Instruction/ maintenance manual of the product X-Type (2001) Jaguar
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Workshop Manual X-TYPE Sedan and Estate (Wagon) 2.0 L , 2.5 L and 3.0 L Gasoline; 2.0 L and 2.2 L, Diesel 2001 to 2009 www.JagDocs.com JagDocs.com.
TABLE OF CONTENTS 1: General Informa tion 10 0: Service Information 100 -00: General Information Description and Op eration About This Manual Application and Use of Spec ifications General Service Inf.
2: Chassis 20 4: Suspension 204 -00: Suspension System - Gene ral Information Specification Description and Op eration Wheel Alignment Angles Diagnosis and Testing Suspension System General Procedures Front Toe Adjustment (57.65.01) Rear Toe Adjustment ( 57.
Removal and Installation Damper Front Lower Arm (64.35.51) - 4-Door Front Lower Arm (64.35.51) - Wagon Rear Lower Arm (64.35.52) Spring (64.20.01) Rear Stabilizer Bar (64.35.08) Rear Stabilizer Bar Link (64 .35.24) Upper Arm (64 .25.31) Wheel Hub (64.
Diagnosis and Testing Driveline System 205 -01: Driveshaft Specification Description and Op eration Driveshaft Diagnosis and Testing Driveshaft General Procedures Driveshaft Runout an d Balancing Removal and In stallation Driveshaft (47.
Front Halfshaft RH (47.10.16) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110 kW/150PS) - Puma Inner Constant Velocity ( CV) Joint Boot (47.10.18) Intermediate Shaft Outer Constant Velocity (CV) Joint Boot (47.
Brake Pads (70.40.02) 206 -04: Rear Disc Brake Specification Description and Op eration Rear Disc Brake Diagnosis and Testing Rear Disc Brake Removal and In stallation Brake Caliper (70.55.03) (70.55.25) Brake Disc (70.10.11) Brake Disc Shield (7 0.10.
Brake Pedal and Bracket (70.35.03) Brake Pedal Cross-Shaft 206 -07: Power Brake Actuation Specification Description and Op eration Brake Booster Diagnosis and Testing Power Brake System Removal and In stallation Brake Booster (70.50.17) - LHD AWD/LHD FWD Brake Booster (70.
211: S teering System 211 -00: Steering System - General I nformation Specification Description and Op eration Steering System Diagnosis and Testing Steering System General Procedures Power Steering System Filling Power Steering System Flushing ( 57.15.
211-03 : Steering Linkage Specification Description and Op eration Steering Linkage Diagnosis and Testing Steering Linkage Removal and In stallation Steering Gear Boot (57.
3: Powertrain 30 3: Engine 303 -00: Engine System - General Inform ation Specification Description and Op eration Engine Diagnosis and Testing Engine General Procedures Bearing Inspection Camshaft Bea.
Leakage Test Using Smoke Test Equipm ent 303 -01A: Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Engine Diagnosis and Testing Engine General Procedures Valve Clearance Adjustment (12.29.48) Valve Clearance Check (12.
Engine (12.41.01) - Veh icles With: 5-Speed Au tomatic Transaxle - JATCO/6-Speed Automatic Transaxle - AWF21 Disassembly Engine Disassembly and Assemb ly of Subassemblies Cylinder Head (12.29.22) Piston (12.17.02) Assembly Engine Installation Engine (12.
Installation Engine (12.41.01) - 2.0L Du ratorq-TDCi Engine (12.41.01) - 2.2L Du ratorq-TDCi (110kW/150P S) – Puma 303 -03A: Engine Cooling - 2.0L NA V6 - AJV6/2.
Cooling Module (26.40.16) Radiator (26.40.01) Water Pump (26.50.01) 303 -04A: Fuel Charging and Con trols - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Fuel Charging and Controls Diagnosis and Testing Fuel Charging and Controls - 2.
303 -04C: Fuel Charging and Con trols - Turbocharger Specification Description and Op eration Turbocharger Diagnosis and Testing Turbocharger Removal and In stallation Turbocharger 303 -05: Accessory .
Starting System Diagnosis and Testing Starting System - 2.0L NA V6 - AJV6 Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Removal and In stallation Starter Motor (86.60.01) - 2.0L Du ratorq-TDCi Starter Motor (86.60.01) - 2.2L Du ratorq-TDCi (110kW/150 PS) - Puma Starter Motor (86.
Removal and In stallation Exhaust Gas Recirculation ( EGR) Cooler Exhaust Gas Recirculation ( EGR) Cooler to EGR Valve Tube Exhaust Gas Recirculation ( EGR) Valve (17 .45.01) 303 -12A: Intake Air Distribution a nd Filtering - 2 .0L NA V6 - AJV6/2. 5L NA V6 – AJV6/3.
Removal and In stallation Evaporative Emission Canister (17.15.13) - 2.0L NA V6 - AJV6 Evaporative Emission Canister (17.15.13) - 2.5L NA V6 - AJV6/3 .0L NA V6 - AJ27 Evaporative Emission Canister Purge Valve (17.15.30) 303 -14A: Electronic Engine Controls - 2.
Description and Op eration Electronic Engine Controls Diagnosis and Testing Electronic Engine Controls Removal and In stallation Camshaft Position (CMP) Sensor (18.30.63) Catalytic Converter Temperatu re Sensor Crankshaft Position (CKP) Sensor (18.30.
Transmission Control Module (TCM) (44.15.32) Transmission Range (TR) Sensor Removal Transaxle (44.20.01) Disassembly and Assemb ly of Subassemblies Input Shaft Seal (44.
307 -02A: Transmission/Transaxle Cooli ng - Vehicles Wit h: 5-Speed Automati c Transaxle - JATCO Specification Description and Op eration Transmission Cooling - Veh icles With: 5-Speed Automatic Transaxle - JATC O Diagnosis and Testing Transmission Cooling Removal and In stallation Transmission Fluid C ooler (44.
307 -05B: Automatic Transmission/Tra nsaxle External C ontrols - Vehicles Wi th: 6-Speed Automat ic Transaxle - AWF21 Specification Description and Op eration External Controls - Vehicle s With: 6-Spee d Automatic Transaxle - AWF21 Diagnosis and Testing External Controls General Procedures Selector Lever Cable Adjustment ( 44.
Clutch Disc and Pressure Plate (12.53.13) (3 3.10.01) 308 -02: Clutch Controls Specification Description and Op eration Clutch Controls Diagnosis and Testing Clutch Controls Removal and In stallation Clutch Master Cylinder (3 3.20.01) Clutch Slave Cylinder (33.
Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 Installation Transaxle (37.20.01) - 2 .0L Duratorq-TDCi Transaxle (37.20.01) - 2 .2L Duratorq-TDCi (110kW/150PS) - Puma Transaxle (37.20.01) - 2 .0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.
30 9: Exhaust System 309 -00: Exhaust System Specification Description and Op eration Exhaust System Diagnosis and Testing Exhaust System Removal and In stallation Catalytic Converter (17.50.05) - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (110kW/1 50PS) - Puma Catalytic Converter LH (17.
General Procedures Fuel System Pressure C heck Fuel System Pressure Release (19.50.02) Fuel Tank Draining - 2.0L Duratorq-TDCi/2.2L Durato rq-TDCi (110kW/15 0PS) – Pum a Fuel Tank Draining - 2.
310 -02: Acceleration Control Specification Description and Op eration Acceleration Control Diagnosis and Testing Acceleration Control General Procedures Accelerator Cable Adju stment (12.20.05) - 2.0L NA V6 - AJV6 Removal and In stallation Accelerator Cable ( 19.
Air Conditioning (A/C) System Flushing Air Conditioning (A/C) System Recovery, Evacuation an d Charging (82 .30.30) Contaminated Refrigerant Han dling Discharging and Recovery (82.
412 -02B: Auxiliary Heating Specification Description and Op eration Electric Booster Heater Fuel Fired Booster Heater Diagnosis and Testing Auxiliary Heater Fuel Fired Booster Heater Removal and In s.
Air Discharge Temperatu re Sensor (82.20.64) Ambient Air Temperature Sensor (82.20.02) Climate Control Assembly ( 82.20.07) Defrost Vent/Register Blend Door Actuator (82.20.8 4) Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85) Sunload Sensor (82.
Removal and In stallation Message Center Message Center Switch (86.66.11) 413 -09: Warning Devices Description and Op eration Warning Devices Diagnosis and Testing Warning Devices General Procedures Oil Change In dicator Reset Removal and In stallation Low Washer Fluid Warning I ndicator Switch (84.
Quiescent Drain Diagnosis and Testing Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 Charging System - 2.0L Durato rq-TDCi/2.
41 5: Information and Entertainmen t Systems 415 -00: Information and Entertai nment System - Gen eral Information Diagnosis and Testing Audio System 415 -01: Audio Unit Description and Op eration Audio System Diagnosis and Testing Audio System Removal and In stallation Audio Unit (86.
Parcel Shelf Speaker (86 .51.06) Rear Door Speaker (86.50.14) Rear Door Tweeter Spe aker (86.50.62) 41 7: Lighting 417 -01: Exterior Lighting Specification Description and Op eration Exterior Lighting Diagnosis and Testing Headlamps General Procedures Headlamp Adjustment (8 6.
417 -04: Daytime Running Lamps ( DRL) Description and Op eration Daytime Running Lamps (DRL) Diagnosis and Testing Daytime Running Lamps (DRL) 41 8: Electrical Distribution 418 -00: Module Communicati.
419 -01B: Anti-Theft - Passive Description and Op eration Anti-Theft - Passive Diagnosis and Testing Anti-Theft - Passive General Procedures Anti-Theft Security Acce ss Key Programming Using Diagnostic Equip ment Removal and In stallation Passive Anti-Theft System (PATS) Transceiver ( 86.
Cellular Phone Cellular Phone - Veh icles With: Bluetooth Removal and In stallation Bluetooth Module Handset Holder (86.51.12) Module - 4-Door Module – Wagon 419 -10: Multifunction Electronic Modul .
General Procedures Door Alignmen t Hood Alignment (76 .16.02) Liftgate Alignment (76.19.54.60) Luggage Compartment Lid Alignment (76.19.03) Removal and In stallation Weatherstrip 501 -05: Interior Trim and Ornamentation Specification Description and Op eration Interior Trim Removal and In stallation A-Pillar Trim Panel (76.
Removal and In stallation Door Moulding (76 .43.72) Liftgate Moulding (7 6.43.79) Radiator Grille (76.55.03) Rear Spoiler (76.19.86.60) - Wagon Rocker Panel Moulding (76.
Front Seat Track Motor (86.75. 33) Lumbar Assembly (86.75.12) Rear Seat Backrest (76.70.38) - 4-Door Rear Seat Backrest (76.70.38) - 4-Door, Vehicles With : 70/30 Split Seat Rear Seat Backrest (76.70.38) - Wagon, Vehicles With : 70/30 Split Seat Rear Seat Backrest Latch (76.
Rear Quarter Window Glass (76.31.31) Rear Window Glass Using Che ese Wire (76.81.41) Rear Window Glass Using Cut ting Tool Window Control Switch ( 86.25.
501 -16: Wipers and Washers Specification Description and Op eration Wipers and Washers Diagnosis and Testing Wipers and Washers Removal and In stallation Headlamp Washer Pum p (84.20.21) Rain Sensor (84.12.10) ( 86.56.62) Rain Sensor Module (86 .56.60) Rear Window Wiper Motor (8 4.
501-19: Bumpers Specification Description and Op eration Bumpers Removal and In stallation Front Bumper Cover (7 6.22.78) Front Bumper Cover In sert (76.22.73) Rear Bumper (76.22.27) (76.22.52) - 4-Door Rear Bumper (76.22.27) (76.22.52) - Wagon Rear Bumper Cover (76 .
General Procedures Air Bag Disposal Removal and In stallation Clockspring (86.65.92) Crash Sensor (76.73.55) Driver Air Bag Module (7 6.73.39) Driver Lower Air Bag Module (76.73.75) Occupant Classification Senso r (76.73.60) Passenger Air Bag Deactivation (PAD) Indicat or (76.
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - A bout Th is Man ual Des cr ipt i o n a nd O pe r a t i o n Note s, Ca u tions a n d Warn ings Thr oug hout t hi s manua l , i mpor t a nt i nfo rm at i on i s hi ghl i gh te d by t he us e o f no t e s , ca ut i ons a nd wa rning s.
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - A pplicatio n and U se o f S pecifi cation s Des cr ipt i o n a nd O pe r a t i o n Torque S pecif ica tions To r que s pe ci fi cat i on s a r e s ho wn i n t he t orque s pe cif i ca t i o ns c ha rt l o cat e d a t t he fro nt of t he rel e v a nt s e c t i o n.
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - General Service I nform atio n Des cr ipt i o n a nd O pe r a t i o n Repa irs an d Repla cem en ts W he n s e r vi c e pa r t s a r e requi r ed, it i s e s s e nt ia l tha t onl y g e nui ne Ja g uar/ Dai mle r r ep l a ceme nt s a r e us e d.
Re - e nt e r t he radi o recei ve r /cas s e t t e pl ayer /min i di s c pl a y e r and co mpact d i s c pl a y e r k e yc od e s a nd pr es e t ' f r e que ncie s , i f kno wn.
I t is o f f unda ment a l i m po r t ance t ha t c e rta i n e s s e nti a l e qui pme nt e . g. t o r que wren c he s , mult i met e r s , e xhaus t ga s a nal yse r s, r o ll i ng roads e t c., are regul arly cal i br a t e d i n a ccor da nce wi t h t he m a nufa ct ur ers i ns t r u cti ons .
I n t he i nt e re st o f cla r it y, s i ngl e l i ne s may repr e se nt mul t i pl e wi r es . Re fe r to the col o r code (1s t a l pha ) f ol lo we d by t he wi r e ref e rence (num eric/al pha/n umer ic) t o t r ace o r i g in a nd de s t i n at io n.
T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on Dat a O ut p ut Li ne DOL Ci r cui t th a t s e n ds certa i n i nf orm at i o n f r o m t he ECM to the i ns t ru me nt cl ust e r Deg r.
T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on He a t e d O x ygen S e nso r HO2S El e ct rica ll y he at e d o xy ge n s e ns or w hi ch i ndu c e s f ue l i ng c orr e ct i ons He r .
T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on On -Boa rd Dia g nos t i c OB D A s ys t e m t ha t moni t o r s s o me o r a l l comput e r i npu t a nd o ut p ut cont r o l s i gna l s .
T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on Tr an s mi s s i o n O i l Te mpe r at ur e TO T I ndi cat e s t e mpe rat ur e o f t rans mis s i o n fl ui d Tr an s mi s s i o n Ran g.
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - H ealth and Safety Pre cautio n s Des cr ipt i o n a nd O pe r a t i o n P r o l onge d a nd repe a t ed c on t a ct wi t h mine ral o i l wi l l res ul t i n t he r e mov a l of na t ural o i ls f r o m t he s kin , l e adi ng t o dr ynes s , i rr i t a t io n a nd de r m a t i t i s .
Hi ghl y fl ammabl e , combus t i bl e – o bs e rv e No Sm oking po l i cy . S kin co nt a ct may res ul t in f r os tb i te . I nst r ucti o ns gi ven b y t he manufa ct ur e r m us t be f o l l owe d. A voi d na ked l i ght s , we ar s u i t a b l e p r o te cti v e g lo ves and gogg l e s .
Do wa s h b e fo re br ea ks , bef ore e a t i ng, s mokin g, d rinking o r us i ng t o i l et fa ci l i t i e s w he n ha ndl i ng che mica l m a t e ria l s . Do ke e p wo r k a r ea s cl e a n, unclut t e r ed a nd f r e e o f s pi l l s . Do s t ore che mica l mat e ria l s acco r d i ng t o na t i o na l and l o cal regul at i o ns .
S ee L ubr ica nt s a nd Gr ea se . Exh a ust Fume s The s e c ont a i n a s phyxia t i ng , harm f ul a nd t oxi c chemi ca l s a nd p a r t i cl e s s uch a s ca r bo n o xide s , ni t r oge n o x i d e s , a l dehyde s , l ea d and aromat i c hydr o carbons .
Mot or ga s o li ne may cont ai n a pp r e cia b l e qua nt i t i e s o f b e nz e ne , whi ch is t o xic u po n i n hal at i o n, a nd t he concen trat i o n of ga s o l i ne v a po r s mus t be ke p t v e r y lo w.
The Fa ct or i e s A ct (1961). The As bes t os Re gul at i o ns (1969). Hi ghl y Fl a mm a b l e Li q ui ds a nd L iq ui f i e d P e t r o l e um Gas e s Re g ul a t i o ns (1972) . Cont rol o f P o l l ut i on A c t (1974). He a l t h a nd S a fe t y a t W o r k Act (1974).
a voi de d. Re moval o f e xc e s s s o ld e r s houl d be underta ke n wi t h care, t o make s ure t hat f i ne l e ad d ust i s no t p r o d uced, wh ich ca n gi ve t o xic e ff e ct s i f in ha l e d. Re sp i r a t ory prote c t i o n may b e ne ce s s a r y .
S ee a l s o Fi r e , El e ct ric Shoc k, Ga s Cyli nde rs. W e l di ng pr oce s s e s i ncl ude Res i st a nce W e ld i ng (S pot W e l di ng), A r c W e l d in g and Gas W e l d i ng.
3. J ag ua r vehi cle s a nd r e pl a ce ment parts whi ch cont a i n a s be s t os a r e i de nt i fi ed by t hi s s y mbol . S ee A sb e s t o s i n t hi s s ub s e ct i o n. 3. 4. Componen t s o r as s e mbli e s d is pl a yi ng t hi s s ym bol gi ve wa r ni ng t ha t t he compone n t cont a i ns a co r r os ive s ubs t a nce.
Ensu r e t hat d ry s a nd is a va i l abl e t o s o ak up a ny f ue l s pi l l a ge . Empty fue l us i ng s ui t ab l e fi r e p r oo f e qui pment i nto an a ut ho r i ze d expl o s i on pr oo f c o nt a i ner. Do no t e m pt y fue l whi l e wo r ki ng i n a wo r ksh op o r a pi t .
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - H o w To Us e T hi s Manua l Des cr ipt i o n a nd O pe r a t i o n C opyrigh t Sta t em en t Cop y r i ght .
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Important Safety Instructio ns Des cr ipt i o n a nd O pe r a t i o n S af e t y N o t i ce App r opr i at e s e r vi ce met ho d s a nd co r r e.
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - R oa d /R oll e r Tes ting Des cr ipt i o n a nd O pe r a t i o n Roa d o r r o l l e r t e s t i ng may b e carr i e d out f o r vario us reas o.
Abnorm a l te mperat ur e o f an y movi ng comp one nt s or as s e mbl i e s , e .g. whe e l hubs , t r ans mis s i o n, a xl e e t c., whi ch mi ght i ndi ca t e overti ght ne s s o r l a ck o f l ub r i cat i o n.
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Solvents, Sealants and Adh esives Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: A l wa ys ha ndl e a l l s ol ve nt s , s e a l e r s a nd a d he s i ves wi t h e xtre me ca r e . S ome co nt a i n che mical s o r g i ve of f f um e s whi ch ca n be d a nge rous to hea l th .
P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Sta ndard Works ho p Practices Des cr ipt i o n a nd O pe r a t i o n Protecting th e V eh icl e Al wa ys i ns t a ll cove rs t o pr ot e ct t he fe nd e r s be f ore co mm enci ng wo rk i n th e e ng i ne co mpa r t ment .
P ubl i s he d: 11-May-2 011 Identifi cation C odes - Ide ntif icatio n C o des Des cr ipt i o n a nd O pe r a t i o n V eh icl e Ide ntifi cation Num be r (VIN) The o ff i ci a l VI N i s s t a mped o n t he right han d s i de o f t he b o ot compart m e nt fl o o r.
Item Par t N u m ber Desc ri pti on 1 — W orld manuf act ur er i de nt i fi e r 2 — Ma r k e t , a i r ba g s pe cif i ca t i on 3 — T r ans mis s i o n a nd s t e e ring co d e 4 — B o dy cod.
VI N Po si t i o n 8 • NO T E: *1 EU . I ncl ude s t he f ol l o wi ng mar ket s ; Au s t ria , Be lg i um , Cy pru s , Cz e ch Rep , Den m a rk , Es t o ni a , Fi nla nd, France , Ger many, Gr e e ce, Ne t he rla nds , Hunga r y, It a l y, La t vi a , Li t huani a, L uxe mbour g, Mal t a, P o l and, P o r t uga l , Rep.
VI N Po si t i o n 1 2 throug h 1 7 Seque nce Nu m ber C00001 - C99999 D0000 1 - D99999 E00001 - E 99999 J00001 - J9999 9 K00001 - K99999 S 000 01 - S9 9999 T00001 - T99999 V00001 - V99999 V eh icl e C ertif i cation La bel The vehi cl e ce r t i f i ca ti on l a b e l al s o cont a i ns t he 17 charact e r vehi cl e i den t i f i cat i o n number.
It e m Pa rt Nu mb e r Descri pti o n 1 — Maximum perm i t t e d front a xle l o a di ng 2 — Dat e of ma nufa ct ur e 3 — Gr o s s ve hi cle w ei ght 4 — Maximum perm i t t e d r ea r a xle l .
It e m Pa rt Nu mb e r Descri pti o n 1 — Maximum perm i t t e d front a xle l o a di ng 2 — Dat e of ma nufa ct ur e 3 — Gr o s s ve hi cle w ei ght 4 — Maximum perm i t t e d r ea r a xle l .
P ubl i s he d: 11-May-2 011 Ja cking and L ifti ng - J ackin g Des cr ipt i o n a nd O pe r a t i o n Sa f et y Precau tion s CAU TIO N : Th e j ack prov i de d wi t h t he vehi cl e i s i nt ende d t o b e us e d i n a n e me r ge ncy f o r cha ngi ng a d e fl a t e d t i re .
P ubl i s he d: 11-May-2 011 Ja cking and L ifti ng - Li ftin g Des cr ipt i o n a nd O pe r a t i o n Liftin g Poi nt s—Twi n-Post Hoist an d Floor Ja ck • CAU TI O N S : Do not a l lo w t he ho .
V eh icl e R ecove ry • NO T E: P r i o r t o vehi cl e r e covery , ma k e su r e t hat t he vehi cl e ke ys a r e avai l a bl e a nd t he s e cur it y s y s t e m i s di s a r me d. Ve hi cl e recove r y met ho ds a r e : By f l a t -be d t r ans porte r.
W he n t he vehi cl e i s b e i ng re c ove r e d b y f r ont s us pe nde d t ow : CAU TIO N : Th e dr i ves ha ft mus t be di s c on ne ct e d. The i gni t i on k e y must b e r emove d from t he i gni t i o n s wi t ch t o l o ck th e s t e e r ing.
P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - No ise, V ibration and Harsh ness (NV H) Des cr ipt i o n a nd O pe r a t i o n No i s e , vibr a t i o n a n d ha r s hne ss (NVH) i s be comi ng more i mporta nt a s vehi cl e s be come mor e s op hi s t i ca t e d a nd p a s s eng e r comf ort le vel s in cr e a s e .
P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - No ise, V ibration and Harsh ness (NV H) Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e .
lo o s e d r i ve ha l f s ha f t j oi nt b oot cl a mps a not h e r compone nt c on t a ct i ng t he d r i ve ha l f s haf t wor n, da mag e d o r in cor r ect ly i ns t a ll ed whee l b e a r i ng, .
* * * * * * * * * * * * * * * * * * * * * * * * 1 Road C ondit ions An e xperie nce d te chni cia n wi l l a l wa ys e s t a b l is h a rout e t ha t wi l l be u se d fo r a l l NV H di a gnos i s roa d t es t s .
1 1 1 1 1 1 1 1 Doe s t he vi brat i o n di s ap pe a r dur ing t he ne ut r a l coa s t t e s t ? Ye s CHECK and INSTAL L ne w e ng i ne /ge a r b o x/ t r an s fe r box mount s as nece s sa ry . RE PE AT Ro a d T e s t a s out li ned . No GO t o D1 .
1 1 1 1 1 1 1 Are t he t i r e s O K? Ye s GO t o D2 . No INS P ECT t he whee l s . Fo r a ddi t i o nal i nfo r mat i o n, refe r to REFER t o : W h e e l s a nd Ti r es (204-04 W he e l s and Ti r e s , Di a gno s i s a nd T e s t i ng). D2: IN SPEC T WHEEL BEAR I NG S Ins p ect t he whe el be a r i n gs .
P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - Exh aust S y stem N eutraliz ing Gene ral P r ocedures 1. Loos e n t he muff le r i nl e t pi p e a nd res o na t o r pip e t o e xha us t mani fo l d f as t e ne rs a t t he f l a nge s a nd t he muf fl e r i nl e t conne ct i on.
P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Gen eral S p ec if ic a t ions It e m Speci fi cati on C l e a r V i si on Cle a r vis i o n (neg a t i ve val ue i s co unt.
P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Wheel Alignmen t Angles Des cr ipt i o n a nd O pe r a t i o n To e is ad j us t a bl e o n the f r ont a nd rea r s us pe ns io n s ys t e m . The f r ont t oe i s a d j us t e d b y us e o f t he front t i e -r od.
I te m Descri pti on 1 Re a r r ide he i ght m e a s u r e m e nt Whe el Tra ck It e m De sc ri pti on 1 Fr ont t r a ck 2 Re a r t r ack C ra bbing It e m De sc ri pti on 1 Fr ont t r a ck 2 Re a r t.
a s s mal l rot a t io na l os ci l l a t i o ns of t he s t ee r in g whe e l . Poo r Retu rn ability of the Ste e rin g P oor ret urnabi l i t y of t he s t e e r i ng i s use d t o de s cr ibe t he p oo r r et ur n o f t he s t e e r i ng whe e l t o ce nt e r a ft e r a t ur n or t h e s te e ring co r r ect i o n i s compl e t e d.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Suspensio n Sy stem Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P oo r Ret ur nab il i t y o f t he s te e r i ng. Ba l l jo i nt s. CHECK t he Ba l l Jo i nt (s ). Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o B al l J o i nt ins pe cti o n i n t his s e ct i on .
P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Front To e Adj ustment Gene ral P r ocedures • NO T E: T he checki ng a nd s ubs equ e nt a dj us tme nt o f t he front t .
6. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Rot at e t he t ie -r o d s a n e q ual a mount i n e i t her a cl ockwis e o r a count e r cl o ckwis e d ire c t i o n to a dj us t t he t o e s e t t i ng. 7. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r .
P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - R ear T oe Adjustment Gene ral P r ocedures • NO T E: T he checki ng a nd s ubs equ e nt a dj us tme nt o f t he r e a r t.
7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t he r e a r l o we r a r m cam bo l t nut s . Ti ght e n t o 115 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Wheel B earing Inspecti on Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng .
P ubl i s he d: 11-May-2 011 Front Su spensio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b- i n Lo we r arm front ret a i nin g b o lt A A A Lo we r arm r e a r r e t a i ni ng nut a.
P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Suspensi on Des cr ipt i o n a nd O pe r a t i o n It e m Par t Nu m ber Descri pti o n 1 — Fr o nt sub f r ame m ount ing b us h 2 — S ta b.
Item P a rt N um be r Desc ri pti on 1 — S pring a s s embl y 2 — Thru s t b e a r i ng 3 — S t r ut a nd s pr i ng t op mount 4 — S pring i s o l at o r 5 — Bump s t o p 6 — Dampe r pis t o n ga i t er 7 — Dampe r as s e mbl y JagDocs.
P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Suspensi on Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 4-00 Suspe ns i on S ys t e m - Ge neral Inf orm at i on JagDocs.
P ubl i s he d: 11-May-2 011 Front Su spensio n - Lo w e r Arm Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep a r at o r, Ba l l Joi nt 204-192 (J D-219) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1.
6. NOT E: W he n t he t i e-rod e nd i s s e p a r at ed from t he whe e l hub as s e m bl y, th e ba l l j o i nt s e a l sho ul d be pr ot e ct ed t o pr e vent da mage . Us i ng t he s p e ci a l t o ol , d e t a ch t he t i e -r o d e nd . Vehi c le s with high i ntensity dis char ge hea dlam ps 7.
10. Ins t a l l t he s p e cia l t o o l . 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s.
15. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, make s ur e t he s ubf r ame i s l o we r ed be fo re d e t a chi ng t he l owe r a rm ba l l j o i nt . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle .
Insta llat ion All v e h icle s 1. Ins t a l l the l owe r arm . Ins t al l a ne w l owe r arm r e a r r e t ai n ing b ol t . 2. Repo s i t i on t he l owe r arm . 3. NOT E: Ins t a l l a new r e t a i ni ng bol t . Lo o s e l y i ns t a l l the l owe r arm front ret a i nin g b o lt .
5. Usi ng t he s pe cia l t oo l rai s e t he f ront s u bframe . 6. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s . 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r .
10. Remove t he s pe ci a l t o o l . Vehi c le s with autom at ic tra ns m ission 11. At t ach t he s e l e ct o r l eve r cab l e . All v e h icle s 12. At t ach t he s t ee ring ge a r s uppl y pi p e . Vehi c le s with high i ntensity dis char ge hea dlam ps 13.
14. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . At t a ch bo t h t he t ie -r o d end s . Ti ght e n t o 35 Nm. 15. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover. 16. Ins t a l l t he f r ont whe e ls a nd t i r e s .
20. CAUT I O N: T he fi nal t ig ht e ni ng of t he l o wer a rm r e a r r e t ai ni ng nut a nd b ol t, must b e carr i e d out wi th th e v e hi cl e o n i t s whe e l s . Fa i l ure t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n d amage t o t he ve hi cl e .
P ubl i s he d: 11-May-2 011 Front Su spensio n - Sho ck A bsorber a nd Spr ing Assem bly Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep a r at o r, Ba l l Joi nt 204-192 (J D-219) P owe.
3. D et a ch t he brake ho s e r e t ai ni ng bracket . 4. D et a ch t he s t a bi l i z er l ink b a r. 5. D i s conne ct t he f r ont whe e l sp e e d s e nso r e l e ctrica l conne ct o r . 6. CAU TI O N : S ecur e t he br ake c a l i p e r a nd a nchor pl a t e a s s e m bl y t o one s id e .
8. NOT E: W he n t he t i e-rod e nd i s s e p a r at ed from t he whe e l hub as s e m bl y, th e ba l l j o i nt s e a l sho ul d be pr ot e ct ed t o pr e vent da mage . Us i ng t he s p e ci a l t o ol , d e t a ch t he t i e -r o d e nd . Vehi c le s with high i ntensity dis char ge hea dlam ps 9.
12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 13. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rea r mount ret a i ni ng b o lt s .
17. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, make s ur e t he s ubf r ame i s l o we r ed be fo re d e t a chi ng t he l owe r a rm ba l l j o i nt . Det ach t he whe e l knuck l e . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning nut a nd b o lt .
1. NOT E: Make s ure o r i ent a t i on a r r ow o n t he s trut to p r ubber mount f a ces from fr on t t o r ea r of t he vehi cle . • NO T E: Make s ur e t he ret a i ni ng st ud mark e d wi t h a pa i nt s po t i s corr e ct l y or i e nt a te d.
6. Usi ng t he s pe cia l t oo l rai s e t he f ront s u bframe . 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s . 8. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r .
11. Remove t he s pe ci a l t o o l . Vehi c le s with high i ntensity dis char ge hea dlam ps 12. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h icle s 13. At t ach t he t i e -r od e nd . Ti ght e n t o 35 Nm. 14. At t ach t he b rak e ca l i per a nd a n chor pl a t e a s s e mbly.
15. Conne ct t he f r o nt whe e l s pe e d s e ns or e l e ct rica l c on ne ct or . 16. At t ach t he s t abi l i z e r li nk ba r. Ti ght e n t o 48 Nm. 17. At t ach t he b rak e ho s e ret a i ni ng br acket . Ti ght e n t o 48 Nm. 18. Ins t a l l t he whe e l a nd t i r e .
P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Stabilizer B a r Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he r oa d whe e ls a re i n t he s t r ai ght a he a d p o si t i o n. Ce nt ral i z e t he s t e e r i ng a n d l o ck it i n po s i t i o n.
4. Tig ht e n t o 26 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Stabilizer B a r Bus hing Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 02 R em ova l All v e h icle s 1. Cent e r t he s t e ering w hee l .
5. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Re move t h e whe e l a rc h l i ne r acces s pa ne l . 6. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.
10. W A RNING: Ro t at e t he s pe ci al t o o l he i ght a dj us t ment val v e s l o wl y. Fa il ure t o f ol lo w thi s i ns truc t i o n ma y r e s ul t i n p e r s o nal i njur y. Us i ng t he s p e ci a l t o ol , l ow er t h e rear o f t he f ront s ubf r a m e t o a m a ximum of 50 mm (1.
2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . I nst a l l t he s t a bi l i z e r bar bus h ret a i ni ng br acket . Ti ght e n t he ret a i ni ng bol t s to 4 8 Nm. 3. Usi ng t he s pe cia l t oo l , r ai s e t he re ar of t he front s ubf r a me .
7. Tig ht e n t he f r ont s ubf r a m e r ei nf or ce ment bol t s . M8 t o 35 N m. M10 t o 70 Nm. 8. Remove t he s p e cia l to o l . Vehi c le s with diese l engine 9. Ins t a l l the a i r def le cto r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.
13. NO TE: I ns t a ll a new r e t a i ni ng bo l t . At t a ch t he s t e e r i ng col umn. Ins t al l a ne w s t ee r i ng co l umn l o we r r et a i ni ng bo l t.
P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Wheel Bea ring and Wheel Hub Re moval a n d I ns t a l l a t i on Speci al T ool (s) Fr o nt h ub carr i e r sup po r t 204-310 Hub fl a nge r e.
2. NOT E: W he n r emovi ng t he whe e l hu b f r o m t he whe e l k nuckle t he bea ring wi l l be d e s troyed and th e be a r i ng i nne r r i ng wi l l r e m a i n o n t he whe el hub . Us i ng s pe cia l t o o l s , remov e t he w he e l hub. 3. Usi ng a s ui t a bl e t o o l , r emove t he be a r i ng i nne r r i ng.
3. Usi ng s peci a l t ool s , pr e s s b ea ring i n to whee l knuck le . 4. NOT E: Chan ge s pe ci al t o o l 204-312 t o 204-313. Al ig n t he be aring a nd w hee l knuck l e ove r s p eci a l t ool . 5. S l i de w hee l h ub o ver t he gui de a nd a l ig n t o t he b e aring.
P ubl i s he d: 11-May-2 011 Front Su spensio n - Wheel K nuck le Re moval a n d I ns t a l l a t i on Speci al T ool (s) Bal l jo i nt s pl i t t e r 204-1 92 W he el hub pu ll e r 205-4 91 Adap t er nut s 205-4 91-01 For c i n g s cr ew 204-2 69 Knuck le s p l i t t e r 204-1 59 R em ova l 1.
4. CAU TI O N : O nl y on e s i de o f t he s ubfra m e ne e ds t o be l o we r ed t o det a ch t he lo we r arm ba l l jo i nt . Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 5. Loos e n t he front s ub frame re ar mount re ta i ni ng bo l t .
9. Usi ng t he s pe cia l t oo l s, d e t ach t he ha l f s ha f t . 10. Remove t he whe e l k nuckle p i nc h bo l t . 11. Remove t he whe e l k nuckle . 1. Us i ng t h e s pe ci al t o ol , s p r e a d t he whe el knuck l e. 2. Re move t he whe e l knuc kle .
2. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. At t a ch t he l o we r a r m b a l l jo i nt r et ai ni ng nut a nd bo l t . 4. Ti g ht e n t o 83 N m. 3. Tig ht e n t he f r ont s ubf r a m e front mount ret a i ni ng b ol t .
7. Att a ch t he brake cal i pe r and ancho r pl a t e as s e m bl y. 8. Att a ch t he s t ab i l i ze r ba r conne ct i ng l i nk. Ti ght e n t o 48 Nm. 9. Att a ch t he brake hos e re ta i ni ng br a ck et . Ti ght e n t o 48 Nm. 10. Ins t a l l t he ne w w hee l hub nut .
12. Ti g ht e n t he wh e e l hub nut . Ti ght e n t o 270 Nm. 13. Carr y out f r ont s ubfr a me a l i gnm e nt proced ur e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: U nde r b o dy Mis a li g nment Che ck (502-00 U ni -Bo dy, Subframe a nd Mount i ng S y s t e m, Ge neral Proced ur es ).
P ubl i s he d: 11-May-2 011 Front Su spensio n - Sho ck A bsorber a nd Spr ing Assem bly Dis a s s e mbl y a nd As s e mbl y Speci al T ool (s) S pring co i l compr e s s o r 204-112 S pring a d a pt e r s 204-167-0 1 S pring a d a pt e r s 204-112-0 3 D isa ssem bly 1.
4. D i s a s s e mble t he sho ck a bs o rb e r and s pr i ng a s s e mbl y. 1. Re move t he t hru s t b e a r i ng nut . 2. Re move t he s pa ce r . 3. Re move t he t o p mount . 4. Re move t he t hru s t b e a r i ng. 5. Re move t he s pring s e a t .
P ubl i s he d: 11-May-2 011 Rear Suspensio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Fr o nt l owe r a rm t o whe e l knuck le ret a i ni ng b o l t 124 91 - Fr o nt l owe r.
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Suspensio n Des cr ipt i o n a nd O pe r a t i o n I te m P art N um be r Desc ri pti on 1 — W he e l k nuck l e mount i ng br acket 2 — S ubfr.
is of a s te e l des i gn a nd ha s cam bo l t s a t the s ubframe mount i ng p o in t s t o a d jus t whe e l a l i g nment . is t he rea r l o we r su ppo r t f o r th e w hee l knu ckle .
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Suspensio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 204-00 S us pe ns i on Sy s t e m - Ge ne r a l I nfo r mat i o n .
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Damper Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
3. Tig ht e n t o 25 Nm. 4. Tig ht e n t o 130 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Front Lo w e r Arm4-Door Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
4. Tig ht e n t o 124 Nm. 5. Tig ht e n t o 124 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Front Lo w e r ArmWago n Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
5. D et a ch t he f ront l o we r arm . 6. Remove t he f r ont l o we r arm . Insta llat ion All v e h icle s • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l e o n i t s whe e l s .
3. Loos e l y i nst a l l t he f ue l t a nk prot e ct i on br a ck et re ta ini ng bo l t . 4. Usi ng a s ui t a bl e t o r x ada p t o r , 10 mm combi na t i on sp a nne r and 3 /8 dr i ve t orque wr ench, i ns t a l l t he f ue l t a nk pr ot e ct i on br a cket r e t a i ni ng bo l t .
6. Usi ng a s ui t a bl e t o r x ada p t o r , 10 mm combi na t i on sp a nne r and 3 /8 dr i ve t orque wr ench, i ns t a l l t he f ue l t a nk pr ot e ct i on br a cket r e t a i ni ng bo l t .
10. Ti g ht e n t o 115 N m. 11. Ti g ht e n t o 115 N m. JagDocs.com.
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Lo we r Arm Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
1. Ins t a l l the rear l o we r arm . 2. Att a ch t he rear l o we r arm . 3. Att a ch t he s t ab i l i ze r ba r l i nk . 4. Ins t a l l the rear whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
6. Tig ht e n t o 124 Nm. 7. Tig ht e n t o 35 Nm. 8. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n).
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Spring Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
7. Remove t he s p r i ng. Re mov e t he i s ol a t o r. Insta llat ion • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l e o n i t s whe e l s . 1. Ins t a l l the s p r i ng.
5. Tig ht e n t o 124 Nm. 6. Tig ht e n t o 124 Nm. 7. Tig ht e n t o 35 Nm. 8. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n).
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Stabiliz er Bar Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng .
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Stabiliz er Bar L ink Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng .
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Upper Arm Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
4. Tig ht e n t o 124 Nm. 5. Tig ht e n t o 124 Nm. 6. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n).
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel H ub Re moval a n d I ns t a l l a t i on Speci al T ool (s) Pul l e r , W h e el hub remover 205-49 1 For c i n g Sc r ew, W he e l hub r emove r 204-26 9 Adap t or Nut s , W he e l hub re mover 205-49 1-01 R em ova l All v e h icle s 1.
4. Usi ng t he s pe cia l t oo l s, re move t he whee l hub. Vehi c le s with 2.0L engi n e 5. CAU TI O N : Fai l ure t o fo l l o w t hi s procedu r e may r es ul t i n da mag e t o th e ant i -l ock b r a ke s yst e m (ABS) compon e nt s . Di s conn ect t he a nt i -l ock brak e s ys t e m (ABS ) s e ns or e l ect r i cal conne ct o r.
1. Ins t a l l the whe e l hub. Ti ght e n t o 63 Nm. Vehi c le s with 2.5L or 3.0L engine 2. Ins t a l l a ne w rea r hal f s haf t r e t a in in g nut . Ti ght e n t o 270 Nm. Vehi c le s with 2.0L engi n e 3. Ins t a l l the (AB S ) se ns o r . Ti ght e n t o 7 Nm.
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l hub. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l H ub (204-02, Re mova l a nd I nst a l l at io n).
6. D et a ch t he da mpe r. 7. D et a ch t he uppe r a r m. 8. D et a ch t he f ront l o we r arm . 9. CAU TI O N : Make s ur e t h at exces s i ve s t r ai n i s not pl a ced o n t he lo we r a r m. Us i ng a s ui t a b l e t rans mis s io n j ack, s uppo r t the rear l o we r arm .
11. Remove t he whe e l k nuckle . Det a ch t he r ea r l o we r ar m. 12. CAUT I O N: Ma k e s ure co r r ect po s i t i o n o f t he mount i ng b r ack e t i s not e d b e fo re r emoval .
3. Att a ch t he whe e l knuck le mount i ng b rack e t. 4. Ins t a l l the f r ont l o we r a rm . 5. Att a ch t he upp e r arm . 6. Att a ch t he da mpe r .
8. Att a ch t he pa r ki ng b r ake ca bl e a nd condui t . 9. Att a ch t he ABS whe e l s p ee d s e ns or wi ring ha r ne s s. 10. Ins t a l l a n ew AB S whe e l s pe e d s e ns o r wi r i ng ha r nes s r et ai ni ng s t r ap . 11. Ins t a l l t he whe e l hub.
13. Ti g ht e n t o 124 N m. 14. Ti g ht e n t o 124 N m. 15. Ti g ht e n t o 115 N m. No t e : I f y ou a re re-us i ng t hi s f ixi ng o n a ve hi cl e bu i l t p r i o r t o VI N J29472, t he n t i gh te n t o 130 N m.
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e F ro nt B ush ing Re moval a n d I ns t a l l a t i on Speci al T ool (s) S upp o r t Cup , Re a r whe e l knuck le front b us h 204-30 0 Remove r , Rea r whe e l knuck l e f r o nt b us h 204-30 1 Ins t a l l e r , Re a r whe e l knuck l e f r ont b ush 204-30 2 R em ova l 1.
P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e Rear Bus hing Re moval a n d I ns t a l l a t i on Speci al T ool (s) For cing S cr e w, Re a r W he e l Knuckle Re a r Bus h 204-246 S u.
4. D et a ch t he r e a r l o we r a r m. 5. CAU TI O N : Ca r ef ul l y l o wer t he t r a ns mis s i o n j a c k. Us i ng t he s p e ci a l t o ol s , r emove t he whe e l knuck le rear bus hi ng.
3. Att a ch t he s t ab i l i ze r ba r l i nk . 4. Ins t a l l the rear whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 5. Tig ht e n t o 124 Nm.
P ubl i s he d: 11-May-2 011 Wheels and Ti res - T i re Pres s ur es Whe e l Si ze T i re Si z e T i re Manu f acturer R i m Eng i ne C om for t N orm al Front R e a r F ront Re a r 16" 205/55 R16 91 V Pi r e l li P 6000 6.5Jx 16 2.0L 2. 07 ba r (30 l b f/i n² ) 2.
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Safety P recautio ns Des cr ipt i o n a nd O pe r a t i o n • W ARNINGS : Do not mix d i f fe re nt t ype s of t i r e s o n t he s a me ve hi cl e s uch a s radi a l , b i a s or bi a s bel t e d t i re s e xc ep t i n e mer ge nci e s (t e mpor a ry s p are us a ge ).
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel s and T ires Des cr ipt i o n a nd O pe r a t i o n It e m Par t N um be r Descri pti on 1 — L ocki ng wh ee l nut a nd wrench s o cket Locking.
Item Part Nu mber D escri pt i on 1 - T i re va l ve a nd pr e s s ur e s e ns or 2 - T i re f it t i ng/r e mova l t o o l in i t i al s t art po s i t i o n 3 - H i gh t i r e a nd b e a d t e nsi o.
Tir e Pressur e Monit oring Syste m The TP MS i s a dr i ver as s i s t a nce s yst e m whi ch a s s i s t s t he dr i ver t o mai n ta i n th e t i re pres s ur es a t t he o p t i mum l e vel . The TPM S i s a s t a nda r d fi tme nt o n NA S vehi cl e s a nd a n o pt i o nal f i t ment i n o t her ma r ke t s .
The i ni t i at o r i s a p a ss i ve LF t rans mi t t e r . I t t rans mi t s s i gna l s whi ch are recei ve d b y t he t ire pr e s s ur e s e n s ors p r o mpt i ng t he m t o mo di fy th e i r m o de s t at us . The TP MS modul e e ne rg i z es ea ch i ni t i a to r i n t ur n us i ng LF drive r s .
I f a T P MS fa ul t wa r nin g me s s a ge is d et e cte d b y t he i ns t r um e nt cl us t e r a t i gni t i o n on , t he wa r ni ng i ndi ca t o r wi l l f l a s h fo r 72 s e conds a f t e r t he 3 s e cond bul b c he ck pe r i od a nd t he n remai n pe rm a nent l y i l l umina t e d.
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel s and T ires Dia gn os i s a nd Te s t i ng G ene r al note s Fa c t o r y i ns t a l l e d t i r es a nd whe e l s are de s i gne d t o o pera te sa t i s fa ct or y whe n i nfl a t e d t o th e r ecommende d i nfl a t i on pr es s ures ; refe r t o t he S peci fi ca t i o ns s ub-s ect i on .
* * * * * * * * * * * * * * * * * * * * Mechani cal Bul ge s (b li s t e r ) P ly s e pa r a t io n Embed ded o bj e ct s I m pa ct d a m a ge I nc o r r ect s pe e d rat i ng I nc o r r ect l o a d r at ing I nc o r r ect r ot at i on a l di rect i on 3.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * Exces s ive l a t e ral o r radi a l runout of whe e l o r t i r e Che ck , r epa i r or i nst a l l a n e w a s nece s s a ry . Ref e r t o t he pr oce dure in t hi s s ect i on .
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Lo w Pre ssu re Senso rV IN Range: J28 493- >V99999 Re moval a n d I ns t a l l a t i on R em ova l • NO T E: I t i s s t r ong l y r e com .
2. CAU TI O N : Make s ur e s o l ve nt s or cl e a ni ng a ge nt s of a ny t ype a r e not use d t o cl e a n t he t ire l o w pr e s s ure s e ns o r. Fa i l ur e t o fo l l ow t his in s t ruc t i o n may r es ul t i n da mag e t o t he ti r e l ow pres s ur e s e ns o r .
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Fro nt AntennaVI N Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Main AntennaVIN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1.
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 5 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Mo duleV IN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1.
6. Repo s i t i on t he t i re p r es s ur e moni t o r i ng s yst e m modul e . Re mov e t he re ta i ni ng nut s . 7. Remove t he t i re pr e s s ur e moni t o ring s ys te m modul e . Dis conne ct t he e xt ernal ant e nna conne ct o r . Insta llat ion 1.
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Rear AntennaVIN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel and T ire Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : Do no t us e hea t t o l o os e n a s e i ze d whe e l nut , e x ce s s i ve he at ma y caus e da ma ge t o t he whe el a nd t he whe e l be a r i ngs .
P ubl i s he d: 11-May-2 011 Driveline System - G eneral In fo rm ation - Driv eline System Des cr ipt i o n a nd O pe r a t i o n The dr i vel in e t r ans fe rs e ngi ne t orque t o t he drive whe e l s .
P ubl i s he d: 11-May-2 011 Driveline System - G eneral In fo rm ation - Driv eline System Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on Ce r t a i n drive l i ne condi t i o ns a r.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 2 No i s e i s a t co ns t a nt t o ne ove r a na r r ow vehi cl e s p e ed r ange . Us ual l y he a r d o n l i g ht dr ivi ng a nd coa s ti ng condi ti o ns Re a r d r i v e di f f e r ent i a l .
P ubl i s he d: 11-May-2 011 Driveshaft - T o rque Sp eci f i cat ions Descri pti on Nm l b-ft l b-i n Dr ive s ha f t cent er be a r i ng r et a i ni ng bol t s 25 18 - Dr ive s ha f t front uni versa l j oi nt r e t ai n in g b ol t s 44 32 - Dr ive s ha f t r ea r uni ver s a l j o int r et a i ni ng b ol t s 44 32 - JagDocs.
P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Des cr ipt i o n a nd O pe r a t i o n I te m Pa rt N um be r De sc ri pti on 1 — Li nk was he r 2 — Dr ive s ha f t uni versa l j o i nt ret .
P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 205-00 Dr i ve l i ne S yst e m - Gene ral I nfo rm at i on .
P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Runo ut and B alanc ing Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t o t he a pproved Ja guar di agno s t i c s yst e m.
P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Re moval o f t he dr i v e s ha f t rear uni versa l j oi nt s hown, removal o f t he dr ive s ha f t front uni vers al j o i nt s i mil a r.
7. CAU TI O N : Make s ur e t h e front a nd r e a r d r i ves ha ft s e cti o ns a re s uppo r t e d . Re move t h e dr i ves ha ft . Re mov e dr ive s haf t ce nt e r bea ring ret a i ni ng bo l t s. Insta llat ion 1. CAU TI O N : Make s ur e t h e front a nd r e a r d r i ves ha ft s e cti o ns a re s uppo r t e d .
P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Gen eral S p ec if ic a t ions I te m Speci fi ca ti on Oi l t ype M2C1 92A synt he t i c Oi l cap a c i t y 1.
P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Re ar Drive A xle a nd Differential Des cr ipt i o n a nd O pe r a t i o n I te m Pa rt Nu mber De sc ri pti on 1 — Vi br at i o n d a.
P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Re ar Drive A xle a nd Differential Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n .
P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Ax le Shaf t Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Re mover , Axl e S ha f t O i l S e a l 308-208 I nst a l l er, O i l S e a l 204-264 R em ova l 1. Remove t he rear hal fs haf t .
P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - D rive Pinio n Flange I n-v e hi c l e Re pa i r Speci al T ool (s) To r que T o T ur n Ro t a r y T ool 205-518 W r e nch, Fl a ng e 20.
4. Remove t he vibrat i on d amper ret a i ni ng b o l t . 5. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e f r ont r e t a i ni ng bol t s . Re mov e t he vi br at i o n da m pe r br acket . 6. Remove t he a xle a s s e mbly r ea r r et ai ni ng bo l t .
10. Us i ng t he s pe ci a l t o o l , i ns t a l l a brea ker ba r a nd r e move a nd di sca r d t he dr i ve p i ni on f l a nge ret a i ni ng n ut . 11. NO TE: Mark t he pi ni o n f l a ng e i n r e l a t i on t o t he drive pi ni o n s t e m t o e ns ure corr e ct a l i gnment dur i ng i ns t al l a t i on.
3. CAU TI O N : Do no t unde r any ci rc ums t a nce, l o o s e n t he p i ni on nut t o r e duce p r el o a d, if prel o a d i s excee de d i nst a l l a ne w col l a p s i b le s pa cer an d pi ni o n nut . Us i ng t he s p e ci a l t o ol , h ol d t he p i nio n f l a nge whi l e t i ght e ni ng t he d r i ve pi ni on r et a i ni ng nut .
9. Tig ht e n t he a xle a s s e mbly f r on t ret a i ni ng bo l t s t o 90 N m. 10. Ti g ht e n t he a xl e a s s embl y rear r e t a i nin g b o lt t o 110 Nm a nd t he n s l o wl y ti gh te n t o 135 N m . 11. Ins t a l l t he vibrat i on d amper.
P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - D rive Pinio n Seal I n-v e hi c l e Re pa i r Speci al T ool (s) To r que T o T ur n Ro t a r y T ool 205-518 W r e nch, Fl a ng e 205-.
4. Remove t he vibrat i on d amper ret a i ni ng b o l t . 5. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e f r ont r e t a i ni ng bol t s . Re mov e t he vi br at i o n da m pe r br acket . 6. Remove t he a xle a s s e mbly r ea r r et ai ni ng bo l t .
10. Us i ng t he s pe ci a l t o o l , i ns t a l l a brea ker ba r a nd r e move a nd di sca r d t he dr i ve p i ni on f l a nge ret a i ni ng n ut . 11. NO TE: Mark t he pi ni o n f l a ng e i n r e l a t i on t o t he drive pi ni o n s t e m t o e ns ure corr e ct a l i gnment dur i ng i ns t al l a t i on.
3. CAU TI O N : Do no t unde r any ci rc ums t a nce, l o o s e n t he p i ni on nut t o r e duce p r el o a d, if prel o a d i s excee de d i nst a l l a ne w col l a p s i b le s pa cer an d pi ni o n nut . Us i ng t he s p e ci a l t o ol , h ol d t he p i nio n f l a nge whi l e t i ght e ni ng t he d r i ve pi ni on r et a i ni ng nut .
9. Tig ht e n t he a xle a s s e mbly f r on t ret a i ni ng bo l t s t o 90 N m. 10. Ti g ht e n t he a xl e a s s embl y rear r e t a i nin g b o lt t o 110 Nm a nd t he n s l o wl y ti gh te n t o 135 N m . 11. Ins t a l l t he vibrat i on d amper.
P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Ax le Ass embly Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l e ft -hand rear hal f s haf t. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Hal fs ha ft (205-05 Re a r Dr i v e Ha l f s ha f t s , Re moval a nd I ns t a l l a t i o n).
6. Remove t he vibrat i on d amper. 7. Remove t he vibrat i on d amper bracket r et a i ni ng bo l t . 8. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e a s s embl y f r ont r et a i ni ng bo l t s . Re mov e t he vi br at i o n da m pe r br acket .
Insta llat ion 1. NOT E: S uppo r t t he a xl e a s s embl y. • NO T E: W he n i nst a l l in g t he ha lf s ha ft ma k e s ure t he s pring cl i p i s ful l y e ngag e d i n t he di ff e r e nt i a l . I nst a l l t he a xl e a s s e mbl y. 1. I ns t a l l t he a x l e a s s e mbl y.
6. Tig ht e n t o 150 Nm. 7. CAU TI O N : S lo wl y t i ght e n t he a x l e ret a i ni ng b ol t to f i nal t or que . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . Ti ght e n t o 150 Nm. I f you are refi t t ing a n ol d fi xing (be f o r e V IN J24258), t i g ht e n t o 135 N m.
11. At t ach t he d rives ha f t r e a r uni ver s al j o int . 1. I ns t a l l a ne w ga s ke t . 2. I ns t a l l ne w drive s ha ft r et a i ni ng bo l t l in k was he r s . 3. I ns t a l l ne w drive s ha ft r et a i ni ng bo l t s . 1. Tight en t o 4 0 Nm .
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n W he e l hub nut 270 200 - Ti e r o d e n d ret a i ni ng nut 35 26 - Lo we r arm.
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Drive Halfsh afts Des cr ipt i o n a nd O pe r a t i o n Front Drive Half sha f ts I te m P ar t N u m ber Descri pti on 1 — O ut e r co.
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Drive Halfsh afts Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n .
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft LH Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j oi nt s pl i t te r 204-192 W he e l hub pu ll e r 205-491 .
2. Remove t he f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 3. Remove t he t i e r o d e nd ret a i ni ng nut . 4. Usi ng t he s pe cia l t oo l de t a ch t h e t i e rod e nd.
7. Loos e n t he s ubf r a me front mount ret a i ni ng b ol t. 8. Remove and di s card t he whee l hub n ut . 9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m .
13. Us i ng t he s pe ci a l t o o l s , re m o v e t he hal fs ha ft . 14. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o pr ot ect t he b a r s ha ft . Re move t h e ha l fs ha ft s na p ring. Insta llat ion All v e h icle s 1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft .
3. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l t he lo we r ar m ba l l j o i n t r e t a i ni ng bo l t . Ti ght e n t o 83 Nm. 4. Tig ht e n t he f r ont s ubf r a m e front mount ret a i ni ng b ol t .
8. Ins t a l l the t ie r od e nd. Ti ght e n t o 35 Nm. 9. Loos e l y i nst a l l a ne w whee l hub nut . 10. Ins t a l l t he f r ont r oa d w hee l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft RH2. 0L NA V6 - A JV6 /2. 5L N A V 6 - A JV 6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba .
All v e h icle s 1. Loos e n t he whee l hub n ut. 2. Remove t he f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 3. Remove t he t i e r o d -end ret a i ni ng n ut .
6. Loos e n t he s ubf r a me r ea r m ou nt bol t . 7. Loos e n t he s ubf r a me front mount bo l t . 8. Remove and di s card t he whee l hub n ut . 9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t .
Vehi c le s with 2.5L or 3.0L engine 11. Remove t he e xhaus t muff l e r i nl e t pi p e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Muff l e r Inl e t Pi p e - 2.0L N A V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ27 (309- 00 Exhaus t S y s t e m, Re moval a n d I ns t a l l a t i o n).
16. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o pr ot ect t he b a r s ha ft . Re move a nd di s ca r d t he ha l f s ha f t s nap r in g. Insta llat ion All v e h icle s 1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. Ins t a l l a ne w ha lf sha f t se a l .
4. Remove t he s p e cia l to o l . 1. Re move t he t rans f e r cas e Y brack e t ret a i ni ng bo l t. 2. Re move t he s pe cia l t oo l . 5. CAU TI O N : Make s ur e t h e CV j o i nt s pl i ne s a re l o ca t e d f ul l y . Do not use e x ce s s i v e fo rc e wh en e nga gi ng t he CV jo i nt i nt o t he l i nk s haf t .
9. Tig ht e n t he s ubf r ame front mount r e t a i nin g b o lt . Ti ght e n t o 142 Nm. 10. Ins t a l l t he s ub frame r ei nfo r cemen t pl a t e r et a i ni ng bol t s . Ti ght e n t o 35 Nm. 11. Ti g ht e n t o 142 N m. 12. Ins t a l l t he t i e -r od e nd .
14. Ins t a l l t he f r ont r oa d w hee l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 15. Ti g ht e n t he wh e e l hub nut . Ti ght e n t o 270 Nm.
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft RH2. 0L Duratorq-TDCi / 2.2L Durato rq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j oi nt s pl i t te r 204-192 W he e l hub pu ll e r 205-491 Ada pt e r nut s 205-491- 01 For cing s cr e w 204-269 R em ova l 1.
4. Usi ng t he s pe cia l t oo l , de t a ch th e t i e -r od end. 5. Remove t he s ub frame rei nfo rc emen t pl a t e ret a i ni ng bol t s . 6. Loos e n t he s ubf r a me r ea r m ou nt bol t . 7. Loos e n t he s ubf r a me front mount bo l t . 8. Remove and di s card t he whee l hub n ut .
9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e . 10. Us i ng t he s pe ci a l t o o l s , d e t ach t he h a lf sha f t.
1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. Ins t a l l the ha l f s haf t . Ti ght e n t o 25 Nm. 3. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l t he lo we r ar m ba l l j o i n t r e t a i ni ng bo l t .
6. Tig ht e n t o 142 Nm. 7. Ins t a l l the t ie -r o d e nd . Ti ght e n t o 35 Nm. 8. Loos e l y i nst a l l a ne w whee l hub nut . 9. Ins t a l l the f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Inner C on stant Velo city (CV ) J o in t Bo o t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont ha l f s ha f t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o Ha l f s ha f t L H .
7. Remove t he i nne r CV jo i nt b oo t r e t a in ing cl i p. Re mov e a nd di s c a r d t he r et a i ni ng cli p. 8. Remove t he i nne r CV jo i nt b oo t . Insta llat ion 1. Ins t a l l the i nner CV j oi nt b o ot . 2. NOT E: Ins t a l l a new r e t a i ni ng cl ip .
3. CAU TI O N : Do no t da mage t he r o l l e r be a rings . I nst a l l t he t ripo d s t a r . 4. Ins t a l l the t r i p od s t a r circ l i p. 5. NOT E: Ins t a l l ne w grea s e . I nst a l l t he t ripo d s t a r hous ing . 6. NOT E: Make s ure e noug h a i r i s pres e n t in t he CV boo t .
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Intermediate Sh aft Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he right -ha nd ha l fs ha ft . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Ha l fs ha ft RH i n t hi s s e cti o n.
2. CAU TI O N : Be f o r e i ns t a l l i ng t he be a r i n g carr i e r r e t ai n in g b ol t s m a ke s ur e t ha t t he be a r i ng ca r r ie r i s l o cat e d i n t he s a me po s i t i o n t ha t i t wa s r e moved f r om, f ai l ur e t o f ol l ow th i s p r o ced ure wi l l r e s ul t i n d a mage to th e v e hi cl e .
P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Outer C on stant V elo c ity (CV ) J o int B oo t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont ha l f s ha f t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o Ha l f s ha f t L H .
1. Ins t a l l the o ut er CV jo i nt b oo t . 2. CAU TI O N : Do no t da mage t he bea ring ret a i ne r . • NO T E: T he o ut e r CV j o in t is r e t a i ne d t o t he s ha ft by a s pr ing cl i p. I nst a l l t he o ut e r CV j o i nt . 3. Att a ch t he o ut e r CV jo i nt bo o t .
P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Item S pe ci fi ca ti on Cons t a nt vel o c i t y (CV) gr e a s e Ol i s t amol y L N 584 .
P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Driv e Hal fshafts Des cr ipt i o n a nd O pe r a t i o n Rea r Drive Half sh a fts I te m P ar t N u m ber Descri pti on 1 — O ut e r con.
P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Driv e Hal fshafts Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n .
P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Halfsh aft Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover , Axl e S ha f t O i l S e a l 308-208 I nst a l l er, O i l S e a l 204-264 R em ova l 1. Remove t he whe e l knuck le .
2. NOT E: W he n i ns t a l l i ng t he ha l fs haf t make s ur e t he s p r i ng cli p i s f ul l y e ngag e d i n t he di ff e r e nt i a l . I nst a l l t he ha l f s ha f t .
P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Ou ter Co nst ant Vel oci ty (CV ) J oi nt Bo ot Re moval a n d I ns t a l l a t i on R em ova l • NO T E: O ut er Cons t a nt Ve l o ci t y (C V) Jo i nt B oo t s hown, i nner Co nst a nt V e l o c i t y (CV) Jo in t Bo o t si mil a r .
1. Ins t a l l the o ut er CV jo i nt b oo t . Ins t al l a ne w ret a i ni ng cl i p. Us i ng a s u it a b le t oo l , i ns t a ll the r et ai ni ng cli p. 2. Ins t a l l the ne w r e t a i n in g cl i p. Ins t al l a ne w ret a i ni ng cl i p. Us i ng a s u it a b le t oo l , i ns t a ll the r et ai ni ng cli p.
P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e .
P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: B r ake fl ui d con ta i ns p ol ygl yc o l e t he rs a nd pol ygl yc ol s. Avoi d cont a ct wi t h t he e yes . W a s h hand s t hor ou ghl y a ft e r handl i ng.
* * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System Dia gn os i s a nd Te s t i ng P r i nci pl e s o f O pe r at i o ns The br ake s yst e m op e rat e s by t r ans fe rr i ng ef f ort a ppl i e d t o t he b r a ke p e da l , by t he dr i ver, t o t he brakes a t e a ch wh e e l .
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 1 1 1 The br ake s pul l o r dr i ft T i re p r e s s ur es /wea r . Ca li pe rs. Br ake p a ds . Br ake d i s cs . W he e l a l i gnme nt a dj us t me nt .
1 1 1 1 1 1 1 1 Is a vib r a t i o n p res e nt ? Ye s CHECK t he br ake cal i pe r mount i ng b ol t s and whee l hub nu ts and TI GHTEN a s ne ces s a r y. CHECK t h e ba l a nce of a l l r oa d whee l s a nd REP AIR a s ne ce s s a ry . CHECK t he b r a ke d i scs f o r exces s i ve we ar, r unout , t h i ckn e s s va r i a t i on or cr ack s .
1 1 1 2 3 4 5 6 1 1 1 1 I s t he a l i gnment wi t hi n s peci f i ca t i o n? Ye s Ve hi cl e i s O K. No Adj us t t h e a l i gnment a s ne ce s s a r y. Fo r a ddi t i o nal i nfo r m at i o n, r ef e r t o REFER t o : U nde rb od y Mi s al i gnme nt Che ck (502-00 Uni -Bod y , S ubframe a nd Mount in g Sy st e m, Ge ne r a l P r o ce dures ).
1 1 1 1 1 1 2 3 4 1 2 3 4 1 Check f o r e xt e r nal b r ake s yst e m l e a ks. For add i t i ona l i nf o r m a t i o n, r e f er t o Ma s t er Cyl i nd er i n t hi s s e ct i on. Ar e l e a k s fo un d? Ye s REPAI R a s ne ce ss a r y, ADD fl ui d a n d B LEED b r ake s yst e m.
1 1 1 1 1 1 1 2 1 1 T EST C ONDI T IONS DET AI LS/RE S U LT S/ACT IONS H1 : T EST B R AKE LOC KUP Roa d t e s t t he vehi cl e a nd a ppl y t he br a ke pe d al l ig ht l y.
2 3 4 5 6 1 1 2 3 4 5 1 Appl y t he br ake pe da l l i g ht l y t hr e e o r f o ur t i m e s . W a i t 15 s e con ds fo r t he v a cuum t o repl e ni s h. P ush do wn on th e bra k e ped a l unt i l it s t o ps movi ng downwa r d o r a n i ncr ea s e d res i s t a n c e t o t he brak e p e da l t ravel occur s .
The fo l lo wi ng condi t i on s a r e c o ns i de r e d norm al a nd a r e no t i ndi cat i o ns t ha t t he brak e ma s t e r c yl i nde r i s i n ne ed o f r e pa i r . Ne w b rak e s ys t e ms a r e d e s ig ne d t o pr od uce a p e da l e f fo rt t ha t i s not a s hard a s i n t he pa s t .
P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake Dis c Runo ut C heck Gene ral P r ocedures C heck 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System B leeding Gene ral P r ocedures W ARNI N G: B r ake Fl ui d cont ai ns po l ygl yc ol e t he r s a nd p o l yglycol s . Avoi d c ont a ct wi t h t he e ye s . W a s h ha nds tho r ou ghl y a f t e r han dl i ng.
br ake ci rcu i t s . 6. F i l l up t h e mas t e r cy li nde r r es e r voi r t o t he MAX mar k . 7. Ins t a l l the mas t e r cy li nde r r es e rv oi r cap.
P ubl i s he d: 11-May-2 011 Front Dis c B rake - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e .
P ubl i s he d: 11-May-2 011 Front Dis c B rake - Front Dis c B rake Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um be r Descri pti on 1 — B r a k e hos e 2 — B r a k e cal ip e r r e t .
P ubl i s he d: 11-May-2 011 Front Dis c B rake - Front Dis c B rake Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 206-00 Br ake Sy s t e m - Gene r a l I nfo r mat i on .
P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake C al iper Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Sect i on 204-04 W hee l s a nd T ire s .
1. CA UT I O NS: I f t he pi s t o ns a r e pus he d b a c k i nt o t he ho us i ng , br a ke f l ui d wi l l be fo rc e d o ut o f t he i nl e t po rt of t he b rak e ca l i p er. Make s ur e t ha t the br a k e di s c fa ce s a r e c l e a n be f o r e i ns t a l l a t i o n.
P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake Di sc Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he brake pa ds , r ef e r t o t he p r oce dur e i n t hi s s e c t i o n : P a ds . 2. Remove and di s card t he br a ke cal i p e r a n c hor pl a t e r e t a in in g b ol t s .
P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake Pads Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Sect i on 204-04 W hee l s a nd T ire s . 2. Pi vot t he brake cal i pe r upwa r ds .
3. Pi vot t he brake cal i pe r downwa rds . 4. Ins t a l l a ne w b r ake ca l i per l o we r r et a i ni ng bo l t . Ti ght e n t o 30 Nm. 5. Ins t a l l the whe e l . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o Sect io n 204-04 W he e l s a nd Ti r es .
P ubl i s he d: 11-May-2 011 Rear Disc Brake - Lubr i cant s, Flu ids , sea l e rs and Ad hesi ves CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e .
P ubl i s he d: 11-May-2 011 Rear Disc Brake - R ear Disc Brak e Des cr ipt i o n a nd O pe r a t i o n Item Pa rt Nu mb e r Descri pti on 1 — Pa r k in g brake cabl e 2 — Hub ca r rie r 3 — Br .
P ubl i s he d: 11-May-2 011 Rear Disc Brake - R ear Disc Brak e Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 206-00 Br ake Sy s t e m - Gene r a l I nfo r mat i on .
P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Cali per Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 Brak e ca l i per pi st o n re t r act o r t oo l 206-080 Cr anks haf t pul l e y/dampe r r emover 303-588 R em ova l 1.
4. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: T o pr e vent the l os s o f brak e fl ui d, a ppl y t he b r ake p e dal ho l d dow n t o o l a nd a dj us t to h ol d t he b r ake pe da l d own 40m m.
3. NOT E: Ins t a l l ne w brake ho s e s e a l i ng wa s hers . At t a ch t he b r a ke h os e. Ti ght e n t o 38 Nm. 4. Remove t he brake pe da l hol d do wn t o o l .
P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Disc Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he brake pa ds . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P a ds (206-04 Re a r Di s c Br ake , Re moval a n d I ns t a l l a t i o n).
P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Disc S hield Re moval a n d I ns t a l l a t i on 1. Remove t he rear whe e l hub. Fo r add i t i o nal i nf or ma ti on, re fe r to S ect i o n 204-02 Rea r S usp e ns io n .
P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake P ads Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e ca l i per pi st o n re t r act o r t oo l 206-080 Cr anks haf t pul l e y/dampe r r emover 303-588 R em ova l 1. Remove t he whe e l a nd t i r e .
5. Remove t he brake pa ds . Insta llat ion 1. CAU TI O N : If t he pi s t o n i s pus he d ba ck i nt o th e ho us i ng, b r a ke fl ui d wi l l be f o r ced ba ck i nt o t he f lui d r es e r voir.
4. Att a ch t he pa r ki ng b r ake ca bl e ret a i ni ng cl i p. 5. Att a ch t he pa r ki ng b r ake ca bl e . 1. Re l e a s e t he t e ns i o n. 2. At t a ch t he p ark in g b rak e ca bl e .
P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - T o rque Sp eci f i cat ions Descri pti o n Nm l b-f t l b- i n P a r ki ng br ake cont r ol ret a i ni ng nut s 20 15 - JagDocs.
P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake Des cr ipt i o n a nd O pe r a t i o n It e m Pa r t Nu m be r D escri pti on 1 — Fr ont ca bl e 2 — Re a r cabl e 3 .
* * * * * * 1 1 1 1 1 P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m t o dupl i cat e t he co ndi t i on.
1 1 Dis conne ct t he p a rk i ng br ake f r o nt cabl e f r o m t he rea r br ake cab l e a nd condui t a t t h e e q ual iz e r . Rot a t e t he w hee ls b y hand. Did t he rear whe e l s r ot a t e O K? Ye s INS TA LL a ne w front p a r k i ng b r a ke cabl e .
P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C a bleVehic les W ith: Manuall y Adju sted Par kin g Brake Re moval a n d I ns t a l l a t i on Speci al T ool (s) P a r ki ng b r ake cab l e a dj us t e r s ocket . 206-087 R em ova l 1.
6. Remove t he rear pa rk i ng br ake ca b le ret a i ni ng cli p. 7. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 8. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 9. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it .
P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C a bleVehic les W ith: Self-A dj us ting Par kin g Brake Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear r oa d whe e l a nd t i re. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i on 204-04 W he e l s an d T i res .
7. D et a ch t he pa rk in g b r ake ca bl e a nd co nd ui t . 8. D et a ch t he r e a r p ark ing b r ake cabl e . 9. Remove t he pa r ki ng b r ake rear ca bl e a n d co ndui t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C ontro lV ehicles With: Manuall y A dj usted Par kin g Brake Re moval a n d I ns t a l l a t i on Speci al T ool (s) P a r ki ng b r ake cab l e a dj us t e r s ocket . 206-087 R em ova l All v e h icle s 1.
7. NOT E: 2.5L o r 3.0L s ho wn, 2. 0L s imi l a r . Det ach t he rear pa rk i ng br ake cabl e s . Vehi c le s with 2.5L or 3.0L engine 8. Remove t he drive sha f t. Fo r a ddi t i ona l i nf o r m at i o n ref e r t o Sect i o n 205-01 Dr i ve s haf t .
P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C ontro lV ehicles With: Self-Ad j us ting Par kin g Brake Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1.
9. Remove t he e xhaus t re ar hea t s hi e l d. 10. Remove t he p a r k i ng b r a ke cont r ol ret a i ni ng nut s . 11. Lowe r t he vehi c l e . 12. Det a ch t he pa r k i ng br a ke cont rol . 1. De ta ch t he pa r king br ake c a bl e g r o mmet .
1. To i ns t a l l , rever s e t he remov a l procee d ur e. Ti ght e n t o 20 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e .
P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Hy draulic B rake A ctua tio n Des cr ipt i o n a nd O pe r a t i o n I te m Pa r t Nu m be r De scr i pti on 1 — Br a ke mas t e r cyli n.
P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Hy draulic B rake A ctua tio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 6-00 Br a ke S yst e m - Ge neral I nf orm at i on .
P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Fluid Reservoir Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r.
5. NOT E: Re m o ve a nd d i sca r d t he O -r ing s e a l s f r om t he br ake mas t e r c yl i nde r . Re move t h e br a ke f l ui d r e s e r vo i r. 1. Re l e a s e o ne le g of t h e res e rv oi r from t he r et a i ni ng pi n. 2. Re move t he b r a ke f l uid res ervoir.
4. F i l l t he b r a ke f lu id r es e r voi r. 5. Ble e d t he br ake s y s t e m. For a ddi t i o na l i nf orm at i o n, r ef e r t o Sect i on 206-00 Br ake S y s t e m - Ge ne r al I nf o r mat i on . 6. Ins t a l l the brake f l ui d res e r voi r fi l l e r cap.
P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Master C y l inder Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r.
5. D et a ch t he cl ut ch mas t er cyli nde r f ee d hos e . All v e h icle s 6. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. Re move t he coo l a nt e xpans i o n t a nk ret a i ni ng b ol t . 2. Tur n t he co o l a nt e xpans i o n t a nk count e r clo ckwis e .
9. NOT E: Re m o ve a nd d i sca r d t he O -r ing s e a l at t he re ar of t he br a ke m a s t e r cy l i nde r . Re move t h e br a ke mas t er cyli nde r a nd res e rv o i r . 1. Re move t he b r a ke ma s t e r cyli nde r r et a i ni ng nut s . 2.
4. Att a ch t he coo l a nt e x pa ns i o n t a nk. 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. Tur n t he co o l a nt e xpans i o n t a nk cl ockwi se . 3. I ns t a l l t he c oo l a nt e xpans i o n t a nk ret a i ni ng bol t . Vehi c le s with ma nual tra nsmission 5.
8. F i l l t he b r a ke f lu id r es e r voi r. 9. Ble e d t he br ake s y s t e m. For a ddi t i o na l i nf orm at i o n, r ef e r t o Sect i on 206-00 Br ake S y s t e m - Ge ne r al I nf o r mat i on . 10. Ins t a l l t he brake f l ui d r es e r voir f i l le r cap.
P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Pedal and B racket Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with ma nual tra nsmission 1. W ARNING: Bra k e fl ui d co nt a i ns po l ygl ycol et he r s a nd p o l ygl ycols .
4. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Ins t al l s ui t a bl e bl a nk i ng p lug s . • NO T E: Ri ght -ha n d d r i ve s ho wn, l e f t -ha nd d r i v e s i mil a r .
9. Remove t he s up port p a nel . Le ft-hand dr ive ve hi c le s 10. Po s i t i o n t he f r o nt whe e l s i n a s t r a ig ht a he a d po s i t i o n a nd ce nt r a l i z e t he s te e r i ng wh e e l . Lock i n po s i ti o n a n d remove t he i gni t i on key.
15. Repo s i t i o n t he a nt i -c o ll ap s e bracket . R ight-hand driv e v ehi c le s 16. Remove t he b rak e bo o s t e r pus h r o d r et a i ni ng nut . 17. Remove t he a ccel erat o r pe da l mount bracket . Le ft-hand dr ive ve hi c le s 18. Remove t he b rak e bo o s t e r pus h r o d r et a i ni ng cli p.
19. Remove t he a ccel erat o r pe da l mount bracket . 20. Remove t he b rak e pe da l a nd br a ck et re ta i ni ng nut s . All v e h icle s 21. Remove t he b rak e pe da l a nd br a ck et re ta i ni ng nut s . 22. NO TE: Ri ght -hand d r i ve s ho wn, l e ft -hand drive s i mi l a r.
1. NOT E: Ri g ht -hand drive s h own , l e ft -hand drive s i mil a r. I nst a l l t he b r ake pe dal a nd bracket . Conne ct t he e l e ct r i cal co nnect o r. 2. Ins t a l l the brake pe da l a nd b r ack e t ret a i ni ng n ut s . Ti ght e n t o 25 Nm.
5. Ins t a l l the brake bo o s t e r pus h r od r et ai ni ng cli p. R ight-hand driv e v ehi c le s 6. Ins t a l l the a ccel e r at o r pe da l mount brack e t . Ti ght e n t o 25 Nm. 7. Ins t a l l the brake bo o s t e r pus h r od r et ai ni ng nut .
9. Ins t a l l the a nt i -c ol l a ps e br acket cl e vis pi n ret a in ing cl i p. 1. I ns t a l l t he a nt i -col l a ps e b r acket cle vi s pi n. 2. I ns t a l l t he a nt i -col l a ps e b r acket cle vi s pi n r e t a i nin g cl i p. 10. At t ach t he wi r i ng harnes s .
15. Ins t a l l t he drive r si de i ns t rum e nt pan e l l o we r t r i m pa ne l . R ight-hand driv e v ehi c le s 16. Ins t a l l t he brake p e da l a nd br a ck e t ret a i ni ng nut s . Ti ght e n t o 25 Nm. Vehi c le s with ma nual tra nsmission 17.
19. NO TE: Ve hicl e s wi t h 2.5L o r 3.0L eng i ne o nl y. At t a ch t he e ngi ne wi ring harnes s . Ti ght e n t o 10 Nm. 20. Bl e e d t he hydr aul ic clut ch s ys t em.
P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Pedal C ro ss-Shaft Re moval a n d I ns t a l l a t i on Speci al T ool (s) Dis conne ct t o ol , f ue l l i ne . 310-076 Dis conne ct t o ol , f ue l l i ne . 310-D 005 Dis conne ct t o ol , f ue l l i ne .
5. D et a ch t he wi ring ha r ne s s . 6. D et a ch t he DPF d i ff e r e nt ia l pr es s ur e s e ns o r r et a i ni ng br acket . Re mov e t he re ta i ni ng nut s . 7. D i s conne ct t he DPF di ff e r e nt i al pres s ur e s e ns o r e l e ct rical co nnect or.
10. Dis c o nne ct t he up pe r fue l vap or ho s e from t he e vapo rat i ve e mi s s i o n cani s t e r pur ge va lve . 11. Det a ch t he oxyge n s ens or e l e ct rica l c o nne ct or s . 12. Dis c o nne ct t he e va porat o r s o l e no i d e l ect r i cal conne cto r.
14. Det a ch t he wi ring ha r nes s from t he r e t a i ni n g b r ack e t . 15. Remove t he e va porat i ve e mis s i o n ca ni s t e r pur ge v a l ve r e t ai ni ng br acke t . Vehi c le s with 2.0L engi n e 16. Remove t he i nt a ke mani f o l d.
19. Remove t he A /C refr i g e r ant l i ne r e t a i ni ng cl i p . 20. NO TE: I ns t a ll b l anking pl ugs to t he e xpo s e d po rts . Us i ng t he s p e ci a l t o ol , d i s co nne ct t he A/C r e frige rant l i ne . Re mov e a nd di s c a r d t he O -r ing s e a l s .
23. Dis c o nne ct t he e n gi ne wi r i ng ha r ne ss e l e ct rical co nnect or. 24. Det a ch t he eng i ne wi ring ha r nes s ret a i ni ng cl i p. 25. Det a ch t he eng i ne wi ring ha r nes s e l e ct rica l c on ne ct or . 26. NO TE: T he b ol t r e mai ns ca pt i ve in t he ECM e l e ct rical conne ct or.
All v e h icle s 28. Remove t he b rak e pe da l cr os s -s haf t s uppo r t bra c ket r e t a in ing bol t . 29. Rot a te t he b r a k e pe da l cr os s-s haf t cl o ck wi s e.
33. Remove t he g l ove co mpa r t ment fi nis her t r im. 34. Remove t he g l ove co mpa r t ment . Re mov e t he g l o ve compa r t m e nt ret a i ni ng screws . 35. Remove t he b l owe r mot or t rim. 36. Remove t he ce nt ral j unct i o n bo x (CJB) ret a i ni ng n ut .
38. Repo s i t i o n t he br a ke pe d a l c ross -sh a f t s e cur i ng br acket . 1. Un do b ut do no t r e move t he br a ke pe d a l cross -s ha ft s e cur i ng brack e t r et a i ni ng nut . 2. Re pos i ti on t he br ake ped a l cr o s s -s ha f t s e cur in g b rack et .
43. Det a ch t he br a k e l i ne s . 44. Remove t he A /C refr i g e r ant l i ne. Re mov e t he re ta i ni ng cl i p. 45. Remove t he A /C refr i g e r ant l i ne. 46. NO TE: No t e t he po s i t i o n o f th e brake ped a l cr o s s-s haf t s pr i ng.
47. Det a ch t he br a k e pe da l cr os s -s ha ft l ef t -ha nd mount i ng br acket . 48. Det a ch t he br a k e pe da l cr os s -s ha ft g r ommet . 49. NO TE: Re move t he b r ake p e da l cr os s -s ha f t sp ring b us h. Re move t h e br a ke pe d al cross -s ha ft .
2. Att a ch t he brake pe da l cr os s -s haf t gr ommet . 3. Att a ch t he brake pe da l cr os s -s haf t le f t -hand m o unt i ng brack e t . 4. NOT E: Make s ure t he brake pe da l cr os s -s ha ft s pr i ng i s l ocat e d i n i t s or i gi nal po s i t i o n.
7. Att a ch t he brake l i ne s . 8. NOT E: Re m o ve t he bl a nki ng p l ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 9. NOT E: Re m o ve t he bl a nki ng p l ugs . Conn ect t he A/C r ef r i ge rant l i ne .
12. Repo s i t i o n t he br a ke pe d a l c ross -sh a f t s e cur i ng br acket . 1. Ti g ht e n t he brake pe da l cr os s-s haf t s e cur ing bracket r e t a i ni ng nut . 2. Re pos i ti on t he br ake ped a l cr o s s -s ha f t s e cur in g b rack et .
17. Ins t a l l t he gl o ve compa r t ment f i ni s her t rim. 18. Ins t a l l t he gl o ve compa r t ment hi ng e ret a i ni ng s cr ew s. 19. Ins t a l l t he s o und i ns u lt at i o n.
22. Ins t a l l t he brake p e da l cr os s -s haf t s uppo r t b rack e t r e t a i ni ng bol t . Ti ght e n t o 25 Nm. All e x cept ve hicles with die s el engine 23. Conne ct t he E CM el e ct r i cal co nnect or. Us i ng s pe c i a l t o o l 418-5 35, t ig ht e n t o 5 Nm.
26. At t ach t he e ngi ne wi r i ng ha r ne ss e l e ct rical co nnect or. 27. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 28. Conne ct t he e ngi ne wi r i ng ha r ne s s e l e ct rica l co nnect o r . Ti ght e n t o 10 Nm. 29.
30. NO TE: Re move t he b l a nking pl ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 31. Ins t a l l t he A/C ref r i ge r a nt l i ne r et a i ni ng cl i p . 32. NO TE: Re move t he b l a nking pl ugs . Conn ect t he A/C r ef r i ge rant l i ne .
35. Ins t a l l t he e vapo rat i ve e m i s s i on ca ni s t e r pur ge val v e r e t a i ni ng br acke t . Ins t al l t he re t a i ni ng nut s . Ti ght e n t o 5 Nm.
39. At t ach t he o xygen s e ns o r el e ct r i cal co nnect o rs. 40. Conne ct t he up pe r fue l v ap o r hos e to t he e va porat i ve e mis s i o n cani s t e r pur ge va lve .
44. At t ach t he DP F d i f f eren ti al p res s ur e s e ns or r et ai ni ng brack e t . Ins t al l t he re t a i ni ng nut s . Ti ght e n t o 5 Nm. 45. At t ach t he wi r i ng harnes s . 46. CAUT I O N: I ns t a l l t he re t a i ni ng cl i p t o t he o rigi na l po s i ti o n.
P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - T o rque Sp eci f i cat ions Descri pti o n Nm l b- ft l b- i n Brak e b oo s t e r r et a i ni ng nut s 25 18 - Brak e ma s t e r cyli nd er .
P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo oster Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: B r ake fl ui d con ta i ns p ol ygl yc o l e t he rs a nd pol ygl yc ol s. Avoi d cont a ct wi t h e ye s . W a s h ha nds af t e r hand l i ng.
P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - P ower Brake S y stem Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 6-00 Br a ke S yst e m - Ge neral I nf orm at i on .
P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo osterLHD A WD/LHD FWD Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he brake boo s t e r pus h r od r e t ai ni ng cl i p . 1. Re l e a s e t he b r ake b oos t e r pus h rod ret a ini ng cl i p.
5. Remove t he coo l a nt e xpa ns i o n t a nk r e t ai ni ng bo l t . 6. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. De ta ch t he co ol a nt expa ns i on t ank. 2. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . Vehi c le s with 2.
9. D et a ch t he i d l e ai r cont r ol (IAC) val ve wi r i ng harnes s . 10. Det a ch t he t hr ot t l e ca bl e r e t a i ni n g b r ack e t . 11. Dis c o nne ct t he s pe e d cont r ol modul e e l e ct r i cal co nnect o r. 12. Remove t he s pe e d cont r ol modul e ret a i ni ng b o l t .
Vehi c le s with ma nual tra nsmission 14. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Fa i l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .
18. Det a ch t he br a k e boo s t e r v a cuum hos e. 19. Det a ch t he br a k e boo s t e r. Re mov e t he b rak e boo s t e r r et a i ni ng nut s . 20. Remove t he b rak e bo o s t e r s uppo r t br acket . 21. Remove t he b rak e bo o s t e r. Insta llat ion All v e h icle s JagDocs.
1. NOT E: Make s ure t he brake bo os t e r pus h rod i s c orr e ct l y a l i gne d t o t he br ake p e dal . • NO T E: Do no t i ns t al l t he brake boo s t er r e ta i ni ng nut s a t t hi s s t a ge . I nst a l l t he b r ake bo o s t e r . 2. Ins t a l l the brake bo o s t e r s up port b r a cket .
6. NOT E: Ins t a l l a new br ake mas t er cyli nde r t o b r ake bo o s t e r O-r i ng s e a l . • NO T E: Make s ur e t he b r a ke b o o s t e r pus h r od i s cor r ect ly a l i gne d t o t he br ake mas t e r cyli nde r as s e mbl y. At t a ch t he b r a ke ma s t er cyli nde r a s s e mbl y t o t he b r ake b oos t e r .
10. Ins t a l l t he s p e ed c on t r ol m od ul e ret a i ni ng bo l t . Ti ght e n t o 4 Nm. 11. Conne ct t he s pe e d cont r ol modul e el e ct r i cal co nnect o r. 12. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket . 13. At t ach t he I A C va lve wi r i ng harne ss .
15. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 16. At t ach t he co o l a nt e xpans i o n t a nk . 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. At t a ch t he coo l a nt e xpans i o n t a nk. 17. Ins t a l l t he coo l a nt e xpan s i o n t a nk r et ai ni ng bo l t .
19. At t ach t he b rak e f l ui d l ow le vel warnin g i ndi cat o r wi ring ha rn e s s t o t he cool a nt expa n si o n t ank. 20. Conne ct t he b rak e fl ui d l ow le vel wa r ni ng i ndi cat o r e le ctrica l conne ct o r . 21. Ins t a l l t he brake b oo s t e r pus h r od r e t a i nin g cl i p.
P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo osterRHD AWD/ RH D FWD Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e pe da l ho l d do wn t o o l JDS 9013 R em ova l All v e h icle s 1. D i s conne ct t he brake f lui d l o w l e ve l wa r n in g i ndi cat o r e l e ctrica l conne ct or.
4. Remove t he coo l a nt e xpa ns i o n t a nk r e t ai ni ng bo l t . 5. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. De ta ch t he co ol a nt expa ns i on t ank. 2. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . Vehi c le s with 2.
8. D et a ch t he i d l e ai r cont r ol (IAC) val ve wi r i ng harnes s . 9. D et a ch t he t hrot t l e ca b le ret a i ni ng br acket . 10. Dis c o nne ct t he s pe e d cont r ol modul e e l e ct r i cal co nnect o r. 11. Remove t he s pe e d cont r ol modul e ret a i ni ng b o l t .
Vehi c le s with ma nual tra nsmission 13. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Fa i l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .
17. Det a ch t he br a k e boo s t e r v a cuum hos e. 18. Det a ch t he br a k e boo s t e r. Re mov e t he b rak e boo s t e r r et a i ni ng nut s .
22. Remove t he b rak e bo o s t e r pus h r o d pi n. 23. Remove t he b rak e bo o s t e r. Insta llat ion All v e h icle s 1. NOT E: Do not i ns ta l l t he br ake b o os t e r r e t a i ni ng nut s a t t hi s s t a ge . I nst a l l t he b r ake bo o s t e r .
3. Ins t a l l the brake bo o s t e r pus h r od pi n re t a in i ng cl i p. 4. Remove t he brake pe da l hol d do wn t o o l . 5. Ins t a l l the brake bo o s t e r s up port b r a cket . Loo s e l y i ns t a l l t h e br a ke bo o s t e r s uppo r t brack et r et a i ni ng bo l t .
9. NOT E: Ins t a l l a new br ake mas t er cyli nde r t o b r ake bo o s t e r O-r i ng s e a l . • NO T E: Make s ur e t he b r a ke b o o s t e r pus h r od i s cor r ect ly a l i gne d t o t he br ake mas t e r cyli nde r as s e mbl y. At t a ch t he b r a ke ma s t er cyli nde r a s s e mbl y t o t he b r ake b oos t e r .
13. Ins t a l l t he s p e ed c on t r ol m od ul e ret a i ni ng bo l t . Ti ght e n t o 4 Nm. 14. Conne ct t he s pe e d cont r ol modul e el e ct r i cal co nnect o r. 15. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket . 16. At t ach t he I A C va lve wi r i ng harne ss .
18. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 19. At t ach t he co o l a nt e xpans i o n t a nk . 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. At t a ch t he coo l a nt e xpans i o n t a nk. 20. Ins t a l l t he coo l a nt e xpan s i o n t a nk r et ai ni ng bo l t .
22. At t ach t he b rak e f l ui d l ow le vel warnin g i ndi cat o r wi ring ha rn e s s t o t he cool a nt expa n si o n t ank. 23. Conne ct t he b rak e fl ui d l ow le vel wa r ni ng i ndi cat o r e le ctrica l conne ct o r . 24. Check a nd t op up t he coo l i ng s yst e m as r eq ui r ed .
P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Va cuum Pump2.0L N A V6 - AJ V 6 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he vacuum ho se . Re l e a s e t he re t a i ni ng cl i p. 2. D i s conne ct t he e l ect r i cal conne ct o r.
P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Va cuum Pump2.0L D uratorq- TDC i/2.2L Durato rq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover /Ins t al l , Co o l i ng Ho s e Cl a mp 303-397 R em ova l 1.
6. D i s conne ct t he brake vacuum hos e f rom t he b rak e v a cuum pum p. 7. Remove t he po we r s t e e r i ng ho s e s upp o r t bracket . 8. D et a ch t he cyli n der he a d t e m pe r a ture (CHT) s e ns o r el e c t rical co nne cto r a wa y f r om t he brak e vacuum pump.
11. Us i ng t he s pe ci a l t o o l 303-397, di s conne ct t he cool a nt hos e s . 12. Remove t he b rak e va cuum pu m p. Re mov e a nd di s c a r d t he gas ke t. Insta llat ion 1. CAU TI O N : Make s ur e t h e dr i ve coup l i ng i s al ig ne d wi th t he c a msha f t c o upl i ng.
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss ist Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um be r Desc ri pti on 1 — Ins.
e nabl e s t he sys t e m t o r e cog ni z e th e dr ive r 's i nt e nt i ons . The DS C s yst e m a l s o i nco r por at e s e me r gen c y b r ake a s si s t (EBA), whi c h mea s ures t he r a t e a t wh ich t he br a ke pr e s s ur e i ncr e as e s d ur i ng a br aki ng ma noe uvr e .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss istVIN R ange: C 00344->J12991 Dia gn os i s a nd Te s t i ng Principle of oper at ion .
1. Vi s ua ll y i ns pe ct f or ob vio us s ig ns o f mecha ni cal o r e l e ct rical da mage . 1. Mechani cal El e ct ri cal Che ck th e t i re s i z e s , condi t i o n, a nd i nf l a t io n Brak e .
1 2 3 4 1 1 DT C D escri pti on P oss i bl e Source Act i on C1278 S t e e r i ng a ngl e s e ns or CAN me s s a ge no t pl a us i bl e S te e r in g a ng l e s e ns or no t cal i b r a t e d S te e r.
1 2 1 1 1 2 3 4 1 1 1 2 1 I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams. CLEAR t he DTC, t e s t t he s y s t e m f o r norm a l ope rat i on.
1 1 2 3 4 1 1 1 2 1 1 1 2 3 4 Mea s ur e t he res i s t a nce b et we e n LF01, p i n 01 (N ) and GROU ND. I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams.
1 1 1 2 1 1 1 2 3 4 1 2 3 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C, t e s t t he s ys t e m fo r n or mal o perat i o n.
1 2 1 2 3 4 1 2 3 1 1 2 1 2 3 4 1 2 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s GO t o E4 . No For CAN circu i t t es t s, REFER t o : Communica t i ons Ne t wo r k - V IN Rang e : E96603->J28492 (418-00 Modul e Co mm u nica t i o ns Ne t wo rk , Di a gnos i s and Te s t in g).
3 1 2 1 2 1 2 1 2 3 1 2 3 1 1 2 3 1 2 3 Mea s ur e t he r es i s t a nce be t we en JB89, p in 03 (GB) and JB 185, pi n 42 (GB) . Is t he res i s t a nce g r ea t er t h a n 5 o hms ? Ye s REP AIR t he hi gh r e s i s t ance ci rc ui t .
4 1 2 Mea s ur e t he vol t a ge bet we e n JB45/J B185, pi n 06 (R) and GRO UN D. I s e it he r vol t a ge l e s s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n t he AB S / DS C modul e a nd ba t t e r y. Th is ci rcu i t i ncl ude s t he b at t e r y j unct i o n bo x (fu s e 03) a nd ha r ne s s s pl i ce , JBS 27.
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss istVIN R ange: J1 2992-> V99999 Dia gn os i s a nd Te s t i ng Principles of Ope ra tio.
DT C D escri pti on P oss i bl e cause Ac ti on C007298 Brak e Te mpe r at ur e Too Hi g h Compo nent o r s yst e m over t e m pe r at ur e . T he HCU ha s de t e ct ed t ha t th e t e mpe r a t ur e .
DT C D escri pti on P oss i bl e cause Ac ti on to bat t e ry Modul e s up pl y vol t a ge gr ea t e r t ha n 16.8 vol t s Ove r v ol t a ge o f t he ba t t e r y cha r gin g s yst e m Ove r v ol t a .
DT C D escri pti on P oss i bl e cause Ac ti on P oor W S S s i g na l at hi ghe r freque ncy . At a ppr oxi mat el y 50 kph (31 mph) W S S may no t c ompa re a n d s how a var i a nc e C1A7614 Va l v.
DT C D escri pti on P oss i bl e cause Ac ti on op en ci r cuit W S S i nt e rn a l f a i l ure C1A9229 Re a r L e ft W hee l S pe e d S e nso r Ci r cuit S ig na l i nval i d.
DT C D escri pti on P oss i bl e cause Ac ti on cir cuit s ho r t t o ground W S S s upp l y f r ont right cir cuit s ho r t t o po we r W S S s upp l y f r ont right op en ci r cuit W S S i nt e rn a l f a i l ure C1A9429 Fr ont Ri ght W h ee l Spee d S en s or Ci r cuit S ig na l i nval i d.
DT C D escri pti on P oss i bl e cause Ac ti on Gr o und l i ne t o yaw r a t e s e n so r op e n cir cuit Y a w rat e s e ns or s en di ng i nva l i d CA N m e s s a g e Y a w rat e s e ns or s en di.
DT C D escri pti on P oss i bl e cause Ac ti on C1B0271 Re t ur n P ump Ci r cuit Act ua t o r s tuck. Low o r di s cha r ged ba t t e r y Ve hi cl e cha r gi ng s yst e m f a i l ure P ump s uppl y l.
DT C D escri pti on P oss i bl e cause Ac ti on s t e e r i n g whe e l r o t a t i on s ens o r o pen cir cuit CAN H o pen cir cuit be t we e n yaw rat e s en s o r , s t e ering w hee l r o t a t i .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock Brake System (ABS) ModuleVI N Range : C 00001->J12991 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he a nt i-l o ck br a ke s yst e m (ABS) mod ul e e l e ct r ica l conne ct or.
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Front Whe el Speed Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e as s e mbl y. Fo r addi t i ona l i nf o r m at i o n, r e f er t o S ect i on 204-04 W he e l s an d T i res .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Hydraulic C on tro l U ni t (HC U)V IN Range: C 00001->J12991 Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
8. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he ef fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Di s conn ect t he hydr aul i c co nt rol uni t b r a ke t ube s . 9. Remove t he hydr a uli c cont r ol uni t .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Hydraulic C on tro l U ni t (HC U)V IN Range: J1 2992-> V99999 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 R em ova l 1.
8. Remove t he HCU . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 8 Nm. 2. CAU TI O N : Make s ur e t h e br a ke t ubes are i ns t a l l e d to t he co r re c t port s. Fa i l ur e t o f o l l o w t hi s ins t r ucti on may res ul t i n da mag e t o t he vehi cl e .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Rear Wheel Speed Senso r Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.
7. D i s conne ct t he ABS whe e l s p ee d s e ns or el e ct r i c a l co nnect o r. 8. Remove t he ABS whe e l s p ee d s e ns o r . Insta llat ion Vehi c le s with 2.5L or 3.0L engine 1. To i ns t a l l , rever s e t he remov a l proced ur e . 1. Ti g ht e n t o 22 N m.
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Stability Assi st Mo dule Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: S t a bi l i t y as s is t modul e is a n int e gral co mponen t o f t he A BS m o dul e a n d ca nnot b e s e pa r a t e d.
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Steering Wheel Ro t ation Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he s t ee r in g whe e l r ot a ti on s ens o r e l e ct rica l co nnect o r .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Yaw Rate Sensor2 .0L Durato rq- TDCi /2. 0L NA V6 - A JV 6/2.5 L NA V 6 - AJV6/3. 0L NA V6 - AJ2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f l o or cons o l e trim p ane l .
P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Yaw Rate Sensor2 .2L Durato rq- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with autom at ic tra ns m ission 1. D et a ch t he J-gat e s ur r ound.
5. CAU TI O N : Make s ur e t h e ya w rat e s e ns or i s no t s ubj e c t e d t o a ny fo rm of i mpa ct a nd i s no t d r opp ed or damag e d. Fai l ure t o fo l l o w t hi s in s t ruc t i o n may r es ul t i n f ai l ure o f t he s e ns or. Det ach t he yaw rat e s e ns or .
P ubl i she d: 20-Jul-2011 Steering System - G eneral Inf orm atio n - Ste eri ng L i nk age Sp ec if i cat io ns St ee r i ng Li nk age Free Pl ay Mea sur e men t (mm ) Me a surem e nt (i n) Fr e e pl a y (meas ur e d at t he s t ee r in g whe e l r i m) 0-6 0-0.
P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - Stee ring S y stem Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N u mber Des cri pti o n 1 — Flui d cool e r 2 — Lo .
P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - Stee ring S y stem Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by drivi ng t he ve hi cle . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
Item Descri pti on 1 St e e r ing t rans ducer ground 2 I g ni t io n f e ed 3 St e e r ing t rans ducer f e ed 4 Ground 5 Spe e d s e ns o r s i gna l 6 Seria l i nt erfa ce Ste e ring Lin ka g e In spect ion an d Ba c kla sh (Fr eep la y) C he ck CAU TIO N : S t e e ring ge a r boo t s mus t b e ha nd l e d ca r e ful l y t o a voi d da mage .
It e m Speci a l T o ol Nu mb e r Desc ri pti on 1 21 1-011 Pres su r e Ga uge Ho s e 2 21 1-011-08 Pump Re t urn Ho s e 3 21 1-011-07 Pump Re t urn Ho s e Co nnect o r 4 211 -011- 03/ 2 Tes t Eq ui p.
C ondi ti on Possi bl e Sources Acti on Damag e d f l ui d cap . INS TA LL a ne w f l ui d c a p. Loo s e o r d a mage d hos e f i t t i ngs . TIGHT EN or IN S TALL a ne w ho s e a s ne ces s ary. Lea ka ge a t powe r s t e e ring pump . I NS TALL a ne w po we r st e e r i ng pump a s ne ce s s ary .
C on di ti on Po ss i bl e Sou rces Act i on Lo o s e o r worn rear s us pen s i o n. TIGHT EN l o o se , o r I NS TAL L n e w rea r su s p e ns i on compone nt s . Fo r a ddi t i ona l i nf o r m at i o n, REFER t o Sect i on 204-02 Rea r S us pen s i o n .
C on di ti on Po ss i bl e Sou rces Act i on Damage d or w orn f r o nt s us pe ns i o n co mpone nt s . INS TA LL ne w f r ont s usp e ns i on co m po nent s a s nece s sa ry . Fo r a ddi t i o nal i nfo r mat i o n, REFER t o Sect i on 204-01 Front S us p e ns i on .
C on di ti on Po ss i bl e Sou rces Act i on Flu id l o ss a t t he po we r st e e r i ng p ump s haf t s e al . CHECK t he po we r s t e e r i ng pu m p f or s i gns of s t e ering f l ui d l o s s . INS TA LL a ne w powe r s t ee ring p ump as ne ce s s a ry .
C on di ti on Poss i bl e S ources Ac ti on Acces s o r y dr ive bel t s quea l I nc o r r ect a cces so ry d r i ve be l t t e ns i o n or a cces s o r y drive b e l t gl a z e d. CHECK a cces so ry d r i v e be l t cond i t i on a nd IN S TAL L a ne w a cc e s s o r y drive b e l t a s ne ce s s a r y.
C ondi ti on Possi bl e Sources Acti on CHECK and TI GHTEN t he s te e r i ng col umn ret a i nin g bo l t s /nut s and pi nch bo l ts i f r e qui red. For a dd i t i o na l in f orm a t i o n, REFER t o Sect i on 211-04 S t ee r i ng Co l umn . Ex ces s i ve we a r i n s t ee ring co l umn a s s embl y.
Dee p, l o ng, prol o nged s o und l i ke a n a n imal , o r wi nds a nd o cea n wa ves . Rum b le Lo w, he a vy cont i nuo us s o und l i ke t ha t made by wa go ns o r th under. Sc r ap e Gr a t i ng no i s e l i ke one hard p la s t i c ru bbi ng pa rt r ubbi ng a ga i ns t a no t he r .
is a s t ruc t ur e-bo rne n oi s e t r ans mit te d t hrough t he i nt e r medi at e s ha ft a nd co l umn. Ra ck knock ca n a l s o be he a rd a s a "t hump" o r i mpact no is e t hat o cc.
ba l l j o i nt s a r e worn, t he l o we r s t e e r i ng col umn j oi nt s a re wo r n o r t he ba ckl a s h o f t he s t e ering ge a r is e xces si v e .
P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - P ower Steer ing S y stem Fillin g Gene ral P r ocedures 1. NOT E: W he n fi l l ing t he r e s e r vo i r, make s ur e t ha t t he fl ui d i s cl e an a nd not agi t a t ed p r i or t o us e .
P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - P ower Steer ing S y stem Flushi ng Gene ral P r ocedures • NO T E: I f hea vy s t e e ring o r cont a mina t io n wi t hi n .
6. NOT E: The s ui t a bl e f unnel s ho ul d ha ve t he a ca pa ci t y o f 4 l it r e s a nd O-ring s e a l • NO T E: T he s ui t a bl e f unne l must be t i g ht l y s e a l e d t o t he po we r s t e e r i ng fl ui d res e rv oi r t o avo id fl ui d l e akag e .
10. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id s . Re move t h e s ui ta bl e fun ne l . 11. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id s . Re move t h e s ui ta bl e pi p e t o t he p o we r s t e e r ing r et ur n ho s e .
P ubl i s he d: 11-May-2 011 Pow er Steering - Gen eral S p ec if ic a t ions Item Speci f i cati on P owe r a ss i s t e d s te e r i ng f lu id Dexr on 2E T o rque Sp eci f i cat ions Desc ri pti on.
P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N u mber Des cri pti o n 1 — Flui d cool e r 2 — Lo w p r e s s ur e pi p e - f l.
P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 211-00 S t e e r i ng S y s t em - Gene r a l I nf o r mat i on .
P ubl i s he d: 11-May-2 011 Pow er Steering - Start U p Pr o cedure After P ower Ste ering Pump/Gear O verh aul Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t oS e cti o n 211-00 S t ee r in g Sy s t e m - Gene r a l I nf o r m at i o n .
P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering C o ntrol Va lve Actuato r2.5L N A V6 - AJV6/3. 0L NA V 6 - A J27 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng .
1. To i ns t a l l , rever s e t he remov a l proced ur e . 1. I ns t a l l a ne w f il t e r 2. CAU TI O N : Make s ur e bo l t s a r e t i ght e ne d e venl y .
P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid C oo ler2 .0L Durato rq- TDCi Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld .
P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid C oo ler2 .2L Durato rq- TDCi (110kW / 150PS) - Puma Re moval a n d I ns t a l l a t i on R em ova l 1.
I n s ome ca s e s where t he fl ui d cl ea rly co nt a i ns pa rti c ul a t e ma t t e r , a nd t he s y s t e m cont i nues t o f unct i o n, fl us h t he s ys t e m wi t h f r e s h f l ui d a nd r.
P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid Reserv o ir Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : If po we r s t e e r i ng f l ui d is s pi l t o n t he pai nt wo r k , t he e ff e ct e d a r e a mus t be i mm e di a t e l y wa s he d d own wi th cold wa t e r.
P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Pump2.0L N A V6 - AJV6 / 2.5L N A V6 - AJV6/3. 0L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a cc e s s o r y drive b e l t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Acces s or y Dr ive Be lt - 2.
3. Tig ht e n t o 30 Nm. 4. NOT E: If t he s t e e r i ng ge ar, pump o r coo l e r are be ing rep l a ced f o r le a kage or noi s e r e la t e d i s s ue s a nd t he re i s no e vid ence of f l ui d c on t a mina t i o n, t he r e i s no ne e d t o repl a c e t he re se r voi r .
Name Gr ea s e P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Pump2.0L Durato rq- TDC i/2.2 L D urato rq - T DCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Mate ri a l s Speci fi cati on W S S -M 12 A4-A2 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
7. D et a ch t he po we r s t ee ring hi gh-pr e s s ure pi pe . 8. CAU TI O N : W he ne ver t h e po we r s t e ering pump fe e d ho s e i s di s conne c t e d t he p o we r s t e e r ing pump p or t a nd ho s e s houl d be pl ugg e d t o pr eve nt d i r t i ngres s .
11. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y. Re move t h e po we r s t e ering pump s ecur i n g b r a cket . 12. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y.
1. Coat t he p o we r s t e e r i ng pump dr i ve s pl i ne s wi t h gr ea s e . 2. Ins t a l l a ne w wa t er pump O -r ing s e a l. 3. Ins t a l l the po we r s t e e r i ng pump. 4. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y.
5. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. I nst a l l t he p o wer s t e ering pum p s e cur i ng b r acket . Ti ght e n t o 25 Nm. 6. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y.
9. NOT E: Re m o ve t he pl ug s f r om t he po we r s t ee ring pump port a nd t he fe e d ho s e . • NO T E: Shown wi t h t he EGR co o l e r t o EGR va l ve t ube r e m ove d fo r cla rit y . Conn ect t he po we r st e e r ing fe e d ho s e. 10. At t ach t he p o we r s t e e r i ng hi gh-pres s ur e pi p e .
14. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.0L Durat o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150P S ) - P uma, Re moval a nd I ns ta l l a t i on).
P ubl i s he d: 11-May-2 011 Pow er Steering - Steering G ear2.0 L D uratorq- TDC i/2.2L Durato rq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Cent e r t he s t e ering w hee l . Lock i n po s i ti o n a n d remove t he i gni t i on key.
7. D et a ch t he s t e e r i ng ge a r coo l e r p ip e . 8. D et a ch t he r i ght -hand s i d e of t he s te e ring g e a r . 9. D et a ch t he l e f t -hand s i de o f t he s t ee ring g e a r . 10. Remove t he b ul k he a d pa ne l s e a l . 1. Re pos i ti on t he st e e r i ng ge a r.
Insta llat ion 1. Ins t a l l the s t ee r i ng g e a r . 2. Repo s i t i on t he s t e e ring ge a r . 1. I ns t a l l t he bul k he a d pa ne l s e a l. 2. Re pos i ti on t he st e e r i ng ge a r. 3. Att a ch t he l e ft -hand s i d e o f t he s t e e r i ng ge a r .
5. Att a ch t he s t ee r in g g e a r coo l er pi p e. 6. Att a ch t he s t ee r in g g e a r coo l er pi p e. 7. Ins t a l l new O -r ing s e a l s . 8. Att a ch t he s t ee r in g g e a r f l ui d l i ne s . Ti ght e n t o 10 Nm. 9. Ins t a l l the a i r def le cto r.
10. NO TE: Ri ght -hand s ho wn, Le f t ha nd s i m i l a r . Conn ect t ie -r o d e nd ba l l j oi nt s . 1. At t a ch bo t h t i e r o d s t o previou s l y not e d p o si t i o ns. 2. Ti g ht e n t he t i e r o d l o c ki ng nut . 11. NO TE: I ns t a ll a new b ol t .
P ubl i s he d: 11-May-2 011 Pow er Steering - Steering G ear2.0 L N A V6 - AJV6 / 2.5L NA V6 - AJV6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1.
Vehi c le s with high i ntensity dis char ge hea dlam ps 6. D et a ch t he l i nk r od f r om t he hea dl a mp l e ve l in g s e ns o r . All v e h icle s 7. D et a ch t he po we r s t ee ring hi gh p r es su r e p ip e . Vehi c le s with autom at ic tra ns m ission 8.
10. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s.
14. Remove t he ret a i ni ng cl ip from t he po we r s t e e r ing hi g h a nd l o w pr es s ur e pi pe s . All v e h icle s 15. CAUT I O N: W h e neve r t he pow er s t e ering pi pe s are d i s co nnect ed, th e s t e e r ing gea r val ve bo d y po r t s a nd po we r st e e r in g pi p e s s houl d b e pl ugg ed to prevent d i r t i ngres s .
18. CAUT I O N: W h e neve r t he pow er s t e ering hi gh pr es s ur e pi p e i s di s conne c t e d, t he po we r s t e e ring pump po rt a nd pi pe s houl d be p l ugg e d t o pr eve nt d i r t i ngres s . Fa i l ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t i n d a mage to the ve hi cle .
22. NO TE: L e ft -hand drive ve hi cl e s s ho wn, r i ght -ha nd d rive vehi cl e s s i mi l a r . Re move t h e s t e e r i ng ge ar bul k he a d s e a l. 23. NO TE: L e ft -hand drive ve hi cl e s s ho wn, r i ght -ha nd d rive vehi cl e s s i mi l a r .
3. NOT E: Le f t -hand drive vehi cl e s s hown , r i ght -hand d r i ve vehi cl e s s imi l a r. At t a ch t he r i g ht -hand s i de o f t he s t e e r i ng g e a r . Loo s e l y i ns t a l l t h e s te e r i ng ge a r r e ta i ni ng bo l t . 4. NOT E: Le f t -hand drive vehi cl e s s hown , r i ght -hand d r i ve vehi cl e s s imi l a r.
7. NOT E: Re m o ve t he bl a nki ng p l ug. I nst a l l a ne w O -r ing s e a l . 8. NOT E: Re m o ve t he bl a nki ng p l ug. Conn ect t he po we r st e e r ing hi gh pr e s s ur e pi pe to the po we r s t e e r in g pump. Ti ght e n t o 30 Nm 9. Ins t a l l the po we r s t e e r i ng hi gh pres s ur e pi pe br a cket r e t a i ni ng bo l t .
Le ft-hand dr ive ve hi c le s 12. Ins t a l l t he r e t a i ni ng cl i p t o t he po we r s t e e r i ng hi gh a nd l o w p res s ur e pi pe s . All v e h icle s 13. Us i ng t he s pe ci a l t o o l rai s e t he f r ont s u bframe. 14. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar.
16. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t o 142 Nm. 17. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 18. Remove t he s pe ci a l t o o l .
20. At t ach t he p o we r s t e e r i ng hi gh pres s ur e pi pe . Vehi c le s with high i ntensity dis char ge hea dlam ps 21. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h icle s 22. Conne ct t he p o we r s t e e r i ng cont r o l va l ve a ct ua t or e l ect r i cal co nnect o r (if e qu ip pe d).
24. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover. All v e h icle s 25. Carr y out s t ee ring s ys t e m bl e e d p r o ce d ur e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: P o we r S t e e r i ng S y s t e m Fil l i ng (211-00 Ste e ring S yst e m - Ge neral I nfo rm at i on, Ge ne r al P roced ur es ).
P ubl i s he d: 11-May-2 011 Steering L inkage - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Ti e -r od e nd ret a i ni ng nut 35 26 - Ti e -r od e nd l o c k nut 40 30 - W he e l nut s - Ve hi cle s wit h s t e e l whe e l s 80 59 - W he e l nut s - Ve hi cle s wit h a lumi ni um whee l s 103 76 - JagDocs.
P ubl i s he d: 11-May-2 011 Steering L inkage - Steering Li nka ge Des cr ipt i o n a nd O pe r a t i o n Item Pa r t Nu m be r D escri pti on 1 — S t e e r i ng g e a r 2 — Ti e-r od end boo t 3.
P ubl i s he d: 11-May-2 011 Steering L inkage - Steering Li nka ge Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 211-00 S t e e r i ng S y s t em - Gene r a l I nf o r mat i on .
P ubl i s he d: 11-May-2 011 Steering L inkage - Steering G ear Bo ot Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he t i e -r o d e n d. For a ddi t i o na l i nf orm at i o n, r ef e r t o p r oce dur e i n t hi s s e ct io n: Ti e Ro d En d 2.
P ubl i s he d: 11-May-2 011 Steering L inkage - Ti e Rod End Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep e r at or, B a ll Joi nt 204-192 (JD- 219) R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n re fe r t o Sect i o n 204-04 W hee l s a nd T ire s .
5. NOT E: Make a not e o f t h e numbe r of t ur n s re qui r ed t o remove t he ti e -r od e nd. Re move t h e t i e -r od e nd. Insta llat ion 1. NOT E: Make s ure t he t i e-rod e nd i s i ns t a l l ed o n t he t i e -r od by t he s a me a m o unt o f t ur ns u s e d t o r emove i t .
P ubl i s he d: 11-May-2 011 Steering Co lu mn - T o rque Sp eci f i cat ions Desc ri pti on N m l b- ft l b- i n S t ee r in g whe e l r et a i ni ng bo l t 47 35 - S t ee r in g co l umn l o we r r .
P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Des cr ipt i o n a nd O pe r a t i o n Item Pa r t Nu m be r Desc ri pti on 1 — S te e r i ng col umn 2 — S te e r i ng wh e e .
P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 21 1-00 Ste e ring S yst e m - Ge neral In fo rm at i on .
P ubl i s he d: 11-May-2 011 Steering Co lu mn - Ignitio n Switch L o ck Cylinder Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l pocke t . 2. Remove t he drive r s s i de i ns t rum ent pa ne l l o we r t r i m pa ne l .
P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he clo cksp ring. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Cl o ckspring (501-20B S uppl e me nt a l Re s t rai nt Sy s t e m, Re moval a nd I nst a l l at io n).
6. D i s conne ct t he s t ee r in g whe e l r ot a ti on s ens o r e l e ct rica l co nnect o r . 7. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 8. Remove t he s t ee ring co l umn. 1. Re move t he s t e e r i ng col umn ret a i ni ng bol ts .
2. Tig ht e n i n t he s eque n c e s ho wn. Ti ght e n t o 24 Nm. 3. Ins t a l l a ne w b o l t . Ti ght e n t o 25 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn C ouplin g Re moval a n d I ns t a l l a t i on R em ova l 1. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 2. Remove t he s t ee ring co l umn coupl i ng.
P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing W heel Re moval a n d I ns t a l l a t i on R em ova l 1. Pos it i o n t he f r ont whe e l s i n a s t r ai ght a he a d po s i t i o n a nd cent r al i z e s t e e ring whe e l. 2. Remove t he drive r ai r b a g mod ul e.
P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n S wit ches Des cr ipt i o n a nd O pe r a t i o n Ste e ring C olu mn Multif u nction Switch RH The s t e e r i ng co lu .
P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n S wit ches Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage .
P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n Multi func tio n Switch LH Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l pocke t . 2. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l .
5. D et a ch t he s t e e r i ng col umn m ul t i funct i o n s wi t ch l e f t -ha nd. Re l e a s e t he re t a i ni ng t ang. 6. Remove t he s t ee ring co l umn mult i f unct i o n s wit ch l e f t-h a nd. Dis conne ct t he e l e ct r i cal co nnect o r.
P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n Multi func tio n Switch RH Re moval a n d I ns t a l l a t i on R em ova l 1. Lowe r t he s t e e r i ng col umn. 2. Remove t he s t ee ring co l umn uppe r s hr ou d. 3. D et a ch t he s t e e r i ng col umn m ul t i funct i o n s wi t ch rig ht -hand.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Gen eral sp eci fi cat ions 2.0 l it r e d i es el . I te m Speci fi cati on Cod e FMBA/FMB B Firing o rder 1- 3-4-2 Cyli nder b.
C ranks haft D im ensi o ns 2.0 l i tr e and 2 .2 li t re d i es el . Desc ri pti on m m Mai n be a ring j o ur nal – di a met e r 69·950 - 69·970 Mai n be a ring j o ur nal – e nd fl oa t 0·09.
I te m Sp eci f i cati on Va l ve he a d di a met e r e x ha us t (m m) 3 0.15 - 29.85 I nt a ke val ve f ace a ngl e deg r e e 45.75° Exhaus t va l ve f ace a n gl e d egree 45.25° Va l ve s t e m di amet e r i nt a ke (m m) 5.492 - 5.477 Va l ve s t e m di amet e r e x hau s t (mm ) 5.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Engin e Des cr ipt i o n a nd O pe r a t i o n 2.0 L, 2 .5 L an d 3. 0L Engine s The 2.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform a.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * Exces s ive cr anks ha ft e n d p la y. I NS TALL a new e ngi ne. Exces s ive conne ct i ng rod b e a r ing oi l cl e arance. I NS T AL L a new e ngi ne. P i s t o n/cy li nde r wor n. I NS TALL a ne w e ngi ne.
a nd r e pe a t the compr es s io n m e a s urement . I f t he r e adi ng gr e a t l y i mpr o ve s t he n t he pi s t o n r i ngs a r e da mag e d. I f t he r e adi ng s ta ys t he s ame t hen t he ca us e i s e i t he r d a mage d val v e se a t s o r val ve s t e m s e a l s .
5. I f t he o i l cons umpt i on rate i s un a cc ept abl e go t o S tep 6 . 6. Check t he p o si t i ve cr a n kc as e ve nt i la t i o n (PCV ) s ys t e m. Make s ur e th e s ys t e m i s no t p l ugg e d. 6. 7. Check fo r pl ugge d oi l d r ai n-ba ck hol e s i n t he cy l i nde r hea d and c yli nder bl ock.
i ndi cat e d. The r e a di ng a t i dl e co ul d be rel a t ive l y s t ea d y. 10. LATE VALVE TI MING: A s t e a dy b ut l o w r ea d in g co ul d be cau s ed by l a t e va l ve t imi ng. 10. 11. IGNIT IO N TIMIN G RETA RDING: Re t a r d e d i gni t i o n ti mi ng wi l l produce a s t e a dy but so mewh a t l o w r ea d i ng.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Bearin g I nspectio n Gene ral P r ocedures 1. Ins pect b e a r i ngs f o r th e fo l l o wing d e fe ct s . 1. Cr at e r i ng - fa t i gue f a i l ure 2. S po t pol i s hi ng - i ncorr e ct s e a t i ng.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Bea ring J ournal Cl earance Gene ral P r ocedures 1. NOT E: Make s ure t ha t t he f ol l o wi ng s t a ge s a r e f o l l owe d exact l y . The ta p pe t s or f o ll owe rs mus t be remov e d t o car ry o ut t hi s me a s ur e ment .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Bea ring J ournal Diam eter Gene ral P r ocedures 1. D et e r mine t he di a met e r of t he cams haf t jo urn al s .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft E nd Play Gene ral P r ocedures 1. NOT E: Make s ure t ha t t he cams ha f t i s t o s pe ci fi cat io n. Us i ng t he s p e ci a l t o ol , me a s ur e t he e nd pl ay.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft L obe L ift Gene ral P r ocedures 1. M e as ur e t he di a met e r (1) and di a met e r (2) wi t h a ve rn i e r cal i p e r . T he di f fe r e nce i n me a s ur e ment s i s t he l obe l i f t .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Surfac e Inspecti on Gene ral P r ocedures 1. Ins pect ca ms haf t l o b e s f or pi t t i ng or da mag e i n t he a c t i ve a rea . Mi nor pi t t i ng i s a c ce pt a bl e out s i de t h e a ct i ve area .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C onn ecting Rod C leani ng Gene ral P r ocedures 1. CAU TI O N : Do no t us e a ca us t i c cle a ni ng s o l ut io n or da mag e t o c on ne ct ing r od s m a y occur . Mark a nd s ep a r at e t he p a r t s a nd cle a n wi th so l vent .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C onn ecting Rod L arge End B ore Gene ral P r ocedures 1. M e as ur e t he be a ring bo r e i n t wo di r ect i ons . The di f f e rence i s t he conne ct i ng r od bore o ut -of -r ound.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft E n d P lay Gene ral P r ocedures 1. Usi ng t he Di a l Indi cat or Gauge wi t h Br ack e t s , me as ure t he e nd pl a y . Mea s ure t he e nd pl a y by l i ft i ng t he crank s haf t us i ng a l e ver.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft Main B earing Jo u rnal C lea rance Gene ral P r ocedures 1. The mai n be a ring m a chi ne co de s a r e d is pl a ye d o n t he cr anksha ft (1) a nd t he cyli nde r bl o ck (2) 2.
3. NOT E: Mai n be aring numbe r 1 r e l at e s t o t he f ront of t he e ngi ne . Re a d t he i d ent i f i ca t i on number s on t he cyli nder bl o ck (2 ). The fi r s t t wo number s r e pres e nt th e code f o r m a i n be a ring number 1. The s e cond pa i r o f number s r e pres e nt s th e code f o r m a i n be a ring number 2.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft Main B earing Jo u rnal Di ameter Gene ral P r ocedures Ge nera l Equi pm ent Mi c rom e t e r 1. M e as ur e t he di a met e r of t he mai n be a ring j ournal s a nd t he b i g-end be a r i ng j ou r na l s .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Blo ck Disto rtio n Gene ral P r ocedures 1. Usi ng a St r ai ght Ed ge a nd a Fe e l e r Gaug e, mea s ur e t he cyli nde r bl o ck/ cylind e r he ad di s t o rti o n.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Bore O u t- o f- Round Gene ral P r ocedures 1. NOT E: The mai n be a r i ng cap s or l o we r cr ankc a se must be i n pl a ce and ti g ht e ne d t o t he s pe ci f i e d t o r q ue ; ho we ver , t he b e a r ing she ll s s h oul d no t be i ns t al le d.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Head Disto r tio n Gene ral P r ocedures 1. M e as ur e t he cyli n der bl ock/ cyli nde r he a d di s t orti o n. Us i ng t he s pe ci a l t o ol , m e a s ur e t he m a t i ng f ace di s t o r t i o n.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Exh aust Manifo ld C leaning a nd Inspectio n Gene ral P r ocedures 1. Ins pect t he cy l i nde r hea d jo i ni ng fl ange s o f t he e xhaus t mani f ol d f or e vid e nce of e xha ust g a s l e aks .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Flyw h eel In spectio n Gene ral P r ocedures 1. CA UT I O NS: Do no t rework t he f l ywhee l i f i t is di s t o rte d. Do no t cle a n t he d ual mas s f l ywhee l wit h a ny kind o f f l ui d .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Diam eter Gene ral P r ocedures Ge nera l Equi pm ent Mi c rom e t e r 1. NOT E: Mark t he pi s t o n t o mak e s ure t he pi s t o n i s i ns t a ll ed corr e ct l y. Us i ng a Micromet e r me a s ur e t he pi s t on d i a met e r.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ins pection Gene ral P r ocedures 1. CAU TI O N : Do no t us e a ny a ggres s i ve cl ea ni ng fl ui d or a wi r e b r us h to c l e a n t he pi s t o n. Ca r ry out a vis ua l i ns p ect i on.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Pin Dia meter Gene ral P r ocedures 1. NOT E: The pi st o n a nd p is t o n pi n ar e a ma tche d p a i r . Do not mix up t he c ompo ne nt s . Mea s ur e t he pi s t o n pi n d i a me t e r.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Pin to B ore D iam eter Gene ral P r ocedures 1. NOT E: The pi st o n a nd p is t o n pi n fo r m a ma t ched pai r . Do not mi x up th e compone nt s . Mea s ur e t he di a met e r of t he pi st o n p i n bore.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ring En d Ga p Gene ral P r ocedures 1. CAU TI O N : Do no t mi x u p t he pi s t o n r i ngs . Ins t al l t he pi st o n ring s in t he s a me p o s i t i on a nd l o cat i o n.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ring- to-G roo ve Clea rance Gene ral P r ocedures 1. NOT E: The pi st o n ring mus t prot r ude f r om t he pi s t o n gr oo ve.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Seat Inspectio n Gene ral P r ocedures Ge nera l Equi pm ent Va l ve s e a t wi dt h s cal e 1. M e as ur e t he wi d t h o f t he val ve s e a t . Mea s ure t he v a l ve s ea t wi dt h usi ng t he Va l v e s e a t wi dt h s ca le .
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Spring Free Length Gene ral P r ocedures 1. Usi ng a ve r ni er ga ug e , mea s ure t he fre e l e ng t h o f e a ch val ve s pr i ng. Ve r i fy t he l e ngt h i s wi t hin s p e ci fi cat io n.
P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Stem Di ameter Gene ral P r ocedures 1. Usi ng a mi cr omet er me as u r e t he di a me t e r of t he v a l ve s t e ms . If t he m e a s u r e m e nt s a r e no t t o s p eci fi ca t i o n, ins t a l l a new val ve .
P ubl i s he d: 02-J un-2011 E ngine System - G eneral I nform atio n - Leaka ge Test U si ng Smo ke Test E quipm ent Gene ral P r ocedures CAU TIO N : Th e co mpr e s s e d a i r li ne s uppl y pr e s s ur e must b e b e t wee n 3.5 a nd 12 ba r (50 a nd 175 ps i ) fo r t h e s moke t e s t e q ui pment t o funct i on corr e ct l y.
6. NOT E: In s o me c a s e s i t may be ne ces s a ry t o r emove t he a i r c l e a ne r (s ) to a ll o w a cces s t o t he a i r cl e an e r out l e t pi p e s. • NO T E: In s ome cas e s i t wi l l be ne ce s s a ry t o cap one o f t he a i r c l e ane r out l e t pi pes .
Publ i s he d: 23-S ep -2011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Descri pti o n Speci fi cati on Engi ne oi l 2. 0L ga s o l i ne , S AE 5W -30 (NAS ) API S L a nd I LS AC GF –3 Engi ne oi l 2.
Descri pti o n N m l b-ft l b- i n W i r i ng ha r ne s s t o val ve cover r et a i ni ng nut s 6 - 53 Thr ot t l e ca bl e ret a i ni ng b r ack e t bo l t s 9 - 80 A = ref e r t o th e proced ur e fo r corr e ct t orque s e que nce - - - JagDocs.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Des cr ipt i o n a nd O pe r a t i o n 2.
The 2.0, 2.5 a nd 3.0 l i t r e 24 val ve V6 e n gi ne s ha ve fo ur o ver he ad c a msha f t s a n d a re dr i v e n by t wo t i ming cha in s . A l l t hree e ngi ne s in cor po r at e e l e ct roni c e ng i ne mana ge ment wi t h d i s t r i but o r l e s s i gni t i on s ys t e m , s e que nt i a l e l e ct roni c fue l inj ect i on.
The r ot a r y o i l pump d e v e l op s t he o i l pres s ur e: The o il p ump i s l o ca t e d at t he f r on t of t he cr anks ha ft . The o il p ump i s d r i ven by t he cr a nk s ha ft . A f u ll f lo w oi l f il t e r i s e xt e r nal l y mount ed o n t he oi l fi l t e r hous i ng.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 303-00 Engine S ys t em - Gen e r al I nf or mat i o n .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C learanc e A djustment Gene ral P r ocedures 1. Remove t he ca m s haf t s . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o Ca ms ha f t 2.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C learanc e C heck Gene ral P r ocedures 1. Remove t he l e ft ha nd val ve co ver. For ad di t i o na l i nfo rm at i on, refe r t o Va l ve Co ver — LH 2.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C amsh afts LH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he t i mi ng chai ns. For a dd it i o nal i nfo r mat i on, ref e r t o Ti mi ng Dr ive Co mpone nt s .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Fro nt Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Cr a nk s ha f t Front S e a l Remo ver 303-700 Cr a nk s ha f t Front S e a l Ins t a l l e r 303-542 Cr a nk s ha f t Dampe r Ins t a l l e r 303-102 R em ova l 1.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Pu lley I n-v e hi c l e Re pa i r Speci al T ool (s) W r e nch s t r ap-uni vers al 3.
3. D i s conne ct t he cr a n ks haf t p o si t i on s e ns o r (CKP) e l e ct r ica l conne ct o r . 4. Remove t he CKP s e ns or. 5. D et a ch t he a cces s o r y d r i ve be lt . 1. Us i ng t h e s pe ci al t o ol , r ot a t e t he b e l t te ns i o ne r c o unt e r cl ockwis e .
8. Usi ng t he s pe cia l t oo l s, re move t he cr anksh a ft vib rat i on dampe r. Insta llat ion 1. NOT E: Coa t t he cr a nks ha ft da mpe r keyway wit h s i l i cone gas ke t s e a l ant W S E- M4G 323-A6 o r equi va l e nt mee t i ng Ja guar s p e ci fi c a t io n.
4. Ins t a l l the CKP . Ti ght e n t o 10 Nm. 5. Connect t he CKP el e ct r i cal co nnect o r. 6. Ins t a l l the s p l a s h s hi e ld . 7. Ins t a l l the whe e l a nd t i r e. Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S e cti o n 204-04 W hee l s a nd T ire s .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Re ar Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Cr anks haf t Re a r S ea l R.
3. NOT E: Al t e r nat e bo l t t i ght e ni ng t o corr e ct l y s e a t t he cr anks haf t r e a r oi l s ea l unt i l i t i s fl us h wi t h t he cyl in de r bl o ck . Us i ng t he s p e ci a l t o ol , i ns t a l l t he cr anksh a ft rear oi l s e a l .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C ylinder Head LH I n-v e hi c l e Re pa i r R em ova l Vehi c le s with 2.5L or 3.0L engine 1. D i s conne ct t he e ngi ne co ol a nt t e mperat ur e (ECT) a nd f uel t e mperat ure s e ns o r (F TS) el e ct r ica l conne ct o r s .
5. D et a ch t he f ue l chargin g wi ring harnes s . 2.5 a nd 3. 0L s hown, 2. 0L s i m i l a r . 6. W ARNING: Fue l m a y s t i l l be pres e nt i n t he f ue l i nj e ct i on s uppl y m a ni f ol d, e xt r eme c a re mus t be t a k en as t his coul d c a us e pe r s o na l i nj ury .
10. Remove t he co o l a nt bypas s t ube. Re mov e a nd di s c a r d t he cool ant b ypa ss t ub e O -r i ng s e a l s . 11. Remove t he e xhaus t mani f o l d. Re mov e a nd di s c a r d t he e x ha us t m a ni f ol d g a s ket . 12. Remove t he l ef t -han d cams ha f t s .
5. Ins t a l l the co ol a nt by pa s s t ube . Ins t al l t he n e w coo la nt bypas s t ub e O -r i ng s ea l s. Ti ght e n t o 10 Nm. 6. Ins t a l l the wa t e r pump out l et p i pe. Ins t al l t he n e w wa t e r pump ou t l e t pi pe O -r i ng s e al s .
10. At t ach t he f uel cha r ging wi ring ha r nes s . 2.5 a nd 3. 0L s hown, 2. 0L s i m i l a r . Vehi c le s with 2.0L engi n e 11. Conne ct t he co o l a nt t e mpe rat ur e (ECT) e l e ct r i cal c onn e cto r . Vehi c le s with 2.5L or 3.0L engine 12.
14. Conne ct t he e ngi ne co o l a nt t e mpe rat ur e (ECT) a nd f uel t e mperat ure s e ns o r (F TS) el e ct r ica l conne ct o r s . JagDocs.com.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Front C o ver I n-v e hi c l e Re pa i r R em ova l CAU TIO N : I t i s ne ce s s a r y t o r e move t h e e ngi ne i n o r de r t o r e move t he e ngi ne f r on t c o ve r .
6. D i s conne ct t he t hr o t t l e po s i t i o n s e ns o r e l e ct r i cal c onn e cto r . 7. D et a ch t he cr uis e co nt rol ca b le . 8. D et a ch t he t hrot t l e ca b le . 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n.
11. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 12. Det a ch t he wi ring ha r nes s. Vehi c le s with 2.5L or 3.0L engine 13. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 14. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 15.
16. Det a ch t he vacuum hos e. All v e h icle s 17. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt a k e mani fo l d s uppo rt b r a cket . 18. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt a k e mani fo l d s uppo rt b r a cket .
20. Dis c o nne ct t he l ef t -han d i g nit i o n coi l e l e ct r i c a l co nnect o rs. 21. Remove t he l ef t -han d i g nit i o n coi l s . 22. Dis c o nne ct t he va r i a bl e ca m s ha f t t i m i ng (VCT) s o l e no i d e l ect r i cal conne ct or.
Vehi c le s with 2.0L engi n e 26. Det a ch t he hea t ed pos i t i ve cr an k cas e vent i l a ti on val v e cool ant h os e s . All v e h icle s 27. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Det ach t he co ol a nt h os e . 28. Remove t he l ef t -han d va l ve cover.
30. Remove t he rig ht -ha nd i g ni t i o n coi l s . 31. Det a ch t he wi ring ha r nes s. 32. Dis c o nne ct a nd repos i t i on the v a r i a bl e ca ms ha ft t i mi ng (VCT) s ol e no i d e l e ct r i cal conne c t o r . 33. Remove t he e n gi ne co ver r e ta i ni ng br a cket .
35. Remove t he rig ht -ha nd val ve cover . Re mov e a nd di s c a r d t he val ve cove r g a ske t s. 36. Det a ch t he acce s s o r y driveb e l t . 1. Us i ng t h e s pe ci al t o ol , r ot a t e t he b e l t te ns i o ne r c o unt e r- cl ockwis e .
40. Dis c o nne ct t he g e ne r at o r po s i t i ve ca bl e e l e ct r i cal conne cto r. 41. Dis c o nne ct t he g e ne r at o r e l e ct r i cal conne cto r. 42. Remove t he g e ne r at o r. 43. Us i ng t he s pe ci a l t o o l , r e move t he cr anksha ft vi br a t i o n da mper r et a i ni ng b ol t .
45. Remove t he CKP . 46. Ins t a l l t he s p e cia l t o o l . 47. Us i ng t he s pe ci a l t o o l s , re m o v e t he cr anks ha ft vib rat i o n dampe r. 48. Remove t he a i r cond i t i o ni ng co m pr es s or . 49. Remove t he p o we r s t e e r i ng pump.
50. Remove t he o i l pa n . Re mov e a nd di s c a r d t he o il pa n g a ske t . 51. Remove t he i dl e r pul l e y. 52. Remove t he i dl e r pul l e y. 53. Remove t he e n gi ne f r o nt co ver. Re mov e a nd di s c a r d t he e ngi ne front cove r g as ke t s .
1. Ins t a l l the ne w f ront t imi ng co v e r gas ket s . 2. NOT E: Prio r t o a p pl yin g s e a l e r cle a n t he f ront t imi ng co ver t o e ng ine bl o ck a nd cyli nd e r he a d s e a l i ng s urface s wi t h met a l s ur face cle a ne r .
5. Ins t a l l the i dl e r p ul l e y. Ti ght e n t o 25 Nm. 6. NOT E: Appl y a 10 mm dia me t e r dot of s i l i co ne s e al a nt W S E-M 4G323- A6 or eq ui val ent mee t i ng Ja gua r s pe ci fi cat io n t o t h e e ng i ne f r on t cover t o th e c yl i nde r bl o ck mat i ng j o i nt s .
10. Us i ng t he s pe ci a l t o o l , t i ght e n t he c r a nk s ha f t vibra ti on d ampe r r et a i ni ng b ol t . Ins t al l a ne w cr anks haf t vib r a t i o n ret a i ni ng bo l t . Compl e t e t he ti ght e ni ng s e que nce. S ta g e 1: T o r que t o 120 N m .
15. Conne ct t he g e ne r a t or po s i t i ve ca bl e . Ti ght e n t o 12 Nm. 16. At t ach t he g e ne r a to r po s i t i ve ca bl e prot e ct i ve cove r . 17. At t ach t he a cces s or y drive be l t . 18. Ins t a l l t he a cc e s s o r y drive b e l t t e nsi o ner.
20. NO TE: Ap pl y a 5 mm di amet e r b e ad o f s i li cone ga s k et s e a l a nt W S E- M4G 323-A6 o r equi va l e nt mee t i ng Ja guar s p e ci fi c a t io n on t he ha l f r o und g a s ket s a .
Vehi c le s with 2.0L engi n e 25. Ins t a l l t he he a t e d po s it i ve crank ca s e ve nt i l a t i o n val ve cool a nt ho s e s . All v e h icle s 26. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he (CMP) s e mso r s . Ti ght e n t o 7 Nm.
29. Ins t a l l t he l e f t -hand ig ni t io n c oi l s . Ti ght e n t o 6 Nm. 30. Conne ct t he l e f t -ha nd i g ni ti on coi l s e l ect r i cal conne cto rs.
34. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Ti ght e n t o 6 Nm. Vehi c le s with 2.5L or 3.0L engine 35. Conne ct t he va cuum h os e . 36. At t ach t he wi r i ng harnes s . Ti ght e n t o 10 Nm. 37. Conne ct t he e l e ct r i cal conne ct o rs.
39. At t ach t he wi r i ng harnes s . 40. Conne ct t he e l e ct r i cal conne ct o rs. 41. Ins t a l l t he coo l a nt hos e s . 42. At t ach t he t hr ot t l e cabl e br acket . Ti ght e n t o 9 Nm. 43. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n.
44. At t ach t he cr ui s e cont r ol cab l e . 45. Conne ct t he t hr ot t l e po s i t i o n s e ns o r e l e ct r i cal c onn e cto r . 46. Conne ct t he i dl e a ct ua t or co ntrol val v e e l e ct rical co nnect or . 47. At t ach t he p o s i t i ve cr a n k cas e veni l a t i on ho se .
48. At t ach t he p o s i t i ve cr a n k cas e vent i l at i o n hos e . All v e h icle s 49. Ins t a l l t he a ut omat i c or manua l t rans mis s io n.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Front Mount I n-v e hi c l e Re pa i r Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-0 2 R em ova l 1. D r ai n t he coo l i ng s yst em.
4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 5. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 6. D et a ch t he coo l a nt pi p e .
8. Remove t he e ngi ne mount . 9. Remove t he hydr o mount . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 83 Nm.
3. Tig ht e n t o 80 Nm. 4. Tig ht e n f ixi ngs t o 40 N m o r 48 Nm a s o ut l ine d b e l o w. • NO T E: I f r e usi ng e xis t i ng f i xi ngs , o n vehi cl es bui l t prio r to V IN J24252, t ig ht e n t o 48 Nm. I f ne w fi x i ng s a r e us e d o n a ny vehi cl e t i ght e n t o 40 N m .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Ex haust Manifo ld LH I n-v e hi c l e Re pa i r R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o S e c t i o n 303-03A Engi ne Co o l i ng S ect i o n 303-03B Engi ne Co o li ng .
8. D et a ch t he coo l a nt ho s e. 9. Rai s e t he vehi cl e. 10. Remove t he co o l a nt hos e . 11. Dis c o nne ct t he he a te d o xygen s ens or (HO2S) el e ct r ica l conne ct o r . 12. Remove t he e xhaus t mani f o l d he a t s hie ld r et ai ni ng bo l t .
14. Remove t he e xhaus t mani f o l d he a t s hie ld . 15. Det a ch t he cat al yti c conver t e r . Dis car d t he ret a i ni ng nut s . Re mov e a nd di s c a r d t he r et a i ni ng s t uds . 16. Us i ng a s uit a bl e t o ol remove t he HO 2S . 17.
1. Ins t a l l the e xha us t mani fo l d. Ins t al l t he n e w e xhaus t m a ni fo l d g a ske t . Compl e t e t he ti ght e ni ng s e que nce. Ti ght e n t o 20 Nm. 2. Ins t a l l the H02S. Ti ght e n t o 40 Nm. 3. NOT E: Make s ure t ha t t he r e t a ini ng nut s a r e ti ght e ned twi ce i n th e s eq ue nce sho wn.
7. Connect t he he a t e d oxygen s e nso r (HO 2S ) e l ect r i cal co nne cto r. 8. Ins t a l l the co ol a nt hos e . 9. Lowe r t he vehi cl e . 10. At t ach t he co o l a nt hos e . 11. Ins t a l l t he coo l a nt p ip e ret a ini ng br a ck et . Ti ght e n t o 10 Nm.
12. At t ach t he co o l a nt pi p e . 13. At t ach t he co o l a nt hos e . 14. Ins t a l l t he a ir f i l te r ret a i ni ng br acket . 15. At t ach t he g e ne r a to r wi r i ng ha r ne s s . 16. Ins t a l l t he a ir f i l te r i nt a ke pi pe .
17. Ins t a l l t he coo l i ng fa n mot o r a nd s hroud. For a ddi ti o nal i nfo r mat i o n, r ef e r t o S ect i o n 303-03A Engi ne Coo l i ng S e ct i on 303-03B Engi ne Coo l i ng .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Flexplate I n-v e hi c l e Re pa i r R em ova l 1.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Ex haust Manifo ld RH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he t hree wa y cat al yti c conver t e r (TW C). For add i t i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 309-00 Exhaus t Sy s t e m .
2. Tig ht e n t o 40 Nm. 3. Ins t a l l the t hr ee wa y cat al yti c conve r t e r (TW C). Fo r add it i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 309-00 Exhaus t Sy s t e m .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Flyw he el I n-v e hi c l e Re pa i r R em ova l 1. Remove t he clut ch d i s c a n d p r e s s ur e pl at e . For ad di t i ona l inf o rm a t i o n, r ef e r t o S ect i o n 308-01 Cl ut ch .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Intake Man ifo ld I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1. Remove t he e ngi ne cover (if e q uip pe d ). 2. Remove t he a i r fi l t e r out l e t pi p e .
6. D et a ch t he cr uis e co nt rol ca b le . 7. D et a ch t he t hrot t l e ca b le . 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. De ta ch t he t hr ot t le cabl e . 8. D et a ch t he t hrot t l e ca b le ret a i ni ng br acket .
11. Dis c o nne ct t he e l e ct r ica l conne ct o r s . Vehi c le s with 2.5L or 3.0L engine 12. Dis c o nne ct t he t hr ot t l e bo dy el e c t r i cal co nne ct ors . 13. Dis c o nne ct t he e l e ct r ica l conne ct o r s . All v e h icle s 14. NO TE: 2.
15. Det a ch t he coo l a nt ho se from t he ret a i ni ng cl i ps . Vehi c le s with 2.5L or 3.0L engine 16. Dis c o nne ct t he va cuum ho s e . All v e h icle s 17. Det a ch t he i nj e cto r ha r nes s e l e ct rica l c on ne ct or from t he i nta ke m a ni f o l d s upp o r t bracket .
19. NO TE: 2. 0L s hown , 2.5L a nd 3.0L s i mil a r. Det ach t he e ngi ne wi r i ng ha r ne ss br a ck et . 20. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Det ach t he i nt a ke m a ni f o l d s upp ort br a cket . Vehi c le s with 2.0L engi n e 21.
23. NO TE: Re move a nd di s ca r d the O -ring s e a l . Det ach t he t hr o t t l e b ody. Re mov e t he re ta i ni ng bo l t s. All v e h icle s 24. Remove t he i nt a ke mani f o l d. Re mov e a nd di s c a r d t he i nt a ke m a ni fo l d g a ske t s.
3. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . • NO T E: Do no t ful l y t i g ht en t he r e ta i ni ng bo l t s . I nst a l l t he i nt a k e mani fo l d s uppo rt b r ack e t .
Vehi c le s with 2.5L or 3.0L engine 8. NOT E: Ins t a l l a new O -r i ng s e a l . At t a ch t he t hrot t le bod y. Ins t al l t he re t a i ni ng b ol t s . 9. Connect t he vacuum ho se . All v e h icle s 10. At t ach t he wi r i ng harnes s . Ti ght e n t o 10 Nm.
12. NO TE: Re move t he co ol a nt hos e ca p s. At t a ch t he i nt a k e mani fo l d cool a nt hos e s . 13. At t ach t he co o l a nt hos e t o t he ret ai ni ng cl ip s . 14. Conne ct t he e l e ct r i cal conne ct o rs. Vehi c le s with 2.5L or 3.
16. Conne ct t he t hr ot t l e bo dy e l e ct r i cal conn ect ors . Vehi c le s with 2.0L engi n e 17. Conne ct t he t hr ot t l e bo dy e l e ct r i cal conn ect or. 18. Conne ct t he t hr ot t l e bo dy e l e ct r i cal conn ect or. 19. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket .
20. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. At t a ch t he t hrot t l e ca b le . 21. At t ach t he cr ui s e cont r ol cab l e . 22. At t ach t he p o s i t i ve cr a n k cas e vent i l at i o n hos e .
25. Ins t a l l t he po s i t i ve cr ankc a s e ve nt i l a t i o n ho s e. All v e h icle s 26. Ins t a l l t he a ir f i l te r o ut l e t pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r Out l e t P i pe (303-12A I nt a ke Ai r Di s t ribut i o n a nd Fi l t e r i ng - 2.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Lo w e r Intak e Manifo ld I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1. Remove t he i nt a ke man if ol d . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: I nt a ke Ma nif ol d (303-01A Engi n e - 2.
6. Remove t he e ngi ne cover ret a i nin g b r a cket (i f equi p pe d). 7. D i s conne ct t he f uel i nj e ct or ha r nes s e l e ct rica l conne ct or . 8. W ARNING: Fue l m a y s t i l l be pres e nt i n t he f ue l i nj e ct i on s uppl y m a ni f ol d.
2. Connect t he f ue l i nj e ct o r ha r ne s s e l e ct rica l conne ct o r . 3. Ins t a l l the e ng ine co ver ret a i ni ng br acket (i f e qui pp e d). Vehi c le s with 2.0L engi n e 4. Connect t he e ngi ne co ol a nt t empe rat ure (ECT) e l e ct rica l c o nne ct or .
6. Connect t he e ngi ne co ol a nt t empe rat ure (ECT) a nd f uel t e mpe r at ure s e ns o r e le ctrica l conne ct o r s . 7. Connect t he s p r i ng lo ck co upl i ng. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Spr i ng L ock Co upl i ngs (310-00 Fue l S yst e m - Ge neral I nf o rm a t i o n, Ge ne r a l P roc e dur e s ).
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il Co o ler I n-v e hi c l e Re pa i r R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o S e c t i o n 303-03A Engi ne Co o l i ng S ect i o n 303-03B Engi ne Co o li ng .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il P an I n-v e hi c l e Re pa i r Speci al T ool (s) Acces s o r y Bel t De t e ns i o ner 303-703 R em ova l All v e h icle s 1. D r ai n t he e ngi ne oi l .
6. Remove t he s ump t o t r ans m i s s i on se cur i ng bol t . 7. S l a cken b ut no t r emove t he u ppe r cat a l y s t ret a i ni ng b r acket s u pport s e cur ing b ol t . 8. Repo s i t i on t he ca t a l ys t ret a i ni ng br acket s upport. All v e h icle s 9.
10. NO TE: Do not remove t he A /C compr es s o r uppe r r et a i ni ng bol t s . Re po s i t i o n t he a i r condi t i oni ng (A/C) compr es s o r . 1. Re move t he A /C compr es s o r lo we r ret a i ni ng bo l ts . 2. Lo os e n t he A/C co mpr e s s o r upp e r r e t ai ning b ol t s .
14. Remove t he o i l pa n . Re mov e a nd di s c a r d t he gas ke t. Cle a n a nd i nsp e ct t he o i l pa n a nd t he cyli nd e r b l ock s e al in g s ur fa ce s us ing met a l s urface cle a ner or e qui va le nt mee t i ng Jagua r s pe ci f i ca ti o n W SE-M 5B392- A.
4. Tig ht e n t o 10 Nm. 5. Tig ht e n t o 25 Nm. Vehi c le s with 2.0L engi n e 6. Tig ht e n t o 25 Nm. 7. Tig ht e n t o 45 Nm. JagDocs.com.
8. Tig ht e n t o 25 Nm, 9. Tig ht e n t o 55 Nm. 10. Ti g ht e n t o 55 N m. Vehi c le s with 2.5L or 3.0L engine 11. Ins t a l l t he t r a ns f e r cas e . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Sect i on 308-07 Trans f er Cas e . All v e h icle s 12.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il P ressure Sender I n-v e hi c l e Re pa i r R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 100-02 Ja cking a nd L i f t i ng .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - O il P um p I n-v e hi c l e Re pa i r R em ova l 1. Remove t he t i mi ng chai ns. For a dd it i o nal i nfo r mat i on, ref e r t o Ti mi ng Dr ive Co mpone nt s .
2. Ins t a l l the o i l pump t ube . Ins t al l a ne w O -r i ng s e a l . Ti ght e n t o 10 Nm. 3. Tig ht e n t o 5 Nm + 45°. 4. Ins t a l l a ne w e ngi ne o i l f i l t e r. 5. Ins t a l l the t imi ng chai ns . Fo r add i t i o nal i nf or ma ti on, re fe r to T i m i n g Dr ive Co mpone nt s .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Ti mi ng Drive C om ponents I n-v e hi c l e Re pa i r R em ova l 1. Remove t he e ngi ne f r ont co v e r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Eng i ne Fr ont Co ver (303-01A Engi ne - 2.
7. NOT E: Ke e p t he t imi ng chai n t ens i o ne r r a t che t rel e a s e d. Re po s i t i o n t he t i ming chai n t e ns i o ne r pl unger. 8. Ret a i n t he t imi ng chai n t e ns i one r plun ge r . 9. Remove t he right -ha nd t i mi ng chai n t e ns i o ne r .
12. CAUT I O N: I ns p e ct a nd repl a ce the O -r ing s e a l i f ne ces s a r y. Re move t h e r i ght -ha nd t i mi ng cha i n i nner gui de . 13. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e.
17. Remove t he l ef t -han d t i mi ng cha i n t e ns i o ne r . 18. Remove t he l ef t -han d t i mi ng cha i n i nne r g ui de . 19. Remove t he l ef t -han d t i mi ng cha i n. 20. CAUT I O N: I ns p e ct a nd repl a ce the O -r ing s e a l i f ne ces s a r y.
22. Remove t he cr anks haf t s pr ocket . Insta llat ion 1. NOT E: Make s ure t he cr anks ha ft s pr ocket t i ming marks a r e f a cing out wa r ds .
4. Rot a t e t he right -hand i nt a k e c a msha f t c l ockwi s e unt i l t he cams ha ft s p r o cket a l i gnment ma r k i s a t t he 5 O' c l o ck pos i t i o n a nd rot a t e t he r i ght -.
9. CAU TI O N : Do no t manual l y a dj us t t he t i mi ng chai n t ens i one r . I nst a l l t he l e f t-ha nd t i ming cha in t e ns i o ne r . Ti ght e n t o 25 Nm. 10. CAUT I O N: Do no t manu al l y a d j us t t he t i mi ng cha i n t ens i o ne r .
14. CAUTI O N S : Make s ur e t he cr anks ha f t keyway i s a t t he 3 O 'c l ock p os i t io n, the a li g nment mark o n t he r i ght -han d i nt a ke ca msh af t s pr ock e t i s a t the 5 O&.
19. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e. • NO T E: Ro t a t e t he cr a nk s ha ft u s i ng ha nd t oo l s o nl y Rot at e t he cr anksha f t t wo c ompl et e t ur ns cl o ckwis e t o make s ur e t he val ve s a nd p i s t ons do n ot cl as h.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C o v er LH I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1.
6. D et a ch t he po s i t i ve cr a nk cas e ve nt i l a t i o n ho se . 7. D et a ch t he he a t e d po si t i v e cr ankc a s e ve nt il a t i on val ve coo l ant p i pe s . All v e h icle s 8. D i s conne ct t he var i a bl e ca ms haf t t i ming (VCT) s o l e no i d e l ect r i cal conne ct or.
10. Remove t he va l ve cover. Re mov e a nd di s c a r d t he val ve cove r g a ske t s. 1. 2.5 and 3.0L sh o wn, 2.0L s i m i l a r. Insta llat ion 1.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C o v er RH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he i g ni t i o n coi l s . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o Sect i on 303-07A Engi ne I g ni t io n S ect i o n 303-07B Gl o w P l ug S ys t e m .
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P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gineVehi cles With: 5-Spee d Manual Transm i ssi on - MT7 5/ 6-Spe ed Manual T ransaxl e - MM T.
Ri g ht -hand ha l f s haf t s pl i t t e r 307-442 Ri g ht -hand ha l f s haf t s pl i t t e r ha nd le 307-443 P i ni o n oi l s e a l r e m o ver 308-208 Li nk s ha f t l i mi t i ng t o ol 307-446 Engi ne l i f t i ng kit 303-707 R em ova l All v e h icle s 1.
For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Co ndi t io ni ng (A/C) S ys t e m Re cover y, Eva cuat i on a nd Cha r ging (412- 00 Cl imat e Co nt r o l S ys t em - Gene r a l I nf o r m at i o n, Ge neral Proced ur e s ). 6. Remove t he f r ont whe e ls a nd t i res .
12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 13. NO TE: Suppor t t h e br a ke ca l ip e r as s e mbl y us ing t i e s t r a p s . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re po s i t i o n a n d s e cur e t he br a ke cal i p e r a s s e mbl y.
17. Remove t he co o l i ng f a n mot o r a nd s hroud. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Fan Mot o r a nd Shr o ud (303-03 A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V 6 - A JV6/3 .0L NA V6 - AJ27, Remova l a nd I ns t a ll a t i o n).
25. Det a ch t he coo l a nt ho se . 26. Det a ch t he coo l a nt ho se . 27. Det a ch t he coo l a nt ho se s . Vehi c le s with 2.0L engi n e 28. Det a ch t he cr uis e co nt r ol ca bl e .
29. Det a ch t he acce l e r at o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n. 2. De ta ch t he a ccel e rat o r cabl e . 30. Det a ch t he acce l e r at o r cab l e r et ai ni ng bracket . 31.
33. NO TE: U pp e r s el e ct or cabl e s hown, l ow er s e l e ct o r cab l e s i mil ar. Det ach t he s e le cto r cabl e s. 1. P r es s t he but t o n. 2. De ta ch t he s e l e ct or cabl e s . 34. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps .
38. Us i ng s pe ci a l t ool 418-535, di s conne ct th e e ng i ne co nt rol modul e (ECM) e l e c t r i cal co nne ct or. 39. Dis c o nne ct t he g round cab l e . 40. NO TE: Drai n t he f lui d i nt o a s ui t a bl e co nt a i ne r. • NO T E: U s e a s ui t a bl e b l a nking pl ug t o s e a l t h e ho s e .
43. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he s t r ut a nd s pr ing as s e m bl y. 44. Rai se th e v e hi cl e . 45. Ins t a l l t he s p e cia l t o o l . 46. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er.
48. Po s i t i o n and adj ust t he s p e ci al t oo l e ngi ne he i ght a d j us t e r s . 49. Remove t he e n gi ne s upp ort br a cket . 50. Remove t he t r ans a x l e mount br a ck et s e cur ing nut . 51. Remove t he cl ut ch mas t e r cyli nd e r t o cl ut ch s l a ve cyli nde r hi gh-pr e s s ure pi pe s u pport b r acket .
53. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e . 54. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he f r ont s ubf r ame. 55. W A RNING: Ro t at e t he s pe ci al t o o l he i ght a dj us t ment val v e s l o wl y.
58. Ins t a l l t he s p e cia l t o o l . 59. Remove t he l ef t -han d e xhaus t mani f o l d he a t s hi e l d. 60. Ins t a l l t he s p e cia l t o o l .
62. Remove t he ce nt e r e xhaus t he at s hi e l d ret a i ni ng bol t s . 63. Remove t he ce nt e r e xhaus t he at s hi e l d . 64. Ins t a l l t he s p e cia l t o o l . 65. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front wh ee l hub ret a i ni ng nut s .
66. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Us i ng t he s p e ci a l t o ol s , de ta ch t he hal fs ha ft s . 67. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e t i e rod e nd r et a i ni ng nut s. 68. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r .
71. Us i ng t he s pe ci a l t o o l s , re m o v e t he l e ft -han d ha l f s haf t . 72. Remove a nd di s car d t he hal fs ha ft s na p r i ng. 73. Remove t he p o we r s t e e r i ng hi gh-pres s ur e pi p e ret a i ni ng bol t . 74. Dis c o nne ct t he p o we r s t e e r i ng hi gh-pres s ur e pi p e .
75. Ins t a l l t he s p e cia l t o o l . 76. Remove t he e n gi ne rol l r e s t r i ct o r r e t ai ni ng bo l t . 77. Remove t he e n gi ne rol l r e s t r i ct o r .
78. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent . Us i ng t he s p e ci a l t o ol , re mov e t he e ng i ne and t rans a xle f r om t he s ub frame.
81. Remove t he t r ans fe r ca se Y b r acket . 82. Remove t he ha l f s haf t s ea l . 83. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.
86. Dis c o nne ct t he rig ht -ha nd h ea t e d oxy ge n s e n s or (HO 2S ) e l e ct rical conne ct or. 87. Remove t he rig ht -ha nd cat a l yti c co nver t e r r et a i ni ng b o l t s . 88. Remove t he rig ht -ha nd cat a l yti c co nver t e r . Re mov e a nd di s c a r d t he r et a i ni ng nut s .
91. Us i ng t he s pe ci a l t o o l , det a ch t he t r a ns fe r ca s e l i nk sha f t. 92. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.
95. Remove t he t r ans fe r ca se . 96. Remove a nd di s car d t he t r ans f er cas e O -r i ng s e a l . 97. Remove a nd di s car d t he li nk s ha ft s na p ring. 98. Remove t he l i nk s ha f t l imi t i ng to o l . 1. Re move t he r e t a i ni ng bo l t .
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104 . Re move t he t r a ns axl e r et a i ni ng bol t s . 105 . Re move t he t r a ns axl e r et a i ni ng bol t s . 106 . Re move t he t r a ns axl e.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gineVehi cles With: 5-Spee d Autom atic T ransa xle - JATC O / 6-Sp eed Autom atic T r ansaxl e.
Ri g ht -hand ha l f s haf t s pl i t t e r 307-442 Ri g ht -hand ha l f s haf t s pl i t t e r ha nd le 307-443 P i ni o n oi l s e a l r e m o ver 308-208 Li nk s ha f t l i mi t i ng t o ol 307-446 Engi ne l i f t i ng kit 303-707 R em ova l All v e h icle s 1.
For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Co ndi t io ni ng (A/C) S ys t e m Re cover y, Eva cuat i on a nd Cha r ging (412- 00 Cl imat e Co nt r o l S ys t em - Gene r a l I nf o r m at i o n, Ge neral Proced ur e s ). 6. Remove t he f r ont whe e ls a nd t i res .
12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 13. NO TE: Suppor t t h e br a ke ca l ip e r as s e mbl y us ing t i e s t r a p s . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re po s i t i o n a n d s e cur e t he br a ke cal i p e r a s s e mbl y.
17. Remove t he co o l i ng f a n mot o r a nd s hroud. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Fan Mot o r a nd Shr o ud (303-03 A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V 6 - A JV6/3 .0L NA V6 - AJ27, Remova l a nd I ns t a ll a t i o n).
24. NO TE: Secur e t he s e le cto r cabl e us i ng t i e s t r aps Di s conn ect t he s el e ct or cabl e. 25. Dis c o nne ct t he a ut o mat i c t rans a xle e l e ct r i cal co nne cto rs. 26. Lowe r t he vehi c l e . 27. Remove t he a i r cl ea n e r .
30. Det a ch t he coo l a nt ho se . 31. Det a ch t he coo l a nt ho se s . Vehi c le s with 2.0L engi n e 32. Det a ch t he cr uis e co nt r ol ca bl e . 33. Det a ch t he acce l e r at o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n.
34. Det a ch t he acce l e r at o r cab l e r et ai ni ng bracket . 35. Det a ch t he coo l a nt ho se s . All v e h icle s 36. Det a ch t he ba t t e ry cab l e s. 37. Dis c o nne ct t he e n gi ne h a r ne s s e l e ct rica l conne ct o r . JagDocs.
38. Us i ng s pe ci a l t ool 418-535 di s conne ct t he e ngi ne cont r ol modul e ( ECM) e l e ct r i cal conne c t o r . 39. Dis c o nne ct t he g round cab l e . 40. NO TE: Drai n t he f lui d i nt o a s ui t a bl e co nt a i ne r. • NO T E: U s e a s ui t a bl e b l a nking pl ug t o s e a l t h e ho s e .
43. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he s t r ut a nd s pr ing as s e m bl y. 44. Rai se th e v e hi cl e . 45. Ins t a l l t he s p e cia l t o o l . 46. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er.
48. Po s i t i o n and adj ust t he s p e ci al t oo l e ngi ne he i ght a d j us t e r s . 49. Remove t he e n gi ne s upp ort br a cket . 50. Det a ch t he s upp or t ba r .
53. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 54. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e .
58. Remove t he t r ans a x l e mount . 59. Ins t a l l t he s p e cia l t o o l . 60. Remove t he l ef t -han d e xhaus t mani f o l d he a t s hi e l d.
62. Remove t he up pe r exha us t he a t s hie ld . 63. Remove t he ce nt e r e xhaus t he at s hi e l d ret a i ni ng bol t s . 64. Remove t he ce nt e r e xhaus t he at s hi e l d .
66. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front wh ee l hub ret a i ni ng nut s . 67. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Us i ng t he s p e ci a l t o ol s , de ta ch t he hal fs ha ft s . 68. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar.
71. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he whe e l knuck l e s . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e s . 72. Us i ng t he s pe ci a l t o o l s , re m o v e t he l e ft -han d ha l f s haf t .
76. Ins t a l l t he s p e cia l t o o l . 77. Remove t he e n gi ne rol l r e s t r i ct o r r e t ai ni ng bo l t . 78. Remove t he e n gi ne rol l r e s t r i ct o r .
79. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent . Us i ng t he s p e ci a l t o ol , re mov e t he e ng i ne and t rans a xle f r om t he s ub frame.
82. Remove t he t r ans fe r ca se Y b r acket . 83. Remove t he ha l f s haf t s ea l . 84. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.
87. Dis c o nne ct t he rig ht -ha nd h ea t e d oxy ge n s e n s or (HO 2S ) e l e ct rical conne ct or. 88. Remove t he rig ht -ha nd cat a l yti c co nver t e r r et a i ni ng b o l t s . 89. Remove t he rig ht -ha nd cat a l yti c co nver t e r . Re mov e a nd di s c a r d t he r et a i ni ng nut s .
92. Us i ng t he s pe ci a l t o o l , det a ch t he t r a ns fe r ca s e l i nk sha f t. 93. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r cas e in te r nal s e a l , m a ke s ur e t he l i nk s haf t i s not ret ract e d f ur t her t hat 200 mm (7.
96. Remove t he t r ans fe r ca se . 97. Remove a nd di s car d t he t r ans f er cas e O -r i ng s e a l . 98. Remove a nd di s car d t he li nk s ha ft s na p ring. 99. Remove t he l i nk s ha f t l imi t i ng to o l . 1. Re move t he r e t a i ni ng bo l t .
101 . Us i ng t he sp e ci a l t oo l , re move a nd d i s card t he l i nk s h af t o i l s e a l. All v e h icle s 102 . Re move t he s ta rte r mot o r .
105 . NO TE: Ro t at e t h e t o r q ue co nver t e r t o gai n a cces s t o t h e r e m a i n ing r e t a i ni ng bo l t s . Re move t h e t o rqu e conve r t e r r et ai ni ng bo l t s . 106 . Re move t he t r a ns axl e r et a i ni ng bol t s . 107 .
110 . W ARNIN G: Do no t l et t he t o r que converte r dr op out o f t he tra nsa xl e . Fa i l ur e t o f ol lo w t hi s i ns truc t i o n may r e s ul t i n p e r s o nal i njur y.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Dis a s s e mbl y Speci al T ool (s) W r e nch s t r ap-uni vers al 303-D 055 Cr a n ks ha.
3. D i s conne ct t he po s it i ve cr ankcas e ve nt i l a t i o n (P CV) hos e . 4. D i s conne ct t he e l ect r i cal conne ct o rs. 5. D i s conne ct t he f uel p res s ur e r eg ul a t or va cu um ho s e . 6. Remove t he f uel p res s ur e r eg ul a t or bracket .
8. D et a ch t he e ngi ne wiring ha r ne s s f r om t he i nt a ke mani fo l d r e a r r et a i ni ng b r ack e t . 9. D et a ch t he i nt a ke mani fo l d r ea r r et a i ni ng brack e t .
13. Remove t he e n gi ne b reat he r hos e . 14. Remove t he e va porat i ve e mis s i o n p ur ge v a l ve hos e . 15. Dis c o nne ct t he o i l co o le r cool a nt ho s e s . 16. Remove t he co o l a nt hos e . 17. Remove t he co o l a nt hos e . JagDocs.
18. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 19. Det a ch t he eng i ne harnes s . 20. Det a ch e ngi ne ha r nes s . 21. Remove t he rea r k no c k s e ns o r . 1. De ta ch t he knock s e ns or wi r i ng ha r nes s . 2. Re move t he r e a r knock s e ns o r.
23. Det a ch t he eng i ne harnes s ret a i ni ng br a cket . 24. Det a ch t he eng i ne harnes s . 25. Dis c o nne ct t he rig ht -ha nd i g ni t i o n coi l s . 26. Det a ch t he eng i ne harnes s . 27. Dis c o nne ct t he l ef t -han d cams ha f t p os i t i on s e ns or .
28. Dis c o nne ct t he l ef t -han d i g nit i o n coi l s . 29. Dis c o nne ct t he e n gi ne wi r i ng ha r ne ss e l e ct rical co nnect ors. 30. Remove t he e n gi ne wi r i ng ha r ne ss . 31. Remove t he i gni t i o n coi l s . 32. Remove t he l ow er i nt a ke mani f ol d and in je ct o r s uppl y m a nif ol d .
33. Remove a nd di s car d t he lo we r int ake ma ni f ol d ga s ke t s . 34. Remove t he l ef t -han d knock s e ns o r. 35. Remove t he a cces s o r y drive be l t . 1. Us e a 3/8 i nch drive ba r t o r e l e a s e t h e a cces s ory dr ive be l t t e nsi o ner.
38. Remove t he p o we r s t e e r i ng pump. 39. Remove t he a i r cond i t i o ni ng (A/C) compr es s o r . 40. Remove t he A /C co mpr e s s or mount i ng bracket . 41. Remove t he o i l l e v e l i ndi cat or t ube . 1. Re move a nd di s car d t he O -r i ng s ea l .
43. NO TE: Ri ght -hand s ho wn, Le f t -ha nd s imi l a r . Re move t h e e xhaus t mani f ol ds . 44. Remove t he f l ywhe el . P r e vent t he e ng ine f r om r o t a t i ng. 45. Remove t he e n gi ne re ar ba cking pl a t e . 46. Remove t he o i l f i l t e r hous i ng a s s e mbl y.
48. Remove t he co o l a nt cr os s o ve r t ub e . Re mov e a nd di s c a r d t he O -r ing s e a l s . 49. Remove t he wa t e r pum p a nd coo l an t ho s e a s s e mbl y. 1. De ta ch t he ho s e . 2. Re move t he wa t e r pump a nd coo l a nt h os e as s e mbly.
53. Us i ng t he s pe ci a l t o o l , r e move t he cr anksha ft vi br a t i o n da mper. 54. Remove t he l ef t -han d i d l e r pu l l e y. 55. Remove t he o i l pa n .
58. Remove t he cr anks haf t p os i t i on (CKP) s e ns o r puls e whe e l . 59. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e. I nst a l l t he cr an k s ha ft p ul le y r et a ini ng bol t a nd wa s he r.
63. Remove t he rig ht -ha nd t i ming c ha i n o ut e r g ui de . 64. Remove t he rig ht -ha nd t i ming c ha i n. 65. Remove t he rig ht -ha nd t i ming c ha i n i nne r gui de . 66. Remove t he cr anks haf t o ut e r s proc ket . 67. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se .
68. CAUT I O N: Do no t r ot a t e t he cr anks haf t count erc l ockwi se . The ti ming c ha i ns ma y bi nd ca usi ng e ngi ne da mag e. Rot at e t he cr anksha f t c l o ckwis e unt il t he cr anks.
73. Remove t he l ef t -han d t i mi ng cha i n o ut e r g ui de . 74. Remove t he cr anks haf t i nne r s prock e t. 75. Remove t he RH exha ust cams ha ft b e a r i ng cap b ol ts eve nl y. Re mov e t he e xha us t ca msh a ft be a r i ng caps . 76.
78. Remove t he RH in le t ca m s ha f t . 79. Remove t he L H e xhaus t ca msh a ft be ar i ng cap bol t s e ve nl y. Re mov e t he e xha us t ca msh a ft be a r i ng caps . 80. Remove t he L H e xhaus t ca msh a ft . 81. Remove t he L H i nl e t ca ms haf t b ea ring ca p b o lt s e ve nl y.
83. NO TE: Re move t he b o l t s i n t he i ndi cat e d s e q uence . Re move t h e RH cyli nder he a d. Dis car d t he ga s ke t . 84. NO TE: Re move t he b o l t s i n t he i ndi cat e d s e q uence . Re move t h e L H cyli nd e r he ad. Dis car d t he ga s ke t .
88. Remove t he o i l pump. Re mov e a nd di s c a r d t he O -r ing s e a l . Ins p e ct t he o i l pump fo r da mage a nd we a r . 89. CAUT I O N: P i s t o ns , conne c t i ng r ods a nd conne ct i ng r od be a r i ng s s houl d be number e d t o m a ke s ur e t he y a re r e a s s embl e d i n t he sa me pos i t i on.
94. NO TE: Mark t he pos i t i on o f the upp e r a nd l o we r cr a nks ha ft ma i n bea ring a nd t he cr anks ha f t t hru s t be a r i ng fo r r e as s e mbl y. Re move t h e l o we r cr a nksh a f t be a rings . 1. Re move t he l o we r cr a nks ha ft t hr us t mai n b e aring.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C ylinder Head Dis a s s e mbl y a nd As s e mbl y o f Sub a s s e mbli e s Speci al T ool (s) Va l ve S p r i ng Co mpr es s o r 303-252 D isa ssem bly 1.
Gene r a l I nf o r m at i o n . 6. Remove t he pi pe pl ugs a nd a l i gnm e nt do we l s a s nece s s ary t o cl e an t he cyli nde r he ad s . A ssemb ly 1. W ARNING: Eye p rot e cti o n i s requi r ed during us e o f compr e s s e d a ir. Fai lu r e t o fo l l o w t he s e i nst ru ct i o ns may res ul t in pe rso na l i nj ur y.
6. Ins t a l l the bucket t a ppe t a nd s hi m a s s e mbl i e s . JagDocs.com.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Pisto n Dis a s s e mbl y a nd As s e mbl y o f Sub a s s e mbli e s D isa ssem bly 1.
6. W ARNING: T he re ta ini ng r i ngs ha ve a t e nde nc y t o s pr i ng o ut dur ing r emova l . Co v e r t he e nd o f th e pi n bo r e wit h a ha nd o r a rag whe n r e m o ving th e ret a i ni ng r i ng. Eye p r o te cti on s houl d b e wo r n. Fa i l ur e t o fo l lo w t he s e ins t ruc t i o ns m a y r e s ult in pers ona l i nj ur y.
5. Ins t a l l the s e cond oi l cont r o l r i ng. 6. Ins t a l l the o i l cont rol s pa ce r r ing. 7. Ins t a l l the f i rst oi l cont r ol r i ng. 8. Ins t a l l the s e cond compr es s i o n r ing. The t o p of t h e s e cond co mpr e s s io n ring h a s a "0" m arked on i t .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine As se mbl y Speci al T ool (s) W r e nch Strap-Uni ve r s a l 303-D 055 Cr anks haf t Re a.
4. Ins t a l l the upp e r cr anks ha ft mai n b e a r ing s . Lubricat e t he b e a r i ngs and t hru s t wa s he r . 5. CAU TI O N : Avoi d d a mage t o an y c r a nk s ha f t j o ur nal bea ring s ur fa ce s .
9. CAU TI O N : Bo l t s 1 t hr o ug h 16 a r e t i g ht e n-t o -y i e l d a nd mus t be r e pl a ce d. • NO T E: T ig ht e n t he bo l t s i n t he i ndi ca t e d s e que nce i n f our s t ag e s .
11. NO TE: Al t e rn a t e bo l t t ig ht eni ng to c orr e ct l y s e at the cr anks ha f t r ea r oi l s e al unt i l i t i s f l us h wi t h t he cyli nd e r b l o ck . Us i ng t he s p e ci a l t o ol s , i ns t al l t he cr anks haf t r ea r oi l s e a l .
17. CAUT I O N: O i l p a n ba ff l e nut s a r e t i ght e ned t o yie ld a nd mus t no t be r e us e d. • NO T E: T ig ht e n t he bo l t s i n t he i ndi ca t e d s e que nce i n t wo s ta g e s . I nst a l l t he o i l pa n ba f f l e . S ta g e 1: 5 Nm S ta g e 2: 45° 18.
22. Ins t a l l a n ew cy l i nd e r h ea d ga s ket (LH s ho wn - RH s i mil a r ). 1. Make s ur e t he cyli nde r he ad dow el s a r e corr e ct l y lo ca t e d . 2. I ns t a l l a ne w cyli nde r he a d g a s ket . 23. NO TE: I ns t a ll t he bo l t s i n th e i ndi cat e d s e quence .
27. Ins t a l l t he LH e xhau st ca ms ha ft . 28. CAUT I O N: Do no t i ns t a l l the cyli nde r hea d cams ha f t j o ur n a l th r ust cap s unt i l the ca msh af t j ournal ca ps a r e in s t a l l e d or dama ge t o t he th r ust cap s may occur .
32. Ins t a l l t he RH exha us t c a msha f t be a r i n g cap bol t s eve nl y. Ins t al l t he e xhaus t ca ms ha ft be a r i ng caps . 33. Rot a te t he righ t -ha nd i nt a ke cams ha ft cl ockwi.
37. Ins t a l l t he l e f t -hand t i mi ng chai n i nne r gui de . 38. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers o n t he vi ce j aws to pr ot ect t he t i mi ng cha in te ns i o ne r . S ecur e t he l e f t -ha nd ti ming c ha i n t e ns i one r in t he vi ce j a ws .
42. Ins t a l l t he l e f t -hand t i mi ng chai n t e ns i on e r . Ti ght e n t o 25 Nm. 43. Rel e as e t he t e ns i on i n t he l e ft -hand t imi ng chai n t ens i o ne r .
48. Ins t a l l t he cr a nks haf t o ut e r s proc ket . 49. Ins t a l l t he r i ght -ha nd t i m in g chai n i nne r gui de . Ti ght e n t he ret a i ni ng bol t s in t he s e que nce s ho wn i n t wo s t a ge s . S ta g e 1: T i ght en bol t 1 t o 25 N m.
53. CAUT I O N: Dur ing t i m i ng cha i n t e ns i o ner compres s i o n, d o no t r e l e a s e t he rat chet s t e m unt i l t he t i ming cha in t e ns io ne r pi s t on i s f ul ly bot t ome d i n i t s bo r e o r da m a ge t o t he r at chet s t e m wi l l r e s ul t .
58. CAUT I O N: Ma k e s ure t he r i ght -ha nd t i mi ng cha i n a l i gnment m a r k s ha ve remai ne d corr e ct l y po s i t io ne d t o t he c a m s ha f t s p r ocket and c r a nk s ha f t s p r ocket al i g nment mark s . Make s ur e al l th e t i m i ng cha i n a l i g nment mar ks a re i n th e pos i t i o ns s ho wn.
63. Carr y out a v a l ve cl e aran c e check. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Va l ve Cl e a r a nce Check i n t hi s s e ct i o n.
68. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he val ve covers. Compl e t e t he ti ght e ni ng s e que nce. Ti ght e n t o 10 Nm. 69. Ins t a l l t he l e f t -hand id l er pul l e y. Ti ght e n t o 25 Nm. 70. Us i ng t he s pe ci a l t o o l s , i ns t a ll t he cr anksha f t pul l e y.
73. Ins t a l l t he wa t e r pum p a nd cool ant ho s e a s s e mbl y . 1. At t a ch t he hos e . 2. I ns t a l l t he wa t e r pum p a n d co o l a nt hos e as s e mbl y. Ti ght e n t o 25 Nm. 74. NO TE: I ns t a ll n e w coo la n t cr o s s ove r O-r i ng s e a l s .
78. Ins t a l l t he e ngi ne rear ba cking pl a t e . 79. Ins t a l l t he f l ywhee l . P r e vent t he e ng ine f r om r o t a t i ng. Ti ght e n t o 80 Nm. 80. NO TE: Ri ght -hand s ho wn, Le f t -ha nd s imi l a r . I nst a l l t he e xhaus t mani f ol ds .
83. Ins t a l l t he A/C co mpr e s s or mount i ng b rack e t. Ti ght e n t o 25 Nm. 84. Ins t a l l t he a ir co ndi t io ni ng (A/C) co m pr es s or . Ti ght e n t o 25 Nm. 85. Ins t a l l t he po we r s t e e r i ng pu m p. Ti ght e n t o 25 Nm. 86.
88. Ins t a l l t he a cc e s s o r y drive b e l t . 1. Us e a 3/8 i nch drive ba r t o r e l e a s e t h e a cces s ory dr ive be l t t e nsi o ner. 2. I ns t a l l t he a c ce ss o ry d r i v e be l t . 89. Ins t a l l t he l e f t -hand knock s e ns or.
93. Ins t a l l t he e ngi ne wi r i n g ha r ne s s . Ti ght e n t o 10 Nm. 94. Conne ct t he e ngi ne wi r i ng ha r ne s s e l e ct rica l co nnect o r s . 95. Conne ct t he l e f t -ha nd i g ni ti on coi l s . 96. Conne ct t he l e f t -ha nd ca ms haf t pos i t i on s ens or .
98. Conne ct t he rig ht -ha nd ig ni t io n c oi l s . 99. At t ach t he e ngi ne h a r n e s s . 100 . At t ach t h e e ng i ne ha r ne s s ret a i ni ng br a c ket . 101 . Di s conne c t t h e right -ha nd cams ha ft p o s i t i on s e ns or. 102 .
103 . At t ach e ngi ne ha rn es s . 104 . At t ach t h e e ng i ne ha r ne s s . 105 . Conne c t t he e l e ct r ica l conne ct o r s . 106 . In s t a l l t he co ol a nt hos e .
108 . Conne c t t he o i l coo l e r coo l a nt ho s e s . 109 . In s t a l l t he e va porat i ve emi s s i o n p ur ge v a l ve ho s e . 110 . In s t a l l t he e n gi ne b reat her ho s e . 111 . In s t a l l ne w i nt a ke mani fo l d gas ke ts . 112 .
113 . Conne c t t he e va porat i v e e mis s i o n ca ni s t e r pur g e val v e t rans f er pi pe. 114 . At t ach t h e i nt a ke mani f o l d r e ar r e t a i ni ng b r a cket . Ti ght e n t o 10 Nm. 115 . At t ach t h e e ng i ne wi r i ng harnes s from t he in t a ke man if ol d rear r et a i ni ng b r ack e t .
118 . Ti ght e n t o 7 Nm. 119 . Conne c t t he f ue l pres s ur e r e gul a t o r vacuum ho s e . 120 . Conne c t t he e l e ct r ica l conne ct o r s . 121 . Conne c t t he po s i t i ve cr an kc as e ve nt i la t i o n (P CV) ho s e . 122 . Conne c t t he t hr ot t l e po s i ti o n s ens o r .
123 . Conne c t t he t hr ot t l e mot or e l ect r i cal co nnect o r. JagDocs.com.
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3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 47 Nm. 4. Ins t a l l the a cces s co ver. Ti ght e n t o 10 Nm. 5. Ins t a l l the dus t cover . Ti ght e n t o 10 Nm. 6. Ins t a l l the s t art er mot o r . Ti ght e n t o 35 Nm.
7. NOT E: Us i ng a s ui t a bl e s ur f a ce cl ea ne r , W S E- M5B392 -A o r e qui val e n t, m e e t i ng t he Jagua r s pe ci f i cat i on . Cl e a n t he s e a l f a ce o n t he t r a nsf e r cas e bef o r e i ns ta l l i ng t he ne w l i nk s ha ft o i l se a l.
12. NO TE: Do not t ig ht e n t he engi ne r o l l res t ricto r br acket t o p re ta i ni ng bol t s a t t hi s s t a ge a t t hi s s t a ge . I nst a l l t he e n gi ne r o l l r e s t rict o r br acket . Ins t al l t he e ngi ne r o ll re st r i ct o r br acket t o p ret a i ni ng bol t s .
17. NO TE: Do not t ig ht e n t he c a t a l yt i c conver t e r r et ai ni ng bo l t s a t t hi s s t a ge . I nst a l l t he cat a l yt i c co nverte r moun t br acket . 18. Ins t a l l t he cat a l yti c converte r mount br acke t r e t ai ni ng bo l t .
22. CAUT I O N: N e v e r us e j oi nti ng compound f o r war d o f the ca t a l yt i c c on ver t e r . Fa i l ur e t o f ol l ow th i s i ns t r uct io n m a y r e s ul t i n d a mage t o th e c ompo ne nt . • NO T E: Make s ur e t he ret a i ni ng nut s a r e t i ght e ne d tw i ce in t he s e que nc e s hown.
27. Ins t a l l a n ew ha l f s ha f t s e a l . 28. CAUT I O N: Do no t us e e x ces s i ve f o rc e when e ngag ing t he hal fs h a ft t o t he l i nk s ha f t . Fa i l ur e t o f o l l ow t hi s i ns t r u cti o n may res ul t i n dama ge t o t he co mpon ent .
31. Ins t a l l t he ha l f s ha f t a nd i nt erm ed ia t e s haf t a s s e mbl y. Ti ght e n t o 20 Nm. All v e h icle s 32. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent .
35. Remove t he s pe ci a l t o o l . 36. Conne ct t he p o we r s t e e r i ng hi gh-pres s ur e pi p e . Ins t al l a ne w O -r i ng s e a l . Ti ght e n t o 30 Nm. 37. Ins t a l l t he po we r s t e e r i ng hi gh-pres s ur e pi pe ret a i ni ng b ol t.
39. Ins t a l l t he l e f t -hand ha l f s ha ft . 40. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. • NO T E: Make s ur e t he ha l f s ha f t i s a l i gne d t o t he f r ont whe e l hub. At t a ch t he whe e l knuc kl es . 1. Re pos i ti on t he l owe r a r m .
44. Remove t he s pe ci a l t o o l . 45. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d. Ti ght e n t o 10 Nm. 46. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d ret a ini ng bol t s . Ti ght e n t o 10 Nm. 47. Ins t a l l t he uppe r exhau st he a t s hi e l d .
48. Remove t he s pe ci a l t o o l . 49. Ins t a l l t he l e f t -hand e xh a us t m a ni f o l d he a t s hi e l d . Ti ght e n t o 10 Nm. 50. Remove t he s pe ci a l t o o l . 51. Ins t a l l t he t r a ns a xl e mount . Ti ght e n t o 80 Nm. JagDocs.
52. Ins t a l l t he coo l a nt s ys t em t o p ho se . Ins t al l a ne w ga s k e t . Ti ght e n t o 9 Nm. 53. W A RNING: Ra i s e t he s pe ci a l t o o l pl a t f o r m s l o wl y. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n ca n res ul t i n pe r s o na l i nj ury .
57. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 58. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame ret a i ni ng b ol t.
62. Ti g ht e n t he e ngi ne s uppo rt b r a cket ret a i ni ng bol t s . Ti ght e n t o 40 Nm. • NO T E: I f fi x i ngs can be r e -use d o n ve hi cl e s bui l t pr i o r to VIN J24254, t he n t he ol d t or que must b e us e d (48 Nm). If ne w f i xing s a re us ed on a ny ve hi cle us e t he ne w t or que .
68. NO TE: Re move t he b l a nking pl ug from t he ho se . At t a ch t he p owe r s t e ering ho s e . 69. Conne ct t he g round ca bl e . Ti ght e n t o 10 Nm. 70. Conne ct t he e ngi ne co nt rol modul e (ECM ) el e ct r i cal co nnect o r. Us i ng s pe c i a l t o o l 418-5 35, t ig ht e n t o 5 Nm.
73. Ins t a l l t he clut ch mas t e r cyl i nde r t o c l ut ch s l a ve cyli nd e r hi g h pre ss ur e pi pe sup po r t b rack e t. 74. CAUT I O N: I f brake fl ui d i s s pi lt o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r.
Vehi c le s with 2.0L engi n e 78. At t ach t he co o l a nt hos e s . 79. At t ach t he a ccel erat o r cab l e ret a i ni ng br acket . Ti ght e n t o 9 Nm. 80. At t ach t he a ccel erat o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n.
82. At t ach t he co o l a nt hos e s . 83. At t ach t he co o l a nt hos e . 84. At t ach t he co o l a nt hos e . 85. Ins t a l l t he a ir f i l te r i nt a ke pi pe .
88. At t ach t he co o l a nt hos e . 89. NO TE: Re move t he t i e s t r ap s . • NO T E: Re move t he bl a nk i ng p lu gs from t he t ube a nd t he A/C c ompres s o r. At t a ch t he A /C compr es s o r s uppl y a nd r et ur n t ube s . Ins t al l new O-r i ng s e a l s .
95. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he A BS whe e l s pe e d s e ns o r. 96. NO TE: Re move t he t i e s t r ap s . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Det ach a nd rep os i t i on t he brake cal i pe r a ss e mbly.
100 . NO TE: Ri ght -hand s h own, le ft -hand s i mil ar. Re move t h e r e a r ve hi cle t ie down s t rap. 101 . NO TE: Ri ght -hand s h own, le ft -hand s i mil ar. Re move t h e front vehi cl e t i e d o wn s t r a p. 102 . In s t a l l t he f r o nt whe el s a nd t i res .
109 . NO TE: Le f t -ha nd s ho wn, r i ght -hand s i mi l ar. Ti ght e n t he f r ont hub ret a i nin g nu ts . Ti ght e n t o 290 Nm. 110 . Carr y o ut t he u nderbody mis a l i gnment che ck .
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4. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 5. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 6. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 7. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s .
9. Ins t a l l the a cces s co ver. Ti ght e n t o 10 Nm. 10. Ins t a l l t he dus t c o ver . Ti ght e n t o 10 Nm. 11. Ins t a l l t he s t arte r mot o r .
14. Ins t a l l a n ew l i nk s ha f t s n ap r i ng. 15. Ins t a l l a n ew t r ans fe r cas e O -r i ng s e a l . 16. NO TE: Eng a ge the l i nk s ha f t int o t he t r ans a xle .
19. Ins t a l l t he e ngi ne roll r e s t r i cto r br acket s i de re t a i ni ng bo l t s . Ti ght e n t o 35 Nm. 20. Ti g ht e n t he e ngi ne r ol l r e s t rict or bracket r et a i ni ng nut s. Ti ght e n t o 35 Nm. 21. Ti g ht e n t he e ngi ne r ol l r e s t rict or bracket t o p r e t ai ni ng bo l t s .
24. Ti g ht e n t he cat a l yt i c co nverte r m ou nt br acket ret a i ni ng bo l t s. Ti ght e n t o 55 Nm. 25. Ins t a l l a n ew ca t a l yt i c co nv e rte r s e a l i ng r i ng . 26. Ins t a l l ne w c a t al yt i c conver t e r r e t a i ni ng s t uds .
29. Conne ct t he rig ht -ha nd cat a l ys t m on it o r s e ns o r e l e ct r i cal co nnect o r. 30. Ins t a l l t he r i ght -ha nd cat a lyt i c conver t e r r e t a i ni ng bo l t s . Ti ght e n t o 25 Nm. 31. Ins t a l l a n ew ha l f s ha f t s na p ring.
34. Ins t a l l t he t r a ns f e r cas e Y br acket . Ti ght e n t o 55 Nm. 35. Ins t a l l t he t r a ns f e r cas e Y br acket r et a i ni ng bo l t s . Ti ght e n t o 25 Nm. Vehi c le s with 2.0L engi n e 36. Ins t a l l t he ha l f s ha f t a nd i nt erm ed ia t e s haf t a s s e mbl y.
37. CAUT I O N: Ma k e s ure t he r i ght -ha nd drive ha l f s haf t i s su ppo r t e d, fa i lu r e t o fo l l ow t h is i ns t r uct i o n may res ul t i n d a m a ge t o t he co mponent . Us i ng t he s p e ci a l t o ol , i ns t a l l t he e ngi ne a nd t rans a xle to t he s ubframe .
40. Remove t he s pe ci a l t o o l . 41. Conne ct t he p o we r s t e e r i ng hi gh-pres s ur e pi p e . Ins t al l a ne w O -r i ng s e a l . Ti ght e n t o 30 Nm. 42. Ins t a l l t he po we r s t e e r i ng hi gh-pres s ur e pi pe ret a i ni ng b ol t.
44. Ins t a l l t he l e f t -hand ha l f s ha ft . 45. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. • NO T E: Make s ur e t he ha l f s ha f t i s a l i gne d t o t he f r ont whe e l hub. At t a ch t he whe e l knuc kl es . 1. Re pos i ti on t he l owe r a r m .
49. Remove t he s pe ci a l t o o l . 50. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d. Ti ght e n t o 10 Nm. 51. Ins t a l l t he ce nt e r e xhaus t he at s hi e l d ret a ini ng bol t s . Ti ght e n t o 10 Nm. 52. Ins t a l l t he uppe r exhau st he a t s hi e l d .
53. Remove t he s pe ci a l t o o l . 54. Ins t a l l t he l e f t -hand e xh a us t m a ni f o l d he a t s hi e l d . Ti ght e n t o 10 Nm. 55. Remove t he s pe ci a l t o o l . 56. Ins t a l l t he t r a ns a xl e mount . Ti ght e n t o 80 Nm. JagDocs.
57. Ins t a l l t he coo l a nt s ys t em t o p ho se . Ins t al l a ne w ga s k e t . Ti ght e n t o 9 Nm. 58. W A RNING: Ra i s e t he s pe ci a l t o o l pl a t f o r m s l o wl y. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n ca n res ul t i n pe r s o na l i nj ury .
62. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 63. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame ret a i ni ng b ol t.
67. Ti g ht e n t o t he s uppo r t ba r ret a i ni ng bol t s . Ti ght e n t o 25 Nm. 68. Ins t a l l t he e ngi ne s up port b r acket . Ti ght e n t o 80 Nm. 69. Ti g ht e n t he s uppo rt ba r ret a i ni ng bo l t s . Ti ght e n t o 25 Nm. 70. Remove t he s pe ci a l t o o l .
73. At t ach t he co o l a nt pi p e . Ti ght e n t o 9 Nm. 74. Conne ct t he s pr i ng l o ck coupl in g. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Spr i ng L ock Co upl i ngs (310-00 Fue l S yst e m - Ge neral I nf o rm a t i o n, Ge ne r a l P roc e dur e s ).
78. Conne ct t he e ngi ne h a r nes s e l e ct r i cal conne cto r . Ti ght e n t o 10 Nm. 79. At t ach t he b a t t e r y cab le s . Ti ght e n t o 10 Nm. Vehi c le s with 2.0L engi n e 80. At t ach t he co o l a nt hos e s . 81. At t ach t he a ccel erat o r cab l e ret a i ni ng br acket .
82. At t ach t he a ccel erat o r cab l e . 1. Re pos i ti on t he acce l e r at o r l e ver t o t he f ul l y op e n p o s i t i o n. 2. At t a ch t he a ccel e r a t or cabl e . 83. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 84. At t ach t he co o l a nt hos e s .
86. At t ach t he co o l a nt hos e . 87. Ins t a l l t he a ir f i l te r i nt a ke pi pe . 88. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12A In t a ke A i r Di s t r i b ut i o n and Fil t e r i ng - 2.
94. Ins t a l l t he coo l i ng fa n mot o r a nd s hroud. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Fan Mot o r a nd Shr o ud (303-03 A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V 6 - A JV6/3 .0L NA V6 - AJ27, Remova l a nd I ns t a ll a t i o n).
99. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he b r a ke p i pe . 100 . NO TE: Le f t -ha nd s ho wn, r i ght -hand s i mi l ar. • NO T E: Ins t al l n ew br a ke ca li pe r anchor pl at e ret a i ni ng bo l t s. At t a ch t he b r a ke ca l i pe r a s se mbl y.
104 . In s t a l l t he f r o nt whe el s a nd t i res . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Oil C apa ci ty Descri pti on Li ters I nit i a l f i l l i ncl udi ng oi l fi lt er 6·.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Des cr ipt i o n a nd O pe r a t i o n Gene ral Vi e w Item Pa r t Nu m be r De scri pt .
14 - O i l pres s ur e s wi t ch 15 - Fuel i nj e ct i on pum p 16 - O i l l evel ind i ca t or a nd t ub e 17 - Exhaus t gas r eci rc ula t i on (EGR) val ve Engin e Ide nt ifica tion C ode Engi ne c.
Item Pa rt Nu m ber De scr i pti on 1 - Cyli nder he a d 2 - Cyli nder he a d bo l t s 3 - I nt a ke val ve s 4 - Cyli nder he a d ga s ke t 5 - Exh a us t va l ve s 6 - Exh a us t cams ha f t 7 - I n.
I te m Pa rt Nu m ber Desc ri pti on 1 - Rock er s haf t , e xha us t roc ker a r m 2 - Rock er s haf t , i nt a ke rock er arm 3 - S t ud o n r ock e r ar m The val ve s a r e op e r at e d by l i ght we i ght a l umin iu m r ocker arm s , whi ch a r e mount e d o n t wo rocker s haf t s .
3 - Engi ne f r o nt co ver gas ke t Fr o nt Co ver The t imi ng cover i s of s t e el co nst r uct i o n a nd i s fi tt e d us i ng s e a l i ng compo und. Prio r t o f i t t i ng, t he m a t ing f a ces o n t he t i m i ng ca s e and cover m us t b e cl e a ne d t ho roughly.
I te m Pa rt N um be r De s cri pti on 1 - Oi l s pray noz z l e 2 - Ta b The pi s t on a ls o i nco r por a t e s a n o i l ga l l e r y f o r c oo l i ng pur po s e s . T hi s is s uppl ie d b y oi l s pray no z z l e s whi ch a r e l ocat e d i n e ngi ne b l ock o i l ga l l e ry .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - C ranksha ft Front Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Re l e a s e t ool , b el t t ens io ne r 303-676 W r e nch s t rap-unive r s a l 303-D 055 Re mover /Ins t a l l e r , Front O il Seal 303-679 (21- 238) R em ova l 1.
5. Usi ng t he s pe cia l t oo l , r emove t he cr a nk s ha ft f r ont o i l s e a l. Dis car d t he o il s e a l . Insta llat ion 1. NOT E: Ins t a l l a new cr a nks ha ft front oi l s e a l .
4. Ins t a l l the right -ha nd whe e l a rc h l i ne r acces s pa ne l . 5. Ins t a l l the f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - C ranksha ft Rear Seal I n-v e hi c l e Re pa i r R em ova l 1. Remove t he f l ywhe e l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl ywhe e l (303-01B Eng in e - 2.
4. Tig ht e n t he cr a n ksha f t r e a r o i l s e al ca r r ie r r et a i nin g bo l t s . Ti ght e n t he b ol t s i n t he s e q ue nce s ho wn. Ti ght e n t o 10 Nm. 5. Remove t he cr a nks haf t r e a r o i l s e a l al i g nment s l e e v e . 6.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Front C o v er I n-v e hi c l e Re pa i r Speci al T ool (s) Al ig ne r , Fr o nt Co ve r 303-682 (21- 241) R em ova l 1. Remove t he e ngi ne f r ont mount .
6. D et a ch t he ge ne r a t o r pos i t i ve cabl e . 7. D i s conne ct t he ge ne r a t or e l e ct r i cal co nne cto r. 8. Remove t he ge ne r a t or upp e r r e t ai n ing b ol t .
11. Det a ch t he acce s s o r y drive be l t . 12. Remove t he a cces s o r y drive be l t t e ns i one r. 13. Remove t he e n gi ne f r o nt co ver l owe r r e t a i ni ng nut s a nd bo l t s . 14. Lowe r t he vehi c l e . 15. NO TE: Eng in e s ho wn removed f o r cl a r i t y.
16. NO TE: Eng in e s ho wn removed f o r cl a r i t y. Re move t h e front e ngi ne m ou nt br a c ket a nd i dl e r pul l e y. 17. NO TE: Eng in e s ho wn removed f o r cl a r i t y. Re move t h e e ngi ne f r on t c o ver uppe r r et a i ni ng bol t s .
2. CA UT I O NS: A ne w e ngi ne f r ont c o ver must be i ns t a l le d. Fai l ur e to f o ll o w t hi s in s t ruc t i o n may r es ul t i n da mag e t o t he v eh icl e. I ns t a ll t he e ngi ne front cove r wi t hi n f i ve mi nut e s o f a ppl yi ng t he s ea l er.
7. Tig ht e n t he e ngi ne f r ont cove r l o we r r et a i ni ng nut s a nd bo l t s . Ti ght e n t he e n gi ne f r o nt co ver nuts and bol t s t o 3 Nm. Ti ght e n t he e n gi ne f r o nt co ver nuts and bol t s in t he f ol l o wi ng s eq ue nce: Ti ght e n t he 2 bo l ts i ndi cat e d t o 11 Nm.
10. NO TE: Eng in e s ho wn removed f o r cl a r i t y. I nst a l l t he i d l e r pu ll e y r e t a i ni ng nut . Ti ght e n t o 43 Nm. 11. Ins t a l l t he a cc e s s o r y drive b e l t t e nsi o ner. 12. At t ach t he a cces s or y drive be l t . 13.
15. Ins t a l l t he ge ne r a t or upp e r r e t a i ni ng b ol t . Ti ght e n t o 47 Nm. 16. Ti g ht e n t o 47 N m. 17. Conne ct t he g e ne r a t or e l ect r i cal co nne cto r. 18. At t ach t he g e ne r a to r po s i t i ve ca bl e . Ti ght e n t o 8 Nm.
20. Ins t a l l t he r e t a i ni ng nut s . 1. I ns t a l l t he r e t a i ni ng bracket . 2. I ns t a l l t he r e t a i ni ng nut s . 21. At t ach t he e ngi ne wi r i ng ha r ne ss . 22. At t ach t he e ngi ne wi r i ng ha r ne ss . 23. Ins t a l l t he e ngi ne f r ont mount .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Front Mou nt I n-v e hi c l e Re pa i r Speci al T ool (s) Engi ne s up po r t b r acke t 303-021 Engi ne l i f t i ng e ye 303-1067 R em ova l All v e h icle s 1.
4. D et a ch t he wi ring ha r ne s s f r om t he e ng i ne co ve r mount i ng bracket . 5. D et a ch t he e l e c t r i cal co nne ct or f r om t he e ngi ne c ove r mount i ng b r a cket . 6. Remove t he e ngi ne cover mount ing bra c ket . 7. Ins t a l l the s p e ci a l t o ol .
Vehi c le s bu ilt up to VI N: E4 386 8 9. D i s conne ct t he f uel p ump f ue l s upp l y an d r e t ur n l i ne s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
13. S e cur e t he p o we r s t e e r i ng fl ui d r e s e rv oi r to one s id e . 14. Remove t he e n gi ne mount da mpe r . 15. NO TE: Mark t he pos i t i on o f the e ng ine mo unt b e fo re remo v al . Re move t h e e ngi ne mount a nd b r a cket a s s e mbl y.
17. Dis c o nne ct t he f uel pump fue l sup pl y and r e t urn l i ne s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
22. Remove t he e n gi ne mount . Insta llat ion Vehi c le s bu ilt from VIN :E4 38 69 1. NOT E: Cl e an t he front e ngi ne mount mat in g f a c e s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 80 Nm. 2. Tig ht e n t o 80 Nm.
4. NOT E: Cl e an t he front e ngi ne mount mat in g f a c e s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 80 Nm. 5. Tig ht e n t o 80 Nm.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Flexplate I n-v e hi c l e Re pa i r R em ova l 1.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Flyw h eel I n-v e hi c l e Re pa i r R em ova l 1.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Intake Manifo ld I n-v e hi c l e Re pa i r R em ova l 1. Remove t he a i r cl ea ne r a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.
6. Remove t he i nt a ke man if ol d . Re mov e a nd di s c a r d t he i nt a ke m a ni fo l d g a ske t s. Insta llat ion 1. NOT E: Ins t a l l ne w i nt a ke mani fo l d gas ket s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 15 Nm.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - Oi l Pan I n-v e hi c l e Re pa i r R em ova l All v e h icle s 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def l e ct o r - 2.
Insta llat ion All v e h icle s 1. CAU TI O N : Avoi d d a mage t o the oi l pan mat i ng f ace o f t he cy l i nd e r bl o ck . Fa i l ur e t o f o l l ow th i s i ns t r uct i on may ca us e d a mage t o t he ve hi cle . Cl e a n t he cyl i nde r bl o ck m a t i ng f a ces .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - T imin g C hain I n-v e hi c l e Re pa i r Speci al T ool (s) Ti mi ng To o l , Cr anks ha f t 303-698 (2 1-251 ) R em ova l 1. Remove t he e ngi ne f r ont co v e r.
7. Usi ng s uit ab l e 6 mm ba r , l o ck t he t i mi ng d rive s p r o cket s . 8. D et e ns i o n a nd lo ck t he t i mi ng cha i n t e ns io ne r . 1. Re t ract t he p a wl . 2. P us h t he l o ck i n. 3. I ns e rt a p in . 9. NOT E: Engi ne r e moved fo r cla rit y .
10. Remove t he t i mi ng cha i n. Insta llat ion 1. CAU TI O N : Make s ur e t h e col or e d l i nks a l i g n t o t he ti ming mark s. Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . I nst a l l t he t i mi ng cha in.
2. CAU TI O N : Make s ur e t h e t i m i ng chai n te ns i o ne r i s f ul l y r e t r a cte d bef o r e i ns ta l l a t i on. Fa i l u r e t o f o l l ow t hi s i ns t r uct i on m a y r es ult i n da mag e to the ve hi cle . • NO T E: Engi ne r emove d f o r cl a r it y.
5. Tig ht e n t o 33 Nm. 6. Remove t he s ui t a bl e 6 mm ba r. 7. Remove t he s p e cia l to o l from t h e cr anks ha f t pos i t io n ( CKP ) s e ns o r hol e . 8. NOT E: O nl y t ur n t he e ngi ne i n t he norm a l di rect i o n o f rot a t i o n.
9. Ch eck t he cams ha f t ti ming by i ns e rti ng a s ui t a bl e 6 mm b ar t hr oug h t he ho le s i n t he cams ha ft and fue l i nj e ct i on pump s pr ocket s . 10. Check t he t i ming by ins e r t i ng t he s peci a l t o ol i n t he CKP s e ns o r hol e .
Name Hi g h p r es s ur e f ue l s u ppl y l i ne uni o n l ubrica nt TBD P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - V alve C over I n-v e .
2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he e ng i ne o i l f i l l e r cap t o pr e vent f o r ei gn mat e ria l e nt e r i ng t he val v e c ove r .
7. NOT E: O ne pi pe s h own o t he r pip e s a re s i mi l a r . Re move a nd di s ca r d t he hig h-pr e s s ure f uel s uppl y li ne . 8. Usi ng t he p neumat i c va cuum g un , va cuum forei g n mat e r i a l from t h e fu e l i nj e ct o r a nd t he f ue l i nj e ct i o n s uppl y mani f o l d.
13. Dis c o nne ct t he mas s a i r fl o w (MA F) s e ns or e l ect r i cal conne ct o r. 14. Det a ch t he s t ar t e r moto r wi r i ng harne ss . 15. Det a ch t he cy li nde r he a d t e mperat ure (CH T) s e n s or e l e c t r i cal conne ct or. 16.
18. Det a ch t he s t ar t e r moto r a nd i nj e ct o r wiring ha rn e s s . Re pos i t i o n a nd t i e t he wiring ha r ne s s a s i de . 19. NO TE: Ri ght -hand s ho wn l ef t -hand s i m i l a r. Det ach t he mas s a i r fl o w (MA F) s e ns or wi r i n g ha r ne s s .
23. Remove t he va l ve cover. Re mov e a nd di s c a r d t he val ve cove r g a ske t . Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t ype whe n wo rk i ng on o r ne ar an y f uel rel a t ed com po ne nt s .
3. NOT E: Do not t i ght e n t he r et ai ni ng bo l t s a t t h is s t age . I nst a l l t he f ue l r ai l br a c ket s . 4. NOT E: Do not t i ght e n t he r et ai ni ng bo l t s a t t h is s t age . I nst a l l t he f ue l i nj e c t i o n s upp l y mani f o l d r e t ai ni ng bo l t s .
8. Connect t he po s it i ve cr ankcas e ve nti l a t i o n (P CV) hos e t o t h e va l ve cover. 9. Connect t he CHT se ns o r e l e c t r i cal co nne ct or. 10. At t ach t he (CH T) s e ns o r e l e c t r i cal co nne ct or. 11. At t ach t he s t arte r mot o r wi ring ha rn es s .
13. NO TE: O ne f ue l i nj e ct or s ho wn o t he r fue l i nje ct o rs a r e s i mil a r . I nst a l l a ne w v a l ve cove r f ue l i nj e c t o r se al . 14. Lubr i cat e t he hi g h-pr e ss ure f ue l s uppl y l i ne u nio n t hr e a ds wi t h cl e a n l ubrica nt .
19. NO TE: Hi gh pr e s s ur e f uel s upp ly l i ne s s hown r emove d f o r cl arit y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif o ld ret a i ni ng bo l t s. Ti ght e n t o 23 Nm. 20. NO TE: Hi gh pr e s s ur e f uel s upp ly l i ne s s hown r emove d f o r cl arit y.
24. Conne ct t he f uel i nje ct o r e le ctrica l conne ct o r s . 25. Conne ct t he f uel ret urn l i ne s to t he f ue l i nj e ct o rs. 26. Ins t a l l t he e ngi ne cover. 27. Ins t a l l t he oi l f il l e r cap . 28. Ins t a l l t he oi l l e vel i ndi cat o r .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine2.0L Duratorq-TDCi Re moval Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho .
Engine li f t i ng e ye 303-1 067 5 P o i nt S e cur i t y T or x Bi t 418-5 35 R em ova l 1. D et a ch t he l o we r s t e e r i ng col um n s ha ft . 2. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n).
7. D i s conne ct t he radi a t o r l owe r coo l a nt hos e . 8. CAU TI O N : To pr eve nt t he veh icl e beco ming uns t ab l e whe n t he e ngi ne a nd tra nsmi s s i o n a s s e mbl y a r e r e m ove d , i ns t a l l t he ve hi cl e ti e -do wn s t r a ps .
14. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake ca l i pe r a nd brake cal i pe r a nchor p l a t e a s s e mbl y. 15. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 16. CAUT I O N: Su ppo r t t he brake ca l i per a s s e mbly us i ng t i e s t raps .
19. CAUT I O N: Secur e the AB S wh ee l s pe ed s e ns or us i n g t i e s t r aps . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re po s i t i o n a n d a t t a ch t he ABS whe e l s p e ed s e ns o r .
24. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps . Det ach t he s e le cto r cabl e s. 1. P r es s t he r et a i ni ng c l i p . 2. De ta ch t he s e l e ct or cabl e s . 25. Remove t he f ront bumpe r s pl i t te r vai n. 26. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar.
29. Dis c o nne ct t he b rak e va cuum pum p va cuum hos e . 30. Dis c o nne ct t he e xhaus t ga s recircu l a t i o n (E.G.R) va lve modul e vacuum ho s e. 31. Dis c o nne ct t he e xpa ns i o n t a nk ve nt hos e . 32. Det a ch t he coo l i ng s y s t e m hos e .
34. NO TE: T he ret a i ni ng bo l t remai ns ca pt i ve i n t he e l e ct r ica l conne c t o r . Di s conn ect t he e ngi ne ha r ne s s e le ctrica l co nnect o r . 35. Dis c o nne ct t he g l ow pl ug ha r nes s e l e ct rical c onn e cto r . 36. Dis c o nne ct t he b a t t e r y cabl e s .
39. CAUT I O N: I f f l ui d i s s p il t o n t he pa i nt wo rk , t he a f f e ct e d a rea m us t b e i mmedi a t e l y wa s he d do wn wit h col d wa t e r . Fa i l ure t o f ol lo w t hi s in s t ruc t i o n may r es ul t i n da mag e t o t he v eh icl e.
44. Det a ch t he powe r a s si s te d s t e ering ho s e . 45. NO TE: Ca p t he e xpos e d po rts . Di s conn ect t he po we r as s i s t e d s t e e r i ng hos e . 46. NO TE: Ca p t he e xpos e d po rts . Di s conn ect t he E.G. R va lve va cuum p i pe .
49. Dis c o nne ct t he f uel l ine s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
53. NO TE: Bo l t r emai ns cap ti ve i n t he e ngi ne cont r ol m od ul e (ECM) e l e ct r i cal conne ct o r . Us i ng t he s p e ci a l t o ol , d i s co nne ct t he ECM ha r n e s s e l e ctrica l conne ct o r . 54. Det a ch t he eng i ne wi ring ha r nes s ret a i ni ng cl i p.
59. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 60. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r .
63. NO TE: Di s card t he r e t ai ni ng nut s . Re move t h e e ngi ne f r on t mount r et a i ni ng nut s . 64. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 65.
68. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the co m po ne nt . P la ce t he e ng i ne , s us pe ns i on a nd t ransmi s s i o n a s s e mbl y t o a s ui t a bl e work i ng a r ea .
73. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move a nd di s ca r d t he whe e l hub nut s . 74. CAUT I O N: W h e n t he ti e -r od e nd i s se pa r at e d from t he whe e l hub a ss e mbly, t he b a l l jo i nt s e a l s houl d b e pr o t e c t e d t o pr e ve nt damag e .
78. Us i ng t he s pe ci a l t o o l s , re m o v e t he drive ha l f s ha f t . 79. Remove a nd di s car d t he dr ive ha l f s haf t s nap r i ng. 80. Remove t he d rive ha l f s ha f t . 81. NO TE: Di s card t he O -r ing s e a l s . • NO T E: Ca p t he e xpos e d po r t s .
83. Remove t he e n gi ne rol l r e s t r i ct o r . 84. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the co m po ne nt .
88. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 89. Remove t he va cuum r e gul a t o r s o l e no i d val ve. 1. Dis con nect t he e l e c t rical co nnect ors . 2. De ta ch t he va c uum hos e s . 3. Re move t he vacuum r e gul a t o r s o le noi d va lve .
92. Dis c o nne ct t he s t arte r mot o r wi ring ha rn es s e l e ct r i ca l conne cto r . 93. Det a ch t he s t ar t e r moto r wi r i ng harne ss . 1. Dis con nect t he s t a r t e r mot o r e l e ct r i cal conne cto r. 2. Dis con nect t he s t a r t e r mot o r s o l e no i d e l e c t r i cal co nnect o r.
96. Remove t he t r ans mis s i o n up pe r r e t a i ni ng bo l t s . 97. Remove t he t r ans mis s i o n right -hand ret a i ni ng bol t s . 98. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine2.2L Duratorq-TDCi (1 10kW/150P S) - Pu ma Re moval Speci al T ool (s) Remove r /I ns t a.
1. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 2. Remove t he s t ee ring co l umn coupl i ng. 3. Remove t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n).
8. D et a ch t he e l e c t r i c bo o st e r hea t e r el e c t r i cal co nnect or fr om t he s ub frame r e t a i ni ng t a ng. 9. D et a ch t he coo l a nt ho s es from t he r e t a i ni ng cl ip s . 10. Det a ch t he coo l a nt ho se . Dis conne ct t he co o l a nt ho s e .
12. Det a ch t he coo l a nt ho se . 13. Dis c o nne ct t he co o l a nt hos e . All v e h icle s 14. Dis c o nne ct t he radi a to r l owe r co o la n t hos e .
16. CAUT I O N: T o p r eve nt t he vehi cl e be co ming uns t abl e whe n t he e ngi ne a nd tra nsmi s s i o n a s s e mbl y a r e r e m ove d , i ns t a l l t he ve hi cl e ti e -do wn s t r a ps . Fai l ur e t o f ol l o w t hi s i nst r ucti o n may res ul t i n da ma ge t o th e v e hi cl e .
22. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he brake p i pe. 23. CAUT I O N: Su ppo r t t he brake ca l i per a s s e mbly us i ng t i e s t raps . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle .
27. NO TE: Re move a nd di s ca r d the O -ring s e a l . • NO T E: Ca p t he e xpos e d po r t s . Di s conn ect t he s uct io n a cc umul a to r pi pe . 28. Dis c o nne ct t he a i r t e m pe r at ur e s e ns or e l ect r i cal co nnect o r. 29. Dis c o nne ct t he hi g h i nt e ns it y di s charge (H.
32. NO TE: Drai n t he f lui d i nt o a s ui t a bl e co nt a i ne r. • NO T E: Ca p t he e xpos e d po r t s . • NO T E: U s e care wh e n rep os i t i oni ng p ow er as s i s t e d s t e e r i ng hos e . Di s conn ect t he po we r as s i s t e d s t e e r i ng hos e .
37. Det a ch t he coo l i ng s y s t e m hos e . 38. Dis c o nne ct t he e xpa ns i o n t a nk o ut l e t hos e . 39. NO TE: T he ret a i ni ng bo l t remai ns ca pt i ve i n t he e l e ct r ica l conne c t o r . Di s conn ect t he e ngi ne ha r ne s s e le ctrica l co nnect o r .
42. Det a ch t he wi ring ha r nes s from t he ba t t e r y t ray mount . 43. CAUT I O N: I f f l ui d i s s p il t o n t he pa i nt wo rk , t he a f f e ct e d a rea m us t b e i mmedi a t e l y wa s he d do wn wit h col d wa t e r . Fa i l ure t o f ol lo w t hi s in s t ruc t i o n may r es ul t i n da mag e t o t he v eh icl e.
47. Loo s e n t he ai r condi t i o ni ng (A/C) compr e ss o r li ne ret a i ni ng bol t . 48. NO TE: Re move a nd di s ca r d the O -ring s e a l s . • NO T E: Ca p t he e xpos e d po r t s . Di s conn ect t he A/C compr es s or l i ne s. 49. Dis c o nne ct t he f uel l ine s .
52. Det a ch t he eng i ne wi ring ha r nes s e l e ct rica l c on ne ct or . 53. NO TE: Bo l t r emai ns cap ti ve i n t he e ngi ne cont r ol m od ul e (ECM) e l e ct r i cal conne ct o r . Us i ng t he s p e ci a l t o ol , d i s co nne ct t he ECM ha r n e s s e l e ctrica l conne ct o r .
57. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps . Det ach t he s e le cto r cabl e s. 58. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Det ach t he s t r ut a nd s pr ing as s e m bl y. 59. Rai se th e v e hi cl e . 60.
62. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 63. Po s i t i o n and adj ust t he s p e ci al t oo l e ngi ne he i ght a d j us t e r s . 64. Remove t he e n gi ne re ar mount re ta i ni ng nut .
66. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 67. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e .
71. Remove t he e n gi ne , s us pe ns i o n a nd t r a nsmi s s i o n a s s e mbl y. Rot a t e th e s pe ci a l t o o l he i ght a d ju s t ment va l ve co unt e r cl o ck wi s e . 72. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n.
76. Ins t a l l t he e ngi ne rear l i f t i ng e ye. 77. Remove a nd di s car d t he r i g ht -hand whe e l hub nut . 78. CAUT I O N: W h e n t he ti e -r od e nd i s se pa r at e d from t he whe e l hub a ss e mbly, t he b a l l jo i nt s e a l s houl d b e pr o t e c t e d t o pr e ve nt damag e .
81. Remove t he rig ht -ha nd wh e el knuck l e a nd s t rut. 1. Re move a nd di s car d t he l owe r a rm ba l l j o i nt r e t a i ni ng nut a nd bo l t. 2. Re pos i ti on t he l owe r a r m s . 3. Re move t he whe e l knuc kle a nd s t ru t . 82. Remove t he rig ht -ha nd d r i v e hal fs ha ft .
.
91. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 92. Dis c o nne ct t he e mi s s i on c ont r ol s o l e noi d e l e ct r ica l conne ct o r . 93. Dis c o nne ct t he e mi s s i on c ont r ol s o l e noi d ho s e. 94. Remove t he e mi s s i on c ont r ol s o l e noi d a s s e mbl y.
96. Remove t he s t arte r mot o r wi ring ha rn es s ret a i ni ng b r ack e t . 97. Dis c o nne ct t he s t arte r mot o r wi ring ha rn es s e l e ct r i ca l conne cto r . 98. Det a ch t he s t ar t e r moto r wi r i ng harne ss . 1. Dis con nect t he s t a r t e r mot o r e l e ct r i cal conne cto r.
101 . Re move t he t r a ns mis s i o n up pe r r et ai ni ng bo l t s . 102 . Re move t he t r a ns mis s i o n rig ht -ha nd r e t a i ni ng bol t s . 103 . CAU T IO N: Do no t s upp or t t he e ng i ne a nd t r ans a x l e a s s e mbl y di rect l y on t he o i l pa n.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine Dis a s s e mbl y Speci al T ool (s) Engine st a nd 303-0 11 Uni vers al Fl ange Ho l di.
2. D et a ch t he gl ow pl ug wi r i ng ha r ne s s . Re mov e t he g l o w pl ug wiring ha r ne s s s e cur ing nut . 3. D et a ch t he wi ring ha r ne s s f r om t he i nt a ke mani f o l d.
4. D et a ch t he wi ring ha r ne s s f r om t he a i r cond it i o ni ng (AC) compr e s s o r. 5. D i s conne ct t he AC compr e s s o r e le ctrica l conne ct o r . 6. D et a ch t he wi ring ha r ne s s f r om t he ret a i ni ng s t ud . 7. D et a ch t he mas s a i r f l o w (MAF) se ns o r wiring ha r ne s s .
9. Remove t he wi r i ng ha r ne s s . 10. Det a ch t he acce s s o r y drive be l t . 1. Re pos i ti on t he acce s s o r y dr ive be l t t e ns io ne r . 2. De ta ch t he a cces s ory dr i ve be lt . 11. Remove t he a cces s o r y drive be l t . 1. Re move t he a cces s ory d r i v e be l t t e n s i o ne r .
14. Dis c o nne ct t he g e ne r at o r e l e ct r i cal conne cto r. 15. Remove t he g e ne r at o r. Re mov e t he w i r i ng ha r nes s s uppor t br acket f r om t he ge n e r at or uppe r r et a i ni ng bol t . 16. Remove t he a cces s o r y drive be l t t e ns i one r br acket .
18. Remove t he t ur bo o ut le t pi pe ret a i ni ng b o lt . 19. Remove t he t ur bo o ut le t pi pe a nd cha r g e a i r coo l e r i nt a ke p i pe a s s e mbl y. All v e h icle s 20. Remove t he t ur bo c ha rg e r he a t s hi e l d. 21. Remove t he ca t a l y t i c co nverte r r e t a i ni ng b ol t s .
22. Remove t he ca t a l y t i c co nverte r. Re mov e a nd di s c a r d t he r et a i ni ng nut s . 23. Remove t he ca t a l y t i c co nverte r r e t a i ni ng b r a cket . 24. Remove t he ha l f s haf t r e t a i ni ng bracket . 25. Remove t he e xhaus t ga s recircu l a t i o n (EGR) coo l e r coo l ant ho s e .
27. Dis c o nne ct t he t ur bo c ha rg e r va cuum ho s e . 28. Remove t he a i r f i l t e r o ut l e t tu be re t a i ni ng cl i p. 29. Remove t he a i r f i l t e r o ut l e t tu be . 30. Remove t he p o we r a s s i s t e d s t e e ring hi gh -pr es s ure p ip e .
32. Remove t he co o l a nt hos e . 33. Remove t he co o l a nt hos e . 34. Remove t he s t arte r mot o r t o ge ne rat o r wi ring ha rn e s s . 35. Remove t he i nt a ke mani f o l d. Re mov e a nd di s c a r d t he i nt a ke m a ni fo l d g a ske t s.
37. Remove t he g l ow pl ug wi r i ng ha r ne s s . 38. Remove t he g l ow pl ugs . 39. Remove t he o i l l e v e l i ndi cat or and t ube . 40. Remove t he b rak e va cuum pu m p re ta i ni ng bo l t s . Re mov e t he p o we r s t e e ring pump be l t cove r .
42. Remove t he p o we r a s s i s t e d s t e e ring pu m p b rack e t r e t a i ni ng bo l t s . 43. Dis c o nne ct t he co o l a nt hos e f r om t he wa t e r pump. 44. Remove t he wa t e r pum p a nd pow er a s s i s t e d s t e e r i ng pump a s se mbl y .
47. Dis c o nne ct t he kno ck se n s o r (KS ) e l e ct rica l c o nne ct or . 48. Det a ch t he wi ring ha r nes s. 49. NO TE: P rot e ct t he f ue l met e ring val ve a nd f ue l t e mper a t ur e s e ns o r e l e ct r i cal conne ct o r s wi t h l i nt f r e e cl o t h t o pre v e nt cont a mina t i o n f r o m t he c l e a nin g f l ui d .
51. Remove t he f l ywhe el . Re mov e a nd di s c a r d t he r et a i ni ng bo l t s . 52. Remove t he i dl e r pul l e y. 53. Remove t he e n gi ne f r o nt mount br acket . 54. Dis c o nne ct t he o i l s uppl y t ube from t he t ur b o c ha rg e r.
56. Remove t he o i l s uppl y t ube . 57. Dis c o nne ct t he o i l ret urn t ube from t he t urbocha r ge r . Re mov e a nd di s c a r d t he gas ke t. 58. Remove t he o i l ret urn t ube. Re mov e a nd di s c a r d t he O -r ing s e a l . 59. Remove t he EGR co o l e r m ount b r acket ret a i ni ng b o l t .
61. Remove t he e xhaus t mani f o l d. Re mov e a nd di s c a r d t he r et a i ni ng bo l t s a nd nut s . 62. Det a ch t he cy li nde r he a d t e mperat ure (CH T) s e n s or e l e c t r i cal conne ct or. 63. Dis c o nne ct t he CHT s e ns or el e ct r i cal co nnect o r.
• NO T E: Inj e ct or numb e r 4 s ho wn, i nj e ct or numbers 1, 2 a n d 3 s i mil a r . Lo o s e n t he hi gh-pr e s s ure f uel s uppl y l i ne f r om t he f ue l i nj e ct o r a nd f uel i nj e ct i o n s uppl y mani fo l d.
73. CAUT I O N: Ma k e s ure t hat t he f uel i nj e cto r do es not mo v e when lo o s eni ng th e fue l inj e ct or l o ck ing col l a r . Fa i l ur e t o f o l l o w t hi s ins t r ucti on wil l r e s ul t i n d ama ge t o t he f u e l i nje ct o r an d t he fue l i nj e cto r se a li ng wa she r .
m a ni f ol d unt i l b ot h uni o ns ha ve be e n de ta che d a nd cl e ane d . Fa i l ure t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n f o r ei gn m a t t e r i ngres s t o t he f uel in j ect i o n s yst e m.
86. Remove t he f u el i nje ct i on s upp l y mani f o l d ret a i ni ng bol t s . 87. Loo s e n t he fue l i nj e ct io n s up pl y mani f o l d s up po r t br a cket s . 88. Remove t he s o und pr oo f p add i ng. 89. Remove t he f u el i nje ct i on s upp l y mani f o l d .
91. Us i ng t he s pe ci a l t o o l s , re m o v e t he cr anks ha ft da mpe r . 92. Remove a nd di s car d t he engi ne front co ver. Re mov e t he e n gi ne f ront co ver ret a i ni ng n ut s a nd b ol t s .
94. Us i ng s ui t a b l e 6 mm ba r , l o ck th e t i ming d r i ve s pr ocket s. 95. Loo s e n t he c a msha f t s p r ocket r e t ai ni ng bo l t s . 96. Loo s e n t he fue l i nj e ct io n pump s p r ocket r e t ai ni ng bo l t s . 97. Us i ng a s uit a bl e t o ol , ret a in t he t i mi ng chai n t e ns i o ne r pi s t on.
98. Remove t he t i mi ng cha i n t e nsi one r a nd gui de s . 99. Remove t he t i mi ng cha i n. 100 . Re move t he hi gh-pres sure fue l pump ret a i ni ng b o lt s .
101 . Re move t he t imi ng chai n o i l f e e d p i pe . 102 . Re move t he hi gh-pres sure fue l pump. 1. Re move t he r e t a i ni ng bo l t s . 2. Re move t he hi g h-pr es s ur e f ue l pump. 103 . Re move t he KS . 104 . Re move t he rock e r sha f ts .
105 . CAU T IO N: Remove t he ca mshaf t ca r rie r bol ts i n t he s e quence s hown. Re move t h e cams ha f t carr i er. 106 . Re move t he ca msha f t s .
107 . CAU T IO N: Remove t he cyli nder he a d bo l t s in t he s e que nce s hown. Re move t h e cy l i nd e r he a d. Re mov e a nd di s c a r d t he cy l i nde r hea d ga s ket a nd t he bo l t s . 108 . Re move t he CKP s e ns o r. 109 . Re move t he CKP s e ns o r br acket .
110 . NO TE: Do not d i sca r d t he cranks haf t rea r o i l s e a l c a rr i e r . Re move t h e cr anks ha ft rea r oi l s ea l ca r r i e r . 111 . Re move a nd d i sca r d t he o i l pa n. Re mov e t he o i l pan r et ai ni ng nut s a nd b ol t s .
114 . CAU T IO N: Remove t he l a dde r f r a m e b ol t s i n t he s equ e nce s hown. Re move t h e l a dd e r f rame. Re mov e a nd di s c a r d t he l a dde r frame g a s ket . 115 . NO TE: O ne pi s t o n o i l coo l e r j et s ho wn, o t he r pi s t on oi l coo l er j e t s s i mi l a r .
118 . CAU T IO N: Kee p t he cr a n ks haf t mai n b ea ring ca ps i n orde r f or in s t a l l a t i o n. Re move t h e cr anks ha ft ma i n b e a r i ng caps .
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine As se mbl y Speci al T ool (s) P is t o n r i ng compr es s or 303-372 Uni ve r s a l Fl.
Re mover /Ins t a l l e r , Co o l i ng Ho s e Cla m p 303-397 Engi ne s t and 303-011 A ssemb ly All v e h icle s • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t ype whe n wo rk i ng on o r ne ar an y f uel rel a t ed com po ne nt s .
4. CA UT I O NS: As se mbl e ca ps wit h a r rows po i nt i ng f o r war d. Ca ps a r e i de nt i fi ed from fr on t t o r ea r, F, 2, 3, 4, R. Cr anks ha f t mai n b ea ring cap b ol t s mus t on ly b e us e d f o ur t i mes . Ti g ht en t he bo l ts i n t hr e e s t a ge s i n t he s eq ue nce s ho wn.
9. Ins t a l l the pi s t o n o il co o l e r je t s . 10. CAUT I O N: Do no t t rim o r da mage pr o t r udi ng f o am p a ds . • NO T E: Ins t al l n ew l a dd e r f rame g a s ket s . • NO T E: Do no t ful l y t i g ht en t he la d der f r ame r et ai ni ng n ut s a nd b ol t s a t th i s s t a ge .
12. Ins t a l l t he ol d cr anksha f t rea r s e a l an d carr i e r . 13. CAUT I O N: T he la dde r f r ame a nd t he cy l i nd er bl ock mu s t be a li g ne d s o t ha t t he rea r c l e arance doe s not e xc ee d 0. 01 m m o v e rla p t o 0. 2 m m gap .
15. Remove t he o l d c r a nk s ha f t rea r s e a l a n d carr i e r . Re mov e a nd di s c a r d t he cr a n k s ha ft re a r oi l s e a l . 16. NO TE: I ns t a ll a new cr anks ha ft rea r oi l s ea l car rie r a nd cr anks ha ft rea r oi l s e al ca r r ie r ret a i ni ng bol ts .
19. Us i ng a s uit a bl e di a l i ndi cat o r ga uge t a k e a ref e r ence m e a s urement f r om t he f r ont f a ce of t he cr a nksha f t s procket .
26. CAUTI O N S : A ne w o i l pa n must be i ns t al l e d I ns t a ll t he o il pa n wi t hi n f ive minut e s of a pp lyi ng t he s e a l e r. App l y a 3 mm be a d of s ea l er W SE- M 4G323- A4 t o t he o i l pa n. 27. NO TE: Do not f ul l y ti g ht e n t he o i l p a n ret a i ni ng bol t s a t thi s s t a ge .
30. NO TE: T i ght e n t he r e t a i ni ng bo l t s i n t he s equ e nce s ho wn. I nst a l l t he cl ut ch d i s c and pr e s s ure pl a t e. Ti ght e n t o 29 Nm. 31. NO TE: Do not f ul l y ti g ht e n t he cr a nksha f t po s i t i o n s e ns or br acket r e t a i ni ng bo l t s a t t his s t age .
35. Mar k t he p o si t i o n o n t he fl ywh e e l pr i mar y mas s . 36. NO TE: Ro t a t e t he cr a nks haf t count erclo ck wi s e . Rot at e t he cr anksha f t unt i l t h e pi s t on numb e r one a chi e ves z e ro o n t h e di a l i ndi cat or gau ge .
41. NO TE: Mark t he c a l cul at e d a mount o n t he fl y whe e l pr i ma r y mas s by m e a s uring f r o m TDC co unt e r clo ckwis e . Mul t i pl y t he cir cumference by 0.1388. 1. Fi rst mar k. 2. S e c o nd mark. 3. De te r mine d TDC. 4. De te r mine d 50 deg rees be f o r e t o p de a d cen t e r ( BT DC).
46. NO TE: T he l a r ge s t me a su r eme nt d e t e r m i nes t he choi ce of t he cyl in der hea d gas ket . Us i ng a s ui t a b l e t o o l , m e as ur e t he pi s t o n prot ru s i on. 47. Det e r mi ne t h e cy l i nd e r he a d ga s ket t hi cknes s .
50. Appl y a 2.5 mm di a met er be a d o f s e al e r W SE- M 4G323- A4 t o t he m a t ing f a ce of t he cyli nder he a d. 51. Remove t he ca ms haf t s .
52. NO TE: T i ght e n t he bol t s i n t h e s e que nce s hown i n t wo s t a ge s . I nst a l l t he cams ha f t carr i er. S ta g e 1: T i ght en bol t s 1 t hrough 22 t o 23 Nm. S ta g e 2: T i ght en bol t s 23 t hrough 25 t o 10 Nm. 53. Us i ng s pe ci a l t ool 308-417, i ns t a l l a ne w ca msha f t r ea r s e a l.
55. NO TE: I ns t a ll n e w r ock e r s ha ft ret a i ni ng bol t s . • NO T E: L ubr ica t e t he roc ker s h af t s wit h cle a n e ng in e o i l. • NO T E: T he o i l s uppl y ho l e s i n t he r o ck er s ha f t s mus t p oi nt do wn. • NO T E: T ig ht e n t he bo l t s i n t wo s t a g e s .
59. Ins t a l l t he hi gh-pr e s s ure f uel p ump r e t a i nin g b o lt s . Ti ght e n t o 22 Nm. 60. CAUTI O N S : Do no t t ig ht e n t he hi gh-pr e s s ure f uel s uppl y l i ne uni o n a t t h is s t a ge .
64. CAUT I O N: Ma k e s ure t he col o r ed l i nks a l i gn t o the t i ming marks. Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . I nst a l l t he t i mi ng cha in. 65. CAUT I O N: Ma k e s ure t he ti mi ng c ha i n t e ns i on e r i s f ul l y r et r act e d bef o r e i ns ta l l a t i on.
66. Unl o ck t he t i mi ng chai n t e ns i one r . 67. Ti g ht e n t o 33 N m. 68. Ti g ht e n t o 33 N m. 69. Remove t he l ocking pi ns from t h e t i ming d r i ve s pr ocket s.
70. Remove t he s pe ci a l t o o l 303-69 8. 71. Rot a te t he cranksha f t t wo r evo l ut i o ns . 72. Us i ng s pe ci a l t ool 303-698, check t h e t i ming b y in s e r t i ng t he s pe ci al t o ol i n t he CKP s e ns or ho l e .
75. Remove t he s pe ci a l t o o l . 76. Ins t a l l t he CKP s e ns or. 77. CAUT I O N: I ns t a l l t he e ngi ne f r o nt co ver wi t hi n f i ve mi nut e s o f a ppl yi ng t he s e a l e r. • NO T E: Ins t al l a ne w e ngi ne f r o nt co ver. App l y a 3 mm dia me t e r bea d of s e a l e r W S E-M4G 3 23-A4 t o t he engi ne f r ont cove r.
79. Ins t a l l t he f r ont cove r r et a i ni ng nut s a nd bo l t s . Ti ght e n t he b ol t s t o 14 Nm. Ti ght e n t he nut s t o 10 N m. 80. Remove s pe ci a l t o o l.
82. NO TE: Ne w c rank s ha f t pul l e y bo l t s m us t b e i ns t al l e d. Us i ng t he s p e ci a l t o ol s 205-053 a nd 205-0 53-02, i ns t a l l t he cr a nks ha ft da mpe r . S ta g e 1: 45 Nm. S ta g e 2: 120 de g r ee s . 83. NO TE: I ns t a ll a new val ve cover ga s ket .
87. At t ach t he s t arte r mot o r a nd i nj ect or w ir i n g ha r ne s s . 88. Ins t a l l t he s o und pr oo f pad di ng. 89. NO TE: Do not f ul l y ti g ht e n t he f uel i nje c t i o n s up pl y ma ni fo l d s uppo r t br acket bo l t s a t t his s t age .
bl ue co l o r ed col l a r i s f i t t ed a t t he f ue l i nj e ct i o n s uppl y mani f ol d e nd of t he hi gh p res s ur e fue l sup pl y l ine . • NO T E: T o a i d i d e nt i f i ca t i o n o f t he hi g h pr e s s ur e f ue l s up pl y l i ne s , t he uni on a t t he f ue l pump e nd i s e t ched wi t h t he wo r d P ump .
99. NO TE: Hi gh-pr es s u r e f ue l s up pl y l i ne s s ho wn r e moved f o r c l a r i t y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif o ld s uppo r t br acke t s . Ti ght e n t o 14 Nm. 100 . NO TE: Hi gh-pr e s s ur e f uel s uppl y l i ne s s h own r emove d f o r cl arit y.
104 . CAU T IO N: Make s ure t he t o o l us ed t o t i ght e n t he hi g h-pr es s ur e fue l s uppl y l i ne uni on s i s us e d a t t he t o p of t he uni o n a s t hi s i s whe re th e re i s most mat e r i a l . Fa i l ur e t o f ol l o w t hi s i ns truc t i o n may r e s ul t i n dama ge t o t he u nio n.
109 . CAU T IO N: Make s ure t he t o o l us ed t o t i ght e n t he hi g h pres s ur e fue l s uppl y l i ne uni on i s use d a t t he t o p o f t he uni on a s t hi s is where th e re i s most mat e r i a l . Fa i l ur e t o f ol l o w t hi s i ns truc t i o n may r e s ul t i n dama ge t o t he u nio n.
114 . Conne c t t he ca ms haf t po s i t i o n (CMP) s e ns or el e ct r i cal co nnect o r. 115 . Conne c t t he cyli nd e r he ad t e mpe rat ur e (C HT) s e nso r e l e ct r i cal conne ct or. 116 . At t ach t h e CHT s e ns or e l ect r i c a l conne ct o r .
119 . In s t a l l t he EGR co o l e r mount b r ack e t ret a i ni ng bo l t . Ti ght e n t o 10 Nm. 120 . NO TE: I nst a l l a ne w O -r ing se al . I nst a l l t he o i l ret ur n t ube . Ti ght e n t o 10 Nm. 121 . NO TE: I nst a l l a ne w gas ke t .
124 . NO TE: I nst a l l ne w s e a l i ng wa s he rs. Conn ect t he o i l s u ppl y t ube t o t he t ur bocha rger . Ti ght e n t o 14 Nm. 125 . In s t a l l t he e n gi ne f r o nt mount br acket . Ti ght e n t o 80 Nm. 126 . In s t a l l t he i dl e r pul l e y.
129 . NO TE: I nst a l l a ne w wa t e r pump ga s ket . I nst a l l t he wa t e r pump a nd po we r a s s i s t e d s t e e ring p ump as s e mbly. Ti ght e n t o 22 Nm. 130 . Conne c t t he co o la nt hos e t o t h e wa t er pump. 131 . In s t a l l t he p owe r a ss i s t e d s te e r i ng pump bracket r et a i ni ng bo l t s .
134 . In s t a l l t he o i l l e v e l i ndi cat or a nd t ube . 135 . In s t a l l t he g lo w pl ugs . Ti ght e n t o 13 Nm. 136 . In s t a l l t he g lo w pl ug wi r e . Ti ght e n t o 2 Nm. 137 . NO TE: I nst a l l ne w ma ni fo l d g a ske t s .
139 . In s t a l l t he co ol a nt hos e s . 140 . In s t a l l t he a i r f i l t e r o ut l e t tub e . 141 . NO TE: I nst a l l a ne w a i r fi l t e r o ut l e t t ub e r e t a i ni ng cl ip . I nst a l l t he a i r f i lt e r o ut l e t t ube . 142 .
144 . Conne c t t he co o la nt hos e . 145 . NO TE: I nst a l l a ne w pow e r a s s i s te d s t e e r i ng hi gh-pres s ur e O -r ing s ea l . I nst a l l t he p o wer as s i s t ed s t e e r i ng hi gh pres s ur e pi pe. 146 . Us i ng t he sp e ci a l t oo l , i ns t a l l t he wa t e r pump hos e s .
149 . In s t a l l t he ca t a l yt i c co nverte r brack e t. Ti ght e n t o 46 Nm. 150 . NO TE: I nst a l l ne w ret a i nin g nut s . I nst a l l t he cat a l yt i c co nverte r . Ti ght e n t o 46 Nm. 151 . In s t a l l t he ca t a l yt i c co nverte r r e t a in i ng bol t s .
153 . NO TE: Do not t i gh t e n t he r e t a i ni ng cl i p. Al ig n t he turbo o ut l et pi p e a nd charge a i r coo l e r i nt ake pi p e a s se mbl y . 154 . In s t a l l t he t ur bo o ut l e t pi pe ret a i ni ng b ol t . 155 . In s t a l l t he charge a i r coo l e r in t a ke p i pe r et a i ni ng b ol t s .
157 . In s t a l l t he a cces s ory drive be l t t e ns i one r br a cke t . Ti ght e n t o 25 Nm. 158 . NO TE: I nst a l l t he wi ring harnes s s upport b r acket t o t he g e ne r at o r uppe r r et a i ni ng bol t . I nst a l l t he g e nerat o r .
162 . In s t a l l t he a cces s ory drive be l t t e ns i one r. 1. I ns t a l l t he a c ce ss o ry d r i v e be l t . 2. I ns t a l l t he a c ce ss o ry d r i v e be l t te ns i o ne r . 163 . At t ach t h e a cces s ory dr ive be l t . 1. Re pos i ti on t he acce s s o r y dr ive be l t t e ns io ne r .
167 . At t ach t h e wi r i ng harnes s to t h e ret a i ni ng s t ud . 168 . Conne c t t he AC c ompres s o r e l e ct rical conne ct o r . 169 . At t ach t h e wi r i ng harnes s to t h e AC c ompres s o r . 170 . At t ach t h e gl o w p l ug wi r i ng harne ss .
172 . Re move t he e ng in e f r om th e eng i ne s t a nd. JagDocs.com.
P ubl i s he d: 11-May-2 011 E ngine - 2.0L Durato rq- TDCi/2.2L Duratorq- TDC i (110kW/150PS) - Puma - E ngine2.0L Duratorq-TDCi I nst a l l a t io n Speci al T ool (s) Remove r /I ns t a l l e r, Co.
3. Ins t a l l the t r a n s mis s i o n uppe r r et a i ni ng bo l ts . Ti ght e n t o 40 Nm. 4. Connect t he crank s haf t s e ns o r e le ctrica l conne ct o r . 5. Ins t a l l the s t art er mot o r . Ti ght e n t o 25 Nm. 6. Att a ch t he s t art er mot o r wiring ha rn e s s .
7. Connect t he s t a r t er mo to r wi ring harnes s e l ect r i cal co nnect o r. 8. Ins t a l l the s t art er mot o r wi ring ha rnes s re ta i ni ng br a ck et . Ti ght e n t o 20 Nm. 9. Att a ch t he s t art er mot o r wiring ha rn e s s . 10. Ins t a l l t he vacuum r e gul a t or s ol eno i d val ve.
11. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 12. Ins t a l l t he cha r g e a i r coo l e r pi pe . Ti ght e n t o 4 Nm. 13. At t ach t he re v e r se l a m p s wi t ch wi r i ng ha r ne s s r e t a i ni ng cl i p .
16. Ins t a l l t he e ngi ne roll r e s t r i cto r . Ti ght e n t o 80 Nm. 17. At t ach t he wi r i ng harnes s . 18. NO TE: U n-Ca p th e expo s ed p ort s. • NO T E: Ins t al l n ew O -r i ng s e a l s . Conn ect t he t he p owe r s t ee ring l ine s .
21. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he whe e l knuc kl e. 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l a ne w l o we r a r m bal l j oi nt re t a i ni ng nut a nd b ol t .
26. Ins t a l l t he e ngi ne cover r e a r mount brack e t . Ti ght e n t o 23 Nm. 27. At t ach t he e le ct r ica l conne ct o r . 28. At t ach t he e ngi ne h a r n e s s . 29. W A RNING: Ra i s e t he s pe ci a l t o o l pl a t f o r m s l o wl y.
31. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e t ai ni ng bol t s . 32. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. I nst a l l t he f ront sub f r ame rei nf orcement pl at e .
36. NO TE: I ns t a ll n e w r et a i ni ng nut s . I nst a l l t he e n gi ne f ront mount r et a i ni ng nut s . Ti ght e n t o 80 Nm. 37. NO TE: I ns t a ll a new r e t a i ni ng nut . I nst a l l t he e n gi ne r e a r m ount r e t a i ni ng nut .
42. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 43. CAUT I O N: Ma k e s ure t hat t he e l e ct r i cal conne cto r l oca t e s c orr e ctl y i n t he ECM. Do not f o r ce o r o ver t i g ht e n t he e le ct r ica l conne ct o r .
47. Conne ct t he f uel l in e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ). Re mov e t he b l a nki ng pl ug s.
51. NO TE: U n-cap t he e xpo s e d po rts . I nst a l l t he p o wer as s i s t ed s t e e r i ng hos e . 52. At t ach t he p o we r a s s i s t e d s t e e r in g ho s e. 53. Conne ct t he p o we r a s s i s t e d s t e e r in g ho s e. 54. Ins t a l l t he e xhaus t mani f o l d t o EGR v a l ve t ub e .
56. Conne ct t he radi a t or upp er coo l a nt ho s e . 57. CAUT I O N: I f brake fl ui d i s s pi lt o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: U n-cap t he e xpos e d p o r t s .
61. Conne ct t he g l ow pl ug ha rn es s e l e ct r i ca l conne ct o r . 62. Conne ct t he e ngi ne h a r nes s e l e ct r i cal conne cto r . Ti ght e n t o 10 Nm. 63. At t ach t he t he e xpans io n t a n k out l et ho s e . 64. Conne ct t he e xpans i on t a nk o ut l e t hos e .
66. Conne ct t he b rak e v a cuum pump vacuum hos e. 67. Rai se th e v e hi cl e . 68. NO TE: U n-cap t he e xpo s e d po rts . Conn ect t he po we r as s i s t ed s t e e r i ng ho s e . 69. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. I nst a l l t he f ront bumper s pl i t t e r v ai n f i nis he r t r i m s .
71. NO TE: Re move t he s e l e ct o r cab l e s t i e s t rap s. At t a ch t he s el e ct or cabl es . 72. At t ach t he s e l e ct o r cabl e s . 73. Conne ct t he hi gh i nt ens it y di s cha r ge (HID) s e ns or drop a r m. 74. Conne ct t he a i r te m pe r a t ur e s e ns or e l e ct r i cal conne ct o r .
76. NO TE: Re move t he a nti -l o ck braki ng s y s t e m (ABS) whe e l s p e ed s ens o r ti e s t rap s. • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . • NO T E: Re move t he ti e s t rap. Det ach a nd rep os i t i on t he ABS whee l s p e ed s e ns o r .
81. NO TE: I ns t a ll n e w br a k e cal i p e r a nchor pl a t e r e t a i nin g b o lt s . At t a ch t he b r a ke ca l i pe r a nd br a ke cal i pe r anchor pl at e a s s e mbl y. Ti ght e n t o 133 Nm. 82. Ins t a l l t he f r ont br a ke pa d s.
87. Conne ct t he he a t e r hos es to the he a t e r cor e . 88. Ins t a l l t he e xhaus t f l e xibl e pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Exhaus t Fl e xib le P i pe - 2. 0L Dur a t o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150PS ) - P uma (309-00 Exhaus t Sy st e m, Re moval a nd I ns ta l l a t i on).
.
3. Ins t a l l the t r a n s mis s i o n uppe r r et a i ni ng bo l ts . Ti ght e n t o 40 Nm. 4. Connect t he crank s haf t po si t i o n (CKP) s e ns o r e l e ct r i cal conne ct o r. 5. Ins t a l l the s t art er mot o r . Ti ght e n t o 25 Nm. 6.
7. Connect t he s t a r t er mo to r wi ring harnes s e l ect r i cal co nnect o r. 8. Ins t a l l the s t art er mot o r wi ring ha rnes s re ta i ni ng br a ck et . Ti ght e n t o 20 Nm. 9. Att a ch t he s t art er mot o r wiring ha rn e s s . 10. Ins t a l l t he e mi ss i on cont r o l s o l e noi d a s s embl y.
12. Conne ct t he e m i s s i o n cont r o l s o l e no i d e l ect r i cal conne cto r. 13. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 14. Ins t a l l t he cha r g e a i r coo l e r pi pe . Ti ght e n t o 4 Nm. 15. Ins t a l l t he cha r g e a i r coo l e r pi pe ret a i nin g b o lt .
17. CAUT I O N: Do no t s uppo r t t he e ngi ne a n d t r ans a x l e a s se mbl y di rect l y on t he o i l pa n. Fai l ure t o fo l l ow t h is i ns t r uct io n may cau s e da mag e to the co m po ne nt . Us i ng a s ui t a b l e hydr aul i c l i f t , l o we r t he e ngi ne a nd t r a ns mi s s i o n from t he s ubfr a m e .
23. NO TE: U n-Ca p th e expo s ed p ort s. • NO T E: Ins t al l n ew O -r i ng s e a l s . Conn ect t he t he p owe r s t ee ring l ine s . Ti ght e n t o 10 Nm. 24. Ins t a l l a n ew dr i ve ha lf s ha f t s n a p ring . 25. CAUTI O N S : Make s ur e t he CV j o i nt s pl i ne s are l oca t ed f ul l y.
28. Ins t a l l a n ew right -ha nd t i e r od -e nd r et ai ni ng nut . Ti ght e n t o 35 Nm. 29. Loo s e l y i ns t a l l a ne w whee l righ t-h and hub nut . 30. Remove t he e n gi ne re ar l i f t i ng e ye. 31. Ins t a l l t he e ngi ne cover r e a r mount brack e t .
33. At t ach t he e ngi ne h a r n e s s . 34. Rai se th e eng i ne , s usp e ns io n a nd t r a ns mis s i o n a s s e mbly t o a s ui t a bl e he i ght . 35. NO TE: Re move t he t i e s t r ap s . Re po s i t i o n t he a i r condi t i oni ng (A/C) pi pe t o t he e ngi ne , s us p e ns i on a nd t r a ns mis s i o n a s s e mbly.
38. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e t ai ni ng bol t s . 39. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. I nst a l l t he f ront sub f r ame rei nf orcement pl at e .
43. NO TE: I ns t a ll n e w r et a i ni ng nut s . I nst a l l t he e n gi ne f ront mount r et a i ni ng nut s . Ti ght e n t o 80 Nm. 44. NO TE: I ns t a ll a new r e t a i ni ng nut . I nst a l l t he e n gi ne r e a r m ount r e t a i ni ng nut .
49. At t ach t he s e l e ct o r cabl e s . 50. At t ach t he e ngi ne wi r i ng ha r ne ss e arth le a d. Ti ght e n t o 10 Nm. 51. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 52. CAUT I O N: Ma k e s ure t hat t he e l e ct r i cal conne cto r l oca t e s c orr e ctl y i n t he ECM.
54. Ins t a l l t he e ngi ne wi r i n g ha r ne s s t rim p a nel . 55. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 56. Conne ct t he f uel l in e s .
59. Conne ct t he p o we r a s s i s t e d s t e e r in g ho s e. 60. Conne ct t he cha r ge a i r cool e r ho s e . Ti ght e n t o 4 Nm. 61. Conne ct t he radi a t or upp er coo l a nt ho s e .
64. Conne ct t he b a t te r y cabl e s . 65. Conne ct t he g l ow pl ug ha rn es s e l e ct r i ca l conne ct o r . 66. Conne ct t he e ngi ne h a r nes s e l e ct r i cal conne cto r . Ti ght e n t o 10 Nm. 67. At t ach t he t he e xpans io n t a n k out l et ho s e .
69. Conne ct t he e xhaus t ga s reci r cula t i o n (EGR) val ve mo dul e va cuum ho s e. 70. Conne ct t he b rak e v a cuum pump vacuum hos e. 71. Rai se th e v e hi cl e . 72. NO TE: U n-cap t he e xpo s e d po rts . • NO T E: U s e care wh e n rep os i t i oni ng p ow er as s i s t e d s t e e r i ng hos e .
74. At t ach t he cha r ge a ir coo l e r o utl e t ho s e t o t h e charge a i r coo l e r . 75. Conne ct t he hi gh i nt ens it y di s cha r ge (HID) s e ns or drop a r m. 76. Conne ct t he a i r te m pe r a t ur e s e ns or e l e ct r i cal conne ct o r .
79. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Conn ect t he AB S whe e l s pe e d s e ns o r. 80. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he A BS whe e l s pe e d s e ns o r. 81. NO TE: Re move t he b r ake ca l i per a s s embl y t i e s t r a p s .
84. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. • NO T E: Ins t al l n ew br a ke ca li pe r anchor pl at e ret a i ni ng bo l t s. At t a ch t he b r a ke ca l i pe r a nd br a ke cal i pe r anchor pl at e a s s e mbl y. Ti ght e n t o 133 Nm.
89. Conne ct t he co o l a nt hos e . 90. At t ach t he co o l a nt hos e . 91. Conne ct t he f uel f i red bo os t e r hea t e r e l e c t r i cal co nne cto r t o t he s ub frame r e t a i ni ng t a ng. Vehi c le s without ele ctri c boo s te r h ea ter 92.
93. At t ach t he co o l a nt hos e s t o t h e r e t a i ni ng cl ip s . 94. At t ach t he e le ct r ic bo o s t e r he a t e r el e ct r ica l conne ct o r t o t he sub f r ame r et a i ni ng t a ng . Vehi c le s without auxil ia r y h ea ting 95. Conne ct t he he a t e r hos es to the he a t e r cor e .
102 . In s t a l l t he s t e e ring col umn coupl i ng. 103 . At t ach t h e l owe r s t ee ring co lumn s ha f t . Ins t al l a ne w ret a i ni ng b o l t .
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P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - En gine C oo li ng Des cr ipt i o n a nd O pe r a t i o n C ooli ng M odule Com ponen t .
It e m Pa r t Nu m be r Desc ri pti on 1 — Uppe r cool a nt hos e 2 — W a te r pump 3 — Cool ant e xpa ns i on t a nk 4 — Cool ant p res s ur e cap 5 — Therm os t a t 6 — Engi ne oi l coo .
To a voi d the po s si bi l i t y of pe rsona l inj ur y, do n ot ope rat e t he e ngi ne wi th t he ho o d o p e n un ti l t he f a n b l a de s ha ve b e en e x ami ned fo r cr a cks and s e p a r at i on . Fai lu r e t o fo l l o w t hi s i ns t ru ct i o n may r es ul t i n pe rso nal i nj ury .
Coo l a nt e x pa ns i o n d ur i ng wa r m- up. Ai r s e pa r a t i o n dur i ng o perat i on. S yst e m pres s ur i z at i o n by t he co ol a nt p r es s ure ca p. The cool a nt e xpa nsi o n t a nk i s de s i gne d t o have a ppr oxi mat e l y 0.5 t o 1 l it e r o f ai r w he n col d t o a l l ow f or coo l a nt e xpans i o n.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 2 3 1 1 2 P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - En gine C oo li ng Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n .
3 4 5 6 7 1 2 3 1 1 1 1 1 1 1 2 Conn e ct t he co ol ing f a n co nt r o l mod ul e e l e ct rical co nnect or JB187 (t o VI N E71957) an d c onn e cto r JB190 (from VIN 71958) and t ur n t he ig ni t io n s wi t ch t o t he RU N po s it i o n. The coo l i ng f a ns wi ll run a t maximum s pe e d .
1 1 1 1 1 2 1 2 I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he cir cuit b e t we e n t h e e ng i ne co mpar t me nt fus e b o x and t he cool i ng f a n mot or co nt r o l m o dul e . CLEAR t he DTC. T ES T t he sys t e m f or norm al op e rat i o n.
1 2 3 1 1 1 1 1 1 2 Ar e the drive s pl i nes O K? Ye s I nst a l l a n e w wat e r p ump. For a dd i t i o na l i nf orm a t i o n, r e fe r t o REFER t o : W a t e r P ump (303-03A Engi ne Coo l i ng - 2.0L NA V6 - AJV6/2.5L N A V6 - A JV6/3.0L NA V6 - AJ27, Re moval a n d I ns t a l l a t i on).
1 1 2 1 1 2 3 1 2 . TEST t he s ys t e m f or norm al op e rat i o n. PINPOIN T TE ST D : THE ENG INE B LOCK HEATER DOES NOT OPERATE T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS D1: C HECK CO NT .
W ARNI N G: N eve r r emove t he coo l a nt e x pa ns i o n t a nk cap unde r a ny ci r cum s t a nce s whi l e t he e ngi ne i s o pe r at i ng . Fa i l ure t o fo l l o w t he s e i nst r ucti o ns m a y r es ult i n da mag e t o t he coo l i ng s yst e m or e ngi ne and/or pe rso na l inj ur y.
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4. CAU TI O N : Do no t o v e r t i ght en t he drai n p l ug. Fa i l ur e t o f o l lo w thi s in s t ruc t i o n may caus e da mag e t o t he vehi cl e . I nst a l l t he d r ai n pl ug whe n a l l coo l a nt h a s d r ai ne d . Ti ght e n t o 1 Nm.
13. Loo s e l y i ns t a l l a p i pe cl a mp t o t he he at e r r et ur n ho s e . 14. S T ART a nd RU N t he e ngi ne at 2000 r pm . 15. W i t h t he e ng i ne a t 2000 r p m, f ul l y cl a mp t he he a t e r out l e t hos e a n d t he n ful l y cl a m p t he he a t e r i nl e t hos e .
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing System Flus hing Gene ral P r ocedures • NO T E: T o remov e r us t , s l u.
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Bl o ck Heater Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o Co o l i ng S yst e m Dr a i ni ng, Fi l l i ng a nd Bl e e di ng .
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1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 3 Nm. 2. Ch eck a nd t o p up t he coo l i ng s yst e m. JagDocs.com.
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6. D et a ch t he coo l i ng f a n modul e wi r i ng harnes s from t he coo l i ng f a n s hr oud . 7. Remove t he coo l i ng fa n mod ul e . Insta llat ion 1.
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing Fa n Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he coo l i ng fa n mot o r a nd s hr oud. Fo r a ddi t i o nal i nfo r mat i o n, r ef e r t o Coo l i ng Fa n Mot or and S hroud .
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing Fa n Mo to r and Shro ud Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1.
8. Repo s i t i on t he co ol a nt hos e f r om t he e ngi ne o i l coo l e r t o t he t he rm o s t a t ho us i ng a nd s e cur e i t t o t he f r on t cr o s s m e mber us i n g a s ui t a bl e ret a i ni ng s t rap. 9. Remove t he radi a t o r s uppo r t bea m.
Insta llat ion 1. CA UT I O NS: Make s ur e t ha t the r adi a t or i s no t d ama ged when in s t a l l in g t he c oo l i ng f an mot o r and s hr oud.
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - C o ol ing Module Re moval a n d I ns t a l l a t i on R em ova l All Ve hicles 1.
7. Lowe r t he vehi cl e . Vehi c le s bu ilt up to VI N: E7 195 6 8. D et a ch t he r a di a t or v e nt ho s e from t h e radi a t o r . 9. D et a ch t he uppe r cool a nt ho s e f r o m t he r adi a t or. 10. Dis c o nne ct t he co o l i ng f a n mot o r c on t r ol mod ul e e l ect r i cal co nnect o rs.
12. Det a ch t he uppe r cool ant ho s e f r o m t he radi a t o r. 13. Dis c o nne ct t he co o l i ng f a n mot o r c on t r ol mod ul e e l ect r i cal co nnect o r. All v e h icle s 14. Rai se th e v e hi cl e . 15. Remove t he a i r s p li t t e r g r i l le .
17. NO TE: L e ft -hand s i de s hown, right -ha nd s i de s i mi l a r . Det ach t he po we r a ss i st e d s te e ring o i l co o l e r i nl et a nd ret urn pi pe s . Al l ow t he powe r a s s i s t e d s t e e r ing fl ui d t o dr ai n i nt o a s ui t a bl e c on t a i ne r .
21. Lowe r t he coo l i ng modul e and the A/C conde ns e r t o a po s i t i o n whe r e t he a i r condi t i o ni ng pi pe i s f orwa r d of t he f r ont b umper . 22. Remove t he l ef t -han d s i de A/C co nde ns e r r e t ai ni ng bo l t f r om t he r adi a t o r .
25. NO TE: L e ft -hand s i de s hown, right -ha nd s i de s i mi l a r . Det ach t he co ol i ng modul e f r om t he A/C co nde ns e r . 26. CAUT I O N: Ma k e s ure t hat t he r a di a t o r and t he A /C conde n se r a r e not damag e d d ur i ng t he r e m o val o f the co ol i ng modul e .
3. NOT E: Le f t -hand s i de s hown, rig ht -ha nd s i de s i mi l a r. I nst a l l t he a ut o mat i c t r ans m i s s i on o i l c oo l e r t o t he r ad i a t o r . All Ve hicles 4. Ins t a l l the l e ft -hand s i d e A /C co ndens e r r e t a i ni ng bo l t .
9. Ins t a l l the radi a t o r s uppo rt be a m. Ti ght e n t o 25 Nm. Vehi c le s With Au tom a tic Transm ission 10. NO TE: L e ft -hand s i de s hown, right -ha nd s i de s i mi l a r . Conn ect t he po we r as s i s t ed s t e e r i ng o i l cool e r i nl e t a nd ret ur n p i pe s .
13. Remove t he ret a i ni ng s t rap from t h e e ng i ne o i l co o le r cool a nt ho s e . 14. Ins t a l l t he f r ont t owi ng e ye t r ims . 15. Ins t a l l t he a ir s p l i t t e r gr i l l e . Re mov e t he p rote cti ve t a pe f r om t he front b umper.
18. Conne ct t he co o l i ng f a n mot o r c o nt r o l m o dul e e l e ct r i cal co nnect o r. 19. Conne ct t he up pe r coo la n t ho s e on to t h e radi a t o r. 20. Conne ct t he radi a t or ve nt hos e o nt o t he r ad i a t o r . Vehi c le s bu ilt up to VI N: E7 195 6 21.
22. Conne ct t he up pe r coo la n t ho s e on to t h e radi a t o r. 23. Conne ct t he radi a t or ve nt hos e o nt o t he r ad i a t o r . All v e h icle s 24. Ins t a l l t he a ir cl e a ne r i nt a ke duct . 25. Ins t a l l t he a ir cl e a ne r .
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Radiator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he coo l i ng m o dul e . For a ddi t i o na l i nfo rm at i o n, ref e r t o Coo l i ng Modul e .
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - T hermo stat Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Water Pump Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o Co o l i ng S yst e m Dr a i ni ng, Fi l l i ng a nd Bl e e di ng .
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L NA V6 - AJV6 /2 .5L NA V 6 - A JV 6/ 3.0L N A V6 - AJ27 - Water Pump Ho usi ng Re moval a n d I ns t a l l a t i on R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o Co o l i ng S yst e m Dr a i ni ng, Fi l l i ng a nd Bl e e di ng .
9. Remove t he wa t e r pump ho us i ng. Re mov e a nd di s c a r d t he gas ke t. 10. Remove t he wa t e r pum p from t he wa t er pump hou s i ng. Re mov e a nd di s c a r d t he gas ke t from t he wa t e r pum p. Insta llat ion 1. NOT E: Ins t a l l a new ga s ket .
3. NOT E: Ins t a l l a new ga s ket . Ti ght e n t o 9 Nm. 4. NOT E: Ins t a l l ne w O -r ing s e a l s t o t h e wa t er pump c oo l a nt o ut l e t p ip e .
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - Fl ui d s and Lubr i cant s Desc ri pti on Speci fi cati on Ja guar P r e m i u m Co o .
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - E ngine Co o ling Des cr ipt i o n a nd O pe r a t i o n • W ARNINGS : Ne ve r r e m ove t he coo l a nt pres s ur e cap unde r a ny ci r cums t a nce s whi l e t he e ngi ne is o pe r at i ng.
Item Pa r t Nu m be r De sc ri pti o n 1 - Cool i ng modul e 2 - Cool i ng f a n mot o r and s hroud 3 - Cool i ng f a n 4 - Radi a t o r upper i s ol a t or mount i ng 5 - Radi a t o r s i de s e a l.
The t herm os t a t i s l o cat e d i n t he t he r mos t a t hous i ng whi ch i s bol t e d t o t h e cyli nd e r he ad a nd a l l o ws r api d e ng i ne warm -up b y r es t r i ct i ng cool a nt f lo w t hrough t he radi a t o r be l ow 88°C (190°F).
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng System D raining, Filling and Bl e eding Gene ral P r ocedures 1.
8. Remove t he a i r cl ea ne r mount br acket . 9. Loos e n t he coo li ng s yst e m ai r b le e d s cr ew. 10. Fi ll t he cool ant e xpans i on t a nk unt i l coo l a nt e merges from t he cool i ng s yst e m ai r bl e e d s cr e w. 11. Ti g ht e n t he coo l i ng s ys t e m a ir bl e e d s cr e w.
14. At t ach t he wi r i ng harnes s . 15. Ins t a l l t he a ir cl e a ne r a ss e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.0L Durat o r q-TDCi/2.
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng System D raining and V acuum F illi ng Gene ral P r ocedures W ARNI N G: To .
7. Ins t a l l the co ol i ng s ys t e m va c uum r ef il l a d a pt o r t o t he e x pa ns io n t a nk. 8. Ins t a l l the vacuum fi l l e r ga uge t o t h e coo l ing s yst e m vacuum r ef i l l a da pt o r . 9. Ins t a l l the ve nt uri t ube a s s e mbl y t o t he vacuum f i l l e r ga uge .
11. O pen th e a i r s upp l y val v e . 12. NO TE: Make s ur e th e coo la nt s uppl y ho s e i s po s it i o ne d i nt o a c on t a i ne r of f i f t y pe r cent mi xture o f Jag ua r P r e mi um Coo l i ng Sy s t e m Fl ui d or eq ui val ent , mee t i ng Jagua r s pe ci f i cat i o n W SS M97B44- D a nd f i f t y percent wa t e r .
15. Al l o w o ne minut e t o ch e ck t he vacuum i s he l d. Dis conne ct t he a i r s up pl y. 16. NO TE: Cl o se th e co o l a nt s uppl y val ve whe n t he coo l a nt e xpans i o n t a nk MAX mark i s r e a ch e d or co ol a nt m ove ment has ce a s e d.
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng Fa n Mo to r and Sh roud Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he coo l i ng m o dul e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co o l i ng Modul e (303-0 3B Engi ne Coo l i ng - 2.
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - C oo li ng Module Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover /in st a l l e r , co ol in g ho s e cl a mp. 303-397 R em ova l 1.
I nst a l l at io n) / Cha r ge Ai r Coo l e r - 2.2L Dur a t o r q-TDCi (110k W /150PS ) - P uma (303- 12B I nt a ke Ai r Di s t ribut i o n a nd Fi l t e r i ng - 2.0L Dur a t orq-TDCi/2.2L Dur a t o r q-TDCi (110k W /150PS ) - P uma, Re m ova l and Ins t a l l a t i o n).
1. W ARNING: U s ing an a s s i s t a nt , i ns t a l l t he cool i ng modul e . Fa i l ure to fo l l o w t hi s i nst r uct i o n may res ul t i n pe rs ona l i nj ur y. CAUTI O N : Make s ur e t ha t the radi a t o r and t he a ir con di t i o ni ng c on de ns e r are no t da mage d during t he i ns t a l la t i o n o f t he coo l i ng modu le .
6. Connect t he e l ect r i cal co nnect o r. 7. Connect t he radi a t o r uppe r cool a nt ho s e . 8. Connect t he radi a t o r vent hos e . 9. Ins t a l l the ba t t e r y t ray. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n).
P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - Radiator Re moval a n d I ns t a l l a t i on R em ova l 1.
Name Gr ea s e P ubl i s he d: 11-May-2 011 E ngine Co o ling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW / 150PS) - P uma - Water Pump Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho s e Cl amp 303-3 97 (24- 003) Mate ri a l s Speci fi cati on W S S -M 12 A4-A2 R em ova l Vehi c le s with 2.
5. NOT E: S hown wi t h t he exha ust g a s reci r cul a t i o n (EGR) coo l e r t o EGR val ve t ube removed f o r cl a rit y. Re move t h e po we r s t e ering pump r e t a i ni ng bo l t s . 6. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y.
9. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. Det ach t he wi r i ng harnes s . 10. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y. Det ach t he wa t e r pump. Det a ch t he wi ring ha rn es s f r om t he wat e r pump l owe r r et a i ni ng bol t s .
13. Remove t he e n gi ne o i l t e mpe r a t ur e co nt rol t he r mos t a t . Re mov e a nd di s c a r d t he O -r ing s e a l . Insta llat ion All v e h icle s 1. NOT E: Ins t a l l a new e ngi ne o il t e mpe r at ure cont rol t he r mos t a t O -ring s ea l .
4. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. At t a ch t he wa t e r pump. Ti ght e n t he wa t e r pum p r et a i ni ng bo l t s t o 24 Nm. At t a c h t he w i r i ng ha r ne s s t o t he wa t e r pump l owe r ret a i ni ng bo l t s.
8. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. At t a ch t he p owe r s t e ering pump t o th e w at e r p ump. 9. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. I nst a l l t he p o wer s t e ering pum p s e cur i ng b r acket .
12. At t ach t he p o we r s t e e r i ng pump be lt . Rot a t e th e powe r s t e e ring p ump be l t t e ns i one r c l o ckwis e . 13. At t ach t he p o we r s t e e r i ng fl ui d pi pe. 14. Carr y out t he co ol i ng s ys t e m fi l l ing a nd bl e e di ng procedur e .
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b-i n Lo we r in.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols Des cr ipt i o n a nd O pe r a t i o n I t.
CAU TIO N : Th e us e o f s uppl ement a r y oi l or fu e l add i t i ve s i s no t a ppr oved unl es s s pe c i fi e d by Jag ua r Ca r s i n t h e fo rm of a s e rvice comm unica t i on o r di r ect i ve. A f u e l pre ss ur e rel ie f val ve i s fi t t ed to the f ue l r a i l a t t he front of t he ca ms haf t cove r.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols 2.0L NA V6 - AJV6 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m.
Publ i s he d: 24-No v-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols 2.5L NA V6 - AJV6 / 3.0L NA V 6 - AJ2 7, VIN Range: E 96603->J28492 Dia gn os i s a nd Te s t i ng 1.
DT C C ondi ti o n P oss i bl e Ca uses Ac ti o n P 0112, P 0113 Conce rn wi t h IAT s e ns o r Engi ne fa ul t y l e a di ng t o overhea t i ng Int ake a ir t e mperat ure (IAT ) s ens or fa ul t Ha .
1 2 3 1 2 1 2 3 1 2 DT C C ondi ti o n P oss i bl e Ca uses Ac ti o n P 1338 Conce r n wi t h fue l pump c o m mands (fue l p ump not a cti vat e d whe n r e que s t e d by ECM) ECM t o f ue l pump co.
3 1 1 1 2 3 4 1 2 1 2 1 1 2 Mea s ure t he r es i s t a nce b e t we en the rel e va nt i nje cto r ha r nes s e l e ct rical c onn e cto r (IJ1 t o 6) pi n 1 and EN16 pi ns a s fo l lo ws - Inj e ct o r 1 pi n 1 (NW ) a nd ECM pi n 115. Inj e ct o r Cyl 3 pi n 1 (N) a nd ECM pi n 114.
1 1 1 2 3 1 2 1 2 1 2 1 2 3 1 2 REFER t o: Fue l P ul s e Dampe r - 2.5L NA V 6 - A JV6/3.0L NA V6 - AJ27 (303- 04A Fue l Charging a nd Co ntrol s - 2. 0L NA V6 - AJV6/2.5L NA V 6 - AJV6/3.0L NA V6 - AJ27, Re moval a nd I ns t al l a t i o n). CLEA R t he DTC.
1 2 1 2 1 2 3 1 1 2 1 2 3 4 1 2 I s t he r es i s t a nce l e s s t ha n 5 o hms? Ye s GO t o C7 . No REP AIR t he ci r cuit b e t we e n FT3 pi n 1 (W B) a nd I P 10 p i n 8 (W B ). Fo r a ddi t i o na l i nf o r mat io n, r e f e r t o wi ring di a g r ams.
1 2 3 1 2 3 1 2 3 1 1 2 3 1 i nf o r ma t i o n, ref e r t o wi ring di a g rams. CLEA R t he DT C. TES T t he s ys t e m fo r nor mal o p e r a t i o n.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging and C o ntrols 2.5L NA V6 - AJV6 / 3.0L NA V 6 - AJ2 7, VIN Range: J2 8493-> V99999 Dia gn os i s a nd Te s t i ng 1.
DT C C on di ti on Possi bl e C a u ses Acti o n P 0116, P 0117, P 0118, P 0125 Conce r n wi t h e ng i ne c oo l a nt t e mpe r at ure Engine c oo l a nt t e mperat ure s e ns o r Harnes s fa ul t ECM f a i lur e REFER t o : E le ctroni c Eng i ne Co nt rol s - 2.
1 2 3 1 2 1 2 3 1 2 3 1 1 DT C C on di ti on Possi bl e C a u ses Acti o n ope n circu i t , s ho r t ci r cuit , hi gh r e s i s ta n ce Thr ot t l e mo t o r f a i l ur e Thr ot t l e b o dy f a i l ure P 1656 Conce r n wit h TP se n s o r a m pl i f i e r c i r cuit ECM REF ER t o : El e ct roni c Eng i ne Co nt rol s - 2.
1 2 3 4 1 2 1 2 1 1 2 1 1 1 Be fo re repl aci ng a ECM, cont a ct De a l e r t e c hni ca l s uppo r t . PINPOIN T TE ST B : F UEL PU L S E DAM PER SENSOR.
2 3 1 2 1 2 1 2 1 2 3 1 2 1 2 1 2 Tur n t he i gn it i o n s wi t ch t o t he O N po s i t i o n. Mea s ur e t he res i s t a nce b et we e n e l e ctrica l conne c t o r FT2 pi n 3 (B) a nd GROU ND. I s t he r es i s t ance l e s s t ha n 5 o hms? Ye s GO t o C2 .
1 2 3 1 2 3 1 2 3 1 1 2 3 1 1 2 1 2 3 4 PINPOIN T TE ST D : FU EL P U MP CONTROL MODU LE. P062 7, P0 62 8, P062 9 T EST C ONDI T I ONS DET AI LS/RE SULT S/A CT IONS D1: C HECK S IGN AL P O WER C I RC UIT T O FUEL PUMP MODULE Dis conne ct fue l p ump modul e e l e ct rica l co nnect o r CA105.
1 2 1 2 3 1 I s t he v ol t a ge grea t e r tha n 10 vo lt s ? Ye s GO t o E5 . No I NS TALL a ne w fue l p ump modul e . REFER t o: Fue l P ump Modul e - 2. 5L N A V 6 - A JV6/ 3.0L NA V 6 - AJ27 (310-01 Fue l T a nk a nd Li ne s , Re moval a nd I nst a l l at io n).
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel C harging Wiri ng Harness Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.5L or 3.0L engine 1. Remove t he i nt a ke man if ol d .
7. NOT E: Fue l may s t i l l be pres e nt i n t he fue l i nj e ct i on s uppl y mani f o l d. Det ach t he f uel i nj e ct i on su ppl y mani fo l d a nd l o we r i nt a ke ma nif ol d a nd pl a ce t o o ne s i de . Re mov e a nd di s c a r d t he l owe r in t a ke man if ol d O -r i ng s e a l s .
12. Dis c o nne ct t he e l e ct r ica l conne ct o r . 13. Remove t he f u el cha r ging wi ring ha r nes s. Insta llat ion Vehi c le s with 2.0L engi n e 1. To i ns t a l l , rever s e t he remov a l proced ur e . Vehi c le s with 2.5L or 3.0L engine 2.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel Injecti on S upp ly Manif ol d Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
7. Remove t he f uel rai l ret a i ni ng bol t s . 8. D i s conne ct t he f uel rai l f r o m t he i nj e ct o r s. 9. Remove t he f uel i nj e ct i on r a i l . 1. Ro t a t e t he fu e l i nj e ct i o n rai l t hr ough 180°. 2. Re move t he f ue l i nj e ct i o n rai l .
2. NOT E: Ins t a l l a new ga s ket . Ti ght e n t o 10 Nm. Vehi c le s with 2.0L engi n e 3. Tig ht e n t o 10 Nm. 4. Tig ht e n t o 6 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel Injecto rs Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.5L or 3.0L engine 1. Remove t he f uel cha r gi ng wi ring ha r ne s s .
6. Remove and di s card t he O -r ing s e a ls . 7. Insta llat ion 1. NOT E: Ins t a l l ne w f ue l i nje ct or O -r i ng s e a l s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Lubricat e t he f u el i nje ct o r O-r i ng s ea l s wit h cl e a n e ngi ne o i l .
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - F uel Pulse D amper2.5L NA V6 - AJV 6/ 3.0L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he t hrot t l e b o dy.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L N A V 6 - AJ27 - Throttl e Bo dy Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s CAU TIO N : Do no t a t te m pt t o cl e a n t he t hr o tt l e bo dy.
5. D i s conne ct t he e l ect r i cal conne ct o r. Vehi c le s with 2.5L or 3.0L engine 6. D i s conne ct t he e l ect r i cal conne ct o r. 7. D i s conne ct t he e l ect r i cal conne ct o r. 8. Remove t he t hrot t l e b o dy. Vehi c le s with 2.
9. Remove t he t hrot t l e b o dy. All v e h icle s 10. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move a nd di s ca r d t he O-r i n g s e al . Insta llat ion All v e h icle s CAU TIO N : Do no t a t te m pt t o cl e a n t he t hr o tt l e bo dy.
3. Tig ht e n t o 10 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - T o rque Sp eci f i cat ions Descri pti o n Nm l b-f t l b- i n Hi gh-.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel C harging and Co ntrols Des cr ipt i o n a nd O pe r a t i o n Hi.
It e m Pa rt N um be r Descri pti on 1 - Fue l pum p r et a i ni ng bo l t 2 - Fue l pum p gas ke t 3 - Fue l pum p fue l r e t ur n l in e 4 - Fue l pum p fue l s uppl y l i ne 5 - Fue l pum p 6 - Fu.
The fue l i nj e ct io n s up pl y mani fo l d i s a r e s e r vo i r fo r the pres s ur i ze d f ue l t ha t i s p r o d uced by t he f ue l pump. I t a l s o i ncor po r at e s a p res s ur e s e ns o r s o t hat t he ECM can moni t o r/ ad jus t t he p r es su r e o f th e fue l to be i nj ect ed i n t o t he cyl in der.
P ubl i she d: 12-Jul-2011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel C harging and Co ntrols Dia gn os i s a nd Te s t i ng Principle of.
Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Cr anks haf t po si t i o n (CKP) s e ns or f a ul t Cyli nder he a d t e m perat ure (CHT) s e ns o r f aul t Fue l pu m p f.
Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Dual -mas s fl ywh e e l f aul t I dl e s pe e d hi g h o r lo w Accel erat o r pe da l po s i t i o n (AP P ) s e ns or f aul t I nt a ke a i r t e mper a t ur e (IAT ) s e nso r f aul t Check f o r DTCs i nd i cat i ng a n A P P o r IA T se ns o r f a ul t .
Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Cyli nder he a d t e m perat ure (CHT) s e ns o r f aul t Ca m s ha f t po s it i o n (CMP) s e ns o r fa ul t Cr anks haf t .
Name Cl e a ni ng Fl ui d P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel In jec tio n C o m ponent C leanin g Ge.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel In jec tio n Pump Re moval a n d I ns t a l l a t i on Speci al T.
1. Remove t he e xhaus t g a s reci r cul a t i o n (EGR) coo l e r t o EGR va l ve t ube. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Exhaus t Gas Re ci r cula t io n (EGR) Coo l e r t o EGR Va l ve T ube (303-08 Engin e Emi s s i on Cont r ol - 2.
6. Remove t he i nt a ke man if ol d . Dis car d t he i nt a ke m a ni f ol d g a s ket s . 7. D i s conne ct t he f uel me t e r i ng val ve a nd f ue l t e mper a tu r e s e ns o r e l e ct r i cal conne c t o r s . 8. D et a ch t he wi ring ha r ne s s .
11. CAUTI O N S : Make s ur e t he t o ol us e d t o l o o s e n t he hi g h pres s ur e fue l s upp l y l i ne uni on i s use d a t t he t o p o f t he uni on a s t hi s is where t here i s mos t m a t e ria l . Fa i l u r e t o f o l l ow t hi s i ns t r uct i o n may res ul t i n d a mage t o t he uni on .
18. Dis c o nne ct t he f uel i nje ct i on pump f ue l s uppl y a nd r et ur n l in e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
23. Det a ch t he fue l sup pl y and fue l r e t urn l i ne s uppo rt br acket . 24. Remove t he p o we r s t e e r i ng fl ui d re se r voi r r e t a ini ng nut s . 25. Det a ch t he powe r s te e ring f lui d r es e r voi r . 26. S e cur e t he p o we r s t e e r i ng fl ui d r e s e rv oi r to one s id e .
28. Remove t he e n gi ne mount da mpe r . Vehi c le s bu ilt from VIN :E4 38 69 29. Dis c o nne ct t he f uel i nje ct i on pump f ue l s uppl y a nd r et ur n l in e s .
32. Remove t he f u el s u ppl y a nd ret ur n l i ne s uppo r t brack e t r et a i ni ng nut . 33. Det a ch t he fue l sup pl y and r e turn l in e s. 34. Dis c o nne ct t he HCU e l e c t r i cal co nne ct or. 35. Det a ch t he powe r s te e ring p i pe t o e ngi ne wiring ha r ne s s ret a i ni ng cli p .
37. Det a ch t he powe r s te e ring f lui d r es e r voi r . All v e h icle s 38. Us i ng t he s pe ci a l t o o l , r e move t he fue l inj ect i on pump s prock e t a cces s cover. 39. NO TE: T urn t he engi ne in t he no r mal di r e cti on o f r o t at i o n onl y .
42. NO TE: Fo r a d di t i on al i nfo r mat i o n, s e e s te p 41. • NO T E: T he s peci a l t o ol l ocking pi n ho l e s a re o f f s e t . Dur i ng i ns t a l l a t io n o f th e s pe ci a l t o o l , che ck t ha t t he o ff se t p i n ho l e i s l o cat e d a t t he t o p.
47. NO TE: Fo r a d di t i on al i nfo r mat i o n, s e e s te p 41. • NO T E: Acces s t he f ue l i nj e ct i o n p ump r e t a i nin g b ol t s t hr ough t he ho l es pr ovid e d i n t he s pe cia l t o o l (To ol n o. 303-11 51 and t o o l no. 303-083A) a nd th e fue l inj e ct i on pump s pr ocket .
51. Dis c o nne ct t he kno ck se n s o r (KS ) e l e ct rica l c o nne ct or . 52. Det a ch t he eng i ne wi ring ha r nes s . 53. Remove t he f u el i nje ct i on p ump s uppo rt brack et . 54. Remove t he f u el i nje ct i on p ump s uppo rt brack et t o e ngi ne cyl i nde r bl o ck r et a ini ng bol t s .
56. Remove t he f u el i nje ct i on p ump s hi e l d from t he fue l i nj e ct io n pump. 57. Det a ch t he fue l r e t ur n l i ne ve nt uri f r o m t he fu e l i nj ect i o n p ump. Dis car d t he f uel ret u r n l i ne v e nt ur i O -r i ng s e a l .
1. NOT E: Ins t a l l ne w f ue l i nje ct i o n p ump s up pl y l ine O -r i ng s e a l s . I nst a l l t he f ue l i nj e c t i o n p ump fue l s upp l y l i ne and f ue l r et ur n l i ne a s s embl y t o t he f ue l i nj e ct i o n p ump. Ti ght e n 20 Nm.
6. NOT E: Ins t a l l t he f ue l i nje ct i o n pump r e t a ini ng b ol t s e ve nl y i n o r d e r t o pul l t he f ue l i nj e ct i o n pump s q ua r el y i nt o pos i t i on. Lo o s e l y i ns t a l l the f ue l i nj e ct i on pump s uppo r t br acket t o e ng i ne cyli nde r bl o ck r e t a in i ng b ol t s .
11. Conne ct t he f uel i nje ct o r t o f ue l i nj e c t i o n pump fue l r e t u r n l ine . At t a c h t he f ue l i nje cto r t o f uel i nje c t i o n pump r e t ur n l i ne ret a i ni ng c l i p (i f e qui ppe d).
16. Ins t a l l t he f uel i nj e cti on p ump s p r ock e t ret a i ni ng b ol ts . Ti ght e n t o 32 Nm. 17. Remove t he s pe ci a l t o o l s . 18. NO TE: I ns t a ll t he f uel i nj e ct i on pum p r et a i ni ng bo l t s e venl y i n o r de r t o pul l t he f ue l i nj e ct i o n pump s q ua r el y i nt o pos i t i on.
21. Us i ng t he s pe ci a l t o o l , i ns t a l l t he f uel i nje ct i o n pump s pr ocket a cces s cover. Vehi c le s bu ilt from VIN :E4 38 69 22. At t ach t he p o we r s t e e r i ng fl ui d r e s e rv oi r . 23. Ins t a l l t he po we r s t e e r i ng fl ui d res e rv oi r r et a i ni ng n ut s .
25. Conne ct t he H CU e le c t rical co nnect or. 26. At t ach t he f uel s uppl y a nd ret ur n li ne s . Ti ght e n t o 23 Nm. 27. Ins t a l l t he f uel s upp ly a nd ret ur n l i ne s sup po r t b rack e t r et ai ni ng n ut . Ti ght e n t o 8 Nm.
30. Conne ct t he f uel i nje ct i on p ump f uel s uppl y a nd ret ur n l i ne s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
34. At t ach t he p o we r s t e e r i ng fl ui d r e s e rv oi r . 35. Ins t a l l t he po we r s t e e r i ng fl ui d res e rv oi r r et a i ni ng n ut s . 36. At t ach t he f uel s uppl y a nd f uel re t urn l i ne s uppo r t br a ck et . 37. At t ach t he wi r i ng harnes s r et ai ni ng cli p.
39. At t ach t he p o we r s t e e r i ng fl ui d ho s e t o t he fue l r e t ur n l i ne . 40. Ti g ht e n t he f ue l s uppl y a nd r e t ur n l i ne s s up port b r acket ret a i ni ng n ut. Ti ght e n t o 8 Nm. 41. Conne ct t he f uel i nje ct i on p ump f uel s uppl y a nd ret ur n l i ne s .
44. CAUT I O N: Do no t a l l o w t he uni ons t o hi t the ol ive e nds o f t he hi gh-pr es s ur e fue l s up pl y l ine as t hi s may d a mage t he e nds of t he l i ne a nd a ll o w f o r e i gn m a t te r t o e nt e r t he fue l inj e ct i on s ys te m .
50. At t ach t he wi r i ng harnes s . 51. Conne ct t he f uel met e r i ng val ve a nd f ue l t e mper a tu r e s e ns o r el e ct rica l conne ct ors. 52. NO TE: I ns t a ll n e w i nt a ke mani fo l d g as ke t s . I nst a l l t he i nt a k e mani fo l d.
55. Ins t a l l t he a ir cl e a ne r moun t br acket . 56. At t ach t he wi r i ng harnes s . 57. Ins t a l l t he EGR coo l e r t o E GR val ve t ube. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Exhaus t Gas Re ci r cula t io n (EGR) Coo l e r t o EGR Va l ve T ube (303-08 Engin e Emi s s i on Cont r ol - 2.
Name Hi g h p r es s ur e f ue l s u ppl y l i ne uni o n l ubrica nt TBD P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.
3. D et a ch t he wi ring ha r ne s s . 4. D et a ch t he hi g h p r e s s ur e f ue l s upp ly l i ne s upp ort br a cket . 5. Cle a n t he fue l p ump, hi gh p r es s ure f ue l s up pl y l in e a nd s ur roundi ng a r e a s .
9. CAU TI O N : Make s ur e t h at th e hi gh pr e s s ure f uel s uppl y l i ne r e m a i ns in con ta ct wi t h b o t h t he f ue l pump a nd t he f ue l i nj e ct i o n s upp l y m a ni f ol d unt i l b ot h uni o ns ha ve be e n de ta che d a nd cl e ane d .
17. Remove a nd di s car d t he hi gh p r es s ure f ue l s up pl y l in e . 18. Repe a t s t e p s 14 a nd , 15 t o r emove t he 3 remai ni ng hi gh p r es s ur e f ue l s up pl y l i ne s. 19. Us i ng t he pne umat i c vacuum gun , vacuum f orei gn mat e r i a l f r om t he f uel i nj e cto r a nd t he fue l in je ct i o n s uppl y mani f o l d.
Th is proc e dur e i nvol ve s fue l h a ndl i ng. B e p r ep a r e d f o r fue l s pi l l a ge a t al l t i me s a nd a l wa ys ob s e r ve f uel ha nd li ng pr e caut i ons . Fa i l ur e t o fo l l o w t he s e ins t ruc t i o ns may r e s ul t i n pers o nal i njur y.
4. Lubr icat e t he ne w hi gh pr e s s ure f uel s uppl y l i ne uni on t hr ea d s wi t h cle a n l ubr ica nt . 5. CAU TI O N : Do no t a l l ow t he uni o ns t o hi t t he o l i ve e nd s of t he .
10. CAUT I O N: Do no t a l l o w t he uni ons t o hi t the ol ive e nds o f t he hi gh p res s ur e fue l sup pl y l ine as t hi s may d a mage t he e nds o f t he l i ne a nd a ll o w f o r e i gn m a t te r t o e nt e r t he fue l inj e ct i on s ys te m .
15. NO TE: Hi gh pr e s s ur e f uel s upp ly l i ne s s hown r emove d f o r cl arit y. Ti ght e n t he f ue l i nje ct i o n s uppl y m a nif o ld ret a i ni ng bo l t . Ti ght e n t o 23 Nm. 16. NO TE: T wo fue l i nj e ct or s ho wn, o t he r f ue l i nj e ct o r s s i mi l ar.
20. CAUT I O N: Ma k e s ure t he to o l us ed to ti ght e n t he hi g h pres s ur e fue l s uppl y l i ne uni on s i s us e d a t t he t o p of t he uni o n a s t hi s i s whe re th e re i s most mat e r i a l . Fa i l ur e t o f ol l o w t hi s i ns truc t i o n may r e s ul t i n dama ge t o t he u nio n.
25. At t ach t he hi g h pr e s s ure fue l s uppl y li ne s uppo rt brack e t . Ti ght e n t o 8 Nm. 26. CAUTI O N S : Make s ur e t he t o ol us e d t o t i ght e n t h e hi gh pr es s ure f ue l s uppl y l i ne uni on i s use d a t t he t o p o f t he uni on a s t hi s is where t here i s mos t m a t e ria l .
30. Ins t a l l t he i nt a ke man if ol d . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: I nt a ke Ma nif ol d (303-01B Engi ne - 2.0L Dur at o rq -TDCi /2.2L Dur at o r q-TDCi (110kW /150PS ) - Puma, I n-v e hi cle Re pa i r) . 31. Ins t a l l t he e ngi ne cover.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel In jec tor Re moval a n d I ns t a l l a t i on Speci al T ool (s.
2. Remove t he oi l f il l e r cap. 3. NOT E: Ins t a l l t he o i l f i l le r cap a nd o i l l e ve l i ndi ca t o r t o pr e ven t fo r ei gn m a t e ria l e nt e ring t he val ve cover.
7. Remove and di s card t he hi gh-pr es s ur e f ue l s up pl y l i ne . 8. Usi ng t he p neumat i c va cuum gun, vacuum f orei gn mat e r i a l f r om t he f ue l i nj e ct o r a nd t he f ue l i nj e ct i o n s uppl y mani f o l d.
13. CAUT I O N: Ma k e s ure t hat t he f uel i nj e cto r do es not mo v e when lo o s eni ng th e fue l inj e ct or l o ck ing col l a r . Fa i l ur e t o f o l l o w t hi s ins t r ucti on wil l r e s ul t i n d ama ge t o t he f u e l i nje ct o r an d t he fue l i nj e cto r se a li ng wa she r .
2. NOT E: Do not t i ght e n t he fue l in j ect or l o ck i ng col la r a t t hi s s t a ge . Us i ng t he s p e ci a l t o ol , i ns t a l l t he fue l in j ect or. 3. D i s conne ct t he f uel i nj e ct or e l e ct rica l c on ne ct or . 4. Usi ng t he s pe cia l t oo l s, t i gh t e n t he f ue l i nj e cto r l o cking col l a r .
7. NOT E: Hi g h-pr e s s u r e f ue l s up pl y l i ne s s ho wn removed f o r c l a r i t y. Lo o s e n t he f uel i nje cti on s uppl y ma nif ol d ret a i ni ng bol t s . 8. NOT E: Hi g h-pr e s s u r e f ue l s up pl y l i ne s s ho wn removed f o r c l a r i t y.
13. CAUT I O N: Ma i nt a i n pr e s s ur e on t he hi gh-pr es s ure f uel s uppl y l i ne to k ee p t he ol i ves in co nta ct wi t h t he f uel i nj e ct o r s and t he f ue l i nje cti o n s uppl y mani f ol d co ne s whi l e ins t a l l ing t he u nio ns .
uni on a t t he f ue l i nje ct o r . Ti ght e n t o 40 Nm. 18. Remove t he s pe ci a l t o o l . 19. CAUT I O N: Ma k e s ure t he to o l us ed to ti ght e n t he hi g h-pr e ss ur e fue l s uppl y l i ne uni on s i s us e d a t t he t o p of t he uni o n a s t hi s i s whe re th e re i s most mat e r i a l .
22. NO TE: Re move t he o i l f i l l e r cap and oi l le vel i nd i cat o r . I nst a l l t he e n gi ne cove r. 23. Ins t a l l t he oi l f il l e r cap .
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel Metering Valve Re moval a n d I ns t a l l a t i on R em ova l .
4. D i s conne ct t he f uel me t e r i ng val ve a nd f ue l t e mper a tu r e s e ns o r e l e ct r i cal conne c t o r s . 5. CAU TI O N : Al wa ys car ry o ut t he cl e a ni ng proces s b e fo re carr yi ng out any repai r s t o t he f uel i nj e cti on s yst em compone nt s.
4. CAU TI O N : The fu e l met ering val ve r et a i ni ng bo l t s m us t be ti g ht e ne d i n t he f ol l owi ng s t a ge s . Fai l ur e t o fo l l o w t hi s i ns t r ucti o n may r e s ul t i n d a mage to the fue l me t e ring va l ve . Ti ght e n t he f ue l met e ring val ve re ta i ni ng bo l t s i n t wo s t a g es .
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - 2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (1 10kW/150P S) - P uma - Fuel Return L ine Venturi Re moval a n d I ns t a l l a t i on Ge nera l Equi pm ent P ne umat i c vacuum gun R em ova l 1.
4. NOT E: Prot e ct t he fue l met e r in g va l ve e l ect r i cal conne ct o r wi t h l i nt -fr ee m a t e ria l t o pr e vent cont a mi na t i on from t h e cl e a ni ng f l ui d. Di s conn ect t he fu e l met ering v al v e el e ct r i cal co nnect or.
9. Remove t he f uel p ump s hi el d uppe r r e ta i ni ng bo l t s . 10. Us i ng t he pne umat i c vacuum gun, vacuum f orei gn mat e r i a l f r o m t he f uel p ump, f ue l ret ur n l ine v e nt ur i a nd t he fue l p ump fue l ret u r n l ine s . 11.
2. Tig ht e n t o 8 Nm. 3. Tig ht e n t o 33 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - Turboc harger - T o rque Sp eci f i cat ions Descri pti on Nm l b - f t l b-i n Oi l s upp l y t ub e uni o n ret a i ni n g b o lt 14 10 -.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - Turboc harger - Turbocha rger Des cr ipt i o n a nd O pe r a t i o n Va r i abl e vane t urbochar ge r - Ve hi cl e s bu il t up t o VIN :E.
It e m Part N u mber Desc ri pti on 1 - Co mpr es s o r c a s i ng 2 - Va r i a b l e va ne a d jus t ment ring 3 - Ro t ary e l e ct r o ni c a ctu a t or 4 - Va r i a b l e va ne 5 - Exhaus t t ur b.
Item Pa r t Nu m ber De sc ri pti o n 1 - V ane a dj us t ment s o l e noi d va l ve 2 - A t mos ph e r ic pr e s s ure 3 - V acuum 4 - A dj us t i ng r i ng 5 - V ane s 6 - V ane s 7 - T ur bi ne 8 -.
Item Pa r t Nu m ber De sc ri pti o n 1 - V ane a dj us t ment s o l e noi d va l ve 2 - A t mos ph e r ic pr e s s ure 3 - V acuum 4 - A dj us t i ng r i ng 5 - V ane s 6 - V ane s 7 - T ur bi ne 8 -.
P ubl i she d: 26-Jul-2011 Fuel Ch arging and C ontro ls - Turboc harger - Turbocha rger Dia gn os i s a nd Te s t i ng Over view For i nfo rm at i o n o n t he ope rat i on o f the t ur bocharger: REFER t o : T ur bo charger (303- 04C Fue l Charging a nd Co nt rol s - Turbocha r ge r , Des cr ipt i o n a nd O pe r at i o n).
DT C Descri pti on . Thi s DTC may be caus e d b y: . Low bat t ery v o lt a ge . Che ck t he cond it i o n o f t he ba t t e r y. Che ck t he wi r i ng and t he a p pr op r i a te fus e . Hi g h ba t t e r y vol t a g e . Che ck t he bat t e ry charging s ys t e m.
Po i nt H ea l th Che ck : 6. C heck for l o os e or brok en turb i ne a nd com pre ss or hous i ng f asteners. I f m oun t i ng fl ange s are dam age d, re pl a ce or ti ghten ( t orque to m a nufa c ture r' s speci fi ca ti on): Le gend - 1. Bo o s t pr e ss ure a ct ua t o r - 2.
Po i nt H ea l th Che ck : 8. C heck Vac uu m suppl y s ys te m : Le gend - 1. At mos phe r i c pi pe f r om a i r cle a n e r - 2. Va cuum from brak e boo s t er - 3. Va cuum t o VGT a ctua t o r - 4. T ur bo cha r g e r s o l e noi d va l ve - 5. Va cuum r es e r voi r W ARNI N G: K e ep hands a wa y f r om r o d and mechani s m .
T urbocharge r T r oubl e sh ooti ng Gui de 1. Le ge n d - 1. Di r t y a i r duct - 2. Ai r Cl e ane r - 3. MAF s e ns or - 4. EGR va lve - 5. T ur bocharger compr es s o r i nt ake a i r p i pe - 6. T ur bocharger - 7. P o s t c ha r ge ai r cool er pi pe - 8.
T urbocharge r T r oubl e sh ooti ng Gui de T urboch ar ge r Boos t Ci rc ui t – Check f or: 6. P re Charge Ai r Co ol e r Pi pes: - 1. Spli t hos e - 2. Ba d l y l o cat e d ho se - 3. Ba d l y l o cat e d cla mp - 4. I ncorr e ct cl a mp t o r que - 5.
P ubl i s he d: 11-May-2 011 Fuel Ch arging and C ontro ls - Turboc harger - Turbocha rger Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he ca ta l yt ic convert er. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ca t a l y t i c Conve r t e r - 2.
6. Remove t he oi l s upp l y t ub e. All v e h icle s 7. D et a ch t he oi l r e t ur n t ube from t he t ur b o charger . Dis car d t he ga s ke t . 8. Remove t he oi l re tu r n t ube . Dis car d t he O -r i ng s ea l . 9. D et a ch t he e xhaus t ga s r e ci r cul a t i o n (EGR) coo l e r fr om t he exha us t m a ni f o l d.
10. Det a ch t he coo l a nt pi pe f r om t he EGR cool e r . 11. Remove t he EGR co o l e r m ount b r acket ret a i ni ng b o l t . 12. Remove t he EGR co o l e r m ount b r acket . 13. Remove t he e xhaus t mani f o l d r e t a i nin g b ol t s a nd nut s .
16. Dis c o nne ct t he va cuum ho s e . 17. Det a ch t he pos i t ive crankcas e vent i la t i o n ho s e f r o m t he v al ve cove r . Dis car d t he po s i t i ve cr ankcas e ve nt i l a t i o n ho s e r e t ai ni ng cl i p . 18. Det a ch t he ai r cl e a ne r out l e t pi pe f r om t he t ur bocharge r .
20. Det a ch t he pos i t ive crankcas e vent i la t i o n ho s e f r o m t he v al ve cove r . Dis car d t he po s i t i ve cr ankcas e ve nt i l a t i o n ho s e r e t ai ni ng cl i p . 21. Det a ch t he ai r cl e a ne r out l e t pi pe f r om t he t ur bocharge r .
24. Det a ch t he t ur bocha r ge r from t he cy l i nde r hea d . 25. Remove a nd di s car d t he exha ust ma ni f o l d ga s ke t . 26. Remove t he t ur bo c ha rg e r . Re mov e a nd di s c a r d t he t urbochar ge r r e t a ini ng s t u ds . Vehi c le s bu ilt from VIN :E4 38 69 27.
28. Remove a nd di s car d t he exha ust ma ni f o l d ga s ke t . 29. Remove t he t ur bo c ha rg e r . Re mov e a nd di s c a r d t he t urbochar ge r r e t a ini ng s t u ds . Insta llat ion Vehi c le s bu ilt from VIN :E4 38 69 1. NOT E: Ins t a l l ne w t urbocha r ger r et ai ni ng s t uds .
3. Att a ch t he t u r b o charger t o t he cyli nd e r he a d. Vehi c le s bu ilt up to VI N: E4 386 8 4. NOT E: Ins t a l l ne w t urbocha r ger r et ai ni ng s t uds . I nst a l l t he t urbocha r ger . 5. NOT E: Ins t a l l a new ga s ket . I nst a l l t he e xhaus t mani f ol d ga s k et .
7. NOT E: Ins t a l l ne w e xhaus t mani fo l d r e t a i ni ng nut s a nd bo l t s • NO T E: Ve hicl e s ho wn rai s e d fo r cla rit y. Lo o s e l y i ns t a l l the e xha us t mani fo l d r e t a i ni ng nut s a nd bol t s . 8. Ins t a l l the e xha us t mani fo l d ga s ke t r e t ai ni ng s t uds .
11. NO TE: I ns t a ll a new p os i t i v e c r a nk cas e vent i l a t i on hos e r et a i ni ng cl i p. At t a ch t he p os i t i ve cr a nk cas e ve nt i l a t i on hos e to t h e va lve co ver. 12. Conne ct t he e l e ct r i cal conne ct o r. Vehi c le s bu ilt up to VI N: E4 386 8 13.
15. Conne ct t he va cuum h os e . All v e h icle s 16. Ins t a l l t he cowl vent s cr ee n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co wl Ve nt S cr e e n (501-02 Fr ont End Bo dy P a nel s , Re mova l a nd Ins t al l a t io n). 17. Rai se th e v e hi cl e .
21. At t ach t he co o l a nt pi p e t o t he E GR cool e r . 22. NO TE: I ns t a ll a new g a ske t . At t a ch t he EGR co ol e r t o t he e xhaus t mani fo l d . Ti ght e n t o 37 Nm. 23. NO TE: I ns t a ll a new O -r ing s e a l . I nst a l l t he o i l ret ur n t ube .
25. CAUT I O N: I f a ne w o i l s uppl y t ube is t o b e i ns t a l l ed , e ns ur e t ha t th e bl a nki ng c a ps ha ve be e n r e moved prio r to ins t a l la t i o n. Fai l ur e to fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he t urb ocha r ge r .
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b- i n Acces s o r y dr ive b e l t t e ns i o ne r ret a i ni ng bol t - ve hi cl e s wi t h 2. 0L, 2. 5L o r 3.0L e ng i ne 47 35 - Be l t i dl e r pul l e y ret a i ni ng b o lt - A b ank pul l e y - ve hi cl e s wi th 2.
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e Des cr ipt i o n a nd O pe r a t i o n 2.0 L, 2 .5 L an d 3. 0L e ngin e Item Par t N u m ber Desc ri pti on 1 — P o we r s t e.
Item Par t N u m ber Desc ri pti on 1 — A cc e s so ry dr i ve b e l t i dl e r pul l e y 2 — A cc e s so ry dr i ve b e l t t ens io ne r 3 — A cc e s so ry dr i ve b e l t i dl e r pul l e y 4.
It e m De sc ri pti on 1 Accep t a bl e Dr i ve Be l t Cracking 2 U na ccept a b le Dr i v e Be l t Da mag e The dr i ve b el t s houl d be i ns p e ct e d a t e ver y r o ut ine s e rv i ce fo r e xc e s s i ve we a r and d a mag e.
* * * * * * * * * * P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e .
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt2.0L Durato rq- TDC i/2.2L Durato rq- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re l e a s e t ool , b e l t t ens io ne r 303-676 R em ova l 1.
7. D i s conne ct t he ge ne r a t or e l e ct r i cal co nne cto r. 8. Remove t he ge ne r a t or upp e r r e t ai n ing b ol t . 9. D et a ch t he ge ne r a t o r . S li de t he g e ne r at or r e a r ward s a s f a r awa y f r om t he a cces s o r y drive bel t t ens i one r a ss e mbl y a s po s s ib l e .
Insta llat ion 1. Ins t a l l the a cces s o r y dr ive b e l t . 2. Att a ch t he a cc e s s o r y drive b e l t t e nsi o ner a s s emb ly. Ti ght e n t o 47 Nm. 3. NOT E: Lo o s el y i ns t a l l t he gene r a t o r r e t ai n in g nut s . At t a ch t he g e nerat o r .
6. Connect t he ge ne r a t or e l e c t r i cal co nne cto r. 7. Att a ch t he ge ne r a t or po s i t i ve ca bl e . Ti ght e n t o 8 Nm. 8. Usi ng t he s pe cia l t oo l , i ns t a l l t he a cc e s s ory drive be lt . 9. Ins t a l l the right -ha nd whe e l a rc h l i ne r acces s pa ne l .
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt2.0L N A V6 - AJ V6 / 2.5L N A V6 - AJV6/3.0L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Acces s o r y Be l t De -t e ns i one r 303-703 R em ova l 1.
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 47 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt T ensio n er2.0L Durato rq- TDCi/2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re l e a s e t ool , b e l t t ens io ne r 303-676 R em ova l 1.
7. D i s conne ct t he ge ne r a t or e l e ct r i cal co nne cto r. 8. Remove t he ge ne r a t or upp e r r e t ai n ing b ol t . 9. D et a ch t he ge ne r a t o r . S li de t he g e ne r at or r e a r ward s a s f a r awa y f r om t he a cces s o r y drive bel t t ens i one r a ss e mbl y a s po s s ib l e .
12. Remove t he a cces s o r y drive be l t t e ns i one r. Insta llat ion 1. Ins t a l l the a cces s o r y dr ive b e l t t e ns i o ne r . 2. Att a ch t he a cc e s s o r y drive b e l t . 3. Att a ch t he a cc e s s o r y drive b e l t t e nsi o ner a s s emb ly.
4. NOT E: Lo o s el y i ns t a l l t he gene r a t o r r e t ai n in g nut s . At t a ch t he g e nerat o r . 5. Ins t a l l the ge n e r at or r et a i ni ng bo l t . Ti ght e n t o 47 Nm. 6. Tig ht e n t o 47 Nm. 7. Connect t he ge ne r a t or e l e c t r i cal co nne cto r.
9. Usi ng t he s pe cia l t oo l , i ns t a l l t he a cc e s s ory drive be lt . 10. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s pa nel .
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Accesso ry Driv e B elt T ensio n er2.0L N A V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a cc e s s o r y drive b e l t . For add i t i o na l i nf or m a t io n, r e fe r t o t h e Acces s o r y D rive Be l t .
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Power Steering P um p Belt2.0L Duratorq-TDCi / 2.2L Durato rq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1.
6. Remove t he EGR coo l e r t o EGR val ve t ube s uppo rt brack e t . 7. Remove t he po we r s t e e r i ng pu m p b e l t . Rot a t e t he t e ns i one r c l o ckwis e . Insta llat ion 1. Ins t a l l the po we r s t e e r i ng pump be lt . Rot a t e t he t e ns i one r c l o ckwis e .
3. Ins t a l l the EGR cool e r t o EGR val ve t ube s u pport brack e t l owe r r et a i ni ng bo l t s . Ti ght e n t o 23 Nm. 4. Tig ht e n t o 10 Nm. 5. Ins t a l l the po we r s t e e r i ng pump b e l t cover. 6. Ins t a l l the po we r s t e e r i ng pump b e l t cover r e t a i nin g nut .
7. Att a ch t he po we r s t e e r i n g f l ui d pi pe . 8. Ins t a l l the a i r c l e a ne r a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - Power Steering P um p Belt Ten sion er2. 0L Duratorq-TDC i/2. 2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e xhaus t g a s reci r cul a t i o n (EGR) coo l e r t o EGR va l ve t ube.
6. Remove t he po we r s t e e r i ng p ump be l t t e ns i o ne r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 23 Nm.
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - W ater Pu mp B elt2.0L N A V6 - AJV6 / 2.5L N A V 6 - AJV6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ba t t e r y t ray . Fo r a d di t i o na l i nf o r mat i on , refe r t o S ect io n 414-01 Bat t e ry , Mount i ng a nd Ca bl e s .
P ubl i s he d: 11-May-2 011 A cces so ry Dr i v e - W ater Pu mp B elt T ens io ner2.0L N A V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he wa t e r pump be lt . For a ddi t i o na l i nfo rm at i on, ref e r t o t he W a t e r P ump Be l t .
P ubl i s he d: 11-May-2 011 Starting System - T o rque Sp eci f i cat ions Descri pti on N m l b-f t l b- i n S t arte r mot o r r et a i ni ng b o l t s - vehi cl e s wi t h 2.0L, 2.5L o r 3.0L e ngi ne s 35 26 - S t arte r mot o r c a bl e r e t ai ni ng nut - vehi cl e s wi t h 2.
P ubl i s he d: 11-May-2 011 Starting System - Starting S y stem Des cr ipt i o n a nd O pe r a t i o n The funct i o n o f t he st a r t i ng s ys te m i s t o cr ank t h e e ng i ne f a s t e n oug h t o a l l ow t he e ngi ne t o s t a r t .
I te m P a rt N um ber Descri p ti on 1 — Engi ne cont rol mod ul e (ECM ) 2 — S ta rte r m o t o r 3 — S ta rte r m o t o r r e la y Ve hi cl e s wi th 2.
I te m P a rt N um ber Descri p ti on 1 — Engi ne cont rol mod ul e (ECM ) 2 — S ta rte r m o t o r r e la y 3 — S ta rte r m o t o r JagDocs.com.
P ubl i s he d: 11-May-2 011 Starting System - Starting S y stem 2.0L N A V6 - A JV 6 Dia gn os i s a nd Te s t i ng W ARNI N G: B ewa re of r ot a t i ng p a r t s. Fa i l ur e t o f o l l ow t hes e i ns t r ucti o ns may res ul t i n pe r s o na l i nj ury .
1 1 1 2 3 P ubl i s he d: 11-May-2 011 Starting System - Starting S y stem 2.5L N A V6 - A JV 6 /3. 0L NA V6 - AJ27 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
1 2 3 1 1 2 3 1 2 1 2 1 1 1 2 3 1 2 Is t he vol t a ge gr e a t e r t han 10 vol t s? Ye s GO t o A 20 . No GO t o A 4 . A4 : CHEC K F OR C R ANK SUPP LY VO LT AGE T O EC M Dis conne ct t he ECM e l e ct rica l con nect or EN16. Tur n t he i gn i t i on s w i t ch t o t he CRAN K p os i t io n, an d ho l d .
1 2 1 2 3 1 2 1 2 1 2 3 1 1 1 1 Is t he vol t a ge gr e a t e r t han 10 vol t s? Ye s INS TA LL a ne w ECM . REFER t o Sect io n 303-14A El e ct r oni c Eng i ne Co nt r ol s / 303-14 B El e ct roni c Engi n e Co nt rol s . Be fo r e r ep l a cing a ECM, cont a ct Dea le r t e chnica l s up po r t .
1 2 1 2 No REPAI R s t art er GROU ND s t rap o r conne ct i o ns . For add i t i o na l i nf o r mat i o n, r e fe r t o wi ri ng d i a gr ams . CL EAR th e DTC.
P ubl i s he d: 11-May-2 011 Starting System - Starter Moto r2 . 0L Duratorq-TDC i Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ).
7. D et a ch t he wi ring ha r ne s s ret a i ni ng c l i p s f r om t he wiring ha r ne s s s up port b r a cket . 8. Remove t he wi r i ng ha r ne s s s up po r t b r a ck et . 9. D et a ch t he s t a r t e r m o to r. 10. Po s i t i o n t he s t art er mot o r t o p r o vi de a cc e s s t o t he s t a rte r m ot o r cabl e s .
12. Remove t he s t arte r mot o r . Re mov e t he s t a r t e r mot or e l e ct rica l c on ne ct or r et a i ni ng nut . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 12 Nm. 2. Tig ht e n t o 6 Nm. 3. Tig ht e n t o 25 Nm.
4. Tig ht e n t o 23 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Starting System - Starter Moto r2 . 2L Duratorq-TDC i (110k W/150P S) - P uma Re moval a n d I ns t a l l a t i on R em ova l 1.
7. Remove t he wi r i ng ha r ne s s s up po r t b r a ck et . 8. Remove t he cha r g e a i r c oo l e r i nt a ke pi pe ret a i ni n g b o lt s . Re pos i t i o n t he cha r ge a i r c o ol e r i nta ke p i pe f o r acce s s . 9. D et a ch t he coo l a nt ho s e.
12. Remove t he va cuum s ol e noi d mount b r acket a s s e mbly. 13. Remove t he s t arte r mot o r . Insta llat ion 1. To i ns t a l l r evers e t he r emova l pr oced ure.
3. Tig ht e n t o 35 Nm. 4. Tig ht e n t o 12 Nm. 5. Tig ht e n t o 6 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Starting System - Starter Moto r2 . 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
5. Pos it i o n and adj us t t he s pe ci a l t o o l front he i g ht a dj us t er. Rig ht -ha nd s hown , l e f t -ha nd s i mi l a r . 6. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 7. D et a ch t he s up po r t b a r .
9. D et a ch t he s t a r t e r m o to r s o l e no i d cove r . 10. Dis c o nne ct t he s t arte r mot o r e l e ct rica l co nnect o r . 11. Dis c o nne ct t he s t arte r mot o r s ol e noi d e l e ct rica l conne ct o r . 12. Remove t he s t arte r mot o r r e a r r e t a i ni ng bol t .
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 35 Nm. 2. Tig ht e n t o 35 Nm. 3. Tig ht e n t o 6 Nm. 4. Tig ht e n t o 12 Nm.
6. Tig ht e n t o 25 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - Gen eral S p ec if ic a t ions I te m Speci fi cati on Firing O rde r 1,4, 2,5,3, 6 S pa r k P l ug Ga p mm (in ) 1.
P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - En gine Ignitio n Des cr ipt i o n a nd O pe r a t i o n Compo nent L o c a t i o ns It e.
P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - En gine Ignitio n 2.0L N A V 6 - AJV6 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m.
P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - En gine Ignitio n 2.5L N A V 6 - AJV6/3. 0L NA V 6 - A J2 7 Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m.
E ngine C o ntrol M o du l e (E C M) Ha rness Co n nector Pi n Nu m ber C i rcui t F unc t i on C i rc ui t Col or 61 1 B i gni t io n c oi l t r i gg er Gr een /Bl ue 62 2 B i gni t io n c oi l t r i.
1 2 1 2 3 4 5 1 2 3 4 5 1 2 1A, 2A, 3 A, 1B, 2 B , 3B I g nit ion C oil s Pi n N um be r C i rcui t Fu n cti on 1 I gni t i o n coi l v o l t a g e s upp ly 2 I gni t i o n coi l di a g nos t i c s ig.
1 Cy l B 2. EN055 pi n 4, (GW ) a nd EN 016 pi n 62, (GW ) Cy l B 3. EN056 pi n 4, (GR) a nd EN 016 pi n 63, (GR ) Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o A 5 .
P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - I g niti on C oi l-On-P lug LH Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 E ngine Igniti on - 2.0L NA V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - AJ27 - I g niti on C oi l-On-P lug RH Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Gl ow Plug System - T o rque Sp eci f i cat ions Descri pti o n Nm l b-f t l b- i n Gl ow pl ug 13 10 - Gl ow pl ug e l ect r i cal conne ct o r ret a i ni ng nut 2 - 18 Mai n wi ring ha rn es s t o gl o w pl ug wi r i ng harnes s nut 4 - 35 Gl ow pl ug t e r mina l bl o ck r et a i ni ng s cr e w 5 - 44 JagDocs.
P ubl i s he d: 11-May-2 011 Gl ow Plug System - G lo w Plug System Des cr ipt i o n a nd O pe r a t i o n It e m P a rt N um b er Descri pti on 1 - Glo w pl ug i ndi ca t o r l a mp 2 - Glo w pl ug f.
of 30 s e conds a t -20° C (-4° F) o r l o we r . A t t e mper a t ures a bo ve 50°C (122° F) t he r e is no a f t e r- gl ow pha s e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Gl ow Plug System - G lo w Plug System Dia gn os i s a nd Te s t i ng Principle of oper at ion As comm o n rai l di e s e l en gi ne s ha ve be tt e r col d -s ta rti ng c.
1 2 3 4 1 2 1 1 2 1 1 2 3 4 E ng i ne control m o d ul e ( E C M) con nect o r C i rcui t P i n Gl o w pl ug - cont r ol 20 Gl ow p l ug r el ay con nect o r C i rcui t Pi n Gl o w pl ug r el a y - cont r ol 02 P e rm a nent 12 vo l t sup pl y 03 ECM r e l ay cont r ol l e d 12 vol t s uppl y 01 Gl o w pl ug r el a y - out p ut 05 Ke y o f f.
1 2 3 4 1 1 1 2 3 4 1 1 2 3 4 1 2 3 4 1 Ke y o f f. Gl o w pl ug r el a y conne ct o r di s conne ct e d. Ke y o n, e ngi ne o f f. Mea s ur e t he res i s t a nce b e t we e n: G l ow pl ug re l ay c.
1 2 3 4 1 2 3 4 1 2 3 I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s S us pe c t : - Glo w pl ug re l a y f aul t No GO t o A15 . A1 5: CHEC K WHET HER T HE SHOR T CIRC UIT T O GR O UND I S I N T HE EC M H ARNESS O R EC U Ke y o f f. ECM conne ct o r d i s conne ct e d .
P ubl i s he d: 11-May-2 011 Gl ow Plug System - G lo w Plug s Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ).
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 13 Nm. 2. Tig ht e n t o 2 Nm. 3. Tig ht e n t o 5 Nm. 4. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ).
P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - T o rque Sp eci f i cat ions Descri pti on Nm l b- f t l b-i n Exha.
P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - En gine E mis sio n Co ntrol Des cr ipt i o n a nd O pe r a t i o n.
P ubl i she d: 12-Jul-2011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - En gine E mis sio n Co ntrol Dia gn os i s a nd Te s t i ng Over view.
P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - Ex haust Gas Recircula tio n (EG R ) Co oler Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove r /I ns t a l l e r, Co ol in g Ho s e Cl amp 303-3 97 (24- 003) R em ova l 1.
8. Remove t he EGR coo l e r m o unt br acket . 9. Remove t he EGR coo l e r. Dis car d t he ga s ke t . 10. Remove t he co o l a nt hos e f r om t he EGR co ol e r .
2. NOT E: Ins t a l l a new EGR coo l e r gas ket . I nst a l l t he EGR co ol e r . Ti ght e n t o 37 Nm. 3. Ins t a l l the EGR cool e r mount br a cket . Ti ght e n t o 10 Nm. 4. Ins t a l l the EGR cool e r mount br a cket re ta i ni ng bo l t . Ti ght e n t o 10 Nm.
7. Usi ng t he s pe cia l t oo l , conne ct t he EGR co o l e r coo l a nt ho s e t o t he t he rm o s t a t ho us i ng . 8. Ins t a l l the a i r c l e a ne r o ut l et pi p e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r Out l e t P i pe (303-12B I nt a ke Ai r Di s t ribut i o n a nd Fi l t e r i ng - 2.
P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - Ex haust Gas Recircula tio n (EG R ) Co oler to EGR Va lve Tube Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r .
6. Remove t he EGR val v e t ube t o EGR val ve ret a i ni ng s t ud s . Re mov e a nd di s c a r d t he gas ke t. 7. Remove t he EGR coo l e r t o EGR val ve t ube. Insta llat ion 1. CAU TI O N : The t i ght e ni ng s e que nce o f t he EGR cool e r t o EG R val ve tu be re t a i ni ng nut s a nd bo l t s i s cr i t i c a l .
3. Loos e l y i nst a l l t he EGR va l ve t u be t o EGR val ve r et a i ni ng nut s . 4. NOT E: Ins t a l l a new EGR val ve t ube t o EGR cool e r gas ket . Lo o s e l y i ns t a l l the EGR v a l ve t ub e t o EGR co o l e r r et a i ni ng bol t s .
8. Tig ht e n t he EGR coo l e r t o EGR val ve t ube mount i ng brack e t l owe r r et a i ni ng b ol t . Ti ght e n t o 10 Nm. 9. Tig ht e n t he EGR coo l e r t o EGR val ve t ube mount i ng brack e t upp er r et a i ni ng b ol t . Ti ght e n t o 10 Nm.
P ubl i s he d: 11-May-2 011 E ngine Em i ssi on C o ntrol - 2.0 L D urato rq - TDC i/2.2L Durato rq- TDC i (11 0kW/150P S) - Puma - Ex haust Gas Recircula tio n (EG R ) Va lve Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r cl ea ne r .
6. D et a ch t he char ge ai r coo l e r ho s e . 7. Loos e n t he EGR coo l e r to EGR val v e t ube mount in g b rack et lo we r r et a i ni ng b ol t . 8. Remove t he EGR val v e t ube t o EGR val ve ret a i ni ng nut s . 9. Remove t he EGR val v e t ube t o EGR val ve ret a i ni ng s t ud s .
11. Remove t he EGR va l ve. Insta llat ion 1. NOT E: Ins t a l l a new EGR val ve O -r i ng s e al . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 10 Nm. 2. NOT E: Ins t a l l a new EGR val ve ga s ket . Ti ght e n t o 11 Nm.
4. Tig ht e n t o 10 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - Intake A i r Distributio n a nd Filtering Des cr ipt i o n a nd.
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - Intake A i r Distributio n a nd Filtering Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n .
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - A ir C leaner Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - A ir C leaner E lemen t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e ngi ne cover. 2. D i s conne ct t he mas s a i r fl o w s e ns or el e ct r i cal co nnect o r.
5. Remove t he a i r cl ea ne r cover. 6. Remove t he a i r cl ea ne r e l e ment . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L NA V 6 - A JV 6/2.5 L N A V6 - AJV6 / 3.0L NA V 6 - AJ27 - A ir C leaner Ou tlet Pipe Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he po s it i ve cr ankcas e ve nt i l a t i o n ho s e.
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - T o rque Sp eci f i cat ions Desc ri pti on N m l b-f t l b- i n .
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Inta ke Air Distributio n and Filterin g Des cr ipt i o n a nd O pe r a t i o n V eh icl es wi th 2.
12 - I nt a ke mani f o l d i nl e t ho s e 13 - Ai r cl ea ne r e l e ment 14 - Ai r cl ea ne r cover V eh icl es wi th 2.2 L diesel eng ine I te m Pa rt N um be r Descri pti on 1 - Ai r cl ea ne r o.
1 2 3 1 2 1 2 3 1 1 P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Inta ke Air Distributio n and Filterin g Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1.
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Air Cl eaner Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he oi l l e vel i ndi cat o r .
5. D et a ch t he a i r cle a ner out l e t p ip e . Vehi c le s bu ilt up to VI N: E4 386 8 6. D i s conne ct t he e l ect r i cal conne ct o rs. Vehi c le s bu ilt from VIN :E4 38 69 7. D i s conne ct t he e l ect r i cal conne ct o r. All v e h icle s 8.
9. D et a ch t he a i r cle a ner i nt a ke p ip e . 10. Remove t he a i r cl ea n e r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Air Cl eaner E lem ent Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2.
5. D et a ch t he a i r cle a ner out l e t p ip e . 6. D et a ch t he a i r cle a ner cover. 7. Remove t he a i r cl ea ne r cover. Dis conne ct t he b reat he r p i pe . 8. Remove t he a i r cl ea ne r e l e ment . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - Air Cl eaner O utlet P ipe Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he oi l l e vel i ndi cat o r .
5. Remove t he po s i t i ve cr ankc a s e ve nt i l a t i o n ho s e. Re mov e a nd di s c a r d t he pos i t i v e cr ankcas e vent il a t i on hos e r e t a i ni ng cl i p s . 6. Remove t he a i r cl ea ne r ou tl et pi pe. Re mov e a nd di s c a r d t he a i r cle a ner ou t l e t p i pe ret a i ni n g cl i p.
9. Remove t he a i r cl ea ne r ou tl et pi pe. Re mov e a nd di s c a r d t he a i r cle a ner ou t l e t p i pe ret a i ni n g cl i p. Insta llat ion 1. NOT E: Ins t a l l ne w po s i t i ve c rank cas e v ent i l at io n hos e ret a i ni ng cl i ps .
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - C harge A ir C ooler2.0L D urato rq - T DCi Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld .
6. D et a ch t he char ge ai r coo l e r i nt a ke ho s e from t he cha r ge a i r c oo l e r. 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Re move t h e charge a i r cool e r r e t ai n ing b ol t . 8. Remove t he cha r g e a i r c oo l e r.
3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. 5. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t o 7 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Intake Air Di stributio n a nd Filtering - 2. 0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma - C harge A ir C ooler2.2L D urato rq - T DCi (110kW / 150P S) - Puma Re moval a n d I ns t a l l a t i on R em ova l 1.
To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. 2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t o 7 Nm. 3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. 5. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r .
P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - T o rque Sp eci f i cat ions Descri pti o n Nm l b -f t l b- i n Evapo rat i ve e mis s io n ca nis t e r r et a in i ng nut s a nd bo l t s 5 - 44 Accel erat o r cabl e ret a i ni ng b r ack e t ret a i ni ng b o l t s - vehi cl e s wi t h 2.
P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on s Des cr ipt i o n a nd O pe r a t i o n I te m P ar t N um be r Desc ri pti on 1 — Evapo r a ti ve e mis s i o n cani s t er - no n fe d e r al mar ket ve hi cl e s 2 — Evapo r a ti ve e mis s i o n cani s t er - f e de r a l mar ket ve hi cl e s • NO T E: 2.
P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on s2.0L N A V6 - A JV 6 Dia gn os i s a nd Te s t i ng 1. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage , bl o wn f us e s , e t c.
P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on s2.5L N A V6 - A JV 6 /3. 0L NA V6 - AJ27 Dia gn os i s a nd Te s t i ng Prelimina ry Inspe ction 1. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage , bl o wn f us e s , e t c.
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1 2 3 1 1 I f s uf fi ci ent a d a pt i o ns have o ccu rr e d, t he Ev a po r at i ve val ve s ho ul d no w be o pe rat i ng . Thi s can b e verif i e d manua l l y by e i t her t o uchi ng o r li s t e ni ng t o t he val ve . By t o uchi ng t h e Evapo r at i ve va lve , i t s ho ul d b e po s s i bl e t o fe e l the v a l ve s wi t chin g.
1 2 1 2 1 2 3 1 2 1 1 2 3 1 PINPOIN T TE ST B : P04 42 . L EAK DETECTED. 4 0 THOU T EST C ONDI T IONS DET AI LS/RE S U LT S/ACT IONS B1: C HEC K F UEL F ILLER CAP FI T MENT AN D CO NDI T I ON OF PI PE S AN D C O NN EC T O R S Mak e s ure t hat t he f uel f il l e r c a p i s co r r ect l y ins t a l l e d a n d t i ght e n e d.
1 2 3 1 2 1 2 3 1 2 1 2 1 T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I O NS E1: CHEC K EVAPO R AT IV E PU R GE VA LVE S I GNA L WI R E FOR SH OR T T O GR O UND Dis c on ne ct Eva po r at i ve pur ge va l ve e l ect r i cal co nnect o r JB1 70. Dis c on ne ct ECM e le ctrica l co nnect o r , EN 16.
1 2 3 1 2 3 1 2 3 4 1 2 3 1 1 H1 : CHEC K CC V SI G NA L WI R E F O R SH OR T T O GR O UND. Dis conne ct CCV e le ct r ica l conne ct o r , FT 5. Dis conne ct ECM e l e ct r i cal conne cto r, EN16. Mea s ur e t he r es i s t a nce be t we en FT5, p i n 2 (O ) a nd gr ound .
2 1 2 1 2 1 2 3 1 2 1 2 Mea s ure t he r es i s t ance b e t wee n CA5, p i n 4 (RG) a nd GROU ND. Thi s t e s t wi l l no t che ck t he i nt e gr it y o f t he h arnes s from CA5 t o FT1. I f t he ci rc ui t i s s o und t o CA5, t he f uel t a nk m us t b e r e moved a nd t he ha r ne s s a nd s ens o r c on t i nui t y checke d.
P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on C anister2 .0 L N A V6 - AJV6 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 5 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on C anister2 .5 L N A V6 - AJV6/3.0L NA V6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe rtrai.
6. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. De-pres suriz e t he fue l s y s t e m. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o: Fue l S yst e m P r e s s ur e Re l e a s e (310-00 Fuel Sy s t e m - Ge neral Inf or mat io n, Ge ne r a l P rocedur e s ).
13. NO TE: Fe d e r al mar ket ve hi cl e s o nly. • NO T E: No t e t he o rie nt a t io n o f t he f ue l t ank fi l le r pi p e t o f ue l ta nk hos e r e t a i ni ng cl i p b e fo re l o o s e ni ng. Det ach t he f uel t a nk fi l l er pi pe hos e f rom t he f ue l t ank.
18. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Us i ng t he s p e ci a l t o ol , s uppo rt t he f ue l t a nk. 19. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Re move t h e fu e l t ank s up po r t s t raps r et a i ni ng bo l t s . 20. NO TE: Fe d e r al mar ket ve hi cl e s o nly.
Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl a mm a b l e vapo r s are a l ways pre se nt a nd m a y i g ni t e .
5. W ARNING: T he f uel t a nk canno t be dr ai ned i n ve hi cl e . Due t o t he hea vy we i ght , make s ur e t ha t t he f ue l t a nk i s s ecur e l y a t t a ched t o t h e pow ertrai n as s e mbly j a ck when r e m o ving. Fa i lure t o f ol l o w t hi s i ns t ruc t i on m a y r es ult i n pe r s o na l i nj ury .
10. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Conn ect t he e vapo rat i ve e mi s si o n ca ni s t e r cl o s e val ve e l e ctrica l conne ct or. 11. NO TE: Fe d e r al mar ket ve hi cl e s o nly. • NO T E: Re move t he bl a nk i ng p lu gs .
15. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Conn ect t he e l e ct rica l conne ct o r . 16. NO TE: Fe d e r al mar ket ve hi cl e s o nly. At t a ch t he e l e ct rica l conne ct o r . 17. NO TE: Fe d e r al mar ket ve hi cl e s o nly. At t a ch t he wi ring ha rn es s gromm et .
P ubl i s he d: 11-May-2 011 E v aporative E mis si o ns - Evaporative Em i ssi on C anister Purge Valve Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.0L engi n e 1. D et a ch t he s p e e d cont rol ca b l e . 2. D et a ch t he a ccel e r a t o r cab l e .
5. D i s conne ct t he upp e r f ue l v a po ur h os e from t he e v ap o r a t i ve e mi s si o n cani s t e r pur ge va lve . 6. D et a ch t he e vap o r a t i ve e mi s s i on cani s t e r purge val ve f r om t he ret a i ni ng br acke t . 7. Remove t he e vap orat i ve e mis s i on ca ni s t e r pur ge val v e.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b-i n Ca m s h.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls Des cr ipt i o n a nd O pe r a t i o n 2.
I te m P a r t Nu m be r De scri pti on 1 — I nt a ke Mani f ol d Tuni ng (IMT) V a l ve - uppe r 2 — I nt a ke Mani f ol d Tuni ng (IMT) V a l ve - l o we r 3 — Engi ne Coo l a nt T e mperat ur.
Item P a r t Nu m be r De sc ri pti on 1 — Knock S e ns or (KS ) 2 — T hr ot t le P os i t i on (TP ) S e ns or 3 — O i l Te m pe r a t ur e Sens or 4 — O i l P res s ur e S wi t ch JagDocs.
It e m Pa rt N um be r Descr i pti on 1 — Hea t e d Oxygen S e ns o r (HO2S ) LH 2 — Cat a l ys t Mo ni t or S e ns or RH 3 — Hea t e d Oxygen S e ns o r (HO2S ) RH 4 — Cat a l ys t Mo ni t or S e ns or LH Item P a rt N um be r Desc ri pti on 1 — Mas s A i r fl ow (MAF) S ens o r JagDocs.
Item P a r t Nu m be r De sc ri pti on 1 — Engi ne Co nt rol Mod ule (ECM ) Engi ne Con trol Modul e (ECM) The e l e ct roni c e ngi ne co nt r ol s ys t e m cons i s t s o f a e ngi ne co nt r ol modul e (ECM ) a nd a num be r of s e nsi ng a nd a ct uat ing de vice s .
e ngi ne s p ee d . Engi ne Coo l a nt T emp erat ure (ECT) S e nso r The e ngi ne co ol a nt te m pe r at ur e (ECT ) s e ns or i s a t he r mis t or t yp e s ens or t ha t pr ovi de s a n i nput si gna l t o t he ECM whi ch i s pr opo r t i o na l t o t he e ngi ne coo l ant t e mper a t ur e .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls2.
DT C Desc ri pti on Possi bl e C ause Act i on Ca ta l yst co nversi on f ai lu r e P 0300 Ra nd o m Mis fi r e Det e ct e d I gni t i on s ys t e m compo nent s I gni t i on s ys t e m wi r i ng harne ss Che ck a l l ig ni t io n coi l s f o r s e cur e f i xi ng a nd check wi ring ha rnes s conne ct or f o r da mage a nd cor rect e ng a geme nt .
DT C Desc ri pti on Possi bl e C ause Act i on e ngi ne cont rol modul e f or op e n ci rc ui t s or s ho r t t o g round/powe r. Mini mum s up pl y vol t a ge a t c oi l i s 10.5 vol t s . maximum res i s t a nce i n s i gna l l i ne s i s 5 o hms. Re p a i r wi r i ng us i ng a p pr op r i at e rep ai r kit a s requi r e d.
DT C Desc ri pti on Possi bl e C ause Act i on W i r i ng b e t we e n ups trea m O 2 s e ns or a nd E CM Fue l i nje cto r f l ow pa r t i a l ly b l ocke d Ca ta l yst e f fi cie ncy de cr ea s e P .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls2.5L N A V6 - AJV6 / 3.0L NA V6 - AJ27, VIN Range: E 96603->J28492 Dia gn os i s a nd Te s t i ng 1.
DT C De scri pti o n Possi bl e Sour ce A cti on H02S 1/1 s ho r t ci rc ui t t o ground. H02S 1/1 wi r i ng s hi e l d op e n ci rcu i t . H02S 1/1 he a t e r ci r c ui t f a ul t . Exhaus t l e ak. Lo w exha us t t e m pe r at ur e . I nje ct o r f lo w pa rti a l ly bl ocked .
DT C De scri pti o n Possi bl e Sour ce A cti on f a i l ure. P 0430 Co ncern wi th l e ft -hand ba nk cat a l yt ic converte r s yst e m (Eff i ci e ncy be l o w t hr e s hol d ). HO 2 s ens o r di sco nne ct e d. HO 2 s ens o r t o ECM wi r i ng f au l t .
DT C De scri pti o n Possi bl e Sour ce A cti on P 1215, P 1216, P 1344 Conce r n wi t h a ccel e r at or pe da l po s i t i o n s e ns o r ; T r a ck 3. AP P s e ns or . AP P s e ns or ci r cui t s . GO t o Pi npoi nt T es t AA . P 0480 Co ncern wi th radi a t o r coo l i ng f an mod ule drive .
1 2 3 4 1 1 DT C De scri pti o n Possi bl e Sour ce A cti on P 0565, P 0566, P 0567, P 0568, P 0569, P 0570, P 0831, P 0832, P 0834, P 0835, P 1571 Conce r n wi t h ve hi cl e s pe e d cont rol . S wi t chpa ck. S wi t chpa ck ci r cuit s . Cl ut ch can c e l s wi t ch.
1 2 1 2 3 1 2 1 1 2 3 1 1 1 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o A 4 . No REPAI R t he ci r c ui t. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o th e wi r i ng di a gr a m s . CL EAR t he DTCs . T ES T t he s yst em f o r no r mal o p e r at i o n.
1 2 1 2 1 2 1 1 2 3 1 1 1 I s t he res i s t a nce l e s s t ha n 10, 000 ohms? Ye s REPAI R t he s hor t t o GROU ND. For ad di t i on a l in fo rm at i on, r e fe r t o t he wi r i ng d i agrams . Reco nnect a l l co nnect ors. CLEAR t he DT Cs . T ES T t he s ys t e m f or no r m al o pe r a t i o n.
1 2 1 2 1 2 1 1 2 3 1 1 1 2 Is t he res i s t a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t t o GROU ND. Fo r ad di t i on a l in f o r m at i on , r ef e r t o t he wi r i ng di a g r a ms . CL EAR t he DTCs . TE S T t he s yst e m f o r norm al ope rat i on.
1 2 1 2 1 2 3 1 2 3 1 1 1 1 Is t he res i s t a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t t o GROU ND. Fo r ad di t i on a l in f o r m at i on , r ef e r t o t he wi r i ng di a g r a ms . CL EAR t he DTCs . TE S T t he s yst e m f o r norm al ope rat i on.
1 2 1 2 3 4 1 1 1 2 3 1 2 3 1 2 3 4 I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR s ho rt t o ground b et we e n t he e ngi ne compartme nt f us e b ox a nd t he right -hand ba nk HO 2S . For ad di t i ona l i nf o r ma t i o n, r e f e r t o th e wi r i ng di a gr ams .
1 2 1 1 1 2 3 1 2 3 4 1 2 3 4 1 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s GO t o G2 . No REPAI R t he ci r c ui t. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTCs . T ES T t he sys t em f or norm a l op erat i o n.
1 2 3 1 2 3 1 2 3 1 2 3 1 1 2 3 1 2 1 no r mal o p e r at i o n. H3 : CHEC K T HE OIL T EMP ER AT UR E SENS O R GRO U ND C IRC U IT F OR SHOR T T O BAT T ER Y Conne ct ECM e l e ct r i cal conn e cto r , EN16. Tur n t he i gni t i on s wi t ch to the O N p o si t i on.
1 2 3 1 2 3 4 1 2 3 1 1 1 1 1 2 3 I6 : CHEC K T HE VAR I A BLE CIRC UIT OF T HE R IGH T - HA ND BAN K HO2S FOR SH OR T T O BA T T ER Y Conne ct t he ECM e l e ct rica l conne ct o r EN16. Tur n t he i gni t i on s wi t ch to the O N p o si t i on. Mea s ure t he vol t a ge be t we e n EN37, pi n 3 (Y ) a nd GROU ND.
1 1 1 1 2 3 1 1 2 3 1 2 3 1 1 2 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s INS TA LL a ne w ECM . For a ddi ti o nal i nfo r mat i o n, REFER t o : E ngi ne Co nt rol Modul e (ECM) (303 -14B El e ct roni c Eng in e Co nt rol s - 2.0L Dur a t o r q- TDCi /2.
3 1 2 3 4 1 2 3 1 1 1 1 1 2 3 Mea s ure t he vol t a ge be t we e n EN32 pi n 3 (Y ) a nd GRO UN D. Is t he vol t a ge gr e a t e r t ha n 5 vol t s ? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i o nal i nfo r m a t i o n, r e f e r to the wi r i ng di a g r ams .
1 1 1 1 2 3 4 1 2 3 1 1 1 1 REPAI R t he ci r cui t . Fo r addi t i o na l i nf orm at i o n, r ef er t o t he wi r ing di a g r ams . CLEAR t he DT Cs . T ES T t he sys t e m fo r norm a l ope rat i on. L8: CHEC K FUSE 42 OF T HE ENGI N E C O MPAR T MENT FUSE BOX Check t h e fus e .
1 1 2 3 4 1 1 2 3 1 1 2 3 1 2 I s t he res i s t a nce l e s s t ha n 10, 000 ohms? Ye s REPAI R s hort t o g r ound be t we e n t he e ng i ne co mpa r t ment f us e bo x a nd t he MAF s e ns o r . Fo r add i t i o na l i nf o r mat i o n, r e fe r t o wi r i ng di a g r a ms .
1 2 3 1 1 1 1 1 1 1 1 GO t o O 2 . O2: C HEC K T HE GRO UND CIRC UI T T O T H E LEF T - HAN D BA NK HO 2 S H EAT E R Tur n t he i gni t i o n s wi t ch to the O FF p os i t io n.
1 1 1 1 2 3 1 1 1 1 2 1 2 1 Mea s ur e t he vol t a ge be t we e n t he ECM co nt rol r e la y e l ect r i cal co nnect o r JB3 4 pi n 132 a n d GRO UN D. I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s Re pa i r t he ci r c ui t from t he e ngi ne compart ment fus e bo x t o th e ECM cont r o l rel a y .
2 1 2 1 2 3 4 1 2 3 1 2 3 1 2 1 1 2 1 2 Mea s ure t he v ol t a ge be t wee n t he MAP s e ns o r e l e ctrical co nne ct or EN8 pi n 2 (OY ) a nd GRO UN D. Is t he vol t a ge gr e a t e r t ha n 6 vol t s ? Ye s REPAI R t he s h or t t o ba t t e r y.
1 2 1 1 2 1 2 1 2 1 2 1 2 3 4 Is t he vol t a ge gr e a t e r t ha n 1 vol t ? Ye s REP AIR t he s h or t circ ui t . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o wi ring di a g r ams. CLEA R t he DTC. T ES T t he s ys t e m f or no r mal o p e r at i o n.
1 1 1 1 1 2 1 2 1 1 2 3 T 4: CHEC K T HE T HR O T T LE MO T O R RELAY SI GN AL W IRE FOR SH OR T T O GR OU ND Mea s ur e t he res i s t a nce be t we e n th e t hrot t le mot o r r el ay bas e p i n 2 a nd GRO UN D. I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t t o GROU ND.
1 2 1 2 1 1 2 3 1 1 2 3 1 1 2 3 PINPOIN T TE ST V : P15 32 . I MT VA LVE 2 T EST C O NDI T IONS DET AI LS/RE SULT S /ACT IONS V1: C HEC K T HE PO WER SUP PLY CIRC UIT T O T HE I MT VA LVE 2 Tur n t he i gni t i o n s wi t ch to the O N p o si t i on.
1 1 2 3 1 1 2 3 1 1 2 1 1 2 I s t he v ol t a ge grea t e r tha n 4 vol t s ? Ye s GO t o X4 . No REP AIR t he ci r cuit be t we e n t he MAP s e ns or e l ect r i cal co nnect o r EN8 pi n 2 (O Y ) a n d t h e s e ns o r 5 vo l t s u ppl y bu s. CLEA R t he DTC.
1 1 1 1 1 1 1 1 I s t he v ol t a ge grea t e r tha n 4 vol t s ? Ye s GO t o X12 . No REP AIR t he ci r cuit be t we e n t he ACP s e nso r e l e ct r ica l conne cto r JB106 pi n 2 (O Y ) a nd t he s e ns o r 5 vol t s uppl y bus . CLEAR t he DTC. T ES T t he s ys t e m f o r no r mal o p e r at i on .
1 1 1 1 2 1 2 3 1 2 3 1 2 3 1 2 3 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o Y 8 . No REPAI R t he ci r c ui t bet we e n t he AP P s e ns o r e l e ct rical conne c t o r PA1 p i n 3 (BG) a nd GR O UN D. CL EAR t he DTC. TES T t he s ys t e m f o r no r mal o p e r at i on .
1 2 1 2 1 2 3 1 2 3 1 2 3 1 1 2 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o Z 6 . No REPAI R t he ci r c ui t bet we e n t he AP P s e ns o r e l e ct rical conne ct o r PA1 pi n 4 (R) a nd t he ECM el e ct r ica l conne ct o r E N16 pi n 102 (R).
1 2 3 1 2 3 1 2 3 4 1 2 1 1 1 1 REFER t o : A cc e l erat o r Pe d al (310-02 Acc e l e r a t i o n Co nt rol , Re moval a nd I ns t a l l a t i on). CLEAR t he DT C.
2 1 2 1 2 1 2 3 1 2 1 1 1 2 3 Mea s ure t he r es i s t ance b e t w ee n fus e bo x e l e ct rica l conne ct o r JB34 pi n 79 a nd GROU ND. Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o w iring d ia g r ams .
1 2 3 4 5 1 2 1 2 1 2 1 1 2 1 W ARNI N G: Ma k e s ur e t he s t a rte r m ot o r do e s no t e nga ge i n t he co ur s e o f t he s e t e st s . Fa i lur e t o fo l l o w t hes e i ns tru ct i o ns may res ul t i n pe r s o nal i nj ur y .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E lectron ic E ngine C on tro ls2.5L N A V6 - AJV6 / 3.0L NA V6 - AJ27, VIN Range: J2 8493-> V99999 Dia gn os i s a nd Te s t i ng 1.
DT C Descri pti on P oss i bl e S ourc e Acti on ground. H02S 1/1 wi r i ng shi e l d op e n ci rc ui t . H02S 1/1 he a t e r ci r c ui t f a ul t . Exhaus t l e ak. Lo w exha us t t e mper a t ur e . I nje ct o r f lo w pa rti a l ly bl ocked . Ca t a l yst e f fi ci e ncy de cr ea s e.
DT C Descri pti on P oss i bl e S ourc e Acti on Up s t r ea m HO 2 s ens or f a i l ure. Downs t r e a m HO2 s ens o r f a i l ure. HO 2 s e ns o r fa i l e d. Ca t a l yt i c conver t e r f a i l ure. P 0430 Co ncern wi t h l e f t -ha nd ba nk cat a l yti c conve r t er s ys t e m.
DT C Descri pti on P oss i bl e S ourc e Acti on P 0226, P 00227, P 0228 Conce rn wi t h a ccel e r at o r p eda l po s i t i o n s e ns or ; T r a ck 1. AP P s e ns or . AP P s e ns or ci r cui t s . GO t o Pi npoi nt T es t Z. . P 2122, P 2123 Co ncern wi th a ccel e r at o r p eda l po s i t i o n s e ns or ; T r a ck 3.
DT C Descri pti on P oss i bl e S ourc e Acti on Va po r l i ne s . P 0460 Co ncern wi t h f ue l l e ve l s e ns o r s . Fue l l e vel s e ns ors. Fue l l e ve l s e ns or ci r cuit s . I ns t ru me nt cl ust e r . REFER t o : Fu e l Charging a nd Co nt rols - 2.
1 2 3 4 1 1 1 2 1 2 3 1 2 1 1 2 DT C Descri pti on P oss i bl e S ourc e Acti on P 0860, P 1637, P 1638. P 1642, P 1643, P 1699 Conce rn wi t h CAN ne t wo rk .
3 1 1 1 1 2 1 2 1 2 1 1 2 3 Meas ur e t he r es i s t a nce be t we e n t he CKP s e ns o r e l e ct r i cal conne ct o r EN12, pi n 1 (Y ) a n d t he ECM el e ct rica l conne ct o r EN16, p i n 37 (Y ). I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s GO t o B 4 .
1 1 1 1 2 1 2 1 2 1 1 2 3 I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s GO t o C4 . No REPAI R t he ci r cui t . For a ddi t i o na l i nf orm at i o n, r ef e r t o t he wiring di a grams. CLEAR the DTCs . TE S T t he s ys t e m f or norm a l ope rat i on.
1 1 1 2 1 2 1 2 1 2 3 1 2 3 1 I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s GO t o D4 . No REPAI R t he ci r cui t . For a ddi t i o na l i nf orm at i o n, r ef e r t o t he wiring di a grams. CLEAR the DTCs . TE S T t he s ys t e m f or norm a l ope rat i on.
1 1 1 1 2 1 2 3 4 1 1 1 2 3 1 2 3 GO t o E4 . E4: CHEC K T HE R I G HT -HAN D BA N K HO2S GR O UND CIR C UI T FO R SHOR T T O BAT T ER Y Che ck fo r a vol t a ge b e t we e n t he HO 2S el e ct r ica l conne ct o r EN 37, pi n 1 (RU ) a nd GROU N D. I s t he v ol t a ge gr e a t e r th a n 1 vo l t ? Ye s REP AIR t he s h or t t o ba t t e r y.
1 2 3 4 1 2 1 1 1 2 3 1 2 3 4 I s t he v ol t a ge grea t e r tha n 10 vo lt s ? Ye s REP AIR t he sh or t to ba t t e ry . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o t he w i r i ng di a g r a m s . CL EAR t he DTCs . TE S T t he s ys t e m fo r nor m al op e r at i o n.
1 2 3 4 1 1 2 3 1 2 3 1 2 3 1 2 3 1 1 2 3 PINPOIN T TE ST H : DTC P01 96 , P01 97 , P01 98 . OIL TEMPERATU RE SENS OR T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS H1 : CHEC K T HE OIL T EMP ER AT UR E SENS O R S I GNA L WI R E FOR OP EN CI R C UI T Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n.
1 2 1 1 2 3 1 2 3 4 1 2 3 1 1 1 Is t he vol t a ge gr e a t e r t han 5 vol t s? Yes REPAI R t he s hor t circ uit . Fo r add i t i ona l i nf o r m a t i o n, r e f er t o t h e wi r i ng di a gr ams . CLEAR t he DTCs . TEST t he s ys t e m fo r nor m al o p e r at i o n.
1 1 2 3 1 1 1 1 2 3 1 1 2 3 No INS TA LL a ne w RH b a nk cat a lys t m o nit or s e ns or. For a ddi t i o na l i nf orm at i o n, REFER t o : Ca t a l yst Mon it o r Sens o r RH (303-14A El e ct roni c Engi ne Co nt rols - 2.0L N A V 6 - A JV6/ 2.5L NA V6 - AJV6/3 .
1 2 3 1 1 2 3 1 2 3 4 1 2 3 1 1 1 K4: C HECK T HE VARIAB LE CI RC U I T OF T HE LEFT - HAN D BA N K H O2S FOR O PE N CIRC UIT Dis conne ct t he HO 2S e l e ct rical co nnect or EN32.
1 1 2 3 1 1 1 1 2 3 4 1 2 3 1 1 REFER t o : E ngi ne Cont rol Mo dul e (ECM) (30 3-14A El e ct roni c Eng i ne Co nt rol s - 2. 0L NA V6 - AJV6/ 2.5L N A V 6 - AJV6/ 3.0L N A V 6 - A J27, Re moval a nd I nst a l l at io n). Bef o r e r ep l a cing a n ECM, co nt a ct dea l e r t e chni cal s uppo rt.
1 1 1 1 2 3 4 1 1 2 3 1 1 2 3 I s t he res i s t a nce grea t e r t ha n 10,000 o hms? Ye s INS TA LL a ne w MAF se ns o r . For add i ti ona l i nf o r m a t i o n, REFER t o : Ma ss A ir Fl o w (M AF) S e ns o r (30 3-14 A El e ct roni c Engi ne Co nt rol s - 2.
1 2 1 2 3 1 1 1 1 1 1 I s t he v ol t a ge grea t e r tha n 1 vol t ? Ye s REP AIR t he s h or t circu i t . Fo r a ddi t i o nal i nfo r mat i on, ref e r t o t he wiring di a g rams. CL EAR t he DTCs . T ES T t he s ys t e m f or norm al op e rat i o n.
1 1 1 1 1 1 2 3 1 1 1 1 2 I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s GO t o P 3 . No REP AI R t he cir cuit f r om t he ECM cont r ol rel a y t o t he ECM. Fo r ad di t io nal i nf or ma t i on , ref e r t o wi ring di agrams . CLEAR t he DTC.
1 2 1 2 1 2 1 2 3 4 1 2 3 1 2 3 1 2 I s t he r es i s t a nce l e s s t ha n 5 ohms? Ye s P os s ib l e i nt e rm it t ent f a ul t . Reche ck DTCs . No I NS TALL a ne w ECM cont rol r e la y di o de . Ma ke s ur e t ha t t he ECM co nt rol rel a y di o de i s i ns t al l e d co r re c t l y.
1 1 2 1 2 1 2 1 1 2 1 2 1 2 Is t he res i s t a nce l e s s t han 5 ohms ? Ye s GO t o R2 . No REP AIR t he ci r c ui t bet we e n VVT s o l e no i d e l e ct r i cal co nnect o r EN61 pi n 2 (BG) a nd GRO U ND. For ad di t io na l in f o r ma t i o n, r e f er t o wi r i ng d ia g r ams .
1 2 1 2 3 4 1 1 1 1 1 2 1 2 I s t he v ol t a ge gr e a t e r th a n 10 vo l t s ? Ye s GO t o T2 . No REP AIR t he ci r cuit be t we e n pi n 1 of t he t hrot t l e mo t o r r e l a y b as e and t he EMS cont ro l r el a y. Fo r add i t i ona l i nf o r ma t i o n, r e f e r t o th e wi r i ng di a gr ams .
1 1 2 3 1 2 1 2 1 1 2 3 1 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s GO t o U 3 . No REPAI R t he ci r c ui t bet we e n t he IMT val v e 1 e l e ct rica l conne ct o r EN 999 pi n 2 (OY ) a nd t he ECM e l ect r i c a l conne ct o r EN16 p i n 38 (OY ).
1 1 1 1 1 1 1 1 1 Te s t not ap pl i cabl e. PINPOIN T TE ST X : P12 43 . S ENSOR G ROU ND CIRCU ITS . T EST C ONDI T I ONS DET AI LS/RE SULT S /ACT IONS X1: C HEC K T HE GR O UND CIR C UI T T O T HE EC T SEN SOR Mea s ure t he r es i s t ance b e t wee n ECT se n s o r e le c t rical co nnect or EN18 pi n 1 (BG) a nd GRO U ND.
1 1 2 3 1 2 3 1 2 1 2 3 1 2 3 1 2 3 Is t he res i s t a nce l e s s t han 5 oh m s ? Ye s GO t o X 10 . No REPAI R t he ci r c ui t bet we e n t he AP P s e ns o r e l e ct rical conne c t o r PA1 p i n 6 (BG) a nd GR O UN D. CL EAR t he DTC. TES T t he s ys t e m f o r no r mal o p e r at i on .
1 2 3 1 2 1 2 1 2 3 1 2 3 1 2 3 1 Is t he vol t a ge gr e a t e r t ha n 1 vol t ? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o w iring d ia g r ams . CLE A R t he DT C. TES T t he s yst e m fo r norm a l op erat i o n.
1 2 1 2 3 4 5 1 2 1 2 1 2 1 1 2 1 AA 6: CHEC K CO NT I NUI T Y O F T HE APP SENSOR PO T E NT IOM ET E R Mea s ure t he r es i s t ance b e t w ee n APP s e ns o r el e ct r i cal co nnect or PA 1 pi ns 1 a nd 3. Op e r at e th e acce l e r at o r pe da l through i t 's f ul l r a nge whil e o bs erv ing t he res i s t a nc e r e a di ng.
1 2 3 1 1 2 3 1 1 2 3 1 1 2 3 fo r no r m a l op e r at i o n. If t h e DTC i s r e pe a t e d , I NS TAL L a ne w ECM. REFER t o : E ngi ne Cont rol Mo dul e (ECM) (30 3-14B El e ct roni c Eng in e Co nt rol s - 2. 0L Dur a t orq- TDCi /2.2L Dur at o rq-TDCi (110k W /150PS ) - P uma, Removal a nd Ins t al la t i o n).
1 1 2 1 1 2 1 1 2 3 1 2 3 4 Mea s ur e t he vol t age bet we e n AP P s e ns o r e le ctrica l conne ct o r P A 1 pi n 5 (OY ) a nd GRO U N D. I s t he v ol t a ge grea t e r tha n 6 vol t s ? Ye s REP AIR t he ci r cuit be t we e n t he AP P s e nso r e l e ctrica l conne ct o r P A 1 p in 5 (O Y ) and th e s e nso r 5 v ol t s upp l y bus .
1 2 1 1 1 1 2 1 2 1 2 1 2 3 1 2 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s REPAI R t he ci r c ui t bet we e n EN30 p i n 2 (B) a nd GROU ND. Fo r a ddi t i o nal i nfo r mat i on, re fe r t o wi r i ng d i agrams . CLEAR th e DTC. T EST t h e s y s t e m fo r norm al o pe rat i on.
1 1 Is t he res i st a nce l e s s t han 5 oh m s ? Ye s GO t o A E11 . No REPAI R t he ci r c ui t. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o w i r i ng di a g r a ms .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Pow ertrain C o ntrol Mo d ule (PCM) Lo ng Drive C y cle Se lf-Test Gene ral P r ocedures W ARNI N G: W here pos s ib l e , a l l roa d te s t s s hou l d be o n we l l s urfaced a nd dr y r oad s .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Pow ertrain C o ntrol Mo d ule (PCM) Sho rt Drive Cycle Self-Te st Gene ral P r ocedures • NO T E: T hi s p rocedur e i s a n o ve r check onl y .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C amsh aft Pos itio n (C M P ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e ngi ne cover. 2. D i s conne ct t he CMP s e ns o r el e ctr i cal co nne ct or.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C atalyst Moni to r Sensor LH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
1. CAU TI O N : Make s ur e t h at th e ca t a l y s t moni t or s e nso r cas i ng a nd c a bl e a r e not da ma ge d. To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 40 Nm. 2. NOT E: For NAS v e hi cl e s o nl y. I f r e qui red, ca r r y o ut a l ong dr ive cycle .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C atalyst Moni to r Sensor RH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
8. CA UT I O NS: Do no t cut t he HO 2S ha r ne s s . Make s ur e t ha t the cat al ys t mo ni to r s e ns o r cas i ng a nd ca bl e a r e not dama ge d. Us i ng S nap -on s o cket Y A8875 re mov e th e ca t al yst moni to r s e ns o r. Insta llat ion 1.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - C rankshaft Pos i tio n (C K P) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he right -ha nd front r oa d whe e l.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - E ngine Co n trol Module (E CM ) Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
6. D et a ch t he ge ne r i c e l e ct r o nic modul e (GEM ) f r om t he ECM . 1. Re l e a s e t he GEM l ocki ng t a ng. 2. De ta ch t he GEM f r o m t he ECM. 7. Remove t he ECM. 1. Re move t he ECM ret a i ni ng nut . 2. Re move t he ECM. 8. Remove t he ECM f r om t he ECM ret a i ni ng br acket .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Fuel Tem perature Senso r2.5L N A V6 - AJV6 / 3.0L N A V6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Qui ck fi t conne ct o r r e l ea s ing t o o l 310-0 45 R em ova l 1.
Insta llat ion 1. NOT E: Ins t a l l a new O -r i ng s e a l . I nst a l l t he f ue l t empe r a t ure s ens o r . 2. Connect t he f ue l t e mpe r at ur e s e ns or e l e ct r i cal co nne cto r. 3. Ins t a l l the ret a i ni ng cl i p to the s pr i ng lo ck co upl i ng.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Heated Oxygen Senso r (HO2S) L H Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Heated Oxygen Senso r (HO2S) RH Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - K no ck Senso r (KS) Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
8. NOT E: Fue l may s t i l l be pres e nt i n t he fue l s up pl y m a ni fo l d. Det ach t he f uel i nj e ct i on su ppl y mani fo l d a nd l o we r i nt a ke ma nif ol d a nd pl a ce t o o ne s i de . 9. Remove t he f uel i nj e ct i on s uppl y mani f ol d a nd l owe r i nt a ke mani f o l d .
13. Remove t he e n gi ne co o l a nt i nl e t p i pe . Re mov e a nd di s c a r d t he s e a l . 14. Remove t he KS. Insta llat ion All v e h icle s 1. NOT E: Prio r t o i ns t al li ng t he KS , cl e a n t h e e ng i ne b lo ck a nd KS ma t i ng s ur fa ce s wi t h met a l s ur f a ce cl e a ne r (W S W -M5 B392-A).
3. Ins t a l l a ne w s e a l . Ti ght e n t o 10 Nm. 4. Tig ht e n i n t he s eque n c e s ho wn. Ti ght e n t o 10 Nm. Vehi c le s with 2.0L engi n e 5.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Mass A ir Flo w (MA F ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ba t t e r y cover . 2. D i s conne ct t he MAF se n s o r e l e c t r i cal co nne cto r.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - Oi l T em peratu re Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 100-02 Ja cking a nd L i f t i ng .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - T hrottle Po si tio n (TP) S ensor Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.
6. Remove t he t he t hr ot t le pos i t i on (TP ) s e ns o r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n t o 7 Nm.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L N A V 6 - A JV 6/2 .5L N A V6 - AJV6/3. 0L NA V6 - A J27 - V ariable C amsh aft T im ing ( VC T) Oil C on trol Sol eno id Re moval a n d I ns t a l l a t i on R em ova l R ight-H and Bank 1.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - T o rque Sp eci f i cat ions Descri pti o n N m l b-ft l b- i n Ca m s h.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ele ctro nic Engine C o ntro ls Des cr ipt i o n a nd O pe r a t i o n I.
id e nt i fi e d. S houl d t he CMP se ns o r fa i l t he e ng i ne wi l l no t s t a r t . Engi ne Con trol Modul e (ECM) The e ngi ne co nt r o l mod ul e (ECM ) i s l o ca t e d i n t he s ame p o si t i on a s t he p e t r ol ve r s i on.
P ubl i she d: 12-Jul-2011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ele ctro nic Engine C o ntro ls Dia gn os i s a nd Te s t i ng Over view Thi s s e cti on cove r s t he co mpon ent s of t he e ngi ne ma nage me nt s ys t e m .
Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Engi ne cont rol mod ul e (ECM) f a ul t Di ff i cul t t o s t a rt Di ff i cul t t o s t a r t co l d Gl ow pl ug (s)/circu .
Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Engi ne sp e e d ou t of co nt r ol Engi ne oi l l e vel t o o hi gh Exc es s ive b l o w-by Accel erat o r pe da l po s i t i o n (AP P ) s e ns or f aul t Tur bo charger be a r i ng/s e a l f ai l ure Check/ cor r e ct t he e ng i ne o i l l e v e l .
Sym ptom (ge ner al ) Sym ptom ( speci fi c ) Po s si bl e sou rce Acti on Mani f o l d a bs o l ut e pr es s ur e (MAP) s e nso r f aul t Kno c k s e ns o r f a ul t Fue l rai l pr e s s ur e (FRP ) .
DT C C ondi ti o n Poss i bl e sourc e Act i o n W he e l s pe e d s e ns o r in put ci r cuit : s ho r t cir cui t to powe r C1155 Le f t -ha nd front whe e l s pee d se n s o r i np ut ci r cuit f a.
DT C C ondi ti o n Poss i bl e sourc e Act i o n P 0191 Fue l pr e s s ur e s e nso r A ci r cuit r a n ge/p e r fo r m a nce Pump d e t e r i o r at i o n - Co nt a mina t e d f ue l Lea ki ng f ue l rai l Fuel pr e s s ur e s e nso r c i r cuit f a ul t Fuel pr e s s ur e s e nso r fa ul t Che ck f o r cont a mina t e d fue l .
DT C C ondi ti o n Poss i bl e sourc e Act i o n c i r cuit (s i gnal re t urn ) MAPT s ens or fa ul t P 0243 Turbocha r ger a ct ua t o r A c i r cuit Turbochar ge r a ct ua t o r c i r cuit : h ig h.
DT C C ondi ti o n Poss i bl e sourc e Act i o n op en ci r cuit , hi gh res i s t a nce. Fo r furthe r di a gno s t i c i nfo rm at i on REFER t o : T ur bo charger (303- 04C Fue l Charging a nd Co nt rol s - Tur bo charg e r, Dia g no si s a nd T e st i ng).
DT C C ondi ti o n Poss i bl e sourc e Act i o n P 0530 A i r condi t i oni ng r e f r i ge rant pr es s ure s e ns o r ci rc uit Ai r cond i t i oni ng p r es s ure se n s o r ci r cuit : hi g h r e .
DT C C ondi ti o n Poss i bl e sourc e Act i o n Engi ne c o nt r ol m od ul e (ECM ) f aul t P 0623 Gene r at or wa r ni ng l a mp ci r cuit W a r ni ng la mp fa i l ur e W a r n i ng l a mp c i r cu.
DT C C ondi ti o n Poss i bl e sourc e Act i o n P 132B Turbocha r g e r b o os t s ys t e m perform a nce Memor y check fa i l ur e dur ing i ni t i a l i za t i o n Tur bocha r ge r va nes st i ckin.
DT C C ondi ti o n Poss i bl e sourc e Act i o n sho rt t o po we r Fai l ur e o f ECM Fai l ur e o f TCM P 1937 Fue l fi r ed hea t er (FFH) cont r ol c i r cuit FFH s upp l y or ground c i r cuit f .
DT C C ondi ti o n Poss i bl e sourc e Act i o n t he DTCs , t e s t f o r norm a l op erat i o n. P 2337 Cyl i nde r 2 a b ove k nock th r es hol d - knock s e ns o r t r im fo r cyli nd e r 2 (i nje.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ca msh aft Posi tio n (CMP) Sensor Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Ca talyt ic C on v erter Temperature S ensor Re moval a n d I ns t a l l a t i on Speci al T ool (s) Exhaus t g a s t e mperat ure s e nso r wrench 303-1184 R em ova l 1.
4. Remove t he t urbocharger hea t s hi e l d. 5. D i s conne ct t he ca t a l yt i c c o nver t e r t e mpe r a t ur e s e ns or e l ect r i cal conne ct or.
2. CAU TI O N : Make s ur e t h e t orque wr ench s e t t i ng procedur e i s fo l lo we d co r r ect l y. Fai lure t o fo l l o w t hi s i ns t ru ct i on may r e s ul t i n d amage to the ve hi cle . I nst a l l t he cat a l yt i c co nverte r t empe rat ure s e ns o r .
7. Ins t a l l the o i l l e v el i ndi c a t o r . JagDocs.com.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Cra nkshaft Positio n (CKP ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he e l ect r i cal conne ct o r.
3. Connect t he CKP s e ns or el e ct r i cal con nect o r . JagDocs.com.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Cylin der Head Temperature (CH T) Senso r Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ock e t , CHT S e ns o r 303-680 (21 -239) R em ova l 1.
5. D et a ch t he cycli nde r he a d te mperat ur e (CHT) s e ns or e l e ct r i ca l conne ct or. 6. D i s conne ct t he CHT se ns o r e l e c t r i cal co nne cto r. 7. Usi ng t he s pe cia l t oo l 303-680, r e move t he CHT s e ns or. Insta llat ion 1.
2. Tig ht e n t o 10 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Dies el P articul ate Filter (DPF ) T emperature Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - En gine C ontro l Mo dule (EC M) Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
6. D et a ch t he ge ne r i c e l e ct r o nic modul e (GEM ) f r om t he ECM . 1. Re l e a s e t he GEM l ocki ng t a ng. 2. De ta ch t he GEM f r o m t he ECM. 7. Remove t he ECM. 1. Re move t he ECM ret a i ni ng nut . 2. Re move t he ECM. 8. Remove t he ECM f r om t he ECM ret a i ni ng br acket .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - En gine Oi l Pressu re (EO P) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Fuel T emperature Senso r Re moval a n d I ns t a l l a t i on R em ova l 1.
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 15 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Kn o ck Senso r (KS) Re moval a n d I ns t a l l a t i on R em ova l 1.
6. D i s conne ct t he e l ect r i cal conne ct o r. 7. Remove t he knock s e ns o r (KS ). Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Manifo ld Abso lute Pressure and T emperature (MA PT) Sen sor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r .
5. CAU TI O N : Make s ur e t h at th e radi a t o r i s not da mage d whe n in s t a l l in g t he ret a i nin g s t raps . Fit s ui t a bl e re t a i ni ng s t r a ps t o t he r a di a t o r.
11. Remove t he cha r ge a i r coo l e r ho se s and mani fo l d a bs o l ut e pre ss ur e a nd t e mperat ure (MAPT) s e ns or a s s e mbl y. 12. Remove t he MAP T s e ns or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 4 Nm.
3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Manifo ld Abso lute Pressure (MA P) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r .
5. D i s conne ct t he ho s e . Det a ch t he r et a i ni ng cli p . 6. Remove t he MAP s e ns o r . Re mov e t he re ta i ni ng bo l t . Insta llat ion 1.
P ubl i s he d: 11-May-2 011 E lectron ic E ngine C on tro ls - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (1 10kW/150P S) - Puma - Mass Air Flo w (MA F ) Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2.
5. Remove t he mas s a i r f l ow (MAF ) s e ns or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Lubr i cant , Sea le r s and Solve nts Descri pti on Speci f i ca ti.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on D escriptio nV ehicl es Wi th: 5-Speed Auto mati c T.
t he re i s no p owe r fl o w t hrough t he a ut oma t i c t rans mi s s i o n. t he pa r king pa wl l o cks t he out put s ha ft t o t he cas e . t he e ngi ne may be s t art ed .
It e m Pa rt Nu mb e r De s cri pti on 1 — T o r que co nv e rte r 2 — T e r mina l as s e mbly 3 — P l a t e 4 — Re t ai ni ng bo l t 5 — I nhi b i t o r swi t ch 6 — Ma i n cont r o l va.
I te m P a rt Nu m ber Descri pti on 1 — O i l pump 2 — O i l s trai ne r 3 — I np ut s ha ft 4 — Di ff e r e nt i a l gea r 5 — Re duct io n gea r 6 — Re duct io n br ake b a nd 7 — Sun.
I te m P a rt N um be r D e s cri pti on 1 — TCM 2 — Ant i -lo ck Br aki ng S yst e m (ABS ) 3 — Engi ne Cont rol Modul e (ECM) 4 — D/4 s wi t ch, (t es t s wi t ch), s po r t s mode s wi t ch.
It e m Pa r t Nu m ber Desc ri pti o n 1 — T orque conver t e r 2 — Inp ut s haf t 3 — O ut pu t ge a r 4 — L ow cl ut ch 5 — L ow a nd r eve r s e b rak e 6 — Re a r pl ane t a r y pi ni .
23 — D ire c t clut ch 24 — Park ing g e a r 25 — Park ing p a wl 26 — Fina l ge a r 27 — D if fe rent i a l g e ar 28 — D r i ves h a ft Torque C onvert er It e m Pa rt N um be r Descri p.
It e m Pa rt Nu mb e r Desc ri pti on 1 — O i l s e a l 2 — O -r i ng 3 — O i l pump hous i ng 4 — I nne r r ot o r 5 — O ut er r ot o r 6 — O i l pump cove r 7 — Sea l ring 8 — Bo l t s A t r ocho i d o i l pump i s us e d wi t h JF506E a ut o mat i c t r a ns mis s i o n.
Item Pa r t Nu m be r De s cri pti on 1 — Fr ont s un ge a r 2 — Fr ont p i ni on ge a r 3 — Rea r s un ge a r 4 — Fr ont i nt e r na l ge a r 5 — Rea r pi ni o n ge a r 6 — Rea r i nt e r nal ge a r The r e a re 3 pl ane t ary ge a r s e t s .
I te m P a rt N um be r Descri pti on 1 — H i g h cl ut c h pi s t o n 2 — Ca n ce l f o r ce 3 — H i g h cl ut c h pr e s s ure 4 — L ubr i cat i ng pres s ur e 5 — Ca n ce l f o r ce co ve.
Item Par t Nu m be r Descri pti on 1 — Brak e b a nd e nga ge ment pres s ur e 2 — P is t o n s te m 3 — Tr an s mi s s i o n cas e 4 — Anchor en d b o lt 5 — Brak e b a nd 6 — Di r ect cl.
cam a nd i nne r r ace t he y a r e uni te d t o t r ans mi t to rque. I n t he r e ver s e di rect i on , be c a us e t he r ol l e r s move i n t he di r ect i on whe r e t he cle a r a nce i s l a r ge r , cl ea r a nces o cc ur be twe e n races and t he i nne r and o ut e r r aces ca n rot a t e t o e ach o t he r .
I te m P a rt N um be r Descri pti on 1 — S ub lo we r body 2 — Br ack e t 3 — Cli p 4 — Li ne pr es s ure d ut y s ol e noi d 5 — Low cl ut ch t i mi ng s o l e no i d 6 — Br ack e t 7 .
21 — S e p a r a t e pl a t e C 22 — Uppe r bo dy 23 — Manual va l ve The r e a re 9 s ol e noi d s whi ch c a n b e cl a ss i f i e d as two t ype s b y t he wa y i n whi ch t he y o pe r a t e . Thr e e o f the m a r e dut y s o l e no i ds , t he o t he r s i x a re o n/of f t ype s .
The TSS us e s a magne ti c coi l . As t he i np ut s ha f t r ot a t e s , th e s e ns or de t e c t s a pul se si g nal a ccor di ng t o t h e ge ar t e e t h on t he o ut si d e o f t he r e ver s e cl ut ch dr um a nd s end s i t to t he TCM.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Diagnos tic Stra te gyVehicles Wi th: 5- Speed A utom atic Trans axl.
1 2 CAU TIO N : W hen probi ng conne ct o r s t o t a ke me a s ur e ment s i n t he co ur s e of t he p in po i nt t e s t s , use t he a d a pt o r ki t , part numbe r 3548-135 8-00 . • NO T E: Che ck and r ect i fy ba s i c f a ul t s bef or e be gi nni ng di a gnos t i c rout in e s i n v ol v i n g pi npo i nt t es t s.
1 1 2 1 1 2 1 1 2 1 1 2 1 1 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s GO t o A 3 . No GO t o A 2 . A2 : CHEC K T HE LOW C LUT C H T IMI N G SOLENOID RESI ST ANCE. Mea s ur e t he res i s t a nce b et we e n t r a ns mis s i o n e l e ct r i cal conne ct o r JB155 pi n 18 a nd pi n 12 a t t he t rans m i s s i o n.
2 1 1 2 3 1 2 1 2 1 2 1 2 1 2 Mea s ur e t he res i s t a nce b et we e n JB155, p in 18 (B) a nd JB131, p i n 17 (B). I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams .
1 1 2 1 1 1 1 1 1 2 3 1 2 Ca r r y o ut t he a dj us t ment pr o ce dur e f o r t he t r a n s mi s s i o n r a nge s e ns o r . REFER t o T r ans mis s i on Ra nge (TR ) S e ns o r A dj us t me nt i n t hi s s e c t i o n. Re check t he ci rc u i t .
1 1 2 3 1 1 2 1 2 1 1 1 2 Is t he res i s t a nce g r ea t er t h a n 5 o hms ? Ye s REP AIR t he hi gh r e s i s t ance ci rc ui t . Fo r a d di t i o na l i nf o r mat i o n, refe r to t he wi r i ng di a gr a m s . CL EAR t he DTC. TES T t he s yst e m f o r norm al op erat i o n.
1 2 1 1 1 2 1 2 1 1 1 2 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m fo r n or mal o perat i o n.
1 1 1 2 1 1 2 1 1 2 1 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m fo r n or mal o perat i o n.
1 1 2 1 1 2 1 1 2 1 1 2 1 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C. TES T t he s ys t e m fo r n or mal o perat i o n.
1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 Cont a ct d e a l e r t e chn ical s upp ort f or a dvice o n po s s i b le modul e f ai lu r e. PINPOIN T TE ST O : P07 48 . LINE PRESS U RE CONTROL SO LENO ID MALFU NC TION T EST C ONDI T IONS DET AI LS /R ESULT S/ACT IONS O1: C HEC K T HE LI NE PR ESSUR E CO NT R O L S OLE NOID GR O UND C IRC UIT .
2 1 2 3 1 2 1 2 3 1 2 1 2 1 1 1 2 3 Mea s ur e t he res i s t a nce b et we e n JB155, p in 18 (B) a nd JB131, p i n 17 (B). I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams .
1 2 1 2 1 1 1 2 1 2 1 1 Does t he s ys t e m funct i on corr e ct l y? Ye s No f ur t he r act i on require d. No Cont a ct d ea l er t e chni cal s uppo rt fo r ad v i ce on po s s i bl e modul e f a i l u r e .
1 2 1 2 1 1 U1: CHEC K T HE T U R BIN E SPEED S ENSOR GR O UND C I R C UI T . Di s conn ect t he t r ans mi s s i o n e l e ct r ica l conne ct o r , JB155. Mea s ur e t he res i s t a nce b et we e n JB155, p in 01 (B) a nd GROU ND (s hi e l ded cabl e ).
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Flu id Drain an d Refill Gene ral P r ocedures D ra in 1.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Flu id Level C heck Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng .
11. Ins t a l l t he a ut omat i c t rans mi ss i on fl ui d cha r g i ng pi pe cap . 12. Lowe r t he vehi c l e . 13. Dis c o nne ct t he Ja gua r Appr o ved Dia gno st i c S y s t em.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Range (T R) Senso r Adjustment Gene ral P r ocedures Speci al T ool (s) S e t t i ng p l a t e rot a r y s wi t ch 307-44 5 1.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Halfsh aft Seal L H I n-v e hi c l e Re pa i r Speci al T ool (s) Li nk s ha ft o i l s e a l ins t a l le r 205-115 P ini on o i l s ea l remover 308-208 R em ova l 1.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Halfsh aft Seal RH I n-v e hi c l e Re pa i r Speci al T ool (s) Li nks haf t oi l s e al i ns t al l er 205-115 P ini on o i l s e al remover 308-208 1.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Ma in Co ntro l Valve B ody I n-v e hi c l e Re pa i r R em ova l 1. D et a ch t he wi ring ha r ne s s . 2. Remove t he mai n val ve b o dy cover.
4. D et a ch t he wi ring ha r ne s s . 5. Remove t he mai n co nt r ol val ve b od y. 6. Remove and di s card t he O -r ing s e a ls . Insta llat ion JagDocs.
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ins t al l t he n e w O -r ing s e a ls . 2. To i ns t a l l , rever s e t he remov a l proced ur e .
4. NOT E: Appl y a n e v e n be a d o f s i l i con e ga ske t s e al a nt W S E-M 4G 323-A6 or eq ui val ent mee t i ng Ja gua r s pe ci fi cat io n t o t h e mai n val ve bo dy cove r s ea l i ng s u r f a c e . Ti ght e n t o 8 Nm. 5. Ch eck a nd a dj us t t he t rans mi s s i on fl ui d l e v el .
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Shift Solen oi ds (SS) I n-v e hi c l e Re pa i r R em ova l 1. Remove t he mai n co nt r ol val ve b od y. For add i t i o na l i nf orm a t i o n, r e fe r t o Mai n Co nt r ol Va l ve B od y .
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transax le Support In sul ator I n-v e hi c l e Re pa i r Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l 1.
4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 5. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 6. D et a ch t he s up po r t b a r .
8. Remove t he s p a c e r. 9. Remove t he t r a ns a xl e s uppo rt i ns ul a t o r. Re mov e t he t rans a xle s u pport i ns ul a t or ret a i ni ng nut s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 47 Nm.
3. Tig ht e n t o 25 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on C ontrol Modul e (TC M) I n-v e hi c l e Re pa i r R em ova l 1. Remove t he rai n s e ns or modul e. Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S ect i o n 501-16 W i pers a nd W as h e r s .
4. Remove t he TCM. 1. Dis con nect t he e l e c t rical co nnect or. 2. Re move t he T CM. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
2. Tig ht e n t o 10 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transm i ssi on Range (T R) Senso r I n-v e hi c l e Re pa i r R em ova l 1.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transax le Re moval Speci al T ool (s) S li de ha mm er 100-012 100-.
3. Loos e n t he l e ft -hand s ho ck a bs orber an d s pr i ng a s s e m bl y s e cur i ng nut s . 4. Loos e n t he r i ght -ha nd s ho ck abs o r b e r and s pr i ng a s s e mbl y s e cur i ng nut s . 5. Remove t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.
8. Remove t he s t ee ring ge a r he a t s hi e l d. 9. Remove t he t r a ns f e r cas e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans fe r Cas e (308-0 7 T r ans fe r Ca s e, Re moval ).
13. NO TE: P l ug the t rans a xle t o p revent fl ui d l os s o r di r t i n gr es s . Us i ng t he s p e ci a l t o ol s , de ta ch t he l e f t -han d hal fs ha ft . 14. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e .
18. NO TE: Ro t a t e t he t o r que co nverte r t o g a i n a cces s f o r the remai ni ng r e t a i ni ng bo l t s . Re move t h e t o rqu e conve r t e r r et ai ni ng bo l t s . 19. NO TE: L owe r tran sa xl e fl ui d co ol e r t ube s ho wn, uppe r t r ans axl e fl ui d c oo l er t u be s i mi la r.
24. Ins t a l l t he e ngi ne s up port b r acket . 25. Det a ch t he pos i t ive crankcas e vent i la t i o n (P CV ) hos e from t he i nt a k e m a ni f o l d. 26. Det a ch t he el e ct r i cal co nnect o r fr om th e i nt a ke mani fo l d s uppo r t br acke t .
29. Ins t a l l t he e ngi ne s up port b r acket . 30. Ins t a l l t he e ngi ne s up port b r acket . Adj us t th e e ng i ne s upp or t bracket t o s upp or t t he we i g ht o f t he pow ertrai n as s e mbly. 31. Remove t he s uppo rt ba r r et a i ni ng b o l t s .
34. Det a ch t he s t ar t e r moto r s o l e no i d cover. 35. Det a ch t he s t ar t e r moto r e l e ct r i cal c onn e cto r . 36. Det a ch t he s t ar t e r moto r s o l e no i d e l ect r i cal co nne cto r. 37. Remove t he s uppo rt ba r mount bracket /t r ans a xle uppe r r et a i ni ng bol t .
39. Remove t he s t arte r mot o r . 40. Det a ch t he t rans a xle ground l e a d. 41. Remove t he t r ans a x l e ret a i ni ng bol ts . 42. Remove t he t r ans a x l e mount br a ck et s e cur ing bol t s .
45. Remove t he t r ans a x l e ret a i ni ng bol ts . 46. Al i gn t he po we r t r a i n a s s e mbl y j a ck t o t he t rans a xle . S ecur e t he t rans a xle t o t h e po we rtr a i n a s s e mbl y j a ck . 47. Remove t he t r ans a x l e ret a i ni ng bol t.
50. NO TE: Ca rr y t his s t e p i f a l a t er cond it i o n t r ans axl e i s be i ng r emove d. • NO T E: Ve hicl e s wi t h 2. 5L a nd 3.0L e ngi ne s s ho wn, ve hi cl e s w i t h 2.0L e ngi ne s i mi l a r . Re move t h e t rans a xle r e t a i ni ng bo l t .
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Input Shaft S eal Dis a s s e mbl y a nd As s e mbl y o f Sub a s s e mbli e s Speci al T ool (s) Li nk s haf t o i l s e al i n st a l l er 205-11 5 1.
6. CAU TI O N : Do no t l e t t he t orque conve r t e r dr op o ut o f t he tra nsmi s si o n. Fai l ur e to fo l l o w t hi s i ns t r ucti o n may res ul t i n p e rson a l in j ur y. • NO T E: T he t o rqu e conve r t e r hub must eng a ge f ul l y i n t he o i l pump drive gea r.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 5- Speed A uto m atic Tran saxle - JATC O - Transax le I nst a l l a t io n Speci al T ool (s) Ha l fs ha ft o i.
4. W ARNING: Do not l e t t he t o r que co nverte r drop o ut of t he tra nsa xl e . Fa i l ur e t o f ol lo w t hi s i ns truc t i o n may r e s ul t i n p e r s o nal i njur y. I nst a l l t he t rans a xle . 5. NOT E: Carr y o ut t hi s s t ep i f a la t e r co ndi t i on t r a ns a xl e i s be i ng in s t a l l e d.
9. Remove t he po we r t r ai n a s s e mbl y j a ck. Re mov e t he t rans a xle t o t h e po we r t r ai n a ss e mbly ja ck s ecur i ng s t rap. 10. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 11. Ins t a l l t he t r a ns a xl e ret a i ni ng nut .
14. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 15. At t ach t he t r ans a xle gr oun d l ea d . Ti ght e n t o 25 Nm. 16. Ins t a l l t he s t arte r mot o r . Ti ght e n t o 35 Nm. 17. Ins t a l l t he s up port b a r m o unt bracket .
19. At t ach t he s t arte r mot o r s ol e noi d e l e ct rica l conne ct o r . Ti ght e n t o 6 Nm. 20. At t ach t he s t arte r mot o r e l e ct rica l co nnect o r . Ti ght e n t o 12 Nm. 21. At t ach t he s t arte r mot o r s ol e noi d co v e r.
24. Ins t a l l t he s up port b a r r e ta i ni ng bo l t s . Ti ght e n t o 25 Nm. 25. Remove t he e n gi ne s upp ort br a cket . 26. Remove t he e n gi ne s upp ort br a cket . 27. At t ach t he wi r i ng harnes s from t he camsh a f t cover r et a i ni ng s t ud.
29. At t ach t he e le ct r ica l conne ct o r t o t he i nt a ke mani fo ld s upport bracket . 30. At t ach t he p o s i t i ve cr a n kc as e ve nt i la t i o n (P CV) ho s e t o t he i nt a k e m a ni f o l d. 31. Remove t he e n gi ne s upp ort br a cket .
34. Rai se th e v e hi cl e . 35. Conne ct t he t r ans a xle e l e ct rica l c o nne ct or s . 36. Conne ct t he t r ans a xle f l ui d c oo l e r t ube s . 37. NO TE: Ro t a t e t he t o r que co nverte r t o g a i n a cces s f o r the remai ni ng r e t a i ni ng bo l t s .
40. Ins t a l l a n ew ha l f s ha f t s na p ring. 41. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s .
44. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w ha l f s ha ft s e a l. 45. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s .
49. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he f e nde r s pl a sh sh i e l d a cces s pa ne l . 50. Ins t a l l t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L NA V 6 - AJV6/2.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Lubr i cant , Sea le r s, So l vent s and Ad hesi ves Desc ri pti on.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Descriptio n Vehicl es With: 6- Speed A uto mati c T.
Des i gne d t o be mai nt e nance f r ee To r que ca pa cit y o f 450 Nm Tr an s mis s i o n f l ui d i s fi ll f o r l i f e The t or que conver t e r fe a t ure s a co ntrol l e d s l i p f e a t ur.
For add i t i o na l i nf or m a t io n, ref er t o : Tr an s mis s i o n Co o l i ng - Ve hi cl e s W it h: 6-S pe e d Aut o mat i c Tr an s a xl e - A W F 21 (307-02B Tr an s mis s i o n/Trans a xle Coo l i ng - Ve h icl e s W i t h : 6-S p e e d Aut o mat i c Trans a xl e - AW F21, Des cr ipt i o n a nd O pe rat i o n).
Item Par t N u m ber Desc ri pti on 1 - 3-W a y s o le no id - S2 2 - Shif t cont r ol s ol e noi d - SLC2 3 - Shif t cont r ol s ol e noi d - SLC1 4 - V a l ve bl ock 5 - L o c k-up cont r ol s o l e.
I te m Par t Nu m ber Desc ri pti o n 1 - S p e e d S e ns or (S P) - O ut put s haf t s pe e d 2 - Count er drive ge a r 3 - C2 clut ch drum 4 - S p e e d s e n so r (NIN) Two s pe e d s ens o r s (NIN a nd S P) a r e us e d i n t he t rans mi s s i on a nd a r e l o ca t e d wi thi n t he t rans m i s s i o n ho usi ng.
7 - Di a phragm s pr i ng 8 - O ut put s ha f t 9 - Be a r i ng 10 - Dy na mic pres s ur e e qual i s a t i on chambe r 11 - Pi s t on chambe r 12 - Lubr i cat i o n cha nne l The r e a re t hr e e dr.
Item Pa rt N um ber Descri pt i on 1 - Cl ut ch C2 2 - B rak e B2 3 - O ne wa y cl ut ch F1 4 - Co unt e r drive g e a r 5 - B rak e B1 6 - Cl ut ch C1 7 - Cl ut ch C3 8 - Fl ui d pump 9 - I n put s h.
It e m Pa r t Nu m be r De scri pt i o n 1 - Clut ch - C2 2 - Br ake - B2 3 - One -wa y cl ut ch - F1 4 - Br ake - B1 5 - Clut ch - C1 6 - Clut ch - C3 Pow er F low - 1 s t Ge ar Eng in e B raki ng So.
The i nput s haf t r ot a t e s i n a cl ockwis e di r e cti on, d riven by t he t o rque conve r t e r . T h e pl a ne ta r y r i ng ge a r r ot a t e s i n a cl o ck wi s e d i r e ct io n a l on g wit h t he pl a ne t a ry pin i on gea r whi ch al s o r ot a t e s cl o ckwis e o n i t s axi s a nd o r bit .
wit h t he pl a ne t a ry pin i on gea r whi ch al s o r ot a t e s cl o ckwis e o n i t s axi s a nd o r bit . T he p la n e t a ry s un g e ar i s l o cked by t he fl ui d p ump whi ch caus e s i t t o pr e s s a ga i ns t t h e pl a ne ta ry r i n g g e a r an d orbit t he s un ge a r, r ot a t i ng o n i t s a xis .
The i nput s haf t r ot a t e s i n a cl ockwis e di r e cti on, d riven by t he t o rque conve r t e r . T h e pl a ne ta r y r i ng ge a r r ot a t e s i n a cl o ck wi s e d i r e ct io n a l on g wit h t he pl a ne t a ry pin i on gea r whi ch al s o r ot a t e s cl o ckwis e o n i t s axi s a nd o r bit .
- I nput : Midd le s un ge a r - Lo cked: Ca r r ie r - O ut put : Ri ng ge a r Fr o nt P l a ne ta ry Ge a r Tr a in The i nput s haf t r ot a t e s i n a cl ockwis e di r e cti on, d riven by t he t o rque conve r t e r . T h e pl a ne ta r y r i ng ge a r r ot a t e s cl ockwi s e wi t h t he i npu t s haf t.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on E lectro nic Co ntrol S ystemVe hicl es Wi th: 6-S p.
Item Par t N um be r Descri pti on 1 - TCM 2 - ' Ne ut r al 'N' p os i t i o n 3 - Pa r k 'P' po s i t i o n 4 - Po s i ti o n s e ns o r /m anua l sha f t 5 - Ele ct rica l c.
For add i t i o na l i nf or m a t io n, ref er t o : Comm uni cat i o ns Ne t wo r k (418- 00 Modul e Co mm unica t i o ns Net wo r k, De s cr ip t i o n a n d O p e rat i on ).
Fa st o f f r eco gni t i on mod e a s si s t s ve hi cl e s t a bi l i ty a nd i s us e d i n conj unct i on wi th a l a t e r al a ccel e rat i o n i npu t dur ing co r nering t o mai nt a in t he cur r e nt g e ar unt i l t he c orner i s ne got i a t e d.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Diagnos tic S trategy Vehic les Wi th: 6-S peed A utom atic T ransax.
DT C D escri pti on P ossi bl e C ause Act i on Tr an s mis s i o n f l ui d l e ve l l ow Tr an s mis s i o n f l ui d cool e r /h o s e s a r e o bs t r u cte d , da mage d, b l ocke d Mechani ca l .
DT C D escri pti on P ossi bl e C ause Act i on modul e/co mponent i ns t al la t i o n no t e a t the t o p o f t h e DTC I ndex. Re f e r t o s e r v i ce r ou ti ne s a t the t op o f t he DTC I nd.
DT C D escri pti on P ossi bl e C ause Act i on S hor t t o gr ound o n CA N ci r cuit be t we e n ECM a nd TCM P 072900 Gea r 6 I ncorr e ct Ra t i o Incor r e ct ly r e gul a t i ng s o l e no i d M.
DT C D escri pti on P ossi bl e C ause Act i on P 074100 To r que Co nve r t e r Cl ut ch S ol e no i d Ci r cuit P e r fo r mance/S t uck O ff Hi gh cont a ct res i st a nce i n t he conne ct or t er.
DT C D escri pti on P ossi bl e C ause Act i on Mechani ca l fa i l ur e i n t r a nsmi s s i o n P 074E00 Un a bl e t o En ga ge Gea r 6 Hi gh cont a ct res i st a nce i n t he conne ct or t erm i na.
DT C D escri pti on P ossi bl e C ause Act i on val ue wa s e xpe ct e d S hor t t o po we r on t he L I N comm unica t i on ci r cuit be t we e n t he T CM and GS M I nt e r nal f a i l ur e i n GS M I nt e r nal f a i l ur e i n T CM r e fe r t o t he new modul e /compone nt ins t a l l a ti o n no t e a t t he t o p o f t he DTC Ind e x.
DT C D escri pti on P ossi bl e C ause Act i on conne ct or t erm i nal s Op e n ci rc ui t on t he S FL s hi ft l o ck circ ui t b et we e n t he TCM a nd GS M Op e n ci rc ui t on t he gr ound circ .
DT C D escri pti on P ossi bl e C ause Act i on P 096900 P r es s ur e Cont r o l S ol e no i d C Co nt rol Ci r cuit Ra nge /Pe r f or mance Hi gh cont a ct res i st a nce i n t he conne ct or t erm .
DT C D escri pti on P ossi bl e C ause Act i on ob s t r uct e d/dama ge d /bl o c ked Mechani ca l fa i l ur e o f t r a nsmi s s i o n Tr an s mis s i o n ha s b e e n e xpos e d t o e xces s i ve h.
DT C D escri pti on P ossi bl e C ause Act i on P 273300 P r es s ur e Cont r o l S ol e no i d F S tu ck On S LC1 pr e s sure cont r ol no t e ngag e d i n dr i ve Mechani ca l fa u lt i n t he t r a.
DT C D escri pti on P ossi bl e C ause Act i on pa r t o f t he CAN ne t wo rk I nt e r nal f a i l ur e i n T CM car ry o ut s e r vi ce rout i ne s a s requi r e d us i ng t he manu f act ur e r a ppr oved di a gnos t i c s yst e m U210511 S wi t ch P a ck Signa l "A" Ci rc u i t s hort t o g r o und.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Fluid Drain a nd Refill Gene ral P r ocedures W ARNI N G: O b se r v e due care whe n dr a i n ing , as t he f lu i d can b e ve r y hot .
11. Remove t he t r ans mis s i o n f l ui d dr ai n p l ug. Al l ow t he t rans mi s s i o n fl ui d t o drai n. 12. NO TE: I ns t a ll a new g a ske t . I nst a l l t he t rans mi s s i o n f l ui d dr ai n pl ug. Ti ght e n t o 47 Nm. 13. Lowe r t he vehi c l e .
18. S e cur e t he b a t te r y carr i er brack et . Ti ght e n t o 25 Nm. 19. Ins t a l l t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n).
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Fluid L ev el C heck Gene ral P r ocedures W ARNI N G: O b se r v e due care whe n dr a i n ing , as t he f lu i d can b e ve r y hot .
13. S e cur e t he b a t te r y carr i er brack et . Ti ght e n t o 25 Nm. 14. Ins t a l l t he ba t t e r y t ray . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Tray (414-0 1 Ba t t e r y, Mount i ng a nd Ca bl e s, R e moval a nd Ins t al l a t i o n).
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Main Co ntrol Va lve B ody I n-v e hi c l e Re pa i r R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . 2. Remove t he t r a ns mis s i o n f l ui d p a n.
6. CAU TI O N : Dis card t he bo l t s. Re move t h e s ucti o n cover. Re mov e t he 2 bol ts . Re mov e a nd di s c a r d t he gas ke t. 7. CAU TI O N : Dis card t he bo l t s. • NO T E: W i t h eve ry pas s , un do t he bol ts o ne t ur n a t a t i me al t e rnat e l y.
2. CA UT I O NS: Make s ur e t ha t new b ol t s a r e ins t a l l e d. O nl y ti ght e n t he b ol t s fi nge r- t i ght a t thi s s t a ge . S ecur e t he t r an smi s s i o n mai n co nt r ol va l ve bo dy. 3. CA UT I O NS: Make s ur e t ha t new b ol t s a r e ins t a l l e d.
5. CAU TI O N : Make s ur e t h at th e s e compone nt s are i n st a l l ed t o t he not e d removal po s i t i o n. S ecur e t he t r an smi s s i o n i nt e r na l wiring harnes s . S ecur e i n t he cl i ps . Conne ct t he e l e ct r i cal co nnect o rs .
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Selecto r Shaft S eal I n-v e hi c l e Re pa i r R em ova l • NO T E: Re moval s t e ps in t hi s p rocedur e may cont a in i nst a l l a t i on det a i l s.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on C o ntrol Module (TC M) I n-v e hi c l e Re pa i r R em ova l 1. Remove t he cover a nd d i s co nnect t he ba t t e r y ground ca b le .
2. Ins t a l l the t r a n s mis s i o n s e l ect or l e v e r and co nnect t he e l e ctrica l conne ct or. Ti ght e n t he nut t o 13 Nm. 3. S e cur e and c onn e ct t he s e l e ct or l e ve r cabl e.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Internal W i ring Harness I n-v e hi c l e Re pa i r R em ova l 1. Rai s e a nd s uppo r t the ve hi cle .
1. CA UT I O NS: Make s ur e t ha t the wi ring ha r ne s s do e s not cat ch. Th e co mponen t must b e a l i gne d wi t h t he i ns t a l l a t i o n mark i ngs . I nst a l l t he t rans mi s s i o n i nt e r nal wi ring ha rn e s s . S ecur e wi t h t he cl i p.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Fluid Pan I n-v e hi c l e Re pa i r R em ova l • NO T E: Re moval s t e ps in t hi s p rocedur e may cont a in i nst a l l a t i on det a i l s.
1. CAU TI O N : Make s ur e t h at th e mat i ng f a ces are cl e a n a nd f r ee of fo rei gn mat e r i a l . App l y s i l ico ne ru bbe r s e al a nt t o t he t r a ns mis s i o n f l ui d p a n. 2. Ins t a l l the t r a n s mis s i o n f lui d pa n.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - To rque C onverter Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . 2. Remove t he t r a ns mis s i o n.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - To rque C onverter Seal Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . 2. Remove t he t o r que co nverte r.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Turbine Sh aft Speed (TSS) S enso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he mai n co nt r ol val ve b od y.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on Re moval Speci al T ool (s) I m pul s e e xt racto r.
7. Usi ng t he s pe cia l t oo l s, re l e a s e t he LH ha l f s ha f t . 8. CAU TI O N : Make s ur e t h e ha l f s ha ft cons t a nt ve lo ci t y (CV) j o i nt s do not over a r t i cula t e . Fa i l ur e t o f o l l ow t hi s i ns t r ucti o n may res ul t in da mag e to the CV j o i nt s .
11. Rel e as e t he e m i s s i on c o nt r ol val ve . Re mov e t he 2 bol ts . P os i t i on a s i d e. 12. Rel e as e co o l a nt pi pe f r om t he e ngi ne .
14. Rel e as e t he t o r que co nverto r from t he f l e xpl a t e . Re mov e t he 6 bol ts . 15. Dis c o nne ct t he 2 trans mi s s i on f l ui d co o le r tu be s . Re mov e t he 2 Torx bo l t s . P os i t i on a s i d e. 16. Lowe r t he vehi c l e .
19. Rel e as e t he t r ans mis s i o n s e l e ct or l e v e r cabl e f r om t he TCM . Re mov e t he nut . Re l e a s e t he s e l e ct or cabl e a nd l e v er. P os i t i on a s i d e. 20. Dis c o nne ct t he b a t t e r y ground cab l e. Re mov e t he b o l t .
22. Rel e as e t he t r ans mis s i o n mo unt i ng. Re mov e t he nut . 23. Lowe r t he e ngi ne s uffi ci e nt l y a l l owi ng t he t rans mi s s i o n a s se mbl y t o cle a r the mount i ng. 24. Remove t he 3 t rans mi s s i on a s s e mbly uppe r bo lt s .
27. NO TE: Som e varia t i o n i n t he i l l ust rat i o ns may occur , b ut t he e s s e nt i al in f orm a t i o n i s a l wa ys corr e ct . Al ig n t he po wert r ai n as s e mbly ja ck t o t he t rans mi s s i on. S ecur e t he t rans mi ss i on t o t he p o we rtrai n a s s embl y j ack.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle - Vehi cles With: 6- Speed A uto m atic Tran saxle - A WF21 - Transm i ssi on I nst a l l a t io n Speci al T ool (s) P owe r t r ai n a s s e mbl y ja ck HTJ1200 -2 Engi ne s uppo r t b rack e t 303-02 1 Insta llat ion 1.
3. Ins t a l l the t r a n s mis s i o n as s e mbly rea r bo l ts . Ti ght e n t he b ol t s t o 48 Nm. 4. NOT E: S ome varia t io n i n t he i l l us t rat i o ns may o c cur , but t he e ss e nt i a l in f orm a t i o n i s a l wa ys corr e ct . Re move t h e po we rtr a i n as s e mbl y j a ck .
7. Rai s e t he e ngi ne a nd t rans mi s s i o n a s se m bl y o nt o t he mount i ng. Ti ght e n t he nut t o 130 Nm. 8. Remove t he s p e cia l to o l . 9. Att a ch t he ba t t e r y gr oun d cab l e . Ti ght e n t he b ol t t o 25 Nm. 10. At t ach t he t r ans mis s i o n s e l e ct or ca bl e t o t he br a cket .
11. At t ach t he t r ans mis s i o n s e l e ct or ca bl e a nd l e ver t o t he t r a ns mi s s i o n cont rol mod ul e (TCM). Ti ght e n t he nut t o 13 Nm. 12. Conne ct t he T CM e l e c t r i cal co nne ct or. 13. Rai se th e v e hi cl e . 14. Conne ct t he t r ans mis s i o n fl ui d cool e r t ube s .
15. S e cur e t he t o r que co nv e rto r t o t he f l e xpla t e . Ti ght e n t he b ol t s 60 N m. 16. Ins t a l l t he f l e xpl a t e cover . 17. S e cur e t he co o l a nt pi p e t o t he e ngi ne.
18. S e cur e t he e m i s s i o n cont r ol va l ve . Ti ght e n t he b ol t s t o 30 Nm. 19. Rel e as e t he p o we r s t e e r i ng fl ui d pi pe. 20. Ins t a l l t he cha r g e a i r coo l e r int a ke p ip e . Ti ght e n t he ho s e cl i ps . Ti ght e n t he b ol t s t o 35 Nm.
22. At t ach t he L H h a l f s haf t t o t he t rans mi s s i on. 23. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s .
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Aut o mat ic t.
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on C ooli ngVeh icles With: 5-Spee d Autom atic T rans ax.
* * * * P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on C ooli ng Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m.
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on Flu id C oo ler Re moval a n d I ns t a l l a t i on S.
1. To i ns t a l l r evers e t he r emova l pr oced ure. 1. Ti g ht e n t o 7 N m. 2. Tig ht e n t o 7 Nm. 3. CAU TI O N : U s e o f a ny t rans mi s s i o n fl ui d o t he r t ha n t he r e comm e nded fl ui d, wil l caus e t r ans mis s i o n da mag e .
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 5- Spe ed A uto m atic T r ansaxle - JATC O - Transm i ssi on Flu id C oo ler T ubes Re moval a n d I ns t a l l a t.
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Aut o mat ic t.
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on C o ol ingV ehicles W ith: 6-Sp eed Au to ma tic T ran.
* * * * P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on C o ol ing Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m.
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on Fluid C oo ler Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on Fluid C oo ler Return T u be Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld .
2. Connect t he t r a ns mi ss i o n fl ui d cool e r r et ur n t u be t o t he t ransmi s s i on f l ui d coo l e r. 3. Connect t he t r a ns mi ss i o n fl ui d cool e r r et ur n t u be t o t he t ransmi s s i on. Ti ght e n t o 10 Nm. 4. Ins t a l l the cha r ge a i r coo l e r i nt a ke pi p e .
P ubl i s he d: 11-May-2 011 T ransm iss io n/Transaxle Co oling - Vehi cles With : 6- Spe ed A uto m atic T r ansaxle - A WF21 - Transm i ssi on Fluid C oo ler S upply Tube Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld .
2. Connect t he t r a ns mi ss i o n fl ui d cool e r su ppl y t ube t o t h e t rans mi s s i on f l ui d coo l e r. 3. Connect t he t r a ns mi ss i o n fl ui d cool e r su ppl y t ube t o t h e t rans mi s s i on . Ti ght e n t o 10 Nm. 4. Ins t a l l the cha r ge a i r coo l e r i nt a ke pi p e .
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b- i n S el e cto r cabl e s hie ld 10 7 - S el e cto r cabl e ret a i ni ng br acket 10 7 - JagDocs.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - External C o n trols V ehicles With : 5- Spe.
is conne ct e d t o t he d r i ve r' s s e l e ct o r m odu le by a cab l e . op erat e s t he man ua l se l e c t o r v al ve, whi ch i s pa r t of t he e l e ct ro-hydr a ul i c cont r o l u ni t . op erat e s t he rot a r y s w i t ch, whi ch i s co nne cte d t o t he ECM.
1 2 3 1 2 1 2 3 P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - External C o n trols Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1.
1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 1 Is t he vol t a ge l e s s t han 10 vol t s ? Ye s REPAI R t he ci r c ui t bet we e n I P14, pi n 01 (W R) a nd t he ig ni t i o n s wi t ch (t hi s c i r cuit i ncl ude s t he Ce nt ral Junc t i o n fu s e box, I gni t i on rel a y , a nd i n ert i a s wi t ch).
1 1 2 3 Is t he res i s t a nce g r ea t e r t han 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC. TEST t he s yst em f o r norm al ope rat i on.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - Selector L ever Cable Adju stme nt Gene ral P r ocedures Se ttin g Procedure -All Ve hicle s 1.
1. Usi ng t he corner o f t he gr ey f e a t ur e l i ne t ha t f ol l o ws t h e e d ge of t he 'J' ga t e a s a da t um, us e a r u le a nd m o ve t he ge a r s e l e ct o r f orwar ds o r ba ck t wo mil l i met e rs.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - Selector L ever Cable and Bracket Re moval a n d I ns t a l l a t i on R em ova l 1.
6. D i s conne ct t he ge a r s e l e c t o r cabl e f rom t he J-ga t e. 7. D et a ch t he ge a r s e l e ct o r cabl e gr omme t. 8. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng .
10. Remove t he g e a r s e l e ct o r cabl e shi e l d . 11. Det a ch t he ge a r s e l e ct o r cabl e b r a cket . 12. Dis c o nne ct t he g e a r s e l e ct o r cab le . 13. Remove t he g e a r s e l e ct o r cabl e from t he ge a r bo x mount i ng b r a cket .
Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. 2. Tig ht e n t o 10 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 5-S pe ed A uto m atic T rans axle - JATC O - Selector L ever A ss embly Re moval a n d I ns t a l l a t i on R em ova l 1.
7. Remove t he a s ht ray r e t a i ni ng s cr e ws . 8. Remove t he a s ht ray. Dis conne ct t he ci gar l i g ht e r el e ct rica l conne ct o r . 9. Remove t he s e l e ct o r l eve r r et a i ni ng s crew. 10. Remove t he s e l e ct o r l eve r . 11.
12. Remove t he s e l e ct o r l eve r f r o m t he s e l e ct o r l eve r br a cket . Re mov e t he s e l e ct or l e v e r r e ta i ni ng s c r e ws . Insta llat ion 1. NOT E: Do not ful l y t ig ht e n t he s e le ct o r le ve r r et a i ni ng s cr ews at t hi s s t a ge .
4. Att a ch t he e l ect r i cal conne ct o r t o t he se l e ct o r l e ver. 5. Ins t a l l the s e le cto r l e ver. 6. Ins t a l l the s e le cto r l e ver ret a i ni ng s crew. 7. Ins t a l l the a s htray. Conne ct t he ci gar l ig ht e r el e ct r ica l conne ct o r .
9. Connect t he s e le cto r l e ver cabl e t o t he s el e ct o r le ver . 10. Ins t a l l t he s e l e ct o r l eve r cabl e l o cking pi n. 11. Ins t a l l t he f l oo r cons o l e brack e t r et a i ni ng scr ews . 12. Conne ct t he s e l e ct o r l eve r el e ct rica l conne ct o r .
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b- i n S el e cto r cabl e s hie ld 10 7 - S el e cto r cabl e ret a i ni ng br acket 10 7 - JagDocs.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - External C ontrol sV ehicles With : 6- Speed.
Item Pa rt N um be r Desc ri pti on 1 - Int erlock s o le no id - E m e rgency r e l e a se l e ve r 2 - Cabl e a d jus t ment /s e t t i ng ape r t ure 3 - S e l ect o r le ver but t o n 4 - Cabl e a.
M/S (Manual /Spor t Mod e ) - Ini ti al s e l e ct i on o f t hi s po s i ti o n a ct i vat e s t he t r ans m i s s i on 'S po r t ' mo de. Thi s pos i t i o n ha s t h e s a me funct i on .
The s e le c t o r le ver e nd o f t he ca bl e ha s a n a dj ust a bl e e ye e nd whi ch l o cat e s on a b a l l pi n o n t he s e l e c t o r l e ver . An a but me nt o n th e ca bl e ou te r s hea t h l oca t e s in a n ap e rtur e i n th e s e l e ct or l ever s h if t hous i ng .
1 2 3 1 2 1 2 3 P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - External C ontrol s Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1.
1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 1 Is t he vol t a ge l e s s t han 10 vol t s ? Ye s REPAI R t he ci r c ui t bet we e n I P14, pi n 01 (W R) a nd t he ig ni t i o n s wi t ch (t hi s c i r cuit i ncl ude s t he Ce nt ral Junc t i o n fu s e box, I gni t i on rel a y , a nd i n ert i a s wi t ch).
1 1 2 3 Is t he res i s t a nce g r ea t e r t han 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC. TEST t he s yst em f o r norm al ope rat i on.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - Selector Lever Cable Adjustment Gene ral P r ocedures 1. Ch eck t he o p erat i o n o f t he t r ans mi s s i on se l e ct o r l e ver.
8. Ins t a l l the ce nt e r cons o l e LH s i de f in is he r t r i m pa ne l . JagDocs.com.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - Selector Lever A ss embly Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f l o or cons o l e .
5. Remove t he s e l e ct o r l eve r a s s e mbl y. Re mov e t he 4 nut s . Insta llat ion 1. NOT E: Ti ght e n t he front 2 bo l t s fi r s t . I nst a l l t he s el e ct o r le ver as s e mbly. Ti ght e n t o 10 Nm. 2. Att a ch t he t r a ns mis s i o n s e l ect or l e ver cab l e .
3. Connect t he s e le cto r l e ver a s s e mbl y e l e ct rica l conne ct o r . 4. Ins t a l l the f l o o r cons ol e r ei nf orceme nt bracket . Ti ght e n t o 3 Nm.
P ubl i s he d: 11-May-2 011 A uto m atic T rans mis sio n /Transaxle E xternal C on trols - Vehi cles Wi th: 6-S pe ed A uto m atic T rans axle - AWF2 1 - Selector Lever K nob Re moval a n d I ns t a l l a t i on R em ova l 1. Rel e as e t he s e le cto r l e ver ga i t e r f r om t he s el e ct o r le ver k nob .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Lubr i cant s, Flu ids , Seal er s and A dh e si v es It e m Speci fi ca ti on Brak e f l ui d I TT S upe r Dot 4 JagDocs.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Manual T ransm iss io n and C lutch Des cr ipt i o n a nd O pe r a t i o n The clu tch s ys t e.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * - - * * * * P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Manual T rans.
* * * * * * * * * * * * - * * * * * * * * * * - * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * ge a r s The e ngi ne /tr a ns mis s i o n a s s e mbly i s in cont a ct wi t h t he cha s s i s/b o dy.
1 2 3 4 1 2 1 1 1 2 3 1 1 1 1 1 2 PINPOIN T TE ST A : CLUTCH S LIPPAG E T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I ONS A1 : T EST CLUT C H SL I PP AGE Lock whe e l s a nd put p a r k in g brak e o n . S t a r t t he e ngi ne a nd e n ga ge 4t h g e a r .
1 1 2 3 1 2 1 2 1 2 3 1 1 2 Is t he mea s ur ed di mens i o n wi t hi n 15 mm ? Ye s INS TA LL a ne w clut ch pr e s s ur e pl at e . TE S T t he s ys t e m f o r no r mal o p e r at i on .
1 2 1 2 3 1 1 1 1 Are t he r e no i s e s whe n t he c l ut ch i s o p erat e d? Ye s GO t o G2 . No S yst e m O K. G2: T E ST CLU T C H PEDAL FREE T R AVEL P r es s t he clu t ch down manua l l y unt i l r es i s t a nce i s f el t, t he n rel e as e i t a g a i n.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Cl utch Syste m B leeding V ehicl es Wit h: 5-Speed Manual Trans mi ss io n - MT 75 Gene ral P r ocedures 1. W ARNING: Bra k e fl ui d co nt a i ns po l ygl ycol et he r s a nd p o l ygl ycols .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Cl utch Syste m B leeding V ehicl es Wit h: 6-Speed Manual Trans axle - MMT6 Gene ral P r ocedures 1. W ARNING: Bra k e fl ui d co nt a i ns po l ygl ycol et he r s a nd p o l ygl ycols .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - G earshift C ab le A djustment Gene ral P r ocedures Speci al T ool (s) Gea r s hi f t s e l e ct o r s e t t ing t o o l 308-436 1. Remove t he whe e l a nd t i r e .
• NO T E: S hi f t cabl e has a bl a ck co v e r t o ca bl e e nd a nd t he s e l e ct o r c a bl e ha s a whi t e cover t o ca b l e e nd . 6. D et a ch t he r e d l o ck i ng t a b o n t he s hi f t cab l e. 7. Att a ch t he s hi f t cabl e t o t he ba l l pi n o n t h e t r ans mis s i on s e le cto r.
10. Det a ch t he r ed l ocking t a b o n t he s e l e cto r ca bl e . 11. At t ach t he s e l e ct o r cabl e t o t h e ba l l p i n o n t he ge a r bo x mas s d a mper . 12. Pres s t he red l ocking t a b t o s e cur e t he p os i t i on o f t he s e le cto r cab l e .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle and Cl utch - General Inf orma tio n - Release Hu b and B earing Check Gene ral P r ocedures 1. Tur n t he clut ch rel e a s e hub a nd be aring i n b ot h di rect i o ns a nd che ck f or a ny bi ndi ng or ab no r mal n oi s e .
P ubl i s he d: 11-May-2 011 C lutch - T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n P r e s s ur e p l a te ret a i ni ng bo l t s 25 18 - JagDocs.
P ubl i s he d: 11-May-2 011 C lutch - Cl utch Des cr ipt i o n a nd O pe r a t i o n Item Pa rt Nu m be r Descri pt i o n 1 — P r es s ure p la t e ret a i ni ng bo l t 2 — P r es s ure p la t e .
P ubl i s he d: 11-May-2 011 C lutch - Cl utch Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 30 8-00 Manu al Trans mi s si o n/Tr ans a x l e a nd Cl ut ch - Gene ral Inf orm at i o n .
P ubl i s he d: 11-May-2 011 C lutch - Cl utch Dis c and Pr ess ure Plate Re moval a n d I ns t a l l a t i on Speci al T ool (s) Cl ut ch a li g nm e nt t o o l 308-441 R em ova l All e x cept ve hicles with die s el engine 1. Remove t he manua l t rans mi s s i on.
2. NOT E: The cl ut ch d i s c i s mar ked "Tr a ns mis s i o n s i de" f o r c o r r ect in s t a l l a t i o n. Lo cat e t he cl ut ch p res s ur e pl a t e on t he f l ywhee l d o wel s a nd t i gh te n t he bo l t s p r ogres s ive l y i n a d i a gona l s e que nce.
P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Gen eral S p ec if ic a t ions I te m Speci fi cati on Brak e f l ui d I TT s uper do t 4 T o rque Sp eci f i cat ions Desc ri pti on N m l b- f t l .
P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch C on tro ls Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 5-sp ee d manual t r ans mis s i o n I te m P ar t N u m ber Descri pt.
Item P ar t N u m ber De s cri pti on 1 - Fl ywhee l 2 - Bl ee d ni ppl e 3 - Cl ut ch mas t e r cyli nde r 4 - Vi br at i o n d a mper 5 - Hydr aul i c l i ne 6 - Cl ut ch s l a ve cyli nd e r 7 - S e lf -adj ust i ng clu t ch Thi s ve hi cle has a hydr aul i ca l l y ope rat e d cl ut ch .
It e m Pa rt Nu mb e r Desc ri pti on 1 - Rel e a s e be aring 2 - Pr ot e c t i ve ca p 3 - Pr es s ur e s pr i ng 4 - Hy dr aul i c channe l 5 - Oi l s e a l 6 - Pl a s t i c ho us i ng The cent r a.
P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch C on tro ls Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 30 8-00 Manu al Trans mi s si o n/Tr ans a x l e a nd Cl ut ch - Gene ral Inf orm at i o n JagDocs.
P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch Mas te r C ylinder Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. W ARNING: Do not a l l ow brake f l ui d t o co nt a ct th e s kin or e ye s .
4. D i s conne ct t he clu t ch m a s t e r cy l i nde r s uppl y l i ne . 5. D i s conne ct t he clu t ch s l a ve cy l i nd e r s up pl y li ne from t he clut ch mas t e r cyli nde r . Re l e a s e t he re t a i ni ng cl i p t o d i s conne ct t he l i ne .
9. Remove t he clut ch mas t e r cy l i nde r r et a i ni ng nut s a n d b o lt s . 10. Remove t he cl ut ch mas t e r cyli nd e r a nd cl ut ch p e da l . 11. Remove t he cl ut ch mas t e r cyli nd e r f rom t he cl ut ch pe da l . Insta llat ion All v e h icle s 1.
2. Ins t a l l the cl ut ch ped a l . 1. At t a ch t he cl ut ch p e da l t o t he cl ut ch mast e r cy l i nde r . 2. At t a ch t he cl ut ch p e da l t o t he s up port b r ack e t . 1. Tight en t o 2 3 Nm . 3. Ins t a l l the cl ut ch ped a l ret ur n sp ring p i n.
6. NOT E: Re po s i t i o n t he r e t a in in g cl i p. Conn ect t he cl ut ch s l ave cyli n der s up pl y l ine t o t he cl ut ch mas t e r cyli nde r . 7. Connect t he clu t ch mas t e r cyli nde r s uppl y l i ne. All e x cept ve hicles with die s el engine 8.
P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch S lav e C ylinderVehicle s W ith: 5-Sp eed Ma nual Tran smi s sion - MT75 Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: The cl ut ch s l a ve cy l i nd e r a s s e mbly must be r e pl a ce d whe ne ver it is removed .
P ubl i s he d: 11-May-2 011 C lutch C o ntro ls - Cl u tch S lav e C ylinderVehicle s W ith: 6-Sp eed Ma nual Tran saxle - MM T6 Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: The cl ut ch s l a ve cy l i nd e r a s s e mbly must be r e pl a ce d whe ne ver it is removed .
2. Ins t a l l the cl ut ch s l a ve cyli nd e r bl e e d uni o n. Ful ly s e a t t he r e t ai ning cl i p. 3. Ins t a l l the cl ut ch s l a ve cyli nd e r hi g h p r e s s ur e pi pe to t he ret a i ni ng br acke t and clu tch s l a ve cyli nd e r b l e e d uni o n.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Desc ri pti on Speci f i ca ti on Manua l t rans a xle f l ui d W S D-M 2C200- C C apaci ti es Descri pti o n Qua nti ty Manua l t rans mi ss i on fl ui d 1.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - M anual T rans axleV ehicles With: 5-Speed Manual T ransm iss io n - MT75 Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um b.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - M anual T rans axleV ehicles With: 6-Speed Manual T ransaxle - MMT6 Des cr ipt i o n a nd O pe r a t i o n Thi s ve hi cle i s e qui.
It e m Descri pti on I tem De sc ri pti o n 1 O ut put s haf t — 5 t h /6th a nd rev e rse ge a rs 13 S ync h r oni ze r a s s embl y – 3r d/4t h g e a r 2 Input s ha f t 14 4t h ge ar whee l 3 1s.
It e m De sc ri pti on 1 S el e c t o r m e chani s m 2 Input s haf t 3 Ou tp ut s haf t — 1s t t o 4t h ge a r s 4 Dif f e rent i a l ho us i ng 5 Ou tp ut s haf t — 5t h/6t h a nd re ver s e ge ars Inp ut S ha f t JagDocs.
I te m De sc ri pti on I te m De sc ri pti o n 1 Clut ch hous i ng r o l l e r be a ring 6 3r d ge a r whee l 2 Oi l s e a l 7 Be a r i ng r et ai ne r 3 1s t g ea r whee l 8 Be a r i ng r et ai ni ng.
Item Descri pti on I te m Descri pti on 1 T a pe r r ol l e r bea ring , t rans mis s i o n ho usi ng 1 7 Inne r s y nchr oni z e r r i ng 2 4t h g e ar whe e l 18 2n d ge a r s ync hr oni z e r cone .
It e m Descri pti on It em Descri pti on 1 Trans mi s s i on hous i ng ta p e r r o ll e r bea ring 11 Snap ring 2 Ne e d l e be a ring 12 O i l col le cto r r ing 3 6t h ge a r whee l 13 Ta pe r r o .
Item Desc ri pti on 1 Sli di ng bl ock as s embl y 2 Sy nchr on i z e r hub 3 Sli di ng col l ar The ge ars 1s t , 2nd , 3r d and 4t h ha ve do ubl e co ne s y nchr o ni z e r s , 5t h, 6t h a nd rever s e ge a rs have s i ngl e co ne s ynchr on iz e r s .
G ea r Se lection Pow er Flow • NO T E: T he p os i t i o n o f t he trans a xl e s ha ft s ha s be e n a l t e r ed f o r cl a r it y. The fo l lo wi ng di a g r a m s s ho w a sche mat i c repres e nt at io n of t he p o we r -fl o w t hr oug h t ra ns a xle f o r ea ch g ea r s e l e ct i o n.
Fif th G ea r The 5t h ge a r- whee l o n t he i npu t sha f t is p o s i t i vel y co nnect e d t o t he 5t h g e a r -whe el on t he o ut put s ha f t by t he 5t h/6th g ea r s ynchr oni ze r .
It e m De sc ri pti on 1 Count e r b a l a nce 2 Re ver s e ge a r s wi t ch 3 S el e ct o r s haf t 4 S el e ct o r f i nger 5 S el e ct o r ga t e The s e le c t o r in t e r l o ck mecha ni s m a nd s e l e cto r f in ge r a r e mount e d o n a s l ee ve i n t he s el e cto r mechani s m ho us i ng.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - M anual T rans axle Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 30 8-00 Manu al Trans mi s si o n/Tr ans a x l e a nd Cl ut ch - Gene ral Inf orm at i o n JagDocs.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle D raini ng and Fillin g V ehicl es Wi th: 5-Spe ed Manual T ransm iss io n - MT7 5 Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i on 100-02 Jacki ng a nd Li ft i ng 2.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle D raini ng and Fillin g V ehicl es Wi th: 6-Spe ed Manual T ransaxl e - M MT6 Gene ral P r ocedures 1.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - H alfs haft S eal LH I n-v e hi c l e Re pa i r Speci al T ool (s) Li nk s ha ft o i l s e a l ins t a l le r 205-115 P ini on o i l s ea l remover 308-208 R em ova l 1. D r ai n t he t rans mi s s i on.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - H alfs haft S eal RH I n-v e hi c l e Re pa i r Speci al T ool (s) Li nk s ha ft o i l s e a l ins t a l le r 205-115 P ini on o i l s ea l remover 308-208 1. D r ai n t he t rans mi s s i on.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - In put Shaft S eal I n-v e hi c l e Re pa i r R em ova l 1. Remove t he clut ch s l a ve cy l i nd e r .
Name Gas ket El i mi na t o r S ea l a nt P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - S electo r Mechani sm Vehi cles With: 5- Speed Manual T ransm iss io n - MT75 I n-v e hi c.
4. D i s conne ct t he brake f lui d l o w l e ve l wa r n in g i ndi cat o r e l e ctrica l conne ct or. 5. D et a ch t he brake fl ui d l o w l e vel wa r ni ng i ndi ca t o r wi r i ng harnes s from t he coo l a nt e xpa ns i on t a nk.
All e x cept ve hicles with die s el engine 9. D et a ch t he ge ne r a t o r wi ring ha r ne s s ret ai ni ng cl i p from t h e cams ha f t cover r e t a i ni ng cl i p. 10. Remove t he a i r cl ea n e r mount b r ack e t . 11. Ins t a l l t he s p e cia l t o o l .
14. Remove t he i nt a ke mani f o l d s up port b r acket . 15. Det a ch t he wi ring ha r nes s from t he cams haf t cover r et a in i ng s t ud. 16. Ins t a l l t he s p e cia l t o o l . 17. Ins t a l l t he s p e cia l t o o l . Adj us t th e e ng i ne s upp or t bracket t o s upp or t t he we i g ht o f t he pow ertrai n as s e mbly.
18. Det a ch t he eng i ne harnes s . 19. Det a ch t he el e ct r i cal co nnect o r. 20. Remove t he e n gi ne co ver r e a r mount bracket . 21. Ins t a l l t he s p e cia l t o o l . 22. Us i ng t he s pe ci a l t o o l , sup po r t t he e ngi ne a nd t r a ns mis s i o n a s s embl y.
All v e h icle s 23. Remove t he t r ans a x l e mount br a ck et s e cur ing nut . 24. Remove t he t r ans a x l e s u pport i ns ul a t o r. 25. Det a ch t he cl ut ch mas te r cyli nde r t o cl ut ch s l ave cyli n der hi gh p r es sure pi pe from t he s uppo r t brack et .
27. Remove t he cha r ge a i r coo l e r pi pe ret a i ni ng nu t. 28. Remove t he cl ut ch mas t e r cyli nd e r t o cl ut ch s l a ve cyli nde r hig h pr es s ur e pi pe s uppo r t br ack e t . All v e h icle s 29. Remove t he t r ans a x l e mount br a ck et .
31. NO TE: Shown f r om th e unde r s i de of t he vehi cle f or cl arit y. • NO T E: L owe r s hi f t cabl e s how n, uppe r shi ft ca b l e s i mil ar. Di s conn ect t he s hi ft ca bl e s f r om t he t rans a xle s e le ct ors . 32. Det a ch t he uppe r s hi f t ca bl e f r om t he r e t a i ni ng bra c ket .
3. Att a ch t he upp e r s hi ft ca bl e t o t h e r et a i ni ng br acket . 4. NOT E: Li ft t he r e ver s e ge a r s e le c t o r t o fi t s pe ci a l t ool . Us i ng t he s p e ci a l t o ol , ma ke s ur e t he ge a rshi ft l eve r is i n t he ne ut ral po s i t i o n.
8. NOT E: S hown f r o m t he unde r s i de of t he ve hi cl e f o r c l a r i t y. P r es s t he red l ocki ng t ab t o s e cur e t he po s it i o n o f t h e s hi ft cabl e . 9. Pl a ce t he t rans mi s s i on s e l e ct o r i nt o t he ne ut r al po s i t i o n.
13. Remove t he s pe ci a l t o o l . 14. At t ach t he g e a r s hi f t l e ve r s urr o und. 15. Check f or cor r e c t o pe r at i o n o f ge a r cont r ol s . 16. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 17. Ins t a l l t he t r a ns a xl e mount b r ack e t .
18. Ins t a l l t he clut ch mas t e r cyl i nde r t o c l ut ch s l a ve cyli nd e r hi g h pre ss ur e pi pe sup po r t . 19. Ins t a l l t he cha r g e a i r coo l e r pi pe ret a i nin g nut .
22. Ins t a l l t he t r a ns a xl e s uppo rt i ns ul a t o r. Ti ght e n t o 47 Nm. 23. Ins t a l l t he t r a ns a xl e mount b r ack e t s e cur i ng nut . Ti ght e n t o 133 Nm. Vehi c le s with diese l engine 24. Remove t he s pe ci a l t o o l .
26. Ins t a l l t he e ngi ne cover r e a r mount brack e t . Ti ght e n t o 23 Nm. 27. At t ach t he e le ct r ica l conne ct o r . 28. At t ach t he e ngi ne h a r n e s s .
30. Remove t he s pe ci a l t o o l . 31. At t ach t he wi r i ng harnes s t o t he ca ms haf t co ver r et a i ni ng s t u d. Ti ght e n t o 6 Nm. 32. Ins t a l l t he i nt a ke man if ol d s upport br acket . Ti ght e n t o 10 Nm. 33. At t ach t he e le ct r ica l conne ct o r t o t he i nt a ke mani fo ld s upport bracket .
35. Remove t he s pe ci a l t o o l . 36. Ins t a l l t he a ir cl e a ne r moun t br acket . Ti ght e n t o 6 Nm. 37. At t ach t he g e ne r a to r wi r i ng ha r ne s s r e t ai ni ng cl i p t o t he cams ha f t cover r e t a i ni ng cl i p. 38. At t ach t he co o l a nt e xpans i o n t a nk .
40. NO TE: Re move t he b l a nking pl ugs f r om t he c oo l i ng s yst e m v en t ho se s a nd t he cool a nt e xp a ns i o n t a nk. At t a ch t he coo l ing s yst e m vent ho s es to the co o la nt e x pa ns io n t a nk.
Name Gas ket El i mi na t o r S ea l a nt P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - S electo r Mechani sm Vehi cles With: 6- Speed Manual T ransaxle - MMT6 I n-v e hi c l e Re pa i r Mate ri a l s Speci fi cati on W S K-M2G 34 8-A5 R em ova l 1.
6. D i s conne ct t he rev e rse l a mp swi t ch e l e ct r i cal co nnect o r. 7. Remove t he ba t t e r y t ray r et a i ni ng brack e t r et a i ni ng bol ts . 8. Remove t he ba t t e r y t ray r et a i ni ng brack e t r et a i ni ng bol ts . Re pos i t i o n t he ba t t e r y t ray 9.
2. Ins t a l l the s e le cto r m e cha ni s m. Ti ght e n t o 20 Nm. 3. Loos l y i ns t a l l t he ba tt e r y t r ay r e ta i ni ng br a cket r e t a i ni ng b ol t s . Re pos i t i o n t he ba t t e r y t ray . 4. Ins t a l l the ba t t e r y t ray r et a i ni ng brack e t r et a i ni ng bol t s .
6. Connect t he rev e rs e l a mp sw i t ch el e ct r i cal co nnect o r. 7. Att a ch t he s e l e cto r cab l e s . 8. Att a ch t he f us e b ox. 9. Att a ch t he wi r i n g ha r ne s s e s . 10. At t ach t he wi r i ng harnes s e s . 11. Ins t a l l t he ba t t e r y t ray .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - S upport In sul ator I n-v e hi c l e Re pa i r Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle .
4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 5. Pos it i o n and adj us t t he s pe ci a l t o o l engi ne hei ght ad j us t e r s . 6. Remove t he ret a i ni n g nut .
7. D et a ch t he s up po r t b a r . 8. Remove t he s up port b a r . 9. Remove t he s p a c e r. All v e h icle s 10. Remove t he t r ans mis s i o n mo unt . Re mov e t he t rans mi ss i on mount r e ta i ni ng nut s . Insta llat ion All v e h icle s JagDocs.
1. Ins t a l l the t r a n s mis s i o n mount . Ti ght e n t o 47 Nm. Vehi c le s with 5- spee d m anual transa x le 2. Ins t a l l the s p a cer. 3. Ins t a l l the s u pport b a r .
5. Tig ht e n t o 133 Nm. 6. Remove t he s p e cia l to o l . 7. Lowe r t he vehi cl e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L D uratorq- TDC i Re moval Speci al T ool (s) S li de ha mm er 100-012 100-012- 02 S li de ha mm er s ha f t Ha l f s.
3. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e n t he s ho ck abs o r be r a nd s p r i ng a ss e mbly s e cur i ng nut s . 4. Remove t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.
8. Remove t he vacuum s o l e noi ds a nd va cuum r e s e r voi r m ount br ack e t a s s e mbl y. 9. D et a ch t he coo l a nt pi p e from t he e ngi ne. 10. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e .
13. CAUT I O N: Ma k e s ure t he ha l fs h a ft CV j o i nt s do no t o ve r a r t i cul a t e . Fa i l ur e t o f o ll o w t hi s i ns t r ucti on may res ul t i n d a mage t o t he CV jo i nt s . S upport t he le ft -hand ha l fs ha f t . 14. Remove a nd di s car d t he le ft -hand ha l f s haf t s nap r i ng.
18. Det a ch t he ge a rshi f t ca bl e s uppo rt br a ck et f r o m t he t rans a xle . 19. Remove t he t r ans a x l e mount br a ck et r e t a i nin g b o lt . 20. Lowe r t he vehi c l e . 21. Det ach t he ge n erat o r and s t arte r mot o r pos i t i ve cabl e from t he e ngi ne cover mount i ng b r a ck et .
23. Ins t a l l t he s p e cia l t o o l . 24. Us i ng t he s pe ci a l t o o l , sup po r t t he e ngi ne a nd t r a ns mis s i o n a s s embl y. 25. Det a ch t he char ge ai r coo l er pi pe . 26. Det a ch t he t rans a xle ground cabl e . 27. Remove t he t r ans a x l e upp er r e t a i ni ng b ol t s .
28. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 29. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r. Fai l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .
33. Us i ng t he eng i ne s upp o r t b rack e t l owe r t he p ow ertrai n as s e m bl y a ppr oxi mat e l y 60 mm (2.36 i nches ) b e t we e n t h e t r ans axl e a nd t rans a xl e m o unt br acket . 34. Rai se th e v e hi cl e . 35. Al i gn t he po we r t r a i n a s s e mbl y j a ck t o t he t rans a xle .
38. Remove t he t r ans a x l e . Det a ch t he t rans a xle from t he cl ut ch p l a te . Lowe r t h e po we r t r a i n a s s e mbl y j a ck a nd t r a ns a xl e a s s e m bl y.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .2 L D uratorq- TDC i (110kW / 150PS) - Puma Re moval Speci al T ool (s) S li de ha mm er 100-012 100-012- 02 S li de ha .
4. CAU TI O N : Make s ur e t h e ha l f s ha ft cons t a nt ve lo ci t y (CV) j o i nt s do not over a r t i cula t e . Fa i l ur e t o f o l l ow t hi s i ns t r ucti o n may res ul t in da mag e to the CV j o i nt s . Det ach t he right -ha nd hal fs ha ft .
9. NOT E: Pl ug t he t rans a xle t o prevent f lui d l o s s o r di r t i ngr e s s . Us i ng t he s p e ci a l t o ol , re mov e t he l e ft -hand ha l f s haf t s ea l . 10. NO TE: Secur e t he po we r st e e r i ng fl ui d p i pe u si ng t i e s t r ap s .
14. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r. Fai l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .
19. NO TE: Secur e t he s e le cto r cabl e s usi ng t ie s t r a ps . Det ach t he s e le cto r cabl e s. 20. Dis c o nne ct t he cr an ks haf t p os i t i on (CKP) s e ns o r el e ct rica l conne ct o r . 21. Remove t he t r ans a x l e upp er r e t a i ni ng b ol t s .
24. Us i ng t he s pe ci a l t o o l , l owe r the po we rtrai n a s s embl y a p pr oximat e l y 60 mm (2.36 i nche s ) b et we e n t h e t rans a xle a nd t rans a xl e mount br acke t . 25. Rai se th e v e hi cl e . 26. Al i gn t he s p e ci a l t o ol t o t he t r a n s a xl e .
29. NO TE: Shown wi t h t he s pe ci a l t o o l r emove d f o r cl arit y. Re move t h e t rans a xle r e t a i ni ng bo l t s . 30. Us i ng t he s pe ci a l t o o l , r e move t he t rans a xle . Det a ch t he t rans a xle from t he cl ut ch p l a te .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L N A V6 - AJV6/2.5L NA V6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval Speci al T ool (s) S li de ha mm er 100-012 100-012- .
3. Loos e n t he l e ft -hand s ho ck a bs orber an d s pr i ng a s s e m bl y s e cur i ng nut s . 4. Loos e n t he r i ght -ha nd s ho ck abs o r b e r and s pr i ng a s s e mbl y s e cur i ng nut s . 5. Remove t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.
8. Remove t he s t ee ring ge a r he a t s hi e l d. 9. Remove t he t r a ns f e r cas e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: T r ans fe r Cas e (308-0 7 T r ans fe r Ca s e, Re moval ).
13. Us i ng t he s pe ci a l t o o l s , d e t ach t he l ef t-h a nd ha lf s ha f t . 14. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s .
18. Det a ch t he ge a rshi f t ca bl e s uppo rt br a ck et f r o m t he t rans a xle . 19. Remove t he t r ans a x l e mount br a ck et r e t a i nin g b o lt . 20. Lowe r t he vehi c l e . 21. Det a ch t he ge ne r at o r wi ring ha r nes s ret a i ni ng c l i p f r om t he c a msha f t cover r e t a i ni ng cl i p.
24. Det a ch t he pos i t ive crankcas e vent i la t i o n (P CV ) hos e from t he i nt a k e m a ni f o l d. 25. Det a ch t he el e ct r i cal co nnect o r fr om th e i nt a ke mani fo l d s uppo r t br acke t . 26. Remove t he i nt a ke mani f o l d s up port b r acket .
29. Ins t a l l t he e ngi ne s up port b r acket . Adj us t th e e ng i ne s upp or t bracket t o s upp or t t he we i g ht o f t he pow ertrai n as s e mbly. 30. Det a ch t he s t ar t e r moto r s o l e no i d cover. 31. Det a ch t he s t ar t e r moto r e l e ct r i cal c onn e cto r .
34. Remove t he t r ans a x l e ret a i ni ng bol t. 35. Remove t he t r ans a x l e ret a i ni ng bol ts . 36. Dis c o nne ct t he reverse l a mp s wi t ch e l ect r i cal co nne cto r. 37. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r.
39. Remove t he cl ut ch mas t e r cyli nd e r t o cl ut ch s l a ve cyli nde r hig h pr es s ur e pi pe s uppo r t . 40. Remove t he t r ans a x l e mount br a ck et s e cur ing s t uds .
45. Al i gn t he po we r t r a i n a s s e mbl y j a ck t o t he t rans a xle . S ecur e t he t rans a xle t o t h e po we rtr a i n a s s e mbl y j a ck . 46. Remove t he t r ans a x l e ret a i ni ng bol t. 47. NO TE: Ve hicl e s wi t h 2.5L a nd 3.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L D uratorq- TDC i I nst a l l a t io n Speci al T ool (s) Ha l fs ha ft o i l s e a l ins t a l le r 205-115 P owe r t r ai n a s s embl y j ack HTJ1200-2 Engi ne sup po r t b rack et 303-021 Engi ne li f t i ng e ye 303-1067 Insta llat ion 1.
3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 4. Remove t he po we r t r ai n a s s e mbl y j a ck. Re mov e t he t rans a xle t o t h e po we r t r ai n a ss e mbly ja ck s ecur i ng s t rap. 5. Lowe r t he vehi cl e .
8. Ins t a l l the t r a n s a xl e mount b r acket ret a i ni ng s t uds . Ti ght e n t o 80 Nm. 9. Ins t a l l the cl ut ch mas t e r cy l i nde r to c l ut ch s l a ve cyli nde r high pres s ur e pi pe sup po r t b rack e t.
13. Ins t a l l t he t r a ns a xl e up per ret a i ni ng b o lt s . Ti ght e n t o 48 Nm. 14. At t ach t he t r ans a xle gr oun d ca b le . 15. At t ach t he cha r ge a ir coo l e r pi pe ret a i ni ng nu t. 16. Remove t he e n gi ne s upp ort br a cket .
18. Ins t a l l t he e ngi ne cover r e a r mount brack e t . Ti ght e n t o 23 Nm. 19. At t a ch t he g ene rat o r a nd s t a rte r mot or po s i t i ve cab l e f r o m t he e ngi ne cover mount i ng b r a ck et . 20. Rai se th e v e hi cl e . 21. Ti g ht e n t he t r an sa xl e mount brack e t ret a i ni ng b ol t .
23. At t ach t he g e a r s hi f t cabl es t o t he t r a ns a xl e . 24. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w r i ght -hand ha l f s ha f t s e a l . 25. Ins t a l l a n ew right -ha nd ha l f s ha f t s na p r i ng .
28. CAUTI O N S : Make s ur e t he ha l f s haf t CV j oi nt s do not ove r a r t i cul a t e. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n d amage t o t he CV jo i nt s . Make s ur e t he ha l f s haf t s ea l i s not damag e d.
33. At t ach t he wi r i ng harnes s t o t he va cuum s o l e noi ds a nd vacuum r es e rv o i r mount bracket . 34. Conne ct t he va cuum s o l e noi d va l ve s e le ctrica l conne ct o r s . 35. Conne ct t he va cuum p i pe s t o t he vacuum s o l e no i d val v e s a nd t he vacuum r e s e r voi r.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .2 L D uratorq- TDC i (110kW / 150PS) - Puma I nst a l l a t io n Speci al T ool (s) Ha l f s ha f t o i l s e al i n st a l l er 205-115 P owe r t r ai n a ss e mbl y ja ck HTJ1200- 2 Engi ne s up port b r a cket 303-021 Insta llat ion 1.
3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 4. Att a ch t he t u r b o charger o i l fe e d pi p e ret a i ni ng br acket . Ti ght e n t o 22 Nm. 5. Remove t he s p e cia l to o l . Re mov e t he s pe ci a l t o o l s ecur i ng s t rap.
8. Loos e l y i nst a l l t he t rans a xle mount bra c ket r e t a in ing bol t s . 9. Ins t a l l the t r a n s a xl e mount b r acket ret a i ni ng b o lt s . Ti ght e n t o 80 Nm. 10. Ti g ht e n t o 80 N m. 11. Ins t a l l t he t r a ns a xl e up per ret a i ni ng b o lt s .
13. NO TE: Re move t he s e l e ct o r cab l e t ie s t r a ps . At t a ch t he s el e ct or cabl es . 14. At t ach t he s e l e ct o r cabl e s . 15. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 16. At t ach t he b a t t e r y ground c a bl e.
18. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be wa s he d d o wn i m medi a t el y wi th col d wa t e r. Fai l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .
24. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w r i ght -hand ha l f s ha f t s e a l . 25. Ins t a l l a n ew right -ha nd ha l f s ha f t s na p r i ng . 26. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e .
28. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w l e ft - ha nd ha l f s ha f t s ea l . 29. CAUT I O N: Ma k e s ure t he ha l fs h a ft CV j o i nt s do no t o ve r a r t i cul a t e . Fa i l ur e t o f o ll o w t hi s i ns t r ucti on may res ul t i n d a mage t o t he CV jo i nt s .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle - Transaxle2 .0 L N A V6 - AJV6/2.5L NA V6 - A JV 6/3.0 L NA V 6 - AJ27 I nst a l l a t io n Speci al T ool (s) Ha l fs ha ft o i l s .
3. Ins t a l l the t r a n s a xl e ret a i ni ng bol t . Ti ght e n t o 48 Nm. 4. Remove t he po we r t r ai n a s s e mbl y j a ck. Re mov e t he t rans a xle t o t h e po we r t r ai n a ss e mbly ja ck s ecur i ng s t rap. 5. Ins t a l l the t r a n s a xl e ret a i ni ng bol t s .
8. Usi ng t he e ngi ne s uppo r t b r a c ket r a i s e t he powe rtrai n a s s e mbl y. Adj us t th e e ng i ne s upp or t bracket t o al i gn t he t r a n s a xl e t o t he tra nsa xl e mount b rack e t . 9. Ins t a l l the t r a n s a xl e mount b r acket s e cur i ng st ud s.
13. Conne ct t he re v e r se l a m p s wi t ch e l e ct r i c a l co nnect o r. 14. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t s . Ti ght e n t o 48 Nm. 15. Ins t a l l t he t r a ns a xl e ret a i ni ng bol t . Ti ght e n t o 48 Nm. 16. Ins t a l l t he s t arte r mot o r .
18. At t ach t he s t arte r mot o r e l e ct rica l co nnect o r . Ti ght e n t o 12 Nm. 19. At t ach t he s t arte r mot o r s ol e noi d co v e r. 20. Remove t he e n gi ne s upp ort br a cket . 21. Remove t he e n gi ne s upp ort br a cket . 22. At t ach t he wi r i ng harnes s t o t he ca ms haf t co ver r et a i ni ng s t u d.
23. Ins t a l l t he i nt a ke man if ol d s upport br acket . Ti ght e n t o 10 Nm. 24. At t ach t he e le ct r ica l conne ct o r t o t he i nt a ke mani fo ld s upport bracket . 25. At t ach t he p o s i t i ve cr a n kc as e ve nt i la t i o n (P CV) ho s e t o t he i nt a k e m a ni f o l d.
28. At t ach t he g e ne r a to r wi r i ng ha r ne s s r e t ai ni ng cl i p t o t he cams ha f t cover r e t a i ni ng cl i p. 29. Rai se th e v e hi cl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
33. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w ha l f s ha ft s e a l. 34. Ins t a l l a n ew ha l f s ha f t s na p ring. 35. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e .
Vehi c le s with 2.0L engi n e 38. NO TE: Re move t he t r an s axl e pl ug . Us i ng t he s p e ci a l t o ol , i ns t a l l a ne w ha l f s ha ft s e a l. 39. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e .
43. Ins t a l l t he f e nde r s pl a s h s hie ld acce s s pane l . 44. Ins t a l l t he f r ont s ubfr a me. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L NA V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ27 (502- 00 U ni -Bod y, S u bf r a m e a nd Mo unt i ng Sy s t e m , Re moval a nd I nst a l l at io n).
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n S el e cto r cabl e gromm e t - - 60 l b -i n Gea r s hi f t l e ve r mount r et a i ni ng nut s - - 80 l b-i n JagDocs.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - External C ontro ls Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 5-sp ee d manual t r ans mis s i o.
It e m De s cri pti o n I tem De s cri pti on 1 Int e r na l shi ft me cha ni s m 8 Sel e ct or ca bl e 2 Count e r b a l a nce 9 Bod y s e a l 3 S el e ct o r cab l e a dj us t m e nt mecha ni s m 10.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - External C ontro ls Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift C ablesVe hic les W ith: 5-Spe ed Manual T ransm iss io n - MT7 5 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 2 R em ova l 1.
4. Remove t he i ns t r um e nt pa ne l ce nt e r m ount b r acket . 5. Remove t he ce nt e r ai r duct r et ai ni ng s cr ew. 6. Repo s i t i on t he ce nt e r a i r duc t upwards. 7. D et a ch t he ge a rshi ft s e l e ct or ca bl e g romm et . 8. Rai s e a nd s uppo r t the ve hi cle .
9. D et a ch t he e xhaus t he a t s hi e l d . 10. CAUT I O N: U s i ng t he pow ertrai n a s s e mbly j ack, s uppo r t t he r e a r of t he s ubf rame. • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re move t h e s ubfr a me r e in f o r ce me nt pl a t e r e t ai ni ng bo l t s .
13. NO TE: P res s t he b ut t o n t o r e l e a s e t he cab l e fi t t i ng b e fo re di s conne c t i ng t he ca b l e . Re move t h e ge arshi f t s e le ct or cab l e . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2.
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift C ablesVe hic les W ith: 6-Spe ed Manual T ransaxl e - M MT6 Re moval a n d I ns t a l l a t i on R em ova l 1.
6. D et a ch t he ge a rshi ft ca bl e s f r o m t he t r ans mi ss i o n r et ai ni ng bracket . 7. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
10. Repo s i t i o n t he ge a r s hi f t cabl e s f r o m t he s ubf r a m e . 11. CAUT I O N: Ma k e s ure t he ge ars hi ft ca bl e s a re fe d t hrough t he vehi cl e f lo o r pan i nd i vidu a ll y. Fa i l ur e t o f o l l ow t hi s i ns t r uct i on may res ul t in damag e t o t he ve hi cl e .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift L everVehicles With: 5-Spe ed Manual T ransm iss io n - MT7 5 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ge a r s hi f t l e ve r k nob .
5. D i s conne ct t he ge a r s hi f t s el e ct o r cab l e s . 6. NOT E: Ri g ht -hand s ho wn, l e f t hand s i mil a r . Re move t h e cent e r c o ns o l e r ig ht -ha nd s i d e t r i m pa ne l . 7. Remove t he ge a r s hi f t l e ve r . 1. Re move t he g ea rshi ft l e v e r m ount i ng r et a i ni ng nut s .
P ubl i s he d: 11-May-2 011 Manual T ransm is sio n / Trans axle External Co ntro ls - Gears hift L everVehicles With: 6-Spe ed Manual T ransaxl e - M MT6 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ge a r s hi f t l e ve r k nob .
6. D et a ch t he ge a rshi ft l eve r as se m bl y t o a ll ow a cces s t o t he ge a rshi f t cabl e s . Re mov e t he re ta i ni ng nut s . 7. D i s conne ct t he ge a r s hi f t cab l es . Re mov e t he g e a r s hi f t l e ve r a s s e mbl y . Insta llat ion 1.
P ubl i s he d: 11-May-2 011 T ransfer C ase - C apaci ti es Desc ri pti on Li t e rs Tr an s fe r ca s e l ubr i cant , d r ai n and r ef i ll 0.50 T o rque sp e ci fi cat i o ns Descri pti o n Nm Lb.
P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase Des cr ipt i o n a nd O pe r a t i o n It e m P a r t Nu m be r De scri pti o n 1 — Trans f e r cas e 2 — Trans f e r cas e fi l l pl.
P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase D raining and Fil ling Gene ral P r ocedures Speci al T ool (s) Fla nge hol d i ng t o ol 205-05 3 Fla nge r e move r /ins t a l l e r 20.
2. NOT E: Mark t he po s i t i o n of t he d rives haf t in r e la t i o n t o t he dr i v e pi ni o n fl a nge. Re move t wo o ppos i ng d r i v e s ha f t uni ve r s a l j o i nt r e t a i nin g b o lt s . 3. Loos e n t he r emai ni ng dr i ves ha ft uni ve r s a l jo i nt r e t a i ni ng bo l t s .
6. Usi ng s uit ab l e t i e s t r a ps , se cur e t he o ut e r cas i ng of t he d r ive s haf t uni ver s a l j o i nt . 7. CAU TI O N : Make s ur e t h at th e drive s ha f t do e s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t .
10. NO TE: Make a not e o f t he compl e t e number of t ur n s requi red t o r e m o ve t he co m pani o n f l a nge r e t ai ning nut . • NO T E: Make a no t e o f t he numbe r of de gree s p as t t he l a s t compl e t e r o t a t i on r eq ui red to r e m ove t he compani on f l a nge r e t a i n ing nut .
14. Remove t he co mpani o n f l a nge . Rot a t e th e s pe ci a l t o o l count e r -c l o c kwi s e . 15. Us i ng t he s pe ci a l t o o l s r e move t he pi ni on o i l s ea l . 16. NO TE: Make s ur e th e v e hi cl e i s compl e t e l y l e vel whe n drai ni ng t he tra nsf e r cas e .
21. Appl y s ea l ant (C2S 1209 9) t o t he a r e a o f t r ans fe r ca s e r ea r o ut put f l a nge whe r e s e cur in g nut s e a t s . 22. Ins t a l l t he s p e cia l t o o l t o t he compa ni o n f l a ng e. 23. Appl y s ea l ant (C2S 1209 9) t o t he mat i ng f a ce of t he t r ans fe r cas e r e a r ou tp ut f l a ng e s ecur i ng nut .
25. CAUT I O N: Ma k e s ure t hat t he drive sha f t doe s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Cut a nd r emove t he t i e s t r aps s e cur ing t he o ut er cas i ng of t he d r i v e s ha f t uni ver s a l j o i nt .
29. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm. 30. W A RNING: Do not wo rk o n or unde r a vehi cl e s uppo r t e d o nl y by a ja ck. Al wa ys s uppo r t t he vehi cl e o n sa f e t y s t a nds . • NO T E: T he l o we r li p o f t he s i l l mus t be 540m m from t he f l o o r .
P ubl i s he d: 11-May-2 011 T ransfer C ase - Hal fshaft Seal RH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he right -ha nd ha l fs ha ft s e a l . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o T rans f e r Ca s e i n t hi s s e ct i o n.
P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase Rear O utput Shaft S eal I n-v e hi c l e Re pa i r Speci al T ool (s) Fla nge hol d i ng t o ol 205-05 3 Fla nge r e move r /ins t a l l.
2. NOT E: Mark t he po s i t i o n of t he d rives haf t in r e la t i o n t o t he dr i v e pi ni o n fl a nge. Re move t wo o ppos i ng d r i v e s ha f t uni ve r s a l j o i nt r e t a i nin g b o lt s . 3. Loos e n t he r emai ni ng dr i ves ha ft uni ve r s a l jo i nt r e t a i ni ng bo l t s .
6. Usi ng s uit ab l e t i e s t r a ps , se cur e t he o ut e r cas i ng of t he d r ive s haf t uni ver s a l j o i nt . 7. CAU TI O N : Make s ur e t h at th e drive s ha f t do e s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t .
10. NO TE: Make a not e o f t he compl e t e number of t ur n s requi red t o r e m o ve t he co m pani o n f l a nge r e t ai ning nut . • NO T E: Make a no t e o f t he numbe r of de gree s p as t t he l a s t compl e t e r o t a t i on r eq ui red to r e m ove t he compani on f l a nge r e t a i n ing nut .
14. Remove t he co mpani o n f l a nge . Rot a t e th e s pe ci a l t o o l a nt i - clo ckwis e . 15. Us i ng t he s pe ci a l t o o l s r e move t he pi ni on o i l s ea l . 16. NO TE: Make s ur e th e v e hi cl e i s compl e t e l y l e vel whe n drai ni ng t he tra nsf e r cas e .
5. Appl y s ea l a nt (C2S 12099) t o t he a r ea of t r a n s fe r ca s e r ea r o ut put f l a nge whe r e s e cur in g nut s e a t s . 6. Ins t a l l the s p e ci a l t o ol to t he co m pa ni o n f la ng e. 7. Appl y s ea l a nt (C2S 12099) t o t he mat i ng f a ce of t he t r a ns f e r cas e r e a r ou tp ut f l a ng e s ecur i ng nut .
9. CAU TI O N : Make s ur e t h at th e drive s ha f t do e s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Cut a nd r emove t he t i e s t r aps s e cur ing t he o ut er cas i ng of t he d r i v e s ha f t uni ver s a l j o i nt .
13. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm. 14. W A RNING: Do not wo rk o n or unde r a vehi cl e s uppo r t e d o nl y by a ja ck. Al wa ys s uppo r t t he vehi cl e o n sa f e t y s t a nds . • NO T E: T he l o we r li p o f t he s i l l mus t be 540m m from t he f l o o r .
P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase Re moval Speci al T ool (s) S l i de ha mm er a da pt e r 100-012-0 3 S l i de ha mm er 100-012 100-012-0 2 S l i de ha mm er s ha f t Ri.
2. D et a ch t he s t e e r i ng col umn. Re mov e a nd di s c a r d t he s t e e r i ng col u m n l ow er r e t a i ni ng b ol t . 3. Loos e n t he s ho ck ab so rber and s pring a s s e mbl y s e cur ing nut s . 4. Remove t he right -ha nd front whe e l a nd t i re.
8. Remove t he s e l e ct o r l eve r cabl e s hi e l d. 9. D et a ch t he s e l ect o r l e ver cab l e bracket . 10. Dis c o nne ct t he s e l e ct o r l eve r cab l e .
14. Loo s e n t he r e m a i ni ng d r i ves ha ft uni ve r s a l jo i nt r et a i ni ng bo l t s . 15. Det a ch t he eng i ne r ol l res t r i cto r . Re mov e t he e n gi ne r ol l res t r i ct or r et a i ni ng bo l t . 16. Remove t he e n gi ne rol l r e s t r i ct o r .
18. Us i ng s ui t a b l e t i e s t r ap s , s e cur e t he o ut e r cas i ng of t he drives haf t uni ver s a l j o i nt . 19. CAUT I O N: Ma k e s ure t hat t he drive sha f t doe s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t .
22. Loo s e n t he le ft -hand f r ont s ubframe r ea r mount r et a i ni ng bol t . 23. CAUT I O N: Ma k e s ure t he cons t ant ve l oci t y (CV) j o i nt bo o t i s pr ot ect ed. Fa il ur e t o f o l l ow th i s i ns t r uct i on m a y r es ult i n da mag e t o t he CV jo i nt bo o t .
27. Remove t he t r ans fe r ca se sup po r t b rack e t . 28. Remove t he ca t a l y t i c co nverte r mount br acke t r et ai ni ng bo l t s . 29. Remove t he ca t a l y t i c co nverte r mount br acke t t o t rans f er cas e r et a i ni ng b ol t .
32. Remove t he ca t a l y t i c co nverte r mount br acke t . 33. Remove t he e n gi ne a n t i -r ol l res t r i cto r br acket ret a i ni ng bo l t s. 34. Remove t he e n gi ne a n t i -r ol l res t r i cto r br acket ret a i ni ng nut s . 35. Remove t he e n gi ne a n t i -r ol l res t r i cto r br acket .
37. CAUT I O N: T o p r eve nt da m a ge t o t he t r a ns fe r bo x i nt e r nal s e a l , m a ke s ur e t ha t t he l i nk s ha ft i s no t r et r act e d f ur t he r t ha n 200 mm (7.87 in ches ) f r om t he trans f er cas e. Us i ng t he s p e ci a l t o ol , re t r act t he t r ans f e r cas e l ink s ha ft .
42. CAUT I O N: Ma k e s ure t here i s no l os s o f f l ui d from t he t r a n sf e r c a s e . Fai l ure t o fo l l ow t his i ns t ru ct io n may r e s ul t i n d ama ge t o the tra nsf e r cas e . Re move t h e l i nk s ha f t from t he t r a n s fe r cas e .
P ubl i s he d: 11-May-2 011 T ransfer C ase - Tra nsfer C ase I nst a l l a t io n Speci al T ool (s) Li nk s ha ft l i mit er bracket 307-446 To r que a d a pt e r 303-1069 Li nk s ha ft oi l se a l ins t al le r 205-115 Insta llat ion All v e h icle s 1.
4. CAU TI O N : Make s ur e t h ere i s no l os s o f f l ui d f rom t he t r ans fe r c a s e . Fai l ure t o fo l l ow t his i ns t ru ct io n may r e s ul t i n d ama ge t o the tra nsf e r cas e . I nst a l l a ne w O -r ing s e a l . 5. CAU TI O N : Make s ur e t h ere i s no l os s o f f l ui d f rom t he t r ans fe r c a s e .
9. NOT E: Do not t i ght e n t he e ngi ne a nt i -rol l r es t rict or brack e t r et a i ni ng nut s a t t his s t age . I nst a l l t he e n gi ne a n ti -r ol l r e s t r ict or br a c ket ret ai ni ng nut s . 10. NO TE: Do not t ig ht e n t he engi ne a nt i-r o l l r e s t rict o r br acket r e t a in in g bol t s a t t hi s s t a ge .
14. Ti g ht e n t he cat a l yt i c co nverte r m ou nt br acket ret a i ni ng bo l t s. Ti ght e n t o 55 Nm. 15. Ti g ht e n t he cat a l yt i c co nverte r m ou nt br acket ret a i ni ng bo l t . Ti ght e n t o 55 Nm. 16. Ins t a l l t he cat a l yti c converte r mount br acke t t o t rans f er ca s e r e t a i ni ng bo l t .
19. Ti g ht e n t he e ngi ne a nt i -r ol l r e s t r i ct o r brack et s i de ret a i ni ng b o l t s . Ti ght e n t o 35 Nm. 20. Ins t a l l t he cat a l yti c converte r t o cat a l yti c converte r mount br acke t r et a i ni ng b ol t s . Ti ght e n t o 25 Nm.
24. Ins t a l l a n ew ha l f s ha f t s e a l . 25. CAUT I O N: Ma k e s ure t he ha l fs h a ft co ns t a nt vel o ci ty (CV) j oi nt s do no t o ver ar t i cul a t e . Fai l ur e to f o l l o w t hi s i nst r ucti o n may res ul t i n dama ge t o t he CV j oi nt s .
29. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l a t e r et a i ni ng bo l t s . 30. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t o 142 Nm. 31.
33. Cut a nd remove t he t i e s t raps s e cur i ng t he out e r c a s i ng of t he dr i ves ha f t uni v e rsal j oi nt. 34. Conne ct t he d rives ha f t to t he t r a n s fe r cas e . 35. At t ach t he d rives ha f t uni v ersa l j oi nt . 1. At t a ch t he d r ive s haf t uni ver s a l j o i nt .
37. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm 38. Ti g ht e n t o 80 N m. Vehi c le s with ma nual tra nsmission 39. Fi ll t he manual t r ans mis s i o n t o t he co r r ect oi l l e vel .
Aut o mat ic Trans a xle - JATCO , Ge ne r a l P r o ced ures ). 43. Ins t a l l t he s e l e ct o r l eve r cabl e s hi e l d. Ti ght e n t o 10 Nm. All v e h icle s 44. Ins t a l l t he m uf fl e r in le t pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Muff l e r Inl e t Pi p e - 2.
49. NO TE: I ns t a ll a new s t e e r i ng col u m n l o wer r e ta i ni ng bo l t . At t a ch t he s t e e r i ng col umn. JagDocs.com.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - T o rque Sp eci f i cat ions Descri pti o n N m l b- ft l b- i n Ca ta l yt ic c onve r t er ret a i ni ng s t uds - vehi cl e s wi t hou t di e s e l e.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - E xhaust System Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 2.0L pe t rol e ng i ne I te m P a rt N um be r Des cri pti o n 1 - E xhaus t .
Item Par t N um be r Desc ri pti on 1 — Exhaus t mani f o l d - R/H 2 — Muf fl e r a nd t a i l pi p e a s se m bl y 3 — Exhaus t ha nge r 4 — Exhaus t ha nge r i s o l at o r 5 — Exhaus t h.
I te m P a rt Nu mb e r De sc ri pti o n 1 — Cat a l yt ic converte r 2 — Ex hau s t f l e xi bl e pi pe 3 — Ex hau s t han ge r is o l a t or 4 — Fr o nt muff l e r 5 — Ex hau s t han ge r .
I te m P a rt Nu mb e r De sc ri pti o n 1 — Cat a l yt ic converte r 2 — Ex hau s t han ge r 3 — DPF 4 — Ex hau s t han ge r is o l a t or 5 — Re ar pi pe 6 — Ex hau s t han ge r is o l a.
DPF co nt r ol s o ft wa r e i ncorporat e d i nt o t he engi ne c o nt r o l m o dul e (ECM) Dif f e rent i a l pr e s s ur e s e n s or The DPF reduce s t he pol l ut i o n ge ne rat e d by di e s e l ve hi cle s b y f i l te r i ng s o ot pa rti cl e s o ut of t he e xhaus t g a s e s .
The fi r s t po s t-i nj ect io n o f f ue l bur ns i ns i de t he cy l i nd er, whi ch i ncr ea s e s t he t e mp e rat ure o f t he e xha us t ga s The s e c ond p os t -i nj e ct i o n o f f uel i s i nj e ct e d l a t e i n the po we r s t roke cy cle .
It e m Pa r t Nu m be r Descri pti o n 1 - H ig h p r es s ur e co nnect i o n 2 - Lo w p r e s s ure co nne cti o n 3 - El e c t r i cal co nne cto r The di f f e rent i a l pr e s s ur e s e nso r i s l o ca t e d i n t h e e ngi ne co mpar t me nt , o n t he l o we r RH si d e o f t he bul khea d.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - E xhaust System Dia gn os i s a nd Te s t i ng Over view For i nfo rm at i o n o n t he des cr i pt i on a nd o perat i on o f t he d i e s e l pa r t i.
DT C Descri pti on P ossi bl e cause Act i on s en s o r f a ul t P 0546 Exhaus t ga s t e mpe r a t ur e s e ns o r c i r cuit h ig h, right -ha nd ba nk, ups t r e a m s e ns or Ex ha us t g as t e .
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Catalytic C o n verte r2. 0L Duratorq-TDCi / 2.2L Durato rq- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap.
5. Remove t he ca ta l yt ic convert er t o t ur bo charger r et a i ni ng nut s . Re mov e a nd di s c a r d t he r et a i ni ng nut s . 6. D i s conne ct t he ca t a l yt i c c o nver t e r t e mpe r a t ur e s e ns or e l ect r i cal conne ct or. 7.
10. Remove t he ca t a l y t i c co nverte r. Re mov e t he s e cur ing bol t . Re mov e a nd di s c a r d t he gas ke t. Insta llat ion 1. CAU TI O N : Ne ver us e j oi nt i ng compou nd f or wa rd of t he ca t al yti c c on ver t e r . • NO T E: Co at t he ca t a l y t i c convert er s t uds wi t h a nt i -s e i z e grea s e .
6. Att a ch t he t u r b o charger o ut le t pi pe . 1. Re pos i ti on t he pi pe . 2. Ti g ht e n t he r e t a i nin g cl i p. Ti ght e n t o 4 Nm. 7. Ins t a l l the t ur bocharger out l e t p ip e ret a i ni ng bo l t . Ti ght e n t o 46 Nm. 8. Ins t a l l the e xha us t f l e xib l e pi p e .
11. NO TE: Re move t he o i l f i l l e r cap and oi l le vel i nd i cat o r . I nst a l l t he e n gi ne cove r. 12. Ins t a l l t he oi l f il l e r cap .
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Catalytic C o n verte r LH 2.0L N A V 6 - AJV6 / 2.5L NA V6 - AJV6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1.
7. Remove t he f r ont pi p e . 8. Remove t he t he r mos t a t ho us ing t o o i l co ol e r coo l an t pi pe. 9. Remove t he ca ta l yt ic convert er he a t s hi e l d l o we r r e t ai ni ng bo l t . 10. Lowe r t he vehi c l e . 11. Det a ch a nd r e po s i t i o n t he wi ring ha rnes s e s .
13. Det a ch a nd r e po s i t i o n t he r adi a t o r i nl e t co o l a nt pi p e . 14. Remove t he ca t a l y t i c co nverte r he a t s hi e ld . 15. Remove t he ca t a l y t i c co nverte r. Dis car d t he ret a i ni ng nut s . 16. Remove t he HO 2S.
18. Remove a nd di s car d t he se a li ng r i ng. Insta llat ion 1. CAU TI O N : Ne ver us e j oi nt i ng compou nd f or wa rd of t he ca t al yti c c on ver t e r . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ins t al l a ne w s e a li ng r i ng.
5. Tig ht e n t o 10 Nm. 6. Tig ht e n t o 6 Nm. 7. Tig ht e n t o 10 Nm. 8. Tig ht e n t o 55 Nm. 9. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r .
10. Ti g ht e n t o 25 N m. 11. NO TE: Fo r N AS ve hi cle s o nl y. I f r e qui red, ca r r y o ut a l ong dr ive cycle . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o: P o we r t r ai n Co nt rol Mo dul e (PCM) Lo ng Dr i ve Cyc l e S e l f -Te s t ( 303-14A El e c t r on ic Engi ne Cont r ol s - 2.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Catalytic C o n verte r RH2.0L NA V 6 - AJV 6/ 2.5L N A V6 - AJV6 / 3.0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s ubfr a me. Fo r a d di t i o nal i nfo r mat i o n, refe r to For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.
6. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Re move a nd di s ca r d t he r e t a i ni ng nut s . 7. Remove and di s card t he r et ai ni ng s t uds . 8. Remove t he HO 2S . 9. Remove and di s card t he s e a l i ng ring . Insta llat ion 1. CAU TI O N : Ne ver us e j oi nt i ng compou nd f or wa rd of t he ca t al yti c c on ver t e r .
2. Tig ht e n t o 40 Nm. 3. Ins t a l l new r et a i ni ng s t uds . Ti ght e n t o 9 Nm. 4. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . • NO T E: Make s ur e t ha t t he ret a i ni ng nut s a re t i ght e ne d t wi ce i n t he s eq ue nce sho wn.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Diesel Particul ate Filter (DPF ) Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
6. Remove t he di es e l pa r t i cul a t e f i l t er t o f l e xib l e pi pe ret a i ni ng n ut s . Re mov e a nd di s c a r d t he gas ke t a nd n uts . 7. Remove t he di es e l pa r t i cul a t e f i l t er. Re mov e a nd di s c a r d t he gas ke t a nd n uts .
2. Tig ht e n t o 46 Nm. Ins t al l a ne w ga s k e t a nd nut s. www.JagDocs.com JagDocs.com.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Diesel Particul ate Filter (DPF ) Diff erential Pressu re Senso r Re moval a n d I ns t a l l a t i on R em ova l 1.
6. NOT E: Not e t h e o r i e nt a t i o n o f t he DPF di ff e r e nt i a l pres su r e hi gh-pr es s ur e and lo w-pres s ure ho s e s a nd make sure t hey a re i ns t a l le d i n th e s a me p os i t i on . Di s conn ect t he DP F di f fe rent i a l p r e s s ur e s e ns o r hi gh-pr es s ure a nd l ow -pr es s ur e ho s e s .
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - E xhaust Flexible Pipe2.0L Durato rq- TDCi /2 .2L Durato r q- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.
2. Tig ht e n t o 46 Nm. Ins t al l a ne w e xha us t f l e xib l e pi p e ga s ket a nd nut s . JagDocs.com.
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1. CAU TI O N : The e xhaus t hange r is o l a t or s a r e cons t r uct e d o f a s pe ci a l mat e r ia l . Us e onl y t he cor r e ct s pe cif ica t i o n e xhaus t ha nge r is o l a t or s . • NO T E: Check t he e xhaus t ha nge r i s o l a t o r s f or da mag e o r fa t i gue .
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Front Muffl er2. 0L NA V6 - A JV6 /2. 5L NA V 6 - A JV 6/3.0 L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 100-01 Id e nt i fi cat i o n Cod e s .
6. D et a ch t he f ront muff l e r hange r i s o l a t o r s . 7. Remove t he f r ont muff l e r. Loo s e n t he f ront muffl e r cla mp ret a i ni ng nut s . Insta llat ion Vehi c le s with 2.5L or 3.0L engine 1. CAU TI O N : The e xhaus t hange r is o l a t or s a r e cons t r uct e d o f a s pe ci a l mat e r ia l .
3. CAU TI O N : The e xhaus t hange r is o l a t or s a r e cons t r uct e d o f a s pe ci a l mat e r ia l . Us e onl y t he cor r e ct s pe cif ica t i o n e xhaus t ha nge r is o l a t or s . • NO T E: Check t he e xhaus t ha nge r i s o l a t o r s f or da mag e o r fa t i gue .
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler and T ailpipe2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Pu ma, 2.0L Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler and T ailpipe2.5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler In let Pipe2. 0L NA V6 - A JV6 /2. 5L NA V 6 - A JV 6/3.0 L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he f r ont whe e l and t i r e. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i o n 204-04 W he e l s a nd Ti r e s .
6. D et a ch t he muff l e r . S la cken t he m uf fl e r r et a i ni ng cl a mp nut s . All v e h icle s 7. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Re move t h e muff l e r i nl e t p ip e . 8. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r .
2. NOT E: 2.5L a nd 3.0L s h own, 2.0L s i mi la r . Ti ght e n t o 55 Nm. Vehi c le s with 2.0L engi n e 3. Tig ht e n t o 55 Nm. 4. Tig ht e n t o 55 Nm. Vehi c le s with 2.5L or 3.0L engine 5. NOT E: Ins t a l l a new ga s ket . Ti ght e n t o 55 Nm.
6. Tig ht e n t o 55 Nm. 7. Tig ht e n t o 10 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 E xhaust Sys tem - Muffler In let PipeVehicles With : Diesel Particula te Filter (DPF ) Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
2. Tig ht e n t o 55 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Gen eral S p ec if ic a t ions I te m Speci fi cati on Fue l t a nk capa ci t y 61.5 l trs T o rque Sp eci f i cat ions Descri pti o n Nm l b-ft l b-i n Fue l t a nk s e nder uni t l ock r ing s 70 52 - JagDocs.
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 2.0L e ngi ne I te m P art Nu mber De sc ri pti on 1 — F.
The e l e ct ric t ur b i ne fu e l pump, whi ch o pe rat e s i n a f u e l r es ervoir , ha s a n i nt e g r al t o p pl a t e f or t he e xte rn al p i pe wor k an d e l ect r i cal conne ct ors. T he pump is s e cur ed t o t he f ue l t a nk by a s crew-on pl a s t i c cl o s u r e r ing.
6 — Fue l t rans f e r pu m p (j e t p ump ) modul e The e l e ct roni c ret ur nl es s f ue l s ys t e m u ti l i ze d ha s t he f ol l o wi ng a dvant a ge s : r e duced fue l t a nk va po r . r e qui res l e s s e l e ct r ica l p o wer. do es not req ui r e a f ue l ret ur n l i ne.
It e m Pa r t Nu m be r De scr i pti on 1 - Fuel t a nk f i l l e r p i pe 2 - Fuel f i l t er 3 - S e n der uni t 4 - Fuel t a nk The fue l t ank i s co nst r ucte d of h i g h de nsi t y po l yt hyl e ne a nd i s l o c a t e d un dernea t h t he ve hi c l e be l o w t he rea r pa s s e nge r s e a t .
* * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
1 2 3 4 1 2 1 2 1 1 2 3 4 1 1 2 1 1 Pi n Nu m be r C i r cu i t F u nc ti on C i r cui t Col or 2 Gr ound Bl a ck 3 Fue l pump ground Y e l l ow 4 T hr ot t l e s c reen Bl a ck/ gr ee n 5 Fue l pump .
2 1 2 3 4 1 2 3 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2 3 4 Meas ur e t he res is t a nce b e t we e n t h e f ue l pump co nt roll e r CA105 p i n 2, and GRO UN D. I s t he r es i s t a nce l e s s t ha n 0. 5 O hm? Ye s REPAI R t he ci r cui t b e t we en t he f ue l pump c o nt r ol l e r CA105 pi n 2, (B) and GR O U ND.
1 2 1 2 3 4 1 2 3 1 2 Is t he vol t a ge gr e a t e r t han 10.5 Vo l t s ? Yes GO t o B 2 . No GO t o B 3 . B2: C HEC K T HE GR O UND SUPP LY T O T HE F UEL T ANK ELECT R IC AL CO NNECT OR S wit ch t he i g ni t i o n t o t he O FF p os i t i on.
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Pressure C heck Gene ral P r ocedures • NO T E: T hi s p rocedur e i s f o r t he i nst a l l at io n of t he a d a pt o r i nt o t he fue l l i ne d ue t o t he r e m ova l o f t he s c hr a ede r va lve f r o m th e fue l li ne .
6. Ins t a l l the f uel p res s ur e g auge . 7. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ). 8.
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Syste m Pressure Release Gene ral P r ocedures R el ease 1. W ARN INGS : Do no t s moke , carr y l ig ht e d to b a c co o r an o p e n f l a me o f a ny t ype whe n wo r king on o r nea r an y f uel rel a t e d co mpone nt s .
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Tank D raini ng2.0 L D uratorq- TDC i/2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Gene ral P r ocedures Speci al T ool (s) Fuel s uppl y l i ne a da pt o r 310-1 31 1.
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Fu el Tank D raini ng2.0 L N A V6 - AJV6 / 2.5L NA V6 - A JV6 / 3.0L N A V6 - AJ27 Gene ral P r ocedures Speci al T ool (s) Re move/Re fi t fue l p ump/ s e nd er l o ck i ng nut 310-072A 2.
Af t e r car r yi ng o ut repai r s , t he f ue l s y s t e m mu s t b e che cked vi s ua l l y fo r l ea ks . F a i l ur e t o fo l l o w t he s e i ns truc t i o ns may res ul t i n pe rsona l inj ur y. Di s conn ect t he ba tt e r y ground ca bl e .
7. Remove t he f uel t r ans fe r pump. Dis conne ct t he cros s o ver pi pe s Re mov e a nd di s c a r d t he O -r ing s e a l . 8. D i s conne ct t he e l ect r i cal conne ct o r. 9. D et a ch t he e l e c t r i cal co nne ct or. 10. Dis c o nne ct t he f uel s u ppl y pi p e .
12. CAUT I O N: Ma k e s ure t he fl oa t or a rm are no t da ma ged whi l e r e m o ving th e f ue l pump modul e . Guide t he f u e l pump modul e t hr o ug h t he a perture. 13. CAUT I O N: Ma k e s ure d a mage t o t he fue l c r o s s o v e r pip e s do e s not occur .
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Quic k Releas e Co upli ng - Push C o nnect Gene ral P r ocedures Disc onn e ct 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Fue l Va p or s " s i gns a b ou t th e ve hi cle .
5. D i s conne ct t he f uel l i ne q ui ck r e l e a s e coupl i ng. 1. P r es s t he fue l li ne qui ck rel e as e coupl i ng l o ck i ng t a ngs . 2. Dis con nect t he f ue l l i ne q ui ck r e l e a s e co upl i ng. 6. D i s conne ct t he f uel l i ne q ui ck r e l e a s e coupl i ng.
9. Rel e as e t he f uel l i ne qui ck rel e a s e coupl i ng. P r e s s t he f ue l l i ne q ui ck r e l ea s e co upl i ng l o cking r e l e a s e co ll ar.
C onne ct • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or ope n f l a me o f any t ype whe n wo rk i ng on o r ne ar an y f uel rel a t ed com po ne nt s . Hi ghl y fl a mm a b l e vapo r s are a l ways pre se nt a nd m a y i g ni t e .
5. CAU TI O N : Make s ur e t h e fue l l i ne cl i cks i nt o pl ace w hen i ns t a l l i ng th e l i ne . T o make s ur e t ha t t he f ue l l i ne i s ful l y s e at e d , pul l o n t he l i ne . I nst a l l t he f ue l l i ne q uick r e l e as e cou pl i ng.
P ubl i s he d: 11-May-2 011 Fuel System - Gen eral Info r ma tio n - Spring Loc k C ou plin g s Gene ral P r ocedures Speci al T ool (s) S pr ing Lo ck Co upl e r Too l o r E qui val e nt 23-040 D isco nn e ction 1.
4. Ins t a l l the s p r i ng l ock co upl i ng t oo l . P la ce s ui t a b l e a bs o rb e nt mat e r i al be lo w t he pi pe t o col l e ct f ue l s pi l l ag e 5. Clo s e a nd pus h t he s p r i ng l o ck coupl i ng t o o l in to t he o pe n s i d e of t he cage .
1. Ins pect a nd cl e a n bo t h coupl i ng e nds . I ns t a l l ne w O -r ing s an d g a r t e r s p r i ngs if ne ces s a r y. 2. F i t t he ma le f i t t i ng i nt o t he f e mal e e nd a nd pus h unt i l t he ga r t e r s pring s na ps over t he fl a r e d e n d o f t he mal e f i t t i ng.
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b-i n Fue l t a nk s u pport s t r ap r et ai ni ng b o l t s 25 18 - Fue l pu m p modul e l ocking ring - v e hicl es wi t h 2.
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank a nd Lin es Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s wi th 2.0L e ngi ne It e m P a rt N um be r De scri pt i on 1 - Fue l pu.
Item Pa rt Nu m ber De scr i pti on 1 - Fue l l e ve l se n s o r 2 - Fue l t a nk 3 - Fue l t a nk f i l l e r pi p e 4 - Fue l t a nk f i l l e r pi p e brea t he r hos e 5 - Fue l t a nk he a t s hi e l d 6 - Fue l t a nk s up port s t raps 7 - Fue l t a nk s up port s t rap i ns ul a t or 8 - Fue l fi l t e r Ve hi cl e s wi th 2.
I te m P a r t Nu m be r Des cri pti o n 1 — Fue l f i l le r ca p 2 — Fue l t a nk f i ll e r pi pe 3 — Fue l t rans f e r pump 4 — Fue l t a nk 5 — Fue l t a nk s uppo rt s t raps 6 — Fu.
Fu el Tan k Filler Pi pe The fue l t ank fi l l e r pi pe i s o f a s t e e l con st r uct i o n a nd i s r e t a i ne d t o t he vehi cl e by mea n s of t hree r e t a i ni ng nut s, o ne ret a i ni ng t he fi l l er ne ck t o t h e bo d y a nd t wo nut s re t a i ni ng t he f i ll er pi pe t o th e ve hi cle chas s i s .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank a nd Lin es Dia gn os i s a nd Te s t i ng Insp ection a nd verif ica tion 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
Ve hi cl e s wi th di ese l engi ne onl y. Do no t i nt e r change fue l i nj e ct ors . Improper i n je ct o r i ns t al l a t i o n ca n caus e mi s fi r e s , po or r unni ng a nd s e vere e ngi ne da mag e. Make s ur e tha t a ny pr ot ect i ve clo t hi ng worn i s c l e a n and made from l i nt -fr e e no n-fl o cking mat e r i a l .
Sym ptom P ossi bl e s ource Acti on Di ff i cul t t o s t a rt hot Inj ect or l e a k Fuel t empe rat ure s ens o r IAT s e ns or MAF s e ns o r Engi ne c o ol a nt te m pe r a t ur e (ECT) s ens o r.
Sym ptom P ossi bl e s ource Acti on c a ni s t e r S no w o r i ce pa ck around th e ca ni s te r o ut le t or fi l t er Fue l s m e l ls i n/around t he vehi c l e Fil l er ca p i ncorr e ct l y f i.
1 2 3 DT C C ondi ti on Possi bl e s ource Ac ti on P 0441 Evapo r at i ve e mi s s i o ns s ys t e m, in c orr e ct p ur ge f l o w Ca ni s t er purg e pi p e ; r e s t rict ed, l e aki ng o r di sco.
1 2 1 1 1 FT06, p i n 02 (B ) and GROU ND. FT06, p i n 04 (B ) and GROU ND. Ve hi cl e s wi th 2.0 L pet r ol ; CA415, p i n 04 (B) a nd GROU ND. Ve hi cl e s wi th 2.0 /2.2 L di e s el e ngi ne s ; CA415, p i n 04 (B) a nd GROU ND. I s t he r es i s t a nce gr ea t e r t ha n 5 oh m s ? Ye s REP AIR t he hi gh r e s i s t a nce ci rcu i t .
1 1 1 2 3 1 1 2 F06, pi n 05 (W B) a nd GRO UN D. I s t he r es i s t a nce l e s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t ci r cuit . For a ddi t i o na l i nfo rm at i on, ref e r t o t he wiring di a g rams. CL EAR t h e DTC, t e s t t he s yst em f o r no r mal o p e r at i o n.
1 2 3 4 1 2 1 2 3 4 5 6 7 8 1 No GO t o B4 . B4: C HEC K T HE PO WER SUP PLY CIRC UIT T O T HE F UEL PUMP Re conne ct t he f uel pump modul e conne ct o r , CA105. Dis conne ct t he fu e l pump co nnect o r: Ve hi cl e s wi th 2.5/3.0 L e ng ine , RO W ; FT02.
2 3 4 1 2 3 4 5 1 2 Mak e s ure t he gea r s e le ct o r i s i n t he NEUT R AL pos i t i on f or ve hi cle s f i t t e d wi th manual t r ans mis s i on , P AR K po s i t i o n fo r vehi cle s fi tt e d wi t h aut o mat i c tran smi s s i o n. S t a r t t he e ngi ne a nd a l l o w t o i dl e .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Filter2.0L Du rat o rq-TDCi/2. 2L Duratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ha nd P r e s s .
4. D i s conne ct t he f uel f il t e r t o f uel pump f u e l s uppl y l i ne f r om t he fu e l f i l t e r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
3. NOT E: Make s ure t ha t t he ha nd p r i mer arr o w i ndi ca t i ng t he fue l f l o w i s poi nt i ng t o wa rds t he fue l f i l t er. I nst a l l t he ha nd p r e s s ure pump s p e ci a l t oo l b et we e n t he fue l fi lt e r and t he fue l f i l t e r fue l s uppl y l i ne .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Filter2.0L N A V6 - AJV6/2.5L NA V 6 - A JV6/3.0L N A V6 - A J2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Pe t rol Fum e s " s i gn s a bo ut t he ve hi cl e .
Insta llat ion 1. W ARN INGS : Do no t s moke o r car r y l i ght e d t ob a cc o or ope n f l a me of a ny t ype whe n wo r king on o r nea r an y f uel rel a t e d co mpone nt s . Hi ghl y f l a mmabl e vapors a r e a l wa y s pr es ent a nd may i gni t e .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender2 .0L NA V 6 - A JV 6 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s .
5. Remove t he f uel l e vel s e nder. Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s . Hi ghl y fl a mm a b l e vapo r s are a l ways pre se nt a nd m a y i g ni t e .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender2 .0L Duratorq-TDC i/2. 2L Duratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : D.
Do not ca r ry or o perat e c e l l ul a r pho nes w he n work ing o n o r ne a r a ny f ue l r e l at e d co mpo nent s . Hi ghl y f l a mm abl e vapo rs a r e a l wa y s pr es e nt an d may i gni t e . Fa i l ure t o fo l lo w t he se in s t ruc t i o ns may r e s ul t i n p ers ona l i nj ur y.
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender LH2.5L NA V6 - AJV6 / 3.0L NA V6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s .
5. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. Re move t h e fu e l l e ve l se n de r a nd h arnes s . Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Sender R H2.5L N A V6 - A JV 6/3. 0L NA V6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel L ev el Senso r2.0L Durato rq- TDCi/2.2L D uratorq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mov.
4. D et a ch t he t o p o f t he fue l l e ve l s ens or . 5. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e r e m o ving th e f ue l l e v e l s e ns o r. Re move t h e fu e l l e ve l se n s o r . 1. Ro t a t e t he l o we r pa r t o f t he fue l le vel s e ns o r .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Pump Mo dule2.0L N A V6 - AJV6 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re move/In st a l l f ue l pump/trans f e r pum p l o c.
5. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e r e m o ving th e f ue l pump modul e . Re move t h e fu e l pump modul e . 1. Ro t a t e t he l o we r pa r t o f t he fue l pump modul e . 2. Re move t he f ue l pump modu le .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel Pump Mo dule2.5L N A V6 - AJV6 / 3.0L NA V6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove /Ins t a l l f ue l pum p/t .
3. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Det ach t he e l e ct r i ca l conne cto r . 4. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y.
8. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Re move t h e fu e l pump modul e a nd cr os s ove r pi pe s . Re mov e a nd di s c a r d t he O -r ing s e a l . 9. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. Re move t h e fu e l t ank. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o: Fue l Ta nk - 2.
13. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Det ach t he f uel p ump m o dul e f la n ge f rom t he f uel pump mo dul e ba s e . 14. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he e l e ct rica l conne ct o r . 15. NO TE: Fe d e r al mar ket ve hi cl e s o nly.
18. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he fu e l cr o s s ove r pi pe f r om t he fue l p ump modul e b a s e . 19. CAUT I O N: Ma k e s ure t he fl oa t or a rm are no t da ma ged whi l e r e m o ving th e f ue l pump modul e .
1. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e in s t a l l in g t he f ue l p ump mod ul e . • NO T E: Fed e ral market vehi cl e s onl y. • NO T E: Make s ur e t he f ue l pump modul e is corr e ct l y o r i en t a t e d .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank2.0L N A V6 - A JV 6 Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : P l a ce t he ve hi cl e i n a we l l v e nt il a t e d, quarant i ne d a rea a nd a r r ange No S m ok i ng/P e trol Fu mes s i gn s a bo ut t he ve hi cl e .
7. D i s conne ct t he f uel f il t e r l i ne qui ck rel e a s e coupl i ng. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
12. NO TE: An as s i s t a nt w i l l be req uir e d to r e move t he fu e l t a nk. Re move t h e fu e l t ank. Re mov e t he f ue l t a nk s uppo rt s t raps . Insta llat ion • W ARNINGS : Do not s moke o r car r y l i ght e d t ob a cc o or an o pe n f l ame o f a ny t ype whe n wo rk i ng o n o r nea r any f ue l r e l a t e d compo ne nt s .
4. Connect t he e va porat i ve e mis s i on ca ni s t er ho s e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
10. At t ach t he wi r i ng harnes s gr omm e t . 11. Ins t a l l t he r e ar s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t i o n). 12. Conne ct t he b a t te r y g r o und cab l e .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank2.0L D urato rq - T DCi/2. 2L Duratorq-TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : P l a ce t he ve hi cl e i n a we l l v e nt il a t e d, quarant i ne d a rea a nd a r r ange No S m ok i ng s i gns abo ut t he v e hi cl e.
6. D et a ch t he brea t he r ho se from t he fue l t ank. 7. NOT E: Not e t h e o r i e nt a t i o n o f t he fue l t a nk f il l e r pi pe t o f uel t a nk hos e r e t a i ni ng cl i p b e fo re l o o s e ni ng. Lo o s e n t he f uel t a nk fi l l er pi p e t o fu e l t a nk ho s e ret a i ni ng cl i p.
1. NOT E: An a s s i s t a nt wi ll b e r e qui r ed t o i ns ta l l t he f uel t a nk. • NO T E: Make s ur e t he f ue l f i l l e r pi pe ho s e i s conne c t e d t o t he fue l t a nk a s it i s i ns t al l e d. I nst a l l t he f ue l t ank. Ins t al l t he f ue l t a nk s u pport s t raps .
6. Lowe r t he vehi cl e . 7. F i l l t he fu e l t ank w it h fue l . 8. Connect t he e l ect r i cal co nnect o r. 9. Att a ch t he wi r i n g ha r ne s s g r omm et .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank2.5L N A V6 - A JV 6/3.0 L N A V6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ.
6. D et a ch t he e l e c t r i cal co nne ct or. 7. D i s conne ct t he e l ect r i cal conne ct o r. 8. Usi ng a s ui t a bl e s uct i on devi c e dr a i n t he f uel t a nk fi l l e r pi pe .
13. Remove t he a xl e as s e m bl y rea r r e t ai n in g b ol t . 14. Remove t he a xl e as s e m bl y f r ont ret a i ni ng bol t s . 15. Us i ng t he s pe ci a l t o o l , l owe r the a xle a ss e mbly a pproximat e l y 75 mm (2.95 i nches ) . 16.
18. At t ach t he s e cur ing s t r a p s upp li e d wi t h t he s pe cia l t oo l HT J1200-2 t o t he r ea r t owi ng e ye t hr e a d a nd s uppo r t t he rea r of t he a xl e a s s e m bl y.
23. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Di s conn ect t he e vapo r at i ve e mi s si o n cani s t e r cl o s e val ve e l e ctrica l conne ct or. 24. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Det ach t he e va porat i v e e mis s i o n ca ni s te r pur ge ho s e f r om t he fue l t a nk r e t a i ni ng cl i ps .
28. NO TE: Fe d e r al mar ket ve hi cl e s o nly. Us i ng t he s p e ci a l t o ol , l ow er t h e f ue l t a nk a ppr o x i mat e l y 100 mm (3.94 i nche s ). Det a ch t he fue l fi ll er pi pe ho se from t he fue l t ank. Ins t al l bl a nki ng pl ugs t o t he f ue l t a nk a nd f ue l f il l e r pi pe ho s e .
33. W A RNING: T he f u el t a nk c a nno t be dr ai ne d i n ve hi cl e . Due t o t he hea vy we i ght , make s ur e t ha t t he f ue l t a nk i s s ecur e l y a t t a ched t o t h e pow ertrai n as s e mbly j a ck when r e m o ving. Fa i lure t o f ol l o w t hi s i ns t ruc t i on m a y r es ult i n pe r s o na l i nj ury .
3. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Conn ect t he e vapo rat i ve e mi s si o n ca ni s t e r ho s e t o t he e vap orat i ve e mi ss i on cani st e r . 4. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. Conn ect t he e vapo rat i ve e mi s si o n ca ni s t e r ho s e t o t he e vap orat i ve e mi ss i on cani st e r .
8. Ins t a l l the f uel t a nk s uppo r t s t r aps re ta i ni ng bo l t s. Ti ght e n t o 25 Nm. 9. Remove t he s p e cia l to o l . 10. NO TE: Fe d e r al mar ket ve hi cl e s o nly. At t a ch t he e vapo r a t i ve e mi s si o n cani s t e r p ur ge ho s e t o t he f ue l t a nk r e t a i ni ng cl i ps .
13. Conne ct t he e vapora ti ve e mis s i o n ca ni s t e r pur ge hos e qui ck rel e a s e coupl in g. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Q ui ck Re l e a s e Co upl i ng - P us h Conn ect (310-00 Fue l S ys t e m - Ge neral I nf orm at i o n, Gene ral P r o ce d ur es ).
18. Remove a nd di s car d t he axl e a ss e mbl y wa s he r. 19. Ins t a l l a n ew a xl e a s s e mbl y wa s he r . 20. Remove t he cha i n f r om t he a xl e a s s e mbl y front s upp o r t bracket . 21. Us i ng t he s pe ci a l t o o l , i ns t a l l t he a xl e a s s e m bl y.
23. Loo s e l y i ns t a l l a ne w axl e a ss e mbl y r ea r r et a i ni ng bol t. 24. Ti g ht e n t o 90 N m. 25. Ti g ht e n t o 110 N m. 26. Remove t he s pe ci a l t o o l . 27. Ins t a l l t he f r ont muff l e r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Muff l e r - 2.
30. Conne ct t he e l e ct r i cal conne ct o r. 31. At t ach t he e le ct r ica l conne ct o r . 32. At t ach t he wi r i ng harnes s gr omm e t . 33. Ins t a l l t he r e ar s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t i o n).
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ank Fill er Pipe Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Pe t rol Fum e s " s i gn s a bo ut t he ve hi cl e .
7. Remove t he f uel t a nk fi l l er pi p e a nd ho s e . 1. Re move t he r e t a i ni ng nut s . 2. Re move t he f ue l t a nk f i l le r pi pe a nd hos e . Insta llat ion 1. W ARN INGS : Do no t s moke o r car r y l i ght e d t ob a cc o or ope n f l a me of a ny t ype whe n wo r king on o r nea r an y f uel rel a t e d co mpone nt s .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - G as F uel T ank Pre ss ure Senso r Re moval a n d I ns t a l l a t i on R em ova l • NO T E: T he f ue l t a nk pr e s s ure s e ns o r i s fi t t e d t o f e de r a l mark et ve hi cl e s o nl y.
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Fuel T ransfe r Pump Re moval a n d I ns t a l l a t i on Speci al T ool (s) Remove /Ins t a l l f ue l pum p/t r a ns f e r p ump lo cking r i ng .
3. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. Det ach t he e l e ct r i ca l conne cto r . 4. NOT E: Non fe d e r al mar ket ve hi cl e s o nl y. • NO T E: No t e t he o rie nt a t io n o f t he f ue l t r ans fe r pump be f o r e r e moval .
8. NOT E: Fe de r al ma r k e t vehi cl e s o nl y. • NO T E: No t e t he o rie nt a t io n o f t he f ue l t r ans fe r pump be f o r e r e moval . Us i ng t he s p e ci a l t o ol , re mov e t he l o c ki ng r i ng. 9. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e r e m o ving th e f ue l t r a ns f e r pump.
• NO T E: Fe de ral mar ket vehi cle s, re fe r t o s t e p 1. • NO T E: No n f e de ral ma r k e t vehi c l e s , re fe r t o s t e p 2. 1. CAU TI O N : Make s ur e t h e fl o a t or arm are n ot da mage d whi l e in s t a l l in g t he f ue l p ump mod ul e .
P ubl i s he d: 11-May-2 011 Fuel Tan k and Li nes - Ine rtia Fuel Shuto ff (IF S) S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cowl s i de t rim pa ne l . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on .
P ubl i s he d: 24-Ma r -2 011 Fuel Tan k and Li nes - Fuel T ank Fill er Pipe Hos e Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : P l a ce t he vehi cl e i n a qua r a nt i ne d a r e a a nd a rr a nge "No S m oki ng/Pe t rol Fum e s " s i gn s a bo ut t he ve hi cl e .
a nd may i gni t e . Fa i lu r e t o f ol l o w t he s e i ns t r ucti ons ma y r es ul t i n pe r s o nal in j ur y. Th is p roc e dur e i nvol ves fue l ha ndl i ng. Be p r e pa r ed f o r fue l s pi l l age a t a l l ti mes a nd a l w ays o b s e r ve f uel ha n dl i ng precaut i o ns .
P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b-i n Accel erat o r pe da l 9 - 80 JagDocs.
P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele ratio n Co n trol Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um b e r Desc ri pti on 1 — E ngi ne cont r ol modul e (ECM).
* * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele ratio n Co n trol Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
1 2 3 1 2 3 4 1 2 Pi n N um be r C i r cu i t Fun cti on Ci r c ui t Col or 12 Out put (5 v ol t s ) O range /Y e ll o w 13 Out put (5 v ol t s ) Y e l l o w 19 G r o und Bl a ck /Gr e e n 20 G r o un.
1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 I s t he r es i s t ance great e r t ha n 10,000 o hms ? Ye s DIA GNOSE t he e l e ct r o ni c e ngi ne co nt r o l s yst e m. Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Sect i o n 303-14A El e ct r oni c Engi ne Cont r ol s S e c t i o n 3 03-14B El e c t roni c Engi ne Co nt rol s .
1 2 3 1 2 1 2 1 2 1 2 1 1 1 2 3 1 1 2 Turn t he i gn it i o n s wi tch t o t he O FF p o si t i on. Di s c onn e ct t he t hr ot t le pos i t i on s e ns o r e l e ct rical co nnect or EN13. Mea s ur e t he res i s t a nce b et we e n EN13-1 and ground.
1 1 1 2 1 2 1 1 2 1 2 1 2 3 I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he t hrott l e mot o r r e l ay po we r s uppl y ci rc ui t . CL EAR t he DTC. TES T t he s ys t e m f o r no r mal o p e r at i o n. No I NS TALL a ne w t hr o t t l e mot o r r el a y.
P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele rator Cable Adj ustme nt2. 0L NA V 6 - A JV 6 Gene ral P r ocedures 1. Remove t he primary cabl e r et a i ni ng cli p . 2. NOT E: Make s ure t he acce l e r a t o r cabl e i s s e a t e d ful l y i n the ret a i ni ng br acket .
P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele rator Cable2.0L N A V6 - AJV 6 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 414-01 B at t e ry , Mount i ng a nd Ca b l e s .
6. Remove t he a cc e l e r a to r cab l e . Det a ch t he a ccel e rat o r cab l e gr ommet . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n t o 5 Nm. 3. Adjus t t he a cc e l e r a t o r cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Acce l e r a t o r Cabl e A dj us t me nt -2.
P ubl i s he d: 11-May-2 011 A ccele ratio n Co n trol - A ccele rator P ed al Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.0L engi n e 1. D et a ch t he a ccel e r a t o r cab l e . 1. P o si t i on t he a ccel e rat o r a c t ua t o r t o t he ful l y o pe n po s i t i o n.
5. Remove t he a cc e l e r a to r pe da l. Insta llat ion 1. NOT E: Ve hi cl e s wit h 2.5L , 3.0L o r di e s e l e ngi ne s hown, 2.0L s i mil a r . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure.
P ubl i s he d: 11-May-2 011 Speed C o ntrol - T o rque Sp eci f i cat ions Descri pti o n Nm l b- f t l b- i n Cr ui s e cont r o l s wi t ch r e t a i ni ng s cr e ws 3 - 27 JagDocs.
P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Des cr ipt i o n a nd O pe r a t i o n 2.0L ve hi cl e s It e m Pa rt Nu mb e r Descri pt i on 1 — Engi ne cont r o l modu le (ECM ) 2 .
It e m Pa rt Nu mb e r Descri pt i on 1 — Engi ne cont r o l modu le (ECM ) 2 — Cr ui s e cont r o l s wi t ch 3 — Thr o tt l e b ody 4 — Ins t r um e nt cl us t e r (IC) 5 — S pee d cont ro.
Actua tor Switche s ON Sw itc h W he n t he O N s w it ch i s o pe r a t ed t he s p e e d cont rol s ys t e m i s a ct i vat e d a nd providi ng t he v eh i cl e i s t ravel li ng at a s pe e d great e r t ha n 40k m/ h (25m il e /h), t he s p e e d cont rol s yst e m wil l a ccep t t he s pe e d i npu ts .
P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol2 .0L NA V6 - AJV 6 Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the v e hi cle s pe e .
P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol2 .5L NA V6 - AJV 6/3 .0L N A V6 - A J2 7 Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h .
1 2 3 1 1 2 3 1 2 1 2 1 1 2 1 DT C De sc ri pti o n Poss i bl e Sour ce Acti on t o ground, hi gh re si s t a nce. Brak e cance l s wi tch po we r s uppl y ci r cui t o pe n ci rc ui t . Brak e cance l s wi tch f a i l ure. Pinpoint Test s PINPOIN T TE ST A : P056 8 .
1 2 1 2 1 2 1 2 1 2 3 1 2 3 I s t he r es i s t a nce 0 o hms? Ye s No el e ct r i cal f a ul t i n s wi t chpa ck . RECHECK DTCs. No I NS TALL a ne w s wi t chpack. REFER t o Spee d Cont r ol Swit ch i n t hi s se ct i o n. CLEA R t he DTC. TES T t he s yst e m f or no r m al o p e r at i on .
1 2 1 2 3 4 5 1 2 3 1 2 3 1 2 3 1 2 1 2 3 4 5 1 2 3 Conne ct a n o hmm e t e r bet we e n pi ns 1 and 3 o f t he cl ut ch cance l s w i t c h. Op e r at e t he cl ut ch pe d a l up and do wn, whi l e o b s e r ving t he res i st a nce r e a di ng.
1 2 3 1 2 1 2 1 1 1 2 3 1 2 3 1 2 1 EN16, pi n 31 (B). Fo r add i t i o nal i nf or ma ti on, re fe r t o wiring di ag rams. CLEAR t he DT C. T ES T t he s ys t e m f o r no r mal op e r at i o n.
1 Is t he s wi t ch o p e n ci rc uit ? Ye s GO t o I 10 . No INS TA LL a ne w br ake can ce l swi t ch. CL EAR t he DTC. T ES T t he s y s t e m fo r norm al o pe r a t i on.
P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Deactivato r Switch Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he s p e e d cont r o l d e a ct iva t o r s wi t ch e l e ct r i cal c onn e cto r . 2. Remove t he s p e e d cont r o l de a ct i vat o r s wi t ch.
P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Module Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s p e e d cont r o l modul e cab le r et ai ni ng t i e st r ap . 2. D et a ch t he i nne r c a bl e . 3. D et a ch t he ou t e r cabl e .
5. D i s conne ct t he e l ect r i cal conne ct o r. 6. Remove t he modul e r e t a ini ng bo l t . 7. Remove t he modul e . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
3. Tig ht e n t o 3 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Speed C o ntrol - Speed Co n trol Switch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s t ee ring whe e l. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ste e ring W h e e l (211-04 S te e r i ng Col umn, Re moval a nd Ins t a l la t i o n).
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Re frige r a nt HFC 134a Compr es s o r oi l P ol yal ky l e ne gl y col S yst e m oi l quant i t y Tot a l s ys t e m o i l qua nt i t y = 160ml.
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Cli m ate Co ntro l System Des cr ipt i o n a nd O pe r a t i o n The pur po s e o f t he a i r di s t ribu ti o n s yst e m i s t o rout e a i r t o t he de s i gnat e d regi st e r s .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Cli m ate Co ntro l System Dia gn os i s a nd Te s t i ng Principle of Ope ra tion REFER t o : Cl i mat e Co nt rol Sy s t e m (412-00 Cl i ma te Co nt r o l Sy s t e m - Gene r a l I nfo r mat i on, De s cr ip t i o n a nd O p e rat i o n).
DT C De s cri pti o n Poss i bl e Cause A c ti o n B1253 A i r Te mpe r at ure Int ernal S e ns o r Cir cuit Shor t t o Gr o und I n ca r t e mp s e ns or fe e d s ho r t t o g r ound Re fe r t o t he.
DT C De s cri pti o n Poss i bl e Cause A c ti o n B1946 Cl i mat e Co nt r ol A /C Po s t Eva porat o r S e ns o r Ci rc uit Fai l ur e Evapo rat or t empe r a t ure s e ns o r f ee d ope n ci r cuit.
DT C Descri pti on Poss i bl e Ca use Ac ti on B1318 Ba t t e r y Vol ta ge L o w Bat t ery di s char ge d W iring harnes s f a u lt Charging s ys t e m fa ul t Check ba t t e r y i s f ul l y charged .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Air Co nditio nin g (A /C) C o mpress or Leak Detectio n Gene ral P r ocedures 1. Remove t he A/C co mpr e s s or f r om t he vehi c l e . For add i t i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 412-03 Ai r Condi t io ni ng .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Air Co nditio nin g (A /C) System Flushin g Gene ral P r ocedures 1. W ARNING: U s e e xt r e me ca r e a nd o bs e rv e al l s af e t y precaut i o ns r e l at e d t o t he us e of r ef r i ge r an t s .
9. Ins t a l l new r ef r i gerant l i ne s i f clo gge d wi t h de bris . 10. Reco nnect t he h ea t e xchange r be i ng f l us hed . 11. Add ad di t i ona l r e f r i gerant oi l a s r e qui red. Fo r ad di t io na l i nf o r mat i on , r ef e r t o Ref r i g e r ant O i l A ddi ng .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Air Co nditio nin g (A /C) System Reco v ery, Evacuation an d Charging Gene ral P r ocedures 1.
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Co ntam inated Refrigerant Handli ng Gene ral P r ocedures 1. If cont a mi nat e d ref r i ge rant i s de t ect e d DO NO T r eco v e r t he ref r i ge rant i nt o your R-134a O R R-12 recover y/ r e c ycli ng e qui pme nt .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Dischargin g and Recovery Gene ral P r ocedures 1. W ARNING: U s e e xt r e me ca r e a nd o bs e rv e al l s af e t y precaut i o ns r e l at e d t o t he us e of r ef r i ge r an t s .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - El ectroni c L eak Detectio n Gene ral P r ocedures 1. W ARNING: Go od ve nt i la t i o n i s nece s s a r y in t he area whe r e A/C le a k t e s t i ng i s t o be ca r r ie d o ut .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Inspectio n a nd Assembly Requ i re me nts Gene ral P r ocedures 1.
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Leak Dete cti on Gene ral P r ocedures 1. NOT E: O n vehi cl e s wi t h R-134a Le a k T race Dye i ncorpor at e d i nt o t he A/C s ys t em.
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Refrige rant Oi l Ad ding Gene ral P r ocedures 1. A ne w repl a cement A /C co m pr es s or co nt a i ns 1 50 ml (5 o z .
P ubl i s he d: 11-May-2 011 C lima te C on trol S y stem - Ge neral Info rmation - Refrige rant System Tests Gene ral P r ocedures 1. W ARNING: U s e e xt r e me ca r e a nd o bs e rv e al l s af e t y precaut i o ns r e l at e d t o t he us e of r ef r i ge r an t s .
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - A ir Dis tributio n and Filterin g Des cr ipt i o n a nd O pe r a t i o n It e m Pa r t Nu m be r De sc ri pti on 1 — Le f t -hand s.
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - A ir Dis tributio n and Filterin g Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 412-00 Cli mat e Con trol Sy s t em - Ge ne r a l I nfo r mat i o n JagDocs.
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - Center Registers Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i ns t r um e nt pa ne l vene e r t rim. 2. Remove t he ce nt e r r egi st e r s . Re mov e t he ce nt e r regi s t e r r e t a in in g s cr ews .
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - Driver Sid e Register Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i ns t r um e nt pa ne l vene e r t rim. 2. Remove t he i ns t r um e nt pa ne l s urr o und. Re mov e t he i ns t r ument p a ne l s urr o und ret a ini ng s cr ews .
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - F ron t Foo tw ell Duct L H Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f o ot we l l l a mp. 2. D et a ch t he f l oo r regi s t e r . Re mov e t he f lo o r r egi s t e r r e t a i ni ng s cr e ws 3.
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - F ron t Foo tw ell Duct RH Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f o ot we l l l a mp. 2. D et a ch t he f l oo r regi s t e r . Re mov e t he f lo o r r egi s t e r r e t a i ni ng s cr e ws .
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - P assen ger Side Register Re moval a n d I ns t a l l a t i on R em ova l 1. W ARNING: T o a voi d acci de nt a l d e pl o ym e nt and.
P ubl i s he d: 11-May-2 011 A ir Di stributi on a nd Filtering - P o llen Filter Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cowl vent s cr ee n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co wl Ve nt S cr e e n (501-02 Fr ont End Bo dy P a nel s , Re mova l a nd Ins t al l a t io n).
P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Speci fi ca ti on I n ve hi cle cr os s b e a m bon di ng W SKM 2G37 9-A1 I n ve hi cle c.
P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Heating a nd Ventil atio n Des cr ipt i o n a nd O pe r a t i o n The he at i ng a nd de f r os t i n g s yst e m i s a b l e nded a i r s ys t e m a n d co ns i st s o f a he a t e r co r e, a bl ow er mot o r , d i s t r i but i on d oors a n d a n e vapo rat or core.
P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Heating a nd Ventil atio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 41 2-00 Cl i m a t e Co nt r ol S ys t e m - Ge ne r a l Info rm at i o n .
P ubl i s he d: 11-May-2 011 Heating and V entilatio n - B lo we r Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he bl owe r mot o r l o we r cover. 2. D i s conne ct t he e l ect r i cal conne ct o r. 3. Remove t he bl owe r mot o r .
P ubl i s he d: 11-May-2 011 Heating and V entilatio n - E va po rator C o re Ho usin g Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
9. Usi ng a s ui t a bl e t o o l di s con nect t he r e f r i geran t li ne . 10. Remove t he ref rige r a nt l i ne r et a i ni ng cl i p . 11. Us i ng a s uit a bl e t o ol di sco nne ct t he r ef r i ge rant l i ne . 12. Remove t he e va porat o r cor e ho us in g l ow er s e cur ing nut .
14. Remove t he ce nt e r r eg i s t e r a ir duct . 15. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 1. O n ma nual A /C o nl y. 2. Al l ve hi cle s . 16. Dis c o nne ct t he e l e ct r ica l conne ct o r . 17. Remove t he g l ove b o x mount i ng f r a m e .
19. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 20. Det a ch t he wi ring ha r nes s. 21. Det a ch t he wi ring ha r nes s. 22. Det a ch t he wi ring ha r nes s. Re mov e t he e a r th l e a d r e t a i ni ng bol t . Det a ch t he wi ring ha rn es s .
24. Det a ch t he cent e r o f t he i n v ehi cl e cr os s be a m. 25. Remove t he i n ve hi cl e cr os s be a m ret a i nin g b o lt s . Lef t-h a nd s i de s ho wn, r i g ht -ha nd s i de s i mil a r . 26. Remove t he i n ve hi cl e cr os s be a m a nd t he e va porat o r cor e ho us i ng .
3. Tig ht e n t o 25 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Heating and V entilatio n - Heater C ore Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: If a l e ak i s s us pe ct e d, t he h e a t e r core must b e l e ak t e s t e d i n t h e vehi cl e b e fo re r emova l.
7. Remove t he he a t e r cor e ai r duct ho us i ng. 1. Re move t he he a t e r c ore a i r duct hous i ng ret a i ni ng s cr e ws . 2. Re move t he he a t e r c ore a i r duct hous i ng . Re l e a s e t he re t a i ni ng t abs . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r .
12. Remove t he he a te r co r e. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Heating and V entilatio n - E va po rator C o re Ho usin g Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he e vap orat o r co r e h ou s i ng. For add i t i o na l i nf orm a t i o n, r e fe r t o Evapo rat or Co r e H ous i ng .
5. Rel e as e t he he a t e r cor e hous in g ret a i ni ng t abs . 6. Remove t he he a t e r cor e hous ing . 7. Remove t he rub be r s e a l . 8. Remove t he he a t e r cor e r et a i ni ng bo l t .
10. Remove t he b l owe r mot or . Re mov e t he b l o we r mo t o r r e t a i ni ng s cr e ws . 11. Remove t he manu a l c on t r ol bl o we r mot or r es i s t o r. Re mov e t he ma nua l cont r ol b l o we r m ot o r r e s i s to r ret a i ni n g s cr ew.
14. Remove t he e va porat o r cor e up pe r hous i ng . 15. Remove t he e va porat o r cor e . A ssemb ly 1. To a s s e mbl e , reverse t he di s as s e mbly proced ur e.
3. Tig ht e n t o 5 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 A uxil iary Heating - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n El e ctric bo o s t e r he a t e r r et a in i ng nut s 10 - 89 He a t i ng e le m e nt e l e ct rica l conne ct or r et a i ni ng nut s 4 - 35 JagDocs.
P ubl i s he d: 11-May-2 011 A uxil iary Heating - E lectric B o os ter Heater Des cr ipt i o n a nd O pe r a t i o n Due t o t he hi gh -ef fi ci ency o f t he di e s el e ngi ne , t here i s i ns uff i ci e nt wa s t e -hea t a v ai l a b l e t o t he h e a t e r cor e.
5 - TMAP s e ns or 6 - CHT s ens o r 7 - Gene rat o r P r o vi de d t he t emp erat ure cond i ti ons a re s a t i sf ie d and de pe nd i ng o n t he l o a d cond i t i o n o f t he ge ne rat o r , t .
P ubl i s he d: 11-May-2 011 A uxil iary Heating - Fuel Fired Bo os ter Heater Des cr ipt i o n a nd O pe r a t i o n For mar ket s th a t e x pe rie nce e x t r e mel y l o w t e m pe rat ur e s , a f uel f ire d b o os t e r hea t e r i s i nst a l l e d in pl ace o f t he e l e ct rica l boo s t e r hea t e r .
It e m Pa r t Nu m be r Descri pti o n 1 - Combus t i o n a i r f a n 2 - Burner ho us i ng 3 - El e c t r on ic c ont r ol mod ul e 4 - H ea t e xchange r 5 - Burner i nse rt 6 - Exhaus t 7 - Coo l a.
Over he at Protec tion Ove r he a t pr ot e ct i o n i s cont r ol l e d by a t e m pe r at ur e res i s t o r lo ca t e d in t he he a t excha nge r. Thi s p r ot ect s a g ai nst e xces s i ve op e rat i ng t e mperat ures .
P ubl i s he d: 11-May-2 011 A uxil iary Heating - Auxilia ry Heater Dia gn os i s a nd Te s t i ng Principle of oper at ion The r e a re t wo t ype s of a uxil i a r y hea t e r , t he e l e ctri c boost er hea ter , whi ch i s f i t t e d a s s t a nda rd, a nd t h e f ue l f i re d boost er hea ter , wh i ch is an opt i on.
1 2 3 1 2 Auxi l iary heat er 1 f use connect or C i r cu i t Pi n Auxil i a ry hea t e r r e l a y 1 o ut put 01 Auxil i a ry hea t e r 1 cont r ol 02 Auxi l iary heat er 1 co nnect o r C i r cui t P.
1 2 1 2 3 4 1 1 2 3 4 1 1 2 3 4 5 6 7 1 I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s S US P ECT:- Auxi l i a r y he a t er 1 a s s e mbly No REP AI R t he sh ort c i r cuit . For a ddi t i o na l i nfo rm at i o n, r ef e r t o t he wiring di a gr ams .
1 2 3 4 1 2 3 4 1 1 2 3 4 1 2 3 I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s GO t o A14 . No GO t o A13 . A1 0: CHEC K T HE AUXI LIA RY HEA T E R 1 CO NT R O L LI NE 'O F F' S T.
1 2 3 4 5 6 7 1 2 3 4 1 Auxi l iary heat er connector C i r cu i t Pi ns Auxil i a ry hea t e r cont r ol 03/05 Auxi l iary heat er rel a y 2 conn ec tor C i r cui t P i n Auxil i a ry hea t e r r e l.
1 2 3 4 1 2 3 4 1 1 2 3 4 1 2 3 4 1 1 2 I s t he r es i s t a nce l e s s t ha n 10 o hms? Ye s GO t o B4 . No REP AI R t he o pen c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di a gr ams . B4: C HEC K T HE SUPP LI ES T O T HE AUXI LIA R Y HEA T ER 2 R ELAY Ke y o f f.
3 4 1 2 3 4 1 2 3 Ke y o n, e ngi ne o f f. Mea s ur e t he res i s t a nce b e t we e n: Au xi l i ary hea ter rel ay 2 conn e c tor, harne s s s i de Ve hi cl e ba ttery Auxil i a ry hea t e r 2 cont r ol , p i n 02 Ne g at i ve po s t I s t he r es i s t a nce great e r t ha n 10 ohms ? Ye s S US P ECT:- ECM No REP AI R t he sh ort c i r cuit .
1 2 3 4 1 2 1 1 2 1 Auxi l iary heat er connector C i rcui t P i n Auxil i a ry hea t e r cont r ol 01 Auxi l iary heat er rel a y co nnector C i rcui t P i n Auxil i a ry hea t e r r e l a y cont rol 02 P e rm a nent 12 vo l t sup pl y 03 ECM r e l ay cont r ol l e d 12 vol t s uppl y 01 Auxil i a ry hea t e r r e l a y out p ut 05 Ke y o f f.
1 2 3 4 1 2 3 4 1 1 1 2 3 4 1 1 2 3 4 di a gr ams . C 6: C HEC K T HE AUXI L IA RY HEAT ER C ONT R O L LI NE ' ON' ST AT E S can t o ol co nnect ed . Acce s s t he ECM a nd cont r ol t he a uxil i a r y hea t e r cont r ol P ID. Act iva t e t he a uxil i a r y hea t er.
1 2 3 4 1 1 2 3 4 1 2 3 4 1 2 3 Ke y o f f. Auxil i a ry hea t e r r e l a y conne c t o r di s conne c t e d. Ke y o n, e ngi ne o f f. Mea s ur e t he res i s t a nce b e t we e n: Au xi l i a r y h.
P ubl i s he d: 11-May-2 011 A uxil iary Heating - Fuel Fired Bo os ter Heater Dia gn os i s a nd Te s t i ng Principle of oper at ion The fue l f ir e d bo o s t e r he a t e r i s a vai la b l e as an o pt io n in pl ace o f t he e l e ct ric ve rsi o n, a nd i s l i kel y t o be m o r e co mm on i n e xtreme cli mat e s .
1 2 3 1 1 2 3 4 Fuel fi red h e ate r modul e con nect or C i r cu i t P i n Fue l fi r ed he a t e r modul e g r ound 02 Fue l fi r ed he a t e r modul e i g ni t i o n s up pl y 04 Fue l fi r ed he .
1 1 2 3 4 1 1 2 3 4 1 1 2 3 4 1 2 3 4 1 Mea s ur e t he res i s t a nce b e t we e n: Fuel fi r e d hea te r rel ay co nn e ctor, h ar ness si de Ve hi cl e batter y Fue l fi r ed he a t e r modul e r e l ay s i gna l , p i n 01 P os i t i ve p o st I s t he r es i s t a nce great e r t ha n 100 K ohms ? Ye s GO t o A6 .
1 2 1 1 2 I s t he vol t a ge be t we e n 9 vo lt s a nd 15 vo l t s ? Ye s GO t o A12 . No NO s uppl y t o t he f ue l fi r ed he a t e r modul e c i r cuit . REP AI R t he circ ui t as ne ce s s a r y. Fo r a ddi t i o nal i nfo r m at i o n, r ef e r t o t he wi r i ng d ia gr ams .
P ubl i s he d: 11-May-2 011 A uxil iary Heating - E lectric B o os ter Heater Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 10 Nm. 2. Tig ht e n t o 4 Nm. 3. Ch eck a nd t o p up t he coo l ant i f ne ce s s a ry .
P ubl i s he d: 11-May-2 011 A uxil iary Heating - Fuel Fired Bo os ter Heater Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.
6. NOT E: Cl a mp t he ho s e t o mini miz e coo l a nt l o s s . Di s conn ect t he coo l ant ho s e . 7. Remove t he ret a i ni n g b o lt s . 8. Remove t he f uel f i re d b o os t e r he a t e r . Re mov e t he re ta i ni ng bo l t s. Insta llat ion 1.
2. Ins t a l l the ret a i ni ng b o l t s . 3. Connect t he coo l a nt h os e . Re mov e t he ho s e cl a mp. 4. Connect t he coo l a nt h os e . Re mov e t he ho s e cl a mp. 5. Att a ch t he coo l a nt hos e . 6. Connect t he f ue l f ire d b o os t e r hea t e r f ue l l i ne.
7. Connect t he f ue l f ire d b o os t e r hea t e r e l e c t r i cal co nne ct or. 8. Ins t a l l the a i r def le cto r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (501-0 2 Fr ont End Bod y P a nel s , R emoval a nd I ns t a l l a t i o n).
P ubl i s he d: 11-May-2 011 A ir C onditio ning - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b-i n Ai r condi t i o ni ng (A /C) clut ch r et a i ni ng nut 26 19 - A/C co mpr e s s or .
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing Des cr ipt i o n a nd O pe r a t i o n The a i r condi t i o ni ng (A /C) s yst e m i s a cl ut ch cy cl i ng , fi x e d o rif i ce t ube t ype . The A/C compres so r i s dr i ven by t he e n gi ne .
Fixe d orifi ce tub e The fi xed o r i fi ce t ub e s yst e m al l o ws t he co mpr e s se d l i qui d t o e xpand , by met e ring t he l iq ui d i nt o t he l ow pr es s ur e a re a o f t he eva po r at or.
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n refe r t o S ect i on 412-00 Cl i ma te Co nt r o l Sy s t e m - Ge neral Inf orm a t i o n .
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing (A/C) Co mpre ss o r2. 0L NA V 6 - A JV 6/2.5 L N A V6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1.
7. Remove t he compr es s o r . Insta llat ion 1. NOT E: Ins t a l l ne w O -r ing s e a l s . • NO T E: Co at t he re frige r a nt l i ne O -r i ng s e a l s i n c l e a n r ef rige rant oi l p rior to ins t a l la t i o n. • NO T E: 5o z o f oi l a r e cont a i ned i n t he ne w co mpr e s s or .
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing (A/C) Co mpre ss o r2. 0L Duratorq-TDC i/ 2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re l e a s e t ool , b e l t t ens io ne r 303-676 R em ova l 1.
7. NOT E: Roa d whe e l s hown r e moved f or cla rit y. Re move t h e r i ght -ha nd whe e l a r ch l i ne r a c ce s s p ane l s. 8. Usi ng t he s pe cia l t oo l , de t a ch th e a cces s o r y drive be l t . 9. D et a ch t he e xhaus t fl e xi bl e p i pe s up po r t i s o l at o r .
11. CAUT I O N: Ca r e mus t be t a ken t o avoi d dama gi ng compone nts whe n p o si t i oni ng t he bl o c k. Di s pl ace t he e ngi ne a ppr o ximat e l y 40mm rearwar ds .
2. NOT E: If i ns t al l i ng t he ol d A/C compr es s or, in s t a l l new O -r i ng s e a l s . • NO T E: If i n st a l l ing a ne w A/C compr es s or, mak e s ure t hat ne w O -r i ng s ea l s a r e al r e a dy i ns t al l e d.
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Air Co n d itio n ing (A/C) Pressure T ransducer Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont whe e l and t i r e. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i o n 204-04 W he e l s a nd Ti r e s .
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Cl utch a nd Clu tch F ield C o il2.0L NA V6 - A JV 6/2.5 L N A V6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P ull e y Re pl a c e r 412-109 W r e nch Strap-Uni ve r s a l 303-D 055 Cr a nk s ha f t Dampe r Re m o v er 303-D 121 R em ova l 1.
4. Remove t he A/C cl ut ch s hi m . 5. Remove t he A/C cl ut ch pul l e y ci rcli p. 6. CAU TI O N : Do no t us e a i r t oo l s. Fa i l ur e t o f o l l ow t hi s i ns t r u cti o n m a y r es ult i n da mag e t o t he compon e nt . Us i ng t he s p e ci a l t o ol , re mov e t he A/C clu t ch pul l e y.
9. Remove t he A/C cl ut ch a nd cl ut ch f i e l d c oi l ci r cli p. 10. Remove t he A /C cl ut c h and c l ut ch f i e l d coi l . Insta llat ion 1. Ins t a l l the A/C clut ch a nd cl ut ch f i e l d coi l . 2. CAU TI O N : Make s ur e t h e ci rc l i p i s i ns t al l e d a nd s e a t e d corr e ct l y .
3. Att a ch t he A/C t e mpe r at ure s e n so r. 4. Ins t a l l the A/C t e mpe r at ure s e nso r r et a i ni ng p l a te . Ti ght e n t o 6 Nm. 5. NOT E: The A/C cl ut ch be aring a nd p ul l e y i s a s l i p fi t o n t he compr e s s o r. If co r r ect l y al ig ne d i t sho ul d sl i p on e as i ly.
8. Ins t a l l the A/C clut ch. Ins t al l t he A /C cl ut ch r et a i ni ng nut . 9. Usi ng t he s pe cia l t oo l , t i ght e n t he A/C cl ut ch re ta i ni ng nut . Ti ght e n t o 26 Nm. 10. Meas ur e a nd a dj us t t he A/C cl ut ch a i r g a p by remov i ng o r ins t a l l ing A/C cl ut ch s hi m s .
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Co n den ser C ore Re moval a n d I ns t a l l a t i on R em ova l 1. Recla i m t he re frige r a nt . Fo r a d di t i ona l i nf o r mat i on , refe r t o S ect io n 412-00 Cl i mat e Co nt rol S ys t e m - Gen e r al Inf or m a t i o n .
1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. Tig ht e n 7 Nm. 3. NOT E: Coa t t he r e f r i gerant li ne O -r ing s e a l s i n cl e a n refrige r a n t oi l p r i o r to ins t a l la t i o n. I nst a l l a ne w O -r ing s e a l . 4.
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Evaporato r Co re Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i n ve hicl e cr o s s be a m and e vap o r a t or cor e hous in g.
6. Remove t he e vap orat o r co r e s up po r t br a cket . Re mov e t he re ta i ni ng s c r e w. 7. Remove t he e vap orat o r co r e h ou s i ng. 8. Remove t he e vap orat o r co r e. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Evaporato r Co re Orific e Re moval a n d I ns t a l l a t i on R em ova l 1. Recla i m t he re frige r a nt . Fo r a d di t i ona l i nf o r mat i on , refe r t o S e cti on 412-00 Cl i mat e Co nt rol S ys t e m - Gen e r al Inf or m a t i o n .
P ubl i s he d: 11-May-2 011 A ir C onditio ning - Suctio n Accumu lato r Re moval a n d I ns t a l l a t i on R em ova l 1. Recla i m t he re frige r a nt . Fo r a d di t i ona l i nf o r mat i on , refe r t o S e cti on 412-00 Cl i mat e Co nt rol S ys t e m - Gen e r al Inf or m a t i o n .
7. Remove t he s uct i on a ccum ula t or. Re mov e t he re ta i ni ng bo l t s. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. NOT E: Coa t t he r e f r i gerant li ne O -r ing s e a l s i n cl e a n refrige r a n t oi l p r i o r to ins t a l la t i o n.
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - C ontro l C o mp o nents Des cr ipt i o n a nd O pe r a t i o n I te m P a rt Nu m ber Descri pti o n 1 — A ir i n le t bl e nd do o r a ct ua.
Item Pa r t Nu m be r De sc ri pti o n 1 — Touch s cr e e n s wi t ch 2 — Re ci r cula t e d a i r s wi t ch 3 — Incr ea s e s e t t e mpe rat ur e s w i t c h 4 — De c r e as e s e t t e mper.
Item Pa r t Nu m be r De sc ri pti o n 1 — Fan s pe e d a nd O N/O FF s wi t ch 2 — Re ci r cula t e d a i r s wi t ch 3 — S c r e en d i s p l a y 4 — Ce l s i us /Fahr e nhe i t s e le ct s .
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - C ontro l C o mp o nents Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 41 2-00 Cl i m a t e Co nt r ol S ys t e m - Ge ne r a l Info rm at i o n . JagDocs.
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Air Disc harg e T em p erature Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2. D i s conne ct t he a i r di s char ge t e m pe r at ur e s e ns or e l e ctr i cal co nne cto r.
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Ambient Air T emperature Sens or Re moval a n d I ns t a l l a t i on R em ova l CAU TIO N : Make s ur e t he i gni t i on s wi t ch i s i n t he o f f p os i t io n be f ore di s conne ct i n g t he a mbie nt a i r t empe r a t ure s e ns o r .
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - C lima te C ontro l A ssem bly Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with autom at ic tra ns ax l e 1. NOT E: To ai d r e mov a l of t he cl i mat e co nt rol a s s e mbl y pl ace t he J-ga t e s el e ct o r i n t h e ne ut ral po s i t i o n.
6. Remove t he cli mat e cont r ol a s se m bl y mount i ng b r a ck et up pe r r et ai ni ng s cr ews co ver. 7. Remove t he cli mat e cont r ol a s se m bl y mount i ng b r a ck et up pe r r et ai ni ng s cr ews . 8. Remove t he cli mat e cont r ol a s se m bl y mount i ng b r a ck et l o wer r e t a i ni n g s cr ews .
11. Dis c o nne ct t he cl i mat e cont r o l a s s e mbl y e l e ct rica l co nnect or s . 12. Remove t he cl i mat e cont r o l a s s e mbl y r et a i ni ng s cr e ws . 13. Remove t he cl i mat e cont r o l a s s e mbl y. 1. Re move t he r e t a i ni ng s cr e ws .
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Defros t V ent/R eg ist er Blen d Doo r Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2.
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Foo tw ell Vent/Duct Blen d Doo r Actuato r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2. D i s conne ct t he f o ot we l l vent /d uct bl end doo r a ctua t o r e l e ct r ica l conne ct or.
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - Sunlo ad Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i ns t r um e nt clu s t e r a nd ve nt f i ni s h p a nel . 2. Remove t he i ns t r um e nt clu s t e r f i ni s h pa ne l .
5. Remove t he s unl o a d s e nso r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 C ontro l C o m po nents - T emperature Blend Do o r Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o we r ve nt . 1. De ta ch t he bu lb ho l der. 2. Re move t he l o we r vent . 2. D i s conne ct t he t e mper a t ur e b le nd d o or a ct ua t o r e l e ct rica l conne ct o r .
P ubl i s he d: 11-May-2 011 Instrum ent Cl uster and Panel Il lumi natio n - Instrument Cl uster an d Panel Illu min atio n Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the i ns t ru me nt cl ust e r pr e c l ude t he us e o f wo rk s ho p g e ne r al e le ctrica l t e s t e qui pme nt .
P ubl i s he d: 11-May-2 011 Instrum ent Cl uster - Instrumen t C luster Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s W it h 2.0L , 2.5L An d 3.
It e m Pa r t N u m ber Desc ri pti on 1 — Engi ne t e m pe r at ur e gau ge 2 — Le f t hand di r e cti o n i nd i cat or 3 — Doo r aj ar warning 4 — Lo w e xt e r i or t e mpe r at ur e wa rn.
It e m Pa r t N u m ber Desc ri pti on 1 — Engi ne t e m pe r at ur e gau ge 2 — Le f t hand di r e cti o n i nd i cat or 3 — Doo r aj ar warning 4 — Gl o w pl ug wa r ning la m p 5 — Lo w e.
P ubl i s he d: 11-May-2 011 Instrum ent Cl uster - Instrumen t C luster Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he i ns t ru ment cl us t e r , ref e r to the rel e va nt De s cr i pt i o n and O pe r a t i o n s e ct i o ns i n t he worksho p ma nua l.
P ubl i s he d: 11-May-2 011 Instrum ent Cl uster - Instrumen t C luster Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : Do no t l e a ve t he i ns t r ument cl us t e r fa ce d o wn f o r any le ngt h of t ime . Lo we r a nd e x t e nd t he st e e r i ng col umn t o i t s m a ximum r e arwar d po s i t i o n.
P ubl i s he d: 11-May-2 011 Ho rn - Horn Des cr ipt i o n a nd O pe r a t i o n Ve hi cl e s W it h 2.0L , 2.5L An d 3. 0L e ngi nes It e m P ar t N u m ber De scr i pti on 1 — Ho rn s wi t c h 2 .
It e m P a r t Nu m be r De s cri pti on 1 — Hor n s wit ch 2 — Hor n r el ay 3 — Hor n The ho r n s ys t e m cons i s t s o f t he fo l l owi ng : P owe r di s t rib ut i o n bo x fus e 3 (20A).
P ubl i s he d: 11-May-2 011 Ho rn - Horn Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
P ubl i s he d: 11-May-2 011 Ho rn - Horn Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i on 100-02 Jacki ng a nd Li ft i ng . 2. D et a ch t he ho r n.
P ubl i s he d: 11-May-2 011 Ho rn - Horn Switch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r ai r ba g modul e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Driver Ai r B a g Modul e (501-20B S uppl e men ta l Re st rai nt Sy s t e m, Remo val a nd I nst a l l a t i on).
P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Inform atio n and Message Cen ter Des cr ipt i o n a nd O pe r a t i o n It e m Par t N u m ber De scri pt i o n 1 — Ins t rum ent C.
P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Inform atio n and Message Cen ter Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage .
P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Message Cen ter Re moval a n d I ns t a l l a t i on 1. The i nfo rm a ti o n a n d mes s age ce nt e r i s bui l t i nt e gral t o t he s p e edo met e r . Fo r ad di t i ona l inf or mat i o n, r e f er t o Sect i on 413-01 I nst r um e nt Cl ust e r .
P ubl i s he d: 11-May-2 011 Info rma tio n and Mess age Center - Message Cen ter Sw itch Re moval a n d I ns t a l l a t i on 1. The t rip comput e r s wi tch i s b ui l t i n te gr al t o t he h ea dl amp s wi t ch. Fo r a ddi t i o na l i nfo rm at i on, ref e r t o Sect io n 417-01 Ext e r i or Li ght i ng .
P ubl i s he d: 11-May-2 011 Warning Devices - Warning Dev ic es Des cr ipt i o n a nd O pe r a t i o n 4-doo r I te m P a r t Nu m be r Des cri pti on 1 — Do or a ct ua t or 2 — Safe t y be l t b.
It e m Par t Nu m ber De scri pt i on 1 — Doo r act ua t o r 2 — S af et y be l t buckl e 3 — I ns t rum e nt cl ust e r 4 — J Gat e (Aut o mat i c o nl y) 5 — Engi ne c ompa r t ment s wi t.
The i ns t r um e nt cl us t e r a ct s a s a sys t em monit o r fo r t he vi s u a l w arnings . It recei ve s i nput s f r om s wi t che s a nd s e ns o rs di rect l y o r t hr oug h t he m ul t i p.
P ubl i s he d: 11-May-2 011 Warning Devices - Warning Dev ic es Dia gn os i s a nd Te s t i ng The compl e xit y o f t he e l ect r o ni cs i nv ol ve d wi t h the i ns t ru me nt cl ust e r and gene.
P ubl i s he d: 11-May-2 011 Warning Devices - Oil Chan ge Indicato r Reset Gene ral P r ocedures 1. NOT E: S t e ps 2 t o 5 mus t be compl e t e d wi t hi n 3 s e cond s f or s ucces s ful s ervice mod e res e t t i n g. • NO T E: Ig ni t i on key i n t he OFF po s i t i o n.
P ubl i s he d: 11-May-2 011 Warning Devices - Low Washer Fluid W arni ng Indicato r Switch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to S ect i o n 204-04 W hee l s a nd T ire s .
P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Des cr ipt i o n a nd O pe r a t i o n Item P ar t N um be r Descri pt i o n 1 — P a r king a i d s wi t c h 2 — Fr o nt pa r king a i d .
(2 ft ), at t he vehi cl e cor ne rs. The ve r t i ca l r ang e i s a de qua t e t o p r ot e ct t he hi gh e s t a nd l o we s t po i nt s o f t he front o f t he ve hicl e . The s ys t e m wil l d et e ct cur bs wi t h he i ght s o f a t l e a st 18 c m (7.
P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he pa rk i ng a i d, ref e r to the rel e va nt Des cr i p t i on a nd O pe rat i o n s e ct i o ns i n t he wo r ks hop manua l .
DT C Descri pti on Pos si bl e Ca use A ct i on C1714 Ri ght Fr on t S e ns o r Cir cuit Shor t t o V ba t W i r in g harnes s co ncern Re fe r t o e le ctrica l ci r cuit di a gr a ms.
P ubl i s he d: 11-May-2 011 Par kin g A id - F ron t Parking Aid Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont bu m pe r cover . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont B umper Cover (501-19 Bumpe r s , Re moval a nd I ns t a l l a t i on).
P ubl i s he d: 11-May-2 011 Par kin g A id - F ron t Parking Aid Speaker Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e .
5. Remove t he a s ht ray Dis conne ct t he e l e ct r i cal co nnect o rs. Re mov e t he a s ht ray. 6. Remove t he s wi t ch pa ck t rim cove r. 7. Remove t he ret a i ni n g s cr ew co ver pl a t e . 8. Remove t he di sp l ay mount i ng br a c ket up pe r ret a i ni ng s cr ews .
10. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 11. Remove t he d i s p la y modul e a nd a udi o uni t . 1. Dis con nect t he e l e c t rical co nnect ors a nd t h e fi br e op t i c conne ct o r . 2. Re move t he d is pl a y modu le and audi o uni t .
P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Mo d ule4 -D oo r Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o S ect i o n 414-01 Ba t t e r y, Mount i ng and Cabl es .
P ubl i s he d: 11-May-2 011 Par kin g A id - P arking Aid Mo d uleW agon Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e t he l o a ds p a ce fl o o r cove r i ng. 2. Remove t he l o ad s p a ce fl oo r covering. 3. Remove t he ce nt re l o a ds pace s t o wage compartment .
5. D i s conne ct t he e l ect r i cal conne ct o r. 6. D i s conne ct t he e l ect r i cal conne ct o r. 7. Remove t he pa r ki ng a i d modul e. Insta llat ion 1.
P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he bumpe r l ow er bl a ck out p a nel .
P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid Speaker4-D o or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear pa rc e l s he l f . Fo r a d di t i ona l i nf o r mat i on , refe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on .
P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid SpeakerWagon, VIN R ange: D86655 - >E43419 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e t he l o a ds p a ce fl o o r cove r i ng. 2. Remove t he l o ad s p a ce s t owa g e compa rtment t r i m pan e l .
5. Remove t he rear pa rk i ng a i d s pe a ker. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Par kin g A id - Rea r Parking Aid SpeakerWagon, VIN R ange: E4 3420-> V 99999 Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: The l i f t g a t e we a t he r s t r i p must b e repl a ced on ce removed. Re move a nd di s ca r d t he l i f t g a t e o pe ni ng we a t he r s t rip.
8. D i s conne ct r e a r p ark ing a i d s pe a ke r el e c t r i cal co nne ct or. 9. Remove t he rear pa rk i ng a i d s pe a ker. Re mov e t he 2 s cr ews . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ins t al l a ne w l if tg a t e o pe ni ng we at he r s t r ip.
P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Cha rg i ng Sy stem Des cr ipt i o n a nd O pe r a t i o n V eh icl es wi th 2.
P ubl i she d: 14-Jul-2011 B attery and Chargin g Syste m - General Info rm atio n - Battery C are Des cr ipt i o n a nd O pe r a t i o n 12 V LEAD ACID BAT TER Y CARE MANUAL FOR DE AL ER / RE T AILE R US E 1. INTRODU CTION 2. GENERAL RU LES FO R BA TTERY CA RE 3.
s uppo rte d wi th a po we r sup pl y / char ge r / vehi cl e ma i nt a i ner ca pab l e o f d e l ive r i ng 5 0 Amps or more. Ju mp Sta rting Ne w v ehic le s Bef ore They Hav e B een Delive re d to the Cus tom er.
Digi t a l Mult i -Met e r o r Digi ta l Vo l t -Oh m Met er (DVOM) Midt r oni cs GR-1 Di agno s t i c Charge r JagDocs.com.
4. HE ALTH A ND S A FETY PR ECAUTION S • W ARNINGS : BA TT ERY CELLS CO NT AI N S UL P HUR IC ACID AND EXP LO S IV E MIX TURES O F H Y DRO GEN AND O XY GEN GAS ES . I T I S THEREFORE ES S ENT I AL T HAT T HE FO L LO W I N G S AFETY PRECAU T IO NS ARE O BSERVED .
Sc e nar io 1 - Dea lers hi p / Retailer ( Res p ons ib ility: De aler / Retailer ) 1. W i t hi n 24 ho ur s o f a r r iva l a t t he d e a l e r / ret a i l e r pr ocee d as fo l l o ws: P e r form a Mi dt r oni cs ba t t e ry t e s t (S ee A ppe ndi x A.
I t is e s s ent i a l t ha t a s ui ta b l y vent i l a t e d d e fi ned area e xis t s in e a ch d e a l e r s hi p / r e t a i l e r f o r bat t e ry ch a rging. Li kew i s e , an a r ea s ho ul d be a ll ot t ed f o r s cr a p ba t t e r i e s , a nd cl e a rly i ndi cat e d a s s uch.
CAU TIO N : DO NO T conne ct t he t e s t e r t o a ny o t he r circ ui t o r c ha s s i s po i nt . 1. Att a ch t he Mi dt roni cs Te s t e r t o t he ba t t e ry . 2. Fol l ow th e i ns t r uct i o ns o n t he te s t er t o t e st t he ba t t e r y .
• NO T E: O n ve hi cl e s f i t t e d wi t h a Ba t t e ry Mon it o r ing S ys t em (BMS ) , t he di a gnos t ic ro ut i ne fo r qui e s c e nt dr a i n t e s t i ng i n t he a p pr oved di a gno s t ic s ys t e m s houl d be ut i li z e d.
1. If 24 hours have pa s s e d s i nce th e l a s t ti me t h e e ng i ne wa s run o r th e ba t t e ry charge d, p rocee d t o `P a r t 2 - Bat t e ry Te st '. 2. Tur n on t he i gni t i on. S wi t ch o n t he he a d l a mps o n hi gh be a m fo r a mini mum 3 minut es .
Publ i s he d: 28-S ep -2011 B attery and Chargin g Syste m - General Info rm atio n - Qu iescen t Drain Des cr ipt i o n a nd O pe r a t i o n QUIES C ENT D RA IN - TYP ICAL VALUES • NO T E: T he q ui e s cen t dr ai n a f t e r t he ini t i a l s hut do wn p e r i od s houl d not excee d t he val ue s ho wn i n t h e t abl e .
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Cha rg i ng Sy stem 2.0L N A V6 - A JV 6/2.5 L NA V 6 - AJV6/3. 0L NA V6 - AJ2 7 Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1.
1 2 1 1 2 1 1 Pi n Num be r C i r cu i t F u nc ti on Ci rcui t Col or 4 Ge ne r at o r Cha rge W a rning I n di cat or La mp O ut pu t S ig na l t o ECM Bl ue E ngine C o ntrol M o du l e (E C M) E l.
2 1 1 2 1 2 1 1 1 1 2 1 2 1 Mea s ur e t he res i s t a nce be t we e n e l e ct r i cal c onn e cto r EN49-1 a nd t he gen e rat o r ba t t e r y po s i t i ve ca bl e . I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR s ho rt t o t he ge ne r a t or ba t t e ry p os i t i ve cab l e .
1 1 1 1 1 2 1 1 1 1 1 I s t he r es i s t a nce le s s t ha n 10,000 o hms? Ye s REP AIR s ho rt t o t he ge ne r a t or ba t t e ry p os i t i ve cab l e .
1 1 2 1 1 1 1 1 2 1 1 1 1 ope rat i o n. E10: CHEC K FUSE 8 2 OF T HE PASSEN GER C O MPAR T M ENT FUSE BOX FOR A S HOR T T O GR O UND Meas ur e t he res is t a nce b e t we e n e l ect r i cal conn e cto r JB51-14 of t he pa s s e nge r compart ment f us e bo x a nd gr oun d.
1 2 1 1 1 1 1 2 1 1 2 1 2 I s t he v ol t a ge l es s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n t he pa s s e nge r c ompa rtment f us e box a nd t he i gni t i on r el ay.
1 2 1 2 3 1 2 3 T EST C ONDI T IONS DET AI L S/R ESULT S/ACT IONS H1 : CHEC K T HE GENER AT OR FO R T HE CAUSE OF RADIO I NT ER FER ENC E S TART a nd RU N t he e ngi ne a t 1500 RP M. TU RN t he radi o s wi t c h t o t he O N po s i t i o n. Is r a di o i nt e rfe rence p res e nt ? Ye s GO t o H3 .
P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Cha rg i ng Sy stem 2.0L Durato rq- T DCi/2. 2L Duratorq-TDC i (110k W/1 50PS) - P uma Dia gn os i s a nd Te s t .
1 2 3 1 1 1 2 3 4 1 2 3 1 DT C Co ndi ti on Pos si bl e Sour ce Act i on No ne The ba t t e ry kee ps di s cha r g i ng Ba t t e r y f a ul t Ba t t e r y cabl e s Ba t t e r y qui e s ce nt d r ai n .
2 3 4 5 6 7 8 9 1 2 3 4 5 1 2 1 1 2 3 4 5 1 2 1 Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Di s conn ect t he ge nerat o r t hr e e -way con nect or . Conn ect a vol t met e r bet we e n t he g ene rat o r , p i n 01 a nd GRO UN D.
1 1 1 1 1 1 2 1 2 T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I O NS E1: CHEC K T HE GENER AT O R FOR SECU R IT Y Ins p ect t he g e nerat o r f ixi ngs . I s t he ge ne rat o r s e cur e? Ye s GO t o E2 . No S ECU RE t he ge ne r a t o r . REFER t o : Ge nerat o r.
1 2 1 2 3 1 2 3 1 2 3 T EST C O NDI T IONS DET AI LS/RE SULT S/ACT IONS F1: C HEC K IF T HE GENERAT O R I S T HE CAUSE OF T HE RADI O I N T ER FER E NCE S ta rt an d r un t he e n gi ne a t 1500 r pm . Tur n t he radi o t o t he O N po s i t i o n, a nd s e l e c t t he a f f e ct e d s t at io n.
P ubl i s he d: 11-May-2 011 B attery and Chargin g Syste m - General Info rm atio n - Battery C harging Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t o t he b at t e ry car e ma nua l (BCM ).
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Gen eral S p ec if ic a t ions It e m Speci fi ca ti on Ba t t e r y Capa ci t y Ve hi cl e s W it h P e t rol Engi ne s 80 Ah Ba t t e .
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I te m P a rt N um be r De scr i pti on 1 — B at t e r y t o g e nerat o r a nd s t arte r mot o r p os i t i v e c a bl e 2 — B at t e r y cover 3 — B at t e r y 4 — B at t e r y t r a y 5 .
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o t h e ba t t e r y car e manual .
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Co nnec t Gene ral P r ocedures • W ARNINGS : Ba t t e r i e s no r m al l y produce e xpl o s ive g a s e s which may ca use pers ona l i nj ur y, t he ref o r e do not a l l o w l i g ht e d s ubs t ance s t o come ne a r t he ba t t ery.
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Disco n nect and Co nnect Gene ral P r ocedures Disc onn e ct • W ARNINGS : Ba t t e r i e s no r m al l y produce e xpl o s ive g a s e s which may ca use pers ona l i nj ur y, t he ref o r e do not a l l o w l i g ht e d s ubs t ance s t o come ne a r t he ba t t ery.
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ).
6. NOT E: Pe t r ol e ngi ne s how n, d i es e l e ngi ne s i mi l a r. Re move t h e ba tt e r y he a t s hi e ld . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Cables2 .0L NA V6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1.
7. D et a ch t he ba t t e ry t o s t a rte r mot o r so l eno i d c a bl e cove r . 8. Remove t he ba t t e r y t o s t a r t e r m o to r s o l e no i d ca bl e .
12. Remove t he a i r f i l t e r ret a i ni ng b r ack e t . Re mov e t he re ta i ni ng nut s . 13. Det a ch t he ge ne r at o r ba t te r y po s i t i ve cabl e p r ot e ct ive co ver. 14. Remove t he b a t t e r y pos i t ive cab l e . Det a ch t he ge ne rat o r b a t t e r y po s i t i ve ca bl e e l e ct r i cal conne cto r.
2. Tig ht e n t o 6 Nm. 3. Tig ht e n t o 12 Nm. 4. Tig ht e n t o 25 Nm. 5. Tig ht e n t o 25 Nm. 6. Tig ht e n t o 4 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Cables2 .0L Durato rq- TDCi / 2.2L Du ratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1.
7. D et a ch t he ge ne r a t o r a nd st a r t e r mot or po s it i ve ca bl e f r om t he st a r t e r m o t o r . 8. D et a ch t he ge ne r a t o r a nd st a r t e r mot or po s it i ve ca bl e f r om t he ai r cle a ne r mount i ng bracket .
12. Det ach t he ge n erat o r and s t arte r mot o r pos i t i ve cabl e from t he e ngi ne cover mount i ng b r a ck et . 13. Dis c o nne ct t he g e ne r at o r wi r i ng ha r ne ss e l e ct rical co nnect or. 14. Det a ch t he ge ne r at o r an d s t a r t e r mot or po s it i ve ca bl e f r om t he ge ne r a t or ca bl e moun t i ng bracket .
16. Dis c o nne ct t he g e ne r at o r e l e ct r i cal conne cto r. 17. Det a ch t he ba t t e ry g r ound ca bl e f r o m th e t rans mis s i on r et a i ni ng br acke t and bat t e ry br a cket . 18. Det a ch t he ba t t e ry g r ound ca bl e f r o m th e t rans mis s i on .
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 25 Nm. 2. Tig ht e n t o 25 Nm. 3. Tig ht e n t o 8 Nm. 4. Tig ht e n t o 8 Nm.
P ubl i s he d: 11-May-2 011 B attery , Mou nting and C ables - Battery Tray Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ba t t e r y . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y (414- 01 Ba t t e ry , Mount i ng a nd Ca b l e s , Remo v al a nd I ns t a l l a t i o n).
P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - T o rque Sp eci f i cat ions Descri pti on Nm l b -f t l b- i n Gene r a t or uppe r r et ai ni ng bo l t 4 7 35 - Gene r a t or l o we r r et a i ni ng b o l t s - vehi cl e s wi t h 2.0L, 2. 5L o r 3.
P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator Des cr ipt i o n a nd O pe r a t i o n C ha r ging syste m componen ts Ve hi cl e s wi th 2.0L, 2. 5L o r 3.0L e ngi ne Item P a r t Nu m be r De sc ri pti on 1 — Engi ne Co nt rol Mod ule (ECM ) 2 — Ge nerat o r Ve hi cl e s wi th 2.
Item P a r t Nu m be r De sc ri pti on 1 — Engi ne Co nt rol Mod ule (ECM ) 2 — Ge nerat o r • NO T E: Ge ne r at o rs s houl d b e s e r v ice d a s a uni t a nd no t di s mant l ed fo r overhaul .
P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator Dia gn os i s a nd Te s t i ng 2.0L/2.5L/3.0L Ve hi cl e s REFER t o : Cha r g i ng Sy s t em - 2. 0L NA V6 - AJV 6/2.5L NA V6 - AJV6/3.0L N A V 6 - A J27 (414-00 B a t t e r y a nd Cha rging Sy st e m - Gene ral I nfo r m at i o n, Dia gno si s a nd Te s t i ng).
P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator2.0L N A V6 - A JV 6/ 2.5L NA V6 - AJV6 / 3.0L NA V6 - A J27 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . Fo r ad di t io na l i nf o r ma t i on, ref e r t o S ect i o n 414-01 Ba t t e r y, Mount i ng and Cabl es .
7. Remove t he ge ne r a t or . Re mov e t he g e ne r at o r uppe r r e t a i ni ng bo l t s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 47 Nm. 2. Tig ht e n t o 25 Nm. 3. Tig ht e n t o 12 Nm. JagDocs.
P ubl i s he d: 11-May-2 011 Gen erator and Regulato r - Gen erator2.0L Durato r q -TDCi/2.2L Duratorq-TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) S epa rat o r, ba l l j o i nt 204-192 Re l e a s e t o o l , bel t t e ns i on e r 303-676 R em ova l 1.
7. D et a ch t he r i ght -hand s t ab i l i z e r ba r li nk. Re pos i t i o n t he a nt i -lo ck br a ke s yst e m (ABS) wi ring ha r ne s s m o unt i ng b r a cket . 8. Usi ng t he s pe cia l t oo l , de t a ch th e a cces s o r y drive be l t . 9.
12. Remove t he g e ne r at o r uppe r r e t ai ni ng bo l t . 13. Remove t he g e ne r at o r r e t a i ni n g nut s . 14. Remove t he g e ne r at o r mount i ng s t uds .
1. Ins t a l l the ge n e r at or. 2. Ins t a l l the ge n e r at or mount i ng s t uds . Ti ght e n t o 15 Nm. 3. Loos e l y i nst a l l t he g ene rat o r r e t a i nin g nut s . 4. Ins t a l l the ge n e r at or uppe r r e t ai ni ng bo l t . 1. Ti g ht e n t o 47 N m.
6. Connect t he ge ne r a t or e l e c t r i cal co nne cto r. 7. Att a ch t he ge ne r a t or po s i t i ve ca bl e . Ti ght e n t o 12 Nm. 8. Ins t a l l the ge n e r at or coo li ng duct t o t he ge ne rat o r . Ti ght e n t o 4 Nm. 9. Usi ng t he s pe cia l t oo l , at t a ch t he a cces s o r y drive be l t .
11. Ins t a l l t he t i e -r od e nd a nd t he t i e -r od e nd ret a i ni ng nut . Ti ght e n t o 35 Nm. 12. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover.
P ubl i s he d: 11-May-2 011 Info rma tio n and E ntertainm ent System - G eneral In fo rmati on - Audio System Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr i.
DT C Descri pti on Poss i bl e Ca uses Ac ti on U0194 Los t Comm uni ca t i o n wi t h Digi t a l Audi o Co nt rol Modul e B Di gi t a l Aud io Broa dcas t Modul e Gat e wa y modul e - l o s t c ommun.
DT C De scr i pti on Poss i bl e Ca uses Act i on C1977 Audi o S t e e ring W h e e l S w i t c h Ci r cui t Shor t T o Gr o und Ra di o hea d uni t , a ud io s t ee ring whe e l s wi t c h ci r cuit .
DT C De s cri pti o n P ossi bl e Ca uses Act i on B11A413 L -Band a nt e nna DAB L -Band a nt enna Ci r cuit - ope n ci r cuit Re f e r t o e l e ctr i cal ci rc ui t d ia g r ams a nd che ck DAB L -.
P ubl i s he d: 11-May-2 011 A udio U nit - A udio System Des cr ipt i o n a nd O pe r a t i o n Ba s e cas s e t t e I te m Pa rt N um ber De sc ri pti o n 1 — Dol b y n oi s e reduct i on but t o .
I te m Pa rt N um ber De sc ri pti o n 1 - Mu t e s a ud i o 2 - Repe a t CD but t o n 3 - Audi o s yst e m di sp l ay 4 - S e e k a st o r ed numbe r fr om t he p hon e s m e mor y 5 - Radi o s t a t.
I te m Pa rt N um ber De sc ri pti o n 1 - O n/Of f pus h f o r t ou ch -s cr e e n cont r ol s 2 - Touch-s cr ee n di s pl a y 3 - Pres s to a cce ss t o uch-s c r e e n o p t i ons 4 - CD t r a ck m.
3 - Pres s to a cce ss t o uch-s c r e e n o p t i ons 4 - Eje c t CD or MD 5 - Mix CDs o r CD/M D t r acks but t o n 6 - Prio r i t y p r o g r amme t ype but t o n 7 - Tr a ff i c a nno unce ment bu.
P ubl i s he d: 11-May-2 011 A udio U nit - A udio System Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 415-00 Info rm at i o n a nd Ent e rta i nment Sy s t e m - Ge neral Inf or m a t io n .
P ubl i s he d: 11-May-2 011 A udio U nit - A udio Un it Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cli mat e cont r ol p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 412-04 Cont r ol Co mpone nt s . 2.
P ubl i s he d: 11-May-2 011 A udio U nit - A udio Un it A mplifi er4-D o o r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l ugga g e co mpar t me nt front f lo o r car pe t . 2. Remove t he l ugga g e co mpar t me nt r ea r fl o or car pe t .
5. Remove t he a udi o uni t a mpl if ie r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 9 Nm. 2. Usi ng t he Jag ua r a pproved di agno s t i c s yst e m con fi gur e t he a udi o uni t a m pl i fi e r . JagDocs.
P ubl i s he d: 11-May-2 011 A udio U nit - A udio Un it A mplifi erWagon Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he au di o uni t pi n cod e i s a vai l a bl e bef or e di s conne c t i ng t he b a t te r y gr ound cabl e .
6. Remove t he l e ft -hand lo a d s p ace s i de t rim p a nel ret a i ni ng s cr e w. 7. D i s conne ct t he pa r ki ng a id s pe a ker e le ct r ica l conne cto r . 8. Remove t he pa r ki ng a i d s pe a ker. 9. Remove t he a udi o uni t a mpl if ie r ret a i ni ng bol t .
11. Remove t he a ud i o uni t ampl i f i e r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 9 Nm. 2. Tig ht e n t o 9 Nm.
P ubl i s he d: 11-May-2 011 A udio U nit - Com pact Disc (C D ) Ch anger4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he ICE pi n co de i s a vai l abl e be fo re di s conne ct i ng t he bat t ery ground ca bl e . Di s conn ect t he ba tt e r y ground ca bl e .
7. D i s conne ct t he e l ect r i cal conne ct o rs. 8. Remove t he compa ct di s c (CD ) pl a ye r r e t a ini ng bo l t s . 9. Remove t he CD p l a yer . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 1 Nm.
2. Tig ht e n t o 1 Nm. 3. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ).
P ubl i s he d: 11-May-2 011 A udio U nit - Com pact Disc (C D ) Ch angerWagon Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he au di o uni t pi n cod e i s a vai l a bl e bef or e di s conne c t i ng t he b a t te r y gr ound cabl e .
6. Remove t he l o ad s p a ce s t owa g e compa rtment . 7. Remove t he l o ad s p a ce fl oo r covering r e t a i nin g s cr ews . 8. D et a ch t he l o a d sp a ce fl o o r cove r i ng upwards. 9. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt ret a i ni ng screw.
11. Det a ch t he modul e ret a i ni ng brack e t . 12. Dis c o nne ct t he na vi ga t i o n s y s t e m module e l e ct rica l con nect or s . 13. Dis c o nne ct t he co mpact d i sc (CD) change r e l e ct r i cal c onn e cto r s . 14. Dis c o nne ct t he mul t i funct i on v o i ce a c t i va t e d m odul e e l e ctrica l conne ct ors.
16. Remove t he CD pl a yer r e t a i ni ng b o lt s . 17. Remove t he CD pl a yer. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
3. Tig ht e n t he modul e r e t a i n in g b r a cke t uppe r a nd l owe r f i xin gs . Ti ght e n t he l ow er r e t a i ni n g nut s t o 4 N m . Ti ght e n t he up pe r r et a i ni ng bo l t t o 9 Nm.
P ubl i s he d: 11-May-2 011 A udio U nit - Steering Wheel Audio C ontro ls Re moval a n d I ns t a l l a t i on 1. Remove t he s t ee ring whe e l. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ste e ring W h e e l (211-04 S te e r i ng Col umn, Re moval a nd Ins t a l la t i o n).
P ubl i s he d: 11-May-2 011 A ntenna - T o rque Sp eci f i cat ions Descri pti o n Nm l b- f t l b-i n Modul e r e t a i nin g b o lt - 4 Door 9 – 80 Ant e nna ret a i ni n g nut - W a go n 7 – 62 JagDocs.
P ubl i s he d: 11-May-2 011 A ntenna - Antenna Des cr ipt i o n a nd O pe r a t i o n ANT ENNA - 4 DOOR I te m Pa rt N u mber De sc ri pti on 1 — Roof pod ant e nna modul e (vehi cl es from 2009MY .
The DAB s ys t e m us e s t he a nt e nna i n t he r oo f p od a nt e n na modul e a nd a l s o t he r e a r win do w he a t e r e l e ment s f or DAB r ece pt i on . The a nt e nna mod ul e r ece i ves L ba nd s i g nal s whi ch a re p a s s e d di r e ctl y t o t he DAB modul e i n t he lu gga ge compa r t ment .
Wag on - V eh icle s fr om 20 0 9MY Ve hi cl e s f r om 2009MY a r e f i t t e d w i t h a roof po d a nt e nna mo dul e . Th e mo dul e i s s e cur e d t o t he ve hi cl e roof pa ne l wi t h 2 l o ck nut s a nd wa s he rs s cr ewe d o nt o cap t i ve s t uds i n t he mod ul e .
P ubl i s he d: 11-May-2 011 A ntenna - Antenna Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n .
P ubl i s he d: 11-May-2 011 A ntenna - AntennaWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: O ve r hea d Co ns ol e (501-1 2 I nst r um e nt P a ne l a nd Co ns ol e , Re mov a l a nd I n st a l l at i o n).
8. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he B-pi l l a r uppe r t r im pa ne l f r om t he B -pi l l a r t r i m l o we r t rim pa ne l .
14. Det a ch t he hea d l i n er. 15. CAUT I O N: T he hea dl i ne r must no t be cr ea s e d o r fo l ded dur ing r e m o val o r i ns t a l l at i on. Fa i l ur e t o f o l lo w thi s i ns t r ucti on may res ul t i n dama ge t o t he co mpon ent . Lo we r th e he a d l i ne r.
19. Det a ch t he ant e nna harnes s . 20. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 21. Remove t he a nt e n na . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 7 Nm. 2. NOT E: The l i f t g a t e we a t he r s t r i p must b e repl a ced on ce removed.
P ubl i s he d: 11-May-2 011 A ntenna - Modul e Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he C-pi l l a r t rim. Fo r add i t i o nal i nf or ma ti on, re fe r t oSect i on 501-05 Int e rio r T r i m and O r namen ta t i o n . 2. D i s conne ct t he a nt enna ca b l e e l e ct r i cal co nnect o r.
P ubl i s he d: 11-May-2 011 Speakers - Speakers Des cr ipt i o n a nd O pe r a t i o n Al l Ve hi cl e s Op t i m um a cous t i c d et a il i s a chi eve d t hr o ugh moun ti ng t he s pea ker s hi gh o n e a ch doo r pa ne l . The pr e m i u m s oun d s y s t e m s pe a k e r s a r e powe re d b y a s e pa r at e , remot e ampl i f i e r.
P ubl i s he d: 11-May-2 011 Speakers - Speakers Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n .
P ubl i s he d: 11-May-2 011 Speakers - F ro nt Do or Speaker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n .
P ubl i s he d: 11-May-2 011 Speakers - F ro nt Do or Tweete r Speaker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n .
P ubl i s he d: 11-May-2 011 Speakers - Parc el Shelf Speaker Re moval a n d I ns t a l l a t i on 1. Remove t he pa r cel s hel f. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: P a r cel S he l f (501- 05 I nt e rio r Tr i m a nd O rnament a t i o n, Re moval a nd Ins t a l la t i o n).
P ubl i s he d: 11-May-2 011 Speakers - Re ar Doo r Spe aker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n .
P ubl i s he d: 11-May-2 011 Speakers - Re ar Doo r Twee ter Speaker Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For ad di t i ona l inf o rm a t i o n, r e fe r t o Sect i o n 501-05 Int e rio r T r i m and O r namen ta t i o n .
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Gen eral S p ec if ic a t ions It e m Speci fi cati on Fr o nt t ur n s i gna l l a mp b ul b PY 21W Fr o nt f og l a mp bul b H1-55W P a r ki ng/Si.
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Exterior L igh ting Des cr ipt i o n a nd O pe r a t i o n The he ad l a mp s wit ch is l o cat e d o n t he dr i ver s i de o f t he i n st r um e nt pa ne l.
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamps Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he l i g ht i ng s yst e m, ref e r t o t he rel e vant Des cr i pt i on a nd O perat i o n s e ct i on s i n th e wo r k s hop manual .
DT C De sc ri pti o n P os si bl e Ca use Acti on B2615 Fr ont or rea r axl e vehi cl e le vel s e ns o r s upp l y circ ui t fa i l ur e W i ring ha r ne s s concern Re fe r t o e l e ct r i cal cir cuit d i a grams , check l e ve l se ns o r powe r s up pl y circ ui t f o r s ho r t t o p o we r .
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp Adjustment Gene ral P r ocedures 1. NOT E: He a dl a mp a dj us t men t s ho ul d be made at roo m t e mper a t ur e . P r epa re t he vehi cl e fo r he a dl a mp a dj us t me nt . 1. P l a ce t he vehi cl e o n a le vel s ur f a c e .
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Ballast Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl a mp a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o He a d l a mp A ss e mbl y - i n t hi s se ct i o n.
P ubl i s he d: 11-May-2 011 E xterior L i ghting - F ront Fo g Lam p Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o S ect i on 501-02 Fr ont End Bo dy P a nel s .
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp Ass embly Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he f r ont bu m pe r cover .
Vehi c le s with headla m p w asher s 6. Remove t he he a dl a mp w as he r mot o r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp B u lbV ehicles With: High Intensi ty Dis charge Headlam ps Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl a mp a s s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o He a d l a mp A ss e mbl y - i n t hi s se ct i o n.
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp L eveling Mo d ule Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl a mp a s s e mbl y. For a ddi t i o na l i nf orm at i o n, r e fe r t o He a dl a mp As s e m bl y 2.
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp L eveling Sens or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e as s e mbl y. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 204-04 W h e e l s a nd Ti r es .
6. Remove t he he a dl a mp l e v e l ing s e ns or. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 E xterior L i ghting - Head lamp S witch Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he he a dl a mp s wi t ch. 1. Re l e a s e t he r e t ai n in g t a ng. 2. De ta ch t he he a dl a mp s wi t ch. 2. Remove t he he a dl a mp s wi t ch.
P ubl i s he d: 11-May-2 011 E xterior L i ghting - High Mounted Sto plam p4- Door Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he he a dl i ne r, fo r a d di t i ona l i n fo r mat i on , refe r t o S e cti on 501-05 I nt e r i o r Tr im a nd O rname nt a ti o n .
P ubl i s he d: 11-May-2 011 E xterior L i ghting - High Mounted Sto plam pWag o n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s po i l e r For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S p o i l e r - W a g on (501-08 Exte rio r T r i m an d O rname nt a t i o n, Re moval a nd I ns t a l la t i o n).
P ubl i s he d: 11-May-2 011 E xterior L i ghting - R ear Lamp As sembl y4- D o o r Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch a nd r ep o s i t i on t he r e a r qua r t e r t rim pane l . 2. D i s conne ct t he rear l a mp a s s emb l y e le ct r ica l conne cto r .
P ubl i s he d: 11-May-2 011 E xterior L i ghting - R ear Lamp As sembl yW agon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce t rim p a nel .
P ubl i s he d: 11-May-2 011 Interio r Li ghting - Interior Li ghting Des cr ipt i o n a nd O pe r a t i o n The i nt e r i or l i gh ti ng s yst e m cons i s t s of t he f ol l o wi ng compo ne nt s : On e f r ont int e r i or l a m p. Two map r ea d i ng l amp s.
P ubl i s he d: 11-May-2 011 Interio r Li ghting - Interior Li ghting Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2.
P ubl i s he d: 11-May-2 011 Interio r Li ghting - Front Interio r Lam p Re moval a n d I ns t a l l a t i on 1. Remove t he ove r he a d co ns o l e . Fo r a ddi t i ona l i nfo r m at i o n, r ef e r t o S ect i o n 501-12 Ins t r ument P a nel a nd Co ns ol e .
P ubl i s he d: 11-May-2 011 Interio r Li ghting - Rear Interior Lam p Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he i nt e rio r la mp. 2. Remove t he i nt e r i o r l a mp. Dis conne ct t he e l e ct r i cal co nnect o rs. Insta llat ion 1.
P ubl i s he d: 11-May-2 011 Daytime Runni ng Lamps (DRL ) - D aytime Runni ng L amps (DRL ) Des cr ipt i o n a nd O pe r a t i o n DRL us e t he ful l i nte ns i t y l o w bea m he a dl a mps whi ch a re p e r m ane nt l y i l l umina t e d whe n t he ve hi c l e i s b e i ng dr i ven.
P ubl i s he d: 11-May-2 011 Daytime Runni ng Lamps (DRL ) - D aytime Runni ng L amps (DRL ) Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
P ubl i s he d: 11-May-2 011 Module C o mm un icatio ns N etw ork - C o mmu nic ation s N e tw ork Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um be r D e s cri pti on 1 — Ant i -lo ck br.
P ubl i s he d: 11-May-2 011 Module C o mm un icatio ns N etw ork - C o mmu nic ation s N e tw orkV IN Range: E 96603->J28492 Dia gn os i s a nd Te s t i ng Principles of Ope ra tion The vehi cl e ha s f our modul e commun i cat io n net wo r ks . O nl y t hr e e o f whi ch are co nne cte d to t he di agn os t i c conne ct o r .
REFER t o : Ai r Bag S up pl e ment a l Re s t r ai nt S ys t e m (S RS ) (501-2 0B S u ppl e ment a l Res t r ai nt Sy s t e m, Di a gnos i s a nd Te s t i ng). The voi ce a ct i va t e d cont r ol modul e (VACM) i s c o nne ct e d t o t he D2B communica t i on net wo r k.
fo r one e rr or , o r, a s i n t he ca s e of a n o p en ci r cuit , no DTC be i ng s e t . DT C Desc ri pti on Possi bl e S ource Ac ti on P 1573 CAN t hr ot tl e a ngl e e rr or TP s ens or fa ul t.
DT C Desc ri pti on Possi bl e S ource Ac ti on P 1699 CAN ECM t o EATCM ne t w ork m a l funct i on Modul e po we r s up pl y o r gr ound i nt err upt i o n CAN op en ci r cuit f a ul t ; EATCM t o ECM CAN s hort ci rc uit fa ul t ; EATCM t o ECM EATCM f a il ur e ECM f a i lur e Re f e r t o po we r a nd g r ound t e st f or s us p e ct modul e .
DT C Desc ri pti on Possi bl e S ource Ac ti on U2196 I ns t r ument cl us t er CAN e ngi ne s p e e d mes sa g e i nval i d Verif y i nt e gr it y o f e ngi ne m a nage m e nt s yst e m CAN ne t wo r k fa ul t For i ns t r um e nt cl us t e r CAN ne t wor k t e st s , GO t o P i npoi nt T e s t D.
DT C Desc ri pti on Possi bl e S ource Ac ti on sup pl y fa ul t Modul e ig ni t io n s wi t che d sup pl y fa ul t U2614 Ampl i f i e r not r es pond i ng on D2B net wo r k D2 B ne t wo rk 'wake.
1 2 Descri pti o n Possi bl e s ource Acti on fa i lu r e TCM s up pl y o r gr ound f a ul t (16 b it ) B+ s upp l y f a i l ure Ig n + s uppl y f a i lur e GR O UND f ai l ure For 16 b it TCM ci r cuit t es t s , GO t o P i npo i nt T e s t AD.
1 2 1 2 1 1 2 1 1 2 1 1 2 1 1 2 Is t he res i s t a nce b e t we e n 50 a nd 70 ohms ? Ye s GO t o A 3 . No GO t o A 2 . A2 : CHEC K T HE C AN N ET W O R K FOR SHOR T CIRC UIT Tur n t he i gni t i o n s wi t ch to the O F F p os i t i on. Mea s ure t he r es i s t a nce b e t we en pi ns 06 (Y ) a nd 14 (G) of t he di a gno s t i c conne ct or .
1 1 1 1 1 1 1 1 Is t he res i s t a nce g r ea t e r t ha n 5 o hms ? Ye s REP AIR t he hi gh r e s is t a nce ci rc ui t . Fo r a ddi t i o na l i nf o r m at i o n, r ef e r t o t he wi r i ng di a gr a ms. Cle a r a ny DTCs , t e s t th e s yst e m f o r norm al op erat i o n.
1 1 1 1 1 2 1 GO t o C5 . C 5: C HEC K CAN - FOR SHOR T C IRC UIT T O BAT T ER Y Mea s ur e t he res i s t a nce b et we e n t he di a g nos t i c co nnect or, pi n 14 (G ) a nd pi n 16 (O Y ). I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit .
1 1 1 1 1 2 1 1 1 Mea s ur e t he res i s t a nce b et we e n: Ve hi cl e s wi th 2.5 a nd 3. 0L e ngi ne - EN16, pi n 123 (G) a nd IP 10, p in 18 (G). Ve hi cl e s wi th 2.0L p e t rol eng i ne - EN65, pi n 88 (G) a nd I P10, pi n 18 (G ). Ve hi cl e s wi th 2.
1 2 1 2 1 1 2 1 1 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n.
1 1 1 1 1 1 1 1 1 Mea s ure t he r es i s t ance b e t w ee n: Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - pi ns 123 a nd 124 o f t he ECM. Vehi cl e s wi t h 2. 0L pet r ol e ng i ne - pi ns 88 a nd 89 o f t he ECM. Vehi cl e s wi t h 2. 0L di e s e l e ng in e - pi ns 54 a nd 73 o f t he ECM.
1 1 2 1 1 1 Meas ur e t he r es i s t a nce be t we e n I P 22 p in 06 (Y ) a nd EN65, p in 89 (Y ). Vehi cl e s wi t h 2. 0L di e s e l e ng in e - Dis c on ne ct t he ECM conne ct o r , DL01. Meas ur e t he r es i s t a nce be t we e n t he d ia g no st i c conne ct o r , p i n 06 (Y ) and DL01, p in 54 (Y ).
1 1 1 1 2 1 1 1 2 1 2 Vehi cl e s wi t h 2. 0L pet r ol e ng i ne - pi ns 88 a nd 89 o f t he ECM. Vehi cl e s wi t h 2. 0L di e s e l e ng in e - pi ns 54 a nd 73 o f t he ECM. Is t he res i st a nce b et we e n 110 a nd 140 o hms ? Ye s GO t o E13 .
1 1 2 1 1 1 1 GO t o F8 . F8: C HEC K FOR O PE N C IR C UIT ON CAN - BET W EEN T HE DI AGNOST I C C O NN EC T O R AN D T HE EAT C M ODU LE Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 14 (G) a nd IP 101, pi n 23 (G).
1 1 2 1 1 1 1 2 1 2 1 1 2 CLEAR t he DT C, t e st t he s ys t e m fo r n or mal o pe r a ti o n. PINPOIN T TE ST G : P17 9 9: CAN NET WORK MALF UNCTI ON, ANTI- LOCK B RAK E (A BS ) /DYNAMI C STA B ILI.
1 1 1 1 1 1 To t es t : Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - Dis conne ct t he ECM conne ct o r , EN16, a nd t he I C conne ct or , I P 10. Meas ure t he r es is t a nce b e t we e n EN16, p i n 124 (Y ) a nd I P 10, pi n 17 (Y ). Vehi cl e s wi t h 2.
1 1 1 1 1 2 3 4 1 1 2 3 1 2 3 1 2 1 2 GO t o H3 . H3 : CHEC K T HE SCP + FOR SH OR T C IRC U I T T O BA T T ER Y Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi ns 02 (Y ) a n d 16 ( O Y ). Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t .
1 1 1 1 1 1 1 1 2 3 4 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on.
1 2 3 1 2 3 4 1 2 1 2 1 1 2 3 4 5 6 1 Re conne ct t he I CE conne ct o r , I P 65. Re conne ct t he b a t t e r y ne g a t i ve te r mina l . Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 02 (Y ) a nd GROU ND. Is t he res i st a nce 150 t o 210 ohms ? Ye s INS TA LL a ne w ICE he a d uni t .
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 1 1 2 3 4 5 6 K1: C HECK T HE ' WAKE-UP ' SI GNA L T O T HE CD CHAN GER Di s c onn e ct t he CD cha nge r connect or, CA301.
1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 2 3 4 5 6 I s U 2019 se t ? Ye s CHECK t he 'wake-up' s i gna l t o t h e modul e . No GO t o M2 . M2: C HEC K F O R DT C U260 2 O R U 2 603 Che ck DTCs . Ar e c od e s U 2602 o r U 2603 l o gg ed? Ye s CHECK f o r br e a k in opt i ca l harnes s .
.
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 1 2 1 2 Q1: C HEC K F IBRE OP T I C LEA D BET WE EN LUGGAGE CO M P ART MENT JOIN T AND AMPLIFI ER Dis c on ne ct t he f i b r e o pt i c conne c t o r , CD06. Dis c on ne ct t he f i b r e o pt i c conne c t o r , CD07.
1 2 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 No CHECK t he m o dul e f or GROU ND. IN S TAL L a ne w 'phone m o dul e . REFER t o: M odul e - 4-D oo r (419-0 8 Ce l l ul ar Ph one , Remova l a nd I ns t a l l a t io n). CLEA R t he DTC, te s t t he sys t e m fo r nor mal o pe r at i o n.
1 2 1 2 1 2 1 1 2 3 1 2 3 1 2 1 2 3 Is t he vol t a ge l e s s t han 10 vol t s ? Ye s REPAI R t he ci r c ui t bet we e n t he 'pho ne mod ul e co nnect o r, P H01, pi n 29 a n d t he c e nt r a l j unct i o n fus e bo x, fus e 78. For a ddi t i o nal i nfo r m at i o n, r e f e r t o t he wi r i ng di a g r a ms .
1 2 3 1 1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 I s t he v ol t a ge l e ss t ha n 4 vol t s ? Ye s GO t o W 2 . No GO t o W 3 . W2: C H ECK T HE MO DULE SUPPLY CIRC UIT T O T HE YAW R AT E S ENS O R FOR HI GH R ESI ST ANCE Tur n t he i gn it i o n s wi t ch t o t he O FF po s i t i o n.
1 2 1 2 1 1 2 3 1 1 2 3 1 1 2 I s t he v ol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n JB185, p i n 02 a nd ba t t e r y. T hi s circu i t i ncl ud e s t he front powe r di s t r i but i o n bo x, fus e 41. For a ddi ti o nal i nfo r m a t i o n, r e f e r t o th e wi r i ng di a gr a m s .
1 2 1 2 1 1 2 1 1 2 1 2 1 1 1 2 Turn t he i gni t i o n s wi t ch t o t he O N pos i t i o n. Mea s ur e t he vol t a ge be t we e n I P 101, p in 02 (W R) a nd GRO U ND. I s t he vol t a ge l e ss t ha n 10 vol t s ? Ye s REP AI R t he cir cuit be t wee n IP 101, pi n 02 a nd ba t t e r y.
1 2 1 2 1 2 1 1 2 1 2 1 2 1 2 1 I s t he vol t age le s s t ha n 10 v ol t s ? Ye s REPAI R t he ci r cui t b e t we en JB131, pi n 06 and bat t e ry . Thi s ci r cui t i ncl ude s t he f r on t po we r di s t rib uti o n b o x , f us e 32. For a dd i t i o na l i nf o r mat i o n, refe r t o t he wi ring di agrams .
1 2 3 1 2 1 2 1 1 2 3 1 2 1 2 1 1 2 3 PINPOIN T TE ST A F : ECM S U PPLY OR G ROU ND F A U LT (V EHIC LES WITH 2 . 0 L PETROL ENG I NE) T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I ONS AF1 : CHEC K T HE B+ SUPP LY T O T HE ECM Turn t he i gn it i o n s wi tch t o t he O FF po s it i o n.
1 2 1 2 1 1 1 1 1 2 3 1 2 1 2 I s t he vol t age le s s t ha n 10 v ol t s ? Ye s REPAI R t he ci r cui t b e t we en DL 01, pi n 03 a nd ba t t e r y. Th is ci rc ui t i ncl ude s t he front po we r di s t r ib ut io n bo x, fus e 21, and t he EMS cont r ol r el ay.
1 2 3 1 1 2 3 1 2 1 2 1 2 3 1 2 1 2 1 AJ1: CHEC K T HE B+ SUPPLY T O T HE C D CHAN GER Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Di s conne ct t he CD cha nge r connect o r, CA301. Mea s ur e t he vol t age bet we e n CA301, pi n 02 (O Y ) a nd GROU ND.
2 3 4 1 2 1 2 3 4 1 2 1 2 1 1 1 Di s conn ect t he pa r k a i d modul e co nne ct or, CA 418. Tur n t he i gni t i o n s wi t ch t o th e O N po s i t i o n.
1 2 3 4 1 1 1 1 2 1 1 1 1 2 3 AP4: CHEC K FOR O PE N C IR C UIT O N K- LI N E BET WEE N DI A GNOST I C C O NNECT O R A ND RC M Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Di s conn ect t he ba tt e r y ne ga t i v e t e rm ina l .
4 1 1 1 1 2 3 4 1 1 1 Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 07 (W ) a nd : Vehi cl e s wi t h l ow-l i ne cons o l e - RC23, pi n 08 (W ). Vehi cl e s wi t h hi gh-l i ne cons o l e - RC33, pi n 03 (W ).
1 2 1 1 1 1 2 3 4 1 2 3 4 1 2 3 Tur n t he i gn i t i on s w i t ch t o t he O FF pos it i o n. Dis conne ct t he b a t t e r y ne gat i ve t e r m i na l .
P ubl i s he d: 11-May-2 011 Module C o mm un icatio ns N etw ork - C o mmu nic ation s N e tw orkV IN Range: J2 8493-> V99999 Dia gn os i s a nd Te s t i ng Principles of Ope ra tion The vehi cl e ha s f our modul e commun i cat io n net wo r ks .
REFER t o : Ai r Bag S up pl e ment a l Re s t r ai nt S ys t e m (S RS ) (501-2 0B S u ppl e ment a l Res t r ai nt Sy s t e m, Di a gnos i s a nd Te s t i ng). The voi ce a ct i va t e d cont r ol modul e (VACM) i s c o nne ct e d t o t he D2B communica t i on net wo r k.
DT C Desc ri pti on Possi bl e S ource Ac ti on CAN s hort ci rc uit fa ul t JG M fa i l ur e ECM f a i lur e P 1573 CAN t hr ot tl e a ngl e e rr or TP s ens or fa ul t (a d di t io nal DTCs lo g ged ) ECM CA N me s s a ge e r r or For TP s e n so r circ ui t t e s t s, REFER t o : El e ct roni c Engi ne Co nt rol s - 2.
DT C Desc ri pti on Possi bl e S ource Ac ti on P 1656 TP s e ns or a mpl i f i e r ci r cuit m a l f unct i on ECM f a i lur e P l e as e che ck part is not o n a ny f o r m o f pr i or a ut horiz a t i o n be fo re r e pl a ceme nt .
DT C Desc ri pti on Possi bl e S ource Ac ti on U2019 VACM not res po nd i ng o n D2B ne t wo r k D2 B ne t wo rk 'wake-up' c i r cuit ; s hort ci r cuit t o B+, sho rt ci r cuit t o gr ou nd D2 B ne t wo rk fa ul t For D2B 'wa ke-up' ci rc ui t t e s t s, GO t o P i npo i nt T e s t K.
DT C Desc ri pti on Possi bl e S ource Ac ti on U2613 Na vig a t i on cont r o l m o dul e not re s po ndi ng on D2B net wo r k D2 B ne t wo rk 'wake-up' c i r cuit ; s hort ci r cuit t o B+.
Descri pti o n Possi bl e s ource Acti on Memory s ea t mod ul e s uppl y o r ground fa ul t B+ 1 s uppl y f a i l ur e B+ 2 s uppl y f a i l ur e Ig n + s uppl y f a i lur e El e ctroni c GR O UND fa.
1 2 1 2 1 2 1 1 2 1 1 2 1 1 2 1 • NO T E: T he f o l l o wi ng t e s t i s bas e d on t he maxi m um num be r o f modul e s i n t he net wo r k. Re fe r t o t he wi ring di agra m s f or i nfo r mat i on o n ne t wo r ks wi t h f e wer modul e s .
1 2 1 1 1 1 1 1 1 Is t he res i s t a nce g r ea t e r t ha n 5 o hms ? Ye s REP AIR t he hi gh r e s is t a nce ci rc ui t . Fo r a ddi t i o na l i nf o r m at i o n, r ef e r t o t he wi r i ng di a gr a ms. Cle a r a ny DTCs , t e s t th e s yst e m f o r norm al op erat i o n.
1 1 1 1 1 1 2 1 I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams. CLEAR t he DTC, t e s t t he s y s t e m f or no r ma l op e r at i o n.
1 1 1 1 1 2 1 1 Di s conne ct t he ECM co nnect o r, DL01, a n d t he IC conne ct o r , I P 10. Mea s ur e t he res i s t a nce be t we e n DL01, pi n 54 (Y ) and I P 10, pi n 17 (Y ). I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he CAN + ci r cui t .
1 1 2 1 2 1 1 2 1 1 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n.
1 1 1 1 1 1 1 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on.
1 1 1 2 1 1 Dis conne ct t he b a t t e r y ne gat i ve t e r m i na l . Vehi cl e s wi t h 2. 5 a nd 3.0L e ngi ne - Dis c on ne ct t he ECM conne ct o r , EN16. Meas ur e t he r es i s t a nce be t we e n I P 22 p in 06 (Y ) a nd EN16, p in 124 (Y ) .
1 1 1 1 1 2 1 1 1 2 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on.
1 2 1 1 2 1 1 1 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n.
1 1 1 2 1 1 1 1 2 1 2 1 pi ns 54 a nd 73 o f t he ECM. Is t he res i st a nce b et we e n 110 a nd 140 o hms ? Ye s GO t o F13 . No P le a se c he ck pa r t i s no t o n a n y f o rm o f p r i or a ut ho r i za t i o n b e f ore repl a cemen t .
1 2 1 1 1 1 Is t he res i s t a nce g r ea t e r t han 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc ui t . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o t h e wi r i ng d i a gr ams . CL EAR t he DTC, t e s t t he s yst e m f o r norm al ope rat i on.
1 1 1 1 1 1 1 2 3 4 1 1 2 3 1 2 3 T EST C O NDI T IONS DET AI LS/RE SULT S/ACT IONS H1 : CHEC K GEM F OR DAMA GE Ins p e ct t he GEM f o r da mage . Does t he GEM i ndi ca t e any s i gns of da mage ? Ye s INS TA LL a ne w GE M.
1 2 1 2 1 1 1 1 1 1 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . CLEAR t he DTC, t e st t he s yst em f o r norm al ope rat i on.
1 2 3 4 1 1 2 3 1 2 3 4 1 2 1 2 1 1 2 3 4 5 Tur n t he i gn i t i on s w i t ch t o t he O FF pos it i o n. Dis conne ct t he b a t t e r y ne gat i ve t e r m i na l . Dis conne ct t he I CE conne ct or, IP 65. Mea s ure t he r es i s t ance b e t w ee n th e di ag no s t i c conne ct o r , pi n 02 (Y ) a nd IP 65, pi n 09 (Y ).
6 1 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 Che ck f o r 'not r e s po ndi ng' DTCs . Is U 2003 s e t ? Ye s CHECK t he 'wake-up' si gna l t o t he modul e . No GO t o J2 . J2: CHEC K F OR DT C U2 602 OR U26 03 Che ck DTCs . Ar e c od e s U 2602 o r U 2603 l o g ged ? Ye s CHECK f or brea k i n op t ica l h a r nes s .
1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 1 2 3 4 5 L2: CHEC K FOR DT C U260 2 O R U2603 Che ck DTCs . Ar e c od e s U 2602 o r U 2603 l o gg ed? Ye s CHECK f o r br e a k in opt i ca l harnes s . No RECHECK DT Cs. N o br e a k in opt i cal ha r n e ss .
6 1 2 3 4 5 6 1 2 3 4 5 1 2 3 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 6 1 2 Check f or l i ght p ul s e s a t the r ecei ver pi n o f d is conne ct e d D2B co nnect o r , CD02. Are l i ght pul s e s v i s ib l e ? Ye s GO t o P 2 . No INS TA LL a ne w t e l e mat ic ha r nes s be t we e n CD06 a nd CD02.
3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 1 2 Conne ct t he O p t i ca l B us Tes t er t o CD05. S e t t he Op t ical B us Te s t e r t o T X . S e t t he Op t ical B us Te s t e r t o O N . Check f or l i ght p ul s e s a t the t rans m i t t e r pi n o f di s conne cte d D2B conne c t o r , CD07.
1 2 1 2 1 2 3 1 2 3 1 2 3 1 2 3 I s t he v ol t a ge l es s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n t he voi ce a cti vat e d cont r ol modu le conne ct o r , P H02, pi n 22, a n d f us e 71 of t he ce nt ral j unct i o n f us e box.
1 2 3 1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 3 1 2 T 1: CHEC K T HE I G NI T ION SWI T C HED SUPP LY T O T HE VO I CE AC T I VA T ED C ONT R O L MO DULE Dis conne ct t he vo ice a ct i va t e d cont rol mo dul e conne ct o r, PH02. Tur n t he i gn i t i on s w i t ch t o t he O N po s i t i o n.
1 2 3 1 2 3 1 1 2 3 1 2 1 2 1 2 1 1 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . No No fa ul t f o und wi t h p o we r or ground sup pl i e s .
2 3 1 2 1 2 1 2 1 1 2 3 1 1 2 3 1 Tur n t he i gni t i o n s wi t ch t o th e O N po s i t i o n. Mea s ur e t he vol t a ge bet we e n JB185, p i n 23 (GW ) a nd GRO UN D. I s t he v ol t a ge l e ss t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n JB45, pi n 23 a nd ba t t e r y.
1 2 1 2 1 2 1 1 2 1 1 2 1 2 1 1 T EST C ONDI T I O NS DET AI LS/R ESULT S/AC T I ONS AB1 : CHEC K T HE B+ SUPPLY T O T HE EA T C MODULE Di s c onn e ct t he EA TC mod ul e conne ct o r , I P 101. Mea s ur e t he vol t a ge be t we e n I P 101, p in 14 (O G) a nd GROU ND.
1 2 1 2 1 2 1 2 1 1 2 1 2 1 2 1 2 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . No No fa ul t f o und wi t h p o we r o r ground s uppl i e s .
1 1 2 3 1 2 1 2 1 1 2 3 1 2 1 2 1 I s t he res i s t a nce grea t e r t ha n 5 o hms ? Ye s REPAI R t he hi gh res i s t a nce ci r cuit . For ad di t io na l inf or mat io n, r e fe r t o t h e wi ring di a grams .
1 2 3 1 2 1 2 1 1 1 1 1 2 3 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh res i s t a nc e ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . No No fa ul t f o und wi t h p o we r o r ground su ppl i e s .
1 2 1 2 3 1 1 2 3 1 2 1 2 1 2 3 1 2 GO t o A I 3 . AI 3: C HEC K T HE G R O UND T O T HE I C E Tur n t he i gni t i o n s wi t ch to the O F F p os i t i on. Mea s ure t he r es i s t a nce b e t we en IP 65, pi n 01 (B) and GRO UN D. Is t he res i s t a nce g r ea t e r t ha n 5 o hms ? Ye s REP AIR t he hi gh r e s is t a nce ci rc ui t .
1 2 1 2 3 4 1 2 1 2 3 4 1 2 1 2 1 1 Tur n t he i gni t i o n s wi t ch t o th e O FF pos i t i on. Mea s ur e t he r es i s t a nce be t we en JB232, p in 02 (B) a nd GROU ND. Is t he res i s t a nce g r ea t er t h a n 5 o hms ? Ye s REP AIR t he hi gh r e s i s t ance ci rc ui t .
1 1 2 3 4 1 1 1 1 2 1 1 I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t ci r cuit . For a ddi t i o na l i nfo rm at i on, ref e r t o t he wiring di a g rams. CL EAR t h e DTC, t e s t t he s yst e m fo r no r m a l op e r at i o n.
1 1 2 3 4 1 1 1 1 2 3 4 1 1 GO t o A R3 . AR3: CHEC K K -LINE FOR S HOR T CIRC U IT T O BAT T E R Y Mea s ure t he r es i s t ance b e t w ee n di a gnos t i c conne ct or, pi n 07 (W ) a nd pi n 16 (O Y ). Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t .
1 1 2 1 1 1 1 2 3 4 1 2 3 4 Is t he res i st a nce l e s s t han 10,000 ohms? Ye s REPAI R t he s h or t circ ui t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o t he wi r i ng di a gr a m s . CL EAR the DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n.
1 2 3 1 1 1 1 1 1 1 1 1 2 AV2 : CHEC K T HE GR O UND T O T HE A MPLIF I ER Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Mea s ur e t he res i s t a nce be t we e n CA425, p i n 02 (B) and GR O U ND. Mea s ur e t he res i s t a nce be t we e n CA425, p i n 08 (B) and GR O U ND.
1 1 1 1 1 2 3 4 Is t he res i st a nce b et we e n 50 a nd 70 o hms ? Ye s P le a se c he ck pa r t i s no t o n a n y f o rm o f p r i or a ut ho r i za t i o n b e f ore repl a cemen t . No GO t o A W 10 . AW10 : C HEC K C ONT IN UI T Y OF T HE CAN + C I R C UI T To t es t : Vehi cl e s wi t h 2.
1 2 No GO t o A X2 . AX2 : CHEC K T HE GR O UND T O T HE JGM Tur n t he i gni t i o n s wi t ch t o th e O FF po s i t i o n. Mea s ur e t he res i s t a nce be t we e n I P14, pi n 2 (B) a nd GRO UN D. I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci rcu i t .
P ubl i s he d: 11-May-2 011 Module C o nfi guratio n - Mo dule C onfi guration Dia gn os i s a nd Te s t i ng Principles of Ope ra tion • NO T E: Ne wl y r el e a s e d modul e s wi l l requi r e co nfi gur a t i on a ft er be i ng i ns t a l le d o n t he vehi cl e .
P ubl i s he d: 11-May-2 011 Module C o nfi guratio n - Mo dule C onfi guration Gene ral P r ocedures 1. The compl exi t y of t he e l e ct roni cs in vol ve d wi t h mo dul e conf i gur a t i o n, o .
P ubl i s he d: 11-May-2 011 Wiring Harnesse s - Wiring Harn ess Des cr ipt i o n a nd O pe r a t i o n Introd uction CAU TIO N : Do not us e a ny o t her he a t s hrink s l ee ve o t her t ha n t he a pproved gl ue l i ned hea t s hr i nk s l e e ve me nt i o ne d i n t he repa i r pr oce dure.
The i l l us t rat i o n s hows : The pr e -te r mina t e d wi ring ha r ne s s (s) whi ch a re in clud e d i n t he wi ring ha r nes s repa i r ki t The pa r t number o f t he pre-t e r m i n at e d .
The P r e-T erm i nat e d W i r i ng Ha r ne s s (s ) i l lus t rat i on sh ows t he e l e ct r i cal conne cto r t er m i na l t y pe , t he p a r t numbe r o f t he p r e-t erm i nat e d wi r i ng h.
By pr e s s i ng t he ou te r e d ge s o f the wi r i ng ha r ne s s cabl e le ngt h s t o p t o ge t he r th e a dj us t e r ca n b e s l id up or down t he j aw.
The cr i mpin g p li e r s ha ve a mov i ng j a w a nd a s t at i o na r y j a w, wi t h t hr ee di ff e r e nt s i z e d cr i mping e ncl o s ures . Ea ch o f t he e nclo s ur e s i s id e nt i fi e .
CAU TIO N : Se vera l di f fe re nt t y pe s and si ze s of ter m i nal m ay b e found i n a s i ngl e e l e ct ri cal con nector hous i ng. I t is ne ces s a r y t o i de nt i f y: The conduct o r (w.
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• NO T E: T he chart s hows t he e l e ct r i cal co nnect o r t ypes , t erm i nal p ins /s o cket s , e xtr a ct o r t i p a nd ant i -ba ckout t i p.
CAU TIO N : : A numb e r of e l e ct r i cal conne c t o r t e rm ina l s a r e go l d pl a t e d or go l d fl a she d . W he n d e fe ct i ve , t he y mus t be i ns t a l l e d wit h a gol d pr e-t e rm in a t e d wi ring ha rn es s (s) f r om t he wiring ha r ne s s r e pa i r ki t.
S pi ce Co r r ect l y Loca t e d JagDocs.com.
P ubl i s he d: 11-May-2 011 Wiring Harnesse s - Wiring Harn ess Repair Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t o: W i ring Ha rnes s (418-02 W i ring Ha r nes s e s , Des cr ipt i o n a nd O pe rat i o n).
P ubl i s he d: 11-May-2 011 A nti-Th eft - Activ e - A nti- Th eft - Ac tive Des cr ipt i o n a nd O pe r a t i o n Item Pa rt N u mber Descri pt i on 1 — Ge ne r a l e l e ct roni c modul e 2 — .
P ATS s yst e m whe n t he i gni t i on is s wi tche d t o p os i t i o n II . W he n t h e i gni t i o n i s swi t c he d in t he of f po s i ti o n, t he LED wi l l f l a s h e very f our s e cond s whe n t he s ecur i t y s ys t e m i s i n t he p re-ar m or a r m ed s t a te .
P ubl i s he d: 11-May-2 011 A nti-Th eft - Activ e - A nti- Th eft - Ac tive Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
P ubl i s he d: 11-May-2 011 A nti-Th eft - Activ e - A nti- Th eft Alarm Ho rn Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l e ft -hand f r ont fe nde r sp l as h shi el d.
P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Anti- T heft - Pass ive Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um be r Des cri pti o n 1 — P AT S t r a ns cei ver modul e The .
P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Anti- T heft - Pass ive Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Anti- T heft Security Access Gene ral P r ocedures 1. The compl exi t y of t he e l e ct roni cs in vol ve d wi t h t he a nt i t h e ft , o f wh.
P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Key P ro g ram min g Us ing Diagno s tic E quipment Gene ral P r ocedures 1. The compl exi t y of t he e l e ct roni cs in vol ve d wi t h t he a.
P ubl i s he d: 11-May-2 011 A nti-Th eft - P assive - Passi v e Anti-Theft Sy stem (PATS) Tra nsceiver Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s without driv e r low e r a ir bag 1. Remove t he i ns t r um e nt pa ne l l o we r t rim pa ne l .
P ubl i s he d: 11-May-2 011 Remo te Co n v enience - U niversal T rans mitter Des cr ipt i o n a nd O pe r a t i o n The Ho meL ink unive r s a l t rans mi t t e r pr ovi de s a conve ni e nt wa y t o r e pl a ce up t o t hr ee h a nd-hel d t rans mit t e r s w i t h a s i ng le bui l t -i n de vice .
1 1 P ubl i s he d: 11-May-2 011 Remo te Co n v enience - U niversal T rans mitter Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e .
P ubl i s he d: 11-May-2 011 Remo te Co n v enience - U niversal T rans mitter Program m ing Gene ral P r ocedures W ARNI N G: A g a r a g e d o or o pen in g s ys t e m t hat ca nnot s t o p o r r e ver s e i t s e l f a f te r de te ct i ng a n o bj e ct i n i t s pa t h d o e s no t mee t cur r e n t fe de r a l s a fe t y s t a nda r ds .
a s t he uni ve r s a l t r ans mi t t e r red l i ght f l a s he s (1-2 s e conds ). Re l ea s e t he b ut t o n a nd re-pr e s s t he b ut t o n t o conf i rm t ha t t he uni versa l t r ans mit t e r i s t r ai ne d t o t he r e ce i ver . 5. The ga r a ge d o o r ope ne r s ho ul d r e cog ni z e th e uni versa l t rans mi t t e r .
P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Des cr ipt i o n a nd O pe r a t i o n 4-D oo r I te m P a rt Nu m ber Descri pti o n 1 — Ro o f p od a nt e nna modu le (from 2009.
I te m P a rt Nu m ber Descri pti o n 1 - Roo f pod a nt e nna modul e (f rom 2009MY ) 2 - Na vig a t i o n GPS ant e nna (up t o 2009M Y ) 3 - Na vig a t i o n comput e r 4 - Na vig a t i o n s ys t e m di s pl ay The na v i g at io n sys t e m ut i l i z e s the f o l l o wi ng fu ncti o ns .
P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he na vig a t i o n s yst e m, ref e r to t he rel e va nt Des cr i p t i on a nd O pe rat i o n s e c t i o ns i n t he wo r ks hop manua l .
DT C De s cri pti o n Po ssi bl e C ause Ac ti on B2205 GPS r ece i ve r f a ul t S at e l l i t e na vi ga t i on s ys t e m modul e - gl o ba l p os i t i o ni ng s a t e l l i t e rece i ver fa ul t Ca r ry out a ny p i npo i nt t es t s a s s oci a t ed wi t h t his DT C us i ng t he m a nufa ct ur er a pprov e d d i a gno s ti c s y s t e m.
P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Antenna4-Doo r, VIN R ange : E96603 -> J39905 Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r d oo r o pe n in g we a t he r -st r i ps . Lef t-h a nd s hown, rig ht -ha nd s i mi l a r .
7. Remove t he GPS ant e nna. 1. Dis con nect t he GP S a n te nna e l e ct rica l conne ct o r . 2. Re move t he GP S a nt e nna. 1. Remove th e po p ri ve t.
P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Antenna4-Doo r, VIN R ange : J399 06- >V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. F ol d d o wn t he r e a r s e at b a ckr e s t s . 2. D et a ch t he r e a r s ea t b a ck r e st bo l s t e r s .
6. Remove t he C-pi l l a r t rim pa ne l s . 7. D et a ch t he cove r s t o e xpo s e t he s cr ews and r emove t he r ea r pa s s e nger a s s i s t ha ndl e s . 8. NOT E: S ome varia t io n i n t he i l l us t rat i o ns may o c cur , but t he e ss e nt i a l in f orm a t i o n i s a l wa ys corr e ct .
P ubl i s he d: 11-May-2 011 Navigation System - Navigation System AntennaWagon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s po i l e r For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S p o i l e r - W a g on (501-08 Exte rio r T r i m an d O rname nt a t i o n, Re moval a nd I ns t a l la t i o n).
P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Di splay Module Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with autom at ic tra ns m ission 1. NOT E: To ai d r e mov a l of t he na vi gat i o n mod ul e a nd a udi o un it p l ace t he J-gat e i n t h e 'D' po s i t i on .
6. Remove t he s wi t ch pa ck t rim cove r. 7. Remove t he ret a i ni n g s cr ew co ver pl a t e . 8. Remove t he di sp l ay mount i ng br a c ket up pe r ret a i ni ng s cr ews . 9. Remove t he di sp l ay mount i ng br a c ket l o we r ret a i ni ng s cr ews .
11. Remove t he d i s p la y modul e a nd a udi o uni t . 1. Dis con nect t he e l e c t rical co nnect ors a nd t h e fi br e op t i c conne ct o r . 2. Re move t he d is pl a y modu le and audi o uni t . 12. Remove t he na vi ga t i o n s y s t e m di s pl ay modul e .
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6. Remove t he a udi o uni t a mpl if ie r . 7. D et a ch t he mod ul e ret a i ni ng br acket . 8. D i s conne ct t he e l ect r i cal conne ct o rs. 9. Remove t he na vig a ti o n mod ul e ret a i ni ng bo l t s. 10. Remove t he na vi ga t i o n modul e .
Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 3 Nm. 2. Tig ht e n t o 3 Nm. 3. Tig ht e n t o 9 Nm. 4. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ).
P ubl i s he d: 11-May-2 011 Navigation System - Navigation System Mo duleWago n Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he na viga t i o n DVD di s c ha s be e n r e m o ved a nd t he a udi o uni t p in code i s a va il a b l e be f o r e di s conne ct i ng t he ba tt e r y ground c a bl e.
6. Remove t he l o ad s p a ce s t owa g e compa rtment . 7. Remove t he l o ad s p a ce fl oo r covering r e t a i nin g s cr ews . 8. D et a ch t he l o a d sp a ce fl o o r cove r i ng upwards. 9. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt ret a i ni ng screw.
11. Det a ch t he modul e ret a i ni ng brack e t . 12. Dis c o nne ct t he na vi ga t i o n s y s t e m module e l e ct rica l con nect or s . 13. Dis c o nne ct t he co mpact d i sc (CD) change r e l e ct r i cal c onn e cto r s . 14. Dis c o nne ct t he vo i ce a ct i vat e d cont r o l modul e (VACM) e l e ct r i ca l conne ct ors.
16. Remove t he na vi ga t i o n s y s t e m module r et a i ni ng bo l t s . 17. Remove t he s yst e m navi ga t i o n modu le . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 3 Nm. 2. Tig ht e n t o 3 Nm. JagDocs.
3. Tig ht e n t he modul e r e t a i n in g b r a cke t uppe r a nd l owe r f i xin gs . Ti ght e n t he l ow er r e t a i ni n g nut s t o 4 N m . Ti ght e n t he up pe r r et a i ni ng bo l t t o 9 Nm.
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - T o rque Sp eci f i cat ions Descri pti on N m l b- ft l b-i n Ce l l ul a r phone mo dul e 5 - 44 JagDocs.
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Cellu lar Pho ne Des cr ipt i o n a nd O pe r a t i o n C ELLULA R PHONE - UP TO 2 006 M Y The po r t a bl e ce l l ul a r phone s ys t e m cons i s t s o f : Ce l l ul a r phone ha nds e t (GS M) . Cr a d l e (GS M).
it ma y b e ne ce s s ary t o reduce t he s y s t e m vol ume s l ig ht ly whe n us ing ce r t a i n mob i le p hone s . P hone r e la t e d mes s a ge s a re s hown on t he a udi o uni t pa ne l di sp l ay o r t o uc h-s cr e en whe n the phone s ys te m i s a cti ve.
Item P a rt N um ber Descri pt i on 1 - Rot a r y Vol ume cont r ol 2 - Rot a r y cont rol Te l e pho ne m o de - s cr ol l t hr oug h s t ore d numbe r s 3 - Pho ne mode s e l e ct b ut t on 4 - S t .
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Cellu lar Pho ne Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he pho ne s yst e m, ref e r t o th e rel e va nt Des cr i pt i on a nd O perat i o n s e ct io ns i n t he wo r ks hop manua l .
• NO T E: W he n pe rfo r mi ng vol t a ge o r r e s i s t a nce t e s t s , a l wa ys use a di g i t a l mult i me t e r (DMM ) a c cur a t e t o t hree d e ci m a l pl a ces and wi t h a cur r e nt ca l i brat i on certi fi c a t e .
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Cellu lar Pho neVe hicles W i th: Bl ueto oth Dia gn os i s a nd Te s t i ng Over view Thi s s e cti on cove r s t he co mpon ent s of t he B l ue t o ot h c e l lul a r pho ne s yst e m.
1 1 1 1 1 1 1 1 1 • NO T E: I ns pe ct conne c t o r s f or s i g ns of wa t e r ing res s , a nd p i ns f o r damag e and /or co r ros i o n. • NO T E: I f a cont r o l modu le or compone nt i s .
1 1 1 1 1 1 1 1 1 1 1 Is t he co nnect i on be t w ee n t he B l ue t oo t h upgr a de modul e a nd t he p hone h a rn es s l oo s e ? Ye s Re conne ct t he B l ue t oot h u pgr a de mod ul e a nd check f or norm a l ope rat i o n.
1 1 1 1 1 1 1 1 1 1 1 Ha s t he hand s e t pai r ed wi th t he s ys t e m s ucces s f u ll y ("Phone con nect e d" di sp l a yed (t ouch s cr ee n) o r "S IG* " di s pl a y e d (audi o he a d un i t di s pl a y))? Ye s P r o b l e m may ha ve be e n d ue t o a f aul ty Bl ue to o t h conne c t i o n.
1 1 1 1 1 1 1 1 1 1 Che ck al l c onn e cti o ns /connect i vit y t o a nd f r o m t he p o rta bl e s upp o r t e l e ct r oni cs (PS E) mod ul e a nd t he B l uet oo t h upgrade m o dul e . A re a ny o f the ha rn e s s co nnect i o ns lo o s e o r d ama ge d? Ye s Re ct i f y as ne ce ss a r y.
1 1 1 1 1 1 1 1 1 1 I n t he ha nds e t Bl ue t o o t h menu, is "Jag ua r " l i s t e d a s a p a i red de vi c e ? Ye s GO t o F3 . No Fol l ow p a iring p r oce s s f or t he s peci f i c han ds et . GO to F6 . F3: I s t he hand s e t 'conne ct e d' t o ano t h er Bl ue t o o t h de vice (i .
1 1 1 1 1 1 1 1 1 1 1 1 Che ck th e ha nd se t menu. Ha s a ut o conne c t bee n t ur ne d o n? Ye s GO t o G4 . No S wi t ch a ut o conne ct o n and che ck f o r nor mal o p e r at i on .
1 1 1 1 1 1 1 1 1 1 Ha s t he us e r f ol l o we d ve hi cle and hands e t i ns truc t i o ns f or do wnl o a di ng phone b oo k? Ye s GO t o H4 . No Re fe r t o t he vehi c l e ha ndbo o ks/ha nds e t 'quick gui d e i nfo rm at i o n' r e gardin g p ho nebo o k do wnl o a d.
1 1 1 1 1 1 1 1 1 1 1 1 I5 : I s t he r e a ny 3r d p a r t y au di o ? Ye s End. No Dis conne ct t he Bl ue to o t h l i nk be t we e n t he ha nds e t a nd vehi cl e pho ne s yst em a nd re -t r y t he ca ll .
1 1 1 1 1 1 1 1 1 1 Ar e the mi cr o p ho ne harne ss conne ct i o ns da mag e d? Ye s Re cti f y as ne ces s a r y . Re fe r t o t he e l e ct rica l g ui de s .
1 1 1 1 1 1 1 1 1 1 1 W he n t he r e i s no ca l l i n pr og r es s , a nd t he a udi o s o urc e i s cha nge d, i s any aud i o hea rd e .g. f r om r adi o ? Ye s GO t o K3 . No Che ck D2 B conne ct i ons a re no t l o o s e a nd t hat a l l node s a r e conne ct e d on t he D2B ring .
1 1 1 1 1 1 1 1 1 1 1 1 Ca n a ny r i ngi ng be he a r d t hrough t he ve hi cl e s pe a kers? Ye s P r o b l e m due t o a f a ul t y Bl ue t o o t h l i nk .
1 1 1 1 1 1 1 1 1 1 1 1 I s ca l l vo lu m e s t il l l o w whe n ca l l t r a ns f e rr e d t o 'hands et ' mod e ? Ye s GO t o L 6 . No Key of f i g ni t i o n a nd wai t 6 minu te s f or t he p o r t a bl e s upp o r t e l e ct r oni cs (PS E) modul e t o s hut d own.
1 1 1 1 1 1 1 1 1 1 I s vo l ume s t i l l l o w? Ye s Ref e r t o t he wa rr a nt y pol i cy a nd p r oce dur e s manua l i f a modul e i s s us p ect .
1 1 1 1 1 1 1 1 1 1 1 1 Ca nnot di a l us i ng voi c e cont r o l ? Ye s GO t o N8 . No GO t o N6 . N6 : Ca nnot t ur n phone o n/of f? Ye s GO t o N8 . No GO t o N10 . N7 : I s t he hand s e t o n t he ap prov e d pho ne li s t ? Ye s Ca ll T e chni cal He l p l i ne .
1 1 1 1 1 1 1 1 1 1 Is t he ca l l droppe d a ga i n? Ye s P a ir a nd conne ct a d if fe rent known 'goo d' hands e t t o t he vehi cl e p hone s ys t e m a nd ma ke a n i ncomi ng cal l. GO t o O 7 . No S wit ch o ff t he ha nds e t, remove t he b at t ery f r o m the ba ck o f t he hand s e t .
1 1 Ca n t he cal l be t rans f e r r e d b e t we e n ha nds f r e e a nd ha nds e t ? Ye s P r obl em may have b e e n caus e d b y t he Bl uet o ot h l in k be i ng di s conne ct e d. No Ke y o f f i g ni t i o n f or 6 mi nut e s f or t he po r t a bl e s uppo r t e l e ct roni c s (P S E) modul e t o s hut down.
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Blu etoo th Mo dule Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f l o or cons o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a nd Co ns o l e , Re mov al a nd I ns t a l l at i o n).
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Handset Ho lde r Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he f l o or cons o l e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a nd Co ns o l e , Re mov al a nd I ns t a l l at i o n).
6. Remove t he a rm r e s t . 7. Remove t he no n s li p mat . 8. Remove t he ha nds e t ha ng up cup. Insta llat ion Vehi c le s with c or de d cellular phone 1.
2. Ins t a l l the no n s l i p mat . 3. Ins t a l l the a rm r e s t . Vehi c le s with c or dle ss cell ular phone 4. Ins t a l l the a rm r e s t . 5. Att a ch t he ha nds e t ho l de r . 1. I ns t a l l t he hands e t hol de r . 2. At t a ch t he ha nds e t hol der.
6. Ins t a l l the ce l l ula r phone . All v e h icle s 7. NOT E: US mode l s o nl y have a n a d di t i on a l a nt e nna conne cto r . Conn ect t he cel l ul ar phone e l e ct rica l conne ct or .
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - Module4-Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he compa ct di s c (CD ) cha nge r For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Co mpact Di s c (CD) Cha nger - 4-Door (415-01 A udi o U ni t, Re moval a nd I ns t a l l a t i o n).
P ubl i s he d: 11-May-2 011 C ellula r P ho ne - ModuleWago n Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nne ct (414-01 Ba t t e r y, Mou nti ng a nd Cabl e s , Ge ne r al P r oce dur es ).
P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - T o rque Sp eci f i cat ions Descri pti o n N m l b- ft l b- i n Vo i ce a ct i vat e d co nt r ol modul e 5 - 44 JagDocs.
P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M o dule C o ntrol led Functio ns Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um be r Descri pti on 1 — V oi ce a cti vat e d co nt rol mod ul e (VACM) 2 — Ge ne r i c e le ctroni c modu le (GEM) V oic e Activa te d Cont rol Comp one n t Loc at ion JagDocs.
I te m P a rt N um be r Descri pti o n 1 — Micr opho ne 2 — Vi s ua l fe e d back mes s a ge cent er di sp l a y 3 — Audi b l e f e e dba ck (incorpor a te d i n a u di o s ys t e m) 4 — S te .
P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M ulti functio n Ele ctronic Modul e Dia gn os i s a nd Te s t i ng Principle of Ope ra tion For a d e t a i l e d d e s cr ip t i.
cur r e nt ca l i brat i on certi fi c a t e . W he n t e st i ng r e s i s t a nce, a l wa ys t a ke t he r es i s t a nce o f t he DM M l e a d s i nt o a ccount . • NO T E: Che ck and r ect i fy ba s i c f a ul t s fi r s t be fo r e be gi nni ng di a gno s t i c rout i ne s th a t i nvo l ve pi npo i nt t e s t s .
DT C D escri pti on Possi bl e Ca us es Ac ti o n B2282 Le f t turn s wi t ch s hort to gr ound Tur n s wi t ch f a ul t y W i ring ha r ne s s co ncer n Che ck le ft t ur n s w i t c h ope rat i o n f o r s t i ck ing . Re pl a ce s wi t ch a s r eq ui red.
P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - Generic E lectron ic Module (G E M) Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : El e ct roni c modul e s a r e s e ns i t i ve t o s t a t i c e l e ct rical c ha rg e s .
P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M ulti functio n Vo ice Activated Module4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : El e ct roni c modul e s a r e s e ns i t i ve t o s t a t i c e l e ct rical c ha rg e s .
6. Remove t he VACM. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 6 Nm. 2. Connect t he ba t t e ry gr ound cabl e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Conne c t (414- 01 Ba t t e ry , Mount i ng a nd Ca bl e s, Ge ne r a l P rocedur e s ).
P ubl i s he d: 11-May-2 011 Multif unctio n Electro ni c Mo d ules - M ulti functio n Vo ice Activated ModuleWago n Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Front E nd B ody P anel s Des cr ipt i o n a nd O pe r a t i o n Fr o nt B umper As s e mbly and Unde rtray The front b ody s t r ucture i s d e.
P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Air Deflector2 .0L Durato rq- TDCi / 2.2L Duratorq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1.
P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Co w l Vent Screen Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he wi p er arm s a nd b l ade s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W i pe r Pi vot A rm (501- 16 W i p e r s a nd W a s he r s , Re moval a nd I ns t a l l a t i on ).
P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Fen der Splash Shield Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e as s e mbl y. Fo r addi t i ona l i nf o r m at i o n, r e f er t o S ect i on 204-04 W he e l s an d T i res .
P ubl i s he d: 11-May-2 011 Front E nd Bo d y Panels - Radiator S p las h Shi eld Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i on 100-02 Jacki ng a nd Li ft i ng .
P ubl i s he d: 11-May-2 011 B ody Cl osures - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-ft l b-i n Doo r hi ng e b o lt - hi nge to bo dy 35 26 – Doo r hi ng e b o lt - hi nge to do o r 47.
P ubl i s he d: 11-May-2 011 B ody Cl osures - Body Cl os ures Des cr ipt i o n a nd O pe r a t i o n Doo r s The pa s s e nger compa r t ment d o or s e a ch compr is e o f a n i nner a nd ou t e r pane l, cli nched a nd b o nded t o ge t he r t o fo rm a do or as s e mbly.
P ubl i s he d: 11-May-2 011 B ody Cl osures - D o o r A l ignment Gene ral P r ocedures 1. NOT E: Re a r do o r sho wn, front doo r s i mi l a r. Re move t h e r e a r do o r ape rtur e s ea l . 2. Remove t he s t r i k e r pla t e . 3. Loos e n t he doo r hin ge b o l t s .
6. Ins t a l l the s t r i ker pl a t e . Ti ght e n t o 25 Nm. 7. Ins t a l l the rear do o r a p ert ur e s e a l . JagDocs.com.
P ubl i s he d: 11-May-2 011 B ody Cl osures - Hoo d Alignment Gene ral P r ocedures 1. Remove t he ho od l at ch. Fo r ad di t io na l i nf o r ma t i on, ref e r t o Sect i on 501-14 Hand l e s , Locks , La t c he s a nd Ent r y Sy s t e ms . 2. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar.
7. Tig ht e n t he ho o d hi ng e s cr e ws t o 20 Nm. 8. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar. I nst a l l t he l o we r A-pi l l ar dr a i na ge channe l . 9. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar. I nst a l l t he A -pi l l a r ext e rio r t r i m.
P ubl i s he d: 11-May-2 011 B ody Cl osures - Liftgate Alignment Gene ral P r ocedures 1. Ope n t he l i f t ga t e. 2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Adj us t bo t h l i ft gat e b ump s t o ps count e r- clo ckwis e t o t hei r f ul ly s e a t e d po s i t i o n.
9. Tig ht e n t he l i f t g a t e s t r i ker r e t a i ni ng b ol t s . Ti ght e n t o 25 Nm. 10. Loo s e n t he uppe r l i ft ga t e hi n ge r e t ai n in g b ol t s . 11. NO TE: Make s ur e th e ga p be t we e n t he l if t ga t e a nd t he r e a r qua r t er pane l s , rear l a mp a s s e mbl i e s a nd rea r bumpe r co v e r are e qual .
15. NO TE: Make s ur e th e ga ps be t wee n t he l i f t ga t e a nd r e a r la mp a ss e mbli e s a r e equ a l on bo t h s i des . S et t he l i ft gat e g a ps t o t he r e a r l a mp as s e mbl i e s . 16. Ti g ht e n t he l o we r l i f t g a t e hi ng e r e t a i ni ng bo l t s .
22. Mak e s ure t he r ea r wi pe r pi vot a r m i s i n t h e pa r ke d po s it i o n. 23. O pen th e l i f t ga t e wi nd o w gl a s s . 24. O pen th e l i f t ga t e.
P ubl i s he d: 11-May-2 011 B ody Cl osures - Lugg age Co m partment L id Alignm ent Gene ral P r ocedures 1. Remove t he l ugga g e co mpar t me nt l i d a p erture s e a l . 2. Remove t he s t r i k e r pla t e . 3. NOT E: Le f t ha nd s ho wn, r i g ht ha nd s i mi l ar.
5. Pul l up/pus h down o n l ugg a ge compartment l i d. 6. NOT E: S et t he a li gnment t o 2 mm lo we r t ha n no mi nal . S et t he l ugg age c ompa rtment l i d a l i gnme nt . 7. Tig ht e n t he l ugga g e comp artme nt l i d hi ng e b ol t s . Ti ght e n t o 25 Nm.
10. Ins t a l l t he s t r ike r pla t e . Ti ght e n t o 10 Nm. 11. Ins t a l l t he l ugga g e co mpar t me nt l i d a pe rture s e al . JagDocs.com.
P ubl i s he d: 11-May-2 011 B ody Cl osures - We atherstri p Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Fr ont do o r s hown, rear do o r s i mi la r. Det ach t he do o r che ck s t r a p . 2. Remove t he wi ndo w a pe rture t r i m. 3.
6. Usi ng a s ui t a bl e t o o l remove a ny r es i dua l a dhe s i ve f r om t he doo r. Insta llat ion 1. NOT E: Doo r wea t he rst r i ps a r e i de nt i fi e d by a col o r cod e d do t whi ch i s a ls o t he s t a rt poi nt .
6. Ins t a l l the do o r che ck s t rap. Ti ght e n t o 35 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b-i n S ea t bel t a nchor i ng bo l t 5 5 41 – Lo a ds p a c e r et a i ni ng ho o k - W ago n 8 – 71 JagDocs.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Interior T r im Des cr ipt i o n a nd O pe r a t i o n Thi s s e cti on cove r s r emova l a nd i nst a l l a t i on of t he i nt e r i o r mold i ngs a nd t r i m pa ne l s . I n many i nst a nces , o ne c ompo ne nt o v e rla ps a not he r compone nt .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - A - Pillar Trim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f ront do o r op eni ng we a t he r -s t rip. 2. NOT E: The A-pi l l a r t rim p a nel i s s e cur ed t o t he t op o f t he A-pi ll a r by a r e t a i ni ng s t r a p.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - B- Pilla r Lo w er T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s c uf f p l a t e t rim pa nel . For ad di t io na l i nf o r mat i o n, r ef e r t o S c uf f Pl a t e Tr im Pa nel —Fr o nt .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - B- Pilla r Upper Trim P anel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r d oo r o pe n in g we a t he r -st r i p. 2. D et a ch t he f ront do o r op eni ng we a t he r -s t rip.
5. D et a ch t he s a f e ty b e l t lo we r a nc ho r from t he unders i de o f t he s ea t . 6. Remove t he B-pi l l a r uppe r t r i m pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 55 Nm. JagDocs.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Co wl Side T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he f ront do o r op eni ng we a t he r -s t rip. 2. Remove t he f r ont s c uf f p l a t e t rim pa nel .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - C-P illa r T rim Panel4 -D o or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t s i de bo l s t e r . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 501-10 S e at in g .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - C-P illa r T rim PanelW agon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce cove r . 2. F ol d d o wn t he r e a r s e at b a ckr e s t . 3. D e t a ch t he l o a d s p ace co ver ret a i ni ng br acket fi ni s he r t r i m.
7. D et a ch t he r e a r d oo r o pe n in g we a t he r st rip. 8. Remove t he C-pi l l a r t rim pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - D- Pillar Tri m P anel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he l i f t ga t e o pe ni ng we a t he rst r i p. 2. D et a ch t he D-Pi l l a r t r i m pa ne l .
3. Ins t a l l the D-Pi l l a r t rim p a nel . 4. Att a ch t he l i f tg a t e o pe ni ng we at he r s t r ip. JagDocs.com.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Front Doo r Trim Pa nel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ret a i ni n g s cr ew co ver. 2. Remove t he ret a i ni n g s cr ew. 3. Remove t he ret a i ni n g s cr ews .
5. D et a ch t he do o r handl e ca bl e . 6. Remove t he do o r han dl e cabl e. 7. Remove t he f r ont do o r t r i m pane l . Dis conne ct t he e l e ct r i cal co nnect o rs a nd de t a ch t he wi r i ng ha r nes s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Front Scuff Plate Trim P anel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s cuff pl a t e t r i m pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Headliner4-Door Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: O ve r hea d Co ns ol e (501-1 2 I nst r um e nt P a ne l a nd Co ns ol e , Re mov a l a nd I n st a l l at i o n).
8. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he rear do o r op eni ng we a t he r -s t rip. 9. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he B-pi l l a r uppe r t r im pa ne l . 10. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r .
13. Remove t he C-p il l a r trim pa nel s . 14. Det a ch t he cove r s t o e xpo s e t he s cr e ws a nd re m o ve t he dr ive r a nd pa s se n ge r as s i s t ha n dl e s .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - HeadlinerWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: O ve r hea d Co ns ol e (501-1 2 I nst r um e nt P a ne l a nd Co ns ol e , Re mov a l a nd I n st a l l at i o n).
8. D i s conne ct t he right -ha nd e l e ct rica l conne ct or and det a ch t he w i r i ng ha r nes s. 9. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he B-pi l l a r uppe r t r im pa ne l . 10. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r .
13. Remove bo t h C-pi ll ar t rim p ane l s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: C-Pi l l a r Tr i m P a nel - W ago n (501- 05 I nt e r i o r Tr im a nd O rname nt a ti o n, Re m o val a nd Ins t al l a t i o n). 14. Remove bo t h D-pi l l a r t rim p ane l s.
19. Dis c o nne ct t he roof o pe ni ng pa ne l m o to r e l e ct rical conne c t o r . 20. Dis c o nne ct t he rea r was he r hos e co nne ct o r . 21. NO TE: He a d l i n er s ho wn removed fo r cl a r i t y. Us i ng a s ui t a b l e a dhe s i ve t a pe , pr ot e ct b o th f r ont co r ne r s of t h e he a dl i ne r.
Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . 2. NOT E: The l i f t g a t e we a t he r s t r i p must b e repl a ced on ce removed.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Liftgate Trim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he l i f t ga t e wi ndow g la s s we a t he r s t r i p. 2. Remove t he l i f t g a t e wi ndo w gl as s l a t ch a ct ua t or fi ni s he r t r i m pa ne l .
5. Remove t he l i f t g a t e fi ni s her t r i m pa ne l . 6. D ea t ch t he l i f t ga t e t r i m pa ne l . 7. Remove t he l i f t g a t e t rim pa nel .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Loa dspace Scuf f Plate Tri m P anel Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e t he l o a ds p a ce fl o o r cove r i ng. 2. Remove t he l o ad s p a ce fl oo r covering.
5. D et a ch t he l o a d sp a ce s c uf f p l a t e t rim pa nel . 6. Remove t he l o ad s p a ce s cuff pl at e t r i m pa ne l . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Loa dspace Trim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce s cuff pl at e t r i m pa ne l .
8. Remove t he ret a i ni n g ho ok. 9. Remove t he l o ad s p a ce t rim p a nel ret a i ni ng screws . 10. Det a ch t he l o a ds pa ce t r im pa ne l rea r r e t a i n ing cl i ps . 11. Det a ch t he l o a ds pa ce t r im pa ne l f r ont ret a i ni ng c l i p s .
Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 8 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - P arcel Shelf Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with s plit r ea r se at back r est 1.
6. Remove t he pa r cel s hel f. P as s t he re ar cent re s a f e t y be l t t hr ough t he pa rc el s he l f. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Rear Doo r T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ret a i ni n g s cr ew co ver. 2. Remove t he ret a i ni n g s cr ew. 3. Remove t he ret a i ni n g s cr ew.
6. Remove t he do o r han dl e cabl e. 7. Remove t he rear do or t r i m pa ne l . Dis conne ct t he e l e ct r i cal co nnect o rs a nd de t a ch t he wi r i ng ha r nes s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Rear Scuff P late T rim Panel Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he s cuff pl at e t r i m pa ne l . 2. Remove t he s cuff pl a t e t r i m pa ne l . Insta llat ion 1.
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Rear Window Bli nd Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r d oo r o pe n in g we a t he r -st r i ps . 2. Remove t he rear s e a t s i de bo l s t e r .
7. Remove t he rear wi nd ow bl i nd r e t a i ni ng cl ip s . 8. Remove t he rear wi nd ow bl i nd. P r e s s t he s i de s o f t he rea r wi ndo w b l i nd i nwa rds. 9. Remove t he rear wi nd ow bl i nd r o o f f i xing . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Interio r Tri m and Orn am entatio n - Sun Vi s or Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s un vis o r r e t a i ni ng s cr e w cover . 2. D et a ch t he s un v i s o r . 3. Remove t he s un vis o r .
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P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Ex terio r Trim Des cr ipt i o n a nd O pe r a t i o n 4-Do or I te m Pa r t Nu m be r Descri pti on 1 — Ra d ia t o r g r il le 2 .
It e m Pa r t Nu m be r Descri pti on 1 - Roo f r ai l 2 - Re a r s po i l e r 3 - Li f t ga t e m o uld i ng 4 - Rocker pa nel moul di ng JagDocs.com.
P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Do or Mouldin g Re moval a n d I ns t a l l a t i on R em ova l 1. Appl y s uit a b l e pr ot ect i ve t a pe to adj a c e nt a r ea s o f pa i nt wo r ks . 2. Usi ng a ha n d-hel d hea t g un, a ppl y he at uni fo r mly a l ong t he moul di ng l e ngt h.
P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Li ftgate Moul ding Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l i f t g a t e t rim pa nel .
6. Remove t he l i f t g a t e moul di ng r et a i ni ng s cr e ws . 7. D et a ch t he gromm et . 8. Remove t he l i f t g a t e moul di ng . Insta llat ion 1.
P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Radiator G rille Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r gr i l l e . Re mov e t he rad i a t or gril l e ret a i ni ng bol t s . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Rear Spo ilerWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove and di s card t he t a i l ga t e o p e ni ng wi nd ow fi ni s he r t rim p ane l . 2. Remove t he rear s po i l e r r e t a i n in g nut s .
1. NOT E: A ne w t a i l ga t e op eni ng wi ndo w f ini s he r t r i m pa ne l must b e in s t a l l e d. To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure.
P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Ro cker Panel Mou lding Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roc ker pa ne l mould i ng r e t a ini ng s cr e ws . 2. NOT E: Bot h do o r s wi ll n e e d t o be o p e n t o r e move t he rock e r pane l m o uld i ng.
P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Ro of Rail Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Us i ng a s ui t a bl e t i e s t r ap remove t he r o o f r a i l f r ont t r i m. Re move t h e r oo f r ai l front t rim.
1. NOT E: Ins t a l l ne w s e a l s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 14 Nm. 2. Tig ht e n t o 14 Nm. JagDocs.
P ubl i s he d: 11-May-2 011 E xterior T rim and Ornam entatio n - Wi ndow Moul ding Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he do o r wi ndow g l a s s a pe rture s e a l . 2. Remove t he wi ndo w moul di ng . Re mov e a nd di s c a r d t he r i v e t s .
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b- i n Exte rio r mi r r or r et a i ni ng nut 12 9 - JagDocs.
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Rea r Vie w Mirro rs Des cr ipt i o n a nd O pe r a t i o n The manua l d i p pi ng i nt e r i or mirr o r is a pr i s mat i c uni t wi t h mi r r or di p pi ng a chie ved b y pul l i ng th e l e ver fo r wa r d.
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Rea r Vie w Mirro rs Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage .
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - A uto-Dimm in g Interio r Mirror Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he i nt e rio r m i r ror trim pane l . 2. D et a ch t he i nt e rio r m i r ror . 3. Remove t he i nt e r i o r mirr o r.
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on .
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 12 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror C ontrol S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on .
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror C ov er Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e xte rio r m i r ror gl a s s . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Exte rio r Mi rr or Gl as s .
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror G lass Re moval a n d I ns t a l l a t i on R em ova l 1. Appl y l i ght p r e s s ur e t o t he mi rr o r g l a s s . 2. D et a ch t he mirr o r gl a s s . 1. App l y l i g ht pr e s s ur e t o t he i nne r e dge of t h e mi r r or gl a s s .
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Exterio r Mirror Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he e xte rio r m i r ror gl a s s . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Exte rio r Mi rr or Gl as s .
P ubl i s he d: 11-May-2 011 Rear Vie w Mirrors - Interior Mi rror Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i nt e r i o r mirr o r.
P ubl i s he d: 11-May-2 011 Seating - T o rque Sp eci f i cat ions Desc ri pti on N m l b-f t l b-i n Fr o nt s e a t r e t a i ni ng b ol t s 20 15 - Fr o nt s e a t ba ckr e s t r et a i ni ng bo l.
P ubl i s he d: 11-May-2 011 Seating - Seats Des cr ipt i o n a nd O pe r a t i o n Fr o nt Seat - Hi gh S pe ci fi c a t i o n, V e hi cl e s wi tho ut Seat P o s i t i o n Memory It e m Pa rt Nu mbe.
It e m Pa rt Nu mber Desc ri pti o n 1 — Fr ont s ea t memo r y s t ore s wi t ch 2 — Fr ont s ea t memo r y s wi t ch 3 — Fr ont s ea t ba ckr es t r ecl i ne r s wi t ch 4 — Fr ont s ea t l .
I te m Pa r t N u m ber Descri pti on 1 — Fr o nt s e a t t rack a dj us t me nt l o ck i ng ba r 2 — Fr o nt s e a t ba ckr e s t r ecl i ner ha nd whe e l 3 — Fr o nt s e a t cus hi o n he i g ht a dj us t me nt s wi t ch (Dr i ver s i de o nl y) 4-D oo r, Ve hi cl es wit h 70/30 S p l i t Sea t JagDocs.
Item P a rt N um be r De sc ri pti on 1 — Re a r s ea t b a ck r e s t bol st e r - RH 2 — Re a r s ea t b a ck r e s t 3 — Re a r s ea t h e a d r es t r a i nt s (Ce nt e r r e a r s e at h e .
Item P a rt N um be r De sc ri pti on 1 — Re a r s ea t b a ck r e s t bol st e r - RH 2 — Re a r s ea t b a ck r e s t 3 — Re a r s ea t h e a d r es t r a i nt s (Ce nt e r r e a r s e at h e .
It e m Pa rt Nu mber Des cri pti o n 1 — Fr ont s e a t b ackr e s t r ecl i ner mot o r 2 — Fr ont s e a t cus hi o n f r o nt he i ght a d ju s t ment mot o r 3 — Fr ont s e a t t rack mot o r.
I te m P a r t Nu m be r De s cri pti on 1 — Fr ont s e at l umba r s upp o r t b a g 2 — Fr ont s e at l umba r mot o r P a ss e nge r Fr ont Sea t W e i g ht S e ns ing s ys t e m I te m Pa rt N.
s e ns o r a nd t he pas s e n ger s e a t has a we i ght s e ns i ng s y s t em. I n bot h i ns t a nces t he comp one nt s fo rm a n i nt e gr a l pa r t o f t he o ccupant r e s t r ai nt s ys t e m.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 1 2 3 4 1 1 P ubl i s he d: 11-May-2 011 Seating - Seats Dia gn os i s a nd Te s t i ng 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
2 3 4 1 1 1 2 1 1 2 3 1 2 1 2 1 1 2 Dis c on ne ct t he s e a t cont r ol s wi t ch e l e ct rical co nnect or RS 1. S wi t ch t he i gni t i o n s wit ch t o t he O N p os i t i on. Meas ur e t he vol t a ge be t we e n t he s e a t cont r ol s wit ch e l e c t r i cal co nnect or RS 1 pi n 6, (O Y ), a n d g r o un d.
1 1 2 3 1 2 1 2 1 1 1 2 3 1 2 1 2 1 2 Mea s ure t he r es i s t ance b e t wee n the s e a t cont r o l s wi t ch e l e ct rical conne c t o r RS 16 pi n 3, (B), a n d g r o un d a nd be t we e n RS 16 pi n 6, (B), and ground. Ar e t h e res i st a nces l e s s th a n 5 ohms ? Ye s GO t o B 10 .
1 2 3 1 2 1 2 1 2 1 1 1 2 3 1 2 1 2 1 2 C 6: C HEC K T HE R H FRO NT S EAT T R ACK MOT O R C I R C UI T Di s c onn e ct t he s e a t t rack mo to r e l e ct rica l c on ne ct or RS 4. O pe rat e t he s e a t cont r ol s wi t c h t o t he R EARW ARD t rack pos i t i o n.
1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 1 2 1 2 Is t he res i s t a nce l e s s t han 5 ohms ? Ye s I NS T AL L a ne w s e a t co nt rol s wi tch. For a dd i t i o na l i nfo rm a ti o n, re fe r t o Sea t Cont r ol S wit ch . No REP AIR t he ci r c ui t. TEST t he s y s t e m fo r norm al o pe rat i on.
1 2 3 1 2 1 2 1 2 1 1 2 3 1 2 1 2 1 2 REP AIR t he ci r c ui t. TEST t he s y s t e m fo r norm al o pe rat i on. D16 : CHEC K T HE RH F R ONT SEAT CUSHI ON RE AR H EIGHT A DJUST MENT MO T OR CIRC U I T S Dis conne ct t he s e a t cus hi on r ea r he i ght a dju s t ment mot o r e l e ct r i cal co nnect or RS 2.
1 2 3 1 2 1 2 1 2 1 1 2 1 1 2 3 1 2 1 2 Dis conne ct t he s e a t b a c kr es t mot o r e l e ct r i cal conn ect or RS 6. Op e r at e th e s e a t co nt r o l s wi t ch t o t he REARW ARD RECLI NE p os i t io n.
1 2 1 1 2 1 2 1 1 2 3 1 2 1 2 1 2 1 1 2 REPAI R t he ci r cui t . T ES T t he s ys t e m fo r nor mal op e r at i o n. F7: C HEC K T HE L H S EAT LUMBAR AS SEMBLY I N FLA T E CIRC UI T Ope rat e the s e a t l umbar cont r ol s wi t ch t o t he IN FLATE p os i t i on.
I s t he res i s t a nce l e s s t ha n 5 ohms? Ye s INS TA LL a ne w s e a t l umbar cont r ol s wi t ch. TE S T t he s yst e m f o r norm a l op erat i o n.
P ubl i s he d: 11-May-2 011 Seating - Front Seat Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : An RCM modu le o nl y r e qui res r e pl a ce ment i f t he s y s t em ha s i ncur red f i ve s e parat e de pl o ym e nt s. At no t i me chang e a n RCM f o r l e s s t ha n fi ve s e pa r a t e de p l o ym ent s .
5. D et a ch t he s a f e ty b e l t lo we r a nc ho r from t he unders i de o f t he s ea t . 6. Remove t he s e a t r e a r r e t a i ni ng bol t covers. 7. Remove t he s e a t . Re mov e t he re ta i ni ng bo l t s. 8. D i s conne ct t he ba t t e r y gr oun d cab l e .
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 20 Nm. 2. Tig ht e n t o 55 Nm. 3. Tig ht e n t o 20 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Seating - Front Seat Ba ckrest Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n).
6. D et a ch t he i nne r si de t rim pa ne l . 7. Remove t he i nne r s i de t rim p ane l . 8. Remove and di s card t he cabl e ti e . 9. D et a ch t he r e cl in e r m ot o r el e ctr i cal co nne ct or. 10. Dis c o nne ct t he recl i ne r mot or e l e ct r i ca l conne ct o r .
11. Det a ch t he r ecl i ne r mot o r wiring ha r ne s s . Re mov e a nd di s c a r d t he r et a i ni ng cli p. 12. Det a ch t he s e a t ha r ne s s e l e ct rica l conne ct o r . 13. Dis c o nne ct t he s i de a i r bag modul e e l ect rical conne cto r.
16. Remove t he f ront s e a t ba ckr e s t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e Ti ght e n t o 25 Nm. 2. Tig ht e n t o 25 Nm.
P ubl i s he d: 11-May-2 011 Seating - Front Seat C ushi on Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : The front se a t cus hi on i s ca l i b r at e d t o t he o ccupant c l a s s i f i cat i o n s e ns o r, a nd can onl y be repl ace d a s pa rt of t he s e r vice ki t .
P ubl i s he d: 11-May-2 011 Seating - Front Seat Fron t Height Adj ustm ent Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n).
6. Remove t he f r ont s e at front h e i ght a dj us t me nt mo t o r . Re mov e t he re ta i ni ng bo l t s. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e .
P ubl i s he d: 11-May-2 011 Seating - Front Seat Rear Height Adjustment Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n).
6. Remove t he t r i m fi ni she r . 7. Remove t he f r ont s e at r ea r hei ght a dj u st ment mot or. Re mov e t he re ta i ni ng bo l t . Insta llat ion 1.
P ubl i s he d: 11-May-2 011 Seating - Front Seat Reclin er Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at backr es t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t B ackr e s t (501-1 0 S ea t i ng, Re mova l and In s t a l l a t i o n).
6. D i s conne ct t he f r ont s e at ba ckr e s t m o to r e l ect r i cal conne cto r. 7. D et a ch t he f ront s e a t ba ckr e s t recl i ne r bar f r om t he moto r. 1. Re move t he r e cli ner ba r r et a i ni ng cl i p. 2. De ta ch t he f r ont s ea t b a ck r e s t r e cli ne r ba r from t he mot o r .
P ubl i s he d: 11-May-2 011 Seating - Front Seat T rack Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n).
1. NOT E: Make s ure t he f ront s e a t t r a c k mot o r cont rol rods a r e co r r ect l y lo ca t e d . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure.
P ubl i s he d: 11-May-2 011 Seating - Lu mbar Assem bly Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at backr es t . Fo r a d di t i ona l i nf o r mat i o n, refe r to Fr o nt Sea t B ackr e s t . 2. Remove t he he a d res t r a i nt .
6. D et a ch t he ba ckr e s t cove r . Cut t he ho g rings . 7. D et a ch t he ba ckr e s t cove r . Cut t he ho g rings . 8. Rol l t he b a ckr e s t cover up t he ba ckr e s t. 9. D et a ch t he l umba r mot o r fr o m t he s e a t b a c kr e st f r a me .
Insta llat ion 1. NOT E: Ins t a l l ne w cab l e t i e s a nd h og r i ngs . Us e ho g ring pl i e r s t o cl os e th e hog r i ng s . Do no t us e an y ot he r to o l . The hog r ing s mus t b e cl os e d t o overla p a s i ll us t r a t e d. To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure.
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n. Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Re a r S ea t Cushi o n . 2. Remove t he rear cent e r s af e t y be l t a nd buckl e.
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest4- Doo r, Vehi cles Wi th: 70/3 0 Split Seat Re moval a n d I ns t a l l a t i on R em ova l 1. F ol d d o wn t he r e a r s e at b a ckr e s t . 2. Remove t he rear s e a t b a ck r es t . 1. De ta ch t he rear s e a t backr e s t .
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krestWago n, Ve hicle s W ith: 70/3 0 Spl it Seat Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a t i o n).
1. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 55 Nm. 2. Tig ht e n t o 55 Nm.
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest La tchWagon Re moval a n d I ns t a l l a t i on R em ova l 1. D i s a s s e mble t he r e a r se a t ba ck res t .
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bo ls ter4- Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. F ol d d o wn t he r e a r s e at b a ckr e s t . 2. D et a ch t he r e a r s ea t b a ck r e st bo l s t e r . P r e s s t he t a ng .
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bo ls terWagon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce cove r . 2. F ol d d o wn t he r e a r s e at b a ckr e s t . 3. D e t a ch t he l o a d s p ace co ver ret a i ni ng br acket fi ni s he r t r i m.
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Cu shi on Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Re m o ve a nd d i sca r d o l d re ta ini ng cl ip s . Re move t h e r e a r s e at cush io n. 1. De ta ch t he rear s e a t c us hi o n f r ont ret a i ni ng c l i p s .
P ubl i s he d: 11-May-2 011 Seating - Seat Ba se Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at backr es t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t B ackr e s t (501-1 0 S ea t i ng, Re mova l and In s t a l l a t i o n).
1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 15 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Seating - Seat Co n trol S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont s e at . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t (501-10 S e a t i ng , Re moval a n d I ns t a l l a t i o n).
6. Remove t he s e a t c ont r ol s wi t c h. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Seating - Front Seat Ba ckrest Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he f r ont s e at backr es t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Sea t B ackr e s t (501-1 0 S ea t i ng, Re mova l and In s t a l l a t i o n).
6. D et a ch t he f ront s e a t ba ckr e s t co ver r e ta ini ng hoo k. 7. D et a ch t he f ront s e a t ba ckr e s t co ver. Re mov e a nd di s c a r d t he hog r i ngs . 8. D et a ch t he f ront s e a t ba ckr e s t co ver. Re mov e a nd di s c a r d t he hog r i ngs .
11. Remove t he f ront s e a t he a d res t r a i n t gui de s . Us i ng a s u it a b le t oo l , p r es s t he l o cking t a ngs . 12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Det ach t he f r ont s e at b a ckr e s t cover t e ns i o n cor ds f r om t he front s e a t ba ck r e s t .
P ubl i s he d: 11-May-2 011 Seating - Front Seat C ushi on Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he f r ont s e at cush io n. For a dd i t i o na l i nf o r mat i o n, refe r t o Fr ont S ea t Cushi o n . 2. Remove t he s e a t c us hi o n co ve r .
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest4- Doo r, Vehi cles Wi th: 70/3 0 Split Seat Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t b a ck r es t - f o l di ng. For add i t i o na l i nf orm a t i o n, r ef e r t o Rea r S e a t Ba ck r es t —Fo l di ng .
1. NOT E: Ins t a l l ne w hog r i ngs . U s e ho g ring pl i e r s t o clo s e t he ho g ring s. Do no t u se a ny o th e r t o o l . Th e ho g rings mus t be clo s e d t o ove r la p as il l us tra te d. To a s s e mble , r e ver s e t he d is a s se mbl y pr oce dur e .
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krestWago n, Ve hicle s W ith: 70/3 0 Spl it Seat Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1.
7. D et a ch t he r e a r cen t r e s a f et y be l t g ui de f i nis her. 8. Remove t he rear cent re s a fe t y be l t g uid e f ini s he r . 9. D et a ch t he r e a r s ea t b a ck r e st cove r . Re mov e a nd di s c a r d t he hog r i ngs . 10. Det a ch t he r ea r s e a t ba ckr es t co ver .
12. Det a ch t he r ea r s e a t ba ckr es t co ver . Re mov e a nd di s c a r d t he hog r i ngs . 13. Det a ch t he r ea r s e a t ba ckr es t co ver . Re mov e a nd di s c a r d t he hog r i ngs . 14. Det a ch t he r ea r s e a t ba ckr es t co ver .
17. Remove t he rea r s e a t ba ckr e s t co ver. P as s t he ce ntre s a fe t y bel t t hrough t he re a r s e a t ba c kr es t co ver. A ssemb ly 1. NOT E: Ins t a l l ne w hog r i ngs . U s e ho g ring pl i e r s t o clo s e t he ho g ring s. Do no t u se a ny o th e r t o o l .
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bac krest Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t b a ck r es t - f i xed . For ad di t i on a l in fo rm at i on, refe r t o Re a r S ea t B a ck r e st —Fi x e d .
5. Remove t he he a d res t r a i nt gui de s . 1. Us i ng a s ui ta b l e s cr ew dr ive r , pres s th e l o c king t a ng. 2. Re move t he he a d r e s t rai nt g ui de . 6. Remove t he ba ck res t frame f rom t he b a ck r e st cus hi o n a nd co v e r.
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Bo ls ter Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t b a ck r es t - bo l s t e r . Fo r addi t i ona l i nf o r m at i o n, r ef e r t o Rea r S e a t Ba ck r es t —B ol s t er .
P ubl i s he d: 11-May-2 011 Seating - Rear Seat Cu shi on Dis a s s e mbl y a nd As s e mbl y D isa ssem bly 1. Remove t he rear s e a t cus hi o n. Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o Re a r S ea t Cushi o n . 2. D et a ch t he s e a t cus hi on cove r .
7. Remove t he s e a t c us hi o n co ve r . Cut t he ho g rings . A ssemb ly 1. NOT E: Ins t a l l ne w hog r i ngs . U s e ho g ring pl i e r s t o clo s e t he ho g ring s. Do no t u se a ny o th e r t o o l . Th e ho g rings mus t be clo s e d t o ove r la p as il l us tra te d.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Ad hesi ve Desc ri pti on Speci fi cati on W i nd s hi e l d A dhe s i ve W S S -M2G 379- A6A T o rque Sp eci f i cat ions Desc ri pti on.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Gl ass, Frames and Mechani sms Des cr ipt i o n a nd O pe r a t i o n Thi s ve hi cle has a ful l y bo nd ed, l ami na t e d front wi nds hi e l d gl a s s gl a z e d d ire c t l y t o t he b od y.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Gl ass, Frames and Mechani sms Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l a nd e l e ct r i cal dama ge .
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Doo r W indow Moto r In itiali zati on Gene ral P r ocedures 1. NOT E: Af t e r t he ba t t e r y has be e n d is co nnect e d it i s nece s s a ry t o in it i a l i z e e a ch do or wi nd ow mot or s e pa r a t e l y t o o pe r a t e th e "one -t o uch" up f unct i o n.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Liftgate Windo w Glass Adj ustm ent Gene ral P r ocedures 1. M ake s ure t he r e a r wip e r m oun ti ng a r m i s i n t he pa r ked po s it i o n. 2. Ope n t he l i f t ga t e win do w gl a s s .
Tr i m a nd O r na m e nt a t io n, Re mov al a n d I ns t a l l a t i o n). JagDocs.com.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Front Doo r Win dow Gla ss Re moval a n d I ns t a l l a t i on R em ova l 1. Lowe r t he f ront doo r wi ndo w gl a s s a ppr oxi mat e l y 290 mm (11.41 i n). 2. Remove t he f r ont do o r t r i m pane l .
4. Tig ht e n t o 8 Nm. 5. CAU TI O N : Do no t t ou ch t he a d hes ive s urface a s r eb on di ng wi l l b e impa i r e d. At t a ch t he front doo r wea t he rshi el d.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Front Doo r Win dow Reg ulato r and Mo to r Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Liftgate Windo w Glass Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s po i l e r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S p o i l e r - W a g on (501-08 Exte rio r T r i m an d O rname nt a t i o n, Re moval a nd I ns t a l la t i o n).
6. D et a ch t he l i f t ga t e wi ndow g la s s r el ea s e s wi t ch e l e ct rica l c o nne ct or . 7. D i s conne ct t he l i f tg a t e wi ndo w gl as s re le a s e s wi t ch e l e ct rica l co nnect o r . 8. D et a ch t he l i f t ga t e wi ndow g la s s wi ring ha rn es s ret a i ni ng cl i ps .
Insta llat ion 1. CAU TI O N : Make s ur e t h e l i ft ga t e w i nd ow gl a s s do e s no t cont act th e v e hi cl e bod y work whe n t he l i ft ga t e win do w gl a s s i s cl o s ed. Fa i l ur e t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n d amage t o t he ve hi cl e .
6. Connect t he de f r o s t gr id wi re e le ct rica l conne ct o r . 7. Att a ch t he de f r o s t grid wi re e l e ct rical c onn e cto r . 8. Connect t he na vig a t i o n s yst e m a nt e nna e l e c t r i cal co nnect o r. 9. Att a ch t he na vig a t i o n s yst e m a nt enna e l e ct r i cal co nnect o r.
11. Al i gn t he l if tg a t e wi nd ow gl as s t o t he li ft g a t e wi ndo w g l a s s a p e r t ur e. 12. Ti g ht e n t he l i ft ga t e w i ndow g la s s ret a i ni ng bol ts .
21. Loo s e n t he r e a r wip e r mot or r e t a i ni ng nut s . 22. Clo s e t he l i f t ga t e . 23. NO TE: T he a i d o f a n a s s i st a nt i n t he l oa ds pa ce wi l l be r eq uired t o a li g n t he r e a r wi p e r mot o r t o t he l i ft ga t e wi ndow g la s s .
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Fixed Window G las s Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear do or t r i m pa ne l . Fo r add it i o na l i nf orm at i o n, r e f er t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on .
6. D et a ch t he wi nd o w gl a s s a pe r t ur e s e a l . 7. Remove and di s card t he r i vet s. 8. D et a ch t he r e a r q uarte r wi ndo w gl a s s gui de rai l r et a i ni ng brack e t . 9. Remove t he ret a i ni n g s cr ews . 10. CAUT I O N: U s e care whe n r e mov i ng t he r e a r q uarte r wi ndo w gl a s s .
Insta llat ion 1. CAU TI O N : U s e care whe n i nst a l l i ng t he r e a r qu a r t er w i ndow g la s s . Fai l ure t o fo l l o w t he s e i ns t ruc t i o ns may r es ul t i n da mage t o t he wi ndow gl a s s a n d t he ext e r i or t r i m.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Win dow Gla ss Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear qua r t e r wind o w gl a s s . For add i ti ona l i nf o r m a t i o n, r e f er t o W i nd ow Gla s s —Re a r Q uarte r .
1. CAU TI O N : U s e care whe n i nst a l l i ng t he s l e e ve a nd t he pi n i nt o t he win do w gl as s . Fa il ure t o fo l l o w t he s e i ns truc t i o ns may r es ul t i n da mage t o th e wi ndo w g l a s s . I nst a l l t he p i n. 1. CAU TI O N : Make s ur e t h e s le e ve i s f i t t ed cent r al i n t he win do w gl as s .
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Win dow Re gulator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he do o r t rim p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 501-05 In t e r i o r Trim a nd Ornament a t i o n .
7. Remove t he rear do or wi ndo w r e gul a t o r. Insta llat ion 1. Ins t a l l the rear do o r wi ndo w r e gul a t o r . Ti ght e n t o 7 Nm. 2. CAU TI O N : S uppor t t he wi ndow g l a s s p r i o r to removal o f t he pr ot ect ive t a pe . Re move t h e pr o t e ct i ve t a pe from t he t op o f the w i ndow g l a s s .
4. NOT E: Ins ert t he gl a s s i nt o t he r e gul a t or gl a s s c l a mp a nd f i r mly pus hed dow n. Che ck b ot h s i de s of t he cl a mp have s na ppe d ove r t he s pace r br acket pi n. At t a ch t he wi ndo w gl a ss i nt o t he regul a t o r cla mp.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Do o r Win dow Re gulator and Mo tor Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Q uarter Wi ndow Gl ass Re moval a n d I ns t a l l a t i on Speci al T ool (s) S pray B ot t l e W K9 Lubr i cant Co ncent r at e .
2. Remove t he rear qua r t e r wind o w gl a s s fi ni she r t r i m. 3. Remove t he l o ad s p a ce t rim p a nel . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L o ads pa ce T r im P a ne l (501-05 I nt e r i o r Tr im a nd O rname nt a ti o n, Re m o val a nd Ins t al l a t i o n).
2. If t he o r i gi na l r e a r q uarte r wi ndo w gl a s s i s t o b e i ns t a l l e d r emove a ny r es i dua l a dhe s i ve from t h e r ea r qua r t e r wind o w gl a s s us ing t he s pe c i al t o ol . 3. Thoroughly cl e an r e a r quarte r wi n dow g la s s s u r f ace us i ng Be t a wi pe s p irit .
7. Cu t t he no z z l e o f t he JLM 20452 gl a s s bo ndi ng a dhe s ive t o a chi e ve a t r i an gul a r s e ct i o n be a d 8 m m (0.32 i n) wi d e b y 10 mm (0.
14. NO TE: Make s ur e th e r ea r qua r t e r wi ndow gl a s s a dhe s i ve ha s s e t bef o r e i ns ta l l i ng t he rear qua r t e r wi ndo w g l a s s e xt erio r we a t herst rip. I nst a l l t he r e a r qua r t er w i ndow g l a s s we a t he rst r i p.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Wi ndow G las s U sin g Che ese Wire Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he hi gh l e ve l s t op l a mp. For a ddi ti o nal i nfo r mat i o n, ref e r t o S ect i o n 417-01 Ex t e r i o r Li ght i ng .
6. D i s conne ct t he e l ect r i cal conne ct o rs. 7. D i s conne ct t he e l ect r i cal conne ct o r. 8. D i s conne ct t he e l ect r i cal conne ct o r. 9. Appl y s uit a b l e pr ot ect i ve t a pe a r o und t he wind s hi e ld gl a s s ape rtur e .
12. Prepare t he che e s e wi r e and the cut t ing hand l e . P os i t i on t he cut t i ng ha ndl e cen t r a l t ube f ul l y up wa r ds i n t he handl e. Cut a s ui t a bl e l e ng t h o f chee s e wire a nd pa s s o ne e nd t hrough t he handl e t ub e a nd t he l oca t i ng a pe r t ur e .
19. Appl y s ui t a bl e pr ot ect i ve t a pe t o t he wi nds hi e l d g la s s a pe r t u r e . 20. NO TE: T o ai d b on di ng of a ne w w i nds hi el d g l a s s , make s ur e a t l e a s t 1 m m (0.3 i n) of res i dual a d hes i ve r e mai ns on t he bo dy f l a nge .
3. Appl y gl a s s pr i mer t o th e ma t i ng f a ce o f the bod y f la nge . 4. Cu t t he a dhe s i v e noz z l e t o achi e ve a tria ng ul a r s e ct i on be a d 8 mm (0.
7. CAU TI O N : Make s ur e t h e wi nds hi e l d gl a s s d oe s not move o ut o f pos i t i on i n t he wi nds hi e l d g la s s a pe r t ur e . App l y s ui t a bl e p rot e ct i ve t a p e t o t he t op o f t he wi nd sh i e l d gl a s s . 8. Remove t he t a p e f rom t he i nne r e d ge o f t he r oo f pane l.
13. CAUT I O N: Do no t conne ct t he e l ect r i cal conne ct o rs fo r at le a s t 1 hour af t e r i ns t al l a t io n of t he wi nd s hi e l d gl a s s . Fa i l ur e t o f o l l o w t he s e in s t ruc t i o ns may r e s ult i n dama ge t o t he wi nd shi el d gl a s s a dhe s i v e.
19. CAUT I O N: Ma k e s ure t he wind s h ie ld gl a s s a dhe s i ve i s s e t bef o r e r e m o ving th e prot e ct i v e t a pe . Re move t h e pr o t e ct i ve t a pe from t he t op o f the w i nds hi el d g l a s s .
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - R ear Wi ndow G las s U sin g Cuttin g T oo l Re moval a n d I ns t a l l a t i on Speci al T ool (s) Lub r i cant conce nt rat e BTB -W .
3. Remove t he rear s e a t b a ck r es t l at ch co v e rs. 4. D et a ch t he pa rc el s he l f t r i m pa ne l . 5. D i s conne ct t he e l ect r i cal conne ct o rs. 6. D i s conne ct t he e l ect r i cal conne ct o rs. 7. D i s conne ct t he e l ect r i cal conne ct o r.
8. D i s conne ct t he e l ect r i cal conne ct o r. 9. Appl y s uit a b l e pr ot ect i ve t a pe a r o und t he wind s hi e ld gl a s s ape rtur e . 10. Pl a c e a p r ot e c t i ve s he e t ove r t he parcel s he lf a nd pl a ce a pr ot e ct i ve bo a r d o ver t he s he e t .
16. Appl y c ut t i ng l ubrica nt t o b ot h s i de s o f t he i nne r C -pi l la r wi nds hi e l d gl a s s a d he s i ve. 17. Ins t a l l t he cutt i ng t oo l cont r ol l e r arm BTB-W K11B t o t h e cut t in g t o ol BTB -W K10HD. S et the cut t ing cont rol l e r a rm t o 45 mm .
24. Remove t he wi nds hi e l d gl a s s . At t a c h l i ft ing ha nd l e s t o t he wi nds hi e l d gl a s s . 25. NO TE: T o ai d b on di ng of a ne w w i nds hi el d g l a s s , make s ur e a t l e a s t 1 m m (0.3 i n) of res i dual a d hes i ve r e mai ns on t he bo dy f l a nge .
4. Cu t t he a dhe s i v e noz z l e t o achi e ve a tria ng ul a r s e ct i on be a d 8 mm (0.31in ) wi de b y 13 mm (0.51 i n) hi gh. 5. NOT E: Appl y wi nds hi e l d a dhe s i ve W S S -M 2G3 79-A6A o r e qui val ent m e e t i ng Ja gua r s pe ci f i ca ti o n a r o und t he wi nd s hi e l d gl a s s edg e .
8. Remove t he t a p e f rom t he i nne r e d ge o f t he r oo f pane l. 9. Remove t he prot e ct i ve she e t a nd t he pr ot e ct i ve bo a r d f r om t he pa r cel s he l f . 10. Remove t he p rote c t i ve t a p e f r om a r o un d t he win ds hie ld gl as s a pe r t ur e .
14. CAUT I O N: Do no t conne ct t he e l ect r i cal conne ct o rs fo r at le a s t 1 hour af t e r i ns t al l a t io n of t he wi nd s hi e l d gl a s s . Fa i l ur e t o f o l l o w t he s e in s t ruc t i o ns may r e s ult i n dama ge t o t he wi nd shi el d gl a s s a dhe s i v e.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Windo w C ontro l S wit ch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on .
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Windshi eld Gl ass U s ing Ch eese Wire Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he s un vis o r s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 501-05 In t e r i o r Trim a nd Ornament a t i o n .
handl e. Cut a s ui t a bl e l e ng t h o f chee s e wire a nd pa s s o ne e nd t hrough t he handl e t ub e a nd t he l oca t i ng a pe r t ur e . Mov e t he cut t i ng h andl e ce nt r a l t ube do wnwa rd s t o s e cur e t he c he e s e wi r e. 10.
16. NO TE: T o ai d b on di ng of a ne w w i nds hi el d g l a s s , make s ur e a t l e a s t 1 m m (0.3 i n) of res i dual a d hes i ve r e mai ns on t he bo dy f l a nge . Us i ng a s ui t a b l e t o o l remov e t he re si dua l a dhe s i v e from t he bo dy f l a nge .
5. NOT E: Appl y wi nds hi e l d a dhe s i ve W S S -M 2G3 79-A6A o r e qui val ent m e e t i ng Ja gua r s pe ci f i ca ti o n a r o und t he wi nd s hi e l d gl a s s edg e .
10. Remove t he p rote c t i ve t a p e f r om th e w i nds hi el d g l a s s a p e r t ur e. 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Conn ect t he t he h ea t e d wi nd s h ie ld gl a s s e l e ct rical conn ect o r s . 12. Ins t a l l t he A-pi l l a r ext e r i or t r i m.
P ubl i s he d: 11-May-2 011 Gl ass, F rames and Mechanis ms - Windshi eld Gl ass U s ing Cu tting To o l Re moval a n d I ns t a l l a t i on Speci al T ool (s) Lubr i cant co nc e nt r at e BTB-W K9.
4. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Di s conn ect t he he a t e d wi nds hi e l d gl a s s e le ctrica l conne ct o r s . 5. Remove t he A-pi l l a r e xt e r i or t rim. 6. Appl y s uit a b l e pr ot ect i ve t a pe a r o und t he wind s hi e ld gl a s s ape rtur e t o pr ot e ct t he p a i nt wo r k.
12. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Us i ng t he cut t i ng t o o l, cut t hrough t he l owe r wi nds hi el d g l a s s a d he s i ve a nd a p pr oxi mat e l y 150 mm (5.9 i n) u p t he A-pi l l a r. 13. Appl y c ut t i ng l ubrica nt t o b ot h s i de s o f t he i nne r A-pil l a r wi nd s hi e l d gl a s s a d he s i ve.
19. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Us i ng t he s p e ci a l t o ol cut t hr o ugh a ny r e mai ni ng wi nds hi e l d gl a s s a dhe s i v e o n t he A -pil l a rs. 20. W i t h a s s i s t a nce remov e t he wi nds hie l d gl a s s .
3. Appl y gl a s s pr i mer t o th e ma t i ng f a ce o f the bod y f la nge . 4. Cu t t he a dhe s i v e noz z l e t o achi e ve a tria ng ul a r s e ct i on be a d 8 mm (0.
7. CAU TI O N : Make s ur e t h e wi nds hi e l d gl a s s d oe s not move o ut o f pos i t i on i n t he wi nds hi e l d g la s s a pe r t ur e . App l y s ui t a bl e p rot e ct i ve t a p e t o t he t op o f t he wi nd sh i e l d gl a s s . 8. Remove t he prot e ct i ve ta p e f r o m t he i nner l e a di ng e dge o f t he roof pa nel .
For a ddi ti ona l i nf o r m a t i o n, r e f e r t o S e cti o n 501-09 Re a r Vi e w Mi r r or s . 14. Ins t a l l t he cowl vent s cr ee n. For a dd i t i o na l i nf o r mat i o n, refe r t o S ect i o n 501-02 Fr ont End Bo dy P a ne l s . 15. Ins t a l l t he s un vis or s .
P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Instrum ent Panel Des cr ipt i o n a nd O pe r a t i o n I te m Pa r t Nu m be r Descri pti o n 1 — Le f t h a nd s i de regi s t e .
P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Floor Co n so le Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D et a ch t he e l e c t r o ni c p as s i ve a nt i -t he ft s ys t e m (PA TS) l i ght . 2. Remove t he P AT S l i g ht .
5. Remove t he ret a i ni n g s cr ews . 6. Remove t he ce nt e r cons o le t rim pa ne l . 7. Remove t he ce nt e r cons o le t rim pa ne l . 8. NOT E: Ri g ht hand s ho wn, le ft hand s i mil ar. Re move t h e r e t a i ni ng s cr e ws . Vehi c le s with autom at ic tra ns m ission JagDocs.
9. Remove t he J-gat e s ur r ound. Vehi c le s with ma nual tra nsmission 10. Det a ch t he ge a r s e l e ct o r s ur r ound. All v e h icle s 11. Remove t he ret a i ni ng s cr e ws. Vehi c le s with c or dle ss cell ular phone 12. Dis c o nne ct t he b l ue t oot h upgr a de modul e e l e ct rica l co nnect o r .
13. Remove t he f l o o r c on s o l e . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Instrum ent Panel Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he cons o l e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fl o o r Co ns o l e (501- 12 Ins t rum e nt P a nel a nd Co ns o l e , Re mov al a nd I ns t a l l at i o n).
All v e h icle s 11. Remove t he rig ht ha nd e nd pane l. 1. De ta ch t he f r ont doo r ope nin g we a t he r s t r ip . 2. Re move t he r i ght ha nd e nd pa ne l . 12. Remove s uppo r t pa nel . 13. Remove t he l ow er vent . 1. De ta ch t he bu lb ho l der.
16. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ew. 17. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ews . 18. Remove t he l ef t ha nd e nd p a nel . 1. De ta ch t he f r ont doo r ope nin g we a t he r s t r ip . 2. Re move t he l e f t hand e nd pa ne l .
21. Det a ch t he el e ct r i cal ha r nes s . 22. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ew. 23. Remove t he i ns t r ume nt pa ne l ret a i nin g s cr ews . 24. Remove a nd di s car d t he pop r i ve t s. 25. Remove t he i ns t r ume nt pa ne l .
1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Overhea d C o nso le Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r o of cons o l e . 2. Remove t he roof co ns ol e . Dis conne ct t he e l e ct r i cal co nnect o r( s ).
P ubl i s he d: 11-May-2 011 Instrum ent P anel and C o ns ol e - Overhea d C o nso le S w itch Mo ulding Re moval a n d I ns t a l l a t i on R em ova l • NO T E: S o m e va r i a t i on i n t he i l l ust r at i o ns may o cc ur, but the e s s e nt i a l i nf o r m a t i o n i s a l wa ys co r r ect .
4. CAU TI O N : Make s ur e t h at onl y t he hea d o f t he f i xing i s r e moved . Do no t d r i l l a ny de e pe r t ha n nece s s a ry . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on m a y r es ult i n da mag e t o t he compon e nt . Re move t h e pr i nt e d ci rc ui t boa rd (P CB) co ver .
7. Remove t he f o am pa d. 8. Car ef ul l y remove s unroof roc ker s wi t ch f or r eus e i n t he new r e a r s wit ch m o uld i ng. Insta llat ion 1. S e l e c t t he co r rect s wi t ch moul di ng fo r t he vehi c l e f r om t he pa rts ki t . 2.
8. Ins t a l l the co ver . Ins t al l t he 4 Torx s cr e ws Ti ght e n t o 1. 5 Nm. 9. Ins t a l l the ga r a ge d o o r op ene r modul e . 10. Ins t a l l t he f r ont i nt r us i on s e ns or.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - T o rque Sp eci f i cat ions Descri pti o n Nm l b- ft l b- i n Doo r l a t ch act uat o r r e t a i ni ng s cr e ws 7 - 62 .
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Handles, L ock s, Latc hes and E ntry Systems Des cr ipt i o n a nd O pe r a t i o n I te m P a rt N um b e r Desc ri pti on.
Item Pa rt N um be r Desc ri pti on 1 - L i f t g at e wi ndow gl a s s r e l e as e s wi t ch 2 - L i f t g at e wi ndow la t ch a ct uat o r 3 - L i f t g at e l a t ch a ct ua t o r 4 - L i f t g a.
K ey less Entry The i nt e gr at e d k e y remot e t rans mi t t e r op erat e s t he f ol l o wi ng f unct i on s : unl ocki ng th e dr ive r do or unl ocki ng/lo cking a l l do o r s r e l e a s i n.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Lo cks, Latches and En try Sy stem s Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
1 1 1 1 2 1 1 2 1 Sym tom ( Ge ner a l ) Sym ptom (Speci f i c) P os si bl e S ourc e A c ti on Doo r (s ) fa i l t o op e n An i ndi vi dua l d o o r f ai ls t o o p e n f r om t he e xt e r i o r ha.
Are a n y of t he cab le s d i sco nnect e d o r d amage d ? Ye s RECTI FY a s nece s s a ry . For a dd i t i o na l i nfo rm at i on, re fe r t o r e mova l a nd i ns t a l l a t i on i n th i s s ect io n. No CARRY OU T fun cti o nal t e s t s us i ng t h e Ja gua r ap pr oved d i a gnos t i c s ys t e m.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Remote T r ansm itter Programm in g Gene ral P r ocedures 1. NOT E: Al l r e mot e t r a ns mit t e rs a r e pr ogr a mm abl e an d mus t b e pr ogr a mmed a t t he s a me t i me.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Exterio r F ront Do o r Handle Re moval a n d I ns t a l l a t i on R em ova l 1.
6. Remove t he f r ont do o r ext e r i or ha ndl e . Insta llat ion 1. NOT E: Ins t a l l ne w f ront do o r s ecur i t y s hi e ld ret a i ni ng cli p s . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure. Ti ght e n t o 5 Nm. 2. Tig ht e n t o 7 Nm.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F ro nt Do or Lo ck A ctuato r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r t r i m pane l . For a dd i t i o na l i nf orm a ti on, re fe r t o S ect i on 501-05 Int e r io r Tr i m a nd Orna ment a t io n .
6. D i s conne ct t he f r ont d oo r l a t ch a ct ua t o r el e ct r i c a l co nnect o rs. 7. Remove t he f r ont do o r la tch a ctua t o r . 1. De ta ch t he f r ont doo r l a t ch a ct ua t o r r el e a s e c a bl e. 2. Dis con nect t he f ront do o r l a t ch a ct ua t o r r e l e as e ca bl e .
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F ro nt Do or Lo ck C y lin der Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont do o r ext e r i or ha ndl e . For a dd i t i o na l i nf or m a t io n, r e fe r t o Ha ndl e —Fr on t Doo r E x t e r i o r .
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F uel Fill er Do or Release Handl e and C able4- Doo r Re moval a n d I ns t a l l a t i on R em ova l • NO T E: T he p r o ce d ur e s ho wn is f or LHD ve hi cl e s . The pr oce dure is s i m i l a r fo r RHD ve hi cl e s .
8. Repo s i t i on t he f l o o r cove r i ng t o o ne s i de . 9. D et a ch t he r e a r d oo r o pe n in g we a t he r st rip a nd po s i t i o n t o o ne s i de . 10. Repo s i t i o n t he wi r i ng harnes s t o o ne s i de. Loo s e n t he r e t a in ing s cr e ws .
Vehi c le s bu ilt up to VI N: J38 978 13. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . 14. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . Vehi c le s bu ilt from VIN :J38 97 9 15. Remove t he l ugga ge co m pa r t ment fl oor covering .
18. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . 19. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . All v e h icle s 20. Det a ch a nd r e po s i t i o n t he RH re ar qua r t e r t rim pa ne l . 21. Remove t he f u el f i l l e r d oor rel e a s e cabl e.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - F uel Fill er Do or Release Handl e and C ableWagon Re moval a n d I ns t a l l a t i on R em ova l 1.
9. D i s conne ct t he s ub wo of e r e ncl os ur e e l e ct rica l co nnect or (i f e qui pp e d). 10. Remove t he s ubwo of e r e nclos ur e (i f e qui ppe d). 11. Det a ch t he fue l fi ll e r do o r r e l e a s e ca bl e . 1. Ro t a t e t he fu e l fi l l e r doo r r el e as e c a bl e cl o ck wis e .
14. Repo s i t i o n t he ca bl e t hr o ugh t he boo t . 15. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he f ue l f i l l e r doo r r e l e a s e ca bl e . Det ach f ue l fi l l e r do or r el e a s e ca bl e . 16. Det a ch fue l f i l l er do o r r e l e a s e ca bl e .
19. Remove t he f u el f i l l e r d oor rel e a s e ha ndl e. 1. De ta ch t he f ue l f i l l e r doo r r el e a se c a bl e f rom t he ha ndl e . 2. Re move t he f ue l fi l l er doo r r el ea s e ha nd l e . 20. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he f ue l f i l l e r doo r r e l e a s e ca bl e .
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Li ftgate Latch Actuato r Re moval a n d I ns t a l l a t i on R em ova l 1.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Li ftgate Window G las s Release S w itch Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear wi nd ow wi per pi vot a r m ret a i ni ng nut c ove r . 2. Remove t he rear wi nd ow wi per pi vot a r m.
5. Remove t he rear wi pe r m o unt i ng arm cover . 6. Remove t he rear wi pe r m o unt i ng arm . 7. Remove t he l i f t g a t e wi ndo w gl as s rel e a s e s wi t ch. Dis conne ct t he l i f t ga t e wind o w gl a s s r el e a s e s wi t ch e l e ct rical c on ne ct or .
2. Ins t a l l the rear wi p e r mount i ng arm . Ti ght e n t o 8 Nm. 3. Ins t a l l the rear wi p e r mount i ng arm cove r . 4. Ins t a l l the rear wi p e r mount i ng arm cove r r e t ai ni ng nut t r i m covers . 5. Ins t a l l the l if tg a t e wi nd ow gl as s re le a s e s wi t ch r e t a i ni ng nut .
7. Ins t a l l the rear wi nd ow wi per pi vot a r m ret a i ni ng nut . Ti ght e n t o 7 Nm. 8. Ins t a l l the rear wi nd ow wi per pi vot a r m ret a i ni ng nut cover .
14. CAUTI O N S : W i t h t he ai d o f a n a s s i s t a nt i n the l oa ds pa ce, f u ll y t i ght e n t he r ea r wip e r mot or r e t a i ni ng nut s . Fa i l ure t o f ol l o w t hi s i ns t ruc t i o n ma y r es ul t i n dama ge t o t he ve hi cl e .
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Luggage Com partm ent Lid L atc h Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l ugga g e co mpar t me nt l i d l a t ch a ct uat o r trim pa nel . 2.
P ubl i s he d: 11-May-2 011 Handles, Lo cks, Latches and E ntry Sy stems - Rear Door Lo c k Actuator Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear do or t r i m pa ne l . Fo r add it i o na l i nf orm at i o n, r e f er t o S ect i on 501-05 Int e r io r Tr i m a nd Orna ment a t io n .
6. D i s conne ct t he e l ect r i cal conne ct o rs. 7. Remove t he rear do or l a t c h a ct ua t or . 1. De ta ch t he rear do o r l a t ch act uat o r r e le a s e ca bl e . 2. Dis con nect t he r e a r d oor l a tch a ctu a t or rel e a s e cabl e.
P ubl i s he d: 11-May-2 011 Wipers and Was hers - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- f t l b- i n Fr o nt mount i ng a r m and p ivo t s h af t ret a i ni ng bol t s 8 - 7 1 Fr o nt .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p ers and W ashers Des cr ipt i o n a nd O pe r a t i o n Al l ve hicl e s Item Par t N um be r Desc ri pti on 1 — Mo is t ur e s e ns or 2 — .
Item P a rt N um ber D e scr i pti on 1 - Re a r wi ndo w wa s he r je t 2 - Re s e r voi r 3 - W i nds he i l d a nd rea r w i ndow wa s her mot o r 4 - Re a r wi ndo w wi pe r m ot o r 5 - Re a r wi.
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p ers and W ashers Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Headlam p Wash er P um p Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to S ect i o n 204-04 W hee l s a nd T ire s .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Rain S ensor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he i nt e r i o r r e a r vi e w mi rr o r . Fo r ad di t i ona l i n fo r mat i on, refe r t o S ect i o n 501-09 Re ar Vi e w Mi r r or s .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Rain S ensor Module Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he cowl s i de t rim pa ne l . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S ect i on 501-05 Int e r io r Tr i m a nd Orna ment a t io n .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Rear Windo w Wiper Motor Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l i f t g a t e t rim pa nel .
1. NOT E: Do not t i ght e n t he r ea r wind o w w i pe r mot or ret a i ni ng nut s a t th i s s t a ge . I nst a l l t he r e a r wi ndow wip e r mot o r.
6. M ake s ure t he r e a r wip e r m oun ti ng a r m i s i n t he pa r ked po s it i o n. 7. NOT E: The a i d o f a n a s si s t a nt in t he l o ads pa ce wi l l be r eq ui red t o a l ig n th e r ea r wi pe r mot or t o t h e l i ft ga t e wi nd o w gl a s s .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d and Rear Wi ndow Washer Pump Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he right -ha nd front whe e l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on).
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d Was her Pump Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to S ect i o n 204-04 W hee l s a nd T ire s .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d Was her Reservoir Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he ABS e l e ct r i cal co nnect o r. 2. D et a ch t he A BS modul e . 3. Remove t he ABS modul e s u pport brack e t ret a i ni ng b ol ts .
5. Remove t he res e rv o i r fi l l e r ne ck . 6. Remove t he f r ont bu m pe r cover . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o S ect i o n 501-19 Bumpe r s . 7. D i s conne ct t he he a dl a mp w as he r s uppl y hos e . 8. Remove t he res e rv o i r .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi ndshiel d Wi per M o to r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he mount i ng a rm a nd pi v ot s ha ft a s s e mbl y. For add i t i o na l i nf o r ma t i o n, r e f e r t o Mount i ng Arm an d P i v o t S haf t .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p er Mou nting Arm a nd Pivot Shaft Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he pl enum cove r . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S e ct i on 501-02 Fr ont En d B od y P a ne l s .
P ubl i s he d: 11-May-2 011 Wipers and Was hers - Wi p er Pivot Arm Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover - wi nd s cr ee n wi pe r 501-065 R em ova l 1. Remove t he wi p er arm nut co vers 2. Remove t he wi p er arm nut s .
Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 17 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b- i n Roo f o pen ing pa ne l frame ret a i ni ng bo l t s 9 - 80 Roo f o pen ing pa ne .
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Des cr ipt i o n a nd O pe r a t i o n Item Pa rt Nu mb e r Descri pti on 1 — Roof o pe ni ng pa ne l s hi e l d 2 — Lif.
- Th e roof op e ni ng gl a s s wi l l cl o s e unt i l the roo f op e ni ng pa ne l s wi t ch i s pres s e d i n a ny di rect i o n o r t he r oo f o p eni ng gl a s s r ea che s t he f ul l cl os e d po s i ti o n.
* * * * * * * P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Dia gn os i s a nd Te s t i ng Principles of Ope ra tion Roof Op en ing Pan el Control Modu le Ba t t e r y po we r i s cont i nuo us l y s uppl i e d t o t he r o o f op eni ng pane l co nt r ol mod ul e .
* * * * * * * * * * * * * * * * * * * * * * * 1 2 1 1 1 1 1 1 The roof o pe ni ng p a ne l i s no i s y du r i ng o pera ti o n Ro o f ope ni ng p a ne l gl a s s . Roo f ope n ing p a ne l . Roo f ope n ing p a ne l mot o r . GO t o Pi npoi nt T es t C.
1 1 1 1 No GO t o C3 . C 3: C HEC K T HE R O OF O PE NI NG PAN EL MO T O R Cycle t he r o of o pe nin g g l a s s f r om t he ful l -ope n t o t he ful l -cl o se d pos i t io n. Doe s t he r o of o pe ni ng pa n el mot or make e xc e s s i ve no i s e ? Ye s CHECK t he r o of o pe n in g p a ne l mot o r for cor r e ct mo unt i ng.
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Mot or Synchroniz atio n Gene ral P r ocedures Ne w R oof Ope n ing Pan e l Motor Synch roniza tion Procedure • NO T E: T he roof op e ni ng pa .
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel A li gnment Gene ral P r ocedures 1. Pl a ce a s ui t abl e 1.0 - 1.2 mm t h ick p la s t i c s p a cer be t we e n t he roof op e ni ng pa ne l a nd t he roof p a ne l . 2. Adjus t t he r e ar e dge o f t he r o o f op e ni ng pa ne l .
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Air Deflec to r Re moval a n d I ns t a l l a t i on R em ova l 1. M ove t he roof ope nin g p a ne l gl a s s ful l y rearwar d. 2. D et a ch t he a i r de f l e ct or. 3. Remove t he a i r de f l e ct or.
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Li fter Arms Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roof o pe n in g p a ne l gl a s s . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o Roo f O pen i ng P ane l Gla s s .
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel C ontro l S wit ch Re moval a n d I ns t a l l a t i on 1. Remove t he ove r he a d co ns o l e . Fo r a ddi t i ona l i nfo r m at i o n, r ef e r t o S ect i o n 501-12 Ins t r ument P a nel a nd Co ns ol e .
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Drain H os e Re moval a n d I ns t a l l a t i on R em ova l 1. D et a ch t he r e a r q uarte r t r i m pa ne l . 2. D et a ch t he drai n hos e f r o m t he r et ai ni ng cl i p.
6. Remove t he drai n ho s e. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com.
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Fra me Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roof o pe n in g p a ne l gl a s s . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o Roo f O pen i ng P ane l Gla s s .
7. D et a ch t he r o of o pen i ng p ane l r ea r dr a i n ho se s . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . 8. D et a ch t he r o of o pen i ng p ane l frame . 9. Remove t he roof o pe n in g p a ne l frame ret a i ni ng br acket s.
12. Remove t he roof o pe ni ng pa ne l m o to r. 13. Remove t he a i r de f l e ct o r . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . 14. Det a ch t he cont rol a r m s . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r .
17. Remove t he l i f t e r a r ms . Rig ht -ha nd s i d e s ho wn, l e ft -hand s id e s i mil a r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 9 Nm. 2. Tig ht e n t o 9 Nm. 3. Tig ht e n t o 9 Nm. 4. Tig ht e n t o 3 Nm.
5. CAU TI O N : If mot o r os ci ll a t i o n i s de t e ct e d , l o o s e n t he mot o r s cr ews , o p e r at e t he r o o f op e ni ng pa ne l , th e n ret i ght e n t he mot o r s cr ews . If ne ce ss a r y r ep e at t hi s pr ocedu r e . S ync r oni z e t he r oo f o peni ng pan e l mot o r .
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Gl ass Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Make s ur e t he roof o p e ni ng pa ne l gl a ss i s i n t he cl o s e d po s i t i o n. 1. Remove t he roof o pe n in g p a ne l gl a s s s cr ew s.
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Moto r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he ove r he a d co ns o l e . Fo r a ddi t i ona l i nfo r m at i o n, r ef e r t o S ect i o n 501-12 Ins t r ument P a nel a nd Co ns ol e .
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Shi eld Re moval a n d I ns t a l l a t i on R em ova l 1. Parti a l ly o pe n t he r o of o pe nin g p a ne l . 2. D et a ch t he f ront o f t he r o o f o pe ni ng pa ne l s hi e l d.
P ubl i s he d: 11-May-2 011 Roo f O p ening Pa nel - Ro of Ope ning P anel Weatherstrip Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he roof o pe n in g p a ne l gl a s s . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o Roo f O pen i ng P ane l Gla s s .
P ubl i s he d: 11-May-2 011 B umpers - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Fr o nt b umper cover uppe r s e cur ing bo l t s 7 5 - Fr o nt b umper cover s i d e s e cur in.
P ubl i s he d: 11-May-2 011 B umpers - Bum pers Des cr ipt i o n a nd O pe r a t i o n Thi s ve hi cle i s f it t e d w i t h a cha s s is mount e d a l umi ni um be a m a nd i s c ove r ed b y a on e pi e ce col o r co-o r di na t e d f ront bum pe r cover whi ch in cor po r at e s t he en e rg y a bs o r bi ng f o a m .
P ubl i s he d: 11-May-2 011 B umpers - F ron t B umper Co v er Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he radi a t o r s pl a s h s hie ld r et ai ni ng bo l t s . 2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r .
5. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . App l y s ui t a bl e t a p e t o t he b ump e r cover t o prevent da mage t o t he bumpe r c o ver . 6. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Re po s i t i o n t he hea d la mp wa s hers t o t he f ul l y o pe n po s i t i o n.
9. CAU TI O N : Make s ur e t h e bu m pe r c o ver i s s up porte d bef or e r e m o ving th e s e cur ing bo l ts . • NO T E: L ef t -hand s hown, right -ha nd s imi l a r . Re move t h e bu m per cove r . Re mov e t he b umper cover s e cur ing b ol t s .
P ubl i s he d: 11-May-2 011 B umpers - F ron t B umper Co v er Insert Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont bu m pe r cover . For a ddi ti o nal i nfo r m a t i o n, r e f e r t o S ect i on 501-19 Bumper s . 2. Remove t he e ne r gy a bs or bi ng fo a m.
P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per4- Door Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a dd i t i o na l i nf orm a t i o n, r e fe r t o Bumpe r Cover—Rea r . 2. Remove t he bumpe r i ns ul a t or.
P ubl i s he d: 11-May-2 011 B umpers - Rear Bum perWag o n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Bumper Cove r - W a go n (501-1 9 Bumpe r s , Re moval a nd I ns t a l l a t i on).
P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co ver4- Door Re moval a n d I ns t a l l a t i on R em ova l All Ve hicles 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng .
7. D i s conne ct t he e l ect r i cal conne ct o r. All v e h icle s 8. D i s conne ct t he e l ect r i cal conne ct o r. 9. D et a ch t he gromm et .
11. Det a ch t he s i d e o f t he b umper cover. 12. CAUT I O N: Ma k e s ure t he bumper cover i s s up porte d be f o r e r e m o ving th e s e cur ing nut s. Re move t h e bu m per cove r se cur i ng nut s . 13. Remove t he b umper cover . Insta llat ion 1.
4. Tig ht e n t o 7 Nm. 5. Tig ht e n t o 7 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co verWa go n Re moval a n d I ns t a l l a t i on R em ova l All Ve hicles 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n).
7. D et a ch t he l o a d s p ace f lo o r covering. 8. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt ret a i ni ng screw. 9. Remove t he l e ft -hand lo a d s p ace s t owa ge compa r t m e nt . 10. Det a ch t he modul e ret a i ni ng brack e t .
12. Dis c o nne ct t he co mpact d i sc (CD) change r e l e ct r i cal c onn e cto r s (i f e qui pp e d). 13. Dis c o nne ct t he vo i ce a ct i vat e d cont r o l (VACM) modul e e l e ct r i ca l conne ct ors (i f e qui p ped ). 14. Dis c o nne ct t he ce l l ul a r pho ne mod ul e e l e ct rica l co nnect o r s (i f e qui pp e d).
17. Det a ch t he r igh t -ha nd l oa d s p ace s i de t rim p a nel . 18. Remove t he rig ht -ha nd l o a d sp a ce s i de t rim p ane l . 19. Dis c o nne ct t he s ubwo of e r e nclos ur e e l e ct rical conn ect or (i f e q ui pp e d) . 20. Remove t he s ubwo of e r e nclos ur e (i f e qui ppe d).
22. CAUT I O N: Ma k e s ure t he bumper cover i s s up porte d be f o r e r e m o ving th e ret a i ni ng nut s . Re move t h e bu m per cove r r e ta i ni ng nut s . Vehi c le s with park ing aid 23. Dis c o nne ct t he e l e ct r ica l conne ct o r .
2. Tig ht e n t o 4 Nm. 3. Tig ht e n t o 4 Nm. 4. Tig ht e n t o 4 Nm. 5. Tig ht e n t o 4 Nm. 6. Tig ht e n t o 4 Nm. JagDocs.com.
7. Tig ht e n t o 8 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co ver Insert4-D oo r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i on 501-19 Bumper s . 2. Remove t he e ne r gy a bs or bi ng fo a m.
P ubl i s he d: 11-May-2 011 B umpers - Rear Bum per Co ver InsertWagon Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear bumper cover. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Bumper Cove r - W a go n (501-1 9 Bumpe r s , Re moval a nd I ns t a l l a t i on).
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - T o rque Sp eci f i cat ions Desc ri pti on N m l b- f t l b -i n Fr o nt s a fe t y be lt b uck l e a nd pr et en s i o ne r r e t a i ni ng bol t .
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Safety Be lt System Des cr ipt i o n a nd O pe r a t i o n • W ARNINGS : To a voi d accid e nt a l de pl o y ment a nd po s s i bl e pe rs ona l i.
(gene r i c e l e ct roni c modu le ) ) o f an i nt erm i t t e nt t one wi ll s t a rt or r e s ume a ccompani e d by t he s e a t be l t wa r ning la mp f l a s hi ng i n t he in s t r um en t clus t e r .
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Safety Be lt System Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e .
cor r e ct b y l oo s e ni ng t he r e t a i ni ng bol t , a l i gni ng t he r et r act o r t o ce nt ral i z e t he s a fe t y bel t we b bi ng a nd ret i ght e n t he bol t . The vehi cl e i s e qui ppe d wit h t wo f r o nt a nd t hree r ea r i ne rti a r ee l s a fe t y b el ts .
1 2 3 4 5 6 7 8 DT C C ondi ti o n Poss i bl e s ource Ac ti on pr et e ns i one r circ ui t fa u lt s qu i b t e s t s , GO t o P i npo i nt T e s t E.
1 2 3 4 5 6 1 1 1 1 1 1 2 3 Ar e t h e r e a ny DTCs a nd/or f la s h co de s se t wi t h t he s i mula t o r( s ) i n p la ce ? Ye s GO t o A 2 . No INS TA LL a ne w pr e t e ns i o ne r . REFER t o : Safe t y Be lt B uck l e a nd P r e t e ns i one r (501-20 A S a fe t y Bel t Sy st e m, Re moval a nd I ns t a l l a t i on).
4 5 6 7 8 1 2 3 4 5 6 1 1 1 1 1 1 Conne ct t he s i mula t or i n pl a ce of t he p r e t e ns i o ne r . Re conne ct t he b a t t e r y ne g a t i ve te r mina l . Cle a r th e DTC. Tur n t he i gn i t i on s w i t ch t o t he O N po s i t i o n. Re check t he DTCs an d fl a s h co de s.
2 3 4 5 1 1 1 1 1 2 3 4 5 1 W a it o ne mi nut e f o r t he ba cku p pow er s u ppl y t o de p l e t e. Di s c onn e ct t he RCM c on ne ct or , For ve hi c l e s wi t h 2. 0L e ngi ne; CA165. For ve hi c l e s wi t h 2. 5/3.0L en gi ne ; CA450. Di s c onn e ct t he dr i ver s a f e t y be l t s wi t ch co nnect o r, CA 65.
1 1 1 1 2 3 4 5 6 7 8 1 2 3 4 5 1 I s t he r es i s t a nce l e s s t ha n 10,000 o hms? Ye s REP AI R t he sh ort c i r cuit . For a ddi t i o na l i nfo rm at i o n, r ef e r t o t he wiring di a grams. Cl e a r t he DTC, t e s t t he s ys t e m fo r nor mal o p e r at i o n.
1 1 1 1 1 2 3 4 5 6 7 8 1 2 3 4 5 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . Cl e a r t he DTC, t e s t t he s ys t e m fo r n or mal o pe r a t i o n.
1 1 1 1 1 1 2 3 1 1 1 1 No GO t o F3 . F3: C HEC K T HE RE T R ACT OR PR ET E NS IONER GR O UND CI RC UIT F O R H IGH RE SI ST AN CE Mea s ur e t he res i s t a nce b e t we e n CA422, pi n 03 (B R) a nd t he RCM conne ct o r, pi n 38 (BR). I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit .
1 1 1 1 GO t o G6 . G6: CHEC K T HE BELT T ENSI ON SEN SOR GR O UND CI R C UI T FOR S HOR T C IRC UI T T O BA T T ER Y Meas ur e t he res is t a nce b e t we e n W S 1 9, p i n 03 (G) and t he ba t t e ry p os i t i v e t e rm ina l . I s t he res i s t a nce l e s s t ha n 10, 000 ohms? Ye s REPAI R t he s hor t cir cui t .
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - F ront Safety Bel t Retractor Re moval a n d I ns t a l l a t i on R em ova l • NO T E: T he f r o nt s e a t be l t s , whi ch i ncor po r at e t he s e at be l t r e t r a cto r s a nd p r e te ns i o ne r s are s up pl i e d a s an a s s e m bl y and no t s e r vi cea bl e compone nt s .
Insta llat ion • NO T E: T he f r o nt s e a t be l t s , whi ch i ncor po r at e t he s e at be l t r e t r a cto r s a nd p r e te ns i o ne r s are s up pl i e d a s an a s s e m bl y and no t s e r vi cea bl e compone nt s . • NO T E: Re p ai r is made by r e pl a ce ment o nl y.
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - F ront Safety Bel t Sho ulder Hei g ht Adj uster Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he uppe r B-pil l a r t r i m pa ne l fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S ect i o n 501-05 Int e r i or Trim a nd O rn ament a t i on .
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r C enter Safety Belt Retra cto r4-Door Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Re p ai r is made by r e pl a ce ment o nl y.
2. Tig ht e n t o 55 Nm. 3. NOT E: Make s ure t he an t i r ot a t i on pi ns o n t he bo dy a nd s a f e t y b e l t a nchor pl a t e a r e l o c a t e d corr e ct l y be fo re t ig ht e ni ng the bo l t .
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r C enter Safety Belt Retra cto rWago n Re moval a n d I ns t a l l a t i on R em ova l 1. D i s a s s e mble t he r e a r se a t ba ck res t .
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r Safe ty Belt Bu ckle Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n fo r a ddi t i o nal i nfo r mat i o n, ref e r t o S ect i o n 501-10 S e at in g . 2.
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r Safe ty Belt Retractor4-Door Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Re p ai r is made by r e pl a ce ment o nl y.
1. To i ns t a l l r evers e t he r emova l pr oced ure. Ti ght e n t o 55 Nm. 2. Tig ht e n t o 55 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Rea r Safe ty Belt RetractorWago n Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l o ad s p a ce t rim p a nel .
2. Tig ht e n t o 55 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Safety Belt S y stem - Safety Be lt Bu ckl e and Pr etensio n er Re moval a n d I ns t a l l a t i on R em ova l • W ARNINGS : To a voi d accid e nt a l de pl o y ment a.
6. Remove t he s a f e t y be l t buckl e a nd pr e t e nsi one r. Re mov e t he re ta i ni ng bo l t . Insta llat ion • W ARNINGS : To a voi d accid e nt a l de pl o y ment a nd po s s i bl e pe rs ona l i nj ur y, t he backup pow er s up pl y mus t be de p l e t e d b e fo r e r ep a i r i ng o r r epl aci ng a ny a i r ba g O RS compone nt s .
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P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Air Ba g Supplemental Restrain t System (SRS) Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: A l l pyr ot e chni c de vi ces a r e da nge r o us .
The pr i mar y purpos e o f t h e res t r ai nt s cont rol s ys t e m i s t o di s cr i mina t e be t we e n a n e vent t hat wa r r a n ts s upp l e ment a l res t rai nt s s yst e m de p lo yment a nd a n e vent t ha t doe s no t .
The s e at t r ack po s i t i o n s e ns or: The s e at t r ack po s i t i o n s e ns or i s l o ca t e d o n t he d river s e a t t r a ck. The s e a t p o si t i o n s e ns o r de t e rm ine s t he po si t i o n o f t he dr ive r s e a t , which i s t hen com muni c a t e d t o t he r es t r a i nt s cont r ol modul e .
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Air Ba g Supplemental Restrain t System (SRS) Dia gn os i s a nd Te s t i ng Principle of oper at ion The S RS is a n in t e ll i ge nt s.
W a rning l i ght ON s o l i d f o r s i x s e conds . W a rning l i ght goe s o f f fo r t wo s e c o nds . W a rning l i ght fl as he s t he a ppr o pr ia t e numbe r of t i m e s fo r t he f aul t l o gge d (s e e be l o w). W a rning l i ght goe s o f f fo r t wo s e c o nds .
DT C / Fl a sh cod e C o ndi ti on Poss i bl e s ource Acti on B2294 Cur t a i n ai r bag circ ui t s t a t us fa ul t Pa s s e nge r cur t a i n ai r ba g ci r cui t; st a t us fa ul t For cur ta i n a i rb a g ci r cuit t e s t s , GO t o P i npo i nt T e s t D.
1 2 3 4 5 1 2 1 2 1 2 1 2 1 2 DT C Co ndi ti on P ossi bl e sou rce Act i on B2290 O cc upant cl a s s i f i ca t i on se n s o r (O CS ) s yst e m f a ul t OCS modul e communicat io ns f aul t For communica ti on ci r cuit t e s t s , GO t o P i npoi nt T e s t N.
1 1 2 3 4 5 6 7 1 2 3 4 5 1 Is t he res i st a nce g r ea t e r t h an 5 o hms ? Ye s REPAI R t he hi gh r e s i s t a nce ci rc uit . Fo r ad di t i on a l in f o r ma t i o n, r e f er t o t he wi r i ng di a gr a m s . Cle ar t he DTC, t e s t t he s yst em f o r norm al ope rat i on.
1 2 1 1 2 3 4 5 6 7 1 2 3 4 I P 37, pi n 01 (RW ) a nd t he RCM co nnect or , pi n 13 (RW ) I P 37, pi n 02 (BW ) a nd t he R CM connect or, pi n 14 (BW ) Are a n y of t he r e s i s t a nce s gr ea t e r t ha n 5 o hms ? Ye s GO t o C4 . No I NS TALL a ne w RCM.
5 1 2 3 4 5 6 7 1 2 3 4 5 CA450. Mea s ur e t he res i s t a nce b e t we e n: For fl a s h code 24 The RCM conne ct o r , p i n 03 (RW ) a nd CA 144, p i n 01 (RW ) The RCM conne ct o r , p i n 04 (B.
1 2 3 4 5 6 1 2 3 4 1 1 2 3 4 5 6 1 2 3 I NS TALL a ne w RCM. REFER t o : Re s t r ai nt s Co nt rol Modul e (RC M) (501-20B S uppl e ment a l Re s t rai nt S y s t e m, Re moval a nd I ns t a l l a t i o n). Cl e a r t he DT C, t es t t he s ys t e m f o r n or mal o perat i o n.
4 1 1 2 3 4 5 6 1 2 3 4 1 For ve hi c l e s wi t h 2. 5/3.0L en gi ne ; CA450. Mea s ur e t he res i s t a nce b e t we e n CA215, pi n 02 (W ) a nd t he RCM conne ct o r , p i n 27 (W ). I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit .
1 2 3 4 5 6 1 2 3 4 1 1 2 3 4 5 6 1 2 3 W ARNI N G: T o a voi d a cci den t a l de p lo yment a nd po s s i bl e pe r s o na l i nju r y , t he ba ckup po w e r s uppl y mus t b e de pl e t e d be f or e repa i r i ng or r ep l a cing any ai r b ag SRS compone nt s .
1 2 3 4 5 6 7 8 1 2 3 4 5 1 1 1 2 3 4 5 W ARNI N G: T o a voi d a cci den t a l de p lo yment a nd po s s i bl e pe r s o na l i nju r y , t he ba ckup po w e r s uppl y mus t b e de pl e t e d be f or e repa i r i ng or r ep l a cing any ai r b ag SRS compone nt s .
1 1 1 1 1 2 3 4 5 1 1 1 No GO t o L 2 . L2: CHEC K T HE DRI VER SEAT T R ACK PO SI T ION SEN SOR S UP PLY CIRC UIT FOR SHOR T CI R C UIT T O BA T T ER Y Mea s ur e t he res i s t a nce b e t we e n CA65, p in 20 (U ) a nd t he b a t t e r y p o s i t i ve t e r mi nal .
1 1 2 3 4 5 1 1 2 1 1 1 1 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s REP AI R t he hi gh r es i s t a nce ci r cuit . For ad di t io na l i nf o r mat i o n, refe r t o t he wi ring d i a grams . Cl e a r t he DTC, t e s t t he s ys t e m fo r n or mal o pe r a t i o n.
1 1 1 1 1 2 1 No GO t o N8 . N8 : CHEC K T HE 5V C IRC U IT BET W EEN T HE OC S A ND T HE SEAT T R ANS DUCE R FOR S HOR T C IRC UI T T O GR O UND Mea s ur e t he res i s t a nce be t we e n W S 17, pi n J (W ) and GROU ND. I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he s h or t ci r cuit .
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Air Ba g Dispos al Gene ral P r ocedures Deployed A ir Ba g 1. W ARNING: A l wa ys wea r s a fe t y g la s s es when r e pa i ring a n a i r b ag s uppl e men t a l r e s t rai nt s y s t e m (S RS ) v e hi cl e a nd whe n ha ndl i ng a n a i r ba g m o dul e .
8. W ARNING: Be f ore p roc e e di ng , make s ur e precaut i o ns have be e n ta ke n t o wa r n pers o nnel of a p os s i b l e l o ud noi s e upon a ct i vat i o n. Do not a ll o w a n y bo dy t o a pproa c h cl os e r t o res t r a in t de vi ce t han s i x m e t e r s .
3. W ARNING: Make s ur e t ha t t he t yre s t a ck is s t ab l e b e f ore a nd a f te r dep l o yment . Fai l ure t o f o l l o w t hi s i nst ru ct i o n my r es ul t i n p e r s ona l i njur y.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - C lo cksprin g Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : Al wa ys we a r s a fe t y gl a s se s w he n r e pa i r i ng a n a i r ba g s upp l e ment a l r e s t rai nt s s yst e m (S RS ) vehi cl e a nd whe n ha ndl i ng a n a i r ba g m od ul e .
3. Remove t he s t ee ring co l umn uppe r s hr ou d. 4. D i s conne ct t he mul t i f unct i on s wi t c h el e ct r i cal co nnect ors. 1. Re move t he mult i f unct i o n s wit ch s pr i ng. 2. Dis con nect t he mult i f unct i o n s wi t ch e l e ct r i cal c onn e cto r s .
pers o nal i njur y. • NO T E: A repai r is mad e by r e pl a ce men t onl y. I f a pa r t is re pl a ced and th e new part d oe s n ot c orr e ct t he co ndi t io n, in s t a l l t he o r i gi na l part a nd c a rr y out t he di a gno s t i c pr oced ur e a ga i n.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - C rash S enso r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i b.
Ne ve r pr obe t he e l e c t rical co nnect ors o f a i r ba g modul e s or any o t her s up pl e ment a l res t r a i nt s ys te m (S RS) compone nt . Fai lur e t o fo l lo w t hi s i ns truc t i o n may r e s ul t i n p e r s o nal i njur y. • NO T E: Re p ai r is made by r e pl a ce ment o nl y.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Driver Air Bag Mo d ule Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : An RCM modul e o nl y r e qui r e s r e pl a ceme nt i f t he s ys t e m ha s incur red fi v e s e pa rat e de pl o yment s .
3. D i s conne ct t he drive r ai r b a g modul e e l e ct r i cal co nnect o r. 4. Remove t he drive r ai r ba g modul e . Dis conne ct t he d river a i r ba g modu le el e ct r i cal co nnect o r.
3. NOT E: Make s ure t he driver a i r ba g mod ule s na p f it co nne ct o r s a re ful l y s ea t e d. I nst a l l t he d r i v e r a i r ba g mo dul e.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Driver Lo wer Air B ag M o dule Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt s cont rol (RCM ) modul e o nl y requi r e s repl a cement i f t h e s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s.
3. D et a ch t he r i ght -hand drive r l o we r a ir ba g modul e ret a i ni ng cl i p. 4. D et a ch t he l e f t -hand drive r lo we r a i r ba g mod ul e r et ai ni ng cli p. 5. Remove t he drive r lo we r ai r ba g modul e . Dis conne ct t he d river l owe r a ir ba g modul e e l e ctrical co nnect or.
2. NOT E: Make s ure t he driver l o we r ai r ba g mod ul e r et a i ni ng cl i p s a r e f ul l y s ea t e d. I nst a l l t he d r i v e r l ow er ai r ba g m o dul e .
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - O ccupant C las si ficatio n Sen sor Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y.
5. Remove t he e l ect r o nic cont rol uni t (ECU). 1. Re move t he t wo cl i ps . 1. Remove th e ECU. 6. D i s conne ct t he e l ect r i cal conne ct o r fr o m t he s e ns or. 7. D et a ch t he wi ring ha r ne s s f r om t he s e a t ba s e by cut t i ng a nd r emovi ng t he cabl e t i e s .
10. Remove t he s e a t b as e ret a i ni ng nu ts . 11. Det a ch t he pa s s e nge r wei gh t s e n so r e l e ctrica l conne ct o r f rom t he r et a i ni ng cl i p. 12. Remove t he s e a t cove r . Uncl i p t h e s e a t cover from t he s e a t bas e .
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Passenger Air B ag Deactiva tio n (PA D) Indica tor Re moval a n d I ns t a l l a t i on R em ova l 1.
6. Remove t he P AD i ndi ca t o r . Dis conne ct t he e l e ct r i cal co nnect o r. Insta llat ion 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s s i bl e pe rso na l i nj ur y,.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Passenger Air B ag Module Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt s cont rol modul e (RCM) o nl y requi r e s repl a cement i f t h e s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s.
4. D et a ch t he pa s s e nge r f i nis h p a ne l . 5. Remove t he pa s se n ge r a i r ve nt . 6. W ARNING: Di sco nnect t he pa s s e n ger a i r bag modul e right -ha nd e l e ct r i cal conne ct o r bef or e t he l e f t -ha nd e l e ct rical conne c t o r .
9. Remove t he pa s se n ge r c o mpartment f i ni s he r trim. 10. Remove t he p a s s e ng e r compa r t m e nt . Re mov e t he p a s s eng e r compa r t me nt ret a i ni ng s cr ews . 11. Dis c o nne ct t he p a s s e ng e r compa r t m e nt l amp e le ctrica l conne ct o r .
Ca r r y a l i ve a i r ba g modul e wi t h t he a i r ba g a nd de p lo yment d oor poi nt e d a wa y f r om your bod y. T hi s wi ll r e duce th e r i s k of i njur y i n t he e v e nt o f a n a cc i d ent a l de pl o ym e nt . Ne ver probe t he conne ct o r s o n t he a i r bag modul e .
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Restraints C ontro l M odule (RCM) Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y m.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Seat P os itio n Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd p.
Ne ver probe t he el e ct r i cal co nnect o rs o f a i r ba g mod ul e s o r any ot he r s uppl ement a l r e s t rai nt s y s t e m compone nt . Fai lu r e t o fo l l o w t hi s r e s t rai nt s yst e m compone nt . Fa il ure t o f ol l ow th is i ns t r ucti o n ma y r e s ul t i n pers o nal i njur y.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Side Air C urtain Module4-Doo r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt cont r ol mod ule (RCM) onl y req ui r es rep l a c e ment i f t he s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s.
4. NOT E: To ai d i ns t a l l a t i o n, n ot e t he rout i ng of t he re ta ini ng cord. Det ach t he s i d e ai r cur ta i n m o dul e co r d from t he ret a i ni ng cl i p. 5. D i s conne ct t he s i d e ai r cur ta i n m od ul e e l e ct r i cal co nnect o r.
1. W ARN INGS : An res t r a i nt c on t r ol mod ul e (RCM) o nl y r e qui r e s repl a cemen t i f t he s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s. A t no t i me chang e a n RCM fo r l es s t ha n fi ve s e parat e de p l oyment s .
5. Ins t a l l the s i d e ai r cur t a i n modul e cord r et a i ni ng bo l t. Ti ght e n t o 9 Nm. 6. Ins t a l l the he a d li ne r . For ad di t io na l inf o r mat i o n, refe r t o S e c t i o n 501-05 I nt e r i o r Tr im a nd O rname nt a ti o n .
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Side Air C urtain ModuleWago n Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : A r e s t rai nt cont r ol mod ule (RCM) onl y req ui r es rep l a c e ment i f t he s yst em ha s i ncur re d f ive s e pa rat e de pl o ym e nt s.
4. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Det ach t he f r ont d o or o pe n ing we a t he r s t rips . 5. Remove t he A-pi l l a r t rim p a nel s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: A-P i l l ar Trim P a nel (501-05 Int e r i o r Tr i m a nd O r na m e nt a t io n, Re mov al a n d I ns t a l l a t i o n).
10. Le ver o pen the co ver s t o e xpos e t he s cr e ws a nd remove t he drive r a nd pa s se n ge r as s i s t ha n dl e s . 11. Remove t he D-pi l l a r t rim p a nel s.
16. Dis c o nne ct t he rea r was he r hos e co nne ct o r . 17. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he ret a i ni ng c ord. Re move t h e s id e a i r cur t a i n mod ul e f r on t cor d ret a i ni ng bol t . 18. NO TE: T o ai d i ns t a ll a t i o n, no t e t he rout ing of t he ret a i ni ng c ord.
21. Remove t he s i de a i r cur ta i n modul e . 1. Re move t he r e t a i ni ng bo l t s . 2. De ta ch t he ret a i ni ng c l i p . Insta llat ion • W ARNINGS : An res t rai nt cont r ol mod ule (RCM) onl y req ui r es rep l a c e ment i f t he s ys te m ha s i ncurr e d f i ve s e p a r at e d e pl o ym e nt s .
3. Tig ht e n t o 9 Nm. JagDocs.com.
P ubl i s he d: 11-May-2 011 Supplemental Restraint S y stem - Side I mpact Sens o r Re moval a n d I ns t a l l a t i on R em ova l 1. W ARN INGS : To a voi d a ccid e nt a l de pl o y ment a nd po s.
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Speci fi ca ti on Bus h i ns t al l a t i on l ubr ica t i on S hel l.
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Frame Ass embly Des cr ipt i o n a nd O pe r a t i o n FRONT SU B-FRAM E A SS EMBLY The front s ub-f rame i s bol t e d to the bo d y an d a i d s i n s t ruc t ur al s uppo rt.
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - U nderbody Mis alignm ent Ch eck Gene ral P r ocedures Speci al T ool (s) Al ig nment e qui pment 501-081 1.
5. CAU TI O N : Make s ur e t h e mea s ur ing equi p ment i s us e d t he right wa y up a s s ho wn i n t he i ll us t r a t i o n. The Z me a sureme nt i s s e t on t he s pe ci a l t oo l be f o r e t he X mea s ur eme nt i s t a ke n o n t he ve hi cle .
8. NOT E: The s mal l e s t di a met er pi n a nd br acket (D) i s fi t t e d t o ve hi cl e s wit h a ut omat i c t rans mi ss i on. Th e l a r ge r di a met e r pi n a nd br a ck et (D) i s fi tt e d t o ve hi cle s wi t h man ua l t rans mis s i o n.
9. CAU TI O N : W he n i ns t a l l i n g o r r e m ovi ng the s pe ci a l t o ol m a ke s ur e th e br a k e pi pe s a r e not da mag e d or de t a che d f r o m t he ret a i ni ng cl i ps .
Underbod y Di m en si o ns X-Di mens i on Mi l l i meter In c h 1-Al l v e hi cl e s 674.00 26.28 2-Al l v e hi cl e s 977.00 38.10 3-M anua l t rans mi s si o n 877.00 34.20 4-M anua l t rans mi s si o n 708.00 27.61 3-Aut o mat i c t r a nsmi s s i o n 92 4.
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe2.0L N A V 6 - AJV6 / 2.5L NA V 6 - A JV 6/3.0 L N A V 6 - AJ27 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1.
7. D et a ch t he e ngi ne r o l l res t ricto r. Re mov e t he e n gi ne r ol l res t r i ct or r et a i ni ng bo l t . 8. Remove t he e ngi ne roll r es t r i ct o r . Re mov e t he e n gi ne r ol l res t r i ct or r et a i ni ng bo l t . 9. NOT E: If i ns t al l e d, r e move a n d d i s ca r d t he ga s ke t .
11. CAUT I O N: Ma k e s ure t hat t he drive sha f t doe s no t ha ng o n t he c e nt e r uni versa l j o i nt . Fa i l ur e t o f o l l ow t hi s i ns t r ucti on may res ul t i n dama ge t o t he d rives ha f t . Us i ng s ui t a bl e t i e s t raps , s e cur e t he dr i ves ha ft t o t he front exha us t ha nger .
15. Det a ch t he front of t he s t e e r i ng ge a r co o li ng pi p e . 16. Det a ch t he r ea r o f t he s t ee r i ng g e a r coo l i ng p i pe . Vehi c le s with autom at ic tra ns m ission 17. Remove t he s e l e ct o r cabl e s hi e l d . 18. Det a ch t he s e l ect or ca bl e .
19. Dis c o nne ct t he s e l e ct o r cabl e . 20. NO TE: Secur e t he s e le cto r cabl e us i ng t i e s t r aps . Det ach t he s e le cto r cabl e . All v e h icle s 21. Ins t a l l t he s p e cia l t o o l . 22. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar.
23. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . P os i t io n a nd a dju s t t he s pe cia l t oo l f r on t he i ght a dj us t e r . 24. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s.
27. Det a ch t he s t e e r ing gea r s up pl y pi pe f r om t he s t e e r i ng ge ar hea t s hi e l d mount br a c ket . 28. Det a ch t he s t e e r ing gea r he a t s hi e l d mount b r acke t . 29. Det a ch t he r igh t -ha nd s i de o f t he s t e e ring ge ar .
32. Remove t he s t ee ring ge a r hea t s hi e l d l o we r r et a i ni ng b ol t s . 33. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, d et a ch th e l o we r a r m bal l j o i nt a s th e s ubframe i s bei ng l owe r e d. Fa il ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .
2. CAU TI O N : To pr eve nt da mage t o t he l ow er arm bus hi ng, a tt a ch th e l o we r a r m bal l j o i nt a s th e s ubframe i s bei ng rai s ed . Fa i l ur e t o f ol l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e .
7. Att a ch t he right -ha nd s id e o f t he s te e r i ng ge ar. Ti ght e n t o 133 Nm. 8. Att a ch t he s t ee r in g g e a r he at s hi e l d mount br a ck et . 9. Att a ch t he s t ee r in g g e a r s uppl y p i pe t o t he s te e r i ng ge ar he a t s hie ld m o unt br acket .
12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l a t e r et a i ni ng bo l t s . 13. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Ti ght e n t o 142 Nm. 14.
17. At t ach t he s e l e ct o r cabl e . 18. Conne ct t he s e l e ct o r cabl e . Ti ght e n t o 10 Nm. 19. At t ach t he s e l e ct o r cabl e . 20.
21. At t ach t he re ar of t he s t e e r i ng ge ar coo li ng pi p e . Ti ght e n t o 7 Nm. 22. At t ach t he f r o nt o f t he s t e e r ing ge a r co ol i ng p i p e. Ti ght e n t o 7 Nm. Vehi c le s with high i ntensity dis char ge hea dlam ps 23.
25. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he l o we r a r m ba l l j oi nt r e t ai ni ng nut a nd b ol t . Ti ght e n t o 83 Nm. 26. Ins t a l l t he m uf fl e r in le t pi pe . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Muff l e r Inl e t Pi p e - 2.
30. Ins t a l l t he e ngi ne roll r e s t r i cto r . Ins t al l t he e ngi ne r o ll re st r i ct o r r e t a i ni ng bo l t . 31. At t ach t he e ngi ne rol l r e s t r i ct o r . Ti ght e n t o 80 Nm 32. Ti g ht e n t o 80 N m. 33. Ins t a l l t he r a di a t o r s pl a s h s hie ld .
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe2.0L D uratorq- TDC i/2.2L Duratorq-TDC i (110k W/ 150PS) - Puma Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1.
7. D i s conne ct t he hi gh i nt ens i t y di s cha r ge (H.I .D) s e ns or dr op a r m. All v e h icle s 8. D et a ch t he f ront o f t he s t e e r i n g g e a r coo l i ng p i pe . 9. D et a ch t he r e a r o f t he s t e ering ge a r cool i ng pi pe .
11. Det a ch t he coo l a nt ho se s f rom t he r e t a ini ng cl i ps . 12. NO TE: Cl a mp t he ho se t o mini miz e co o l a nt l o s s . Det ach t he co ol a nt h os e . Dis conne ct t he co o l a nt ho s e . Vehi c le s with f uel fire d boo ster he ate r 13.
15. Det a ch t he wi ring ha r nes s. 16. Ins t a l l t he s p e cia l t o o l . 17. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 18. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r .
19. Det a ch t he eng i ne r ol l res t r i cto r . 20. Remove t he e n gi ne rol l r e s t r i ct o r . Re mov e t he rol l res t r i c t o r r et a i ni ng bo l t . 21. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s.
24. Det a ch t he r igh t -ha nd s i de o f t he s t e e ring ge ar . 25. Det a ch t he l e ft -hand s i de of t he s t e e ring ge a r . 26. Us i ng s ui t a b l e s e cur i ng s trap s , s e cu re t he s t e e r i ng ge a r t o t he ve hi cle bo dy.
1. W ARNING: Ra i s e t he s p e cia l to o l p la t f or m s lo wl y. Fa i l ure t o f o l l o w th i s i ns t r uct io n c a n res ul t i n pe rsona l inj ur y.
7. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame f ront mount r et a i ni ng bo l t . 8. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s .
12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 13. Ins t a l l t he e ngi ne roll r e s t r i cto r . Ti ght e n t o 80 Nm. 14. At t ach t he e ngi ne rol l r e s t r i ct o r .
Vehi c le s with f uel fire d boo ster he ate r 17. At t ach t he co o l a nt hos e . 18. At t ach t he f uel f i red bo os t e r hea t er e l e c t r i cal co nne cto r t o t he s ub frame r e t a i ni ng t a ng. Vehi c le s with ele ctric booste r he ate r 19.
21. At t ach t he e le ct r ic bo o s t e r he a t e r el e ct r ica l conne ct o r t o t he sub f r ame r et a i ni ng t a ng . All v e h icle s 22. At t ach t he re ar of t he s t e e r i ng ge ar coo li ng pi p e . Ti ght e n t o 7 Nm. 23. At t ach t he f r o nt o f t he s t e e r ing ge a r co ol i ng p i p e.
25. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. At t a ch t he s t a bi l iz e r b ar l i nk a rm s . Ti ght e n t o 48 Nm. 26. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he l o we r a r m ba l l j oi nt r e t ai ni ng nut a nd b ol t .
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe Front B u shing Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ada p t or nut 204-274 For cing s cr.
2. NOT E: Not e t h e o r i e nt a t i o n o f t he bus hi ng be f or e removal . Us i ng t he s p e ci a l t o ol s , r emove t he f r ont s ubf r a me mount i ng b us hi ng.
4. Usi ng t he s pe cia l t oo l s, f ul l y e nga ge t he b ushi ng i nt o t he s ubf r a me . 5. Ins t a l l the f r ont s ubf r ame For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Front Subframe Rear B ushin g Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ada p t or nut 204-274 For cing s cr .
Thr us t b e aring JAG- 061 R em ova l 1. Remove t he f r ont s ubfr a me For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L Dur at o rq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (502-0 0 U ni -Body, S ubframe a nd Mount i ng Sy s t e m, Re moval a nd I nst a l l at io n).
4. Usi ng t he s pe cia l t oo l s, f ul l y s ea t t he b us hi n g. 5. Ins t a l l the f r ont s ubf r ame For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Fr ont Subframe - 2.0L Dur at o rq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (502-0 0 U ni -Body, S ubframe a nd Mount i ng Sy s t e m, Re moval a nd I nst a l l at io n).
P ubl i s he d: 11-May-2 011 Un i-Bo dy , Su b fram e and Moun ting System - Rear Ax l e Cro ss m ember Bus hing Re moval a n d I ns t a l l a t i on Speci al T ool (s) For cing nut 204-274 For cing s cr e w 204-275 S upport cup 204-299 Bus h r emove r 204-271 Bus h i ns ta l l e r 204-245 R em ova l 1.
An important point after buying a device Jaguar X-Type (2001) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Jaguar X-Type (2001) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Jaguar X-Type (2001) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Jaguar X-Type (2001) you will learn all the available features of the product, as well as information on its operation. The information that you get Jaguar X-Type (2001) will certainly help you make a decision on the purchase.
If you already are a holder of Jaguar X-Type (2001), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Jaguar X-Type (2001).
However, one of the most important roles played by the user manual is to help in solving problems with Jaguar X-Type (2001). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Jaguar X-Type (2001) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
