Spark
PRE-DELIVERY INSPECTION
PDI Inspection
FOREWORD
GENERAL INTRODUCTION
1. EQUIPMENT AND MATERIAL FOR PDI AND SERVICE
TOOLS
FLUIDS
2. PRE-DELIVERY INSPECTION FORM
ENGINE COMPARTMENT
1. COMPONENTS CONNECTION LOOSE
2. HOSE AND ELECT. WIRES ROUTING
3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER COMPONENTS
4. UNUSUAL NOISES
5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS, ETC.
6. POWER STEERING SYSTEM
7. ENGINE COOLANT PROTECTION
8. ALL FLUID LEVELS CHECK
9. THROTTLE LINKAGE
10. BELTS TENSION
BODY ACCESSORIES
1. HEADLAMPS OPERATION AND AIM
2. INDICATOR LAMPS
3. HAZARD WARNING LAMPS
4. REVERSE LAMPS
5. BRAKE LAMPS
6. TAIL LAMPS, POSITION LAMPS, NUMBER PLATE LAMPS, ADDITIONAL INDICATOR LAMPS
7. INSTRUMENT PANEL WARNING LAMPS AND INDICATORS
8. DOME AND COURTESY LIGHTS
OPTION
11. INSTRUMENT PANEL GAUGE OPERATION
14. REAR WINDOW AND OUTSIDE MIRROR DEMISTER BUTTON
16. HORN SWITCH
17. WIPER AND WASHER OPERATION
20. CUP HOLDER
21. CIGARETTE LIGHTER
22. CLOCK
23. DOOR LOCK
24. DOOR WINDOW
25. OUTSIDE REARVIEW MIRRORS
28. SEAT
29. FUEL FILLER DOOR RELEASE LEVER
30. BOOT LID RELEASE LEVER
31. ENGINE BONNET RELEASE LEVER
34. SUNGLASSES HOLDER
UNDER VEHICLE
UNDER VEHICLE INSPECTION
1. STEERING GEAR AND LINKAGE
2. PROPER TRACK ROD CLAMP POSITION
3. EXHAUST SYSTEM FOR PROPER ALIGNMENT AND CLEARANCE
4. FRONT AND REAR SUSPENSION
5. CHECK AXLE AND MANUAL GEARBOX FLUID LEVEL
6. BRAKE SYSTEM
7. FUEL SYSTEM
8. DRIVE SHAFT OF FRONT DRIVE AXLES
9. VISUALLY INSPECT WHEEL STUD AND FLANGE NUTS
10. INFLATE TYRES TO SPECIFIED PRESSURE
ROAD TEST
1. SEAT BELTS
2. FREE PLAY OF BRAKE AND CLUTCH
3. HORN
4. WIND NOISE
5. OPTIONS AND ACCESSORIES
6. HEATER AND AIR CONDITIONING
CONTROL PANEL
INCLUDES AIM WASHER IF NECESSARY
8. ENGINE AND TRANSMISSION PERFORMANCE DURING ACCELERATION, DECELERATION, IDLE, CRUISE AND DOWN SHIFTS
9. SQUEAKS AND RATTLES
10. STEERING COLUMN IGNITION LOCK
11. INSTRUMENTS AND GAUGES
12. THROTTLE CONTROL FOR FREE OPERATIONS
WHEEL CENTRE POSITION AND HANDLING
INCLUDES PARKING BRAKE AND WARNING LIGHT
APPEARANCE
1. INSPECT CONDITION AND PERFORM DETAIL OPERATION
2. CHECK FOR PROPER ASSEMBLY, FIT AND RETENTION OF PARTS AND COMPONENTS
3. EXTERIOR FINISH
4. INTERIOR TRIM AND CARPETS PROTECTIVE COVERINGS
5. SPARE WHEEL, JACK AND VEHICLE TOOLS
6. BATTERY
ANNEX
1. RECEIVING INSPECTION
2. DIRECTION FOR THE USE OF HY-600 TRANSIT COATING REMOVER IN A HAND WASH OPERATION
3. STORAGE AND MAINTENANCE OF NEW VEHICLE IN EXTREMELY HOT AND HUMID LOCATIONS
DESCRIPTION:
LABOUR TIME GUIDE
0. General Information
1. INTRODUCTION
1-1. PAGE LAYOUT
1-2. TYPES OF OPERATION
Major Operation
Supplementary Operation (Adds)
1-3. TIME ALLOWANCES
2. HOW TO READ THIS MANUAL
Section
Illustration Number
Operation Description
3A. Major Operation
3B. Supplementary Operation
Operation Code
1) Main Group Code
2) Basic Code
3) Auxiliary Code
Major Operation
Supplementary Operation (ADD)
Operation Times
Model Code
Engine Type
3. HOW TO USE THIS MANUAL
4. PAINT REPAIR
4-1. INSTRUCTION
4-2. LABOR TIME
4-3. REPAIR TYPE
4-4. HOW TO USE OPERATION CODE FOR PARTIAL PAINTING
5. DEFECT CODE
5-1. NATURE CODES
5-2. CAUSE CODES
5-3. PAINT CODES
6. ABBREVIATIONS
7. MAIN GROUP CODE
1. Engine
DOHC ENGINE MECHANICAL
DOHC ENGINE UNIT (111)
BELT SYSTEM (113)
ENGINE BLOCK (121)
CRANKSHAFT & PISTON (122)
OIL SUMP & PUMP (123)
CYLINDER HEAD (131)
CAM SUPPORT & SHAFT (132)
TIMING COVER (133)
ENGINE & TRANSAXLE MOUNT (138)
ENGINE COOLING
RADIATOR (141)
COOLING FAN (143)
RADIATOR HOSE & PIPE (145)
THERMOSTAT (148)
ENGINE ELECTRICAL
IGNITION CABLE & DISTRIBUTOR (151)
ALTERNATOR UNIT (154)
STARTER (156)
BATTERY (157)
FUSE & RELAY (158)
ENGINE CONTROLS
FUEL TANK (171)
FUEL LINE (172)
CANISTER & FUEL VACUUM (173)
FUEL INJECTION (181)
ACCELERATOR CONTROL (182)
EMISSION CONTROL (186)
ENGINE INTAKE & EXHAUST
AIR INTAKE SYSTEM (191)
INTAKE MANIFOLD (193)
EXHAUST MANIFOLD (194)
EXHAUST PIPE LINE (196)
2. Suspension
FRONT SUSPENSION
KNUCKLE & HUB (213)
FRONT SHOCK ABSORBER (214)
CONTROL ARM (215)
REAR SUSPENSION
REAR AXLE (231)
TYRES & WHEEL
WHEELS & WHEEL COVER (241)
TYRE PRESSURE MONITORING SYSTEM (242)
3. Driveline Axle
DRIVE LINE / AXLE
AXLE SHAFT PARTS (321)
4. Brakes
HYDRAULIC BRAKE
BRAKE PIPE (425)
BRAKE PEDAL & MOUNT (428)
MASTER CYLINDER & POWER BOOSTER
MASTER CYLINDER & BOOSTER (431)
FRONT BRAKES
FRONT BRAKE (445)
REAR BRAKES
REAR BRAKE (456)
ANTI-LOCK BRAKES SYSTEM
ANTI-LOCK BRAKE SYSTEM (462)
PARKING BRAKES
PARKING BRAKE (478)
5. Transmissions/Transaxle
JATCO JF405E AUTO T/A
AUTOMATIC TRANSAXLE I (501)
AUTOMATIC TRANSAXLE II (502)
AUTOMATIC TRANSAXLE III (503)
AUTOMATIC TRANSAXLE IV (504)
FIVE-SPEED MANUAL TRANSAXLE: Y4M-HD
MANUAL TRANSAXLE (571)
TRANSAXLE GEAR (572)
GEAR SHIFT COVER & FORK (573)
DIFFERENTIAL GEAR (574)
SHIFT CONTROL (575)
CLUTCH
CLUTCH PARTS (581)
CLUTCH PEDAL (583)
6. Steering
POWER STEERING SYSTEM
POWER STEERING GEAR (621)
POWER STEERING PIPE LINE (623)
MANUAL STEERING GEAR
MANUAL STEERING GEAR (635)
STEERING WHEEL & COLUMN
STEERING WHEEL (641)
STEERING COLUMN COVER (642)
STEERING COLUMN (643)
TYRE ROD (647)
7. (HVAC) Heating, Ventilation, and Air Conditioning
HEATING & VENTILATION
AIR DISTRIBUTION (711)
EVAPORATOR (713)
BLOWER (714)
HVAC CONTROL
COMPRESSOR (732)
COMPRESSOR MOUNT (733)
A/C HOSE & PIPE LINE (734)
A/C CONTROL SWITCH (735)
8. Restraints
SEAT BELTS
FRONT SEAT BELT (812)
REAR SEAT BELT (822)
SUPPLEMENTAL INFLATABLE RESTRAINTS
AIR BAG SYSTEM (832)
IMMOBILIZER (833)
9. Body and Accessories
BODY WIRING SYSTEM
WIRING HARNESS (911)
LIGHTING SYSTEM
FRONT LAMP (916 / 917)
REAR LAMP (918)
WIPER/WASHER SYSTEM
WINDSCREEN WIPER (921)
WINDSCREEN WASHER (923)
INSTRUMENT DRIVER SYSTEM
INSTRUMENT CLUSTER (925)
AUDIO SYSTEM
ELECTRICAL PARTS (928)
AERIAL (929)
INTERIOR TRIM
INSTRUMENT PANEL (931)
MOULDING & SWITCH (932)
CONSOLE (934)
FRONT DOOR TRIM (935)
REAR DOOR TRIM (936)
PILLAR TRIM (938)
FLOOR CARPET (939)
SEATS
FRONT SEAT (941)
REAR SEAT (942)
GLASS & MIRRORS
GLASS & OUT SIDE MIRRORS (946)
EXTERIOR PARTS
EMBLEM & LETTERING (951)
MUD GUARD (952)
BUMPERS & FASCIAS
FRONT BUMPER (956)
REAR BUMPER (957)
DOORS
FRONT DOOR & LOCK (961A)
FRONT WINDOW LIFTER (961B)
FRONT WEATHERSTRIP (961C)
REAR DOOR & LOCK (963A)
REAR WINDOW LIFTER (963B)
REAR WEATHERSTRIP (963C)
ELECTRIC DOOR LOCK (965)
FUEL FILLER LOCK & QUARTERLIGHT LOCK (966)
BOOT LID LOCK & TAILGATE LOCK (967)
CAR LOCK (968)
ROOF
HEADLINING & ROOF PANEL (971)
SUNSHADE & INSIDE MIRROR (972A)
SUN ROOF (972B)
BODY FRONT END
BONNET PANEL (973)
FRONT PANEL (974)
WING PANEL (975)
BODY REAR END
BOOT LID PANEL & SPOILER (978)
10. Paint
PAINT EXTERIOR
10 PAINT EXTERIOR
SERVICE MANUAL
1. Preface
Dangers, Warnings, and Cautions
Introduction
Definition of Danger, Warning, Caution, and Note
ABS Component Handling Warning
Actions to Take When Working with Fuel Warning
Approved Equipment for Collision Repair Warning
Assistant Driving Warning
Batteries Produce Explosive Gases Warning
Battery Disconnect Warning
Brake Dust Warning
Brake Fluid Irritant Warning
Brake Fluid Warning
Checking Hot Transmission Fluid through Drain Plug Hole Warning
Cleaning Solvent Warning
Collision Sectioning Warning
Cracked Window Warning
Defroster Outlet Warning
Exhaust Service Warning
Eye Protection Warning
Fuel and Evaporative Emission Pipe Warning
Fuel gauge Leak Warning
Fuel Pipe Fitting Warning
Fuel Storage Warning
Fuel Vapour in Evaporative Emission Components Warning
Petrol/Petrol Vapours Warning
Glass and Sheet Metal Handling Warning
Halogen Bulb Warning
Bonnet Hold-Open Device Warning
Hot Exhaust System Warning
Moving Parts and Hot Surfaces Warning
Protective Goggles and Glove Warning
Radiator Cap Removal Warning
Relieving Fuel Pressure Warning
Road Test Warning
Safety Glasses and Compressed Air Warning
Safety Glasses Warning
Safety Goggles and Fuel Warning
SIR Deployed Inflator Modules Are Hot Warning
SIR Inflatable Module Deployment Outside Vehicle Warning
SIR Inflator Module Disposal Warning
SIR Inflator Module Handling and Storage Warning
SIR Seatbelt Pretensioner Handling Warning
SIR Warning
Air in the Power Steering System Caution
Avoid Chipping or Scratching the Coating Caution
Ball Stud Removal Caution
Belt Dressing Caution
Brake Calliper Caution
Brake Fluid Effects on Paint and Electrical Components Caution
Clearcoat/Ultraviolet Screeners Caution
Component Fastener Tightening Caution
Drive Axle Caution
Exterior Trim Emblem Removal Caution
Fastener Caution
Filling the Master Cylinder Caution
Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
Heated Oxygen and Oxygen Sensor Caution
Heated Oxygen Sensor Resistance Learn Reset Caution
Installing Hoses without Twists or Bends Caution
Power Steering Hose Disconnected Caution
Steering Column in Lock Position Caution
Steering Gear Preload Adjustment Caution
Steering Wheel in the Full Turn Position Caution
Steering Wheel Straight and Column Locked Caution
Test Probe Caution
Torque-to-Yield Fastener Caution
Transmission Fluid Vent Cap Removal Caution
Transmission Overfill Caution
Vehicle Lifting and Jacking Caution
2. General Information
General Information
Introduction
US English/Metric Conversion
Decimal and Metric Equivalents
Arrows and Symbols
Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage
Vehicle Certification, Tyre Placard, Anti-Theft, and Service Parts ID Label
RPO Code List
Fasteners
Thread Inserts
Abbreviations and Meanings
Lifting and Jacking the Vehicle
Diagnostic Information and Procedures
Customer Concern Verification Sheets
Repair Instructions
Key and Lock Cylinder Coding
Air/Wind Noise
Diagnostic Information and Procedures
Air/Wind Noise
Tracing Powder or Chalk Test
Air Pressure Test
Soap Suds or Bubble Test
Repair Instructions
Exterior Wind noise
Interior Wind noise
Special Tools and Equipment
Special Tools
Maintenance and Lubrication
Specifications
Approximate Fluid Capacities
Fluid and Lubricant Recommendations
Maintenance Items
Maintenance
Maintenance Schedule
Squeaks and Rattles
Diagnostic Information and Procedures
Squeaks and Rattles
Symptoms - Squeaks and Rattles
Special Tools and Equipment
Special Tools
Vibration Diagnosis and Correction
Specifications
Tyre and Wheel Runout Specifications
Diagnostic Information and Procedures
Vibration Analysis - Road Testing
Component Rotational Speed Calculation
Vibration Analysis - Tyre and Wheel
Vibration Analysis - Hub and/or Axle Input
Vibration Analysis - Engine
Engine Order Classification
Vibration Analysis - Engine/Accessory Isolation
Vibration Analysis - Engine Balance
Vibration Diagnostic Aids
Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated
Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified
Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component
Vibration Diagnostic Aids - Vibration Duplicated, Appears to Be Potential Operating Characteristic
Symptoms - Vibration Diagnosis and Correction
Vehicle-to-Vehicle Diagnostic Comparison
Tyre and Wheel Inspection
Tyre and Wheel Assembly Runout Measurement - On-Vehicle
Tyre and Wheel Assembly Runout Measurement - Off Vehicle
Brake Disc/Drum Balance Inspection
Hub/Axle Flange and Wheel Stud Runout Inspection
Tyre and Wheel Assembly Isolation Test
Repair Instructions
Tyre and Wheel Assembly Balancing - Off Vehicle
Description and Operation
Vibration Theory and Terminology
Electronic Vibration Analyzer (EVA) Description and Operation
Vibrate Software Description and Operation
Water leaks
Diagnostic Information and Procedures
Water leak Test Preparation
Water Hose Test
Air Hose Test
Repair Instructions
Body Water leak Repair
Stationary Window Water leak Repair
3. Body Hardware and Trim
Exterior Trim
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Fog Lamp Bezel Replacement — SPARK, SPARK LS
Front Fog Lamp Bezel Replacement — SPARK LT
Front Number Plate Bracket Replacement
Radiator Grille Emblem/Nameplate Replacement
Liftgate Emblem/Nameplate Replacement
Radiator Grille Replacement
Radiator Upper Grille Replacement
Radiator Lower Grille Replacement
Sill Panel Moulding Replacement
Roof Panel Joint Finish Molding Replacement
Rear End Spoiler Replacement
Floor Coverings and Headlinings
Repair Instructions
Floor Carpet Drying
Floor Panel Carpet Replacement
Headlining Trim Panel Replacement
Instrument Panel and Console Trim
Specifications
Fastener Tightening Specifications
Repair Instructions
Steering Column Opening Filler Replacement
Steering Column Upper Trim Cover Replacement
Steering Column Lower Trim Cover Replacement
Instrument Panel Outer Trim Cover Replacement
Instrument Panel Compartment Replacement
Instrument Panel Centre Moulding Replacement
Instrument Panel Assembly Replacement
Instrument Panel Tie Bar Replacement
Front Floor Console Replacement
Special Tools and Equipment
Special Tools
Interior Trim and Panelling
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Side Door Window Switch Bezel Replacement
Rear Side Door Window Switch Bezel Replacement
Front Side Door Trim Panel Replacement
Front Side Door Trim Panel Applique Replacement
Rear Side Door Trim Panel Replacement
Rear Side Door Upper Rear Trim Panel Replacement
Front Side Door Sill Trim Plate Replacement
Rear Side Door Sill Trim Plate Replacement
Assist Handle Replacement
Sunshade Replacement
Windscreen Garnish Moulding Replacement
Center Pillar Upper Trim Panel Replacement
Center Pillar Lower Trim Panel Replacement
Quarterlight Garnish Moulding Replacement
Quarter Lower Rear Trim Panel Replacement
Rear Wheel Housing Trim Finish Panel Replacement
Tailgate Trim Panel Replacement
Special Tools and Equipment
Special Tools
4. Body Repair
Bolted Exterior Body Panels and Closures
Specifications
Fastener Tightening Specifications
Repair Instructions
Bonnet Primary Catch Release Cable Replacement
Rear Side Door Check Replacement
Front Side Door Adjustment
Front Side Door Replacement
Rear Side Door Adjustment
Rear Side Door Replacement
Front Fender Replacement
Liftgate Adjustment
Liftgate Replacement
Front Side Door Wiring Harness Replacement
Liftgate Wiring Harness Replacement
Rear Side Door Wiring Harness Replacement
Bonnet Primary Catch Release Cable Handle Replacement
Front Side Door Upper Hinge and Lower Hinge Replacement
Hood Hinge Replacement
Tailgate Hinge Replacement
Rear Side Door Upper Hinge and Lower Hinge Replacement
Bonnet Adjustment
Hood Replacement
Front Wing Insulator Replacement
Bonnet Primary and Secondary Catch Replacement
Front Side Door Check Replacement
Fuel Tank Filler Door Replacement
Bonnet Hold-Open Rod Replacement
Bonnet Rear Weatherstrip Replacement
Plenum Lower Panel Replacement
Liftgate Strut Replacement
Liftgate Strut Bracket Replacement
Front Side Door Weatherstrip Replacement - Door Side
Front Side Door Weatherstrip Replacement - Body Side
Liftgate Weatherstrip Replacement
Rear Side Door Weatherstrip Replacement - Door Side
Rear Side Door Weatherstrip Replacement - Body Side
Bumpers and Fascias
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Bumper Energy Absorber Replacement
Front Bumper Impact Bar Replacement
Front Bumper Lower Impact Bar Replacement
Front Bumper Fascia Replacement
Front Bumper Fascia Guide Replacement
Front Bumper Fascia Opening Lower Cover Replacement
Rear Bumper Fascia Replacement
Rear Bumper Fascia Guide Replacement
Rear Bumper Lower Fascia Replacement
Rear Bumper Impact Bar Replacement
Special Tools and Equipment
Special Tools
Collision Repair
Specifications
Dimensions - Body
Visual Identification
Structure Identification
Repair Instructions
Overlap/Backing Plate Sectioning
Drivetrain and Front Suspension Frame Front Support Replacement
Front Compartment Side Rail Bracket Replacement
Front Wheel housing Panel Replacement
Front Compartment Upper Side Rail Replacement
Front Hinge Pillar Body Sectioning
Body Hinge Pillar Lower Reinforcement Replacement
Roof Outer Panel Replacement
Roof Front Header Panel Replacement
Roof Rear Header Panel Replacement
Rocker Inner Panel Replacement
Body Lock Pillar Outer Panel Sectioning
Body Lock Pillar Outer Panel Reinforcement Replacement
Body Lock Pillar Inner Panel Replacement
Rocker Outer Panel Sectioning
Body Side Outer Panel Reinforcement Replacement
Rear Compartment Floor Panel Replacement
Quarter Outer Panel Sectioning
Quarter Inner Panel Replacement
Rear Rail Sectioning
Rear End Panel Replacement
Tail Lamp Pocket Replacement
Description and Operation
Dual Phase Steel
High Strength Low Alloy Steel
Mild Steel
Ultra High Strength Dual Phase Steel
Special Tools and Equipment
Special Tools
Frame and Underbody
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Compartment Splash Shield Replacement
Drivetrain and Front Suspension Frame Replacement — with EN-49802
Drivetrain and Front Suspension Frame Replacement — with CH-49289
Front Wheel housing Liner Replacement
Special Tools and Equipment
Special Tools
Paint and Coatings
Introduction
Basecoat/Clearcoat Paint Systems
Anti-Corrosion Treatment and Repair
Repair Instructions
Clearcoat Repair without Repainting
Environmental Fallout (Acid Rain)
Paint Gauges
Clearcoat Thickness
Rail Dust Damage Repair
Plastic Panel Information and Repair
Repair Instructions
General Plastic Repair
Introduction
How to Identify Plastic Parts
Plastic Identification and Refinishing Systems
5. Body Systems
Fixed and Movable Windows
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Moveable Window Schematics
Defogger Schematics
Diagnostic Information and Procedures
Symptoms - Fixed and Moveable Windows
Rear Window Defogger Malfunction
Power Windows Malfunction — Front and Rear Door
Power Windows Malfunction — Front Door
Repair Instructions
Windscreen Replacement
Front Side Door Window Replacement
Rear Side Door Window Replacement
Rear Window Replacement
Tailgate Window Strut Replacement
Front Side Door Window Channel Replacement
Rear Side Door Window Channel Replacement
Front Side Door Stationary Window Replacement
Front Side Door Window Switch Replacement - Right Side
Front Side Door Window Switch Replacement - Left Side
Rear Side Door Window Switch Replacement
Front Side Door Window Regulator Replacement
Rear Side Door Window Regulator Replacement
Rear Side Door Window Regulator Handle Replacement
Front Side Door Window Outer Sealing Strip Replacement
Description and Operation
Power Windows Description and Operation
Rear Window Defogger Description and Operation
Stationary Window Description
Special Tools and Equipment
Special Tools
Horns
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Horn Schematics
Diagnostic Information and Procedures
Symptoms - Horns
Horns Malfunction
Repair Instructions
Horn Replacement
Steering Wheel Horn Contact Replacement
Description and Operation
Horns System Description and Operation
Lighting
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Headlights/Daytime Running Lights (DRL) Schematics
Fog Lamps Schematics
Exterior Lamps Schematics
Interior Lights Schematics
Interior Lights Dimming Schematics
Diagnostic Information and Procedures
Symptoms - Lighting
Reversing Lamps Malfunction — Manual Gearbox
Reversing Lamps Malfunction — Automatic Transmission
Interior Lights Malfunction
Front Fog Lamps Malfunction
Hazard Lamps Malfunction
Headlamps Malfunction
Interior Backlighting Malfunction
Park, License, and/or Tail Lamps Malfunction
Stop Lamps Malfunction
Indicator Lamps and/or Indicators Malfunction
Repair Instructions
Brake Lamp Switch Replacement
Hazard Warning Switch Replacement
Interior Lamp Replacement
Headlamp Replacement
Headlamp Bulb Replacement
Headlamp Bracket Replacement
Headlamp Aiming
Front Fog Lamp Replacement
Front Fog Lamp Bulb Replacement
Fog Lamp Aligning
Parking and Turn Signal Lamp Bulb Replacement
High Mount Brake lamp Replacement
High Mount Stop Lamp Bulb Replacement
Rear Number plate Lamp Replacement
Tail Lamp Replacement
Tail Lamp Bulb Replacement
Rear Compartment Courtesy Lamp Replacement
Description and Operation
Exterior Lighting Systems Description and Operation
Interior Lighting Systems Description and Operation
Mirrors
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Outside Rearview Mirror Schematics
Diagnostic Information and Procedures
Symptoms - Mirrors
Heated Mirrors Malfunction
Power Mirrors Inoperative
Repair Instructions
Outside Rearview Mirror Replacement
Outside Remote Control Rearview Mirror Switch Replacement
Outside Rearview Mirror Motor Replacement
Outside Rearview Mirror Glass Replacement
Inside Rearview Mirror Replacement
Description and Operation
Outside Mirror Description and Operation
Vehicle Access
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Door Lock/Indicator Schematics
Diagnostic Information and Procedures
Symptoms - Vehicle Access
Door Ajar Indicator Malfunction
Power Door Locks Malfunction
Repair Instructions
Fuel Tank Filler Door Catch Release Cable Replacement
Front Side Door Lock Cylinder Replacement
Tailgate Lock Cylinder Replacement
Front Side Door Inside Handle Replacement
Front Side Door Outside Handle Replacement
Tailgate Outside Handle Replacement
Liftgate Catch Replacement
Rear Side Door Outside Handle Replacement
Front Side Door Lock Replacement
Rear Side Door Lock Replacement
Door Lock Striker Adjustment
Front Side Door Lock Striker Replacement
Tailgate Lock Striker Replacement
Description and Operation
Fuel Fill Door Description and Operation
Power Door Locks Description and Operation
Rear Hatch/Gate Description and Operation
Wipers and Washers
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Wiper/Washer Schematics
Diagnostic Information and Procedures
Symptoms - Wiper/Washer Systems
Windscreen Wiper System Malfunction
Washer Malfunction
Rear Wiper System Malfunction
Repair Instructions
Windscreen Wiper and Washer Switch Replacement
Windscreen Washer Nozzle Hose Replacement
Windscreen Washer Nozzle Replacement
Rear Window Washer Nozzle Replacement
Windscreen Washer Solvent Container Filler Tube Replacement
Windscreen Washer Solvent Container Replacement
Windscreen Washer Pump Replacement
Air Inlet Grille Panel Replacement
Windscreen Wiper Arm Replacement
Rear Window Wiper Arm Replacement
Windshield Wiper Blade Replacement
Rear Window Wiper Blade Replacement
Windscreen Wiper Motor Replacement
Rear Window Wiper Motor Replacement
Windshield Wiper Transmission Replacement
Windshield Wiper Arm Adjustment
Description and Operation
Rear Wiper/Washer System Description and Operation
Wiper/Washer System Description and Operation
6. Brakes
Antilock Brake System
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Antilock Brake System Schematics
Diagnostic Information and Procedures
DTC B2745
DTC C0035, C0040, C0045, or C0050
DTC C0110
DTC C0131
DTC C0161
DTC C0179
DTC C0186
DTC C0196
DTC C0201
DTC C0292
DTC C056D
DTC C056E
DTC C0710
DTC C0800
Symptoms - Antilock Brake System
ABS Indicator Malfunction
Traction Control/Stability Control Indicator Malfunction
Repair Instructions
Antilock Brake System Automated Bleed
Steering Angle Sensor Centring
Electronic Brake Control Module Replacement
Brake Pressure Modulator Valve Replacement
Brake Pressure Modulator Valve Bracket Replacement
Front Wheel Speed Sensor Replacement — Left Side
Front Wheel Speed Sensor Replacement — Right Side
Rear Wheel Speed Sensor Replacement
Vehicle Yaw Sensor Learn
Vehicle Yaw Sensor Replacement
Description and Operation
ABS Description and Operation
Disc Brakes
Specifications
Fastener Tightening Specifications
Disc Brake Component Specifications
Diagnostic Information and Procedures
Brake Disc Thickness Measurement
Brake Disc Thickness Variation Measurement
Brake Disc Surface and Wear Inspection
Brake Disc Assembled Lateral Runout Measurement
Brake Pad Inspection
Brake Calliper Inspection
Front Disc Brake Mounting and Hardware Inspection
Repair Instructions
Front Disc Brake Pads Replacement
Brake Pad and Rotor Burnishing
Front Brake Calliper Replacement
Front Brake Calliper Overhaul
Front Brake Calliper Bracket Replacement
Front Brake Disc Replacement
Front Brake Shield Replacement
Brake Disc Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction - Indexing
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Brake Disc Refinishing
Description and Operation
Disc Brake System Description and Operation
Special Tools and Equipment
Special Tools
Drum Brakes
Specifications
Fastener Tightening Specifications
Drum Brake Component Specifications
Diagnostic Information and Procedures
Brake Drum Diameter Measurement
Brake Drum Surface and Wear Inspection
Drum Brake Hardware Inspection
Drum Brake Adjusting Hardware Inspection
Repair Instructions
Brake Drum Replacement
Brake Drum Refinishing
Brake Shoe Replacement
Rear Brake Backing Plate Replacement
Drum Brake Hardware Replacement
Drum Brake Adjusting Hardware Replacement
Rear Brake Cylinder Replacement
Drum Brake Adjustment
Description and Operation
Drum Brake System Description and Operation
Special Tools and Equipment
Special Tools
Hydraulic Brakes
Specifications
Fastener Tightening Specifications
Brake Component Specifications
Brake System Specifications
Schematic and Routing Diagrams
Hydraulic Brake Schematics
Diagnostic Information and Procedures
Symptoms - Hydraulic Brakes
Brake Booster Pump Motor Malfunction
Brake Warning Indicator Malfunction
Brake Pulsation
Brake System Noise
Braking Action Uneven - Pulls to One Side
Braking Action Uneven - Front to Rear
Brake Pedal Excessive Travel
Brake Pedal Excessive Effort
Brakes Drag
Brake System Slow Release
Brake Fluid Loss
Disc Brake System Diagnosis
Drum Brake System Diagnosis
Hydraulic Brake System Diagnosis
Brake Assist System Diagnosis
Brake System Vehicle Road Test
Brake Pedal Travel Measurement and Inspection
Brake System Vacuum Source Test
Brake System External Leak Inspection
Brake System Internal Leak Test
Hydraulic Brake Component Operation Visual Inspection
Brake Pipe and Hose Inspection
Brake Pedal Pushrod Inspection
Repair Instructions
Master Cylinder Reservoir Filling
Master Cylinder Reservoir Replacement
Master Cylinder Replacement — Left Hand Drive
Master Cylinder Replacement — Right Hand Drive
Master Cylinder Bench Bleeding
Brake Fluid Level Indicator Switch Replacement
Brake Pedal Assembly Replacement — Left Hand Drive
Brake Pedal Assembly Replacement — Right Hand Drive
Brake Proportion Valve Replacement — Left Hand Drive
Brake Proportion Valve Replacement — Right Hand Drive
Brake Pipe Replacement
Front Brake Hose Replacement
Rear Brake Hose Replacement
Hydraulic Brake System Bleeding — Manual
Hydraulic Brake System Bleeding — Pressure
Hydraulic Brake System Flushing
Power Vacuum Brake Booster Replacement — Left Hand Drive
Power Vacuum Brake Booster Replacement — Right Hand Drive
Power Brake Booster Vacuum Check Valve and Hose Replacement — Left Hand Drive
Power Brake Booster Vacuum Check Valve and Hose Replacement — Right Hand Drive
Power Brake Booster Vacuum Hose Replacement
Servo Unit Pump Replacement
Description and Operation
Brake Assist System Description and Operation
Brake Booster Vacuum Assist Description and Operation
Brake Warning System Description and Operation
Hydraulic Brake System Description and Operation
Special Tools and Equipment
Special Tools
Park Brake
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms - Park Brake
Park Brake Will Not Hold or Release
Park Brake System Diagnosis
Parking Brake Hardware Inspection
Repair Instructions
Handbrake Lever Replacement
Handbrake Indicator Switch Replacement
Handbrake Cable Replacement
Handbrake Adjustment
Description and Operation
Park Brake System Description and Operation
7. Diagnostic Overview, Starting Point, and Programming
Programming and Setup
Diagnostic Information and Procedures
Control Module References
Repair Instructions
Communication Interface Module Programming and Setup
Electronic Brake Control Module Programming and Setup
Engine Control Module Programming and Setup
Inflatable Restraint Sensing and Diagnostic Module Programming and Setup
Instrument Cluster Programming and Setup
Keyless Entry Control Module Programming and Setup
Service Programming System (SPS)
Transmission Control Module Programming and Setup — JF405E
Special Tools and Equipment
Special Tools
Vehicle Diagnostic Information
Specifications
Communication Interface Module Scan Tool Information
Electronic Brake Control Module Scan Tool Information
Engine Control Module Scan Tool Information — Without FX3
Engine Control Module Scan Tool Information — FX3
Inflatable Restraint Sensing and Diagnostic Module Scan Tool Information
Instrument Cluster Scan Tool Information
Keyless Entry Control Module Scan Tool Information
Theft Deterrent Module Scan Tool Information
Transmission Control Module Scan Tool Information
Diagnostic Information and Procedures
Strategy Based Diagnosis
Diagnostic Procedure Instructions
Diagnostic System Check Instructions
Diagnostic Starting Point - Vehicle
Diagnostic System Check - Vehicle
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Diagnostic Trouble Code (DTC) List - Vehicle
Symptoms - Vehicle
Engine Does Not Crank
Engine Cranks But Does Not Run
Diagnostic Repair Verification
8. Driveline/Axle
Wheel Drive Shafts
Specifications
Fastener Tightening Specifications
Adhesives, Fluids, Lubricants, and Sealers
Diagnostic Information and Procedures
Symptoms - Wheel Drive Shafts
Click Noise In Turns
Clunk When Accelerating from Freewheel
Clunk Noise When Accelerating During Turns
Repair Instructions
Front Wheel Drive Shaft Replacement
Front Wheel Drive Shaft Inner Joint Replacement
Front Wheel Drive Shaft Outer Joint Replacement
Wheel Drive Shaft Inner Joint Inspection
Description and Operation
Wheel Drive Shafts Description and Operation
Special Tools and Equipment
Special Tools
9. Driver Information and Entertainment
Mobile, Entertainment, and Navigation
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Radio/Navigation System Schematics
OnStar Schematics
Cellular Telephone Schematics
Diagnostic Information and Procedures
Symptoms - Entertainment
Radio Poor Reception
Speaker Malfunction
Repair Instructions
Compact Disc Care and Cleaning
Radio Replacement
Radio Antenna Base Replacement
Radio Front Speaker Replacement
Radio Rear Quarter Trim Panel Speaker Replacement
Description and Operation
Radio/Audio System Description and Operation
Displays and Gauges
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Instrument Cluster Schematics
Driver Information System Schematics
Audible Warnings Schematics
Diagnostic Information and Procedures
DTC B1512-B1537
DTC P0461-P0463
DTC P0656
Symptoms - Displays and Gauges
Charge Indicator Malfunction
Fuel Gauge Inaccurate or Inoperative
Instrument Cluster Gauges Inoperative
Odometer Trip/Reset Switch Inoperative
Repair Instructions
Instrument Cluster Replacement
Instrument Panel Multifunction Switch Replacement
Description and Operation
Audible Warnings Description and Operation
Indicator/Warning Message Description and Operation
Instrument Cluster Description and Operation
Secondary and Configurable Customer Controls
Schematic and Routing Diagrams
Steering Wheel Secondary/Configurable Control Schematics
Diagnostic Information and Procedures
Symptoms - Secondary and Configurable Customer Controls
Steering Wheel Controls Malfunction
Repair Instructions
Steering Wheel Control Switch Assembly Replacement
Description and Operation
Steering Wheel Controls Description and Operation
10. Engine
Engine Controls and Fuel - 1.0L, 1.19L, or 1.2L
Specifications
Temperature Versus Resistance
Altitude Versus Barometric Pressure
Ignition System Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Engine Controls Schematics — Delphi ECM - FX3
Engine Controls Schematics — Siemens ECM - Gas without FX3 or LCP
Engine Controls Schematics — Siemens ECM - LPG with LCP
Diagnostic Information and Procedures
DTC P0016 or P0340
DTC P0031, P0032, P0037, or P0038
DTC P0031, P0032, P0037, P0038, P0053, P0054, P0135, or P0141 — Without FX3
DTC P0031, P0032, P0037, P0038, P0053, P0054, P0135, or P0141 — FX3
DTC P0101
DTC P0106
DTC P0107 or P0108 — Without FX3
DTC P0107 or P0108 — FX3
DTC P0112 or P0113 — Without FX3
DTC P0112 or P0113 — FX3
DTC P0117 or P0118 — Without FX3
DTC P0117 or P0118 — FX3
DTC P0122, P0123, P0222, P0223, or P2135 — Without FX3
DTC P0122, P0123, P0222, P0223, or P2135 — FX3
DTC P0130-P0134, P0137, P0138, P013A, P013B, or P0140 — Without FX3
DTC P0130-P0134, P0137, P0138, P013A, P013B, or P0140 — FX3
DTC P0171 or P0172 — Without FX3
DTC P0171 or P0172 — FX3
DTC P0230
DTC P0261, P0262, P0264, P0265, P0267, P0268, P0270, or P0271 — Without FX3
DTC P0261, P0262, P0264, P0265, P0267, P0268, P0270, or P0271 — FX3
DTC P0300-P0304
DTC P0315 — Without FX3
DTC P0315 — FX3
DTC P0325 or P0326 — Without FX3
DTC P0325 or P0326 — FX3
DTC P0335-P0337 — Without FX3
DTC P0335-P0337 — FX3
DTC P0341 or P0342
DTC P0351-P0354 — Without FX3
DTC P0351-P0354 — FX3
DTC P0400-P0402 — Without FX3
DTC P0400-P0402 — FX3
DTC P0403-P0406 or P042E — Without FX3
DTC P0403-P0406 or P042E — FX3
DTC P0420
DTC P0458 or P0459 — Without FX3
DTC P0458 or P0459 — FX3
DTC P0501 or P0502 — Without FX3
DTC P0501 or P0502 — FX3
DTC P0504 or P0571
DTC P0506 or P0507
DTC P0511
DTC P0601, P0602, P0604-P0607, P060A-P060D, P061A, or P2610 — Without FX3
DTC P0601, P0602, P0604-P0607, P060A-P060D, P061A, or P2610 — FX3
DTC P0628 or P0629
DTC P0641, P0651, or P0697
DTC P0650
DTC P0685, P0686, or P0687 — FX3
DTC P0685, P0686, or P0687 — Without FX3
DTC P0700
DTC P1325
DTC P1391
DTC P2009 or P2010 — Without FX3
DTC P2009 or P2010 — FX3
DTC P2101 or P2119
DTC P2104-P2106 or P2110
DTC P2122, P2123, P2127, P2128, or P2138
DTC P2184 or P2185
Symptoms - Engine Controls
Malfunction Indicator Lamp (MIL) Diagnosis
Engine Cranks But Does Not Run
Fuel System Diagnosis
Fuel Pump Electrical Circuit Diagnosis
Fuel Injector Diagnosis with Special Tool
Alcohol/Contaminants-in-Fuel Diagnosis
Electronic Ignition System Diagnosis
Repair Instructions
Engine Control Module Replacement
Throttle/Idle Learn
Engine Coolant Temperature Sensor Replacement - Radiator
Engine Coolant Temperature Sensor Replacement - Thermostat
Inlet Air Temperature Sensor Replacement
Manifold Absolute Pressure Sensor Replacement
Heated Oxygen Sensor Replacement - Sensor 1
Heated Oxygen Sensor Replacement - Sensor 2
Knock Sensor Replacement
Throttle Position Sensor Replacement
Idle Air Control Valve Replacement
Throttle Body Assembly Replacement — Without FX3
Throttle Body Assembly Replacement — FX3
Fuel Pressure Relief
Fuel Pressure Gauge Installation and Removal
Fuel Tank Replacement
Fuel Tank Pressure Sensor Replacement
Fuel Pump Replacement
Fuel Injection Fuel Rail Assembly Replacement
Fuel Injector Replacement
Evaporative Emission Canister Replacement
Evaporative Emission Canister Purge Solenoid Valve Replacement
Evaporative Emission Canister Vent Solenoid Valve Replacement
Intake Manifold Tuning Valve Replacement
Ignition Coil Replacement
Spark Plug Inspection
Spark Plug Replacement
Crankshaft Position Sensor Replacement
Crankshaft Position System Variation Learn
Camshaft Position Sensor Replacement
Exhaust Gas Recirculation Valve Replacement
Exhaust Gas Recirculation Valve Pipe Replacement
Air Cleaner Element Replacement
Air Cleaner Assembly Replacement
Air Cleaner Resonator Replacement
Description and Operation
Air Inlet System Description
Crankcase Ventilation System Description
Electronic Ignition System Description
Engine Control Module Description
Exhaust Gas Recirculation (EGR) System Description
Fuel System Description
Knock Sensor System Description
Throttle Actuator Control (TAC) System Description
Special Tools and Equipment
Special Tools
Engine Cooling
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Engine Cooling Schematics
Diagnostic Information and Procedures
DTC P0480 or P0481
DTC P0597-P0599
Symptoms - Engine Cooling
Cooling Fan Always On
Cooling Fan Inoperative
Engine Overheating
Loss of Coolant
Thermostat Diagnosis
Engine Fails To Reach Normal Operating Temperature
Cooling System Leak Testing
Repair Instructions
Cooling System Draining and Filling
Coolant System Flushing
Radiator Cleaning
Radiator Surge Tank Replacement
Radiator Inlet Hose Replacement
Radiator Outlet Hose Replacement
Engine Coolant Inlet Pipe Replacement
Engine Coolant Outlet Pipe Replacement
Radiator Mounting Stud Repair
Throttle Body Heater Inlet Hose Replacement
Throttle Body Heater Outlet Hose Replacement
Engine Coolant Fan Replacement
Engine Coolant Thermostat Housing Replacement
Engine Coolant Thermostat Replacement
Water Pump Replacement
Radiator Replacement
Radiator Support Bracket Replacement
Radiator Support Replacement
Description and Operation
Cooling Fan Description and Operation
Cooling System Description and Operation
Thermostat Heater Control System Description
Engine Electrical
Specifications
Fastener Tightening Specifications
Battery Usage
Starter Usage
Generator Usage
Schematic and Routing Diagrams
Starting and Charging Schematics
Diagnostic Information and Procedures
DTC B1325
DTC P0562 or P0563
Symptoms - Engine Electrical
Battery Inspection/Test
Battery Charging
Charging System Test
Generator Noise Diagnosis
Starter Solenoid Does Not Click
Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks Slowly
Starter Noise Diagnosis
Repair Instructions
Battery Negative Cable Disconnection and Connection
Battery Replacement
Battery Tray Replacement
Starter Replacement
Generator Replacement
Description and Operation
Battery Description and Operation
Charging System Description and Operation
Starting System Description and Operation
Engine Exhaust
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms - Engine Exhaust
Restricted Exhaust
Exhaust Leakage
Exhaust Noise
Repair Instructions
Exhaust Manifold Replacement
Exhaust Pipe Replacement
Catalytic Converter Replacement
Exhaust Silencer Replacement
Fuel Tank Heat Shield Replacement
Exhaust Manifold Heat Shield Replacement
Exhaust Rear Silencer Heat Shield Replacement
Description and Operation
Exhaust System Description
Special Tools and Equipment
Special Tools
Engine Mechanical - 1.0L Diesel
Specifications
Fastener Tightening Specifications
Engine Mechanical Specifications
Adhesives, Fluids, Lubricants, and Sealers
Visual Identification
Disassembled Views
Engine Identification
Diagnostic Information and Procedures
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Base Engine Misfire without Internal Engine Noises
Upper Engine Noise, Regardless of Engine Speed
Coolant in Combustion Chamber
Coolant in Engine Oil
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Tensioner Diagnosis
Engine Compression Test
Cylinder Leakage Test
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Fuel in Engine Oil
Lower Engine Noise, Regardless of Engine Speed
Oil Pressure Diagnosis and Testing
Oil Consumption Diagnosis
Oil Leak Diagnosis
Symptoms - Engine Mechanical
Turbocharger Hissing Noise
Turbocharger Lack of Oil Supply
Turbocharger Oil Leak From Compressor Seal
Turbocharger Oil Leak From Turbine Seal
Turbocharger Whine Noise
Dual Mass Flywheel Diagnosis
Repair Instructions
Engine Mount Bracket Removal
Drive Belt Tensioner Removal
Crankshaft Pulley Removal
Water Pump Removal
Catalytic Converter Heat Shield Removal
Catalytic Converter Removal
Turbocharger Oil Feed Pipe Removal
Turbocharger Oil Return Hose Removal
Thermostat Bypass Pipe Removal
Oil Filter Housing Removal
Turbocharger Heat Shield Removal
Turbocharger Removal
Exhaust Manifold Removal
Glow Plug Removal
Generator Removal
Exhaust Gas Recirculation Valve Vacuum Tank Removal
Alternator Bracket Removal
Positive Crankcase Ventilation Pipe Removal
Positive Crankcase Ventilation Oil Separator Removal
Oil Level Indicator and Tube Removal
Exhaust Gas Recirculation Pipe Removal
Exhaust Gas Recirculation Valve Cooler Removal
Starter Removal
Engine Oil Cooler Inlet Pipe Removal
Engine Coolant Thermostat Removal
Throttle Body Assembly Removal
Inlet Manifold Removal
Diesel Fuel Separator Removal
Vacuum Pump Removal
Fuel Injection Fuel Feed Pipe Removal - Fuel Injection Pump to Fuel Rail
Fuel Injection Pump Removal
Fuel Injection Fuel Feed Pipe Removal - Fuel Rail to Fuel Injector
Fuel Rail Removal
Fuel Injector Removal
Sump Removal
Oil Pump Housing Removal
Timing Chain Tensioner Removal
Timing Chain Tensioner Shoe Removal
Timing Chain Guide Removal
Camshaft Sprocket Removal
Camshaft Timing Chain Adjustment
Camshaft Timing Chain Inspection
Crankshaft Sprocket Removal
Balancer Shaft Drive Gear Removal
Balancer Shaft Driven Gear Removal
Balancer Shaft Removal
Crankshaft Position Sensor Removal
Camshaft Position Sensor Removal
Camshaft Housing Removal
Hydraulic Valve clearance Adjuster Removal
Cylinder Head Removal
Piston, Connecting Rod, and Bearing Removal
Oil Filter Housing Disassemble
Oil Filter Housing Assemble
Water Pump Cleaning and Inspection
Intake Manifold Disassemble
Inlet Manifold Cleaning and Inspection
Intake Manifold Assemble
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Cylinder Head Assemble
Piston and Connecting Rod Disassemble
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Piston and Connecting Rod Assemble
Engine Flywheel Removal
Crankshaft Rear Oil Seal Removal
Crankshaft and Bearing Removal
Crankshaft and Bearing Cleaning and Inspection
Engine Block Disassemble
Engine Block Cleaning and Inspection
Engine Block Assemble
Oil Pump Disassemble
Oil Pump Cleaning and Inspection
Oil Pump Assemble
Crankshaft and Bearing Installation
Crankshaft Rear Oil Seal Installation
Engine Flywheel Installation
Piston, Connecting Rod, and Bearing Installation
Cylinder Head Installation
Hydraulic Valve clearance Adjuster Installation
Camshaft Housing Installation
Camshaft Position Sensor Installation
Crankshaft Position Sensor Installation
Balancer Shaft Installation
Balancer Shaft Driven Gear Installation
Balancer Shaft Drive Gear Installation
Crankshaft Sprocket Installation
Camshaft Sprocket Installation
Timing Chain Guide Installation
Timing Chain Tensioner Shoe Installation
Timing Chain Tensioner Installation
Oil Pump Housing Installation
Sump Installation
Fuel Injector Installation
Fuel Rail Installation
Fuel Injection Fuel Feed Pipe Installation - Fuel Rail to Fuel Injector
Fuel Injection Pump Installation
Fuel Injection Fuel Feed Pipe Installation - Fuel Injection Pump to Fuel Rail
Vacuum Pump Installation
Diesel Fuel Separator Installation
Inlet Manifold Installation
Throttle Body Assembly Installation
Engine Coolant Thermostat Installation
Engine Oil Cooler Inlet Pipe Installation
Starter Installation
Exhaust Gas Recirculation Valve Cooler Installation
Exhaust Gas Recirculation Pipe Installation
Oil Level Indicator and Tube Installation
Positive Crankcase Ventilation Oil Separator Installation
Positive Crankcase Ventilation Pipe Installation
Alternator Bracket Installation
Exhaust Gas Recirculation Valve Vacuum Tank Installation
Generator Installation
Glow Plug Installation
Exhaust Manifold Installation
Turbocharger Installation
Turbocharger Heat Shield Installation
Oil Filter Housing Installation
Turbocharger Oil Return Hose Installation
Thermostat Bypass Pipe Installation
Turbocharger Oil Feed Pipe Installation
Catalytic Converter Installation
Catalytic Converter Heat Shield Installation
Water Pump Installation
Crankshaft Pulley Installation
Drive Belt Tensioner Installation
Engine Mount Bracket Installation
Description and Operation
Cleanliness and Care
Drive Belt System Description
Engine Component Description
Lubrication Description
Replacing Engine Gaskets
Separating Parts
Use of Room Temperature Vulcanising (RTV) and Anaerobic Sealant
Special Tools and Equipment
Special Tools
Engine Mechanical - 1.0L, 1.19L, or 1.2L
Specifications
Fastener Tightening Specifications
Engine Mechanical Specifications
Visual Identification
Disassembled Views
Diagnostic Information and Procedures
Symptoms - Engine Mechanical
Oil Pressure Diagnosis and Testing
Engine Compression Test
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Oil Leak Diagnosis
Coolant in Engine Oil
Engine Noise Under Load
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Will Not Crank - Crankshaft Will Not Rotate
Crankcase Ventilation System Inspection/Diagnosis
Repair Instructions
Drive Belt Replacement
Drive Belt Tensioner Replacement
Power Steering Pump Belt Replacement
Engine Mount Replacement — with EN-50176
Engine Mount Replacement — with CH-49290
Engine/Transmission Mounting — with EN-49802 and EN-50176
Engine/Transmission Mounting — with CH-49289 and CH-49290
Upper Intake Manifold Replacement
Lower Intake Manifold Replacement
Cylinder Head Replacement — with EN-50176
Cylinder Head Replacement — with CH-49290
Oil Pan Replacement
Automatic Transmission Flex Plate Replacement
Engine Flywheel Replacement
Crankshaft Balancer Replacement
Crankshaft Front Oil Seal Replacement
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Engine Front Cover with Oil Pump Replacement — with EN-50176
Engine Front Cover with Oil Pump Replacement — with CH-49290
Camshaft Timing Chain Replacement and Adjustment
Oil Pump Replacement
Oil Level Indicator Tube Replacement
Engine Replacement — with EN-49802 and EN-50176
Engine Replacement — with CH-49289 and CH-49290
Engine Replacement — with Engine Lifting Device and MT
Engine Oil and Oil Filter Replacement
Piston, Connecting Rod, and Bearing Replacement
Camshaft Cover Replacement
Camshaft Exhaust Sprocket Replacement
Camshaft Replacement
Valve Stem Oil Seal and Valve Spring Replacement
Valve Clearance Adjustment
Valve Stem and Valve Guide Clearance Inspection
Camshaft Cleaning and Inspection
Drive Belt Removal
Drive Belt Tensioner Removal
Crankshaft Balancer Removal
Crankshaft Sprocket Removal
Engine Flywheel Removal
Automatic Transmission Flex Plate Removal
Oil Level Indicator and Tube Removal
Engine Coolant Thermostat Removal
Throttle Body Assembly Removal
Inlet Manifold Removal
Ignition Coil Removal
Camshaft Cover Removal
Power Steering Pump Belt Removal
Engine Front Cover and Oil Pump Removal
Camshaft Timing Chain Removal
Timing Chain Tensioner Removal
Timing Chain Guide Removal
Camshaft Removal
Cylinder Head Removal
Oil Pump Disassemble
Oil Pump Assemble
Sump Removal
Piston, Connecting Rod, and Bearing Removal
Crankshaft Front Oil Seal Removal
Crankshaft Rear Oil Seal Removal
Crankshaft and Bearing Removal
Engine Block Disassemble
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Engine Block Assemble
Service Prior to Assembly
Crankshaft and Bearing Installation
Crankshaft Rear Oil Seal Installation
Piston, Connecting Rod, and Bearing Installation
Camshaft Timing Chain Installation
Timing Chain Tensioner Installation
Timing Chain Guide Installation
Camshaft Installation
Cylinder Head Installation
Engine Front Cover and Oil Pump Installation
Crankshaft Front Oil Seal Installation
Sump Installation
Power Steering Pump Belt Installation
Camshaft Cover Installation
Ignition Coil Installation
Oil Level Indicator and Tube Installation
Inlet Manifold Installation
Throttle Body Assembly Installation
Draining Fluids and Oil Filter Removal
Engine Coolant Thermostat Installation
Drive Belt Tensioner Installation
Drive Belt Installation
Crankshaft Sprocket Installation
Crankshaft Balancer Installation
Automatic Transmission Flex Plate Installation
Engine Flywheel Installation
Exhaust Manifold Removal
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Cylinder Head Assemble
Exhaust Manifold Installation
Description and Operation
Engine Component Description
Cleanliness and Care
Separating Parts
Replacing Engine Gaskets
Tools and Equipment
Special Tools and Equipment
Special Tools
11. HVAC
Heating, Ventilation, and Air Conditioning
Specifications
Fastener Tightening Specifications
Refrigerant System Specifications
Diagnostic Information and Procedures
Leak Testing
Noise Diagnosis - Blower Motor
Air Conditioning Compressor Oil Diagnosis
Noise Diagnosis - Air Conditioning (A/C) System
Noise Diagnosis - HVAC Module
Repair Instructions
Refrigerant Recovery and Recharging
Air Conditioning Compressor Oil Balancing
Air Conditioning Compressor Replacement
Air Conditioning Clutch Replacement
Air Conditioning O-Ring Seal Replacement
Air Conditioning Compressor and Condenser Hose Replacement
Air Conditioning Evaporator Hose Assembly Replacement
Air Conditioning (AC) Refrigerant Filter Replacement
Air Conditioning Refrigerant Service Valve Core Replacement
Air Conditioning Evaporator Thermal Expansion Valve Replacement
Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
Air Conditioning Condenser Replacement
Air Conditioning (A/C) Evaporator and Blower Module Assembly Replacement
Air Conditioning Evaporator Core Replacement — Left Hand Drive
Air Conditioning Evaporator Core Replacement — Right Hand Drive
Heater Inlet Hose Replacement
Heater Outlet Hose Replacement
Passenger Compartment Air Filter Replacement — Left Hand Drive
Passenger Compartment Air Filter Replacement — Right Hand Drive
Blower Motor Resistor Replacement — Left Hand Drive
Blower Motor Resistor Replacement — Right Hand Drive
Blower Motor Replacement — Left Hand Drive
Blower Motor Replacement — Right Hand Drive
Instrument Panel Outer Air Outlet Replacement - Left Side
Instrument Panel Centre Air Outlet Replacement
Instrument Panel Outer Air Outlet Replacement - Right Side
Instrument Panel Outer Air Outlet Duct Replacement
Windscreen Defroster Nozzle Replacement
Floor Air Outlet Duct Replacement - Left Side — Left Hand Drive
Floor Air Outlet Duct Replacement - Left Side — Right Hand Drive
Floor Air Outlet Duct Replacement - Right Side — Left Hand Drive
Floor Air Outlet Duct Replacement - Right Side — Right Hand Drive
Heater Core Replacement — Left Hand Drive
Heater Core Replacement — Right Hand Drive
Description and Operation
Heating and Air Conditioning System Description and Operation
Special Tools and Equipment
Special Tools
HVAC - Automatic
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
HVAC Schematics
Diagnostic Information and Procedures
Diagnostic System Check - HVAC Systems - Automatic
DTC 1
DTC 2
DTC 3
DTC 4
DTC 5
DTC 6
DTC 7
DTC P0537 or P0538
DTC P0646 or P0647
Symptoms - HVAC Systems - Automatic
Air Conditioning Compressor Malfunction
Blower Motor Malfunction
Air Temperature Malfunction
Repair Instructions
Heater and Air Conditioning Control Replacement
Air Conditioning Module Wiring Harness Replacement — Left Hand Drive
Air Conditioning Module Wiring Harness Replacement — Right Hand Drive
Air Inlet Valve Actuator Replacement — Left Hand Drive
Air Inlet Valve Actuator Replacement — Right Hand Drive
Automatic A/C Engine Coolant Temperature Sensor Replacement — Left Hand Drive
Automatic A/C Engine Coolant Temperature Sensor Replacement — Right Hand Drive
Mode Valve Actuator Replacement — Left Hand Drive
Mode Valve Actuator Replacement — Right Hand Drive
Mode Valve Link Replacement — Left Hand Drive
Mode Valve Link Replacement — Right Hand Drive
Temperature Valve Actuator Replacement — Left Hand Drive
Temperature Valve Actuator Replacement — Right Hand Drive
Ambient Air Temperature Sensor Replacement
Evaporator Air Temperature Sensor Replacement
Inside Air Temperature Sensor Replacement
Sun Load Temperature Sensor Replacement
Blower Motor Control Module Replacement — Left Hand Drive
Blower Motor Control Module Replacement — Right Hand Drive
Description and Operation
Automatic HVAC Description and Operation
HVAC - Manual
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
HVAC Schematics
Diagnostic Information and Procedures
DTC P0537 or P0538
DTC P0646 or P0647
Symptoms - HVAC Systems - Manual
Air Conditioning Compressor Malfunction
Blower Motor Malfunction
Repair Instructions
Heater and Air Conditioning Control Replacement — Left-Hand Drive
Heater and Air Conditioning Control Replacement — Right-Hand Drive
Mode Valve Link Replacement — Left-Hand Drive
Mode Valve Link Replacement — Right-Hand Drive
Temperature Valve Link Replacement — Left-Hand Drive
Temperature Valve Link Replacement — Right-Hand Drive
Air Inlet Valve Link Replacement — Left-Hand Drive
Air Inlet Valve Link Replacement — Right-Hand Drive
Temperature Control Cable Replacement — Left-Hand Drive
Temperature Control Cable Replacement — Right-Hand Drive
Mode Control Cable Replacement — Left-Hand Drive
Mode Control Cable Replacement — Right-Hand Drive
Inside Air Recirculating Control Cable Replacement — Left Hand Drive
Inside Air Recirculating Control Cable Replacement — Right Hand Drive
Evaporator Air Temperature Sensor Replacement
Description and Operation
Manual HVAC Description and Operation
13. Power and Signal Distribution
Data Communications
Schematic and Routing Diagrams
Data Communication Schematics
Diagnostic Information and Procedures
Control Module U Code List
DTC B101D
DTC B101E
DTC U0001
DTC U0073
DTC U0100-U02FF
Symptoms - Data Communications
Scan Tool Does Not Power Up
Scan Tool Does Not Communicate with Chassis High Speed GMLAN Device
Scan Tool Does Not Communicate with High Speed GMLAN Device
Scan Tool Does Not Communicate with Keyword Data Line
Data Link References
Description and Operation
Data Link Communications Description and Operation
Power Outlets
Schematic and Routing Diagrams
Cigar Lighter/Power Outlet Schematics
Diagnostic Information and Procedures
Symptoms - Power Outlets
Power Outlet Receptacle Malfunction
Repair Instructions
Accessory Power Receptacle Retainer Replacement
Accessory Power Receptacle Replacement
Description and Operation
Power Outlets Description and Operation
Special Tools and Equipment
Special Tools
Wiring Systems and Power Management
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Harness Routing Views
Electrical Schematic Symbols
Vehicle Zoning Strategy — Passenger Car
Master Electrical Schematic Icons
Power Distribution Schematics
Ground Distribution Schematics
Component Locator
Master Electrical Component List
Front of Vehicle/Engine Compartment Component Views
Powertrain Component Views
Instrument Panel/Centre Console Component Views
Passenger Compartment/Roof Component Views
Door Component Views
Luggage Compartment/Rear of Vehicle Component Views
Wheels/Vehicle Underbody Component Views
Ground Views
Visual Identification
Electrical Centre Identification Views
Component Connector End Views
Inline Harness Connector End Views
Diagnostic Information and Procedures
Symptoms - Wiring Systems
General Electrical Diagnosis
Checking Aftermarket Accessories
Circuit Testing
Using Connector Test Adapters
Probing Electrical Connectors
Fault-finding with a Digital Multimeter
Fault-finding with a Test Lamp
Using Fused Jumper Wires
Measuring Voltage
Measuring Voltage Drop
Measuring Frequency
Testing Ground and Low Reference Circuits
Testing for Continuity
Testing for Short to Ground
Testing for a Short to Voltage
Testing for Intermittent Conditions and Poor Connections
Inducing Intermittent Fault Conditions
Testing for Electrical Intermittents
Scan Tool Snapshot Procedure
Circuit Protection - Fuses
Circuit Protection - Circuit Breakers
Circuit Protection - Fusible Links
Wiring Repairs
Repairing Damaged Wire Insulation
Flat Wire Repairs
GMLAN Wiring Repairs
High Temperature Wiring Repairs
Heated Oxygen Sensor Wiring Repairs
Splicing Copper Wire Using Splice Sleeves
Splicing Twisted or Shielded Cable
Splicing Inline Harness Diodes
SIR/SRS Wiring Repairs
Connector Repairs
Connector Position Assurance Locks
Terminal Position Assurance Locks
AFL/EPC Connectors
Bosch Connectors - BSK
Bosch Connectors - 0.64
Bosch Connectors - 2.8 JPT
Bosch Connectors - ECM
Delphi Connectors - Weather Pack
Delphi Connectors - Push To Seat
Delphi Connectors - Pull To Seat
Delphi Connectors - Micro-Pack 100W
Delphi Connectors - Micro .64
Delphi Connectors - 12-Way
Delphi Connectors — Steering Gear
FCI Connectors — Lever Lock
FCI Connectors — SIR
FEP Connectors — Steering Gear
JST Connectors
Kostal Connectors - Glow Plug Control Module
Kostal Connectors - Transmission
Molex Connectors
Sumitomo Connectors
Tyco/AMP Connectors - CM 42-Way
Tyco/AMP Connectors - Sensor
Tyco/AMP Connectors - 0.25 Cap
Tyco/AMP Connectors - 43-Way
Tyco/AMP Connectors - Door Module
Tyco/AMP Connectors - 102-Way Inline
Tyco/AMP Connectors - Seat
Tyco/AMP Connectors - SIR
Yazaki Connectors - 2-Way
Yazaki Connectors - 16-Way
Repairing Connector Terminals — Terminated Lead Repair
Repairing Connector Terminals — Terminal Repair
Terminal Removal
Repair Instructions
Relay Replacement - Attached to Wire Harness
Relay Replacement - Within an Electrical Centre
Fuse Block Replacement
Instrument Panel Wiring Harness Junction Block Replacement
Ignition Lock Cylinder Replacement
Ignition and Start Switch Replacement
Ignition Lock Cylinder Casing Replacement
Special Tools and Equipment
Special Tools
14. Roof
Luggage Rack and Roof Trim
Specifications
Fastener Tightening Specifications
Repair Instructions
Luggage Carrier Replacement
15. Safety and Security
Immobilizer
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Immobilizer Schematics
Diagnostic Information and Procedures
DTC P1648
Symptoms - Immobilizer
Repair Instructions
Theft Deterrent Module Replacement
Immobilizer System Component Programming
Adding Keys
Replacing Keys
Description and Operation
Immobilizer Description and Operation
Object Detection
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Object Detection Schematics
Diagnostic Information and Procedures
Symptoms - Object Detection
Parking Assist System Malfunction
Rear Parking Assist Malfunction
Repair Instructions
Rear Object Alarm Control Module Replacement
Rear Object Alarm Replacement
Rear Parking Assist Alarm Sensor Replacement
Description and Operation
Object Detection Description and Operation
Remote Functions
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Remote Function Schematics
Diagnostic Information and Procedures
Symptoms - Keyless Entry
Keyless Entry System Malfunction
Repair Instructions
Keyless Entry Control Module Replacement
Remote Control Door Lock Receiver Antenna Replacement
Remote Control Door Lock Transmitter Programming
Description and Operation
Keyless Entry System Description and Operation
Special Tools and Equipment
Special Tools
Seat Belts
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Seat Belt Schematics
Diagnostic Information and Procedures
Symptoms - Seat Belts
Seat Belt Does Not Retract
Seat Belt Indicator Circuit Malfunction - Driver
Seat Belt Indicator Circuit Malfunction - Passenger
Seat Belt Indicator Circuit Malfunction - Rear
Repair Instructions
Repairs and Inspections Required After a Collision
Front Seat Belt Buckle Replacement
Rear Seat Belt Buckle Replacement
Rear Seat Centre Belt Replacement
Driver or Passenger Seat Belt Replacement
Shoulder Belt Replacement - Rear
Front Seat Belt Guide Adjuster Replacement
Description and Operation
Seat Belt System Description and Operation
Supplemental Inflatable Restraints
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
SIR Schematics
Component Locator
SIR Identification Views
Diagnostic Information and Procedures
DTC B0012
DTC B0014-B0045
DTC B0052
DTC B0082
DTC B0083-B0088
DTC B0091
DTC B0098
DTC B1001
DTC B1019
Symptoms - SIR
Air Bag Indicator Circuit Malfunction — Passenger
Air Bag Indicator Circuit Malfunction — Driver
SIR Disabling and Enabling
Introduction
SIR Service Precautions
Repair Instructions
Front End Inflatable Restraint Discriminating Sensor Replacement
Inflatable Restraint Side Impact Sensor Replacement
Inflatable Restraint Sensing and Diagnostic Module Replacement
Steering Wheel Inflatable Restraint Module Replacement
Steering Wheel Inflatable Restraint Module Coil Replacement
Inflatable Restraint Steering Wheel Module Coil Centring
Instrument Panel Inflatable Restraint Module Replacement
Driver or Passenger Seat Side Inflatable Restraint Module Replacement
Inflatable Restraint Instrument Panel Module Indicator Replacement
Instrument Panel Inflatable Restraint Module Switch Replacement
Roof Side Rail Inflatable Restraint Module Replacement
Repairs and Inspections Required After a Collision
Inflatable Restraint Module Handling and Scrapping
Pretensioner Handling and Scrapping
Description and Operation
SIR System Description and Operation
Special Tools and Equipment
Special Tools
Theft Deterrent
Schematic and Routing Diagrams
Theft Deterrent System Schematics
Diagnostic Information and Procedures
Symptoms - Theft Deterrent
Content Theft Deterrent Malfunction
Security Indicator Malfunction
Description and Operation
Content Theft Deterrent (CTD) Description and Operation
16. Seats
Seat Hardware, Trim, and Upholstery
Specifications
Fastener Tightening Specifications
Repair Instructions
Driver or Passenger Seat Replacement
Driver or Passenger Seat Adjuster Handle Knob Replacement
Front Seat Armrest Replacement
Driver or Passenger Seat Head Restraint Replacement
Driver or Passenger Seat Head Restraint Guide Replacement
Front Seat Cushion Cover Replacement
Front Seat Cushion Outer Trim Panel Replacement
Front Seat Cushion Inner Trim Panel Replacement
Driver or Passenger Seat Cushion Pad Replacement
Driver or Passenger Seat Back Cushion Cover Replacement
Front Seat Back Cushion Pad Replacement
Driver or Passenger Seat Back Cushion Frame Replacement
Driver or Passenger Seat Recliner Handle Replacement
Rear Seat Head Restraint Replacement
Rear Seat Head Restraint Guide Replacement
Rear Seat Cushion Replacement
Rear Seat Back Cushion Latch Replacement
Rear Seat Back Cushion Replacement
Rear Seat Back Cushion Pad Replacement
Rear Seat Back Cushion Cover Replacement
Rear Seat Back Cushion Latch Release Handle Replacement
Description and Operation
Manual Seats Description
Seat Heating and Cooling
Schematic and Routing Diagrams
Heated/Cooled Seat Schematics
Diagnostic Information and Procedures
Symptoms - Seats
Front Heated Seat Malfunction
Repair Instructions
Driver or Passenger Seat Backrest Cushion Heater Replacement
Driver Seat Cushion Heater Replacement
Description and Operation
Heated Seats Description and Operation
17. Steering
Manual Steering
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms - Manual Steering Gear
Hard Steering
Poor Returnability
Repair Instructions
Steering Linkage Outer Track rod Replacement
Steering Gear Replacement
Description and Operation
Manual Steering Gear Description and Operation
Special Tools and Equipment
Special Tools
Power Steering
Specifications
Fastener Tightening Specifications
Power Steering Pump Specifications
Diagnostic Information and Procedures
Symptoms - Power Steering System
Power Steering System Test
Power Steering Fluid Leaks
Rattle, Clunk, or Shudder Noise from the Power Steering System
Whine or Growl Noise from the Power Steering System
Steering Effort Hard or Too Easy in One or Both Directions
Repair Instructions
Power Steering System Bleeding
Checking and Adding Power Steering Fluid
Power Steering System Flushing
Power Steering Fluid Reservoir Replacement
Power Steering Pump Replacement
Power Steering Pump Bracket Replacement
Power Steering Fluid Reservoir Replacement - Off Vehicle
Steering Linkage Outer Track rod Replacement
Steering Gear Boot Replacement
Power Steering Fluid Reservoir Outlet Hose Replacement
Power Steering Gear Inlet Pipe/Hose Replacement
Power Steering Gear Outlet Pipe/Hose Replacement
Steering Gear Replacement
Description and Operation
Power Steering System Description and Operation
Special Tools and Equipment
Special Tools
Steering Wheel and Column
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms - Steering Wheel and Column
Lock System Does Not Unlock
High Effort While Tilting Column
Lock System Does Not Lock
Noise in Steering Column
Looseness in Steering Column
Repair Instructions
Intermediate Steering Shaft Replacement
Steering Column Upper Trim Cover Replacement
Steering Column Lower Trim Cover Replacement
Indicator Switch Replacement
Steering Wheel Replacement
Steering Column Replacement
Steering Angle Sensor Replacement
Description and Operation
Steering Wheel and Column Description and Operation
Special Tools and Equipment
Special Tools
18. Suspension
Front Suspension
Specifications
Fastener Tightening Specifications
Repair Instructions
Stabiliser Shaft Replacement
Stabilizer Shaft Link Replacement
Stabiliser Shaft Insulator Replacement
Front Wheel Bearing and Hub Replacement
Steering Knuckle Replacement
Lower Control Arm Replacement
Front Lower Control Arm Bush Replacement
Wheel Stud Replacement
Strut Assembly Removal and Installation
Shock Absorber Disposal
Strut, Strut Component, or Spring Replacement
Description and Operation
Front Suspension Description and Operation
Special Tools and Equipment
Special Tools
Rear Suspension
Specifications
Fastener Tightening Specifications
Repair Instructions
Rear Wheel Bearing and Hub Replacement
Shock Absorber Replacement
Rear Spring Replacement
Rear Axle Replacement
Wheel Stud Replacement
Description and Operation
Rear Suspension Description and Operation
Special Tools and Equipment
Special Tools
Suspension General Diagnosis
Specifications
Trim Height Specifications
Diagnostic Information and Procedures
Symptoms - Suspension General Diagnosis
Ride Diagnosis
Vehicle Leads/Pulls
Body Leans or Sways in Corners
Suspension Bottoms
Torque Steer
Memory Steer
Noise Diagnosis - Front Suspension
Noise Diagnosis - Rear Suspension
Suspension Strut and Shock Absorber Testing - On Vehicle
Wheel Bearings Diagnosis
Trim Height Inspection
Special Tools and Equipment
Special Tools
Tyres and Wheels
Specifications
Tyre and Wheel Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Tire Diagnosis - Irregular or Premature Wear
Tyre Diagnosis - Waddle Complaint
Radial tyre Lead/Pull Correction
Repair Instructions
Aluminum Wheel Porosity Repair
Aluminum Wheel Refinishing
Tyre and Wheel Removal and Installation
Tyre Dismounting and Mounting
Tyre Rotation
Description and Operation
P-Metric Sized tyres Description
Replacement Wheels Description
Steel Wheel Repair Description
Tyre Inflation Description
Tyres and Wheels Description and Operation
Wheel Alignment
Specifications
Wheel Alignment Specifications
Fastener Tightening Specifications
Repair Instructions
Wheel Alignment Measurement
Front Caster Adjustment
Front Camber Adjustment
Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment
Description and Operation
Camber Description
Caster Description
Lead/Pull Description
Memory Steer Description
Scrub Radius Description
Thrust Angles Description
Toe Description
Torque Steer Description
Wander Description
19. Transmission
Automatic Transmission - Jatco
Specifications
Fastener Tightening Specifications
Transmission General Specifications
Control Valve Upper Body Spring Specifications
Control Valve Centre Body Spring Specifications
Control Valve Lower Body Spring Specifications
Range Reference
Shift Solenoid Valve Signal State
Shift Speed
Schematic and Routing Diagrams
Automatic Transmission Controls Schematics
Component Locator
Disassembled Views
Component Location
Bearing and Race Locations
Control Valve Body Bolt Locations
Diagnostic Information and Procedures
DTC P0705
DTC P0710
DTC P0715
DTC P0720
DTC P0731-P0734
DTC P0740
DTC P0741
DTC P0748
DTC P0753
DTC P0758
DTC P174A
Symptoms - Automatic Transmission
Transmission Fluid Level and Condition Check
Line Pressure Check
Stall Speed Test
Road Test
Noise and Vibration Analysis
Fluid Leak Diagnosis
Inaccurate Shift Points
First Gear Range Only - No Upshift
No 1-2 Upshift
No 2-3 Upshift
No 3-4 Upshift
Transmission Slips
Slips in Reverse
No Engine Braking in First Gear
No Torque Converter Clutch Apply
Slipping 1-2 Upshift
Slipping 2-3 Upshift
Slipping 3-4 Upshift
Abrupt 1-2 Upshift
Abrupt 2-3 Upshift
Abrupt 3-4 Upshift
Harsh Park or Neutral to Drive Engagement
Harsh Park or Neutral to Reverse Engagement
Drives in Neutral
Engine Stall
Oil Out the Vent
Starter Solenoid Does Not Click
Unable to Run in All Ranges
No Drive in Drive Range
No Reverse
No Shift in All Ranges
Lack of Power or Hesitation
Repair Instructions
Front Wheel Drive Shaft Seal Replacement - Left Side
Front Wheel Drive Shaft Seal Replacement - Right Side
Transmission Control Module Replacement
Range Selector Lever Cable Replacement
Range Selector Lever Cable Adjustment
Range Selector Lever Cable Bracket Replacement
Transmission Control Replacement
Automatic Transmission Range Selector Lever Replacement
Park/Neutral Position Switch Replacement
Control Valve Body Cover Replacement
Control Valve Body Replacement
Transmission Fluid Replacement
Engine Oil and Transmission Fluid Cooler Replacement
Fluid Cooler Outlet Hose Replacement
Fluid Cooler Inlet Hose Replacement
Automatic Transmission Fluid Pressure Test Hole Plug Replacement
Input Speed Sensor Replacement
Output Speed Sensor Replacement
1-2 Shift Solenoid Valve Replacement
2-3 Shift Solenoid Valve Replacement
Pressure Control Solenoid Valve Replacement
Torque Converter Clutch Solenoid Valve Replacement
Wiring Harness Replacement
Transmission Mount Bracket Replacement - Rear
Transmission Mount Strut Replacement
Transmission Mount Bracket Replacement - Left Side — with EN-50176
Transmission Mount Replacement - Left Side — with CH-49290
Transmission Mount Replacement - Left Side — with EN-50176
Transmission Replacement
Park/Neutral Position Switch Adjustment
Transmission Disassemble
Transmission Assemble
Brake Clutch Band Inspection
Servo Piston Rod Inspection
Planetary Rear Carrier Inspection
Overrun Clutch Inspection
Park Pawl and Spring Inspection
Rear Internal Gear Inspection
Input and Reaction Carrier Inner Shaft Inspection
Reverse Clutch Disassemble
Reverse Clutch Inspection
Reverse Clutch Assemble
High Clutch Disassemble
High Clutch Inspection
High Clutch Assemble
Low Clutch Disassemble
Low Clutch Inspection
Low Clutch Assemble
1-2-Reverse Clutch Piston Disassemble
1-2-Reverse Clutch Piston Inspection
1-2-Reverse Clutch Piston Assemble
Oil Pump Disassemble
Oil Pump Cleaning and Inspection
Oil Pump Assemble
Control Valve Body Disassemble
Control Valve Body Assemble
Control Valve Upper Body Disassemble
Control Valve Upper Body Assemble
Control Valve Centre Body Disassemble
Control Valve Centre Body Assemble
Control Valve Lower Body Disassemble
Control Valve Lower Body Assemble
Description and Operation
First Gear, First Range
First Gear, Drive and Second Ranges
Second Gear
Third Gear
Fourth Gear
Reverse
Third Gear (Lock-Up)
Fourth Gear (Lock-Up)
Definitions and Abbreviations
Transmission Identification Information
Transmission General Description
Transmission Component and System Description
Transmission Indicators and Messages
Electronic Component Description
Special Tools and Equipment
Special Tools
Clutch
Specifications
Fastener Tightening Specifications
General Specifications
Component Locator
Clutch Component Locator View
Diagnostic Information and Procedures
Symptoms - Clutch
Clutch Does Not Disengage
Clutch Drag Hard Shifting
Clutch Slipping
Clutch Grabbing
Clutch Noisy
Pedal Stays on Floor (Clutch Disengaged)
Clutch Vibration
Repair Instructions
Clutch Pedal Replacement
Clutch Cable Replacement
Clutch Pressure and Driven Plate Replacement
Clutch Pedal Arm Replacement
Clutch Release Bearing Replacement
Clutch Pedal Free Travel Adjustment
Clutch Release Bearing and Door Shaft Inspection
Clutch Assembly Adjustment
Description and Operation
Clutch System Description and Operation
Special Tools and Equipment
Special Tools
Manual Transmission - Y4M
Specifications
Fastener Tightening Specifications
Manual Gearbox Specifications
Schematic and Routing Diagrams
Gearbox Schematics
Component Locator
Manual Gearbox Component Views
Diagnostic Information and Procedures
Symptoms - Manual Transmission
Transmission Shifts Hard
Transmission Gear Clash When Shifting Gears
Transmission Noisy
Transmission Jumps Out of Gear
Transmission Fluid Leak Diagnosis
Repair Instructions
Transmission Rear Mount Bracket Replacement
Transmission Rear Mount Replacement
Transmission Mount Replacement - Left Side — with EN-50176
Transmission Mount Replacement - Left Side — with CH-49290
Transmission Replacement
Manual gearbox Gear lever and Selector Lever Cable Replacement
Transmission Control Replacement
Selector and Gear Lever Cable Bracket Replacement
Reverse Lamp Switch Replacement
Speedometer Driven Gear Replacement
Front Wheel Drive Shaft Seal Replacement - Left Side
Front Wheel Drive Shaft Seal Replacement - Right Side
Transmission Fluid Level Inspection
Transmission Fluid Replacement
Transmission Mount Bracket Replacement - Left Side — with EN-50176
Transmission Mount Bracket Replacement - Left Side — with CH-49290
Transmission Disassemble
Synchronisers Cleaning and Inspection
Transmission Assemble
Input Shaft Disassemble
Input Shaft Assemble
Counter Gear Shaft Disassemble
Counter Gear Shaft Assemble
Shift Shaft and Fork Assemblies Disassemble
Shift Shaft and Fork Assemblies Cleaning and Inspection
Selector fork Cleaning and Inspection
Shift Shaft and Fork Assemblies Assemble
Differential Case Disassemble
Gears Cleaning and Inspection
Differential Case Assemble
Description and Operation
Transmission System Description and Operation
Special Tools and Equipment
Special Tools
Shift Lock Control
Schematic and Routing Diagrams
Shift Lock Control Schematics
Diagnostic Information and Procedures
Symptoms - Automatic Transmission Shift Lock Control
Transmission Control Lever Malfunction
Repair Instructions
Automatic Transmission Shift Lock Control Actuator Replacement
Description and Operation
Automatic Transmission Shift Lock Control Description and Operation