Description
Clear printable bookmarked and fully searchable PDF format. Instant digital download.
This PDF service manual contains all the necessary instructions needed for any repair your vehicle may require from bumper to bumper. This is the same manual Jaguar technicians use to diagnose and repair your vehicle. Whether its routine maintenance such as tune-ups and brake service or more extensive repairs involving engine and transmission disassembly this manual provides the most reliable information to perform the job. Accurate clear and concise text combined with illustrations make it possible for anyone with even a bit of basic mechanical knowledge to safely and easily service and repair their vehicle. Comprehensive diagrams in depth illustrations and all the manufacturers specifications and technical information you will need is included.
Covers: 2002.5 2003 2004 2005 2006 2007 2008 Jaguar S Type (X200 – Worldwide – all gas and diesel engine options)
Format: PDF (high resolution, bookmarked, searchable, printable with linked table of contents) in zip file
Pages: 3316 plus 133 pg S-Type Technical Manual
Topics covered in the Factory OEM Jaguar Workshop/Repair Manual (each topic contains detailed subtopics):
1: General Information
100: Service Information
100-00: General Information
Description and Operation
About This Manual
Application and Use of Specifications
General Service Information
Health and Safety Precautions
How To Use This Manual
Important Safety Instructions
Road/Roller Testing
Solvents Sealants and Adhesives
Standard Workshop Practices
100-01: Identification Codes
Description and Operation
Identification Codes – VIN Range: M45255->N52047
Identification Codes – VIN Range: N52048->N99999
100-02: Jacking and Lifting
Description and Operation
Jacking
Lifting
100-04: Noise Vibration and Harshness
Description and Operation
Noise Vibration and Harshness (NVH)
Diagnosis and Testing
Noise Vibration and Harshness (NVH)
General Procedures
Exhaust System Neutralizing
2: Chassis
204: Suspension
204-00: Suspension System – General Information
Specification
Description and Operation
Wheel Alignment Angles
Diagnosis and Testing
Suspension System
General Procedures
Camber and Caster Adjustment
Four-Wheel Alignment
Front Toe Adjustment (57.65.01)
Rear Toe Adjustment (57.65.08)
Wheel Bearing Inspection
204-01: Front Suspension
Specification
Description and Operation
Front Suspension
Diagnosis and Testing
Front Suspension
Removal and Installation
Front Lower Arm (60.35.53)
Rear Lower Arm (60.35.54)
Rear Lower Arm Bushing (60.35.56)
Shock Absorber and Spring Assembly (60.30.02)
Shock Absorber Bushing (60.30.16) (60.30.23)
Front Stabilizer Bar (60.10.01) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Front Stabilizer Bar (60.10.01) – 2.7L V6 – TdV6
Front Stabilizer Bar (60.10.01) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Front Stabilizer Bar Link (60.10.02)
Stabilizer Bar Link Bushing (60.10.03)
Upper Arm LH (60.35.41)
Upper Arm RH (60.35.42)
Front Wheel Bearing and Wheel Hub (60.25.03)
Wheel Knuckle (60.25.23)
Disassembly and Assembly
Shock Absorber and Spring Assembly (60.30.21)
204-02: Rear Suspension
Specification
Description and Operation
Rear Suspension
Diagnosis and Testing
Rear Suspension
Removal and Installation
Lower Arm (64.35.43)
Shock Absorber and Spring Assembly
Shock Absorber Lower Bushing (64.30.39)
Rear Stabilizer Bar (64.35.08)
Upper Arm (64.25.31)
Rear Wheel Bearing (64.15.14)
Disassembly and Assembly
Shock Absorber and Spring Assembly
204-04: Wheels and Tires
Specification
Description and Operation
Wheels and Tires
Diagnosis and Testing
Wheels and Tires
Removal and Installation
Wheel and Tire (74.20.05)
204-05: Vehicle Dynamic Suspension
Description and Operation
Vehicle Dynamic Suspension
Diagnosis and Testing
Vehicle Dynamic Suspension
Removal and Installation
Accelerometer (86.56.54)
Adaptive Damping Module (86.56.35)
Front Vertical Accelerometer (86.56.53)
Rear Vertical Accelerometer (86.56.55)
205: Driveline
205-00: Driveline System – General Information
Description and Operation
Driveline System
Diagnosis and Testing
Driveline System
General Procedures
Driveline Angle Inspection
205-01: Driveshaft
Specification
Description and Operation
Driveshaft
Diagnosis and Testing
Driveshaft
General Procedures
Driveshaft Runout and Balancing
Removal and Installation
Driveshaft (47.15.01)
205-02: Rear Drive Axle/Differential
Specification
Description and Operation
Rear Drive Axle and Differential
Diagnosis and Testing
Rear Drive Axle and Differential
In-Vehicle Repair
Drive Pinion Seal (51.20.01)
Removal and Installation
Axle Assembly (51.25.13) – Vehicles Without: Differential Drain Plug
Axle Assembly (51.25.13) – Vehicles With: Differential Drain Plug
Axle Housing Bushing (64.25.30)
205-05: Rear Drive Halfshafts
Specification
Description and Operation
Rear Drive Halfshafts
Diagnosis and Testing
Rear Drive Halfshafts
Removal and Installation
Rear Halfshaft (47.10.13)
Inner Constant Velocity (CV) Joint Boot (47.10.33)
Outer Constant Velocity (CV) Joint Boot (47.10.32)
206: Brake System
206-00: Brake System – General Information
Specification – VIN Range: M45255->N52047
Specification – VIN Range: N52048->N99999
Description and Operation
Brake System – VIN Range: M45255->N52047
Brake System – VIN Range: N52048->N99999
Diagnosis and Testing
Brake System
General Procedures
Brake Disc Runout Check
Brake System Bleeding (70.25.03) – VIN Range: M45255->N52047
Brake System Bleeding (70.25.03) – VIN Range: N52048->N99999
206-03: Front Disc Brake
Specification – VIN Range: M45255->N52047
Specification – VIN Range: N52048->N99999
Description and Operation
Front Disc Brake – VIN Range: M45255->N52047
Front Disc Brake – VIN Range: N52048->N99999
Diagnosis and Testing
Front Disc Brake
Removal and Installation
Brake Disc Shield (70.10.18) – Vehicles With: Standard Brakes
206-04: Rear Disc Brake
Specification – VIN Range: M45255->N52047
Specification – VIN Range: N52048->N99999
Description and Operation
Rear Disc Brake – VIN Range: M45255->N52047
Rear Disc Brake – VIN Range: N52048->N99999
Diagnosis and Testing
Rear Disc Brake
Removal and Installation
Brake Caliper (70.55.03) (70.55.25) – VIN Range: N52048->N99999
Brake Disc (70.10.11) – VIN Range: N52048->N99999
Brake Disc Shield (70.10.19)
Brake Pads (70.40.03) – VIN Range: N52048->N99999
206-05: Parking Brake and Actuation
Specification
Description and Operation
Parking Brake
Diagnosis and Testing
Parking Brake – VIN Range: M45255->N13088
Parking Brake – VIN Range: N13089->N52047
Parking Brake – VIN Range: N52048->N99999
General Procedures
Parking Brake Cable Tension Release
Removal and Installation
Parking Brake Cable (70.35.29)
Parking Brake Module (70.35.47)
Parking Brake Pads (70.40.04) – Vehicles With: High Performance Brakes
Parking Brake Release Actuator (70.35.45)
Parking Brake Switch (70.35.46)
206-06: Hydraulic Brake Actuation
Specification
Description and Operation
Hydraulic Brake Actuation
Diagnosis and Testing
Hydraulic Brake Actuation
Removal and Installation
Brake Fluid Reservoir (70.30.16) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27
Brake Fluid Reservoir (70.30.16) – 2.7L V6 – TdV6
Brake Master Cylinder (70.30.08) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27
Brake Master Cylinder (70.30.08) – 2.7L V6 – TdV6
206-07: Power Brake Actuation
Specification
Description and Operation
Brake Booster
Diagnosis and Testing
Power Brake System
Removal and Installation
Brake Booster (70.50.17)
Brake Vacuum Pump – 2.7L V6 – TdV6
206-09: Anti-Lock Control – Stability Assist
Specification
Description and Operation
Anti-Lock Control – Stability Assist – VIN Range: M45255->N52047
Anti-Lock Control – Stability Assist – VIN Range: N52048->N99999
Diagnosis and Testing
Anti-Lock Control – Stability Assist – VIN Range: M45255->N52206
Anti-Lock Control – Stability Assist – VIN Range: N52207->N99999
Removal and Installation
Anti-Lock Brake System (ABS) Module (70.60.02)
Brake Master Cylinder Pressure Transducer
Brake Pedal Travel Sensor – VIN Range: M45255->N52206
Front Wheel Speed Sensor (70.60.03)
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) – VIN Range: M45255->N52206
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19) – VIN Range: N52207->N99999
Rear Wheel Speed Sensor (70.60.04)
Steering Wheel Rotation Sensor (86.56.58)
Yaw Rate Sensor and Accelerometer (86.56.64)
211: Steering System
211-00: Steering System – General Information
Specification
Description and Operation
Steering System
Diagnosis and Testing
Steering System
General Procedures
Power Steering System Bleeding (57.15.02 )
Power Steering System Flushing (57.15.08)
211-02: Power Steering
Specification
Description and Operation
Power Steering
Diagnosis and Testing
Power Steering
Removal and Installation
Power Steering Control Valve Actuator (57.10.32) – Vehicles Built From: 02/2004
Power Steering Control Valve Actuator (57.10.32) – Vehicles Built Up To: 01/2004
Power Steering Fluid Cooler (57.15.11) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA
V6 – AJV6/3.0L NA V6 – AJ27
Power Steering Fluid Cooler (57.15.11) – 2.7L V6 – TdV6
Power Steering Fluid Reservoir (57.15.08)
Power Steering Pump (57.20.14) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Power Steering Pump (57.20.14) – 2.7L V6 – TdV6
Power Steering Pump (57.20.14) – 2.7L V6 – TdV6
Power Steering Pump (57.20.14) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Steering Gear (57.10.01)
Steering Gear Bushing (57.10.30)
211-03: Steering Linkage
Specification
Description and Operation
Steering Linkage
Diagnosis and Testing
Steering Linkage
Removal and Installation
Steering Gear Boot (57.10.29)
Tie Rod End (57.55.02)
211-04: Steering Column
Specification
Description and Operation
Steering Column
Diagnosis and Testing
Steering Column
Removal and Installation
Ignition Switch Lock Cylinder (57.40.29)
Steering Column (57.40.01)
Steering Wheel (57.60.01)
Disassembly and Assembly
Steering Column
211-05: Steering Column Switches
Description and Operation
Steering Column Switches
Diagnosis and Testing
Steering Column Switches
Removal and Installation
Steering Column Lock Actuator (57.40.41)
Steering Column Multifunction Switch LH (86.65.78)
Steering Column Multifunction Switch RH (86.65.41)
3: Powertrain
303: Engine
303-00: Engine System – General Information
Diagnosis and Testing
Engine – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Engine – 2.7L V6 – TdV6
General Procedures
Bearing Inspection
Camshaft Bearing Journal Clearance
Camshaft Bearing Journal Diameter
Camshaft End Play
Camshaft Lobe Lift
Camshaft Surface Inspection
Connecting Rod Cleaning
Connecting Rod Large End Bore
Crankshaft End Play
Crankshaft Main Bearing Journal Clearance – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Crankshaft Main Bearing Journal Clearance – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Cylinder Bore Out-of-Round
Cylinder Head Distortion
Exhaust Manifold Cleaning and Inspection
Piston Inspection
Piston Pin Diameter
Piston Pin to Bore Diameter
Piston Ring End Gap
Piston Ring-to-Groove Clearance
Valve Spring Free Length
Valve Stem Diameter
Leakage Test Using Smoke Test Equipment
303-01A: Engine – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Specification
Description and Operation
Engine
Diagnosis and Testing
Engine
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
In-Vehicle Repair
Camshafts LH (12.13.19)
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.09)
Crankshaft Rear Seal (12.21.20)
Cylinder Head (12.29.01)
Engine Front Cover (12.65.01)
Engine Mount LH (12.45.01)
Exhaust Manifold LH (30.15.55) – VIN Range: M45255->N52047
Exhaust Manifold LH (30.15.55) – VIN Range: N52048->N99999
Flexplate (12.53.13)
Flywheel (12.53.07)
Intake Manifold (30.15.01)
Lower Intake Manifold (30.15.61)
Oil Cooler (12.60.68)
Oil Pan (12.60.44)
Oil Pump (12.60.26)
Timing Drive Components (12.65.13)
Valve Cover LH (12.29.43)
Valve Cover RH (12.29.44)
Removal
Engine (12.41.01)
Disassembly
Engine
Disassembly and Assembly of Subassemblies
Cylinder Head (12.29.22)
Piston (12.17.02)
Assembly
Engine
Installation
Engine (12.41.01)
303-01B: Engine – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Specification
Description and Operation
Engine
Diagnosis and Testing
Engine
General Procedures
Valve Clearance Adjustment (12.29.48)
Valve Clearance Check (12.29.47)
In-Vehicle Repair
Camshafts RH (12.13.18) – VIN Range: M45255->N52047
Camshafts RH (12.13.18) – VIN Range: N52048->N99999
Crankshaft Front Seal (12.21.14)
Crankshaft Pulley (12.21.09)
Crankshaft Rear Seal (12.21.20)
Cylinder Head LH (12.29.02) – VIN Range: M45255->N52047
Cylinder Head LH (12.29.02) – VIN Range: N52048->N99999
Engine Front Cover (12.65.01) – VIN Range: M45255->N52047
Engine Front Cover (12.65.01) – VIN Range: N52048->N99999
Engine Mount LH (12.45.01)
Exhaust Manifold RH (30.15.56) – VIN Range: M45255->N52047
Exhaust Manifold RH (30.15.56) – VIN Range: N52048->N99999
Flexplate (12.53.13)
Intake Manifold (30.15.01) – VIN Range: M45255->N52047
Intake Manifold (30.15.01) – VIN Range: N52048->N99999
Oil Cooler (12.60.68) – Vehicles With: Supercharger
Oil Cooler (12.60.68) – Vehicles Without: Supercharger
Oil Pan (12.60.44)
Oil Pan Extension (12.60.48)
Oil Pump (12.60.26) – VIN Range: M45255->N52047
Oil Pump (12.60.26) – VIN Range: N52048->N99999
Secondary Timing Chain Tensioner
Timing Drive Components (12.65.13) – VIN Range: M45255->N52047
Timing Drive Components (12.65.13) – VIN Range: N52048->N99999
Valve Cover LH (12.29.43) – VIN Range: M45255->N52047
Valve Cover LH (12.29.43) – VIN Range: N52048->N99999
Valve Cover RH (12.29.44) – VIN Range: M45255->N52047
Valve Cover RH (12.29.44) – VIN Range: N52048->N99999
Removal and Installation
Crankshaft Main Bearing Carrier
Removal
Engine (12.41.01)
Disassembly
Engine
Disassembly and Assembly of Subassemblies
Cylinder Head (12.29.22)
Assembly
Engine
Installation
Engine (12.41.01)
303-01C: Engine – 2.7L V6 – TdV6
Specification
Description and Operation
Engine
Diagnosis and Testing
Engine
In-Vehicle Repair
Camshaft Front Seal
Camshaft Rear Seal
Camshafts LH (12.13.19)
Crankshaft Front Seal (12.21.14)
Crankshaft Rear Seal (12.21.20)
Crankshaft Vibration Damper (12.21.09)
Cylinder Head LH (12.29.02)
Engine Mount LH (12.45.01)
Engine Mount RH (12.45.03)
Exhaust Manifold LH (30.15.55)
Exhaust Manifold RH (30.15.56)
Flexplate (12.53.13)
Flywheel (12.53.07)
Oil Filter Element (12.60.02)
Oil Pan (12.60.44)
Oil Pan Extension (12.60.48)
Oil Pump (12.60.26)
Timing Belt
Timing Belt Cover
Valve Cover
Removal
Engine (12.41.01)
Installation
Engine (12.41.01)
303-03A: Engine Cooling – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27
Specification
Description and Operation
Engine Cooling
Diagnosis and Testing
Engine Cooling
General Procedures
Cooling System Backflushing
Cooling System Draining Filling and Bleeding
Cooling System Draining and Vacuum Filling
Cooling System Flushing
Removal and Installation
Coolant Expansion Tank (26.15.01)
Cooling Fan Motor and Shroud (26.25.25)
Cooling Module (26.40.16) – Vehicles Without: Supercharger
Radiator (26.40.01)
Thermostat (26.45.07) – 2.5L/3.0L
Thermostat (26.45.07) – 4.2L Vehicles With: Supercharger
Thermostat (26.45.07) – 4.2L Vehicles Without: Supercharger
Water Pump (26.50.01) – 4.2L Vehicles With: Supercharger
Water Pump (26.50.01) – 4.2L Vehicles Without: Supercharger
303-03B: Supercharger Cooling
Specification
Description and Operation
Supercharger Cooling
Diagnosis and Testing
Supercharger Cooling
General Procedures
Supercharger Cooling System Draining Filling and Bleeding
Removal and Installation
Radiator
Water Pump
303-03C: Engine Cooling – 2.7L V6 – TdV6
Specification
Description and Operation
Engine Cooling
Diagnosis and Testing
Engine Cooling
General Procedures
Cooling System Draining Filling and Bleeding
Removal and Installation
Coolant Expansion Tank (26.15.01)
Cooling Fan Motor and Shroud (26.25.25)
Radiator (26.40.01)
Thermostat (26.45.07)
Water Pump (26.50.01)
303-04A: Fuel Charging and Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Specification
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls – VIN Range: M45255->N52047
Fuel Charging and Controls – VIN Range: N52048->N99999
Removal and Installation
Fuel Charging Wiring Harness (86.70.22)
Fuel Injection Supply Manifold (19.60.13)
Fuel Injectors (18.10.02)
Fuel Pressure Regulator (19.45.11)
Throttle Body (19.70.04) – VIN Range: M45255->N52047
Throttle Body (19.70.04) – VIN Range: N52048->N99999
303-04B: Fuel Charging and Controls – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Specification
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls – VIN Range: M45255->N52047
Fuel Charging and Controls – VIN Range: N52048->N99999
Removal and Installation
Fuel Injection Supply Manifold (19.60.13)
Fuel Injectors (18.10.02)
Fuel Pressure Regulator (19.45.11)
303-04C: Fuel Charging and Controls – 2.7L V6 – TdV6
Specification
Description and Operation
Fuel Charging and Controls
Diagnosis and Testing
Fuel Charging and Controls
General Procedures
Fuel Injection Component Cleaning
Removal and Installation
Fuel Injection Pump
Fuel Injector (18.10.01)
Intake Air Shutoff Throttle
Swirl Plate Actuator Diaphragm
303-04D: Fuel Charging and Controls – Turbocharger – 2.7L V6 – TdV6
Specification
Description and Operation
Turbocharger
Diagnosis and Testing
Turbocharger
Removal and Installation
Turbocharger LH
Turbocharger RH
303-05: Accessory Drive
Specification
Description and Operation
Accessory Drive
Diagnosis and Testing
Accessory Drive – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA V6 –
AJ27
Accessory Drive – 2.7L V6 – TdV6
Removal and Installation
Accessory Drive Belt (12.10.40) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Accessory Drive Belt (12.10.40) – 2.7L V6 – TdV6
Accessory Drive Belt (12.10.40)
Accessory Drive Belt Idler Pulley (12.10.43) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Accessory Drive Belt Idler Pulley (12.10.43) – 2.7L V6 – TdV6
Accessory Drive Belt Idler Pulley (12.10.43) – V8 4.2L Petrol/V8 S/C 4.2L Petrol VIN
Range: M44998->N52047
Accessory Drive Belt Idler Pulley (12.10.43) – V8 4.2L Petrol/V8 S/C 4.2L Petrol VIN
Range: N52048->R99999
Accessory Drive Belt Tensioner (12.10.41) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Accessory Drive Belt Tensioner (12.10.41) – 2.7L V6 – TdV6
Accessory Drive Belt Tensioner (12.10.41) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Fuel Injection Pump Belt
Fuel Injection Pump Pulley
Supercharger Belt (18.50.08)
Supercharger Belt Idler Pulley (18.50.09)
Supercharger Belt Tensioner (18.50.24)
303-06: Starting System
Specification
Description and Operation
Starting System
Diagnosis and Testing
Starting System
Removal and Installation
Starter Motor (86.60.01) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L
NA V6 – AJ27
Starter Motor (86.60.01) – 2.7L V6 – TdV6
303-07A: Engine Ignition – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Specification
Description and Operation
Engine Ignition
Diagnosis and Testing
Engine Ignition – VIN Range: M45255->N52047
Engine Ignition – VIN Range: N52048->N99999
Removal and Installation
Ignition Coil-On-Plug LH (18.20.44)
Ignition Coil-On-Plug RH (18.20.43)
303-07B: Engine Ignition – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Specification
Description and Operation
Engine Ignition
Diagnosis and Testing
Engine Ignition – VIN Range: M45255->N52047
Engine Ignition – VIN Range: N52048->N99999
Removal and Installation
Ignition Coil-On-Plug (18.20.40)
303-07C: Glow Plug System
Specification
Description and Operation
Glow Plug System
Diagnosis and Testing
Glow Plug System
Removal and Installation
Glow Plugs
303-08A: Engine Emission Control – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27
Specification – VIN Range: M45255->N52047
Specification – VIN Range: N52048->N99999
Description and Operation
Engine Emission Control – VIN Range: M45255->N52047
Engine Emission Control – VIN Range: N52048->N99999
Diagnosis and Testing
Engine Emission Control – VIN Range: M45255->N52047
Engine Emission Control – VIN Range: N52048->N80180
Engine Emission Control – VIN Range: N80181->R99999
Removal and Installation
Exhaust Gas Recirculation (EGR) Valve (17.45.01)
Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube (17.45.11)
Secondary Air Injection (AIR) Control Valve – 3.0L
Secondary Air Injection (AIR) Control Valve – 4.2L Vehicles Without: Supercharger
Secondary Air Injection (AIR) Control Valve – 4.2L Vehicles With: Supercharger
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube LH – 3.0L
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube RH – 3.0L
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube – 4.2L Vehicles
Without: Supercharger
Secondary Air Injection (AIR) Control Valve to Exhaust Manifold Tube – 4.2L Vehicles
With: Supercharger
Secondary Air Injection (AIR) Pump
303-08B: Engine Emission Control – 2.7L V6 – TdV6
Specification
Description and Operation
Engine Emission Control
Diagnosis and Testing
Engine Emission Control
Removal and Installation
Exhaust Gas Recirculation (EGR) Valve LH
Exhaust Gas Recirculation (EGR) Valve Outlet Tube (17.45.11)
Exhaust Gas Recirculation (EGR) Valve RH
303-12A: Intake Air Distribution and Filtering – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Specification
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering – VIN Range: M45255->N13088
Intake Air Distribution and Filtering – VIN Range: N13089->N52047
Intake Air Distribution and Filtering – VIN Range: N52048->N99999
Removal and Installation
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Air Cleaner Outlet Pipe (19.10.31) – VIN Range: M45255->N52047
Air Cleaner Outlet Pipe (19.10.31) – VIN Range: N52048->N99999
303-12B: Intake Air Distribution and Filtering – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Specification
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering – VIN Range: M45255->N13088
Intake Air Distribution and Filtering – VIN Range: N13089->N52047
Intake Air Distribution and Filtering – VIN Range: N52048->N99999
Removal and Installation
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Air Cleaner Outlet Pipe (19.10.31)
Charge Air Cooler
Supercharger (18.50.15) – VIN Range: M45255->N52047
Supercharger (18.50.15) – VIN Range: N52048->N99999
Supercharger Outlet Pipe (18.50.16)
303-12C: Intake Air Distribution and Filtering – 2.7L V6 – TdV6
Specification
Description and Operation
Intake Air Distribution and Filtering
Diagnosis and Testing
Intake Air Distribution and Filtering
Removal and Installation
Air Cleaner (19.10.05)
Air Cleaner Element (19.10.08)
Charge Air Cooler
303-13: Evaporative Emissions
Specification
Description and Operation
Evaporative Emissions – VIN Range: M45255->N52047
Evaporative Emissions – VIN Range: N52048->N99999
Diagnosis and Testing
Evaporative Emissions – VIN Range: M45255->N52047
Evaporative Emissions – VIN Range: N52048->N99999
Removal and Installation
Evaporative Emission Canister (17.15.13) – VIN Range: M45255->N52047
Evaporative Emission Canister (17.15.13) – VIN Range: N52048->N99999
Evaporative Emission Canister Purge Valve (17.15.30) – VIN Range: M45255-
>N52047
Evaporative Emission Canister Vent Solenoid (17.15.45)
Fuel Tank Pressure Sensor (19.55.31) – Vehicles Built Up To: 01/2004
303-14A: Electronic Engine Controls – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls – VIN Range: M45255->N52047
Electronic Engine Controls – VIN Range: N52048->N80180
Electronic Engine Controls – VIN Range: N80181->R99999
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Removal and Installation
Brake Pedal Position (BPP) Switch
Camshaft Position (CMP) Sensor LH (18.31.12)
Camshaft Position (CMP) Sensor RH (18.31.11)
Catalyst Monitor Sensor (18.30.66)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor (18.30.10) – VIN Range: M45255-
>N52047
Engine Coolant Temperature (ECT) Sensor (18.30.10) – VIN Range: N52048-
>N99999
Fuel Temperature Sensor (18.30.99)
Heated Oxygen Sensor (HO2S)
Intake Manifold Tuning (IMT) Valve LH (19.70.30)
Knock Sensor (KS) LH (18.30.92)
Knock Sensor (KS) RH (18.30.93)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
303-14B: Electronic Engine Controls – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls – VIN Range: M45255->N52047
Electronic Engine Controls – VIN Range: N52048->N80180
Electronic Engine Controls – VIN Range: N80181->R99999
General Procedures
Powertrain Control Module (PCM) Long Drive Cycle Self-Test
Powertrain Control Module (PCM) Short Drive Cycle Self-Test
Removal and Installation
Brake Pedal Position (BPP) Switch
Camshaft Position (CMP) Sensor LH (18.31.12)
Camshaft Position (CMP) Sensor RH (18.31.11)
Catalyst Monitor Sensor (18.30.66)
Crankshaft Position (CKP) Sensor (18.30.12)
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Fuel Temperature Sensor (18.30.99)
Heated Oxygen Sensor (HO2S)
Intake Air Temperature (IAT) Sensor (18.30.52)
Knock Sensor (KS) LH (18.30.92)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
Oil Temperature Sensor (18.31.01)
Variable Camshaft Timing (VCT) Oil Control Solenoid (18.30.90)
303-14C: Electronic Engine Controls – 2.7L V6 – TdV6
Specification
Description and Operation
Electronic Engine Controls
Diagnosis and Testing
Electronic Engine Controls
Removal and Installation
Brake Pedal Position (BPP) Switch
Camshaft Position (CMP) Sensor (18.30.63)
Crankshaft Position (CKP) Sensor (18.30.12)
Crankshaft Position (CKP) Sensor Ring
Engine Control Module (ECM) (18.30.01)
Engine Coolant Temperature (ECT) Sensor (18.30.10)
Engine Oil Pressure (EOP) Sensor
Fuel Rail Pressure (FRP) Sensor (18.30.98)
Fuel Temperature Sensor (18.30.99)
Knock Sensor (KS) LH (18.30.92)
Knock Sensor (KS) RH (18.30.93)
Manifold Absolute Pressure (MAP) Sensor (18.30.86)
Mass Air Flow (MAF) Sensor (18.30.15)
307: Automatic Transmission/Transaxle
307-01: Automatic Transmission/Transaxle
Specification
Description and Operation
Transmission Description
Diagnosis and Testing
Diagnostic Strategy – VIN Range: M45255->N52047
Diagnostic Strategy – VIN Range: N52048->N99999
General Procedures
Transmission Fluid Drain and Refill (44.24.02)
Transmission Fluid Level Check
In-Vehicle Repair
Extension Housing Seal (44.20.18)
Transmission Fluid Pan Gasket and Filter (44.24.07)
Transmission Control Module (TCM) and Main Control Valve Body
Removal
Transmission (44.20.01) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Transmission (44.20.01) – 2.7L V6 – TdV6
Transmission (44.20.01) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Disassembly and Assembly of Subassemblies
Input Shaft Seal (44.32.07)
Installation
Transmission (44.20.01) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Transmission (44.20.01) – 2.7L V6 – TdV6
Transmission (44.20.01) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
307-02: Transmission/Transaxle Cooling
Specification
Description and Operation
Transmission Cooling
Diagnosis and Testing
Transmission Cooling
Removal and Installation
Transmission Fluid Cooler (44.24.10)
Transmission Fluid Cooler Tubes (44.24.19)
307-05: Automatic Transmission/Transaxle External Controls
Specification
Description and Operation
External Controls
Diagnosis and Testing
External Controls
General Procedures
Selector Lever Cable Adjustment (44.15.07)
Removal and Installation
Selector Lever Cable and Bracket (44.15.08)
Selector Lever Assembly (44.15.04)
308: Manual Transmission/Transaxle Clutch and Transfer Case
308-00: Manual Transmission/Transaxle and Clutch – General Information
Specification
Description and Operation
Manual Transmission and Clutch
Diagnosis and Testing
Manual Transmission and Clutch
General Procedures
Clutch System Bleeding (33.15.01)
Release Hub and Bearing Check
308-01: Clutch
Specification
Description and Operation
Clutch
Diagnosis and Testing
Clutch
Removal and Installation
Clutch Disc and Pressure Plate (12.53.13) (33.10.01)
308-02: Clutch Controls
Specification
Description and Operation
Clutch Controls
Diagnosis and Testing
Clutch Controls
Removal and Installation
Clutch Master Cylinder (33.20.01)
Clutch Slave Cylinder (33.35.01)
308-03A: Manual Transmission/Transaxle – Vehicles With: 5-Speed Manual Transmission –
GETRAG 221
Specification
Description and Operation
Manual Transmission
Diagnosis and Testing
Manual Transmission
General Procedures
Drain Procedure
Fill Procedure
In-Vehicle Repair
Gearshift Control Shaft Seal (37.23.08)
Input Shaft Seal (37.23.09)
Output Shaft Seal (37.23.01)
Support Insulator (37.16.42)
Removal
Transmission (37.20.01)
Installation
Transmission (37.20.01)
308-03B: Manual Transmission/Transaxle – Vehicles With: S6-53 6-Speed Manual
Transmission
Specification
Description and Operation
Manual Transmission
Diagnosis and Testing
Manual Transmission
General Procedures
Drain Procedure
Fill Procedure
In-Vehicle Repair
Countershaft Seal
Gearshift Control Shaft Seal (37.23.08)
Input Shaft Seal (37.23.09)
Output Shaft Seal (37.23.01)
Support Insulator (37.16.42)
Removal
Transmission (37.20.01)
Installation
Transmission (37.20.01)
308-06: Manual Transmission/Transaxle External Controls
Specification
Description and Operation
External Controls
Diagnosis and Testing
External Controls
Removal and Installation
Gearshift Lever Bushing
Gearshift Linkage (37.16.03) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Gearshift Linkage (37.16.03) – 2.7L V6 – TdV6
309: Exhaust System
309-00: Exhaust System
Specification – VIN Range: M45255->N52047
Specification – VIN Range: N52048->N99999
Description and Operation
Exhaust System – VIN Range: M45255->N52047
Exhaust System – VIN Range: N52048->N99999
Diagnosis and Testing
Exhaust System – VIN Range: M45255->N13088
Exhaust System – VIN Range: N13089->N99999
Removal and Installation
Catalytic Converter (17.50.05) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27
Catalytic Converter (17.50.05) – 2.7L V6 – TdV6
Diesel Particulate Filter (DPF)
Diesel Particulate Filter (DPF) Differential Pressure Sensor
Exhaust System – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA V6 –
AJ27
Front Muffler (30.10.18)
Muffler and Tailpipe (30.10.52)
310: Fuel System
310-00: Fuel System – General Information
Specification
Description and Operation
Fuel System – VIN Range: M45255->N52047
Fuel System – VIN Range: N52048->N99999
Diagnosis and Testing
Fuel System
General Procedures
Fuel System Pressure Check
Fuel System Pressure Release (19.50.02)
Fuel Tank Draining – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA V6
– AJ27 VIN Range: M45255->N52047
Fuel Tank Draining – 2.7L V6 – TdV6 VIN Range: M45255->N52047
Fuel Tank Draining – VIN Range: N52048->N99999
High-Pressure Fuel System Bleeding
Low-Pressure Fuel System Bleeding
Quick Release Coupling – Push Connect
Quick Release Coupling
Spring Lock Couplings
310-01: Fuel Tank and Lines
Specification
Description and Operation
Fuel Tank and Lines – VIN Range: M45255->N52047
Fuel Tank and Lines – VIN Range: N52048->N99999
Diagnosis and Testing
Fuel Tank and Lines – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27 VIN Range: M45255->N52047
Fuel Tank and Lines – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27 VIN Range: N52048->N80180
Fuel Tank and Lines – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27 VIN Range: N80181->R99999
Fuel Tank and Lines – 2.7L V6 – TdV6
Removal and Installation
Fuel Filter (19.25.02) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27
Fuel Filter (19.25.02) – 2.7L V6 – TdV6
Fuel Level Sender LH – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27 VIN Range: M45255->N52047
Fuel Level Sender LH – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27 VIN Range: N52048->N99999
Fuel Level Sender RH – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27 VIN Range: M45255->N52047
Fuel Level Sender RH – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27 VIN Range: N52048->N99999
Fuel Pump Module (19.45.08) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27 VIN Range: M45255->N52047
Fuel Pump Module (19.45.08) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27 VIN Range: N52048->N99999
Fuel Pump Module (19.45.08) – 2.7L V6 – TdV6
Fuel Tank (19.55.01) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA
V6 – AJ27
Fuel Tank (19.55.01) – 2.7L V6 – TdV6
Fuel Tank Filler Pipe (19.55.33)
Fuel Transfer Pump (19.45.21) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27 VIN Range: M45255->N52047
Fuel Transfer Unit – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA V6
– AJ27 VIN Range: N52048->N99999
Fuel Transfer Unit – 2.7L V6 – TdV6
Inertia Fuel Shutoff (IFS) Switch (18.30.35)
310-02: Acceleration Control
Specification
Description and Operation
Acceleration Control
Diagnosis and Testing
Acceleration Control
Removal and Installation
Accelerator Pedal (19.20.01)
Accelerator Pedal (19.20.01) – Vehicles With: Adjustable Pedals
310-03: Speed Control
Specification
Description and Operation
Speed Control – VIN Range: M45255->N52047
Speed Control – VIN Range: N52048->N99999
Diagnosis and Testing
Speed Control – VIN Range: M45255->N13088
Speed Control – VIN Range: N13089->N52047
Speed Control – VIN Range: N52048->N99999
General Procedures
Speed Control Module Alignment
Removal and Installation
Speed Control Deactivator Switch (19.75.20)
Speed Control Module (19.75.26)
Speed Control Sensor
Speed Control Switch (19.75.25)
4: Electrical
412: Climate Control System
412-00: Climate Control System – General Information
Specification
Description and Operation
Climate Control System
Diagnosis and Testing
Climate Control System
General Procedures
Air Conditioning (A/C) System Flushing
Air Conditioning (A/C) System Recovery Evacuation and Charging (82.30.30)
Contaminated Refrigerant Handling
Electronic Leak Detection
Fluorescent Dye Leak Detection
Inspection and Assembly Requirements
Manifold Gauge Set Connection
Refrigerant Oil Adding
Refrigerant System Tests
412-01: Air Distribution and Filtering
Specification
Description and Operation
Air Distribution and Filtering
Diagnosis and Testing
Air Distribution and Filtering
Removal and Installation
Cabin Air Filter (76.10.09)
Center Registers (82.20.38)
Driver Side Register (82.20.39)
Driver Side Register Duct (82.20.49)
Floor Console Register Duct (82.20.37)
Front Footwell Duct LH (82.20.91)
Front Footwell Duct RH (82.20.92)
Passenger Side Register (82.20.40)
Passenger Side Register Duct (82.20.51)
Rear Footwell Duct (82.20.96)
412-02A: Heating and Ventilation
Specification
Description and Operation
Heating and Ventilation
Diagnosis and Testing
Heating and Ventilation
Removal and Installation
Auxiliary Coolant Flow Pump (82.25.59) – 2.7L V6 – TdV6
Auxiliary Coolant Flow Pump (82.25.59) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Blower Motor (82.25.66)
Dual Coolant Flow Valve (82.20.33) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27
Dual Coolant Flow Valve (82.20.33) – 2.7L V6 – TdV6
Heater Core and Evaporator Core Housing (82.25.21)
Heater Hose (80.25.01) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L
NA V6 – AJ27
Disassembly and Assembly
Heater Core and Evaporator Core Housing
412-02B: Auxiliary Heating
Specification
Description and Operation
Auxiliary Heater
Diagnosis and Testing
Auxiliary Heater
Fuel Fired Booster Heater
Removal and Installation
Auxiliary Heater
412-03: Air Conditioning
Specification
Description and Operation
Air Conditioning
Diagnosis and Testing
Air Conditioning
Removal and Installation
Air Conditioning (A/C) Compressor (82.10.20) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Air Conditioning (A/C) Compressor (82.10.20) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Air Conditioning (A/C) Compressor (82.10.20) – 2.7L V6 – TdV6
Clutch and Clutch Field Coil (82.10.25)
Condenser Core (82.15.07)
Desiccant Bag (82.17.03)
Pressure Cutoff Switch (82.10.32) – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 –
AJV6/3.0L NA V6 – AJ27
Pressure Cutoff Switch (82.10.32) – 2.7L V6 – TdV6
412-04: Control Components
Specification
Description and Operation
Control Components
Diagnosis and Testing
Control Components
Removal and Installation
Air Discharge Temperature Sensor (82.20.64)
Ambient Air Temperature Sensor (82.20.02)
Climate Control Assembly (82.20.07)
Cold Air Bypass Blend Door Actuator (82.20.86)
Defrost Vent/Register Blend Door Actuator (82.20.84)
Footwell Vent/Duct Blend Door Actuator (80.20.20 or 82.20.85)
Instrument Panel Blend Door Actuator (82.20.83)
In-Vehicle Temperature Sensor (82.20.03)
Recirculation Blend Door Actuator (82.20.67)
Sunload Sensor (82.20.70)
413: Instrumentation and Warning Systems
413-00: Instrument Cluster and Panel Illumination
Diagnosis and Testing
General Procedures
Instrument Cluster and Panel Illumination
413-01: Instrument Cluster
Specification – Vehicles Built Up To: 01/2004
Description and Operation
Instrument Cluster
Diagnosis and Testing
Instrument Cluster
Removal and Installation
Indicator Bulb (86.45.61) – Vehicles Built Up To: 01/2004
Instrument Cluster (88.20.01)
Instrument Cluster Lens (88.20.28)
413-06: Horn
Specification
Description and Operation
Horn
Diagnosis and Testing
Horn
Removal and Installation
Horn (86.30.02) (86.30.10)
Horn Switch (86.30.01)
413-08: Information and Message Center
Description and Operation
Information and Message Center
Diagnosis and Testing
Information and Message Center
Removal and Installation
Message Center Switch (86.66.11)
413-09: Warning Devices
Description and Operation
Warning Devices
Diagnosis and Testing
Warning Devices
General Procedures
Oil Change Indicator Reset
413-13: Parking Aid
Description and Operation
Parking Aid
Diagnosis and Testing
Parking Aid
Removal and Installation
Front Parking Aid Sensor (86.62.33) – Vehicles Built From: 02/2004
Parking Aid Module (86.80.39)
Parking Aid Speaker (86.62.02)
Rear Parking Aid Sensor (86.54.14) (86.62.01) – Vehicles Built From: 02/2004
Rear Parking Aid Sensor (86.54.14) (86.62.01) – Vehicles Built Up To: 01/2004
414: Battery and Charging System
414-00: Battery and Charging System – General Information
Description and Operation
Charging System
Battery Care
Quiescent Drain
Diagnosis and Testing
Charging System – V8 4.2L Petrol/V8 S/C 4.2L Petrol/2.5L NA V6 – AJV6/3.0L NA V6 –
AJ27
Charging System – 2.7L V6 – TdV6
General Procedures
Battery Charging
414-01: Battery Mounting and Cables
Specification
Description and Operation
Battery and Cables
Diagnosis and Testing
Battery
General Procedures
Battery Connect (86.15.15)
Battery Disconnect and Connect
Removal and Installation
Battery (86.15.01)
Battery Ground Cable (86.15.19)
Battery Tray (86.15.11)
414-02: Generator and Regulator
Specification
Description and Operation
Generator
Diagnosis and Testing
Generator
Removal and Installation
Generator (86.10.02) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Generator (86.10.02) – 2.7L V6 – TdV6
Generator (86.10.02) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
415: Information and Entertainment Systems
415-00: Information and Entertainment System – General Information
Diagnosis and Testing
Audio System
General Procedures
Cassette Player Cleaning
415-01: Audio Unit
Specification
Description and Operation
Audio System
Diagnosis and Testing
Audio System
Removal and Installation
Amplifier (86.50.10)
Audio Unit (86.50.03)
Compact Disc (CD) Changer (86.50.06)
Steering Wheel Audio Controls (86.50.42)
415-02: Antenna
Description and Operation
Antenna
Diagnosis and Testing
Antenna
Removal and Installation
Antenna Isolator Module (86.51.08)
415-03: Speakers
Description and Operation
Speakers
Diagnosis and Testing
Speakers
Removal and Installation
Front Door Speaker (86.50.13)
Rear Door Speaker (86.50.14)
Subwoofer Speaker (86.51.05)
417: Lighting
417-01: Exterior Lighting
Specification
Description and Operation
Exterior Lighting
Diagnosis and Testing
Headlamps
General Procedures
Headlamp Adjustment (86.40.18)
Removal and Installation
Ballast (86.41.52) – Vehicles With: High Intensity Discharge Headlamps
Front Fog Lamp (86.40.96) – Vehicles Built From: 02/2004
Front Fog Lamp (86.40.96) – Vehicles Built Up To: 01/2004
Headlamp Assembly (86.41.33)
Headlamp Bulb (86.42.14) – Vehicles With: High Intensity Discharge Headlamps
Headlamp Leveling Module
Headlamp Leveling Motor (86.42.04) – Vehicles With: High Intensity Discharge
Headlamps
Headlamp Leveling Motor (86.42.04) – Vehicles Without: High Intensity Discharge
Headlamps
Headlamp Leveling Sensor (86.42.15)
Headlamp Leveling Switch (86.65.87)
Rear Lamp Assembly (86.40.70) – Vehicles Built From: 02/2004
Rear Lamp Assembly (86.40.70) – Vehicles Built Up To: 01/2004
Stoplamp Switch
417-02: Interior Lighting
Description and Operation
Interior Lighting
Diagnosis and Testing
Interior Lighting
417-04: Daytime Running Lamps (DRL)
Description and Operation
Daytime Running Lamps (DRL)
Diagnosis and Testing
Daytime Running Lamps (DRL)
418: Electrical Distribution
418-00: Module Communications Network
Description and Operation
Communications Network
Diagnosis and Testing
Communications Network – VIN Range: M45255->N52047
Communications Network – VIN Range: N52048->N99999
418-01: Module Configuration
Diagnosis and Testing
Module Configuration
418-02: Wiring Harnesses
Description and Operation
Wiring Harness
General Procedures
Wiring Harness Repair
419: Electronic Feature Group
419-01A: Anti-Theft – Active
Description and Operation
Anti-Theft – Active
Diagnosis and Testing
Anti-Theft – Active
Removal and Installation
Anti-Theft Alarm Horn (86.52.03)
419-01B: Anti-Theft – Passive
Description and Operation
Anti-Theft – Passive
Diagnosis and Testing
Anti-Theft – Passive
General Procedures
Anti-Theft Security Access
Key Programming Using Diagnostic Equipment
Key Programming Using Two Programmed Keys
Removal and Installation
Passive Anti-Theft System (PATS) Transceiver (86.52.30)
419-05: Telematics
Description and Operation
Telematics
Diagnosis and Testing
Telematics
Removal and Installation
Global Positioning System (GPS) Antenna (86.56.61)
Module (86.56.59)
419-07: Navigation System
Description and Operation
Navigation System
Diagnosis and Testing
Navigation System
Removal and Installation
Navigation System Antenna (86.62.06)
Navigation System Display Module (86.62.07)
Navigation System Module (86.62.05)
419-08: Cellular Phone
Description and Operation
Cellular Phone – VIN Range: M45255->N52047
Cellular Phone – VIN Range: N52048->N99999
Diagnosis and Testing
Cellular Phone
Cellular Phone – Vehicles With: Bluetooth
Removal and Installation
Bluetooth Module
Cellular Phone Antenna (86.51.17)
419-10: Multifunction Electronic Modules
Specification
Description and Operation
Module Controlled Functions
Diagnosis and Testing
Multifunction Electronic Module
Removal and Installation
Driver Door Module (DDM) (86.80.29)
Driver Seat Module (DSM) (86.75.28)
Front Electronic Module (FEM) (86.80.41)
Multifunction Voice Activated Module (86.53.13) (86.80.40)
Rear Electronic Module (REM) (86.80.37)
5: Body and Paint
501: Body and Paint
501-02: Front End Body Panels
Description and Operation
Front End Body Panels
Removal and Installation
Air Deflector (76.11.41)
Cowl Panel Grille (76.10.01) (76.43.39)
Fender Splash Shield (76.10.90)
Radiator Grille Opening Panel (76.10.06)
Radiator Splash Shield (76.22.90)
501-03: Body Closures
Specification
Description and Operation
Body Closures
General Procedures
Hood Alignment (76.16.02)
Luggage Compartment Lid Alignment (76.19.03)
Rear Door Alignment (76.28.08)
Removal and Installation
Front Door Opening Weatherstrip (76.40.01)
Hood (76.16.01)
501-05: Interior Trim and Ornamentation
Specification
Description and Operation
Interior Trim
Removal and Installation
A-Pillar Trim Panel (76.13.31)
B-Pillar Lower Trim Panel (76.13.29)
B-Pillar Upper Trim Panel (76.13.28)
Cowl Side Trim Panel (76.13.30)
C-Pillar Trim Panel (76.13.73)
Front Door Trim Panel (76.34.01)
Headliner (76.64.01)
Parcel Shelf (76.67.06)
Rear Door Trim Panel (76.34.04)
Rear Window Blind (76.14.04)
Rear Window Blind Arm
Rear Window Blind Motor
Scuff Plate Trim Panel (76.13.81)
Sun Visor (76.10.48)
501-08: Exterior Trim and Ornamentation
Description and Operation
Exterior Trim
Removal and Installation
Radiator Grille (76.55.03)
Window Moulding (76.43.20)
501-09: Rear View Mirrors
Specification
Description and Operation
Rear View Mirrors
Diagnosis and Testing
Rear View Mirrors
Removal and Installation
Auto-Dimming Interior Mirror (76.10.56)
Exterior Mirror (76.10.52)
Exterior Mirror Cover (76.10.55)
Exterior Mirror Glass (76.10.53)
Exterior Mirror Motor (76.10.57) (76.11.09)
501-10: Seating
Specification
Description and Operation
Seats
Diagnosis and Testing
Seats
Removal and Installation
Front Seat (76.70.01)
Front Seat Backrest (76.70.06) – Vehicles Built From: 02/2004
Front Seat Backrest (76.70.06) – Vehicles Built Up To: 01/2004
Front Seat Backrest Cover (76.70.15)
Front Seat Cushion Cover (76.70.33) – Vehicles Built From: 02/2004
Front Seat Cushion Cover (76.70.33) – Vehicles Built Up To: 01/2004
Front Seat Head Restraint Motor (86.75.17)
Front Seat Height Adjustment Motor (86.75.29)
Front Seat Recliner Motor (86.75.04)
Front Seat Track Motor (86.75.33)
Lumbar Motor (86.75.12) – Vehicles Built From: 02/2004
Lumbar Motor (86.75.12) – Vehicles Built Up To: 01/2004
Rear Seat Backrest Cover (76.70.48) (78.90.12)
Rear Seat Bolster (76.70.67)
Rear Seat Cushion (76.70.37)
Seat Base (76.70.08) – Vehicles Built From: 02/2004
Seat Base (76.70.08) – Vehicles Built Up To: 01/2004
Seat Control Switch (86.75.23)
501-11: Glass Frames and Mechanisms
Specification
Description and Operation
Glass Frames and Mechanisms
Diagnosis and Testing
Glass Frames and Mechanisms
General Procedures
Door Window Motor Initialization
Removal and Installation
Front Door Window Glass (76.31.01)
Front Door Window Regulator and Motor (76.31.45)
Rear Door Fixed Window Glass
Rear Door Window Glass (76.31.02)
Rear Door Window Regulator and Motor (86.25.09)
Rear Window Glass (76.81.11)
Window Control Switch (86.25.08)
Windshield Glass Using Cheese Wire (76.81.40)
Windshield Glass Using Cutting Tool (76.81.01)
501-12: Instrument Panel and Console
Specification
Description and Operation
Instrument Panel
Removal and Installation
Floor Console (76.25.01)
Glove Compartment (76.52.03)
Instrument Panel (76.46.01)
Instrument Panel Console (88.20.34)
Overhead Console (76.13.69)
Overhead Console Switch Moulding
501-14: Handles Locks Latches and Entry Systems
Specification
Description and Operation
Handles Locks Latches and Entry Systems
Diagnosis and Testing
Locks Latches and Entry Systems
General Procedures
Remote Transmitter Programming
Removal and Installation
Exterior Front Door Handle (76.58.01)
Exterior Rear Door Handle (76.58.02)
Front Door Lock Actuator (76.37.74)
Front Door Lock Cylinder (76.37.71)
Interior Door Handle (76.37.31)
Luggage Compartment Lid Latch Actuator (76.19.25) – Vehicles Built From: 02/2004
Luggage Compartment Lid Latch Actuator (76.19.25) – Vehicles Built Up To: 01/2004
Luggage Compartment Lid Lock Cylinder (76.19.19) – Vehicles Built From: 02/2004
Luggage Compartment Lid Lock Cylinder (76.19.19) – Vehicles Built Up To: 01/2004
Rear Door Lock Actuator (76.37.09)
501-16: Wipers and Washers
Specification
Description and Operation
Wipers and Washers
Diagnosis and Testing
Wipers and Washers
Removal and Installation
Headlamp Washer Jet (84.20.08)
Headlamp Washer Pump (84.20.21)
Rain Sensor (84.12.10) (86.56.62)
Rain Sensor Module (86.56.60)
Windshield Washer Pump (84.10.21)
Windshield Washer Reservoir (84.10.01) (84.10.03)
Wiper Mounting Arm and Pivot Shaft (84.15.24)
Wiper Pivot Arm (84.15.03) – Vehicles Built From: 02/2004
Wiper Pivot Arm (84.15.03) – Vehicles Built Up To: 01/2004
501-17: Roof Opening Panel
Specification
Description and Operation
Roof Opening Panel
Diagnosis and Testing
Roof Opening Panel
General Procedures
Motor Synchronization (76.82.48)
Roof Opening Panel Alignment
Removal and Installation
Air Deflector (76.82.07)
Roof Opening Panel Frame (76.82.01)
Roof Opening Panel Front Drain Hose (76.82.21)
Roof Opening Panel Glass (76.82.05)
Roof Opening Panel Motor (86.76.01)
Roof Opening Panel Rear Drain Hose (76.82.22)
Roof Opening Panel Shield (76.82.06)
Roof Opening Panel Weatherstrip (76.82.15)
Trough Assembly (76.82.58)
501-19: Bumpers
Specification
Description and Operation
Bumpers
Removal and Installation
Front Bumper Cover (76.22.78)
Front Bumper Cover Insert (76.22.73) – Vehicles Built From: 02/2004
Front Bumper Cover Insert (76.22.73) – Vehicles Built Up To: 01/2004
Rear Bumper (76.22.27) (76.22.52)
Rear Bumper Cover (76.22.74) (76.22.77)
Rear Bumper Cover Insert (76.22.75) – Vehicles Built From: 02/2004
501-20A: Safety Belt System
Specification
Description and Operation
Safety Belt System
Diagnosis and Testing
Safety Belt System
Removal and Installation
Front Safety Belt Buckle (76.73.49)
Front Safety Belt Retractor (76.73.10)
Front Safety Belt Shoulder Height Adjuster (76.73.12)
Rear Center Safety Belt Retractor (76.73.20)
Rear Safety Belt Buckle (76.73.50)
Rear Safety Belt Retractor (76.73.18)
501-20B: Supplemental Restraint System
Specification
Description and Operation
Air Bag Supplemental Restraint System (SRS)
Diagnosis and Testing
Air Bag Supplemental Restraint System (SRS)
General Procedures
Air Bag Disposal
Removal and Installation
B-Pillar Side Impact Sensor (76.73.68)
Clockspring (86.65.92)
C-Pillar Side Impact Sensor (76.73.69)
Crash Sensor (76.73.55)
Driver Air Bag Module (76.73.39)
Front Passenger Seat Occupant Classification Sensor (76.73.60)
Passenger Air Bag Deactivation (PAD) Indicator (76.73.58)
Passenger Air Bag Module (76.73.37)
Restraints Control Module (RCM) (76.73.48)
Seat Position Sensor (76.73.62)
Side Air Bag Module (76.73.47)
Side Air Curtain Module (76.73.64)
502: Frame and Mounting
502-00: Uni-Body Subframe and Mounting System
Specification
Description and Operation
Frame Assembly
Removal and Installation
Front Subframe (76.10.05) – 2.5L NA V6 – AJV6/3.0L NA V6 – AJ27
Front Subframe (76.10.05) – 2.7L V6 – TdV6
Front Subframe (76.10.05) – V8 4.2L Petrol/V8 S/C 4.2L Petrol
Rear Subframe (64.25.01)
Rear Subframe Front Bushing (64.25.34)
Rear Subframe Rear Bushing (64.25.36)
