Workshop Manual MPI

Wo rkshop Man u al
Werkplaatshandboek
Manuel D’Atelier
Werkstatthandbuch
Manuale D’Officina
Manual De Taller
Manual de Oficina
AMENDMENT INSTRUCTION SHEET
MINI WORKSHOP MANUAL

Publication Number RCL 0193ENG - 2nd Edition
Amendment Number: XN-001/97ENG Date: 12/96
To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an
Amendment Instruction Sheet will be issued with each set of revised pages.
• The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the
Contents pages, all revised and new pages have the issue date at the foot of each page, together with an
indication of whether the pages are revised or new.
• This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment
has been incorporated. Do not discard previous Amendment Instruction sheets.
• Your manual is only complete to this issue providing all prior Amendments are included.
• The filing instructions give section and page numbers affected. Additional pages or complete new sections may
be issued, insert the pages as instructed.
FILING INSTRUCTIONS
Section Discard Existing Insert New Pages Reason for Amendment

Pages
Introduction Title Page Title Page Introduction of new sections. Part number
raised to next edition.
Information Contents Page Contents Page Corrections to existing information and

addition of new torque figures.
General data,1 General data,1
Torque wrench Torque wrench
settings, 1&3 settings, 1-5
Engine Contents Page Contents Page Corrections to existing information and

addition of new repair procedures.
Repairs, 33-37 Repairs, 33-41
Emission Control Description and Description and Corrections to existing information.

operation, 1 operation, 1
Repairs, 1 Repairs, 1
Engine Management Contents Page Contents Page Corrections to existing information.

System - MEMS
Description and Description and
operation, 1-11 operation, 1-11
Fuel Delivery System Contents Page Contents Page Corrections to existing information and
introduction of Adjustments section.
- Adjustments
Repairs, 1 Repairs, 1
Cooling System Repairs, 3 Repairs, 3 Corrections to existing information.
Manifold & Exhaust Description and Description and Corrections to existing information.
Systems operation, 3 operation, 3
Clutch Contents page Contents Page Corrections to existing information and

Adjustments, 1 Adjustments, 1
Repairs, 1-7 Repairs,1-11
Continued.....
Pages
Manual Gearbox Contents page Contents Page Corrections to existing information and
- Repairs, 1-5
Drive shafts - Contents Page New Section

- Repairs, 1-5
Steering Contents page Contents Page Corrections to existing information and

- Adjustments, 1
Repairs, 1 Repairs, 1-11
Suspension - Contents Page New Section.

- Adjustments, 1
- Repairs, 1&3
Brakes Contents Page Contents Page Corrections to existing information and

Repairs, 1&3 Repairs, 1-17
Restraint Systems Description and Description and Corrections to existing information.

Repairs, 3&5 Repairs, 3&5
Body Contents Page Contents Page Corrections to existing information and

Exterior fittings, Exterior fittings,
1&3 1-7
Interior trim Interior trim
components, 1 components, 1-7
Screens, 1 Screens, 1
- Seats and seat
belts, 1&3
Heating & Ventilation - Contents Page New Section.

- Repairs, 1-7
Wipers & Washers Contents Page Contents page Addition of new repair procedures
Repairs, 1 Repairs, 1-7
Electrical Contents Page Contents Page Corrections to existing information and

Description and Description and
Repairs, 1-19 Repairs, 1-27
Instruments Repairs, 7 Repairs, 7 Corrections to existing information.


Publication Number RCL0193ENG (3rd Edition)
Amendment Number: XN003.98ENG Date: 11/98
FILING INSTRUCTIONS

Pages
TITLE PAGE Title page Title page Part number raised to 4th Edition and year
of copyright amended.
INSTRUMENTS Contents page Contents page Additional jobs added
INSTRUMENTS Page 9 Pages 9 and 11 Speedometer cable upper and lower added

Publication Number RCL0193ENG (4th Edition)
Amendment Number: XN002.99ENG Date: 06/99
FILING INSTRUCTIONS

Pages
TITLE PAGE Title Page Title Page Part number raised to 5th Edition.
ELECTRICAL Contents page Contents page Contents changed.

Adjustments pages Adjustments pages Auxiliary Drive Belt - Check and Adjust -
1&2 1&2 Caution regarding drive belt adjusting bolt
added.
Repairs pages 1 & Repairs pages 1 & Auxiliary Drive Belt - Remove and Refit -
2 2 Cautions regarding drive belt adjusting bolt
added.
Repairs page 27 Repairs pages 27 CD Player - Remove and Refit - New
& 28 operation issued herewith.
INTRODUCTION
GENERAL INFORMATION
INFORMATION
ENGINE
EMISSION CONTROL
ENGINE MANAGEMENT SYSTEM
FUEL DELIVERY SYSTEM
COOLING SYSTEM
WORKSHOP
MANUAL MANIFOLD & EXHAUST SYSTEMS
This manual covers changes to Mini models CLUTCH

manufactured from VIN SAXXNNAZEBD 134455
and should be used in conjunction with the following
manuals.
MANUAL GEARBOX
AKM 7169 Mini Repair Manual
RCL 0194 Mini Electrical Circuit Diagrams
DRIVE SHAFTS
STEERING
SUSPENSION
BRAKES
RESTRAINT SYSTEMS
BODY
HEATING & VENTILATION
WIPERS & WASHERS

Publication Part No. RCL 0193ENG (5th Edition) ELECTRICAL
Published by Rover Technical Communication INSTRUMENTS
 1998 Rover Group Limited
INTRODUCTION
CONTENTS Page
INTRODUCTION
INTRODUCTION ...................................................................................................... 1
REPAIRS AND REPLACEMENTS ........................................................................... 2
SPECIFICATION ...................................................................................................... 2
ABBREVIATIONS AND SYMBOLS .......................................................................... 3
INTRODUCTION
INTRODUCTION References
How to use this Manual References to the LH or RH side given in this

Manual are made when viewing the vehicle from the
To assist in the use of this Manual the section title is rear. With the engine and gearbox assembly
given at the top and the relevant sub-section is given removed, the crankshaft pulley end of the engine is
at the bottom each page. referred to as the front.
Each major section starts with a contents page, Operations covered in this Manual do not include
listing the information contained in the relevant reference to testing the vehicle after repair. It is
sub-sections. To assist filing of revised information essential that work is inspected and tested after
each sub-section is numbered from page 1. completion and if necessary a road test of the
vehicle is carried out particularly where safety
The individual items comprising repair operations related items are concerned.
are to be followed in the sequence in which they
appear. Items numbers in the illustration are referred Dimensions
to in the text.
The dimensions quoted are to design engineering
Adjustment and repair operations include reference specification with Service limits where applicable.
to Service tool numbers and the associated
illustration depicts the tool. Where usage is not
obvious the tool is shown in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Repair
Operation Time number. WARNINGS, CAUTIONS
and NOTES have the following meanings:
WARNING: Procedures which must be

followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures

which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
INTRODUCTION 1
INTRODUCTION
REPAIRS AND REPLACEMENTS SPECIFICATION
When replacement parts are required it is essential Rover are constantly seeking to improve the
that only Rover recommended parts are used. specification, design and production of their vehicles
and alterations take place accordingly. While every
Attention is particularly drawn to the following points effort has been made to ensure the accuracy of this
concerning repairs and the fitting of replacement Manual, it should not be regarded as an infallible
parts and accessories. guide to current specifications of any particular
vehicle.
Safety features and corrosion prevention treatments
embodied in the car may be impaired if other than This Manual does not constitute an offer for sale of
Rover recommended parts are fitted. In certain any particular vehicle. Rover Dealers are not agents
territories, legislation prohibits the fitting of parts not of Rover and have no authority to bind the
to the manufacturer’s specification. Torque wrench manufacturer by any expressed or implied
setting figures given in this Manual must be used. undertaking or representation.
Locking devices, where specified, must be fitted. If
the efficiency of a locking device is impaired during
removal it must be renewed.
Owners purchasing accessories while travelling

abroad should ensure that the accessory and its
fitted location on the car conform to legal
requirements.
The Terms of the vehicle Warranty may be

invalidated by the fitting of other than Rover
recommended parts.
All Rover recommended parts have the full backing

of the vehicle Warranty.
Rover Dealers are obliged to supply only Rover

recommended parts.
2 INTRODUCTION
INTRODUCTION
ABBREVIATIONS AND SYMBOLS
After Bottom Dead Centre ABDC

Manifold absolute pressure MAP
After Top Dead Centre ATDC
Mass air flow MAF
Air conditioning A/C
Maximum max.
Air fuel ratio AFR
Mercury Hg
Alternating current ac
Metre m
Amperes A
Metric unit of horse power PS
Anti-lock brake system ABS
Miles per hour mph
Automatic temperature control ATC
Millimetre mm
Before Bottom Dead Centre BBDC Minimum min
Before Top Dead Centre BTDC Minus (of tolerance) -
Bottom Dead Centre BDC Minute (angle) ’
British Standards BS Model Year MY
Multi-point injection MPi
Camshaft Position CMP
Carbon monoxide CO Negative (electrical) (-)
Celcius (Centigrade) C Newton metre Nm
Centimetre cm Number No.
Chlorofluorocarbons CFC’s
Outside diameter o.dia.
Cubic centimetres cm3
Crankshaft position CKP Percentage %
Plus or minus ±
Degree (angle) deg. or °
Plus (tolerance) +
Degree (temperature) deg. or °
Positive (electrical) +
Dial test indicator DTI
Positive crankcase ventilation PCV
Diameter dia.
Direct current dc Radius r
Ratio :
Electronic Control Unit ECU
Reference ref
Exhaust gas recirculation EGR
Revolutions per minute rev/min
Engine Control Module ECM
Right-hand RH
Engine coolant temperature ECT
Right-hand drive RHD
Fuel Injection Pump FIP Rover Engineering Standards RES
Second (angle) "
Gramme (mass) g
Single overhead camshaft SOHC
High compression hc Specific gravity sp.gr
High Tension h.t. Square centimetres cm2
Hour h Standard std.
Supplementary Restraint System SRS
Idle Air Control Valve IACV
Synchronizer/synchromesh synchro
Inertia Fuel Shut-off IFS
Intake air temperature IAT Thousand k
Internal diameter i.dia. Top dead centre TDC
International Organisation for ISO Throttle position TP
Standardization
United Kingdom UK
Kilometre km
United States US
Kilogramme kg
Variable induction system VIS
Left-hand LH
Vehicle identification number VIN
Left-hand drive LHD
Volt V
Light emitting diode LED
Litre l Watt W
Low Compression lc
INTRODUCTION 3
GENERAL INFORMATION
CONTENTS Page
VEHICLE IDENTIFICATION NUMBER

VEHICLE IDENTIFICATION NUMBER .................................................................... 1
IDENTIFICATION NUMBER LOCATIONS ............................................................... 1
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS .................................. 1
Dangerous substances ............................................................................................. 1
Engine oils ................................................................................................................ 1
Health Protection Precautions .................................................................................. 1
Environmental Protection Precautions ...................................................................... 1
SAFETY INSTRUCTIONS ........................................................................................ 2
FUEL HANDLING PRECAUTIONS

FUEL HANDLING PRECAUTIONS .......................................................................... 1
ELECTRICAL PRECAUTIONS
ELECTRICAL PRECAUTIONS ................................................................................. 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER Paint and Trim colour codes
3-letter codes identifying the original Paint and Trim

Location colours are stamped on the VIN plate.
The Vehicle Identification Number (VIN) plate is Paint

attached to the RH inner wing valance.
The VIN is also etched into the lower LH corners of Example: H A M
the windscreen and rear window.
H= Basic colour
A= Mark identifier
M= Colour/Shade name
Trim
Example: L P R
L= Basic colour
P= Mark identifier
R= Colour/Shade name
Vehicle identification number
Example: S A X X N N A Z E B D 134455 IDENTIFICATION NUMBER LOCATIONS
S= Geographic area Engine number
A= Country Stamped on the front face of the cylinder block

adjacent to the alternator.
X= Manufacturer
Gearbox number
XN= Marque/Model
Shown on a label attached to the upper face of the
N= Class final drive housing.
A= Body Body number
Z= Engine The body number is stamped on a plate fixed to the

bonnet locking platform.
E= Transmission and Steering
B= Model change
D= Assembly plant
6 figures= Serial number
VEHICLE IDENTIFICATION NUMBER 1

GENERAL INFORMATION
GENERAL PRECAUTIONS AND FITTING Health Protection Precautions

INSTRUCTIONS
• Avoid prolonged and repeated contact with oils,
Ignition system safety precautions particularly used engine oils.
• Wear protective clothing, including impervious
WARNING: Before commencing work on gloves where practicable.
an ignition system, all high tension • Do not put oily rags in pockets.
terminals, adapters and diagnostic • Avoid contaminating clothes, particularly
equipment for testing should be inspected to underpants, with oil.
ensure that they are adequately insulated and • Overalls must be cleaned regularly. Discard
shielded to prevent accidental personal contacts heavily soiled clothing and oil impregnated
and minimise the risk of shock. Wearers of footwear.
surgically implanted pacemaker devices should • First aid treatment should be obtained
not be in close proximity to ignition circuits or immediately for open cuts and wounds.
diagnostic equipment. • Use barrier creams, applying before each work
period, to help the removal of oil from the skin.
Dangerous substances • Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
WARNING: Many liquids and other help). Preparations containing lanolin replace the
substances used in motor vehicles are natural skin oils which have been removed.
poisonous and should under no • Do not use petrol, kerosene, diesel fuel, gas oil,
circumstances be consumed and should, as far thinners or solvents for cleaning skin.
as possible, be kept from contact with the skin. • If skin disorders develop, obtain medical advice
These substances among others include acid, without delay.
anti- freeze, asbestos, brake fluid, fuel, • Where practicable, degrease components prior
windscreen washer additives, lubricants, to handling.
refrigerant and various adhesives. • Where there is a risk of eye contact, eye
Always read carefully the instructions printed on protection should be worn, for example, chemical
labels or stamped on components and obey goggles or face shields; in addition an eye wash
them implicitly. Such instructions are included facility should be provided.
for reasons of your health and personal safety.
Never disregard them. Environmental Protection Precautions
Used engine oils: Prolonged exposure to used
engine oils can cause serious skin disorders, It is illegal to pour used oil on to the ground, down
avoid excessive skin contact and always adhere sewers or drains, or into water courses.
to the following recommendations:
Burning of used engine oil in small space heaters or
Engine oils boilers can be recommended only for units of
approved design. The heating system must meet the
Prolonged and repeated contact with mineral oil will regulatory standards of HMIP for small burners of
result in the removal of natural fats from the skin, less than 0.4 MV. If in doubt check with the
leading to dryness, irritation and dermatitis. In appropriate local authority and/or manufacturer of
addition, used engine oil contains potentially harmful approved appliance.
contaminants which may cause skin cancer.
Adequate means of skin protection and washing Dispose of used oil and used filters through
facilities must be provided. authorised waste disposal contractors to licensed
waste disposal sites, or to the waste oil reclamation
trade. If in doubt, contact the Local Authority for
advice on disposal facilities.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1

GENERAL INFORMATION
SAFETY INSTRUCTIONS Brake hydraulics
Jacking WARNING: It is imperative that the correct

brake fittings are used and that threads of
The recommended jacking points are given in components are compatible.
LIFTING AND TOWING, always ensure that any
lifting apparatus has adequate load and safety Always use two spanners when slackening or
capacity for the weight to be lifted. Ensure the tightening brake pipe or hose connections. Ensure
vehicle is standing on level ground prior to lifting or that hoses run in a natural curve and are not kinked
jacking. Apply the handbrake and chock the wheels. or twisted. Fit brake pipes securely in their retaining
clips and ensure that the pipe run cannot contact a
Never rely on a jack as the sole means of support potential chafing point.
when working beneath the vehicle. Use additional
safety supports beneath the vehicle. Containers used for hydraulic fluid must be kept
absolutely clean. Do not store hydraulic fluid in an
Do not leave tools, lifting equipment, spilt oil, etc. unsealed container, it will absorb water and in this
around or on the work bench area. condition would be dangerous to use. Do not allow
hydraulic fluid to be contaminated with mineral oil, or
Precautions against damage use a container which has previously contained
mineral oil. Do not re-use fluid from the system.
Always fit wing and seat covers before commencing Always use clean brake fluid or a recommended
work. Avoid spilling brake fluid or battery acid on alternative to clean hydraulic components. Fit a
paintwork. Wash off with water immediately if this blanking cap to an hydraulic union and a plug to its
occurs. socket after removal to prevent the ingress of dirt.
Absolute cleanliness must be observed with
Disconnect the battery earth lead before starting hydraulic components.
work, see ELECTRICAL PRECAUTIONS.
Engine coolant caps and plugs
Always use the recommended service tool or a
satisfactory equivalent where specified. Extreme care is necessary when removing engine
coolant caps and plugs when the engine is hot and
Protect exposed bearing and sealing surfaces and especially if it is overheated. To avoid the possibility
screw threads from damage. of scalding allow the engine to cool before
attempting coolant cap or plug removal.
Brake shoes and pads
Cleaning components
WARNING: Always fit the correct grade
and specification of brake linings and Always use the recommended cleaning agent or
renew brake pads and brake shoes in axle equivalent.
sets only.
Do not use degreasing equipment for components
containing items which could be damaged by the
use of this process. Whenever possible clean
components and the area surrounding them before
removal. Always observe scrupulous cleanliness
when cleaning dismantled components.
2 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

GENERAL INFORMATION
Joints and joint faces Bolt identification
Fit joints dry unless otherwise specified in this

Manual.
If gaskets and/or jointing compound is

recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use a
tool which will damage the joint faces and smooth
out any scratches or burrs on the joint faces using
an oil stone. Do not allow dirt or jointing material to
enter any tapped holes.
Prior to reassembly, blow through any pipes,

channels or crevices with compressed air. An ISO metric bolt or screw made of steel and larger
than 6 mm in diameter can be identified by either of
Screw threads the symbols ISO M or M embossed or indented on
top of the head.
Both UNF and metric threads to ISO standards are
used. In addition to marks to identify the manufacturer, the
head is also marked with symbols to indicate the
Damaged nuts, bolts and screws must always be strength grade, e.g. 8.8; 10.9; 12.9; 14.9. As an
discarded. alternative, some bolts and screws have the M and
strength grade symbol on the flats of the hexagon.
Cleaning up damaged threads with a die or tap
impairs the strength and closeness of fit of the
threads and is not recommended.
Castellated nuts must not be slackened back to

accept a split-pin, except in those recommended
cases when this forms part of an adjustment.
Do not allow oil or grease to enter blind threaded

holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended

torque figure. Damaged or corroded threads can
affect the torque reading.
To check or re-tighten a bolt or screw to a specified

torque figure, first slacken a quarter of a turn, then
retighten to the correct torque figure.

GENERAL INFORMATION
Nut identification Locking devices
Always release locking tabs and fit new locking

washers, do not re-use locking tabs. Always use a
backing spanner when slackening or tightening
brake and fuel pipe unions.
Fitting a split pin
A nut with an ISO metric thread is marked on one

face or on one of the flats of the hexagon with the Always fit new split-pins of the correct size for the
strength grade symbol 8, 12, or 14. Some nuts with hole in the bolt or stud. Do not slacken back nut to
a strength grade 4, 5 or 6 are also marked and some enter split-pin.
have the metric symbol M on the flat opposite the
strength grade marking. Always fit new roll pins of an interference fit in the
hole.
A clock face system is used as an alternative
method of indicating the strength grade. The Always fit new circlips of the correct size for the
external chambers or a face of the nut is marked in a groove.
position relative to the appropriate hour mark on a
clock face to indicate the strength grade.
Self-locking nuts
A dot is used to locate the 12 o’clock position and a
dash to indicate the strength grade. If the grade is
above 12, two dots identify the 12 o’clock position.
Self-locking nuts, i.e. nylon insert or metal stiff nuts

can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.

GENERAL INFORMATION
Self-locking bolts and screws Encapsulated bolts and screws
Self-locking bolts and screws, i.e. nylon patched or Encapsulated bolts and screws have a
trilobular thread can be re-used providing resistance micro-encapsulated locking agent pre-applied to the
can be felt when the locking portion enters the thread. They are identified by the presence of a
female thread. coloured section of thread which extends completely
around the thread - 360°. The locking agent is
Nylon patched bolts and screws have a locking released and activated by the assembly process and
agent pre-applied to the threads. They are identified is then chemically cured to provide the locking
by the presence of a coloured section of thread action.
which extends for up to 180° around the thread.
Unless a specific repair procedure states otherwise,
Trilobular i.e. Powerlok bolts have a special thread encapsulated bolts may be re-used providing the
form which creates a slight interference in the threads are undamaged and the following procedure
tapped hole or threads of the nut into which it is is adopted.
screwed.
Remove loose adhesive from the bolt and housing
DO NOT re-use self-locking fasteners in critical threads, ensure threads are clean and free of oil and
locations eg engine bearings flywheel. Always use grease. Apply an approved adhesive.
the correct replacement self-locking nut, bolt or
screw. Fit a new encapsulated bolt, or if not available a bolt
of equivalent specification treated with an approved
DO NOT fit non self-locking fasteners in applications adhesive.
where a self-locking nut, bolt or screw is specified.

GENERAL INFORMATION
Oil seals Body repairs
Always renew oil seals which have been removed Any damage found, that would affect the corrosion
from their working location either as an individual resistance of the vehicle during the Warranty period
component or as part of an assembly. must be rectified by an authorised Rover Dealer to
the standards, and by the methods, detailed in the
Ensure the surface on which the new seal is to run is Body Repair Manual.
free of burrs or scratches. Renew the component if
the original sealing surface cannot be completely Replacement body panels
restored.
Body panels are supplied coated in cathodic
Protect the seal from any surface which it has to electrocoat primer.
pass when being fitted. Use a protective sleeve or
tape to cover the relevant surface. Synthetic rubber
Lubricate the sealing lips with a recommended Many ’O’ rings, seals, hoses, flexible pipes and other
lubricant before use to prevent damage in initial use. similar items which appear to be natural rubber, are
On dual lipped seals, smear the area between the in fact, made of synthetic materials called
lips with grease. Fluoroelastomers. Under normal operating
conditions this material is safe and does not present
Use the recommended service tool to fit an oil seal. a health hazard. However, if the material is
damaged by fire or excessive heating, it can break
If the correct service tool is not available, use a down and produce highly corrosive Hydrofluoric acid
suitable tube approximately 0.4 mm smaller than the which can cause serious burns on contact with skin.
outside diameter of the seal. If skin contact does occur:
Press or drift the seal in to the depth of its housing, • Remove any contaminated clothing immediately.
with the sealing lip facing the lubricant to be retained • Irrigate effected area with a copious amount of
if the housing is shouldered, or flush with the face of cold water or limewater for 15 to 60 minutes.
the housing where no shoulder is provided. • Obtain medical assistance immediately
Service tools and garage equipment Should the material be in a burnt or over-heated
condition handle only with seamless industrial
Special service tools have been developed to gloves. Decontaminate and dispose of loves
facilitate removal, dismantling and assembly of immediately after use.
mechanical components in a cost effective and
practical manner without causing damage. Some
operations in this Manual cannot be carried out
without the aid of the relevant service tools.
TestBook
TestBook is a computerised workshop tool which

provides your dealership with instant access to the
very latest Technical Information from ROVER,
allowing for accurate and effective fault diagnosis
and repair of all Rover Vehicles.
Where specific garage equipment is required for

diagnosis and repair, reference should be made to
the Service Tools and Equipment Programme where
details of the equipment recommended by Rover
Service may be found.

GENERAL INFORMATION
FUEL HANDLING PRECAUTIONS Fuel tank drainage
General WARNING: Petrol/gasoline must not be

extracted or drained from any vehicle
The following information provides basic precautions whilst it is standing over a pit.
which must be observed if petrol (gasoline) is to be Draining or extraction of petrol/gasoline from a
handled safely. It also outlines other areas of risk vehicle fuel tank must be carried out in a well
which must not be ignored. This information is ventilated area.
issued for basic guidance only, and if in doubt The receptacle used to contain the
appropriate enquiries should be made of your local petrol/gasoline must be more than adequate for
Fire Officer. the full amount of fuel to be extracted or drained.
The receptacle should be clearly marked with its
Petrol - Gasoline contents, and placed in a safe storage area
which meets the requirements of local authority
Petrol/gasoline vapour is highly flammable and in regulations.
confined spaces is also explosive and toxic.
CAUTION: When petrol/gasoline has been
When petrol/gasoline evaporates it produces 150 extracted or drained from a fuel tank the
times its own volume in vapour which when diluted precautions governing naked lights and
with air becomes a readily ignitable mixture. The ignition sources should be maintained.
vapour is heavier than air and will always fall to the
lowest level. It can readily be distributed throughout Fuel tank removal
a workshop by air currents; consequently, even a
small spillage of petrol/ gasoline is potentially very When the fuel line is secured to the fuel tank outlet
dangerous. by a spring steel clip, the clip must be released
before the fuel line is disconnected or the fuel tank is
Always have a fire extinguisher containing FOAM, removed. This procedure will avoid the possibility of
CO2, GAS or POWDER close at hand when residual petrol fumes in the fuel tank being ignited
handling or draining fuel or when dismantling fuel when the clip is released.
systems and in other areas where fuel containers
are stored. As an added precaution fuel tanks should have a
’PETROL (GASOLINE) VAPOUR’ warning label
Always disconnect the vehicle battery before attached to them as soon as they are removed from
carrying out dismantling or draining work on a fuel the vehicle.
system.
Whenever petrol/gasoline is being handled, drained

or stored or when fuel systems are being
dismantled, all forms of ignition must be
extinguished or removed; any leadlamps must be
flameproof and kept clear of spillage.
WARNING: No one should be permitted to

repair components associated with
petrol/gasoline without first having
specialist training.
FUEL HANDLING PRECAUTIONS 1

GENERAL INFORMATION
Fuel tank repairs
Under no circumstances should a repair to any fuel

tank involving heat treatment be carried out without
first rendering the tank SAFE, by using one of the
following methods:
a. STEAMING: With the filler cap and tank unit

removed, empty the tank. Steam the tank for at least
two hours with low pressure steam. Position the tank
so that condensation can drain away freely, ensuring
that any sediment and sludge not volatized by the
steam is washed out during the steaming process.
b. BOILING: With the filler cap and tank unit

removed, empty the tank. Immerse the tank
completely in boiling water containing an effective
alkaline degreasing agent or a detergent, with the
water filling and also surrounding the tank for at least
two hours.
After steaming or boiling, a signed and dated label to

this effect should be attached to the tank.
Body and chassis repairs
When a body or chassis repairs involve the use of

heat, all fuel pipes which run in the vicinity of the
repair area must be removed, and the tank outlet
plugged, BEFORE HEAT IS APPLIED. If the repair
is in the vicinity of the fuel tank, the tank must be
removed.
Plastic fuel pipes are particularly susceptible to heat,

even at relatively low temperature, and can be
melted by heat conducted from some distance away.
Fuel lines or tanks must not be removed whilst the

vehicle is over an inspection pit.
2 FUEL HANDLING PRECAUTIONS

GENERAL INFORMATION
ELECTRICAL PRECAUTIONS Having confirmed a component to be faulty switch

off the ignition and disconnect the battery. Remove
General the component and support the disconnected
harness. When replacing the component keep oily
The following guidelines are intended to ensure the hands away from electrical connection areas and
safety of the operator whilst preventing damage to push connectors home until any locking tabs fully
the electrical and electronic components fitted to the engage.
vehicle. Where necessary specific precautions are
detailed in the relevant sections of this Manual which Battery disconnection
should be referred to prior to commencing repair
operations. Before disconnecting the battery, switch off all
electrical equipment. If the radio is to be serviced,
Equipment - Prior to commencing any test ensure the security code has been deactivated.
procedure on the vehicle ensure that the relevant
test equipment is working correctly and any harness CAUTION: To prevent damage to electrical
or connectors are in good condition, this particularly components ALWAYS disconnect the
applies to mains lead and plugs. battery when working on the vehicle
electrical system. The earth lead must be
WARNING: Before commencing work on disconnected first and reconnected last.
an ignition system all high tension Always ensure that battery leads are routed
terminals, adapters and diagnostic correctly and are not close to any potential
equipment for testing should be inspected to chafing points.
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts Battery charging
and minimise the risk of shock. Wearers of
surgically implanted pacemaker devices should Recharge the battery out of the vehicle and keep the
not be in close proximity to ignition circuits or top well ventilated. While being charged or
diagnostic equipment. discharged, and for approximately fifteen minutes
afterwards, batteries emit hydrogen gas. This gas is
Polarity - Never reverse connect the vehicle battery inflammable.
and always observe the correct polarity when
connecting test equipment. Always ensure any battery charging area is well
ventilated and that every precautions is taken to
High Voltage Circuits - Whenever disconnecting live avoid naked flames and sparks.
ht circuits always use insulated pliers and never
allow the open end of the ht lead to come into
contact with other components particularly ECU’s.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.
Connectors and Harness - The engine compartment

of a vehicle is a particularly hostile environment for
electrical components and connectors. Always
ensure these items are dry and oil free before
disconnecting and connecting test equipment. Never
force connectors apart either by using tools or by
pulling on the wiring harness. Always ensure locking
tabs are disengaged before removal and not
orientation to enable correct reconnection. Ensure
that any protective covers and substances are
replaced if disturbed.
ELECTRICAL PRECAUTIONS 1
GENERAL INFORMATION
Disciplines
Switch off ignition prior to making any connection or

disconnection in the system as electrical surge
caused by disconnecting ’live’ connections can
damage electronic components.
Ensure hands and work surfaces are clean and free

of grease, swarf, etc. as grease collects dirt which
can cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as

you would a disc - hold by the edges only; note that
some electronic components are susceptible to body
static.
Connectors should never be subjected to forced

removal or refit, especially inter-board connectors,
damaged contacts will cause short- circuit and
open-circuit conditions.
Prior to commencing test, and periodically during

test, touch a good earth, i.e. cigar lighter socket, to
discharge body static as some electronic
components are vulnerable to static electricity.
Grease for electrical connectors
All under bonnet and under body connectors are

protected against corrosion by the application of a
special grease on production. Should connectors be
disturbed in service or repaired or replaced, a
grease of this type, available in 150 gm tubes under
Part No. BAU 5811, should again be applied.
NOTE: The use of other greases must be

avoided as they can migrate into relays,
switches etc. contaminating the contacts
and leading to intermittent operation or failure.
2 ELECTRICAL PRECAUTIONS
INFORMATION
CONTENTS Page
LIFTING AND TOWING

JACKING, SUPPORTING AND TOWING ................................................................ 1
WORKSHOP JACK .................................................................................................. 2
WHEEL-FREE LIFT .................................................................................................. 2
TOWING ................................................................................................................... 2
GENERAL DATA
ENGINE .................................................................................................................... 1
FUEL SYSTEM ......................................................................................................... 1
COOLING SYSTEM .................................................................................................. 1
CLUTCH ................................................................................................................... 2
MANUAL GEARBOX ................................................................................................ 2
AUTOMATIC GEARBOX .......................................................................................... 2
FINAL DRIVE ............................................................................................................ 2
WHEELS ................................................................................................................... 3
TYRE SIZE ............................................................................................................... 3
TYRE PRESSURES ................................................................................................. 3
ELECTRICAL ............................................................................................................ 3
DIMENSIONS ........................................................................................................... 4
WEIGHTS ................................................................................................................. 4
ENGINE TUNING DATA

Model: SPi with manual gearbox .............................................................................. 1
Model: SPi with automatic gearbox ........................................................................... 2
Model: MPi ................................................................................................................ 3
TORQUE WRENCH SETTINGS

GENERAL ................................................................................................................. 1
ENGINE .................................................................................................................... 1
EMISSION CONTROL .............................................................................................. 2
ENGINE MANAGEMENT SYSTEM .......................................................................... 2
FUEL SYSTEM ......................................................................................................... 2
COOLING ................................................................................................................. 2
MANIFOLD AND EXHAUST ..................................................................................... 3
CLUTCH ................................................................................................................... 3
MANUAL GEARBOX ................................................................................................ 3
STEERING ............................................................................................................... 3
SUSPENSION .......................................................................................................... 4
BRAKES ................................................................................................................... 4
RESTRAINT SYSTEMS ........................................................................................... 4
BODY ........................................................................................................................ 5
HEATING AND VENTILATION ................................................................................. 5
WIPERS AND WASHERS ........................................................................................ 5
ELECTRICAL ............................................................................................................ 5
INSTRUMENTS ........................................................................................................ 5
CAPACITIES, FLUIDS AND LUBRICANTS

CAPACITIES ............................................................................................................. 1
FLUIDS ..................................................................................................................... 1
LUBRICATION .......................................................................................................... 2
INFORMATION
JACKING, SUPPORTING AND TOWING
Jacking and support points
1. Lashing/towing eye - front 6. RH subframe longitudinal - front

2. LH floor front reinforcement 7. Sill reinforced brackets - rear
3. RH floor front reinforcement 8. RH subframe longitudinal - rear
4. Sill reinforced brackets - front 9. LH subframe longitudinal - rear
5. LH subframe longitudinal - front 10. Lashing eye - rear
WARNING: In accordance with normal WARNING: Do not position a jack, jack

workshop practice and to avoid the stand or wheel free support under the
possibility of damage or personal injury, subframe transverse members.
work must not be carried out on or under a
vehicle when it is supported solely on a jack. CAUTION: Use suitable hardwood or
Place safety supports under the sill reinforced rubber pads when jacking and supporting
brackets (4 and 7). the vehicle.
LIFTING AND TOWING 1

INFORMATION
WORKSHOP JACK TOWING
Front It is recommended that a recovery trailer or two

Locate the jack head under the front subframe wheel car ambulance be used. When a recovery
longitudinal (5 or 6) towards the rear directly below trailer, the car should be secured using the front
the drive shaft. lashing/towing eye (1) and the rear lashing points on
Position a safety support under the appropriate floor the subframe (10). No other attachment points may
front reinforcement (2 or 3). be used for this purpose. In an emergency, the car
may be towed on its own wheels using the front
Side lashing/towing eye.
Locate the jack head under the appropriate front sill
reinforced bracket (4). CAUTION: Do not use the car for towing
Position a safety support under the nearest floor another light vehicle, or a trailer, as it not
front reinforcement (2 or 3). suitable for this purpose.
CAUTION: The side jacking points are Suspended tow

designed to accommodate the vehicle jack A front wheel lift should be used with a cross beam
only. and body protection.
Rear Before towing commences release the handbrake,

Locate the jack head under the triangular depression place the gear lever in neutral and the ignition switch
on the appropriate rear subframe longitudinal (8 or at ’I’. Do not tow at a speed greater than 30 mph, 50
9). km/h.
Position a safety support under the adjacent rear sill
reinforcement (7). CAUTION: On no account should the car
be towed with the front wheels on the
ground if the transmission is faulty, the
transmission fluid level is low, or the towing
distance exceeds 30 miles, 50 km.
WHEEL-FREE LIFT
Two-post lift and crossbeams: Locate the pads

under the floor front reinforcements (2, 3), and under
the rear sill reinforcements (5, 7).
Longitudinal beams: Locate the beams under the

front and rear subframe longitudinals (5, 6) and (8,
9). Raise the lift a few inches and ensure the car is
firmly supported. Raise the lift to full height and
inspect the lifting points for security.
2 LIFTING AND TOWING

INFORMATION
Manual gearbox models

Use the front lashing/towing eye (1) for towing the
car on all four wheels from the front.
WARNING: To ensure that the steering

does not lock when the car is being towed,
it is essential that the starter key is turned
to position ’I’, and remains there while the car is
moving.
Ensure the following precautions are observed:
Do not tow if the gearbox or a drive shaft is
faulty.
Do not tow if a wheel or drive shafts are touching
the body or frame.
Ensure the gear lever is in neutral and the
handbrake is released.
Remember that greater effort than normal will be
necessary to apply the brakes if the car is being
towed without the engine running.
Automatic gearbox models

When a car with an automatic gearbox is to be
towed, a suspended tow must be used because the
gearbox is not adequately lubricated without the
engine running. The following precautions must be
observed:
The selector must be at ’N’.
CAUTION: A rear suspended tow must not

be attempted as serious damage will be
caused to the automatic transmission.
NOTE: A vehicle fitted with an automatic

gearbox cannot be started by towing or
pushing.
LIFTING AND TOWING 3

INFORMATION
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 valve OHV

Cylinder arrangement . . . . . . . . . . . . . . . . . . . . . . . . 4 in line - transverse
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.61 mm
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.28 mm
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1275 cm3
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise, viewed from front of engine
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 : 1
Valve timing
Inlet:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9°BTDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41°ABDC
Exhaust:
Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55°BBDC
Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17°ATDC
Lubrication
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet sump, crankshaft driven eccentric rotor pump
Relief valve opening pressure . . . . . . . . . . . . . . . . . . 2.0 bar
Pressure at idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 bar
Oil pressure warning light switch opens . . . . . . . . . . 0.2 to 0.3 bar
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow with disposable canister
FUEL SYSTEM
Electronic fuel injection data . . . . . . . . . . . . . . . . . . . See Engine Tuning Data

Fuel Pump:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric immersible
Pump maximum pressure at 16V . . . . . . . . . . . . . . 2.7 bar
Regulated injection pressure range . . . . . . . . . . . . . 1.0 to 3.0 bar ± 0.2 bar
COOLING SYSTEM
Pressure cap opens . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 bar

Thermostat starts to open . . . . . . . . . . . . . . . . . . . . . 88°C ± 2°
Thermostat fully open . . . . . . . . . . . . . . . . . . . . . . . . 100°C ± 2°
Cooling fan operation:
On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105°C
Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98°C
REVISED: 12/96 GENERAL DATA 1

INFORMATION
CLUTCH
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diaphragm spring, hydraulically operated

Clutch plate diameter . . . . . . . . . . . . . . . . . . . . . . . . . 180 mm
MANUAL GEARBOX
Gear ratios:
Fourth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.000 : 1
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.425 : 1
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.185 : 1
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.647 : 1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.667 : 1
AUTOMATIC GEARBOX
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-speed, torque converter

Gear ratios:
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.000 : 1
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.460 : 1
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.845 : 1
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.690 : 1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.690 : 1
FINAL DRIVE
Manual gearbox:
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.213 : 1
Road speed at 1000 rev/min:
Fourth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.6 km/h 17.8 mph
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1 km/h 12.5 mph
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 km/h 8.2 mph
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 km/h 4.9 mph
Automatic gearbox:
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.690 : 1
Road speed at 1000 rev/min:
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3 km/h 18.2 mph
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1 km/h 12.5 mph
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9 km/h 9.9 mph
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 km/h 6.8 mph
2 GENERAL DATA
INFORMATION
WHEELS
Wheel size and type:

Steel wheel (spare only) . . . . . . . . . . . . . . . . . . . . . 4«J x 12
Standard alloy wheel . . . . . . . . . . . . . . . . . . . . . . . . 4«J x 12
Optional alloy wheel . . . . . . . . . . . . . . . . . . . . . . . . 6J x 13
TYRE SIZE
Steel spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 145/70-SR 12

Standard alloy wheel . . . . . . . . . . . . . . . . . . . . . . . . . 145/70-SR 12
Optional alloy wheel . . . . . . . . . . . . . . . . . . . . . . . . . 175/50-VR 13
TYRE PRESSURES
Pressures (cold):
Loading conditions bar lbf/in
All load conditions

145/70-SR 12
Front 2.0 28
Rear 2.0 28
175/50-VR 13
Front 2.0 28
Rear 1.8 26
ELECTRICAL
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, negative earth
Battery
Cold crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 amps
Reserve capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 minutes
Alternator
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A115l - 65
Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Amps
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21TR
Starter motor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M79
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 kW
GENERAL DATA 3
INFORMATION
DIMENSIONS
Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 m

Overall width (including mirrors) . . . . . . . . . . . . . . . . 1.58 m
Overall height * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34 m
Ground clearance * . . . . . . . . . . . . . . . . . . . . . . . . . . 163 mm
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04 m
Turning circle (kerb to kerb):
145/70 SR-12 tyres . . . . . . . . . . . . . . . . . . . . . . . . . 8.60 m
175/VR-13 tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.80 m
* At unladen weight
WEIGHTS
Unladen (fuel tank full, excluding optional fittings) . . . 715 kg

Maximum gross vehicle weight . . . . . . . . . . . . . . . . . 1050 kg
Maximum roof rack load (distributed) . . . . . . . . . . . . 50 kg
CAUTION: Do not use the vehicle for towing a trailer, as it is not suitable for this purpose.
4 GENERAL DATA
INFORMATION
Model: SPi with manual gearbox
Engine
Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A2EK71/1275 cm3
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Idle speed, controlled by the ECM * . . . . . . . . . . . . . 900 æ 50 rev/min
Exhaust gas CO content at idle . . . . . . . . . . . . . . . . . less than 0.4% hot
Ignition timing at idle speed ç . . . . . . . . . . . . . . . . . . 15°BTDC (nominal)
Valve rocker clearance (cold) . . . . . . . . . . . . . . . . . . 0.27 to 0.33 mm
Ignition Coil
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quad type dry
Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEC 1000710
Primary resistance at 20°C . . . . . . . . . . . . . . . . . . . . 0.41 to 0.61 ohm
Secondary resistance at 20°C . . . . . . . . . . . . . . . . . . 6200 to 6700 ohm
Consumption at engine idle speed . . . . . . . . . . . . . . 4.7 to 6.7 amps
Spark Plugs
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK BPR6E
Plug gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 to 0.90 mm
Engine Management System

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single point throttle body injection
MEMS ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MNE 101350
Fuel pump module . . . . . . . . . . . . . . . . . . . . . . . . . . . WFX 10047
Injector/fuel pressure regulator . . . . . . . . . . . . . . . . JZX 3300
Fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 æ 0.2 bar constant
Throttle position (TP) sensor . . . . . . . . . . . . . . . . . . . MJC 10020
Intake air temperature (IAT) sensor . . . . . . . . . . . . . . NNK 10001
Crankshaft position (CKP) sensor . . . . . . . . . . . . . . . ADU 7340
Engine coolant temperature (ECT) sensor . . . . . . . . ADU 7161
Heated oxygen sensor (HO2S) . . . . . . . . . . . . . . . . . MHK 10004
Lost motion gap at engine idle speed . . . . . . . . . . . . Equal either side of lever
TP sensor voltage:
Throttle closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 1v
Throttle open 90° . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 to 5v
Fuel grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON minimum - UNLEADED fuel
CAUTION: Do not use LEADED fuel as it will damage the catalyst. Serious damage to the engine may
occur if a lower octane number fuel than that recommended is used.
* No electrical load present
ç Crankshaft degrees and rev/min
ENGINE TUNING DATA 1

INFORMATION
Model: SPi with automatic gearbox
Engine
Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A2EK72/1275 cm3
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Ignition Coil
Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEC 1000710
Spark Plugs
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK BPR6E
Plug gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 to 0.90 mm

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single point throttle body injection
MEMS ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MNE 101350
Injector/fuel pressure regulator . . . . . . . . . . . . . . . . JZX 3300
Engine coolant temperature (ECT) sensor . . . . . . . . ADU 7161
Lost motion gap at engine idle speed . . . . . . . . . . . . Equal either side of lever
TP sensor voltage:
2 ENGINE TUNING DATA

INFORMATION
Model: MPi
Engine
Type / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A2LK70/1275 cm3
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Ignition Coil
Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEC 1000710
Spark Plugs
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NGK BPR6E
Plug gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 to 0.90 mm

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two point injection
MEMS ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MNE 104290
Injector/fuel pressure regulator . . . . . . . . . . . . . . . . MKW 10016
Camshaft position (CMP) sensor . . . . . . . . . . . . . . . . NSC 100390
Engine coolant temperature (ECT) sensor . . . . . . . . MEK 100060
TP sensor voltage:
ENGINE TUNING DATA 3

INFORMATION
Refer to the appropriate section heading for component torque figures, e.g.
Road wheel nuts - refer to SUSPENSION,
Exhaust front pipe to manifold - refer to MANIFOLD AND EXHAUST
GENERAL
Bolt M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Bolt M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Bolt M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Bolt M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
1/4 UNC/UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
5/16 UNC/UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
3/8 UNC/UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
7/16 UNC/UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Nm
1/2 UNC/UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
5/8 UNC/UNF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Nm
ENGINE
Timing gear cover bolts . . . . . . . . . . . . . . . . . . . . . . . 16 Nm

Timing gear nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Timing chain tensioner bolts . . . . . . . . . . . . . . . . . . . 22 Nm
Cylinder head nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm then a further 34 Nm
Front cover plate bolts . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm
Rocker shaft nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Camshaft thrust plate screws . . . . . . . . . . . . . . . . . . 11 Nm
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm
Engine LH mounting:
Mounting to subframe - nuts . . . . . . . . . . . . . . . . . . 25 Nm
Mounting to engine - bolts . . . . . . . . . . . . . . . . . . . . 25 Nm
Engine RH mounting:
Mounting to flywheel housing cover - bolts . . . . . . . 18 Nm
Mounting to subframe - nuts . . . . . . . . . . . . . . . . . . 22 Nm
Engine steady bar upper bolts . . . . . . . . . . . . . . . . . . 22 Nm
Engine steady bar lower:
Bar to subframe bolt . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Bar to flywheel housing bolt . . . . . . . . . . . . . . . . . . . 40 Nm
Oil pressure gauge sensor . . . . . . . . . . . . . . . . . . . . 60 Nm
Oil pressure relief valve cap . . . . . . . . . . . . . . . . . . . 60 Nm
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Oil pump to engine - bolts . . . . . . . . . . . . . . . . . . . . . 11 Nm
Flywheel housing to engine/gearbox - bolts . . . . . . . 25 Nm
Earth lead to engine - bolt . . . . . . . . . . . . . . . . . . . . . 10 Nm
Engine to gearbox - nuts and bolts . . . . . . . . . . . . . . 8 Nm
Flywheel to crankshaft - bolt . . . . . . . . . . . . . . . . . . . 150 Nm
Flywheel housing cover - bolts . . . . . . . . . . . . . . . . . 10 Nm
Engine mounting adaptor plate to engine - bolts . . . . 25 Nm
REVISED: 12/96 TORQUE WRENCH SETTINGS 1

INFORMATION
EMISSION CONTROL
Oil breather/separator to flywheel housing . . . . . . . . 18 Nm

Catalytic converter to tail pipe nuts . . . . . . . . . . . . . . 9 Nm
Catalytic converter to front pipe nuts . . . . . . . . . . . . . 45 Nm
Emission canister purge valve to body - bolts . . . . . . 9 Nm
ECT sensor to thermostat housing . . . . . . . . . . . . . . 15 Nm

MAP sensor to inlet manifold . . . . . . . . . . . . . . . . . . . 6 Nm
IAT sensor to inlet manifold . . . . . . . . . . . . . . . . . . . . 7 Nm
TP sensor to throttle body screws . . . . . . . . . . . . . . . 1.5 Nm
Throttle housing to inlet mainifold - bolts . . . . . . . . . . 8 Nm
Throttle pedal nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Ignition coil to bracket - bolts . . . . . . . . . . . . . . . . . . . 10 Nm
HO2S to exhaust manifold . . . . . . . . . . . . . . . . . . . . . 55 Nm
Air cleaner to inlet manifold . . . . . . . . . . . . . . . . . . . . 7 Nm
ECM to mounting bracket . . . . . . . . . . . . . . . . . . . . . 10 Nm
ECM mounting bracket to body . . . . . . . . . . . . . . . . . 10 Nm
IACV to inlet manifold - bolts . . . . . . . . . . . . . . . . . . . 7 Nm
CMP sensor to engine - bolt . . . . . . . . . . . . . . . . . . . 10 Nm
CKP sensor to flywheel housing - bolts . . . . . . . . . . . 6 Nm
CKP sensor multiplug to flywheel housing - bolt . . . . 3 Nm
FUEL SYSTEM
Fuel breather valve nut . . . . . . . . . . . . . . . . . . . . . . . 9 Nm

Fuel pump to fuel tank nuts . . . . . . . . . . . . . . . . . . . . 9 Nm
IFS to bulkhead - screws . . . . . . . . . . . . . . . . . . . . . . 2 Nm
Fuel filter mounting bracket to body . . . . . . . . . . . . . . 9 Nm
Fuel pipe unions to fuel filter . . . . . . . . . . . . . . . . . . . 30 Nm
Fuel feed/return pipes to fuel rail . . . . . . . . . . . . . . . . 5 Nm
Fuel rail to inlet manifold - bolts . . . . . . . . . . . . . . . . . 10 Nm
COOLING
Radiator brackets to bonnet platform . . . . . . . . . . . . . 9 Nm

Thermostat housing bolts . . . . . . . . . . . . . . . . . . . . . 11 Nm
Coolant pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Coolant pump pulley bolts . . . . . . . . . . . . . . . . . . . . . 10 Nm
Expansion tank to mounting bracket . . . . . . . . . . . . . 10 Nm
Expansion tank mounting bracket to body . . . . . . . . . 10 Nm
2 TORQUE WRENCH SETTINGS REVISED: 12/96

INFORMATION
MANIFOLD AND EXHAUST
Front pipe to manifold nuts . . . . . . . . . . . . . . . . . . . . 22 Nm

Front pipe to differential housing . . . . . . . . . . . . . . . . 22 Nm
Inlet and exhaust manifold nuts . . . . . . . . . . . . . . . . . 22 Nm
Catalytic converter to tail pipe nuts . . . . . . . . . . . . . . 9 Nm
Catalytic converter to front pipe nuts . . . . . . . . . . . . . 45 Nm
CLUTCH
Flywheel centre bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm

Pressure plate to flywheel bolts . . . . . . . . . . . . . . . . . 25 Nm
Flywheel housing to engine block bolts . . . . . . . . . . . 25 Nm
Slave cylinder to mounting bracket . . . . . . . . . . . . . . 37 Nm
Slave cylinder mounting bracket to flywheel
housing:
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
M5 bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm
Pipe union to master cylinder . . . . . . . . . . . . . . . . . . 14 Nm
Pipe union to slave cylinder . . . . . . . . . . . . . . . . . . . . 14 Nm
MANUAL GEARBOX
Gearbox to engine bolts . . . . . . . . . . . . . . . . . . . . . . 28 Nm

Third motion shaft bearing retaining bolts . . . . . . . . . 18 Nm
First motion shaft gear nut . . . . . . . . . . . . . . . . . . . . . 200 Nm
Speedometer drive housing to gearbox - bolts . . . . . 25 Nm
Speedometer drive housing cover - bolts . . . . . . . . . 8 Nm
Speedometer drive pinion clamping plate - bolt . . . . . 8 Nm
STEERING
Steering wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Nm

Drivers air bag module Torx screws . . . . . . . . . . . . . 9 Nm
Steering column upper mounting to fascia rail bolt . . 25 Nm
Inner column to steering rack pinion clamp bolt . . . . 16 Nm
Track rod ball joint to steering arm nut . . . . . . . . . . . 30 Nm
Steering rack U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Steering rack pinion cover bolts . . . . . . . . . . . . . . . . . 15 Nm
Steering arm to front hub bolts . . . . . . . . . . . . . . . . . 45 Nm
Steering column to pinion - bolt . . . . . . . . . . . . . . . . . 15 Nm
REVISED: 12/96 TORQUE WRENCH SETTINGS 3

INFORMATION
SUSPENSION
Wheel nuts:
Alloy wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Steel wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Upper arm to front hub . . . . . . . . . . . . . . . . . . . . . . . 52 Nm
Lower arm to front hub . . . . . . . . . . . . . . . . . . . . . . . 52 Nm
Front hub to drive shaft - nut . . . . . . . . . . . . . . . . . . . 260 Nm
Front subframe turret bolts . . . . . . . . . . . . . . . . . . . . 67 Nm
Front damper to body bracket - nut . . . . . . . . . . . . . . 37 Nm
Front damper to upper arm - nut . . . . . . . . . . . . . . . . 48 Nm
Front subframe to body - nuts and bolts . . . . . . . . . . 25 Nm
Rear damper to body . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Rear damper to suspension arm . . . . . . . . . . . . . . . . 25 Nm
BRAKES
Bleed screw to caliper . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm

Brake master cylinder nuts . . . . . . . . . . . . . . . . . . . . 25 Nm
Brake servo banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm
Brake servo to bracket nuts . . . . . . . . . . . . . . . . . . . . 25 Nm
Brake servo bracket nuts and bolts to body . . . . . . . . 25 Nm
Brake caliper to swivel hub bolts . . . . . . . . . . . . . . . . 52 Nm
Brake disc to drive flange bolts . . . . . . . . . . . . . . . . . 57 Nm
Brake drum back plate to radius arm bolts . . . . . . . . 28 Nm
Pressure limiting valve to body bolt . . . . . . . . . . . . . . 17 Nm
Brake pipe to master cylinder - union . . . . . . . . . . . . 14 Nm
Brake drum to hub - screw . . . . . . . . . . . . . . . . . . . . 7 Nm
Brake pipe union to pressure reducing valve . . . . . . . 14 Nm
Pressure reducing valve to body - bolt . . . . . . . . . . . 17 Nm
Brake pedal pivot bolt - nut . . . . . . . . . . . . . . . . . . . . 15 Nm
Brake light switch bracket to pedal box . . . . . . . . . . . 5 Nm
Brake hose union to caliper . . . . . . . . . . . . . . . . . . . . 15 Nm
Brake pipe unon to wheel cylinder . . . . . . . . . . . . . . . 14 Nm
RESTRAINT SYSTEMS
Rotary coupler bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Diagnostic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
Airbag module screws . . . . . . . . . . . . . . . . . . . . . . . . 7 Nm
Diagnostic harness earth lead bolt . . . . . . . . . . . . . . 10 Nm
Front seat belt stalk bolt . . . . . . . . . . . . . . . . . . . . . . 32 Nm
Front seat belt upper mounting bolt . . . . . . . . . . . . . . 32 Nm
Front seat belt lower mounting bolt . . . . . . . . . . . . . . 30 Nm
Front seat belt upper mounting bolt . . . . . . . . . . . . . . 30 Nm
Seat belt pre-tensioner reel bolt . . . . . . . . . . . . . . . . . 30 Nm
Seat belt pre-tensioner tube nut . . . . . . . . . . . . . . . . 6 Nm
Seat belt pre-tensioner tube screw . . . . . . . . . . . . . . 1.2 Nm
Rear seat belt buckle to body - bolt . . . . . . . . . . . . . . 30 Nm
Rear seat belt reel to body - bolt . . . . . . . . . . . . . . . . 30 Nm
Rear seat belt lower mounting bolt . . . . . . . . . . . . . . 30 Nm
Rear seat belt upper mounting bolt . . . . . . . . . . . . . . 30 Nm
4 TORQUE WRENCH SETTINGS REVISED: 12/96

INFORMATION
BODY
Bonnet hinge nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm

Front/Rear bumper to body - nuts . . . . . . . . . . . . . . . 10 Nm
Door striker to body - screws . . . . . . . . . . . . . . . . . . . 18 Nm
Bonnet latch to body - bolts . . . . . . . . . . . . . . . . . . . . 9 Nm
Wheel arch extension to body - nuts . . . . . . . . . . . . . 9 Nm
Fascia top rail to body - nuts . . . . . . . . . . . . . . . . . . . 9 Nm
Front seat to body - nut and bolt . . . . . . . . . . . . . . . . 25 Nm
HEATING AND VENTILATION
Heater to bulkhead - nut . . . . . . . . . . . . . . . . . . . . . . 9 Nm
WIPERS AND WASHERS
Wiper wheel boxes to body - nut . . . . . . . . . . . . . . . . 10 Nm
ELECTRICAL
Alternator pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm

Auxiliary drive belt tensioner pulley nut . . . . . . . . . . . 25 Nm
Auxiliary drive belt tensioner to engine . . . . . . . . . . . 22 Nm
Starter motor to flywheel housing bolts . . . . . . . . . . . 37 Nm
Starter solenoid terminal nuts . . . . . . . . . . . . . . . . . . 4 Nm
Horn mounting bracket to body . . . . . . . . . . . . . . . . . 9 Nm
Horn to mounting bracket . . . . . . . . . . . . . . . . . . . . . 10 Nm
INSTRUMENTS
Oil temperature gauge sensor . . . . . . . . . . . . . . . . . . 60 Nm
ISSUED: 12/96 TORQUE WRENCH SETTINGS 5

INFORMATION
CAPACITIES
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.0 litres

Engine/gearbox oil refill and filter change . . . . . . . . . 4.8 litres
Automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 litres
Cooling system refill . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres
Windscreen washer reservoir . . . . . . . . . . . . . . . . . . 2.3 litres
FLUIDS
Fuel
Octane rating: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNLEADED fuel - 95 RON minimum
CAUTION: Catalyst equipped vehicles MUST NOT be run on LEADED fuel as damage to the catalyst
will result.
Brake/Clutch Fluid
For topping-up Rover recommend the use of AP

CAUTION: No other ’universal’ anti-freeze
New Premium Super DOT 4 brake fluid or Castrol
should be used with UNIPART
Universal DOT 4 brake/clutch fluid.
SUPERPLUS 3 ANTI-FREEZE AND
SUMMER COOLANT.
Anti-freeze solutions
The cooling system should be drained, flushed and
The overall anti-freeze concentration should not fall,
refilled with the correct amount of anti-freeze
by volume below 30% to ensure that the
solution at three years and every two years
anti-corrosion properties of the coolant are
thereafter.
maintained. Anti-freeze concentrations greater than
60% are not recommended as cooling efficiency will
After filling with anti-freeze solution, attach a warning
be impaired.
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
Use UNIPART SUPERPLUS 3 ANTI-FREEZE AND
system to ensure that the correct type is used for
SUMMER COOLANT to protect the cooling system.
topping-up.
If this is not available, use an ethylene glycol based
The recommended quantities of anti-freeze for
anti-freeze, containing no methanol with
different degrees of frost protection are:
non-phosphate corrosion inhibitors suitable for use
in mixed metal engines to ensure the protection of
the cooling system against frost and corrosion.
Solution Amount of anti-freeze Commences freezing Frozen solid
50% Litres °C °F °C °F
331/3 1.2 - 19 -2 - 36 - 33
50 1.8 - 36 - 33 - 48 - 53
CAPACITIES, FLUIDS AND LUBRICANTS 1

INFORMATION
LUBRICATION Gear linkage - Manual

Use a grease Part No. AFU 1500.1509 containing
The engine and other lubricating systems are filled 3% Molybdenum Disulphide.
with high-performance lubricants giving prolonged
life. Steering rack
Use Sterak grease specification 31.815.252 in
CAUTION: You should always use a high accordance with specification 31.820.194; a toal
quality oil of the correct viscosity range in quantity of 100 cm3 is required to fill a rack from the
the engine and gearbox during dry condition.
maintenance and when topping-up. The use of
oil not to the correct specification can lead to General Greasing
high oil and fuel consumption and ultimately to Use Multipurpose Lithium Base Grease N.L.G.I.
damaged components. consistency No. 2.
Oil to the correct specification contains additives Bonnet latch

which disperse the corrosive acids formed by Lubricate cable and latch with oil.
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives Locks, latches and hinges
should not be used. Use Door Lock and Latch Lubricant, Part No. VWN
Always adhere to the recommended servicing 10075.
intervals.
Engine/Gearbox oil
Use oil meeting specification ACEA A2 and having a

viscosity of 10W/30.
2 CAPACITIES, FLUIDS AND LUBRICANTS

ENGINE
CONTENTS Page
ADJUSTMENTS
CRANKSHAFT PRIMARY GEAR END-FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VALVE ROCKER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REPAIRS
CAMSHAFT THRUST PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CRANKSHAFT FRONT PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CRANKSHAFT FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAIN BEARING CAP OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT PLATE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROCKER COVER GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ROCKER SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE AND GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE LH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ENGINE RH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENGINE STEADY BAR - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ENGINE STEADY BAR - LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FLYWHEEL HOUSING OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FLYWHEEL HOUSING GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE TO GEARBOX GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TIMING GEAR COVER AND OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TIMING CHAIN AND GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ENGINE
CRANKSHAFT PRIMARY GEAR END-FLOAT Adjust
Service repair no - 12.21.28 4. Remove flywheel housing oil seal. See

Repairs.
Check and Adjust 5. Remove primary gear front thrust washer.
6. Measure thickness of thrust washer.
Check 7. Select a thrust washer which will give the
correct end-float figure.
1. Remove clutch assembly. See CLUTCH,
Repairs. NOTE: Thrust washers are available in
sizes from 2.79 mm to 3.04 mm in steps of
0.05 mm.
8. Grease the selected washer and fit with

chamfered inner edge against the crankshaft.
9. Fit primary gear (without the oil seal), fit
backing ring and ’C’ shaped washer.
10. Check that end-float is now within tolerance.
11. Remove ’C’ shaped washer, backing ring and
primary gear.
12. Fit flywheel housing oil seal. See Repairs.
13. Fit clutch assembly. See CLUTCH, Repairs.
2. Using feeler gauges, check primary gear

end-float between backing ring and primary
gear.
DATA: End-float = 0.089 to 0.165 mm.
3. Adjust end-float if outside of tolerance.
ADJUSTMENTS 1
ENGINE
VALVE ROCKER ADJUSTMENT
Service repair no - 12.29.48
Remove
1. Disconnect battery earth lead.

2. Remove rocker cover. See Repairs.
3. Check clearance between the valve rocker

arms and valve stems with a feeler gauge.
Data: Clearance = 0.30 mm.
4. Check clearance of each valve in the following
order:
Check No. 1 valve with No. 8 fully open.
NOTE: The gauge should be a sliding fit

when the engine is cold.
5. Loosen adjusting screw lock nut.

6. Rotate the adjusting screw, clockwise to
decrease or anti-clockwise to increase the
clearance.
7. Tighten locknut when clearance is correct,
holding the screw against rotation.
8. Fit rocker cover. See Repairs.
9. Connect battery earth lead.
2 ADJUSTMENTS
ENGINE
CAMSHAFT THRUST PLATE CRANKSHAFT FRONT PULLEY
Service repair no - 12.13.23. Service repair no - 12.21.01
Remove Remove
1. Remove timing chain and gears. See this 1. Remove coolant pump pulley. See COOLING
section. SYSTEM, Repairs.
2. Remove starter motor. See ELECTRICAL,
Repairs.
3. Fit flywheel locking tool and secure with 2

bolts.
4. Position jack under engine.
CAUTION: Use a block of wood or hard

rubber pad between jack and engine.
2. Remove 3 bolts securing camshaft thrust plate
and remove camshaft thrust plate. 5. Take the weight off engine LH mounting.
Refit
1. Clean camshaft thrust plate and engine front

plate.
2. Lubricate face of camshaft thrust plate.
3. Fit camshaft thrust plate and tighten bolts to 11
Nm.
4. Fit timing chain and gears. See this section.
6. Remove bolts securing engine LH mounting

bracket to gearbox casing.
7. Raise engine to allow access to crankshaft
pulley bolt.
REPAIRS 1
ENGINE
11. Disconnect multiplug from ECT sensor.
8. Remove nuts securing expansion tank to

mounting bracket and position tank aside.
12. Tap back lock washer from crankshaft pulley

bolt and remove bolt.
13. Remove lockwasher from bolt.
14. Remove crankshaft pulley.
9. Remove nuts securing expansion tank

mounting bracket to body and remove bracket.
10. Remove bolts securing horn bracket to body
and position horn aside.
2 REPAIRS
ENGINE
Refit CRANKSHAFT FRONT SEAL
1. Clean crankshaft pulley and ensure Woodruff Service repair no - 12.21.14

key is in position in crankshaft.
2. Lubricate oil seal surface on crankshaft pulley Remove
and fit pulley to crankshaft.
3. Fit new lock washer to pulley bolt, fit pulley bolt 1. Remove crankshaft front pulley. See this
and tighten to 150 Nm. section.
4. Secure crankshaft pulley bolt with lock washer.
5. Remove bolts securing flywheel locking tool.
6. Fit starter motor. See ELECTRICAL, Repairs.
7. Connect multiplug to ECT sensor.
8. Position horn mounting bracket to body, fit
bolts and tighten to 9 Nm.
9. Position expansion tank mounting bracket to
body fit nuts and tighten to 10 Nm.
10. Fit expansion tank to mounting bracket fit and
tighten nuts to 10 Nm.
11. Fit coolant pump pulley. See COOLING
SYSTEM, Repairs.
12. Lower jack to align engine LH mounting to
engine, fit bolts and tighten to 25 Nm.
13. Remove jack.
2. Remove bolts securing drive belt tensioner to

engine.
3. Remove tensioner and collect spacer.
REPAIRS 3
ENGINE
Refit
1. Clean mating faces of timing gear cover and

engine front plate.
2. Lubricate inner lip of new seal with oil and
outer lip with grease.
4. Disconnect breather hose from timing gear

cover.
5. Remove 11 bolts securing timing gear cover to
engine front plate.
6. Remove timing gear cover and discard gasket.
7. Remove cable tie from timing gear cover and
release harness.
8. Remove oil seal from timing gear cover.
3. Using tool 18G 134 BD support timing gear

cover.
4. Position seal on tools 18G 134 and 18G 134
BD with the lips of the seal facing upwards.
5. Drift seal into timing gear cover.
6. Using a new gasket fit the timing gear cover,
centralise the seal over the crankshaft using
tool 18G 1044.
7. Fit bolts securing timing gear cover and tighten
to 16 Nm.
8. Position harness to cover and secure with
cable tie.
9. Connect breather hose to timing gear cover.
10. Locate spacer on tensioner bolt, position drive
belt tensioner, and tighten bolts to 22 Nm.
11. Fit crankshaft front pulley. See this section.
4 REPAIRS
ENGINE
MAIN BEARING CAP OIL SEAL FRONT PLATE GASKET
Service repair no - 12.21.38 Service repair no - 12.25.10.
Remove Remove
1. Remove front mounting plate gasket. See this 1. Remove timing chain and gears. See this
section. section.
2. Remove seal from recess under front main

bearing cap.
Refit
1. Clean seal recess.

2. Apply RTV sealant to ends of new seal and
lubricate remainder of seal with clean engine
oil. 2. Remove 5 remaining bolts securing front cover
3. Fit seal into recess by first inserting the ends plate.
and then working the seal into position until the 3. Remove camshaft thrust plate.
seal face is flush with cylinder block face. 4. Remove front cover plate and discard gasket.
4. Fit front mounting plate gasket. See this
section. Refit
5. Check and if necessary top up engine oil. See
MAINTENANCEMaintenance. 1. Clean front cover plate and mating face,
dowels and dowel holes.
2. Fit gasket and position front plate to cylinder
block.
3. Fit camshaft thrust plate.
4. Fit and tighten bolts to 11 Nm.
5. Fit timing chain and gears. See this section.
REPAIRS 5
ENGINE
CYLINDER HEAD GASKET
Remove

2. Remove bonnet. See BODY, Exterior
fittings.
3. Remove air cleaner. See ENGINE
MANAGEMENT SYSTEM - MEMS, Repairs.
4. Remove front pipe to manifold gasket. See
MANIFOLD & EXHAUST SYSTEMS, Repairs.
10. Disconnect multiplug from MAP sensor.
5. Release throttle cable adjustment nut from

abutment bracket.
6. Disconnect throttle cable from throttle cam and
position aside.
11. Disconnect 2 multiplugs from fuel injectors.
7. Depress plastic collar on quick fit connector

and disconnect brake servo vacuum pipe from
inlet manifold.
8. Disconnect multiplug from TP sensor.
9. Disconnect multiplug from IACV.
6 REPAIRS
ENGINE
15. Disconnect HO2S multiplug from harness.

16. Remove cable tie securing HO2S cable to
harness.
12. Disconnect multiplug from IAT sensor. 17. Position absorbent cloth around fuel line quick
fit connectors.
13. Release clip securing engine harness to air

cleaner bracket and move harness clear. 18. Release quick fit connector and disconnect fuel
14. Release harness clip from rear of air cleaner return hose from fuel pipe.
bracket. 19. Release quick fit connector and disconnect fuel
feed hose from fuel pipe.
CAUTION: Plug the connections.
REPAIRS 7
ENGINE
23. Disconnect multiplug from coolant temperature

sensor.
24. Loosen top hose, expansion hose and heater
hose clips and disconnect hoses from
thermostat housing.
20. Disconnect 2 engine breather hoses from

connecting pipe.
21. Release clip and disconnect evaporative
emission canister purge hose from inlet
manifold.
22. Drain cooling system. See COOLING
SYSTEM, Adjustments.
25. Remove 2 bolts securing top hose support

bracket.
26. Remove support bracket.
27. Disconnect h.t. leads from spark plugs.
28. Remove auxiliary drive belt. See
ELECTRICAL, Repairs.
8 REPAIRS
ENGINE
33. Remove 5 remaining cylinder head nuts

34. Remove push rods and retain them in original
order.
35. Remove cylinder head assembly.
29. Loosen 2 lower bolts securing alternator to 36. Remove and discard cylinder head gasket.
engine.
30. Remove upper nut and bolt securing alternator Refit
to mounting bracket.
31. Move alternator away from bracket on cylinder 1. Clean joint surfaces of cylinder head and
head. cylinder block and ensure rocker shaft oil feed
32. Remove rocker shaft assembly. See this drilling is clear.
section. 2. Clean mating faces exhaust manifold and
exhaust front pipe.
3. Fit new cylinder head gasket dry and ensure
that marks "TOP" and "FRONT" are correctly
positioned.
4. Clean and lubricate push rods, and fit them in
original positions.
5. Fit rocker shaft assembly. See this section.
REPAIRS 9
ENGINE
15. Connect engine breather hoses to connecting

pipe.
16. Clean ends of fuel pipes.
17. Connect fuel feed hose to fuel pipe.
18. Connect fuel return hose to pipe.
19. Connect HO2S multiplug to harness.
20. Secure HO2S lead to harness with cable tie.
21. Secure harness clip to rear of air cleaner
bracket.
22. Connect multiplug to coolant temperature
sensor.
23. Connect multiplug to IAT sensor.
24. Connect multiplugs to fuel injectors.
25. Connect multiplug to IACV.
26. Connect multiplug to TP sensor.
6. Fit cylinder head nuts and tighten progressively 27. Connect multiplug to MAP sensor.
in order shown to 34 Nm initially. Finally, 28. Connect brake servo vacuum pipe to inlet
tighten in order shown to 68 Nm. manifold.
7. Tighten rocker shaft bracket nuts to 25 Nm. 29. Fit strap securing engine harness to heater
8. Align alternator to bracket on cylinder head, fit hose.
and tighten upper nut and bolt to 25 Nm. 30. Secure engine harness clip to air cleaner
9. Tighten lower bolts securing alternator to bracket.
engine to 25 Nm. 31. Connect throttle cable to throttle cam and
10. Fit auxiliary drive belt. See ELECTRICAL, locate adjusting nut to abutment bracket.
Repairs. 32. Adjust throttle cable. See ENGINE
11. Connect h.t. leads to spark plugs. MANAGEMENT SYSTEM - MEMS,
12. Fit top hose support bracket to coil bracket and Adjustments.
secure with bolts. 33. Fit front pipe to manifold gasket. See
13. Connect top hose, expansion tank hose and MANIFOLD & EXHAUST SYSTEMS, Repairs.
heater hoses to thermostat housing and tighten 34. Fit bonnet See BODY, Exterior fittings.
hose clips. 35. Connect battery earth lead.
14. Connect evaporative emission canister purge
hose to inlet manifold and secure with clip.
10 REPAIRS
ENGINE
ROCKER COVER GASKET ROCKER SHAFT ASSEMBLY
Service repair no - 12.29.40. Service repair no - 12.29.54
Remove Remove
1. Disconnect battery earth lead. 1. Drain cooling system. See COOLING

2. Remove rocker cover. See this section.
3. Loosen in the sequence shown the 13 nuts

securing rocker shaft brackets and cylinder
2. Remove 2 bolts securing rocker cover to
head then remove the 8 nuts securing the
cylinder head.
rocker shaft brackets only.
3. Collect sealing rubbers and retainers.
4. Remove rocker cover and gasket.
Refit
1. Clean mating face of rocker cover and cylinder

head.
2. Clean retainers and sealing rubbers.
3. Position gasket and cover. Fit sealing rubbers
and retainers.
4. Fit bolts securing rocker cover to cylinder head
and tighten to 5 Nm.
4. Remove rocker shaft lock plate.

5. Remove the rocker shaft assembly.
REPAIRS 11
ENGINE
Refit
1. Ensure rocker shaft is clean and oil passage is

clear.
2. Fit rocker shaft assembly locating the rocker
screws in the push rods.
3. Fit rocker shaft lock plate.
4. Working in sequence shown, tighten the

cylinder head nuts to 34 Nm then to 68 Nm.
5. Tighten rocker shaft nuts to 25 Nm.
6. Adjust valve to rocker clearances. See
Adjustments.
7. Fit rocker cover. See this section.
8. Fill cooling system. See COOLING SYSTEM,
Adjustments.
12 REPAIRS
ENGINE
VALVE
Remove
1. Remove cylinder head. See this section.

2. Remove bolt securing engine breather pipe to
cylinder head.
3. Remove 6 nuts securing inlet and exhaust
manifolds to cylinder head.
4. Remove inlet and exhaust manifolds.
5. Remove and discard manifold gasket.
6. Remove inlet manifold locating rings.
7. Remove 4 spark plugs.
REPAIRS 13
ENGINE
Refit
1. Recut valve seat in cylinder head.

2. Grind in valve.
3. Clean combustion space in cylinder head.
4. Use an air line to blow out combustion space
and valve guide.
5. Clean valve.
6. Clean valve, spring, cap and collets.
7. Lubricate valve and oil seal.
8. Fit oil seal to valve guide.
9. Fit valve to cylinder head.
10. Position valve spring and cap.
11. Using tool 18G 1519, compress valve spring.
12. Fit collets securing spring cap to valve.
13. Release valve spring and remove 18G 1519.
14. Clean mating faces of cylinder head and inlet
manifold.
15. Clean inlet manifold locating rings.
16. Fit locating rings to inlet manifold.
17. Fit NEW manifold gasket to cylinder head.
18. Fit inlet and exhaust manifolds.
8. Position tool 18G 1519 to valve. 19. Fit nuts and washers securing manifolds to
9. Compress valve spring with tool. cylinder head. Working in sequence illustrated,
10. Remove 2 collets securing spring cap to valve. tighten nuts to 22 Nm.
11. Release valve spring and remove tool 18G 20. Align breather pipe to cylinder, fit and tighten
1519. bolt.
12. Remove valve spring and cap. 21. Set gap of spark plugs to 0.85 mm.
13. Remove oil seal from valve stem. 22. Fit spark plugs and tighten to 25 Nm.
14. Remove valve from cylinder head. 23. Fit cylinder head. See this section.
14 REPAIRS
ENGINE
ENGINE AND GEARBOX
Service repair no - 12.37.01/99
Remove

2. Raise front of vehicle.
WARNING: Support on safety stands.
3. Drain engine oil. See

MAINTENANCEMaintenance.
4. Fit new sealing washer to drain plug.
5. Fit drain plug and tighten to 34 Nm.
fittings.
7. Remove radiator. See COOLING SYSTEM,
Repairs.
8. Remove engine steady bar - upper. See this
section.
9. Remove ECM. See ENGINE MANAGEMENT
SYSTEM - MEMS, Repairs.
10. Remove servo and mounting bracket
assembly. See BRAKES, Repairs.
Repairs.
12. Remove horn. See ELECTRICAL, Repairs.
13. Remove cover from engine compartment fuse

box.
14. Remove fusible link.
15. Release retaining tag and disconnect engine
harness lead from fuse box.
16. Release engine compartment fuse box from
ECM mounting bracket.
REPAIRS 15
ENGINE
17. Release clip securing main harness to ECM

mounting bracket.
18. Remove bolt securing ECM mounting bracket
to body.
19. Release ECM mounting bracket from body and
remove.
20. Remove bolt securing earth leads to body.
22. Disconnect fresh air intake hose from duct

under RH front wing.
23. Release and remove fresh air intake duct from
inner wing.
21. Disconnect Lucar from bonnet switch.
24. Loosen unions and disconnect brake pipes

from pressure reducing valve.
16 REPAIRS
ENGINE
31. Release clip and disconnect coolant feed hose

25. Disconnect multiplug from ECT sensor. from expansion tank.
26. Release clip securing ECT sensor harness to 32. Remove coolant expansion tank and mounting
mounting bracket. bracket.
27. Loosen clip and disconnect expansion tank
hose from thermostat housing.
28. Loosen clip and remove radiator top hose from
thermostat housing.
33. Remove 2 bolts securing clutch slave cylinder

to bracket on flywheel housing.
34. Withdraw slave cylinder from push rod and
position aside.
35. Position absorbent cloth around fuel line quick
fit connectors.
29. Remove 2 nuts securing coolant expansion

tank mounting bracket to body.
30. Release mounting bracket from body.
REPAIRS 17
ENGINE
39. Release clip and disconnect purge hose from

pipe.
36. Release quick fit connector and disconnect fuel

return hose from fuel pipe.
feed hose from fuel pipe.

abutment bracket.
41. Disconnect inner cable from throttle cam and
position aside.
38. Release clips and disconnect heater hoses.
18 REPAIRS
ENGINE
47. Using a suitable punch, drive out roll pin

securing selector rod to selector shaft.
48. Release selector rod from shaft.
49. Select neutral.
50. Remove nut and bolt securing gear change
42. Disconnect multiplug from evaporative
steady bar to gearbox.
emission canister purge valve.
43. Disconnect engine harness multiplug from

main harness.
44. Release engine harness multiplug from bracket
on body. 51. Using tool 18G 1240 release drive shafts from
45. Remove exhaust front pipe. See MANIFOLD differential housing.
& EXHAUST SYSTEMS, Repairs. 52. Remove both front road wheels.
46. Select reverse gear. 53. Raise one side of front suspension using a jack
positioned beneath lower suspension arm.
REPAIRS 19
ENGINE
57. Remove nut securing steering rack track rod

end to front hub.
58. Break taper joint using tool 18G 1584.
59. Disconnect track rod end from front hub.
54. Remove screw securing rebound rubber to

subframe.
55. Remove rebound rubber.
56. Fit a wedge between suspension arm and
subframe, lower suspension onto wedge and
remove jack.
CAUTION: Ensure that an appropriate

wedge is used to prevent any damage 60. Remove 2 bolts and collect washers securing
occuring to the suspension components. brake caliper to front hub.
61. Release brake caliper from front hub and
position aside.
CAUTION: Do not allow caliper to hang on

brake hose.
20 REPAIRS
ENGINE
69. Remove 2 nuts and bolts securing engine LH

mounting to subframe, collect washers.
62. Remove nut and washer securing front hub

upper ball joint to suspension arm.
CAUTION: Be careful not to damage the

rubber boot on ball joint.
64. Support front hub on stand.

65. Repeat procedure to release suspension arm
from front hub on other side. 70. Remove 2 nuts and bolts securing engine RH
66. Withdraw drive shafts from differential housing. mounting to subframe, collect washers.
67. Fit suitable lifting brackets to engine. 71. Raise engine to gain access to speedometer
68. Connect hoist to engine lifting brackets and cable union.
raise hoist to take weight of engine without
exerting load on engine mounting bolts.
REPAIRS 21
ENGINE
Refit
1. Using assistance, raise engine and manoeuvre

into position in vehicle.
2. Connect speedometer cable to gearbox and
tighten union.
3. Align engine RH mounting to subframe. Fit
bolts, washers and nuts securing engine
mounting to subframe.
4. Align engine LH mounting to subframe. Fit
bolts, washers and nuts securing engine
5. Disconnect hoist from engine lifting brackets
and remove lifting brackets.
6. Tighten nuts and bolts securing engine
mountings to subframe to 22 Nm.
7. Thoroughly clean splines of drive shaft.
8. Fit new circlip to drive shaft.
9. Engage drive shaft in differential and push fully
home.
CAUTION: Pull drive shaft to ensure circlip

72. Loosen union and disconnect speedometer is fully engaged and retains shaft.
cable from gearbox.
73. Using assistance, raise engine and manoeuvre 10. Clean front hub upper ball joint and suspension
from vehicle. arm.
11. Locate suspension arm on front hub upper ball
joint.
12. Fit nut and washer securing suspension arm to
ball joint and tighten nut to 52 Nm.
13. Clean front brake disc.
14. Fit brake caliper to front hub.
15. Fit 2 bolts and washer securing brake caliper to
front hub and tighten to 52 Nm.
16. Connect steering rack track rod end to front
hub, fit nut and tighten to 30 Nm.
17. Position jack beneath lower suspension arm
and raise front suspension.
18. Remove wedge between suspension arm and
subframe.
19. Position rebound rubber and secure with
screw.
20. Remove jack from beneath suspension arm.
21. Repeat procedure to connect suspension arm
to front hub on other side.
22. Fit both front road wheels.
22 REPAIRS
ENGINE
23. Align gear change steady bar to gearbox and 44. Connect multiplug to ECT sensor.
secure with nut and bolt. 45. Remove plugs from brake pressure reducing
24. Connect selector rod to selector shaft and align valve.
holes. 46. Clean brake pipe unions.
25. Fit new roll pin securing selector rod to shaft. 47. Connect brake pipes to pressure reducing
26. Fit exhaust front pipe. See MANIFOLD & valve and tighten unions to 14 Nm.
EXHAUST SYSTEMS, Repairs. 48. Position earth leads to body, fit bolt and tighten
27. Connect engine harness multiplug to main to 10 Nm.
harness and secure to bracket on body. 49. Connect Lucar to bonnet switch.
28. Connect multiplug to evaporative emission 50. Fit fresh air intake duct to inner wing.
canister purge valve. 51. Connect fresh air intake hose to duct beneath
29. Ensure throttle cable is correctly routed and wing.
connect inner cable to throttle cam. 52. Locate ECM mounting bracket on body, fit bolt
30. Secure throttle cable adjusting nut to abutment and tighten to 10 Nm.
bracket. 53. Secure clip on main harness to ECM mounting
31. Connect purge hose to pipe and secure with bracket.
clip. 54. Secure engine compartment fuse box to ECM
32. Connect heater hoses and secure with clips. mounting bracket.
33. Clean ends of fuel return and fuel feed pipes. 55. Connect engine harness lead to engine
34. Identify and connect fuel return hose to fuel compartment fuse box.
pipe. 56. Fit fusible link.
35. Identify and connect fuel feed hose to fuel pipe. 57. Fit cover to engine compartment fuse box.
58. Fit horn. See ELECTRICAL, Repairs.
CAUTION: Ensure hoses are correctly 59. Fit starter motor. See ELECTRICAL, Repairs.
located on fuel pipes. 60. Fit servo and mounting bracket assembly. See
BRAKES, Repairs.
36. Fit clutch slave cylinder onto push rod. 61. Fit ECM. See ENGINE MANAGEMENT
37. Align clutch slave cylinder to mounting bracket SYSTEM - MEMS, Repairs.
on flywheel housing, fit bolts and tighten to 37 62. Fit engine steady bar - upper. See this
Nm. section.
38. Position coolant expansion tank and mounting 63. Fit radiator. See COOLING SYSTEM,
bracket to body. Repairs.
39. Connect coolant feed hose to expansion tank 64. Remove stand(s) and lower vehicle.
and secure with clip. 65. Connect battery earth lead.
40. Fit 2 nuts securing coolant expansion tank 66. Refill engine with oil. See
mounting bracket to body and tighten to 10 MAINTENANCEMaintenance.
Nm. 67. Adjust throttle cable. See ENGINE
41. Connect expansion tank hose to thermostat MANAGEMENT SYSTEM - MEMS,
housing and tighten clip. Adjustments.
42. Connect radiator top hose to thermostat 68. Fit bonnet. See BODY, Exterior fittings.
housing and tighten clip.
43. Secure ECT sensor harness clip to expansion
tank mounting bracket.
REPAIRS 23
ENGINE
ENGINE LH MOUNTING
Service repair no - 12.45.11.
Remove
8. Remove engine mounting and bracket.

9. Position bracket in a vice, remove 2 bolts
securing mounting to bracket and remove
mounting.
Refit
1. Position mounting to bracket, fit bolts and

tighten to 22 Nm.
2. Remove bracket from vice, fit mounting to
subframe and tighten bolts to 22 Nm.
3. Lower engine and align to mounting bracket fit
and tighten bolts to 25 Nm.
4. Remove jack
5. Fit bolt securing radiator bottom hose to engine
mounting.
6. Remove stand(s) and lower vehicle.
3. Remove bolt securing radiator bottom hose to
engine mounting.
4. Position jack to support engine.

5. Take weight off engine mounting.

6. Remove 2 bolts securing engine mounting
bracket to gearbox.
7. Remove 2 bolts securing engine mounting to
subframe.
24 REPAIRS
ENGINE
ENGINE RH MOUNTING ENGINE STEADY BAR - UPPER
Service repair no - 12.45.12 Service repair no - 12.45.16
Remove Remove
1. Remove flywheel housing cover. See 1. Remove air cleaner. See ENGINE
CLUTCH, Repairs. MANAGEMENT SYSTEM - MEMS, Repairs.

flywheel housing cover, collect washers.
3. Remove engine mounting.
2. Remove nut and bolt securing steady bar to
Refit
body.
3. Release earth strap from body.
1. Clean mating face of flywheel housing cover
4. Remove bolt securing steady bar to engine and
and engine mounting.
collect washers.
2. Position engine mounting to cover, fit bolts and
5. Remove bolt securing engine steady bar
washers and tighten to 18 Nm.
bracket to engine and remove bracket.
3. Fit flywheel housing cover. See CLUTCH,
6. Remove engine steady bar and earth strap.
Repairs.
REPAIRS 25
ENGINE
Do not carry out further dismantling if
component is removed for access only. ENGINE STEADY BAR - LOWER
Remove
7. Remove spacers from steady bar bushes.

8. Remove bushes from steady bar.
9. Clean engine steady bar.
10. Fit bushes to steady bar.
11. Fit spacers to steady bar bushes.
Refit
1. Fit steady bar to bracket on body and align to

engine.
2. Fit washer between steady bar and engine.
3. Fit steady bar bracket to engine, fit bolt and
tighten to 22 Nm.
4. Fit earth strap to bolt, fit bolt securing steady
bar to engine and tighten to 22 Nm.
5. Fit bolt securing steady bar to body and
connect earth strap.
6. Fit nut and tighten bolt to 22 Nm. 2. Remove nut and bolt securing steady bar to
7. Fit air cleaner. See ENGINE MANAGEMENT bracket on flywheel housing.
SYSTEM - MEMS, Repairs. 3. Collect steady bar washers.
subframe.
5. Remove engine steady bar and collect
washers.
26 REPAIRS
ENGINE
component is removed for access only. FLYWHEEL HOUSING OIL SEAL
Remove
1. Remove clutch assembly. See CLUTCH,

Repairs.
6. Remove spacers from steady bar bushes.

7. Remove bushes from steady bar.
8. Clean engine steady bar.
9. Fit bushes to steady bar.
10. Fit spacers to steady bar bushes.
Refit
1. Position steady bar to mounting on subframe.

2. Fit washer between steady bar and subframe.
2. Remove dust shield from primary gear.
3. Fit nut and bolt securing steady bar to
3. Remove ’C’ washer securing primary gear to
subframe and tighten to 40 Nm.
crankshaft.
4. Align steady bar to bracket on flywheel housing
4. Remove backing ring from crankshaft.
and position washers.
5. Fit nut and bolt securing steady bar to flywheel
housing bracket and tighten to 40 Nm.
REPAIRS 27
ENGINE
Refit
1. Clean primary gear, crankshaft bearing

surface, backing ring and ’C’ washer.
2. Clean oil seal housing and dust shield.
3. Lubricate inner face of new oil seal with oil and
apply grease to outer face.
5. Position seal removing tool 18G 1068B and

screw centre bolt of tool into end of crankshaft.
6. Pull the primary gear outwards as far as
possible by hand.
7. Locate collets of tool 18G 1068B into the
groove on the primary gear.
8. Loosen wing nut on tool to withdraw primary
gear and oil seal out of housing.
9. Undo wing nut on tool and remove tool.
10. Collect collets.
11. Remove primary gear and oil seal.
4. Fit protective sleeve 18G 1043 to primary gear.
12. Remove and discard oil seal from primary
5. Lubricate protective sleeve with oil.
gear.
6. Position new oil seal on primary gear.
7. Remove protective sleeve from primary gear.
8. Locate primary gear onto crankshaft until the
gear teeth are just starting to mesh with those
of the idler gear.
CAUTION: DO NOT fully engage primary

gear with idler gear or the seal will become
displaced.
9. Position tool 18G 1068 over crankshaft.

10. Tighten wing nut of tool 18G 1068 to press oil
seal into flywheel housing.
NOTE: The seal is correctly fitted when the

base of the tool contacts the lip of the
housing bore.
11. Loosen wing nut on tool 18G 1068 and

remove tool.
12. Position backing ring on crankshaft.
13. Fit ’C’ washer to crankshaft.
14. Fit dust shield onto primary gear with its
stepped face marked ’FLYWHEEL SIDE’
facing away from the engine.
15. Fit clutch assembly. See CLUTCH, Repairs.
28 REPAIRS
ENGINE
FLYWHEEL HOUSING GASKET
Remove
1. Drain engine/gearbox oil. See

2. Remove brake master cylinder. See BRAKES,
Repairs.
3. Remove clutch assembly and release bearing.
See CLUTCH, Repairs.
5. Fit protective sleeve 18G 1043 to primary gear

splines.
4. Loosen unions and disconnect brake pipes

from pressure reducing valve.

body.
7. Release earth strap from body.
8. Remove bolt securing steady bar to engine and
collect washers.
9. Remove bolt securing engine steady bar
bracket to engine and remove bracket.
10. Remove engine steady bar and earth strap.
REPAIRS 29
ENGINE
11. Remove 3 bolts securing top of flywheel

housing to engine.
12. Remove 4 bolts securing bottom of flywheel
housing to gearbox and collect bracket.
13. Remove 8 inner bolts securing flywheel
housing to engine and gearbox.
NOTE: The 3 upper bolts securing the

centre of the flywheel housing to engine 15. Release flywheel housing from 2 locating
and gearbox have a different thread than dowels on engine.
the other 5. 16. Manoeuvre flywheel housing from engine
compartment and remove.
14. Raise engine on jack. 17. Remove locating dowels from engine and
gearbox.
30 REPAIRS
ENGINE
Refit
1. Remove all traces of gasket material from

mating faces of flywheel housing, engine and
gearbox.
2. Clean flywheel housing locating dowels.
3. Fit locating dowels to engine and gearbox.
4. Position flywheel housing on a flat surface and
support underside of housing with a block.
5. Clean oil seal aperture in flywheel housing.
6. Lubricate NEW flywheel housing oil seal.
18. Using a suitable drift, remove primary gear oil

seal from flywheel housing.
NOTE: The oil seal can be renewed

without removing the flywheel housing.
Refer to Flywheel housing oil seal. See
this section.
7. Position oil seal to flywheel housing and using

tools 18G 134 and 18G 134BC drift oil seal
into place.
8. Fit NEW gasket to engine and gearbox.
9. Ensure protective sleeve is fitted to primary
gear splines, manoeuvre flywheel housing into
position and locate on dowels.
10. Clean Loctite from threads of flywheel housing
bolts with a wire brush.
11. Apply Loctite 242 to first 3 threads of each bolt.
12. Fit 8 inner bolts securing flywheel housing to
engine and gearbox and tighten to 25 Nm.
NOTE: Ensure 3 bolts with the finer thread

are fitted at the top.
REVISED: 12/96 REPAIRS 31

ENGINE
13. Position bracket to housing, fit lower bolts FLYWHEEL

securing housing to gearbox and tighten to 25
Nm. Service repair no - 12.53.07
14. Fit upper bolts securing housing to engine and
tighten to 25 Nm. Remove
15. Fit steady bar to bracket on body and align to
engine. 1. Remove clutch assembly and release bearing.
16. Fit washer between steady bar and engine. See CLUTCH, Repairs.
17. Fit steady bar bracket to engine, fit bolt and
tighten to 22 Nm.
18. Fit earth strap to bolt, fit bolt securing steady
bar to engine and tighten to 22 Nm.
19. Fit bolt securing steady bar to body and
connect earth strap.
20. Fit nut and tighten bolt to 22 Nm.
21. Remove protective sleeve 18G 1043 from
primary gear splines.
22. Remove plugs from brake pressure reducing
valve.
23. Clean brake pipe unions.
24. Connect brake pipes to pressure reducing
valve and tighten unions to 14 Nm.
25. Fit clutch assembly and release bearing. See
CLUTCH, Repairs.
26. Fit brake master cylinder. See BRAKES,
Repairs.
27. Refill engine/gearbox with oil. See
32 REPAIRS
ENGINE
OIL FILTER Refit
Service repair no - 12.60.04 1. Clean mating face of filter head.

2. Lubricate sealing ring of new filter with clean
Remove engine oil.
3. Fit new filter and tighten by hand until it seats
then tighten a further half turn.
4. Secure radiator top hose to clip on ignition coil
mounting bracket.
5. Top up engine with oil to specification 10w/40
until level is correct.
6. Start and run engine and check for leaks.
7. Stop engine, wait a few minutes, then check oil
level. Top up if necessary.
1. Release radiator top hose from clip on ignition

coil mounting bracket.
2. Clean area around filter head and place a
container beneath engine.
3. Unscrew and discard filter.
REPAIRS 33
ENGINE
OIL PUMP ENGINE TO GEARBOX GASKET
Remove Remove
1. Remove flywheel housing gasket. See this 1. Remove engine and gearbox from vehicle. See
section. this section.
2. Remove 2 bolts securing oil pump to engine.

3. Remove pump and discard gasket.
Refit
2. Remove 2 bolts securing starter motor to
1. Clean mating faces of oil pump and cylinder flywheel housing.
block. 3. Remove starter motor.
2. Prime oil pump with clean engine oil
3. Rotate pump to align drive and fit pump with a
new gasket.
4. Fit bolts and tighten to 11 Nm.
5. Fit flywheel housing gasket. See this section.

mounting bracket to flywheel housing.
5. Remove slave cylinder mounting bracket and
collect spacer.
34 REPAIRS REVISED: 12/96

ENGINE
10. Remove thrust bearing sleeve from clutch hub.

11. Rotate crankshaft and knock back tabs on
clutch hub lock washer.
12. Rotate crankshaft until clutch hub slots are
6. Remove 6 bolts securing cover to flywheel
aligned horizontally.
housing.
7. Remove flywheel housing cover.
CAUTION: If crankshaft is not positioned
correctly, primary drive ’C’ shaped washer
may become displaced and make it
impossible to remove flywheel.
13. Fit flywheel locking tool and secure with bolts.
8. Remove 2 bolts securing CKP sensor to

flywheel housing.
9. Remove CKP sensor.

ENGINE
14. Using tool 18G 1303, remove flywheel

retaining bolt.
15. Remove key plate from crankshaft.
23. Fit protective sleeve 18G 1043 to primary gear
splines.
16. Fit thrust button of tool 18G 1381 to crankshaft.

17. Loosen centre bolt of tool 18G 1381 and
position to flywheel.
18. Fit and tighten bolts securing tool 18G 1381 to
flywheel
19. Tighten centre bolt of tool to release flywheel
from crankshaft taper.
20. Remove tool 18G 1381 from flywheel.
21. Remove flywheel and clutch assembly.
22. Remove oil seal dust shield from primary gear. 24. Remove 3 bolts securing top of flywheel
housing to engine.
25. Remove 4 bolts securing bottom of flywheel
housing to gearbox and collect bracket.
26. Remove 8 inner bolts securing flywheel
housing to engine and gearbox.
NOTE: The 3 upper bolts securing the

centre of the flywheel housing to engine
and gearbox have a different thread than
the other 5.
27. Release flywheel housing from 2 locating

dowels on engine and remove housing.

ENGINE
28. Using a suitable drift, remove primary gear oil

seal from flywheel housing.
32. Remove and discard gaskets.

33. Remove and discard main bearing cap oil seal.
34. Remove and discard ’O’ ring.
29. Remove nut and bolt securing gearbox to

engine.
30. Remove 11 bolts and 2 nuts securing gearbox
to engine.
31. Take weight of engine on lifting chains and
release gearbox from engine.

ENGINE
Refit 17. Ensure protective sleeve is fitted to primary

gear splines and locate flywheel housing on
1. Clean all traces of gasket and sealing materials dowels.
from engine and gearbox mating faces. 18. Clean Loctite from threads of flywheel housing
2. Clean locating dowels. bolts with a wire brush.
3. Lubricate with clean engine oil and fit new ’O’ 19. Apply Loctite 242 to first 3 threads of each bolt.
ring and main bearing cap oil seal to gearbox. 20. Fit 8 inner bolts securing flywheel housing to
4. Fit gaskets to face of gearbox. engine and gearbox and tighten to 25 Nm.
5. Move primary drive gear to end of crankshaft.
6. Lower engine onto gearbox. NOTE: Ensure 3 bolts with the finer thread
7. Fit nuts and bolts securing gearbox to engine are fitted at the top.
8. Fit nut and bolt securing engine to gearbox and 21. Position bracket to housing, fit lower bolts
tighten to 8 Nm. securing housing to gearbox and tighten to 25
9. Position primary drive gear into mesh. Nm.
10. Remove all traces of gasket material from 22. Fit upper bolts securing flywheel housing to
mating face of flywheel housing, engine and engine and tighten to 25 Nm.
gearbox. 23. Remove protective sleeve 18G 1043 from
11. Clean flywheel housing locating dowels. primary gear splines.
12. Position flywheel housing on a flat surface and 24. Clean crankshaft taper and flywheel.
support underside adjacent to seal aperture. 25. Fit dust shield on primary gear.
13. Clean oil seal aperture in flywheel housing. 26. Fit flywheel and clutch assembly to crankshaft.
14. Lubricate new flywheel housing oil seal. 27. Fit key plate and NEW flywheel retaining bolt.
28. Tighten flywheel retaining bolt to 150 Nm.
29. Stake lock washer into slots on clutch hub.
30. Remove bolts securing flywheel locking tool.
31. Remove flywheel locking tool.
32. Clean thrust bearing sleeve.
33. Fit thrust bearing sleeve to clutch hub.
34. Clean CKP sensor and mating face of flywheel
housing.
35. Fit CKP sensor to flywheel housing, fit bolts
36. Clean flywheel housing cover and mating face
of flywheel housing.
37. Position cover to flywheel housing, fit bolts and
tighten to 10 Nm.
38. Fit clutch slave cylinder mounting bracket and
spacer to flywheel housing.
39. Fit 3 bolts securing mounting bracket to
flywheel housing, tighten bolts:
M8 bolts to 37 Nm.
15. Position oil seal to flywheel housing and using M5 bolt to 7 Nm.
tools 18G 134 and 18G 134BC drift oil seal 40. Clean mating face of starter motor and flywheel
into place. housing.
16. Fit new gasket to engine and gearbox. 41. Fit starter motor and tighten bolts to 37 Nm.
42. Fit engine and gearbox. See this section.

ENGINE
OIL PRESSURE SWITCH OIL PRESSURE RELIEF VALVE
Remove Remove
1. Remove ignition coil. See ENGINE 1. Remove starter motor. See ELECTRICAL,
MANAGEMENT SYSTEM - MEMS, Repairs. Repairs.
2. Disconnect multiplug from oil pressure switch.

3. Loosen oil pressure switch and remove.
Refit
1. Clean threads of oil pressure switch and hole

in cylinder block.
2. Apply Loctite 572 to threads of oil pressure
switch. 2. Remove oil pressure relief valve cap.
3. Fit oil pressure switch and tighten to 25 Nm. 3. Remove and discard sealing washer from cap.
4. Fit ignition coil. See ENGINE MANAGEMENT 4. Remove spring and relief valve from cylinder
SYSTEM - MEMS, Repairs. block.
ISSUED: 12/96 REPAIRS 39

ENGINE
Refit TIMING CHAIN AND GEARS
1. Clean oil pressure relief valve, spring, cap and Service repair no - 12.65.12.
seating area of cylinder block.
2. Check the face of the relief valve is not pitted Remove
or scored, and that the valve seats correctly in
cylinder block. Renew if necessary. 1. Remove timing gear tensioner. See this
3. Measure the length of the spring. If the length section.
of the spring is less than 72.5 mm, renew
spring.
4. Fit oil pressure relief valve and spring.
5. Fit new sealing washer to cap.
6. Fit oil pressure relief valve cap and tighten to
60 Nm.
TIMING GEAR COVER AND OIL SEAL
Remove
1. Refer to crankshaft front seal for details. See

this section.
2. Remove oil thrower.

3. Bend back the lock washer tab on the
camshaft gear retaining nut.
4. Using tool 18G 98 A. unscrew the camshaft
gear retaining nut and remove the lock washer.
5. Rotate the crankshaft until the two timing

marks are aligned.
6. Gently lever off the crankshaft and camshaft
gears complete with timing chain.
40 REPAIRS ISSUED: 12/96

ENGINE
Refit
1. Fit the timing gears without the chain.
8. Position the crankshaft key at TDC and the

camshaft key at 2 o’clock.
9. Fit timing chain and gears and check
alignment.
10. Fit camshaft gear retaining nut and new lock
washer. Tighten nut to 90 Nm.and tap over
lock washer.
11. Fit oil thrower with the ’F’ mark facing
outwards.
12. Fit timing chain tensioner. See this section.
2. Check the alignment of the gears with a

straight edge.
3. Use feeler gauges to determine the thickness
of shim required.
DATA: Shim thickness = 0.152 mm.
4. Remove the crankshaft gear and the
crankshaft driving key.
5. Fit the required thickness of shims to obtain the
correct alignment.
6. Refit the driving key to the crankshaft.
7. Clean timing gears,timing chain and crankshaft
and camshaft ends.

ENGINE
TIMING CHAIN TENSIONER
Remove
1. Remove timing gear cover. See this section.
2. Remove 2 bolts securing timing chain

tensioner to engine.
3. Remove tensioner.
Refit
1. Fit tensioner and tension the chain by applying

firm pressure on the tensioner.
2. Fit bolts securing tensioner to engine and
tighten to 22 Nm.
3. Fit timing gear cover. See this section.

EMISSION CONTROL
CONTENTS Page
DESCRIPTION AND OPERATION

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REPAIRS
ENGINE BREATHER/OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EVAPORATIVE EMISSION CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EMISSION CANISTER PURGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CATALYTIC CONVERTER HEAT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EMISSION CONTROL
EMISSION CONTROL SYSTEMS The correct operation of the catalytic converter is

dependent upon close control of the oxygen
The vehicle is fitted with various emission and concentration of the exhaust gas entering the
evaporative control components to comply with converter. The quantity of oxygen in the exhaust gas
emission regulation requirements. is determined by a heated oxygen sensor situated in
the exhaust manifold. The heated oxygen sensor
The following control systems are used to reduce provides the engine control module with a signal
harmful emissions released into the atmosphere at dependent on the oxygen content. The ECM can
all times, and under all conditions: then adjust the amount of injected fuel, so that it can
implement the necessary changes to achieve the
1. Exhaust emission control correct exhaust gas content.
2. Fuel vapour evaporative loss control
3. Crankcase emission control CAUTION: Serious damage to catalytic
converter will occur if leaded fuel is used.
In many countries it is against the law for a vehicle The filler neck is designed to
owner or an unauthorised repair shop to modify or accommodate only unleaded fuel pump nozzles.
tamper with emission control equipment. In this
event the vehicle owner and/or the repairer may be Evaporative emission canister
liable for prosecution.
The evaporative emission (EVAP) canister is
The emission control system fitted to the vehicle is situated beneath the LH inner wing valance, and
designed to keep the emissions within the legal contains charcoal which absorbs and stores fuel
limits, provided that the engine is correctly from the fuel tank when the engine is not running.
maintained and is in good mechanical condition. When the engine is running the vapour is purged
from the canister into the engine and burned.
Exhaust emission control
The EVAP canister is purged when the EVAP
The engine management system provides canister purge valve is opened. Manifold depression
accurately metered quantities of fuel to the draws fresh air into the canister through the
combustion chambers, to ensure the most efficient charcoal, which releases fuel vapour into the inlet
air to fuel ratio under all conditions of operation. A manifold.
further improvement to combustion is made by
measuring the oxygen content of the exhaust gases. Evaporative emission canister purge valve
This enables the quantity of injected fuel to be
varied, which allows the ratio needed for efficient The EVAP canister purge valve is operated by the
gas conversion by the catalytic converter to be ECM. The valve remains closed until engine
maintained. temperature rises above 70°C. This is to maintain
engine tune and catalyst performance. If the valve
The catalytic converter is situated between the was to open with the engine cold or at idling speed,
exhaust front pipe and exhaust tail pipe. The the enriched mixture would delay catalyst light off
catalytic converter reduces emissions of carbon time and cause erratic idling. When the purge valve
monoxide, oxides of nitrigen (NOx) and opens, fuel vapour from the EVAP canister is drawn
hydrocarbons. The active constituents of the along a pipe through the valve and into the inlet
converter are the precious metals palladium and manifold for combustion.
rhodium.
DESCRIPTION AND OPERATION 1

EMISSION CONTROL
Crankcase emission and evaporative loss

control systems
1. Throttle disc 6. MEMS ECM

2. Fuel cut-off/two way valves 7. Crankcase breather hose
3. Evaporative emission canister 8. Oil breather/separator
4. Evaporative emission canister purge valve 9. Clean air pipe
5. Fuel filler cap 10. Restrictor
Crankcase emission control system The gases are then drawn through a restrictor into
the inlet manifold below the throttle disc to be
To ensure crankcase depression is maintained, consumed in the combustion chambers. The oil filler
clean air is drawn into the system through a pipe cap on the rocker cover also incorporates an internal
connected to the air cleaner side of the inlet breather passage and a filter, to reduce crankcase
manifold above the throttle disc. The increase in emissions.
manifold depression causes air and crankcase
gases to pass along pipes through oil
breather/separators on the engine front cover and
flywheel housing.
2 DESCRIPTION AND OPERATION REVISED: 12/96

EMISSION CONTROL
ENGINE BREATHER/OIL SEPARATOR EVAPORATIVE EMISSION CANISTER
Remove Remove

2. Disconnect breather hose from oil separator.

3. Remove 2 nuts and washers securing
1. Remove ’E’ clip securing emission canister
breather/oil separator to flywheel housing.
pipe to mounting bracket.
4. Remove engine breather/oil separator from
2. Release emission canister pipe from mounting
flywheel housing.
bracket.
5. Remove and discard gasket.
3. Remove and discard ’O’ ring from valve.
4. Release clip and disconnect hose from fuel
Refit
tank vent pipe.
1. Clean mating face of breather/oil separator and
flywheel housing.
2. Wash out breather/oil separator with cleaning
fluid.
3. Using an air line, dry breather/oil separator.
4. Fit new gasket to flywheel housing.
5. Fit breather/oil separator to flywheel housing,
fit washers and nuts and tighten to 18 Nm.
6. Connect breather hose to breather/oil
separator.
7. Fit air cleaner. See ENGINE MANAGEMENT

EMISSION CONTROL
EMISSION CANISTER PURGE VALVE
Remove
6. Disconnect vent pipe from emission canister.

7. Release strap securing emission canister to
mounting bracket beneath wing. 1. Disconnect multiplug from valve.
8. Release emission canister from mounting 2. Release clip and disconnect purge hose from
bracket and remove. valve.
Refit pipe to mounting bracket.
1. Fit emission canister to mounting bracket and bracket.
secure with strap. 5. Slide purge valve from mounting bracket and
2. Connect vent hose to emission canister. remove.
3. Lubricate new ’O’ ring with silicone grease and 6. Remove and discard ’O’ ring from valve.
fit to purge valve.
4. Connect emission canister pipe to purge valve. Refit
5. Secure emission canister pipe to mounting
bracket with ’E’ clip. 1. Lubricate new ’O’ ring with silicone grease and
6. Connect hose to fuel tank vent pipe and secure fit to valve.
with clip. 2. Fit purge valve to mounting bracket.
7. Remove stand(s) and lower vehicle. 3. Connect emission canister pipe to valve.
4. Secure emission canister pipe to mounting
bracket with ’E’ clip.
5. Connect purge hose to valve and secure with
clip.
6. Connect multiplug to purge valve.

EMISSION CONTROL
CATALYTIC CONVERTER Refit
Service repair no - 17.50.01 1. Clean mating faces of catalytic converter, front

pipe and tail pipe.
Remove 2. Fit new gasket to catalytic converter flange.
3. Fit catalytic converter to front pipe and connect
1. Raise front of vehicle. to tail pipe.
4. Fit nuts securing front pipe to catalytic
WARNING: Support on safety stands. converter and tighten to 45 Nm.
5. Fit nuts securing tail pipe to catalytic converter
and tighten evenly to 9 Nm.
2. Remove 2 nuts securing catalytic converter to

front pipe.
3. Remove 2 nuts securing catalytic converter to
tail pipe.
4. Disconnect catalytic converter from tail pipe
and remove from front pipe.
5. Remove and discard gasket from flange on
catalytic converter.
CAUTION: Catalytic converters are

manufactured from ceramic material
which is very fragile, avoid heavy impacts
on converter casing.
REPAIRS 3
EMISSION CONTROL
CATALYTIC CONVERTER HEAT SHIELD
Remove
1. Remove intermediate pipe heat shield. See

2. Remove 2 nuts securing catalytic converter

heat shield to body.
3. Release heat shield from studs and slide
forward.
4. Manoeuvre heat shield around exhaust pipe
and remove.
Refit
1. Manoeuvre heat shield into position and locate

on studs.
2. Fit and tighten nuts securing heat shield to
body.
3. Fit intermediate pipe heat shield. See
4 REPAIRS
ENGINE MANAGEMENT SYSTEM - MEMS
CONTENTS Page

ENGINE COMPARTMENT COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . 1
ENGINE MANAGEMENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REPAIRS
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
THROTTLE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
THROTTLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE CONTROL MODULE (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IDLE AIR CONTROL VALVE (IACV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INTAKE AIR TEMPERATURE (IAT) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE COOLANT TEMPERATURE (ECT) SENSOR . . . . . . . . . . . . . . . . . . . . . 9
CRANKSHAFT POSITION (CKP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
THROTTLE POSITION (TP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR . . . . . . . . . . . . . . . . . . . . . 12
ENGINE MANAGEMENT RELAY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CAMSHAFT POSITION (CMP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEATED OXYGEN SENSOR (HO2S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE COMPARTMENT COMPONENT

LOCATIONS
1. Engine Control Module (ECM) 8. Intake Air Temperature (IAT) sensor

2. Relay module 9. Evaporative emission canister purge valve
3. Idle Air Control Valve (IACV) 10. Camshaft Position (CMP) sensor
4. Fuel pressure regulator 11. Engine Coolant Temperature (ECT) sensor
5. Throttle Position (TP) sensor 12. Ignition coil
6. Air cleaner 13. Heated Oxygen Sensor (HO2S)
7. Manifold Absolute Pressure (MAP) sensor 14. Crankshaft Position (CKP) sensor


IGNITION SYSTEM
The Engine Control Module (ECM) monitors the
conditions required for optimum combustion of fuel The ECM determines the optimum ignition timing
in the cylinder through sensors located at strategic based on the signals from the following sensors:
points around the engine. As a result of these
sensor inputs, the engine control module can adjust 1. Crankshaft position sensor - Engine speed and
the fuel quantity and timing of the fuel being crankshaft position
delivered to the cylinders. 2. Manifold absolute pressure sensor - Engine
load
The main features are as follows: 3. Engine coolant temperature sensor - Engine
temperature
• A single ECM controls the fuel injection system 4. Throttle position sensor - Throttle pedal
and the ignition system. The ECM incorporates released
short circuit protection and can store intermittent
faults on certain inputs. TestBook can interrogate The engine management system uses no centrifugal
the ECM for these stored faults. or vacuum advance. Timing is controlled by the
ECM which is energised by the main relay, located
• The ECM is electronically immobilised which within the relay module. Spark distribution is
prevents the engine from being started unless it achieved by a direct ignition system which consists
receives a coded signal from the anti-theft control of a twin-ignition coil driven directly from the ECM.
unit.
• In conjunction with the throttle position sensor

the ECM uses the speed/density method of air
flow measurement to calculate fuel delivery. This
method measures the inlet air temperature and
inlet manifold pressure and assumes that the
engine is a calibrated vacuum pump, with its
characteristics stored in the ECM, it can then
determine the correct amount of fuel to be
injected.
• The vehicle diagnostic connector allows engine

tuning or fault diagnosis to be carried out using
TestBook without disconnecting the ECM
harness multiplug.
• The ECM harness multiplug incorporates

specially plated pins to minimise oxidation and
give improved reliability.
• The ECM controls the operation of the radiator

and air conditioning cooling fans, based on
signals received from the engine coolant
temperature sensor.
• If certain system inputs fail, the ECM implements

a back-up facility to enable the system to
continue functioning, although at a reduced level
of performance.

BASIC IGNITION TIMING
Crankshaft position sensor Camshaft position sensor
The speed and position of the engine is detected by The camshaft position sensor has two functions. The
the crankshaft position (CKP) sensor which is bolted first is to enable the ECM to run a sequential fuelling
to, and projects through, the engine adaptor plate mode. The second is to measure the actual cam
adjacent to the flywheel. period, this measurement is achieved using teeth on
the camshaft to indicate when the valve opens and
The CKP sensor is an inductive sensor consisting of closes.
a bracket mounted body containing a coil and a
permanent magnet which provides a magnetic field. If the camshaft position sensor fails when the engine
The CKP sensor is situated so that an air gap exists is running, the engine will continue to run normally in
between it and the flywheel. Air gap distance is sequential fuelling mode. If the sensor fails before
critical for correct operation. the engine is started, the engine will start but run at
a reduced rev limit in comparison to the normal rev
The flywheel incorporates a reluctor ring which limit of 6500 rpm. Camshaft position sensor failure
consists of 32 poles spaced at 10° intervals, with 4 can be identified using TestBook.
missing poles at 30°, 60°, 210° and 250°. The
missing poles inform the ECM when to operate the
groups of injectors. When the flywheel rotates, as a
pole passes the CKP sensor it disturbs the magnetic
field inducing a voltage pulse in the coil. This pulse
is transmitted to the ECM.
By calculating the number of pulses that occur within

a given time, the ECM can determine the engine
speed. This is a primary input necessary to make
the engine run.
REVISED: 12/96 DESCRIPTION AND OPERATION 3

Manifold absolute pressure sensor IGNITION TIMING COMPENSATION
Engine coolant temperature sensor
The manifold absolute pressure (MAP) sensor is

mounted directly on the inlet manifold. The MAP
sensor converts pressure variations within the inlet The engine coolant temperature (ECT) sensor is a
manifold into graduated electrical signals which can ’thermistor’ (a temperature dependent resistor), i.e.
be read by the ECM. Increases and decreases in the the voltage output varies in proportion to
manifold pressure provide the ECM with an accurate temperature. The ECT sensor is located on top of
representation of the load being placed on the the coolant outlet elbow. The ECM constantly
engine allowing the ECM to adjust the quantity of monitors this signal and uses the information to
fuel being injected and the ignition timing to achieve provide optimum driveability and emissions by
optimum fuelling of the engine. advancing or retarding the ignition timing.
Idle speed control
With the throttle pedal released and the engine at

idle, the ECM uses the fast response of the engine
to ignition timing to maintain idle stabilisation.
When loads are placed on or removed from the

engine, the ECM responds to changes in engine
speed and in conjunction with adjusting the idle air
control valve (IACV), advances or retards the
ignition timing to maintain a specified idle speed.
When load is removed from the engine the IACV
returns to its original position and the ignition timing
returns to the idle setting.
NOTE: Due to the sensitivity of this

system the ignition timing will be
constantly changing at idle speed.
4 DESCRIPTION AND OPERATION

IGNITION COMPONENTS
Ignition coil
The coil for the programmed ignition system is

mounted on the front of the engine. The coil has a
lower primary winding resistance (0.63 to 0.77 ohms
at 20°C) than a coil in a conventional ignition
system. This allows the full h.t. output to be reached
faster and so makes the coil operation more
consistent throughout the engine speed range.

FUEL SYSTEM The Modular Engine Management System (MEMS)

is controlled by an ECM mounted in the engine
Engine Control Module (ECM) compartment. The ECM is an adaptive unit which
over a period of time learns the load and wear
characteristics of the engine it controls. The ECM
remembers and updates two main engine
requirements when the engine is running at normal
operating temperature:
1. The position of the idle air control (IAC) valve

required to achieve a specified idle speed. This
is then used as a reference for IAC valve
movement to achieve idle speed under all load
conditions.
2. The fuelling change or offset required to
achieve a set oxygen sensor voltage. This
allows the system to provide the correct
fuelling without having to apply excessive
adjustments to the fuelling which can adversely
affect the emissions and driveability.
NOTE: After fitting a different ECM,

TestBook will be required to reprogramme
the ECM with the code from the anti-theft
control unit and to perform a full engine tune
procedure.
The ECM inputs and outputs are shown in the

following table:
INPUTS OUTPUTS
Crankshaft position sensor

Camshaft position sensor Purge valve
Manifold absolute pressure sensor Ignition coil
Engine coolant temperature sensor Injectors
Intake air temperature sensor Idle air control valve
Heated oxygen sensor ECM Fuel pump relay
Throttle position sensor Diagnostic connector
Diagnostic input Heated oxygen sensor relay
Battery supply Main relay
Starter signal Cooling fans
Earth supply Air conditioning
Anti-theft control unit

Intake air temperature sensor Injectors
The intake air temperature (IAT) sensor is located in

the side of the inlet manifold. The IAT sensor is of
the negative temperature coefficient (NTC) type,
designed to reduce its resistance with increasing
The two fuel injectors are fitted between the
temperature. The ECM receives a signal
pressurised fuel rail and inlet manifold. Each injector
proportional to the temperature of the intake air.
comprises a solenoid operated needle valve and a
When used in conjunction with the signal from the
specially designed nozzle to ensure good fuel
manifold absolute pressure sensor the ECM can
atomisation.
calculate the volume of oxygen in the air and adjust
the quantity of fuel being injected to achieve
The ECM determines when to operate the injectors
optimum fuelling of the engine.
based on the signal it receives from the crankshaft
position sensor.
The ECM provides an earth signal for the period the

injectors are required to be open, the injector
solenoids are energised and fuel is sprayed into the
inlet manifold onto the back of the inlet valves. The
ECM carefully meters the amount of fuel injected by
adjusting the injector opening period (pulse width).
During cranking, when the engine speed is below
approximately 400 rev/min, the ECM increases the
injector pulse width to aid starting. The amount of
increase depends upon engine coolant temperature.
To prevent flooding, the ECM periodically inhibits the
operation of the injectors.

Throttle housing Throttle position sensor
The throttle housing is located between the inlet

manifold and air intake hose and is sealed to the
manifold by an ’O’ ring. The throttle housing
incorporates a throttle disc which is connected to the
throttle pedal via the throttle lever and a cable.
There are two breather pipes connected to the

throttle housing; one either side of the throttle disc.
When the engine is running with the throttle disc
open, both pipes are subject to manifold depression
and draw crankcase fumes into the manifold. When
the throttle disc is closed, only the pipe on the inlet
manifold side of the disc is subject to manifold
depression. This pipe incorporates a restrictor to
prevent engine oil being drawn into the engine by
the substantially greater manifold depression.
Mounted on the throttle housing are the throttle

position sensor and idle air control valve.
The throttle position (TP) sensor is a potentiometer
attached to the throttle housing and is directly
coupled to the throttle disc. The TP sensor is
non-adjustable. Closed throttle is detected by the TP
sensor which initiates idle speed control via the idle
air control valve.
The ECM supplies the TP sensor with a 5 volt

supply and an earth path. The TP sensor returns a
signal proportional to throttle disc position.
Throttle disc movement causes voltage across the

TP sensor to vary. The ECM calculates the rate of
change of the voltage signal in positive
(acceleration) or negative (deceleration) directions.
From this the ECM can determine the required
engine speed, rate of acceleration or rate of
deceleration and apply acceleration enrichment,
deceleration fuel metering or over-run fuel cut-off.

Idle air control valve Relay module
The idle air control valve (IACV) is mounted on the The relay module is located in the engine
inlet manifold and controlled by the ECM. The IACV compartment adjacent to the engine control module.
opens a pintle valve situated in an air passage in the The relay module contains the following relays:
throttle housing, allowing air to bypass the throttle • Main relay - energised when the ignition is
disc and flow straight into the inlet manifold. switched on and supplies power to the ECM.
• Fuel pump relay - energised by the ECM for a
By changing the amount the IACV is open the ECM short period when the ignition is switched on,
can control engine idle speed and cold start air flow during cranking and while the engine is running.
requirements by adjusting the flow of air in the • Starter relay - energised by the cranking signal
passage. from the ignition switch.
• Heated oxygen sensor (HO2S) relay - energised
During cold starting the ECM indexes the IACV open by the ECM and supplies current to the heated
slightly to provide a level of fast idle, dependent on oxygen sensor element.
engine coolant temperature. As the engine warms,
fast idle is gradually decreased until normal
operating temperature is reached. Purge valve
The position of the IACV should be within the range The purge valve is driven directly from by the ECM.
of 20 to 40 steps when the engine is running. When the purge valve is opened it allows the EVAP
canister to vent into the engine inlet manifold. The
NOTE: Adjustment of the IACV only valve is opened by the ECM for varying periods
applies to the ’learnt’ position, not the under specific engine conditions to avoid degrading
actual position at idle, so adjustment is engine performance.
not recommended.
If the valve is identified as being outside this range it

can be adjusted to within range using TestBook.
This ensures that the IACV is at the optimum
position within its range for providing further
movement to compensate for changes in engine
load or temperature in accordance with signals from
the ECM.
NOTE: The position of the throttle disc is

preset during manufacture and the throttle
position setting screw MUST NOT be
adjusted.

Fuel pump Fuel pressure regulator
The pressure regulator is a mechanical device

controlled by manifold depression and is mounted
on one end of the fuel rail. The regulator ensures
that fuel rail pressure is maintained at a constant
The electric fuel pump is located inside the fuel tank pressure difference to that in the inlet manifold, as
and is energised by the ECM via the fuel pump relay manifold depression increases the regulated fuel
in the relay module and the fuel cut-off switch. pressure is reduced in direct proportion.
The fuel pump delivers more fuel than the maximum When pressure exceeds the regulator setting,
load requirement for the engine, pressure is excess fuel is returned to the fuel tank swirl pot
therefore maintained in the fuel system under all which contains the fuel pump pick-up.
conditions.

Inertia fuel shut-off switch Vehicle diagnostic connector
The electrical circuit for the fuel pump incorporates The diagnostic connector, located on a bracket by
an inertia fuel shut-off (IFS) switch which, in the the foot pedals, allows engine tuning or fault
event of a sudden deceleration, breaks the circuit to diagnosis to be carried out using TestBook without
the fuel pump preventing fuel being delivered to the disconnecting the ECM harness multiplug.
engine. The IFS switch is situated in the engine
compartment, fixed to the bonnet switch bracket
which is located on the bulkhead, and must be reset
by pressing the rubber top before the engine can be
restarted.
WARNING: ALWAYS check for fuel leaks

and the integrity of fuel system
connections before resetting the switch.

Heated oxygen sensor Acceleration enrichment
When the throttle pedal is depressed the ECM

receives a rising voltage from the throttle position
sensor and detects a rise in manifold pressure from
the manifold absolute pressure sensor. The ECM
provides additional fuel by increasing the normal
injector pulse width and also provides a small
number of extra additional pulses on rapid throttle
openings.
Over-run fuel cut-off
The ECM implements over-run fuel cut-off when the

engine speed is above 1600 rev/min with engine at
normal operating temperature and the TP sensor in
the closed position, i.e. the vehicle is ’coasting’ with
the throttle pedal released. The ECM indexes the
IACV open slightly to increase the air flow through
the engine to maintain a constant manifold
depression to keep emissions low.
The modular engine management system operates
a closed loop emission system to ensure the most Fuel is immediately reinstated if the throttle is
efficient level of exhaust gas conversion. opened. If the engine speed drops below 1600
rev/min on over-run, fuel is progressively reinstated.
A heated oxygen sensor (HO2S) fitted in the
exhaust manifold monitors the exhaust gases. It
supplies a small voltage proportional to exhaust Over-speed fuel cut-off
oxygen content to the ECM. As the air/fuel mixture
weakens, the exhaust oxygen content increases and To prevent damage at high engine speeds the ECM
the voltage to the ECM decreases. If the mixture will implement fuel cut-off at engine speeds above
becomes richer, the oxygen content decreases and approximately 6500 rev/min; fuel being gradually
the voltage to the ECM increases. reinstated as speed falls.
From this signal the ECM can determine the air/fuel

mixture being delivered to the engine and can adjust Ignition switch off
the duration the injectors are open to maintain the
ratio necessary for efficient gas conversion by the When the starter switch is turned off, the ECM will
catalyst. keep the main relay energised for approximately 30
seconds while it drives the idle air control valve to its
The HO2S has an integral heating element to power down position, ready for the next engine start.
ensure an efficient operating temperature is quickly
reached from cold. The electrical supply to the The ECM monitors the engine coolant temperature
heater element is controlled by the ECM via the for a minimum of 2 minutes after the starter switch is
HO2S relay in the relay module. turned off.If the coolant temperature rises above a
certain limit, the ECM switches on the radiator fans.
Once the fans are running the ECM will not power
down until either the coolant temperature falls below
a certain limit or 8 minutes have elapsed since the
starter switch was turned off. If the coolant
temperature has not risen above the limit after 2
minutes, the ECM will power down.

THROTTLE CABLE
NOTE: Before adjusting cable, ensure that

cable is correctly routed and located. Do
not attempt to adjust throttle cable or
engine idle speed by means of the throttle stop
screw.
Adjust
1. Remove air cleaner. See Repairs.
4. Hold throttle cam in fully closed position,

ensure throttle cam contacts throttle stop
screw.
5. Rotate cable adjusting nut until all slack is
taken out of inner cable. Ensure throttle does
not open.
6. Locate throttle cable adjusting nut in abutment
bracket.
7. Operate throttle pedal and ensure that full
throttle pedal movement is available.
8. Fit air cleaner. See Repairs.
2. Release cable adjusting nut from abutment

bracket.
3. Position outer cable to abutment bracket so
that adjusting nut contacts top of the abutment
bracket.
ADJUSTMENTS 1
THROTTLE CABLE
Remove
1. Remove air cleaner. See this section.

2. Remove ECM. See this section.

abutment bracket.
4. Disconnect inner cable from throttle cam.
5. Release heater air intake duct from adaptor

inside vehicle.
6. Position air intake duct aside.
7. Remove clip securing inner cable to throttle
pedal.
8. Release inner cable from pedal.
9. Remove throttle cable.
Refit
1. Feed throttle cable through bulkhead.

2. Connect inner cable to throttle pedal and
secure with clip.
3. Connect heater air intake duct to adaptor on
body.
4. Ensure throttle cable is correctly routed and
connect inner cable to throttle cam.
5. Locate throttle cable adjusting nut on abutment
bracket.
6. Fit ECM. See this section.
7. Adjust throttle cable. See Adjustments.
REPAIRS 1
THROTTLE PEDAL Refit
Service repair no - 19.20.01 1. Fit return spring clip to throttle pedal.

2. Fit throttle pedal to studs on bulkhead.
Remove 3. Fit nuts securing throttle pedal to bulkhead and
tighten to 25 Nm.
4. Connect return spring to pedal.
5. Connect inner cable to throttle pedal and
secure with clip.
6. Connect heater air intake duct to adaptor on
body.
1. Release heater air intake duct from adaptor

inside vehicle.
2. Position air intake duct aside.
3. Remove clip securing inner cable to throttle
pedal.
4. Release inner cable from pedal.
5. Disconnect return spring from throttle pedal.
6. Release carpet retainer and fold back carpet.
7. Remove 2 nuts securing throttle pedal to
bulkhead.
8. Remove throttle pedal.
9. Remove return spring clip from throttle pedal.
2 REPAIRS
THROTTLE HOUSING
Remove

8. Disconnect air bypass hose from throttle body.

10. Remove 3 bolts securing throttle housing to
inlet manifold.
11. Remove throttle housing.
3. Release throttle cable adjusting nut from 12. Remove and discard ’O’ ring from throttle
abutment bracket. housing.
position aside.
5. Remove 3 bolts securing air cleaner mounting
bracket to fuel rail and inlet manifold.
6. Release 2 clips securing harnesses to
mounting bracket.
7. Remove air cleaner mounting bracket.
REPAIRS 3

component is removed for access only.
CAUTION: The TP sensor can be easily

damaged during fitting. When pressing the
sensor onto the throttle spindle, use
fingers only, and only apply pressure to the area
shown shaded in the illustration.
13. Remove and discard 2 screws and wave
washers securing TP sensor to throttle 18. Rotate TP sensor in an anti-clockwise direction
housing. to align fixing holes.
14. Remove TP sensor specification plate.
15. Pull TP sensor from throttle spindle. CAUTION: Do not rotate sensor in a
clockwise direction, and ensure that it is
CAUTION: Do not twist or apply leverage not rotated beyond its internal stops.
to TP sensor.
19. Fit TP sensor specification plate.
16. Clean mating faces of throttle housing and TP 20. Fit NEW screws and wave washers, and
sensor. tighten to 1.5 Nm.
17. Fit TP sensor to throttle spindle. Ensure that
during fitting, the machined flat on the throttle CAUTION: Do not exceed specified torque
spindle is aligned with the mating portion of the figure.
TP sensor.
Refit
1. Clean mating faces of throttle housing and inlet

manifold.
2. Lubricate new ’O’ ring with silicone grease and
fit to throttle housing.
3. Position throttle housing to inlet manifold, fit
5. Connect air bypass hose to throttle body.
6. Position air cleaner mounting bracket to fuel
rail and inlet manifold, fit and tighten bolts to 9
Nm.
7. Secure harness clips to air cleaner mounting
bracket.
8. Connect throttle cable to throttle cam and
locate adjusting nut to abutment bracket.
4 REPAIRS
AIR CLEANER AIR CLEANER ELEMENT
Remove Remove
1. Remove 3 screws securing air cleaner to

throttle body. Collect washers.
2. Remove air cleaner.
Refit
2. Release 4 clips securing 2 halves of air
1. Clean mating face of air cleaner and throttle cleaner.
body. 3. Remove upper halve of air cleaner.
2. Fit air cleaner to throttle body and align. 4. Remove and discard air cleaner element.
3. Fit screws securing air cleaner to throttle body
and tighten to 7 Nm. Refit
1. Clean inside of air cleaner.

2. fit new air cleaner element.
3. Position upper half of air cleaner and secure
with clips.
4. Fit air cleaner. See this section.
REPAIRS 5
SPARK PLUGS IGNITION COIL
Remove Remove
1. Disconnect h.t. leads from spark plugs.

2. Using a spark plug socket, remove 4 spark
plugs.
Refit
1. Fit terminals to new spark plugs.
1. Disconnect multiplug from ignition coil.

2. Noting fitted positions, disconnect h.t. leads
from ignition coil.
3. Remove 4 bolts securing ignition coil to engine.
4. Remove ignition coil.
2. Set gap of each spark plug to 0.85 mm.

3. Fit spark plugs and tighten to 25 Nm.
4. Connect h.t. leads to spark plugs.
CAUTION: Ensure that h.t. leads connect

to spark plug terminals.
6 REPAIRS
Refit ENGINE CONTROL MODULE (ECM)
1. Position ignition coil to mounting bracket, fit Service repair no - 18.30.01

Remove
2. Identify and connect h.t. leads to ignition coil.

3. Connect multiplug to ignition coil.
2. Remove bolt securing ECM to mounting

bracket.
3. Release ECM from mounting bracket.
4. Disconnect 2 multiplugs from ECM.
5. Remove ECM.
REPAIRS 7
Refit IDLE AIR CONTROL VALVE (IACV)
1. Position ECM and connect 2 multiplugs. Service repair no - 18.30.05

2. Locate ECM on mounting bracket.
Remove
CAUTION: Ensure mounting rubbers are
correctly located in mounting bracket. 1. Remove air cleaner. See this section.
3. Fit and tighten bolt securing ECM to mounting

bracket to 10 Nm.
NOTE: If a new ECM has been fitted, the

ECM will need to be programmed with the
code from the anti-theft security unit using
TestBook, before the engine can be started.
2. Disconnect air bypass hose from throttle body

and position aside.
4. Remove 2 screws securing IACV to inlet
manifold.
5. Remove IACV from inlet manifold.
6. Remove and discard ’O’ ring from IACV.
Refit
1. Clean mating faces of IACV and inlet manifold.

fit to IACV.
3. Fit IACV to inlet manifold. Fit screws and
tighten to 7 Nm.
8 REPAIRS
INTAKE AIR TEMPERATURE (IAT) SENSOR ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
Remove
Remove
1. Disconnect multiplug from IAT sensor.

2. Remove IAT sensor.
Refit
1. Clean threads of IAT sensor.

2. Clean mating faces of IAT sensor and inlet
manifold.
3. Fit IAT sensor to inlet manifold and tighten to 7
Nm.

2. Position container to collect spillage.
3. Remove ECT sensor and discard sealing
washer.
REPAIRS 9
Refit CRANKSHAFT POSITION (CKP) SENSOR
1. Clean threads of ECT sensor. Service repair no - 18.30.12

2. Clean mating faces of ECT sensor and
thermostat housing. Remove
3. Fit new sealing washer to ECT sensor.
4. Fit ECT sensor and tighten to 15 Nm.
6. Top-up coolant. See
1. Disconnect CKP sensor multiplug from

harness.
2. Remove bolt securing CKP sensor multiplug to
flywheel housing.
3. Remove 2 bolts securing CKP sensor to

flywheel housing.
4. Remove CKP sensor.
10 REPAIRS
Refit THROTTLE POSITION (TP) SENSOR
1. Clean CKP sensor and mating face on flywheel Service repair no - 18.30.17
housing.
2. Position CKP sensor, fit bolts and tighten to 6 Remove
Nm.
3. Position CKP sensor multiplug to flywheel 1. Remove air cleaner. See this section.
housing, fit bolt and tighten to 3 Nm.
4. Connect harness to CKP sensor multiplug.
2. Disconnect air bypass hose from throttle body.

3. Depress plastic collar on quick release
connector and disconnect brake servo vacuum
pipe from inlet manifold.
5. Remove and discard 2 screws and wave
washers securing TP sensor to throttle
housing.
6. Remove TP sensor specification plate.
7. Pull TP sensor from throttle spindle.
CAUTION: Do not twist or apply leverage

to TP sensor.
REPAIRS 11
Refit MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR
1. Clean mating faces of throttle housing and TP
sensor. Service repair no - 18.30.56
2. Fit TP sensor to throttle spindle. Ensure that
during fitting, the machined flat on the throttle Remove
spindle is aligned with the mating portion of the
TP sensor. 1. Remove air cleaner. See this section.
CAUTION: The TP sensor can be easily

damaged during fitting. When pressing the
sensor onto the throttle spindle, use
fingers only, and only apply pressure to the area
3. Remove 2 bolts securing MAP sensor to inlet
shown shaded in the illustration.
manifold.
4. Remove MAP sensor.
3. Rotate TP sensor in an anti-clockwise direction
5. Remove and discard ’O’ ring from MAP sensor.
to align fixing holes.
Refit
CAUTION: Do not rotate sensor in a
clockwise direction, and ensure that it is
1. Clean sealing faces of sensor and manifold
not rotated beyond its internal stops.
chamber.
2. Lubricate and fit new ’O’ ring to MAP sensor.
4. Fit TP sensor specification plate.
3. Fit sensor to inlet manifold and tighten bolts to
5. Fit NEW screws and wave washers, and
6 Nm.
tighten to 1.5 Nm.
4. Connect multiplug to sensor.
CAUTION: Do not exceed specified torque
figure.

7. Connect brake servo vacuum pipe to inlet
manifold.
9. Operate throttle cable cam 2 or 3 times and
ensure that full travel to the throttle open and
the throttle closed positions is available.
12 REPAIRS
ENGINE MANAGEMENT RELAY MODULE CAMSHAFT POSITION (CMP) SENSOR
The engine management relay module contains the Remove

following relays:
Main relay WARNING: The exhaust manifold reaches
Starter relay very high temperatures when the engine is
Fuel pump relay running and can cause serious burns.
HO2S relay Allow engine to cool before commencing work.
Remove 1. Remove air cleaner. See this section.
2. Disconnect multiplug from CMP sensor.

1. Release relay module from mounting bracket. 3. Remove bolt (8 mm) securing CMP sensor to
2. Disconnect 2 multiplugs from relay module. cylinder block.
3. Remove relay module. 4. Remove CMP sensor.
5. Remove ’O’ ring from CMP sensor.
Refit
Refit
1. Position relay module and connect 2
multiplugs. Ensure multiplugs are correctly 1. Clean sealing faces of sensor and cylinder
engaged. head.
2. Secure relay module to mounting bracket. 2. Lubricate and fit new ’O’ ring to CMP sensor.
3. Fit sensor to cylinder block and tighten bolt to
10 Nm.
4. Connect multiplug to CMP sensor.
REPAIRS 13
HEATED OXYGEN SENSOR (HO2S) FUEL RAIL
Remove Remove
1. Remove inlet and exhaust manifold gasket. 1. Disconnect battery earth lead.
See MANIFOLD & EXHAUST SYSTEMS, 2. Remove air cleaner. See this section.
Repairs.
3. Release throttle cable adjusting nut from

abutment bracket.
position aside.
5. Position absorbent cloth around fuel feed pipe
2. Using a 22mm open ended spanner, remove
to fuel rail connection.
HO2S.
6. Remove 2 bolts securing fuel feed pipe to fuel
3. Remove and discard sealing washer.
rail.
7. Release fuel feed pipe from fuel rail.
Refit
1. Clean mating faces of HO2S and exhaust
manifold.
2. Fit new sealing washer to HO2S.
3. Fit HO2S and tighten to 55 Nm.
4. Fit inlet and exhaust manifold gasket. See
14 REPAIRS
15. Disconnect 2 multiplugs from injectors.

mounting bracket.
19. Remove 2 spring clips securing fuel rail to
injectors.
20. Release fuel rail from injectors and remove.
9. Disconnect breather hose from throttle body
21. Remove and discard ’O’ rings from injectors.
and position aside.
10. Depress plastic collar on quick release
connector and disconnect brake servo vacuum
hose from inlet manifold.
11. Release clip and disconnect vacuum hose from
fuel pressure regulator.
12. Remove 2 bolts securing fuel return pipe to fuel
rail.
13. Release fuel return pipe from fuel rail.
REPAIRS 15
Refit FUEL INJECTORS
1. Lubricate new ’O’ rings with silicone grease Service repair no - 19.60.12
and fit to injectors.
2. Position fuel rail and fit to injectors. Remove
3. Fit 2 spring clips securing fuel rail to injectors.
4. Position air cleaner mounting bracket to fuel 1. Disconnect battery earth lead.
rail and inlet manifold. 2. Remove fuel rail. See this section.
5. Align fuel return pipe ’P’ clip to inlet manifold.
6. Fit 3 bolts securing air cleaner mounting
bracket to inlet manifold and fuel rail. Tighten
bolts to 9 Nm.
7. Secure harness clips to air cleaner mounting
bracket.
8. Remove plugs from fuel rail, fuel feed pipe and
fuel return pipe.
9. Clean fuel rail and fuel pipe connections.
fit to fuel return pipe connection.
11. Connect fuel return pipe to fuel rail, fit bolts and
tighten to 4 Nm.
fit to fuel feed pipe connection.
13. Connect fuel feed pipe to fuel rail, fit bolts and 3. Remove injectors.
tighten to 4 Nm. 4. Remove and discard ’O’ rings from injectors.
14. Connect vacuum hose to pressure regulator 5. Fit protective caps to each end of injectors.
and secure with clip.
15. Connect brake servo vacuum hose to inlet Refit
manifold.
16. Connect breather hose to throttle body. 1. remove protective caps from injectors.
17. Connect throttle cable to throttle cam and 2. Clean injectors and recesses in inlet manifold.
locate adjusting nut to abutment bracket. 3. Lubricate new ’O’ rings with silicone grease
18. Connect battery earth lead. and fit to injectors.
19. Adjust throttle cable. See Adjustments. 4. Fit injectors to inlet manifold.
5. Fit fuel rail. See this section.
16 REPAIRS
CONTENTS Page
ADJUSTMENTS
FUEL SYSTEM - PRESSURE TEST ........................................................................ 1
REPAIRS
FUEL TANK DRAINING ............................................................................................ 1
INERTIA FUEL SHUT-OFF (IFS) SWITCH .............................................................. 1
FUEL FILTER ........................................................................................................... 2
FUEL PUMP ............................................................................................................. 3
FUEL TANK .............................................................................................................. 3
FUEL TANK BREATHER VALVE ............................................................................. 5
FUEL SYSTEM - PRESSURE TEST
Remove
1. Position absorbent clotch around fuel line quick

fit connector.
3. Fit adapter hose 18G 1500-A to fuel pipe.

2. Release quick fit connector and disconnect fuel 4. Fit adaptor 18G 1500-5 to 18G 1500-A.
feed hose from fuel pipe. 5. Fit pressure gauge 18G 1500 to 18G 1500-A.
6. Connect fuel feed hose quick fit connector to
18G 1500-5.
7. Start engine check reading and pressure drop
over one minute and then stop engine.
8. Disconnect quick fit connector from 18G
1500-5.
9. Remove 18G 1500 from 18G 1500-A.
10. Remove 18g 1500-5 from 18G 1500-A.
11. Remove 18G 1500-A from fuel pipe.
12. Clean end of fuel pipe.
13. Connect fuel feed hose connector to fuel feed
pipe.
CAUTION: Ensure quick fit connector is

correctly engaged on fuel pipe.
14. Remove cloth positioned to absorb fuel

spillage.
ISSUED: 12/96 ADJUSTMENTS 1

FUEL TANK DRAINING INERTIA FUEL SHUT-OFF (IFS) SWITCH
WARNING: Before removing the fuel tank Remove

from the vehicle it must be drained.
WARNING: Petrol/gasoline vapour is

highly flammable and in confined spaces
is also explosive and toxic. Always have a
fire extinguisher containing FOAM, CO2, GAS or
POWDER close at hand when handling or
draining fuel. See GENERAL INFORMATION,
Fuel handling precautions.
Drain
1. Disconnect multiplug from IFS switch.

2. Remove 2 screws securing IFS switch to
mounting bracket.
3. Remove IFS switch.
Refit
1. Remove fuel tank filler cap and allow fuel tank 1. Align IFS switch to mounting bracket.
to vent in an open space before commencing 2. Fit screws securing IFS switch to mounting
work. bracket and tighten to 2 Nm.
2. Disconnect battery earth lead. 3. Connect multiplug to IFS switch.
3. Using a bowser, drain fuel from the tank into a 4. Press top of IFS switch to reset.
sealed container. Follow the manufacturers
instructions for the connection and safe use of
the bowser.
4. Continue draining until air bubbles appear and
fuel ceases to flow.
5. Disconnect bowser from fuel tank.

FUEL FILTER 10. Remove fuel filter and bracket.
Service repair no - 19.25.02 Do not carry out further dismantling if

Remove 11. Remove bolt securing bracket to fuel filter.
12. Remove bracket from fuel filter.
1. Disconnect battery earth lead. 13. Remove inlet pipe adapter union from fuel filter
2. Raise rear of vehicle, one side. and discard ’O’ ring.
WARNING: Support on safety stands. fit to fuel filter.
15. Fit inlet pipe adapter union to fuel filter and
tighten to 30 Nm.
3. Position absorbent cloth around fuel pipe 16. Fit bracket to fuel filter and secure with bolt.
union.
Refit
1. Clean fuel filter and fuel pipe unions.

2. Position fuel filter and bracket to subframe, fit
3. Remove plugs from fuel pipes.
4. Connect fuel pipes to filter and tighten unions
to 30 Nm.
4. Loosen union to relieve fuel pressure.
CAUTION: To prevent damage to fuel

system pipes and components, use two
spanners when loosening or tightening
unions.
5. Disconnect fuel outlet pipe from fuel filter.

6. Position absorbent cloth around fuel filter
union.
7. Loosen union and allow fuel to seep into cloth.
8. Disconnect fuel inlet pipe from fuel filter.
9. Remove 2 bolts securing fuel filter to subframe.
2 REPAIRS
FUEL PUMP FUEL TANK
Remove Remove
1. Remove fuel tank. See this section. 1. Drain fuel tank. See Adjustments.
2. Remove spare wheel.
2. Remove 6 nuts securing fuel pump.

3. Remove fuel pump and discard seal. 3. Remove studs securing fuel tank side cover
and remove cover.
Refit
1. Clean mating faces fuel pump and fuel tank.

2. Using a new seal fit the fuel pump.
3. Fit nuts securing fuel pump to fuel tank and
tighten to 9 Nm.
4. Fit fuel tank. See this section.
REPAIRS 3
13. Release clip and disconnect breather hose

4. Disconnect 2 Lucars from fuel tank sender unit.
from tank.
5. Release clip and disconnect fuel feed hose,
14. Release breather pipe from clips.
identified by orange coloured band.
15. Remove nut securing breather valve to fuel
6. Release clip and disconnect fuel return hose.
tank and remove breather valve.
7. Remove bolt securing fuel tank retaining strap

16. Remove 6 nuts securing fuel pump to tank.
and move strap aside.
17. Remove fuel pump and discard seal.
8. Release tank from filler neck grommet.
18. Remove filler neck seal.
9. Manoeuvre fuel tank into boot space.
from pipe.
11. Disconnect multiplug from fuel pump.

12. Remove fuel tank.
4 REPAIRS
FUEL TANK BREATHER VALVE
Remove

2. Remove fuel tank. See this section.
19. Using tool 18G 1467 remove fuel gauge

sender unit and discard seal.
Refit
1. Clean mating faces of fuel tank and sender

unit.
2. Using a new seal fit sender unit to fuel tank.
3. Clean mating faces of fuel pump and fuel tank.
4. Using a new seal fit the fuel pump to fuel tank.
5. Fit nuts securing fuel pump to fuel tank and
tighten to 9 Nm.
6. Fit breather valve to fuel tank, fit nut and
tighten to 9 Nm.
7. Connect breather hose to fuel tank and secure
with clip.
8. Secure hose to clips on tank.
9. Fit seal to filler neck.
10. Position tank in vehicle.
11. Connect breather hose to pipe and secure with
clip.
12. Connect multiplug to fuel pump.
13. Manoeuvre tank into position and position
restraining strap.
14. Fit and tighten strap retaining bolt.
15. Connect fuel feed and return hoses and to fuel
tank and secure with clips.
16. Connect Lucars to sender unit.
from fuel tank.
17. Fit fuel tank side cover and secure with studs. 4. Release breather pipe from clips.
18. Fit spare wheel. 5. Remove nut securing bracket and remove two
19. Refill fuel tank with fuel. way valve assembly.
Refit
1. Fit two way valve and bracket to fuel tank. Fit

nut and tighten to 9 Nm.
2. Connect two way valve hose to fuel tank and
secure with clip.
3. Secure hose in clips.
4. Refit fuel tank. See this section.
REPAIRS 5
COOLING SYSTEM
CONTENTS Page

COOLING SYSTEM COMPONENTS ....................................................................... 1
COOLING SYSTEM OPERATION ........................................................................... 2
ADJUSTMENTS
DRAIN AND REFILL ................................................................................................. 1
REPAIRS
COOLANT EXPANSION TANK ................................................................................ 1
COOLANT PUMP PULLEY ...................................................................................... 2
RADIATOR COOLING FAN ...................................................................................... 2
COOLING FAN RELAY ............................................................................................ 3
RADIATOR ............................................................................................................... 4
THERMOSTAT ......................................................................................................... 5
COOLANT PUMP ..................................................................................................... 6
COOLING SYSTEM
COOLING SYSTEM COMPONENTS
1. Top hose 6. Bottom hose

2. Radiator upper mounting 7. Coolant pump
3. Thermostat housing 8. Radiator
4. Hose - expansion tank to thermostat 9. Cooling fan and cowl
5. Expansion tank

COOLING SYSTEM
COOLING SYSTEM OPERATION
Flow diagram
A = COLD B = HOT

COOLING SYSTEM
Operation
The cooling system employed is the bypass type.
When the engine is cold the thermostat closes off the coolant feed from the radiator bottom hose (1). Coolant in the
cylinder head and heater matrix (2) begins to rise in temperature after the engine is started. The heater is regulated
by a control valve (3) from the dashboard. Coolant circulates back into the heater circuit through a by-pass hose (4)
prior to the thermostat opening.
As temperature increases the thermostat (5) gradually opens, allowing hot coolant to flow to the radiator (6) via the
top hose (7). As the thermostat opens further so the full flow of coolant is drawn through the radiator.
Any excess coolant created by heat expansion is returned to the expansion tank (8) via hose (9).
The radiator is an aluminium cross-flow type with integral end tanks and is mounted on rubber bushes directly into
the subframe transverse member. The top of the radiator is supported by means of mounting brackets bolted to the
radiator and bonnet locking platform.
For additional air flow, at times when the vehicle is stationary, an electric cooling fan is fitted. It is triggered by the
Engine Control Module (ECM).
The coolant pump (10) is a rotor type pump which draws coolant directly from the radiator. The pump is driven by a
poly-V pulley from the alternator drive belt.

COOLING SYSTEM
DRAIN AND REFILL Refill
Service repair no - 26.10.01 1. Flush system with water under low pressure.
Drain CAUTION: High pressure water could

damage the radiator.
1. Visually check engine and cooling system for
signs of coolant leaks. 2. Connect bottom hose to radiator and tighten
2. Examine hose for signs of cracking, distortion clip.
and security of connections. 3. Prepare coolant to required concentration. See
3. Position heater temperature control to INFORMATION, Capacities, fluids and
maximum heat position. lubricants.
4. Turn heater temperature control to maximum
heat position.
5. Fill system slowly until coolant level reaches
’MAX’ mark on expansion tank.
6. Start and run engine until radiator cooling fan
operates.
7. Switch off engine and allow to cool.
8. Check for leaks and top-up coolant to ’MAX’
mark on expansion tank.
4. Remove expansion tank filler cap.

5. Position drain tin to collect coolant.
6. Loosen clip and disconnect bottom hose from
radiator.
7. Allow cooling system to drain.
ADJUSTMENTS 1
COOLING SYSTEM
COOLANT EXPANSION TANK Refit
Service repair no - 26.15.01 1. Position coolant expansion tank.

2. Connect coolant feed hose to expansion tank
Remove and secure with clip.
3. Position expansion tank on mounting bracket,
1. Drain cooling system. See Adjustments. fit nuts and tighten to 10 Nm.
4. Connect hose to expansion tank and tighten
clip.
5. Refill cooling system. See Adjustments.
2. Loosen clip and disconnect hose from

expansion tank.
3. Remove 2 nuts securing expansion tank to
mounting bracket.
4. Release expansion tank from mounting
5. Release clip and disconnect coolant feed hose
from expansion tank.
6. Remove coolant expansion tank.
REPAIRS 1
COOLING SYSTEM
COOLANT PUMP PULLEY RADIATOR COOLING FAN
Remove Remove
1. Remove front grille. See BODY, Exterior

fittings.
2. Disconnect radiator cooling fan multiplug from

harness.
1. Loosen 4 bolts securing coolant pump pulley. 3. Remove 4 bolts securing 2 upper radiator
2. Remove auxiliary drive belt. See mounting bracket to bonnet locking platform.
ELECTRICAL, Repairs. 4. Remove 2 upper radiator mounting brackets.
3. Remove 4 bolts securing coolant pump pulley. 5. Remove bolt securing cooling fan multiplug to
4. Remove pulley. radiator.
6. Release radiator from lower mountings.
Refit 7. Manoeuvre radiator to gain access to bolts and
remove 4 bolts securing cooling fan to radiator.
1. Ensure mating faces of pulley and coolant 8. Remove radiator cooling fan.
pump flange are clean.
2. Fit pulley to pump and tighten bolts to 10 Nm.
3. Fit auxiliary drive belt. See ELECTRICAL,
Repairs.
2 REPAIRS
COOLING SYSTEM
Refit COOLING FAN RELAY
1. Position radiator cooling fan in vehicle. Service repair no - 26.25.41

2. Align cooling fan to radiator, fit bolts and
tighten to 7 Nm. Remove
3. Align radiator to lower mountings.
4. Position cooling fan multiplug to radiator, fit bolt 1. Open bonnet.
5. Fit upper mounting brackets to radiator and
align to bonnet locking platform.
6. Fit bolts securing radiator upper mounting
brackets to bonnet locking platform and tighten
to 9 Nm.
7. Connect cooling fan multiplug to harness.
8. Fit front grille. See BODY, Exterior fittings.
2. Remove relay from multiplug on bulkhead.
Refit
1. Fit relay to multiplug on bulkhead.

2. Close bonnet.
REPAIRS 3
COOLING SYSTEM
RADIATOR component is removed for access only.
Remove
1. Drain cooling system. See Adjustments.

fittings.
3. Remove alternator. See ELECTRICAL,
Repairs.
10. Remove bolt securing cooling fan multiplug to

radiator.
11. Remove 4 bolts securing cooling fan to radiator
and remove cooling fan.
12. Align cooling fan to radiator, fit bolts and
tighten to 7 Nm.
13. Position cooling fan multiplug to radiator, fit bolt
Refit
1. Position radiator in vehicle.

2. Align radiator to lower mountings.
4. Loosen clip and disconnect top hose from 3. Fit upper mounting brackets to radiator and
radiator. align to bonnet locking platform.
5. Disconnect radiator cooling fan multiplug from 4. Fit bolts securing radiator upper mounting
harness. brackets to bonnet locking platform and tighten
6. Remove 4 bolts securing 2 upper radiator to 9 Nm.
mounting bracket to bonnet locking platform. 5. Connect cooling fan multiplug to harness.
7. Remove 2 upper radiator mounting brackets. 6. Connect top hose to radiator and tighten clip.
8. Release radiator from lower mountings. 7. Fit alternator. See ELECTRICAL, Repairs.
9. Remove radiator from vehicle. 8. Fit front grille. See BODY, Exterior fittings.
9. Refill cooling system. See Adjustments.

COOLING SYSTEM
THERMOSTAT
Remove

3. Loosen clip and disconnect top hose from

thermostat housing.
4. Loosen clip and disconnect expansion tank
hose from thermostat housing.
5. Loosen clip and disconnect heater hose from
thermostat housing.
7. Remove 3 bolts securing thermostat housing.
8. Remove thermostat upper housing and discard
gasket.
9. Remove thermostat.
10. Remove thermostat lower housing and discard
gasket.
REPAIRS 5
COOLING SYSTEM
COOLANT PUMP
Remove

2. Remove coolant pump pulley. See
Adjustments.
11. Test thermostat using thermostat test

equipment, renew thermostat if necessary.
thermostat opening temperature is 88°C.
Refit
1. Clean thermostat housings and mating faces. 3. Loosen clip and disconnect hose from coolant
2. Fit gasket and lower housing to cylinder head. pump.
3. Fit thermostat and upper housing gasket. 4. Remove 4 bolts securing coolant pump to
4. Fit thermostat upper housing and tighten bolts engine.
to 11 Nm. 5. Remove coolant pump and discard gasket.
5. Connect top hose, heater hose and expansion
tank hose. Tighten hose clips Refit
7. Connect battery earth lead. 1. Clean mating faces of coolant pump and
8. Fill cooling system. See Adjustments. engine.
2. Using a new gasket, fit coolant pump to
engine.
3. Fit bolts securing coolant pump to engine and
tighten to 22 Nm.
4. Fit coolant hose to coolant pump and tighten
clip.
5. Fit coolant pump pulley. See Adjustments.
6. Fill cooling system. See Adjustments.
6 REPAIRS
MANIFOLD & EXHAUST SYSTEMS
CONTENTS Page

EXHAUST SYSTEM COMPONENTS ...................................................................... 1
EXHAUST MANIFOLD COMPONENTS ................................................................... 2
INLET MANIFOLD COMPONENTS ......................................................................... 3
INLET MANIFOLD .................................................................................................... 4
EXHAUST MANIFOLD ............................................................................................. 4
EXHAUST SYSTEM ................................................................................................. 4
REPAIRS
FRONT PIPE ............................................................................................................ 1
TAIL PIPE ................................................................................................................. 1
FRONT PIPE TO MANIFOLD GASKET ................................................................... 2
INTERMEDIATE PIPE HEAT SHIELD ..................................................................... 3
INLET MANIFOLD .................................................................................................... 4
EXHAUST MANIFOLD ............................................................................................. 5
INLET AND EXHAUST MANIFOLD GASKET .......................................................... 6
EXHAUST SYSTEM COMPONENTS
1. Gasket - front pipe to manifold 6. Catalytic converter

2. Front pipe 7. Nut - Tail pipe to catalytic converter
3. Nut - Front pipe to manifold 8. Tail pipe
4. Nut - Front pipe to catalytic converter 9. Mounting rubbers
5. Gasket - front pipe to catalytic converter

EXHAUST MANIFOLD COMPONENTS
1. Bolt - Heat shield to exhaust manifold 4. Sealing washer - HO2S

2. Heat shield 5. Heated Oxygen Sensor - (HO2S)
3. Exhaust manifold

INLET MANIFOLD COMPONENTS
1. Throttle housing 8. Bolt - Fuel rail to inlet manifold

2. Bolt - Throttle housing to inlet manifold 9. ’O’ ring - Injector to inlet manifold
3. ’O’ ring - Throttle housing to inlet manifold 10. Inlet manifold
4. Bolt - MAP sensor to inlet manifold 11. Bolt - IACV to inlet manifold
5. MAP sensor 12. Idle Air Control Valve (IACV)
6. ’O’ ring - MAP sensor to inlet manifold 13. ’O’ ring - IACV to inlet manifold
7. Fuel rail and injectors 14. Inlet manifold locating ring

INLET MANIFOLD
The inlet manifold is an aluminium casting, which

incorporates a throttle housing, MAP sensor, IACV,
IAT sensor, fuel rail and injectors. The inlet manifold
is attached to the cylinder head and sealed by two
locating rings and a gasket.
EXHAUST MANIFOLD
The cast iron exhaust manifold is fitted with a

Heated Oxygen Sensor (HO2S). To assist the
extraction of exhaust gases the manifold is divided
into two outlets, No.2 and 3 cylinders discharge into
one half of the manifold and No.1 and 4 cylinders
into the other half.
EXHAUST SYSTEM
The exhaust system consists of a front pipe,

catalytic converter and a silencer/tail pipe assembly,
which incorporates two silencers. Both silencers
contain a series of expansion chambers, resonators
and baffles designed to give an improved exhaust
system, reduce condensation and increase the life of
the system.
The catalytic converter operates in ’closed loop’

system. A Heated Oxygen Sensor (HO2S), located
in the exhaust manifold is used to monitor the
exhaust gases and provide a signal to the Engine
Control Module (ECM). The ECM uses this signal to
modify the fuelling and maintain emissions
acceptable to the catalytic converter. For information
on the operation of the catalytic converter. See
EMISSION CONTROL, Description and operation.

FRONT PIPE TAIL PIPE
Remove Remove
1. Remove front pipe to manifold gasket. See this 1. Raise vehicle on a 4 post ramp.
section.
2. Remove 2 nuts securing tail pipe to catalytic

2. Remove 2 nuts securing front pipe to catalytic converter.
converter. 3. Release 2 rubber mountings securing tail pipe
3. Release front pipe from catalytic converter and to body.
remove. 4. Remove tail pipe.
4. Remove and discard flange gasket.
Refit
Refit
1. Clean mating faces of catalytic converter and
1. Clean mating faces of front pipe and catalytic tail pipe.
converter. 2. Fit tail pipe to catalytic converter and secure to
2. Fit new flange gasket to catalytic converter. rubber mountings on body.
3. Fit front pipe to catalytic converter. 3. Fit nuts securing tail pipe to catalytic converter
4. Fit nuts securing front pipe to catalytic and tighten evenly to 9 Nm.
converter and tighten to 45 Nm. 4. Lower vehicle.
5. Fit front pipe to manifold gasket. See this
section.
REPAIRS 1
FRONT PIPE TO MANIFOLD GASKET Refit
Service repair no - 30.10.26 1. Clean manifold and front pipe flanges.

2. Fit new gasket to exhaust manifold flange.
Remove 3. Align front pipe to exhaust manifold.
4. Fit nuts securing front pipe to manifold and
1. Raise front of vehicle. tighten to 22 Nm.
5. Align front pipe clamp to bracket on differential
WARNING: Support on safety stands. housing, fit nut and bolt and tighten to 22 Nm.
3. Remove 3 nuts securing front pipe to exhaust

manifold.
4. Remove nut and bolt securing front pipe to
mounting bracket on differential housing.
5. Release front pipe from exhaust manifold.
6. Remove gasket from manifold flange.
2 REPAIRS
INTERMEDIATE PIPE HEAT SHIELD
Remove
1. Raise vehicle on a 4 post ramp.
2. Remove 4 nuts securing intermediate pipe heat

shield to body.
3. Release heat shield from studs and slide
forward.
4. Manoeuvre heat shield around exhaust pipe
and remove.
Refit
1. Manoeuvre heat shield into position and locate

on studs.
2. Fit and tighten nuts securing heat shield to
body.
3. Lower vehicle.
REPAIRS 3
INLET MANIFOLD
Remove
1. Remove inlet and exhaust manifold gasket.

See this section.
2. Remove 2 screws securing MAP sensor to inlet 8. Remove and discard ’O’ rings from injectors.
manifold. 9. Disconnect air bypass hose from throttle body.
3. Remove MAP sensor and discard ’O’ ring. 10. Remove 3 bolts securing throttle body to inlet
4. Remove IAT sensor and adaptor. manifold.
5. Disconnect pressure regulator vacuum hose 11. Remove throttle body and discard ’O’ ring.
from inlet manifold. 12. Remove 4 screws securing IACV to inlet
6. Release fuel injectors from inlet manifold. manifold.
7. Remove fuel rail and injectors. 13. Remove IACV and discard ’O’ ring.
4 REPAIRS
Refit EXHAUST MANIFOLD
1. Clean mating face of IACV and inlet manifold. Service repair no - 30.15.10
fit to IACV. Remove
3. Fit IACV to inlet manifold, fit screws and tighten
to 7 Nm. 1. Remove inlet and exhaust manifold gasket.
4. Clean mating face of inlet manifold and throttle See this section.
body.
fit to throttle body.
6. Fit throttle body to inlet manifold, fit bolts and
tighten to 8 Nm.
8. Clean injectors and recesses in inlet manifold.
9. Lubricate new ’O’ rings with silicone grease
and fit to fuel injector.
10. Fit fuel rail and injector assembly to inlet
manifold.
11. Connect pressure regulator vacuum hose to
inlet manifold.
12. Clean mating face of IAT sensor and inlet
manifold.
13. Fit IAT sensor and adaptor to inlet manifold, 2. Using a 22 mm open ended spanner, remove
tighten to 7 Nm. HO2S.
14. Clean mating face of MAP sensor and inlet 3. Remove and discard sealing washer.
manifold. 4. Remove 3 bolts securing heat shield to
15. Lubricate and fit new ’O’ ring to MAP sensor. exhaust manifold.
16. Fit MAP sensor to inlet manifold, fit screws and 5. Remove exhaust manifold heat shield.
tighten to 6 Nm.
17. Fit inlet and exhaust manifold gasket. See this Refit
section.
1. Position heat shield to exhaust manifold, fit and
tighten bolts.
2. Clean mating faces of HO2S and exhaust
manifold.
3. Fit new sealing washer to HO2S.
4. Fit HO2S and tighten to 55 Nm.
5. Fit inlet and exhaust manifold gasket. See this
section.
REPAIRS 5
INLET AND EXHAUST MANIFOLD GASKET
Remove


abutment bracket.
position aside.
9. Disconnect 2 multiplugs from fuel injectors.
5. Depress plastic collar on quick fit connector

and disconnect brake servo vacuum pipe from
inlet manifold.
6 REPAIRS
10. Disconnect multiplug from IAT sensor.

11. Position absorbent cloth around fuel line quick
fit connectors.
mounting bracket.

return hose from fuel pipe.
13. Release quick fit connector and disconnect fuel 17. Disconnect breather hose from inlet manifold.
feed hose from fuel pipe. 18. Release clip and disconnect evaporative
emission canister purge hose from inlet
CAUTION: Plug the connections. manifold.
REPAIRS 7
19. Remove 4 nuts securing inlet manifold to

cylinder head.
20. Remove inlet manifold.
21. Collect 2 locating rings.
22. Remove front pipe to manifold gasket. See this
section.
25. Remove 2 nuts and washers securing exhaust

manifold to cylinder head.
26. Remove bolt securing breather pipe to cylinder
23. Disconnect HO2S multiplug from harness. head.
24. Release cable tie securing HO2S lead to 27. Release breather pipe from exhaust manifold
harness. stud.
28. Remove exhaust manifold.
29. Remove and discard exhaust manifold gasket.
8 REPAIRS
Refit
1. Clean mating faces of inlet manifold, exhaust 14. Connect breather hose to inlet manifold.
manifold and cylinder head. 15. Position air cleaner mounting bracket to fuel
2. Fit new exhaust manifold gasket to cylinder rail and inlet manifold.
head. 16. Align fuel return pipe ’P’ clip to inlet manifold.
3. Fit exhaust manifold to cylinder head. 17. Fit bolts securing mounting bracket to inlet
4. Locate breather pipe on exhaust manifold stud. manifold and fuel rail. Tighten bolts to 9 Nm.
5. Align breather pipe to cylinder head, fit bolt and 18. Secure harness clips to mounting bracket.
tighten to 9 Nm. 19. Remove plugs from fuel pipes and fuel hose
6. Connect HO2S multiplug to harness. quick fit connectors.
7. Secure HO2S lead to harness with cable tie. 20. Clean ends of fuel pipes.
8. Clean inlet manifold locating rings. 21. Connect fuel return hose connector to fuel
9. Fit 2 inlet manifold locating rings to cylinder return pipe.
head. 22. Connect fuel feed hose connector to fuel feed
10. Fit inlet manifold to cylinder head. pipe.
CAUTION: Ensure quick fit connectors are

correctly engaged on fuel pipes.
23. Remove cloth position to absorb fuel spillage.

26. Connect multiplugs to fuel injectors.
28. Connect multiplug to MAP sensor.
29. Connect brake servo vacuum pipe to inlet
manifold.
11. Fit nuts and washers securing manifolds to 30. Connect throttle cable to throttle cam and
cylinder head. Working in the sequence locate adjusting nut to abutment bracket.
illustrated, tighten nuts to 22 Nm. 31. Connect battery earth lead.
12. Fit front pipe to manifold gasket. See this 32. Adjust throttle cable. See ENGINE
section. MANAGEMENT SYSTEM - MEMS,
13. Connect evaporative emission canister purge Adjustments.
hose to inlet manifold and secure with clip.
REPAIRS 9
CLUTCH
CONTENTS Page
ADJUSTMENTS
THROW-OUT STOP CLEARANCE .......................................................................... 1
CLUTCH BLEED ....................................................................................................... 2
REPAIRS
FLYWHEEL HOUSING COVER ............................................................................... 1
CLUTCH ASSEMBLY AND RELEASE BEARING .................................................... 6
RELEASE BEARING ................................................................................................ 8
MASTER CYLINDER ................................................................................................ 8
SLAVE CYLINDER ................................................................................................. 10
CLUTCH
THROW-OUT STOP CLEARANCE

mounting bracket.
Service repair no - 33.25.03 4. Remove bolt securing ECM mounting bracket
to body.
Check and Adjust 5. Release ECM mounting bracket from body and
remove.
1. Remove ECM. See ENGINE MANAGEMENT 6. Depress clutch pedal to load clutch lever and
SYSTEM - MEMS, Repairs. remove any free play.

ADJUSTMENTS 1
CLUTCH
CLUTCH BLEED
Bleed
CAUTION: Never reuse fluid that has been

bled from the system. Do not allow fluid
level in master cylinder to fall below half
during bleeding.
CAUTION: Do not allow fluid to contact

paint finished surfaces as paint may be
damaged. If spilled, remove fluid and
clean area with warm water.
7. Measure clearance between throw out stop
lock nut and flywheel housing cover. 1. Remove ECM. See ENGINE MANAGEMENT
8. The correct clearance is 6.5 mm. If the SYSTEM - MEMS, Repairs.
clearance is incorrect, loosen lock nut and 2. Top up the clutch master cylinder with brake
adjust throw out stop to obtain correct fluid. See INFORMATION, Capacities, fluids
clearance. and lubricants.
9. Tighten lock nut and recheck clearance.
10. Locate ECM mounting bracket on body, fit bolt
11. Secure clip on main harness to ECM mounting
bracket.
12. Secure engine compartment fuse box to ECM
mounting bracket.
13. Fit ECM. See ENGINE MANAGEMENT
3. Attach bleed tube to bleed screw on clutch

slave cylinder and submerge free end in a
clear container containing fluid.
4. Open the bleed screw three-quarters of a turn,
depress the clutch pedal slowly, tighten bleed
screw whilst holding pedal at end of downward
stroke. Allow pedal to return and repeat
procedure until a flow of clean air-free fluid is
purged into container.
CAUTION: Maintain fluid level above half

in reservoir during this procedure.
5. Tighten bleed screw and remove bleed tube.

6. Top up the clutch master cylinder.
2 ADJUSTMENTS REVISED: 12/96

CLUTCH
FLYWHEEL HOUSING COVER
Service repair no - 33.10.04.99
Remove

Repairs.
fittings.
4. Remove engine breather/oil separator. See
EMISSION CONTROL, Repairs.

mounting bracket.
to body.
remove.
12. Remove bolt securing earth leads to body.
5. Remove cover from engine compartment fuse

box.
6. Remove fusible link.
7. Release retaining tag and disconnect engine
harness lead from fuse box.
REPAIRS 1
CLUTCH
15. Remove bolt securing engine harness retaining

bracket to flywheel housing.
16. Position engine harness aside.
17. Release battery feed cable grommet from
bracket on flywheel housing.
13. Disconnect fresh air intake hose from duct

under RH front wing.
14. Release and remove fresh air intake duct from
inner wing.
18. Disconnect Lucar from bonnet switch.
2 REPAIRS
CLUTCH

to mounting bracket and collect washers.
position aside.
23. Remove nut and bolt securing engine lower
steady bar to bracket on flywheel housing.
24. Collect steady bar washers and position aside.
21. Remove 3 bolts securing slave cylinder

mounting bracket to flywheel housing.
22. Remove slave cylinder mounting bracket and
collect spacer.
25. Remove 2 nuts securing brake master cylinder

to servo.
26. Release master cylinder from studs on servo.
REPAIRS 3
CLUTCH
27. Release radiator top hose from clip on ignition

coil mounting bracket.
28. Fit wooden block to jack and position jack to
support engine.
29. Remove 2 nuts and bolts securing engine RH 31. Remove 6 bolts securing cover to flywheel
mounting to subframe, collect washers. housing.
30. Raise engine on jack. 32. Release cover from flywheel housing.
33. Lower engine on jack.
34. Manoeuvre flywheel housing cover through
gap between brake master cylinder and
engine, remove cover.
4 REPAIRS
CLUTCH
Refit
1. Clean flywheel housing cover and mating face

of flywheel housing.
2. Manoeuvre cover through gap between brake
master cylinder and engine.
3. Position cover to flywheel housing.
4. Raise engine on jack.
5. Fit and tighten bolts securing cover to flywheel
housing.
6. Lower engine on jack and align engine RH
7. Fit bolts, washers and nuts securing engine
8. Remove jack supporting engine.
9. Align engine lower steady bar to bracket on 17. Measure clearance between throw out stop
flywheel housing and position washers. lock nut and flywheel housing cover.
10. Fit bolt and nut securing engine lower steady 18. The correct clearance is 6.5 mm. If the
bar to flywheel housing bracket and tighten to clearance is incorrect, loosen lock nut and
40 Nm. adjust throw out stop to obtain correct
11. Fit brake master cylinder to studs on servo, fit clearance.
nuts and tighten to 25 Nm. 19. Tighten lock nut and recheck clearance.
12. Position clutch slave cylinder mounting bracket 20. Secure battery feed cable grommet to bracket
and spacer to flywheel housing. on flywheel housing.
13. Fit 3 bolts securing mounting bracket to 21. Position engine harness retaining bracket to
flywheel housing, tighten bolts: flywheel housing, fit bolt and tighten to 25 Nm.
M8 bolts to 37 Nm. 22. Connect Lucar to bonnet switch.
M5 bolt to 7 Nm. 23. Position earth leads to body, fit bolt and tighten
14. Fit clutch slave cylinder onto push rod. to 9 Nm.
15. Align slave cylinder to mounting bracket, fit 24. Fit fresh air intake duct to inner wing.
bolts and tighten to 37 Nm. 25. Connect fresh air intake hose to duct beneath
16. Depress clutch pedal to load clutch lever and wing.
remove any free play. 26. Locate ECM mounting bracket on body, fit bolt
bracket.
mounting bracket.
29. Connect engine harness lead to engine
compartment fuse box.
30. Fit fusible link.
31. Fit cover to engine compartment fuse box.
32. Fit engine breather/oil separator. See
34. Fit bonnet. See BODY, Exterior fittings.
REPAIRS 5
CLUTCH
CLUTCH ASSEMBLY AND RELEASE BEARING
Remove
1. Remove CKP sensor. See ENGINE

2. Remove clutch release bearing. See this
section.
7. Using tool 18G 1303, remove flywheel

retaining bolt.
8. Remove key plate from crankshaft.
3. Remove thrust bearing sleeve from clutch hub.

4. Rotate crankshaft and knock back tabs on
clutch hub lock washer.
5. Rotate crankshaft until clutch hub slots are
aligned horizontally.
CAUTION: If crankshaft is not positioned

correctly, primary drive ’C’ shaped washer 9. Fit thrust button of tool 18G 1381 to
may become displaced and make it crankshaft.
impossible to remove flywheel. 10. Loosen centre bolt of tool 18G 1381 and
position to flywheel.
11. Fit and tighten bolts securing tool 18G 1381 to
flywheel.
12. Tighten centre bolt of tool to release flywheel
from crankshaft taper.
13. Remove tool 18G 1381 from flywheel.
14. Remove flywheel and clutch assembly.
6. Fit flywheel locking tool and secure with bolts.
6 REPAIRS
CLUTCH
15. Remove 6 bolts securing pressure plate to

flywheel.
16. Remove pressure plate assembly.
17. Remove drive plate from flywheel.
Refit
1. Clean flywheel and pressure plate. Check

diaphragm spring for wear and fractures.
Renew flywheel and pressure plate as an
assembly if either component shows signs of
wear or damage. 6. Fit clutch aligning tool 18G 684.
2. Clean crankshaft and pressure plate hub. 7. Tighten pressure plate to flywheel bolts to 25
3. Clean inside of flywheel housing. Nm.
4. Position drive plate on flywheel. 8. Remove clutch aligning tool.
5. Fit pressure plate and align to flywheel, fit bolts 9. Check crankshaft primary gear end-float. See
but DO NOT tighten. ENGINE, Adjustments.
10. Grease splines of crankshaft primary gear.
11. Fit flywheel and clutch assembly to crankshaft.
12. Fit keyplate and NEW flywheel retaining bolt.
13. Tighten flywheel retaining bolt to 150 Nm.
14. Stake lock washer into slots on clutch hub.
15. Remove bolts securing flywheel locking tool to
flywheel housing.
16. Remove flywheel locking tool.
17. Clean thrust bearing sleeve.
18. Fit thrust bearing sleeve to clutch hub.
19. Fit clutch release bearing. See this section.
20. Fit CKP sensor. See ENGINE

CLUTCH
RELEASE BEARING MASTER CYLINDER
Remove Remove
1. Remove flywheel housing cover. See this 1. Remove ECM. See ENGINE MANAGEMENT
section. SYSTEM - MEMS, Repairs.
2. Remove ’O’ ring retaining bearing to plunger.

3. Remove bearing assembly from plunger.
4. Remove retainer securing locating plate to 3. Release engine management relay module
bearing. from mounting bracket and position aside.
5. Remove locating plate from bearing.
Refit
1. Clean mating face of locating plate and release

bearing.
2. Examine release bearing for signs of wear or
damage, renew if necessary.
CAUTION: Bearing is packed with grease,

DO NOT eash in solvent.
3. Apply grease to plunger shaft.

4. Position locating plate to bearing.
5. Fit location plate retainer.
6. Fit bearing assembly onto plunger. 4. Release brake servo vacuum pipe from clip,
7. Fit new ’O’ ring securing bearing to plunger. move vacuum pipe and engine harness aside.
8. Fit flywheel housing cover. See this section.

CLUTCH
5. Attach bleed tube to bleed screw on slave

cylinder. Remove cylinder cap and open bleed 8. Release heater air intake duct from adapter
screw, pump clutch pedal to drain fluid from inside vehicle and remove duct.
cylinder. 9. Remove split pin from clutch pedal clevis pin.
10. Remove clutch pedal clevis pin.
6. Loosen unions securing pipe to master and

slave cylinders. 11. Remove 2 nuts securing master cylinder to
7. Remove clutch pipe. body.
12. Remove master cylinder and discard gasket.

CLUTCH
Refit SLAVE CYLINDER
1. Clean mating face of master cylinder and body. Service repair no - 33.35.01
2. Fit master cylinder with new gasket to body.
3. Align push rod to clutch pedal. Remove
4. Fit and tighten nuts securing master cylinder to
body. 1. Remove ECM. See ENGINE MANAGEMENT
5. Lubricate and fit clevis pin securing push rod to SYSTEM - MEMS, Repairs.
pedal. 2. Remove engine breather/oil separator. See
6. Secure clutch pedal clevis pin with a new split EMISSION CONTROL, Repairs.
pin.
7. Fit fresh air intake duct to heater and connect
to adapter on body.
8. Clean unions on clutch pipe, master cylinder
and slave cylinder. Fit clutch pipe and tighten
unions to 14 Nm.
9. Reposition engine harness and secure brake
servo vacuum pipe to clip.
10. Secure engine management relay module to
mounting bracket.
11. Bleed clutch. See Adjustments.
12. Fit air cleaner. See ENGINE MANAGEMENT
3. Attach bleed tube to bleed screw on slave

cylinder. Remove master cylinder cap and
open bleed screw, pump clutch pedal to drain
fluid from cylinder.
4. Loosen unions securing pipe to master and

slave cylinder.
5. Remove clutch pipe.

CLUTCH
6. Remove nut securing hose to bracket and

remove washer.
7. Release hose from bracket.
8. Remove 2 bolts securing slave cylinder to
mounting bracket.
remove. 10. Holding slave cylinder in a soft jawed vice,
loosen union and remove hose and sealing
washers from slave cylinder.
11. Remove old slave cylinder from vice and
replace with new.
12. Ensure mating faces of cylinder and hose
union are clean.
13. Using new sealing washers, fit hose and
tighten union.
14. Remove cylinder from vice.
Refit
1. Position slave cylinder to mounting bracket on

flywheel housing, fit bolts and tighten to 37 Nm.
2. Fit hose to bracket and secure with washer and
nut.
3. Clean unions on clutch pipe, master cylinder
and slave cylinder.
4. Fit pipe to master cylinder and slave cylinder
and tighten unions to 14 Nm.
5. Fit engine breather/oil separator. See
6. Bleed clutch. See Adjustments.

MANUAL GEARBOX
CONTENTS Page
ADJUSTMENTS
IDLER GEAR END-FLOAT ....................................................................................... 1
REPAIRS
GEAR SELECTOR MOUNTINGS ............................................................................ 1
MANUAL GEARBOX ................................................................................................ 1
SPEEDOMETER DRIVE GEAR ............................................................................... 2
SPEEDOMETER DRIVE PINION ............................................................................. 4
REVERSE LIGHT SWITCH ...................................................................................... 5
MANUAL GEARBOX
IDLER GEAR END-FLOAT
Check and Adjust
Check
1. Remove flywheel housing gasket. See

ENGINE, Repairs.
2. Remove ’C’ washer securing primary gear to
crankshaft.
3. Remove backing ring from crankshaft.
4. Remove primary gear from crankshaft.
5. Remove idler gear assembly.
6. Remove selective washers from idler gear.
7. Clean selective washers, idler gear and
flywheel housing.
8. Fit selective washers to idler gear.
ADJUSTMENTS 1
MANUAL GEARBOX
9. Fit idler gear assembly to flywheel housing.

10. Position tool 18G 1383 across flywheel
housing and idler gear, centralise tool.
11. Using feeler gauges, measure gap between
tool 18G 1383 and selective washer on idler
gear.
DATA: End-float = 0.101 to 0.177 mm.
Adjust
12. Remove idler gear assembly from flywheel

housing.
13. Remove selective washers from idler gear
assembly.
14. Select washers which will give the correct
end-float figure.
15. Clean selective washers and fit to idler gear.
16. Fit idler gear assembly to flywheel housing.
17. Position tool 18G 1383 and centralise.
18. Check that end-float is now within tolerance.
18G 1383.
19. Remove idler gear assembly from flywheel
housing and fit to engine.
20. Clean primary gear, backing ring and ’C’
shaped washer.
21. Fit primary gear to crankshaft.
22. Position backing ring on crankshaft.
23. Fit ’C’ washer to crankshaft.
24. Fit flywheel housing gasket. See ENGINE,
Repairs.
2 ADJUSTMENTS
MANUAL GEARBOX
GEAR SELECTOR MOUNTINGS MANUAL GEARBOX
Service repair no - 37.16.25 Service repair no - 37.20.02.99
Remove Remove
1. Remove carpet See BODY, Interior trim 1. The procedure for removing the gearbox is
components. identical to that for renewing the Engine to
2. Raise front of vehicle. gearbox gasket. See ENGINE, Repairs.
3. Remove 2 nuts securing selector mountings to

floor.
4. Lower gear selector.
5. Remove nut and bolt securing mounting
bracket to gear selector and remove.
6. Remove nuts securing mountings to mounting
bracket and remove mountings.
Refit
1. Position mountings to mounting bracket and

secure with nuts.
2. Position mounting bracket to gear selector,
secure with nut and bolt.
3. Raise gear selector and locate mountings to
floor, fit and tighten nuts.
4. Fit carpet. See BODY, Interior trim
components.

MANUAL GEARBOX
SPEEDOMETER DRIVE GEAR
Remove
1. Remove front pipe to manifold gasket. See

4. Remove bolt securing radiator bottom hose to

engine mounting.
5. Position jack to support engine.

6. Take weight off engine mounting.

7. Remove 2 bolts securing engine mounting
bracket to gearbox.
subframe.
2. Disconnect multiplug from horn. 9. Remove engine mounting and bracket.
3. Remove 2 bolts securing horn to body and
remove.

MANUAL GEARBOX
Refit
1. Position speedometer drive gear in housing

ensuring correct engagement with mainshaft
and speedometer pinion.
2. Clean mating faces of cover plate and housing.
3. Position cover plate and new gasket.
4. Fit bolts securing cover plate to housing and
tighten to 8 Nm.
5. Position adaptor plate to gearbox and align bolt
holes.
6. Fit bolts securing adaptor plate to to gearbox
7. Tighten bolt securing adaptor plate to gearbox
to 25 Nm.
8. Position engine mounting and bracket.
9. Lower engine to align engine mounting to
subframe.
10. Fit bolts securing engine mounting to adaptor
plate and tighten to 25 Nm.
11. Fit bolts securing engine mounting to subframe
12. Remove jack.
10. Remove 3 bolts securing engine mounting 13. Fit bolt securing radiator bottom hose to engine
adaptor plate to gearbox. lower front bolt. mounting.
11. Loosen lower bolt securing adaptor plate to 14. Position horn to body, fit bolts and tighten to 9
gearbox. Nm.
12. Release adaptor plate from gearbox and rotate 15. Connect multiplug to horn.
anti-clokwise to gain access to speedometer 16. Fit front pipe to manifold gasket. See
drive gear cover plate. MANIFOLD & EXHAUST SYSTEMS, Repairs.
NOTE: Engine may have to be raised for

adaptor plate to clear crankshaft front
pully.
13. Remove 2 bolts securing drive gear cover plate

to housing.
14. Remove cover plate and discard gasket.
15. Remove speedometer drive gear.

MANUAL GEARBOX
SPEEDOMETER DRIVE PINION
Remove
5. Remove bolt securing drive pinion housing to

gearbox and remove clamping plate.
6. Remove drive pinion housing.
7. Remove drive pinion from housing.
8. Remove bush from drive pinion.
9. Remove and discard gasket and oil seal from
housing.
Refit
1. Clean drive pinion, housing and bush.

2. Lubricate inner lip of oil seal with clean engine
oil, and grease outer surface.
3. Fit oil seal to housing
4. Fit bush to drive pinion.
5. Fit drive pinion to housing.
3. Loosen knurled nut and disconnect 6. Clean mating faces of drive pinion housing and
speedometer cable from housing. gearbox.
4. Position speedometer cable aside. 7. Using a new gasket, fit drive pinion housing to
gearbox.
8. Fit clamping plate.
9. Fit bolt securing clamping plate to gearbox and
tighten to 8 Nm.
10. Connect speedometer cable to gearbox and
tighten nut.

MANUAL GEARBOX
REVERSE LIGHT SWITCH
Service repair no - 37.27.01.
Remove
2. Disconnect 2 reverse lamp switch leads from

harness.
3. Loosen locknut securing switch to gear
selector housing.
4. Remove reverse light switch.
5. Remove locknut from switch.
Refit
1. Fit locknut to new switch.

2. Fit switch to gear selector housing but DO NOT
tighten.
3. Connect reverse lamp switch leads to harness.
4. Switch on ignition and select reverse gear.
5. Adjust switch until reverse lights are
illuminated, screw switch in a further half turn
and tighten lock nut.
6. Select neutral and switch off ignition.

DRIVE SHAFTS
CONTENTS Page
REPAIRS
DRIVE SHAFT OUTER JOINT ................................................................................. 1
DRIVE SHAFT INNER JOINT ................................................................................... 1
DRIVE SHAFT AND OUTER JOINT ......................................................................... 2
DRIVE SHAFTS
DRIVE SHAFT OUTER JOINT DRIVE SHAFT INNER JOINT
Remove Remove
1. Remove drive shaft and outer joint. See this 1. Raise front of vehicle, one side.
section.
2. Place drive shaft in vice. WARNING: Support on safety stands.
2. Remove drive shaft and outer joint, but DO

NOT remove drive shaft from front hub. See
this section.
3. Position container beneath differential to collect
fluid loss.
3. Remove clip securing gaiter to outer joint.

4. Fold back gaiter to gain access to outer joint.
5. Using a suitable drift against the inner part of
the joint, remove joint from shaft.
6. Remove circlip from shaft and discard.
7. Inspect gaiter for signs of damage and renew if
necessary.
Refit
1. Thoroughly clean outer joint and drive shaft.

4. Using tool 18G 1240 release inner joint from
2. Fit new circlip to drive shaft.
differential.
3. Position outer joint to shaft, use a screwdriver
to press circlip into groove and push joint fully
onto shaft.
4. Apply grease from the sachet supplied to the
joint.
5. Fold back gaiter and locate on outer joint.
6. Using a Band-it thrift tool secure gaiter to outer
joint with clip.
7. Remove drive shaft from vice.
8. Fit drive shaft and outer joint. See this
section.

DRIVE SHAFTS
DRIVE SHAFT AND OUTER JOINT
Remove
1. Raise front of vehicle, one side.
2. Remove road wheel(s).
5. Remove drive shaft inner joint.

6. Remove and discard circlip from inner joint.
Refit
1. Clean drive shaft inner joint.

2. Inspect differential end cover oil seal for signs
of damage and renew if necessary.
3. Fit new circlip to inner joint.
4. Fit inner joint to differential. 3. Remove split pin retaining drive shaft nut.
4. Loosen nut securing front hub to drive shaft.
CAUTION: Ensure inner is securely
retained in differential by circlip.
5. Fit drive shaft and outer joint. See this

section.
7. Top-up engine oil. See

DRIVE SHAFTS
5. Remove 2 bolts and collect washers securing

brake caliper to front hub.
6. Release brake caliper from front hub and tie
aside.
CAUTION: Do not allow weight of caliper

to hang on brake hose.
7. Raise front suspension using a jack positioned

beneath lower suspension arm.
subframe.
9. Remove rebound rubber.
10. Fit a wedge between suspension arm and
subframe, lower suspension onto wedge and
remove jack.
CAUTION: Ensure that an appropriate

wedge is used to prevent any damage
occurring to the suspension components.

DRIVE SHAFTS
11. Remove nut securing steering rack track end to

front hub.
13. Disconnect track rod end from front hub.

lower ball joint to suspension arm.
18. Loosely fit nut securing upper ball joint to
suspension arm.

upper ball joint to suspension arm.
CAUTION: Be careful not to damage the

rubber boot on ball joint.

DRIVE SHAFTS
19. Using a suitable drift, release drive shaft from

inner joint.
CAUTION: Take care not to damage gaiter

on drive shaft inner joint.
20. Remove nut and disconnect front hub from

upper suspension arm.
21. Retain position of inboard joint gaiter and
remove drive shaft and hub as an assembly.
22. Remove hub nut and split collar securing front

hub to drive shaft. Withdraw drive shaft from
hub.

23. Remove hub bearing water shield.

DRIVE SHAFTS
Refit
1. Clean both ends of drive shaft.
2. Fit hub bearing water shield onto drive shaft as

shown:
’A’ = 6 mm approximately.
3. Lubricate end of drive shaft and fit to inboard
joint.
NOTE: Ensure shaft is securely retained

by joint.
4. Clean front hub ball joints and mating faces of

suspension arms.
5. Fit front hub to drive shaft and engage upper
and lower ball joints on suspension arms.
6. Fit nuts and washers securing suspension
arms to front hub and tighten to 52 Nm.
7. Connect steering rack track rod end to front
hub, fit nut and tighten to 30 Nm.
8. Clean front brake disc.
9. Fit brake caliper to front hub.
10. Fit 2 bolts and washers securing brake caliper
to front hub and tighten to 52 Nm.
11. Fit road wheel.
12. Position jack beneath lower suspension arm
and raise front suspension.
13. Remove wedge between suspension arm and
subframe.
14. Position rebound rubber and secure with
screw.
15. Remove jack from beneath suspension arm.
17. Fit split collar and tighten hub nut to 260 Nm.
18. Align nut to next split pin hole and fit new split
pin.

STEERING
CONTENTS Page
ADJUSTMENTS
FRONT WHEEL ALIGNMENT .................................................................................. 1
REPAIRS
STEERING RACK AND PINION ............................................................................... 1
STEERING COLUMN NACELLE .............................................................................. 5
STEERING COLUMN LOCK .................................................................................... 6
STEERING COLUMN ASSEMBLY ........................................................................... 8
STEERING WHEEL ................................................................................................ 11
STEERING
FRONT WHEEL ALIGNMENT 7. Check front wheel alignment is within

tolerance.
DATA: Front wheel alignment.
Check = Toe out 0° 15" ± 7.5" per side
1. Ensure tyre pressures are correct and vehicle Adjust

is at kerbside weight.
2. With the wheels in the straight ahead position, 1. Mark position of track rod ends for reference.
roll vehicle backwards and forwards at least a
vehicle length to relieve any stresses in the
steering and suspension.
2. Loosen track rod end locknuts.

3. Loosen clip securing gaiter to the track rod.
4. Rotate track rod to obtain correct alignment.
CAUTION: Both track rod ends must be

rotated an equal amount.
5. Recheck front wheel alignment and adjust if

necessary.
6. Tighten track rod end locknuts to 52 Nm.
7. Ensure gaiters are not strained or twisted then
3. Release carpet from LH foot well to access tighten clip.
grommet, remove grommet from floor. 8. Remove 6mm rod from steering rack, fit and
4. Using an Allen key, remove plug from steering tighten blanking plug.
rack. 9. Fit grommet to floor and reposition carpet.
5. Using assistance, move road wheels until a
6mm diameter rod can be inserted into the
centralising hole in the steering rack.
6. Ensure that equipment is properly calibrated
and take an average of 3 readings.
NOTE: Only use equipment recommended

in the STEP (Service Tools and Equipment
Programme) Manual.
ADJUSTMENTS 1
STEERING
STEERING RACK AND PINION
Remove
WARNING: SRS procedures must be

followed and all precautions observed.
See RESTRAINT SYSTEMS, Precautions.
2. Remove both front road wheels.

4. Remove steering column nacelle. See this 6. Disconnect multiplug from windscreen washer
section. and wiper switch.
7. Disconnect multiplug from rotary coupler.
8. Disconnect multiplug from ignition/starter

switch.
9. Release carpet from around steering column.
5. Disconnect 2 multiplugs from
indicator/headlamp switch.
REPAIRS 1
STEERING
16. Remove nuts and bolts securing front dampers

to suspension upper arms, collect spacers and
washers.
10. Remove bolt securing steering column to

steering rack pinion.
support bracket.
12. Remove steering column assembly.
13. Remove nuts securing steering rack track ends

to front hubs.
14. Break taper joints using tool 18G 1584.
15. Disconnect track rod ends from front hubs.
2 REPAIRS
STEERING
17. Remove 4 nuts and bolts securing front

subframe to mounting brackets on body, collect
washers. 18. Remove 2 bolts securing emission canister
purge valve to body.
19. Position purge valve aside.
20. Fit wooden block or hard rubber pad to jack
and position jack to support rear of front
subframe.
21. Remove 2 bolts securing subframe turrets to
body.
22. Lower subframe to give a clearance of
approximately 20 mm between the subframe
turrets and body.
REPAIRS 3
STEERING
23. Remove 4 nuts securing the 2 steering rack ’U’ Refit

bolts to body.
24. Release steering rack and remove ’U’ bolts 1. Inspect steering rack pinion seal and
and anti-friction strips. anti-friction strips for signs of damage and
25. Manoeuvre steering rack out from the RH side replace if necessary.
of the vehicle. 2. Fit steering rack pinion seal to body.
26. Remove steering rack pinion seal from vehicle. 3. Manoeuvre steering rack into position in
vehicle.
4. Fit anti-friction strips and ’U’ bolts securing
steering rack to body, but DO NOT tighten ’U’
bolt securing nuts.
5. Raise subframe into position.
6. Fit bolts securing subframe turrets to body and
tighten to 67 Nm.
7. Position emission canister purge valve to body,
fit bolts and tighten to 9 Nm.
8. Position front dampers to suspension upper
arms.
4 REPAIRS
STEERING
9. Fit spacers, washers, nuts and bolts securing STEERING COLUMN NACELLE
front dampers to suspension upper arms,
tighten nuts to 48 Nm. Service repair no - 57.40.29
10. Align subframe to mounting brackets on body.
11. Fit nuts, bolts and washers securing subframe Remove
to mounting bracket and tighten nuts to 25 Nm.
12. Connect steering rack track rod ends to front
hubs, fit nuts and tighten to 30 Nm.
13. Release carpet from LH foot well to access
grommet, remove grommet from floor.
14. Using an Allen key, remove plug from steering
rack.
16. Fit steering column assembly to steering rack
pinion.
17. Fit pinch bolt securing column to pinion and
tighten to 15 Nm.
18. Tighten nuts securing steering rack ’U’ bolts to
body, to 15 Nm.
19. Reposition carpet round steering column. 1. Remove 3 screws securing steering column
20. Align steering column to mounting bracket, fit nacelle.
bolt and tighten to 25 Nm. 2. Separate and remove upper and lower halves
21. Connect multiplugs to column switches and of nacelle.
ignition/starter switch.
22. Connect multiplug from rotary coupler. CAUTION: Care must be taken when
23. Fit steering column nacelle. See this section. removing upper half of nacelle to avoid
24. Fit air cleaner. See ENGINE MANAGEMENT damaging the steering wheel.
25. Fit road wheels. Refit
27. Remove 6 mm rod from steering rack, fit and 1. Fit upper and lower half of column nacelle and
tighten blanking plug. fasten together.
28. Fit grommet to floor and reposition carpet. 2. Align nacelle to bracket on column and secure
with screws.
REPAIRS 5
STEERING
STEERING COLUMN LOCK
Remove
WARNING: SRS procedures must be

followed and all precautions observed.
See RESTRAINT SYSTEMS, Precautions.
1. Remove steering column nacelle. See this

section.
5. Disconnect 2 multiplugs from rotary coupler.



steering rack.
3. Disconnect multiplug from windscreen washer

and wiper switch.
switch.
6 REPAIRS
STEERING
Refit
1. Locate steering column lock in position on

steering column, fit but do not tighten shear
bolts.
2. Insert key, confirm correct operation of steering
lock and that key turns freely.
3. Tighten shear bolts until heads shear off.
4. Remove steering column assembly from vice.

support bracket.
10. Position steering column in vice.
11. Centre punch shear bolts securing lock to
column.
5. Release carpet from LH foot well to access

grommet, remove grommet from floor.
6. Using an Allen key, remove plug from steering
rack.
8. Fit steering column assembly to steering rack
pinion.
tighten to 15 Nm.
12. Using a 5mm drill, drill out 2 shear bolts 10. Reposition carpet round steering column.
securing column to lock.
CAUTION: Take care not to damage lock

body if lock is to be refitted.
13. Remove steering column lock.
REPAIRS 7
STEERING
11. Align steering column to mounting bracket, fit STEERING COLUMN ASSEMBLY
bolt and tighten to 25 Nm.
12. Connect multiplugs to column switches and Service repair no - 57.50.01
13. Connect 2 multiplugs to rotary coupler. Remove
14. Fit steering column nacelle. See this section.
15. Remove 6mm rod from steering rack, fit and 1. Disconnect battery earth lead.
tighten blanking plug. 2. Remove rotary coupler. See ELECTRICAL,
16. Fit grommet to floor and reposition carpet. Repairs.
18. Carry out system check by turning the ignition
on and checking that the SRS warning light
illuminates then extinguishes after 3 seconds.

8 REPAIRS
STEERING

switch.
4. Disconnect multiplug from windscreen washer

and wiper switch.

steering rack pinion.
5. Remove 2 screws securing column switch

assembly to steering column.
6. Remove steering column switch assembly.
REPAIRS 9
STEERING
12. Position steering column in a vice.

13. Centre punch shear bolts securing lock to
column.

support bracket.
14. Using a 5mm drill, drill out 2 shear bolts

securing lock to column.
CAUTION: Take care not to damage lock

body if lock is to be refitted.
15. Remove steering column lock.

17. Position new steering column assembly in vice.
18. Locate steering column lock in position on
steering column, fit but do not tighten shear
bolts.
19. Insert key, confirm correct operation of steering
lock and that key turns freely.
20. Tighten shear bolts until heads shear off.
10 REPAIRS
STEERING
Refit STEERING WHEEL
Remove
1. Remove driver’s airbag module. See

RESTRAINT SYSTEMS, Repairs.
2. Disconnect horn multiplug from rotary coupling.

3. Centralise steering wheel with road wheels in
1. Release carpet from LH foot well to access straight ahead position.
grommet, remove grommet from floor. 4. Restrain steering wheel and loosen self-locking
2. Using an Allen key, remove plug from steering nut securing steering wheel to column. Loosen
rack. 2 turns only.
3. Using assistance, move road wheels until a 5. Release steering wheel from column splines by
6mm diameter rod can be inserted into the rocking steering wheel from side-to-side and
centralising hole in the steering rack. pulling with both hands.
4. Fit steering column assembly to steering rack 6. Remove and discard self-locking nut.
pinion. 7. Remove steering wheel.
tighten to 15 Nm.
6. Reposition carpet round steering column.
7. Align steering column to mounting bracket, fit
8. Fit steering column switch assembly and
secure with screws.
9. Connect multiplugs to column switches and
10. Fit rotary coupler. See ELECTRICAL,
Repairs.
11. Remove 6 mm rod from steering rack, fit and
tighten blanking plug.
12. Fit grommet to floor and reposition carpet.
REPAIRS 11
STEERING
Refit
1. Fit horn harness to steering wheel.

2. Position horn switches to wheel, connect
Lucars and fit switches.
3. Remove retaining tape from rotory coupler.
4. Ensure road wheels are in straight ahead
position and indicator cancel cam aligned
vertical.
5. Engauge rotory coupling and fit steering wheel
to column, ensure wheel spokes are horizontal.
6. Fit NEW self-locking nut, and tighten to 49 Nm.
7. Connect horn multiplug to rotary coupler.
8. Fit driver’s airbag module. See RESTRAINT
SYSTEMS, Repairs.
8. Attach tape across edge of rotary coupler to

retain in central setting.

9. Release horn switches from steering wheel.

10. Disconnect Lucar connections from switches
and remove switches.
11. Remove horn harness from steering wheel.
12 REPAIRS
SUSPENSION
CONTENTS Page
ADJUSTMENTS
DAMPER ADJUSTMENT ......................................................................................... 1
REPAIRS
FRONT BUMP RUBBER .......................................................................................... 1
FRONT REBOUND RUBBER ................................................................................... 1
FRONT DAMPER ..................................................................................................... 2
REAR DAMPER ........................................................................................................ 3
SUSPENSION
DAMPER ADJUSTMENT
Service repair no -
Front - 68.15.16.01
Rear - 68.15.22.01
WARNING: Dampers must be adjusted

equally, in axle pairs only, otherwise
handling characteristics may be impaired.
Adjust
1. Remove damper.
Front damper. See Repairs.
Rear damper. See Repairs.
2. Hold damper vertically with lower eye in vice.
CAUTION: Use soft jaws to prevent

damage to damper. 6. Compress damper whilst at the same time
turning dust cover anti-clockwise to engage
3. Extend damper. adjusting pins with holes on damper.
7. Keeping damper compressed, turn dust cover
fully anti-clockwise until it stops.
8. Using a felt tipped pen, mark relationship
between dust cover and damper cylinder.
9. Adjust damper by turning dust cover 1/2 turn
clockwise for each 48,000 miles completed.
10. Extend damper to release adjusting pins.
11. Fit rebound rubber to dust cover.
12. Fit plastic collar to damper shaft.
13. Remove damper from vice.
14. Fit damper.
Front damper. See Repairs.
Rear damper. See Repairs.
4. Remove plastic collar from damper shaft.

5. Remove rebound rubber from dust cover.
ISSUED: 12/96 ADJUSTMENTS 1

SUSPENSION
FRONT BUMP RUBBER FRONT REBOUND RUBBER
Remove Remove
1. Raise front of vehicle, one side. 1. Raise front of vehicle, one side.
WARNING: Support on safety stands. WARNING: Support on safety stands.
2. Remove road wheel(s). 2. Remove road wheel(s).

3. Raise front suspension using a jack positioned
beneath lower suspension arm.

subframe.
3. Using an 11mm spanner remove nut securing 5. Remove rebound rubber.
bump rubber to subframe.
4. Remove bump rubber and collect spacer. Refit
Refit 1. Position rebound rubber and secure with

screw.
1. Fit spacer, position bump rubber to subframe. 2. Remove jack from beneath suspension arm.
2. Fit and tighten nut securing bump rubber to 3. Fit road wheel and tighten nuts
subframe. 4. Remove stand(s) and lower vehicle.
3. Fit road wheel and tighten nuts.

SUSPENSION
FRONT DAMPER Refit
Service repair no - 68.15.16 1. Hold new damper in vice, compress and

extend it through its full stroke until there is no
Remove free travel when changing direction of stroke.
2. Fit spacer and washer to suspension upper
1. Raise front of vehicle, one side. arm bolt.
3. Fit washer to bolt on body and locate damper
WARNING: Support on safety stands. on mounting bolts.
4. Fit nut and washer securing damper to bracket
on body and tighten to 37 Nm.
2. Remove road wheel(s). 5. Fit nut and washer securing damper to
suspension upper arm and tighten to 48 Nm.
3. Remove nut and washers securing damper to

bracket on body.
4. Remove nut and washers securing damper to
suspension upper arm and remove spacer.
5. Remove front damper.
NOTE: Store damper upright if it is to be

refitted.

SUSPENSION
REAR DAMPER Refit
Service repair no - 1. Hold new damper in vice, compress and and

LH side - 68.15.22 extend it through its full stroke until there is no
RH side - 68.15.23 free travel when changing direction of stroke.
2. Fit rubber bush and washer to top of damper.
Remove 3. Fit damper to suspension arm.
4. Fit nut and washer securing damper to
1. LH damper only: Remove fuel tank. See suspension arm and tighten to 25 Nm.
FUEL DELIVERY SYSTEM, Repairs. 5. Extend damper and locate shaft in hole on
2. Raise rear of vehicle, one side. body.
6. Fit bush and washer to damper shaft.
WARNING: Support on safety stands. 7. Fit nut securing damper to body, hold damper
shaft and tighten nut to 25 Nm.
8. LH damper only: Fit fuel tank. See FUEL
3. Remove road wheel(s). DELIVERY SYSTEM, Repairs.
4. From inside luggage compartment, remove

nut, washer and bush securing damper to
body.
5. Remove nut and washer securing damper to
suspension arm.
6. Compress damper and remove from
suspension arm.
7. Remove rubber bush and washer from
damper.
NOTE: Store damper upright if it is to be

refitted.

BRAKES
CONTENTS Page
ADJUSTMENTS
BRAKE SYSTEM BLEED ......................................................................................... 1
BRAKE LIGHT SWITCH ........................................................................................... 2
REPAIRS
REAR BRAKE DRUM ............................................................................................... 1
BRAKE FAILURE WARNING SWITCH .................................................................... 2
PRESSURE REDUCING VALVE ............................................................................. 3
BRAKE LIGHT SWITCH ........................................................................................... 5
MASTER CYLINDER ................................................................................................ 5
BRAKE PEDAL ......................................................................................................... 7
FRONT BRAKE PADS .............................................................................................. 9
REAR BRAKE SHOES ........................................................................................... 10
SERVO ASSEMBLY ............................................................................................... 12
FRONT BRAKE CALIPER ...................................................................................... 14
REAR WHEEL BRAKE CYLINDER ........................................................................ 15
HANDBRAKE CABLE - FRONT ............................................................................. 15
BRAKES
4. Attach bleed tube to front brake caliper bleed
BRAKE SYSTEM BLEED screw (A), submerge free end in a clear
container containing brake fluid.
NOTE: Bleed brakes with handbrake in
The following procedure covers bleeding the OFF position.
complete system but where only the primary or
secondary circuit have been disturbed in isolation, it 5. Apply pressure to brake pedal several times,
should only be necessary to bleed that system. then apply steady pressure.
Partial bleeding of the hydraulic system is only 6. Loosen bleed screw to release brake fluid and
permissable if a brake pipe or hose has been air.
disconnected with only minor loss of fluid. 7. Depress brake pedal steadily through its full
stroke and allow to return unassisted. Repeat
CAUTION: Never reuse fluid that has been procedure until a flow of clean air-free fluid is
bled from the brake system. Do not allow purged into container then, whilst holding pedal
fluid level in master cylinder to fall below at end of downward stroke, tighten bleed screw
’MIN’ mark during bleeding. Do not fill reservoir to 9 Nm.
above ’MAX’ mark.
CAUTION: Maintain brake fluid level above
CAUTION: Do not allow brake fluid to ’MIN’ mark during this procedure.
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid 8. Top-up brake fluid level.
and clean area with clean warm water. 9. Repeat procedure at each wheel in the
sequence shown.
Bleed
CAUTION: Braking efficiency may be
1. Raise front and rear of vehicle. seriously impaired if wrong bleed
sequence is used.
10. Remove bleed tube. Apply brakes and check
for leakage.
2. Check all pipe and hose connections are tight 11. Remove stand(s) and lower vehicle.
and there are no signs of leakage. 12. Road test vehicle. Check brake pedal for short
3. Top-up fluid level in brake reservoir to ’MAX’ firm travel when brakes are applied.
mark. See INFORMATION, Capacities, fluids
and lubricants.
CAUTION: Use only new brake fluid of the

recommended grade.
REVISED: 12/96 ADJUSTMENTS 1

BRAKES
BRAKE LIGHT SWITCH
Adjust
1. Remove heater air intake hose

2. Disconnect throttle pedal return spring from
mounting bracket.
3. Disconnect Lucars from brake light switch.
4. Loosen locknut securing brake light switch
bracket to pedal box.
5. Connect an ohmmeter across switch terminals.
6. Adjust position of switch until an open circuit
condition exists with the pedal released and a
closed circuit condition exists with the pedal
depressed.
7. Tighten nut securing brake light switch bracket
to pedal box, to 5 Nm.
CAUTION: Ensure the switch does not

prevent the brake pedal returning fully.
8. Connect Lucars to brake light switch.

9. Connect throttle pedal return spring to bracket
on pedal box.
10. Fit heater air intake hose.
2 ADJUSTMENTS ISSUED: 12/96

BRAKES
REAR BRAKE DRUM
Remove
1. Raise rear of vehicle.
2. Remove road wheel(s).

3. Release handbrake.
3. Measure inside diameter of drum at 2 points.

Drum internal diameter:
New = 177.75 - 177.85 mm
Service limit = 179 mm
Drum ovality limit = 0.012 mm
Renew drum if outside limits.
4. Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if free fluid is
apparent, lift dust seal and check for excessive
leakage.
Renew wheel cylinder if brake linings have
become contaminated.
5. Check wheel cylinder pistons for freedom of
movement.
Refit
4. Remove wheel spacer from rear hub.
1. Apply Molycote 111 grease to brake shoe and
5. Remove screw securing brake drum to hub.
spring contact points.
6. Loosen brake shoe adjuster.
2. Fit brake drum, tighten screw to 7 Nm.
7. Withdraw brake drum from hub.
NOTE: Clean inside of NEW brake drum
Inspect
with brake cleaning fluid.
1. Clean backplate and brake drum with brake
3. Fit wheel spacer to rear hub.
cleaning fluid.
WARNING: Do not use an air line to blow
6. Adjust rear brakes. See
dust from brake assembly.
Do not use petroleum based fluid as
damage will occur to rubber components.
2. Renew brake drum if scored, grooved or

cracked.

BRAKES
BRAKE FAILURE WARNING SWITCH Refit
Service repair no - 70.25.09 1. Position switch to panel.

2. Connect multiplug and Lucars to switch.
Remove 3. Fit switch to switch panel.
4. Position heater to fascia rail and secure with
screws.
1. Remove 2 screws securing heater to fascia

lower rail and lower heater.
2. Release switch from switch panel.

3. Disconnect multiplug and 2 Lucars from switch.
4. Remove switch.

BRAKES
PRESSURE REDUCING VALVE
Remove


mounting bracket.
to body.
remove.
6. Position cloth beneath valve to absorb spilled
fluid.
ECM mounting bracket. CAUTION: Do not allow brake fluid to
contact paint finished surfaces as paint
may be damaged. If spilled, remove fluid
and clean area with clean warm water.

BRAKES
Refit
1. Remove blanking plugs from new valve.

2. Clean master cylinder brake pipe and pressure
reducing valve unions.
3. Fit pipes to valve and tighten unions. 14 Nm.
4. Position valve and pipe assembly to body, fit
5. Remove plugs from master cylinder.
6. Clean master cylinder and brake pipe unions.
7. Connect pipes to master cylinder and tighten
unions to 14 Nm.
8. Connect brake pipes to valve and tighten
unions to 14 Nm.
9. Remove cloth positioned to absorb fluid.
7. Loosen unions and disconnect lower brake 10. Locate ECM mounting bracket on body, fit bolt
pipes from valve and tighten to 10 Nm.
CAUTION: Plug the connections. bracket.
mounting bracket.
8. Position cloth under master cylinder to absorb 13. Fit ECM. See ENGINE MANAGEMENT
spilled fluid. SYSTEM - MEMS, Repairs.
9. Loosen unions and disconnect brake pipes 14. Bleed brakes. See Adjustments.
from master cylinder.
10. Remove bolt securing valve to body.

11. Remove valve and pipes as an assembly.
12. Loosen unions and remove pipes from
pressure reducing valve.

BRAKES
BRAKE LIGHT SWITCH MASTER CYLINDER
Remove Remove
1. Disconnect 2 Lucars from fluid reservoir filler

cap.
2. Position cloth under master cylinder to absorb
spilled fluid.
1. Remove heater air intake hose.
2. Disconnect Lucars from brake light switch. CAUTION: Do not allow brake fluid to
3. Loosen locknut securing brake light switch to contact paint finished surfaces as paint
pedal box bracket and remove switch may be damaged. If spilled, remove fluid
and clean area with clean warm water.
Refit
3. Loosen union and disconnect secondary
1. Fit brake light switch and tighten locknut. system pipe from master cylinder.
2. Adjust brake light switch. See Adjustments. 4. Loosen union and disconnect primary system
pipe from master cylinder.
5. Move brake pipes aside.
6. Remove 2 nuts securing master cylinder to
servo.
7. Remove master cylinder.
8. Remove and discard ’O’ ring from master
cylinder.

BRAKES
9. Using a suitably sized, flat ended punch, drive Refit

out roll pin securing reservoir to cylinder body.
10. Remove reservoir from master cylinder. 1. Lubricate new ’O’ ring with clean brake fluid
11. Remove 2 sealing washers from reservoir. and fit to master cylinder.
12. Extract 2 metal seating washers from master 2. Clean mating faces of master cylinder and
cylinder. brake servo.
13. Clean 2 metal seating washers and fit to 3. Clean brake servo push rod and lubricate.
master cylinder. 4. Locate master cylinder on servo ensuring push
14. Lubricate 2 new sealing washers with clean rod is correctly seated.
brake fluid and fit to reservoir. 5. Fit nuts securing master cylinder to servo and
15. Fit reservoir to master cylinder and secure with tighten to 25 Nm.
new roll pin. 6. Remove plugs from master cylinder and brake
pipes.
7. Clean brake pipe unions.
8. Connect brake pipes to master cylinder and
tighten unions to 14 Nm.
9. Connect Lucars to fluid reservoir filler cap.
10. Bleed brake system. See Adjustments.

BRAKES
BRAKE PEDAL
Remove
6. Remove 2 screws securing heater to lower

fascia rail.
1. Release engine management relay module

from mounting bracket.
2. Remove and discard split pin from clevis pin.
7. Loosen nut securing rear of heater to

bulkhead.
8. Release heater and move aside.
3. Remove clevis pin securing brake pedal push

rod to fulcrum
4. Remove heater air intake hose.
5. Disconnect demister tubes from heater.

BRAKES
9. Release throttle pedal return spring from

bracket. 12. Remove and discard split pin from clevis pin.
10. Remove nut and washer securing brake light 13. Remove clevis pin securing master cylinder
switch mounting bracket to pedal box. push rod to clutch pedal.
11. Release brake light switch mounting bracket 14. Release return spring from clutch pedal.
from pedal box. 15. Remove nut securing pedal pivot bolt to pedal
box.
16. Withdraw pivot bolt from pedal box and remove
pedals and return spring.
17. Remove rubber from pedal.

BRAKES
Refit FRONT BRAKE PADS
1. Fit rubber to pedal. Service repair no - 70.40.02

2. Clean pedal bushes and pivot bolt.
3. Lubricate pedal pivot bolt. Remove
4. Position pedals and return spring to pedal box .
5. Align push rods to pedals, fit pedal pivot bolt. 1. Raise front of vehicle.
NOTE: Ensure pivot bolt is correctly WARNING: Support on safety stands.

located.
6. Fit nut securing pivot bolt to pedal box and 2. Remove road wheel(s).
tighten to 15 Nm.
7. Clean and lubricate clutch master cylinder WARNING: Brake pads must be renewed
clevis pin. in axle sets only. Braking efficiency may
8. Align clutch master cylinder push rod to pedal, outerwise be impaired.
fit clevis pin and secure with new split pin.
9. Connect return spring to clutch pedal.
10. Position brake light switch mounting bracket to
pedal box, fit nut and tighten to 5 Nm.
11. Secure throttle pedal return spring to mounting
bracket.
12. Locate heater on bulkhead.
13. Tighten nut securing heater to bulkhead to 9
Nm.
14. Fit and tighten screws securing front of heater
to lower fascia rail.
15. Connect demister tubes to heater.
16. Fit heater air intake hose.
17. Align brake pedal push rod to fulcrum, fit clevis
pin and secure with NEW split pin.
mounting bracket.
19. Adjust brake light switch. See Adjustments.
3. Remove 2 split pins retaining brake pads.

4. Remove brake pad anti-rattle spring.
5. Remove 2 brake pads.

BRAKES
Refit REAR BRAKE SHOES
1. Rotate disc by hand and scrape all scale and Service repair no - 70.40.03
rust from around edge of disc.
2. Scrape rust from pad locating surfaces on Remove
caliper.
3. Clean dust from calipers using brake cleaning WARNING: Brake shoes must be renewed
fluid or industrial alcohol. in axle sets only. Braking efficiency may
otherwise be impaired.
dust from brake assembly. Do not use 1. Remove both rear brake drums. See this
petroleum based fluid as damage will section.
occur to rubber components.
4. Position bleed bottle, connect bleed hose to

bleed screw and loosen screw.
5. Press piston back into housing.
6. Tighten bleed screw to 9 Nm.
7. Remove bleed bottle.
8. Fit brake pads to caliper.
NOTE: Fit pad with wear indicator on the

inside.
9. Position brake pad anti-rattle spring.

10. Fit split pins retaining brake pad anti-rattle
spring.
11. Repeat procedure for other side.
12. Fit road wheel and tighten nuts to the correct
torque.
14. Depress brake several times to set pad to disc 2. Release brake shoes from adjuster.
clearance. 3. Release brake shoes from wheel cylinder and
15. Check and top-up brake fluid See disengage from handbrake lever.
INFORMATION, Capacities, fluids and
lubricants. CAUTION: Ensure edges of brake shoes
do not damage wheel cylinder dust
covers.
4. Release spring from a trailing brake shoe and

remove brake shoe assembly
NOTE: The forward shoe is the LEADING

shoe, the TRAILING shoe has the
handbrake lever attached to it.

BRAKES
Refit
1. Lubricate brake shoe contact points with

MolyKote 111 grease, ensure grease does not
contact linings or dust covers.
2. Fit return spings to leading brake shoe
3. Connect return sping to trailing brake shoe.
4. Position brake shoe assembly to back plate.
5. Remove elastic band from wheel cylinder.
6. Connect return spring to trailing brake shoe.
7. Connect handbrake linkage to trailing brake
shoe.
8. Locate brake shoes in slots on wheel cylinder
pistons.
9. Locate brakes shoes in slots on adjuster.
10. Fit rear brake drums. See this section.
5. Remove springs from brake shoes.

6. Fit an elastic band around wheel cylinder to
retain pistons.
Inspect
1. Clean back plate and drum with brake cleaning

fluid.

dust from brake assembly.
Do not use petroleum based fluid as
damage will occur to rubber components.
2. Use a wire brush to remove any corrosion

taking care not to damage wheel cylinder
covers.
3. Inspect all parts for wear or damage.
4. Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if free fluid is
apparent, lift dust shield and check for
excessive leakage.
Renew wheel cylinder if brake linings have
become contaminated.
5. Check wheel cylinder pistons for freedom of
movement.
6. Check condition of springs, renew if necessary.

BRAKES
SERVO ASSEMBLY
Remove
1. Remove master cylinder. See this section.
5. Remove clevis pin securing brake pedal push

rod to fulcrum.
6. Remove bolt and 2 nuts securing servo
2. Depress plastic collar on quick release mounting bracket to body and collect washers.
connector and disconnect servo vacuum hose 7. Release and remove servo and mounting
from inlet manifold. bracket assembly.

from mounting bracket.
4. Remove and discard split pin from clevis pin.

BRAKES
8. Remove and discard split pin from clevis pin. Refit

9. Remove clevis pin securing servo push rod to
fulcrum. 1. Clean mating faces of servo mounting bracket
10. Remove 4 nuts securing servo to mounting and bulkhead.
bracket. 2. Fit servo and mounting bracket assembly to
11. Remove bracket from stud on servo. bulkhead.
12. Release vacuum pipe from clip on mounting 3. Fit bolt, washers and nuts securing servo
bracket. mounting bracket to bulkhead and tighten to 25
13. Remove servo from mounting bracket. Nm.
14. Remove vacuum pipe from servo and remove 4. Align brake pedal push rod to fulcrum, fit clevis
sealing rubber. pin and secure with NEW split pin.
15. Clean servo. 5. Secure engine management relay module to
16. Fit sealing rubber to servo. mounting bracket.
17. Fit vacuum pipe to servo. 6. Connect brake servo vacuum pipe to inlet
18. Fit servo to mounting bracket. manifold.
19. Fit bracket to stud on servo, fit nuts securing 7. Fit master cylinder. See this section.
servo to mounting bracket and tighten to 25
Nm.
20. Secure vacuum pipe to clip on mounting
bracket.
21. Align servo push rod to fulcrum, fit clevis pin
and secure with NEW split pin.

BRAKES
FRONT BRAKE CALIPER Refit
Service repair no - 70.55.02 1. Remove plugs from new caliper and fit to old
caliper.
Remove 2. Ensure bleed nipple is clean and fit to new
brake caliper.
1. Raise front of vehicle, one side. 3. Remove plug from brake hose and clean
union.
WARNING: Support on safety stands. 4. Fit NEW sealing washer to brake hose union.
5. Position caliper and connect brake hose.
6. Position brake caliper to front hub.
2. Remove road wheel(s). 7. Fit bolts securing caliper to hub and tighten to
52 Nm.
8. Tighten brake hose union to 15 Nm.
9. Remove clamp from brake hose.
10. Fit brake pads. See this section.
11. Bleed brakes. See Adjustments.
12. Fit road wheel.
3. Clamp brake hose to prevent fluid loss.
CAUTION: A brake hose clamp must be

used.
4. Remove front brake pads. See this section.

5. Loosen union securing brake hose to caliper.
6. Remove 2 bolts securing brake caliper to front
hub.
7. Release brake caliper from front hub.
8. Disconnect brake hose from caliper.
9. Remove brake caliper.
10. Remove bleed nipple.

BRAKES
REAR WHEEL BRAKE CYLINDER HANDBRAKE CABLE - FRONT
Service repair no - 70.60.19 Service repair no - 70.35.14.
Remove Remove
1. Remove rear brake shoes. See this section. 1. Remove drivers front seat. See BODY, Seats
2. Clamp rear brake hose to prevent fluid loss. and seat belts.
CAUTION: A brake hose clamp must be

used.
2. Remove Torx screw securing seat belt stalk to

3. Remove bleed nipple. body and remove stalk.
4. Loosen union and disconnect brake pipe from
wheel cylinder.
5. Remove ’C’ clip securing wheel cylinder to

back plate.
6. Remove wheel cylinder and discard gasket.
Refit
1. Clean mating faces of cylinder and backplate.

2. Remove plugs from new cylinder and fit to old
cylinder.
3. Using a new gasket position wheel cylinder to
back plate and secure with clip.
4. Remove plug from brake pipe and clean brake
pipe union.
5. Connect brake pipe to wheel cylinder and
tighten union to 14 Nm.
6. Ensure bleed nipple is clean and hole is clear.
7. Fit bleed nipple and tighten 9 Nm.
8. Remove brake hose clamp.
9. Fit rear brake shoes. See this section.
10. Bleed brakes. See Adjustments.

BRAKES
6. Loosen locknut, unscrew cable adjusting nut

and release cable from handbrake lever.
7. Remove 2 screws securing cable guide plate to
body, remove guide plate and seal.
8. Remove locknut from cable.
9. Remove intermediate pipe heat shield. See
10. Withdraw cable through floor.
3. Remove seat belt lower mounting bolt and
collect spacer and washers.
4. Release carpet from door seal and clips on
bulkhead.
5. Fold back carpet to access handbrake lever.
11. Remove clip retaining cable to compensator.

12. Disconnect cable from compensator and
remove handbrake cable.

BRAKES
Refit
1. Connect cable to compensator and secure with

clip.
2. Feed cable into vehicle.
3. Fit intermediate pipe heat shield. See
4. Fit locknut to cable.
5. Position cable guide plate and seal, secure
with screws.
6. Connect cable to handbrake lever and fit cable
adjusting nut.
7. Adjust handbrake. See Adjustments.
8. Position carpet and secure to door seal and
clips on bulkhead.
9. Extend seat belt and align to lower mounting.
Fit lower mounting bolt, spacers and washers
10. Position seat belt stalk, spacer and washers, fit
Torx bolt and tighten to 32 Nm.
11. Fit drivers front seat. See BODY, Seats and
seat belts.

RESTRAINT SYSTEMS
CONTENTS Page

COMPONENT LOCATION ....................................................................................... 1
DESCRIPTION ......................................................................................................... 2
OPERATION ............................................................................................................. 3
PRECAUTIONS
PRECAUTIONS ........................................................................................................ 1
WARNING LABELS .................................................................................................. 4
AIRBAG AND PRE-TENSIONER, MANUAL DEPLOYMENT ................................... 6
REPAIRS
DRIVERS AIR BAG MODULE .................................................................................. 1
FRONT SEAT BELT PRE-TENSIONER ................................................................... 2
SRS AND DIAGNOSTIC CONTROL UNIT ............................................................... 3
SUPPLEMENTARY RESTRAINT SYSTEM HARNESS ........................................... 4
RESTRAINT SYSTEMS
COMPONENT LOCATION
NOTE: LHD type is symmetrical to RHD type.
1. Driver’s airbag module * 4. Diagnostic control unit *

2. Seat belt pre-tensioners * 5. Rotary coupler *
3. SRS warning lamp 6. SRS harness (YELLOW) *
* Components to be renewed following system deployment.
NOTE: Following deployment of the Supplementary Restraint System (SRS) within the vehicle, under
any circumstances, all system components including the yellow harnesses MUST be replaced.

RESTRAINT SYSTEMS
DESCRIPTION OPERATION
CAUTION: The diagnostic control unit is a

non-serviceable component and no
attempt should be made to repair or
modify the unit.
The diagnostic control unit (DCU) which is mounted

within the passenger compartment performs two
functions:
1. It continually monitors the airbag system for

faults;
2. It provides a fire signal to the airbag and
pre-tensioners in the event of a crash.
The SRS warning lamp illuminates to inform the

driver of any airbag system faults and during a
system self test.
The diagnostic control unit comprises of the

following circuits which control the airbag system:
1. The crash sensor determines the severity of

any impact and can discriminate between
rough road conditions and an actual crash.
2. The safing sensor is wired in series with the
crash sensor. The fire signal from the crash
sensor therefore, passes through the safing
sensor which confirms a crash is taking place.
3. The regulator circuit maintains stability of the
system in the event of battery voltage drop.
The airbag Supplementary Restraint System (SRS) 4. The back-up power supply provides power to
is a safety device which, when deployed in the event the system in the event of the battery being
of a severe frontal impact, provides additional damaged or disconnected during the impact.
protection to the driver’s face and upper torso. The
airbag is designed to inflate when the vehicle is
exceeding a set speed and receives a frontal impact
within the area shaded.
The pre-tensioner consists of the seat belt buckle

and stalk, a piston and a pyrotechnic device. The
pre-tensioners, fitted to both driver and passenger
seat belt mechanisms are designed to remove any
play in the the lap and diagonal belts in the event of
a severe frontal impact.

RESTRAINT SYSTEMS
Sequence of operation:
Airbag
1. The main sensor and the safing sensor detect
crash conditions.
2. The DCU supplies an electrical pulse to the
airbag igniter and pre-tensioners.
3. Airbag and pre-tensioners deploy.
It takes about 0.1 seconds from the beginning of the

airbag deployment until it is completely deflated.
System check
When triggered, the fire signal from the diagnostic

control unit passes via the airbag harness to the
airbag module. Grains of Nitrocellulose and
Nitroglycerine inside the airbag module, ignite and
combine in a chemical reaction to form a large
amount of Nitrogen gas, leading to inflation of the
airbag in approximately 30 milli-seconds.
As the driver moves forward into the airbag it rapidly

deflates to provide progressive deceleration and
reduce the risk of injuries.
The SRS warning lamp, located on the fascia,
illuminates when the electrical circuits are switched
Seat belt pre-tensioners on whilst the system performs a self diagnosis test. If
the system finds no fault during self diagnosis the
light will extinguish after approximately 5 seconds
and remain extinguished.
In the event of a fault in the system, the warning light

will either:
1. Illuminate continuously;
2. Illuminate for 0.5 second, extinguish, then
illuminate continuously;
3. Fail to illuminate during the self diagnosis test.
Fault diagnosis
Diagnosis is accomplished using TestBook

connected to the vehicle diagnostic connector which
The front seat belt reels are linked by cables to gas is located on a bracket by the foot pedals.
generators housed within remote steel tubes. The
generators are driven by small quantities of
nitrocellulose. On receiving a fire signal from the
DCU, the generators deploy to force pistons down
the steel tubes, pulling the cables tight. The cables
are connected to the seat belt reels which in turn pull
the seat belts tight, reducing any slack in the belts.

RESTRAINT SYSTEMS
PRECAUTIONS
Making the system safe
• Always disconnect the battery and wait 10

minutes to allow the SRS back-up circuit to fully
discharge before commencing work on the
airbag system.
NEVER:
• Drop any component.
• Always disconnect both battery leads, earth lead NOTE: The airbag diagnostic control unit
first before commencing work. is a shock sensitive device and must be
handled with extreme care.
Care Points • Wrap arms around an airbag module.

• Attach anything to the airbag cover.
ALWAYS: • Attempt to repair any component.
• Apply electrical power to a component except as
• Carefully inspect any SRS part before part of an approved test procedure.
installation. • Transport airbag modules in the passenger
• Use a digital circuit tester to check the system. compartment of a car.
• Install any SRS component that shows signs of
WARNING: Using an analogue circuit being dropped or improperly handled, such as
tester may cause an accidental dents, cracks or deformation.
deployment and possible injury. • Install used SRS parts from another car. When
repairing an SRS, use only genuine new parts.
• Check SRS harness is correctly routed.
• Check SRS connectors are mated correctly after
completion of work.
PRECAUTIONS 1
RESTRAINT SYSTEMS
Handling and Storage CAUTION: Improper handling or storage

can internally damage the airbag
• Do not try to disassemble the airbag assembly or assembly, making it inoperative. If you
pretensioner. They have no serviceable parts. suspect the airbag assembly has been damaged,
Once an airbag or pre-tensioner has been install a new unit and refer to the
deployed, it cannot be repaired or reused. Deployment/Disposal Procedures for disposing
• Do not carry a seat belt pre-tensioner assembly of the damaged airbag.
by the electrical lead, or allow the reel or tube to
hang on the flexible link. Overnight storage
• Be careful that the airbag assembly receives no
strong shocks; it could deploy. Airbag modules are classed as explosive articles
• Special bolts are necessary for installing the and as such must be stored in an approved secure
airbag assembly. Do not use other bolts. steel cabinet which has been registered by the local
authority.
Airbag storage
Seat belt pre-tensioner storage
For temporary storage of the seat belt pre-tensioner

during service, observe the following precautions:
• Place the pre-tensioner in designated storage
area.
• Store the removed pre-tensioner on a secure, flat
surface away from heat, oil, grease, detergent or
water.
CAUTION: Improper handling or storage

can damage the pre-tensioner assembly. If
damage is suspected, install a new
assembly.
Overnight storage
For temporary storage of the airbag assembly during The seat belt pre-tensioners are classed as
service, observe the following precautions: explosive articles and as such must be stored in an
approved secure steel cabinet which has been
• Always keep components dry. registered by the local authority.
• Always carry the airbag module with the pad
surface face up.
• Store the removed airbag assembly with the pad
surface face up.
• Do not allow anything to rest on the airbag
module.
• Place the airbag module in a designated storage
area.
WARNING: If the airbag is improperly

stored face down, accidental deployment
could propel the unit with enough force to
cause serious injury.
• Store the removed airbag assembly on a secure

flat surface away from any electrical equipment
or high heat source (exceeding 85°C/185°F) and
free of any oil, grease, detergent or water.
2 PRECAUTIONS
RESTRAINT SYSTEMS
Wiring and connectors
• Ensure all airbag harness connectors are mated

correctly and securely fastened. Do not leave the
connectors hanging loose.
• Never attempt to modify, splice or repair SRS

wiring. Never install electronic equipment such
as; a mobile telephone, two way radio or in-car
entertainment system in such a way that it
interferes electrically with the airbag harness.
NOTE: SRS wiring can be identified by

special yellow outer protective covering.
• Always ensure SRS harnesses are routed

correctly. Be careful to avoid trapping or pinching
the SRS harness. Look out for possible points of
chafing.
• Always use specified earth fixings tightened to
the correct torque. Poor earthing can cause
intermittent problems that are difficult to
diagnose.
PRECAUTIONS 3
RESTRAINT SYSTEMS
WARNING LABELS 1. Front windscreen
Refer to the Owner’s Handbook for information

on the airbag system.
A combination of symbols/icons is displayed (either

in a suitable, prominent position or is attached to the
component itself) to indicate:
(a) The need for caution when working in close

proximity to SRS components.
(b) The publication where suitable reference and

advice can be found (usually Workshop Manual or
Owner’s Handbook). 2. Rotary coupler
NOTE: It is imperative that before any A - Refer to the Workshop Manual for detailed
work is undertaken on the SRS system, instructions.
the appropriate publication is read B - Ensure wheels are in the straight ahead
thoroughly. position before removal and refitting.
C - ROVER Part Number/Bar code - The code
The following list indicates current locations for must be recorded and quoted for ordering
warning labels. Exact positions may vary dependent purposes.
on legislation and market trends.
4 PRECAUTIONS
RESTRAINT SYSTEMS
3. Airbag module 5. Diagnostic control unit.
A - ROVER Part Number/Bar code - If the A - Refer to the Workshop Manual for
airbag module is to be replaced, the code must information on the airbag system.
be recorded and quoted for ordering purposes. B - ROVER Part Number/Bar Code - If the
airbag diagnostic control unit is to be replaced,
the code must be recorded and quoted for
ordering purposes.
4. Seat belt pre-tensioner
A - Refer to the Workshop Manual for detailed

instructions. DO NOT attempt to disassemble.
PRECAUTIONS 5
RESTRAINT SYSTEMS
AIRBAG AND PRE-TENSIONER, MANUAL Deployment of pre-tensioner fitted to vehicle

DEPLOYMENT
These guidelines are written to aid authorised
If a vehicle is to be scrapped and contains an personnel to carry out the safe disposal of the
undeployed airbag module, or pre-tensioner, the pre-tensioner.
components must be manually deployed. This
operation should only be carried out using the WARNING:
following recommended manual deployment
procedure.
• Only use the Rover approved deployment
Before deployment is started the deployment tool equipment.
self test procedure should be carried out. • Deploy pre-tensioner in a designated area.
• Ensure pre-tensioner is not damaged or
Deployment tool SMD 4082/1 self test procedure ruptured before deploying.
• Notify relevant authorities.
1. Carry out deployment tool self test.

2. Remove 3 screws securing rear cubby hole
cover to body and remove cover.
3. Disconnect pre-tensioner harness connector.
WARNING: Ensure deployment tool SMD

4082/1 is not connected to battery.
1. Insert blue and yellow connectors of tool lead

into corresponding sockets on face of tool.
2. Connect crocodile clips of second tool lead to
battery, red to positive and black to negative.
3. Red "READY" light should illuminate.
4. Press and hold both operating buttons.
5. Green "DEFECTIVE" light should illuminate.
6. Release both operating buttons.
7. Red "READY" light should illuminate.
8. Disconnect tool from battery.
9. Disconnect blue and yellow connectors from
tool face sockets.
10. Self test now complete.
6 PRECAUTIONS
RESTRAINT SYSTEMS
7. Press both operating buttons to deploy

pre-tensioner.
8. DO NOT return to the vehicle for 5 minutes.
9. Using gloves, remove pre-tensioner from body,
place pre-tensioner in plastic bag, and seal
bag.
10. Transport deployed pre-tensioner to
designated area for incineration.
NOTE: DO NOT transport pre-tensioner in

the vehicle passenger compartment.
4. Connect flylead SMD 4082/5 to pre-tensioner

connector.
5. Connect flylead SMD 4082/5 to tool SMD
4082/1.
6. Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are

standing at least 15 metres away from
vehicle.
PRECAUTIONS 7
RESTRAINT SYSTEMS
Deployment of pre-tensioner removed from

vehicle

personnel to carry out the safe disposal of the
pre-tensioner.
WARNING:

equipment.
• Deploy pre-tensioner in a designated area.
• Ensure pre-tensioner is not damaged or
ruptured before deploying.
1. Carry out deployment tool self test.

2. Remove seat belt pre-tensioner from vehicle.
See Repairs.
3. Remove reel from gas generator by cutting

flexible link approximately 10 mm from end of
gas generator tube.
8 PRECAUTIONS
RESTRAINT SYSTEMS
8. Press both operating buttons to deploy

pre-tensioner.
9. DO NOT return to the vehicle for 5 minutes.
WARNING: If a suspected ’live’ unit fails to

deploy using the above procedure, store
the unit in accordance to the Storage
Procedures outlined in this section and inform
Rover Group.
10. Using gloves, remove pre-tensioner from vice,

place pre-tensioner in plastic bag, and seal
bag.
11. Transport deployed pre-tensioner to
designated area for incineration.
4. Position gas generator tube vertically in vice
with fly lead at bottom and tube bracket NOTE: DO NOT transport pre-tensioner in
positioned on vice side to prevent tube being the vehicle passenger compartment.
forced out of vice. Tighten vice to hold tube
rigid and secure. DO NOT OVERTIGHTEN. 12. Scrap all remaining parts of pre-tensioner
assembly. DO NOT re-use or salvage any
WARNING: Ensure deployment tool SMD parts of the pre-tensioner assembly.
5. Connect flylead SMD 4082/5 to pre-tensioner

connector.
4082/1.
WARNING: Do not lean over gas generator

tube whilst connecting.
7. Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are

standing at least 15 metres away from
vehicle.
PRECAUTIONS 9
RESTRAINT SYSTEMS
Deployment of airbag module

personnel to carry out the safe disposal of airbag
modules when removed from the vehicle.
WARNING:

equipment.
• Deploy airbag modules in a well ventilated
designated area.
• Ensure airbag module is not damaged or
ruptured before deploying.
1. Carry out deployment tool self test. 4. Secure airbag module to tool SMD 4082/2.
2. Remove airbag module from steering wheel. Ensure module is correctly secured using both
See Repairs. fixings.
5. Ensure airbag module mounting brackets are
secure.
WARNING: Ensure deployment tool SMD

3. Position tool SMD 4082/2 in vice, ensuring that

vice jaws grip tool above bottom flange to
prevent possibility of tool being forced upwards
from vice. Tighten vice.
10 PRECAUTIONS
RESTRAINT SYSTEMS
9. Press both operating buttons to deploy airbag

module.
10. DO NOT return to airbag module for 30
minutes.
6. Connect flylead SMD 4082/4 to airbag module.

4082/1.
WARNING: Do not lean over airbag

module whilst connecting.
11. Using gloves and face mask, remove airbag
8. Connect tool SMD 4082/1 to battery. module from tool, place airbag module in
plastic bag, and seal bag.
WARNING: Ensure all personnel are 12. Wipe down tool with damp cloth.
standing at least 15 metres away from 13. Transport deployed airbag module to
module. designated area for incineration.
NOTE: DO NOT transport airbag module in

the vehicle passenger compartment.
14. Scrap all remaining parts of airbag system. DO

NOT re-use or salvage any parts of the airbag
system.
PRECAUTIONS 11
RESTRAINT SYSTEMS
DRIVERS AIRBAG MODULE Refit
Service repair no - 76.73.71 1. Position air bag module and make connection
with harness upwards as shown in illustration.
CAUTION: See safety precautions before 2. Fit air bag to steering wheel and hand start the
commencement of repair. 2 Torx screws. Tighten screws to 7 Nm.
3. Connect battery leads, earth lead last.
Remove 4. Carry out system check by turning the ignition
1. Remove key from starter switch, disconnect illuminates then extinguishes after 3 seconds.
both battery leads, earth lead first, and wait 10
minutes for the SRS back-up power circuit to
discharge before commencing work.
2. Remove 2 Torx bolts securing the air bag

module to steering wheel.
3. Release air bag module from steering wheel.
CAUTION: Do not allow the air bag module

to hang by the air bag harness.
4. Disconnect harness connector from air bag

module.
5. Remove air bag module.
CAUTION: Store the air bag module in

accordance with the storage procedures
outlined in the precautions part of this
section.
NOTE: If the air bag module is to be

replaced, the bar code must be recorded.
REPAIRS 1
RESTRAINT SYSTEMS
FRONT SEAT BELT PRE-TENSIONER
WARNING: SRS safety procedures must be followed and ALL precautions observed. See
Precautions.
Replace pre-tensioner every 15 years.
Remove
1. Remove key from starter switch. 5. Remove nut and bolt securing pre-tensioner to
2. Disconnect both battery leads, earth lead first, body.
and wait 10 minutes for the SRS back-up 6. Remove cover from seat belt upper securing
power circuit to discharge before commencing bolt.
work. 7. Remove 3 bolts securing seat belt to body,
3. Remove rear quarter companion box. See collect spacers and washers.
BODY, Interior trim components. 8. Remove seat belt and pre-tensioner assembly.
4. Release multiplug from body and disconnect
pre-tensioner harness multiplug.
2 REPAIRS
RESTRAINT SYSTEMS
SRS AND DIAGNOSTIC CONTROL UNIT
Remove
CAUTION: See safety precautions before

commencement of repair.
1. Remove key from starter switch, disconnect

discharge before starting work.
2. Slide drivers seat forward and fold down
squab.
9. Remove Torx screw securing seat belt stalk 3. Release carpet from under rear seat for access
and remove stalk. to SRS control unit.
Refit
1. Position seat belt stalk, spacer and washers, fit

Torx bolt and tighten to 32 Nm.
2. Position seat belt and pre-tensioner assembly
to body, fit and tighten bolt to 30 Nm.
3. Extend seat belt and align to upper mounting.
Fit upper mounting bolt, spacer and washers
4. Fit cover to upper seat belt securing bolt.
5. Extend seat belt and align to lower mounting.
Fit lower mounting bolt, spacer and washers
6. Fit nut and screw securing pre-tensioner to
body. Tighten nut to 6 Nm and screw to 1.5
Nm.
7. Connect multiplug to pre-tensioner harness
and secure to bracket on body.
4. Disconnect multiplug from control unit.
8. Fit rear quarter companion box. See BODY,
5. Remove and discard 3 Torx screws securing
Interior trim components.
control unit to floor.
9. Connect both battery leads, earth lead last.
6. Remove control unit.
10. Carry out system check by turning ignition on
and check that the SRS warning light
Refit
CAUTION: Ensure unit and bracket faces
are clean and free from burrs. An
incorrectly mounted unit could cause the
system to malfunction.
1. Position control unit, fit NEW Torx screws and

tighten to 9 Nm.
2. Connect harness multiplug to control unit.
3. Position floor carpet.
4. Reposition drivers seat.
illuminates the extinguishes after 3 seconds.

RESTRAINT SYSTEMS
SUPPLEMENTARY RESTRAINT SYSTEM

HARNESS
CAUTION:
• Do not install used SRS parts from another car. When repairing an SRS, use only genuine new ROVER parts.
• Never attempt to modify, splice, or repair SRS wiring.
NOTE: SRS wiring can be identified by its yellow or black with yellow stripe outer protective covering.
4 REPAIRS
RESTRAINT SYSTEMS
Remove Refit
1. Remove key from starter switch, disconnect 1. Fit NEW clips to harness.
both battery leads, earth lead first, and wait 10 2. Fit harness to vehicle.
minutes for the SRS back-up circuit to
discharge before commencing work. CAUTION: Always ensure SRS harness is
2. Remove fascia. See BODY, Interior trim routed correctly. Avoid trapping or
components. pinching the SRS harness. Look out for
3. Remove carpet. See BODY, Interior trim possible points of chafing.
components.
4. Remove steering column nacelle. See 3. Route the harness to position and secure with
STEERING, Repairs. cable ties.
5. Remove quarter panel companion boxes. See 4. Connect harness to rotary coupler and secure
BODY, Interior trim components. to steering column with cable ties.
6. Release and disconnect multiplugs from seat 5. Connect harness multiplug to fuse box.
belt pre-tensioners. 6. Secure SRS harness clips to bulkhead.
7. Release pre-tensioner leads from companion 7. Secure SRS harness clips to rear seat pan.
box panels. 8. Connect harness multiplug to SRS control unit.
8. Disconnect multiplug from SRS control unit. 9. Fit bolt securing harness earth lead to body
9. Raise rear seat cushion and release 6 harness and tighten to 10 Nm.
clips. 10. Fit harness leads through companion box
10. Remove bolt securing SRS harness earth lead panels, secure grommets and connect seat
to body. belt pre-tensioner multiplugs.
11. Release 2 clips securing SRS harness to 11. Position rear seat cushion.
bulkhead.
12. Release and disconnect multiplug from fuse CAUTION: Ensure all SRS harness
box feed. connectors are mated correctly and
13. Disconnect multiplug from rotary coupler. securely fastened. Do not leave the
14. Remove 2 cable ties securing SRS harness to connectors hanging loose.
steering column.
15. Remove 2 clips securing SRS harness to body. 12. Fit rear quarter companion boxes. See BODY,
16. Remove 5 cable ties securing SRS harness to Interior trim components.
bulkhead and remove SRS harness. 13. Fit steering column nacelle. See STEERING,
17. Remove clips from harness. Repairs.
14. Fit carpet. See BODY, Interior trim
components.
15. Fit fascia. See BODY, Interior trim
components.

BODY
CONTENTS Page
EXTERIOR FITTINGS
BONNET ................................................................................................................... 1
BONNET ALIGNMENT ............................................................................................. 2
BONNET RELEASE CABLE ..................................................................................... 3
DOOR STRIKER - ADJUST ..................................................................................... 4
FRONT GRILLE ........................................................................................................ 5
FRONT BUMPER ..................................................................................................... 5
REAR BUMPER ........................................................................................................ 6
FRONT WHEEL ARCH EXTENSION ....................................................................... 6
REAR WHEEL ARCH EXTENSION ......................................................................... 7
INTERIOR TRIM COMPONENTS

REAR QUARTER WOODEN FINISHER .................................................................. 1
REAR QUARTER TRIM PAD ................................................................................... 1
REAR QUARTER COMPANION BOX ...................................................................... 2
DOOR WOODEN FINISHER .................................................................................... 2
DOOR TRIM CASING ............................................................................................... 3
FASCIA TOP RAIL .................................................................................................... 4
FASCIA PANEL ........................................................................................................ 5
CARPET ................................................................................................................... 6
GLOVE BOX ............................................................................................................. 7
SCREENS
WINDSCREEN ......................................................................................................... 1
SEATS AND SEAT BELTS

FRONT SEAT BELT ................................................................................................. 1
FRONT SEAT ........................................................................................................... 1
REAR SEAT BELT .................................................................................................... 2
REAR SEAT SQUAB ................................................................................................ 3
REAR SEAT CUSHION ............................................................................................ 3
BODY
BONNET Refit
Service repair no - 76.16.01.99 1. Using assistance, position bonnet on hinges.

2. Fit nuts and washers securing bonnet to
Remove hinges.
3. Align bonnet to hinge outlines.
1. Support the bonnet in the fully open position. 4. Tighten nuts securing hinges to body to 10 Nm.
2. Fit protective covers to wings. 5. Remove protective covers.
6. Lower and close bonnet.
7. Adjust bonnet alignment. See this section.
3. Mark outlines of hinges on bonnet.

4. Remove nuts and washers securing hinges to
bonnet.
5. Release bonnet stay from body and secure to
bonnet.
6. Remove bonnet.
REVISED: 12/96 EXTERIOR FITTINGS 1

BODY
BONNET ALIGNMENT
Adjust
1. Check alignment of bonnet against both wings.
2. Open bonnet and mark outline of hinges.

3. Loosen 4 nuts and adjust position of bonnet.
4. Lightly tighten nuts securing hinges to body.
5. Close bonnet and check alignment against
both wings.
6. Open bonnet and re-adjust bonnet position if
necessary.
7. Tighten nuts securing hinges to body to 10 Nm.
8. Close bonnet and check alignment against
both wings.
9. Open bonnet and repaint bare areas on
hinges.
2 EXTERIOR FITTINGS
BODY
BONNET RELEASE CABLE
Remove
4. Disconnect bonnet lock return spring from

body.
5. Remove 2 bolts securing bonnet catch to
bonnet locking platform.
6. Release bonnet catch to gain access to bonnet
release cable.
7. Disconnect cable from bonnet catch.
1. Loosen lock nut securing bonnet release
handle to mounting bracket.
2. Release handle from mounting bracket.
8. Withdraw bonnet release cable through

bulkhead into passenger compartment.
9. Remove bonnet release cable
3. Release clip securing cable to body.
REVISED: 12/96 EXTERIOR FITTINGS 3

BODY
Refit DOOR STRIKER - ADJUST
1. Feed bonnet release cable through grommet in Service repair no - 76.28.05

bulkhead into engine compartment.
2. Secure cable to clip on body. Adjust
3. Connect cable to bonnet release catch.
4. Position bonnet release catch to bonnet locking
platform, fit bolts but do not tighten.
5. Connect bonnet lock return spring to body.
6. Locate bonnet release handle on mounting
bracket and tighten nut.
7. Lower bonnet and adjust position of bonnet
catch to meet the bonnet lock pin.
8. Open bonnet and tighten bolts securing bonnet
catch to bonnet locking platform to 9 Nm.
1. Loosen 2 screws securing striker to body and

close door.
2. Check door for flush fit to adjacent panels and
edges for equal gap.
3. Open door and tighten striker screws to 18 Nm.
4 EXTERIOR FITTINGS REVISED: 12/96

BODY
FRONT GRILLE FRONT BUMPER
Remove Remove
1. Remove 3 nuts securing front bumper to body

and collect washers.
2. Remove front bumper.
1. If fitted, lower the driving lamps for access to Refit

grille.
2. Remove 8 screws securing front grille 1. Fit front bumper to body.
assembly to body. 2. Fit nuts and washers securing bumper to body
3. Remove grille. and tighten nuts.

4. Remove 2 screws securing side finishers to
grille.
5. Remove side finishers.
Refit
1. Fit side finishers to grille and secure with

screws.
2. Fit grille and secure with screws.
3. Reposition driving lamps if fitted.
ISSUED: 12/96 EXTERIOR FITTINGS 5

BODY
REAR BUMPER FRONT WHEEL ARCH EXTENSION
Remove Remove
1. Remove front bumper. See this section.

2. Raise front of vehicle, one side.
1. Remove 3 nuts securing rear bumper to body

and collect washers.
2. Remove rear bumper.
3. Using a 5mm drill, drill out rivet securing wheel
arch extension to sill panel.
Refit
4. Remove 5 nuts securing wheel arch extension
to wing.
1. Fit rear bumper to body.
5. Remove wheel arch extension.
2. Fit nuts and washers securing bumper to body
and tighten nuts.
Refit
1. Clean mating faces of wheel arch extension

and wing.
2. Fit wheel arch extension to wing ensuring
sealing rubber is correctly seated.
3. Fit nuts securing wheel arch extension to body
4. Rivet wheel arch extension to sill panel.
5. Fit front bumper. See this section.
6 EXTERIOR FITTINGS ISSUED: 12/96

BODY
REAR WHEEL ARCH EXTENSION
Remove
RH side only
1. Release washer reservoir from mounting

bracket in boot.
LH side only

3. Drain fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
7. Remove fuel filler cap.
Both sides
11. Remove rear quarter trim pad. See Interior

trim components.
5. Remove studs securing fuel tank side cover

and remove cover.
ISSUED: 12/96 EXTERIOR FITTINGS 7

BODY
Refit
1. Clean mating faces of wheel arch extension

and body.
2. Fit wheel arch extension to body ensuring
sealing rubber is correctly seated.
3. Fit nuts securing wheel arch extension to body
4. Rivet wheel arch extension to sill panel.
5. Fit rear quarter trim pad. See Interior trim
components.
LH side only
6. Manoeuvre fuel tank into position and position

restraining strap.
9. Fit fuel tank side cover and secure with studs.
10. Fit spare wheel.
11. Refill fuel tank with fuel.
RH side only
13. Secure washer reservoir to mounting bracket.
12. Using a 5mm drill, drill out rivet securing wheel

arch extension to sill panel.
13. Remove 5 nuts securing wheel arch extension
to body.
14. Remove wheel arch extension.
8 EXTERIOR FITTINGS ISSUED: 12/96

BODY
REAR QUARTER WOODEN FINISHER REAR QUARTER TRIM PAD
Remove Remove
1. Remove rear quarter companion box. See this

section.
2. Remove rear quarter wooden finisher. See this
section.
1. Remove 2 screws securing rear quarter

wooden finisher to body.
2. Remove rear quarter finisher.
Refit 3. Release rear quarter trim pad from body.

4. Remove rear quarter trim pad.
1. Position rear quarter finisher and secure with
screws. Refit
1. Fit rear quarter trim pad.

2. Fit rear quarter wooden finisher. See this
section.
3. Fit rear quarter companion box. See this
section.
REVISED: 12/96 INTERIOR TRIM COMPONENTS 1

BODY
REAR QUARTER COMPANION BOX DOOR WOODEN FINISHER
Remove Remove
1. Remove 3 screws securing wooden finisher to

front door.
2. Remove door finisher.
1. Release 2 seat belt guides from companion
box. Refit
2. Remove 2 rivets securing companion box to
body. 1. Position finisher to front door and secure with
3. Raise companion box and release seat belts screws.
through slots.
4. Remove companion box.
Refit
1. Position rear quarter companion box and

locate seat belts.
2. Position companion box and secure with rivets.
3. Secure seat belt guides to companion box.
2 INTERIOR TRIM COMPONENTS REVISED: 12/96

BODY
DOOR TRIM CASING
Remove
1. Remove wooden finisher from door. See this 9. Remove screw securing door interior release
section. handle.
2. Remove cover from door glass regulator 10. Remove door interior release handle.
handle. 11. Remove 5 screws securing door pocket to
3. Remove screw securing handle to door glass door.
regulator. 12. Remove door pocket from door.
4. Remove door glass regulator handle and 13. Carefully release 9 studs securing trim casing
bezel. to door.
5. Release screw covers from door pull. 14. Remove door trim casing.
6. Remove 2 screws securing door pull to door.
7. Remove door pull.
8. Remove interior door lock escutcheon from
trim casing.
ISSUED: 12/96 INTERIOR TRIM COMPONENTS 3

BODY
Refit FASCIA TOP RAIL
1. Fit new studs as necessary to trim casing and Service repair no - 76.46.04
ensure all studs are slotted fully into position.
2. Position trim casing to door, align studs and Remove
press to engage on door.
3. Position door pocket to door and secure with 1. Remove windscreen. See Screens.
screws. 2. Remove fascia panel. See this section.
4. Fit door interior release handle and secure with
screw.
5. Fit interior door lock escutcheon an secure to
trim casing.
6. Position door pull and secure with screws.
7. Fit screw covers to door pull.
8. Fit handle and bezel to door glass regulator
and tighten screw.
9. Fit screw cover to door glass regulator handle.
10. Fit wooden finisher to door. See this section.
3. Remove 3 nuts securing fascia rail to body and

release rail.
4. Remove fascia rail.
5. Remove demister ducts from fascia rail.
Refit
1. Fit demister ducts to fascia rail.

2. Position fascia rail to body, fit nuts and tighten
to 9 Nm.
3. Fit fascia panel. See this section.
4. Fit windscreen. See Screens.
4 INTERIOR TRIM COMPONENTS ISSUED: 12/96

BODY
FASCIA PANEL
Service repair no - 76.46.23.99
Remove

2. Remove radio. See ELECTRICAL, Repairs.
7. Disconnect speedometer cable.

8. Disconnect multiplugs from headlamp levelling
switch, alarm warning light, main harness and
instrument pack.
9. Disconnect leads from tachometer.
10. Release and remove fascia panel.
Refit
1. Position fascia panel.

2. Connect leads to tachometer.
3. Connect multiplugs to headlamp levelling
switch, alarm warning light, main harness and
3. Remove locking rings from fascia air vents.
instrument pack.
Release and remove air vents.
4. Connect speedometer cable.
4. Remove air vent tubes.
5. Position fascia panel and tighten bracket nuts.
6. Fit air vent tubes.
7. Fit air vents and secure with locking rings.
8. Fit radio. See ELECTRICAL, Repairs.
5. Remove 3 nuts securing fascia panel retaining

brackets to body.
6. Release retaining brackets and carefully pull
fascia forward for access.

BODY
CARPET
Remove
1. Remove both front seats. See Seats and seat Refit

belts.
2. Remove 2 bolts securing front seat belt stalks 1. Position carpet in vehicle and fit around pedals,
to body. gear lever and handbrake lever.
3. Remove front seat belt stalks, collect washers. 2. Secure carpet to bulkhead with retaining clips.
4. Remove bolts securing front seat belt lower 3. Secure carpet under door seals.
anchorage points to body, collect washers. 4. Align front seat belt lower anchorage points to
5. Release carpet from door seals, and bulkhead body, position washers, position washers, fit
retainers. bolts and tighten to 30 Nm.
6. Ease carpet from around foot pedals, gear 5. Position front seat belt stalks to body, fit bolts
lever and handbrake lever and remove carpet. and tighten to 30 Nm.
6. Fit front seats. See Seats and seat belts.
6 INTERIOR TRIM COMPONENTS ISSUED: 12/96

BODY
GLOVE BOX
Remove
1. Remove fascia panel. See this section.
2. Release glove box lid support stud from glove

box.
3. Remove 11 screws and remove glove box.
Refit
1. Fit glove box and tighten screws.

2. Align glove box lid support and secure
retaining stud.
3. Fit fascia panel. See this section.

BODY
WINDSCREEN
Remove
1. Fit protective covers to bonnet and wings.

2. Remove both windscreen wiper arms. See
WIPERS & WASHERS, Repairs.
3. Remove the chrome finisher plate from the

windscreen sealing rubber.
4. Use a small screwdriver to extract one end of 6. Remove windscreen and sealing rubber.
the finisher strip and withdraw it from the
sealing rubber. Inspection
5. With an assistant supporting the glass from the
outside, commencing at the top corner, press 7. Remove any glass particles from sealing
the windscreen outwards from the sealing rubber channels and examine sealing rubber
rubber. for cuts and other damage.
8. Check body aperture for distortion or damage
to flange.
9. If windscreen has broken, ensure that all
particles of glass have been removed from
demister ducts, tubes and apertures.
Refit
1. Align windscreen sealing rubber to aperture

and secure to body flange.
2. Insert a cord into the windscreen groove of the
sealing rubber.
3. Position windscreen to sealing rubber.
4. Apply pressure to outside of screen and use
cord to pull lip of seal over the edge of the
screen.
NOTE: Apply a soap solution around seal

to aid fitment of screen.
SCREENS 1
BODY
5. Thread end of the finisher strip through the eye

of tool 18G 468B and under the roller.
6. Starting at the top centre of the windscreen
sealing rubber, insert eye of tool into finisher
strip groove.
7. Slowly push tool around entire length of sealing
rubber, feeding the finisher strip into the groove
as the eyelet on the tool opens it and use the
roller to bed it into the seal.
8. Remove tool 18G 468B and fit chrome finisher
plate into sealing rubber to cover the ends of
the finisher strip.
9. Clean windscreen.
10. Fit windscreen wiper arms. See WIPERS &
WASHERS, Repairs.
11. Remove protective covers from bonnet and
wings.
2 SCREENS
BODY
FRONT SEAT BELT FRONT SEAT
Remove Remove
The front seat belt and pre-tensioner can only be

renewed as an assembly, refer to Front seat belt
pre-tensioner. See RESTRAINT SYSTEMS,
Repairs.
1. Raise lever and slide seat fully rearwards.

2. Remove 2 nuts and bolts securing seat to
mounting brackets.
3. Pull rear seat access lever to release seat from
floor and remove seat.
Refit
1. Position seat in vehicle.

2. Align seat to mounting brackets.
3. Fit nuts and bolts securing seat to mounting
brackets and tighten to 25 Nm.
ISSUED: 12/96 SEATS AND SEAT BELTS 1

BODY
REAR SEAT BELT
Remove
1. Remove rear quarter companion box. See Refit

Interior trim components.
2. Release rear seat cushion from seat panel. 1. Position rear seat buckle to body, fit bolt and
3. Remove cover from seat belt upper anchorage washer and tighten to 30 Nm.
bolt. 2. Position seat belt reel to body, fit bolt and
4. Remove bolt securing seat belt upper tighten to 30 Nm.
anchorage point to body, collect spacer and 3. Align seat belt lower anchorage point to body,
washers. position spacer and washers, fit bolt and
5. Remove bolt securing seat belt lower tighten to 30 Nm.
anchorage point to body, collect spacer and 4. Align seat belt upper anchorage point to body,
washers. position spacer and washers, fit bolt and
6. Remove bolt securing seat belt reel to body. tighten to 30 Nm.
7. Remove rear seat belt reel. 5. Fit cover to seat belt upper anchorage point.
8. Remove bolt and collect washer securing rear 6. Position rear seat cushion.
seat belt buckle to body. 7. Fit rear quarter companion box. See Interior
9. Remove rear seat belt buckle. trim components.
2 SEATS AND SEAT BELTS ISSUED: 12/96

BODY
REAR SEAT SQUAB REAR SEAT CUSHION
Service repair no - 78.10.56.99 Service repair no - 78.40.29
Remove Remove
1. Remove rear seat cushion. See this section.

2. Open luggage compartment.
1. Release rear seat cushion from seat panel.

2. Remove 2 screws securing cushion straps to
body.
3. Remove rear seat cushion.
Refit
1. Position rear seat cushion in vehicle.

2. Align cushion straps to body and secure with
screws.
3. Remove 2 screws securing seat squab to 3. Position seat cushion on seat panel.
body.
4. Pull seat belt harnesses away from squab.
5. Release and remove rear seat squab.
Refit
1. Position rear seat squab in vehicle.

2. Ensure seat belts are routed over squab.
3. Fit and tighten screws securing squab to body.
4. Fit rear seat cushion. See this section.
ISSUED: 12/96 SEATS AND SEAT BELTS 3

CONTENTS Page
REPAIRS
HEATER VALVE CONTROL CABLE ....................................................................... 1
HEATER VALVE ....................................................................................................... 2
HEATER FAN SWITCH ............................................................................................ 4
HEATER UNIT .......................................................................................................... 4
HEATER MOTOR AND FAN .................................................................................... 6
RESISTOR UNIT ...................................................................................................... 7
HEATER MATRIX ..................................................................................................... 8
HEATER VALVE CONTROL CABLE
Remove
4. Remove clip securing control cable to heater

valve.
5. Disconnect control cable from lever on valve.
2. Remove 2 screws securing heater to lower
fascia rail.
6. Remove 2 nuts securing switch panel to lower

fascia rail.
3. Remove nut securing heater valve to fascia 7. Release switch panel from fascia rail.
rail. 8. Remove nut securing control cable to switch
panel.
NOTE: An earth lead is located on the 9. Remove heater control cable.
heater valve stud.

Refit HEATER VALVE
1. Fit heater control cable to switch panel and Service repair no - 80.10.16
secure with nut.
2. Feed the cable over the top of the heater. Remove
3. Ensure cable is routed correctly and heater
valve is in the OFF position. 1. Drain cooling system. See COOLING
4. Connect control cable to lever on heater valve SYSTEM, Adjustments.
and secure with clip. 2. Position container beneath heater to collect
5. Check that heater valve control lever operates coolant spillage.
through its full range of travel, adjust position of
outer cable if necessary.
6. Fit switch panel to fascia rail and secure with
nuts.
7. Align heater to fascia rail and secure with
screws.
8. Fit heater valve to fascia support rail, fit earth
lead to heater valve stud and tighten nut.
3. Disconnect demister duct from heater.

4. Release clip securing feed hose to heater.
5. Disconnect hose from heater.
6. Ensure heater valve is in the open position and
allow coolant to drain.
7. Remove nut securing heater valve to fascia
rail.
NOTE: An earth lead is located on the

heater valve stud.

8. Lower heater valve to gain access to heater

hose.
9. Release clip and disconnect heater hose from
valve.
10. Remove clip securing heater control cable to

valve.
11. Disconnect control cable from lever on valve.
12. Remove heater valve. 13. Release clip and remove hose from heater
valve.
Refit
1. Fit heater hose to valve and secure with clip.

2. Position heater valve to fascia support rail.
3. Connect hose to heater valve and secure with
clip.
4. Connect heater control cable to lever on valve
and secure with clip.
5. Fit heater valve to fascia support rail, fit earth
lead to heater valve stud and tighten nut.
6. Connect hose to heater and secure with clip.
7. Connect demister duct to heater.
8. Remove container to collect coolant spillage
from heater.
9. Refill cooling system. See COOLING

HEATER FAN SWITCH HEATER UNIT
Remove Remove
1. Drain cooling system. See COOLING

1. Release switch from heater panel.

2. Disconnect 2 Lucars from switch.
3. Remove switch.
Refit
1. Position switch and connect Lucars.

2. Fit switch to heater panel.
2. Release heater air intake duct from adaptor on

body.
3. Remove air intake duct from heater.

4. Disconnect both demister ducts from heater.

5. Position container to collect coolant spillage
from heater.
8. Loosen nut securing heater to bulkhead.
6. Release clips and disconnect coolant hoses

from heater.
7. Allow coolant to drain then plug the heater
connections.

rail.
10. Lower heater.

HEATER MOTOR AND FAN
Remove
1. Remove heater unit. See this section.
11. Disconnect multiplug from heater harness.

12. Release heater from bulkhead and remove
heater.
Refit 2. Disconnect 2 Lucars from heater motor.

3. Remove 3 screws securing heater motor to
1. Position heater in vehicle and locate on housing.
mounting brackets on bulkhead. 4. Withdraw heater motor and fan from housing
2. Connect multiplug to heater harness. and remove.
3. Align heater to fascia rail and secure with
screws. NOTE: The heater motor and fan can only
4. Tighten nut securing heater to bulkhead. be renewed as an assembly.
5. Remove plugs from heater connections.
6. Connect coolant hoses to heater and secure Refit
with clips.
7. Fit air intake duct to heater. 1. Fit heater motor and fan to housing and secure
8. Connect heater air intake duct to adaptor on with screws.
body. 2. Connect Lucars to heater motor.
9. Connect demister ducts to heater. 3. Fit heater unit. See this section.
10. Refill cooling system. See COOLING
11. Remove container positioned to collect coolant
spillage

RESISTOR UNIT
Remove
3. Disconnect both demister ducts from heater.

rail.
1. Release heater air intake duct from adaptor on

body.
2. Remove air intake duct from heater.
5. Loosen nut securing heater to bulkhead.
6. Lower heater.

HEATER MATRIX
Remove
1. Remove heater unit. See this section.
7. Disconnect multiplug from resistor unit.

8. Remove 2 nuts securing resistor unit to heater.
9. Remove resistor unit.
Refit 2. Remove 2 screws securing heater matrix

end-plate to housing.
1. Fit resistor unit to heater and secure with nuts. 3. Withdraw heater matrix from housing.
2. Connect multiplug to resistor unit. 4. Remove 4 screws securing heater pipe clamp
3. Align heater to fascia rail and secure with plates to matrix.
screws. 5. Remove 2 heater pipe clamp plates.
4. Tighten nut securing heater to bulkhead. 6. Remove heater pipes from matrix.
5. Fit air intake duct to heater. 7. Remove and discard ’O’ rings from heater
6. Connect heater air intake duct to adaptor on pipes.
body.
7. Connect demister ducts to heater. Refit
1. Lubricate new ’O’ rings and fit to heater pipes.

2. Fit heater pipes to matrix.
3. Fit heater pipe clamp plates and secure with
screws.
4. Insert matrix into heater and secure with
screws.
5. Fit heater unit. See this section.

WIPERS & WASHERS
CONTENTS Page
REPAIRS
WASHER TUBE ........................................................................................................ 1
WIPER ARM ............................................................................................................. 3
WINDSCREEN WIPER MOTOR .............................................................................. 3
WINDSCREEN WIPER WHEEL BOX AND CABLE RACK TUBE ........................... 5
WINDSCREEN WASHER AND WIPER SWITCH .................................................... 7
DELAY UNIT ............................................................................................................. 8
WIPERS & WASHERS
WASHER TUBE
Remove
7. Withdraw washer tube through grommet in

bulkhead.
8. Attach draw string to washer tube and secure
with tape.
1. Disconnect washer tube from ’T’ connector

underbonnet.
2. Release sound deadening pad from bulkhead.
3. Remove locking ring securing RH air vent to

fascia.
4. Release and remove air vent from fascia.
5. Remove air vent tube.
6. Release sound deadening pad from bulkhead.

WIPERS & WASHERS
Refit
1. Measure and cut new length of washer tube.

2. Attach washer tube to draw string and secure
with tape.
3. Using assistance feed/draw washer tube
through body.
4. Remove tape securing draw string to washer
tube and remove draw string.
5. Connect washer tube to one-way valve.
6. Secure washer tube to clip on body and fit
foam strip between body panels.
7. Pass tube through grommet in bulkhead into
engine compartment.
8. Secure sound deadening pad to bulkhead.
9. Fit air vent tube.
10. Fit air vent to fascia and secure with locking
ring.
11. Secure sound deadening pad to bulkhead
underbonnet.
12. Connect washer tube to ’T’ connector.
13. Top up washer reservoir.
9. Remove foam strip from between body panels

in boot.
10. Release washer tube from clip on body.
11. Disconnect washer tube from one-way. valve.
12. Pull tube through body into boot space.
13. Remove tape securing draw string to washer
tube.
14. Remove washer tube.

WIPERS & WASHERS
WIPER ARM WINDSCREEN WIPER MOTOR
Remove Remove

2. Remove both windscreen wiper arms. See this
section.
1. Carefully lever wiper arm from splines on

wheelbox spindle using a flat bladed
screwdriver.
2. Remove wiper arm from wheelbox spindle.

pipe to mounting bracket.
bracket.
5. Remove 2 bolts securing emission canister
purge valve to body.
6. Position purge valve aside.
3. Press clip and remove wiper blade from arm.
Refit
1. Fit wiper blade to arm.

2. Align wiper arm to screen and push onto
wheelbox spindle.

WIPERS & WASHERS
7. Disconnect earth lead from wiper motor.

8. Loosen nut securing cable rack tube to wiper
motor.
9. Remove 2 screws securing wiper motor calmp
to body and remove clamp.
13. Remove 4 bolts securing cover to wiper motor

gearbox.
14. Remove cover from wiper motor gearbox.
Note position of earth lead lug.
15. Remove circlip and washer securing cable rack
connecting rod to wiper motor crank.
16. Remove connecting rod and cable rack
assembly.
17. Collect flat washer from under cable rack
connecting rod.
18. Fit flat washer to wiper motor crank.
10. Disconnect multiplug from wiper motor.
19. Fit cable rack connecting rod to wiper motor
11. Remove wiper motor complete with cable rack.
crank and secure with flat washer and circlip.
12. Collect wiper motor mounting pad.
20. Position cover and earth lead lug to wiper
motor gearbox and secure with screws.

WIPERS & WASHERS
Refit WINDSCREEN WIPER WHEEL BOX AND CABLE

RACK TUBE
1. Position wiper motor mounting pad to body.
2. Lubricate wiper motor cable rack. Service repair no - 84.15.27
3. Feed cable rack into tube, ensuring the rack
engages with the wheelbox teeth. Remove
4. Position wiper motor to mounting pad.
5. Connect multiplug to wiper motor. 1. Remove windscreen wiper motor. See this
6. Position wiper motor retaining strap and secure section.
with screws. 2. Remove air cleaner. See ENGINE
7. Tighten nut securing cable rack tube to wiper MANAGEMENT SYSTEM - MEMS, Repairs.
motor.
8. Connect earth lead to wiper motor.
9. Position emission canister purge valve to body,
fit bolts and tighten to 9 Nm.
10. Connect emission canister pipe to purge valve
and secure with ’E’ clip.
11. Fit wiper arms. See this section.
3. Disconnect washer tube from washer jets.

4. Remove 2 nuts securing wiper wheel boxes to
body.
5. Remove rubber spacers from wheel boxes.

WIPERS & WASHERS
10. Loosen nuts securing wiper wheel boxes to

cable rack tube.
11. Remove wiper wheel boxes.
Refit
from mounting bracket and position aside.
7. Release wheel boxes from body.
1. Lubricate wheel box gears and spindles.
2. Fit wheel boxes to cable rack tube but do not
tighten securing nuts.
3. Fit rubber spacers to wheel box spindles.
4. Position wheel box and cable rack tube
assembly to body.
5. Fit rubber spacers to wheel box spindles, fit
nuts and tighten to 10 Nm.
mounting bracket.
7. Fit wiper motor. See this section.
8. Operate wiper motor and check that wipers
move smoothly across screen.
9. Tighten nuts securing wheel boxes to cable
rack tube.
10. Connect washer tube to washer jets.
8. Rotate wheel box and cable rack tube 11. Fit air cleaner. See ENGINE MANAGEMENT
assembly and remove from vehicle. SYSTEM - MEMS, Repairs.
9. Collect 2 rubber spacers.

WIPERS & WASHERS
WINDSCREEN WASHER AND WIPER SWITCH
Remove
1. Remove rotary coupler. See ELECTRICAL,

Repairs.
3. Remove 2 screws securing switch to switch

assembly
4. Depress retaining tag and remove switch.
Refit
1. Fit windscreen washer and wiper switch to

switch assembly and secure with screws.
2. Connect multiplug to switch.
3. Fit rotary coupler. See ELECTRICAL,
Repairs.
2. Disconnect multiplug from switch.

WIPERS & WASHERS
DELAY UNIT
Remove
1. Remove fascia panel. See BODY, Interior

trim components.
2. Release delay unit multiplug from mounting

bracket.
3. Remove delay unit from multiplug.
Refit
1. Fit delay unit to multiplug and secure multiplug

to mounting bracket.
2. Fit fascia panel. See BODY, Interior trim
components.

ELECTRICAL
CONTENTS Page

ELECTRICAL CONTROL UNIT LOCATIONS .......................................................... 1
ADJUSTMENTS
AUXILIARY DRIVE BELT ......................................................................................... 1
HEADLAMP ADJUST ............................................................................................... 2
REPAIRS
ALTERNATOR .......................................................................................................... 1
AUXILIARY DRIVE BELT ......................................................................................... 2
ALTERNATOR PULLEY ........................................................................................... 2
AUXILIARY DRIVE BELT TENSIONER ................................................................... 3
HORN ....................................................................................................................... 4
HEADLAMP .............................................................................................................. 5
FRONT INDICATOR LAMP ...................................................................................... 6
SIDE REPEATER LAMP .......................................................................................... 6
TAIL LAMP ............................................................................................................... 7
FOG OR DRIVING LAMP ......................................................................................... 9
HEADLAMP ADJUSTER UNIT ................................................................................. 9
RADIO .................................................................................................................... 10
REAR SPEAKER .................................................................................................... 11
AERIAL ................................................................................................................... 11
COAXIAL CABLE .................................................................................................... 12
HORN RELAY ......................................................................................................... 14
DIRECTION INDICATOR RELAY ........................................................................... 14
FOG/DRIVING LAMP RELAY ................................................................................. 15
AUXILIARY CIRCUITS RELAY .............................................................................. 15
FLASHER UNIT ...................................................................................................... 16
ANTI THEFT ALARM - ECU ................................................................................... 16
STARTER MOTOR ................................................................................................. 17
HEADLAMP LEVELLING SWITCH ........................................................................ 18
DRIVING/FOG LAMP SWITCH .............................................................................. 19
HEATED REAR SCREEN SWITCH ....................................................................... 20
HAZARD WARNING LIGHT SWITCH .................................................................... 21
INDICATOR/HEADLAMP SWITCH ........................................................................ 22
STEERING COLUMN SWITCH ASSEMBLY .......................................................... 22
REAR FOG LAMP SWITCH ................................................................................... 24
ROTARY COUPLER ............................................................................................... 25
ENGINE COMPARTMENT FUSE BOX .................................................................. 26
PASSENGER COMPARTMENT FUSE BOX ......................................................... 27
CD PLAYER ........................................................................................................... 28
ELECTRICAL
ELECTRICAL CONTROL UNIT LOCATIONS
1. Front fog light relay 7. Wash/wipe delay unit

2. Driving light relay 8. Direction indicator/hazard warning flasher unit
3. Direction indicator relay 9. Anti theft alarm - ECU
4. Engine management relay module 10. Cooling fan relay
5. Horn relay 11. Engine compartment fuse box
6. Auxiliary circuits relay

ELECTRICAL
AUXILIARY DRIVE BELT
Check Adjust
1. Remove nut and bolt securing auxiliary drive

belt cover.
2. Remove auxiliary drive belt cover.
3. Check condition of drive belt, renew a drive
belt that shows signs of wear and splitting.
1. Loosen tensioner pulley retaining nut.

2. Increase drive belt tension by turning the
tension adjusting bolt clockwise.
CAUTION: Do not apply excessive torque

4. Apply a force of 10 kg to the drive belt at to adjusting bolt or damage to bolt will
position ’X’ and measure the deflection result. If bolt appears to be seized or is
between the crankshaft pulley and alternator difficult to turn, apply suitable anti-seize
pulley. lubricant to bolt.
Deflection must be 6 - 8 mm.
3. Tighten tensioner pulley retaining nut to 25
Nm.
4. Recheck drive belt tension.
5. Fit auxiliary drive belt cover and secure with
nut and bolt.
REVISED: 06/99 ADJUSTMENTS 1

ELECTRICAL
HEADLAMP ADJUST
Inspect Adjust
1. Align suitable beam setting equipment to

headlamp.
2. Ensure headlamp levelling switch is in position
’0’ and switch on headlamps.
Headlamp setting = 1.4% below horizontal and
parallel.
1. Remove screw securing headlamp finisher and

remove.
2. Turn screws for vertical alignment.
3. Turn screw for horizontal alignment.
4. Fit headlamp finisher and secure with screw.
5. Align beam setting equipment to 2nd
headlamp.
6. Adjust 2nd headlamp as detailed in steps 1 to
3 above.
7. Switch off headlamps.
8. Remove beam setter.
2 ADJUSTMENTS REVISED: 12/96

ELECTRICAL
ALTERNATOR
Remove
1. Remove auxiliary drive belt. See this section.
5. Hold alternator shaft with an 8 mm Allen key

and remove pulley retaining nut with 18G 1653.
6. Remove alternator pulley.
Refit
1. Clean mating face of alternator pulley and

shaft.
2. Fit pulley to alternator and tighten nut to 25
Nm.
3. Fit alternator.
4. Fit and tighten bolts and nut and bolt securing
alternator.
5. Connect leads to alternator and tighten nuts.
6. Fit auxiliary drive belt. See this section.
2. Remove 2 nuts and disconnect leads from

alternator.
3. Remove 2 bolts and nut and bolt securing
alternator.
4. Remove alternator.
REPAIRS 1
ELECTRICAL
AUXILIARY DRIVE BELT ALTERNATOR PULLEY
Remove Remove
1. Disconnect battery earth lead. 1. Remove auxiliary drive belt. See this section.
2. Remove nut and bolt securing drive belt cover
and remove cover.
2. Hold alternator shaft with an 8 mm Allen key

and remove pulley retaining nut with 18G 1653.
3. Remove alternator pulley.
Refit
3. Loosen tensioner pulley retaining nut. 1. Clean mating face of alternator pulley and
4. Release drive belt tension by turning the shaft.
tension adjusting bolt clockwise and remove 2. Fit pulley to alternator and tighten nut to 25
drive belt. Nm.
3. Fit auxiliary drive belt. See this section.
CAUTION: Do not apply excessive torque
to adjusting bolt or damage to bolt will
result. If bolt appears to be seized or is
difficult to turn, apply suitable anti-seize
lubricant to bolt.
Refit
1. Clean pulleys.
2. Fit new drive belt to pulleys. Ensure grooves
on pulleys and drive belt are correctly located.
3. Adjust drive belt tension. See Adjustments.

ELECTRICAL
AUXILIARY DRIVE BELT TENSIONER Refit
Service repair no - 86.10.06 1. Clean mating face of pulley and pulley

mounting bracket.
Remove 2. Fit tensioner pulley and tighten nut sufficiently
only to stop pulley tilting.
1. Disconnect battery earth lead. 3. Tension auxiliary drive belt. See
2. Remove auxiliary drive belt cover. See Adjustments.
Adjustments. 4. Connect battery earth lead.
3. Loosen nut securing auxiliary drive belt

tensioner pulley.
4. Turn tensioner adjusting bolt clockwise to
release belt tension.
5. Remove nut securing tensioner pulley and
remove pulley.
6. Remove Torx screw and bolt securing
tensioner.
7. Remove tensioner and spacer.
REPAIRS 3
ELECTRICAL
HORN Refit
Service repair no - 86.30.10 1. Fit horn to mounting bracket.

2. Fit nut and washer securing horn to mounting
Remove bracket and tighten to 10 Nm.
3. Align horn mounting bracket to body, fit bolts
4. Connect multiplug to horn.
1. Disconnect multiplug from horn.

2. Remove 2 bolts securing horn mounting
bracket to body.
3. Remove horn and mounting bracket.
4. Remove nut and washer securing horn to

mounting bracket.
5. Remove horn.

ELECTRICAL
HEADLAMP
Remove
3. Pull unit forward and disconnect headlamp

bulb multiplug and pilot lamp bulb.
4. Remove headlamp.
5. Release clip securing bulb to headlamp and
remove bulb.
Refit
1. Fit bulb to headlamp and secure with clip.

2. Position headlamp unit, connect pilot lamp bulb
and multiplug. Secure bulb cover.
3. Position headlamp unit to levelling pivot and
secure to retaining screws.
4. Fit headlamp finisher and tighten screw.
1. Remove screw securing headlamp finisher and

remove finisher.
2. Release headlamp unit from RH retaining
screw and levelling pivot.

ELECTRICAL
FRONT INDICATOR LAMP SIDE REPEATER LAMP
Remove Remove
1. Squeeze lugs on repeater lamp to release from

wing.
2. Release bulb holder from repeater lamp.
1. Remove 2 screws securing lamp to body.
Refit
2. Release lamp and disconnect bulb holder.
1. Connect bulb holder to repeater lamp.
Refit
2. Fit repeater lamp to wing.
1. Connect bulb holder to lamp.
2. Position lamp to body and secure with screws.
6 REPAIRS
ELECTRICAL
TAIL LAMP
Service repair no -
LH - 86.40.70
RH - 86.40.71
Remove
1. Remove boot carpet.
LH side only
2. Drain fuel tank. See FUEL DELIVERY

SYSTEM, Repairs.

5. Remove studs securing fuel tank side 12 cover
and remove cover.

ELECTRICAL
Both sides Refit
1. Fit seal to tail lamp.

2. Clean mating faces of tail lamp and body.
3. Fit tail lamp assembly to body, fit earth lead(s)
to stud.
4. Fit nuts securing tail lamp to body and tighten
to 9 Nm.
5. Connect multiplug to tail lamp.
LH side only
6. Manoeuvre fuel tank into position and position

restraining strap.
10. Position spare wheel
11. Fit boot carpet.
12. Refill fuel tank with fuel.
10. Disconnect multiplug from tail lamp.

11. Disconnect Lucar from tail lamp.
12. Remove 4 nuts securing tail lamp to body.
13. Disconnect earth lead(s) from stud.
14. Remove tail lamp assembly.
15. Remove tail lamp seal.

ELECTRICAL
FOG OR DRIVING LAMP HEADLAMP ADJUSTER UNIT
Remove Remove
1. Remove front grille. See BODY, Exterior 1. Remove headlamp light unit. See this section.
fittings. 2. Raise front of vehicle.
2. Disconnect multiplug from lamp.

3. Release cable tie securing harness to body.
4. Remove bolt securing lamp to mounting
bracket and remove lamp.
3. Locate headlamp adjuster under wing and pull
Refit back multiplug cover. Disconnect multiplug.
4. Rotate adjuster clockwise and release from
1. Position lamp to mounting bracket, fit and headlamp.
tighten bolt.
2. Connect multiplug to lamp and secure harness Refit
to body with cable tie.
3. Fit front grille. See BODY, Exterior fittings. 1. Position adjuster to headlamp and rotate to
position.
2. Connect multiplug to adjuster and secure
cover.
3. Fit headlamp light unit. See this section.

ELECTRICAL
RADIO Refit
Service repair no - 86.50.03 1. Position radio to aperture. Connect multiplugs

and aerial lead.
Remove 2. Slide radio into fascia until retaining clips
engage.
3. Enter security code and check radio for correct
operation.
1. Fit radio removal tools SMD 4091 to release

retaining clips. Pull on tools to release radio
from fascia.
2. Disconnect 2 multiplugs and aerial lead from

radio.
3. Remove radio and remove tools from radio.

ELECTRICAL
REAR SPEAKER AERIAL
Remove Remove
1. Remove windscreen. See BODY, Screens.
2. Unscrew and remove aerial from aerial base.
1. Disconnect speaker multiplug from harness.

2. From within boot area, remove 3 nuts securing
speaker to body.
3. Remove speaker from rear parcel shelf.
Refit
1. Fit speaker to parcel shelf.

2. Fit nuts securing speaker to body and tighten
to 9 Nm.
3. Connect speaker multiplug to harness.
3. Remove 2 screws securing LH sun visor to roof

and remove.

ELECTRICAL
COAXIAL CABLE
Remove
1. Remove fascia. See BODY, Interior trim

components.
2. Remove windscreen. See BODY, Screens.
4. Release roof lining from front upper flange of

windscreen aperture.
5. Carefully lower front edge of roof lining to gain
access to aerial.
6. Remove cover from coaxial cable.
7. Remove nut securing coaxial cable to aerial
base.
8. Remove aerial base from roof.
Refit
1. Clean mating face of aerial base and vehicle

roof.
2. Fit aerial base to roof.
3. Connect coaxial cable to aerial base. 3. Remove 2 screws securing LH sun visor to
4. Fit nut securing coaxial cable to aerial base roof.
5. Fit cover to coaxial cable.
6. Apply adhesive to edge of roof lining and
carefully secure to windscreen aperture.
7. Position LH sun visor and secure with screws.
8. Fit windscreen. See BODY, Screens.

ELECTRICAL
Refit
1. Attach draw string to the radio end of the new

coaxial cable and pull cable into position.
2. Remove draw string.
3. Secure coaxial cable to main harness with
cable ties.
4. Connect coaxial cable to aerial base.
5. Fit nut securing coaxial cable to aerial base
6. Fit cover to coaxial cable.
7. Apply adhesive to edge of roof lining and
carefully secure to windscreen aperture.
8. Position LH sun visor and secure with screws.
9. Fit windscreen. See BODY, Screens.
10. Fit fascia. See BODY, Interior trim
components.
4. Release roof lining from front upper flange of

windscreen aperture.
5. Carefully lower front edge of roof lining to gain
access to aerial.
6. Remove cover from coaxial cable.
7. Remove nut securing coaxial cable to aerial
base.
8. Remove 3 cable ties securing coaxial cable to

body harness.
9. Tie a draw string to the radio end of the coaxial
cable and withdraw cable into roof area.
10. Untie draw string and remove coaxial cable.

ELECTRICAL
HORN RELAY DIRECTION INDICATOR RELAY
Remove Remove
1. Remove fascia panel. See BODY, Interior 1. Open bonnet.

trim components.
2. Remove relay from mounting bracket on RH

2. Release relay multiplug from mounting bracket. wing valance.
3. Remove relay from multiplug.
Refit
Refit
1. Fit relay to mounting bracket.
1. Fit relay to multiplug and secure multiplug to 2. Close bonnet.
mounting bracket.
components.

ELECTRICAL
FOG/DRIVING LAMP RELAY AUXILIARY CIRCUITS RELAY
Remove Remove
1. Open bonnet. 1. Remove fascia panel. See BODY, Interior

trim components.
Driving lamp relay 2. Release relay multiplug from mounting bracket.

3. Remove relay from multiplug.
Refit
1. Fit relay to multiplug and secure multiplug to

mounting bracket.
components.
Fog lamp relay
2. Remove relay from mounting bracket on RH

wing valance.
Refit
1. Fit relay to mounting bracket.

2. Close bonnet.

ELECTRICAL
FLASHER UNIT ANTI THEFT ALARM - ECU
Remove Remove
1. Remove fascia panel. See BODY, Interior 1. Remove fascia panel. See BODY, Interior
trim components. trim components.
2. Release flasher unit multiplug from mounting

bracket.
3. Remove flasher unit from multiplug.
Refit
1. Fit flasher unit to multiplug and secure

multiplug to mounting bracket.
components.
2. Disconnect multiplug from anti theft alarm

ECU.
3. Remove 2 screws securing ECU to mounting
bracket.
4. Remove ECU.
Refit
1. Fit ECU to mounting bracket.

2. Fit and tighten screws.
3. Connect multiplug.
components.

ELECTRICAL
STARTER MOTOR
Remove


fittings.
6. Remove cable tie securing harness to starter

motor solenoid.
7. Remove nut securing leads to starter solenoid.
4. Remove 4 bolts securing radiator upper 8. Release Lucar connection from solenoid.
mountings to bonnet platform. 9. Disconnect multiplug from oil temperature
5. Remove radiator from its lower mountings and transmitter
move it to LH side for access to starter motor.
10. Remove 2 bolts securing starter motor.

11. Remove starter motor.

ELECTRICAL
Refit HEADLAMP LEVELLING SWITCH
1. Ensure starter and mating face on flywheel Service repair no - 86.65.16

housing is clean.
2. Fit starter motor and tighten bolts to 37 Nm. Remove
3. Connect leads to solenoid terminal, fit nut and
tighten to 4 Nm.
4. Connect Lucar to solenoid.
5. Connect multiplug to oil temperature
transmitter.
6. Fit radiator to lower brackets
7. Align radiator upper brackets and secure with
bolts.
8. Fit front grille. See BODY, Exterior fittings.
1. Remove fascia RH air vent locking ring.

Release and remove air vent.
2. Remove air vent hose.
3. Disconnect multiplug from headlamp levelling

switch.
4. Remove knob from switch and remove nut
securing switch to fascia panel.
5. Remove switch.

ELECTRICAL
Refit
1. Position switch and tighten nut. Fit switch knob.

2. Connect multiplug.
3. Fit air vent hose.
4. Fit air vent and secure with locking ring.
DRIVING/FOG LAMP SWITCH
Remove

4. Remove switch.
Refit
1. Position switch to panel.

3. Fit switch to panel
screws.


ELECTRICAL
HEATED REAR SCREEN SWITCH
Remove

1. Remove 2 screws securing heater to fascia 4. Remove switch.
Refit

screws.

ELECTRICAL
HAZARD WARNING LIGHT SWITCH
Remove

Refit

3. Fit switch to panel.
screws.

ELECTRICAL
INDICATOR/HEADLAMP SWITCH STEERING COLUMN SWITCH ASSEMBLY
Remove Remove
1. Remove rotary coupler. See this section. 1. Remove rotary coupler. See this section.
2. Remove indicator cancelling cam from column.

3. Remove 2 screws securing switch assembly to
steering column.
2. Disconnect 2 multiplugs from switch.
3. Remove 2 screws securing switch to switch

assembly.
4. Depress retaining tag and remove switch.
Refit
1. Fit indicator/headlamp switch to switch

assembly and secure with screws.
2. Connect multiplugs to switch assembly.
3. Fit rotary coupler. See this section.

ELECTRICAL
6. Remove 2 screws securing indicator/headlamp

switch to switch assembly.
7. Depress retaining tag and remove
4. Release switch assembly from column and

disconnect 3 multiplugs.
5. Remove switch assembly.
8. Remove 2 screws securing windscreen washer
and wiper switch to switch assembly.
9. Depress retaining tag and remove windscreen
washer and wiper switch.
10. Fit washer and wiper switch to switch assembly
and secure with screws.
11. Fit indicator/headlamp switch to switch
assembly and secure with screws.
Refit
1. Position switch assembly to steering column,

connect multiplugs and tighten retaining
screws.
2. Fit direction indicator cancelling cam to
steering column.
3. Fit rotary coupler. See this section.

ELECTRICAL
REAR FOG LAMP SWITCH
Remove

Refit

screws.

ELECTRICAL
ROTARY COUPLER Refit
Service repair no - 86.65.85 1. Fit rotary coupler and secure with screws.
2. Connect multiplugs to rotary coupler.
CAUTION: See SRS safety precautions 3. Remove retaining tape from rotary coupler.
before commencement of repair. See 4. Fit steering column nacelle. See STEERING,
RESTRAINT SYSTEMS, Precautions. Repairs.
• Ensure wheels are aligned straight ahead. 5. Fit steering wheel. See STEERING, Repairs.
Remove
1. Remove key from starter switch, disconnect

discharge before commencing work.
2. Remove steering column nacelle. See
STEERING, Repairs.
3. Remove steering wheel. See STEERING,
Repairs.
4. If the rotary coupler is being re-used place

adhesive tape around moulding to prevent
rotation.
5. Disconnect 2 multiplugs from rotary coupler.
6. Remove 4 screws and remove rotary coupler.
CAUTION: Do not dismantle the rotary

coupler, It has no serviceable parts and
must be replaced as a complete assembly.

ELECTRICAL
ENGINE COMPARTMENT FUSE BOX Refit
Service repair no - 86.70.01 1. Remove cover from NEW fuse box.

2. Position starter lead to fuse box and tighten nut
Remove and bolt.
3. Remove anti-back out plates and secure leads
1. Disconnect battery earth lead. to fuse box. Fit anti-back out plates to fuse box.
2. Release fuse box retainers from ECM 4. Fit fuses and fuse box top cover.
mounting bracket. 5. Position and secure fuse box to ECM mounting
bracket.
3. Remove fuse box top cover and remove 4

fuses.
4. Release fuse box lower cover.
5. Remove fuse box lead anti-back out plates and
release 4 leads from fuse box.
6. Remove nut and bolt and release starter lead
from fuse box lower cover.

ELECTRICAL
PASSENGER COMPARTMENT FUSE BOX Refit
Service repair no - 86.70.04 1. Remove terminal retaining plates from new

fuse box.
Remove 2. Fit wires to fuse box.
3. Fit terminal retaining plates.
1. Disconnect battery earth lead. 4. Fit fuse box and secure with 4 screws.
5. Secure harness to stud on wheel arch.
6. Fit and secure cover to fuse box.
2. Release turnbuckle and remove fuse box

cover.
3. Note position and remove all fuses.

4. Release fuse box harness clip from stud on
wheel arch.
5. Remove 4 screws and lower fuse box.
6. Release and remove 6 terminal retaining
plates.
7. Note position and disconnect wires from rear of
fuse box.
REPAIRS 27
ELECTRICAL
CD PLAYER Refit
Remove 1. Position unit, connect multiplugs and aerial

lead plug.
1. Disconnect battery earth lead. 2. Fit unit, tighten 2 captive screws.
3. Secure access tab to each side of unit.
5. Enter security code and check unit for correct
operation.
2. Release access tab from each side of unit.

3. Using a 2.5 mm Allen key, slacken 2 captive
screws securing unit.
4. Withdraw unit sufficiently to gain access to

multiplugs and aerial lead.
CAUTION: Take care not to damage face

of unit.
5. Noting their fitted positions, disconnect 2

multiplugs and aerial lead plug; remove unit.

INSTRUMENTS
CONTENTS Page
REPAIRS
BATTERY CONDITION INDICATOR ....................................................................... 1
CLOCK ..................................................................................................................... 2
INSTRUMENT PANEL .............................................................................................. 3
PRINTED CIRCUIT ................................................................................................... 3
INSTRUMENT PANEL WINDOW ............................................................................. 4
OIL TEMPERATURE GAUGE .................................................................................. 5
COMBINED COOLANT TEMPERATURE GAUGE AND FUEL GAUGE ................. 6
OIL TEMPERATURE GAUGE SENSOR .................................................................. 7
FUEL GAUGE TANK UNIT ....................................................................................... 7
SPEEDOMETER ...................................................................................................... 8
SPEEDOMETER DRIVE CABLE .............................................................................. 9
CABLE ASSEMBLY - SPEEDOMETER - UPPER .................................................. 10
CABLE ASSEMBLY - SPEEDOMETER - LOWER ................................................. 11
TACHOMETER ....................................................................................................... 12
INSTRUMENTS
BATTERY CONDITION INDICATOR
Remove

6. Remove nuts from battery condition indicator

gauge and collect retainer.
7. Disconnect Lucar connectors and illumination
lamp from gauge.
8. Remove battery condition indicator gauge.
Refit
1. Position gauge, identify and connect leads.

3. Remove both fascia air vent locking rings. Connect illumination lamp.
Release and remove air vents. 2. Position gauge to fascia, fit retainer and tighten
nuts.
3. Position fascia panel and tighten nuts.
4. Fit air vents and secure locking rings.

brackets to body.
fascia forward for access to gauges.
REPAIRS 1
INSTRUMENTS
CLOCK
Remove

6. Remove nut and release retainer from clock.

7. Disconnect lucar connectors and illumination
lamp from clock.
8. Remove clock.
Refit
1. Position clock, identify and connect leads.

Connect illumination lamp.
3. Remove both fascia air vent locking rings. 2. Position clock to fascia, fit retainer and tighten
Release and remove air vents. nut.

brackets to body.
2 REPAIRS
INSTRUMENTS
INSTRUMENT PANEL PRINTED CIRCUIT
Service repair no - 88.20.01/99 Service repair no - 88.20.19
Remove Remove
1. Remove fascia panel. See BODY, Interior 1. Remove fascia panel. See BODY, Interior
trim components. trim components.
2. Remove 6 screws and remove instrument 2. Remove illumination and warning light bulbs
panel from fascia panel. from instrument pack. Note position of yellow
bulbs.
Refit 3. Remove 7 screws securing printed circuit to
instrument pack, noting position of long
1. Position instrument panel to fascia panel and screws.
secure with screws. 4. Release and remove printed circuit.
components. Refit
1. Position printed circuit. Fit and tighten screws.

2. Fit illumination and warning light bulbs.
components.
REPAIRS 3
INSTRUMENTS
INSTRUMENT PANEL WINDOW
Remove
1. Remove fascia panel. See BODY, Interior

trim components.
2. Remove 6 screws securing instrument housing

to panel.
3. Remove instrument housing and release
tachometer from housing.
4. Release retainers, remove window from
speedometer housing.
Refit
1. Fit window to speedometer to housing.

2. Fit tachometer to housing.
3. Fit instrument housing to panel. Fit and tighten
screws.
components.
4 REPAIRS
INSTRUMENTS
OIL TEMPERATURE GAUGE
Remove

6. Remove nuts from oil temperature gauge and

collect retainer.
7. Disconnect Lucar connectors and illumination
lamp from gauge.
8. Remove oil temperature gauge.
Refit
1. Position gauge, identify and connect leads.

3. Remove both fascia air vent locking rings. Connect illumination lamp.
Release and remove air vents. 2. Position gauge to fascia, fit retainer and tighten
nuts.

brackets to body.
REPAIRS 5
INSTRUMENTS
COMBINED COOLANT TEMPERATURE GAUGE

AND FUEL GAUGE
Remove
1. Remove printed circuit See this section.
Refit
2. Remove 6 screws securing housing to
instrument panel. 1. Fit gauge to housing.
3. Remove instrument housing and release 2. Fit surround and window to housing.
tachometer from housing. 3. Fit tachometer to housing.
4. Release retainers, remove window and 4. Fit housing to instrument panel. Fit and tighten
surround from gauge housing. screws.
5. Remove gauge from housing. 5. Fit printed circuit. See this section.
6 REPAIRS
INSTRUMENTS
OIL TEMPERATURE GAUGE SENSOR FUEL GAUGE TANK UNIT
Remove Remove
1. Remove front grille. See BODY, Exterior 1. Drain fuel tank. See FUEL DELIVERY
fittings. SYSTEM, Repairs.
2. Remove studs securing fuel tank side cover

and remove cover.
3. Disconnect 2 Lucars from tank unit.
2. Disconnect multiplug from sensor.

3. Loosen oil temperature gauge sensor and
remove.
4. Remove and discard sealing washer.
Refit
1. Clean mating face of oil temperature gauge

sensor and cylinder block.
2. Fit new sealing washer to sensor.
3. Fit sensor and tighten to 60 Nm.
4. Connect multiplug to sensor. 4. Using tool 18G 1467 remove the tank unit
5. Fit front grille. See BODY, Exterior fittings. retaining ring.
5. Remove the tank unit and discard seal.
Refit
1. Clean tank and tank unit mating faces.

2. Using a new seal locate the tank unit.
3. Position retaining ring and secure with tool 18G
1467.
4. Connect 2 Lucars to tank unit.
6. Return fuel to fuel tank.

INSTRUMENTS
SPEEDOMETER
Remove
1. Remove printed circuit See this section.
Refit
2. Remove 6 screws securing instrument housing
to panel. 1. Fit speedometer to housing. Fit and tighten
3. Remove instrument housing and release screws.
tachometer from housing. 2. Fit surround and lens to housing.
4. Release retainers, remove lens and surround 3. Fit tachometer to housing.
from speedometer housing. 4. Fit housing to instrument panel. Fit and tighten
5. Remove 2 screws and remove speedometer screws.
from housing. 5. Fit printed circuit. See this section.
8 REPAIRS
INSTRUMENTS
SPEEDOMETER DRIVE CABLE
Remove

6. Loosen knurled nut securing speedometer

cable to gearbox.
7. Release cable grommet from bulkhead.
8. Release cable and remove from vehicle.
Refit
1. Fit cable to vehicle.

2. Connect cable to gearbox and tighten nut.
3. Connect cable to instrument pack and secure
4. Disconnect speedometer cable from rear of grommet.
instrument pack. 4. Ensure cable is routed correctly and is not
5. Raise front of vehicle. kinked or twisted.
WARNING: Support on safety stands. 6. Fit air cleaner. See ENGINE MANAGEMENT
REPAIRS 9
INSTRUMENTS
CABLE ASSEMBLY - SPEEDOMETER - UPPER 2. Connect upper cable to lowercable and secure
retaining clip.
Service repair no - 88.30.08 3. Ensure cable is routed correctly and is not
kinked or twisted.
Remove 4. Connect cable to instrument pack and secure
grommet.
1. Disconnect battery earth lead. 5. Fit radio. See ELECTRICAL, Repairs.
2. Remove air cleaner. See ENGINE 6. Fit air cleaner. See ENGINE MANAGEMENT
MANAGEMENT SYSTEM - MEMS, Repairs. SYSTEM - MEMS, Repairs.
3. Remove radio. See ELECTRICAL, Repairs. 7. Connect battery earth lead.
4. Using the radio aperture for access disconnect

speedometer cable from rear of instrument
pack.
5. Release cable grommet from bulkhead.
6. Slide back retaining clip and release upper

cable from lower cable.
Refit

INSTRUMENTS
CABLE ASSEMBLY - SPEEDOMETER - LOWER 2. Connect lower cable to upper cable and secure
retaining clip.
Service repair no - 88.30.09 3. Ensure cable is routed correctly and is not
kinked or twisted.
Remove 4. Connect cable to gearbox and tighten nut.
1. Disconnect battery earth lead. 6. Connect battery earth lead.
3. Loosen knurled nut securing speedometer

cable to gearbox.
4. Slide back retaining clip and release lower

cable from upper cable.
Refit

INSTRUMENTS
TACHOMETER Refit
Service repair no - 88.30.21 1. Fit tachometer to housing. Fit and tighten

screws.
Remove 2. Fit surround and lens to housing.
3. Fit housing to instrument panel. Fit and tighten
1. Remove fascia panel. See BODY, Interior screws.
trim components. 4. Align printed circuit to tachometer, fit and
tighten screw.
5. Fit illumination bulb.
components.
2. Remove screw securing printed circuit to

tachometer.
3. Remove 2 screws securing tachometer
housing to instrument panel and remove
housing.
4. Remove illumination light bulb from
tachometer.
5. Release retainers, remove lens and surround

from housing.
6. Remove 2 screws and remove tachometer
from housing.

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MINI WORKSHOP MANUAL

Amendment Number: XN-001/97ENG Date: 12/96

Section Discard Existing Insert New Pages Reason for Amendment

Information Contents Page Contents Page Corrections to existing information and

Engine Contents Page Contents Page Corrections to existing information and

Emission Control Description and Description and Corrections to existing information.

Engine Management Contents Page Contents Page Corrections to existing information.

Cooling System Repairs, 3 Repairs, 3 Corrections to existing information.

Clutch Contents page Contents Page Corrections to existing information and

Drive shafts - Contents Page New Section

Steering Contents page Contents Page Corrections to existing information and

Suspension - Contents Page New Section.

Brakes Contents Page Contents Page Corrections to existing information and

Restraint Systems Description and Description and Corrections to existing information.

Body Contents Page Contents Page Corrections to existing information and

Heating & Ventilation - Contents Page New Section.

Electrical Contents Page Contents Page Corrections to existing information and

Instruments Repairs, 7 Repairs, 7 Corrections to existing information.

MINI WORKSHOP MANUAL

Amendment Number: XN003.98ENG Date: 11/98

Section Discard Existing Insert New Pages Reason for Amendment

INSTRUMENTS Contents page Contents page Additional jobs added

MINI WORKSHOP MANUAL

Amendment Number: XN002.99ENG Date: 06/99

Section Discard Existing Insert New Pages Reason for Amendment

ELECTRICAL Contents page Contents page Contents changed.

This manual covers changes to Mini models CLUTCH

HEATING & VENTILATION

WIPERS & WASHERS

How to use this Manual References to the LH or RH side given in this

WARNING: Procedures which must be

CAUTION: Calls attention to procedures

NOTE: Gives helpful information.

REPAIRS AND REPLACEMENTS SPECIFICATION

Owners purchasing accessories while travelling

The Terms of the vehicle Warranty may be

All Rover recommended parts have the full backing

Rover Dealers are obliged to supply only Rover

ABBREVIATIONS AND SYMBOLS

After Bottom Dead Centre ABDC

VEHICLE IDENTIFICATION NUMBER

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS

FUEL HANDLING PRECAUTIONS

VEHICLE IDENTIFICATION NUMBER Paint and Trim colour codes

3-letter codes identifying the original Paint and Trim

The Vehicle Identification Number (VIN) plate is Paint

Vehicle identification number

Example: S A X X N N A Z E B D 134455 IDENTIFICATION NUMBER LOCATIONS

S= Geographic area Engine number

A= Country Stamped on the front face of the cylinder block

A= Body Body number

Z= Engine The body number is stamped on a plate fixed to the

6 figures= Serial number

VEHICLE IDENTIFICATION NUMBER 1

GENERAL PRECAUTIONS AND FITTING Health Protection Precautions

GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1

SAFETY INSTRUCTIONS Brake hydraulics

Jacking WARNING: It is imperative that the correct

2 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS