facilitate bleeding.
6. Check and top up coolant reservoir.
FSM00709
2. Disconnect low temperature coolant hoses at

battery connection.
3. Allow cooling system to drain.
Bleed
1. Ensure hoses are connected.
2. Lower vehicle.
3. Open hood.
20-3
COOLING SYSTEM
Coolant - Low Temp - Motors, Generators

and Inverters - Drain and Refill
FRT No.: 20010900
Drain & Refill

operation.
FSM00739
4. Remove cap from low temperature

electronics coolant reservoir.
5. Refill until coolant is at upper level mark.
electric pumps to run until sufficient coolant
has entered system to facilitate bleeding.
6. Bleed cooling system.
7. Check and top up coolant reservoir.
FSM00740
2. Release clip and disconnect rear drive motor

coolant hose.
3. Allow cooling system to drain.
Bleed
1. Ensure hoses are connected.
2. Lower vehicle.
3. Open hood.
20-4
COOLING SYSTEM
Pump - Coolant - Auxiliary Heating

FRT No.: 20100100
Remove
operation.
2. Drain Engine and Cabin coolant. Refer to
FRT: 20010100, page 20-2. FSM00685
3. Lower vehicle. 6. Release clips (x2) and disconnect coolant

hoses from pump.
4. Remove Wiper motor assembly. Refer to
FRT: 90900100, page 90-27. NOTE: Place suitable absorbent material
7. Remove screw securing coolant pump
retaining strap. Torque - 10 Nm.
8. Remove retaining strap.
FSM00686
5. Disconnect coolant pump and temperature

sensor harness connectors.
FSM00684
9. Release and remove pump from mounting.
Installation
to installation.
20-5
COOLING SYSTEM
Pump - Coolant - Low Temp - Generator

and DC/DC - Front
FRT No.: 20100500
Remove
operation.
2. Open vehicle hood. FSM00928
3. Isolate low voltage battery. Refer to FRT: 7. Disconnect harness connector from AC/DC
90010100, page 90-2. inverter, remove bolt securing ECM harness
connector and position harness aside.
16200100, page 16-6. 8. Drain low temperature coolant. Refer to FRT:
20010900, page 20-4.
60500100, page 60-12.
FSM00681
9. Release clips (x3) disconnect and remove

FSM00880 coolant bridging hose assembly.
6. Depress latches and disconnect ECM NOTE: Place suitable absorbent material
harness connectors (x2), remove nut around the affected area to absorb any
securing ECM harness connector and possible fluid spillage.
position harness aside. CAUTION: Plug all open connections to
20-6
COOLING SYSTEM
Pump - Low Temp - Coolant - Rear

FRT No.: 20100700
Remove
operation.
FSM00682
90010100, page 90-2.
10. Disconnect coolant pump harness 3. Isolate high voltage battery. Refer to FRT:
connector. 16200100, page 16-6.
11. Release clip and disconnect coolant pump 4. Drain low temperature coolant. Refer to FRT:
outlet hose. 20010900, page 20-4.
5. Remove rear diffuser closing panel. Refer to
FRT: 70100300, page 70-3.
FSM00683
12. Remove screws (x2) securing coolant pump

clamp to mounting bracket. Torque - 10 Nm. FSM00205
13. Remove pump clamp 6. Disconnect coolant pump harness

14. Remove pump from mounting. connectors (x2).
Installation
to installation.
20-7
COOLING SYSTEM
FSM00664 FSM00665
7. Release clips (x4) and disconnect coolant 9. Remove both pumps from mounting bracket.
hoses from pump. NOTE: Note fitted position of components
NOTE: Position a suitable container to before removal.
Installation
prevent ingress of moisture and dirt. 1. Installation procedure is reverse of removal
to installation.
2. Ensure pump ridges are correctly installed to
mounting bracket.
FSM00206
8. Remove nuts (x3) securing coolant pump to

20-8
COOLING SYSTEM
Pump - Coolant - Low Temperature -

Battery Cooling
FRT No.: 20101000
Remove
ı

operation.
2. Isolate low voltage battery. Refer to FRT: FSM00782
90010100, page 90-2. 7. Disconnect electrical harness connector from

3. Isolate high voltage battery. Refer to FRT: pump.
16200100, page 16-6. 8. Remove bolt securing pump clamp to
4. Remove front bumper reinforcement. Refer mounting bracket. Torque - 10 Nm.
to FRT: 70202200, page 70-11.
5. Drain battery low temperature cooling circuit.
FSM00783
9. Release clamp and remove pump.

FSM00781 before removal.
6. Release clips (x2) and disconnect both
coolant hoses from pump. Installation
NOTE: Position a suitable container to 1. Installation procedure is reverse of removal

contain fluid spillage. except for the following.
to installation.
2. Ensure register on pump is correctly located
to mounting bracket prior to tightening bolt.
20-9
COOLING SYSTEM
Radiator Pack
FRT No.: 20200100
Remove
operation.
2. Drain engine and cabin coolant. Refer to FRT:
20010100, page 20-2. FSM00690
3. Remove cooling fan assembly. Refer to FRT: 10. Release clip and disconnect radiator bottom
20200200, page 20-11. hose.
4. Open vehicle hood to service position. NOTE: Place suitable absorbent material
5. Remove intercooler assembly. Refer to FRT:
12704000, page 12-71.
6. Remove cooling fan assembly. Refer to FRT:
20200200, page 20-11.
11. Position a suitable height adjustable support
beneath the radiator.
12. Check all mounts, pipes hoses are clear or
radiator.
13. Protect radiator and condenser elements
with cardboard to prevent damage during
removal.
FSM00688
7. Release clip and disconnect radiator top

hose.
CAUTION: Plug all open connections to FSM01027
14. Tilt lower edge of radiator assembly
8. Release ties securing radiator.
rearwards and with assistance remove from
9. Raise vehicle. vehicle.
20-10
COOLING SYSTEM
CAUTION: Take care not to damage Cooling Fan Assembly

component(s).
FRT No.: 20200200
Installation
1. Installation procedure is reverse of removal Remove
except for the following. 1. Raise and support vehicle.
NOTE: Clean component mating faces, prior WARNING: Make sure the vehicle is correctly
to installation. supported before commencing work.
2. Refill and bleed engine and cabin coolant. WARNING: To avoid serious injury, use
operation.
90010100, page 90-2.
16200100, page 16-6.
4. Remove intercooler. Refer to FRT:
12704000, page 12-71.
FSM00130
5. Remove bolts (x2) securing each sway bar

bush clamp to chassis. Torque - 30 Nm.
6. Release sway bar from chassis and tie aside.
7. Lower vehicle.
20-11
COOLING SYSTEM
FSM01019 FSM01021
8. Remove screws (x4) securing upper radiator 14. Remove screw securing A/C pipe mount to
mounting bracket to chassis. Torque - 6 Nm. radiator and remove mount. Torque - 6 Nm.
9. Release radiator top mounting bracket from 15. Release condenser from radiator lower
radiator, reposition and remove from vehicle. mounts.
10. Carefully release air baffle from condenser,
reposition and remove from vehicle.
component(s).
FSM01022
16. Remove screws (x2) securing coolant link

pipe to skid frame rail. Torque - 6 Nm.
FSM01020
11. Remove bolts (x2) securing cooling fan,

radiator and condenser assembly. Torque - 4
Nm.
12. Secure radiator using suitable ties.
13. Raise vehicle.
20-12
COOLING SYSTEM
FSM01023 FSM01025
17. Remove screws (x2) securing skid frame rail 23. Carefully lower fan and cowl assembly past
to chassis mounting bracket. RH illustrated. radiator and bottom radiator hose.
Torque - 25 Nm. CAUTION: Take care not to damage
18. Release low temp radiator mounts (x4) and component(s).
radiator assembly mounts (x2) from skid
frame rail.
19. Remove skid frame rail from vehicle.
20. Carefully reposition radiator assembly away
from engine to improve access and tie aside.
FSM00564
24. Remove cooling fan assembly.
Installation
FSM01024
21. Disconnect harness connector from fan

speed module.
22. Carefully lift fan cowl and release lugs (x2)
from radiator hooks.
20-13
COOLING SYSTEM
Module - Cooling Fan Speed Radiator - Low Temp - LH

FRT No.: 20200300 FRT No.: 20200400
Remove Remove
1. Open hood. 1. Raise and support vehicle.
2. Isolate low voltage battery. WARNING: Make sure the vehicle is correctly
3. Remove Cooling fan assembly. Refer to FRT: supported before commencing work.
20200200, page 20-11. WARNING: To avoid serious injury, use
operation.
5 2. Open vehicle hood to service position. Note:
4 Illustration has hood removed for clarity.
5
6
FSM00565
4. Remove screw securing cooling fan module

to shroud. Torque - 3 Nm.
5. Release cooling fan module lugs (x2) from
cowl.
FSM00695
6. Disconnect cooling fan module harness 3. Remove screws (x2) securing LH low
connector. temperature radiator upper mounting bracket
to chassis. Torque - 10 Nm.
7. Remove cooling fan speed module.
4. Remove front bumper assembly for access.
Installation Refer to FRT: 70202101, page 70-10.
1. Installation procedure is reverse of removal. 5. Remove LT cooling fan. Refer to FRT:

20200600, page 20-16.
to installation. 6. Drain battery low temperature coolant. Refer
to FRT: 20010500, page 20-3.
20-14
COOLING SYSTEM
FSM00696 FSM00698
7. Release clip and disconnect LT top coolant 11. Remove screws (x4) securing intake duct to
hose. radiator. Torque - 3 Nm.
CAUTION: Plug all open connections to 12. Remove duct.
Installation
8 to installation.
2. Refill and bleed battery low temperature
coolant.
9
FSM00697
8. Lift radiator upper mounting bracket clear of

spigot isolator.
9. Lift and tilt radiator to release lower spigots
from isolators
10. Remove radiator assembly.
component(s).
20-15
COOLING SYSTEM
Cooling Fan Assembly - Low Temp - LH 2. Clear radiator debris prior to installing cooling
fan assembly.
FRT No.: 20200600
Remove
operation.
FRT: 78100100, page 78-2.
FSM00560
3. Remove fasteners (x4) securing fan assy to

radiator shroud.
4. Disconnect fan motor harness connector.
FSM00561
5. Remove fan assembly.
Installation
20-16
COOLING SYSTEM
Coolant Reservoir Assembly - High Voltage

Battery
FRT No.: 20300800
Remove
1. Open hood.
FSM00757
7. Remove screws (x3) securing coolant

reservoir to chassis. Torque - 3 Nm.
FSM00755
2. Clamp coolant reservoir outlet hoses at a

suitable points.
3. Remove reservoir cap and siphon coolant
into clean container.
4. Replace cap.
FSM00758
8. Remove coolant reservoir.
Installation
to installation.
2. Fill reservoir to coolant upper level mark.
FSM00756
3. Remove clamps from coolant hoses.
5. Release clip and disconnect coolant outlet

hose.
6. Disconnect coolant pressure relief hose from
reservoir.
20-17
COOLING SYSTEM
Heater - Electric - PTC

FRT No.: 20400500
Remove
operation.
90010100, page 90-2. FSM00699
3. Isolate high voltage battery. Refer to FRT: 9. Release clips and disconnect coolant hoses
16200100, page 16-6. from PTC heater.
4. Remove engine cover. Refer to FRT: NOTE: Place suitable absorbent material
12301000, page 12-29. around the affected area to absorb any
10. Remove screws (x4) securing PTC heater to
mounting bracket.
걠ı
FSM00759
5. Disconnect MAF sensor harness connector.

6. Remove screws (x3) securing battery low
temperature reservoir to PTC mounting
bracket.
FSM00700
7. Release battery coolant reservoir from
mounting and tie aside for access. 11. Raise PTC heater and disconnect high and
low voltage harness connectors.
8. Clamp coolant hoses either side of PTC
heater as close to connections as possible. Installation
to installation.
20-18
COOLING SYSTEM
2. Prime PTC heater with coolant prior to Chiller with TXV - Low Temp Battery
connecting final hose. Cooling
3. Check and top up coolant reservoir
FRT No.: 20403000
Remove
90010100, page 90-2.
16200100, page 16-6.
operation.
5. Recover Refrigerant from A/C system. Refer
to FRT: 30010100, page 30-2.
6. Drain battery low temperature coolant. Refer
to FRT: 20010500, page 20-3.
7. Remove front bumper cover for access. Refer
to FRT: 70202101, page 70-10.
8. Lower vehicle.
FSM00671
9. Release clips (x2) and disconnect coolant

hoses from chiller.
20-19
COOLING SYSTEM
FSM00672 FSM00674
10. Remove nut and collect A/C pipe retainer 13. Remove chiller assembly.
plate. Torque - 10 Nm. CAUTION: Take care not to damage
11. Disconnect A/C pipes from TXV block and component(s).
discard 'O' ring seals.
Installation
prevent ingress of moisture and dirt. 1. Installation procedure is reverse of removal
to installation.
refrigerant oil.
2. Refill and bleed battery low temperature
coolant.
FSM00673
12. Remove screws (x3) securing chiller

assembly to intake baffle. Torque - 10 Nm.
20-20
HVAC SYSTEM
Contents Page
Refrigerant - Recovery and Recharge ...................................................................................... 30-2

HVAC Assembly........................................................................................................................ 30-3
Air Temperature Actuator - LH.................................................................................................. 30-5
Mode Actuator .......................................................................................................................... 30-5
Recirculation Actuator .............................................................................................................. 30-6
Heater Core............................................................................................................................... 30-7
Blower Motor ............................................................................................................................ 30-8
Compressor .............................................................................................................................. 30-9
Condenser............................................................................................................................... 30-12
Evaporator............................................................................................................................... 30-14
Thermal Expansion Valve (TXV) ............................................................................................. 30-15
Switch - AC - System Pressure .............................................................................................. 30-16
Sensor - HVAC - Core Temperature ....................................................................................... 30-17
Pollen Filter ............................................................................................................................. 30-18
Face Level Vent - Outboard.................................................................................................... 30-18
Face Level Vent - Inboard....................................................................................................... 30-19
30-1
HVAC SYSTEM
Refrigerant - Recovery and Recharge 11. Once charging is complete, disconnect high
HVAC SYSTEM
and low pressure hoses from charge ports.

FRT No.: 30010100
12. Fit dust caps to charge port connectors.
WARNING: Read Vehicle refrigerant label

prior to De-gas. European vehicle systems
are filled with H1234YF and must not be
de-gassed using an A/C station designed to
recover R134a.
Recover, Recycle And Recharge

1. Remove dust caps from high and low
pressure charge port connectors.
operation.
CAUTION: Identify refrigerant used in vehicle
system and use the appropriate A/C station to
recover refrigerant.
2. Connect high and low pressure recovery/
charging station hoses to vehicle charge
ports.
3. Check and note existing level of recovered
refrigerant oil.
4. Follow instructions supplied with recovery/
charging station, recover refrigerant from
HVAC system.
5. Measure and record quantity of oil recovered
from system.
6. Carry out required service procedure now
refrigerant has been recovered.
7. If any part of system has been opened during
course of a service procedure, a refrigerant
recovery (evacuate) process must be carried
out prior to recharging system.
8. Ensure recovery/charging station has enough
refrigerant to allow the system to be fully
charged.
9. Add required quantity of recommended
refrigerant oil to oil charger on recovery/
charging station.
10. Follow instructions supplied with recovery/
charging station, recharge HVAC system with
correct quantity of refrigerant.
30-2
HVAC SYSTEM
HVAC Assembly 8. Remove screw securing dash panel lower

flange to passenger side lower rail.
FRT No.: 30100100
Remove
1. Remove instrument panel. Refer to FRT:
90300100, page 90-13.
2. Remove topper panel. Refer to FRT:
80200200, page 80-8.
FSM00340
9. Carefully remove dash panel from dash

assembly.
10. Release harness and any attached clips.
FSM00338
3. Remove screws (x7) securing glove box

assembly to dash panel.
4. Release glove box assembly.
FSM00341
11. Remove screws (x3) securing frost vent

assembly to cross car beam.
FSM00339
5. Disconnect lamp and latch release harness

connectors.
6. Remove glove box assembly.
7. Remove screws (x3) securing dash panel
upper surface to cross car beam.
30-3
HVAC SYSTEM
15. Remove HVAC assembly.
Installation
FSM00342
12. Remove frost vent assembly from cross car

beam.
FSM00343
13. Remove bolts (x2) securing HVAC assembly

to cross car beam.
FSM00344
14. Disconnect HVAC harness connector.
30-4
HVAC SYSTEM
Air Temperature Actuator - LH Mode Actuator

FRT No.: 30100200 FRT No.: 30100400
Remove Remove
1. Remove HEVAC assembly. Refer to FRT: 1. Remove HEVAC assembly. Refer to FRT:
30100100, page 30-3. 30100100, page 30-3.
FSM00359 FSM00354
2. Remove screw securing drivers lower air duct 2. Disconnect actuator harness connector.
to HVAC assembly. 3. Remove screws (x2) securing actuator to
3. Remove driver's lower air duct. casing.
FSM00350 FSM00355
4. Disconnect actuator harness connector. 4. Remove mode actuator.

5. Remove screws (x2) securing actuator to
Installation
casing.
6. Remove air temperature actuator.
Installation
30-5
HVAC SYSTEM
Recirculation Actuator 8. Remove screw securing dash panel lower

flange to passenger side lower rail.
FRT No.: 30100500
Remove
1. Remove instrument panel. Refer to FRT:
90300100, page 90-13.
2. Remove topper panel. Refer to FRT:
80200200, page 80-8.
FSM00340
9. Carefully remove dash panel from dash

assembly release harness and any attached
clips.
FSM00338
3. Remove screws (x7) securing glove box

assembly to dash.
4. Release glove box assembly.
FSM00341
10. Remove screws (x3) securing frost vent

assembly to cross car beam.
FSM00339
5. Disconnect lamp and latch release harness

connectors.
6. Remove glove box assembly.
7. Remove screws (x3) securing dash panel
upper surface to cross car beam.
30-6
HVAC SYSTEM
Heater Core
FRT No.: 30102000
Remove
1. Remove HEVAC assembly. Refer to FRT:
30100100, page 30-3.
FSM00342
11. Remove frost vent assembly from cross car

beam.
12 FSM00345
2. Remove HVAC bulkhead gaskets (x2).
13
13
FSM00349
12. Disconnect recirculation actuator connector.

13. Remove screws (x2) securing actuator to
casing.
14. Remove recirculation actuator.
FSM00705
Installation
3. Remove perimeter screws (x22) securing
1. Installation procedure is reverse of removal. upper and lower HVAC housing.
4. Separate HVAC housing.
5. Remove heater core from casing.
Installation
2. Clean interior of HVAC housing.
30-7
HVAC SYSTEM
Blower Motor
FRT No.: 30200100
Remove
30100100, page 30-3.
FSM00358
5. Release and remove blower motor.
Installation
FSM00356
2. Remove any debris from blower motor
housing.
2. Remove screws (x2) securing passenger
lower air duct to HVAC assembly.
3. Remove passenger lower duct from HVAC
assembly.
FSM00357
4. Remove screws (x3) securing blower motor

to HVAC assembly.
30-8
HVAC SYSTEM
Compressor
FRT No.: 30300100
Remove
2. Open hood.
90010100, page 90-2.
16200100, page 16-6.
5. Drain engine and cabin coolant. Refer to FRT: FSM00827
20010100, page 20-2.
10. Disconnect high voltage A/C compressor
6. Remove front cross brace. Refer to FRT:
harness connector.
60500300, page 60-13.
11. Disconnect high voltage PTC harness
7. Recover refrigerant from A/C system. Refer
connector. Tie PTC harness aside.
to FRT: 30010100, page 30-2.
FSM00823
FSM00726
12. Release clip securing heater feed pipe to PTC
8. Disconnect turbocharger boost pressure
fluid heater. Release pipe.
sensor connector and pipe. Move connector
and harness aside. NOTE: Place suitable absorbent material
9. Release clips (x2) and remove intercooler to
intake manifold charge hose/pipe.
13. Release clip securing heater return hose to
inline connector. Release hose from
connector.
30-9
HVAC SYSTEM
14. Tie heater hoses aside.
FSM00825
FSM00824
18. Disconnect front knock sensor connector.
15. Release clip securing coolant top hose.
Release hose and tie aside
FSM00826
19. Disconnect low voltage A/C compressor

harness connector.
20. Tie engine harness aside.
FSM00659
16. Disconnect charge air bypass solenoid

connector, fuel injection rail connector and
engine to body harness connectors (x2).
17. Remove nut securing engine harness earth
strap to engine block and release harness
clips (x3).
30-10
HVAC SYSTEM
FSM00828 FSM01026
21. Release clip securing charge air pipe elbow 24. Remove bolt securing brake hose mount to
and remove elbow. chassis and carefully reposition hose and
CAUTION: Plug all open connections to pipe for access to A/C compressor lower
prevent ingress of moisture and dirt. bolts. Torque - 10 Nm.
component(s).
25. Turn LH front upright to full left hand lock for
access.
FSM00661
22. Remove bolts and disconnect A/C high and

low pressure lines from compressor. Discard
'O' ring seals. Tie pipes aside. Torque - 20
Nm. FSM00662
CAUTION: Plug all open connections to 26. Through aperture between upper and lower
prevent ingress of moisture and dirt. chassis rails, carefully reposition coolant
23. Remove LH front wheel arch liner. Refer to pipes to improve access to lower bolts on A/
FRT: 78100100, page 78-2. C compressor. Note: spring and shocker
removed for clarity.
27. Through aperture between upper and lower
chassis rails, remove lower bolts (x2)
securing A/C compressor to mounting
28. Lower vehicle.
30-11
HVAC SYSTEM
Condenser
FRT No.: 30400100
Remove
2. Open hood.
90010100, page 90-2.
16200100, page 16-6.
FSM00663
to FRT: 30010100, page 30-2.
29. Remove upper bolt securing A/C compressor
6. Remove intercooler. Refer to FRT:
to mounting bracket. Torque - 45 Nm.
12704000, page 12-71.
ıııı
FSM00829
FSM01021
30. Release A/C compressor and remove from
7. Remove screw securing A/C pipe mount to
vehicle.
radiator and remove mount. Torque - 6 Nm.
Installation
30-12
HVAC SYSTEM
FSM00691 FSM01020
8. Remove nuts (x2) securing high and low 15. Remove bolts (x2) securing cooling fan,
pressure A/C lines to condenser. Torque - 10 radiator and condenser assembly. Torque - 4
Nm. Nm.
9. Disconnect high and low pressure A/C lines 16. Release condenser from radiator lower
from condenser. mounts.
10. Remove and discard 'O' ring seals. 17. Protect radiator and condenser elements
CAUTION: Plug all open connections to with cardboard to prevent damage during
prevent ingress of moisture and dirt. removal.
11. Lower vehicle.

12. Remove screws (x4) securing upper radiator
mounting bracket to chassis. Torque - 6 Nm.
13. Release radiator top mounting bracket from
radiator, reposition and remove from vehicle.
14. Carefully release air baffle from condenser,
reposition and remove from vehicle.
component(s).
FSM01028
18. Carefully tilt and maneuver condenser

assembly from vehicle.
component(s).
Installation
to installation.
30-13
HVAC SYSTEM
NOTE: Lubricate new 'O' ring seals with clean Evaporator

refrigerant oil.
FRT No.: 30450200
2. Refill A/C system.
Remove
30100100, page 30-3.
FSM00356
2. Remove screws (x2) securing passenger

lower air duct to HVAC assembly.
3. Remove passenger lower air duct.
FSM00359
4. Remove screw securing driver lower air duct

to HVAC.
5. Remove driver lower air duct.
30-14
HVAC SYSTEM
Thermal Expansion Valve (TXV)

FRT No.: 30600100
Remove
1. Ensure ignition is off.
to FRT: 30010100, page 30-2.
3. Remove wiper motor assembly. Refer to
FRT: 90900100, page 90-27.
FSM00345
6. Remove HVAC assembly gaskets (x2).
FSM00257
4. Remove nut securing A/C pipe clamp to TXV.

Torque - 20 Nm.
FSM00705
7. Remove perimeter screws (x22) securing
upper HVAC assembly housing to lower
housing.
8. Separate HVAC assembly housing.
9. Remove evaporator.
Installation
2. Clean HVAC housing interior thoroughly.
5. Release clamp and disconnect A/C pipes

from TXV.
30-15
HVAC SYSTEM
Switch - AC - System Pressure

FRT No.: 30600200
Remove
to FRT: 30010100, page 30-2.
FSM00259
6. Discard 'O' ring seals.
FSM00265
2. Disconnect pressure switch connector.
FSM00260
7. Remove screws (x2) securing TXV to

bulkhead.
8. Remove TXV from bulkhead and discard 'O'
ring seals.
prevent ingress of moisture and dirt. FSM00266
Installation 3. Loosen and remove A/C pressure switch.

1. Installation procedure is reverse of removal CAUTION: Plug all open connections to
except for the following. prevent ingress of moisture and dirt.
2. Clean all component mating faces. Installation
WARNING: Only use cleaning agents and 1. Installation procedure is reverse of removal
solvents in a well ventilated area. except for the following.
3. Replace all disturbed 'O' ring seals. 2. Clean all component mating faces.
NOTE: Lubricate new 'O' ring seals with clean WARNING: Only use cleaning agents and
refrigerant oil. solvents in a well ventilated area.
30-16
HVAC SYSTEM
Sensor - HVAC - Core Temperature

FRT No.: 30600300
Remove
30100100, page 30-3.
FSM00365
5. Rotate selected sensor counterclockwise

and withdraw from HVAC housing.
Installation
FSM00359
2. Remove screw securing driver lower air duct

to HVAC assembly.
3. Remove driver lower air duct.
FSM00364
4. Disconnect driver or passenger core

temperature harness connector.
30-17
HVAC SYSTEM
Pollen Filter Face Level Vent - Outboard

FRT No.: 30700100 FRT No.: 30700200
Remove Remove
FSM00233 FSM00798
1. Release clips (x2) securing pollen filter cover 1. Carefully release clips (x3) and remove side
to plenum cover and remove filter cover. screen defroster vent from dash panel.
component(s).
FSM00234
2. Remove pollen filter.

FSM00799
Installation
2. Using a suitable tool, carefully release clips
1. Installation procedure is reverse of removal (x3) pull vent evenly and progressively to
except for the following. release from dash.
2. Remove any debris from pollen filter housing. CAUTION: Exercise caution during removal of
the face level vents to avoid damage to the
vanes.
30-18
HVAC SYSTEM
Face Level Vent - Inboard

FRT No.: 30700300
Remove
FSM00800
3. Remove outboard face level vent.
Installation
1. Installation procedure is reverse of removal FSM00801
1. Using a suitable tool, carefully release clips
2. Remove any debris from vent duct. (x3) pull vent evenly and progressively to
release from dash.
CAUTION: Exercise caution during removal of
the face level vents to avoid damage to the
vanes.
FSM00802
2. Remove inboard face level vent.
Installation
2. Remove any debris from vent duct.
30-19
HVAC SYSTEM
30-20
FINAL DRIVE
Contents Page
Differential Assembly ................................................................................................................ 42-2

Differential - Oil Level - Check .................................................................................................. 42-3
Differential - Oil - Drain and Refill ............................................................................................. 42-4
Oil Seal - Differential - Input...................................................................................................... 42-5
Oil Seal - Differential - Output - LH........................................................................................... 42-5
Half Shaft Assembly - LH.......................................................................................................... 42-6
Gaiter - Half Shaft - Inner - LH.................................................................................................. 42-8
Gaiter - Half Shaft - Outer - LH................................................................................................. 42-9
CV Joint Assembly - Outer - LH ............................................................................................... 42-9
Joint Assembly - Inner - LH .................................................................................................... 42-10
42-1
FINAL DRIVE
Differential Assembly
FINAL DRIVE
FRT No.: 42100100
Remove
1. Remove rear subframe. Refer to FRT:
60200600, page 60-9.
2. Position differential and traction motor
assembly on a suitable support.
operation.
FSM00654
8. Remove bolts (x8) securing pre-differential

traction motor to differential housing. Torque
- 45 Nm.
9. Separate mating faces and disconnect
harness connections (x4).
10. With assistance carefully remove
pre-differential traction motor.
WARNING: This component is extremely
FSM00653 relevant safety precautions before removal.
3. Remove bolts (x7) securing LH bracket to CAUTION: Take care not to damage
differential. Torque - 55 Nm. component(s).
4. Remove bracket.
5. Remove bolts (x8) securing RH bracket to
differential. Torque - 55 Nm.
6. Remove bracket.
7. Support weight of pre-differential traction
motor.
FSM00655
11. Remove bolts (x8) securing post-differential

traction motor to differential housing. Torque
- 45 Nm.
12. With assistance carefully remove
post-differential traction motor.
42-2
FINAL DRIVE
WARNING: This component is extremely Differential - Oil Level - Check

relevant safety precautions before removal. FRT No.: 42100200
Check
component(s).
1. Remove RH rear road wheel. Refer to FRT:
54100501, page 54-2.
FSM00656
13. Secure differential assembly to prevent

FSM00536
movement.
2. Clean area surrounding filler/level plug.
Installation 3. Position a container to collect fluid spillage.
1. Installation procedure is reverse of removal 4. Remove oil level/filler plug. Torque - 35 Nm.
CAUTION: The vehicle must be level during
NOTE: Clean component mating faces, prior this procedure.
to installation.
5. Remove and discard sealing washer.
2. Ensure dowels and locating holes are free of
debris. Adjust
1. If oil runs from differential allow flow to stop,
then replace drain plug.
2. If no oil is present, add oil until a thin bead
flows from differential casing.
3. Replace level/filler plug.
to installation.
42-3
FINAL DRIVE
Differential - Oil - Drain and Refill 9. Fit new sealing washer and replace drain
plug.
FRT No.: 42100300
to installation.
Drain & Refill
10. Add oil until a thin bead flows from differential
1. Remove RH rear road wheel. Refer to FRT:
casing filler hole.
54100501, page 54-2.
11. Fit new sealing washer and replace level/filler
plug.
to installation.
FSM00536
2. Clean area surrounding filler/level plug.
FSM00537
3. Clean area surrounding drain plug.

4. Position a container to collect fluid spillage.
5. Remove oil level/filler plug. Torque - 35 Nm.
CAUTION: The vehicle must be level during
this procedure.
6. Remove differential oil drain plug. Torque - 35
Nm.
7. Allow oil to drain.
8. Remove and discard filler/drain plug sealing
washers.
42-4
FINAL DRIVE
Oil Seal - Differential - Input Oil Seal - Differential - Output - LH

FRT No.: 42100400 FRT No.: 42100500
Remove Remove
1. Remove differential assembly for access. 1. Remove LH half shaft assembly. Refer to
Refer to FRT: 42100100, page 42-2. FRT: 42200100, page 42-6.
2. Position differential at a safe working height. 2. Protect half shaft output flange oil seal face
and spline to prevent damage.
3. Using a suitable tool remove output shaft oil
seal from differential casing.
Installation
2. Check differential casing oil seal register for
burrs and damage.
FSM00657
3. Using a suitable tool, install differential casing
3. Using a suitable tool remove input oil seal.
output shaft oil seal.
4. Replace output shaft snap-ring.
component(s).
5. Install LH half shaft assembly.
4. Repeat previous steps and remove additional
input oil seal.
Installation
to installation.
2. Clean seal registers and install new oil seals
using a suitable tool.
42-5
FINAL DRIVE
Half Shaft Assembly - LH

FRT No.: 42200100
Remove
FSM00532
8. Remove bolts (x6) securing inboard half shaft

joint to output drive flange. Torque - 65 Nm.
Rotate half shaft for access.
FSM00530 9. Collect keeper plates (x3).
1. Remove wheel centre finisher.
FSM00014
FSM00531 10. Remove bolts (x2) securing rear brake caliper

to upright. Torque - 100 Nm.
2. Remove and discard LH half shaft hub nut.
Torque - 200 Nm. CAUTION: Replace all patch bolt(s).
3. Remove road wheel. Refer to FRT: 11. Release caliper from brake rotor and tie
54100501, page 54-2. aside.
4. Ensure parking pawl is disengaged.
90010100, page 90-2.
16200100, page 16-6.
7. Mark fitted position of inner half shaft joint to
output flange.
42-6
FINAL DRIVE
FSM00065 FSM00534
12. Remove nut and bolt securing rear toe link to 17. Carefully withdraw half shaft assembly from
upright. Torque - 50 Nm. vehicle.
FSM00535
FSM00533 18. If half shaft outer joint is going to be handled,

13. Remove nut and bolt securing rear lower arm cable tie inner pot joint cover to main joint
to upright. Torque - 165 Nm. preventing separation and dirt ingress.
CAUTION: Only tighten suspension nuts and Installation

bolts when the suspension is in the ride
height position.
14. Tap exposed end of half shaft with nylon
to installation.
mallet to break stiction.
15. With assistance swing brake rotor and
upright assembly aside and release outer half
shaft spline from rear hub.
16. Tie brake rotor and upright assembly aside
for access.
42-7
FINAL DRIVE
Gaiter - Half Shaft - Inner - LH 2. Clean half shaft, inner joint and gaiter. If
refitting original joint, remove all old grease
FRT No.: 42200400 from joint using a solvent based cleaner.
3. Install new gaiter to inner joint flange and
Remove
drive fully home.
1. Remove half shaft assembly. Refer to FRT:
4. Apply recommended grease to joint and
42200100, page 42-6.
gaiter.
2. Position half shaft in vice.
5. Position gaiter and secure with new clip.
FSM00539
3. Remove and discard clip (x1) securing gaiter

to inner joint.
FSM00538
4. Using a suitable drift positioned against the

inner face of joint, release inner joint from half
shaft.
5. Slide gaiter along joint, lever press fit section
from joint flange and discard gaiter.
Installation
42-8
FINAL DRIVE
Gaiter - Half Shaft - Outer - LH CV Joint Assembly - Outer - LH

FRT No.: 42201000 FRT No.: 42201500
Remove Remove
1. Remove LH CV joint assembly. Refer to FRT: 1. Remove half shaft assembly. Refer to FRT:
42201500, page 42-9. 42200100, page 42-6.
2. Position half shaft in vice.
FSM00543
2. Remove gaiter from half shaft. FSM00540
3. Remove and discard clips (x2) securing gaiter

Installation
to CV joint.
4. Slide gaiter along shaft to gain access to
joint.
FSM00541
5. Flex joint to expose inner face of CV joint.

6. Using a suitable drift positioned against the
inner face of joint, release CV joint from half
shaft.
42-9
FINAL DRIVE
Joint Assembly - Inner - LH

FRT No.: 42201700
Remove
1. Remove LH rear half shaft inner gaiter. Refer
to FRT: 42200400, page 42-8.
Installation
FSM00542
7. Remove snap-ring from half shaft and

discard.
Installation
2. Clean half shaft, CV joint and gaiter. If refitting
a CV joint, remove all old grease from joint
using a solvent based cleaner.
3. Install new snap-ring to half shaft.
4. Inspect gaiter for damage and renew if
necessary.
5. Apply 120 grams of recommended grease to
CV joint and gaiter. Approximately 50 grams
to CV joint and 70 grams to the gaiter.
6. Position gaiter and secure with new clips.
42-10
STEERING
Contents Page
Steering Wheel.......................................................................................................................... 44-2

Column - Complete................................................................................................................... 44-3
Column - Lower ........................................................................................................................ 44-6
Steering Rack............................................................................................................................ 44-7
Pump - Power Steering Fluid.................................................................................................... 44-9
Power Steering - Refill and Bleed .......................................................................................... 44-12
Power Steering - Drain and Replenish................................................................................... 44-12
44-1
STEERING
Steering Wheel NOTE: If component has been removed for

STEERING
access, do not dismantle beyond this point.

FRT No.: 44100100
Remove
1. Remove driver front airbag. Refer to FRT:
84200100, page 84-4.
FSM00954
9. Remove screws (x3) securing trim to steering

wheel.
10. Release trim from steering wheel for access
to steering wheel switches.
FSM00952
2. Install steering column locking tool.
FSM00955
11. Disconnect LH switch bank connector.

FSM00953
12. Disconnect RH switch bank connector.

3. Disconnect steering wheel switch connector.
13. Remove trim from steering wheel.
4. Mark fitted position of steering wheel to
column.
5. Loosen, but do not remove, nut securing
steering wheel to column. Torque - 50 Nm.
6. Release steering wheel by pulling sharply
towards vehicle rear.
7. Remove nut securing steering wheel to
column.
8. Remove steering wheel.
44-2
STEERING
Column - Complete
FRT No.: 44200100
Remove
1. Ensure front road wheels are in straight
ahead position.
2. Power column fully upwards and forwards.
3. Remove steering column upper cowl. Refer
to FRT: 82200100, page 82-4.
FSM00956
14. Disconnect LH paddle switch connector.

15. Remove screw securing LH paddle switch to
steering wheel and remove switch.
16. Repeat previous two steps and remove RH
paddle switch.
Installation
FSM00974
4. Remove screws (x2) securing turn / lighting

column switch to steering column boss.
FSM00975
5. Disconnect turn / lighting column switch

connectors (x3).
6. Remove turn / lighting column switch
assembly.
44-3
STEERING
FSM00976 FSM00167
7. Release clips (x2) securing wash / wipe 11. Release clips (x2) securing footwell lamp
column switch to steering column boss. panel to dash, release panel from hooks and
position aside.
FSM00977
8. Disconnect wash / wipe column switch

FSM00978
connector. 12. Disconnect steering column harness

9. Remove wash / wipe column switch. connectors (x3).
10. Remove clock spring. Refer to FRT: 13. Mark fitted position of steering column to
90454000, page 90-16. lower column.remove nut and bolt securing
lower column to steering column. Torque - 55
Nm.
44-4
STEERING
FSM00170 FSM00979
14. Remove nut and bolt securing lower column 16. With assistance, remove bolts (x2) securing
to steering column. Torque - 55 Nm. steering column lower fixings to dash and
remove column. Torque - 27 Nm.
Installation
NOTE: Ensure the steering column locking
tool is in position to ensure correct installation
of the clock spring.
2. Fit but do not fully tighten bolts (x4) securing
steering column to dash.
3. Working in a diagonal sequence, evenly and
progressively tighten steering column bolts.
FSM00980
15. Remove bolts (x2) securing steering column

upper fixings to dash. Torque - 27 Nm.
44-5
STEERING
Column - Lower
FRT No.: 44200300
Remove
FSM01006

FSM00167 8. Move exhaust system aside for access.
1. Release clips (x2) securing courtesy light
panel to dash, release panel from hooks and
position aside.
FSM01012

FSM00170
2. Mark fitted position of lower column to
steering column.
3. Remove nut and bolt securing lower column
to steering column. Torque - 55 Nm.
44-6
STEERING
Steering Rack
FRT No.: 44300100
Remove
FSM00174
11. Release lower column boot seal.

NOTE: Note fitted position of components ıııı
before removal.
FSM00760
2. Remove power steering fluid reservoir cap.

3. Using a syringe, remove power steering fluid
from reservoir.
FSM00146
12. Mark fitted position of lower column to

steering rack.
13. Remove nut and bolt securing lower column
to steering rack. Torque - 28 Nm.
14. Release and remove lower column.
Installation
CAUTION: Replace all patch bolt(s). FSM00247
4. Remove nuts (x2) securing tie rod ends to

suspension uprights. Torque - 135 Nm.
5. Using a suitable tool, release both tie rod end
ball joints.
44-7
STEERING
FSM00146 FSM00187
6. Turn steering column for spanner access and 9. Remove nut and bolt (x2) securing steering
remove bolt securing intermediate shaft to rack to subframe. Torque - 70 Nm.
rack. Torque - 28 Nm.
before removal.
7. Disconnect intermediate shaft and position
aside.
FSM00189
10. Remove remaining nut and bolt securing

steering rack to subframe. Torque - 70 Nm.
11. Reposition steering rack and tie aside for
access.
FSM00839
8. Remove compressor bracket lower fixing bolt

securing A/C pipe bracket. Tie pipe aside for
access. - Torque - 20 Nm.
44-8
STEERING
Pump - Power Steering Fluid

FRT No.: 44400100
Remove
90010100, page 90-2.
2. Open hood to service position.
FSM00248
12. Disconnect steering rack pressure sensor

connector.
13. Remove bolt and disconnect feed and return
hoses from steering rack. Torque - 10 Nm.
FSM00726
prevent ingress of moisture and dirt. 3. Disconnect boost pressure sensor harness
connector.
14. Remove and discard 'O' ring seals.
4. Disconnect boost pressure pipe.
15. Release steering rack from tied aside position
and remove from vehicle. CAUTION: Plug all open connections to
Installation 5. Release clips (x2) securing charge air inlet
1. Installation procedure is reverse of removal pipe to intercooler and throttle body.
except for the following. CAUTION: Plug all open connections to
CAUTION: Replace all Nyloc nut(s). prevent ingress of moisture and dirt.
CAUTION: Replace all patch bolt(s). 6. Tie hose aside for access.
to installation.
2. Refill and bleed power steering system. Refer
to FRT: 44401000, page 44-12.
to FRT: 46010100, page 46-2.
44-9
STEERING
ıııı
FSM00738 FSM00179
7. Release clips (x2) securing headlamp and 9. Remove screws (x3) securing fuse box
dash harness to power steering pump bracket to chassis. Remove bracket. Torque
bracket studs. Move harness aside. - 25 Nm.
10
11
12
FSM00181 FSM00178
8. Release clips (x3) securing fuse box to 10. Release clip securing return hose to power
mounting and position aside for access. steering pump housing. Release hose from
housing. Remove clip.
11. Remove bolt and disconnect high pressure
hose from power steering pump. Remove
and discard 'O' ring seal. Torque - 20 Nm.
44-10
STEERING

12. Remove bolt securing clamp for high
pressure and return hoses to standoff
bracket. Move hoses aside for access.
Torque - 10 Nm.
FSM00183
16. Remove screws (x3) securing mounting

bracket to pump. Torque - 6 Nm.
FSM00180
13. Disconnect pump harness connectors (x2).
FSM00184
17. Remove screws (x2) securing mounting

bracket to pump. Torque - 6 Nm.
Installation
FSM00182 except for the following.
14. Remove bolts (x4) securing bracket to NOTE: Clean component mating faces, prior
chassis. Torque - 25 Nm. to installation.
15. Maneuver bracket and pump assembly from WARNING: Only use cleaning agents and
vehicle. solvents in a well ventilated area.
to FRT: 44401000, page 44-12.
44-11
STEERING
Power Steering - Refill and Bleed Power Steering - Drain and Replenish
FRT No.: 44401000 FRT No.: 44401100
Bleed Drain
1. Clean reservoir around filler cap. 1. Raise and support vehicle.
12301000, page 12-29.
ıııı
ıııı
FSM00760
2. Remove filler cap from reservoir. Fill reservoir

with power steering fluid to cold level mark.
possible fluid spillage. 3. Remove power steering fluid reservoir cap.

3. Start engine and allow to run at idle for 10 4. Using a syringe, remove power steering fluid
seconds. Stop engine. from reservoir.
4. Check and top-up steering fluid reservoir. NOTE: Place suitable absorbent material
5. Start engine and turn steering fully to LH and around the affected area to absorb any
RH locks. Stop engine. possible fluid spillage.
CAUTION: Do not hold steering at full lock for 5. Raise the vehicle.
longer than 10 seconds. 6. Remove bolt and disconnect feed and return
6. Start and run engine for 2 minutes, turn hoses from steering rack. Torque - 10 Nm.
steering fully to RH and LH locks. NOTE: Place suitable absorbent material
7. Check and top-up steering fluid reservoir. around the affected area to absorb any
8. Switch off engine. possible fluid spillage.
9. Check power steering fluid, if aerated, wait CAUTION: Plug all open connections to
until fluid is free from bubbles then top-up prevent ingress of moisture and dirt.
reservoir to max level mark. 7. Remove and discard 'O' ring seals.
10. Fit reservoir filler cap.
Replenish
44-12
STEERING

to installation.
to FRT: 44401000, page 44-12.
44-13
STEERING
44-14
SUSPENSION
Contents Page
Four Wheel Alignment Check ................................................................................................... 46-2

Spring and Shock Absorber Assembly - Front - LH ................................................................. 46-3
Shock Absorber - Front - LH .................................................................................................... 46-5
Spring and Shock Absorber Assembly - Rear - LH .................................................................. 46-6
Shock Absorber - Rear - LH ..................................................................................................... 46-7
Lower Arm - Front - LH............................................................................................................. 46-8
Upper Wishbone - Front - LH ................................................................................................... 46-9
Lower Arm - Rear - LH............................................................................................................ 46-10
Upper Wishbone - Rear - LH .................................................................................................. 46-11
Tie Rod End - Front - LH......................................................................................................... 46-12
Toe Link - Rear - LH................................................................................................................ 46-13
Link - Sway Bar - Front - LH................................................................................................... 46-14
Sway Bar - Front ..................................................................................................................... 46-15
Link - Sway Bar - Rear - LH.................................................................................................... 46-16
Sway Bar - Rear...................................................................................................................... 46-17
Hub - Front - LH...................................................................................................................... 46-18
Upright - Suspension - Front - LH .......................................................................................... 46-19
Hub - Rear - LH....................................................................................................................... 46-20
Upright - Suspension - Rear - LH ........................................................................................... 46-20
46-1
SUSPENSION
Four Wheel Alignment Check

SUSPENSION
FRT No.: 46010100
Check and Adjust

1. Check four wheel alignment equipment for
condition and calibration. Repair and adjust if
required.
2. Check vehicle steering and suspension
components for condition. Replace
components showing signs of wear or
damage.
3. Place vehicle on level surface. FSM00962
4. Place steering turntables under front wheels 8. Check camber angle of rear suspension and
and slip plates under rear wheels if required. adjust as required.
5. Fit four wheel alignment equipment to vehicle 9. Fit steering wheel holding tool if required.
and align for use.
6. Fit brake pedal holding tool if required.
FSM00963
10. Check front wheel alignment and evenly

FSM00961
adjust as required.
7. Check camber angle of front suspension and
adjust as required.
46-2
SUSPENSION
Spring and Shock Absorber Assembly -

Front - LH
FRT No.: 46200100

operation.
Remove
54100501, page 54-2.
FSM00964 WARNING: Make sure the vehicle is correctly
11. Check rear wheel alignment and evenly
adjust as required. 2. Open hood.
12. Finally recheck all alignment is within
tolerance.
13. Remove steering wheel and brake pedal
holding tools.
14. Remove four wheel alignment equipment,
turntables and slip plates.
15. Road test vehicle.
FSM00020
3. Remove nuts (x3) securing spring and shock

absorber to suspension turret. Torque - 30
Nm.
4. Raise vehicle.
46-3
SUSPENSION
Installation
to installation.
FSM00025
5. Remove nut and disconnect sway bar link

from lower arm. Torque - 90 Nm.
CAUTION: Use two wrenches to prevent
damage.
6. Remove nut securing tie rod end ball joint to
upright. Torque - 115 Nm.
7. Using a suitable tool, release tie rod end ball
joint from upright.
FSM00027
8. Remove nut securing lower arm ball joint to

9. Using a suitable tool, release lower arm ball
joint from upright.
10. Remove nuts and bolts (x2) securing shock
absorber to lower arm. Torque - 20 Nm.
11. With assistance, remove spring and shock
absorber assembly.
46-4
SUSPENSION
Shock Absorber - Front - LH
FRT No.: 46200400

operation.
Remove
1. Remove spring and shock absorber
assembly. Refer to FRT: 46200100, page
46-3.
2. Assemble coil spring compressor and secure FSM00030
in a vice.
6. Remove gaiter from shock absorber rod.
3. Locate spring and shock absorber assembly
to spring compressor. Tighten lead screw to 7. Remove shock absorber bump stop.
compress spring.
FSM00031
FSM00029 8. Remove shock absorber and collect lower

4. Remove shock absorber rod retaining nut. spring cup.
Collect shock absorber mounting and spring
Installation
cup. Torque - 35 Nm.
5. Release spring tension. Remove spring and
shock absorber assembly from compressor.
to installation.
component(s).
46-5
SUSPENSION
Spring and Shock Absorber Assembly -

Rear - LH
FRT No.: 46200900

operation.
Remove
supported before commencing work. FSM00135
2. Open trunk lid. 8. Remove bolt securing lower shock absorber

3. Remove trunk closing panel. Refer to FRT: mounting to lower arm. Torque - 250 Nm.
70401700, page 70-30. 9. With assistance, remove spring and shock
absorber assembly.
Installation
to installation.
FSM00134
4. Remove nuts (x3) securing spring and shock

absorber assembly to suspension turret.
Torque - 30 Nm.
5. Raise vehicle.
54100501, page 54-2.
7. Remove sway bar link. Refer to FRT:
46500600, page 46-16.
46-6
SUSPENSION
Shock Absorber - Rear - LH
FRT No.: 46201200

operation.
Remove
1. Remove spring and shock absorber
assembly. Refer to FRT: 46200900, page
46-6.
2. Assemble coil spring compressor and secure FSM00030
in a vice.
6. Remove gaiter from shock absorber rod.
3. Locate spring and shock absorber assembly
to spring compressor. Tighten lead screw to 7. Remove shock absorber bump stop.
compress spring.
FSM00031
FSM00029 8. Remove shock absorber and collect lower

4. Remove shock absorber rod retaining nut. spring cup.
Collect shock absorber mounting and spring
Installation
cup. Torque - 35 Nm.
5. Release spring tension. Remove spring and
shock absorber assembly from compressor.
to installation.
component(s).
46-7
SUSPENSION
Lower Arm - Front - LH
FRT No.: 46300100

operation.
Remove
2. Remove LH muffler assembly. Refer to FRT: FSM00037
12800100, page 12-74. 6. Remove nut securing sway bar link to arm
and release sway bar link. Torque - 90 Nm.
damage.
7. Remove nuts (x2) and bolts (x2) securing
shock absorber to arm. Torque - 25 Nm.
8. Remove nut securing lower arm ball joint to
9. Tie upright to shock absorber and spring
assembly and support weight of
components.
10. Using a suitable tool, release arm ball joint
FSM01012 from upright.
3. Remove screws (x3) securing lower 11. Support lower arm.
5. Mark fitted position of lower arm camber
adjustment cams, prior to removal, to aid
installation.
FSM00039
12. Remove nuts (x2) and bolts (x2) securing arm

to body. Collect washers (x4). Torque - 165
Nm.
13. Remove lower arm.
46-8
SUSPENSION
Installation Upper Wishbone - Front - LH

FRT No.: 46300300
to installation. WARNING: To avoid serious injury, use
WARNING: Only use cleaning agents and operation.
CAUTION: Only tighten suspension nuts and Remove
bolts when the suspension is in the ride 1. Remove road wheel. Refer to FRT:
height position. 54100501, page 54-2.
CAUTION: Replace all Nyloc nut(s). WARNING: Make sure the vehicle is correctly
CAUTION: Replace all patch bolt(s). supported before commencing work.
2. Align marks on cam washers with lower arm 2. Remove wheel arch liner. Refer to FRT:
to body fixings. 78100100, page 78-2.
3. Carry out four wheel alignment check. Refer 3. Support suspension upright to prevent
to FRT: 46010100, page 46-2. damage.
FSM00036
4. Remove nut securing wishbone to upright.

Torque - 90 Nm.
5. Using a suitable tool, release wishbone ball
joint from upright.
6. Remove nuts (x2) and bolts (x2) securing
wishbone to body and release wishbone.
Torque - 165 Nm.
7. Remove upper wishbone.
Installation
to installation.
46-9
SUSPENSION
WARNING: Only use cleaning agents and Lower Arm - Rear - LH

FRT No.: 46300500
CAUTION: Only tighten suspension nuts and
height position. WARNING: To avoid serious injury, use
CAUTION: Replace all Nyloc nut(s). appropriate equipment to carry out this
operation.
2. Carry out four wheel alignment check. Refer Remove
to FRT: 46010100, page 46-2. 1. Remove wheel arch liner. Refer to FRT:
78100100, page 78-2.
FSM00054
2. Remove nut securing sway bar link to arm

and release link. Torque - 110 Nm.
damage.
3. Remove nut and bolt securing lower arm to
4. Remove bolt securing spring and shock
absorber assembly to arm and release
assembly. Torque - 250 Nm.
5. Remove bolts (x2) securing lower forward
bush to subframe and release arm. Torque -
165 Nm.
6. Remove bolt securing lower arm rear bush to
subframe. Torque - 165 Nm.
7. Remove lower arm.
Installation
46-10
SUSPENSION
NOTE: Clean component mating faces, prior Upper Wishbone - Rear - LH

to installation.
FRT No.: 46300700
CAUTION: Only tighten suspension nuts and WARNING: To avoid serious injury, use
bolts when the suspension is in the ride appropriate equipment to carry out this
height position. operation.
CAUTION: Replace all Nyloc nut(s). Remove

CAUTION: Replace all patch bolt(s). 1. Remove wheel arch liner. Refer to FRT:
2. Carry out four wheel alignment check. Refer 78100300, page 78-3.
to FRT: 46010100, page 46-2. 2. Support upright and half shaft.
3. Mark fitted position of cam washer on upper
wishbone to upright fixing to aid installation.
FSM00057
4. Remove nut and bolt securing wishbone to

5. Remove bolts (x2) securing front upper rear
wishbone bush to subframe. Torque - 115
Nm.
6. Remove nut and bolt securing rear upper arm
bush to subframe. Torque - 80 Nm.
7. Remove upper wishbone.
Installation
1. Installation procedure reverse of removal
to installation.
46-11
SUSPENSION
CAUTION: Only tighten suspension nuts and Tie Rod End - Front - LH
height position. FRT No.: 46400100
CAUTION: Replace all patch bolt(s). WARNING: To avoid serious injury, use
2. Align marks on cam washer to upper operation.
wishbone and upright fixing.
3. Carry out four wheel alignment check. Refer Remove
to FRT: 46010100, page 46-2. 1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
4
FSM00007
2. Loosen tie rod end locknut. Torque - 115 Nm.

damage.
3. Remove Nyloc nut securing tie rod end to
4. Release tie rod end ball joint from upright.
5. Noting the number of turns required, remove
tie rod end.
Installation
to installation.
46-12
SUSPENSION
2. Carry out four wheel alignment check. Refer Toe Link - Rear - LH
to FRT: 46010100, page 46-2.
FRT No.: 46400400

operation.
Remove
1. Remove rear wheel arch liner. Refer to FRT:
78100300, page 78-3.
FSM00058
2. Remove bolt and Nyloc nut securing link to

3. Remove nut securing link to subframe and
release link. Torque - 80 Nm.
4. Remove toe link.
Installation
to installation.
to FRT: 46010100, page 46-2.
46-13
SUSPENSION
Link - Sway Bar - Front - LH CAUTION: Only tighten suspension nuts and
FRT No.: 46500100 height position.

operation.
Remove
54100501, page 54-2.
2. Position steering on LH lock for access.
FSM00032
3. Remove nut securing sway bar link to lower

arm. Torque - 110 Nm.
damage.
4. Remove nut securing sway bar link to sway
bar, and release link. Torque - 110 Nm.
5. Remove sway bar link.
Installation
to installation.
46-14
SUSPENSION
Sway Bar - Front
FRT No.: 46500500

operation.
Remove
FSM00130
4. Remove bolts (x2) securing each sway bar

bush clamp to chassis. Torque - 30 Nm.
5. Remove sway bar.
Installation
to installation.
FSM00133
2. Remove nut and disconnect sway bar link CAUTION: Replace all Nyloc nut(s).
from sway bar. Torque - 90 Nm. CAUTION: Only tighten suspension nuts and
CAUTION: Use two wrenches to prevent bolts when the suspension is in the ride
damage. height position.
3. Repeat the above step and disconnect

opposite side.
46-15
SUSPENSION
Link - Sway Bar - Rear - LH CAUTION: Only tighten suspension nuts and
FRT No.: 46500600 height position.

operation.
Remove
54100501, page 54-2.
FSM00044
2. Remove nut securing link to lower arm.

Torque - 110 Nm.
damage.
3. Remove nut securing link to sway bar, and
release link. Torque - 110 Nm.
damage.
4. Remove sway bar link.
Installation
to installation.
46-16
SUSPENSION
Sway Bar - Rear
FRT No.: 46501000

operation.
Remove
90010100, page 90-2.
16200100, page 16-6. FSM00138
3. Remove rear diffuser closing panel. Refer to 6. Remove bolt securing sway bar link to
FRT: 70100300, page 70-3. subframe. Torque - 80 Nm.
7. Repeat the above step on opposite side of
vehicle.
FSM00137
4. Remove nut and disconnect sway bar link.

Torque - 90 Nm. FSM00139
CAUTION: Use two wrenches to prevent 8. Carefully remove rear sway bar assembly.
damage.
5. Repeat the above step on opposite side of Installation
vehicle. 1. Installation procedure is reverse of removal
to installation.
height position.
46-17
SUSPENSION
Hub - Front - LH
FRT No.: 46600100

operation.
Remove
54100501, page 54-2.
2. Remove brake rotor. Refer to FRT: 5. Remove bolts (x4) securing hub to upright.
50300100, page 50-8. Torque - 140 Nm.
6. Remove front hub.
7. Collect rotor shield.
4 Installation
to installation.
5 CAUTION: Replace all patch bolt(s).

FSM00004
3. Remove bolt securing ABS sensor to upright

and release ABS sensor. Torque - 10 Nm.
4. Release clip securing ABS sensor harness to
lower suspension arm, position harness and
sensor aside.
46-18
SUSPENSION
Upright - Suspension - Front - LH
FRT No.: 46600300

operation.
Remove
54100501, page 54-2.
2. Remove hub. Refer to FRT: 46600100, page 5. Remove nut securing upper arm to upright.
46-18. Torque - 90 Nm.
6. Support upper arm to prevent damage.
7. Using a suitable tool, release upper arm ball
joint from upright.
8. Remove nut securing lower arm to upright.
Torque - 150 Nm.
9. Using a suitable tool, release lower arm ball
joint from upright.
10. Remove front upright.
Installation
FSM00008 except for the following.
3. Remove nut securing tie rod end to upright. NOTE: Clean component mating faces, prior
Torque - 135 Nm. to installation.
4. Using a suitable tool, release tie rod end ball WARNING: Only use cleaning agents and
joint from upright. solvents in a well ventilated area.
height position.
to FRT: 46010100, page 46-2.
46-19
SUSPENSION
Hub - Rear - LH Upright - Suspension - Rear - LH
FRT No.: 46600500 FRT No.: 46600700
WARNING: To avoid serious injury, use WARNING: To avoid serious injury, use
appropriate equipment to carry out this appropriate equipment to carry out this
operation. operation.
Remove Remove
1. Raise and support vehicle. 1. Remove road wheel. Refer to FRT:
WARNING: Make sure the vehicle is correctly 54100501, page 54-2.
supported before commencing work. 2. Remove and discard half shaft nut and
2. Remove upright. Refer to FRT: 46600700, locking washer.
page 46-20. 3. Tether half shaft to body to prevent
movement during this procedure.
4. Release park brake if applied.
5. Remove brake rotor. Refer to FRT:
50300600, page 50-10.
6. Loosen park brake adjuster nut fully.
FSM00068
3. Remove bolts (x4) securing hub to upright.

Torque - 140 Nm.
4. Remove rear hub.
Installation FSM00062

7. Remove bolt securing park brake cable to
8. Release park brake cable from mechanism
to installation.
and position cable aside.
height position.
46-20
SUSPENSION
12. Mark fitted position of cam washer on upper

wishbone to upright fixing to aid installation.
FSM00064
9. Remove bolt from ABS sensor, release

sensor and position aside. Torque - 10 Nm. FSM00067
13. Remove nut and bolt securing upper

wishbone to upright. Torque - 115 Nm.
14. Release upright from upper wishbone, lower
arm, toe link and half shaft.
15. Remove rear upright.
16. Position rear upright and hub assembly in a
vice and secure.
FSM00065
10. Remove nut and bolt securing toe link to

FSM00069
17. Remove nuts (x2) securing park brake

assembly to upright and remove assembly.
Torque - 55 Nm.
18. Remove bolts (x4) securing hub to upright
and remove hub. Torque - 140 Nm.
19. Release rear upright from vice.
FSM00066
11. Remove nut and bolt securing lower arm to

46-21
SUSPENSION
Installation
to installation.
height position.
2. Align marks on cam washer to upper
wishbone and upright fixing.
3. Apply anti-seize compound to half shaft
outboard splines.
4. Install new half shaft nut and locking washer.
Torque - 215 Nm.
to FRT: 46010100, page 46-2.
46-22
BRAKES
Contents Page
Bleed Procedure - System........................................................................................................ 50-2

Brake Fluid Reservoir................................................................................................................ 50-3
Master Cylinder......................................................................................................................... 50-4
Electronic Brake Control Module (EBCM)................................................................................. 50-5
Sensor - ABS - Rear - LH ......................................................................................................... 50-7
Sensor - ABS - Front - LH ........................................................................................................ 50-8
Brake Rotor - Front - LH ........................................................................................................... 50-8
Brake Caliper - Front - LH......................................................................................................... 50-9
Brake Rotor - Rear - LH .......................................................................................................... 50-10
Brake Caliper - Rear - LH ....................................................................................................... 50-11
Brake Pads - Front.................................................................................................................. 50-12
Brake Pads - Rear................................................................................................................... 50-13
Motor - Parking Brake............................................................................................................. 50-14
Parking Brake Cable - Adjust.................................................................................................. 50-16
Cable - Cable Link to Hub - LH .............................................................................................. 50-16
Park Brake Shoes - Adjust...................................................................................................... 50-17
Park Brake Shoes ................................................................................................................... 50-18
50-1
BRAKES
Bleed Procedure - System

BRAKES
FRT No.: 50010102

operation.
Bleed
54100501, page 54-2.
2. Repeat above step and remove remaining
road wheels (x3). FSM00023
8. Bleed brakes in sequence shown.

CAUTION: If the ABS modulator or brake
master cylinder has been removed, or you are
unable to achieve a firm brake pedal, the
system will need to be bled in conjunction
with the diagnostic tool.
9. Remove cover from caliper inboard bleed
nipple.
9 15
FSM00022
3. Clean area surrounding brake fluid reservoir

cap and remove cap.
4. Using a syringe, remove brake fluid from
reservoir.
5. Refill brake fluid reservoir with new FSM00024
recommended brake fluid. 10. Install brake bleed container to inboard bleed
6. Fit pressure bleeder adaptor to reservoir nipple.
ensuring a tight seal. NOTE: Place suitable absorbent material
7. Install pressure bleeder to reservoir adaptor around the affected area to absorb any
and fill with sufficient brake fluid to replace all possible fluid spillage.
fluid used. 11. Loosen bleed nipple a ¼ turn
counterclockwise.
12. Tighten bleed nipple once a flow of clean,
air-free fluid is purged into container.
13. Remove brake bleed container.
50-2
BRAKES
14. Install bleed nipple cover. Brake Fluid Reservoir

15. Remove cover from outboard bleed nipple.
FRT No.: 50100100
16. Install brake bleed container to outboard
bleed nipple. Remove
17. Loosen bleed nipple a ¼ turn 1. Open hood.
counterclockwise.
18. Tighten bleed nipple once a flow of clean,
air-free fluid is purged into container. 2
19. Remove bleed container. 4
20. Install bleed nipple cover.
21. Clean any brake fluid from caliper.
22. Repeat bleed procedure for each caliper in
sequence.
5
23. Once brakes have been bled, remove
pressure bleeder and adaptor in accordance
with manufacturer's instructions.
6
CAUTION: If brake fluid is spilt on the FSM00041
paintwork, wash off immediately with clean 2. Remove reservoir cap.

water.
24. Check and top-up brake fluid if required. around the affected area to absorb any
25. Install brake fluid reservoir cap. possible fluid spillage.
26. Install road wheels. CAUTION: If brake fluid is spilt on the
paintwork, wash off immediately with clean
27. Switch ON ignition and pump brake pedal at
water.
least five times to ensure a short, firm pedal
travel. 3. Using a syringe, remove all fluid from
reservoir.
4. Disconnect pipes (x2) from reservoir.
5. Disconnect brake fluid level sensor
connector.
6. Remove reservoir location pins (x2).
50-3
BRAKES
Master Cylinder
FRT No.: 50100200
Remove
1. Open hood.
2. Remove brake fluid reservoir. Refer to FRT:
50100100, page 50-3.
FSM00042
3
7. Release connections (x3) to master cylinder.
8. Remove reservoir.
9. Remove seals (x3) from master cylinder.
CAUTION: Plug all open connections to 4
Installation FSM00043
1. Installation procedure is reverse of removal 3. Loosen tube nuts (x5) securing brake pipes to
except for the following. master cylinder and disconnect brake pipes.
NOTE: Clean component mating faces, prior Torque - 21 Nm.
to installation. NOTE: Place suitable absorbent material
WARNING: Only use cleaning agents and around the affected area to absorb any
solvents in a well ventilated area. possible fluid spillage.
2. Replace master cylinder seals. CAUTION: If brake fluid is spilt on the
3. Bleed brake system. Refer to FRT: paintwork, wash off immediately with clean
50010102, page 50-2. water.
4. Remove nuts (x2) securing master cylinder to
5. Remove master cylinder.
Installation
to installation.
2. Bleed brake system. Refer to FRT:
50010102, page 50-2.
50-4
BRAKES
Electronic Brake Control Module (EBCM)

9 10
FRT No.: 50200100
WARNING: To avoid serious injury, use 10

operation.
ıııı
Remove
90010100, page 90-2.
16200100, page 16-6. FSM00045
3. Remove front LH wheel arch liner. Refer to 7. Disconnect hoses (x2) from EBCM. Note:
FRT: 78100100, page 78-2. Illustration has fender removed for clarity.
4. Open hood. 8. Release tube nuts (x5) securing pipes to
EBCM and disconnect pipes. Torque - 21
Nm.
before removal.
FSM00022
5. Remove brake fluid reservoir cap.

6. Using a syringe, remove brake fluid from
reservoir.
CAUTION: If brake fluid is spilt on the
water. FSM00052
9. Remove bolts (x2) securing EBCM bottom

bracket to body. Torque - 20 Nm.
50-5
BRAKES
FSM00047 FSM00053
10. Remove bolts (x2) securing EBCM top 14. Release bolt securing EBCM to bracket and
bracket to body and release EBCM. Torque - remove bracket from module. Note fitted
20 Nm. position of bracket location dowel to EBCM.
Torque - 20 Nm.
Installation
13 1. Installation procedure is reverse of removal
14 except for the following.
to installation.
50010102, page 50-2.
FSM00046
11. Disconnect EBCM connector.

12. Release clips (x2) securing harness to EBCM
bracket.
13. Remove EBCM assembly.
50-6
BRAKES
Sensor - ABS - Rear - LH 5. Remove bolt securing sensor to upright.

Torque - 10 Nm.
FRT No.: 50200300
6. Remove ABS sensor.
WARNING: To avoid serious injury, use Installation

appropriate equipment to carry out this 1. Installation procedure is reverse of removal.
operation.
Remove to installation.
1. Remove road wheel. Refer to FRT: WARNING: Only use cleaning agents and
54100501, page 54-2. solvents in a well ventilated area.
90010100, page 90-2.
FSM00566
3. Disconnect ABS sensor connector from rear

ABS harness.
FSM00607
5
4. Release clips (x3) securing sensor cable to
rear subframe.
50-7
BRAKES
Sensor - ABS - Front - LH Brake Rotor - Front - LH
FRT No.: 50200500 FRT No.: 50300100
Remove
CAUTION: Brake rotors must be renewed in
pairs.
90010100, page 90-2.
2. Remove front wheel arch liner. Refer to FRT: Remove
78100100, page 78-2. 1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
5 WARNING: Make sure the vehicle is correctly

6 7
FSM00034
3. Disconnect ABS sensor connector from

engine compartment harness.
4. Release clips (x3) securing sensor cable to FSM00003
body. 2. Remove bolts (x2) securing caliper to upright

5. Remove bolt securing sensor to upright. and tie caliper aside. Torque - 135 Nm.
Torque - 10 Nm. CAUTION: To avoid damage to the brake line,
6. Remove ABS sensor. the brake caliper must be supported at all
times.
Installation
to installation.
50-8
BRAKES
Brake Caliper - Front - LH
FRT No.: 50300400

operation.
CAUTION: Brake rotors must be renewed in
pairs.
Remove
FSM00002
3. Remove screw securing rotor to hub. Torque 54100501, page 54-2.
- 12 Nm. WARNING: Make sure the vehicle is correctly
4. Remove front brake rotor. supported before commencing work.
Installation
to installation.
4
WARNING: Do not use compressed air to
clean brake components.
CAUTION: Replace all patch bolt(s). 3
2. Pump brake pedal at least 5 times to seat FSM00028
pads against brake rotor. 2. Loosen bolt securing brake hose union to
WARNING: Always check brake pads are caliper and disconnect union. Torque - 20
seated correctly before driving the vehicle. Nm.
WARNING: Do not clamp brake hoses as they
will be damaged and require replacing.
water.
3. Remove bolts (x2) securing caliper to upright.
Torque - 135 Nm.
50-9
BRAKES
4. Retract brake pads to clear brake rotor. Brake Rotor - Rear - LH

5. Remove caliper.
FRT No.: 50300600
6. Remove both pads from caliper.
Installation WARNING: To avoid serious injury, use

1. Installation procedure is reverse of removal operation.
to installation. CAUTION: Brake rotors must be renewed in
pairs.
solvents in a well ventilated area. Remove
WARNING: Do not use compressed air to 1. Remove road wheel. Refer to FRT:
clean brake components. 54100501, page 54-2.
CAUTION: Replace all patch bolt(s). WARNING: Make sure the vehicle is correctly
2. Remove any scale or corrosion from around supported before commencing work.
edge of rotor.
3. Apply anti-seize compound to pad rear
mating faces.
50010102, page 50-2.
FSM00014
2. Remove bolts (x2) securing caliper to upright

and tie caliper aside. Torque - 100 Nm.
CAUTION: To avoid damage to the brake line,
the brake caliper must be supported at all
times.
50-10
BRAKES
Brake Caliper - Rear - LH
FRT No.: 50300900

operation.
Remove
54100501, page 54-2.
FSM00015
3. Remove screw securing rotor to hub. Torque supported before commencing work.
- 12 Nm.
4. Remove brake rotor.
Installation
1. Installation procedure is reverse of removal 4
except for the following. 3
to installation.
clean brake components. FSM00021
CAUTION: Replace all patch bolt(s). 2. Loosen bolt securing brake hose union to
2. Pump brake pedal at least 5 times to seat caliper and disconnect union. Torque - 20
pads against brake rotor. Nm.
WARNING: Always check brake pads are WARNING: Do not clamp brake hoses as they
seated correctly before driving the vehicle. will be damaged and require replacing.
3. Check operation of park brake and adjust if CAUTION: Plug all open connections to
required. prevent ingress of moisture and dirt.
water.
3. Remove bolts (x2) securing caliper to upright.
Torque - 100 Nm.
4. Retract brake pads to clear brake rotor.
5. Remove caliper.
50-11
BRAKES
6. Remove both pads and shims from caliper. Brake Pads - Front
Installation FRT No.: 50302000

except for the following. WARNING: To avoid serious injury, use
NOTE: Clean component mating faces, prior appropriate equipment to carry out this
to installation. operation.
WARNING: Only use cleaning agents and WARNING: Eye protection must be worn.
solvents in a well ventilated area. WARNING: Brake pads must be renewed in
WARNING: Do not use compressed air to axle sets only, otherwise braking efficiency
clean brake components. may be impaired.
CAUTION: Replace all patch bolt(s). Remove

2. Remove any scale or corrosion from around 1. Remove road wheel. Refer to FRT:
edge of rotor. 54100501, page 54-2.
3. Apply anti-seize compound to pad rear WARNING: Make sure the vehicle is correctly
mating faces. supported before commencing work.
4. Bleed brake system. Refer to FRT: 2. Turn steering onto full RH lock for access.
50010102, page 50-2.
FSM00009
3. Depress edge of spring clip, carefully drift

pad retaining pin inboard. Repeat process
and remove additional pin. LH illustrated.
50-12
BRAKES
Brake Pads - Rear
FRT No.: 50302100

operation.
WARNING: Brake pads must be renewed in
axle sets only, otherwise braking efficiency
may be impaired.
FSM00010 Remove
4. Remove bolt securing pad retainer, drift to 1. Remove road wheel. Refer to FRT:
release and remove pad retainer from caliper. 54100501, page 54-2.
Collect anti squeal spring. Torque - 10 Nm. WARNING: Make sure the vehicle is correctly
NOTE: Note fitted position of components supported before commencing work.
before removal.
5. Place suitable absorbent material around
master cylinder reservoir.
6. Compress pistons and remove both pads
from caliper.
7. Repeat above procedure and replace RH
front pads.
Installation
1. Installation procedure is reverse of removal,
NOTE: Clean component mating faces, prior FSM00013
to installation.
2. Remove brake pad retaining pins (x2) from
WARNING: Only use cleaning agents and LH rear caliper and collect anti-rattle spring.
3. Position absorbent material around master
WARNING: Do not use compressed air to cylinder reservoir.
4. Compress pistons and remove both pads
2. Remove any scale or corrosion from around and shims from caliper.
edge of rotor.
5. Repeat above procedure and replace RH rear
3. Apply anti-seize compound to pad rear pads.
mating faces.
4. Pump brake pedal at least 5 times to seat Installation
pads against brake rotors. 1. Installation is reverse of removal except for
WARNING: Always check brake pads are the following.
seated correctly before driving the vehicle. NOTE: Clean component mating faces, prior
5. Check and top up brake fluid reservoir. to installation.
50-13
BRAKES
WARNING: Only use cleaning agents and Motor - Parking Brake

FRT No.: 50400100
2. Remove any scale or corrosion from around WARNING: To avoid serious injury, use
edge of rotor. appropriate equipment to carry out this
operation.
3. Apply anti-seize compound to pad rear
mating faces. WARNING: Eye protection must be worn.
4. Pump brake pedal at least 5 times to seat Remove

pads against brake rotor.
WARNING: Always check brake pads are FRT: 70100300, page 70-3.
seated correctly before driving the vehicle.
2. Release park brake.
5. Check and top up brake fluid reservoir.
3. Remove both rear brake rotors. Refer to FRT:
50300600, page 50-10.
FSM00033
4. Loosen park brake adjusters to loosen park

brake cables.
50-14
BRAKES
2. Adjust park brake shoes. Refer to FRT:

50401100, page 50-18.
FSM00061
5. Disconnect LH and RH park brake cables

from motor drive cable link.
7 9
8
FSM00059
6. Release clip securing park brake drive cable

to body.
7. Disconnect park brake motor harness
connector.
8. Remove bolts (x2) securing park brake motor
bracket to body and remove motor. Torque -
20 Nm.
Installation
to installation.
50-15
BRAKES
Parking Brake Cable - Adjust Cable - Cable Link to Hub - LH
FRT No.: 50400200 FRT No.: 50400400
WARNING: Eye protection must be worn. WARNING: Eye protection must be worn.
Remove Remove
1. Remove diffuser closing panel. Refer to FRT: 1. Raise and support vehicle. Refer to FRT:
70100300, page 70-3. 54100501, page 54-2.
2. Release the park brake. 2. Remove lug nuts (x10) securing rear road
3. Check operation parking brake mechanism. wheels and remove road wheels. Torque -
205 Nm.
FRT: 70100300, page 70-3.
4. Release park brake.
5. Remove both rear brake rotors. Refer to FRT:
50300600, page 50-10.
6. Loosen park brake adjusters to loosen
cables.
7
8
FSM00894
4. Check and adjust free play if required.

5. Check operation parking brake mechanism.
Installation
9
FSM00063
7. Disconnect LH park brake cable from cable

link.
8. Depress clips and release park brake cable
from body support bracket.
9. Remove bolt securing park brake cable clip
to body. Torque - 20 Nm.
50-16
BRAKES
Park Brake Shoes - Adjust
FRT No.: 50401000

operation.
Adjust
1. Remove LH rear brake rotor. Refer to FRT:
50300600, page 50-10.
FSM00062
2. Remove RH rear brake rotor.
10. Remove bolt securing park brake cable outer 3. Release park brake.
to rear upright. Torque - 10 Nm.
11. Retract spring and disconnect inner cable
from park brake actuator arm.
12. Release and remove cable assembly from
upright.
Installation
to installation.
WARNING: Do not use compressed air to 4. Tighten adjuster nut.

clean brake components. 5. Install brake rotor.
2. Using a suitable lubricant, grease inner cable 6. Repeat step 4 and 5 until rotor is held firmly
link and park brake actuator contact faces. by park brake shoes.
3. Adjust park brake shoes. Refer to FRT: 7. Remove rotor and loosen adjuster nut by two
50401000, page 50-17. clicks.
8. Repeat step 4 - 7 for opposite side.
9. Install LH rear brake rotor.
10. Install RH rear brake rotor.
11. Apply and release the park brake at least five
times to ensure shoes are firmly seated.
12. Install rear road wheels.
50-17
BRAKES
Park Brake Shoes
FRT No.: 50401100

operation.
Remove
2. Remove lug nuts (x10) securing rear road 6. Remove screw securing brake rotor to hub
wheels and remove wheels. Torque - 205 and remove rotor. Torque - 12 Nm.
Nm. 7. Repeat step 6 to remove opposite brake
3. Release park brake. rotor.
FSM00014 FSM00055
4. Remove bolts (x2) securing rear brake caliper 8. Depress clips, release and remove shoe
to upright and position caliper aside. Torque retainers.
- 100 Nm. 9. Noting fitted position, release shoe upper and
CAUTION: To avoid damage to the brake line, lower retaining springs.
the brake caliper must be supported at all 10. Remove park brake shoes from brake
times. actuator and adjuster, collect brake adjuster.
5. Repeat step 4 to release opposite brake
caliper. Installation
to installation.
50-18
BRAKES

2. Adjust park brake shoes. Refer to FRT:
50401000, page 50-17.
50-19
BRAKES
50-20
WHEELS & TIRES
Contents Page
Wheel - Remove for Access ..................................................................................................... 54-2

Tire - Each................................................................................................................................. 54-2
Wheel Sensor - TPMS............................................................................................................... 54-4
54-1
WHEELS & TIRES
Wheel - Remove for Access Tire - Each

WHEELS & TIRES
FRT No.: 54100501 FRT No.: 54200100
Remove
appropriate equipment to carry out this 1. Remove road wheel. Refer to FRT:
operation. 54100501, page 54-2.
Remove supported before commencing work.
1. Raise and support vehicle. WARNING: To avoid serious injury, use
WARNING: Make sure the vehicle is correctly appropriate equipment to carry out this
supported before commencing work. operation.
2. Remove lug nuts (x5) securing road wheel 2. Remove cap and inner core from valve to
and remove road wheel. Torque - 205 Nm. deflate tire.
3. Use a suitable tire removing machine for
Installation
following steps.
NOTE: Check direction of tire machine
NOTE: Clean component mating faces, prior rotation before starting procedure.
to installation.
FSM00048
4. Release tire beading from rim on both sides,

ensuring all operations are carried out
opposite valve and sensor.
CAUTION: The TPMS wheel sensor may be
damaged if the instructions are not followed
correctly.
5. Apply suitable lubricant to each tire bead.
6. Position and secure wheel on tire machine,
front face up.
54-2
WHEELS & TIRES
2. Clean and inspect wheel rim. Remove any

dirt, burrs or swarf.
3. Inflate tire until both tire beads are seated on
the rim.
4. Adjust tire pressure to recommended
pressure and fit valve cap.
5. Check tire for air leaks.
100 mm
6. Balance wheel.
FSM00049
7. Rotate wheel and tire so mounting head is

100 mm in front of valve. Using a tire lever, lift
tire bead on to mounting head.
NOTE: Ensure tire bead does not slip on the
rim during removal/installation.
8. Release tire bead from wheel rim by rotating
machine.
100 mm
FSM00050
9. Rotate wheel and tire so mounting head is

100 mm in front of the valve. Using a tire lever
with a rim protector, lift bottom tire bead on
to mounting head.
NOTE: Ensure tire bead does not slip on the
rim during removal/installation.
10. Release tire bead from wheel rim by rotating
machine and remove tire.
Installation
54-3
WHEELS & TIRES
Wheel Sensor - TPMS

FRT No.: 54300100
Remove
54100501, page 54-2.
operation.
2. Remove tire. Refer to FRT: 54200100, page
54-2.
FSM00051
3. Mark fitted position of wheel sensor.

4. Release and remove TPM sensor from wheel
rim.
Installation
2. Clean all component mating faces.
54-4

2012 Fisker Karma Service Manual Part 1

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2012 Fisker Karma Service Manual Part 1

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KARMA 2012

Publication number: C1810ASD0054.02

WHEELS & TIRES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

Mounting - LH ........................................................................................................................... 12-2

Mounting - LH WARNING: To avoid serious injury, use

appropriate equipment to carry out this

2. Remove nut securing engine mounting to Installation

5. Using suitable lifting equipment, support

Mounting - RH WARNING: To avoid serious injury, use

6. Remove nut securing RH mounting to engine

2. Remove nut securing engine mounting to

WARNING: To avoid serious injury, use

15. Remove screws (x3) securing lower

21. Loosen clip securing charge air pipe to FSM00732

30. Disconnect boost pressure sensor harness

CAUTION: Plug all open connections to

37. Release clips (x2) securing generator harness

38. Remove power steering pump reservoir cap

43. Remove LH suspension turret cross brace.

39. Remove bolt securing high pressure union to

possible fluid spillage. 46. Disconnect engine harness connectors from

49. Disconnect engine harness connectors (x2)

42. Remove bolt securing power steering hose

NOTE: Place suitable absorbent material

51. Remove bolts (x2) securing bulkhead wall

56. Remove nut and disconnect A/C pipes from

53. Release clip and disconnect bulkhead heater

61. Remove nut and disconnect A/C high

57. Remove bolt and disconnect bulkhead A/C

WARNING: Only use cleaning agents and

69. Remove front bolts (x2) securing subframe to

Gasket - Cylinder Head 6. Remove fuel pump acoustic cover.

FRT No.: 12150100

12300300, page 12-27. 7. Disconnect fuel pump unions (x2). Torque -

5. Disconnect fuel pump harness connector.

11. Remove fuel pump.

17. Disconnect turbo boost pressure modulator

from modulator. 21. Remove bolt securing manifold support

23. Remove intake manifold.

26. Remove fuel rail acoustic cover.

31. Remove spark plugs.

27. Remove bolts (x4) securing fuel rail to

cylinder head. 32. Remove bolts (x2) securing catalyst to engine

29. Remove fuel rail and injectors. FSM00901

NOTE: Place suitable absorbent material

40. Release oil feed pipe union from turbo.

39. Release coolant feed and return unions to

- 25 Nm. 41. Remove nuts (x4) securing turbo to exhaust

FSM00945 46. Remove exhaust manifold.

48. Rotate crankshaft in clockwise direction to

50. Remove bolt securing timing chain tensioner

58. Using sequence shown, progressively loosen

4. Working in the sequence shown, 7. Check crankshaft sprocket timing position.

Oil Seal - Crankshaft - Rear WARNING: This component is extremely

7. Remove crankshaft rear oil seal. Discard oil

5. Remove bolts (x8) securing flywheel to

Oil - Drain and Refill WARNING: To avoid serious injury, use

8. Remove oil pan drain plug.

7. Remove and discard filter cartridge from

Gasket - Camshaft Cover

5. Remove bolts (x2) securing camshaft inlet

2. Release turbo breather pipe from cam cover

9. Remove camshaft cover.

Gasket - Timing Cover