2012 Fisker Karma Service Manual Part 1
2012 Fisker Karma Service Manual Part 1
2012 Fisker Karma Service Manual Part 1
SERVICE MANUAL
Chapter Number
ENGINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
ELECTRIC DRIVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
HEVAC SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
FINAL DRIVE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
STEERING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
SUSPENSION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
BRAKES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
CHASSIS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
BODY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
ROOF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
GLAZING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76
EXTERIOR FITTINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
DASH ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80
INTERIOR TRIM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82
RESTRAINT SYSTEMS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84
SEATS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
ELECTRICAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90
INFOTAINMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94
1-1
ENGINE
Contents Page
12-1
ENGINE
FSM00616
8. Remove LH mounting.
NOTE: Note fitted position of components
before removal.
FSM00830
FSM00615
12-2
ENGINE
Remove
1. Raise and support vehicle
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
FSM00617
FSM00832
FSM00618
8. Remove RH mounting.
NOTE: Note fitted position of components
before removal.
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
FSM00831
WARNING: Only use cleaning agents and
5. Using suitable lifting equipment, support solvents in a well ventilated area.
weight of engine. CAUTION: Replace all Nyloc nut(s).
12-3
ENGINE
Engine and Generator - Remove and Refit 11. Repeat previous two steps for RH lower arm.
for Access 12. Raise vehicle.
FRT No.: 12100601
Remove
1. Remove LH wheel arch liner. Refer to FRT:
78100100, page 78-2.
2. Repeat the above procedure and remove RH
wheel arch liner.
3. Remove high voltage battery assembly. Refer FSM00146
to FRT: 16200200, page 16-7.
13. Turn column for spanner access and remove
4. Drain cooling system. Refer to FRT: clamp bolt securing steering column
20010100, page 20-2. intermediate shaft to rack. Torque - 30 Nm.
5. Evacuate refrigerant from A/C system. Refer NOTE: Note fitted position of components
to FRT: 30010100, page 30-2. before removal.
6. Remove air cleaner assembly. Refer to FRT: 14. Disconnect intermediate shaft from steering
12700200, page 12-63. rack.
7. Remove front sway bar. Refer to FRT:
46500500, page 46-15.
8. Remove exhaust system complete. Refer to
FRT: 12800301, page 12-75.
FSM01012
12-4
ENGINE
19. Position and support hood in service 26. Release battery coolant hose from clip.
position. 27. Release clip and remove clean air inlet hose
20. Remove engine cover. Refer to FRT: from turbocharger.
12301000, page 12-29. CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
FSM00151
intercooler hose. 28. Release clip and disconnect top hose from
22. Release intercooler hose and position aside. high temperature radiator.
CAUTION: Plug all open connections to CAUTION: Plug all open connections to
prevent ingress of moisture and dirt. prevent ingress of moisture and dirt.
23. Remove bolts (x2) securing charge air outlet 29. Tie top hose aside to engine.
flange to turbocharger. Torque - 25 Nm.
24. Remove charge air pipe assembly, collect
and discard gasket.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
FSM00726
25. Disconnect PCV pipe from cam cover. 32. Release clips (x2) securing charge air inlet
CAUTION: Plug all open connections to pipe to intercooler and throttle body.
prevent ingress of moisture and dirt. 33. Remove charge air inlet pipe.
12-5
ENGINE
FSM00155
ıııı
ııı
FSM00760
12-6
ENGINE
FSM00727
FSM00730
FSM00728
12-7
ENGINE
FSM00500
FSM00221
FSM00219
12-8
ENGINE
FSM00223
12-9
ENGINE
FSM00225
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
12-10
ENGINE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
3. Remove timing cover gasket. Refer to FRT:
FSM00852
FSM00851
12-11
ENGINE
FSM00855 FSM00862
10. Remove fuel pressure regulator. 13. Release harness clip from intake manifold
support bracket stud.
14. Loosen nut securing manifold support
bracket to cylinder block. Torque 50 Nm.
FSM00853
NOTE: Place suitable absorbent material 15. Disconnect manifold absolute pressure
around the affected area to absorb any sensor connector.
possible fluid spillage.
12. Remove and discard fuel pump gasket.
12-12
ENGINE
FSM00867 FSM00863
16. Disconnect throttle body harness connector. 19. Remove bolt securing dipstick tube support
bracket to intake manifold. Torque - 25 Nm.
20. Release clip securing engine harness to
intake manifold.
FSM00859
12-13
ENGINE
FSM00866 FSM00869
22. Evenly and progressively loosen / remove 24. Remove and discard intake manifold gasket.
bolts (x5) and nuts (x2) securing intake NOTE: Note fitted position of components
manifold to cylinder head. Torque - 25 Nm. before removal.
FSM00868
FSM00870
FSM0871
12-14
ENGINE
FSM00875
FSM0876
CAUTION: Plug all open connections to 33. Remove bolt securing turbo brace to cylinder
prevent ingress of moisture and dirt. block. Torque - 50 Nm.
CAUTION: Injector seals swell when exposed 34. Remove nut securing turbo support bracket
to atmospheric conditions for more than one to turbo. Torque - 25 Nm.
minute. Ensure protective sleeves are 35. Remove turbo brace.
installed.
36. Release turbo oil return pipe from engine
NOTE: Do not remove protective sleeve from block.
injector until moment of assembly.
CAUTION: Remove and discard 'O' ring
NOTE: Injector seals are not available seals.
individually. The injector must be replaced as
CAUTION: Plug all open connections to
a unit.
prevent ingress of moisture and dirt.
30. Remove camshaft cover. Refer to FRT:
12300100, page 12-25.
12-15
ENGINE
FSM00899
FSM00898
12-16
ENGINE
FSM00904 FSM00946
43. Remove and discard turbo to exhaust 45. Progressively loosen and remove nuts (x10)
manifold flange gasket. securing exhaust manifold to cylinder head.
NOTE: Note fitted position of components Discard nuts. Torque - 25 Nm.
before removal.
FSM00947
12-17
ENGINE
72mm
FSM00948 FSM00990
47. Remove and discard exhaust manifold 49. Remove timing chain tensioner from cylinder
gasket. head casting and discard sealing washer.
NOTE: Note fitted position of components Torque - 75 Nm.
before removal. CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
NOTE: Check condition of timing chain
tensioner. If tensioner is not in fully
compressed active state (72mm) replace
tensioner.
FSM00989
FSM00991
12-18
ENGINE
FSM00992 FSM00994
51. Remove bolts (x2) securing upper timing 57. Remove fixed timing chain guide access plug
chain guide to cylinder head and remove from cylinder head.
guide. Torque - 10 Nm.
4 8 12 14 10 6
1 5 9 13 11 7
FSM00995
52. Hold exhaust camshaft in position using 24 cylinder head bolts (x14). Remove and
mm spanner on hexagonal on camshaft. discard bolts.
53. Remove bolt securing camshaft sprocket to CAUTION: Replace all cylinder head bolts.
camshaft and discard bolt. Torque - 85 Nm.
54. Release timing chain from exhaust camshaft
sprocket. Remove sprocket from camshaft.
55. Repeat previous 3 steps for inlet camshaft
sprocket.
56. Release timing chain clear of cylinder head.
12-19
ENGINE
FSM00996 FSM00998
59. Remove cylinder head from cylinder block. 65. Check cylinder head for warping, across
CAUTION: Plug all open connections to centre and from corner to corner as shown. If
prevent ingress of moisture and dirt. specified maximum tolerance exceeded,
replace cylinder head (Refer to technical
data).
66. Check cylinder head height. If specified
maximum reface tolerance exceeded,
replace cylinder head (Refer to technical
data).
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
FSM00997
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
60. Remove and discard cylinder head gasket.
2. Replace all disturbed 'O' ring seals.
NOTE: Note fitted position of components
before removal. NOTE: Apply a suitable lubricant to all 'O' ring
seals.
61. Clean mating faces of cylinder head and
cylinder block. 3. Fit new cylinder head gasket over cylinder
block locating dowels.
62. Remove debris from all oil and coolant
passages. NOTE: Ensure the cylinder head gasket is
fitted correct way up.
63. Check cylinder head for damage, pay
particular attention to gasket face of cylinder
head.
64. Check cylinder block gasket face for
damage.
12-20
ENGINE
7 3 1 5 9
10 6 2 4 8
FSM00999 FSM01001
2 9
1 2 3 4 1
6
8 10
5
3
7 4
FSM01000 FSM00949
6. Fit remaining cylinder head bolts (x4). Torque 9. Tighten exhaust manifold nuts in sequence.
35 Nm.
12-21
ENGINE
FSM00939
Installation
1. Installation procedure is reverse of removal
except for following.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
FSM00937
CAUTION: Replace all patch bolt(s).
3. Remove bolts (x6) securing damper to NOTE: Clean component mating faces, prior
flywheel. Torque - 45 Nm. to installation.
4. Remove damper from flywheel. 2. Fit new crankshaft rear oil seal.FST1011
3. Evenly and progressively tighten bolts
securing flywheel to crankshaft.
4. Evenly and progressively tighten bolts
securing damper to flywheel.
FSM00938
12-22
ENGINE
FSM00612
12-23
ENGINE
Filter - Oil
FRT No.: 12250200
Remove
1. Open vehicle hood.
FSM00614
Installation
FSM00613
1. Installation procedure is reverse of removal.
2. Clean area surrounding oil filter housing.
NOTE: Clean component mating faces, prior
3. Position fuel line and engine harness aside for to installation.
access.
2. Replace 'O' ring seals.
4. Loosen oil filter housing cap. Torque - 25
Nm.FST1009 NOTE: Lubricate new 'O' ring seals with clean
engine oil.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
5. Wait approximately one minute for oil to
return to oil pan.
6. Remove oil filter cap and filter element from
housing.
12-24
ENGINE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
FSM00765
FSM00941
12-25
ENGINE
FSM00942 FSM00944
8. Progressively loosen and remove bolts (x11) 10. Remove camshaft cover gaskets. Discard
securing camshaft cover. Torque - 10 Nm. gaskets.
NOTE: Note fitted position of components
before removal.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
2. Fit new camshaft cover gaskets.
FSM00943
12-26
ENGINE
Remove
1. Remove engine and generator assembly.
Refer to FRT: 12100601, page 12-4.
FSM00988
FSM00925
FSM00926
Installation
1. Installation procedure is reverse of removal
except for following.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
FSM00924 NOTE: Clean component mating faces, prior
3. Remove bolts (x11) securing timing cover. to installation.
Torque - 18 Nm. 2. Fit new timing cover oil seal.FST1032
NOTE: Note fitted position of components 3. Fit new timing cover gasket.
before removal. 4. Fit new crankshaft pulley bolt.
12-27
ENGINE
Oil Seal - Timing Cover 2. Fit new timing cover oil seal.FST1032
3. Fit new crankshaft pulley bolt.
FRT No.: 12300500
Remove
1. Remove engine and generator assembly.
Refer to FRT: 12100601, page 12-4.
FSM00925
FSM00926
Installation
1. Installation procedure is reverse of removal
except for following.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
NOTE: Clean component mating faces, prior
to installation.
12-28
ENGINE
Remove Remove
1. Remove front cross brace. Refer to FRT: 1. Remove engine cover. Refer to FRT:
60500300, page 60-13. 12301000, page 12-29.
2. Remove AC/DC Inverter. Refer to FRT:
16400100, page 16-11.
FSM00152
FSM00741
12-29
ENGINE
FSM00913
FSM00912
12-30
ENGINE
FSM00911
FSM00880
FSM00912
12-31
ENGINE
FSM00916 FSM00918
10. Release clip and disconnect positive 13. Remove bolts (x4) securing water pump
crankcase ventilation tube. Move tube aside. pulley access cover. Remove cover and
11. Release turbo air intake hose clips and discard gasket. Torque - 10 Nm.
remove intake hose. NOTE: Clean component mating faces, prior
to installation.
14. Remove bolts (x2) securing water pump.
Torque - 18 Nm.
NOTE: Note fitted position of components
before removal.
FSM00917
CAUTION: Plug all open connections to 15. Install special tool to restrain water pump
prevent ingress of moisture and dirt. drive sprocket, tighten bolts (x4) securing tool
to timing cover.FST1007
NOTE: Clean component mating faces, prior
to installation.
16. Tighten tool bolts (x3) to secure tool to water
pump drive sprocket.
17. Remove bolts (x3) securing water pump drive
sprocket to water pump. Torque - 7 Nm.
12-32
ENGINE
FSM00923
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
2. Fit but do not fully tighten rear bolts (x2)
FSM00922
securing water pump.
21. Release coolant feed union to turbo. 3. Install bolts (x2) securing water pump
Disconnect coolant pipe from thermostat through timing case.
housing and position aside. Discard washers.
Torque - 20 Nm. 4. Torque tighten bolts (x4).
22. Remove bolts (x3) securing thermostat 5. Remove water pump retaining tool.FST1007
housing and discard gasket. Torque - 10 Nm. 6. Replace 'O' ring seals.
23. Remove thermostat housing from water 7. Replace gaskets and seals.
pump inlet pipe. Discard 'O' ring seal.
8. Refill and bleed Engine and Cabin coolant.
12-33
ENGINE
Remove
1. Open hood.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
3. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
4. Remove RH cross brace. Removal procedure
is similar to LH cross brace. Refer to FRT:
60500100, page 60-12. FSM00677
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
FSM00676
12-34
ENGINE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2. FSM00190
3. Isolate high voltage battery. Refer to FRT: 8. Remove screws (x4), release clips (x3)
16200100, page 16-6. securing central heatshield to subframe and
remove shield. Torque - 10 Nm.
4. Disconnect catalyst upstream oxygen sensor
harness connector. 9. Using a suitable block between generator
and exhaust. Position exhaust aside for
5. Apply suitable release agent to catalyst
access.
manifold nuts and studs.
FSM00849
FSM01006
10. Disconnect oil pressure sensor harness
6. Remove nuts (x2) securing center muffler
connector.
flange to catalyst. Torque - 45 Nm.
7. Release exhaust flange.
12-35
ENGINE
Remove
FSM00752
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area. FSM00753
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
12-36
ENGINE
WARNING: Only use cleaning agents and Sensor - Manifold - Mass Air Flow and
solvents in a well ventilated area. Temperature (MAFIAT)
FRT No.: 12400500
Remove
FSM00743
FSM00744
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
12-37
ENGINE
WARNING: Only use cleaning agents and Modulator - Turbocharger Boost Pressure
solvents in a well ventilated area.
FRT No.: 12400600
Remove
1. Remove engine cover. Refer to FRT:
12301000, page 12-29.
FSM00745
FSM00746
12-38
ENGINE
Remove
1. Remove upstream oxygen sensor. Refer to
FRT: 12402100, page 12-48.
2. Release heat protective sheathing covering
FSM00747 coolant temperature sensor.
4. Depress clips (x2) and remove modulator
from bracket.
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
FSM00892
FSM00893
12-39
ENGINE
FSM00750
ıııı
FSM00751
Installation
1. Installation procedure is reverse of removal.
12-40
ENGINE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2. FSM00190
3. Isolate high voltage battery. Refer to FRT: 8. Remove screws (x4), release clips (x3)
16200100, page 16-6. securing central heatshield to subframe and
remove shield. Torque - 10 Nm.
4. Disconnect catalyst upstream oxygen sensor
harness connector. 9. Using a suitable block between generator
and exhaust. Position exhaust aside for
5. Apply suitable release agent to catalyst
access.
manifold nuts and studs.
FSM00847
FSM01006
10. Disconnect crankshaft position (CKP) sensor
6. Remove nuts (x2) securing center muffler
harness connector.
flange to catalyst. Torque - 45 Nm.
11. Remove bolt securing CKP sensor to cylinder
7. Release exhaust flange.
block. Torque - 8 Nm.
12-41
ENGINE
Remove
1. Remove high pressure fuel pump. Refer to
FRT: 12501000, page 12-61.
FSM00848
FSM00857
12-42
ENGINE
FSM00870
FSM0871
12-43
ENGINE
Remove
1. Remove engine cover. Refer to FRT:
12301000, page 12-29.
FSM00878
8. Remove KS.
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
12-44
ENGINE
Remove
1. Remove ignition coil. Refer to FRT:
12401200, page 12-44.
2. Remove bolts (x3) securing remaining ignition
coils to cam cover and remove coils. Torque
- 5 Nm.
Installation
FSM00742 1. Installation procedure is reverse of removal.
7. Remove bolt securing ignition coil to cam
cover and remove coil. Torque - 5 Nm.
Installation
1. Installation procedure is reverse of removal.
12-45
ENGINE
Remove Remove
1. Remove ignition coil. Refer to FRT: 1. Remove engine cover. Refer to FRT:
12401200, page 12-44. 12301000, page 12-29.
2. Remove remaining coils (x3).
3. Using a spark plug socket, remove 4 spark
plugs. Torque - 25 Nm.
Installation
1. Installation procedure is reverse of removal.
2. Set spark plug gaps to 0.9 mm ± 0.1 mm.
FSM00748
FSM00749
Installation
1. Installation procedure is reverse of removal.
12-46
ENGINE
FSM00764
FSM00765
12-47
ENGINE
FSM00880
ıııı
FSM00881
12-48
ENGINE
Remove
1. Open hood.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
3. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
4. Remove RH cross brace. Removal procedure
is similar to LH cross brace. Refer to FRT:
60500100, page 60-12.
FSM00882
Installation ıııı
12-49
ENGINE
FSM01029
12-50
ENGINE
Fuel Tank
FRT No.: 12500100
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove rear subframe assembly. Refer to
FRT: 60200200, page 60-2. FSM00648
FSM00842
12-51
ENGINE
FSM00840
2 1
13. Remove and discard 'O' ring seal.
FSM00651
FSM00845
12-52
ENGINE
2
3
3
FSM00647
12-53
ENGINE
Fuel Rail
FRT No.: 12500300
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove fuel injector harness. Refer to FRT:
FSM00648
90101400, page 90-3.
5. Carefully remove sender module from fuel
tank.
CAUTION: Take care not to damage
component(s).
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
6. Remove and discard 'O' ring seal.
Installation
FSM00874
1. Installation procedure is reverse of removal
except for the following. 3. Release unions (x2) securing high pressure
pump to fuel rail feed pipe. Torque - 25 Nm.
NOTE: Clean component mating faces, prior
to installation. NOTE: Place suitable absorbent material
around the affected area to absorb any
WARNING: Only use cleaning agents and possible fluid spillage.
solvents in a well ventilated area.
WARNING: Eye protection must be worn.
CAUTION: Replace all patch bolt(s).
WARNING: Petrol/gasoline vapour is highly
2. Install new 'O' ring seal to module. flammable and in confined spaces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2 GAS, or
POWDER close at hand when handling or
draining fuel.
WARNING: Care must be taken during fuel
line disconnection as residual fuel pressure
may be present.
4. Remove fuel rail feed pipe.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
12-54
ENGINE
FSM00875 FSM00877
5. Remove bolts (x4) securing fuel rail to 8. Release clips (x4) and remove injectors from
cylinder head. Torque - 25 Nm. fuel rail.
6. Carefully release injectors and rail from CAUTION: Plug all open connections to
cylinder head. prevent ingress of moisture and dirt.
CAUTION: Injector seals swell when exposed
to atmospheric conditions for more than one
minute. Ensure protective sleeves are
installed.
Installation
1. Installation procedure is reverse of removal.
NOTE: Injector seals are not available
individually. The injector must be replaced as
a unit.
NOTE: Do not remove protective sleeve from
injector until moment of assembly.
FSM0876
NOTE: Clean component mating faces, prior
7. Remove fuel rail and injectors. to installation.
CAUTION: Plug all open connections to WARNING: Only use cleaning agents and
prevent ingress of moisture and dirt. solvents in a well ventilated area.
CAUTION: Injector seals swell when exposed
to atmospheric conditions for more than one
minute. Ensure protective sleeves are
installed.
12-55
ENGINE
Injector - Each
FRT No.: 12500400
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove fuel injector harness. Refer to FRT:
90101400, page 90-3. FSM00875
FSM00874
12-56
ENGINE
Injector - Set
FRT No.: 12500500
Remove
1. Remove fuel rail. Refer to FRT: 12500300,
page 12-54.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
FSM00877
Installation
8. Release clip and remove injector from fuel
rail. 1. Installation procedure is reverse of removal.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
CAUTION: Injector seals swell when exposed
to atmospheric conditions for more than one
minute. Ensure protective sleeves are
installed.
Installation
1. Installation procedure is reverse of removal.
NOTE: Injector seals are not available
individually. The injector must be replaced as
a unit.
NOTE: Do not remove protective sleeve from
injector until moment of assembly.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
12-57
ENGINE
FSM00854
WARNING: Care must be taken during fuel 8. Remove fuel pressure regulator.
line disconnection as residual fuel pressure
may be present. Installation
12-58
ENGINE
Remove
1. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
2. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
3. Remove RH inverter. Removal procedure is
similar to LH inverter. Refer to FRT:
16400200, page 16-14.
FSM00650
FSM00649
2 1
4. Disconnect fuel tank pump harness
connector.
5. Release clip and disconnect fuel feed pipe
from fuel tank pump module.
WARNING: Eye protection must be worn.
WARNING: Petrol/gasoline vapour is highly
flammable and in confined spaces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2 GAS, or FSM00651
POWDER close at hand when handling or 8. Disconnect internal fuel pipe from module
draining fuel. cover. Disconnection is a two stage process.
NOTE: Place suitable absorbent material Release blue clip and then depress white clip.
around the affected area to absorb any NOTE: Ensure internal fuel pipe two stage clip
possible fluid spillage. is returned to closed position before
CAUTION: Plug all open connections to connecting to module cover.
prevent ingress of moisture and dirt.
12-59
ENGINE
FSM00652
FSM00840
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all patch bolt(s).
12-60
ENGINE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove engine cover. Refer to FRT:
12301000, page 12-29. FSM00852
3. Remove bolts (x3) securing fuel pump around the affected area to absorb any
support bracket. Remove bracket. Torque - possible fluid spillage.
10 Nm. CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
7. Loosen bolts (x2) securing fuel pressure
regulator brackets. Torque - 10 Nm.
8. Remove bolts (x2) securing fuel pump to
cylinder head. Torque - 10 Nm.
FSM00851
12-61
ENGINE
Purge Valve
FRT No.: 12600200
Remove
1. Raise and support vehicle.
FSM00853
FSM00861
Installation
1. Installation procedure is reverse of removal
except for the following.
12-62
ENGINE
FSM00107
8 8
7 7
FSM00106
7
6. Release clips (x3) securing engine bay
harness to bumper armature and position
harness aside.
12-63
ENGINE
FSM00110
FSM00109
12-64
ENGINE
Remove
1. Open hood.
2
3
FSM00140
FSM00754
Installation
1. Installation procedure is reverse of removal
except for the following.
12-65
ENGINE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2. FSM00190
3. Isolate high voltage battery. Refer to FRT: 8. Remove screws (x4), release clips (x3)
16200100, page 16-6. securing central heatshield to subframe and
remove shield. Torque - 10 Nm.
4. Disconnect catalyst upstream oxygen sensor
harness connector. 9. Using a suitable block between generator
and exhaust. Position exhaust aside for
5. Apply suitable release agent to catalyst
access.
manifold nuts and studs.
FSM00862
FSM01006
10. Release harness clip from intake manifold
6. Remove nuts (x2) securing center muffler
support bracket stud. Illustration shows
flange to catalyst. Torque - 45 Nm.
engine removed for clarity.
7. Release exhaust flange.
11. Loosen nut securing manifold support
bracket to cylinder block. Torque 50 Nm.
12. Lower vehicle to convenient height.
13. Remove engine cover. Refer to FRT:
12301000, page 12-29.
14. Remove LH cross brace. Refer to FRT:
60500100, page 60-12.
12-66
ENGINE
FSM00726 FSM00748
15. Disconnect turbocharger boost pressure 18. Disconnect manifold absolute pressure
sensor connector and pipe. sensor connector.
16. Release clips (x2) and remove intercooler to
intake manifold charge hose/pipe.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
FSM00859
12-67
ENGINE
FSM00858
FSM00863
FSM00851
25. Remove fuel pressure regulator. Refer to 27. Release dipstick tube from crankcase. Raise
FRT: 12500600, page 12-58. dipstick tube approximately 30 mm for
access.
WARNING: Eye protection must be worn.
NOTE: Place suitable absorbent material
WARNING: Petrol/gasoline vapour is highly around the affected area to absorb any
flammable and in confined spaces is also possible fluid spillage.
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2 GAS, or CAUTION: Plug all open connections to
POWDER close at hand when handling or prevent ingress of moisture and dirt.
draining fuel. 28. Release clip securing engine harness to
intake manifold.
12-68
ENGINE
FSM00865 FSM00867
29. Remove bolt securing manifold support 33. Disconnect throttle body harness connector.
bracket to intake manifold. Torque - 25 Nm.
FSM00868
FSM00869
12-69
ENGINE
FSM00889
FSM00890
12-70
ENGINE
Remove
1. Open vehicle hood.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
3. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
4. Remove air cleaner assembly for access.
Refer to FRT: 12700200, page 12-63.
FSM00891
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
2. Fit new `O' ring seal to intake manifold.
FSM01010
NOTE: Apply a suitable lubricant to all 'O' ring
seals. 5. Remove clips (x3) securing bumper
absorption pad to body.
6. Remove bumper absorption pad.
FSM01014
12-71
ENGINE
FSM01015 FSM01016
9. Remove screw securing battery cooling low 14. Remove screws (x2) securing air baffle to
temperature coolant pump bracket. radiator bracket. Torque - 10 Nm.
10. Carefully reposition battery cooling low 15. Raise and support vehicle.
temperature coolant pump.
FSM01017
12-72
ENGINE
FSM00669
FSM00670
Installation
1. Installation procedure is reverse of removal
except for the following.
12-73
ENGINE
Muffler Assembly - LH
FRT No.: 12800100
Remove
1. Disconnect post catalyst oxygen sensor
harness connector.
2. Remove LH front wheel arch liner. Refer to
FRT: 78100100, page 78-2.
3. Apply suitable release agent to catalyst
manifold nuts and studs.
FSM00969
FSM00593
FSM00590
FSM00968
12-74
ENGINE
Remove
1. Disconnect post catalyst oxygen sensor
harness connector.
2. Apply suitable release agent to catalyst
manifold nuts and studs.
FSM00591
FSM01006
FSM00592
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
12-75
ENGINE
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
FSM01007
FSM01008
12-76
ENGINE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove turbocharger. Refer to FRT:
12800700, page 12-79. FSM00947
FSM00945
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
FSM00946
solvents in a well ventilated area.
4. Progressively loosen and remove nuts (x10) CAUTION: Replace all Nyloc nut(s).
securing exhaust manifold to cylinder head. 2. Fit new manifold gasket.
Discard nuts. Torque - 25 Nm.
12-77
ENGINE
2 9 Remove
5
3
7 4
FSM00949
FSM01009
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
2. Apply suitable anti-seize lubricant to oxygen
sensor thread.
12-78
ENGINE
Turbocharger
FRT No.: 12800700
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Drain engine coolant. Refer to FRT:
20010100, page 20-2. FSM00896
3. Remove front cross brace. Refer to FRT: 8. Release turbo air intake hose clip. Release
60500300, page 60-13. intake hose from turbo.
4. Remove exhaust catalyst. Refer to FRT: CAUTION: Plug all open connections to
12800900, page 12-82. prevent ingress of moisture and dirt.
FSM00895 FSM00897
5. Release clip securing turbo outlet flexible 9. Release clip and disconnect vacuum tube
hose to charge air pipe. from turbo. Position hose aside.
6. Remove bolts (x2) securing turbo outlet pipe 10. Disconnect boost pressure regulator
to turbo outlet flange. Torque - 25 Nm. connector. Position harness aside.
7. Remove turbo outlet elbow. Remove and
discard gasket.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
12-79
ENGINE
FSM00900
FSM00899
12-80
ENGINE
FSM00901 FSM00903
16. Remove nut securing turbo support bracket 22. Maneuver turbo clear of exhaust manifold
to turbo. Torque - 25 Nm. studs and remove.
17. Remove bolt securing turbo brace to cylinder
block. Torque - 50 Nm.
18. Remove turbo brace.
19. Release turbo oil return pipe from engine
block.
CAUTION: Remove and discard 'O' ring
seals.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage. FSM00904
FSM00902
12-81
ENGINE
Catalyst - Exhaust
FRT No.: 12800900
Remove
1. Remove LH front road wheel. Refer to FRT:
54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
FSM00905
2. Remove RH front road wheel. Refer to FRT:
24. Remove bolts (x2) securing oil return pipe to 54100501, page 54-2.
turbo. Remove pipe and discard gasket. 3. Isolate low voltage battery. Refer to FRT:
Torque - 10 Nm. 90010100, page 90-2.
CAUTION: Plug all open connections to 4. Isolate high voltage battery. Refer to FRT:
prevent ingress of moisture and dirt. 16200100, page 16-6.
FSM00883
12-82
ENGINE
FSM00884 FSM01006
8. Remove screw securing catalyst heatshield 14. Remove nuts (x2) securing center muffler
to upper chassis rail. Torque - 8 Nm. flange to catalyst. Torque - 45 Nm.
15. Release flange and remove exhaust pipe.
FSM00885
turbocharger flange. Torque - 50 Nm. 16. Remove screw securing catalyst heatshield
10. Raise vehicle to convenient height. to subframe. Torque - 8 Nm.
11. Remove RH muffler assembly. Removal 17. Remove catalyst heatshield.
procedure is similar to LH muffler assembly.
Refer to FRT: 12800100, page 12-74.
12. Disconnect catalyst downstream oxygen
sensor harness connector.
13. Apply suitable release agent to catalyst
manifold nuts and studs.
12-83
ENGINE
FSM00887
FSM00888
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
12-84
ELECTRIC DRIVE
Contents Page
16-1
ELECTRIC DRIVE
Generator
ELECTRIC DRIVE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
2. Remove engine and generator assembly.
Refer to FRT: 12100601, page 12-4.
3. Position subframe assembly at a suitable
working height.
FSM00634
FSM00633
FSM00635
16-2
ELECTRIC DRIVE
FSM00637
FSM00636
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
16-3
ELECTRIC DRIVE
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove high voltage battery. Refer to FRT:
16200200, page 16-7. FSM00632
FSM00631
FSM00716
4. Remove concealed nut securing bushing to
generator mounting bracket. Torque - 65 6. Remove bolt securing mounting bracket to
Nm. body. Torque - 125 Nm.
FSM00717
16-4
ELECTRIC DRIVE
16-5
ELECTRIC DRIVE
Remove
1. Disconnect 12V battery. Refer to FRT:
90010100, page 90-2.
2. Remove rear LH seat cushion. Refer to FRT:
86100400, page 86-3.
FSM00619
Installation
FSM00822
1. Installation procedure is reverse of removal.
3. Release latch pin from (MSD) latch. NOTE: Clean component mating faces, prior
WARNING: HIGH VOLTAGE battery contains to installation.
lethal voltage.
WARNING: Do not remove the Manual
Service Disconnect (MSD) if the vehicle is
switched on or running.
WARNING: Intentional disconnection of the
Manual Service Disconnect (MSD) under load
could potentially damage the battery pack
and cause injury to the person performing the
act.
4. Lift cover for access to (MSD) plug.
16-6
ELECTRIC DRIVE
Battery Assembly
CAUTION: Plug all open connections to 10. Disconnect generator HV plug from battery,
prevent ingress of moisture and dirt. release trunking and tie harness aside.
CAUTION: Take care not to damage
component(s).
16-7
ELECTRIC DRIVE
FSM00711 FSM00624
11. Remove nuts (x2) and bolt (x1) securing HV 16. Evenly and progressively loosen and remove
cable harness tray to battery. Torque - 3 Nm. bolts (x26) securing battery to body. Torque -
20 Nm.
NOTE: Note fitted position of components
before removal.
FSM00712
CAUTION: Take care not to damage 17. With assistance lower battery and remove
component(s). from vehicle.
13. Release lock ring and disconnect lower body WARNING: This component is extremely
harness bayonet connector. heavy, to avoid personal injury observe all
14. Check high voltage cables are clear for relevant safety precautions before removal.
access to battery.
Installation
15. Position tool FST1001to a suitable scissor lift
1. Installation procedure is reverse of removal
to support weight of high voltage battery.
except for the following.
WARNING: To avoid serious injury, use
NOTE: Clean component mating faces, prior
appropriate equipment to carry out this
to installation.
operation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
16-8
ELECTRIC DRIVE
FSM00714
16-9
ELECTRIC DRIVE
Charging Port
FRT No.: 16250100
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
3. Remove LH rear wheel arch liner. Refer to
FRT: 78100300, page 78-3.
FSM00715
16-10
ELECTRIC DRIVE
Remove
1. Raise and support vehicle.
2. Open vehicle hood.
3. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
4. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
FSM00776
5. Remove RH cross brace. Removal procedure
is similar to LH cross brace. Refer to FRT:
7. Remove nuts (x4) securing plug to charging 60500100, page 60-12.
port. Torque - 6 Nm.
FSM00880
FSM00777
6. Depress latches and disconnect ECM
8. Remove socket and harness from charging harness connectors (x2), remove nut
port. securing ECM harness connector and
position harness aside.
Installation
1. Installation procedure is reverse of removal.
NOTE: Clean component mating faces, prior
to installation.
16-11
ELECTRIC DRIVE
FSM00928 FSM00930
7. Disconnect harness connector from AC/DC 11. Release clip and disconnect AC/DC inverter
inverter, remove bolt securing ECM harness coolant hose.
connector and position harness aside. 12. Release clips (x2) on high voltage
8. Drain and recover low temperature coolant. connectors.
Refer to FRT: 20010900, page 20-4.
ıııı
FSM00881
9. Release clip and disconnect AC/DC inverter 14. Release clip securing sensor connector to
coolant hose. camshaft cover.
NOTE: Position a suitable container to
contain fluid spillage.
10. Release clips (x2), disconnect and remove
coolant bridging hose.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
16-12
ELECTRIC DRIVE
FSM00882 FSM00932
15. Remove oxygen sensor from catalyst. Torque 20. Remove screws (x2) and remove water pump
- 30 Nm. bracket. Position water pump aside.
CAUTION: Plug all open connections to 21. Lower vehicle.
prevent ingress of moisture and dirt.
16. Release hood switch and position aside.
17. Remove RH front wheel arch liner. Removal
procedure is similar to LH front wheel arch
liner. Refer to FRT: 78100100, page 78-2.
FSM00933
18. Remove bolt securing AC/DC inverter to 25. Remove all brackets, supports and grounds
bracket. mounted to brace.
19. Remove bolts (x2) securing inverter bracket 26. Remove dash wall brace.
to dash wall.
27. Remove inverter bracket.
28. With assistance disconnect inverter from
high voltage connectors (x2) and remove
from vehicle.
16-13
ELECTRIC DRIVE
FSM00640
16-14
ELECTRIC DRIVE
FSM00641 FSM00643
8. Disconnect high voltage connections (x2) 13. Remove inverter from bracket.
from inverter.
9. Disconnect low voltage harness connector
from inverter.
FSM00644
16-15
ELECTRIC DRIVE
DC/DC Converter
FRT No.: 16400400
Remove
1. Raise and support vehicle.
2. Open vehicle hood.
3. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
4. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
5. Remove suspension turret cross brace. Refer FSM00190
to FRT: 60500300, page 60-13.
11. Remove screws (x4) securing central
6. Remove LH suspension turret cross brace.
heatshield to subframe and remove shield.
Refer to FRT: 60500100, page 60-12.
Torque - 10 Nm.
7. Raise vehicle.
8. Drain and recover low temperature coolant.
Refer to FRT: 20010900, page 20-4.
9. Remove exhaust system complete. Refer to
FRT: 12800301, page 12-75.
FSM00784
FSM00148
16-16
ELECTRIC DRIVE
FSM00785
FSM00680 FSM00786
17. Release clip and disconnect coolant hose 24. Release clip and tie heater hoses aside for
from DC/DC converter. access.
NOTE: Place suitable absorbent material 25. Disconnect harness connectors (x2) from
around the affected area to absorb any DC/DC converter.
possible fluid spillage.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
18. Remove bolts (x2) securing ground cables to
DC/DC converter. Torque - 10 Nm.
16-17
ELECTRIC DRIVE
FSM00787 FSM00789
26. Working through aperture created by removal 28. Carefully raise DC/DC converter and
of charge air pipe. Remove screws (x2) mounting bracket until the lower harness
securing DC/DC mounting bracket to connection can be accessed.
suspension turret. Torque - 10 Nm. Note: CAUTION: Take care not to damage
Heater hoses have been removed from component(s).
graphic for clarity.
29. Disconnect remaining harness connector.
CAUTION: Replace all patch bolt(s).
30. Remove DC/DC converter from vehicle.
31. Remove bolts (x2) and remove bracket from
converter. Torque - 10 Nm.
CAUTION: Replace all patch bolt(s).
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
FSM00788
16-18
COOLING SYSTEM
Contents Page
20-1
COOLING SYSTEM
Refill
FSM00093
Bleed
1. Install drain plug to radiator.
NOTE: Clean component mating faces.
2. Using suitable equipment, fill to upper level
mark with coolant and evacuate system.
FSM00092
CAUTION: To prevent damage, do not allow
2. Remove engine and cabin coolant reservoir electric pumps to run until sufficient coolant
pressure cap. has entered system to facilitate bleeding.
NOTE: Place suitable absorbent material 3. Check and top up coolant reservoir.
around the affected area to absorb any 4. Install reservoir cap.
possible fluid spillage.
NOTE: Clean component mating faces.
3. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
4. Position container to collect coolant.
20-2
COOLING SYSTEM
FSM00709
Bleed
1. Ensure hoses are connected.
2. Lower vehicle.
3. Open hood.
20-3
COOLING SYSTEM
FSM00740
Bleed
1. Ensure hoses are connected.
2. Lower vehicle.
3. Open hood.
20-4
COOLING SYSTEM
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Drain Engine and Cabin coolant. Refer to
FRT: 20010100, page 20-2. FSM00685
FSM00686
FSM00684
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
2. Refill and bleed Engine and Cabin coolant.
20-5
COOLING SYSTEM
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Open vehicle hood. FSM00928
3. Isolate low voltage battery. Refer to FRT: 7. Disconnect harness connector from AC/DC
90010100, page 90-2. inverter, remove bolt securing ECM harness
connector and position harness aside.
4. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6. 8. Drain low temperature coolant. Refer to FRT:
20010900, page 20-4.
5. Remove RH cross brace. Removal procedure
is similar to LH cross brace. Refer to FRT:
60500100, page 60-12.
FSM00681
20-6
COOLING SYSTEM
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Isolate low voltage battery. Refer to FRT:
FSM00682
90010100, page 90-2.
10. Disconnect coolant pump harness 3. Isolate high voltage battery. Refer to FRT:
connector. 16200100, page 16-6.
11. Release clip and disconnect coolant pump 4. Drain low temperature coolant. Refer to FRT:
outlet hose. 20010900, page 20-4.
5. Remove rear diffuser closing panel. Refer to
FRT: 70100300, page 70-3.
FSM00683
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
2. Refill and bleed low temperature coolant.
20-7
COOLING SYSTEM
FSM00664 FSM00665
7. Release clips (x4) and disconnect coolant 9. Remove both pumps from mounting bracket.
hoses from pump. NOTE: Note fitted position of components
NOTE: Position a suitable container to before removal.
contain fluid spillage.
Installation
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt. 1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
2. Ensure pump ridges are correctly installed to
mounting bracket.
3. Refill and bleed low temperature coolant.
FSM00206
20-8
COOLING SYSTEM
Remove
1. Raise and support vehicle.
ı
FSM00783
20-9
COOLING SYSTEM
Radiator Pack
FRT No.: 20200100
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Drain engine and cabin coolant. Refer to FRT:
20010100, page 20-2. FSM00690
3. Remove cooling fan assembly. Refer to FRT: 10. Release clip and disconnect radiator bottom
20200200, page 20-11. hose.
4. Open vehicle hood to service position. NOTE: Place suitable absorbent material
around the affected area to absorb any
5. Remove intercooler assembly. Refer to FRT:
possible fluid spillage.
12704000, page 12-71.
CAUTION: Plug all open connections to
6. Remove cooling fan assembly. Refer to FRT:
prevent ingress of moisture and dirt.
20200200, page 20-11.
11. Position a suitable height adjustable support
beneath the radiator.
12. Check all mounts, pipes hoses are clear or
radiator.
13. Protect radiator and condenser elements
with cardboard to prevent damage during
removal.
FSM00688
20-10
COOLING SYSTEM
FSM00130
20-11
COOLING SYSTEM
FSM01019 FSM01021
8. Remove screws (x4) securing upper radiator 14. Remove screw securing A/C pipe mount to
mounting bracket to chassis. Torque - 6 Nm. radiator and remove mount. Torque - 6 Nm.
9. Release radiator top mounting bracket from 15. Release condenser from radiator lower
radiator, reposition and remove from vehicle. mounts.
10. Carefully release air baffle from condenser,
reposition and remove from vehicle.
CAUTION: Take care not to damage
component(s).
FSM01022
FSM01020
20-12
COOLING SYSTEM
FSM01023 FSM01025
17. Remove screws (x2) securing skid frame rail 23. Carefully lower fan and cowl assembly past
to chassis mounting bracket. RH illustrated. radiator and bottom radiator hose.
Torque - 25 Nm. CAUTION: Take care not to damage
18. Release low temp radiator mounts (x4) and component(s).
radiator assembly mounts (x2) from skid
frame rail.
19. Remove skid frame rail from vehicle.
20. Carefully reposition radiator assembly away
from engine to improve access and tie aside.
FSM00564
Installation
1. Installation procedure is reverse of removal.
FSM01024
20-13
COOLING SYSTEM
Remove Remove
1. Open hood. 1. Raise and support vehicle.
2. Isolate low voltage battery. WARNING: Make sure the vehicle is correctly
3. Remove Cooling fan assembly. Refer to FRT: supported before commencing work.
20200200, page 20-11. WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
5 2. Open vehicle hood to service position. Note:
4 Illustration has hood removed for clarity.
5
6
FSM00565
6. Disconnect cooling fan module harness 3. Remove screws (x2) securing LH low
connector. temperature radiator upper mounting bracket
to chassis. Torque - 10 Nm.
7. Remove cooling fan speed module.
4. Remove front bumper assembly for access.
Installation Refer to FRT: 70202101, page 70-10.
20-14
COOLING SYSTEM
FSM00696 FSM00698
7. Release clip and disconnect LT top coolant 11. Remove screws (x4) securing intake duct to
hose. radiator. Torque - 3 Nm.
CAUTION: Plug all open connections to 12. Remove duct.
prevent ingress of moisture and dirt.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
8 to installation.
2. Refill and bleed battery low temperature
coolant.
9
FSM00697
20-15
COOLING SYSTEM
Cooling Fan Assembly - Low Temp - LH 2. Clear radiator debris prior to installing cooling
fan assembly.
FRT No.: 20200600
Remove
1. Raise and support vehicle.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove LH front wheel arch liner. Refer to
FRT: 78100100, page 78-2.
FSM00560
FSM00561
Installation
1. Installation procedure is reverse of removal
except for the following.
20-16
COOLING SYSTEM
Remove
1. Open hood.
FSM00757
FSM00755
FSM00758
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
2. Fill reservoir to coolant upper level mark.
FSM00756
3. Remove clamps from coolant hoses.
20-17
COOLING SYSTEM
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2. FSM00699
3. Isolate high voltage battery. Refer to FRT: 9. Release clips and disconnect coolant hoses
16200100, page 16-6. from PTC heater.
4. Remove engine cover. Refer to FRT: NOTE: Place suitable absorbent material
12301000, page 12-29. around the affected area to absorb any
possible fluid spillage.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
10. Remove screws (x4) securing PTC heater to
mounting bracket.
걠ı
FSM00759
20-18
COOLING SYSTEM
2. Prime PTC heater with coolant prior to Chiller with TXV - Low Temp Battery
connecting final hose. Cooling
3. Check and top up coolant reservoir
FRT No.: 20403000
Remove
1. Open vehicle hood.
2. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
3. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
4. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
5. Recover Refrigerant from A/C system. Refer
to FRT: 30010100, page 30-2.
6. Drain battery low temperature coolant. Refer
to FRT: 20010500, page 20-3.
7. Remove front bumper cover for access. Refer
to FRT: 70202101, page 70-10.
8. Lower vehicle.
FSM00671
20-19
COOLING SYSTEM
FSM00672 FSM00674
10. Remove nut and collect A/C pipe retainer 13. Remove chiller assembly.
plate. Torque - 10 Nm. CAUTION: Take care not to damage
11. Disconnect A/C pipes from TXV block and component(s).
discard 'O' ring seals.
Installation
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt. 1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
NOTE: Lubricate new 'O' ring seals with clean
refrigerant oil.
2. Refill and bleed battery low temperature
coolant.
FSM00673
20-20
HVAC SYSTEM
Contents Page
30-1
HVAC SYSTEM
Refrigerant - Recovery and Recharge 11. Once charging is complete, disconnect high
HVAC SYSTEM
30-2
HVAC SYSTEM
Remove
1. Remove instrument panel. Refer to FRT:
90300100, page 90-13.
2. Remove topper panel. Refer to FRT:
80200200, page 80-8.
FSM00340
FSM00338
FSM00341
FSM00339
30-3
HVAC SYSTEM
Installation
1. Installation procedure is reverse of removal.
FSM00342
FSM00343
FSM00344
30-4
HVAC SYSTEM
Remove Remove
1. Remove HEVAC assembly. Refer to FRT: 1. Remove HEVAC assembly. Refer to FRT:
30100100, page 30-3. 30100100, page 30-3.
FSM00359 FSM00354
2. Remove screw securing drivers lower air duct 2. Disconnect actuator harness connector.
to HVAC assembly. 3. Remove screws (x2) securing actuator to
3. Remove driver's lower air duct. casing.
FSM00350 FSM00355
Installation
1. Installation procedure is reverse of removal.
30-5
HVAC SYSTEM
Remove
1. Remove instrument panel. Refer to FRT:
90300100, page 90-13.
2. Remove topper panel. Refer to FRT:
80200200, page 80-8.
FSM00340
FSM00338
FSM00341
FSM00339
30-6
HVAC SYSTEM
Heater Core
FRT No.: 30102000
Remove
1. Remove HEVAC assembly. Refer to FRT:
30100100, page 30-3.
FSM00342
12 FSM00345
13
13
FSM00349
Installation
1. Installation procedure is reverse of removal
except for the following.
2. Clean interior of HVAC housing.
30-7
HVAC SYSTEM
Blower Motor
FRT No.: 30200100
Remove
1. Remove HEVAC assembly. Refer to FRT:
30100100, page 30-3.
FSM00358
Installation
1. Installation procedure is reverse of removal
except for the following.
FSM00356
2. Remove any debris from blower motor
housing.
2. Remove screws (x2) securing passenger
lower air duct to HVAC assembly.
3. Remove passenger lower duct from HVAC
assembly.
FSM00357
30-8
HVAC SYSTEM
Compressor
FRT No.: 30300100
Remove
1. Raise and support vehicle.
2. Open hood.
3. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
4. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
5. Drain engine and cabin coolant. Refer to FRT: FSM00827
20010100, page 20-2.
10. Disconnect high voltage A/C compressor
6. Remove front cross brace. Refer to FRT:
harness connector.
60500300, page 60-13.
11. Disconnect high voltage PTC harness
7. Recover refrigerant from A/C system. Refer
connector. Tie PTC harness aside.
to FRT: 30010100, page 30-2.
FSM00823
FSM00726
12. Release clip securing heater feed pipe to PTC
8. Disconnect turbocharger boost pressure
fluid heater. Release pipe.
sensor connector and pipe. Move connector
and harness aside. NOTE: Place suitable absorbent material
around the affected area to absorb any
9. Release clips (x2) and remove intercooler to
possible fluid spillage.
intake manifold charge hose/pipe.
CAUTION: Plug all open connections to
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
prevent ingress of moisture and dirt.
13. Release clip securing heater return hose to
inline connector. Release hose from
connector.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
30-9
HVAC SYSTEM
FSM00825
FSM00824
18. Disconnect front knock sensor connector.
15. Release clip securing coolant top hose.
Release hose and tie aside
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
FSM00826
FSM00659
30-10
HVAC SYSTEM
FSM00828 FSM01026
21. Release clip securing charge air pipe elbow 24. Remove bolt securing brake hose mount to
and remove elbow. chassis and carefully reposition hose and
CAUTION: Plug all open connections to pipe for access to A/C compressor lower
prevent ingress of moisture and dirt. bolts. Torque - 10 Nm.
CAUTION: Take care not to damage
component(s).
25. Turn LH front upright to full left hand lock for
access.
FSM00661
CAUTION: Plug all open connections to 26. Through aperture between upper and lower
prevent ingress of moisture and dirt. chassis rails, carefully reposition coolant
23. Remove LH front wheel arch liner. Refer to pipes to improve access to lower bolts on A/
FRT: 78100100, page 78-2. C compressor. Note: spring and shocker
removed for clarity.
27. Through aperture between upper and lower
chassis rails, remove lower bolts (x2)
securing A/C compressor to mounting
bracket. Torque - 45 Nm.
28. Lower vehicle.
30-11
HVAC SYSTEM
Condenser
FRT No.: 30400100
Remove
1. Raise and support vehicle.
2. Open hood.
3. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
4. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6.
FSM00663
5. Recover refrigerant from A/C system. Refer
to FRT: 30010100, page 30-2.
29. Remove upper bolt securing A/C compressor
6. Remove intercooler. Refer to FRT:
to mounting bracket. Torque - 45 Nm.
12704000, page 12-71.
ıııı
FSM00829
FSM01021
30. Release A/C compressor and remove from
7. Remove screw securing A/C pipe mount to
vehicle.
radiator and remove mount. Torque - 6 Nm.
Installation
1. Installation procedure is reverse of removal
except for the following.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all patch bolt(s).
30-12
HVAC SYSTEM
FSM00691 FSM01020
8. Remove nuts (x2) securing high and low 15. Remove bolts (x2) securing cooling fan,
pressure A/C lines to condenser. Torque - 10 radiator and condenser assembly. Torque - 4
Nm. Nm.
9. Disconnect high and low pressure A/C lines 16. Release condenser from radiator lower
from condenser. mounts.
10. Remove and discard 'O' ring seals. 17. Protect radiator and condenser elements
CAUTION: Plug all open connections to with cardboard to prevent damage during
prevent ingress of moisture and dirt. removal.
FSM01028
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
30-13
HVAC SYSTEM
FSM00356
FSM00359
30-14
HVAC SYSTEM
Remove
1. Ensure ignition is off.
2. Recover refrigerant from A/C system. Refer
to FRT: 30010100, page 30-2.
3. Remove wiper motor assembly. Refer to
FRT: 90900100, page 90-27.
FSM00345
FSM00257
Installation
1. Installation procedure is reverse of removal
except for the following.
2. Clean HVAC housing interior thoroughly.
WARNING: Only use cleaning agents and
solvents in a well ventilated area. FSM00258
30-15
HVAC SYSTEM
Remove
1. Recover refrigerant from A/C system. Refer
to FRT: 30010100, page 30-2.
FSM00259
FSM00265
FSM00260
30-16
HVAC SYSTEM
Remove
1. Remove HEVAC assembly. Refer to FRT:
30100100, page 30-3.
FSM00365
Installation
1. Installation procedure is reverse of removal.
FSM00359
FSM00364
30-17
HVAC SYSTEM
Remove Remove
FSM00233 FSM00798
1. Release clips (x2) securing pollen filter cover 1. Carefully release clips (x3) and remove side
to plenum cover and remove filter cover. screen defroster vent from dash panel.
CAUTION: Take care not to damage
component(s).
FSM00234
Installation
2. Using a suitable tool, carefully release clips
1. Installation procedure is reverse of removal (x3) pull vent evenly and progressively to
except for the following. release from dash.
2. Remove any debris from pollen filter housing. CAUTION: Exercise caution during removal of
the face level vents to avoid damage to the
vanes.
30-18
HVAC SYSTEM
Remove
FSM00800
Installation
1. Installation procedure is reverse of removal FSM00801
except for the following.
1. Using a suitable tool, carefully release clips
2. Remove any debris from vent duct. (x3) pull vent evenly and progressively to
release from dash.
CAUTION: Exercise caution during removal of
the face level vents to avoid damage to the
vanes.
FSM00802
Installation
1. Installation procedure is reverse of removal
except for the following.
2. Remove any debris from vent duct.
30-19
HVAC SYSTEM
30-20
FINAL DRIVE
Contents Page
42-1
FINAL DRIVE
Differential Assembly
FINAL DRIVE
Remove
1. Remove rear subframe. Refer to FRT:
60200600, page 60-9.
2. Position differential and traction motor
assembly on a suitable support.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
FSM00654
FSM00655
42-2
FINAL DRIVE
FSM00656
42-3
FINAL DRIVE
Differential - Oil - Drain and Refill 9. Fit new sealing washer and replace drain
plug.
FRT No.: 42100300
NOTE: Clean component mating faces, prior
to installation.
Drain & Refill
10. Add oil until a thin bead flows from differential
1. Remove RH rear road wheel. Refer to FRT:
casing filler hole.
54100501, page 54-2.
11. Fit new sealing washer and replace level/filler
plug.
NOTE: Clean component mating faces, prior
to installation.
FSM00536
FSM00537
42-4
FINAL DRIVE
Remove Remove
1. Remove differential assembly for access. 1. Remove LH half shaft assembly. Refer to
Refer to FRT: 42100100, page 42-2. FRT: 42200100, page 42-6.
2. Position differential at a safe working height. 2. Protect half shaft output flange oil seal face
and spline to prevent damage.
3. Using a suitable tool remove output shaft oil
seal from differential casing.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces.
2. Check differential casing oil seal register for
burrs and damage.
FSM00657
3. Using a suitable tool, install differential casing
3. Using a suitable tool remove input oil seal.
output shaft oil seal.
CAUTION: Take care not to damage
4. Replace output shaft snap-ring.
component(s).
5. Install LH half shaft assembly.
4. Repeat previous steps and remove additional
input oil seal.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
2. Clean seal registers and install new oil seals
using a suitable tool.
42-5
FINAL DRIVE
Remove
FSM00532
FSM00014
42-6
FINAL DRIVE
FSM00065 FSM00534
12. Remove nut and bolt securing rear toe link to 17. Carefully withdraw half shaft assembly from
upright. Torque - 50 Nm. vehicle.
CAUTION: Replace all Nyloc nut(s).
FSM00535
42-7
FINAL DRIVE
Gaiter - Half Shaft - Inner - LH 2. Clean half shaft, inner joint and gaiter. If
refitting original joint, remove all old grease
FRT No.: 42200400 from joint using a solvent based cleaner.
3. Install new gaiter to inner joint flange and
Remove
drive fully home.
1. Remove half shaft assembly. Refer to FRT:
4. Apply recommended grease to joint and
42200100, page 42-6.
gaiter.
2. Position half shaft in vice.
5. Position gaiter and secure with new clip.
FSM00539
FSM00538
Installation
1. Installation procedure is reverse of removal
except for the following.
42-8
FINAL DRIVE
Remove Remove
1. Remove LH CV joint assembly. Refer to FRT: 1. Remove half shaft assembly. Refer to FRT:
42201500, page 42-9. 42200100, page 42-6.
2. Position half shaft in vice.
FSM00543
FSM00541
42-9
FINAL DRIVE
Remove
1. Remove LH rear half shaft inner gaiter. Refer
to FRT: 42200400, page 42-8.
Installation
1. Installation procedure is reverse of removal.
FSM00542
Installation
1. Installation procedure is reverse of removal
except for the following.
2. Clean half shaft, CV joint and gaiter. If refitting
a CV joint, remove all old grease from joint
using a solvent based cleaner.
3. Install new snap-ring to half shaft.
4. Inspect gaiter for damage and renew if
necessary.
5. Apply 120 grams of recommended grease to
CV joint and gaiter. Approximately 50 grams
to CV joint and 70 grams to the gaiter.
6. Position gaiter and secure with new clips.
42-10
STEERING
Contents Page
44-1
STEERING
Remove
1. Remove driver front airbag. Refer to FRT:
84200100, page 84-4.
FSM00954
FSM00955
44-2
STEERING
Column - Complete
FRT No.: 44200100
Remove
1. Ensure front road wheels are in straight
ahead position.
2. Power column fully upwards and forwards.
3. Remove steering column upper cowl. Refer
to FRT: 82200100, page 82-4.
FSM00956
Installation
1. Installation procedure is reverse of removal.
FSM00974
FSM00975
44-3
STEERING
FSM00976 FSM00167
7. Release clips (x2) securing wash / wipe 11. Release clips (x2) securing footwell lamp
column switch to steering column boss. panel to dash, release panel from hooks and
position aside.
FSM00977
10. Remove clock spring. Refer to FRT: 13. Mark fitted position of steering column to
90454000, page 90-16. lower column.remove nut and bolt securing
lower column to steering column. Torque - 55
Nm.
44-4
STEERING
FSM00170 FSM00979
14. Remove nut and bolt securing lower column 16. With assistance, remove bolts (x2) securing
to steering column. Torque - 55 Nm. steering column lower fixings to dash and
remove column. Torque - 27 Nm.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Ensure the steering column locking
tool is in position to ensure correct installation
of the clock spring.
2. Fit but do not fully tighten bolts (x4) securing
steering column to dash.
3. Working in a diagonal sequence, evenly and
progressively tighten steering column bolts.
FSM00980
44-5
STEERING
Column - Lower
FRT No.: 44200300
Remove
FSM01006
FSM01012
44-6
STEERING
Steering Rack
FRT No.: 44300100
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
FSM00174
FSM00760
FSM00146
Installation
1. Installation procedure is reverse of removal.
CAUTION: Replace all Nyloc nut(s).
CAUTION: Replace all patch bolt(s). FSM00247
44-7
STEERING
FSM00146 FSM00187
6. Turn steering column for spanner access and 9. Remove nut and bolt (x2) securing steering
remove bolt securing intermediate shaft to rack to subframe. Torque - 70 Nm.
rack. Torque - 28 Nm.
NOTE: Note fitted position of components
before removal.
7. Disconnect intermediate shaft and position
aside.
FSM00189
44-8
STEERING
Remove
1. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
2. Open hood to service position.
FSM00248
44-9
STEERING
ıııı
FSM00738 FSM00179
7. Release clips (x2) securing headlamp and 9. Remove screws (x3) securing fuse box
dash harness to power steering pump bracket to chassis. Remove bracket. Torque
bracket studs. Move harness aside. - 25 Nm.
10
11
12
FSM00181 FSM00178
8. Release clips (x3) securing fuse box to 10. Release clip securing return hose to power
mounting and position aside for access. steering pump housing. Release hose from
housing. Remove clip.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
11. Remove bolt and disconnect high pressure
hose from power steering pump. Remove
and discard 'O' ring seal. Torque - 20 Nm.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
44-10
STEERING
FSM00183
FSM00180
FSM00184
Installation
1. Installation procedure is reverse of removal
FSM00182 except for the following.
14. Remove bolts (x4) securing bracket to NOTE: Clean component mating faces, prior
chassis. Torque - 25 Nm. to installation.
15. Maneuver bracket and pump assembly from WARNING: Only use cleaning agents and
vehicle. solvents in a well ventilated area.
2. Refill and bleed power steering system. Refer
to FRT: 44401000, page 44-12.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
44-11
STEERING
Power Steering - Refill and Bleed Power Steering - Drain and Replenish
FRT No.: 44401000 FRT No.: 44401100
Bleed Drain
1. Clean reservoir around filler cap. 1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
2. Remove engine cover. Refer to FRT:
12301000, page 12-29.
ıııı
ıııı
FSM00760
9. Check power steering fluid, if aerated, wait CAUTION: Plug all open connections to
until fluid is free from bubbles then top-up prevent ingress of moisture and dirt.
reservoir to max level mark. 7. Remove and discard 'O' ring seals.
10. Fit reservoir filler cap.
Replenish
1. Installation procedure is reverse of removal
except for the following.
CAUTION: Replace all Nyloc nut(s).
44-12
STEERING
44-13
STEERING
44-14
SUSPENSION
Contents Page
46-1
SUSPENSION
4. Place steering turntables under front wheels 8. Check camber angle of rear suspension and
and slip plates under rear wheels if required. adjust as required.
5. Fit four wheel alignment equipment to vehicle 9. Fit steering wheel holding tool if required.
and align for use.
6. Fit brake pedal holding tool if required.
FSM00963
46-2
SUSPENSION
Remove
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
FSM00964 WARNING: Make sure the vehicle is correctly
supported before commencing work.
11. Check rear wheel alignment and evenly
adjust as required. 2. Open hood.
12. Finally recheck all alignment is within
tolerance.
13. Remove steering wheel and brake pedal
holding tools.
14. Remove four wheel alignment equipment,
turntables and slip plates.
15. Road test vehicle.
FSM00020
46-3
SUSPENSION
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
FSM00025
FSM00027
46-4
SUSPENSION
Remove
1. Remove spring and shock absorber
assembly. Refer to FRT: 46200100, page
46-3.
2. Assemble coil spring compressor and secure FSM00030
in a vice.
6. Remove gaiter from shock absorber rod.
3. Locate spring and shock absorber assembly
to spring compressor. Tighten lead screw to 7. Remove shock absorber bump stop.
compress spring.
FSM00031
46-5
SUSPENSION
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work. FSM00135
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
CAUTION: Replace all patch bolt(s).
FSM00134
46-6
SUSPENSION
Remove
1. Remove spring and shock absorber
assembly. Refer to FRT: 46200900, page
46-6.
2. Assemble coil spring compressor and secure FSM00030
in a vice.
6. Remove gaiter from shock absorber rod.
3. Locate spring and shock absorber assembly
to spring compressor. Tighten lead screw to 7. Remove shock absorber bump stop.
compress spring.
FSM00031
46-7
SUSPENSION
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
2. Remove LH muffler assembly. Refer to FRT: FSM00037
12800100, page 12-74. 6. Remove nut securing sway bar link to arm
and release sway bar link. Torque - 90 Nm.
CAUTION: Use two wrenches to prevent
damage.
7. Remove nuts (x2) and bolts (x2) securing
shock absorber to arm. Torque - 25 Nm.
8. Remove nut securing lower arm ball joint to
upright. Torque - 135 Nm.
9. Tie upright to shock absorber and spring
assembly and support weight of
components.
10. Using a suitable tool, release arm ball joint
FSM01012 from upright.
3. Remove screws (x3) securing lower 11. Support lower arm.
suspension arm bush heatshield.
4. Release clips (x2) and remove heatshield.
5. Mark fitted position of lower arm camber
adjustment cams, prior to removal, to aid
installation.
FSM00039
46-8
SUSPENSION
FSM00036
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
46-9
SUSPENSION
FSM00054
Installation
1. Installation procedure is reverse of removal
except for the following.
46-10
SUSPENSION
FSM00057
Installation
1. Installation procedure reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
46-11
SUSPENSION
CAUTION: Only tighten suspension nuts and Tie Rod End - Front - LH
bolts when the suspension is in the ride
height position. FRT No.: 46400100
CAUTION: Replace all Nyloc nut(s).
CAUTION: Replace all patch bolt(s). WARNING: To avoid serious injury, use
appropriate equipment to carry out this
2. Align marks on cam washer to upper operation.
wishbone and upright fixing.
3. Carry out four wheel alignment check. Refer Remove
to FRT: 46010100, page 46-2. 1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
4
FSM00007
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
46-12
SUSPENSION
2. Carry out four wheel alignment check. Refer Toe Link - Rear - LH
to FRT: 46010100, page 46-2.
FRT No.: 46400400
Remove
1. Remove rear wheel arch liner. Refer to FRT:
78100300, page 78-3.
FSM00058
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
2. Carry out four wheel alignment check. Refer
to FRT: 46010100, page 46-2.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
46-13
SUSPENSION
Link - Sway Bar - Front - LH CAUTION: Only tighten suspension nuts and
bolts when the suspension is in the ride
FRT No.: 46500100 height position.
Remove
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
2. Position steering on LH lock for access.
FSM00032
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
46-14
SUSPENSION
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
FSM00130
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
FSM00133
solvents in a well ventilated area.
2. Remove nut and disconnect sway bar link CAUTION: Replace all Nyloc nut(s).
from sway bar. Torque - 90 Nm. CAUTION: Only tighten suspension nuts and
CAUTION: Use two wrenches to prevent bolts when the suspension is in the ride
damage. height position.
46-15
SUSPENSION
Link - Sway Bar - Rear - LH CAUTION: Only tighten suspension nuts and
bolts when the suspension is in the ride
FRT No.: 46500600 height position.
Remove
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
FSM00044
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
46-16
SUSPENSION
Remove
1. Isolate low voltage battery. Refer to FRT:
90010100, page 90-2.
2. Isolate high voltage battery. Refer to FRT:
16200100, page 16-6. FSM00138
3. Remove rear diffuser closing panel. Refer to 6. Remove bolt securing sway bar link to
FRT: 70100300, page 70-3. subframe. Torque - 80 Nm.
7. Repeat the above step on opposite side of
vehicle.
FSM00137
CAUTION: Use two wrenches to prevent 8. Carefully remove rear sway bar assembly.
damage.
5. Repeat the above step on opposite side of Installation
vehicle. 1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
CAUTION: Replace all patch bolt(s).
CAUTION: Only tighten suspension nuts and
bolts when the suspension is in the ride
height position.
46-17
SUSPENSION
Hub - Front - LH
Remove
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
supported before commencing work. FSM00001
2. Remove brake rotor. Refer to FRT: 5. Remove bolts (x4) securing hub to upright.
50300100, page 50-8. Torque - 140 Nm.
6. Remove front hub.
7. Collect rotor shield.
4 Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
46-18
SUSPENSION
Remove
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
supported before commencing work. FSM00762
2. Remove hub. Refer to FRT: 46600100, page 5. Remove nut securing upper arm to upright.
46-18. Torque - 90 Nm.
6. Support upper arm to prevent damage.
7. Using a suitable tool, release upper arm ball
joint from upright.
8. Remove nut securing lower arm to upright.
Torque - 150 Nm.
9. Using a suitable tool, release lower arm ball
joint from upright.
10. Remove front upright.
Installation
1. Installation procedure is reverse of removal
FSM00008 except for the following.
3. Remove nut securing tie rod end to upright. NOTE: Clean component mating faces, prior
Torque - 135 Nm. to installation.
4. Using a suitable tool, release tie rod end ball WARNING: Only use cleaning agents and
joint from upright. solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
CAUTION: Only tighten suspension nuts and
bolts when the suspension is in the ride
height position.
2. Carry out four wheel alignment check. Refer
to FRT: 46010100, page 46-2.
46-19
SUSPENSION
WARNING: To avoid serious injury, use WARNING: To avoid serious injury, use
appropriate equipment to carry out this appropriate equipment to carry out this
operation. operation.
Remove Remove
1. Raise and support vehicle. 1. Remove road wheel. Refer to FRT:
WARNING: Make sure the vehicle is correctly 54100501, page 54-2.
supported before commencing work. 2. Remove and discard half shaft nut and
2. Remove upright. Refer to FRT: 46600700, locking washer.
page 46-20. 3. Tether half shaft to body to prevent
movement during this procedure.
4. Release park brake if applied.
5. Remove brake rotor. Refer to FRT:
50300600, page 50-10.
6. Loosen park brake adjuster nut fully.
FSM00068
Installation FSM00062
46-20
SUSPENSION
FSM00064
FSM00065
FSM00069
46-21
SUSPENSION
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
CAUTION: Replace all patch bolt(s).
CAUTION: Only tighten suspension nuts and
bolts when the suspension is in the ride
height position.
2. Align marks on cam washer to upper
wishbone and upright fixing.
3. Apply anti-seize compound to half shaft
outboard splines.
4. Install new half shaft nut and locking washer.
Torque - 215 Nm.
5. Carry out four wheel alignment check. Refer
to FRT: 46010100, page 46-2.
46-22
BRAKES
Contents Page
50-1
BRAKES
Bleed
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
2. Repeat above step and remove remaining
road wheels (x3). FSM00023
9 15
FSM00022
recommended brake fluid. 10. Install brake bleed container to inboard bleed
6. Fit pressure bleeder adaptor to reservoir nipple.
ensuring a tight seal. NOTE: Place suitable absorbent material
7. Install pressure bleeder to reservoir adaptor around the affected area to absorb any
and fill with sufficient brake fluid to replace all possible fluid spillage.
fluid used. 11. Loosen bleed nipple a ¼ turn
counterclockwise.
12. Tighten bleed nipple once a flow of clean,
air-free fluid is purged into container.
13. Remove brake bleed container.
50-2
BRAKES
50-3
BRAKES
Master Cylinder
FRT No.: 50100200
Remove
1. Open hood.
2. Remove brake fluid reservoir. Refer to FRT:
50100100, page 50-3.
FSM00042
3
7. Release connections (x3) to master cylinder.
8. Remove reservoir.
9. Remove seals (x3) from master cylinder.
CAUTION: Plug all open connections to 4
prevent ingress of moisture and dirt.
Installation FSM00043
1. Installation procedure is reverse of removal 3. Loosen tube nuts (x5) securing brake pipes to
except for the following. master cylinder and disconnect brake pipes.
NOTE: Clean component mating faces, prior Torque - 21 Nm.
to installation. NOTE: Place suitable absorbent material
WARNING: Only use cleaning agents and around the affected area to absorb any
solvents in a well ventilated area. possible fluid spillage.
2. Replace master cylinder seals. CAUTION: If brake fluid is spilt on the
3. Bleed brake system. Refer to FRT: paintwork, wash off immediately with clean
50010102, page 50-2. water.
4. Remove nuts (x2) securing master cylinder to
body. Torque - 25 Nm.
5. Remove master cylinder.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
2. Bleed brake system. Refer to FRT:
50010102, page 50-2.
50-4
BRAKES
3. Remove front LH wheel arch liner. Refer to 7. Disconnect hoses (x2) from EBCM. Note:
FRT: 78100100, page 78-2. Illustration has fender removed for clarity.
4. Open hood. 8. Release tube nuts (x5) securing pipes to
EBCM and disconnect pipes. Torque - 21
Nm.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
NOTE: Note fitted position of components
before removal.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
FSM00022
50-5
BRAKES
FSM00047 FSM00053
10. Remove bolts (x2) securing EBCM top 14. Release bolt securing EBCM to bracket and
bracket to body and release EBCM. Torque - remove bracket from module. Note fitted
20 Nm. position of bracket location dowel to EBCM.
Torque - 20 Nm.
Installation
13 1. Installation procedure is reverse of removal
14 except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
2. Bleed brake system. Refer to FRT:
50010102, page 50-2.
FSM00046
50-6
BRAKES
FSM00566
FSM00607
5
4. Release clips (x3) securing sensor cable to
rear subframe.
50-7
BRAKES
WARNING: To avoid serious injury, use WARNING: To avoid serious injury, use
appropriate equipment to carry out this appropriate equipment to carry out this
operation. operation.
WARNING: Eye protection must be worn.
Remove
CAUTION: Brake rotors must be renewed in
1. Isolate low voltage battery. Refer to FRT:
pairs.
90010100, page 90-2.
2. Remove front wheel arch liner. Refer to FRT: Remove
78100100, page 78-2. 1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
6 7
FSM00034
50-8
BRAKES
Remove
FSM00002
1. Remove road wheel. Refer to FRT:
3. Remove screw securing rotor to hub. Torque 54100501, page 54-2.
- 12 Nm. WARNING: Make sure the vehicle is correctly
4. Remove front brake rotor. supported before commencing work.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
4
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
WARNING: Do not use compressed air to
clean brake components.
CAUTION: Replace all patch bolt(s). 3
2. Pump brake pedal at least 5 times to seat FSM00028
pads against brake rotor. 2. Loosen bolt securing brake hose union to
WARNING: Always check brake pads are caliper and disconnect union. Torque - 20
seated correctly before driving the vehicle. Nm.
WARNING: Do not clamp brake hoses as they
will be damaged and require replacing.
CAUTION: Plug all open connections to
prevent ingress of moisture and dirt.
CAUTION: If brake fluid is spilt on the
paintwork, wash off immediately with clean
water.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
3. Remove bolts (x2) securing caliper to upright.
Torque - 135 Nm.
50-9
BRAKES
FSM00014
50-10
BRAKES
Remove
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
FSM00015
WARNING: Make sure the vehicle is correctly
3. Remove screw securing rotor to hub. Torque supported before commencing work.
- 12 Nm.
4. Remove brake rotor.
Installation
1. Installation procedure is reverse of removal 4
except for the following. 3
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
WARNING: Do not use compressed air to
clean brake components. FSM00021
CAUTION: Replace all patch bolt(s). 2. Loosen bolt securing brake hose union to
2. Pump brake pedal at least 5 times to seat caliper and disconnect union. Torque - 20
pads against brake rotor. Nm.
WARNING: Always check brake pads are WARNING: Do not clamp brake hoses as they
seated correctly before driving the vehicle. will be damaged and require replacing.
3. Check operation of park brake and adjust if CAUTION: Plug all open connections to
required. prevent ingress of moisture and dirt.
CAUTION: If brake fluid is spilt on the
paintwork, wash off immediately with clean
water.
NOTE: Place suitable absorbent material
around the affected area to absorb any
possible fluid spillage.
3. Remove bolts (x2) securing caliper to upright.
Torque - 100 Nm.
4. Retract brake pads to clear brake rotor.
5. Remove caliper.
50-11
BRAKES
6. Remove both pads and shims from caliper. Brake Pads - Front
WARNING: Only use cleaning agents and WARNING: Eye protection must be worn.
solvents in a well ventilated area. WARNING: Brake pads must be renewed in
WARNING: Do not use compressed air to axle sets only, otherwise braking efficiency
clean brake components. may be impaired.
FSM00009
50-12
BRAKES
FSM00010 Remove
4. Remove bolt securing pad retainer, drift to 1. Remove road wheel. Refer to FRT:
release and remove pad retainer from caliper. 54100501, page 54-2.
Collect anti squeal spring. Torque - 10 Nm. WARNING: Make sure the vehicle is correctly
NOTE: Note fitted position of components supported before commencing work.
before removal.
5. Place suitable absorbent material around
master cylinder reservoir.
6. Compress pistons and remove both pads
from caliper.
7. Repeat above procedure and replace RH
front pads.
Installation
1. Installation procedure is reverse of removal,
except for the following.
NOTE: Clean component mating faces, prior FSM00013
to installation.
2. Remove brake pad retaining pins (x2) from
WARNING: Only use cleaning agents and LH rear caliper and collect anti-rattle spring.
solvents in a well ventilated area.
3. Position absorbent material around master
WARNING: Do not use compressed air to cylinder reservoir.
clean brake components.
4. Compress pistons and remove both pads
2. Remove any scale or corrosion from around and shims from caliper.
edge of rotor.
5. Repeat above procedure and replace RH rear
3. Apply anti-seize compound to pad rear pads.
mating faces.
4. Pump brake pedal at least 5 times to seat Installation
pads against brake rotors. 1. Installation is reverse of removal except for
WARNING: Always check brake pads are the following.
seated correctly before driving the vehicle. NOTE: Clean component mating faces, prior
5. Check and top up brake fluid reservoir. to installation.
50-13
BRAKES
FSM00033
50-14
BRAKES
FSM00061
7 9
8
FSM00059
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
WARNING: Do not use compressed air to
clean brake components.
50-15
BRAKES
WARNING: To avoid serious injury, use WARNING: To avoid serious injury, use
appropriate equipment to carry out this appropriate equipment to carry out this
operation. operation.
WARNING: Eye protection must be worn. WARNING: Eye protection must be worn.
Remove Remove
1. Remove diffuser closing panel. Refer to FRT: 1. Raise and support vehicle. Refer to FRT:
70100300, page 70-3. 54100501, page 54-2.
2. Release the park brake. 2. Remove lug nuts (x10) securing rear road
3. Check operation parking brake mechanism. wheels and remove road wheels. Torque -
205 Nm.
3. Remove rear diffuser closing panel. Refer to
FRT: 70100300, page 70-3.
4. Release park brake.
5. Remove both rear brake rotors. Refer to FRT:
50300600, page 50-10.
6. Loosen park brake adjusters to loosen
cables.
7
8
FSM00894
Installation
9
1. Installation procedure is reverse of removal.
FSM00063
50-16
BRAKES
Adjust
1. Remove LH rear brake rotor. Refer to FRT:
50300600, page 50-10.
FSM00062
2. Remove RH rear brake rotor.
10. Remove bolt securing park brake cable outer 3. Release park brake.
to rear upright. Torque - 10 Nm.
11. Retract spring and disconnect inner cable
from park brake actuator arm.
12. Release and remove cable assembly from
upright.
Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area. FSM00033
50-17
BRAKES
Remove
1. Raise and support vehicle.
WARNING: Make sure the vehicle is correctly
supported before commencing work. FSM00015
2. Remove lug nuts (x10) securing rear road 6. Remove screw securing brake rotor to hub
wheels and remove wheels. Torque - 205 and remove rotor. Torque - 12 Nm.
Nm. 7. Repeat step 6 to remove opposite brake
3. Release park brake. rotor.
FSM00014 FSM00055
4. Remove bolts (x2) securing rear brake caliper 8. Depress clips, release and remove shoe
to upright and position caliper aside. Torque retainers.
- 100 Nm. 9. Noting fitted position, release shoe upper and
CAUTION: To avoid damage to the brake line, lower retaining springs.
the brake caliper must be supported at all 10. Remove park brake shoes from brake
times. actuator and adjuster, collect brake adjuster.
5. Repeat step 4 to release opposite brake
caliper. Installation
1. Installation procedure is reverse of removal
except for the following.
NOTE: Clean component mating faces, prior
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
50-18
BRAKES
50-19
BRAKES
50-20
WHEELS & TIRES
Contents Page
54-1
WHEELS & TIRES
Remove
WARNING: To avoid serious injury, use
appropriate equipment to carry out this 1. Remove road wheel. Refer to FRT:
operation. 54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
Remove supported before commencing work.
1. Raise and support vehicle. WARNING: To avoid serious injury, use
WARNING: Make sure the vehicle is correctly appropriate equipment to carry out this
supported before commencing work. operation.
2. Remove lug nuts (x5) securing road wheel 2. Remove cap and inner core from valve to
and remove road wheel. Torque - 205 Nm. deflate tire.
3. Use a suitable tire removing machine for
Installation
following steps.
1. Installation procedure is reverse of removal.
NOTE: Check direction of tire machine
NOTE: Clean component mating faces, prior rotation before starting procedure.
to installation.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
CAUTION: Replace all Nyloc nut(s).
FSM00048
54-2
WHEELS & TIRES
100 mm
6. Balance wheel.
FSM00049
FSM00050
Installation
1. Installation procedure is reverse of removal
except for the following.
54-3
WHEELS & TIRES
Remove
1. Remove road wheel. Refer to FRT:
54100501, page 54-2.
WARNING: Make sure the vehicle is correctly
supported before commencing work.
WARNING: To avoid serious injury, use
appropriate equipment to carry out this
operation.
2. Remove tire. Refer to FRT: 54200100, page
54-2.
FSM00051
Installation
1. Installation procedure is reverse of removal
except for the following.
2. Clean all component mating faces.
WARNING: Only use cleaning agents and
solvents in a well ventilated area.
54-4