Scorpio 1995 (10.1994-06.1998) Workshop Manual
- Mechanical Repairs
- 1 General Information
- 100 About this Manual
- 100-04 Feedback Forms
- Description and Operation
- 100-03 How to Use this Manual
- Description and Operation
- 100-02 Important Safety Instructions
- Description and Operation
- 100-01 Introduction
- Description and Operation
- 100-04 Feedback Forms
- 101 General Service Information
- 101-03 Standard Workshop Practices
- Description and Operation
- 101-01 Health and Safety Precautions
- Description and Operation
- 101-02 Vehicle Identification
- Description and Operation
- 101-06 Road or Roller Testing
- Description and Operation
- 101-05 Solvents, Sealers and Adhesives
- Description and Operation
- 101-04 Application and Use of Specifications
- Description and Operation
- 101-03 Standard Workshop Practices
- 100 About this Manual
- 2 Chassis
- 211 Wheels, Tyres
- 211-01 Wheels, Tyres
- 212 Braking System
- 212-01 Standard Braking System
- SpecificationsGeneral Specifications
- Description and Operation
- 212-01 Standard Braking System|Description and Operation
- Removal and Installation
- Brake System – Hydraulic Fluid – Replace (12 154 0)
- Disc – Front Brake – Remove and Install (One side) (12 223 0)
- Brake System – Bleed (12 141 0)
- Brake Disc – Runâ€out – Check (Both sides) (12 221 0)
- Caliper Assembly – Rear – Remove and Install (One side) (12 253 0)
- Disc – Rear Brake – Remove and Install (One side) (12 225 0)
- Caliper Assembly – Front – Remove and Install (One side) (12 243 0)
- Brake Pedal – Remove and Install (12 333 0)
- Brake Fluid Reservoir – Remove and Install (12 341 0)
- Splash Shield – Rear – Remove and Install (Caliper removed) (12 259 4)
- Lever Assembly – Handbrake – Remove and Install (12 664 0)
- Vacuum Pump – Remove and Install (12 414 0)
- Servo – Remove and Install (12 451 0)
- Vacuum Hose – Servo – Replace (12 481 0)
- Master Cylinder – Remove and Install (12 343 0)
- Handbrake Cable – Adjust (12 662 0)
- Rear Cable – Handbrake – Replace (12 675 0)
- 212-02 Antiâ€lock Braking System
- SpecificationsGeneral Specifications
- Description and Operation
- 212-02 Antiâ€lock Braking System|Description and Operation
- Removal and Installation
- 212-03 Traction Control
- SpecificationsGeneral Specifications
- Description and Operation
- 212-01 Standard Braking System
- 213 Steering
- 213-01 Power Assisted Steering
- SpecificationsGeneral Specifications
- Description and Operation
- 213-01 Power Assisted Steering|Description and Operation
- Removal and Installation
- Pump Assembly – Power Steering – Remove and Install (DOHC) (13 434 0)
- Power Steering System - Bleed (13 416 1)
- Gaiter - Steering Rack - Remove And Install (13 134 0)
- Steering Gear Assembly - Remove And Install (13 116 0)
- Pump Assembly – Power Steering – Remove and Install (V6) (13 434 0)
- Pump Assembly – Power Steering – Remove and Install (VM Diesel) (13 434 0)
- Module (Servotronic) – Power Steering – Remove and Install (13 480 0)
- Fluid Cooler – Power Steering – Remove and Install (13 444 0)
- Steering Wheel – Remove and Install (13 524 0)
- Fluid Hoses – Power Steering – Replace (13 442 0)
- Actuator (Servotronic) – Power Steering – Remove and Install (13 481 0)
- Steering Wheel – Centralise (13 523 0)
- Flexible Coupling – Steering Column – Remove and Install (13 566 0)
- Steering Column Assembly – Remove and Install (13 542 0)
- 213-01 Power Assisted Steering
- 214 Front Suspension
- 214-01 Front Suspension
- SpecificationsGeneral Specifications
- Description and Operation
- 214-01 Front Suspension|Description and Operation
- Removal and Installation
- Toe-In - Adjust (14 111 3)
- Front Wheel Alignment - Check (14 111 0)
- Crossmember - Front Axle-Engine Mounting - Remove And Install (14 234 0)
- Spindle Carrier - Remove And Install (14 343 0)
- Arm Assembly - Lower - Right-hand Side - Remove And Install (14 707 0)
- Suspension Unit Assembly - Front - Remove And Install (14 781 0)
- Stabiliser Bar - Remove And Install (14 752 0)
- Wheel Bearing - Front Inner And Outer - Renew (Spindle Carrier Assembly Removed) (14 411 4)
- Connecting Link - Stabiliser Bar - Remove And Install (14 757 0)
- 214-01 Front Suspension
- 215 Rear Axle and Suspension
- 215-01 Rear Axle (Saloon)
- SpecificationsGeneral Specifications
- Removal and Installation
- Rear Axle and Suspension †Remove and Install (15 212 0)
- Driveshaft Assembly †Remove and Install (15 514 0)
- Differential Assembly †Remove and Install (15 254 0)
- Differential Assembly †Dismantle and Assemble (Assembly Removed) (15 254 6)
- Shaft †Rear Axle â€Remove and Install (One Side) (15 321 0)
- Drive Pinion Oil Seal †Renew (15 302 0)
- Rear Axle Driveshaft †Overhaul (rear axle driveshaft removed) (15 321 8)
- Hub Assembly †Rear †Remove and Install (One Side) (15 373 0)
- Bearings â€Rear Wheel †Inner and Outer †Renew (Hub Assembly Removed) (15 413 4)
- Rear Wheel Stud †Renew (One) (15 441 0)
- Insulator †Rear Suspension Crossmember †Remove and Install (One) (15 681 0)
- Rear Spring Assembly â€Remove and Install (One Side) (15 621 0)
- Insulator †Rear Axle Assembly †Remove and Install (15 686 0)
- Lower Arm †Rear Axle †Remove and Install (One Side) (15 705 0)
- Stabiliser Bar †Rear †Remove and Install (15 752 0)
- Rear Shock Absorber †Remove and Install (15 791 0)
- 215-02 Rear Axle and Suspension
- SpecificationsGeneral Specifications
- Removal and Installation
- 215-01 Rear Axle (Saloon)
- 211 Wheels, Tyres
- 3 Powertrain
- 316 Manual Transmission and Clutch
- 316-01 MT 75 Manual Transmission and Clutch
- SpecificationsGeneral Specifications
- Description and Operation
- 316-01 MT 75 Manual Transmission and Clutch|Description and Operation
- Removal and Installation
- Manual Transmission - Remove and Install (2,0 DOHC 8V Engine) (16 114 0)
- Manual Transmission - Remove and Install (2,5l TCI Diesel Engine) (16 114 0)
- Manual Transmission - Overhaul (transmission removed) (16 118 8)
- Clutch Disc and Pressure Plate - Remove and Install (Engine or Transmission Removed) (16 724 4)
- Hydraulic Clutch Operating System - Bleed (16 843 0)
- Clutch Master Cylinder - Remove and Install (16 856 0)
- Clutch Slave Cylinder - Remove and Install (16 862 0)
- 316-01 MT 75 Manual Transmission and Clutch
- 317 Automatic Transmission
- 317-01 A4LDE Automatic Transmission
- SpecificationsGeneral Specifications
- Description and Operation
- 317-01 A4LDE Automatic Transmission|Description and Operation
- Removal and Installation
- 317-02 A4LDE Automatic Transmission
- 317-03 A4LDE Automatic Transmission
- SpecificationsGeneral Specifications
- Removal and Installation
- Brake Bands †Adjust (17 132 0)
- Automatic Transmission Assembly †Remove and Install (17 214 4)
- Automatic Transmission †Renew (Transmission Removed) (17 214 5)
- Automatic Transmission Assembly †Remove and Install (2.3l DOHC 16V engine) (17 214 0)
- Gear †Speedometer Driven †Remove and Install (17 382 0)
- Gear Selector Mechanism †Remove and Install (17 634 0)
- Gear Selector Mechanism †Dismantle and Assemble (Selector Mechanism Removed) (17 634 8)
- Drive Position Sensor †Remove and Install (17 705 0)
- Rod †Selector †Adjust (17 672 0)
- 317-01 A4LDE Automatic Transmission
- 321 Engine
- 321-01 2,0 DOHC 8V Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 321-01 2,0 DOHC 8V Engine|Description and Operation
- Removal and Installation
- Engine Compression †Check (engine hot) (21 111 0)
- Oil Pressure †Check (engine hot) (21 113 0)
- Engine †Remove and Install (21 134 0)
- Engine †Dismantle and Assemble (engine removed) (21 134 8)
- Valve Guide †Ream (One) (Valve Removed) (21 233 4)
- Cylinder Head †Remove and Install (21 163 0)
- Valve Seat †Cut (One)(Valve(s) Removed) (21 231 9)
- Camshafts †Remove and Install (both) (21 284 0)
- Seals †Valve Stem †Renew (all) (21 238 0)
- Oil Seal †Crankshaft Front †Renew (21 467 0)
- Timing Chain †Renew (21 314 0)
- 321-02 2,0 DOHC 16V Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 321-02 2,0 DOHC 16V Engine|Description and Operation
- Removal and Installation
- Oil Pressure †Check †Engine Hot (21 113 0)
- Engine and Transmission Assembly †Remove and Install (21 132 0)
- Compression Pressure †Check †Engine Hot (21 111 0)
- Engine †Remove and Install (21 134 0)
- Engine †Dismantle and Assemble (21 134 8)
- Valve Seat †Cut (one) (valve removed) (21 231 9)
- Cylinder Head †Remove and Install (21 164 0)
- Valve Guide †Ream (one) (valve removed) (21 233 4)
- Renew Valve Stem Seals (21 238 0)
- 321-03 2,5 TCI Diesel Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 321-03 2,5 TCI Diesel Engine|Description and Operation
- Removal and Installation
- Oil Pressure †Engine Hot †Check (21 113 0)
- Compression †Engine Hot †Check (21 111 0)
- Engine †Remove and Install (automatic transmission) (21 134 0)
- Engine †Remove and Install (manual transmission) (21 134 0)
- Engine Assembly †Dismantle and Reassemble (engine assembly removed) (21 134 8)
- Retaining Bolts †Cylinder Head †Torque (21 161 0)
- Cylinder Heads (all) †Remove and Install (21 164 0)
- Seal †Crankshaft Front †Renew (21 467 0)
- Seal †Crankshaft Rear †Renew (engine or transmission removed) (21 468 4)
- 321-04 2,9 V6 12V Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 321-04 2,9 V6 12V Engine|Description and Operation
- Removal and Installation
- Compression †Engine Hot †Check (21 111 0)
- Oil Pressure †Engine Hot †Check (21 113 0)
- Engine †Remove and Install (21 134 0)
- Engine †Dismantle and Assemble (21 134 8)
- Cylinder Heads †Remove and Install (21 164 0)
- Seals †Valve Stem †Renew (all) (21 238 0)
- Oil Seal †Crankshaft Front †Renew (21 467 0)
- Timing Chain †Renew (21 314 0)
- 321-05 2,9 V6 24V Cosworth Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 321-05 2,9 V6 24V Cosworth Engine|Description and Operation
- Removal and Installation
- Oil Pressure †Engine Hot †Check (21 113 0)
- Compression †Engine Hot †Check (21 111 0)
- Engine and Transmission Assembly †Remove and Install (21 132 0)
- Sump †Remove and Install (21 154 0)
- Engine Assembly †Dismantle and Assemble (21 134 8)
- Exhaust Manifold †Remove and Install (one, rightâ€hand cylinder head) (21 186 0)
- Exhaust Manifold †Remove and Install (one, leftâ€hand cylinder head) (21 187 0)
- Cylinder Heads †Remove and Install (All) (21 164 0)
- Valves (all, one cylinder head) (cylinder head removed) †Remove and Install (21 217 4)
- Seals †Valve Stem †Renew (all) (21 238 0)
- Timing Chain †Renew (21 314 0)
- Seal †Crankshaft Front †Renew (21 467 0)
- 321-06 2,3 DOHC 16V Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 321-06 2,3 DOHC 16V Engine|Description and Operation
- Removal and Installation
- Oil Pressure †Engine Hot †Check (21 113 0)
- Compression †Engine Hot †Check (21 111 0)
- Engine and Transmission Assembly †Remove and Install (21 132 0)
- Engine Assembly †Remove and Install (21 134 0)
- Engine †Dismantle and Assemble (21 134 8)
- Cylinder Head †Remove and Install (21 163 0)
- Camshafts †Remove and Install (both) (21 284 0)
- Seals †Valve Stem †Renew (all) (21 238 0)
- Cylinder Head †Renew (new head supplied with valves) (cylinder head removed) (21 165 6)
- Timing Chain †Renew (21 314 0)
- 321-01 2,0 DOHC 8V Engine
- 323 Fuel System
- 323-01 General Fuel System
- Description and Operation
- 323-01 General Fuel System|Description and Operation
- Removal and Installation
- Air Cleaner Assembly (V6 24V Variants) - Remove and Install (23 174 0)
- Air Cleaner Assembly (Diesel Variants 97 ¼ MY onwards) - Remove And Install (23 174 0)
- Air Cleaner Assembly (DOHC Variants) - Remove and Install (23 174 0)
- Air Cleaner Assembly (Diesel Variants up to 97 ¼ MY) - Remove and Install (23 174 0)
- Fuel Filter (Diesel Variants) - Remove and Install (23 545 0)
- Element - Air Cleaner (Petrol Variants) - Replace (23 184 0)
- Element - Air Cleaner (Diesel Variants up to 97 ¼ MY) - Remove And Install (23 184 0)
- Fuel Pump (Petrol Variants) - Remove and Install (23 534 0)
- Fuel Filter (Petrol Variants) - Remove and Install (23 545 0)
- Element - Air Cleaner (Diesel Variants 97 ¼ MY Onwards) - Remove And Install (23 184 0)
- Fuel Tank Filler Pipe - Remove and Install (23 572 0)
- Roll Over Valve - Remove and Install (23 576 0)
- Fuel Tank - Remove and Install (23 554 0)
- Element - Fuel Filter (Diesel Variants) - Replace (23 546 0)
- Cable - Accelerator (Petrol Variants With Traction Control) - Adjust (23 811 0)
- Cable - Accelerator (Diesel Variants up to 97 ¼ MY) - Adjust (23 811 0)
- Switch - Fuel Shut Off - Remove and Install (33 577 0)
- Cable - Accelerator (Diesel Variants) - Remove and Install (23 826 0)
- Cable - Accelerator (Petrol Variants With Traction Control) - Remove and Install (23 826 0)
- Description and Operation
- 323-02 Petrol Injection Equipment DOHC 8V Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 323-03 Petrol Injection Equipment DOHC 16V Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 323-04 Petrol Injection Equipment V6 24V Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 323-05 Diesel Injection Equipment
- SpecificationsGeneral Specifications
- Description and Operation
- 323-05 Diesel Injection Equipment|Description and Operation
- Removal and Installation
- Fuel Injection Pump (Up to 97 ¼ MY) - Remove And Install (23 414 0)
- Fuel Injection Pump (97 ¼ MY Onwards-Engine Build Code Up To 43B †02076) - Remove And Install (23 414 0)
- Fuel Injection Pump (97 ¼ MY Onwards-Engine Build Code 43B †02076 Onwards) - Remove And Install (23 414 0)
- Delivery Pipes - Fuel Injector - Remove And Install (23 483 0)
- Fuel Injector - Renew (23 455 0)
- Charge Air Cooler - Remove And Install (23 620 0)
- Turbocharger - Remove And Install (23 612 0)
- Glow Plugs - Remove And Install (23 777 0)
- Heater - Diesel Fuel - Remove And Install (23 769 0)
- 323-06 Petrol Injection Equipment - V6 12V Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 323-01 General Fuel System
- 324 Cooling System
- 324-01 Cooling System - Petrol Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 324-01 Cooling System - Petrol Engines|Description and Operation
- Removal and Installation
- Expansion Tank - Remove and Install (24 284 0)
- Cooling System - Pressure Test (24 111 0)
- Cooling System - Drain and Refill (24 122 0)
- Radiator - Remove and Install (24 254 0)
- Water Pump Assembly (DOHC Variants) - Remove and Install (24 404 0)
- Thermostat (V6 24V Variants) - Remove and Install (24 454 0)
- Water Pump Assembly (V6 24V Variants) - Remove and Install (24 404 0)
- Thermostat (DOHC Variants) - Remove and Install (24 454 0)
- 324-02 Cooling System - 2,5l TCI Diesel Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 324-02 Cooling System - 2,5l TCI Diesel Engines|Description and Operation
- Removal and Installation
- 324-01 Cooling System - Petrol Engines
- 325 Exhaust System
- 325-01 Exhaust System
- SpecificationsGeneral Specifications
- Description and Operation
- 325-01 Exhaust System|Description and Operation
- Removal and Installation
- Exhaust System (DOHC 8V and 16V) - Remove and Install (25 204 0)
- Exhaust System (V6 12V) - Remove and Install (25 204 0)
- Exhaust System (V6 24V) - Remove and Install (25 204 0)
- Exhaust System (Diesel) - Remove and Install (25 204 0)
- Catalyst (DOHC 8V) - Remove and Install (25 250 0)
- Catalyst (V6 24V) - Remove and Install (25 250 0)
- Catalyst (DOHC 16V) - Remove and Install (25 250 0)
- Catalyst (V6 12V) - Remove and Install (25 250 0)
- 325-01 Exhaust System
- 326 Starting System
- 326-01 Starting System
- SpecificationsGeneral Specifications
- Description and Operation
- 326-01 Starting System
- 329 Engine Management
- 329-01 General Engine Management
- SpecificationsGeneral Specifications
- Removal and Installation
- Regulator - Variable Inlet System Vacuum (Petrol Variants) - Remove and Install (23 401 0)
- Valve - Exhaust Gas Recirculation (DOHC Variants) - Remove and Install (23 312 0)
- Pipe - Exhaust Manifold to Exhaust Gas Recirculation Valve (DOHC Variants) - Remove and Install (23 301 0)
- Regulator - Exhaust Gas Recirculation Vacuum - Remove and Install (23 313 0)
- Module - Electronic Ignition System - Remove and Install (29 205 0)
- Sensor - Heated Oxygen (Pre †Catalyst) (DOHC Variants) - Remove and Install (29 200 0)
- Module - Powertrain Control (Petrol Variants) - Remove and Install (29 200 0)
- Module - Powertrain Control (Diesel Variants) - Remove and Install (29 200 0)
- Sensor - Heated Oxygen (Post †Catalyst) (DOHC Variants) - Remove and Install (29 220 0)
- Valve - Evaporative Emission Canister Purge - Remove and Install (33 772 0)
- Transducer - Exhaust Gas Recirculation System Pressure - Remove and Install (29 242 0)
- Sensor - Crankshaft Position (DOHC Variants) - Remove And Install (29 230 0)
- Sensor - Mass Air Flow (DOHC Variants) - Remove and Install (29 226 0)
- Canister - Evaporative Emission - Remove and Install (29 250 0)
- 329-02 Engine Management DOHC 8V Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 329-02 Engine Management DOHC 8V Engines|Description and Operation
- Removal and Installation
- Sensor - Intake Air Temperature - Remove and Install (29 622 0)
- Valve - Idle Air Control - Remove and Install (23 323 0)
- Sensor - Throttle Position - Remove and Install (23 325 0)
- Sensor - Engine Coolant Temperature - Remove and Install (21 190 0)
- Sensor - Camshaft Position - Remove and Install (29 232 0)
- 329-03 Engine Management DOHC 16V Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 329-03 Engine Management DOHC 16V Engines|Description and Operation
- Removal and Installation
- Sensor - Throttle Position (2.0 DOHC) - Remove And Install (23 325 0)
- Valve - Idle Air Control - Remove and Install (23 323 0)
- Sensor - Engine Coolant Temperature - Remove and Install (21 190 0)
- Sensor - Intake Air Temperature (2.3 DOHC) - Remove And Install (29 622 0)
- Actuator - Variable Inlet System (2.0 DOHC) - Remove and Install (23 400 0)
- Sensor - Air Intake Temperature (2.0 DOHC) - Remove and Install (29 622 0)
- Sensor - Camshaft Position - Remove and Install (29 232 0)
- Sensor - Throttle Position (2.3 DOHC) - Remove And Install (23 325 0)
- 329-04 Engine Management - V6 24V Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 329-04 Engine Management - V6 24V Engines|Description and Operation
- Removal and Installation
- Sensor – Engine Coolant Temperature – Remove and Install (21 190 0)
- Valve – Idle Air Control – Remove and Install (23 323 0)
- Valve – Exhaust Gas Recirculation – Remove and Install (23 312 0)
- Actuator – Variable Inlet System – Remove and Install (23 400 0)
- Pipe - Intake Manifold To Exhaust Gas Recirculation Valve - Remove And Install (23 300 0)
- Sensor – Throttle Position – Remove and Install (23 325 0)
- Sensor – Intake Air Temperature – Remove and Install (29 622 0)
- Sensor – Mass Air Flow – Remove and Install (29 226 0)
- Sensor – Camshaft Position – Remove and Install (29 232 0)
- Sensor – Heated Oxygen (Post †Catalyst) – Remove and Install (29 220 0)
- Sensor – Crankshaft Position – Remove and Install (29 230 0)
- 329-05 Engine Management - 2.5l TCI Diesel Engines
- SpecificationsGeneral Specifications
- Description and Operation
- 329-05 Engine Management - 2.5l TCI Diesel Engines|Description and Operation
- Removal and Installation
- Sensor - Mass Air Flow (97 ¼ MY Onwards) - Remove and Install (29 226 0)
- Pipe – Exhaust Manifold to EGR Valve – Remove and Install (23 301 0)
- Sensor – Engine Coolant Temperature – Remove and Install (21 190 0)
- Sensor – Crankshaft Position – Remove and Install (29 230 0)
- Exhaust Gas Recirculation Valve – Remove and Install (23 312 0)
- Electronic Vacuum Regulator - Remove And Install (29 245 0)
- 329-06 Engine Management - V6 12V Engine
- SpecificationsGeneral Specifications
- Description and Operation
- 329-01 General Engine Management
- 316 Manual Transmission and Clutch
- 4 Electrical
- 431 Charging System
- 431-01 Charging System
- SpecificationsGeneral Specifications
- Description and Operation
- 431-01 Charging System|Description and Operation
- Removal and Installation
- Alternator Assembly (V6 24V) - Remove and Install (21 414 0)
- Drive Belt - Alternator (Diesel) - Remove And Install (31 413 0)
- Drive Belt - Alternator (DOHC 8V and 16V) - Remove And Install (31 413 0)
- Drive Belt - Alternator (2,3 DOHC 16V) - Remove And Install (31 413 0)
- Drive Belt - Alternator (V6 24V) - Remove And Install (31 413 0)
- Alternator Assembly (DOHC 16V) Remove and Install (31 414 0)
- Alternator Assembly (Diesel) (Up To 97 ¼ MY) - Remove And Install (31 414 0)
- Alternator Assembly (Diesel) (97 ¼ MY Onwards) - Remove And Install (31 414 0)
- 431-01 Charging System
- 432 Exterior Electrical Systems
- 432-01 Exterior Electrical Systems
- SpecificationsGeneral Specifications
- Description and Operation
- 432-01 Exterior Electrical Systems|Description and Operation
- Removal and Installation
- Headlamp Assembly (One Side) †Remove and Install (32 115 0)
- Reflector Assembly †Headlamp (One Side) †Remove and Install (32 123 0)
- Motor †Windscreen Wiper †Remove and Install (32 524 0)
- Headlamps †Align (Both Sides) (32 113 0)
- Linkage †Windscreen Wiper †Remove and Install (32 554 0)
- Pivot Shaft †Windscreen Wiper (One) †Remove and Install (32 563 0)
- Wiper Arm (All) †Adjust (32 591 0)
- 432-01 Exterior Electrical Systems
- 433 Basic Interior Electrical System
- 433-01 Basic Interior Electrical System
- SpecificationsGeneral Specifications
- Description and Operation
- 433-01 Basic Interior Electrical System|Description and Operation
- Removal and Installation
- Glass - Instrument Cluster - Remove and Install (Instrument Cluster Removed) (33 226 4)
- Bulb - Instrument Cluster - Remove and Install (Instrument Cluster Removed) (33 228 4)
- Sender Unit - Fuel Tank - Remove and Install (33 286 0)
- Head - Speedometer - Remove and Install (33 254 0)
- Gauge - Fuel - Remove and Install (33 284 0)
- Tachometer - Remove and Install (33 264 0)
- Gauge - Temperature - Remove and Install (33 304 0)
- Instrument Cluster Assembly - Remove And Install (33 214 0)
- Facia - Instrument Panel - Remove And Install (33 213 0)
- Sender Unit - Temperature (DOHC 16V only) - Remove and Install (33 306 0)
- Clock - Remove and Install (33 374 0)
- Lock Barrel - Ignition Switch - Remove and Install (33 513 0)
- Sender Unit - Temperature (except DOHC 16V) - Remove and Install (33 306 0)
- Switch - De †activator - Pedal (Clutch) - Remove and Install (33 502 0)
- Switch - Luggage Compartment Lamp - Remove and Install (33 529 0)
- Switch - Door Mirror Control - Remove and Install (33 519 0)
- Switch - Light - Remove and Install (33 514 0)
- Switch - Headlamp Levelling - Remove and Install (33 515 0)
- Switch - Handbrake Warning Light - Remove and Install (33 546 0)
- Switch - Oil Pressure Warning Light (VM Diesel) - Remove And Install (33 554 0)
- Switch - Stop Light - Remove and Install (33 548 0)
- Switch - Thermal - Radiator Fan - Remove and Install (33 555 0)
- Switch - Heated Windscreen - Remove and Install (33 571 0)
- Switch - Oil Pressure Warning Light (DOHC) - Remove And Install (33 554 0)
- Switch - Memory - Mirror-Seat - Remove and Install (33 593 0)
- Speed Sender Unit - Remove and Install (33 654 0)
- Switch - Heated Rear Window - Remove and Install (33 572 0)
- Switch - Multifunction (Steering Column) - Remove And Install 33 612 0
- Switch - Blower Motor - Heater (High †Series) - Remove and Install (33 574 0)
- Module - Central Control - Remove and Install (33 668 0)
- Switch - Blower Motor - Heater (Low †Series) - Remove and Install (33 574 0)
- Trip Computer Module - Remove and Install (33 651 0)
- Module - Multiplex (Door) - Remove and Install (33 669 0)
- Motor - Window Operating - Front Door - Remove and Install (33 782 0)
- Motor - Lock - Front Door - Remove and Install (33 779 0)
- Motor - Window Operating - Rear Door - Remove and Install (33 783 0)
- Motor - Lock - Rear Door - Remove and Install (33 780 0)
- Motor - Seat Operating (Height Adjust) - Front Seat - Remove and Install (33 784 0)
- Module - Multiplex (Seat) - Remove and Install (33 669 0)
- Motor - Lock - Fuel Filler Flap - Remove and Install (33 792 0)
- Motor - Sliding Roof Operating - Remove and Install (33 786 0)
- 433-02 Auxiliary Warning System
- Description and Operation
- 433-02 Auxiliary Warning System|Description and Operation
- Removal and Installation
- Display Assembly - Park Position (Notchback) - Remove and Install (33 368 0)
- Sender Unit - Fuel Tank - Remove and Install (33 286 0)
- Display Assembly - Warning Indicator - Remove and Install (33 367 0)
- Display Assembly - Park Position (Wagon) - Remove and Install (33 368 0)
- Sender Unit - Low Air Temperature Warning - Remove and Install (33 309 0)
- Bulb - Auxiliary Warning Light - Remove and Install (33 143 0)
- Module - Park Position (Notchback) - Remove and Install (33 370 0)
- Switch - Door Ajar (Rear Door) - Remove and Install (33 507 0)
- Switch - Door Ajar (Front Door) - Remove and Install (33 507 0)
- Sensor - Park Position (Notchback) - Remove and Install (33 369 0)
- Module - Park Position (Wagon) - Remove and Install (33 370 0)
- Sensor - Park Position (Wagon) - Remove and Install (33 369 0)
- Switch - Low Coolant Warning (Diesel) - Remove and Install (33 606 0)
- Switch - Low Washer Fluid - Remove and Install (33 607 0)
- Switch - Luggage Compartment Ajar - Remove and Install (33 509 0)
- Module - Central Timer - Remove and Install (33 646 0)
- Switch - Low Coolant Warning (Petrol) - Remove and Install (33 606 0)
- Description and Operation
- 433-03 Anti †Theft Systems
- SpecificationsGeneral Specifications
- Description and Operation
- 433-03 Anti †Theft Systems|Description and Operation
- Removal and Installation
- Switch - Door Ajar (Rear Door) - Remove and Install (33 507 0)
- Switch - Door Ajar (Front Door) - Remove and Install (33 507 0)
- Switch - Hood Alarm - Remove and Install (33 539 0)
- Switch - Luggage Compartment Ajar - Remove and Install (33 509 0)
- Module - Immobiliser (PATS) - Remove and Install (33 660 0)
- Switch - Door Lock - Key Activated - Alarm System - Remove and Install (33 506 0)
- Transceiver - Immobiliser (PATS) - Remove and Install (33 662 0)
- LED - Immobiliser (PATS) - Remove And Install (33 663 0)
- Module - Central Control - Remove and Install (33 668 0)
- Horn - Alarm System - Remove and Install (33 774 0)
- 433-04 Speed Control
- Description and Operation
- 433-04 Speed Control|Description and Operation
- Removal and Installation
- Sensor - Accelerator Pedal Position (Diesel 97 ½ MY Onwards) - Remove And Install (29 228 0)
- Module - Powertrain Control (Diesel 97 ½ MY Onwards) - Remove And Install (29 200 0)
- Switch - Speed Control - Remove and Install (33 500 0)
- Actuator - Speed Control - Remove and Install (33 678 0)
- Vehicle Speed Sensor - Remove And Install (33 654 0)
- Switch - De †activator - Pedal - Remove and Install (33 502 0)
- Description and Operation
- 433-01 Basic Interior Electrical System
- 434 Heating and Air Conditioning
- 434-01 Heating and Ventilation
- SpecificationsGeneral Specifications
- Description and Operation
- 434-01 Heating and Ventilation|Description and Operation
- Removal and Installation
- Cables †Heater Controls †Front †Remove and Install (34 316 0)
- Heater Controls †Front †Remove and Install (34 311 0)
- Heater Assembly †Dismantle and Reassemble (Heater Assembly Removed) Manually Controlled Air Conditioning System (34 354 8)
- Heater Assembly †Remove and Install (34 354 0)
- Heater Assembly †Dismantle and Reassemble (Heater Assembly Removed) Electronically Controlled Air Conditioning System (34 354
- Vent †Face Level †Passengers Side †Remove and Install (34 487 0)
- Vent †Face Level †Drivers Side †Remove and Install (34 488 0)
- Vent †Face Level †Centre †Remove and Install (34 489 0)
- 434-02 Air Conditioning
- SpecificationsGeneral Specifications
- Description and Operation
- 434-02 Air Conditioning|Description and Operation
- Removal and Installation
- Switch †Deâ€Ice †Evaporator †Remove and Install (33 560 0)
- Control Panel †Heating-Air Conditioning †Remove and Install (34 300 0)
- Refrigerant †Air Conditioning †Drain and Refill (34 620 0)
- Evaporator †Air Conditioning †Remove and Install (2.0l DOHC 16V engine) (34 622 0)
- Evaporator †Air Conditioning †Remove and Install (2.9l V6â€24V Cosworth engine) (34 622 0)
- Air Conditioning Accumulator-Dehydrator †Remove and Install (34 630 0)
- Compressor †Air Conditioning †Remove and Install (2.9l V6â€24V Cosworth engine) (34 626 0)
- Compressor †Air Conditioning †Remove and Install (2.0l DOHC 16V engine) (34 626 0)
- Expansion Valve †Remove and Install (34 623 0)
- Clutch †Air Conditioning Compressor †Remove and Install (34 628 0)
- Pipe †Compressor to Condenser †Remove and Install (34 641 0)
- Pipe †Accumulator-Dehydrator to Condenser †Remove and Install (34 643 0)
- Pipe †Compressor to Expansion Valve †Remove and Install (34 640 0)
- Sensor †Sun Load †Remove and Install (34 665 0)
- Air Conditioning Condenser †Remove and Install (34 632 0)
- Pipe †Expansion Valve to Dehydrator †Remove and Install (34 642 0)
- Module †Heating-Air Conditioning †Remove and Install (34 680 0)
- Sensor †Exterior Temperature †Automatic Temperature Control †Remove and Install (34 676 0)
- Sensor †Interior Temperature †Footwell †Remove and Install (34 671 0)
- 434-01 Heating and Ventilation
- 438 Audio Systems
- 438-01 In †Car Entertainment
- Description and Operation
- 438-01 In †Car Entertainment|Description and Operation
- Removal and Installation
- Radio Receiver-Cassette Player (Up To 96 MY) - Remove And Install (38 222 0)
- Radio Receiver-Cassette Player (96 MY Onwards) - Remove And Install (38 222 0)
- Radio Loudspeaker - Rear Parcel Shelf - Remove And Install (38 277 0)
- Radio Loudspeaker - Load Space Trim Panel - Remove and Install (38 284 0)
- Radio Antenna - Manual - Remove and Install (38 352 0)
- Autochanger - CD Player - Remove and Install (Wagon) (38 446 0)
- Autochanger - CD Player - Remove and Install (Notchback) (38 446 0)
- Power Amplifier - Radio-Cassette - Remove and Install (38 456 0)
- Radio Loudspeaker - Front Door - Remove and Install (38 268 0)
- Module - Remote Control - In †Car Entertainment - Remove and Install (38 481 0)
- Control - Remote - In †Car Entertainment - Remove and Install (38 471 0)
- Description and Operation
- 438-01 In †Car Entertainment
- 431 Charging System
- 5 Body and Paint
- 540 Seats, Seat Belts, Air Bags
- 540-01 Seats
- SpecificationsGeneral Specifications
- Description and Operation
- 540-01 Seats|Description and Operation
- Removal and Installation
- Switch - Multi Front Seat - Remove and Install (33 581 0)
- Cover and Pad Assembly - Cushion - Front Seat (High Series) - Remove and Install (40 104 0)
- Motor - Seat Operating (High Series) - Remove and Install (33 784 0)
- Cover and Pad Assembly - Cushion - Front Seat (Low Series) - Remove and Install (40 104 0)
- Seat Assembly - Front Bucket (Low Series) - Remove and Install (40 100 0)
- Seat Assembly - Front Bucket (High Series) - Remove and Install (40 100 0)
- Cover And Pad Assembly - Backrest - Front Seat (98 ½ MY Onwards) - Remove And Install (40 106 0)
- Cover and Pad Assembly - Backrest - Front Seat (Low Series) - Remove and Install (40 106 0)
- Backrest - Rear Seat - Remove and Install (40 128 0)
- Cover and Pad Assembly - Backrest - Front Seat (High Series) - Remove and Install (40 106 0)
- Side Bolster - Rear Seat Backrest - Remove and Install (40 135 0)
- Cushion - Rear Seat - Remove and Install (40 122 0)
- Slide - Front Seat (Low Series) - Remove and Install (Seat Removed) (40 420 4)
- Slide - Front Seat (High Series) - Remove and Install (40 420 0)
- Catch - Rear Seat Backrest - Remove and Install (40 534 0)
- Hinge - Rear Seat Backrest - Remove and Install (40 512 0)
- 540-02 Seat Belts
- SpecificationsGeneral Specifications
- Description and Operation
- 540-02 Seat Belts|Description and Operation
- Removal and Installation
- Belt - Front Seat - Remove and Install (40 222 0)
- Stalk - Front Seat - Remove and Install (40 232 0)
- Belt And Stalk - Rear Seat - Centre (Three Point - Wagon) - Remove And Install (40 241 0)
- Belt And Stalk - Rear Seat - Centre (Three Point - Notch) - Remove And Install (40 241 0)
- Stalk - Front Seat (Pyrotechnic) - Remove And Install (40 232 0)
- Catch - Rear Seat Backrest (Centre Three Point - Wagon) - Remove And Install (40 534 0)
- Belt and Stalk - Rear Seat - Remove and Install (40 240 0)
- 540-03 Air Bags
- SpecificationsGeneral Specifications
- Description and Operation
- 540-03 Air Bags|Description and Operation
- Removal and Installation
- Module - Side Air Bag - Remove And Install (40 698 0)
- Clockspring - Air Bag Control - Remove and Install (33 392 0)
- Sensor - Side Air Bag Module - Remove And Install (40 699 0)
- Control Module – Air Bag – Remove and Install (33 650 0)
- Module – Passenger Side – Air Bag – Remove and Install (40 701 0)
- Module – Driver Side – Air Bag – Remove and Install (40 700 0)
- Module - Airbag - Deploy (Outside the Vehicle) (40 702 0)
- 540-01 Seats
- 541 Body Closures
- 541-01 Body Closures
- SpecificationsGeneral Specifications
- Description and Operation
- 541-01 Body Closures|Description and Operation
- Removal and Installation
- Sliding Roof Assembly - Remove and Install (41 114 0)
- Bumper Rubber - Hood - Remove and Install (41 253 0)
- Hood Assembly - Remove and Install (41 214 0)
- Door Assembly - Rear - Remove and Install (41 317 0)
- Cable - Hood Release - Remove and Install (41 224 0)
- Safety Catch - Hood - Remove and Install (41 236 0)
- Door Assembly - Front - Passenger Side - Remove and Install (41 315 0)
- Lock Assembly - Front Door - Remove and Install (41 351 0)
- Handle - Door Exterior (Rear) - Remove and Install (41 333 0)
- Handle - Door Remote Control - Remove and Install (41 334 0)
- Handle - Door Exterior (Front) - Remove and Install (41 333 0)
- Barrel - Door Lock - Remove and Install (41 336 0)
- Plate - Door Striker - Remove and Install (41 356 0)
- Lid Assembly - Luggage Compartment - Remove (41 714 0)
- Weatherstrip - Door Aperture - Remove and Install (41 375 0)
- Lock Assembly - Rear Door - Remove and Install (41 352 0)
- Flap – Fuel Filler – Remove and Install (41 816 0)
- Barrel - Luggage Compartment Lock - Remove and Install (41 724 0)
- Striker Post Luggage Compartment Lid - Remove and Install (41 734 0)
- Lock - Luggage Compartment Lid- Remove and Install (41 726 0)
- 541-01 Body Closures
- 542 Windows
- 542-01 Windows
- SpecificationsGeneral Specifications
- Description and Operation
- 542-01 Windows|Description and Operation
- Removal and Installation
- Windscreen - Remove and Install (42 114 0)
- Glass - Door Window - Front - Remove and Install (42 314 0)
- Glass - Door Window - Rear - Remove and Install (42 315 0)
- Regulator Assembly - Door Window (Front) - Remove and Install (42 338 0)
- Glass - Fixed Rear Quarter Window - Remove and Install (42 514 0)
- Regulator Assembly - Door Window (Rear) - Remove and Install (42 338 0)
- Glass - Fixed Rear Quarter Window (Wagon) - Remove And Install (42 514 0)
- Glass - Tailgate Window (Wagon) - Renew (42 655 0)
- Glass - Rear Window - Remove and Install (42 614 0)
- 542-01 Windows
- 543 Interior and Exterior Trim
- 543-01 Interior Trim
- SpecificationsGeneral Specifications
- Removal and Installation
- Headlining - Remove and Install (43 612 0)
- B - Pillar Trim (Upper) - Remove and Install (43 617 0)
- B - Pillar Trim (Lower) - Remove and Install (43 617 0)
- Mirror - Interior - Remove and Install (43 636 0)
- Crash Padding - Facia - Remove and Install (Up To 95 ½ MY) (43 644 0)
- A - Pillar Trim - Remove and Install (43 616 0)
- C - Pillar Trim - Remove and Install (43 618 0)
- Panel - Door Trim - Front - Remove and Install (43 705 0)
- Crash Padding - Facia - Remove And Install (95 ½ MY Onwards) (43 644 0)
- Panel - Cowl Side Trim (Rear) - Remove and Install (43 735 0)
- Panel - Cowl Side Trim (Front) - Remove and Install (43 735 0)
- Panel - Door Trim - Rear - Remove and Install (43 706 0)
- Panel - Luggage Compartment Lid Trim - Remove and Install (43 745 0)
- Panel - Load Space Trim (Wagon) - Remove and Install (43 746 0)
- Panel - Load Space Trim (Notchback) - Remove and Install (43 746 0)
- 543-02 Exterior Trim
- SpecificationsGeneral Specifications
- Removal and Installation
- Grille Assembly - Cowl Top Outer - Remove and Install (43 230 0)
- Liner - Wheelhouse (Rear) - Remove and Install (43 228 0)
- Insulation Panel - Hood - Remove and Install (43 221 0)
- Grille - Radiator - Remove and Install (43 232 0)
- Liner - Wheelhouse (Front) - Remove and Install (43 228 0)
- Mirror - Door - Remove and Install (43 364 0)
- Bumper and Bracket Assembly - Rear - Remove and Install (43 443 0)
- Bumper Assembly - Front - Remove and Install (43 423 0)
- 543-01 Interior Trim
- 540 Seats, Seat Belts, Air Bags
- 1 General Information
