Jaguar X-Type (2001) manuel d'utilisation

Workshop Manual X-TYPE Sedan and Estate (Wagon) 2.0 L , 2.5 L and 3.0 L Gasoline; 2.0 L and 2.2 L, Diesel 2001 to 2009 www.JagDocs.com JagDocs.com[...]

TABLE OF CONTENTS 1: General Informa tion 10 0: Service Information 100 -00: General Information Description and Op eration About This Manual Application and Use of Spec ifications General Service Information Health and Safety Precau tions How To Use This Manu al Important Safety Instruc tions Road/Roller Testing Solvents, Sealants and Ad hesives S[...]

2: Chassis 20 4: Suspension 204 -00: Suspension System - Gene ral Information Specification Description and Op eration Wheel Alignment Angles Diagnosis and Testing Suspension System General Procedures Front Toe Adjustment (57.65.01) Rear Toe Adjustment ( 57.65.08) Wheel Bearing In spection 204 -01: Front Suspension Specification Description and Op [...]

Removal and Installation Damper Front Lower Arm (64.35.51) - 4-Door Front Lower Arm (64.35.51) - Wagon Rear Lower Arm (64.35.52) Spring (64.20.01) Rear Stabilizer Bar (64.35.08) Rear Stabilizer Bar Link (64 .35.24) Upper Arm (64 .25.31) Wheel Hub (64.15.14) Wheel Knuckle ( 64.15.22) Wheel Knuckle Front Bush ing (64.15.28) Wheel Knuckle Rear Bushin [...]

Diagnosis and Testing Driveline System 205 -01: Driveshaft Specification Description and Op eration Driveshaft Diagnosis and Testing Driveshaft General Procedures Driveshaft Runout an d Balancing Removal and In stallation Driveshaft (47.15.01) 205 -02: Rear Drive Axle/Differe ntial Specification Description and Op eration Rear Drive Axle and Differ[...]

Front Halfshaft RH (47.10.16) - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110 kW/150PS) - Puma Inner Constant Velocity ( CV) Joint Boot (47.10.18) Intermediate Shaft Outer Constant Velocity (CV) Joint Boot (47.10.19) 205 -05: Rear Drive Halfshafts Specification Description and Op eration Rear Drive Halfshafts Diagnosis and Testing Rear Drive Halfshaft[...]

Brake Pads (70.40.02) 206 -04: Rear Disc Brake Specification Description and Op eration Rear Disc Brake Diagnosis and Testing Rear Disc Brake Removal and In stallation Brake Caliper (70.55.03) (70.55.25) Brake Disc (70.10.11) Brake Disc Shield (7 0.10.19) Brake Pads (70.40.03) 206 -05: Parking Brake and Actuatio n Specification Description and Op e[...]

Brake Pedal and Bracket (70.35.03) Brake Pedal Cross-Shaft 206 -07: Power Brake Actuation Specification Description and Op eration Brake Booster Diagnosis and Testing Power Brake System Removal and In stallation Brake Booster (70.50.17) - LHD AWD/LHD FWD Brake Booster (70.50.17) - RHD AWD/RHD FWD Brake Vacuum Pump - 2.0L NA V6 - AJV6 Brake Vacuum P[...]

211: S teering System 211 -00: Steering System - General I nformation Specification Description and Op eration Steering System Diagnosis and Testing Steering System General Procedures Power Steering System Filling Power Steering System Flushing ( 57.15.08) 211 -02: Power Steering Specification Description and Op eration Power Steering Diagnosis and[...]

211-03 : Steering Linkage Specification Description and Op eration Steering Linkage Diagnosis and Testing Steering Linkage Removal and In stallation Steering Gear Boot (57.10.29) Tie Rod End ( 57.55.02) 211 -04: Steering Column Specification Description and Op eration Steering Column Diagnosis and Testing Steering Column Removal and In stallation I[...]

3: Powertrain 30 3: Engine 303 -00: Engine System - General Inform ation Specification Description and Op eration Engine Diagnosis and Testing Engine General Procedures Bearing Inspection Camshaft Bearing Journal Clear ance Camshaft Bearing Journal Diam eter Camshaft End Play Camshaft Lobe Lift Camshaft Surface Inspec tion Connecting Rod Clean ing [...]

Leakage Test Using Smoke Test Equipm ent 303 -01A: Engine - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Engine Diagnosis and Testing Engine General Procedures Valve Clearance Adjustment (12.29.48) Valve Clearance Check (12.29.47) In-Vehicle Repair Camshafts LH (12.13.19) Crankshaft Front Seal (12 .[...]

Engine (12.41.01) - Veh icles With: 5-Speed Au tomatic Transaxle - JATCO/6-Speed Automatic Transaxle - AWF21 Disassembly Engine Disassembly and Assemb ly of Subassemblies Cylinder Head (12.29.22) Piston (12.17.02) Assembly Engine Installation Engine (12.41.01) - Veh icles With: 5-Speed Manual Transmission - MT75/6- Spe ed Manual Transaxle - MMT6 En[...]

Installation Engine (12.41.01) - 2.0L Du ratorq-TDCi Engine (12.41.01) - 2.2L Du ratorq-TDCi (110kW/150P S) – Puma 303 -03A: Engine Cooling - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Engine Cooling Diagnosis and Testing Engine Cooling General Procedures Cooling System Backflush ing Cooling Sys[...]

Cooling Module (26.40.16) Radiator (26.40.01) Water Pump (26.50.01) 303 -04A: Fuel Charging and Con trols - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op eration Fuel Charging and Controls Diagnosis and Testing Fuel Charging and Controls - 2.0L NA V6 - AJV6 Fuel Charging and Controls - 2.5L NA V6 - AJV6/3.0L[...]

303 -04C: Fuel Charging and Con trols - Turbocharger Specification Description and Op eration Turbocharger Diagnosis and Testing Turbocharger Removal and In stallation Turbocharger 303 -05: Accessory Drive Specification Description and Op eration Accessory Drive Diagnosis and Testing Accessory Drive Removal and In stallation Accessory Drive Belt (1[...]

Starting System Diagnosis and Testing Starting System - 2.0L NA V6 - AJV6 Starting System - 2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Removal and In stallation Starter Motor (86.60.01) - 2.0L Du ratorq-TDCi Starter Motor (86.60.01) - 2.2L Du ratorq-TDCi (110kW/150 PS) - Puma Starter Motor (86.60.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 – AJ[...]

Removal and In stallation Exhaust Gas Recirculation ( EGR) Cooler Exhaust Gas Recirculation ( EGR) Cooler to EGR Valve Tube Exhaust Gas Recirculation ( EGR) Valve (17 .45.01) 303 -12A: Intake Air Distribution a nd Filtering - 2 .0L NA V6 - AJV6/2. 5L NA V6 – AJV6/3.0L NA V6 - AJ27 Description and Op eration Intake Air Distribution and Filtering D[...]

Removal and In stallation Evaporative Emission Canister (17.15.13) - 2.0L NA V6 - AJV6 Evaporative Emission Canister (17.15.13) - 2.5L NA V6 - AJV6/3 .0L NA V6 - AJ27 Evaporative Emission Canister Purge Valve (17.15.30) 303 -14A: Electronic Engine Controls - 2.0L NA V6 - AJV6/2.5L NA V 6 - AJV6/3.0L NA V6 - AJ27 Specification Description and Op era[...]

Description and Op eration Electronic Engine Controls Diagnosis and Testing Electronic Engine Controls Removal and In stallation Camshaft Position (CMP) Sensor (18.30.63) Catalytic Converter Temperatu re Sensor Crankshaft Position (CKP) Sensor (18.30.12) Cylinder Head Temp erature (CHT) Sensor (18 .30.97) Diesel Particulate Filter ( DPF) Temperatur[...]

Transmission Control Module (TCM) (44.15.32) Transmission Range (TR) Sensor Removal Transaxle (44.20.01) Disassembly and Assemb ly of Subassemblies Input Shaft Seal (44.32.07) Installation Transaxle (44.20.01) 307 -01B: Automatic Transmission/Tra nsaxle - Vehicles With: 6-Speed Automatic Transaxle - AWF21 Specification Description and Op eration Tr[...]

307 -02A: Transmission/Transaxle Cooli ng - Vehicles Wit h: 5-Speed Automati c Transaxle - JATCO Specification Description and Op eration Transmission Cooling - Veh icles With: 5-Speed Automatic Transaxle - JATC O Diagnosis and Testing Transmission Cooling Removal and In stallation Transmission Fluid C ooler (44.24.10) Transmission Fluid C ooler Tu[...]

307 -05B: Automatic Transmission/Tra nsaxle External C ontrols - Vehicles Wi th: 6-Speed Automat ic Transaxle - AWF21 Specification Description and Op eration External Controls - Vehicle s With: 6-Spee d Automatic Transaxle - AWF21 Diagnosis and Testing External Controls General Procedures Selector Lever Cable Adjustment ( 44.15.07) Removal and In [...]

Clutch Disc and Pressure Plate (12.53.13) (3 3.10.01) 308 -02: Clutch Controls Specification Description and Op eration Clutch Controls Diagnosis and Testing Clutch Controls Removal and In stallation Clutch Master Cylinder (3 3.20.01) Clutch Slave Cylinder (33.35.01) - Vehicles With: 5-Speed Manu al Transmission – MT75 Clutch Slave Cylinder (33.3[...]

Transaxle (37.20.01) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 Installation Transaxle (37.20.01) - 2 .0L Duratorq-TDCi Transaxle (37.20.01) - 2 .2L Duratorq-TDCi (110kW/150PS) - Puma Transaxle (37.20.01) - 2 .0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 308 -06: Manual Transmission/Tr ansaxle External C ontrols Specification [...]

30 9: Exhaust System 309 -00: Exhaust System Specification Description and Op eration Exhaust System Diagnosis and Testing Exhaust System Removal and In stallation Catalytic Converter (17.50.05) - 2.0L Du ratorq-TDCi/2.2L Duratorq-TDCi (110kW/1 50PS) - Puma Catalytic Converter LH (17.50.15) - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Ca[...]

General Procedures Fuel System Pressure C heck Fuel System Pressure Release (19.50.02) Fuel Tank Draining - 2.0L Duratorq-TDCi/2.2L Durato rq-TDCi (110kW/15 0PS) – Pum a Fuel Tank Draining - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6/3.0L NA V6 - AJ27 Quick Release Couplin g - Push Connect Spring Lock Coup lings 310 -01: Fuel Tank and Lines Specificatio[...]

310 -02: Acceleration Control Specification Description and Op eration Acceleration Control Diagnosis and Testing Acceleration Control General Procedures Accelerator Cable Adju stment (12.20.05) - 2.0L NA V6 - AJV6 Removal and In stallation Accelerator Cable ( 19.20.06) - 2.0L NA V6 - AJV6 Accelerator Pedal ( 19.20.01) 310 -03: Speed Control Specif[...]

Air Conditioning (A/C) System Flushing Air Conditioning (A/C) System Recovery, Evacuation an d Charging (82 .30.30) Contaminated Refrigerant Han dling Discharging and Recovery (82.30.30) Electronic Leak De tection Inspection and Assembly Requirements Leak Detection Refrigerant Oil Addin g Refrigerant System Tests 412 -01: Air Distribution and Filte[...]

412 -02B: Auxiliary Heating Specification Description and Op eration Electric Booster Heater Fuel Fired Booster Heater Diagnosis and Testing Auxiliary Heater Fuel Fired Booster Heater Removal and In stallation Electric Booster Heater Fuel Fired Booster Heater 412 -03: Air Conditioning Specification Description and Op eration Air Conditioning Diagno[...]

Air Discharge Temperatu re Sensor (82.20.64) Ambient Air Temperature Sensor (82.20.02) Climate Control Assembly ( 82.20.07) Defrost Vent/Register Blend Door Actuator (82.20.8 4) Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85) Sunload Sensor (82.20.70) Temperature Blend Door Actu ator (82.20.86) 41 3: Instrumentation and Warning System[...]

Removal and In stallation Message Center Message Center Switch (86.66.11) 413 -09: Warning Devices Description and Op eration Warning Devices Diagnosis and Testing Warning Devices General Procedures Oil Change In dicator Reset Removal and In stallation Low Washer Fluid Warning I ndicator Switch (84.10.17) 413 -13: Parking Aid Description and Op era[...]

Quiescent Drain Diagnosis and Testing Charging System - 2.0L NA V6 - AJV6/2.5L NA V6 - AJV6 /3.0L NA V6 - AJ27 Charging System - 2.0L Durato rq-TDCi/2.2L Durator q-TDCi (110 kW/150PS) – Pum a General Procedures Battery Charging 414 -01: Battery, Mounting and Cables Specification Description and Op eration Battery and Cable s Diagnosis and Testing[...]

41 5: Information and Entertainmen t Systems 415 -00: Information and Entertai nment System - Gen eral Information Diagnosis and Testing Audio System 415 -01: Audio Unit Description and Op eration Audio System Diagnosis and Testing Audio System Removal and In stallation Audio Unit (86.50.03) Audio Unit Amplifier (8 6.50.10) (86.50.36) - 4-Door Audi[...]

Parcel Shelf Speaker (86 .51.06) Rear Door Speaker (86.50.14) Rear Door Tweeter Spe aker (86.50.62) 41 7: Lighting 417 -01: Exterior Lighting Specification Description and Op eration Exterior Lighting Diagnosis and Testing Headlamps General Procedures Headlamp Adjustment (8 6.40.18) Removal and In stallation Ballast (86.41.52) Front Fog Lamp (86 .4[...]

417 -04: Daytime Running Lamps ( DRL) Description and Op eration Daytime Running Lamps (DRL) Diagnosis and Testing Daytime Running Lamps (DRL) 41 8: Electrical Distribution 418 -00: Module Communication s Network Description and Op eration Communications Network Diagnosis and Testing Communications Network - V IN Range: E96603->J 28492 Communica[...]

419 -01B: Anti-Theft - Passive Description and Op eration Anti-Theft - Passive Diagnosis and Testing Anti-Theft - Passive General Procedures Anti-Theft Security Acce ss Key Programming Using Diagnostic Equip ment Removal and In stallation Passive Anti-Theft System (PATS) Transceiver ( 86.52.30) 419 -02: Remote Convenience Description and Op eration[...]

Cellular Phone Cellular Phone - Veh icles With: Bluetooth Removal and In stallation Bluetooth Module Handset Holder (86.51.12) Module - 4-Door Module – Wagon 419 -10: Multifunction Electronic Modul es Specification Description and Op eration Module Controlled Functions Diagnosis and Testing Multifunction Electronic Mod ule Removal and In stallati[...]

General Procedures Door Alignmen t Hood Alignment (76 .16.02) Liftgate Alignment (76.19.54.60) Luggage Compartment Lid Alignment (76.19.03) Removal and In stallation Weatherstrip 501 -05: Interior Trim and Ornamentation Specification Description and Op eration Interior Trim Removal and In stallation A-Pillar Trim Panel (76.13.31) B-Pillar Lower Tri[...]

Removal and In stallation Door Moulding (76 .43.72) Liftgate Moulding (7 6.43.79) Radiator Grille (76.55.03) Rear Spoiler (76.19.86.60) - Wagon Rocker Panel Moulding (76.11.36) Roof Rail (76.43.86.60) Window Moulding (76 .43.20) 501 -09: Rear View Mirrors Specification Description and Op eration Rear View Mirrors Diagnosis and Testing Rear View Mir[...]

Front Seat Track Motor (86.75. 33) Lumbar Assembly (86.75.12) Rear Seat Backrest (76.70.38) - 4-Door Rear Seat Backrest (76.70.38) - 4-Door, Vehicles With : 70/30 Split Seat Rear Seat Backrest (76.70.38) - Wagon, Vehicles With : 70/30 Split Seat Rear Seat Backrest Latch (76.70.62.60) - Wagon Rear Seat Bolster (76.70.67) - 4-Door Rear Seat Bolster ([...]

Rear Quarter Window Glass (76.31.31) Rear Window Glass Using Che ese Wire (76.81.41) Rear Window Glass Using Cut ting Tool Window Control Switch ( 86.25.08) Windshield Glass Using C heese Wire (76.81.40) Windshield Glass Using C utting Tool (76.81.01) 501 -12: Instrument Panel and Cons ole Description and Op eration Instrument Pan el Removal and In[...]

501 -16: Wipers and Washers Specification Description and Op eration Wipers and Washers Diagnosis and Testing Wipers and Washers Removal and In stallation Headlamp Washer Pum p (84.20.21) Rain Sensor (84.12.10) ( 86.56.62) Rain Sensor Module (86 .56.60) Rear Window Wiper Motor (8 4.15.48.60) (84.35.12) Windshield and Rear Win dow Washer Pum p (84.1[...]

501-19: Bumpers Specification Description and Op eration Bumpers Removal and In stallation Front Bumper Cover (7 6.22.78) Front Bumper Cover In sert (76.22.73) Rear Bumper (76.22.27) (76.22.52) - 4-Door Rear Bumper (76.22.27) (76.22.52) - Wagon Rear Bumper Cover (76 .22.74) (76.22.77) - 4-Door Rear Bumper Cover (76 .22.74) (76.22.77) - Wagon Rear B[...]

General Procedures Air Bag Disposal Removal and In stallation Clockspring (86.65.92) Crash Sensor (76.73.55) Driver Air Bag Module (7 6.73.39) Driver Lower Air Bag Module (76.73.75) Occupant Classification Senso r (76.73.60) Passenger Air Bag Deactivation (PAD) Indicat or (76.73.58) Passenger Air Bag Module ( 76.73.37) Restraints Control Module (RC[...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - A bout Th is Man ual Des cr ipt i o n a nd O pe r a t i o n Note s, Ca u tions a n d Warn ings Thr oug hout t hi s manua l , i mpor t a nt i nfo rm at i on i s hi ghl i gh te d by t he us e o f no t e s , ca ut i ons a nd wa rning s. NO TES gi v e a ddi t i o nal i nfo r m at i o n on a t o pi [...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - A pplicatio n and U se o f S pecifi cation s Des cr ipt i o n a nd O pe r a t i o n Torque S pecif ica tions To r que s pe ci fi cat i on s a r e s ho wn i n t he t orque s pe cif i ca t i o ns c ha rt l o cat e d a t t he fro nt of t he rel e v a nt s e c t i o n. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - General Service I nform atio n Des cr ipt i o n a nd O pe r a t i o n Repa irs an d Repla cem en ts W he n s e r vi c e pa r t s a r e requi r ed, it i s e s s e nt ia l tha t onl y g e nui ne Ja g uar/ Dai mle r r ep l a ceme nt s a r e us e d. At t e nt i o n i s drawn t o t he fo l lo wi ng [...]

Re - e nt e r t he radi o recei ve r /cas s e t t e pl ayer /min i di s c pl a y e r and co mpact d i s c pl a y e r k e yc od e s a nd pr es e t ' f r e que ncie s , i f kno wn. Fol l o wi ng r e conne cti o n o f t he ba t te r y, t he e ngi ne s h oul d be al lo we d t o i dl e unt i l i t ha s reache d no r m al o p e r at i ng t e mpe r a[...]

I t is o f f unda ment a l i m po r t ance t ha t c e rta i n e s s e nti a l e qui pme nt e . g. t o r que wren c he s , mult i met e r s , e xhaus t ga s a nal yse r s, r o ll i ng roads e t c., are regul arly cal i br a t e d i n a ccor da nce wi t h t he m a nufa ct ur ers i ns t r u cti ons . U se of C ontr ol Mo du les Cont rol mod ul es m a [...]

I n t he i nt e re st o f cla r it y, s i ngl e l i ne s may repr e se nt mul t i pl e wi r es . Re fe r to the col o r code (1s t a l pha ) f ol lo we d by t he wi r e ref e rence (num eric/al pha/n umer ic) t o t r ace o r i g in a nd de s t i n at io n. e .g. B W 647B002. BW (bl a ck wi t h whi t e t r ace) 647 (wi r e r e fe rence ) B002 (s t a[...]

T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on Dat a O ut p ut Li ne DOL Ci r cui t th a t s e n ds certa i n i nf orm at i o n f r o m t he ECM to the i ns t ru me nt cl ust e r Deg r ee de g , ° Angle o r t e mpe r a ture Dep a r t ment o f Tr an s p or t a t i o n (US) DOT W h i ch is a f i br e o pt ic ring ne tw ork, can b e d[...]

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T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on On -Boa rd Dia g nos t i c OB D A s ys t e m t ha t moni t o r s s o me o r a l l comput e r i npu t a nd o ut p ut cont r o l s i gna l s . S ig nal (s ) ou ts i de th e pre -det e rm ine d l i mi t s i mpl y a f a ul t i n t he s ys t e m o r a r el a t e d s ys te m Orig i na l Equi [...]

T e rm ( s) Acr onym / Un i t / Abbrevi a ti on Def i ni ti on Tr an s mi s s i o n O i l Te mpe r at ur e TO T I ndi cat e s t e mpe rat ur e o f t rans mis s i o n fl ui d Tr an s mi s s i o n Ran ge TR T he range i n whi ch t he t r ans mis s i o n i s op e r at i ng Tur bi ne Sh af t Sp e e d TS S I ndi cat e s r o t a t i ona l s p ee d of t r[...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - H ealth and Safety Pre cautio n s Des cr ipt i o n a nd O pe r a t i o n P r o l onge d a nd repe a t ed c on t a ct wi t h mine ral o i l wi l l res ul t i n t he r e mov a l of na t ural o i ls f r o m t he s kin , l e adi ng t o dr ynes s , i rr i t a t io n a nd de r m a t i t i s . In a dd[...]

Hi ghl y fl ammabl e , combus t i bl e – o bs e rv e No Sm oking po l i cy . S kin co nt a ct may res ul t in f r os tb i te . I nst r ucti o ns gi ven b y t he manufa ct ur e r m us t be f o l l owe d. A voi d na ked l i ght s , we ar s u i t a b l e p r o te cti v e g lo ves and gogg l e s . I f r e frige r a nt come s in t o cont a ct wi t h t[...]

Do wa s h b e fo re br ea ks , bef ore e a t i ng, s mokin g, d rinking o r us i ng t o i l et fa ci l i t i e s w he n ha ndl i ng che mica l m a t e ria l s . Do ke e p wo r k a r ea s cl e a n, unclut t e r ed a nd f r e e o f s pi l l s . Do s t ore che mica l mat e ria l s acco r d i ng t o na t i o na l and l o cal regul at i o ns . Do ke e p[...]

S ee L ubr ica nt s a nd Gr ea se . Exh a ust Fume s The s e c ont a i n a s phyxia t i ng , harm f ul a nd t oxi c chemi ca l s a nd p a r t i cl e s s uch a s ca r bo n o xide s , ni t r oge n o x i d e s , a l dehyde s , l ea d and aromat i c hydr o carbons . Engi ne s s houl d b e r un onl y unde r co ndi t i o ns of ade qua t e e xhaus t e xt [...]

Mot or ga s o li ne may cont ai n a pp r e cia b l e qua nt i t i e s o f b e nz e ne , whi ch is t o xic u po n i n hal at i o n, a nd t he concen trat i o n of ga s o l i ne v a po r s mus t be ke p t v e r y lo w. Hi g h conce nt rat i o ns wi ll ca us e eye, no se a nd throa t i r rit a t i o n, na us ea , he a d ache , d epres s i on a nd symp[...]

The Fa ct or i e s A ct (1961). The As bes t os Re gul at i o ns (1969). Hi ghl y Fl a mm a b l e Li q ui ds a nd L iq ui f i e d P e t r o l e um Gas e s Re g ul a t i o ns (1972) . Cont rol o f P o l l ut i on A c t (1974). He a l t h a nd S a fe t y a t W o r k Act (1974). The Cl a s s i f i cat i o n, P a c kagi ng a nd La be l l in g o f Dange[...]

a voi de d. Re moval o f e xc e s s s o ld e r s houl d be underta ke n wi t h care, t o make s ure t hat f i ne l e ad d ust i s no t p r o d uced, wh ich ca n gi ve t o xic e ff e ct s i f in ha l e d. Re sp i r a t ory prote c t i o n may b e ne ce s s a r y . S ol de r sp i l l age and fi l i ng s s ho ul d be co ll e ct e d a nd r emove d prom[...]

S ee a l s o Fi r e , El e ct ric Shoc k, Ga s Cyli nde rs. W e l di ng pr oce s s e s i ncl ude Res i st a nce W e ld i ng (S pot W e l di ng), A r c W e l d in g and Gas W e l d i ng. Resista nce W el ding Thi s proces s may ca use parti cl e s o f mol t e n met a l t o b e emi t t e d a t a hi gh ve lo ci t y , a nd t he e yes a nd s k i n m us [...]

3. J ag ua r vehi cle s a nd r e pl a ce ment parts whi ch cont a i n a s be s t os a r e i de nt i fi ed by t hi s s y mbol . S ee A sb e s t o s i n t hi s s ub s e ct i o n. 3. 4. Componen t s o r as s e mbli e s d is pl a yi ng t hi s s ym bol gi ve wa r ni ng t ha t t he compone n t cont a i ns a co r r os ive s ubs t a nce. See Aci ds a nd Al[...]

Ensu r e t hat d ry s a nd is a va i l abl e t o s o ak up a ny f ue l s pi l l a ge . Empty fue l us i ng s ui t ab l e fi r e p r oo f e qui pment i nto an a ut ho r i ze d expl o s i on pr oo f c o nt a i ner. Do no t e m pt y fue l whi l e wo r ki ng i n a wo r ksh op o r a pi t . Ensu r e t hat wo rking a r e a i s we l l v e nt il a t e d. En[...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - H o w To Us e T hi s Manua l Des cr ipt i o n a nd O pe r a t i o n C opyrigh t Sta t em en t Cop y r i ght . © Jagu a r Cars Lt d. 1999 Al l right s r es e r ved. No part of t hi s publ i ca t i on may be repr od uced, s t o red i n a r e t r i e val s yst e m or t r ans mit t e d i n a ny f [...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Important Safety Instructio ns Des cr ipt i o n a nd O pe r a t i o n S af e t y N o t i ce App r opr i at e s e r vi ce met ho d s a nd co r r ect repai r pr oced ur es a re e s s e nt i a l fo r t he s a fe , r el i a bl e o pe r at i o n o f a l l mot o r vehi cl e s , a s wel l a s t he s a[...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - R oa d /R oll e r Tes ting Des cr ipt i o n a nd O pe r a t i o n Roa d o r r o l l e r t e s t i ng may b e carr i e d out f o r vario us reas on s an d a proced ur e de t a i l i ng pre - t e s t checks, t h r o ug h e ng i ne s t arti ng a nd s t o pp i ng, p r e - drivi ng c he ck s , o n -[...]

Abnorm a l te mperat ur e o f an y movi ng comp one nt s or as s e mbl i e s , e .g. whe e l hubs , t r ans mis s i o n, a xl e e t c., whi ch mi ght i ndi ca t e overti ght ne s s o r l a ck o f l ub r i cat i o n. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Solvents, Sealants and Adh esives Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: A l wa ys ha ndl e a l l s ol ve nt s , s e a l e r s a nd a d he s i ves wi t h e xtre me ca r e . S ome co nt a i n che mical s o r g i ve of f f um e s whi ch ca n be d a nge rous to hea l th . Al wa ys f o [...]

P ubl i s he d: 11-May-2 011 Gen eral Info rm atio n - Sta ndard Works ho p Practices Des cr ipt i o n a nd O pe r a t i o n Protecting th e V eh icl e Al wa ys i ns t a ll cove rs t o pr ot e ct t he fe nd e r s be f ore co mm enci ng wo rk i n th e e ng i ne co mpa r t ment . A l wa ys i ns t a l l t he i nt e rio r pr ot e ct i o n kit , we a r [...]

P ubl i s he d: 11-May-2 011 Identifi cation C odes - Ide ntif icatio n C o des Des cr ipt i o n a nd O pe r a t i o n V eh icl e Ide ntifi cation Num be r (VIN) The o ff i ci a l VI N i s s t a mped o n t he right han d s i de o f t he b o ot compart m e nt fl o o r. A n a ddi ti o nal q ui ck r e fe r e nce a nd a nt i f o r ge r y id e nt i fi c[...]

Item Par t N u m ber Desc ri pti on 1 — W orld manuf act ur er i de nt i fi e r 2 — Ma r k e t , a i r ba g s pe cif i ca t i on 3 — T r ans mis s i o n a nd s t e e ring co d e 4 — B o dy code 5 — E ngi ne e mis s i on sys te m 6 — Ch eck di gi t 7 — Mo del ye a r 8 — A s s e mbl y p l a nt , mode l l i ne 9 — P r o duct i on se [...]

VI N Po si t i o n 8 • NO T E: *1 EU . I ncl ude s t he f ol l o wi ng mar ket s ; Au s t ria , Be lg i um , Cy pru s , Cz e ch Rep , Den m a rk , Es t o ni a , Fi nla nd, France , Ger many, Gr e e ce, Ne t he rla nds , Hunga r y, It a l y, La t vi a , Li t huani a, L uxe mbour g, Mal t a, P o l and, P o r t uga l , Rep. o f I r el a nd , S lo ve[...]

VI N Po si t i o n 1 2 throug h 1 7 Seque nce Nu m ber C00001 - C99999 D0000 1 - D99999 E00001 - E 99999 J00001 - J9999 9 K00001 - K99999 S 000 01 - S9 9999 T00001 - T99999 V00001 - V99999 V eh icl e C ertif i cation La bel The vehi cl e ce r t i f i ca ti on l a b e l al s o cont a i ns t he 17 charact e r vehi cl e i den t i f i cat i o n number.[...]

It e m Pa rt Nu mb e r Descri pti o n 1 — Maximum perm i t t e d front a xle l o a di ng 2 — Dat e of ma nufa ct ur e 3 — Gr o s s ve hi cle w ei ght 4 — Maximum perm i t t e d r ea r a xle l o a di ng 5 — Ve hi cl e i de nt i f i ca t i on number 6 — Ty pe 7 — Int e r i or t rim code 8 — Pa i nt cod e Ve hi cl e I d e nt i f i ca t[...]

It e m Pa rt Nu mb e r Descri pti o n 1 — Maximum perm i t t e d front a xle l o a di ng 2 — Dat e of ma nufa ct ur e 3 — Gr o s s ve hi cle w ei ght 4 — Maximum perm i t t e d r ea r a xle l o a di ng 5 — Ve hi cl e i de nt i f i ca t i on number 6 — Pa i nt cod e 7 — Int e r i or t rim code 8 — Ty pe Automa tic Tran smission Num b[...]

P ubl i s he d: 11-May-2 011 Ja cking and L ifti ng - J ackin g Des cr ipt i o n a nd O pe r a t i o n Sa f et y Precau tion s CAU TIO N : Th e j ack prov i de d wi t h t he vehi cl e i s i nt ende d t o b e us e d i n a n e me r ge ncy f o r cha ngi ng a d e fl a t e d t i re . To a v oi d da mage t o t he v e hi c l e , ne ve r us e th e j a c k [...]

P ubl i s he d: 11-May-2 011 Ja cking and L ifti ng - Li ftin g Des cr ipt i o n a nd O pe r a t i o n Liftin g Poi nt s—Twi n-Post Hoist an d Floor Ja ck • CAU TI O N S : Do not a l lo w t he ho i s t a d a pt e r s t o co nt a ct t he s t e e r i ng l i nk ag e , s us pe ns i on a r m s , s t ab i l i z e r bar , rear s ub frame s t abi l i z[...]

V eh icl e R ecove ry • NO T E: P r i o r t o vehi cl e r e covery , ma k e su r e t hat t he vehi cl e ke ys a r e avai l a bl e a nd t he s e cur it y s y s t e m i s di s a r me d. Ve hi cl e recove r y met ho ds a r e : By f l a t -be d t r ans porte r. By f r ont s us pe nd ed to w. Tran s p orter or Trailer Re c ove ry W he n t he vehi cl e[...]

W he n t he vehi cl e i s b e i ng re c ove r e d b y f r ont s us pe nde d t ow : CAU TIO N : Th e dr i ves ha ft mus t be di s c on ne ct e d. The i gni t i on k e y must b e r emove d from t he i gni t i o n s wi t ch t o l o ck th e s t e e r ing. The front whe e l s mus t b e co r r ect l y po s it i o ne d i n t he l i f t i ng cr adl e and s[...]

P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - No ise, V ibration and Harsh ness (NV H) Des cr ipt i o n a nd O pe r a t i o n No i s e , vibr a t i o n a n d ha r s hne ss (NVH) i s be comi ng more i mporta nt a s vehi cl e s be come mor e s op hi s t i ca t e d a nd p a s s eng e r comf ort le vel s in cr e a s e . Thi s s e c t[...]

P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - No ise, V ibration and Harsh ness (NV H) Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l da mag e . 2. 3. If a n obvi o us cau se fo r an ob s e rv e d [...]

lo o s e d r i ve ha l f s ha f t j oi nt b oot cl a mps a not h e r compone nt c on t a ct i ng t he d r i ve ha l f s haf t wor n, da mag e d o r in cor r ect ly i ns t a ll ed whee l b e a r i ng, s u s pe ns io n or brake compone nt Vi brat i o n at hi g hway sp e e ds may b e ca us ed by t he f ol l o wi ng: ou t-o f -bal a nce f r o nt o r re[...]

* * * * * * * * * * * * * * * * * * * * * * * * 1 Road C ondit ions An e xperie nce d te chni cia n wi l l a l wa ys e s t a b l is h a rout e t ha t wi l l be u se d fo r a l l NV H di a gnos i s roa d t es t s . T he r o a d s e l e ct e d s ho ul d be r e a s o nab l y s moo th , l e ve l a nd f ree o f undula t i o ns (unl e s s a pa r t i cul [...]

1 1 1 1 1 1 1 1 Doe s t he vi brat i o n di s ap pe a r dur ing t he ne ut r a l coa s t t e s t ? Ye s CHECK and INSTAL L ne w e ng i ne /ge a r b o x/ t r an s fe r box mount s as nece s sa ry . RE PE AT Ro a d T e s t a s out li ned . No GO t o D1 . PINPOIN T TE ST B : TIP-I N MOA N T EST C ONDI T I ONS DET AI LS/RE SULT S/A CT IONS B1: C HEC K [...]

1 1 1 1 1 1 1 Are t he t i r e s O K? Ye s GO t o D2 . No INS P ECT t he whee l s . Fo r a ddi t i o nal i nfo r mat i o n, refe r to REFER t o : W h e e l s a nd Ti r es (204-04 W he e l s and Ti r e s , Di a gno s i s a nd T e s t i ng). D2: IN SPEC T WHEEL BEAR I NG S Ins p ect t he whe el be a r i n gs . Fo r a ddi t i o na l i nf o r m at i o [...]

P ubl i s he d: 11-May-2 011 No is e, Vibratio n and Harshness - Exh aust S y stem N eutraliz ing Gene ral P r ocedures 1. Loos e n t he muff le r i nl e t pi p e a nd res o na t o r pip e t o e xha us t mani fo l d f as t e ne rs a t t he f l a nge s a nd t he muf fl e r i nl e t conne ct i on. 2. Pl a ce a s t a nd t o s up port t he muffl e r pa[...]

P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Gen eral S p ec if ic a t ions It e m Speci fi cati on C l e a r V i si on Cle a r vis i o n (neg a t i ve val ue i s co unt e rc l ockwis e ) 0° ± 3° R i de Hei ght Fr o nt 371 mm ± 15 mm Re a r 370 mm ± 15 mm Bal l Joi nt Ra di a l Pl a y Lo we r bal l jo i nt — m [...]

P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Wheel Alignmen t Angles Des cr ipt i o n a nd O pe r a t i o n To e is ad j us t a bl e o n the f r ont a nd rea r s us pe ns io n s ys t e m . The f r ont t oe i s a d j us t e d b y us e o f t he front t i e -r od. The r ea r t oe i s a dj us t e d by t he us e of ca m bo[...]

I te m Descri pti on 1 Re a r r ide he i ght m e a s u r e m e nt Whe el Tra ck It e m De sc ri pti on 1 Fr ont t r a ck 2 Re a r t r ack C ra bbing It e m De sc ri pti on 1 Fr ont t r a ck 2 Re a r t r ack cr abbi ng Cr a b bi ng i s t he condi t i on i n whi ch t he i nd epe nde nt r e a r s us pe ns i on (IRS) s y s t em i s n o t sq ua r e to t[...]

a s s mal l rot a t io na l os ci l l a t i o ns of t he s t ee r in g whe e l . Poo r Retu rn ability of the Ste e rin g P oor ret urnabi l i t y of t he s t e e r i ng i s use d t o de s cr ibe t he p oo r r et ur n o f t he s t e e r i ng whe e l t o ce nt e r a ft e r a t ur n or t h e s te e ring co r r ect i o n i s compl e t e d. Drift/Pull [...]

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Suspensio n Sy stem Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer 's conce r n by carr ying o ut a roa d t es t o n a s mo [...]

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P oo r Ret ur nab il i t y o f t he s te e r i ng. Ba l l jo i nt s. CHECK t he Ba l l Jo i nt (s ). Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o B al l J o i nt ins pe cti o n i n t his s e ct i on . S t e e r i ng compone nts . C HECK a n [...]

P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Front To e Adj ustment Gene ral P r ocedures • NO T E: T he checki ng a nd s ubs equ e nt a dj us tme nt o f t he front t o e s e t t ing s ho ul d be ca rr i ed o ut on a f l a t s ur fa ce a nd i n a ccor dance wi t h t he m a nufa ct ures i ns t ruc t i o ns f o r t he[...]

6. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Rot at e t he t ie -r o d s a n e q ual a mount i n e i t her a cl ockwis e o r a count e r cl o ckwis e d ire c t i o n to a dj us t t he t o e s e t t i ng. 7. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Ti ght e n t he t i e-rod e nd l ocknut s . Ti ght e n t o 40 Nm. 8. [...]

P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - R ear T oe Adjustment Gene ral P r ocedures • NO T E: T he checki ng a nd s ubs equ e nt a dj us tme nt o f t he r e a r to e se t t i ng s houl d be ca r rie d o ut o n a f l a t s ur fa ce a nd in a ccor da nce w it h th e m a nufa ct ures i ns t ruc t i o ns f o r t he[...]

7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Ti ght e n t he r e a r l o we r a r m cam bo l t nut s . Ti ght e n t o 115 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Suspens io n System - General Info rma tio n - Wheel B earing Inspecti on Gene ral P r ocedures 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. NOT E: Make s ure t he whe e l rot a t e s freel y a nd t he brake pa ds are r e[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b- ft l b- i n Lo we r arm front ret a i nin g b o lt A A A Lo we r arm r e a r r e t a i ni ng nut a nd bo l t A A A Lo we r arm ba l l j o i nt ret a i ni ng nut a nd bol t 83 61 - S t ab i l i z e r bar t o l i nk ba r r e t a in i ng nut s 48 35 -[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Suspensi on Des cr ipt i o n a nd O pe r a t i o n It e m Par t Nu m ber Descri pti o n 1 — Fr o nt sub f r ame m ount ing b us h 2 — S ta b il i z e r bar 3 — S ta b il i z e r li nk ba r 4 — S u s p e ns i o n s t rut a nt i s l i p f i n 5 — S u s p e ns i o n s t rut s pring 6 ?[...]

Item P a rt N um be r Desc ri pti on 1 — S pring a s s embl y 2 — Thru s t b e a r i ng 3 — S t r ut a nd s pr i ng t op mount 4 — S pring i s o l at o r 5 — Bump s t o p 6 — Dampe r pis t o n ga i t er 7 — Dampe r as s e mbl y JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Suspensi on Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 4-00 Suspe ns i on S ys t e m - Ge neral Inf orm at i on JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Lo w e r Arm Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep a r at o r, Ba l l Joi nt 204-192 (J D-219) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1. Pos it i o n t he f r ont whe e l s i n a s t r ai ght a he a d po s i t i o n a nd cent r al i z e t he[...]

6. NOT E: W he n t he t i e-rod e nd i s s e p a r at ed from t he whe e l hub as s e m bl y, th e ba l l j o i nt s e a l sho ul d be pr ot e ct ed t o pr e vent da mage . Us i ng t he s p e ci a l t o ol , d e t a ch t he t i e -r o d e nd . Vehi c le s with high i ntensity dis char ge hea dlam ps 7. D et a ch t he l i nk r od f r om t he hea dl [...]

10. Ins t a l l t he s p e cia l t o o l . 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 13. NO TE: L e ft -hand [...]

15. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, make s ur e t he s ubf r ame i s l o we r ed be fo re d e t a chi ng t he l owe r a rm ba l l j o i nt . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . Det ach t he l owe r arm f r om t he wh e el knuck l e. 1. Re move t he l [...]

Insta llat ion All v e h icle s 1. Ins t a l l the l owe r arm . Ins t al l a ne w l owe r arm r e a r r e t ai n ing b ol t . 2. Repo s i t i on t he l owe r arm . 3. NOT E: Ins t a l l a new r e t a i ni ng bol t . Lo o s e l y i ns t a l l the l owe r arm front ret a i nin g b o lt . 4. NOT E: Ins t a l l a new r e t a i ni ng nut . At t a ch t [...]

5. Usi ng t he s pe cia l t oo l rai s e t he f ront s u bframe . 6. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s . 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l [...]

10. Remove t he s pe ci a l t o o l . Vehi c le s with autom at ic tra ns m ission 11. At t ach t he s e l e ct o r l eve r cab l e . All v e h icle s 12. At t ach t he s t ee ring ge a r s uppl y pi p e . Vehi c le s with high i ntensity dis char ge hea dlam ps 13. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h ic[...]

14. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . At t a ch bo t h t he t ie -r o d end s . Ti ght e n t o 35 Nm. 15. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover. 16. Ins t a l l t he f r ont whe e ls a nd t i r e s . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a[...]

20. CAUT I O N: T he fi nal t ig ht e ni ng of t he l o wer a rm r e a r r e t ai ni ng nut a nd b ol t, must b e carr i e d out wi th th e v e hi cl e o n i t s whe e l s . Fa i l ure t o fo l lo w t hi s i nst ru ct i o n may r e s ul t i n d amage t o t he ve hi cl e . • NO T E: Ri ght -ha n d s hown, l ef t -hand s i m i l a r. Ful l y t i gh[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Sho ck A bsorber a nd Spr ing Assem bly Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep a r at o r, Ba l l Joi nt 204-192 (J D-219) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 W he e l hub pul l er 205-491 Ada p t e r nuts 205-491- 01 For cing s cr e w 204-269 Knuck l e s p li t t er[...]

3. D et a ch t he brake ho s e r e t ai ni ng bracket . 4. D et a ch t he s t a bi l i z er l ink b a r. 5. D i s conne ct t he f r ont whe e l sp e e d s e nso r e l e ctrica l conne ct o r . 6. CAU TI O N : S ecur e t he br ake c a l i p e r a nd a nchor pl a t e a s s e m bl y t o one s id e . Re move t h e br a ke ca l ip e r and a nchor pl a t[...]

8. NOT E: W he n t he t i e-rod e nd i s s e p a r at ed from t he whe e l hub as s e m bl y, th e ba l l j o i nt s e a l sho ul d be pr ot e ct ed t o pr e vent da mage . Us i ng t he s p e ci a l t o ol , d e t a ch t he t i e -r o d e nd . Vehi c le s with high i ntensity dis char ge hea dlam ps 9. D et a ch t he l i nk r od f r om t he hea dl [...]

12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 13. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rea r mount ret a i ni ng b o lt s . 14. Us i ng t he s pe ci a l t o o l , l owe r the f r ont s ubf rame t o a max[...]

17. CAUT I O N: T o p r eve nt da m a ge t o t he l owe r arm bus hi ng, make s ur e t he s ubf r ame i s l o we r ed be fo re d e t a chi ng t he l owe r a rm ba l l j o i nt . Det ach t he whe e l knuck l e . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning nut a nd b o lt . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe [...]

1. NOT E: Make s ure o r i ent a t i on a r r ow o n t he s trut to p r ubber mount f a ces from fr on t t o r ea r of t he vehi cle . • NO T E: Make s ur e t he ret a i ni ng st ud mark e d wi t h a pa i nt s po t i s corr e ct l y or i e nt a te d. I nst a l l t he s t rut and sp ring a s s embl y. Ti ght e n t o 25 Nm. 2. Usi ng t he s pe cia [...]

6. Usi ng t he s pe cia l t oo l rai s e t he f ront s u bframe . 7. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r m ount r e t a in ing bol t s . 8. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l l the f r ont s ubf rame r e i n fo r cement p l [...]

11. Remove t he s pe ci a l t o o l . Vehi c le s with high i ntensity dis char ge hea dlam ps 12. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h icle s 13. At t ach t he t i e -r od e nd . Ti ght e n t o 35 Nm. 14. At t ach t he b rak e ca l i per a nd a n chor pl a t e a s s e mbly. Ti ght e n t o 133 Nm. JagDocs[...]

15. Conne ct t he f r o nt whe e l s pe e d s e ns or e l e ct rica l c on ne ct or . 16. At t ach t he s t abi l i z e r li nk ba r. Ti ght e n t o 48 Nm. 17. At t ach t he b rak e ho s e ret a i ni ng br acket . Ti ght e n t o 48 Nm. 18. Ins t a l l t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd [...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Stabilizer B a r Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: Make s ure t he r oa d whe e ls a re i n t he s t r ai ght a he a d p o si t i o n. Ce nt ral i z e t he s t e e r i ng a n d l o ck it i n po s i t i o n. 2. Remove t he s t ee ring co l umn l o we r r e t a i nin g b [...]

4. Tig ht e n t o 26 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Stabilizer B a r Bus hing Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n a ss e mbly j a ck HTJ1200- 02 R em ova l All v e h icle s 1. Cent e r t he s t e ering w hee l . Lock i n po s i ti o n a n d remove t he i gni t i on key. 2. D et a ch t he s t e e r i ng col u[...]

5. NOT E: Ri g ht -hand s ho wn, l e f t -hand s i mil a r . Re move t h e whe e l a rc h l i ne r acces s pa ne l . 6. Remove t he a i r de f l e ct or. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) - Puma (501-0 2 Fr ont End Bod y P a nel s , R emoval [...]

10. W A RNING: Ro t at e t he s pe ci al t o o l he i ght a dj us t ment val v e s l o wl y. Fa il ure t o f ol lo w thi s i ns truc t i o n ma y r e s ul t i n p e r s o nal i njur y. Us i ng t he s p e ci a l t o ol , l ow er t h e rear o f t he f ront s ubf r a m e t o a m a ximum of 50 mm (1.97 i n c he s ). 11. NO TE: L e ft -hand s h own, r i[...]

2. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . I nst a l l t he s t a bi l i z e r bar bus h ret a i ni ng br acket . Ti ght e n t he ret a i ni ng bol t s to 4 8 Nm. 3. Usi ng t he s pe cia l t oo l , r ai s e t he re ar of t he front s ubf r a me . 4. NOT E: Le f t -hand s ho wn, r i ght -ha nd s i mil a r . Lo o s e l y i ns t a l [...]

7. Tig ht e n t he f r ont s ubf r a m e r ei nf or ce ment bol t s . M8 t o 35 N m. M10 t o 70 Nm. 8. Remove t he s p e cia l to o l . Vehi c le s with diese l engine 9. Ins t a l l the a i r def le cto r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.0L Du r a t orq- TDCi /2.2L Durat o r q-TDCi (110k W / 150P S ) -[...]

13. NO TE: I ns t a ll a new r e t a i ni ng bo l t . At t a ch t he s t e e r i ng col umn. Ins t al l a ne w s t ee r i ng co l umn l o we r r et a i ni ng bo l t. Ti ght e n t o 25 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Front Wheel Bea ring and Wheel Hub Re moval a n d I ns t a l l a t i on Speci al T ool (s) Fr o nt h ub carr i e r sup po r t 204-310 Hub fl a nge r e m o ver 204-116 -03 Be aring remover 204-262 Hub car r i e r s up po r t 204-309 Be aring s u ppo r t 204-313 Be aring gui de 204-312 Be aring i nst [...]

2. NOT E: W he n r emovi ng t he whe e l hu b f r o m t he whe e l k nuckle t he bea ring wi l l be d e s troyed and th e be a r i ng i nne r r i ng wi l l r e m a i n o n t he whe el hub . Us i ng s pe cia l t o o l s , remov e t he w he e l hub. 3. Usi ng a s ui t a bl e t o o l , r emove t he be a r i ng i nne r r i ng. 4. Usi ng s peci a l t oo[...]

3. Usi ng s peci a l t ool s , pr e s s b ea ring i n to whee l knuck le . 4. NOT E: Chan ge s pe ci al t o o l 204-312 t o 204-313. Al ig n t he be aring a nd w hee l knuck l e ove r s p eci a l t ool . 5. S l i de w hee l h ub o ver t he gui de a nd a l ig n t o t he b e aring. 6. Usi ng s peci a l t ool s i ns t a l l t he whee l hub . 7. Ins t [...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Wheel K nuck le Re moval a n d I ns t a l l a t i on Speci al T ool (s) Bal l jo i nt s pl i t t e r 204-1 92 W he el hub pu ll e r 205-4 91 Adap t er nut s 205-4 91-01 For c i n g s cr ew 204-2 69 Knuck le s p l i t t e r 204-1 59 R em ova l 1. Loos e n t he whee l hub n ut. 2. Remove t he whe e l [...]

4. CAU TI O N : O nl y on e s i de o f t he s ubfra m e ne e ds t o be l o we r ed t o det a ch t he lo we r arm ba l l jo i nt . Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 5. Loos e n t he front s ub frame re ar mount re ta i ni ng bo l t . 6. Loos e n t he front s ub frame f r o nt mount r e t a i ni ng bo l [...]

9. Usi ng t he s pe cia l t oo l s, d e t ach t he ha l f s ha f t . 10. Remove t he whe e l k nuckle p i nc h bo l t . 11. Remove t he whe e l k nuckle . 1. Us i ng t h e s pe ci al t o ol , s p r e a d t he whe el knuck l e. 2. Re move t he whe e l knuc kle . Insta llat ion 1. Att a ch t he whe e l knuck le t o t he s t r ut a nd s pring a s s e [...]

2. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. At t a ch t he l o we r a r m b a l l jo i nt r et ai ni ng nut a nd bo l t . 4. Ti g ht e n t o 83 N m. 3. Tig ht e n t he f r ont s ubf r a m e front mount ret a i ni ng b ol t . Ti ght e n t o 142 Nm. 4. Loos e l y i nst a l l t he [...]

7. Att a ch t he brake cal i pe r and ancho r pl a t e as s e m bl y. 8. Att a ch t he s t ab i l i ze r ba r conne ct i ng l i nk. Ti ght e n t o 48 Nm. 9. Att a ch t he brake hos e re ta i ni ng br a ck et . Ti ght e n t o 48 Nm. 10. Ins t a l l t he ne w w hee l hub nut . 11. Ins t a l l t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m [...]

12. Ti g ht e n t he wh e e l hub nut . Ti ght e n t o 270 Nm. 13. Carr y out f r ont s ubfr a me a l i gnm e nt proced ur e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: U nde r b o dy Mis a li g nment Che ck (502-00 U ni -Bo dy, Subframe a nd Mount i ng S y s t e m, Ge neral Proced ur es ). JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Su spensio n - Sho ck A bsorber a nd Spr ing Assem bly Dis a s s e mbl y a nd As s e mbl y Speci al T ool (s) S pring co i l compr e s s o r 204-112 S pring a d a pt e r s 204-167-0 1 S pring a d a pt e r s 204-112-0 3 D isa ssem bly 1. Remove t he s ho ck abs o r be r a nd s p r i ng a ss e mbly. For a ddi ti ona[...]

4. D i s a s s e mble t he sho ck a bs o rb e r and s pr i ng a s s e mbl y. 1. Re move t he t hru s t b e a r i ng nut . 2. Re move t he s pa ce r . 3. Re move t he t o p mount . 4. Re move t he t hru s t b e a r i ng. 5. Re move t he s pring s e a t . 6. Re move t he s pring . 7. Re move t he b ump s t o p. 8. Re move t he g ai te r . 9. Re move [...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Fr o nt l owe r a rm t o whe e l knuck le ret a i ni ng b o l t 124 91 - Fr o nt l owe r a rm t o s ub frame ret a i ni ng b ol t 124 91 - Re a r l o we r a r m t o whe e l knuc kl e r e t a ini ng bol t 124 91 - Re a r l o we r a r m t o[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Suspensio n Des cr ipt i o n a nd O pe r a t i o n I te m P art N um be r Desc ri pti on 1 — W he e l k nuck l e mount i ng br acket 2 — S ubfr a me mount b us hin g 3 — U ppe r arm 4 — S hock ab s orbe r 5 — S pr ing 6 — Fr ont l o we r a r m 7 — S t a bi l iz e r ba r l i nk 8 —[...]

is of a s te e l des i gn a nd ha s cam bo l t s a t the s ubframe mount i ng p o in t s t o a d jus t whe e l a l i g nment . is t he rea r l o we r su ppo r t f o r th e w hee l knu ckle . car r i e s t he r oa d s pr i ng. is us e d t o a dj us t t he r ea r whe e l al i gnme nt Bus hi ngs : a r e a moul de d co ns t r uct i o n wi t h al umini [...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Suspensio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 204-00 S us pe ns i on Sy s t e m - Ge ne r a l I nfo r mat i o n . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Damper Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. D et a ch t he da mpe r. 3. Remove t he da mpe r . Insta l[...]

3. Tig ht e n t o 25 Nm. 4. Tig ht e n t o 130 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Front Lo w e r Arm4-Door Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. D et a ch t he f ront l o we r arm . 3. [...]

4. Tig ht e n t o 124 Nm. 5. Tig ht e n t o 124 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Front Lo w e r ArmWago n Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). Vehi c le s with 2.0L engi[...]

5. D et a ch t he f ront l o we r arm . 6. Remove t he f r ont l o we r arm . Insta llat ion All v e h icle s • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l e o n i t s whe e l s . 1. Ins t a l l the f r ont l o we r a rm . 2. Att a ch t he f r ont l o we r arm[...]

3. Loos e l y i nst a l l t he f ue l t a nk prot e ct i on br a ck et re ta ini ng bo l t . 4. Usi ng a s ui t a bl e t o r x ada p t o r , 10 mm combi na t i on sp a nne r and 3 /8 dr i ve t orque wr ench, i ns t a l l t he f ue l t a nk pr ot e ct i on br a cket r e t a i ni ng bo l t . 5. Usi ng t he t o rx a dap t o r , 10 mm combina t i o n s[...]

6. Usi ng a s ui t a bl e t o r x ada p t o r , 10 mm combi na t i on sp a nne r and 3 /8 dr i ve t orque wr ench, i ns t a l l t he f ue l t a nk pr ot e ct i on br a cket r e t a i ni ng bo l t . 7. Usi ng t he t o rx a dap t o r , 10 mm combina t i o n s pa nne r a nd 3/8 d r i ve t o r que wrench, t i ght e n t he fue l t an k prot e ct i o n b[...]

10. Ti g ht e n t o 115 N m. 11. Ti g ht e n t o 115 N m. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Lo we r Arm Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 2. Usi ng s uit ab l e t i e s t r a ps , se cur[...]

1. Ins t a l l the rear l o we r arm . 2. Att a ch t he rear l o we r arm . 3. Att a ch t he s t ab i l i ze r ba r l i nk . 4. Ins t a l l the rear whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 5. Tig ht e n t o 124 Nm. JagDo[...]

6. Tig ht e n t o 124 Nm. 7. Tig ht e n t o 35 Nm. 8. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n). JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Spring Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 2. Usi ng s uit ab l e t i e s t r a ps , se cur e t he s [...]

7. Remove t he s p r i ng. Re mov e t he i s ol a t o r. Insta llat ion • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l e o n i t s whe e l s . 1. Ins t a l l the s p r i ng. Ins t al l t he i s ol a t o r. 2. Att a ch t he rear l o we r arm . 3. Att a ch t he a[...]

5. Tig ht e n t o 124 Nm. 6. Tig ht e n t o 124 Nm. 7. Tig ht e n t o 35 Nm. 8. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n). JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Stabiliz er Bar Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. D et a ch t he s t a bi l i z er ba r l i nks . Rig ht -ha nd s hown , l e f t -ha nd s [...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Rear Stabiliz er Bar L ink Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. D et a ch t he s t a bi l i z er ba r l i nk. 3. Remove t he s t abi l i ze r ba r[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Upper Arm Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear whe e l a nd t ir e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 2. D et a ch t he uppe r a r m. 3. Remove t he uppe r a[...]

4. Tig ht e n t o 124 Nm. 5. Tig ht e n t o 124 Nm. 6. Ch eck t he wh e el a l i gnment and a dj us t as nece s s a ry . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Al i gnment A ngl e s (204-00 S us pe ns i o n S yst e m - Ge neral Inf or mat io n, De s cr i pt i o n a nd O pe r a t io n). JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel H ub Re moval a n d I ns t a l l a t i on Speci al T ool (s) Pul l e r , W h e el hub remover 205-49 1 For c i n g Sc r ew, W he e l hub r emove r 204-26 9 Adap t or Nut s , W he e l hub re mover 205-49 1-01 R em ova l All v e h icle s 1. Remove t he rear brak e di s c. For a ddi ti ona l i nf o[...]

4. Usi ng t he s pe cia l t oo l s, re move t he whee l hub. Vehi c le s with 2.0L engi n e 5. CAU TI O N : Fai l ure t o fo l l o w t hi s procedu r e may r es ul t i n da mag e t o th e ant i -l ock b r a ke s yst e m (ABS) compon e nt s . Di s conn ect t he a nt i -l ock brak e s ys t e m (ABS ) s e ns or e l ect r i cal conne ct o r. 6. Remove [...]

1. Ins t a l l the whe e l hub. Ti ght e n t o 63 Nm. Vehi c le s with 2.5L or 3.0L engine 2. Ins t a l l a ne w rea r hal f s haf t r e t a in in g nut . Ti ght e n t o 270 Nm. Vehi c le s with 2.0L engi n e 3. Ins t a l l the (AB S ) se ns o r . Ti ght e n t o 7 Nm. 4. Reconnect t he (ABS ) s e ns o r el e ct r ica l conne ct o r . All v e h icle[...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l hub. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l H ub (204-02, Re mova l a nd I nst a l l at io n). 2. Remove t he a nt i-l o ck br ake s yst e m (ABS) whe e l s p e ed s ens o r wi ring ha r nes[...]

6. D et a ch t he da mpe r. 7. D et a ch t he uppe r a r m. 8. D et a ch t he f ront l o we r arm . 9. CAU TI O N : Make s ur e t h at exces s i ve s t r ai n i s not pl a ced o n t he lo we r a r m. Us i ng a s ui t a b l e t rans mis s io n j ack, s uppo r t the rear l o we r arm . 10. Det a ch t he whee l knu ckle mount i ng br acket . JagDocs.c[...]

11. Remove t he whe e l k nuckle . Det a ch t he r ea r l o we r ar m. 12. CAUT I O N: Ma k e s ure co r r ect po s i t i o n o f t he mount i ng b r ack e t i s not e d b e fo re r emoval . Re move t h e whe e l knuc kl e mount i ng br acket . Insta llat ion • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m[...]

3. Att a ch t he whe e l knuck le mount i ng b rack e t. 4. Ins t a l l the f r ont l o we r a rm . 5. Att a ch t he upp e r arm . 6. Att a ch t he da mpe r . 7. Att a ch t he pa r ki ng b r ake ca bl e a nd condui t . JagDocs.com[...]

8. Att a ch t he pa r ki ng b r ake ca bl e a nd condui t . 9. Att a ch t he ABS whe e l s p ee d s e ns or wi ring ha r ne s s. 10. Ins t a l l a n ew AB S whe e l s pe e d s e ns o r wi r i ng ha r nes s r et ai ni ng s t r ap . 11. Ins t a l l t he whe e l hub. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l H ub (204-02, Re mov[...]

13. Ti g ht e n t o 124 N m. 14. Ti g ht e n t o 124 N m. 15. Ti g ht e n t o 115 N m. No t e : I f y ou a re re-us i ng t hi s f ixi ng o n a ve hi cl e bu i l t p r i o r t o VI N J29472, t he n t i gh te n t o 130 N m. If yo u a re r epl a ci ng a fi xi ng o n a ny v e hi cl e, t he n you mus t r e pl a ce b ot h nut and bol t a nd t i g ht e n [...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e F ro nt B ush ing Re moval a n d I ns t a l l a t i on Speci al T ool (s) S upp o r t Cup , Re a r whe e l knuck le front b us h 204-30 0 Remove r , Rea r whe e l knuck l e f r o nt b us h 204-30 1 Ins t a l l e r , Re a r whe e l knuck l e f r ont b ush 204-30 2 R em ova l 1. Remove t [...]

P ubl i s he d: 11-May-2 011 Rear Suspensio n - Wheel Knuckl e Rear Bus hing Re moval a n d I ns t a l l a t i on Speci al T ool (s) For cing S cr e w, Re a r W he e l Knuckle Re a r Bus h 204-246 S upport Cup , Rea r W h e e l Knuckle Rea r Bus h 204-296 Re mover , Re a r W he e l Knuckle Re a r Bus h 204-298 I nst a l l er, Re a r W he el Knuck l[...]

4. D et a ch t he r e a r l o we r a r m. 5. CAU TI O N : Ca r ef ul l y l o wer t he t r a ns mis s i o n j a c k. Us i ng t he s p e ci a l t o ol s , r emove t he whe e l knuck le rear bus hi ng. Insta llat ion • NO T E: T he f i na l t i ght e ni ng o f t he r e a r s us pe nsi o n compon e nt s m us t be carr i e d o ut w it h t he vehi c l [...]

3. Att a ch t he s t ab i l i ze r ba r l i nk . 4. Ins t a l l the rear whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 5. Tig ht e n t o 124 Nm. 6. Tig ht e n t o 35 Nm. 7. Ch eck t he wh e el a l i gnment and a dj us t as nec[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - T i re Pres s ur es Whe e l Si ze T i re Si z e T i re Manu f acturer R i m Eng i ne C om for t N orm al Front R e a r F ront Re a r 16" 205/55 R16 91 V Pi r e l li P 6000 6.5Jx 16 2.0L 2. 07 ba r (30 l b f/i n² ) 2.07 bar (30 l b f/i n² ) 2.41 bar (35 l bf /i n² ) 2.21 bar (32 l bf /i n²) 2[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Safety P recautio ns Des cr ipt i o n a nd O pe r a t i o n • W ARNINGS : Do not mix d i f fe re nt t ype s of t i r e s o n t he s a me ve hi cl e s uch a s radi a l , b i a s or bi a s bel t e d t i re s e xc ep t i n e mer ge nci e s (t e mpor a ry s p are us a ge ). Fai l ure t o fo l l o w t h[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel s and T ires Des cr ipt i o n a nd O pe r a t i o n It e m Par t N um be r Descri pti on 1 — L ocki ng wh ee l nut a nd wrench s o cket Locking W he e l Nuts Lo ck ing whee l nut s are f i t t e d t o a l l UK a nd Mexico ve hi cl e s wi th a l lo y whe e ls , a nd a r e ava i l a bl e a s a [...]

Item Part Nu mber D escri pt i on 1 - T i re va l ve a nd pr e s s ur e s e ns or 2 - T i re f it t i ng/r e mova l t o o l in i t i al s t art po s i t i o n 3 - H i gh t i r e a nd b e a d t e nsi on a r e a 4 - L o w t i re a nd b e ad te ns i o n a re a W he n re m ovi ng t h e t i r e , t he b e ad b r ea ker mu s t no t b e us e d wi t h in 9[...]

Tir e Pressur e Monit oring Syste m The TP MS i s a dr i ver as s i s t a nce s yst e m whi ch a s s i s t s t he dr i ver t o mai n ta i n th e t i re pres s ur es a t t he o p t i mum l e vel . The TPM S i s a s t a nda r d fi tme nt o n NA S vehi cl e s a nd a n o pt i o nal f i t ment i n o t her ma r ke t s . The T P MS s yst e m ha s t he f o[...]

The i ni t i at o r i s a p a ss i ve LF t rans mi t t e r . I t t rans mi t s s i gna l s whi ch are recei ve d b y t he t ire pr e s s ur e s e n s ors p r o mpt i ng t he m t o mo di fy th e i r m o de s t at us . The TP MS modul e e ne rg i z es ea ch i ni t i a to r i n t ur n us i ng LF drive r s . T he corr e s po ndi n g t ir e pr e s s ure[...]

I f a T P MS fa ul t wa r nin g me s s a ge is d et e cte d b y t he i ns t r um e nt cl us t e r a t i gni t i o n on , t he wa r ni ng i ndi ca t o r wi l l f l a s h fo r 72 s e conds a f t e r t he 3 s e cond bul b c he ck pe r i od a nd t he n remai n pe rm a nent l y i l l umina t e d. I f a t i r e pr es s ure wa r ni ng mes s a ge i s d e t[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel s and T ires Dia gn os i s a nd Te s t i ng G ene r al note s Fa c t o r y i ns t a l l e d t i r es a nd whe e l s are de s i gne d t o o pera te sa t i s fa ct or y whe n i nfl a t e d t o th e r ecommende d i nfl a t i on pr es s ures ; refe r t o t he S peci fi ca t i o ns s ub-s ect i on .[...]

* * * * * * * * * * * * * * * * * * * * Mechani cal Bul ge s (b li s t e r ) P ly s e pa r a t io n Embed ded o bj e ct s I m pa ct d a m a ge I nc o r r ect s pe e d rat i ng I nc o r r ect l o a d r at ing I nc o r r ect r ot at i on a l di rect i on 3. If a n obvi o us cau se fo r an ob s e rv e d o r r epo r t e d conce r n i s f o und, co r r [...]

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * Exces s ive l a t e ral o r radi a l runout of whe e l o r t i r e Che ck , r epa i r or i nst a l l a n e w a s nece s s a ry . Ref e r t o t he pr oce dure in t hi s s ect i on . W he e l mount i ng i s di ff i cul t In c orr e ct a ppl[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Lo w Pre ssu re Senso rV IN Range: J28 493- >V99999 Re moval a n d I ns t a l l a t i on R em ova l • NO T E: I t i s s t r ong l y r e com me nde d t ha t a ne w t i re l ow p r e s s ur e s e ns o r O-r i ng s e al , wa s he r , nut , va l ve cor e a nd ca p a re i ns t a l l e d e a ch [...]

2. CAU TI O N : Make s ur e s o l ve nt s or cl e a ni ng a ge nt s of a ny t ype a r e not use d t o cl e a n t he t ire l o w pr e s s ure s e ns o r. Fa i l ur e t o fo l l ow t his in s t ruc t i o n may r es ul t i n da mag e t o t he ti r e l ow pres s ur e s e ns o r . • NO T E: If t h e t i re l o w pr e s s ur e s e nso r i s r e pl a ce[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Fro nt AntennaVI N Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Jackin g (100-02 Ja ck i ng a nd Li f t i ng , Des cr ipt i o n [...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Main AntennaVIN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Jackin g (100-02 Ja ck i ng a nd Li f t i ng , Des cr ipt i o n a n[...]

1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 5 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Mo duleV IN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Re moval a n d I ns t a l l a[...]

6. Repo s i t i on t he t i re p r es s ur e moni t o r i ng s yst e m modul e . Re mov e t he re ta i ni ng nut s . 7. Remove t he t i re pr e s s ur e moni t o ring s ys te m modul e . Dis conne ct t he e xt ernal ant e nna conne ct o r . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 5 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Ti re Pressure Mo nitori ng System (T PM S) Rear AntennaVIN Range: J2 8493-> V99999 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Jackin g (100-02 Ja ck i ng a nd Li f t i ng , Des cr ipt i o n a n[...]

P ubl i s he d: 11-May-2 011 Wheels and Ti res - Wheel and T ire Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : Do no t us e hea t t o l o os e n a s e i ze d whe e l nut , e x ce s s i ve he at ma y caus e da ma ge t o t he whe el a nd t he whe e l be a r i ngs . Lo o s e n t he whe e l nut s . 2. Rai s e a nd s uppo r t the ve hi[...]

P ubl i s he d: 11-May-2 011 Driveline System - G eneral In fo rm ation - Driv eline System Des cr ipt i o n a nd O pe r a t i o n The dr i vel in e t r ans fe rs e ngi ne t orque t o t he drive whe e l s . O n vehi cl e s wit h 2.0L o r d i e s e l e ngi nes t he po we r is t rans mi t t e d t hr oug h t he t r a nsa xl e t o t he f r ont d r i ve[...]

P ubl i s he d: 11-May-2 011 Driveline System - G eneral In fo rm ation - Driv eline System Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on Ce r t a i n drive l i ne condi t i o ns a re a l s o co mm o n t o t h e e ng i ne , t rans a xle , t r a nsf e r cas e , whe el b e a r i ngs , whe e l s a nd t i res a nd o t he r pa r t s o [...]

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 2 No i s e i s a t co ns t a nt t o ne ove r a na r r ow vehi cl e s p e ed r ange . Us ual l y he a r d o n l i g ht dr ivi ng a nd coa s ti ng condi ti o ns Re a r d r i v e di f f e r ent i a l . Trans f e r cas e . Trans a xle . For a ddi t[...]

P ubl i s he d: 11-May-2 011 Driveshaft - T o rque Sp eci f i cat ions Descri pti on Nm l b-ft l b-i n Dr ive s ha f t cent er be a r i ng r et a i ni ng bol t s 25 18 - Dr ive s ha f t front uni versa l j oi nt r e t ai n in g b ol t s 44 32 - Dr ive s ha f t r ea r uni ver s a l j o int r et a i ni ng b ol t s 44 32 - JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Des cr ipt i o n a nd O pe r a t i o n I te m Pa rt N um be r De sc ri pti on 1 — Li nk was he r 2 — Dr ive s ha f t uni versa l j o i nt ret a i ni ng bol t 3 — Dr ive s ha f t front col l a ps i bl e t ube 4 — Dr ive s ha f t cent e r be a ring 5 — Dr ive s ha f t uni versa l j o i n[...]

P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 205-00 Dr i ve l i ne S yst e m - Gene ral I nfo rm at i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Runo ut and B alanc ing Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t o t he a pproved Ja guar di agno s t i c s yst e m. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Driveshaft - Driv eshaft Re moval a n d I ns t a l l a t i on R em ova l • NO T E: Re moval o f t he dr i v e s ha f t rear uni versa l j oi nt s hown, removal o f t he dr ive s ha f t front uni vers al j o i nt s i mil a r. 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r [...]

7. CAU TI O N : Make s ur e t h e front a nd r e a r d r i ves ha ft s e cti o ns a re s uppo r t e d . Re move t h e dr i ves ha ft . Re mov e dr ive s haf t ce nt e r bea ring ret a i ni ng bo l t s. Insta llat ion 1. CAU TI O N : Make s ur e t h e front a nd r e a r d r i ves ha ft s e cti o ns a re s uppo r t e d . I nst a l l t he d r i v e s [...]

P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Gen eral S p ec if ic a t ions I te m Speci fi ca ti on Oi l t ype M2C1 92A synt he t i c Oi l cap a c i t y 1.2 l it e r s T o rque Sp eci f i cat ions Descri pti on Nm l b-f t l b- i n Dr ive s ha f t front uni versa l j oi nt r e t ai n in g b ol t s 40 3 0 - Dr ive s ha f t r ea r [...]

P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Re ar Drive A xle a nd Differential Des cr ipt i o n a nd O pe r a t i o n I te m Pa rt Nu mber De sc ri pti on 1 — Vi br at i o n d a m pe r br acket 2 — Ax l e s ha ft o i l s e a l 3 — Ax l e ho us i ng 4 — Ax l e s ha ft o i l s e a l 5 — Dr i v e pi ni o n s e a l 6 — [...]

P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Re ar Drive A xle a nd Differential Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Ax le Shaf t Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Re mover , Axl e S ha f t O i l S e a l 308-208 I nst a l l er, O i l S e a l 204-264 R em ova l 1. Remove t he rear hal fs haf t . For a dd it i o na l i nfo rm at i on, ref e r t o Sect i on 205-05 Rea r Dr i ve Ha l f s[...]

P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - D rive Pinio n Flange I n-v e hi c l e Re pa i r Speci al T ool (s) To r que T o T ur n Ro t a r y T ool 205-518 W r e nch, Fl a ng e 205-053 Re mover , Fl a nge P la t e 204-295 Re mover , Fl a nge Bo s s 204-266 Re mover , Fl a nge S haf t 204-268A I nst a l l e r, O i l Sea l 204-26[...]

4. Remove t he vibrat i on d amper ret a i ni ng b o l t . 5. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e f r ont r e t a i ni ng bol t s . Re mov e t he vi br at i o n da m pe r br acket . 6. Remove t he a xle a s s e mbly r ea r r et ai ni ng bo l t . 7. CAU TI O N : Make s ur e CV j o in t s d o no t e xc e e d 18 de gr ee s[...]

10. Us i ng t he s pe ci a l t o o l , i ns t a l l a brea ker ba r a nd r e move a nd di sca r d t he dr i ve p i ni on f l a nge ret a i ni ng n ut . 11. NO TE: Mark t he pi ni o n f l a ng e i n r e l a t i on t o t he drive pi ni o n s t e m t o e ns ure corr e ct a l i gnment dur i ng i ns t al l a t i on. Us i ng t he s p e ci a l t o ol s , [...]

3. CAU TI O N : Do no t unde r any ci rc ums t a nce, l o o s e n t he p i ni on nut t o r e duce p r el o a d, if prel o a d i s excee de d i nst a l l a ne w col l a p s i b le s pa cer an d pi ni o n nut . Us i ng t he s p e ci a l t o ol , h ol d t he p i nio n f l a nge whi l e t i ght e ni ng t he d r i ve pi ni on r et a i ni ng nut . 4. CAU[...]

9. Tig ht e n t he a xle a s s e mbly f r on t ret a i ni ng bo l t s t o 90 N m. 10. Ti g ht e n t he a xl e a s s embl y rear r e t a i nin g b o lt t o 110 Nm a nd t he n s l o wl y ti gh te n t o 135 N m . 11. Ins t a l l t he vibrat i on d amper. Ti ght e n t o 48 Nm. 12. Ins t a l l t he drive sha f t . For a ddi ti ona l i nf o r m a t i o n[...]

P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - D rive Pinio n Seal I n-v e hi c l e Re pa i r Speci al T ool (s) To r que T o T ur n Ro t a r y T ool 205-518 W r e nch, Fl a ng e 205-053 Re mover , Fl a nge P la t e 204-295 Re mover , Fl a nge Bo s s 204-266 Re mover , Fl a nge S haf t 204-268A I nst a l l e r, O i l Sea l 204-264 [...]

4. Remove t he vibrat i on d amper ret a i ni ng b o l t . 5. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e f r ont r e t a i ni ng bol t s . Re mov e t he vi br at i o n da m pe r br acket . 6. Remove t he a xle a s s e mbly r ea r r et ai ni ng bo l t . 7. CAU TI O N : Make s ur e CV j o in t s d o no t e xc e e d 18 de gr ee s[...]

10. Us i ng t he s pe ci a l t o o l , i ns t a l l a brea ker ba r a nd r e move a nd di sca r d t he dr i ve p i ni on f l a nge ret a i ni ng n ut . 11. NO TE: Mark t he pi ni o n f l a ng e i n r e l a t i on t o t he drive pi ni o n s t e m t o e ns ure corr e ct a l i gnment dur i ng i ns t al l a t i on. Us i ng t he s p e ci a l t o ol s , [...]

3. CAU TI O N : Do no t unde r any ci rc ums t a nce, l o o s e n t he p i ni on nut t o r e duce p r el o a d, if prel o a d i s excee de d i nst a l l a ne w col l a p s i b le s pa cer an d pi ni o n nut . Us i ng t he s p e ci a l t o ol , h ol d t he p i nio n f l a nge whi l e t i ght e ni ng t he d r i ve pi ni on r et a i ni ng nut . 4. CAU[...]

9. Tig ht e n t he a xle a s s e mbly f r on t ret a i ni ng bo l t s t o 90 N m. 10. Ti g ht e n t he a xl e a s s embl y rear r e t a i nin g b o lt t o 110 Nm a nd t he n s l o wl y ti gh te n t o 135 N m . 11. Ins t a l l t he vibrat i on d amper. Ti ght e n t o 48 Nm. 12. Ins t a l l t he drive sha f t . For a ddi ti ona l i nf o r m a t i o n[...]

P ubl i s he d: 11-May-2 011 Rear Driv e Axle/D iffe re ntial - Ax le Ass embly Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he l e ft -hand rear hal f s haf t. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r Hal fs ha ft (205-05 Re a r Dr i v e Ha l f s ha f t s , Re moval a nd I ns t a l l a t i o n). 2. Loos e l y i[...]

6. Remove t he vibrat i on d amper. 7. Remove t he vibrat i on d amper bracket r et a i ni ng bo l t . 8. NOT E: S uppo r t t he a xl e a s s embl y. Re move t h e a xl e a s s embl y f r ont r et a i ni ng bo l t s . Re mov e t he vi br at i o n da m pe r br acket . 9. Remove and di s card t he axl e a s se mbl y r e a r r et a ini ng bol t a nd l[...]

Insta llat ion 1. NOT E: S uppo r t t he a xl e a s s embl y. • NO T E: W he n i nst a l l in g t he ha lf s ha ft ma k e s ure t he s pring cl i p i s ful l y e ngag e d i n t he di ff e r e nt i a l . I nst a l l t he a xl e a s s e mbl y. 1. I ns t a l l t he a x l e a s s e mbl y. 2. I ns t a l l t he hal fs h a ft i nt o t he a xl e as s e m[...]

6. Tig ht e n t o 150 Nm. 7. CAU TI O N : S lo wl y t i ght e n t he a x l e ret a i ni ng b ol t to f i nal t or que . Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n d amage t o th e ve hi cle . Ti ght e n t o 150 Nm. I f you are refi t t ing a n ol d fi xing (be f o r e V IN J24258), t i g ht e n t o 135 N m. 8. Tig ht e n t[...]

11. At t ach t he d rives ha f t r e a r uni ver s al j o int . 1. I ns t a l l a ne w ga s ke t . 2. I ns t a l l ne w drive s ha ft r et a i ni ng bo l t l in k was he r s . 3. I ns t a l l ne w drive s ha ft r et a i ni ng bo l t s . 1. Tight en t o 4 0 Nm . 12. Carr y out t he unde r bod y m i s al i gnment ch e ck. For a ddi ti ona l i nf o r [...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - T o rque Sp eci f i cat ions Descri pti on Nm l b- ft l b- i n W he e l hub nut 270 200 - Ti e r o d e n d ret a i ni ng nut 35 26 - Lo we r arm ba l l j o i nt ret a i ni ng nut 83 61 - Fr o nt s ubf rame r e i nfo r cement p l a t e r et a i ni ng bo l t 35 26 - Fr o nt s ubf rame r e a r m [...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Drive Halfsh afts Des cr ipt i o n a nd O pe r a t i o n Front Drive Half sha f ts I te m P ar t N u m ber Descri pti on 1 — O ut e r cons t a nt ve l oci t y (CV) j o i nt 2 — CV jo i nt bo o t r e t a i ni ng cl ip 3 — CV jo i nt bo o t 4 — CV jo i nt bo o t r e t a i ni ng cl [...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Drive Halfsh afts Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft LH Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j oi nt s pl i t te r 204-192 W he e l hub pu ll e r 205-491 Ada pt e r nut s 205-491- 01 For cing s cr e w 204-269 S li de ha mm er 100-012 100-012- 02 S li de ha mm er s ha f t Ha l f s ha f t r emove r fo rk [...]

2. Remove t he f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 3. Remove t he t i e r o d e nd ret a i ni ng nut . 4. Usi ng t he s pe cia l t oo l de t a ch t h e t i e rod e nd. 5. Remove t he s ub frame rei nfo rc e[...]

7. Loos e n t he s ubf r a me front mount ret a i ni ng b ol t. 8. Remove and di s card t he whee l hub n ut . 9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e . 10. Us i ng t he s pe ci a l t o o l s , d e t ach t he[...]

13. Us i ng t he s pe ci a l t o o l s , re m o v e t he hal fs ha ft . 14. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o pr ot ect t he b a r s ha ft . Re move t h e ha l fs ha ft s na p ring. Insta llat ion All v e h icle s 1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. CAU TI O N : Make s ur e t h e CV j o i nt s pl [...]

3. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l t he lo we r ar m ba l l j o i n t r e t a i ni ng bo l t . Ti ght e n t o 83 Nm. 4. Tig ht e n t he f r ont s ubf r a m e front mount ret a i ni ng b ol t . Ti ght e n t o 142 Nm. 5. Loos e l y i nst a l l t he s ubf r a [...]

8. Ins t a l l the t ie r od e nd. Ti ght e n t o 35 Nm. 9. Loos e l y i nst a l l a ne w whee l hub nut . 10. Ins t a l l t he f r ont r oa d w hee l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). Vehi c le wi th aut om a tic t ra nsmi[...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft RH2. 0L NA V6 - A JV6 /2. 5L N A V 6 - A JV 6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j o i nt s pl i tt e r 204-192 W h ee l hub pul l e r 205-491 Ada p t e r nuts 205-491-0 1 For ci ng s crew 204-269 RH hal fs ha ft s pl i t t e r[...]

All v e h icle s 1. Loos e n t he whee l hub n ut. 2. Remove t he f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 3. Remove t he t i e r o d -end ret a i ni ng n ut . 4. Usi ng t he s pe cia l t oo l , de t a ch th e t[...]

6. Loos e n t he s ubf r a me r ea r m ou nt bol t . 7. Loos e n t he s ubf r a me front mount bo l t . 8. Remove and di s card t he whee l hub n ut . 9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e . 10. Us i ng t h[...]

Vehi c le s with 2.5L or 3.0L engine 11. Remove t he e xhaus t muff l e r i nl e t pi p e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Muff l e r Inl e t Pi p e - 2.0L N A V 6 - AJV6/2.5L N A V6 - AJV 6/3.0L NA V6 - AJ27 (309- 00 Exhaus t S y s t e m, Re moval a n d I ns t a l l a t i o n). 12. Remove t he ha l f s haf t s ea l . 13. R[...]

16. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o pr ot ect t he b a r s ha ft . Re move a nd di s ca r d t he ha l f s ha f t s nap r in g. Insta llat ion All v e h icle s 1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. Ins t a l l a ne w ha lf sha f t se a l . Vehi c le s with 2.0L engi n e 3. Ins t a l l the ha l f s [...]

4. Remove t he s p e cia l to o l . 1. Re move t he t rans f e r cas e Y brack e t ret a i ni ng bo l t. 2. Re move t he s pe cia l t oo l . 5. CAU TI O N : Make s ur e t h e CV j o i nt s pl i ne s a re l o ca t e d f ul l y . Do not use e x ce s s i v e fo rc e wh en e nga gi ng t he CV jo i nt i nt o t he l i nk s haf t . I nst a l l t he ha l f[...]

9. Tig ht e n t he s ubf r ame front mount r e t a i nin g b o lt . Ti ght e n t o 142 Nm. 10. Ins t a l l t he s ub frame r ei nfo r cemen t pl a t e r et a i ni ng bol t s . Ti ght e n t o 35 Nm. 11. Ti g ht e n t o 142 N m. 12. Ins t a l l t he t i e -r od e nd . Ti ght e n t o 35 Nm. 13. Loo s e l y i ns t a l l a ne w whee l hub nut . JagDocs.[...]

14. Ins t a l l t he f r ont r oa d w hee l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 15. Ti g ht e n t he wh e e l hub nut . Ti ght e n t o 270 Nm. 16. Check t he s ubframe al i gnmen t. For a ddi ti ona l i nf o r m a t i o n, r [...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Front Hal fshaft RH2. 0L Duratorq-TDCi / 2.2L Durato rq-TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Ba l l j oi nt s pl i t te r 204-192 W he e l hub pu ll e r 205-491 Ada pt e r nut s 205-491- 01 For cing s cr e w 204-269 R em ova l 1. Loos e n t he whee[...]

4. Usi ng t he s pe cia l t oo l , de t a ch th e t i e -r od end. 5. Remove t he s ub frame rei nfo rc emen t pl a t e ret a i ni ng bol t s . 6. Loos e n t he s ubf r a me r ea r m ou nt bol t . 7. Loos e n t he s ubf r a me front mount bo l t . 8. Remove and di s card t he whee l hub n ut . JagDocs.com[...]

9. D et a ch t he wh ee l knuck le . 1. Re move t he l o we r a r m ba l l j o i nt r e t ai ning b ol t . 2. Re pos i ti on t he l owe r a r m . 3. De ta ch t he whe e l k nuck l e . 10. Us i ng t he s pe ci a l t o o l s , d e t ach t he h a lf sha f t. 11. Remove t he ha l f s haf t. 12. CAUT I O N: U s e s ui t a bl e p r ot ect ive co vers t o[...]

1. Ins t a l l a ne w s na p r i ng t o th e hal fs ha ft . 2. Ins t a l l the ha l f s haf t . Ti ght e n t o 25 Nm. 3. Att a ch t he whe e l knuck le . 1. Re pos i ti on t he l owe r a r m . 2. At t a ch t he whe e l knuc kle . 3. I ns t a l l t he lo we r ar m ba l l j o i n t r e t a i ni ng bo l t . Ti ght e n t o 83 Nm. 4. Tig ht e n t he s u[...]

6. Tig ht e n t o 142 Nm. 7. Ins t a l l the t ie -r o d e nd . Ti ght e n t o 35 Nm. 8. Loos e l y i nst a l l a ne w whee l hub nut . 9. Ins t a l l the f r ont road whee l a nd t i re. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mova l a nd Ins t al l a t i on). 10. Ti g ht e n[...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Inner C on stant Velo city (CV ) J o in t Bo o t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont ha l f s ha f t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o Ha l f s ha f t L H . For a ddi t i o na l i nfo rm at i o n, ref e r t o H a lf sha f t RH . 2. CA[...]

7. Remove t he i nne r CV jo i nt b oo t r e t a in ing cl i p. Re mov e a nd di s c a r d t he r et a i ni ng cli p. 8. Remove t he i nne r CV jo i nt b oo t . Insta llat ion 1. Ins t a l l the i nner CV j oi nt b o ot . 2. NOT E: Ins t a l l a new r e t a i ni ng cl ip . Us i ng a s ui t a b l e t o o l , ins t a l l t he i nne r CV j o i nt bo o[...]

3. CAU TI O N : Do no t da mage t he r o l l e r be a rings . I nst a l l t he t ripo d s t a r . 4. Ins t a l l the t r i p od s t a r circ l i p. 5. NOT E: Ins t a l l ne w grea s e . I nst a l l t he t ripo d s t a r hous ing . 6. NOT E: Make s ure e noug h a i r i s pres e n t in t he CV boo t . • NO T E: Ins t al l a ne w re t a i ni ng cl i[...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Intermediate Sh aft Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he right -ha nd ha l fs ha ft . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o Ha l fs ha ft RH i n t hi s s e cti o n. Vehi c le s with autom at ic tra ns m ission 2. D r ai n t he a ut om[...]

2. CAU TI O N : Be f o r e i ns t a l l i ng t he be a r i n g carr i e r r e t ai n in g b ol t s m a ke s ur e t ha t t he be a r i ng ca r r ie r i s l o cat e d i n t he s a me po s i t i o n t ha t i t wa s r e moved f r om, f ai l ur e t o f ol l ow th i s p r o ced ure wi l l r e s ul t i n d a mage to th e v e hi cl e . I nst a l l t he b r[...]

P ubl i s he d: 11-May-2 011 Front Drive Halfs haft s - Outer C on stant V elo c ity (CV ) J o int B oo t Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f r ont ha l f s ha f t . Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o Ha l f s ha f t L H . For a ddi t i o na l i nfo rm at i o n, ref e r t o H a lf sha f t RH . 2. C[...]

1. Ins t a l l the o ut er CV jo i nt b oo t . 2. CAU TI O N : Do no t da mage t he bea ring ret a i ne r . • NO T E: T he o ut e r CV j o in t is r e t a i ne d t o t he s ha ft by a s pr ing cl i p. I nst a l l t he o ut e r CV j o i nt . 3. Att a ch t he o ut e r CV jo i nt bo o t . Ins t al l new gr ea s e . 4. NOT E: Make s ure e noug h a i [...]

P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Item S pe ci fi ca ti on Cons t a nt vel o c i t y (CV) gr e a s e Ol i s t amol y L N 584 LO Fi l l C apaci ti es Descri pti on Grams Gr ea s e f o r i nne r CV jo i nt boo t 90 Gr ea s e f o r i nne r CV jo i nt 90 Gr ea s e f o r o ut e r[...]

P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Driv e Hal fshafts Des cr ipt i o n a nd O pe r a t i o n Rea r Drive Half sh a fts I te m P ar t N u m ber Descri pti on 1 — O ut e r cons t a nt ve l oci t y (CV) j o i nt 2 — An t i -l o ck br ake s yst e m (ABS) r i ng 3 — O ut e r CV j o i nt boo t 4 — I nne r CV jo i nt bo o [...]

P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Driv e Hal fshafts Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 5-00 Drivel i ne S yst e m - Ge ne r al Inf orm a t i o n . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Rear Halfsh aft Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover , Axl e S ha f t O i l S e a l 308-208 I nst a l l er, O i l S e a l 204-264 R em ova l 1. Remove t he whe e l knuck le . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Knuck le (204- 02 Re a r S [...]

2. NOT E: W he n i ns t a l l i ng t he ha l fs haf t make s ur e t he s p r i ng cli p i s f ul l y e ngag e d i n t he di ff e r e nt i a l . I nst a l l t he ha l f s ha f t . 3. Ins t a l l the whe e l knuckle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l Knuck le (204- 02 Re a r S us pe ns i o n, Re m o v al a nd I ns t a [...]

P ubl i s he d: 11-May-2 011 Rear Driv e Hal fshafts - Ou ter Co nst ant Vel oci ty (CV ) J oi nt Bo ot Re moval a n d I ns t a l l a t i on R em ova l • NO T E: O ut er Cons t a nt Ve l o ci t y (C V) Jo i nt B oo t s hown, i nner Co nst a nt V e l o c i t y (CV) Jo in t Bo o t si mil a r . 1. Remove t he ha l f s ha f t . For a ddi ti ona l i n[...]

1. Ins t a l l the o ut er CV jo i nt b oo t . Ins t al l a ne w ret a i ni ng cl i p. Us i ng a s u it a b le t oo l , i ns t a ll the r et ai ni ng cli p. 2. Ins t a l l the ne w r e t a i n in g cl i p. Ins t al l a ne w ret a i ni ng cl i p. Us i ng a s u it a b le t oo l , i ns t a ll the r et ai ni ng cli p. 3. CAU TI O N : Make s ur e t h e [...]

P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d[...]

P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: B r ake fl ui d con ta i ns p ol ygl yc o l e t he rs a nd pol ygl yc ol s. Avoi d cont a ct wi t h t he e yes . W a s h hand s t hor ou ghl y a ft e r handl i ng. I f brak e fl ui d co nt a ct s t he e ye s , f l [...]

* * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System Dia gn os i s a nd Te s t i ng P r i nci pl e s o f O pe r at i o ns The br ake s yst e m op e rat e s by t r ans fe rr i ng ef f ort a ppl i e d t o t he b r a ke p e da l , by t he dr i ver, t o t he brakes a t e a ch wh e e l . The br[...]

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 1 1 1 1 The br ake s pul l o r dr i ft T i re p r e s s ur es /wea r . Ca li pe rs. Br ake p a ds . Br ake d i s cs . W he e l a l i gnme nt a dj us t me nt . W he e l b ea ring. S uspe ns i o n b us he s and ba l l jo i nt s . GO t o Pi npoi nt Te[...]

1 1 1 1 1 1 1 1 Is a vib r a t i o n p res e nt ? Ye s CHECK t he br ake cal i pe r mount i ng b ol t s and whee l hub nu ts and TI GHTEN a s ne ces s a r y. CHECK t h e ba l a nce of a l l r oa d whee l s a nd REP AIR a s ne ce s s a ry . CHECK t he b r a ke d i scs f o r exces s i ve we ar, r unout , t h i ckn e s s va r i a t i on or cr ack s . [...]

1 1 1 2 3 4 5 6 1 1 1 1 I s t he a l i gnment wi t hi n s peci f i ca t i o n? Ye s Ve hi cl e i s O K. No Adj us t t h e a l i gnment a s ne ce s s a r y. Fo r a ddi t i o nal i nfo r m at i o n, r ef e r t o REFER t o : U nde rb od y Mi s al i gnme nt Che ck (502-00 Uni -Bod y , S ubframe a nd Mount in g Sy st e m, Ge ne r a l P r o ce dures ). .[...]

1 1 1 1 1 1 2 3 4 1 2 3 4 1 Check f o r e xt e r nal b r ake s yst e m l e a ks. For add i t i ona l i nf o r m a t i o n, r e f er t o Ma s t er Cyl i nd er i n t hi s s e ct i on. Ar e l e a k s fo un d? Ye s REPAI R a s ne ce ss a r y, ADD fl ui d a n d B LEED b r ake s yst e m. Fo r a ddi t i on a l i nf o r m at i o n, ref e r t o REFER t o : [...]

1 1 1 1 1 1 1 2 1 1 T EST C ONDI T IONS DET AI LS/RE S U LT S/ACT IONS H1 : T EST B R AKE LOC KUP Roa d t e s t t he vehi cl e a nd a ppl y t he br a ke pe d al l ig ht l y. Do t he br akes l o ck up? Yes GO t o H2 . No Vehi cl e i s O K. H2 : I NS PE C T B R AKE PADS Ins p e ct brake pa ds f o r cont a mina t i o n, co r r e c t i nst a l l a ti o[...]

2 3 4 5 6 1 1 2 3 4 5 1 Appl y t he br ake pe da l l i g ht l y t hr e e o r f o ur t i m e s . W a i t 15 s e con ds fo r t he v a cuum t o repl e ni s h. P ush do wn on th e bra k e ped a l unt i l it s t o ps movi ng downwa r d o r a n i ncr ea s e d res i s t a n c e t o t he brak e p e da l t ravel occur s . Ho ld t he b r ake p e da l i n t h[...]

The fo l lo wi ng condi t i on s a r e c o ns i de r e d norm al a nd a r e no t i ndi cat i o ns t ha t t he brak e ma s t e r c yl i nde r i s i n ne ed o f r e pa i r . Ne w b rak e s ys t e ms a r e d e s ig ne d t o pr od uce a p e da l e f fo rt t ha t i s not a s hard a s i n t he pa s t . Compl a i nt s o f l i g ht pe d a l e f f o r t s s[...]

P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake Dis c Runo ut C heck Gene ral P r ocedures C heck 1. Rai s e a nd s uppo r t the ve hi cle . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: L i f t i ng (100-0 2 Jacking a nd Li f t i ng, Des cr ipt i o n a nd O pe rat i o n). 2. Remove t he whe e l a nd t i r e [...]

P ubl i s he d: 11-May-2 011 B rake System - G eneral Inf orm atio n - B rake System B leeding Gene ral P r ocedures W ARNI N G: B r ake Fl ui d cont ai ns po l ygl yc ol e t he r s a nd p o l yglycol s . Avoi d c ont a ct wi t h t he e ye s . W a s h ha nds tho r ou ghl y a f t e r han dl i ng. I f brak e fl ui d co nt a ct s t he e ye s , f l us [...]

br ake ci rcu i t s . 6. F i l l up t h e mas t e r cy li nde r r es e r voi r t o t he MAX mar k . 7. Ins t a l l the mas t e r cy li nde r r es e rv oi r cap. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Dis c B rake - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d IT T S up e r Do t 4[...]

P ubl i s he d: 11-May-2 011 Front Dis c B rake - Front Dis c B rake Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um be r Descri pti on 1 — B r a k e hos e 2 — B r a k e cal ip e r r e t ai n in g b ol t s 3 — B r a k e pad s 4 — B r a k e cal ip e r a ncho r pl a t e 5 — B r a k e di s c 6 — W hee l hub 7 — W hee l knuc kle [...]

P ubl i s he d: 11-May-2 011 Front Dis c B rake - Front Dis c B rake Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 206-00 Br ake Sy s t e m - Gene r a l I nfo r mat i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake C al iper Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Sect i on 204-04 W hee l s a nd T ire s . 2. CAU TI O N : If brak e fl ui d i s[...]

1. CA UT I O NS: I f t he pi s t o ns a r e pus he d b a c k i nt o t he ho us i ng , br a ke f l ui d wi l l be fo rc e d o ut o f t he i nl e t po rt of t he b rak e ca l i p er. Make s ur e t ha t the br a k e di s c fa ce s a r e c l e a n be f o r e i ns t a l l a t i o n. • NO T E: Ins t al l n ew br a ke ca li pe r r e ta i ni ng bo l t s.[...]

P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake Di sc Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he brake pa ds , r ef e r t o t he p r oce dur e i n t hi s s e c t i o n : P a ds . 2. Remove and di s card t he br a ke cal i p e r a n c hor pl a t e r e t a in in g b ol t s . 3. D et a ch t he brake cal i pe r , brake cal i[...]

P ubl i s he d: 11-May-2 011 Front Dis c B rake - Brake Pads Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n, r e f e r to Sect i on 204-04 W hee l s a nd T ire s . 2. Pi vot t he brake cal i pe r upwa r ds . 1. Re move a nd di s car d t he br ake ca l i pe r l o wer r e[...]

3. Pi vot t he brake cal i pe r downwa rds . 4. Ins t a l l a ne w b r ake ca l i per l o we r r et a i ni ng bo l t . Ti ght e n t o 30 Nm. 5. Ins t a l l the whe e l . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o Sect io n 204-04 W he e l s a nd Ti r es . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Disc Brake - Lubr i cant s, Flu ids , sea l e rs and Ad hesi ves CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d IT T S up e r Do t 4 ha s[...]

P ubl i s he d: 11-May-2 011 Rear Disc Brake - R ear Disc Brak e Des cr ipt i o n a nd O pe r a t i o n Item Pa rt Nu mb e r Descri pti on 1 — Pa r k in g brake cabl e 2 — Hub ca r rie r 3 — Br ake ho s e 4 — Br ake d i s c s hi el d 5 — Br ake ca l i per 6 — Br ake ca l i per a nchor pl a t e 7 — Br ake p a ds 8 — W hee l hu b 9 ?[...]

P ubl i s he d: 11-May-2 011 Rear Disc Brake - R ear Disc Brak e Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 206-00 Br ake Sy s t e m - Gene r a l I nfo r mat i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Cali per Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 Brak e ca l i per pi st o n re t r act o r t oo l 206-080 Cr anks haf t pul l e y/dampe r r emover 303-588 R em ova l 1. Remove t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m a[...]

4. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: T o pr e vent the l os s o f brak e fl ui d, a ppl y t he b r ake p e dal ho l d dow n t o o l a nd a dj us t to h ol d t he b r ake pe da l d own 40m m. Ins t a l l a bl [...]

3. NOT E: Ins t a l l ne w brake ho s e s e a l i ng wa s hers . At t a ch t he b r a ke h os e. Ti ght e n t o 38 Nm. 4. Remove t he brake pe da l hol d do wn t o o l . 5. Ble e d t he br ake s y s t e m. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke S ys te m Bl e e d i ng (206-00 Brak e Sy s t e m - Gene r a l Inf o r m at i o [...]

P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Disc Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he brake pa ds . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P a ds (206-04 Re a r Di s c Br ake , Re moval a n d I ns t a l l a t i o n). Vehi c le s with 2.5L or 3.0L engine 2. D et a ch t he A[...]

P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake Disc S hield Re moval a n d I ns t a l l a t i on 1. Remove t he rear whe e l hub. Fo r add i t i o nal i nf or ma ti on, re fe r to S ect i o n 204-02 Rea r S usp e ns io n . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Rear Disc Brake - Brake P ads Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e ca l i per pi st o n re t r act o r t oo l 206-080 Cr anks haf t pul l e y/dampe r r emover 303-588 R em ova l 1. Remove t he whe e l a nd t i r e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (2[...]

5. Remove t he brake pa ds . Insta llat ion 1. CAU TI O N : If t he pi s t o n i s pus he d ba ck i nt o th e ho us i ng, b r a ke fl ui d wi l l be f o r ced ba ck i nt o t he f lui d r es e r voir. • NO T E: T he l e f t -ha nd brake cal ip e r pi s t o n r e t r a ct s co unt e r cl o ck wi s e a n d th e r igh t -ha nd ret ract s cl o ck wi s[...]

4. Att a ch t he pa r ki ng b r ake ca bl e ret a i ni ng cl i p. 5. Att a ch t he pa r ki ng b r ake ca bl e . 1. Re l e a s e t he t e ns i o n. 2. At t a ch t he p ark in g b rak e ca bl e . 6. Ins t a l l the whe e l a nd t i r e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: W he e l a nd T i re (204-0 4 W he e ls a nd Ti res , Re mo[...]

P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - T o rque Sp eci f i cat ions Descri pti o n Nm l b-f t l b- i n P a r ki ng br ake cont r ol ret a i ni ng nut s 20 15 - JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake Des cr ipt i o n a nd O pe r a t i o n It e m Pa r t Nu m be r D escri pti on 1 — Fr ont ca bl e 2 — Re a r cabl e 3 — Brake cal i pe rs The pa r king brake cont r ol s ys t e m i s cabl e -ope r a t e d a nd cont r ol l e d b y a n i nde pe nde nt ha nd-op e r at ed[...]

* * * * * * 1 1 1 1 1 P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by o pe r a t i ng t he s yst e m t o dupl i cat e t he co ndi t i on. 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o[...]

1 1 Dis conne ct t he p a rk i ng br ake f r o nt cabl e f r o m t he rea r br ake cab l e a nd condui t a t t h e e q ual iz e r . Rot a t e t he w hee ls b y hand. Did t he rear whe e l s r ot a t e O K? Ye s INS TA LL a ne w front p a r k i ng b r a ke cabl e . For ad di t i on a l in fo rm at i on, refe r t o t he p r oced ure i n thi s s e ct [...]

P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C a bleVehic les W ith: Manuall y Adju sted Par kin g Brake Re moval a n d I ns t a l l a t i on Speci al T ool (s) P a r ki ng b r ake cab l e a dj us t e r s ocket . 206-087 R em ova l 1. Rel e as e t he pa r ki ng br ake . 2. Rai s e a nd s uppo r t the ve hi cle . For [...]

6. Remove t he rear pa rk i ng br ake ca b le ret a i ni ng cli p. 7. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 8. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 9. D et a ch t he r e a r p ark ing b r ake cabl e a nd condu it . 10. Remove t he rea r park i ng br ake ca bl e a nd co ndui t . Insta llat ion 1. [...]

P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C a bleVehic les W ith: Self-A dj us ting Par kin g Brake Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he rear r oa d whe e l a nd t i re. For a dd i t i o na l i nf orm a t i o n, r e fe r t o S ect i on 204-04 W he e l s an d T i res . 2. D et a ch t he r [...]

7. D et a ch t he pa rk in g b r ake ca bl e a nd co nd ui t . 8. D et a ch t he r e a r p ark ing b r ake cabl e . 9. Remove t he pa r ki ng b r ake rear ca bl e a n d co ndui t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C ontro lV ehicles With: Manuall y A dj usted Par kin g Brake Re moval a n d I ns t a l l a t i on Speci al T ool (s) P a r ki ng b r ake cab l e a dj us t e r s ocket . 206-087 R em ova l All v e h icle s 1. Remove t he ce nt e r cons o le . Fo r a ddi t i o nal i nfo r m[...]

7. NOT E: 2.5L o r 3.0L s ho wn, 2. 0L s imi l a r . Det ach t he rear pa rk i ng br ake cabl e s . Vehi c le s with 2.5L or 3.0L engine 8. Remove t he drive sha f t. Fo r a ddi t i ona l i nf o r m at i o n ref e r t o Sect i o n 205-01 Dr i ve s haf t . All v e h icle s 9. Remove t he pa r ki ng b r ake . Insta llat ion 1. To i ns t a l l , rever[...]

P ubl i s he d: 11-May-2 011 Par kin g Brake and A ctuatio n - Parking Brake C ontro lV ehicles With: Self-Ad j us ting Par kin g Brake Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he ce nt e r cons o le . Fo r a ddi t i o nal i nfo r m at i o n, r e f e r t o S ect i o n 501-12 Ins t r ument P a ne l a nd Cons o l e[...]

9. Remove t he e xhaus t re ar hea t s hi e l d. 10. Remove t he p a r k i ng b r a ke cont r ol ret a i ni ng nut s . 11. Lowe r t he vehi c l e . 12. Det a ch t he pa r k i ng br a ke cont rol . 1. De ta ch t he pa r king br ake c a bl e g r o mmet . 2. De ta ch t he pa r king br ake c ont r ol . 13. Remove t he p a r k i ng b r a ke cont r ol . [...]

1. To i ns t a l l , rever s e t he remov a l procee d ur e. Ti ght e n t o 20 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui d IT T S up [...]

P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Hy draulic B rake A ctua tio n Des cr ipt i o n a nd O pe r a t i o n I te m Pa r t Nu m be r De scr i pti on 1 — Br a ke mas t e r cyli nder 2 — Br a ke f l ui d r e s e rv oi r 3 — Br a ke bo o s t e r 4 — Rea r brake cal i pe r 5 — Br a ke t ube s 6 — Fr ont b r ake cal i pe[...]

P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Hy draulic B rake A ctua tio n Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 6-00 Br a ke S yst e m - Ge neral I nf orm at i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Fluid Reservoir Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Make s ur e t he f i l l[...]

5. NOT E: Re m o ve a nd d i sca r d t he O -r ing s e a l s f r om t he br ake mas t e r c yl i nde r . Re move t h e br a ke f l ui d r e s e r vo i r. 1. Re l e a s e o ne le g of t h e res e rv oi r from t he r et a i ni ng pi n. 2. Re move t he b r a ke f l uid res ervoir. Insta llat ion All v e h icle s 1. NOT E: Ins t a l l ne w O -r ing s e[...]

4. F i l l t he b r a ke f lu id r es e r voi r. 5. Ble e d t he br ake s y s t e m. For a ddi t i o na l i nf orm at i o n, r ef e r t o Sect i on 206-00 Br ake S y s t e m - Ge ne r al I nf o r mat i on . 6. Ins t a l l the brake f l ui d res e r voi r fi l l e r cap. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Master C y l inder Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Make s ur e t he f i [...]

5. D et a ch t he cl ut ch mas t er cyli nde r f ee d hos e . All v e h icle s 6. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. Re move t he coo l a nt e xpans i o n t a nk ret a i ni ng b ol t . 2. Tur n t he co o l a nt e xpans i o n t a nk count e r clo ckwis e . 3. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 7. D i s conne [...]

9. NOT E: Re m o ve a nd d i sca r d t he O -r ing s e a l at t he re ar of t he br a ke m a s t e r cy l i nde r . Re move t h e br a ke mas t er cyli nde r a nd res e rv o i r . 1. Re move t he b r a ke ma s t e r cyli nde r r et a i ni ng nut s . 2. Re move t he b r a ke ma s t e r cyli nde r a nd r es e r v o ir. Insta llat ion All v e h icle s[...]

4. Att a ch t he coo l a nt e x pa ns i o n t a nk. 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. Tur n t he co o l a nt e xpans i o n t a nk cl ockwi se . 3. I ns t a l l t he c oo l a nt e xpans i o n t a nk ret a i ni ng bol t . Vehi c le s with ma nual tra nsmission 5. Att a ch t he clu t ch m a s t e r cy l i nde r fe e d ho s [...]

8. F i l l t he b r a ke f lu id r es e r voi r. 9. Ble e d t he br ake s y s t e m. For a ddi t i o na l i nf orm at i o n, r ef e r t o Sect i on 206-00 Br ake S y s t e m - Ge ne r al I nf o r mat i on . 10. Ins t a l l t he brake f l ui d r es e r voir f i l le r cap. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Pedal and B racket Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with ma nual tra nsmission 1. W ARNING: Bra k e fl ui d co nt a i ns po l ygl ycol et he r s a nd p o l ygl ycols . Av o i d co nt a ct wit h t he e yes . W a s h ha nd s t ho roughl y a f t e r hand l i n[...]

4. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he af fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. • NO T E: Ins t al l s ui t a bl e bl a nk i ng p lug s . • NO T E: Ri ght -ha n d d r i ve s ho wn, l e f t -ha nd d r i v e s i mil a r . Di s conn ect t he cl ut ch mas t e r c[...]

9. Remove t he s up port p a nel . Le ft-hand dr ive ve hi c le s 10. Po s i t i o n t he f r o nt whe e l s i n a s t r a ig ht a he a d po s i t i o n a nd ce nt r a l i z e t he s te e r i ng wh e e l . Lock i n po s i ti o n a n d remove t he i gni t i on key. 11. Det a ch t he s t e e r ing c ol umn . Re mov e a nd di s c a r d t he s t e e r [...]

15. Repo s i t i o n t he a nt i -c o ll ap s e bracket . R ight-hand driv e v ehi c le s 16. Remove t he b rak e bo o s t e r pus h r o d r et a i ni ng nut . 17. Remove t he a ccel erat o r pe da l mount bracket . Le ft-hand dr ive ve hi c le s 18. Remove t he b rak e bo o s t e r pus h r o d r et a i ni ng cli p. 1. Re l e a s e t he b r ake b o[...]

19. Remove t he a ccel erat o r pe da l mount bracket . 20. Remove t he b rak e pe da l a nd br a ck et re ta i ni ng nut s . All v e h icle s 21. Remove t he b rak e pe da l a nd br a ck et re ta i ni ng nut s . 22. NO TE: Ri ght -hand d r i ve s ho wn, l e ft -hand drive s i mi l a r. Re move t h e br a ke pe d al a nd bracket . Dis conne ct t he[...]

1. NOT E: Ri g ht -hand drive s h own , l e ft -hand drive s i mil a r. I nst a l l t he b r ake pe dal a nd bracket . Conne ct t he e l e ct r i cal co nnect o r. 2. Ins t a l l the brake pe da l a nd b r ack e t ret a i ni ng n ut s . Ti ght e n t o 25 Nm. Le ft-hand dr ive ve hi c le s 3. Ins t a l l the brake pe da l a nd b r ack e t ret a i ni[...]

5. Ins t a l l the brake bo o s t e r pus h r od r et ai ni ng cli p. R ight-hand driv e v ehi c le s 6. Ins t a l l the a ccel e r at o r pe da l mount brack e t . Ti ght e n t o 25 Nm. 7. Ins t a l l the brake bo o s t e r pus h r od r et ai ni ng nut . Ti ght e n t o 3 Nm. All v e h icle s 8. Repo s i t i on t he a nt i -col l a ps e bracket . J[...]

9. Ins t a l l the a nt i -c ol l a ps e br acket cl e vis pi n ret a in ing cl i p. 1. I ns t a l l t he a nt i -col l a ps e b r acket cle vi s pi n. 2. I ns t a l l t he a nt i -col l a ps e b r acket cle vi s pi n r e t a i nin g cl i p. 10. At t ach t he wi r i ng harnes s . 11. Ins t a l l t he a cc e l e rat o r pe da l . For a ddi ti ona l [...]

15. Ins t a l l t he drive r si de i ns t rum e nt pan e l l o we r t r i m pa ne l . R ight-hand driv e v ehi c le s 16. Ins t a l l t he brake p e da l a nd br a ck e t ret a i ni ng nut s . Ti ght e n t o 25 Nm. Vehi c le s with ma nual tra nsmission 17. CAUT I O N: I f brake fl ui d i s s pi lt o n t he pa i nt wo r k, t he a f fe ct e d a r e [...]

19. NO TE: Ve hicl e s wi t h 2.5L o r 3.0L eng i ne o nl y. At t a ch t he e ngi ne wi ring harnes s . Ti ght e n t o 10 Nm. 20. Bl e e d t he hydr aul ic clut ch s ys t em. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Cl ut ch S y s t e m Bl e e di ng - Ve hi c l e s W i t h: 6-S pee d Manual Tr ans axl e - MMT6 (308-00 Manua l Tr an s[...]

P ubl i s he d: 11-May-2 011 Hydra uli c Bra ke Actuation - Brake Pedal C ro ss-Shaft Re moval a n d I ns t a l l a t i on Speci al T ool (s) Dis conne ct t o ol , f ue l l i ne . 310-076 Dis conne ct t o ol , f ue l l i ne . 310-D 005 Dis conne ct t o ol , f ue l l i ne . 412-038 5 P o i nt S e c urit y T o r x Bi t . 418-535 R em ova l All v e h [...]

5. D et a ch t he wi ring ha r ne s s . 6. D et a ch t he DPF d i ff e r e nt ia l pr es s ur e s e ns o r r et a i ni ng br acket . Re mov e t he re ta i ni ng nut s . 7. D i s conne ct t he DPF di ff e r e nt i al pres s ur e s e ns o r e l e ct rical co nnect or. 8. NOT E: Not e t h e o r i e nt a t i o n o f t he DPF di ff e r e nt i a l pres s[...]

10. Dis c o nne ct t he up pe r fue l vap or ho s e from t he e vapo rat i ve e mi s s i o n cani s t e r pur ge va lve . 11. Det a ch t he oxyge n s ens or e l e ct rica l c o nne ct or s . 12. Dis c o nne ct t he e va porat o r s o l e no i d e l ect r i cal conne cto r. 13. Dis c o nne ct t he l ow er f ue l va po r h os e f r om t he e v ap o r[...]

14. Det a ch t he wi ring ha r nes s from t he r e t a i ni n g b r ack e t . 15. Remove t he e va porat i ve e mis s i o n ca ni s t e r pur ge v a l ve r e t ai ni ng br acke t . Vehi c le s with 2.0L engi n e 16. Remove t he i nt a ke mani f o l d. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: I nt a ke Ma nif ol d (303-01A Engi n e - [...]

19. Remove t he A /C refr i g e r ant l i ne r e t a i ni ng cl i p . 20. NO TE: I ns t a ll b l anking pl ugs to t he e xpo s e d po rts . Us i ng t he s p e ci a l t o ol , d i s co nne ct t he A/C r e frige rant l i ne . Re mov e a nd di s c a r d t he O -r ing s e a l s . All e x cept ve hicles with die s el engine 21. NO TE: T he b ol t r e ma[...]

23. Dis c o nne ct t he e n gi ne wi r i ng ha r ne ss e l e ct rical co nnect or. 24. Det a ch t he eng i ne wi ring ha r nes s ret a i ni ng cl i p. 25. Det a ch t he eng i ne wi ring ha r nes s e l e ct rica l c on ne ct or . 26. NO TE: T he b ol t r e mai ns ca pt i ve in t he ECM e l e ct rical conne ct or. Di s conn ect t he ECM ha r nes s e [...]

All v e h icle s 28. Remove t he b rak e pe da l cr os s -s haf t s uppo r t bra c ket r e t a in ing bol t . 29. Rot a te t he b r a k e pe da l cr os s-s haf t cl o ck wi s e. 30. Remove t he b rak e pe da l a nd br a ck et . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P e da l a nd B r a cket (206-06 Hydr aul i c Br ake A ct [...]

33. Remove t he g l ove co mpa r t ment fi nis her t r im. 34. Remove t he g l ove co mpa r t ment . Re mov e t he g l o ve compa r t m e nt ret a i ni ng screws . 35. Remove t he b l owe r mot or t rim. 36. Remove t he ce nt ral j unct i o n bo x (CJB) ret a i ni ng n ut . 37. Det a ch t he CJB. JagDocs.com[...]

38. Repo s i t i o n t he br a ke pe d a l c ross -sh a f t s e cur i ng br acket . 1. Un do b ut do no t r e move t he br a ke pe d a l cross -s ha ft s e cur i ng brack e t r et a i ni ng nut . 2. Re pos i ti on t he br ake ped a l cr o s s -s ha f t s e cur in g b rack et . 39. Remove t he rig ht -ha nd f e nde r sp l a s h shi el d. For a ddi t[...]

43. Det a ch t he br a k e l i ne s . 44. Remove t he A /C refr i g e r ant l i ne. Re mov e t he re ta i ni ng cl i p. 45. Remove t he A /C refr i g e r ant l i ne. 46. NO TE: No t e t he po s i t i o n o f th e brake ped a l cr o s s-s haf t s pr i ng. Det ach t he brake p e da l cr os s -s ha f t s pring. JagDocs.com[...]

47. Det a ch t he br a k e pe da l cr os s -s ha ft l ef t -ha nd mount i ng br acket . 48. Det a ch t he br a k e pe da l cr os s -s ha ft g r ommet . 49. NO TE: Re move t he b r ake p e da l cr os s -s ha f t sp ring b us h. Re move t h e br a ke pe d al cross -s ha ft . Insta llat ion All v e h icle s 1. NOT E: Make s ure t ha t t he b r ake pe [...]

2. Att a ch t he brake pe da l cr os s -s haf t gr ommet . 3. Att a ch t he brake pe da l cr os s -s haf t le f t -hand m o unt i ng brack e t . 4. NOT E: Make s ure t he brake pe da l cr os s -s ha ft s pr i ng i s l ocat e d i n i t s or i gi nal po s i t i o n. At t a ch t he b r a ke p e da l cr os s -s ha ft s pring. 5. Ins t a l l the A/C r e[...]

7. Att a ch t he brake l i ne s . 8. NOT E: Re m o ve t he bl a nki ng p l ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 9. NOT E: Re m o ve t he bl a nki ng p l ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 10. Ins t a l l t he A/C ref r i ge r a nt l i ne s r e ta i n[...]

12. Repo s i t i o n t he br a ke pe d a l c ross -sh a f t s e cur i ng br acket . 1. Ti g ht e n t he brake pe da l cr os s-s haf t s e cur ing bracket r e t a i ni ng nut . 2. Re pos i ti on t he br ake ped a l cr o s s -s ha f t s e cur in g b rack et . 13. At t ach t he CJB . Ti ght e n t o 6 Nm. 14. Ins t a l l t he CJB ret a i ni ng nut . Ti[...]

17. Ins t a l l t he gl o ve compa r t ment f i ni s her t rim. 18. Ins t a l l t he gl o ve compa r t ment hi ng e ret a i ni ng s cr ew s. 19. Ins t a l l t he s o und i ns u lt at i o n. 20. Ins t a l l t he pe d a l bo x. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke P e da l a nd B r a cket (206-06 Hydr aul i c Br ake A ct ua[...]

22. Ins t a l l t he brake p e da l cr os s -s haf t s uppo r t b rack e t r e t a i ni ng bol t . Ti ght e n t o 25 Nm. All e x cept ve hicles with die s el engine 23. Conne ct t he E CM el e ct r i cal co nnect or. Us i ng s pe c i a l t o o l 418-5 35, t ig ht e n t o 5 Nm. Vehi c le s with diese l engine 24. At t ach t he e ngi ne wi r i ng ha [...]

26. At t ach t he e ngi ne wi r i ng ha r ne ss e l e ct rical co nnect or. 27. At t ach t he e ngi ne wi r i ng ha r ne ss r et ai ni ng cli p . 28. Conne ct t he e ngi ne wi r i ng ha r ne s s e l e ct rica l co nnect o r . Ti ght e n t o 10 Nm. 29. NO TE: Re move t he b l a nking pl ugs f r om t he fue l p ump f uel s uppl y a nd r e t ur n l i [...]

30. NO TE: Re move t he b l a nking pl ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 31. Ins t a l l t he A/C ref r i ge r a nt l i ne r et a i ni ng cl i p . 32. NO TE: Re move t he b l a nking pl ugs . Conn ect t he A/C r ef r i ge rant l i ne . Ins t al l new O-r i ng s e a l s . 33. Ins t a l l t he r e f[...]

35. Ins t a l l t he e vapo rat i ve e m i s s i on ca ni s t e r pur ge val v e r e t a i ni ng br acke t . Ins t al l t he re t a i ni ng nut s . Ti ght e n t o 5 Nm. 36. At t ach t he wi r i ng harnes s t o t he re ta i ni ng br a ck et . 37. Conne ct t he l o wer f ue l vapo r hos e to t he e va porat i v e e mis s i o n cani s t e r pur ge va [...]

39. At t ach t he o xygen s e ns o r el e ct r i cal co nnect o rs. 40. Conne ct t he up pe r fue l v ap o r hos e to t he e va porat i ve e mis s i o n cani s t e r pur ge va lve . All v e h icle s 41. Ins t a l l t he brake b oo s t e r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Br a ke Bo o s t e r - RHD AW D/R HD FW D (206-07 P o [...]

44. At t ach t he DP F d i f f eren ti al p res s ur e s e ns or r et ai ni ng brack e t . Ins t al l t he re t a i ni ng nut s . Ti ght e n t o 5 Nm. 45. At t ach t he wi r i ng harnes s . 46. CAUT I O N: I ns t a l l t he re t a i ni ng cl i p t o t he o rigi na l po s i ti o n. Fai l ure t o fo l l o w t hi s i ns t ru ct io n may r e s ul t i n[...]

P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - T o rque Sp eci f i cat ions Descri pti o n Nm l b- ft l b- i n Brak e b oo s t e r r et a i ni ng nut s 25 18 - Brak e ma s t e r cyli nd er r e t a i ni ng nut s 25 18 - Coo l a nt e x pa ns i o n t a nk r e t a i ni ng bo l t 3 - 27 S pe ed cont r o l m o dul e re ta i ni ng bo l t - V e [...]

P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo oster Des cr ipt i o n a nd O pe r a t i o n W ARNI N G: B r ake fl ui d con ta i ns p ol ygl yc o l e t he rs a nd pol ygl yc ol s. Avoi d cont a ct wi t h e ye s . W a s h ha nds af t e r hand l i ng. I f br ake f l uid cont a ct s t he e yes , f l us h t he e y es f or 15 mi nut [...]

P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - P ower Brake S y stem Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 20 6-00 Br a ke S yst e m - Ge neral I nf orm at i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo osterLHD A WD/LHD FWD Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he brake boo s t e r pus h r od r e t ai ni ng cl i p . 1. Re l e a s e t he b r ake b oos t e r pus h rod ret a ini ng cl i p. 2. Re move t he b r a ke b o os t e r pus h rod ret a i [...]

5. Remove t he coo l a nt e xpa ns i o n t a nk r e t ai ni ng bo l t . 6. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. De ta ch t he co ol a nt expa ns i on t ank. 2. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . Vehi c le s with 2.0L engi n e 7. D et a ch t he cr uis e co nt rol ca b le . 8. D et a ch t he t hrot t l e ca b le[...]

9. D et a ch t he i d l e ai r cont r ol (IAC) val ve wi r i ng harnes s . 10. Det a ch t he t hr ot t l e ca bl e r e t a i ni n g b r ack e t . 11. Dis c o nne ct t he s pe e d cont r ol modul e e l e ct r i cal co nnect o r. 12. Remove t he s pe e d cont r ol modul e ret a i ni ng b o l t . 13. Repo s i t i o n t he s p ee d cont r o l mod ul e [...]

Vehi c le s with ma nual tra nsmission 14. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Fa i l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . • NO T E: Ins t al l b l a nk i ng pl [...]

18. Det a ch t he br a k e boo s t e r v a cuum hos e. 19. Det a ch t he br a k e boo s t e r. Re mov e t he b rak e boo s t e r r et a i ni ng nut s . 20. Remove t he b rak e bo o s t e r s uppo r t br acket . 21. Remove t he b rak e bo o s t e r. Insta llat ion All v e h icle s JagDocs.com[...]

1. NOT E: Make s ure t he brake bo os t e r pus h rod i s c orr e ct l y a l i gne d t o t he br ake p e dal . • NO T E: Do no t i ns t al l t he brake boo s t er r e ta i ni ng nut s a t t hi s s t a ge . I nst a l l t he b r ake bo o s t e r . 2. Ins t a l l the brake bo o s t e r s up port b r a cket . Loo s e l y i ns t a l l t h e br a ke bo[...]

6. NOT E: Ins t a l l a new br ake mas t er cyli nde r t o b r ake bo o s t e r O-r i ng s e a l . • NO T E: Make s ur e t he b r a ke b o o s t e r pus h r od i s cor r ect ly a l i gne d t o t he br ake mas t e r cyli nde r as s e mbl y. At t a ch t he b r a ke ma s t er cyli nde r a s s e mbl y t o t he b r ake b oos t e r . Ti ght e n t o 25 [...]

10. Ins t a l l t he s p e ed c on t r ol m od ul e ret a i ni ng bo l t . Ti ght e n t o 4 Nm. 11. Conne ct t he s pe e d cont r ol modul e el e ct r i cal co nnect o r. 12. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket . 13. At t ach t he I A C va lve wi r i ng harne ss . 14. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t[...]

15. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 16. At t ach t he co o l a nt e xpans i o n t a nk . 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. At t a ch t he coo l a nt e xpans i o n t a nk. 17. Ins t a l l t he coo l a nt e xpan s i o n t a nk r et ai ni ng bo l t . Ti ght e n t o 3 Nm. 18. NO TE: Re move t he [...]

19. At t ach t he b rak e f l ui d l ow le vel warnin g i ndi cat o r wi ring ha rn e s s t o t he cool a nt expa n si o n t ank. 20. Conne ct t he b rak e fl ui d l ow le vel wa r ni ng i ndi cat o r e le ctrica l conne ct o r . 21. Ins t a l l t he brake b oo s t e r pus h r od r e t a i nin g cl i p. 22. Check a nd t op up t he coo l i ng s yst [...]

P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Bo osterRHD AWD/ RH D FWD Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e pe da l ho l d do wn t o o l JDS 9013 R em ova l All v e h icle s 1. D i s conne ct t he brake f lui d l o w l e ve l wa r n in g i ndi cat o r e l e ctrica l conne ct or. 2. D et a ch t he brake f[...]

4. Remove t he coo l a nt e xpa ns i o n t a nk r e t ai ni ng bo l t . 5. Repo s i t i on t he co ol a nt expa ns i on t ank. 1. De ta ch t he co ol a nt expa ns i on t ank. 2. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . Vehi c le s with 2.0L engi n e 6. D et a ch t he cr uis e co nt rol ca b le . 7. D et a ch t he t hrot t l e ca b le[...]

8. D et a ch t he i d l e ai r cont r ol (IAC) val ve wi r i ng harnes s . 9. D et a ch t he t hrot t l e ca b le ret a i ni ng br acket . 10. Dis c o nne ct t he s pe e d cont r ol modul e e l e ct r i cal co nnect o r. 11. Remove t he s pe e d cont r ol modul e ret a i ni ng b o l t . 12. Repo s i t i o n t he s p ee d cont r o l mod ul e . JagDo[...]

Vehi c le s with ma nual tra nsmission 13. CAUT I O N: I f brake fl ui d i s s pl it o n t he pa i nt wo r k, t he a f fe ct e d a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Fa i l ur e t o fo l l o w th i s i ns t r uct io n m a y r e s ul t i n d a mage t o t he vehi c l e . • NO T E: Ins t al l b l a nk i ng pl [...]

17. Det a ch t he br a k e boo s t e r v a cuum hos e. 18. Det a ch t he br a k e boo s t e r. Re mov e t he b rak e boo s t e r r et a i ni ng nut s . 19. Remove t he b rak e bo o s t e r s uppo r t br acket . 20. Us i ng t he br a ke pe da l ho l d do wn t o o l, a ppl y t he b rak e p e da l unt i l t he br ake b o os t e r pus h r od pi n ca n [...]

22. Remove t he b rak e bo o s t e r pus h r o d pi n. 23. Remove t he b rak e bo o s t e r. Insta llat ion All v e h icle s 1. NOT E: Do not i ns ta l l t he br ake b o os t e r r e t a i ni ng nut s a t t hi s s t a ge . I nst a l l t he b r ake bo o s t e r . 2. Ins t a l l the brake bo o s t e r pus h r od pi n. JagDocs.com[...]

3. Ins t a l l the brake bo o s t e r pus h r od pi n re t a in i ng cl i p. 4. Remove t he brake pe da l hol d do wn t o o l . 5. Ins t a l l the brake bo o s t e r s up port b r a cket . Loo s e l y i ns t a l l t h e br a ke bo o s t e r s uppo r t brack et r et a i ni ng bo l t . 6. Att a ch t he brake bo os t e r. Ti ght e n t o 25 Nm. 7. Tig [...]

9. NOT E: Ins t a l l a new br ake mas t er cyli nde r t o b r ake bo o s t e r O-r i ng s e a l . • NO T E: Make s ur e t he b r a ke b o o s t e r pus h r od i s cor r ect ly a l i gne d t o t he br ake mas t e r cyli nde r as s e mbl y. At t a ch t he b r a ke ma s t er cyli nde r a s s e mbl y t o t he b r ake b oos t e r . Ti ght e n t o 25 [...]

13. Ins t a l l t he s p e ed c on t r ol m od ul e ret a i ni ng bo l t . Ti ght e n t o 4 Nm. 14. Conne ct t he s pe e d cont r ol modul e el e ct r i cal co nnect o r. 15. At t ach t he t hr ot t l e cabl e r e t a i ni ng br a c ket . 16. At t ach t he I A C va lve wi r i ng harne ss . 17. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t[...]

18. At t ach t he cr ui s e cont r ol cab l e . All v e h icle s 19. At t ach t he co o l a nt e xpans i o n t a nk . 1. Re pos i ti on t he cool a nt e xp a ns i o n t a n k . 2. At t a ch t he coo l a nt e xpans i o n t a nk. 20. Ins t a l l t he coo l a nt e xpan s i o n t a nk r et ai ni ng bo l t . Ti ght e n t o 3 Nm. 21. NO TE: Re move t he [...]

22. At t ach t he b rak e f l ui d l ow le vel warnin g i ndi cat o r wi ring ha rn e s s t o t he cool a nt expa n si o n t ank. 23. Conne ct t he b rak e fl ui d l ow le vel wa r ni ng i ndi cat o r e le ctrica l conne ct o r . 24. Check a nd t op up t he coo l i ng s yst e m as r eq ui r ed . Vehi c le s with ma nual tra nsmission 25. Bl e e d t[...]

P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Va cuum Pump2.0L N A V6 - AJ V 6 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he vacuum ho se . Re l e a s e t he re t a i ni ng cl i p. 2. D i s conne ct t he e l ect r i cal conne ct o r. 3. Remove t he vacuum pump. Insta llat ion 1. To i ns t a l l , rever s e[...]

P ubl i s he d: 11-May-2 011 Pow er B rake A ctua tio n - Brake Va cuum Pump2.0L D uratorq- TDC i/2.2L Durato rq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Speci al T ool (s) Re mover /Ins t al l , Co o l i ng Ho s e Cl a mp 303-397 R em ova l 1. Remove t he oi l l e vel i ndi cat o r . 2. Remove t he oi l f il l e r cap. 3. [...]

6. D i s conne ct t he brake vacuum hos e f rom t he b rak e v a cuum pum p. 7. Remove t he po we r s t e e r i ng ho s e s upp o r t bracket . 8. D et a ch t he cyli n der he a d t e m pe r a ture (CHT) s e ns o r el e c t rical co nne cto r a wa y f r om t he brak e vacuum pump. 9. Usi ng t he s pe cia l t oo l 303-397, d i s conne ct t he coo l [...]

11. Us i ng t he s pe ci a l t o o l 303-397, di s conne ct t he cool a nt hos e s . 12. Remove t he b rak e va cuum pu m p. Re mov e a nd di s c a r d t he gas ke t. Insta llat ion 1. CAU TI O N : Make s ur e t h e dr i ve coup l i ng i s al ig ne d wi th t he c a msha f t c o upl i ng. • NO T E: Ins t al l a ne w b rak e vacuum pum p ga s ke t [...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Lubr i cant s, Flu ids , Seal er s and A dh e si v es CAU TIO N : Do no t us e br a ke f l ui d IT T S up e r Do t 4 o n 2006my vehi cl e s o nwa r ds . Fai l ure t o fo l l o w t hi s ins t ru ct i o n may r es ul t i n dama ge t o the v e hi cl e . • NO T E: Br a ke f l ui [...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss ist Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N um be r Desc ri pti on 1 — Ins t r ument cl us t e r 2 - D ynamic s t a bi l i t y cont r o l 'O N/O FF' s wi t ch 3 - ABS /Tr act i on c o ntrol h y draul i c uni t 4 - [...]

e nabl e s t he sys t e m t o r e cog ni z e th e dr ive r 's i nt e nt i ons . The DS C s yst e m a l s o i nco r por at e s e me r gen c y b r ake a s si s t (EBA), whi c h mea s ures t he r a t e a t wh ich t he br a ke pr e s s ur e i ncr e as e s d ur i ng a br aki ng ma noe uvr e . I f t he s ys t e m d et e ct s a n e me r ge ncy br aki[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss istVIN R ange: C 00344->J12991 Dia gn os i s a nd Te s t i ng Principle of oper at ion The a nt i - l ock b r a k e s ys t e m (ABS ) modul at e s br ake pres s u r e on e ach w hee l i nd e pe nde nt l y t o mai nt a i n vehi cle s t a [...]

1. Vi s ua ll y i ns pe ct f or ob vio us s ig ns o f mecha ni cal o r e l e ct rical da mage . 1. Mechani cal El e ct ri cal Che ck th e t i re s i z e s , condi t i o n, a nd i nf l a t io n Brak e f l ui d l e ve l or l e a k a ge W he e l s pee d s e ns o r fi t me nt W he e l s pee d s e ns o r ai r gap W he e l s pee d s e ns o r to o t he d [...]

1 2 3 4 1 1 DT C D escri pti on P oss i bl e Source Act i on C1278 S t e e r i ng a ngl e s e ns or CAN me s s a ge no t pl a us i bl e S te e r in g a ng l e s e ns or no t cal i b r a t e d S te e r in g a ng l e s e ns or po we r s uppl y ci r c ui t ; o pe n circ uit , hi g h r es i s t a nce S te e r in g a ng l e s e ns or f a i l ur e For s [...]

1 2 1 1 1 2 3 4 1 1 1 2 1 I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams. CLEAR t he DTC, t e s t t he s y s t e m f o r norm a l ope rat i on. No GO t o A 4 . A4 : CHEC K T HE R IGH T -HAND FRO NT WSS PO WER CIRC UIT FOR HI GH R[...]

1 1 2 3 4 1 1 1 2 1 1 1 2 3 4 Mea s ur e t he res i s t a nce b et we e n LF01, p i n 01 (N ) and GROU ND. I s t he r es i s t ance l e s s t ha n 10,000 o hms? Ye s REP AIR t he sh or t c i r cuit . For a ddi t i o na l i nfo rm at i o n, ref e r t o t he wiring di ag rams. CLEAR t he DTC, t e s t t he s y s t e m f o r norm a l ope rat i on. No I[...]

1 1 1 2 1 1 1 2 3 4 1 2 3 1 2 I s t he r es i s t ance great e r t ha n 5 ohms ? Ye s REP AIR t he hi gh r e s i s t a nce ci r cui t . For ad di t i on a l i nfo rm at i on, refe r t o t he wi ring di a g r ams . CLEA R t he DT C, t e s t t he s ys t e m fo r n or mal o perat i o n. No GO t o D2 . D2: C HECK T H E LEF T - HAN D REAR WSS SENSOR C I[...]

1 2 1 2 3 4 1 2 3 1 1 2 1 2 3 4 1 2 I s t he r es i s t a nce great e r t ha n 5 o hms? Ye s GO t o E4 . No For CAN circu i t t es t s, REFER t o : Communica t i ons Ne t wo r k - V IN Rang e : E96603->J28492 (418-00 Modul e Co mm u nica t i o ns Ne t wo rk , Di a gnos i s and Te s t in g). E4: CHEC K T HE ST E ER I N G AN GLE S ENSOR GR O UND C[...]

3 1 2 1 2 1 2 1 2 3 1 2 3 1 1 2 3 1 2 3 Mea s ur e t he r es i s t a nce be t we en JB89, p in 03 (GB) and JB 185, pi n 42 (GB) . Is t he res i s t a nce g r ea t er t h a n 5 o hms ? Ye s REP AIR t he hi gh r e s i s t ance ci rc ui t . Fo r a d di t i o na l i nf o r mat i o n, refe r to t he wi r i ng di a gr a m s , t e s t t he s yst e m f o r[...]

4 1 2 Mea s ur e t he vol t a ge bet we e n JB45/J B185, pi n 06 (R) and GRO UN D. I s e it he r vol t a ge l e s s t ha n 10 vol t s ? Ye s REP AIR t he ci r cuit b e t we e n t he AB S / DS C modul e a nd ba t t e r y. Th is ci rcu i t i ncl ude s t he b at t e r y j unct i o n bo x (fu s e 03) a nd ha r ne s s s pl i ce , JBS 27. Fo r addi t i o[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock C ontro l - Stabilit y A ss istVIN R ange: J1 2992-> V99999 Dia gn os i s a nd Te s t i ng Principles of Ope ra tion For a d e t a i l e d d e s cr ip t i o n o f t he Ant i -Lock Co nt r o l - S ta b i l i t y As si s t sys t ems , ref e r t o t he r e l e vant De[...]

DT C D escri pti on P oss i bl e cause Ac ti on C007298 Brak e Te mpe r at ur e Too Hi g h Compo nent o r s yst e m over t e m pe r at ur e . T he HCU ha s de t e ct ed t ha t th e t e mpe r a t ur e i s t oo hi gh f or t he co r r e c t op erat i o n o f compone nt o r s ys t em Ove r he a t i ng o f at le a s t o ne hy draul i c br aki ng ci rcu [...]

DT C D escri pti on P oss i bl e cause Ac ti on to bat t e ry Modul e s up pl y vol t a ge gr ea t e r t ha n 16.8 vol t s Ove r v ol t a ge o f t he ba t t e r y cha r gin g s yst e m Ove r v ol t a ge m e a s ur e d b e t we e n m o dul e i gni t i o n a nd gr ound Ove r v ol t a ge m e a s ur e d b e t we e n m o dul e p ump s up pl y a nd mot o[...]

DT C D escri pti on P oss i bl e cause Ac ti on P oor W S S s i g na l at hi ghe r freque ncy . At a ppr oxi mat el y 50 kph (31 mph) W S S may no t c ompa re a n d s how a var i a nc e C1A7614 Va l v e Rel a y Ci r cuit Circ ui t s ho rt t o ground or o pen S ol e noi d s up pl y ci r cuit op en S ol e noi d s up pl y ci r cuit s hort t o g r ound[...]

DT C D escri pti on P oss i bl e cause Ac ti on op en ci r cuit W S S i nt e rn a l f a i l ure C1A9229 Re a r L e ft W hee l S pe e d S e nso r Ci r cuit S ig na l i nval i d. A fa i lu r e where t h e val ue of t he s i gnal i s no t pl a us i b l e g i ven th e ope r at ing condi t io ns Incor rect s i z e whe e l o r ti r e Ex ces s i ve a ir g[...]

DT C D escri pti on P oss i bl e cause Ac ti on cir cuit s ho r t t o ground W S S s upp l y f r ont right cir cuit s ho r t t o po we r W S S s upp l y f r ont right op en ci r cuit W S S i nt e rn a l f a i l ure C1A9429 Fr ont Ri ght W h ee l Spee d S en s or Ci r cuit S ig na l i nval i d. A fa i lu r e where t h e val ue of t he s i gnal i s n[...]

DT C D escri pti on P oss i bl e cause Ac ti on Gr o und l i ne t o yaw r a t e s e n so r op e n cir cuit Y a w rat e s e ns or s en di ng i nva l i d CA N m e s s a g e Y a w rat e s e ns or s en di ng i ni t i a l iz a t i on s t a t us fa ul t Y a w rat e s e ns or in t e r na l fa i l ur e C1A9900 P r e s s ur e S ens or Ci r cuit HCU i nte r [...]

DT C D escri pti on P oss i bl e cause Ac ti on C1B0271 Re t ur n P ump Ci r cuit Act ua t o r s tuck. Low o r di s cha r ged ba t t e r y Ve hi cl e cha r gi ng s yst e m f a i l ure P ump s uppl y li ne i s op en ci r cuit P ump s uppl y li ne s hort to pow er P ump m ot o r a ct uat i o n fa i lu r e P ump m ot o r r e l a y fa i lu r e HCU f a [...]

DT C D escri pti on P oss i bl e cause Ac ti on s t e e r i n g whe e l r o t a t i on s ens o r o pen cir cuit CAN H o pen cir cuit be t we e n yaw rat e s en s o r , s t e ering w hee l r o t a t i on s ens o r a nd m o dul e CAN L o p e n ci rcu i t be t we e n yaw rat e s en s o r , s t e ering w hee l r o t a t i on s ens o r a nd m o dul e S [...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Anti-Lock Brake System (ABS) ModuleVI N Range : C 00001->J12991 Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he a nt i-l o ck br a ke s yst e m (ABS) mod ul e e l e ct r ica l conne ct or. 2. D et a ch t he hydr aul ic cont rol u nit (HCU). 3. Remove t[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Front Whe el Speed Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he whe e l a nd t i r e as s e mbl y. Fo r addi t i ona l i nf o r m at i o n, r e f er t o S ect i on 204-04 W he e l s an d T i res . 2. D i s conne ct t he f r ont whe e l sp e e d s e nso[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Hydraulic C on tro l U ni t (HC U)V IN Range: C 00001->J12991 Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ba t t e r y Di s conne ct a nd Co nn[...]

8. CAU TI O N : If brak e fl ui d i s s pi l t o n t he pa i nt wo r k , t he ef fe ct ed a r e a mus t be i mm e di a t e l y wa s he d d o wn wi t h co ld wa t e r. Di s conn ect t he hydr aul i c co nt rol uni t b r a ke t ube s . 9. Remove t he hydr a uli c cont r ol uni t . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Hydraulic C on tro l U ni t (HC U)V IN Range: J1 2992-> V99999 Re moval a n d I ns t a l l a t i on Speci al T ool (s) Brak e p e da l hol d-do wn t o o l JDS 9013 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e [...]

8. Remove t he HCU . Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t o 8 Nm. 2. CAU TI O N : Make s ur e t h e br a ke t ubes are i ns t a l l e d to t he co r re c t port s. Fa i l ur e t o f o l l o w t hi s ins t r ucti on may res ul t i n da mag e t o t he vehi cl e . Ti ght e n t o 16 Nm. 3. Ble e d t he[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Rear Wheel Speed Senso r Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with 2.5L or 3.0L engine 1. Remove t he rear s e a t cus hi o n. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Re a r S e a t Cus hi o n (501-10 Seat i ng, Di s a s s embl y a nd As s[...]

7. D i s conne ct t he ABS whe e l s p ee d s e ns or el e ct r i c a l co nnect o r. 8. Remove t he ABS whe e l s p ee d s e ns o r . Insta llat ion Vehi c le s with 2.5L or 3.0L engine 1. To i ns t a l l , rever s e t he remov a l proced ur e . 1. Ti g ht e n t o 22 N m. Vehi c le s with 2.0L or die sel engine 2. To i ns t a l l r evers e t he r [...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Stability Assi st Mo dule Re moval a n d I ns t a l l a t i on R em ova l 1. NOT E: S t a bi l i t y as s is t modul e is a n int e gral co mponen t o f t he A BS m o dul e a n d ca nnot b e s e pa r a t e d. Di s conn ect t he a nt i -l ock brak e s ys t e m (ABS ) modul e e l[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Steering Wheel Ro t ation Senso r Re moval a n d I ns t a l l a t i on R em ova l 1. D i s conne ct t he s t ee r in g whe e l r ot a ti on s ens o r e l e ct rica l co nnect o r . 2. Remove t he uppe r st e e r i ng col umn. For a ddi ti ona l i nf o r m a t i o n, r e f e r t[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Yaw Rate Sensor2 .0L Durato rq- TDCi /2. 0L NA V6 - A JV 6/2.5 L NA V 6 - AJV6/3. 0L NA V6 - AJ2 7 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he f l o or cons o l e trim p ane l . 2. D i s conne ct t he yaw rat e s e ns or e l e ct rical con nect or . 3. W ARNI[...]

P ubl i s he d: 11-May-2 011 A nti-Lo ck Co ntrol - Stability Assi st - Yaw Rate Sensor2 .2L Durato rq- TDCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l Vehi c le s with autom at ic tra ns m ission 1. D et a ch t he J-gat e s ur r ound. Vehi c le s with ma nual tra nsmission 2. D et a ch t he ge a r s e l e ct o r s ur r o[...]

5. CAU TI O N : Make s ur e t h e ya w rat e s e ns or i s no t s ubj e c t e d t o a ny fo rm of i mpa ct a nd i s no t d r opp ed or damag e d. Fai l ure t o fo l l o w t hi s in s t ruc t i o n may r es ul t i n f ai l ure o f t he s e ns or. Det ach t he yaw rat e s e ns or . Re mov e t he re ta i ni ng nut s . 6. Remove t he yaw r a t e s e ns[...]

P ubl i she d: 20-Jul-2011 Steering System - G eneral Inf orm atio n - Ste eri ng L i nk age Sp ec if i cat io ns St ee r i ng Li nk age Free Pl ay Mea sur e men t (mm ) Me a surem e nt (i n) Fr e e pl a y (meas ur e d at t he s t ee r in g whe e l r i m) 0-6 0-0.24 Pow er Stee ri ng Pump Sp eci fic ati o ns I te m Speci fi cati on P owe r st e e r[...]

P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - Stee ring S y stem Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N u mber Des cri pti o n 1 — Flui d cool e r 2 — Lo w p r e s s ur e pi p e - f lui d coo l e r t o res e rv o i r 3 — Flui d res e r voir 4 — Po we r s t e e r i ng pump 5 — He a t s h ie ld 6 ?[...]

P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - Stee ring S y stem Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n by drivi ng t he ve hi cle . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f mechani c a l o r e l e ct rical da mage . 2. Mec hani cal I nsp[...]

Item Descri pti on 1 St e e r ing t rans ducer ground 2 I g ni t io n f e ed 3 St e e r ing t rans ducer f e ed 4 Ground 5 Spe e d s e ns o r s i gna l 6 Seria l i nt erfa ce Ste e ring Lin ka g e In spect ion an d Ba c kla sh (Fr eep la y) C he ck CAU TIO N : S t e e ring ge a r boo t s mus t b e ha nd l e d ca r e ful l y t o a voi d da mage . U [...]

It e m Speci a l T o ol Nu mb e r Desc ri pti on 1 21 1-011 Pres su r e Ga uge Ho s e 2 21 1-011-08 Pump Re t urn Ho s e 3 21 1-011-07 Pump Re t urn Ho s e Co nnect o r 4 211 -011- 03/ 2 Tes t Eq ui pment t o Hi g h P res s ur e Ho s e Ada pt or 5 211 -011- 03/ 1 Pump H ig h P res s ur e O ut l e t t o Hos e A da p t or 6 21 1-011-02 Pump Ad apt o [...]

C ondi ti on Possi bl e Sources Acti on Damag e d f l ui d cap . INS TA LL a ne w f l ui d c a p. Loo s e o r d a mage d hos e f i t t i ngs . TIGHT EN or IN S TALL a ne w ho s e a s ne ces s ary. Lea ka ge a t powe r s t e e ring pump . I NS TALL a ne w po we r st e e r i ng pump a s ne ce s s ary . For add i t i o na l i nf o r mat i o n, REFER t[...]

C on di ti on Po ss i bl e Sou rces Act i on Lo o s e o r worn rear s us pen s i o n. TIGHT EN l o o se , o r I NS TAL L n e w rea r su s p e ns i on compone nt s . Fo r a ddi t i ona l i nf o r m at i o n, REFER t o Sect i on 204-02 Rea r S us pen s i o n . Ve hi cl e t e nd s t o pul l t o o ne s i de whe n d r i ven o n a l eve l s ur f ace Inco[...]

C on di ti on Po ss i bl e Sou rces Act i on Damage d or w orn f r o nt s us pe ns i o n co mpone nt s . INS TA LL ne w f r ont s usp e ns i on co m po nent s a s nece s sa ry . Fo r a ddi t i o nal i nfo r mat i o n, REFER t o Sect i on 204-01 Front S us p e ns i on . Incor rect t o e a dj us t ment . ADJUS T a s nece s s a r y . For a ddi ti o na[...]

C on di ti on Po ss i bl e Sou rces Act i on Flu id l o ss a t t he po we r st e e r i ng p ump s haf t s e al . CHECK t he po we r s t e e r i ng pu m p f or s i gns of s t e ering f l ui d l o s s . INS TA LL a ne w powe r s t ee ring p ump as ne ce s s a ry . For a ddi t i o nal i nfo r m at i o n, REFER t o Sect io n 211-02 P owe r S te e r i n[...]

C on di ti on Poss i bl e S ources Ac ti on Acces s o r y dr ive bel t s quea l I nc o r r ect a cces so ry d r i ve be l t t e ns i o n or a cces s o r y drive b e l t gl a z e d. CHECK a cces so ry d r i v e be l t cond i t i on a nd IN S TAL L a ne w a cc e s s o r y drive b e l t a s ne ce s s a r y. Fo r a ddi t i o nal i nfo r m at i o n, REF[...]

C ondi ti on Possi bl e Sources Acti on CHECK and TI GHTEN t he s te e r i ng col umn ret a i nin g bo l t s /nut s and pi nch bo l ts i f r e qui red. For a dd i t i o na l in f orm a t i o n, REFER t o Sect i on 211-04 S t ee r i ng Co l umn . Ex ces s i ve we a r i n s t ee ring co l umn a s s embl y. CHECK f o r st e e r i ng col umn f or we a [...]

Dee p, l o ng, prol o nged s o und l i ke a n a n imal , o r wi nds a nd o cea n wa ves . Rum b le Lo w, he a vy cont i nuo us s o und l i ke t ha t made by wa go ns o r th under. Sc r ap e Gr a t i ng no i s e l i ke one hard p la s t i c ru bbi ng pa rt r ubbi ng a ga i ns t a no t he r . Sq u eak Hi gh-pi t che d s ou nd l i k e r ubbi ng a cl e[...]

is a s t ruc t ur e-bo rne n oi s e t r ans mit te d t hrough t he i nt e r medi at e s ha ft a nd co l umn. Ra ck knock ca n a l s o be he a rd a s a "t hump" o r i mpact no is e t hat o ccur s wi t h t he vehi cl e s t a t i ona r y whe n t he s t e e r i ng whe e l i s rel e a se d f rom a l o ad e d po s it i o n a nd a l l owe d t o [...]

ba l l j o i nt s a r e worn, t he l o we r s t e e r i ng col umn j oi nt s a re wo r n o r t he ba ckl a s h o f t he s t e ering ge a r is e xces si v e . CAU TIO N : DO NO T a t t e m pt t o a dj us t th e s t e e r i ng gea r yoke. Fa i l ur e t o f ol l ow t hi s i ns t r ucti on wi l l r e s ul t i n t he st e e r in g ge a r wa r ra nty t o[...]

P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - P ower Steer ing S y stem Fillin g Gene ral P r ocedures 1. NOT E: W he n fi l l ing t he r e s e r vo i r, make s ur e t ha t t he fl ui d i s cl e an a nd not agi t a t ed p r i or t o us e . T he f l ui d s ho ul d b e p our e d sl o wl y i nt o t he r e s e r voi r t o mi [...]

P ubl i s he d: 11-May-2 011 Steering System - G eneral Inf orm atio n - P ower Steer ing S y stem Flushi ng Gene ral P r ocedures • NO T E: I f hea vy s t e e ring o r cont a mina t io n wi t hi n t he powe r s t e e ring s ys t e m i s f o und , i t is ne ces s a r y t o carr y out t he s ys t e m fl us h pr oce dure a s d e t a i l e d b e l o[...]

6. NOT E: The s ui t a bl e f unnel s ho ul d ha ve t he a ca pa ci t y o f 4 l it r e s a nd O-ring s e a l • NO T E: T he s ui t a bl e f unne l must be t i g ht l y s e a l e d t o t he po we r s t e e r i ng fl ui d res e rv oi r t o avo id fl ui d l e akag e . I nst a l l a s ui t a bl e f unnel o nt o t he po we r s t e e ring f l ui d res [...]

10. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id s . Re move t h e s ui ta bl e fun ne l . 11. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id s . Re move t h e s ui ta bl e pi p e t o t he p o we r s t e e r ing r et ur n ho s e . 12. CAUT I O N: B e p r epa r e d t o co l l e c t e s cap i ng f l u id [...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Gen eral S p ec if ic a t ions Item Speci f i cati on P owe r a ss i s t e d s te e r i ng f lu id Dexr on 2E T o rque Sp eci f i cat ions Desc ri pti on N m l b- ft l b- i n Ti e r o d e n d ret a i ni ng nut 35 26 - P owe r st e e r i ng p ump r et a in ing bol t s 2 5 18 - Exte ns i o n s ha ft l o [...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Des cr ipt i o n a nd O pe r a t i o n It e m Pa rt N u mber Des cri pti o n 1 — Flui d cool e r 2 — Lo w p r e s s ur e pi p e - f lui d coo l e r t o res e rv o i r 3 — Flui d res e r voir 4 — Po we r s t e e r i ng pump s uct i o n hos e 5 — Po we r s t e e r i ng pump 6 ?[...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 211-00 S t e e r i ng S y s t em - Gene r a l I nf o r mat i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Start U p Pr o cedure After P ower Ste ering Pump/Gear O verh aul Gene ral P r ocedures 1. F or ad di t i o na l i nfo rm at i on, refe r t oS e cti o n 211-00 S t ee r in g Sy s t e m - Gene r a l I nf o r m at i o n . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering C o ntrol Va lve Actuato r2.5L N A V6 - AJV6/3. 0L NA V 6 - A J27 Re moval a n d I ns t a l l a t i on R em ova l 1. Rai s e a nd s uppo r t the ve hi cle . For add i ti ona l i nf o r m a t io n, r e f er t o S ect i o n 100-02 Jacking a nd Li f t i ng . 2. Remove t he e xhaus t f r o [...]

1. To i ns t a l l , rever s e t he remov a l proced ur e . 1. I ns t a l l a ne w f il t e r 2. CAU TI O N : Make s ur e bo l t s a r e t i ght e ne d e venl y . Ti ght e n t o 3 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid C oo ler2 .0L Durato rq- TDCi Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . Fo r a ddi t i ona l i nf o r m at i o n, r ef e r t o For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d ia t o r S pl a s h S hie l d (501-0 [...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid C oo ler2 .2L Durato rq- TDCi (110kW / 150PS) - Puma Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he radi a t o r s pl a s h s hie ld . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ra d ia t o r S pl a s h S hie l d (501-0 2 Fr o nt End B o dy P a nel s ,[...]

I n s ome ca s e s where t he fl ui d cl ea rly co nt a i ns pa rti c ul a t e ma t t e r , a nd t he s y s t e m cont i nues t o f unct i o n, fl us h t he s ys t e m wi t h f r e s h f l ui d a nd r e pl a ce the res e rv oi r , a s t he r e i s t he p o ss i bi l i t y t ha t t he res e rv oi r i nt e r na l fi lt e r may be d a mage d o r fa ul[...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Fluid Reserv o ir Re moval a n d I ns t a l l a t i on R em ova l 1. CAU TI O N : If po we r s t e e r i ng f l ui d is s pi l t o n t he pai nt wo r k , t he e ff e ct e d a r e a mus t be i mm e di a t e l y wa s he d d own wi th cold wa t e r. Re move t h e po we r s t e ering f l ui[...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Pump2.0L N A V6 - AJV6 / 2.5L N A V6 - AJV6/3. 0L NA V 6 - AJ27 Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he a cc e s s o r y drive b e l t . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Acces s or y Dr ive Be lt - 2.0L N A V 6 - AJV6/2.5L N A V6 - AJV 6/3.0[...]

3. Tig ht e n t o 30 Nm. 4. NOT E: If t he s t e e r i ng ge ar, pump o r coo l e r are be ing rep l a ced f o r le a kage or noi s e r e la t e d i s s ue s a nd t he re i s no e vid ence of f l ui d c on t a mina t i o n, t he r e i s no ne e d t o repl a c e t he re se r voi r . I n s ome ca s e s where t he fl ui d cl ea rly co nt a i ns pa rti[...]

Name Gr ea s e P ubl i s he d: 11-May-2 011 Pow er Steering - Powe r Steering Pump2.0L Durato rq- TDC i/2.2 L D urato rq - T DCi (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on Mate ri a l s Speci fi cati on W S S -M 12 A4-A2 R em ova l 1. D i s conne ct t he ba t t e r y gr oun d cab l e . For a ddi ti ona l i nf o r m a t i o n, r e f [...]

7. D et a ch t he po we r s t ee ring hi gh-pr e s s ure pi pe . 8. CAU TI O N : W he ne ver t h e po we r s t e ering pump fe e d ho s e i s di s conne c t e d t he p o we r s t e e r ing pump p or t a nd ho s e s houl d be pl ugg e d t o pr eve nt d i r t i ngres s . Fa i l ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t i n d a mag[...]

11. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y. Re move t h e po we r s t e ering pump s ecur i n g b r a cket . 12. NO TE: Shown wi t h t he EGR coo l e r t o EGR va l ve tub e removed f o r c l a r i t y. Det ach t he po we r s t e e r i ng pump f r om t he co o l a nt pump. 13. Remove t he p o we r s[...]

1. Coat t he p o we r s t e e r i ng pump dr i ve s pl i ne s wi t h gr ea s e . 2. Ins t a l l a ne w wa t er pump O -r ing s e a l. 3. Ins t a l l the po we r s t e e r i ng pump. 4. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. At t a ch t he p owe r s t e ering pump t o th e co o la nt pump. JagDocs.co[...]

5. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. I nst a l l t he p o wer s t e ering pum p s e cur i ng b r acket . Ti ght e n t o 25 Nm. 6. NOT E: S hown wi t h t he EG R cool er t o EGR v al v e t ube removed f o r cla r i t y. I nst a l l t he p o wer s t e ering pum p r et a i ni ng bo l t s . Ti ght [...]

9. NOT E: Re m o ve t he pl ug s f r om t he po we r s t ee ring pump port a nd t he fe e d ho s e . • NO T E: Shown wi t h t he EGR co o l e r t o EGR va l ve t ube r e m ove d fo r cla rit y . Conn ect t he po we r st e e r ing fe e d ho s e. 10. At t ach t he p o we r s t e e r i ng hi gh-pres s ur e pi p e . 11. At t ach t he p o we r s t e e[...]

14. Ins t a l l t he a ir cl e a ne r . For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Cl e ane r (3 03-12B Int a ke A ir Di s t r i b ut i o n and Fil t e r i ng - 2.0L Durat o r q-TDCi/2.2L Dur at orq- TDCi (110k W /150P S ) - P uma, Re moval a nd I ns ta l l a t i on). 15. Ins t a l l t he a ir de f le cto r . For a ddi ti ona l i [...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Steering G ear2.0 L D uratorq- TDC i/2.2L Durato rq- TDC i (110kW/150PS) - Pu ma Re moval a n d I ns t a l l a t i on R em ova l 1. Cent e r t he s t e ering w hee l . Lock i n po s i ti o n a n d remove t he i gni t i on key. 2. Remove and di s card t he ext e ns i on s haf t lo we r r e t a i ni ng b[...]

7. D et a ch t he s t e e r i ng ge a r coo l e r p ip e . 8. D et a ch t he r i ght -hand s i d e of t he s te e ring g e a r . 9. D et a ch t he l e f t -hand s i de o f t he s t ee ring g e a r . 10. Remove t he b ul k he a d pa ne l s e a l . 1. Re pos i ti on t he st e e r i ng ge a r. 2. Re move t he b ul k he a d pa nel s e a l . 11. Remove [...]

Insta llat ion 1. Ins t a l l the s t ee r i ng g e a r . 2. Repo s i t i on t he s t e e ring ge a r . 1. I ns t a l l t he bul k he a d pa ne l s e a l. 2. Re pos i ti on t he st e e r i ng ge a r. 3. Att a ch t he l e ft -hand s i d e o f t he s t e e r i ng ge a r . Ti ght e n t o 133 Nm. 4. Att a ch t he right -ha nd s id e o f t he s te e r i[...]

5. Att a ch t he s t ee r in g g e a r coo l er pi p e. 6. Att a ch t he s t ee r in g g e a r coo l er pi p e. 7. Ins t a l l new O -r ing s e a l s . 8. Att a ch t he s t ee r in g g e a r f l ui d l i ne s . Ti ght e n t o 10 Nm. 9. Ins t a l l the a i r def le cto r. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Ai r Def le cto r - 2.[...]

10. NO TE: Ri ght -hand s ho wn, Le f t ha nd s i m i l a r . Conn ect t ie -r o d e nd ba l l j oi nt s . 1. At t a ch bo t h t i e r o d s t o previou s l y not e d p o si t i o ns. 2. Ti g ht e n t he t i e r o d l o c ki ng nut . 11. NO TE: I ns t a ll a new b ol t . At t a ch t he l o we r s t e e ring co l umn. Ti ght e n t o 25 Nm. 12. Carr [...]

P ubl i s he d: 11-May-2 011 Pow er Steering - Steering G ear2.0 L N A V6 - AJV6 / 2.5L NA V6 - AJV6/3. 0L NA V 6 - A J2 7 Re moval a n d I ns t a l l a t i on Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-2 R em ova l All v e h icle s 1. Cent e r t he s t e ering w hee l . Lock i n po s i ti o n a n d remove t he i gni t i on key[...]

Vehi c le s with high i ntensity dis char ge hea dlam ps 6. D et a ch t he l i nk r od f r om t he hea dl a mp l e ve l in g s e ns o r . All v e h icle s 7. D et a ch t he po we r s t ee ring hi gh p r es su r e p ip e . Vehi c le s with autom at ic tra ns m ission 8. D et a ch t he s e l ect o r l e ver cab l e . All v e h icle s 9. Ins t a l l t[...]

10. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. P os i t io n a nd a dju s t t he s pe cia l t oo l rea r he i gh t a dj us t er. 11. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move t h e front s ub f r ame rei nf orcement pl at e ret a i ni ng bo l t s. 12. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Re move[...]

14. Remove t he ret a i ni ng cl ip from t he po we r s t e e r ing hi g h a nd l o w pr es s ur e pi pe s . All v e h icle s 15. CAUT I O N: W h e neve r t he pow er s t e ering pi pe s are d i s co nnect ed, th e s t e e r ing gea r val ve bo d y po r t s a nd po we r st e e r in g pi p e s s houl d b e pl ugg ed to prevent d i r t i ngres s . Fa[...]

18. CAUT I O N: W h e neve r t he pow er s t e ering hi gh pr es s ur e pi p e i s di s conne c t e d, t he po we r s t e e ring pump po rt a nd pi pe s houl d be p l ugg e d t o pr eve nt d i r t i ngres s . Fa i l ur e t o f o l l ow th i s i ns t r uct io n m a y r e s ul t i n d a mage to the ve hi cle . Di s conn ect t he po we r s t e ering h[...]

22. NO TE: L e ft -hand drive ve hi cl e s s ho wn, r i ght -ha nd d rive vehi cl e s s i mi l a r . Re move t h e s t e e r i ng ge ar bul k he a d s e a l. 23. NO TE: L e ft -hand drive ve hi cl e s s ho wn, r i ght -ha nd d rive vehi cl e s s i mi l a r . Re move t h e s t e e r i ng ge ar. Rot a t e th e s t e e r i ng gea r. Re mov e t he s t [...]

3. NOT E: Le f t -hand drive vehi cl e s s hown , r i ght -hand d r i ve vehi cl e s s imi l a r. At t a ch t he r i g ht -hand s i de o f t he s t e e r i ng g e a r . Loo s e l y i ns t a l l t h e s te e r i ng ge a r r e ta i ni ng bo l t . 4. NOT E: Le f t -hand drive vehi cl e s s hown , r i ght -hand d r i ve vehi cl e s s imi l a r. At t a [...]

7. NOT E: Re m o ve t he bl a nki ng p l ug. I nst a l l a ne w O -r ing s e a l . 8. NOT E: Re m o ve t he bl a nki ng p l ug. Conn ect t he po we r st e e r ing hi gh pr e s s ur e pi pe to the po we r s t e e r in g pump. Ti ght e n t o 30 Nm 9. Ins t a l l the po we r s t e e r i ng hi gh pres s ur e pi pe br a cket r e t a i ni ng bo l t . Ti [...]

Le ft-hand dr ive ve hi c le s 12. Ins t a l l t he r e t a i ni ng cl i p t o t he po we r s t e e r i ng hi gh a nd l o w p res s ur e pi pe s . All v e h icle s 13. Us i ng t he s pe ci a l t o o l rai s e t he f r ont s u bframe. 14. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Lo o s e l y i ns t a l l the f r ont s ubf rame r e a r[...]

16. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t o 142 Nm. 17. NO TE: L e ft -hand s h own, r i g ht -hand s i mil ar. Ti ght e n t he f r ont s ub frame rei nfo rc eme nt bo l t s . M8 t o 35 N m. M10 t o 70 Nm. 18. Remove t he s pe ci a l t o o l . Vehi c le s with autom at ic tra ns m ission 19. At t ach t he s e l e ct o[...]

20. At t ach t he p o we r s t e e r i ng hi gh pres s ur e pi pe . Vehi c le s with high i ntensity dis char ge hea dlam ps 21. At t ach t he l i nk rod t o t he he a d la mp l e vel i ng s e ns or. All v e h icle s 22. Conne ct t he p o we r s t e e r i ng cont r o l va l ve a ct ua t or e l ect r i cal co nnect o r (if e qu ip pe d). 23. NO TE: [...]

24. Ins t a l l t he r i ght -ha nd whe el a rc h l i ne r acces s cover. All v e h icle s 25. Carr y out s t ee ring s ys t e m bl e e d p r o ce d ur e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: P o we r S t e e r i ng S y s t e m Fil l i ng (211-00 Ste e ring S yst e m - Ge neral I nfo rm at i on, Ge ne r al P roced ur es ). 26. CA[...]

P ubl i s he d: 11-May-2 011 Steering L inkage - T o rque Sp eci f i cat ions Desc ri pti on Nm l b-f t l b- i n Ti e -r od e nd ret a i ni ng nut 35 26 - Ti e -r od e nd l o c k nut 40 30 - W he e l nut s - Ve hi cle s wit h s t e e l whe e l s 80 59 - W he e l nut s - Ve hi cle s wit h a lumi ni um whee l s 103 76 - JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Steering L inkage - Steering Li nka ge Des cr ipt i o n a nd O pe r a t i o n Item Pa r t Nu m be r D escri pti on 1 — S t e e r i ng g e a r 2 — Ti e-r od end boo t 3 — Ti e-r od 4 — Ti e-r od end 5 — W h ee l hub a s se mbl y 6 — Ti e-r od end r et ai ni ng nut 7 — Ti e-r od end l o ck nut The l e f t a [...]

P ubl i s he d: 11-May-2 011 Steering L inkage - Steering Li nka ge Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 211-00 S t e e r i ng S y s t em - Gene r a l I nf o r mat i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Steering L inkage - Steering G ear Bo ot Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he t i e -r o d e n d. For a ddi t i o na l i nf orm at i o n, r ef e r t o p r oce dur e i n t hi s s e ct io n: Ti e Ro d En d 2. Remove t he s t ee ring ge a r bo ot . 1. Re move a nd di s car d t he s t e e r in g g [...]

P ubl i s he d: 11-May-2 011 Steering L inkage - Ti e Rod End Re moval a n d I ns t a l l a t i on Speci al T ool (s) S ep e r at or, B a ll Joi nt 204-192 (JD- 219) R em ova l 1. Remove t he whe e l a nd t i r e . Fo r a ddi t i ona l i nf o r m at i o n re fe r t o Sect i o n 204-04 W hee l s a nd T ire s . 2. Loos e n t he t i e -r od e nd lo ck[...]

5. NOT E: Make a not e o f t h e numbe r of t ur n s re qui r ed t o remove t he ti e -r od e nd. Re move t h e t i e -r od e nd. Insta llat ion 1. NOT E: Make s ure t he t i e-rod e nd i s i ns t a l l ed o n t he t i e -r od by t he s a me a m o unt o f t ur ns u s e d t o r emove i t . To i ns t a ll , r e ver s e t he r e m ova l p r o ced ure.[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn - T o rque Sp eci f i cat ions Desc ri pti on N m l b- ft l b- i n S t ee r in g whe e l r et a i ni ng bo l t 47 35 - S t ee r in g co l umn l o we r r e t a i ni ng bo l t 25 18 - S t ee r in g co l umn r e t a i ni ng bo l t s 24 18 - S t ee r in g co l umn f l e xi bl e coupl i ng re ta ini ng bo l[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Des cr ipt i o n a nd O pe r a t i o n Item Pa r t Nu m be r Desc ri pti on 1 — S te e r i ng col umn 2 — S te e r i ng wh e e l 3 — S te e r i ng wh e e l a ng l e s e ns or 4 — S te e r i ng col umn f l e xib le coupl i ng The s t e e r i ng co lu m n l o c k i s s e cur[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o S e cti on 21 1-00 Ste e ring S yst e m - Ge neral In fo rm at i on . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn - Ignitio n Switch L o ck Cylinder Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l pocke t . 2. Remove t he drive r s s i de i ns t rum ent pa ne l l o we r t r i m pa ne l . 3. Remove t he s t ee ring co l umn l o we r s hr [...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn Re moval a n d I ns t a l l a t i on R em ova l All v e h icle s 1. Remove t he clo cksp ring. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Cl o ckspring (501-20B S uppl e me nt a l Re s t rai nt Sy s t e m, Re moval a nd I nst a l l at io n). Vehi c le s without Dr ive[...]

6. D i s conne ct t he s t ee r in g whe e l r ot a ti on s ens o r e l e ct rica l co nnect o r . 7. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 8. Remove t he s t ee ring co l umn. 1. Re move t he s t e e r i ng col umn ret a i ni ng bol ts . 2. Re move t he s t e e r i ng col umn. Insta llat ion 1. To i ns [...]

2. Tig ht e n i n t he s eque n c e s ho wn. Ti ght e n t o 24 Nm. 3. Ins t a l l a ne w b o l t . Ti ght e n t o 25 Nm. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing C ol u mn C ouplin g Re moval a n d I ns t a l l a t i on R em ova l 1. Remove and di s card t he s t e e r i ng c o l umn l o we r r et a i ni ng bol t . 2. Remove t he s t ee ring co l umn coupl i ng. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . Ti ght e n t [...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn - Steer ing W heel Re moval a n d I ns t a l l a t i on R em ova l 1. Pos it i o n t he f r ont whe e l s i n a s t r ai ght a he a d po s i t i o n a nd cent r al i z e s t e e ring whe e l. 2. Remove t he drive r ai r b a g mod ul e. For a ddi ti ona l i nf o r m a t i o n, r e f e r t o: Driver Ai r[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n S wit ches Des cr ipt i o n a nd O pe r a t i o n Ste e ring C olu mn Multif u nction Switch RH The s t e e r i ng co lu m n mul t i funct i on s wi t ch RH cont rol s t he f o l l o wi ng f unct i o ns whe n t h e i g ni t i on s w i t c h i s i n po s i t i o n I I: Fl[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n S wit ches Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on 1. Ve r i f y t he cu s t o mer c on ce r n . 1. 2. Vis ua l l y i ns pe ct f or obvi ou s s i gns o f e l e ct r i cal damage . 2. Vi sual Inspect i on C h art El e ct ri cal W i r i ng ha r ne s[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n Multi func tio n Switch LH Re moval a n d I ns t a l l a t i on R em ova l 1. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l pocke t . 2. Remove t he drive r si de i ns t r um e nt pa ne l l owe r t r i m pa ne l . 3. Remove t he s t ee ring c[...]

5. D et a ch t he s t e e r i ng col umn m ul t i funct i o n s wi t ch l e f t -ha nd. Re l e a s e t he re t a i ni ng t ang. 6. Remove t he s t ee ring co l umn mult i f unct i o n s wit ch l e f t-h a nd. Dis conne ct t he e l e ct r i cal co nnect o r. Insta llat ion 1. To i ns t a l l , rever s e t he remov a l proced ur e . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 Steering Co lu mn Sw itches - Steer i ng Co lum n Multi func tio n Switch RH Re moval a n d I ns t a l l a t i on R em ova l 1. Lowe r t he s t e e r i ng col umn. 2. Remove t he s t ee ring co l umn uppe r s hr ou d. 3. D et a ch t he s t e e r i ng col umn m ul t i funct i o n s wi t ch rig ht -hand. Re l e a s e t he[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Gen eral sp eci fi cat ions 2.0 l it r e d i es el . I te m Speci fi cati on Cod e FMBA/FMB B Firing o rder 1- 3-4-2 Cyli nder bo r e di a met e r 86 mm S t r oke 86 mm Di s pl ace ment 1998 c c Compr es s i o n ra ti o 19:1 Engi ne we i ght 195 kg (e xcludi ng front end acce s[...]

C ranks haft D im ensi o ns 2.0 l i tr e and 2 .2 li t re d i es el . Desc ri pti on m m Mai n be a ring j o ur nal – di a met e r 69·950 - 69·970 Mai n be a ring j o ur nal – e nd fl oa t 0·090 - 0·305 Bi g-e nd b e aring j o ur nal – di a met e r 52·980 - 53·000 Mai n be a ring j o ur nal s 1 t o 4 – di amet e r 64·950 - 64·970 C [...]

I te m Sp eci f i cati on Va l ve he a d di a met e r e x ha us t (m m) 3 0.15 - 29.85 I nt a ke val ve f ace a ngl e deg r e e 45.75° Exhaus t va l ve f ace a n gl e d egree 45.25° Va l ve s t e m di amet e r i nt a ke (m m) 5.492 - 5.477 Va l ve s t e m di amet e r e x hau s t (mm ) 5.479 - 5.464 Va l ve s p r i ng f r ee l engt h (mm ) 4 4. 2 [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Engin e Des cr ipt i o n a nd O pe r a t i o n 2.0 L, 2 .5 L an d 3. 0L Engine s The 2.0L, 2.5L a nd 3. 0L e ngi ne s c o ns i s ts of : A s i x cyl in de r 60 de gree 'V' conf i gur a t i o n l i q ui d coo l e d a l umini um cyli nde r bl o ck wi t h d r y cas t i r[...]

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Engin e Dia gn os i s a nd Te s t i ng Insp ection a nd Ve rificat i on S ince di a gno s i s a nd t es t in g a ct ua l l y be g in s wh e n [...]

* * * * * * * * * * * * * * * * * * * * * * * * * * * * Exces s ive cr anks ha ft e n d p la y. I NS TALL a new e ngi ne. Exces s ive conne ct i ng rod b e a r ing oi l cl e arance. I NS T AL L a new e ngi ne. P i s t o n/cy li nde r wor n. I NS TALL a ne w e ngi ne. P i s t o n ring da mag e d. I NS T AL L a new e ngi ne. Conn e cti ng r od be nt [...]

a nd r e pe a t the compr es s io n m e a s urement . I f t he r e adi ng gr e a t l y i mpr o ve s t he n t he pi s t o n r i ngs a r e da mag e d. I f t he r e adi ng s ta ys t he s ame t hen t he ca us e i s e i t he r d a mage d val v e se a t s o r val ve s t e m s e a l s . I f t he mea s u r e m e nt s fo r t wo cyli nd e r s next t o e a ch[...]

5. I f t he o i l cons umpt i on rate i s un a cc ept abl e go t o S tep 6 . 6. Check t he p o si t i ve cr a n kc as e ve nt i la t i o n (PCV ) s ys t e m. Make s ur e th e s ys t e m i s no t p l ugg e d. 6. 7. Check fo r pl ugge d oi l d r ai n-ba ck hol e s i n t he cy l i nde r hea d and c yli nder bl ock. 7. 8. If t he co ndi t i on s t i l [...]

i ndi cat e d. The r e a di ng a t i dl e co ul d be rel a t ive l y s t ea d y. 10. LATE VALVE TI MING: A s t e a dy b ut l o w r ea d in g co ul d be cau s ed by l a t e va l ve t imi ng. 10. 11. IGNIT IO N TIMIN G RETA RDING: Re t a r d e d i gni t i o n ti mi ng wi l l produce a s t e a dy but so mewh a t l o w r ea d i ng. 11. 12. INS UFFI CI [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Bearin g I nspectio n Gene ral P r ocedures 1. Ins pect b e a r i ngs f o r th e fo l l o wing d e fe ct s . 1. Cr at e r i ng - fa t i gue f a i l ure 2. S po t pol i s hi ng - i ncorr e ct s e a t i ng. 3. I mbedde d d i r t e ngi ne o i l . 4. S cr a t chi ng - di r t y e ng[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Bea ring J ournal Cl earance Gene ral P r ocedures 1. NOT E: Make s ure t ha t t he f ol l o wi ng s t a ge s a r e f o l l owe d exact l y . The ta p pe t s or f o ll owe rs mus t be remov e d t o car ry o ut t hi s me a s ur e ment . • NO T E: Make s ur e t ha t [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Bea ring J ournal Diam eter Gene ral P r ocedures 1. D et e r mine t he di a met e r of t he cams haf t jo urn al s . Us i ng a mi cr o met e r mea s ure t he di a met e r a t 90 de gr ee s i nt e r val s to det e r mine i f t he j o ur nal s a re o ut -o f -r o und [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft E nd Play Gene ral P r ocedures 1. NOT E: Make s ure t ha t t he cams ha f t i s t o s pe ci fi cat io n. Us i ng t he s p e ci a l t o ol , me a s ur e t he e nd pl ay. S li de t he ca ms ha ft i n b o th di r ect i o ns . Re a d a nd not e t he maxi m um a nd mini [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft L obe L ift Gene ral P r ocedures 1. M e as ur e t he di a met e r (1) and di a met e r (2) wi t h a ve rn i e r cal i p e r . T he di f fe r e nce i n me a s ur e ment s i s t he l obe l i f t . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C amsh aft Surfac e Inspecti on Gene ral P r ocedures 1. Ins pect ca ms haf t l o b e s f or pi t t i ng or da mag e i n t he a c t i ve a rea . Mi nor pi t t i ng i s a c ce pt a bl e out s i de t h e a ct i ve area . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C onn ecting Rod C leani ng Gene ral P r ocedures 1. CAU TI O N : Do no t us e a ca us t i c cle a ni ng s o l ut io n or da mag e t o c on ne ct ing r od s m a y occur . Mark a nd s ep a r at e t he p a r t s a nd cle a n wi th so l vent . Cl e a n t he oi l pa s sa g e s . Ja[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C onn ecting Rod L arge End B ore Gene ral P r ocedures 1. M e as ur e t he be a ring bo r e i n t wo di r ect i ons . The di f f e rence i s t he conne ct i ng r od bore o ut -of -r ound. Verif y t he o ut -o f -r o und i s wi t hi n s p e cif i c a t i o n. 2. M e as ur e t h[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft E n d P lay Gene ral P r ocedures 1. Usi ng t he Di a l Indi cat or Gauge wi t h Br ack e t s , me as ure t he e nd pl a y . Mea s ure t he e nd pl a y by l i ft i ng t he crank s haf t us i ng a l e ver. If t he val ue i s o ut o f t he s pe ci fi cat io n, in s t [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft Main B earing Jo u rnal C lea rance Gene ral P r ocedures 1. The mai n be a ring m a chi ne co de s a r e d is pl a ye d o n t he cr anksha ft (1) a nd t he cyli nde r bl o ck (2) 2. NOT E: Mai n be aring numbe r 1 r e l at e s t o t he f ront of t he e ngi ne . Re [...]

3. NOT E: Mai n be aring numbe r 1 r e l at e s t o t he f ront of t he e ngi ne . Re a d t he i d ent i f i ca t i on number s on t he cyli nder bl o ck (2 ). The fi r s t t wo number s r e pres e nt th e code f o r m a i n be a ring number 1. The s e cond pa i r o f number s r e pres e nt s th e code f o r m a i n be a ring number 2. The t hi r d[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C rankshaft Main B earing Jo u rnal Di ameter Gene ral P r ocedures Ge nera l Equi pm ent Mi c rom e t e r 1. M e as ur e t he di a met e r of t he mai n be a ring j ournal s a nd t he b i g-end be a r i ng j ou r na l s . Re pea t t he mea s ur emen t wit h t he mi cr omet e r[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Blo ck Disto rtio n Gene ral P r ocedures 1. Usi ng a St r ai ght Ed ge a nd a Fe e l e r Gaug e, mea s ur e t he cyli nde r bl o ck/ cylind e r he ad di s t o rti o n. Mea s ure t he mat i n g f a ce di s t or t i o n. If t he val ue i s no t t o s pe cif i ca t i [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Bore O u t- o f- Round Gene ral P r ocedures 1. NOT E: The mai n be a r i ng cap s or l o we r cr ankc a se must be i n pl a ce and ti g ht e ne d t o t he s pe ci f i e d t o r q ue ; ho we ver , t he b e a r ing she ll s s h oul d no t be i ns t al le d. Mea s ur [...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - C y lin der Head Disto r tio n Gene ral P r ocedures 1. M e as ur e t he cyli n der bl ock/ cyli nde r he a d di s t orti o n. Us i ng t he s pe ci a l t o ol , m e a s ur e t he m a t i ng f ace di s t o r t i o n. If t he val ue i s no t t o s pe cif i ca t i on r ewo r k t h[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Exh aust Manifo ld C leaning a nd Inspectio n Gene ral P r ocedures 1. Ins pect t he cy l i nde r hea d jo i ni ng fl ange s o f t he e xhaus t mani f ol d f or e vid e nce of e xha ust g a s l e aks . 2. Ins pect t he e xh a us t ma nif ol d f o r c rac ks , da ma ged gas ke t[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Flyw h eel In spectio n Gene ral P r ocedures 1. CA UT I O NS: Do no t rework t he f l ywhee l i f i t is di s t o rte d. Do no t cle a n t he d ual mas s f l ywhee l wit h a ny kind o f f l ui d . Cl e a n th e fl ywhe e l wi t h a dry cl ot h o nly. Do no t cle a n t he g a p[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Diam eter Gene ral P r ocedures Ge nera l Equi pm ent Mi c rom e t e r 1. NOT E: Mark t he pi s t o n t o mak e s ure t he pi s t o n i s i ns t a ll ed corr e ct l y. Us i ng a Micromet e r me a s ur e t he pi s t on d i a met e r. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ins pection Gene ral P r ocedures 1. CAU TI O N : Do no t us e a ny a ggres s i ve cl ea ni ng fl ui d or a wi r e b r us h to c l e a n t he pi s t o n. Ca r ry out a vis ua l i ns p ect i on. Cle a n t he p i s t o n s ki r t , pi n bu s h, r i ng grooves a nd crown a[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Pin Dia meter Gene ral P r ocedures 1. NOT E: The pi st o n a nd p is t o n pi n ar e a ma tche d p a i r . Do not mix up t he c ompo ne nt s . Mea s ur e t he pi s t o n pi n d i a me t e r. Mea s ure t he di a met e r i n t wo di rect i o ns . If t he val ue s a r e n[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Pin to B ore D iam eter Gene ral P r ocedures 1. NOT E: The pi st o n a nd p is t o n pi n fo r m a ma t ched pai r . Do not mi x up th e compone nt s . Mea s ur e t he di a met e r of t he pi st o n p i n bore. Mea s ure t he di a met e r i n t wo di rect i o ns . If t[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ring En d Ga p Gene ral P r ocedures 1. CAU TI O N : Do no t mi x u p t he pi s t o n r i ngs . Ins t al l t he pi st o n ring s in t he s a me p o s i t i on a nd l o cat i o n. Us i ng t he Fe e l e r Gauge , mea s ur e t he p i s t o n ring ga p . The val ue s g i ve[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - Pisto n Ring- to-G roo ve Clea rance Gene ral P r ocedures 1. NOT E: The pi st o n ring mus t prot r ude f r om t he pi s t o n gr oo ve. T o det e r mine t he pi s t on r i ng cle a r a n c e , i nse r t t he Fe e le r Ga uge r i ght to t h e back o f t he gr oo ve , beh ind t[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Seat Inspectio n Gene ral P r ocedures Ge nera l Equi pm ent Va l ve s e a t wi dt h s cal e 1. M e as ur e t he wi d t h o f t he val ve s e a t . Mea s ure t he v a l ve s ea t wi dt h usi ng t he Va l v e s e a t wi dt h s ca le . If t he val ue i s no t t o s pe cif[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Spring Free Length Gene ral P r ocedures 1. Usi ng a ve r ni er ga ug e , mea s ure t he fre e l e ng t h o f e a ch val ve s pr i ng. Ve r i fy t he l e ngt h i s wi t hin s p e ci fi cat io n. JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine System - G eneral I nform atio n - V alv e Stem Di ameter Gene ral P r ocedures 1. Usi ng a mi cr omet er me as u r e t he di a me t e r of t he v a l ve s t e ms . If t he m e a s u r e m e nt s a r e no t t o s p eci fi ca t i o n, ins t a l l a new val ve . JagDocs.com[...]

P ubl i s he d: 02-J un-2011 E ngine System - G eneral I nform atio n - Leaka ge Test U si ng Smo ke Test E quipm ent Gene ral P r ocedures CAU TIO N : Th e co mpr e s s e d a i r li ne s uppl y pr e s s ur e must b e b e t wee n 3.5 a nd 12 ba r (50 a nd 175 ps i ) fo r t h e s moke t e s t e q ui pment t o funct i on corr e ct l y. Do no t e xc e[...]

6. NOT E: In s o me c a s e s i t may be ne ces s a ry t o r emove t he a i r c l e a ne r (s ) to a ll o w a cces s t o t he a i r cl e an e r out l e t pi p e s. • NO T E: In s ome cas e s i t wi l l be ne ce s s a ry t o cap one o f t he a i r c l e ane r out l e t pi pes . U s e t he b la n king ca ps s upp li e d i n t he ki t t o cap t h e [...]

Publ i s he d: 23-S ep -2011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - Lubr i cant s, Flu ids , Seal er s and A dh e si v es Descri pti o n Speci fi cati on Engi ne oi l 2. 0L ga s o l i ne , S AE 5W -30 (NAS ) API S L a nd I LS AC GF –3 Engi ne oi l 2. 0L ga s o l i ne , S AE 5W -30 (ROW ) AP I SJ / EC a nd ACEA A1[...]

Descri pti o n N m l b-ft l b- i n W i r i ng ha r ne s s t o val ve cover r et a i ni ng nut s 6 - 53 Thr ot t l e ca bl e ret a i ni ng b r ack e t bo l t s 9 - 80 A = ref e r t o th e proced ur e fo r corr e ct t orque s e que nce - - - JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Des cr ipt i o n a nd O pe r a t i o n 2.0 Li t re 2.5 and 3.0 Li t re JagDocs.com[...]

The 2.0, 2.5 a nd 3.0 l i t r e 24 val ve V6 e n gi ne s ha ve fo ur o ver he ad c a msha f t s a n d a re dr i v e n by t wo t i ming cha in s . A l l t hree e ngi ne s in cor po r at e e l e ct roni c e ng i ne mana ge ment wi t h d i s t r i but o r l e s s i gni t i on s ys t e m , s e que nt i a l e l e ct roni c fue l inj ect i on. Al l t hr [...]

The r ot a r y o i l pump d e v e l op s t he o i l pres s ur e: The o il p ump i s l o ca t e d at t he f r on t of t he cr anks ha ft . The o il p ump i s d r i ven by t he cr a nk s ha ft . A f u ll f lo w oi l f il t e r i s e xt e r nal l y mount ed o n t he oi l fi l t e r hous i ng. I f t he f i l t e r e l e ment s ho ul d be come b l ocked[...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Dia gn os i s a nd Te s t i ng For add i t i o na l i nf or m a t io n, ref er t o Sect i o n 303-00 Engine S ys t em - Gen e r al I nf or mat i o n . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C learanc e A djustment Gene ral P r ocedures 1. Remove t he ca m s haf t s . Fo r a ddi t i o nal i nfo r mat i o n, ref e r t o Ca ms ha f t 2. Use com pres s e d a i r to remove t he s hi ms t ha t r e qui r e r e pl a ci ng. Bl o w com [...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - V alv e C learanc e C heck Gene ral P r ocedures 1. Remove t he l e ft ha nd val ve co ver. For ad di t i o na l i nfo rm at i on, refe r t o Va l ve Co ver — LH 2. Remove t he right ha nd val ve cover . Fo r a ddi t i o nal i nfo r mat i on, ref[...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C amsh afts LH I n-v e hi c l e Re pa i r R em ova l 1. Remove t he t i mi ng chai ns. For a dd it i o nal i nfo r mat i on, ref e r t o Ti mi ng Dr ive Co mpone nt s . 2. Remove t he ca m s haf t be a r in g cap s e venl y. 3. Remove t he ca m s h[...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Fro nt Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Cr a nk s ha f t Front S e a l Remo ver 303-700 Cr a nk s ha f t Front S e a l Ins t a l l e r 303-542 Cr a nk s ha f t Dampe r Ins t a l l e r 303-102 R em ova l 1. Remove t he [...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Pu lley I n-v e hi c l e Re pa i r Speci al T ool (s) W r e nch s t r ap-uni vers al 303-D 055 Cr a n ks haf t Da mper Remove r 303-D 121 Thr us t P ad 303-D 121- 01 Cr a n ks haf t Da mper Ins t a l l e r Dr a w Bol t 303-102 Cr a n ks[...]

3. D i s conne ct t he cr a n ks haf t p o si t i on s e ns o r (CKP) e l e ct r ica l conne ct o r . 4. Remove t he CKP s e ns or. 5. D et a ch t he a cces s o r y d r i ve be lt . 1. Us i ng t h e s pe ci al t o ol , r ot a t e t he b e l t te ns i o ne r c o unt e r cl ockwis e . 2. De ta ch t he a cces s ory dr i vebe l t . 6. Usi ng t he s pe [...]

8. Usi ng t he s pe cia l t oo l s, re move t he cr anksh a ft vib rat i on dampe r. Insta llat ion 1. NOT E: Coa t t he cr a nks ha ft da mpe r keyway wit h s i l i cone gas ke t s e a l ant W S E- M4G 323-A6 o r equi va l e nt mee t i ng Ja guar s p e ci fi c a t io n. Us i ng t he s p e ci a l t o ol , i ns t a l l t he cr anksh a ft vib rat i o[...]

4. Ins t a l l the CKP . Ti ght e n t o 10 Nm. 5. Connect t he CKP el e ct r i cal co nnect o r. 6. Ins t a l l the s p l a s h s hi e ld . 7. Ins t a l l the whe e l a nd t i r e. Fo r a ddi t i ona l i nf o r m a t i o n, r e f e r t o S e cti o n 204-04 W hee l s a nd T ire s . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C rankshaft Re ar Seal I n-v e hi c l e Re pa i r Speci al T ool (s) Cr anks haf t Re a r S ea l Re m over 303-566 Cr anks haf t Re a r S ea l I ns t a l l e r 303-178 Cr anks haf t Re a r S ea l I ns t a l l e r Ada pt e r Bo l t s 303-384 Cr anks[...]

3. NOT E: Al t e r nat e bo l t t i ght e ni ng t o corr e ct l y s e a t t he cr anks haf t r e a r oi l s ea l unt i l i t i s fl us h wi t h t he cyl in de r bl o ck . Us i ng t he s p e ci a l t o ol , i ns t a l l t he cr anksh a ft rear oi l s e a l . Vehi c le s With Manual Tra nsmi ss io n 4. Ins t a l l the f l ywhe e l . Fo r ad di t i o [...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - C ylinder Head LH I n-v e hi c l e Re pa i r R em ova l Vehi c le s with 2.5L or 3.0L engine 1. D i s conne ct t he e ngi ne co ol a nt t e mperat ur e (ECT) a nd f uel t e mperat ure s e ns o r (F TS) el e ct r ica l conne ct o r s . 2. D i s conn[...]

5. D et a ch t he f ue l chargin g wi ring harnes s . 2.5 a nd 3. 0L s hown, 2. 0L s i m i l a r . 6. W ARNING: Fue l m a y s t i l l be pres e nt i n t he f ue l i nj e ct i on s uppl y m a ni f ol d, e xt r eme c a re mus t be t a k en as t his coul d c a us e pe r s o na l i nj ury . Det ach t he f uel i nj e ct i on su ppl y mani fo l d, l o we[...]

10. Remove t he co o l a nt bypas s t ube. Re mov e a nd di s c a r d t he cool ant b ypa ss t ub e O -r i ng s e a l s . 11. Remove t he e xhaus t mani f o l d. Re mov e a nd di s c a r d t he e x ha us t m a ni f ol d g a s ket . 12. Remove t he l ef t -han d cams ha f t s . Fo r ad di t i on a l in f orm at io n, r e f er t o Ca m s ha f t . 13.[...]

5. Ins t a l l the co ol a nt by pa s s t ube . Ins t al l t he n e w coo la nt bypas s t ub e O -r i ng s ea l s. Ti ght e n t o 10 Nm. 6. Ins t a l l the wa t e r pump out l et p i pe. Ins t al l t he n e w wa t e r pump ou t l e t pi pe O -r i ng s e al s . Ti ght e n t o 10 Nm. 7. Ins t a l l the o i l l e v el i ndi c a t o r t ube . Ins t al [...]

10. At t ach t he f uel cha r ging wi ring ha r nes s . 2.5 a nd 3. 0L s hown, 2. 0L s i m i l a r . Vehi c le s with 2.0L engi n e 11. Conne ct t he co o l a nt t e mpe rat ur e (ECT) e l e ct r i cal c onn e cto r . Vehi c le s with 2.5L or 3.0L engine 12. At t ach t he f uel s e nso r vacuum l i ne . 13. Conne ct t he e l e ct r i cal conne ct o[...]

14. Conne ct t he e ngi ne co o l a nt t e mpe rat ur e (ECT) a nd f uel t e mperat ure s e ns o r (F TS) el e ct r ica l conne ct o r s . JagDocs.com[...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Front C o ver I n-v e hi c l e Re pa i r R em ova l CAU TIO N : I t i s ne ce s s a r y t o r e move t h e e ngi ne i n o r de r t o r e move t he e ngi ne f r on t c o ve r . All v e h icle s 1. Usi ng a s ui t a bl e co nt a i ne r dr ai [...]

6. D i s conne ct t he t hr o t t l e po s i t i o n s e ns o r e l e ct r i cal c onn e cto r . 7. D et a ch t he cr uis e co nt rol ca b le . 8. D et a ch t he t hrot t l e ca b le . 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. De ta ch t he t hr ot t le cabl e . 9. D et a ch t he t hrot t l e ca b le ret [...]

11. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 12. Det a ch t he wi ring ha r nes s. Vehi c le s with 2.5L or 3.0L engine 13. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 14. Dis c o nne ct t he e l e ct r ica l conne ct o r s . 15. Det a ch t he wi ring ha r nes s. JagDocs.com[...]

16. Det a ch t he vacuum hos e. All v e h icle s 17. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt a k e mani fo l d s uppo rt b r a cket . 18. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt a k e mani fo l d s uppo rt b r a cket . 19. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Re move t h e i nt [...]

20. Dis c o nne ct t he l ef t -han d i g nit i o n coi l e l e ct r i c a l co nnect o rs. 21. Remove t he l ef t -han d i g nit i o n coi l s . 22. Dis c o nne ct t he va r i a bl e ca m s ha f t t i m i ng (VCT) s o l e no i d e l ect r i cal conne ct or. 23. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . Di s conn ect t he cams ha f t [...]

Vehi c le s with 2.0L engi n e 26. Det a ch t he hea t ed pos i t i ve cr an k cas e vent i l a ti on val v e cool ant h os e s . All v e h icle s 27. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Det ach t he co ol a nt h os e . 28. Remove t he l ef t -han d va l ve cover. Re mov e a nd di s c a r d t he val ve cove r g a ske t s. 29. Dis c o [...]

30. Remove t he rig ht -ha nd i g ni t i o n coi l s . 31. Det a ch t he wi ring ha r nes s. 32. Dis c o nne ct a nd repos i t i on the v a r i a bl e ca ms ha ft t i mi ng (VCT) s ol e no i d e l e ct r i cal conne c t o r . 33. Remove t he e n gi ne co ver r e ta i ni ng br a cket . 34. Repo s i t i o n t he right -hand wi ring ha r nes s f or ac[...]

35. Remove t he rig ht -ha nd val ve cover . Re mov e a nd di s c a r d t he val ve cove r g a ske t s. 36. Det a ch t he acce s s o r y driveb e l t . 1. Us i ng t h e s pe ci al t o ol , r ot a t e t he b e l t te ns i o ne r c o unt e r- cl ockwis e . 2. De ta ch t he a cces s ory dr i vebe l t . 37. Remove t he a cces s o r y drive be l t t e n[...]

40. Dis c o nne ct t he g e ne r at o r po s i t i ve ca bl e e l e ct r i cal conne cto r. 41. Dis c o nne ct t he g e ne r at o r e l e ct r i cal conne cto r. 42. Remove t he g e ne r at o r. 43. Us i ng t he s pe ci a l t o o l , r e move t he cr anksha ft vi br a t i o n da mper r et a i ni ng b ol t . Re mov e a nd di s c a r d t he cr a n k [...]

45. Remove t he CKP . 46. Ins t a l l t he s p e cia l t o o l . 47. Us i ng t he s pe ci a l t o o l s , re m o v e t he cr anks ha ft vib rat i o n dampe r. 48. Remove t he a i r cond i t i o ni ng co m pr es s or . 49. Remove t he p o we r s t e e r i ng pump. JagDocs.com[...]

50. Remove t he o i l pa n . Re mov e a nd di s c a r d t he o il pa n g a ske t . 51. Remove t he i dl e r pul l e y. 52. Remove t he i dl e r pul l e y. 53. Remove t he e n gi ne f r o nt co ver. Re mov e a nd di s c a r d t he e ngi ne front cove r g as ke t s . Insta llat ion All v e h icle s JagDocs.com[...]

1. Ins t a l l the ne w f ront t imi ng co v e r gas ket s . 2. NOT E: Prio r t o a p pl yin g s e a l e r cle a n t he f ront t imi ng co ver t o e ng ine bl o ck a nd cyli nd e r he a d s e a l i ng s urface s wi t h met a l s ur face cle a ne r . • NO T E: Ap pl y a 6 mm di a met er do t o f s i l icone se al a nt W S E-M4G 32 3-A6 o r e qui v[...]

5. Ins t a l l the i dl e r p ul l e y. Ti ght e n t o 25 Nm. 6. NOT E: Appl y a 10 mm dia me t e r dot of s i l i co ne s e al a nt W S E-M 4G323- A6 or eq ui val ent mee t i ng Ja gua r s pe ci fi cat io n t o t h e e ng i ne f r on t cover t o th e c yl i nde r bl o ck mat i ng j o i nt s . • NO T E: L oos e l y i ns t a l l t he o i l p a n t[...]

10. Us i ng t he s pe ci a l t o o l , t i ght e n t he c r a nk s ha f t vibra ti on d ampe r r et a i ni ng b ol t . Ins t al l a ne w cr anks haf t vib r a t i o n ret a i ni ng bo l t . Compl e t e t he ti ght e ni ng s e que nce. S ta g e 1: T o r que t o 120 N m . S ta g e 2: L o o se n t he b ol t (mi ni mum 1 t ur n) . S ta g e 3: T o r que[...]

15. Conne ct t he g e ne r a t or po s i t i ve ca bl e . Ti ght e n t o 12 Nm. 16. At t ach t he g e ne r a to r po s i t i ve ca bl e prot e ct i ve cove r . 17. At t ach t he a cces s or y drive be l t . 18. Ins t a l l t he a cc e s s o r y drive b e l t t e nsi o ner. Ti ght e n t o 47 Nm. 19. At t ach t he a cces s or y drive be l t . 1. Us i[...]

20. NO TE: Ap pl y a 5 mm di amet e r b e ad o f s i li cone ga s k et s e a l a nt W S E- M4G 323-A6 o r equi va l e nt mee t i ng Ja guar s p e ci fi c a t io n on t he ha l f r o und g a s ket s a nd a ppl y a n 8 m m di a met e r be a d o f s i l i cone gas ke t s ea l ant o n th e t wo pl ace s whe r e t he cyl i n der he a d a nd f r ont t i [...]

Vehi c le s with 2.0L engi n e 25. Ins t a l l t he he a t e d po s it i ve crank ca s e ve nt i l a t i o n val ve cool a nt ho s e s . All v e h icle s 26. NO TE: Ri ght -hand s ho wn, l e ft -hand s i mil a r . I nst a l l t he (CMP) s e mso r s . Ti ght e n t o 7 Nm. 27. NO TE: Ri ght -hand s ho wn, l e ft ha nd s i m i l ar. Conn ect t he cams[...]

29. Ins t a l l t he l e f t -hand ig ni t io n c oi l s . Ti ght e n t o 6 Nm. 30. Conne ct t he l e f t -ha nd i g ni ti on coi l s e l ect r i cal conne cto rs. 31. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. • NO T E: T he i nt a k e mani fo l d ret a i ni ng bo l t s num be red 1, 2 a nd 3 a re lo ng e r t ha n t he r e t a i ni ng bo [...]

34. NO TE: 2. 5L a nd 3.0L s ho wn, 2.0L s i mil a r. Ti ght e n t o 6 Nm. Vehi c le s with 2.5L or 3.0L engine 35. Conne ct t he va cuum h os e . 36. At t ach t he wi r i ng harnes s . Ti ght e n t o 10 Nm. 37. Conne ct t he e l e ct r i cal conne ct o rs. 38. Conne ct t he e l e ct r i cal conne ct o rs. Vehi c le s with 2.0L engi n e JagDocs.com[...]

39. At t ach t he wi r i ng harnes s . 40. Conne ct t he e l e ct r i cal conne ct o rs. 41. Ins t a l l t he coo l a nt hos e s . 42. At t ach t he t hr ot t l e cabl e br acket . Ti ght e n t o 9 Nm. 43. At t ach t he t hr ot t l e cabl e. 1. Re pos i ti on t he t hr ot tl e l e ver t o t he fu ll y o pe n po s i ti o n. 2. At t a ch t he t hrot [...]

44. At t ach t he cr ui s e cont r ol cab l e . 45. Conne ct t he t hr ot t l e po s i t i o n s e ns o r e l e ct r i cal c onn e cto r . 46. Conne ct t he i dl e a ct ua t or co ntrol val v e e l e ct rical co nnect or . 47. At t ach t he p o s i t i ve cr a n k cas e veni l a t i on ho se . Vehi c le s with 2.5L or 3.0L engine JagDocs.com[...]

48. At t ach t he p o s i t i ve cr a n k cas e vent i l at i o n hos e . All v e h icle s 49. Ins t a l l t he a ut omat i c or manua l t rans mis s io n. For a dd it i o na l i nf o r ma t i o n, r e f e r t o S e ct i on 307-01A Aut omat i c Tr an s mi s s i o n/T r a nsa xl e S e ct i on 307-01B Aut o mat ic Tr an s mi s s i o n/T r a nsa xl e [...]

P ubl i s he d: 11-May-2 011 E ngine - 2.0L NA V 6 - AJV6/2. 5L NA V 6 - A JV 6/3.0 L N A V6 - AJ27 - En gine Front Mount I n-v e hi c l e Re pa i r Speci al T ool (s) P owe r t r ai n A s s e mbl y Ja ck HTJ1200-0 2 R em ova l 1. D r ai n t he coo l i ng s yst em. F o r a dd i t i o na l i nf o r mat i o n, refe r t o . For a ddi ti ona l i nf o r[...]