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2011 Jaguar X Type Workshop Manual – PDF DOWNLOAD
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Description
2011 Jaguar X Type Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
2011 Jaguar X Type Workshop Manual – PDF DOWNLOAD
General Information – About This Manual
Description and Operation
Notes, Cautions and Warnings
Throughout this manual, important information is highlighted by the use of notes, cautions and warnings. NOTES give additional information on a topic or procedure, CAUTIONS are given to prevent damage to the vehicle, and WARNINGS are given to prevent personal injury.
General Information – General Service Information
Description and Operation
Repairs and Replacements
- When service parts are required, it is essential that only genuine Jaguar/Daimler replacements are used. Attention is drawn to the following points concerning repairs and the fitting of replacement parts and accessories: Safety features embodied in the vehicle may be impaired if other than genuine parts are fitted. In certain territories, legislation prohibits the fitting of parts which are not produced to the vehicle manufacturer’s specification.
- Torque wrench setting figures given in this manual must be strictly adhered to. 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 make sure that the accessory and its fitted location on the vehicle conform to mandatory requirements existing in their country of origin.
- The vehicle warranty may be invalidated by the fitting of other than genuine Jaguar/Daimler parts. All Jaguar/Daimler replacements have the full backing of the factory warranty. Jaguar/Daimler dealers are obliged to supply only genuine service parts. Vehicle Specifications Purchasers are advised that the specification details set out in this manual apply to a range of vehicles and not to any specific one.
- For the specification of a particular vehicle, purchasers should consult their dealer. The Manufacturer reserves the right to vary the specifications, with or without notice, and at such times and in such manner as the Manufacturer thinks fit. Major as well as minor changes may be involved, in accordance with the Manufacturer’s policy of continuous improvement. Whilst every effort is made to make sure the accuracy of the particulars contained in this manual, neither the Manufacturer nor the Dealer, by whom the manual is supplied, shall in any circumstances be held liable for any inaccuracy or the consequences thereof.
- Service Repair Operation Numbering A master index of numbered operations has been compiled for universal application to all vehicles manufactured by Jaguar Cars Ltd. Each operation is allocated a number from the master index and cross-refers with an identical number in the Repair Operation Times schedule. The number consists of six digits arranged in three pairs. Each maintenance procedure in this manual is described in the sequence necessary to complete the operation in the minimum time, as specified in the Repair Operation Times schedule. References to Bank-1 and Bank-2 References to Bank-1 and Bank-2 are made with regard to the engine.
- When viewed from the flywheel the right-hand bank will be Bank-1 and the left-hand bank will be Bank-2. Special Tools Any special tools and equipment required to perform a maintenance procedure, are shown at the beginning of each procedure. When possible, illustrations are given to assist in identifying the tool needed. Disconnecting/Connecting the Battery Always stop the engine before disconnecting the battery negative lead and make sure the battery positive lead is isolated i.e. wrapped in a suitable cloth.
TABLE OF CONTENTS:
2011 Jaguar X Type Workshop Manual – PDF DOWNLOAD
Front Page................................................................................................................... 1 TABLE OF CONTENTS............................................................................................................ 2 1: General Information....................................................................................................... 46 100: Service Information................................................................................................. 48 100-00: General Information.......................................................................................... 48 Description and Operation........................................................................................ 48 About This Manual............................................................................................ 46 Application and Use of Specifications........................................................................ 47 General Service Information.................................................................................. 48 Health and Safety Precautions................................................................................ 56 How To Use This Manual....................................................................................... 66 Important Safety Instructions................................................................................ 67 Road/Roller Testing.......................................................................................... 68 Solvents, Sealants and Adhesives............................................................................. 70 Standard Workshop Practices.................................................................................. 71 100-01: Identification Codes......................................................................................... 72 Description and Operation........................................................................................ 72 Identification Codes......................................................................................... 72 100-02: Jacking and Lifting.......................................................................................... 78 Description and Operation........................................................................................ 78 Jacking...................................................................................................... 78 Lifting...................................................................................................... 79 100-04: Noise, Vibration and Harshness............................................................................... 82 Description and Operation........................................................................................ 82 Noise, Vibration and Harshness (NVH)......................................................................... 82 Diagnosis and Testing............................................................................................ 83 Noise, Vibration and Harshness (NVH)......................................................................... 83 General Procedures............................................................................................... 88 Exhaust System Neutralizing.................................................................................. 88 2: Chassis................................................................................................................... 89 204: Suspension.......................................................................................................... 89 204-00: Suspension System - General Information...................................................................... 89 Specification.................................................................................................... 89 Description and Operation........................................................................................ 90 Wheel Alignment Angles....................................................................................... 90 Diagnosis and Testing............................................................................................ 93 Suspension System............................................................................................ 93 General Procedures............................................................................................... 95 Front Toe Adjustment (57.65.01).............................................................................. 95 Rear Toe Adjustment (57.65.08)............................................................................... 97 Wheel Bearing Inspection..................................................................................... 99 204-01: Front Suspension............................................................................................. 100 Specification.................................................................................................... 100 Description and Operation........................................................................................ 101 Front Suspension............................................................................................. 101 Diagnosis and Testing............................................................................................ 103 Front Suspension............................................................................................. 103 Removal and Installation......................................................................................... 104 Lower Arm (60.35.02)......................................................................................... 104 Shock Absorber and Spring Assembly (60.30.02)................................................................ 113 Front Stabilizer Bar (60.10.01).............................................................................. 122 Front Stabilizer Bar Bushing (60.10.04)...................................................................... 124 Front Wheel Bearing and Wheel Hub (60.25.03)................................................................. 130 Wheel Knuckle (60.25.23)..................................................................................... 133 Disassembly and Assembly......................................................................................... 139 Shock Absorber and Spring Assembly (60.30.21)................................................................ 139 204-02: Rear Suspension.............................................................................................. 141 Specification.................................................................................................... 141 Description and Operation........................................................................................ 142 Rear Suspension.............................................................................................. 142 Diagnosis and Testing............................................................................................ 144 Rear Suspension.............................................................................................. 144 Removal and Installation......................................................................................... 145 Damper....................................................................................................... 145 Front Lower Arm (64.35.51) - 4-Door.......................................................................... 147 Front Lower Arm (64.35.51) - Wagon........................................................................... 149 Rear Lower Arm (64.35.52).................................................................................... 154 Spring (64.20.01)............................................................................................ 157 Rear Stabilizer Bar (64.35.08)............................................................................... 160 Rear Stabilizer Bar Link (64.35.24).......................................................................... 161 Upper Arm (64.25.31)......................................................................................... 162 Wheel Hub (64.15.14)......................................................................................... 164 Wheel Knuckle (64.15.22)..................................................................................... 167 Wheel Knuckle Front Bushing (64.15.28)....................................................................... 173 Wheel Knuckle Rear Bushing (64.15.30)........................................................................ 174 204-04: Wheels and Tires............................................................................................. 177 Specification.................................................................................................... 177 Description and Operation........................................................................................ 178 Safety Precautions........................................................................................... 178 Wheels and Tires......................................................................................... 178 Diagnosis and Testing............................................................................................ 184 Wheels and Tires............................................................................................. 184 Removal and Installation......................................................................................... 187 Tire Low Pressure Sensor - VIN Range: J28493->V99999......................................................... 187 Tire Pressure Monitoring System (TPMS) Front Antenna - VIN Range: J28493->V99999............................. 189 Tire Pressure Monitoring System (TPMS) Main Antenna - VIN Range: J28493->V99999.............................. 190 Tire Pressure Monitoring System (TPMS) Module - VIN Range: J28493->V99999.................................... 192 Tire Pressure Monitoring System (TPMS) Rear Antenna - VIN Range: J28493->V99999.............................. 194 Wheel and Tire (74.20.05).................................................................................... 195 205: Driveline........................................................................................................... 196 205-00: Driveline System - General Information....................................................................... 196 Description and Operation........................................................................................ 196 Driveline System............................................................................................. 196 Diagnosis and Testing............................................................................................ 197 Driveline System............................................................................................. 197 205-01: Driveshaft................................................................................................... 199 Specification.................................................................................................... 199 Description and Operation........................................................................................ 200 Driveshaft................................................................................................... 200 Diagnosis and Testing............................................................................................ 201 Driveshaft................................................................................................... 201 General Procedures............................................................................................... 202 Driveshaft Runout and Balancing.............................................................................. 202 Removal and Installation......................................................................................... 203 Driveshaft (47.15.01)........................................................................................ 203 205-02: Rear Drive Axle/Differential................................................................................. 205 Specification.................................................................................................... 205 Description and Operation........................................................................................ 206 Rear Drive Axle and Differential............................................................................. 206 Diagnosis and Testing............................................................................................ 207 Rear Drive Axle and Differential............................................................................. 207 In-Vehicle Repair................................................................................................ 208 Axle Shaft Seal (51.20.04) (51.20.36)........................................................................ 208 Drive Pinion Flange.......................................................................................... 209 Drive Pinion Seal (51.20.01)................................................................................. 214 Removal and Installation......................................................................................... 219 Axle Assembly (51.25.13)..................................................................................... 219 205-04: Front Drive Halfshafts....................................................................................... 224 Specification.................................................................................................... 224 Description and Operation........................................................................................ 225 Front Drive Halfshafts....................................................................................... 225 Diagnosis and Testing............................................................................................ 226 Front Drive Halfshafts....................................................................................... 226 Removal and Installation......................................................................................... 227 Front Halfshaft LH (47.10.15)................................................................................ 227 Front Halfshaft RH (47.10.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 – AJ27......................... 233 Front Halfshaft RH (47.10.16) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma.................... 241 Inner Constant Velocity (CV) Joint Boot (47.10.18)........................................................... 246 Intermediate Shaft........................................................................................... 249 Outer Constant Velocity (CV) Joint Boot (47.10.19)........................................................... 251 205-05: Rear Drive Halfshafts........................................................................................ 253 Specification.................................................................................................... 253 Description and Operation........................................................................................ 254 Rear Drive Halfshafts........................................................................................ 254 Diagnosis and Testing............................................................................................ 255 Rear Drive Halfshafts........................................................................................ 255 Removal and Installation......................................................................................... 256 Rear Halfshaft (47.10.13).................................................................................... 256 Outer Constant Velocity (CV) Joint Boot (47.10.32)........................................................... 258 206: Brake System........................................................................................................ 260 206-00: Brake System - General Information........................................................................... 260 Specification.................................................................................................... 260 Description and Operation........................................................................................ 261 Brake System................................................................................................. 261 Diagnosis and Testing............................................................................................ 262 Brake System................................................................................................. 262 General Procedures............................................................................................... 270 Brake Disc Runout Check...................................................................................... 270 Brake System Bleeding (70.25.03)............................................................................. 271 206-03: Front Disc Brake............................................................................................. 273 Specification.................................................................................................... 273 Description and Operation........................................................................................ 274 Front Disc Brake............................................................................................. 274 Diagnosis and Testing............................................................................................ 275 Front Disc Brake............................................................................................. 275 Removal and Installation......................................................................................... 276 Brake Caliper (70.55.02)..................................................................................... 276 Brake Disc (70.10.10)........................................................................................ 278 Brake Pads (70.40.02)........................................................................................ 279 206-04: Rear Disc Brake.............................................................................................. 281 Specification.................................................................................................... 281 Description and Operation........................................................................................ 282 Rear Disc Brake.............................................................................................. 282 Diagnosis and Testing............................................................................................ 283 Rear Disc Brake.............................................................................................. 283 Removal and Installation......................................................................................... 284 Brake Caliper (70.55.03) (70.55.25).......................................................................... 284 Brake Disc (70.10.11)........................................................................................ 287 Brake Disc Shield (70.10.19)................................................................................. 288 Brake Pads (70.40.03)........................................................................................ 289 206-05: Parking Brake and Actuation.................................................................................. 292 Specification.................................................................................................... 292 Description and Operation........................................................................................ 293 Parking Brake................................................................................................ 293 Diagnosis and Testing............................................................................................ 294 Parking Brake................................................................................................ 294 Removal and Installation......................................................................................... 296 Parking Brake Cable (70.35.29) - Vehicles With: Manually Adjusted Parking Brake.............................. 296 Parking Brake Cable (70.35.29) - Vehicles With: Self-Adjusting Parking Brake................................. 298 Parking Brake Control (70.35.08) - Vehicles With: Manually Adjusted ParkingBrake............................. 300 Parking Brake Control (70.35.08) - Vehicles With: Self-Adjusting Parking Brake............................... 302 206-06: Hydraulic Brake Actuation.................................................................................... 305 Specification.................................................................................................... 305 Description and Operation........................................................................................ 306 Hydraulic Brake Actuation.................................................................................... 306 Diagnosis and Testing............................................................................................ 307 Hydraulic Brake Actuation.................................................................................... 307 Removal and Installation......................................................................................... 308 Brake Fluid Reservoir (70.30.16)............................................................................. 308 Brake Master Cylinder (70.30.08)............................................................................. 311 Brake Pedal and Bracket (70.35.03)........................................................................... 316 Brake Pedal Cross-Shaft...................................................................................... 326 206-07: Power Brake Actuation........................................................................................ 347 Specification.................................................................................................... 347 Description and Operation........................................................................................ 348 Brake Booster................................................................................................ 348 Diagnosis and Testing............................................................................................ 349 Power Brake System........................................................................................... 349 Removal and Installation......................................................................................... 350 Brake Booster (70.50.17) - LHD AWD/LHD FWD................................................................... 350 Brake Booster (70.50.17) - RHD AWD/RHD FWD................................................................... 360 Brake Vacuum Pump - 2.0L NA V6 - AJV6........................................................................ 371 Brake Vacuum Pump - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)– Puma................................ 372 206-09: Anti-Lock Control - Stability Assist......................................................................... 375 Specification.................................................................................................... 375 Description and Operation........................................................................................ 376 Anti-Lock Control - Stability Assist......................................................................... 376 Diagnosis and Testing............................................................................................ 378 Anti-Lock Control - Stability Assist - VIN Range: C00344->J12991............................................. 378 Anti-Lock Control - Stability Assist - VIN Range: J12992->V99999............................................. 387 Removal and Installation......................................................................................... 396 Anti-Lock Brake System (ABS) Module (70.60.02) - VIN Range: C00001->J12991................................... 396 Front Wheel Speed Sensor (70.60.03).......................................................................... 397 Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: C00001->J12991............................... 398 Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) - VIN Range: J12992->V99999............................... 400 Rear Wheel Speed Sensor (70.60.04)........................................................................... 402 Stability Assist Module...................................................................................... 404 Steering Wheel Rotation Sensor (86.56.58).................................................................... 405 Yaw Rate Sensor (86.56.57) - 2.0L Duratorq-TDCi/2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27......... 406 Yaw Rate Sensor (86.56.57) - 2.2L Duratorq-TDCi (110kW/150PS) – Puma......................................... 407 211: Steering System..................................................................................................... 409 211-00: Steering System - General Information........................................................................ 409 Specification.................................................................................................... 409 Description and Operation........................................................................................ 410 Steering System.............................................................................................. 410 Diagnosis and Testing............................................................................................ 411 Steering System.............................................................................................. 411 General Procedures............................................................................................... 423 Power Steering System Filling................................................................................ 423 Power Steering System Flushing (57.15.08).................................................................... 424 211-02: Power Steering............................................................................................... 427 Specification.................................................................................................... 427 Description and Operation........................................................................................ 428 Power Steering............................................................................................... 428 Diagnosis and Testing............................................................................................ 429 Power Steering............................................................................................... 429 General Procedures............................................................................................... 430 Start Up Procedure After Power Steering Pump/Gear Overhaul................................................... 430 Removal and Installation......................................................................................... 431 Power Steering Control Valve Actuator (57.10.32) - 2.5L NA V6 - AJV6/3.0L NAV6 - AJ27........................ 431 Power Steering Fluid Cooler (57.15.11) - 2.0L Duratorq-TDCi.................................................. 433 Power Steering Fluid Cooler (57.15.11) - 2.2L Duratorq-TDCi (110kW/150PS) –Puma.............................. 434 Power Steering Fluid Reservoir (57.15.08).................................................................... 436 Power Steering Pump (57.20.14) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27........................ 437 Power Steering Pump (57.20.14) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma................... 439 Steering Gear (57.10.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma......................... 446 Steering Gear (57.10.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27.............................. 451 211-03: Steering Linkage............................................................................................. 463 Specification.................................................................................................... 463 Description and Operation........................................................................................ 464 Steering Linkage............................................................................................. 464 Diagnosis and Testing............................................................................................ 465 Steering Linkage............................................................................................. 465 Removal and Installation......................................................................................... 466 Steering Gear Boot (57.10.29)................................................................................ 466 Tie Rod End (57.55.02)....................................................................................... 467 211-04: Steering Column.............................................................................................. 469 Specification.................................................................................................... 469 Description and Operation........................................................................................ 470 Steering Column.............................................................................................. 470 Diagnosis and Testing............................................................................................ 471 Steering Column.............................................................................................. 471 Removal and Installation......................................................................................... 472 Ignition Switch Lock Cylinder (57.40.29)..................................................................... 472 Steering Column (57.40.01)................................................................................... 473 Steering Column Coupling..................................................................................... 476 Steering Wheel (57.60.01).................................................................................... 477 211-05: Steering Column Switches..................................................................................... 478 Description and Operation........................................................................................ 478 Steering Column Switches..................................................................................... 478 Diagnosis and Testing............................................................................................ 479 Steering Column Switches..................................................................................... 479 Removal and Installation......................................................................................... 480 Steering Column Multifunction Switch LH (86.65.78)........................................................... 480 Steering Column Multifunction Switch RH (86.65.41)........................................................... 482 3: Powertrain................................................................................................................ 483 303: Engine.............................................................................................................. 483 303-00: Engine System - General Information.......................................................................... 483 Specification.................................................................................................... 483 Description and Operation........................................................................................ 486 Engine....................................................................................................... 486 Diagnosis and Testing............................................................................................ 487 Engine....................................................................................................... 487 General Procedures............................................................................................... 492 Bearing Inspection........................................................................................... 492 Camshaft Bearing Journal Clearance........................................................................... 493 Camshaft Bearing Journal Diameter............................................................................ 494 Camshaft End Play............................................................................................ 495 Camshaft Lobe Lift........................................................................................... 496 Camshaft Surface Inspection.................................................................................. 497 Connecting Rod Cleaning...................................................................................... 498 Connecting Rod Large End Bore................................................................................ 499 Crankshaft End Play.......................................................................................... 500 Crankshaft Main Bearing Journal Clearance.................................................................... 501 Crankshaft Main Bearing Journal Diameter..................................................................... 503 Cylinder Block Distortion.................................................................................... 504 Cylinder Bore Out-of-Round................................................................................... 505 Cylinder Head Distortion..................................................................................... 506 Exhaust Manifold Cleaning and Inspection..................................................................... 507 Flywheel Inspection.......................................................................................... 508 Piston Diameter.............................................................................................. 509 Piston Inspection............................................................................................ 510 Piston Pin Diameter.......................................................................................... 511 Piston Pin to Bore Diameter.................................................................................. 512 Piston Ring End Gap.......................................................................................... 513 Piston Ring-to-Groove Clearance.............................................................................. 514 Valve Seat Inspection........................................................................................ 515 Valve Spring Free Length..................................................................................... 516 Valve Stem Diameter.......................................................................................... 517 Leakage Test Using Smoke Test Equipment...................................................................... 518 303-01A: Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27.............................................. 520 Specification.................................................................................................... 520 Description and Operation........................................................................................ 522 Engine....................................................................................................... 522 Diagnosis and Testing............................................................................................ 525 Engine....................................................................................................... 525 General Procedures............................................................................................... 526 Valve Clearance Adjustment (12.29.48)........................................................................ 526 Valve Clearance Check (12.29.47)............................................................................. 527 In-Vehicle Repair................................................................................................ 528 Camshafts LH (12.13.19)...................................................................................... 528 Crankshaft Front Seal (12.21.14)............................................................................. 529 Crankshaft Pulley (12.21.09)................................................................................. 530 Crankshaft Rear Seal (12.21.20).............................................................................. 534 Cylinder Head LH (12.29.02).................................................................................. 536 Engine Front Cover (12.65.01)................................................................................ 542 Engine Front Mount (12.45.01)................................................................................ 564 Exhaust Manifold LH (30.15.55)............................................................................... 568 Flexplate (12.53.13)......................................................................................... 575 Exhaust Manifold RH (30.15.56)............................................................................... 576 Flywheel (12.53.07).......................................................................................... 578 Intake Manifold (30.15.01)................................................................................... 579 Lower Intake Manifold (30.15.61)............................................................................. 591 Oil Cooler (12.60.68)........................................................................................ 595 Oil Pan (12.60.44)........................................................................................... 596 Oil Pressure Sender.......................................................................................... 602 Oil Pump (12.60.26).......................................................................................... 603 Timing Drive Components (12.65.13)........................................................................... 605 Valve Cover LH (12.29.43).................................................................................... 614 Valve Cover RH (12.29.44).................................................................................... 617 Removal.......................................................................................................... 619 Engine (12.41.01) - Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed Manual Transaxle - MMT6........ 619 Engine (12.41.01) - Vehicles With: 5-Speed Automatic Transaxle - JATCO/6-SpeedAutomatic Transaxle - AWF21.... 643 Disassembly...................................................................................................... 668 Engine....................................................................................................... 668 Disassembly and Assembly of Subassemblies........................................................................ 688 Cylinder Head (12.29.22)..................................................................................... 688 Piston (12.17.02)............................................................................................ 691 Assembly......................................................................................................... 694 Engine....................................................................................................... 694 Installation..................................................................................................... 720 Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed Manual Transaxle - MMT6............................ 720 EngineVehiclesWith: 5-Speed Automatic Transaxle - JATCO/6-Speed Automatic Transaxle - AWF21.................. 743 303-01B: Engine - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma......................................... 766 Specification.................................................................................................... 766 Description and Operation........................................................................................ 767 Engine....................................................................................................... 767 In-Vehicle Repair................................................................................................ 773 Crankshaft Front Seal (12.21.14)............................................................................. 773 Crankshaft Rear Seal (12.21.20).............................................................................. 776 Engine Front Cover (12.65.01)................................................................................ 778 Engine Front Mount (12.45.01)................................................................................ 787 Flexplate (12.53.13)......................................................................................... 794 Flywheel (12.53.07).......................................................................................... 795 Intake Manifold (30.15.01)................................................................................... 796 Oil Pan (12.60.44)........................................................................................... 798 Timing Chain................................................................................................. 800 Valve Cover.................................................................................................. 806 Removal.......................................................................................................... 817 Engine (12.41.01) - 2.0L Duratorq-TDCi....................................................................... 817 Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma.................................................. 838 Disassembly...................................................................................................... 860 Engine....................................................................................................... 860 Assembly......................................................................................................... 888 Engine....................................................................................................... 888 Installation..................................................................................................... 928 Engine (12.41.01) - 2.0L Duratorq-TDCi....................................................................... 928 Engine (12.41.01) - 2.2L Duratorq-TDCi (110kW/150PS) – Puma.................................................. 947 303-03A: Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...................................... 968 Specification.................................................................................................... 968 Description and Operation........................................................................................ 969 Engine Cooling............................................................................................... 969 Diagnosis and Testing............................................................................................ 973 Engine Cooling............................................................................................... 973 General Procedures............................................................................................... 979 Cooling System Backflushing.................................................................................. 979 Cooling System Draining, Filling and Bleeding................................................................ 980 Cooling System Flushing...................................................................................... 983 Removal and Installation......................................................................................... 984 Block Heater (86.62.18)...................................................................................... 984 Coolant Expansion Tank (26.15.01)............................................................................ 985 Cooling Fan Module (26.25.38)................................................................................ 987 Cooling Fan Motor (26.25.24)................................................................................. 989 Cooling Fan Motor and Shroud (26.25.25)...................................................................... 990 Cooling Module (26.40.16).................................................................................... 993 Radiator (26.40.01)..........................................................................................1004 Thermostat (26.45.07)........................................................................................1005 Water Pump (26.50.01)........................................................................................1006 Water Pump Housing (26.50.07)................................................................................1007 303-03B: Engine Cooling - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma..................................1010 Specification....................................................................................................1010 Description and Operation........................................................................................1011 Engine Cooling...............................................................................................1011 General Procedures...............................................................................................1014 Cooling System Draining, Filling and Bleeding................................................................1014 Cooling System Draining and Vacuum Filling...................................................................1017 Removal and Installation.........................................................................................1021 Cooling Fan Motor and Shroud (26.25.25)......................................................................1021 Cooling Module (26.40.16)....................................................................................1022 Radiator (26.40.01)..........................................................................................1026 Water Pump (26.50.01)........................................................................................1027 303-04A: Fuel Charging and Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27...........................1034 Specification....................................................................................................1034 Description and Operation........................................................................................1035 Fuel Charging and Controls...................................................................................1035 Diagnosis and Testing............................................................................................1037 Fuel Charging and Controls - 2.0L NA V6 - AJV6...............................................................1037 Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:E96603->J28492...................1038 Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:J28493->V99999...................1045 Removal and Installation.........................................................................................1052 Fuel Charging Wiring Harness (86.70.22)......................................................................1052 Fuel Injection Supply Manifold (19.60.13)....................................................................1055 Fuel Injectors (18.10.02)....................................................................................1058 Fuel Pulse Damper (18.30.98) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...........................................1060 Throttle Body (19.70.04).....................................................................................1061 303-04B: Fuel Charging and Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma......................1065 Specification....................................................................................................1065 Description and Operation........................................................................................1066 Fuel Charging and Controls...................................................................................1066 Diagnosis and Testing............................................................................................1069 Fuel Charging and Controls...................................................................................1069 General Procedures...............................................................................................1073 Fuel Injection Component Cleaning............................................................................1073 Removal and Installation.........................................................................................1074 Fuel Injection Pump..........................................................................................1074 Fuel Injection Supply Manifold (19.60.13)....................................................................1099 Fuel Injector (18.10.01).....................................................................................1110 Fuel Metering Valve..........................................................................................1119 Fuel Return Line Venturi.....................................................................................1122 303-04C: Fuel Charging and Controls - Turbocharger...................................................................1126 Specification....................................................................................................1126 Description and Operation........................................................................................1127 Turbocharger.................................................................................................1127 Diagnosis and Testing............................................................................................1131 Turbocharger.................................................................................................1131 Removal and Installation.........................................................................................1137 Turbocharger.................................................................................................1137 303-05: Accessory Drive..............................................................................................1150 Specification....................................................................................................1150 Description and Operation........................................................................................1151 Accessory Drive..............................................................................................1151 Diagnosis and Testing............................................................................................1154 Accessory Drive..............................................................................................1154 Removal and Installation.........................................................................................1155 Accessory Drive Belt (12.10.40) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma..................1155 Accessory Drive Belt (12.10.40) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27.......................1159 Accessory Drive Belt Tensioner (12.10.41) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma.......1161 Accessory Drive Belt Tensioner (12.10.41) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27.............1166 Power Steering Pump Belt - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma.........................1167 Power Steering Pump Belt Tensioner - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma...............1171 Water Pump Belt (12.10.44) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27............................1173 Water Pump Belt Tensioner (12.10.45) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27..................1174 303-06: Starting System..............................................................................................1175 Specification....................................................................................................1175 Description and Operation........................................................................................1176 Starting System..............................................................................................1176 Diagnosis and Testing............................................................................................1179 Starting System - 2.0L NA V6 - AJV6..........................................................................1179 Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27........................................................1180 Removal and Installation.........................................................................................1184 Starter Motor (86.60.01) - 2.0L Duratorq-TDCi................................................................1184 Starter Motor (86.60.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma...........................................1188 Starter Motor (86.60.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27..............................1192 303-07A: Engine Ignition - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27.....................................1197 Specification....................................................................................................1197 Description and Operation........................................................................................1198 Engine Ignition..............................................................................................1198 Diagnosis and Testing............................................................................................1199 Engine Ignition - 2.0L NA V6 - AJV6..........................................................................1199 Engine Ignition - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27........................................................1200 Removal and Installation.........................................................................................1204 Ignition Coil-On-Plug LH (18.20.44)..........................................................................1204 Ignition Coil-On-Plug RH (18.20.43)..........................................................................1205 303-07B: Glow Plug System............................................................................................1206 Specification....................................................................................................1206 Description and Operation........................................................................................1207 Glow Plug System.............................................................................................1207 Diagnosis and Testing............................................................................................1209 Glow Plug System.............................................................................................1209 Removal and Installation.........................................................................................1213 Glow Plugs...................................................................................................1213 303-08: Engine Emission Control - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma..........................1215 Specification....................................................................................................1215 Description and Operation........................................................................................1216 Engine Emission Control......................................................................................1216 Diagnosis and Testing............................................................................................1217 Engine Emission Control......................................................................................1217 Removal and Installation.........................................................................................1218 Exhaust Gas Recirculation (EGR) Cooler.......................................................................1218 Exhaust Gas Recirculation (EGR) Cooler to EGR Valve Tube.....................................................1222 Exhaust Gas Recirculation (EGR) Valve (17.45.01).............................................................1226 303-12A: Intake Air Distribution and Filtering - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27................1230 Description and Operation........................................................................................1230 Intake Air Distribution and Filtering........................................................................1230 Diagnosis and Testing............................................................................................1231 Intake Air Distribution and Filtering........................................................................1231 Removal and Installation.........................................................................................1232 Air Cleaner (19.10.05).......................................................................................1232 Air Cleaner Element (19.10.08)...............................................................................1233 Air Cleaner Outlet Pipe (19.10.31)...........................................................................1235 303-12B: Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma..........1236 Specification....................................................................................................1236 Description and Operation........................................................................................1237 Intake Air Distribution and Filtering........................................................................1237 Diagnosis and Testing............................................................................................1239 Intake Air Distribution and Filtering........................................................................1239 Removal and Installation.........................................................................................1240 Air Cleaner (19.10.05).......................................................................................1240 Air Cleaner Element (19.10.08)...............................................................................1243 Air Cleaner Outlet Pipe (19.10.31)...........................................................................1245 Charge Air Cooler - 2.0L Duratorq-TDCi.......................................................................1248 Charge Air Cooler - 2.2L Duratorq-TDCi (110kW/150PS) – Puma..................................................1251 303-13: Evaporative Emissions........................................................................................1253 Specification....................................................................................................1253 Description and Operation........................................................................................1254 Evaporative Emissions........................................................................................1254 Diagnosis and Testing............................................................................................1255 Evaporative Emissions - 2.0L NA V6 - AJV6....................................................................1255 Evaporative Emissions - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27..................................................1256 Removal and Installation.........................................................................................1263 Evaporative Emission Canister (17.15.13) - 2.0L NA V6 - AJV6.................................................1263 Evaporative Emission Canister (17.15.13) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...............................1265 Evaporative Emission Canister Purge Valve (17.15.30).........................................................1273 303-14A: Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27...........................1275 Specification....................................................................................................1275 Description and Operation........................................................................................1276 Electronic Engine Controls...................................................................................1276 Diagnosis and Testing............................................................................................1282 Electronic Engine Controls - 2.0L NA V6 - AJV6...............................................................1282 Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:E96603->J28492...................1286 Electronic Engine Controls - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27, VIN Range:J28493->V99999...................1316 General Procedures...............................................................................................1347 Powertrain Control Module (PCM) Long Drive Cycle Self-Test...................................................1347 Powertrain Control Module (PCM) Short Drive Cycle Self-Test..................................................1348 Removal and Installation.........................................................................................1349 Camshaft Position (CMP) Sensor (18.30.63)....................................................................1349 Catalyst Monitor Sensor LH (18.30.81)........................................................................1350 Catalyst Monitor Sensor RH (18.30.80)........................................................................1352 Crankshaft Position (CKP) Sensor (18.30.12)..................................................................1354 Engine Control Module (ECM) (18.30.01).......................................................................1355 Fuel Temperature Sensor (18.30.99) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27.....................................1357 Heated Oxygen Sensor (HO2S) LH (18.30.79)....................................................................1359 Heated Oxygen Sensor (HO2S) RH (18.30.78)....................................................................1360 Knock Sensor (KS) (18.30.69).................................................................................1361 Mass Air Flow (MAF) Sensor (18.30.15)........................................................................1365 Oil Temperature Sensor (18.31.01)............................................................................1366 Throttle Position (TP) Sensor (18.30.17).....................................................................1367 Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)...............................................1369 303-14B: Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma......................1370 Specification....................................................................................................1370 Description and Operation........................................................................................1371 Electronic Engine Controls...................................................................................1371 Diagnosis and Testing............................................................................................1373 Electronic Engine Controls...................................................................................1373 Removal and Installation.........................................................................................1386 Camshaft Position (CMP) Sensor (18.30.63)....................................................................1386 Catalytic Converter Temperature Sensor.......................................................................1387 Crankshaft Position (CKP) Sensor (18.30.12)..................................................................1391 Cylinder Head Temperature (CHT) Sensor (18.30.97)............................................................1393 Diesel Particulate Filter (DPF) Temperature Sensor...........................................................1396 Engine Control Module (ECM) (18.30.01).......................................................................1397 Engine Oil Pressure (EOP) Sensor.............................................................................1399 Fuel Temperature Sensor (18.30.99)...........................................................................1400 Knock Sensor (KS) (18.30.69).................................................................................1402 Manifold Absolute Pressure and Temperature (MAPT) Sensor.....................................................1404 Manifold Absolute Pressure (MAP) Sensor (18.30.86)...........................................................1408 Mass Air Flow (MAF) Sensor (18.30.15)........................................................................1410 307: Automatic Transmission/Transaxle....................................................................................1412 307-01A: Automatic Transmission/Transaxle - Vehicles With: 5-Speed AutomaticTransaxle - JATCO........................1412 Specification....................................................................................................1412 Description and Operation........................................................................................1413 Transmission Description - Vehicles With: 5-Speed Automatic Transaxle - JATCO................................1413 Diagnosis and Testing............................................................................................1428 Diagnostic Strategy - Vehicles With: 5-Speed Automatic Transaxle - JATCO.....................................1428 General Procedures...............................................................................................1441 Transmission Fluid Drain and Refill (44.24.02)...............................................................1441 Transmission Fluid Level Check...............................................................................1442 Transmission Range (TR) Sensor Adjustment (44.15.37).........................................................1444 In-Vehicle Repair................................................................................................1445 Halfshaft Seal LH (37.23.10).................................................................................1445 Halfshaft Seal RH............................................................................................1446 Main Control Valve Body (44.40.01)...........................................................................1447 Shift Solenoids (SS) (44.15.50)..............................................................................1451 Transaxle Support Insulator (37.16.42).......................................................................1452 Transmission Control Module (TCM) (44.15.32).................................................................1456 Transmission Range (TR) Sensor...............................................................................1459 Removal..........................................................................................................1460 Transaxle (44.20.01).........................................................................................1460 Disassembly and Assembly of Subassemblies........................................................................1471 Input Shaft Seal (44.32.07)..................................................................................1471 Installation.....................................................................................................1473 Transaxle (44.20.01).........................................................................................1473 307-01B: Automatic Transmission/Transaxle - Vehicles With: 6-Speed AutomaticTransaxle - AWF21........................1484 Specification....................................................................................................1484 Description and Operation........................................................................................1485 Transmission Description - Vehicles With: 6-Speed Automatic Transaxle - AWF21................................1485 Transmission Electronic Control System - Vehicles With: 6-Speed Automatic....................................1497 Diagnosis and Testing............................................................................................1501 Diagnostic Strategy - Vehicles With: 6-Speed Automatic Transaxle - AWF21.....................................1501 General Procedures...............................................................................................1513 Transmission Fluid Drain and Refill (44.24.02)...............................................................1513 Transmission Fluid Level Check...............................................................................1516 In-Vehicle Repair................................................................................................1518 Main Control Valve Body (44.40.01)...........................................................................1518 Selector Shaft Seal..........................................................................................1522 Transmission Control Module (TCM) (44.15.32).................................................................1523 Transmission Internal Wiring Harness (44.15.35)..............................................................1525 Transmission Fluid Pan (44.24.04)............................................................................1527 Removal and Installation.........................................................................................1529 Torque Converter.............................................................................................1529 Torque Converter Seal........................................................................................1530 Turbine Shaft Speed (TSS) Sensor.............................................................................1531 Removal..........................................................................................................1532 Transmission (44.20.01)......................................................................................1532 Installation.....................................................................................................1539 Transmission (44.20.01)......................................................................................1539 307-02A: Transmission/Transaxle Cooling - Vehicles With: 5-Speed AutomaticTransaxle - JATCO..........................1546 Specification....................................................................................................1546 Description and Operation........................................................................................1547 Transmission Cooling - Vehicles With: 5-Speed Automatic Transaxle - JATCO....................................1547 Diagnosis and Testing............................................................................................1548 Transmission Cooling.........................................................................................1548 Removal and Installation.........................................................................................1549 Transmission Fluid Cooler (44.24.10).........................................................................1549 Transmission Fluid Cooler Tubes (44.24.19)...................................................................1551 307-02B: Transmission/Transaxle Cooling - Vehicles With: 6-Speed AutomaticTransaxle - AWF21..........................1552 Specification....................................................................................................1552 Description and Operation........................................................................................1553 Transmission Cooling - Vehicles With: 6-Speed Automatic Transaxle - AWF21....................................1553 Diagnosis and Testing............................................................................................1554 Transmission Cooling.........................................................................................1554 Removal and Installation.........................................................................................1555 Transmission Fluid Cooler (44.24.10).........................................................................1555 Transmission Fluid Cooler Return Tube (44.24.13) (44.24.29)..................................................1556 Transmission Fluid Cooler Supply Tube (44.24.14) (44.24.28)..................................................1558 307-05A: Automatic Transmission/Transaxle External Controls..........................................................1560 Specification....................................................................................................1560 Description and Operation........................................................................................1561 External Controls - Vehicles With: 5-Speed Automatic Transaxle - JATCO.......................................1561 Diagnosis and Testing............................................................................................1563 External Controls............................................................................................1563 General Procedures...............................................................................................1566 Selector Lever Cable Adjustment (44.15.07)...................................................................1566 Removal and Installation.........................................................................................1568 Selector Lever Cable and Bracket (44.15.08)..................................................................1568 Selector Lever Assembly (44.15.04)...........................................................................1572 307-05B: Automatic Transmission/Transaxle External Controls - Vehicles With:6-Speed Automatic Transaxle - AWF21......1577 Specification....................................................................................................1577 Description and Operation........................................................................................1578 External Controls - Vehicles With: 6-Speed Automatic Transaxle - AWF21.......................................1578 Diagnosis and Testing............................................................................................1582 External Controls............................................................................................1582 General Procedures...............................................................................................1585 Selector Lever Cable Adjustment (44.15.07)...................................................................1585 Removal and Installation.........................................................................................1587 Selector Lever Assembly (44.15.04)...........................................................................1587 Selector Lever Knob (44.15.06)...............................................................................1590 308: Manual Transmission/Transaxle, Clutch and Transfer Case.............................................................1591 308-00: Manual Transmission/Transaxle and Clutch - General Information...............................................1591 Specification....................................................................................................1591 Description and Operation........................................................................................1592 Manual Transmission and Clutch...............................................................................1592 Diagnosis and Testing............................................................................................1593 Manual Transmission and Clutch...............................................................................1593 General Procedures...............................................................................................1598 Clutch System Bleeding (33.15.01) - Vehicles With: 5-Speed ManualTransmission - MT75.........................1598 Clutch System Bleeding (33.15.01) - Vehicles With: 6-Speed Manual Transaxle –MMT6............................1599 Gearshift Cable Adjustment (37.16.47)........................................................................1600 Release Hub and Bearing Check................................................................................1603 308-01: Clutch.......................................................................................................1604 Specification....................................................................................................1604 Description and Operation........................................................................................1605 Clutch.......................................................................................................1605 Diagnosis and Testing............................................................................................1606 Clutch.......................................................................................................1606 Removal and Installation.........................................................................................1607 Clutch Disc and Pressure Plate (12.53.13) (33.10.01).........................................................1607 308-02: Clutch Controls..............................................................................................1609 Specification....................................................................................................1609 Description and Operation........................................................................................1610 Clutch Controls..............................................................................................1610 Diagnosis and Testing............................................................................................1613 Clutch Controls..............................................................................................1613 Removal and Installation.........................................................................................1614 Clutch Master Cylinder (33.20.01)............................................................................1614 Clutch Slave Cylinder (33.35.01) - Vehicles With: 5-Speed Manual Transmission –MT75..........................1619 Clutch Slave Cylinder (33.35.01) - Vehicles With: 6-Speed Manual Transaxle –MMT6.............................1620 308-03: Manual Transmission/Transaxle................................................................................1622 Specification....................................................................................................1622 Description and Operation........................................................................................1623 Manual Transaxle - Vehicles With: 5-Speed Manual Transmission - MT75.........................................1623 Manual Transaxle - Vehicles With: 6-Speed Manual Transaxle - MMT6............................................1624 Diagnosis and Testing............................................................................................1634 Manual Transaxle.............................................................................................1634 General Procedures...............................................................................................1635 Transaxle Draining and Filling (44.24.02) - Vehicles With: 5-Speed ManualTransmission - MT75.................1635 Transaxle Draining and Filling (44.24.02) - Vehicles With: 6-Speed ManualTransaxle - MMT6....................1636 In-Vehicle Repair................................................................................................1637 Halfshaft Seal LH............................................................................................1637 Halfshaft Seal RH............................................................................................1638 Input Shaft Seal (37.23.09)..................................................................................1639 Selector Mechanism - Vehicles With: 5-Speed Manual Transmission - MT75.......................................1640 Selector Mechanism - Vehicles With: 6-Speed Manual Transaxle - MMT6..........................................1657 Support Insulator (37.16.42).................................................................................1661 Removal..........................................................................................................1666 Transaxle (37.20.01) - 2.0L Duratorq-TDCi....................................................................1666 Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma...............................................1675 Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27.................................1682 Installation.....................................................................................................1692 Transaxle (37.20.01) - 2.0L Duratorq-TDCi....................................................................1692 Transaxle (37.20.01) - 2.2L Duratorq-TDCi (110kW/150PS) - Puma...............................................1700 Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27.................................1707 308-06: Manual Transmission/Transaxle External Controls..............................................................1717 Specification....................................................................................................1717 Description and Operation........................................................................................1718 External Controls............................................................................................1718 Diagnosis and Testing............................................................................................1720 External Controls............................................................................................1720 Removal and Installation.........................................................................................1721 Gearshift Cables (37.16.45) - Vehicles With: 5-Speed Manual Transmission –MT75...............................1721 Gearshift Cables (37.16.45) - Vehicles With: 6-Speed Manual Transaxle - MMT6.................................1725 Gearshift Lever (37.16.04) - Vehicles With: 5-Speed Manual Transmission - MT75...............................1728 Gearshift Lever (37.16.04) - Vehicles With: 6-Speed Manual Transaxle - MMT6..................................1730 308-07: Transfer Case................................................................................................1732 Specification....................................................................................................1732 Description and Operation........................................................................................1733 Transfer Case................................................................................................1733 General Procedures...............................................................................................1734 Transfer Case Draining and Filling...........................................................................1734 In-Vehicle Repair................................................................................................1742 Halfshaft Seal RH (46.10.03).................................................................................1742 Transfer Case Rear Output Shaft Seal (46.10.04)..............................................................1743 Removal..........................................................................................................1751 Transfer Case (46.10.01).....................................................................................1751 Installation.....................................................................................................1761 Transfer Case (46.10.01).....................................................................................1761 309: Exhaust System......................................................................................................1772 309-00: Exhaust System...............................................................................................1772 Specification....................................................................................................1772 Description and Operation........................................................................................1773 Exhaust System...............................................................................................1773 Diagnosis and Testing............................................................................................1780 Exhaust System...............................................................................................1780 Removal and Installation.........................................................................................1782 Catalytic Converter (17.50.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma...................1782 Catalytic Converter LH (17.50.15) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27.....................1787 Catalytic Converter RH (17.50.16) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NAV6 - AJ27.....................1793 Diesel Particulate Filter (DPF)..............................................................................1796 Diesel Particulate Filter (DPF) Differential Pressure Sensor.................................................1799 Exhaust Flexible Pipe (30.10.57) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma.................1801 Front Muffler (30.10.18) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma.........................1803 Front Muffler (30.10.18) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27.............................1805 Muffler and Tailpipe (30.10.52) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma, 2.0L............1808 Muffler and Tailpipe (30.10.52) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27........................................1809 Muffler Inlet Pipe (30.10.06) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27.........................1810 Muffler Inlet Pipe (30.10.06) - Vehicles With: Diesel Particulate Filter (DPF)...............................1814 310: Fuel System.........................................................................................................1816 310-00: Fuel System - General Information............................................................................1816 Specification....................................................................................................1816 Description and Operation........................................................................................1817 Fuel System..................................................................................................1817 Diagnosis and Testing............................................................................................1821 Fuel System..................................................................................................1821 General Procedures...............................................................................................1825 Fuel System Pressure Check...................................................................................1825 Fuel System Pressure Release (19.50.02)......................................................................1827 Fuel Tank Draining - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma...............................1828 Fuel Tank Draining - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...................................1829 Quick Release Coupling - Push Connect........................................................................1833 Spring Lock Couplings........................................................................................1838 310-01: Fuel Tank and Lines..........................................................................................1841 Specification....................................................................................................1841 Description and Operation........................................................................................1842 Fuel Tank and Lines..........................................................................................1842 Diagnosis and Testing............................................................................................1846 Fuel Tank and Lines..........................................................................................1846 Removal and Installation.........................................................................................1855 Fuel Filter (19.25.02) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma...........................1855 Fuel Filter (19.25.02) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...............................1858 Fuel Level Sender - 2.0L NA V6 - AJV6........................................................................1860 Fuel Level Sender - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma................................1862 Fuel Level Sender LH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...................................................1864 Fuel Level Sender RH - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...................................................1866 Fuel Level Sensor (88.25.32) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma.....................1867 Fuel Pump Module (19.45.08) - 2.0L NA V6 - AJV6..............................................................1869 Fuel Pump Module (19.45.08) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27............................................1871 Fuel Tank (19.55.01) - 2.0L NA V6 - AJV6.....................................................................1877 Fuel Tank (19.55.01) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma.............................1882 Fuel Tank (19.55.01) - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27...................................................1886 Fuel Tank Filler Pipe (19.55.33).............................................................................1899 Gas Fuel Tank Pressure Sensor (19.55.31).....................................................................1901 Fuel Transfer Pump (19.45.21)................................................................................1902 Inertia Fuel Shutoff (IFS) Switch (18.30.35).................................................................1906 Fuel Tank Filler Pipe Hose...................................................................................1907 310-02: Acceleration Control.........................................................................................1909 Specification....................................................................................................1909 Description and Operation........................................................................................1910 Acceleration Control.........................................................................................1910 Diagnosis and Testing............................................................................................1911 Acceleration Control.........................................................................................1911 General Procedures...............................................................................................1916 Accelerator Cable Adjustment (12.20.05) - 2.0L NA V6 - AJV6..................................................1916 Removal and Installation.........................................................................................1917 Accelerator Cable (19.20.06) - 2.0L NA V6 - AJV6.............................................................1917 Accelerator Pedal (19.20.01).................................................................................1919 310-03: Speed Control................................................................................................1921 Specification....................................................................................................1921 Description and Operation........................................................................................1922 Speed Control................................................................................................1922 Diagnosis and Testing............................................................................................1925 Speed Control - 2.0L NA V6 - AJV6............................................................................1925 Speed Control - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27..........................................................1926 Removal and Installation.........................................................................................1932 Speed Control Deactivator Switch (19.75.20)..................................................................1932 Speed Control Module (19.75.26)..............................................................................1933 Speed Control Switch (19.75.25)..............................................................................1936 4: Electrical................................................................................................................1937 412: Climate Control System..............................................................................................1937 412-00: Climate Control System - General Information.................................................................1937 Specification....................................................................................................1937 Description and Operation........................................................................................1938 Climate Control System.......................................................................................1938 Diagnosis and Testing............................................................................................1939 Climate Control System.......................................................................................1939 General Procedures...............................................................................................1943 Air Conditioning (A/C) Compressor Leak Detection.............................................................1943 Air Conditioning (A/C) System Flushing.......................................................................1944 Air Conditioning (A/C) System Recovery, Evacuation and Charging (82.30.30)...................................1946 Contaminated Refrigerant Handling............................................................................1947 Discharging and Recovery (82.30.30)..........................................................................1948 Electronic Leak Detection....................................................................................1949 Inspection and Assembly Requirements.........................................................................1950 Leak Detection...............................................................................................1951 Refrigerant Oil Adding.......................................................................................1952 Refrigerant System Tests.....................................................................................1953 412-01: Air Distribution and Filtering...............................................................................1954 Description and Operation........................................................................................1954 Air Distribution and Filtering...............................................................................1954 Diagnosis and Testing............................................................................................1955 Air Distribution and Filtering...............................................................................1955 Removal and Installation.........................................................................................1956 Center Registers (82.20.38)..................................................................................1956 Driver Side Register (82.20.39)..............................................................................1957 Front Footwell Duct LH (82.20.91)............................................................................1958 Front Footwell Duct RH (82.20.92)............................................................................1959 Passenger Side Register (82.20.40)...........................................................................1960 Pollen Filter (76.10.09).....................................................................................1961 412-02A: Heating and Ventilation.....................................................................................1962 Specification....................................................................................................1962 Description and Operation........................................................................................1963 Heating and Ventilation......................................................................................1963 Diagnosis and Testing............................................................................................1964 Heating and Ventilation......................................................................................1964 Removal and Installation.........................................................................................1965 Blower Motor (82.25.66)......................................................................................1965 Evaporator Core Housing (80.20.01)...........................................................................1966 Heater Core (80.20.29).......................................................................................1972 Disassembly and Assembly.........................................................................................1975 Evaporator Core Housing......................................................................................1975 412-02B: Auxiliary Heating...........................................................................................1980 Specification....................................................................................................1980 Description and Operation........................................................................................1981 Electric Booster Heater......................................................................................1981 Fuel Fired Booster Heater....................................................................................1983 Diagnosis and Testing............................................................................................1986 Auxiliary Heater.............................................................................................1986 Fuel Fired Booster Heater....................................................................................1996 Removal and Installation.........................................................................................2000 Electric Booster Heater......................................................................................2000 Fuel Fired Booster Heater....................................................................................2002 412-03: Air Conditioning.............................................................................................2006 Specification....................................................................................................2006 Description and Operation........................................................................................2007 Air Conditioning.............................................................................................2007 Diagnosis and Testing............................................................................................2009 Air Conditioning.............................................................................................2009 Removal and Installation.........................................................................................2010 Air Conditioning (A/C) Compressor (82.10.20) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27..........2010 Air Conditioning (A/C) Compressor (82.10.20) - 2.0L Duratorq-TDCi/2.2LDuratorq-TDCi (110kW/150PS) - Puma.....2012 Air Conditioning (A/C) Pressure Transducer (82.10.47)........................................................2016 Clutch and Clutch Field Coil (82.10.25) - 2.0L NA V6 - AJV6/2.5L NA V6 –AJV6/3.0L NA V6 - AJ27...............2017 Condenser Core (82.15.07)....................................................................................2022 Evaporator Core (82.25.20)...................................................................................2024 Evaporator Core Orifice (82.25.67)...........................................................................2026 Suction Accumulator (82.17.02)...............................................................................2027 412-04: Control Components...........................................................................................2029 Description and Operation........................................................................................2029 Control Components...........................................................................................2029 Diagnosis and Testing............................................................................................2032 Control Components...........................................................................................2032 Removal and Installation.........................................................................................2033 Air Discharge Temperature Sensor (82.20.64)..................................................................2033 Ambient Air Temperature Sensor (82.20.02)....................................................................2034 Climate Control Assembly (82.20.07)..........................................................................2035 Defrost Vent/Register Blend Door Actuator (82.20.84).........................................................2038 Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85)................................................2039 Sunload Sensor (82.20.70)....................................................................................2040 Temperature Blend Door Actuator (82.20.86)...................................................................2042 413: Instrumentation and Warning Systems.................................................................................2043 413-00: Instrument Cluster and Panel Illumination....................................................................2043 Diagnosis and Testing............................................................................................2043 Instrument Cluster and Panel Illumination....................................................................2043 413-01: Instrument Cluster...........................................................................................2044 Description and Operation........................................................................................2044 Instrument Cluster...........................................................................................2044 Diagnosis and Testing............................................................................................2047 Instrument Cluster...........................................................................................2047 Removal and Installation.........................................................................................2048 Instrument Cluster (88.20.01)................................................................................2048 413-06: Horn.........................................................................................................2049 Description and Operation........................................................................................2049 Diagnosis and Testing............................................................................................2051 Removal and Installation.........................................................................................2052 Horn (86.30.02) (86.30.10)...................................................................................2052 Horn Switch (86.30.01).......................................................................................2053 413-08: Information and Message Center...............................................................................2054 Description and Operation........................................................................................2054 Information and Message Center...............................................................................2054 Diagnosis and Testing............................................................................................2055 Information and Message Center...............................................................................2055 Removal and Installation.........................................................................................2056 Message Center...............................................................................................2056 Message Center Switch (86.66.11).............................................................................2057 413-09: Warning Devices..............................................................................................2058 Description and Operation........................................................................................2058 Warning Devices..............................................................................................2058 Diagnosis and Testing............................................................................................2061 Warning Devices..............................................................................................2061 General Procedures...............................................................................................2062 Oil Change Indicator Reset...................................................................................2062 Removal and Installation.........................................................................................2063 Low Washer Fluid Warning Indicator Switch (84.10.17).........................................................2063 413-13: Parking Aid..................................................................................................2064 Description and Operation........................................................................................2064 Parking Aid..................................................................................................2064 Diagnosis and Testing............................................................................................2066 Parking Aid..................................................................................................2066 Removal and Installation.........................................................................................2068 Front Parking Aid Sensor (86.62.33)..........................................................................2068 Front Parking Aid Speaker (86.54.18) (86.62.34)..............................................................2069 Parking Aid Module (86.80.39) - 4-Door.......................................................................2072 Parking Aid Module (86.80.39) - Wagon........................................................................2073 Rear Parking Aid Sensor (86.54.14) (86.62.01)................................................................2075 Rear Parking Aid Speaker (86.54.19) (86.62.02) - 4-Door......................................................2076 Rear Parking Aid Speaker (86.54.19) (86.62.02) - Wagon, VIN Range: D86655->E43419............................2077 Rear Parking Aid Speaker (86.54.19) (86.62.02) - Wagon, VIN Range: E43420->V99999............................2079 414: Battery and Charging System.........................................................................................2081 414-00: Battery and Charging System - General Information............................................................2081 Description and Operation........................................................................................2081 Charging System..............................................................................................2081 Battery Care.................................................................................................2082 Quiescent Drain..............................................................................................2091 Diagnosis and Testing............................................................................................2092 Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27......................................2092 Charging System - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma..................................2099 General Procedures...............................................................................................2104 Battery Charging.............................................................................................2104 414-01: Battery, Mounting and Cables.................................................................................2105 Specification....................................................................................................2105 Description and Operation........................................................................................2106 Battery and Cables...........................................................................................2106 Diagnosis and Testing............................................................................................2108 Battery......................................................................................................2108 General Procedures...............................................................................................2109 Battery Connect (86.15.15)...................................................................................2109 Battery Disconnect and Connect...............................................................................2110 Removal and Installation.........................................................................................2111 Battery (86.15.01)...........................................................................................2111 Battery Cables (86.15.32) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27.............................2113 Battery Cables (86.15.32) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma........................2117 Battery Tray (86.15.11)......................................................................................2122 414-02: Generator and Regulator......................................................................................2123 Specification....................................................................................................2123 Description and Operation........................................................................................2124 Generator....................................................................................................2124 Diagnosis and Testing............................................................................................2126 Generator....................................................................................................2126 Removal and Installation.........................................................................................2127 Generator (86.10.02) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27.................................2127 Generator (86.10.02) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) –Puma.............................2129 415: Information and Entertainment Systems...............................................................................2135 415-00: Information and Entertainment System - General Information...................................................2135 Diagnosis and Testing............................................................................................2135 Audio System.................................................................................................2135 415-01: Audio Unit...............................................................................................2139 Description and Operation....................................................................................2139 Audio System.............................................................................................2139 Diagnosis and Testing........................................................................................2143 Audio System.............................................................................................2143 Removal and Installation.....................................................................................2144 Audio Unit (86.50.03)....................................................................................2144 Audio Unit Amplifier (86.50.10) (86.50.36) - 4-Door......................................................2145 Audio Unit Amplifier (86.50.10) (86.50.36) - Wagon.......................................................2147 Compact Disc (CD) Changer (86.50.06) - 4-Door............................................................2150 Compact Disc (CD) Changer (86.50.06) - Wagon.............................................................2153 Steering Wheel Audio Controls (86.50.42).................................................................2158 415-02: Antenna..................................................................................................2159 Specification................................................................................................2159 Description and Operation....................................................................................2160 Antenna..................................................................................................2160 Diagnosis and Testing........................................................................................2163 Antenna..................................................................................................2163 Removal and Installation.....................................................................................2164 Antenna (86.51.17.60) - Wagon............................................................................2164 Module...................................................................................................2168 415-03: Speakers.................................................................................................2169 Description and Operation....................................................................................2169 Speakers.................................................................................................2169 Diagnosis and Testing........................................................................................2170 Speakers.................................................................................................2170 Removal and Installation.....................................................................................2171 Front Door Speaker (86.50.13)............................................................................2171 Front Door Tweeter Speaker (86.50.63)....................................................................2172 Parcel Shelf Speaker (86.51.06)..........................................................................2173 Rear Door Speaker (86.50.14).............................................................................2174 Rear Door Tweeter Speaker (86.50.62).....................................................................2175 417: Lighting............................................................................................................2176 417-01: Exterior Lighting............................................................................................2176 Specification....................................................................................................2176 Description and Operation........................................................................................2177 Exterior Lighting............................................................................................2177 Diagnosis and Testing............................................................................................2178 Headlamps....................................................................................................2178 General Procedures...............................................................................................2180 Headlamp Adjustment (86.40.18)...............................................................................2180 Removal and Installation.........................................................................................2181 Ballast (86.41.52)...........................................................................................2181 Front Fog Lamp (86.40.96)....................................................................................2182 Headlamp Assembly (86.41.33).................................................................................2183 Headlamp Bulb (86.42.14) - Vehicles With: High Intensity Discharge Headlamps.................................2185 Headlamp Leveling Module.....................................................................................2186 Headlamp Leveling Sensor (86.42.15)..........................................................................2187 Headlamp Switch (86.65.26)...................................................................................2189 High Mounted Stoplamp (86.41.01) (86.41.32) - 4-Door.........................................................2190 High Mounted Stoplamp (86.41.01) (86.41.32) - Wagon..........................................................2191 Rear Lamp Assembly (86.40.70) - 4-Door.......................................................................2192 Rear Lamp Assembly (86.40.70) – Wagon........................................................................2193 417-02: Interior Lighting............................................................................................2194 Description and Operation........................................................................................2194 Interior Lighting............................................................................................2194 Diagnosis and Testing............................................................................................2195 Interior Lighting............................................................................................2195 Removal and Installation.........................................................................................2196 Front Interior Lamp (86.45.12)...............................................................................2196 Rear Interior Lamp (86.46.03)................................................................................2197 417-04: Daytime Running Lamps (DRL)..................................................................................2198 Description and Operation........................................................................................2198 Daytime Running Lamps (DRL)..................................................................................2198 Diagnosis and Testing............................................................................................2199 Daytime Running Lamps (DRL)..................................................................................2199 418: Electrical Distribution.............................................................................................2200 418-00: Module Communications Network................................................................................2200 Description and Operation........................................................................................2200 Communications Network.......................................................................................2200 Diagnosis and Testing............................................................................................2201 Communications Network - VIN Range: E96603->J28492...........................................................2201 Communications Network - VIN Range: J28493->V99999...........................................................2239 418-01: Module Configuration.........................................................................................2280 Diagnosis and Testing............................................................................................2280 Module Configuration.........................................................................................2280 General Procedures...............................................................................................2281 Module Configuration.........................................................................................2281 418-02: Wiring Harnesses.............................................................................................2282 Description and Operation........................................................................................2282 Wiring Harness...............................................................................................2282 General Procedures...............................................................................................2293 Wiring Harness Repair........................................................................................2293 419: Electronic Feature Group............................................................................................2294 419-01A: Anti-Theft - Active.........................................................................................2294 Description and Operation........................................................................................2294 Anti-Theft - Active..........................................................................................2294 Diagnosis and Testing............................................................................................2296 Anti-Theft - Active..........................................................................................2296 Removal and Installation.........................................................................................2297 Anti-Theft Alarm Horn (86.52.03).............................................................................2297 419-01B: Anti-Theft - Passive........................................................................................2298 Description and Operation........................................................................................2298 Anti-Theft - Passive.........................................................................................2298 Diagnosis and Testing............................................................................................2299 Anti-Theft - Passive.........................................................................................2299 General Procedures...............................................................................................2300 Anti-Theft Security Access...................................................................................2300 Key Programming Using Diagnostic Equipment...................................................................2301 Removal and Installation.........................................................................................2302 Passive Anti-Theft System (PATS) Transceiver (86.52.30)......................................................2302 419-02: Remote Convenience...........................................................................................2303 Description and Operation........................................................................................2303 Universal Transmitter........................................................................................2303 Diagnosis and Testing............................................................................................2304 Universal Transmitter........................................................................................2304 General Procedures...............................................................................................2305 Universal Transmitter Programming............................................................................2305 419-07: Navigation System............................................................................................2307 Description and Operation........................................................................................2307 Navigation System............................................................................................2307 Diagnosis and Testing............................................................................................2309 Navigation System............................................................................................2309 Removal and Installation.........................................................................................2311 Navigation System Antenna (86.62.06) - 4-Door, VIN Range: E96603->J39905.....................................2311 Navigation System Antenna (86.62.06) - 4-Door, VIN Range: J39906->V99999.....................................2313 Navigation System Antenna (86.62.06) - Wagon.................................................................2315 Navigation System Display Module (86.62.07)..................................................................2316 Navigation System Module (86.62.05) - 4-Door.................................................................2319 Navigation System Module (86.62.05) – Wagon..................................................................2322 419-08: Cellular Phone...............................................................................................2327 Specification....................................................................................................2327 Description and Operation........................................................................................2328 Cellular Phone...............................................................................................2328 Diagnosis and Testing............................................................................................2331 Cellular Phone...............................................................................................2331 Cellular Phone - Vehicles With: Bluetooth....................................................................2333 Removal and Installation.........................................................................................2350 Bluetooth Module.............................................................................................2350 Handset Holder (86.51.12)....................................................................................2351 Module - 4-Door..............................................................................................2355 Module – Wagon...............................................................................................2356 419-10: Multifunction Electronic Modules.............................................................................2357 Specification....................................................................................................2357 Description and Operation........................................................................................2358 Module Controlled Functions..................................................................................2358 Diagnosis and Testing............................................................................................2360 Multifunction Electronic Module..............................................................................2360 Removal and Installation.........................................................................................2363 Generic Electronic Module (GEM) (86.55.75) (86.80.38)........................................................2363 Multifunction Voice Activated Module (86.53.13) (86.80.40) - 4-Door..........................................2364 Multifunction Voice Activated Module (86.53.13) (86.80.40) – Wagon...........................................2366 5: Body and Paint............................................................................................................2367 501: Body and Paint......................................................................................................2367 501-02: Front End Body Panels........................................................................................2367 Description and Operation........................................................................................2367 Front End Body Panels........................................................................................2367 Removal and Installation.........................................................................................2368 Air Deflector (76.11.41) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS)- Puma.........................2368 Cowl Vent Screen (76.10.01)..................................................................................2369 Fender Splash Shield (76.10.90)..............................................................................2370 Radiator Splash Shield (76.22.90)............................................................................2371 501-03: Body Closures................................................................................................2372 Specification....................................................................................................2372 Description and Operation........................................................................................2373 Body Closures................................................................................................2373 General Procedures...............................................................................................2374 Door Alignment...............................................................................................2374 Hood Alignment (76.16.02)....................................................................................2376 Liftgate Alignment (76.19.54.60).............................................................................2378 Luggage Compartment Lid Alignment (76.19.03).................................................................2382 Removal and Installation.........................................................................................2385 Weatherstrip.................................................................................................2385 501-05: Interior Trim and Ornamentation..............................................................................2388 Specification....................................................................................................2388 Description and Operation........................................................................................2389 Interior Trim................................................................................................2389 Removal and Installation.........................................................................................2390 A-Pillar Trim Panel (76.13.31)...............................................................................2390 B-Pillar Lower Trim Panel (76.13.29).........................................................................2391 B-Pillar Upper Trim Panel (76.13.28).........................................................................2392 Cowl Side Trim Panel (76.13.30)..............................................................................2394 C-Pillar Trim Panel (76.13.73) - 4-Door......................................................................2395 C-Pillar Trim Panel (76.13.73) - Wagon.......................................................................2396 D-Pillar Trim Panel (76.13.73.60)............................................................................2398 Front Door Trim Panel (76.34.01).............................................................................2400 Front Scuff Plate Trim Panel (76.13.81)......................................................................2402 Headliner (76.64.01) - 4-Door................................................................................2403 Headliner (76.64.01) - Wagon.................................................................................2406 Liftgate Trim Panel (76.19.65.60)............................................................................2411 Loadspace Scuff Plate Trim Panel (76.19.90.60)...............................................................2413 Loadspace Trim Panel (76.13.73.60)...........................................................................2415 Parcel Shelf (76.67.06)......................................................................................2418 Rear Door Trim Panel (76.34.04)..............................................................................2420 Rear Scuff Plate Trim Panel (76.13.82).......................................................................2422 Rear Window Blind (76.14.04).................................................................................2423 Sun Visor (76.10.48).........................................................................................2425 501-08: Exterior Trim and Ornamentation..............................................................................2426 Specification....................................................................................................2426 Description and Operation........................................................................................2427 Exterior Trim................................................................................................2427 Removal and Installation.........................................................................................2429 Door Moulding (76.43.72).....................................................................................2429 Liftgate Moulding (76.43.79).................................................................................2430 Radiator Grille (76.55.03)...................................................................................2432 Rear Spoiler (76.19.86.60) - Wagon...........................................................................2433 Rocker Panel Moulding (76.11.36).............................................................................2435 Roof Rail (76.43.86.60)......................................................................................2436 Window Moulding (76.43.20)...................................................................................2438 501-09: Rear View Mirrors............................................................................................2439 Specification....................................................................................................2439 Description and Operation........................................................................................2440 Rear View Mirrors............................................................................................2440 Diagnosis and Testing............................................................................................2441 Rear View Mirrors............................................................................................2441 Removal and Installation.........................................................................................2442 Auto-Dimming Interior Mirror (76.10.56)......................................................................2442 Exterior Mirror (76.10.52)...................................................................................2443 Exterior Mirror Control Switch (86.65.75)....................................................................2445 Exterior Mirror Cover (76.10.55).............................................................................2446 Exterior Mirror Glass (76.10.53).............................................................................2447 Exterior Mirror Motor (76.10.57) (76.11.09)..................................................................2448 Interior Mirror (76.10.51)...................................................................................2449 501-10: Seating......................................................................................................2450 Specification....................................................................................................2450 Description and Operation........................................................................................2451 Seats........................................................................................................2451 Diagnosis and Testing............................................................................................2459 Seats........................................................................................................2459 Removal and Installation.........................................................................................2468 Front Seat (76.70.01)........................................................................................2468 Front Seat Backrest (76.70.06)...............................................................................2471 Front Seat Cushion (76.70.11)................................................................................2475 Front Seat Front Height Adjustment Motor (86.75.31)..........................................................2476 Front Seat Rear Height Adjustment Motor (86.75.32)...........................................................2478 Front Seat Recliner Motor (86.75.04).........................................................................2480 Front Seat Track Motor (86.75.33)............................................................................2482 Lumbar Assembly (86.75.12)...................................................................................2484 Rear Seat Backrest (76.70.38) - 4-Door.......................................................................2487 Rear Seat Backrest (76.70.38) - 4-Door, Vehicles With: 70/30 Split Seat......................................2488 Rear Seat Backrest (76.70.38) - Wagon, Vehicles With: 70/30 Split Seat.......................................2489 Rear Seat Backrest Latch (76.70.62.60) - Wagon...............................................................2491 Rear Seat Bolster (76.70.67) - 4-Door........................................................................2492 Rear Seat Bolster (76.70.67) - Wagon.........................................................................2493 Rear Seat Cushion (76.70.37).................................................................................2494 Seat Base (76.70.08).........................................................................................2495 Seat Control Switch (86.75.23)...............................................................................2497 Disassembly and Assembly.........................................................................................2499 Front Seat Backrest (76.70.23)...............................................................................2499 Front Seat Cushion (76.70.34)................................................................................2502 Rear Seat Backrest (76.70.48) - 4-Door, Vehicles With: 70/30 Split Seat......................................2503 Rear Seat Backrest (76.70.48) - Wagon, Vehicles With: 70/30 Split Seat.......................................2505 Rear Seat Backrest (76.70.48)................................................................................2509 Rear Seat Bolster............................................................................................2511 Rear Seat Cushion (76.70.47).................................................................................2512 501-11: Glass, Frames and Mechanisms.................................................................................2514 Specification....................................................................................................2514 Description and Operation........................................................................................2515 Glass, Frames and Mechanisms.................................................................................2515 Diagnosis and Testing............................................................................................2516 Glass, Frames and Mechanisms.................................................................................2516 General Procedures...............................................................................................2517 Door Window Motor Initialization.............................................................................2517 Liftgate Window Glass Adjustment.............................................................................2518 Removal and Installation.........................................................................................2520 Front Door Window Glass (76.31.01)...........................................................................2520 Front Door Window Regulator and Motor (76.31.45).............................................................2522 Liftgate Window Glass (76.31.22) (76.81.11.60)...............................................................2523 Rear Door Fixed Window Glass.................................................................................2529 Rear Door Window Glass (76.31.02)............................................................................2532 Rear Door Window Regulator (76.31.46)........................................................................2534 Rear Door Window Regulator and Motor (86.25.09)..............................................................2537 Rear Quarter Window Glass (76.31.31).........................................................................2538 Rear Window Glass Using Cheese Wire (76.81.41)...............................................................2543 Rear Window Glass Using Cutting Tool.........................................................................2551 Window Control Switch (86.25.08).............................................................................2559 Windshield Glass Using Cheese Wire (76.81.40)................................................................2560 Windshield Glass Using Cutting Tool (76.81.01)...............................................................2565 501-12: Instrument Panel and Console.................................................................................2572 Description and Operation........................................................................................2572 Instrument Panel.............................................................................................2572 Removal and Installation.........................................................................................2573 Floor Console (76.25.01).....................................................................................2573 Instrument Panel (76.46.01)..................................................................................2577 Overhead Console (76.13.69)..................................................................................2582 Overhead Console Switch Moulding.............................................................................2583 501-14: Handles, Locks, Latches and Entry Systems....................................................................2587 Specification....................................................................................................2587 Description and Operation........................................................................................2588 Handles, Locks, Latches and Entry Systems....................................................................2588 Diagnosis and Testing............................................................................................2591 Locks, Latches and Entry Systems.............................................................................2591 General Procedures...............................................................................................2594 Remote Transmitter Programming...............................................................................2594 Removal and Installation.........................................................................................2595 Exterior Front Door Handle (76.58.01)........................................................................2595 Front Door Lock Actuator (76.37.74)..........................................................................2597 Front Door Lock Cylinder (76.37.71)..........................................................................2599 Fuel Filler Door Release Handle and Cable (76.11.39) - 4-Door................................................2600 Fuel Filler Door Release Handle and Cable (76.11.39) - Wagon.................................................2604 Liftgate Latch Actuator (86.25.65.60)........................................................................2608 Liftgate Window Glass Release Switch (76.19.59.60)...........................................................2609 Luggage Compartment Lid Latch Actuator (76.19.25)............................................................2614 Rear Door Lock Actuator (76.37.09)...........................................................................2615 501-16: Wipers and Washers...........................................................................................2617 Specification....................................................................................................2617 Description and Operation........................................................................................2618 Wipers and Washers...........................................................................................2618 Diagnosis and Testing............................................................................................2620 Wipers and Washers...........................................................................................2620 Removal and Installation.........................................................................................2621 Headlamp Washer Pump (84.20.21)..............................................................................2621 Rain Sensor (84.12.10) (86.56.62)............................................................................2622 Rain Sensor Module (86.56.60)................................................................................2623 Rear Window Wiper Motor (84.15.48.60) (84.35.12).............................................................2624 Windshield and Rear Window Washer Pump (84.10.21.60).........................................................2627 Windshield Washer Pump (84.10.21)............................................................................2628 Windshield Washer Reservoir (84.10.01) (84.10.03)............................................................2629 Windshield Wiper Motor (84.15.13)............................................................................2631 Wiper Mounting Arm and Pivot Shaft (84.15.24)................................................................2632 Wiper Pivot Arm (84.15.03)...................................................................................2633 501-17: Roof Opening Panel...........................................................................................2635 Specification....................................................................................................2635 Description and Operation........................................................................................2636 Roof Opening Panel...........................................................................................2636 Diagnosis and Testing............................................................................................2638 Roof Opening Panel...........................................................................................2638 General Procedures...............................................................................................2641 Motor Synchronization (76.82.48).............................................................................2641 Roof Opening Panel Alignment.................................................................................2642 Removal and Installation.........................................................................................2643 Air Deflector (76.82.07).....................................................................................2643 Lifter Arms (76.82.57).......................................................................................2644 Roof Opening Panel Control Switch (86.76.05).................................................................2645 Roof Opening Panel Drain Hose (76.82.26).....................................................................2646 Roof Opening Panel Frame (76.82.01)..........................................................................2648 Roof Opening Panel Glass (76.82.05)..........................................................................2653 Roof Opening Panel Motor (86.76.01)..........................................................................2654 Roof Opening Panel Shield (76.82.06).........................................................................2655 Roof Opening Panel Weatherstrip (76.82.15)...................................................................2656 501-19: Bumpers......................................................................................................2657 Specification....................................................................................................2657 Description and Operation........................................................................................2658 Bumpers......................................................................................................2658 Removal and Installation.........................................................................................2659 Front Bumper Cover (76.22.78)................................................................................2659 Front Bumper Cover Insert (76.22.73).........................................................................2662 Rear Bumper (76.22.27) (76.22.52) - 4-Door...................................................................2663 Rear Bumper (76.22.27) (76.22.52) - Wagon....................................................................2664 Rear Bumper Cover (76.22.74) (76.22.77) - 4-Door.............................................................2665 Rear Bumper Cover (76.22.74) (76.22.77) - Wagon..............................................................2669 Rear Bumper Cover Insert (76.22.75) - 4-Door.................................................................2676 Rear Bumper Cover Insert (76.22.75) – Wagon..................................................................2677 501-20A: Safety Belt System..........................................................................................2678 Specification....................................................................................................2678 Description and Operation........................................................................................2679 Safety Belt System...........................................................................................2679 Diagnosis and Testing............................................................................................2681 Safety Belt System...........................................................................................2681 Removal and Installation.........................................................................................2691 Front Safety Belt Retractor (76.73.10).......................................................................2691 Front Safety Belt Shoulder Height Adjuster (76.73.12)........................................................2693 Rear Center Safety Belt Retractor (76.73.20) - 4-Door........................................................2694 Rear Center Safety Belt Retractor (76.73.20) - Wagon.........................................................2696 Rear Safety Belt Buckle (76.73.50)...........................................................................2697 Rear Safety Belt Retractor (76.73.18) - 4-Door...............................................................2698 Rear Safety Belt Retractor (76.73.18) - Wagon................................................................2700 Safety Belt Buckle and Pretensioner (76.73.49)...............................................................2702 501-20B: Supplemental Restraint System...............................................................................2704 Specification....................................................................................................2704 Description and Operation........................................................................................2705 Air Bag Supplemental Restraint System (SRS)..................................................................2705 Diagnosis and Testing............................................................................................2708 Air Bag Supplemental Restraint System (SRS)..................................................................2708 General Procedures...............................................................................................2722 Air Bag Disposal.............................................................................................2722 Removal and Installation.........................................................................................2725 Clockspring (86.65.92).......................................................................................2725 Crash Sensor (76.73.55)......................................................................................2728 Driver Air Bag Module (76.73.39).............................................................................2730 Driver Lower Air Bag Module (76.73.75).......................................................................2733 Occupant Classification Sensor (76.73.60)....................................................................2736 Passenger Air Bag Deactivation (PAD) Indicator (76.73.58)....................................................2739 Passenger Air Bag Module (76.73.37)..........................................................................2741 Restraints Control Module (RCM) (76.73.48)...................................................................2745 Seat Position Sensor (76.73.62)..............................................................................2746 Side Air Curtain Module (76.73.64) - 4-Door..................................................................2748 Side Air Curtain Module (76.73.64) - Wagon...................................................................2752 Side Impact Sensor (76.73.53)................................................................................2758 502: Frame and Mounting..................................................................................................2759 502-00: Uni-Body, Subframe and Mounting System.......................................................................2759 Specification....................................................................................................2759 Description and Operation........................................................................................2760 Frame Assembly...............................................................................................2760 General Procedures...............................................................................................2761 Underbody Misalignment Check (57.65.20)......................................................................2761 Removal and Installation.........................................................................................2766 Front Subframe (76.10.05) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 –AJ27.............................2766 Front Subframe (76.10.05) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi(110kW/150PS) - Puma........................2781 Front Subframe Front Bushing (60.35.51)......................................................................2793 Front Subframe Rear Bushing (60.35.26).......................................................................2796 Rear Axle Crossmember Bushing (64.25.02).....................................................................2799 Rear Subframe (64.25.01).....................................................................................2802 Rear Subframe Bushing (64.25.04).............................................................................2808
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