MG TFWORKSHOPMANUALThis manual should be used in conjunction with thefollowing overhaul manuals.RCL 0057 'K' Series EngineRCL 0124 'PG1' Manual GearboxPublication Part No. RCL0493ENG - 1st EditionPublished by MG Rover Group After SalesMG Rover Group Limited 2002NTRODUCTONGENERAL NFORMATONNFORMATONMANTENANCEENGNEEMSSON CONTROLENGNE MANAGEMENT SYSTEM- MEMS 3FUEL DELVERY SYSTEMCOOLNG SYSTEMMANFOLD & EXHAUST SYSTEMSCLUTCHMANUAL GEARBOXAUTOMATC GEARBOX - Em-CVTDRVE SHAFTSSTEERNGSUSPENSONBRAKESRESTRANT SYSTEMSBODYHEATNG & VENTLATONAR CONDTONNGWPERS & WASHERSELECTRCALNSTRUMENTSwww.easyfixed.comwww.easyfixed.comINTRODUCTIONCONTENTS PageINTRODUCTIONNTRODUCTON 1 ......................................................................................................REPARS AND REPLACEMENTS 2 ...........................................................................SPECFCATON 2 ......................................................................................................ABBREVATONS AND SYMBOLS 3 ..........................................................................www.easyfixed.comwww.easyfixed.comINTRODUCTIONINTRODUCTION 1INTRODUCTIONHow to use this ManuaITo assist in the use of this Manual the section title isgiven at the top and the relevant sub-section is givenat the bottom each page.Each major section starts with a contents page,listing the information contained in the relevantsub-sections. To assist filing of revised informationeach sub-section is numbered from page 1.The individual items comprising repair operationsare to be followed in the sequence in which theyappear. tem numbers in illustrations are referred toin the text.Adjustment and repair operations include referenceto Service tool numbers and the associatedillustration depicts the tool. Where usage is notobvious the tool is shown in use. Adjustment andrepair operations also include reference to wearlimits, relevant data, torque figures, and specialistinformation and useful assembly details. Eachadjustment or repair operation is given a RepairOperation Time number.WARNNGS, CAUTONS and NOTES have thefollowing meanings:WARNING: Procedures which must befoIIowed preciseIy to avoid the possibiIityof injury.CAUTION: CaIIs attention to procedureswhich must be foIIowed to avoid damageto components.NOTE: Gives heIpfuI information.ReferencesReferences to the LH or RH side given in thisManual are made when viewing the vehicle from therear. With the engine and gearbox assemblyremoved, the crankshaft pulley end of the engine isreferred to as the front.Operations covered in this Manual do not includereference to testing the vehicle after repair. t isessential that work is inspected and tested aftercompletion and if necessary a road test of thevehicle is carried out particularly where safetyrelated items are concerned.DimensionsThe dimensions quoted are to design engineeringspecification with Service limits where applicable.www.easyfixed.comINTRODUCTION2 INTRODUCTIONREPAIRS AND REPLACEMENTSWhen replacement parts are required it is essentialthat only MG Rover recommended parts are used.Attention is particularly drawn to the following pointsconcerning repairs and the fitting of replacementparts and accessories.Safety features and corrosion prevention treatmentsembodied in the car may be impaired if other thanMG Rover recommended parts are fitted. n certainterritories, legislation prohibits the fitting of parts notto the manufacturer's specification. Torque wrenchsetting figures given in this Manual must be used.Locking devices, where specified, must be fitted. fthe efficiency of a locking device is impaired duringremoval it must be renewed.Owners purchasing accessories while travellingabroad should ensure that the accessory and itsfitted location on the car conform to legalrequirements.The Terms of the vehicle Warranty may beinvalidated by the fitting of other than MG Roverrecommended parts.All MG Rover recommended parts have the fullbacking of the vehicle Warranty.MG Rover Dealers are obliged to supply only MGRover recommended parts.SPECIFICATIONMG Rover are constantly seeking to improve thespecification, design and production of their vehiclesand alterations take place accordingly. While everyeffort has been made to ensure the accuracy of thisManual, it should not be regarded as an infallibleguide to current specifications of any particularvehicle.This Manual does not constitute an offer for sale ofany particular vehicle. MG Rover Dealers are notagents of MG Rover and have no authority to bindthe manufacturer by any expressed or impliedundertaking or representation.www.easyfixed.comINTRODUCTIONINTRODUCTION 3ABBREVIATIONS AND SYMBOLSAfter Bottom Dead Centre ABDCAfter Top Dead Centre ATDCAir Conditioning A/CAir Fuel Ratio AFRAlternating Current acAmbient Air Temperature AATAmperes AAnti-Lock Brake System ABSBefore Bottom Dead Centre BBDCBefore Top Dead Centre BTDCBottom Dead Centre BDCBrake proportioning valve BPVBritish Standards BSCamshaft Position CMPCarbon Dioxide CO2Carbon Monoxide COCelsius (Centigrade) CCentimetre cmChlorofluorocarbons CFC'sCrankshaft Position CKPCubic Centimetres cm3Degree (angle) deg. orDegree (temperature) deg. orDiagnostic Control Unit DCUDial Test ndicator DTDiameter dia.Direct Current dcDouble Overhead Camshaft DOHCEngine Coolant Temperature ECTElectric Power Assisted Steering EPASElectrically EraseableProgrammable Read Only Memory EEPROMElectronic Control Unit ECUElectronic Air Control Valve EACVElectro Mechanical - ContinuouslyVariable Transmission Em-CVTElectromotive force e.m.f.Engine Control Module ECMExhaust Gas Recirculation EGREvaporative Emission EVAPField Effect Transistor FETGramme (mass) gGearbox nterface Unit GUHeated Oxygen Sensor HO2SHertz HzHigh Compression hcHigh Tension (electrical) h.t.Hour hHydraulic Control Unit HCUHydrocarbons HCHydrofluorocarbon HFCnches indle Air Control ACnstant Mobility System MSnertia Fuel Shutoff FSntake Air Temperature ATnternal Diameter i.dia.nternational Organisationfor Standardization SOKilogramme kgKilometre kmKilometres per hour km/hKiloOhms kKiloWatts kWLeft-Hand LHLeft-Hand Drive LHDLight Emitting Diode LEDLiquid Crystal Display LCDLitre lLow Compression lcLow tension ltMalfunction ndicator Lamp MLManifold Absolute Pressure MAPMaximum maxMegaWatts MWMercury HgMetre mMiles Per Hour mphMilliamp mAMillimetre mmMinimum minMinus (of tolerance) -Minute (angle) 'Modular Engine ManagementSystem MEMSModel Year MYMulti-Function Unit MFUMulti-Point njection MPiwww.easyfixed.comINTRODUCTION4 INTRODUCTIONNegative (electrical) -Negative Temperature Coefficient NTCNewton Metre NmNitrous Oxide NOxNumber No.On Board Diagnostics OBDOhmsOrganic Acid Technology OATOutside Diameter o.dia.Percentage %Plus or MinusPlus (tolerance) +Positive (electrical) +Positive Crankcase Ventilation PCVPositive Temperature Coefficient PTCPounds Per Square nch lbf/in2Pounds Per Square nch psiPounds (mass) lbPulse Width Modulation PWMRadius rRatio :Reference refRevolutions Per Minute rev/min or rpmRight-Hand RHRight-Hand Drive RHDRover Engineering Standards RESSecond (angle) "Single Overhead Camshaft SOHCSpecific Gravity sp.grSquare Centimetres cm2Square inches in2Standard std.Supplementary Restraint System SRSSynchronizer/Synchromesh synchroThousand kThrottle Position TPTop Dead Centre TDCUnited Kingdom UKUnited States USVariable Valve Control VVCVehicle dentification Number VNVolt VWater H2OWatt Wwww.easyfixed.comGENERAL INFORMATIONCONTENTS PageVEHICLE IDENTIFICATION NUMBERVEHCLE DENTFCATON NUMBER 1 ....................................................................DENTFCATON NUMBER LOCATONS 2 ...............................................................GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSDANGEROUS SUBSTANCES 1 .................................................................................Health Protection Precautions 1 ...............................................................................ENVRONMENTAL PRECAUTONS 2 ........................................................................PRECAUTONS AGANST DAMAGE 5 .......................................................................SAFETY NSTRUCTONS 6 ........................................................................................Jacking 6 ...................................................................................................................Brake shoes and pads 6 ...........................................................................................Brake hydraulics 6 ....................................................................................................Cooling system caps and plugs 6 .............................................................................GENERAL FTTNG NSTRUCTONS 7 ......................................................................FLEXBLE PPES AND HOSES 14 .............................................................................SERVCE TOOLS 16 ...................................................................................................TestBook 16 ..............................................................................................................Body repairs 16 .........................................................................................................Replacement body panels 16 ...................................................................................DYNAMOMETER TESTNG 17 ...................................................................................FUEL HANDLING PRECAUTIONSFUEL HANDLNG PRECAUTONS 1 ..........................................................................ELECTRICAL PRECAUTIONSELECTRCAL PRECAUTONS 1 .................................................................................SRS PRECAUTIONSSUPPLEMENTARY RESTRANT SYSTEM PRECAUTONS 1 ..................................NSTALLATON 2 ........................................................................................................WARNNG LABELS 6 ..................................................................................................VEHCLE RECOVERY 8 .............................................................................................SRS COMPONENT DEPLOYMENT 8 ........................................................................SRS COMPONENT REPLACEMENT POLCY 9 ........................................................AIR CONDITIONING PRECAUTIONSAR CONDTONNG SYSTEM PRECAUTONS 1 ......................................................AR CONDTONNG COMPRESSOR REPLACEMENT 3 ..........................................www.easyfixed.comwww.easyfixed.comGENERAL INFORMATIONVEHICLE IDENTIFICATION NUMBER 1VEHICLE IDENTIFICATION NUMBERLocationThe Vehicle dentification Number (VN) is providedat the following locations:Stamped on a plate attached to the RH side of theunder bonnet compartment and stamped into thebody above the RH front suspension strut.Behind the LH lower corner of the windscreen.VIN pIate detaiIsThe VN plate contains the following information:1. Vehicle dentification Number (VN)2. Gross Vehicle Weight (GVW)3. Gross train weight (GTW)4. Maximum front axle load5. Maximum rear axle load6. Paint code7. Trim codeVIN code keyExample: S A R R D L B K J 2 D 000001SAR = World dentifier : MG Rover Group (UK)RD = Model: MG TFL = Trim Level: 7.1B = Body Style (2 door convertible)K = Engine: K1.8 MPi, 100 kWJ = Steering and transmission: RHD CVT2 = Model Year: 2002D = Assembly Plant: Longbridge6 figures = Serial number: 000001www.easyfixed.comGENERAL INFORMATION2 VEHICLE IDENTIFICATION NUMBERPaint and Trim coIour codes3-letter codes identifying the original Paint and Trimcolours are stamped on the VN platePaintK M NK = Basic colourM = Mark identifierN = Colour/Shade nameTrimL Q PL = Basic colourQ = Mark identifierP = Colour/Shade nameIDENTIFICATION NUMBER LOCATIONSEngine numberK Series Engine: Stamped on the front face of thecylinder block adjacent to the gearbox.Gearbox numberManual Gearbox: Stamped on a label attached tothe front face of the clutch housing.www.easyfixed.comGENERAL INFORMATIONVEHICLE IDENTIFICATION NUMBER 3Automatic Gearbox (Em-CVT): Stamped on a labelattached by the gearbox to engine mounting bolt.Body numberThe body number is stamped on the bulkhead at theback of the boot.www.easyfixed.comwww.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1DANGEROUS SUBSTANCESModern vehicles contain many materials and liquidswhich if not handled with care can be hazardous toboth personal health and the environment.WARNING: Many Iiquids and othersubstances used in motor vehicIes arepoisonous and shouId not be consumedunder any circumstances. As far as possibIe,ensure such substances are prevented fromcontact with the skin. These Iiquids andsubstances incIude but are not Iimited to: acid,anti-freeze, asbestos, brake fIuid, fueI,windscreen washer additives, Iubricants,refrigerant and various adhesives.WARNING: AIways read the instructionsprinted on IabeIs or stamped oncomponents and obey them impIicitIy.Such instructions are incIuded for reasons ofyour heaIth and personaI safety. Never disregardthem.Synthetic rubberMany 'O' rings, seals, hoses, flexible pipes and othersimilar items which appear to be natural rubber, arein fact made of synthetic materials calledFluoroelastomers. Under normal operatingconditions this material is safe and does not presenta health hazard. However, if the material isdamaged by fire or excessive heating, it can breakdown and produce highly corrosive Hydrofluoricacid.Contact with Hydrofluoric acid can cause seriousburns on contact with skin. f skin contact doesoccur: Remove any contaminated clothing immediately. rrigate affected area of skin with a copiousamount of cold water or limewater for 15 to 60minutes. Obtain medical assistance immediately.Should any material be in a burnt or overheatedcondition, handle with extreme caution and wearprotective clothing (seamless industrial gloves,protective apron etc.).Decontaminate and dispose of gloves immediatelyafter use.Lubricating oiIsAvoid excessive skin contact with used lubricatingoils and always adhere to the health protectionprecautions.WARNING: Avoid excessive skin contactwith used engine oiI. Used engine oiIcontains potentiaIIy harmfuI contaminantswhich may cause skin cancer or other seriousskin disorders.WARNING: Avoid excessive skin contactwith mineraI oiI. MineraI oiIs remove thenaturaI fats from the skin, Ieading todryness, irritation and dermatitis.HeaIth Protection Precautions Avoid prolonged and repeated contact with oils,particularly used engine oils. Wear protective clothing, including imperviousgloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes (particularly thosenext to the skin) with oil. Overalls must be cleaned regularly. Discardheavily soiled clothing and oil impregnatedfootwear. First aid treatment should be obtainedimmediately for open cuts and wounds. Apply barrier creams before each work period, tohelp prevent lubricating oil from contaminatingthe skin. Wash with soap and water to ensure all oil isremoved (skin cleansers and nail brushes willhelp). Use moisturisers after cleaning; preparationscontaining lanolin help replace the skin's naturaloils which have been removed. Do not use petrol/gasoline, kerosene, diesel fuel,oil, thinners or solvents for cleaning skin. f skin disorders develop, obtain medical advicewithout delay. Where practicable, degrease components priorto handling. Wear eye protection (e.g. goggles or face shield)if there is a risk of eye contamination. Eye washfacilities should be provided in close vicinity ofthe work area.www.easyfixed.comGENERAL INFORMATION2 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSENVIRONMENTAL PRECAUTIONSGeneraIThis section provides general information which ifobserved, can help reduce environmental damagecaused by activities carried out in workshops.Emissions to airMany of the activities that are carried out inworkshops emit gases and fumes which contributeto global warming, depletion of the ozone layerand/or the formation of photochemical smog atground level. By considering how the workshopactivities are carried out, these gases and fumes canbe minimised, thus reducing the impact on theenvironment.Exhaust fumesRunning car engines is an essential part ofworkshop activities and exhaust fumes need to beventilated to atmosphere. However, the amount oftime engines are running and the position of thevehicle should be carefully considered at all times, toreduce the release of poisonous gases and minimisethe inconvenience to people living nearby.SoIventsSome of the cleaning agents used are solvent basedand will evaporate to atmosphere if used carelessly,or if cans are left unsealed. All solvent containersshould be firmly closed when not being used andsolvent should be used sparingly. Suitablealternative methods may be available to replacesome of the commonly used solvents. Similarly,many paints are solvent based and the spray shouldbe minimised to reduce solvent emissions.Refrigerantt is illegal to release any refrigerants into theatmosphere. Discharge and replacement of thesematerials from air conditioning units should only becarried out using the correct equipment.CheckIistAlways adhere to the following:Engines: Don't leave engines running unnecessarily. Minimise testing times and check where theexhaust fumes are being blown.Materials: Keep lids on containers of solvents. Only use the minimum quantity. Consider alternative materials. Minimise over-spray when painting.Gases: Use the correct equipment for collectingrefrigerants. Don't burn rubbish on site.Discharges to waterMost sites will have two systems for dischargingwater: storm drains and foul drains. Storm drainsshould only receive clean water, foul drains will takedirty water.The foul drain will accept many of the normal wastewaters such as washing water, detergents anddomestic type wastes but oil, petrol, solvent, acids,hydraulic oil, antifreeze and other such substancesshould never be poured down the drain. f in anydoubt, consult the Water Authority responsible foryour locality first.Every precaution must be taken to prevent spillageof oil, fuel, solvents etc. reaching the drains. Allhandling of such materials must take place wellaway from the drains and preferably in an area witha kerb or wall around it, to prevent discharge into thedrain. f a spillage occurs, it should be soaked upimmediately. Having a spill kit available will makethis easier.AdditionaI precautionsCheck whether the surface water drains areconnected to an oil/water separator, this couldreduce the pollution if an incident was to occur.Oil/water separators do need regular maintenance toensure effectiveness.CheckIistAlways adhere to the following:Disposal: Never pour anything down a drain without firstchecking that it is environmentally safe to do so,and that it does not contravene any localregulations or bye-laws. Have oil traps emptied regularly.Spillage prevention: Store liquids in a walled area. Make sure that taps on liquid containers aresecure and cannot be accidently turned on. Protect bulk storage tanks from vandalism bylocking the valves. Transfer liquids from one container to another inan area away from open drains. Ensure lids are replaced securely on containers. Have spill kits available near to points of storageand handling of liquids.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 3SpiII kitsSpecial materials are available to absorb a numberof different substances. They can be in granularform, ready to use and bought in convenientcontainers for storage. Disposal of usedspill-absorbing material is dealt with in the 'WasteManagement' section.Land contaminationOil, fuels and solvents etc. can contaminate any soilthat they are allowed to contact. Such materialsshould never be disposed of by pouring onto soiland every precaution must be taken to preventspillage reaching soil. Waste materials stored onopen ground could also leak, or have pollutingsubstances washed off them that would contaminatethe land. Always store these materials in suitableskips or other similarly robust containers.CheckIistAlways adhere to the following: Don't pour or spill anything onto the soil or bareground. Don't store waste materials on bare ground, see'Spillage prevention' list in 'AdditionaIPrecautions CheckIist'.LegaI compIianceSome sites may have a discharge consent foreffluent discharge to the foul drain for a car washetc. t is important to know what materials areallowed in the drain and to check the results of anymonitoring carried out by the local Water authority.Where paint-spraying operations are carried out, itmay be necessary to apply to the Local Authority foran air emissions licence to operate the plant. f sucha licence is in operation, additional precautions willbe necessary to comply with the requirements, andthe results of any air quality monitoring must bechecked regularly.CheckIistAlways adhere to the following: Know what legal consents and licences apply tothe operations. Check that the emissions and discharges complywith legal requirements.LocaI issuesA number of environmental issues will be ofparticular concern to residents and other neighboursclose to the site. The sensitivity of these issues willdepend on the proximity of the site and the layoutand amount of activity conducted at the site.Noise is a major concern and thereforeconsideration should be given to the time spentcarrying out noisy activities and the location of thoseactivities that can cause excessive noise.Car alarm testing, panel beating, hammering andother such noisy activities should, wheneverpossible, be carried out indoors with doors andwindows shut, or as far away as possible from localresidents and others who may be affected by thedisturbance.Running vehicle engines may be an outside activitywhich could cause nuisance to neighbours becauseof noise and smell.Be sensitive with regards the time of day when theseactivities are performed, and minimise the time ofthe noisy operation, particularly in the early morningand late evening.Another local concern will be the smell from thevarious materials used. Using less solvent, paint andpetrol could help prevent this annoyance.Local residents and other business users will also beconcerned about traffic congestion, noise andexhaust fumes, be sensitive to these concerns andtry to minimise inconvenience caused by deliveries,customers and servicing operations.CheckIistAlways adhere to the following: dentify where the neighbours who are likely tobe affected are situated. Minimise noise, smell and traffic nuisance. Prevent litter by putting waste in the correctcontainers. Have waste skips emptied regularly.www.easyfixed.comGENERAL INFORMATION4 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSUse of resourceAnother environmental concern is the waste ofmaterials and energy that can occur in day to dayactivities.Electricity for heating, lighting and compressed airuses resources and releases pollution during itsgeneration.Fuel used for heating, running cars or vans andmobile plant is another limited resource whichconsumes large amounts of energy during itsextraction and refining processes.Water has to be cleaned, piped to site and disposedof; all of which creates more potential pollution.Oil, spares, paint etc., have all produced pollution inthe process of manufacture and they become awaste disposal problem if discarded.CheckIistAlways adhere to the following:Electricity and heating: Keep doors and windows closed in the Winter. Switch off machinery or lights when not needed. Use energy efficient heating systems. Switch off computers and photocopiers when notneeded.Fuel: Don't run engines unnecessarily Think about whether journeys are necessary anddrive to conserve fuel.Water: Don't leave taps and hose pipes running. Mend leaks quickly, don't be wasteful.Compressed air: Don't leave valves open. Mend leaks quickly. Don't leave the compressor running when notneeded.Use of environmentally damaging materials: Check whether a less toxic material is available.Handling and storage of materials: Have the correct facilities available for handlingliquids to prevent spillage and wastage as listedabove. Provide suitable locations for storage to preventfrost damage or other deterioration.Burning used engine oiIBurning of used engine oil in small space heaters orboilers can be recommended only for units ofapproved design. The heating system must meet theregulatory standards for small burners(s) with a netrated thermal input of less than 3MW. The use ofwaste oil burners must be licensed by the localauthority.Waste ManagementOne of the major ways that pollution can be reducedis by the careful handling, storage and disposal of allwaste materials that occur on sites. Legislationmakes it illegal to dispose of waste materials otherthan to licensed waste carriers and disposal sites.This means that it is necessary to not only knowwhat the waste materials are, but also to have thenecessary documentation and licenses.HandIing and storage of wasteEnsure that waste materials are not poured downthe drain or onto soils. They should be stored insuch a way as to prevent the escape of the materialto land, water or air.They must also be segregated into different types ofwaste e.g. oil, metals, batteries, used vehiclecomponents. This will prevent any reaction betweendifferent materials and assist in disposal.DisposaI of wasteDisposal of waste materials must only be to wastecarriers who are licensed to carry those particularwaste materials and all the necessarydocumentation must be completed. The wastecarrier is responsible for ensuring that the waste istaken to the correct disposal sites.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 5Dispose of waste in accordance with the followingguidelines: FueI, hydrauIic fIuid, anti-freeze and oiI: keepseparate and dispose of to specialist contractor. Refrigerant: collect in specialist equipment andreuse. Detergents: safe to pour down the foul drain ifdiluted. Paint, thinners: keep separate and dispose of tospecialist contractor. Components: send back to supplier forrefurbishment, or disassemble and reuse anysuitable parts. Dispose of the remainder inordinary waste. SmaII parts: reuse any suitable parts, dispose ofthe remainder in ordinary waste. MetaIs: can be sold if kept separate from generalwaste. Tyres: keep separate and dispose of tospecialist contractor. Packaging: compact as much as possible anddispose of in ordinary waste. Asbestos-containing: keep separate anddispose of to specialist contractor. OiIy and fueI wastes (e.g. rags, used spiII kitmateriaI): keep separate and dispose of tospecialist contractor. Air fiIters: keep separate and dispose of tospecialist contractor. Rubber/pIastics: dispose of in ordinary waste. Hoses: dispose of in ordinary waste. Batteries: keep separate and dispose of tospecialist contractor. Airbags - expIosives: keep separate anddispose of to specialist contractor. EIectricaI components: send back to supplierfor refurbishment, or disassemble and reuse anysuitable parts. Dispose of the remainder inordinary waste. EIectronic components: send back to supplierfor refurbishment, or disassemble and reuse anysuitable parts. Dispose of the remainder inordinary waste. CataIysts: can be sold if kept separate fromgeneral waste. Used spiII-absorbing materiaI: keep separateand dispose of to specialist contractor. Office waste: recycle paper and toner and inkcartridges, dispose of the remainder in ordinarywaste.PRECAUTIONS AGAINST DAMAGEAlways fit wing and seat covers before commencingwork.Avoid spilling brake fluid or battery acid onpaintwork. Wash off with water immediately if thisoccurs.Disconnect the battery earth lead before startingwork, see ELECTRICAL PRECAUTIONS.Always use the recommended service tool or asatisfactory equivalent where specified.Protect exposed bearing and sealing surfaces andscrew threads from damage.www.easyfixed.comGENERAL INFORMATION6 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSSAFETY INSTRUCTIONSJackingThe recommended jacking points are given inLIFTING AND TOWING.Always ensure that any lifting apparatus hasadequate load and safety capacity for the weight tobe lifted.Ensure the vehicle is standing on level ground priorto lifting or jacking.Apply the handbrake and chock the wheels.Never rely on a jack as the sole means of supportwhen working beneath the vehicle. Use additionalsafety supports beneath the vehicle.Do not leave tools, lifting equipment, spilt oil, etc.around or on the work bench area.Brake shoes and padsWARNING: AIways fit the correct gradeand specification of brake Iinings andrenew brake pads and brake shoes in axIesets onIy.Brake hydrauIicsObserve the following recommendations whenworking on the brake system: Always use two spanners when loosening ortightening brake pipe or hose connections. Ensure that hoses run in a natural curve and arenot kinked or twisted. Fit brake pipes securely in their retaining clipsand ensure that the pipe cannot contact apotential chafing point. Containers used for hydraulic fluid must be keptabsolutely clean. Do not store hydraulic brake fluid in an unsealedcontainer, it will absorb water and in thiscondition would be dangerous to use due to alowering of its boiling point. Do not allow hydraulic brake fluid to becontaminated with mineral oil, or put new brakefluid in a container which has previouslycontained mineral oil. Do not re-use brake fluid removed from thesystem. Always use clean brake fluid or a recommendedalternative to clean hydraulic components. After disconnection of brake pipes and hoses,immediately fit suitable blanking caps or plugs toprevent the ingress of dirt. Only use the correct brake fittings withcompatible threads. Absolute cleanliness must be observed whenworking with hydraulic components.WARNING: It is imperative that the correctbrake fittings are used and that threads ofcomponents are compatibIe.CooIing system caps and pIugsExtreme care is necessary when removing enginecoolant caps and plugs when the engine is hot andespecially if it is overheated. To avoid the possibilityof scalding allow the engine to cool beforeattempting coolant cap or plug removal.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 7GENERAL FITTING INSTRUCTIONSComponent removaIWhenever possible, clean components andsurrounding area before removal. Blank off openings exposed by componentremoval. mmediately seal fuel, oil or hydraulic lines whenapertures are exposed; use plastic caps or plugsto prevent loss of fluid and ingress of dirt. Close the open ends of oilways exposed bycomponent removal with tapered hardwood plugsor conspicuous plastic plugs. mmediately a component is removed, place it ina suitable container; use a separate container foreach component and its associated parts. Clean bench and provide marking materials,labels and containers before dismantling acomponent.DismantIingObserve scrupulous cleanliness when dismantlingcomponents, particularly when brake, fuel orhydraulic system parts are being worked on. Aparticle of dirt or a cloth fragment could cause aserious malfunction if trapped in these systems. Blow out all tapped holes, crevices, oilways andfluid passages with an air line. Ensure that any'O' rings used for sealing are correctly replacedor renewed, if disturbed during the process. Use marking ink to identify mating parts andensure correct reassembly. Do not use a centrepunch or scriber to mark parts, they could initiatecracks or distortion in marked components. Wire together mating parts where necessary toprevent accidental interchange (e.g. rollerbearing components). Wire labels on to all parts which are to berenewed, and to parts requiring further inspectionbefore being passed for reassembly; place theseparts in separate containers from thosecontaining parts for rebuild. Do not discard a part due for renewal until aftercomparing it with a new part, to ensure that itscorrect replacement has been obtained.CIeaning componentsAlways use the recommended cleaning agent orequivalent.Ensure that adequate ventilation is provided whenvolatile degreasing agents are being used.Do not use degreasing equipment for componentscontaining items which could be damaged by theuse of this process.Whenever possible clean components and the areasurrounding them before removal. Always observescrupulous cleanliness when cleaning dismantledcomponents.GeneraI inspectionAll components should be inspected for wear ordamage before being reassembled. Never inspect a component for wear ordimensional check unless it is absolutely clean; aslight smear of grease can conceal an incipientfailure. When a component is to be checkeddimensionally against recommended values, usethe appropriate measuring equipment (surfaceplates, micrometers, dial gauges etc.). Ensurethe measuring equipment is calibrated and ingood serviceable condition. Reject a component if its dimensions are outsidethe specified tolerances, or if it appears to bedamaged. A part may be refitted if its critical dimension isexactly to its tolerance limit and it appears to bein satisfactory condition. Use 'Plastigauge' 12Type PG-1 for checking bearing surfaceclearances.www.easyfixed.comGENERAL INFORMATION8 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSBaII and RoIIer BearingsWhen removing and installing bearings, ensure thatthe following practices are observed to ensurecomponent serviceability. Remove all traces of lubricant from bearingunder inspection by cleaning with a suitabledegreasant; maintain absolute cleanlinessthroughout operations. Conduct a visual inspection for markings onrolling elements, raceways, outer surface of outerrings or inner surface of inner rings. Reject anybearings found to be marked, since marking inthese areas indicates onset of wear. Hold inner race of bearing between finger andthumb of one hand and spin outer race to checkthat it rotates absolutely smoothly. Repeat,holding outer race and spinning inner race. Rotate outer ring gently with a reciprocatingmotion, while holding inner ring; feel for anycheck or obstruction to rotation. Reject bearing ifaction is not perfectly smooth. Lubricate bearing with generous amounts oflubricant appropriate to installation. nspect shaft and bearing housing fordiscoloration or other markings which indicatemovement between bearing and seatings. Ensure that shaft and housing are clean and freefrom burrs before fitting bearing. f one bearing of a pair shows an imperfection, itis advisable to replace both with new bearings;an exception could be if the faulty bearing hadcovered a low mileage, and it can be establishedthat damage is confined to only one bearing. Never refit a ball or roller bearing without firstensuring that it is in a fully serviceable condition. When hub bearings are removed or displaced,new bearings must be fitted; do not attempt torefit the old hub bearings. When fitting a bearing to a shaft, only apply forceto the inner ring of the bearing. When fitting abearing into a housing, only apply force to theouter ring of the bearing. n the case of grease lubricated bearings (e.g.hub bearings) fill the space between bearing andouter seal with the recommended grade ofgrease before fitting seal. Always mark components of separable bearings(e.g. taper roller bearings) when dismantling, toensure correct reassembly. Never fit new rollersin a used outer ring; always fit a complete newbearing assembly.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 9OiI seaIsAlways renew oil seals which have been removedfrom their working location (whether as an individualcomponent or as part of an assembly). NEVER usea seal which has been improperly stored or handled,such as hung on a hook or nail. Carefully examine seal before fitting to ensurethat it is clean and undamaged. Ensure the surface on which the new seal is torun is free of burrs or scratches. Renew thecomponent if the original sealing surface cannotbe completely restored. Protect the seal from any surface which it has topass when being fitted. Use a protective sleeveor tape to cover the relevant surface. Lubricate the sealing lips with a recommendedlubricant before use to prevent damage duringinitial use. On dual lipped seals, smear the areabetween the lips with grease. Note: some oilseals are coated with a protective wax and mustbe fitted dry, unless instructed otherwise. f a seal spring is provided, ensure that it is fittedcorrectly. Place lip of seal towards fluid to besealed and slide into position on shaft. Use fittingsleeve where possible to protect sealing lip fromdamage by sharp corners, threads or splines. f afitting sleeve is not available, use plastic tube ortape to prevent damage to the sealing lip. Grease outside diameter of seal, place square tohousing recess and press into position usinggreat care, and if possible a 'bell piece' to ensurethe seal is not tilted. n some cases it may bepreferable to fit seal to housing before fitting toshaft. Never let weight of unsupported shaft restin seal. Use the recommended service tool to fit an oilseal. f the correct service tool is not available,use a suitable tube approximately 0.4 mm (0.015in) smaller than the outside diameter of the seal.Use a hammer VERY GENTLY on drift if asuitable press is not available. Press or drift the seal in to the depth of itshousing, with the sealing lip facing the lubricantto be retained if the housing is shouldered, orflush with the face of the housing where noshoulder is provided. Ensure that the seal doesnot enter the housing in a tilted position.www.easyfixed.comGENERAL INFORMATION10 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSJoints and joint facesFit joints dry unless specified otherwise. When jointing compound is used, apply in a thinuniform film to metal surfaces; take care toprevent jointing compound from entering oilways,pipes or blind tapped holes. f gaskets and/or jointing compound isrecommended for use; remove all traces of oldjointing material prior to reassembly. Do not usea tool which will damage the joint faces andsmooth out any scratches or burrs on the jointfaces using an oil stone. Do not allow dirt orjointing material to enter any tapped holes orenclosed parts. Prior to reassembly, blow through any pipes,channels or crevices with compressed air.Locking DevicesAlways replace locking devices with one of the samedesign.Tab washers - always release locking tabs and fitnew locking washers. Do not re-use locking tabs.Locking nuts - always use a backing spannerwhen loosening or tightening locking nuts, brake andfuel pipe unions.Roll pins - always fit new roll pins of an interferencefit in the hole.Circlips - always fit new circlips of the correct sizefor the groove.Keys and keyways - remove burrs from edges ofkeyways with a fine file and clean thoroughly beforeattempting to refit key.Clean and inspect key closely; keys are suitable forrefitting only if indistinguishable from new, as anyindentation may indicate the onset of wear.Split pins -Always fit new split-pins of the correct size for thehole in the bolt or stud. Do not sIacken back nut toenter spIit-pin.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 11Screw threadsMetric threads to SO standards are used.Damaged nuts, bolts and screws must always bediscarded.Cleaning up damaged threads with a die or tapimpairs the strength and closeness of fit of thethreads and is not recommended.Castellated nuts must not be slackened back toaccept a split-pin, except in those recommendedcases when this forms part of an adjustment.Do not allow oil or grease to enter blind threadedholes. The hydraulic action on screwing in the bolt orstud could split the housing.Always tighten a nut or bolt to the recommendedtorque figure. Damaged or corroded threads canaffect the torque reading.To check or re-tighten a bolt or screw to a specifiedtorque figure, first slacken a quarter of a turn, thenretighten to the correct torque figure.Oil thread lightly before tightening to ensure a freerunning thread, except in the case of threads treatedwith sealant/lubricant, and self-locking nuts.BoIt identificationAn SO metric bolt or screw made of steel and largerthan 6 mm in diameter can be identified by either ofthe symbols SO M or M embossed or indented ontop of the head.n addition to marks to identify the manufacturer, thehead is also marked with symbols to indicate thestrength grade, e.g. 8.8; 10.9; 12.9; 14.9. As analternative, some bolts and screws have the M andstrength grade symbol on the flats of the hexagon.www.easyfixed.comGENERAL INFORMATION12 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSNut identificationA nut with an SO metric thread is marked on oneface or on one of the flats of the hexagon with thestrength grade symbol 8, 12, or 14. Some nuts witha strength grade 4, 5 or 6 are also marked and somehave the metric symbol M on the flat opposite thestrength grade marking.A clock face system is used as an alternativemethod of indicating the strength grade. Theexternal chamfers or a face of the nut is marked in aposition relative to the appropriate hour mark on aclock face to indicate the strength grade.A dot is used to locate the 12 o'clock position and adash to indicate the strength grade. f the grade isabove 12, two dots identify the 12 o'clock position.When tightening a slotted or castellated nut, neverloosen it to insert a split pin except whererecommended as part of an adjustment. f difficulty isexperienced, alternative washers or nuts should beselected, or the washer thickness reduced.Where bearing pre-load is involved, nuts should betightened in accordance with special instructions.SeIf-Iocking nutsSelf-locking nuts, i.e. nylon insert or metal stiff nutscan be re-used providing resistance can be feltwhen the locking portion of the nut passes over thethread of the bolt or stud.Where self-locking nuts have been removed, it isadvisable to replace them with new ones of thesame type.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 13SeIf-Iocking boIts and screwsSelf-locking bolts and screws, i.e. nylon patched ortrilobular thread can be re-used providing resistancecan be felt when the locking portion enters thefemale thread.Nylon patched bolts and screws have a lockingagent pre-applied to the threads. They are identifiedby the presence of a coloured section of threadwhich extends for up to 180 around the thread.Trilobular i.e. Powerlok bolts have a special threadform which creates a slight interference in thetapped hole or threads of the nut into which it isscrewed.DO NOT re-use self-locking fasteners in criticallocations (eg. engine bearings). Always use thecorrect replacement self-locking nut, bolt or screw.DO NOT fit non self-locking fasteners in applicationswhere a self-locking nut, bolt or screw is specified.EncapsuIated boIts and screwsEncapsulated bolts and screws have amicro-encapsulated locking agent pre-applied to thethread. They are identified by the presence of acoloured section of thread which extends completelyaround the thread - 360. The locking agent isreleased and activated by the assembly process andis then chemically cured to provide the lockingaction.Unless a specific repair procedure states otherwise,encapsulated bolts may be re-used providing thethreads are undamaged and the following procedureis adopted. Remove loose adhesive from the bolt andhousing threads. Ensure threads are clean and free of oil andgrease. Apply an approved locking agent.An encapsulated bolt may be replaced with a bolt ofequivalent specification provided it is treated with anapproved locking agent.www.easyfixed.comGENERAL INFORMATION14 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSFLEXIBLE PIPES AND HOSESGeneraIWhen removing and installing flexible hydraulicpipes and hoses, ensure that the following practicesare observed to ensure component serviceability. Before removing and refitting brake or powersteering hose, clean end fittings and areasurrounding them as thoroughly as possible. Obtain appropriate plugs or caps beforedetaching hose end fittings, so that the ports canbe immediately covered to prevent the ingress ofdirt. Clean hose externally and blow through withairline. Examine carefully for cracks, separationof plies, security of end fittings and externaldamage. Reject any faulty hoses. When refitting a hose, ensure that nounnecessary bends are introduced, and that thehose is not twisted before or during tightening ofunion nuts. Fit a cap to seal a hydraulic union and a plug toits socket after removal to prevent ingress of dirt. Absolute cleanliness must be observed withhydraulic components at all times. After any work on hydraulic systems, carefullyinspect for leaks underneath the vehicle while asecond operator applies maximum brakepressure to the brakes (engine running) andoperates the steering.FueI system hosesAll fuel hoses are made up of two laminations, anarmoured rubber outer sleeve and an inner vitoncore. f any of the fuel system hoses have beendisconnected, it is imperative that the internal bore isinspected to ensure that the viton lining has notbecome separated from the armoured outer sleeve.A new hose must be fitted if separation is evident.CooIing system hosesThe following precautions MUST be followed toensure the integrity of cooling hoses and theirconnections to system components are maintained.Hose orientation and connectionCorrect orientation of cooling hoses is important inensuring that the hose does not become fatigued ordamaged through contact with adjacentcomponents. Where 'timing' marks (2) are providedon the hose and corresponding connection, thesemust be used to ensure correct orientation. Hosesmust be pushed fully onto their connection points.Usually, a moulded form (3) on the stub pipeprovides a positive indicator.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 15Hose clipsMarkings (4) are usually provided on the hose toindicate the correct clip position. f no markings areprovided, position the clip directly behind theretaining lip at the end of the stub as shown. Wormdrive clips should be oriented with the crimped sideof the drive housing (5) facing towards the end of thehose, or the hose may become pinched between theclip and the stub pipe retaining lip. Worm drive clipsshould be tightened to 3 Nm (2lbf.ft) unlessotherwise stated. Ensure that hose clips do not fouladjacent components.Heat protectionAlways ensure that heatshields and protectivesheathing are in good condition. Replace if damageis evident. Particular care must be taken whenrouting hoses close to hot engine components, suchas the exhaust manifold. Hoses will deflect slightlywhen hot; ensure this movement is taken intoaccount when routing and securing hoses.www.easyfixed.comGENERAL INFORMATION16 GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSSERVICE TOOLSGeneraISpecial service tools have been developed tofacilitate removal, dismantling and assembly ofmechanical components in a cost effective and timeefficient manner. The use of special tools also helpsprevent the potential for damage to components.Some operations described in this Manual cannot becarried out properly without the aid of the relevantservice tools.Special service tools can be obtained from thefollowing suppliers:CartooI (UK) LimitedUnit 3, Sterling Business ParkSalthouse RoadBrackmillsNorthamptonNN4 7EXEnglandTEL: +44 (0) 1604 760099FAX: +44 (0) 1604 760017e-maiI: salescartooluk.co.ukCARTOOL GmbHStraussenlettenstrasse 1585053 ngolstadtGermanyTEL: +49 (0) 841 9650080FAX: +49 (0) 841 9650090e-maiI: i.amanncartool.deTestBookTestBook is a computerised workshop tool whichprovides your dealership with instant access to thevery latest Technical nformation from MG ROVER,allowing for accurate and effective fault diagnosisand repair of all MG Rover Vehicles.Where specific garage equipment is required fordiagnosis and repair, reference should be made tothe Service Tools and Equipment Programme wheredetails of the equipment recommended by MGRover Service may be found.Body repairsAny damage found, that would affect the corrosionresistance of the vehicle during the Warranty periodmust be rectified by an authorised MG Rover Dealerto the standards, and by the methods, detailed in theBody Repair Manual.RepIacement body paneIsBody panels are supplied coated in cathodicelectrocoat primer.www.easyfixed.comGENERAL INFORMATIONGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 17DYNAMOMETER TESTINGGeneraIMPORTANT: Use a four wheel dynamometer forbrake testing if possible.WARNING: Do not attempt to test an ABSfunction on a dynamometer.Four wheeI dynamometersProvided that front and rear rollers are rotating atidentical speeds and that normal workshop safetystandards are applied, there is no speed restrictionduring testing except any that may apply to thetyres.Before testing a vehicle with anti-lock brakes on afour wheel dynamometer, disconnect the ABSmodulator. The ABS function will not work, the ABSwarning light will illuminate. Normal braking will beavailable.Two wheeI dynamometersABS will not function on a two wheel dynamometer.The ABS light will illuminate during testing. Normalbraking will be available.f brake testing on a two wheel dynamometer isnecessary, the following precautions should betaken: Traction control must be disabled Neutral selected in gearboxWhen checking brakes, run engine at idle speed tomaintain servo-vacuum.www.easyfixed.comwww.easyfixed.comGENERAL INFORMATIONFUEL HANDLING PRECAUTIONS 1FUEL HANDLING PRECAUTIONSGeneraIThe following information provides basic precautionswhich must be observed if petrol (gasoline) is to behandled safely. t also outlines other areas of riskwhich must not be ignored. This information isissued for basic guidance only, if in doubt consultyour local Fire Officer.Fuel vapour is highly flammable and in confinedspaces is also explosive and toxic. The vapour isheavier than air and will always fall to the lowestlevel. The vapour can be easily distributedthroughout a workshop by air currents;consequently, even a small spillage of fuel ispotentially very dangerous.Always have a fire extinguisher containing FOAM,CO2, GAS or POWDER close at hand whenhandling or draining fuel or when dismantling fuelsystems. Fire extinguishers should also be locatedin areas where fuel containers are stored.Always disconnect the vehicle battery beforecarrying out dismantling or draining work on a fuelsystem.Whenever fuel is being handled, drained or stored,or when fuel systems are being dismantled, all formsof ignition must be extinguished or removed; anyleadlamps must be flameproof and kept clear ofspillage.WARNING: No one shouId be permitted torepair components associated with fueIwithout first having speciaIist training.WARNING: Do not remove fueI systemcomponents whiIe the vehicIe is over a pit.FueI tank drainingFuel tank draining should be carried out inaccordance with the procedure outlined in the 'FUELDELIVERY' section of this manual and observingthe following precautions:WARNING: FueI must not be extracted ordrained from any vehicIe whiIst it is over apit.Draining or extraction of fueI must be carried outin a weII ventiIated area.The capacity of containers for fueI must be morethan adequate for the fuII amount of fueI to beextracted or drained. The container shouId becIearIy marked with its contents and pIaced in asafe storage area which meets the requirementsof IocaI authority reguIations.CAUTION: When fueI has been extractedor drained from a fueI tank the precautionsgoverning naked Iights and ignitionsources shouId be maintained.FueI tank removaIWhen the fuel line is secured to the fuel tank outletby a spring steel clip, the clip must be releasedbefore the fuel line is disconnected or the fuel tank isremoved. This procedure will avoid the possibility ofresidual fumes in the fuel tank being ignited whenthe clip is released.As an added precaution fuel tanks should have a'FUEL VAPOUR' warning label attached to them assoon as they are removed from the vehicle.FueI tank repairsNo attempt should be made to repair a plastic fueltank. f the structure of the tank is damaged, a newtank must be fitted.Body repairsPlastic fuel pipes are particularly susceptible to heat,even at relatively low temperature, and can bemelted by heat conducted from some distance away.When body repairs involve the use of heat, all fuelpipes which run in the vicinity of the repair area mustbe removed, and the tank outlet plugged, BEFOREHEAT S APPLED. f the repair is in the vicinity ofthe fuel tank, the tank must be removed.WARNING: If weIding is to be carried outin the vicinity of the fueI tank, the fueIsystem must be drained and the tankremoved before weIding commences.www.easyfixed.comGENERAL INFORMATION2 FUEL HANDLING PRECAUTIONSQuick fit fueI hose connectorsWARNING: Hose connections between thefueI pump and the fueI raiI contain fueIunder pressure, which MUST be reIievedprior to disconnection of the hoses. SeeENGINE MANAGEMENT SYSTEM - MEMS,Adjustments.1. Wipe connection and surrounding area using alint free cloth.NOTE: If the connection is heaviIy soiIedwith road saIt and dirt, gentIy twistconnector whiIe spraying with WD40.2. f necessary use an air line to removecontaminates from the retainer area of theconnector.3. Depress collar and disconnect hose.4. Ensure pipe end is clean and free fromcorrosion.5. Lubricate pipe end with clean engine oil.6. Connect hose to pipe and push firmly intoposition until a click is heard.7. Check security of connection by pulling onconnector.CAUTION: When checking security ofconnector puII on connector body NOT onthe hose.www.easyfixed.comGENERAL INFORMATIONELECTRICAL PRECAUTIONS 1ELECTRICAL PRECAUTIONSGeneraIThe following guidelines are intended to ensure thesafety of the operator whilst preventing damage tothe electrical and electronic components fitted to thevehicle. Where necessary, specific precautions aredetailed in the relevant sections of this Manual whichshould be referred to prior to commencing repairoperations.EquipmentPrior to commencing any test procedure on thevehicle, ensure that the relevant test equipment isworking correctly and any harness or connectors arein good condition. t is particularly important to checkthe condition of the lead and plugs of mainsoperated equipment.PoIarityNever reverse connect the vehicle battery andalways ensure the correct polarity when connectingtest equipment.High VoItage CircuitsWhenever disconnecting live ht circuits, always useinsulated pliers and never allow the open end of theht lead to contact other components, particularlyECU's. Exercise caution when measuring thevoltage on the coil terminals while the engine isrunning, high voltage spikes can occur on theseterminals.Connectors and HarnessThe engine compartment of a vehicle is aparticularly hostile environment for electricalcomponents and connectors: Always ensure electrically related items are dryand oil free before disconnecting and connectingtest equipment. Ensure disconnected multiplugs and sensors areprotected from being contaminated with oil,coolant or other solutions. Contamination couldimpair performance or result in catastrophicfailure. Never force connectors apart using tools to priseapart or by pulling on the wiring harness. Always ensure locking tabs are disengagedbefore disconnection, and match orientation toenable correct reconnection. Ensure that any protection (covers, insulationetc.) is replaced if disturbed.Having confirmed a component to be faulty: Switch off the ignition and disconnect the battery. Remove the component and support thedisconnected harness. When replacing the component keep oily handsaway from electrical connection areas and pushconnectors home until any locking tabs fullyengage.Battery disconnectionBefore disconnecting the battery, disable the alarmsystem and switch off all electrical equipment. f theradio is to be serviced, ensure the security code hasbeen deactivated.CAUTION: To prevent damage to eIectricaIcomponents, ALWAYS disconnect thebattery when working on the vehicIe'seIectricaI system. The ground Iead must bedisconnected first and reconnected Iast.AIways ensure that battery Ieads are routedcorrectIy and are not cIose to any potentiaIchafing points.Battery chargingOnly recharge the battery with it removed from thevehicle. Always ensure any battery charging area iswell ventilated and that every precaution is taken toavoid naked flames and sparks.Ignition system safety precautionsThe vehicle's ignition system produces high voltageand the following precautions should be observedbefore carrying out any work on the system.WARNING: Before commencing work onan ignition system, ensure aII high tensionterminaIs, adapters and diagnosticequipment are adequateIy insuIated andshieIded to prevent accidentaI personaI contactsand minimise the risk of shock.WARNING: Wearers of surgicaIIyimpIanted pacemaker devices shouId notbe in cIose proximity of ignition circuits ordiagnostic equipment.www.easyfixed.comGENERAL INFORMATION2 ELECTRICAL PRECAUTIONSDiscipIinesSwitch off the ignition prior to making any connectionor disconnection in the system to prevent electricalsurges caused by disconnecting 'live' connectionsdamaging electronic components.Ensure hands and work surfaces are clean and freeof grease, swarf, etc. Grease collects dirt which cancause electrical tracking (short-circuits) orhigh-resistance contacts.When handling printed circuit boards, treat with careand hold by the edges only; note that someelectronic components are susceptible to bodystatic.Connectors should never be subjected to forcedremoval or refit, especially inter-board connectors.Damaged contacts can cause short- circuit andopen-circuit fault conditions.Prior to commencing test, and periodically during atest, touch a good vehicle body earth to dischargestatic. Some electronic components are vulnerableto static electricity that may be generated by theoperator.Grease for eIectricaI connectorsSome under bonnet and under body connectors maybe protected against corrosion by the application ofa special grease during vehicle production. Shouldconnectors be disturbed in service, repaired orreplaced, additional grease should be applied:Part No. BAU 5811, available in 150 g tubs.NOTE: The use of greases other thanBAU 5811 must be avoided as they canmigrate into reIays, switches etc.contaminating the contacts and Ieading tointermittent operation or faiIure.www.easyfixed.comGENERAL INFORMATIONSRS PRECAUTIONS 1SUPPLEMENTARY RESTRAINT SYSTEMPRECAUTIONSGeneraIThe SRS system contains components which couldbe potentially hazardous to the service engineer ifnot serviced and handled correctly. The followingguidelines are intended to alert the service engineerto potential sources of danger and emphasise theimportance of ensuring the integrity of SRScomponents fitted to the vehicle.WARNING: AIways foIIow the 'SRSPrecautions' and the correct proceduresfor working on SRS components. Personsworking on SRS systems must be fuIIy trainedand have been issued with copies of the safetyguideIines.WARNING: It is imperative that before anywork is undertaken on the SRS system theappropriate information is readthoroughIy.WARNING: Some airbag moduIes containsodium azide which is poisonous andextremeIy fIammabIe. Contact with water,acid or heavy metaIs may produce harmfuI orexpIosive compounds. Do not dismantIe,incinerate or bring into contact with eIectricity,before the unit has been depIoyed.WARNING: AIways repIace a seat beItassembIy that has withstood the strain ofa severe vehicIe impact, or if the webbingshows signs of fraying.WARNING: AIways disconnect the vehicIebattery before carrying out any eIectricaIweIding on a vehicIe fitted with an SRSsystem.CAUTION: Do not expose an airbagmoduIe or seat beIt pre-tensioner to heatexceeding 85C (185F).t should be noted that these precautions are notrestricted to operations performed when servicingthe SRS system, the same care should be exercisedwhen working on ancillary systems and componentslocated in the vicinity of SRS components; theseinclude, but are not limited to: Steering system - steering wheel airbag, rotarycoupler Front fascia - passenger front airbag (wherefitted) Centre consoIe - SRS DCU and SRSharnesses. EIectricaI system - SRS harnesses, link leadsand connectorsMaking the system safeBefore working on, or in the vicinity of SRScomponents, ensure the system is rendered safe byperforming the following procedures: Remove the ignition key from the ignition switch.www.easyfixed.comGENERAL INFORMATION2 SRS PRECAUTIONS Disconnect both battery leads, earth lead firstbefore beginning work. Wait 10 minutes for the SRS DCU back-uppower circuit to discharge.The SRS system uses energy reserve capacitors tokeep the system active in the event of electricalsupply failure under crash conditions. t is necessaryto allow the capacitor sufficient time to discharge (10minutes) in order to avoid the risk of accidentaldeployment.WARNING: AIways disconnect bothbattery Ieads before beginning work onthe SRS system. Disconnect the negativebattery Iead first. Never reverse connect thebattery.INSTALLATIONn order to assure system integrity, it is essential thatthe SRS system is regularly checked andmaintained so that it is ready for effective operationin the event of a collision. Carefully inspect SRScomponents before installation. Do not install a partthat shows signs of being dropped or improperlyhandled, such as dents, cracks or deformation.WARNING: The integrity of the SRSsystem components are criticaI for safetyreasons. Ensure the foIIowing precautionsare aIways adhered to: Never instaII used SRS components fromanother vehicIe or attempt to repair an SRScomponent. When repairing an SRS system, onIy usegenuine new parts. Never appIy eIectricaI power to an SRScomponent unIess instructed to do so as partof an approved test procedure. SpeciaI Torx boIts are necessary for instaIIingthe airbag moduIe - do not use other boIts.Ensure boIts are tightened to the correcttorque. AIways use new fixings when repIacing anSRS component. Ensure the SRS Diagnostic ControI Unit(DCU) is aIways instaIIed correctIy. Theremust not be any gap between the DCU andthe bracket to which it is mounted. AnincorrectIy mounted DCU couId cause thesystem to maIfunction.CAUTION: Ensure SRS components arenot contaminated with oiI, grease,detergent or water.CAUTION: Torque wrenches shouId bereguIarIy checked for accuracy to ensurethat aII fixings are tightened to the correcttorque.NOTE: If the SRS component is to berepIaced, the bar code of the new unitmust be recorded.www.easyfixed.comGENERAL INFORMATIONSRS PRECAUTIONS 3SRS component testing precautionsThe SRS components are triggered using relativelylow operating currents, always adhere to thefollowing precautions:WARNING: Do not use a muItimeter orother generaI purpose test equipment onSRS system components or accidentaIdepIoyment may occur. OnIy use 'Testbook' todiagnose SRS system fauIts.WARNING: Do not use eIectricaI testequipment on the SRS harness whiIe it isconnected to any of the SRS systemcomponents. It may cause accidentaIdepIoyment and personaI injury.HandIing and storageThere are regulations for the safe storage of SRScomponents which must be observed, consult yourlocal authority for details.WARNING: The SRS components aresensitive and potentiaIIy hazardous if nothandIed correctIy; aIways compIy with thefoIIowing handIing precautions: Never drop a SRS component. The airbagdiagnostic controI unit is a particuIarIy shocksensitive device and must be handIed withextreme care. Airbag moduIes couId depIoy ifsubjected to a strong shock. Never wrap your arms around an airbagmoduIe. If an airbag moduIe has to be carried,hoId it by the cover, with the cover uppermostand the base away from your body. Never transport airbag moduIes in the cabinof a vehicIe. AIways use the Iuggagecompartment of the vehicIe for carryingairbag moduIes.WARNING: Never attach anything to anairbag cover or any trim componentcovering an airbag moduIe. Do not aIIowanything to rest on top of an airbag moduIe.WARNING: AIways keep components cooI,dry and free from contamination.www.easyfixed.comGENERAL INFORMATION4 SRS PRECAUTIONSWARNING: Store airbag moduIes with thedepIoyment side uppermost. If airbagmoduIes are stored depIoyment sidedown, accidentaI depIoyment wiII propeI theairbag moduIe with enough force to causeserious injury.WARNING: Airbag moduIes are cIassed asexpIosive devices. For overnight andIonger term storage, they must me storedin a secure steeI cabinet which has beenapproved as suitabIe for the purpose and hasbeen registered by the IocaI authority.WARNING: Store the airbag moduIe in adesignated storage area. If there is nodesignated storage area avaiIabIe, store inthe Iocked Iuggage compartment/Ioadspace ofthe the vehicIe and inform the workshopsupervisor.CAUTION: Improper handIing or storagecan internaIIy damage the airbag moduIe,making it inoperative. If you suspect theairbag moduIe has been damaged, instaII a newmoduIe and refer to the DepIoyment/DisposaIProcedures to determine the correct method fordisposaI of the damaged moduIe.WARNING: When handIing front seat beItbuckIe pre-tensioners, hoId by the pistontube, with the open end of the piston tubepointing towards the ground and the buckIefacing away from your body. DO NOT cover the end of the piston tube. DO NOT hoId buckIe pre-tensioners by thebracket assembIy or steeI cabIe. NEVER point the piston tube towards yourbody or other peopIe.www.easyfixed.comGENERAL INFORMATIONSRS PRECAUTIONS 5SRS Harnesses and ConnectorsCAUTION: AIways observe the foIIowingprecautions with regards to the SRSsystem eIectricaI wiring: Never attempt to modify, spIice or repair SRSwiring. Never instaII eIectronic equipment (such as amobiIe teIephone, two-way radio or in-carentertainment system) in such a way that itcouId generate eIectricaI interference in theSRS system harness. Seek speciaIist advicewhen instaIIing such equipment.NOTE: SRS system wiring can usuaIIy beidentified by a speciaI yeIIow outer sIeeveprotecting the wires (bIack with yeIIowstripe protective coverings are sometimes used).WARNING: AIways ensure SRS wiring isrouted correctIy. Be carefuI to avoidtrapping or pinching the SRS wiring. Donot Ieave the connectors hanging Ioose or aIIowSRS components to hang from their harnesses.Look for possibIe points of chafing.CAUTION: Ensure aII SRS componentharness connectors are mated correctIyand secureIy fastened. Do not Ieave theconnectors hanging Ioose.Rotary CoupIer PrecautionsCAUTION: AIways foIIow the procedure forfitting and checking the rotary coupIer asinstructed in the 'SRS Repairs' section ofthis manuaI. CompIy with aII safety andinstaIIation procedures to ensure the systemfunctions correctIy. Observe the foIIowingprecautions: Do not unIock and rotate the rotary coupIerwhen it is removed from the vehicIe. Do not turn the road wheeIs when the rotarycoupIer is removed from the vehicIe. AIways ensure the rotary coupIer is removedand instaIIed in its centered position and withthe front road wheeIs in a straight aheadposition - refer to the 'SRS Repairs' section ofthis manuaI for the correct removaI andinstaIIation procedure. If a new rotary coupIer is being instaIIed,ensure the Iocking tab hoIding the coupIer'srotationaI position is not broken; units with abroken Iocking tab shouId not be used.www.easyfixed.comGENERAL INFORMATION6 SRS PRECAUTIONSWARNING LABELSWarning symbols relating to the SRS system aredisplayed at various positions in the vehicle. SRScomponents have additional warning labelsdisplayed on them to indicate that particular care isneeded when handling them. These include airbagmodules, DCU and the rotary coupler.The following warning labels may be displayedtogether or individually at various locations on thevehicle:A - The need for caution when working in closeproximity to SRS components.B - Refer to the publication where the procedures,instructions and advice can be found (usuallyWorkshop Manual or Owner's Handbook) forworking on the SRS system.C - Do not use rear facing child seats in the frontpassenger seat if the vehicle is fitted with apassenger airbag.WARNING: It is imperative that before anywork is undertaken on the SRS system theappropriate information is readthoroughIy.NOTE: The foIIowing Iist indicates currentIocations for warning IabeIs. Exactpositions may vary dependent onIegisIation and market trends.Bonnet Iocking pIatformRefer to the Owner's Handbook for information onthe airbag systemRotary CoupIerA - SRS - Refer to the Workshop Manual for detailedinstructions.B - Ensure wheels are in the straight ahead positionbefore removal and refitting of the rotary coupler.C - MG Rover Part number/Bar code: the codenumber must be recorded if the rotary coupler is tobe replaced.CAUTION: DO NOT ROTATE THE ROTARYCOUPLER MECHANISMwww.easyfixed.comGENERAL INFORMATIONSRS PRECAUTIONS 7Door gIassRefer to the Owner's Handbook for information onthe airbag system.Airbag moduIe - driverA - MG Rover Part Number / Bar Code - The codenumber must be quoted when ordering areplacement module.An 'SRS ARBAG' legend is also moulded into thecentre pad to identify the presence of a driver'sairbag.Diagnostic ControI UnitA - Refer to the Workshop Manual for information onthe airbag system.B - MG Rover Part Number / Bar Code - The codenumber must be recorded if the airbag control anddiagnostic unit is to be replaced.Airbag moduIe - passengerA - MG Rover Part Number / Bar code - The codenumber must be quoted when ordering areplacement module.Front seat beIt pre-tensioners Exercise caution. Refer to the publication where the procedures,instructions and advice can be found (usuallyWorkshop Manual or Owner's Handbook) forworking on the SRS system. Do not attempt to repair or disassemble.Bar codesBar codes are fitted to SRS components and othercomponents which are critically related to SRSoperation. The code number(s) must be recorded ifthe component is to be replaced.www.easyfixed.comGENERAL INFORMATION8 SRS PRECAUTIONSVEHICLE RECOVERYTowing - SRS components not depIoyed:Normal towing procedures are unlikely to cause anairbag to deploy. However, as a precaution, switchthe ignition off and then disconnect both batteryleads. Disconnect the '-ve' lead first.Towing - SRS components depIoyed:f the driver's airbag has been deployed, the vehiclemust have a suspended tow. However, as aprecaution, switch the ignition off and thendisconnect both battery leads. Disconnect the '-ve'lead first.SRS COMPONENT DEPLOYMENTf a vehicle is to be scrapped and it contains anundeployed airbag or seat belt pre-tensionermodule, the module must be manually deployed.Always observe the following precautions:WARNING: OnIy personneI who haveundergone the appropriate training shouIdundertake depIoyment of air bag and seatbeIt pre-tensioner moduIes.WARNING: A depIoyed airbag or seat beItpre-tensioner is very hot, DO NOT returnto a depIoyed airbag moduIe or seat beItpre-tensioner untiI at Ieast 30 minutes haveeIapsed since depIoyment.WARNING: OnIy use approveddepIoyment equipment, and onIy depIoySRS components in a weII ventiIated andspeciaIIy designated area. Ensure SRScomponents are not damaged or ruptured beforedepIoyment. Notify the reIevant authorities.WARNING: If a vehicIe is to be scrapped,undepIoyed airbag moduIes and seat beItpre-tensioner units must be depIoyed inaccordance with the instructions provided in thismanuaI.WARNING: Contact with chemicaIs fromdepIoyed and damaged SRS componentscouId present a heaIth hazard, wearprotective cIothing when handIing. DO NOT eat,drink or smoke when handIing SRS components.WARNING: DepIoyment of airbag moduIesand seat beIt pre-tensioners can causeinjury to personneI in the cIose vicinity ofthe depIoying unit. In case of injury seek urgentmedicaI advice. PossibIe sources of injuryincIude: Impact - due to infIating airbag or depIoyingseat beIt pre-tensioner operation causingcomponent 'kick'. Hearing - due to noise produced by depIoyingairbags and seat beIt pre-tensioner units. Burns - hot component parts and gases. Irritation to eyes and Iungs - from depIoyinggases or combustion residue.WARNING: Ensure the SRS component tobe depIoyed is secureIy fastened to itsmounting.www.easyfixed.comGENERAL INFORMATIONSRS PRECAUTIONS 9WARNING: DepIoyment proceduresdetaiIed in this manuaI shouId be strictIyadhered to. CompIiance with the foIIowingprecautions MUST be ensured: OnIy use depIoyment equipment approved forthe intended purpose. Before commencing depIoyment procedure,ensure the depIoyment tooI functionsproperIy by performing the seIf testprocedure detaiIed in the 'SRS Repairs'section of this manuaI. DepIoyment of airbag / seat beIt pre-tensionermoduIes shouId be performed in a weIIventiIated area which has been speciaIIydesignated for the purpose. Ensure the airbag / seat beIt pre-tensionermoduIes are not damaged or ruptured beforeattempting to depIoy Notify the reIevant authorities of the intentionto depIoy airbag and seat beIt pre-tensionerunits. When depIoying airbag and seat beItpre-tensioner units, ensure that aII personneIare at Ieast 15 metres way from thedepIoyment zone. Ensure the depIoyment tooI is connectedcorrectIy, in compIiance with the instructionsdetaiIed in this manuaI. In particuIar, ensurethe depIoyment tooI is not connected to thebattery suppIy before connecting to theairbag or seat beIt pre-tensioner moduIeconnector. When depIoying seat beIt pre-tensioners inthe vehicIe, ensure the pre-tensioner unit isfuIIy secured to its fixing point. When removing depIoyed airbag and seat beItpre-tensioner moduIes, wear protectivecIothing. Use gIoves and seaI depIoyed unitsin a pIastic bag. FoIIowing depIoyment of any component ofthe SRS system within the vehicIe, aII SRScomponents must be repIaced. DO NOTre-use or saIvage any parts of the SRSsystem. Do not Iean over airbag moduIes or seat beItpre-tensioner units when connectingdepIoyment equipment.SRS COMPONENT REPLACEMENT POLICYThe following information details the policy forreplacement of SRS components; either as a resultof a vehicle accident or as a result of vehicle age.Impacts which do not depIoy the airbags or seatbeIt pre-tensionersCheck for structural damage in the area of theimpact, paying particular attention to bumperarmatures, longitudinals, crash cans and bracketry.Impacts which depIoy the airbags orpre-tensionersThe replacement and inspection policy is dependenton the type and severity of the crash condition. Thefollowing guidelines are the minimum that should beexercised as a result of the deployment of specificSRS components.Front airbag depIoyment (driver and passenger)f the front airbags are deployed, the following partsmust be replaced: Driver airbag module Passenger airbag module (where fitted) Flyleads (where applicable) connecting frontairbag modules to SRS harness Front seat buckle pre-tensioners Driver's seat belt retractor Rotary coupler SRS DCUn addition, the following should be inspected fordamage and replaced as necessary. Front passenger's seat belt retractor (webbing,tongue latching and anchorage point) Fascia moulding adjacent to passenger airbagmodule (where fitted) Steering wheel (if damage is evident) Front seat frames and head restraints (if there isevidence of damage to the seat frame or cushionpan) Steering column (if adjustment is lost or there aresigns of collapse)www.easyfixed.comGENERAL INFORMATION10 SRS PRECAUTIONSRear impactsRear impacts may cause the seat beltpre-tensioners to deploy. f this occurs, bothpre-tensioner units must be replaced. n addition, thefollowing components should be inspected fordamage and replaced as necessary: Seat frames Seat belts (retractors, webbing, tongue latchingand body anchorage points) SRS DCUPeriodic repIacement of SRS componentsThe performance of the propellants within airbagsand pre-tensioners will deteriorate over a period oftime. As a result, it is essential that the airbags andpre-tensioners are periodically replaced to maintainoccupant safety. Airbags, seat belt pre-tensionersand the rotary coupler should be replaced at 15 yearintervals.www.easyfixed.comGENERAL INFORMATIONAIR CONDITIONING PRECAUTIONS 1AIR CONDITIONING SYSTEM PRECAUTIONSGeneraIThe air conditioning system contains fluids andcomponents which could be potentially hazardous tothe service engineer or the environment if notserviced and handled correctly. The followingguidelines are intended to alert the service engineerto potential sources of danger and emphasise theimportance of ensuring the integrity of the AirConditioning operating conditions and componentsfitted to the vehicle.Where necessary, additional specific precautionsare detailed in the relevant sections of this Manual,which should be referred to prior to commencingrepair operations.The refrigerant used in the air conditioning system isHFC-134a (Hydrofluorocarbon) R134a.WARNING: Servicing must onIy be carriedout by personneI famiIiar with both thevehicIe system and the charging andtesting equipment. AII operations must becarried out in a weII ventiIated area away fromopen fIame and heat sources.WARNING: R134a is a hazardous Iiquidand when handIed incorrectIy can causeserious injury. SuitabIe protectivecIothing, consisting of face protection, heatproof gIoves, rubber boots and rubber apron orwaterproof overaIIs, must be worn when carryingout operations on the air conditioning system.RemediaI actionsf an accident involving R134a should occur, conductthe following remedial actions: f liquid R134a enters the eye, do not rub it.Gently run large quantities of eye wash over theaffected eye to raise the temperature. f an eyewash is not available, cool clean water may beused to flush the eye. After rinsing, cover the eyewith a clean pad and seek immediate medicalattention. f liquid R134a is splashed onto the skin, runlarge quantities of water over the affected area toraise the temperature. mplement the sameaction if the skin comes in contact withdischarging cylinders. Wrap the contaminatedbody parts in blankets (or similar materials) andseek immediate medical attention. f the debilitating effects of inhalation of R134avapour is suspected, seek fresh air. f theaffected person is unconscious, move them awayfrom the contaminated area to fresh air and applyartificial respiration and / or oxygen and seekimmediate medical attention.WARNING: Due to its Iow evaporatingtemperature, R134a must be handIed withcare. R134a spIashed on any part of thebody wiII cause immediate freezing of that area.AIso, refrigerant cyIinders and repIenishmenttroIIeys when discharging wiII freeze skin tothem if contact is made.www.easyfixed.comGENERAL INFORMATION2 AIR CONDITIONING PRECAUTIONSService precautionsObserve the following precautions when handlingcomponents used in the air conditioning system: Air conditioning units must not be lifted by theirhoses, pipes or capillary lines. Hoses and lines must not be subjected to anytwist or stress; the efficiency of the system will beimpaired by kinks or restrictions. Ensure thathoses are correctly positioned before tighteningcouplings, and ensure that all clips and supportsare utilised. Flexible hoses should not be positioned close tothe exhaust manifold (less than 100 mm) unlessprotected by heat shielding. Completed assemblies must be checked forrefrigeration lines touching metal panels. Anydirect contact of components and panels maytransmit noise and so must be eliminated. The appropriate torque wrench must be usedwhen tightening refrigerant connections to thestipulated value. An additional spanner must beused to hold the union to prevent twisting of thepipe when tightening connections. Before connecting any hose or pipe, ensure thatrefrigerant oil is applied to the seat of the new 'O'rings BUT NOT to the threads of the connection. All protective plugs must remain in place to sealthe component until immediately prior toconnection. Ensure components are at room temperaturebefore uncapping, to prevent condensation ofmoisture from the air that enters it. Components must not remain uncapped forlonger than 15 minutes. n the event of a delay,the caps must be fitted. When disconnecting, immediately cap all airconditioning pipes to prevent ingress of dirt andmoisture into the system. The receiver / drier contains dessicant whichabsorbs moisture. t must be positively sealed atall times. A receiver / drier that has been leftuncapped must not be used, fit a new unit. The receiver / drier should be the last componentconnected to the system to ensure optimumdehydration and maximum moisture protection ofthe system. Whenever the refrigerant system is opened, thereceiver / drier must be renewed immediatelybefore evacuating and recharging the system. Use alcohol and a clean lint-free cloth to cleandirty connections. Ensure that all new parts are marked for use withR13a.When a major repair has been completed, a leaktest should be conducted; refer to the 'ARCONDTONNG' section of this manual for thecorrect procedure.www.easyfixed.comGENERAL INFORMATIONAIR CONDITIONING PRECAUTIONS 3AIR CONDITIONING COMPRESSORREPLACEMENTAir Conditioning Compressor RepIacementA new compressor is supplied filled with a fullcharge of (X cm3) of refrigerant oil. Refer to the'CAPACITIES, FLUIDS AND LUBRICANTS'section of this manuaI for the actuaI capacities.A calculated quantity of oil must be drained from thenew compressor before fitting. To calculate thequantity of oil to be drained:1. Remove the drain plug from the oldcompressor.2. nvert the compressor and gravity drain the oilinto a calibrated measuring cylinder. Rotate thecompressor clutch to ensure the compressor iscompletely drained.3. Note the quantity of oil drained (Y cm3).4. Calculate the quantity of oil to be drained fromthe new compressor using the followingformula:X cm3- (Y cm3+ 20 cm3) = Q cm35. Remove the drain plug from the newcompressor and drain Q cm3of oil.6. Fit and tighten the compressor drain plug.www.easyfixed.comwww.easyfixed.comINFORMATIONCONTENTS PageGENERAL DATAENGNE - K SERES 1 ................................................................................................1.6MPi 1 ....................................................................................................................1.8MPi 1 ....................................................................................................................1.8 VVC 1 ..................................................................................................................ENGNE - LUBRCATON 6 .........................................................................................FUEL SYSTEM 6 .........................................................................................................COOLNG SYSTEM 6 ..................................................................................................CLUTCH 7 ...................................................................................................................MANUAL GEARBOX 7 ................................................................................................STEPSPEED (Em-CVT) GEARBOX 8 ........................................................................GEARBOX - LUBRCATON 8 .....................................................................................Manual Gearbox 8 ....................................................................................................Stepspeed (Em-CVT) 8 .............................................................................................FNAL DRVE 9 ............................................................................................................Manual gearbox - MPi 9 ............................................................................................Manual gearbox - VVC 9 ...........................................................................................Stepspeed (Em-CVT) - 1.8 MPi 10 ...........................................................................STEERNG 11 .............................................................................................................FRONT SUSPENSON 12 ...........................................................................................REAR SUSPENSON 12 .............................................................................................BRAKES 13 .................................................................................................................WHEELS 14 .................................................................................................................TYRE SZES 14 ...........................................................................................................TYRE PRESSURES 15 ...............................................................................................AR CONDTONNG 15 ..............................................................................................ELECTRCAL 16 ..........................................................................................................DMENSONS 16 .........................................................................................................WEGHTS 17 ...............................................................................................................BULBS 18 ....................................................................................................................ENGINE TUNING DATAENGNE TUNNG DATA 1 ...........................................................................................TORQUE WRENCH SETTINGSENGNE 1 ....................................................................................................................MODULAR ENGNE MANAGEMENT SYSTEM - MEMS 3 3 ......................................COOLNG 4 .................................................................................................................MANFOLD AND EXHAUST 4 .....................................................................................CLUTCH 4 ...................................................................................................................MANUAL GEARBOX 5 ................................................................................................STEPSPEED (Em-CVT) GEARBOX 5 ........................................................................DRVE SHAFTS 6 ........................................................................................................STEERNG 6 ...............................................................................................................SUSPENSON 7 ..........................................................................................................BRAKES 8 ...................................................................................................................SUPPLEMENTARY RESTRANT SYSTEM 9 .............................................................BODY 9 ........................................................................................................................HEATNG AND VENTLATON 10 ...............................................................................AR CONDTONNG 10 ..............................................................................................WPERS AND WASHERS 10 ......................................................................................www.easyfixed.comINFORMATIONCONTENTS PageELECTRCAL 11 ..........................................................................................................LIFTING AND TOWINGJACKNG, SUPPORTNG AND TOWNG 1 ................................................................WORKSHOP JACK 2 ..................................................................................................WHEEL-FREE LFT 2 ..................................................................................................RECOVERY 2 ..............................................................................................................TOWNG 3 ...................................................................................................................CAPACITIES, FLUIDS AND LUBRICANTSCAPACTES 1 .............................................................................................................FLUDS 1 .....................................................................................................................LUBRCATON 3 ..........................................................................................................www.easyfixed.comINFORMATIONGENERAL DATA 1ENGINE - K SERIES1.6 MPiType 16 valve DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder arrangement 4 in line - transverse, No.1 cylinder at front of engine . . . . . . . . . . . . . . . . . . . . . . . .Bore - liner 80.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stroke 79.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Capacity 1589 cm3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Firing order 1 - 3 - 4 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotation Clockwise, viewed from the front of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compression ratio 10.5 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .dle speed1.6 MPi MEMS 3 825 50 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum power 85 kW (114 bhp) 6,250 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum torque 145 Nm 4,700 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maximum engine speed 6,800 rev/min. . . . . . . . . . . . . . . . . . . . . . .1.8 MPiType 16 valve DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cyli