Cruze
PRE-DELIVERY INSPECTION
PDI Inspection
FOREWORD
GENERAL INTRODUCTION
1. EQUIPMENT AND MATERIAL FOR PDI AND SERVICE
TOOLS
FLUIDS
2. PRE-DELIVERY INSPECTION FORM
ENGINE COMPARTMENT
1. COMPONENTS CONNECTION LOOSE
2. HOSE AND ELECT. WIRES ROUTING
3. FREENESS OF MOVEMENT OF LINKAGE, VALVES AND OTHER COMPONENTS
4. UNUSUAL NOISES
5. SEEPAGE AND LEAKS AT HOSES AND PIPE CONNECTIONS, ETC.
6. POWER STEERING SYSTEM
7. ENGINE COOLANT PROTECTION
8. ALL FLUID LEVELS CHECK
9. THROTTLE LINKAGE
10. BELTS TENSION
BODY ACCESSORIES
1. HEADLAMPS OPERATION AND AIM
2. INDICATOR LAMPS
3. HAZARD WARNING LAMPS
4. REVERSE LAMPS
5. BRAKE LAMPS
6. TAIL LAMPS, POSITION LAMPS, NUMBER PLATE LAMPS, ADDITIONAL INDICATOR LAMPS
7. INSTRUMENT PANEL WARNING LAMPS AND INDICATORS
8. DOME AND COURTESY LIGHTS
9. GLOVE BOX ILLUMINATION, OPTION
10. HEADLIGHT LEVELLING SWITCH, OPTION
11. INSTRUMENT PANEL GAUGE OPERATION
12. FRONT FOG LIGHT SWITCH, OPTION
13. REAR FOG LIGHT SWITCH, OPTION
14. REAR WINDOW AND OUTSIDE MIRROR DEMISTER BUTTON
15. INSTRUMENT ILLUMINATION CONTROL SWITCH, OPTION
16. HORN SWITCH
17. WIPER AND WASHER OPERATION
18. TAILGATE WINDOW WIPER AND WASHER SWITCH, OPTION
19. RADIO/CASSETTE, SPEAKERS, AERIAL, OPTION
20. CUP HOLDER
21. CIGARETTE LIGHTER
22. CLOCK
23. DOOR LOCK
24. DOOR WINDOW
25. OUTSIDE REARVIEW MIRRORS
26. TILTABLE STEERING WHEEL, OPTION
27. POWER SUN ROOF, OPTION
28. SEAT
29. FUEL FILLER DOOR RELEASE LEVER
30. BOOT LID RELEASE LEVER
31. ENGINE BONNET RELEASE LEVER
32. THEFT DETERRENT SYSTEM, OPTION
33. KEYLESS ENTRY SYSTEM WITH ANTITHEFT FUNCTION, OPTION
34. SUNGLASSES HOLDER
35. SEAT HEATER SWITCH, OPTION
UNDER VEHICLE
UNDER VEHICLE INSPECTION
1. STEERING GEAR AND LINKAGE
2. PROPER TRACK ROD CLAMP POSITION
3. EXHAUST SYSTEM FOR PROPER ALIGNMENT AND CLEARANCE
4. FRONT AND REAR SUSPENSION
5. CHECK AXLE AND MANUAL GEARBOX FLUID LEVEL
6. BRAKE SYSTEM
7. FUEL SYSTEM
8. DRIVE SHAFT OF FRONT DRIVE AXLES
9. VISUALLY INSPECT WHEEL STUD AND FLANGE NUTS
10. INFLATE TYRES TO SPECIFIED PRESSURE
ROAD TEST
1. SEAT BELTS
2. FREE PLAY OF BRAKE AND CLUTCH
3. HORN
4. WIND NOISE
5. OPTIONS AND ACCESSORIES
6. HEATER AND AIR CONDITIONING
CONTROL PANEL
7. OPERATION OF WINDSCREEN WIPER AND WASHER FOR PATTERN, SPEED, AND PARKING POSITION INCLUDES AIM WASHER IF NECESSARY
8. ENGINE AND TRANSMISSION PERFORMANCE DURING ACCELERATION, DECELERATION, IDLE, CRUISE AND DOWN SHIFTS
9. SQUEAKS AND RATTLES
10. STEERING COLUMN IGNITION LOCK
11. INSTRUMENTS AND GAUGES
12. THROTTLE CONTROL FOR FREE OPERATIONS
13. STEERING WHEEL CENTRE POSITION AND HANDLING
14. BRAKES, INCLUDES HANDBRAKE AND WARNING LIGHT
APPEARANCE
1. INSPECT CONDITION AND PERFORM DETAIL OPERATION
2. CHECK FOR PROPER ASSEMBLY, FIT AND RETENTION OF PARTS AND COMPONENTS
3. EXTERIOR FINISH
4. INTERIOR TRIM AND CARPETS PROTECTIVE COVERINGS
5. SPARE WHEEL, JACK AND VEHICLE TOOLS
6. BATTERY
ANNEX
1. RECEIVING INSPECTION
2. DIRECTION FOR THE USE OF HY-600 TRANSIT COATING REMOVER IN A HAND WASH OPERATION
3. STORAGE AND MAINTENANCE OF NEW VEHICLE IN EXTREMELY HOT AND HUMID LOCATIONS
DESCRIPTION:
LABOUR TIME GUIDE
SERVICE MANUAL
1. Preface
Preface
Introduction
Danger
Title Page
Dangers, Warnings, and Cautions
Introduction
Definition of Danger, Warning, Caution, and Note
ABS Component Handling Warning
Actions to Take When Working with Fuel Warning
Approved Equipment for Collision Repair Warning
Assistant Driving Warning
Battery Disconnect Warning
Brake Dust Warning
Brake Fluid Irritant Warning
Checking Hot Transmission Fluid through Drain Plug Hole Warning
Cleaning Solvent Warning
Collision Sectioning Warning
Cracked Window Warning
Defroster Outlet Warning
DOT 4 Brake Fluid Warning
Exhaust Service Warning
Express Window Down Warning
Eye Protection Warning
Foam Sound Deadeners Warning
Fuel and Evaporative Emission Pipe Warning
Fuel Escape Warning
Fuel gauge Leak Warning
Fuel Pipe Fitting Warning
Fuel Storage Warning
Fuel Vapour in Evaporative Emission Components Warning
Petrol/Petrol Vapours Warning
Glass and Sheet Metal Handling Warning
Halogen Bulb Warning
Bonnet Hold-Open Device Warning
Hot Exhaust System Warning
Moving Parts and Hot Surfaces Warning
Parking Brake and Drive Wheels Warning
Protective Goggles and Glove Warning
Relieving Fuel Pressure Warning
Road Test Warning
Safety Glasses and Compressed Air Warning
Safety Glasses Warning
Safety Goggles and Fuel Warning
SIR Deployed Inflator Modules Are Hot Warning
SIR Inflatable Module Deployment Outside Vehicle Warning
SIR Inflator Module Disposal Warning
SIR Inflator Module Handling and Storage Warning
SIR Seatbelt Pretensioner Handling Warning
SIR Special Tool Warning
SIR Warning
Steering Angle Sensor Initialisation Warning
Torque-to-Yield Fastener Warning
Window Retention Warning
Work Stall Test Warning
Air in the Power Steering System Caution
Avoid Chipping or Scratching the Coating Caution
Ball Stud Removal Caution
Belt Dressing Caution
Brake Calliper Caution
Brake Fluid Effects on Paint and Electrical Components Caution
Clearcoat/Ultraviolet Screeners Caution
Component Fastener Tightening Caution
Drive Axle Caution
Engine Coolant Thermostat Housing Caution
Exhaust Flexible Pipe Bending Caution
Exterior Trim Emblem Removal Caution
Fastener Caution
Filling the Master Cylinder Caution
Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
Heated Oxygen and Oxygen Sensor Caution
Heated Oxygen Sensor Resistance Learn Reset Caution
Installing Hoses without Twists or Bends Caution
Pipe Spanner Positioning Caution
Power Steering Hose Disconnected Caution
Silicon Contamination of Heated Oxygen Sensors Caution
Steering Column in Lock Position Caution
Steering Gear Preload Adjustment Caution
Steering Wheel in the Full Turn Position Caution
Steering Wheel Straight and Column Locked Caution
Test Probe Caution
Three-Way Catalytic Converter Damage Caution
Torque Reaction Against Timing Drive Chain Caution
Torque-to-Yield Fastener Caution
Transmission Fluid Vent Cap Removal Caution
Transmission Overfill Caution
Using Proper Power Steering Fluid Caution
Tappet Priming Caution
Window Edge Damage Caution
2. General Information
General Information
Specifications
Volatile Memory Programming
Introduction
Arrows and Symbols
Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage
Vehicle Certification, Tyre Placard, Anti-Theft, and Service Parts ID Label
RPO Code List — India
RPO Code List — Europe
RPO Code List — Thailand, Vietnam
Fasteners
Thread Inserts
Registered and Non-Registered Trademarks
Lifting and Jacking the Vehicle
Diagnostic Information and Procedures
Customer Concern Verification Sheets
Repair Instructions
Key and Lock Cylinder Coding
Air/Wind Noise
Diagnostic Information and Procedures
Air/Wind Noise
Tracing Powder or Chalk Test
Air Pressure Test
Soap Suds or Bubble Test
Repair Instructions
Exterior Wind noise
Interior Wind noise
Special Tools and Equipment
Special Tools
Maintenance and Lubrication
Specifications
Approximate Fluid Capacities
Fluid and Lubricant Recommendations
Maintenance Items
Maintenance
Maintenance Schedule
GM Oil Life System Resetting
Squeaks and Rattles
Diagnostic Information and Procedures
Squeaks and Rattles
Symptoms - Squeaks and Rattles
Special Tools and Equipment
Special Tools
Vibration Diagnosis and Correction
Specifications
Tyre and Wheel Runout Specifications
Diagnostic Information and Procedures
Vibration Analysis - Road Testing
Component Rotational Speed Calculation
Vibration Analysis - Tyre and Wheel
Vibration Analysis - Hub and/or Axle Input
Vibration Analysis - Engine
Engine Order Classification
Vibration Analysis - Engine/Accessory Isolation
Vibration Analysis - Engine Balance
Vibration Diagnostic Aids
Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated
Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified
Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component
Vibration Diagnostic Aids - Vibration Duplicated, Appears to Be Potential Operating Characteristic
Symptoms - Vibration Diagnosis and Correction
Vehicle-to-Vehicle Diagnostic Comparison
Tyre and Wheel Inspection
Tyre and Wheel Assembly Runout Measurement - On-Vehicle
Tyre and Wheel Assembly Runout Measurement - Off Vehicle
Brake Disc/Drum Balance Inspection
Hub/Axle Flange and Wheel Stud Runout Inspection
Tyre and Wheel Assembly Isolation Test
Repair Instructions
Tyre and Wheel Assembly Balancing - Off Vehicle
Description and Operation
Vibration Theory and Terminology
Electronic Vibration Analyzer (EVA) Description and Operation
Vibrate Software Description and Operation
Special Tools and Equipment
Special Tools and Equipment
Water leaks
Diagnostic Information and Procedures
Water leak Test Preparation
Water Hose Test
Air Hose Test
Repair Instructions
Body Water leak Repair
Stationary Window Water leak Repair
3. Body Hardware and Trim
Exterior Trim
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Fender Emblem/Nameplate Replacement — 1.8L 2H0 or 2.0L Diesel
Body Side Upper Front Applique Replacement
Body Side Upper Rear Applique Replacement — 4-Door Saloon 69
Body Side Upper Rear Applique Replacement — 5-Door Hatchback 68
Rear Compartment Lid Applique Replacement
Front Fog Lamp Bezel Replacement
Front Bumper Fascia Front Tow Eye Access Hole Cover Replacement
Rear Bumper Fascia Rear Tow Eye Access Hole Cover Replacement
Front Side Door Window Frame Cover Replacement
Front Side Door Window Frame Rear Cover Replacement
Rear Side Door Window Frame Front Cover Replacement
Radiator Grille Emblem/Nameplate Replacement — Chevrolet
Rear Compartment Lid Emblem/Nameplate Replacement - Bowtie
Rear Compartment Lid Emblem/Nameplate Replacement - Chevrolet
Rear Compartment Lid Emblem/Nameplate Replacement — CDX
Rear Compartment Lid Emblem/Nameplate Replacement — Cruze - Right Hand Side
Rear Compartment Lid Emblem/Nameplate Replacement — Cruze - Left Hand Side
Rear Compartment Lid Emblem/Nameplate Replacement — Rear Emblem
Rear Compartment Lid Emblem/Nameplate Replacement — LT or LTZ
Rear Compartment Lid Emblem/Nameplate Replacement — VCDi
Rear Compartment Lid Emblem/Nameplate Replacement — VCDi AT
Rear Compartment Lid Emblem/Nameplate Replacement — Diesel
Front Bumper Lower Fascia Centre Grille Replacement
Radiator Upper Grille Replacement
Radiator Lower Grille Replacement
Sill Panel Moulding Replacement
Roof Front Drip Moulding Replacement
Rear End Spoiler Replacement
Description and Operation
Water Management Description and Operation
Floor Coverings and Headlinings
Repair Instructions
Floor Carpet Drying
Front Floor Panel Carpet Replacement
Rear Compartment Floor Panel Carpet Replacement — 5-Door Hatchback 68
Headlining Trim Panel Replacement — 5-Door Hatchback 68 with Sunroof
Headlining Trim Panel Replacement — 5-Door Hatchback 68 without Sunroof
Headlining Trim Panel Replacement — 4-Door Saloon 69 with Sunroof
Headlining Trim Panel Replacement — 4-Door Saloon 69 without Sunroof
Instrument Panel and Console Trim
Specifications
Fastener Tightening Specifications
Repair Instructions
Instrument Panel Insulator Seal Replacement
Instrument Panel Location Guide Replacement
Instrument Panel Centre Upper Moulding Replacement
Instrument Panel Upper Trim Panel Replacement - Right Side
Instrument Panel Upper Trim Panel Replacement - Left Side
Instrument Panel Accessory Bezel Replacement
Driver Information Display Bezel Replacement
Instrument Panel Cluster Trim Plate Replacement
Instrument Panel Outer Trim Cover Replacement - Right Side
Instrument Panel Outer Trim Cover Replacement - Left Side
Instrument Panel Lower Trim Pad Cover Replacement — without Knee Airbag
Instrument Panel Lower Trim Panel Replacement - Left Side
Instrument Panel Cluster Lower Trim Plate Replacement
Instrument Panel Lower Trim Panel Replacement - Right Side
Instrument Panel Upper Compartment Replacement
Instrument Panel Compartment Replacement
Instrument Panel Moulding Replacement
Instrument Panel Upper Trim Pad Insert Replacement
Instrument Panel Inflatable Restraint Module Bracket Replacement
Instrument Panel Assembly Replacement
Instrument Panel Tie Bar Replacement — Left Hand Drive
Instrument Panel Tie Bar Replacement — Right Hand Drive
Instrument Panel Wiring Harness Replacement
Front Floor Console Stowage Tray Replacement
Front Floor Console Compartment Replacement
Automatic or Manual Gearbox Control Lever Trim Cover Replacement
Front Floor Console Replacement
Front Floor Console Armrest Replacement
Front Floor Console Rear Cover Replacement
Roof Console Replacement
Interior Trim and Panelling
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Side Door Window Switch Bezel Replacement
Rear Side Door Window Switch Bezel Replacement
Front or Rear Side Door Locking Rod Knob Trim Cover Replacement
Front Side Door Upper Trim Cover Replacement
Front Side Door Trim Replacement
Front Side Door Water Deflector Replacement
Rear Side Door Water Deflector Replacement
Rear Side Door Window Garnish Moulding Replacement
Front Side Door Window Garnish Moulding Replacement
Front Side Door Sill Trim Plate Replacement
Rear Side Door Sill Trim Plate Replacement — 5-Door Hatchback 68
Rear Side Door Sill Trim Plate Replacement — 4-Door Notchback 69
Assist Handle Replacement
Sunshade Replacement
Sunshade Support Replacement
Windscreen Garnish Moulding Replacement
Centre Pillar Upper Garnish Moulding Replacement
Centre Pillar Lower Garnish Moulding Replacement
Quarterlight Garnish Moulding Replacement — 5-Door Hatchback 68
Quarter Window Garnish Moulding Replacement — 4-Door Notchback 69
Body Side Trim Panel Replacement — 4-Door Notchback 69
Body Side Trim Panel Replacement — 5-Door Hatchback 68
Radio Front Side Door Speaker Grille Bezel Replacement
Radio Rear Side Door Speaker Grille Bezel Replacement
Rear Window Panel Trim Replacement
Rear Compartment Floor Stowage Compartment Tray Replacement - Right Side
Rear Compartment Floor Stowage Compartment Tray Replacement - Left Side
Rear Compartment Floor Panel Trim Replacement
Rear Side Door Trim Replacement
Luggage Shade Replacement — 5-Door Hatchback 68
Luggage Shade Strap Replacement
Luggage Shade Pivot Replacement
Luggage Shade Bumper Replacement
Tailgate Trim Finish Panel Replacement
Tailgate Upper Trim Finish Panel Replacement
Tailgate Lower Trim Finish Panel Replacement
Rear Compartment Lid Pull Handle Replacement
Rear Compartment Sill Trim Plate Replacement — 5-Door Hatchback 68
Rear Compartment Sill Trim Plate Replacement — 4-Door Notchback 69
Rear Compartment Lid Inner Panel Trim Replacement
Rear Compartment Lid Catch Cover Replacement
Rear Compartment Side Trim Replacement - Left Side
Rear Compartment Side Trim Replacement - Right Side
Cargo Tie Down Hook Replacement
Cargo Net Loop Replacement
Tailgate Inside Pull Handle Replacement
Special Tools and Equipment
Special Tools
4. Body Repair
Bolted Exterior Body Panels and Closures
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
DTC B3006
Symptoms - Bolted Exterior Body Panels and Closures
Bonnet Ajar Indicator/Message Malfunction
Repair Instructions
Front End Upper Tie Bar Replacement
Front Wing Front Lower Bracket Replacement
Bonnet Primary Catch Release Cable Replacement
Rear Side Door Check Replacement
Front Side Door Adjustment
Front Side Door Replacement
Rear Side Door Adjustment — 4-Door Saloon 69
Rear Side Door Adjustment — 5-Door Hatchback 68
Rear Side Door Replacement
Front Fender Replacement
Front Wing Shipping Cover Replacement
Liftgate Adjustment
Liftgate Replacement
Front Side Door Wiring Harness Replacement
Liftgate Wiring Harness Replacement
Rear Compartment Lid Wiring Harness Replacement
Rear Side Door Wiring Harness Replacement
Bonnet Primary Catch Release Cable Handle Replacement
Front Side Door Upper Hinge and Lower Hinge Replacement
Hood Hinge Replacement
Tailgate Hinge Replacement
Rear Compartment Lid Rear Hinge Replacement
Rear Side Door Upper Hinge and Lower Hinge Replacement
Bonnet Adjustment
Hood Replacement
Front Wing Insulator Replacement
Bonnet Insulator Replacement
Bonnet Primary and Secondary Catch Replacement
Rear Compartment Lid Adjustment
Rear Compartment Lid Replacement
Front Side Door Check Replacement
Fuel Tank Filler Door Replacement
Fuel Tank Filler Pipe Housing Replacement
Bonnet Hold-Open Rod Replacement
Rear Compartment Lid Hinge Torque Rod Replacement
Bonnet Rear Weatherstrip Replacement
Liftgate Strut Replacement
Radiator Grille Reinforcement Support Replacement
Front or Rear Side Door Lower Weatherstrip Replacement
Front Side Door Weatherstrip Replacement - Door Side
Front Side Door Weatherstrip Replacement - Body Side
Liftgate Weatherstrip Replacement
Rear Compartment Lid Weatherstrip Replacement
Rear Side Door Weatherstrip Replacement - Door Side
Rear Side Door Weatherstrip Replacement - Body Side
Description and Operation
Bonnet Ajar Indicator Description and Operation
Special Tools and Equipment
Special Tools
Bumpers and Fascias
Specifications
Fastener Tightening Specifications
Repair Instructions
Front Bumper Energy Absorber Replacement
Front Bumper Energy Absorber Bracket Replacement
Front Bumper Impact Bar Replacement
Front Bumper Fascia Replacement
Front Bumper Fascia Guide Replacement
Front Bumper Fascia Opening Lower Cover Replacement
Front Bumper Fascia Outer Bracket Replacement
Front Bumper Fascia Lower Stiffener Replacement
Front Bumper Fascia Air Deflector Replacement
Rear Bumper Fascia Lower Skid Plate Replacement — 5-Door Hatchback 68
Rear Bumper Fascia Replacement — 4-Door Saloon 69
Rear Bumper Fascia Replacement — 5-Door Hatchback 68
Rear Bumper Fascia Bracket Replacement - Outer — 4-Door Saloon 69
Rear Bumper Fascia Bracket Replacement - Outer — 5-Door Hatchback 68
Rear Bumper Fascia Guide Replacement — 4-Door Saloon 69
Rear Bumper Fascia Guide Replacement — 5-Door Hatchback 68
Rear Bumper Fascia Inner Guide Replacement — 4-Door Saloon 69
Rear Bumper Fascia Inner Guide Replacement — 5-Door Hatchback 68
Rear Bumper Fascia Outer Guide Replacement — 4-Door Saloon 69
Rear Bumper Fascia Outer Guide Replacement — 5-Door Hatchback 68
Rear Bumper Impact Bar Replacement
Special Tools and Equipment
Special Tools
Collision Repair
Specifications
Fastener Tightening Specifications
Dimensions - Body — 4-Door Saloon 69
Dimensions - Body — 5-Door Hatchback 68
Visual Identification
Structure Identification — 4-Door Saloon 69
Structure Identification — 5-Door Hatchback 68
Repair Instructions
Overlap/Backing Plate Sectioning - Welding
Front Bumper Impact Bar Replacement
Headlamp Mount Panel Replacement - MAG-Welding
Headlamp Mount Panel Replacement - MIG-Brazing
Front End Upper Tie Bar Support Sectioning — MAG Welding
Front End Upper Tie Bar Support Sectioning — MIG Brazing
Front End Upper Tie Bar Replacement — Welding
Front End Upper Tie Bar Replacement — Brazing
Front Wheelhouse Front Panel Replacement - MAG-Welding
Front Wheelhouse Front Panel Replacement - MIG-Brazing
Front Wheelhouse Panel Replacement - MAG-Welding
Front Wheelhouse Panel Replacement - MIG-Brazing
Front Wheelhouse Panel Rear Reinforcement Replacement - MIG-Brazing
Front Wheelhouse Panel Rear Reinforcement Replacement - MAG-Welding
Front Compartment Upper Side Rail Replacement - MAG-Welding
Front Compartment Upper Side Rail Replacement - MIG-Brazing
Front Compartment Upper Side Rail Sectioning - MAG-Welding
Front Compartment Upper Side Rail Sectioning - MIG-Brazing
Front Compartment Side Rail Sectioning — Welding
Front Hinge Pillar Body Sectioning - MAG-Welding
Front Hinge Pillar Body Sectioning - MIG-Brazing
Body Hinge Pillar Lower Reinforcement Replacement - MAG-Welding
Body Hinge Pillar Lower Reinforcement Replacement - MIG-Brazing
Roof Outer Panel Replacement — MAG-Welding, 4-Door Saloon 69
Roof Outer Panel Replacement — MIG-Brazing, 4-Door Saloon 69
Roof Outer Panel Replacement — 5-Door Hatchback 68
Roof Front Header Panel Replacement - MAG-Welding
Roof Front Header Panel Replacement - MIG-Brazing
Roof Rear Header Panel Replacement — MAG-Welding, 4-Door Saloon 69
Roof Rear Header Panel Replacement — MIG-Brazing, 4-Door Saloon 69
Roof Rear Header Panel Replacement — MAG-Welding, 5-Door Hatchback 68
Roof Rear Header Panel Replacement — MIG-Brazing, 5-Door Hatchback 68
Rocker Inner Panel Replacement - MAG-Welding
Rocker Inner Panel Replacement - MIG-Brazing
Body Lock Pillar Outer Panel Sectioning - MAG-Welding
Body Lock Pillar Outer Panel Sectioning - MIG-Brazing
Body Lock Pillar Outer Panel Reinforcement Replacement - MAG-Welding
Body Lock Pillar Outer Panel Reinforcement Replacement - MIG-Brazing
Body Lock Pillar Inner Panel Replacement - MAG-Welding
Body Lock Pillar Inner Panel Replacement - MIG-Brazing
Body Lock Pillar Upper Reinforcement Replacement — MAG-Welding
Body Lock Pillar Upper Reinforcement Replacement — MIG-Brazing
Rocker Outer Panel Sectioning - MAG-Welding
Rocker Outer Panel Sectioning - MIG-Brazing
Body Side Outer Panel Reinforcement Replacement - MAG-Welding
Body Side Outer Panel Reinforcement Replacement - MIG-Brazing
Body Side Inner Panel Sectioning — MAG-Welding, 4-Door Saloon 69
Body Side Inner Panel Sectioning — MIG-Brazing, 4-Door Saloon 69
Body Side Inner Panel Sectioning — MAG-Welding, 5-Door Hatchback 68
Body Side Inner Panel Sectioning — MIG-Brazing, 5-Door Hatchback 68
Body Side Outer Lower Panel Replacement - MAG-Welding
Body Side Outer Lower Panel Replacement - MIG-Brazing
Rear Compartment Floor Panel Sectioning - MAG-Welding
Rear Compartment Floor Panel Sectioning - MIG-Brazing
Rear Wheelhouse Panel Replacement - MAG-Welding
Rear Wheelhouse Panel Replacement - MIG-Brazing
Quarter Outer Panel Sectioning — MAG-Welding, 4-Door Saloon 69
Quarter Outer Panel Sectioning — MIG-Brazing, 4-Door Saloon 69
Quarter Outer Panel Sectioning — MAG-Welding, 5-Door Hatchback 68
Quarter Outer Panel Sectioning — MIG-Brazing, 5-Door Hatchback 68
Body Rear End Panel Replacement — MAG-Welding, 4-Door Saloon 69
Body Rear End Panel Replacement — MIG-Brazing, 4-Door Saloon 69
Body Rear End Panel Replacement — MAG-Welding, 5-Door Hatchback 68
Body Rear End Panel Replacement — MIG-Brazing, 5-Door Hatchback 68
Rear Bumper Impact Bar Stud Plate Replacement — MAG-Welding, 4-Door Saloon 69
Rear Bumper Impact Bar Stud Plate Replacement — MIG-Brazing, 4-Door Saloon 69
Rear Bumper Impact Bar Stud Plate Replacement — MAG-Welding, 5-Door Hatchback 68
Rear Bumper Impact Bar Stud Plate Replacement — MIG-Brazing, 5-Door Hatchback 68
Front Side Door Outer Panel Replacement - MAG-Welding
Front Side Door Outer Panel Replacement - MIG-Brazing
Rear Side Door Outer Panel Replacement - MAG-Welding
Rear Side Door Outer Panel Replacement - MIG-Brazing
Rear Rail Sectioning - MAG-Welding
Rear Rail Sectioning - MIG-Brazing
Underbody Rear Side Rail Reinforcement Replacement - MAG-Welding
Underbody Rear Side Rail Reinforcement Replacement - MIG-Brazing
Rear Floor Panel Filler Replacement — MAG-Welding, 4-Door Saloon 69
Rear Floor Panel Filler Replacement — MIG-Brazing, 4-Door Saloon 69
Tail Lamp Pocket Replacement — MAG-Welding, 4-Door Saloon 69
Tail Lamp Pocket Replacement — MIG-Brazing, 4-Door Saloon 69
Tail Lamp Pocket Replacement — MAG-Welding, 5-Door Hatchback 68
Tail Lamp Pocket Replacement — MIG-Brazing, 5-Door Hatchback 68
Description and Operation
Dual Phase Steel
High Strength Low Alloy Steel
Mild Steel
Ultra High Strength Dual Phase Steel
Special Tools and Equipment
Special Tools
Frame and Underbody
Specifications
Fastener Tightening Specifications
Repair Instructions
Engine Shield Replacement
Front Compartment Insulator Replacement
Front Compartment Splash Shield Replacement
Drive train and Front Suspension Frame Replacement
Drivetrain and Front Suspension Frame Insulator Replacement
Front Wheel housing Liner Replacement
Rear Wheel housing Panel Liner Replacement
Special Tools and Equipment
Special Tools
Paint and Coatings
Introduction
Basecoat/Clearcoat Paint Systems
Anti-Corrosion Treatment and Repair - Base
Repair Instructions
Clearcoat Repair without Repainting
Environmental Fallout (Acid Rain)
Paint Gauges
Clearcoat Thickness
Rail Dust Damage Repair
Plastic Panel Information and Repair
Repair Instructions
General Plastic Repair
Introduction
How to Identify Plastic Parts
Plastic Identification and Refinishing Systems
5. Body Systems
Fixed and Movable Windows
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Moveable Window Schematics
Defogger Schematics
Component Locator
Window Systems Component Views — 4-Door Saloon 69
Window Systems Component Views — 5-Door Hatchback 68
Diagnostic Information and Procedures
DTC B0283
DTC B316B, B317A, B318A, or B319A
DTC B3205
Symptoms - Fixed and Moveable Windows
Rear Window Defogger Malfunction
Power Windows Malfunction — All Windows Express Down Only
Power Windows Malfunction — Driver Window Express Up and Down
Repair Instructions
Windscreen Replacement
Windscreen Upper Reveal Moulding Replacement
Front Side Door Window Adjustment
Front Side Door Window Replacement
Rear Side Door Window Adjustment
Rear Side Door Window Replacement
Rear Side Door Stationary Window Replacement
Rear Side Door Stationary Window Divider Channel Replacement
Rear Window Replacement
Rear Window Reveal Moulding Replacement
Tailgate Window Replacement
Rear Side Door Window Channel Insulator Replacement
Front Side Door Window Switch Replacement - Right Side
Front Side Door Window Switch Replacement - Left Side
Rear Side Door Window Switch Replacement
Front Side Door Window Regulator Replacement
Window Motor Programming - Express Function
Front Side Door Window Regulator Motor Replacement
Rear Side Door Window Regulator Replacement
Rear Side Door Window Regulator Motor Replacement
Front Side Door Window Regulator Handle Replacement
Rear Side Door Window Regulator Handle Replacement
Front Side Door Window Outer Sealing Strip Replacement
Front Side Door Window Inner Sealing Strip Replacement
Rear Side Door Window Inner Sealing Strip Replacement
Rear Side Door Window Outer Sealing Strip Replacement
Front Side Door Window Weatherstrip Replacement
Rear Side Door Window Weatherstrip Replacement
Description and Operation
Adhesive Service Kit Description
Power Windows Description and Operation
Rear Window Defogger Description and Operation
Stationary Window Description
Special Tools and Equipment
Special Tools
Horns
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Horn Schematics
Diagnostic Information and Procedures
DTC B2750
Symptoms - Horns
Horns Malfunction
Repair Instructions
Horn Replacement
Steering Wheel Horn Contact Replacement
Description and Operation
Horns System Description and Operation
Special Tools and Equipment
Special Tools
Lighting
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Headlights/Daytime Running Lights (DRL) Schematics
Fog Lamps Schematics
Exterior Lamps Schematics
Interior Lights Schematics
Interior Lights Dimming Schematics
Diagnostic Information and Procedures
DTC B096A
DTC B1395
DTC B2530
DTC B2540
DTC B2545
DTC B2575 or B2699
DTC B257A
DTC B257B
DTC B2580
DTC B2585 or B3867
DTC B2610
DTC B2740
DTC B3445 or B3878
DTC B3588
DTC B3596
DTC B3600
DTC B3650
DTC B3806
DTC B3883
DTC B3884
DTC B3885 or B3886
DTC B3887 or B3888
DTC B3889
DTC B3890
DTC B3891
DTC B3948 or B3949
DTC B3950 or B3951
DTC C0277 or C0890
DTC P057B-P057E
Symptoms - Lighting
Automatic Light Malfunction
Reversing Lamps Malfunction - AT
Reversing Lamps Malfunction - MT
Courtesy Lamps Malfunction
Interior Lights Malfunction
Front Fog Lamps Malfunction
Rear Fog Lamps Malfunction
Glove Box Illumination Malfunction
Hazard Lamps Malfunction
Headlamps Malfunction
Headlamp Levelling Malfunction
Interior Backlighting Malfunction
Lights On Indicator Malfunction
Park, License, and/or Tail Lamps Malfunction
Reading Lamps Malfunction
Stop Lamps Malfunction
Sunshade Illumination Malfunction
Indicator Lamps and/or Indicators Malfunction
Repair Instructions
Brake Pedal Position Sensor Calibration
Brake Pedal Position Sensor Replacement
Headlight Switch Replacement
Hazard Warning Switch Replacement
Headlamp Automatic Control Ambient Light Sensor Replacement
Reading Lamp Bulb Replacement
Reading Lamp Replacement
Dome and Reading Lamp Lens Replacement
Instrument Panel Compartment Lamp Replacement
Instrument Panel Compartment Light Bulb Replacement
Sun Visor Illuminated Mirror Lamp Bulb Replacement
Sun Visor Illuminated Mirror Lamp Lens Replacement
Dome Lamp Replacement — with Sunroof
Dome Lamp Replacement — without Sunroof
Interior Light Bulb Replacement
Headlamp Replacement
Headlamp Bulb Replacement
Headlamp Bracket Replacement
Headlamp Aiming
Front Fog Lamp Replacement
Front Fog Lamp Bulb Replacement
Rear Fog Lamp Replacement — 5-Door Hatchback 68
Rear Fog Lamp Bulb Replacement — 5-Door Hatchback 68
Fog Lamp Aligning
Front Side Indicator Lamp Replacement
Front Side Indicator Lamp Bulb Replacement
High Mount Brake Lamp Replacement — 4-Door Saloon 69
High Mount Brake Lamp Replacement — 5-Door Hatchback 68
Cargo Centre Courtesy Lamp Bulb Replacement — Notchback
Reversing Lamp Replacement — 4-Door Saloon 69
Reversing Lamp Replacement — 5-Door Hatchback 68
Reversing Lamp Bulb Replacement — 4-Door Saloon 69
Reversing Lamp Bulb Replacement — 5-Door Hatchback 68
Forward Lamp Wiring Harness Replacement
Rear Number plate Lamp Replacement
Rear Number Plate Light Bulb Replacement
Rear Number Plate Light Wiring Harness Replacement
Tail Lamp Replacement — 4-Door Saloon 69
Tail Lamp Replacement — 5-Door Hatchback 68
Tail Lamp Bulb Replacement
Tail Lamp Control Module with Bulb Replacement — 4-Door Saloon 69
Tail Lamp Control Module with Bulb Replacement — 5-Door Hatchback 68
Rear Compartment Courtesy Lamp Replacement — 4-Door Saloon 69
Rear Compartment Courtesy Lamp Replacement — 5-Door Hatchback 68
Description and Operation
Exterior Lighting Systems Description and Operation
Interior Lighting Systems Description and Operation
Special Tools and Equipment
Special Tools
Mirrors
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Inside Rearview Mirror Schematics
Outside Rearview Mirror Schematics
Diagnostic Information and Procedures
Symptoms - Mirrors
Heated Mirrors Malfunction
Automatic Day-Night Mirrors Malfunction
Power Mirror Folding Malfunction
Power Mirror Malfunction
Repair Instructions
Outside Rearview Mirror Replacement
Outside Remote Control Rearview Mirror Switch Replacement
Outside Rearview Mirror Inner Actuator Replacement
Outside Rearview Mirror Glass Replacement
Outside Rearview Mirror Housing Replacement
Inside Rearview Mirror Replacement
Description and Operation
Automatic Day-Night Mirror Description and Operation
Outside Mirror Description and Operation
Special Tools and Equipment
Special Tools
Vehicle Access
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Door Lock/Indicator Schematics
Release Systems Schematics
Diagnostic Information and Procedures
DTC B1474
DTC B1534 or B1535
DTC B250B
DTC B2516
DTC B251A-B251F
DTC B252A or B252B
DTC B297B or B297C
DTC B3125, B3130, or B3135
DTC B3140 or B3150
DTC B3155
DTC B3265
DTC B3618
DTC B3797
DTC B3849
Symptoms - Vehicle Access
Fuel Filler Door Release Malfunction
Door Ajar Indicator Malfunction
Power Door Catch System Malfunction
Power Door Locks Malfunction — Dead Lock
Boot Release Malfunction
Boot Ajar Indicator Malfunction
Repair Instructions
Fuel Tank Filler Door Lock Actuator Replacement
Front Side Door Inside Handle Cable Replacement
Rear Side Door Inside Handle Cable Replacement
Front Side Door Lock Cylinder Replacement
Front Side Door Inside Handle Replacement
Front Side Door Outside Handle Replacement
Front Side Door Outside Handle Bracket Replacement
Rear Side Door Outside Handle Bracket Replacement
Tailgate Outside Handle Replacement
Liftgate Catch Replacement
Rear Side Door Inside Handle Replacement
Rear Side Door Outside Handle Replacement
Front Side Door Latch Replacement
Rear Compartment Lid Catch Replacement
Rear Side Door Latch Replacement
Front Side Door Locking Rod Replacement
Front Side Door Lock Cylinder Rod Replacement
Front Side Door Outside Handle Rod Adjustment
Front Side Door Outside Handle Rod Replacement
Rear Side Door Locking Rod Replacement
Rear Side Door Outside Handle Rod Adjustment
Rear Side Door Outside Handle Rod Replacement
Front Side Door Lock Striker Replacement
Liftgate Catch Striker Replacement
Rear Compartment Lid Latch Striker Replacement
Rear Side Door Lock Striker Replacement
Tailgate Release Switch Replacement
Door Lock Switch Replacement
Description and Operation
Door Ajar Indicator Description and Operation
Fuel Fill Door Description and Operation
Luggage Compartment Description and Operation
Power Door Catch Description and Operation
Power Door Locks Description and Operation
Wipers and Washers
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Wiper/Washer Schematics
Diagnostic Information and Procedures
DTC B370A
DTC B3715 or B3875
DTC B3873
Symptoms - Wiper/Washer Systems
Windscreen Wiper System Malfunction
Washer Malfunction
Rain Sensor Malfunction
Repair Instructions
Windscreen Wiper and Washer Switch Replacement
Windscreen Washer Nozzle Hose Replacement
Windscreen Washer Nozzle Replacement
Rear Window Washer Nozzle Replacement
Rear Window Washer Nozzle Hose Replacement
Windscreen Washer Solvent Container Filler Tube Replacement
Windscreen Washer Solvent Container Grommet Replacement
Windscreen Washer Solvent Container Replacement
Windscreen Washer Pump Replacement
Windscreen Washer Pump Seal Replacement
Air Inlet Grille Panel Replacement
Windscreen Wiper Arm Replacement
Rear Window Wiper Arm Replacement
Windscreen Wiper Blade Replacement — Complete Assembly
Windscreen Wiper Blade Replacement — Holden Service Kit
Rear Window Wiper Blade Replacement
Windscreen Wiper Motor Replacement
Rear Window Wiper Motor Replacement
Windscreen Wiper Transmission Replacement — Left Hand Drive
Windscreen Wiper Transmission Replacement — Right Hand Drive
Windscreen Outside Moisture Sensor Cover Replacement
Windscreen Outside Moisture Sensor Replacement
Wiper Blade Element Cleaning
Windshield Wiper Arm Adjustment
Description and Operation
Wiper/Washer System Description and Operation
Special Tools and Equipment
Special Tools
6. Brakes
Antilock Brake System
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Antilock Brake System Schematics
Diagnostic Information and Procedures
DTC B0000, C0055, C0246, C1207-C1210, C1221-C1228, or C1232-C1235
DTC B2745
DTC C0000
DTC C0035, C0040, C0045, or C0050
DTC C0110
DTC C0131
DTC C0161
DTC C0186, C0196, or C019B
DTC C0280
DTC C0710
DTC P0856
Symptoms - Antilock Brake System
ABS Indicator Malfunction
Traction Control/Stability Control Indicator Malfunction
Repair Instructions
Steering Angle Sensor Centring
Electronic Brake Control Module Replacement
Brake Pressure Modulator Valve Replacement
Brake Pressure Modulator Valve Pressure Sensor Calibration
Brake Pressure Modulator Valve Bracket Replacement
Front Wheel Speed Sensor Replacement
Rear Wheel Speed Sensor Replacement - Disc Brake
Rear Wheel Speed Sensor Replacement - Drum Brake
Vehicle Yaw Sensor Learn
Vehicle Yaw Sensor Replacement
Description and Operation
ABS Description and Operation
Special Tools and Equipment
Special Tools
Disc Brakes
Specifications
Fastener Tightening Specifications
Disc Brake Component Specifications
Adhesives, Fluids, Lubricants, and Sealers
Diagnostic Information and Procedures
Brake Disc Thickness Measurement
Brake Disc Thickness Variation Measurement
Brake Disc Surface and Wear Inspection
Brake Disc Assembled Lateral Runout Measurement
Brake Pad Inspection
Brake Calliper Inspection
Front Disc Brake Mounting and Hardware Inspection
Rear Disc Brake Mounting and Hardware Inspection
Repair Instructions
Front Disc Brake Pads Replacement
Rear Disc Brake Pads Replacement
Brake Pad and Rotor Burnishing
Front Brake Calliper Replacement
Rear Brake Caliper Replacement — without Dampener
Rear Brake Caliper Replacement — with Dampener
Front Brake Calliper Overhaul
Rear Brake Caliper Vibration Dampener Replacement
Front Brake Calliper Hardware Replacement
Rear Brake Calliper Hardware Replacement
Front Brake Caliper Bracket Replacement — 15 inch Brake System
Front Brake Caliper Bracket Replacement — 16 inch Brake System
Rear Brake Calliper Bracket Replacement
Front Brake Disc Replacement
Rear Brake Rotor Replacement
Front Brake Shield Replacement
Rear Brake Shield Replacement
Brake Disc Assembled Lateral Runout Correction
Brake Rotor Assembled Lateral Runout Correction - Indexing
Brake Rotor Assembled Lateral Runout Correction - Correction Plates
Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe
Brake Disc Refinishing
Description and Operation
Disc Brake System Description and Operation
Special Tools and Equipment
Special Tools
Drum Brakes
Specifications
Fastener Tightening Specifications
Drum Brake Component Specifications
Adhesives, Fluids, Lubricants, and Sealers
Component Locator
Rear Drum Brakes Component Views
Diagnostic Information and Procedures
Brake Drum Diameter Measurement
Brake Drum Surface and Wear Inspection
Drum Brake Hardware Inspection
Drum Brake Adjusting Hardware Inspection
Repair Instructions
Brake Shoe Inspection
Brake Drum Replacement
Rear Brake Drum Refinishing
Brake Shoe Replacement
Rear Brake Backing Plate Replacement
Drum Brake Hardware Replacement
Drum Brake Adjusting Hardware Replacement
Rear Brake Cylinder Replacement
Drum Brake Adjustment
Description and Operation
Drum Brake System Description and Operation
Special Tools and Equipment
Special Tools
Hydraulic Brakes
Specifications
Fastener Tightening Specifications
Brake Component Specifications
Adhesives, Fluids, Lubricants, and Sealers
Schematic and Routing Diagrams
Hydraulic Brake Schematics
Diagnostic Information and Procedures
DTC C0267
DTC C1100
Symptoms - Hydraulic Brakes
Brake Booster Pump Motor Malfunction
Brake Warning Indicator Malfunction - With Antilock Brake System
Brake Warning Indicator Malfunction - Without Antilock Brake System
Brake Pulsation
Brake System Noise
Braking Action Uneven - Pulls to One Side
Braking Action Uneven - Front to Rear
Brake Pedal Excessive Travel
Brake Pedal Excessive Effort
Brakes Drag
Brake System Slow Release
Brake Fluid Loss
Disc Brake System Diagnosis
Drum Brake System Diagnosis
Hydraulic Brake System Diagnosis
Brake Assist System Diagnosis
Brake System Vehicle Road Test
Brake Pedal Travel Measurement and Inspection
Brake System Vacuum Source Test
Brake System External Leak Inspection
Brake System Internal Leak Test
Hydraulic Brake Component Operation Visual Inspection
Brake Pipe and Hose Inspection
Brake Pedal Pushrod Inspection
Repair Instructions
Master Cylinder Reservoir Filling
Master Cylinder Reservoir Replacement
Master Cylinder Replacement — Right Hand Drive
Master Cylinder Replacement — Left Hand Drive
Master Cylinder Bench Bleeding
Brake Fluid Level Indicator Switch Replacement
Brake, Accelerator, and Clutch Pedal Replacement — Right Hand Drive
Brake, Accelerator, and Clutch Pedal Replacement — Left Hand Drive
Brake Pipe Replacement
Front Brake Hose Replacement
Rear Brake Hose Replacement — Disc Brake
Hydraulic Brake System Bleeding
Hydraulic Brake System Flushing
Power Brake Booster Vacuum Pipe Replacement — Left Hand Drive
Power Brake Booster Vacuum Pipe Replacement — Right Hand Drive
Power Brake Booster Replacement — Right Hand Drive
Power Brake Booster Replacement — Left Hand Drive
Servo Unit Pump Replacement
Description and Operation
Brake Assist System Description and Operation
Brake Booster Vacuum Assist Description and Operation
Brake Fluid and Brake Fluid Handling
Brake Warning System Description and Operation - With Antilock Brake System
Brake Warning System Description and Operation - Without Antilock Brake System
Hydraulic Brake System Description and Operation
Special Tools and Equipment
Special Tools
Park Brake
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms - Park Brake
Park Brake System Diagnosis
Repair Instructions
Handbrake Lever Replacement
Parking Brake Lever Boot Replacement
Handbrake Indicator Switch Replacement
Parking Brake Cable Replacement — Conventional Parking Brake
Parking Brake Rear Cable Replacement
Parking Brake Adjustment — Conventional Parking Brake
7. Diagnostic Overview, Starting Point, and Programming
Programming and Setup
Diagnostic Information and Procedures
Control Module References
Repair Instructions
Body Control Module Programming and Setup
Control Solenoid Valve and Transmission Control Module Assembly Programming and Setup — 6T30/6T40/6T45/6T50
Electronic Brake Control Module Programming and Setup
Engine Control Module Programming and Setup - LLW
Engine Control Module Programming and Setup — LNP
Engine Control Module Programming and Setup - LXT
Engine Control Module Programming and Setup — LDE
Engine Control Module Programming and Setup — LUD
Heated Seat Control Module Programming and Setup
HVAC System Control Module Programming and Setup
Inflatable Restraint Sensing and Diagnostic Module Programming and Setup
Instrument Cluster Programming and Setup
Keyless Entry Control Module Programming and Setup
Mobile Telephone Control Module Programming and Setup
Multimedia Player Interface Module Programming and Setup
Object Alarm Module Programming and Setup
Power Steering Control Module Programming and Setup
Radio Control Programming and Setup
Radio Programming and Setup
Remote Control Door Lock Receiver Programming and Setup
Service Programming System (SPS)
Steering Column Lock Control Module Programming and Setup
Sunroof Control Module Programming and Setup
Theft Deterrent Module Programming and Setup
Trailer Lamp Control Module Programming and Setup
Window Regulator Motor Programming and Setup
Special Tools and Equipment
Special Tools
Vehicle Diagnostic Information
Specifications
Body Control Module Scan Tool Information
Digital Radio Receiver Scan Tool Information
Driver Seat and Passenger Seat Heater Control Module Scan Tool Information
Electronic Brake Control Module Scan Tool Information
Engine Control Module Scan Tool Information - LLW
Engine Control Module Scan Tool Information - LXV, 2H0
Engine Control Module Scan Tool Information - LXT
Engine Control Module Scan Tool Information — LNP
Engine Control Module Scan Tool Information — LUJ
Heating, Ventilation and Air Conditioning Control Module Scan Tool Information
Inflatable Restraint Sensing and Diagnostic Module Scan Tool Information
Instrument Cluster Scan Tool Information
Keyless Entry Control Module Scan Tool Information
Mobile Telephone Control Module Scan Tool Information
Multimedia Player Interface Module Scan Tool Information
Object Alarm Module Scan Tool Information
Power Steering Control Module Scan Tool Information
Radio Scan Tool Information
Steering Column Lock Control Module Scan Tool Information
Trailer Lamp Control Module Scan Tool Information
Diagnostic Information and Procedures
Strategy Based Diagnosis
Diagnostic Procedure Instructions
Diagnostic System Check Instructions
Diagnostic Starting Point - Vehicle
Diagnostic System Check - Vehicle
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Symptoms - Vehicle
Engine Does Not Crank
Engine Cranks But Does Not Run
Inspection/Maintenance System Check
Diagnostic Repair Verification
8. Driveline/Axle
Wheel Drive Shafts
Specifications
Fastener Tightening Specifications
Diagnostic Information and Procedures
Symptoms - Wheel Drive Shafts
Click Noise In Turns
Clunk When Accelerating from Freewheel
Clunk Noise When Accelerating During Turns
Repair Instructions
Front Wheel Drive Intermediate Shaft Replacement
Front Wheel Drive Intermediate Shaft Bracket Replacement
Front Wheel Drive Intermediate Shaft Bearing Replacement
Front Wheel Drive Shaft Replacement - Left Side
Front Wheel Drive Shaft Replacement - Right Side
Front Wheel Drive Shaft Inner Joint and Boot Replacement
Front Wheel Drive Shaft and Intermediate Shaft Assembly Replacement - Right Hand Side — 1.7L Diesel
Front Wheel Drive Shaft Outer Joint and Boot Replacement
Description and Operation
Wheel Drive Shafts Description and Operation
Special Tools and Equipment
Special Tools
9. Driver Information and Entertainment
Mobile, Entertainment, and Navigation
Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Radio/Navigation System Schematics
Cellular Telephone Schematics
Diagnostic Information and Procedures
DTC B1020
DTC B1025, B1035, B1045, or B1055
DTC B125A
DTC B1271
DTC B1278 or B1279
DTC B2462
Symptoms - Entertainment
Auxiliary Audio Input Malfunction — Without Navigation
Auxiliary Audio Input Malfunction — With Navigation
Mobile Telephone Conversation Partner Cannot Be Heard
No Global Positioning System (GPS) Reception
Radio Poor Reception
Speaker Replacement Reference
Speaker Malfunction
Navigation System Malfunction
Repair Instructions
Mobile Telephone Microphone Replacement
Compact Disc Care and Cleaning
Radio Replacement
Audio Disc Player Receptacle Replacement
Radio Speaker Amplifier Replacement
Multimedia Player Interface Module Replacement
Navigation Signal Splitter Replacement
Navigation Signal Splitter Bracket Replacement
Mobile Telephone Control Module Replacement
Radio Aerial Coil Replacement - High Side
Radio Aerial Coil Replacement - Ground Side
Radio Antenna Base Replacement
Radio Aerial Module Replacement
Radio Control Module Replacement
Radio Front Speaker Replacement
Radio Windscreen Side Garnish Moulding Speaker Replacement
USB Receptacle Replacement
Radio Front Side Door Speaker Replacement
Radio Control Switch Replacement - Steering Wheel
Radio Rear Side Door Speaker Replacement
Radio Rear Compartment Speaker Replacement
Description and Operation
Navigation System Description and Operation
Radio/Audio System Description and Operation
Special Tools and Equipment
Special Tools
Displays and Gauges
Specifications
Fastener Tightening Specifications
Ambient Air Temperature Sensor Resistance
Schematic and Routing Diagrams
Instrument Cluster Schematics
Audible Warnings Schematics
Diagnostic Information and Procedures
DTC B0158
DTC B0550
DTC B1370
DTC B3567
DTC P0461-P0464
DTC P0520
DTC P0521
Symptoms - Displays and Gauges
Charge Indicator Malfunction
Chime Malfunction
Driver Information Centre Switch Malfunction
Engine Oil Pressure Indicator Malfunction
Fuel Gauge Malfunction
Instrument Cluster Gauges Malfunction
Outside Air Temperature Display Malfunction
Speedometer and/or Odometer Malfunction
Repair Instructions
Ambient Air Temperature Gauge Sensor Replacement
Driver Information Display Replacement
Instrument Cluster Replacement
Instrument Panel Multifunction Switch Replacement — Traction Control
Description and Operation
Audible Warnings Description and Operation
Compass Calibration and Magnetic Variance — Driver Information Centre (DIC)
Driver Information Centre (DIC) Description and Operation
Indicator/Warning Message Description and Operation
Instrument Cluster Description and Operation
Secondary and Configurable Customer Controls
Schematic and Routing Diagrams
Steering Wheel Secondary/Configurable Control Schematics
Diagnostic Information and Procedures
DTC B1529
DTC B3622
Symptoms - Secondary and Configurable Customer Controls
Steering Wheel Controls Malfunction
Description and Operation
Steering Wheel Controls Description and Operation
10. Engine
Cruise Control
Schematic and Routing Diagrams
Cruise Control Schematics
Diagnostic Information and Procedures
DTC B3794
DTC P0564
DTC P0571
DTC P0575
DTC P0703
Symptoms - Cruise Control
Cruise Control Indicator Malfunction
Cruise Control Malfunction
Repair Instructions
Cruise Control Switch Replacement
Description and Operation
Cruise Control Description and Operation
Engine Controls/Fuel - 1.2L L2Q LDC LWD or 1.4L L2I L2N LDD LUH LUJ LUV
Specifications
Temperature Versus Resistance
Ignition System Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Engine Controls Schematics
Diagnostic Information and Procedures
DTC P0010 or P0013
DTC P0011 or P0014
DTC P0016 or P0017
DTC P0030, P0036, P0053, P0054, P0135, or P0141
DTC P0033-P0035
DTC P0068 or P1101
DTC P0096, P0097, or P0098
DTC P00C7
DTC P0101
DTC P0102 or P0103
DTC P0106
DTC P0107 or P0108
DTC P0111
DTC P0112, P0113, or P0114
DTC P0116
DTC P0117 or P0118
DTC P0121-P0123, P0222, P0223, or P2135
DTC P0128
DTC P0131, P0132, P0137, or P0138
DTC P0133, P0134, P013A, P013B, P013E, P013F, P0140, P1133, P2270, P2271, or P2A00
DTC P0171 or P0172
DTC P0201, P0202, P0203, or P0204
DTC P0234 or P0299
DTC P0236, P0237, or P0238
DTC P0243, P0245, or P0246
DTC P0300-P0304
DTC P0315
DTC P0324, P0326, or P06B6
DTC P0325, P0327, or P0328
DTC P0335 or P0336
DTC P0340 or P0365
DTC P0341 or P0366
DTC P0351-P0354
DTC P0420
DTC P0442
DTC P0443 or P0449
DTC P0446
DTC P0451-P0454
DTC P0455
DTC P0496
DTC P0506 or P0507
DTC P050A
DTC P050B
DTC P050D
DTC P050E
DTC P059F
DTC P0601-P0604, P0606, P062F, P16F3, or P2610 — Engine Control Module
DTC P0610
DTC P0630
DTC P0641, P0651, P0697, or P06A3
DTC P0650
DTC P0685, P0689, or P0690
DTC P069E
DTC P0700
DTC P1104
DTC P1258
DTC P150C
DTC P1516, P2100-P2103, P2119, or P2176
DTC P160A
DTC P160D
DTC P160E
DTC P1682
DTC P2122, P2123, P2127, P2128, or P2138
DTC P2227-P2229 or P2230
DTC P2261
DTC P2544
Symptoms - Engine Controls
Poor Fuel Fill Quality
Ignition Relay Diagnosis
Engine Cranks But Does Not Run
Fuel System Diagnosis
Fuel Pump Electrical Circuit Diagnosis
Fuel Injector Diagnosis
Fuel Injector Circuit Diagnosis
Alcohol/Contaminants-in-Fuel Diagnosis
Electronic Ignition System Diagnosis
Fuel Pressure Measurement
Repair Instructions
Engine Control Module Replacement
Crankshaft Position System Variation Learn
Engine Coolant Temperature Sensor Replacement - Radiator
Engine Coolant Temperature Sensor Replacement - Thermostat
Engine Coolant Temperature Sensor Replacement — Water Outlet
Mass Airflow Sensor Replacement — 1.4L LUH and LUJ
Manifold Absolute Pressure Sensor Replacement — 1.4L LUH and LUJ
Heated Oxygen Sensor Replacement - Sensor 1 — 1.4L LUH and LUJ
Heated Oxygen Sensor Replacement - Sensor 2
Engine Oil Pressure Indicator Switch Replacement — 1.4L LUH and LUJ
Accelerator Pedal Position Sensor Replacement
Throttle Body Assembly Replacement — 1.4L LUH and LUJ
Throttle Body Inspection and Cleaning
Fuel Pressure Relief
Fuel Tank Draining
Fuel Tank Replacement
Fuel Tank Filler Pipe Replacement
Fuel Feed Pipe Replacement — 1.4L LUH and LUJ
Fuel Tank Fuel Pump Module Replacement
Fuel Sender Assembly Replacement
Plastic Collar Quick Connect Fitting Service
Fuel System Cleaning
Fuel Injection Fuel Rail Assembly Replacement
Fuel Injector Replacement
Evaporative Emission Canister Replacement
Evaporative Emission Canister Purge Solenoid Valve Replacement — 1.4L LUH and LUJ
Ignition Coil Replacement
Spark Plug Inspection
Spark Plug Replacement
Camshaft Position Actuator Solenoid Valve Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement
Knock Sensor Replacement
Air Cleaner Inlet Duct Replacement
Air Cleaner Outlet Duct Replacement — 1.4L LUH and LUJ
Air Cleaner Element Replacement — 1.4L LUH and LUJ
Air Cleaner Assembly Replacement — 1.4L LUH and LUJ
Charge Air Cooler Inlet Air Hose Replacement
Charge Air Cooler Outlet Air Hose Replacement — Manual Gearbox
Description and Operation
Air Inlet System Description
Boost Control System Description
Camshaft Actuator System Description
Electronic Ignition System Description
Evaporative Emission Control System Description
Fuel System Description
Knock Sensor System Description
Throttle Actuator Control (TAC) System Description
Turbocharger System Description
Special Tools and Equipment
Special Tools
Engine Controls/Fuel - 1.6L LDE LED LFJ LGE LLU LXV or 1.8L 2H0 LFH LUW LWE
Specifications
Temperature Versus Resistance
Altitude Versus Barometric Pressure
Ignition System Specifications
Fastener Tightening Specifications — LDE, LXV, LUW, 2H0
Schematic and Routing Diagrams
Engine Controls Schematics
Diagnostic Information and Procedures
DTC P0010 or P0013 — LDE
DTC P0011 or P0014 — LDE
DTC P0016 or P0017 — LDE
DTC P0030, P0036, P0053, P0054, P0135, or P0141 — LDE
DTC P0068 or P1101 — LDE or LLU
DTC P0101 — LDE
DTC P0102 or P0103 — LDE
DTC P0106 — LDE or LLU
DTC P0107 or P0108 — LDE or LLU
DTC P0112, P0113, or P0114 — LDE
DTC P0121-P0123, P0222, P0223, or P2135 — LDE
DTC P0131, P0132, P0137, or P0138 — LDE or LLU
DTC P0133, P0134, P0140, P1133, P2270, P2271, or P2A00 — LDE or LLU
DTC P0171 or P0172 — LDE
DTC P018B-P018D
DTC P0201, P0202, P0203, or P0204 — LDE
DTC P025A
DTC P0231, P0232, or P023F
DTC P0300-P0304 — LDE
DTC P0315 — LDE or LLU
DTC P0324 or P06B6 — LDE
DTC P0335 or P0336 — LLU
DTC P0340 or P0365 — LDE
DTC P0341 or P0366 — LDE
DTC P0420 — LDE
DTC P0443 — LDE or LLU
DTC P0601-P0604, P0606, P0607, P16F3, or P2610 — LDE
DTC P0601-P0604, P0606, or P062F
DTC P0610 — LDE
DTC P0627-P0629 — LDE
DTC P0630 — LDE
DTC P0641 or P06A6
DTC P0660 — LDE
DTC P0685, P0689, or P0690 — LDE or LLU
DTC P1104 — LDE or LLU
DTC P1255 or P064A
DTC P1516, P2100-P2103, P2119, or P2176 — LDE
DTC P1682 — LDE or LLU
DTC P1700
DTC P2122, P2123, P2127, P2128, or P2138 — LDE
DTC P2534
DTC P2635
Poor Fuel Fill Quality
Malfunction Indicator Lamp (MIL) Diagnosis
Engine Cranks But Does Not Run
Fuel Pump Electrical Circuit Diagnosis — LDE
Fuel Injector Diagnosis
Fuel Injector Circuit Diagnosis
Alcohol/Contaminants-in-Fuel Diagnosis
Ignition Relay Diagnosis
Electronic Ignition System Diagnosis
Fuel Pressure Measurement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Repair Instructions
Engine Control Module Replacement
Crankshaft Position System Variation Learn
Inlet Air Temperature Sensor Replacement
Mass Airflow Sensor Replacement
Intake Manifold Runner Control Valve Actuator Solenoid Valve Replacement — 1.6L LDE
Manifold Absolute Pressure Sensor Replacement — 1.6L LDE and LXV
Manifold Absolute Pressure Sensor Replacement — 1.8L 2H0 and LUW
Engine Coolant Temperature Sensor Replacement - Radiator Side
Engine Coolant Temperature Sensor Replacement - Thermostat Side — 1.6L LDE, LXV, and 1.8L 2H0
Heated Oxygen Sensor Replacement - Sensor 1 — LDE, LXV, LUW, 2H0
Heated Oxygen Sensor Replacement - Sensor 2
Engine Oil Pressure Indicator Switch Replacement
Accelerator Pedal Position Sensor Replacement
Throttle Body Assembly Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Throttle Body Inspection and Cleaning — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Fuel Pressure Relief
Plastic Collar Quick Connect Fitting Service
Fuel Tank Draining
Fuel Tank Replacement — 1.6L LDE, LXV, and 1.8L 2H0
Fuel Tank Vent Pipe Replacement — LDE with Electrical Power Steering
Fuel Tank Vent Pipe Replacement — 1.8L LUW
Fuel Tank Filler Pipe Replacement
Fuel Feed Pipe Replacement — 1.6L LDE and LXV
Fuel Feed Pipe Replacement — 1.8L 2H0
Fuel Tank Fuel Pump Module Replacement — 1.6L LDE, LXV, and 1.8L 2H0
Fuel System Cleaning
Fuel Injector Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Evaporative Emission Canister Replacement
Evaporative Emission Canister Purge Solenoid Valve Replacement — 1.6L LDE and LXV
Evaporative Emission Canister Purge Solenoid Valve Replacement — 1.8L 2H0
Ignition Coil Replacement
Spark Plug Inspection
Spark Plug Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement — LDE, LXV, LUW, 2H0
Knock Sensor Replacement — LDE, LXV, 2H0 and LUW
Air Cleaner Inlet Duct Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Air Cleaner Outlet Duct Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Air Cleaner Element Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Air Cleaner Assembly Replacement — LDE, LXV, LUW, 2H0
Description and Operation
Engine Control Module Description
Fuel System Description
Throttle Actuator Control (TAC) System Description
Camshaft Actuator System Description — LDE
Evaporative Emission Control System Description
Electronic Ignition System Description
Knock Sensor System Description
Crankcase Ventilation System Description
Air Inlet System Description
Special Tools and Equipment
Special Tools — Removal and Installation
Engine Controls/Fuel - 1.6L L2W or LXT
Specifications
Temperature Versus Resistance - ECT
Altitude Versus Barometric Pressure
Ignition System Specifications
Fastener Tightening Specifications
Schematic and Routing Diagrams
Engine Controls Schematics
Diagnostic Information and Procedures
DTC P0016 or P0340
DTC P0031, P0032, or P0135
DTC P0037, P0038, or P0141
DTC P0068
DTC P0106, P0107, or P0108
DTC P0112 or P0113
DTC P0117 or P0118
DTC P0122, P0123, P0222, P0223, or P2135
DTC P0131-P0134
DTC P0137, P0138, or P0140
DTC P0171, P0172, P2187, or P2188
DTC P0230
DTC P0261, P0262, P0264, P0265, P0267, P0268, P0270, or P0271
DTC P0300-P0304
DTC P0315
DTC P0324
DTC P0325
DTC P0335 or P0336
DTC P0351 or P0352
DTC P0401 or P0402
DTC P0403-P0406 or P042E
DTC P0420
DTC P0458 or P0459
DTC P0480 or P0481
DTC P0506 or P0507
DTC P0601, P0602, P0604, P0606, P061A, or P2610
DTC P0630
DTC P0641, P0651, or P0697
DTC P0650
DTC P0685
DTC P0700
DTC P1166
DTC P1392 or P1393
DTC P1516, P2101, or P2119
DTC P2008
DTC P2104-P2106 or P2110
DTC P2122, P2123, P2127, P2128, or P2138
DTC P2297
Symptoms - Engine Controls
Poor Fuel Fill Quality
Malfunction Indicator Lamp (MIL) Inoperative
Malfunction Indicator Lamp (MIL) Always On
Engine Cranks But Does Not Run
Fuel System Diagnosis
Fuel Pump Electrical Circuit Diagnosis
Fuel Injector Diagnosis
Alcohol/Contaminants-in-Fuel Diagnosis
Inlet Manifold Tuning Valve Diagnosis
Electronic Ignition System Diagnosis
Repair Instructions
Engine Control Module Replacement
Crankshaft Position System Variation Learn
Engine Coolant Temperature Sensor Replacement - Radiator
Engine Coolant Temperature Sensor Replacement - Engine Block
Inlet Air Temperature Sensor Replacement
Manifold Absolute Pressure Sensor Replacement
Heated Oxygen Sensor Replacement - Sensor 1
Heated Oxygen Sensor Replacement - Sensor 2
Accelerator Pedal Position Sensor Replacement
Throttle Body Assembly Replacement
Throttle Body Inspection and Cleaning
Fuel Pressure Gauge Installation and Removal
Fuel Feed Pipe Replacement
Fuel Tank Vent Pipe Replacement
Fuel Tank Draining
Fuel Tank Replacement
Fuel Tank Fuel Pump Module Replacement
Fuel Tank Filler Pipe Replacement
Fuel System Cleaning
Fuel Injector and Fuel Rail Replacement
Evaporative Emission Canister Purge Solenoid Valve Replacement
Evaporative Emission Canister Replacement
Ignition Coil Replacement
Spark Plug Inspection
Spark Plug Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement
Knock Sensor Replacement
Exhaust Gas Recirculation Valve Replacement
Exhaust Gas Recirculation Pipe Replacement
Exhaust Gas Recirculation Valve Adapter Replacement
Engine Oil Pressure Indicator Switch Replacement
Air Cleaner Inlet Duct Replacement
Air Cleaner Outlet Duct Replacement
Air Cleaner Assembly Replacement
Description and Operation
Engine Control Module Description
Fuel System Description
Throttle Actuator Control (TAC) System Description
Evaporative Emission Control System Description
Electronic Ignition System Description
Knock Sensor System Description
Exhaust Gas Recirculation (EGR) System Description
Crankcase Ventilation System Description
Air Inlet System Description
Special Tools and Equipment
Special Tools
Engine Controls/Fuel - 1.7L Diesel
Specifications
Temperature Versus Resistance — ECT and IAT Sensor
Temperature Versus Resistance - Exhaust Temperature Sensor
Schematic and Routing Diagrams
Engine Controls Schematics
Diagnostic Information and Procedures
DTC P0016
DTC P0047 or P0048
DTC P0088
DTC P0093
DTC P0094
DTC P0097 or P0098
DTC P0100, P0101, P0102, or P0103
DTC P0110 or P0111
DTC P0116, P0117, or P0118
DTC P0130
DTC P0131 or P0132
DTC P0133
DTC P0134
DTC P0135
DTC P0168
DTC P0182 or P0183
DTC P0187 or P0188
DTC P0191, P0192, or P0193
DTC P0201, P0202, P0203, or P0204
DTC P0217
DTC P0234 or P0299
DTC P0236, P0237, or P0238
DTC P0252-P0254
DTC P0301-P0304
DTC P0313
DTC P0335 or P0336
DTC P0340 or P0341
DTC P037E or P037F
DTC P0383 or P0384
DTC P0400-P0402
DTC P0403-P0406
DTC P0409
DTC P0545 or P0546
DTC P0601, P0606, P060A, P060E, P0610, P061A, P062A, P062B, or P062F
DTC P0611
DTC P0630
DTC P0633
DTC P0642 or P0643
DTC P0652 or P0653
DTC P0686, P0687, P0689, or P0690
DTC P1259
DTC P1407
DTC P1471
DTC P160D
DTC P160E
DTC P161C
DTC P161F
DTC P1700
DTC P2002 or P2003
DTC P2009 or P2010
DTC P2014
DTC P2015
DTC P2016 or P2017
DTC P2032 or P2033
DTC P2080 or P2081
DTC P2084 or P2085
DTC P2102 or P2103
DTC P2122, P2123, P2127, P2128, or P2138
DTC P2147, P2148, P2150, or P2151
DTC P2228 or P2229
DTC P2243
DTC P2262
DTC P2297
DTC P2428
DTC P242F
DTC P244A or P244B
DTC P2452, P2454, or P2455
DTC P245C or P245D
DTC P2688 or P2689
DTC P268A or P2696
Symptoms - Engine Controls
Malfunction Indicator Lamp (MIL) Diagnosis
Engine Cranks But Does Not Run
Fuel Pump Electrical Circuit Diagnosis
Fuel System Diagnosis
Ignition Relay Diagnosis
Fuel Tank Leak Test
Contaminants-in-Fuel Diagnosis
Repair Instructions
Fuel Injector Flow Rate Programming
Exhaust Pressure Sensor Replacement
Engine Coolant Temperature Sensor Replacement
Mass Airflow Sensor Replacement
Inlet Air Duct Replacement
Rear Inlet Air Duct Replacement
Accelerator Pedal Position Sensor Replacement
Plastic Collar Quick Connect Fitting Service
Water-in-Fuel Draining
Fuel Filter Assembly Replacement
Fuel Tank Draining
Fuel System Cleaning
Fuel Injector Replacement
Glow Plug Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement
Air Cleaner Element Replacement
Air Cleaner Outlet Front Duct Replacement
Air Cleaner Outlet Rear Duct Replacement
Charge Air Cooler Inlet Pipe Replacement
Description and Operation
Accelerator Pedal Position System Description
Exhaust Gas Recirculation (EGR) System Description
Exhaust Particulate Filter System Description
Fuel System Description
Glow Plug System Description
Engine Controls/Fuel - 2.0L Diesel
Specifications
Temperature Versus Resistance
Temperature Versus Resistance - Exhaust Temperature Sensor
Altitude Versus Barometric Pressure
Fastener Tightening Specifications
Fuel System Specifications
Schematic and Routing Diagrams
Engine Controls Schematics
Diagnostic Information and Procedures
DTC P0016
DTC P0045
DTC P0069
DTC P0089
DTC P0090
DTC P0095
DTC P0100
DTC P0101
DTC P0105
DTC P0110
DTC P0115
DTC P0116
DTC P0180
DTC P0190 or P0191
DTC P0201, P0202, P0203, P0204, P1224, P1227, P122A, or P1233
DTC P0234 or P0299
DTC P0263, P0266, P0269, or P0272
DTC P02E0
DTC P02E1
DTC P0335
DTC P0340
DTC P0401 or P0402
DTC P0403
DTC P0544 or P2031
DTC P0601, P0602, P0603, P0604, P0605, P0606, P0607, P060A, P060B, P061C, P062B, or P062F
DTC P0627
DTC P0630
DTC P0641, P0651, or P0697
DTC P0649
DTC P064C
DTC P0650
DTC P0670
DTC P0671, P0672, P0673, or P0674
DTC P0683
DTC P0700
DTC P1446 or P1447
DTC P161C
DTC P161E
DTC P161F
DTC P1793
DTC P2002
DTC P2080 or P2084
DTC P2120, P2125, or P2138
DTC P2146 or P2149
DTC P2226
DTC P2264
DTC P244B
DTC P244C
DTC P2452
DTC P2453
DTC P2463
DTC P2458
DTC P2510
DTC P2533
DTC P2544
DTC P2687
DTC P268A
Symptoms - Engine Controls
Engine Cranks But Does Not Run
Fuel Pump Electrical Circuit Diagnosis
Fuel System Diagnosis
Fuel Leak Diagnosis
Ignition Relay Diagnosis
Fuel Tank Leak Test
Fuel Specific Gravity Testing
Contaminants-in-Fuel Diagnosis
Fuel Injector Balance Test with Scan Tool
Repair Instructions
Engine Control Module Replacement
Fuel Injector Flow Rate Programming
Exhaust Particulate Filter Cleaning
Exhaust Pressure Sensor Replacement
Engine Coolant Temperature Sensor Replacement
Mass Airflow Sensor with Inlet Air Temperature Sensor Replacement
Inlet Air Pressure and Temperature Sensor Replacement
Inlet Air Duct Replacement
Rear Inlet Air Duct Replacement
Rear Inlet Air Duct Resonator Insulator Replacement
Accelerator Pedal Position Sensor Replacement
Throttle Body Assembly Replacement
Fuel Pressure Gauge Installation and Removal
Plastic Collar Quick Connect Fitting Service
Fuel System Priming
Fuel Filter Replacement
Fuel Heater Replacement
Water in Fuel Indicator Sensor Replacement
Water-in-Fuel Draining
Fuel Tank Draining
Fuel Tank Replacement
Fuel Sender Assembly Replacement
Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump
Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block
Fuel Feed Pipe Replacement
Fuel Return Pipe Replacement
Fuel Tank Filler Pipe Replacement
Fuel System Cleaning
Fuel Injector Fuel Feed Pipe Replacement
Fuel Injection Fuel Rail Assembly Replacement
Fuel Injection Pump Replacement
Fuel Injector Replacement
Glow Plug Replacement
Glow Plug Controller Replacement
Crankshaft Position Sensor Replacement
Camshaft Position Sensor Replacement
Exhaust Gas Recirculation Valve Replacement
Exhaust Gas Recirculation Valve Cooler Replacement
Exhaust Gas Recirculation Valve Vacuum Tank Replacement
Vacuum Pump Assembly Replacement
Exhaust Gas Recirculation Valve Solenoid Replacement
Exhaust Temperature Sensor Replacement - Position 1
Exhaust Temperature Sensor Replacement - Position 2
Air Cleaner Element Replacement
Air Cleaner Assembly Replacement
Air Cleaner Outlet Front Duct Replacement
Description and Operation
Accelerator Pedal Position System Description
Engine Control Module Description
Exhaust Gas Recirculation (EGR) System Description
Exhaust Particulate Filter System Description
Fuel System Description
Glow Plug System Description
Turbocharger System Description
Special Tools and Equipment
Special Tools
Engine Controls/Fuel - 2.0L LNP or 2.2L LNQ Diesel
Specifications
Fastener Tightening Specifications
Altitude Versus Barometric Pressure
Temperature Versus Resistance — ECT and IAT Sensor
Temperature Versus Resistance - Exhaust Temperature Sensor
Schematic and Routing Diagrams
Engine Controls Schematics
Diagnostic Information and Procedures
DTC P0002-P0004
DTC P0011
DTC P0016
DTC P003A
DTC P0045, P0047, or P0048
DTC P0069
DTC P0087 or P0088
DTC P0090, P0091, or P0092
DTC P0093
DTC P0096, P0097, P0098, or P0099
DTC P0101, P0102, or P0103
DTC P0107 or P0108
DTC P0111-P0113
DTC P0116-P0119
DTC P0181, P0182, or P0183
DTC P0190, P0191, P0192, or P0193
DTC P0201, P0202, P0203, or P0204
DTC P0219
DTC P0253 or P0254
DTC P0263, P0266, P0269, or P0272
DTC P029C, P02A0, P02A4, or P02A8
DTC P02CC-P02D3
DTC P02E0-P02E3, P02E8, P02E9, P02EB, or P122B
DTC P0326 or P0331
DTC P0335
DTC P0336 or P0339
DTC P0340 or P0341
DTC P0344
DTC P037E or P037F
DTC P0383 or P0384
DTC P0400-P0402
DTC P0404-P0406
DTC P049D
DTC P0524
DTC P0545 or P0546
DTC P0604
DTC P0606
DTC P0627 or P0628
DTC P062B
DTC P0641
DTC P064C
DTC P064D
DTC P0650
DTC P0651
DTC P066A
DTC P0670
DTC P0671, P0672, P0673, or P0674
DTC P0689, P068A, P068B, or P0690
DTC P0697
DTC P06B8
DTC P1125
DTC P1159, P1161, P1168, P1402, or P1407
DTC P122C or P122D
DTC P1248, P1249, P124A, or P124B
DTC P160E
DTC P161C
DTC P16F3
DTC P2008-P200A, P2010, P2016, or P2017
DTC P2032 or P2033
DTC P2080
DTC P2081, P2085, or P242E
DTC P2122, P2123, P2127, P2128, or P2138
DTC P2147, P2148, P2150, or P2151
DTC P2195
DTC P2228 or P2229
DTC P2237 or P2238
DTC P2245, P2246, or P2251
DTC P2263
DTC P2264
DTC P2269
DTC P228C or P228D
DTC P2428
DTC P242B
DTC P242C or P242D
DTC P2453-P2455
DTC P2463 or P246C
DTC P2564 or P2565
DTC P2687-P2689
DTC P268C-P268F
DTC P2A00
Symptoms - Engine Controls
Malfunction Indicator Lamp (MIL) Diagnosis
Water-in-Fuel Lamp Diagnosis
Engine Cranks But Does Not Run
Fuel Leak Diagnosis
Fuel Pump Electrical Circuit Diagnosis
Fuel System Diagnosis
Ignition Relay Diagnosis
Fuel Specific Gravity Testing
Fuel Injector Balance Test with Scan Tool
Fuel Tank Leak Test
Contaminants-in-Fuel Diagnosis
Repair Instructions
Exhaust Particulate Filter Cleaning
Fuel Injector Flow Rate Programming
Engine Control Module Replacement
Accelerator Pedal Position Sensor Replacement
Heated Oxygen Sensor Replacement
Throttle Body Assembly Replacement
Engine Coolant Temperature Sensor Replacement
Inlet Air Pressure and Temperature Sensor Replacement
Mass Airflow Sensor with Inlet Air Temperature Sensor Replacement
Fuel Pressure Gauge Installation and Removal
Fuel System Cleaning
Fuel System Priming
Camshaft Position Sensor Replacement
Crankshaft Position Sensor Replacement
Fuel Tank Draining
Fuel Tank Filler Pipe Replacement
Fuel Tank Filler Hose Replacement
Fuel Tank Replacement
Fuel Tank Fuel Pump Module Replacement
Fuel Tank Fuel Pump Module Wiring Harness Replacement
Plastic Collar Quick Connect Fitting Service
Fuel Filter Replacement
Fuel Feed Pipe Replacement
Fuel Feed Pipe Replacement - Fuel Filter to Fuel Feed Pipe
Fuel Feed Pipe Replacement - Fuel Tank Fuel Pump to Fuel Filter Housing
Fuel Return Pipe Replacement
Fuel Return Pipe Replacement - Fuel Return Pipe to Fuel Pump
Fuel Injector Replacement
Fuel Injection Fuel Rail Assembly Replacement
Fuel Injection Fuel Return Hose Replacement
Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail
Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector
Fuel Injection Pump Replacement
Vacuum Pump Assembly Replacement
Vacuum Pump Hose Replacement
Vacuum Modulator Replacement
Inlet Air Tuning Valve Vacuum Control Solenoid Valve Replacement
Intake Manifold Tuning Valve Vacuum Control Solenoid Valve Hose Replacement
Exhaust Gas Recirculation Valve Cooler Replacement
Exhaust Gas Recirculation Valve Replacement
Exhaust Gas Recirculation Pipe Replacement
Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve Vacuum Hose Replacement
Exhaust Gas Recirculation Valve Cooler Bypass Control Solenoid Valve Replacement
Exhaust Temperature Sensor Replacement - Position 1
Exhaust Temperature Sensor Replacement - Position 2
Exhaust Temperature Sensor Replacement - Position 3
Exhaust Pressure Differential Sensor Replacement
Glow Plug Controller Replacement
Glow Plug Replacement
Glow Plug Controller Bracket Replacement
Knock Sensor 1 Replacement
Knock Sensor 2 Replacement
Air Cleaner Assembly Replacement
Air Cleaner Replacement
Inlet Air Duct Replacement
Rear Inlet Air Duct Replacement
Air Cleaner Outlet Duct Replacement
Description and Operation
Fuel System Description
Engine Control Module Description
Turbocharger System Description
Accelerator Pedal Position System Description
Exhaust Gas Recirculation (EGR) System Description
Exhaust Particulate Filter System Description
Glow Plug System Description
Special Tools and Equipment
Special Tools — Removal and Installation
Engine Cooling
Specifications
Fastener Tightening Specifications - 2.0L Diesel LLW
Fastener Tightening Specifications — 1.6L LXT, L2W
Fastener Tightening Specifications — 1.4L LDD, LUH and LUJ
Fastener Tightening Specifications — 2.0L Diesel LNP
Fastener Tightening Specifications — 1.6L LDE, LLU, LXV, 1.8L 2H0, and LUW
Engine Cooling System Specifications — LDE, LLU, LXV, 2H0, LUW
Engine Cooling System Specifications — 1.4L LDD and LUJ
Engine Cooling System Specifications — 2.0L Diesel LLW
Engine Cooling System Specifications — 2.0L Diesel LNP
Schematic and Routing Diagrams
Engine Cooling Schematics
Diagnostic Information and Procedures
DTC P00B3 or P00B4
DTC P00B6
DTC P0480 or P0481 — LUJ
DTC P0480, P0481, or P0482
DTC P0597-P0599
DTC P0691-P0694 — LDE, LXV or 2H0
DTC P0691-P0694 — LNP or LNQ
Symptoms - Engine Cooling
Cooling Fan Always On - LLW
Cooling Fan Always On - LXT
Cooling Fan Always On - LXV, 2H0
Cooling Fan Inoperative - LXT
Cooling Fan Inoperative - LXV, 2H0
Cooling Fan Inoperative - LLW
Engine Overheating
Loss of Coolant
Thermostat Diagnosis — LDE, L2W, LXT, LXV, 2H0, and LUW
Thermostat Diagnosis — 1.4L LDD and LUJ
Thermostat Diagnosis - 2.0L Diesel LLW
Thermostat Diagnosis — 2.0L Diesel LNP
Engine Fails To Reach Normal Operating Temperature
Cooling System Leak Testing
Repair Instructions
Cooling System Draining and Filling
Coolant System Flushing
Radiator Cleaning
Radiator Surge Tank Replacement
Radiator Expansion Tank Inlet Hose/Pipe Replacement — 1.6L LXT,L2W
Radiator Expansion Tank Outlet Hose/Pipe Replacement — 1.6L LXT,L2W
Radiator Surge Tank Outlet Hose Replacement — 2.0L Diesel LNP
Radiator Expansion Tank Outlet Hose Replacement — LDE, LLU, LXV, 2H0, and LUW
Radiator Inlet Hose Replacement — 2.0L Diesel LNP
Radiator Inlet Hose Replacement - 2.0L Diesel LLW
Radiator Inlet Hose Replacement — 1.6L LXT,L2W
Radiator Inlet Hose Replacement — LDD, LUH, and LUJ
Radiator Inlet Hose Replacement — LDE, LLU, LXV, 2H0, and LUW
Radiator Outlet Hose Replacement — 2.0L Diesel LNP
Radiator Outlet Hose Replacement - 2.0L Diesel LLW
Radiator Outlet Hose Replacement — 1.6L LXT,L2W
Radiator Outlet Hose Replacement — LDD, LUH, and LUJ
Radiator Outlet Hose Replacement — LDE, LLU, LXV, 2H0, and LUW
Engine Coolant Inlet Pipe Replacement - 2.0L Diesel LLW
Engine Coolant Outlet Pipe Replacement - 2.0L Diesel LLW
Engine Coolant Inlet Hose Replacement — 2.0L Diesel LNP
Radiator Mounting Stud Repair
Charge Air Cooler Replacement — 1.4L LUH, LUJ - M32-6 MZ4
Charge Air Cooler Replacement — 2.0L Diesel LLW
Charge Air Cooler Replacement — 1.4L LUH, LUJ - AT
Charge Air Cooler Replacement — 2.0L Diesel LNP
Radiator and Charge Air Cooler Bracket Repair
Engine Coolant Fan Wiring Harness Replacement — 2.0L Diesel LNP
Engine Coolant Fan Resistor Mount Repair
Radiator Vent Valve Replacement
Charge Air Cooler Inlet Hose Replacement — 2.0L Diesel LNP
Charge Air Cooler Inlet Hose Replacement - 2.0L Diesel LLW
Charge Air Cooler Outlet Hose Replacement - 2.0L Diesel LLW
Charge Air Cooler Outlet Hose Replacement — 2.0L Diesel LNP - AT
Charge Air Cooler Outlet Hose Replacement — 2.0L Diesel LNP - MT
Throttle Body Heater Inlet Hose Replacement — LDE, LXV, 2H0, and LUW
Throttle Body Heater Outlet Hose Replacement — LDE, LXV, 2H0, and LUW
Engine Oil Cooler Replacement — 2.0L Diesel LNP
Engine Oil Cooler Replacement - 2.0L Diesel LLW
Engine Oil Cooler Replacement — 1.4L LUH, LUJ
Engine Oil Cooler Replacement — LDE, LXV, LUW, 2H0
Engine Oil Cooler Outlet Hose Replacement — 2.0L Diesel LNP
Engine Oil Cooler Outlet Hose Replacement — 1.4L LUH and LUJ
Engine Oil Cooler Inlet Hose Replacement — 1.4L LUH and LUJ
Engine Oil Cooler Inlet Pipe Replacement - 2.0L Diesel LLW
Engine Oil Cooler Inlet Pipe Replacement — 1.4L LUH, LUJ
Engine Oil Cooler Inlet Pipe Replacement — LDE, LXV, LUW, 2H0
Engine Oil Cooler Outlet Pipe Replacement - 2.0L Diesel LLW
Engine Oil Cooler Outlet Pipe Replacement — LDE, LXV, LUW, 2H0
Engine Coolant Fan Replacement — 2.0L Diesel LNP
Engine Coolant Fan Replacement - 2.0L Diesel LLW
Engine Coolant Fan Replacement — 1.4L LUH, LUJ - M32-6 MZ4
Engine Coolant Fan Replacement — LDE, LLU, LUJ, LUW, LXV, LXT, L2W, 2H0-AT
Engine Coolant Fan Replacement — LDE,LXT,LXV,L2W,2H0-MT
Engine Coolant Fan Resistor Replacement - 2.0L Diesel LLW
Engine Coolant Fan Resistor Replacement — Petrol
Engine Coolant Level Indicator Module Replacement
Turbocharger Coolant Feed Pipe Replacement — 2.0L Diesel LNP
Turbocharger Coolant Feed Pipe Replacement — 1.4L LUH and LUJ
Turbocharger Coolant Return Pipe Replacement — 2.0L Diesel LNP
Turbocharger Coolant Return Pipe Replacement — 1.4L LUH and LUJ
Exhaust Gas Recirculation Cooling Pipe Replacement - Lower - 2.0L Diesel LLW
Exhaust Gas Recirculation Cooling Pipe Replacement - Upper - 2.0L Diesel LLW
Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement
Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement — 2.0L Diesel LNP
Thermostat Bypass Hose Replacement
Water Pump Inlet Hose Replacement
Engine Coolant Thermostat Housing Replacement — 1.6L LDE, LXV, 1.8L 2H0, LUW
Engine Coolant Thermostat Housing Replacement — 1.4L LUH and LUJ
Engine Coolant Thermostat Replacement — 1.6L LDE, LXV, LUW, 2H0
Engine Coolant Thermostat Replacement — 2.0L Diesel LNP
Engine Coolant Thermostat Replacement - 2.0L Diesel LLW
Engine Coolant Thermostat Replacement — 1.6L LXT,L2W
Engine Coolant Thermostat Housing Cover Replacement
Engine Coolant Air Bleed Hose Replacement — 2.0L Diesel LNP
Engine Coolant Air Bleed Hose Replacement - 2.0L Diesel LLW
Engine Coolant Air Bleed Hose Replacement — 1.6L LXT,L2W
Engine Coolant Air Bleed Hose Replacement — 1.4L LDD, LUH and LUJ
Engine Coolant Air Bleed Hose Replacement — 1.6L LDE, LXV, 1.8L 2H0 and LUW
Water Outlet Replacement — 1.4L LUH and LUJ
Engine Water Outlet Adapter Replacement — 2.0L Diesel LNP
Thermostat Bypass Pipe Replacement
Heater Inlet Pipe Replacement - 2.0L Diesel LLW
Heater Outlet Pipe Replacement - 2.0L Diesel LLW
Water Pump Pulley Replacement — 2.0L Diesel LNP
Water Pump Pulley Replacement — LDD, LUH, and LUJ
Water Pump Pulley Replacement — LDE, LXV, 2H0, and LUW
Water Pump Replacement — 2.0L Diesel LNP
Water Pump Replacement - 2.0L Diesel LLW
Water Pump Replacement — 1.6 LXT,L2W
Water Pump Replacement — LDD and LUJ
Water Pump Replacement — LDE, LXV, 2H0, and LUW
Radiator Drain Cock Replacement
Engine Coolant Fan Shroud Replacement — 2.0L Diesel LNP
Engine Coolant Fan Shroud Replacement — 1.4L LUH and LUJ - M32-6 MZ4
Engine Coolant Fan Shroud Replacement — LDE, LLU, LUJ, LUW, LXT, LXV, L2W, 2HO-AT
Engine Coolant Fan Shroud Replacement — LDE,LXT,LXV,L2W,2H0, LUW-MT
Radiator Replacement — 2.0L Diesel LNP and LLW with AT
Radiator Replacement — 2.0L Diesel LNP and LLW with MT
Radiator Replacement — 1.4L LUH and LUJ - AT
Radiator Replacement — 1.4L LUH and LUJ - MT
Radiator Replacement — 1.6L LDE, LXT, LXV, L2W and 1.8L 2H0
Radiator Support Bracket Replacement
Radiator Support Replacement
Description and Operation
Cooling System Description and Operation — 1.4L LDD and LUJ
Cooling System Description and Operation — LDE, LLU, LXV, 2H0 and LUW
Cooling System Description and Operation — 2.0L Diesel LLW
Cooling System Description and Operation — 2.0L Diesel LNP
Special Tools and Equipment
Special Tools
Engine Electrical
Specifications
Fastener Tightening Specifications — 1.6L LDE, LLU, LXV, 1.8L 2H0, and LUW
Fastener Tightening Specifications — 1.6L LXT,L2W
Fastener Tightening Specifications - 2.0L Diesel LLW
Fastener Tightening Specifications — 2.0L Diesel LNP
Schematic and Routing Diagrams
Starting and Charging Schematics
Diagnostic Information and Procedures
DTC B1325
DTC B1516
DTC B1517
DTC B151A
DTC B1527
DTC C0800
DTC P0562
DTC P0563
DTC P0615, P0616, or P0617
DTC P0621
DTC P0622
DTC P0625 or P0626
DTC P2500 or P2501
Symptoms - Engine Electrical
Battery Charging
Battery Electrical Drain/Parasitic Load Test
Charging System Test
Generator Noise Diagnosis
Starter Solenoid Does Not Click
Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks Slowly
Starter Noise Diagnosis
Repair Instructions
Battery Negative Cable Disconnection and Connection
Battery Current Sensor Replacement
Battery Positive and Negative Cable Replacement - 2.0L Diesel LLW
Battery Positive and Negative Cable Replacement — Petrol
Battery Positive and Negative Cable Replacement — 2.0L Diesel LNP
Battery Negative Cable Replacement — without Start/Stop System
Battery Positive Cable Replacement
Battery Replacement — Diesel
Battery Replacement — Petrol
Battery Tray Replacement
Battery Cover Replacement
Starter Replacement - 2.0L Diesel LLW
Starter Replacement — 1.6L LXT,L2W
Starter Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Starter Replacement — 1.4L LDD, LUH, and LUJ
Starter Replacement — 2.0L Diesel LNP with AT
Starter Replacement — 2.0L Diesel LNP with MT
Auxiliary Alternator Bracket Replacement — 1.6L LXT,L2W
Alternator Replacement — 1.4L LDD, LUH, and LUJ
Alternator Replacement — 1.6L LDE, LXV, LLU, 1.8L 2H0, and LUW
Alternator Replacement — 1.6L LXT,L2W
Alternator Replacement - 2.0L Diesel LLW
Generator Replacement — 2.0L Diesel LNP
Engine Control Module Wiring Harness Replacement — 2.0L Diesel LNP
Engine Control Module Wiring Harness Replacement — 1.6 LDE, LXV, 1.8L 2H0
Description and Operation
Battery Description and Operation
Charging System Description and Operation
Electrical Power Management Description and Operation
Alternator Oscilloscope Information
Load Shed System Description and Operation
Starting System Description and Operation
Special Tools and Equipment
Special Tools
Engine Exhaust
Specifications
Fastener Tightening Specifications — 2.0L Diesel LNP
Fastener Tightening Specifications - 2.0L Diesel LLW
Fastener Tightening Specifications — 1.4L LDD, LUH, and LUJ
Fastener Tightening Specifications — 1.6L LXT, L2W
Fastener Tightening Specifications — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Diagnostic Information and Procedures
Symptoms - Engine Exhaust
Restricted Exhaust
Exhaust Leakage
Exhaust Noise
Repair Instructions
Exhaust Manifold Replacement — 2.0L Diesel LNP
Exhaust Manifold Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Exhaust Manifold Replacement - 2.0L Diesel LLW
Exhaust Manifold Replacement — 1.6L LXT,L2W
Exhaust Front Pipe Replacement — 2.0L Diesel LNP
Exhaust Front Pipe Replacement — LDE,LLU,LXT,LXV,L2W,2H0
Exhaust System Replacement — 2.0L Diesel LNP
Exhaust System Replacement - 2.0L Diesel LLW
Exhaust System Replacement — 1.6L LDE, LXT, LXV, 1.8L 2H0, and LUW
Catalytic Converter Replacement - 2.0L Diesel LLW
Catalytic Converter Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Catalytic Converter Replacement — 1.6L LXT,L2W
Catalytic Converter Replacement — 1.4L LUH and LUJ
Warm Up Three-Way Catalytic Converter Replacement — 1.4L LUH and LUJ
Exhaust Particulate Filter Replacement — 2.0L Diesel LNP
Exhaust Particulate Filter Replacement - 2.0L Diesel LLW
Exhaust Particulate Filter Heat Shield Replacement - Front
Exhaust Particulate Filter Heat Shield Replacement - Rear
Exhaust Pipe Front Hanger Bracket Replacement
Exhaust Flexible Pipe Replacement - 2.0L Diesel LLW
Catalytic Converter Heat Shield Replacement - 2.0L Diesel LLW
Catalytic Converter Heat Shield Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Catalytic Converter Heat Shield Replacement — 1.4L LUH and LUJ
Exhaust Heat Shield Replacement
Fuel Tank Heat Shield Replacement — 2.0L Diesel LNP
Fuel Tank Heat Shield Replacement - 2.0L Diesel LLW
Fuel Tank Heat Shield Replacement — Petrol
Exhaust Manifold Heat Shield Replacement — 2.0L Diesel LNP
Exhaust Manifold Heat Shield Replacement - 2.0L Diesel LLW
Exhaust Manifold Heat Shield Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Exhaust Manifold Heat Shield Replacement — 1.4L LUH and LUJ
Exhaust Manifold Heat Shield Replacement — 1.6L LXT, L2W
Turbocharger Heat Shield Replacement
Exhaust Rear Silencer Heat Shield Replacement
Exhaust Rear Silencer Replacement
Description and Operation
Exhaust System Description — 2.0L Diesel LNP
Exhaust System Description - 2.0L Diesel LLW
Exhaust System Description — 1.6L LDE, LXT, LXV, 1.8L 2H0, and LUW
Special Tools and Equipment
Special Tools
Engine Mechanical - 1.2L L2Q LDC LWD or 1.4L L2I L2N LDD LUH LUJ LUV
Specifications
Fastener Tightening Specifications — 1.4L LUH and LUJ
Engine Mechanical Specifications
Adhesives, Fluids, Lubricants, and Sealers
Visual Identification
Disassembled Views
Engine Identification
Diagnostic Information and Procedures
Symptoms - Engine Mechanical
Oil Pressure Diagnosis and Testing — 1.4L LUH and LUJ
Oil Leak Diagnosis
Oil Consumption Diagnosis
Engine Noise Under Load
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Will Not Crank - Crankshaft Will Not Rotate
Engine Compression Test
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Repair Instructions
Drive Belt Replacement
Drive Belt Tensioner Replacement
Engine Mount Replacement - Right Side
Engine Mount Bracket Replacement - Right Side
Air Conditioning Compressor Bracket Replacement
Intake Manifold Replacement — 1.4L LUH and LUJ
Camshaft Timing Chain Replacement
Timing Chain Tensioner Replacement
Hydraulic Valve Lash Adjuster Arm Replacement
Hydraulic Valve clearance Adjuster Replacement
Camshaft Intake Sprocket Replacement
Camshaft Exhaust Sprocket Replacement
Cylinder Head Replacement — 1.4L LUH and LUJ
Oil Pan Replacement — 1.4L LUH and LUJ
Automatic Transmission Flex Plate Replacement
Engine Flywheel Replacement — 1.4L LUH and LUJ
Crankshaft Balancer Replacement
Crankshaft Front Oil Seal Replacement
Crankshaft Rear Oil Seal Replacement — Automatic Transmission
Crankshaft Rear Oil Seal Replacement — Manual Gearbox
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement
Engine Front Cover with Oil Pump Replacement
Oil Pump Replacement
Engine Replacement — 1.4L LUH and LUJ - M32
Engine Replacement — 1.4L LUJ - 6T40
Engine Oil and Oil Filter Replacement
Turbocharger Replacement
Turbocharger Oil Feed Pipe Replacement
Turbocharger Oil Return Pipe Replacement
Piston, Connecting Rod, and Bearing Replacement
Camshaft Cover Replacement — 1.4L LUH and LUJ
Intake Camshaft Replacement
Exhaust Camshaft Replacement
Engine Support Fixture
Engine Mount Bracket Removal
Camshaft Timing Chain Inspection
Camshaft Timing Chain Adjustment
Draining Fluids and Oil Filter Removal
Positive Crankcase Ventilation Pipe Removal
Exhaust Manifold Heat Shield Removal — 1.4L LUH and LUJ
Warm Up Three-Way Catalytic Converter Removal — 1.4L LUH and LUJ
Turbocharger Removal
Engine Oil Cooler Removal
Engine Coolant Thermostat Housing Removal — 1.4L LUH and LUJ
Water Outlet Removal — 1.4L LUH and LUJ
Drive Belt Tensioner Removal
Air Conditioning Compressor Bracket Removal
Water Pump Pulley Removal
Crankshaft Balancer Removal
Water Pump Removal
Throttle Body Removal — 1.4L LUH and LUJ
Intake Manifold Removal — 1.4L LUH and LUJ
Generator Removal
Starter Removal
Engine Flywheel Removal — 1.4L LUH and LUJ
Ignition Coil Removal
Camshaft Cover Removal
Camshaft Position Actuator Solenoid Valve Removal
Sump Removal
Engine Front Cover and Oil Pump Removal
Camshaft Timing Chain Removal
Timing Chain Tensioner Removal
Engine Front Cover Gasket Removal
Camshaft Sprocket Removal
Intake Camshaft Removal
Exhaust Camshaft Removal
Hydraulic Valve Lash Adjuster Arm Removal
Hydraulic Valve clearance Adjuster Removal
Cylinder Head Removal
Piston, Connecting Rod, and Bearing Removal
Crankshaft and Bearing Removal
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Cylinder Head Assemble
Engine Block Disassemble — 1.4L LUH and LUJ
Engine Block Assemble — 1.4L LUH and LUJ
Piston and Connecting Rod Disassemble — 1.4L LUH and LUJ
Piston, Connecting Rod, and Bearing Cleaning and Inspection — 1.4L LUH and LUJ
Piston and Connecting Rod Assemble — 1.4L LUH and LUJ
Intake Manifold Disassemble — 1.4L LUH and LUJ
Inlet Manifold Cleaning and Inspection
Intake Manifold Assemble — 1.4L LUH and LUJ
Crankshaft and Bearing Cleaning and Inspection
Engine Front Cover and Oil Pump Cleaning and Inspection
Engine Front Cover and Oil Pump Disassemble
Turbocharger Disassemble
Turbocharger Cleaning and Inspection
Turbocharger Assemble
Engine Oil Cooler Disassemble
Engine Oil Cooler Assemble
Sump Cleaning and Inspection
Crankshaft and Bearing Installation
Piston, Connecting Rod, and Bearing Installation
Cylinder Head Installation
Hydraulic Valve clearance Adjuster Installation
Hydraulic Valve Lash Adjuster Arm Installation
Intake Camshaft Installation
Exhaust Camshaft Installation
Camshaft Sprocket Installation
Timing Chain Tensioner Installation
Engine Front Cover Gasket Installation
Camshaft Timing Chain Installation
Engine Front Cover and Oil Pump Installation
Sump Installation
Camshaft Position Actuator Solenoid Valve Installation
Camshaft Cover Installation
Ignition Coil Installation
Engine Flywheel Installation — 1.4L LUH and LUJ
Generator Installation
Starter Installation
Intake Manifold Installation — 1.4L LUH and LUJ
Throttle Body Installation — 1.4L LUH and LUJ
Water Pump Installation
Crankshaft Balancer Installation
Water Pump Pulley Installation
Air Conditioning Compressor Bracket Installation
Drive Belt Tensioner Installation
Drive Belt Installation
Engine Oil Cooler Installation
Water Outlet Installation — 1.4L LUH and LUJ
Engine Coolant Thermostat Housing Installation — 1.4L LUH and LUJ
Turbocharger Installation
Exhaust Manifold Heat Shield Installation — 1.4L LUH and LUJ
Warm Up Three-Way Catalytic Converter Installation — 1.4L LUH and LUJ
Positive Crankcase Ventilation Pipe Installation
Engine Mount Bracket Installation
Engine Front Cover and Oil Pump Assemble
Drive Belt Removal
Engine Block Cleaning and Inspection
Description and Operation
Engine Component Description
Lubrication Description
Introduction
Cleanliness and Care
Use of Room Temperature Vulcanising (RTV) and Anaerobic Sealant
Special Tools and Equipment
Special Tools
Engine Mechanical - 1.6L LDE LED LFJ LGE LLU LXV or 1.8L 2H0 LFH LUW LWE
Specifications
Fastener Tightening Specifications — 1.6L LDE, LXV, and 1.8L 2H0
Engine Mechanical Specifications — 1.8L 2H0
Engine Mechanical Specifications — 1.6L LDE, LED, LFJ
Adhesives, Fluids, Lubricants, and Sealers
Schematic and Routing Diagrams
Engine Mechanical Schematics
Visual Identification
Disassembled Views
Engine Identification — 1.6L LDE, LED, LFJ, LXV, and 1.8L 2H0
Diagnostic Information and Procedures
Symptoms - Engine Mechanical
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Oil Consumption Diagnosis
Coolant in Combustion Chamber
Coolant in Engine Oil
Engine Noise Under Load
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Will Not Crank - Crankshaft Will Not Rotate
Engine Compression Test
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Cylinder Leakage Test — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Crankcase Ventilation System Inspection/Diagnosis — LDE, LED, LFJ, LXV, 2H0, LUW
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Dual Mass Flywheel Diagnosis
Repair Instructions
Drive Belt Replacement
Drive Belt Tensioner Replacement
Power Steering Pump Belt Replacement
Engine Mount Replacement
Engine/Transmission Mounting
Engine Mount Bracket Replacement
Intake Manifold Replacement — 1.6L LDE and LXV
Timing Belt Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Timing Belt Idler Pulley Replacement
Timing Belt Tensioner Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Timing Belt Centre Front Cover Replacement
Timing Belt Upper Front Cover Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Timing Belt Lower Front Cover Replacement
Timing Belt Rear Cover Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Tappet Replacement
Cylinder Head Replacement — 1.6L LDE, LXV, and 1.8L 2H0,LUW
Oil Pan Replacement
Automatic Transmission Flex Plate Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Engine Flywheel Replacement
Crankshaft Balancer Replacement — LLU, LDE - AT
Crankshaft Balancer Replacement — LXV, LXT, 2H0, LUW - AT
Crankshaft Balancer Replacement — MT - D16, D20
Crankshaft Balancer Replacement — MT - F17, M32
Crankshaft Front Oil Seal Replacement
Crankshaft Rear Oil Seal Replacement
Crankshaft Sprocket Replacement
Positive Crankcase Ventilation Hose/Pipe/Tube Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Engine Front Cover with Oil Pump Replacement
Oil Pressure Relief Valve Replacement
Engine Oil Cooler Housing Replacement
Oil Flow Check Valve Replacement
Oil Level Indicator Tube Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Engine Replacement — Manual Gearbox - D16
Engine Replacement — Automatic Transmission
Engine Oil and Oil Filter Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Camshaft Seal Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Camshaft Cover Replacement — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Camshaft Position Actuator Adjuster Replacement
Camshaft Position Actuator Solenoid Valve Replacement
Camshaft Replacement — 1.6L LDE, LXV, and 1.8L 2H0
Valve Clearance Adjustment — 1.6L LDE, LXV, 1.8L 2H0
Valve Stem Oil Seal and Valve Spring Replacement
Valve Guide Reaming, and Valve and Seat Grinding
Valve Spring Inspection and Measurement
Engine Support Fixture
Timing Belt Inspection — LDE, LED, LFJ, LXV, 2H0, LUW
Timing Belt Adjustment — LDE, LED, LFJ, LXV, 2H0, LUW
Draining Fluids and Oil Filter Removal — 1.6L LDE, LXV, 1.8L 2H0, and LUW
Automatic Transmission Flex Plate Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Engine Flywheel Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Crankshaft Rear Oil Seal Removal
Power Steering Pump Belt Removal
Drive Belt Removal
Drive Belt Tensioner Removal
Timing Belt Upper Front Cover Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Timing Belt Centre Front Cover Removal
Crankshaft Balancer Removal
Timing Belt Lower Front Cover Removal
Timing Belt Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Timing Belt Tensioner Removal
Timing Belt Idler Pulley Removal
Crankshaft Sprocket Removal
Camshaft Position Actuator Solenoid Valve Removal
Camshaft Position Actuator Adjuster Removal
Crankshaft Front Oil Seal Removal
Timing Belt Rear Cover Removal
Throttle Body Assembly Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Intake Manifold Removal — 1.8L 2H0
Oil Level Indicator and Tube Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Exhaust Manifold Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Engine Coolant Thermostat Removal
Engine Coolant Thermostat Housing Removal
Engine Oil Cooler Housing Removal — LDE, LED, LFJ, LXV, 2H0, LUW
Engine Oil Cooler Removal
Water Pump Pulley Removal
Water Pump Removal
Sump Removal
Engine Front Cover and Oil Pump Removal
Ignition Coil Removal
Camshaft Cover Removal
Camshaft Removal
Tappet Removal
Cylinder Head Removal
Piston, Connecting Rod, and Bearing Removal
Crankshaft and Bearing Removal
Intake Manifold Disassemble — 1.6L LDE, LED, LFJ, and LXV
Intake Manifold Disassemble — 1.8L 2H0
Cylinder Head Disassemble
Piston and Connecting Rod Disassemble — LDE, LED, LFJ, LXV, 2H0, LUW
Engine Block Disassemble — LDE, LED, LFJ, LXV, 2H0, LUW
Intake Manifold Cleaning and Inspection — LDE, LED, LFJ, LXV, 2H0, LUW
Exhaust Manifold Cleaning and Inspection — LDE, LED, LFJ, LXV, 2H0, LUW
Sump Cleaning and Inspection
Oil Pump Cleaning and Inspection
Cylinder Head Cleaning and Inspection
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Crankshaft and Bearing Cleaning and Inspection — LDE, LED, LFJ, LXV, 2H0, LUW
Engine Block Cleaning and Inspection
Service Prior to Assembly
Engine Block Assemble — LDE, LED, LFJ, LXV, 2H0, LUW
Piston and Connecting Rod Assemble
Cylinder Head Assemble
Intake Manifold Assemble — 1.8L 2H0
Intake Manifold Assemble — 1.6L LDE, LED, LFJ, and LXV
Crankshaft and Bearing Installation
Piston, Connecting Rod, and Bearing Installation
Cylinder Head Installation
Tappet Installation
Camshaft Installation
Camshaft Cover Installation
Ignition Coil Installation
Engine Front Cover and Oil Pump Installation
Sump Installation
Water Pump Installation
Water Pump Pulley Installation
Engine Oil Cooler Installation
Engine Oil Cooler Housing Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Engine Coolant Thermostat Housing Installation
Engine Coolant Thermostat Installation
Exhaust Manifold Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Oil Level Indicator and Tube Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Intake Manifold Installation — 1.8L 2H0
Throttle Body Assembly Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Crankshaft Front Oil Seal Installation
Timing Belt Rear Cover Installation
Camshaft Position Actuator Adjuster Installation
Camshaft Position Actuator Solenoid Valve Installation
Crankshaft Sprocket Installation
Timing Belt Idler Pulley Installation
Timing Belt Tensioner Installation
Timing Belt Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Timing Belt Lower Front Cover Installation
Crankshaft Balancer Installation
Timing Belt Centre Front Cover Installation
Timing Belt Upper Front Cover Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Drive Belt Installation
Drive Belt Tensioner Installation
Power Steering Pump Belt Installation
Engine Flywheel Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Automatic Transmission Flex Plate Installation — LDE, LED, LFJ, LXV, 2H0, LUW
Crankshaft Rear Oil Seal Installation
Introduction
Cleanliness and Care
Replacing Engine Gaskets
Separating Parts
Tools and Equipment
Use of Room Temperature Vulcanising (RTV) and Anaerobic Sealant
Description and Operation
Engine Component Description — LDE, LED, LFJ, LXV, 2H0, LUW
Lubrication Description — LDE, LED, LFJ, LXV, 2H0, LUW
Special Tools and Equipment
Special Tools
Engine Mechanical - 1.6L L2W or LXT
Specifications
Fastener Tightening Specifications
Engine Mechanical Specifications
Adhesives, Fluids, Lubricants, and Sealers
Visual Identification
Disassembled Views
Engine Identification
Diagnostic Information and Procedures
Symptoms - Engine Mechanical
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Oil Consumption Diagnosis
Coolant in Engine Oil
Coolant in Combustion Chamber
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Will Not Crank - Crankshaft Will Not Rotate
Engine Noise Under Load
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Base Engine Misfire with Abnormal Valve Train Noise
Engine Compression Test
Crankcase Ventilation System Inspection/Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Cylinder Leakage Test
Dual Mass Flywheel Diagnosis
Repair Instructions
Engine Support Fixture
Alternator, Air Conditioning Compressor, and Power Steering Pump Belt Replacement
Drive Belt Tensioner Replacement
Engine Mount Replacement - Right Side
Engine Mount Bracket Replacement - Right Side
Positive Crankcase Ventilation Valve Hose Replacement
Inlet Manifold Replacement
Timing Belt Replacement
Timing Belt Tensioner Replacement
Timing Belt Idler Pulley Replacement
Timing Belt Upper Front Cover Replacement
Timing Belt Lower Front Cover Replacement
Timing Belt Rear Cover Replacement
Camshaft Cover Replacement
Camshaft Seal Replacement
Hydraulic Valve clearance Adjuster Replacement
Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement
Cylinder Head Replacement
Oil Pan Replacement
Oil Pump Cover Replacement
Oil Pressure Relief Valve Replacement
Engine Replacement - Manual Gearbox D16
Engine Replacement — Automatic Transmission
Engine Oil and Oil Filter Replacement
Piston, Connecting Rod, and Bearing Replacement
Camshaft Replacement
Camshaft Gear Replacement
Crankshaft Pulley Replacement
Engine Flywheel Replacement
Crankshaft Front Oil Seal Replacement
Crankshaft Rear Oil Seal Replacement
Engine Sight Shield Replacement
Engine/Transmission Mounting
Automatic Transmission Flex Plate Replacement
Timing Belt Inspection - Inspection
Timing Belt Inspection - Adjustment
Draining Fluids and Oil Filter Removal
Alternator, Air Conditioning Compressor, and Power Steering Pump Belt Removal
Drive Belt Tensioner Removal
Crankshaft Pulley Removal
Automatic Transmission Flex Plate Removal
Engine Flywheel Removal
Oil Pump Cleaning and Inspection
Exhaust Manifold Removal
Exhaust Gas Recirculation Pipe Removal
Exhaust Gas Recirculation Valve Removal
Exhaust Gas Recirculation Valve Adapter Removal
Crankshaft Position Sensor Removal
Engine Coolant Thermostat Removal
Ignition Coil Removal
Ignition Coil Bracket Removal
Generator Removal
Generator Adjust Bracket Removal
Throttle Body Assembly Removal
Fuel Rail Removal
Inlet Manifold Brace Removal
Inlet Manifold Removal
Power Steering Pump Removal
Air Conditioning Compressor and Power Steering Pump Bracket Removal
Timing Belt Upper Front Cover Removal
Timing Belt Lower Front Cover Removal
Timing Belt Removal
Timing Belt Tensioner Removal
Timing Belt Idler Pulley Removal
Exhaust Camshaft Gear Removal
Inlet Camshaft Gear Removal
Camshaft Position Sensor Removal
Engine Mount Bracket Removal
Timing Belt Rear Cover Removal
Water Pump Removal
Crankshaft Gear Removal
Sump Removal
Oil Pump Cover Removal
Crankshaft Front Oil Seal Removal
Crankshaft Rear Oil Seal Removal
Camshaft Cover Removal
Camshaft Removal
Hydraulic Valve clearance Adjuster Removal
Cylinder Head Removal
Piston, Connecting Rod, and Bearing Removal
Engine Block Disassemble
Engine Block Cleaning and Inspection
Engine Block Assemble
Crankshaft and Bearing Cleaning and Inspection
Piston and Connecting Rod Disassemble
Piston, Connecting Rod, and Bearing Cleaning and Inspection
Piston and Connecting Rod Assemble
Cylinder Head Disassemble
Cylinder Head Cleaning and Inspection
Valve Spring Inspection and Measurement
Cylinder Head Assemble
Sump Cleaning and Inspection
Intake Manifold Disassemble
Inlet Manifold Cleaning and Inspection
Intake Manifold Assemble
Exhaust Manifold Cleaning and Inspection
Service Prior to Assembly
Crankshaft and Bearing Installation
Piston, Connecting Rod, and Bearing Installation
Cylinder Head Installation
Hydraulic Valve clearance Adjuster Installation
Camshaft Installation
Camshaft Cover Installation
Crankshaft Rear Oil Seal Installation
Crankshaft Front Oil Seal Installation
Oil Pump Cover Installation
Sump Installation
Crankshaft Gear Installation
Camshaft Position Sensor Installation
Inlet Camshaft Gear Installation
Exhaust Camshaft Gear Installation
Water Pump Installation
Timing Belt Rear Cover Installation
Engine Mount Bracket Installation
Timing Belt Idler Pulley Installation
Timing Belt Tensioner Installation
Timing Belt Installation
Timing Belt Lower Front Cover Installation
Timing Belt Upper Front Cover Installation
Air Conditioning Compressor and Power Steering Pump Bracket Installation
Power Steering Pump Installation
Inlet Manifold Installation
Inlet Manifold Brace Installation
Fuel Rail Installation
Throttle Body Assembly Installation
Generator Adjust Bracket Installation
Generator Installation
Ignition Coil Bracket Installation
Ignition Coil Installation
Engine Coolant Thermostat Installation
Crankshaft Position Sensor Installation
Exhaust Gas Recirculation Pipe Installation
Exhaust Gas Recirculation Valve Installation
Exhaust Gas Recirculation Valve Adapter Installation
Exhaust Manifold Installation
Engine Flywheel Installation
Automatic Transmission Flex Plate Installation
Crankshaft Pulley Installation
Drive Belt Tensioner Installation
Alternator, Air Conditioning Compressor, and Power Steering Pump Belt Installation
Oil Filter Installation
Replacing Engine Gaskets
Tools and Equipment
Description and Operation
Engine Component Description
Crankcase Ventilation System Description
Lubrication Description
Separating Parts
Use of Room Temperature Vulcanising (RTV) and Anaerobic Sealant
Introduction
Cleanliness and Care
Special Tools and Equipment
Special Tools — 1.6L LXT
Engine Mechanical - 1.7L Diesel
Specifications
Fastener Tightening Specifications — 1.7L Diesel LUD, LUE
Engine Mechanical Specifications — 1.7L Diesel LUD, LUE
Adhesives, Fluids, Lubricants, and Sealers
Schematic and Routing Diagrams
Engine Mechanical Schematics
Visual Identification
Disassembled Views
Engine Identification
Diagnostic Information and Procedures
Symptoms - Engine Mechanical
Base Engine Misfire without Internal Engine Noises
Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Turbocharger Whine Noise
Turbocharger Hissing Noise
Turbocharger Oil Leak From Compressor Seal
Turbocharger Oil Leak From Turbine Seal
Turbocharger Lack of Oil Supply
Engine Compression Test
Oil Consumption Diagnosis
Crankcase Ventilation System Inspection/Diagnosis
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Drive Belt Chirping, Squeal, and Whine Diagnosis
Drive Belt Rumbling and Vibration Diagnosis
Drive Belt Falls Off and Excessive Wear Diagnosis
Repair Instructions
Timing Belt Inspection
Timing Belt Adjustment
Draining Fluids and Oil Filter Removal
Charge Air Cooler Inlet Pipe Removal
Oil Level Indicator and Tube Removal — 1.7L Diesel LUD, LUE
Belt Idler Pulley Removal
Exhaust Manifold Heat Shield Removal - Right Side
Exhaust Gas Recirculation Valve Cooler Removal — 1.7L Diesel LUD, LUE
Exhaust Manifold Heat Shield Removal - Left Side
Catalytic Converter Heat Shield Removal — 1.7L Diesel LUD, LUE
Catalytic Converter Removal — 1.7L Diesel LUD, LUE
Exhaust Manifold Removal — 1.7L Diesel LUD, LUE
Thermostat Bypass Pipe Removal
Water Inlet Removal
Fuel Injection Fuel Return Hose Removal — 1.7L Diesel LUD, LUE