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2002 Bantam
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3
03-01B-39
E
ngin
e — 1.6L / 1.3L RoCa
m
3
03
-01
B-39
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410
412
Table of Contents
Main Page
Main Index
2
General Information
2
General Information
3
Table of Contents
4
Description and Operation
6
About this Manual
6
Introduction
6
Replacement Parts
6
Special Tools
6
Important Safety Instructions
6
Warnings, Cautions and Notes in this Manual
6
How to Use this Manual
6
Inspection and Verification
7
Sympton Chart
7
Pinpoint Tests
7
Component Tests
7
Samples
7
Health and Safety Precautions
8
Acids and Alkalis
8
Air Bags
8
Air Conditioning Refrigerant
8
Introduction
8
Adhesives and Sealers
9
Water-Based Adhesives/Sealers
9
Hot Melt Adhesives
9
Antifreeze
10
Asbestos
10
Battery Acids
10
Chemical Materials
10
Brake and Clutch Linings and Pads
10
Brakes Fluids (Polyalkylene Glycols)
10
Brazing
10
Chlorofluorocarbons (CFC)
11
Clutch Fluids
11
Dusts
11
Electric Shock
11
Clutch Linings and Pads
11
Corrosion Protection Materials
11
Cutting
11
Dewaxing
11
Exhaust Fumes
12
Gasolene (Petrol) Engine
12
Fibre Insulation
12
First Aid
12
Engine Oils
12
Fire
12
Fluoroelastomer
12
Foams - Polyurethane
13
Fuels
13
Gasoline (Petrol)
13
Alternative Fuel
13
Freon
13
Gas Cylinders
14
General Workshop Tools and Equipment
14
High Pressure Air, Lubrication and Oil Test Equipment
14
Legal Aspects
14
Gases
14
Gaskets (Fluoroelastomer)
14
Halon
14
Lubricants and Greases
15
Used Engine Oil
15
Health Protection Precautions
15
Environmental Precautions
15
Noise
15
Noise Insulation Materials
15
O-Rings (Fluoroelastomer)
15
Paints
15
Pressurized Equipment
16
Solder
16
Solvents
16
Suspended Loads
16
Sound Insulation
16
Transmission Brake Bands
16
Underseal
16
Viton
16
Welding
17
Resistance Welding
17
Arc Welding
17
Gas Welding (and Cutting)
17
Warning Symbols on Vehicles
18
White Spirit
19
Standard Workshop Practices
20
Vehicle in Workshop
20
Alternative Fuel
20
Alternative Fuel - Do's
20
Alternative Fuel - Do Nots
20
Towing the Vehicle
21
Connecting a Slave Battery Using Jumper Cables
21
Component Cleaning
22
Cleaning Methods
22
Calibration of Essential Measuring Equipment
22
Solvents, Sealers and Adhesives
23
General Specifications
23
Introduction
23
Road/Roller Testing
24
Pre-Test Checks
24
Starting the Engine
24
On Road or Roller Test Check
24
Brake Testing
25
Identification Codes
26
Vehicle Identification Number (VIN)
27
Vehicle Identification Number
28
World Manufacturer
28
Year of Manufacture
28
Month of Manufacture
29
Vehicle Certification Label (Typical) or VIN Plate
30
Body Colour Code
31
Interior Trim Colour
31
Jacking and Lifting
32
Jacking
33
Lifting
34
Noise, Vibration and Harshness
35
Noise, Vibration and Harshness (NVH)
36
Diagnostic Theory
36
Know the System
36
Diagnostic Charts
36
Description and Operation
36
Know the History of the System
36
Know the History of the Condition
36
Know the Probability of Certain Conditions Developing
36
Do Not Cure the Symptom and Leave the Cause
36
Be Positive the Cause Is Found
36
Customer Interview
38
Identifying the Condition
38
Noise Diagnostic Procedure
38
How to Use this Diagnostic Procedure Section
38
Diagnosis and Testing
38
Noise, Vibration and Harshness (NVH)
38
Inspection and Verification
38
Noise Conditions
39
Vibration Conditions
39
Leakage Conditions
39
Inoperative Conditions
39
Road Test Quick Checks
40
Vehicle Preparation
41
Lift Test
41
Road Conditions
41
Symptom Chart
42
100-04-41A
42
Pinpoint Tests
43
100-04-41B/53
43
High Speed Shake
46
Tip-In Moan
47
Idle Boom/Shake/Vibration
48
General Procedures
58
Powertrain/Drive Train Mount Neutralizing
58
Exhaust System Neutralizing (25 001 0)
59
Lubricants, Fluids, Sealers and Adhesives
60
Specifications
60
Chassis
61
Suspension — General Information
62
Suspension System
63
Torque Sensitive
63
Vehicle Speed Sensitive
63
Engine Speed Sensitive
63
Front Suspension
63
Ball Joint – Lower, Inspection
64
Suspension Unit Checks
64
Vehicle Inspection
64
Rear Suspension
64
Lift Check
65
Bench Test
65
Rear Suspension
65
Pinpoint Tests
71
Pinpoint Test A: Drift Left or Right
71
A1: Check for Drift Left or Right
71
A2: Check the Steering Linkage
71
A3: Check the Wheel Alignment
72
A4: Check the Tyres
72
A5: Rotate the Tyres
72
Pinpoint Test B: Steering Wheel Off-Center
72
B1: Inspect the Steering Components
72
B2: Check the Wheel Alignment
73
Pinpoint Test C: Tracks Incorrectly
73
C1: Check the Caster Angle
73
C2: Check the Rear Suspension
73
Pinpoint Test D: Rough Ride
74
D1: Check the Suspension Units
74
Pinpoint Test E: Excessive Noise
74
E1: Inspect the Suspension
74
E2: Inspect the Springs
74
E3: Inspect the Front Suspension Lower Arm
75
E4: Inspect the Ball Joint
75
E5: Inspect the Front Wheel Bearings
75
E6: Inspect the Tyres
75
Pinpoint Test F: Incorrect Tyre Wear
76
F1: Inspect the Tyres
76
F2: Check for Cupped Tyres
76
Pinpoint Test G: Vibration
76
G1: Inspect the Tyres
76
G2: Inspect the Front Wheel Bearings
77
G3: Measure the Front Wheel Bearing End Play
77
G4: Inspect the Rear Wheel Bearings
77
G5: Measure the Rear Wheel Bearing End Play
78
G6: Measure the Wheel/Tyre Run out on the Vehicle
78
G7: Measure the Wheel/Tyre Run out off the Vehicle
78
Wheels and Tyres
78
G8: Match Mounting
79
G9: Measure the Wheel Run out
79
G10: Rear Hub and Stud Circle Run out
79
G11: Front Hub and Stud Circle Run out
80
G12: Wheel Balance
80
Front Suspension
81
Diagnosis and Testing
82
Front Suspension
82
Front Toe Adjustment (14 117 0)
83
General Procedures
83
Wheel Bearing Inspection (14 117 0)
85
Wheel Bearing (14 411 0)
87
Removal and Installation
87
Lower Arm
90
Wheel Knuckle (14 343 0)
92
Lower Arm Ball Joint (14 735 0)
98
Strut and Spring Assembly (14 781 0)
99
Strut and Spring Assembly (14 783 4)
104
DISASSEMBLY and ASSEMBLY Strut and Spring Assembly
104
Front Wheel Alignment (at Kerb Weight) - Caster and Camber
106
Front Wheel Alignment (at Kerb Weight) - Total Toe Setting
106
Torque Specifications
106
Description and Operation
109
Rear Suspension
109
Diagnosis and Testing
110
Rear Suspension
110
Beam Axle and Suspension Assembly Removal (15 231 0)
111
Removal and Installation
111
Tube - Rear Axle - Replace (15 730 0)
114
Leaf Spring (15 366 0)
117
Spring Bushes (15 781 0)
119
Bump Rubber (15 413 4)
120
Shock Absorber - Rear (15 783 4)
122
Specifications
123
Wheels and Tyres
124
Description and Operation
125
Safety Precautions
125
Wheels and Tyres
125
Winter Tyres
126
Tyre Wear Diagnosis
127
Diagnosis and Testing
127
Wheels and Tyres
127
Inspection and Verification
127
Symptom Chart
128
Wheel and Tyre Removal
132
Wheel and Tyre Installation
132
Tyre Pressures - Kpa
133
Wheel and Tyre Size
133
Torque Specifications
133
Front Drive Halfshafts
134
Description and Operation
135
Front Drive Halfshafts
135
Exploded View of the Front Drive Halfshaft
136
Working Principle of the Front Drive Halfshafts
137
Handling Front Drive Halfshafts
137
Wheel Balancing, Front
137
Underbody Protection and Corrosion Prevention
137
Raise the Vehicle
137
Towing the Vehicle
137
Diagnosis and Testing
138
Front Drive Halfshafts
138
Symptom Chart
138
Halfshaft LH (14 320 0)
139
Removal and Installation
139
Halfshaft RH (14 321 0)
143
Inner Constant Velocity (CV) Joint Boot (14 336 4)
147
Outer Constant Velocity (CV) Joint Boot (14 338 4)
152
Outer Constant Velocity (CV) Joint
155
Halfshaft LH (14 320 8)
160
Disassembly and Assembly
160
Halfshaft RH (14 320 8)
164
Lubricants, Fluids, Sealers and Adhesives
169
Capacities
169
Fill Capacities
169
Torque Specifications
169
Brake System — General Information
170
Drum Brake
170
Brake System
171
Description and Operation
171
Visual Inspection Chart
172
Brake System
172
Diagnosis and Testing
172
Inspection and Verification
172
Road Test
172
Symptom Chart
173
Pinpoint Tests
176
Brakes Pull or Drift
178
Brake Warning Indicator Always on
179
Vibration When Brakes Are Applied
180
Pedal Goes down Fast
181
Pedal Eases down Slowly
182
Pedal Is Low or Feels Spongy
183
Brake Lock up During Light Brake Pedal Force
184
Excessive or Erratic Brake Pedal Travel
185
Brakes Drag
185
Excessive Brake Pedal Effort
186
Brake Noise
187
Slow or Incomplete Brake Pedal Return
188
Hydraulic Leak Check
188
Component Tests
188
Brake System Check
189
Brake Pedal Reserve Check
189
Brake Booster Functional Test
189
Brake Master Cylinder
189
Abnormal Conditions
190
Bypass Condition Test
190
Non-Pressure Leaks
190
Brake System Bleeding (12 141 0)
191
General Procedures
191
Load Active Valve (LAV)
193
Load Apportioning Valve Adjust
195
Brake Disc Run out Check
197
Lubricants, Fluids, Sealers and Adhesives
199
Front Disc Brake Specification
199
Drum Brake Specification
199
Drum Brake
200
DESCRIPTION and OPERATION Drum Brake
201
DIAGNOSIS and TESTING Drum Brake
202
Brake Drum Replacement (12 275 0) Removal
203
REMOVAL and INSTALLATION Brake Drum Replacement
203
Brake Drum Replacement (12 275 0) Installation
204
Brake Shoes (12 285 0) Removal
205
Brake Shoes (12 285 0) Installation
207
Wheel Cylinder (12 305 0) Removal
210
Wheel Cylinder (12 305 0) Installation
210
Backing Plate (12 313 0) Removal
212
Backing Plate (12 313 0) Installation
212
Front Disc Brake
214
SPECIFICATIONS Specifications
214
Front Brake Disc
215
DESCRIPTION and OPERATION Front Brake Disc
215
REMOVAL and INSTALLATION Brake Pads
217
Wheels and Tyres
217
Brake Pads Installation
218
Brake Caliper (12 243 0)
220
DISASSEMBLY and ASSEMBLY Brake Caliper
222
Specifications
224
Lubricants, Fluids, Sealers and Adhesives
224
Front Disc Brake Specification
224
Parking Brake and Actuation
227
Parking Brake
228
Parking Brake
229
Diagnosis and Testing
229
Inspection and Verification
229
Symptom Chart
229
The Parking Brake will Not Release
230
Parking Brake Control (12 664 0)
232
Removal and Installation
232
Parking Brake Cable and Conduit (12 675 0)
234
Parking Brake Warning Indicator Switch
237
Parking Brake Cable Adjustment (12 662 0)
238
General Procedures
238
Hydraulic Brake Actuation
240
Description and Operation
241
Hydraulic Brake Actuation
241
Diagnosis and Testing
242
Hydraulic Brake Actuation
242
Brake Master Cylinder (12 343 0)
243
Removal and Installation
243
Brake Pedal
245
Brake Fluid Reservoir (12 341 0)
247
Brake Pedal Cross-Shaft (12 338 0)
249
Brake Pedal and Bracket
252
Specifications
255
Lubricants, Fluids, Sealers and Adhesives
255
Torque Specifications
255
Power Brake Actuation
256
DESCRIPTION and OPERATION Brake Booster
257
Power Brake System
258
Diagnosis and Testing
258
Brake Booster (12 451 0)
259
Removal and Installation
259
Specifications
261
Torque Specifications
261
Steering System — General Information
262
Steering System
263
Principles of Operations
263
Inspection and Verification
263
Symptom Chart
263
Power Steering
263
Steering Linkage
264
Steering Linkage
265
Component Tests
265
Steering Column
265
Power Steering System Filling (13 416 1)
266
General Procedures
266
Power Steering System Bleeding (13 416 1)
267
Power Steering System Flushing (13 416 1)
269
Power Steering System Purging (13 416 1)
272
Manual Steering
276
Manual Steering
277
DESCRIPTION and OPERATION Manual Steering
277
DIAGNOSIS and TESTING Manual Steering
278
Steering Gear (13 116 0)
279
REMOVAL and INSTALLATION Steering Gear
279
Power Steering - Petrol
286
Power Steering
287
Vehicles with 1.8L Endura de Engine
288
Description and Operation
288
Power Steering
288
Diagnosis and Testing
290
Power Steering
290
Power Steering Pump — Vehicles with 1.8L Endura de Diesel Engine
291
Removal and Installation
291
Power Steering Pump — Vehicles with 1.3L Engine (13 434 0)
295
Power Steering Pump — Vehicles with 1.6L Engine (13 434 0)
299
Drive Belt - Power Steering Pump (with Air Conditioning) - Remove
302
Power Steering Gear (13 116 0)
307
Steering Gear Pinion Oil Seal (13 468 0)
316
Power Steering Fluid Cooler (13 444 0)
319
Power Steering Pump to Steering Gear Pressure Line
321
Steering Gear to Fluid Cooler Return Hose
331
Steering Linkages
341
Description and Operation
342
Steering Linkage
342
Diagnosis and Testing
343
Steering Linkage
343
Tie-Rod End (13 273 0)
344
Removal and Installation
344
Steering Gear Boot (13 134 0)
346
Steering Column
348
Steering Wheel (13 524 0)
350
Air Bag Sliding Contact (33 392 0)
351
Steering Column (13 542 0)
352
Steering Column Switches
356
A3: Check Circuit 30 Rd) for Short to Ground
362
A4: Check for Open on Circuit 30 (Rd)
362
A5: Check the Ignition Switch
363
B1: Check for Open /Short to Ground on Circuit 75 (Ye)
363
No Power in Run
364
C1: Check Fuse 38 (60A)
364
C2: Check for Short to Ground on Circuit 30 (Rd)
364
C3: Check the Ignition Switch
364
C4: Check for Open on Circuits 15 (Gn) and 15 (Gn/Bu)
365
C5: Check the Ignition Relay Ground
365
C6: Check the Ignition Relay Power Feed
365
No Power in Start
366
C7: Check for Open on Circuit 15 (Gn)
366
D1: Check Fuse 36 (60A)
366
D2: Check for Short to Ground on Circuit 30 (Rd)
367
D3: Check the Ignition Switch
367
D4: Check for Short/Open on Circuit 50 (Gy)
367
D5: Check the Start Inhibit Relay Ground
368
D6: Check the Start Inhibit Relay Power Feed
368
D7: Check for Open on Circuit 50 (Gy/Bk)
369
E1: Check the Exterior Lighting
369
E2: Check the Wiper and Washer
369
Steering Column Multifunction Switch (33 612 0)
370
Ignition Switch (36 424 0)
371
Engine System — General Information
373
Engine
374
Inspection and Verification
374
Bearing Inspection
375
Camshaft Journal Diameter
376
Camshaft Journal Clearance
377
Camshaft End Play
378
Camshaft Lobe Surface
379
Camshaft Lobe Lift
380
Crankshaft End Play
381
Crankshaft Main Bearing Journal Diameter
382
Crankshaft Main Bearing Journal Clearance
383
Cylinder Bore Taper
384
Piston Diameter
385
Piston Ring End Gap
386
Piston Pin Diameter
387
Piston Pin to Bore Diameter
388
Piston Inspection
389
Piston Ring-To-Groove Clearance
390
Connecting Rod Large End Bore
391
Cylinder Head Distortion
392
Valve Stem Diameter
393
Valve Seat Inspection
394
Exhaust Manifold Inspection
395
Flywheel Inspection
395
Engine — 1.6L / 1.3L Rocam
396
Serial Number and Engine Code Location
399
Valve Train
400
Rear Oil Seal Retainer
401
Cylinder Head
402
Oil Pan
403
Camshaft Chain Drive
404
Coolant Flow Control Housing
405
Intake Manifold (21 183 0)
407
Valve Cover (21 140 0)
412
Crankshaft Front Oil Seal (21 467 0)
415
Valve Seals (21 238 0)
418
Camshaft (21 283 0)
421
Timing Chain
424
Crankshaft Rear Oil Seal
428
Exhaust Manifold (21 186 0)
430
Cylinder Head (21 163 0)
433
Oil Pan (21 154 0)
443
Oil Pump (21 154 0)
447
Engine (21 132 0)
449
Cylinder Head (21 165 6)
469
Engine ASSEMBLY
476
Engine (21 134 8)
476
Engine INSTALLATION
488
Crankshaft
500
Piston
500
Connecting Rod
501
Cylinder Block
501
Camshaft
501
Engine — 1.8L Diesel - Endura de
505
Timing Belt Pulley - Crankshaft
507
Crankshaft Central Bolt
507
Camshaft Timing Belt
507
Valve Tappets & Adjusting Shims
508
Crankshaft Oil Seals
508
Crankcase Ventilation
508
Auxiliary Shaft Oil Seal (21 556 0)
525
Timing Belt — Engines with Automatic Timing Belt Tensioner (21 304 0)
538
Timing Belt — Engines with Manual Timing Belt Tensioner (21 304 0)
553
Camshaft Oil Seal (21 288 0)
570
Valve Clearance (21 213 0)
669
Engine Cooling - 1.8L Diesel - Endura de
680
Engine Cooling
681
Changing Coolant
681
Thermostat — Vehicles with 1.8L Endura de Diesel Engine (24 454 0)
683
Coolant Expansion Tank (24 284 0)
696
Cooling System Draining, Filling and Bleeding
697
Cooling System Flushing
699
Cooling System Back Flushing
700
Heater Core Back Flushing
701
Starting System - 1.8L Diesel - Endura de
703
Starting System
704
The Engine Does Not Crank or the Relay Clicks
707
The Engine Cranks Slowly
712
Unusual Starter Motor Noise
713
Starter Motor — Vehicles with 1.8L Endura de Diesel Engine (26 204 0)
715
Engine Emission Control — Diesel Engine
718
Engine Emission Control
719
Positive Crankcase Ventilation
719
Exhaust Gas Re-Circulation
719
Exhaust Manifold to Exhaust Gas Re-Circulation (EGR) Valve Tube (23 301 0)
721
Exhaust Gas Re-Circulation (EGR) Valve (23 312 0)
722
Exhaust Gas Re-Circulation (EGR) Valve — Vehicles with 1.8L Endura de Diesel Engine (23 312 0)
724
Electronic Engine Controls — Diesel Engine
728
Engine Emission Controls
729
Electronic Engine Controls
730
Crankshaft Position (CKP) Sensor — Vehicles Wi Th 1.8L Endura de Diesel Engine (29 230 0)
731
Engine Coolant Temperature (ECT) Sensor (21 190 0)
732
Vehicles with Diesel Engine
736
Pressure Test
741
Thermostat Test
741
Radiator Leak Test, Removed from Vehicle
741
Thermostat — Vehicles with 1.6L / 1.3L Engine (24 454 0)
742
Thermostat Housing — Vehicles with 1.6L / 1.3L Engine (24 001 0)
746
Water Pump — Vehicles with 1.6L / 1.3L Engine (24 404 0)
749
Water Pump — Vehicles with Diesel Engine (24 404 0)
752
Radiator (24 254 0)
756
Cooling Fan Motor (24 222 0)
765
Cooling System Draining, Filling and Bleeding (24 122 0)
769
Fuel Charging and Controls
776
Fuel Charging Wiring Harness
776
Fuel Pressure Regulator
776
Fuel Injection Supply Manifold
777
Throttle Body
777
Fuel Injectors
777
Throttle Body (23 198 0)
779
Fuel Injectors (23 455 0)
782
Fuel Charging Wiring Harness (36 437 0)
786
Fuel Charging and Controls — 1.8L Diesel Engine
790
Idle Speed Adjustment (23 413 0) (Vehicles Without Air Conditioning)
794
Idle Speed Adjustment — (Vehicles with Air Conditioning) (23 413 0)
795
Fuel Injection Pump (23 414 0)
798
Fuel Injection Delivery Pipes
816
Waxstat Cable Adjustment
820
Cable - Idle Speed Control - (Adjust)
821
Accessory Drive
826
Accessory Drive Belt
827
Idler Pulley(S)
827
Belt Tensioner
827
Manual Belt Tensioner and Idler Pulley(S)
830
Automatic Tensioner - Static Check
830
Automatic Tensioner - Dynamic Check
831
Accessory Drive Belt Tensioner — Vehicles with 1.6L / 1.3L Engine
832
Accessory Drive Belt — Vehicles with 1.8L Endura de Diesel Engine (31 413 0)
835
Accessory Drive Belt — Vehicles with 1.8L Endura de Diesel Engine and Air Conditioning (31 413 0)
836
Starter Motor — Vehicles with 1.6L / 1.3L Engine (26 204 0)
851
Engine Ignition
857
Ignition Coil Pack — Vehicles with 1.6L / 1.3L Engine (22 414 0)
859
Intake Air Distribution and Filtering
863
Air Cleaner Intake Pipe (23 175 0)
866
Air Cleaner (23 174 0)
869
Powertrain Control Module (PCM) — Vehicles with Petrol Engine (29 200 0)
876
Crankshaft Position (CKP) Sensor — Vehicles with 1.6L / 1.3L Engines (29 230 0)
878
Power Steering Pressure (PSP) Switch — Vehicles with Petrol Engine (33 611 0)
879
Throttle Position (TP) Sensor — Vehicles with 1.6L / 1.3L Engines (23 325 0)
880
Engine Coolant Temperature (ECT) Sensor — Vehicles with 1.6L / 1.3L Engines
881
Engine Knock Sensor — Vehicles with 1.3L Engines
882
Manual Transaxle and Clutch
890
Clutch Slippage
898
Clutch Chatter or Shudder
899
Clutch Drag
900
Clutch Pedal Pulsation
900
Clutch Related Vibrations
901
Hard Shifting
902
Fluid Leakage
904
Clutch Disc Check
905
Clutch Master Cylinder Check
906
Clutch Pressure Plate Check
907
Clutch Slave Cylinder Check
908
Clutch System Bleeding (16 843 0)
909
Gearshift Linkage Adjustment (16 513 0)
911
Clutch
915
Clutch Components
916
Clutch Disc and Pressure Plate
918
Clutch Controls
922
Clutch Master Cylinder
922
Slave Cylinder - Clutch
922
Pre-Load Valve
922
Clutch Operating Mechanism Components
923
Clutch Master Cylinder (16 856 0)
925
Clutch Slave Cylinder (16 862 0)
927
Manual Transaxle
929
Components of the Ib5 Manual Transmission
931
Internal Gearshift Mechanism
932
Input Shaft
933
Output Shaft
934
Double Synchronization
935
Differential
935
Power Flow
936
First Gear
936
Second Gear
936
Third Gear
936
Fourth Gear
937
Fifth Gear
937
Reverse Gear
937
Input Shaft Oil Seal
939
LH Halfshaft Oil Seal (14 303 0)
941
RH Halfshaft Oil Seal (14 304 0)
943
Transaxle — Vehicles with 1.6L / 1.3L Engine (16 114 0)
946
Selector Plate (16 284 5)
963
Transaxle (16 118 8)
977
Transaxle (16 114 0)
989
Bearing Check
999
External Controls
1004
Overview - Gearshift Mechanism
1004
Gearshift Linkage (16 534 0)
1007
Gearshift Stabilizer Bar Bushing (16 589 4)
1012
Gearshift Stabilizer Bar (16 588 0)
1013
Exhaust System
1021
Exhaust Flexible Pipe — Vehicles with Diesel Engines
1024
Muffler and Tailpipe (25 202 0)
1026
Fuel System — General Information
1030
Fuel System
1031
Diesel Fuel System Description and Operation
1032
Fuel Injection Pump
1032
Light Load Retard Device
1032
Cold Start Advance Solenoid
1032
Fuel System Pressure Relief (23 420 0)
1033
Fuel Tank Draining (23 551 0)
1034
Push Connect Fittings
1035
Fuel Tank and Lines — Petrol Engines
1039
Fuel Tank and Lines
1040
Fuel Tank (23 554 0)
1042
Fuel Pump Module (23 534 0)
1048
Fuel Tank Filler Pipe (23 572 0)
1050
Fuel Pump to Fuel Filter Line (23 588 0)
1051
Fuel Filter to Fuel Supply Manifold Line (23 590 0)
1053
Fuel Return Line (23 594 0)
1057
Inertia Fuel Shutoff (IFS) Switch (33 577 0)
1061
Fuel Tank and Lines — Diesel Engines
1064
Fuel Sender Unit (33 286 0)
1070
Fuel Filter Element (23 546 0)
1073
Fuel Tank to Fuel Filter Line (23 588 0)
1074
Acceleration Control
1084
Accelerator Cable Adjustment — Vehicles with 1.6L / 1.3L Engine (23 811 0)
1087
Accelerator Cable Adjustment — Vehicles with Diesel Engine (23 811 0)
1088
Electrical
1089
Climate Control System — General Information
1090
Climate Control System
1091
No/Insufficient Heating Power
1097
Pinpoint Test B
1103
The Heater Blower System Is Inoperative
1113
Spring Lock Coupling (34 639 1)
1131
Air Conditioning (A/C) Clutch Air Gap Adjustment (34 628 6)
1133
Electronic Leak Detection (34 620 5)
1134
Air Conditioning (A/C) System Flushing
1135
Tracer Dye Leak Detection (34 620 5)
1139
Vacuum Leak Detection (34 620 5)
1140
Air Conditioning (A/C) System Evacuation and Charging (34 620 2)
1141
Refrigerant Oil Addition (34 621 1)
1144
Air Distribution System Cleaning
1145
Contaminated Refrigerant Handling (34 620 5)
1147
Air Distribution and Filtering
1149
Ventilation Nozzles
1150
Center Vent Nozzle (34 489 0)
1152
Heating and Ventilation
1153
Blower Motor (34 374 0)
1156
Heater Core Housing (34 354 0)
1160
Heater Core (34 364 0)
1164
Heater Control Valve (34 328 0)
1168
Heater Core Housing (34 354 8)
1172
Air Conditioning
1176
Refrigerant Circuit with Fixed Orifice Tube
1177
Air Conditioning System Components
1179
Compressor
1180
Air Conditioning (A/C) Compressor
1182
Evaporator Core (34 622 0)
1188
Evaporator Core Orifice (34 624 0)
1192
Suction Accumulator (34 630 0)
1195
Low Pressure Cut-Off Switch (34 629 0)
1198
High Pressure Cut-Off Switch (34 631 0)
1201
Evaporator to Condenser Line (34 645 0)
1203
Suction Accumulator to Evaporator Line (34 644 0)
1209
Control Components
1214
Climate Control Assembly (34 300 0)
1217
Blower Motor Switch (33 574 0)
1220
Air Inlet Blend Door Actuator (34 606 0)
1222
Instrument Cluster
1223
Low Fuel Warning Indicator
1226
Worldwide Diagnostic System (WDS) Tester Diagnostics – All Vehicles
1230
Instrument Cluster Diagnostic Trouble Code (DTC) Index
1230
Incorrect Fuel Gauge Indication
1233
The Speedometer Is Inoperative
1236
Incorrect Temperature Gauge Indication
1237
The Tachometer Is Inoperative
1238
The Low Oil Pressure Indicator Is Inoperative
1240
The Brake Warning Indicator Is Inoperative – from 01/99 Onwards
1240
The Charging System Warning Indicator Is Inoperative – from 01/99 Onwards
1243
Instrument Cluster (33 214 0)
1244
Instrument Cluster Printed Circuit (33 224 4)
1247
Charging System — General Information
1252
Charging System
1253
The Charging System Warning Indicator Stays on
1256
The Charging System Warning Indicator Is Inoperative
1257
Radio Interference
1259
No-Load Test
1259
Load Test
1259
Battery Charging
1260
Battery, Mounting and Cables
1263
Battery and Cables
1264
Battery to Starter Motor Solenoid Cable — Vehicles with 1.6L / 1.3L Engine
1268
Battery to Starter Motor Solenoid Cable — Vehicles with 1.8L Endura de Diesel Engine
1272
Battery Tray (44 271 4)
1275
Generator and Regulator
1277
Generator — Vehicles with 1.6L / 1.3L Engine (31 414 0)
1279
Generator — Vehicles with 1.8L Endura de Diesel Engine (31 414 0)
1284
Generator — Vehicles with 1.8L Endura de Diesel Engine and Air Conditioning
1287
Audio System — General Information
1291
Audio System
1292
The Audio Unit Is Inoperative/Does Not Operate Correctly
1295
Poor Reception
1298
Distorted Sound from One or more Speakers
1300
Audio Unit
1305
General Equipment
1307
Antenna
1308
Front Door Speaker (38 268 0)
1316
Exterior Lighting
1317
Headlamp System
1319
Multifunction Switch
1319
Side Lamps
1319
License Plate Lamps
1319
Exterior Lighting
1319
Reversing Lamps
1320
Turn Signal and Hazard Warning Lamps
1320
Hazard Warning Lamp Switch
1320
Turn Signal Relay
1320
Central Junction Box (CJB)- Front View, Fuses
1321
Central Junction Box (CJB)- Top View
1322
Both Headlamps Are Inoperative
1327
The Low Beams Are Inoperative
1328
The High Beams Are Inoperative
1330
One Low Beam Headlamp Is Inoperative
1331
The Flash-To-Pass Feature Is Inoperative
1343
Relays
1344
Measure the Resistance between Pin 3 and 5
1344
Stop Lamps
1345
One or more Stop Lamps Are Inoperative
1346
Stop Lamps Are on Continuously
1349
Turn Signal and Hazard Lamps
1350
Turn Signal Lamps Are Inoperative or on Continuously
1353
One Turn Signal/Hazard Lamp Is Inoperative
1361
Hazard Lamps Are Inoperative or on Continuously
1368
Parking, Rear and License Lamps
1372
The Parking, Rear or License Plate Lamps Are Oncontinuously
1382
The Parking, Rear and License Plate Lamps Are Inoperative
1383
The Reversing Lamp Is Inoperative
1385
Fog Lamps
1389
The Fog Lamps Are Inoperative
1389
The Individual Fog Lamp Is Inoperative
1393
The Fog Lamps Are on Continuously
1395
Check Relay Contact in Normal Condition
1396
Check Relay Contact in Activated Condition
1396
Headlamp Assembly (32 115 0)
1397
Rear Lamp Assembly (32 305 0)
1398
Headlamp Adjustment
1399
Module Communications Network
1402
Communications Network
1403
Powertrain Control Module (Pcm) Does Not Respond to Thewds
1404
Instrument Cluster Does Not Respond to the Wds
1404
Air Bag Module Does Not Respond to the Wds
1405
Anti-Theft/Central Locking Module Does Not Respond to the Wds
1406
No One of the Installed Modules Responds to the Wds
1406
Anti-Theft — Passive
1409
Passive Anti-Theft System (PATS)
1410
Keys
1410
Key Programming
1410
Anti-Theft
1411
Principles of Operation
1411
Encoded Ignition Key
1411
Transceiver Module
1411
Diagnostic Trouble Code (DTC) Index
1412
Pats Transceiver Signal Is Not Received
1414
The Anti—Theft System Does Not Operate Correctly – Engine Does Not Crank but Anti-Theft Led Proves out Normally
1417
Passive Anti-Theft System (PATS) Module
1419
Fuel Injection Pump Actuator — Vehicles with Diesel Engine
1420
Passive-Theft System (PATS) Transceiver (33 662 0)
1424
Key Programming Using Two Programmed Keys (33 005 0)
1425
Key Programming Switch State Control
1427
Erasing All Key Codes Using Diagnostic Equipment (33 005 0)
1428
Anti-Theft Security Access (33 004 0)
1430
Body and Paint
1431
Interior Trim and Ornamentation
1432
Interior Trim
1433
Front Door Trim Panel (43 705 0)
1434
A-Pillar Trim Panel (43 616 0)
1439
B-Pillar Trim Panel (43 617 0)
1440
Cab Back Panel Trim (Plastic Panel)
1442
Rear View Mirrors
1444
Rear View Mirrors
1445
The Mirrors Are Inoperative
1446
A Single Mirror Is Inoperative
1447
A Single Mirror Does Not Function with Switch Logic
1448
Exterior Mirror (Electrically Operated)
1452
Exterior Mirror — Manually Operated (43 364 0)
1454
Exterior Mirror Glass (43 366 0)
1456
Seats
1459
Front Seat
1460
Front Seat Cushion
1464
Front Seat Backrest
1465
Front Seat Cushion (40 104 0)
1467
Front Seat Backrest (40 106 0)
1469
Glass, Frames and Mechanisms
1473
Single Power Window Is Inoperative - Driver Side
1475
Front Door Window Glass (42 314 0)
1481
Rear Window Glass
1489
Front Door Window Regulator and Motor (42 338 0)
1493
Door Window Glass Adjustment (42 001 0)
1503
Instrument Panel (43 644 0)
1507
Handles, Locks, Latches and Entry Systems
1512
Locks, Latches and Entry Systems
1514
Front Door Latch (41 351 0)
1516
Hood Latch Release Handle (41 226 0)
1520
Exterior Door Handle (41 333 0)
1521
Door Latch Remote Control
1523
Tailgate - Hinge
1524
Tailgate Handle Assembly
1525
Tailgate - Actuating Rods and Latches
1526
Ignition Lock Cylinder (33 513 0)
1527
Door Lock Cylinder (41 336 0)
1528
Wipers and Washers
1534
Windshield Wiper
1535
Windshield Wiper Functions
1535
Wiper Lever in the off Position
1535
Wiper Lever in the WIPE ONCE Position
1535
Wipers and Washers
1535
Wiper Lever in the FAST WIPE Position
1536
Windshield Washer
1536
Wiper Lever in the off or INTERMITTENT Position
1536
Washer Fluid Level Warning Light
1536
The Wipers Are Inoperative
1538
The High/Low Wiper Speeds
1539
The Wipers will Not Park at the Correct Position
1540
The High/Low Wiper Speeds Do Not Operate Correctly (Intermittent Wiper Mode Ok)
1549
The Intermittent Wiper Speed Does Not Operate Correctly (High/Low Speeds Ok)
1551
Mounting Arm and Pivot Table (32 554 0)
1562
Windshield Wiper Motor (32 524 0)
1564
Windshield Washer Pump (32 624 0)
1567
Windshield Washer Reservoir (32 622 0)
1569
Wiper Blade and Pivot Arm Adjustment (32 591 0)
1571
Bumpers
1573
Front Bumper (43 423 0)
1574
Rear Bumperette (43 432 0)
1576
Occupant Restraints — Active
1578
Occupant Restraint System
1579
Emergency Locking Retractor (ELR)
1580
Vehicle Motion Sensor (VMS)
1580
Webbing Motion Sensor (WMS)
1580
Safety Belt Testing
1581
Poor Retraction
1581
Vehicle Motion Sensor Test
1581
Front Safety Belt Retractor (40 222 0)
1582
Safety Belt Buckle and Pretensioner
1585
Occupant Restraints — Passive — Supplemental Air Bag System
1588
Air Bag Supplemental Restraint System (SRS)
1589
Lamp Fault Codes (LFC)
1591
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
1592
Diagnosing Customer Concerns with Hard Dtcs / Lfcs
1592
Air Bag Simulator
1593
Deactivate the System
1593
Prove out the System
1593
Supplemental Restraint System (SRS) Operation
1593
Air Bag Control Module
1594
Air Bag Warning Indicator
1594
Diagnostic Instructions — Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
1595
Pinpoint Tests — Air Bag and Safety Belt Pretensioner Supplemental Restraint System (Srs)
1600
No Communication with the Module
1600
Air Bag Warning Indicator Ground Monitoring Circuit Open
1601
Battery Voltage Low
1603
Air Bag Warning Indicator Open Circuit or Short to Ground
1604
Air Bag Warning Indicator Short to Battery
1608
Driver Air Bag Short to Ground
1610
Driver Air Bag Circuit Short to Battery
1612
Driver Air Bag Open Circuit or High Resistance
1614
Driver Air Bag Circuit Low Resistance
1616
Passenger Air Bag Short to Ground
1618
Passenger Air Bag Short to Battery
1619
Passenger Air Bag Open Circuit or High Resistance
1620
Passenger Air Bag Circuit Low Resistance
1621
Driver Safety Belt Pretensioner Circuit Capacitance out of Range
1623
Driver Safety Belt Pretensioner Open Circuit
1624
DTC B1878 Driver Safety Belt Pretensioner Short to Battery
1625
Driver Safety Belt Pretensioner Short to Ground
1627
Driver Safety Belt Pretensioner Low Resistance
1629
Passenger Safety Belt Pretensioner Circuit Capacitance out of Range
1631
Passenger Safety Belt Pretensioner Open Circuit
1631
Passenger Safety Belt Pretensioner Short to Battery
1633
Passenger Safety Belt Pretensioner Short to Ground
1635
Passenger Safety Belt Pretensioner Low Resistance
1637
Driver Air Bag Module (40 700 0)
1639
Passenger Air Bag Module (40 701 0)
1641
Air Bag Control Module (33 650 0)
1646
Unserviceable Air Bag Disposal
1648
Scrapped Vehicle Air Bag Disposal
1650
Uni-Body, Subframe and Mounting Frame — General Information
1655
Subframe
1656
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